JPS6075657A - Nonwoven fabric comprising ultra-fine filament and its production - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a <26 nonwoven 15 made of ultrafine filaments that are excellent in dimensional stability, yet soft and dense, and to a method for producing the same.

Conventional textile stables are used as raw materials 1 and 11. Nonwoven fabrics are formed into webs with a random or parallel 18M orientation through the opening and carding processes of raw cotton, and are formed into webs with a random or parallel 18M orientation. Stabilization of the morphology was achieved through addition and processing.

These nonwoven fabrics are usually bulky, have poor flexibility, and have a rough structure, which makes them unusable for certain applications. In general, attempts have been made to use 4!17 fine grained rice grains to improve the softness of 11I (although there have been attempts to improve the softness of 11I with a fineness of 0.8 denier,
It is difficult to easily produce and process the fibers through the warding process, so in general, in order to ensure fineness in the production fibers, non-woven fabrics are fabricated using multicore 474 fibers. Once formed, the culm may be treated with mulberry liquor if necessary.The culm must be removed.In addition, these core/sheath fibers are introduced.
However, there were inconveniences such as damage to the Vl'f part, exposure of the core, and cutting during processing, and a great deal of effort was required to set up the interlacing means.

In addition, in order to overcome the difficulty of classifying Suavere for textiles as one royal fee, 41i! <Formation of IFI[The so-called spunbond method, in which wedges are created by directly connecting the culms, has been proposed and put into practical use. Sotong is the most commonly used method. (Melt-bubbling is also used to reduce the fineness of 14-component fibers.) However, since the molten polymer is generally blown out with a heated air stream, It is difficult to maintain excellent quality due to non-uniformity of thickness, mixing of λ7 and 4T, etc.

The present invention provides a dense nonwoven fabric with superior flexibility and dimensional stability that cannot be achieved with these conventional techniques.

(1) Consisting of ficimen 1 to 1 with a fineness of 0.5 denier or less, d3 mutual filaments are three-dimensionally intertwined, intertwined, and have a density of 0.1 g/cc to 0.7 g,/
Weight per unit area (Q/m') in cc! Five! 50g 15cm width,
A non-woven fabric made of ultra-fine filaments that has a morphological stability of less than 40% under the influence of fishing.

(2) The nonwoven fabric according to claim 1 Fid, in which filaments having a fineness of 0.6 denier or more are mixed.

(3) Ficimene: Is ~ a polyfunmid? '! j
A nonwoven fabric comprising the ultrafine ficimen 1 described in item 1 of the ir1 requirements.

(4) A nonwoven fabric made of ultrafine filaments according to claim 1, wherein the nonwoven fabric contains at least 0.1% of a sheath component.11. .

(!i) tJ) ,? -7, ll phase f74 ri no 2 no 戊j) M J2 one chassis is molded into a sheath structure fiber eave r, fisimen 1 ~ bundle is opened and J Tsu f
Then, the L-shaped tubes were loaded on a perforated plate, and the sheath structure was destroyed by impact treatment with a columnar flow of water with a rectangular diameter of 0.3 mm or less pressurized to 11 force 20 k11017 or more from the -1 side. , a method for producing a nonwoven fabric comprising filament 1, which is characterized by simultaneously opening and entangling a filament bundle.

(6) C. Apply a stream of water at n pressure from one side of the tube to destroy it.
Feature 3, characterized in that it is filtered (within a layer) and retained within the layer.
+1 claim number! ') Method for making non-woven fabric made from ultra-fine filaments listed in 'J'int! 1゜The present invention includes a weaving method for making non-woven fabrics made of ultra-fine filaments listed in J''i nt! 0.1g/0.1g of J3.7i ficimen 1-3-dimensional entanglement and entanglement without adding any external bonding agent.
It is possible to provide a non-woven fabric that can withstand deformation of 40% or less under 10 (J/!5 cm width) per cc to 0.7 (J/cc or more dense < 1 g/m'). .

These non-woven fabrics were first made from sea urchin.

Polymer to be used (A 241 polymer with a cutting ability is used. Regarding its selection, the requirement is that C is incompatible, and in order to avoid the core/¥1'1 structure. In the spinning process, it is necessary to avoid mixing A3 with each other to form boundaries.Usually, these 11 components are typically polyester, polyamide, polyA resin, and polyvinyl polymer. However, it may also be a mixture of Borisdylene, polyvinylidene, or other materials.

:I [Compatible one is after spinning the target two-stranded polymer into a 1v1 combined structure and stretching it to increase the strength.
It can be easily determined by peeling off each other's components with your fingers.

Regarding the formation of the fibers, it is effective for the flexibility, density, and one-method stability of the present invention that the cross-sectional shape of the fibers is a core/Vl'I 1M structure, preferably a multifilament structure. Usually, the fineness of the core is less than 0.5 denier, and the number of cores is several to several thousand in parallel. The material of the core component is also determined by the material of the sheath component, but it is preferable that each single component is woven under the same conditions with the weave shoulder f1, so that the brittleness of the fibers makes the sheath component h more favorable than the core component. Preferably, the core component is polystyrene, polyamide, polyolefin, or polyacrylic, and the sheath component is polystyrene or a 13L-modified polymer. 4KI'll is suitable for increasing the water absorption and swelling properties of the constituent core/sheath component polymers.

In this inquiry V, lI'! i1. f- The peeling process of the core component and sheath component by the water flow proceeds smoothly to 1- and improves the confounding effect of u1. Specifically, N-G, N, -66 and others! It is a polymer of n-polyamide and polystyrene.

[Another effect] For example, by using a polymer mixed with carbon as the core component and a normal single-component polymer as the sheath component and combining it with high-pressure water flow treatment J111, a part of the sheath component can be peeled off, and the core component can be removed. It is easy to make a non-woven material that exhibits conductivity by exposing the material. Generally, these fibers are made using a spinneret for core/sheath formation, but when incompatible polymers are brought together, the Φm of the polymer used can be reduced by ordinary mixed spinning without the use of a special spinneret. The component with a low ratio becomes the core component, and the one with a high ratio becomes the sheath component, which causes intoxication.

Usually, the spun and discharged core/sheath filaments are drawn and heat treated until they reach practical strength/elongation and yield #Iiii properties. Here, the practical strength is small. It is preferable to define the following specifications: a breaking strength of 2 g/denier, a breaking II of 150% or more, an elongation of 5, and a boiling water shrinkage rate of 30% or less. Since these fibers are often damaged by the above-mentioned drawing process, they are not mechanically drawn and the spinning speed is increased to give a draft effect, resulting in a strong elongation of 1α. A method that brings it up to the practical level is more preferable. The spinning speed at this time depends on the quantitative ratio of the core/sheath and the thickness of the filament, but is preferably 2,500 m/min or more, preferably 3,500 m/min.
/min or more and a draft rate of 70 or more are required. A bundle of ficimen thus spun at high speed is electrostatically or aerodynamically opened, collected as a random uniform nip, and then subjected to smooth hydroprocessing. As it progresses, it becomes a double thread.

In reality, whelks are collected on a collection surface such as gold and transported, but they are directly connected to the collection stage, or once rolled.
- After getting it, move on to the next water treatment process. Adding a process of pressurizing the collected globules before entering the water treatment and applying heat if necessary means that once the whelk is rolled up (
j4: To stabilize the web for storage (of course, apply stress to the core and sheath structure by applying water jet impact C and stress to make it easier to split). Heat treatment is also applied. Likewise, it is not a scale that contributes, but a combination of +i91 Song and UnrQ of the woven fiber 111 direction and perpendicular 1] direction /\
It undergoes deformation and exceeds the effect of the subsequent addition of the culm.

In order to bring out these effects in the order of J, I: To make the IIJi string jα shrinkage (it is preferable to decorate the addition added to J, for example, 4 pieces), or 1 ．． ! The crimp of the core/sheath fibers increases the entangling effect of the subsequent hydroimpact treatment.

The feature of the present invention is that it can be used for impact treatment using high-pressure water flow as described below.
: It's humiliatingly improved.

High pressure water flow has a pressure of 20 kv/aK JJ, above, 20
Water pressurized to a range of 0 to 'j/cnf to a diameter of 0.05n
A large number of orifices from wn to 0°5 are installed to eject water through a nozzle plate. Although it depends on the shape of the orifice, the water flow from a hole that is close to a perfect circle shows a columnar shape, and the impact saw reaches a small nozzle force (3Qcm).At Mizumoto UJI, this region shows multiflora. I placed the above-mentioned tube on a flat support and received one blow from the water stream.
Pull. Unfortunately, the aggregated web of r-laments partially becomes three-dimensionally entangled and intertwined, and only the core of the multi-filament structure remains. There is a non-woven iron made of thin filaments (!-f').Moreover, the core component filament avoids cutting despite the strong impact force of the water flow, and is sufficiently entangled and knotted. It exerts its power to contribute to densification and stabilization.

In the non-woven material of the present invention, filaments of 0.5 denier or less are entangled three-dimensionally on the surface or inside of the sheet, and maintain entangled bonding points.

This structure is like a tangled ALC or B fishing line, and when an external force is applied, it does not unravel and has an effective connection point, which is strange!
32 In the present invention, the chess shoulder 1 is thin, which promotes the effect of entanglement, and has less resistance to bending. 1. Forms dense and fine intertwined points. As a result, not only the flexibility and abrasion resistance are improved, but also the sunset 9 is smooth and the mechanical properties ↑1 are better than the conventional spunbond non-woven fabric or spunbond non-woven fabric PJ+ 717
It provides significant stability compared to (fishing).

Below, I have explained -C regarding the entangled structure of the water invention in 1-1, but in the present invention, it is essential that all of the r lamens 1- are not cut (not 1, but of course the present invention The purpose of this is to have an unopened area 1-2 ay, and have a cut part or fluff (b) that does not interfere in any way. J(1
11) The /r arrogance has a rather velvety tinge to it.

Normally, water treatment is performed before Nfi treatment, JIJ, I shock treatment (
In order to add = J, initially I L (5 l ('j /
c! This is done within the range of 50'kq/c&. This is from the viewpoint of defense against unconstrained filaments being blown away by the impact force of water and making the non-woven t+; non-uniform.
The purpose of this method is to prevent the easily movable filament from moving partially upwards on the surface of the tube. In the main processing in line 4 following the above preliminaries processing, if the I-tube has a low basis weight of, for example, 100g/Tr12 or less, 2
The purpose is achieved with relatively low density strips ('l) of 0-100 kq/cXK.
100-20 for high f rewebs like '
High water pressure of 0kq/d ('l is required.)
The water treatment process of the lens 1 tube is suitable when the seams 1 to 1 have a structure in which the entangling property varies by 1 degree in the thickness direction. In other words, the surface of the sheet is highly entangled with water flow, and the inner layer has a low intersection F of 8 degrees. This product has 1 drain hole + 1) Door 4A
4. This is an effect. Also, if the surface to be treated is only the C side, one side will be preferentially entangled, making it possible to create a sheet with relatively loose fibers on the C side. .

This material has a relatively low density, ranging from 0.1 g/cc to 0.
．． It is in the range of 5q/cc.

Another effect of the preliminary treatment is that when the polymer core of the core/sheath component is polytunomide and the sheath is borisdylene, absorption and swelling of the polyamide component improves the releasability of the core component. Suitable examples of polytsunomides include the copolymerized polymers of Kai 1 Konro, Bui 66J3, and Kof'l.

Continued e f'J '-K a:X 1. 'l:
I! n Flow W HaJE force 10kq/cJ to 200
The range of kq/ri (゛treatment). This treatment makes the intertwined portions formed in the pretreatment stronger and more entangled, increasing the splitting and peeling of the core component. The nonwoven fabric of the present invention has a fineness of 0°5 denier or less, and has excellent dimensional stability even in the state of The desired non-woven fabric has a density of 0.1/cc to 0.7 g/cc, has good abrasion resistance 11, has little fuzz, is hard to pull out, and has a high density (Q/m2). To make a flexible nonwoven fabric with good shape stability that can withstand deformation of 40% or more under a load of 40 g and 15 cm width.

By applying the present invention, many additional effects can be achieved. By leaving a portion of the sheath component of the filaments of the core and sheath components intact, entanglement can be controlled and flexibility, bulkiness, and feel can be changed. In addition, by preventing the destroyed part of the sheath component from remaining in the non-woven material of the present invention, it is possible to change the flexibility and feel of the material. You can also play as a 3L assistant. In particular, when polyburene is used as the sheath component, it retains Uo (wt%) or more than 5% of amorphous powdery residue, resulting in suitable softness.
It is also possible to apply IU to a nonwoven fabric exhibiting elasticity, and further heat-treat the remaining U to reduce the remaining amount to powder and M1.

The present invention may be applied to other non-woven fabrics (i) and laminated with other non-woven fabrics (i). Particularly suitably (when laminated and processed on a non-woven fabric web consisting of relatively thick 0.6-3 deniers), the entanglement effect of the lament component is effective for thick fibers. It extends to the layers, and the overall form is significantly stabilized, with a smooth and well-defined surface.

Roughly, in the entanglement of the ultrafine fibers of the present invention, the impact treatment with a strong high-pressure water jet causes 11 tons of fibers to be cut in an entangling manner, thereby increasing entanglement and causing fluff that cannot be handled practically. A nonwoven fabric containing N can also be obtained.

The non-woven/Ir LL material of the present invention is actually used as a synthetic leather in which the conventional binder content is reduced by 80% and the lees are eliminated. It is also suitable for industrial or medical fields where no fluff or waste is produced, such as dust-free clothing, and for children's bars from the standpoint of quality.

Furthermore, fine Nourament entangles and becomes -C, so food,)
Including filtration! An industrial value of 1III has been found as a letter of 1 to 1.

The following examples are explained below.

In addition, the measurement methods in the examples are as follows and are by one person.

Density: Thick eNM weight 240GJ/cd) grin 1ll
Determine lζ from the thickness value and the j value.

Tensile strength crab 5cm width strip method (Tensile speed', Qcm
Constant speed tensile test for Z minute (number of uses) Tensile elongation: 50g per 1n'(g/1n') Elongation under 14 folds of 150m width: Tensile strength/strength (-) when measuring elongation - From the elongation curve, the sample opening is X! j I read the elongation value which corresponds to the strength value of O-ri.

Strong tearing crab tongue method (tearing speed 1.K 10 am/min) Bending resistance: 45° cantilever method.

Abrasion resistance: Size 5 x 20 (a () sheets 1~ are pasted on a flat plate, +13 sheets]-2 are in surface contact with each other)
Ask for 1- sheet. C side 1 [2
Roller 2.5cm, cycle 2cps ``Cu i!
Perform IJ motion and read the number of reciprocating motions until fluff or light appears on the friction part.

Example 1 A filament with a core/sheath structure in which the core component is 0.2 denier and the number of filaments is 10 nylon 6 and the sheath component is polystyrene was melt-spun and fabricated by the method of Minoru Kamiura. A randomly arranged web of 12 ri(-3/rn2 was prepared. At this time, the number of filaments 1 to 1 was 1 rl
16 pieces per gold [using 1 gold, the core/sheath m
The zero ratio was 80/20. In addition, the take-up speed of the filament 1- in the air soil was 455°0 II l/min.

This web was rolled between smooth metal rollers at room temperature for 100 hours.
The material was pressurized (rolled up) at a pressure of 104 mm and then placed on a conveyor made of a wire mesh of 100 mm at a speed of 0.7 m/min and subjected to impact treatment by being exposed to a stream of water at a height of 1 mm.

The nozzle used was placed at a vertical position of 45 mm above the Tsuzo Katsumokin silk, hole diameter 0.15 mm, number of holes 400. Pitch 0.
5mm method (・IL arrangement is 2 mm in the width direction of the knob.
The nozzle was oscillated in the width direction at a period of 1 cps and a stroke of 2 mm.

The first high-pressure water treatment is 30k as a pre-1iifI treatment.
i/of, 2 times [1 was turned over and performed with the same 1-1 force. Subsequently, the water pressure was maintained at 100 ki/ffl, and water flow treatment was performed four times on the front and 11 sides alternately. Subsequently, it was dehydrated by being sandwiched between rubber rollers and dried in hot air at a temperature of 105°C.

1; The core component of the rolled nonwoven sheet is exposed, and the sheets are entangled three-dimensionally on the surface, making it unnecessary to remove the entanglement, but the surface is smooth and dense. 1!7 for products that also have a good feel.

In addition, the ttF-treated nonwoven sheet is made from polysbrene, which is the original mf
It was separated and removed by 95% against f1-. 1! As shown in Table 1, it had excellent flexibility and mechanical properties, making it suitable for synthetic leather or MIG1 filters.

(Table 1) Dimensions: 108 (g/m2) Density: 0.23 (q/cffl) Tensile Crab 4
0. 3 (kq15cm) Tensile elongation: 168 (%) 50 J/5 c per area weight (Q/m')
Elongation under m-wide cart Near, 8 (%) Tear strength: 3.5 (h) Bending resistance: 33 (Sono) Abrasion resistance: 1050 (times) Example 2 Water flow with polyethylene terephthalate as the core component Pretreatment pressure 50 ki/cJ 2 times, main treatment 15
Formation of a single nonwoven bulge, pressure treatment, high-pressure water jet treatment, and dehydration*2 drying treatment were carried out under the same conditions as in Example 1, except that 0/aK was used 11 times. Obtained nonwoven sheet 1
～ is J3 with polystyrene removed by 88% of the original amount.
As shown in Table 2, the synthetic leather has particularly excellent mechanical properties.
-Also suitable for dustproof clothing, etc.

(Table 2) Grid: 105 (<)/m') Density: 0.20 ((J/cn) Tensile strength crab 38.8 (h/!5cm) Tensile elongation: 1
53(%) Weight ((ko,, /, nl): 35!j OC
J / 5 am width (D iJ m under 1.α near, 2<%) Tear strength ratio: 3.3 (for) Flash softness a: 4j) (nvn) Abrasion resistance: 550 (times) )

[Brief explanation of drawings]

FIG. 1 is a sectional view of an example of filament 1 having a core-sheath structure according to the present invention. In the figure 1: Core component 2: Sheath component 3: Filament

Claims (1)

[Claims] (1) Consisting of filaments with a m degree of 0.5 or more, the filaments are intertwined and intertwined in a cubic manner, and the density Iα is 0.1 g/cc and 0.゜7Q/cc
50CI15cm per I'f'J (g/ln')
A nonwoven fabric made of ultrafine filaments that exhibits morphological stability under the load of width /IO%Jx. G-filament with a fineness of 0.6 denier or more is mixed,
([The nonwoven fabric according to claim 1 comprising
A nonwoven fabric comprising ultrafine filaments according to item 1 of the claims. (4) A nonwoven fabric made of ultrafine filamentons according to claim 1, wherein the nonwoven fabric is characterized by a sheath component of at least 0.1%. The polymer of 749721~ is formed into long fibers with a core/sheath structure, and the bundles of 749721~ are opened to form a single tube.Then, the web is loaded on a perforated plate, and a pressure of 20 kg/a (or more) is applied from the top surface. The method is characterized in that the impact treatment is carried out with a 1.1-shaped flow of water having a diameter of 0.3 mm or less to simultaneously destroy the sheath structure, open the ficimen 1 bundle, and intertwine it (fine filament 1).
- A manufacturing method of non-woven IJ from 4 to 4. (6) C) A high-pressure water stream is applied from one side of the whelk, and at least a portion of the destroyed sheath component passes through the non-woven 111 layer and is retained within the layer. A method for producing a nonwoven fabric comprising the ultrafine filament described in Section 1.