US20220018044A1 - Drawn composite fiber, non-woven fabric, and method of producing drawn composite fiber - Google Patents

Drawn composite fiber, non-woven fabric, and method of producing drawn composite fiber Download PDF

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Publication number
US20220018044A1
US20220018044A1 US17/429,623 US202017429623A US2022018044A1 US 20220018044 A1 US20220018044 A1 US 20220018044A1 US 202017429623 A US202017429623 A US 202017429623A US 2022018044 A1 US2022018044 A1 US 2022018044A1
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Prior art keywords
composite fiber
sheath
core material
drawn
fiber
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Satoshi Kusaka
Kotaro TOMITA
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Ube Exsymo Co Ltd
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Ube Exsymo Co Ltd
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Assigned to UBE EXSYMO CO., LTD. reassignment UBE EXSYMO CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KUSAKA, SATOSHI, Tomita, Kotaro
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    • 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
    • D01D5/12—Stretch-spinning methods
    • 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
    • D01D5/08—Melt spinning methods
    • D01D5/082—Melt spinning methods of mixed yarn
    • 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
    • D01D5/08—Melt spinning methods
    • D01D5/098—Melt spinning methods with simultaneous stretching
    • 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
    • D01D5/12—Stretch-spinning methods
    • D01D5/16—Stretch-spinning methods using rollers, or like mechanical devices, e.g. snubbing pins
    • 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
    • D01D5/34—Core-skin structure; Spinnerette packs therefor
    • 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
    • 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
    • D04H1/43828—Composite fibres sheath-core
    • 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
    • D04H1/54—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 by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed 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
    • 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
    • D04H1/54—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 by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
    • 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
    • D04H1/54—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 by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres
    • D04H1/544—Olefin series
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
    • D10B2321/022—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polypropylene

Definitions

  • the present invention relates to a drawn composite fiber having a sheath-core structure, a non-woven fabric, and a method of producing the drawn composite fiber. More specifically, the present invention relates to a drawn composite fiber having a thin fineness of 0.6 dtex or less, a method of producing the drawn composite fiber, and a non-woven fabric using the drawn composite fiber having the thin fineness.
  • Composite fibers with a sheath-core structure are utilized in various fields because of having a thermal adhesion property and excellent chemical resistance.
  • such composite fibers with a sheath-core structure can be produced by drawing treatment of undrawn fibers with a sheath-core structure, formed by melt-spinning.
  • non-woven fabrics used in various filter materials, separators for batteries, and the like are thin films and have a high mechanical strength.
  • the thinner fineness and improved single yarn strength of raw material fibers in comparison with conventional ones are required for achieving such a non-woven fabric that is a thin film and has a high mechanical strength.
  • Common examples of methods of increasing the single yarn strength and elastic modulus of drawn composite fibers include an increase in draw magnification.
  • draw magnification has problems of resulting in yarn breakage in drawing, the deterioration of non-woven fabric processability, caused by an increase in the thermal shrinkage of drawn fibers, and the deterioration of the appearance of a processed non-woven fabric.
  • Patent Literatures 1 and 2 technologies of producing drawn composite fibers having a high strength and a thin fineness by methods other than an increase in draw magnification have been conventionally proposed (see, for example, Patent Literatures 1 and 2).
  • the higher strength of the composite fiber is intended to be achieved by specifying the ratio between the weight-average molecular weights of a crystalline propylene-based polymer which is a core material and an olefinic polymer which is a sheath material, the melt flow rates (MFR) of the sheath material and the core material, and the like.
  • Patent Literature 1 Japanese Patent Laid-Open No. 2007-107143
  • Patent Literature 2 International Publication No. WO 2015/012281
  • a raw material fiber having a suitable fineness is selected and used depending on intended characteristics such as a thickness, a basis weight, a filling rate, a pore diameter, and strength.
  • the non-woven fabric may be produced from one raw material fiber; however, an ultrafine fiber having a fineness of around 0.1 dtex and a thin fineness fiber having a fineness of around 0.2 to 0.6 dtex may be kneaded to obtain the non-woven fabric having two characteristics such as a fine pore diameter and a non-woven fabric strength.
  • Enhancement of the physical properties such as a single yarn strength and an elastic modulus of both the ultrafine fiber and the thin-fineness fiber which are raw materials is required for improving the strength of such a non-woven fabric.
  • the composite fiber having a fineness of around 1 dtex is targeted, and, in addition, the obtained composite fiber has a high thermal shrinkage of 10% or more.
  • the drawn composite fiber having a single yarn strength of 5 cN/dtex or more, a Young's modulus of 50 cN/dtex or more, and a thermal shrinkage of 8% or less at 120° C. can be obtained.
  • the technology targets an ultrafine composite fiber having a fineness of 0.3 dtex or less, and it is difficult to obtain the equivalent characteristics of a thin-fineness composite fiber that is thicker than the composite fiber.
  • an objective of the present invention is to provide a drawn composite fiber having a fineness of 0.6 dtex or less, a low thermal shrinkage, and a high single yarn strength, a non-woven fabric, and a method of producing the drawn composite fiber.
  • a drawn composite fiber according to the present invention is a drawn composite fiber including a sheath-core structure in which a resin containing a crystalline propylene-based polymer as a main component is a core material, and a resin containing, as a main component, an olefinic polymer of which a melting point is lower than that of the core material is a sheath material, wherein the drawn composite fiber has a fineness of 0.6 dtex or less, a melt flow rate of the core material at a load of 21.18 N at 230° C.
  • the drawn composite fiber has a single yarn elastic modulus of 70 cN/dtex or more.
  • a ratio between a melt flow rate of the core material at a load of 21.18 N at 230° C. and a melt flow rate of the sheath material at a load of 21.18 N at 230° C. is, for example, 0.3 to 1.
  • a non-woven fabric according to the present invention is formed using the drawn composite fiber described above.
  • a method of producing a drawn composite fiber according to the present invention includes: a spinning step of obtaining, by melt-spinning, an undrawn fiber including a sheath-core structure in which a resin containing a crystalline propylene-based polymer as a main component is a core material, and a resin containing, as a main component, an olefinic polymer of which a melting point is lower than that of the core material is a sheath material; and a drawing step of obtaining a drawn composite fiber having a fineness of 0.6 dtex or less by drawing treatment of the undrawn fiber, wherein the undrawn fiber has a fineness of 4.0 dtex or less, and has a ratio between cross-sectional areas of the sheath material and the core material (sheath material/core material) of 50/50 to 10/90, the core material has a melt flow rate of 10 to 30 g/10 min at a load of 21.18 N at 230° C., and the spinning step and the drawing
  • a ratio between a melt flow rate of the core material at a load of 21.18 N at 230° C. and a melt flow rate of the sheath material at a load of 21.18 N at 230° C. may be set in a range of 0.3 to 1.
  • the draw magnification of the undrawn fiber in the drawing step is, for example, 2 to 7 times.
  • a value of a melt flow rate in the present invention is a value measured under conditions of a temperature of 230° C. and a load of 21.18 N according to A-method in JIS K7210, and the same applies in the following description unless otherwise specified.
  • a single yarn strength in a drawn composite fiber having a fineness of 0.6 dtex or less, a single yarn strength can be enhanced without increasing a thermal shrinkage.
  • FIG. 1 is a view schematically illustrating an example of the cross-section structure of a drawn composite fiber of an embodiment of the present invention.
  • FIG. 2 is a flow chart illustrating a method of producing a drawn composite fiber of an embodiment of the present invention.
  • FIG. 3 is a schematic view illustrating a configuration example of an apparatus in the case of consecutively performing each step illustrated in FIG. 2 .
  • FIGS. 4A and 4B are schematic views illustrating apparatus configurations in the case of separately performing each step illustrated in FIG. 2 , FIG. 4A illustrates the spinning step, and FIG. 4B illustrates the drawing step.
  • FIG. 1 is a view schematically illustrating an example of the cross-section structure of a drawn composite fiber of the present embodiment.
  • a drawn composite fiber of the present embodiment is a sheath-core composite fiber including a core portion 1 and a sheath portion 2 formed in the periphery thereof, and has a fineness of 0.6 dtex or less, and preferably 0.2 to 0.6 dtex.
  • the core portion 1 contains a crystalline propylene-based polymer as a main component, and is formed of a resin having a melt flow rate (MFR) of 10 to 30 g/10 min at a load of 21.18 N at 230° C. (hereinafter referred to as “core material”).
  • MFR melt flow rate
  • core material a resin having a melt flow rate (MFR) of 10 to 30 g/10 min at a load of 21.18 N at 230° C.
  • MFR of the core material is less than 10 g/10 min, the melt tension of the molten resin is prone to be higher, it is difficult to obtain an undrawn fiber having an intended fineness, and, in addition, drawing of an undrawn fiber at a high magnification tends to result in an increase in the frequency of occurrence of yarn breakage.
  • the MFR of the core material is more than 30 g/10 min, the melt tension of the molten resin is lower, and therefore, the orientation crystallinity degree of an undrawn fiber is decreased, whereby it is impossible to sufficiently enhance the single yarn strength and elastic modulus of the drawn composite fiber, and it is difficult to obtain intended single yarn physical properties.
  • the MFR of the core material is preferably set at 15 to 25 g/10 min, and the setting of the MFR in this range enables the strength of the drawn composite fiber to be expressed while decreasing the fineness of the undrawn fiber.
  • crystalline propylene-based polymer which is the main component of the core material
  • an isotactic propylene homopolymer having crystallinity for example, an isotactic propylene homopolymer having crystallinity, an ethylene-propylene random copolymer having a low ethylene unit content, a propylene block copolymer including a homo portion including a propylene homopolymer and a copolymerization portion including an ethylene-propylene random copolymer having a relatively high ethylene unit content
  • a crystalline propylene-ethylene- ⁇ -olefin copolymer in which each homo portion or copolymerization portion in a propylene block copolymer includes a substance obtained by copolymerization of an ⁇ -olefin such as butene-1, or the like can be used, and isotactic polypropylene is particularly preferred from the viewpoint of drawability, fiber physical properties, and suppression of thermal shrinkage.
  • the core material can be blended with an additive such as a nucleating agent or an antioxidant at an appropriate rate.
  • an additive such as a nucleating agent or an antioxidant
  • the additive blended into the core material is preferably an additive which is melted together to develop an affinity, or an additive which is not completely melted and of which part adapts to the resin.
  • the sheath portion 2 is formed of a resin containing, as a main component, an olefinic polymer of which the melting point is lower than that of the core material (hereinafter referred to as “sheath material”).
  • a resin containing, as a main component, an olefinic polymer of which the melting point is lower than that of the core material hereinafter referred to as “sheath material”.
  • the olefinic polymer which is the main component of the sheath material for example, an ethylene polymer such as a high-density polyethylene, medium-density polyethylene, low-density polyethylene and a linear low-density polyethylene, a copolymer of propylene and another ⁇ -olefin, specifically, propylene-butene-1-random copolymer, propylene-ethylene-butene-1 random copolymer, or an amorphous propylene-based polymer such as soft polypropylene, poly 4-methylpenten
  • the sheath material can be blended with an additive such as a nucleating agent or an antioxidant at an appropriate rate.
  • an additive such as a nucleating agent or an antioxidant
  • the additive blended into the sheath material is preferably an additive which is melted together to develop an affinity, or an additive which is not completely melted and of which part adapts to the resin.
  • the drawn composite fiber of the present embodiment has a sheath-core ratio, i.e., an area ratio between the core portion 1 and the sheath portion 2 in a cross section (cross section perpendicular to lengthwise direction) (sheath material/core material) of 50/50 to 10/90.
  • a sheath-core ratio i.e., an area ratio between the core portion 1 and the sheath portion 2 in a cross section (cross section perpendicular to lengthwise direction) (sheath material/core material) of 50/50 to 10/90.
  • the ratio of the core portion 1 in the cross section is less than 50%, the single yarn strength and elastic modulus of the drawn composite fiber are insufficient, and, in addition, a thermal shrinkage is also increased.
  • the sheath material contributing to thermal fusion is insufficient, and the strength of a processed product such as a non-woven fabric is decreased.
  • a draw magnification is decreased, whereby yarn breakage is prone to occur, in the drawing step.
  • the drawn composite fiber of the present embodiment preferably has a ratio the MFR of the core material (pellet) at a load of 21.18 N at 230° C. and the MFR of the sheath material (pellet) at a load of 21.18 N at 230° C. (core material MFR/sheath material MFR) of 0.3 to 1.
  • core material MFR/sheath material MFR is less than 0.3, the melt tension of a molten resin is prone to be higher, and it may be impossible to produce an undrawn fiber having an intended fineness.
  • the drawn composite fiber of the present embodiment has a single yarn elastic modulus of 70 cN/dtex or more.
  • the mechanical strength of a thin-film non-woven fabric is insufficient, and rupture or poor appearance is prone to occur, when the drawn composite fiber is processed into the thin-film non-woven fabric.
  • FIG. 2 is a flow chart illustrating the method of producing a drawn composite fiber of the present embodiment
  • FIG. 3 is a schematic view illustrating a configuration example of an apparatus in the case of consecutively performing each step illustrated in FIG. 2 .
  • the spinning step (step S 1 ) of obtaining an undrawn fiber having a sheath-core structure by melt-spinning, and the drawing step (step S 2 ) of obtaining a drawn composite fiber by drawing treatment of the undrawn fiber are consecutively performed in the method of producing a drawn composite fiber of the present embodiment.
  • an undrawn fiber with a sheath-core structure having a fineness of 4.0 dtex or less, preferably 0.35 to 4.0 dtex and a sheath-core ratio (sheath material/core material) of 50/50 to 10/90 is melt-spun.
  • a resin containing a crystalline propylene-based polymer as a main component, and having a melt flow rate of 10 to 30 g/10 min at a load of 21.18 N at 230° C. is used in the core material, and a resin containing, as a main component, an olefinic polymer of which the melting point is lower than that of the core material is used in the sheath material.
  • core material MFR/sheath material MFR is preferably set in a range of 0.3 to 1 for the reason described above.
  • the sheath material/core material of an undrawn fiber is also set at 50/50 to 10/90 because the sheath-core ratio of the undrawn fiber is the sheath-core ratio of the drawn composite fiber.
  • the fineness of the undrawn fiber is set at 4.0 dtex or more, the enhancement of a draw magnification is required for setting the fineness of the drawn composite fiber at 0.6 dtex or less, yarn breakage is prone to occur in drawing, and the thermal shrinkage of the drawn fiber is prone to be deteriorated. Therefore, in the drawn composite fiber of the present embodiment, the fineness of the undrawn fiber is set at 4.0 dtex or less.
  • the fineness of the undrawn fiber is preferably set in a range of 0.35 to 4.0 dtex.
  • the drawn composite fiber having a fineness of 0.6 dtex or less, preferably 0.2 to 0.6 dtex, is obtained by drawing treatment of the undrawn fiber.
  • the draw magnification is less than 2 times, the single yarn strength and elastic modulus of the obtained drawn composite fiber may be decreased, and intended single yarn physical properties may be prevented from being obtained.
  • the draw magnification is more than 7 times, a frequency at which yarn breakage occurs may be increased, and productivity may be deteriorated.
  • the draw magnification in the drawing step S 2 is preferably set at 2 to 7 times.
  • the drawn composite fiber of the present embodiment is produced by a direct spinning drawing method (spin-draw method) in which the spinning step S 1 and the drawing step S 2 , described above are consecutively performed.
  • spin-draw method spin-draw method
  • an undrawn fiber 10 with a sheath-core structure, discharged from a spinneret 11 is introduced into a vapor drawing bath 13 through an introduction roller 12 , and drawn at a predetermined magnification, and a drawn composite fiber 20 is then delivered by a delivery roller 14 , and wound by a winder 15 .
  • a drawn composite fiber having a fineness of 0.6 dtex or less, a high single yarn strength, a high single yarn elastic modulus, and a low thermal shrinkage can be produced from an undrawn fiber having a fineness of 4.0 dtex or less.
  • the drawn composite fiber produced by the method described above can be allowed to be in the form of a long-fiber filament used for a woven fabric through oil solution treatment and drying treatment.
  • the drawn composite fiber may also be allowed to be a staple fiber through oil solution treatment, crimping processing treatment, and drying treatment subsequently to the drawing step. Further, the drawn composite fiber may also be cut into short fibers through or without through drying treatment after oil solution treatment, and allowed to be chopped fibers.
  • the drawn composite fiber of the present embodiment has the MFR of the core material, the sheath-core ratio, and the single yarn elastic modulus, set in the specific ranges, and can therefore have a single yarn strength of 6 cN/dtex or more and a bundle thermal shrinkage at 120° C., reduced to 8% or less, despite having a thin fineness of 0.6 dtex.
  • the drawn composite fiber of the present embodiment has a high strength and a low thermal shrinkage, and can be therefore preferably used in various applications for non-woven fabrics, and applications such as battery separators and filters.
  • a thin-film non-woven fabric formed using the drawn composite fiber of the present embodiment has a high mechanical strength and suppressed thermal shrinkage in processing, and can therefore result in elimination of occurrence of poor processing, such as rupture, and poor appearance.
  • the finenesses of an undrawn fiber and a drawn composite fiber were measured in conformity with JIS L1015.
  • the MFR of each material pellet used in the core material and the sheath material was measured according to A-method in JIS K7210 under conditions of a test temperature of 230° C. and a test load of 21.18 N.
  • the single yarn strength and elastic modulus of a drawn composite fiber were measured by a method in conformity with JIS L1015.
  • the thermal shrinkage of a fiber bundle was measured by a method in conformity with JIS L1015.
  • the number of filaments was set at 12018
  • heat treatment temperature was set at 120° C.
  • heat treatment time was set at 10 minutes.
  • the spinning step and the drawing step were consecutively performed using the apparatus illustrated in FIG. 3 , to produce a drawn composite fiber having a sheath-core structure.
  • An undrawn fiber with a sheath-core structure having a fineness of 1.88 dtex was produced by melt-spinning using a core material A and a sheath material a.
  • a sheath-core-type composite spinneret was used, and a sheath-core ratio (sheath material/core material) was set at 35/65.
  • extruder cylinder temperature was set at 255° C.
  • spinneret temperature was set at 270° C.
  • a spinning speed was set at 180 m/min.
  • the drawing step was performed subsequently to the spinning step. Specifically, the undrawn fiber 10 obtained in the spinning step was introduced into the introduction roller 12 at a speed of 180 m/min, the speed of the drawn fiber delivery roller 14 was increased, and the undrawn fiber 10 was drawn in the vapor drawing bath 13 with ordinary pressure vapor at 100° C.
  • the speed of the drawn fiber delivery roller 14 and a draw magnification, at which yarn breakage did not occur in the spinning step and the drawing step, and it was possible to perform industrially stable drawing were 910 m/min and 5.10 times, respectively.
  • the fineness of the drawn composite fiber of Example 1 produced under such conditions was 0.4 dtex.
  • An undrawn fiber having a fineness of 1.72 dtex was melt-spun by a method and under conditions similar to those in Example 1 except that a core material B was used instead of the core material A, and a sheath-core ratio (sheath material/core material) was set at 25/75, and the undrawn fiber was drawn by a method and under conditions similar to those in Example 1.
  • the speed of a drawn fiber delivery roller 14 and a draw magnification, at which yarn breakage did not occur in a spinning step and a drawing step, and it was possible to perform industrially stable drawing were 841 m/min and 4.67 times, respectively.
  • the fineness of a drawn composite fiber of Example 2 produced under such conditions was 0.4 dtex.
  • An undrawn fiber having a fineness of 1.60 dtex was melt-spun by a method and under conditions similar to those in Example 1 except that a sheath-core ratio (sheath material/core material) was set at 50/50, and the undrawn fiber was drawn by a method and under conditions similar to those in Example 1.
  • the speed of a drawn fiber delivery roller 14 and a draw magnification, at which yarn breakage did not occur in a spinning step and a drawing step, and it was possible to perform industrially stable drawing were 781 m/min and 4.34 times, respectively.
  • the fineness of a drawn composite fiber of Example 3 produced under such conditions was 0.4 dtex.
  • An undrawn fiber having a fineness of 0.80 dtex was melt-spun by a method and under conditions similar to those in Example 1 except that a core material D was used instead of the core material A, and a sheath-core ratio (sheath material/core material) was set at 50/50, and the undrawn fiber was drawn by a method and under conditions similar to those in Example 1.
  • the speed of a drawn fiber delivery roller 14 and a draw magnification, at which yarn breakage did not occur in a spinning step and a drawing step, and it was possible to perform industrially stable drawing were 781 m/min and 4.34 times, respectively.
  • the fineness of a drawn composite fiber of Example 4 produced under such conditions was 0.2 dtex.
  • An undrawn fiber having a fineness of 0.80 dtex was melt-spun by a method and under conditions similar to those in Example 1 except that the core material D and a sheath material b were used, and a sheath-core ratio (sheath material/core material) was set at 50/50, and the undrawn fiber was drawn by a method and under conditions similar to those in Example 1.
  • the speed of a drawn fiber delivery roller 14 and a draw magnification, at which yarn breakage did not occur in a spinning step and a drawing step, and it was possible to perform industrially stable drawing were 781 m/min and 4.34 times, respectively.
  • the fineness of a drawn composite fiber of Example 5 produced under such conditions was 0.2 dtex.
  • An undrawn fiber having a fineness of 1.60 dtex was melt-spun by a method and under conditions similar to those in Example 1 except that the core material C and the sheath material b were used, and a sheath-core ratio (sheath material/core material) was set at 50/50, and the undrawn fiber was drawn by a method and under conditions similar to those in Example 1.
  • An undrawn fiber having a fineness of 1.60 dtex was melt-spun by a method and under conditions similar to those in Example 1 except that a sheath-core ratio (sheath material/core material) was set at 60/40, and the undrawn fiber was drawn by a method and under conditions similar to those in Example 1.
  • a spinning step and a drawing step were inconsecutively performed using apparatuses illustrated in FIGS. 4A and 4B , to produce a drawn composite fiber having a sheath-core structure.
  • Undrawn fibers 110 having a fineness of 2.95 dtex were melt-spun using a melt spinning apparatus including a spinneret 101 , rollers 102 and 103 , and a winding device 104 illustrated in FIG. 4A under conditions similar to those in Comparative Example 1.
  • the undrawn fibers 110 were drawn using a two-stage drawing apparatus in which a preliminary drawing bath 112 performing heating in warm water and a main drawing bath 114 performing heating with heated saturated vapor were arranged between three rollers 111 , 113 , and 115 illustrated in FIG. 4B , to obtain a drawn composite fiber 120 .
  • the speed of the introduction roller 111 was set at 10 m/min
  • the speed of the preliminary drawing delivery roller 113 was set at 29 m/min
  • a bundle (fiber bundle) in which the undrawn fibers 110 obtained in the spinning step were tied was subjected to preliminary drawing treatment in warm water at 93° C. in the preliminary drawing bath 112 .
  • the speed of the drawn fiber delivery roller 115 was increased, main drawing was performed in pressurization saturated vapor at 124° C. in the main drawing bath 114 , and the obtained drawn composite fiber 120 was wound by a winder 116 .
  • the speed of the drawn fiber delivery roller 115 and a draw magnification, at which yarn breakage did not occur in a spinning step and a drawing step, and it was possible to perform industrially stable drawing were 80 m/min and 8.0 times, respectively.
  • the fineness of a drawn composite fiber of Comparative Example 3 produced under such conditions was 0.4 dtex.
  • An undrawn fiber having a fineness of 2.95 dtex was melt-spun by a method and under conditions similar to those in Comparative Example 3 except that the core material A and the sheath material a were used.
  • the undrawn fiber was drawn, in a step other than the spinning step, by a method and under conditions similar to those in Comparative Example 3.
  • the speed of the drawn fiber delivery roller 115 and a draw magnification, at which yarn breakage did not occur in a spinning step and a drawing step, and it was possible to perform industrially stable drawing were 80 m/min and 8.0 times, respectively.
  • the fineness of a drawn composite fiber of Comparative Example 4 produced under such conditions was 0.4 dtex.
  • An undrawn fiber having a fineness of 3.98 dtex was melt-spun by a method and under conditions similar to those in Comparative Example 4 except that the rotation number of a gear pump was adjusted as appropriate so that an intended fineness was achieved.
  • the undrawn fiber was drawn, in a step other than the spinning step, by a method and under conditions similar to those in Comparative Example 3.
  • the speed of the drawn fiber delivery roller 115 and a draw magnification, at which yarn breakage did not occur in a spinning step and a drawing step, and it was possible to perform industrially stable drawing were 54 m/min and 5.4 times, respectively.
  • the fineness of a drawn composite fiber of Comparative Example 5 produced under such conditions was 0.8 dtex.
  • An undrawn fiber having a fineness of 1.88 dtex was melt-spun by a method and under conditions similar to those in Example 1 except that a sheath-core ratio was set at 35/65.
  • Undrawn fibers were drawn in a step other than the spinning step using a drawing apparatus in which a warm water drawing bath was arranged between two rollers. Specifically, a bundle (fiber bundle) in which the undrawn fibers obtained in the spinning step were tied was subjected to drawing treatment in warm water at 93° C. in the warm water drawing bath under conditions of an introduction roller speed of 10 m/min and a drawn fiber delivery roller speed of 51 m/min.
  • the drawn composite fibers of Comparative Examples 1 and 3 in which resins having MFRs of more than 30 g/10 min were used in the core materials, had low single yarn strengths and low elastic moduli.
  • the drawn composite fiber of Comparative Example 2 having a sheath-core ratio (sheath material/core material) of 60/40 and a small content of core material, had a low single yarn strength and a low elastic modulus.
  • the drawn composite fibers of Examples 1 to 5 produced in the scope of the present invention, had a bundle thermal shrinkage of 8% or less at 120° C. and a single yarn strength of 6 cN/dtex or more although having a fineness of 0.6 dtex or less, as set forth in Table 1 above.

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  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Multicomponent Fibers (AREA)
  • Nonwoven Fabrics (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
US17/429,623 2019-03-29 2020-03-18 Drawn composite fiber, non-woven fabric, and method of producing drawn composite fiber Abandoned US20220018044A1 (en)

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PCT/JP2020/011925 WO2020203286A1 (ja) 2019-03-29 2020-03-18 延伸複合繊維、不織布及び延伸複合繊維の製造方法

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US10077518B2 (en) * 2008-10-29 2018-09-18 Mitsui Chemicals, Inc. Crimped conjugated fiber and nonwoven fabric comprising the same
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