JPH10251953A - Nonwoven fabric and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a nonwoven fabric excellent in surface durability, and to provide a method for producing the nonwoven fabric. SOLUTION: This nonwoven fabric is obtained by integrally integrating superfine fibers A generated from removal type splitting fibers from which at least one resin component can be removed to generate the superfine fibers A having an average fiber diameter of <=3μm, with physical splitting fibers capable of being split by a physical action to generate superfine fiber B and with superfine fibers B generated from the physical splitting fibers.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] The present invention relates to a nonwoven fabric and a method for producing the same.

[0002]

2. Description of the Related Art A resin component (island component) which is hardly soluble in a solvent capable of dissolving and removing the resin component in one resin component (sea component).
A so-called sea-island type fiber in which is dispersed in an island shape is known. A nonwoven fabric has been known in which a fiber web containing this sea-island type fiber is formed and entangled, and then the sea component of the sea-island type fiber is dissolved and removed to generate ultrafine fibers composed of the island component. Since this nonwoven fabric contains ultrafine fibers, it is excellent in feeling and filtration performance, and it is highly useful because artificial leather can be formed by impregnating with a urethane resin.

However, when the sea component of the sea-island type fiber is removed, the structure becomes coarse as much as the sea component is removed. Therefore, even if further processing is performed, there is no morphological stability sufficient to withstand the processing step. And poor surface resistance. Therefore, the applicant of the present application has proposed a nonwoven fabric which has solved these problems in Japanese Patent Application No. 8-103188.

[0004]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a nonwoven fabric which is more excellent in surface resistance than the previously proposed nonwoven fabric, and a method for producing this nonwoven fabric.

[0005]

According to the present invention, there is provided a non-woven fabric comprising at least one type of resin component, and at least one type of ultrafine fiber A having an average fiber diameter of 3 μm or less. Fiber A, split by physical action, physically splittable fibers capable of generating ultrafine fibers B, and those in which ultrafine fibers B generated from the physically splittable fibers are entangled and integrated, or at least 1. One or more types of resin components are removed, and extra fine fibers A generated from removable splittable fibers capable of generating extra fine fibers A having an average fiber diameter of 3 μm or less, and two or more types are divided by physical action. It consists of a resin component and removes one or more kinds of resin components to obtain ultrafine fibers B ′.
Since ultrafine fibers B ′ generated from physically splittable fibers capable of generating ultrafine fibers B capable of generating entangled fibers are entangled and integrated, the surface resistance is excellent. That is, since the ultrafine fibers A (in some cases, the ultrafine fibers B ′) generated by the removal of the resin component are entangled and integrated, the surface resistance is excellent.

The method for producing a nonwoven fabric according to the present invention comprises the steps of: forming a fiber web containing at least a removable splittable fiber capable of generating an ultrafine fiber A having an average fiber diameter of 3 μm or less and a physically splittable fiber; By applying a fluid flow to the web,
A step of splitting the physically splittable fibers to generate ultrafine fibers B and entangled to form an entangled fiber web; and removing one or more resin components of the removable splittable fibers to form ultrafine fibers. Producing a non-woven fabric by generating fluid A and forming a non-woven fabric by again applying a fluid flow to the removed entangled fiber web, or at least an average fiber diameter of 3 μm or less. Of ultra-fine fibers B, which are composed of removable splittable fibers capable of generating ultrafine fibers A of the above and two or more types of resin components and capable of generating ultra-fine fibers B ′ by removing one or more types of resin components. Forming a fibrous web containing the physically splittable fibers, and applying a fluid flow to the fibrous web to split the physically splittable fibers to generate ultrafine fibers B and to entangle them. A step of forming a fiber web; Generating ultrafine fibers A from the conductive fibers, and generating ultrafine fibers B ′ from the ultrafine fibers B to form a removed entangled fiber web, and applying a fluid flow to the removed entangled fiber web again to form a nonwoven fabric. , A nonwoven fabric having excellent surface resistance can be easily produced.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION In the present invention, by using a removable splittable fiber capable of removing one or more resin components and generating an ultrafine fiber A having an average fiber diameter of 3 μm or less, the feeling and the feeling are improved. It is possible to form a nonwoven fabric having excellent filtration performance. When the average fiber diameter exceeds 3 μm, the feeling and the filtration performance are not so much improved. Therefore, the average fiber diameter is preferably 2 μm or less, and the average fiber diameter is 1 μm or less so that the feeling and the filtration performance are more excellent. Is more preferable. When the average fiber diameter of the ultrafine fibers A is 1 μm or less (preferably 0.8 μm or less, more preferably 0.6 μm or less), the surface frictional resistance of the nonwoven fabric can be increased, so that the use requiring grip properties (for example, , Sports gloves). On the other hand, if the average fiber diameter is too small, the number of fibers may drop off, so that the average fiber diameter is preferably 0.01 μm or more.

In the present invention, when the fiber has an irregular cross-sectional shape, the diameter of a circle having the same area as the cross-sectional area is defined as the fiber diameter, and the average of 50 randomly selected fibers is determined as the average fiber diameter. That.

As the removable splittable fiber, for example,
As shown in the fiber cross-sectional schematic diagram in FIG. 1, a sea-island type fiber in which a hardly removable Y component is dispersed and / or arranged in the form of an island in the X component removable by the remover is shown. In addition, by removing the X component of the sea-island type fiber, it is possible to generate the ultrafine fiber A composed of the Y component.

[0010] Examples of the removing agent capable of removing one or more resin components of the removable splittable fiber include a solvent, an enzyme, and a microorganism. Among these, the solvent is preferable because the removal rate is high and the handling is easy. Can be used for Among these solvents, aqueous solvents can be suitably used because they are easier to handle and easier to process. In the present invention, "removable" means that 95% by mass or more of the resin component can be removed, and "removability" means that only 5% by mass or less of the resin component can be removed under the conditions for removing the removable resin component.

As another removable splittable fiber, as shown in a schematic cross-sectional view of the fiber in FIG. 2, an X component and a Y component or a Y component or a Y component, There is a multi-bimetal type fiber in which the hard-to-removal X component is alternately laminated in a layered form in the removing agent, and by removing the X component or the Y component of the multi-bimetal type fiber, it is composed of the Y component or the X component. Ultrafine fibers A having a substantially trapezoidal cross-sectional shape can be mainly generated.

FIG. 3 shows another removal type splittable fiber.
(A) and (b), as shown in the schematic cross-sectional view of the fiber, the X component is divided into the X component remover extending from the inside of the fiber (preferably the fiber axis) to the fiber surface by the Y component, which is difficult to remove. There is a chrysanthemum-shaped fiber obtained by dividing the hard-to-removable X component by the Y component, or by removing the X component or the Y component of the chrysanthemum-shaped fiber, thereby removing the Y component or the X component. , The microfiber A having a U-shaped or fan-shaped cross section can be generated.

In each case, the case where the removable splittable fiber is composed of two kinds of resin components has been described.
It may be composed of more than three kinds of resin components, and if it is composed of three kinds of resin components, two or less kinds of ultrafine fibers A can be generated. Can occur.

In the case where the removable splittable fiber comprises three or more resin components, at least one island component of the sea-island fiber is a sea-island type, a multi-bimetal type, a chrysanthemum type, a core-sheath type, an eccentric type, Or at least one resin component of side-by-side type, multi-bimetal type fiber, sea-island type, multi-bimetal type, chrysanthemum type, core-sheath type, eccentric type or side-by-side type, chrysanthemum type fiber Resin components are sea-island type, multiple bimetal type, chrysanthemum type, core-sheath type,
An eccentric type or a side-by-side type can be exemplified.

If ultrafine fibers A are generated from such removable splittable fibers and ultrafine fibers A 'are further generated by physical treatment and / or chemical treatment, the fineness of the feeling and the filtration performance can be improved. An excellent nonwoven fabric can be obtained, and if the ultrafine fibers A and / or the ultrafine fibers A ′ generated from such removable splittable fibers can be fused, they are more excellent in form stability by fusing. Can be nonwoven fabric,
Alternatively, if the microfiber A and / or the microfiber A ′ are composed of two or more components and the shrinkage of the resin component is different, it is possible to develop a non-woven fabric having more excellent elasticity and flexibility by expressing crimp. it can.

Among the above-mentioned removable splittable fibers,
The sea-island type fiber or the removable type splittable fiber having the sea-island type portion can be preferably used because the ultrafine fiber A having an average fiber diameter of 3 μm or less can be easily generated.

The ultrafine fibers A that can be generated from such removable splittable fibers do not need to have a single fiber diameter, but may have a mixture of ultrafine fibers A having various fiber diameters. . Further, the number of ultrafine fibers A that can be generated from one removable splittable fiber is not particularly limited, but may be 5 to 1
Approximately 0000 are suitable.

The resin component constituting the removable splittable fiber may be any resin component capable of forming a fiber, for example, polyamide such as nylon 6, nylon 66, nylon copolymer, polyethylene terephthalate, polyethylene terephthalate. -Based copolymer, polybutylene terephthalate, polyester such as polybutylene terephthalate-based copolymer, polyethylene, polypropylene, polyolefin such as polymethylpentene, polyurethane,
Vinyl polymers such as polyacrylonitrile and polystyrene, or aliphatic polyester polymers such as polyglycolic acid, glycolic acid copolymer, polylactic acid, and lactic acid copolymer; and coupleramide and tetramethylene Adipamide, undecanamide, laurolactamide, aliphatic polyester amide copolymers such as hexamethylene adipamide are copolymerized with aliphatic amides, among them, a resin that can be removed with respect to a certain removing agent, and What is necessary is just to combine so that it may contain at least one kind of resin which is difficult to remove. In the case of including one type of removable resin and one type of hard-to-removable resin, for example, it is possible to remove polystyrene, hard-to-removable polyamide, and toluene with respect to the remover of perclene. What is necessary is just to combine removable polyester with hard-to-removable polypropylene, etc. with respect to polyethylene, polyamide with hard-to-removal, and remover of alkaline aqueous solution.
Among them, a combination of polyester and polypropylene, which can use an easy-to-handle alkaline aqueous solution as a removing agent, is preferable.

On the other hand, since the ultrafine fibers B are generated and entangled using the physically splittable fibers capable of splitting by physical action to generate the ultrafine fibers B, the fibers are generated from the removable splittable fibers. Form stability and surface resistance can be improved without impairing properties such as feeling and filtration performance of the ultrafine fibers A.

The physically splittable fibers include, for example,
As shown in the fiber cross-sectional schematic diagram in FIG. 1, among the X components that can be divided by a physical action, there is a sea-island type fiber in which a Y component poorly compatible with the X component is dispersed and / or arranged in an island shape. By dividing the sea-island type fiber, the ultrafine fiber B ₁ composed of the X component, the ultrafine fiber B ₂ composed of the Y component, and the X component and the Y
The microfine fibers B ₃ where the components mixed can be generated. It is to be noted that if the island components are of various sizes, they are more easily divided by physical action, and thus are suitable sea-island fibers. In particular, for the fiber diameter of the sea-island type fiber, 0.0
If an island component having a diameter of 6 to 0.2 times (preferably 0.08 to 0.18 times) is present, the island component can be more easily divided and entangled, so that it can be suitably used.

The physical actions in the present invention include, for example, the action of a needle punch, the action of a fluid stream such as a water stream,
There is an operation of a calender or an operation of a flat plate press.
Among these, the action of a fluid stream such as a needle punch or a water stream that can be entangled simultaneously with the division of the physically splittable fiber is preferable, and the action of a fluid stream such as a water stream that can be more uniformly split and entangled. Is more preferable.

The poor compatibility of the present invention means that the side-by-side type composite fiber is spun with the target resin component,
By applying a shearing force to the side-by-side type composite fiber with a finger, it can be divided into two resin components.

Another physically splittable fiber of the present invention includes:
As shown in the schematic cross-sectional view of the fiber in FIG. 2, there is a multiple bimetallic fiber in which an X component and a Y component that is poorly compatible with the X component are alternately laminated in a layered form. When applied, the ultrafine fiber B ₁ composed of the X component and Y
The microfine fibers B ₂ consisting of components can be generated.

FIG. 3 shows another physically splittable fiber.
(A) and (b), as shown in the schematic cross-sectional view of the fiber, a Kiku flower type in which the X component extends from the inside of the fiber (preferably the fiber axis) to the fiber surface and is divided by the Y component which is poorly compatible with the X component. There are fiber, if Hodokose a physical action on the chrysanthemum-type fiber, the microfine fibers B ₁ consisting of the X component, it is possible to generate and microfine fibers B ₂ consisting of Y component.

In each case, the case where two types of resin components are used has been described. However, the physically splittable fibers may be made of three or more types of resin components, and three or more types of physically splittable fibers may be used. Can generate three types of ultrafine fibers B, and can generate four types of ultrafine fibers B when composed of four types of resin components.

Examples of the physically dividable fiber composed of three or more resin components include, for example, a sea-island type fiber which can be split by physical action, wherein at least one island component is a sea-island type, a multi-bimetal type, a chrysanthemum type, and a core. Sheath type, eccentric type, or side-by-side type, at least one resin component of multi-bimetal type fiber that can be split by physical action is sea-island type, multi-bimetal type, chrysanthemum type, core-sheath type, eccentric type, Or at least one resin component of a chrysanthemum type fiber which can be split by physical action, a sea-island type (FIG. 4), a multi-bimetal type, a chrysanthemum type, a core-sheath type, an eccentric type, or a side-by-side type Can be used. In this way, the ultrafine fibers B generated by splitting are composed of two or more types of resin components, and one or more types of resin components can be removed to generate ultrafine fibers B ′ (Z component in FIG. 4), or If the ultra-fine fibers B ′ can be generated by physical action, the generation of the ultra-fine fibers B ′ can form a nonwoven fabric having better feeling and filtering performance, and thus can be suitably used.
In addition, if the ultrafine fibers B and / or the ultrafine fibers B ′ can be fused, the nonwoven fabric can be formed into a nonwoven fabric having more excellent form stability by fusing, and the ultrafine fibers B or the ultrafine fibers B ′ can be obtained. Is composed of two or more kinds of resin components, and if the shrinkage of the resin components is different, a nonwoven fabric having excellent elasticity and flexibility can be obtained by exhibiting crimping.

As the resin component constituting the physically splittable fiber of the present invention, two or more kinds of resin components having poor compatibility with each other are selected from the resin components having the same fiber forming ability as the above-mentioned removable splittable fiber. It is sufficient to combine them. In the case of two types, for example, there are combinations of a polyester resin and a polyamide resin, a polyamide resin and a polyolefin resin, and a polyester resin and a polyolefin resin.

If the resin component of the ultrafine fiber B that can be generated from the physically splittable fiber includes a resin that can be partially removed by the remover for the resin component of the removable splittable fiber, the removal is possible. This is preferable because, at the same time as the resin component of the mold-dividing fiber is removed, a part of the resin component of the microfine fiber B can be removed, and a nonwoven fabric having a better feeling can be formed. Assuming that the removal rate of the resin component of the removable splittable fiber is 1, the resin component constituting the ultrafine fiber B is 0.2 to 0.
A removal rate of 7 is preferred, and a removal rate of 0.3 to 0.6 is more preferred. Examples of the resin component of the ultrafine fiber B include a condensation polymer of a diol and a dicarboxylic acid such as polyethylene terephthalate and polybutylene succinate when the remover is a suitable alkaline aqueous solution.

As described above, if the ultrafine fibers B are composed of two or more resin components and one or more resin components can be removed to generate the ultrafine fibers B ', the feeling becomes more excellent. This is a preferred embodiment because a nonwoven fabric can be formed. In addition,
The generation of the ultra-fine fibers B ′ can increase the surface friction resistance of the nonwoven fabric, and is therefore suitable for use in applications requiring grip (for example, sports gloves).

As the resin component constituting the ultrafine fiber B capable of generating the ultrafine fiber B ', if the resin component of the ultrafine fiber B is removed simultaneously with the removal of the resin component of the removable splittable fiber, The resin component to be removed from the mold-dividing fiber and the resin component to be removed from the ultrafine fiber B are the same, or the combination of the resin component to be removed from the removable moldable fiber and the resin component to be removed from the ultrafine fiber B is, for example, Copolymerized polyester and polylactic acid can be removed simultaneously with a suitable alkaline aqueous solution.

The resin component of the ultrafine fiber B may be removed separately from the removal of the resin component of the removable splittable fiber. The combination of the resin component to be removed from the removable splittable fiber and the resin component to be removed from the ultrafine fiber B is, for example, in the case of low-density polyethylene and copolyester, the low-density polyethylene is toluene and the copolyester is alkali aqueous solution. In the case of polystyrene and a copolymerized polyester, it is necessary to remove polystyrene with perchrene and separately remove the copolymerized polyester with an aqueous alkali solution.

The ultrafine fibers B that can be generated from such physically splittable fibers do not need to have a single fiber diameter, and may have various fiber diameters. The average fiber diameter of the ultrafine fibers B is preferably 6 μm or less, more preferably 5 μm or less, so as not to impair the feeling and filtration performance. On the other hand, when the average fiber diameter of the ultrafine fibers B is smaller than 0.1 μm, the ultrafine fibers B easily fall off due to physical action.
It is preferable that this is the case. In addition, the number of the ultrafine fibers B that can be generated from the physically splittable fibers is not particularly limited, but is preferably about 2 to 600.

The ultrafine fibers B 'need not have a single fiber diameter, and may have various fiber diameters. Furthermore, the average fiber diameter of the ultrafine fibers B ′ is preferably 2 μm or less, more preferably 1 μm or less. The average fiber diameter of the ultrafine fibers B ′ is 1 μm or less (preferably 0.8 μm or less, more preferably 0.6 μm or less).
In this case, the surface friction resistance of the nonwoven fabric can be increased, so that the nonwoven fabric is suitable for use in applications requiring grip properties (for example, sports gloves). On the other hand, this ultra-fine fiber B '
If the average fiber diameter is smaller than 0.01 μm, the ultrafine fibers B ′ easily fall off. Therefore, the average fiber diameter is preferably 0.01 μm or more. The number of ultra-fine fibers B ′ that can be generated from the fine fibers B is not particularly limited, but is preferably about 1 to 6,000.

The removable splittable fiber and the physically splittable fiber used in the present invention can be obtained by a conventional composite spinning method, a mixed spinning method, or an appropriate combination thereof.
It can be easily spun. Note that a flame retardant, an antistatic agent, a moisture absorbent, a coloring agent, a dye, a conductive agent, a hydrophilizing agent, and the like may be mixed as long as spinnability and fiber strength are not reduced. The fineness of the removable splittable fiber and the physically splittable fiber is preferably about 89 to 560 μg / m.

The nonwoven fabric of the present invention is formed from the removable splittable fibers and the physically splittable fibers as described above. In addition, in order to be excellent in form stability and surface resistance, the releasable splittable fiber is 90 mass% or less and the physical splittable fiber is 10 mass% or less.
It is preferably at least s%, and the removable splittable fiber is preferably at least 25 mass% and the physical splittable fiber is at most 75 mass% so that the feeling and the filtering performance are excellent. More preferably, it contains 90 to 40 mass% of the removable splittable fiber and 10 to 60 mass% of the physically splittable fiber, and contains 90 to 50 mass% of the removable splittable fiber and 10 to 50 mass% of the physically splittable fiber. Is most preferred.

The nonwoven fabric of the present invention may contain fibers other than the above-mentioned releasable splittable fibers and physically splittable fibers depending on the use. Examples thereof include natural fibers such as silk, wool, cotton, and hemp. Regenerated fiber such as rayon fiber, semi-synthetic fiber such as acetate fiber, polyamide fiber, polyvinyl alcohol fiber, acrylic fiber, polyester fiber, polyvinyl chloride fiber, polyvinylidene chloride fiber, polyurethane fiber, polyethylene fiber, polypropylene fiber, aromatic Synthetic fibers such as polyamide fibers may be included. In addition, a conjugate fiber composed of two or more kinds of resin components and having properties such as adhesiveness and crimping property may be included.

The nonwoven fabric of the present invention is obtained by entanglement-integrating ultrafine fibers A generated from removable splittable fibers, physically splittable fibers, and ultrafine fibers B generated from physically splittable fibers. is there. More precisely, especially in the vicinity of the surface, the ultrafine fibers A and the ultrafine fibers B are not in a bundle state, but are more dispersed and entangled with the surrounding fibers. As described above, the nonwoven fabric of the present invention generates and entangles the ultrafine fibers A and the ultrafine fibers B, and thus has excellent morphological stability, surface resistance, feeling, and filtration performance.

When the removal rate of the resin component of the removable splittable fiber is set to 1 as the resin component constituting the microfine fiber B, a removing agent used for removing the resin component of the removable splittable fiber. Therefore, when the resin component of the removable type splittable fiber is removed when a resin component that can be removed at a removal rate of 0.2 to 0.7 is included, a part of the ultrafine fiber B is removed at the same time. It is a nonwoven fabric with a better feel. Also in this nonwoven fabric, especially near the surface, the ultrafine fibers A and the ultrafine fibers B are not in a bundle state, but are more dispersed and entangled with surrounding fibers.

Further, it is composed of two or more resin components.
By removing more than one type of resin component, the non-woven fabric in which the ultra-fine fibers B 'are generated from the ultra-fine fibers B capable of generating the ultra-fine fibers B' is further contained because the ultra-fine fibers B 'are contained. Excellent feeling and filtering performance. In addition, especially in the vicinity of the surface, the ultrafine fibers B ′ are not in a bundle state,
It is in a state of being more dispersed and entangled with the surrounding fibers.

Such a nonwoven fabric of the present invention can be easily produced, for example, by the following method. First, the releasable splittable fiber as described above (preferably 90 to 25 mass
%) And physically splittable fibers (preferably 10 to 75 mass
%). As a method of forming the fiber web, for example, there are a dry method such as a card method and an air lay method, and a wet method. The fiber length varies depending on the method of forming the fiber web. When the former is formed by the dry method, the fiber having a length of about 20 to 110 mm is used. When the latter is formed by the wet method, the length is 1 to 30 m.
Use fibers with a length of about m. Further, different types of fiber webs may be laminated, such as laminating fiber webs having different production methods or fiber webs having different fiber compositions.

Next, a fluid flow is applied to the fiber web to divide the physically splittable fiber to generate ultrafine fibers B and entangle to form an entangled fiber web. The entangled fiber web obtained in this manner is a tangible integrated fiber of a removable splittable fiber that has not yet been split, a physically splittable fiber, and an ultrafine fiber B generated from the physically splittable fiber. It is. The processing conditions by the fluid flow are not particularly limited as long as the conditions are such that the physically splittable fibers can be split and entangled.
A nozzle plate having a diameter of 0.3 mm, preferably 0.08 to 0.2 mm, a pitch of 0.2 to 3 mm, and preferably 0.4 to 2 mm and having nozzles arranged in one or more rows is used. .98 to 29 MPa, preferably 4.9 to 2
A fluid stream of 5 MPa is sprayed on the fiber web. The pressure of the fluid flow may be changed, or the nozzle plate may be swung or vibrated.

When the non-perforated portion of the support such as a net or a perforated plate, which transports the fiber web when entangled by the fluid flow, is enlarged, a nonwoven fabric having holes can be formed in appearance and the support can be formed. When the non-opening portion is reduced, a nonwoven fabric having no external appearance can be formed. Specifically, the former nonwoven fabric uses a coarse net of less than 50 mesh or a perforated plate corresponding to this, which is made of a thick wire exceeding a wire diameter of 0.25 mm, and the latter nonwoven fabric has a fiber diameter of 0.25 mm. It can be formed by using a fine net of 50 mesh or more consisting of the following thin wires, or a perforated plate corresponding thereto.

Next, one or more resin components of the removable splittable fibers constituting the entangled fiber web are removed to generate ultrafine fibers A, and the removed fibers have more excellent feeling and filtration performance. Form a composite fiber web. Since this removed entangled fiber web has only removed one or more resin components of the removable splittable fibers, the ultrafine fibers A still exist in a bundle state. As a method of removing the one or more resin components of the removable splittable fiber to generate the ultrafine fibers A, for example, it can be performed by immersion in a bath filled with a removing agent.

When the removal rate of one or more resin components of the releasable splittable fiber is set to 1 as the resin component constituting the ultrafine fiber B, it is used for removing the resin component of the releasable splittable fiber. If the removal agent contains one that can be removed at a removal rate of 0.2 to 0.7, the removal of one or more resin components of the releasable splittable fiber to generate the ultrafine fiber A Since a part of the resin component of the microfine fiber B is also removed at the same time, the nonwoven fabric has a better feeling.

In the case where the physically splittable fiber is composed of two or more types of resin components and the ultrafine fibers B capable of generating the ultrafine fibers B ′ can be generated by removing one or more types of resin components, Removes one or more types of resin components of the releasable splittable fiber to generate microfine fibers A, and at the same time, removes one or more types of resin components of microfine fibers B to generate ultrafine fibers B ′, After removing one or more resin components of the removable splittable fiber to generate the ultrafine fiber A, the ultrafine fiber B
Removal of more than one type of resin component to generate ultra-fine fibers B ′, or removal of one or more types of resin components of ultra-fine fibers B to generate ultra-fine fibers B ′, followed by removal type division One or more resin components of the conductive fibers are removed to generate ultrafine fibers A, thereby forming a removed entangled fiber web. In addition to the removal of the resin component of the removable splittable fiber, a method of removing one or more resin components of the ultrafine fiber B to generate the ultrafine fiber B ′ is performed by the method of removing the resin component of the removable splittable fiber. In a bath filled with a removing agent, in the same manner as in the method of removing the water.

Next, a fluid flow is again applied to the removed entangled fiber web to form the nonwoven fabric of the present invention. As described above, in the removed entangled fiber web, the ultrafine fibers A are still present in a bundle state. However, since the fluid flow is applied again, the nonwoven fabric of the present invention is generated from the removable splittable fibers. The ultrafine fiber A, the physically splittable fiber, and the ultrafine fiber B generated from the physically splittable fiber are entangled and integrated. In addition, especially in the vicinity of the surface, the state of the bundle of the ultrafine fibers A and the ultrafine fibers B slightly spreads, and the ultrafine fibers A and the ultrafine fibers B are entangled and integrated with the surrounding fibers.

The conditions of the fluid entanglement treatment are, for example, a nozzle diameter of 0.05 to 0.3 mm, preferably 0.08
~ 0.2mm, pitch 0.2 ~ 3mm, preferably 0.4
A pressure of 0.98 to 29.4 MPa, preferably 2 to 2, from a nozzle plate in which nozzles are arranged in one or more rows at
A stream of 4.5 MPa fluid is sprayed against the removed entangled fiber web. The pressure of the fluid flow may be changed, or the nozzle plate may be swung or vibrated.

When forming a nonwoven fabric having no pores in appearance, the surface density of the removed entangled fiber web is set to X (g / g).
m ² ), it is preferable that the fluid flow be blown against the removed entangled fiber web at a pressure of {(X / 10) +2} (MPa) or less, and {(X / 10) +1} (MPa) More preferably, the fluid flow is sprayed at the following pressure. In addition, it is made of a thin wire having a wire diameter of 0.25 mm or less.
By using a fine net of 0 mesh or more or a perforated plate corresponding to this, a nonwoven fabric having no pores in appearance can be formed. In addition, you may use these conditions together.

On the other hand, in the case of forming a nonwoven fabric having a hole in appearance, a fluid flow is sprayed at a pressure exceeding {(X / 10) +2} (MPa) onto the entangled fiber web, It consists of a thick wire exceeding 0.25mm in diameter,
By using a coarse net of less than 50 mesh or a perforated plate corresponding to this, a nonwoven fabric having holes in appearance can be formed. In addition, you may use these conditions together.

As the physically splittable fiber, a fiber which is composed of two or more types of resin components and which can generate ultrafine fibers B 'which can generate ultrafine fibers B' by removing one or more types of resin components can be used. When used, it is a nonwoven fabric in which at least the ultrafine fibers A and the ultrafine fibers B 'are entangled and integrated. In addition, especially in the vicinity of the surface, the ultrafine fibers B ′ are also in a state in which the bundle is slightly spread, dispersed and entangled with the surrounding fibers.

The nonwoven fabric of the present invention obtained as described above is excellent in properties such as form stability, surface resistance, feeling and filtration performance, and is therefore suitable for artificial leather such as gloves, outer garments, and bags. It can be used for various purposes such as base materials, interlining for clothing, cotton filling, leakproof sheets, masks, battery separators, air or liquid filters, wallpapers, interior materials for automobiles, and base materials for partitions. In addition, since the nonwoven fabric of the present invention has excellent morphological stability, processing for adapting to various applications, for example, kneading, water repellent, resin processing, raising such as buffing, dyeing,
Coloring with a pigment, softener, antistatic agent, antibacterial agent, and the like can be efficiently performed.

Hereinafter, embodiments of the present invention will be described, but the present invention is not limited to the following embodiments.

[0053]

【Example】

(Examples 1 to 3) 40 parts of polypropylene and 60 parts of polyethylene terephthalate containing 5-sulfoisophthalic acid and polyethylene glycol as a copolymer component were mixed in a pellet state, and mixed and spun at 280 ° C. to obtain a fineness of 66.
Winding was performed so as to be 0 μg / m to obtain an undrawn yarn.

Next, this undrawn yarn was drawn 3.3 times at 90 ° C., cut, and about 1,600 island components made of polypropylene having an average fiber diameter of 0.28 μm were dispersed. The fineness was 220 μg / m. A removable splittable fiber having a fiber length of 51 mm and a circular cross section was formed.

On the other hand, as the physical splitting fiber, fineness of 12
A chrysanthemum flower-type splittable fiber (Kanebo (Japanese fiber) having a cross-sectional shape of 0 μg / m, a fiber length of 38 mm, and a cross-sectional shape obtained by splitting a polyester component with 6 nylon components extending radially from the fiber axis as shown in the cross-sectional shape in FIG. Co., Ltd., trade name: Berima X,
3.1 fiber diameter, fan-shaped cross section made of polyester component
and microfine fibers B ₁ 8 pieces of [mu] m, the sectional cross shape consisting of nylon 6 component, the fiber diameter 4.5μm and microfine fibers B ₂ 1 present, the cross-section one character shape consisting of 6-nylon components, fiber diameter 3.2μm of microfine fibers B ₃ 4 present and can generate a) was prepared.

The releasable splittable fiber and the physical splittable fiber are mixed in various ratios as shown in Table 1, and the unidirectional fiber web formed by a carding machine is processed by a cross layer in the direction of travel of the fiber web. To form a cross fiber web.

[0057]

[Table 1]

Next, this crossed fiber web is opened with a mesh size of 0.
After placing on a 147mm net, the diameter is 0.13mm,
From a nozzle plate with a pitch of 0.6 mm, alternately on both sides,
A stream of water having a pressure of 7.8 MPa, 12 MPa, or 12 MPa is sprayed on the cross fiber web to split the chrysanthemum flower-type splittable fibers and entangle them at the same time to form an entangled fiber web (Example 1: area density 93 g / m ² , Example 2: area density of 98 g / m ² , Example 3: area density of 88 g / m ² ).

Next, the entangled fiber web was heated at a temperature of 80 ° C.
At 30 ° C. for 30 minutes in a 12 mass% aqueous sodium hydroxide solution, thereby decomposing and extracting the copolymerized polyethylene terephthalate of the removable splittable fiber, and at the same time, extracting a part of the polyester component of the ultrafine fiber B. A web was formed.

Then, after placing the removed entangled fiber web on a net having an opening of 0.147 mm, a diameter of 0.13 m
m, from a nozzle plate having a pitch of 0.6 mm, a water stream having a pressure of 5 MPa, 5 MPa, 2 MPa, and 2 MPa was alternately sprayed onto the removed entangled fiber web to alternately form a nonwoven fabric of the present invention. .

(Example 4) In a composite spinning apparatus for sea-island type fibers, polypropylene was extruded from a nozzle serving as an island component, and polyethylene containing 5-sulfoisophthalic acid and polyethylene glycol as copolymerization components from a nozzle serving as a sea component. A mixture of 60 parts of terephthalate and 40 parts of polypropylene in the form of pellets is extruded at a gear pump ratio of 8: 15.8, and is composite-spun at 280 ° C., wound up to a fineness of 830 μg / m, and undrawn. Obtained.

Next, the undrawn yarn is drawn 3.3 times at 90 ° C., cut, and cut to a fiber diameter of polypropylene.
Large island component 2 with 6 μm (ratio to diameter 0.11)
One fiber is arranged and the average fiber diameter of polypropylene is 0.1 mm.
A physically splittable fiber having a fineness of 280 μg / m, a fiber length of 51 mm, and a circular cross section was formed in which about 5,000 small island components of 17 μm were dispersed.

Except that this physically splittable fiber was used in an amount of 50 mass%, a cross fiber web was formed, an entangled fiber web was formed, a removable entangled fiber web was formed, and a nonwoven fabric was formed. Was formed. In this nonwoven fabric, when the copolymerized polyethylene terephthalate of the removable splittable fiber is decomposed and extracted, the copolymerized polyethylene terephthalate of the physically splittable fiber is also decomposed and extracted, and the average fiber diameter is 2.6.
Since the ultrafine fibers B ′ having an average fiber diameter of 0.17 μm and a micron diameter of 0.1 μm were generated, the nonwoven fabric of Example 3 had a softer feel and an excellent feel.

Example 5 In a composite spinning apparatus of chrysanthemum flower type fiber, a mixture of 60 parts of polylactic acid and 40 parts of polypropylene in a pellet state, and 60 parts of polybutylene succinate and 40 parts of polypropylene in a pellet state were used. The mixture was alternately extruded between adjacent nozzles at a gear pump ratio of 1: 1 and composite-spun at 240 ° C. and wound up to a fineness of 880 μg / m to obtain an undrawn yarn.

Next, this undrawn yarn was drawn 3.3 times at 90 ° C. and cut, and about 120 island components of polypropylene having an average fiber diameter of 0.28 μm were dispersed therein. And eighteen resin components having a fan-shaped cross section in which approximately 180 island components having an average fiber diameter of 0.23 μm made of polypropylene are dispersed, and having a fineness of 280 μg / m, a fiber length of 51 mm, and a circular physical cross-linkable fiber. Formed.

Except that this physically splittable fiber was used in an amount of 50 mass%, a cross fiber web was formed, an entangled fiber web was formed, a removable entangled fiber web was formed, and a nonwoven fabric was formed. Was formed. When decomposing and extracting the copolymerizable polyethylene terephthalate of the removable type splittable fiber, polylactic acid and polybutylene succinate of the physically splittable fiber are also decomposed and extracted, and the average fiber diameter is 0.28 μm and the average fiber diameter is 0. Since the ultra-fine fibers B ′ of 0.23 μm were generated, the non-woven fabric of Example 3 was more excellent in the feeling of softness. Also, from any of the removable splittable fiber and the physical splittable fiber,
In order to generate fine fibers with an average fiber diameter of 0.6 μm or less,
The nonwoven fabric had high friction resistance.

(Surface Resistance) The surface resistance of the nonwoven fabrics of Examples 1 to 5 was measured according to JIS L 1076 (Method A, ICI type testing machine).
Was evaluated. The results were as shown in Table 1.

(Surface Friction Resistance) The surface friction coefficient of the nonwoven fabrics of Examples 1 to 5 was measured using a surface tester (manufactured by Kato Tech Co., Ltd.).
KES-FB4). The results are also shown in Table 1.

[0069]

The nonwoven fabric of the present invention comprises, at least, one or more types of resin components, and an ultrafine fiber A generated from a removable splittable fiber capable of generating an ultrafine fiber A having an average fiber diameter of 3 μm or less; Physically splittable fibers that can be split by physical action to generate microfine fibers B, and microfine fibers B generated from the physical splittable fibers are entangled and integrated, or at least one or more The resin component is removed and the microfiber A generated from the releasable splittable fiber capable of generating the microfiber A having an average fiber diameter of 3 μm or less, and is divided by a physical action and comprises two or more resin components. One or more types of resin components are removed, and ultrafine fibers B ′ generated from physically splittable fibers capable of generating microfine fibers B capable of generating microfine fibers B ′ are entangled and integrated. Because of this, it has excellent surface resistance

The method for producing a nonwoven fabric according to the present invention comprises the steps of: forming a fiber web containing at least a removable splittable fiber capable of generating an ultrafine fiber A having an average fiber diameter of 3 μm or less and a physically splittable fiber; By applying a fluid flow to the web,
A step of splitting the physically splittable fibers to generate ultrafine fibers B and entangled to form an entangled fiber web; and removing one or more resin components of the removable splittable fibers to form ultrafine fibers. Producing a non-woven fabric by generating fluid A and forming a non-woven fabric by again applying a fluid flow to the removed entangled fiber web, or at least an average fiber diameter of 3 μm or less. Of ultra-fine fibers B, which are composed of removable splittable fibers capable of generating ultrafine fibers A of the above and two or more types of resin components and capable of generating ultra-fine fibers B ′ by removing one or more types of resin components. Forming a fibrous web containing the physically splittable fibers, and applying a fluid flow to the fibrous web to split the physically splittable fibers to generate ultrafine fibers B and to entangle them. A step of forming a fiber web; Generating ultrafine fibers A from the conductive fibers, and generating ultrafine fibers B ′ from the ultrafine fibers B to form a removed entangled fiber web, and applying a fluid flow to the removed entangled fiber web again to form a nonwoven fabric. , A nonwoven fabric having excellent surface resistance can be easily produced.

[Brief description of the drawings]

FIG. 1 shows an example of a cross-sectional shape of a removable or physically splittable fiber of the present invention.

FIG. 2 shows another example of the cross-sectional shape of the removable or physically splittable fiber of the present invention.

FIG. 3 (a) Another example of the cross-sectional shape of the removable or physically splittable fiber of the present invention (b) Another example of the cross-sectional shape of the removable or physically splittable fiber of the present invention

FIG. 4 shows another example of the cross-sectional shape of the removable or physically splittable fiber of the present invention.

[Explanation of symbols]

 X resin component Y resin component Z resin component

Claims (6)

[Claims] At least one kind of resin component is removed, and ultrafine fibers A generated from a releasable splittable fiber capable of generating ultrafine fibers A having an average fiber diameter of 3 μm or less are separated by a physical action. A non-woven fabric characterized in that a physically splittable fiber capable of generating ultrafine fibers B and an ultrafine fiber B generated from the physically splittable fibers are entangled and integrated. 2. As a resin component constituting the ultrafine fiber B,
When the removal rate of the resin component of the removable splittable fiber is set to 1, it can be removed at a removal rate of 0.2 to 0.7 by the removing agent used to remove the resin component of the removable splittable fiber. The nonwoven fabric according to claim 1, characterized in that the nonwoven fabric comprises: 3. At least one type of resin component is removed, and ultrafine fibers A generated from a removable splittable fiber capable of generating ultrafine fibers A having an average fiber diameter of 3 μm or less are separated by a physical action. And composed of two or more resin components,
By removing one or more resin components, the ultrafine fibers B ′ generated from the physically splittable fibers capable of generating the ultrafine fibers B capable of generating the ultrafine fibers B ′ are entangled and integrated. Characteristic nonwoven fabric. 4. A step of forming a fiber web containing at least a releasable splittable fiber capable of generating an ultrafine fiber A having an average fiber diameter of 3 μm or less and a physically splittable fiber, and applying a fluid flow to the fiber web. A step of forming the entangled fiber web by splitting the physically splittable fiber to generate ultrafine fibers B and removing one or more resin components of the removable splittable fiber; Producing a nonwoven fabric by removing the ultrafine fibers A and forming a nonwoven fabric by applying a fluid flow again to the removed entangled fiber web. . 5. When the removal rate of the resin component of the removable splittable fiber is set to 1, the removal agent used for removing the resin component of the removable splittable fiber is 0.2 to 0.7. A physically splittable fiber capable of generating an ultrafine fiber B containing a resin component that can be removed at a removal rate is used.
The method for producing a nonwoven fabric according to claim 4, wherein in the step of removing the resin components of at least one kind and generating the ultrafine fibers A, a part of the resin component of the ultrafine fibers B is also removed at the same time. 6. An ultrafine fiber B comprising at least a removable splittable fiber capable of generating an ultrafine fiber A having an average fiber diameter of 3 μm or less and two or more types of resin components and removing one or more types of resin components. 'Forming an ultrafine fiber B capable of generating a fiber web including physically splittable fibers capable of generating;
A step of applying a fluid flow to the fiber web to split the physically splittable fibers to generate ultrafine fibers B and entangle them to form an entangled fiber web; Generating A, and generating ultra-fine fibers B ′ from the ultra-fine fibers B, forming a removed entangled fiber web, and applying a fluid flow to the removed entangled fiber web again to form a nonwoven fabric, And a method for producing a nonwoven fabric.