Polyphenylene sulfide fiber and nonwoven fabric

a polyphenylene sulfide fiber and nonwoven fabric technology, applied in textiles, papermaking, textiles and papermaking, etc., can solve the problems of significant thermal shrinkage of fibers or nonwoven fabrics, poor thermal bonding properties, poor thermal dimensional stability, etc., and achieve excellent thermal bonding properties and excellent mechanical strength.

Inactive Publication Date: 2014-07-03
TORAY IND INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0009]In consideration of the above problems in the conventional art, the present invention aims to provide a fiber comprising a PPS resin as a main component and having both excellent heat resistance and excellent thermal bonding properties, and a nonwoven fabric comprising the fiber.
[0013]The polyphenylene sulfide fiber (hereinafter also referred to as PPS fiber) of the first aspect of the present invention having the sum of the crystallinity and the rigid amorphous fraction of 30% or more, preferably 35% or more, is excellent in thermal dimensional stability. The polyphenylene sulfide fiber having the sum of the crystallinity and the rigid amorphous fraction of 90% or less, more preferably 70% or less, still more preferably 50% or less, is preferred in terms of thermal bonding properties.
[0014]The crystallinity is not limited to a specific range. However, the crystallinity is preferably 5% or more, more preferably 10% or more, and still more preferably 15% or more. When a nonwoven web of the fiber having such crystallinity is thermally bonded, the resulting sheet is prevented from breakage due to being wound up around a roll. The crystallinity is preferably less than 25%, more preferably 23% or less, and still more preferably 20% or less so that a large amount of the amorphous phase (including the rigid amorphous fraction) is present in the fiber and contributes to excellent thermal bonding properties for thermal bonding of the nonwoven web.
[0016]The PPS fiber of the present invention has excellent thermal bonding properties while maintaining the properties of a PPS resin, namely, heat resistance, chemical resistance, and flame retardancy. Consequently, the nonwoven fabric of the present invention also has excellent mechanical strength while maintaining the properties of a PPS resin, namely, heat resistance, chemical resistance, and flame retardancy and is therefore usable for various industrial applications.

Problems solved by technology

However, in cases where a PPS resin is spun into fibers to form a nonwoven fabric, problems may arise concerning poor thermal dimensional stability, which may lead to significant thermal shrinkage of the fibers or the nonwoven fabric.
These proposals, however, suffer from poor thermal bonding properties.
Thus there has been no proposal for a PPS fiber or PPS nonwoven fabric having both heat resistance and thermal bonding properties.

Method used

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
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  • Polyphenylene sulfide fiber and nonwoven fabric

Examples

Experimental program
Comparison scheme
Effect test

example 1

PPS Resin

[0085]A 100 mol % linear polyphenylene sulfide resin that was intentionally not copolymerized with trichlorobenzene (made by Toray Industries, Inc., Product No. E2280, MFR: 160 g / 10 min) was dried in a nitrogen atmosphere at 160° C. for 10 hours, and used in the following procedure.

Spinning and Forming into Nonwoven Web

[0086]The PPS resin was molten in an extruder, and spun from a rectangular spinneret having a hole diameter of 0.50 mm at a spinning temperature of 320° C. and at a discharge rate per hole of 1.38 g / min. The spun filamentary streams were allowed to cool down and solidify between the rectangular spinneret and a rectangular ejector at a distance of 55 cm in an atmosphere at room temperature (20° C.). The filamentary streams that had cooled down and solidified were passed through the rectangular ejector and were pulled and drawn by compressed air that was heated to 230° C. with an air heater and blown out from the ejector at an ejector pressure of 0.15 MPa. The ...

example 2

[0090]PPS Resin, Spinning, and Forming into Nonwoven Web

[0091]The same PPS resin as in Example 1 was spun and formed into a nonwoven web in the same manner as in Example 1 except that the temperature of the compressed air was 200° C.

[0092]The obtained filaments had an average single fiber fineness of 2.8 dtex, a crystallinity of 17.3%, the sum of the rigid amorphous fraction and the crystallinity of 37.3%, and a boiling water shrinkage of 7.0%. The spinning speed was 4,991 m / min. During the one-hour spinning, the occurrence of the breakage of the filaments was zero and thus good spinnability was observed.

Temporary Bonding and Thermal Bonding

[0093]Next, the nonwoven web was temporarily bonded and then thermally bonded in the same manner as in Example 1 to produce a filament nonwoven fabric of Example 2.

[0094]The obtained nonwoven fabric had no significant shrinkage in width due to thermal shrinkage by thermal bonding with the embossing roll pair and showed good quality without wrinkl...

example 3

[0095]PPS Resin, Spinning, and Forming into Nonwoven Web

[0096]The same PPS resin as in Example 1 was spun and formed into a nonwoven web in the same manner as in Example 1 except that the temperature of the compressed air was 140° C.

[0097]The obtained filaments had an average single fiber fineness of 2.9 dtex, a crystallinity of 15.1%, the sum of the rigid amorphous fraction and the crystallinity of 31.3%, and a boiling water shrinkage of 17.5%. The spinning speed was 4,824 m / min. During the one-hour spinning, the occurrence of the breakage of the filaments was zero and thus good spinnability was observed.

Temporary Bonding and Thermal Bonding

[0098]Next, the nonwoven web was temporarily bonded and then thermally bonded in the same manner as in Example 1 to produce a filament nonwoven fabric of Example 3.

[0099]The obtained nonwoven fabric had no significant shrinkage in width due to thermal shrinkage by thermal press-bonding with the embossing roll pair and showed good quality without...

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Abstract

Provided are a polyphenylene sulfide fiber including a PPS resin as a main component and having both excellent heat resistance and excellent thermal bonding properties, and a nonwoven fabric including the fiber. The polyphenylene sulfide fiber includes polyphenylene sulfide as a main component and having the sum of the crystallinity and the rigid amorphous fraction of 30% to 90%. The crystallinity is preferably not less than 5% and less than 25%. The polyphenylene sulfide fiber is used to form a nonwoven fabric. The nonwoven fabric is preferably produced by consolidation by thermal bonding or mechanical entanglement.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This is the U.S. National Phase application of PCT / JP2012 / 064256, filed Jun. 1, 2012, which claims priority to Japanese Patent Application No. 2011-123994, filed Jun. 2, 2011, the disclosures of these applications being incorporated herein by reference in their entireties for all purposes.FIELD OF THE INVENTION[0002]The present invention relates to a fiber comprising a resin comprising polyphenylene sulfide (hereinafter sometimes abbreviated to “PPS”) as a main component, and a nonwoven fabric comprising the fiber.BACKGROUND OF THE INVENTION[0003]PPS resins are excellent in heat resistance, flame retardancy and chemical resistance and are therefore suitably used as engineering plastics, films, fibers, nonwoven fabrics, or the like. Especially nonwoven fabrics utilizing these excellent properties are expected to be used in industrial applications such as heat-resistant filters, electrical insulation materials, and battery separators.[0004]...

Claims

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D01F6/76D04H1/4326
CPCD04H1/4326D01F6/765D01D5/08D04H1/44D04H1/54Y10T442/60Y10T442/69D01F6/76D04H3/009D04H3/10D04H3/14
Inventor NAKANO, YOHEIYAKAKE, YOSHIKAZUITO, MASASHI
Owner TORAY IND INC
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