WO2013084524A1 - 複合繊維およびこの複合繊維を含む繊維構造体 - Google Patents
複合繊維およびこの複合繊維を含む繊維構造体 Download PDFInfo
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- WO2013084524A1 WO2013084524A1 PCT/JP2012/064628 JP2012064628W WO2013084524A1 WO 2013084524 A1 WO2013084524 A1 WO 2013084524A1 JP 2012064628 W JP2012064628 W JP 2012064628W WO 2013084524 A1 WO2013084524 A1 WO 2013084524A1
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
- D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
- D01F8/10—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one other macromolecular compound obtained by reactions only involving carbon-to-carbon unsaturated bonds as constituent
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/22—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising organic material
- B01J20/26—Synthetic macromolecular compounds
- B01J20/264—Synthetic macromolecular compounds derived from different types of monomers, e.g. linear or branched copolymers, block copolymers, graft copolymers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/22—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising organic material
- B01J20/26—Synthetic macromolecular compounds
- B01J20/265—Synthetic macromolecular compounds modified or post-treated polymers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
- B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
- B01J20/28023—Fibres or filaments
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/30—Processes for preparing, regenerating, or reactivating
- B01J20/3085—Chemical treatments not covered by groups B01J20/3007 - B01J20/3078
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F1/00—Treatment of water, waste water, or sewage
- C02F1/28—Treatment of water, waste water, or sewage by sorption
- C02F1/285—Treatment of water, waste water, or sewage by sorption using synthetic organic sorbents
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
- D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
- D01F8/06—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
- D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
- D01F8/08—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyacrylonitrile as constituent
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
- D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
- D01F8/12—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyamide as constituent
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
- D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
- D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
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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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
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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
- D06M14/00—Graft polymerisation of monomers containing carbon-to-carbon unsaturated bonds on to fibres, threads, yarns, fabrics, or fibrous goods made from such materials
- D06M14/18—Graft polymerisation of monomers containing carbon-to-carbon unsaturated bonds on to fibres, threads, yarns, fabrics, or fibrous goods made from such materials using wave energy or particle radiation
- D06M14/26—Graft polymerisation of monomers containing carbon-to-carbon unsaturated bonds on to fibres, threads, yarns, fabrics, or fibrous goods made from such materials using wave energy or particle radiation on to materials of synthetic origin
- D06M14/28—Graft polymerisation of monomers containing carbon-to-carbon unsaturated bonds on to fibres, threads, yarns, fabrics, or fibrous goods made from such materials using wave energy or particle radiation on to materials of synthetic origin of macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2029/00—Use of polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals or derivatives thereof as moulding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2079/00—Use of polymers having nitrogen, with or without oxygen or carbon only, in the main chain, not provided for in groups B29K2061/00 - B29K2077/00, as moulding material
- B29K2079/08—PI, i.e. polyimides or derivatives thereof
- B29K2079/085—Thermoplastic polyimides, e.g. polyesterimides, PEI, i.e. polyetherimides, or polyamideimides; Derivatives thereof
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- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F2101/00—Nature of the contaminant
- C02F2101/10—Inorganic compounds
- C02F2101/20—Heavy metals or heavy metal compounds
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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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/542—Adhesive fibres
- D04H1/545—Polyvinyl alcohol
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- 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
- Y10T428/2929—Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
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- 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]
- Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
- Y10T442/641—Sheath-core multicomponent strand or fiber material
Definitions
- the present invention relates to a composite fiber that can be used as a filter or an adsorbent (for example, a filter or adsorbent for recovering metal from a liquid containing metal), a fiber structure (molded body) including the composite fiber, and
- a method for producing the composite fiber or fiber structure relates to a composite fiber that can be used as a filter or an adsorbent (for example, a filter or adsorbent for recovering metal from a liquid containing metal), a fiber structure (molded body) including the composite fiber, and The present invention relates to a method for producing the composite fiber or fiber structure.
- the graft polymerization (graft copolymerization) method is a polymerization method for producing a copolymer having a structure in which other monomer units are arranged as side chains at the monomer units constituting the polymer main chain. It is known as a method for modifying or modifying a polymer by introduction.
- Non-Patent Document 1 Non-Patent Document 1 [Nisshin Electric Technical Report, Vol. 53 (issued in October 2008)] an ethylene-vinyl alcohol copolymer having a particle size of about 0.1 to 1 mm is subjected to electron beam graft polymerization of sodium p-styrenesulfonate, and the graft ratio is 100 at maximum. % Graft copolymer was obtained.
- the obtained graft copolymer is used as an adsorbent, and Mg 2+ or NH 4 + is grafted from a mixed solution containing NH 4 + , Na + , Ca 2+ , Mg 2+ and Mn 2+. It is described that it was adsorbed by a copolymer.
- Patent Document 1 JP 2010-1392 A discloses a step of irradiating a polymer base material (such as ethylene-vinyl alcohol copolymer) containing a repeating structural unit having at least one hydroxyl group with ionizing radiation, A step of introducing a graft chain having a quaternary ammonium group into the polymer substrate by bringing the polymer substrate irradiated with radiation into contact with vinylbenzyltrimethylammonium chloride or the like.
- the form of the polymer substrate can be a shape such as particles, fibers, yarns, films, hollow fiber membranes, woven fabrics, and nonwoven fabrics.
- the shape of the ion exchanger is also described as preferably being particulate.
- the ethylene-vinyl alcohol copolymer cannot be sufficiently modified or modified.
- the surface area (adsorption area) involved in adsorption cannot be sufficiently increased due to aggregation of the graft copolymer, and sufficient adsorption performance and ion exchange performance may not be obtained. There is.
- JP 2010-1392 A (claims, paragraphs [0066] and [00076], examples)
- an object of the present invention is to provide a composite fiber that can efficiently graft polymerize a graft component (such as a radically polymerizable monomer) to an ethylene-vinyl alcohol copolymer, and the composite fiber (or a fiber assembly including the composite fiber). It is in providing the fiber structure formed in (1), and its manufacturing method.
- a graft component such as a radically polymerizable monomer
- Another object of the present invention is to provide a composite fiber (or a fiber containing the composite fiber) that can be used as a filter or adsorbent (recovery filter, cartridge filter, etc.) or a separator (eg, battery separator).
- An object of the present invention is to provide a fiber structure formed by an aggregate and a method for producing the same.
- Still another object of the present invention is to provide a fiber structure formed of a composite fiber (or a fiber assembly including a composite fiber) that can efficiently adsorb or recover a metal (metal in a mixed solution) with excellent adsorptivity, and the fiber structure. It is to provide a manufacturing method.
- the present inventors have determined that the ethylene-vinyl alcohol copolymer is not simply in the form of particles, but in the form of fibers, particularly a core-sheath structure, After forming a composite fiber having an ethylene-vinyl alcohol copolymer on the fiber surface [and forming a fiber structure (molded body) with a fiber aggregate containing the composite fiber], graft polymerization (particularly, Surprisingly, it is possible to carry out graft polymerization with high polymerizability (or graft polymerization rate) with respect to an ethylene-vinyl alcohol copolymer by using radiation such as electron beam graft polymerization.
- a monomer having a functional group is introduced as a component for graft polymerization, and a desired functional group is further introduced. It is excellent in adsorption performance of metals (rare metal, rare earth, etc.) in the mixed solution by further modifying or modifying through functional groups introduced by monomers (for example, monomers having epoxy groups such as glycidyl methacrylate).
- monomers for example, monomers having epoxy groups such as glycidyl methacrylate.
- the conjugate fiber of the present invention is composed of a graft polymer in which a graft chain is bonded to an ethylene-vinyl alcohol copolymer (sometimes referred to as EVOH, ethylene-vinyl alcohol polymer, etc.) and another resin. And at least a part of the fiber surface is composed of the graft polymer.
- a graft polymer in which a graft chain is bonded to an ethylene-vinyl alcohol copolymer (sometimes referred to as EVOH, ethylene-vinyl alcohol polymer, etc.) and another resin.
- EVOH ethylene-vinyl alcohol copolymer
- the ethylene unit content may be, for example, about 5 to 65 mol%.
- the graft chain may be composed of, for example, a polymer chain formed by polymerization of a radical polymerizable monomer containing at least a radical polymerizable monomer having a functional group (particularly, radiation polymerization such as electron beam polymerization).
- the graft chain may be composed of such a polymer chain, and the polymer chain may be further modified.
- the graft chain may have a polymer chain and a chain (unit or unit) derived from a compound that can react and bond with a functional group of the polymer chain.
- the radically polymerizable monomer having a functional group typically includes an amino group, a substituted amino group, an imino group, an amide group, a substituted amide group, a hydroxyl group, a carboxyl group, a carbonyl group, an epoxy group, a thio group, and a sulfo group.
- a (meth) acrylic monomer having at least one selected functional group may be included.
- the graft chain formed in the composite fiber may have a multidentate functional group (such as an iminodiacetic acid unit).
- the multidentate functional group may be possessed by the polymer chain or may be a functional group introduced via a functional group of the polymer chain.
- the composite fiber of the present invention has a high graft polymerization rate.
- the graft polymerization rate with respect to the ethylene-vinyl alcohol copolymer is 100% or more (particularly 200% or more) on a weight basis. May be.
- the structure of the composite fiber of the present invention may be a core-sheath type composite fiber formed of a sheath part made of a graft polymer and a core part made of another resin.
- the conjugate fiber of the present invention includes a sheath portion made of a graft polymer, and at least one other resin selected from a polypropylene resin, a styrene resin, a polyester resin, and a polyamide resin.
- a core-sheath type composite fiber formed with a core part constituted, and the ratio of the graft polymer to the other resin is the former / the latter (weight ratio) 95/5 to 30/70, and the graft weight
- the graft polymerization rate with respect to the ethylene-vinyl alcohol copolymer may be 150% or more by weight.
- the ratio of graft chains (when other resins have graft chains, the total amount of graft chains bonded to the ethylene-vinyl alcohol copolymer and graft chains bonded to other resins). May be 50 parts by weight or more (for example, 100 parts by weight or more) with respect to 100 parts by weight of the total amount of the ethylene-vinyl alcohol copolymer and other resins.
- the present invention also includes a fiber structure formed of a fiber assembly including the composite fiber.
- a fiber structure may have, for example, a non-woven fiber structure fused by wet heat bonding (fibers are fused together).
- the structure of such a fiber structure may be a woven or knitted fabric (structure) such as a double raschel (structure).
- the fiber structure has appropriate voids.
- the air permeability according to the Frazier method may be 5 to 400 cm 3 / (cm 2 ⁇ sec).
- the apparent density of the fiber structure is about 0.05 to 0.35 g / cm 3
- the basis weight is about 50 to 3000 g / m 2
- the air permeability according to the Frazier method is 5 to 300 cm 3 / (cm 2. ⁇ It may be about seconds).
- the fiber structure may be used as an adsorbent for adsorbing metal (particularly, rare earth).
- the fiber structure of the present invention is, for example, for a treated fiber structure in which at least a part of the fiber surface is formed of a fiber assembly including at least a composite fiber made of an ethylene-vinyl alcohol copolymer.
- the graft component constituting the graft chain can be produced by graft polymerization.
- the grafted component is brought into contact by immersing the treated fiber structure in which active species are generated by irradiation with radiation in a graft component-containing liquid containing the graft component (for example, a dispersion containing the graft component). May be graft polymerized.
- the ratio of the graft component in the graft component-containing liquid may be, for example, about 5 to 50% by weight.
- an ethylene-vinyl alcohol copolymer is graft-polymerized in the form of a composite fiber and further a fiber structure containing the composite fiber, whereby the graft component is efficiently converted into an ethylene-vinyl alcohol copolymer.
- Graft polymerization is possible. Therefore, in the present invention, a composite fiber or fiber structure having a high graft polymerization rate can be obtained efficiently, and the ethylene-vinyl alcohol copolymer can be efficiently modified or modified according to the type of graft component. For example, characteristics or functions such as hydrophilicity, water repellency, and deodorizing properties can be easily imparted depending on the type of graft component.
- a graft chain having a functional group having an affinity for an adsorbed substance can be combined with an ethylene-vinyl alcohol copolymer by graft polymerization to be used as a filter or separator.
- a fiber or fiber structure is obtained.
- the composite fiber or fiber structure having a metal adsorbing ability it is possible to easily impart antibacterial property (for example, antibacterial property by adsorbing silver) by metal adsorption or plating the fiber. Is possible.
- the modification compared to a fiber modification method such as plasma treatment, the modification can be efficiently carried out over the inside of the fiber, so that a large amount of functional groups can be introduced into the composite fiber or fiber structure, which is suitable for the above applications. is there.
- a composite fiber or a fiber structure capable of efficiently adsorbing or recovering metal (metal in the mixed solution) with excellent adsorptivity.
- Such composite fibers or fiber structures can be adsorbed or recovered with high adsorption performance or recovery efficiency even in rare metals such as rare earths and rare metals. Useful.
- the fiber structure of the present invention has appropriate voids between the fibers, and graft chains are bonded to the fiber surface at a high graft polymerization rate, and is excellent in filter or adsorption performance.
- such a fiber structure has a proper fabric while having an appropriate gap and the composite fiber is firmly bonded by fusion or the like, or a strong fabric structure having a gap like a woven or knitted fabric.
- it is possible to achieve both high adsorption performance and high strength. Therefore, it is possible to easily adsorb an adsorbed substance such as a metal with excellent adsorbability compared to a granular form, and the adsorbed adsorbed substance can be easily recovered.
- it can be used repeatedly, such as removing the adsorbed substance after recovery and then reusing it.
- the present invention can be formed by combining an ethylene-vinyl alcohol copolymer and another resin, not only can the ethylene-vinyl alcohol copolymer be modified or modified depending on the type of graft component.
- other resins it is possible to easily obtain composite fibers or fiber structures having physical properties and functions derived from other resins (for example, ensuring physical properties, suppressing aggregation, and providing a framework for forming structures). Is possible.
- the composite fiber of the present invention includes a graft polymer in which a graft chain is bonded to an ethylene-vinyl alcohol copolymer (or its main chain) (or an ethylene-vinyl alcohol copolymer and the ethylene-vinyl alcohol copolymer).
- a graft polymer having a graft chain bonded to the polymer) and another resin, and at least a part of the fiber surface is a composite fiber composed of the graft polymer.
- the ethylene unit content is, for example, 2 to 80 mol% (eg, 5 to 65 mol%), preferably 15 to 60 mol. It may be about mol%, more preferably about 15 to 55 mol%.
- the graft component may not be able to bond (or introduce) a sufficient graft chain to EVOH unless the ratio of ethylene units to vinyl alcohol units is appropriate.
- EVOH in the above range usually has wet heat adhesiveness but has a unique property that it has no hot water solubility, so that it is easy to obtain a fiber structure by wet heat bonding as described later.
- the proportion of ethylene units is too small, the ethylene-vinyl alcohol copolymer easily swells or gels with low-temperature steam (water), and forms only after being wet once with water. Is easy to change.
- the proportion of ethylene units is too large, the hygroscopicity is lowered, and fiber fusion due to wet heat becomes difficult to occur. Therefore, it is difficult to ensure practical strength by wet heat bonding.
- the proportion of ethylene units is in the range of 15 to 55 mol%, the processability to a sheet or plate is particularly excellent.
- the saponification degree of the vinyl alcohol unit in the ethylene-vinyl alcohol copolymer is, for example, about 90 to 99.99 mol%, preferably 95 to 99.99 mol%, more preferably 96 to 99.99 mol%. %.
- the saponification degree is too small, the thermal stability is lowered, and the stability is lowered by thermal decomposition or gelation.
- the degree of saponification is too large, the meltability by heat deteriorates and the moldability such as spinning is affected.
- the viscosity average degree of polymerization of the ethylene-vinyl alcohol copolymer can be selected as necessary, but is, for example, about 200 to 2500, preferably 300 to 2000, and more preferably about 400 to 1800. When the degree of polymerization is within this range, the spinnability is excellent and wet heat adhesion can be secured.
- the graft polymer (or graft chain) is obtained, for example, by polymerizing (graft polymerization) an ethylene-vinyl alcohol copolymer and a component for forming the graft chain (graft component, graft polymerization component).
- graft component graft polymerization component
- the graft chain is formed by polymerization of a graft component (graft polymerization component), and so to speak, can be said to be composed of a polymer chain (or oligomer chain) obtained by polymerizing the graft component.
- the graft polymerization may be performed at any stage of the production process of the composite fiber or the fiber structure.
- Such polymerization is not particularly limited and may be emulsion polymerization or the like, but usually radiation polymerization (particularly electron beam polymerization) that is polymerized by radiation irradiation can be suitably used.
- radiation polymerization polymerization can be performed without using a dispersant (emulsifier) or an initiator (crosslinking agent), and in particular, electron beam polymerization is preferable because it can be polymerized at a low temperature in a short time. is there.
- the electron beam is easily modified to the inside of the fiber, and a higher graft polymerization rate is easily obtained as compared with plasma and ultraviolet rays.
- graft polymerization depends on the polymerization method, usually, in radiation polymerization or the like, active species (radicals) are generated at least in ethylene units of the ethylene-vinyl alcohol copolymer, and the graft components are polymerized from these active species. It progresses in the form to do.
- a radically polymerizable monomer can usually be used.
- the radical polymerizable monomer is not particularly limited, and can be appropriately selected depending on the characteristics imparted to the ethylene-vinyl alcohol copolymer (or composite fiber).
- a (meth) acrylic monomer for example, (meta ) Acrylates (eg, (meth) acrylic acid alkyl esters such as methyl (meth) acrylate)], styrenic monomers (eg, styrene, ⁇ -methylstyrene, vinyltoluene, etc.), halogen-containing monomers (eg, chloride) Vinyl halides such as vinyl), olefin monomers (eg, ⁇ -C 3-6 olefins such as propylene and 1-butene), vinyl cyanide monomers (eg, (meth) acrylonitrile), vinyl ether monomers (eg, Alkyl vinyl ethers such as methyl vinyl ether Like monofunctional polymerizable monomers such as (monomer having one radically polymerizable group).
- styrenic monomers eg, styrene, ⁇ -methylstyrene, vinyltoluene, etc.
- the graft component may be a polyfunctional polymerizable monomer having a plurality of radical polymerizable groups, but is often composed of at least a monofunctional polymerizable monomer.
- the graft component particularly preferably contains a radical polymerizable monomer having a functional group.
- a radically polymerizable monomer having such a functional group is used as a graft component, a functional group corresponding to a desired property can be easily introduced into an ethylene-vinyl alcohol copolymer (or composite fiber) as described later. Further, it is easy to introduce a desired functional group by utilizing the reactivity of the introduced functional group.
- Examples of the functional group include a nitrogen atom-containing functional group ⁇ eg, amino group, substituted amino group [eg, alkylamino group (eg, mono- or di-C 1-4 alkylamino group such as methylamino group)], imino group Amide group or carbamoyl group (NH 2 CO—), N-substituted carbamoyl group [eg, N-alkylcarbamoyl group (eg, N-mono- or di-C 1-4 alkylcarbamoyl group such as N-methylcarbamoyl group), etc.
- a nitrogen atom-containing functional group ⁇ eg, amino group, substituted amino group [eg, alkylamino group (eg, mono- or di-C 1-4 alkylamino group such as methylamino group)], imino group Amide group or carbamoyl group (NH 2 CO—), N-substituted carbamoyl group [eg, N-
- Oxygen atom-containing functional groups eg, hydroxyl groups, carboxyl groups (including acid anhydride groups), carbonyl groups (—CO—), epoxy groups, etc.
- sulfur atom-containing functional groups eg, mercapto groups, A thio group (—S—), a sulfo group, etc.
- a halogen atom eg, a chlorine atom, a bromine atom, an iodine atom, etc.
- these functional groups may form a salt (for example, a metal salt such as a sodium salt, an ammonium salt, or the like).
- the radical polymerizable monomer having a functional group may have these functional groups alone or in combination of two or more.
- amino groups, substituted amino groups, imino groups, amide groups, substituted amide groups, hydroxyl groups, carboxyl groups, carbonyl groups (ketone groups), epoxy groups, thio groups, sulfo groups and the like are typical. is there.
- These functional groups often have an affinity for a substance to be adsorbed such as a metal, and are suitable for filter applications and the like.
- radical polymerizable monomer having a functional group examples include a radical polymerizable monomer having an amino group (or imino group) or a substituted amino group ⁇ for example, aminoalkyl (meth) acrylate [for example, N, N-dimethyl N-mono or di C 1-4 alkylamino C 1-4 alkyl (meth) acrylate such as aminoethyl (meth) acrylate, N, N-diethylaminoethyl (meth) acrylate], (meth) acryloylmorpholine, vinylpyridine (2-vinyl pyridine, 4-vinyl pyridine, etc.), N-vinyl carbazole, etc. ⁇ , radical polymerizable monomer having an amide group or a substituted amide group ⁇ eg (meth) acrylamide monomer [eg (meth) acrylamide N-substituted (meth) acrylamides (eg N Isopropyl (meth)
- Hydroxyalkyl vinyl ethers such as 2-hydroxyethyl vinyl ether
- radical polymerizable monomers having a carboxyl group for example, C 3 -3 such as alkene carboxylic acid (for example, (meth) acrylic acid, crotonic acid, 3-butenoic acid, etc.) etc.
- alkene carboxylic acid alkene dicarboxylic acids (e.g., itaconic acid, maleic acid, maleic anhydride, C 4-8 alkene dicarboxylic acid or anhydride such as fumaric acid), and vinyl benzoate], carbonyl group Radical polymerizable monomer having ⁇ e.g., acyl acetoxy alkyl (meth) acrylates [for example, 2- etc.
- (acetoacetoxy) C 2-4 alkyl (meth) acrylates such as (acetoacetoxy) ethyl (meth) acrylate], etc. ⁇ , epoxy Radical polymerizable monomer having a group [eg, alkenyl glycidyl ether (eg, C 3-6 alkenyl-glycidyl ether such as allyl glycidyl ether), glycidyl ether such as glycidyl (meth) acrylate], radical polymerizable having thio group monomer ⁇ e.g., have a thio group such as alkylthioalkyl (meth) acrylates [for example, 2- (methylthio) ethyl (meth) (C 1-4 alkylthio) C 1-4 alkyl, such as acrylates (meth) acrylate] That (meth) acrylates ⁇ , C 6-10 aromatic, such as a sulfo group (or a
- the radical polymerizable monomer having a typical functional group includes a (meth) acrylic monomer having a functional group [for example, aminoalkyl (meth) acrylate, (meth) acrylic acid, glycidyl (meth) acrylate, thio group (Meth) acrylate etc.] and the like are included.
- the graft chain preferably has a functional group (such as the functional group exemplified above), although it depends on the application.
- a functional group is preferably a graft component having a functional group as described above (particularly a functional group).
- the graft chain is a functional group having a relatively high affinity for a substance to be adsorbed such as a metal, such as an amino group (or imino group), a substituted amino group, an amide group, and a substituted amide group.
- a carboxyl group preferably has a carboxyl group, a carbonyl group (ketone group), a thio group, a sulfo group or the like.
- These functional groups are particularly suitable for metal adsorption applications because they are easily bonded to metals by coordination or the like.
- these functional groups from the viewpoint of adsorption, they have functional groups [ionic functional groups (anionic groups, cationic groups)] that can easily form ions such as carboxyl groups and sulfo groups.
- anionic group anionic functional group
- a multidentate functional group is also preferable.
- the radical polymerizable monomer preferably contains a radical polymerizable monomer having a functional group as described above, but may be combined with a radical polymerizable monomer having no functional group.
- the ratio of the radical polymerizable monomer having a functional group to the entire graft component (radical polymerizable monomer) is, for example, 20 mol%. It can be selected from the above range (for example, 25 to 100 mol%), 30 mol% or more (for example, 40 to 100 mol%), preferably 50 mol% or more (for example, 60 to 100 mol%), and more preferably 70 mol%. It may be at least mol% (for example, 80 to 100 mol%), particularly at least 90 mol%.
- the graft chain may be composed only of a polymer chain, and may have a polymer chain and a modified unit.
- a polymer chain (or modified polymer chain) having such a modified unit for example, it has a polymer chain and a chain (unit or unit) derived from a compound capable of binding by reacting with a functional group of the polymer chain. Examples include polymer chains.
- the graft chain has a functional group (or a functional group capable of multidentate coordination or a multidentate functional group) in a form capable of multidentate coordination (multidentate coordination to a metal atom). It is preferable. It seems that it is easy to form a strong bond with a metal when it has a functional group in such a form, and it is excellent in the metal adsorption ability.
- the form capable of multidentate coordination is not particularly limited.
- a graft chain is a unit or a unit of a compound capable of multidentate coordination (polydentate coordination compound) [for example, a functional group such as an iminodiacetic acid unit.
- a unit containing at least a carboxyl group as a group, an acetylacetone unit, a unit in which an adjacent carbon atom is substituted with a functional group (hydroxyl group, carboxyl group, etc.) for example, a unit in which a hydroxyl group is substituted on an adjacent carbon atom such as a glucamine unit) Etc.
- Such a functional group in a form capable of multidentate coordination is, for example, (1) a method using a radical polymerizable monomer having a functional group as a graft component as described above (or a unit of a compound capable of multidentate coordination). Or a method using a graft component having a unit), (2) using a radical polymerizable monomer having a functional group (A) as a graft component, and reacting with the introduced functional group (A) to form a bond.
- a method of reacting a compound having a functional group (B1) and a functional group (B2) (or a method of reacting a functional group (B1) and a compound having a unit or unit of a multidentate compound) (3) It can be introduced into the graft chain by a method of combining them.
- an acetylacetone unit can be directly introduced into a graft chain by using 2- (acetoacetoxy) ethyl (meth) acrylate or the like as a graft component.
- the iminoacetic acid unit and the glucamine unit are functional groups that can be bonded to the graft chain by reacting with an imino group (or amino group) of iminoacetic acid, glucamine or N-substituted glucamine (such as N-methylglucamine) in advance.
- an epoxy group for example, a radical polymerizable monomer having an epoxy group such as glycidyl (meth) acrylate is used as a graft component
- iminodiacetic acid, glucamine or N-substituted glucamine Can be introduced.
- the ratio of the functional group in the form capable of multidentate coordination (multidentate functional group) to the entire functional group in the graft chain is, for example, 5 mol% or more (for example, 8 to 95 mol%), preferably 10 mol% or more (eg 15 to 90 mol%), more preferably 20 mol% or more (eg 25 to 80 mol%), especially 30 mol% or more (eg 35 To 70 mol%), and usually about 10 to 90 mol% (for example, 15 to 80 mol%, preferably 20 to 70 mol%, more preferably 30 to 60 mol%).
- the functional group in a form capable of multidentate coordination is calculated using a plurality of functional groups capable of multidentate coordination as one functional group (for example, an acetylacetone unit or an iminodiacetic acid unit includes a plurality of functional groups. However, it is calculated as one functional group).
- the graft polymerization rate with respect to the ethylene-vinyl alcohol copolymer can be selected depending on the application and the like, for example, 30% or more (for example, 40 to 2000%), preferably 50% or more (by weight) ( For example, it may be 70 to 1500%), more preferably 80% or more (for example, 85 to 1200%), particularly 90% or more (for example, 95 to 1000%).
- the graft polymerization rate with respect to the ethylene-vinyl alcohol copolymer is, for example, 100% or more (for example, 120 to 1800%), preferably 130% or more (for example, 140 to 1500%) on a weight basis, Preferably 150% or more (eg 170 to 1300%), in particular 180% or more (eg 190 to 1000%), usually 200% or more [eg 200 to 1500%, preferably 220% or more (eg 240 to 1200). %), More preferably 250% or more (for example, 260 to 900%)].
- the graft polymer may have wet heat adhesiveness.
- the wet heat adhesiveness can be imparted to the graft polymer usually by using an ethylene-vinyl alcohol copolymer having wet heat adhesiveness.
- the other resin may be any resin that is not an ethylene-vinyl alcohol copolymer.
- polyolefin resin polyethylene resin (polyethylene, etc.), polypropylene resin (eg, polypropylene, propylene-ethylene copolymer, etc.) Propylene copolymers), (meth) acrylic resins, vinyl chloride resins, styrene resins (such as polystyrene), polyester resins, polyamide resins, polycarbonate resins, polyurethane resins, thermoplastic elastomers, cellulose Resin (cellulose ether such as methylcellulose, hydroxyalkylcellulose such as hydroxyethylcellulose, carboxyalkylcellulose such as carboxymethylcellulose), polyalkylene glycol resin (polyethylene Oxide, polypropylene oxide, etc.), polyvinyl resins (polyvinyl pyrrolidone, polyvinyl ether, polyvinyl acetal, etc.), acrylic copo
- non-wet heat adhesive resins include polyolefin resins (polypropylene resins, etc.), (meth) acrylic resins, vinyl chloride resins, styrene resins, polyester resins (aromatic polyester resins).
- Polyamide-based resin, polycarbonate-based resin, polyurethane-based resin, thermoplastic elastomer, etc., and wet heat adhesive resins include aliphatic polyester resins (for example, polylactic acid-based resins such as polylactic acid), cellulose-based resins, Examples include polyalkylene glycol resins, polyvinyl resins, acrylic copolymers, and modified vinyl copolymers.
- the other resin may be composed of at least a non-wet heat adhesive resin.
- polypropylene resins for example, polypropylene resins, styrene resins, polyester resins, and polyamide resins are preferable, and polyester resins and polyamide resins are particularly preferable.
- these resins are excellent in balance of heat resistance, dimensional stability, and fiber forming property, and can be suitably used.
- these resins generate a relatively small amount of radicals when irradiated with an electron beam, that is, the molecular chain in the resin is not easily broken by an electron beam or the like, and the strength is hardly lowered, or the generation of radicals is small. Has the property that graft polymerization hardly occurs. Resins that are easy to graft polymerize tend to generate radicals.
- the fiber structure when the fiber structure is composed of a large number of wet heat adhesion points, the structure may be sufficiently maintained even if there is some deterioration of the core. Therefore, other resin may contain at least these resins. Further, these resins are usually non-wet heat adhesive resins having a melting point higher than that of the ethylene-vinyl alcohol copolymer, and are also suitable for wet heat bonding as described later.
- polyester resins include aromatic polyester resins such as poly C 2-4 alkylene arylate resins (polyethylene terephthalate (PET), polytrimethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, etc.), particularly polyethylene such as PET.
- PET polyethylene terephthalate
- a terephthalate resin is preferred.
- the polyethylene terephthalate-based resin includes other dicarboxylic acids (for example, isophthalic acid, naphthalene-2,6-dicarboxylic acid, phthalic acid, 4,4′-diphenylcarboxylic acid, bis (carboxyphenyl) ethane.
- diols eg, diethylene glycol, 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, cyclohexane-1,4-dimethanol, Units composed of polyethylene glycol, polytetramethylene glycol, etc.
- diols eg, diethylene glycol, 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, cyclohexane-1,4-dimethanol, Units composed of polyethylene glycol, polytetramethylene glycol, etc.
- Units composed of polyethylene glycol, polytetramethylene glycol, etc. may be included at a ratio of about 20 mol% or less.
- Polyamide resins include polyamides 6, polyamides 66, polyamides 610, polyamides 10, polyamides 12, polyamides 6-12, and other aliphatic polyamides and copolymers thereof, half-synthesized from aromatic dicarboxylic acids and aliphatic diamines. Aromatic polyamide is preferred. These polyamide-based resins may also contain other copolymerizable units.
- the other resin may have a graft chain (polymer chain obtained by polymerizing the graft component) depending on the resin to be selected.
- the graft component may be polymerized to another resin.
- the graft chain is usually mostly bonded to an ethylene-vinyl alcohol polymer, and in particular, it is not graft-polymerized as another resin (or When a resin (such as aromatic polyester resin) is selected, it may be bonded only to the ethylene-vinyl alcohol polymer.
- Ethylene-vinyl alcohol polymers are often more easily graft-polymerized than other resins, and since they constitute a large part of the fiber surface, graft polymerization is usually carried out using ethylene-vinyl alcohol. It seems to proceed in the polymer.
- a resin that can be graft-polymerized for example, a polypropylene-based resin
- the graft polymerization may proceed in the other resin.
- the graft polymerization conditions for example, the electron beam irradiation conditions
- the graft polymerization may proceed mainly in the ethylene-vinyl alcohol copolymer depending on the application, and vice versa.
- a polypropylene resin is excellent in hydrolysis resistance (particularly alkali hydrolysis), and as in the former, when graft polymerization proceeds mainly in an ethylene-vinyl alcohol copolymer, By preventing the generation of radicals or degradation due to graft polymerization, it has high hydrolysis resistance, but has excellent solvent resistance derived from ethylene-vinyl alcohol copolymer and characteristics derived from high graft polymerization rate. Bicomponent fibers or fiber structures can be obtained.
- the ratio of the non-wet heat adhesive resin (for example, at least one selected from a polyester resin and a polyamide resin) to the entire other resin is 50% by weight or more ( For example, it may be 60 to 100% by weight), preferably 70% by weight or more (for example, 80 to 100% by weight), and more preferably 90% by weight or more (for example, 95 to 100% by weight).
- the ratio of the wet heat adhesive resin to 100 parts by weight of the ethylene-vinyl alcohol copolymer is 50. It may be not more than parts by weight (for example, 1 to 40 parts by weight), preferably not more than 30 parts by weight (for example, 1 to 20 parts by weight), more preferably not more than 10 parts by weight (for example, 1 to 8 parts by weight). .
- the structure of the composite fiber is not particularly limited as long as the structure has at least a graft polymer (or ethylene-vinyl alcohol copolymer, hereinafter the same) on the surface thereof.
- the cross-sectional structure of the composite fiber occupying the surface of the graft polymer is, for example, a core-sheath type, a sea-island type, a side-by-side type, or a multi-layer type, or a radial type Type, random composite type, and the like.
- the core-sheath structure that is, the structure of the composite fiber, is a core formed of a sheath part made of a graft polymer and a core part made of another resin.
- a sheath-type composite fiber that is, a core-sheath structure in which the sheath part is composed of an ethylene-vinyl alcohol copolymer
- an ethylene-vinyl alcohol copolymer which is a raw material for graft polymerization, covers the entire surface of the fiber, and the graft polymerization rate can be increased efficiently.
- the presence of the core in the fiber makes it possible to efficiently fix the sheathed ethylene-vinyl alcohol copolymer that swells or shrinks during graft polymerization, and as a result, the graft polymerization efficiency can be improved efficiently.
- the ethylene-vinyl alcohol copolymer constituting the sheath is easy to permeate (contact) the graft component due to its hydrophilicity and the generated radical (active point) is relatively stable. The effect of fixing the ethylene-vinyl alcohol copolymer as described above is combined, and the graft polymerizability seems to be further promoted.
- this structure is also preferable from the viewpoint of easily obtaining a fiber structure having a high adhesiveness and capable of achieving both moderate voids and high strength.
- the cross-sectional shape of the composite fiber is not limited to a general solid cross-sectional shape such as a round cross-section or an irregular cross-section [flat shape, elliptical shape, polygonal shape, etc.], and may be a hollow cross-sectional shape.
- the composite fiber may have a graft polymer at least on a part of the fiber surface, but preferably has a graft polymer continuous in the length direction on the fiber surface.
- the coverage of the graft polymer (or EVOH) (or the ratio of the graft polymer in the entire surface of the composite fiber) may be, for example, 35% or more, preferably 50% or more, and more preferably 80% or more. . As described above, in the core-sheath type composite fiber, the coverage is 100% (almost 100%).
- / 70 for example, 94/6 to 35/65
- more preferably 93/7 to 40/60 for example, 92/8 to 45/55
- 90/10 to 50/50 for example, 88/12 to 55/45) or about 98/2 to 15/85 (for example, 95/5 to 30/70).
- the proportion of graft chains is the total amount of the ethylene-vinyl alcohol copolymer and other resins.
- 10 parts by weight or more for example, 15 to 1800 parts by weight
- 20 parts by weight or more for example, 25 to 1500 parts by weight
- more preferably 30 parts by weight or more for example, 35 parts by weight
- To 1200 parts by weight particularly 40 parts by weight or more (for example, 45 to 1000 parts by weight).
- the ratio of the graft chain to 100 parts by weight of the total amount of the ethylene-vinyl alcohol copolymer and other resins is, for example, 50 parts by weight or more (for example, 60 to 1500 parts by weight), preferably 70 parts by weight or more. (For example, 80 to 1200 parts by weight), more preferably 100 parts by weight or more (for example, 110 to 1000 parts by weight), particularly 120 parts by weight or more (for example, 130 to 900 parts by weight), particularly preferably 150 parts by weight or more ( For example, it may be 160 to 800 parts by weight.
- the ratio of such a graft chain is synonymous with the graft-polymerization rate (%) with respect to the whole ethylene vinyl alcohol type copolymer and other resin.
- the ratio of the graft chain bonded to the ethylene-vinyl alcohol copolymer to the graft chain bonded to the other resin can be appropriately selected.
- the former / the latter (weight ratio) 99/1 to 1/99 (for example, 99/1 to 3/97), preferably 95/5 to 10/90, more preferably 93 / It may be about 7 to 15/85 (for example, 90/10 to 17/83), particularly about 88/12 to 20/80 (for example, 85/15 to 25/75).
- such a ratio can indirectly determine the graft polymerization rate (or polymerization amount) bonded to another resin, for example, as follows. Graft polymerization rate (or polymerization amount) in the composite fiber A using a resin that forms a graft chain as another resin (or a resin that undergoes graft polymerization), and a resin that does not form or hardly forms a graft chain as another resin ( First, ethylene-vinyl in the composite fiber A is obtained using the graft polymerization rate (or polymerization amount) in the composite fiber B separately prepared in the same manner except that a resin that does not undergo graft polymerization or hardly graft polymerization) is used.
- the graft polymerization rate (or polymerization amount) with respect to the alcohol-based copolymer is obtained, and the graft polymerization rate (or polymerization amount) with respect to another resin in the composite fiber A obtained from this value is obtained, and the above ratio can be calculated.
- the average fineness of the composite fiber can be selected from the range of, for example, about 0.01 to 100 dtex depending on the application, preferably 0.1 to 50 dtex, more preferably 0.5 to 30 dtex (particularly 0.8 to 10 dtex). Degree. When the average fineness is within this range, the fiber has sufficient strength, and when wet-heat bonding is performed, the balance with the expression of wet-heat adhesiveness is excellent.
- the composite fiber before being subjected to graft polymerization (or having no graft chain) (that is, composed of an ethylene-vinyl alcohol copolymer and another resin, and at least a part of the fiber surface is ethylene vinyl alcohol-based)
- the average fineness of the composite fiber composed of a copolymer can be selected from the range of, for example, about 0.01 to 80 dtex, preferably 0.05 to 50 dtex, more preferably 0.1 to 30 dtex, depending on the application. (Especially about 1 to 10 dtex).
- the average fiber length of the composite fibers can be selected from the range of about 10 to 100 mm, preferably about 20 to 80 mm, more preferably about 30 to 65 mm (particularly about 35 to 55 mm). Also good. When the average fiber length is within this range, the fibers are sufficiently entangled, so that the mechanical strength of the fiber structure described later is improved.
- the crimp rate of the composite fiber is, for example, about 1 to 50%, preferably 3 to 40%, more preferably 5 to 30% (particularly 10 to 20%).
- the number of crimps is, for example, about 1 to 100 pieces / inch, preferably about 5 to 50 pieces / inch, and more preferably about 10 to 30 pieces / inch.
- a composite fiber when used as a spun yarn, it is used as a spun yarn by a general method using raw cotton. Further, when the filament yarn is used, the same fiber as the fineness is used, and after spinning and drawing, false twisting is performed according to the purpose or the filament is used as it is.
- mixing with other fibers as described below is performed by mixing in a general manner in both spun yarn and filament yarn.
- the composite fiber includes conventional additives such as stabilizers (heat stabilizers such as copper compounds, ultraviolet absorbers, light stabilizers, antioxidants, etc.), fine particles, colorants, antistatic agents, flame retardants, A plasticizer, a lubricant, a crystallization rate retarder, and the like may be contained. These additives can be used alone or in combination of two or more. These additives may be carried on the surface of the fiber or may be contained in the fiber.
- the fiber structure (molded body) of the present invention is formed of a fiber assembly including the composite fiber.
- the fiber assembly may be composed of only composite fibers or may contain other fibers.
- polyester fibers polyethylene terephthalate fibers, polytrimethylene terephthalate fibers, polybutylene terephthalate fibers, polyethylene naphthalate fibers and other aromatic polyester fibers
- polyamide fibers polyamide 6, Polyamide 66, polyamide 11, polyamide 12, polyamide 610, polyamide 612 and other aliphatic polyamide fibers, semi-aromatic polyamide fibers, polyphenylene isophthalamide, polyhexamethylene terephthalamide, poly p-phenylene terephthalamide and other aromatic polyamides Fiber), polyolefin fiber (poly C 2-4 olefin fiber such as polyethylene and polypropylene), acrylic fiber (acrylonitrile-vinyl chloride copolymer) Acrylonitrile fibers having acrylonitrile units, etc.), polyvinyl fibers (polyvinyl acetal fibers, etc.), polyvinyl chloride fibers (
- Fibers polyvinylidene chloride fibers (fibers such as vinylidene chloride-vinyl chloride copolymers, vinylidene chloride-vinyl acetate copolymers), polyparaphenylene benzobisoxazole fibers, polyphenylene sulfide fibers, cellulose fibers (for example, , Rayon fiber, acetate fiber, etc.). These other fibers can be used alone or in combination of two or more.
- polyvinylidene chloride fibers fibers such as vinylidene chloride-vinyl chloride copolymers, vinylidene chloride-vinyl acetate copolymers
- polyparaphenylene benzobisoxazole fibers polyphenylene sulfide fibers
- cellulose fibers for example, Rayon fiber, acetate fiber, etc.
- the other fiber may be either a wet heat adhesive fiber or a non-wet heat adhesive fiber, but in the case where the fiber structure is formed by wet heat adhesion, the non-wet heat adhesive fiber can be usually used.
- Cellulosic fibers include natural fibers (cotton, wool, silk, hemp, etc.), semi-synthetic fibers (acetate fibers such as triacetate fiber), regenerated fibers (rayon, polynosic, cupra, lyocell (for example, registered trademark name: “ Tencel "etc.)).
- semi-synthetic fibers such as rayon can be suitably used, and a highly hydrophilic fiber structure can be obtained.
- polyolefin fibers when importance is attached to lightness, it is preferable to use, for example, polyolefin fibers, polyester fibers, polyamide fibers, and particularly polyester fibers (polyethylene terephthalate fiber, etc.) that have an excellent balance of various properties.
- polyester fibers polyethylene terephthalate fiber, etc.
- polyester fibers polyethylene terephthalate fiber, etc.
- average fineness and average fiber length of other fibers can be selected from the same range as that of the composite fiber.
- the ratio of the composite fiber in the fiber assembly can be selected from the range of 10% by weight or more (for example, 30% by weight or more), and is usually 50% by weight or more, preferably 60% by weight or more, more preferably 70% by weight. % Or more, particularly 80% by weight or more.
- the fiber assembly may contain a conventional additive (for example, the additive exemplified in the section of the composite fiber).
- the fiber structure is formed of a fiber assembly (an assembly of fibers including the composite fiber).
- the shape (or form) of the fiber structure is usually a sheet (or plate or fabric), although it depends on the application.
- the structure of the fiber structure can be selected according to the use, and may be a nonwoven fabric (nonwoven fabric structure), a woven fabric (or a woven fabric structure or a knitted fabric, for example, a woven fabric, a knitted fabric, etc.).
- a nonwoven fabric such as a nonwoven fabric having a structure in which fibers are heat-sealed
- warp knitting such as double raschel
- a fiber assembly (or composite fiber) is usually composed of an ethylene-vinyl alcohol copolymer (or graft polymer) having wet heat adhesion
- the fiber assembly (or composite fiber) is fused.
- Fiber structure having a non-woven fiber structure (fused by wet heat adhesion) [fiber assembly (or composite fiber, ethylene-vinyl alcohol copolymer in composite fiber composite fiber) fixed fiber by fusion
- a fiber structure in the form of a nonwoven fabric (or non-woven fiber structure)] may be suitably used.
- the apparent density of the fiber structure can be selected, for example, from the range of about 0.05 to 0.7 g / cm 3 , for example, 0.05 to 0.5 g / cm 3 , preferably 0.08 to 0.4 g / cm 3 . cm 3 , more preferably 0.09 to 0.35 g / cm 3 , especially about 0.1 to 0.3 g / cm 3 , usually 0.05 to 0.35 g / cm 3 (for example, 0 .05 to 0.3 g / cm 3 ). If the apparent density is too small or too large, there is a possibility that the substance to be adsorbed cannot be sufficiently adsorbed in the filter application.
- the fiber structure of the present invention has a fiber structure to be treated before grafting [that is, a composite in which at least a part of the fiber surface is composed of an ethylene-vinyl alcohol copolymer. It can also be obtained by polymerizing a graft component to a fiber structure (processed fiber structure) formed of a fiber assembly (processed fiber assembly) including at least fibers. In such cases, the apparent density usually tends to increase after graft polymerization.
- the difference between the apparent density of the fiber structure and the apparent density of the treated fiber structure is, for example, 0.05 to 0.5 g / cm 3 , preferably 0.1 to 0.4 g / cm 3 , and more preferably May be about 0.1 to 0.3 g / cm 3 .
- Basis weight of the fibrous structure for example, 5 ⁇ 7000g / m 2 (e.g., 10 ⁇ 6000g / m 2) , preferably 30 ⁇ 5000g / m 2 (e.g., 50 ⁇ 4000g / m 2) , more preferably from 100 to It may be about 3500 g / m 2 (for example, 150 to 3000 g / m 2 ), particularly about 200 to 3000 g / m 2 (for example, 250 to 2500 g / m 2 ), and usually about 50 to 3000 g / m 2. Also good. If the basis weight is too small, it is difficult to secure hardness or ensure sufficient adsorption performance for filter applications. If the basis weight is too large, sufficient adsorption performance cannot be ensured or if wet heat bonding is used. In some cases, it may be difficult to obtain a uniform structure in the thickness direction.
- the basis weight tends to be larger than the basis weight of the fiber structure to be treated, similarly to the apparent density.
- the difference between the basis weight of the fiber structure and the basis weight of the treated fiber structure is 10 to 5000 g / m 2 (eg, 20 to 4500 g / m 2 ), preferably 25 to 4000 g / m 2 (eg, 30 About 3000 to 3000 g / m 2 ), more preferably about 40 to 2500 g / m 2 (for example, 50 to 2000 g / m 2 ), particularly about 60 to 1500 g / m 2 (for example, 70 to 1000 g / m 2 ). .
- the thickness of the fiber structure can be selected according to the application and is not particularly limited.
- the thickness is about 0.5 to 100 mm, preferably 1 to 50 mm, more preferably about 1.5 to 30 mm. It is.
- the fiber structure can be selected according to the use, but it is preferable that the fiber structure has an appropriate void from the viewpoint of adsorbing a substance to be adsorbed in a filter application or the like.
- the air permeability is 5 to 500 cm 3 / cm 2 / sec (for example, 7 to 450 cm 3 / cm 2 / sec), preferably 10 to 400 cm 3 / cm in terms of the air permeability according to the Frazier method. 2 / second (for example, 10 to 350 cm 3 / cm 2 / second), more preferably about 20 to 300 cm 3 / cm 2 / second, and usually about 30 to 260 cm 3 / cm 2 / second.
- it may be about 5 to 400 cm 3 / cm 2 / sec (for example, 5 to 300 cm 3 / cm 2 / sec).
- the air permeability tends to be the same as or smaller than the air permeability of the treated fiber structure, contrary to the apparent density.
- the difference between the air permeability of the treated fiber structure by the Frazier method and the air permeability of the fiber structure by the Frazier method is 0 to 400 cm 3 / cm 2 / sec, preferably 1 to 300 cm 3 / cm 2.
- / Second (for example, 3 to 280 cm 3 / cm 2 / second), more preferably about 5 to 250 cm 3 / cm 2 / second, and usually about 5 to 200 cm 3 / cm 2 / second.
- the air permeability of the fiber structure to be treated is not sufficiently in contact with the graft component even in consideration of such swelling. You may adjust so that it may become the space
- the fiber adhesion rate by fusion is, for example, 85% or less (eg, 1 to 85%), preferably It may be about 3 to 70%, more preferably about 5 to 60% (particularly 10 to 35%), and usually about 20 to 80% (for example, 30 to 75%).
- the fiber adhesion rate indicates the ratio of the number of cross sections of two or more fibers bonded to the total number of cross sections of the non-woven fiber cross section. Therefore, a low fiber adhesion rate means that a ratio of a plurality of fibers fused to each other (a ratio of fibers fused by fusing) is small.
- the fiber structure constituting the non-woven fiber structure is bonded at the contact point of each fiber.
- This bonding point extends from the surface of the molded body to the inside (center) and the back surface along the thickness direction. It is preferable that they are uniformly distributed. Therefore, in the cross section in the thickness direction of the molded body, it is preferable that the fiber adhesion rate in each region divided in three in the thickness direction is in the above range. Further, the difference between the maximum value and the minimum value of the fiber adhesion rate in each region is 20% or less (for example, 0.1 to 20%), preferably 15% or less (for example, 0.5 to 15%), and more preferably Is 10% or less (for example, 1 to 10%).
- the “region divided into three equal parts in the thickness direction” means each region divided into three equal parts by slicing in a direction orthogonal to the thickness direction of the fiber structure.
- single fiber i.e., fiber present alone without adhesive, single fiber end surface
- occurrence frequency of is not particularly limited, for example, any of 1 mm 2 of the cross section
- the frequency of existing single fibers may be 100 pieces / mm 2 or more (for example, about 100 to 300 pieces), but in particular, when mechanical properties are required rather than light weight,
- the presence frequency is, for example, 100 pieces / mm 2 or less, preferably 60 pieces / mm 2 or less (eg, 1 to 60 pieces / mm 2 ), more preferably 25 pieces / mm 2 or less (eg, 3 to 25 pieces / mm 2 ).
- the presence frequency of the single fiber is too high, the fiber is less fused and the strength of the fiber structure is lowered.
- the presence frequency of a single fiber is measured as follows. That is, the range corresponding to 1 mm 2 selected from the scanning electron microscope (SEM) photograph of the cross section of the compact is observed, and the number of single fiber cross sections is counted. Arbitrary several places (for example, 10 places selected at random) are observed in the same manner, and the average value per unit area of the single fiber end face is defined as the existence frequency of single fibers. At this time, all the number of fibers in a single fiber state are counted in the cross section.
- SEM scanning electron microscope
- the tensile strength at break of the fiber structure varies greatly depending on the application, purpose and use form. For example, it is 15000 N / 5 cm or less, preferably 30 to 10000 N / 5 cm, more preferably about 200 to 8000 N / 5 cm. There may be.
- the fiber structure of the present invention often has sufficient strength even when irradiated with radiation.
- the retention rate of the tensile breaking strength with respect to the treated fiber structure is, for example, 40% or more (for example, 45 to 100%), preferably 50% or more (for example, 55 to 100%), and more preferably 60% or more. (For example, 70 to 100%).
- the breaking elongation of the fiber structure is, for example, 10% or more (for example, 15 to 200%), preferably 15% or more (for example, 15 to 180%), more preferably 20% or more (for example, 25 to 25%). 150%).
- the composite fiber or fiber structure of the present invention can be applied to various uses depending on the form and type of graft chain (graft component).
- a fiber structure (or composite fiber) in which a functional group is introduced into a graft chain can be used as an adsorbent (or filter) for adsorbing or separating an adsorbed substance.
- the fiber structure is suitable as a filter for adsorbing (or recovering) a metal as an adsorbed substance.
- the composite fiber or fiber structure of the present invention is excellent in metal adsorption because the graft component is polymerized at a high graft polymerization rate and has many functional groups capable of adsorbing metal on the fiber surface. .
- the metal can be adsorbed more efficiently.
- the conjugate fiber or fiber structure of the present invention has a high graft polymerizability, it is very easy to control the optimum graft polymerization rate according to various functional groups. it can. Therefore, it is optimal for a material having a wider range of functions.
- an alkali or alkaline earth metal for example, lithium, sodium, rubidium, cesium, Periodic Table Group 3 metals such as beryllium, magnesium, strontium, barium), transition metals (eg, scandium, yttrium, lanthanoids (samarium, terbium, etc.); periodic table Group 4 metals such as titanium, zirconium, hafnium; vanadium Periodic table Group 5 metals such as chromium, molybdenum and tungsten; Group 7 metals such as manganese and rhenium; Iron, nickel, cobalt, ruthenium, rhodium and palladium , Rhenium, osmium, iridium, Periodic Table Group 8-10 metals such as gold; Periodic Table Group 11 metals such as copper, silver, and gold), Periodic Table Group 12
- an alkali or alkaline earth metal for example, lithium, sodium, rubidium, cesium, Periodic Table Group 3 metals such as beryllium
- the fiber structure (or adsorbent) of the present invention is a rare metal (for example, lithium, rubidium, cesium, beryllium, strontium, barium, scandium, yttrium, lanthanoid, titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum.
- a rare metal for example, lithium, rubidium, cesium, beryllium, strontium, barium, scandium, yttrium, lanthanoid, titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum.
- Tungsten manganese, rhenium, nickel, cobalt, ruthenium, rhodium, palladium, rhenium, iridium, boron, gallium, indium, thallium, germanium, antimony, bismuth, selenium, tellurium, etc., especially rare earths (or rare earths, scandium, yttrium) Lanthanoids) can be adsorbed, and is suitable as a filter for adsorbing these metals.
- the fiber structure (adsorbent) of the present invention can also selectively adsorb a specific metal (for example, rare metal, rare earth, etc.) from a mixed system containing a plurality of metals.
- a specific metal for example, rare metal, rare earth, etc.
- Metal can be adsorbed by bringing a liquid containing metal (metal-containing liquid) into contact with an adsorbent, for example.
- a liquid containing metal metal-containing liquid
- the metal-containing liquid and the adsorbent may be brought into contact with each other by immersing the adsorbent in the metal-containing liquid, or may be brought into contact with each other by circulating the metal-containing liquid through the filter-like fibrous structure (adsorbent). May be.
- adsorption conditions suitably (for example, pH adjustment etc.).
- the metal adsorbed on the fiber structure varies depending on the adsorption method with the fiber structure, but can be performed by selecting an optimum method depending on the individual state, for example, pH adjustment, acid washing, strong acid, It can be easily recovered by a method such as treatment with a reducing agent.
- the composite fiber (or fiber structure) of the present invention is not particularly limited.
- a composite fiber in which at least a part of the fiber surface is made of an ethylene-vinyl alcohol copolymer (hereinafter sometimes referred to as a treated composite fiber)
- a fiber structure formed of a previous fiber structure that is, a fiber assembly (treated fiber assembly) including at least a composite fiber in which at least a part of the fiber surface is composed of an ethylene-vinyl alcohol copolymer).
- Body hereinafter referred to as a treated fiber structure, etc.
- a treated fiber structure, etc. can be obtained by graft polymerization of a graft component constituting (forming) a graft chain.
- the composite fiber before being subjected to graft polymerization may be made into a fiber assembly, and then graft polymerization may be performed.
- the composite fiber of this invention is obtained.
- the treated composite fiber is fixed (and has an appropriate void), or the graft component is easily polymerized and is a composite fiber with another resin. In combination with this, it is easy to efficiently improve the graft polymerization rate.
- the large surface area and the tendency of the ethylene-vinyl alcohol copolymer to generate radicals also cause a high graft polymerization rate.
- the fiber structure to be treated can be obtained by a conventional method according to the structure.
- a web-like treated fiber assembly (treated fiber web) is treated with superheated or high-temperature steam (for example, superheated or treated at high temperature). It can be produced by spraying water vapor).
- high-temperature steam at a predetermined temperature (for example, about 70 to 150 ° C., preferably about 80 to 120 ° C., more preferably about 90 to 110 ° C.) is applied to the treated fiber web at a predetermined pressure (for example, It may be obtained by a method of spraying at 0.05 to 2 MPa, preferably 0.05 to 1.5 MPa, more preferably about 0.1 to 1 MPa.
- a predetermined pressure for example, It may be obtained by a method of spraying at 0.05 to 2 MPa, preferably 0.05 to 1.5 MPa, more preferably about 0.1 to 1 MPa.
- the method of graft polymerization with respect to the treated composite fiber or the treated fiber aggregate is not particularly limited, but radiation polymerization can be particularly preferably used.
- the radiation include ⁇ rays, ⁇ rays, ⁇ rays, electron beams, X rays, and the like, and ionizing radiation such as electron beams is particularly preferable.
- a graft component is brought into contact with (or attached to) a polymer to be treated or a treated fiber structure in which active species (radicals) are generated (or activated) by radiation irradiation and polymerized.
- Method pre-irradiation method
- Method of irradiating a treated composite fiber or treated fiber structure to which a graft component is attached to generate active species and polymerizing the graft component can be broadly divided.
- the active species are usually generated or generated mainly in the ethylene-vinyl alcohol copolymer as described above.
- pre-irradiation method it is preferable to perform radiation polymerization by the method (i) (pre-irradiation method).
- the active species generated in the treated composite fiber or treated fiber structure (or graft polymer) is relatively stable, if the pre-irradiation method is used, radiation can be grafted efficiently, It is easy to improve the polymerization rate.
- the pre-irradiation method not only the graft component attached as in the simultaneous irradiation method but also the graft component-containing liquid described later can be used to easily increase the amount of the graft component to be contacted through the graft polymerization reaction. This is also a factor for improving the graft polymerization rate.
- the method of contacting or adhering the graft component is not particularly limited, and may be a method of spraying the graft component, but is usually treated in a liquid containing the graft component (graft component-containing liquid). It is often performed by immersing the composite fiber or the treated fiber structure.
- the graft component-containing liquid may be composed of only the graft component when the graft component is a liquid, but is usually a mixed liquid containing the graft component and a solvent (or a dispersion medium) in many cases.
- the solvent is not particularly limited, and examples thereof include alcohols (alkanols such as methanol, ethanol, propanol and isopropanol), ethers (chain ethers such as diethyl ether and diisopropyl ether), and cyclic ethers such as dioxane and tetrahydrofuran.
- esters such as acetates such as ethyl acetate and butyl acetate
- ketones such as dialkyl ketones such as acetone and methyl ethyl ketone
- glycol ether esters ethylene glycol monomethyl ether acetate, propylene glycol monomethyl ether acetate, Cellosolve acetate, butoxycarbitol acetate, etc.
- cellosolves methylcellosolve, ethylcellosolve, butylcellosolve, etc.
- carbito S such as carbitol
- halogenated hydrocarbons methylene chloride, chloroform
- the graft component-containing liquid may be a graft component dispersion (emulsion, for example, an aqueous dispersion).
- a graft component dispersion emulsion, for example, an aqueous dispersion
- the pre-irradiation method in the dispersion may be able to improve the graft polymerization rate as compared with the case of performing in the solution.
- a dispersion liquid may contain the dispersing agent (or surfactant) normally.
- the surfactant is not particularly limited, and examples thereof include an anionic surfactant, a cationic surfactant, a nonionic surfactant (such as a surfactant having a polyoxyethylene unit), and an amphoteric surfactant. Etc., and a polymeric dispersant may be used. You may use a dispersing agent (dispersion stabilizer) individually or in combination of 2 or more types.
- the concentration of the graft component can be selected from the range of about 1 to 80% by weight, for example, 2 to 60% by weight (for example, 3 to 50% by weight), preferably 4 to 40% by weight. % (For example, 4.5 to 35% by weight).
- the concentration of the graft component may be about 5 to 50% by weight (for example, 5 to 30% by weight), preferably about 6 to 20% by weight, and more preferably about 7 to 15% by weight.
- the higher the concentration of the graft component the easier it is to improve the graft polymerization rate, but if it is too large, the emulsion particle diameter becomes too large and the diffusion rate decreases, making it difficult to react with the active species, resulting in grafting. It may be difficult to improve the polymerization rate.
- the appropriate ratio of the dispersant varies depending on the type of the dispersant, it is preferable to determine the ratio by appropriately checking the appropriateness.
- 1 to The amount may be about 1000 parts by weight, preferably about 2 to 800 parts by weight, more preferably about 3 to 500 parts by weight.
- the temperature of the graft component-containing liquid is not particularly limited, but is, for example, 10 to 150 ° C., preferably 20 to 120 ° C. More preferably, it may be about 30 to 90 ° C. (for example, 40 to 80 ° C.).
- the immersion time is not particularly limited, and may be about 1 minute to 24 hours, preferably about 5 minutes to 12 hours, and preferably about 10 minutes to 6 hours.
- Radiation irradiation conditions can be appropriately selected according to the type of radiation.
- the radiation dose may be, for example, about 1 to 1000 kGy, preferably 1 to 600 kGy, and more preferably about 5 to 300 kGy (for example, 10 to 200 kGy).
- the acceleration voltage may be, for example, about 5 to 800 kV, preferably about 10 to 500 kV, and more preferably about 50 to 200 kV.
- radiation irradiation may be usually performed in a sealed or inert atmosphere, and in order to prevent deactivation of active species in the pretreatment method, it is usually performed in an inert atmosphere when attaching the graft component. Also good. Further, the irradiation with radiation may be performed under cooling in order to efficiently prevent the deactivation of the active species.
- the treated composite fiber or treated fiber structure after being immersed in the graft component-containing liquid is separated from the graft component-containing liquid and washed as necessary.
- the treated composite fiber or treated fiber structure separated from the graft component-containing liquid may be allowed to cure (leave) for a predetermined time in order to advance graft polymerization. Curing may be performed under an inert atmosphere or under an active atmosphere (in an oxidizing atmosphere such as air).
- the curing time (reaction temperature) may be about 1 minute to 24 hours, preferably about 5 minutes to 12 hours, preferably about 10 minutes to 6 hours.
- the curing temperature is not particularly limited, and may be room temperature.
- heating for example, it may be about 40 to 120 ° C., preferably 45 to 100 ° C., more preferably about 50 to 80 ° C.
- the curing may be performed by covering (covering) the treated composite fiber or the treated fiber structure with a resin film or the like.
- a composite fiber or fiber structure is obtained as described above.
- a fiber structure is normally obtained as a sheet form (or plate shape)
- Conventional methods include, for example, compression molding, pressure forming (extrusion pressure forming, hot plate pressure forming, vacuum pressure forming, etc.), free blow molding, vacuum forming, bending, matched mold forming, hot plate forming, wet heat press forming. Thermoforming such as can be used.
- Weight per unit area (g / m 2 ) Measured according to JIS L1913 “Testing method for general short fiber nonwoven fabric”.
- Air permeability According to JIS L1096, it measured by the fragile type method.
- Fiber adhesion rate (%) (number of cross sections of fibers bonded two or more) / (total number of cross sections of fibers) ⁇ 100
- the fiber adhesion rate was calculated
- Graft polymerization rate It calculated by the following formula from the weight change before and after the graft polymerization treatment.
- the weight of the sample was measured on a sample dried at 60 ° C. under reduced pressure or at 100 ° C. for 2 hours without reducing the pressure. [(Weight after treatment (g) ⁇ weight before treatment (g)) / weight before treatment (g)] ⁇ 100 (%) (6)
- Iminodiacetic acid introduction ratio From the weight change before and after the iminodiacetic acid introduction treatment, the introduction ratio (%) of iminodiacetic acid (molecular weight 133) to the epoxy group of glycidyl methacrylate (GMA, molecular weight 142) was determined by the following formula. It was.
- the weight of the sample was measured for a sample dried at 60 ° C. for 2 hours under reduced pressure. ⁇ [(Weight after treatment (g) ⁇ weight before treatment (g)) / 133] / (weight of GMA contained in fiber structure (g) / 142) ⁇ ⁇ 100 (%) (7)
- Metal adsorption rate was measured as follows from the concentration change of the metal solution before and after the metal adsorption experiment. After the adsorption treatment, the absorbance of the solution is measured with a UV-VIS spectrophotometer (“UV-1700” manufactured by Shimadzu Corporation) using the remaining solution after removing the sample, and the absorbance at a plurality of metal concentrations is measured in advance.
- the concentration of the metal remaining in the solution was determined using the calibration curve prepared in this way. That is, since the metal concentration has almost no absorption in the visible region of the metal solution, the absorbance at 570 nm is measured by using a colorimetric analysis method in which color formation is performed by using complex formation between xylenol orange and metal. It was calculated
- a sample having a width of 5 cm and a length of 30 cm was cut out from each sample, and a tensile test was performed using a constant speed extension type tensile tester (manufactured by Shimadzu Corporation) with a grip distance of 20 cm.
- the obtained stress and the stress at the time of breaking the strain curve were read and used as evaluation values.
- the number of n was set to 5, and the average value of these was used as a numerical value.
- the tensile breaking strength was measured about the flow (MD) direction and width (CD) direction of the nonwoven fabric.
- a card web having a basis weight of about 31 g / m 2 was prepared by a card method, and four webs were stacked to form a card web having a total basis weight of about 125 g / m 2 . Two more card webs were stacked and transferred to a belt conveyor equipped with a 30 mesh, 120 mm wide stainless steel endless net.
- the belt conveyor which has the same metal mesh is equipped in the upper part of the metal mesh of this belt conveyor, and it rotated in the same direction at the same speed, and used the belt conveyor which can adjust the space
- the steam web is introduced into the steam jetting device provided in the lower conveyor, and steam treatment is performed by ejecting high-temperature steam of 0.1 MPa from this device in the thickness direction of the card web (perpendicularly).
- Treated fabric structure having a non-woven fiber structure [weight per unit area 250 g / m 2 , thickness 2 mm, apparent density 0.125 g / cm 3 , air permeability 58.5 cm 3 / cm 2 / sec, fiber adhesion rate (average 71%, surface 72%, center 67%, opposite surface 74%).
- a nozzle is installed in the lower conveyor so as to spray high-temperature steam toward the web via a conveyor net, and a suction device is installed in the upper conveyor.
- another jetting device which is a combination of the arrangement of the nozzle and the suction device reversed, is installed on the downstream side in the web traveling direction of the jetting device, and steam treatment is performed on both the front and back sides of the web. did.
- the hole diameter of the steam spray nozzle was 0.3 mm, and a steam spray device in which the nozzles were arranged in a line at a pitch of 2 mm along the width direction of the conveyor was used.
- the processing speed was 5 m / min, and the interval (distance) between the upper and lower conveyor belts on the nozzle side and the suction side was adjusted so as to obtain a treated fiber structure having a thickness of 2 mm.
- the nozzles were arranged on the back side of the conveyor belt so as to be almost in contact with the belt.
- Example 1 Put the treated fiber structure obtained in Synthesis Example 1 in a polyethylene bag, replace with nitrogen gas, and lay dry ice under the polyethylene bag to cool the electron beam irradiation device ((stock) )
- An electron beam (acceleration voltage 250 kV) was irradiated at an irradiation dose of 100 kGy using a product name “Curetron” manufactured by NHV Corporation.
- the fiber structure to be treated after electron irradiation was subjected to an aqueous dispersion containing glycidyl methacrylate (hereinafter referred to as GMA) in a proportion of 30% [GMA and polyoxygen in a proportion of about 7.5% by weight with respect to water.
- GMA aqueous dispersion containing glycidyl methacrylate
- a solution obtained by removing dissolved oxygen by bubbling with nitrogen gas was used as the aqueous dispersion.
- the weight ratio of the fiber structure to be treated and the aqueous dispersion was 1: 100.
- the graft polymerization rate of GMA to EVOH is 272% (the graft rate of GMA to the whole fiber structure is 136%), the basis weight is 590 g / m 2 , the thickness is 3.34 mm, and the apparent density is 0. .177 g / cm 3 , and air permeability was 44 cm 3 / cm 2 / sec.
- the tensile strength was 590 N / 5 cm and the width was 195 N / 5 cm.
- the tensile strength was 700 N / 5 cm in length, and the width was 200 N / 5 cm.
- the strength retention (strength after treatment / strength before treatment ⁇ 100) of the fiber structure calculated from these values was 84% for the vertical length and 98% for the width.
- the elongation at break was 35% for the length and 47% for the width.
- the tensile elongation of the fiber structure to be treated was 38% for the vertical length and 52% for the width.
- the physical property deterioration was not seen by electron beam irradiation, but it was favorable.
- Example 2 A fiber structure was obtained in the same manner as in Example 1, except that the aqueous dispersion was replaced with a 10% GMA aqueous dispersion.
- the graft polymerization rate of GMA to EVOH is 720% (the graft rate of GMA to the entire fiber structure is 360%)
- the basis weight is 1150 g / m 2
- the thickness is 4.32 mm
- the apparent density is 0. .266 g / cm 3
- air permeability was 21 cm 3 / cm 2 / sec.
- Example 3 A fiber structure was obtained in the same manner as in Example 1 except that the aqueous dispersion was replaced with a 5% GMA aqueous dispersion in Example 1.
- the graft polymerization rate of GMA to EVOH is 292% (the graft rate of GMA to the whole fiber structure is 146%)
- the basis weight is 615 g / m 2
- the thickness is 3.40 mm
- the apparent density is 0. .181 g / cm 3
- air permeability was 42 cm 3 / cm 2 / sec.
- Example 4 In Example 1, a fiber structure was obtained in the same manner as in Example 1 except that the aqueous dispersion was replaced with a 20% GMA aqueous dispersion.
- the graft polymerization rate of GMA to EVOH is 346% (the graft rate of GMA to the whole fiber structure is 173%)
- the basis weight is 683 g / m 2
- the thickness is 3.56 mm
- the apparent density is 0. 192 g / cm 3
- air permeability was 38 cm 3 / cm 2 / sec.
- Example 5 a fiber structure was obtained in the same manner as in Example 1 except that the aqueous dispersion was changed to a 20% GMA aqueous dispersion and the immersion time was changed to 30 minutes.
- the graft polymerization rate of GMA to EVOH is 394% (the graft rate of GMA to the entire fiber structure is 197%)
- the basis weight is 743 g / m 2
- the thickness is 3.69 mm
- the apparent density is 0. .201 g / cm 3
- air permeability was 35 cm 3 / cm 2 / sec.
- Example 6 In Example 1, a fiber structure was obtained in the same manner as in Example 1 except that the aqueous dispersion was changed to a 20% GMA aqueous dispersion and the immersion time was changed to 120 minutes.
- the graft polymerization rate of GMA to EVOH is 472% (the graft rate of GMA to the entire fiber structure is 236%)
- the basis weight is 840 g / m 2
- the thickness is 3.87 mm
- the apparent density is 0. .217 g / cm 3
- air permeability was 31 cm 3 / cm 2 / sec.
- Example 7 The fiber structure obtained in Example 1 was immersed in a solution (water 46.5%, dimethyl sulfoxide 50%) containing iminodiacetic acid at a ratio of about 3.5%, and reacted at 80 ° C. for 72 hours. Iminodiacetic acid units were introduced into the graft chain. In addition, 38.4 mol% of the GMA unit (epoxy group) constituting the graft chain reacted with iminodiacetic acid.
- the basis weight was 818 g / m 2
- the thickness was 3.22 mm
- the apparent density was 0.254 g / cm 3
- the air permeability was 28 cm 3 / cm 2. / Sec.
- Example 8 Place the treated fiber structure obtained in Synthesis Example 1 in a polyethylene bag, replace with nitrogen gas, and apply an electron beam irradiation device (trade name “Curetron” manufactured by NHV Corporation) to the treated fiber structure.
- An electron beam (acceleration voltage 250 kV) was irradiated at an irradiation dose of 250 kGy.
- the treated fiber structure after electron irradiation was immersed in an aqueous solution containing acrylic acid (hereinafter referred to as AA) at a rate of 17.5% at 50 ° C. for 60 minutes.
- AA acrylic acid
- the aqueous solution used what removed the dissolved oxygen by bubbling with nitrogen gas, and immersion was performed stirring an aqueous solution with a small dyeing machine.
- the weight ratio of the fiber structure to be treated and the solution was 1:25.
- the graft polymerization rate of AA to EVOH is 342% (the graft rate of AA to the entire fiber structure is 171%), the basis weight is 678 g / m 2 , the thickness is 3.55 mm, and the apparent density is 0. 191 g / cm 3 , and air permeability was 38 cm 3 / cm 2 / sec.
- Example 9 a fiber structure was obtained in the same manner as in Example 8 except that the solution was replaced with a 15% AA solution.
- the graft polymerization rate of AA to EVOH was 314% (the graft rate of AA to the whole fiber structure was 157%)
- the basis weight was 643 g / m 2
- the thickness was 3.47 mm
- the apparent density was 0 .185g / cm 3
- air permeability was 41cm 3 / cm 2 / sec.
- the tensile strength was 505 N / 5 cm and the width was 198 N / 5 cm.
- the tensile strength was 700 N / 5 cm in length and 200 N / 5 cm in width.
- the strength retention (strength after treatment / strength before treatment ⁇ 100) of the fiber structure calculated from these values was 72% for the vertical length and 99% for the horizontal width.
- the elongation at break was 31% for the vertical length and 43% for the width.
- the tensile elongation of the fiber structure to be treated was 38% for the vertical length and 52% for the width.
- the physical property deterioration was not seen by electron beam irradiation, but it was favorable.
- a card web having a basis weight of about 25 g / m 2 was prepared by a card method, and two sheets of this web were stacked to obtain a card web having a total basis weight of about 50 g / m 2 .
- This card web was transferred to a belt conveyor equipped with a 30-mesh, 120-mm-wide stainless steel endless net, passed through a hot-air treatment furnace, and a hot-fused body was formed between the fibers by hot air.
- the produced fiber structure was subjected to a thermocompression calendering treatment with a calender equipment comprising a cotton roll and a heated metal flat roll, and a non-woven fabric (weight per unit area 50 g / m 2 , thickness 0.2 mm, apparent density 0.25 g / cm 3).
- the air permeability was 250 cm 3 / cm 2 / sec).
- the obtained nonwoven fabric (to-be-processed fiber structure) was processed by the method similar to Example 8, and the fiber structure was obtained.
- the graft polymerization rate of AA to copolymer polypropylene is 60%
- the graft polymerization rate of AA to homopolypropylene is 20%
- the graft rate of AA to the entire fiber structure is 40%
- the basis weight is The thickness was 60.0 g / m 2
- the thickness was 0.25 mm
- the apparent density was 0.24 g / cm 3
- the air permeability was 229 cm 3 / cm 2 / sec.
- Example 2 of JP 2010-1392 A was additionally tested. That is, after an EVOH film (manufactured by Kuraray Co., Ltd., thickness 25 ⁇ m, basis weight 2.85 g / m 2 , density 1.14 g / cm 3 ) was placed in a thin plastic bag, this bag was replaced with nitrogen several times. Sealed the bag. Subsequently, the base material was irradiated with an electron beam at 100 kGy in a nitrogen atmosphere under dry ice cooling conditions to generate radical active sites.
- an EVOH film manufactured by Kuraray Co., Ltd., thickness 25 ⁇ m, basis weight 2.85 g / m 2 , density 1.14 g / cm 3
- the film after irradiation was immediately immersed in an aqueous solution (30 wt%) of vinylbenzyltrimethylammonium chloride (VBTMA) prepared in advance and substituted with nitrogen, and reacted for 24 hours while maintaining at 70 ° C. As a result, the graft ratio was 60%.
- VTMA vinylbenzyltrimethylammonium chloride
- Example 10 The fiber structure obtained by introducing the iminodiacetic acid unit obtained in Example 7 was placed in an aqueous solution (solution temperature 30 ° C., pH 6.5, containing trace amounts of sodium and nitric acid) containing samarium at a concentration of about 10 ppm for 2 hours. Soaked.
- the weight ratio between the fiber structure and the mixed solution was 1: 500.
- the fiber structure adsorbed samarium at an adsorption rate of 99.3%.
- Example 11 The fiber structure obtained in Example 8 was immersed in an aqueous solution (pH: about 2, containing a small amount of nitric acid) containing samarium at a concentration of 10 ppm at room temperature (about 20 ° C.) for 20 hours.
- the weight ratio between the fiber structure and the mixed liquid was 1:50.
- the fiber structure adsorbed samarium at an adsorption rate of 95%.
- Example 3 (Comparative Example 3) In Example 11, samarium was adsorbed in the same manner as in Example 11 except that the treated fiber structure obtained in Synthesis Example 1 was used instead of the fiber structure obtained in Example 8. The adsorption rate was 24%.
- Example 12 The fiber structure obtained in Example 8 was immersed in an aqueous solution (pH: about 2.3, containing a small amount of nitric acid) containing terbium at a concentration of 10 ppm at room temperature (about 25 ° C.) for 6 hours.
- the weight ratio between the fiber structure and the mixed liquid was 1:50.
- the fiber structure adsorbed terbium at an adsorption rate of 76%.
- Example 12 terbium was adsorbed in the same manner as in Example 12 except that the treated fiber structure obtained in Synthesis Example 1 was used instead of the fiber structure obtained in Example 8. The adsorption rate was 21%.
- a card web having a basis weight of about 30 g / m 2 was prepared by a card method, and four webs were stacked to obtain a card web having a total basis weight of about 120 g / m 2 .
- Two more card webs were stacked and treated fiber structure having a non-woven fiber structure in the same manner as in Synthesis Example 1 [weight per unit area 240 g / m 2 , thickness 2 mm, apparent density 0.120 g / cm 3 , air permeability 61.9 cm 3 / cm 2 / sec, fiber adhesion rate (average 69%, surface 70%, center 66%, opposite surface 72%)].
- Example 13 In Example 1, a fiber structure was obtained in the same manner as in Example 1 except that the treated fiber structure prepared in Synthesis Example 2 was used and replaced with an aqueous dispersion containing GMA at a rate of 10%. . In the obtained fiber structure, the dimensions slightly changed and expanded.
- the graft polymerization rate of GMA to EVOH is 720%
- the graft polymerization rate of GMA to polypropylene is 486%
- the ratio of graft chain bonded to EVOH and graft chain bonded to polypropylene is 60/40
- fiber structure The graft polymerization rate of GMA with respect to the whole body (total amount of EVOH and polypropylene) is 603%
- the basis weight is 1362 g / m 2
- the thickness is 4.50 mm
- the apparent density is 0.303 g / cm 3
- the air permeability is 11 cm 3. / Cm 2 / sec.
- the graft polymerization rate of GMA with respect to EVOH and the graft polymerization rate of GMA with respect to polypropylene are GMA graft polymerization rate (or polymerization amount) with respect to the entire fiber structure, and the core component constituting the wet heat adhesive fiber is polyethylene terephthalate. Except for this, it was determined using the graft polymerization rate (or polymerization amount) of GMA on the fiber structure produced in the same manner.
- Example 14 In Example 8, the treated fiber structure prepared in Synthesis Example 2 was used, and this was irradiated with an electron beam (acceleration voltage 250 kV) at an irradiation dose of 100 kGy. Thereafter, the fiber structure to be treated after electron irradiation was immersed in an aqueous solution containing AA at a rate of 10.0% at 50 ° C. for 60 minutes in a nitrogen atmosphere. In addition, the aqueous solution used what removed the dissolved oxygen by bubbling with nitrogen gas, and immersion was performed stirring an aqueous solution with a small dyeing machine. The weight ratio of the fiber structure to be treated and the solution was 1: 100. And the to-be-processed fiber structure after immersion was wash
- an electron beam acceleration voltage 250 kV
- the graft polymerization rate of AA to EVOH was 240%
- the graft polymerization rate of AA to polypropylene was 420%
- the ratio of the graft chain bonded to EVOH and the graft chain bonded to polypropylene was 36/64.
- the graft ratio of AA to the entire fiber structure (total amount of EVOH and polypropylene) is 339%
- the basis weight is 957 g / m 2
- the thickness is 3.77 mm
- the apparent density is 0.254 g / cm 3
- the air permeability is 16 cm 3. / Cm 2 / sec.
- the graft polymerization rate of AA with respect to EVOH and the graft polymerization rate of AA with respect to polypropylene are the graft polymerization rate (or polymerization amount) of AA with respect to the entire fiber structure, and the core component constituting the wet heat adhesive fiber is polyethylene terephthalate. Except for this, it was determined using the graft polymerization rate (or polymerization amount) of AA with respect to the entire fiber structure prepared in the same manner.
- the conjugate fiber containing an ethylene-vinyl alcohol copolymer is modified or modified at a high graft polymerization rate and applied to various uses depending on the type of graft component.
- the fiber structure of the present invention has an appropriate gap between the fibers and has a high graft polymerization rate and a graft chain bonded to the fiber surface, so that the filter structure or the adsorption performance is excellent. It is useful as an adsorbent (or a filter) for adsorbing.
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Abstract
Description
本発明の複合繊維は、エチレン-ビニルアルコール系共重合体(又はその主鎖)にグラフト鎖が結合したグラフト重合体(又はエチレン-ビニルアルコール系共重合体およびこのエチレン-ビニルアルコール系共重合体に結合したグラフト鎖を有するグラフト重合体)と、他の樹脂とで構成され、繊維表面の少なくとも一部がグラフト重合体で構成された複合繊維である。
グラフト重合体を構成するエチレン-ビニルアルコール系共重合体において、エチレン単位の含有量(共重合割合)は、例えば、2~80モル%(例えば、5~65モル%)、好ましくは15~60モル%、さらに好ましくは15~55モル%程度であってもよい。なお、グラフト成分は、エチレン単位とビニルアルコール単位との割合が適当でないと、十分なグラフト鎖をEVOHに結合(又は導入)できない場合がある。また、上記の範囲のEVOHは、通常、湿熱接着性を有するが、熱水溶解性はないという特異な性質が得られるため、後述のように湿熱接着により繊維構造体を得やすい。なお、湿熱接着の観点からは、エチレン単位の割合が少なすぎると、エチレン-ビニルアルコール系共重合体が、低温の蒸気(水)で容易に膨潤又はゲル化し、水に一度濡れただけで形態が変化し易い。一方、エチレン単位の割合が多すぎると、吸湿性が低下し、湿熱による繊維融着が発現し難くなるため、湿熱接着により、実用性のある強度の確保が困難となる。特に、エチレン単位の割合が15~55モル%の範囲にあると、シート又は板状への加工性が特に優れる。
他の樹脂としては、エチレン-ビニルアルコール系共重合体でない樹脂であればよく、例えば、ポリオレフィン系樹脂[ポリエチレン系樹脂(ポリエチレンなど)、ポリプロピレン系樹脂(例えば、ポリプロピレン、プロピレン-エチレン共重合体などのプロピレン共重合体)など]、(メタ)アクリル系樹脂、塩化ビニル系樹脂、スチレン系樹脂(ポリスチレンなど)、ポリエステル系樹脂、ポリアミド系樹脂、ポリカーボネート系樹脂、ポリウレタン系樹脂、熱可塑性エラストマー、セルロース系樹脂(メチルセルロースなどのセルロースエーテル、ヒドロキシエチルセルロースなどのヒドロキシアルキルセルロース、カルボキシメチルセルロースなどのカルボキシアルキルセルロースなど)、ポリアルキレングリコール樹脂(ポリエチレンオキサイド、ポリプロピレンオキサイドなど)、ポリビニル系樹脂(ポリビニルピロリドン、ポリビニルエーテル、ポリビニルアセタールなど)、アクリル系共重合体[(メタ)アクリル酸、(メタ)アクリルアミドなどのアクリル系単量体で構成された単位を含む共重合体又はその塩など]、変性ビニル系共重合体(イソブチレン、スチレン、エチレン、ビニルエーテルなどのビニル系単量体と、無水マレイン酸などの不飽和カルボン酸又はその無水物との共重合体又はその塩など)などが挙げられる。これらの他の樹脂は、単独で又は二種以上組み合わせて使用できる。
複合繊維の構造は、グラフト重合体(又はエチレン-ビニルアルコール系共重合体、以下同じ)をその表面に少なくとも有する構造であれば特に限定されない。例えば、グラフト重合体が表面を占める複合繊維の横断面構造(繊維の長さ方向に垂直な断面形状)としては、例えば、芯鞘型、海島型、サイドバイサイド型又は多層貼合型、放射状貼合型、ランダム複合型などが挙げられる。これらの構造(横断面構造)のうち、芯鞘型構造、すなわち、複合繊維の構造は、グラフト重合体で構成された鞘部と、他の樹脂で構成された芯部とで形成された芯鞘型複合繊維(すなわち、鞘部がエチレン-ビニルアルコール系共重合体で構成された芯鞘型構造)であるのが好ましい。このような芯鞘型構造では、グラフト重合の原料となるエチレン-ビニルアルコール系共重合体が繊維の全表面を被覆する構造であり、効率よくグラフト重合率を高めることができる。すなわち、繊維に芯が存在することによって、グラフト重合時に膨潤や収縮する鞘のエチレン-ビニルアルコール系共重合体を効率よく固定することができ、結果としてグラフト重合性効率よく向上できる。また、鞘を構成するエチレン-ビニルアルコール系共重合体は、その親水性などに起因してグラフト成分に浸透(接触)させやすく、しかも、発生したラジカル(活性点)が比較的安定であるため、前記のようなエチレン-ビニルアルコール系共重合体を固定する効果があいまって、より一層グラフト重合性が促進されるようである。さらに、後述のように、接着性が高い構造であり、適度な空隙および高強度を両立できる繊維構造体を得やすいという観点からも好適である。
本発明の繊維構造体(成形体)は、前記複合繊維を含む繊維集合体で形成されている。繊維集合体は、複合繊維のみで構成してもよく、他の繊維を含んでいてもよい。
他の繊維としては、特に限定されず、ポリエステル系繊維(ポリエチレンテレフタレート繊維、ポリトリメチレンテレフタレート繊維、ポリブチレンテレフタレート繊維、ポリエチレンナフタレート繊維などの芳香族ポリエステル繊維など)、ポリアミド系繊維(ポリアミド6、ポリアミド66、ポリアミド11、ポリアミド12、ポリアミド610、ポリアミド612などの脂肪族ポリアミド系繊維、半芳香族ポリアミド系繊維、ポリフェニレンイソフタルアミド、ポリヘキサメチレンテレフタルアミド、ポリp-フェニレンテレフタルアミドなどの芳香族ポリアミド系繊維など)、ポリオレフィン系繊維(ポリエチレン、ポリプロピレンなどのポリC2-4オレフィン繊維など)、アクリル系繊維(アクリロニトリル-塩化ビニル共重合体などのアクリロニトリル単位を有するアクリロニトリル系繊維など)、ポリビニル系繊維(ポリビニルアセタール系繊維など)、ポリ塩化ビニル系繊維(ポリ塩化ビニル、塩化ビニル-酢酸ビニル共重合体、塩化ビニル-アクリロニトリル共重合体の繊維など)、ポリ塩化ビニリデン系繊維(塩化ビニリデン-塩化ビニル共重合体、塩化ビニリデン-酢酸ビニル共重合体などの繊維)、ポリパラフェニレンベンゾビスオキサゾール繊維、ポリフェニレンサルファイド繊維、セルロース系繊維(例えば、レーヨン繊維、アセテート繊維など)などが挙げられる。これらの他の繊維は、単独で又は二種以上組み合わせて使用できる。
繊維構造体は、繊維集合体(前記複合繊維を含む繊維の集合物)で形成されている。繊維構造体の形状(又は形態)は、用途にもよるが、通常、シート状(又は板状又は布帛)であってもよい。
本発明の複合繊維又は繊維構造体は、その形態やグラフト鎖(グラフト成分)の種類などに応じて種々の用途に適用できる。代表的には、グラフト鎖に官能基が導入されている繊維構造体(又は複合繊維)は、被吸着物質を吸着又は分離するための吸着材(又はフィルター)として利用できる。例えば、繊維構造体は、被吸着物質としての金属を吸着(又は回収)するためのフィルターとして好適である。本発明の複合繊維又は繊維構造体は、高いグラフト重合率でグラフト成分が重合されており、繊維表面に金属を吸着可能な官能基を多く有しているため、金属の吸着性に優れている。しかも、繊維構造体では、適度な空隙を有しつつ、繊維が強固に固定されている場合が多いため、より一層、効率よく金属を吸着可能である。また、本発明の複合繊維又は繊維構造体は、高いグラフト重合性を有するために、各種の官能基に応じた最適なグラフト重合率を制御することなども非常に自由度が高く、容易に実現できる。従って、より広範囲な機能を有する材料とするには最適である。
本発明の複合繊維(又は繊維構造体)は、特に限定されないが、例えば、(A)グラフト重合に供される前の複合繊維(すなわち、エチレン-ビニルアルコール系共重合体と、他の樹脂とで構成され、繊維表面の少なくとも一部がエチレン-ビニルアルコール系共重合体で構成されている複合繊維、以下、被処理複合繊維などということがある)、又は(B)グラフト重合に供される前の繊維構造体(すなわち、繊維表面の少なくとも一部が、エチレン-ビニルアルコール系共重合体で構成されている複合繊維を少なくとも含む繊維集合体(被処理繊維集合体)で形成された繊維構造体、以下、被処理繊維構造体などということがある)に対して、グラフト鎖を構成(形成)するグラフト成分をグラフト重合することにより得ることができる。
JIS L1913「一般短繊維不織布試験方法」に準じて測定した。
目付を評価した試料を用いて、12g/cm2の加重をかけ、厚みを測定した。1試料から5箇所で評価し、平均値を試料の厚みとした。
JIS L1096に準じ、フラジール形法にて測定した。
走査型電子顕微鏡(SEM)を用いて、構造体断面を100倍に拡大した写真を撮影した。撮影した構造体の厚み方向における断面写真を厚み方向に三等分し、三等分した各領域(表面、内部(中央)、裏面)において、そこに見出せる繊維切断面(繊維端面)の数に対して繊維同士が接着している切断面の数の割合を求めた。各領域に見出せる全繊維断面数のうち、2本以上の繊維が接着した状態の断面の数の占める割合を以下の式に基づいて百分率で表わした。なお、繊維同士が接触する部分には、融着することなく単に接触している部分と、融着により接着している部分とがある。但し、顕微鏡撮影のために構造体を切断することにより、構造体の切断面においては、各繊維が有する応力によって、単に接触している繊維同士は分離する。従って、断面写真において、接触している繊維同士は、接着していると判断できる。
但し、各写真について、断面の見える繊維は全て計数し、繊維断面数100以下の場合は、観察する写真を追加して全繊維断面数が100を超えるようにした。なお、三等分した各領域についてそれぞれ繊維接着率を求め、その最大値に対する最小値の割合(最小値/最大値)も併せて求めた。
グラフト重合処理前後の重量変化から次式により算出した。なお、試料の重量は、減圧下、60℃で又は減圧することなく100℃で、2時間乾燥したものについて測定した。
[(処理後重量(g)-処理前重量(g))/処理前重量(g)]×100(%)
(6)イミノ二酢酸の導入割合
イミノ二酢酸導入処理前後の重量変化から次式によりメタクリル酸グリシジル(GMA、分子量142)のエポキシ基に対するイミノ二酢酸(分子量133)の導入率(%)を求めた。なお、試料の重量は、減圧下、60℃で2時間乾燥したものについて測定した。
{[(処理後重量(g)-処理前重量(g))/133]/(繊維構造体中に含まれるGMAの重量(g)/142)}×100(%)
(7)金属吸着率
金属の吸着率は、金属吸着実験前後での金属溶液の濃度変化から以下のように測定した。吸着処理後、試料を取り除いた残溶液を用いて、UV-VIS分光光度計((株)島津製作所製「UV-1700」)により溶液の吸光度を測定し、あらかじめ複数の金属濃度における吸光度を測定することで作成しておいた検量線を用いて、溶液中に残った金属濃度を求めた。すなわち、金属濃度は、金属溶液の可視領域にほとんど吸収がないことから、キシレノールオレンジと金属との錯形成を利用して発色させる比色分析法を利用して、570nmにおける吸光度を測定することで求められ、吸着率は下記式により算出した。
[(金属吸着前の金属濃度-金属吸着後の金属濃度)/金属吸着前の金属濃度]×100(%)
(8)引張破断強度
各条件にて、電子線照射処理した試料を用いて、電子線照射前後の基材の物性変化を観察した。すなわち、各試料から、巾5cm、長さ30cmの試料を切り出し、つかみ間距離20cmとして、定速伸長形引張試験機((株)島津製作所製)を用いて引張り試験を行った。得られた応力、歪み曲線の破断時の応力を読み取り評価値とした。n数を5として、これらの平均値を数値として用いた。なお、引張破断強度は不織布の流れ(MD)方向及び幅(CD)方向について測定した。
(8)で得られた応力、歪み曲線の破断時の伸度を読み取り評価値とした。n数を5として、これらの平均値を数値として用いた。なお、破断伸度は不織布の流れ(MD)方向及び幅(CD)方向について測定した。
被処理繊維構造体を次のようにして製造した。すなわち、湿熱接着性繊維として、芯成分がポリエチレンテレフタレート、鞘成分がエチレン-ビニルアルコール共重合体(エチレン含有量44モル%、鹸化度98.4モル%、以下EVOHという)である芯鞘型複合ステープル繊維((株)クラレ製、「ソフィスタ」、繊度3dtex、繊維長51mm、芯鞘質量比=50/50、捲縮数21個/25mm、捲縮率13.5%)を準備した。
ポリエチレン袋に合成例1で得られた被処理繊維構造体を入れ、窒素ガス置換し、ドライアイスをポリエチレン袋の下に敷いて冷却しながら、被処理繊維構造体に電子線照射装置((株)NHVコーポレーション製、商品名「キュアトロン」)を用いて電子線(加速電圧250kV)を照射線量100kGyで照射した。その後、電子照射後の被処理繊維構造体を、30%の割合でグリシジルメタクリレート(以下、GMAという)を含む水分散液[GMAと、水に対して約7.5重量%の割合のポリオキシエチレンノニルフェニルエーテル(和光純薬(株)製)を含む水溶液とを混合したもので、液温度60℃の水分散液]に、窒素雰囲気下で60分間攪拌しながら浸漬した。なお、水分散液には、窒素ガスでバブリングして溶存酸素を除去したものを用いた。また、被処理繊維構造体と水分散液との重量比は、1:100であった。そして、浸漬後の被処理繊維構造体を水およびテトラヒドロフランで洗浄、乾燥し、繊維構造体を得た。
実施例1において、水分散液を10%のGMA水分散液に代えたこと以外は、実施例1と同様にして繊維構造体を得た。得られた繊維構造体において、EVOHに対するGMAのグラフト重合率は720%(繊維構造体全体に対するGMAのグラフト率は360%)、目付は1150g/m2、厚みは4.32mm、見掛け密度は0.266g/cm3、通気度は21cm3/cm2/秒であった。
実施例1において、水分散液を5%のGMA水分散液に代えたこと以外は、実施例1と同様にして繊維構造体を得た。得られた繊維構造体において、EVOHに対するGMAのグラフト重合率は292%(繊維構造体全体に対するGMAのグラフト率は146%)、目付は615g/m2、厚みは3.40mm、見掛け密度は0.181g/cm3、通気度は42cm3/cm2/秒であった。
実施例1において、水分散液を20%のGMA水分散液に代えたこと以外は、実施例1と同様にして繊維構造体を得た。得られた繊維構造体において、EVOHに対するGMAのグラフト重合率は346%(繊維構造体全体に対するGMAのグラフト率は173%)、目付は683g/m2、厚みは3.56mm、見掛け密度は0.192g/cm3、通気度は38cm3/cm2/秒であった。
実施例1において、水分散液を20%のGMA水分散液に、浸漬時間を30分に代えたこと以外は、実施例1と同様にして繊維構造体を得た。得られた繊維構造体において、EVOHに対するGMAのグラフト重合率は394%(繊維構造体全体に対するGMAのグラフト率は197%)、目付は743g/m2、厚みは3.69mm、見掛け密度は0.201g/cm3、通気度は35cm3/cm2/秒であった。
実施例1において、水分散液を20%のGMA水分散液に、浸漬時間を120分に代えたこと以外は、実施例1と同様にして繊維構造体を得た。得られた繊維構造体において、EVOHに対するGMAのグラフト重合率は472%(繊維構造体全体に対するGMAのグラフト率は236%)、目付は840g/m2、厚みは3.87mm、見掛け密度は0.217g/cm3、通気度は31cm3/cm2/秒であった。
実施例1で得られた繊維構造体を、イミノ二酢酸を約3.5%の割合で含む溶液(水46.5%、ジメチルスルホキシド50%)に浸漬し、80℃で72時間反応させ、グラフト鎖にイミノ二酢酸単位を導入した。なお、グラフト鎖を構成するGMA単位(エポキシ基)の38.4モル%がイミノ二酢酸と反応していた。得られた繊維構造体(イミノ二酢酸処理された繊維構造体)において、目付は818g/m2、厚みは3.22mm、見掛け密度は0.254g/cm3、通気度は28cm3/cm2/秒であった。
ポリエチレン袋に合成例1で得られた被処理繊維構造体を入れ、窒素ガス置換し、被処理繊維構造体に、電子線照射装置((株)NHVコーポレーション製、商品名「キュアトロン」)を用いて電子線(加速電圧250kV)を照射線量250kGyで照射した。その後、電子照射後の被処理繊維構造体を、17.5%の割合でアクリル酸(以下、AAという)を含む水溶液に、窒素雰囲気下、50℃で60分間浸漬した。なお、水溶液には、窒素ガスでバブリングして溶存酸素を除去したものを用い、浸漬は小型染色器で水溶液を攪拌しながら行った。また、被処理繊維構造体と溶液との重量比は、1:25であった。そして、浸漬後の被処理繊維構造体を水で洗浄、乾燥し、繊維構造体を得た。
実施例8において、溶液を15%のAA溶液に代えたこと以外は、実施例8と同様にして繊維構造体を得た。得られた繊維構造体において、EVOHに対するAAのグラフト重合率は314%(繊維構造体全体に対するAAのグラフト率は157%)、目付は643g/m2、厚みは3.47mm、見掛け密度は0.185g/cm3、通気度は41cm3/cm2/秒であった。
芯成分としてホモポリプロピレン、鞘成分として共重合ポリプロピレン(ダイワボウポリテック(株)製、商品名「NBF(P-2)」)である原綿を用いて繊維構造体を次のようにして製造した。すなわち、前記芯鞘型複合ステープル繊維(繊度2.5dtex、繊維長51mm、芯鞘質量比=50/50)を準備した。この芯鞘型複合ステープル繊維を用いて、カード法により目付約25g/m2のカードウェブを作製し、このウェブを2枚重ねて合計目付約50g/m2のカードウェブとした。このカードウェブを30メッシュ、幅120mmのステンレス製エンドレスネットを装備したベルトコンベアに移送し、熱風処理炉を通過させ熱風により繊維間を熱融着体を作成した。次いでコットンロール、加熱した金属フラットロールからなるカレンダー設備により、この作成した繊維構造体を熱圧着カレンダー処理して、不織布(目付50g/m2、厚み0.2mm、見掛け密度0.25g/cm3、通気度250cm3/cm2/秒)を得た。
特開2010-1392号公報の実施例2を追試した。すなわち、EVOHフィルム((株)クラレ製、厚み25μm、目付2.85g/m2、密度1.14g/cm3)を、薄いプラスチックバッグの中に入れ、このバッグを窒素で数回置換した後にバッグを封着した。続いて上記基材に、窒素雰囲気中、ドライアイスによる冷却条件下、電子線を100kGy照射し、ラジカル活性点を生成させた。照射後のフィルムを、すぐに、予め調製し窒素置換された塩化ビニルベンジルトリメチルアンモニウム(VBTMA)水溶液(30重量%)に浸漬させ、70℃に保持しながら24時間反応させた。その結果、グラフト率は60%であった。
実施例7で得られたイミノ二酢酸単位が導入された繊維構造体を、サマリウムを約10ppmの濃度で含む水溶液(液温30℃、pH6.5、微量のナトリウムおよび硝酸を含む)に2時間浸漬した。なお、繊維構造体と混合液との重量比は、1:500とした。繊維構造体はサマリウムを吸着率99.3%で吸着していた。
実施例8で得られた繊維構造体を、サマリウムを10ppmの濃度で含む水溶液(pH約2、微量の硝酸を含む)に室温(約20℃)で20時間浸漬した。なお、繊維構造体と混合液との重量比は、1:50とした。繊維構造体はサマリウムを吸着率95%で吸着していた。
実施例11において、実施例8で得られた繊維構造体に代えて、合成例1で得られた被処理繊維構造体を使用したこと以外は、実施例11と同様にサマリウムを吸着させたところ、吸着率は24%であった。
実施例8で得られた繊維構造体を、テルビウムを10ppmの濃度で含む水溶液(pH約2.3、微量の硝酸を含む)に室温(約25℃)で6時間浸漬した。なお、繊維構造体と混合液との重量比は、1:50とした。繊維構造体はテルビウムを吸着率76%で吸着していた。
実施例12において、実施例8で得られた繊維構造体に代えて、合成例1で得られた被処理繊維構造体を使用したこと以外は、実施例12と同様にテルビウムを吸着させたところ、吸着率は21%であった。
被処理繊維構造体を次のようにして製造した。すなわち、湿熱接着性繊維として、芯成分がポリプロピレン、鞘成分がエチレン-ビニルアルコール共重合体(エチレン含有量44モル%、鹸化度98.4モル%、以下EVOHという)である芯鞘型複合ステープル繊維(試験紡糸品、繊度3dtex、繊維長51mm、芯鞘質量比=50/50、捲縮数20個/25mm、捲縮率13.9%)を準備した。
実施例1において、合成例2で作成した被処理繊維構造体を用い、10%の割合でGMAを含む水分散液に代えたこと以外は、実施例1と同様にして繊維構造体を得た。得られた繊維構造体において、若干寸法が変化し広がった。繊維構造体において、EVOHに対するGMAのグラフト重合率は720%、ポリプロピレンに対するGMAのグラフト重合率は486%、EVOHに結合したグラフト鎖とポリプロピレンに結合したグラフト鎖との割合は60/40、繊維構造体全体(EVOHとポリプロピレンとの総量)に対するGMAのグラフト重合率は603%であり、目付は1362g/m2、厚みは4.50mm、見掛け密度は0.303g/cm3、通気度は11cm3/cm2/秒であった。なお、EVOHに対するGMAのグラフト重合率及びポリプロピレンに対するGMAのグラフト重合率は、繊維構造体全体に対するGMAのグラフト重合率(又は重合量)と、湿熱接着性繊維を構成する芯成分がポリエチレンテレフタレートであること以外は同様にして作成した繊維構造体に対するGMAのグラフト重合率(又は重合量)とを用いて求めた。
実施例8において、合成例2で作成した被処理繊維構造体を用い、これに電子線(加速電圧250kV)を照射線量100kGyで照射した。その後、電子照射後の被処理繊維構造体を、10.0%の割合でAAを含む水溶液に、窒素雰囲気下、50℃で60分間浸漬した。なお、水溶液には、窒素ガスでバブリングして溶存酸素を除去したものを用い、浸漬は小型染色器で水溶液を攪拌しながら行った。また、被処理繊維構造体と溶液との重量比は、1:100であった。そして、浸漬後の被処理繊維構造体を水で洗浄、乾燥し、繊維構造体を得た。
Claims (21)
- エチレン-ビニルアルコール系共重合体にグラフト鎖が結合したグラフト重合体と、他の樹脂とで構成され、繊維表面の少なくとも一部が前記グラフト重合体で構成されている複合繊維。
- エチレン-ビニルアルコール系共重合体において、エチレン単位の含有割合が5~65モル%であり、グラフト鎖が、官能基を有するラジカル重合性モノマーを少なくとも含むラジカル重合性モノマーの放射線重合により形成されたポリマー鎖で構成されている請求項1記載の複合繊維。
- 官能基を有するラジカル重合性モノマーが、アミノ基、置換アミノ基、イミノ基、アミド基、置換アミド基、ヒドロキシル基、カルボキシル基、カルボニル基、エポキシ基、チオ基およびスルホ基から選択された少なくとも1種の官能基を有する(メタ)アクリル系モノマーを含む請求項2記載の複合繊維。
- グラフト鎖が、多座配位性の官能基を有する請求項1~3のいずれかに記載の複合繊維。
- グラフト鎖が、イミノ二酢酸単位を有する請求項1~4のいずれかに記載の複合繊維。
- グラフト重合体において、エチレン-ビニルアルコール系共重合体に対するグラフト重合率が重量基準で100%以上である請求項1~5のいずれかに記載の複合繊維。
- グラフト重合体で構成された鞘部と、他の樹脂で構成された芯部とで形成された芯鞘型複合繊維である請求項1~6のいずれかに記載の複合繊維。
- グラフト重合体と他の樹脂との割合が、前者/後者(重量比)=98/2~15/85である請求項1~7のいずれかに記載の複合繊維。
- グラフト重合体で構成された鞘部と、ポリプロピレン系樹脂、スチレン系樹脂、ポリエステル系樹脂およびポリアミド系樹脂から選択された少なくとも1種の他の樹脂で構成された芯部とで形成された芯鞘型複合繊維であり、グラフト重合体と他の樹脂との割合が、前者/後者(重量比)=95/5~30/70であり、グラフト重合体において、エチレン-ビニルアルコール系共重合体に対するグラフト重合率が重量基準で150%以上である請求項1~8のいずれかに記載の複合繊維。
- グラフト重合体において、エチレン-ビニルアルコール系共重合体に対するグラフト重合率が重量基準で200%以上である請求項1~9のいずれかに記載の複合繊維。
- グラフト鎖の割合が、エチレン-ビニルアルコール系共重合体および他の樹脂の総量100重量部に対して100重量部以上である請求項1~10のいずれかに記載の複合繊維。
- 請求項1~11のいずれかに記載の複合繊維を含む繊維集合体で形成された繊維構造体。
- 繊維集合体が湿熱接着により融着した不織繊維構造を有する請求項12記載の繊維構造体。
- フラジール形法による通気度が5~400cm3/(cm2・秒)である請求項12又は13記載の繊維構造体。
- 見掛け密度が0.05~0.35g/cm3であり、目付が50~3000g/m2であり、フラジール形法による通気度が5~300cm3/(cm2・秒)である請求項12~14のいずれかに記載の繊維構造体。
- 金属を吸着するための吸着材として用いる請求項12~15のいずれかに記載の繊維構造体。
- レアアースを吸着するための吸着材として用いる請求項12~16のいずれかに記載の繊維構造体。
- 繊維表面の少なくとも一部が、エチレン-ビニルアルコール系共重合体で構成されている複合繊維を少なくとも含む繊維集合体で形成された被処理繊維構造体に対して、グラフト鎖を構成するグラフト成分をグラフト重合する請求項12~17のいずれかに記載の繊維構造体の製造方法。
- 放射線照射により活性種が発生した被処理繊維構造体を、グラフト成分を含むグラフト成分含有液中に浸漬することによりグラフト成分を接触させてグラフト重合する請求項18記載の製造方法。
- グラフト成分含有液中のグラフト成分の割合が5~50重量%である請求項19記載の製造方法。
- 被処理繊維構造体を、グラフト成分を含む分散液中に浸漬する請求項19又は20記載の製造方法。
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JP2014159547A (ja) * | 2013-01-23 | 2014-09-04 | Kuraray Co Ltd | エチレン−ビニルアルコール系グラフト共重合体粒子、その製造方法及び金属イオン吸着材 |
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JP2015030731A (ja) * | 2013-07-31 | 2015-02-16 | 株式会社クラレ | エチレン−ビニルアルコール系グラフト共重合体及びその製造方法、並びに半金属吸着材 |
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JP2000178832A (ja) * | 1998-12-17 | 2000-06-27 | Ube Nitto Kasei Co Ltd | 鞘芯複合型ポリオレフィン系繊維およびグラフト化ポリオレフィン系不織布 |
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JP2014159547A (ja) * | 2013-01-23 | 2014-09-04 | Kuraray Co Ltd | エチレン−ビニルアルコール系グラフト共重合体粒子、その製造方法及び金属イオン吸着材 |
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JP2015030731A (ja) * | 2013-07-31 | 2015-02-16 | 株式会社クラレ | エチレン−ビニルアルコール系グラフト共重合体及びその製造方法、並びに半金属吸着材 |
JP2015087369A (ja) * | 2013-10-30 | 2015-05-07 | 株式会社 環境浄化研究所 | イミノジ酢酸基をグラフト鎖に導入した繊維によるストロンチウム除去方法 |
JP2016098461A (ja) * | 2014-11-21 | 2016-05-30 | 倉敷紡績株式会社 | 繊維成形体 |
JP2017179669A (ja) * | 2016-03-31 | 2017-10-05 | Kbセーレン株式会社 | 金属吸着材用ウェッブ及び不織布、それらの製造方法 |
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KR20140105502A (ko) | 2014-09-01 |
JP5853031B2 (ja) | 2016-02-09 |
CA2857444C (en) | 2018-12-04 |
CA2857444A1 (en) | 2013-06-13 |
JPWO2013084524A1 (ja) | 2015-04-27 |
US20140363653A1 (en) | 2014-12-11 |
KR101938926B1 (ko) | 2019-01-15 |
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