JPH08226064A - Tubular formed article and its production - Google Patents

Abstract

PURPOSE: To obtain a tubular formed article having excellent filtration performance, pressure resistance and water-permeability and suitable as a filter or a draining material by winding a spun-bonded web composed of a multi-component conjugate filament around a core while heating the web above the heat-welding temperature of the web. CONSTITUTION: A conjugate spun-bonded web composed of two components having a fineness of 0.2-300d/f or 17-70,000d/f and the maximum/minimum fineness ratio of >=1.5 is produced by the conjugate spinning of 10-90wt.% of a low-melting resin component selected from polyethylene, a crystalline copolymer of α-olefins such as propylene and butene-1 and a low-melting polyester and 90-10wt.% of a high-melting resin component (the melting point difference between the low-melting resin and the high-melting resin is >=10 deg.C) such as polypropylene or polyethylene terephthalate in such a manner as to form at least a part of the fiber surface with the low-melting resin component and taking-up the spun fiber through an air sucker at a take-up speed of 500-20,000m/min under quenching at a rate of 0.1-5m/sec. The web or the web and other fibers such as polyamide are laminated or mixed in layers and the formed web is wound around a core under heating at or above the welding temperature of the low-melting component to obtain the objective tubular formed article.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a tubular molded body and a method for manufacturing the same. More specifically, long fibers are spun by the composite spunbond method, and the fibers are heat-sealed to form a tubular shape.
The present invention relates to a molded body suitable for a filter, a drain material, etc., and a method for manufacturing the molded body.

[0002]

2. Description of the Related Art Cylindrical moldings using heat-fusible fibers have characteristics such as excellent filtering performance, hardness and light weight, and are used as cartridge filters and drain materials. . Conventionally, as a tubular molded body of this type, a product obtained by forming a parallel type heat-fusible composite fiber staple into a web by a card method and winding the web around a core while heating the web (Japanese Patent Publication No. No. 56-43139) or a heat-fusible multi-division composite fiber staple, which is formed into a non-woven fabric, and the non-woven fabric is wound on a porous core (JP-A-4-108506, JP-A-6-108506).
No. 091105) is known.

However, the manufacturing process of the cylindrical molded body disclosed in the above Japanese Patent Publication No. 56-43139 is very complicated. That is, the fiber once composite-spun is drawn and crimpered.
After crimping by the above, drying of the fiber, cutting with a cutter, etc., to form a short fiber so-called staple, this staple is subjected to a carding process, etc., and formed into a tubular shape while heating the web. Since it is manufactured by winding, the productivity is extremely low. Moreover, such a composite fiber is usually attached with an oil agent for improving the card passage property and the staple opening property during spinning. Therefore, when this tubular molded product is used as a filter or the like, there is a problem that the oil agent foams at the time of filtration, or the oil agent is mixed in the filtrate, and its use is limited in the fields of food, drinking water, chemicals, etc. It was Further, since this tubular molded body uses staples, the inside and the surface of the fiber layer of the tubular molded body are easily fluffed. This fluff has the effect of easily trapping particles during filtration, but on the other hand,
When used once and then reused by so-called back washing or the like, there is a problem that the captured particles are difficult to remove and cannot be reused. Further, when the fibers having a large fineness are used, the composite fibers are easily delaminated during carding, and fibril-like fibers are easily generated. At the time of carding, the fibril-like fibers are cut to form a powdery substance, which is mixed with the web and the environment is disturbed. Also, this powdery substance is deposited in various units such as a card machine, a heating machine, and a molding machine, and solidifies into a lump or a block,
Easy to fall and mix on the web. Therefore, such a station
The object using pull has a problem that the filtration accuracy varies, that is, the stability of the filtration accuracy is poor.

Further, the tubular molded body using the splittable composite fiber staple requires a spinneret having a special structure, and further has a needle punch or water-needle process for splitting. Extra steps are required. Therefore, productivity is extremely low and expensive. Further, since staples are used, there is a problem due to an oil agent, fluff, etc., as described above. Since this splittable conjugate fiber is designed to be easily split into three or more splits by the impact of a needle punch, a water needle, a card, etc. Even if a fine fiber having a fineness of about 1 d / f or less is used, a part of the composite fiber is divided at the time of carding, and a fibril-like substance is likely to be generated. It is easy to form a lump-shaped fiber in which the fibril-like single fibers are entangled with each other or a powdered substance of the separated fiber. Further, a large amount of undivided fibers having a large fineness are mixed. Further, a needle punch for dividing and a needle hole by a water needle can be formed. Therefore, there is a problem that the filtration accuracy, the stability of the filtration accuracy, and the like are inferior even if the single fiber after division is a fine fiber.

Japanese Patent Laid-Open No. 2-14582 discloses a sheath-core type composite spunbond heat-bonding nonwoven fabric in which the sheath component is polypropylene and the core component is polyethylene terephthalate, and in Japanese Patent Laid-Open Publication No. 5-263353. A sheath-core type composite spunbonded non-woven fabric having a high density polyethylene as a component and an ethylene / propylene random copolymer as a core component is disclosed. Further, in JP-A-2-182963, polymers having different heat shrinkability are spun by a composite spunbond method with a parallel type, an eccentric sheath core type, etc., and the web is ultrasonically bonded to obtain latent crimp and heat shrinkability. Certain non-woven fabrics are disclosed. The composite spunbonded nonwoven fabric composed of two components having different melting points has advantages such as high productivity and high nonwoven fabric strength. Therefore, it is said that it is suitable for use as a surface material for disposable diapers and various packaging materials. However, there is no suggestion of application to a tubular molded body in the above-mentioned patent application.

[0006]

The object of the present invention is to solve the above-mentioned problems, to improve productivity and drainage of underground water.
It is intended to provide a tubular molded body having no filtration performance such as filtration accuracy, filtration accuracy stability, filtration life, pressure resistance, and the like, and a manufacturing method thereof. Another object is to provide a tubular molded body which can be easily washed after being used as a filter and, in some cases, can be reused.

[0007]

The present invention provides the following (1) to
(20). (1) Wrapped by a multi-component composite spunbond continuous fiber composed of at least two components of a low melting point resin component and a high melting point resin component having a melting point difference of 10 ° C. or more, and heat fusion bonding with the low melting point resin component Tubular molded product. (2) The multi-component composite spunbond continuous fiber comprises 10 to 90% by weight of a low melting point resin component and 90 to 10% by weight of a high melting point resin component, and the low melting point resin component forms at least a part of the surface of the fiber. The cylindrical molded body according to item (1), characterized in that (3) The multi-component composite spunbond filament having a fineness ratio of maximum to minimum of 1.5 or more is used and arranged along the thickness direction of the tubular molded body. Cylindrical molded body. (4) The filtration accuracy dispersion index is 0.7 or less (1) to
The cylindrical molded body according to any one of (3). (5) The tubular molded article according to any one of (1) to (3), in which other fibers are laminated or mixed with the composite spunbond continuous fibers. (6) The fineness of the multi-component composite spunbond filament is 0.2 to 7
The cylindrical molded body according to any one of the items (1) to (3), which has a durometer of 10,000 d / f. (7) The low melting point resin component is a resin selected from polyethylene, a crystalline copolymer of propylene and another α-olefin, or a low melting point polyester, and the high melting point resin component is polypropylene (1) to The cylindrical molded body according to any one of (3). (8) Low melting point resin is polyethylene, propylene and other α
-Cylinder according to any one of items (1) to (3), which is a resin selected from a crystalline copolymer with olefin and a low melting point polyester, and the high melting point resin component is polyethylene terephthalate. Shaped body. (9) The cylindrical molded body according to any one of the items (1) to (3), wherein either the surface or the inside of the cylindrical molded body is molded in an uneven shape. (10) Multi-component composite spun bond method with melting point difference of 10 ° C.
A composite continuous fiber composed of at least two kinds of components having a low melting point resin component and a high melting point resin component is spun into a web,
A method for producing a tubular molded body, which comprises winding the web around a core while heating the web to a fusion temperature of a low-melting resin or higher and heat-sealing the composite long fibers. (11) The multi-component composite spunbond continuous fiber comprises 10 to 90% by weight of a low melting point resin component and 90 to 10% by weight of a high melting point resin component, and the low melting point resin component forms at least a part of the surface of the fiber. The method for producing a tubular molded body according to item (10), characterized in that (12) A web in which the ratio of the maximum and the minimum of the fineness of the same fibers of the composite long fibers is 1.5 or more is produced by spinning while changing either the extrusion amount of the composite fibers or the take-up speed during spinning. , The web is wound around a core while being heated to a fusion temperature or higher, and the low melting point resin of the long fibers is heat-fused to obtain a fineness of 1.5 times or more along the thickness direction of the tubular molded body. The method for producing a tubular molded body according to item (10) or (11), characterized in that changing long fibers are arranged. (13) The composite fiber after spinning is introduced into an air sucker-type traction device while being quenched at a wind speed of 0.1 to 5 m / sec, and spun at a speed of 500 to 20,000 m / min in a high-speed air flow to obtain the fineness of long fibers. Is set to 0.2 to 100 d / f (10) to
(12) A method for producing a tubular molded body according to any one of items. (14) Spinning is performed by its own weight at the time of spinning or by a take-up roll, and the composite fiber is spun without quenching or while quenching during spinning, and the fineness of the long fiber is 30 to 70,000 d / f (10) to The manufacturing method according to any one of (12). (15) From the spinning to the production of the tubular molded body,
The method for producing a tubular molded body according to any one of (10) to (12), which comprises stretching 1.2 to 9 times. (16) The low melting point resin component is a resin selected from polyethylene, a crystalline copolymer of propylene and other α-olefin, and a low melting point polyester, and the high melting point resin component is polypropylene or polyethylene terephthalate ( The method for producing a tubular molded body according to any one of items 10) to 12). (17) From the spinning to the production of the tubular molded body,
The method for producing a tubular molded article according to any one of items (10) to (12), which comprises laminating other fibers in a layered manner with a composite spunbond long-fiber web or mixing with the composite spunbond long-fiber web. . (18) When a tubular molded body is molded, a roll with a mold is brought into contact with the web or the tubular molded body to make the surface or the inside of the molded body uneven, (10) to (12). The method for producing a tubular molded body according to any one of claims. (19) A filter using the tubular molded body according to any one of (1) to (3). (20) A drain material using the tubular molded body according to any one of (1) to (3).

The web used in the tubular molded body of the present invention is
A multi-component composite spunbond continuous fiber web. The long fibers are fibers in which at least two kinds of resin components having melting points of 10 ° C. or more are composite-spun by a composite spunbond method. When the difference in melting point is less than 10 ° C., it is difficult to control the temperature in the heat treatment described later, heat fusion of the web is insufficient, and a molded article having high hardness cannot be obtained. A wrinkle is generated due to abnormal shrinkage of the web or the nonwoven fabric, so that a tubular molded body having good filtering performance and uniform filtering material cannot be obtained. Practically, about 2 to 4 kinds of resins can be used as the resin component, and the difference between the highest melting point and the lowest melting point is 1
It may be 0 ° C or higher. However, for most applications two are sufficient. The low melting point resin component may form a part of the fiber surface of the composite long fiber. As the composite fiber, a sheath-core type, an eccentric sheath-core type, a parallel type, a sea-island type fiber or the like can be used.

In the composite long fiber, the composite ratio of the low melting point resin component and the high melting point resin component is 10 to 90 for the low melting point resin component.
%, And the high melting point resin component is 90 to 10% by weight. When the low-melting point resin component is less than 10%, the heat treatment during molding into a tubular shape causes insufficient heat fusion, resulting in insufficient hardness of the tubular molded body, resulting in poor pressure resistance. It also becomes fluffy. Therefore, when the molded product is used as a filter, the filter layer is likely to open due to pressure and vibration during filtration and the filtration accuracy is poor. When used as a drain material, it is easily deformed. When the low melting point resin component of the composite long fiber exceeds 90% by weight, the low melting point resin component is melted by the heat treatment for forming into a tubular shape, and the web becomes a film to block the pores of the tubular shaped body. In addition, wrinkles are generated or deformed in the molded body due to shrinkage during heating and melting. Further, in order to stably avoid the above-mentioned drawbacks, the weight ratio of low melting point resin / high melting point resin is 30.
The range of / 70 to 70/30 is more preferable. The fineness of the long fibers varies depending on the intended use of the tubular molded body, but in the case of a filter, it is about 0.2 to about 10,000 d /
f, in the case of a drain material, it is about 3 to about 70,000 d / f. The basis weight of the web or the non-woven fabric is not particularly limited, but it is about 4 to 2,000 g / m @ 2 from the viewpoint of ease of heat fusion when heating the tubular molded body.

The resin component used in the present invention includes polyamides, polyethylene terephthalate, polybutylene terephthalate, low melting point polyesters obtained by copolymerizing diol with terephthalic acid / isophthalic acid, polyester elastomers, etc. Polyester, polypropylene, high density polyethylene, medium density polyethylene, low density polyethylene,
Linear low density polyethylene, polyolefins such as crystalline 2 or 3 terpolymers of propylene and other α-olefin, fluororesins, mixtures of the above resins, and other melt-spinnable resins can be used.

The combination of the composite spinning is such that the melting point difference is 10 ° C. or more. For example, high density polyethylene / polypropylene, low density polyethylene / propylene / ethylene / butene-1 crystalline copolymer, high density polyethylene / polyethylene terephthalate, nylon-6 /
Examples thereof include nylon 66, low melting point polyester / polyethylene terephthalate, polypropylene / polyethylene terephthalate, and polyvinylidene fluoride / polyethylene terephthalate. A mixture of linear low density polyethylene and high density polyethylene / polypropylene, etc. can also be used. Furthermore, high density polyethylene / polypropylene, low density polyethylene / propylene / ethylene / butene-1 crystalline copolymer, high density polyethylene / polyethylene terephthalate, low melting point polyester / polyethylene terephthalate, polypropylene / polyethylene terephthalate A combination of polyolefin / polyolefin, polyolefin / polyester, polyester / polyester such as -G, etc. is preferable, and a combination of polyolefin / polyolefin is particularly preferable in view of chemical resistance.

The composite spunbond method is a method in which a plurality of resin components are melt-extruded from a plurality of extruders, a multicomponent fiber is spun from a spinneret for composite spinning, and the spun fiber is pulled by an air stream such as an air sucker. A non-heat-bonded web or a heat-bonded non-woven fabric by collecting the fibers with a web collecting device such as a net conveyer together with the air flow, and then subjecting the web to a bonding process if necessary. It is a manufacturing method such as. In the present invention, when a fine fiber is targeted, a high-pressure air stream is introduced for spinning, but when a fine fiber is targeted, the air flow may be stopped to perform spinning. That is, it may be spun by its own weight substantially during spinning. Alternatively, it may be taken up by a take-up roll or a pinch roll. Further, two or more sets of the air flow towing type device may be provided before and after the take-up roll or the like. The preferred range of fineness of the multi-component composite spunbond continuous fibers used in the present invention is 0.2 to 70,000 d / f. The spinning speed for producing such fibers may be any speed that meets the required fineness. Fineness is about 0.2-300d /
For f, preferably 0.5-100 d / f, the spinning speed is about 500-20000 m / min. The fineness is about 17
~ 70,000 d / f, preferably 30 to 60,000 d / f
In the case of f, the suction of the air sucker may be almost stopped and the spinning may be carried out by its own weight, or the spinning may be carried out by a take-up roll. Also, the high speed airflow traction device may be located after the take-up roll, or may be substantially absent for low speed spinning.
As the spinneret, a spinneret type, a parallel type, a sea-island type, an eccentric sheath-core type spinneret can be used. A plurality of the caps and the air cleaner may be provided.

It is also possible to use an apparatus equipped with a drawing roll, a pinch roll, or an air flow type drawing apparatus for drawing the fiber after spinning. This drawing device is used to spin air from the spinneret.
Between the air cleaner and the net conveyor.
It may be provided at a position between the molding machines and a position between the net conveyor and the molding machine. Of course, it may be provided in a plurality of places. When a stretching device is used, the strength of the fibers and the non-woven fabric is improved, and the pressure resistance and compression degree of the obtained tubular molded product are improved. Also, stretching causes three-dimensional crimping,
The microporous property of the tubular molded body is improved. Further, a device in which a heating device is incorporated in any part from the base to various devices may be used. A device incorporating a heating device can be used as a heat-bonded non-woven fabric or can develop crimps by appropriately setting heating conditions. In the present invention,
It is also possible to use a device in which another collection assisting device is incorporated at a position between the spinneret and the molding device. Examples of the auxiliary device include devices such as a yarn quench device, a needle punching device, and a water entanglement device. In the case of a quenching device, gas, water, etc. can be used. The needle punching device, the hydroentangling device, and the like may be in a different system from the spinning.

As an example of incorporating a stretching device, various devices can be exemplified. For example, a device in which a plurality of drawing rolls are installed at a position between the spinneret and the air flow type traction device,
The spun fiber is collected between a pair of rotating pinch rolls having a temporary collecting function, and stretched while sandwiching the web between the pair of pinch rolls provided at the bottom of the spun fiber. An example is a device that collects the web on a provided net conveyor. The pinch roll or the like having the temporary collecting function is a metal roll having a large number of holes for discharging the blown gas, or an object having a function of being caught by a pair of net-shaped rotating bodies. , A plurality of stretching rolls, and the like. The roll or the like having the temporary collecting function may be an apparatus having a pair of upper and lower sides and having a stretching function and other functions such as heating. or,
The web once collected by a collecting device such as a net conveyor may be applied to a stretching device or the like in which a roll, a net conveyor and the like are combined. Further, after spinning, the air flow blown together with the web is usually removed by a suction removing device. Needless to say, when spinning is carried out by its own weight or at a low speed without using an air flow, this is not necessary.

The tubular molded article of the present invention can be obtained by molding the web and / or the heat-bonded non-woven fabric collected by the spinning method into a tubular shape. As such an apparatus, it is possible to manufacture using a tubular molded body manufacturing apparatus or the like that includes a heater, a cylindrical molding machine, and the like as main constituent members. For example, a winding type molding apparatus or a manufacturing method provided with an infrared heater and a metal core as described in JP-B-56-43139 can be used. The heating device is an air-heater, an infrared heating device,
Either a heating roll or a heating embossing roll can be used.
Further, as the tubular molding machine, any of a type in which a metal core is extracted after molding and a state in which a metal core is wound around a porous core and a core is present can be used. In the tubular molded product of the present invention, the spunbond spinning and the tubular molding may be performed by a continuous method, or the spunbond spinning and the tubular molding may be separately performed. In the case of the continuous method, a device equipped with a heating machine, a core winding type molding machine or the like may be used on the downstream side of the web collecting device such as the net conveyor. In the case of the discontinuous method, once spun,
Using an apparatus equipped with a non-heat-bonded web, a heat-bonded non-woven fabric, etc., such as a heating device and a core winding type molding machine, the spinning and cutting are separated,
It may be molded. Immediately after the winding or during winding, a concavo-convex shape may be imparted to the surface or the inside of the tubular molded body by a method of contact-rotating a metal roll or the like having irregularities engraved on the surface. . In this case, the surface area of the molded body becomes large, or a bypass path is formed inside the molded body to improve the filtration life.

Using the above-mentioned tubular molding device, while heating at a temperature above the melting point of the low-melting point resin component of the composite fiber and below the melting point of the high-melting point resin component, it is wound around the core and the low melting point resin component is fused. Thus, the intersections of the fibers are heat-sealed to form a tubular shape.
After cooling, the core may be removed, and if necessary, the end face may be subjected to an end face seal treatment by a heat fusion method, a hot melt method, a binder method, or adhesion to a film or a metal plate by the above method.

The tubular molded article of the present invention may have the same or different fineness in the thickness direction. When the fineness is different, for example, the fineness becomes large to small along the flow direction of the fluid to be filtered, or the fineness becomes large, small, large, etc., the filtering accuracy, the filtering life, Any or all of pressure resistance and the like are good. In order to further improve the filtration performance, the fineness is set to a ratio of maximum fineness / minimum fineness of 1.5 or more,
It is preferably 1.8 or more. In the case where the fineness is changed, the take-up speed is constant during the spinning time corresponding to one tubular molded body during spinning, and the extrusion amount from the spinneret is changed from large to small in order of large, medium and small as the spinning time elapses. It can be produced by a method such as changing the order of the above, or by making the extrusion rate constant and changing the take-up speed as described above.

In the present invention, other fibers may be laminated or mixed together with the composite spunbond long-fiber web on the tubular molded body. As the other fiber, a fiber having a fineness, a resin or the like different from that of the composite long fiber can be used. For example, polyamide fibers, activated carbon fibers, polyester fibers, regular fibers such as rayon, and monofilaments having a large fineness can be exemplified. By laminating other fibers, it is possible to improve gas adsorbability, filtration accuracy, hardness of the molded body, and the like. Examples of the other fiber include a web, a monofilament, a woven / knitted fabric, a non-woven fabric, a net, and monofilament-like pieces that have been separated.
For example, when a sheet for a membrane filter having a fiber diameter of 0.1 to 8 μm is laminated, the filtration accuracy is improved.
Further, a laminate of a non-woven fabric or a woven fabric containing carbon fiber has a gas adsorbing property. Other fibers may be supplied from a device different from the composite spinning device during or after spinning the composite spunbond continuous fiber. For example, at the time of spinning, a method of supplying other fibers together with air from the spinning direction and the oblique direction of the long fibers, a method of laminating other fibers on the long fiber web collected on a net conveyor after spinning, etc. It is possible with. Further, in the present application, the mixing amount of other fibers is not particularly limited, but it may be about 1 to 50% by weight from the viewpoint of hardness of the tubular molded body, filtration accuracy and the like.

The filter and drain material of the present invention using the tubular molded product of the present invention showed good practical characteristics, which are shown in detail in the examples.

[0020]

The present invention will be described in more detail with reference to Examples and Comparative Examples. In each example, the physical properties of the tubular molded body, the filtration performance, and the like are evaluated by the methods described below. (Filtration Accuracy) A circulating filtration tester including a water tank containing 30 liters of water, a pump, and a filter provided with a housing was used. One filter medium is attached to the housing of the filter, and 5 g of a predetermined cake is added to the water tank while circulating water at a flow rate of 30 liters per minute. 100 cc of filtered water collected 1 minute after the cake was added to the membrane filter.
Filter through. The size of the particles captured on the membrane filter is measured by a particle size distribution analyzer, and the size of the largest particle is measured (μm). The same measurement was performed on five filter media, and the average of the maximum values was used as the filtration accuracy (μ
m).

(Filtration Accuracy Dispersion Index) From the data of the maximum particle diameters of five particles measured in the filtration accuracy test, it was calculated by the following formula. When the filtration accuracy dispersion index is 0.7 or less,
It was judged that there was little variation in filtration accuracy. Filtration accuracy dispersion index = (A−B) / XX: average value (μm) of the maximum particle diameter of each of the five filter media. A: The particle size (μm) of the particles having the largest maximum particle size among the five filter media. B: The particle size (μm) of the particles having the smallest maximum particle size among the five filter media.

(Filtration Life and Compressive Strength) In the circulation type filtration accuracy test, as a cake, volcanic ash soil (mean particle size: 12.9 microns, particle size: 1.0 to 30 microns: 99% by weight) 20 g of the above) is added, circulation filtration is continued, and when the water in the water tank becomes transparent, the differential pressure before and after filtration is measured. The addition of the powder and the measurement of the differential pressure are repeated until the filter is deformed or the difference between the inlet pressure and the outlet pressure of the filter becomes 10 kg / cm @ 2. The time from the first addition of powder to the deformation of the filter is defined as the filtration life (min), and the pressure difference at that time is the pressure resistance (kg / cm2).
).

(Bubbling) In the filtration accuracy test,
Before adding the cake, only water was circulated for 1 minute, and then the foaming in the water tank was observed. When the bubbling was over the entire surface of the water tank, it was determined that there was bubbling, and when there was almost no bubbling, it was determined that there was no bubbling.

(Example 1) Composite spinning machine, air sucker,
Manufacture a tubular molded body using a composite spunbond spinning device equipped with a net conveyor, etc., and a tubular molding machine equipped with a net conveyor, a far infrared heating machine, a metal core winding type molding machine, etc. did. The spinneret used was a sheath-core type composite spinning spinneret having a hole diameter of 0.4 mm. Melting point 133 as the first component
℃, MFR22 (190 ℃, g / 10 minutes) high density polyethylene is used on the sheath side, the second component is a melting point 164
C., polypropylene of MFR60 (230.degree. C., g / 10 minutes) is used on the core side, and the compounding ratio is 50/50 (wt%), the spinning temperature is the first component, 290.degree. C., the second component is 310.degree. The fibers were spun, the fibers were sucked with an air sucker at a speed of 3,000 m / min, and the fibers were blown together with the air onto a net conveyor. The blown air is a net conveyor.
It was removed by suction with a suction device provided at the bottom. The obtained fiber was a sheath-core type continuous fiber having a fineness of 1.5 d / f. The basis weight was 20 g / m 2. The web is heated at a temperature of 145 ° C. while being transferred to a tubular molding machine with a net conveyer, and wound around a metal core having an outer diameter of 30 mm while being heated,
After having a predetermined outer diameter, it is cooled to 25 ° C., and then the core is extracted and cut to have an inner diameter of 30 mm, an outer diameter of 60 mm, and a length of 250.
A cylindrical filter of mm was obtained. This filter was a hard product with fibers fused together. Table 1 shows the test results of the filtration performance of the tubular filter.

[0025]

[Table 1] This filter had good performance such as filtration accuracy, filtration accuracy dispersion index, and filtration life. The product was free from foaming during filtration. Further, compared with the method using staples shown in Comparative Examples 1 and 2 below, equipment such as a crimper and a cutter are not required, and since spinning and molding are performed by a continuous method, the product can be manufactured with high productivity.

Example 2 A spinning speed of 1,500 m / min was set with an air sucker, other spinning conditions and molding conditions were the same as in Example 1, and the inner diameter was 30 mm and the outer diameter was 60 m.
A cylindrical filter having a length of m and a length of 250 mm was obtained. The fineness of the obtained web was 3 d / f. This filter was a hard product with fibers fused together. Table 1 shows the test results of the filtration performance of the tubular filter. This filter had good properties such as filtration accuracy, filtration accuracy dispersion index, and filtration life, and did not cause foaming during filtration. Further, compared with the method using staples, equipment such as a crimper and a cutter is unnecessary, and since spinning and molding are performed by a continuous method, the productivity is good.

(Comparative Example 1) and (Comparative Example 2) The sheath component is high-density polyethylene, the core component is polypropylene, the composite ratio is 50/50 (wt%), and the fineness is 1.
4 d / f, fiber length 51 mm, crimp number 12 threads / 25 mm staple (Comparative Example 1), and fineness 3.0 d / f, fiber length 51 mm, crimp number 12 threads / 25 mm (Comparative Example 2) Each staple was used to make a carded web having a basis weight of 20 g / m @ 2. This web was transferred to the tubular molding machine described in Example 1, heated at a temperature of 145 ° C., wound around a metal core, cooled, cut, and the like, and a tubular filter-2 of the same size as Example 1 was used. Got seeds. Table 1 shows the test results of the filtration performance of the tubular filter. In this filter, Comparative Example 1 and Comparative Example 2 were both excellent in performance such as filtration accuracy, filtration accuracy dispersion index, and filtration life. However, all of them had foaming during filtration and were judged to be unusable for liquid filtration in the food field.

Comparative Example 3 and Comparative Example 4 Two types of HDPE / PP used in Comparative Examples 1 and 2 above.
The composite fiber was washed with warm water at a temperature of 60 ° C. for 1 hour, and then washed with water to wash off the attached oil agent. After centrifugal dehydration and drying at 105 ° C., a basis weight of 20 was obtained in the same manner as in Comparative Examples 1 and 2.
A carded web of g / m @ 2 was prepared. The uniformity of the web during carding was extremely poor, the openability of the fibers was poor, and a large number of lumpy webs having a diameter of about 3 to 8 cm were mixed. In addition, static electricity was generated strongly during carding, and a cylindrical molded body was molded while the card was occasionally stopped. This web was transferred to the tubular molding machine described in Example 1 above, heated at a temperature of 145 ° C., wound around a metal core, cooled, cut, and the like.
A cylindrical filter-2 type having the same size as the above was obtained. Table 1 shows the test results of the filtration performance of the tubular filter. This filter is used in Comparative Example 3 (fineness 1.4 d / f), Comparative Example 4
Foaming was improved in all of the cases (fineness 3.0 d / f), but the performances such as filtration accuracy and filtration life were worse than those of Examples 1 and 2. Moreover, the filter had a large filtration dispersion index and was inferior in uniformity. The performance of the filter is shown in Table 1.

(Example 3) Using the composite spunbond spinning apparatus of Example 1 and the apparatus for producing a tubular molded body, filters having different fineness in the thickness direction of the filter were molded.
However, instead of the spinneret of Example 1, a parallel type composite spinneret having a hole diameter of 0.4 mm was used. MFR65 as the first component
(G / 10 min, 230 ° C.), melting point 138 ° C. propylene / ethylene / butene-1 random copolymer (ethylene 4.0% by weight, butene 1 4.5% by weight)
MFR75 (230 ° C, g / 10min) and polypropylene with a melting point of 163 ° C are used as components, and the spinning temperature is 29 for each.
Spinning was carried out under the conditions of 0 ° C. and a composite ratio of 50/50 (% by weight). The suction speed of the air sucker is set to the beginning of the filter winding 11
25m / min, middle 2667m / min, end 750m / min, and fineness of 4d / f, 1.7d / f, 6 respectively.
A density gradient type tubular filter having a d / f ratio was obtained. The weight of the web is 20 g / m2 and the heating temperature is 1
It was 48 ° C. This filter has fibers fused by heat,
It was hard. Also, the cylindrical filter has an inner diameter of 30 m.
m, outer diameter 60 mm, and length 250 mm. Table 1 shows the test results of the filtration performance of the tubular filter. This filter had good filtration accuracy and filtration accuracy dispersion index. The product was free from foaming during filtration. Comparative Example 1
Compared with No. 2 and No. 2, equipment such as a crimper and a cutter were not necessary, and since spinning and molding were performed by a continuous method, the product could be manufactured with high productivity.

Example 4 A filter was molded using the composite spunbond spinning apparatus of Example 1 and the apparatus for producing a tubular molded body. However, an apparatus equipped with a drawing roll was used at a position between the spinneret and the air sucker. The apparatus was equipped with a cool air blowing type quench device at a position between the die and the drawing roll. As the spinneret, the parallel spinneret with the same hole diameter of 0.4 mm as in Example 3 was used. The same two kinds of resins as in Example 3 were used, and spinning was performed under the same conditions as in Example 3 with respect to the composite ratio, spinning temperature and the like. Air heater
The fiber before being sucked at was drawn twice by a drawing roll at a temperature of 80 ° C., and the drawn yarn was sucked by an air sucker at a speed of 1500 m / min and sprayed onto a net conveyor. During spinning, the temperature between the spinneret and the drawing roll is 24
Quench with air at 0 ° C. with a wind speed of 0.3 m / sec. The fineness of the fiber was 3.2 d / f, which was slightly larger than the theoretical value because of the slip due to stretching. The basis weight of the web was 21 g / m 2. Temperature of collected web 1
Heated at 50 ℃, inner diameter 30mm, outer diameter 60mm, length 2
A 50 mm tubular filter was obtained. This filter was hard because the fibers were heat-sealed. Table 1 shows the test results of the filtration performance of the tubular filter. This filter
Compared to the product using the staple of Comparative Example 2 having the same fineness as that of the product of this example, the product had better filtration life and pressure resistance. The product was free from foaming during filtration. Further, compared to Comparative Examples 1 and 2, equipment such as a crimper and a cutter are not required, and since spinning and molding are performed by a continuous method, the product can be manufactured with high productivity.

(Example 5) A filter was formed by using the spinning apparatus for composite spunbonding method of Example 1 and the apparatus for producing a tubular molded body. However, an apparatus equipped with a drawing roll was used at a position between the spinneret and the air sucker. The apparatus was equipped with a cool air blowing type quench device at a position between the die and the drawing roll. Poly (ethylene terephthalate co-ethylene isophthalate) having an intrinsic viscosity of 0.56 and a melting point of 190 ° C. and polyethylene terephthalate having an intrinsic viscosity of 0.65 and a melting point of 254 ° C. were used. .
Using the low melting point resin on the sheath side and the high melting point resin on the core side,
Composite spinning was carried out at a composite ratio of 50/50 (wt%) and a spinning temperature of 280 ° C. for the low melting point resin and 290 ° C. for the high melting point resin. At the time of spinning, the film was drawn twice at a temperature of 90 ° C. by the above-mentioned drawing roll and sprayed on a net conveyer at a speed of 750 m / min with an air sucker. During spinning, the fiber was quenched from the side of the fiber between the spinneret and the drawing roll with air at a temperature of 26 ° C. at a wind speed of 0.4 m / sec. The obtained long fibers were slightly larger than the theoretical value because of the slip due to stretching, and the fineness was 6.2 d / f. The basis weight of the web was 21 g / m 2. Then, the web was molded into a heating cylinder at a temperature of 195 ° C. as in Example 1, and the inner diameter was 30 mm, the outer diameter was 60 mm, and the length was 250.
A cylindrical filter of mm was obtained. This filter was hard because the fibers were heat-sealed. Table 1 shows the test results of the filtration performance of the tubular filter. This filter had good filtration accuracy dispersion index and pressure resistance. The product was free from foaming during filtration.

(Example 6) Using the composite spunbond spinning apparatus of Example 1 and the apparatus for producing a tubular molded body, a tubular drain material was molded. However, a spinneret type spinneret with a hole diameter of 0.6 mm is used as the spinneret, and the outer diameter of the core of the tubular molding machine is 100 m.
m metal core was used. MFR22 (190 ℃, g /
10 minutes), high-density polyethylene having a melting point of 132 ° C on the sheath side, MFR18 (230 ° C, g / 10 minutes), melting point 164
℃ polypropylene is used on the core side and the composite ratio is 40/60
(Wt%), spinning temperature is 285 ° C. on sheath side, 300 ° C. on core side,
300m so that the fiber is sandwiched between a pair of pinch rolls.
The fiber was spun at a speed of 1 / min, sucked with an air sucker provided under the pinch roll, and sprayed onto a net conveyor at a speed of 338 m / min. The fiber had a fineness of 32 d / f. Then, the long fiber web was heated at a temperature of 147 ° C. as in Example 1, and was wound around a metal core having an outer diameter of 100 mm until a predetermined outer diameter was obtained. Then cool to 28 ° C,
The core was taken out and cut with a cutter to obtain a drain material having an inner diameter of 100 mm, an outer diameter of 150 mm and a length of 1000 mm.
Five drain materials were connected by a vinyl chloride pipe having a length of 12 cm to form a drain material having a length of 5 m. Thereafter, only one end was fused and sealed with a polypropylene resin plate having a thickness of 1.2 mm. Using 30 sets of these connected drain materials, the end face seal side is the upstream side, the no seal side is opened to the concrete drain groove, and it is buried in the sloping ground of the golf course at intervals of 2 m. Used as drainage material. It was confirmed that the place where the drain material was used had better drainage than the other place where the drain material was not used.

Example 7 Using the composite spunbond spinning apparatus of Example 1 and the apparatus for producing a tubular molded body, a tubular drain material was molded. However, as the spinneret, a sheath-core type composite spinneret having a hole diameter of 1.0 mm was used. The same propylene / ethylene / butene-1 random copolymer and polypropylene as in Example 3 were used, the random copolymer was used on the sheath side and polypropylene on the core side, and the spinning temperature was 28 each.
It was spun at 0 ° C. For the spinning, the suction of the air sucker was stopped, the spinning was performed by the weight of the spinning, and the web was collected on the net conveyor. The fibers obtained were 480 d / f. Thereafter, the continuous fiber web was treated at a temperature of 15 with the same method as in Example 1.
While heating at 0 ° C., the metal core having an outer diameter of 80 mm was wound to a predetermined outer diameter. After that, it was cooled to 28 ° C, the core was taken out, and it was cut with a cutter to give an inside diameter of 80 mm and an outside diameter of
A drain material having a length of 80 mm and a length of 1000 mm was obtained. This drain material was a hard material in which the fibers were heat-sealed. This drain material is two pieces, and the connecting portion is wound with a water-permeable non-woven fabric having a width of 150 mm and fastened with a wire to make a drain with a length of 2 m.
Made into wood. Then, a polypropylene resin plate having a thickness of 1.2 mm was fused and sealed on only one end. Using 40 sets of the drain materials connected to each other, the end face seal side is set to the upstream side, and the non-sealing side is opened to the concrete drainage groove.
It was buried as a drainage material at intervals of 5 m on the slope of soft ground land. It was confirmed that the place where this drain material was used had good drainage.

Example 8 The filter after the filtration life test was washed with water by a back washing method and a re-filtration test was conducted. The test apparatus used was the filtration accuracy test apparatus. Cylindrical filter
Used the tubular filters of Example 1 and Comparative Example 1. The tubular filter was subjected to a filtration life test under the same conditions as the filtration life test, and when the pressure difference reached 3 kg / cm @ 2, the filtration life test was once stopped. After that, 6 liters of water only from the inside to the outside of the filter /
For 20 minutes, the cake was backwashed.
After that, the cake was added again to the water tank under the same conditions as in the filtration life test, and the filtration life test was conducted. The filter of Example 1 had a total of 62 minutes, including the filtration time before backwashing and the filtration life after backwashing (34 minutes until the differential pressure reached 3 kg / cm, the filtration life after backwashing). 28 minutes). The pressure resistance after backwashing was 6.7 kg / cm @ 2. The filter of Comparative Example 1 had a total filtration time of 46 minutes before the backwashing and a filtration life after the backwashing (the differential pressure was 3 kg.
It takes 25 minutes to reach 1 / cm, and the filtration life after backwashing is 2
1 minute). The pressure resistance after backwashing was 5.9 kg / cm @ 2. The filter of the present invention could be extended in filtration life by backwashing and could be reused. However, in the product of Comparative Example 1, the extension time of the filtration life due to the back washing was short.

[0035]

EFFECTS OF THE INVENTION The cylindrical molded article of the present invention has characteristics such as excellent filtration performance, high pressure resistance, no foaming during water passage, high hardness, excellent water permeability, and backwash capability. Therefore, it is preferably used as a filter or a drain material. Further, the method for producing a tubular molded body of the present invention can efficiently and easily produce a tubular molded body having a fineness to a large fineness with simple equipment. Since the obtained fiber does not use a spinning oil agent, the oil agent does not adhere to it.

Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI Technical display location D04H 3/14 D04H 3/14 A

Claims (20)

[Claims] 1. A multi-component composite spunbond filament consisting of at least two components, a low-melting point resin component and a high-melting point resin component having a melting point difference of 10 ° C. or more, is wound and heated by the low-melting point resin component. A fused cylindrical molded body. 2. A multicomponent composite spunbond filament is 10 to 10.
The low melting point resin component of 90% by weight and the high melting point resin component of 90 to 10% by weight, the low melting point resin component forming at least a part of the surface of the fiber. Cylindrical molded body. 3. A multi-component composite spunbond filament having a ratio of maximum to minimum of fineness of 1.5 or more, which is arranged along the thickness direction of the tubular molded body. The cylindrical molded body according to item 1. 4. The tubular molded article according to claim 1, which has a filtration accuracy dispersion index of 0.7 or less. 5. The tubular molded body according to claim 1, wherein other fibers are laminated or mixed with the composite spunbond continuous fibers. 6. The tubular molded product according to claim 1, wherein the multicomponent composite spunbond continuous fibers have a fineness of 0.2 to 70,000 d / f. 7. The resin having a low melting point is a resin selected from polyethylene, a crystalline copolymer of propylene and other α-olefin, and a low melting point polyester,
The tubular molded body according to any one of claims 1 to 3, wherein the high melting point resin component is polypropylene. 8. The low melting point resin is a resin selected from polyethylene, a crystalline copolymer of propylene and other α-olefin, and a low melting point polyester, and the high melting point resin component is polyethylene terephthalate. Claims 1-3
The cylindrical molded body according to any one of 1. 9. The cylindrical molded body according to claim 1, wherein either the surface or the inside of the cylindrical molded body is shaped in an uneven shape. 10. A multi-component composite spunbond method is used to spin a composite long fiber composed of at least two components, a low melting point resin component and a high melting point resin component having a melting point difference of 10 ° C. or more, into a web. A method for producing a tubular molded body, which comprises winding a composite core fiber around a core while heating at a fusion temperature of the low melting point resin or above and heat-sealing the composite long fiber. 11. A multicomponent spunbond filament is 10 fibers.
11. A low melting point resin component of 90% by weight and a high melting point resin component of 90% by weight, the low melting point resin component forming at least a part of the surface of the fiber. A method for producing the cylindrical molded body described. 12. A web which is spun by changing either the extrusion amount of the composite fiber or the take-up speed during spinning, and the ratio of the maximum and the minimum of the fineness of the same fiber of the composite filament is 1.5 or more. Manufactured, wound around the core while heating the web above the fusion temperature, by heat-sealing the low melting point resin of the long fibers,
11. Long fibers whose fineness is changed by 1.5 times or more are arranged along the thickness direction of the tubular molded body.
Alternatively, the method for producing a tubular molded body according to item 11. 13. The spun composite fiber is introduced into an air sucker type traction device while being quenched at a wind speed of 0.1 to 5 m / sec and spun in a high speed air stream at a speed of 500 to 20,000 m / min to obtain a long fiber. The method for producing a tubular molded body according to any one of claims 10 to 12, wherein the fineness is 0.2 to 300 d / f. 14. Spinning with the dead weight at the time of spinning or with a take-up roll, and spinning with or without quenching the conjugate fiber at the time of spinning, and the fineness of the long fiber is from 17 to 70,000 d.
/ F, The manufacturing method in any one of Claims 10-12. 15. The method for producing a tubular molded article according to claim 10, wherein the stretching is performed 1.2 to 9 times during the period from spinning to production of the tubular molded article. 16. The low melting point resin component is a resin selected from polyethylene, a crystalline copolymer of propylene and other α-olefin, and a low melting point polyester, and the high melting point resin component is polypropylene or polyethylene terephthalate. The method for producing a tubular molded body according to any one of claims 10 to 12. 17. A method comprising laminating other fibers with a composite spunbond long-fiber web or mixing them with the composite spunbond long-fiber web between the spinning and the production of the tubular molded body. Item 13. A method for producing a tubular molded body according to any one of Items 10 to 12. 18. The method according to claim 10, wherein a roll with a mold is brought into contact with the web or the cylindrical molded body when the cylindrical molded body is molded to make the surface or the inside of the molded body uneven. A method for producing a tubular molded body according to claim 1. 19. A filter using the tubular molded body according to claim 1. 20. A drain material using the tubular molded body according to any one of claims 1 to 3.