JPH0118178B2 - - Google Patents
Info
- Publication number
- JPH0118178B2 JPH0118178B2 JP58176397A JP17639783A JPH0118178B2 JP H0118178 B2 JPH0118178 B2 JP H0118178B2 JP 58176397 A JP58176397 A JP 58176397A JP 17639783 A JP17639783 A JP 17639783A JP H0118178 B2 JPH0118178 B2 JP H0118178B2
- Authority
- JP
- Japan
- Prior art keywords
- fibers
- nonwoven fabric
- ultrafine
- fiber
- intertwined
- 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.)
- Expired
Links
- 239000004745 nonwoven fabric Substances 0.000 claims description 110
- 229920001410 Microfiber Polymers 0.000 claims description 105
- 239000000835 fiber Substances 0.000 claims description 105
- 229920000642 polymer Polymers 0.000 claims description 10
- 239000000126 substance Substances 0.000 claims description 7
- 239000002904 solvent Substances 0.000 claims description 4
- 230000001172 regenerating effect Effects 0.000 claims 1
- 239000012530 fluid Substances 0.000 description 31
- 238000011282 treatment Methods 0.000 description 17
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 17
- 239000004744 fabric Substances 0.000 description 16
- -1 polyethylene terephthalate Polymers 0.000 description 15
- 239000004372 Polyvinyl alcohol Substances 0.000 description 13
- 229920002451 polyvinyl alcohol Polymers 0.000 description 13
- 239000010410 layer Substances 0.000 description 12
- 238000000034 method Methods 0.000 description 11
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 10
- 230000014759 maintenance of location Effects 0.000 description 10
- 239000000853 adhesive Substances 0.000 description 8
- 239000004793 Polystyrene Substances 0.000 description 7
- 229920002223 polystyrene Polymers 0.000 description 7
- ZMXDDKWLCZADIW-UHFFFAOYSA-N N,N-Dimethylformamide Chemical compound CN(C)C=O ZMXDDKWLCZADIW-UHFFFAOYSA-N 0.000 description 6
- 230000001070 adhesive effect Effects 0.000 description 6
- 239000000463 material Substances 0.000 description 6
- 229920000139 polyethylene terephthalate Polymers 0.000 description 5
- 239000005020 polyethylene terephthalate Substances 0.000 description 5
- 238000009987 spinning Methods 0.000 description 5
- 239000002131 composite material Substances 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 229920002635 polyurethane Polymers 0.000 description 4
- 239000004814 polyurethane Substances 0.000 description 4
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 3
- 229920002292 Nylon 6 Polymers 0.000 description 3
- 239000004952 Polyamide Substances 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- XSTXAVWGXDQKEL-UHFFFAOYSA-N Trichloroethylene Chemical group ClC=C(Cl)Cl XSTXAVWGXDQKEL-UHFFFAOYSA-N 0.000 description 3
- 239000007864 aqueous solution Substances 0.000 description 3
- 239000003795 chemical substances by application Substances 0.000 description 3
- 229920001577 copolymer Polymers 0.000 description 3
- 238000004043 dyeing Methods 0.000 description 3
- 238000002347 injection Methods 0.000 description 3
- 239000007924 injection Substances 0.000 description 3
- 239000010985 leather Substances 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 239000003658 microfiber Substances 0.000 description 3
- 229920002647 polyamide Polymers 0.000 description 3
- 229920005989 resin Polymers 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- 238000004513 sizing Methods 0.000 description 3
- 229920002554 vinyl polymer Polymers 0.000 description 3
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 239000002202 Polyethylene glycol Substances 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- 150000001298 alcohols Chemical class 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 238000004090 dissolution Methods 0.000 description 2
- 239000003292 glue Substances 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 229920001707 polybutylene terephthalate Polymers 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 229920001223 polyethylene glycol Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
- 230000037303 wrinkles Effects 0.000 description 2
- GOXQRTZXKQZDDN-UHFFFAOYSA-N 2-Ethylhexyl acrylate Chemical compound CCCCC(CC)COC(=O)C=C GOXQRTZXKQZDDN-UHFFFAOYSA-N 0.000 description 1
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 1
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 1
- JHWNWJKBPDFINM-UHFFFAOYSA-N Laurolactam Chemical compound O=C1CCCCCCCCCCCN1 JHWNWJKBPDFINM-UHFFFAOYSA-N 0.000 description 1
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical group OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 1
- 240000002853 Nelumbo nucifera Species 0.000 description 1
- 235000006508 Nelumbo nucifera Nutrition 0.000 description 1
- 235000006510 Nelumbo pentapetala Nutrition 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 229920000299 Nylon 12 Polymers 0.000 description 1
- 229920002302 Nylon 6,6 Polymers 0.000 description 1
- 239000005062 Polybutadiene Substances 0.000 description 1
- 241001481789 Rupicapra Species 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 239000012670 alkaline solution Substances 0.000 description 1
- 239000003242 anti bacterial agent Substances 0.000 description 1
- 239000002216 antistatic agent Substances 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 239000001768 carboxy methyl cellulose Substances 0.000 description 1
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 1
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 238000010036 direct spinning Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 239000000986 disperse dye Substances 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000000975 dye Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000000796 flavoring agent Substances 0.000 description 1
- 235000013355 food flavoring agent Nutrition 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000012510 hollow fiber Substances 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 239000011229 interlayer Substances 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 238000009981 jet dyeing Methods 0.000 description 1
- 229920000126 latex Polymers 0.000 description 1
- 239000004816 latex Substances 0.000 description 1
- 239000002649 leather substitute Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229920003145 methacrylic acid copolymer Polymers 0.000 description 1
- 229920000609 methyl cellulose Polymers 0.000 description 1
- 239000001923 methylcellulose Substances 0.000 description 1
- 235000010981 methylcellulose Nutrition 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 229920000233 poly(alkylene oxides) Polymers 0.000 description 1
- 229920002285 poly(styrene-co-acrylonitrile) Polymers 0.000 description 1
- 229920002401 polyacrylamide Polymers 0.000 description 1
- 229920002239 polyacrylonitrile Polymers 0.000 description 1
- 229920001515 polyalkylene glycol Polymers 0.000 description 1
- 229920002857 polybutadiene Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 235000019422 polyvinyl alcohol Nutrition 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 210000004243 sweat Anatomy 0.000 description 1
Landscapes
- Chemical Or Physical Treatment Of Fibers (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Nonwoven Fabrics (AREA)
Description
【発明の詳細な説明】
本発明は、極細繊維と束内の該極細繊維同志が
相互に動きうる形態の極細繊維束とが実質的に全
層にわたつて三次元交絡していることを特徴とす
る交絡不織布に関する。Detailed Description of the Invention The present invention is characterized in that the ultrafine fibers and the ultrafine fiber bundle in which the ultrafine fibers within the bundle can move relative to each other are three-dimensionally intertwined over substantially the entire layer. This invention relates to an interlaced nonwoven fabric.
従来公知の不織布としては、普通繊維のステ
ープルをランダムウエブとなし、次いで、ニード
ルパンチして得られた不織布、多数の単繊維が
集束せしめられている繊維束を主体として該繊維
束は繊維束同志が繊維束の状態のまま相互に絡合
せしめられた不織布、極細単繊維と、該極細単
繊維が自己接着されて形成された繊維束とが交絡
した構造を有する不織布、単繊維と、自己接着
短繊維または割繊性短繊維からなる単繊維が結合
した繊維束とが織編物とからみ合い一体化された
構造を有する布帛不織布、長さの短かい極細単
繊維と布帛とが交絡され一体化された構造を有す
る布帛不織布などが知られている。 Conventionally known nonwoven fabrics include nonwoven fabrics obtained by forming staples of ordinary fibers into a random web and then needle-punching them, and fiber bundles consisting mainly of fiber bundles in which a large number of single fibers are bundled together. A nonwoven fabric, a nonwoven fabric having a structure in which ultrafine single fibers are intertwined with each other in the state of a fiber bundle, and a fiber bundle formed by self-adhering the ultrafine single fibers, and a self-adhesive nonwoven fabric and single fibers. Non-woven fabrics have a structure in which a fiber bundle of short fibers or splittable short fibers is intertwined and integrated with a woven or knitted fabric, and a short ultra-fine single fiber and a fabric are intertwined and integrated. Fabrics and nonwoven fabrics having such a structure are known.
しかし、のものは、比較的太い繊維１本１本
が立体的に絡合した構造を有し、それ故に柔軟性
に乏しく感触など極めて悪いものであり、このた
め、不織布の用途が著しく制限されてきた。の
ものは、前者にくらべ柔軟性に優れているが、不
織布単独では形態保持性がきわめて悪いものであ
る。のものは、のものよりは形態保持性はよ
いがまだ不充分である。また不織布に含まれる繊
維束は、極細繊維が相互に自己接着された構造で
あるため、極細繊維からなる繊維束といえども柔
軟性がなく剛性の高いものである。このため、こ
のことが不織布の風合やその他の性状に影響を及
ぼし持に柔軟性の高い不織布が得られなかつたの
である。また、この不織布を手でなぜてみると、
自己接着された繊維束が手にひつかかりザラザラ
した感触をしている。更に不織布を折り曲げてみ
ると紙様の折れ方をし、折り曲げられた外側がつ
の状にでこぼこした見苦しい形態を示すものであ
る。のものは、織編物が含まれているため形態
保持性は良好である。しかし、布帛不織布に含ま
れる繊維束は、のものと同様、極細繊維が相互
に結合された剛直な構造をしているため、やはり
のものと同様の欠点を有しているものである。
更に、織編物の界面で剥離がおきやすいこと、平
面方向の伸び方にかなりの片寄りがあること、繊
維長がきわめて短かいため極細繊維や繊維束が抜
け落ちやすいこと、表面に織編物の目が浮き出や
すいこと、場合によつては切り口から織編物の繊
維がほつれ出ることがあることなどの欠点を有し
ているものである。のものは、のものを同
様、布帛が含まれているため形態保持性は良好で
ある。また、極細単繊維と布帛のみから構成され
ており、剛直な繊維束は含まれていないため、
のもののような欠点はないものである。しかし。
布帛に極細単繊維のみが交絡しているため交絡が
緻密になりすぎ風合が硬くなりやすいという欠点
に加え、やはり、のものと同様、布帛の界面で
剥離がおきやすいこと、平面方向の伸びにかなり
の片寄りがあること、繊維長がきわめて短かいた
め極細単繊維が抜け落ちやすいこと、場合によつ
ては切り口から布帛の繊維がほつれ出ることがあ
ることなどの欠点を有しているものである。 However, nonwoven fabrics have a structure in which relatively thick fibers are intertwined one by one in a three-dimensional manner, resulting in poor flexibility and an extremely poor feel.For this reason, the uses of nonwoven fabrics are severely limited. It's here. The nonwoven fabric has excellent flexibility compared to the former, but the shape retention is extremely poor when used as a nonwoven fabric alone. This product has better shape retention than other products, but it is still insufficient. Furthermore, since the fiber bundles contained in the nonwoven fabric have a structure in which ultrafine fibers are self-adhered to each other, even fiber bundles made of ultrafine fibers are inflexible and highly rigid. Therefore, this affected the texture and other properties of the nonwoven fabric, making it impossible to obtain a highly flexible nonwoven fabric. Also, when you try this nonwoven fabric with your hands,
The self-adhesive fiber bundles stick to your hands and feel rough. Furthermore, when the nonwoven fabric is folded, it folds like paper, and the outside of the folded fabric exhibits an unsightly uneven shape. This type has good shape retention because it contains a woven or knitted fabric. However, the fiber bundles contained in the nonwoven fabric have a rigid structure in which ultrafine fibers are interconnected, and therefore have the same drawbacks as the nonwoven fabric.
Furthermore, peeling is likely to occur at the interface of the woven or knitted material, there is considerable deviation in the elongation in the plane direction, the fiber length is extremely short, so ultrafine fibers or fiber bundles are likely to fall off, and the surface of the woven or knitted material has grains. This method has drawbacks such as the fact that the fibers of the woven or knitted material may come loose from the cut end in some cases. Like the one above, this one has good shape retention because it contains fabric. In addition, it is composed only of ultra-fine single fibers and fabric, and does not contain rigid fiber bundles.
It doesn't have any drawbacks like the others. but.
In addition to the disadvantage that only ultra-fine single fibers are intertwined with the fabric, the intertwining becomes too dense and the texture tends to be hard. There are disadvantages such as the fact that the fibers are quite unbalanced, the ultra-fine single fibers are easy to fall off because the fiber length is extremely short, and in some cases, the fibers of the fabric may fray from the cut end. It is.
本発明の目的は、かかる従来の不織布のような
欠点がなく、柔軟性に優れ、しかも織編物が内部
に含まれていないにもかかわらず形態保持性が良
好で、更に、手に吸い付くような感触を有し、折
り曲げたときにつのが出難く、なめらかな曲面形
態が得られ、厚さが薄くても強力が高い交絡不織
布を提供することにある。 The object of the present invention is to avoid the drawbacks of conventional non-woven fabrics, to have excellent flexibility, to have good shape retention even though no woven or knitted fabric is contained therein, and to be able to stick to the hand. To provide an intertwined nonwoven fabric which has a soft feel, is hard to produce when folded, has a smooth curved shape, and has high strength even if it is thin.
かかる本発明の目的を達成するために、本発明
は次の構成を有する。 In order to achieve the object of the present invention, the present invention has the following configuration.
交絡不織布の実質的に全層にわたつて、(A)0.5
デニール以下の極細繊維と、(B)極細繊維束を構成
する該極細繊維が極細繊維同志相互に動きうる自
由度のある状態で配列された構造を有する極細繊
維束とが主体に混在し緻密に三次元交絡している
構造を有することを特徴とする交絡不織布。 (A)0.5 over substantially the entire layer of the interlaced nonwoven fabric;
Ultrafine fibers of denier or less and (B) ultrafine fiber bundles that have a structure in which the ultrafine fibers constituting the ultrafine fiber bundle are arranged with a degree of freedom that allows mutual movement among the ultrafine fibers are mixed and densely formed. An intertwined nonwoven fabric characterized by having a three-dimensional intertwined structure.
本発明に使用される極細繊維としては、スーパ
ードローによる方法、多数の微細孔より吐出する
方法、ガス流を利用したジエツト紡糸による方法
などで直接製造した極細繊維を束ねて別の結合成
分で結合して一本の複合繊維とし、不織布製造工
程のしかるべき時期に該結合成分を除去し極細繊
維に再生して用いてもよいが、繊維が細くなると
紡糸が不安定になること、不織布製造工程の途中
で繊維が剥離してトラブルが発生するなど加工が
むつかしく取扱いにくいこと、超極細繊維は直接
紡糸では製造困難であること、得られた不織布は
柔軟性にやや劣ることなどから、つぎに述べる多
成分からなる極細繊維形成型繊維を用い不織布製
造工程中のしかるべき時期にその少なくとも１成
分を溶解除去して極細繊維に変成して用いること
がより好ましい。すなわち、本発明に好ましく使
用される極細繊維形成型繊維は、たとえば、１成
分を他成分間に放射状に介在せしめた菊花状断面
の繊維、多層バイメタル型繊維、ドーナツ状断面
の多層バイメタル型繊維、２種以上の高分子物質
のチツプやビーズを混合し溶融混合するかあるい
は２種以上の高分子物質の溶融成分を混合して紡
糸したいわゆる混合紡糸繊維、繊維軸方向に連続
した極細繊維が多数配列集合し他の成分で結合さ
れ１本の繊維を形成した高分子相互配列体繊維な
どであり、これらの２種以上の繊維を混合あるい
は組み合わせ用いてもよい。溶剤に対する溶解性
の異なる２種以上の高分子物質からなる海島構造
を有する高分子相互配列体繊維や混合紡糸繊維な
どの極細繊維形成型繊維は、その少なくとも１成
分を溶解除去することにより、特に柔軟性に優
れ、手に吸い付くようなきわめてなめらかな感触
を有し、形態保持性に優れた不織布が得られるた
め、最も好ましく用いられる。 The ultrafine fibers used in the present invention include ultrafine fibers that are directly produced by a super draw method, a method of discharging through a large number of micropores, a method of jet spinning using a gas flow, etc., and are bundled together and bonded with another binding component. It is also possible to make a composite fiber into a single composite fiber, remove the binding components at an appropriate time in the nonwoven fabric manufacturing process, and regenerate it into ultrafine fibers. However, if the fiber becomes thin, spinning becomes unstable, and the nonwoven fabric manufacturing process Processing is difficult and difficult to handle, as the fibers may peel off during the process, causing problems; ultra-fine fibers are difficult to produce by direct spinning; and the resulting nonwoven fabric is somewhat less flexible. It is more preferable to use ultrafine fiber-forming fibers made of multiple components and to dissolve and remove at least one of the components at an appropriate time during the nonwoven fabric manufacturing process to convert the fibers into ultrafine fibers. That is, the microfiber-forming fibers preferably used in the present invention include, for example, fibers with a chrysanthemum-shaped cross section in which one component is radially interposed between other components, multilayer bimetal fibers, multilayer bimetal fibers with a donut-shaped cross section, So-called mixed spun fibers are made by mixing and melting chips or beads of two or more types of polymer substances, or by mixing and spinning melt components of two or more types of polymer substances, and there are many ultrafine fibers that are continuous in the fiber axis direction. These include polymer mutually arranged fibers that are arranged and aggregated and bonded with other components to form a single fiber, and two or more of these fibers may be mixed or used in combination. Ultra-fine fiber-forming fibers such as polymer mutual array fibers and mixed spun fibers having a sea-island structure consisting of two or more types of polymer substances with different solubility in solvents can be treated by dissolving and removing at least one component thereof. It is most preferably used because it provides a nonwoven fabric with excellent flexibility, an extremely smooth feel that sticks to the hand, and excellent shape retention.
また、本発明における極細繊維は繊維形成能を
有する高分子物質からなり、たとえば、ナイロン
６、ナイロン66、ナイロン12、共重合ナイロンな
どのポリアミド、ポリエチレンテレフタレート、
共重合ポリエチレンテレフタレート、ポリブチレ
ンテレフタレート、共重合ポリブチレンテレフタ
レートなどのポリエステル、ポリエチレン、ポリ
プロピレンなどのポリオレフイン、ポリウレタ
ン、ポリアクリルニトリルおよびビニル重合体な
どがあげられる。また本発明における極細繊維は
異種あるいは同種の高分子物質からなる複合繊維
であつてもよく、捲縮繊維、異形断面繊維、中空
繊維、レンコン状多孔繊維をも使用しうる。更
に、不織布内に含まれる極細繊維として異種の極
細繊維が混合されたものであつてもよい。また、
該極細繊維形成型繊維の結合成分あるいは溶解除
去成分としては、たとえば、ポリスチレン、ポリ
エチレン、ポリプロピレン、ポリアミド、ポリウ
レタン、アルカリ溶液に易溶出型の共重合ポリエ
チレンテレフタレート、ポリビニルアルコール、
共重合ポリビニルアルコール、スチレン―アクリ
ロニトリル共重合体、スチレンとアクリル酸の高
級アルコールエステルおよび／またはメタクリル
酸の高級アルコールエステルとの共重合体などが
用いられる。複合紡糸しやすいこと、溶解除去し
やすいこと、高速流体流の打撃によつて破壊され
やすいことなどのため、ポリスチレン、スチレン
とアクリロニトリルとの共重合体、スチレンとア
クリル酸の高級アルコールエステルおよび／また
はメタクリル酸の高級アルコールエステルとの共
重合体などのポリスチレン系重合体は好ましく用
いられる。更に延伸倍率が高くとれ強度の高い極
細繊維が得られるという点でスチレンとアクリル
酸の高級アルコールエステルおよび／またはメタ
クリル酸の高級アルコールエステルとの共重合体
は更に好ましく用いられる。また、高速流体流に
よる処理において該極細繊維形成型繊維を枝分か
れしやすくするという点で、結合成分あるいは溶
解除去成分にポリアルキレングリコール類などの
重合体を0.5〜30重量％混合して用いることが好
ましい。かかる極細繊維形成型繊維の繊度は特に
限定されるものではないが、紡糸における安定
性、不織布形成のしやすさなどから0.5〜10デニ
ールのものが好ましい。 Further, the ultrafine fibers in the present invention are made of polymeric substances having fiber-forming ability, such as polyamides such as nylon 6, nylon 66, nylon 12, copolymerized nylon, polyethylene terephthalate,
Examples include polyesters such as copolymerized polyethylene terephthalate, polybutylene terephthalate, and copolymerized polybutylene terephthalate, polyolefins such as polyethylene and polypropylene, polyurethane, polyacrylonitrile, and vinyl polymers. Further, the ultrafine fibers in the present invention may be composite fibers made of different or the same types of polymeric substances, and crimped fibers, irregular cross-section fibers, hollow fibers, and lotus root-like porous fibers may also be used. Furthermore, the nonwoven fabric may contain a mixture of different types of microfibers. Also,
Examples of the binding component or the dissolving and removing component of the microfiber-forming fiber include polystyrene, polyethylene, polypropylene, polyamide, polyurethane, copolymerized polyethylene terephthalate easily soluble in alkaline solutions, polyvinyl alcohol,
Copolymerized polyvinyl alcohol, styrene-acrylonitrile copolymer, copolymer of styrene and higher alcohol ester of acrylic acid and/or higher alcohol ester of methacrylic acid, etc. are used. Polystyrene, copolymers of styrene and acrylonitrile, higher alcohol esters of styrene and acrylic acid and/or Polystyrene polymers such as copolymers of methacrylic acid with higher alcohol esters are preferably used. Furthermore, a copolymer of styrene and a higher alcohol ester of acrylic acid and/or a higher alcohol ester of methacrylic acid is more preferably used because it can obtain a high stretching ratio and ultrafine fibers with high strength. In addition, in order to facilitate branching of the ultrafine fiber-forming fibers during treatment with high-speed fluid flow, it is recommended to mix 0.5 to 30% by weight of a polymer such as polyalkylene glycol with the binding component or the dissolution/removal component. preferable. The fineness of such microfiber-forming fibers is not particularly limited, but is preferably 0.5 to 10 deniers from the viewpoint of stability during spinning and ease of forming nonwoven fabrics.
極細繊維を束ねて一時的に接着処理をするのに
用いる結合成分としては、工業的安価さから水に
よつて除去できるもの、たとえばでんぷん、ポリ
ビニルアルコール、メチルセルロース、カルボキ
シメチルセルロースなどが好ましく、このほかに
も他の溶剤で溶解可能なポリビニール系ラテツク
ス、ポリブタジエン系接着剤、ポリウレタン系接
着剤、ポリエステル系接着剤、ポリアミド系接着
剤などの合成のり、天然のり、接着剤が用いられ
る。 As the binding component used to bundle the microfibers and temporarily bond them, it is preferable to use materials that can be removed with water due to their industrial cost, such as starch, polyvinyl alcohol, methyl cellulose, and carboxymethyl cellulose. Synthetic glues, natural glues, and adhesives such as polyvinyl latex, polybutadiene adhesives, polyurethane adhesives, polyester adhesives, and polyamide adhesives that can be dissolved in other solvents are also used.
本発明における極細繊維の繊度は0.5デニール
以下であることが必要である。0.5デニールより
太い場合は、繊維の剛性が過大で不織布の柔軟性
や感触が悪く、繊維を緻密に交絡させることが困
難である。好ましくは0.1デニール以下、より好
ましくは0.01デニール以下が適当である。更に、
0.005デニール未満の場合は繊維の交絡がきわめ
て緻密に行なえ、不織布の形態保持性がきわめて
良好なため特に好ましい。 The fineness of the ultrafine fibers in the present invention must be 0.5 denier or less. If it is thicker than 0.5 denier, the rigidity of the fibers is too high, resulting in poor flexibility and feel of the nonwoven fabric, and it is difficult to intertwine the fibers closely. It is preferably 0.1 denier or less, more preferably 0.01 denier or less. Furthermore,
When it is less than 0.005 denier, the fibers can be intertwined very closely, and the shape retention of the nonwoven fabric is very good, which is particularly preferable.
本発明の極細繊維束とは多数本の異種または同
種のステープルあるいはフイラメント状の極細繊
維が並列的に相互配列されたものであり、極細繊
維束を構成する極細繊維は極細繊維同志が相互に
動きうる自由度のある形態をしているものであ
る。このことは本発明においてきわめて重要な要
件である。すなわち、極細繊維が自由度己接着あ
るいは結合されて形成された繊維束においては、
束内において極細繊維は動くことができず、極細
繊維束とはいえども実際は、その繊維束のトータ
ル繊度に相当する１本の太い単繊維と同じ挙動を
示すものである。従つて前述した欠点のある不織
布しか得られないのである。 The ultrafine fiber bundle of the present invention is one in which a large number of staple or filament-like ultrafine fibers of different or similar types are arranged in parallel, and the ultrafine fibers constituting the ultrafine fiber bundle move with each other. It has a shape that allows for flexibility. This is an extremely important requirement in the present invention. In other words, in a fiber bundle formed by self-adhering or bonding ultrafine fibers with a degree of freedom,
The ultrafine fibers cannot move within the bundle, and although it is an ultrafine fiber bundle, it actually exhibits the same behavior as one thick single fiber corresponding to the total fineness of the fiber bundle. Therefore, only nonwoven fabrics with the above-mentioned drawbacks can be obtained.
本発明の不織布は、極細繊維と、束内の極細繊
維同志が相互に動きうる自由度のある形態の上記
極極細繊維束とが主体に実質的に不織布の全層に
わたつて混在し緻密に三次元交絡した構造を有す
るものである。 The non-woven fabric of the present invention is composed mainly of ultra-fine fibers and the above-mentioned ultra-fine fiber bundles that have a degree of freedom in which the ultra-fine fibers within the bundle can move relative to each other, and are densely mixed throughout substantially all the layers of the non-woven fabric. It has a three-dimensional entangled structure.
本発明の交絡不織布は、かかる構造を有するた
め、一体感のある風合を有するばかりでなく、柔
軟性に優れ、しかも織編物が内部に含まれていな
いにもかかわらず、形態保持性が良好で、更に、
手に吸い付くような感触を有し、折り曲げたとき
につのが出ずなめらかな曲面形態が得られ、厚さ
が薄くても高い強力を有する。 Because the intertwined nonwoven fabric of the present invention has such a structure, it not only has a unified texture but also has excellent flexibility, and has good shape retention even though it does not contain any woven or knitted fabric. And furthermore,
It feels like it sticks to your hand, has a smooth curved surface with no protrusions when bent, and has high strength even if it is thin.
また、本発明の交絡不織布を構成する繊維のほ
とんどは、一本の極細繊維がある部分では束を構
成し、またある部分では枝分かれしているため単
繊維と束とに別々には分けられない構造をしてい
るものが好ましい。このため、更に一体感の優れ
た風合を有し、しかも極細繊維が抜け落ちにくい
交絡不織布が得られるのである。 In addition, most of the fibers constituting the interlaced nonwoven fabric of the present invention form bundles in some areas where there is a single ultrafine fiber, and are branched in some areas, so they cannot be separated into single fibers and bundles. Preferably, it has a structure. Therefore, it is possible to obtain an interlaced nonwoven fabric that has a more unified feel and that the ultrafine fibers are less likely to fall off.
また、実質的に極細繊維束のみからなり繊維束
同志が繊維束の状態のまま相互に交絡した部分
と、極細繊維束と極細繊維が主体に緻密に交絡し
た部分を有し、両部分が厚み方向に偏つて分布し
た構造の不織布は、両部分での繊維の充てん度合
すなわち繊維の見掛密度や絡合の緻密さが大きく
異なるため、ルーズな方を外にして折り曲げると
紙様の深い折れジワになるのである。また、ルー
ズな部分が不織布の内部にある場合も同様に深い
折れジワが発生する。一方、ルーズな部分が外側
にある場合は、表面繊維がほつれて見苦しく毛羽
立ち、更には毛玉が発生しやすい欠点を有してい
る。すなわち、本発明の不織布におけるように、
極細繊維と極細繊維束が実質的に不織布の全層に
わたつて緻密に交絡した繊維構造にすることによ
つてはじめてこれらの欠点が解消されるのであ
る。 In addition, there is a part where the fiber bundles are essentially only made of ultra-fine fiber bundles and are intertwined with each other in the state of fiber bundles, and a part where the ultra-fine fiber bundles and ultra-fine fibers are mainly densely intertwined, and both parts have a thickness. Nonwoven fabrics with a structure that is unevenly distributed in one direction have large differences in the degree of fiber filling in the two parts, that is, the apparent density of fibers and the fineness of entanglement. This causes wrinkles. Furthermore, deep creases also occur when loose parts are inside the nonwoven fabric. On the other hand, if the loose parts are on the outside, the surface fibers become unsightly and fluffy, and furthermore, there is a drawback that pilling is likely to occur. That is, as in the nonwoven fabric of the present invention,
These drawbacks can only be overcome by creating a fiber structure in which ultrafine fibers and ultrafine fiber bundles are densely intertwined over substantially all layers of the nonwoven fabric.
また、本発明の不織布において、極細繊維束の
太さ（含まれる極細繊維の数）は、すべての束が
同じ太さである必要はなく、細いものから太いも
のまでバラエテイに富んだものである。束の形状
についても、含まれる極細繊維束間の距離が大き
くひらいたものもあれば小さく接近したものもあ
り、あるいは極細繊維同志が接触していてもよ
い。更に、極細繊維束の長さも、どこからどこま
でといつた明確なものでなく、極細繊維束からの
極細繊維の枝分かれの仕方によつていろいろであ
る。このように本発明の不織布はいろいろな形状
の極細繊維束と極細繊維とが混在し複雑に絡み合
つているものである。また、繊維の絡み合いの緻
密さについては、高速流体流の強い打撃によつて
打たれた極細繊維束や極細繊維が高速流体流の分
散とともにいろんな方向に押しやられ、割り込ん
だり、ねじれたり、絡んだりして高い交絡密度が
達成されているものである。この交絡の緻密さ
は、従来のニードルパンチのみによる交絡、縮じ
ゆうや収縮による交絡密度の向上などでは、とう
てい到達きない密度の高いものである。また、不
織布を構成している極細繊維や繊維束内の極細繊
維の長さは、あまりに短かいものでは不織布の強
力が弱くなつてしまう。不織布の製造するときに
使うもとの極細形成型繊維の長さをもとに言え
ば、15mm以上、好ましくは25mm以上、更に好まし
くは35mm以上が適当である。 Furthermore, in the nonwoven fabric of the present invention, the thickness of the ultrafine fiber bundles (the number of ultrafine fibers included) does not necessarily have to be the same for all bundles, but can vary from thin to thick. . Regarding the shape of the bundles, the distances between the bundles of ultrafine fibers may be wide apart in some cases, close to each other, or the ultrafine fibers may be in contact with each other. Furthermore, the length of the ultrafine fiber bundle is not clearly determined from where to where it ends, but varies depending on the way the ultrafine fibers are branched from the ultrafine fiber bundle. As described above, the nonwoven fabric of the present invention is a mixture of ultrafine fiber bundles and ultrafine fibers of various shapes and are intricately intertwined. In addition, regarding the density of fiber entanglement, the ultrafine fiber bundles and ultrafine fibers that are hit by the strong impact of the high-speed fluid flow are pushed in various directions as the high-speed fluid flow disperses, causing them to intertwine, twist, or become entangled. A high entanglement density has been achieved. The density of this intertwining is so high that it cannot be achieved by conventional methods such as intertwining only by needle punching or improving the intertwining density by shrinkage or shrinkage. Furthermore, if the length of the ultrafine fibers constituting the nonwoven fabric or the ultrafine fibers in the fiber bundle are too short, the strength of the nonwoven fabric will be weakened. Based on the length of the original ultrafine fibers used in producing the nonwoven fabric, the appropriate length is 15 mm or more, preferably 25 mm or more, and more preferably 35 mm or more.
本発明の交絡不織布は、次に述べる新規な方法
による具体的に実現させることができる。 The intertwined nonwoven fabric of the present invention can be specifically realized by the novel method described below.
先ず、前記の直接製造方法で製造した極細繊維
を束ね、１本の繊維として繊維束の状態を保持す
るために一時的に結合成分で接着処理を施した結
合繊維束、あるいは前記極細繊維形成型繊維のフ
イラメントもしくはしかるべき長さに切断したス
テープルを用いてウエブを形成する。次でニード
リングを施し、あるいは施さず他の方法などで一
次絡合構造を形成する。あるいは、異なる繊維か
らなるウエブ又は不織布を積層してニードリング
する。しかる後高速流体流を衝突させて、結合成
分あるいは溶解除去成分を破壊したり剥離したり
してもとの繊維を極細繊維や極細繊維のかたまり
や極細繊維束などに分散させ、同時に相互に緻密
の２次絡合させる。ここでいう流体とは、液体で
あつて、特別な場合は、きわめて微細な固体を含
むものであつてもよいが、取り扱いやすさ、コス
ト、流体としての衝突エネルギー量の点から、水
あるいは水に少量のポリアルキレンオキサイドや
ポリアクリルアミドを添加したものが最も好まし
く用いられる。更に目的に応じて、該極細繊維形
成型繊維の一部成分を溶解可能な種々の有機溶剤
あるいは水酸化ナトリウムなどのアルカリまたは
酸の水溶液なども使用できる。これらの流体を加
圧し、孔径の小さいノズルあるいは間隔のせまい
スリツトから噴射させ高速の柱状流あるいはカー
テン状流とし、繊維シートに衝突させ繊維の枝分
かれおよび交絡を行なう。液体にかける圧力は、
該極細繊維成形型繊維あるいは極細繊維束の枝分
かれのしやすさによつて異なり、枝分かれしやす
い繊維では、５〜100Kg／cm2の比較的低圧でよい
が、高分子配列体繊維や混合紡糸繊維など枝分か
れしにくい繊維では、100Kg／cm2を越え300Kg／cm2
の高圧が好ましい。また、処理回数をふやすこと
により枝分かれおよび交絡の程度および交絡深度
を高めることも可能であり、処理のたびごとに圧
力を変化させてもよい。また、ノズルを揺動させ
ることも好ましく採用される。次いで、結合成分
あるいは溶解除去成分のみを溶解し得る溶剤で該
結合成分あるいは溶解除去成分を溶解除去する。
ここで、高速流体流処理を結合成分または溶解除
去成分の除去後に行なつてもよい。この場合は、
ニードリングなどを施し絡合構造を形成した後ポ
リビニルアルコールなどの糊剤を付与して不織布
全体を一時固定し結合成分あるいは溶解除去成分
の溶解除去後該糊剤を除去し、または糊剤除去と
同時に高速流体処理を行ない、結合成分の溶解除
去時の不織布の形くずれを防止する工程を挿入す
ることも好ましい方法である。また、一部成分の
溶解除去の工程の前と後で高速流体流の処理を行
なつてもよい。 First, the ultrafine fibers produced by the above-mentioned direct production method are bundled together, and the bonded fiber bundle is temporarily adhesive-treated with a binding component to maintain the fiber bundle state as a single fiber, or the ultrafine fiber forming mold is produced. The web is formed using filaments of fibers or staples cut to length. Next, a primary entangled structure is formed by performing needling or by other methods without needling. Alternatively, webs or nonwoven fabrics made of different fibers are laminated and needled. After that, high-speed fluid streams are collided to destroy or separate the bonded components or dissolved and removed components, thereby dispersing the original fibers into ultra-fine fibers, clusters of ultra-fine fibers, and bundles of ultra-fine fibers, and at the same time making them mutually dense. Secondary entanglement of The fluid referred to here is a liquid, and in special cases it may contain extremely fine solids, but from the viewpoint of ease of handling, cost, and amount of collision energy as a fluid, water or water may be used. Most preferably used is one in which a small amount of polyalkylene oxide or polyacrylamide is added. Furthermore, depending on the purpose, various organic solvents capable of dissolving some components of the ultrafine fiber-forming fibers, or aqueous solutions of alkali or acids such as sodium hydroxide can be used. These fluids are pressurized and injected from a nozzle with a small diameter or narrowly spaced slits to form a high-speed columnar flow or curtain-like flow, which collides with the fiber sheet to branch and entangle the fibers. The pressure applied to the liquid is
It depends on the ease of branching of the ultrafine fiber moldable fibers or ultrafine fiber bundles. For fibers that are easy to branch, a relatively low pressure of 5 to 100 kg/cm 2 is sufficient, but for polymer array fibers and mixed spun fibers, For fibers that are difficult to branch, such as fibers that are difficult to branch, it exceeds 100Kg/cm 2 and 300Kg/cm 2
A high pressure of . It is also possible to increase the degree of branching and entanglement and the depth of entanglement by increasing the number of treatments, and the pressure may be changed each time the treatment is performed. It is also preferably employed to swing the nozzle. Next, the bound component or the dissolved and removed component is dissolved and removed using a solvent that can dissolve only the bound component or the dissolved and removed component.
Here, high velocity fluid flow treatment may be performed after removal of the bound or dissolved components. in this case,
After performing needling etc. to form an entangled structure, a sizing agent such as polyvinyl alcohol is applied to temporarily fix the entire nonwoven fabric, and the sizing agent is removed after dissolving and removing binding components or dissolving and removing components, or the sizing agent is removed. It is also a preferable method to simultaneously perform high-speed fluid treatment and insert a step to prevent the nonwoven fabric from deforming when the binding components are dissolved and removed. Further, high-speed fluid flow treatment may be performed before and after the step of dissolving and removing some components.
ただし、本発明の交絡不織布は、単に上記の方
法を実施したのでは得られず、以下の述べる多数
の要因のいくつかを適宜組み合せなければ達成さ
れない。これらの要因にもとづく交絡不織布の構
造に対する影響は、複雑に関係しあつており、本
発明を達成するに足る上記要因の組み合せは、一
律に規定し難いが、たとえば下記する諸要因の影
響力を参考にすることにより、得ることが可能と
なる。 However, the intertwined nonwoven fabric of the present invention cannot be obtained simply by implementing the above method, but can only be achieved by appropriately combining some of the many factors described below. The effects of these factors on the structure of the interwoven nonwoven fabric are intricately related to each other, and it is difficult to uniformly define a combination of the above factors that is sufficient to achieve the present invention. By referring to it, you can obtain it.
Ａ 一次絡合構造体の見掛密度、厚さ
高速流体流の処理をする前の一次絡合構造体の
見掛密度はあまりに低すぎると、高速流体流によ
る繊維の過度の移動が起り、単に高速流体流が一
次絡合構造体を貫通すると結果となり、極細繊維
とその束が緻密に三次元交絡している構造をとり
得ない。逆にこの見掛密度があまりに高すぎる
と、高速流体流の影響が一次絡合構造体の表面付
近にとどまり、実質的に全層にわたつて極細繊維
と極細繊維束が混在して交絡した構造の不織布が
得られない。一次絡合構造体の見掛密度は、好ま
しくは0.15ｇ／cm3ないし0.25ｇ／cm3が適当であ
る。A. Apparent density and thickness of the primary entangled structure If the apparent density of the primary entangled structure before high-speed fluid flow treatment is too low, excessive movement of fibers due to the high-speed fluid flow will occur, and the As a result, when a high-speed fluid flow penetrates the primary entangled structure, a structure in which ultrafine fibers and their bundles are densely entangled in three dimensions cannot be obtained. On the other hand, if this apparent density is too high, the influence of the high-speed fluid flow will remain near the surface of the primary entangled structure, resulting in an entangled structure in which ultra-fine fibers and ultra-fine fiber bundles are mixed and intertwined over virtually the entire layer. nonwoven fabric cannot be obtained. The apparent density of the primary entangled structure is preferably 0.15 g/cm 3 to 0.25 g/cm 3 .
一方、一次絡合構造体の厚さが過度に薄い場合
は、高速流体流により結合成分や溶解除去成分を
破壊したり剥離したりして本発明の構造の不織布
を得ようとすると、一次絡合構造体の破壊・切断
が起こり、本発明の目的を達成できない。一次絡
合構造体の厚さが過度に厚い場合は、高速流体流
の影響が一次絡合構造体の全層におよび難い。後
者の場合においては、流体噴射ノズルの孔径を
0.2mmφないし0.5mmφと大きくし、しかも表裏両
面から高速流体流処理を行なうという特別な手段
により、高速流体流の影響を一次絡合構造体の全
層にわたり及ばせることができる。 On the other hand, if the thickness of the primary entangled structure is excessively thin, attempting to obtain a nonwoven fabric having the structure of the present invention by destroying or peeling off the bonded components and dissolved/removed components using a high-speed fluid flow will result in the primary entangled structure being too thin. In this case, the composite structure is destroyed or cut, and the object of the present invention cannot be achieved. If the thickness of the primary entangled structure is excessively thick, it is difficult for the high-speed fluid flow to affect all layers of the primary entangled structure. In the latter case, the hole diameter of the fluid injection nozzle should be
By making the diameter larger to 0.2 mmφ to 0.5 mmφ and performing high-speed fluid flow treatment from both the front and back sides, the influence of the high-speed fluid flow can be spread over all layers of the primary entangled structure.
すなわち、本発明の不織布を得るための高速流
体流処理における要件としては、高速流体流によ
る交絡深度が片面からの処理で不織布の厚さの少
なくとも２分の１まで到達する条件で処理するこ
とが必要である。 That is, the requirements for the high-speed fluid flow treatment to obtain the nonwoven fabric of the present invention are that the treatment must be performed under conditions such that the entanglement depth due to the high-speed fluid flow reaches at least one half of the thickness of the nonwoven fabric when treated from one side. is necessary.
Ｂ 高速流体流処理の方法
本発明を達成するための有利な高速流体流処理
方法としては、流体噴射ノズルの孔径を0.2mmφ
ないし0.5mmφと大きくすること、流体にかける
圧力を100Kg／cm2を越える高圧にすること、流体
流の形状を柱状に保つこと、噴射した流体をすみ
やかに一次絡合構造体から除去して流体の滞留を
防ぐこと、および、多数回の処理を行なうこと等
が挙げられ、とりわけ、流体噴射ノズルの孔径を
大きくすることが効果的である。B. Method of high-speed fluid flow treatment An advantageous high-speed fluid flow treatment method for achieving the present invention is to reduce the hole diameter of the fluid injection nozzle to 0.2 mmφ.
or 0.5mmφ, the pressure applied to the fluid should be high pressure exceeding 100Kg/ cm2 , the shape of the fluid flow should be maintained in a columnar shape, and the injected fluid should be promptly removed from the primary entangled structure to For example, it is effective to prevent the accumulation of fluid and to perform the treatment multiple times, among others, it is effective to increase the hole diameter of the fluid injection nozzle.
Ｃ 一次絡合構造体を構成する結合繊維束または
極細繊維形成型繊維の特性
結合繊維束の結合成分または極細繊維形成型繊
維の溶解除去成分の高速流体流の打撃による被破
壊特性を考慮する必要がある。C Characteristics of the bonded fiber bundle or ultrafine fiber-forming fibers constituting the primary entangled structure It is necessary to consider the characteristics of the bonded components of the bonded fiber bundle or the dissolved and removed components of the ultrafine fiber-formed fibers due to impact from high-speed fluid flow. There is.
本発明を達成するためには、この被破壊特性が
高いものが有利である。また、結合繊維束あるい
は極細繊維形成型繊維の太さおよび形態、形成さ
れる極細繊維の太さおよび形態、およびこれらを
構成する成分の種類、比率等が上記被破壊特性に
影響に及ぼすので、考慮する必要がある。 In order to achieve the present invention, it is advantageous to have high breakage resistance. In addition, the thickness and form of the bonded fiber bundle or ultrafine fiber-forming fiber, the thickness and form of the formed ultrafine fiber, and the types and ratios of the components constituting these affect the above-mentioned breakage characteristics. need to be considered.
本発明の不織布をつくるにあたつて必ずしも
100％極細繊維を用いる必要はなく、本発明の目
的をそこなわない範囲で他の繊維を混入したりす
ることもできる。また、本発明の不織布に、バイ
ンダー樹脂の付与、バフイングや針布などによる
起毛加工、染色加工、揉み加工などの処理を必要
に応じて行なつてもよく、更に、柔軟剤付与、加
脂、帯電防止剤付与、抗菌剤付与、香料剤付与な
どを行なつて機能性をもたせることも不織布の適
用範囲を拡大するうえで好ましい。とくに、本発
明の不織布をそのままかあるいは少量のバインダ
ー樹脂を付与し染色仕上げを行なうことにより、
きわめて柔軟で感触がよく、特別に起毛処理を行
なわなくても短かい毛羽が密生し、ヌバツク調の
外観を有する素肌に着ても異和感のないものが得
られる。 In making the nonwoven fabric of the present invention, it is not necessary to
It is not necessary to use 100% ultrafine fibers, and other fibers may be mixed in as long as the purpose of the present invention is not impaired. Furthermore, the nonwoven fabric of the present invention may be subjected to treatments such as applying a binder resin, buffing or raising with a cloth, dyeing, and rubbing as necessary. It is also preferable to impart functionality by adding an antistatic agent, an antibacterial agent, a flavoring agent, etc. to expand the range of application of the nonwoven fabric. In particular, by dyeing the nonwoven fabric of the present invention as it is or adding a small amount of binder resin,
It is extremely soft and has a good feel, has short fluff that grows densely even without special napping treatment, and has a nubuck-like appearance that does not feel strange when worn on bare skin.
このようにして得られた本発明の不織布は、柔
軟性に優れかつ不織布単独でも形態がくずれにく
く、特に水など液体を含んだ湿潤状態での形態保
持性に優れ、手に吸い付くような感触や高い吸水
性を有し、紙様の深い折れジワが発生し難く、薄
くても高い強力を有するなどの優れた特徴を有す
るものである。こをため、おむつ、包帯、おしぼ
り、テイツシユペーパー、布巾、タオル、各種フ
イルター、化学ぞうきん、グリツプなどの把手部
材、各種カバー、人工皮革の基布、家具・自動
車・ガラス用みがきクロス、研摩布、カセツトパ
ツド、人工セーム革、ライターの燃料調整弁、各
種手袋などに好ましく用いられる。 The nonwoven fabric of the present invention obtained in this way has excellent flexibility and does not easily lose its shape even when used as a nonwoven fabric alone, has excellent shape retention especially in wet conditions containing liquids such as water, and has a texture that sticks to the hand. It has excellent characteristics such as high water absorbency, low paper-like deep creases, and high strength even though it is thin. For this purpose, diapers, bandages, wet towels, tissue paper, dish cloths, towels, various filters, chemical cloths, handles such as grips, various covers, artificial leather base fabrics, polishing cloths for furniture, automobiles, and glass, polishing cloths. It is preferably used for cassette pads, artificial chamois, lighter fuel control valves, various types of gloves, etc.
以下に示す実施例は、本発明をより明確にする
ためのものであつて、本発明はこれに限定される
ものではない。実施例において、部および％とあ
るのは特に記載のないかぎり重量に関するもので
ある。 The examples shown below are for the purpose of clarifying the present invention, and the present invention is not limited thereto. In the examples, parts and percentages are by weight unless otherwise specified.
実施例 １
ポリスチレン94部とポリエチレングリコール６
部の混合物を結合成分として45部、極細繊維成分
としてポリエチレンテレフタレート55部なる割合
で１フイラメント中に240本の極細繊維が含まれ
る形態の、特開昭57−39209号公報に示されたご
とき装置を用いて製造した高分子相互配列体繊維
の3.5デニール、51mmのステープルを用いてカー
ド、クロスラツパーを通してウエブを形成し、し
かる後フツクの数が１個のデニールを用いてデニ
ールパンチをして該高分子相互配列体繊維を絡合
させ不織布(a)をつくつた。不織布(a)の見掛密度は
約0.19ｇ／cm2、厚さは約1.85mmであつた。Example 1 94 parts of polystyrene and 6 parts of polyethylene glycol
A device as shown in JP-A No. 57-39209, in which 240 ultrafine fibers are contained in one filament in a ratio of 45 parts of a mixture of 50% and 50% of polyethylene terephthalate as a binding component and 55 parts of polyethylene terephthalate as an ultrafine fiber component. A 3.5 denier, 51 mm staple of polymeric interlayer fibers produced using a 3.5 denier, 51 mm staple is passed through a card and a cross wrapper to form a web, and then denier punched using a denier with a hook number of 1 to form a web. A nonwoven fabric (a) was created by intertwining the molecularly arranged fibers. The nonwoven fabric (a) had an apparent density of about 0.19 g/cm 2 and a thickness of about 1.85 mm.
孔径0.25mmφの孔が孔の中心間距離2.2mmのピ
ツチで一列に並んだノズルから、ノズルを５Hzで
揺動させながら105Kg／cm2の圧力をかけた水を高
速で柱状流噴射させ、移動しているステンレス金
網支持体の上に乗せた不織布(a)に衝突させ、同じ
条件で表裏２回ずつ処理し不織布(b)を得た。得ら
れた不織布(b)は、全層にわたつて、結合成分であ
るポリスチレンとポリエチレングリコールが破壊
され、高分子配列体繊維が極細繊維と極細繊維束
のかたまりに枝分かれされ複雑に三次元交絡して
いるものであつた。しかし、柔軟性はまだそれほ
どでなく、感触もなめらかでなく、紙様の折れジ
ワを有するものであつた。 From a nozzle in which holes with a hole diameter of 0.25 mmφ are arranged in a row with a pitch of 2.2 mm between the centers of the holes, water under a pressure of 105 kg/cm 2 is jetted in a columnar flow at high speed while the nozzle is oscillated at 5 Hz. The nonwoven fabric (a) placed on a stainless steel wire mesh support was subjected to collision with the nonwoven fabric (a), and treated twice on both sides under the same conditions to obtain a nonwoven fabric (b). In the obtained nonwoven fabric (b), the binding components polystyrene and polyethylene glycol are destroyed throughout the entire layer, and the polymer array fibers are branched into ultrafine fibers and ultrafine fiber bundles and are intricately intertwined in three dimensions. It was something I had. However, the flexibility was still not that great, the feel was not smooth, and there were folds and wrinkles similar to paper.
次に、不織布(a)および不織布(b)とそれぞれ95℃
に加温したポリビニルアルコール（以下PVAと
いう）の５％水溶液に浸漬しPVAの含浸と同時
に不織布の収縮を行ない乾燥して水分を除去した
後、ロルエチレン中につけ、浸漬、絞液をくり返
し結合成分を抽出除去し乾燥した。さらに温水で
PVAを抽出除去し乾燥した。不織布(a)から得ら
れた不織布は極細繊維が実質的に束のまま交絡し
た不織布で、柔軟性にはきわめて優れていたが、
ちよつと手で張つただけで大きな伸びを示し手を
はなしてもほとんど元にもどらず形くずれや毛羽
立ちしやすいものであつた。一方、不織布(b)から
得られたものは束内の極細繊維同志が相互に動き
うる極細繊維束と枝分かれした極細繊維が不織布
の全層にわたつて複雑に緻密にからみ合つている
もので、少々手で引つ張つた程度では形くずれし
ないものであつた。また、手でにぎつてみると表
面感触が手に吸い付くようであり折り曲げ端もな
めらかな曲面を描いていた。極細繊維の繊度は約
0.008デニールで不織布(b)から得られた不織布の
見掛密度は約0.40ｇ／cm3、厚さは0.55mmであつ
た。これだけ厚さが薄いにもかかわらず、不織布
の破断強力は11Kg／１cm巾当りときわめて高いも
のであつた。 Next, the nonwoven fabric (a) and the nonwoven fabric (b) were heated at 95°C.
The nonwoven fabric is immersed in a 5% aqueous solution of polyvinyl alcohol (hereinafter referred to as PVA) heated to 100 mL, and simultaneously impregnated with PVA, the nonwoven fabric is shrunk, dried to remove water, and then immersed in rollethylene and repeatedly immersed and squeezed to remove the bonding components. It was extracted and dried. More warm water
PVA was extracted and removed and dried. The nonwoven fabric obtained from nonwoven fabric (a) was a nonwoven fabric in which ultrafine fibers were entangled in substantially bundles, and had extremely excellent flexibility.
It would stretch a lot just by stretching it with your hands, and it would hardly return to its original shape even if you removed your hands, making it easy to lose its shape and become fluffy. On the other hand, the material obtained from non-woven fabric (b) consists of ultra-fine fiber bundles in which the ultra-fine fibers within the bundle can move with each other and branched ultra-fine fibers that are intricately and densely intertwined throughout the entire layer of the non-woven fabric. It did not lose its shape even after being pulled a little by hand. Furthermore, when pressed with the hand, the surface felt as if it would stick to the hand, and the bent edges had a smooth curved surface. The fineness of the ultra-fine fiber is approximately
The nonwoven fabric obtained from nonwoven fabric (b) with a denier of 0.008 had an apparent density of about 0.40 g/cm 3 and a thickness of 0.55 mm. Despite its small thickness, the breaking strength of the nonwoven fabric was extremely high at 11 kg/cm width.
一方、不織布(b)において、トリクロルエチレン
で結合成分と溶解除去し乾燥した後、ポリウレタ
ンの７％ジメチルホルムアミド溶液を含浸し、絞
浸水中で凝固し、しかる後80℃の熱水中で十分洗
浄しジメチルホルムアミドを除去し乾燥した。し
かる後、表裏両面をサンドペーパーで軽くバフイ
ングし、サーキユラー液流染色機を用い、分散染
料で120℃高温染色し仕上げ処理を行なつた。得
られた不織布は、厚さが0.45mmときわめて薄くて
ドレープ性があり柔軟なもので、高級なスエード
調外観を有しているものであつた。 On the other hand, in the nonwoven fabric (b), after dissolving and removing the bound components with trichlorethylene and drying, impregnated with a 7% dimethylformamide solution of polyurethane, coagulated in squeezing water, and then thoroughly washed in hot water at 80°C. The dimethylformamide was removed and the mixture was dried. After that, both the front and back sides were lightly buffed with sandpaper, and finished by dyeing with disperse dye at a high temperature of 120°C using a circular jet dyeing machine. The obtained nonwoven fabric was extremely thin with a thickness of 0.45 mm, had drapability, was flexible, and had a high-grade suede-like appearance.
実施例 ２
実施例１でつくつた不織布(a)を95℃に加温した
PVAの５％水溶液に浸漬しPVAの含浸と同時に
不織布の収縮を行ない乾燥して水分を除去した
後、トリクロルエチレン中につけ、浸漬、絞液を
くり返し結合成分を抽曲除去し乾燥した。得られ
た不織布は極細繊維が実質的に束のまま交絡した
不織布であり、この両面に実施例１と同じノズル
を用いて90Kg／cm2の圧力をかけた水を高速で噴射
させ、あとは実施例１と同り条件でそれぞれの面
に合計２回ずつの処理を行ないPVAの溶解と同
時に枝分かれ、交絡を行なつた。残つたPVAを
温水で抽出除去後乾燥した。得られた不織布は、
不織布の全層にわたつてもとの極細繊維束が高度
に枝分かれしており、極細繊維同志が自由に動き
うる極細繊維束と枝分かれした極細繊維が緻密に
交絡した繊維構造を有するものであつた。この不
織布は、きわめて形態保持性がよく柔軟なもの
で、３mm巾にスリツトし靴ひもとして使用した
が、なかなか切れず革ひものようにきわめて丈夫
であつた。Example 2 The nonwoven fabric (a) produced in Example 1 was heated to 95°C.
The nonwoven fabric was immersed in a 5% aqueous solution of PVA, and simultaneously impregnated with PVA, the nonwoven fabric was shrunk and dried to remove moisture, and then immersed in trichlorethylene, immersed and squeezed repeatedly to remove the bonded components and dried. The obtained nonwoven fabric is a nonwoven fabric in which ultrafine fibers are essentially intertwined in bundles, and water under a pressure of 90 kg/cm 2 is sprayed on both sides of this fabric at high speed using the same nozzle as in Example 1, and the rest is done. Each surface was treated twice in total under the same conditions as in Example 1 to dissolve PVA and simultaneously branch and entangle. The remaining PVA was extracted and removed with warm water and then dried. The obtained nonwoven fabric is
The original ultrafine fiber bundles were highly branched throughout the entire layer of the nonwoven fabric, and the fabric had a fiber structure in which the ultrafine fiber bundles and branched ultrafine fibers were densely intertwined, allowing the ultrafine fibers to move freely among themselves. . This nonwoven fabric has excellent shape retention and flexibility, and when it was slit into 3 mm width and used as shoelaces, it did not easily break and was extremely strong, like a leather lace.
実施例 ３
静止形分割素子が内部に組み込まれた構造を有
する多成分繊維用紡糸装置を用いて、２―エチル
ヘキシルアクリレート20部、スチレン80部の割合
で共重合させたビニール系ポリマ（以下AS樹脂
という）を結合成分として60部、極細繊維成分と
してナイロン６が40部からなる割合で１フイラメ
ント中に７本の島成分を有し、更にそのおのおの
の島成分中に極細繊維成分が約100本ずつ含まれ
る形態の高分子相互配列体繊維の4.0デニール、
51mmのステープルを得、これを用いて実施例１と
同様の方法で、見掛密度0.17ｇ／cm3、厚み2.2mm
の不織布をつくつた。この不織布に、高速流体流
処理、PVA付与、結合成分の溶解除去を順次実
施例１と同じ条件で行なつた。得られた不織布の
極細繊維の繊度は太いものでも0.005デニールに
は達せずほとんどは0.001〜0.004デニールのもの
であつた。また得られた不織布は、全層にわたつ
て極細繊維とと自由度のある極細繊維束が複雑に
緻密に交絡しており、柔軟性に優れ、なめらなか
感触を有し、折れジワの発生もなく強力の強いも
のであつた。Example 3 A vinyl polymer (hereinafter referred to as AS resin) was copolymerized with 20 parts of 2-ethylhexyl acrylate and 80 parts of styrene using a multicomponent fiber spinning device having a structure in which a stationary splitting element was incorporated. ) as a binding component and 40 parts of nylon 6 as an ultrafine fiber component, each filament has seven island components, and each island component has approximately 100 microfiber components. 4.0 denier of polymeric interarray fibers in the form of
Obtain a 51 mm staple and use it in the same manner as in Example 1 to obtain an apparent density of 0.17 g/cm 3 and a thickness of 2.2 mm.
We made non-woven fabric. This nonwoven fabric was subjected to high-speed fluid flow treatment, application of PVA, and dissolution and removal of bound components under the same conditions as in Example 1. The fineness of the ultrafine fibers of the obtained nonwoven fabric did not reach 0.005 denier even if it was thick, and most of them were 0.001 to 0.004 denier. In addition, the obtained nonwoven fabric has ultrafine fibers and ultrafine fiber bundles with a high degree of freedom intertwined in a complex and dense manner throughout the entire layer, and has excellent flexibility, a smooth feel, and no creases or creases. It was incredibly powerful.
この不織布を含金染料を用い95℃常圧で染色し
仕上げ処理を行なつたところ、表裏両面に微細で
毛羽が密生したヌバツク調外観の不織布が得られ
た。厚さが、0.49mmと薄く柔軟であつたため、Ｔ
シヤツにしたてて着用したところ、夏においても
暑くるしさは感じられず、むしろ、汗の外気への
放出が早いためさわやかで肌ざわりのよいもので
あつた。また、ひと夏ずつと着用してみたが、み
ぐるしい形くずれや破れはみられなかつた。 When this nonwoven fabric was dyed using a metal-containing dye at 95°C under normal pressure and subjected to finishing treatment, a nonwoven fabric with a nubuck-like appearance was obtained, with fine fluff densely growing on both the front and back sides. Because the thickness was 0.49 mm and flexible, T
When I wore it as a shirt, I didn't feel hot even in the summer; in fact, it was refreshing and felt nice to the touch because the sweat was released quickly into the outside air. I also wore it one summer at a time, but it didn't show any noticeable deformation or tearing.
実施例 ４
ポリスチレンを結合成分として55部、極細繊維
成分としてナイロン６を45部の割合で１フイラメ
ント中に多数の極細繊維が含まれる海島構造の混
合紡糸繊維の５デニール、63mmのステープルを用
いてランダムウエツパーを通してウエブを形成
し、しかる後ニードルパンチをして不織布をつく
つた。不織布の見掛密度は0.15ｇ／cm2、厚さは
2.5mmであつた。Example 4 Using a 5-denier, 63-mm staple of a sea-island structure mixed spun fiber in which one filament contains a large number of ultra-fine fibers in a ratio of 55 parts of polystyrene as a binding component and 45 parts of nylon 6 as an ultra-fine fiber component. A web was formed by passing it through a random wetper, and then needle punched to make a nonwoven fabric. The apparent density of the nonwoven fabric is 0.15g/cm 2 and the thickness is
It was 2.5mm.
孔径0.13mmの孔が孔の中心間距離0.6mmのピツ
チで一列に並んだノズルから160Kg／cm2の圧力を
かけた水を、不織布を小孔のあけられた多孔板に
のせて移動させ、更にノズルを振動させながら、
不織布の表面の高速で衝突させた。同じ条件で裏
面側からも処理した。しかる後、ぬれたまま95℃
の熱水中へ導びき収縮を行ないマングルで軽くニ
ツプした後乾燥した。つぎに、トリクロルエチレ
ン中につけ、絞液、浸漬をくり返してポリスチレ
ンを溶解除去し、ついで乾燥した。得られた不織
布の極細繊維は、太いものでも0.01デニール以下
でほとんどは0.003〜0.008デニールのものであつ
た。また、得られた不織布は、全層にわたつて、
束内の極細繊維が動きうる形態の極細繊維束と極
細繊維とが緻密に交絡しており、きわめて肌ざわ
りがソフトでやわらかく、水に浸して強くねじつ
て絞つてみてもほとんど形くずれしないものであ
つた。また、水の浸透性や水のふき取り性もよ
く、ワイピングクロスとして天然皮革のカーム革
と同等の性能を有するものであつた。 A nonwoven fabric was placed on a perforated plate with small holes and water was applied with a pressure of 160 kg/cm 2 from a nozzle in which holes with a diameter of 0.13 mm were arranged in a row with a center-to-center distance of 0.6 mm. Furthermore, while vibrating the nozzle,
Impacted at high speed on the surface of the non-woven fabric. The back side was also treated under the same conditions. After that, keep it wet at 95℃.
The material was placed in hot water to shrink, lightly nipped with a mangle, and then dried. Next, it was immersed in trichlorethylene, and the polystyrene was dissolved and removed by repeated squeezing and dipping, and then dried. The ultrafine fibers of the obtained nonwoven fabric were 0.01 denier or less even if they were thick, and most of them were 0.003 to 0.008 denier. In addition, the obtained nonwoven fabric has the following characteristics throughout the entire layer:
The ultra-fine fiber bundles and ultra-fine fibers are tightly intertwined with each other in a form in which the ultra-fine fibers within the bundle can move, making it extremely soft to the touch and barely retaining its shape even when soaked in water and strongly twisted and squeezed. Ta. In addition, it had good water permeability and water wiping properties, and had the same performance as a natural leather, Calm Leather, as a wiping cloth.
Claims (1)
0.5デニール以下の極細繊維と、(B)極細繊維束を
構成する該極細繊維が極細繊維同志相互に動きう
る自由度のある状態で配列された構造を有する極
細繊維束とが主体に混在し緻密に三次元交絡して
いる構造を有することを特徴とする交絡不織布。 ２ 極細繊維の繊度が0.01デニール以下であるこ
とを特徴とする特許請求の範囲第１項に記載の交
絡不織布。 ３ 極細繊維の繊度が0.005デニール未満である
ことを特徴とする特許請求の範囲第１項に記載の
交絡不織布。 ４ 極細繊維および極細繊維束が、複数の極細繊
維成分が他の結合成分により介在的に結合された
横断面を有する結合繊維束から極細繊維を再生し
て得られたものであることを特徴とする特許請求
の範囲第１項〜第３項のいずれかに記載の交絡不
織布。 ５ 極細繊維および極細繊維束が、溶剤に対する
溶解性の異なる２種以上の高分子物質からなる極
細繊維形成型繊維の少なくとも１成分を溶解除去
して得られたものであることを特徴とする特許請
求の範囲第１項〜第３項のいずれかに記載の交絡
不織布。 ６ 極細繊維形成型繊維が海島構造を有する高分
子相互配列体繊維および／または混合紡糸繊維で
あることを特徴とする特許請求の範囲第５項に記
載の交絡不織布。[Scope of Claims] 1. Over substantially the entire layer of the interlaced nonwoven fabric, (A)
A dense fiber mainly composed of ultrafine fibers of 0.5 denier or less and (B) an ultrafine fiber bundle having a structure in which the ultrafine fibers constituting the ultrafine fiber bundle are arranged with a degree of freedom in which the ultrafine fibers can mutually move. An intertwined nonwoven fabric characterized by having a three-dimensional intertwined structure. 2. The interlaced nonwoven fabric according to claim 1, wherein the ultrafine fibers have a fineness of 0.01 denier or less. 3. The interlaced nonwoven fabric according to claim 1, wherein the fineness of the ultrafine fibers is less than 0.005 denier. 4. The ultrafine fibers and the ultrafine fiber bundle are obtained by regenerating ultrafine fibers from a bonded fiber bundle having a cross section in which a plurality of ultrafine fiber components are interposedly bonded by other bonding components. The interlaced nonwoven fabric according to any one of claims 1 to 3. 5. A patent characterized in that the ultrafine fibers and ultrafine fiber bundles are obtained by dissolving and removing at least one component of ultrafine fiber-forming fibers made of two or more types of polymer substances with different solubility in solvents. The intertwined nonwoven fabric according to any one of claims 1 to 3. 6. The interlaced nonwoven fabric according to claim 5, wherein the ultrafine fiber-forming fibers are polymeric mutual array fibers and/or mixed spun fibers having a sea-island structure.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP58176397A JPS6071752A (en) | 1983-09-26 | 1983-09-26 | Interlaced nonwoven fabric |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP58176397A JPS6071752A (en) | 1983-09-26 | 1983-09-26 | Interlaced nonwoven fabric |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS6071752A JPS6071752A (en) | 1985-04-23 |
| JPH0118178B2 true JPH0118178B2 (en) | 1989-04-04 |
Family
ID=16012948
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP58176397A Granted JPS6071752A (en) | 1983-09-26 | 1983-09-26 | Interlaced nonwoven fabric |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS6071752A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2005007960A1 (en) | 2003-07-18 | 2005-01-27 | Toray Industries, Inc. | Micro staple fiber nonwoven fabric and leather-like article in sheet form, and method for their production |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS63219653A (en) * | 1987-03-06 | 1988-09-13 | 東レ株式会社 | Extremely fine multifilament nonwoven fabric and its production |
| JP2000345406A (en) * | 1999-06-09 | 2000-12-12 | Toray Ind Inc | Handkerchief and its production |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS49101510A (en) * | 1973-02-07 | 1974-09-25 |
-
1983
- 1983-09-26 JP JP58176397A patent/JPS6071752A/en active Granted
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS49101510A (en) * | 1973-02-07 | 1974-09-25 |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2005007960A1 (en) | 2003-07-18 | 2005-01-27 | Toray Industries, Inc. | Micro staple fiber nonwoven fabric and leather-like article in sheet form, and method for their production |
| US7998887B2 (en) | 2003-07-18 | 2011-08-16 | Toray Industries, Inc. | Nonwoven fabric containing ultra-fine fibers, leather-like sheet, and production methods thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| JPS6071752A (en) | 1985-04-23 |
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