WO2005012605A2

WO2005012605A2 - Filler-fixed fiber, fiber structure, molded fiber, and processes for producing these

Info

Publication number: WO2005012605A2
Application number: PCT/JP2004/011397
Authority: WO
Inventors: Hisatoshi Motoda; Kouki Shigeta
Original assignee: Daiwabo Co., Ltd.
Priority date: 2003-08-04
Filing date: 2004-08-02
Publication date: 2005-02-10
Also published as: WO2005012605A3; US20070128434A1; KR20060059990A; HK1091244A1; KR101138567B1

Abstract

A filler-fixed fiber which comprises a fiber (2), a binder resin (1) disposed on the surface thereof, and a filler (3) fixed to the binder resin (1), wherein the binder resin (1) is a moisture/heat-gelling resin which gels upon heating in the presence of water and the filler (3) has been fixed to the gel obtained by causing the moisture/heat-gelling resin to gel. Due to this, the fiber (2) retains its fiber form and the gel formed by the gelation of the moisture/heat-gelling resin functions as a binder for fixing the filler (3).

Description

TECHNICAL FIELD The present invention relates to a filler-fixed fiber in which a filler is fixed to a fiber surface, a fiber structure, a fiber molded article, and production thereof. About the method.

Background art

Conventionally, as a method of attaching a filler to the surface of a fiber, a method has been proposed in which particles are carried on the surface of a nonwoven fabric by a dry method, and then heated to a temperature above the softening point of the fiber to attach the particles ( Patent Document 1) below. Furthermore, a method is proposed in which a sheet-like or block fiber molded product is impregnated with an aqueous dispersion solution containing particles, pressed, and then heated at a temperature not higher than the melting point of the fiber or not more than 60 ° C from the melting point of the fiber to adhere the particles. (Patent Document 2 below).

Conventionally, fiber products having a filler attached to the fiber surface have been used for various purposes. For example, for fibers and cloths intended for polishing and cleaning, filament fibers for polishing between teeth (densyl floss) are generally well known as fibers for cleaning purposes. For industrial applications, polishing cloths or papers are used in various fields such as lenses, semiconductors, metals, plastics, ceramics and glass. Polishing cloth is also used in household or commercial kitchens.

In addition, since the occurrence of allergic symptoms such as Sick House Syndrome due to inhalation of volatile organic compounds (hereinafter abbreviated as VOC) is increasing, gas adsorbents that adsorb harmful gases such as v〇c gas are required. ing. As the gas adsorbent, for example, Patent Document 3 proposes a gas adsorption sheet having an effect of adsorbing VOC gas in general. Proposed in Patent Document 3 In the gas adsorption sheet, activated carbon particles are sandwiched and fixed between two sheet materials, and the adsorbent particles are fixed to at least one of the sheet materials. The adsorbent particles can be immobilized by (1) mixing the adsorbent particles into a binder-resin solution, coating one sheet material, and overlaying the other sheet material on it, or (2) A method in which one sheet material is coated with a hot-melt agent or the like, adsorbent particles are sprayed thereon, and the other sheet material is further stacked thereon is exemplified. Further, as a water purification material for purifying industrial wastewater and the like, various water purification materials using fibrous activated carbon, that is, activated carbon fibers have been proposed (for example, Patent Document 4 and the like). However, in the case of a water purification material using activated carbon fibers, the activated carbon constituting the activated carbon fibers may fall off during use and the purification performance may be degraded. In addition, there is a possibility that activated carbon that has fallen may be mixed into the purified liquid. On the other hand, Patent Document 5 proposes a water purification filter in which organic matter-adsorbing particles such as activated carbon particles are fixed to a sheet-like member via an insoluble binder.

Further, there is a fiber product having a form of a fiber molded product as a fiber product in which a filler is attached to a fiber surface. For example, there has been proposed a method for producing a fibrous molded body in which a fleece is formed by mixing particles and a binder resin with a fiber material, and a bulky mat is produced by fusing with the binder resin, and then press-molded into a predetermined shape. (Patent Document 6 below). Further, a three-dimensional molded article has been proposed in which a functional fiber sheet made of a plant fiber, a heat-fusible fiber, and a powdery or fibrous functional material is formed by thermoforming (Patent Document 7 below). .

[Patent Document 1] JP-A-7-268767

[Patent Document 2] Japanese Patent Publication No. 5-22-5557

[Patent Document 3] Japanese Patent Application Laid-Open No. 2000-246 827

[Patent Document 4] JP-A-9-1234343 [Patent Document 5] Japanese Patent Application Laid-Open No. 9-210583

[Patent Document 6] Japanese Patent Application Laid-Open No. Hei 9-125 4 2 6 4

[Patent Literature 7] Japanese Patent Application Laid-Open No. 2004-5-211 16

However, as described in Patent Documents 1 and 2, when the fiber is heated to a temperature higher than the softening point or the melting point, the fiber shrinks and becomes hard, and at about the softening point, the particles can be effectively fixed to the fiber. However, the temperature must be higher than the melting point, and there is a problem that the fiber form cannot be maintained. In addition, the fibers shrink and become hard, and as a result, when formed into a nonwoven fabric, there is a problem that the nonwoven fabric cannot be maintained due to shrinkage.

Further, in the fixing method of (1) in the gas adsorption sheet proposed in Patent Document 3, the adsorbent particles may be buried in the binder resin solution, and a sufficient gas adsorption effect may not be obtained. . Further, in the immobilization method (2), the contact area between the hot melt agent and the adsorbent particles is small, so that the adsorbent particles may fall off. Further, the gas adsorption sheet proposed in Patent Document 4 uses a porous sheet material for at least one of the two sheet materials in order to enhance air permeability. When sandwiching the activated carbon particles between the sheet materials, it was necessary to increase the particle size of the activated carbon particles to be larger than the maximum pore size of the porous sheet material so that the activated carbon particles did not fall off. Therefore, activated carbon particles having a particle size of 100 m to 100,000 are used, and there is a possibility that a sufficient gas adsorption effect may not be obtained because the specific surface area of the activated carbon particles is small. In the water purification filter proposed in Patent Document 5, the organic substance-adsorbing particles may be buried in the binder, and the specific surface area of the organic substance-adsorbing particles may decrease, so that sufficient purification performance may not be obtained.

In the molded article proposed in Patent Document 6, since particles and a binder resin are preliminarily mixed and the particles are fixed to the fiber surface, the particles are embedded in the binder resin. As a result, there was a problem that the functions of the particles could not be sufficiently exhibited. Further, Patent Document 7 attempts to melt the heat-fusible fiber to fix the particulate functional material.However, in this method, the particles cannot be melted unless the heat-fusible fiber is melted at a considerably high temperature. It cannot be fixed, and if it is melted at a high temperature, it may shrink, and it may be difficult to obtain a uniform molded body. In some cases, it was difficult to produce a deep drawn compact.

Disclosure of the invention

In order to solve the above-mentioned conventional problems, the present invention provides a filler-fixed fiber in which a filler is effectively fixed to a fiber surface while maintaining the properties of the original fiber. To provide a fiber structure that is useful for abrasives, gas adsorbents, water purification materials, etc., which can prevent the reduction of the specific surface area of the filler and prevent the decrease in the specific surface area of the filler, and effectively fix the filler to the fiber surface The present invention provides a fiber molded body that can be formed uniformly, can obtain a deep drawn shape, and can reduce the molding cost even for general use, and a method for producing the same.

The filler fixing fiber of the present invention is a filler fixing fiber including a fiber, a binder resin on the surface thereof, and a filler fixed to the binder resin, wherein the binder resin is heated in the presence of moisture. This is a wet heat gelling resin that is gelled by the above method, and the filler is characterized in that the wet heat gelling resin is fixed by a gelled gel.

The fibrous structure of the present invention is a fibrous structure containing fibers, a binder resin on the surface thereof, and a filler-fixing fiber containing a filler fixed to the binder resin, wherein the binder resin contains water. It is a wet heat gelling resin that gels when heated below, and the filler is characterized in that the wet heat gelled resin is fixed by a gelled gel. The fiber molded article of the present invention is a fiber molded article formed by molding a fiber, a binder resin on the surface thereof, and a fibrous structure including filler-fixed fibers fixed to the binder resin, wherein the binder resin is The fiber structure comprises a wet heat gelling resin that gels when heated in the presence of moisture, and the fibrous structure is formed into a predetermined shape while the fibers are fixed by a gel formed by wet heat gelation of the wet heat gelling resin. It is characterized by having. The method for producing a fiber-fixed fiber according to the present invention is a method for producing a fiber-fixed fiber, comprising: a fiber; a binder resin on the surface thereof; and a filler fixed to the binder resin. A wet-heat gelling fiber in which the resin gels by heating in the presence of moisture; applying a filler dispersion in which the filler is dispersed in a solution to the wet-heat gelled fiber; and then applying the wet heat in a wet-heat atmosphere. It is characterized in that the gelled fiber is subjected to wet heat treatment to gel the wet heat gelled fiber, and the filler is fixed to the fiber surface by a gelled substance.

Another method for producing a filler-fixed fiber according to the present invention is a method for producing a filler-fixed fiber including a fiber, a binder resin on the surface thereof, and a filler fixed to the binder resin, wherein the fiber and the binder are provided. One resin is another fiber and a wet heat gelling resin, and after adding the wet heat gelling resin to the other fiber, a filler is added, or the filler and the wet heat gelling resin are dispersed in a solution. Applying the filler dispersion solution to the other fibers, and then performing a wet heat treatment in a wet heat atmosphere to gel the wet heat gelled resin, and fixing the filler to the surface of the other fibers by a gel. And

The method for producing a fiber structure of the present invention is a method for producing a fiber structure containing fibers, a binder resin on the surface thereof, and a filler-fixed fiber including a filler fixed to the binder resin, The binder resin is water Is a moist heat gelling resin that gels when heated in the presence of a minute, wherein the fiber and the binder resin are:

(I) a composite fiber comprising a wet heat gelled resin fiber component and another thermoplastic synthetic fiber component,

(I I) a mixture of the composite fiber and another fiber,

(I I I) a mixture of the composite fiber and a wet heat gelling resin, and

(IV) a mixture of a wet heat gelling resin and other fibers,

At least one combination selected from the group consisting of: preparing a fibrous structure from the fibers and the binder resin; applying a filler dispersion in which the filler is dispersed in a solution to the fibrous structure; The wet heat gelling resin is subjected to wet heat treatment in an atmosphere to gel the wet heat gelling resin, and the filler is fixed to the fiber surface by the gelling material to form filler-fixed fibers.

The method for producing a fiber molded article of the present invention is a method for producing a fiber molded article formed by molding a fiber, a binder resin on the surface thereof, and a fiber structure including a fiber-fixed fiber fixed to the binder resin. And wherein the binder resin includes a wet heat gelling resin that gels by heating in the presence of moisture to form a fibrous structure containing the fibers and the binder resin, and the fibrous structure is wet-heated in a mold. It is characterized in that the heat-and-humidity gelling resin is made into a heat-and-humidity gel in an atmosphere and then subjected to wet heat molding.

Brief Description of Drawings

1A to 1C are cross-sectional views of filler-fixed fibers according to one embodiment of the present invention.

FIG. 2 is a cross-sectional view of a three-layer nonwoven fabric according to one embodiment of the present invention.

FIG. 3 is a process chart of an example of the production method of the present invention. FIG. 4A is a scanning electron microscope plan photograph (magnification: 100) showing the nonwoven fabric obtained in Example 1 of the present invention.

FIG. 4B is a photograph of the same section (magnification: 100).

FIG. 4C is an enlarged photograph of the fiber surface of the nonwoven fabric surface (magnification: 1 000). FIG. 4D is a scanning electron microscope plane photograph (magnification: 100) showing the nonwoven fabric of the other part.

FIG. 4E is a photograph of the same section (magnification 100).

Fig. 4F is an enlarged photograph of the fiber surface of the nonwoven fabric surface (magnification: 1 000). FIG. 5A is a scanning electron microscope plane photograph (magnification: 100) showing the nonwoven fabric obtained in Example 6 of the present invention.

FIG. 5B is a photograph of the same cross section (magnification: 100).

FIG. 5C is an enlarged photograph (magnification 100,000) of the fiber surface of the nonwoven fabric surface. FIG. 6 is a schematic perspective view of a simple water circulation type testing machine.

FIG. 7 is a diagram illustrating an example of a process of applying moisture to a nonwoven fabric according to an embodiment of the present invention.

FIG. 8 is a perspective view of a fiber molded body (mask) according to one embodiment of the present invention.

FIG. 9 is a perspective view of a fiber molded body (a pleated product of the air purifier Fil Yuichi) in one embodiment of the present invention.

FIG. 10 is a process chart in another embodiment of the manufacturing method of the present invention. FIG. 11A is a scanning electron micrograph (200 magnification) showing the nonwoven fabric obtained in Example 7 of the present invention.

FIG. 11B is an enlarged fiber surface photograph (magnification: 20000) of the surface of the nonwoven fabric.

1: sheath component (binder resin), 2: core component, 3: filler, 4:) indah resin, 5, 6, 9: composite fiber, 7: ethylene-vinyl alcohol Copolymer resin (binder resin), 8: polypropylene, 11: filler—Fixed fiber layer, 12: rayon fiber layer, 20: simple water circulation type testing machine, 21: stand, 22a, 22b : Fixing jig, 23: Container, 23a: Opening, 24: Pump, 24a, 24b: Tube, 25: Small piece, 26: Tea pack, 27: Test sample, 2 8: wire, 31: fiber or non-woven fabric, 32: tank, 33: filler dispersion solution, 34: squeezing roll, 35: steamer, 36: suction, 37: heating roll, 38: patterning Camber roll, 39: Winder, 40: Mask, 41: Dryer, 50: Pre-processed product of air purifier filter

BEST MODE FOR CARRYING OUT THE INVENTION

In the present invention, a wet heat gelled resin is used as a binder resin that gels when heated in the presence of moisture. Examples of the form of the wet heat gelling resin include powder, chip, and fiber. In particular, the wet heat gelling resin is preferably fibrous. The fibrous wet heat gelling resin (hereinafter referred to as “wet heat gelled fiber”) may be a fiber made of a wet heat gelled resin alone or a compound containing a wet heat gelled resin fiber component and another thermoplastic synthetic fiber component. Synthetic fiber (hereinafter referred to as “wet-heat gelled conjugate fiber”) is used. As a result, the other fibers or at least the other thermoplastic synthetic fiber components maintain the fiber form, and exhibit a function as a binder for fixing the filler by gelling the wet heat gelling resin. In the filler, the wet heat gelling resin fiber component or the wet heat gelling resin fixed on the surface of the fiber is fixed by a wet heat gelled gel. Preferably, the filler is exposed and secured. Further, the moist heat gelled fibers and Z or other fibers are fixed by the moist heat gelling resin gel component formed by moist heat gelling of the moist heat gelling resin component or the moist heat gelling resin adhered to the fiber surface.

Further, the fiber molded article of the present invention has a state in which a fiber structure is gelled in a mold. By performing wet heat molding in a state, it can be molded into a molded body having a predetermined shape. Examples of the form of the wet heat gelling resin include powder, chip, and fiber. In particular, in consideration of moldability, fibrous, that is, wet heat gelled fiber is preferable.

The preferred gelling temperature of the wet heat gelling resin is 50 ° C. or higher. A more preferred gelling temperature is 80 ° C. or higher. If a resin that can gel at less than 50 ° C is used, the adhesion to rolls, molds, etc. will become severe during gel processing, making it difficult to produce fiber structures and fiber molded products. It may not be able to be used below. The “gel processing” refers to processing for gelling the wet heat gelling resin.

The wet heat gelling resin is preferably an ethylene-vinyl alcohol copolymer resin. This is because it can be gelled by moist heat and does not deteriorate other fibers and / or other thermoplastic synthetic fiber components. The ethylene-vinyl alcohol copolymer resin is a resin obtained by testing an ethylene-vinyl acetate copolymer resin, and its degree of degradation is preferably 95% or more. A more preferred degree of degradation is 98% or more. The preferred ethylene content is 20 mol% or more. The preferred ethylene content is 50 mol% or less. A more preferred ethylene content is 25 mol% or more. A more preferred ethylene content is 45 mol% or less. If the degree of vulcanization is less than 95%, it may be difficult to produce a fibrous structure and a fibrous molded product due to sticking to a roll, a mold or the like during gel processing. Similarly, when the ethylene content is less than 20 mol%, the production of the fibrous structure and the fibrous molded product may be difficult due to adhesion to a roll, a mold or the like during gel processing. On the other hand, if the ethylene content exceeds 50 mol%, the wet heat gelation temperature rises, and the processing temperature must be raised to near the melting point, and as a result, the dimensional stability of the fibrous structure and the fibrous molding is adversely affected. May be exerted. As a preferable combination of the fiber and the binder resin,

(Π) a mixture of the composite fiber and another fiber,

(I I I) a mixture of the composite fiber and a wet heat gelling resin, and

(IV) A mixture of wet heat gelling resin and other fibers

At least one selected from the following (hereinafter, referred to as “forms (I) to (IV)”). The form (I) is a wet heat gelled composite fiber in which “binder resin” is a wet heat gelled resin fiber component and “fiber” is another thermoplastic synthetic fiber component. In the form (II), the “binder resin” is a wet heat gelled conjugate fiber, and the “fiber” is another fiber, which is a mixture thereof. In the form (III), the “fiber” is a wet heat gelling composite fiber, and the “binder resin” is a wet heat gelling resin. In the form (IV), the “binder resin” is a wet heat gelling resin (for example, a wet heat gelled resin alone fiber) that takes a form other than the wet heat gelled conjugate fiber, and the “fiber” is another fiber. This is a mixture of these.

It is preferable that the wet heat gelled conjugate fiber used in the forms (I) to (III) is a conjugate fiber in which the wet heat gelled resin fiber component is exposed or partially divided. The composite shapes are concentric, eccentric core-sheath, side-by-side, split, sea-island, etc. In particular, the concentric type is preferable because the filler easily adheres to the fiber surface. The cross-sectional shape may be any of a circle, a hollow, an irregular shape, an ellipse, a star, a flat shape, and the like, but is preferably a circle for ease of fiber production. It is preferable that the splittable conjugate fiber is partially split by injecting a high-pressure water flow or the like in advance. In this way, the split moist heat gelled resin fiber component gels by wet heat treatment, forms a gelled substance, adheres to the surface of other fibers, and fixes the filler. That is, Functions as a binder.

The proportion of the wet heat gelled resin fiber component in the wet heat gelled conjugate fiber,

The content of the wet-heat gelling resin fiber component is preferably in the range of 1 Omass% to 90 mAss%, and more preferably 30 mAss% or more. A more preferable content of the moist heat gelled resin fiber component is 70% by mass or less. When the content of the wet heat gelling resin fiber component is less than 1 Omass%, the filler tends to be hardly fixed. When the content of the wet heat gelling resin fiber component exceeds 9 Omass%, the fiber forming properties of the composite fiber tend to decrease.

The other thermoplastic synthetic fiber component in the wet heat gelled conjugate fiber may be any of polyolefin, polyester, polyamide and the like, but is preferably polyolefin. When an ethylene-vinyl alcohol copolymer resin is used as the wet heat gelling resin fiber component, it is easy to form a conjugate fiber (conjugate fiber) by melt spinning.

Further, it is preferable to use, as the other thermoplastic synthetic fiber component, a thermoplastic synthetic fiber component having a melting point higher than the temperature at which the wet heat gelled resin fiber component is gelled. If the other thermoplastic synthetic fiber component is a thermoplastic synthetic fiber component having a melting point lower than the temperature at which a gel is formed, the other thermoplastic synthetic fiber component itself tends to melt and become harder. When formed into a compact, it may become non-uniform with shrinkage.

The proportion of the wet heat gelled conjugate fiber in the fibrous structure is not particularly limited as long as it can fix the filler, but the fiber is fixed by the gelled material, and the Z or filler is effectively fixed. The ratio of the conjugate fiber required for this is preferably 1 O mass% or more. A more preferable ratio of the composite fiber is 3 O mass% or more. A more preferable ratio of the conjugate fiber is 5 O mass% or more. For example, in a textile structure In the case where a web containing conjugate fibers is present on both surfaces and other fibers are present inside, it refers to the content in the web containing conjugate fibers.

In the form (III), it is possible to form a gel on the surface of the conjugate fiber by further adding a moist heat gelling resin to the wet heat gelled conjugate fiber. Thereby, the effect of fixing the filler can be further improved.

Other fibers used in the form (II) or the form (IV) include:

— Any fiber, such as synthetic fiber such as Yong and other synthetic fibers, natural fiber such as cotton, hemp and wool, and synthetic resin such as polyolefin resin, polyester resin, polyamide resin, acrylic resin, and polyurethane resin. You can select and use the appropriate one.

In the above mode (IV), the wet heat gelling resin is preferably contained in a range of lmass% to 9 O mass% with respect to the fiber structure. A more preferred content is at least 3 mass%. A more preferred content is 7 O mass% or less. When the content of the wet heat gelling resin is less than lmass%, it becomes difficult to fix other fibers by the gelled matter, or it becomes difficult to fix the filler. If the content of the wet heat gelling resin exceeds 9 O mass%, the fiber shape may be lost and the film may be formed, or the filler may be buried in the gelled material. The filler can be any particle. For example, the filler is preferably inorganic particles. This is because inorganic particles have a large polishing effect when used as an abrasive. Examples of the inorganic particles include alumina, silica, tripoly, diamond, corundum, emery, garnet, flint, synthetic diamond, boron nitride, silicon carbide, boron carbide, chromium oxide, cerium oxide, iron oxide, colloidal silicate, Carbon, graphite, zeolite and titanium dioxide, kaolin, clay And the like. These particles can also be used as an appropriate mixture.

When the filler is a gas-adsorbing particle, the gas-adsorbing particle is not particularly limited as long as it has a function of adsorbing gaseous substances in the air.Activated carbon particles, zeolite, silica gel, activated clay, layered phosphorus Preferred are porous particles such as acid salts, and porous particles in which a chemical adsorbent is supported on these porous particles. Among porous particles, activated carbon particles are particularly preferred.

When the filler is an organic substance-adsorbing particle, the organic substance-adsorbing particle is not particularly limited as long as it has a function of adsorbing an organic substance in a liquid.Activated carbon particles, zeolite, silica gel, activated clay, layered phosphate, etc. The porous particles are preferable, and the porous particles in which an organic adsorbent is carried on these porous particles are preferable. Among porous particles, activated carbon particles are particularly preferred. Further, in addition to the abrasive, the gas adsorbing particles and the organic adsorbing particles, for example, silica gel as a drying agent, titanium dioxide as a photocatalyst, a virus adsorbing / decomposing agent, an antibacterial agent, a deodorant, a conductive agent, an antistatic agent One or more functional fillers such as humectants, insect repellents, fungicides, and flame retardants can be used.

The average particle size of the filler is preferably in the range of 0.01 to 100 m. A more preferred average particle size is 0.5 m or more, and a more preferred average particle size is 1 m or more. A more preferred average particle size is 80 im or less. If the average particle size is less than 0.01 m, the filler may be buried in the gel. On the other hand, when the average particle size exceeds 100 m, the specific surface area of the filter becomes small, and a sufficient function of the filter, for example, a gas adsorption effect may not be obtained.

The fibrous structure contains the fibers and the binder resin. The term “fiber structure” here refers to a fiber bundle, a fiber mass, a nonwoven fabric, a woven or knitted fabric, It is made of fibers such as fibers. In particular, nonwoven fabrics can be applied to various uses because of their high workability. For example, when the fibrous structure of the present invention is used as an abrasive nonwoven fabric containing a liquid, it is preferable that the fixed fibers are present in a web form on both surfaces and hydrophilic fibers are present inside. The hydrophilic fiber is preferably at least one fiber selected from rayon fiber, cotton fiber and pulp. This is because when a liquid such as water, a surfactant or a cleaning agent is applied and polished, water retention is high.

As one embodiment of the present invention, for example, a gas adsorbent using gas adsorbing particles as a filler is not limited to a nonwoven fabric, and a fiber bundle formed by bundling a plurality of the fixed fibers of the filler is referred to as a gas adsorber. Alternatively, the gas adsorption module may be used. In addition, a material obtained by winding the aggregate of the filler-fixed fibers in a cylindrical shape or a pleated shape can be used as a gas adsorption filter. The water purification material using the organic substance-adsorbing particles as the filler is not limited to a nonwoven fabric, and may be a water purification module in which a fiber bundle formed by bundling a plurality of the filler-fixed fibers is used as the organic substance-adsorbing section. In addition, an aggregate of the filler-fixed fibers wound in a cylindrical shape or a shape formed into a plied shape can also be used as a water purification filter. Further, in order to mold and process the fiber structure with a mold, the fiber structure is preferably a nonwoven fabric. Non-woven fabrics have low manufacturing costs, are easy to process, and when moistened during the molding process, they stretch moderately and easily conform to the shape of the mold, making it easier to obtain deep drawn compacts. .

The preferred basis weight of the fiber structure is 20 g / m ² or more and 600 g / m ² or less. The preferred thickness of the fibrous structure (under a load of 2.94 cN / cm ² ) is in the range from 0.1 mm to 3 mm.

The fiber structure, in order to efficiently exhibit the functionality of the filler, Preferably the amount sticking of the filler is fibrous structure lm ² per 2 g or more, more preferably 1 at 0 g or more, particularly preferably and this is 20 g or more.

Next, a method for producing the filler-fixed fiber and the fiber structure of the present invention will be described. The wet heat treatment in the present invention is performed in a wet heat atmosphere. Here, the term “moist heat atmosphere” refers to a heated atmosphere containing moisture. The wet heat treatment may be, for example, a treatment in which a fiber containing a binder resin, a fiber containing a wet heat gelling fiber component, or a fiber structure containing these fibers is heated after applying a filler monodispersed solution containing a filler. And a process of heating while applying the filler dispersion solution. Examples of the heating method include a method of exposing to a heated atmosphere, a method of penetrating through heated air, and a method of contacting a heated body.

When heating after applying the filler dispersion solution, the ratio of water to be applied to the fiber or fiber structure in the wet heat treatment (hereinafter referred to as “moisture percentage”) is 2 Omass% to 80 Omass%. Preferably, there is. A more preferable moisture regain is 3 Omass% or more. A more preferable moisture content is 70 Omass% or less. An even more preferred moisture content is 4 Omass% or more. An even more preferable moisture content is 600 mass% or less. If the water content is less than 2 Omass%, the gelation under wet heat may not occur sufficiently. On the other hand, when the moisture content exceeds 80 Omass%, the wet heat treatment is not performed uniformly between the surface and the inside of the fibrous structure, and the degree of wet heat gelation tends to be non-uniform. In addition, as a method for imparting water, a known method such as spraying or immersion in a water tank can be used. In particular, the method of impregnating the fiber structure with the filler dispersion solution is preferable because a large amount of filler is easily taken into the fiber structure. The moisture-imparted fiber or fiber structure is adjusted to a predetermined moisture content by squeezing with a squeeze roll or the like. Can be adjusted.

When heating while applying the filler dispersion solution, since the gelling of the wet heat gelling resin proceeds simultaneously with the application of moisture, the concentration of the filler in the filler dispersion solution and the temperature of the filler dispersion solution are adjusted. Then, the amount of sticking of the filler may be adjusted. Specifically, by impregnating the fiber or the fibrous structure in hot water (90 ° C. or higher) containing the filler, the filler can be fixed to the fiber surface.

The fibrous structure before the wet heat treatment may be subjected to a hydrophilic treatment. By performing the hydrophilic treatment, when the fibrous structure contains hydrophobic fibers, the fibrous structure can be provided with water substantially uniformly. As a result, the composite fiber is almost uniformly wet-gelled, and the filler is easily fixed, which is preferable. Hydrophilic treatments include surfactant treatment, corona discharge method, glow discharge method, plasma treatment method, electron beam irradiation method, ultraviolet irradiation method, T-ray irradiation method, photon method, flame method, fluorine treatment method, and graft treatment. And sulfonation treatment methods. The wet heat treatment temperature in the wet heat treatment is not less than the gelation temperature of the wet heat gelling resin or the wet heat gelling resin fiber component (hereinafter, both are also referred to as “binder resin”) and the melting point is not more than 20 ° C. Is preferred. A more preferred moist heat treatment temperature is 50 ° C or higher. An even more preferred wet heat treatment temperature is 80 ° C. or higher. On the other hand, a more preferable wet heat treatment temperature is a melting point of the binder resin—30 ° C. or lower. An even more preferable wet heat treatment temperature is a melting point of the binder resin of 140 ° C. or less. If the wet heat treatment temperature is lower than the gelling temperature of the binder resin, the filler may not be fixed effectively in some cases. If the temperature of the wet heat treatment exceeds the melting point of the binder resin, ie, more than 120 ° C, the melting point of the binder resin becomes close to that of the binder resin.

In the above-mentioned wet heat treatment, when contacting with a heating body, the surface pressure is 0.01 to It is preferably 0.2 MPa. A more preferable lower limit of the surface pressure is 0.02 MPa. A more preferable upper limit of the surface pressure is 0.08 MPa. When the heating body is a compression molding process using a hot roll, the linear pressure of the hot roll is preferably 10 to 40 ON / cm. A more preferable linear pressure of the hot hole is 50 N / cm. A more preferable upper limit of the linear pressure of the heat roll is 20 ON / cm. According to this method, the wet-heat gelling of the resin fiber component can be instantaneously wet-gelled, and at the same time, the gelled material can be pushed and spread, so that the filler can be fixed over a wide area. Further, according to this method, when the gel is wet-heated, the filler is pushed into the gelled material, and the filler can be more firmly fixed to the fiber surface.

When imparting bulkiness and noness or flexibility to the fibrous structure, the fiber and the web containing the wet heat gelling resin are subjected to a steam treatment to form a gelled product of the wet heat gelling resin. The filler can be fixed. Examples of the method of the steam treatment include a method of spraying steam from above and / or below a web or the like, a method of exposing to steam with an autoclave or the like, and the like. According to this method, pressure is not applied to the fiber structure more than necessary at the time of gel processing. As a result, the fibrous structure can be fixed in a state where the filler is exposed on the fiber surface while maintaining the fibrous form.

Next, a method for producing the fiber molded article of the present invention will be described. In the present invention, the term “wet heat forming” refers to a treatment in which a filler dispersion solution is applied to a fibrous structure and then heating, or heating while applying a filler dispersion solution to form the fiber structure into a predetermined shape. Examples of the heating method include a method of exposing to a heating atmosphere and a method of contacting with a heating body. The water content at the time of applying the filler monodispersed solution to the fiber structure is the same as the water content described above, and the description is omitted. In the wet heat forming process, it is preferable that a fibrous structure containing a filler dispersion solution is inserted into a pair of molds and subjected to a heat and pressure treatment. When heated in a state where moisture is contained, the nonwoven fabric itself expands moderately and easily conforms to the shape of the mold, so that it is easy to obtain a deep drawn compact. When heating while applying the filler dispersion solution, for example, a molded article can be obtained by inserting a fibrous structure into a pair of molds and impregnating it in hot water (90 ° C. or more). it can.

The wet heat forming process is performed in a wet heat atmosphere. It is preferable that the wet heat forming temperature is not lower than the gelling temperature of the gelling resin and not higher than the melting point−20 ° C. A more preferred wet thermoforming temperature is 50 ° C. or higher. An even more preferable wet thermoforming temperature is 80 ° C. or higher. On the other hand, a more preferable wet heat molding processing temperature is not more than 30 ° C of the melting point of the wet heat gelled resin. An even more preferable wet heat molding processing temperature is a melting point of the wet heat gelling resin of 140 ° C. or less. If the wet heat molding temperature is lower than the gelling temperature of the wet heat gelling resin, it is difficult to form a gel. If the wet heat molding processing temperature exceeds the melting point of the wet heat gelled resin _20, the temperature of the wet heat gelled resin approaches the melting point of the wet heat gelled resin.

In the present invention, when the wet heat gelling resin is wet heat gelled in a wet heat atmosphere, it is preferable to produce a fiber molded body by contact pressure molding in a mold. Here, the contact pressure forming refers to a process of applying pressure to such an extent that the fibrous structure and the mold come into contact with each other. The contact pressure is a concept that includes the pressure up to this point, when the fibrous structure and the mold adhere to each other, the mold's own weight is applied. The moist heat gelling resin becomes soft when gelled in a moist heat atmosphere. Therefore, in the case of simple molding only, the molding pressure does not need to be so high. According to the contact pressure molding process, the fiber molded body maintains its fiber shape, and the fibers are fixed by the gelled material, so that a bulky and flexible molded body can be obtained. Can be As the mold, for example, a light and thin mold such as a stainless steel plate is sufficient, and a dense mesh mold may be used.

In the present invention, when the hardness of the fibrous molded body is to be obtained, or when the gelled material in the form of a film is obtained by expanding the wet heat gelling resin, it is necessary to perform the heating and pressurizing at a pressure for producing a normal fibrous molded body. Can be.

Next, the present invention will be described with reference to the drawings. 1A to 1C are cross-sectional views of filler-fixed fibers according to one embodiment of the present invention. FIG. 1A shows a composite fiber 5 having polypropylene as a core component 2 and an ethylene-vinyl alcohol copolymer resin as a sheath component 1, wherein the sheath component 1 functions as a binder resin and is contained in the sheath component 1. This is an example in which a filler 3 is fixed to the substrate. FIG. 1B shows a composite fiber 6 having polypropylene as a core component 2 and an ethylene-vinyl alcohol copolymer resin as a sheath component 1, and an ethylene-vinyl alcohol copolymer resin as a binder component outside the sheath component 6. This is an example in which filler 3 is mixed into binder 4. Figure 1C shows a composite fiber 9 in which polypropylene 8 and ethylene-vinyl alcohol copolymer resin 7 are arranged in multiple segments. Ethylene-vinyl alcohol copolymer resin 7 functions as a binder-resin, and a filler 3 This is an example in which is fixed. FIG. 2 is a cross-sectional view of a three-layer nonwoven fabric according to an embodiment of the present invention, in which filler-fixed fiber layers 11 and 11 are arranged on the outside and rayon fiber layer 12 is arranged on the inside. is there.

FIG. 3 is a process chart of an example of the production method of the present invention. The fiber or non-woven fabric 31 is impregnated with a filler dispersion solution containing a filler or a filler dispersion solution containing a filler and an ethylene-vinyl alcohol copolymer resin 33 in a tank 32, squeezed with a squeezing roll 34, and steamer 35. And a suction heat, and then wind it as it is, or in the case of non-woven fabric, compress it with a pair of heating rolls 37, 37 for patterning canvas rolls 38, 38. Shape, give a predetermined pattern to the surface of the non-woven fabric, and then wind up

3 Wind up to 9. Instead of the steamer 35 and the suction 36, pressure treatment may be performed using upper and lower hot plates at a temperature of 150 ° C. for 5 minutes, for example. Other embodiments include a method of compression molding with only a pair of heating rolls without a steamer 35, and a pattern Ninda canvas roll 38, 38 applied to a pair of heating rolls 37, 37 without a steamer 35. There is also a method in which compression molding is performed only by using the compression molding.

4A to 4F show a state in which a filler is fixed to the nonwoven fabric obtained in one example of the present invention and its constituent fibers, and A is a scanning electron microscope plane photograph (magnification 100) showing the nonwoven fabric. B is a cross-sectional photograph (magnification: 100) of the same, C is an enlarged fiber surface photograph of the same nonwoven fabric (magnification: 100,000), D is the same, a scanning electron microscope plane photograph showing the other part of the nonwoven fabric (Magnification 100), E is a photograph of the same cross section (magnification 100), and F is an enlarged photograph of the fiber surface of the nonwoven fabric surface (magnification 100).

FIGS. 5A to 5C show a nonwoven fabric obtained in another embodiment of the present invention and a state in which a filler is fixed to the constituent fibers thereof, wherein A is a scanning electron microscope plane photograph showing the nonwoven fabric (magnification: 10). 0) and B are photographs of the same cross section (magnification 100) and C is an enlarged photograph of the surface of the nonwoven fabric (magnification 100).

FIG. 7 is a process chart of an example of a method for producing a nonwoven fabric containing water and a filler in one embodiment of the fiber molded article of the present invention. The raw nonwoven fabric 31 is impregnated with a filler-dispersed solution containing a filler or a filler-dispersed solution 33 containing an ethylene-vinyl alcohol copolymer resin containing a filler in a tank 32, and squeezed with a squeezing roll 34. As a result, about 500 mass% of moisture and filler are added to the nonwoven fabric. Next, it is brought into close contact with a 0.3 mm thick stainless steel plate mold, brought into contact pressure state, put into a hot air dryer at a processing temperature of 140 ° C, and heat-treated for 10 minutes for contact pressure processing. Did. Fig. 8 shows the compact A mask 40 for covering the mouth and nose of the human body and a pleated product 50 of an air purifier filter shown in FIG. 9 were produced.

FIG. 10 is a process diagram illustrating an example of a method for producing a filler-fixed fiber or a nonwoven fabric according to another embodiment of the present invention. The fibrous or non-woven fabric 31 is converted into an aqueous liquid or filler (for example, gas-adsorbing particles) containing a filler (for example, gas-adsorbing particles) and an ethylene-vinyl alcohol copolymer in a tank 32. It is impregnated with the dispersion liquid 33, squeezed by the squeezing roll 34, steam-processed by a steamer 35 from which steam is blown out from below, dried by the dryer 41, and wound up by the winder 39. FIGS. 11A and 11B show the nonwoven fabric obtained in one example of the present invention and the state in which the filler is fixed to the constituent fibers thereof, and A is a scanning electron microscope plane photograph (200 magnification) showing the nonwoven fabric. Panels B and B are enlarged photographs of the fiber surface of the nonwoven fabric (magnification: 2000).

Example

Hereinafter, the present invention will be described more specifically with reference to examples.

[Example 1]

The following were prepared as the polishing nonwoven fabric.

(Non-woven fabric)

The following three-layered hydroentangled nonwoven fabric was formed.

The first layer and the third layer are composed of a sheath component ethylene-vinyl alcohol copolymer resin (EV〇H, ethylene 38 mol%, melting point 1760, and a core component polypropylene having a core component polypropylene ratio of 50:50). Fineness: 2.8 dte X, fiber length: 5 lmm) Card web with a basis weight of 30 g for each layer

/ m. ² and 7

The second layer was a card web made of rayon fiber (fineness: 1.7 dte X, fiber length: 40 mm), and the basis weight was 30 gZm ² .

The basis weight of the three-layered hydroentangled nonwoven fabric was 90 gZm ² . This These nonwoven fabrics were superposed in the order of first layer / second layer / third layer and subjected to a high-pressure water flow treatment of 6 MPa to entangle the fibers in the thickness direction.

(Fila monodispersed solution)

As a filler, "Alumina" (average particle diameter 0.7 m) manufactured by Nippon Light Metal Co., Ltd. was suspended in water at a ratio of 3 mass% to prepare a filler dispersion solution (abrasive solution).

(Abrasive application and gel processing)

The nonwoven fabric was immersed in the abrasive solution and squeezed with a mangle roll. The pickup rate was adjusted at about 500%, and the amount of the adhered filler was adjusted to the value shown in Table 1. The pickup rate is a value obtained by multiplying the sum of the amount of water and the amount of filler with respect to the mass of the nonwoven fabric by 100. Subsequently, canvas nets were placed on the upper and lower hot plates heated to 120, the nonwoven fabric was sandwiched between the hot plates, and gel processing was performed at a pressure of 0.064 MPa for 2 seconds. Next, it was dried with hot air at 100 ° C.

(Polishing property evaluation test)

The following inks were applied to a stainless steel plate and a ceramic dish, and after drying, dirt was removed using each abrasive. To remove the dirt, human samples were rubbed with the same force applied to each sample. Ink, evaluation object and evaluation points are as follows.

(1) Ink

A: Teranishi Kagaku Kogyo Co., Ltd. oil-based ink (No. 500)

B: Shachihata oil-based ink (art1ine)

C: Zebra oil-based ink (high macchi)

D: Mitsubishi Pencil Oil Ink (Mitsubishi Marker One Piece)

E: Sakura Crepa's oil-based ink (My name)

(2) Condition of evaluation object and abrasive a: Stainless steel plate

b: Ceramic dish

d r y: Use in a dry state.

we t: Use with water and squeezed.

(3) Evaluation points

6 points: The number of frictions is 5 and the dirt is completely removed.

5 points: The number of times of rubbing is 10 and the dirt is completely removed.

4 points: The number of times of friction is 20 and the dirt is completely removed.

3 points: The number of rubs is 30 and the dirt is completely removed.

2 points: The number of times of rubbing is 30 and slight dirt remains partially.

1 point: The number of times of friction is 30 and about half of the dirt remains.

0 point: The number of rubs is 30 and dirt is hardly removed.

In addition, each evaluation sample was tested five. The results of the polishing test are summarized in Table 1 below.

FIGS. 4A to 4F show the state where the filler is fixed to the obtained nonwoven fabric and its constituent fibers.

[Comparative Example 1]

The following three-layered hydroentangled nonwoven fabric was formed.

The first and third layers are made of a core-sheath composite fiber of ethylene-vinyl acetate copolymer resin (EVA, melting point: 101 ° C) and polypropylene in a ratio of 50:50 (density: 2.2 dte X , Fiber length: 51 mm), and the basis weight was 30 g / m ^{2 for} each layer.

The second layer was a force web composed of rayon fiber (fineness: 1.7 dte X, fiber length: 40 mm), and the basis weight was 30 g / m ² .

The basis weight of the three-layered hydroentangled nonwoven fabric was 90 gZm ² . This non-woven fabric is superposed in the order of 1st layer Z 2nd layer Z 3rd layer, high pressure of 6 MPa Water flow treatment was performed to entangle the fibers in the thickness direction.

Other conditions, such as application of an abrasive, were the same as in Example 1. Table 1 summarizes the results of the polishing test.

[Comparative Example 2]

The following three-layered hydroentangled nonwoven fabric was formed.

The first and third layers are made of a core-sheath composite fiber of ethylene-methyl acrylate copolymer resin (EMA, melting point 86) and polypropylene in a ratio of 50:50 (fineness: 2.2 dte X, fiber length) : a Kaduebu consisting 45 mm), weight per unit area was each with 30 gZm ^2.

The second layer, rayon fiber (fineness: 1. 7 dtex, fiber length: 40 m m) is a card web of a basis weight was 30 g / m ^2.

The basis weight of the three-layered hydroentangled nonwoven fabric was 90 gZm ² . This nonwoven fabric was superimposed in the order of first layer Z second layer Z third layer, and subjected to a high-pressure water flow treatment of 6 MPa to entangle the fibers in the thickness direction.

[Conventional product 1]

An abrasion test was conducted in the same manner as in Example 1 using a commercially available nonwoven cloth scourer with abrasive particles (manufactured by 3M). The results are summarized in Table 1 below.

[Conventional product 2]

An abrasion test was performed in the same manner as in Example 1 using a commercially available sponge scourer with abrasive particles (manufactured by Este Chemical Co., Ltd.). The results are summarized in Table 1 below. Abrasiveness test

Example Alumina A B C D E Total average point Comparative example Adhesion rate a a b a a b a a b a a b a a b

(mass%) dry wet wet dry wet wet dry wet wet dry wet wet dry wet wet Example 1 1 6 6-6 6-3.2 4.7-3.6 6-0.4 6-

1 1 4 6 6 6 6 6 5.6 3 4.7 6 3.2 6 6 0.6 6 6

1 6 6 6 ― 6 6 ― 2.8 5 ― 3.4 6 ― 0.8 6 ―

1 8 1 ― 5.6 ― ― 6 ― ― 6 ― ― 6 ― ― 6 Average 6 6 5.8 6 6 5.8 3 4.8 6 3.4 6 6 0.6 6 6 5.2 Comparative example 1 2 3 3 5 0 3 5 0 0 5 0 2.8 5.6 0 3.9 6

1 1 7 3 2.8 4.8 3.4 3.8 5.4 0 3.4 5 0 3 6 0 3.5 6

Average 3 2.9 4.9 1.7 3.4 5.2 0 1.7 5 0 2.9 5.8 0 3.7 6 3.1 Comparative Example 1 6 4.3 5 4.7 2 4.7 5.3 0 3 5 0 4.3 6 0 4.3 6

2 Average 4.3 5 4.7 2 4.7 5.3 0 3 5 0 4.3 6 0 4.3 6 3.6 Conventional 1 Average 5.3 6 6 4.3 6 5.7 4 4.3 5.7 3.7 6 6 3.3 5.7 6 5.2 Conventional 2 Average 6 6 6 6 6 6 3 5 5.3 6 5.7 5.7 2.7 6 6 5.4

As shown in Table 1, the nonwoven fabric containing the filler-fixed fibers of this example exhibited almost the same level of abrasiveness as a commercially available abrasive. In addition, the nonwoven fabric containing the filler-fixed fibers of the present example did not lose the filler, and a good durability was obtained. The absence of fillers is especially useful for polishing lenses and semiconductors.

[Example 2]

(Non-woven fabric)

A hydroentangled nonwoven fabric having a basis weight of 100 g Zm ² and a high-pressure water flow treatment at a water pressure of 6 MPa comprising the core-sheath type composite fiber of Example 1 was used.

(Processing procedure and conditions)

The nonwoven fabric was pretreated by immersing it in an aqueous solution containing 0.1% by mass of a surfactant (polyoxyethylene alkylphenol ether having an alkyl group having 9 carbon atoms) and squeezing. Next, an ethylene-vinyl alcohol copolymer resin (EV0H) powder (manufactured by Nippon Synthetic Chemical Co., Ltd., trade name "Soanol", powder type B-7, ethylene 29 mol%, melting point 188 ° C) and activated carbon ( The product was immersed in an aqueous dispersion of Kuraray Chemical PL-D) (trade name, manufactured by Kuraray Chemical Co., Ltd.) and squeezed with a mulled roll. After that, using a hot plate hydraulic press (heating the upper and lower hot plates), gel processing was performed with nonwoven fabric sandwiched between canvas nets. The heating temperature was 120 ° C, the press pressure was 0.032 MPa, and the heating time was 2 minutes. Then, the excess filler was washed away and dried with hot air at 100 ° C.

The activated carbon was firmly and uniformly fixed. Table 2 summarizes the results of the obtained nonwoven fabric containing filler-fixed fibers.

[Example 3]

The treatment was carried out in the same manner as in Example 2 except that a 60 g / m ² hydroentangled nonwoven fabric (high-pressure water treatment at a water pressure of 6 MPa) consisting of rayon fiber 1.7 dtex and 51 iMi was used.

The activated carbon was firmly and uniformly fixed. Obtained filler fixation Table 2 summarizes the results for the nonwoven fabric.

[Example 4]

The treatment was carried out in the same manner as in Example 2 except that a 50 g / m ² hydroentangled nonwoven fabric (high-pressure water treatment at a water pressure of 6 MPa) composed of polyester fiber 1.7 dtex and 51 mm was used. The activated carbon was firmly and uniformly fixed. Table 2 summarizes the results of the obtained filler-bonded nonwoven fabric.

[Example 5]

The treatment was carried out in the same manner as in Example 2 except that a hydro-entangled nonwoven fabric of 60 g / m ² (high-pressure water treatment at a water pressure of 6 MPa) composed of polypropylene fiber 1.7 dtex and 51 thighs was used. The activated carbon was firmly and uniformly fixed. Table 2 summarizes the results of the obtained filler-bonded nonwoven fabric.

Table 2

[Example 6]

The first layer and the third layer are made of a splittable conjugate fiber (fineness: 3.3 dtex, fineness: 3.3 dtex, ethylene / biel alcohol copolymer resin (EVOH) of Example 1) and polypropylene of Example 1 in a ratio of 50:50. Fiber length: 5 1mm) It was eb and the basis weight was 30 g / m ^{2 for} each layer. The second layer between the first and third layers is a card web in which the rayon fiber of Example 1 and polyester fiber (fineness: 1.7 dtex, fiber length: 51 mm) are mixed at a ratio of 1: 1. , is with the eye was 30 gZm ^2. Thereafter, a hydroentangled nonwoven fabric was formed in the same manner as in Example 1 and gel-processed. As in Example 1, the filler was firmly and uniformly fixed. FIGS. 5A to 5C show a state in which the filler is fixed to the obtained nonwoven fabric and its constituent fibers.

[Example 7]

(Preparation of raw nonwoven fabric)

The sheath component is ethylene-vinyl alcohol copolymer resin (EVOH, 38 mol% of ethylene, melting point: 176 ° C), the core component is polypropylene (PP, melting point: 161 ° C), and EVOH: PP A core-sheath composite fiber (fineness: 3.3 dtex, fiber length: 5 lmm) having a ratio of 50:50 (volume ratio) was prepared. In addition, the sheath component is polyethylene (PE, melting point 1 32 ° C) and the core component is polypropylene (PP, melting point 16 1 ° C). Composite fiber (manufactured by Daiwa Spinning Co., Ltd., NB F (H)) was prepared.

75 mass% of the core-sheath type composite fiber and 25iass% of the dry heat-adhesive fiber were mixed and opened with a semi-random card machine to produce a card web having a basis weight of 45 gZm ² . Then, the card web was placed on a 90-mesh plain weave support, and the orifices (diameter: 0.12 mm, pitch: 0.6 mm) were arranged in a line in the width direction of the card web. The water stream was sprayed at a pressure of 3 MPa toward the card web, and was further sprayed at a pressure of 4 MPa. Subsequently, the card web was turned over, and a water stream was jetted from the nozzle at a water pressure of 4 MPa to produce a hydro-entangled nonwoven fabric.

(Preparation for Fila) Activated carbon particles: “Taiko SA 100000” (manufactured by Nimura Chemical Co., average particle diameter 10 / xm) was used as the filter.

(Preparation of non-woven fabric containing filler fiber)

The raw nonwoven fabric is immersed in a filter dispersion solution (20 ° C) in which 8% by mass of the activated carbon particles are dispersed in water, and the pickup rate is reduced with a linear pressure of about 60 NZcm using a mangle roll. It was adjusted. Next, the nonwoven fabric impregnated with the filler dispersion solution was subjected to steam treatment at a bath temperature of 102 ° C and a processing time of 15 seconds using a steamer in which steam was blown from the lower part of the nonwoven fabric web. And dried with a hot air dryer (lo ot :) to obtain the nonwoven fabric of the present invention. The basis weight of the obtained nonwoven fabric was 68 g / m ² , and about 23 g / m ² of the filler was fixed. Figures 11A-B show the obtained nonwoven fabric and the state in which the filler is fixed to the constituent fibers. The obtained nonwoven fabric maintained the fiber morphology, and was fixed with the filler exposed on the fiber surface.

[Examples 8 to 11]

The following were prepared as gas adsorbents.

(Preparation of raw nonwoven fabric)

The sheath component is ethylene-vinyl alcohol copolymer resin (EV〇H, ethylene content 38 mol%, melting point 176 ° C), and the core component is polypropylene (PP, melting point 161 ° C).芯 A core-sheath composite fiber (fineness: 2.8 dtex, fiber length: 5 lmm) having a H: PP ratio of 50:50 (volume ratio) was prepared.

The core-sheath type composite fiber was opened with a semi-random card machine to produce a card web having a basis weight shown in Table 3. Then, the force web was placed on a 90-mesh plain weave support, and orifices (diameter: 0.12 mm, pitch: 0.6 mm) were arranged in a line in the width direction of the card web. A water stream was jetted from the spill toward the card web at a water pressure of 3 MPa, and then jetted at a water pressure of 4 MPa. Subsequently, the card web was turned upside down, and a water stream was jetted from the nozzle at a water pressure of 4 MPa, to produce a hydro-entangled nonwoven fabric used in Examples 8 to 11.

(Preparation for Fila)

Gas adsorbent particles were prepared as a filter. Activated carbon particles: “Kuraray Coal PL-D” (manufactured by Kuraray Chemical Co., Ltd., coconut shell charcoal, average particle size 40 to 50 / m) were used as the gas absorbing particles.

(Preparation of non-woven fabric containing filler fiber)

The raw nonwoven fabric was immersed in a filter dispersion solution (20 ° C) in which 10% by mass of the activated carbon particles were dispersed in water, and the pick-up rate was adjusted by the squeezing pressure of a mangle roll to obtain the activated carbon particles. The amount of fixation was adjusted so that the values shown in Table 3 were obtained. The pickup rate is a value obtained by multiplying 100 by the sum of the amount of water and the amount of activated carbon particles with respect to the mass of the nonwoven fabric. Next, the above-mentioned nonwoven fabric impregnated with the monofilament dispersion solution was treated with two plain weave plastic nets having a wire diameter of 0.3 mm, a mesh number of 30 vertical / inch X 25 horizontal 25 Z inch (length 40 c). mX horizontal 40 cm) was sandwiched between, 1 5 0 is placed on a hot plate heated to ° C, further, the wet heat treatment for 15 minutes covered with aluminum above the plastic Kunetto sheet (lg / cm ²⁾ did. The obtained nonwoven fabric was washed with water and dried with a hot air drier (100 ° C) to obtain a nonwoven fabric (gas adsorbent) of the present invention.

[Example 12]

The same nonwoven fabric as the hydroentangled nonwoven fabric used in Example 8 was immersed in a filler dispersion solution (95 ° C) in which 5 mass% of the activated carbon particles were dispersed in water for 30 seconds, and then pulled up. . Then, the nonwoven fabric was supported until the temperature of the nonwoven fabric reached 50 ° C. Then, the nonwoven fabric Is washed with water and dried with a hot air drier (100 ° C) to obtain the nonwoven fabric of the present invention.

(Gas adsorbent) was obtained.

Table 3 shows the basis weight of the nonwoven fabric web, the fixed amount of activated carbon particles, the fixed rate of activated carbon particles, and the basis weight of the nonwoven fabric (gas adsorbent) for the nonwoven fabrics (gas adsorbents) of Examples 8 to 12.

Table 3

[Comparative Example 3]

A filler dispersion solution containing 15 mass% of self-crosslinking acrylic ester emulsion (trade name “Nikkizol FX-5555A” manufactured by Nippon Carbide Industry Co., Ltd.) and 10 mass% of the activated carbon particles is used. Got ready. Next, the same nonwoven fabric as the hydroentangled nonwoven fabric used in Example 8 described above was immersed in the solution, squeezed with a mangle roll, and heated at a temperature of 140 ° C using a hot air drier for 15 minutes. And cured to obtain a chemically bonded nonwoven fabric having a fixed amount of activated carbon particles of 38 g / m ² .

[Comparative Example 4]

As Comparative Example 4, a V〇C gas adsorption sheet (made by Asahi Kasei Fibers Co., Ltd., in which activated carbon particles were fixed with a hot melt agent) between two spun-pound nonwoven fabrics on the surface of which a deodorant was fixed. Semia V ”, a basis weight of 134 g / m ² , and a fixed amount of activated carbon particles of about 40 gZm ² ) were prepared.

[V〇C gas adsorption test method]

Each of the sheets of Examples 8 to 12 and Comparative Examples 3 and 4 was cut into a size of 10 cm in length and 10 cm in width, and a pollution analysis bag having a capacity of 5 liters. (Trade name “Tedra bag”), and each VOC gas mixed with air so as to have the initial concentration shown in Tables 4 to 6 was injected. The injection time was set as the start time, and the concentration of each VOC gas in the bag was measured with a gas detector tube every time. The results are shown in Tables 4-6. In Tables 4 to 6, “NDJ indicates the case where the concentration of each VOC gas is less than the measurement limit (2 ppm) of the gas detector tube used.

Table 4

Table 5

[Result]

As shown in Tables 4 to 6, when the nonwoven fabrics of Examples 8 to 11 were used, the reduction rate of the concentration of each VOC gas was faster than that of Comparative Examples 3 and 4, and the gas absorption was higher. The wearing performance has improved. Further, as shown in Table 4, Example 12 exhibited the same formaldehyde adsorption performance as Comparative Example 3 even though the fixed amount of activated carbon particles was smaller than Comparative Example 3. Further, as shown in Tables 5 and 6, Example 12 exhibited improved gas adsorption performance, despite the smaller amount of activated carbon particles fixed than Comparative Example 4. This is because the activated carbon particles (gas-adsorbing particles) in the nonwoven fabrics of Examples 8 to 12 are fixed by the wet-heat gelled gel on the fiber surface, so that the gas-adsorbing particles are exposed on the surface. It is considered that the decrease in the specific surface area of the gas-adsorbing particles was suppressed as compared with Comparative Examples 3 and 4. The nonwoven fabrics of Examples 8 to 12 retained the fiber shape, and the nonwoven fabric did not shrink during gel processing. Further, the nonwoven fabrics of Examples 8 to 12 did not have the gas-adsorbing particles falling off.

[Example 13]

The following materials were prepared as water purification materials.

(Preparation of raw nonwoven fabric)

The sheath component is ethylene-vinyl alcohol copolymer resin (EV〇H, ethylene content 38 mol%, melting point 176 ° C), and the core component is polypropylene (PP, melting point 161 ° C). A core-sheath composite fiber (fineness: 2.8 dtex, fiber length: 5 lmm) having a ratio of EV: H: PP of 50: 50 (volume ratio) was prepared.

The core-sheath type composite fiber was opened with a semi-random card machine to produce a card web having a basis weight of 101 g Zm ² . Next, the card web is placed on a 90-mesh plain weave support, and orifices (diameter: 0.12 mm, pitch: 0.6 mm) are arranged in a line in the width direction of the force web. A water stream was jetted from the nozzle to the card web at a water pressure of 3 MPa, and further jetted at a water pressure of 4 MPa. Then, turn over the card web and A water stream was jetted from the nozzle at a water pressure of 4 MPa to produce a hydro-entangled nonwoven fabric used in Example 1.

(Preparation for Fila)

Organic substance-adsorbing particles were prepared as fillers. Activated carbon particles: “Kuraray Coal PLD” (Kuraray Chemical Co., Ltd., coconut husk charcoal, average particle size 40 to 50 m) were used as the organic substance adsorbing particles.

(Preparation of non-woven fabric containing filler fiber)

The raw nonwoven fabric was immersed in a monofilament dispersion solution (20 ° C) in which 1 Omass% of the activated carbon particles were dispersed in water, and the pick-up rate was adjusted with a squeezing pressure of a mangle roll to obtain the activated carbon particles. The amount of fixation was adjusted so that the values shown in Table 7 were obtained. Next, the above nonwoven fabric impregnated with the filler dispersion solution was treated with two plain weave plastic nets having a wire diameter of 0.3 mm and a mesh number of 30 / inch X 25 / inch. (cm x 40 cm) and placed on a hot plate heated to 150 ° C. Cover the upper plastic net with aluminum sheet (1 g / cm ² ) and wet for 15 minutes. Heat treatment was performed. The obtained nonwoven fabric was washed with water and dried with a hot air dryer (100 ° C) to obtain a nonwoven fabric (water purification material) of the present invention.

[Example 14]

Using a card web having a basis weight 40 gZm ^2, wherein the concentration of the activated carbon particles in the aqueous dispersion at the time of Ru by fixing activated charcoal particles with 5 mass%, the adhesion amount of the activated carbon particles to adjust the Pikkuappu rate Man dull A non-woven fabric (water purification material) of the present invention was obtained in the same manner as in Example 13 except that the values were adjusted to the values shown in Table 1.

Table 7 shows the nonwoven fabric fabric weight, the amount of activated carbon particles fixed, the fixed rate of activated carbon particles, and the nonwoven fabric of the nonwoven fabrics (water purification materials) of Examples 13 and 14 in Example 7. The basis weight of the cloth (water purification material) is shown. The nonwoven fabrics of Examples 13 and 14 retained the fiber shape and did not shrink during gel processing. Table 7

[Comparative Example 5]

As Comparative Example 5, an activated carbon fiber nonwoven fabric (manufactured by Kuraray Chemical Co., Ltd., trade name “Cractive”, weight per unit area: about 180 gZm ² ) was prepared.

[Water purification performance test method]

For Examples 13 and 14, and Comparative Examples 3 and 5, a water purification performance test was performed using a water circulation type simple testing machine shown in FIG. As shown in FIG. 6, the water circulating simple tester 20 is fixed to the stand 21 by the stand 21, the fixing jigs 22 a and 22 b attached to the stand 21, and the fixing jig 22 a. And a pump 24 that circulates water in the container 23. The pump 24 includes a tube 24 a attached to the opening 23 a at the bottom of the container 23 and a tube 24 b fixed to the stand 21 by a fixing jig 22 b. The water in the container 23 is sucked from the tube 3a by the tube 24a from 3a, and the sucked water is discharged to the upper part of the container 23 by the tube 24b. In this test, Examples 13 and Comparative Example 5 were carried out by placing factory wastewater having a chemical oxygen demand (COD) of 4 Oppm in the container 23. About, the factory wastewater with COD of 20 ppm was put. In addition, the power circulation device (not shown) connected to the pump 24 set the circulation flow rate of water to 6 liters Z minutes, and maintained the liquid volume of the industrial wastewater in the container 23 at 1 liter during the test. [Method of preparing test sample]

Each of the nonwoven fabrics of Examples 13 and 14 and Comparative Examples 3 and 5 was cut into small pieces 25 of 3 cm × 3 cm (see FIG. 6). Next, for each of Examples 13 and 14 and Comparative Examples 3 and 5, a small piece 25 was weighed so that the amount of activated carbon became 10 g, and the weighed small piece 25 was replaced with a commercially available tea pack 26. (See Fig. 6) and a test sample 27 (see Fig. 6) was prepared. At the time of the water purification performance test, the test sample 27 was immersed in the above-mentioned factory wastewater in the container 23 and fixed to the fixing jig 22 with the wire 28 as shown in FIG.

[Method of measuring COD concentration]

The COD concentration is determined by collecting the above-mentioned factory wastewater in the container 23 into a beaker with a spot at every measurement time, and using a simple water quality analysis product “Pack Test” (WAK-C〇D, measurement range 0 to L) manufactured by Kyoritsu RIKEN. (00 mg / liter) and colorimetrically measured with the standard color. Table 8 shows the results.

Table 8

[Result]

As shown in Table 8, when the nonwoven fabrics of Examples 13 and 14 were used, the COD concentration was reduced faster than in Comparative Examples 3 and 5, and good water purification performance was exhibited. In particular, 120 minutes after the start of the measurement, the COD concentration of Example 14 became half of the COD concentration of Comparative Example 3, and the water purification performance was improved. This is because the activated carbon particles (organic substance-adsorbing particles) in the nonwoven fabric of Example 14 are fixed by a gel formed by the heat and heat gelation fixed on the surface of the fiber. Therefore, it is considered that the organic substance-adsorbing particles were fixed in a state of being exposed on the surface, and the decrease in the specific surface area of the organic substance-adsorbing particles was suppressed as compared with Comparative Example 3.

[Activated carbon shedding rate]

For Example 14 and Comparative Example 5, the activated carbon shedding rate was measured by the following method.

Each of the nonwoven fabrics of Example 14 and Comparative Example 5 was cut so that the amount of activated carbon became 1.21 g. The size of the cut sample was 30 cm × 20 c in Example 14, and 6.6 cm × 10 cm in Comparative Example 5. Next, 2 liters of water was placed in a 3 liter beaker, and the samples of Example 13 and Comparative Example 5 were respectively placed in water in the beaker and stirred with a magnetic stirrer for 4 hours. Thereafter, the sample was taken out, and the remaining liquid in the vial was removed from a glass filter paper (manufactured by Toyo Roshi Kabushiki Kaisha, trade name “Advantech”, model number “GLASS FIBER GS25J, diameter 47 mm”) whose weight was measured in advance. The filtered glass filter paper was dried, the dried glass filter paper was dried, the weight of the dried glass filter paper was measured, and the amount and rate of the activated carbon falling off were determined from the obtained glass filter paper. The amount of activated carbon falling off was the value obtained by subtracting the mass of glass filter paper before filtration from the mass of glass filter paper after drying. 1.21g) and multiplied by 100. The results are shown in Table 9. Table 9

[Result]

As shown in Table 9, the nonwoven fabric of Example 14 was able to reduce the amount and rate of activated carbon falling off as compared with Comparative Example 5. This is the nonwoven fabric of Example 14. This is presumably because the activated carbon (activated carbon particles) in the inside was fixed by the gelled gel which was fixed to the surface of the fiber by the heat-moisture gelation, so that the activated carbon could be held more firmly than in Comparative Example 5.

[Example 15]

(Preparation of raw nonwoven fabric)

The sheath component is ethylene-vinyl alcohol copolymer resin (EV〇H, 38 mol% of ethylene, melting point 176 ° C), the core component is polypropylene (PP, melting point 161 ° C), A core-sheath composite fiber (fineness: 2.8 dtex, fiber length: 5 lmm) having a ratio of EVOH: PP of 50: 50 (volume ratio) was prepared.

The core-sheath type composite fiber was opened by a semi-random card machine to produce a card web having a basis weight of 40 g / m ² . Next, the card web is placed on a 90-mesh plain weave support, and the orifices (diameter: 0.12 mm, pitch: 0.6 mm) are arranged in a row in the width direction of the force web. The water stream was sprayed at a pressure of 3 MPa toward, and was further sprayed at a water pressure of 4 MPa. Subsequently, the force web was turned upside down, and a water flow was jetted from the nozzle at a water pressure of 4 MPa to produce a raw hydroentangled nonwoven fabric.

(Preparation for Fila)

Activated carbon particles: Kuraray Coal PL-DJ (Kuraray Chemical Co., Ltd., Yashigara charcoal, average particle diameter 40 to 50 im) was used as the filler.

(Filtration and sticking wet heat forming)

The raw nonwoven fabric was immersed in a filler dispersion solution (20 ° C.) in which 10 mass% of the activated carbon particles were dispersed in water, and the pick-up rate was adjusted by the squeezing pressure of a mangle roll.

A non-woven fabric containing water and filler is sandwiched between a pair of 0.3 mm thick stainless steel plate molds, and then hot air dried at a processing temperature of 140 ° C. The mixture was placed in a dryer and heat-treated at a contact pressure for 10 minutes. Using a bowl-shaped mold, the mask 40 shown in Fig. 8 is used to cover the mouth and nose of the human body, and a pleated mold is used to form a pleated product such as an air purifier filter shown in Fig. 9. It was made. When the fixation ratio of the activated carbon particles of the obtained mask and pleated product was determined, they were all about 100 mass%.

The mask shown in FIG. 8 was a deep drawn bowl-shaped molded body having appropriate flexibility, retaining the fiber morphology, and uniformly dispersing the fibers. The activated carbon particles fixed by the gelled material did not fall off from the compact. Even wearing the mask, she did not feel stuffy. The pre-processed product in Fig. 9 was a deep-drawn molded product that retained the fiber morphology, had a uniform distribution of the fibers, and had clear pleated peaks and valleys (folds). The activated carbon particles fixed by the gelled matter did not fall off from the compact. The processed pleated product in Fig. 9 was firmly folded, and the workability of the pleated cartridge fill was good.

The present invention can provide a filler-fixed fiber, a fibrous structure, a fibrous molded article, and a method for producing the same, which can effectively exhibit the function of the filler while maintaining the properties of the original fiber.

In the present invention, since the filler is fixed to the fiber surface by the gel, the filler can be fixed in a state of being exposed on the fiber surface without easily falling off. For example, when the fibrous structure of the present invention is used as a gas adsorbent, the gas adsorbing particles are fixed by the gelled material on the fiber surface, so that the gas adsorbing particles are fixed while being exposed on the surface. can do. As a result, it is possible to prevent the gas-adsorbing particles fixed on the fiber surface from falling off and to suppress the decrease in the specific surface area of the gas-adsorbing particles. Performance can be improved. Further, when the fiber structure of the present invention is used for a water purification material, However, since the particles are fixed by the gelled substance on the fiber surface, the organic substance-adsorbing particles can be fixed while being exposed on the surface. As a result, the organic substance-adsorbing particles fixed to the fiber surface can be prevented from falling off, and the specific surface area of the organic substance-adsorbing particles can be prevented from decreasing.Therefore, the purification performance is improved compared to conventional water purification materials. Can be done.

In the fiber molded article of the present invention, the binder resin contains a wet heat gelling resin, and the fiber structure is formed into a predetermined shape by fixing the fiber by the wet heat gelling of the wet heat gelling resin. Therefore, in the case of clothing use, it is flexible even when it comes into direct or indirect contact with human skin. In addition, the forming is uniform, and a deep drawn shape can be obtained. Further, the filler can be effectively fixed to the fiber surface.

In addition, the method for producing a fiber molded article of the present invention is capable of forming a fiber aggregate containing fibers and a wet heat gelling resin and performing a wet heat forming process, whereby uniform molding can be performed, and a deep drawn shape can be obtained. It can be easily formed. The molding cost can be reduced even for general use.

Industrial applicability

The filler-fixing fiber and the fiber structure of the present invention are used for polishing fibers between teeth (dental floss), abrasives for various fields such as lenses, semiconductors, metals, plastics, ceramics, and glass as industrial abrasives. Abrasives used in home or commercial kitchens, gas adsorbents that absorb harmful gases, antibacterial materials, deodorant materials, ion exchange materials, sewage treatment materials, oil absorbing materials, metal adsorbent materials, battery separators, etc. It is useful for woven materials, conductive materials, antistatic (antistatic) materials, humidity control, dehumidifying (condensation prevention) materials, sound absorbing and soundproofing materials, insect repellents, force-proofing materials, and boys' materials. For example, gas adsorbents and antiviral materials can be used for curing sheets for building materials, wallpapers, masks, filters for air conditioning, and the like. In the case of clothing use, the fiber molded article of the present invention includes, for example, a shoulder pad, a breast pad, a jacket collar upholstery, a sleeve interlining, a pocket interlining, a front body, a rearward lookout, a return, a pants waistliner, and the like. is there. In the case of non-clothing applications, masks, air purifiers, pre-processed products of filters and filter media used in clean rooms, insulation materials for air-conditioned air ducts, pipes, pipes, plates, and calendars It can be formed into various shapes such as a sheet having

Claims

The scope of the claims

1. A filler-fixing fiber comprising a fiber, a binder resin on the surface thereof, and a filler fixed to the binder resin,

The binder resin is a wet heat gelling resin that gels when heated in the presence of moisture.

The filler-fixed fiber, wherein the filler is fixed by a gel formed by gelling the wet heat gelling resin.

2. The filler-fixed fiber according to claim 1, wherein the wet heat gelling resin is an ethylene-vinyl alcohol copolymer resin.

3. The filler-fixed fiber according to claim 1, wherein the average particle diameter of the filler is in the range of 0.01 to 100 x m.

4. A fibrous structure containing fibers, a binder resin on the surface thereof, and a filler fixed fiber containing a filler fixed to the binder resin, wherein the binder resin is heated in the presence of moisture. This is a wet heat gelled resin that gels

The fibrous structure, wherein the filler is fixed by a gel of the wet heat gelling resin.

5. The fiber structure according to claim 4, wherein the wet heat gelling resin is an ethylene-vinyl alcohol copolymer resin.

6. The fibers and the binder resin are:

(I) a composite fiber containing a moist heat gelling resin component and another thermoplastic synthetic fiber component,

(I I) a mixture of the composite fiber and another fiber,

(I I I) a mixture of the composite fiber and a wet heat gelling resin, and

(IV) A mixture of wet heat gelling resin and other fibers

The fiber according to claim 4, comprising at least one combination selected from the group consisting of: Weir structure.

7. The fiber structure according to claim 4, wherein the average particle diameter of the filler is in a range of 0.01 to 100 Aim.

8. The fiber structure according to claim 4, wherein the filler is an inorganic particle.

9. The inorganic particles are alumina, silica, tripoly, diamond, corundum, emery, garnet, flint, synthetic diamond, boron nitride, silicon carbide, boron carbide, chromium oxide, cerium oxide, iron oxide, colloidal silicate, 9. The fibrous structure according to claim 8, which is at least one particle selected from carbon, graphite, zeolite, titanium dioxide, kaolin, clay, and silica gel.

10. The fiber structure according to claim 9, wherein the filler is an abrasive, and the fiber structure is an abrasive nonwoven fabric.

1 1. The fiber structure according to claim 4, wherein the filler contains porous particles.

12. The fiber structure according to claim 11, wherein the porous particles are activated carbon particles.

13. The fiber structure according to claim 12, wherein the fiber structure is a gas adsorbent.

14. The fiber structure according to claim 12, wherein the fiber structure is a water purification material.

1 5. The fiber structure according to claim 4, wherein the filler-fixed fibers are present on both surfaces, and hydrophilic fibers are present therein.

16. The fiber structure according to claim 15, wherein the hydrophilic fiber is at least one fiber selected from rayon fiber, cotton fiber, and pulp.

17. The fibrous structure according to claim 4, wherein the fibrous structure is compression molded in a thickness direction and fixed.

1 8. The fibers, the binder resin on the surface, and the binder resin A fibrous structure formed by molding a fibrous structure containing the attached fiber and fixed fibers,

The binder resin includes a wet heat gelling resin that gels when heated in the presence of moisture,

The fibrous structure is characterized in that the fiber structure is fixed to a predetermined shape while the fiber is fixed by a gel formed by hydrothermal gelation of the wet heat gelling resin.

19. The fiber molded article according to claim 18, wherein the fiber molded article is molded by contact pressure molding.

20. A method for producing a filler-fixed fiber including a fiber, a binder resin on the surface thereof, and a filler adhered to the binder resin, wherein the fiber and the binder resin are heated in the presence of moisture. It is a wet heat gelled fiber that gels due to

A filler dispersion solution in which the filler is dispersed in a solution is applied to the wet heat gelled fiber,

Next, the wet heat gelled fiber is subjected to wet heat treatment in a wet heat atmosphere to gel the wet heat gelled fiber, and the filler is adhered to the fiber surface with a gelled material. Production method.

21. The production of the filler-fixed fiber according to claim 20, wherein the wet heat gelled fiber is a wet heat gelled resin alone or a composite fiber containing a wet heat gelled resin component and another thermoplastic synthetic fiber component. Method.

22. The method for producing a filler-fixed fiber according to claim 20, wherein the moist heat atmosphere has a temperature range from the gelling temperature of the moist heat gelling resin to the melting point and less than or equal to 2 Ot :.

23. A method for producing a filler-fixed fiber comprising a fiber, a binder resin on the surface thereof, and a filler fixed to the binder resin, The fibers and the binder resin are other fibers and a wet heat gelling resin,

Applying a filler after applying the wet heat gelling resin to the other fiber, or applying a filler dispersion solution in which the filler and the wet heat gelling resin are dispersed in a solution to the other fiber;

Next, a method for producing filler-fixed fibers, characterized in that the heat-moisture gelling resin is gelled by wet heat treatment in a moist heat atmosphere, and the filler is fixed to another fiber surface with a gelled material.

24. A method for producing a fibrous structure comprising fibers, a binder resin on the surface thereof, and filler-fixed fibers containing a filler fixed to the binder resin,

The binder resin is a wet heat gelled resin that gels when heated in the presence of moisture,

The fiber and the binder resin are,

(I) a composite fiber containing a wet heat gelled resin fiber component and another thermoplastic synthetic fiber component,

(I I) a mixture of the composite fiber and another fiber,

(I I I) a mixture of the composite fiber and a wet heat gelling resin, and

(IV) A mixture of wet heat gelling resin and other fibers

At least one combination selected from

Producing a fiber structure with the fibers and the binder resin,

A filler dispersion in which the filler is dispersed in a solution is applied to the fibrous structure,

Next, a fibrous structure in which the moist heat gelling resin is subjected to wet heat treatment in a moist heat atmosphere to gel the moist heat gelling resin, and the filler is adhered to the fiber surface by the gelled material to form filler-fixed fibers. Manufacturing method.

25. The method for producing a fibrous structure according to claim 24, wherein the wet heat atmosphere has a temperature in a range from a gelling temperature of the wet heat gelling resin to a melting point of not more than 20 ° C.

26. The method for producing a fibrous structure according to claim 24, wherein the wet heat treatment is a process of compression molding in a thickness direction.

27. The method according to claim 24, wherein the wet heat treatment is a treatment with steam.

28. The method for producing a fibrous structure according to claim 24, wherein the filler dispersion solution is an aqueous solution or an aqueous solution containing a wet heat gelling resin.

29. A method for producing a fibrous molded article, comprising: forming a fiber, a binder resin on a surface thereof, and a fibrous structure including a fiber-fixed fiber fixed to the binder resin,

Forming a fiber structure comprising the fiber and the binder resin,

A method for producing a fibrous molded body, characterized in that the fibrous structure is subjected to wet heat molding in a wet heat atmosphere in a mold in a wet heat atmosphere.

30. The method for producing a fiber molded article according to claim 29, wherein the wet heat molding processing is a processing in which a fibrous structure containing water and a filler is inserted into a pair of molds and subjected to heat and pressure treatment. .

31. The method for producing a fiber molded article according to claim 29, wherein the wet heat molding is a contact pressure molding in which the fiber structure and the mold are processed under a contact pressure.