JP4881544B2 - クリンプを施したフィラメントの高ロフト低密度不織ウェブ及びその製造方法 - Google Patents
クリンプを施したフィラメントの高ロフト低密度不織ウェブ及びその製造方法 Download PDFInfo
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Description
しかしながら、当業界には、良好なウェブ形態、及び絶縁性、パディング性及びその類似の特性を含む他の上述の特性と同時に、速い取り込み速度、低い逆流性及び高い水平分配性能を有する良好な流体制御バランスを示す代替的な高ロフト、低密度布に対する必要性が存在する。
本明細書において使用する用語「不織ウェブ」又は「不織材料」は、個々の繊維、フィラメント又は糸が互いに交錯しているが、編地又はフィブリル化されたフィルムにおける形態のように規則的又は識別可能な形態でではない構造を有するウェブを意味する。不織ウェブ又は不織材料は、例えば、メルトブローイング工程、スパンボンディング工程、及びボンデッドカーデッドウェブ工程のような多くの工程から形成されている。不織ウェブ又は不織材料の坪量は通常、1平方ヤード当たりの材料のオンス数(osy)又は1平方メートル当たりのグラム数(gsm)で表され、繊維の直径は通常、ミクロンで表される(osyからgsmへ換算するにはosyに33.91を乗じることに留意されたい)。
図1は、クリンプ可能な2成分並列のほぼ連続する繊維を製造しかつそれらを拘束されない環境でクリンプさせることにより高ロフト、低密度材料を製造するための本発明の方法及び装置を示す概略図である。
・ワイヤ下排気装置は、それを通して周囲の空気を引き込むことによりウェブを冷却することになり、それが、結合を防止するがロフトの形成に制限を加える。
・ウェブが真空域を出て第2のワイヤへ移送される際に、真空力が除去され、拘束を除去された繊維は、自由にクリンプする。
・機械的に、高度にMD配向された表面層のMD表面層収縮は、表面繊維に座屈を生じさせることができる。
・高度にMD配向された表面のシャーリング及び結合により表面下の繊維のずれが継続することになるために機械的ずれ応力が生じ、それにより層のシングリングを生じさせることによりロフトが生成されることになる。
・機械的座屈のパターンをFDU噴射の固有周波数で生成することができ、加熱された繊維に同一の周波数でロフトを生じさせることになる。
・繊維が真空領域を出て次いで真空装置29の方にやや引き戻されるときに繊維が成形ワイヤ27から解放される際に機械的力が生成される。
・摩擦電気の(摩擦性)静電荷がウェブ上に蓄積され、繊維が互いに反発してウェブ内に更なるロフトを可能にする。
坪量:3インチ(7.6cm)直径の円形のサンプルが切り取られ、はかりを用いて計量される。重量は、グラムで記録される。重量は、サンプルの面積で除算される。5つのサンプルが測定され、平均される。
透過性=[流速×厚さ×粘度/圧力低下][等式1]
ここで、単位は:
透過性:cm2又はダルシー 1ダルシー=9.87×10-9cm2
流速:cm/sec
粘度:パスカル−秒
圧力低下:パスカル
とする。
23 繊維
25 繊維引き出し装置(FDU)
27 移動式成形ワイヤ
29 ワイヤ下排気装置
31 ホットエアナイフ(HAK)
33 ホットエアディフューザ
35 第2のワイヤ
37 不織ウェブ
39 通気結合(TAB)装置
43 巻き取りロール
Claims (30)
- 機械方向のx寸法、機械横方向のy寸法及びロフト方向のz寸法を有する不織ウェブを製造する方法であって、
a)非加熱繊維引き延ばし装置(FDU)内で一群のA/B並列形態のクリンプ可能な連続したスパンボンドの2成分繊維を形成し、該一群の繊維を成形ワイヤ上に堆積する段階と、
b)前記繊維の前記成形ワイヤと対向する側の面の溶融を開始させるべく、前記繊維に第1の加熱を行う段階と、
c)前記第1の加熱後に、結晶化温度以下に前記一群の繊維を冷却して、前記繊維に螺旋状クリンプを生じさせる段階と、
d)前記繊維がz方向にクリンプできるようにしてウェブを形成する段階と、
e)第2の加熱を行ってウェブを固定し整える段階と、
を含む不織ウェブを製造する方法。 - 前記第2の加熱のための温度は華氏450度(232.2℃)より低いものである請求項1に記載の方法。
- 前記第2の加熱を真空を発生させないで行う請求項2に記載の方法。
- 前記一群の繊維は25fpm(0.127m/s)以上の速度で前記第2の加熱のための領域を通って運ばれる請求項2又は3のいずれか1項に記載の方法。
- 前記成形ワイヤの下で真空を発生させて前記繊維が堆積されるようにする段階を更に含む請求項1〜4のいずれか1項に記載の方法。
- 前記第1の加熱後に前記真空を除去するか又は減少させる段階を更に含む請求項5に記載の方法。
- 前記第1の加熱のために熱風の吹き付けを行い、前記段階b)及びc)の間に該熱風の吹き付けを除去するか又は減少させる請求項1〜6のいずれか1項に記載の方法。
- 前記繊維を前記機械方向配向で前記成形ワイヤに当てがう段階を更に含む請求項1〜7のいずれか1項に記載の方法。
- 請求項1の工程により作られた前記不織ウェブを備える防音材。
- 請求項1の工程により作られた前記不織ウェブを含む断熱材。
- 前記ウェブ内に微粒子を更に含む請求項9に記載の防音材。
- 前記ウェブ内に微粒子を更に含む請求項10に記載の断熱材。
- 請求項1〜8のいずれか1項の工程により作られた不織ウェブ。
- 前記ウェブの坪量が0.3osy(10.2g/m2)と25osy(847.8g/m2)の間にある請求項13に記載の不織ウェブ。
- 前記ウェブの密度が0.002g/ccと0.05g/ccの間にある請求項13に記載の不織ウェブ。
- 前記ロフトが0.02インチ(0.05cm)と1.50インチ(3.81cm)の間にある請求項13に記載の不織ウェブ。
- 坪量が0.5osy(17.0g/m2)、ロフトが0.03インチ(0.076cm)から0.3インチ(0.76cm)、密度が0.022g/ccから0.002g/ccである請求項13に記載の不織ウェブ。
- 坪量が3.0osy(101.7g/m2)、ロフトが0.1インチ(0.25cm)から1.5インチ(3.8cm)、密度が0.04g/ccから0.003g/ccである請求項13に記載の不織ウェブ。
- 前記繊維はz方向の座屈を呈する請求項13〜18のいずれか1項に記載の不織ウェブ。
- 前記繊維がポリプロピレン重合体及びポリエチレン重合体を含む請求項13〜18のいずれか1項に記載の不織ウェブ。
- 前記繊維は、ポリエチレンテレフタレート(PET)、ポリプロピレン主鎖全体に3重量%のポリエチレンが分散されているポリエチレン/ポリプロピレンコポリマー(コポリ−PP+3%PE)、ポリ乳酸(PLAu)、ポリトリメチレンテレフタレート(PTT)、ナイロン、及びポリブチレンテレフタレート(PBT)を含む群から選択される重合体を含む請求項13〜18のいずれか1項に記載の不織ウェブ。
- 前記繊維は前記ウェブ内で互いに一体に結合されている請求項13〜18のいずれか1項に記載の不織ウェブ。
- 前記繊維は、ランダムにクリンプされて、不均一なz方向配向及び座屈したz配向域が重なり合うように配置された層を含んだ不均一な繊維配向を有するロフトを備えた材料を生成することにより、前記ウェブのロフトを形成する請求項13〜18のいずれか1項に記載の不織ウェブ。
- 前記繊維は、ランダムにクリンプされて、不均一なz方向配向、及びクリンプした繊維間が不規則に離間した開口部を含む不均一な繊維配向を有するロフトを備えた材料が生成されることにより、前記ウェブのロフトを形成する請求項13〜18のいずれか1項に記載の不織ウェブ。
- 前記不織ウェブは、0.3osy(10.2g/m2)から25osy(847.8g/m2)の秤量を有する請求項1に記載の方法。
- 前記不織ウェブは、0.002g/ccから0.05g/ccの密度を有する請求項1に記載の方法。
- 前記不織ウェブは、0.02インチ(0.05cm)から1.50インチ(3.81cm)のロフトを有する請求項1に記載の方法。
- 前記不織ウェブの繊維は、一定の周波数でz方向の座屈を示す請求項1に記載の方法。
- 前記繊維は、ポリプロピレンとポリエチレンのポリマーを含む請求項1に記載の方法。
- 前記第1の加熱は、ホットエアナイフ又はホットエアディフューザの下方で行われる請求項1に記載の方法。
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US10/037,467 | 2001-12-21 | ||
US10/037,467 US20030118816A1 (en) | 2001-12-21 | 2001-12-21 | High loft low density nonwoven webs of crimped filaments and methods of making same |
PCT/US2002/039560 WO2003056089A1 (en) | 2001-12-21 | 2002-12-10 | High loft low density nonwoven webs of crimped filaments and methods of making same |
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- 2002-12-10 WO PCT/US2002/039560 patent/WO2003056089A1/en active IP Right Grant
- 2002-12-10 AU AU2002351352A patent/AU2002351352B2/en not_active Expired
- 2002-12-10 CN CNB028239652A patent/CN100445452C/zh not_active Expired - Lifetime
- 2002-12-10 MX MXPA04005295A patent/MXPA04005295A/es active IP Right Grant
- 2002-12-10 EP EP02787007A patent/EP1456454B1/en not_active Expired - Lifetime
- 2002-12-10 JP JP2003556596A patent/JP4881544B2/ja not_active Expired - Lifetime
- 2002-12-10 KR KR1020047008561A patent/KR100947397B1/ko active IP Right Grant
- 2002-12-10 CZ CZ2004646A patent/CZ2004646A3/cs unknown
- 2002-12-10 BR BRPI0214790-4A patent/BR0214790B1/pt active IP Right Grant
- 2002-12-18 AR ARP020104975A patent/AR037921A1/es active IP Right Grant
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2003
- 2003-12-31 US US10/749,805 patent/US20040198124A1/en not_active Abandoned
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AU2002351352A1 (en) | 2003-07-15 |
CN100445452C (zh) | 2008-12-24 |
EP1456454A1 (en) | 2004-09-15 |
AR037921A1 (es) | 2004-12-22 |
BR0214790B1 (pt) | 2012-10-02 |
WO2003056089A1 (en) | 2003-07-10 |
KR100947397B1 (ko) | 2010-03-12 |
BR0214790A (pt) | 2004-12-14 |
US20040198124A1 (en) | 2004-10-07 |
US20050098256A1 (en) | 2005-05-12 |
EP1456454B1 (en) | 2012-04-25 |
KR20040073455A (ko) | 2004-08-19 |
AU2002351352B2 (en) | 2007-07-05 |
US7291239B2 (en) | 2007-11-06 |
JP2005514528A (ja) | 2005-05-19 |
ZA200404470B (en) | 2005-08-31 |
CN1599818A (zh) | 2005-03-23 |
US20030118816A1 (en) | 2003-06-26 |
CZ2004646A3 (cs) | 2004-11-10 |
MXPA04005295A (es) | 2004-09-13 |
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