WO2012077638A1 - メルトブロー不織布、その製造方法および装置 - Google Patents
メルトブロー不織布、その製造方法および装置 Download PDFInfo
- Publication number
- WO2012077638A1 WO2012077638A1 PCT/JP2011/078082 JP2011078082W WO2012077638A1 WO 2012077638 A1 WO2012077638 A1 WO 2012077638A1 JP 2011078082 W JP2011078082 W JP 2011078082W WO 2012077638 A1 WO2012077638 A1 WO 2012077638A1
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- WO
- WIPO (PCT)
- Prior art keywords
- nonwoven fabric
- melt
- blown nonwoven
- fibers
- melt blown
- Prior art date
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Classifications
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- 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
- D04H3/007—Addition 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
- D04H3/016—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the fineness
-
- 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
- D04H3/16—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 filaments produced in association with filament formation, e.g. immediately following extrusion
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/409—Separators, membranes or diaphragms characterised by the material
- H01M50/411—Organic material
- H01M50/414—Synthetic resins, e.g. thermoplastics or thermosetting resins
- H01M50/417—Polyolefins
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/409—Separators, membranes or diaphragms characterised by the material
- H01M50/44—Fibrous material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0253—Polyolefin fibres
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/489—Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/489—Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
- H01M50/491—Porosity
-
- 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
-
- 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
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
-
- 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
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/608—Including strand or fiber material which is of specific structural definition
- Y10T442/614—Strand or fiber material specified as having microdimensions [i.e., microfiber]
- Y10T442/626—Microfiber is synthetic polymer
Definitions
- the present invention relates to a melt-blown nonwoven fabric made of ultrafine fibers, flexible and excellent in uniformity, and suitable for use in filters, sanitary materials and battery separators, and a method and apparatus for producing the same.
- melt blown nonwoven fabrics can be made into ultrafine fibers compared to spunbond nonwoven fabrics, they are superior in flexibility, and can be used alone, or laminated with other nonwoven fabrics, for filter applications, sanitary materials, clothing, Used in packaging materials, battery separators, and the like.
- Melt blown non-woven fabrics are obtained by pulling molten resin with a high-temperature and high-speed fluid, so that ball-shaped products (shots) and fly-shaped products are likely to occur, and various methods for eliminating them have been proposed.
- Patent Document 1 Japanese Patent Laid-Open No. 54-103466
- Patent Document 2 JP-A-4-91267
- Patent Document 3 Japanese Patent Application Laid-Open No.
- Patent Document 4 Japanese Patent Application Laid-Open No. 11-200135
- Patent Document 5 JP-A-4-163353 publication
- Patent Document 6 Japanese Patent Laid-Open No. 2006-83511
- melt blown nonwoven fabric having a somewhat narrow fiber diameter distribution can be produced by the proposed method, it is possible to completely prevent the generation of thick fibers that are more than twice the average fiber diameter due to fiber fusion that occurs during melt extrusion. The current situation is not possible.
- the present invention is a method for producing a melt blown nonwoven fabric which is stably a fine fiber and has a large number of thick fibers (number of fusions) generated by fusion of thermoplastic resin fibers, It aims at obtaining the manufacturing apparatus of a melt blown nonwoven fabric, and the said melt blown nonwoven fabric.
- the present invention comprises a polyolefin fiber, (I) The average fiber diameter is 2.0 ⁇ m or less, (Ii) Fiber diameter distribution CV value is 60% or less, (Iii) The number of fusions per 100 fibers is 15 or less, A melt-blown nonwoven fabric, and The melted thermoplastic resin pumped to the melt-blowing die is spun from a nozzle in which a large number of small holes are arranged, and is pulled by high-temperature high-speed air that is ejected from a slit provided so as to sandwich the row of small holes.
- the melt blow is characterized by cooling the spun thermoplastic resin fiber by supplying a cooling fluid of 30 ° C. or lower, preferably cooling air, from both sides of the outlet of the slit from which the high-temperature high-speed air is jetted.
- a method for producing a nonwoven fabric characterized in that an attachment for introducing a cooling fluid for cooling the spun thermoplastic resin fibers is detachably attached to the tip of the meltblowing die. It relates to a manufacturing apparatus.
- melt-blown nonwoven fabric of the present invention has very few thick fibers due to the fusion of fibers, for example, a filter using the melt-blown nonwoven fabric has a feature of extremely high particulate collection efficiency.
- the manufacturing apparatus according to the present invention has a simple structure and is compact, and can be configured without changing the design of a general-purpose manufacturing apparatus.
- FIG. 1 is a schematic perspective view of a conventional melt blown nonwoven fabric manufacturing apparatus having a basic configuration together with the melt blown nonwoven fabric manufacturing apparatus of the present invention.
- 2 is a schematic perspective view of the melt-blowing die of the melt-blown nonwoven fabric manufacturing apparatus shown in FIG. 1 as viewed from the lower surface side.
- FIG. 3 is a schematic cross-sectional view showing the main parts of the melt blown nonwoven fabric manufacturing apparatus according to one embodiment of the present invention.
- FIG. 4 is a schematic view showing an air flow in the melt blown nonwoven fabric manufacturing apparatus according to one embodiment of the present invention.
- FIG. 5 is a diagram showing a distance between adjacent small holes 14.
- thermoplastic resin Various known thermoplastic resins can be used as the thermoplastic resin as the raw material for the ultrafine fibers forming the melt blown nonwoven fabric of the present invention.
- thermoplastic resins include homo- or copolymers of ⁇ -olefins such as ethylene, propylene, 1-butene, 1-hexene, 4-methyl-1-pentene and 1-octene.
- High pressure method low density polyethylene linear low density polyethylene (so-called LLDPE), high density polyethylene, polypropylene (propylene homopolymer), polypropylene random copolymer, poly 1-butene, poly 4-methyl-1-pentene, ethylene Polypropylene random copolymer, ethylene / 1-butene random copolymer, polyolefin such as propylene / 1-butene random copolymer, polyester (polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, etc.), polyamide (nylon-6, Nylon-66 Poly adipamide, etc.), polyvinyl chloride, polyimide, ethylene-vinyl acetate copolymer, polyacrylonitrile,
- high pressure method low density polyethylene linear low density polyethylene (so-called LLDPE), high density polyethylene, propylene-based polymers such as polypropylene and polypropylene random copolymer, polyethylene terephthalate, polyamide and the like are preferable.
- LLDPE linear low density polyethylene
- propylene-based polymers such as polypropylene and polypropylene random copolymer, polyethylene terephthalate, polyamide and the like are preferable.
- thermoplastic resins the melt blown nonwoven fabric from which the propylene-based polymer is obtained is preferable because it has excellent chemical resistance.
- Such propylene polymers include propylene homopolymers having a melting point (Tm) of 155 ° C. or higher, preferably 157 to 165 ° C., or propylene and a very small amount of ethylene, 1-butene, 1-pentene, 1- A copolymer with one or more ⁇ -olefins having 2 or more carbon atoms, preferably 2 to 8 carbon atoms, such as hexene, 1-octene, 4-methyl-1-pentene, etc., and propylene homopolymers are preferred .
- Tm melting point
- ⁇ -olefins having 2 or more carbon atoms, preferably 2 to 8 carbon atoms, such as hexene, 1-octene, 4-methyl-1-pentene, etc.
- the melt flow rate (MFR: ASTM D 1238, 230 ° C., load 2160 g) is not particularly limited, but is usually 1 to 1000 g / 10 minutes, preferably 5 to 500 g / 10. Min, more preferably in the range of 10-100 g / 10 min.
- a molten thermoplastic resin (molten resin) fed to a melt blow die is spun from a nozzle in which a large number of small holes are arranged, and a row of small holes is sandwiched.
- a method for producing a melt blown nonwoven fabric deposited on a collecting plate that moves fibers that are pulled and thinned by high-temperature high-speed air that is ejected from a slit provided as described above the slit of the slit from which the high-temperature high-speed air is ejected
- a melt blown nonwoven fabric characterized by supplying a cooling fluid of 30 ° C. or less, preferably 5 to 25 ° C., more preferably 5 to 20 ° C. from both side surfaces of the outlet portion, and cooling the spun thermoplastic resin fibers. It is a manufacturing method.
- cooling fluid examples include water and air.
- water when water is used, moisture may remain in the nonwoven fabric and mold may be generated. There is a possibility that it is not preferable as a nonwoven fabric for precision filters or a nonwoven fabric for separators used in industry.
- cooling air is preferable as the cooling fluid.
- the temperature of the air flow is reduced to a predetermined temperature or less by merging with the cooling fluid.
- the cooling fluid By cooling, fusion between fibers can be prevented, thereby reducing the number of thick fibers [number of fusion] generated by fusion between fibers.
- the melt blown nonwoven fabric production apparatus of the present invention spouts molten resin pumped to a melt blow die from a nozzle in which a large number of small holes are arranged and is ejected from a slit provided so as to sandwich a row of small holes.
- a melt blown nonwoven fabric manufacturing apparatus that is deposited on a collecting plate that moves fibers that are pulled and thinned by high-temperature, high-speed air, the thermoplastic resin fibers spun at the tip of the melt-blowing die are cooled.
- An apparatus for producing a melt blown nonwoven fabric wherein an attachment for introducing a cooling fluid, preferably cooling air, is detachably attached.
- the attachment is attached to the tip of the melt-blowing die without any gap.
- cooling air is applied along the nozzle surface, and a vortex flow is also generated by incorporating a cooling fluid, preferably cooling air, for cooling the fibers that are pulled and thinned by high-temperature high-speed air. Therefore, the mixed high-temperature and high-pressure air and the cooling fluid can be led in an orderly manner. Thereby, the resin fiber can be guided downward while preventing the entanglement or fusion of the fibers.
- a cooling fluid preferably cooling air
- FIG. 1 and FIG. 2 are schematic views showing a conventional melt blown nonwoven fabric manufacturing apparatus used conventionally.
- a collection plate comprising a mesh conveyor 6 is disposed below the melt blow die 4, and a suction box 8 capable of sucking the inside by a decompression means below the mesh conveyor 6. Is arranged.
- a roller 9 for moving (rotating) the mesh conveyor 6 is disposed on the side of the suction box 8, and a winding roller (not shown) for winding the melt blown nonwoven fabric is further provided on the downstream side of the roller 9. ) Is arranged.
- a die nose 12 having an isosceles triangle shape is disposed on the lower surface side of the melt blow die 4, and a plurality of small holes 14 are arranged in a row at the center of the die nose 12.
- Arranged nozzles 16 are arranged.
- the molten resin supplied into the resin passage 18 is pushed downward from the small holes 14 of the nozzle 16.
- FIG. 2 shows only one fiber 10 that is extruded.
- slits 31 and 31 are formed so as to sandwich the row of small holes 14 of the nozzle 16 from both sides, and the air passages 20a and 20b are configured by these slits 31 and 31. Then, the high-temperature and high-pressure air sent from the air passages 20a and 20b is ejected obliquely downward when the molten resin is extruded.
- the diameter of the small hole 14 formed in the nozzle 16 is usually preferably 0.05 mm to 0.4 mm. If the diameter of the small holes 14 is smaller than 0.05 mm, the shape becomes uneven due to processing accuracy, and CV% of the fiber diameter becomes large, which is not preferable. Further, it is not preferable because the problem that the pores are easily clogged during long-term operation due to deterioration of the polymer or the like. On the other hand, if it is larger than 0.4 mm, it is difficult to obtain ultrafine fibers, which is not preferable.
- the single-hole discharge rate of the molten resin is usually 0.05 g / min to 3.0 g / min, preferably 0.1 g / min to 2.0 g / min.
- the discharge rate is less than 0.05 g / min, not only the productivity is lowered, but also fiber breakage called fly is likely to occur, and clogging is likely to occur during continuous operation.
- it exceeds 3.0 g / min there is a possibility that sufficient thinning will not be performed.
- the single-hole discharge rate is usually It is 0.2 g / min or more, preferably 0.3 g / min or more. If the discharge amount is smaller than 0.2 g / min, the productivity may be lowered.
- the distance between the small holes 14 (the distance from the outer periphery between adjacent small holes as shown in FIG. 5) is usually 0.01 to 6.0 mm, although it depends on the required fiber diameter. Preferably, it is in the range of 0.15 to 4.0 mm. If the distance between the holes is smaller than the above range, a large number of bundled fibers may be generated as a result of fusion or entanglement of a plurality of fibers. This is presumably because the probability of contact with the adjacent fibers increases, and the fibers are fused or entangled and bundle fibers are easily generated.
- a fiber diameter of 0.1 to 0.8 ⁇ m usually 1.0 mm to 6.0 mm, preferably 1.5 mm to 4.0 mm, more preferably 2 It is in the range of 0.0 mm to 3.0 mm.
- the distance between the small holes 14 is usually in the range of 0.1 mm to 2.0 mm, preferably 0.15 mm to 1.8 mm, and more preferably 0.21 mm to 1.6 mm.
- Air flow high-temperature and high-pressure air ejected from the slit 31 is typically in the range of 200 Nm 3 / h / m ⁇ 1000Nm 3 / hr / m. If the air flow is less than 200 Nm 3 / h / m, there is a possibility that fine of spun yarn becomes insufficient, while when it exceeds 1000 Nm 3 / h / m, pulling air velocity becomes supersonic flow, There is a risk of unsteady flow.
- the conventional melt blown nonwoven fabric manufacturing apparatus 2 is generally configured as described above.
- the fiber 10 formed by pulling and thinning the molten resin spun from the nozzle 16 together with the high-temperature and high-pressure air with the high-temperature and high-speed air is self-bonded on the mesh conveyor 6.
- the melt blown nonwoven fabric manufacturing apparatus newly has an attachment 32 for introducing cooling air detachably attached to the melt blow die 30 as shown in FIG. It is equipped.
- high-temperature and high-pressure air for example, high-temperature and high-pressure air of 280 ° C. or higher is supplied from the air passages 20a and 20b, and 30 ° C. or lower from the horizontal direction via the attachment 32.
- Cooling fluid preferably cooling air
- the fibers are fine fibers, and the number of fusions in 100 fibers is 15 or less, preferably 12 or less, and more preferably 10 or less, which occurs when the fibers are fused. This makes it possible to produce a melt blown nonwoven fabric with few thick fibers.
- the attachment 32 is preferably installed separately from the melt-blowing die 30 and detachably attached to the melt-blowing die 30.
- the melt-blowing die 30 is usually heated to a temperature close to 280 ° C. by, for example, a heater, the attachment 32 for supplying cooling air having a large temperature difference is propagated between the melt-blowing die 30 and heat. It is necessary to install so as not to occur. Therefore, for example, it is preferable to interpose a heat insulating material on the lower surface of the die 30. Alternatively, the melt blow die 30 and the attachment 32 may be attached with a slight gap.
- the cooling air supplied from the attachment 32 becomes high-temperature and high-pressure air supplied from the air passages 20a and 20b as will be described later. Instead of mixing immediately, as shown in FIG. 4, it can be guided downward in a temporarily independent manner along the flow of high-temperature and high-pressure air.
- the melt blow die 30 and the attachment 32 are connected without a gap, that is, if they are connected so as not to form an air passage through which external air is taken in, the upper part of the attachment 32 is provided. No eddy currents are generated. Thereby, the flow of the high-temperature high-pressure air in the direction of arrow A shown in FIG. 3 is not disturbed. Therefore, the fiber is spun and drawn to a desired fiber diameter.
- the cooling air in the direction of arrow B when the cooling air in the direction of arrow B is applied from the horizontal direction, as shown in FIG. 4, the high-temperature high-pressure air and the cooling air are not immediately mixed as described above, but from the position where they collide. It mixes in a slightly lowered position. Therefore, the fiber 10 is pulled and thinned to a predetermined diameter with high-temperature and high-pressure air as described above, and is rapidly cooled.
- the present invention after the cooling air is mixed with the high temperature air, it is possible to prevent heat fusion between the fibers as much as possible by quenching.
- melt blown nonwoven fabric having the following characteristics can be produced by using the melt blown nonwoven fabric production method and production apparatus of the present invention and using polyolefin among the thermoplastic resins as raw materials.
- the average fiber diameter is 2.0 ⁇ m or less
- the fiber diameter distribution CV value is 60% or less, preferably 50% or less
- the number of fusions per 100 fibers is 15 or less, preferably 12 or less, more preferably 10 or less, A melt blown nonwoven fabric.
- melt blown nonwoven fabric having the following characteristics can be produced by using a propylene polymer in the thermoplastic resin as a raw material.
- It consists of propylene polymer fiber, (I) a range in which the average fiber diameter is 2.0 ⁇ m or less, (Ii) Fiber diameter distribution CV value is 60% or less, preferably 50% or less, (Iv) ⁇ crystal fraction is less than 0.9, A meltblown nonwoven fabric.
- the melt blown nonwoven fabric of the present invention is most preferably composed of the propylene polymer fiber and satisfies the above (i), (ii), (iii) and (iv) at the same time.
- (I) Average fiber diameter The average fiber diameter is usually in the range of 2.0 ⁇ m or less, and 2 ⁇ m or less, preferably 1.8 ⁇ m or less is suitable for hygiene material applications. For filter applications, a range of 0.8 ⁇ m or less, preferably 0.3 to 0.6 ⁇ m is suitable.
- the ⁇ crystal fraction in the propylene polymer fiber obtained by melt blowing is less than 0.9, preferably less than 0.7, and more preferably less than 0.6.
- the ratio exceeds 0.9, the cooling of the drawn fibers is not sufficiently effective, and a large number of bundled fibers are generated by fusion or entanglement of a plurality of fibers. For this reason, a big space
- the melt blown nonwoven fabric made of the propylene polymer fiber of the present invention most preferably has a crystallinity of less than 40% in addition to the ⁇ crystal fraction being in the above range.
- the ⁇ crystal fraction in the propylene polymer fiber that is, the crystallinity will be described in detail below.
- the evaluation of crystallinity and orientation characteristics by X-rays has been introduced in many known literatures for a long time, and is now an evaluation method established as a structural analysis of polymers. For example, edited by the Society of Polymer Science, “Experimental Polymer Sciences Vol. 2”, Kyoritsu Shuppan (1958). Supervised by Nita Isamu, “X-ray crystallography, above”, Maruzen (1959). Kadoto, Kawai, Saito, “Polymer Structure and Properties”, Yukichi Kure, Teruichiro Kubo, Koka, 39, 929 (1939).
- crystallinity in the present invention is in accordance with the evaluation methods of these known documents. Specifically, for crystallinity, the X-ray total scattering intensity curve of the wide-angle X-ray diffraction profile is used to determine the scattering contribution of the crystalline region and the scattering of the amorphous region. Separated into contributions, the ratio of each area to the total area was evaluated as the crystallinity index value.
- propylene-based polymers have crystalline diffraction peaks in the vicinity of 2 ⁇ : 14 °, 17 °, 18 °, 21 °, and 22 °, and, for example, polyethylene has 2 ⁇ : 21 °
- polypropylene has 2 ⁇ : 21 °
- polylactic acid is known to have crystalline diffraction peaks around 2 ⁇ : 16 ° and 18 °
- terephthalate has crystalline diffraction peaks in the vicinity of 2 ⁇ : 17 °, 18 ° and 26 °.
- polytrimethylene terephthalate has 2 ⁇ : 9 °, 15 °, 17 °, 19 °, 23 °. , 25 °, around 28 °, and around 29 ° are known to have crystalline diffraction peaks.
- polybutylene terephthalate has 2 ⁇ : 9 °, 16 °, 17 °, 20 °, 23 °, 25 ° , Has a crystalline diffraction peak around 29 ° DOO are known, the area diffraction peaks of crystalline contributes as a crystal region is evaluated from performing the separation of the amorphous region.
- the nonwoven fabric of the present invention is supplied with a cooling fluid of 30 ° C. or less, preferably 5 to 25 ° C., preferably cooling air, and the spun molten resin is cooled to thereby reduce the ⁇ crystal fraction. It can be a range.
- melt blown nonwoven fabric of the present invention may be laminated with other layers according to various uses.
- a knitted fabric, a woven fabric, a non-woven fabric, a film, and the like can be given.
- thermal embossing, thermal fusing methods such as ultrasonic fusing, mechanical entanglement methods such as needle punch and water jet, hot melt adhesive Various known methods such as a method using an adhesive such as a urethane-based adhesive, extrusion lamination, and the like can be adopted.
- nonwoven fabric laminated with the melt blown nonwoven fabric of the present invention examples include various known nonwoven fabrics such as spunbond nonwoven fabric, wet nonwoven fabric, dry nonwoven fabric, dry pulp nonwoven fabric, flash spun nonwoven fabric, and spread nonwoven fabric.
- the filter of the present invention is a filter including a layer made of the melt blown nonwoven fabric, and has a collection efficiency of fine particles having a diameter of 0.5 mm at a basis weight of 90 g / cm 2 of 99% or more.
- the filter of the present invention may be a single layer of the melt blown nonwoven fabric or a laminate of two or more layers.
- the filter of the present invention may be used by being laminated with another filter material such as a dry nonwoven fabric or a porous film depending on the application.
- the nonwoven fabric laminate of the present invention is a nonwoven fabric laminate in which a spunbond nonwoven fabric is laminated on at least one surface of the meltblown nonwoven fabric, and the basis weight (g / m 2 ) of the meltblown nonwoven fabric layer and the basis weight of the entire laminate (g / The ratio (m 2 ) of the melt blown nonwoven fabric layer / weight of the entire laminate is 0.050 or less, preferably 0.040 or less.
- the battery separator of the present invention is a separator including a layer made of the melt blown nonwoven fabric, and has an average fiber diameter of 0.1 to 2.0 ⁇ m, preferably 0.2 to 1.5 ⁇ m, and more preferably 0.00. It is desirable that the average particle size is 3 to 1.0 ⁇ m, and the basis weight is 3 to 30 g / m 2 , preferably 4 to 25 g / m 2 , more preferably 5 to 15 g / m 2 .
- the average fiber diameter is in such a range, a nonwoven fabric having fine pores can be produced, and spinning by the melt blown method and production of the nonwoven fabric can be carried out smoothly and with good productivity. If the weight per unit area is in this range, it is preferable because the internal resistance is small without short-circuiting when used as a battery.
- the lithium ion battery separator of the present invention includes those obtained by press molding such a melt blown nonwoven fabric.
- the press molding means used for producing the lithium ion battery separator of the present invention is not particularly limited, and any press molding means capable of applying pressure in the thickness direction of the melt blown nonwoven fabric is used.
- the elastic modulus of the contact portion having elasticity of such a press molding means is preferably 20 to 600 kg / cm 2 , more preferably 20 to 300 kg / cm 2 .
- Examples of the material having elasticity and high coefficient of friction include paper, cotton, wood, rubber, plastic foam, etc.
- urethane rubber, styrene-butadiene rubber, olefin elastomer, thermoplastic elastomer, Examples include silicon rubber.
- a method of press molding for example, a method of pressing a melt blown nonwoven fabric using a press machine having a pressing surface having elasticity such as rubber and a pressing surface made of metal such as stainless steel, rubber
- a method of calendering a meltblown nonwoven fabric with a roll having elasticity such as a metal and a hard roll such as metal, or a calender roll having a pair of elastic rolls, and sandwiching the meltblown nonwoven fabric with a rubber sheet or the like and pressing or roll molding it The method etc. are mentioned.
- the thermal conductivity of the pressing part made of an elastic material It is preferable that the press portion made of a hard material has a low thermal conductivity.
- a hard material include metals such as stainless steel.
- the pressure molding is preferably accompanied by heating, and can be performed by selecting temperature conditions and pressure conditions at which fibers constituting the meltblown nonwoven fabric are at least partially fused to obtain a nonwoven fabric sheet having a desired pore diameter. .
- the pressure and temperature conditions at the time of press molding may be appropriately selected according to the knowledge of those skilled in the art, depending on the surface material of the pressing means such as a roll.
- the pressing part that contacts at least one surface of the meltblown nonwoven fabric is Conditions under which the temperature is about 80 to 230 ° C., preferably about 150 to 200 ° C., can be selected.
- the temperature of the metal pressing portion is set to 120.
- the temperature condition of the rubber pressing part can be about 90 to 170 ° C.
- the surface temperature of the roll may be in this range.
- the obtained battery separator has an extremely high internal resistance. In some cases, it cannot be used. On the other hand, when the temperature and pressure are too low, a sufficiently fine pore diameter is not formed, and the elongation resistance is low and the strength is inferior.
- the average fiber diameter and basis weight are substantially the same before and after the press molding.
- the lithium ion battery separator of the present invention has a porosity of 30% or more, preferably 40% or more, and the thickness is not particularly limited, but is usually about 10 to 60 ⁇ m, preferably about 15 to 45 ⁇ m. Is desirable. It is preferable for the battery separator to have a porosity in this range because the internal resistance is small and there is no risk of the electrode material passing through and shorting. If the thickness is within this range, it can be suitably used for small battery separator applications.
- Average fiber diameter ( ⁇ m), number of fusion [pieces / 100 pieces] Using an electron microscope (S-3500N, manufactured by Hitachi, Ltd.), a surface photograph is taken after adjusting the magnification so that the number of fibers of the melt blown nonwoven fabric observed in the screen is in the range of 10 to 20. A case having a length of 10 times or more of the diameter was regarded as a fiber, and the width (diameter) of all the fibers in the screen was measured. This was repeated so that the total number was 100, and the average of the obtained diameter measurement results was defined as the average fiber diameter. When the total number of measurements exceeded 100, the average fiber diameter was calculated from the following formula.
- Average fiber diameter average diameter measurement result ⁇ 100 / total number of measurements
- the ratio (Dd / Da) of the standard deviation (Dd) of the measurement result to the average fiber diameter (Da) was defined as the fiber diameter CV value.
- Number of fusions total number of fusions ⁇ 100 / measured total number (2) Maximum pore size ( ⁇ m), minimum pore size ( ⁇ m) and average pore size ( ⁇ m) measured with a basis weight of 90 g / m 2 : A non-woven fabric laminate prepared as a water treatment filter medium in a temperature-controlled room at a temperature of 20 ⁇ 2 ° C.
- Blocking rate (%) and flow rate (l / min) A melt-blown nonwoven fabric with a basis weight of 90 g / m 2 was prepared and filtered using a test liquid in which polystyrene latex particles having a spherical particle diameter of 1.00 ⁇ m were dispersed at a concentration of 0.01% by weight in a 60% by volume isopropyl alcohol (IPA) aqueous solution.
- the concentration (C 1) and concentration (C 0 ) of the filtrate that passed through the melt blown nonwoven fabric (liquid filter) under a pressure of 0.3 MPa were measured with an apparatus (ADVANTEC TSU-90B). Asked.
- the concentrations of the test solution and the filtrate were obtained from a calibration curve measured in advance using a spectrophotometer (Shimadzu UV3100), measuring the absorbance at a wavelength of 500 nm.
- Rejection rate [(C 0 ⁇ C 1 ) / C 0 ] ⁇ 100 (%) Moreover, the blocking rate was calculated
- the flow rate (l / min) was determined by measuring the time when a 500 cc 60 volume% IPA aqueous solution passed through the melt blown nonwoven fabric (liquid filter) under the pressure of 0.3 MPa using the above filtration device.
- [alpha crystal fraction] [alpha crystal peak intensity] / [alpha crystal peak intensity + smectic crystal peak intensity]
- Example 1 Manufacture of spunbond nonwoven fabric> Propylene homopolymer (PP-1, MFR: 60 g / 10 min, melting point: 157 ° C.) using a spunbond nonwoven fabric production apparatus (length in the direction perpendicular to the machine flow direction on the collecting surface: 500 mm) was spun at 240 ° C. to prepare a spunbonded nonwoven fabric having a basis weight of 7 g / m 2 and a fiber diameter of 14 ⁇ m.
- PP-1 Polypropylene homopolymer
- MFR 60 g / 10 min, melting point: 157 ° C.
- Propylene homopolymer (PP-2, MFR: 850 g / 10 minutes, melting point: 159 ° C.) is supplied to the die of the melt blown nonwoven fabric production apparatus on one side of the spunbond nonwoven fabric obtained by the above method, and the set temperature is 280 ° C.
- Example 3 Propylene homopolymer (MFR: 1500 g / 10 min) is supplied to the die of the melt blown nonwoven fabric manufacturing apparatus, and the set temperature: 280 ° C. from the die for melt blow (0.2 mm ⁇ , the distance between the small holes of each nozzle) : 2.62 mm), discharge amount per nozzle hole: 0.08 g / min, discharged with high-temperature high-speed air (280 ° C., 600 m 3 / hr) blown out from both sides of the nozzle, and then cooled air (Temperature: 15 ° C., air volume: 6000 m 3 / hr) Cool and disperse, DCD (distance from spinneret surface to collector): 120 mm, sprayed onto collector, basis weight: 15 g / m 2 A meltblown nonwoven was obtained.
- DCD distance from spinneret surface to collector
- Example 4 Instead of the meltblown nonwoven fabric produced in Example 1, a meltblown nozzle (0.32 mm ⁇ , distance between small holes of each nozzle of 1.02 mm) was used as a meltblown nonwoven fabric to be laminated on the spunbond nonwoven fabric.
- a melt blown nonwoven fabric having a basis weight of 0.7 g / m 2 produced at a discharge rate of 1.26 g / min is used, and the basis weight of the spunbond nonwoven fabric produced in Example 1 is 6.15 g / m as a spunbond nonwoven fabric.
- Example 5 A melt blown nozzle (0.32 mm ⁇ , distance between small holes of each nozzle of 0.33 mm) is used as a melt blown non-woven fabric laminated on a spunbonded non-woven fabric, and the discharge rate per nozzle single hole is produced at 0.63 g / min.
- Example 6 As melt blown non-woven fabric laminated on spunbonded non-woven fabric, a melt blow nozzle (0.32mm ⁇ , distance between small holes of each nozzle: 0.20mm) is manufactured at a discharge rate of 0.51g / min per nozzle single hole.
- Example 7 As melt-blown nonwoven fabric to be laminated on spunbonded nonwoven fabric, a melt-blowing nozzle (0.4 mm ⁇ , distance between small holes of each nozzle: 0.25 mm) is produced at a discharge rate of 0.51 g / min per single nozzle hole.
- Example 1 a melt-blown nonwoven fabric having a basis weight of 15 g / m 2 was obtained in the same manner as in Example 3 except that cooling air was not used when producing the melt-blown nonwoven fabric.
- Comparative Example 3 In Comparative Example 2, the same method as in Comparative Example 2 was used except that a melt-blowing nozzle (0.2 mm ⁇ , distance between small holes of each nozzle: 0.68 mm) was used, and a melt blow with a basis weight of 15 g / m 2 was used. A nonwoven fabric was obtained.
- Comparative Example 4 In Comparative Example 2, the same method as in Comparative Example 2 was used except that a melt-blowing nozzle (0.2 mm ⁇ , distance between small holes of each nozzle: 2.62 mm) was used, and a melt blow with a basis weight of 15 g / m 2 was used. A nonwoven fabric was obtained.
- the present invention can provide a method for producing a melt-blown nonwoven fabric that is stably fine and has very little thick fibers generated by fusion of fibers, an apparatus for producing the melt-blown nonwoven fabric, and the melt-blown nonwoven fabric. .
- melt blown nonwoven fabric of the present invention is sufficiently effective for cooling the spun melted fibers, there are very few bundled fibers produced by fusing or entanglement of a plurality of fibers. For this reason, the voids in the nonwoven fabric are extremely uniform, and the particulate collection efficiency is extremely high, and can be suitably used as a filter.
- the water resistance is extremely high, in addition to being able to obtain the same performance with a lower basis weight than conventional nonwoven fabrics, it is excellent in flexibility. For this reason, it is suitably used for sanitary materials such as disposable diapers and sanitary napkins, and also because it is flexible and has a good texture, it is suitable for medical and bedding such as surgical clothes, packaging cloth, bed sheets, pillow covers, carpets and artificial It can be widely used for leather base fabrics, industrial materials, civil engineering and construction, agricultural and horticultural materials, and life-related materials.
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Abstract
Description
(i)平均繊維径が2.0μm以下、
(ii)繊維径分布CV値が60%以下、
(iii)繊維100本当たりの融着個数が15個以下、
であることを特徴とするメルトブロー不織布、および、
メルトブロー用ダイに圧送された溶融した熱可塑性樹脂を、多数の小孔が並べられたノズルから紡出するとともに、小孔の列を挟むように設けたスリットから噴出される高温高速空気によって牽引細化させてなる繊維を移動する捕集板上に堆積してなるメルトブロー不織布の製造方法において、
前記高温高速空気が噴出される前記スリットの出口部の両側面から30℃以下の冷却流体、好ましくは、冷却空気を供給し、紡出された熱可塑性樹脂繊維を冷却することを特徴とするメルトブロー不織布の製造方法、前記メルトブロー用ダイの先端部に、紡出された熱可塑性樹脂繊維を冷却するための冷却流体を導入するためのアタッチメントを着脱自在に取付けてなることを特徴とするメルトブロー不織布の製造装置に関する。
本発明のメルトブロー不織布を形成する極細繊維の原料となる熱可塑性樹脂は、種々公知の熱可塑性樹脂を用い得る。
前記熱可塑性樹脂の中でも、プロピレン系重合体が得られるメルトブロー不織布の耐薬品性が優れるので好ましい。
本発明のメルトブロー不織布の製造方法は、メルトブロー用ダイに圧送された溶融された熱可塑性樹脂(溶融樹脂)を、多数の小孔が並べられたノズルから紡出するとともに、小孔の列を挟むように設けたスリットから噴出される高温高速空気によって牽引細化させてなる繊維を移動する捕集板上に堆積してなるメルトブロー不織布の製造方法において、前記高温高速空気が噴出される前記スリットの出口部の両側面から30℃以下、好ましくは5~25℃、より好ましくは5~20℃の冷却流体を供給し、紡出された熱可塑性樹脂繊維を冷却することを特徴とするメルトブロー不織布の製造方法である。
本発明のメルトブロー不織布の製造装置は、メルトブロー用ダイに圧送された溶融樹脂を、多数の小孔が並べられたノズルから紡出するとともに、小孔の列を挟むように設けたスリットから噴出される高温高速空気によって牽引細化させてなる繊維を移動する捕集板上に堆積してなるメルトブロー不織布の製造装置において、前記メルトブロー用ダイの先端部に、紡出された熱可塑性樹脂繊維を冷却するための冷却流体、好ましくは冷却空気を導入するためのアタッチメントを着脱自在に取付けてなることを特徴とするメルトブロー不織布の製造装置である。
以下、上記プロピレン系重合体によるメルトブロー不織布の製造方法および製造装置について、更に、図面を参照しながら説明する。
本発明のメルトブロー不織布の製造方法および製造装置を用い、原料となる前記熱可塑性樹脂の内、ポリオレフィンを用いることにより、以下の特徴を有するメルトブロー不織布を製造することができる。
(i)平均繊維径が2.0μm以下
(ii)繊維径分布CV値が60%以下、好ましくは50%以下の範囲、
(iii)繊維100本当たりの融着個数が15個以下、好ましくは12個以下、さらに好ましくは10個以下、
であるメルトブロー不織布、である。
(i)平均繊維径が2.0μm以下の範囲、
(ii)繊維径分布CV値が60%以下、好ましくは50%以下の範囲、
(iv)α晶分率が0.9未満、
であるメルトブロー不織布。
(i)平均繊維径
平均繊維径は通常2.0μm以下の範囲にあり、衛生材料用途には2μm以下、好ましくは1.8μm以下が適している。また、フィルタ用途には0.8μm以下、好ましくは、0.3~0.6μmの範囲が適している。
本発明のフィルタは、前記メルトブロー不織布からなる層を含むフィルタであって、目付90g/cm2における0.5mm径の微粒子の捕集効率が99%以上である。
本発明の不織布積層体は、前記メルトブロー不織布の少なくとも片面にスパンボンド不織布が積層されている不織布積層体であって、メルトブロー不織布層の目付(g/m2)と積層体全体の目付(g/m2)の比〔メルトブロー不織布層の目付/積層体全体の目付〕が0.050以下、好ましくは0.040以下である。
<セパレータ>
本発明の電池用セパレータは、前記メルトブロー不織布からなる層を含むセパレータであって、平均繊維径が、0.1~2.0μm、好ましくは、0.2~1.5μm、より好ましくは0.3~1.0μmであるのが望ましく、また、目付量が3 ~ 30g/m2、好ましくは4 ~ 25g/m2 、より好ましくは5 ~ 15g/m2であるのが望ましい。平均繊維径がこのような範囲にある場合には、微細な細孔を有する不織布が製造でき、かつ、メルトブローン法による紡糸および不織布の製造が円滑に生産性よく行えるため好ましい。目付量がこの範囲にあれば、電池として使用した場合にショートせず、内部抵抗が小さいので好ましい。
前記の押圧成形の前後で平均繊維径及び目付量はほぼ同一である。本発明のリチウムイオン電池用セパレータは空隙率が30%以上 、好ましくは40%以上であり、厚さは特に限定されるものではないが、通常10~60μm 、好ましくは15 ~45 μm程度であるのが望ましい。電池用セパレータは、空隙率がこの範囲にあれば、内部抵抗が小さく、電極物質が通過してショートする虞がないので好ましい。また厚みがこの範囲にあれば、小型の電池用セパレータ用途にも好適に用いることができる。
実施例及び比較例における物性値等は、以下の方法により測定した。
電子顕微鏡(日立製作所製S-3500N)を用いて、画面内に観察されるメルトブロー不織布の繊維本数が10本から20本の範囲となる倍率に調整したうえで表面写真を撮影する。直径の10倍以上の長さを有する場合を繊維とし、画面内の全ての繊維の幅(直径)を測定した。これを合計100本となるように繰り返して、得られた直径測定結果の平均を平均繊維径とした。なお、測定数の合計が100本を越える場合は下記式より平均繊維径を算出した。
また、この測定結果の標準偏差(Dd)の平均繊維径(Da)に対する割合(Dd/Da)を繊維径CV値とした。
(2)目付90g/m2で測定した最大孔径(μm)、最小孔径(μm)及び平均孔径(μm):
目付90g/m2のメルトブロー不織布を調整し、JIS Z8703(試験場所の標準状態)に規定する温度20±2℃、湿度65±2%の恒温室内で、水処理用濾過材となる不織布積層体から採取した試験片をフッ素系不活性液体(3M社製 商品名:フロリナート)に浸漬し、Porous materials,Inc社製のキャピラリー・フロー・ポロメーター(Capillary Flow Porometer)「モデル:CFP-1200AE」を用いて目付90g/m2で測定した最大孔径(μm)、最小孔径(μm)及び平均孔径(μm)を測定した(表中、「最大孔径」、「最小孔径」及び「平均孔径」と示す)。
目付90g/m2のメルトブロー不織布を調整し、球状粒子径1.00μmのポリスチレンラテックス粒子を60容量%のイソプロピルアルコール(IPA)水溶液に0.01重量%の濃度で分散した試験液を用い、ろ過装置(ADVANTEC製TSU-90B)で0.3MPaの圧力のもとメルトブロー不織布(液体用フィルタ)を通過した濾液中の濃度:C1と原液の濃度:C0を測定し、次式で阻止率を求めた。
試験液および濾液の濃度は分光光度計(島津製UV3100)を使用し、波長500nmの吸光度を測定し、予め測定した検量線から求めた。
また、上記方法で、各々、球状粒子径3.00μm及び球状粒子径0.47μmのポリスチレンラテックス粒子を用い、阻止率を求めた。
流量(l/min)は、上記ろ過装置を用い0.3MPaの圧力のもと500ccの60容量%IPA水溶液がメルトブロー不織布(液体用フィルタ)を通過したときの時間を測定し求めた。
JIS L1092A法に準拠して、JIS Z8703(試験場所の標準状態)に規定する温度20±2℃、湿度65±2%の恒温室内で水処理用濾過材となる不織布積層体から採取した15×15cmの試験片10枚を採取し耐水圧試験機を用いて、水が漏れるときの圧力を測定しその平均値を求めた。
広角X線回折装置(リガク社製 RINT2500、付属装置:回転試料台、X線源:CuKα、出力:50kV 300mA、検出器:シンチレーションカウンター)を用いて、不織布を試料ホルダーに充填し、広角X線回折透過法により回折プロファイルを回転しながら測定した。
測定より得られる回折プロファイル結果よりα晶分率についてはプロピレン系重合体の(110)面を示す2θ=14°付近のピーク強度をα晶のピーク強度、2θ=15°付近のピーク強度をスメチカ晶のピーク強度とし、次式より求めた。なお、2θ=15°付近のピークが確認されなかった場合はα晶だけで構成されていると判断し、α晶分率を1.0とした。
[α晶分率]=[α晶ピークの強度]/ [α晶ピークの強度+スメチカ晶のピーク強度]
評価者10人により手触りの評価を行った。以下の基準で評価結果を示す。
◎:手触りが良いと感じた人が、10人のうち10人の場合
○:手触りが良いと感じた人が、10人のうち9~7人の場合
△:手触りが良いと感じた人が、10人のうち6~3人の場合
×:手触りが良いと感じた人が、10人のうち2人以下の場合
<スパンボンド不織布の製造>
スパンボンド不織布製造装置(捕集面上の機械の流れ方向に垂直な方向の長さ:500mm)を用いて、プロピレン単独重合体(PP-1、MFR:60g/10分、融点:157℃)を240℃で溶融し、目付:7g/m2、繊維径:14μmのスパンボンド不織布を用意した。
上記方法で得たスパンボンド不織布に片面に、プロピレン単独重合体(PP-2、MFR:850g/10分、融点:159℃)をメルトブロー不織布製造装置のダイに供給し、設定温度:280℃のダイから、メルトブロー用ノズル(0.32mmφ、各ノズルの小孔の孔間の距離:0.20mm)を用いて、ノズル単孔あたりの吐出量:0.52g/分でノズルの両側から吹き出す高温高速空気(280℃、600m3/hr)と伴に吐出し、その後に冷却空気(温度:15℃、風量:6000m3/hr)にて冷却と分散を行い、DCD(紡糸口金の表面からコレクターまでの距離):120mmでメルトブロー不織布の目付が0.7g/m2となるように上記スパンボンド不織布の上に吹き付けて、スパンボンド不織布とメルトブロー不織布の積層体を得た。次いで、上記と同一条件で製造されるスパンボンド不織布をメルトブロー不織布上に積層して、総目付:14.7g/m2(スパンボンド不織布/メルトブロー不織布/スパンボンド不織布=7.0/0.7/7.0g/m2)の不織布積層体を得た。
実施例1で製造したメルトブロー不織布に替えて、スパンボンド不織布に積層するメルトブロー不織布として、メルトブロー用ノズル(0.32mmφ、各ノズルの小孔の孔間の距離:1.59mm)を用い、ノズル単孔あたりの吐出量を1.27g/分で製造した目付が0.5g/m2のメルトブロー不織布を用いる以外は、実施例1と同様に行い、総目付:14.5g/m2(スパンボンド不織布/メルトブロー不織布/スパンボンド不織布=7.0/0.5/7.0g/m2)の不織布積層体を得た。
プロピレン単独重合体(MFR:1500g/10分)をメルトブロー不織布製造装置のダイに供給し、設定温度:280℃のダイから、メルトブロー用ノズル(0.2mmφ、各ノズルの小孔の孔間の距離:2.62mm)を用いて、ノズル単孔あたりの吐出量:0.08g/分でノズルの両側から吹き出す高温高速空気(280℃、600m3/hr)と伴に吐出し、その後に冷却空気(温度:15℃、風量:6000m3/hr)にて冷却と分散を行い、DCD(紡糸口金の表面からコレクターまでの距離):120mmでコレクターの上に吹き付けて、目付:15g/m2のメルトブロー不織布を得た。
実施例1で製造したメルトブロー不織布に替えて、スパンボンド不織布に積層するメルトブロー不織布として、メルトブロー用ノズル(0.32mmφ、各ノズルの小孔の孔間の距離1.02mm)を用い、ノズル単孔あたりの吐出量を1.26g/分で製造した目付が0.7g/m2のメルトブロー不織布を用いること、スパンボンド不織布として、実施例1で製造したスパンボンド不織布の目付を6.15g/m2とすること、高温高速空気の量を1400m3/hrとすること、DCDを150mmとすること以外は、実施例1と同様に行い、総目付:13.0g/m2(スパンボンド不織布/メルトブロー不織布/スパンボンド不織布=6.15/0.7/6.15g/m2)の不織布積層体を得た。
スパンボンド不織布に積層するメルトブロー不織布として、メルトブロー用ノズル(0.32mmφ、各ノズルの小孔の孔間の距離0.33mm)を用い、ノズル単孔あたりの吐出量を0.63g/分で製造した目付が0.7g/m2のメルトブロー不織布を用いること、高温高速空気の量を1500m3/hrとすること以外は、実施例4と同様に行い、総目付:13.0g/m2(スパンボンド不織布/メルトブロー不織布/スパンボンド不織布=6.15/0.7/6.15g/m2)の不織布積層体を得た。
スパンボンド不織布に積層するメルトブロー不織布として、メルトブロー用ノズル(0.32mmφ、各ノズルの小孔の孔間の距離0.20mm)を用い、ノズル単孔あたりの吐出量を0.51g/分で製造した目付が0.7g/m2のメルトブロー不織布を用いること、高温高速空気の量を700m3/hrとすること以外は、実施例4と同様に行い、総目付:13.0g/m2(スパンボンド不織布/メルトブロー不織布/スパンボンド不織布=6.15/0.7/6.15g/m2)の不織布積層体を得た。
スパンボンド不織布に積層するメルトブロー不織布として、メルトブロー用ノズル(0.4mmφ、各ノズルの小孔の孔間の距離0.25mm)を用い、ノズル単孔あたりの吐出量を0.51g/分で製造した目付が0.7g/m2のメルトブロー不織布を用いること、高温高速空気の量を1200m3/hrとすること以外は、実施例4と同様に行い、総目付:13.0g/m2(スパンボンド不織布/メルトブロー不織布/スパンボンド不織布=6.15/0.7/6.15g/m2)の不織布積層体を得た。
実施例1において、メルトブロー不織布を製造する際に、冷却空気を使用せずに、目付が1.0g/m2のメルトブロー不織布を用いる以外は、実施例1と同様に行い、総目付:15.0g/m2(スパンボンド不織布/メルトブロー不織布/スパンボンド不織布=7.0/1.0/7.0g/m2)の不織布積層体を得た。
実施例1において、メルトブロー不織布を製造する際に、冷却空気を使用しなかった以外は実施例3と同様の方法にて、目付:15g/m2のメルトブロー不織布を得た。
比較例2において、メルトブロー用ノズル(0.2mmφ、各ノズルの小孔の孔間の距離0.68mm)を用いる以外は、比較例2と同様の方法で行い、目付:15g/m2のメルトブロー不織布を得た。
比較例2において、メルトブロー用ノズル(0.2mmφ、各ノズルの小孔の孔間の距離2.62mm)を用いる以外は、比較例2と同様の方法で行い、目付:15g/m2のメルトブロー不織布を得た。
目付が0.7g/m2のメルトブロー不織布を用いる以外は、比較例1と同様に行い、総目付:14.7g/m2(スパンボンド不織布/メルトブロー不織布/スパンボンド不織布=7.0/0.7/7.0g/m2)の不織布積層体を得た。
メルトブロー不織布を製造する際に、冷却空気に替えて、温度:50℃、風量:6000m3/hrの空気を使用すること、DCDを150mmとすること以外は、実施例1と同様に行い、総目付:14.7g/m2(スパンボンド不織布/メルトブロー不織布/スパンボンド不織布=7.0/0.7/7.0g/m2)の不織布積層体を得た。
メルトブロー不織布を製造する際に、冷却空気を使用しないこと、高温高速空気の量を1000m3/hrとすること以外は、実施例5と同様に行い、総目付:13.0g/m2(スパンボンド不織布/メルトブロー不織布/スパンボンド不織布=6.15/0.7/6.15g/m2)の不織布積層体を得た。
4 メルトブロー用ダイ
6 メッシュコンベア
8 サクションボックス
10 繊維
12 ダイノーズ
14 小孔
16 ノズル
18 樹脂通路
20a、20b 空気通路
31 スリット
32 アタッチメント
Claims (10)
- ポリオレフィン繊維からなり、
(i)平均繊維径が2.0μm以下、
(ii)繊維径分布CV値が60%以下、
(iii)繊維100本当たりの融着個数が15個以下、
であることを特徴とするメルトブロー不織布。 - プロピレン系重合体繊維からなり、
(i)平均繊維径が2.0μm以下、
(ii)繊維径分布CV値が60%以下、
(iv)α晶分率が0.9未満、
であることを特徴とするメルトブロー不織布。 - 請求項1または2記載のメルトブロー不織布からなる層を含み、目付90g/cm2における0.5mm径の微粒子の捕集効率が99%以上であるフィルタ。
- 請求項1または2記載のメルトブロー不織布の少なくとも片面にスパンボンド不織布が積層されている不織布積層体であって、メルトブロー不織布層の目付(g/m2)と積層体全体の目付(g/m2)の比が0.05以下であることを特徴とする不織布積層体。
- 請求項4記載の不織布積層体を含む衛生用品。
- 請求項1または2記載のメルトブロー不織布からなる層を含む電池用セパレータ。
- メルトブロー用ダイに圧送された溶融した熱可塑性樹脂を、多数の小孔が並べられたノズルから紡出するとともに、小孔の列を挟むように設けたスリットから噴出される高温高速空気によって牽引細化させてなる繊維を移動する捕集板上に堆積してなるメルトブロー不織布の製造方法において、
前記高温高速空気が噴出される前記スリットの出口部の両側面から30℃以下の冷却流体を供給し、紡出された熱可塑性樹脂繊維を冷却することを特徴とするメルトブロー不織布の製造方法。 - 冷却流体が、冷却空気である請求項7記載のメルトブロー不織布の製造方法。
- メルトブロー用ダイに圧送された溶融した熱可塑性樹脂を、多数の小孔が並べられたノズルから紡出するとともに、小孔の列を挟むように設けたスリットから噴出される高温高速空気によって牽引細化させてなる繊維を移動する捕集板上に堆積してなるメルトブロー不織布の製造装置において、
前記メルトブロー用ダイの先端部に、紡出された熱可塑性樹脂繊維を冷却するための冷却流体を導入するためのアタッチメントを着脱自在に取付けてなることを特徴とするメルトブロー不織布の製造装置。 - 前記アタッチメントは、前記メルトブロー用ダイの先端部に隙間無く取り付けられていることを特徴とする請求項9に記載のメルトブロー不織布の製造装置。
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Also Published As
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KR101781707B1 (ko) | 2017-09-25 |
DK2650419T3 (en) | 2016-11-28 |
MY163077A (en) | 2017-08-15 |
EP2650419B1 (en) | 2016-09-28 |
EP2650419B2 (en) | 2023-11-15 |
US20130266874A1 (en) | 2013-10-10 |
KR20130111591A (ko) | 2013-10-10 |
CN103228832A (zh) | 2013-07-31 |
JP6270750B2 (ja) | 2018-01-31 |
KR20150070433A (ko) | 2015-06-24 |
JP2015092038A (ja) | 2015-05-14 |
US9404207B2 (en) | 2016-08-02 |
EP2650419A1 (en) | 2013-10-16 |
JP5813008B2 (ja) | 2015-11-17 |
KR101984351B1 (ko) | 2019-05-30 |
US20160040335A1 (en) | 2016-02-11 |
EP2650419A4 (en) | 2015-01-21 |
CN105002660A (zh) | 2015-10-28 |
EP2650419B9 (en) | 2017-03-29 |
US9200392B2 (en) | 2015-12-01 |
JPWO2012077638A1 (ja) | 2014-05-19 |
KR20150069039A (ko) | 2015-06-22 |
DK2650419T4 (da) | 2024-01-02 |
CN105002660B (zh) | 2018-01-12 |
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