US20040198127A1 - Non-woven fabric and, a laminate and braided material using the same - Google Patents

Non-woven fabric and, a laminate and braided material using the same Download PDF

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Publication number
US20040198127A1
US20040198127A1 US10/481,127 US48112703A US2004198127A1 US 20040198127 A1 US20040198127 A1 US 20040198127A1 US 48112703 A US48112703 A US 48112703A US 2004198127 A1 US2004198127 A1 US 2004198127A1
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Prior art keywords
woven fabric
fibers
fluoropolymer
set forth
web
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Abandoned
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US10/481,127
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English (en)
Inventor
Seigo Yamamoto
Katsutoshi Yamamoto
Jun Asano
Shinichi Chaen
Tomohisa Konishi
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Daikin Industries Ltd
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Daikin Industries Ltd
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Assigned to DAIKIN INDUSTRIES, LTD. reassignment DAIKIN INDUSTRIES, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ASANO, JUN, CHAEN, SHINICHI, KONISHI, TOMOHISA, YAMAMOTO, KATSUTOSHI, YAMAMOTO, SEIGO
Publication of US20040198127A1 publication Critical patent/US20040198127A1/en
Abandoned legal-status Critical Current

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    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/54Non-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 by welding together the fibres, e.g. by partially melting or dissolving
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/42Non-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
    • D04H1/4282Addition polymers
    • D04H1/4318Fluorine series
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/42Non-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
    • D04H1/4374Non-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 using different kinds of webs, e.g. by layering webs
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/42Non-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
    • D04H1/4382Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43835Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/44Non-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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46Non-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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48Non-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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/49Non-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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation entanglement by fluid jet in combination with another consolidation means
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637Including 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
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/689Hydroentangled nonwoven fabric
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/696Including strand or fiber material which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous compositions, water solubility, heat shrinkability, etc.]
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/697Containing at least two chemically different strand or fiber materials

Definitions

  • the present invention relates to a non-woven fabric made primarily from a fluoropolymer, as well as a laminate and braided material using the same.
  • Fluoropolymers have excellent chemical resistance, excellent heat resistance, excellent insulating abilities, and an extremely low coefficient of friction.
  • it has been difficult to produce a non-woven fabric from fluoropolymers that has excellent mechanical strength because of this extremely low coefficient of friction.
  • using short fluoropolymer fibers to produce a non-woven fabric has thus far been impossible.
  • a fluoropolymer non-woven fabric having a foundation cloth is conventionally employed in which fluoropolymer staple fibers in textiles and the like are laminated and entangled.
  • fluoropolymer staple fibers in textiles and felt that have been laminated and entangled as a fluoropolymer non-woven fabric having a foundation cloth.
  • a cloth-like material that does not have a foundation cloth and which is composed primarily of a fluoropolymer has been proposed, and is a web produced by cutting a fluoropolymer film into fibers and then laminating those fibers.
  • International Patent Publication No. WO96/10668 discloses technology for improving both the ability of fibers to be entangled and the strength of a non-woven fabric by mixing fluoropolymer fibers with non-fluoropolymer fibers.
  • the aforementioned conventional web is merely formed into a laminate in the thickness direction, and thus it will be difficult to obtain a web having excellent tensile strength and elasticity even if pressure is applied to it with a nip roller. Thus, there will be problems with tearing of the web during processing, even when the web is wound up into a roll with low tension.
  • an object of the present invention is to improve the mechanical strength of a non-woven fabric that does not have a foundation cloth and which is composed primarily of fluoropolymer fibers.
  • another object of the present invention is to make it possible to use this type of non-woven fabric in variety of applications.
  • the non-woven fabric disclosed in claim 1 does not have a foundation cloth, is composed primarily of fluoropolymer fibers, and the fibers therein are entangled.
  • this non-woven fabric is primarily composed of a fluoropolymer, it has superior characteristics, such as a strong resistance to chemicals, a strong resistance to heat, strong insulating abilities, and an extremely low coefficient of friction.
  • This non-woven fabric does not have a foundation cloth, and thus its thickness can be reduced. In addition, a homogeneous porosity, air permeability, and elasticity can be obtained.
  • a web composed primarily of fluoropolymer fibers may be one which is composed entirely of fluoropolymer fibers, or may also be one which includes other fibers so long as the aforementioned superior characteristics of the fluoropolymer has not been substantially and completely lost.
  • the ratio of fluoropolymer in the non-woven fabric is normally 50% or more, preferably 70% or more, more preferably 90% or more, and even more preferably 95% or more.
  • the symbol “%” refers to weight % unless otherwise noted.
  • the non-woven fabric disclosed in claim 2 is the non-woven fabric disclosed in claim 1 , in which the average fiber length of the fluoropolymer fibers is approximately 5 to approximately 50 mm.
  • This type of non-woven fabric is not known in the prior art. Conventionally, these fibers were not used in the production of non-woven fabrics and were discarded. This non-woven fabric has the advantage of being inexpensive to produce.
  • the non-woven fabric disclosed in claim 3 is the non-woven fabric disclosed in claim 1 or claim 2 , in which water jet needle punching is performed on a web that is primarily composed of branched chain fluoropolymer fibers, and in which the apparent density thereof is between 0.2 g/cm 3 or greater and 1.5 g/cm 3 or lower.
  • this non-woven fabric will have superior web tensile strength and elasticity because the fibers will be intertwined.
  • the fluoropolymer fibers have branched chains, the fibers can be more strongly intertwined and the mechanical strength thereof will be even better.
  • the apparent density of this non-woven fabric is preferably 0.7 g/cm 3 or greater, more preferably 0.8 g/cm 3 or greater, and even more preferably 1.0 g/cm 3 or greater.
  • the special characteristics of the non-woven fabric will be lost if the apparent density thereof exceeds 1.5 g/cm 3 .
  • the non-woven fabric has a high degree of strength due to these factors. Thus, it is possible to reduce the basis weight of the fabric.
  • a fluoropolymer fiber non-woven fabric can be provided that has a basis weight of 300 g/m 2 or less, 200 g/m 2 or less, or 100 g/m 2 or less. In production tests performed by the inventors, a fluoropolymer fiber non-woven fabric having a basis weight of approximately 30 g/m 2 could be obtained.
  • this non-woven fabric can control peeling that occurs between the surface layer of the web and the adhesive layer, even if other members are adhered thereto with an adhesive or the like, because the strength of this non-woven fabric is improved in the thickness direction by means of water jet needle punching.
  • the non-woven fabric of the present invention can have a variety of members laminated thereon, and a laminated product capable of being used in a variety of applications such as a sliding material, sealing material, or the like can be obtained thereby.
  • the non-woven fabric disclosed in claim 4 is the non-woven fabric disclosed in any of claims 1 to 3 , in which the non-woven fabric is treated with pressure and heat at a temperature below the melting point of the fluoropolymer.
  • the strength of this non-woven fabric is increased by treating it with pressure and heat. In addition, this treatment controls napping and fiber loss, and stabilizes the non-woven fabric in its proper form. In addition, this pressure and heat treatment is conducted below the melting point of the fluoropolymer fibers.
  • the non-woven fabric disclosed in claim 5 is the non-woven fabric disclosed in any of claims 1 to 3 , in which a portion of the fluoropolymer fibers are fused together. Distinguishing the fused fibers can be performed visually with the use of a microscope. Tweezers or the like are used to disentangle the non-fused fibers from the short fibers, but the fused fibers can be easily distinguished because they cannot be disentangled.
  • This type of non-woven fabric e.g., a non-woven fabric in which fluoropolymer fibers are entangled together, is obtained by pressure and heat treating at least a portion of the fluoropolymer fibers at a temperature that is at or above the melting point thereof.
  • non-woven fabrics having these qualities are used, for example, in filters or filter support members for filtering devices in which a large filter pressure is applied, in air permeable sheets, and the like.
  • this non-woven fabric can be used, for example, as a sliding material because napping of the surface fibers is controlled.
  • the non-woven fabric disclosed in claim 6 is the non-woven fabric disclosed in claims 1 to 5 , in which the fluoropolymer fibers are obtained primarily by cutting a uniaxially drawn fluoropolymer film into fibers.
  • the fibers that make up the non-woven fabric of the present invention have branched chains and thus have a superior ability to be entangled.
  • fibers having branched chains are often obtained by means of this method.
  • a non-woven fabric in which the fluoropolymer fibers therein are primarily obtained by means of this method is particularly desirable.
  • the non-woven fabric disclosed in claim 7 is the non-woven fabric disclosed in any of claims 1 to 6 , in which the fluoropolymer is polytetrafluoroethylene (hereinafter referred to as PTFE).
  • PTFE polytetrafluoroethylene
  • PTFE in particular has low frictionality and low dielectric properties, and has qualities that make it easy to form fibers by means of this processing method.
  • Semi-sintered PTFE is a substance which displays both the heat absorbance of unsintered PTFE (approximately 615° K) and the heat absorbance of sintered PTFE (approximately 600° K) during DSC (differential scanning calorimetry). DSC can be performed by means of a commercially available DSC device.
  • the apparent density of the non-woven fabric immediately after entanglement has been completed is between 0.4 g/cm 3 and 0.9 g/cm 3 .
  • the non-woven fabric disclosed in claim 8 is the non-woven fabric disclosed in any of claims 1 to 6 , in which the fluoropolymer is ethylene-tetrafluoroethylene copolymer (hereinafter referred to as ETFE).
  • ETFE ethylene-tetrafluoroethylene copolymer
  • ETFE Like PTFE, ETFE has low frictionality and low dielectric properties, and has qualities that make it easy to form fibers by means of this processing method. Thus here, it is particularly desirable to use ETFE materials as the fluoropolymer fibers.
  • the apparent density of this non-woven fabric immediately after entanglement has been completed is between 0.3 g/cm 3 and 0.8 g/cm 3 .
  • the non-woven fabric disclosed in claim 9 is the non-woven fabric disclosed in any of claims 1 to 8 , in which the non-woven fabric includes one or more types fibers selected from the group consisting of polypropylene (hereinafter referred to as PP) fibers, polyethylene (hereinafter referred to as PE) fibers, polyethylene terephthalate (hereinafter referred to as PET) fibers, aramid fibers, nylon fibers, poly-para-phenylene benzobisoxazole (hereinafter referred to as PBO) fibers, polyimide fibers, carbon fibers, glass fibers, alumina fibers, stainless steel fibers, and compound fibers used for splitting.
  • PP polypropylene
  • PE polyethylene
  • PET polyethylene terephthalate
  • PBO poly-para-phenylene benzobisoxazole
  • this non-woven fabric will have both the superior properties provided by fluoropolymers and the superior properties provided by the other fibers.
  • the non-woven fabric disclosed in claim 10 is the non-woven fabric disclosed in any of claims 1 to 8 , in which the non-woven fabric includes compound fibers used for splitting, and in which the compound fibers therein are split.
  • the splitting is performed simultaneously by means of water jet needle punching when the web is water jet needle punched to obtain the non-woven fabric.
  • the compound fibers are split into ultra fine fibers.
  • this non-woven fabric possesses both the superior properties provided by fluoropolymers and the superior properties provided by the ultra fine fibers.
  • the ultra fine fibers contribute to the ability of the other fibers to become entangled.
  • the non-woven fabric disclosed in claim 1 is the non-woven fabric disclosed in any of claims 1 to 10 , in which the non-woven fabric is elongated below its maximum degree of elongation.
  • This non-woven fabric is the non-woven fabric of any of claims 1 to 10 , and elongated below its maximum degree of elongation in one or two axes. This process controls elongation, and improves tensile strength (maximum point load). In addition, the fabric density can be adjusted by elongation.
  • the laminated material disclosed in claim 12 is comprised of a non-woven fabric and a support material.
  • the non-woven cloth is that disclosed in any of claims 1 to 11 .
  • the support material is laminated on the non-woven fabric.
  • the non-woven fabric disclosed in any of claims 1 to 11 has sufficient strength in and of itself, but its mechanical strength is increased by laminating it with a suitable material.
  • the non-woven fabric disclosed in any of claims 1 to 11 has a high degree of strength in the thickness direction, and thus problems are unlikely to occur when a portion of the fibers that make up the non-woven fabric are left on the surface of the support material when the non-woven fabric is peeled away.
  • This laminate can be used in a variety of applications, such as a sliding material, an insulating material, a sealing material, or a filter, because it has superior characteristics such as low frictionality, a low dielectric constant, and the like provided by the fluoropolymer.
  • the braided material disclosed in claim 13 is produced by twisting the non-woven fabric of any of claims 1 to 11 .
  • the non-woven fabric is cut into tape-shaped portions and then into long and narrow strips, and one or a plurality of these long and narrow strips are twisted in order to obtain the aforementioned braided material.
  • the aforementioned braided material can be twisted together to obtain the braided material disclosed in claim 13 .
  • a method of strengthening a non-woven fabric comprised primarily of a fluoropolymer is comprised of the step of applying pressure and heat to the non-woven fabric.
  • stressen here is defined as increasing the tensile strength and/or the strength in the thickness direction.
  • the non-woven fabric of claim 15 is strengthened by means of the method disclosed in claim 14 .
  • FIG. 1 is a cross section in the thickness direction of a non-woven fabric which employs an embodiment of the present invention.
  • FIG. 2 is a cross section in the thickness direction of a laminated material which employs an embodiment of the present invention.
  • FIG. 1 shows a non-woven fabric which employs a first embodiment of the present invention.
  • the non-woven fabric 1 is composed primarily of semi-sintered PTFE fibers, and these fibers have a branched structure.
  • PTFE is used as a fluoropolymer, but the PTFE may instead be a homopolymer of tetrafluoroethylene (hereinafter referred to as TFE), or may be a PTFE modified by polymerizing a small amount of perfluorovinyl ether with TFE. Note that in the present invention, the term PTFE also includes this modified PTFE unless otherwise noted.
  • PTFE may be substituted with a fluoropolymer capable of being melt processed, such as a copolymer of TFE and hexafluoropropylene (FEP), a copolymer of ethylene and TFE (ETFE), or a copolymer of TFE and perfluoroalkyl vinyl ether (PFA).
  • FEP hexafluoropropylene
  • ETFE ethylene and TFE
  • PFA perfluoroalkyl vinyl ether
  • PTFE is preferred due to its superior chemical resistance and mechanical strength, and semi-sintered PTFE is particularly preferred due to the ease with which it is formed into a web and the ease with which it undergoes secondary processing.
  • Semi-sintered PTFE film is obtained by heat processing a PTFE film obtained by forming a paste from PTFE fine powder obtained with an emulsion polymerization method, or heat processing a PTFE film obtained by applying pressure to a PTFE powder obtained by a suspension polymerization method, at a temperature between the melting point of sintered PTFE (approximately 327° C.) and the melting point of a non-sintered PTFE (approximately 337° C. to 347° C.).
  • Sintered PTFE is obtained by heat processing non-sintered PTFE or semi-sintered PTFE at a temperature at or above the melting point of non-sintered PTFE.
  • the web used in the production of the non-woven fabric of the present invention is comprised only of a fluoropolymer.
  • fibers other than fluoropolymer fibers may be used therewith in the web.
  • These types of fibers include organic fibers such as PP fibers, PE fibers, PET fibers, aramid fibers, nylon fibers, PBO fibers, and polyimide fibers, inorganic fibers such as glass fibers, carbon fibers, and alumina fibers, metal fibers such as stainless steel fibers, and compound fibers that are used for splitting. These fibers may be used independently, or may be used in combinations of two or more.
  • the aforementioned compound fibers used for splitting can be those well know in the art that are obtained by spinning a plurality of resin types.
  • the aforementioned compound fibers used for splitting are split at the same time that the fibers of the web are entangled by means of water jet needle punching, and are formed into ultra fine fibers thereby.
  • the aforementioned plurality of different resin types include polyester/nylon, polyester/polypropylene, and the like.
  • the ratio of fibers other than the fluoropolymer fibers is not particularly limited so long as the aforementioned superior properties of fluoropolymers are not substantially and completely lost. However, the properties provided by fluoropolymers will be harmed as the ratio of the fluoropolymer fibers used decreases.
  • the ratio of fluoropolymer in the web used in the non-woven fabric of the present invention is normally 50% or more, preferably 70% or more, more preferably 90% or more, and even more preferably 95% or more.
  • branched monofilament, staple fibers, and multifilament disclosed in, for example, WO94/23098, WO96/00807, WO96/10662, and the like are preferably used as webs.
  • Each individual fiber of these webs is obtained by mechanically cutting PTFE that has been uniaxially drawn and processed into a film (PTFE film), and then cutting this film into fibers.
  • PTFE film a film
  • These fibers have a branched structure.
  • fluoropolymer fibers that are not used conventionally and which are comparatively short may be used in a non-woven fabric composed primarily of fluoropolymer fibers.
  • fluoropolymer fibers can be used that are 5 to 50 mm in length, and preferably 10 to 20 mm in length.
  • the length of the fluoropolymer fibers are not required to be uniform. Extremely short fluoropolymer fibers may be within a fixed ratio. More specifically, less than 40% of the fibers may be 5 mm or less in length, preferably less than 10%, and more preferably less than 5%. On the other hand, the ratio of long fluoropolymer fibers is not particularly limited. Surprisingly, an ideal non-woven fabric could be produced even when, for example, 20% or less, 10% or less, 5% or less, or 2% or less of the fibers were 25 mm or less in length. In addition, an ideal non-woven fabric can be produced even when less than 1% or substantially 0% of the fibers therein are 50 mm or greater in length. The symbol “%” refers to a number relating to the length of the fibers.
  • the length of the fibers is determined by removing 100 fibers from the non-woven fabric and measuring them by standard methods. If a fiber is branched, it is measured in such a way that the length thereof is maximized.
  • a web that includes fluoropolymer fibers and fibers other than fluoropolymer fibers can be obtained by overlaying a fluoropolymer film with a polymer film other than a fluoropolymer, and mechanically cutting the films and forming fibers therefrom. Or, these fibers can simply be mixed together mechanically.
  • the web of the present embodiment is subjected to water jet needle punching.
  • a preferred example will be described, but the present embodiment is not limited thereto.
  • a web is mounted on a 70 mesh or higher net that supports the web, a nozzle having a nozzle diameter of approximately 1 mm and a nozzle pitch of approximately 1 mm is employed, pre-needle punching is first carried out at a water pressure of 5 MPa or greater, and then a main needle punching is carried out at a maximum water pressure of 10 MPa.
  • Air and water discharge ports that are connected to a vacuum pump or a blower are provided below the transport net that is directly below the nozzle, and the water used to needle punch the web is swiftly discharged thereby.
  • the net that is used as a support material for the web during needle punching be approximately 100 mesh so that the web fibers do not become entangled with the net and that the amount of web (fluoropolymer loss) that remains on the net when it is peeled away is reduced.
  • the amount of web (fluoropolymer loss) that remains on the net when it is peeled away is reduced.
  • the eyes are rough, there will be large variations in the degree to which the web encroaches into the eyes of the net, a net pattern will be transferred to the surface of the web, and through holes will be formed in the web by means of the water jets.
  • the density of the web will be reduced to 0.3 to 0.7 g/cm 3 , thus making it easier for the water jet to flow therethrough.
  • the energy of the water jet will not be applied to the entanglement of the web but rather will be dissipated from the support material.
  • the energy of the collision between the net and the water jet can be effectively used to entangle the web.
  • a net which has been calendared may be used because if the surface thereof has been smoothed, the percentage of open holes in the support material will increase.
  • the fibers By performing water jet needle punching in this manner, the fibers will be moved in the thickness direction, the fibers will be entangled in the thickness direction, tensile strength (maximum point load) will increase, and elongation during this process will be controlled.
  • a non-woven fabric having a plurality of holes that correspond to the positions of these openings can be obtained because the fibers that are positioned in the openings will come out therefrom.
  • the shape of these openings is not particularly limited.
  • the size of the openings that produce these types of holes will be different depending upon the conditions under which water jet needle punching is performed (water pressure, etc.).
  • the term “hole” does not necessarily mean portions that are completely open, but rather includes portions comprised of spaces between separated fluoropolymer fibers.
  • a non-woven fabric having a low density of entangled fibers will not have sufficient strength. There is a strong correlation between the apparent density of a non-woven fabric and the strength thereof. In addition, there will be problems in that, because there is significant napping on the surface of this type of non-woven fabric, the fibers thereon will easily peel away and scatter, and creases will remain visible on the non-woven fabric when it is water jet needle punched.
  • the apparent density of a non-woven fabric that has napping will be increased and the surface thereof will be smoothed by applying heat and pressure thereto at a temperature that is below the melting temperature thereof after the fibers have been entangled.
  • a non-woven fabric can be continuously processed by passing a non-woven fabric whose fibers have been entangled between heated metal rollers or between a heated metal roller and a rubber roller.
  • the non-woven fabric may be intermittently processed by means of a process involving a heat press device.
  • the apparent density of the non-woven fabric is preferably 0.7 g/cm 3 or greater, more preferably 0.8 g/cm 3 or greater, and even more preferably 1.0 g/cm 3 or greater.
  • the special characteristics of the non-woven fabric will be lost if the apparent density thereof exceeds 1.5 g/cm 3 .
  • the apparent density thereof can be increased by increasing the pressure applied thereto.
  • the gap between the rollers may be narrowed if, as noted above, the method used to apply the pressure involves passing the non-woven fabric in between rollers.
  • the gap between the rollers needed to obtain the desired apparent density will differ depending upon the thickness of the non-woven fabric being passed therethrough, the properties of the rollers, the temperature of the rollers, and other factors. However, the gap can be easily determined by changing the parameters and conducting a number of production tests.
  • the temperature used during heat treatment may be higher than room temperature (normally about 25° C.), but with respect to the effects of this pressure and temperature treatment, a high processing temperature will tend to produce better results.
  • the upper limit of the processing temperature is set to be the melting point of the fluoropolymer fibers. In this way, a soft non-woven fabric having a high degree of strength will be obtained.
  • the aforementioned non-woven fabric having a plurality of holes is heat and pressure treated, these plurality of holes will be maintained in that state, and the strength of the non-woven fabric can be increased.
  • the non-woven fabric obtained in this manner is ideally used as a support member of a fluoropolymer membrane.
  • a non-woven fabric having a low density is water jet needle punched as is and a highly viscous adhesive is applied thereto, there will be problems in that the length and the width of the non-woven fabric can be easily deformed by external forces, the density thereof will not be uniform, and the size thereof will not be stable.
  • elongation is controlled and tensile strength (maximum point load) increased by elongating the non-woven fabric in one or two axial directions before water jet needle punching.
  • the non-woven fabric can be continuously elongated in one axial direction by rolling the non-woven fabric up at a speed that is faster than the speed at which it is unrolled.
  • the non-woven fabric can be elongated in two axes by using a horizontal elongation device (tenter) and elongating it in a direction that is perpendicular to the direction in which it is being unrolled.
  • the present invention can easily obtain a cylindrically shaped braid having a high tensile strength by braiding a non-woven fabric that has been subject to elongation.
  • a braided material is obtained by braiding one or a plurality of long and narrow shaped portions of non-woven fabric together. These braids can be formed into a rope by braiding the braids together.
  • the non-woven fabric according to a second embodiment of the present invention is identical to the non-woven fabric according to the first embodiment, except that a portion of the fluoropolymer fibers are fused together.
  • the non-woven fabric of the present embodiment is obtained by pressure and heat treating at least a portion of the fluoropolymer fibers of the non-woven fabric of the first embodiment at a temperature that is at or above the melting point thereof. However, if the aforementioned temperature is too high, the fluoropolymer will break down to an excessive degree. For example, it is preferred that semi-sintered PTFE be processed at 340° C. to 360° C. In addition, it is preferred that only one surface of this non-woven fabric be heat treated in order to control changes in the width of the non-woven fabric due to thermal contraction.
  • the non-woven fabric may be passed between a metal roller that has been heated to 340° C. to 360° C. and an unheated metal roller.
  • this non-woven fabric controls napping of the fibers on the surface thereof.
  • the temperature and processing times be set such that the amount of contraction in the width is 25% or less.
  • the aforementioned non-woven fabric having a plurality of holes is heat and pressure treated, these holes will be maintained in that state, and the strength of the non-woven fabric can be increased.
  • the non-woven fabric obtained in this manner is ideally used as a support member of a fluoropolymer membrane.
  • FIG. 2 shows a laminate 1 which employs an embodiment of the present invention.
  • the laminate 11 is comprised of the non-woven fabric 1 noted above, and a support member 3 that is laminated to the non-woven fabric 1 .
  • the non-woven fabric 1 of the present invention is porous due to formation as a web, and other members can be easily affixed thereto by means of an adhesive. These characteristics can be utilized to obtain the laminate 11 shown in FIG. 2. In addition, the non-woven fabric alone can be used in a variety of applications.
  • a metal, rubber, polymer, wood, ceramic, or other similar material is used as the support member 3 , a sliding member having low frictionality, a sealing member having superior water repellency, or a non-cohesive mold release member can be obtained by affixing one of these materials to the non-woven fabric 1 .
  • the non-woven fabric 1 can be affixed on top thereof by applying a conventional adhesive used for PVC to the PVC member.
  • a rubber adhesive can be used if the member is made from rubber.
  • a general use vinyl acetate adhesive can be used if the member is made from wood.
  • a thermosetting resin adhesive e.g., an epoxy resin
  • a thermoplastic resin adhesive e.g., a urethane adhesive
  • the like can be used if the member is made from metal or ceramic.
  • the adhesive layer can be in combination with the support member.
  • an earthquake damping member for use with pipes can be made that has a PTFE web as the upper layer and rubber as the lower layer.
  • a mold release member is placed between a molded article in, for example, a hot press and the heated surface of the hot press, and allows the molded article to be easily released from the heated surface of the press.
  • a mold release member having superior cushionability is obtained.
  • the support member is a metal or ceramic that is resistant to heat that is at or above the melting point of PTFE or the like, or if the support member is a polymer or the like that is assured of being heat resistant for a short period of time, then the upper layer of the web can be heat treated at a temperature at or higher than the melting temperature thereof if an adhesive having heat resistance, e.g., a polyimide varnish, is used to adhere the non-woven fabric 1 to the support member.
  • an adhesive having heat resistance e.g., a polyimide varnish
  • a PTFE laminate film having superior adhesiveness can be produced by applying a heat resistant soluble polymer adhesive such as the aforementioned polyimide varnish to the non-woven fabric.
  • a non-cohesive belt can be obtained by adhering the non-woven fabric 1 to the main body of an annular belt.
  • a insulating tape for use in electric wires/electric circuits and which has superior insulating capabilities can be obtained by wrapping the conductive surface thereof with the non-woven fabric 1 . More specifically, an insulating layer which has an water resistant layer on the outer circumference thereof can be easily produced by wrapping a standard conductive material with the non-woven fabric 1 , and applying a thermosetting resin, a thermoplastic resin, or the like on the non-woven fabric 1 wrapped thereon.
  • This insulating layer has a low dielectric constant, a low dielectric dissipation factor, and a high degree of porosity, and thus a layer that is suitable as a an insulating material for a high frequency electric circuit/electric wire can be obtained.
  • the non-woven fabric 1 of the present invention is flexible, its ability to be wrapped around an object is superior to that of conventional drawn tape and has superior dielectric capabilities, even if it is comparatively thick. Note that from the point of view of workability, the non-woven fabric 1 preferably has a thickness of 0.05 mm or greater.
  • a low basis weight non-woven fabric having an approximate thickness of 0.1 mm and a porosity of 50% or greater is needed when used as a wrapping tape to insulate high frequency electric wires.
  • changes in the width of the tape and tape breakage during wrapping can be controlled, even if wrapped under a high degree of tension, by using a non-woven fabric whose thickness has been adjusted after one side thereof has been heat fused. This also allows an insulated electric wire having stable quality to be obtained.
  • a printed circuit board can be obtained by using the non-woven fabric 1 as a base material, impregnating it with a thermosetting resin or a thermoplastic resin, and then adhering copper foil to the surface thereof.
  • This printed circuit board can be used as a substrate for high frequency circuits due to the low dielectric constant, the low dielectric dissipation factor, and the like that fluoropolymers have.
  • a conventional fluoropolymer web has low tensile strength because an entangling process is not performed, and because of this, the sheet will be easily damaged when it is handled during fabrication. Thus, it is difficult for a conventional fluoropolymer web to be used in this type of printed circuit board. However, if the non-woven fabric 1 of the present invention is employed, this type of application will become possible because an entangling process is performed and tensile strength is improved.
  • thermosetting resin An epoxy resin can be used as the thermosetting resin.
  • a substrate having even more superior heat resistance can be obtained when a heat resistant polyimide resin is employed as the thermoplastic resin.
  • the non-woven fabric 1 as a boundary membrane, a gas-liquid/solid-liquid separation membrane that is resistant to ozone and other chemicals can be obtained. It is easier to process this membrane into various shapes than compared to a fluoropolymer drawn membrane, because its adhesive workability is superior.
  • the non-woven fabric 1 by forming the non-woven fabric 1 into a heat exchange membrane for an element in a heat exchanger, it can be used as a total heat exchanger because it is air permeable.
  • a surface decoration that is transparent, air permeable, and fire-proof can be obtained by using the non-woven fabric 1 as a surface decoration for indoor walls and fittings (such as shoji screens and the like), thereby providing a comfortable living space.
  • a felt material that has a smooth surface and a low friction sliding functionality can be obtained by adhering the non-woven fabric 1 to, for example, a felt surface that is composed of elastic fibers made from other polymers.
  • This felt material can be used as a support material for supporting the window glass of an automobile when it slides with respect to the door, or as a wiper for cleaning the rollers inside office equipment.
  • a tubular member having the desired length in the axial direction can be obtained by forming the non-woven fabric 1 into oblong strips and then, for example, wrapping it in a spiral pattern around a cylindrical member while adhering the boundary portions of the spiral (the portions of the non-woven fabric that lie on top of each other).
  • This tubular material can be used in the gasification of liquid fuels or solvents, when bubbling ozone gas, oxygen or the like, or in filters, because it can be formed with small diameters of approximately ⁇ 2 mm.
  • a non-woven fabric having a low degree of elongation and a high degree of tensile strength can be obtained by elongating the non-woven fabric.
  • a tape made from this is easily wrapped around the outer circumference of fiber optic cable or power/signal cable, and the task of placing this cable in a protective tube of a conduit tube or the like is thereby made easier.
  • a braided material having a high degree of strength, a superior sliding ability, and low elongation can be obtained by twisting this tape-shaped non-woven fabric. This can be used as a binding material in environments that require these materials to be resistant to chemicals, and as a buffer material in between electric communication cables or optical communication cables.
  • a non-woven fabric according to a second embodiment can be used as a filter or a filter support material for cake-type filter devices.
  • a filter having a high degree of strength is needed because, in order to conduct filtering through a cake layer produced by the filtering, a large amount of filter pressure is required, and that large filter pressure is applied to the filter material.
  • This non-woven fabric is ideal for this application because the air permeability is maintained as is, and the strength thereof is improved.
  • the non-woven fabric of the second embodiment can be used as a sliding member, such as by adhering it to a variety of sliding surfaces, because the strength thereof is improved, it has low frictionality, and napping on the surface thereof is controlled.
  • the non-woven fabric of the second embodiment can be used as an air permeable sheet because it is permeable to air, and because it is water repellant due to the fluoropolymer.
  • the non-woven fabric of the first or second embodiment can be ideally used as a support member for a fluoropolymer membrane because the non-woven fabric has a plurality of 1 to 2 mm holes therein and has an extremely high air permeability.
  • a web comprised of branched fluoropolymer fibers was obtained by means of the method disclosed in International Patent Publication No. WO94/23098. More specifically, after uniaxially drawing a semi-sintered PTFE film (thickness 120 micrometers, width 165 mm, crystal conversion ratio 0.45) 25 times, a roller having needle cutters was used to cut the film into fibers. Note that the crystalline conversion ratio was calculated by means of the method disclosed in International Patent Publication No. WO94/23098.
  • the web obtained thereby (apparent density 0.86 g/cm 3 , basis weight 250 g/m 2 ) was water jet needle punched by means of a horizontal belt type of water jet needle entangling device under the following conditions, and a non-woven fabric was obtained thereby.
  • Nozzle used Inlet hole diameter ⁇ 0.2 mm, outlet hole diameter ⁇ 0.1 mm, nozzle pitch 1 mm
  • Web support material polyethylene net (100 mesh)
  • the apparent density of the web was 0.3 to 0.7 g/cm 3 .
  • nip rollers constructed of a ⁇ 80 mm metal roller having a surface temperature of 250° C. and a ⁇ 80 mm rubber lined pressure roller were used to apply heat and pressure at a line pressure of 4 kg/cm and a line speed of 1.5 m/min to obtain a non-woven fabric having the following characteristics.
  • Air permeability 0.13 to 0.26 cm/s/mm Aq
  • a water jet needle punched non-woven fabric obtained in the same manner as in Example 1 was elongated in one axis. Before elongation, the non-woven fabric had a length of 250 mm, a width of 20 mm, a thickness of 0.38 mm, and an apparent density of ⁇ 0.65 g/cm 3 , and was elongated 60% in one axis to obtain a elongated article having a total length of 400 mm, a width of 8 mm, and a thickness of approximately 0.4 mm. The strength thereof was improved as shown below.
  • Example 2 The elongated article obtained in Example 2 having a width of 8 mm and a thickness of 0.4 mm was twisted one turn/cm in the lengthwise direction to form a braided material having an outer diameter of approximately 1.3 mm and a total length of 400 mm.
  • frayed fibers in the braided material can be repaired by sintering the braided material, and thus a braided material having an even higher tensile strength can be obtained.
  • the maximum point load can be increased from 60N to 175N.
  • a web having a basis weight of 200 g/m 2 was water jet needle punched under the conditions shown in Example 1, and a non-woven fabric was obtained.
  • the 200 g/m 2 basis weight non-woven fabric was heat and pressure treated at a speed of 3 m/min. by rollers set such that the lower roller had a temperature of 300° C., the upper roller had a temperature of 360° C., and the gap between both rollers was 0.2 mm.
  • the strength of the heat fused non-woven fabric obtained in this manner had the following values per 2 cm of width.
  • the non-woven fabric was viewed under a microscope after being pressure and heat treated, and a portion of the fibers on one surface thereof were observed to be heat fused.
  • a web having a basis weight of 75 g/m 2 was water jet needle punched under the conditions shown in Example 4, and then pressure and heat treated by a calendar roller. The treatment took place at a rate of 2 m/min. and the gap between the rollers was adjusted to 0.075 mm.
  • the roller temperature was set as shown in Table 6.
  • Branched fluoropolymer fibers were obtained by means of the method disclosed in International Patent Application Ser. No. WO94/23098. More specifically, after uniaxially drawing a semi-sintered PTFE film (thickness 120 micrometers, width 165 mm, crystal conversion ratio 0.45) 25 times, a roller having needle cutters was used to form the film into fibers, and 5 types of webs were prepared in which the lengths of the branches of the fibers were different.
  • each web was pressure treated with nip rollers in order to continuously supply each to a water jet needle punch device, and then each was water jet needle punched under the same conditions as in Example 1.
  • the strength of the non-woven fabrics obtained thereby were tested.
  • the results are shown in Table 7.
  • non-woven fabrics having a sufficient degree of strength were obtained even if short fibers were used (i.e., fibers having an average fiber length of 20 mm or less). However, when the average fiber length was 3.9 mm, high strength was not obtained.
  • a mixture of a PTFE polymer powder and viscose was spun into thread, and the PTFE staple fiber (Torofluon 201 produced by Toray Fine Chemical Corp, fiber length 100 mm, thickness 6.7 denier, crimping present) produced thereby was cut to obtain PTFE staple fibers that were approximately 25 mm in length.
  • a static electricity prevention agent (Erimina, produced by Maurzen Sekiyu) was sprayed on the PTFE staple fibers, and then an attempt at producing a web by means of a carding machine was made.
  • the gap from the portion in which the fibers exit the machine (doffer) to the drum was set to be 10 mm, but a web could not be continuously produced. Because of this, paper was placed below the doffer, the staple fibers were placed on top thereof, and a web was obtained thereby (width 250 mm, length 500 mm, 50 g/m 2 ).
  • the web was then pressure treated with nip rollers, but a web having sufficient strength could not be obtained and could not be continuously fed into a horizontal belt type of water jet needle entangling device. Because of this, the web was placed on the belt of this device by hand and was then water jet needle punched. However, the fibers scattered, and a non-woven fabric could not be obtained.
  • a non-woven fabric having improved mechanical characteristics such as tensile strength and tensile strain can be obtained because the fibers of the web are strongly entangled by means of water jet need punching.
  • the non-woven fabric of the present invention has fluoropolymer characteristics, and superior adhesive properties due to the porosity of the web, a laminate that can be used in a variety of applications can be obtained by adhering other members to the non-woven fabric.
  • a braided material having superior sliding abilities can be easily obtained by twisting the non-woven fabric.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Woven Fabrics (AREA)
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CN1513069A (zh) 2004-07-14
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JP4029837B2 (ja) 2008-01-09
JPWO2003000977A1 (ja) 2004-10-14
KR100561762B1 (ko) 2006-03-16
WO2003000977A1 (fr) 2003-01-03
EP1403412A1 (en) 2004-03-31
KR20040025687A (ko) 2004-03-24

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