WO2011070999A1 - Procédé pour produire un non tissé à longues fibres - Google Patents

Procédé pour produire un non tissé à longues fibres Download PDF

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Publication number
WO2011070999A1
WO2011070999A1 PCT/JP2010/071790 JP2010071790W WO2011070999A1 WO 2011070999 A1 WO2011070999 A1 WO 2011070999A1 JP 2010071790 W JP2010071790 W JP 2010071790W WO 2011070999 A1 WO2011070999 A1 WO 2011070999A1
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Prior art keywords
nonwoven fabric
long
ejector
temperature
heat
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PCT/JP2010/071790
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English (en)
Japanese (ja)
Inventor
中野洋平
矢掛善和
Original Assignee
東レ株式会社
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Application filed by 東レ株式会社 filed Critical 東レ株式会社
Priority to US13/513,934 priority Critical patent/US9181637B2/en
Priority to BR112012011531-6A priority patent/BR112012011531B1/pt
Priority to RU2012128584/12A priority patent/RU2564238C2/ru
Priority to ES10835919.1T priority patent/ES2564987T3/es
Priority to AU2010329094A priority patent/AU2010329094B2/en
Priority to CN201080053231.9A priority patent/CN102639774B/zh
Priority to KR1020127011872A priority patent/KR101745975B1/ko
Priority to JP2010548305A priority patent/JP5672009B2/ja
Priority to EP10835919.1A priority patent/EP2511409B1/fr
Publication of WO2011070999A1 publication Critical patent/WO2011070999A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05—Filamentary, e.g. strands
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/08—Melt spinning methods
    • D01D5/098—Melt spinning methods with simultaneous stretching
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/08—Melt spinning methods
    • D01D5/098—Melt spinning methods with simultaneous stretching
    • D01D5/0985—Melt spinning methods with simultaneous stretching by means of a flowing gas (e.g. melt-blowing)
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
    • D01F6/76—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from other polycondensation products
    • D01F6/765—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from other polycondensation products from polyarylene sulfides
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/009—Condensation or reaction polymers
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C15/00—Calendering, pressing, ironing, glossing or glazing textile fabrics

Definitions

  • the present invention relates to a method for producing a long-fiber nonwoven fabric made of a resin mainly composed of polyphenylene sulfide (hereinafter sometimes abbreviated as “PPS”). More specifically, the present invention is a long-fiber non-woven fabric (hereinafter referred to as “PPS long-fiber non-woven fabric”) made of a resin having PPS as a main component, which is free from width shrinkage and wrinkles due to thermal shrinkage when the nonwoven web is thermally bonded. )) In a simple process and stably.
  • PPS polyphenylene sulfide
  • PPS resin has excellent heat resistance, chemical resistance, flame retardancy and electrical insulation properties, and is suitably used as engineer plastic, film, fiber, nonwoven fabric, and the like.
  • PPS long fiber nonwoven fabrics are expected to be utilized for industrial applications such as heat-resistant filters, electrical insulating materials, and battery separators by utilizing these characteristics.
  • the PPS long fiber nonwoven fabric has a problem that the dimensional stability against heat is poor and the thermal contraction of the fiber or the nonwoven fabric is large.
  • various proposals have been made as means for improving the dimensional stability of fibers or nonwoven fabrics against this heat.
  • a method has been proposed in which a PPS resin is spun by a spunbond method to form a fabric, which is stretched at a temperature equal to or higher than the glass transition point, preferably biaxially stretched, and then embossed to obtain a long fiber nonwoven fabric.
  • a PPS resin is spun by a spunbond method to form a fabric, which is stretched at a temperature equal to or higher than the glass transition point, preferably biaxially stretched, and then embossed to obtain a long fiber nonwoven fabric.
  • Patent Document 1 a method for producing a long-fiber nonwoven fabric has been proposed.
  • these non-woven fabrics produced by the spunbond method using PPS resin are heat-stretched or tension-heat treated for non-woven webs and fabrics as compared to the production method of spunbond non-woven fabrics using general-purpose resins such as polyester and polypropylene.
  • a heat treatment processing facility for processing is required, and there are problems that the process is complicated and multi-stage, and the capital investment is increased, and the energy consumption is also large.
  • the PPS resin is spun at a high spinning speed of 7,000 to 11,000 m / min, thereby improving the crystallinity of the fiber without stretching or heat treatment under tension.
  • a method for producing a heat-resistant nonwoven fabric in which thermal shrinkage is suppressed is disclosed (see Patent Document 4).
  • Patent Document 4 A method for producing a heat-resistant nonwoven fabric in which thermal shrinkage is suppressed.
  • the amount of deformation of the fiber increases due to high-speed spinning, so the fiber tends to follow deformation and yarn breakage tends to occur frequently, and more compressed air is required, which increases energy consumption. There was a problem.
  • the present situation is that no method has been proposed for producing a PPS long-fiber nonwoven fabric excellent in dimensional stability with a stable spinnability and a simple process.
  • An object of the present invention is to provide a PPS long fiber nonwoven fabric excellent in dimensional stability against heat in a simple process that has stable spinnability and does not perform heat treatment in a subsequent process of the nonwoven web. .
  • the present invention is a method for producing a long-fiber nonwoven fabric characterized by sequentially performing the following steps (a) to (c).
  • steps (a) to (c) After a resin having polyphenylene sulfide as a main component is melted and discharged from a spinneret, the cooled and solidified yarn is subjected to heat treatment up to the ejector outlet, and the spinning speed is 3,000 m / min by the ejector. Step of pulling and stretching to obtain long fibers (b) Step of collecting the long fibers on a moving net to form a non-woven web (c) Step of thermally bonding the obtained non-woven web.
  • a PPS long fiber nonwoven fabric excellent in dimensional stability against heat can be obtained by a simple process that has stable spinnability and does not require heat treatment in the subsequent process of the nonwoven web.
  • the resin is melted and discharged from a spinneret, and then the cooled and solidified yarn is pulled and stretched by an ejector and collected on a moving net to be non-woven.
  • a spunbond method is used in which after web formation, heat bonding is used.
  • the step (a) includes the steps of the spunbond method up to stretching.
  • the resin used in the present invention contains PPS as a main component.
  • PPS is a polymer having phenylene sulfide units such as p-phenylene sulfide units and m-phenylene sulfide units as repeating units.
  • a substantially linear polymer containing 90 mol% or more of p-phenylene sulfide units is preferable from the viewpoint of heat resistance and spinnability.
  • trichlorobenzene is not substantially copolymerized with PPS.
  • Trichlorobenzene has three or more halogen substituents per benzene ring, and copolymerization thereof gives the PPS a branched structure, and the spinnability of the PPS resin is inferior and yarn breakage at the time of spinning and drawing is lost. This is because it tends to occur frequently.
  • the extent that trichlorobenzene is not substantially copolymerized is preferably 0.05 mol% or less, and more preferably 0.01 mol% or less.
  • the content of PPS with respect to the resin is preferably 85% by mass or more, more preferably 90% by mass or more, and still more preferably 95% by mass or more from the viewpoints of heat resistance and chemical resistance.
  • the resin mainly composed of PPS used in the present invention is also referred to as “PPS resin”.
  • a crystal nucleating agent a matting agent, a pigment, an antifungal agent, an antibacterial agent, a flame retardant, a hydrophilic agent, or the like may be added to the PPS resin as long as the effects of the present invention are not impaired.
  • the PPS resin used in the present invention has a melt flow rate (hereinafter sometimes abbreviated as MFR) 100 measured according to ASTM D1238-70 (measurement temperature 315.5 ° C., measurement load 5 kg load). It is preferably ⁇ 300 g / 10 min.
  • MFR melt flow rate
  • the MFR is 300 g / 10 min or less, more preferably 225 g / 10 min or less, the degree of polymerization or the molecular weight can be appropriately increased, and the strength and heat resistance that can be put to practical use can be obtained.
  • the spinning temperature at the time of melting and spinning the PPS resin is preferably 290 to 380 ° C., more preferably 300 to 360 ° C., and further preferably 310 to 340 ° C. By setting the spinning temperature within the above range, a stable molten state can be obtained, and excellent spinning stability can be obtained.
  • the cross-sectional shape of the fiber made of PPS resin is any of circular, hollow round, elliptical, flat, polygonal, and multi-leaf type (such as X type and Y type). It may be in shape.
  • Examples of the method for cooling the yarn of the PPS fiber discharged from the spinneret include a method of forcing cold air to the yarn, a method of natural cooling at the ambient temperature around the yarn, and a distance between the spinneret and the ejector. A method of adjusting, or a combination thereof is adopted. The cooling conditions are appropriately adjusted and adopted in consideration of the discharge amount per single hole of the spinneret, the spinning temperature, the atmospheric temperature, and the like.
  • the boiling water shrinkage of the long fibers is preferably 20% or less, more preferably 15% or less. More preferably, it is 10% or less. When the boiling water shrinkage rate of the long fibers exceeds 20%, the width of the nonwoven web is large at the time of thermal bonding, and shrinkage solidification or wrinkle is generated, which tends to make thermal bonding difficult.
  • the degree of crystallinity is not simply increasing.
  • Patent Document 4 in order to impart thermal dimensional stability to a PPS long fiber nonwoven fabric, it has been considered that a crystallinity of 25% or more is necessary.
  • the PPS fiber obtained by the production method of the present invention has good thermal dimensional stability even when the crystallinity is less than 25%.
  • the crystallinity of the PPS fiber is small, there are many amorphous parts and the thermal dimensional stability is poor, and if the crystallinity is large, the amorphous part is few and the thermal adhesiveness is poor.
  • the PPS fiber obtained by the method has the surprising feature of achieving both good thermal dimensional stability and thermal adhesiveness.
  • the crystallinity of the PPS long fiber obtained in step (a) is preferably 5% or more and less than 25%.
  • the degree of crystallinity is preferably less than 25%, more preferably 23% or less, further preferably less than 23%, more preferably 20% or less, and even more preferably less than 20%.
  • the PPS long fiber nonwoven fabric which improves the adhesiveness at the time of heat bonding and is excellent in mechanical strength can be obtained.
  • the crystallinity by setting the crystallinity to 5% or more, the amount of crystals is maintained and the width of the nonwoven web is reduced by heat shrinkage, wrinkles, melting of fibers at the time of heat bonding, and heat compression by hot embossing rolls. Perforation of the woven web can be suppressed.
  • a method of heating the yarn before being introduced into the ejector with an infrared heater or a hot plate a method of heating the ejector body, a yarn from the ejector
  • a method of heating compressed air that is ejected for drawing or stretching can be used.
  • the method of heating the compressed air from the ejector is preferable because each of the yarns can be heated relatively without unevenness.
  • the temperature is preferably 100 ° C. or higher and lower than the melting point of the PPS resin.
  • Effective for PPS fibers by obtaining effective heating of the PPS fiber yarn by setting the temperature of the compressed air to 100 ° C. or higher, more preferably 120 ° C. or higher, more preferably 160 ° C. or higher, more preferably 200 ° C. or higher.
  • Thermal dimensional stability can be imparted to the nonwoven fabric, and the width and wrinkle of the nonwoven web due to heat shrinkage during thermal bonding of the nonwoven web can be prevented.
  • the melting point of the PPS resin is generally 278 to 285 ° C.
  • the temperature of the compressed air specified here refers to the actual temperature of the compressed air immediately before being introduced into the ejector, not the set temperature of the equipment that heats the compressed air or the surface temperature of the piping that supplies the compressed air.
  • a compressed air supply pipe 2 capable of supplying heated compressed air to an ejector 1 is connected.
  • the compressed air 5 supplied from the compressed air supply pipe 2 is blown onto the yarn 7 that is running on the spinning, and the yarn 7 is pulled and stretched.
  • a temperature sensor 4 of a thermometer 6 is installed at a temperature measurement position 3 immediately before being introduced into the ejector 1 through the compressed air supply pipe 2, and the temperature of the compressed air 5 is measured while the yarn 7 is spinning in the ejector 1. Is done.
  • a method of heating to a desired temperature using an air heater is preferable.
  • the distance 9 from the air gap 8 that is the injection port of the compressed air 5 shown in FIG. 1 to the outlet of the ejector body 1 (hereinafter referred to as the length of the ejector). ) Is preferably 10 cm or more.
  • the length of the ejector is set to 10 cm or more, more preferably 20 cm or more, an effective heat treatment can be performed on the PPS fiber.
  • an upper limit of the length of an ejector it is preferable to set it as 200 cm or less from the point of the fiber opening property.
  • the spinning speed in step (a) is 3,000 m / min or more.
  • the spinning speed is preferably less than 6,000 m / min.
  • the average single fiber fineness of the PPS fiber is preferably 0.5 to 10 dtex.
  • the average single fiber fineness is preferably 0.5 dtex or more, more preferably 1 dtex or more, and even more preferably 2 dtex or more.
  • the spinnability of the fiber can be maintained, and frequent occurrence of yarn breakage during spinning can be suppressed.
  • the average single fiber fineness is set to 10 dtex or less, more preferably 5 dtex or less, and even more preferably 4 dtex or less, it is possible to suppress the discharge amount of the molten resin per spinneret single hole and sufficiently cool the fibers. And a reduction in spinnability due to fusion between fibers can be suppressed.
  • the fabric weight per unit area of the nonwoven fabric is suppressed, the surface quality is excellent, and the average single fiber fineness is preferably 10 dtex or less from the viewpoint of dust collection performance when the PPS long fiber nonwoven fabric is applied to a filter or the like. More preferably, it is 5 dtex or less, More preferably, it is 4 dtex or less.
  • step (b) a step of collecting the long fibers on a moving net and forming a non-woven web is performed.
  • the present invention is particularly suitable for the production of a nonwoven fabric with a high basis weight because of its good thermal adhesiveness.
  • the basis weight of the resulting nonwoven fabric is preferably 100 to 400 g / m 2 , more preferably 150 to 300 g / m 2 .
  • step (d) it is preferable to perform a step of temporarily bonding the nonwoven web with a calender roll at a temperature lower than the crystallization temperature of the long fibers. .
  • a calender roll By doing so, the thickness of the nonwoven fabric obtained can be controlled to improve the transportability, and the thickness variation in the width direction can be made uniform.
  • Temporary adhesion by a calender roll is performed by a calender roll having a flat pair of upper and lower surfaces.
  • the calender roll a combination of upper and lower metal rolls or a combination of a metal roll and a resin or paper roll can be used.
  • the temperature of the calender roll in step (d) is preferably less than the crystallization temperature of the long fibers. By doing so, it is possible to prevent thermal crystallization of the PPS fibers from being excessively promoted and to effectively perform thermal bonding in the step (c) described later. On the other hand, in order to obtain the above temporary bonding effect, the temperature is preferably set to 80 ° C. or higher.
  • the linear pressure of the calender roll in the step (d) is preferably 5 to 70 kgf / cm (49 to 686 N / cm).
  • the linear pressure is preferably 5 kgf / cm (49 N / cm) or more, more preferably 15 kgf / cm (147 N / cm) or more, the above temporary bonding effect can be obtained efficiently.
  • the linear pressure is set to 70 kgf / cm (686 N / cm) or less, more preferably 40 kgf / cm (392 N / cm) or less, the thickness becomes too thin to prevent paper-like and lack of air permeability. It can prevent impairing the characteristics of the nonwoven fabric.
  • step (c) After step (b), preferably further step (d), a step of thermally bonding the obtained nonwoven web is performed as step (c).
  • a heat embossing roll in which engraving is performed on a pair of upper and lower roll surfaces, a roll in which one roll surface is flat (smooth), and an engraving on the other roll surface, respectively.
  • Applying heat-compression using various rolls such as hot embossing rolls made from a combination of applied rolls and hot calender rolls made from a combination of a pair of upper and lower flat (smooth) rolls, and an air-through method that allows hot air to pass in the thickness direction of the nonwoven web I can do it.
  • a circle, an ellipse, a square, a rectangle, a parallelogram, a rhombus, a regular hexagon, a regular octagon, and the like can be used as the shape of the sculpture applied to the hot embossing roll.
  • the surface temperature of the hot embossing roll is preferably 250 to 280 ° C.
  • the thermal bonding temperature is set to 250 ° C. or higher, more preferably 255 ° C. or higher, sufficient thermal bonding can be performed to suppress sheet peeling and fluff generation.
  • the thermal bonding temperature is set to 280 ° C. or lower, more preferably 275 ° C. or lower, it is possible to prevent perforation from being generated in the crimping portion due to fiber melting.
  • the linear pressure of the hot embossing roll during heat bonding is preferably 20 to 150 kgf / cm (196 to 1470 N / cm).
  • the linear pressure of the roll is preferably 20 to 150 kgf / cm (196 to 1470 N / cm).
  • 20 kg / cm (196 N / cm) or more more preferably 30 kgf / cm (294 N / cm) or more, it is possible to sufficiently heat-bond and suppress the peeling of the sheet and the occurrence of fluff.
  • the linear pressure of the roll to 150 kgf / cm (1470 N / cm) or less, more preferably 100 kgf / cm (980 N / cm) or less, the convex portion of the sculpture is difficult to peel off the sheet from the rolled roll. It is possible to prevent the sheet from breaking.
  • the adhesion area by the hot embossing roll is preferably 8 to 40%.
  • the adhesion area is 8% or more, more preferably 10% or more, and still more preferably 12% or more, it is possible to obtain strength that can be practically used as a long fiber nonwoven fabric.
  • the adhesion area is 40% or less, more preferably 30% or less, and even more preferably 20% or less, it is possible to prevent film-like and difficult to obtain features such as breathability.
  • adheresive area refers to the ratio of the portion of the nonwoven fabric in which the convex portion of the upper roll and the convex portion of the lower roll overlap to contact the nonwoven web when heat bonding is performed with a pair of concave and convex rolls.
  • corrugation means the ratio which occupies for the whole nonwoven fabric of the part which contact
  • step (c) it is preferable to heat bond the nonwoven web without performing a stretching treatment or a heat treatment under tension above the crystallization temperature of the PPS long fibers.
  • a stretching process or a heat treatment under tension above the crystallization temperature of the PPS long fiber in order to improve the dimensional stability against heat (described above).
  • the dimensional stability against heat can be improved without performing these treatments. The ability to omit these processes is significant in terms of facility simplicity and energy saving.
  • the long fiber nonwoven fabric obtained by the present invention is excellent in dimensional stability, heat resistance, flame retardancy and chemical resistance, so various industrial filters, electrical insulation materials, battery separators, water treatment membrane substrates, heat insulation groups It can be suitably used for materials and protective clothing.
  • Boiling water shrinkage (%) Long fibers obtained by passing through the ejector are collected, and five fibers are aligned to form one sample (length of about 10 cm). After measuring the length L 0 by applying the load described below to this sample, the sample was immersed in boiling water for 20 minutes in a tensionless state, then taken out from the boiling water, naturally dried, and again subjected to the same load. From measured length L 1 calculates the boiling water shrinkage percentage, to obtain an average value of sample 4 points. Calculation formulas for load and boiling water shrinkage are shown below. The load is rounded off to the second decimal place.
  • Example 1 (PPS resin) A 100 mol% linear polyphenylene sulfide resin (product number: E2280, MFR: 160 g / 10 min, manufactured by Toray Industries, Inc.) in which trichlorobenzene is not intentionally copolymerized is dried at a temperature of 160 ° C. for 10 hours in a nitrogen atmosphere. Used. (Spun / nonwoven web) The PPS resin was melted with an extruder and spun at a spinning temperature of 325 ° C. from a rectangular spinneret with a hole diameter of ⁇ 0.50 mm at a single hole discharge rate of 1.38 g / min. The spun yarn was cooled and solidified in a 20 ° C.
  • PPS resin A 100 mol% linear polyphenylene sulfide resin (product number: E2280, MFR: 160 g / 10 min, manufactured by Toray Industries, Inc.) in which trichlorobenzene is not intentionally copolymerized is dried at a temperature of
  • the cooled and solidified yarn is passed through a rectangular ejector with a length of 30 cm of the ejector, and the ejector is heated to a temperature of 200 ° C. with an air heater to inject compressed air with an ejector pressure of 0.15 MPa, and the yarn is pulled. Stretched and collected on a moving net to form a nonwoven web.
  • the average single fiber fineness of the obtained long fibers was 2.8 dtex, the crystallization temperature was 111.7 ° C., the crystallinity was 9.4%, and the boiling water shrinkage was 6.8%.
  • the spinning speed was 4,991 m / min, and the spinnability was as good as zero yarn breakage during 1 hour spinning.
  • Temporal bonding / thermal bonding Subsequently, the obtained nonwoven web was temporarily bonded at a linear pressure of 20 kgf / cm (196 N / cm) and a temporary bonding temperature of 100 ° C. with a pair of upper and lower metal calender rolls placed on an inline. Next, a linear pressure of 100 kgf / cm (980 N / cm), heat with a pair of upper and lower embossed rolls composed of a metal-made upper roll engraved with a polka dot pattern and a metal-made lower flat roll Thermal bonding was performed at an adhesion temperature of 270 ° C.
  • the obtained long fiber nonwoven fabric has a basis weight of 248 g / m 2 , a vertical tensile strength of 408 N / 5 cm, and a thermal shrinkage of 0.0% in the vertical direction and ⁇ 0.2% in the horizontal direction. Met.
  • Example 2 (PPS resin) The same PPS resin as that used in Example 1 was used. (Spun / nonwoven web) Spinning and nonwoven web formation were performed using the PPS resin in the same manner as in Example 1 except that the temperature of the compressed air was 230 ° C. and the ejector pressure was 0.13 MPa. The obtained long fibers had an average single fiber fineness of 3.2 dtex, a crystallization temperature of 112.4 ° C., a crystallinity of 14.8%, and a boiling water shrinkage of 3.0%. The spinning speed was 4,294 m / min, and the spinnability was as good as 0 yarn breakage during 1 hour spinning.
  • Example 2 (Temporary bonding / thermal bonding) Subsequently, the nonwoven web was temporarily bonded and thermally bonded in the same manner as in Example 1 to obtain a long fiber nonwoven fabric. Even when heat-bonding with an embossing roll, there was no large width due to heat shrinkage, and there was no wrinkle and good quality.
  • the basis weight of the obtained non-woven fabric is 251 g / m 2 , the tensile strength in the vertical direction is 399 N / 5 cm, the thermal shrinkage is ⁇ 0.1% in the vertical direction, and ⁇ 0.2% in the horizontal direction. there were.
  • Example 3 (PPS resin) The same PPS resin as that used in Example 1 was used. (Spun / nonwoven web) Spinning and nonwoven web formation were performed using the PPS resin in the same manner as in Example 1 except that the temperature of the compressed air was 129 ° C. and the ejector pressure was 0.20 MPa. The obtained long fibers had an average single fiber fineness of 2.4 dtex, a crystallization temperature of 111.4 ° C., a crystallinity of 18.5%, and a boiling water shrinkage of 7.5%. The spinning speed was 5,727 m / min, and the spinnability was as good as 0 yarn breakage during 1 hour spinning.
  • thermocompression bonding with the embossing roll, there was no large width due to heat shrinkage, and there was no wrinkle and good quality.
  • basis weight of the obtained non-woven fabric was 245 g / m 2
  • the vertical tensile strength was 382 N / 5 cm
  • the thermal shrinkage was ⁇ 0.1% in the vertical direction, and 0.0% in the horizontal direction. It was.
  • Example 4 The same PPS resin as that used in Example 1 was used. (Spun / nonwoven web) Spinning and nonwoven web formation were performed using the PPS resin in the same manner as in Example 1 except that the temperature of the compressed air was 115 ° C. and the ejector pressure was 0.21 MPa. The obtained long fibers had an average single fiber fineness of 2.4 dtex, a crystallization temperature of 111.5 ° C., a crystallinity of 18.7%, and a boiling water shrinkage of 8.3%. The spinning speed was 5,843 m / min, and the spinnability was as good as zero yarn breakage during 1 hour spinning.
  • thermocompression bonding with the embossing roll, there was no large width due to heat shrinkage, and there was no wrinkle and good quality.
  • basis weight of the obtained non-woven fabric was 248 g / m 2
  • the vertical tensile strength was 385 N / 5 cm
  • the thermal shrinkage was ⁇ 0.1% in the vertical direction, and 0.0% in the horizontal direction. It was.
  • the yarn discharged using heated compressed air is pulled and stretched at a spinning speed of 4,294 to 5,843 m / min. Even if the heat treatment at a temperature higher than the crystallization temperature of the nonwoven web that has been carried out is not performed, thermal bonding with an embossing roll is possible, and a high-quality non-wrinkled long fiber nonwoven fabric can be obtained. Further, the obtained long fiber nonwoven fabric had almost no thermal shrinkage at a temperature of 200 ° C. and was excellent in thermal dimensional stability.
  • Comparative Example 1 using compressed air at room temperature (29 ° C.) and Comparative Example 2 pulled and stretched at a spinning speed of 2,564 m / min, the boiling water shrinkage ratio is large, and thus the nonwoven web is used for thermal bonding. It was in a state where the width was greatly reduced due to heat shrinkage, and it was shrunk and solidified and could not be embossed. Further, in Comparative Example 3 in which the compressed air at normal temperature (29 ° C.) was increased to increase the spinning speed, yarn breakage occurred frequently immediately after the start of spinning, and it was impossible to form a nonwoven web.
  • Ejector 2 Compressed air supply piping 3: Temperature measurement position 4: Temperature sensor 5: Compressed air 6: Thermometer 7: Thread 8: Air gap 9: Ejector length

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Nonwoven Fabrics (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Paper (AREA)
  • Artificial Filaments (AREA)

Abstract

L'invention concerne un procédé pour produire un non tissé à longues fibres qui utilise, en tant que composant principal, du sulfure de polyphénylène présentant de très bonnes aptitudes au filage, et qui comprend une étape simplifiée dans laquelle un traitement thermique, effectué pour conférer une stabilité dimensionnelle vis-à-vis de la chaleur, n'est pas effectué au cours de l'étape suivant la formation d'une nappe fibreuse non tissée. Le procédé de production d'un non tissé à longues fibres comprend : une étape (a) pour obtenir une longue fibre en faisant fondre une résine dont le composant principal est le sulfure de polyphénylène, et en tirant et étirant un fil qui a été congelé et solidifié après avoir été éjecté à travers une filière à une vitesse de filature de 3000 m/min, ou plus, au moyen d'un éjecteur, tout en chauffant ledit fil jusqu'à la sortie de l'éjecteur ; une étape (b) de formation de la longue fibre en une nappe fibreuse non tissée en rassemblant la longue fibre sur un filet mobile ; et une étape (c) d'adhésion thermique de la nappe fibreuse non tissée résultante.
PCT/JP2010/071790 2009-12-09 2010-12-06 Procédé pour produire un non tissé à longues fibres WO2011070999A1 (fr)

Priority Applications (9)

Application Number Priority Date Filing Date Title
US13/513,934 US9181637B2 (en) 2009-12-09 2010-12-06 Method for producing long fiber nonwoven fabric
BR112012011531-6A BR112012011531B1 (pt) 2009-12-09 2010-12-06 Método para produzir um tecido não tecido de fibra longa por fiação
RU2012128584/12A RU2564238C2 (ru) 2009-12-09 2010-12-06 Способ получения длинноволоконного нетканого материала
ES10835919.1T ES2564987T3 (es) 2009-12-09 2010-12-06 Procedimiento para producir tela no tejida de fibra larga
AU2010329094A AU2010329094B2 (en) 2009-12-09 2010-12-06 Method for producing long fiber nonwoven fabric
CN201080053231.9A CN102639774B (zh) 2009-12-09 2010-12-06 长纤维非织造布的制造方法
KR1020127011872A KR101745975B1 (ko) 2009-12-09 2010-12-06 장섬유 부직포의 제조방법
JP2010548305A JP5672009B2 (ja) 2009-12-09 2010-12-06 長繊維不織布の製造方法
EP10835919.1A EP2511409B1 (fr) 2009-12-09 2010-12-06 Procédé pour produire un non tissé à longues fibres

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JP2009279359 2009-12-09
JP2009-279359 2009-12-09

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EP (1) EP2511409B1 (fr)
JP (1) JP5672009B2 (fr)
KR (1) KR101745975B1 (fr)
CN (1) CN102639774B (fr)
AU (1) AU2010329094B2 (fr)
BR (1) BR112012011531B1 (fr)
ES (1) ES2564987T3 (fr)
RU (1) RU2564238C2 (fr)
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WO2012165608A1 (fr) * 2011-06-02 2012-12-06 東レ株式会社 Fibres de poly(sulfure de phénylène) et tissu non tissé
WO2014046120A1 (fr) 2012-09-21 2014-03-27 東レ株式会社 Fibre composite de polysulfure de phénylène et étoffe non tissée
JP2014062342A (ja) * 2012-09-21 2014-04-10 Toray Ind Inc ポリフェニレンスルフィド繊維不織布
JPWO2016031693A1 (ja) * 2014-08-27 2017-06-08 東レ株式会社 メルトブロー不織布およびその製造方法
JP2018168516A (ja) * 2017-03-30 2018-11-01 旭化成株式会社 ポリフェニレンサルファイド不織布
WO2024018828A1 (fr) * 2022-07-20 2024-01-25 東レ株式会社 Fibre de sulfure de polyphénylène ultrafine, tissu non tissé et leurs procédés de production

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CN103320968B (zh) * 2013-07-12 2015-10-14 天津工业大学 一种长丝无纺布的制造方法
CN104369285B (zh) * 2014-11-27 2016-08-24 陶小弟 连续纤维增强热塑性树脂的熔融浸渍设备及方法
JP6965922B2 (ja) * 2018-03-29 2021-11-10 東レ株式会社 延伸装置、ならびに、繊維および繊維ウェブの製造装置および製造方法
CN112714808B (zh) * 2018-09-27 2023-05-12 东丽株式会社 共聚聚苯硫醚纤维

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WO2012165608A1 (fr) * 2011-06-02 2012-12-06 東レ株式会社 Fibres de poly(sulfure de phénylène) et tissu non tissé
CN103562446A (zh) * 2011-06-02 2014-02-05 东丽株式会社 聚苯硫醚纤维及无纺布
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EP2716800A4 (fr) * 2011-06-02 2014-11-05 Toray Industries Fibres de poly(sulfure de phénylène) et tissu non tissé
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WO2014046120A1 (fr) 2012-09-21 2014-03-27 東レ株式会社 Fibre composite de polysulfure de phénylène et étoffe non tissée
JP2014062342A (ja) * 2012-09-21 2014-04-10 Toray Ind Inc ポリフェニレンスルフィド繊維不織布
KR20150056524A (ko) 2012-09-21 2015-05-26 도레이 카부시키가이샤 폴리페닐렌술피드 복합 섬유 및 부직포
JPWO2016031693A1 (ja) * 2014-08-27 2017-06-08 東レ株式会社 メルトブロー不織布およびその製造方法
JP2018168516A (ja) * 2017-03-30 2018-11-01 旭化成株式会社 ポリフェニレンサルファイド不織布
JP6997527B2 (ja) 2017-03-30 2022-01-17 旭化成株式会社 ポリフェニレンサルファイド不織布
WO2024018828A1 (fr) * 2022-07-20 2024-01-25 東レ株式会社 Fibre de sulfure de polyphénylène ultrafine, tissu non tissé et leurs procédés de production

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JPWO2011070999A1 (ja) 2013-04-22
JP5672009B2 (ja) 2015-02-18
EP2511409A4 (fr) 2013-10-23
RU2564238C2 (ru) 2015-09-27
AU2010329094B2 (en) 2016-04-21
EP2511409B1 (fr) 2016-03-09
US20120235316A1 (en) 2012-09-20
KR20120104976A (ko) 2012-09-24
US9181637B2 (en) 2015-11-10
CN102639774B (zh) 2015-12-09
ES2564987T3 (es) 2016-03-30
KR101745975B1 (ko) 2017-06-12
EP2511409A1 (fr) 2012-10-17
BR112012011531B1 (pt) 2019-08-20
AU2010329094A1 (en) 2012-06-07
CN102639774A (zh) 2012-08-15
RU2012128584A (ru) 2014-01-20
BR112012011531A2 (pt) 2016-06-28

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