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Continuous fiber nonwoven fabric

Inactive Publication Date: 2011-06-09
MITSUI CHEM INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0010]The continuous fiber nonwoven fabrics according to the present invention have high fiber strength, in particular mono-filament strength, compared to conventional hollow fiber nonwoven fabrics and have high hollowness even when the propylene polymer fibers forming the nonwoven fabrics are reduced in fiber diameter. In addition, the nonwoven fabrics of the invention have high breathability and particularly high lightweight properties, opacity and reflecting properties.

Problems solved by technology

However, reducing the slit width of a die also increases the pressure in the die and therefore has a limitation.
These nonwoven fabrics, however, are still insufficient in strength, with tensile strength of 7.4 kg / 5 cm (36.3 N / 25 mm) and 6.8 kg / 5 cm (33.3 N / 25 mm), respectively.
The results in the literature show that fine fibers with a fiber diameter of less than 25 μm in fact have a low hollowness of not more than 19% and the production of polypropylene nonwoven fabrics of fine fibers and high hollowness is difficult.

Method used

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Examples

Experimental program
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Effect test

example 1

[0053]A propylene polymer used was a propylene homopolymer (PP-1) having a MFR at 230° C. under 2160 g load of 24 g / 10 min [Achieve 3854 manufactured by Exxon Mobil Chemical, Mw / Mn: 2.3, Mz / Mw: 1.8, melting point (Tm): 148° C., produced with metallocene catalyst]. The propylene homopolymer was molten in an extruder (screw diameter: 75 mm) at a shaping temperature of 210° C. The molten polymer was spun with use of a nonwoven fabric manufacturing apparatus (a spunbonding apparatus, 320 mm in length perpendicular to the machine direction on a collecting surface) as illustrated in FIG. 3 which had a spinneret having nozzle pitches 4.5 mm in vertical direction and 4.0 mm in horizontal direction and orifices as illustrated in FIG. 1 capable of giving a fiber cross section as shown in FIG. 2, at a throughput of 0.6 g / min per orifice and a spinning rate of 2550 m / min. The fibers were cooled with 25° C. cooling air and deposited on a collecting belt. The web was thermally pressure treated wi...

example 2

[0056]A propylene polymer used was a propylene homopolymer (PP-2) having a MFR at 230° C. under 2160 g load of 65 g / 10 min [Mw / Mn: 2.6, Mz / Mw: 1.7, melting point (Tm): 155° C., produced with metallocene catalyst]. The propylene homopolymer was molten in an extruder (screw diameter: 75 mm) at a shaping temperature of 190° C.

[0057]The molten polymer was spun with use of a nonwoven fabric manufacturing apparatus (a spunbonding apparatus, 320 mm in length perpendicular to the machine direction on a collecting surface) as illustrated in FIG. 3 which had a spinneret having nozzle pitches 4.5 mm in vertical direction and 4.0 mm in horizontal direction and orifices as illustrated in FIG. 1 capable of giving a fiber cross section as shown in FIG. 2, at a throughput of 0.6 g / min per orifice and a filament velocity of 3158 m / min. The fibers were cooled with 25° C. cooling air and deposited on a collecting belt. The web was thermally pressure treated with an embossing roll (emboss area percenta...

example 3

[0059]A propylene polymer used was a propylene homopolymer (PP-3) having a MFR at 230° C. under 2160 g load of 65 g / 10 min [Mw / Mn: 2.8, Mz / Mw: 1.8, melting point (Tm): 155° C., produced with metallocene catalyst]. The propylene homopolymer was molten in an extruder (screw diameter: 75 mm) at a shaping temperature of 190° C. The molten polymer was spun with use of a nonwoven fabric manufacturing apparatus (a spunbonding apparatus, 320 mm in length perpendicular to the machine direction on a collecting surface) as illustrated in FIG. 3 which had a spinneret having nozzle pitches 4.5 mm in vertical direction and 4.0 mm in horizontal direction and orifices as illustrated in FIG. 1 capable of giving a fiber cross section as shown in FIG. 2, at a throughput of 0.6 g / min per orifice and a filament velocity of 2769 m / min. The fibers were cooled with 25° C. cooling air and deposited on a collecting belt. The web was thermally pressure treated with an embossing roll (emboss area percentage: 2...

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Abstract

The invention has an object of providing a continuous fiber nonwoven fabric including a hollow fiber having excellent strength, in particular mono-filament strength, and having high hollowness even when formed to a fine filament.A continuous fiber nonwoven fabric includes a hollow fiber including a propylene polymer having a ratio of the Z average molecular weight (Mz) and the weight average molecular weight (Mw), (Mz / Mw), in the range of 1.5 to 1.9, and in a preferred embodiment having a ratio of the weight average molecular weight (Mw) and the number average molecular weight (Mn), (Mw / Mn), in the range of 2.0 to 2.9.

Description

TECHNICAL FIELD[0001]The present invention relates to continuous fiber nonwoven fabrics that comprise propylene polymer fibers having high mono-filament strength and high hollowness even when formed to fine filaments.BACKGROUND ART[0002]Polypropylene nonwoven fabrics have excellent breathability, softness and lightweight properties and are widely used in various applications. The nonwoven fabrics require specific properties depending on the applications and are required to be improved in these properties.[0003]To reduce the weight of nonwoven fabrics, various kinds of processes have been proposed in which fibers that form nonwoven fabrics are hollowed. Reducing the slit width of a die increases the hollowness of the obtainable polypropylene fibers. However, reducing the slit width of a die also increases the pressure in the die and therefore has a limitation. Accordingly, it is necessary that the diameter of a die be increased in order to produce polypropylene fibers having a high h...

Claims

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Application Information

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IPC IPC(8): D04H3/00D01F6/06D04H3/007D04H3/073
CPCD01D5/24D04H3/073D04H3/007D01F6/06Y10T442/612
Inventor MATSUBARA, AKIOYOKOYAMA, TETSUYASUZUKI, KENICHIMOTOMURA, SHIGEYUKI
Owner MITSUI CHEM INC
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