Treatment agent for polyolefin-based synthetic fiber, treatment agent composition for polyolefin-based synthetic fiber, polyolefin-based synthetic fiber, and nonwoven fabric

Abstract

The present invention addresses the problem of improving permeability to a polyolefin-based synthetic fiber and improving emulsion stability. This treatment agent for a polyolefin-based synthetic fiber contains: a polyoxyalkylene derivative (A) including a monovalent polyoxyalkylene derivative (A1); an anionic surfactant (B); and at least one selected from among a polyether-modified silicone (C) and a polyglycerol fatty acid ester (D). The monovalent polyoxyalkylene derivative (A1) is a compound represented by general formula (1), and includes three or more monovalent polyoxyalkylene derivatives each having a different number of carbon atoms in R1.

Description

Treatment agent for polyolefin-based synthetic fibers, treatment composition for polyolefin-based synthetic fibers, polyolefin-based synthetic fibers, and nonwoven fabrics

[0001] The present invention relates to a treatment agent for polyolefin-based synthetic fibers, a treatment agent composition for polyolefin-based synthetic fibers, polyolefin-based synthetic fibers, and nonwoven fabrics.

[0002] Generally, synthetic fibers are used as raw fibers for nonwoven fabrics. For example, nonwoven fabrics are manufactured using synthetic fibers composed of thermoplastic resins such as polyolefins. By applying a treatment agent to the nonwoven fabric, hydrophilic properties and other properties are imparted. Nonwoven fabrics imparted with hydrophilic properties and other properties are used in a wide range of fields, including hygiene products, medical care, and civil engineering.

[0003] Patent Document 1 discloses a nonwoven fabric manufactured using synthetic fibers made of polyolefin. A hydrophilic treatment agent is applied to the synthetic fibers, and the fabric is used as a surface material for sanitary materials.

[0004] Japanese Patent Application Laid-Open No. 2003-201670

[0005]

[0003] Meanwhile, a treatment agent for polyolefin synthetic fibers is required to have the property of quickly penetrating into the fibers when applied to polyolefin synthetic fibers, i.e., further improvement in penetrability. Furthermore, treatment agents for polyolefin synthetic fibers are used in the form of an emulsion dispersed in an aqueous medium. Therefore, a property of stably maintaining the emulsion form, i.e., further improvement in emulsion stability, is also required.

[0006] The treating agent for polyolefin synthetic fibers of Aspect 1 comprises a polyoxyalkylene derivative (A) including a monovalent polyoxyalkylene derivative (A1), an anionic surfactant (B), and at least one selected from a polyether-modified silicone (C) and a polyglycerol fatty acid ester (D).

[0007] The monovalent polyoxyalkylene derivative (A1) is a compound represented by the following general formula (1), １The monovalent polyoxyalkylene derivatives include three or more monovalent polyoxyalkylene derivatives having different carbon numbers.

[0008] In the general formula (1), R １ is a hydrocarbon group having from 22 to 50 carbon atoms or an acyl group having from 22 to 50 carbon atoms, １ O is an alkyleneoxy group having 2 to 4 carbon atoms (the alkyleneoxy group may be one type alone or two or more types), and n is an integer of 5 to 100.

[0009] R in general formula (1) １ When the carbon number of the monovalent polyoxyalkylene derivative having the highest abundance ratio is α, the total abundance ratio of the monovalent polyoxyalkylene derivatives having carbon numbers of (α-4) or more and (α+4) or less is 97 mass% or less.

[0010] In a second aspect, in the treating agent for polyolefin synthetic fibers according to the first aspect, the monovalent polyoxyalkylene derivative (A1) has a molecular weight distribution (Mw / Mn) of 1.03 or more and 1.50 or less.

[0011] In Aspect 3, in the treating agent for polyolefin-based synthetic fibers according to Aspect 1 or 2, when the total content of the polyoxyalkylene derivative (A), the anionic surfactant (B), the polyether-modified silicone (C), and the polyglycerol fatty acid ester (D) is taken as 100% by mass, the treating agent for polyolefin-based synthetic fibers contains the polyoxyalkylene derivative (A) in an amount of 10% by mass to 60% by mass, the anionic surfactant (B) in an amount of 30% by mass to 70% by mass, the polyether-modified silicone (C) in an amount of 0% by mass to 20% by mass, and the polyglycerol fatty acid ester (D) in an amount of 0% by mass to 30% by mass.

[0012] Aspect 4 is the treatment agent for polyolefin-based synthetic fibers according to any one of Aspects 1 to 3, wherein, when the total content of the polyoxyalkylene derivative (A), the anionic surfactant (B), the polyether-modified silicone (C), and the polyglycerin fatty acid ester (D) is taken as 100 mass%, the total content of the polyoxyalkylene derivative (A) and the anionic surfactant (B) is 60 mass% or more.

[0013] A polyolefin synthetic fiber treatment composition according to Aspect 5 comprises the polyolefin synthetic fiber treatment agent according to any one of Aspects 1 to 4 and a solvent. A polyolefin synthetic fiber according to Aspect 6 comprises the polyolefin synthetic fiber treatment agent according to any one of Aspects 1 to 4 adhered thereto.

[0014] The nonwoven fabric of Aspect 7 is made from the polyolefin-based synthetic fiber of Aspect 6.

[0015] The treating agent for polyolefin synthetic fibers of the present invention can improve the permeability into polyolefin synthetic fibers and also improve emulsion stability.

[0016] First Embodiment A first embodiment of the treating agent for polyolefin synthetic fibers (hereinafter also referred to as treating agent) of the present invention will be described below.

[0017] The treatment agent of the present embodiment contains a polyoxyalkylene derivative (A) including the following monovalent polyoxyalkylene derivative (A1), an anionic surfactant (B), and at least one selected from a polyether-modified silicone (C) and a polyglycerol fatty acid ester (D).

[0018] The monovalent polyoxyalkylene derivative (A1) is a compound represented by the following general formula (1), R １ That is, the polyoxyalkylene derivative (A) contains three or more monovalent polyoxyalkylene derivatives each having a different number of carbon atoms, each of which is represented by the general formula (1) R １ The monovalent polyoxyalkylene derivatives include three or more monovalent polyoxyalkylene derivatives having different carbon numbers.

[0019] In the general formula (1), R １ is a hydrocarbon group having 16 to 60 carbon atoms or an acyl group having 16 to 60 carbon atoms, １ O is an alkyleneoxy group having 2 to 4 carbon atoms (the alkyleneoxy group may be one type alone or two or more types), and n is an integer of 5 to 100.

[0020] The treatment agent contains the polyoxyalkylene derivative (A) and the anionic surfactant (B), and also contains at least one selected from the group consisting of the polyether-modified silicone (C) and the polyglycerin fatty acid ester (D), thereby improving the permeability into polyolefin synthetic fibers and also improving emulsion stability.

[0021] <Polyoxyalkylene Derivative (A)> In the monovalent polyoxyalkylene derivative (A1), R １ The hydrocarbon group having 16 to 60 carbon atoms as the alkyl group is not particularly limited, and may be a saturated hydrocarbon group or an unsaturated hydrocarbon group. It may be linear or branched.

[0022] Examples of hydrocarbon groups having 16 to 60 carbon atoms include a hexadecyl group, a heptadecyl group, an octadecyl group, a nonadecyl group, an icosyl group, a heniicosyl group, a docosyl group, a tricosyl group, a tetracosyl group, a pentacosyl group, a hexacosyl group, a heptacosyl group, an octacosyl group, a nonacosyl group, a triacontyl group, a hentriacontyl group, a dotriacontyl group, a tritriacontyl group, a pentatriacontyl group, a hexatriacontyl group, a heptatriacontyl group, an octatriacontyl group, a nonatriacontyl group, a tetracontyl group, a hentetracontyl group, a dotetracontyl group, a tritetracontyl group, a tetratetracontyl group, a pentatetracontyl group, a hexatetracontyl group, a heptatetracontyl group, an octatetracontyl group, a nonatetracontyl group, a pentacontyl group, and a hexacontyl group.

[0023] In the monovalent polyoxyalkylene derivative (A1), R １ The acyl group having 16 to 60 carbon atoms as the acyl group is not particularly limited, and may be a saturated acyl group or an unsaturated acyl group. It may be linear or branched.

[0024] Examples of the acyl group having 16 to 60 carbon atoms include a hexadecanoyl group, a heptadecanoyl group, an octadecanoyl group, a nonadecanoyl group, an icosanoyl group, a henicosanoyl group, a docosanoyl group, a tricosanoyl group, a tetracosanoyl group, a pentacosanoyl group, a hexacosanoyl group, a heptacosanoyl group, an octacosanoyl group, a nonacosanoyl group, a triacontanoyl group, a hentriacontanoyl group, a dotriacontanoyl group, a tritriacontanoyl group, a tetratriacontanoyl group, a pentacosanoyl group, a hexacosanoyl group, a heptacosanoyl group, a octacosanoyl group, a nonacosanoyl group, a triacontanoyl group, a hentriacontanoyl group, a dotriacontanoyl group, a tritriacontanoyl group, a tetratriacontanoyl group, a pentacosanoyl group, a hexacontanoyl group, a heptacosanoyl group, a hexacont ... Examples of such groups include a triacontanoyl group, a hexatriacontanoyl group, a heptatriacontanoyl group, an octatriacontanoyl group, a nonatriacontanoyl group, a tetracontanoyl group, a hentetracontanoyl group, a dotetracontanoyl group, a tritetracontanoyl group, a tetratetracontanoyl group, a pentatetracontanoyl group, a hexatetracontanoyl group, a heptatetracontanoyl group, an octatetracontanoyl group, a nonatetracontanoyl group, a pentacontanoyl group, and a hexacontanoyl group.

[0025] R １ The number of carbon atoms in R is preferably 22 or more and 50 or less. １ When the number of carbon atoms is 22 or more and 50 or less, the durable hydrophilicity of the nonwoven fabric to which the treatment agent is attached can be improved.

[0026] The monovalent polyoxyalkylene derivative (A1) is a compound represented by the general formula (1), R １ Preferably, the polyoxyalkylene derivatives contain 45 or less kinds of monovalent polyoxyalkylene derivatives having different carbon numbers.

[0027] In the monovalent polyoxyalkylene derivative (A1), R in general formula (1) １The abundance ratio of the monovalent polyoxyalkylene derivatives having different carbon numbers is preferably such that, when the carbon number of the monovalent polyoxyalkylene derivative having the highest abundance ratio is α, the total abundance ratio of the monovalent polyoxyalkylene derivatives having carbon numbers of (α-4) or more and (α+4) or less is 97 mass % or less. １ For monovalent polyoxyalkylene derivatives with different carbon numbers, where the carbon number of the monovalent polyoxyalkylene derivative that is most abundant is α, the total proportion of monovalent polyoxyalkylene derivatives with a carbon number in the range of (α-4) to (α+4) is preferably 97% by mass or less. By having the total abundance ratio of monovalent polyoxyalkylene derivatives with a carbon number of (α-4) to (α+4) inclusive be 97% by mass or less, the permeability of the treatment agent into polyolefin synthetic fibers can be further improved. Furthermore, the emulsion stability of the treatment agent can also be further improved. In this embodiment, the total abundance ratio of monovalent polyoxyalkylene derivatives with a carbon number of (α-4) to (α+4) inclusive is, for example, 96% by mass or less, 90% by mass or less, 81% by mass or less, or 41% by mass or less. Similarly, the total abundance ratio of monovalent polyoxyalkylene derivatives having a carbon number of (α-4) or more and (α+4) or less is, for example, 41% by mass or more, 81% by mass or more, 90% by mass or more, or 96% by mass or more.

[0028] In the monovalent polyoxyalkylene derivative (A1), A １ Examples of the alkyleneoxy group having 2 to 4 carbon atoms as O include an ethyleneoxy group, a propyleneoxy group, and a butyleneoxy group.

[0029] The alkyleneoxy group may be one type alone or two or more types. That is, the multiple alkyleneoxy groups contained in the monovalent polyoxyalkylene derivative (A1) may all be the same type of alkyleneoxy group, or may be a combination of different types of alkyleneoxy groups.

[0030] When two or more types of alkyleneoxy groups are present, the polymerization sequence is not particularly limited and may be a random adduct or a block adduct. The molecular weight distribution (Mw / Mn) of the monovalent polyoxyalkylene derivative (A1) is preferably 1.03 or more and 1.50 or less. A molecular weight distribution (Mw / Mn) of 1.03 or more and 1.50 or less can further improve the permeability of the treatment agent into polyolefin-based synthetic fibers. In addition, the emulsion stability of the treatment agent can also be further improved. In this embodiment, the molecular weight distribution (Mw / Mn) of the monovalent polyoxyalkylene derivative (A1) is, for example, 1.02 or more, 1.04 or more, 1.05 or more, 1.06 or more, 1.08 or more, 1.17 or more, or 1.21 or more. Similarly, the molecular weight distribution (Mw / Mn) of the monovalent polyoxyalkylene derivative (A1) is, for example, 1.21 or less, 1.17 or less, 1.08 or less, 1.06 or less, 1.05 or less, 1.04 or less, or 1.02 or less. The method for measuring the molecular weight distribution (Mw / Mn) will be described later.

[0031] <Anionic Surfactant (B)> As the anionic surfactant (B), known surfactants can be appropriately used. Examples of the anionic surfactant (B) include: (1) phosphate salts of aliphatic alcohols, such as lauryl phosphate salts, cetyl phosphate salts, octyl phosphate salts, oleyl phosphate salts, and stearyl phosphate salts; (2) phosphate salts of aliphatic alcohols to which at least one alkylene oxide selected from ethylene oxide and propylene oxide has been added, such as polyoxyethylene lauryl ether phosphate salts, polyoxyethylene oleyl ether phosphate salts, and polyoxyethylene stearyl ether phosphate salts; (3) aliphatic sulfonates or aromatic sulfonates, such as lauryl sulfonate, myristyl sulfonate, cetyl sulfonate, oleyl sulfonate, stearyl sulfonate, tetradecane sulfonate, dodecyl benzene sulfonate, and secondary alkyl sulfonate (C13-15); (4) sulfate salts of aliphatic alcohols, such as lauryl sulfate salts, oleyl sulfate salts, and stearyl sulfate salts; (5) polyoxyethylene (6) sulfates of fatty alcohols to which at least one alkylene oxide selected from ethylene oxide and propylene oxide has been added, such as ethylene lauryl ether sulfate, polyoxyalkylene (polyoxyethylene, polyoxypropylene) lauryl ether sulfate, and polyoxyethylene oleyl ether sulfate; (7) castor oil fatty acid sulfate, sesame oil fatty acid sulfate, tall oil fatty acid sulfate, soybean oil fatty acid sulfate, and rapeseed oil fat; (7) sulfates of fats and oils such as castor oil sulfate, sesame oil sulfate, tall oil sulfate, soybean oil sulfate, rapeseed oil sulfate, palm oil sulfate, lard sulfate, beef tallow sulfate, and whale oil sulfate; (8) fatty acid salts such as laurates, oleates, and stearates;(9) sulfosuccinate salts of aliphatic alcohols such as dioctyl sulfosuccinate, and (10) carboxylic acid ester salts of aliphatic alcohols to which at least one alkylene oxide selected from ethylene oxide and propylene oxide has been added.

[0032] Examples of the counter ion of the anionic surfactant (B) include alkali metal salts such as potassium salts and sodium salts, ammonium salts, and alkanolamine salts such as triethanolamine salts.

[0033] The anionic surfactant (B) may be used alone or in combination of two or more. <Polyether-Modified Silicone (C)> The polyether-modified silicone (C) may be any known one. Examples of the polyether-modified silicone (C) include ABn-type polyether-modified silicones, side-chain-type polyether-modified silicones, both-end-type polyether-modified silicones, alkyl polyether-modified silicones in which both a polyether group and an alkyl group are introduced into the side chain or the end, side-chain-type polyether-modified silicones in which the polyether chain end portions are blocked with an aliphatic compound or a fatty acid compound, and both-end-type polyether-modified silicones in which the polyether chain end portions are blocked with an aliphatic compound or a fatty acid compound.

[0034] The polyether-modified silicone (C) may be a commercially available product specified by its kinematic viscosity. The kinematic viscosity is set as appropriate, but it is preferable that the kinematic viscosity at 25°C is 100 cst (mm ２ / s) or more 10000cst (mm ２ / s) or less, and ２ / s) or more 7000 cst (mm ２ / s) or less is more preferable.

[0035] The mass average molecular weight (Mw) of the polyether-modified silicone (C) is not particularly limited, but is preferably 1,000 or more and 100,000 or less, and more preferably 3,000 or more and 60,000 or less.

[0036] The weight average molecular weight (Mw) of the polyether-modified silicone (C) is determined by gel permeation chromatography (hereinafter also referred to as "GPC"). Details of GPC will be described later.

[0037] The polyether-modified silicone (C) may be used alone or in combination of two or more. <Polyglycerol fatty acid ester (D)> The polyglycerol fatty acid ester (D) is preferably an ester of an aliphatic monocarboxylic acid and polyglycerol.

[0038] The aliphatic monocarboxylic acid preferably has a carbon number of 16 or more and 18 or less. Examples of the aliphatic monocarboxylic acid having a carbon number of 16 or more and 18 or less include hexadecanoic acid, heptadecanoic acid, and octadecanoic acid.

[0039] The number of moles of aliphatic monocarboxylic acid in one ester molecule is preferably from 1 to 4. Examples of polyglycerol include diglycerol, triglycerol, tetraglycerol, pentaglycerol, hexaglycerol, heptaglycerol, and octaglycerol.

[0040] The number of moles of polyglycerin in one ester molecule is preferably 1. The degree of condensation of polyglycerin is preferably from 2 to 8. The polyglycerin fatty acid ester (D) may be used alone or in combination of two or more.

[0041] <Content of Each Component> The content of each of the above components in the treatment agent is not particularly limited. When the total content of the polyoxyalkylene derivative (A), the anionic surfactant (B), the polyether-modified silicone (C), and the polyglycerin fatty acid ester (D) is taken as 100% by mass, the treatment agent preferably contains the polyoxyalkylene derivative (A) in an amount of 10% by mass to 60% by mass and the anionic surfactant (B) in an amount of 30% by mass to 70% by mass. Furthermore, the treatment agent preferably contains the polyether-modified silicone (C) in an amount of 0% by mass to 20% by mass and the polyglycerin fatty acid ester (D) in an amount of 0% by mass to 30% by mass.

[0042] By ensuring that the content ratio of each component falls within the above range, the permeability of the treatment agent into polyolefin-based synthetic fibers can be further improved, the emulsion stability of the treatment agent can be further improved, and the initial hydrophilicity and rewetting resistance of the nonwoven fabric to which the treatment agent is attached can be improved.

[0043] In this embodiment, the content of the polyoxyalkylene derivative (A) in the treatment agent is, for example, 13% by mass or more, 16% by mass or more, 20% by mass or more, 21% by mass or more, 23% by mass or more, 24% by mass or more, 25% by mass or more, 27% by mass or more, 28% by mass or more, 32% by mass or more, 50% by mass or more, 54% by mass or more, 60% by mass or more, 64% by mass or more, or 65% by mass or more. Similarly, the content of the polyoxyalkylene derivative (A) is, for example, 65% by mass or less, 64% by mass or less, 60% by mass or less, 54% by mass or less, 50% by mass or less, 32% by mass or less, 28% by mass or less, 27% by mass or less, 25% by mass or less, 24% by mass or less, 23% by mass or less, 21% by mass or less, 20% by mass or less, 16% by mass or less, or 13% by mass or less.

[0044] In this embodiment, the content of the anionic surfactant (B) in the treatment agent is, for example, 9% by mass or more, 20% by mass or more, 30% by mass or more, 38% by mass or more, 39% by mass or more, 40% by mass or more, 44% by mass or more, 45% by mass or more, 50% by mass or more, 54% by mass or more, or 60% by mass or more. Similarly, the content of the anionic surfactant (B) is, for example, 60% by mass or less, 54% by mass or less, 50% by mass or less, 45% by mass or less, 44% by mass or less, 40% by mass or less, 39% by mass or less, 38% by mass or less, 30% by mass or less, or 20% by mass or less.

[0045] In this embodiment, the content of the polyether-modified silicone (C) in the treatment agent is, for example, 10% by mass or more, 12% by mass or more, 13% by mass or more, 14% by mass or more, or 15% by mass or more. Similarly, the content of the polyether-modified silicone (C) is, for example, 15% by mass or less, 14% by mass or less, 13% by mass or less, 12% by mass or less, or 10% by mass or less.

[0046] In this embodiment, the content of the polyglycerol fatty acid ester (D) in the treatment agent is, for example, 5% by mass or more, 15% by mass or more, 18% by mass or more, 25% by mass or more, 26% by mass or more, 28% by mass or more, 29% by mass or more, 30% by mass or more, or 39% by mass or more. Similarly, the content of the polyglycerol fatty acid ester (D) is, for example, 39% by mass or less, 30% by mass or less, 29% by mass or less, 28% by mass or less, 26% by mass or less, 25% by mass or less, 18% by mass or less, 15% by mass or less, or 5% by mass or less.

[0047] When the total content of the polyoxyalkylene derivative (A), the anionic surfactant (B), the polyether-modified silicone (C), and the polyglycerin fatty acid ester (D) is taken as 100% by mass, the total content of the polyoxyalkylene derivative (A) and the anionic surfactant (B) is preferably 60% by mass or more. By having the content of each component within the above numerical range, the emulsion stability of the treatment agent can be further improved.

[0048] <Other Component (E)> The treatment agent of this embodiment may contain other component (E). Examples of other component (E) include polyethylene having an average carbon number of 22 with a carbon number distribution of 18 to 26, polyethylene having an average carbon number of 30 with a carbon number distribution of 14 to 58, polyethylene having a carbon number of 30, citric acid, olive oil RR (manufactured by Summit Oil Mills Co., Ltd.), shea butter RF (manufactured by Kokyu Alcohol Kogyo Co., Ltd.), rice oil (manufactured by Tsuno Foods Industry Co., Ltd.), Ecofarm Cucumber E (manufactured by Ichimaru Pharcos Co., Ltd.), peach leaf extract LA (manufactured by Maruzen Pharmaceuticals Co., Ltd.), refined palm oil (S) (The Nisshin Oillio Group, Inc.), aloe extract BG-50 (manufactured by Koei Kogyo Co., Ltd.), and jojoba oil (manufactured by Summit Oil Mills Co., Ltd.).

[0049] The other component (E) may be used alone or in combination of two or more. The content of the other component (E) in the treatment agent is not particularly limited. The content of the other component (E) is preferably 15% by mass or less, more preferably 5% by mass or less, and even more preferably 2% by mass or less, when the total mass of the treatment agent including the other component (E) is taken as 100% by mass.

[0050] Second Embodiment A second embodiment of the treating agent composition for polyolefin synthetic fibers (hereinafter also referred to as the composition) of the present invention will be described below.

[0051] The composition of this embodiment includes the treatment agent and a solvent. The composition is used as an emulsion by mixing the treatment agent and the solvent. The solvent is not particularly limited, but examples thereof include water. A specific example of water is ion-exchanged water. In addition to water, an organic solvent may be contained. Specific examples of organic solvents include lower alcohols such as ethanol and propanol, and low-polarity solvents such as hexane.

[0052] The above solvents may be used alone or in combination of two or more. Third Embodiment Hereinafter, a third embodiment of the polyolefin synthetic fiber of the present invention will be described.

[0053] The polyolefin synthetic fiber of this embodiment has the treatment agent of the first embodiment adhered to it. Here, polyolefin synthetic fiber means a synthetic fiber synthesized using olefin or alkene as a monomer. Hereinafter, polyolefin synthetic fiber will also be simply referred to as synthetic fiber.

[0054] Specific examples of synthetic fibers include polyethylene fibers, polypropylene fibers, and polybutene fibers. These may be used alone or in combination of two or more. Furthermore, polypropylene fibers may include modified polypropylene fibers copolymerized with various monomers, composite polypropylene fibers of polyethylene and polypropylene, and the like.

[0055] The fiber may also be a composite fiber with a core-sheath structure in which either the core or the sheath, or both, are polyolefin-based fibers, such as a polyethylene / polypropylene composite fiber or a polyethylene / polyester composite fiber in which the sheath is polyethylene fiber.

[0056] The method for applying the treatment agent to the synthetic fibers is not particularly limited, and the treatment agent can be applied by a known method, for example, a dipping method, a spraying method, etc. It is preferable to apply the treatment agent to a nonwoven fabric after the synthetic fibers are used to prepare the nonwoven fabric.

[0057] The amount of treatment agent applied is preferably 0.1% by mass or more and 2% by mass or less of the treatment agent (excluding the solvent) relative to the synthetic fiber, and more preferably 0.3% by mass or more and 1.2% by mass or less.

[0058] Fourth Embodiment A fourth embodiment of the nonwoven fabric of the present invention will now be described. The nonwoven fabric of this embodiment is made from the synthetic fiber of the third embodiment.

[0059] The method for producing the nonwoven fabric is not particularly limited, and known methods can be used. For example, a web is formed by air-laid, spunbond, papermaking, carding, or the like using synthetic fibers before the treatment agent is applied. The fibers in the resulting web are then bonded to each other by chemical bonding, air-through, needle punching, spunlace, or the like to produce a nonwoven fabric. A treatment agent is applied to the resulting nonwoven fabric, thereby obtaining a nonwoven fabric with the treatment agent applied thereto.

[0060] <Actions and Effects> The actions of the above embodiment will be described. The monovalent polyoxyalkylene derivative (A1) is a compound represented by the general formula (1) above, and R １ The monovalent polyoxyalkylene derivatives R １ R is a hydrocarbon group having 16 to 60 carbon atoms, or an acyl group having 16 to 60 carbon atoms. １is a hydrocarbon group having 16 to 60 carbon atoms or an acyl group having 16 to 60 carbon atoms, so that the alkyl chain of the monovalent polyoxyalkylene derivative (A1) has a predetermined length. １ By containing three or more types of monovalent polyoxyalkylene derivatives having different carbon numbers, the length of the alkyl chain of the monovalent polyoxyalkylene derivative (A1) has a distribution.

[0061] The alkyl chain length of the monovalent polyoxyalkylene derivative (A1) has a predetermined length and a distribution, so that the hydrophilicity of the treatment agent containing the polyoxyalkylene derivative (A) can be made suitable. By making the hydrophilicity of the treatment agent suitable, the emulsion stability of the treatment agent can be improved, and the permeability of the treatment agent into polyolefin synthetic fibers can be improved.

[0062] Furthermore, by including the anionic surfactant (B) in the treatment agent, the emulsion stability of the treatment agent and its penetration into polyolefin-based synthetic fibers can be further improved. Furthermore, by including at least one selected from the polyether-modified silicone (C) and the polyglycerin fatty acid ester (D) in the treatment agent, the emulsion stability can be further improved, and the initial hydrophilicity and durable hydrophilicity can be improved.

[0063] According to the above embodiment, the following effects can be obtained. (1) The treatment agent contains a polyoxyalkylene derivative (A) including a monovalent polyoxyalkylene derivative (A1), and an anionic surfactant (B). It also contains at least one selected from a polyether-modified silicone (C) and a polyglycerin fatty acid ester (D). Therefore, it is possible to improve the permeability into polyolefin-based synthetic fibers. It is also possible to improve emulsion stability.

[0064] (2) In the monovalent polyoxyalkylene derivative (A1), R in the general formula (1) １ By making the number of carbon atoms of the group be 22 or more and 50 or less, the durable hydrophilicity of the nonwoven fabric to which the treatment agent is attached can be improved.

[0065] (3) In the monovalent polyoxyalkylene derivative (A1), the number of carbon atoms of the monovalent polyoxyalkylene derivative present in the largest proportion is defined as α. In this case, R １ In the ratio of monovalent polyoxyalkylene derivatives having different carbon numbers, the total ratio of monovalent polyoxyalkylene derivatives having carbon numbers of (α-4) to (α+4) is 97% by mass or less. This can further improve the permeability of the treatment agent into polyolefin synthetic fibers. It can also further improve the emulsion stability of the treatment agent.

[0066] (4) When the molecular weight distribution (Mw / Mn) of the monovalent polyoxyalkylene derivative (A1) is 1.03 or more and 1.50 or less, the permeability of the treatment agent into polyolefin synthetic fibers can be further improved, and the emulsion stability of the treatment agent can also be further improved.

[0067] (5) When the total content of the polyoxyalkylene derivative (A), the anionic surfactant (B), the polyether-modified silicone (C), and the polyglycerin fatty acid ester (D) is taken as 100% by mass, the treatment agent contains the polyoxyalkylene derivative (A) in an amount of 10% by mass to 60% by mass and the anionic surfactant (B) in an amount of 30% by mass to 70% by mass. The treatment agent also contains the polyether-modified silicone (C) in an amount of 0% by mass to 20% by mass and the polyglycerin fatty acid ester (D) in an amount of 0% by mass to 30% by mass. This can further improve the penetration of the treatment agent into polyolefin-based synthetic fibers. It can also further improve the emulsion stability of the treatment agent. Furthermore, it can also improve the initial hydrophilicity and rewetting resistance of nonwoven fabrics to which the treatment agent is attached.

[0068] (6) When the total content of the polyoxyalkylene derivative (A), the anionic surfactant (B), the polyether-modified silicone (C), and the polyglycerin fatty acid ester (D) is taken as 100% by mass, the total content of the polyoxyalkylene derivative (A) and the anionic surfactant (B) is 60% by mass or more, thereby further improving the emulsion stability of the treatment agent.

[0069] <Modifications> The above embodiment can be modified as follows: The above embodiment and the following modifications can be combined with each other within the scope of technical compatibility.

[0070] The treatment agent may contain components that are typically used in treatment agents, such as stabilizers for maintaining the quality of the treatment agent, antistatic agents, antistatic agents, binders, antioxidants, ultraviolet absorbers, and antifoaming agents (silicone-based compounds), within the scope of not impairing the effects of the present invention.

[0071] Examples will be given below to more specifically explain the configuration and effects of the present invention, but the present invention is not limited to these examples. In the following explanations of the examples and comparative examples, % means % by mass, and parts means parts by mass.

[0072] Test Section 1 (Preparation of Treatment Agent for Polyolefin-Based Synthetic Fibers) (Example 1) The components shown in Table 1 were added to a beaker so that the polyoxyalkylene derivative (A) was 32%, the anionic surfactant (B) was 54%, the polyether-modified silicone (C) was 13%, and the other component (E) was 1%. These were stirred and mixed well. While continuing to stir, ion-exchanged water was gradually added so that the solids concentration was 5%, and a 5% aqueous solution of the treatment agent for polyolefin-based synthetic fibers of Example 1 was prepared.

[0073] (Examples 2 to 51 and Comparative Examples 1 to 8) The polyolefin synthetic fiber treating agents of Examples 2 to 51 and Comparative Examples 1 to 8 were prepared in the same manner as in Example 1 using the components shown in Tables 1 to 4.

[0074] The type and content of the polyoxyalkylene derivative (A), the type and content of the anionic surfactant (B), the type and content of the polyether-modified silicone (C), the type and content of the polyglycerin fatty acid ester (D), and the type and content of the other component (E) in the treatment agent of each example are as shown in the "Polyoxyalkylene derivative (A)" column, the "Anionic surfactant (B)" column, the "Polyether-modified silicone (C)" column, the "Polyglycerin fatty acid ester (D)" column, and the "Other compounds (E)" column in Tables 1 to 4, respectively.

[0075]

[0076]

[0077]

[0078]

[0079] Details of each component shown in Tables 1 to 4 are as follows: (Polyoxyalkylene Derivative (A)) Details of the monovalent polyoxyalkylene derivatives A1-1 to A1-13 and A-14 to A-19 shown in Tables 1 to 4 are as follows.

[0080] For A1-1 to A1-13, A-14 to A-18, R １ Type of R １ The carbon number distribution of R １ The number of types of monovalent polyoxyalkylene derivatives having 22 or more carbon atoms is shown in "R １ The carbon number (α) of the monovalent polyoxyalkylene derivative with the highest abundance ratio is shown in the "α" column of Table 5. The total abundance ratio of monovalent polyoxyalkylene derivatives with a carbon number of (α-4) or more and (α+4) or less is shown in the "Total Abundance Ratio" column of Table 5. A １ The average values ​​of the type of O, the addition form, and the number of n are shown in "A" in Table 5. １ The molecular weight distribution (Mw / Mn) of the monovalent polyoxyalkylene derivative (A1) is shown in the "Molecular weight distribution" column of Table 5.

[0081] The details of A-19 are as follows: A-19: A compound in which 20 moles of ethylene oxide are added to 1 mole of sorbitan monostearate.

[0082]

[0083] In Table 5, EO and PO groups represent ethyleneoxy and propyleneoxy groups, respectively. The method for measuring the molecular weight distribution (Mw / Mn) of the monovalent polyoxyalkylene derivative (A1) will be described. The molecular weight distribution (Mw / Mn) of the monovalent polyoxyalkylene derivative (A1) was measured by GPC under the following measurement conditions.

[0084] Apparatus: HLC-8320GPC manufactured by Tosoh Corporation; Columns: TSK gel Super H4000, TSK gel Super H3000, TSK gel Super H2000 (all manufactured by Tosoh Corporation); Column temperature: 40°C; Detector: Differential refractive index detector; Sample solution: 0.25% by mass tetrahydrofuran solution; Solution flow rate: 0.5 mL / min; Solution injection amount: 10 μL; Standard sample: Polystyrene (TSK STANDARD POLYSTYRENE manufactured by Tosoh Corporation). A calibration curve was prepared using the standard sample, and the number-average molecular weight (Mn) and mass-average molecular weight (Mw) of the mixture of polyoxyalkylene derivatives blended in the treatment agent of each Example and Comparative Example were determined. The molecular weight distribution (Mw / Mn) was calculated using these values.

[0085] (Anionic Surfactant (B)) Details of the anionic surfactants B-1 to B-8 listed in Tables 1 to 4 are shown in Table 6.

[0086]

[0087] In Table 6, the acid value of the anionic surfactant (B) can be measured by a known method. (Polyether-modified silicone (C)) Details of polyether-modified silicones C-1 to C-6 listed in Tables 1 to 4 are shown in Table 7.

[0088] For C-1 to C-6, the type of terminal group is shown in the "Terminus of polyether-modified group". The mass ratio of the portion excluding alkylene oxide from the mass average molecular weight of the polyether-modified silicone is shown in the "Si %" column. The molar ratio of ethylene oxide to alkylene oxide is shown in the "EO % (molar ratio)" column. The addition form of alkylene oxide is shown in the "Addition form" column. The kinematic viscosity of the polyether-modified silicone is shown in the "Kinematic viscosity" column. The mass average molecular weight of the polyether-modified silicone is shown in the "Mass average molecular weight" column.

[0089]

[0090] In Table 7, EO and PO represent ethylene oxide and propylene oxide, respectively. The method for measuring the mass average molecular weight (Mw) of the polyether-modified silicone (C) will be described.

[0091] The mass average molecular weight (Mw) of the polyether-modified silicone was measured under the same conditions as for the molecular weight distribution (Mw / Mn) of the monovalent polyoxyalkylene derivative (A1). A calibration curve was prepared using a standard sample, and the mass average molecular weight (Mw) of each polyether-modified silicone was determined.

[0092] (Polyglycerol fatty acid ester (D)) Details of polyglycerol fatty acid esters D-1 to D-52 listed in Tables 1 to 4 are shown in Table 8. For D-1 to D-52, the name of the aliphatic monocarboxylic acid, the number of carbon atoms, and the number of moles per ester molecule are shown in the "Aliphatic carboxylic acid" column. The name of the polyglycerin, the degree of condensation, and the number of moles per ester molecule are shown in the "Polyglycerin" column.

[0093]

[0094] (Other Components (E)) Details of other components E-1 to E-12 listed in Tables 1 to 4 are shown in Table 9.

[0095]

[0096] Test Section 2 (Production of Polyolefin Synthetic Fibers and Nonwoven Fabrics) Using the treatment agent for polyolefin synthetic fibers prepared in Test Section 1, polyolefin synthetic fibers and nonwoven fabrics were produced.

[0097] First, the 5% aqueous solution of the treatment agent for polyolefin synthetic fibers prepared in Test Section 1 was diluted with hard water to a concentration of 0.25%. Using this aqueous solution, a treatment bath at a bath temperature of 25°C was prepared.

[0098] In addition, a spunbond nonwoven fabric (basis weight 20 g / m) was prepared using polypropylene fibers as polyolefin synthetic fibers. ２The spunbond nonwoven fabric was immersed in the treatment bath for 5 minutes, removed, and wrung out with a mangle at an adjusted wringing ratio so that the amount of aqueous liquid attached was 4 g per 2 g of polypropylene spunbond nonwoven fabric. The nonwoven fabric was then dried with air at 80°C for 30 minutes to prepare a nonwoven fabric for evaluation (hereinafter also referred to as the nonwoven fabric for evaluation).

[0099] The amount of the treatment agent attached to the polyolefin synthetic fiber was 0.5% per gram of polypropylene spunbond nonwoven fabric, which was measured by extracting the nonwoven fabric with a methanol / xylene (50 / 50 volume ratio) mixed solvent using a Soxhlet extractor.

[0100] Test Section 3 (Evaluation) For each of the treatment agents described in Examples 1 to 51 and Comparative Examples 1 to 8, the emulsion was evaluated for its penetration into nonwoven fabric and emulsion stability. The nonwoven fabrics were also evaluated for their initial hydrophilicity, durable hydrophilicity, and rewetting resistance. The procedures for each test are described below. The test results are shown in the "Emulsion Evaluation Items" and "Nonwoven Fabric Evaluation Items" columns of Tables 1 to 4, respectively.

[0101] (Penetration) The treatment agents of each Example and Comparative Example were heated to approximately 75°C. Each heated treatment agent was added to ion-exchanged water heated to approximately 75°C under stirring to prepare a 0.35% aqueous solution of the treatment agent. Next, a polypropylene spunbond nonwoven fabric to which no treatment agent had been applied was conditioned for 24 hours in a thermostatic chamber at 20°C and a relative humidity of 60%. 5 μL of a 0.35% aqueous solution of each treatment agent was dropped onto the conditioned nonwoven fabric. The state of penetration of the treatment agent into the nonwoven fabric was visually observed. The time until the treatment agent completely penetrated was measured, and the penetration was evaluated according to the following evaluation criteria. Penetration is also referred to as wettability.

[0102] Evaluation criteria for penetration: ◎ (Good): Penetration in less than 160 seconds ○ (Fair): Penetration in 160 seconds or more but less than 180 seconds × (Poor): Penetration in 180 seconds or more (Emulsion Stability) The treatment agents of each Example and Comparative Example were diluted with ion-exchanged water to prepare diluted solutions (emulsions) with a nonvolatile content of 1.0%. The temperature was controlled at 20°C, and the diluted solutions were visually observed after 24 hours to confirm the presence or absence of separation. Furthermore, the light transmittance (%) at a wavelength of 750 nm was measured using the diluted solutions under constant temperature conditions of 20°C and a relative humidity of 60%. The measurement device used was a Shimadzu UV-1800 Spectrophotometer. Emulsion stability was evaluated according to the following evaluation criteria.

[0103] Evaluation criteria for emulsion stability: ⊚ (Good): No separation and light transmittance of 85% or more; ∘ (Fair): No separation and light transmittance of 50% or more but less than 85%; × (Poor): Separation or light transmittance of less than 50%. (Initial Hydrophilicity) The nonwoven fabric for evaluation was cut into small pieces of 10 cm x 15 cm and then conditioned for 24 hours in a thermostatic chamber at 20°C and 60% humidity. Ten sheets of commercially available toilet paper were stacked to form an absorbent body. The conditioned nonwoven fabric for evaluation was placed on top of this absorbent body. The absorbent body and the nonwoven fabric for evaluation were placed on a 45° inclined plate, and 0.05 g of saline solution at 37°C was dropped 1 cm above the nonwoven fabric. The flow length, which is the length of saline solution flowing from the drop point to the end of absorption on the surface of the nonwoven fabric for evaluation (i.e., the distance traveled on the surface of the nonwoven fabric until the saline solution dropped on the nonwoven fabric for evaluation traveled until it was absorbed by the nonwoven fabric), was measured. The same test was carried out five times, and the initial hydrophilicity of the nonwoven fabric was evaluated based on the average value according to the following evaluation criteria.

[0104] Evaluation criteria for initial hydrophilicity: ⊚ (Good): Flow length is less than 30 mm; ∘ (Fair): Flow length is 30 mm or more and less than 50 mm; × (Poor): Flow length is 50 mm or more. (Durable Hydrophilicity) The nonwoven fabric for evaluation was cut into small pieces of 10 cm x 25 cm and then conditioned for 24 hours in a thermostatic chamber at 20°C and 60% humidity. Ten sheets of commercially available toilet paper were stacked to form an absorbent body. The nonwoven fabric for evaluation after humidity conditioning was placed on top of this absorbent body. Furthermore, a 414 g stainless steel plate with 20 equally spaced holes of 2 cm diameter was placed on top of the nonwoven fabric for evaluation. 0.05 g of 37°C saline solution was dropped into the 20 holes from a height of 1 cm above the nonwoven fabric for evaluation. The number of holes in the nonwoven fabric where the dropped saline solution was absorbed within 10 seconds was counted. Thereafter, the same measurement was repeated every 3 minutes, and the durable hydrophilicity of the nonwoven fabric was evaluated based on the result of the fifth measurement according to the following evaluation criteria.

[0105] Evaluation criteria for durable hydrophilicity: ⊚ (Good): At the fifth measurement, the number of holes in the stainless steel plate on the nonwoven fabric where the dropped physiological saline solution was absorbed by the nonwoven fabric within 10 seconds was 18 or more. ◯ (Fair): The number was 12 or more but less than 18. × (Unfair): The number was less than 12. (Rewet Prevention) The nonwoven fabric for evaluation was cut into small pieces of 10 cm x 10 cm and then conditioned for 24 hours in a thermostatic chamber at 20°C and 60% humidity. A 10 cm x 10 cm piece of nonwoven fabric was cut from the outermost nonwoven fabric material of a commercially available disposable diaper. The conditioned 10 cm x 10 cm piece was attached to the cut-out portion to prepare a sample for evaluating rewet prevention.

[0106] The sample for evaluating the rewetting prevention property was placed horizontally with the attached small piece facing upward, and a cylinder with an inner diameter of 6 cm and open ends was placed vertically in the center of the small piece. 80 ml of water was poured into the cylinder and left to stand for 5 minutes to allow the water to be absorbed into the disposable diaper.

[0107] Next, after removing the cylinder, 15 sheets of 10 cm x 10 cm filter paper were placed on the small piece. A 10 cm x 10 cm weight plate weighing 5.0 kg was then placed on top of the stack and applied for 2 minutes. The total mass of the 15 stacked filter papers was then measured, and the rate of increase in mass was calculated. The rewetting resistance of the nonwoven fabric was evaluated according to the following evaluation criteria.

[0108] Evaluation criteria for rewetting prevention ⊚ (Good): When the mass increase rate is less than 1% ◯ (Fair): When the mass increase rate is 1% or more and less than 2% × (Unacceptable): When the mass increase rate is 2% or more From the results in Tables 1 to 4, according to the present invention, it is possible to improve the penetration of the treatment agent into polyolefin-based synthetic fibers. It is also possible to improve the emulsion stability of the treatment agent. It is also possible to improve the initial hydrophilicity, durable hydrophilicity, and rewetting prevention properties of the nonwoven fabric to which the treatment agent is attached.

[0109] The present disclosure also encompasses the following aspects: (Appendix 1) A treatment agent for polyolefin-based synthetic fibers, characterized by containing a polyoxyalkylene derivative (A) including a monovalent polyoxyalkylene derivative (A1), an anionic surfactant (B), and at least one selected from a polyether-modified silicone (C) and a polyglycerin fatty acid ester (D), wherein the monovalent polyoxyalkylene derivative (A1) is a compound represented by the following general formula (1), R １ The compound contains three or more monovalent polyoxyalkylene derivatives having different carbon numbers,

[0110] In the general formula (1), R １ is a hydrocarbon group having 16 to 60 carbon atoms or an acyl group having 16 to 60 carbon atoms, １ A treatment agent for polyolefin synthetic fibers, wherein O is an alkyleneoxy group having 2 to 4 carbon atoms (the alkyleneoxy group may be one type alone or two or more types), and n is an integer of 5 to 100.

[0111] (Appendix 2) In the monovalent polyoxyalkylene derivative (A1), R in the general formula (1) １ Attachment 1: The treating agent for polyolefin synthetic fibers, wherein the number of carbon atoms is 22 or more and 50 or less.

[0112] (Appendix 3) In the monovalent polyoxyalkylene derivative (A1), R in the general formula (1) １2. The treatment agent for polyolefin synthetic fibers according to claim 1, wherein the total abundance ratio of monovalent polyoxyalkylene derivatives having different carbon numbers is 97 mass% or less, the total abundance ratio of which is (α-4) to (α+4) carbon atoms, where α is the carbon number of the monovalent polyoxyalkylene derivative having the highest abundance ratio.

[0113] (Appendix 4) The treating agent for polyolefin synthetic fibers according to Appendix 1, wherein the molecular weight distribution (Mw / Mn) of the monovalent polyoxyalkylene derivative (A1) is 1.03 or more and 1.50 or less.

[0114] (Appendix 5) The treatment agent for polyolefin-based synthetic fibers according to Appendix 1, containing the polyoxyalkylene derivative (A) in an amount of 10% by mass or more and 60% by mass or less, the anionic surfactant (B) in an amount of 30% by mass or more and 70% by mass or less, the polyether-modified silicone (C) in an amount of 0% by mass or more and 20% by mass or less, and the polyglycerol fatty acid ester (D) in an amount of 0% by mass or more and 30% by mass or less, where the total amount of the polyoxyalkylene derivative (A), the anionic surfactant (B), the polyether-modified silicone (C), and the polyglycerol fatty acid ester (D) is taken as 100% by mass.

[0115] (Appendix 6) The treatment agent for polyolefin-based synthetic fibers according to Appendix 1, wherein the total content of the polyoxyalkylene derivative (A), the anionic surfactant (B), the polyether-modified silicone (C), and the polyglycerin fatty acid ester (D) is 100% by mass, and the total content of the polyoxyalkylene derivative (A) and the anionic surfactant (B) is 60% by mass or more.

[0116] (Appendix 7) A treatment composition for polyolefin synthetic fibers, comprising the treatment agent for polyolefin synthetic fibers according to any one of Appendices 1 to 6, and a solvent.

[0117] (Appendix 8) Polyolefin synthetic fibers, characterized in that the treating agent for polyolefin synthetic fibers according to any one of Appendices 1 to 6 is adhered to the fibers.

[0118] (Appendix 9) A nonwoven fabric made from the polyolefin synthetic fiber according to Appendix 8.

Claims

1. A treatment agent for polyolefin-based synthetic fibers, comprising a polyoxyalkylene derivative (A) including the following monovalent polyoxyalkylene derivative (A1), an anionic surfactant (B), and at least one selected from the group consisting of a polyether-modified silicone (C) and a polyglycerin fatty acid ester (D). Monovalent polyoxyalkylene derivative (A1): A compound represented by the following general formula (1), R １ The monovalent polyoxyalkylene derivatives include three or more monovalent polyoxyalkylene derivatives having different carbon numbers. (In Chemical Formula 1, R １ A: a hydrocarbon group having 22 to 50 carbon atoms, or an acyl group having 22 to 50 carbon atoms. １ O: an alkyleneoxy group having 2 to 4 carbon atoms (the alkyleneoxy group may be one type or two or more types); n: an integer of 5 to 100. １ When the carbon number of the monovalent polyoxyalkylene derivative having the highest abundance ratio is α, the total abundance ratio of the monovalent polyoxyalkylene derivative having the carbon number of (α-4) or more and (α+4) or less is 97 mass% or less.

2. The agent for treating polyolefin synthetic fibers according to claim 1, wherein the molecular weight distribution (Mw / Mn) of the monovalent polyoxyalkylene derivative (A1) is 1.03 or more and 1.50 or less.

3. The treatment agent for polyolefin-based synthetic fibers according to claim 1, comprising the polyoxyalkylene derivative (A) in an amount of 10% by mass or more and 60% by mass or less, the anionic surfactant (B) in an amount of 30% by mass or more and 70% by mass or less, the polyether-modified silicone (C) in an amount of 0% by mass or more and 20% by mass or less, and the polyglycerin fatty acid ester (D) in an amount of 0% by mass or more and 30% by mass or less, when the total content of the polyoxyalkylene derivative (A), the anionic surfactant (B), the polyether-modified silicone (C), and the polyglycerin fatty acid ester (D) is taken as 100% by mass.

4. The treatment agent for polyolefin-based synthetic fibers according to claim 1, wherein the total content of the polyoxyalkylene derivative (A), the anionic surfactant (B), the polyether-modified silicone (C), and the polyglycerin fatty acid ester (D) is 100% by mass, and the total content of the polyoxyalkylene derivative (A) and the anionic surfactant (B) is 60% by mass or more.

5. A composition for treating polyolefin synthetic fibers, comprising the treating agent for polyolefin synthetic fibers according to any one of claims 1 to 4 and a solvent.

6. A polyolefin synthetic fiber having the treatment agent for polyolefin synthetic fiber according to any one of claims 1 to 4 adhered thereto.

7. A nonwoven fabric made from the polyolefin synthetic fiber according to claim 6.

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