JP4571504B2 - 改善された繊維不織ウェブ - Google Patents
改善された繊維不織ウェブ Download PDFInfo
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- JP4571504B2 JP4571504B2 JP2004553428A JP2004553428A JP4571504B2 JP 4571504 B2 JP4571504 B2 JP 4571504B2 JP 2004553428 A JP2004553428 A JP 2004553428A JP 2004553428 A JP2004553428 A JP 2004553428A JP 4571504 B2 JP4571504 B2 JP 4571504B2
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/68—Melt-blown nonwoven fabric
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/681—Spun-bonded nonwoven fabric
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/69—Autogenously bonded nonwoven fabric
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/69—Autogenously bonded nonwoven fabric
- Y10T442/692—Containing at least two chemically different strand or fiber materials
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Nonwoven Fabrics (AREA)
- Artificial Filaments (AREA)
Description
本発明のウェブを構成する繊維の平均幾何繊維直径は、ウェブ試験片のSEM顕微鏡写真の画像解析によって測定した(「幾何直径」は本明細書では、例えば、「有効繊維直径」を与えるもののような間接測定値とは対照的に、繊維の物理的寸法の直接観察によって得られた測定値を意味する)。繊維の小さな塊を試験中のウェブから分離し、電子顕微鏡スタブに取り付けた。次に繊維を、おおよそ100オングストロームの金/パラジウムでスパッターコートした。スパッターコーティングは、デントン・真空デスクII(DENTON Vacuum Desk II)コールドスパッター装置(デントン・バクウム、LLC、米国、08057、ニュージャージー州、モーレスタウン、1259ノース・チャーチ・ストリート(DENTON Vacuum,LLC,1259 North Church Street,Moorestown,NJ,08057,USA))を用いて100ミリトルのチャンバ圧で30ミリアンペアの電流を有するアルゴンプラズマで行った。これらの条件下での2回の30秒蒸着を用いた。コートした試料を、次にJEOLモデル840走査型電子顕微鏡(JEOL米国、米国、01960、マサチューセッツ州、ピアボディ、11ディアボーン・ロード(11 Dearborn Road,Peabody,MA,01960,USA))中へ挿入し、10KeVのビームエネルギー、おおよそ48mmの作動距離、および0°試料チルトを用いて画像形成した。750倍倍率で撮られた電子画像を用いて繊維直径を測定した。各試料の表面図の電子画像を、パソコン・ランニング・サイオン・イメージ、リリース・ベータ3b(Scion Image,Release Beta 3b)(サイオン・コーポレーション、米国、21703、メリーランド州、フレデリック、スイート・エッチ、82ウォ−マンズ・ミル・コート(Scion Corporation,82 Worman’s Mill Court,Suite H,Frederick,MD,21703,USA))を用いて解析した。画像解析を行うために、先ずサイオン・イメージを画像上のスケールバーを用いて顕微鏡倍率に較正した。次に個々の繊維をそれらの幅を横切って測定した。各画像から個々の繊維(合体していないまたはローピングなしの繊維)だけを測定した。各試料について少なくとも100の繊維を測定した。次にサイオン・イメージからの測定値を統計的解析のためにマイクロソフト・エクセル97(Microsoft Excel 97)(マイクロソフト・コーポレーション、米国、98052、ワシントン州、レッドモンド、ワン・マイクロソフト・ウェイ(Microsoft Corporation,One Microsoft Way,Redmond,WA,98052,USA))中へ取り込んだ。繊維サイズは、所与の番手番号についてマイクロメートル単位の平均直径として報告する。
ウェブ・ソリディティは、ウェブ試験片の嵩密度を、ウェブを構成している材料の密度で割ることによって求めた。ウェブ試験片の嵩密度は、先ずウェブの10cm×10cm部分の重量および厚さを測定することによって求めた。試験片の厚さは、各試料の面上へ0.002ポンド/インチ2(13.8N/m2)を加えるために130.6グラムの質量を用いることで修正した、米国材料試験協会(ASTM)D5736標準試験方法に規定されたように評価した。試料のサイズがASTM D5736で推奨されているサイズ未満のあるものに限定される場合には、プレッシャーフート上の質量を0.002ポンド/インチ2(13.8N/m2)の負荷力を維持するために比例して減らす。先ず試験片を22±5℃でおよび50%±5%相対湿度の雰囲気中で前順化し、結果はセンチメートル単位で報告する。グラム単位の試験片の重量を平方センチメートル単位の試料面積で割ると、g/cm2単位で報告される試験片の基本重量が誘導される。ウェブの嵩密度は、基本重量を試験片の厚さで割ることによって求め、g/cm3として報告する。
式中、
ここで、S−ソリディティ[=]パーセント
ρウェブ−ウェブ嵩密度[=]g/cm3
ρ材料−ウェブを構成する材料の密度[=]g/cm3
ρi−ウェブ成分iの密度[=]g/cm3
χiウェブ中の成分iの重量分率[=]分率
BW−ウェブ基本重量[=]g/cm2
t−ウェブ厚さ[=]cm
ウェブ回復率、すなわち、圧縮後にある程度のその元の厚さを回復するウェブの能力は、圧縮強制を用いて指定ソリディティまでウェブ試料を圧縮し、試料を該ソリディティで指定時間保持し、圧縮強制を解除し、そして指定回復期間後にウェブのソリディティを測定することによって求めた。面積_cm×_cmの試料をウェブの厚さまたはZ軸に沿って圧縮した。圧縮強制は、指定ソリディティと相関する厚さにウェブを圧縮するのに十分な重量の45.7cm×45.7cm平板であった。指定ソリディティに必要とされる厚さよりも大きな圧縮を防止するために板のエッジの下にスペーサーを用いた。指定時間後に圧縮強制を取り除き、回復した試料の厚さを測定した。ソリディティ方法のところで上に記載したように回復した厚さからウェブのソリディティを求めた。ウェブ回復率は、圧縮後に、生じるソリディティまたは相当する充填率ウェブに回復するウェブの能力を表す。多くのウェブ用途のためには、初期のおよび回復したの両方で、ウェブ・ソリディティが低ければ低いほど、かつ、充填率が大きければ大きいほど良い。
耐熱性は、ネッツシェ・インスツルメンツ社、米国、マサチューセッツ州、ボストン(Netzsch Instruments,Inc.,Boston,MA,USA)から入手可能な熱伝導率機器、モデル高速−K(Thermal Conductivity Instrument,model Rapid−K)を用いてASTM C518標準試験方法に規定されているように評価した。厚さは、「ウェブ・ソリディティ(Web Solidity)」という表題のセクションに述べられているようなASTM D5736標準試験方法を用いて評価した。熱伝導係数CTは、W/(m2・K)の単位で報告する。耐熱性は、1Cloが6.457/CTとして報告されるCloとして示す。Kg/m2単位の試料の基本重量(直接形成繊維とステープルファイバーとの組合せ重量)で割ったCloを熱重量効率(TWE)として報告する。
比通気抵抗は、ASTM C522標準試験方法に規定されているように評価した。防音材の比通気抵抗は、その吸音性および伝音性を決定する特性の1つである。比通気抵抗の値rは、mksレイル(Pa・s/m)として報告する。試料は、5.25インチ直径(13.33cm)円形試料をダイス切断することによって調製した。エッジがダイス切断操作によってわずかに圧縮されている場合、エッジは試験前に元の厚さまたは自然の厚さに戻されなければならない。前順化した試料を、あらかじめ測定した厚さの試験片ホルダーに入れ、100cm2面エリアにわたって圧力差を測定した。
音響材料の吸音は、「チューブ、2つのマイクロホンおよびデジタル周波数解析システムを用いるインピーダンスおよび吸収(Impedance and Absorption Using A Tube,Two Microphones and A Digital Frequency Analysis System)」という表題のASTM呼称E1050−98に記載されている試験方法によって測定した。該方法のセクション8.5.4に記載されているような標準発生吸音係数(Normal Incidence Sound Absorption Coefficient)(NISAC)は、250、500、1000および2000ヘルツ・オクターブバンドからの吸音係数の1/3オクターブバンドの相加平均を用いて計算する。
ウェブの繊維構造(ウェブの大スケール構造またはマクロ構造)の一様性または連続性は、画像解析を用いて特徴づけた。説明の目的のために、試料の主x−y−z軸を次の通り指定した:ウェブの流れ方向、すなわち縦方向を「y軸」にあると指定し、ウェブのクロス流れすなわち幅を「x軸」にあると指定し、ウェブの厚さを「z軸」にあると指定した。画像解析用のウェブ試験片は、先ずy軸すなわちウェブの流れ方向に沿って5.1cm幅(x軸)試料をおおよそ19.0センチメートル切断することによって調製した。ウェブは、切断エッジのいかなる融解または***着も防ぐようなやり方で、細いかみそり刃のように鋭い刃を用いて切断した。次に解析用の試験片を、おおよそ16.5センチメートルの長さ(y軸)に試料から切断した。
本発明のウェブを、図1に一般に示すような装置を用いてブローン微細繊維とステープルファイバーとのブレンドから製造した。デュアル−コレクター装置の最上収集面25は、一様に間隔を置いて配置された直径4.7mmの穴より構成された53.7%の孔開口面積を持った直径20.3cmの有孔金属ドラムであった。底収集面26は、ファーネス・ベルト・カンパニー・リミティッド、米国、14216、ニューヨーク州、バッファロー、2316デラウェア・アベニュー(Furnace Belt Company Limited,2316 Delaware Avenue,Buffalo,N.Y.,14216,USA)から入手可能な、直径20.3cm有孔ドラムをカバーするクロスロッド・コネクター部品番号B−72−76−13−16によって一緒に接合された一連の交互の単一左方向および右方向螺旋よりなるバランスした織り構造を有する織り金属ベルトであった。ベルトは、81.3cm離して配置された2つの20.3cm直径ローラー上に支持された。両収集面の後ろに置かれた真空源は、収集面中の空隙を通して合計48m3/分の空気を吸引中であった。60度プレナムは、約10度の真空の収集面が集められた繊維でカバーされて、収集面の直ぐ後ろに配置された0.12m2の面積を有する。両収集面の表面速度は、両前面が繊維流れに向かっておよび通過ギャップへ向きを変えて、140cm/分であった。
比較例1を、ファーネス・ベルト・カンパニー社、米国、14216、ニューヨーク州、バッファロー、2316デラウェア・アベニューから入手可能な、単一の通常の平ベルト・コレクター部品番号B−72−76−13−16上にウェブを集めたことを除いて実施例1のように製造した。平らな垂直コレクター表面は、集められた繊維が全プレナム表面積をカバーして、0.278m2のプレナム表面積を通る真空引き抜き24m3/分空気を有した。ダイ面からコレクター表面までの距離は63.5cmであった。組合せウェブの総基本重量は205g/m2であった。
実施例2を、ステープルファイバー組成物がウェブの総重量の28重量%であることを除いて実施例1のように製造した。総ウェブ基本重量は957g/m2であり、厚さは19.6cmであった。コレクターギャップを14.0cmに設定し、収集速度を指定の基本重量を集めるべく調節した。ウェブ試料を実施例1に記載したように評価した。結果を表1に示す。
比較例2を、ウェブを製造するのに何のステープルファイバーも使用せず、それが100%ポリプロピレンブローン微細繊維の完成ウェブをもたらしたことを除いて実施例1のように製造した。コレクター間のギャップを1.9cmに設定し、コレクター速度を45.7cm/分に設定して、ダイ−コレクター距離が25.4cmであるように装置を調整した。ウェブの基本重量は、20.7cmの厚さで410g/m2であった。ウェブ試料を実施例1に記載したように評価した。結果を表1に示す。
本発明のウェブを、図5に例示するような装置を用いて、溶融紡糸繊維とステープルファイバーとのブレンドから製造した。図5について言及すると、PETポリマーをホッパー41に装入し、一軸スクリュー押出機42に供給した。押出機は、搬送し、溶融し、そして275℃の溶融ポリマーを計量供給ポンプ43に配送した。計量供給ポンプは4.55kg/時の速度でポリマーをダイ40に供給した。ダイ40は長さ(図面のページに垂直の寸法)20.32cm、幅7.62cmであり、275℃の温度に維持した。ダイは、その長さに沿って中心上に5.1mmの間隔を置いて配置された、列当たり21オリフィスの4列の押出オリフィスを有した。オリフィスの列はダイの底面に配置され、各オリフィスは直径0.89mmであり、3.57対1の長さ対直径比を有した。ダイは、オリフィスからの押出物がダイからアテニュエーター46に垂直に落ちるような方向に置いた。アテニュエーターは、ダイ面からアテニュエーター・シュートの入口まで測定した時にダイの下方48.1cmに配置した。12.7cm幅のアテニュエーターを垂直から反時計回りに5°傾け、すなわち、アテニュエーターの縦軸56を装置86の方へ傾けた。アテニュエーターのエアナイフ62は0.76mmのギャップ厚さ60を有し、エアナイフに24℃空気を5.78m3/分の速度で供給した。アテニュエーター・シュート65の長さは15.24cmであり、対向壁板を3.40mmのギャップで平行に維持した。ステープルファイバー流れ85との組合せの前にコレクターの方へ溶融紡糸流れを導くのを助けるために、流れディレクター82をシュートの出口でプレートのベース上にコレクター83へ向けて配置した。
実施例4を、実施例1で使用したもののような非接合性ステープルファイバーを使用したことを除いて実施例3のように製造した。ステープルファイバー成分の重量は、総ウェブ重量のおおよそ44重量%であった。組合せウェブの総基本重量は339g/m2であった。ウェブ試料を実施例1に記載したように評価した。結果を表1に示す。
本発明の繊維ウェブを、メルトブローダイが二成分微細繊維を製造するために改造され、2つの押出機が二成分メルトブローン微細繊維を製造するためにダイに供給したことを除いて図面の図1に示すような装置を用いて製造した。一押出機はポリプロピレンを4.8kg/時で押し出し(エクソン社(Exxon Corp.)から入手可能なエスコレン(Escorene)3505G)、他の押出機はポリエチレンテレフタレートグリコール(PETG)を1.6kg/時で押し出した。PETGはメルトブローン繊維の鞘を形成し、ポリプロピレンは芯を形成する。ダイは、0.38mm直径オリフィスの50.8cm幅列と、0.762mmに設定された66.0cm幅エアナイフ・スロットとを有した。コサから入手可能なステープルポリエステルファイバー6デニール、3.8cm、タイプ295を、図1に描写したようなリッカイン装置によって繊維流れ中へ導入した。ドラムはそれらの間に3.8cmのギャップを有した。ダイから、繊維がデュアルドラム表面上に集まるデュアルドラム・コレクターの表面までの距離は96.5cmであった。65%二成分微細繊維と35%ステープルファイバーとを含有する、208g/m2の基本重量のウェブを集めた。ウェブ試料を実施例1に記載したように評価した。結果を表1に示す。
Claims (5)
- マクロ空隙なしのおよびa)C形状構造でウェブ内に配置された直接形成繊維と、b)前記直接形成繊維の重量の少なくとも5%の量で前記直接形成繊維の間に分散された少なくとも15%の捲縮を有するステープルファイバーとの集塊を含む、防音材もしくは断熱材用不織繊維ウェブ。
- 前記ウェブ内繊維が繊維交差のポイントで一緒に接合されて耐圧縮性マトリックスを提供する、請求項1に記載のウェブ。
- 前記接合が自己接合である、請求項2に記載のウェブ。
- 前記ステープルファイバーが前記直接形成繊維の重量の少なくとも20%の量で存在する、請求項1に記載のウェブ。
- 騒音源と空間との間に請求項1〜4のいずれか1項に記載の不織繊維ウェブを置くことを含む、前記騒音源からの前記空間の防音方法。
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KR (1) | KR101110895B1 (ja) |
CN (1) | CN100593597C (ja) |
AT (1) | ATE423235T1 (ja) |
AU (1) | AU2003272699A1 (ja) |
BR (1) | BR0315655B1 (ja) |
DE (1) | DE60326265D1 (ja) |
ES (1) | ES2322142T3 (ja) |
MX (1) | MXPA05005174A (ja) |
WO (1) | WO2004046443A1 (ja) |
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US20040097155A1 (en) | 2004-05-20 |
JP2006506551A (ja) | 2006-02-23 |
AU2003272699A1 (en) | 2004-06-15 |
ATE423235T1 (de) | 2009-03-15 |
KR101110895B1 (ko) | 2012-03-13 |
CN1714189A (zh) | 2005-12-28 |
EP1570121B1 (en) | 2009-02-18 |
KR20050075405A (ko) | 2005-07-20 |
ES2322142T3 (es) | 2009-06-17 |
CN100593597C (zh) | 2010-03-10 |
EP1570121A1 (en) | 2005-09-07 |
BR0315655B1 (pt) | 2013-06-04 |
WO2004046443A1 (en) | 2004-06-03 |
BR0315655A (pt) | 2005-08-30 |
DE60326265D1 (de) | 2009-04-02 |
US7476632B2 (en) | 2009-01-13 |
MXPA05005174A (es) | 2005-08-18 |
JP2010203033A (ja) | 2010-09-16 |
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