JP7138095B2 - 無機粒子複合繊維、その製造方法、及び成形体 - Google Patents
無機粒子複合繊維、その製造方法、及び成形体 Download PDFInfo
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- JP7138095B2 JP7138095B2 JP2019513264A JP2019513264A JP7138095B2 JP 7138095 B2 JP7138095 B2 JP 7138095B2 JP 2019513264 A JP2019513264 A JP 2019513264A JP 2019513264 A JP2019513264 A JP 2019513264A JP 7138095 B2 JP7138095 B2 JP 7138095B2
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Description
イオン性高分子は、繊維に無機粒子を定着させるための下地として、及び無機粒子同士の間においてはバインダー(結着剤)として存在する。この構成によって、様々な種類の基材に高い付着量で無機粒子を付着させることができる。換言すれば、この構成を採用することによって、選択可能な繊維の種類が多くなる。
本発明に係る複合繊維は、一態様において、下地は、少なくとも1層のイオン性高分子によって形成されていればよいが、イオン性高分子を含む複数の層であってもよい。ここで、複数の層は、カチオン性高分子とアニオン性高分子とが交互に積層されてなる複数の層である。このように、下地が複数の層から形成されている場合、複合繊維は、カチオン性高分子が有している繊維の表面に対する高い親和性と、アニオン性高分子が有している無機粒子の高い定着性との両方の性能により、無機粒子の付着量が高められている。
無機粒子を含む層は、下地であるイオン性高分子を介して繊維の表面に定着している。また、無機粒子は、バインダーであるイオン性高分子を介して互いに結着し、無機粒子を含む層を形成している。ここで、バインダーであるイオン性高分子には、上述の下地に使用されるイオン性高分子として例示されているものと同じイオン性高分子を使用することができる。
本発明に係る無機粒子複合繊維は、例えば、シート等に成形されているか否かによらず、種々の用途に用いることができる。例えば、紙、不織布、繊維、セルロース系複合材料、フィルター材料、塗料、プラスチック、その他の樹脂、ゴム、エラストマー、セラミック、ガラス、タイヤ、建築材料(アスファルト、アスベスト、セメント、ボード、コンクリート、れんが、タイル、合板、及び繊維板等)、各種担体(触媒担体、医薬担体、農薬担体、微生物担体等)、吸着剤(不純物除去、消臭、及び除湿等)、しわ防止剤、粘土、研磨材、改質剤、補修材、断熱材、防湿材、撥水材、耐水材、遮光材、シーラント、シールド材、防虫剤、接着剤、インキ、化粧料、医用材料、ペースト材料、変色防止剤、食品添加剤、錠剤賦形剤、分散剤、保形剤、保水剤、濾過助材、精油材、油処理剤、油改質剤、電波吸収材、絶縁材、遮音材、防振材、半導体封止材、放射線遮断材、化粧品、肥料、飼料、香料、塗料・接着剤用添加剤、難燃材料、及び衛生用品(使い捨ておむつ、生理用ナプキン、失禁者用パッド、及び母乳パッド等、並びにウェットワイパー類(ウェットティシュー等))等のあらゆる用途に広く使用することができる。また、上記用途における各種充填剤、コーティング剤等の物品に用いることができる。
本発明の一態様に係る無機粒子複合繊維の製造方法は、繊維を、イオン性高分子を含む溶液に浸漬、若しくは塗布し、当該イオン性高分子に浸漬、若しくは塗布した繊維を、上記無機粒子を含む分散液に浸漬、若しくは塗布することにより、上記繊維に上記無機粒子を定着する。これによって、基材となる繊維が、例えば合成繊維であっても無機粒子の付着量が多い(つまり、灰分歩留が高い)無機粒子複合繊維を製造することができる。このため、無機粒子に起因する機能をより顕著に発揮することができる無機粒子複合繊維を製造することができる。
一態様において、複合繊維の製造方法では、基材である繊維は、イオン性高分子を含む溶液に浸漬、若しくは塗布する前において、当該繊維の表面を改質するために表面処理が行なわれていることが好ましい。このような表面処理の方法としては、例えば、UV-オゾン処理、フレーム表面処理、プラズマ放電処理、グロー放電処理、コロナ放電処理、及びアルカリによる加水分解処理、酸処理、シランカップリング剤処理、及びプライマー処理等が挙げられる。また、表面処理は、例えば、N-オキシル化合物、及び、臭化物、ヨウ化物、若しくはこれらの混合物からなる群から選択される化合物の存在下で酸化剤を用い、基材である繊維を水中で酸化することで得ることができる。このような表面処理によって、繊維基材の表面に存在する極性基を帯電させたり、新に極性基を形成したりすることができる。ここで、極性基は、例えば、水酸基、カルボニル基、カルボキシル基、アルデヒド基、及びリン酸基、ウレア基、スルホ基、ニトロ基、アミド基、及びシアノ基等であり得る。よって、イオン性高分子と、繊維表面との親和性を高め、イオン性高分子によって繊維表面を好適に被覆することができる。なお、これら表面処理は親水化処理の一態様であり得る。
複合繊維の製造方法では、繊維の表面上に無機粒子を定着させるための下地を少なくとも1層形成する。ここで、下地は、上述のイオン性高分子を含む溶液に基材である繊維を浸漬、若しくは塗布することによって形成する。例えば、基材である繊維が、セルロース等のように表面に水酸基及びカルボキシル基等が多く存在し、マイナスに帯電しやすい繊維である場合、1層目の下地は、カチオン性高分子を含む層であることが好ましい。また、基材である繊維が、カチオン性ポリマー等によって改質されていたり、酸処理されていたりすることにより、その表面がプラスに帯電しやすい繊維である場合、1層目の下地はアニオン性高分子を含むことが好ましい。
イオン性高分子の溶液は、カチオン性高分子の溶液、又はアニオン性高分子の溶液であり、典型的にこれらイオン性高分子の水溶液である。ここで、特に限定されるものではないが、水溶液に含まれるイオン性高分子の量は、カチオン性高分子の溶液、及びアニオン性高分子の溶液の何れの場合においても、各高分子における単量体単位の濃度が、1×10-3~5×10-2Mの範囲内であることが好ましい。イオン性高分子の溶液において、各高分子の単量体単位の濃度が、1×10-3~5×10-2Mの範囲内であれば、高分子の繊維表面への積層を好適に制御することができる。
無機粒子の層は、少なくとも1回、下地を形成した繊維を、無機粒子を含む分散液に浸漬、若しくは塗布することによって当該下地の上に無機粒子を定着させることによって形成する。なお、無機粒子の層は、少なくとも1回、無機粒子を含む分散液に下地を形成した繊維を浸漬、若しくは塗布することによって形成すればよいが、繊維への無機粒子の付着量を高めるという観点からは、下地を形成した繊維を、複数回、無機粒子を含む分散液に浸漬、若しくは塗布することによって形成することが好ましい。ここで、無機粒子の層は、無機粒子を含む分散液とイオン性高分子を含む溶液とに交互に下地を形成した繊維を浸漬、若しくは塗布することによって行なう(交互積層法)。なお、無機粒子の層の形成は、特に限定されるものではないが、例えば、無機粒子を含む分散液への浸漬、若しくは塗布、及びイオン性高分子を含む溶液への浸漬、若しくは塗布を1セットとして、1~10セット行なうことが好ましい。
無機粒子を含む分散液は、無機粒子を分散した分散液であり、典型的には、無機粒子の水分散液である。ここで、分散液に含まれる無機粒子の濃度は、0.005~1%であることが好ましく、0.01~0.5%であることがより好ましい。分散液に含まれる無機粒子の濃度が、0.005~1%であれば、イオン性高分子を含む溶液との交互積層法によって、イオン性高分子の層に好適に無機粒子を定着させることができる。なお、無機粒子の分散液には、本発明の効果を阻害しない範囲において、例えば、分散剤、及びpH調整剤等の公知の添加剤が含まれていてもよい。
無機粒子複合繊維は、例えば、シート等の成形体を形成するための成形材料として好適に使用することができる。また、無機粒子複合繊維は未成形の状態において繊維の表面に無機粒子が定着している。このため、例えば、シート状の成形体の表面に無機粒子を定着させた繊維材料等と比較して、一態様に係る無機粒子複合繊維から成形した成形体は、当該成形体の表面に無機粒子が偏在化することを回避することができ、成形体の内部にまで無機粒子が定着している成形体である。よって、一態様に係る無機粒子複合繊維を成形した成形体も、本発明の範疇である。
本発明は、これに制限されるものでないが、以下の発明を包含する。
無機粒子の平均一次粒子径が3μm以下である、(1)~(6)、(10)の何れかに記載の無機粒子複合繊維。
交互積層(Layer-by-Layer(LbL))法によって、化学繊維の表面に無機粒子を定着させた。各サンプルに使用した繊維、及び無機粒子の分散液は、以下に示す通りである。
化学繊維:
リヨセル(LENZING社製、平均繊維長4mm)
無機粒子の分散液:
炭酸カルシウムの分散液(平均粒子径90nm、0.1%水溶液、pH7.5)
炭酸マグネシウムの分散液(平均粒子径1.5μm、0.1%水溶液、pH9.0)
0.1gのリヨセルを手でほぐし、薬包紙の略全面に広げ、UV-O3クリーナー(Bioforce nanosciences 社製)にて3分間、UV-オゾン処理を行なった。
UVオゾン処理を行なった繊維を用いて、ポリマー溶液及び分散液への浸漬処理、並びリンス処理を行なった。
表1に示す試薬、及び上述の無機粒子の分散液の何れかに繊維を浸漬した。何れの試薬に浸漬するときにおいても、浸漬時間は120秒であり、浸漬回数は1回であった。なお、無機粒子の分散液に浸漬するときにおいても、上記試薬を分散液に代えた以外は、同じ条件にて浸漬処理を行なった。
以下に示すサンプル1~7の作成においては、上記浸漬処理と、その後に続く浸漬処理との間において、試薬(又は分散液)に浸漬した繊維に対してリンス処理を行なった。各浸漬処理の間に行なうリンス処理の回数は2回であり、1回のリンス処理を60秒間行った。また、各サンプルは、最後の浸漬処理を行なった後においても、同じ条件にてリンス処理を行なった。
サンプル1は、UVオゾン処理を行なった繊維を、PEI溶液への浸漬処理、PSS溶液への浸漬処理をこの順にて行ない、PEIの層とPSSの層とが合計5層になるようにして下地層を形成した。続いて、下地層を形成した繊維を、炭酸マグネシウムの分散液への浸漬処理及びPEI溶液への浸漬処理をこの順にて計3回行ない、炭酸マグネシウムの層を形成した。
サンプル2は、UVオゾン処理を行なった繊維を、PEI溶液への浸漬処理を行なうことによって合計1層の下地層を形成した。続いて、下地層を形成した繊維を、炭酸マグネシウムの分散液への浸漬処理、及びPEI溶液への浸漬処理をこの順にて計3回行ない、炭酸マグネシウムの層を形成した。
サンプル3は、UVオゾン処理を行なった繊維を、PEI溶液への浸漬処理、PSS溶液への浸漬処理をこの順にて行ない、合計2層の下地層を形成した。続いて、下地層を形成した繊維を、炭酸マグネシウムの分散液への浸漬処理及びPEI溶液への浸漬処理をこの順にて計3回行なうことによって、炭酸マグネシウムの層を形成した。次いで、炭酸マグネシウムの層を形成した繊維をPEI溶液に浸漬することによってPEIの層を形成した。
サンプル4は、炭酸マグネシウムの分散液を炭酸カルシウムの分散液に置き換えた以外はサンプル1と同じ条件にて作成した。
サンプル5は、炭酸マグネシウムの分散液を炭酸カルシウムの分散液に置き換えた以外はサンプル2と同じ条件にて作成した。
サンプル6は、炭酸マグネシウムの分散液を炭酸カルシウムの分散液に置き換えた以外はサンプル3と同じ条件にて作成した。
サンプル7は、UVオゾン処理を行なった繊維を、PEI溶液への浸漬処理及びPSS溶液への浸漬処理をこの順に行ない、PEIの層とPSSの層とを5層形成し、さらにPAA溶液への浸漬処理を行なうことで、6層の下地層を形成した。続いて、下地層を形成した繊維に、PEI溶液への炭酸カルシウムの分散液への浸漬処理及びPAA溶液への浸漬処理を行ない、炭酸マグネシウムの層を形成した。次いで、炭酸マグネシウムの層を形成した繊維をPEI溶液に浸漬することによって、PEIの層を形成した。
サンプル8は、UVオゾン処理を行なわずに実験を行った以外はサンプル1と同じ条件にて作成した。
サンプル1~7について、無機粒子の分散液にて浸漬処理した後の繊維を、各浸漬処理後ごとに電界放出形走査電子顕微鏡(FE-SEM)にて観察した。図2~9に示すFE-SEM画像の倍率は、3000倍である。図9は、無処理のリヨセルを撮影した画像である。
Claims (12)
- 繊維と、
上記繊維に定着している無機粒子とを備え、
上記繊維の形態が、糸状であり、かつ、パルプであり、
上記無機粒子は、上記繊維にイオン性高分子を介して定着しており、
上記繊維と上記無機粒子との間に介在する上記イオン性高分子を含む層は、複数の層からなり、
当該複数の層は、カチオン性高分子を含む層とアニオン性高分子を含む層とが積層されてなる層であり、
上記繊維が、マイナスに帯電した表面を有している場合、上記複数の層の1層目は、カチオン性高分子を含む層であり、
上記繊維の表面が、プラスに帯電した表面を有している場合、上記複数の層の1層目はアニオン性高分子を含む層であり、
上記繊維は、平均繊維長が100μm~15mmであり、
上記繊維は、再生繊維、又は合成繊維であり、
上記無機粒子が、イオン性高分子を介して互いに結着していることによって、上記無機粒子を含む層が形成され、
上記無機粒子を含む層のイオン性高分子は、上記無機粒子との対電荷を有する高分子であり、
繊維表面の15%以上が無機粒子によって被覆されている、無機粒子複合繊維。 - 上記無機粒子を含む層は、上記無機粒子の層とイオン性高分子の層とが交互に積層されてなる層であり、上記無機粒子の層とイオン性高分子の層とを1セットの層として、3~10セットの層が積層されてなる層である、請求項1に記載の無機粒子複合繊維。
- 上記イオン性高分子は、アニオン性高分子であり、当該アニオン性高分子はキレート能を有している、請求項1又は2に記載の無機粒子複合繊維。
- 上記繊維の表面に極性基を有している、請求項1~3の何れか1項に記載の無機粒子複合繊維。
- 請求項1~4の何れか1項に記載の無機粒子複合繊維の製造方法であって、
上記繊維を、上記イオン性高分子を含む溶液に浸漬、若しくは塗布することにより、当該イオン性高分子に浸漬した繊維を、上記無機粒子を含む分散液に浸漬、若しくは塗布することにより、上記繊維に上記無機粒子を定着する、無機粒子複合繊維の製造方法。 - 繊維と、
上記繊維に定着している無機粒子とを備え、
上記繊維の形態が、糸状であり、かつ、パルプであり、
上記無機粒子を含む層は、上記繊維にカチオン性高分子又はアニオン性高分子を介して定着しており、
上記無機粒子が、イオン性高分子を介して互いに結着していることによって、上記無機粒子を含む層が形成されている無機粒子複合繊維の製造方法であって、
上記繊維は、平均繊維長が100μm~15mmであり、
上記繊維は、再生繊維、又は合成繊維であり、
上記繊維が、マイナスに帯電した表面を有している場合、当該繊維にカチオン性高分子を介して上記無機粒子の層が定着し、
上記繊維が、プラスに帯電に帯電した表面を有している場合、上記繊維にアニオン性高分子を介して上記無機粒子の層が定着し、
繊維表面の15%以上が無機粒子によって被覆されており、
上記繊維を、上記イオン性高分子を含む溶液と、上記無機粒子を含む分散液とに交互に浸漬、若しくは塗布することによって、上記無機粒子の層を形成し、
上記無機粒子を含む層のイオン性高分子は、上記無機粒子との対電荷を有する高分子である、無機粒子複合繊維の製造方法。 - 請求項1に記載の無機粒子複合繊維の製造方法であって、上記無機粒子の層を形成する前に、上記繊維を、上記イオン性高分子を含む溶液であるカチオン性高分子を含む溶液とアニオン性高分子を含む溶液とに浸漬、若しくは塗布することによって、上記複数の層を形成する、無機粒子複合繊維の製造方法。
- 無機粒子の平均一次粒子径が3μm以下である、請求項1~4の何れか1項に記載の無機粒子複合繊維。
- 無機粒子の少なくとも一部に、カルシウム、ケイ酸、マグネシウム、バリウムまたはアルミニウム、チタン、銅、銀、亜鉛、白金、鉄、パラジウム、若しくはジルコニウムを含む、請求項1~4、8の何れか1項に記載の無機粒子複合繊維。
- 上記繊維を、上記イオン性高分子の溶液に浸漬する前に、上記繊維の表面に極性基を形成する処理を行なう、請求項5~7の何れか1項に記載の無機粒子複合繊維の製造方法。
- 繊維と、
上記繊維に定着している無機粒子とを備え、
上記繊維の形態が、糸状であり、かつ、パルプであり、
上記無機粒子を含む層は、上記繊維にカチオン性高分子又はアニオン性高分子を介して定着しており、
上記無機粒子を含む層は、複数の層からなり、
当該複数の層は、無機粒子を含む層とイオン性高分子を含む層とが積層されてなる層であり、
上記繊維は、平均繊維長が100μm~15mmであり、
上記繊維は、再生繊維、又は合成繊維であり、
上記繊維が、マイナスに帯電した表面を有している場合、当該繊維にカチオン性高分子を介して上記無機粒子の層が定着し、
上記繊維が、プラスに帯電に帯電した表面を有している場合、上記繊維にアニオン性高分子を介して上記無機粒子の層が定着し、
上記イオン性高分子を含む層は、上記無機粒子との対電荷を有する高分子であり、
繊維表面の15%以上が無機粒子によって被覆されている、無機粒子複合繊維。 - 請求項1~4、8、9、11の何れか1項に記載の無機粒子複合繊維を成形してなる、成形体。
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