WO2005012605A2 - Fibre tenue par le remplissage, structure de fibre, fibre moulee, et procedes de production correspondants - Google Patents

Fibre tenue par le remplissage, structure de fibre, fibre moulee, et procedes de production correspondants Download PDF

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Publication number
WO2005012605A2
WO2005012605A2 PCT/JP2004/011397 JP2004011397W WO2005012605A2 WO 2005012605 A2 WO2005012605 A2 WO 2005012605A2 JP 2004011397 W JP2004011397 W JP 2004011397W WO 2005012605 A2 WO2005012605 A2 WO 2005012605A2
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WO
WIPO (PCT)
Prior art keywords
fiber
filler
wet heat
resin
fixed
Prior art date
Application number
PCT/JP2004/011397
Other languages
English (en)
Japanese (ja)
Other versions
WO2005012605A3 (fr
Inventor
Hisatoshi Motoda
Kouki Shigeta
Original Assignee
Daiwabo Co., Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP2003286185A external-priority patent/JP3884730B2/ja
Priority claimed from JP2004181415A external-priority patent/JP4565902B2/ja
Priority claimed from JP2004183709A external-priority patent/JP4634072B2/ja
Application filed by Daiwabo Co., Ltd. filed Critical Daiwabo Co., Ltd.
Priority to KR1020067002051A priority Critical patent/KR101138567B1/ko
Priority to US10/566,617 priority patent/US20070128434A1/en
Priority to TW094103356A priority patent/TW200540309A/zh
Publication of WO2005012605A2 publication Critical patent/WO2005012605A2/fr
Publication of WO2005012605A3 publication Critical patent/WO2005012605A3/fr
Priority to HK06111804.7A priority patent/HK1091244A1/xx

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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/327—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated alcohols or esters thereof
    • D06M15/333—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated alcohols or esters thereof of vinyl acetate; Polyvinylalcohol
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • 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
    • D04H1/407—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 containing absorbing substances, e.g. activated carbon
    • 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
    • D04H1/413—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 containing granules other than absorbent substances
    • 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
    • D04H1/425—Cellulose series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425—Cellulose series
    • D04H1/4258—Regenerated cellulose series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43825—Composite fibres
    • D04H1/43828—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
    • D04H1/42—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
    • D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/32—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond
    • D06M11/36—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond with oxides, hydroxides or mixed oxides; with salts derived from anions with an amphoteric element-oxygen bond
    • D06M11/45—Oxides or hydroxides of elements of Groups 3 or 13 of the Periodic Table; Aluminates
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/32—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond
    • D06M11/36—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond with oxides, hydroxides or mixed oxides; with salts derived from anions with an amphoteric element-oxygen bond
    • D06M11/48—Oxides or hydroxides of chromium, molybdenum or tungsten; Chromates; Dichromates; Molybdates; Tungstates
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/32—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond
    • D06M11/36—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond with oxides, hydroxides or mixed oxides; with salts derived from anions with an amphoteric element-oxygen bond
    • D06M11/49—Oxides or hydroxides of elements of Groups 8, 9,10 or 18 of the Periodic Table; Ferrates; Cobaltates; Nickelates; Ruthenates; Osmates; Rhodates; Iridates; Palladates; Platinates
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/73—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with carbon or compounds thereof
    • D06M11/74—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with carbon or compounds thereof with carbon or graphite; with carbides; with graphitic acids or their salts
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/77—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with silicon or compounds thereof
    • D06M11/79—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with silicon or compounds thereof with silicon dioxide, silicic acids or their salts
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/327—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated alcohols or esters thereof
    • 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
    • D04H1/4383—Composite fibres sea-island
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43825—Composite fibres
    • D04H1/43832—Composite fibres side-by-side
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2933—Coated or with bond, impregnation or core

Definitions

  • 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.
  • Patent Document 1 a method of attaching a filler to the surface of a fiber
  • Patent Document 2 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 2 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.
  • fiber products having a filler attached to the fiber surface have been used for various purposes.
  • filament fibers for polishing between teeth are generally well known as fibers for cleaning purposes.
  • 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.
  • 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).
  • 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.
  • 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 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
  • the adsorbent particles may be buried in the binder resin solution, and a sufficient gas adsorption effect may not be obtained. .
  • the contact area between the hot melt agent and the adsorbent particles is small, so that the adsorbent particles may fall off.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • a wet heat gelling resin 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.
  • 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:
  • thermoplastic synthetic fiber component (I) a composite fiber comprising a wet heat gelled resin fiber component and another thermoplastic synthetic fiber component
  • 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.
  • 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.
  • FIG. 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
  • a wet heat gelled resin is used as a binder resin that gels when heated in the presence of moisture.
  • the form of the wet heat gelling resin include powder, chip, and fiber.
  • 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.
  • 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.
  • 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.
  • the filler is exposed and secured.
  • 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.
  • 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.
  • the form of the wet heat gelling resin include powder, chip, and fiber.
  • 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.
  • 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.
  • 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.
  • 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.
  • the fiber and the binder resin As a preferable combination of the fiber and the binder resin,
  • thermoplastic synthetic fiber component (I) a composite fiber comprising a wet heat gelled resin fiber component and another thermoplastic synthetic fiber component
  • 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.
  • the “binder resin” is a wet heat gelled conjugate fiber, and the “fiber” is another fiber, which is a mixture thereof.
  • the “fiber” is a wet heat gelling composite fiber, and the “binder resin” is a wet heat gelling resin.
  • 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.
  • 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.
  • 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.
  • 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 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the filler is preferably inorganic particles.
  • 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.
  • 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.
  • activated carbon particles are particularly preferred.
  • 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.
  • activated carbon particles are particularly preferred.
  • 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
  • silica gel as a drying agent
  • titanium dioxide as a photocatalyst
  • a virus adsorbing / decomposing agent for example, silica gel as a drying agent
  • a virus adsorbing / decomposing agent for example, 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.
  • nonwoven fabrics can be applied to various uses because of their high workability.
  • 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.
  • 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.
  • the gas adsorption module may be used.
  • 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.
  • 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.
  • 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 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.
  • the wet heat treatment in the present invention is performed in a wet heat atmosphere.
  • 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.
  • 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.
  • the ratio of water to be applied to the fiber or fiber structure in the wet heat treatment is 2 Omass% to 80 Omass%.
  • moisture percentage the ratio of water to be applied to the fiber or fiber structure in the wet heat treatment
  • 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.
  • 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.
  • a known method such as spraying or immersion in a water tank can be used.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the surface pressure when contacting with a heating body, 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • a fibrous structure containing a filler dispersion solution is inserted into a pair of molds and subjected to a heat and pressure treatment.
  • the nonwoven fabric 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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
  • 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.
  • FIGS. 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
  • 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)
  • 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.
  • 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
  • squeezed with a squeezing roll 34 As a result, about 500 mass% of moisture and filler are added to the nonwoven fabric.
  • 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.
  • 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).
  • 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 ⁇ 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
  • 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.
  • a filler 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).
  • 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.
  • 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.
  • 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.
  • evaluation object and evaluation points are as follows.
  • FIGS. 4A to 4F show the state where the filler is fixed to the obtained nonwoven fabric and its constituent fibers.
  • 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.
  • EVA ethylene-vinyl acetate copolymer resin
  • 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.
  • 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.
  • EMA ethylene-methyl acrylate copolymer resin
  • 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.
  • the nonwoven fabric containing the filler-fixed fibers of this example exhibited almost the same level of abrasiveness as a commercially available abrasive.
  • 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.
  • 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.
  • 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.
  • a surfactant polyoxyethylene alkylphenol ether having an alkyl group having 9 carbon atoms
  • 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
  • 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.
  • 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.
  • Example 2 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 2 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.
  • 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.
  • FIGS. 5A to 5C show a state in which the filler is fixed to the obtained nonwoven fabric and its constituent fibers.
  • 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
  • EVOH ethylene-vinyl alcohol copolymer resin
  • the core component is polypropylene (PP, melting point: 161 ° C)
  • a core-sheath composite fiber fineness: 3.3 dtex, fiber length: 5 lmm having a ratio of 50:50 (volume ratio) was prepared.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the sheath component is ethylene-vinyl alcohol copolymer resin (EV ⁇ H, ethylene content 38 mol%, melting point 176 ° C), and the core component is polypropylene (PP, melting point 161 ° C). ⁇
  • EV ⁇ H ethylene-vinyl alcohol copolymer resin
  • PP polypropylene
  • 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.
  • 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.
  • 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.
  • 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 8 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.
  • a filler dispersion solution 95 ° C
  • 5 mass% of the activated carbon particles were dispersed in water for 30 seconds, and then pulled up. .
  • the nonwoven fabric was supported until the temperature of the nonwoven fabric reached 50 ° C.
  • 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.
  • 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.
  • 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 .
  • 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.
  • 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.
  • 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.
  • 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.
  • the sheath component is ethylene-vinyl alcohol copolymer resin (EV ⁇ H, ethylene content 38 mol%, melting point 176 ° C), and the core component is polypropylene (PP, melting point 161 ° C).
  • EV ⁇ H ethylene-vinyl alcohol copolymer resin
  • PP polypropylene
  • 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 .
  • 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.
  • 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.
  • 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.
  • 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.
  • 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
  • a water purification performance test was performed using a water circulation type simple testing machine shown in FIG.
  • 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.
  • 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.
  • 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.
  • 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.
  • Example 13 and 14 and Comparative Examples 3 and 5 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.
  • 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 ⁇ 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.
  • Example 14 the activated carbon shedding rate was measured by the following method.
  • Example 14 and Comparative Example 5 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.
  • 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.
  • Example 14 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.
  • the sheath component is ethylene-vinyl alcohol copolymer resin (EV ⁇ 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.
  • EV ⁇ H ethylene-vinyl alcohol copolymer resin
  • PP polypropylene
  • 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 .
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the filler 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.
  • the fibrous structure of the present invention when 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.
  • the fiber structure of the present invention is used for a water purification material
  • 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.
  • 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.
  • the purification performance is improved compared to conventional water purification materials. Can be done.
  • the binder resin contains a wet heat gelling resin
  • 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.
  • 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.
  • 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.
  • gas adsorbents and antiviral materials can be used for curing sheets for building materials, wallpapers, masks, filters for air conditioning, and the like.
  • 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.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

La présente invention concerne une fibre tenue par le remplissage comprenant une fibre (2), une résine de liaison (1) disposée sur la surface de la fibre, et un remplissage (3) tenant à la résine de liaison (1). En l'occurrence, la résine de liaison (1) se forme en gel par chauffage en présence d'eau, le remplissage (3) prenant sur le gel formé par la résine au chauffage en présence d'eau. De cette façon, la fibre (2) conserve sa forme de fibre, et le gel produit par la résine sert de liaison tenant le remplissage (3).
PCT/JP2004/011397 2003-08-04 2004-08-02 Fibre tenue par le remplissage, structure de fibre, fibre moulee, et procedes de production correspondants WO2005012605A2 (fr)

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US10/566,617 US20070128434A1 (en) 2003-08-04 2004-08-02 Filler-affixed fiber, fiber structure, and fiber molded body, and method for producing the same
TW094103356A TW200540309A (en) 2004-06-10 2005-02-03 Filler-fixed fiber, fiber structure, molded fiber, and processes for producing these
HK06111804.7A HK1091244A1 (en) 2003-08-04 2006-10-25 Filler-fixed fiber, fiber structure, molded fiber, and processes for producing these

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JP2003286185A JP3884730B2 (ja) 2003-08-04 2003-08-04 フィラー固着繊維と不織布及びそれらの製造方法
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JP2004172920 2004-06-10
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JP2004181415A JP4565902B2 (ja) 2004-06-18 2004-06-18 繊維成形体及びその製造方法
JP2004183709A JP4634072B2 (ja) 2004-06-22 2004-06-22 水質浄化材
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US20070128434A1 (en) 2007-06-07

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