Classifications

• • 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
  • D01F8/16—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one other macromolecular compound obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds as constituent
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4282—Addition polymers
  • D04H1/4291—Olefin series
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
  • D04H1/43825—Composite fibres
  • D04H1/43828—Composite fibres sheath-core
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
  • D04H1/43825—Composite fibres
  • D04H1/4383—Composite fibres sea-island
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
  • D04H1/43825—Composite fibres
  • D04H1/43832—Composite fibres side-by-side
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/005—Synthetic yarns or filaments
  • D04H3/009—Condensation or reaction polymers
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
  • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
  • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
  • D04H3/147—Composite yarns or filaments
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
  • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
• • 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]
• • 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 PPS composite fiber which is made of a resin mainly composed of polyphenylene sulfide (hereinafter sometimes abbreviated as “PPS”) and has excellent heat resistance and chemical resistance, and a nonwoven fabric composed of the fiber. It is.
• PPS polyphenylene sulfide
• PPS resin has excellent heat resistance, flame retardancy, and chemical resistance, and is suitably used as engineer plastic, film, fiber, nonwoven fabric, and the like.
• non-woven fabrics are expected to be utilized for industrial applications such as heat-resistant filters, electrical insulating materials, and battery separators by taking advantage of these characteristics.
• a heat-resistant nonwoven fabric that has been spun at a spinning speed of 6000 m / min or more, contains 30 wt% or more of PPS fibers having a crystallinity of 25 to 50%, and is integrated by thermal bonding has been proposed (see Patent Document 2).
• the fiber obtained by high-speed spinning at a spinning speed of 6000 m / min or more has a problem of high crystallinity, insufficient thermal adhesion, and a nonwoven fabric with high mechanical strength cannot be obtained.
• JP 2008-223209 A International Publication No. 2008/035775 International Publication No. 2011/070999
• An object of the present invention is to provide a polyphenylene sulfide composite fiber having thermal dimensional stability and excellent thermal adhesiveness, and a nonwoven fabric having high mechanical strength composed of the fiber.
• a resin having polyphenylene sulfide as a main component is component A
• a resin having polyphenylene sulfide as a main component and having a higher melt flow rate (hereinafter, also referred to as MFR) than component A is component B.
• the present invention is a nonwoven fabric characterized by comprising the above polyphenylene sulfide composite fiber.
• the PPS composite fiber of the present invention has excellent thermal adhesiveness while having thermal dimensional stability. Therefore, the nonwoven fabric of the present invention is excellent in mechanical strength while having thermal dimensional stability, and can be used for various industrial applications.
• the composite fiber of the present invention is mainly composed of component A and component B, and it is important that both of them contain PPS as a main component. By doing so, excellent heat resistance, flame retardancy and chemical resistance can be obtained. Being mainly means occupying 90% by mass or more of the whole. Moreover, including as a main component means occupying 85 mass% or more of the whole.
• a resin having polyphenylene sulfide as a main component is component A
• a resin having polyphenylene sulfide as a main component and a melt flow rate higher than component A is component B
• component A and component B It is important that component B forms at least a part of the surface of the fiber.
• Fibers obtained by general spinning have a fiber structure in which the orientation and crystallinity increase as the distance from the center of the fiber cross section approaches the surface.
• the reason for this is that the fibers spun from the spinneret are cooled from the fiber surface to the inside, so that the spinning stress is concentrated on the fiber surface where the fluidity decreases due to cooling, and oriented crystallization is not caused. This is to make progress. For this reason, even if the fiber has low crystallinity as a whole, the essential fiber surface that contributes to thermal adhesion has high crystallinity, and sufficient thermal adhesion cannot be obtained.
• a composite fiber composed of a component A and a component B is a resin having polyphenylene sulfide as a main component as component A, a polyphenylene sulfide as a main component, and a resin having a higher melt flow rate than component A as component B.
• the spinning stress can be concentrated on the component A, and the orientation and crystallinity of the component B can be suppressed.
• the component B which suppressed orientation and crystallinity forms at least a part of the fiber surface, so that a fiber having extremely excellent thermal adhesiveness can be obtained while having thermal dimensional stability.
• the crystallinity of the fiber surface part in the region of 1 ⁇ m or less from the fiber surface toward the fiber diameter direction is compared with the crystallinity of the fiber cross-section central part, and the fiber surface
• the content of p-phenylene sulfide units in the PPS of Component A and Component B is preferably 93 mol% or more.
• 93 mol% or more more preferably 95 mol% or more of p-phenylene sulfide units, a fiber excellent in spinnability and mechanical strength can be obtained.
• the content of the PPS resin in Component A and Component B is preferably 85% by mass or more, more preferably 90% by mass or more, and still more preferably 95% by mass or more from the viewpoints of heat resistance and chemical resistance.
• the component A and the component B may be blended with a thermoplastic resin other than the PPS resin as long as the effects of the present invention are not impaired.
• thermoplastic resin other than the PPS resin include polyetherimide, polyethersulfone, polysulfone, polyphenylene ether, polyester, polyarylate, polyamide, polyamideimide, polycarbonate, polyolefin, and polyetheretherketone.
• a crystal nucleating agent a matting agent, a pigment, a fungicide, an antibacterial agent, a flame retardant, a hydrophilic agent, or the like may be added as long as the effects of the present invention are not impaired.
• Component A of the present invention preferably has an MFR measured according to ASTM D1238-70 (measurement temperature 315.5 ° C., measurement load 5 kg load) of 50 to 300 g / 10 minutes.
• an MFR measured according to ASTM D1238-70 measured according to ASTM D1238-70 (measurement temperature 315.5 ° C., measurement load 5 kg load) of 50 to 300 g / 10 minutes.
• ASTM D1238-70 measurement temperature 315.5 ° C., measurement load 5 kg load
• an appropriate fluidity can be obtained, the rise in the back pressure of the die is suppressed in melt spinning, and yarn breakage during pulling and drawing is also suppressed. Can do.
• the MFR is 300 g / 10 min or less, more preferably 225 g / 10 min or less, the degree of polymerization or the molecular weight can be appropriately increased, and mechanical strength and heat resistance that can be put to practical use can be obtained.
• the MFR (measured according to the above ASTM D1238-70) of the component B of the present invention is higher (lower in viscosity) than the component A.
• the difference obtained by subtracting the MFR of component A from the MFR of component B is preferably 10 g / 10 min or more, more preferably 50 g / 10 min or more, and even more preferably 100 g / 10 min or more. A burden can be reduced and oriented crystallinity can be suppressed.
• the difference obtained by subtracting the MFR of the component A from the MFR of the component B is preferably 1000 g / 10 min or less, more preferably 500 g / 10 min or less, and even more preferably 200 g / 10 min or less. And stable spinning is possible.
• the proportion of component B in the PPS composite fiber of the present invention is preferably 5 to 70% by mass.
• the proportion of component B is preferably 5% by mass or more, more preferably 10% by mass, and even more preferably 15% by mass or more, it is possible to obtain strong thermal bonding efficiently.
• the proportion of component B is 70% by mass or less, more preferably 50% by mass or less, and even more preferably 30% by mass or less, a decrease in mechanical strength can be suppressed.
• component B forms at least a part of the fiber surface. This is because component B is exposed to the fiber surface and contributes to thermal adhesiveness.
• the component A is continuously arrange
• a core-sheath type in which a circular component A is wrapped in a doughnut-shaped component B having the same center in the fiber cross section, the center of the component A is shifted from the center of the component B.
• Core-sheath eccentric type, sea island type with component A as island component, component B as sea component, parallel type with both components in parallel, radial type with both components arranged alternately, component B around component A A multi-leaf type or the like arranged in several can be mentioned.
• a core-sheath type in which component B occupies the entire fiber surface and is excellent in fiber spinnability is preferable.
• the average single fiber fineness of the PPS composite fiber of the present invention is preferably 0.5 to 10 dtex.
• the average single fiber fineness is preferably 0.5 dtex or more, more preferably 1 dtex or more, and even more preferably 2 dtex or more, it is possible to maintain the spinnability of the fiber and to prevent frequent yarn breakage during spinning.
• the average single fiber fineness is set to 10 dtex or less, more preferably 5 dtex or less, and even more preferably 4 dtex or less, it is possible to suppress the discharge amount of the molten resin per spinneret single hole and sufficiently cool the fibers. And a reduction in spinnability due to fusion between fibers can be suppressed.
• the fabric weight per unit area when the nonwoven fabric is formed can be suppressed, and the surface quality can be improved.
• the average single fiber fineness is preferably 10 dtex or less, more preferably 5 dtex or less, and further preferably 4 dtex or less.
• the PPS composite fiber of the present invention can be used as a multifilament, monofilament, or short fiber, and can be used as a fiber constituting any fabric such as a woven fabric and a non-woven fabric. Especially, it is preferable to use the PPS composite fiber of this invention as a constituent fiber of a nonwoven fabric. This is because the nonwoven fabric contributes to the strength of the nonwoven fabric by thermally bonding the constituent fibers together.
• nonwoven fabric examples include a needle punched nonwoven fabric, a wet nonwoven fabric, a spunlace nonwoven fabric, a spunbond nonwoven fabric, a melt blown nonwoven fabric, a resin bond nonwoven fabric, a chemical bond nonwoven fabric, a thermal bond nonwoven fabric, a toe-opening nonwoven fabric, and an airlaid nonwoven fabric.
• a spunbonded nonwoven fabric excellent in productivity and mechanical strength is preferable.
• the nonwoven fabric comprised from the PPS composite fiber of this invention can obtain high mechanical strength by heat bonding, it is preferable to integrate by heat bonding.
• the basis weight of the nonwoven fabric of the present invention is preferably 10 to 1000 g / m 2 .
• the basis weight of the nonwoven fabric of the present invention is preferably 10 to 1000 g / m 2 .
• the basis weight of the nonwoven fabric of the present invention 1000 g / m 2 or less, more preferably 700 g / m 2 or less, more preferably by a 500 g / m 2 or less, has an appropriate air permeability, for use with a filter or the like In this case, it is possible to suppress a high pressure loss.
• the tensile strength product per unit weight calculated by the following formula is 25 or more from the vertical tensile strength, vertical tensile elongation and basis weight of the nonwoven fabric.
• Strong elongation product per unit weight vertical tensile strength (N / 5 cm) ⁇ vertical tensile elongation (%) / unit weight (g / m 2 )
• the nonwoven fabric has mechanical strength that can be used even in harsh environments.
• the upper limit is not particularly defined, but the strength / elongation product per basis weight is preferably 100 or less from the viewpoint of preventing the nonwoven fabric from becoming hard and deteriorating in handleability.
• a known melt spinning method can be employed.
• the PPS resin for the core component and the PPS resin for the sheath component are melted and measured by separate extruders, supplied to the core-sheath type composite die, melt-spun, and the yarn is conventionally used.
• a well-known cooling device such as horizontal spraying or annular spraying, an oil agent is applied and wound on a winder as undrawn yarn through a take-up roller.
• the wound undrawn yarn is drawn between a group of rollers having different peripheral speeds by a known drawing machine, and crimped by a push-type crimping machine or the like. Later, it may be cut to a desired length with a cutter such as an EC cutter.
• a cutter such as an EC cutter.
• it may be wound, and if necessary, processing such as twisting and false twisting may be performed.
• the resin is melted and spun from the spinneret, and then the cooled and solidified yarn is pulled and stretched by an ejector and collected on a moving net to form a nonwoven web, followed by thermal bonding. It is a manufacturing method which requires the process to do.
• the shape of the spinneret or the ejector various shapes such as a round shape and a rectangular shape can be adopted. Among these, a combination of a rectangular base and a rectangular ejector is preferable because the amount of compressed air used is relatively small and the yarns are not easily fused or scratched.
• the spinning temperature at the time of melting and spinning is preferably 290 to 380 ° C., more preferably 295 to 360 ° C., and further preferably 300 to 340 ° C. By setting the spinning temperature within the above range, a stable molten state can be obtained, and excellent spinning stability can be obtained.
• Component A and Component B are melted and measured by separate extruders, supplied to a composite spinneret, and spun as a composite fiber.
• Examples of methods for cooling the spun yarn of the composite fiber include a method of forcing cold air to the yarn, a method of natural cooling at the ambient temperature around the yarn, and adjusting the distance between the spinneret and the ejector. Or a combination thereof can be employed.
• the cooling conditions can be appropriately adjusted and adopted in consideration of the discharge amount per single hole of the spinneret, the spinning temperature, the atmospheric temperature, and the like.
• the cooled and solidified yarn is pulled and stretched by compressed air injected from the ejector.
• the method and conditions for pulling and stretching by the ejector are not particularly limited, but the compressed air injected from the ejector is heated to at least 100 ° C. or higher, and the heated compressed air is used at a spinning speed of 3,000 m / min or more.
• a method of pulling and stretching, or a distance from the lower surface of the spinneret to the compressed air outlet of the ejector is set to 450 to 650 mm, and the ejector compressed air (room temperature) is 5,000 m / min or more, 6
• a method of pulling and stretching at a spinning speed of less than 1,000 m / min is preferable in that crystallization of PPS fibers can be efficiently promoted.
• the nonwoven fabric can be obtained by collecting the PPS composite fibers obtained by stretching on a moving net to form a nonwoven web, and integrating the obtained nonwoven web by thermal bonding.
• thermocompression bonding for example, a combination of a hot embossing roll engraved on a pair of upper and lower roll surfaces, a roll having a flat (smooth) one roll surface and a roll engraved on the other roll surface
• thermocompression bonding with various rolls such as a hot embossing roll made of a combination of the above and a pair of upper and lower flat (smooth) rolls, or an air-through system that allows hot air to pass in the thickness direction of the nonwoven web.
• thermal bonding using a hot embossing roll that can maintain appropriate air permeability while improving mechanical strength can be preferably employed.
• a circle, an ellipse, a square, a rectangle, a parallelogram, a rhombus, a regular hexagon, a regular octagon, and the like can be used as the shape of the sculpture applied to the hot embossing roll.
• the PPS composite fiber of the present invention is extremely excellent in thermal adhesiveness, so that it can be thermally bonded at a temperature lower than the conventional temperature.
• the surface temperature of the hot embossing roll is the melting point of PPS. However, it is preferably ⁇ 150 to ⁇ 5 ° C.
• the surface temperature of the hot embossing roll to ⁇ 5 ° C. or lower with respect to the melting point of PPS, it is possible to prevent perforation from being generated in the crimping part due to melting of the fibers.
• the linear pressure of the hot embossing roll during heat bonding is preferably 200 to 1500 N / cm.
• the linear pressure of the hot embossing roll is preferably 200 to 1500 N / cm.
• the linear pressure of the hot embossing roll is set to 200 N / cm or more, more preferably 300 N / cm or more, it is possible to sufficiently heat-bond and suppress the peeling of the sheet and the occurrence of fluff.
• the linear pressure of the hot embossing roll to 1500 N / cm or less, more preferably 1000 N / cm or less, the convex portions of the sculpture are difficult to separate from the nonwoven fabric and the nonwoven fabric is difficult to peel from the roll or the nonwoven fabric breaks. Can be prevented.
• the adhesion area by the hot embossing roll is preferably 8 to 40%.
• the adhesion area is 8% or more, more preferably 10% or more, and still more preferably 12% or more, it is possible to obtain strength that can be practically used as a nonwoven fabric.
• the adhesion area is 40% or less, more preferably 30% or less, and even more preferably 20% or less, it is possible to prevent film-like and difficult to obtain the characteristics as a nonwoven fabric such as air permeability.
• adheresive area refers to the ratio of the portion of the nonwoven fabric in which the convex portion of the upper roll and the convex portion of the lower roll overlap and contact the nonwoven web when thermally bonded by a pair of concave and convex rolls.
• corrugation means the ratio which occupies for the whole nonwoven fabric of the part which contact
• a non-woven web before thermal bonding can be subjected to a temporary bonding process using a calender roll at a temperature of 70 to 120 ° C. and a linear pressure of 50 to 700 N / cm.
• a calender roll a combination of upper and lower metal rolls or a combination of a metal roll and a resin or paper roll can be used.
• MFR Melt flow rate
• the first decimal place is calculated from the following formula.
• Non-woven fabric thermal shrinkage (%) Measured according to JIS L1913 (2010) 6.10.3 “Dry-heat dimensional change rate”. The temperature in the constant temperature dryer was set to 200 ° C. and heat treated for 10 minutes.
• Example 1 100 mol% linear polyphenylene sulfide resin (manufactured by Toray Industries, Inc., product number: E2280, MFR: 160 g / 10 min) was dried at 160 ° C. for 10 hours in a nitrogen atmosphere and used as component A.
• Component B 100 mol% of a linear polyphenylene sulfide resin (manufactured by Toray Industries, Inc., product number: M2588, MFR: 300 g / 10 minutes) was dried in a nitrogen atmosphere at a temperature of 160 ° C. for 10 hours and used as component B.
• a linear polyphenylene sulfide resin manufactured by Toray Industries, Inc., product number: M2588, MFR: 300 g / 10 minutes
• the component A is melted with a core component extruder and the component B is melted with a sheath component extruder and weighed so that the mass ratio of component A to component B is 80:20.
• a core-sheath composite fiber was spun at a single-hole discharge rate of 1.37 g / min from a rectangular core-sheath spinneret with a hole diameter of 0.55 mm at ° C.
• the spun fiber was cooled and solidified in an atmosphere at a room temperature of 20 ° C., passed through a rectangular ejector installed at a distance of 550 mm from the die, and air heated to a temperature of 200 ° C. with an air heater was ejector pressure 0.17 MPa.
• the obtained core-sheath type composite continuous fiber has an average single fiber fineness of 2.9 dtex, a spinning speed of 4,797 m / min, crystallinity is lower on the fiber surface than the center of the fiber cross section, and spinnability is obtained by spinning for 1 hour. It was good with 0 cuts.
• the nonwoven web was temporarily bonded at a linear pressure of 200 N / cm and a temporary bonding temperature of 90 ° C. using a pair of upper and lower metal calendar rolls installed on the inline.
• a pair of upper and lower embossed rolls composed of a metal-made upper roll engraved with a polka dot pattern and a metal-made lower lower roll, with a linear pressure of 1000 N / cm and a thermal bonding temperature of 200 ° C. Heat-bonded to obtain a core-sheath type composite long fiber nonwoven fabric.
• the obtained core-sheath type composite continuous fiber nonwoven fabric has a basis weight of 260 g / m 2 , a high elongation product per basis weight of 54, a heat shrinkage of 0.1% in the vertical direction, and 0.0% in the transverse direction. It was.
• Example 2 (Component A) A PPS resin similar to that used in Example 1 was used as Component A. (Component B) A PPS resin similar to that used in Example 1 was used as Component B.
• the obtained core-sheath type composite continuous fiber has an average single fiber fineness of 3.2 dtex, a spinning speed of 4,317 m / min, a crystallinity of the fiber surface lower than the center of the fiber cross section, and a spinnability of 1 hour spinning. It was good with 0 cuts.
• the core-sheath type composite continuous fiber nonwoven fabric obtained had a basis weight of 260 g / m 2 , a high elongation product per unit weight of 51, a thermal shrinkage rate of 0.1% in the vertical direction, and 0.1% in the transverse direction. It was.
• Example 2 (Spun / nonwoven web)
• core-sheath type composite spinning and making a nonwoven web were performed.
• the obtained core-sheath type composite continuous fiber has an average single fiber fineness of 2.9 dtex, a spinning speed of 4,797 m / min, crystallinity is lower on the fiber surface than the center of the fiber cross section, and spinnability is obtained by spinning for 1 hour. It was good with 0 cuts.
• the non-woven web was temporarily bonded and heat-bonded in the same manner as in Example 1 except that the heat-bonding temperature was 140 ° C. to obtain a core-sheath type composite continuous fiber non-woven fabric.
• the core-sheath type composite continuous fiber nonwoven fabric obtained had a basis weight of 260 g / m 2 , a high elongation product per basis weight of 62, a heat shrinkage of 0.1% in the vertical direction, and 0.0% in the transverse direction. It was.
• Example 4 A PPS resin similar to that used in Example 1 was used as Component A.
• Component B A PPS resin similar to that used in Example 1 was used as Component B.
• spun / nonwoven web In the same manner as in Example 1, core-sheath type composite spinning and making a nonwoven web were performed.
• the obtained core-sheath type composite continuous fiber has an average single fiber fineness of 2.9 dtex, a spinning speed of 4,797 m / min, crystallinity is lower on the fiber surface than the center of the fiber cross section, and spinnability is obtained by spinning for 1 hour. It was good with 0 cuts.
• the non-woven web was temporarily bonded and heat bonded in the same manner as in Example 1 except that the heat bonding temperature was 240 ° C. to obtain a core-sheath type composite long fiber nonwoven fabric.
• the core-sheath type composite continuous fiber nonwoven fabric obtained had a basis weight of 260 g / m 2 , a high elongation product per unit weight of 50, a heat shrinkage of 0.1% in the vertical direction, and 0.1% in the transverse direction. It was.
• the nonwoven web was temporarily bonded and thermally bonded in the same manner as in Example 1 except that the heat bonding temperature of the embossing roll was set to 260 ° C. to obtain a single-component long fiber nonwoven fabric.
• the obtained single-component long-fiber nonwoven fabric has a basis weight of 260 g / m 2 , a high elongation product per basis weight of 4, and a thermal shrinkage of 0.0% in the vertical direction and 0.1% in the transverse direction. It was.
• the nonwoven fabric composed of the heat-adhesive conjugate fiber of the present invention has excellent mechanical strength while having thermal dimensional stability, so various industrial filters, electrical insulating materials, battery separators, membrane substrates for water treatment, It can utilize suitably for a heat insulation base material, protective clothing, etc.

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Nonwoven Fabrics (AREA)
• Multicomponent Fibers (AREA)

Priority Applications (5)

Applications Claiming Priority (4)

Publications (1)

Family

ID=50341430

Family Applications (1)

Country Status (6)

Cited By (4)

Families Citing this family (9)

Citations (8)

Family Cites Families (14)

• 2013
  • 2013-09-18 EP EP13839069.5A patent/EP2899303B1/de not_active Not-in-force
  • 2013-09-18 US US14/429,957 patent/US20150240390A1/en not_active Abandoned
  • 2013-09-18 JP JP2014536871A patent/JP6102932B2/ja active Active
  • 2013-09-18 WO PCT/JP2013/075134 patent/WO2014046120A1/ja active Application Filing
  • 2013-09-18 KR KR1020157002349A patent/KR102030381B1/ko active IP Right Grant
  • 2013-09-18 CN CN201380048763.7A patent/CN104641027B/zh active Active

Patent Citations (8)

Non-Patent Citations (1)

Also Published As

Similar Documents

Legal Events