JP5266050B2 - 海−島構造の二成分繊維をフィブリル化して製造される高強度で丈夫なマイクロおよびナノ繊維布 - Google Patents
海−島構造の二成分繊維をフィブリル化して製造される高強度で丈夫なマイクロおよびナノ繊維布 Download PDFInfo
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Description
本出願は2005年6月24日付けの米国仮出願第60/694,121号の優先権を主張する。
本発明は、概して、マイクロデニール繊維の製造およびそのような繊維から製造された高強度の不織製品に関する。より詳細には、本発明は海と島構成からそのような繊維を製造することに関し、海の構成要素は島の構成要素をフィブリル化したものである。
(a)ニードルパンチし、続いてどのような熱結合もなくハイドロエンタングルする、ハイドロエンタングル法のエネルギーは鞘核または海の島構造の部分的または完全な***をもたらす。
(b)どのようなニードルパンチも続く熱結合もなくウェブのみをハイドロエンタングルする、ハイドロエンタングル法のエネルギーは鞘核または海の島構造の部分的または完全な***をもたらす。
(c)上記(a)に記載のようにウェブをハイドロエンタングルし、続いてカレンダ加工で熱結合させる。
(d)上記(a)に記載のようにウェブをハイドロエンタングルし、続いて海または鞘が溶融する融点またはそれ以上の温度で、空気中オーブンで熱結合させて強い布を形成する。
Claims (30)
- 不織布を製造する方法であって、
外側繊維要素と、この外側繊維要素に包まれ、円形または多葉形の断面を有する内側繊維要素とを海−島構造または鞘−核構造で備えた1組の二成分繊維を、前記外側繊維要素が凝固する前に前記内側繊維要素を結晶化して凝固させることによって形成するステップと、
前記1組の二成分繊維をウェブ上に配置するステップと、
前記外側繊維要素をフィブリル化して、前記外側繊維要素をマイクロデニール繊維状にするとともに、前記内側繊維要素を露出させ、前記内側繊維要素をマイクロデニール繊維状にし、これらマイクロデニール繊維状となった外側繊維要素および内側繊維要素を絡み合わせることによって、前記外側繊維要素を除去することなく、前記外側繊維要素のマイクロデニール繊維と前記内側繊維要素のマイクロデニール繊維とが絡み合ったウェブを形成するステップと
を含む不織布の製造方法。 - 前記外側繊維要素をフィブリル化するために水力エネルギーを用いることを更に含む請求項1に記載の不織布の製造方法。
- 前記1組の二成分繊維をハイドロエンタングル法に適用するために前記水力エネルギーを用いることを更に含む請求項2に記載の不織布の製造方法。
- 前記内側繊維要素および前記外側繊維要素は、前記外側繊維要素がフィブリル化された後に熱結合にかけられる請求項1に記載の不織布の製造方法。
- 前記外側繊維要素が、前記二成分繊維の前記内側繊維要素よりも、前記二成分繊維を形成するステップの前記凝固前において、粘性が高い請求項1に記載の方法。
- 前記内側繊維要素が熱可塑性重合体の群から選択される熱可塑性樹脂を含み、この熱可塑性重合体が、エステル結合を介して頭尾結合した長鎖エーテルエステル単位と短鎖エステルユニットを有するコポリエーテルエステルエラストマーである請求項1に記載の方法。
- 前記外側繊維要素が熱可塑性重合体の群から選択される熱可塑性樹脂を含み、この熱可塑性重合体が、エステル結合を介して頭尾結合した長鎖エーテルエステル単位と短鎖エステルユニットを有するコポリエーテルエステルエラストマーである請求項1に記載の方法。
- 前記内側繊維要素が熱可塑性重合体の群から選択される重合体を含み、この熱可塑性重合体が、ナイロン6、ナイロン6/6、ナイロン6,6/6、ナイロン6/10、ナイロン6/11、ナイロン6/12ポリプロピレン、またはポリエチレンから選択される請求項1に記載の方法。
- 前記外側繊維要素が熱可塑性重合体の群から選択される重合体を含み、この熱可塑性重合体が、ナイロン6、ナイロン6/6、ナイロン6,6/6、ナイロン6/10、ナイロン6/11、ナイロン6/12ポリプロピレン、またはポリエチレンから選択される請求項1に記載の方法。
- 前記外側繊維要素が、ポリエステル、ポリアミド、熱可塑性コポリエーテルエステルエラストマー、ポリオレフィン、ポリアクリレート、および熱可塑性液晶重合体からなる熱可塑性重合体の群から選択される重合体を含む請求項1に記載の方法。
- 前記内側繊維要素が、ポリエステル、ポリアミド、熱可塑性コポリエーテルエステルエラストマー、ポリオレフィン、ポリアクリレート、および熱可塑性液晶重合体からなる熱可塑性重合体の群から選択される重合体を含む請求項1に記載の方法。
- 前記内側繊維要素が多葉形である請求項1に記載の方法。
- 前記内側繊維要素が円形の断面を有する請求項1に記載の方法。
- 前記外側繊維要素が、繊維全体の5%〜95%を含む請求項1に記載の方法。
- 前記二成分繊維が絡み合ったウェブが2つの外側表面を有し、前記布が両表面でハイドロエンタングルメントに曝される請求項1に記載の方法。
- 前記二成分繊維が絡み合ったウェブの1つの表面だけがハイドロエンタングルメント加工に曝される請求項1に記載の方法。
- 前記二成分繊維が絡み合ったウェブが、10bars〜1000barsの水圧で、1つまたは複数のハイドロエンタングル法分岐管からの水圧に曝される請求項1に記載の方法。
- 前記二成分繊維が絡み合ったウェブが樹脂でコーティングされて不透過材料を形成する請求項1に記載の方法。
- 前記二成分繊維が絡み合ったウェブは、前記外側構成要素がフィブリル化された後、ジェット染色プロセスにかけられる請求項1に記載の方法。
- 前記二成分繊維が絡み合ったウェブが、ハイドロエンタングル法の直後の乾燥プロセスの間、前記2繊維が絡み合ったウェブ内の繊維の再配向のために機械方向に伸ばされる請求項1に記載の方法。
- 前記乾燥プロセスの温度が、重合体のガラス転移より高くて、溶融の開始より低く、前記二成分繊維が絡み合ったウェブで横方向の伸縮と回復を生み出すように、ヒートセットにより記憶する請求項20に記載の方法。
- 前記二成分繊維が前記海−島構造の繊維である請求項1に記載の方法。
- 前記内側構成要素がポリエステルまたはナイロンで、前記外側構成要素がポリオレフィンである請求項1に記載の方法。
- 不織物品の製造に適した絡み合ったウェブ状の不織布を製造する方法であって、
非水溶性の外側海要素と、この外側海要素に包まれ、円形または複数突出した形状の断面を有する非水溶性の内側島要素とを海−島構造で備えた1組の二成分連続フィラメントを、前記外側海要素が凝固する前に前記内側島要素を結晶化して凝固させることによって形成するステップと、
前記1組の二成分連続フィラメントをウェブ上に配置するステップと、
前記二成分連続フィラメントをハイドロエンタングルメント加工して、前記外側海要素をマイクロデニール繊維状に分離するとともに、前記内側島要素を露出させ、前記内側島要素をマイクロデニール繊維状にし、これらマイクロデニール繊維状となった外側海要素および内側島要素を絡み合わせるステップと、
前記外側海要素を除去せずに、維持することによって、前記外側海要素のマイクロデニール繊維と前記内側島要素のマイクロデニール繊維とが絡み合い、強度が向上されたウェブを形成するステップと
を含む不織布の製造方法。 - 前記二成分連続フィラメントが絡み合ったウェブが前記ハイドロエンタングルメント加工の後に熱結合にかけられる請求項24に記載の不織布の製造方法。
- 前記外側海要素が、前記二成分連続フィラメントの前記内側島要素よりも、前記二成分繊維を形成するステップの前記凝固前において、粘性が高い請求項24に記載の方法。
- 前記内側島要素がポリエステルまたはナイロンで、前記外側海要素がポリオレフィンである請求項24に記載の方法。
- 前記内側島要素および前記外側海要素の一方がポリエステルで他方がナイロンである請求項24に記載の方法。
- 前記二成分繊維が絡み合ったウェブから不織物品を形成するステップを更に含む請求項1に記載の方法。
- 前記二成分連続フィラメントが絡み合ったウェブから不織物品を形成するステップを更に含む請求項24に記載の方法。
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-
2006
- 2006-06-23 WO PCT/US2006/024465 patent/WO2007002387A2/en active Application Filing
- 2006-06-23 CA CA 2612691 patent/CA2612691A1/en not_active Abandoned
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- 2006-06-23 ES ES13151392T patent/ES2570965T3/es active Active
- 2006-06-23 CN CN2006800228045A patent/CN101641469B/zh not_active Expired - Fee Related
- 2006-06-23 EP EP13151392.1A patent/EP2597183B1/en not_active Not-in-force
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EP2597183A1 (en) | 2013-05-29 |
CN101641469B (zh) | 2012-10-10 |
EP1907201A2 (en) | 2008-04-09 |
US7981226B2 (en) | 2011-07-19 |
EP1907201B1 (en) | 2013-03-06 |
ES2570965T3 (es) | 2016-05-23 |
HK1185926A1 (zh) | 2014-02-28 |
US8420556B2 (en) | 2013-04-16 |
KR20080034894A (ko) | 2008-04-22 |
WO2007002387A2 (en) | 2007-01-04 |
CA2612691A1 (en) | 2007-01-04 |
CN101641469A (zh) | 2010-02-03 |
KR101280398B1 (ko) | 2013-07-02 |
JP2008544110A (ja) | 2008-12-04 |
BRPI0611878A2 (pt) | 2010-10-05 |
WO2007002387A3 (en) | 2009-04-30 |
US20110250812A1 (en) | 2011-10-13 |
EP1907201A4 (en) | 2010-08-25 |
HK1114058A1 (en) | 2008-10-24 |
EP2597183B1 (en) | 2016-04-06 |
MX2007016348A (es) | 2008-03-05 |
US20060292355A1 (en) | 2006-12-28 |
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