WO2016002940A1 - 立体網状繊維集合体 - Google Patents
立体網状繊維集合体 Download PDFInfo
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- WO2016002940A1 WO2016002940A1 PCT/JP2015/069308 JP2015069308W WO2016002940A1 WO 2016002940 A1 WO2016002940 A1 WO 2016002940A1 JP 2015069308 W JP2015069308 W JP 2015069308W WO 2016002940 A1 WO2016002940 A1 WO 2016002940A1
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- Prior art keywords
- fiber assembly
- dimensional network
- propylene
- network fiber
- mol
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Classifications
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/005—Synthetic yarns or filaments
- D04H3/007—Addition polymers
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/016—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the fineness
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
- D04H3/03—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments at random
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
- D04H3/03—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments at random
- D04H3/033—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments at random reorientation immediately after yarn or filament formation
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—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
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—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
Definitions
- the present invention relates to a three-dimensional network fiber assembly composed of fibers composed of a resin comprising a propylene-based polymer, more specifically, a large number of fibers composed of a resin comprising a propylene-based polymer are randomly melted.
- the present invention relates to a three-dimensional reticulated fiber assembly that is fused with each other.
- Patent Documents 1 and 2 an assembly in which fibers spun from a thermoplastic resin such as polyester is formed into a net shape has been proposed (Patent Documents 1 and 2). For this, there is no problem of irritating residual monomers and uneven distribution of fibers, and since it has higher air permeability, its use has been expanded in various fields in recent years.
- the inventors of the present invention have used a network assembly of fibers spun from a thermoplastic resin such as polyester in a medical field or a nursing field because a part of the fiber aggregate is dissolved by a chemical treatment or an odor is generated. I found that it is not suitable. More specifically, when such a reticulated assembly is used in the medical field or the nursing field, it is necessary to perform a chemical treatment or the like to prevent infection by viruses or bacteria. May cause deformation of the reticulated assembly, which is not suitable for repeated use, and may cause discomfort to the user due to odor, and further, an oil component is mixed in a thermoplastic resin such as polyester. In many cases, oil bleed occurs on the surface of the resin over time, causing a sticky feeling or contaminating medical supplies, which is not suitable for use in the medical field or the nursing field.
- the main object of the present invention is to provide a solid reticulated fiber assembly having better chemical resistance and low odor.
- the present invention comprises fibers composed of a resin containing the propylene-based polymer (a), and a large number of fibers are fused together with random orientation in a molten state.
- a solid reticulated fiber assembly is provided. That is, in the present invention, a three-dimensional network fiber assembly mainly comprising propylene as a structural unit is provided.
- the three-dimensional network fiber assembly of the present invention can also be referred to as a “propylene-based three-dimensional network fiber assembly”. That is, the following preferred embodiments are included in the present invention.
- a three-dimensional network formed of fibers composed of a resin containing the propylene-based polymer (a), in which a large number or a plurality of the fibers are fused together with a random orientation in a molten state.
- a three-dimensional network fiber assembly wherein the propylene-based polymer has 51 to 95 mol% propylene and 5 to 49 mol% ⁇ -olefin as structural units with respect to 100 mol% of all monomers.
- the body is provided.
- the fineness of the fiber is from 150 to 100,000 dtex.
- the three-dimensional network fiber aggregate of the present invention has better chemical resistance and further has low odor.
- the three-dimensional reticulated fiber assembly of the present invention has excellent chemical resistance, so it can be treated with chemicals to prevent infection with viruses and bacteria, and can be used cleanly even in repeated use. Moreover, it is hard to give a user discomfort by an odor.
- the three-dimensional network fiber assembly of the present invention is made of a fiber composed of a resin containing the propylene polymer (a).
- the propylene polymer (a) contained in the resin is a polymer mainly composed of propylene, preferably a copolymer composed of polypropylene or propylene.
- a polymer mainly composed of propylene preferably a copolymer composed of polypropylene or propylene.
- propylene-based polymer (a) in the present invention a solid network fiber aggregate having excellent chemical resistance, low volatility, and less discomfort to the user is obtained, so that propylene and ⁇ - Copolymers with olefins are preferred.
- “mainly composed of propylene” means at least 51 mol%, preferably 60 mol% or more, more preferably 70 mol, with respect to 100 mol% of all monomers of the propylene polymer (a).
- the propylene polymer (a) is typically 95 mol% or less, preferably 93 mol% or less, more preferably 90 mol% or less, and still more preferably 85 mol%, based on 100 mol% of all the monomers. It comprises less than mol%, particularly preferably less than 80 mol% of propylene as a structural unit.
- the propylene-based polymer (a) typically comprises 51 to 95 mol%, preferably 60 to 90 mol%, more preferably 70 to 80 mol% of propylene with respect to 100 mol% of the total monomers. Comprising as a unit.
- the molar ratio of the polymer can be determined on the basis of the monomer charge ratio at the time of producing the polymer, or infrared spectroscopy (IR) or nuclear magnetic resonance spectroscopy (NMR). It represents the molar ratio of the target monomer when the total number of monomers constituting the polymer is 100 mol%.
- the ⁇ -olefin is preferably an ⁇ -olefin having 2 to 20, more preferably 2 to 10, for example 2 to 6 carbon atoms.
- Examples of such ⁇ -olefins include ethylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-heptene, 1-octene, 1-nonene and 1-decene. .
- the ⁇ -olefin may be contained alone or in combination of two or more. Among them, the ⁇ -olefin is one kind selected from the group consisting of ethylene, 1-butene, 1-pentene, 1-hexene and 1-octene from the viewpoint that the three-dimensional network fiber assembly has good elasticity and strength.
- the ⁇ -olefin is the above monomer, the three-dimensional network fiber aggregate is not only excellent in elasticity and strength, but also excellent in chemical resistance and further has low odor.
- the propylene polymer (a) is a copolymer of propylene and ⁇ -olefin
- the propylene polymer (a) is typically 5 mol% or more with respect to 100 mol% of the total monomers. Preferably, it comprises 10 mol% or more, more preferably 15 mol% or more, still more preferably 20 mol% or more, for example, 25 mol% or more ⁇ -olefin as a structural unit.
- the propylene polymer (a) is typically 49 mol% or less, preferably 45 mol% or less, more preferably 40 mol% or less, and still more preferably 35 mol%, based on 100 mol% of all the monomers.
- the propylene polymer (a) is typically 5 to 49 mol%, preferably 10 to 40 mol%, more preferably 20 to 30 mol% of ⁇ based on 100 mol% of all the monomers. -Comprising olefins as structural units. When the ⁇ -olefin unit in the propylene polymer (a) is within the above range, the three-dimensional network fiber assembly is excellent in chemical resistance and has low odor.
- the propylene polymer (a) may contain a small amount of structural units derived from other copolymerizable monomers in addition to propylene and / or ⁇ -olefin.
- the proportion of structural units derived from other copolymerizable monomers is preferably 20 mol% or less with respect to 100 mol% of all monomers constituting the propylene polymer (a), and is preferably 10 mol%. More preferably, it is more preferably 5 mol% or less.
- ⁇ -olefin may be introduced in a random, block, graft or tapered form. From the viewpoint of the propylene polymer (a) having good elasticity, the ⁇ -olefin is preferably introduced into the propylene polymer (a) in a random form.
- the propylene-based polymer (a) preferably has a molecular weight distribution M w / M n of 4.0 or less, more preferably 3.0 or less, even more preferably 2.8 or less, for example 2.6 or less, Typically, it has a molecular weight distribution M w / M n of 1.01 or higher.
- the propylene polymer (a) is preferably 1.01 to 4.0, more preferably 1.1 to 3.0, still more preferably 1.5 to 2.8, for example 2.0 to 2.6. Having a molecular weight distribution M w / M n of When the molecular weight distribution M w / M n is within the above range, the low molecular weight component is small and the volatile component is small.
- the three-dimensional network fiber assembly has low odor and is excellent in chemical resistance.
- a propylene polymer (a) is desirably polymerized using a metallocene catalyst.
- molecular weight distribution Mw / Mn can be adjusted by changing the kind of metallocene catalyst, the polymerization conditions (polymerization temperature, polymerization pressure), etc. at the time of manufacture.
- the number average molecular weight Mn and the weight average molecular weight Mw in the present invention can be measured by gel permeation chromatography and calculated by polystyrene conversion.
- the propylene polymer (a) has a weight average molecular weight Mw of preferably 10,000 to 1,000,000, more preferably 20,000 to 800,000, still more preferably 30,000 to 500,000, and even more preferably 100,000 to 400,000.
- Mw weight average molecular weight of the propylene-based polymer (a)
- the three-dimensional network fiber assembly has good tensile performance and compression set, and the three-dimensional network fiber assembly is more excellent in chemical resistance. Furthermore, the odor is low.
- the MFR of the propylene polymer (a) is typically 0.5 to 60 g / 10 minutes, preferably 1 to 45 g / 10 minutes, more preferably 5 to 35 g / 10 minutes. When the MFR is within the above range, the moldability is good.
- the MFR of the propylene polymer (a) may be measured according to JIS K7210 (230 ° C., 2.16 kg load).
- the melting peak temperature of the propylene polymer (a) is preferably 125 ° C. or higher. When the melting peak temperature is in the above range, it is desirable from the viewpoint of heat resistance in high temperature treatment.
- the flexural modulus of the propylene polymer (a) is typically 600 MPa or less, preferably 500 MPa or less, more preferably 400 MPa or less, further preferably 300 MPa or less, for example 200 MPa or less. Moreover, the bending elastic modulus of the propylene polymer (a) is typically 20 MPa or more.
- the flexural modulus can be measured according to JIS K7171: 1982.
- the propylene polymer (a) is not particularly limited for its production, and can be produced by, for example, a conventionally known method.
- Typical commercial products of the propylene polymer (a) for example Japan Polypropylene Corp. of Werunekusu TM series, WINTEC TM series, and the like.
- the resin may be a polymer alloy composed of a propylene polymer (a) and a propylene homopolymer (b).
- the three-dimensional network fiber assembly is composed of the polymer alloy, the three-dimensional network fiber assembly is superior in chemical resistance and has not only low odor but also high heat resistance.
- the polymer alloy refers to a composite obtained by mixing two or more kinds of resins, inorganic substances, and the like. More specifically, the propylene polymer (a) and the propylene homopolymer (b) are blended, and the blend may further contain an additive or the like.
- the propylene homopolymer (b) has a weight average molecular weight Mw of preferably 10,000 to 1,000,000, more preferably 20,000 to 800,000, still more preferably 50,000 to 600,000, and even more preferably 100,000 to 500,000.
- Mw weight average molecular weight of the propylene homopolymer (b)
- the three-dimensional network fiber aggregate has sufficient mechanical strength, and further has low odor and excellent chemical resistance.
- the propylene homopolymer (b) is preferably 2.0 or more, more preferably 2.5 or more, still more preferably 3.0 or more, still more preferably 3.3 or more, preferably 6.0 or less, more Preferably, it has a molecular weight distribution M w / M n of 5.0 or less, more preferably 4.5 or less, and even more preferably 4.0 or less.
- the propylene homopolymer (b) is preferably 2.0 to 6.0, more preferably 2.5 to 5.0, still more preferably 2.5 to 4.5, for example 3.0 to 4.0.
- the three-dimensional network fiber assembly has low odor and is excellent in chemical resistance.
- the MFR of the propylene homopolymer (b) is not particularly limited, but is typically 0.5 to 60 g / 10 minutes, preferably 1 to 45 g / 10 minutes, more preferably 5 to 35 g / 10 minutes. . When the MFR is within the above range, the moldability is good.
- the said propylene homopolymer (b) is not specifically limited about the manufacture, For example, it can manufacture by a conventionally well-known method.
- Representative commercial products of the propylene homopolymer (b) include, for example, Prime Polypro TM manufactured by Prime Polymer Co., Ltd. and Novatec TM PP manufactured by Nippon Polypro Co., Ltd.
- the resin is a polymer alloy composed of a propylene polymer (a) and a propylene homopolymer (b), it is preferably 4% by weight or more, more preferably 10% by weight with respect to 100% by weight of the whole resin. More preferably, it comprises 20% by weight or more of propylene homopolymer (b). Further, the polymer alloy preferably comprises 90% by weight or less, more preferably 80% by weight or less, and further preferably 70% by weight or less of the propylene homopolymer (b) with respect to 100% by weight of the whole resin. . The polymer alloy comprises 10 to 80% by weight, more preferably 20 to 70% by weight of the propylene homopolymer (b) with respect to 100% by weight of the total resin. When the content of the propylene homopolymer (b) contained in the polymer alloy is in the above range, the three-dimensional network fiber assembly is excellent in chemical resistance, low in odor, and excellent in heat resistance.
- the resin is a polymer alloy composed of a propylene polymer (a) and a propylene homopolymer (b), in addition to the propylene polymer (a) and the propylene homopolymer (b), a further polymer Examples thereof include polyester-based, polyurethane-based and polyamide-based thermoplastic elastomers, polyethylene, and the like.
- the resin may contain various additives. Examples of the additive include an antioxidant, a heat stabilizer, a flame retardant, a pigment, a light stabilizer, an ultraviolet absorber, an inorganic filler, a foaming agent, and a colorant. , Antiblocking agents, lubricants, antistatic agents and plasticizers.
- the resin may contain an inorganic or organic filler such as a glass filler or a carbon filler.
- the three-dimensional network fiber assembly of the present invention fuses a large number or a plurality of fibers composed of a resin comprising the propylene-based polymer (a) to each other with a random or spiral orientation in a molten state. And has a three-dimensional network structure. When the fibers are in contact with each other in a molten state, the fibers can be fused to each other, and the structure as a three-dimensional network fiber aggregate can be firmly held.
- having a random direction means that the fiber is in a state of being randomly and winding.
- having spiral directionality means that the fiber is in a state of being rotated in a direction perpendicular to the rotation surface while rotating.
- a large number of fibers represents the number of fibers necessary to maintain the form of the three-dimensional network fiber aggregate, and specifically, with respect to the number of holes provided in the T-die through which resin fibers are extruded during production.
- a large number of fibers means that, for example, about 50 to 1800 fibers are present in a solid network fiber aggregate having a width of 1000 mm and a thickness of 30 mm.
- the fineness of this fiber is 150 dtex or more, preferably 300 dtex or more, more preferably 1000 dtex or more, 100000 dtex or less, preferably 80000 dtex or less, more preferably 60000 dtex or less, and even more preferably 10,000 dtex or less. Is from 150 to 100,000 dtex, for example from 300 to 60,000 dtex, preferably from 1000 to 10,000 dtex.
- the fineness is within the above range, when the three-dimensional network fiber assembly is compressed, a uniform pressure can be generated on the entire compressed surface, so that a pressure difference uncomfortable for the user is hardly generated.
- Apparent density of the three-dimensional net-like fiber assembly of the present invention preferably 0.020g / cm 3 ⁇ 0.300g / cm 3, more preferably 0.025g / cm 3 ⁇ 0.200g / cm 3, more preferably 0 0.030 g / cm 3 to 0.150 g / cm 3 , still more preferably 0.035 g / cm 3 to 0.100 g / cm 3 , and particularly preferably 0.040 g / cm 3 to 0.080 g / cm 3 .
- the apparent density is within the above range, the three-dimensional network fiber assembly of the present invention has sufficient elasticity and the adhesion point between the fibers increases, so that the structure of the three-dimensional network fiber assembly is firmly held. Can do.
- the cross-sectional structure of the fiber is not particularly limited, and may be, for example, a circular structure, a hollow structure, or a deformed structure.
- the fiber may be comprised with 2 or more types of resin, and the cross-sectional structure of the fiber in that case may be a core-sheath structure, an eccentric core-sheath structure, a side-by-side structure, a division structure, and a sea-island structure, for example.
- the thickness of the solid reticulated fiber aggregate of the present invention is preferably 3 mm to 150 mm, more preferably 5 mm to 120 mm, still more preferably 10 mm to 100 mm, and even more preferably 20 mm to 80 mm.
- the thickness is in the above range, the solid reticulated fiber aggregate has sufficient cushioning properties, and at the same time, has excellent strength as a structure, and has good workability in the cutting step.
- the solid reticulated fiber assembly of the present invention may be composed of fibers made of a single kind of resin, or may be made of fibers made of two or more kinds of resins.
- it may be a three-dimensional reticulated fiber aggregate in which different types of resin and different fibers such as fineness, fiber diameter, and cross-sectional structure are mixed.
- the peripheral area of the three-dimensional network fiber assembly it is composed of high-rigidity fibers in order to increase the retention of the structure, and in the central area of the three-dimensional network fiber assembly, from the high-elasticity fibers in order to increase elasticity. It can also be configured.
- the three-dimensional network fiber assembly in the peripheral area of the three-dimensional network fiber assembly, fibers composed of a low-melting resin are used to firmly bond the fibers to each other, and in the central area of the three-dimensional network fiber assembly, a high melting point rigidity is used. A fiber composed of a high resin can also be used.
- the three-dimensional network fiber assembly of the present invention may be laminated with a three-dimensional network fiber assembly composed of another resin such as a polyethylene polymer.
- the peripheral area refers to an area from 1 to 45% from the surfaces on both sides of the three-dimensional network fiber assembly, with the total thickness of the three-dimensional network fiber assembly being 100%, and the central area is a region other than the peripheral area An area.
- the three-dimensional network fiber assembly of the present invention may be a structure in which a plurality of three-dimensional network fiber assemblies are laminated in layers.
- a structure in which three layers of a three-dimensional network fiber assembly are laminated is used.
- the fineness of the fibers constituting the two outer three-dimensional network fiber assemblies is small, and the three-dimensional network fiber assembly at the center is formed.
- the outer side has a good touch and has sufficient rigidity as a component.
- attachment method of each three-dimensional network fiber assembly is not specifically limited, For example, joining etc. by heat sealing
- the weight of the solid reticulated fiber aggregate of the present invention does not substantially change even when it is immersed in a chemical and sterilized.
- the chemical include alcohol (ethanol and the like).
- the weight change rate is 0%.
- the three-dimensional network fiber assembly of the present invention does not generate odor like the polyester polymer, absorbs the odor of the surrounding area, does not release the odor, and does not cause stickiness. Can be used comfortably.
- the three-dimensional network fiber assembly when the three-dimensional network fiber assembly is composed of the polymer alloy, the three-dimensional network fiber assembly not only has better chemical resistance but also exhibits high heat resistance.
- the solid reticulated fiber aggregate of the present invention when used as a medical / nursing care device, it can be washed and sterilized at high temperatures.
- the weight change rate is based on the weight of each sample before being immersed in the chemical.
- the compressive stress with a low compressibility and the compressive stress with a high compressibility do not change significantly.
- the three-dimensional network fiber assembly of the present invention preferably has a ratio (compression stress stability) of a compression stress when the compression rate is 50% and a compression stress when the compression rate is 25% (compression stress stability). .2 to 5.0, more preferably 1.5 to 3.5, still more preferably 1.7 to 3.0.
- the compressive stress stability is within the above range, the pressure generated when the three-dimensional network fiber assembly is compressed does not change greatly depending on the compressibility, there is no sudden sinking, and it is not too hard when sitting on this.
- the three-dimensional reticulated fiber assembly of the present invention is used in a medical / nursing care device such as a corset, the stress on the user when the corset touches the skin is alleviated.
- this resin is melt-kneaded by a twin-screw extruder heated to a temperature equal to or higher than the melting point of the raw material resin.
- a polymer alloy When a polymer alloy is used, a plurality of raw material resin pellets constituting the polymer alloy are simultaneously put into a twin screw extruder and melt kneaded.
- spinning is performed by continuously discharging a molten resin downward from a T-die having a plurality of holes, and the three-dimensional network fiber assembly of the present invention can be molded.
- a water bath (or hot water bath) is installed immediately below the T-die, and two conveyors are installed in parallel in the water bath so that a part of the conveyor is on the water surface.
- buoyancy is generated and the fiber has a random directionality.
- the large number of fibers are sandwiched between two conveyors, carried in a water bath while heat is removed, and solidified while the fibers are fused to form a solid reticulated fiber aggregate.
- the thickness of the three-dimensional network fiber assembly is determined by the distance between the clearances of the two conveyors. Thereafter, the molded three-dimensional network fiber assembly is cut into an appropriate length and shape. Thereafter, the molded three-dimensional network fiber assembly is dried. You may perform drying before the said cutting
- treatments such as oxidation prevention, flame retardancy, coloring, light stabilization, anti-blocking, antistatic, antifungal, aroma, etc. may be carried out at any stage.
- the solid reticulated fiber assembly of the present invention can be used in medical / nursing equipment and the like.
- medical / nursing equipment refers to auxiliary equipment used in the medical field or the nursing field, for example, medical or nursing beds, chairs, cushions such as operating tables, floor materials such as baths and toilets, etc. , Cushion materials, and medical or nursing care fixtures, particularly core materials such as neck and waist corsets, belts, and the like.
- the three-dimensional reticulated fiber aggregate of the present invention has a cushion feeling, it can be suitably used for the above-mentioned medical / care equipment. Furthermore, the chemical resistance of the three-dimensional reticulated fiber assembly of the present invention enables clean repeated use. Moreover, the three-dimensional reticulated fiber aggregate of the present invention can be used as a core material for furniture such as general beddings such as mattresses and pillows, and chairs and sofas. Because of the chemical resistance of the three-dimensional network fiber assembly of the present invention, even if maintenance such as sterilization is performed with a chemical, the three-dimensional network fiber assembly is unlikely to be deformed, so that it can be used repeatedly and cleanly.
- a non-woven fabric, quilted cloth, woven fabric or knitted fabric is used as the skin (cover), preferably a non-woven fabric, quilted fabric, woven fabric or knitted fabric made of polypropylene.
- the resin used for parts in the automobile industry has been replaced with polypropylene, but since the three-dimensional network fiber assembly of the present invention is mainly made of polypropylene, it can also be used for automobile applications.
- each component was mixed according to the composition shown in Table 1 using a twin screw extruder.
- the temperature of the twin screw extruder is set stepwise from about 140 ° C. to about 200 ° C. from the upstream side to the downstream side, melt-kneaded at 1000 rpm, and subsequently heated to about 200 ° C.
- the molten resin was continuously discharged downward.
- the fibrous resin discharged from a plurality of holes in the T die enters a water bath (room temperature) installed immediately below the T die, and is sandwiched between two parallel conveyors installed there, so that the fibers are fused and solidified.
- a three-dimensional network fiber assembly was molded.
- Wellnex TM STR0730 metalocene random copolymer
- weight average molecular weight Mw 320,000
- molecular weight distribution Mw / Mn 2.50
- propylene 75 mol%)
- Ethylene 25 mol%)
- A-3) Primalloy TM A1700 polyyester thermoplastic elastomer
- Mitsubishi Chemical Corporation A-4
- Kernel TM KS571 polyethylene copolymer [polyethylene / ⁇ -olefin copolymer]) manufactured by Nippon Polyethylene Co., Ltd.
- each three-dimensional network fiber assembly produced as described above was cut into a size of 200 mm ⁇ 200 mm to prepare a sample.
- Each sample was stored for one week in a well-ventilated place in the shade and then left in a hospital room (about 6 tatami mats) in a hospital (Kansai Regional Hospital) for 3 days to conduct a sensory test for odor.
- the sensory test was performed before and after being left in the hospital.
- the sensory test was evaluated by three people (two men and one woman). “No smell or I do n’t care” ⁇ , “Slightly smell, a little concerned” ⁇ , “Odor, The case of “worried” was marked with “x”.
- the sensory test before leaving in the hospital was performed after the sample was sealed in a plastic bag for 10 minutes immediately before the test. The results are shown in Table 3.
- the three-dimensional reticulated fiber assembly of the present invention showed good results in the sensory test both before and after being left in the hospital, and low in odor.
- the three-dimensional network fiber assembly composed of the polyester-based thermoplastic elastomer in Comparative Example 1 was odorous before being left in the hospital, and the odoriness tended to deteriorate after being left in the hospital.
- each three-dimensional network fiber assembly prepared as described above was cut into a size of 20 mm x 50 mm to prepare a sample.
- Each sample was immersed in ethanol (manufactured by Kishida Chemical Co., Ltd., grade 1, product code 010-28555) for 1 day at room temperature.
- Ethanol is a chemical used for sterilization treatment in hospitals and the like.
- the case where the weight change rate of the sample after 1 day elapsed was 0%, the case where it was higher than 0% and 1% or less was evaluated as ⁇ , and the case where it was higher than 1% was evaluated as ⁇ .
- the weight change rate was based on the weight of each sample before being immersed in ethanol. The results are shown in Table 4.
- each solid reticulated fiber assembly produced as described above was cut into a size of 100 mm x 100 mm to produce a sample.
- hot water treatment 100 ° C
- heat treatment at 121-135 ° C is often performed as a sterilization treatment in hospitals, etc., but each sample is kept in a constant temperature bath set at 100 ° C, 121 ° C and 135 ° C under an atmospheric pressure atmosphere. For 30 minutes.
- each solid reticulated fiber assembly produced as described above was cut into a size of 200 mm x 200 mm to produce a sample.
- Each sample was subjected to a compressive stress test according to JIS K 6400 using RTG-1250A Tensilon manufactured by Orientec Co., Ltd. However, a pressure plate having a diameter of 100 was used, the test speed was 50 mm / min, and no preliminary compression was performed. The compression stress at 25% and 50% compression was measured, and the compression stress at 50% compression relative to the compression stress at 25% compression was calculated. If this value is low, the difference in compressive stress between the case where the compression rate is as high as 50% and the case where the compression rate is as low as 25% is small. The results are shown in Table 4.
- the three-dimensional reticulated fiber aggregate of the present invention in Examples 1 and 2 had better chemical resistance.
- the compression stress stability is also good, and the compression stress does not change greatly depending on the compression rate.
- the three-dimensional network fiber assembly of the present invention is compressed by the user, the pressure on the user can be suppressed. Therefore, the user's stress caused by use can be suppressed.
- the three-dimensional network fiber assembly produced using the polymer alloy according to the present invention has good results not only in 100 ° C. but also in heat resistance evaluation at 121 and 135 ° C., and higher heat resistance. Also resulted.
- the three-dimensional network fiber assembly of the present invention is excellent in heat resistance, it is not deformed even if it is washed and sterilized at a high temperature, and can be used repeatedly.
- the three-dimensional network fiber aggregate of the present invention in Examples 1 to 7 showed good results in the odor test.
- Comparative Example 1 the three-dimensional network fiber assembly produced using the polyester-based thermoplastic elastomer results in insufficient chemical resistance, cannot solve the problems of the present invention, and further has odor properties. In the test, the results were insufficient, and the surface of the three-dimensional reticulated fiber assembly was sticky, causing the user to feel an unpleasant feel and odor.
- the three-dimensional network fiber assembly produced using the polyethylene-based polymer had good compression stress stability but was insufficient in chemical resistance and heat resistance.
- the three-dimensional reticulated fiber assembly of the present invention can be used in medical / nursing care equipment and the like.
Abstract
Description
すなわち、本発明には、以下の好適な実施態様が含まれる。
本発明においては、プロピレン系重合体(a)を含んでなる樹脂から構成される繊維からなり、多数又は複数の該繊維を溶融状態でランダムな方向性を持たせて互いに融着させた立体網状繊維集合体であって、プロピレン系重合体は、その全モノマー100モル%に対して、51~95モル%のプロピレンおよび5~49モル%のα-オレフィンを構造単位として有する、立体網状繊維集合体が提供される。1つの実施態様においては、上記繊維の繊度は、150~100000dtexである。本発明の立体網状繊維集合体は、より優れた耐薬品性を有し、さらに臭気性が低い。
本発明の立体網状繊維集合体は、プロピレン系重合体(a)を含んでなる樹脂から構成される繊維からなる。
まず、原料樹脂の融点以上の温度に加熱した二軸押出機によって、この樹脂を溶融混練する。なお、ポリマーアロイを用いる場合、ポリマーアロイを構成する複数の原料樹脂ペレットを同時に二軸押出機に投入し、溶融混練する。続いて、複数の孔を有するTダイから、溶融状態の樹脂を連続的に下方向に吐出することによって紡糸し、本発明の立体網状繊維集合体を成型することができる。このとき、Tダイの直下に水浴(または湯浴)を設置し、水浴中に2つのコンベアを並行に設置し、コンベアの一部が水面上になるように配置する。溶融状態の樹脂からなる繊維が、2つのコンベアのクリアランス間において、水浴水面に達する際に、浮力が発生することで繊維がランダムな方向性を持つ。同時に、この多数の繊維は、2つのコンベアに挟まれ、除熱されながら水浴中を運ばれ、繊維同士が融着しながら固化することによって、立体網状繊維集合体が成型される。なお、2つのコンベアのクリアランス間の距離によって、立体網状繊維集合体の厚みが決定される。その後、成型された立体網状繊維集合体を適当な長さや形状に切断する。その後、成型した立体網状繊維集合体を乾燥する。乾燥は、上記切断の前に行ってもよい。
成分(a):プロピレン系重合体
・(a-1)日本ポリプロ(株)製ウェルネクスTMSTR0729(メタロセン系ランダム共重合体)、重量平均分子量Mw320000、分子量分布Mw/Mn2.50、プロピレン(75モル%):エチレン(25モル%)
・(a-2)日本ポリプロ(株)製ウェルネクスTMSTR0730(メタロセン系ランダム共重合体)、重量平均分子量Mw:320000、分子量分布Mw/Mn:2.50、プロピレン(75モル%):エチレン(25モル%)
・(a-3)三菱化学(株)製プリマロイTMA1700(ポリエステル系熱可塑性エラストマー)
・(a-4)日本ポリエチレン(株)製カーネルTMKS571(ポリエチレン系共重合体[ポリエチレン・α-オレフィン共重合体])
・(b-1)日本ポリプロ(株)製GC4301、重量平均分子量Mw:330000、分子量分布Mw/Mn:3.86
・(b-2)日本ポリプロ(株)製ノバテックTMMA-2、重量平均分子量Mw:426000、分子量分布Mw/Mn:3.41
表1に示す配合に従って、上記のように作製した各立体網状繊維集合体を200mm×200mmのサイズに切断してサンプルを作製した。各サンプルを日陰の風通しの良い場所に1週間保管後、病院(関西地域病院)の病室(6畳程度)に3日間放置し、臭気性についての官能試験を行った。官能試験は、病院での放置前および放置後において行った。官能試験の評価は、3人(男性2人、女性1人)によって実施し、「臭わない、または気にならない」場合を○、「やや臭う、少し気になる」場合を△、「臭う、気になる」場合を×とした。なお、病院での放置前の官能試験は、サンプルを試験直前の10分間ビニール袋に密閉した後に行った。その結果を表3に示す。
表1に示す配合に従って、上記のように作製した各立体網状繊維集合体を20mm×50mmのサイズに切断してサンプルを作製した。この各サンプルを室温下においてエタノール(キシダ化学(株)製、1級、製品コード010-28555)中に1日間浸漬させた。なお、エタノールは、病院等において殺菌処理に使用される薬品である。1日間経過後のサンプルの重量変化率が0%である場合を○、0%より高く1%以下である場合を△、1%より高い場合を×と評価した。ここで、重量変化率は、エタノールに浸漬させる前の各サンプルの重量を基準とした。その結果を表4に示す。
表1に示す配合に従って、上記のように作製した各立体網状繊維集合体を100mm×100mmのサイズに切断してサンプルを作製した。病院等の殺菌処理として通常、熱水処理(100℃)または121~135℃の加熱処理がよく行われるところ、各サンプルを100℃、121℃および135℃に設定した恒温槽に大気圧雰囲気下で30分間置いた。30分経過後のサンプルの縦、横および厚みの方向全ての寸法変化率が±5%以下である場合を○、寸法変化率が±5%より高く70%以下である場合を△、サンプルが溶解した場合を×と評価した。ここで、寸法変化率とは、恒温槽に入れる前の各サンプルの縦、横および厚みの方向のそれぞれの長さを基準とした。その結果を表4に示す。
表1に示す配合に従って、上記のように作製した各立体網状繊維集合体を200mm×200mmのサイズに切断してサンプルを作製した。この各サンプルについて、(株)オリエンテック製RTG-1250Aテンシロンを用い、JIS K 6400に準拠して圧縮応力試験を行った。ただし、加圧板としてΦ100のものを用い、試験速度を50mm/分とし、予備圧縮を行わなかった。25%および50%圧縮時の圧縮応力を測定し、25%圧縮時の圧縮応力に対する50%圧縮時の圧縮応力を算出した。この値が低ければ、圧縮率が50%等の高い場合と、25%等の低い圧縮率の場合との圧縮応力の差が小さくなる。その結果を表4に示す。
一方、比較例1においては、ポリエステル系熱可塑性エラストマーを用いて製造した立体網状繊維集合体は、耐薬品性が不十分な結果となり、本発明の課題を解決することはできず、さらに臭気性試験においては不十分な結果となり、また立体網状繊維集合体の表面にべたつきが見られ、使用者に不快な感触や臭気を感じさせた。また、比較例2および3において、ポリエチレン系重合体を用いて製造した立体網状繊維集合体は、圧縮応力安定性は良好であるものの、耐薬品性および耐熱性は不十分であった。
Claims (10)
- プロピレン系重合体(a)を含んでなる樹脂から構成される150~100000dtexの繊度の繊維からなり、多数の該繊維を溶融状態でランダムな方向性を持たせて互いに融着させた立体網状繊維集合体であって、
前記プロピレン系重合体(a)は、その全モノマー100モル%に対して、51~95モル%のプロピレンおよび5~49モル%のα-オレフィンを構造単位として有する、立体網状繊維集合体。 - 前記α-オレフィンは、2~10個の炭素原子を有するα-オレフィンである、請求項1に記載の立体網状繊維集合体。
- 前記2~10個の炭素原子を有するα-オレフィンは、エチレン、1-ブテン、1-ペンテン、1-ヘキセンおよび1-オクテンからなる群から選択される1種以上である、請求項2に記載の立体網状繊維集合体。
- 前記プロピレン系重合体(a)は、4.0以下の分子量分布Mw/Mnを有する、請求項1~3のいずれかに記載の立体網状繊維集合体。
- 前記樹脂は、前記プロピレン系重合体(a)およびプロピレン単独重合体(b)から構成されるポリマーアロイである、請求項1~4のいずれかに記載の立体網状繊維集合体。
- 前記ポリマーアロイは、該ポリマーアロイの全体100重量%に対して、10~80重量%の前記プロピレン単独重合体(b)を含んでなる、請求項5に記載の立体網状繊維集合体。
- 前記プロピレン単独重合体(b)は、2.0~6.0の分子量分布Mw/Mnを有する、請求項5または6に記載の立体網状繊維集合体。
- アルコール中に1日間浸漬させた場合の前記立体網状繊維集合体の重量変化率が0%である、請求項1~7のいずれかに記載の立体網状繊維集合体。
- 前記立体網状繊維集合体は、圧縮率が50%の時の圧縮応力と圧縮率が25%の時の圧縮応力との比率が、1.7~3.0である、請求項1~8のいずれかに記載の立体網状繊維集合体。
- 医療・介護用器具として使用される、請求項1~9のいずれかに記載の立体網状繊維集合体。
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JP2015553980A JP5873225B1 (ja) | 2014-07-04 | 2015-07-03 | 立体網状繊維集合体 |
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JP6875833B2 (ja) * | 2016-11-21 | 2021-05-26 | Mcppイノベーション合同会社 | 三次元網状繊維集合体用シラン変性ポリオレフィン組成物、三次元網状繊維集合体用シラン架橋ポリプロピレン組成物、及び三次元網状繊維集合体用シラン変性ポリオレフィン組成物、並びに、これらを用いた三次元網状繊維集合体用成形体、三次元網状繊維集合体用架橋成形体及び三次元網状繊維集合体 |
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US11725317B2 (en) | 2018-10-30 | 2023-08-15 | C-Eng Co., Ltd. | Three-dimensional net-like structure |
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JP5873225B1 (ja) | 2016-03-01 |
JPWO2016002941A1 (ja) | 2017-04-27 |
EP3165657A4 (en) | 2018-01-24 |
EP3165657A1 (en) | 2017-05-10 |
US10590576B2 (en) | 2020-03-17 |
CA2954606A1 (en) | 2016-01-07 |
WO2016002941A1 (ja) | 2016-01-07 |
JP5894716B1 (ja) | 2016-03-30 |
US20170121876A1 (en) | 2017-05-04 |
JPWO2016002940A1 (ja) | 2017-04-27 |
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