JPH03128233A - Method for lamination of melt blow unwoven cloth, and peelable melt blow unwoven cloth laminate to be used for this method - Google Patents

Abstract

PURPOSE:To beautifully join a melt blow unwoven cloth to a material to be joined without wrinkling on the melt blow unwoven cloth by joining a laminate of a fibrous sheet and the melt blow unwoven cloth to the material to be joined so that the melt blow unwoven cloth surface abuts against the material to be joined, and then peeling the fibrous sheet of the laminate joined. CONSTITUTION:Extra fine synthetic fibers which hardly adhere to continuous synthetic fibers are sprayed by a melt blow method upon a fibrous sheet, in which the continuous synthetic fibers are accumulated and self-adhesion is made to one another, to be accumulated together to form a melt blow unwoven cloth on the fibrous sheet, thereby preparing a laminate of the fibrous sheet and the melt blow unwoven cloth and joining the laminate to a material to be joined in such a manner that the melt blow unwoven cloth surface abuts against the material to be joined. Then, the fibrous sheet of the laminate joined is peeled so that the melt blow unwoven cloth alone is joined to the material to be joined. The melt blow method is a method wherein a high-polymeric raw liquid is blown by high-speed gas through a pore to obtain extra fine synthetic fibers.

Description

[Detailed description of the invention] [Industrial application field]

The present invention uses a melt-blown nonwoven fabric as a knitted fabric. It relates to a method of bonding to synthetic resin type films, metal foils, etc.

[Conventional technology]

Melt-blown nonwoven fabric is made by blowing a polymer stock solution through pores with high-speed gas (for example, heated air), and collecting the resulting ultrafine fibers into a sheet. Since this melt-blown nonwoven fabric is composed of ultrafine fibers, it has no rigidity unless the weight is about 30g/rd or more.
There were cases where wrinkles appeared due to slight wind pressure. By the way, in general, melt-blown nonwoven fabrics are often used with a basis weight of about 0.5 to 20 g/rd when used in a laminated manner, and are very prone to wrinkles. It has been difficult to bond such melt-blown nonwoven fabrics to objects to be bonded, such as knitted fabrics, non-air permeable films, and metal foils. That is, wrinkles occur when the melt-blown nonwoven fabric is handled before or during bonding, making it impossible to bond it neatly to objects to be bonded.

[Problem to be solved by the invention]

Therefore, it is considered that the melt-blown nonwoven fabric may be placed on a release sheet before joining, and the melt-blown nonwoven fabric may be joined to the object to be joined using the release sheet. However, the melt-blown nonwoven fabric produced once
It was also difficult to place it on a release sheet. In other words, wrinkles occur in the melt-blown non-woven fabric between the time it is produced and the time it is placed on the release sheet.
It is not possible to place it neatly on the release sheet. It is also possible to apply tension to the melt-blown non-woven fabric to prevent wrinkles from forming, but as mentioned above, the melt-blown non-woven fabric is thin and has low strength, so the tension may cause it to break. Therefore, the present invention manufactures a melt-blown nonwoven fabric on a fiber sheet that will later become a release sheet, and handles the melt-blown nonwoven fabric together with this fiber sheet from the time of manufacture until the time of joining to objects to be joined, thereby eliminating wrinkles in the melt-blown nonwoven fabric. This allows for clean bonding to the objects to be bonded without any generation.

[Means and Effects for Solving the Problems] That is, the present invention provides a fiber sheet in which continuous synthetic fibers are accumulated and the continuous synthetic fibers are self-adhered to each other. A laminate of the fiber sheet and the melt-blown non-woven fabric is prepared by blowing and accumulating ultra-fine synthetic fibers that are difficult to adhere to the fabric using a melt-blowing method, and forming a laminate of the fiber sheet and the melt-blown non-woven fabric. A laminate of melt-blown nonwoven fabrics, characterized in that the melt-blown nonwoven fabrics are bonded so as to come into contact with objects to be bonded, and then the fiber sheets in the bonded laminate are peeled off so that only the melt-blown nonwoven fabrics are bonded to the objects to be bonded. It is about the method. In the present invention, first, a fiber sheet that will later become a release sheet is prepared. This fiber sheet is made by stacking continuous synthetic fibers, and the continuous synthetic fibers are self-adhered to each other. Specifically, spunbond nonwoven fabric is used as the fiber sheet. Spunbond nonwoven fabric is made by directly stacking continuous fibers that have been spun from a polymer stock solution and then drawn, and then heated and pressurized to self-adhere between the continuous fibers. On this fiber sheet, ultrafine synthetic fibers obtained by melt blowing are blown and accumulated. The melt-blowing method involves blowing a polymer stock solution through pores with high-speed gas (eg, heated air) to obtain ultrafine synthetic fibers. Therefore, the ultra-fine synthetic fibers are blown onto the fiber sheet together with a gas stream (e.g. air stream). This fiber sheet serves as a collection sheet for the ultra-fine synthetic fibers. The gas flow needs to be removed from the back side of the fiber sheet because the ultra-fine synthetic fibers must be collected on the fiber sheet and collected. If the ultrafine synthetic fibers are not excluded and reflected on the surface of the fiber sheet, the ultrafine synthetic fibers will also be reflected on the surface of the fiber sheet, and the ultrafine synthetic fibers will not be accumulated and collected on the fiber sheet.The fiber sheet used in the present invention is Since it is made by accumulating continuous synthetic fibers, gaps are formed between the continuous synthetic fibers, and the air permeability is high, and gas flow is effectively eliminated from the back side of the fiber sheet. Then, the ultrafine synthetic fibers obtained by the melt-blowing method are accumulated and collected to obtain a melt-blown nonwoven fabric.Furthermore, this fiber sheet is generally thin and has a high degree of flexibility. It has good compatibility with the melt-blown non-woven fabric supported on the melt-blown non-woven fabric, and wrinkles are unlikely to occur in the melt-blown non-woven fabric.In addition, this fiber sheet also serves as a release sheet later. The shaped melt-blown non-woven fabric must be easily peelable. Therefore, in the present invention, the continuous synthetic fibers that make up the fiber sheet and the ultra-fine synthetic fibers that make up the melt-blown non-woven fabric are mutually compatible. A typical example of a case where continuous synthetic fibers and ultrafine synthetic fibers are difficult to bond to each other is when their fiber diameters are different.In other words, continuous synthetic fibers are polyester fibers If so, the ultrafine synthetic fibers are fibers other than polyester fibers, such as polyolefin fibers and polyamide fibers.Also, if the continuous synthetic fibers are polyolefin fibers, the ultrafine synthetic fibers are fibers other than polyester fibers. Fibers such as polyester fibers and polyamide fibers are used.For example, when continuous synthetic fibers and ultra-fine synthetic fibers are the same type, the continuous synthetic fibers and ultra-fine synthetic fibers have good compatibility, and the fiber sheet and melt-blown The adhesive force with the nonwoven fabric increases, and the two tend to be difficult to peel off.As a fiber sheet, its basis weight is 10 to 300 g.
/n (preferably.The basis weight is 10g/rrf
If it is less than that, the fiber sheet becomes too thin and there is a risk that wrinkles may occur in the fiber sheet itself. Also, the basis weight is 30
If it exceeds 0 g/rrf, the fiber sheet becomes too rigid and tends to have poor compatibility with the melt-blown nonwoven fabric. Furthermore, the air permeability of the fiber sheet decreases, making it difficult to obtain a melt-blown nonwoven fabric with a clean surface. Further, the fiber diameter of the continuous synthetic fibers constituting the fiber sheet is preferably about 1 to 4 denier. Continuous synthetic fibers of less than 1 denier are difficult to produce by spunbond methods and are not practical. Moreover, if it exceeds 4 denier, the structure of the fiber sheet becomes rough and the rigidity increases, making it difficult to obtain a melt-blown nonwoven fabric with a clean surface condition, or there is a tendency that the compatibility between the fiber sheet and the melt-blown nonwoven fabric becomes poor. . As described above, the melt-blown nonwoven fabric is formed on the fiber sheet, and a laminate in which the fiber sheet and the melt-blown nonwoven fabric are laminated is obtained. This laminate can be handled in various forms, for example as a roll or cut into rectangular shapes. At this time, since the melt-blown nonwoven fabric is supported on the fiber sheet, it is less likely to wrinkle or break. Therefore, this laminate can be used in a desired form in the subsequent bonding process. Furthermore, since the fiber sheet and the melt-blown nonwoven fabric are made of fibers that are difficult to adhere to each other, this laminate is very easily peelable, that is, it is an easily peelable melt-blown nonwoven fabric laminate. The melt-blown nonwoven fabric surface of the laminate as described above is bonded to an article to be bonded, such as a knitted fabric, 9 pieces of paper, and 1 piece of resin film or metal foil. To join a melt-blown non-woven fabric to an object to be joined, either apply an adhesive to the object and adhere the melt-blown non-woven fabric there, or apply an adhesive to the melt-blown non-woven fabric and adhere it to the object. conduct. In addition, after the laminate and the objects to be joined are stacked so that the melt-blown nonwoven fabric surface is in contact with the objects to be joined, the polymer is heated or pressurized to soften or melt the melt-blown nonwoven fabric, or The melt-blown nonwoven fabric and the object to be joined may be bonded by softening or melting the object. Note that when joining the melt-blown non-woven fabric and the object to be joined, the fiber sheet is laminated on the melt-blown non-woven fabric to prevent wrinkles from forming in the melt-blown non-woven fabric. After the melt-blown nonwoven fabric and the object to be joined are joined, the fiber sheet is peeled off from the melt-blown nonwoven fabric. The bonded product of the melt-blown nonwoven fabric and the object to be bonded thus obtained is used as a filter cloth, a wiping cloth, a cloth for clothing, a medical sanitary material such as gauze, a packaging material, and the like.

[Example] Example 1 Polyester resin (intrinsic viscosity: o, 7 boas) was
Melt it by heating at °C, extrude it with an extruder, spin it, and draw it to obtain a 2-denier continuous fiber, collect it on a collector wire to form a sheet, and heat and pressurize it to make a span with a basis weight of 17 g/rrf. A bonded nonwoven fabric (fiber sheet) was obtained. Next, polypropylene resin (Melt Flowray) 200
) was melted by heating to 310"C, extruded with an extruder, passed through a spinneret, and blown off the resin with high-temperature, high-velocity hot air.
．． A 2-denier ultrafine fiber was obtained, which was blown onto the surface of the spunbond nonwoven fabric, and was accumulated and collected on the spunbond nonwoven fabric to obtain a melt blown nonwoven fabric with a weight of 8 g/rrr. Note that the distance from the spinneret to the surface of the spunbond nonwoven fabric was 25 cm. Thereafter, the melt-blown nonwoven fabric surface of the spunbond nonwoven fabric-melt-blown nonwoven fabric laminate was superimposed on the red-eye fabric whose surface was coated with an acrylic acid adhesive, thereby joining the red-eye fabric and the melt-blown nonwoven fabric. Then, the melt-blown nonwoven fabric and the spunbond nonwoven fabric were separated. This peeling could be easily performed, and almost no fuzz was generated on the surface of the melt-blown nonwoven fabric. Example 2 Polypropylene resin (melt flow rate 30)
Melt by heating to 0''C, extrude with an extruder, spin and draw to obtain a 3 denier continuous fiber, collect this on a collector wire to form a sheet, heat and pressurize it to obtain a fiber with a basis weight of 25 g/rrf. Spunbond nonwoven fabric (fiber sheet)
I got it. Next, polyester resin (intrinsic viscosity: 0.5 poise) was heated and melted at 350"C, extruded with an extruder, passed through a spinneret, and blown away with high-temperature, high-speed hot air to 0.8
A denier ultrafine fiber was obtained, which was blown onto the surface of the spunbond nonwoven fabric, and was collected and collected on the spunbond nonwoven fabric to obtain a melt blown nonwoven fabric weighing 8 g/bo. Note that the distance from the spinneret to the surface of the spunbond nonwoven fabric was 25 cm. Thereafter, the red-eye fabric and the melt-blown non-woven fabric were joined together in the same manner as in Example 1, and then the spunbond non-woven fabric was peeled off from the melt-blown non-woven fabric. This peeling could be easily performed, and almost no fuzz was generated on the surface of the melt-blown nonwoven fabric. Comparative Example 1 Polypropylene resin (melt flow rate 130) was
The resin was melted by heating to 90°C, extruded using an extruder, and passed through a spinneret to blow off the resin with high-temperature, high-speed hot air to obtain ultrafine fibers of 0.2 denier, which were then blown onto a collector wire to accumulate and collect them. A melt-blown nonwoven fabric with a basis weight of 8 g/rrf was obtained. Note that the distance from the spinneret to the surface of the spunbond nonwoven fabric was 25C11. This melt-blown nonwoven fabric was removed from the collector wire and an attempt was made to bond it to the red-eye fabric in the same manner as in Example 1, but when it was removed from the collector wire, wrinkles were generated due to slight wind pressure, and it could not be bonded neatly to the red-eye fabric. There wasn't. Comparative Example 2 Polypropylene resin (melt index 30) was
Melt it by heating to 0°C, extrude it with an extruder, spin it and draw it to obtain a 3 denier continuous fiber, collect it on a collector wire to form a sheet, and heat and pressurize it to have a basis weight of 25 g/rd. A spunbond nonwoven fabric (fiber sheet) was obtained. Next, polypropylene resin (melt flow rate 200
) is heated and melted at 310°C, extruded with an extruder, passed through a spinneret, and blown off with high-temperature, high-speed hot air to form a 0.
A 2-denier ultrafine fiber was obtained, which was blown onto the surface of the spunbond nonwoven fabric, and was accumulated and collected on the spunbond nonwoven fabric to obtain a meltblown nonwoven fabric with a basis weight of 8 g/nf. Note that the distance from the spinneret to the surface of the spunbond nonwoven fabric was 250 mm. Thereafter, the red-eye fabric and the melt-blown non-woven fabric were joined together in the same manner as in Example 1, and then the spunbond non-woven fabric was peeled off from the melt-blown non-woven fabric. This peeling could not be easily performed, and a large number of fluffs were generated on the surface of the melt-blown nonwoven fabric. Comparative Example 3 Polypropylene resin (melt flow rate 130) was
The resin was melted by heating to 10°C, extruded using an extruder, passed through a spinneret, and the resin was blown away with high-temperature, high-speed hot air to obtain 0.2 denier ultrafine fibers, which were blown onto the surface of an aluminum foil (non-breathable sheet). Attempts were made to obtain a melt-blown nonwoven fabric. However, the high-speed hot air was reflected on the back surface of the aluminum foil without being removed, making it impossible to accumulate and collect the ultrafine fibers, making it impossible to obtain a melt-blown nonwoven fabric. Effects of the Invention As explained above, in the present invention, ultrafine synthetic fibers obtained by melt blowing are accumulated and collected on an air-permeable fiber sheet, so a melt-blown nonwoven fabric can be formed satisfactorily. . Further, when handling the melt-blown non-woven fabric, it can be handled together with the fiber sheet, and it is possible to prevent the melt-blown non-woven fabric from wrinkles during handling. Furthermore, the ultrafine composite* fibers that make up the melt-blown nonwoven fabric and the continuous synthetic fibers that make up the fiber sheet are fibers that are difficult to adhere to each other, so they have poor affinity and weak adhesive strength. Therefore, after joining the melt-blown non-woven fabric and the object to be joined, the fiber sheet can be easily peeled off from the melt-blown non-woven fabric, and it is also possible to prevent a large number of fuzz from forming on the surface of the melt-blown non-woven fabric. Furthermore, since the fiber sheet is made of continuous fibers and has high tensile strength, it will not break even under severe handling conditions. Therefore, a laminate in which a fiber sheet and a melt-blown nonwoven fabric are laminated can be handled in various forms such as a roll. Furthermore, the continuous fibers in the fiber sheet are self-adhesive, and there is no binder for adhesion between the fibers. Therefore, the ultrafine fibers in the melt-blown nonwoven fabric do not adhere to the binder, and the peelability between the fiber sheet and the melt-blown nonwoven fabric can be further improved. Note that the fiber sheet is peeled off from the laminate after the melt-blown nonwoven fabric is bonded to the object to be joined, but it is also possible to reuse the peeled and removed fiber sheet.

Claims (2)

[Claims] (1) Ultra-fine synthetic fibers that do not easily adhere to the continuous synthetic fibers are blown onto a fiber sheet made by stacking continuous synthetic fibers and the continuous synthetic fibers are self-adhesive using a melt-blowing method. A laminate of the fiber sheet and the melt-blown non-woven fabric was prepared by accumulating them together to form a melt-blown non-woven fabric. A method for laminating melt-blown nonwoven fabrics, which comprises peeling off the fiber sheets in the laminate so that only the melt-blown nonwoven fabrics are bonded to objects to be bonded. (2) A fiber sheet made of an accumulation of continuous synthetic fibers and self-adhesive between the continuous synthetic fibers, and a melt-blown nonwoven fabric made of ultra-fine synthetic fibers that are difficult to bond to each other are laminated. It is characterized by
An easily peelable melt-blown nonwoven fabric laminate used in the method for laminating melt-blown nonwoven fabrics according to claim (1).