Antimicrobial active fiber yarn, method for manufacturing antimicrobial active fiber yarn, antimicrobial active nonwoven fabric, and antimicrobial active mask

Abstract

To provide an anti-microbial active fiber yarn that has an excellent decontamination effect and hardly causes adhesion of dirt, a method for producing the anti-microbial active fiber yarn, an anti-microbial active nonwoven fabric, and an anti-microbial active mask.SOLUTION: There are provided: an anti-microbial active fiber yarn 10 in which an anti-microbial active substance 2 is embedded in a synthetic yarn 1, wherein the anti-microbial active substance 2 is particulate with a maximum diameter of 0.1 to 10 μm, a maximum diameter in a vertical cross section of the synthetic yarn 1 is 10 to 60 μm, and the anti-microbial active substance 2 is swollen on a surface of the synthetic yarn 1; a method for producing the same; an anti-microbial nonwoven fabric using the anti-microbial fiber yarn 10; and an anti-microbial active mask using the anti-microbial active fiber yarn.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to an antimicrobial active fiber yarn, a method for manufacturing the antimicrobial active fiber yarn, an antimicrobial active nonwoven fabric, and an antimicrobial active mask. More specifically, the present invention relates to an antimicrobial active fiber yarn containing an antimicrobial active substance, a method for manufacturing the antimicrobial active fiber yarn, an antimicrobial active nonwoven fabric using the antimicrobial active fiber yarn, and an antimicrobial active mask using the antimicrobial active fiber nonwoven fabric.

Background Art

[0002] In restaurants and the like, as measures against infectious diseases caused by microorganisms such as viruses such as influenza virus, coronavirus, norovirus, and bacteria such as staphylococcus, in addition to having employees wear masks, gloves, dedicated clothing, etc., decontamination of the store is appropriately performed. As decontamination of the store, for example, decontamination of the store space is performed by an air cleaner using a decontamination air filter, or decontamination is performed by wiping tables and the like in the store with a decontamination cloth.

[0003] Thus, fiber products such as masks, gloves, clothing, air filters, and cloths are used for infectious disease countermeasures. Specific examples of decontamination fiber products include, for example, a filter comprising a cleaning agent, a resin binder, and a cloth or nonwoven fabric, wherein the resin binder comprises an aqueous acrylic resin and a coupling agent, and the aqueous acrylic resin is a polymer obtained by polymerizing a monomer containing an unsaturated monomer having a hydroxyl group-containing (meth)acryloyl group, an unsaturated carboxylic acid containing an unsaturated bond, and another unsaturated monomer having a (meth)acryloyl group, and is an aqueous acrylic resin having a glass transition temperature in the range of 30 to 100°C (see, for example, Patent Document 1). Also, there is known a breathable mask having a shape suitable for covering the mouth and nose of a user and making close contact with the face of the user, comprising means for holding the mask at a predetermined position on the face of the user, and including one or a plurality of filter material layers, the filter material being arranged such that the intake and / or exhalation of the user passes through the filter material. A mask including a breathable base material containing an acidic polymer is known (see, for example, Patent Document 2).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, in the filter material described in Patent Document 1 above, since a resin binder is used, there is a drawback that the cleaning agent is coated by the resin binder and the effect of the cleaning agent itself cannot be fully exhibited. In the mask described in Patent Document 2 above, although an acidic polymer is used, it is likely to fall off and the decontamination effect is not sufficiently excellent.

[0006] Also, the filter material of Patent Document 1 above and the mask described in Patent Document 2 have a drawback that dirt easily adheres to them.

[0007] The present invention has been made in view of the above circumstances, and an object thereof is to provide an antimicrobial active fiber yarn having an excellent decontamination effect and being difficult for dirt to adhere, a method for producing the antimicrobial active fiber yarn, an antimicrobial active nonwoven fabric, and an antimicrobial active mask.

Means for Solving the Problems

[0008] The inventors of the present invention have conducted intensive studies to solve the above problems, and as a result, have found that the above problems can be solved by embedding a predetermined antimicrobial substance in a synthetic fiber and causing a part of the antimicrobial substance to bulge out from the surface of the synthetic fiber, thereby completing the present invention.

[0009] The present invention relates to (1) an antimicrobial active fiber yarn in which an antimicrobial substance is embedded in a synthetic fiber, the antimicrobial substance being in the form of particles having a maximum diameter of 0.1 to 10 μm, the maximum diameter in the vertical cross-section of the synthetic fiber being 10 to 60 μm, and the antimicrobial substance bulging out from the surface of the synthetic fiber and the antimicrobial active substance is an ether-based antiviral agent composed of an organic substance, and the blending ratio of the antimicrobial active substance is 0.5 to 10% by mass and existing in the antimicrobial active fiber yarn.

[0010] The present invention relates to (2) The range of the surface area for bulging at least one of the antimicrobial active substances is 0.5×10 -3 ~3×10 -3 mm 2 and existing in the antimicrobial active fiber yarn according to the above (1).

[0011] The present invention relates to (3) and existing in the antimicrobial active fiber yarn according to the above (1) or (2), wherein the material of the synthetic fiber is polyolefin.

[0012] The present invention relates to (4) a method for producing the antimicrobial active fiber yarn according to any one of the above (1) to (3), which comprises a spinning step of spinning a mixture containing a molten synthetic polymer and an antimicrobial substance with a spinneret having a diameter of 500 to 800 μm into a round linear pre-fiber yarn, and a stretching step of stretching the pre-fiber yarn to cause the antimicrobial substance to bulge out from the surface of the synthetic fiber, and existing in the method for producing the antimicrobial active fiber yarn. wherein the antimicrobial active substance does not bulge The present invention relates to (5) and existing in the antimicrobial active nonwoven fabric using the antimicrobial active fiber yarn according to any one of the above (1) to (3).

[0013] The present invention relates to (6) and existing in the antimicrobial active nonwoven fabric using the antimicrobial active fiber yarn according to any one of the above (1) to (3), which is used as an air filter, has a basis weight of 8 to 400 gsm, a thickness of 0.05 to 5 mm, and an air permeability of 100 to 2000 cc / cm

[0014] The present invention relates to (6) and existing in the antimicrobial active nonwoven fabric using the antimicrobial active fiber yarn according to any one of the above (1) to (3), which is used as an air filter, has a basis weight of 8 to 400 gsm, a thickness of 0.05 to 5 mm, and an air permeability of 100 to 2000 cc / cm 2It exists in the antimicrobial active nonwoven fabric described in the above (5) at / s.

[0015] The present invention exists in the antimicrobial active nonwoven fabric described in the above (5) or (6), wherein (7) recesses are formed on the surface by embossing, and the ratio of the area occupied by the recesses is 5 to 40%.

[0016] The present invention is an antimicrobial active mask using the antimicrobial active nonwoven fabric described in any one of the above (5) to (7), which has a main body part having a meltblown nonwoven fabric, a first nonwoven fabric laminated on the front surface side of the meltblown nonwoven fabric, and a second nonwoven fabric laminated on the back surface side of the meltblown nonwoven fabric, and ear straps respectively attached to both sides of the main body part. When worn, the second nonwoven fabric contacts the wearer's face, and the first nonwoven fabric located on the outside is the antimicrobial active nonwoven fabric.

Effects of the Invention

[0017] In the antimicrobial active fiber yarn of the present invention, since the particulate antimicrobial active substance having the maximum diameter within the above range bulges from the surface of the synthetic yarn having the maximum diameter within the above range, the decontamination effect of the antimicrobial active substance can be fully exerted. In addition, since no adhesive such as a binder or a polymer is attached to the antimicrobial active fiber yarn, the decontamination effect is not inhibited thereby.

[0018] In the antimicrobial active fiber yarn of the present invention, since the antimicrobial active substance is embedded in the synthetic yarn, the antimicrobial active substance can be held in the synthetic yarn without attaching an adhesive such as a binder or a polymer. In this case, even if the antimicrobial active fiber yarn is rubbed, it is possible to suppress the antimicrobial active substance from falling off (hereinafter referred to as the "falling-off suppression effect"). Also, the washing fastness can be improved. In addition, since no adhesive such as a binder or a polymer is attached to the above antimicrobial active fiber yarn, dirt hardly adheres to it.

[0019] In the antimicrobial active fiber yarn of the present invention, when the antimicrobial active substance is an organic substance exhibiting antibacterial activity or antiviral activity, the compatibility with the synthetic yarn becomes excellent. Therefore, the effect of suppressing the dropout of the antimicrobial active substance can be improved. At this time, in the antimicrobial active fiber yarn, when the material of the synthetic yarn is polyolefin, the compatibility with the antimicrobial active substance which is an organic substance becomes more excellent, so that the effect of suppressing dropout can be further improved.

[0020] In the method for producing the antimicrobial active fiber yarn of the present invention, in the drawing step instead of the spinning step, the antimicrobial active substance is bulged on the surface of the synthetic yarn. At this time, since the maximum diameters of the synthetic yarn and the antimicrobial active substance are within the above ranges, the antimicrobial active substance can be bulged relatively easily by the drawing step. Thereby, the antimicrobial active substance is in a state of being moderately bulged, and it is possible to suppress excessive bulging and dropout. Note that the effect of bulging the antimicrobial active substance is as described above.

[0021] Since the antimicrobial active nonwoven fabric of the present invention uses the above-described antimicrobial active fiber yarn, it has an excellent decontamination effect and is difficult to be soiled. Further, when used as an air filter, by setting the basis weight, thickness, and air permeability within the above ranges, it is possible to sufficiently exhibit the decontamination effect while ensuring the function as an air filter.

[0022] In the above antimicrobial active nonwoven fabric, it is preferable to form recesses on the surface by embossing. In this case, the strength of the antimicrobial active nonwoven fabric itself can be further improved. In addition, in the recesses, since the density of the antimicrobial active fiber yarn is high, the decontamination effect becomes more excellent. On the other hand, in the portions other than the recesses, the air permeability peculiar to the nonwoven fabric can be maintained. Therefore, the antimicrobial active nonwoven fabric in this case has an excellent decontamination effect while maintaining air permeability. In addition, by setting the ratio of the area occupied by the concave portion within the above range, the texture can be maintained without deterioration, and the strength can be further improved.

[0023] The mask of the present invention exhibits excellent decontamination effect by using the above-described antimicrobial active nonwoven fabric. Moreover, since the antimicrobial active nonwoven fabric (the first nonwoven fabric) is located on the outside, it is difficult for dirt to adhere.

Brief Description of the Drawings

[0024]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5(a)

Figure 5(b)

Modes for Carrying Out the Invention

[0025] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings as necessary. In the drawings, the same elements will be denoted by the same reference numerals, and redundant descriptions will be omitted. In addition, the positional relationships such as up, down, left, and right are based on the positional relationships shown in the drawings unless otherwise specified. Furthermore, the dimensional ratios in the drawings are not limited to the illustrated ratios.

[0026] The antimicrobial active fiber yarn according to the present invention is a fiber yarn exhibiting antimicrobial activity. Such microorganisms include viruses, bacteria, fungi, parasites, and the like. In addition, the antimicrobial active fiber yarn can be used as a raw yarn for woven fabrics, knitted fabrics, non-woven fabrics, braided fabrics, etc., in the same manner as ordinary yarns.

[0027] FIG. 1 is a schematic perspective view showing an enlarged view of an embodiment of the antimicrobial active fiber yarn according to the present invention. The antimicrobial active fiber yarn 10 according to this embodiment contains a synthetic yarn 1 and an antimicrobial active substance 2. As shown in FIG. 1, the antimicrobial active substance 2 is embedded in the synthetic yarn 1 and has a structure bulging from the surface of the synthetic yarn 1.

[0028] In the antimicrobial active fiber yarn 10, at least a part of the antimicrobial active substance 2 is embedded in the synthetic yarn 1, and the antimicrobial active substance 2 and the synthetic yarn 1 are integrated. Therefore, compared with the case where the antimicrobial active substance is adhered with an adhesive, the effect of suppressing the dropout of the antimicrobial active substance 2 is excellent. In addition, the washing fastness is also improved. In addition, in the antimicrobial active fiber yarn 10, since at least a part of the antimicrobial active substance 2 bulges from the surface of the synthetic yarn 1, the decontamination effect of the antimicrobial active substance 2 can be sufficiently exhibited. In addition, since the antimicrobial active fiber yarn 10 does not separately adhere an adhesive such as a binder or a polymer, dirt is difficult to adhere.

[0029] In the antimicrobial active fiber yarn 10, as the material of the synthetic yarn 1, synthetic polymers such as polyolefins such as polyethylene and polypropylene, polyesters, polyamides such as nylon, polyurethane, polyvinyl alcohol, polyacrylonitrile, and polyvinyl chloride are used. These may be used alone or in combination of a plurality. Among these, when the antimicrobial active substance 2 is an organic substance, the material of the synthetic yarn 1 is preferably a polyolefin from the viewpoints of compatibility and melting point, and more preferably polypropylene from the viewpoints of versatility and strength. Incidentally, when the synthetic fiber 1 has a low melting point, decomposition and deterioration of the antimicrobial active substance 2 can be suppressed during melting.

[0030] The synthetic fiber 1 has a maximum diameter in the vertical cross-section of 10 to 60 μm, preferably 15 to 40 μm. When the maximum diameter in the vertical cross-section of the synthetic fiber 1 is less than 10 μm, the antimicrobial active fiber yarn 10 itself is likely to break easily. Also, the effect of suppressing shedding becomes insufficient. On the other hand, when the maximum diameter in the vertical cross-section of the synthetic fiber 1 exceeds 60 μm, much of the antimicrobial active substance 2 may be buried in the synthetic fiber 1, and there is a risk that the decontamination effect cannot be fully exerted. The maximum diameter means the diameter of the smallest circle drawn from the center of the cross-section so as to include the entire cross-section.

[0031] Examples of the antimicrobial active substance 2 include substances exhibiting antibacterial activity, antifungal activity, antiviral activity, etc. Specifically, inorganic substances such as silver-based, zinc-based, copper-based, zeolite, and organic substances such as alcohol-based, phenol-based, aldehyde-based, carboxylic acid-based, ester-based, ether-based, nitrile-based, peroxide-based, halogen-based, surfactant-based, organometallic-based, and organic complex-based substances can be mentioned. These may be used alone or in combination of a plurality. Among these, the antimicrobial active substance 2 is preferably a substance exhibiting antibacterial activity or antiviral activity, and from the viewpoint of compatibility with the synthetic fiber 1, it is more preferably an organic substance.

[0032] In the antimicrobial active fiber yarn 2, as described above, in order to bulge the antimicrobial active substance 2 from the surface of the synthetic fiber 1, the form of the antimicrobial active substance 2 adopts a solid particle shape. Specifically, the antimicrobial active substance 2 is in the form of particles with a maximum diameter of 0.1 to 10 μm, preferably 2 to 8 μm. When the maximum diameter of the antimicrobial active substance 2 is less than 0.1 μm, much of the antimicrobial active substance 2 may be buried in the synthetic fiber 1, and there is a risk that the decontamination effect cannot be fully exerted. On the other hand, when the maximum diameter of the antimicrobial substance 2 exceeds 10 μm, the synthetic yarn 1 cannot sufficiently hold the antimicrobial substance 2, and the effect of suppressing shedding becomes insufficient.

[0033] Therefore, in the antimicrobial fiber yarn 10, the maximum diameter in the vertical cross-section of the synthetic yarn 1 is 10 to 60 μm, and the maximum diameter of the antimicrobial substance 2 is 0.1 to 10 μm. By satisfying both of these maximum diameters, it becomes possible to sufficiently exhibit the above-described effects.

[0034] In the antimicrobial fiber yarn 10, the blending ratio of the antimicrobial substance 2 is preferably 0.5 to 10% by mass, and more preferably 2 to 5% by mass. When the blending ratio of the antimicrobial substance 2 is less than 0.5% by mass, the decontamination effect tends to be insufficient compared to the case where the blending ratio is within the above range. When the blending ratio of the antimicrobial substance 2 exceeds 10% by mass, the antimicrobial fiber yarn 10 itself tends to be easily broken compared to the case where the blending ratio is within the above range.

[0035] In the surface area of the antimicrobial fiber yarn 10, the range of the surface area (hereinafter also referred to as "unit surface area") for bulging at least one antimicrobial substance 2 is 0.5×10 -3 ~3×10 ―3 mm 2 It is preferably this. In other words, it is preferable to bulge at least one antimicrobial substance 2 per unit surface area in the above range. When the unit surface area for bulging at least one antimicrobial substance 2 is less than 0.5×10 -3 mm 2 the decontamination effect tends to be insufficient compared to the case where the unit surface area is within the above range. When the unit surface area for bulging at least one antimicrobial substance 2 exceeds 3×10 -3 mm 2 the antimicrobial fiber yarn 10 has a drawback of being easily broken compared to the case where the unit surface area is within the above range.

[0036] Note that the antimicrobial active fiber yarn 10 may contain auxiliaries such as antioxidants, light-shielding agents, heat aging inhibitors, antistatic agents, plasticizers, crosslinking agents, flame retardants, colorants, slip agents, anti-pilling agents, deodorants, water repellents, alcohol repellents, and nucleating agents.

[0037] Next, a method for manufacturing the antimicrobial active fiber yarn 10 will be described. FIG. 2 is a flowchart showing a method for manufacturing the antimicrobial active fiber yarn according to the present embodiment. As shown in FIG. 2, the method for manufacturing the antimicrobial active fiber yarn according to the present embodiment includes at least a spinning step S1 and a drawing step S2. In the method for manufacturing the antimicrobial active fiber yarn 10, as will be described later, the antimicrobial active substance 2 is bulged on the surface of the synthetic yarn 1 in the drawing step S2 instead of the spinning step S1.

[0038] The spinning step S1 is a step of spinning a mixture containing a molten synthetic polymer and the antimicrobial active substance 2 to obtain a pre-fiber yarn. That is, in the spinning step S1, a pre-fiber yarn is manufactured by so-called melt spinning.

[0039] In the spinning step S1, first, the molten synthetic polymer and the antimicrobial active substance 2 are mixed to form a mixture. Here, the synthetic polymer (synthetic yarn 1) and the antimicrobial active substance 2 are appropriately selected from those described above. At this time, in order to avoid decomposition of the antimicrobial active substance 2, it is preferable to use a synthetic polymer having as low a melting point as possible. Note that such a mixture may contain the above-described auxiliaries.

[0040] Then, the above mixture is spun. That is, the high-temperature mixture is extruded from a spinneret and solidified by cooling it. At this time, in the spinning step S1, a spinneret having a diameter of 200 to 1000 μm can be used. Among them, it is preferable to use a spinneret with a diameter of 500 to 800 μm, which is larger than a general spinneret (400 μm). In this case, it is possible to produce pre-fiber yarns with good yield. That is, the pre-fiber yarn is difficult to break, and clogging of the spinneret is also less likely to occur. In addition, the antimicrobial active substance 2 can be dispersed as much as possible, and it is possible to prevent the pre-fiber yarn from being formed in a state where the antimicrobial active substance 2 is biased.

[0041] The pre-fiber yarn thus obtained has a round wire shape with a size corresponding to the spinneret diameter. In such a pre-fiber yarn, as described above, the antimicrobial active substance 2 does not bulge from the synthetic polymer (synthetic yarn 2).

[0042] The drawing step S2 is a step of drawing the softened pre-fiber yarn under predetermined temperature conditions. By the drawing step S2, the synthetic polymer is drawn and its diameter becomes smaller, and its molecular arrangement is aligned. At this time, since the diameter of the pre-fiber yarn becomes smaller, the antimicrobial active substance 2 contained therein bulges on its surface. In the drawing step S2, the maximum diameters of the synthetic yarn 1 and the antimicrobial active substance 2 are within the above-described ranges. Thereby, the antimicrobial active substance 2 is in a state of bulging appropriately, and it is possible to suppress the antimicrobial active substance 2 from bulging too much and falling off.

[0043] Then, by cooling, the antimicrobial active fiber yarn 10 is obtained (see FIG. 1). Such an antimicrobial active fiber yarn 10 may be subjected to crimping, oiling, corona treatment, electret treatment, etc. after the drawing step S2. Among them, from the viewpoint of improving the strength, it is preferable to subject the antimicrobial active fiber yarn 10 to crimping. The crimping may be performed by a conventionally known method.

[0044] FIG. 3 is a schematic view showing an embodiment of the antimicrobial active nonwoven fabric according to the present invention. As shown in FIG. 3, the antimicrobial active nonwoven fabric 11 according to this embodiment has drapability, and recesses 3 are provided on the surface. The antimicrobial active nonwoven fabric 11 is a sheet-like material formed by intertwining the above-described antimicrobial active fiber yarns 10 without weaving. Note that the antimicrobial active nonwoven fabric includes felt. Thus, since the antimicrobial active nonwoven fabric 11 is manufactured using the antimicrobial active fiber yarns 10, it has an excellent decontamination effect and is difficult to get dirty.

[0045] A plurality of recesses 3 are formed on the surface of the antimicrobial active nonwoven fabric 11. Such recesses are formed by so-called embossing. That is, the recesses 3 are formed by pressing a heated mold against the surface of the antimicrobial active nonwoven fabric 11 and melting the portion in contact with the mold. Thereby, the strength of the antimicrobial active nonwoven fabric 11 can be further improved. In addition, the antimicrobial active nonwoven fabric 11 has a more excellent decontamination effect while maintaining air permeability.

[0046] Here, the recesses 3 are rectangular in top view and are arranged at equal intervals in the vertical and horizontal directions. At this time, the ratio of the area occupied by the recesses 3 is preferably 5 to 40% of the whole, and more preferably 10 to 20%. When the ratio of the area occupied by the recesses 3 is less than 5%, the improvement in strength is not sufficiently recognized as compared with the case where the ratio is within the above range. When the ratio of the area occupied by the recesses 3 exceeds 40%, the antimicrobial active nonwoven fabric 11 becomes hard and loses its texture as compared with the case where the ratio is within the above range.

[0047] The antimicrobial active nonwoven fabric 11 is manufactured by using the antimicrobial active fiber yarns 10 by a dry method, a wet method, a spunbond method, a meltblown method, a thermal bonding method, a chemical bonding method, a needle punching method, a spunlace method, a stitch bonding method, a steam jet method, an air-through method, or the like. In addition, the antimicrobial active nonwoven fabric 11 can be adopted for applications such as wet-wipe substrates, gauze, clothing, dishcloths, masks, gloves, sound-absorbing boards, sound insulation and vibration damping materials, air filters, hair caps, etc.

[0048] Here, when using the antimicrobial active nonwoven fabric 11 as an air filter such as an air purifier or a mask, the basis weight of the antimicrobial active nonwoven fabric 11 is preferably 8 to 400 gsm, more preferably 10 to 300 gsm, still more preferably 13 to 200 gsm, and even more preferably 13 to 100 gsm. If the basis weight of the antimicrobial active nonwoven fabric 11 is less than 8 gsm, compared with the case where the basis weight is within the above range, the pores will be too coarse, it will be easily torn, and there is a risk that microorganisms cannot be captured. If the basis weight of the antimicrobial active nonwoven fabric 11 exceeds 400 gsm, compared with the case where the basis weight is within the above range, no improvement in the effect of capturing microorganisms can be expected, and on the other hand, there is a drawback that a weight load is generated on the attachment location.

[0049] Also, in this case, the thickness of the antimicrobial active nonwoven fabric 11 is preferably 0.05 to 5 mm, more preferably 0.1 to 2 mm, and still more preferably 0.1 to 1 mm. If the thickness of the antimicrobial active nonwoven fabric 11 is less than 0.05 mm, compared with the case where the thickness is within the above range, it is easily torn and there is a risk that microorganisms cannot be captured. If the thickness of the antimicrobial active nonwoven fabric 11 exceeds 5 mm, compared with the case where the thickness is within the above range, no improvement in the effect of capturing microorganisms can be expected, and on the other hand, there is a drawback that it becomes bulky and requires a certain amount of space at the attachment location.

[0050] Also, in this case, the air permeability of the antimicrobial active nonwoven fabric 11 is preferably 100 to 2000 cc / cm 2 / s. If the air permeability of the antimicrobial active nonwoven fabric 11 is less than 100 cc / cm 2 / s, there is a risk that sufficient ventilation cannot be achieved compared with the case where the air permeability is within the above range. If the air permeability of the antimicrobial active nonwoven fabric 11 is 2000 cc / cm 2If it exceeds / s, there is a possibility that microorganisms cannot be captured as compared with the case where the air permeability is within the above range.

[0051] FIG. 4 is a schematic view showing an embodiment of the antimicrobial active mask according to the present invention. As shown in FIG. 4, the antimicrobial active mask 12 according to the present embodiment includes a main body portion 5 having a melt-blown nonwoven fabric 12a, a first nonwoven fabric 11 laminated on the front surface side of the melt-blown nonwoven fabric 12a, and a second nonwoven fabric 12b laminated on the back surface side of the melt-blown nonwoven fabric 12a, and ear straps 6 respectively attached to both sides of the main body portion 5. In the main body portion 5, the first nonwoven fabric 11, the melt-blown nonwoven fabric 12a, and the second nonwoven fabric 12b are connected by sewing.

[0052] In the antimicrobial active mask 12, the second nonwoven fabric 12b is in contact with the wearer's face, and the first nonwoven fabric 11 is an antimicrobial active nonwoven fabric 11. Thus, since the first nonwoven fabric of the antimicrobial active mask 12 is the antimicrobial active nonwoven fabric 11, it has an excellent decontamination effect. In addition, since the first nonwoven fabric 11 is located on the outside, it is difficult for dirt to adhere.

[0053] The first nonwoven fabric 11 (antimicrobial active nonwoven fabric 11) has pleats 11a formed on its surface by pleating. In addition, at the upper part of the first nonwoven fabric 11, a so-called nose fit 11b for maintaining a deformed state along the shape of the nose is attached. Since the pleats 11a and the nose fit 11b are well-known in the art, detailed description thereof is omitted.

[0054] The first nonwoven fabric 11 (antimicrobial active nonwoven fabric 11) is not particularly limited as long as it uses antimicrobial active fiber yarns 10, and is manufactured by the method described above. In addition, the second nonwoven fabric 12b is manufactured by the method described above in the same manner as the first nonwoven fabric 11, except that ordinary yarns are used. Among them, it is preferable that both the first nonwoven fabric 11 and the second nonwoven fabric 12b are manufactured by the spunbond method. In this case, mass production can be carried out at low cost, and the air permeability of the mask can be adjusted relatively easily. Further, the meltblown nonwoven fabric 12a is manufactured by the meltblown method using nanofibers.

[0055] The ear loops 6 are respectively sewn to both sides of the main body portion 5. The ear loops 6 are not limited to a string shape and may be a belt shape. Since the ear loops 6 are conventionally known, detailed description thereof is omitted.

[0056] The preferred embodiments of the present invention have been described above, but the present invention is not limited to the above embodiments.

[0057] As shown in FIG. 1, the antimicrobial active fiber yarn 10 according to the present embodiment has a round wire shape for the synthetic yarn 1 except that the antimicrobial active substance bulges, but is not limited thereto, and may have an irregular cross section. Also, even in the case of a round wire shape, it may have a core-sheath structure or a hollow portion.

[0058] In the manufacturing method of the antimicrobial active fiber yarn 10 according to the present embodiment, melt spinning is performed in the spinning step S1, but dry spinning or wet spinning may be performed.

[0059] In the manufacturing method of the antimicrobial active fiber yarn 10 according to the present embodiment, after the spinning step S1, the drawing step S2 is performed after once cooling, but the spinning step S1 and the drawing step S2 may be continuously performed without cooling.

[0060] The antimicrobial active nonwoven fabric 11 according to the present embodiment is provided with the concave portions 3 on the surface, but this is not essential. Further, the shape of the concave portions 3 is rectangular in top view, but may be polygonal (excluding rectangular), round, star-shaped, or the like. Further, although the concave portions 3 are arranged at equal intervals in the vertical and horizontal directions, the present invention is not limited thereto. For example, they may be arranged randomly.

[0061] In the antimicrobial activity mask 12 according to the present embodiment, a three-layer structure in which a first nonwoven fabric 11, a melt-blown nonwoven fabric 12a, and a second nonwoven fabric 12b are sequentially laminated from the outside is provided, but further nonwoven fabrics may be laminated. At this time, such a nonwoven fabric may be the antimicrobial activity nonwoven fabric 11. It should be noted that it is preferable not to use the antimicrobial activity nonwoven fabric 11 for the nonwoven fabric that contacts the face during wearing.

Examples

[0062] Hereinafter, the present invention will be described more specifically based on examples and comparative examples, but the present invention is not limited to the following examples.

[0063] (Sample preparation) 95% by mass of molten polypropylene (synthetic polymer) and 5% by mass of an ether-based antiviral agent (maximum diameter 5 μm, antiviral agent) were mixed to form a mixture. Then, this mixture was spun using a spinneret with a diameter of 600 μm (spinning process), and subsequently stretched (stretching process) to obtain antimicrobial activity fiber yarns with a maximum cross-sectional (round) diameter of 30 μm. Electron micrographs of the obtained antimicrobial activity fiber yarns are shown in FIGS. 5(a) and 5(b). Note that FIG. 5(a) is an electron micrograph of the antimicrobial activity fiber yarn magnified 400 times, and FIG. 5(b) is an electron micrograph magnified 1500 times. Next, using the obtained antimicrobial activity fiber yarns, an antimicrobial activity nonwoven fabric (specimen 1) was produced by the spunbond method. On the other hand, as a blank, a nonwoven fabric (specimen 2) produced in the same manner without including an antiviral agent was prepared.

[0064] (Evaluation) In accordance with JIS-L1922 (Test method for antiviral properties of textile products), a test for antiviral activity was conducted under the following conditions. · Test virus: Influenza A virus (H3N2) · Host cell: MDCK cell (dog kidney-derived cell) · Test sample: 0.4 g · Elution solution: SCDLP medium · Incubation condition: 25°C, 2 hours · Method for measuring infectious titer: Plaque assay

[0065] 1. This test The host cells were infected with the virus. After culturing, cell residues were removed by centrifugation, and the cells were diluted 10-fold with sterile distilled water and adjusted to 1 - 5×10 7 PFU / ml to obtain a virus suspension. Then, 0.2 ml of the virus suspension was inoculated into each specimen. After acting at 25°C for 2 hours, 20 ml of the elution solution was added, and the mixture was stirred with a vortex mixer to elute the virus from the specimen. Table 1 shows the results of measuring the virus infectious titer by the plaque assay. 2. Host cell verification test (1) Cytotoxicity confirmation test 20 ml of the elution solution was added to each specimen, and the elution operation was performed in the same manner as in this test. Then, the cells were stained in the same manner as in the plaque assay to confirm the presence or absence of cytotoxicity. The obtained results are shown in Table 1. (2) Confirmation test for cell sensitivity to virus 20 ml of the elution solution was added to each specimen, and the elution operation was performed in the same manner as in this test. Then, this was taken into a 5-ml sterilized test tube, and 0.05 ml of the virus suspension adjusted to 4 - 6×10 4 PFU / ml was added. After standing at 25°C for 30 minutes, the virus infectious titer was measured by the plaque assay to confirm the cell sensitivity to the virus. The obtained results are shown in Table 1.

[0066]

Table 1

[0067] In Table 1, the antiviral activity value (Mv) is the difference between the common logarithm average value immediately after inoculation of Specimen 2 and the common logarithm average value after 2 hours of action of Specimen 1. Also, since the difference between the common logarithm average value immediately after inoculation of Specimen 2 and the common logarithm average value after 2 hours of action of Specimen 2 is 1 or less, "1. This test" is established. Also, since the difference between the common logarithm average value of the virus infection titer (PFU / ml) of Specimen 2 and the common logarithm average value of the virus infection titer (PFU / ml) of Specimen 1 is 0.5 or less, "2. Host cell verification test" is established.

[0068] From the results in Table 1, it was confirmed that the non-woven fabric using the antimicrobial active fiber yarn of the present invention exhibits antiviral activity. Also, the sample of Specimen 1 described above also showed good results in the washing fastness test.

Industrial Applicability

[0069] The antimicrobial active fiber yarn of the present invention and the method for producing the antimicrobial active fiber yarn can be used as the raw yarn of fiber products used for infectious disease countermeasures. The antimicrobial active non-woven fabric of the present invention can be used as a fiber product used for infectious disease countermeasures. The antimicrobial active mask of the present invention can be used as a mask used for infectious disease countermeasures.

Explanation of Signs

[0070] 1 ··· Synthetic yarn 2 ··· Antimicrobial active substance 3 ··· Concave part 10 ··· Antimicrobial active fiber yarn 11 ··· Antimicrobial active non-woven fabric (first non-woven fabric) 11a ··· Pleats 11b ··· Nose fit 12 ··· Antimicrobial active mask 12a ··· Meltblown non-woven fabric 12b ··· Second non-woven fabric 5 ··· Body part 6 ··· Ear string S1 ··· Spinning process S2 ··· Drawing process

Claims

1. An antimicrobial active fiber yarn in which an antimicrobial active substance is embedded in a synthetic yarn, wherein the antimicrobial active substance is in the form of particles having a maximum diameter of 0.1 to 10 μm, the maximum diameter in the vertical cross-section of the synthetic yarn is 10 to 60 μm, the antimicrobial active substance bulges out on the surface of the synthetic yarn, the antimicrobial active substance is an ether-based antiviral agent composed of an organic substance, An antimicrobial active fiber yarn in which the blending ratio of the antimicrobial active substance is 0.5 to 10% by mass.

2. The antimicrobial active fiber yarn according to Claim 1, wherein the range of the surface area for bulging at least one of the antimicrobial active substances is 0.5×10−3 to 3×10−3 mm2.

3. The antimicrobial active fiber yarn according to Claim 1 or 2, wherein the material of the synthetic yarn is polyolefin.

4. A method for producing an antimicrobial active fiber yarn according to any one of Claims 1 to 3, a spinning step of spinning a mixture containing a molten synthetic polymer and the antimicrobial active substance through a spinneret having a diameter of 500 to 800 μm to obtain a round linear pre-fiber yarn in which the antimicrobial active substance does not bulge, a stretching step of stretching the pre-fiber yarn to bulge the antimicrobial active substance on the surface of the synthetic yarn, A method for producing an antimicrobial active fiber yarn comprising the above steps.

5. An antimicrobial active nonwoven fabric using the antimicrobial active fiber yarn according to any one of Claims 1 to 3.

6. It is used as an air filter, has a basis weight of 8 to 400 gsm, and a thickness of 0.05 to 5 mm. The antimicrobial nonwoven fabric according to claim 5, having an air permeability of 100 to 2000 cc / cm ２ / s.

7. Concave portions are formed on the surface by embossing, The antimicrobial active nonwoven fabric according to Claim 5 or 6, wherein the ratio of the area occupied by the concave portions is 5 to 40%.

8. An antimicrobial active mask using the antimicrobial active nonwoven fabric according to any one of Claims 5 to 7, a main body portion having a meltblown nonwoven fabric, a first nonwoven fabric laminated on the front side of the meltblown nonwoven fabric, and a second nonwoven fabric laminated on the back side of the meltblown nonwoven fabric, ear loops respectively attached to both sides of the main body portion, comprising, when worn, the second nonwoven fabric contacts the wearer's face, An antimicrobial active mask in which the first nonwoven fabric located on the outside is the antimicrobial active nonwoven fabric.

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