WO2015147119A1 - 不織布シートとそれを用いた抽出用フィルター及び抽出用バッグ - Google Patents
不織布シートとそれを用いた抽出用フィルター及び抽出用バッグ Download PDFInfo
- Publication number
- WO2015147119A1 WO2015147119A1 PCT/JP2015/059274 JP2015059274W WO2015147119A1 WO 2015147119 A1 WO2015147119 A1 WO 2015147119A1 JP 2015059274 W JP2015059274 W JP 2015059274W WO 2015147119 A1 WO2015147119 A1 WO 2015147119A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- nonwoven fabric
- extraction
- layer
- fabric sheet
- bag
- Prior art date
Links
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Images
Classifications
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- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
- B01D2239/065—More than one layer present in the filtering material
- B01D2239/0672—The layers being joined by welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/12—Special parameters characterising the filtering material
- B01D2239/1233—Fibre diameter
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/20—All layers being fibrous or filamentary
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0276—Polyester fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/726—Permeability to liquids, absorption
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2439/00—Containers; Receptacles
- B32B2439/40—Closed containers
- B32B2439/46—Bags
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2505/00—Industrial
- D10B2505/04—Filters
Definitions
- the present invention relates to a non-woven sheet, and an extraction filter and an extraction bag using the same as a material (hereinafter, the extraction filter and the extraction bag are also referred to as “extraction filter or the like”). Specifically, the present invention relates to a nonwoven fabric sheet formed by laminating a melt-blown nonwoven fabric on the surface of a spunbond nonwoven fabric, and an extraction filter formed by processing the nonwoven fabric sheet such as cutting and sealing.
- Non-woven fabric sheets consisting of two layers, spunbond nonwoven fabric and meltblown nonwoven fabric, are generally relatively strong and have excellent extractability, making them suitable as filter materials for extraction materials and bags. For example, filling and sealing with powdered coffee Drip bags, tea bags filled and sealed with black tea, green tea, etc., soup packs filled and sealed with small pieces of kelp and bonito, etc., bath bags filled and sealed with small pieces of bathing agents, filled with powdered drugs -Sealed medicinal bags are widely distributed.
- the molding machines and molding filling machines for producing these extraction filters etc. are increasing in speed year by year due to technological advances, so the nonwoven fabric sheets are processed by cutting, sealing, etc. Therefore, there is a growing need for sealing in a short time, and therefore, development of a nonwoven fabric sheet used for an extraction filter or the like that can exhibit sufficient sealing strength in a short time is required.
- the layer of the meltblown nonwoven fabric is It is necessary that the fibers forming the nonwoven fabric are softened and fluidized quickly by heating, and that the fluidized resin quickly enters the fiber gaps of the spunbonded nonwoven fabric to be integrated.
- the softening point of the resin forming the meltblown nonwoven fabric must be low and have sufficient fluidity when melted.
- the spunbond nonwoven fabric needs to have heat resistance that can maintain the fiber form even when heated or pressed during sealing.
- the softening point of the resin that forms the spunbond nonwoven fabric is the resin that forms the meltblown nonwoven fabric.
- the spunbonded nonwoven fabric must maintain its fiber form without being deformed even when exposed to high temperatures at which the meltblown nonwoven fabric melts.
- “seal strength” is the breaking strength of a seal portion formed by sealing two nonwoven fabric sheets by welding.
- nonwoven fabric sheet comprising two layers of spunbond nonwoven fabric and meltblown nonwoven fabric .
- a type nonwoven fabric sheet produced by individually producing a spunbond nonwoven fabric and a melt blown nonwoven fabric, and then superimposing them and bonding them together by a partial thermocompression treatment or the like.
- B type non-woven sheet manufactured by laminating and forming a melt-blown non-woven fabric by subjecting a spunbonded non-woven fabric to partial thermocompression treatment and spraying the surface of the spun-bonded non-woven fabric while forming a fiber.
- non-woven sheet produced by laminating and forming a melt blown non-woven fabric by spraying a heat-melted resin into a fibrous form on the surface of a web-like spunbond non-woven fabric that has not been subjected to thermocompression treatment.
- the seal strength of the A-type non-woven fabric sheet is a spunbonded non-woven fabric because it is only partially bonded by a method such as partial thermocompression treatment because it takes a process of integrating both non-woven fabrics and then integrating them. In some cases, the adhesive strength at the interface between the melt-blown nonwoven fabric and the melt-blown nonwoven fabric is small, and sufficient seal strength cannot be obtained.
- the C-type nonwoven fabric sheet uses a web-like spunbond nonwoven fabric in which the fibers forming the spunbond nonwoven fabric are not bonded to each other, the tensile strength is small and it is easy to break or deform. It is difficult to obtain a large seal strength. Furthermore, in order to increase the tensile strength of C-type non-woven fabric sheets, a method of bonding the fibers of the spunbond nonwoven fabric by applying a partial thermocompression treatment after laminating the meltblown nonwoven fabric on the surface of the spunbond nonwoven fabric is considered. It is done.
- meltblown nonwoven fabric since the softening point of the melt blown nonwoven fabric already laminated is lower than the softening point of the spunbond nonwoven fabric, the meltblown nonwoven fabric is softened to the extent that it is not excessively softened and the spunbond nonwoven fabric is integrated. It is difficult to control the temperature so that the partial thermocompression treatment is incomplete, and sufficient tensile strength is often not obtained.
- the B type nonwoven fabric sheet is subjected to partial thermocompression treatment in advance to the spunbonded nonwoven fabric, and the fibers are partially bonded to each other, and the surface is sprayed with heat-melted resin. Since the melt-blown nonwoven fabric is laminated and manufactured, the bond strength at the interface between the spunbond nonwoven fabric and the melt-blown nonwoven fabric is large, a large sealing strength can be obtained, and the nonwoven fabric sheet has a high tensile strength. .
- the present inventors adopted the above-mentioned B type nonwoven fabric sheet as the object of development, and further aimed at developing a nonwoven fabric sheet that can obtain sufficient seal strength even when subjected to a high-speed molding machine.
- the degree of crystallinity of the resin should be kept low and the softening point should be lowered.
- the fiber of the bond nonwoven fabric can be improved in heat resistance by adjusting its crystallinity, crystal orientation, etc. within a specific range, for example, even if a high temperature air flow exceeding the melting point of the resin is blown
- the inventors have found that the fiber form can be maintained without being deformed, and have further researched to complete the present invention.
- Patent Document 1 discloses a drip-type packaging body for filling a drinking material comprising a water-permeable bag body in which an outer layer is a spunbond nonwoven fabric containing 50% or more of polyolefin and an inner layer is composed of a melt blown nonwoven fabric made of polyolefin.
- this package uses the above-mentioned A-type non-woven sheet produced by individually laminating a spunbonded non-woven fabric and a melt-blown non-woven fabric, and then laminating and bonding them together. The strength is small and it is difficult to obtain sufficient seal strength.
- a melt blown nonwoven fabric made of fibers containing polybutylene terephthalate or polytrimethylene terephthalate having a fiber diameter of 1 to 8 ⁇ m and a spunbond nonwoven fabric made of polyester fibers having a fiber diameter of 10 to 30 ⁇ m are laminated and integrated.
- a non-woven fabric for a filter is disclosed.
- this non-woven fabric for filters is intended to improve the dust collection performance, and the integration of the melt blown non-woven fabric and the spunbond non-woven fabric is preferably a partial thermocompression treatment with a pair of hot embossing rolls, etc.
- This also belongs to the A type.
- the melting point difference between the resin forming the melt blown nonwoven fabric and the resin forming the spunbonded nonwoven fabric is small, it is difficult to obtain a sufficient sealing strength.
- Patent Document 3 a non-crystalline ultrafine fiber nonwoven fabric layer formed by a melt blow method is laminated on a long fiber nonwoven fabric layer formed by a spunbond method, and integrated by performing partial thermocompression treatment in-line.
- a food filter comprising a laminated nonwoven fabric is disclosed.
- this food filter uses the above-mentioned C-type non-woven fabric sheet, and its manufacturing method involves entanglement of ultra-fine fibers with a web-like long-fiber non-woven fabric in which long fibers are not bonded and fixed. Then, a partial thermocompression treatment is performed to bond the long fibers together. Therefore, it is difficult to control the temperature so as to soften the ultrafine fibers without excessively softening them, and the partial thermocompression treatment is incomplete and sufficient tensile strength cannot be obtained. As a result, it is difficult to obtain a large seal strength.
- the problem to be solved by the present invention is a non-woven sheet used as a material for an extraction filter or an extraction bag, and can obtain a great sealing strength even when sealed in a short time. It is to provide a non-woven sheet that can sufficiently cope with the speeding up of the molding machine, and to provide an extraction filter and the like having a high sealing strength produced using such a non-woven sheet.
- the first invention for solving the above-mentioned problems is that the IV value is 0.60 to 1.00, the crystallinity is 30 to 80%, the crystal orientation is 60 to 95%, and the birefringence is A first layer made of a spunbonded nonwoven fabric formed of polyester resin fibers having a ( ⁇ n) of 0.040 to 0.100 and provided with a partial thermocompression bonding portion having a thermocompression area ratio of 5 to 30%; A nonwoven fabric sheet comprising: a second layer made of a melt blown nonwoven fabric formed of polyester resin fibers having a crystallinity of 0 to 14%, which is solidified by spraying on the surface of the first layer.
- the second invention is the nonwoven fabric sheet of the first invention, wherein the spunbond nonwoven fabric has a basis weight of 8.0 to 25.0 g / m 2 and a fiber diameter of 10 to 40 ⁇ m, and the basis weight of the melt blown nonwoven fabric is a 2.0 ⁇ 10.0g / m 2, and bulk density of the nonwoven fabric sheet is 0.15 ⁇ 0.40g / cm 3.
- the third invention is an extraction filter formed by using the nonwoven fabric sheet of the first invention or the second invention and arranging the second layer of the nonwoven fabric sheet inside and sealing a predetermined portion by welding. It is.
- the fourth invention uses the nonwoven fabric sheet of the first invention or the second invention, a bag formed by sealing the predetermined portion by welding the second layer of the nonwoven fabric sheet inside, An extraction bag in which an extraction material is enclosed.
- the second layer softens and fluidizes quickly by heating because the softening point of the polyester resin forming the meltblown nonwoven fabric is low.
- the polyester resin forming the spunbonded nonwoven fabric is excellent in heat resistance, the first layer can be used even when the heat seal bar is heated to about 160 to 180 ° C. The fiber form can be maintained without deformation. Therefore, the nonwoven fabric sheet of the present invention can obtain a large sealing strength even if it is sealed in a short time because the resin of the melt blown nonwoven fabric fluidized by heating at the time of sealing quickly penetrates into the fiber gap of the spunbond nonwoven fabric. Can do.
- the nonwoven fabric sheet has sufficient mechanical strength for a high-speed molding machine because sufficient sealing strength can be obtained in a short time, and furthermore, since it has appropriate rigidity, it can be molded thinly, resulting in transparency and It is also excellent in extractability.
- the extraction filter and the like according to the present invention have appropriate rigidity, when the three-dimensional extraction filter or the like is molded, it has excellent shape retention, and the first layer is in a form at a high temperature. Since the retainability is excellent, the seal portion does not shrink and deform at the time of sealing, and a product with good appearance can be obtained.
- the sealing strength is high.
- the extraction bag according to the present invention has excellent extractability because of its low boiling water shrinkage.
- the IV value is 0.60 to 1.00
- the crystallinity is 30 to 80%
- the crystal orientation is 60 to 95%
- the birefringence ( ⁇ n) is 0.040 to
- a first layer made of a spunbond nonwoven fabric formed of polyester resin fibers of 0.100 and provided with a partial thermocompression bonding portion having a thermocompression bonding area ratio of 5 to 30%, and sprayed onto the surface of the first layer
- a second layer made of a melt blown non-woven fabric formed of polyester resin fibers having a crystallinity of 0 to 14%, which is solidified.
- a heated and melted resin is extruded from a spinning nozzle to form a fiber. Then, a method is used in which a melt blown nonwoven fabric is laminated and formed by applying a high-temperature air flow to the surface and spraying it on the surface of the spunbond nonwoven fabric and solidifying it.
- the “crystallinity” is the ratio of the crystallized portion to the entire resin when the resin is partially crystallized. Generally, the lower the crystallinity, the lower the softening point.
- the softening point of such resin can be kept low at about 80 to 115 ° C.
- the resin can be quickly softened by heating at the time of sealing so as to exhibit high fluidity.
- a raw material resin having an IV value of about 0.30 to 0.80 and a relatively small molecular weight is used. It is desirable to select, and it is desirable to melt the resin at a high temperature before spinning so that there is as little crystal portion as possible.
- the temperature of the air flow is set to a high temperature of about 300 to 400 ° C., thereby suppressing the progress of crystallization of the resin. it can.
- the temperature of the air flow applied to the fibrous molten resin is set to a high temperature of about 300 to 400 ° C., so that the fiber surface of the melt blown nonwoven fabric is made the surface of the spunbond nonwoven fabric. Since it can be kept softened at the time of spraying, the fibers of the melt-blown nonwoven fabric can be adhered to each other in many parts, and the fibers of the melt-blown nonwoven fabric and the fibers of the spunbond nonwoven fabric are adhered to each other in many parts.
- the two nonwoven fabrics can be firmly integrated.
- polyester resin forming the melt blown nonwoven fabric of the second layer examples include polyester resins such as linear polyesters and copolymer polyesters, for example, terephthalic acid / isophthalate which is an acid component of polyethylene terephthalate / polyethylene isophthalate copolymer. What adjusted the polymerization ratio of the acid to the appropriate range can be used suitably.
- terephthalic acid as the main component, 5-sodium sulfoisophthalic acid other than isophthalic acid, diethylene glycol, propylene glycol, 1,4-butanediol, bentaerythritol, 4-hydroxybenzoic acid, adipic acid, naphthalenedicarboxylic acid,
- a dicarboxylic acid such as phthalic acid or naphthalenecarboxylic acid and a diol component obtained by polymerizing ethylene glycol and 1,4-butanediol at an appropriate ratio can be preferably used.
- a resin for forming a melt blown nonwoven fabric a resin to which a small amount of a matting agent made of an inorganic metal oxide such as titanium oxide, magnesium stearate, calcium stearate is added may be used.
- a matting agent made of an inorganic metal oxide such as titanium oxide, magnesium stearate, calcium stearate
- the second layer of the nonwoven fabric sheet of the present invention is formed of the melt blown nonwoven fabric described above, but is manufactured by other spinning methods other than the melt blown nonwoven fabric as long as the effects of the present invention are not impaired.
- Non-woven fabric and other materials can be mixed. The mixing ratio of such other nonwoven fabrics is preferably within 10% of the melt blown nonwoven fabric.
- the spunbond nonwoven fabric forming the first layer has an IV value of 0.60 to 1.00, a crystallinity of 30 to 80%, a crystal orientation of 60 to 95%, and a birefringence ( ⁇ n) of 0.1. It is formed of polyester resin fibers in the range of 040 to 0.100 and subjected to partial thermocompression treatment so that the thermocompression area ratio is in the range of 5 to 30%.
- the IV value is an index indicating the molecular weight of the resin constituting the fiber.
- the IV value is less than 0.60, it becomes difficult to sufficiently stretch the fiber during spinning, so that it tends to shrink when exposed to high temperatures, and the softening point decreases. Accordingly, since the first layer of spunbond nonwoven fabric may shrink and deform due to the high-temperature air flow when the second layer melt blown nonwoven fabric is laminated on the surface thereof, a flat and homogeneous nonwoven fabric sheet can be formed. It becomes difficult.
- the IV value exceeds 1.00 the viscosity of the heat-melted resin becomes high, so that it becomes difficult to extrude and stretch from the spinning nozzle and to form a homogeneous spunbonded nonwoven fabric.
- the polyester resin that forms the first layer of the spunbond nonwoven is a polyester resin such as linear polyester or copolymer polyester, and has a IV value of 0.60 to 1.00 as described above.
- Terephthalate, polybutylene terephthalate, or the like can be used.
- the crystallinity, crystal orientation, and birefringence of the polyester resin that forms the first layer of the spunbond nonwoven fabric are all indices representing the properties of the fibers, and the indices are related to each other.
- the crystallinity to 30 to 80%, the crystal orientation to 60 to 95%, and the birefringence ( ⁇ n) to the range of 0.040 to 0.100, for example, a high temperature of about 300 to 400 ° C.
- a spunbonded nonwoven fabric that is imparted with heat resistance that does not deform even when it is blown with an airflow and that is also excellent in rigidity can be obtained.
- the molten resin extruded from the spinning nozzle is 3,500 m / min or more. If it is less than 3,500 m / min, the fiber is not sufficiently stretched, so the fiber strength tends to be low, the heat resistance is low, and the fiber tends to shrink.
- a fiber form of the spunbond nonwoven fabric a monofilament, a multifilament, or a core-sheath composite fiber in which two kinds of resins are combined can be used.
- the cross-sectional shape of these fibers does not necessarily need to be round, and may be an elliptical shape, a triangular shape, a polygonal shape such as a polygon, or a hollow shape.
- the fibers drawn at the appropriate pulling speed are collected as a web on a collector such as a belt conveyor, and then subjected to a partial thermocompression treatment so that the fibers are partially bonded to each other.
- a partial thermocompression treatment By performing such partial thermocompression treatment, the tensile strength of the spunbonded nonwoven fabric is increased, and the rigidity of the spunbonded nonwoven fabric is increased by adjusting the fiber gap to an appropriate range.
- the area ratio of thermocompression bonding when performing partial thermocompression treatment should be in the range of 5-30%.
- the area ratio of thermocompression bonding is less than 5%, the bonded portion between the fibers decreases, and the spunbond nonwoven fabric tends to have insufficient tensile strength and rigidity.
- it exceeds 30% the bonded portion between the fibers becomes excessive and the fiber gap becomes narrow. Therefore, when sealing the nonwoven fabric sheet, the melt-blown non-woven fabric resin melts into the fiber gap of the spunbond nonwoven fabric. It becomes difficult and sufficient seal strength may not be obtained. Moreover, it becomes what becomes easy to clog a nonwoven fabric sheet, and extractability falls.
- a spunbond nonwoven fabric is passed between a pair of rolls composed of an embossed roll having an uneven surface structure and a flat roll having a smooth surface, and the spunbond nonwoven fabric is evenly dispersed throughout.
- a partial thermocompression bonding part may be formed.
- the fibers are bonded to each other at the partial thermocompression bonding section by heating the fibers with a heater and softening the resin, or by softening the fibers by generating heat by ultrasonic vibration.
- the method etc. to do can be employ
- the 1st layer is formed with the spun bond nonwoven fabric, if it is a range which does not impair the effect of the present invention, other than this spun bond nonwoven fabric, for example, the nonwoven fabric manufactured by other spinning methods, and other Material can be mixed.
- the mixing ratio of such other nonwoven fabrics is preferably within about 10% with respect to the spunbonded nonwoven fabric.
- the nonwoven fabric sheet of the present invention is produced by the steps of creating the first layer of spunbond nonwoven fabric as described above and the step of laminating and forming the second layer of meltblown nonwoven fabric on the surface of the first layer. May be performed individually, but the so-called in-line method in which both steps are performed continuously is preferable because the production efficiency can be increased.
- the non-woven fabric sheet thus produced has high heat resistance of the spunbonded non-woven fabric, it not only shrinks and deforms due to a high-temperature air flow of about 300 to 400 ° C. during lamination of the melt blown non-woven fabric, but also has a boiling water shrinkage of 3 Therefore, for example, even when used as an extraction bag immersed in boiling water and boiled, shrinkage deformation hardly occurs.
- the nonwoven fabric sheet of the present invention has high tensile strength and rigidity because the fibers forming the spunbond nonwoven fabric are stretched, so the surface strength, abrasion resistance, and friction resistance of the nonwoven fabric sheet are also high. Yes. Therefore, for example, when such a nonwoven fabric sheet is used as a material for an extraction bag that temporarily bonds a tag and a hanging thread to the surface of the bag, there is a problem that the bag is damaged when the tag and the hanging thread are peeled off. It can be almost non-occurring.
- the softening point of the resin forming the second layer meltblown nonwoven fabric is as low as about 80 to 115 ° C., while the resin forming the first layer spunbond nonwoven fabric is excellent in heat resistance. Therefore, when sealing such a nonwoven fabric sheet with a molding machine, the melt-blown nonwoven fabric softens quickly by heating and exhibits fluidity, but the spunbond nonwoven fabric is sandwiched by a high-temperature heat seal bar of about 160 to 180 ° C., for example. The fiber form can be maintained without being deformed by heating.
- melt blown nonwoven resin fluidized by heating quickly penetrates into the fiber gaps of the spunbond nonwoven fabric to produce a so-called “anchor effect”, so that a sufficient sealing strength can be obtained even if it is sealed in a short time. It can be done.
- the nonwoven fabric sheet of the present invention is used in a high-speed molding machine with a high production capacity as a material for an extraction filter or the like, the occurrence rate of defective products with insufficient seal strength is extremely low and excellent in machine suitability. Is.
- molding machines such as extraction filters have been extremely accelerated. For example, the production capacity of a molding machine that performs sealing by heat sealing has been increased to about 600 to 800 pieces per minute. Further, the production capacity of a molding machine that performs sealing by ultrasonic vibration has been increased to about 200 to 400 pieces per minute. Therefore, the nonwoven fabric sheet, which is a material for the extraction filter, is required to have mechanical suitability capable of obtaining a large seal strength in a shorter time.
- the nonwoven fabric sheet of this invention can obtain big sealing intensity
- the sealing strength by heat sealing in the present invention is to peel off the surface welded portion when the second layer of the two nonwoven fabric sheets is opposed to each other and heat-sealed at a predetermined place and surface-welded. Necessary tensile force.
- the sealing strength by ultrasonic vibration means that when the second layer of the two nonwoven fabric sheets is opposed to each other and ultrasonic welding is applied to a predetermined portion and line welding is performed, the line welding portion is peeled off. Is the tensile force required for
- the nonwoven fabric sheet of the present invention is subjected to thermal calendering treatment or partial thermocompression treatment for the purpose of controlling the thickness of the nonwoven fabric sheet within a certain range or suppressing fuzz on the surface of the melt blown nonwoven fabric of the second layer. Can do. However, since the crystallinity of the resin forming the melt-blown nonwoven fabric may be increased by these treatments, the crystallinity of the resin of the melt-blown nonwoven fabric is kept within the range of 0 to 14% even if these treatments are performed. Caution must be taken.
- a hydrophilic agent may be added to increase the water permeability so that the nonwoven fabric sheet of the present invention can be more suitably used as an extraction filter or the like.
- a hydrophilic agent may be added to increase the water permeability so that the nonwoven fabric sheet of the present invention can be more suitably used as an extraction filter or the like.
- another nonwoven fabric, a woven fabric, etc. can be laminated
- the basis weight of the first layer of the spunbond nonwoven fabric is 8.0 to 25.0 g / m 2 and the fiber diameter is 10 to 40 ⁇ m.
- the nonwoven fabric sheet has a basis weight of the second melt-blown nonwoven fabric layer of 2.0 to 10.0 g / m 2 and a bulk density of the nonwoven fabric sheet of 0.15 to 0.40 g / cm 3 .
- the basis weight of the first layer of spunbonded nonwoven fabric is preferably 8.0 to 25.0 g / m 2 . If the fabric weight of the spunbond nonwoven fabric is within the range, the nonwoven fabric sheet will have a sufficiently high tensile strength, so the nonwoven fabric sheet will not be damaged or deformed when manufacturing an extraction filter or the like with a molding machine. This is because a large seal strength can be obtained and the mechanical suitability is further improved.
- the fiber diameter of the first layer of spunbonded nonwoven fabric is preferably 10 to 40 ⁇ m.
- the fiber diameter of the spunbonded nonwoven fabric is within such a range, sufficient extractability can be obtained when used as an extraction filter or the like.
- the fiber gap of the spunbonded nonwoven fabric is large, and at the time of sealing, a greater amount of the resin of the meltblown nonwoven fabric that has fluidized penetrates into the fiber gap, so that extremely high sealing strength can be obtained.
- the basis weight of the melt blown nonwoven fabric of the second layer is preferably 2.0 to 10.0 g / m 2 . This is because when the basis weight of the melt blown nonwoven fabric is within such a range, the amount of the resin that is fluidized at the time of sealing increases, so that a large sealing strength can be obtained in a shorter time. Also, sufficient extractability can be obtained when used as an extraction filter or the like.
- the bulk density of the nonwoven fabric sheet of the present invention is preferably 0.15 to 0.40 g / cm 3 .
- the bulk density of the second layer spunbond nonwoven fabric mainly affects the seal strength, but it is difficult to measure the first layer and the second layer separately.
- the bulk density of the nonwoven fabric sheet is defined. Spunbond nonwoven fabrics desirably retain sufficient fiber gaps, and further, by keeping the bulk density low, the thickness of the nonwoven fabric sheet increases, so that the nonwoven sheet is “strained” to improve mechanical suitability. be able to. Accordingly, the bulk density is preferably 0.40 g / cm 3 or less. Further, the bulk density is preferably lower from the viewpoint of increasing the sealing strength and increasing the rigidity, but it is difficult to produce a bulk density lower than 0.15 g / cm 3 .
- the non-woven fabric sheet according to the second invention is extremely excellent in mechanical suitability, for example, when a filter for extraction or the like is produced using the nonwoven fabric sheet, a high sealing strength can be obtained in a shorter time using a high-speed molding machine. Is. Moreover, since the nonwoven fabric sheet has high tensile strength and high rigidity, for example, when a continuous long nonwoven fabric sheet is put on a high-speed molding machine, it is difficult to cause a problem of meandering left and right during conveyance. Furthermore, when the extraction bags manufactured using the nonwoven fabric sheet are individually wrapped in the outer bag by the packaging machine, the extraction bag receives a pressing force when being pushed into the outer bag. Since the seal strength is sufficiently large, the problem that the seal portion peels off and is not easily damaged occurs.
- the extraction filter 1 is a drip coffee filter that is used by being set in a funnel-shaped dripper (not shown), and the bottom of the substantially inverted trapezoidal filter portion 2 in which the second layer of the nonwoven fabric sheet is arranged on the inside and A surface weld portion 3 is provided on the side.
- the upper edge part 4 is opened and shaped into a mortar shape, powdered coffee is put in from the opened upper edge part 4, and hot coffee is poured from above to extract a coffee beverage.
- a continuous long nonwoven fabric sheet may be used as a raw material, and cut into a predetermined shape and surface-welded using a high-speed molding machine.
- surface welding is performed by sandwiching and heating the planned welding position of the nonwoven fabric sheet with a heat seal bar, and the first layer of the spunbond nonwoven fabric excellent in heat resistance is not softened, and the softening point of the second layer is low.
- Surface welding can be performed by melting only the melt blown non-woven fabric to function as an adhesive.
- welding by ultrasonic vibration, a fusing seal that simultaneously cuts and welds an extraction sheet, or the like can be employed.
- the extraction filter 1 manufactured in this way has a surface welded portion formed by heat sealing because the first layer of the nonwoven fabric sheet constituting the filter portion 2 is excellent in form retention at high temperatures. No shrinkage deformation is seen in No. 3, and the product has a great sealing strength and a good appearance. Further, the extraction filter 1 is excellent in shape retention due to the appropriate rigidity of the nonwoven fabric sheet constituting the filter portion 2, and is shaped into a state where the upper edge portion 4 is largely opened as shown in FIG. Can be held.
- the shape of the extraction filter 1 is not limited to the substantially inverted trapezoidal shape shown in FIG. 1, but may be any shape such as a substantially inverted triangular shape or a disk shape, and the size and usage thereof are particularly limited. There is no.
- the extraction bag 5 is a product generally called a tea bag.
- the extraction bag 5 and the bag body 6 formed into a tetra shape are used with the nonwoven fabric sheet
- the extraction bag 5 is picked with a fingertip. It consists of a tag 9 for picking up, and a hanging thread 8 having one end bonded to the upper end portion of the bag body 6 and the other end bonded to the tag 9.
- the bag body 6 is formed into a bag shape by arranging the second layer of the nonwoven fabric sheet on the inside and forming the line welded portion 7 at the edge of each side by ultrasonic vibration. Dry tea leaves for black tea are enclosed as an extraction material (not shown).
- a continuous long non-woven fabric sheet is used as a raw material, and a dry tea leaf is filled and sealed while forming the bag body 6 by cutting and wire welding using a high-speed molding and filling machine. do it.
- the linear welding of the bag body 6 generates heat by applying vibration to the welding target portion of the nonwoven fabric sheet by ultrasonic waves, and the first layer spunbond nonwoven fabric having excellent heat resistance is not softened and has a low softening point. Only the melt blown nonwoven fabric of the second layer can be melted so as to function as an adhesive, thereby performing linear welding.
- seat for extraction simultaneously, etc. are employable.
- the bag body 6 formed in this way is attached to the line weld portion 7 formed by the ultrasonic vibration described above. Has no shrinkage deformation and has a high sealing strength and good appearance. Moreover, since the bag body 6 has a low boiling water shrinkage due to the excellent shape retention of the first layer of the nonwoven fabric sheet, the bag body 6 is deformed even if the extraction bag 5 is immersed in boiling water for a long time. There is no problem. Furthermore, the bag body 6 is excellent in shape retention due to the appropriate rigidity of the nonwoven fabric sheet constituting it, and as shown in FIG. 2, holds a beautiful tetra shape with each side extending in a straight line. To get.
- the shape of the bag body 6 is not limited to the tetra shape, and may be any shape such as a pillow shape, a pyramid shape, a disk shape or a stick shape, and there are no particular restrictions on the size, capacity, and usage. Absent. Furthermore, it is possible to temporarily bond the hanging thread 8 and the tag 9 to the surface of the bag body 6 with such a strength that they can be easily peeled off during use.
- the extraction bag 5 is made of a resin film or paper (not shown), one by one or a plurality, in order to maintain the flavor of the dried tea leaves in the bag body 6 and to prevent fouling. It is preferable to enclose in a bag or an outer container. As described above, when the extraction bag 5 is sealed in an outer bag or the like, a pressing force is applied to the extraction bag 5 by the packaging machine, but the bag body 6 has a high sealing strength of the linear weld portion 7. Therefore, there is almost no problem that the wire welded portion 7 is peeled off and damaged.
- Crystallinity (%) ( ⁇ Hm ⁇ Hc) / 141 ⁇ 100 (5) IV value It measured based on JISK7390.
- Crystal orientation (%) (180 ⁇ H) ⁇ 100/180
- Fibers were collected from the part of the spunbonded nonwoven fabric to be tested which was not partially thermocompression bonded, and obtained from retardation and fiber diameter by ordinary interference fringes using a BH-2 polarizing microscope compensator manufactured by OLYMPUS.
- Fiber diameter ( ⁇ m) Ten diameters of the fiber to be tested were visually measured using an optical microscope, and the average value was obtained. When the cross-sectional shape of the fiber was other than a round shape, the diameter was obtained when the cross-sectional shape was virtually converted to a round shape having the same area.
- Machine suitability (heat sealing machine 1) A high-speed molding and filling machine (RF series manufactured by Topack Co., Ltd .: filling capacity of 600 bags / min) was operated for 30 minutes, and mechanical aptitude was evaluated by measuring the number of defective products generated. Specifically, a 160 mm wide long non-woven sheet (test target) is prepared, filled with 3 g of green tea leaves (with green tea) per bag, and a pillow-shaped extraction having a size of 80 mm ⁇ 100 mm. A bag was manufactured. At that time, the rate of occurrence of defective products (hereinafter also referred to as “defective rate”) is less than 1% and no other trouble occurs. It was determined.
- defective rate rate of occurrence of defective products
- the filling suitability was evaluated by operating a high-speed molding filling machine (TWINKLE manufactured by Enomoto Kogyo Co., Ltd .: filling capacity 200 bags / min) for 1 hour and measuring the number of defective products generated. Specifically, after the tetra-shaped extraction bag was prepared according to the above (13), the extraction bag was made into a bag with a pitch of 90 mm by half-folding a 180 mm width PET / PET deposited / PE film. Each bag was pushed into the bag one by one, filled and sealed, and an individual package of the extraction bag was manufactured. Thereafter, the film bag was opened, and the occurrence state of defective products in which the seal portion of the extraction bag was damaged when the film bag was filled was confirmed.
- TWINKLE manufactured by Enomoto Kogyo Co., Ltd .
- Example 1 The polyethylene terephthalate resin is heated and melted by the spunbond method, spun from a spinneret having a diameter of 0.3 mm, stretched and opened at a spinning speed of 5,000 m / min by an ejector, collected on a belt conveyor, and web This was subjected to a partial thermocompression treatment with a thermocompression area ratio of 15% to produce a first layer of spunbond nonwoven fabric.
- the obtained spunbonded nonwoven fabric has a basis weight of 12.0 g / m 2 and a fiber diameter of 13.6 ⁇ m.
- the resin has an IV value of 0.71, a crystallinity of 71%, a crystal orientation of 85%, and a birefringence ( ⁇ n ) 0.080.
- a polyester resin having an acid component terephthalic acid / isophthalic acid polymerization ratio of 86/14 is used on the surface of the spunbond nonwoven fabric, the air flow temperature is set to 370 ° C., and the spout to the surface of the spunbond nonwoven fabric.
- the distance (DCD) was adjusted to 30 mm, and a melt blown nonwoven fabric of a second layer having a basis weight of 6 g / m 2 was laminated to form a nonwoven fabric sheet.
- the crystallinity of the resin of the melt blown nonwoven fabric was 0.4%.
- Example 1 The surface of the first layer spunbond nonwoven fabric prepared under the same conditions as in Example 1 is a polyethylene terephthalate / polyethylene isophthalate copolymer, which is crystallized by changing the polymerization ratio of terephthalic acid / isophthalic acid as an acid component. Resins adjusted to 5 levels of 3.0%, 10.0%, 14.0%, 15.0% and 23.0% were laminated and formed under the same conditions as in Example 1 by the melt blow method. By forming a second layer melt blown nonwoven fabric, samples of five types of nonwoven fabric sheets were prepared. The evaluation results of each of the above tests conducted on the five types of nonwoven fabric sheets obtained in this test example are as shown in the columns “Sample 2” to “Sample 6” in Table 1 below.
- Test Example 2 By changing the IV value of the polyethylene terephthalate resin that is the raw material of the first layer of the spunbond nonwoven fabric and the pulling conditions during spinning, six types of spunbond nonwoven fabrics as shown in Table 2 below were prepared, The second layer meltblown nonwoven fabric was laminated and formed under the same conditions as in Example 1 to prepare six types of nonwoven fabric sheet samples.
- the evaluation results of the above tests conducted on the six types of nonwoven fabric sheets obtained in this test example are as shown in the columns “Sample 7” to “Sample 12” in Table 2 below.
- Example 7 Considering the evaluation results of “Sample 7” to “Sample 12” in Table 2, the IV value of the resin is 0.60 to 1.00, the crystallinity is 30 to 80%, and the crystal orientation is 60 to 95%.
- a nonwoven fabric sheet (sample 7) in which a meltblown nonwoven fabric having a resin crystallinity of 3.0% is laminated on the surface of a spunbonded nonwoven fabric having a birefringence ( ⁇ n) in the range of 0.040 to 0.100. From (10) to (10), it can be seen that both the heat seal type high speed molding and filling machine and the ultrasonic seal type high speed molding and filling machine do not cause any trouble in operation and have good mechanical suitability.
- the IV value is 0.60 to 1.00
- the crystallinity is 30 to 80%
- the crystal orientation is 60 to 95%
- the birefringence ( ⁇ n) is 0.040 to 0.100.
- the polyethylene terephthalate resin has an IV value of 0.71, a crystallinity of 71%, a crystal orientation of 85% and a birefringence ( ⁇ n) of 0.080, and a fiber diameter of 13.6 ⁇ m.
- Table 3 four types of spunbonded nonwoven fabrics having a basis weight changed between 4 and 7 to 27 g / m 2 were prepared.
- a second layer of melt blown nonwoven fabric was laminated and formed under the same conditions as in Example 1 to prepare “Sample 13” to “Sample 16” of the four types of nonwoven fabric sheets.
- Test Example 4 On the surface of the first layer spunbond nonwoven fabric prepared under the same conditions as in Example 1 above, spinning was performed under the same conditions using the same resin as in Example 1, and the basis weight was 1.8 as shown in Table 4 below. Samples of four types of nonwoven fabric sheets were prepared by laminating and forming a second layer of meltblown nonwoven fabric that was varied in four stages between ⁇ 11.0 g / m 2 . The evaluation results of each of the above tests performed on the four types of nonwoven fabric sheets obtained in this test example are as shown in the columns “Sample 22” to “Sample 25” in Table 4 below.
- Example 5 When the second layer melt blown nonwoven fabric is laminated on the surface of the first layer spunbond nonwoven fabric prepared under the same conditions as in Example 1 above, the same resin as in Example 1 is used, and the spunbond nonwoven fabric is formed from the spout. By changing the distance to the surface or performing calendering after laminating the melt-blown nonwoven fabric, the bulk density of the nonwoven fabric sheet was changed as shown in Table 5 to prepare four types of nonwoven fabric sheet samples. The evaluation results by the above tests conducted on the four types of nonwoven fabric sheets obtained in this test example are as shown in the columns “Sample 26” to “Sample 29” in Table 4 below.
- the non-woven fabric sheet according to the present invention has high mechanical suitability when producing a filter for extraction or a bag for extraction using a high-speed molding machine, so that high sealing strength can be obtained in a short time. Filters have high sealing strength and are not easily damaged. Therefore, it can be suitably used in the field of extraction filters and extraction bags for beverages such as powdered coffee, black tea, green tea, and foods such as kelp and bonito, and the non-woven sheet that is the material thereof.
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Abstract
Description
なお、本発明において「シール強度」とは、2枚の不織布シートを溶着によりシールして形成したシール部の破断強度である。
さらに、Cタイプの不織布シートは、その引張強度を大きくするために、スパンボンド不織布の表面にメルトブロー不織布を積層した後に部分熱圧着処理を施して、スパンボンド不織布の繊維同士を接着させる方法が考えられる。しかし、かかる方法では、既に積層されているメルトブロー不織布の軟化点がスパンボンド不織布の軟化点よりも低いために、メルトブロー不織布を過度に軟化させることなく、かつスパンボンド不織布を一体化させる程度に軟化させるように温度コントロールすることは難しく、部分熱圧着処理が不完全になり十分な引張強度が得られない場合が多い。
その結果、シール時の加熱により、メルトブロー不織布を形成する樹脂を速やかに軟化させ、十分な流動性を与えるためには、樹脂の結晶化度を低く抑えて軟化点を下げればよく、他方、スパンボンド不織布の繊維は、その結晶化度や結晶配向度等を特定の範囲内に調整することで耐熱性を高めることができ、例えば、樹脂の融点を超えるような高温の空気流を吹き付けても変形せず繊維形態を保ち得ることを見出し、さらに研究を重ねて本発明を完成するに至った。
しかし、この包装体は、スパンボンド不織布とメルトブロー不織布とを個別に作成した後にこれらを重ね合わせ貼り合せて製造した、上記のAタイプの不織布シートを用いるものであり、両不織布層の界面の接着強度が小さく、十分なシール強度を得ることが難しいものである。
しかし、このフィルター用不織布は、粉塵の捕集性能の向上を目的とするものであり、メルトブロー不織布とスパンボンド不織布の一体化は、一対の熱エンボスロール等による部分熱圧着処理が好ましいとしており、これも上記Aタイプに属するものである。また、メルトブロー不織布を形成する樹脂とスパンボンド不織布を形成する樹脂との融点差が小さいため、十分なシール強度を得ることが難しいものである。
しかし、この食品用フィルターは、上記のCタイプの不織布シートを用いたものであり、その製造方法は、長繊維同士が未接着で固定化されていないウェブ状の長繊維不織布に極細繊維を絡ませ、その後に部分熱圧着処理を施して長繊維同士を接着させるものである。そのため、極細繊維を過度に軟化させることなく、かつ長繊維同士を接着させる程度に軟化させるように温度コントロールすることが難しく、部分熱圧着処理が不完全になり十分な引張強度が得られず、結果として、大きなシール強度を得ることが難しいものである。
したがって、本発明の不織布シートは、シールの際に加熱によって流動化したメルトブロー不織布の樹脂が、スパンボンド不織布の繊維間隙に速やかに浸入するため、短時間でシールしても大きなシール強度を得ることができる。
本発明に係る第1の発明は、IV値が0.60~1.00、結晶化度が30~80%、結晶配向度が60~95%及び複屈折率(Δn)が0.040~0.100であるポリエステル系樹脂の繊維により形成され、熱圧着面積率が5~30%の部分熱圧着部が設けられたスパンボンド不織布からなる第1層と、該第1層の表面に吹き付けられて固化した結晶化度が0~14%のポリエステル系樹脂の繊維により形成されたメルトブロー不織布からなる第2層とを備える不織布シートである。
このようにポリエステル系樹脂の結晶化度を0~14%の範囲内に調整するためには、例えば、原料樹脂としてIV値が0.30~0.80程度の分子量が比較的に小さいものを選定することが望ましく、また、紡糸前に樹脂を高温で溶融させて、結晶部分がなるべく存在しない状態にしておくことが望ましい。さらに、溶融させた樹脂を紡糸ノズルから繊維状に押出して空気流を当てる際に、空気流の温度を約300~400℃の高温に設定することで、樹脂の結晶化の進行を抑えることができる。
かかる第1層を形成するスパンボンド不織布は、IV値が0.60~1.00、結晶化度が30~80%、結晶配向度が60~95%及び複屈折率(Δn)が0.040~0.100の範囲であるポリエステル系樹脂の繊維により形成され、熱圧着面積率が5~30%の範囲になるように部分熱圧着処理が施されている。
他方、IV値が1.00を超えると、加熱溶融させた樹脂の粘度が高くなるため、紡糸ノズルからの押出しと延伸が困難となり、均質なスパンボンド不織布を形成することが難しくなる。
なお、近年、抽出用フィルター等の成形機はきわめて高速化されており、例えば、シールをヒートシールにより行うタイプの成形機の製造能力は、毎分600~800個程度にまで高められており、また、超音波加振によりシールを行うタイプの成形機の製造能力は、毎分200~400個程度にまで高められている。したがって、抽出用フィルターの材料である不織布シートには、より短時間で大きなシール強度が得られる機械適性が必要とされている。
なお、本発明におけるヒートシールによるシール強度とは、2枚の不織布シートの第2層をそれぞれ対向させて所定箇所をヒートシールして面溶着させた場合に、その面溶着部を引き剥がすために必要な引張力である。また、超音波加振によるシール強度とは、2枚の不織布シートの第2層をそれぞれ対向させて所定箇所を超音波加振して線溶着させた場合に、その線溶着部を引き剥がすために必要な引張力である。
なお、本発明の不織布シートは、本発明の効果を損なわない範囲であれば、さらに他の不織布や織布等を積層して3層以上からなる不織布シートとすることができる。
本発明に係る第2の発明は、第1の発明の不織布シートにおいて、第1層のスパンボンド不織布の目付が8.0~25.0g/m2及び繊維径が10~40μmであると共に、第2層のメルトブロー不織布層の目付が2.0~10.0g/m2であり、かつ、不織布シートの嵩密度が0.15~0.40g/cm3である不織布シートである。
また、不織布シートの引張強度が大きく、また剛性が高いため、例えば、連続した長尺状の不織布シートを高速成形機にかけた際に、搬送中に左右に蛇行するような問題が生じ難い。
さらに、不織布シートを用いて製造した抽出用バッグを、包装機によって1個ずつ外装袋に個包装する場合に、抽出用バッグは、外装袋に押し込まれる際に押圧力を受けるが、抽出用バッグのシール強度が十分に大きいため、シール部が剥がれて破損するといった問題が生じ難いものである。
その際の面溶着は、ヒートシールバーによって不織布シートの溶着予定箇所を挟圧して加熱し、耐熱性に優れた第1層のスパンボンド不織布は軟化させることなく、軟化点が低い第2層のメルトブロー不織布だけを溶融させて接着材として機能させることにより面溶着することができる。
なお、他のシール方法としては、超音波加振による溶着や、抽出用シートの切断と溶着を同時に行う溶断シールなどを採用することができる。
また、抽出用フィルター1は、そのフィルター部2を構成する不織布シートが有する適度な剛性によって保形性に優れたものであり、図1に示すとおり上縁部4を大きく開口させた状態に整形して保持させることができる。
なお、抽出用フィルター1の形状は、図1に示す略逆台形状に限らず、略逆三角形状または円盤型など任意の形状にすることができ、また、その大きさや使用方法についても特に制限はない。
なお、他のシール方法としては、ヒートシールバーで挟圧することによる面溶着や、抽出用シートの切断と溶着を同時に行う溶断シールなどを採用することができる。
また、袋体6は、不織布シートの第1層の優れた形態保持性によって、沸水収縮率が低いため、抽出用バッグ5を沸騰水中に長時間浸漬しても、袋体6が変形するといった問題は生じない。
さらに、袋体6は、それを構成する不織布シートが有する適度な剛性によって保形性に優れたものであり、図2に示すように、各辺が直線上に延びた美しいテトラ形を保持し得るものである。
このように、抽出用バッグ5を外装袋等に封入する際には、抽出用バッグ5に対して包装機による押圧力がかかるが、袋体6は、その線溶着部7のシール強度が大きいため、線溶着部7が剥がれて破損するといった問題は殆ど生じないものである。
(1)目付(g/m2)
JIS L-1906に準拠し、試験対象の不織布から10cm四方の試験片を採取して質量を測定して算出した。
(2)厚み(mm)
JIS L-1906に準拠し、不織布の布面に荷重100g/cm2を付加した状態での厚みを測定した。
(3)嵩密度(g/cm3)
上記(1)及び(2)の方法で測定した目付と厚みから、以下の式により単位体積あたりの質量を求めた。
嵩密度(g/cm3)=目付(g/m2)/(厚み(mm)×1000)
試験対象の不織布から試験片を採取し、その試験片を示差走査熱量計にセットして、昇温速度を10℃/分として30℃から240℃まで昇温し、結晶化発熱量ΔHcと結晶融解熱量ΔHmを測定して、以下の式によって算出した。なお、式中の数値「141」は、ポリエステルの完全結晶の融解熱量(単位:J/g)である。
結晶化度χc(%)=(ΔHm-ΔHc)/141×100
(5)IV値
JIS K7390に準拠して測定した。
(6)結晶配向度(%)
結晶配向度X線回折装置を用い、試料の厚みを約0.5mmに調整して、30KV、80A、スキャンニング速度1度/分、チャート速度10mm/分、タイムコンスタント1秒、レシービングスリット0.3mmの条件で、回折角2θが7度から35度までの回折強度曲線を描き、2θ=16度及び22度に描かれる反射を各々(010)、(110)とし、さらに、(110)面を-180度から+180度方位角方向に回折強度曲線を描く±180度で得られる回折強度曲線の平均値をとり、水平線を引きベースラインとし、ピークの頂点からベースラインに垂線をおろし、その高さの中点を求める。中点を通る水平線を引き、これと回折強度曲線との2つの交点間の距離を測定し、この値を角度に換算した値を配向角Hとし、以下の式により求めた。
結晶配向度(%)=(180-H)×100/180
試験対象のスパンボンド不織布の部分熱圧着されていない部分から繊維を採取し、OLYMPUS社製BH-2偏光顕微鏡コンペンセーターを用い、通常の干渉縞によって、レターデーションと繊維径より求めた。
(8)繊維径(μm)
光学顕微鏡を用いて目視により試験対象の繊維について10箇所の直径を測定し、その平均値を求めた。なお、繊維の断面形状が丸形以外の場合は、断面形状を仮想的に同面積の丸形に変換した場合に得られる直径とした。
試験対象の不織布から試験片を採取し、その試験片を融点測定器(アズワン株式会社製,ATM-01)の昇温部に載せ、常温から徐々に昇温しつつ試験片を金属製のヘラで押圧し、目視観察により軟化が認められた時点の温度を軟化点とした。
(10)引張強度(N/15mm)
連続的に製造した長尺状の不織布シートの長手方向(製造の際の流れ方向)に沿って、長さ150mm、幅15mmの試験片を10枚作成し、各試験片をJTトーシ社製リトルセンスターによって100mm/分の速度で引張して強度を測定し、10枚の試験片の測定値の平均値をもって引張強度とした。
高速成形充填機(株式会社トパック製RFシリーズ:充填能力600袋/分)を30分間稼動させ、不良品の発生数を計測することで機械適性を評価した。具体的には、160mm幅の長尺状の不織布シート(試験対象)を用意し、緑茶用の茶葉(抹茶入り)を1袋あたり3gずつ充填し、80mm×100mmの寸法のピロー形の抽出用バッグを製造した。その際の不良品の発生率(以下、「不良率」とも言う。)が1%未満であり、かつ、他のトラブルの発生がなかった場合を「適」とし、その他の場合を「不適」と判定した。
(12)機械適性(ヒートシール機2)
高速成形充填機(株式会社トパック製RFシリーズ:充填能力800袋/分)を30分間稼動させ、不良品の発生数を計測することで機械適性を評価した。具体的には、160mm幅の長尺状の不織布シート(試験対象)を用意し、緑茶用の茶葉(抹茶を含む)を1袋あたり3gずつ充填し、80mm×100mmの寸法のピロー形の抽出用バッグを製造した。その際の不良率が1%未満であり、かつ、他のトラブルの発生がなかった場合を「適」とし、その他の場合を「不適」と判定した。
高速成形充填機(椿本興業株式会社製TWINKLE:充填能力200袋/分)を60分間稼動させ、不良品の発生数を計測することで機械適性を評価した。具体的には、120mm幅の長尺状の不織布シート(試験対象)を用意し、CTC製法による紅茶用の茶葉を1袋あたり2gずつ充填し、袋体が1辺50mmのテトラ形であって、袋体の表面に吊糸とタグが仮接着された抽出用バッグを製造した。その際の不良率が1%未満であり、かつ、他のトラブルの発生がなかった場合を「適」とし、その他の場合を「不適」と判定した。
(14)シール強度
上記(11)、(12)及び(13)の成形充填機により製造された抽出用バッグについて、ランダムに20個ずつ試験対象の抽出用バッグを採取し、シール部について破断強度を測定して、20個の測定値の平均値を算出した。上記(11)及び(12)の高速成形充填機により製造された80mm×100mmのピロー形の抽出用バッグについては、その短辺における両端の25mmずつを除去して30mm幅の試験片を作成し、そのシール部(面溶着部)の破断強度を測定した。また、上記(13)の成形充填機により製造された1辺50mmのテトラ形の抽出用バッグについては、切開した後、1本のシール部(線溶着部)の両端の10mmずつを除去して30mm幅の試験片を作成し、そのシール部の破断強度を測定した。
高速成形充填機(椿本興業株式会社製TWINKLE:充填能力200袋/分)を1時間稼働させ、不良品の発生数を計測することで充填適性を評価した。具体的には、上記(13)によってテトラ形の抽出用バッグを作成した後、その抽出用バッグを、180mm幅のPET/PET蒸着/PEフィルムを半折して90mmのピッチで製袋したフィルム袋に対して、1袋ずつ押し込んで充填密封して抽出用バッグの個包装品を製造した。その後、フィルム袋を開封し、フィルム袋への充填時に抽出用バッグのシール部が破損した不良品の発生状況を確認した。全ての抽出用バッグに破損が見られなかった場合を「問題なし」と判定した。
(16)抽出性
試験対象の不織布シートを用い、上記(13)の成形充填機によって、CTC製法による紅茶用の茶葉2gが封入された、袋体が1辺50mmのテトラ形の抽出用バッグを作成した。この抽出用バッグを95℃の湯中に3分間浸漬し、紅茶の抽出状態を目視観察により評価した。適度な濃さの紅茶が得られた場合を「良好」と判定し、濃さが薄く飲料として不十分な紅茶しか得られなかった場合を「薄い」と判定した。
スパンボンド法により、ポリエチレンテレフタレート樹脂を加熱溶融させて口径0.3mmの紡糸口金から紡出し、エジェクターで紡速5,000m/分にて延伸・開繊し、ベルトコンベア上に捕集してウェブとし、これに熱圧着面積率15%の部分熱圧着処理を施して第1層のスパンボンド不織布を作成した。得られたスパンボンド不織布は、目付12.0g/m2、繊維径13.6μmであり、その樹脂のIV値0.71、結晶化度71%、結晶配向度85%及び複屈折率(Δn)0.080であった。
次いで、かかるスパンボンド不織布の表面に、酸成分のテレフタル酸/イソフタル酸の重合比が86/14であるポリエステル樹脂を用い、空気流温度を370℃とし、紡口からスパンボンド不織布の表面までの距離(DCD)を30mmに調整して、目付6g/m2の第2層のメルトブロー不織布を積層形成して不織布シートを作成した。かかるメルトブロー不織布の樹脂の結晶化度は0.4%であった。
得られた本実施例の不織布シートについて行った上記各試験による評価結果は、下記の表1の「サンプル1」欄に示すとおりである。
実施例1と同条件で作成した第1層のスパンボンド不織布の表面に、ポリエチレンテレフタレート/ポリエチレンイソフタレート共重合物であって、酸成分のテレフタル酸/イソフタル酸の重合比を変化させ、結晶化度を3.0%、10.0%、14.0%、15.0%及び23.0%の5段階に調整した樹脂を、それぞれメルトブロー法によって、実施例1と同条件で積層形成して第2層のメルトブロー不織布を形成することにより、5種類の不織布シートのサンプルを作成した。
得られた本試験例の5種類の不織布シートについて行った上記各試験による評価結果は、下記の表1の「サンプル2」~「サンプル6」欄に示すとおりである。
これに対して、樹脂の結晶化度が14.0%を超えているメルトブロー不織布を積層形成した不織布シート(サンプル5、6)は、シール強度が小さく、シール部が破損する等のトラブルが生じた。
なお、サンプル1~6の不織布シートを用いて作成した抽出用バッグの抽出性は、いずれも良好であった。
第1層のスパンボンド不織布の原料であるポリエチレンテレフタレート樹脂のIV値と、紡糸時の牽引条件を変化させ、下記の表2に示すような6種類のスパンボンド不織布を作成し、それらの表面に、実施例1と同条件で第2層のメルトブロー不織布を積層形成し、6種類の不織布シートのサンプルを作成した。
得られた本試験例の6種類の不織布シートについて行った上記各試験による評価結果は、下記の表2の「サンプル7」~「サンプル12」欄に示すとおりである。
これに対して、IV値が0.60~1.00、結晶化度が30~80%、結晶配向度が60~95%又は複屈折率(Δn)が0.040~0.100のいずれかの条件を満たさないスパンボンド不織布を用いた場合には、その表面にメルトブロー不織布層を積層形成する工程において、スパンボンド不織布が変形してしまうことが分かる(サンプル11及び12)。
第1層のスパンボンド不織布について、ポリエチレンテレフタレート樹脂のIV値0.71、結晶化度71%、結晶配向度85%及び複屈折率(Δn)0.080として、繊維径を13.6μmとし、目付を下記の表3に示すように、7~27g/m2の間で4段階に変化させた4種類のスパンボンド不織布を作成した。次いで、かかる4種類のスパンボンド不織布の表面に、実施例1と同条件で第2層のメルトブロー不織布を積層形成して4種類の不織布シートの「サンプル13」~「サンプル16」を作成した。
また、IV値0.71のポリエチレンテレフタレート樹脂を用い、牽引速度を変化させることで繊維径を表3に示すように、9~42μmの間で5段階に変化させた5種類のスパンボンド不織布を作成した。次いで、かかる5種類のスパンボンド不織布の表面に、実施例1と同条件で第2層のメルトブロー不織布を積層形成して5種類の不織布シートの「サンプル17」~「サンプル21」を作成した。
得られた本試験例の9種類の不織布シートについて行った上記各試験による評価結果は、下記の表3の「サンプル13」~「サンプル21」欄に示すとおりである。
他方、スパンボンド不織布の目付が8.0~25.0g/m2の範囲外である場合、あるいは繊維径が10~40μmの範囲外である場合には、不織布シートの各高速成形充填機に対する機械適性が不十分であるか、あるいは抽出用バッグの抽出性が不十分であること分かる(サンプル13、16、17及び21)。
上記の実施例1と同条件で作成した第1層のスパンボンド不織布の表面に、実施例1と同じ樹脂を用いて同条件で紡糸して、目付を下記表4に示すように1.8~11.0g/m2の間で4段階に変化させた第2層のメルトブロー不織布を積層形成して4種類の不織布シートのサンプルを作成した。
得られた本試験例の4種類の不織布シートについて行った上記各試験による評価結果は、下記の表4の「サンプル22」~「サンプル25」欄に示すとおりである。
上記の実施例1と同条件で作成した第1層のスパンボンド不織布の表面に、第2層のメルトブロー不織布を積層形成する際に、実施例1と同じ樹脂を用い、紡口からスパンボンド不織布表面までの距離を変化させるか、又はメルトブロー不織布の積層形成後にカレンダー加工を行うことで、不織布シートの嵩密度を表5のように変化させて、4種類の不織布シートのサンプルを作成した。
得られた本試験例の4種類の不織布シートについて行った上記各試験による評価結果は、下記の表4の「サンプル26」~「サンプル29」欄に示すとおりである。
2 フィルター部
3 面溶着部
4 上縁部
5 抽出用バッグ
6 袋体
7 線溶着部
8 吊糸
9 タグ
Claims (4)
- IV値が0.60~1.00、結晶化度が30~80%、結晶配向度が60~95%及び複屈折率(Δn)が0.040~0.100であるポリエステル系樹脂の繊維により形成され、熱圧着面積率が5~30%の部分熱圧着部が設けられたスパンボンド不織布からなる第1層と、
該第1層の表面に吹き付けられて固化した結晶化度が0~14%のポリエステル系樹脂の繊維により形成されたメルトブロー不織布からなる第2層とを備える不織布シート。 - 上記スパンボンド不織布の目付が8.0~25.0g/m2及び繊維径が10~40μmであると共に、上記メルトブロー不織布の目付が2.0~10.0g/m2であり、かつ、上記不織布シートの嵩密度が0.15~0.40g/cm3である請求項1に記載の不織布シート。
- 請求項1又は2の不織布シートを用いて、該不織布シートの第2層を内側に配し所定箇所を溶着によりシールして形成されている抽出用フィルター。
- 請求項1又は2の不織布シートを用いて、該不織布シートの第2層を内側に配し所定箇所を溶着によりシールして形成された袋体に、抽出材料が封入されている抽出用バッグ。
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JP2017119932A (ja) * | 2015-12-28 | 2017-07-06 | Kbセーレン株式会社 | 嗜好性飲料抽出フィルター用フィラメント、及びそれからなる嗜好性飲料抽出フィルター用織物 |
JP2021171434A (ja) * | 2020-04-28 | 2021-11-01 | 大紀商事株式会社 | 抽出用シート材および抽出用バッグ |
JP7174972B2 (ja) | 2020-04-28 | 2022-11-18 | 大紀商事株式会社 | 抽出用シート材および抽出用バッグ |
Also Published As
Publication number | Publication date |
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US20170016157A1 (en) | 2017-01-19 |
RU2654183C2 (ru) | 2018-05-16 |
CN106164354A (zh) | 2016-11-23 |
RU2016141979A (ru) | 2018-04-27 |
EP3124667A1 (en) | 2017-02-01 |
RU2016141979A3 (ja) | 2018-04-27 |
CN106164354B (zh) | 2017-10-27 |
US9732453B2 (en) | 2017-08-15 |
EP3124667A4 (en) | 2017-08-30 |
JPWO2015147119A1 (ja) | 2017-04-13 |
EP3124667B1 (en) | 2018-10-03 |
JP5933149B2 (ja) | 2016-06-08 |
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