JPH1072754A - Fibrous form and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a fibrous form separable to a thickness, length or width needed for its aimed use, and also capable of having antimicrobial effect. SOLUTION: This fibrous form comprises a fiber A and a conjugate fiber B and has such a design that the conjugate fiber B is composed of a thermoplastic polymer R1 and another thermoplastic polymer R2, the melting point of the polymer R1 is lower than those of the fiber A and the polymer R2, and the layer (a) where at least part of the mutual conjugate fibers B and the contact paints between the conjugate fibers B and the fibers A lies virtually bonded and the layer (b) where the conjugate fiber B is nonexistent or the weight ratio of the conjugate fiber B is smaller than that in the layer (a) are distributed alternately.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber molded article having an antibacterial property, which can be easily separated into a thickness, length or width required for a target application, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, cushioning materials such as middle materials of bed mats for bedclothes and medical care, middle materials of vehicle seats used in trains and automobiles, middle materials of sofas for furniture, pad materials for clothing, Resin foams such as polyurethane have been mainly used as shielding materials for door trims, sun visors, filters for various applications, sound insulation for houses, heat insulation, etc., but resin foams use Freon gas or a substitute gas when foaming. In addition, there is a problem that the air permeability and the moisture permeability are low and the water is easily stuffed, and the water permeability and the drying property are low. Therefore, as a cushioning material for solving the problems of these resin foams, a fiber molded body in which fibers are heated and compressed to join the contact points with each other is disclosed in, for example, Japanese Patent Publication No. Sho 62-2155.
Japanese Patent Publication No. 1-18183, Japanese Patent Publication No. 4-33
478, JP-A-3-140185 and the like.

[0003] Cushion materials made of these fiber moldings use low-melting-point fibers as heat-adhesive fibers,
By using a composite fiber having a high melting point thermoplastic resin as a core component and a low melting point thermoplastic resin as a sheath component,
It is intended for adhesion between fibers, and some results have been obtained. However, it has been necessary to form a large block like a conventional resin foam, and then cut and bond it to produce a product.

[0004] On the other hand, fiber products imparted with antibacterial properties are widely used for various uses such as clothing, interlining, lining, bedding products and interior products. These fiber products are not only excellent in antibacterial properties but also various. Thus, a considerably high level of washing durability at home can be obtained.

[0005] Recently, however, infection in hospitals due to methicillin-resistant Staphylococcus aureus (hereinafter referred to as MRSA) has become a problem.
It is desired to impart antibacterial properties to covers, sheets, curtains, white coats, and the like. However, since these medical fiber products are usually repeatedly washed industrially at 60 to 85 ° C. many times by linen traders, they are used. On the other hand, the conventional textile products provided with antibacterial properties have a problem that sufficient industrial washing durability cannot be obtained, and the antibacterial properties are lowered every industrial washing.

[0006]

SUMMARY OF THE INVENTION The object of the present invention is to provide an antibacterial property which is excellent in industrial washing durability, is resistant to compression, is soft, has high moisture permeability and high water permeability, and is comfortable. A fiber molded product that has a good feeling of use, is less likely to cause environmental problems, and can be easily separated into the thickness, length, or width required for the intended use, and efficiently manufactures the fiber molded product It is to provide a way to do it.

[0007]

Means for Solving the Problems The fiber molded article of the present invention has the following constitution to solve the above-mentioned problems.

[0008] That is, a fiber molded article containing the fiber A and the conjugate fiber B, wherein the conjugate fiber B is a thermoplastic polymer R1
And a thermoplastic polymer R2.
1 has a melting point lower than any of the melting points of the fiber A and the thermoplastic polymer R2, and at least some of the contact points between the composite fibers B and between the composite fibers B and the fibers A are substantially adhered. Wherein the weight ratio of the composite fiber B is smaller than the weight ratio of the composite fiber B of the layer a or the composite fiber B of the layer a. is there.

Further, the method for producing a fiber molded article of the present invention comprises:
In order to solve the above problems, the following configuration is provided.

That is, when mixing two or more types of fibers, one type mixes a composite fiber B having a melting point of the fiber A and a thermoplastic polymer R1 lower than that of the thermoplastic polymer R2.
The fiber is opened, and a layer a formed by filling the gas-permeable mold with the gas and a layer b formed by filling the composite fiber B with a lower content ratio than the layer a are alternately present, A method for producing a fiber molded body, comprising performing a thermal bonding treatment in a compressed state.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a fiber molded article of the present invention will be described in detail with reference to the drawings.

The fiber molded article of the present invention is composed of two or more kinds of fibers and includes a fiber A and a composite fiber B. Further, the fiber molded article of the present invention is composed of the fiber A and the composite fiber B, and does not include the layer a (a1 to a6) containing a large amount of the composite fiber B and the composite fiber B as shown in FIG. Alternatively, layers b (b1 to b5) having a lower proportion of the composite fiber B than the layer a are alternately present.

The layer a is a portion used for the purpose of the present invention, and is used between the composite fibers B and between the composite fibers B and the fibers A.
And / or at the point of contact with other fibers, such as antimicrobial fibers, being melt bonded by the thermoplastic polymer R1 of the composite fiber B;
Heat fixed to a stable shape. On the other hand, the layer b exists between the layers a, for example, the layers a1, b1, a2, b2, a3
, B3, a4, b4, a5, b5, and a6, and the fusion bonding of the composite fiber B by the thermoplastic polymer R1 is not performed or the degree of the fusion bonding is smaller than that of the layer a. Therefore, the thickness of the layer b may be a thickness necessary for separating the layers a.

[0014] The fiber molded article having a multilayer structure can be cut without using a cutting machine when used.
The necessary layer a can be used after peeling off at the layer b.

The fiber A constituting the fiber molded article of the present invention is:
It is not particularly limited as long as it has a fiber shape.From natural fibers such as cotton and wool, polyester, polyamide, synthetic fibers such as polyacrylonitrile and rayon,
Regenerated fibers such as acetate or semi-synthetic fibers can be used. Among them, polyester-based fibers and polyamide-based fibers are preferably used from the viewpoint of recoverability to compression of the fiber molded body and form stability.

Further, the cross-sectional shape of the fiber A may be a round cross-section, and further, a modified cross-section such as polygonal, multi-lobed or elliptical, or a hollow cross-section thereof is preferred.

The fiber A used in the fiber molded article of the present invention preferably has a crimp in order to impart bulkiness and softness, and to improve recovery from compression. The number of crimps may be appropriately determined according to the use of the fiber molded body. The number of crimps is preferably 3 to 10 ridges / 25 mm, and the degree of crimp is 5 to 30%.
Is preferred. In order to impart more bulkiness, it is preferable that the crimp is a latent crimp developed by asymmetric cooling or the like during spinning.

As the fiber A constituting the fibrous molded product, short fibers having a fineness of 0.5 to 30 denier and a fiber length of 10 to 100 mm are preferably used from the viewpoint of the shape fixability of the fibrous molded product and imparting a soft feeling. Can be

In addition to the pigment such as titanium oxide and carbon black, an antioxidant, a coloring inhibitor, a light stabilizer, an antistatic agent and the like may be added to the fiber A, if necessary.

Next, the conjugate fiber B used in the fiber molded article of the present invention will be described.

The conjugate fiber B is composed of a thermoplastic polymer R2 and a thermoplastic polymer R1. Examples of the thermoplastic polymer R1 include a polyester, polyethylene, polypropylene, ethylene propylene copolymer and ethylene butene copolymer. Coalesced, selected from thermoplastic polymers such as polyolefins or olefin copolymers such as ethylene vinyl acetate copolymer, polyhexamethylene terephthalate, polyhexamethylene butylene terephthalate, polyesters such as polyhexamethylene terephthalate isophthalate, or copolyesters, At least one polymer can be used.

The thermoplastic polymer R2 is, for example, polyethylene terephthalate or polybutylene having terephthalic acid, 2,6-naphthalenedicarboxylic acid or an ester thereof as a main dicarboxylic acid component and ethylene glycol or tetramethylene glycol as a main glycol component. Terephthalate or polyethylene 2,6
-Polyesters such as naphthalate can be used. Of these, polyethylene terephthalate (ordinary polyester) is preferred.

When the conjugate fiber B is of a nylon type,
For example, a thermoplastic polymer R2 of nylon 6 and a thermoplastic polymer R1 of nylon 6 copolymerized with nylon 66 to lower the melting point can be used.

The melting point of the thermoplastic polymer R1 is determined by performing a heat treatment in the production of a fiber molded body and performing heat fusion.
In order to obtain sufficient thermal adhesiveness between the fibers and to avoid unnecessary high-temperature heat treatment, the temperature is preferably lowered by 20 ° C. or more as compared with other fibers or the thermoplastic polymer R2. Components in the range of 170 ° C. are preferred.

The thermoplastic polymer R1 / in the composite fiber B
The weight ratio R1 / R2 of the thermoplastic polymer R2 is from 20/80.
The range of 60/40 is preferable, and especially 20/80 to 50 /.
When the weight ratio of R1 is less than 20%, sufficient thermal adhesion between fibers cannot be obtained,
The shape fixability of the produced fiber-formed body tends to be poor. On the other hand, when the weight ratio of R1 exceeds 60%, the softness of the fiber molded body is impaired, and there is a tendency that a problem that the compression set becomes large is caused.

The conjugate fiber B has a thermoplastic polymer R2 as a core component and a thermoplastic polymer R1 as a sheath component in that the morphological change and dust generation due to the kneading action during use of the fiber molded article are small. Core-sheath type composite fibers are particularly preferred.

The composite fiber B used for at least the layer a of the fiber molded article of the present invention is preferably 15 to 60% by weight in weight ratio. When the amount of the conjugate fiber B is less than 15% by weight, the heat bonding points of the conjugate fiber B are reduced, and the shape stability tends to be deteriorated. On the other hand, if the amount of the conjugate fiber B exceeds 60% by weight, the softness of the fiber molded body tends to decrease, and the touch feeling tends to be coarse and hard.

Composite fiber B used in the fiber molded article of the present invention
In order to impart bulkiness and softness to the fiber molded article and to improve the recovery from compression, the fiber preferably has crimp. The number of crimps may be appropriately determined depending on the use of the fiber molded body, but the number of crimps is preferably 3 to 10 peaks / 25 mm,
The degree of crimp is preferably 5 to 30%. Further, the composite fiber B is
From the viewpoint of shape fixability and softness of the fiber molded body, the fineness is 0.5 to 30 denier, and the fiber length is 10 to 100 mm.
Is preferably used.

In addition to the pigments such as titanium oxide and carbon black other than the thermoplastic polymers R1 and R2, an antioxidant, a coloring inhibitor, a light stabilizer,
Of course, an antistatic agent or the like may be added. Such a conjugate fiber B can be produced by an ordinary conjugate spinning method.

Next, antibacterial fibers are preferably used in the fiber molded article of the present invention in order to impart antibacterial properties.

The antibacterial fiber used in the fiber molded article of the present invention comprises:
It is preferable that the polyester fiber is treated with a treatment liquid containing an antibacterial component and a melamine component. In this case, the amount of the antibacterial component adhered to the antibacterial fiber is preferably 0.05% to 3% owf, and more preferably 0.1% to 2% owf. If it is less than 0.05% owf, the antibacterial performance may be insufficient depending on the mixing ratio of the conjugate fiber B and other fibers. If it exceeds 3% owf, the fiber becomes stiff and recovers from compression. Not only does the property decrease, but the cost tends to increase.

Since the melamine component forms a crosslinked network structure on the surface of the fiber, the melamine component effectively functions to improve the washing durability, particularly the industrial washing durability. The amount of the melamine component attached to the antibacterial fiber is 0.05. ~ 2% owf is preferred,
In particular, the range of 0.1 to 1.2% owf is more preferable,
If it is less than 0.05% owf, the durability of industrial washing may be insufficient. If it exceeds 2% owf, the fiber becomes stiff and the recovery from compression is lowered, and the cost tends to be increased. .

Various compounds are used as the antibacterial component. For example, a compound having a basic group such as an amidine group or a guanidin group or a salt thereof such as a sodium salt, a potassium salt or an ammonium salt, and a quaternary ammonium salt can be used. Specific examples of compounds containing an amidine group include 4,4'-stilbene-dicarboxysamidine-diisethionate (ie, stilbamine isethionate) and N '-(4-chloro-
Specific examples of the compound containing a guanidin group, such as 2-methyl-phenyl) -N, N-dimethyl-methanimide (ie, chlordimeform), include 1,17-diguanidino-9-aza-heptadecane (ie, Specific examples of quaternary ammonium salts include guatatin), p- (chlorophenyldiguanide) -hexane (ie, chlorhexidine), and p-benzoquinone-amidino-hydrazone-thiosemicanevazone (ie, ambazone). Benzalkonium chloride, benzethonium chloride and the like can be used, respectively. Of course, these compounds are merely examples, and compounds other than those described above can be used. Among these compounds, p- (chlorophenyldiguanide) -hexane or a salt thereof is most preferable in that it has high safety and the antibacterial property does not decrease even in the presence of a protein or the like.

The antibacterial component having such a basic functional group includes:
It is preferable to use it after reacting with an acidic group-containing polymer (which may be a homopolymer or a copolymer) which reacts with the polymer. As the acidic group-containing monomer constituting the acidic group-containing polymer, a sulfone group, a carboxyl group, a phosphone group,
A monomer having an acidic group such as a phenolic hydroxyl group or a salt thereof such as a sodium salt, a potassium salt, or an ammonium salt can be used.

Specific examples of the monomer having a sulfone group include styrene sulfonic acid, vinyl sulfonic acid, allyl sulfonic acid, sulfopropyl acrylate, sulfopropyl methacrylate, 3-chloro-4-vinylbenzenesulfonic acid, 2-acrylamide -2-methylpropanesulfonic acid, 2-acryloyloxybenzenesulfonic acid, 2-acryloyloxynaphthalene-2-sulfonic acid, 2-methacryloyloxynaphthalene-2-sulfonic acid, and 2-hydroxy-3-methacryloyloxypropyl sulfonic acid Acids and the like can be used. Specific examples of the monomer having a carboxyl group include acrylic acid, methacrylic acid, itaconic acid, crotonic acid, maleic acid, maleic anhydride, 3-butene-1,2,3- Tricarboxylic acid, and 4- Specific examples of monomers having a phosphonic group include allylphosphonic acid, acid phosphoxyethyl methacrylate, 3-chloro-2-acid phosphoxypropyl methacrylate, and 1-methylvinyl phosphonic acid. ,
1-phenylvinylphosphonic acid, 2-phenylvinylphosphonic acid, 2-methyl-2-phenylvinylphosphonic acid, 2- (3-chlorophenyl) vinylphosphonic acid, 2-diphenylvinylphosphonic acid, and the like can be used. Specific examples of the monomer having a phenolic hydroxyl group include o-oxystyrene and o-vinylanisole.

These monomers may be used alone or in combination of two or more. Further, other monomers copolymerizable with the monomer having an acidic group may be used in combination. Specific examples of such copolymerizable monomers include, for example, acrylonitrile, acrylates, methacrylates, vinyl chloride, vinyl acetate, vinyl propionate, vinylidene chloride, ethylene, propylene, styrene or derivatives thereof, butadiene, Acrylamide or a derivative thereof, hydroxyethyl acrylate, hydroxyethyl methacrylate, or the like can be used.

As the polymerization method, an emulsion polymerization method,
Any of ordinary polymerization methods such as a solution polymerization method and a bulk polymerization method can be employed. Among them, the emulsion polymerization method is preferably used because a large amount of acidic groups tends to be distributed on the particle surface of the obtained polymer.

An antimicrobial reaction product is obtained by reacting an acidic group-containing polymer obtained by polymerizing such a monomer with a basic group-containing antimicrobial component.

Among the quaternary ammonium salts, compounds represented by the following formula [I] are particularly preferably used because they exhibit a highly safe antibacterial and deodorant effect.

[0040]

Embedded image (Wherein R ₁ is an alkyl group having 12 to 16 carbon atoms, R ₂ , R ₃ , and R ₄ are alkyl groups having 1 to 2 carbon atoms;
u represents a butyl group. In the compound of the formula [I], when the number of carbon atoms of the alkyl group represented by R ₁ is 11 or less or 17 or more, the antibacterial property tends to be insufficient, and represented by R ₂ , R ₃ and R _4. When the carbon number of the alkyl group is 3 or more, the viscosity of the compound increases,
The solubility in water may be reduced, which may be inconvenient during production. .

As the anion used for neutralizing the quaternary ammonium salt, an alkyl phosphate ion can be used from the viewpoint of rust prevention. Further, the alkyl group has 4 carbon atoms,
That is, a butyl group can be used. As the butyl group, n
All of -butyl, iso-butyl and tert-butyl are preferably used. When the carbon number of the alkyl group is 3
In the following, it may not be preferable in terms of safety. If the number of carbon atoms of the alkyl group is 5 or more, the viscosity becomes high, the synthesis becomes difficult, and a mixture of alkyl phosphate ions having 1 and 2 alkyl groups is used. , Which may make handling difficult.

Further, by using in combination with a melamine compound,
Further, it is more preferable to use an antibacterial resin having an antibacterial property having excellent durability, capable of safely and easily imparting antibacterial property to a fiber material, and having a property of not corroding a processing device.

In the present invention, as the antibacterial resin, a vinyl polymer or copolymer having a quaternary ammonium salt of a monovalent or divalent phosphate ester group represented by the following formula [II] or [III]: Can be used.

[0044]

Embedded image

Embedded image (In the formulas [II] and [III], R represents a polymer main chain or an organic residue, R ₁ represents an alkyl group having 8 to 18 carbon atoms, and R ₂ represents an alkyl group having 1 to 18 carbon atoms.) , A phenyl group or a substituted aryl group.) A vinyl polymer or copolymer having a quaternary ammonium chloride phosphate group represented by the formula [II] or [III] has excellent antibacterial properties. doing. Moreover,
Since it is an amphoteric polymer substance, it can be firmly attached to synthetic fibers and natural fibers. For this reason, antibacterial properties excellent in durability and washing durability can be obtained. Further, since it is obtained as an aqueous solution or a water-alcohol mixed solution, it has the advantages that it can be used for a fiber material and does not corrode the device.

Next, examples of the melamine compounds used in the present invention include those represented by the following general formula [IV].

[0046]

[Formula 5] (Wherein, R _{0 to} R ₂ : —H, —OH, —C ₆ H ₅ , C _{n
H2n + 1} ( _n : 1 to 10), -COOCnH2n _{+ 1} ( _n : 1)
_{~20), - CONR 3 R 4} , -NR 3 R 4 (R 3, R
_{4: -H, -OH), -} OCnH 2n + 1, -CH 2 OC n
_{H 2n + 1, -CH 2 COOnH} 2n + 1 (n: 1~20), -
_{CH 2 OH, -CH 2 CH 2} OH, -CONH 2, -C
ONHCH ₂ OH, —O (X—O) _n R ₅ (X: —C _{2
H 4 -, - C 3 H} 6 -, - C 4 H 8 -, n: 1~150
0, R ₄ : —H, —CH ₃ , —C ₂ H ₅ , —C ₃ H ₇ ) Among the above-mentioned general formulas, preferred compounds are those in which R ₀ and R ₁ are —
NR ₃ R _{4 wherein} R ₂ is —C
Those which are ONR ₃ R ₄ and —NR ₃ R ₄ are more preferable. Further, R ₃ and R ₄ represent —CH ₂ OH, —CH ₂ CH
Compounds that are ₂ OH, —CONH ₂ , and —CONHCH ₂ OH are particularly preferred.

These compounds are merely examples, and compounds and derivatives other than those described above can also be used.

The melamine compound having at least two polymerizable functional groups is preferable from the viewpoint of improving the durability of the resin film formed on the fiber surface.

The antimicrobial reaction product formed by reacting the antimicrobial component alone or the antimicrobial component with at least one of the acidic group-containing polymer and the copolymer as the antimicrobial component and melamine as the film-forming main component An antimicrobial coating consisting of a compound based on the fiber can be formed on the surface of the fiber. The mechanism of action on the durability of the coating is as follows. The polymer is polymerized or cross-linked to form a two-dimensional or three-dimensional structure, and at the same time, a part of the film is chemically bonded to the functional group of the fiber matrix polymer, so that the film is insolubilized and firmly adheres to the fiber. As a result, it has been found that excellent hot water washing resistance and dry cleaning property can be obtained. As a typical example of a method of applying the antibacterial component and the film-forming main component to the fiber, a polymerization initiator or a crosslinking catalyst is added to an aqueous solution containing the component,
There is a method in which fibers are padded or sprayed in the same treatment bath, and then subjected to a reaction treatment under wet conditions. Although the reaction can be carried out at a temperature higher than room temperature, it is preferable to carry out a steam heat treatment. The two components can be treated in separate baths. That is, first, the fibers are padded or sprayed in a treatment bath containing an antibacterial component, and then dry-heated or steamed, and then in a separate treatment bath in which a polymerization initiator or a cross-linking catalyst is added to an aqueous solution containing a film-forming main component. The fibers can also be padded or sprayed and steamed.

The polymerization initiator can be used when polymerizing an acrylic compound having an alkylene glycol unit. As a specific example, a common vinyl polymerization initiator such as ammonium persulfate, potassium persulfate, azobisisobutyronitrile and the like may be used, and by selecting the type of such a polymerization initiator, the film may be appropriately coated under desired conditions. Can be processed.

On the other hand, the catalyst is used when a melamine compound is subjected to a crosslinking reaction. Specific examples thereof include various organic carboxylic acids such as formic acid and acetic acid and their organic salts such as ammonium, sodium and potassium, and sulfuric acid, persulfuric acid, and the like. Inorganic salts such as ammonium, sodium, potassium, magnesium, zinc, aluminum and iron such as hydrochloric acid, phosphoric acid and nitric acid, and double salts thereof can be used. Of course, the above compounds are not limited.

The steaming heat treatment is preferably carried out at 80 to 140 ° C., more preferably at 100 to 130 ° C. for 0.5 to 30 minutes. The dry heat treatment is preferably performed at 80 to 150 ° C, more preferably at 100 to 130 ° C.
Perform at 00-220 ° C. More preferably 140 to 190
C. for 0.5 to 5 minutes.

According to the method for producing a fiber molded article of the present invention,
Other chemicals such as a softening agent, a water repellent, a water absorbing agent, an antistatic agent, and a hard finish may be added to the processing liquid used for padding or spraying.

Further, the cross-sectional shape of the antibacterial fiber may be a round cross-section, and more preferably, an irregular cross-section such as polygonal, multi-lobed or elliptical, or a hollow cross-section thereof.

The antibacterial fiber used in the fiber molded article of the present invention is
In order to impart bulkiness and softness, and to improve recovery from compression, it is preferable to have crimp. The number of crimps may be appropriately determined depending on the use of the fiber molded body, but the number of crimps is preferably 3 to 10 ridges / 25 mm, and the degree of crimp is preferably in the range of 5 to 30%. In order to impart more bulkiness, it is preferable that the crimp is a latent crimp developed by asymmetric cooling or the like during spinning.

As the antibacterial fiber, short fibers having a fineness of 0.5 to 30 denier and a fiber length of 10 to 100 mm are preferably used from the viewpoints of shape fixability and softness of the molded fiber. The antimicrobial fiber may further contain pigments such as titanium oxide and carbon black, if necessary, as well as an antioxidant, a coloring inhibitor, a light stabilizer, an antistatic agent, and the like.

Next, a method for producing the fiber molded article of the present invention will be described. FIG. 2 is a schematic vertical sectional view of a mold of an apparatus used in an example of the method for producing a fiber molded article of the present invention.

The fiber A, the composite fiber B and the antibacterial fiber are blended and spread to a desired blending ratio by a cotton feeder, a blender and a spreader used in a usual spinning process, and the shape according to the purpose is obtained. Into the air-permeable mold with a gas such as an air flow from a cotton fan. The mold used in the present invention has air permeability. If there is no air permeability, there is a problem that the filling is difficult and the thermal efficiency at the time of heat bonding and fixing is low. For example, when measured by a JIS L 1079-1966 Frazier-type air permeability tester, the air permeability is 5 to 5.
The range is preferably 200 cc / cm ² · sec.

As such a mold, for example, an upper mold 2 and a lower mold 1 using a punched metal plate shown in FIG.
Can be used.

The method of blowing into the air-permeable lower mold 1 is as follows. First, the fiber A and the composite fiber B, or the antibacterial fiber and the composite fiber B, or the fiber A and the composite fiber B and the antibacterial fiber are mixed and opened, and the blowing port is opened. 3 to fill the layer a. Next, the composite fiber B is not mixed with the combination of the above-mentioned cotton blends, or the layer b is blown and filled from the blowing port 3 with the mixing ratio of the composite fiber B lower than that of the layer a. After repeating the blowing and filling of the layer a and the layer b, the filling fiber is compressed by the air permeable upper mold 2, and the air permeable upper mold 2 is compressed and fixed at a desired density. The above-described compression is a preferable method if it is carried out every time the fibers of the layers a and b are blown, since the densities of the respective layers tend to be uniform.

Further, the compression-fixed fibers are heat-treated together with the air-permeable mold to bond a part of the contact points between the composite fibers B and between the composite fibers B and the antibacterial fibers or the fibers A to form a form. Preferably, it is fixed. Heat treatment temperature is composite fiber B
Any temperature may be used as long as it is a temperature at which the thermoplastic polymer R1 melt-bonds. Generally, the temperature is preferably equal to or higher than the melting point of the thermoplastic polymer R1, and is preferably 200 ° C. or lower.

The packing density may be appropriately determined according to the use of the fiber molded product, but is generally 0.01 to 0.1 g.
/ Cm ³ is preferred. If the density is less than 0.01 g / cm ³ , the fiber molded article tends to be too soft and the form stability tends to deteriorate, and if it exceeds 0.1 g / cm ³ , the soft feeling of the fiber molded article tends to be reduced. .

[0063]

The present invention will be described in more detail with reference to examples and comparative examples. The measuring methods of various characteristics described in the present invention are as follows.

(1) Antibacterial activity Staphylococcus A
ureus ATTC 6538p), spread the fibers of layer a of the fiber molded product into a web of fibers, and pour into a web of fibers. Viable bacteria after culturing at 37 ° C for 18 hours in a closed container The number was counted, and the number of bacteria relative to the number of cultured bacteria was measured, and the difference in the number of bacteria was calculated as K = log (B / C).

However, the culture conditions of the bacteria are log (B / A)>
Being 2. A is a normal polyester cotton web without antibacterial treatment
Number of bacteria dispersed and collected immediately after injection. B is the number of bacteria which were dispersed and recovered after 18 hours of culturing by pouring the above bacteria into a web of ordinary polyester cotton which had not been subjected to antibacterial treatment. C is the number of bacteria which were obtained by pouring the above-mentioned bacteria into a web of fibers by opening the fibers of the layer a of the fiber molded body and culturing them for 18 hours. The antibacterial properties after washing were measured using a drum dyeing machine, using a commercially available neutral detergent 2 g / l, hydrogen peroxide 3 cc / l,
Sodium peroxide 1.5 g / l, temperature 85 ± 2 ° C, bath ratio 1:
Wash for 15 minutes at 20 and then drain, drain, and wash with water for 1 minute.
Perform for 0 minutes. After washing with water, it is dried for 20 minutes using a tumbler dryer. This is one wash.

The antibacterial property was determined to be acceptable when K was 1.6 or more. The antibacterial property against MRSA was evaluated by the Japan Food Research Laboratories.

(2) Fineness The fineness was measured according to the method of JIS L 1015-7-51A.

(3) Average fiber length (cut length) Measured according to JIS L 1015A method (staple diagram method).

(4) Number of Crimps and Degree of Crimp The number of crimps and the degree of crimp are determined according to JIS L 1015-7-12.
-1 and JIS L1015-7-12-2.

(5) Density Fiber molded body (length: 20 cm, width: 20 cm, thickness:
(20 cm) was left in an atmosphere of 20 ° C. × 65% RH for 24 hours, and the weight (w) was measured and determined by the following equation.

Density (g / cm ³ ) = w / 8000 (6) Separation property by peeling in layer b Layer a1 and layer a2 are grasped with a finger, and the separation property by peeling in layer b is judged by tactile sensation. Were evaluated in four stages from very easily separating without deformation (A) to difficult to separate (X).

[Examples 1 to 3 and Comparative Example 1]
Normal polyethylene terephthalate at 55 ° C is pelletized, spinning temperature is 280 ° C, and take-off speed is 1350m /
A hollow cross-sectional structure having a hollow ratio of 31% was obtained, and an undrawn yarn which was asymmetrically cooled at the exit of the spinneret was spun.

Then, the undrawn yarn was drawn at a draw ratio of 3.0.
After stretching at a stretching bath temperature of 80 ° C. and applying mechanical crimping with a crimper, cutting to a cut length of 38 mm and heat treatment at 175 ° C., fineness of 6.0 denier, number of crimps 7.6 peaks / 25
mm, a normal polyester hollow fiber A having a crimp degree of 26.6% and not subjected to antibacterial treatment was obtained.

Separately, as the thermoplastic polymer R2, a normal polyethylene terephthalate having a melting point of 255 ° C., and as the thermoplastic polymer R1, a polyethylene terephthalate-based polyester having a melting point of 110 ° C. copolymerized with 40% by mole of isophthalic acid were used. Spinning temperature 285 ° C, take-off speed 1
Concentric composite with 350 m / min, discharge rate 18.11 g / min, thermoplastic polymer R2 with a weight ratio of 50/50 represented by R1 / R2 as core and thermoplastic polymer R1 as sheath An undrawn yarn of the fiber C was spun.

Next, the undrawn yarn is drawn at a draw ratio of 3.0.
The film was stretched at a stretching bath temperature of 80 ° C. twice and mechanically crimped with a crimper. Furthermore, after drying with a heat setter at 70 ° C,
Apply finishing oil and cut to 64 mm cut length.
A composite fiber B having a fineness of about 3.9 denier and a melting point of the surface layer of about 110 ° C. was obtained.

The fiber A and the composite fiber B are blended, further blended and spread with a roller card, and the inner surface of each of the punched surfaces 10 is punched through a mold opening 3 as shown in FIG.
An air flow is blown into the lower mold 1 of 00 × 1000 × 1000 mm together with the air flow, and each time the layers a and b are filled, the layers are compressed by the upper mold 2 having a punched surface, and the layers a and b are multilayered. Then, the filling fiber was fixed in the upper mold 2 at a filling density of 0.04 g / cm ³ and a thickness of 500 mm. Using a heat setter in which the filled and compressed fiber mixture is used for setting the spun yarn together with the mold, steaming at 130 ° C. × 2
Heat setting was performed for 5 minutes to obtain a fibrous formed body in which the layers a and b were laminated in multiple layers.

Table 1 shows the properties of the fiber molded product obtained by changing the mixing ratio of the fiber A and the composite fiber B in the layer b. In Examples 1, 2 and 3, the mixing ratio of the composite fiber B in the layer b was 0 to 3.
At 0% by weight, the mixing ratio of the conjugate fiber B was lower than that of the layer a, and the separation by peeling in the layer b was good without deforming the fiber molded body of the layer a. On the other hand, in Comparative Example 1, the mixing ratio of the composite fibers B contained in the layer a and the layer b was the same, and the separation property by peeling in the layer b was poor.

Example 4 A 2.5% aqueous solution of an antibacterial agent containing 32% of an antibacterial resin consisting of a vinyl polymer having a monovalent phosphate ester group previously quaternary ammonium chloride was prepared. Sum is a melamine compound
Itex M-3 (manufactured by Sumitomo Chemical Co., Ltd.) 1.0% aqueous solution, Sumitex Acx (manufactured by Sumitomo Chemical Co., Ltd.) 0.3% aqueous solution as a crosslinking agent, and 0.7% aqueous solution of softening agent were prepared. Example 1 was prepared by mixing and stirring these aqueous solutions.
The fiber A obtained in the above process is dipped, squeezed and
The mixture was cured for 1 minute to obtain antibacterial fiber C. The obtained antibacterial fiber C has an antibacterial component adhesion amount of 0.52% owf, a melamine-based compound adhesion amount of 0.65% owf, and an antibacterial property of MRSA of 3.8 after washing 50. Was something.

The fiber A and the composite fiber B of Example 1 were mixed with the antibacterial fiber C, and further mixed with a roller card.
The inner surface, which has been opened and has been punched on each side from a mold inlet 3 as shown in FIG. 2, is 1000 × 1000 × 1000.
The lower mold 1 is blown into the lower mold 1 together with the air flow, and is compressed by the upper mold 2 having each surface punched every time the layers a and b are filled, and the layers a and b are blown and filled in multiple layers. After filling, the filling fiber was filled with the upper mold 2 at a packing density of 0.04 g / c.
It was fixed at m ³ and 500 mm in thickness. The filled and compressed fiber mixture is heat-set at 130 ° C. for 25 minutes using a heat setter which is used for setting a spun yarn together with a mold.
Further, a fiber molded body in which the layer b was laminated in multiple layers was obtained.

Table 1 shows the mixing ratio of the fibers A, the conjugate fibers B and the antibacterial fibers C in the layers a and b and the properties of the fiber moldings. In Example 4, since the composite fiber B was not mixed in the layer b, the fiber molded body of the layer a was not deformed and the separation by the peeling in the layer b was good. Further, the blending ratio of the antibacterial fiber C in the layer a was 80% by weight, indicating excellent antibacterial properties.

[0081]

[Table 1] (The antibacterial property after washing is a value after 50 washings.)

[0082]

According to the present invention, it is possible to obtain a fiber molded product which can be separated into a thickness, a length or a width required for the intended use, and which also has antibacterial properties.

[Brief description of the drawings]

FIG. 1 is a schematic perspective view schematically showing an example of a fiber molded article of the present invention.

FIG. 2 is a schematic longitudinal sectional view schematically showing an example of an apparatus used in the method for producing a fiber molded article of the present invention.

[Explanation of symbols]

 1: Lower mold 2: Upper mold 3: Gas inlet A: Fiber A B: Composite fiber B

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification number Agency reference number FI Technical display location D06M 13/463 D06M 13/38 15/356 13/46

Claims (17)

[Claims] 1. A fiber molded product comprising a fiber A and a conjugate fiber B, wherein the conjugate fiber B is composed of a thermoplastic polymer R1 and a thermoplastic polymer R2, and the melting points of the thermoplastic polymer R1 are fibers A and The layer a and the composite fiber, which are lower than any of the melting points of the thermoplastic polymer R2 and in which at least a part of the contact points between the composite fibers B and between the composite fibers B and the fibers A are substantially adhered. B containing no B or having a weight ratio of the conjugate fiber B smaller than the weight ratio of the conjugate fiber B of the layer a
And a fibrous formed body, wherein the fibrous formed body is present alternately. 2. The weight ratio of said composite fiber B in layer a is 1
The fiber molded product according to claim 1, wherein the content is 5 to 60%. 3. The fiber according to claim 1, wherein the conjugate fiber B has a core-sheath structure, wherein the thermoplastic polymer R2 is a core component and the thermoplastic polymer R1 is a sheath component. Molded body. 4. The fiber molded article according to claim 1, wherein the layer a contains antibacterial fibers. 5. The fiber molded article according to claim 4, wherein the antibacterial fiber is an antibacterial polyester fiber provided with an antibacterial component and a melamine component. 6. The weight ratio of the antibacterial fiber in the layer a is 40 to 8
The fiber molded product according to claim 4 or 5, wherein the content is 5%. 7. The fiber molded product according to claim 4, wherein the antibacterial component provided to the antibacterial fiber is a compound having an amidine group and / or a guanidine group. 8. The fiber molded article according to claim 4, wherein the antibacterial component provided to the antibacterial fiber is a quaternary ammonium salt. 9. The fiber molded article according to claim 8, wherein the quaternary ammonium salt is a compound represented by the general formula (I). Embedded image (Wherein R ₁ is an alkyl group having 12 to 16 carbon atoms, R ₂ , R ₃ , and R ₄ are alkyl groups having 1 to 2 carbon atoms;
u represents a butyl group. ) 10. The antibacterial component provided to the antibacterial fiber is a fourth antibacterial component.
The fiber molding according to any one of claims 5 to 7, wherein the fiber molding is an antibacterial resin comprising a vinyl polymer or a vinyl copolymer having a monovalent or divalent phosphate ester group ammonium-chlorinated. body. 11. The method according to claim 5, wherein the amount of the antibacterial component attached to the antibacterial fiber is 0.05 to 3% owf, and the amount of the melamine component attached is 0.05 to 2% owf.
The fiber molded article according to the above. 12. The fiber molded product according to claim 3, wherein the weight ratio of the sheath component / core component of the conjugate fiber B is 20/80 to 60/40. 13. The fiber molded article according to claim 1, wherein each of the fiber A, the composite fiber B, and the antibacterial fiber has crimp. 14. When mixing two or more kinds of fibers, 1
The seed is a layer a formed by mixing and opening a composite fiber B having a fiber A and a thermoplastic polymer R1 having a lower melting point than the thermoplastic polymer R2, and filling the mixture with a gas into a gas-permeable mold.
And a layer b formed by filling the composite fiber B at a lower content ratio than the layer a. The layer b is alternately formed, and a heat bonding process is performed in a compressed state. 15. The method according to claim 14, wherein the heat bonding treatment is performed at a temperature not lower than the melting point of the thermoplastic polymer R1. 16. A compression treatment is performed every time fibers used for the layers a and b are filled.
6. The method for producing a fiber molded article according to 5. 17. The method according to claim 14, wherein at least the layer (a) contains antibacterial fibers.