JPH09268460A - Nonwoven fabric and method for producing the same - Google Patents

Abstract

(57) [PROBLEMS] To provide a nonwoven fabric having an excellent feeling and a low surface friction resistance, and a method for producing the same. SOLUTION: The nonwoven fabric of the present invention includes an entanglement layer mainly composed of a bundle of ultrafine fibers A generated from removable splittable fibers, a physically splittable fiber, and an ultrafine fiber B generated from the physically splittable fiber. And / or having an entanglement layer containing ultrafine fibers B ′ having a fiber diameter of more than 1 μm on at least one surface. This method for producing a non-woven fabric includes a fiber web mainly composed of removable splittable fibers, and a fiber web containing physically splittable fibers,
At least two fibrous webs are laminated so that a fibrous web containing physically splittable fibers can form at least one surface, and a fluid flow is applied to split the physically splittable fibers to form ultrafine fibers B. After generation and entanglement, at least one resin component of the removable splittable fibers is removed to generate ultrafine fibers A.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a nonwoven fabric and a method for producing the same.

[0002]

2. Description of the Related Art A resin component (island component) which is hardly soluble in a solvent capable of dissolving and removing the resin component in one resin component (sea component).
A so-called sea-island type fiber in which is dispersed in an island shape is known. After forming a fiber web containing this sea-island type fiber, and entangled, the sea component of the sea-island type fiber is dissolved and removed to form an island component. Nonwoven fabrics that have produced ultrafine fibers consisting of Since this nonwoven fabric contains ultrafine fibers, it is excellent in feeling and filtration performance, and it is highly useful because artificial leather can be formed by impregnating with a urethane resin. By the same method, when ultrafine fibers having an average fiber diameter of 1 μm or less are generated in order to obtain a nonwoven fabric having more excellent feeling and filtration performance, the surface friction resistance becomes high,
In some cases, the intended use was limited.

[0003]

The present invention has been made to solve the above problems, and an object of the present invention is to provide a non-woven fabric having an excellent feeling and a low surface friction resistance, and a method for producing the same. .

[0004]

The non-woven fabric of the present invention comprises an entanglement layer mainly composed of removable splittable fibers capable of generating ultrafine fibers A having an average fiber diameter of 1 μm or less, and a physical layer capable of producing ultrafine fibers B. At least one surface has an entangled layer containing the optically dissociable fibers and the ultrafine fibers B generated from the physically dissociable fibers. Therefore, if one or more kinds of resin components of the removable splittable fibers of this nonwoven fabric are removed to generate the ultrafine fibers A, an entangled layer mainly composed of the ultrafine fiber A bundles generated from the removable splittable fibers is formed. , Physically splittable fibers and ultrafine fibers B generated from the physically splittable fibers and / or fiber diameter 1 μm
It is possible to form a non-woven fabric having an entanglement layer containing more than m ultrafine fibers B ′ on at least one surface, and the non-woven fabric contains the ultrafine fibers A and the ultrafine fibers B and / or the ultrafine fibers B ′. The texture is excellent, and at least one surface of the nonwoven fabric has a layer in which the ultrafine fibers B and / or the ultrafine fibers B ′ are entangled with each other, so that at least one surface of the nonwoven fabric has low surface friction resistance.

The method for producing a non-woven fabric according to the present invention includes at least two fiber webs, a fiber web mainly composed of removable splittable fibers and a fiber web containing physically splittable fibers, and the physically splittable fibers. After the fibrous webs are laminated so as to form at least one surface and a fluid flow is actuated, the physically splittable fibers are split to generate ultrafine fibers B and are entangled, and then the removable splittable fibers are formed. Since it is a method of removing one or more kinds of resin components to generate the ultrafine fibers A, a nonwoven fabric having excellent feel and low surface friction resistance can be easily and stably manufactured.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION In the present invention, one or more kinds of resin components are removed to form an entangled layer mainly composed of removable dividable fibers capable of generating ultrafine fibers A having an average fiber diameter of 1 μm or less. By doing so, a non-woven fabric excellent in feeling and filtration performance is formed. It is more preferable that the average fiber diameter of the ultrafine fibers A is 0.7 μm or less so that the texture is more excellent. The average fiber diameter of the ultrafine fibers A is preferably 0.01 μm or more so that the fibers do not easily come off. When the ultrafine fibers A have an irregular cross-sectional shape, the value converted into a circular cross-sectional shape is used as the fiber diameter of the ultrafine fibers A, and the average value of 50 randomly selected ultrafine fibers A is called the average fiber diameter. .

Examples of the removable splittable fiber include:
As shown in the fiber cross-sectional schematic diagram in FIG. 1, a sea-island type fiber in which a hard-to-removal Y component is arranged and / or dispersed in an island-like manner in the X component removable by the remover in the X component is shown. In addition, by removing the X component of the sea-island type fiber, it is possible to generate the ultrafine fiber A composed of the Y component.

Examples of the remover capable of removing one or more kinds of resin components of the removable splittable fiber include solvents, enzymes and microorganisms. Among them, the solvent is preferable because the removal rate is fast and the handling is easy. Can be used for Among these solvents, aqueous solvents can be suitably used because they are easy to handle and process. Removable in the present invention means that 95 mass% or more of the resin component can be removed, and difficult removal is that 5 mass% or less of the resin component is removed under the condition of removing the resin component of the removable splittable fiber. Say.

As another removable splittable fiber, as shown in a schematic cross-sectional view of the fiber in FIG. 2, an X component which can be removed by a remover and a Y component which is difficult to remove by the X component remover, or a removable component There is a multi-bimetal type fiber in which a Y component that can be removed with an agent and an X component that is difficult to remove in the Y component are alternately laminated in layers, and the X component or the Y component of this multi-bimetal type fiber is removed. As a result, the ultrafine fibers A having a substantially trapezoidal cross-sectional shape composed of the Y component or the X component can be mainly generated.

As another removable splittable fiber, as shown in FIGS. 3 (a) and 3 (b), which are schematic cross-sectional views of the fiber, the X component which can be removed by the removing agent is difficult to use as the X component removing agent. Removable Y
A chrysanthemum flower which is divided into the X component by extending from the inside of the fiber (preferably the fiber axis) to the fiber surface by the component or by the Y component capable of removing the X component which is difficult to remove by the Y component removing agent. There is a shaped fiber, and by removing the X component or the Y component of this chrysanthemum-shaped fiber, it is possible to generate an ultrafine fiber A having a Y-shaped or X-component and having a cross-sectional shape of an American character or a fan shape.

In each case, the case where the removable splittable fiber is composed of two kinds of resin components has been described.
It may be composed of more than three types of resin components, and if it is composed of three types of resin components, two or less types of ultrafine fibers A can be generated. Can occur.

When the removable splittable fiber is composed of three or more kinds of resin components, for example, at least one island component of the sea-island type fiber is a sea-island type, multiple bimetal type, chrysanthemum type,
Core-sheath type, eccentric type, or side-by-side type, at least one resin component of multi-bimetal type fiber is sea-island type, multi-bimetal type, chrysanthemum type, core-sheath type, eccentric type, or side-by-side A pattern, or
There are those in which at least one resin component of chrysanthemum type fibers is a sea-island type, multiple bimetal type, chrysanthemum type, core-sheath type, eccentric type, or side-by-side type. By using such removable splittable fibers, finer ultrafine fibers A can be formed, and thus a nonwoven fabric having a better texture can be formed. In addition, if the ultrafine fibers A can be fused, the nonwoven fabric having more excellent morphological stability can be formed by the fusion. Furthermore, if the microfiber A is composed of two or more types of resin components, and a crimp can be expressed by utilizing the difference in shrinkage of the resin components, a nonwoven fabric having a better feeling or a nonwoven fabric having an excellent elasticity can be formed. it can.

Among the removable splittable fibers as described above,
The removable splittable fiber including the sea-island type portion in the fiber cross section is likely to generate the ultrafine fiber A having an average fiber diameter of 1 μm or less, and thus can be preferably used.

The ultrafine fibers A which can be generated from such removable splittable fibers do not have to have a single fiber diameter, and may have various fiber diameters of various sizes. The average fiber diameter must be 1 μm or less so as not to impair the above. The number of ultrafine fibers A that can be generated from the removable splittable fibers is not particularly limited, but is 3 to 15,
About 000 is suitable. Further, ultrafine fibers A having different fiber cross-sectional shapes may be mixed.

As the resin component constituting the removable splittable fiber, for example, nylon 6, nylon 66, polyamide such as nylon copolymer, polyethylene terephthalate, polyethylene terephthalate copolymer having fiber forming ability, Polybutylene terephthalate, polyester such as polybutylene terephthalate copolymer, polyethylene, polypropylene, polyolefin such as polymethylpentene, polyurethane, polyacrylonitrile, vinyl polymer such as polystyrene, or polyglycolic acid, glycolic acid copolymer, Aliphatic polyester-based polymers such as polylactic acid, lactic acid copolymer, etc., and this aliphatic polyester-based polymer with capramide, tetramethylene adipamide, undecanamide, laurolactamide, hexamethylene adipami Among aliphatic polyesteramide-based copolymers obtained by copolymerizing aliphatic amides such as, for example, a certain removing agent is combined with at least one removable resin and at least one difficult-to-remove resin. Just go. For example, when one type of removable resin and one type of difficult-to-remove resin are included, it is possible to remove polystyrene with a removable agent of Perkren and removable polystyrene and difficult-removable polyamide and toluene with a removable agent. There are combinations of polyethylene and difficult-to-remove polyamide, and a removable polyester and difficult-to-remove polyolefin with respect to alkaline aqueous solution removers. Among these, the combination of polyester and polyolefin is preferable because the alkaline aqueous solution is easy to handle as a remover.

On the other hand, a physically splittable fiber which can be split by a physical action to generate the ultrafine fiber B, and an entanglement layer containing the ultrafine fiber B and / or the ultrafine fiber B'generated from the physically splittable fiber. Was formed on at least one surface to form a layer having a low surface friction resistance without impairing the properties such as feeling and filtration performance due to the ultrafine fibers A generated from the removable splittable fibers. Therefore, when it is preferable that both surfaces have low frictional resistance, both surface layers are entangled layers containing physically dividing fibers and ultrafine fibers B and / or ultrafine fibers B ′, and only one surface is sufficient. In this case, only one surface is an entangled layer containing the physically splittable fibers and the ultrafine fibers B and / or the ultrafine fibers B ′.

Examples of the physically splittable fiber include, for example,
As shown in the schematic cross-sectional view of the fiber in FIG. 1, among the X components that can be divided by a physical action, there is a sea-island type fiber in which a Y component poorly compatible with the X component is arranged and / or dispersed in an island shape. By dividing the sea-island type fiber, the ultrafine fiber B ₁ composed of the X component, the ultrafine fiber B ₂ composed of the Y component, and the X component and the Y
It is possible to generate the ultrafine fibers B ₃ containing the component. In addition,
A sea-island type fiber is suitable because the Y component is composed of islands of various sizes, because it is easy to split by physical action. In particular, the physically splittable fiber containing an island component having a diameter of 0.06 to 0.2 with respect to the diameter of the physically splittable fiber is easy to split and easily entangled, and thus can be suitably used. In addition,
If the island component has a diameter of 1 to 5 μm, the X component, which is a sea component, is further removed after dividing and intertwining, and the ultrafine fiber B ′ is generated. Friction resistance can be lowered.

As the physical action in the present invention, for example, the action of a needle punch, the action of a fluid flow such as water flow,
There is an operation of a calender or an operation of a flat plate press.
Among these, the action of a fluid stream such as a needle punch or a water stream that can be entangled simultaneously with the division of the physically splittable fiber is preferable, and the action of a fluid stream such as a water stream that can be more uniformly split and entangled. Is more preferable.

The poor compatibility of the present invention means that side-by-side type composite fibers can be spun from a target resin and the composite fibers can be divided by applying shearing force with fingers.

Another physically splittable fiber of the present invention is
As shown in the schematic cross-sectional view of the fiber in FIG. 2, there is a multiple bimetallic fiber in which an X component and a Y component that is poorly compatible with the X component are alternately laminated in a layered form. When applied, the ultrafine fiber B ₁ composed of the X component and Y
The microfine fibers B ₂ consisting of components can be generated.

Another physical splittable fiber is shown in FIG.
As shown in the schematic cross-sectional views of the fibers in (a) and (b), chrysanthemum flower in which the X component is divided by the Y component which is poorly compatible with the X component and extends from the inside of the fiber (preferably the fiber axis) to the fiber surface. has a type fibers, if Hodokose a physical action on the chrysanthemum-type fiber, the microfine fibers B ₁ consisting of the X component, it is possible to generate and microfine fibers B ₂ consisting of Y component.

In each case, the case where two kinds of resin components are used has been described, but the physically splittable fiber may be made of three or more kinds of resin components, and three kinds of physically splittable fibers are available. With the resin component (3), three or more types of ultrafine fibers B can be generated, and with four types of resin components, four or more types of ultrafine fibers B can be generated.

Examples of the physically splittable fiber composed of three or more kinds of resin components include, for example, at least one island component of a sea-island type fiber that can be split by a physical action. Sheath type, eccentric type, or side-by-side type, at least one resin component of multiple bimetal type fibers that can be divided by physical action is a sea-island type, multiple bimetal type, chrysanthemum type, core-sheath type, eccentric type, Alternatively, a side-by-side type, or at least one resin component of chrysanthemum-type fibers that can be divided by physical action is a sea-island type, multiple bimetal type, chrysanthemum type, core-sheath type, eccentric type, or side-by-side type. You can use one. By using such physically splittable fibers, it is possible to generate finer ultrafine fibers B ′, so that a nonwoven fabric having a better texture can be formed, but only ultrafine fibers B ′ having a fiber diameter of 1 μm or less are produced. If so, the surface frictional resistance becomes high and the meaning of entanglement with the ultrafine fibers B ′ becomes meaningless. Therefore, it is preferable to include the ultrafine fibers B ′ exceeding 1 μm. In addition, if the ultrafine fibers B and / or the ultrafine fibers B ′ can be fused, a non-woven fabric having excellent morphological stability can be formed by the fusion, and the ultrafine fibers B and / or the ultrafine fibers B ′ are If two or more kinds of resin components are used and the crimp can be expressed by utilizing the difference in shrinkage between the resin components, a nonwoven fabric having a better feeling and a nonwoven fabric having excellent elasticity can be formed.

As the resin component constituting the physically splittable fiber of the present invention, two or more kinds of resin components having poor fiber compatibility with each other among the resin components having the same fiber-forming ability as those of the above-mentioned removable splittable fiber. You can combine the resin of, for example,
When two kinds of resin components are used, there are combinations of polyamide and polyester, polyamide and polyolefin, polyester and polyolefin and the like.

As the resin component constituting the ultrafine fibers B which can be generated from the physical type splittable fiber, a removing agent for the resin component of the removable splittable fiber, which has a slow removal rate but is removable, is included. This is preferable since the resin component of the removable splittable fiber can be removed and at the same time, a part of the resin component of the ultrafine fiber B can be removed, and a nonwoven fabric having a better texture can be formed. If the removal rate of the resin component of the removable splittable fiber is 1, the resin component constituting the ultrafine fiber B is 0.2 with a remover that removes the resin component of the removable splittable fiber.
A removal rate of ˜0.7 is preferred, and a removal rate of 0.2-0.5 is more preferred. As the resin component of the ultrafine fibers B, for example, when the removing component of the removable splittable fiber is a copolyester and the removing agent is an aqueous alkaline solution, a diol such as polyester or polybutylene succinate and a dicarboxylic acid are condensed. There are polymers, etc.

The ultrafine fibers B are composed of two or more kinds of resin components, and one or more kinds of resin components are removed to obtain a fiber diameter of 1
When it is possible to generate ultrafine fibers B ′ exceeding μm,
A non-woven fabric having a better texture can be formed without impairing the action of lowering the surface frictional resistance. The resin component of the ultrafine fibers B may be removed at the same time as removing the resin component of the removable splittable fiber, or may be removed after removing the resin component of the removable splittable fiber. In the former case of simultaneous removal, if the removal rate of the resin component of the removable splittable fiber is set to 1 as the resin constituting the ultrafine fiber B, a removing agent for removing the resin component of the removable splittable fiber, It is preferable to include those that can be removed at a removal rate of 0.9 or more and those that can be removed by 0.2 or less, preferably 0.1 or less, and most preferably 0.05 or less. As a combination of the resin components of the ultrafine fibers B, when the removal component of the removable splittable fiber is a copolyester and the removal agent is an aqueous alkaline solution, and the removal component is composed of two types of resin components, the removal rate is 0.9 or more. There are combinations such as polyesters having ## STR3 ## and polyolefins having a removal rate of 0.2 or less, polylactic acid having a removal rate of 0.9 or more, and polyolefins having a removal rate of 0.2 or less. On the other hand, as a combination of resin components that needs to remove the resin component of the ultrafine fibers B separately from the removal of the resin component of the removable splittable fiber, the removable component of the removable splittable fiber is a copolyester, and the removal agent Is an alkaline aqueous solution and contains polystyrene and nylon, the removal component of the removable splittable fiber is polylactic acid, and the removing agent is an alkaline aqueous solution, such as polyethylene and nylon.

The ultrafine fibers B and / or the ultrafine fibers B ′ which can be generated from such physically splittable fibers do not have to have a single fiber diameter, but have various large and small fiber diameters. However, it is preferable that the average fiber diameter is 7 μm or less so as not to impair the feel and filtration performance of the nonwoven fabric.
More preferably, it is less than or equal to μm. On the other hand, if the average fiber diameter of the ultrafine fibers B and / or the ultrafine fibers B'is smaller than 0.01 μm, the fibers are likely to fall off, so 0.0
It is preferably 1 μm or more. If the fiber diameter is 1 μm or less and only the ultrafine fibers B and / or ultrafine fibers B ′ are used, it becomes difficult to reduce the surface friction resistance. Therefore, the ultrafine fibers B and / or the ultrafine fibers having a fiber diameter of more than 1 μm are used. It preferably contains fibers B '. In addition, ultrafine fiber B
Alternatively, when the ultrafine fibers B ′ have an irregular cross-sectional shape, the value converted into the circular cross-sectional shape is the ultrafine fibers B or the ultrafine fibers B ′.
The average diameter of 50 randomly selected ultrafine fibers B or ultrafine fibers B ′ is referred to as the average fiber diameter. Ultrafine fibers B or ultrafine fibers B'that can be generated from this physically splittable fiber
Is not particularly limited, but the number is 3 to 1,00.
About 0 is appropriate. Furthermore, ultrafine fibers B and / or ultrafine fibers B ′ having different fiber cross-sectional shapes may be mixed.

Such removable splittable fibers or physically splittable fibers used in the present invention can be prepared by a conventional composite spinning method, a mixed spinning method, or by appropriately combining them.
It can be easily spun. In addition, flame retardants, antistatic agents, moisture absorbents, colorants, and
You may mix a dyeing agent, a conductive agent, a hydrophilizing agent, etc. The fineness of the removable splittable fiber and the physically splittable fiber is
It is preferably 88 to 550 μg / m.

One of the nonwoven fabrics of the present invention comprises the entanglement layer mainly composed of the above-mentioned removable splittable fibers, the physically splittable fibers and the ultrafine fibers B generated from the physically splittable fibers. It has an entangled layer containing at least one surface. As the fibers other than the removable splittable fibers of the entangled layer mainly composed of the removable splittable fibers, for example, physically splittable fibers, ultrafine fibers B generated from the physically splittable fibers, silk, wool, cotton, hemp Natural fibers such as, regenerated fibers such as rayon fibers, semi-synthetic fibers such as acetate fibers, polyamide fibers, polyvinyl alcohol fibers, acrylic fibers, polyester fibers,
Synthetic fibers such as polyvinyl chloride fibers, polyvinylidene chloride fibers, polyurethane fibers, polyethylene fibers, polypropylene fibers and aromatic polyamide fibers can be used.

On the other hand, as the fiber other than the physically splittable fiber and the ultrafine fiber B in the entangled layer containing the physically splittable fiber and the ultrafine fiber B, for example, the removable splittable fiber or the removable splittable fiber is generated. The ultrafine fibers A and fibers similar to the fibers other than the removable splittable fibers of the entangled layer mainly composed of the removable splittable fibers can be used. If the physically disintegrating fiber and the ultrafine fiber B are contained in an amount of 10 mass% or more (the sum of the physically disintegrating fiber and the ultrafine fiber B) or more, the surface friction resistance can be sufficiently low.

The non-woven fabric formed by removing the resin component of the removable splittable fibers composing the above-mentioned non-woven fabric, the entanglement layer mainly consisting of the ultrafine fiber A bundle, the physically splittable fiber and the ultrafine fiber B.
And / or having an entanglement layer containing the ultrafine fibers B ′ on at least one surface. Therefore, this non-woven fabric has excellent feel and filtration performance, and at least one surface has low surface friction resistance. As the resin component that constitutes the ultrafine fibers B, a resin component that can be removed by a remover that removes the resin component of the removable splittable fiber at a rate slower than the rate of removing the resin component of the removable splittable fiber is used. When included, when removing the resin component of the removable splittable fiber,
Since a part of the ultrafine fibers B is removed at the same time, the nonwoven fabric has a better feeling.

The ultrafine fibers B contained in the above non-woven fabric
Is composed of two or more kinds of resin components, and one or more kinds of resin components can be removed to generate ultrafine fibers B ′ having a fiber diameter of more than 1 μm. At least one surface has an entanglement layer mainly composed of a bundle, and an entanglement layer containing a physically splittable fiber and an ultrafine fiber B and / or an ultrafine fiber B ′ bundle. Therefore, this nonwoven fabric has a better texture.

Next, the method for producing the nonwoven fabric of the present invention will be briefly described. First, a fiber web mainly containing the above-mentioned removable splittable fibers and a fiber web containing physically splittable fibers are formed. Examples of the method for forming the fibrous web include a dry method such as a card method, an air lay method, a melt blow method, and a spun bond method, and a wet method. The fiber length varies depending on the method for forming the fiber web, and when the former dry method is used (except when the melt blow method or spun bond method is used), 20 to 1 is used.
When using the latter wet method, fibers of about 1 to 30 mm are used. In addition,
The method for forming the fibrous web mainly composed of removable splittable fibers and the method for forming the fibrous web containing physically splittable fibers may be different.

At least two fiber webs, a fibrous web mainly composed of the removable splittable fibers and a fibrous web containing physically splittable fibers, are used. After laminating so that one surface can be formed, or by applying a fluid flow or a needle to each fibrous web, an entangled fibrous web is formed. Among these, when the fiber web mainly composed of the removable splittable fiber and the fiber web containing the physically splittable fiber are entangled after being laminated, the layer mainly composed of the removable splittable fiber and the physical splittability This is preferable because the step of integrating the fiber-containing layer can be eliminated. Note that the fluid flow is more preferable because it can be entangled uniformly and densely. Further, a fiber web mainly composed of the removable splittable fibers and a fiber web other than the fiber web containing the physically splittable fibers may be laminated.

The preferred fluid stream is preferably water which is easy to handle in production. As the entanglement condition by this fluid flow, for example, the nozzle diameter is 0.05 to 0.3 m.
m, preferably 0.08 to 0.2 mm, pitch 0.2 to 3 mm, preferably 0.4 to 2 mm arranged in one or more rows, using a pressure plate of 0.98 to 290 MPa, preferably 4.
A fluid flow of 9 to 250 MPa is jetted. The pressure of the fluid flow may be changed, or the nozzle plate may be swung or vibrated. Further, when the fluid flow is applied from the side of the fiber web containing the physically splittable fiber, the fluid flow is more easily split.

The non-woven fabric thus obtained has an entanglement layer mainly composed of removable splittable fibers which have not yet been split,
At least one surface has an entangled layer containing a physically splittable fiber and an ultrafine fiber B generated from the physically splittable fiber. There may be a layer in which these fibers are mixed between the entangled layer mainly composed of the removable splittable fiber and the entangled layer containing the physically splittable fiber and the ultrafine fiber B.
On the other hand, when the fiber webs are separately entangled, they are integrated through another adhesive, and there is no layer in which the removable splittable fibers, the physical splittable fibers, and the ultrafine fibers B are mixed, There is a drug layer.

This non-woven fabric further comprises one of removable splittable fibers.
By removing more than one kind of resin component, the ultrafine fibers A can be generated to form a non-woven fabric having excellent feeling and filtration performance. The non-woven fabric obtained by dividing the removable splittable fibers has an entangled layer mainly composed of a bundle of ultrafine fibers A, and an entangled layer containing physically splittable fibers and the ultrafine fibers B and / or the ultrafine fibers B ′. It is a thing. The removal of one or more resin components of the removable splittable fibers to generate the ultrafine fibers A can be performed, for example, by immersing the nonwoven fabric in a bath filled with a removing agent.

As the resin component constituting the ultrafine fibers B, when the removal rate of the resin component is set to 1, the removal agent used for removing the resin component of the removable dividable fiber gives 0.2 to 0.2%. If it contains those that can be removed at a removal rate of 0.7, one or more resin components of the ultrafine fibers B are generated when the ultrafine fibers A are generated by removing one or more resin components of the removable splittable fibers. Since the parts are removed at the same time, the nonwoven fabric has a better feeling.

Further, the ultrafine fibers B which can be generated from the physical type splittable fiber are composed of two or more kinds of resin components, and one or more kinds of resin components can be removed to generate ultrafine fibers B'having a fiber diameter of more than 1 μm. In the case of, the resin component of the removable fiber is removed at the same time as the removal of the resin component of the removable fiber, or after the resin component of the removable fiber is removed. An entanglement layer mainly composed of, and a physically splittable fiber and an ultrafine fiber B generated from the physically splittable fiber and / or
Alternatively, it is possible to form a nonwoven fabric having an entangled layer containing a bundle of ultrafine fibers B ′ on at least one surface and having a more excellent texture. Extra-fine fiber B, in addition to removing the resin component of the removable splittable fiber
The method of removing the resin component can be performed, for example, by immersing the nonwoven fabric in a bath filled with a removing agent.

The non-woven fabric of the present invention obtained as described above is excellent in feeling, filtration performance and the like and has a low surface friction resistance. Therefore, for example, a base material for artificial leather such as gloves, outer garments and bags. , Interlining for clothing, padded cotton, leakproof sheets,
It can be used for applications such as masks, battery separators, air or liquid filters, wallpaper, automobile interior materials, partition substrates, and wiping materials. Further, further processing such as dyeing processing, coloring processing with pigments, raising processing, laminating processing, molding processing, surface treatment processing and embossing processing may be performed so as to be more suitable for various applications.

Examples of the present invention will be described below, but the present invention is not limited to the following examples.

[0042]

【Example】

(Example 1) Copolymerized polyester 57.5 mass% and polypropylene 42.5 mass% were mixed in a pellet state,
The mixture was spun at 280 ° C. to obtain a wound yarn having a fineness of 440 μg / m. Then, this winding yarn is 3.3 at 90 ℃
The film was double-stretched and cut to form removable dividable fibers having a fineness of 160 μg / m, a fiber length of 38 mm, and a circular cross section in which about 2,200 island components made of polypropylene having an average fiber diameter of 0.21 μm were dispersed. Then, this removable splittable fiber was
A unidirectional fiber web formed by a card machine was used at a rate of 00% and was crossed with a cross layer in the traveling direction of the fiber web to form a crossed fiber web A.

On the other hand, as the physically separable fiber, the fineness is 12
As shown in the cross-sectional shape in FIG. 3 (a) of 0 μg / m and fiber length of 38 mm, a chrysanthemum-type splittable fiber (manufactured by Kanebo Co., Ltd., which is a polyester component divided by 6 nylon components extending radially from the fiber axis) Name: Berryma X, Eight microfibers B ₁ with a fiber diameter of 3.1 μm, made of polyester component, and ₁ microfiber B _{2 having a} cross-shaped cross section, made of 6 nylon component, with a fiber diameter of 4.5 μm And 4 ultrafine fibers B _{3 having} a fiber diameter of 3.2 μm and having a single-character cross section composed of 6 nylon component) were prepared. Next, 100% of this physically splittable fiber was used, and the unidirectional fiber web formed by a card machine was crossed with a cross layer in the traveling direction of the fiber web to form a crossed fiber web B.

Next, the crossed fiber web A and the crossed fiber web B were laminated at a weight ratio of 1: 1 to form a laminated fiber web, and the laminated fiber web was placed on a net having an opening of 0.147 mm. After that, from the nozzle plate having a diameter of 0.13 mm and a pitch of 0.6 mm to the crossed fiber web B side, the crossed fiber web A side, and the crossed fiber web B side in this order, pressures of 7.8 and 12,
By jetting a water flow of 12 MPa, the physically splittable fibers were split to generate ultrafine fibers B, and at the same time, the laminated fiber web was entangled to form a nonwoven fabric A having an areal density of 108 g / m ² . Next, this non-woven fabric A is heated at a temperature of 80 ° C. for 12 mass
% Aqueous sodium hydroxide solution for 30 minutes to decompose and extract the copolyester of the removable splittable fiber, and at the same time to extract a part of the polyester component of the ultrafine fiber B to obtain a nonwoven fabric having an area density of 72 g / m ² . B was formed.

(Example 2) As a physically disintegratable fiber, a polypropylene component and a polymethylpentene component were separated from each other as shown in FIG. 3 (b) having a fineness of 330 μg / m and a fiber length of 45 mm. Chrysanthemum-type splittable fiber (manufactured by Daiwabo Co., Ltd., trade name: DF-3, a fan-shaped cross-section made of polypropylene component, and an ultrafine fiber B ₁ having a fiber diameter of 5.4 μm.
Eight fibers and eight ultrafine fibers B ₂ with a fan diameter of 5.4 μm in cross section composed of polymethylpentene component can be generated)
Was prepared. This physically splittable fiber is then 100%
The used unidirectional fiber web formed by the carding machine was crossed by a cross layer with the traveling direction of the fiber web to form a cross fiber web B. afterwards,
In the same manner as in Example 1, the crossed fiber web A formed in the same manner as in Example 1 and the above crossed fiber web B were laminated and hydroentangled to form a nonwoven fabric A having an areal density of 88 g / m ² . Then, in the same manner as in Example 1, the copolyester of the removable splittable fibers was decomposed and extracted to form a nonwoven fabric B having an areal density of 62 g / m ² . This non-woven fabric B was slightly harder than the non-woven fabric B of Example 1. This is because the resin component of the ultrafine fiber B generated from the physically splittable fiber is
This is probably because it was not extracted.

(Example 3) In a sea-island type fiber composite spinning apparatus, polypropylene was extruded from a nozzle forming an island component, while 60 mass% of copolymerized polyester and 40 mass% of polypropylene were pelletized from a nozzle forming an sea component. Gear pump ratio 8: 1
Extrusion at 5.8, composite spinning at 280 ° C, fineness of 83
A wound yarn of 0 μg / m was obtained. Next, this winding yarn is drawn 3.3 times at 90 ° C. and cut to have an average diameter of 2.6 μm.
280 μg / fineness in which 21 large island components made of polypropylene of m (ratio to the diameter of physically splittable fiber: 0.11) and about 5,000 small island components made of polypropylene having an average diameter of 0.18 μm are dispersed. A physically separable fiber having a m, a fiber length of 51 mm and a circular cross section was formed. Next, 100% of this physically splittable fiber was used, and the unidirectional fiber web formed by a card machine was crossed with a cross layer in the traveling direction of the fiber web to form a crossed fiber web B. Then, as in Example 1,
The crossed fiber web A and the crossed fiber web B formed in the same manner as in Example 1 were laminated and hydroentangled to give an areal density of 95.
Non-woven fabric A of g / m ² was formed. During this hydroentangling, the physically splittable fibers were split and entangled. Then, in the same manner as in Example 1, the copolyester of the removable splittable fiber was decomposed and extracted, and at the same time, the copolyester of the physically splittable fiber was also decomposed and extracted to give an areal density of 52 g /
A m ² non-woven fabric B was formed. This non-woven fabric B had a better texture than the non-woven fabric B of Example 1. It is considered that this is because the non-woven fabric B contains ultrafine fibers B ′ generated from the physically splittable fibers, which are as thin as 0.18 μm in average diameter.

(Example 4) 20% by mass of the physically separable fiber as in Example 1 and 80% by mass of the removable type separable fiber formed as in Example 1 were mixed and formed by a card machine. The fiber web is crossed with a cross layer in the traveling direction of the fiber web to cross the fiber web B.
Was formed. Thereafter, as in Example 1, the crossed fiber web A formed in the same manner as in Example 1 and the above crossed fiber web B were laminated and hydroentangled to form a nonwoven fabric A having an areal density of 120 g / m ^2. did. Then, in the same manner as in Example 1, the copolyester of the removable splittable fiber was decomposed and extracted, and at the same time, a part of the polyester component of the physically splittable fiber was also extracted to give a nonwoven fabric B having an areal density of 68 g / m ² . Was formed. This non-woven fabric B had a better texture than the non-woven fabric B of Example 1. It is considered that this is because the ratio of the ultrafine fibers A in the nonwoven fabric B is high.

(Comparative Example) A unidirectional fiber web formed by a card machine using 100% of removable splittable fibers formed in the same manner as in Example 1 was cross-layered with respect to the traveling direction of the fiber web. Crossed to form a crossed fiber web. Then, hydroentangling treatment was carried out in the same manner as in Example 1 to form a nonwoven fabric A having an areal density of 125 g / m ² . Then
In the same manner as in Example 1, the copolyester of removable splittable fibers was decomposed and extracted to form a nonwoven fabric B having an areal density of 63 g / m ² . This non-woven fabric B had an excellent feel, but had a large surface friction resistance.

(Surface Friction Resistance) The coefficient of friction of the non-woven fabric A and non-woven fabric B of Examples 1 to 4 and Comparative Example on the surface containing the physically separable fiber and the ultrafine fiber B and / or the ultrafine fiber B ′ was measured by Katotec. It was measured by a KES-FB4 surface tester manufactured by Co., Ltd. The results were as shown in Table 1.

[0050]

[Table 1]

(Handle) The handfeel of the nonwoven fabrics B of Examples 1 to 4 and Comparative Example was evaluated by 10 panelists. In this evaluation, the texture of the non-woven fabric B of Comparative Example was set to "5", which was the highest point, and 100% of the physically separable fiber used in Example 1 was used. Panels were evaluated on a scale of 5 on the basis that the texture of a non-woven fabric having a density of 60 g / m ² was “1 point” as the lowest point, and the decimal points of the average value of 10 panelists were rounded off. The results are also shown in Table 1.

[0052]

Industrial Applicability The nonwoven fabric of the present invention comprises a entanglement layer mainly composed of removable splittable fibers capable of generating ultrafine fibers A having an average fiber diameter of 1 μm or less, and a physical splittable fiber capable of producing ultrafine fibers B. And an entanglement layer containing ultrafine fibers B generated from the physically splittable fibers on at least one surface. Therefore, if one or more kinds of resin components of the removable splittable fibers of this nonwoven fabric are removed to generate the ultrafine fibers A, an entangled layer mainly composed of the ultrafine fiber A bundles generated from the removable splittable fibers is formed. It is possible to form a non-woven fabric having a entanglement layer containing, on at least one surface thereof, a physically disintegrating fiber and an ultrafine fiber B generated from the physically disintegrating fiber and / or an ultrafine fiber B ′ having a fiber diameter of more than 1 μm. Since this non-woven fabric contains the ultra-fine fibers A and the ultra-fine fibers B and / or the ultra-fine fibers B ′, it has an excellent feeling, and at least one surface of the non-woven fabric has the ultra-fine fibers B and / or the ultra-fine fibers B. 'Since it consists of entangled layers, at least one side of the non-woven fabric has low surface friction resistance.

The method for producing a non-woven fabric according to the present invention includes at least two fiber webs, a fibrous web mainly composed of removable splittable fibers and a fiber web containing physically splittable fibers, and the physically splittable fibers. After the fibrous webs are laminated so as to form at least one surface and a fluid flow is actuated, the physically splittable fibers are split to generate ultrafine fibers B and are entangled, and then the removable splittable fibers are formed. Since it is a method of removing one or more kinds of resin components to generate the ultrafine fibers A, a nonwoven fabric having excellent feel and low surface friction resistance can be easily and stably manufactured.

[Brief description of drawings]

FIG. 1 shows an example of a cross-sectional shape of a removable or physically splittable fiber of the present invention.

FIG. 2 shows another example of the cross-sectional shape of the removable or physically splittable fiber of the present invention.

FIG. 3 (a) Another example of the cross-sectional shape of the removable or physically splittable fiber of the present invention (b) Another example of the cross-sectional shape of the removable or physically splittable fiber of the present invention

[Explanation of symbols] X resin component Y resin component

Claims (7)

[Claims] 1. An entanglement mainly composed of splittable fibers (hereinafter referred to as "removable splittable fibers") capable of generating ultrafine fibers A having an average fiber diameter of 1 μm or less by removing one or more kinds of resin components. A layer, splittable fibers capable of generating ultrafine fibers B by physical action (hereinafter referred to as "physical splittable fibers"), and ultrafine fibers B generated from the physically splittable fibers A nonwoven fabric having an entangled layer on at least one surface. 2. As a resin component constituting the ultrafine fiber B,
When the removal rate of the resin component of the removable splittable fiber is 1, it can be removed at a removal rate of 0.2 to 0.7 depending on the remover used for removing the resin component of the removable splittable fiber. The non-woven fabric according to claim 1, wherein the non-woven fabric contains a non-woven fabric. 3. The ultrafine fibers B are composed of two or more kinds of resin components, and one or more kinds of resin components are removed to obtain a fiber diameter of 1 μm.
The non-woven fabric according to claim 1, which is capable of generating ultrafine fibers B'exceeding the above. 4. An entanglement layer mainly composed of a bundle of ultrafine fibers A generated from removable splittable fibers, a physically splittable fiber, and an ultrafine fiber B and / or an ultrafine fiber B generated from the physically splittable fiber. 'A non-woven fabric having an entangled layer containing a bundle on at least one surface. 5. A fiber web mainly composed of removable splittable fibers and a fiber web containing physically splittable fibers, at least two fiber webs, and a fiber web containing physically splittable fibers has at least one surface thereof. One or more resin components of the removable splittable fiber after the physical splittable fiber is split to generate ultrafine fibers B and entangled by stacking so as to form a fluid flow To produce ultrafine fibers A, and a method for producing a non-woven fabric. 6. When the removal rate of the resin component of the removable splittable fiber is 1, the amount of the remover used for removing the resin component of the removable splittable fiber is 0.2 to 0.7. When physically splittable fibers capable of generating ultrafine fibers B containing a resin component that can be removed at a removal rate are used, and one or more resin components of the removable splittable fibers are removed to generate ultrafine fibers A. At the same time, a part of the resin component of the ultrafine fibers B is also removed, and the method for producing a non-woven fabric according to claim 5. 7. A physically disintegrating fiber which is composed of two or more kinds of resin components and is capable of generating ultrafine fibers B capable of generating ultrafine fibers B ′ having a fiber diameter of more than 1 μm by removing one or more resin components. Is used to remove one or more kinds of resin components of the removable splittable fiber to generate the ultrafine fiber A, and at the same time,
Alternatively, the method for producing a non-woven fabric according to claim 5, wherein the ultrafine fibers B ′ are generated after the ultrafine fibers A are generated.