JP7089736B2 - Manufacturing method of spunlace non-woven fabric - Google Patents
Manufacturing method of spunlace non-woven fabric Download PDFInfo
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- JP7089736B2 JP7089736B2 JP2018016856A JP2018016856A JP7089736B2 JP 7089736 B2 JP7089736 B2 JP 7089736B2 JP 2018016856 A JP2018016856 A JP 2018016856A JP 2018016856 A JP2018016856 A JP 2018016856A JP 7089736 B2 JP7089736 B2 JP 7089736B2
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/425—Cellulose series
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
Description
本発明はスパンレース不織布の製造方法に関する。 The present invention relates to a method for producing a spunlaced nonwoven fabric.
風合いに優れた不織布として、スパンレース不織布が知られている（特許文献１）。スパンレース不織布は、コットン等のセルロース繊維にて構成されたウェブを水流交絡により不織布化したものである。特に湿潤状態で使用されるものがあり、それは、フェイスマスク、おしぼり、消毒綿、ボディワイパー等の用途に供されている。 As a non-woven fabric having an excellent texture, a spunlace non-woven fabric is known (Patent Document 1). The spunlace non-woven fabric is a non-woven fabric made of a web made of cellulose fibers such as cotton by confounding with water flow. Some are used especially in wet conditions, which are used in face masks, hand towels, disinfectant cotton, body wipers and the like.
しかし、湿潤状態で使用される不織布は、特に細菌が繁殖しないように留意することが必要となる。 However, it is necessary to pay particular attention to the non-woven fabric used in a wet state so that bacteria do not grow.
そこで本発明は、細菌数の少ないスパンレース不織布を得ることを目的とする。 Therefore, an object of the present invention is to obtain a spunlace nonwoven fabric having a small number of bacteria.
本発明のスパンレース不織布の製造方法は、以下の特徴を有する。 The method for producing a spunlace nonwoven fabric of the present invention has the following features.
（１）セルロース繊維にて構成されたウェブを水流交絡により不織布化するに際し、複数段の水流交絡処理を、次亜塩素酸ナトリウムを０．１～０．３ｐｐｍ添加して殺菌処理した水にて行うとともに、水流交絡処理後に１３０～１４５℃の温度で乾燥処理することで、一般細菌数（平均）が５０ＣＦＵ／ｇ以下の不織布を得ることを特徴とするスパンレース不織布の製造方法。 (1) When a web composed of cellulose fibers is made into a non-woven fabric by water flow entanglement, a multi-stage water flow entanglement treatment is performed with water sterilized by adding 0.1 to 0.3 ppm of sodium hypochlorite . A method for producing a spunlaced nonwoven fabric, which comprises obtaining a nonwoven fabric having a general bacterial count (average) of 50 CFU / g or less by performing a drying treatment at a temperature of 130 to 145 ° C. after a water flow entanglement treatment.
複数段の水流交絡処理における少なくとも最終段の処理を、水流交絡装置における循環水ではない、水源から直接供給され殺菌処理された水にて行うことを特徴とする上記（１）のスパンレース不織布の製造方法。 The spunlace nonwoven fabric according to (1) above, characterized in that at least the final stage of the multi-stage water flow entanglement treatment is performed with water directly supplied from a water source and sterilized, not circulating water in the water flow entanglement device. Production method.
（３）乾燥処理後における不織布の水分率を８質量％以下とすることを特徴とする上記（１）または（２）のスパンレース不織布の製造方法。 (3) The method for producing a spunlace nonwoven fabric according to (1) or (2) above, wherein the moisture content of the nonwoven fabric after the drying treatment is 8% by mass or less.
本発明によると、複数段の水流交絡処理を殺菌処理した水にて行うとともに、水流交絡処理後に１２０℃以上の温度で乾燥処理することで、湿潤状態を維持したものでありながら細菌数の少ないスパンレース不織布を得ることができる。 According to the present invention, a plurality of stages of water flow entanglement treatment are performed with sterilized water, and after the water flow entanglement treatment, a drying treatment is performed at a temperature of 120 ° C. or higher to maintain a moist state but have a small number of bacteria. A spunlaced nonwoven fabric can be obtained.
スパンレース不織布は、セルロース繊維を構成繊維とし、特に好ましくはコットンを構成繊維とし、高圧水流を適用することによって構成繊維同士を交絡させることにより、不織布形態を保持するものである。スパンレース不織布は、繊維同士の交絡のみによって不織布形態が保持されたものであるため、繊維間空隙が保たれ、嵩高となり、肌触りが良好で柔軟性を有する。またセルロース繊維を構成繊維としていることで、繊維端が鋭利な断面でないことからも肌当たりが滑らかであり、このため肌に直接触れる用途に好適な素材である。 The spunlace non-woven fabric has cellulose fibers as constituent fibers, particularly preferably cotton as constituent fibers, and the constituent fibers are entangled with each other by applying a high-pressure water stream to maintain the nonwoven fabric morphology. Since the spunlace non-woven fabric retains the non-woven fabric morphology only by entanglement of the fibers, the interfiber gaps are maintained, the fabric becomes bulky, and the fabric is soft to the touch and has flexibility. Further, since the cellulose fiber is used as a constituent fiber, the fiber end does not have a sharp cross section, so that the skin feels smooth, and therefore, it is a material suitable for applications in which it comes into direct contact with the skin.
このようなスパンレース不織布を製造する際には、まずコットンなどのセルロース繊維を用いて公知の方法によりウェブを得る。次に、得られたウェブを有孔支持体に担持させる。有孔支持体としては、たとえば金網や合成樹脂製ネットなどの適当なメッシュ数のメッシュ織物を挙げることができる。 When producing such a spunlaced nonwoven fabric, first, a web is obtained by a known method using cellulose fibers such as cotton. Next, the obtained web is supported on a perforated support. Examples of the perforated support include a mesh woven fabric having an appropriate number of meshes such as a wire mesh and a synthetic resin net.
そして、このように有孔支持体に担持させたウェブに高圧水流を付与する。高圧水流は、たとえば孔径０．０５～２．０ｍｍの噴射孔から１０ＭＰａ以下の圧力の水を噴射させて得られるものである。この高圧水流が、有孔支持体に担持されたウェブに衝突すると、高圧水流のエネルギーがウェブを構成する繊維を運動させるエネルギーとなって繊維相互の交絡が生じる。 Then, a high-pressure water flow is applied to the web supported on the perforated support in this way. The high-pressure water flow is obtained by injecting water having a pressure of 10 MPa or less from, for example, an injection hole having a hole diameter of 0.05 to 2.0 mm. When this high-pressure water flow collides with the web supported on the perforated support, the energy of the high-pressure water flow becomes the energy for moving the fibers constituting the web, and the fibers are entangled with each other.
高圧水流は、通常は複数段すなわち複数のステージに分けて付与される。高圧水流に用いる液体としては、水資源を節約する観点から、一度使用した処理水を循環させて再利用する。本発明においては、循環させた水に殺菌処理を施した水を使用する。殺菌処理した水としては、例えば循環水に次亜塩素酸ナトリウムを０．１～０．３ｐｐｍ程度添加したものを用いることができる。循環水以外の水たとえば地下水や河川水などを同様に殺菌処理したものを用いることもできる。
このように殺菌処理した水を用いて高圧水流処理を施すことによって、殺菌処理された不織布を得ることができる。
The high-pressure water flow is usually applied in multiple stages, that is, in a plurality of stages. As the liquid used for the high-pressure water flow, the treated water once used is circulated and reused from the viewpoint of saving water resources. In the present invention, sterilized water is used after circulating water. As the sterilized water, for example, circulating water to which sodium hypochlorite is added in an amount of about 0.1 to 0.3 ppm can be used. Water other than circulating water, for example, groundwater or river water that has been sterilized in the same manner can also be used.
By performing a high-pressure water flow treatment using the water sterilized in this way, a sterilized nonwoven fabric can be obtained.
あるいは、上記に加えて、最終段の高圧水流処理を、循環水では無い、水源から直接供給され殺菌処理された水を用いて、行うこともできる。この場合は、循環水を用いるよりも、製造後の不織布に存在する細菌数を減らす効果を得ることができる。 Alternatively, in addition to the above, the high-pressure water flow treatment in the final stage can be performed using water directly supplied from the water source and sterilized, which is not circulating water. In this case, it is possible to obtain the effect of reducing the number of bacteria present in the non-woven fabric after production, as compared with the case of using circulating water.
高圧水流処理が終わった対象物は、マングルなどの脱水装置によって脱水処理を行い、その後に高温での乾燥処理を行う。高温での乾燥処理によって、さらに確実な殺菌効果を得ることができる。乾燥処理は、たとえば対象物を熱風乾燥機に通すことによって行うことができる。そのときの処理温度、すなわち熱風乾燥機を用いる場合はその設定温度は、１２０～１５０℃とすることが好適である。乾燥前の対象物は湿潤状態にあるため、これを高温で乾燥処理すると、湿熱状態での処理となるので、十分な殺菌効果を得ることができる。処理温度が１２０℃未満であると一般細菌を効果的に殺菌することが困難である。反対に処理温度が１５０℃を超えると、生産上のエネルギーコストが増大してしまう。このため、より好ましい乾燥温度範囲は１３０～１４５℃である。この範囲であると、不織布の目付や生産速度などの生産銘柄に影響を及ぼすことなしに、殺菌状態の不織布を得ることができる。 The object that has been subjected to the high-pressure water flow treatment is dehydrated by a dehydrating device such as a mangle, and then dried at a high temperature. A more reliable bactericidal effect can be obtained by the drying treatment at a high temperature. The drying process can be performed, for example, by passing the object through a hot air dryer. The processing temperature at that time, that is, when a hot air dryer is used, the set temperature is preferably 120 to 150 ° C. Since the object before drying is in a wet state, if it is dried at a high temperature, it will be treated in a moist heat state, so that a sufficient bactericidal effect can be obtained. If the treatment temperature is less than 120 ° C., it is difficult to effectively sterilize general bacteria. On the contrary, if the processing temperature exceeds 150 ° C., the energy cost in production increases. Therefore, a more preferable drying temperature range is 130 to 145 ° C. Within this range, a sterilized nonwoven fabric can be obtained without affecting the production brand such as the basis weight and production speed of the nonwoven fabric.
乾燥処理のための時間は、１分～３分が適当である。最小時間よりも短い場合は、上記の適正範囲に温度設定しても十分な殺菌効果が得られない。反対に最大時間よりも長くすると、生産速度が遅くなり、生産性が悪くなってしまい、コスト高となり無駄である。 The time for the drying treatment is preferably 1 to 3 minutes. If the time is shorter than the minimum time, a sufficient bactericidal effect cannot be obtained even if the temperature is set within the above-mentioned appropriate range. On the contrary, if it is longer than the maximum time, the production speed becomes slow, the productivity deteriorates, the cost becomes high, and it is wasteful.
すなわち本発明によれば、殺菌処理した水を用いて高圧水流処理を施すとともに、その後に１２０～１５０℃という高温での乾燥処理を施すことによって、あるいは、水源から直接供給され殺菌処理された水を用いて最終段の高圧水流処理を施すとともに、その後に同様に１２０～１５０℃という高温での乾燥処理を施すことによって、用途として湿潤状態で用いた場合であっても菌数の少ないスパンレース不織布を得ることができる。乾燥処理後の不織布は、殺菌状態を維持するために、その水分率が８質量％以下であることが好適である。７質量％以下であることが特に好ましい。なお、水分率の下限は、殺菌状態維持の点では、小さいほどよいが、このような低水分率のスパンレース不織布を得るための製造工程管理を考慮すれば、下限は４質量％程度が好ましい。この点から、下限が５質量％であることが、より好ましい。水分率はＪＩＳ Ｋ ００６８：２００１、「化学製品の水分測定方法」の、「７.乾燥減量法」に基づき測定されるものである。なお、同規格では、乾燥温度が１０５±２℃と規定されているが、本明細書に記載の水分率は、乾燥温度を１１０℃に変更して測定されるものである。乾燥温度を変更する理由は、早期の乾燥を実現するためである。 That is, according to the present invention, water subjected to high-pressure water flow treatment using sterilized water and then dried at a high temperature of 120 to 150 ° C., or water directly supplied from a water source and sterilized. By applying high-pressure water flow treatment in the final stage and then drying at a high temperature of 120 to 150 ° C, the spunlace has a small number of bacteria even when used in a wet state. A non-woven fabric can be obtained. In order to maintain the sterilized state, the non-woven fabric after the drying treatment preferably has a water content of 8% by mass or less. It is particularly preferable that it is 7% by mass or less. The lower limit of the water content may be smaller in terms of maintaining the sterilized state, but the lower limit is preferably about 4% by mass in consideration of the manufacturing process control for obtaining such a spunlace nonwoven fabric having a low water content. .. From this point, it is more preferable that the lower limit is 5% by mass. The water content is measured based on "7. Dry weight loss method" of JIS K 0068: 2001, "Method of measuring water content of chemical products". Although the drying temperature is specified as 105 ± 2 ° C. in the same standard, the moisture content described in the present specification is measured by changing the drying temperature to 110 ° C. The reason for changing the drying temperature is to realize early drying.
なお、水源からの水を用いた高圧水流処理は、最終段の処理のみに限られるものではなく、それよりも前段において同様の処理を施すことも可能である。すなわち、少なくとも最終段において当該処理を施せば足りる。 The high-pressure water flow treatment using water from the water source is not limited to the treatment in the final stage, and the same treatment can be performed in the previous stage. That is, it is sufficient to perform the treatment at least in the final stage.
このようにすることで、良好に殺菌処理されたスパンレース不織布、たとえば一般細菌数（平均）が５０ＣＦＵ／ｇ以下の不織布を得ることができる。一般細菌数（平均）は、４０ＣＦＵ／ｇ以下であることが好ましく、より好ましくは３０ＣＦＵ／ｇ以下、さらには２０ＣＦＵ／ｇ以下であることが好ましい。 By doing so, it is possible to obtain a spunlace nonwoven fabric that has been sterilized well, for example, a nonwoven fabric having a general bacterial count (average) of 50 CFU / g or less. The number of general bacteria (average) is preferably 40 CFU / g or less, more preferably 30 CFU / g or less, and further preferably 20 CFU / g or less.
本発明において、一般細菌数（平均）は、次の手法により測定する。すなわち、供試コットンスパンレース不織布を１グラム準備し、この不織布を５ｍｍ角以下の大きさとなるように細かく裁断したうえで、リン酸緩衝生理食塩水２０ミリリットルを加えて混合する。得られた混合液１ミリリットルずつをシャーレ（３枚）にそれぞれ採取し、これに標準寒天培地を２０ミリリットル加え、温度３５℃で４８時間培養した後に、それぞれのシャーレ内のコロニー数を計測する。計測した値から、スパンレース不織布１グラム当たりのコロニー数を算出し、その平均値を一般細菌数（平均）（ＣＦＵ／ｇ）とする。 In the present invention, the number of general bacteria (average) is measured by the following method. That is, 1 gram of the test cotton spunlace non-woven fabric is prepared, the non-woven fabric is cut into small pieces so as to have a size of 5 mm square or less, and then 20 ml of phosphate buffered saline is added and mixed. Each 1 ml of the obtained mixed solution is collected in a petri dish (3 sheets), 20 ml of a standard agar medium is added thereto, and the cells are cultured at a temperature of 35 ° C. for 48 hours, and then the number of colonies in each petri dish is measured. From the measured values, the number of colonies per gram of spunlace nonwoven fabric is calculated, and the average value is taken as the general bacterial count (average) (CFU / g).
（実施例１）
セルロース繊維として、単繊維繊度１．７ｄｔｅｘ、平均繊維長２５ｍｍの木綿繊維を準備し、これをランダムカード機にて開繊し、約１００ｇ／ｍ２の不織ウェブを得た。得られた不織ウェブを、移動式のプラスチック製織物からなる有孔支持体（１８メッシュ）に載置し、不織ウェブに対して、高圧水流噴射装置（噴射孔のノズル孔径が０．１３ｍｍ、噴射孔間隔が０．６ｍｍ）を用いて、一方の面側（表面）に、噴射圧力２ＭＰａにて１回、噴射圧力５ＭＰａにて１回の高圧水流処理を施した。その後、不織ウェブを反転させて他方の面（裏面）に、噴射圧力４ＭＰａにて１回、噴射圧力５ＭＰａにて１回の高圧水流処理を施した。その後、さらに反転させて、表面側に噴射圧力７ＭＰａにて１回の高圧水流処理を施した。この合計５回の高圧水流処理において使用した水は、不織布の製造工場で普通に用いられている循環水であって、高圧水流処理への使用に際し次亜塩素酸ナトリウム０．１ｐｐｍ添加により殺菌処理を施した。
(Example 1)
As the cellulose fibers, cotton fibers having a single fiber fineness of 1.7 dtex and an average fiber length of 25 mm were prepared and opened with a random card machine to obtain a non-woven web of about 100 g / m 2 . The obtained non-woven web was placed on a perforated support (18 mesh) made of a mobile plastic woven fabric, and a high-pressure water flow injection device (nozzle hole diameter of the injection hole was 0.13 mm) was placed on the non-woven web. , Injection hole spacing is 0.6 mm), and one surface side (surface) was subjected to high-pressure water flow treatment once at an injection pressure of 2 MPa and once at an injection pressure of 5 MPa. Then, the non-woven web was inverted and the other surface (back surface) was subjected to high-pressure water flow treatment once at an injection pressure of 4 MPa and once at an injection pressure of 5 MPa. Then, it was further inverted, and the surface side was subjected to one high-pressure water flow treatment at an injection pressure of 7 MPa. The water used in this total of 5 high-pressure water flow treatments is circulating water normally used in non-woven fabric manufacturing plants, and is sterilized by adding 0.1 ppm of sodium hypochlorite when used for high-pressure water flow treatment. Was given.
上記の高圧水流処理を施した不織ウェブは、マングルロールに通すことにより不織ウェブが含んでなる余剰水分を絞って除去し、次いで、１４５℃の温度で乾燥処理を施し、水分率５質量％のセルロース不織布を得た。 The non-woven web subjected to the above-mentioned high-pressure water flow treatment is passed through a mangle roll to squeeze and remove excess water contained in the non-woven web, and then dried at a temperature of 145 ° C. to have a moisture content of 5 mass. % Cellulose non-woven fabric was obtained.
得られたセルロース不織布の一般細菌数（平均値）は、４０ＣＦＵ／ｇであった。 The general bacterial count (average value) of the obtained cellulose non-woven fabric was 40 CFU / g.
（実施例２）
実施例１と比べて、高圧水流処理において、表面および裏面より合計５回の高圧水流処理を施した後、さらに、表面より、噴射圧力５ＭＰａにて１回の高圧水流処理を施した点を変更した。そして、それ以外は実施例１と同様にして、実施例２のセルロース不織布を得た。その水分率は、５質量％であった。なお、最後（６回目）に施した高圧水流処理に用いた水は、循環水ではなく、水源からの直接供給水であって、次亜塩素酸ナトリウム０．１ｐｐｍ添加により殺菌処理した水とした。
(Example 2)
Compared to Example 1, in the high-pressure water flow treatment, a total of 5 high-pressure water flow treatments were performed from the front surface and the back surface, and then one high-pressure water flow treatment was performed from the front surface at an injection pressure of 5 MPa. did. Then, the cellulose non-woven fabric of Example 2 was obtained in the same manner as in Example 1 except for the above. The water content was 5% by mass. The water used for the last (sixth) high-pressure water flow treatment was not circulating water but water directly supplied from the water source and was sterilized by adding 0.1 ppm of sodium hypochlorite. ..
得られたセルロース不織布の一般細菌数（平均値）は、２０ＣＦＵ／ｇであった。 The general bacterial count (average value) of the obtained cellulose non-woven fabric was 20 CFU / g.
（比較例１）
実施例１と比べて、高圧水流処理において、次亜塩素酸ナトリウムを添加せず殺菌処理を施していない循環水を用いた点を変更した。そして、それ以外は実施例１と同様にして、セルロース不織布を得た。その水分率は、５質量％であった。
(Comparative Example 1)
Compared with Example 1, in the high-pressure water flow treatment, the point that circulating water without addition of sodium hypochlorite and sterilization treatment was used was changed. Then, a cellulose non-woven fabric was obtained in the same manner as in Example 1 except for the above. The water content was 5% by mass.
得られたセルロース不織布の一般細菌数（平均値）は、６７ＣＦＵ／ｇであった。なお、一般細菌数測定において、３つのシャーレサンプルの値はバラツキがあり、ひとつのサンプルは１５０ＣＦＵ／ｇを超えるものもあった。 The general bacterial count (average value) of the obtained cellulose non-woven fabric was 67 CFU / g. In the general bacterial count measurement, the values of the three Petri dishes varied, and one sample exceeded 150 CFU / g.
（比較例２）
実施例１と比べて、高圧水流処理後の乾燥処理の温度を９０℃に設定した点を変更した。そして、それ以外は実施例１と同様にして、セルロース不織布を得た。その水分率は、９質量％であった。
(Comparative Example 2)
Compared with Example 1, the point that the temperature of the drying treatment after the high-pressure water flow treatment was set to 90 ° C. was changed. Then, a cellulose non-woven fabric was obtained in the same manner as in Example 1 except for the above. The water content was 9% by mass.
得られたセルロース不織布の一般細菌数（平均値）は、３２０ＣＦＵ／ｇであった。 The general bacterial count (average value) of the obtained cellulose non-woven fabric was 320 CFU / g.
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