EP2455516A1 - Fibre composite crêpée, masse fibreuse et produit textile utilisant celle-ci - Google Patents

Fibre composite crêpée, masse fibreuse et produit textile utilisant celle-ci Download PDF

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Publication number
EP2455516A1
EP2455516A1 EP10799933A EP10799933A EP2455516A1 EP 2455516 A1 EP2455516 A1 EP 2455516A1 EP 10799933 A EP10799933 A EP 10799933A EP 10799933 A EP10799933 A EP 10799933A EP 2455516 A1 EP2455516 A1 EP 2455516A1
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EP
European Patent Office
Prior art keywords
component
conjugate fiber
fiber
crimps
crimped
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Application number
EP10799933A
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German (de)
English (en)
Other versions
EP2455516A4 (fr
Inventor
Hiroshi Okaya
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Daiwabo Holdings Co Ltd
Daiwabo Polytec Co Ltd
Original Assignee
Daiwabo Holdings Co Ltd
Daiwabo Polytec Co Ltd
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Application filed by Daiwabo Holdings Co Ltd, Daiwabo Polytec Co Ltd filed Critical Daiwabo Holdings Co Ltd
Publication of EP2455516A1 publication Critical patent/EP2455516A1/fr
Publication of EP2455516A4 publication Critical patent/EP2455516A4/fr
Withdrawn legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
    • D01D5/34—Core-skin structure; Spinnerette packs therefor
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/22—Formation of filaments, threads, or the like with a crimped or curled structure; with a special structure to simulate wool
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/06—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/50—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by treatment to produce shrinking, swelling, crimping or curling of fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres
    • D04H1/544—Olefin series
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2922—Nonlinear [e.g., crimped, coiled, etc.]
    • Y10T428/2924—Composite

Definitions

  • the present invention mainly relates to an actualized crimping conjugate fiber and a latently crimp able conjugate fiber suitable for a fiber assembly having high elasticity and a high level of bulk recovery properties, in particular a nonwoven fabric, and to a fiber assembly and a fiber product that use such a conjugate fiber.
  • Thermally bonded nonwoven fabrics containing a thermally fused conjugate fiber composed of a low-melting-point component that is exposed at least partially on the surface of the fiber and a high-melting-point component that has a melting point higher than that of the low-melting-point component are used in various applications, such as nonwoven fabrics used for hygienic materials, packaging materials, wet tissue, filters, wipers, and the like, nonwoven fabrics used for hard stuffing, chairs, and the like, and molded articles.
  • Patent Documents 1 and 2 below disclose a conjugate fiber composed of a polyester component having a melting point of 200°C or higher and a polyetherester block copolymer component, i.e., a so-called elastomer component, having a melting point of 180°C or lower.
  • a so-called elastomer component having a melting point of 180°C or lower.
  • Patent Document 3 discloses an actualized crimping conjugate fiber composed of a first component containing a polytrimethylene terephthalate (PTT)-based polymer and a second component that contains a polyolefin-based polymer, in particular, polyethylene, with crimping being obtained by arranging the centroid position of the first component so as not to overlap the centroid position of the fiber on the cross-section of the fiber.
  • PTT polytrimethylene terephthalate
  • a nonwoven fabric that has a high level of bulk recovery properties, that is flexible, and that has a large initial bulk can be obtained.
  • Patent Documents 4 and 5 disclose a crimped conjugate fiber containing a sheath component containing polybutene-1 (hereinafter also referred to as PB-1) and a nonwoven fabric having excellent bulk recovery properties and improved initial bulk recovery properties that uses such a fiber.
  • PB-1 polybutene-1
  • a polyesterether elastomer is used as a sheath component, and a nonwoven fabric having a high level of bulk recovery properties is intended to be obtained by taking advantage of the fact that this polymer has rubber-like elasticity and a high degree of freedom from bonding point deformation.
  • this polyesterether elastomer is a copolymer of a hard polyester and a soft ether, and contains a soft component having low thermal resistance, this polyesterether elastomer is readily thermally softened, and the nonwoven fabric undergoes bulk reduction, or so-called sagging, during thermal processing.
  • a conjugate fiber in which such a polyesterether elastomer is used as a sheath component is problematic in that the initial bulk when formed into a nonwoven fabric is small, only giving a highly dense nonwoven fabric, and its applications are thus limited.
  • a nonwoven fabric being compressed while being heated, or such a nonwoven fabric being repeatedly compressed is problematic in that, for example, the points where pieces of the fiber are bonded to each other and the fiber itself collapse or bend, and the fiber strength is impaired, and thus the hardness of the nonwoven fabric is significantly lower than that of the original nonwoven fabric.
  • Patent Document 3 it is intended to obtain a nonwoven fabric having a high level of bulk recovery properties by selecting a specific polymer used for the core, a specific fiber cross-section, and a specific crimp state.
  • the initial thickness (initial bulk) of the nonwoven fabric is large, the bulk recovery properties, in particular the initial bulk recovery properties immediately after load removal, are not sufficient, and thus there is a problem in that its applications are limited.
  • the conjugate fiber disclosed in Patent Documents 4 and 5 is problematic in that, when a fiber web that uses the conjugate fiber is processed into a nonwoven fabric in which pieces of the component fiber are bonded to each other by thermal processing, or when pieces of the resulting nonwoven fabric are bonded to each other by thermal processing, since the so-called sheath component that occupies for most of the fiber surface is composed of polybutene-1 and polypropylene, which has a higher melting point than polybutene-1, a phenomenon occurs in which the apparent melting point of the sheath component is increased, and thermal bonding properties in a heat treatment at a low temperature and the strength of the nonwoven fabric after thermal bonding are not sufficient, and it is also difficult to adjust the temperature conditions for thermal bonding processing.
  • Patent Documents 1 to 5 extensive research has been made on a nonwoven fabric having excellent bulk recovery properties, a conjugate fiber suitable for such a nonwoven fabric having excellent bulk recovery properties, a nonwoven fabric that uses such a fiber, and the like, but there is still a problem in that deterioration of bulk recovery properties is observed when a load is applied repetitively, and a fiber and a nonwoven fabric that are suitable for use in applications such as cushioning materials for which a high level of bulk recovery properties are needed even after being repetitively compressed are not obtained.
  • the present invention provides a crimped conjugate fiber having high elasticity, a high level of bulk recovery properties, and high durability against repetitive compression as well as having high elasticity, a high level of bulk recovery properties, and high durability when used at high temperatures, and a fiber assembly and a fiber product that use such a fiber.
  • the crimped conjugate fiber of the present invention is a conjugate fiber containing a first component and a second component, the first component containing polybutene-1 and linear low density polyethylene, the content of the linear low density polyethylene in the first component is 2 to 25 mass%, the second component containing a polymer having a melting peak temperature at least 20°C higher than a melting peak temperature of polybutene-1 or a polymer having a melting initiation temperature of 120°C or higher, when viewed from a fiber cross-section the first component occupies at least 20% of the surface of the conjugate fiber and the centroid position of the second component not overlapping the centroid position of the conjugate fiber, and the conjugate fiber is an actualized crimping conjugate fiber in which three-dimensional crimps have been developed or a latently crimpable conjugate fiber in which three-dimensional crimps are developed by heating.
  • the melting initiation temperature as used herein refers to an extrapolated melting initiation temperature measured by differential scanning calorimetry (DSC) as defined in JIS-K-7121.
  • the melting peak temperature as used herein refers to a melting peak temperature obtained from a DSC curve measured according to JIS-K-7121.
  • the fiber assembly of the present invention contains a crimped conjugate fiber in a proportion of 30 mass% or greater, and the crimped conjugate fiber is a conjugate fiber containing a first component and a second component, the first component containing polybutene-1 and linear low density polyethylene.
  • the content of the linear low density polyethylene in the first component is 2 to 25 mass%.
  • the second component contains a polymer having a melting peak temperature at least 20°C higher than the melting peak temperature of polybutene-1 or a polymer having a melting initiation temperature of 120°C or higher.
  • the conjugate fiber When viewed from a fiber cross-section the first component occupies at least 20% of the surface of the conjugate fiber and the centroid position of the second component not overlapping the centroid position of the conjugate fiber, and the conjugate fiber is an actualized crimping conjugate fiber in which three-dimensional crimps have been developed or a latently crimpable conjugate fiber in which three-dimensional crimps are developed by heating.
  • the fiber product of the present invention at least partially contains the fiber assembly of the present invention and is formed into hard stuffing, bedding, a vehicle seat, a chair, a shoulder pad, a brassiere pad, a garment, a hygienic material, a packaging material, a wet wipe, a filter, a sponge-like porous wiping material, a sheet-like wiping material, or wadding.
  • the first component contains polybutene-1 and linear low density polyethylene
  • the second component contains a polymer having a melting peak temperature at least 20°C higher than the melting peak temperature of the polybutene-1 or a polymer having a melting initiation temperature of 120°C or higher, and accordingly the fiber exhibits excellent spinnability, stretchability, crimp formability, and like properties. Accordingly, use of the crimped conjugate fiber of the present invention enables a conjugate fiber that has excellent bulk recovery properties and excellent thermal processability with which pieces of the fiber can be strongly thermally bonded to each other even in low-temperature thermal bonding processing as well as a fiber assembly and a fiber product that use the conjugate fiber to be obtained.
  • a nonwoven fabric that uses the crimped conjugate fiber of the present invention has both excellent initial bulk and excellent bulk recovery properties, and can be suitably used for cushioning materials and like hard stuffing, hygienic materials, packaging materials, filters, materials for cosmetics, women's brassiere pads, shoulder pads, and like low-density nonwoven fabric products.
  • the crimped conjugate fiber of the present invention can be suitably used for wadding for various pieces of bedding such as mattresses and blankets and various clothes due to the sufficient elasticity and repulsive force of the fiber itself.
  • the crimped conjugate fiber of the present invention has high elasticity, a high level of bulk recovery properties, and high durability against repetitive compression as well as having high elasticity, a high level of bulk recovery properties, and high durability when used at high temperatures.
  • a fiber assembly that uses the crimped conjugate fiber of the present invention that has actual crimps (hereinafter also referred to as an actualized crimping conjugate fiber) has large initial bulk.
  • Afiber assembly that uses the crimped conjugate fiber of the present invention that has latent crimps (hereinafter also referred to as a latently crimpable conjugate fiber) develops crimps when multiple layers are placed one over another and thermally processed. Accordingly, entanglement of fibers between layers is enhanced, thus further increasing elasticity and bulk recovery properties.
  • the first component contains polybutene-1 and linear low density polyethylene. Disposing the first component such that the first component occupies for at least 20% of the surface of the conjugate fiber enables a crimped conjugate fiber that makes use of the flexibility and the shape retainability (resilience after being deformed) of polybutene-1 to be obtained.
  • the first component containing linear low density polyethylene in addition to polybutene-1 improves spinnability such as uniform fiber formation and stretchability during melt spinning as well as the spreadability of a staple fiber, the crimp formability of a staple fiber, and like properties. That is, it is thought that, when melt spinning is performed solely with polybutene-1, the viscosity of the polymer discharged from a nozzle is not likely to be stable, thus making it difficult to obtain a uniform fiber. Also, polybutene-1 has a high molecular weight, and the degree of freedom of its molecular chain is poor and it is thus difficult to perform a stretching step. In addition, polybutene-1 has very large heat shrinkability.
  • the fiber would shrink during thermal processing, thus making it difficult to obtain a nonwoven fabric having good texture.
  • the first component contains linear low density polyethylene in addition to polybutene-1, the aforementioned problems such as poor spinnability and poor stretchability of polybutene-1 can be solved.
  • Polybutene-1 has a large molecular weight. That is, the molecular chain constituting polybutene-1 is long, and entanglement between molecules is extensive, and it is thought that the aforementioned problem, i.e., poor stretchability, is thus created.
  • linear low density polyethylene enters between the molecular chains of polybutene-1 having high molecular weight, and adequately suppresses the entanglement of the molecular chains of polybutene-1, thus improving stretchability.
  • a fiber assembly that uses the resulting crimped conjugate fiber exhibits excellent thermal processability (thermal treatment accomplished in a short period of time, uniform thermal bonding between component fibers) due to the linear low density polyethylene contained in the first component of the crimped conjugate fiber.
  • a polymer for example, polypropylene
  • the crimped conjugate fiber of the present invention can be thermally bonded so as to attain sufficient bonding strength even when thermal processing is performed at a lower temperature for a shorter period of time, and thus the post-processability of a fiber assembly containing the crimped conjugate fiber is enhanced.
  • linear low density polyethylene has excellent impact resistance
  • the fiber assembly of the present invention in which pieces of the component fiber are thermally bonded by the first component containing linear low density polyethylene of the crimped conjugate fiber of the present invention is unlikely to result in separation and delamination of bonded points of the fiber even when used in applications where a load is repetitively applied, and thus has excellent resistance to residual set from repetitive compression as well as resistance to residual set from compression.
  • the linear low density polyethylene is not particularly limited, and for example, copolymers with ⁇ -olefins polymerized using Ziegler catalysts and metallocene catalysts are usable. From the viewpoint of attaining a narrow molecular weight range and a uniform branch distribution, it is preferable to use copolymers with ⁇ -olefins polymerized using metallocene catalysts.
  • Afeature of linear low density polyethylene polymerized using a metallocene catalyst is having a uniform distribution of molecular weight, composition, and crystallinity.
  • linear low density polyethylene polymerized using a metallocene catalyst is likely to be uniformly dispersed inside PB-1 even when added in an amount of 2 to 25 mass%, and it is thus presumed that linear low density polyethylene demonstrates an effect of improving the stretchability of PB-1.
  • the ⁇ -olefins are not particularly limited, and examples include 1-butene, 1-hexene, 1-octene, 1-pentene, 3,3-dimethyl-1-butene, 4-methyl-1-pentene, 4,4-dimethyl-1-pentene, 1-decene, 1-dodecene, 1-tetradecene, 1-octadecene, and the like.
  • copolymer polymerized with an ⁇ -olefin using a metallocene catalyst commercially available products such as "Harmorex” (registered trademark) NJ744N, “Kernel” (registered trademark) KS560T and KC571 manufactured by Japan Polyethylene Corporation, and 420SD manufactured by Ube-Maruzen Polyethylene Co., Ltd., may be used.
  • the linear low density polyethylene in the first component has a ratio (Q value) of weight average molecular weight (Mw) to number average molecular weight (Mn) of 6 or less.
  • Q value weight average molecular weight
  • Mn number average molecular weight
  • a more preferable Q value is 2 to 5, and a particularly preferable Q value is 2.2 to 3.5.
  • the stretchability of the crimped conjugate fiber of the present invention containing polybutene-1 in the first component is enhanced when the first component contains, in addition to polybutene-1, linear low density polyethylene, preferably linear low density polyethylene that is polymerized using a metallocene catalyst and that satisfies the foregoing Q value range.
  • the first component that occupies for most of the fiber surface which contains linear low density polyethylene, imparts a slide effect to the fiber surface, and the resulting crimped conjugate fiber exhibits enhanced crimper passability and, once cut so as to obtain a staple fiber having a desired fiber length, enhanced spreadability of the staple fiber, and thus such a first component is preferable.
  • the density measured according to JIS-K-7112 of the linear low density polyethylene is 0.930 g/cm 3 or less, more preferably 0.920 g/cm 3 or less, and particularly preferably 0.915 g/cm 3 or less.
  • the lower limit of the density of the linear low density polyethylene is not particularly limited, and it is preferably 0.870 g/cm 3 or greater, more preferably 0.880 g/cm 3 or greater, and particularly preferably 0.890 g/cm 3 or greater.
  • the heat resistance of the first component constituting the crimped conjugate fiber is likely to be impaired, and it is likely that bulk recovery properties and resistance to residual compression set at temperatures greater than room temperature, for example in the range of 40 to 80°C, are impaired.
  • the flexural modulus measured according to JIS-K-7171 of the linear low density polyethylene is 800 MPa or less, more preferably 20 to 650 MPa, particularly preferably 25 to 300 MPa, and most preferably 30 to 180 MPa.
  • compatibility with PB-1 is good and heat resistance is high, and the resulting fiber assembly exhibits excellent bulk recovery properties and resistance to residual compression set.
  • the flexural modulus of the linear low density polyethylene When the flexural modulus of the linear low density polyethylene is high, the flexibility of the polymer is lost, and the elasticity of the resulting crimped conjugate fiber tends to be impaired, and when the flexural modulus of the linear low density polyethylene exceeds 800 MPa, the bulk recovery properties and the resistance to residual compression set of a fiber assembly prepared using the resulting crimped conjugate fiber are likely to be impaired. Also, when the flexural modulus of the linear low density polyethylene is high, the melting peak temperature of the polymer tends to be low, and when the flexural modulus of the linear low density polyethylene is less than 20 MPa, heat resistance is impaired, and the bulk recovery properties of the resulting fiber assembly at high temperatures are likely to be impaired.
  • the linear low density polyethylene has a melting peak temperature obtained from a DSC curve measured according to JIS-K-7121 of 70 to 130°C, more preferably 80 to 125°C, and even more preferably 90°C to 123°C.
  • melting peak temperature refers to a melting peak temperature obtained from a DSC curve measured according to JIS-K-7121.
  • the melting peak temperature obtained from a DSC curve is also referred to as a melting point.
  • the linear low density polyethylene has a melt flow rate (MFR; a measurement temperature of 190°C, a load of 2.16 kgf (21.18 N), hereinafter referred to as MFR190) according to JIS-K-7210 of 1 to 30 g/10 min, more preferably an MFR190 of 3 to 25 g/10 min, and even more preferably 5 to 20 g/10 min.
  • MFR190 melt flow rate
  • JIS-K-7210 melt flow rate
  • polybutene-1 for use in the present invention has a melting peak temperature obtained from a DSC curve measured according to JIS-K-7121 of 115 to 130°C, and more preferably 120 to 130°C.
  • the melting peak temperature is 115 to 130°C, heat resistance is high, and bulk recovery properties at high temperatures are good.
  • the polybutene-1 has a melt flow rate (MFR; a measurement temperature of 190°C, a load of 2.16 kgf (21.18 N), hereinafter referred to as MFR190) according to JIS-K-7210 of 1 to 30 g/10 min, more preferably an MFR190 of 3 to 25 g/10 min, and even more preferably 3 to 20 g/10 min.
  • MFR190 melt flow rate
  • polybutene-1 has a high molecular weight, and thus heat resistance is good and bulk recovery properties at high temperatures are favorable, and thus this configuration is preferable. Also, spun yarn retrievability and stretchability are good.
  • polybutene-1 is the principal component and is contained in a proportion of 70 mass% or greater relative to the entire first component. From the viewpoint of attaining good productivity, good cushioning properties, and good bulk recovery properties at high temperatures, it is preferable that polybutene-1 is contained in a proportion of 75 to 98 mass%, more preferably 80 to 97 mass%, particularly preferably 85 to 97 mass%, and most preferably 87 to 96 mass%.
  • the amount of the linear low density polyethylene added to the first component is 2 to 25 mass%, when the entire first component being 100 mass%, more preferably 3 to 20 mass%, particularly preferably 3 to 15 mass%, and most preferably 4 to 12 mass%.
  • the amount is within the foregoing range, the flowability of PB-1 is enhanced, stable and uniform spinning can be performed, and stretchability is also improved.
  • the first component contains polybutene-1 and linear low density polyethylene as described above, and further may contain an ethylene-ethylenic unsaturated carboxylic acid copolymer. Since the ethylene-ethylenic unsaturated carboxylic acid copolymer, as with the linear low density polyethylene, shows, compatibility with polybutene-1, the first component further containing an ethylene-ethylenic unsaturated carboxylic acid copolymer is capable of improving spinnability such as uniform fiber formation when melt spinning, stretchability, and the like.
  • a crimped conjugate fiber in which the first component further contains an ethylene-ethylenic unsaturated carboxylic acid copolymer in addition to polybutene-1 and linear low density polyethylene when performing thermal processing such as thermal bonding on a fiber web or a nonwoven fabric containing the fiber, a phenomenon in which the sheath component undergoes shrinking and thermally bonded points shrink, i.e., "bonding point shrinkage" (hereinafter also simply referred to as bonding point shrinkage) is unlikely to occur at the points where pieces of the constituting fiber are thermally bonded to each other, even when the thermal processing is performed for a long period of time at high temperatures. Accordingly, pieces of the constituting fiber can be bonded firmly to each other, and a thermally bonded nonwoven fabric having greater bonding strength can be obtained.
  • bonding point shrinkage hereinafter also simply referred to as bonding point shrinkage
  • the ethylenic unsaturated carboxylic acid constituting the ethylene-ethylenic unsaturated carboxylic acid copolymer for use in the crimped conjugate fiber of the present invention is not particularly limited, and examples include acrylic acid, methacrylic acid, ethacrylic acid, fumaric acid, maleic acid, itaconic acid, monomethyl maleate, monoethyl maleate, maleic anhydride, itaconic anhydride, and the like.
  • ethylene-ethylenic unsaturated carboxylic acid copolymer examples include ethylene-acrylic acid copolymer (EAA), ethylene-methacrylic acid copolymer (EMAA), ethylene-ethacrylic acid copolymer, ethylene-maleic acid copolymer, ethylene-fumaric acid copolymer, ethylene-itaconic acid copolymer, ethylene-maleic anhydride copolymer, ethylene-itaconic anhydride copolymer, and the like.
  • EAA ethylene-acrylic acid copolymer
  • EEMAA ethylene-methacrylic acid copolymer
  • EAA ethylene-ethacrylic acid copolymer
  • ethylene-maleic acid copolymer ethylene-fumaric acid copolymer
  • ethylene-itaconic acid copolymer ethylene-maleic anhydride copolymer
  • ethylene-itaconic anhydride copolymer ethylene-itaconic an
  • ethylene-acrylic acid copolymer, ethylene-methacrylic acid copolymer, and ethylene-maleic acid copolymer are preferable, and ethylene-acrylic acid copolymer and ethylene-methacrylic acid copolymer are more preferable.
  • the ethylene-ethylenic unsaturated carboxylic acid copolymer is not limited to a copolymer composed of ethylene and an ethylenic unsaturated carboxylic acid, and may be a copolymer in which another component is copolymerized, including, for example, a terpolymer in which two or more components including an ethylenic unsaturated carboxylic acid are copolymerized with ethylene.
  • Examples of monomers for use as the other copolymerization components include ethylenic unsaturated carboxylic acid esters such as vinyl acetate, vinyl propionate, and like vinyl esters, methyl acrylate, ethyl acrylate, isopropyl acrylate, n-butyl acrylate, isobutyl acrylate, isooctyl acrylate, and like acrylic acid esters, methyl methacrylate, isobutyl methacrylate, and like methacrylic acid esters, and dimethyl maleate, diethyl maleate, and like maleic acid esters; carbon monoxide; sulfur dioxide; and the like.
  • carboxylic acid esters such as vinyl acetate, vinyl propionate, and like vinyl esters, methyl acrylate, ethyl acrylate, isopropyl acrylate, n-butyl acrylate, isobutyl acrylate, isooctyl acrylate, and like acrylic acid
  • the copolymer in which ethylene, an ethylenic unsaturated carboxylic acid, and an optional copolymerization component are copolymerized is not particularly limited, and an example may be an ethylene-acrylate-maleic acid polymer in which ethylene, maleic anhydride and an acrylic ester are copolymerized ("Bondine" (registered trademark) manufactured by Arkema Japan) or the like.
  • the content of the ethylenic unsaturated carboxylic acid in ethylene-ethylenic unsaturated carboxylic acid copolymer is 1 to 50 mass%, and preferably 1 to 29 mass%. In particular, in the case of acrylic acid, it is preferably 5 to 25 mass%, and in the case of methacrylic acid, it is preferably 5 to 20 mass%.
  • the content of the other copolymerizable component in the ethylene-ethylenic unsaturated carboxylic acid copolymer is in the range of 0 to 30 mass%, and preferably 0 to 20 mass%.
  • an ionomer in which carboxyl groups are partially or entirely in a metal salt form can be used other than the ethylene-ethylenic unsaturated carboxylic acid copolymer itself.
  • metal species constituting metal ionomers include lithium, sodium, potassium, and like monovalent metals, magnesium, calcium, zinc, copper, cobalt, manganese, lead, iron, and like polyvalent metals, and the like, with monovalent metals or zinc being particularly preferable.
  • the ethylene-ethylenic unsaturated carboxylic acid copolymers may be used singly, or may be used in a combination of two or more.
  • the ethylene-ethylenic unsaturated carboxylic acid copolymers can be obtained by, although not particularly limited to, high pressure radical copolymerization.
  • the ethylene-ethylenic unsaturated carboxylic acid copolymer ionomers can be obtained by ionizing the ethylene-ethylenic unsaturated carboxylic acid copolymers by an ordinary method.
  • the first component of the crimped conjugate fiber of the present invention contains an ethylene-ethylenic unsaturated carboxylic acid copolymer that demonstrates a sufficient compatibilizing effect on polybutene-1, and accordingly a problem that occurs due to the poor spinnability of polybutene-1 when the compatibilizing effect on polybutene-1 is excessively low, i.e., a uniform conjugate fiber is unlikely obtained, can be solved.
  • a problem that occurs when the compatibilizing effect on polybutene-1 is excessive i.e., a conjugate fiber composed of a first component mainly containing polybutene-1 can be obtained but bonding point shrinkage occurs due to thermal processing when preparing a thermally bonded nonwoven fabric from the resulting conjugate fiber, can be solved. That is, by blending an ethylene-ethylenic unsaturated carboxylic acid copolymer that demonstrates a sufficient compatibilizing effect on polybutene-1, it is possible to obtain a uniform conjugate fiber containing them. Moreover, the thermal bonding properties of the resulting conjugate fiber is improved, and thus it is possible to overcome bonding point shrinkage, which can occur when bonding is performed by thermal processing at temperatures higher than the melting point of polybutene-1.
  • the amount of the copolymer added is 0.5 to 20 mass%, when the entire first component being 100 mass%, more preferably 1 to 15 mass%, even more preferably 3 to 10 mass%, and particularly preferably 4 to 9 mass%.
  • the amount is 0.5 mass% or greater, a crimped conjugate fiber having excellent thermal bonding properties can be obtained, the bonding strength between pieces of the fiber is not impaired at high temperatures, for example, a temperature of 190°C or higher, and the aforementioned bonding point shrinkage does not occur.
  • the amount is 20 mass% or less, a fiber structure such as a nonwoven fabric that has good hardness retainability (bulk recovery properties) can be obtained.
  • the ethylene-ethylenic unsaturated carboxylic acid copolymer has an MFR190 measured according to JIS-K-7210 of 3 to 60 g/10 min.
  • a more preferable MFR190 is 5 to 40 g/10 min, and even more preferably 5 to 30 g/10 min.
  • the MFR190 being 60 g/10 min or less, the effect of suppressing bonding point shrinkage that can occur when performing thermal processing on a fiber web that contains the resulting crimped conjugate fiber can be enhanced.
  • the MFR190 being 3 g/10 min or greater, it is easy to obtain a uniform crimped conjugate fiber that has excellent operability during a spinning step and a stretching step.
  • the ethylene-ethylenic unsaturated carboxylic acid copolymer has a melting peak temperature obtained from a DSC curve measured according to JIS-K-7121 of 60°C or higher, more preferably 70°C or higher, and even more preferably 70 to 120°C.
  • the melting peak temperature being 60°C or higher, the effect of suppressing bonding point shrinkage is strong, and deterioration of cushioning properties such as deterioration of bulk recovery properties and an increase of a rate of compression set due to thermal processing are unlikely to occur.
  • the melting peak temperature being 70 to 120°C, the effect of suppressing bonding point shrinkage, the effect of suppressing deterioration of cushioning properties, and like effects can be more readily demonstrated.
  • the ethylene-ethylenic unsaturated carboxylic acid copolymer has a softening temperature (Vicat softening point) as measured according to JIS-K-7206 of 40°C or higher, more preferably 50°C or higher, and particular preferably 50 to 100°C.
  • the softening temperature being 40°C or higher, the effect of suppressing bonding point shrinkage is strong, and deterioration of cushioning properties such as deterioration of bulk recovery properties and an increase of a rate of compression set due to thermal processing are unlikely to occur.
  • the softening temperature being 50 to 100°C, the effect of suppressing bonding point shrinkage, the effect of suppressing deterioration of cushioning properties, and like effects can be more readily demonstrated.
  • polymers that further can be blended with the first component, as long as the effect of the present invention is not impaired, include polyolefin-based polymers other than the aforementioned polyolefin-based polymers, copolymerizable polymers with olefins having a polar group such as a vinyl group, a carboxyl group, or maleic anhydride; polyolefin-based, styrene-based, polyester-based, and like various thermoplastic elastomers; and the like.
  • the first component can be mixed with, for example, other polymers, known nucleating agents such as organic or inorganic substances (for example, calcium carbonate, talc, and the like), antistatic agents, pigments, delusterants, thermal stabilizers, photostabilizers, flame retardants (halogen-based, phosphorus-based, nonhalogen-based, antimony trioxide, and like inorganic compound-based flame retardants, and the like), bactericidal agents, lubricants, plasticizers, softening agents, and the like.
  • known nucleating agents such as organic or inorganic substances (for example, calcium carbonate, talc, and the like), antistatic agents, pigments, delusterants, thermal stabilizers, photostabilizers, flame retardants (halogen-based, phosphorus-based, nonhalogen-based, antimony trioxide, and like inorganic compound-based flame retardants, and the like), bactericidal agents, lubricants, plasticizers, softening agents, and the like.
  • Adding a nucleating agent as such an additive brings about the following advantages: an effect of preventing fusion between pieces of the fiber when spinning can be further enhanced, and a nonwoven fabric having soft texture can be obtained.
  • the amount of nucleating agent added is not particularly limited, and it is preferable in light of fiber productivity to add a nucleating agent in a proportion of 20 mass% or less relative to the total mass of the first component, and it is more preferable to add in a proportion of 10 mass% or less.
  • the first component constituting the crimped conjugate fiber of the present invention has the above-described features. That is, the first component contains PB-1 as the principal component in a proportion of 70 mass% or greater, preferably 75 mass% or greater, and contains linear low density polyethylene in a proportion of 2 to 25 mass%. Accordingly, the melting point of the first component after spinning is low, and thus a phenomenon in which the apparent melting point of the first component is increased, which can occur in the case where polypropylene in place of linear low density polyethylene is added to PB-1, is unlikely to occur.
  • the first component after spinning has a melting point (Tf1) obtained from a DSC curve measured according to JIS-K-7121 of 140°C or lower, preferably 90 to 135°C, more preferably 100 to 130°C, particularly preferably 115 to 130°C, and most preferably 120°C to 125°C.
  • Tf1 melting point obtained from a DSC curve measured according to JIS-K-7121 of 140°C or lower, preferably 90 to 135°C, more preferably 100 to 130°C, particularly preferably 115 to 130°C, and most preferably 120°C to 125°C.
  • Tf1 melting point of the first component after spinning
  • Tf2 melting point
  • the lower limit of the melting point (Tf1) of the first component after spinning is not particularly limited, but when the lower limit is lower than 90°C, heat resistance and bulk recovery properties at high temperatures are likely to be impaired.
  • the heat of fusion curve has a so-called double-peak shape having multiple peaks derived from the first component when performing thermal bonding processing.
  • linear low density polyethylene is preferable that has a melting point that mostly overlaps the melting point of post-spinning PB-1, which is the principal component of the first component, and that has a so-called single peak having only one peak derived from the first component on a heat of fusion curve.
  • the second component of the crimped conjugate fiber of the present invention is not particularly limited as long as it is a polymer having a melting peak temperature at least 20°C higher than the melting peak temperature of polybutene-1 or a polymer having a melting initiation temperature of 120°C or higher.
  • Polymers having excellent bending strength and bending elasticity are preferable, and examples include polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphtahalate, polylactic acid, and like polyester-based polymers, Nylon 6, Nylon 66, Nylon 11, Nylon 12, and like polyamides, polypropylene, polymethylpentene, and like polyolefin-based polymers, polycarbonates, polystyrenes, and the like. When such polymers are used as the second component, polymers may be used singly or may be used as a combination of two or more.
  • a polyester-based polymer or a polyolefin-based polymer is preferable as a polymer for use in the second component.
  • the use of a polyolefin-based polymer as the second component together with the use of a polyolefin-based polymer as the first component as described above makes it easy to recycle the crimped conjugate fiber of the present invention.
  • the crimped conjugate fiber of the present invention that uses the polyester-based polymer as the second component has a large melting point difference between the second component that constitutes near the center of the conjugate fiber and the first component that occupies for most of the fiber surface, and therefore even when the conjugate fiber, a fiber web, and a nonwoven fabric are subjected to thermal bonding at a temperature at which the first component undergoes sufficient thermal bonding, the second component maintains its shape, and sagging caused by thermal processing is unlikely to occur, and it is easy to manage the processing temperature in a thermal processing step, allowing a fiber assembly having high bonding strength to readily be obtained.
  • the polymer is not particularly limited insofar as it is a polyester-based polymer having a melting peak temperature at least 20°C higher than the melting peak temperature of polybutene-1 or a polyester-based polymer having a melting initiation temperature of 120°C or higher.
  • polyethylene terephthalate (hereinafter also referred to as PET), polytrimethylene terephthalate (hereinafter also referred to as PTT), and polybutylene terephthalate (hereinafter also referred to as PBT) are preferable, with polyethylene terephthalate or polytrimethylene terephthalate being more preferable.
  • PET polyethylene terephthalate
  • PTT polytrimethylene terephthalate
  • PBT polybutylene terephthalate
  • a polymer that has physical properties suitable for the application of the fiber is selected, and in the case where a polyester-based polymer is used as the second component in the crimped conjugate fiber of the present invention, it is most preferable to use polyethylene terephthalate in light of the availability, the high bulk recovery properties of the fiber, and like features.
  • the polyester-based polymer has a limiting viscosity [ ⁇ ] of 0.4 to 1.2, and more preferably 0.5 to 1.1.
  • the limiting viscosity is less than 0.4, the molecular weight of the polymer is excessively low, and therefore not only is spinnability inferior but also fiber strength is poor, and such a fiber is not practical.
  • the limiting viscosity exceeds 1.2, the molecular weight of the polymer is increased, and the melt viscosity is excessive. Therefore, single-yarn breakage and like phenomena occur, making it difficult to perform good spinning, and thus such limiting viscosity is not preferable.
  • a limiting viscosity [ ⁇ ] within the foregoing range enables a conjugate fiber having excellent productivity and excellent bulk recovery properties to be obtained.
  • the limiting viscosity [ ⁇ ] as referred to herein is measured with an Ostwald viscometer using an o-chlorophenol solution at 35°C and expressed as a value obtained according to Expression 1 below:
  • ⁇ r is a value obtained by dividing the viscosity at 35°C of a diluted solution of a sample dissolved in o-chlorophenol having a purity of 98% or greater by the concentration of the entire solvent measured at the same temperature, and C is the weight value in grams of the solute in 100 ml of the aforementioned solution.
  • the polyester has a melting peak temperature obtained from a DSC curve measured according to JIS-K-7121 of 180°C to 300°C, and more preferably 200°C to 270°C.
  • a melting peak temperature of 180 to 300°C enables the weatherability to be increased and the flexural modulus of the resulting conjugate fiber to be increased.
  • the polymer is not particularly limited insofar as it is a polyolefin-based polymer having a melting peak temperature at least 20°C higher than the melting peak temperature of polybutene-1 or a polyolefin-based polymer having a melting initiation temperature of 120°C or higher.
  • polypropylene (hereinafter also referred to as PP) is preferable.
  • PP polypropylene
  • Such polypropylene is not particularly limited, and for example, homopolymers, random copolymers, block copolymers, or mixtures thereof, and insofar as properties required for nonwoven fabrics and cushioning materials, such as heat resistance and bulk recovery properties, are not impaired, polypropylene in which synthetic rubber or a like elastomer component is dispersed or mixed therewith may be used.
  • homopolypropylene is advantageous in terms of the bulk recovery property and thus is preferable.
  • the random copolymers and the block copolymers include copolymers of propylene and at least one ⁇ -olefin selected from the group consisting of ethylene and ⁇ -olefins having 4 or more carbon atoms.
  • Such ⁇ -olefins having 4 or more carbon atoms are not particularly limited, and examples include 1-butene, 1-pentene, 3,3-dimethyl-1-butene, 4-methyl-1-pentene, 4,4-dimethyl-1-pentene, 1-decene, 1-dodecene, 1-tetradecene, 1-octadecene, and the like.
  • one selected from the group consisting of propylene homopolymers, ethylene-propylene copolymers, and ethylene-butene-1-propylene terpolymers is preferable, and in light of heat resistance of the resulting crimped conjugate fiber, recycling efficiency after use, and economical efficiency (production costs), in the case where a polyolefin-based polymer is used as the second component, the polyolefin-based polymer is particularly preferably homopolypropylene.
  • the homopolypropylene content is 73 to 100 mass%, more preferably 75 to 100 mass%, particularly preferably 85 to 100 mass%, when the entire second component being 100 mass%.
  • the polypropylene has a melt flow rate (MFR; a measurement temperature of 230°C, a load of 2.16 kgf (21.18 N), hereinafter referred to as MFR230) according to JIS-K-7210 of 3 to 40 g/10 min, and a more preferable MFR230 is 5 to 35 g/10 min.
  • MFR230 melt flow rate
  • JIS-K-7210 JIS-K-7210
  • the polypropylene has a ratio (Q value) of weight average molecular weight (Mw) to number average molecular weight (Mn) of 2 or greater.
  • a more preferable Q value is 3 to 12.
  • Amore preferable value of the ratio (Q value) of the weight average molecular weight (Mw) to the number average molecular weight (Mn) of polypropylene in the second component can be selected according to the kind of three-dimensional crimps which are developed in the resulting crimped conjugate fiber.
  • the Q value of polypropylene of the second component is preferably 4 to 12, and more preferably 5 to 9.
  • the Q value is preferably 3 to 5.
  • thermoplastic elastomer When a polyolefin-based polymer such as polypropylene is used as the second component, in addition to the polyolefin-based polymer having a melting peak temperature at least 20°C higher than the melting peak temperature of polybutene-1, a thermoplastic elastomer may also be contained.
  • the second component that contributes to the hardness, the bulk recovery properties, and the resistance to set of a crimped conjugate fiber itself and those of a fiber assembly containing the crimped conjugate fiber preferably contains a thermoplastic elastomer.
  • thermoplastic elastomers can be used, and styrene-based elastomers, olefin-based elastomers, ester-based elastomers, amide-based elastomers, urethane-based elastomers, and vinyl chloride-based elastomers are usable.
  • thermoplastic elastomer in the crimped conjugate fiber of the present invention, in the case where a polyolefin-based polymer is used as the second component, in light of recycling efficiency after use, it is preferable to use a polypropylene homopolymer, a random copolymer, a block copolymer, or a mixture thereof as the polyolefin-based polymer that has a melting peak temperature at least 20°C higher than the melting peak temperature of polybutene-1, and it is preferable to use an olefin-based thermoplastic elastomer as the thermoplastic elastomer.
  • Olefin-based thermoplastic elastomers are thermoplastic elastomers that use a polyolefin resin such as polyethylene or polypropylene as a hard segment, and an ethylene-propylene-based rubber such as ethylene-propylene rubber (EPM), ethylene-butene rubber (EBM), ethylene-propylene-diene rubber (EPDM) as a soft segment.
  • a polyolefin resin such as polyethylene or polypropylene
  • EPM ethylene-propylene rubber
  • EBM ethylene-butene rubber
  • EPDM ethylene-propylene-diene rubber
  • olefin-based thermoplastic elastomers include "Milastomer” (registered trademark) and “Notio” (registered trademark) manufactured by Mitsui Chemicals, Inc., “Espolex” (registered trademark) manufactured by Sumitomo Chemical Co., Ltd., "Thermorun” (registered trademark) and “Zelas” (registered trademark) manufactured by Mitsubishi Chemical Corporation, and the like.
  • the second component constituting the crimped conjugate fiber is a polyolefin-based polymer
  • adding a suitable amount of a thermoplastic elastomer, such as an olefin-based thermoplastic elastomer, to the second component imparts bending elasticity that seems to be derived from the thermoplastic elastomer to the second component containing the polyolefin-based polymer, and recoverability from bending and resistance to repetitive bending fatigue, which are likely to be insufficient in a conjugate fiber in which the second component is composed solely of a polyolefin-based polymer, are enhanced, and durability against repetitive compression required in cushioning materials or the like are enhanced.
  • thermoplastic elastomer to be added is an olefin-based thermoplastic elastomer
  • first component and the second component are both composed of polyolefin-based polymers, thus making it easy to recycle the fiber assembly after use.
  • the olefin-based thermoplastic elastomer added to the second component is an ⁇ -olefin-based thermoplastic elastomer containing an ⁇ -olefin-based rubber-like polymer as a soft segment.
  • the olefin-based thermoplastic elastomer and the ⁇ -olefin-based thermoplastic elastomer are olefin-based thermoplastic elastomers polymerized using metallocene catalysts.
  • the ⁇ -olefin-based rubber-like polymer is not particularly limited, and for example, it is preferable to use a copolymer of ethylene and an ⁇ -olefin having 3 to 20 carbon atoms.
  • the ⁇ -olefin include propylene, 1-butene, 1-pentene, 3,3-dimethyl-1-butene, 4-methyl-1-pentene, 4,4-dimethyl-1-pentene, 1-decene, 1-dodecene, 1-tetradecene, 1-octadecene, and the like.
  • the hard segment contained in the olefin-based thermoplastic elastomer is not particularly limited, and for example, polyolefin-based polymers such as polypropylene and polypropylene are usable.
  • the polypropylene is not particularly limited, and for example, homopolymers, random copolymers, block copolymers, or mixtures thereof are usable. Examples of the random copolymers and the block copolymers include copolymers of propylene and at least one ⁇ -olefin selected from the group consisting of ethylene and ⁇ -olefins having 4 or more carbon atoms.
  • Such ⁇ -olefins having 4 or more carbon atoms are not particularly limited, and examples include 1-butene, 1-pentene, 3,3-dimethyl-1-butene, 4-methyl-1-pentene, 4,4-dimethyl-1-pentene, 1-decene, 1-dodecene, 1-tetradecene, 1-octadecene, and the like.
  • the content of the olefin-based thermoplastic elastomer added to the second component is preferably 3 to 25 mass%, more preferably 3 to 20 mass%, and particularly preferably 5 to 15 mass%, when the entire second component being 100 mass%.
  • the second component when the olefin-based thermoplastic elastomer content is 3 mass% or greater, the second component as a whole exhibits elasticity due to the addition of the elastomer component to the second component, and the resistance to residual repetitive compression set and the resistance to residual compression set of a fiber assembly that uses the crimped conjugate fiber of the present invention can be increased.
  • the olefin-based thermoplastic elastomer content is 25 mass% or less, a crimped conjugate fiber from which a fiber assembly that has excellent resistance to residual repetitive compression set and resistance to residual compression set is obtained is produced without adversely affecting the spinnability and the stretchability of the crimped conjugate fiber.
  • the density of the olefin-based thermoplastic elastomer is preferably 0.8 to 1.0 g/cm 3 , and more preferably 0.85 to 0.88 g/cm 3 .
  • the density is within the foregoing range, excellent heat resistance is obtained, and regarding a fiber assembly that uses the crimped conjugate fiber, a lighter fiber assembly can be obtained if the volume is the same, and is thus preferably used in applications where a light weight is required.
  • the Shore A hardness of the olefin-based thermoplastic elastomer measured according to ASTM D 2240 using a type A durometer is preferably 50 to 95, more preferably 60 to 90, and particularly preferably 65 to 85.
  • Shore A hardness of the olefin-based thermoplastic elastomer added to the second component satisfies the foregoing range, the heat resistance and the durability against repetitive bending of a nonwoven fabric that uses the resulting crimped conjugate fiber is well-balanced.
  • the Shore A hardness is less than 50, the added olefin-based thermoplastic elastomer itself is excessively soft, and the resulting crimped conjugate fiber and a fiber assembly deform easily, and thus bending recovery properties and bulk recovery properties can be poor.
  • the Shore A hardness exceeds 95, the added olefin-based thermoplastic elastomer is excessively hard, bending elasticity attributable to the addition of the olefin-based thermoplastic elastomer to the second component is not demonstrated, and bending recovery properties and bulk recovery properties against repetitive compression tend to be impaired.
  • the melting peak temperature of the olefin-based thermoplastic elastomer used in the present invention is not particularly limited, but in light of the heat treatment performed when producing a fiber assembly from the resulting crimped conjugate fiber as well as the application of the fiber assembly and the heat resistance of the fiber assembly, the melting peak temperature of the olefin-based thermoplastic elastomer is preferably 70°C or higher and 170°C or lower, more preferably 100°C or higher and 160°C or lower, and particularly preferably greater than or equal to the melting peak temperature of polybutene-1 contained in the first component and 160°C or lower.
  • the melting peak temperature of the olefin-based thermoplastic elastomer contained in the second component is 70°C or higher and 170°C or lower, heat resistance is high, and bulk is not likely to be reduced in a thermal treatment performed when obtaining a fiber assembly from the resulting crimped conjugate fiber, thus enabling a bulky fiber assembly to be readily obtained.
  • the crimped conjugate fiber and the fiber assembly are particularly suitable for applications where heat resistance is required.
  • the melt flow rate of the olefin-based thermoplastic elastomer is not particularly limited, and it is preferable that a melt flow rate (MFR; a measurement temperature of 230°C, a load of 2.16 kgf(21.18 N), hereinafter referred to as MFR230) measured according to JIS-K-7210 of 1 to 30 g/10 min, and a more preferable MFR230 is 3 to 20 g/10 min, and a particularly preferable MFR 230 is 5 to 15 g/10 min.
  • MFR230 melt flow rate
  • spun yarn retrievability and stretchability are good.
  • the olefin-based thermoplastic elastomer used have good heat resistance, and therefore bulk is not likely to be reduced in a thermal treatment performed when obtaining a fiber assembly from the resulting crimped conjugate fiber, thus enabling a bulky fiber assembly to be readily obtained.
  • the crimped conjugate fiber and the fiber assembly are particularly suitable for applications where heat resistance is required.
  • thermoplastic elastomers that satisfy the aforementioned density, Shore A hardness, melting peak temperature, and melt flow rate, among such olefin-based thermoplastic elastomers
  • crystalline structure and amorphous structure portions having a size of 300 nm to 1 ⁇ m are scattered throughout the elastomer.
  • a crimped conjugate fiber By adding an elastomer having such a structure to the second component (core component) of a crimped conjugate fiber, it is likely that the resulting crimped conjugate fiber has ample heat resistance and excellent bulk recovery properties and resistance to set after repetitive deformation.
  • An example of the olefin-based thermoplastic elastomer polymerized using a metallocene catalyst may be "Notio" (registered trademark) manufactured by Mitsui Chemicals, Inc., or the like, but the olefin-based thermoplastic elastomer is not limited thereto.
  • the second component can be further blended with a polymer insofar as the effect of the present invention is not impaired.
  • known various additives can be added also to the second component insofar as the effect of the present invention is not impaired and insofar as fiber productivity, nonwoven fabric productivity, thermal bonding properties, and texture are not adversely affected.
  • nucleating agents can be mixed as additives that can be added to the second component according to the applications.
  • Fig. 1 shows a schematic diagram of the cross-section of a crimped conjugate fiber according to one embodiment of the present invention.
  • a first component 1 is disposed around a second component 2, and the first component 1 occupies for at least 20% of the surface of a conjugate fiber 10. Accordingly, the surface of the first component 1 melts during thermal bonding.
  • a centroid position 3 of the second component 2 does not overlap a centroid position 4 of the conjugate fiber 10.
  • the shift ratio (hereinafter also referred to as eccentricity) is a value represented by Expression 2 below, where the centroid position 3 of the second component 2 is C1, the centroid position 4 of the conjugate fiber 10 is Cf, and a radius 5 of the conjugate fiber 10 is rf:
  • the fiber cross-section in which the centroid position 3 of the second component 2 does not overlap the centroid position 4 of the conjugate fiber is preferably in an eccentric core-in-sheath type as shown in Fig. 1 or a parallel type.
  • a fiber in which the centroid position of a multi-core portion as a whole does not overlap the centroid position of the fiber is usable.
  • the fiber has an eccentric core-in-sheath cross-section because the desired wavy crimps and/or spiral crimps are readily developed.
  • the eccentricity of the eccentric core-in-sheath conjugate fiber is preferably 5 to 50%, and more preferably 7 to 30%.
  • the shape of the fiber cross-section of the second component 2 may be, other than being circular, oval, Y, X, #, polygonal, star, and various other shapes
  • the shape of the cross-section of the conjugate fiber 10 may be, other than being circular, oval, Y, X, #, polygonal, star, and various other shapes, or hollow.
  • the second component is disposed as a core component, and the centroid position of the second component does not overlap the centroid position of the conjugate fiber. It is preferable that the second component and the first component (core/sheath) are combined in a volume ratio of 8/2 to 2/8, more preferably 7/3 to 3/7, and even more preferably 6/4 to 4/6.
  • the second component that serves as a core component contributes mainly to bulk recovery properties
  • the first component that serves as a sheath component contributes mainly to the strength of the nonwoven fabric and the hardness of the nonwoven fabric.
  • a combination ratio of 8/2 to 2/8 enables the strength, the hardness, and the bulk recovery properties of the nonwoven fabric to be satisfied simultaneously.
  • the first component that serves as a sheath component is excessive, the strength of the nonwoven fabric is increased, but the resulting nonwoven fabric tends to be hard, and the bulk recovery properties tend to be poor.
  • bonding points are excessively reduced, and the strength of the nonwoven fabric tends to be lowered, and the bulk recovery properties tend to be poor.
  • Fig. 2 shows forms of crimps of a crimped conjugate fiber according to one embodiment of the present invention.
  • conjugate fiber in which three-dimensional crimps have been developed means that the crimp shape have been developed in the crimped conjugate fiber includes wavy crimps and/or spiral crimps.
  • wavy crimps refers to crimps having curved crests as shown in Fig. 2A .
  • spiral crimps refers to crimps having spirally curved crests as shown in Fig. 2B . Crimps in which wavy crimps and spiral crimps are concomitantly present as shown in Fig.
  • crimps in which acutely angled crimps of mechanical crimping and spiral crimps are concomitantly present are also encompassed within the crimp form of the three-dimensional crimps which are developed in the crimped conjugate fiber of the present invention.
  • crimps in which wavy crimps and spiral crimps are concomitantly present as shown in Fig. 2C are particularly preferable because cardability, initial bulk, and bulk recovery properties can be satisfied simultaneously.
  • a first component containing polybutene-1 and linear low density polyethylene and a second component containing a polymer having a melting peak temperature at least 20°C higher than the melting peak temperature of polybutene-1 or a polymer having a melting initiation temperature of 120°C or higher are provided.
  • the first component and the second component are supplied to a compound nozzle, for example, an eccentric core-in-sheath compound nozzle, such that on the fiber cross-section, the first component occupies for at least 20% of the surface of a conjugate fiber, and the centroid position of the second component does not overlap the centroid position of the conjugate fiber, and the second component is subjected to melt spinning at a spinning temperature of 220 to 350°C, and the first component at a spinning temperature of 200 to 300°C.
  • a compound nozzle for example, an eccentric core-in-sheath compound nozzle
  • the spinning temperature of the second component is selected according to the polymer, and it is preferable to perform melt spinning at a spinning temperature of 220°C to 330°C in the case where a polyolefin-based polymer such as polypropylene or polymethylpentene is used, and at a spinning temperature of 240 to 350°C in the case where a polyester-based polymer such as polyethylene terephthalate, polytrimethylene terephthalate, or polybutylene terephthalate is used.
  • the first component and the second component are supplied to an eccentric core-in-sheath compound nozzle at the aforementioned spinning temperatures, and retrieved at a retrieving rate of 100 to 1500 m/min to give an unstretched spinning filament having a fineness of 2 to 120 dtex.
  • a stretching treatment is carried out at a stretch ratio of 1.8 or greater at a stretching temperature of 40°C or higher and lower than the melting point of the first component.
  • a more preferable lower limit of the stretching temperature is 50°C or higher, and a more preferable upper limit of the stretching temperature is a temperature 10°C lower than the melting point of the first component.
  • the stretching temperature When the stretching temperature is lower than 40°C, crystallization of the first component barely proceeds, and thus thermal shrinkage tends to be increased and bulk recovery properties tend to be reduced.
  • the stretching temperature is greater than or equal to the melting point of the first component, pieces of the fiber tend to fuse to each other.
  • a more preferable lower limit of the stretch ratio is 2.
  • a more preferable upper limit of the stretch ratio is 4.
  • the stretch ratio is 1.8 or greater, the stretch ratio is not excessively small, making it easy to obtain a fiber in which the above-described wavy crimps and/or spiral crimps are developed, and the initial bulk and the rigidity of the fiber itself are not small, and nonwoven fabric processability such as cardability and bulk recovery properties are not inferior.
  • the stretching method is not particularly limited, and known stretching treatments can be performed, such as wet stretching in which stretching is performed while heating with high temperature fluid such as hot water; dry stretching in which stretching is performed while heating in high temperature gas or with a high temperature metal roll; and water vapor stretching in which stretching is performed while heating a fiber by water vapor having a temperature of 100°C or higher under ordinary pressure or increased pressure.
  • wet stretching using hot water is preferable because of its productivity and economical efficiency and because it allows the entire unstretched fiber bundle to be readily and uniformly heated.
  • an annealing treatment may be performed as necessary under a dry heat, wet heat, or steaming atmosphere at 90 to 120°C.
  • the polymer having a melting peak temperature at least 20°C higher than the melting peak temperature of polybutene-1 or the polymer having a melting initiation temperature of 120°C or higher contained in the second component constituting the actualized crimping conjugate fiber is a polyolefin-based polymer such as homopolypropylene, an ethylene-propylene copolymer, or an ethylene-butene-1-propylene terpolymer
  • the stretching temperature is preferably 40°C or higher and lower than or equal to the melting peak temperature of polybutene-1 contained in the first component, more preferably 50°C or higher and 100°C or lower, and particularly preferably 60°C or higher and 90°C or lower.
  • the polymer having a melting peak temperature at least 20°C higher than the melting peak temperature of polybutene-1 or the polymer having a melting initiation temperature of 120°C or higher contained in the second component constituting the actualized crimping conjugate fiber is a polyester-based polymer such as polyethylene terephthalate, polytrimethylene terephthalate, or polybutylene terephthalate
  • the stretching temperature is preferably 60°C or higher and lower than or equal to the melting peak temperature of polybutene-1 contained in the first component, more preferably 70°C or higher and 100°C or lower, and particularly preferably 75°C or higher and 95°C or lower.
  • crimps per 25 mm are formed using a known crimper such as a stuffer-box crimper.
  • a more preferable number of crimps is 8 to 20 per 25 mm, and a particularly preferable number of crimps is 10 to 18 per 25 mm.
  • the shape of crimps after a fiber has passed through a crimper is serrated crimps and/or wavy crimps. When the number of crimps is less than 5 per 25 mm, cardability tends to be impaired, and the initial bulk and the bulk recovery properties of the nonwoven fabric tend to be poor.
  • the number of crimps is greater than 25 per 25 mm, the number of crimps is excessive, and not only does cardability tend to be impaired and the texture of the nonwoven fabric tend to deteriorate, but also the initial bulk of the nonwoven fabric tend to be reduced.
  • annealing treatment at a temperature at which an unstretched fiber bundle does not undergo thermal bonding and at which three-dimensional crimps are developed.
  • the first component is composed of a polymer containing polybutene-1
  • crimps are formed by a crimper, and then an annealing treatment and simultaneously a drying treatment are performed in a dry heat atmosphere of 90 to 120°C because the process can be simplified.
  • an annealing treatment is performed at a temperature of 90°C or higher, dry thermal shrinkage is not large, specific actual crimps are readily obtained, the texture of the resulting nonwoven fabric is not roughened, and productivity can be increased.
  • a more preferable range of the treatment temperature is 90 to 115°C, and particularly preferably 95 to 110°C.
  • An actualized crimping conjugate fiber obtained by the above-described method mainly has at least one type of crimp selected from wavy crimps and spiral crimps shown in Fig. 2 .
  • the actualized crimping conjugate fiber has at least one type of crimp selected from wavy crimps only, spiral crimps only, crimps where wavy crimps and spiral crimps are concomitantly present, and crimps where wavy crimps and serrated crimps are concomitantly present, and particularly preferably, the actualized crimping conjugate fiber has at least one type of crimp selected from wavy crimps only, spiral crimps only, and crimps where wavy crimps and spiral crimps are concomitantly present.
  • the number of crimps of the actualized crimping conjugate fiber is preferably 5 per 25 mm or greater, and 25 per 25 mm or less, because a bulky nonwoven fabric can be obtained without reducing cardability. Then, the fiber is cut into a desired fiber length, giving an actualized crimping conjugate fiber. A more preferable number of crimps is 8 to 20 per 25 mm, and a particular preferable number of crimps is 10 to 18 per 25 mm.
  • the actualized crimping conjugate fiber With the actualized crimping conjugate fiber, crimps appear on a conjugate fiber, and at least one type of three-dimensional crimps selected from wavy crimps and spiral crimps are developed and made visible, and therefore the actualized crimping conjugate fiber has actual crimps.
  • the crimps may be actualized crimps in which three-dimensional crimps fully have been developed, or may be actualized crimps in which slightly more crimping that will be developed (that will be developed when the fiber is heated) remains.
  • a first component containing polybutene-1 and linear low density polyethylene and a second component containing a polymer having a melting peak temperature at least 20°C higher than the melting peak temperature of polybutene-1 or a polymer having a melting initiation temperature of 120°C or higher are provided.
  • the first component and the second component are supplied to a compound nozzle, for example, an eccentric core-in-sheath compound nozzle, such that in the fiber cross-section, the first component occupies for at least 20% of the surface of a conjugate fiber, and the centroid position of the second component does not overlap the centroid position of the conjugate fiber, and the second component is subjected to melt spinning at a spinning temperature of 220 to 350°C, and the first component at a spinning temperature of 200 to 300°C.
  • a compound nozzle for example, an eccentric core-in-sheath compound nozzle
  • the spinning temperature of the second component is selected according to the polymer, and it is preferable to perform melt spinning at a spinning temperature of 220°C to 330°C in the case where a polyolefin-based polymer such as polypropylene or polymethylpentene is used, and at a spinning temperature of 240 to 350°C in the case were a polyester-based polymer such as polyethylene terephthalate, polytrimethylene terephthalate, or polybutylene terephthalate is used.
  • the first component and the second component are supplied to an eccentric core-in-sheath compound nozzle at the aforementioned spinning temperatures, and retrieved at a retrieving rate of 100 to 1500 m/min to give an unstretched spinning filament having a fineness of 2 to 120 dtex.
  • a stretching treatment is carried out at a stretch ratio of 1.5 or greater at a stretching temperature of 40°C or higher and lower than the melting point of the first component.
  • a more preferable lower limit of the stretching temperature is 50°C or higher.
  • a more preferable upper limit of the stretching temperature is a temperature 10°C lower than the melting point of the first component.
  • the stretching temperature When the stretching temperature is lower than 40°C, crystallization of the first component barely proceeds, and thus thermal shrinkage tends to be increased and bulk recovery properties tend to be reduced.
  • the stretching temperature is greater than or equal to the melting point of the first component, fibers each other tend to fuse.
  • Amore preferable lower limit of the stretch ratio is 2.
  • a more preferable upper limit of the stretch ratio is 4.
  • the stretch ratio is 1.5 or greater, the stretch ratio is not excessively small, crimps are likely to appear when a thermal treatment is performed, and the initial bulk and the rigidity of the fiber itself are not small, and nonwoven fabric processability such as cardability and bulk recovery properties are not inferior.
  • the stretching method is not particularly limited, and known stretching treatments can be performed, such as wet stretching in which stretching is performed while heating with high temperature fluid such as hot water; dry stretching in which stretching is performed while heating in high temperature gas or with a high temperature metal roll; and water vapor stretching in which stretching is performed while heating a fiber by water vapor having a temperature of 100°C or higher under ordinary pressure or increased pressure.
  • wet stretching using hot water is preferable because of its productivity and economical efficiency and because it allows the entire unstretched fiber bundle to be readily and uniformly heated.
  • the stretching temperature is preferably 40°C or higher and lower than or equal to the melting peak temperature of polybutene-1 contained in the first component, more preferably 50°C or higher and 100°C or lower, and particularly preferably 60°C or higher and 90°C or lower.
  • the stretching temperature is preferably 60°C or higher and lower than or equal to the melting peak temperature of polybutene-1 contained in the first component, more preferably 70°C or higher and 100°C or lower, and particularly preferably 75°C or higher and 95°C or lower.
  • 5 to 25 crimps per 25 mm are formed using a known crimper such as a stuffer-box crimper.
  • a more preferable number of crimps is 8 to 20 per 25 mm, and a particularly preferable number of crimps is 10 to 18 per 25 mm.
  • cardability is likely to be impaired.
  • crimps after crimps are formed by the aforementioned crimper, it is preferable to perform an annealing treatment in a dry heat, wet heat, or steaming atmosphere at 50 to 100°C, preferably 60 to 90°C, more preferably 60 to 80°C, and particularly preferably 60 to 75°C.
  • a fiber treating agent it is preferable that, after a fiber treating agent is added, crimps are formed by a crimper, and then an annealing treatment and simultaneously a drying treatment are performed in a dry heat atmosphere of 50 to 90°C because the process can be simplified.
  • An annealing temperature of 50 to 90°C allows desired heat shrinkage to be obtained, and a latently crimpable conjugate fiber can be obtained in which crimps are developed during heating. Also, a fiber that has high cardability can be obtained.
  • the crimped conjugate fiber of the present invention i.e., the actualized crimping conjugate fiber or the latently crimpable conjugate fiber of the present invention, is subjected to the aforementioned annealing treatment and dried, and then the filament is cut according to the application.
  • the cut fiber length is 1 to 120 mm, but is selected according to the application. If a nonwoven fabric is produced by a known nonwoven fabric production method such as air-through, needle punching, or hydro-entanglement, after producing a fiber web with a carding machine, the filament is cut into fiber lengths of 20 to 100 mm, preferably 30 to 90 mm, and more preferably 40 to 80 mm.
  • a nonwoven fabric is produced by a fiber web production method by air spreading, i.e., a so-called air-laid method
  • the filament is cut into fiber lengths of 1 to 40 mm, preferably 1 to 30 mm, and more preferably 3 to 25 mm.
  • the filament is cut into fiber lengths of 1 to 20 mm, preferably 1 to 10 mm, and more preferably 3 to 8 mm. It is also possible with the crimped conjugate fiber of the present invention that, depending on the application, the filament after an annealing treatment is not cut and used as it is.
  • the fineness of the crimped conjugate fiber of the present invention i.e., the actualized crimping conjugate fiber or the latently crimpable conjugate fiber of the present invention, is not particularly limited.
  • the crimped conjugate fiber is processed so as to have a fineness suitable for applications, for example, various nonwoven fabric applications such as hard stuffing that serves as a material substituted for urethane foam, mattresses for bedding, vehicle seats and various chairs, cushioning materials for clothing such as a shoulder pad and a brassiere pad, sanitary materials, packaging materials, wet wipes, filters, sponge-like porous wiping materials, sheet-like wiping materials; applications as wadding for various kinds of bedding such as blankets and mattresses and clothing articles that make use of the elasticity and the shape recovery properties of the conjugate fiber itself and like applications, but a fineness of 1 to 60 dtex is preferable because elasticity as well as bulk recovery properties and texture when processed into a nonwoven fabric are excellent.
  • a more preferable fineness range is 2 to 50 d
  • the fiber assembly of the present invention contains at least 30 mass% of the crimped conjugate fiber.
  • the crimped conjugate fiber is contained in a proportion of 30 mass% or greater, the elasticity, the bulk recovery properties, and like properties of the fiber assembly can be maintained at a high level.
  • the fiber assembly include knitted fabrics, woven fabrics, nonwoven fabrics, fillings, pads, fiber webs, and the like. It is preferable that the fiber assembly contains 30 to 100 mass% of the crimped conjugate fiber and 0 to 70 mass% of fibers other than the crimped conjugate fiber.
  • Such fibers other than the crimped conjugate fiber contained in the fiber assembly are not particularly limited insofar as the performance of the crimped conjugate fiber is not impaired, including, for example, at least one fiber selected from synthetic fibers, chemical fibers, natural fibers, and inorganic fibers.
  • the method for producing a fiber assembly containing the crimped conjugate fiber of the present invention is not particularly limited. After forming a fiber web by a known method, the fiber web can be processed into a nonwoven fabric by a known nonwoven fabric production method such as air-through, needle punching, or hydro-entanglement. In addition, it is also possible that the crimped conjugate fiber is processed into a fiber ball, and the fiber ball is blown into a frame mold and subjected to a thermal treatment to give a fiber assembly having a specific shape as disclosed in JP 2001-207360A and JP2002-242061A . A production method is preferable in which a fiber web is formed and then processed into a nonwoven fabric.
  • Examples of forms of the fiber web constituting the nonwoven fabric of the present invention include a parallel web, a semi-random web, a random web, a cross-laid web, a criss-cross web, an air-laid web, and the like.
  • the fiber web demonstrates a greater effect when the first component is bonded due to a thermal treatment. If necessary, the fiber web may be subjected to needle punching or hydro-entanglement before thermal processing.
  • the means of thermal processing is not particularly limited insofar as the function of the crimped conjugate fiber of the present invention is sufficiently demonstrated, and it is preferable to use a heating machine that does not impose much pressure such as wind pressure, for example, a heating machine that lets hot air through, a heating machine that vertically blows hot air, an infra-red heating machine, and the like.
  • Fibers that can be blended with a fiber web that uses the crimped conjugate fiber of the present invention are not particularly limited insofar as the performance of the crimped conjugate fiber of the present invention is not impaired.
  • polyesters such as polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, polylactate, and polybutylene succinate
  • single fibers of polyethylenes such as low density polyethylene, high density polyethylene, and linear low density polyethylene
  • single fibers of polyolefins such as polymers in which monomers of such polyolefins are copolymerized, or polyolefins for which metallocene catalysts (also referred to as Kaminsky catalysts) are used when polymerizing such polyolefins
  • single fibers ofpolyamides such as Nylon 6, Nylon 66, Nylon 11, and Nylon 12
  • single fibers of (poly)acryls composed of acrylonitrile and single fibers
  • the term "single fiber” refers to a fiber composed solely of one polymer component.
  • a conjugate fiber containing at least one or more polymer components can also be used insofar as the performance of the crimped conjugate fiber of the present invention is not impaired.
  • Examples of such a conjugate fiber include conjugate fibers in which different types of resins among polyesters, polyolefins, polyamides and engineering plastics, or resins composed of different polymer components of the same type (for example, polyethylene terephthalate and polytrimethylene terephthalate) are mutually combined.
  • the conjugate fiber the combined state is not particularly limited.
  • core-in-sheath conjugate fibers In terms of the cross-sectional shape of the fiber, core-in-sheath conjugate fibers, eccentric core-in-sheath conjugate fibers, parallel conjugate fibers, sectional conjugate fibers in which resin components having a shape of citrus fruit clusters are disposed alternately, and sea-island conjugate fibers may be used.
  • the second component is a polyolefin-based polymer
  • most of the polymer components constituting the crimped conjugate fiber are polyolefin-based polymers, and thus use of a single fiber composed of a polyolefin-based polymer, or use of a conjugate fiber in which polyolefin-based polymers are mutually combined, as a blend fiber is preferable from the viewpoint of recycling efficiency of the fiber assembly.
  • the crimped conjugate fiber of the present invention has excellent thermal bonding properties
  • the crimped conjugate fiber exhibits thermal bonding properties for not only synthetic fibers having the thermoplastic resins as the components, but also natural fibers including cellulose-based fibers, semi-synthetic fibers (also referred to as regenerated fibers) such as viscose rayon, Tencel (registered trademark), Lyocel (registered trademark), and cuprammonium rayon, inorganic fibers such as glass fibers, and carbon fibers.
  • natural fibers include vegetable-based natural fibers and animal-based natural fibers.
  • Examples of vegetable-based natural fibers include fibers of ramie (China grass), linen (flax), kenaf, abaca (Manila hemp), henequen (sisal hemp), jute, hemp (cannabis), coconut, palm, paper mulberry, paper bush, bagasse, and the like.
  • Examples of animal-based natural fibers include fibers of silk, sheep wool, angora, cashmere, mohair, and the like.
  • a vegetable-based natural fiber and an animal-based natural fiber can both be used, but a vegetable-based natural fiber is preferable since the cost of cultivation is inexpensive.
  • a fiber web containing the crimped conjugate fiber of the present invention can be processed into a bulky fiber assembly by performing thermal processing on the fiber web in a monolayer state, but a fiber assembly having superior sulkiness can be readily obtained by forming a laminate web in which fiber webs are stacked before performing thermal processing, or a laminate of fiber assemblies by stacking fiber assemblies after thermal processing. It is preferable that in the fiber assembly, fibers constituting the fiber assembly are arranged parallelly in the thickness direction of the fiber assembly, or in other words, fibers are arranged in the longitudinal direction of the fiber assembly. This is because fibers constituting the fiber assembly arranged parallelly in the thickness direction afford good bulk recovery properties and cushioning properties against pressure applied in the thickness direction.
  • the phrase “fibers constituting the fiber assembly are arranged parallelly in the thickness direction of the fiber assembly (arranged in the longitudinal direction of the fiber assembly)” means that the sharp angle formed by the fibers constituting the fiber assembly and the thickness direction of the fiber assembly is 45° or less, or in other words, when the fiber assembly is cut in the thickness direction and the cut surface is viewed with an optical microscope or a scanning electron microscope for enlargement, the sharp angle formed by the fibers constituting the fiber assembly and the thickness direction of the fiber assembly is 45° or less. It is more preferable that 80% or greater of the total number of the entire fibers constituting the fiber assembly viewed on a specific area of the cut surface are arranged in the longitudinal direction of the fiber assembly.
  • the fiber assembly described above in which fibers constituting the fiber assembly are arranged parallelly in the thickness direction can be produced by a known production method, and examples include so-called Strute nonwoven fabrics produced by shaping a fiber web into a wave form and subjecting it to thermal bonding while compressing it in the length direction, but the fiber assembly is not limited thereto.
  • the temperature of thermal processing on the fiber web is set so as to be within a range in which the developed wavy crimps and/or spiral crimps of the crimped conjugate fiber do not disappear during thermal processing.
  • the thermal processing temperature is Tm -10 (°C) to lower than the melting peak temperature of the second component, preferably Tm -10 (°C) to Tm + 80 (°C), particularly preferably Tm (°C) to Tm + 50 (°C), and most preferably 130 to 160°C.
  • At least one resin component contained in the first component of the actualized crimping conjugate fiber melts, and pieces of the constituent fiber are thermally fused to each other.
  • the temperature is set so as to be within a range in which crimps are developed.
  • the melting peak temperature of polybutene-1 is Tm
  • the temperature is set so as to be within a range of Tm -10 (°C) to lower than the melting point of the second component, preferably Tm -10 (°C) to Tm + 60 (°C), particularly preferably Tm (°C) to Tm + 50 (°C), and most preferably 130 to 160°C.
  • At least one resin component contained in the first component of the latently crimpable conjugate fiber melts, and pieces of the constituent fiber are thermally fused to each other.
  • the nonwoven fabric has a residual compression set rate measured according to JIS-K-6400-4 A of 45% or less, and more preferably 35% or less.
  • the residual compression set rate shows the extent of change of the hardness of the nonwoven fabric when heated to 70°C. The smaller the value, the more the deterioration of the fiber or the nonwoven fabric by heat is suppressed, thus indicating excellent bulk recovery properties.
  • the nonwoven fabric has a residual repetitive compression set rate measured according to JIS-K-6400-4 B of 15% or less, and more preferably 12% or less.
  • the residual repetitive compression set rate shows the extent of change of the hardness of the nonwoven fabric when 50% compression is repeated 80000 times. The smaller the value, the more the deterioration of the fiber or the nonwoven fabric caused by compression is suppressed, thus indicating excellent bulk recovery properties.
  • the fiber product of the present invention at least partially contains the fiber assembly, and is formed into hard stuffing, bedding, vehicle seats, chairs, shoulder pads, brassiere pads, garments, sanitary materials, packaging materials, wet wipes, filters, sponge-like porous wiping materials, sheet-like wiping materials, and wadding.
  • CFC T-100 Cross-fractionation apparatus "CFC T-100” (hereinafter referred to as CFC) manufactured by DIA Instruments Co., Ltd.
  • a fixed wavelength infrared spectrophotometer attached as a detector of the CFC was removed and replaced by the FT-IR spectrometer, and the FT IR spectrometer was used as a detector.
  • the transfer line from the outlet for a solution eluted from the CFC to the FT-IR spectrometer was 1 m, and the temperature was maintained at 140°C during measurement.
  • the flow cell attached to the FT-IR spectrometer had an optical path length of 1 mm and an optical path diameter of 5 mm ⁇ , and the temperature was maintained at 140°C during measurement.
  • the molecular weight distribution was determined using the absorbance at 2945 cm -1 obtained by the FT-IR spectrometer as a chromatogram.
  • the retention volume was converted to the molecular weight using a standard curve prepared in advance with standard polystyrenes.
  • the standard polystyrenes used were "F380", “F288", “F128”, “F80”, “F40”, “F20”, “F10”, “F4", “F1”, “A5000”, “A2500”, and “A1000", all manufactured by Tosoh Corporation.
  • a calibration curve was created by injecting 0.4 ml of a solution in which 0.5 mg/ml of a standard polystyrene was dissolved in ODCB (containing 0.5 mg/ml of BHT).
  • the calibration curve employed a cubic equation obtained by approximation using the least-squares method.
  • the conversion to the molecular weight employed a universal calibration curve in reference to Sadao Mori, "Size Exclusion Chromatography” (Kyoritsu Shuppan).
  • measurements were performed according to gel permeation chromatography (GPC), but measurements may be performed using another model.
  • GPC gel permeation chromatography
  • measurements are performed simultaneously with "MG03B” manufactured by Japan Polypropylene Corporation as described in the 2005 Catalogue for Commercial Transaction of Plastic Molding Materials (Chemical Daily Co., Ltd., published on Aug. 30, 2004 ), the value when the MG03B shows 3.5 is used as a blank condition, and the conditions are adjusted to perform the measurements.
  • the stretchability of a crimped conjugate fiber was evaluated based on the conditions of occurrence of a thread break in a stretching step and the passability through a stuffer-box crimper used for importing crimps using the following criteria:
  • the staple fiber spreadability of a crimped conjugate fiber was evaluated based on the card processability (cardability, conditions of nep generation, and texture of resulting web) when collecting a web by subjecting 100 mass% of a crimped conjugate fiber to a parallel card using the following criteria:
  • a tow after completion of a drying step (annealing and drying step at 100°C for 15 minutes) was visually inspected, and the staple fiber crimp formability of actualized crimping conjugate fibers was evaluated using the following criteria:
  • a tow after completion of a drying step (annealing and drying step at 100°C for 15 minutes) was visually inspected, and the staple fiber crimp formability of latently crimpable conjugate fibers was evaluated using the following criteria:
  • Each crimped conjugate fiber (100 mass%) was subjected to a parallel card to collect a web, and the web was treated at a processing temperature of 150°C for 30 seconds with a convection heating machine and then visually inspected in order to evaluate the crimp formability after thermal processing of an actualized crimping conjugate fiber using the following criteria:
  • a crimped conjugate fiber (100 mass%) was subjected to a parallel card to collect a web, and the web was treated at a processing temperature of 150°C for 30 seconds with a convection heating machine and then visually inspected in order to evaluate the crimp formability after thermal processing of a latently crimpable conjugate fiber using the following criteria:
  • a sample in an amount of 3.2 mg was heated at a heating rate of 10°C/min from ordinary temperature to 200°C (provided that the temperature was increased to 300°C in the case where a polyester-based polymer was used as the second component), and then cooled at a cooling rate of 10°C/min to 40°C. From the resulting heat of fusion curve, the melting point Tf1 of the first component after spinning and the melting point Tf2 of the second component after spinning were obtained.
  • the peak on the lower temperature side was regarded as the melting point (Tf1) of the first component
  • the peak on the higher temperature side was regarded as the melting point (Tf2) of the second component.
  • the last peak i.e., the peak on the higher temperature side
  • the other peaks were regarded as the melting points (Tf1) after spinning of the respective polymers constituting the first component.
  • the set rate after compression at a temperature of 70°C ⁇ 1°C at a compression rate of 50% for 22 hours was measured according to JIS-K-6400-4 A and was regarded as a residual compression set rate. All the thickness measurement was carried out while no load was applied to the test pieces in the thickness direction, and a metal bench rule as specified in JIS-B-7516 was used for measurement.
  • the set rate after compression 80000 times at a temperature of 23°C at a compression rate of 50% was measured according to JIS-K-6400-4 B and was regarded as a residual repetitive compression set rate. All the thickness measurement was carried out while no load was applied to the test pieces in the thickness direction, and a metal bench rule as specified in JIS-B-7516 was used for measurement.
  • the IV value refers to the above-described limiting viscosity
  • MFR230 refers to a melt flow rate measured at 230°C under 21.18N (2.16kgf) in accordance with JIS-K-7210
  • MFR190 refers to a melt flow rate measured at 190°C under 21.18N (2.16kgf) in accordance with JIS-K-7210.
  • a crimped conjugate fiber (100 mass%) was subjected to a parallel card to collect a web, and the web was treated at a processing temperature of 150°C for 30 seconds with a convection heating machine, thus giving a nonwoven fabric having a unit weight of 500 g/m 2 .
  • a nonwoven fabric was prepared under the above-described nonwoven fabric production conditions using the resulting crimped conjugate fiber.
  • a crimped conjugate fiber and a nonwoven fabric were prepared in the same manner as in Example 1 except that only PET was used as the second component.
  • Tables 1 to 4 below show the results of the eccentricity, spinnability during melt spinning, staple fiber spreadability, staple fiber crimp formability, and crimp formability after thermal processing of the resulting crimped conjugate fibers as well as the initial thickness, unit weight, residual repetitive compression set, and residual compression set of the nonwoven fabrics of Examples 1 to 18 and Comparative Examples 1 to 7.
  • the crimped conjugate fibers of Examples 1 to 4, 6 to 9, and 11 to 18 were actualized crimping conjugate fibers, have wavy crimps as shown in Fig. 2A or spiral crimps, or have both wavy crimps and spiral crimps, and the number of crimps was 12 to 18 per 25 mm.
  • the crimped conjugate fibers of Examples 5 and 10 were latently crimpable conjugate fibers in which three-dimensional crimps have been developed due to thermal processing performed when preparing a nonwoven fabric, have at least one of the wavy crimps as shown in Fig. 2A and the spiral crimps.
  • Second component (Core resin) Resin 1 PP-A PP-A PP-A PP-A PP-A PP-A Resin 2 - PPR-1 PPR-1 PPR-1 PPR-1 PPR-1 Resin 1:Resin2 100:0 85:15 85:15 85:15 85:15 85:15 Melting point (Tf2) after spinning (°C) 163.5 - - - - 162.9 First component (Sheath resin) Resin 1 PB-1 PB-1 PB-1 PB-1 PB-1 PB-1 PB-1 Resin 2 LLDPE-A LLDPE-A LLDPE-A LLDPE-A LLDPE-A LLDPE-A LLDPE-B Resin 3 - - - - - - Resin 1:Resin2:Resin 3 92:8 97:3 95:5 92:8 80:20 92:8 Melting point (Tf1) after spinning (°C) 123.2 - -
  • Second component (Core resin) Resin 1 PP-A PP-A PP-A PP-A PET PET Resin 2 PPR-1 PPR-1 PPR-1 PPR-1 PPR-1 - - Resin 1:Resin2 85:15 85:15 99:1 85:15 85:15 100:0 100:0 Melting point (Tf2) after spinning (°C) - - - - - 250.4 - First component (Sheath resin) Resin 1 PB-1 PB-1 PB-1 PB-1 PB-1 PB-1 PB-1 PB-1 Resin 2 - LLDPE-A LDPE EMAA BP PP-A EMAA Resin 3 - - - - - EMAA - Resin 1:Resin2:Resin 3 100:0 70:30 90:10 94:6 85:15 85:10:
  • the conjugate fiber to which low density polyethylene (LDPE) was added to the first component did not have good staple fiber spreadability, thus confirming that addition of linear low density polyethylene as a polymer to be added to the first component containing polybutene-1 as the main ingredient enables crimped conjugate fibers having not only good spinnability and stretchability but also good staple fiber crimp formability, and crimp formability after thermal processing, i.e., all such properties were good, to be obtained.
  • LDPE low density polyethylene
  • the second component that constitutes the inner portion of the conjugate fiber is not particularly limited, and it appears that the second component, while not being limited to a polyester-based polymer or a polyolefin-based polymer, is usable insofar as it is a polymer having a melting peak temperature at least 20°C higher than the melting peak temperature of polybutene-1 or a polymer having a melting initiation temperature of 120°C or higher and having excellent bending strength and bending plasticity.
  • conjugate fibers in which linear low density polyethylene was added in a proportion of 20 mass% relative to the first component had good spinnability
  • conjugate fibers to which linear low density polyethylene was added in a proportion of 30 mass% to the first component had very poor spinnability. Therefore, it can be presumed from a comparison of Example 5 and Comparative Example 2 that there is an upper limit to the amount of linear low density polyethylene added, and the upper limit to the amount is less than 30 mass%, and preferably 25 mass% or less.
  • the crimped conjugate fibers of Examples 1 to 18 the crimp formability of the resulting crimped conjugate fibers and the resistance to residual repetitive compression set and the resistance to residual compression set of nonwoven fabrics that used the crimped conjugate fibers were enhanced.
  • the crimped conjugate fibers of Examples 2 to 4, 7 to 9, 11, 12 and 14 and nonwoven fabrics that used the crimped conjugate fibers had a rate of residual repetitive compression set of 11.5% or less and a rate of residual compression set of 31.5% or less, which were significantly more improved than those of the nonwoven fabric of Comparative Example 1.
  • Examples 2 to 4, 7 to 9, 11, 12, and 14 show that the residual repetitive compression set and the residual compression set of nonwoven fabrics that used the crimped conjugate fibers of Examples 6 and 13 in which linear low density polyethylenes having a relatively high density and a high flexural modulus were used were increased, and therefore it is presumed that it is preferable for the crimped conjugate fiber of the present invention that linear low density polyethylene to be added to the first component is linear low density polyethylene having a lower density and a lower flexural modulus insofar as thermal bonding properties and heat resistance are not affected.
  • Afiber assembly that uses the crimped conjugate fiber of the present invention has both excellent initial bulk and bulk recovery properties and is preferably used in applications such as cushioning materials and like hard stuffing, sanitary materials, packaging materials, materials for cosmetic products, low-density non-woven fabric products such as women's brassiere pads and shoulder pads, wiping materials for people and non-human objects for which urethane foam and urethane sponge have generally been used, powdery or liquid cosmetic coating materials, heat insulating materials, and sound absorbing materials.
  • the crimped conjugate fiber of the present invention has excellent elasticity and shape recoverability, and is therefore preferably used as wadding for various kinds of bedding such as blankets and mattresses and clothing articles.
  • the resin components constituting the conjugate fiber are composed of polyolefin-based polymers, and therefore after being used as the hard stuffing, wadding, and low-density nonwoven fabric products, it is easy to collect the crimped conjugate fiber as a component composed of polyolefin-based polymers, reuse it as a resin material, or reuse it as a polyolefin-based fiber, and preferably is used as various fiber assembly products for which separate collection after use and reuse of components are desired.

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  • Nonwoven Fabrics (AREA)
  • Multicomponent Fibers (AREA)
EP10799933A 2009-07-17 2010-07-16 Fibre composite crêpée, masse fibreuse et produit textile utilisant celle-ci Withdrawn EP2455516A4 (fr)

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JP2009168773 2009-07-17
PCT/JP2010/062103 WO2011007875A1 (fr) 2009-07-17 2010-07-16 Fibre composite crêpée, masse fibreuse et produit textile utilisant celle-ci

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EP2455516A4 EP2455516A4 (fr) 2013-03-27

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JP (1) JP5436558B2 (fr)
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EP3434142B1 (fr) * 2016-03-23 2024-01-17 Inoac Corporation Corps de support de produit cosmétique et contenant pour produit cosmétique le contenant

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WO2016002940A1 (fr) 2014-07-04 2016-01-07 パネフリ工業株式会社 Assemblage de fibres sous forme de réseau tridimensionnel
JP2017536882A (ja) 2014-11-06 2017-12-14 ザ プロクター アンド ギャンブル カンパニー ゾーン状パターン化有孔ウェブ、積層体、及びその作製方法
WO2016073724A1 (fr) 2014-11-06 2016-05-12 The Procter & Gamble Company Bandes/stratifiés de non-tissé filé-lié à fibres frisées
EP3247826B1 (fr) * 2015-01-21 2019-05-01 PrimaLoft, Inc. Nappe ouatée résistant à la migration dotée d'une extensibilité et procédés de fabrication et articles comprenant celle-ci
JP2016141926A (ja) * 2015-02-02 2016-08-08 新光合成繊維股▲ふん▼有限公司 高捲縮性を有する双成分複合繊維、複合ヤーン、及び織物
JP6473362B2 (ja) * 2015-03-27 2019-02-20 ダイワボウホールディングス株式会社 複合繊維、不織布および吸収性物品用シート
JP6788367B2 (ja) * 2015-03-30 2020-11-25 ダイワボウホールディングス株式会社 複合繊維および中綿
CN105648654A (zh) * 2015-12-29 2016-06-08 江苏苏博特新材料股份有限公司 聚氧亚甲基纤维针刺非织造土工布及其制备方法
WO2017130541A1 (fr) * 2016-01-25 2017-08-03 株式会社デンソー Dispositif d'élément chauffant
TW201739603A (zh) * 2016-01-27 2017-11-16 歐拓管理股份公司 用於汽車引擎室的吸音襯及具有其之吸音飾板部件
WO2017164248A1 (fr) * 2016-03-23 2017-09-28 株式会社イノアックコーポレーション Corps de support de produit cosmétique et contenant pour produit cosmétique le contenant
JP6587568B2 (ja) * 2016-03-28 2019-10-09 ダイワボウホールディングス株式会社 潜在捲縮性複合繊維とその製造方法、および繊維集合物、ならびに不織布
JP6776018B2 (ja) * 2016-06-24 2020-10-28 ダイワボウホールディングス株式会社 粒状綿成形体及びその製造方法
US20180229216A1 (en) 2017-02-16 2018-08-16 The Procter & Gamble Company Absorbent articles with substrates having repeating patterns of apertures comprising a plurality of repeat units
AR117108A1 (es) * 2018-11-20 2021-07-14 Dow Global Technologies Llc Fibras multicomponentes onduladas
AR117125A1 (es) * 2018-11-20 2021-07-14 Dow Global Technologies Llc Método de fabricación de fibras rizadas y bandas no tejidas que tienen tales fibras
JP6611969B2 (ja) * 2019-01-25 2019-11-27 ダイワボウホールディングス株式会社 複合繊維、不織布および吸収性物品用シート
KR20200123570A (ko) * 2019-04-22 2020-10-30 현대자동차주식회사 고탄성 및 고강성을 갖는 자동차용 언더커버 및 그 제조방법
JPWO2022044892A1 (fr) * 2020-08-27 2022-03-03
WO2023114355A1 (fr) * 2021-12-17 2023-06-22 Kimberly-Clark Worldwide, Inc. Bandes non tissées fabriquées à partir de filaments multicomposants et procédé de formation de bandes non tissées

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ITUB20155124A1 (it) * 2015-10-21 2017-04-21 Imbotex Srl Imbottitura termica particolarmente per indumenti tecnici per attivita' outdoor
EP3434142B1 (fr) * 2016-03-23 2024-01-17 Inoac Corporation Corps de support de produit cosmétique et contenant pour produit cosmétique le contenant

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JPWO2011007875A1 (ja) 2012-12-27
EP2455516A4 (fr) 2013-03-27
US20120121882A1 (en) 2012-05-17
CN102471945B (zh) 2013-12-18
JP5436558B2 (ja) 2014-03-05
CN102471945A (zh) 2012-05-23
WO2011007875A1 (fr) 2011-01-20

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