KR920007992B1 - 유연한 장섬유 부직포(nonwoven fabric of filaments) - Google Patents

유연한 장섬유 부직포(nonwoven fabric of filaments) Download PDF

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KR920007992B1
KR920007992B1 KR1019900005738A KR900005738A KR920007992B1 KR 920007992 B1 KR920007992 B1 KR 920007992B1 KR 1019900005738 A KR1019900005738 A KR 1019900005738A KR 900005738 A KR900005738 A KR 900005738A KR 920007992 B1 KR920007992 B1 KR 920007992B1
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nonwoven fabric
astm
flow rate
melt flow
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아끼라 가네꼬
요시노리 고바야시
가쓰야 하다
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미쓰이 세끼유 가가꾸 고오교오 가부시끼가이샤
다께바야시 쇼오고
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    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/06—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/22—Formation of filaments, threads, or the like with a crimped or curled structure; with a special structure to simulate wool
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
    • D01D5/32—Side-by-side structure; Spinnerette packs therefor
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4282—Addition polymers
    • D04H1/4291—Olefin series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43825—Composite fibres
    • D04H1/43832—Composite fibres side-by-side
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4391—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres
    • D04H1/43918—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres nonlinear fibres, e.g. crimped or coiled fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23—Sheet including cover or casing
    • Y10T428/237—Noninterengaged fibered material encased [e.g., mat, batt, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24826—Spot bonds connect components
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2922—Nonlinear [e.g., crimped, coiled, etc.]
    • Y10T428/2924—Composite
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2929—Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
    • Y10T428/2931—Fibers or filaments nonconcentric [e.g., side-by-side or eccentric, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/608—Including strand or fiber material which is of specific structural definition
    • Y10T442/614—Strand or fiber material specified as having microdimensions [i.e., microfiber]
    • Y10T442/626—Microfiber is synthetic polymer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Multicomponent Fibers (AREA)
  • Professional, Industrial, Or Sporting Protective Garments (AREA)
  • Materials For Medical Uses (AREA)
  • Artificial Filaments (AREA)

Abstract

내용 없음.

Description

유연한 장섬유 부직포(NONWOVEN FABRIC OF FILAMENTS)
제1a, b, c도는 각각 본 발명의 부직포를 구성하는 장섬유의 단면도.
제2도는 스펀 본드(spun-bonded)법에 의해 부직포를 제조하는 방법을 나타내는 본 발명의 부직포 제조장치의 개략정면도.
본 발명은 유연한 장섬유 부직포에 관한 것이며, 보다 구체적으로는 고속 용융 취출 방사(high-speed take up melt-spinning)에 의해 제조 가능하며, 단위중량당 유연성이 우수한 장섬유 부직포에 관한 것이다.
방사시킨 장섬유를 직접 부직 웨브(web)로 하여 얻어진 스펀 본드(spun-bonded) 부직포는 다른 건식부직포, 습식부직포에 비해 생산성이 높으며, 연속섬유로 되어있으므로 인장강도등의 기계적 성질이 우수하고, 각종 일용잡화품과 산업용 재료등의 분야에 광범위하게 사용되고 있다.
나일론등의 폴리아미드 또는 폴리에틸렌 테레프탈레이트와 같은 폴리에스테르등을 원료로 해서 제조된 것에 비해, 폴리올레핀제의 스펀 본드 부직포는 일반적으로 유연성이 우수하며, 일회용 수건의 시이트 또는 톱 시이트(top sheet) 등의 분야에 사용될 전망이다.
상기와 같은 인체에 직접 접촉되는 용도분야에서 요구되는 충분한 유연성을 갖는 스펀 본드 부직포는 지금까지 개발된 바 없다.
이러한 점을 대상하기 위해서, 장섬유에 주름을 잡아 유연성을 부여한 장섬유 부직포가 제안된 바 있다. 장섬유에 주름을 잡은 부직포로서 2성분으로 된 스펀 본드 부직포가 제안된 바 있다. 이 부직포는 2성분의 장섬유를 병렬형으로 구성하여 수축율의 차에 의해 주름잡아 형성된다. 구체적으로 폴리프로필렌과 고밀도 폴리에틸렌을 병렬형으로 배치하여 구성한 장섬유 부직포는 공지되어 있다(예를 들면 일본특개소 63-282351호 공보).
그러나, 2성분 장섬유로 된 상기의 종래 부직포는 장섬유에 부여된 주름수가 적어서 유연성이 불충분하다. 고속기류 인발에 의해 취출속도 2000m/분이상에서 안정하게 방사할 수 있고, 유연성을 부여하도록 충분한 주름을 잡을 수 있는 수지조성물로서 지금까지 알려진 것이 없다.
본 발명의 목적은 상기 문제를 해결하는데 있으며, 고속기류 인발에 의해 고속 취출속도에서 안정하게 방사할 수 있고, 장섬유에 많은 수의 주름을 잡을 수 있는 유연한 장섬유 부직포를 제공하는데 있다.
본 발명에 의하면, DSC 주 피크(main peak)에 의해 측정한 융점이 110∼150℃이고, 용융유속(ASTM D-1238(L))이 15g/10분이하인 프로필렌/에틸렌 랜덤공중합체 3∼40중량%(a) 및 용융유속(ASTM D-1238(E))이 15g/10분이상인 폴리에틸렌 97∼60중량%(b)로 구성된 제1성분(A)과, 용융유속(ASTM D-1238(L))이 10g/10분이상인 결정성 폴리프로필렌을 주성분으로 제2성분(B)으로 구성된 주름잡힌 2성분 복합 장섬유로 된 유연한 장섬유 부직포가 제공된다.
상기 제1성분(A)에 사용되는 프로필렌/에틸렌 랜덤공중합체(a)의 DSC(시차주사열량계)의 주 피크로부터 측정한 융점은 110∼150℃, 바람직하게는 130∼145℃이며, 그 용융유속(MFR)(ASTM D-1238(L))은 10g/10분이하, 바람직하게는 2∼7g/10분이다. 상기 랜덤공중합체의 에틸렌함량은 그 융점에 의해 측정하였으며, 약 2∼10몰%, 바람직하게는 3∼5몰%이다. 필요에 따라 탄소수 4∼8인 α-올레핀 10몰%이하를 함유할 수도 있다.
상기 프로필렌/에틸렌 폴리프로필렌(a)의 융점이 상기의 범위내이므로, 그에 의한 출발원료는 유연성을 갖는다. 또한 그 MFR이 상기 범위내이므로, 폴리에틸렌과의 혼합성이 보다 양호하며, (A)와 (B)와의 조성물의 방사성(spinnabilituy)이 향상된다. 프로필렌/에틸렌 폴리프로필렌(a)의 양은 제1성분(A) 전체중량에 대해 3∼40중량%, 바람직하게는 10∼30중량%이다. 이러한 범위로 배합하면 상기 중합체들의 혼합은 양호하게 되고, 그로부터 얻어진 혼합물이 방사에 적합한 점도를 갖는다. 따라서 방사성이 향상된다.
본 발명에서 상기 제1성분에 사용되는 폴리에틸렌(b)의 MFR(ASTM D-123(E))은 15g/10분이상, 바람직하게는 20g/10분이상이고, 밀도는 0.935g/㎤이하, 바람직하게는 0.915∼0.930g/㎤이다. 이러한 폴리에틸렌으로는 예를 들어 저밀도 폴리에틸렌과 선형 저밀도 폴리에틸렌이 있으며, 전자가 더 바람직하다.
상기 저밀도 폴리에틸렌으로는 고압법에 의해 제조된 에틸렌 단독중합체 또는 탄소수 3이상, 바람직하게는 4∼20인 α-올레핀 10몰%이하와 에틸렌20몰%이하로 된 공중합체가 있다.
상기 선형 저밀도 폴리에틸렌수지는 에틸렌과 탄소수 4이상, 바람직하게는 4∼20인 α-올레핀 0.5∼40몰%, 바람직하게는 0.5∼30몰%와의 공중합체이다. 이것은 0∼100기압(게이지압)에서 배위촉매를 사용해서 중저압법에 의해 합성할 수 있다.
상기 폴리에틸렌(b)의 MFR과 밀도를 상기 범위내로 함으로써 고속 취출속도에서 안정한 방사가 가능하다. 폴리에틸렌(b)의 양은 상기 제1성분(A)에 대해서 97∼60중량%, 바람직하게는 90∼70중량%이다.
본 발명의 상기 제1성분(A)에 프로필렌/에틸렌 폴리프로필렌(a)와 폴리에틸렌(b)을 혼합하여 얻은 조성물이다. 상기 프로필렌/에틸렌 폴리프로필렌(a)와 폴리에틸렌(b)와의 혼합은 예를 들면 밴부리 믹서, 핫 롤(hot roll) 또는 압출기등의 통상적 혼합수단에 의해 행한다. 이 혼합은 또한 방사압출기에서 펠릿 블렌딩(pellet blending)에 의해 행할 수도 있다. 혼합방법은 긴밀한 혼합히 가능한한 특별한 제한은 없다.
본 발명에 있어서 상기 제2성분(B)인 폴리프로필렌의 MFR(ASTM D-1228(L))은 10g/10분이상, 바람직하게는 12∼40g/10분이다. 이 결정성 폴리프로필렌은 X선 회절법으로 측정한 결정화도가 40%이상, 바람직하게는 55%이상인 것이 바람직하다. 이것은 프로필렌 단독공중합체이거나 또는 프로필렌과 탄소수 2 또는 4∼20인 α-올레핀 20몰%이하, 바람직하게는 10몰%이하와의 공중합체인 것이 바람직하다.
상기 제2성분(B)은 상기와 같은 결정성 폴리프로필렌을 주성분으로 함유하고 있으며, 폴리에틸렌 또는 폴리부텐과 같은 다른 폴리올레핀을 30%이하 함유할 수도 있다.
첨부도면을 참조하여 설명하면, 제1a, b 및 c도는 각각 본 발명의 부직포의 장섬유의 단면도를 나타낸다. 본 발명의 부직포를 구성하는 장섬유(1)은 상기 제1성분(A)과 상기 제2성분(B)가 복합구성된 것이다. 제1a도에 나타난 바와 같이, 상기 장섬유(1)를 구성하는 상기 제1성분(A)과 제2성분(B)을 완전 병렬형으로 구성할 수도 있다. 또는, 제1b 또는 1c도에 나타난 바와 같이 한 성분을 다른 성분위에 부분적으로 겹치게 할 수도 있다.
본 발명의 부직포를 구성하는 장섬유는 상기와 같은 복합구성으로 되어 있으며, 주름 잡혀있다. 상기 제1성분(A)과 제2성분(B)을 병렬로 구성하고, 이들을 복합 구조체로 방사시킴으로써 상기 두 성분간의 수축률차에 의해 주름이 잡힌다. 상기 제1과 제2성분의 비율에는 특별한 제한이 없다. 성분(A) 대 성분(B)의 바람직한 체적비는 20 : 80∼70 : 30, 특히 바람직하게는 30 : 70∼60 : 40이다.
주름수는 특별한 제한이 없다. JIS S1074에 의한 바람직한 주름수는 10/25mm이상, 바람직하게는 30/25mm이다.
상기 주름잡힌 장섬유는 예를 들어 본 발명에서 사용될 장섬유를 고속으로 취출할 수 있는 잇점을 활용해서 고속기류중에서 인발에 의해 장섬유를 취출하는 스펀 본드법에 의해서 부직포로 제조할 수 있다. 제2도는 스펀 본드법에 의해 부직포를 제조하는 장치 및 방법을 나타내는 개략정면도이다. 본 발명의 부직포의 제조는 상기 제1성분과 제2성분의 용융중합체를 병진형 노즐(2)로부터 분출시켜 장섬유들(1)을 방사하고, 고속기류 인발장치(3)로부터 분출되는 공기류에 상기 장섬유(1)을 배치하여 분산판에 의해 분산시키면서 이동포집면에 집적한다. 이 이동포집면(5)에 의해 이송된 장섬유들(1)은 가열된 엠모싱 롤과 원통형 롤사이로 운반되어 서로 가열 융착되어 부직포로 된다. 또는 상기 장섬유들(1)을 가열실에서 융착시키거나 또는 접착제를 사용해서 접착하거나 또는 니들 펀칭(needle-punching)에 의해 장섬유들을 서로 휘감음으로써 부직포를 제조할 수도 있다.
상기에서 제조된 부직포는 그 단일 장섬유 크기가 1∼20데니어, 바람직하게는 1.5∼4데니어이며, 단위중량(X)은 10∼200g/㎠, 바람직하게는 15∼120g/㎠이다.
본 발명의 부직포는 그 장섬유들에 주름수가 많으므로, 단위중량당 높은 유연도를 갖는다. 부직포의 유연성은 JIS L-1096에 준해서 측정한다. 콘베이어 진행방향을 종방향으로 하면, 부직포의 단위중량(X)(g/㎠)당 유연성은 종방향의 유연성 SMD(g)와 횡방향의 유연성 STD(g)와의 기하평균
Figure kpo00002
으로 표시된다.
하기 부등식이 만족될 때 부직포는 우수한 유연성을 갖는다.
Figure kpo00003
상기 부직포는 프로필렌/에틸렌 랜덤공중합체와 저밀도 폴리에틸렌으로 구성된 제1성분과, 결정성 폴리프로필렌으로 된 제2성분으로 구성된 장섬유의 병렬 복합체로 구성돼 있으므로, 상기 복합체를 고속기류 인발법에 의해 2000m/분이상의 고취출속도로 안정하게 방사할 수 있다. 또한 장섬유들중의 주름수가 많으므로 유연한 장섬유 부직포가 얻어진다.
본 발명은 실시예를 들어 보다 구체적으로 설명한다.
[실시예 1]
DSC(퍼킨 엘머 DSC-7)에 의하여 승온속도 10℃/분에서의 주 피크로부터 측정한 융점이 140℃인 프로필렌/에틸렌 랜덤공중합체 17중량%와 MFR[ASTM D-1238(E)]이 22g/10분, 밀도 0.925g/㎤인 저밀도 폴리에틸렌 83중량%로 된 제1성분과, MFR(ASTM D-1238(L))이 36g/10분, 결정화도가 60%인 결정성 폴리프로필렌인 제2성분을 사용하여 구멍이 700개인 병진형 노즐로 0.88g/분. 구멍의 압출속도로 압출하였다. 형성된 장섬유들을 분산판에 분산시키면서 이동 콘베이어에 집적했다. 상기 장섬유들을 가열된 엠보싱 롤과 원통형 롤 사이에서 가열 압축하여 부직포를 제조했다.
상기 부직포를 구성하는 장섬유들은 크기가 2.5데니어였으며, 주름수는 48/25mm였다. 인발속도는 2880/분이었다. 장섬유 파단은 발생치 않았고, 안정하게 방사를 행할 수 있었다.
상기 부직포의 유연성과 두께를 하기 방법으로 측정하였으며 그 결과들을 표 1에 나타냈다.
두께 : JIS L-1096에 준함, 하중 0.1g/mm3에서 측정.
유연성 : JIS L-1096에 기재돼있는 핸들 미터법에 준함, 15×15cm의 시험편을 사용하고 슬롯(slot)폭을 20mm로 하여 측정.
[비교예 1]
융점이 134℃, MFR(ASTM D-1238(L))이 22g/10분인 프로필렌/에틸렌 랜덤공중합체를 사용하였다. 그외는 실시예 1과 동일하게 실시했다. 혼합이 잘 되지 않아서 장섬유 파단이 자주 발생했고, 장섬유 부직포를 제조할 수 없었다.
[비교예 2]
MFR(ASTM D-1238(ED))이 30g/10분인 선형 저밀도 폴리에틸렌을 상기 제1성분으로 단독으로 사용했다. 그외는 실시예 1과 동일하게 실시했다. 방사성은 양호했으나 장섬유에 주름이 잡히지 않았다. 제품의 유연성은 표 1에 나타낸 바와 같이 불충분했다.
[비교예 3]
MFR(ASTM D-1238(E))이 20g/10분, 밀도 0.963g/㎤인 고밀도 폴리에틸렌을 제1성분으로 사용한 외에는 실시예 1과 동일하게 실시했다. 그 결과들을 표 1에 나타냈다.
[비교예 4]
MFR(ASTM D-1238(E))이 12g/10분, 결정화도가 63%인 폴리프로필렌을 제2성분으로 사용한 외에는 실시예 1과 동일하게 실시했다. 그 결과들을 표 1에 나타냈다.
[표 1]
Figure kpo00004

Claims (2)

  1. DSC 주 피크에 의해 측정한 융점이 110∼150℃, 용융유속(ASTM D-1238(L))이 15g/10분이하인 프로필렌/에틸렌 랜덤공중합체 3∼40중량%(a) 및 용융유속(ASTM D-1238(E))이 15g/10분이상인 폴리에틸렌 97∼60중량%(b)로 구성된 제1성분(A)과, 용융유속(ASTM D-1238(L))이 10g/10분이상인 결정성 폴리프로필렌을 주성분으로 하는 제2성분(B)으로 구성된 주름잡힌 2성분 복합 장섬유로 된 유연한 장섬유 부직포.
  2. 제1항에 있어서, 상기 프로필렌/에틸렌 랜덤공중합체가 프로필렌/에틸렌/탄소수 4∼8인 α-올레핀으로 구성된 3원 공중합체인 유연한 장섬유 부직포.
KR1019900005738A 1989-04-25 1990-04-24 유연한 장섬유 부직포(nonwoven fabric of filaments) KR920007992B1 (ko)

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