JP2014037644A - Short-cut fiber for wet-laid nonwoven fabric - Google Patents
Short-cut fiber for wet-laid nonwoven fabric Download PDFInfo
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- JP2014037644A JP2014037644A JP2012180299A JP2012180299A JP2014037644A JP 2014037644 A JP2014037644 A JP 2014037644A JP 2012180299 A JP2012180299 A JP 2012180299A JP 2012180299 A JP2012180299 A JP 2012180299A JP 2014037644 A JP2014037644 A JP 2014037644A
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- CNGYZEMWVAWWOB-VAWYXSNFSA-N 5-[[4-anilino-6-[bis(2-hydroxyethyl)amino]-1,3,5-triazin-2-yl]amino]-2-[(e)-2-[4-[[4-anilino-6-[bis(2-hydroxyethyl)amino]-1,3,5-triazin-2-yl]amino]-2-sulfophenyl]ethenyl]benzenesulfonic acid Chemical compound N=1C(NC=2C=C(C(\C=C\C=3C(=CC(NC=4N=C(N=C(NC=5C=CC=CC=5)N=4)N(CCO)CCO)=CC=3)S(O)(=O)=O)=CC=2)S(O)(=O)=O)=NC(N(CCO)CCO)=NC=1NC1=CC=CC=C1 CNGYZEMWVAWWOB-VAWYXSNFSA-N 0.000 description 2
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Landscapes
- Multicomponent Fibers (AREA)
- Nonwoven Fabrics (AREA)
Abstract
Description
近年、湿式短繊維不織布はフィルター用基材、電池セパレーターなどの用途に広く用いられている。このような用途において、性能の高いフィルターやセパレーターとするには、厚みが薄く、通気度の低い湿式不織布が求められている。 In recent years, wet short fiber nonwoven fabrics have been widely used for applications such as filter substrates and battery separators. In such applications, wet nonwoven fabrics having a small thickness and a low air permeability are required for high performance filters and separators.
通気度の低い不織布を得るには、繊維間の隙間を少なくし、気密性を高くすることが必要である。例えば、特許文献１や特許文献２には単糸繊度が０．５ｄｔｅｘ以下の細繊度の繊維を用いることにより、繊維間の空隙を小さくし、気密性を高くした短繊維不織布を得る方法が提案されている。 In order to obtain a non-woven fabric with low air permeability, it is necessary to reduce the gaps between the fibers and increase the airtightness. For example, Patent Document 1 and Patent Document 2 propose a method of obtaining a short fiber nonwoven fabric in which the gap between the fibers is reduced and the air tightness is increased by using fine fibers having a single yarn fineness of 0.5 dtex or less. Has been.
０．５ｄｔｅｘ以下の繊維を得るには、単一のポリマーで紡糸、延伸して直接繊維を得る方法と、複数のポリマーを用いた複合繊維で紡糸、延伸を行い、ある程度太い繊維を得た後に割繊することで０．５ｄｔｅｘ以下の繊維を得る方法がある。割繊の方法としては、相溶性に乏しい複数のポリマーからなる複合繊維に物理的な衝撃を与えることにより、繊維を構成するポリマーの界面を剥離分割して細繊度の繊維を得る機械的割繊と、有機溶媒に溶けやすいポリマーと溶けにくいポリマーとからなる複合繊維を、有機溶媒を浸す等によって、繊維を構成する一部のポリマー（有機溶媒に溶けやすいポリマー）を溶解させ、有機溶媒に溶けにくいポリマーのみにより構成される細繊度の繊維を得る化学的割繊が挙げられる。 In order to obtain a fiber of 0.5 dtex or less, after spinning and drawing with a single polymer and directly obtaining the fiber, and after spinning and drawing with a composite fiber using a plurality of polymers to obtain a somewhat thick fiber There is a method of obtaining fibers of 0.5 dtex or less by splitting. As a method of splitting, mechanical splitting is performed by giving a physical impact to a composite fiber composed of a plurality of polymers having poor compatibility, thereby separating and dividing the interface of the polymer constituting the fiber to obtain a fine fiber. In addition, by immersing the organic fiber in a composite fiber composed of a polymer that is easily soluble in an organic solvent and a polymer that is difficult to dissolve, a part of the polymer (polymer that is soluble in an organic solvent) is dissolved and dissolved in the organic solvent. Examples include chemical splitting to obtain fine fibers composed only of difficult polymers.
細繊度の繊維を直接得る方法は、紡糸、延伸時に糸切れが発生しやすく、生産性が低下するのでコスト的に不利である。細繊度の繊維を機械的割繊で得る方法は、コスト的には不利ではないが、割繊後に得られた繊維は、相溶性に乏しい複数の繊維が混ざったものとなり、これらの繊維から得られる湿式不織布は性能の劣るものになりやすい。 The method of directly obtaining fine fibers is disadvantageous in terms of cost because yarn breakage is likely to occur during spinning and drawing, and productivity is reduced. The method of obtaining finely divided fibers by mechanical splitting is not disadvantageous in terms of cost, but the fibers obtained after splitting are a mixture of a plurality of fibers having poor compatibility, and are obtained from these fibers. The resulting wet nonwoven fabric tends to be inferior in performance.
細繊度の繊維を化学的割繊で得る方法は、紡糸、延伸で得られた繊維の一部を溶媒で溶解除去をするため、得られる細繊度の繊維の量が減り、コスト的に不利である。さらに、溶媒の再生、回収設備が必要となる点でもコスト的に不利である。 The method of obtaining finely divided fibers by chemical splitting involves dissolving and removing part of the fibers obtained by spinning and drawing with a solvent, which reduces the amount of fine fibers obtained and is disadvantageous in terms of cost. is there. Furthermore, it is disadvantageous in terms of cost in that a solvent regeneration and recovery facility is required.
細繊度の繊維を用いることによって通気度の低い不織布を得る方法では、確かに通気度は低下するものの、不織布内の空隙のサイズも同様に小さくなるため、例えば、フィルターとして用いた場合は目詰まりが早くなり、フィルター寿命が短いものとなる。このため、捕捉する粒子に応じて、フィルターを構成する繊維の繊維径を適宜調節することが必要となり管理が煩雑となる。 In the method of obtaining a non-woven fabric with low air permeability by using fine fibers, although the air permeability is certainly reduced, the size of the voids in the non-woven fabric is similarly reduced, so for example, when used as a filter, it becomes clogged. The filter life is shortened and the filter life is shortened. For this reason, it is necessary to appropriately adjust the fiber diameter of the fibers constituting the filter according to the particles to be captured, and management becomes complicated.
本発明は上記の問題点を解決するものであって、コスト的に有利に製造することができるショートカット繊維であり、性能の優れたフィルターやセパレーター用途に好適な通気度の低い湿式不織布を得ることができる湿式不織布用ショートカット繊維を提供することを技術的な課題とするものである。 The present invention solves the above-mentioned problems, and is a shortcut fiber that can be produced advantageously in terms of cost, and obtains a wet nonwoven fabric with low air permeability suitable for use in filters and separators with excellent performance. It is a technical problem to provide a shortcut fiber for a wet nonwoven fabric that can be used.
本発明者は、上記の課題を解決するために、細繊度の繊維を用いることなく、課題を解決できないかと検討した。その結果、特定のポリマーを複合化して繊維を得ることによって、細繊度にしなくとも、繊維間の空隙を小さくできて通気度を低くすることができ、また、強度などの不織布物性にも優れた湿式不織布用のショートカット繊維を提供することができることを見出した。 In order to solve the above problems, the present inventor has examined whether the problems can be solved without using fine fibers. As a result, by obtaining a fiber by compounding a specific polymer, the air gap between fibers can be reduced and the air permeability can be lowered without reducing the fineness, and the nonwoven fabric properties such as strength are also excellent. It has been found that shortcut fibers for wet nonwoven fabrics can be provided.
すなわち、本発明は、湿式不織布に用いられるショートカット繊維であり、該繊維は機械捲縮が付与されてなく、粘度の異なる２種のポリエチレンテレフタレートによって構成された芯鞘複合型の断面形状を有し、芯部に高粘度ポリエチレンテレフタレート、鞘部に低粘度ポリエチレンテレフタレートが配され、高粘度ポリエチレンテレフタレートと低粘度ポリエチレンテレフタレートの極限粘度差が０．０５〜０．１３であり、芯部と鞘部の複合比率が２０：８０〜８０：２０であることを特徴とする湿式不織布用ショートカット繊維を要旨とするものである。 That is, the present invention is a shortcut fiber used for a wet nonwoven fabric, and the fiber has a core-sheath composite type cross-sectional shape made of two types of polyethylene terephthalate which is not mechanically crimped and has different viscosities. , High-viscosity polyethylene terephthalate in the core, low-viscosity polyethylene terephthalate in the sheath, and the intrinsic viscosity difference between the high-viscosity polyethylene terephthalate and the low-viscosity polyethylene terephthalate is 0.05 to 0.13. A short cut fiber for a wet nonwoven fabric characterized in that the composite ratio is 20:80 to 80:20.
以下、本発明を詳細に説明する。 Hereinafter, the present invention will be described in detail.
本発明のショートカット繊維は、粘度の異なる２種のポリエチレンテレフタレートによって構成される。 The shortcut fiber of the present invention is composed of two types of polyethylene terephthalate having different viscosities.
ポリエチレンテレフタレート（以下、「ＰＥＴ」と称することもある。）を選択する理由は、融点が高いため、耐熱性に優れ、コスト面でも有利であるためである。なお、本発明の効果を阻害しない範囲でイソフタル酸、５−スルホイソフタル酸などの芳香族ジカルボン酸、アジピン酸、コハク酸、スベリン酸、セバシン酸、ドデカン二酸などの脂肪族ジカルボン酸、およびエチレングリコール、プロピレングリコール、１，４−ブタンジオール、１，４−シクロヘキサンジメタノールなどの脂肪族ジオールや、グリコール酸、ヒドロキシ酪酸、ヒドロキシ吉草酸、ヒドロキシカプロン酸、ヒドロキシペンタン酸、ヒドロキシヘプタン酸、ヒドロキシオクタン酸などのヒドロキシカルボン酸、ε−カプロラクトンなどの脂肪族ラクトン等を共重合したものであってもよい。 The reason for selecting polyethylene terephthalate (hereinafter also referred to as “PET”) is that it has a high melting point, is excellent in heat resistance, and is advantageous in terms of cost. In addition, aromatic dicarboxylic acids such as isophthalic acid and 5-sulfoisophthalic acid, aliphatic dicarboxylic acids such as adipic acid, succinic acid, suberic acid, sebacic acid, and dodecanedioic acid, and ethylene within a range not inhibiting the effects of the present invention Aliphatic diols such as glycol, propylene glycol, 1,4-butanediol, 1,4-cyclohexanedimethanol, glycolic acid, hydroxybutyric acid, hydroxyvaleric acid, hydroxycaproic acid, hydroxypentanoic acid, hydroxyheptanoic acid, hydroxyoctane It may be a copolymer of a hydroxycarboxylic acid such as an acid or an aliphatic lactone such as ε-caprolactone.
本発明のショートカット繊維は、粘度の異なる２種のポリエチレンテレフタレートによって構成された芯鞘複合型の断面形状を有している。芯部に高粘度ポリエチレンテレフタレート、鞘部に低粘度ポリエチレンテレフタレートが配され、芯部と鞘部の極限粘度差は０．０５〜０．１３である。芯部に高粘度ポリエチレンテレフタレートを配することにより、芯部は、繊維の剛性や強度を保持する役割を担う。一方、鞘部に低粘度ポリエチレンテレフタレートを配することにより、鞘部は、不織布化の際の熱と圧力が加わったときに、容易に圧着により変形しやすい易圧着効果を奏する役割を担う。両者の極限粘度差が０．０５より低くなると、鞘部において圧着変形しにくく、易圧着効果を奏しにくいものとなって通気度の小さい不織布が得にくくなり、一方、両者の極限粘度差が０．１３より大きくなると、繊維製造工程における延伸肯定で、鞘部の配向結晶化が不十分なものとなり、延伸後の熱セット工程で繊維同士が疑似密着しやすく、このような繊維を用いて湿式不織布を製造したときに、得られる不織布の地合が悪化しやすく好ましくない。なお、本発明のショートカット繊維を構成するポリエチレンテレフタレートの極限粘度は、上記した理由により、高粘度ポリエチレンテレフタレートとしては０．６以上がよく、低粘度ポリエチレンテレフタレートとしては０．３〜０．６がよい。また、高粘度ポリエチレンテレフタレートの極限粘度の上限は１．０程度でよい。また、繊維製造時の影響により、得られる繊維を構成する重合体の極限粘度は、材料の極限粘度と比較して０．０２〜０．０３程度値が小さくなる傾向にあるため、これを考慮して材料となる重合体の極限粘度を選択するとよい。 The shortcut fiber of the present invention has a core / sheath composite type cross-sectional shape constituted by two types of polyethylene terephthalate having different viscosities. High-viscosity polyethylene terephthalate is disposed in the core and low-viscosity polyethylene terephthalate is disposed in the sheath, and the intrinsic viscosity difference between the core and the sheath is 0.05 to 0.13. By arranging high-viscosity polyethylene terephthalate in the core, the core plays a role of maintaining the rigidity and strength of the fiber. On the other hand, by providing low-viscosity polyethylene terephthalate in the sheath, the sheath plays a role of easily crimping easily when deformed by crimping when heat and pressure are applied during the formation of the nonwoven fabric. If the difference in intrinsic viscosity between the two is lower than 0.05, the sheath part is difficult to be crimped and deformed, and it is difficult to obtain a non-woven fabric having a low air permeability, and the intrinsic viscosity difference between the two is 0. When larger than .13, the stretching in the fiber production process is positive, and the oriented crystallization of the sheath becomes insufficient, and the fibers are likely to be in close contact with each other in the heat setting process after stretching. When a nonwoven fabric is manufactured, the formation of the resulting nonwoven fabric tends to deteriorate, which is not preferable. The intrinsic viscosity of the polyethylene terephthalate constituting the shortcut fiber of the present invention is preferably 0.6 or more for high-viscosity polyethylene terephthalate and 0.3 to 0.6 for low-viscosity polyethylene terephthalate for the reasons described above. . The upper limit of the intrinsic viscosity of the high viscosity polyethylene terephthalate may be about 1.0. In addition, due to the influence at the time of fiber production, the intrinsic viscosity of the polymer constituting the obtained fiber tends to be smaller by about 0.02 to 0.03 than the intrinsic viscosity of the material. Thus, the intrinsic viscosity of the polymer used as the material may be selected.
本発明のショートカット繊維の芯部と鞘部の複合比率は、２０：８０〜８０：２０である。また、好ましくは４０：６０〜６０：４０である。芯部の比率が２０％を下回ると、繊維としての剛性が損なわれるため好ましくない。また、鞘部の比率が２０％を下回ると、易圧着効果を奏することができず、本発明の目的が達成しにくい。 The composite ratio of the core part and the sheath part of the shortcut fiber of the present invention is 20:80 to 80:20. Moreover, Preferably it is 40: 60-60: 40. If the ratio of the core part is less than 20%, the rigidity as the fiber is impaired, which is not preferable. On the other hand, if the ratio of the sheath portion is less than 20%, the effect of easy crimping cannot be achieved, and the object of the present invention is difficult to achieve.
本発明のショートカット繊維の断面形状は、上記したように芯鞘型であれば、円形断面に限定されず、異形断面であってもよい。したがって、同心円の芯鞘型のほか、扁平型、トリローバル型など任意の形状から選択することができるが、不織布化において少なくとも圧力を加えるカレンダー加工を施した際に繊維同士の接触面積が大きくなる同心円の芯鞘型あるいは扁平芯鞘型が好ましい。 The cross-sectional shape of the shortcut fiber of the present invention is not limited to a circular cross section as long as it is a core-sheath type as described above, and may be an irregular cross section. Therefore, in addition to the concentric core-sheath type, it can be selected from any shape such as a flat type or a trilobal type, but concentric circles that increase the contact area between fibers when calendering is applied at least under pressure in making a nonwoven fabric The core-sheath type or flat core-sheath type is preferable.
通常、熱可塑性樹脂からなる繊維であって、特定の繊維長を有する繊維を得る場合、スタフィングボックス法や押込加熱ギア法等により機械捲縮を付与することが多いが、本発明のショートカット繊維においては、湿式不織布を得るための繊維であることから、機械捲縮を付与しないもの（ノークリンプの繊維）とする。機械捲縮が付与されないことにより、湿式不織布の製造工程で良好に分散しやすく、地合いが良好で均一な性能を発揮することができるためである。 Usually, when a fiber made of a thermoplastic resin and having a specific fiber length is obtained, a mechanical crimp is often imparted by a stuffing box method or an indentation heating gear method, but the shortcut fiber of the present invention In this case, since it is a fiber for obtaining a wet nonwoven fabric, it is assumed that it does not impart mechanical crimp (no crimp fiber). This is because the mechanical crimping is not imparted, so that it is easy to disperse well in the manufacturing process of the wet nonwoven fabric, the texture is good, and uniform performance can be exhibited.
本発明のショートカット繊維の繊維長は、２〜２０ｍｍ程度であればよく、３〜１５ｍｍの範囲が好ましい。繊維長が２０ｍｍを超えると、不織布を得る工程での繊維の分散が悪くなり、均斉度に劣った湿式不織布となる。一方、繊維長を２ｍｍ未満にしようとすると、繊維を切断する際の発熱で繊維同士の融着が生じやすくなる。 The fiber length of the shortcut fiber of this invention should just be about 2-20 mm, and the range of 3-15 mm is preferable. When the fiber length exceeds 20 mm, fiber dispersion in the step of obtaining the nonwoven fabric is deteriorated, resulting in a wet nonwoven fabric having poor uniformity. On the other hand, if the fiber length is to be less than 2 mm, the fibers tend to be fused by heat generated when the fibers are cut.
ショートカット繊維の単糸繊度は、０．８〜４ｄｔｅｘ程度がよい。中でも１〜３．５ｄｔｅｘであることが好ましい。単糸繊度が４ｄｔｅｘを超えると、得られる湿式不織布の厚みが大きくなり、また繊維間の隙間が大きくなる傾向となり、一方、０．８ｄｔｅｘ未満になると、紡糸時に切れ糸が発生しやすくなり、操業性が悪くなるとともに、繊維同士の融着が生じやすく、強伸度特性に劣る傾向となる。 The single yarn fineness of the shortcut fiber is preferably about 0.8 to 4 dtex. Among these, 1 to 3.5 dtex is preferable. If the single yarn fineness exceeds 4 dtex, the thickness of the resulting wet nonwoven fabric tends to increase and the gap between the fibers tends to increase. On the other hand, if the single yarn fineness is less than 0.8 dtex, breakage tends to occur during spinning and In addition to the worsening of the properties, fusion between fibers tends to occur, and the strength and elongation properties tend to be inferior.
本発明のショートカット繊維は、細繊度のものではないため、実用的な強度を有し、その強度が３〜８ｃＮ／ｄｔｅｘであり、３．５〜７．５ｃＮ／ｄｔｅｘであることが好ましい。強度が３ｃＮ／ｄｔｅｘ未満であると、得られる不織布の機械的特性（強度）が劣るものになる。一方、強度が８ｃＮ／ｄｔｅｘを超えるものを得ようとすれば、より高粘度の重合体を用いる必要があるため、紡糸および延伸工程の操業性が悪くなり、得られる繊維の品位が劣りやすくなる。 Since the shortcut fiber of the present invention is not of a fineness, it has a practical strength, and the strength is 3 to 8 cN / dtex, and preferably 3.5 to 7.5 cN / dtex. If the strength is less than 3 cN / dtex, the resulting nonwoven fabric has poor mechanical properties (strength). On the other hand, if an attempt is made to obtain a material having a strength exceeding 8 cN / dtex, it is necessary to use a higher viscosity polymer, so that the operability of the spinning and stretching process is deteriorated, and the quality of the resulting fiber is likely to be inferior. .
ショートカット繊維の伸度は、２５〜１００％であり、中でも３０〜６０％であることが好ましい。伸度が２５％未満であると、延伸工程での操業性が悪くなり、得られる繊維の品位が劣るものとなり好ましくない。一方、伸度が１００％を超えると、延伸での配向結晶が充分に進んでおらず、熱や圧力の関与で擬似密着が発生しやすくなり、繊維間の密着が生じ、得られる繊維の品位が劣るものとなりやすい。 The elongation of the shortcut fiber is 25 to 100%, and preferably 30 to 60%. When the elongation is less than 25%, the operability in the stretching process is deteriorated, and the quality of the obtained fiber is deteriorated, which is not preferable. On the other hand, when the elongation exceeds 100%, the oriented crystals in the drawing are not sufficiently advanced, and pseudo-adhesion is likely to occur due to the involvement of heat and pressure, resulting in adhesion between fibers, and the quality of the resulting fiber. Tends to be inferior.
本発明においては、上記した本発明のショートカット繊維を用いて湿式不織布を得る。湿式不織布は上記の本発明のショートカット繊維のみから構成されたものであってもよいが、接着成分を用いて構成繊維同士を接着して不織布とするものが好ましい。接着成分としては、熱接着成分を有するバインダー繊維を用いることが好ましい。すなわち、本発明のショートカット繊維とバインダー繊維とを所定量混合したウエブを作成し、熱と圧力を付与することにより、本発明のショートカット繊維の鞘部を圧着により変形させ、かつバインダー繊維を溶融させて構成繊維同士を熱接着により一体化した湿式不織布を得ることが好ましい。なお、湿式不織布を作成する際に付与する熱と圧力は、同時に付与してもよく、あるいは、熱を付与して繊維を軟化させ（バインダー繊維を混合している場合は、バインダー繊維の熱接着成分を溶融または軟化させ）、その後に圧力を付与してもよい。なお、熱と圧力を同時に付与する方法としては、所定の温度に加熱した熱カレンダーロールに通すとよい。熱と圧力を別に付与する方法としては、熱ロールに沿わせる方法や熱風乾燥機内に通す方法により熱を付与した後に、一対のカレンダーロールに通して圧力を付与する方法が挙げられる。 In the present invention, a wet nonwoven fabric is obtained using the above-described shortcut fiber of the present invention. The wet nonwoven fabric may be composed of only the above-described shortcut fiber of the present invention. However, the wet nonwoven fabric is preferably a nonwoven fabric obtained by bonding constituent fibers to each other using an adhesive component. As the adhesive component, it is preferable to use a binder fiber having a thermal adhesive component. That is, by creating a web in which a predetermined amount of the shortcut fiber of the present invention and a binder fiber are mixed, and applying heat and pressure, the sheath of the shortcut fiber of the present invention is deformed by pressure bonding, and the binder fiber is melted. It is preferable to obtain a wet nonwoven fabric in which constituent fibers are integrated by thermal bonding. The heat and pressure applied when preparing the wet nonwoven fabric may be applied at the same time, or the heat is applied to soften the fibers (if the binder fibers are mixed, the binder fibers are thermally bonded. The ingredients may be melted or softened) and then pressure may be applied. In addition, as a method of giving heat and pressure simultaneously, it is good to pass through the heat | fever calendar roll heated to predetermined temperature. Examples of a method of separately applying heat and pressure include a method of applying heat through a pair of calender rolls after applying heat by a method of passing along a hot roll or a method of passing through a hot air dryer.
本発明のショートカット繊維とともに用いるバインダー繊維としては、ポリエチレンテレフタレートのみからなる未延伸糸を好適に用いることができる。未延伸糸は、繊維製造工程で、一旦溶融紡糸した後に巻き取っただけのものであり、溶融紡糸後に熱延伸が施されていないため、繊維を構成する重合体は十分に配向せずに、熱を付与した場合に容易に軟化して繊維同士を接着するバインダー繊維として機能する。 As the binder fiber used together with the shortcut fiber of the present invention, an undrawn yarn composed only of polyethylene terephthalate can be suitably used. In the fiber production process, the unstretched yarn is one that has only been wound after being melt-spun once, and since the heat-stretching has not been performed after melt-spinning, the polymer constituting the fiber is not sufficiently oriented, When heat is applied, it functions as a binder fiber that softens easily and bonds the fibers together.
本発明においては、湿式不織布を得る際に、湿式不織布の用途に応じて、様々な加工を施すことができ、この加工によって、例えば、繊維間の空隙を容易に調整することができ、また、不織布に各種の機能性を付与することができる。例えば、得られる不織布の密度を高めるために、湿式抄造後の乾燥熱処理後にさらにカレンダーロールで熱圧着加工を施したり、各種の機能を付与するために得られた不織布の表面に樹脂加工を行うことができる。このような加工においては、湿式抄造後の乾燥熱処理よりもさらに高温の熱処理を行う場合があるが、上記したポリエチレンテレフタレートのみからなる未延伸糸によるバインダー繊維を用いれば、繊維は、ポリエチレンテレフタレートからなるものであるためポリマーの融点が高く、耐熱性に優れており、これらの加工において高温の熱処理を施しても劣化が生じることがない。 In the present invention, when obtaining a wet nonwoven fabric, it can be subjected to various processing depending on the use of the wet nonwoven fabric, and by this processing, for example, the gap between the fibers can be easily adjusted, Various functionalities can be imparted to the nonwoven fabric. For example, in order to increase the density of the resulting nonwoven fabric, after heat treatment after wet papermaking, further calendering with a calender roll, or processing the surface of the nonwoven fabric obtained to give various functions Can do. In such processing, heat treatment may be performed at a higher temperature than the dry heat treatment after wet papermaking, but if the binder fiber made of undrawn yarn made only of polyethylene terephthalate is used, the fiber is made of polyethylene terephthalate. Therefore, the polymer has a high melting point and excellent heat resistance, and no deterioration occurs even when a high-temperature heat treatment is applied in these processes.
バインダー繊維の単糸繊度は、１〜３ｄｔｅｘ程度がよく、１〜２．５ｄｔｅｘが好ましい。単糸繊度が３ｄｔｅｘを超えると、本発明のショートカット繊維とバインダー繊維とからなるウエブにおいて繊維間の空隙が大きくなり、厚みが大きいものとなる。そして、バインダー繊維を溶融させた後に得られる湿式不織布の繊維間の空隙が大きく、通気度が高く、厚みの大きいものとなりやすい。一方、１ｄｔｅｘ未満のバインダー繊維であると、バインダー繊維を得る際に操業性が悪くなり、品質の劣った繊維となる場合が多く好ましくない。 The single yarn fineness of the binder fiber is preferably about 1 to 3 dtex, and preferably 1 to 2.5 dtex. When the single yarn fineness exceeds 3 dtex, the gap between the fibers becomes large and the thickness becomes large in the web composed of the shortcut fiber and the binder fiber of the present invention. And the space | gap between the fibers of the wet nonwoven fabric obtained after melting a binder fiber is large, air permeability is high, and it tends to become a thing with large thickness. On the other hand, when the binder fiber is less than 1 dtex, the operability is deteriorated when the binder fiber is obtained, and it is often not preferable because the fiber is inferior in quality.
バインダー繊維の繊維長は、本発明のショートカット繊維と同様に２〜２０ｍｍがよく、３〜１５ｍｍが好ましい。繊維長が２０ｍｍを超えると、不織布を得る際の繊維の分散が悪くなり、均斉度の低い不織布となりやすい。一方、繊維長が２ｍｍ未満になると、繊維製造時の切断の際に発熱で繊維同士の融着が生じている場合が多く、やはり不織布を得る際の繊維の分散が悪くなり、均斉度の低い不織布となりやすい。 The fiber length of the binder fiber is preferably 2 to 20 mm, and preferably 3 to 15 mm, like the shortcut fiber of the present invention. When the fiber length exceeds 20 mm, the dispersion of the fibers when obtaining the nonwoven fabric is deteriorated, and the nonwoven fabric tends to be low in uniformity. On the other hand, when the fiber length is less than 2 mm, the fibers are often fused due to heat generation during cutting during fiber production, and the dispersion of fibers in obtaining a nonwoven fabric also deteriorates, resulting in low uniformity. Easy to become non-woven fabric.
本発明のショートカット繊維とバインダー繊維を用いる際の両繊維の混合比率は、質量比（ショートカット繊維／バインダー繊維）で５０／５０〜９０／１０の範囲が好ましい。さらには、６０／４０〜８０／２０がより好ましい。 The mixing ratio of both fibers when using the shortcut fiber and the binder fiber of the present invention is preferably in the range of 50/50 to 90/10 in terms of mass ratio (shortcut fiber / binder fiber). Furthermore, 60 / 40-80 / 20 is more preferable.
本発明のショートカット繊維およびバインダー繊維を構成する重合体中には、本発明の効果を損なわない範囲で、リン酸エステル化合物やヒンダードフェノール化合物のような安定剤、コバルト化合物、蛍光増白剤、染料のような色調改良剤、二酸化チタンのような艶消し剤、可塑剤、顔料、制電剤、難燃剤、易染化剤などの各種添加剤を１種類または２種類以上添加してもよい。 In the polymer constituting the shortcut fiber and the binder fiber of the present invention, a stabilizer such as a phosphate ester compound or a hindered phenol compound, a cobalt compound, a fluorescent brightener, One or more additives such as a color tone improver such as a dye, a matting agent such as titanium dioxide, a plasticizer, a pigment, an antistatic agent, a flame retardant, and an easy dyeing agent may be added. .
本発明の湿式不織布用ショートカット繊維は、ショートカット繊維を構成する単繊維の断面が芯鞘形状であって、芯部に高粘度ポリエチレンテレフタレート、鞘部に低粘度ポリエチレンテレフタレートを配しているため、不織布を構成する際に圧力を付与すると、鞘部の低粘度ポリエチレンテレフタレートが容易に圧着変形するため、不織布の空隙を所望の範囲に調整することができ、容易に通気度が低く、気密性の高い湿式不織布を得ることができる。さらには、芯部の高粘度ポリエチレンテレフタレートは繊維の剛性を維持する骨格としての役割を担い、実用的な強度および伸度を維持することができるため、機械的特性にも優れた湿式不織布を得ることができる。このような優れた特性を有する湿式不織布は、性能の高いフィルターやセパレーター用途に好適に使用することが可能となる。 The shortcut fiber for wet nonwoven fabric of the present invention is a nonwoven fabric because the cross-section of the single fiber constituting the shortcut fiber has a core-sheath shape, and the core portion has high-viscosity polyethylene terephthalate and the sheath portion has low-viscosity polyethylene terephthalate. When a pressure is applied during the construction, the low-viscosity polyethylene terephthalate in the sheath part is easily crimped and deformed, so that the voids of the nonwoven fabric can be adjusted to a desired range, and the air permeability is low and airtightness is high. A wet nonwoven fabric can be obtained. Furthermore, the high-viscosity polyethylene terephthalate at the core plays a role as a skeleton that maintains the rigidity of the fiber, and can maintain practical strength and elongation, so that a wet nonwoven fabric with excellent mechanical properties is obtained. be able to. The wet nonwoven fabric having such excellent characteristics can be suitably used for high performance filters and separators.
次に、実施例を用いて本発明を具体的に説明する。ショートカット繊維の特性値及び湿式短繊維不織布の評価方法は次の通りである。
[単糸繊度]
切断前の繊維束を用いて、ＪＩＳ Ｌ １０１５ 正量繊度のＡ法により測定した。
[繊維長]
得られたショートカット繊維のサイドビュー写真を撮影し、任意の３０本の長さを測定し後、その平均値を撮影倍率で割り返して算出した。
[強度、伸度]
切断前の繊維束を用いて、ＪＩＳ Ｌ １０１５ 引張強さ及び伸び率により測定した。
[不織布の通気度]
得られた湿式維不織布を、ＪＩＳ Ｌ １０９６ 通気性のＡ法により測定した。８ｃｃ／ｃｍ２／ｓｅｃ未満を合格とした。
[不織布の機械的特性]
得られた湿式不織布を、ＪＩＳ Ｌ １０９６ 引張強さ及び伸び率のＡ法によりＭＤ方向（カレンダー加工の際の機械方向）の強力を測定した。１５Ｎ／２．５ｃｍ幅以上を合格とした。
[極限粘度]
フェノールと四塩化エタンとの等質量混合物を溶媒として、試料濃度０．５質量％、温度２０℃の条件下で常法に基づき測定した。
[芯鞘型複合繊維における各重合体の極限粘度]
芯鞘型複合繊維を、フェノールと四塩化エタンとの等質量混合物を溶媒として、試料濃度０．５質量％、温度２０℃の条件下で測定して複合繊維の極限粘度[η]０を得る。一方、同じ芯鞘型複合繊維をアルカリ減量処理して鞘部を溶解除去した後、芯部（高粘度ＰＥＴ）の極限粘度を上記と同様にして測定して、その極限粘度を[η]１とする。
鞘部分を構成するＰＥＴの極限粘度を[η]２としたときに、[η]０、[η]１および[η]２の間には下記式１で示される関係が成立する。
式１ ： [η]０＝（[η]１＋[η]２）／２
したがって、上記の式１から、複合繊維の鞘部を構成するＰＥＴの極限粘度[η]２を下記の式２より求める。
式２ ： [η]２＝２[η]０−[η]１
[不織布の地合]
得られた不織布の地合を目視により以下の３段階で評価した。
○：構成繊維の分布が均一であり、斑が非常に少ない。
△：構成繊維の分布がやや不均一であり、斑がやや目立つ。
×：構成繊維の分布が非常に不均一であり、斑が目立つ。
Next, the present invention will be specifically described using examples. The characteristic value of the shortcut fiber and the evaluation method of the wet short fiber nonwoven fabric are as follows.
[Single yarn fineness]
It measured by A method of JISL1015 positive amount fineness using the fiber bundle before a cutting | disconnection.
[Fiber length]
A side view photograph of the obtained shortcut fiber was taken, the length of any 30 fibers was measured, and the average value was calculated by dividing by the photographing magnification.
[Strength, elongation]
Using the fiber bundle before cutting, it was measured by JIS L 1015 tensile strength and elongation.
[Air permeability of nonwoven fabric]
The obtained wet fiber nonwoven fabric was measured by JIS L 1096 breathable A method. Less than 8 cc / cm 2 / sec was accepted.
[Mechanical properties of nonwoven fabric]
The obtained wet nonwoven fabric was measured for strength in the MD direction (machine direction during calendering) by A method of JIS L 1096 tensile strength and elongation. 15 N / 2.5 cm width or more was considered acceptable.
[Intrinsic viscosity]
The measurement was carried out based on a conventional method under the conditions of a sample concentration of 0.5% by mass and a temperature of 20 ° C. using an equal mass mixture of phenol and ethane tetrachloride as a solvent.
[Intrinsic viscosity of each polymer in core-sheath type composite fiber]
The core-sheath type composite fiber is measured under the conditions of a sample concentration of 0.5% by mass and a temperature of 20 ° C. using an equal mass mixture of phenol and ethane tetrachloride as a solvent to obtain the intrinsic viscosity [η] 0 of the composite fiber. . On the other hand, after the same core-sheath type composite fiber was subjected to alkali weight reduction treatment and the sheath part was dissolved and removed, the intrinsic viscosity of the core part (high viscosity PET) was measured in the same manner as described above, and the intrinsic viscosity was [η] 1 And
The intrinsic viscosity of PET constituting the sheath portion is taken as [η] 2, [η] 0, the relationship is established of the following formula 1 is between [eta] 1 and [eta] 2.
Formula 1: [η] 0 = ([η] 1 + [η] 2 ) / 2
Therefore, the intrinsic viscosity [η] 2 of PET constituting the sheath portion of the composite fiber is obtained from the following equation 2 from the above equation 1.
Formula 2: [η] 2 = 2 [η] 0 − [η] 1
[Nonwoven fabric]
The formation of the obtained nonwoven fabric was visually evaluated in the following three stages.
○: The distribution of the constituent fibers is uniform and the spots are very few.
Δ: The distribution of the constituent fibers is slightly non-uniform, and the spots are slightly noticeable.
X: The distribution of the constituent fibers is very uneven and the spots are conspicuous.
実施例１
[芯鞘型複合繊維の製造]
融点が２５６℃、極限粘度０．６４のＰＥＴを芯部とし、極限粘度０．５３のＰＥＴを鞘部とし、孔数１０１４、円形断面同心芯鞘複合紡糸口金を用い、芯：鞘＝５０：５０となるように計量し、合計吐出量６２１ｇ／分、紡糸温度２８５℃、紡糸速度１１００ｍ／分で溶融紡糸し、複合繊維の未延伸糸を得た。次いで、得られた未延伸糸を延伸温度７３℃、延伸倍率３．８５倍で延伸を行い、続いて１８０℃の熱ローラーにて緊張熱処理を行った。ポリエーテルとポリエーテルエステルアミドを主成分とする分散油剤を付着量が０．２質量％となるように付与した後、カットして単糸繊度１．６ｄｔｅｘ、繊維長５ｍｍの本発明のショートカット繊維を得た。得られたショートカット繊維の芯部ＰＥＴの極限粘度は０．６２、鞘部ＰＥＴの極限粘度は０．５１であった。
Example 1
[Manufacture of core-sheath type composite fiber]
The melting point is 256 ° C., PET having an intrinsic viscosity of 0.64 is used as the core, PET having the intrinsic viscosity of 0.53 is used as the sheath, and a concentric core-sheath composite spinneret with 1014 holes and a circular cross section is used. It was weighed to 50 and melt-spun at a total discharge rate of 621 g / min, a spinning temperature of 285 ° C. and a spinning speed of 1100 m / min to obtain an undrawn yarn of a composite fiber. Subsequently, the obtained undrawn yarn was drawn at a drawing temperature of 73 ° C. and a draw ratio of 3.85 times, and subsequently subjected to tension heat treatment with a hot roller at 180 ° C. After applying a dispersion oil mainly composed of polyether and polyether ester amide so that the adhesion amount is 0.2% by mass, the fiber is cut to a single fiber fineness of 1.6 dtex and a fiber length of 5 mm according to the present invention. Got. The intrinsic viscosity of the core part PET of the obtained shortcut fiber was 0.62, and the intrinsic viscosity of the sheath part PET was 0.51.
[未延伸バインダー繊維の製造]
極限粘度０．６５のポリエチレンテレフタレートペレットを１３０℃で乾燥後、２９５℃で溶融し、紡糸口金（紡糸孔数が１０４０）を通して、吐出量１８０ｇ／分で吐出し、紡糸速度１１５０ｍ／分の速度で引取り、単繊維繊度が１．３５デシテックスの未延伸ポリエチレンテレフタレート繊維を得た。該ポリエチレンテレフタレート繊維を約８０万デシテックスのトウとなし、延伸熱処理を施すことなく、供給ロールと巻取ロールとのローラー間の工程張力（ロール間の速度比が１．０４倍）で繊維を走行させて、ポリエーテルとポリエーテルエステルアミドを主成分とする分散油剤を付着量が０．２質量％となるように付与した後、カットして単糸繊度１．３５ｄｔｅｘ、繊維長５ｍｍのショートカットされた未延伸のバインダー繊維を得た。
[Manufacture of unstretched binder fiber]
Polyethylene terephthalate pellets having an intrinsic viscosity of 0.65 are dried at 130 ° C., melted at 295 ° C., and discharged through a spinneret (number of spinning holes: 1040) at a discharge rate of 180 g / min, at a spinning speed of 1150 m / min. The unstretched polyethylene terephthalate fiber having a single fiber fineness of 1.35 dtex was obtained. The polyethylene terephthalate fiber has a tow of about 800,000 dtex, and the fiber runs with a process tension between the supply roll and the take-up roll (speed ratio between rolls is 1.04 times) without subjecting it to stretching heat treatment. Then, after applying a dispersion oil agent mainly composed of polyether and polyether ester amide so that the adhesion amount is 0.2% by mass, it is cut to be a shortcut with a single yarn fineness of 1.35 dtex and a fiber length of 5 mm. An unstretched binder fiber was obtained.
[湿式不織布の製造]
得られたショートカット繊維を主体繊維として、主体繊維とバインダー繊維とを用い、混率を質量比６０／４０（主体繊維／バインダー繊維）として、パルプ離解機（熊谷理機工業製）に投入し、３０００ｒｐｍにて１分間撹拌した。その後、得られた試料を抄紙機（熊谷理機工業製角型シ−トマシン）にて、ポリエーテルとポリエーテルエステルアミドを主成分とする分散油剤を添加した後、付帯の攪拌羽にて攪拌を行い抄紙し、湿式ウエブとした。そして、湿式ウエブを回転式乾燥機（熊谷理機工業製）にて１４０℃の温度で熱処理し、表面が平滑の熱カレンダー装置にて１６０℃、線圧１００ｋｇ／ｃｍ、処理速度２ｍ／分にて熱圧着を施し、坪量が約８０ｇ／ｍ２のポリエチレンテレフタレート繊維からなる湿式不織布を得た。
[Manufacture of wet nonwoven fabric]
Using the obtained shortcut fiber as the main fiber, using the main fiber and the binder fiber, the mixing ratio is set to 60/40 (main fiber / binder fiber) and put into a pulp disintegrator (manufactured by Kumagai Riki Kogyo Co., Ltd.) at 3000 rpm. For 1 minute. After that, the obtained sample was added with a paper machine (Kumagaya Riki Kogyo Kakuto Sheet Machine) with a dispersion oil mainly composed of polyether and polyetheresteramide, and then stirred with an accompanying stirring blade. To make a wet web. Then, the wet web is heat-treated at a temperature of 140 ° C. with a rotary dryer (manufactured by Kumagai Riki Kogyo Co., Ltd.), 160 ° C. with a smooth surface, a linear pressure of 100 kg / cm, and a processing speed of 2 m / min. The wet nonwoven fabric made of polyethylene terephthalate fibers having a basis weight of about 80 g / m 2 was obtained.
実施例２〜３
主体繊維の芯鞘比率を表１のように変更したこと以外は実施例１と同様に実施した。
Examples 2-3
The same procedure as in Example 1 was performed except that the core-sheath ratio of the main fiber was changed as shown in Table 1.
実施例４
実施例１において、融点が２５６℃、極限粘度０．６４のＰＥＴを芯部とし、極限粘度
０．５６のＰＥＴを鞘部としたこと以外は、実施例１と同様にして、本発明のショートカット繊維を得たこと以外は、実施例１と同様に実施した。得られたショートカット繊維の芯部ＰＥＴの極限粘度は０．６２、鞘部ＰＥＴの極限粘度は０．５４であった。
Example 4
In Example 1, the shortcut of the present invention is the same as in Example 1 except that the melting point is 256 ° C., PET having an intrinsic viscosity of 0.64 is used as the core, and PET having the intrinsic viscosity of 0.56 is used as the sheath. Except having obtained the fiber, it implemented similarly to Example 1. FIG. The intrinsic viscosity of the core part PET of the obtained shortcut fiber was 0.62, and the intrinsic viscosity of the sheath part PET was 0.54.
比較例１
鞘部に極限粘度０．６０のＰＥＴを用いたこと以外は、実施例１と同様に実施した。得られた繊維の鞘部ＰＥＴの極限粘度は０．５９であった。
Comparative Example 1
It implemented like Example 1 except having used PET with intrinsic viscosity 0.60 for a sheath part. The intrinsic viscosity of the obtained sheath PET of the fiber was 0.59.
比較例２
鞘部に極限粘度０．６４のＰＥＴ（芯部と同じ極限粘度のＰＥＴ）を用い、合計吐出量５７８ｇ／分、延伸倍率３．７１倍としたこと以外は実施例１と同様に実施した。
Comparative Example 2
The same procedure as in Example 1 was performed except that PET having an intrinsic viscosity of 0.64 (PET having the same intrinsic viscosity as that of the core) was used for the sheath, and the total discharge rate was 578 g / min and the draw ratio was 3.71 times.
比較例３
鞘部に極限粘度０．４５のＰＥＴを用い、延伸倍率４．００倍としたこと以外は実施例１と同様に実施した。得られた繊維の鞘部ＰＥＴの極限粘度は０．４５であった。
Comparative Example 3
The same procedure as in Example 1 was performed except that PET having an intrinsic viscosity of 0.45 was used for the sheath and the draw ratio was 4.00. The intrinsic viscosity of the obtained sheath PET of the fiber was 0.45.
比較例４〜５
主体繊維の芯鞘比率を表１のように変更したこと以外は実施例１と同様に実施した。
Comparative Examples 4-5
The same procedure as in Example 1 was performed except that the core-sheath ratio of the main fiber was changed as shown in Table 1.
実施例および比較例で得られた繊維および不織布の評価を表１に示す。 Table 1 shows the evaluation of the fibers and nonwoven fabrics obtained in Examples and Comparative Examples.
表１から明らかなように、実施例１〜４のショートカット繊維は、実用的な機械物性を示し、得られた湿式不織布は、通気度が低く、気密性に優れ、機械的特性にも優れたものであった。 As is clear from Table 1, the shortcut fibers of Examples 1 to 4 showed practical mechanical properties, and the obtained wet nonwoven fabric had low air permeability, excellent air tightness, and excellent mechanical properties. It was a thing.
一方、比較例１〜２のショートカット繊維は、極限粘度差が小さい、もしくは無かったため、繊維自体の強度は実用的なものであったが、この繊維を用いて得られた不織布は、実施例と比較して、不織布強力が劣り、通気度も高いものであった。
比較例３のショートカット繊維は、極限粘度差が大きすぎたために、湿式抄造法により不織布製造の際に水分散性が悪く、地合が悪化した。鞘部に低粘度ＰＥＴを使用しているため不織布強力は高かったものの、地合が悪いため通気度は高いものとなった。
比較例４のショートカット繊維は、鞘部ＰＥＴの比率が少ないために、不織布強度が低く、通気度も高いものとなった。
比較例５のショートカット繊維は、鞘部ＰＥＴの比率が大きいために、地合いが悪く、不織布強度が低いものとなった。
On the other hand, the shortcut fibers of Comparative Examples 1 and 2 had a small or no intrinsic viscosity difference, so the strength of the fibers themselves was practical, but the nonwoven fabric obtained using this fiber was In comparison, the nonwoven fabric strength was poor and the air permeability was high.
Since the shortcut fiber of Comparative Example 3 had an excessively large difference in intrinsic viscosity, the water dispersibility was poor when the nonwoven fabric was produced by the wet papermaking method, and the formation deteriorated. Although the nonwoven fabric strength was high because low-viscosity PET was used for the sheath, the air permeability was high due to poor formation.
The shortcut fiber of Comparative Example 4 had a low nonwoven fabric strength and a high air permeability because the ratio of the sheath portion PET was small.
Since the ratio of the sheath part PET was large, the shortcut fiber of Comparative Example 5 was poor in texture and low in nonwoven fabric strength.
本発明は、湿式不織布を得るのに適したショートカット繊維であって、特に高性能なフィルター用途等に好適な湿式不織布を得ることができる湿式不織布用ショートカット繊維に関するものである。 The present invention relates to a shortcut fiber suitable for obtaining a wet nonwoven fabric, and particularly to a shortcut fiber for a wet nonwoven fabric capable of obtaining a wet nonwoven fabric suitable for a high-performance filter application.
近年、湿式短繊維不織布はフィルター用基材、電池セパレーターなどの用途に広く用いられている。このような用途において、性能の高いフィルターやセパレーターとするには、厚みが薄く、通気度の低い湿式不織布が求められている。 In recent years, wet short fiber nonwoven fabrics have been widely used for applications such as filter substrates and battery separators. In such applications, wet nonwoven fabrics having a small thickness and a low air permeability are required for high performance filters and separators.
通気度の低い不織布を得るには、繊維間の隙間を少なくし、気密性を高くすることが必要である。例えば、特許文献１や特許文献２には単糸繊度が０．５ｄｔｅｘ以下の細繊度の繊維を用いることにより、繊維間の空隙を小さくし、気密性を高くした短繊維不織布を得る方法が提案されている。 In order to obtain a non-woven fabric with low air permeability, it is necessary to reduce the gaps between the fibers and increase the airtightness. For example, Patent Document 1 and Patent Document 2 propose a method of obtaining a short fiber nonwoven fabric in which the gap between the fibers is reduced and the air tightness is increased by using fine fibers having a single yarn fineness of 0.5 dtex or less. Has been.
０．５ｄｔｅｘ以下の繊維を得るには、単一のポリマーで紡糸、延伸して直接繊維を得る方法と、複数のポリマーを用いた複合繊維で紡糸、延伸を行い、ある程度太い繊維を得た後に割繊することで０．５ｄｔｅｘ以下の繊維を得る方法がある。割繊の方法としては、相溶性に乏しい複数のポリマーからなる複合繊維に物理的な衝撃を与えることにより、繊維を構成するポリマーの界面を剥離分割して細繊度の繊維を得る機械的割繊と、有機溶媒に溶けやすいポリマーと溶けにくいポリマーとからなる複合繊維を、有機溶媒を浸す等によって、繊維を構成する一部のポリマー（有機溶媒に溶けやすいポリマー）を溶解させ、有機溶媒に溶けにくいポリマーのみにより構成される細繊度の繊維を得る化学的割繊が挙げられる。 In order to obtain a fiber of 0.5 dtex or less, after spinning and drawing with a single polymer and directly obtaining the fiber, and after spinning and drawing with a composite fiber using a plurality of polymers to obtain a somewhat thick fiber There is a method of obtaining fibers of 0.5 dtex or less by splitting. As a method of splitting, mechanical splitting is performed by giving a physical impact to a composite fiber composed of a plurality of polymers having poor compatibility, thereby separating and dividing the interface of the polymer constituting the fiber to obtain a fine fiber. In addition, by immersing the organic fiber in a composite fiber composed of a polymer that is easily soluble in an organic solvent and a polymer that is difficult to dissolve, a part of the polymer (polymer that is soluble in an organic solvent) is dissolved and dissolved in the organic solvent. Examples include chemical splitting to obtain fine fibers composed only of difficult polymers.
細繊度の繊維を直接得る方法は、紡糸、延伸時に糸切れが発生しやすく、生産性が低下するのでコスト的に不利である。細繊度の繊維を機械的割繊で得る方法は、コスト的には不利ではないが、割繊後に得られた繊維は、相溶性に乏しい複数の繊維が混ざったものとなり、これらの繊維から得られる湿式不織布は性能の劣るものになりやすい。 The method of directly obtaining fine fibers is disadvantageous in terms of cost because yarn breakage is likely to occur during spinning and drawing, and productivity is reduced. The method of obtaining finely divided fibers by mechanical splitting is not disadvantageous in terms of cost, but the fibers obtained after splitting are a mixture of a plurality of fibers having poor compatibility, and are obtained from these fibers. The resulting wet nonwoven fabric tends to be inferior in performance.
細繊度の繊維を化学的割繊で得る方法は、紡糸、延伸で得られた繊維の一部を溶媒で溶解除去をするため、得られる細繊度の繊維の量が減り、コスト的に不利である。さらに、溶媒の再生、回収設備が必要となる点でもコスト的に不利である。 The method of obtaining finely divided fibers by chemical splitting involves dissolving and removing part of the fibers obtained by spinning and drawing with a solvent, which reduces the amount of fine fibers obtained and is disadvantageous in terms of cost. is there. Furthermore, it is disadvantageous in terms of cost in that a solvent regeneration and recovery facility is required.
細繊度の繊維を用いることによって通気度の低い不織布を得る方法では、確かに通気度は低下するものの、不織布内の空隙のサイズも同様に小さくなるため、例えば、フィルターとして用いた場合は目詰まりが早くなり、フィルター寿命が短いものとなる。このため、捕捉する粒子に応じて、フィルターを構成する繊維の繊維径を適宜調節することが必要となり管理が煩雑となる。 In the method of obtaining a non-woven fabric with low air permeability by using fine fibers, although the air permeability is certainly reduced, the size of the voids in the non-woven fabric is similarly reduced, so for example, when used as a filter, it becomes clogged. The filter life is shortened and the filter life is shortened. For this reason, it is necessary to appropriately adjust the fiber diameter of the fibers constituting the filter according to the particles to be captured, and management becomes complicated.
本発明は上記の問題点を解決するものであって、コスト的に有利に製造することができるショートカット繊維であり、性能の優れたフィルターやセパレーター用途に好適な通気度の低い湿式不織布を得ることができる湿式不織布用ショートカット繊維を提供することを技術的な課題とするものである。 The present invention solves the above-mentioned problems, and is a shortcut fiber that can be produced advantageously in terms of cost, and obtains a wet nonwoven fabric with low air permeability suitable for use in filters and separators with excellent performance. It is a technical problem to provide a shortcut fiber for a wet nonwoven fabric that can be used.
本発明者は、上記の課題を解決するために、細繊度の繊維を用いることなく、課題を解決できないかと検討した。その結果、特定のポリマーを複合化して繊維を得ることによって、細繊度にしなくとも、繊維間の空隙を小さくできて通気度を低くすることができ、また、強度などの不織布物性にも優れた湿式不織布用のショートカット繊維を提供することができることを見出した。 In order to solve the above problems, the present inventor has examined whether the problems can be solved without using fine fibers. As a result, by obtaining a fiber by compounding a specific polymer, the air gap between fibers can be reduced and the air permeability can be lowered without reducing the fineness, and the nonwoven fabric properties such as strength are also excellent. It has been found that shortcut fibers for wet nonwoven fabrics can be provided.
すなわち、本発明は、湿式不織布に用いられるショートカット繊維であり、該繊維は機械捲縮が付与されてなく、粘度の異なる２種のポリエチレンテレフタレートによって構成された芯鞘複合型の断面形状を有し、芯部に高粘度ポリエチレンテレフタレート、鞘部に低粘度ポリエチレンテレフタレートが配され、高粘度ポリエチレンテレフタレートと低粘度ポリエチレンテレフタレートの極限粘度差が０．０５〜０．１３であり、芯部と鞘部の複合比率が２０：８０〜８０：２０であることを特徴とする湿式不織布用ショートカット繊維を要旨とするものである。 That is, the present invention is a shortcut fiber used for a wet nonwoven fabric, and the fiber has a core-sheath composite type cross-sectional shape made of two types of polyethylene terephthalate which is not mechanically crimped and has different viscosities. , High-viscosity polyethylene terephthalate in the core, low-viscosity polyethylene terephthalate in the sheath, and the intrinsic viscosity difference between the high-viscosity polyethylene terephthalate and the low-viscosity polyethylene terephthalate is 0.05 to 0.13. A short cut fiber for a wet nonwoven fabric characterized in that the composite ratio is 20:80 to 80:20.
以下、本発明を詳細に説明する。 Hereinafter, the present invention will be described in detail.
本発明のショートカット繊維は、粘度の異なる２種のポリエチレンテレフタレートによって構成される。 The shortcut fiber of the present invention is composed of two types of polyethylene terephthalate having different viscosities.
ポリエチレンテレフタレート（以下、「ＰＥＴ」と称することもある。）を選択する理由は、融点が高いため、耐熱性に優れ、コスト面でも有利であるためである。なお、本発明の効果を阻害しない範囲でイソフタル酸、５−スルホイソフタル酸などの芳香族ジカルボン酸、アジピン酸、コハク酸、スベリン酸、セバシン酸、ドデカン二酸などの脂肪族ジカルボン酸、およびエチレングリコール、プロピレングリコール、１，４−ブタンジオール、１，４−シクロヘキサンジメタノールなどの脂肪族ジオールや、グリコール酸、ヒドロキシ酪酸、ヒドロキシ吉草酸、ヒドロキシカプロン酸、ヒドロキシペンタン酸、ヒドロキシヘプタン酸、ヒドロキシオクタン酸などのヒドロキシカルボン酸、ε−カプロラクトンなどの脂肪族ラクトン等を共重合したものであってもよい。 The reason for selecting polyethylene terephthalate (hereinafter also referred to as “PET”) is that it has a high melting point, is excellent in heat resistance, and is advantageous in terms of cost. In addition, aromatic dicarboxylic acids such as isophthalic acid and 5-sulfoisophthalic acid, aliphatic dicarboxylic acids such as adipic acid, succinic acid, suberic acid, sebacic acid, and dodecanedioic acid, and ethylene within a range not inhibiting the effects of the present invention Aliphatic diols such as glycol, propylene glycol, 1,4-butanediol, 1,4-cyclohexanedimethanol, glycolic acid, hydroxybutyric acid, hydroxyvaleric acid, hydroxycaproic acid, hydroxypentanoic acid, hydroxyheptanoic acid, hydroxyoctane It may be a copolymer of a hydroxycarboxylic acid such as an acid or an aliphatic lactone such as ε-caprolactone.
本発明のショートカット繊維は、粘度の異なる２種のポリエチレンテレフタレートによって構成された芯鞘複合型の断面形状を有している。芯部に高粘度ポリエチレンテレフタレート、鞘部に低粘度ポリエチレンテレフタレートが配され、芯部と鞘部の極限粘度差は０．０５〜０．１３である。芯部に高粘度ポリエチレンテレフタレートを配することにより、芯部は、繊維の剛性や強度を保持する役割を担う。一方、鞘部に低粘度ポリエチレンテレフタレートを配することにより、鞘部は、不織布化の際の熱と圧力が加わったときに、容易に圧着により変形しやすい易圧着効果を奏する役割を担う。両者の極限粘度差が０．０５より低くなると、鞘部において圧着変形しにくく、易圧着効果を奏しにくいものとなって通気度の小さい不織布が得にくくなり、一方、両者の極限粘度差が０．１３より大きくなると、繊維製造工程における延伸肯定で、鞘部の配向結晶化が不十分なものとなり、延伸後の熱セット工程で繊維同士が疑似密着しやすく、このような繊維を用いて湿式不織布を製造したときに、得られる不織布の地合が悪化しやすく好ましくない。なお、本発明のショートカット繊維を構成するポリエチレンテレフタレートの極限粘度は、上記した理由により、高粘度ポリエチレンテレフタレートとしては０．６以上がよく、低粘度ポリエチレンテレフタレートとしては０．３〜０．６がよい。また、高粘度ポリエチレンテレフタレートの極限粘度の上限は１．０程度でよい。また、繊維製造時の影響により、得られる繊維を構成する重合体の極限粘度は、材料の極限粘度と比較して０．０２〜０．０３程度値が小さくなる傾向にあるため、これを考慮して材料となる重合体の極限粘度を選択するとよい。 The shortcut fiber of the present invention has a core / sheath composite type cross-sectional shape constituted by two types of polyethylene terephthalate having different viscosities. High-viscosity polyethylene terephthalate is disposed in the core and low-viscosity polyethylene terephthalate is disposed in the sheath, and the intrinsic viscosity difference between the core and the sheath is 0.05 to 0.13. By arranging high-viscosity polyethylene terephthalate in the core, the core plays a role of maintaining the rigidity and strength of the fiber. On the other hand, by providing low-viscosity polyethylene terephthalate in the sheath, the sheath plays a role of easily crimping easily when deformed by crimping when heat and pressure are applied during the formation of the nonwoven fabric. If the difference in intrinsic viscosity between the two is lower than 0.05, the sheath part is difficult to be crimped and deformed, and it is difficult to obtain a non-woven fabric having a low air permeability, and the intrinsic viscosity difference between the two is 0. When larger than .13, the stretching in the fiber production process is positive, and the oriented crystallization of the sheath becomes insufficient, and the fibers are likely to be in close contact with each other in the heat setting process after stretching. When a nonwoven fabric is manufactured, the formation of the resulting nonwoven fabric tends to deteriorate, which is not preferable. The intrinsic viscosity of the polyethylene terephthalate constituting the shortcut fiber of the present invention is preferably 0.6 or more for high-viscosity polyethylene terephthalate and 0.3 to 0.6 for low-viscosity polyethylene terephthalate for the reasons described above. . The upper limit of the intrinsic viscosity of the high viscosity polyethylene terephthalate may be about 1.0. In addition, due to the influence at the time of fiber production, the intrinsic viscosity of the polymer constituting the obtained fiber tends to be smaller by about 0.02 to 0.03 than the intrinsic viscosity of the material. Thus, the intrinsic viscosity of the polymer used as the material may be selected.
本発明のショートカット繊維の芯部と鞘部の複合比率は、２０：８０〜８０：２０である。また、好ましくは４０：６０〜６０：４０である。芯部の比率が２０％を下回ると、繊維としての剛性が損なわれるため好ましくない。また、鞘部の比率が２０％を下回ると、易圧着効果を奏することができず、本発明の目的が達成しにくい。 The composite ratio of the core part and the sheath part of the shortcut fiber of the present invention is 20:80 to 80:20. Moreover, Preferably it is 40: 60-60: 40. If the ratio of the core part is less than 20%, the rigidity as the fiber is impaired, which is not preferable. On the other hand, if the ratio of the sheath portion is less than 20%, the effect of easy crimping cannot be achieved, and the object of the present invention is difficult to achieve.
本発明のショートカット繊維の断面形状は、上記したように芯鞘型であれば、円形断面に限定されず、異形断面であってもよい。したがって、同心円の芯鞘型のほか、扁平型、トリローバル型など任意の形状から選択することができるが、不織布化において少なくとも圧力を加えるカレンダー加工を施した際に繊維同士の接触面積が大きくなる同心円の芯鞘型あるいは扁平芯鞘型が好ましい。 The cross-sectional shape of the shortcut fiber of the present invention is not limited to a circular cross section as long as it is a core-sheath type as described above, and may be an irregular cross section. Therefore, in addition to the concentric core-sheath type, it can be selected from any shape such as a flat type or a trilobal type, but concentric circles that increase the contact area between fibers when calendering is applied at least under pressure in making a nonwoven fabric The core-sheath type or flat core-sheath type is preferable.
通常、熱可塑性樹脂からなる繊維であって、特定の繊維長を有する繊維を得る場合、スタフィングボックス法や押込加熱ギア法等により機械捲縮を付与することが多いが、本発明のショートカット繊維においては、湿式不織布を得るための繊維であることから、機械捲縮を付与しないもの（ノークリンプの繊維）とする。機械捲縮が付与されないことにより、湿式不織布の製造工程で良好に分散しやすく、地合いが良好で均一な性能を発揮することができるためである。 Usually, when a fiber made of a thermoplastic resin and having a specific fiber length is obtained, a mechanical crimp is often imparted by a stuffing box method or an indentation heating gear method, but the shortcut fiber of the present invention In this case, since it is a fiber for obtaining a wet nonwoven fabric, it is assumed that it does not impart mechanical crimp (no crimp fiber). This is because the mechanical crimping is not imparted, so that it is easy to disperse well in the manufacturing process of the wet nonwoven fabric, the texture is good, and uniform performance can be exhibited.
本発明のショートカット繊維の繊維長は、２〜２０ｍｍ程度であればよく、３〜１５ｍｍの範囲が好ましい。繊維長が２０ｍｍを超えると、不織布を得る工程での繊維の分散が悪くなり、均斉度に劣った湿式不織布となる。一方、繊維長を２ｍｍ未満にしようとすると、繊維を切断する際の発熱で繊維同士の融着が生じやすくなる。 The fiber length of the shortcut fiber of this invention should just be about 2-20 mm, and the range of 3-15 mm is preferable. When the fiber length exceeds 20 mm, fiber dispersion in the step of obtaining the nonwoven fabric is deteriorated, resulting in a wet nonwoven fabric having poor uniformity. On the other hand, if the fiber length is to be less than 2 mm, the fibers tend to be fused by heat generated when the fibers are cut.
ショートカット繊維の単糸繊度は、０．８〜４ｄｔｅｘ程度がよい。中でも１〜３．５ｄｔｅｘであることが好ましい。単糸繊度が４ｄｔｅｘを超えると、得られる湿式不織布の厚みが大きくなり、また繊維間の隙間が大きくなる傾向となり、一方、０．８ｄｔｅｘ未満になると、紡糸時に切れ糸が発生しやすくなり、操業性が悪くなるとともに、繊維同士の融着が生じやすく、強伸度特性に劣る傾向となる。 The single yarn fineness of the shortcut fiber is preferably about 0.8 to 4 dtex. Among these, 1 to 3.5 dtex is preferable. If the single yarn fineness exceeds 4 dtex, the thickness of the resulting wet nonwoven fabric tends to increase and the gap between the fibers tends to increase. On the other hand, if the single yarn fineness is less than 0.8 dtex, breakage tends to occur during spinning and In addition to the worsening of the properties, fusion between fibers tends to occur, and the strength and elongation properties tend to be inferior.
本発明のショートカット繊維は、細繊度のものではないため、実用的な強度を有し、その強度が３〜８ｃＮ／ｄｔｅｘであり、３．５〜７．５ｃＮ／ｄｔｅｘであることが好ましい。強度が３ｃＮ／ｄｔｅｘ未満であると、得られる不織布の機械的特性（強度）が劣るものになる。一方、強度が８ｃＮ／ｄｔｅｘを超えるものを得ようとすれば、より高粘度の重合体を用いる必要があるため、紡糸および延伸工程の操業性が悪くなり、得られる繊維の品位が劣りやすくなる。 Since the shortcut fiber of the present invention is not of a fineness, it has a practical strength, and the strength is 3 to 8 cN / dtex, and preferably 3.5 to 7.5 cN / dtex. If the strength is less than 3 cN / dtex, the resulting nonwoven fabric has poor mechanical properties (strength). On the other hand, if an attempt is made to obtain a material having a strength exceeding 8 cN / dtex, it is necessary to use a higher viscosity polymer, so that the operability of the spinning and stretching process is deteriorated, and the quality of the resulting fiber is likely to be inferior. .
ショートカット繊維の伸度は、２５〜１００％であり、中でも３０〜６０％であることが好ましい。伸度が２５％未満であると、延伸工程での操業性が悪くなり、得られる繊維の品位が劣るものとなり好ましくない。一方、伸度が１００％を超えると、延伸での配向結晶が充分に進んでおらず、熱や圧力の関与で擬似密着が発生しやすくなり、繊維間の密着が生じ、得られる繊維の品位が劣るものとなりやすい。 The elongation of the shortcut fiber is 25 to 100%, and preferably 30 to 60%. When the elongation is less than 25%, the operability in the stretching process is deteriorated, and the quality of the obtained fiber is deteriorated, which is not preferable. On the other hand, when the elongation exceeds 100%, the oriented crystals in the drawing are not sufficiently advanced, and pseudo-adhesion is likely to occur due to the involvement of heat and pressure, resulting in adhesion between fibers, and the quality of the resulting fiber. Tends to be inferior.
本発明においては、上記した本発明のショートカット繊維を用いて湿式不織布を得る。湿式不織布は上記の本発明のショートカット繊維のみから構成されたものであってもよいが、接着成分を用いて構成繊維同士を接着して不織布とするものが好ましい。接着成分としては、熱接着成分を有するバインダー繊維を用いることが好ましい。すなわち、本発明のショートカット繊維とバインダー繊維とを所定量混合したウエブを作成し、熱と圧力を付与することにより、本発明のショートカット繊維の鞘部を圧着により変形させ、かつバインダー繊維を溶融させて構成繊維同士を熱接着により一体化した湿式不織布を得ることが好ましい。なお、湿式不織布を作成する際に付与する熱と圧力は、同時に付与してもよく、あるいは、熱を付与して繊維を軟化させ（バインダー繊維を混合している場合は、バインダー繊維の熱接着成分を溶融または軟化させ）、その後に圧力を付与してもよい。なお、熱と圧力を同時に付与する方法としては、所定の温度に加熱した熱カレンダーロールに通すとよい。熱と圧力を別に付与する方法としては、熱ロールに沿わせる方法や熱風乾燥機内に通す方法により熱を付与した後に、一対のカレンダーロールに通して圧力を付与する方法が挙げられる。 In the present invention, a wet nonwoven fabric is obtained using the above-described shortcut fiber of the present invention. The wet nonwoven fabric may be composed of only the above-described shortcut fiber of the present invention. However, the wet nonwoven fabric is preferably a nonwoven fabric obtained by bonding constituent fibers to each other using an adhesive component. As the adhesive component, it is preferable to use a binder fiber having a thermal adhesive component. That is, by creating a web in which a predetermined amount of the shortcut fiber of the present invention and a binder fiber are mixed, and applying heat and pressure, the sheath of the shortcut fiber of the present invention is deformed by pressure bonding, and the binder fiber is melted. It is preferable to obtain a wet nonwoven fabric in which constituent fibers are integrated by thermal bonding. The heat and pressure applied when preparing the wet nonwoven fabric may be applied at the same time, or the heat is applied to soften the fibers (if the binder fibers are mixed, the binder fibers are thermally bonded. The ingredients may be melted or softened) and then pressure may be applied. In addition, as a method of giving heat and pressure simultaneously, it is good to pass through the heat | fever calendar roll heated to predetermined temperature. Examples of a method of separately applying heat and pressure include a method of applying heat through a pair of calender rolls after applying heat by a method of passing along a hot roll or a method of passing through a hot air dryer.
本発明のショートカット繊維とともに用いるバインダー繊維としては、ポリエチレンテレフタレートのみからなる未延伸糸を好適に用いることができる。未延伸糸は、繊維製造工程で、一旦溶融紡糸した後に巻き取っただけのものであり、溶融紡糸後に熱延伸が施されていないため、繊維を構成する重合体は十分に配向せずに、熱を付与した場合に容易に軟化して繊維同士を接着するバインダー繊維として機能する。 As the binder fiber used together with the shortcut fiber of the present invention, an undrawn yarn composed only of polyethylene terephthalate can be suitably used. In the fiber production process, the unstretched yarn is one that has only been wound after being melt-spun once, and since the heat-stretching has not been performed after melt-spinning, the polymer constituting the fiber is not sufficiently oriented, When heat is applied, it functions as a binder fiber that softens easily and bonds the fibers together.
本発明においては、湿式不織布を得る際に、湿式不織布の用途に応じて、様々な加工を施すことができ、この加工によって、例えば、繊維間の空隙を容易に調整することができ、また、不織布に各種の機能性を付与することができる。例えば、得られる不織布の密度を高めるために、湿式抄造後の乾燥熱処理後にさらにカレンダーロールで熱圧着加工を施したり、各種の機能を付与するために得られた不織布の表面に樹脂加工を行うことができる。このような加工においては、湿式抄造後の乾燥熱処理よりもさらに高温の熱処理を行う場合があるが、上記したポリエチレンテレフタレートのみからなる未延伸糸によるバインダー繊維を用いれば、繊維は、ポリエチレンテレフタレートからなるものであるためポリマーの融点が高く、耐熱性に優れており、これらの加工において高温の熱処理を施しても劣化が生じることがない。 In the present invention, when obtaining a wet nonwoven fabric, it can be subjected to various processing depending on the use of the wet nonwoven fabric, and by this processing, for example, the gap between the fibers can be easily adjusted, Various functionalities can be imparted to the nonwoven fabric. For example, in order to increase the density of the resulting nonwoven fabric, after heat treatment after wet papermaking, further calendering with a calender roll, or processing the surface of the nonwoven fabric obtained to give various functions Can do. In such processing, heat treatment may be performed at a higher temperature than the dry heat treatment after wet papermaking, but if the binder fiber made of undrawn yarn made only of polyethylene terephthalate is used, the fiber is made of polyethylene terephthalate. Therefore, the polymer has a high melting point and excellent heat resistance, and no deterioration occurs even when a high-temperature heat treatment is applied in these processes.
バインダー繊維の単糸繊度は、１〜３ｄｔｅｘ程度がよく、１〜２．５ｄｔｅｘが好ましい。単糸繊度が３ｄｔｅｘを超えると、本発明のショートカット繊維とバインダー繊維とからなるウエブにおいて繊維間の空隙が大きくなり、厚みが大きいものとなる。そして、バインダー繊維を溶融させた後に得られる湿式不織布の繊維間の空隙が大きく、通気度が高く、厚みの大きいものとなりやすい。一方、１ｄｔｅｘ未満のバインダー繊維であると、バインダー繊維を得る際に操業性が悪くなり、品質の劣った繊維となる場合が多く好ましくない。 The single yarn fineness of the binder fiber is preferably about 1 to 3 dtex, and preferably 1 to 2.5 dtex. When the single yarn fineness exceeds 3 dtex, the gap between the fibers becomes large and the thickness becomes large in the web composed of the shortcut fiber and the binder fiber of the present invention. And the space | gap between the fibers of the wet nonwoven fabric obtained after melting a binder fiber is large, air permeability is high, and it tends to become a thing with large thickness. On the other hand, when the binder fiber is less than 1 dtex, the operability is deteriorated when the binder fiber is obtained, and it is often not preferable because the fiber is inferior in quality.
バインダー繊維の繊維長は、本発明のショートカット繊維と同様に２〜２０ｍｍがよく、３〜１５ｍｍが好ましい。繊維長が２０ｍｍを超えると、不織布を得る際の繊維の分散が悪くなり、均斉度の低い不織布となりやすい。一方、繊維長が２ｍｍ未満になると、繊維製造時の切断の際に発熱で繊維同士の融着が生じている場合が多く、やはり不織布を得る際の繊維の分散が悪くなり、均斉度の低い不織布となりやすい。 The fiber length of the binder fiber is preferably 2 to 20 mm, and preferably 3 to 15 mm, like the shortcut fiber of the present invention. When the fiber length exceeds 20 mm, the dispersion of the fibers when obtaining the nonwoven fabric is deteriorated, and the nonwoven fabric tends to be low in uniformity. On the other hand, when the fiber length is less than 2 mm, the fibers are often fused due to heat generation during cutting during fiber production, and the dispersion of fibers in obtaining a nonwoven fabric also deteriorates, resulting in low uniformity. Easy to become non-woven fabric.
本発明のショートカット繊維とバインダー繊維を用いる際の両繊維の混合比率は、質量比（ショートカット繊維／バインダー繊維）で５０／５０〜９０／１０の範囲が好ましい。さらには、６０／４０〜８０／２０がより好ましい。 The mixing ratio of both fibers when using the shortcut fiber and the binder fiber of the present invention is preferably in the range of 50/50 to 90/10 in terms of mass ratio (shortcut fiber / binder fiber). Furthermore, 60 / 40-80 / 20 is more preferable.
本発明のショートカット繊維およびバインダー繊維を構成する重合体中には、本発明の効果を損なわない範囲で、リン酸エステル化合物やヒンダードフェノール化合物のような安定剤、コバルト化合物、蛍光増白剤、染料のような色調改良剤、二酸化チタンのような艶消し剤、可塑剤、顔料、制電剤、難燃剤、易染化剤などの各種添加剤を１種類または２種類以上添加してもよい。 In the polymer constituting the shortcut fiber and the binder fiber of the present invention, a stabilizer such as a phosphate ester compound or a hindered phenol compound, a cobalt compound, a fluorescent brightener, One or more additives such as a color tone improver such as a dye, a matting agent such as titanium dioxide, a plasticizer, a pigment, an antistatic agent, a flame retardant, and an easy dyeing agent may be added. .
本発明の湿式不織布用ショートカット繊維は、ショートカット繊維を構成する単繊維の断面が芯鞘形状であって、芯部に高粘度ポリエチレンテレフタレート、鞘部に低粘度ポリエチレンテレフタレートを配しているため、不織布を構成する際に圧力を付与すると、鞘部の低粘度ポリエチレンテレフタレートが容易に圧着変形するため、不織布の空隙を所望の範囲に調整することができ、容易に通気度が低く、気密性の高い湿式不織布を得ることができる。さらには、芯部の高粘度ポリエチレンテレフタレートは繊維の剛性を維持する骨格としての役割を担い、実用的な強度および伸度を維持することができるため、機械的特性にも優れた湿式不織布を得ることができる。このような優れた特性を有する湿式不織布は、性能の高いフィルターやセパレーター用途に好適に使用することが可能となる。 The shortcut fiber for wet nonwoven fabric of the present invention is a nonwoven fabric because the cross-section of the single fiber constituting the shortcut fiber has a core-sheath shape, and the core portion has high-viscosity polyethylene terephthalate and the sheath portion has low-viscosity polyethylene terephthalate. When a pressure is applied during the construction, the low-viscosity polyethylene terephthalate in the sheath part is easily crimped and deformed, so that the voids of the nonwoven fabric can be adjusted to a desired range, and the air permeability is low and airtightness is high. A wet nonwoven fabric can be obtained. Furthermore, the high-viscosity polyethylene terephthalate at the core plays a role as a skeleton that maintains the rigidity of the fiber, and can maintain practical strength and elongation, so that a wet nonwoven fabric with excellent mechanical properties is obtained. be able to. The wet nonwoven fabric having such excellent characteristics can be suitably used for high performance filters and separators.
次に、実施例を用いて本発明を具体的に説明する。ショートカット繊維の特性値及び湿式短繊維不織布の評価方法は次の通りである。
[単糸繊度]
切断前の繊維束を用いて、ＪＩＳ Ｌ １０１５ 正量繊度のＡ法により測定した。
[繊維長]
得られたショートカット繊維のサイドビュー写真を撮影し、任意の３０本の長さを測定し後、その平均値を撮影倍率で割り返して算出した。
[強度、伸度]
切断前の繊維束を用いて、ＪＩＳ Ｌ １０１５ 引張強さ及び伸び率により測定した。
[不織布の通気度]
得られた湿式維不織布を、ＪＩＳ Ｌ １０９６ 通気性のＡ法により測定した。８ｃｃ／ｃｍ２／ｓｅｃ未満を合格とした。
[不織布の機械的特性]
得られた湿式不織布を、ＪＩＳ Ｌ １０９６ 引張強さ及び伸び率のＡ法によりＭＤ方向（カレンダー加工の際の機械方向）の強力を測定した。１５Ｎ／２．５ｃｍ幅以上を合格とした。
[極限粘度]
フェノールと四塩化エタンとの等質量混合物を溶媒として、試料濃度０．５質量％、温度２０℃の条件下で常法に基づき測定した。
[芯鞘型複合繊維における各重合体の極限粘度]
芯鞘型複合繊維を、フェノールと四塩化エタンとの等質量混合物を溶媒として、試料濃度０．５質量％、温度２０℃の条件下で測定して複合繊維の極限粘度[η]０を得る。一方、同じ芯鞘型複合繊維をアルカリ減量処理して鞘部を溶解除去した後、芯部（高粘度ＰＥＴ）の極限粘度を上記と同様にして測定して、その極限粘度を[η]１とする。
鞘部分を構成するＰＥＴの極限粘度を[η]２としたときに、[η]０、[η]１および[η]２の間には下記式１で示される関係が成立する。
式１ ： [η]０＝（[η]１＋[η]２）／２
したがって、上記の式１から、複合繊維の鞘部を構成するＰＥＴの極限粘度[η]２を下記の式２より求める。
式２ ： [η]２＝２[η]０−[η]１
[不織布の地合]
得られた不織布の地合を目視により以下の３段階で評価した。
○：構成繊維の分布が均一であり、斑が非常に少ない。
△：構成繊維の分布がやや不均一であり、斑がやや目立つ。
×：構成繊維の分布が非常に不均一であり、斑が目立つ。
Next, the present invention will be specifically described using examples. The characteristic value of the shortcut fiber and the evaluation method of the wet short fiber nonwoven fabric are as follows.
[Single yarn fineness]
It measured by A method of JISL1015 positive amount fineness using the fiber bundle before a cutting | disconnection.
[Fiber length]
A side view photograph of the obtained shortcut fiber was taken, the length of any 30 fibers was measured, and the average value was calculated by dividing by the photographing magnification.
[Strength, elongation]
Using the fiber bundle before cutting, it was measured by JIS L 1015 tensile strength and elongation.
[Air permeability of nonwoven fabric]
The obtained wet fiber nonwoven fabric was measured by JIS L 1096 breathable A method. Less than 8 cc / cm 2 / sec was accepted.
[Mechanical properties of nonwoven fabric]
The obtained wet nonwoven fabric was measured for strength in the MD direction (machine direction during calendering) by A method of JIS L 1096 tensile strength and elongation. 15 N / 2.5 cm width or more was considered acceptable.
[Intrinsic viscosity]
The measurement was carried out based on a conventional method under the conditions of a sample concentration of 0.5% by mass and a temperature of 20 ° C. using an equal mass mixture of phenol and ethane tetrachloride as a solvent.
[Intrinsic viscosity of each polymer in core-sheath type composite fiber]
The core-sheath type composite fiber is measured under the conditions of a sample concentration of 0.5% by mass and a temperature of 20 ° C. using an equal mass mixture of phenol and ethane tetrachloride as a solvent to obtain the intrinsic viscosity [η] 0 of the composite fiber. . On the other hand, after the same core-sheath type composite fiber was subjected to alkali weight reduction treatment and the sheath part was dissolved and removed, the intrinsic viscosity of the core part (high viscosity PET) was measured in the same manner as described above, and the intrinsic viscosity was [η] 1 And
The intrinsic viscosity of PET constituting the sheath portion is taken as [η] 2, [η] 0, the relationship is established of the following formula 1 is between [eta] 1 and [eta] 2.
Formula 1: [η] 0 = ([η] 1 + [η] 2 ) / 2
Therefore, the intrinsic viscosity [η] 2 of PET constituting the sheath portion of the composite fiber is obtained from the following equation 2 from the above equation 1.
Formula 2: [η] 2 = 2 [η] 0 − [η] 1
[Nonwoven fabric]
The formation of the obtained nonwoven fabric was visually evaluated in the following three stages.
○: The distribution of the constituent fibers is uniform and the spots are very few.
Δ: The distribution of the constituent fibers is slightly non-uniform, and the spots are slightly noticeable.
X: The distribution of the constituent fibers is very uneven and the spots are conspicuous.
実施例１[芯鞘型複合繊維の製造]
融点が２５６℃、極限粘度０．６４のＰＥＴを芯部とし、極限粘度０．５３のＰＥＴを鞘部とし、孔数１０１４、円形断面同心芯鞘複合紡糸口金を用い、芯：鞘＝５０：５０となるように計量し、合計吐出量６２１ｇ／分、紡糸温度２８５℃、紡糸速度１１００ｍ／分で溶融紡糸し、複合繊維の未延伸糸を得た。次いで、得られた未延伸糸を延伸温度７３℃、延伸倍率３．８５倍で延伸を行い、続いて１８０℃の熱ローラーにて緊張熱処理を行った。ポリエーテルとポリエーテルエステルアミドを主成分とする分散油剤を付着量が０．２質量％となるように付与した後、カットして単糸繊度１．６ｄｔｅｘ、繊維長５ｍｍの本発明のショートカット繊維を得た。得られたショートカット繊維の芯部ＰＥＴの極限粘度は０．６２、鞘部ＰＥＴの極限粘度は０．５１であった。
Example 1 [Production of core-sheath type composite fiber]
The melting point is 256 ° C., PET having an intrinsic viscosity of 0.64 is used as the core, PET having the intrinsic viscosity of 0.53 is used as the sheath, and a concentric core-sheath composite spinneret with 1014 holes and a circular cross section is used. It was weighed to 50 and melt-spun at a total discharge rate of 621 g / min, a spinning temperature of 285 ° C. and a spinning speed of 1100 m / min to obtain an undrawn yarn of a composite fiber. Subsequently, the obtained undrawn yarn was drawn at a drawing temperature of 73 ° C. and a draw ratio of 3.85 times, and subsequently subjected to tension heat treatment with a hot roller at 180 ° C. After applying a dispersion oil mainly composed of polyether and polyether ester amide so that the adhesion amount is 0.2% by mass, the fiber is cut to a single fiber fineness of 1.6 dtex and a fiber length of 5 mm according to the present invention. Got. The intrinsic viscosity of the core part PET of the obtained shortcut fiber was 0.62, and the intrinsic viscosity of the sheath part PET was 0.51.
[未延伸バインダー繊維の製造]
極限粘度０．６５のポリエチレンテレフタレートペレットを１３０℃で乾燥後、２９５℃で溶融し、紡糸口金（紡糸孔数が１０４０）を通して、吐出量１８０ｇ／分で吐出し、紡糸速度１１５０ｍ／分の速度で引取り、単繊維繊度が１．３５デシテックスの未延伸ポリエチレンテレフタレート繊維を得た。該ポリエチレンテレフタレート繊維を約８０万デシテックスのトウとなし、延伸熱処理を施すことなく、供給ロールと巻取ロールとのローラー間の工程張力（ロール間の速度比が１．０４倍）で繊維を走行させて、ポリエーテルとポリエーテルエステルアミドを主成分とする分散油剤を付着量が０．２質量％となるように付与した後、カットして単糸繊度１．３５ｄｔｅｘ、繊維長５ｍｍのショートカットされた未延伸のバインダー繊維を得た。
[Manufacture of unstretched binder fiber]
Polyethylene terephthalate pellets having an intrinsic viscosity of 0.65 are dried at 130 ° C., melted at 295 ° C., and discharged through a spinneret (number of spinning holes: 1040) at a discharge rate of 180 g / min, at a spinning speed of 1150 m / min. The unstretched polyethylene terephthalate fiber having a single fiber fineness of 1.35 dtex was obtained. The polyethylene terephthalate fiber has a tow of about 800,000 dtex, and the fiber runs with a process tension between the supply roll and the take-up roll (speed ratio between rolls is 1.04 times) without subjecting it to stretching heat treatment. Then, after applying a dispersion oil agent mainly composed of polyether and polyether ester amide so that the adhesion amount is 0.2% by mass, it is cut to be a shortcut with a single yarn fineness of 1.35 dtex and a fiber length of 5 mm. An unstretched binder fiber was obtained.
[湿式不織布の製造]
得られたショートカット繊維を主体繊維として、主体繊維とバインダー繊維とを用い、混率を質量比６０／４０（主体繊維／バインダー繊維）として、パルプ離解機（熊谷理機工業製）に投入し、３０００ｒｐｍにて１分間撹拌した。その後、得られた試料を抄紙機（熊谷理機工業製角型シ−トマシン）にて、ポリエーテルとポリエーテルエステルアミドを主成分とする分散油剤を添加した後、付帯の攪拌羽にて攪拌を行い抄紙し、湿式ウエブとした。そして、湿式ウエブを回転式乾燥機（熊谷理機工業製）にて１４０℃の温度で熱処理し、表面が平滑の熱カレンダー装置にて１６０℃、線圧１００ｋｇ／ｃｍ、処理速度２ｍ／分にて熱圧着を施し、坪量が約８０ｇ／ｍ２のポリエチレンテレフタレート繊維からなる湿式不織布を得た。
[Manufacture of wet nonwoven fabric]
Using the obtained shortcut fiber as the main fiber, using the main fiber and the binder fiber, the mixing ratio is set to 60/40 (main fiber / binder fiber) and put into a pulp disintegrator (manufactured by Kumagai Riki Kogyo Co., Ltd.) at 3000 rpm. For 1 minute. After that, the obtained sample was added with a paper machine (Kumagaya Riki Kogyo Kakuto Sheet Machine) with a dispersion oil mainly composed of polyether and polyetheresteramide, and then stirred with an accompanying stirring blade. To make a wet web. Then, the wet web is heat-treated at a temperature of 140 ° C. with a rotary dryer (manufactured by Kumagai Riki Kogyo Co., Ltd.), 160 ° C. with a smooth surface, a linear pressure of 100 kg / cm, and a processing speed of 2 m / min. The wet nonwoven fabric made of polyethylene terephthalate fibers having a basis weight of about 80 g / m 2 was obtained.
実施例２〜３
主体繊維の芯鞘比率を表１のように変更したこと以外は実施例１と同様に実施した。
Examples 2-3
The same procedure as in Example 1 was performed except that the core-sheath ratio of the main fiber was changed as shown in Table 1.
実施例４
実施例１において、融点が２５６℃、極限粘度０．６４のＰＥＴを芯部とし、極限粘度０．５６のＰＥＴを鞘部としたこと以外は、実施例１と同様にして、本発明のショートカット繊維を得たこと以外は、実施例１と同様に実施した。得られたショートカット繊維の芯部ＰＥＴの極限粘度は０．６２、鞘部ＰＥＴの極限粘度は０．５４であった。
Example 4
In Example 1, the shortcut of the present invention is the same as in Example 1 except that the melting point is 256 ° C., PET having an intrinsic viscosity of 0.64 is used as the core, and PET having the intrinsic viscosity of 0.56 is used as the sheath. Except having obtained the fiber, it implemented similarly to Example 1. FIG. The intrinsic viscosity of the core part PET of the obtained shortcut fiber was 0.62, and the intrinsic viscosity of the sheath part PET was 0.54.
比較例１
鞘部に極限粘度０．６０のＰＥＴを用いたこと以外は、実施例１と同様に実施した。得られた繊維の鞘部ＰＥＴの極限粘度は０．５９であった。
Comparative Example 1
It implemented like Example 1 except having used PET with intrinsic viscosity 0.60 for a sheath part. The intrinsic viscosity of the obtained sheath PET of the fiber was 0.59.
比較例２
鞘部に極限粘度０．６４のＰＥＴ（芯部と同じ極限粘度のＰＥＴ）を用い、合計吐出量５７８ｇ／分、延伸倍率３．７１倍としたこと以外は実施例１と同様に実施した。
Comparative Example 2
The same procedure as in Example 1 was performed except that PET having an intrinsic viscosity of 0.64 (PET having the same intrinsic viscosity as that of the core) was used for the sheath, and the total discharge rate was 578 g / min and the draw ratio was 3.71 times.
比較例３
鞘部に極限粘度０．４５のＰＥＴを用い、延伸倍率４．００倍としたこと以外は実施例１と同様に実施した。得られた繊維の鞘部ＰＥＴの極限粘度は０．４５であった。
Comparative Example 3
The same procedure as in Example 1 was performed except that PET having an intrinsic viscosity of 0.45 was used for the sheath and the draw ratio was 4.00. The intrinsic viscosity of the obtained sheath PET of the fiber was 0.45.
比較例４〜５
主体繊維の芯鞘比率を表１のように変更したこと以外は実施例１と同様に実施した。
Comparative Examples 4-5
The same procedure as in Example 1 was performed except that the core-sheath ratio of the main fiber was changed as shown in Table 1.
実施例および比較例で得られた繊維および不織布の評価を表１に示す。 Table 1 shows the evaluation of the fibers and nonwoven fabrics obtained in Examples and Comparative Examples.
表１から明らかなように、実施例１〜４のショートカット繊維は、実用的な機械物性を示し、得られた湿式不織布は、通気度が低く、気密性に優れ、機械的特性にも優れたものであった。 As is clear from Table 1, the shortcut fibers of Examples 1 to 4 showed practical mechanical properties, and the obtained wet nonwoven fabric had low air permeability, excellent air tightness, and excellent mechanical properties. It was a thing.
一方、比較例１〜２のショートカット繊維は、極限粘度差が小さい、もしくは無かったため、繊維自体の強度は実用的なものであったが、この繊維を用いて得られた不織布は、実施例と比較して、不織布強力が劣り、通気度も高いものであった。
比較例３のショートカット繊維は、極限粘度差が大きすぎたために、湿式抄造法により不織布製造の際に水分散性が悪く、地合が悪化した。鞘部に低粘度ＰＥＴを使用しているため不織布強力は高かったものの、地合が悪いため通気度は高いものとなった。
比較例４のショートカット繊維は、鞘部ＰＥＴの比率が少ないために、不織布強度が低く、通気度も高いものとなった。
比較例５のショートカット繊維は、鞘部ＰＥＴの比率が大きいために、地合いが悪く、不織布強度が低いものとなった。
On the other hand, the shortcut fibers of Comparative Examples 1 and 2 had a small or no intrinsic viscosity difference, so the strength of the fibers themselves was practical, but the nonwoven fabric obtained using this fiber was In comparison, the nonwoven fabric strength was poor and the air permeability was high.
Since the shortcut fiber of Comparative Example 3 had an excessively large difference in intrinsic viscosity, the water dispersibility was poor when the nonwoven fabric was produced by the wet papermaking method, and the formation deteriorated. Although the nonwoven fabric strength was high because low-viscosity PET was used for the sheath, the air permeability was high due to poor formation.
The shortcut fiber of Comparative Example 4 had a low nonwoven fabric strength and a high air permeability because the ratio of the sheath portion PET was small.
Since the ratio of the sheath part PET was large, the shortcut fiber of Comparative Example 5 was poor in texture and low in nonwoven fabric strength.
Claims (3)
It is a wet nonwoven fabric comprised by the shortcut fiber for wet nonwoven fabrics of Claim 1 or 2, Comprising: This nonwoven fabric is what integrated fibers by heat and a pressure, The wet characterized by the above-mentioned. Non-woven fabric.
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