DE4236667A1 - COMPOSITE FABRIC - Google Patents

Description

The present invention relates to a nonwoven fabric (Non-woven) with excellent air permeability and Water resistance, which is used for surgical clothing, diapers, Filters or the like can be used.

To do justice to the increased use of nonwovens be, it is necessary that these nonwovens ver have different properties. To meet these requirements Excellent air permeability and water count resistance. The main thing is air permeability a property contrary to water resistance. It it is necessary that there are many through holes, which is from the front surface of a nonwoven fabric extend to the rear surface thereof in which Nonwovens are available to allow air to pass through improved, but can be improved air permeability a reduction in what Do not prevent water resistance.

Is the nonwoven used medically, such as as Surgical clothing, become more distinctive  required as a bacterial barrier, d. that is Greater water resistance is required to the wearer to protect against infections. Furthermore, it is necessary agile that blood or the like does not affect the nonwoven fabric penetrates when one by kinking or squeezing caused deformation of the robe occurs. However, superior air permeability is required so that perspiration is minimized and moisture does not accumulate.

It was a composite of different tissues proposed to contradict these two Properties - air permeability and water resistant speed - enough.

For example, the Japanese Unexamined Patent discloses Publication (Kokai) No. 64-61555 a method for Production of a composite layer by a dispersion liquid, the two types of staple fibers with under contains various delicacies on a knitted fabric weave with potential shrinkage to paper is processed and the staple fibers flow in one the water jet under itself and with the knitted Woven fabrics. This composite layer shows rapid air permeability, but is their water resistance poor. The Japanese unchecked Patent Publication (Kokai) No. 1-111056 a composite nonwoven fabric comprising a nonwoven fabric which is composed of a pulp and a stack fiber and a filament nonwoven. Although in the Publication indicated that this composite nonwoven can be used for surgical clothing, however its water resistance does not seem noticeable ver to have been improved.  

The nonwoven fabric described above is likely Allow liquid to leak if he kinked or squeezed.

The aim of the present invention is to provide a nonwoven fabric to make available with which there is sufficient air permeability and water resistance, little liquid escapes when exposed to kinking or collapse pressure or the like caused deformation can be achieved, and the excellent strength and Has elasticity.

The object of the present invention can be achieved with the aid of a composite nonwoven, comprising a Staple fiber nonwoven fabric (A) with the following structure features (1) to (3) and a filament nonwoven (B), which is formed in such a way that filaments partially are tied together, being part of the stack fibers that build up the staple nonwoven fabric (A) in inserted the filament nonwoven (B) and with the fila elements that build up the filament nonwoven (B), ver are braided so that a layered body made of Sta fleece (A) and filament (B) is produced and the number N of staple fibers that a are added to a depth of one to two or more times the thickness of the filament nonwoven (B) in one Area with a length of 500 µm in an optional Cross-section of the composite nonwoven fabric, 20 or less;

• 1) F + G 50% by weight,
• 1/7 F / G 4/3

wherein
F is the ratio of the staple fibers of 0.333 dtex (0.3 denier) or less to all staple fibers;
G is the ratio of the staple fibers with a fineness of 0.556 dtex (0.5 denier) or more to all staple fibers;

• 2) basis weight of the staple fibers: 10 g / m ² to 40 g / m ² ;
• 3) Average degree of orientation (Z): 2.0 to 10.

Fig. 1 is an electron micrograph of a cross section of an example of a composite nonwoven fabric of the present invention;

Fig. 2 is a schematic cross-sectional view of the composite nonwoven fabric shown in Fig. 1;

Fig. 3 is a schematic cross-sectional view of a conventional composite nonwoven fabric;

Fig. 4 is the same schematic cross-sectional view of the composite nonwoven shown in Fig. 2, except that the standard lines X ₀ and Y _{0 have been} added;

Fig. 5 is a view defining a linear component to be used for determining the average degree of orientation (Z) of the fibers;

Fig. 6 is a graph illustrating the relationship between the average degree of orientation of the staple fibers and the water resistance of the nonwoven fabric.

The present invention is summarized below hang described with the accompanying drawings an example of a composite nonwoven according to the invention demonstrate.  

Fig. 1 is an electron micrograph of a cross-sectional view of an example of a composite nonwoven fabric according to the present invention, and Fig. 2 shows a corresponding schematic cross-sectional view of the composite nonwoven fabric shown in Fig. 1. Fig. 3 shows a schematic cross-sectional view of a conventional and typical composite fabric. As shown in FIGS. 1 and 2, a composite nonwoven fabric includes a staple fiber nonwoven fabric A comprising staple fibers 11 having a fineness of 0.333 dtex (0.3 d) or less and staple fibers 12 having a fineness of 0.556 dtex (0.5 d) or more and a filament nonwoven B. A plurality of staple fibers in the staple nonwoven A is arranged in a relatively parallel plane of a surface of the composite nonwoven, and the staple fibers in the stack nonwoven A and the filaments in the filament nonwoven B are only at the interface between the two ver interlaced, and furthermore the staple fibers in the non-woven fabric A are not inserted deep into the non-woven fabric B. In the example shown in Fig. 3 conventional composite nonwoven fabric, the staple fibers 21, which build up a staple fiber nonwoven fabric C are inserted through a column-like flow of fluid under high pressure deep in the filament nonwoven fabric D, and thus the STA pelfasern 21 to a high degree with the filaments 22 ver braided to form a nonwoven filament. Thus, although the composite nonwoven fabric shown in FIG. 3 is formed by the nonwoven fabrics, the composite nonwoven fabric obtained has an appearance similar to that of a single nonwoven fabric formed by blending the staple fibers 21 with the filaments 22 .

A first feature of the composite nonwoven fabric according to the invention is that the sum of the ratio F of the staple fibers with a fineness of 0.333 dtex (0.3 denier) or less and the ratio G of the staple fibers with a fineness of 0.556 dtex (0.5 denier) or less than 50% by weight or more in the staple nonwoven fabric A, the ratio F / G is one to seven or more and four to three or less, and the basis weight of the staple nonwoven fabric A is 10 g / m ² to 40 g / m ² is. The fineness of the staple fiber 11 is 0.333 dtex (0.3 denier) or less, preferably 0.167 dtex (0.15 denier) or less and 0.0011 dtex (0.001 d) or more. The staple fibers 11 do not all need to have the same fineness, and the staple fiber 11 can be produced by cutting a fiber, for example removing a sea composition from a sea island fiber, separating or splitting off a composite fiber with two or more components or an extra fine fiber obtained by a direct spinning method or the like. The fineness of the staple fiber 12 is 0.556 dtex (0.5 denier) or more, preferably 0.833 dtex (0.75 denier) or more and 11.11 dtex (10 denier) or less. The staple fibers 12 do not all need to have the same fineness, and it is preferred that the fiber length of the staple fibers 11 and the staple fibers 12 is greater than the thickness of the composite nonwoven fabric, but the staple fibers 11 and the staple fibers 12 need not be the same fiber length.

The staple fiber 11 contributes to improving the water resistance of the composite nonwoven, but the air permeability is reduced with increasing content of staple fiber 11 in all staple fibers of the staple fiber nonwoven A. The staple fibers 12 have a function reversed to the staple fibers 11 . Accordingly, when F / G is one to seven or more and four to three or less, the staple fibers 11 and 12 have excellent balance, and the composite nonwoven fabric thus achieves excellent air permeability without reducing water resistance. However, it is necessary that the sum of F and G is 50% by weight or more, and if the sum of F and G is less than 50% by weight, it is difficult to obtain an excellent effect. It is preferred that the sum of F and G is 70% by weight or more.

It is necessary that the basis weight be 10 g / m ² or more and up to 40 g / m ² or less. If the weight per unit area is above 40 g / m ² , the air permeability of the composite nonwoven is reduced, and if the weight per unit area is less than 10 g / m ² , the water resistance of the composite nonwoven is reduced.

It is preferred that the apparent density of the staple nonwoven fabric A be 0.1 g / m ² so that the water resistance of the composite nonwoven fabric improves. A method for measuring the apparent density of the nonwoven fabric is described below.

A second feature of the composite nonwoven is that average degree of orientation Z of the staple fibers in the stack nonwoven fabric A 2.0 or higher and 10 or lower is. The mean degree of orientation Z is a value that the ratio indicates between a component in parallel to the surface of the filament nonwoven B and a com component perpendicular to the surface of the filament fleece fabric B in the staple fiber of the staple fiber fleece substance A. A method of generating the average degree of orientation is described below.

The inventors of the present invention found that liquid leakage caused by deformation caused by the application of bending and compression forces to the composite nonwoven depends on the value of the average orientation degree Z. Fig. 6 is a graph showing the relationship between the average degree of orientation of the staple fiber and the water resistance of the nonwoven fabric. As can be seen from the graph of Fig. 6, it is striking that there is a clear linear correlation between the average degree of orientation Z of the staple fiber and the water resistance of the nonwoven fabric with the same composition and the same basis weight, even if bending or compression forces on the Act on composite nonwoven; Liquid leakage can be effectively prevented and this leads to a composite nonwoven with excellent water resistance. If the average degree of orientation Z is greater than 10, the entanglement between the staple fiber that builds the staple fiber nonwoven fabric A and the entanglement between the staple fiber nonwoven fabric A and the filament nonwoven fabric B is reduced, which leads to a composite nonwoven fabric of low strength.

Hence, it is necessary the average orien Degree of orientation to a range from 2.0 to 10, preferably such as 2.3 to 10, more preferably 2.5 to 8.0 lay.

A third characteristic of the composite fleece according to the invention is that the number N of staple fibers, the are inserted to a depth of one to two or Multiple times the thickness of the nonwoven filament (B) in an area with a length of 500 µm in one choice have cross-section of the composite nonwoven, 20 or weni is. One method of determining the number N is described below, and the number N is greater than 20, the water resistance of the Composite nonwoven.  

As described above, the goal of the achieve lying invention by joining the Staple fiber nonwoven A with a special structure and the Filament nonwoven B.

A nonwoven fabric can be used as the filament nonwoven fabric B. be herge using a fleece spinning method was put. The filaments that make up the filament fleece build up fabric B, are by heat melting or under Partially tied together using an adhesive to fix its structure. Because the intertwining the bonded areas in the filament nonwoven B with the Staple fibers in staple fiber nonwoven A is impossible it is preferred that the area ratio of total area of the bound areas to the total surface of the Filament nonwoven B is between 2% and 20% and a 0.556 dtex (0.5 denier) filament is preferably used; and is in two rich Average measured at right angles Elongation at break 40% or less, so the staple fiber when interweaving the two nonwovens easily the above Accept order.

For the composite nonwoven fabric according to the invention, any some kind of fiber can be used. For example a thermoplastic fiber can be used such as a fiber from the group of polyamides, a fiber from the group of polyesters, a fiber from the group of Polyolefins, a fiber from the group of polyacrylics nitrile or the like, a fiber from the group of Acetate, a fiber from the regenerated group Celluloses or the like. Furthermore, if necessary, a natural cellulose fiber, a wool fiber or the like are used, and if the Fiber from the group of regenerated celluloses for  the staple fiber nonwoven A is used, Spu ren of a stream used for the intertwining process water jet and through the flowing water openings are easily removed, and so it is possible to decrease the water resistance prevention.

Becomes a polyester fiber for the staple fiber fleece If fabric A is used, the interlacing is strengthened between filament nonwoven B and staple fiber nonwoven fabric A. Accordingly, special characteristics can be achieved are made as a result of using a fiber from the Group of regenerated celluloses and a fiber the group of polyesters if the fiber is from the group the polyester with a ratio of one to three or more and one or less for the fiber from the group of the regenerated celluloses with a ratio of one is used.

It is also preferred that a fibrillated pulp-like Liche fiber with between 5 and 15 wt .-% on all sta pile fibers in the staple fiber nonwoven A next to a pile 0.333 dtex (0.3 denier) fiber or less and a staple fiber with a fineness of 0.556 dtex (0.5 denier) or more is used to the composite nonwoven with slightly improved water resistance and tensile strength without reducing the To maintain air permeability. The fibrillated pulp Similar fiber can be obtained by heating one natural pulp or a cleavable acrylic fiber.

A process for making the composite nonwoven according to the present invention will be described below ben.  

A 0.333 dtex (0.333 dtex) or less staple fiber ger and a 0.556 dtex (0.5 denier) staple fiber or more with a predetermined mixing ratio dispersed in water, and by paper processing the Dispersion liquid becomes a staple fiber nonwoven A receive. In this case the Disper is preferred sion liquid a surfactant put to ver the dispersion of the fibers in the water improve. Next, one is made using a fleece Filament nonwoven fabric B produced by the spinning process the staple fiber nonwoven A layered. The story The body can also be made by the Staple fiber nonwoven A directly building up staple fibers paper processed on the filament nonwoven B.

The layered body is joined by a columnar stream. For this purpose, a wire mesh with 0.297 mm (50 mesh) to 0.074 mm (200 mesh) is placed between the layered body, which is fastened on a wire mesh conveyor, and a nozzle, and the nozzle rotating at 50 to 1000 rpm becomes one Water jet at 29.42 mPa (30 kg / cm ² ) or less was sprayed through the wire mesh at 0.297 mm (50 mesh) to 0.074 mm (200 mesh) onto the layered body. In general, a nozzle with a large number of holes with diameters between 0.05 mm and 0.3 mm can be used. The average degree of orientation of the staple fiber in the staple fiber nonwoven A can be adjusted in the desired range described above by inserting the wire mesh between the nozzle and conveyor, suitable rotation of the nozzle and regulation of the pressure of the nozzle; a composite nonwoven fabric with excellent air permeability and water resistance can be achieved.

The composite nonwoven is also preferably used treated a water repellent to Ver obtain nonwoven with good water resistance ten. As a known water-repellent agent for Example of a water repellent from the group of Silicones such as dimethylamino silicone or the like or a water repellent from the fluorine group such as perfluoroacrylate or the like is used and the total solids content of water-repellent the average is preferably around 0.1 to 5% of the composite nonwoven weight.

The methods for measuring the valuation of an invented own composite nonwoven used are described below.

Method for determining the average degree of orientation of staple fibers in a staple fiber nonwoven A

• 1. A test piece with a size of 20 cm square is cut from the composite nonwoven.
• 2. The test piece is placed every 5 cm lengthways and Cut crosswise so that 16 sections with a size of 5 cm square can be obtained.
• 3. Three sections are arbitrarily from the 16 Ab cut selected.
• 4. From a cross section of a selected section is using an electron micrograph made a magnification of 100. Now be micrographs of locations made no partially binding areas in the filament nonwoven fabric B on two adjacent sides of one  have each section so that six mikrosko tical recordings are made.
• 5. As shown in Fig. 4, the number of ends of filaments constituting the filament nonwoven fabric B is counted in each electron micrograph from a position outside and away from the surface of the filament nonwoven fabric B toward the inside thereof; a straight line X ₀ is drawn from the cross-sectional center of the fourth end to the cross-sectional center of the fifth end, which is at a position that is at least 300 microns from the fourth end. This line X ₀ denotes a standard line of this composite nonwoven. A further standard line Y _{0 is} drawn in a direction perpendicular to the standard line X ₀ .
• 6. Two vertical lines Y ₁ , Y _{2 are} drawn parallel to the standard line Y ₀ at a distance of 5 cm in the middle part of each electron microscopic image.
• 7. A staple fiber with a fineness of 0.333 dtex (0.3 denier) or less and a staple fiber with a fineness of 0.556 dtex (0.5 denier) or more, the length of which in the longitudinal direction is 10 times the maximum diameter of the fiber, is selected between the vertical lines Y ₁ and Y ₂ .
• 8. As shown in Fig. 5, P ₁ denotes an arbitrary point of the center line L of the staple fiber, the point P ₂ is selected from the center line L and a straight line P ₁ P ₂ which the point P ₁ with the point P ₂ connects. Now the point P _{2 is} determined in such a way that when the straight line P ₁ ′ P ₂ ′ tangential to the center line L is drawn, the distance d between the straight line P ₁ P ₂ and the tangent straight line P ₁ ′ P ₂ ′ is smaller than the diameter r of the fiber and the distance between point P ₁ and point P _{2 is} more than 4 times the diameter r.
• 9. The other points P ₃ , P ₄ . . . P _n are determined by the same procedure and the staple fiber is divided into a plurality of straight lines. The procedure for determining points P ₁ , P ₂ . . . P _n is now applied to all staple fibers selected in step 7 above.
• 10. The components X _n in the direction parallel to the standard line X ₀ and the components Y _n in the direction parallel to the standard line Y ₀ are obtained by applying a scalar analysis to the separate straight lines of each staple fiber, and from the sum of the values of X _n and Y _n is calculated X and Y.
• 11. The X / Y ratio is calculated, and the mean Degree of orientation Z is determined as the mean of X / Y obtained from six electron microscopes recordings.

Method for determining the number (N) of staple fibers, which are introduced into the filament nonwoven B.

• 1. There are the same three sections of the composite non-woven fabric and the same six electron micro made scopic recordings like those for the  Method of determining the average orientation grads Z were used.
• 2. Three filament nonwovens B are produced by peeling the filament nonwoven B from the respective three sections. The thickness of the nonwoven filament B is measured at four points which are determined so that the distance between each point is at least 2 cm or greater under a pressure of 0.981 µPa (1 g / cm ² ) by using a method for measuring the compression properties with a KES-FB testing system using a compression tester (KES-FB-M3, KES-FB-E3), available from KATO TECH Co., Ltd., and the thickness TB of the filament nonwoven fabric B is determined as the average of the 12 obtained Thickness values.
• 3. A straight line 1/2 TB is drawn parallel to the standard line X ₀ at a distance of half the value for TB obtained in step 2 in the six electron microscopic images.
• 4. The number of staple fibers crossing the straight line 1/2 TB is counted between the vertical lines Y ₁ and Y ₂ at a distance of 500 µm, and the number N is determined as the average of the numbers obtained in the six electron micrographs.

Method for measuring the density of a staple fiber fleece substance A

• 1. The same six electron microscopes are used recordings made for the metho  de determining the mean orientation grads Z were used.
• 2. The standard lines X ₁ and X ₂ are drawn along the upper surface and the lower surface of the nonwoven fabric stack A by using the same method that was used to draw the standard line X ₀ in the method for determining the average degree of orientation. The portions of the vertical lines Y ₁ and Y ₂ obtained by cutting the standard lines X ₁ and X ₂ are measured for the six electron microscopic images, and the thickness T (µm) of the stack of nonwoven fabric A is determined as the average value of the in the six thicknesses obtained by electron microscopy.
• 3. The basis weight W (g / m ² ) of the staple fiber nonwoven fabric A is obtained by determining the basis weight of the composite nonwoven fabric in accordance with JIS-L-1 096 and subtracting the value for the basis weight of the filament nonwoven fabric B obtained when the number N was determined of the staple fiber nonwoven A, on the basis weight of the composite nonwoven.
• 4. The density of the staple fiber nonwoven fabric A is obtained after W / T (g / cm ³ ).

Bending hardness

The bending hardness of the composite nonwoven is determined according to a method for measuring the bending properties with the KES-FB testing system. The measurement is taken five times Longitudinal direction, corresponding to a direction,  along the the staple nonwoven fabric A and the Fila ment nonwoven B are interwoven, as well as in the transverse direction the composite nonwoven on a test piece with the help of a pure bending tester, available from KATO TECH Co., Ltd., and the bending hardness of the composite nonwoven is determined as the mean of the obtained Values.

Air permeability

The air permeability of the composite nonwoven is agrees in a kind of brittleness test according to JIS-L-1096 and expressed as the average of five measurements.

Tensile strength

The tensile strength of the composite nonwoven is determined according to JIS-L-1096. This is a test sample with a width of 3 cm and with a distance made between two brackets of 10 cm, and the tensile strength is measured using a tensi lon UTM-1, available from TOYO BALDWIN Co., Ltd., and expressed as the mean (N / cm (kg / cm)) of five Measurements.

Elongation at break

The elongation at break of the composite nonwoven is determined using the same procedure used to determine tensile strength was applied and expressed as the average of five measurements.  

Resistance to hydrostatic pressure

Water resistance is determined using a lower hydrostatic pressure method applied to a sample having a hydrostatic pressure resistance of 9.81 kPa (1000 mmH ₂ O) or less, according to JIS-L-1092, and expressed as an average ( kPa (mmH ₂ O)) from five measurements.

Mason can test (screw cap)

The time (min) from the time at which a water column pressure of 1.118 kPa (114 mmH ₂ O) of a physiological salt solution acts on a test piece of the composite nonwoven until the time at which the liquid begins to run out is according to IST80, 7-70, MASON can method, and the result is expressed as the average of three measurements. A composite nonwoven with a value of 60 min or more is acceptable in the Mason can test.

Leakage resistance when subjected to deformation Pressure or buckling

A 10 cm square test piece is cut out of the composite nonwoven. Two more 10 cm square plates are made with a 6 cm hole in the middle and the test piece is placed between these two plates. 10 cm ^{3 of} a colored physiological saline solution are dropped from a dropper onto the central region of the hole in the upper plate. The test piece with the two plates is fixed on a cylinder made of acrylic resin with an inner diameter of 90 mm and an outer diameter of 100 mm, and the cylinder is placed on a Tensilon OTM-1, available from TOYO BALDWIN Co., Ltd., so that the middle part of the test piece is butted with a butt length of 20 mm with a reciprocating rod having a surface with a curvature of 5 cm. The impact frequency of the rod is counted when the colored physiological salt solution spreads out on the underside of the test piece, which can be seen through the acrylic cylinder. The liquid leakage resistance is rated as the average of five measurements.

The present invention is based on Embodiments of the composite according to the invention described in detail.

All of the composite nonwovens described below Examples are then water-repellent treated the agent, and the properties of the composite nonwovens are measured.

Water repellent

Asahi Guard Series AG-433, too obtained from MEISEI KAGAKU Co., Ltd.

treatment

The composite nonwoven is placed in an aqueous Immersed solution, the 5% water repellent contains, dried at 100 ° C for 2 min and for 1 min heat-treated at 160 ° C.

The layered bodies in the examples become one Compound process with a flowing water jet subjected. The main conditions of water jet treatment lung are as follows:

Diameter of the openings of the injection nozzles for the Water jet: 0.2 mm.  

Distance between nozzle and composite nonwoven: 30 mm.

That in a middle position between nozzle and Ver Wire mesh arranged in a nonwoven fabric has a mesh width of 0.210 mm (70 mesh).

Nozzle rotation conditions:

Rotation radius: 6 mm.

Rotation speed: 200 rpm.

example 1

A predetermined amount of polyethylene terephthalate staple fiber with a 0.111 dtex (0.1 denier) and 5 mm length and a viscose silk staple with a 1.11 dtex (1 denier) length of 5 mm and in an amount similar to the polyethylene terephthalate staple fiber is dispersed in water and stirred to form a slurry with a concentration of 0.63%. A staple nonwoven fabric A having a basis weight of 25 g / m ² is obtained by paper processing the slurry in a paper making machine in the manner of an inclined wire mesh.

A filament nonwoven fabric B is made by melt spinning a polyethylene terephthalate polymer, drawing the molten polymer extruded from a spinneret using an air suction device to give a uniform filament web, and heating and pressing the web using a pair of upper embossing rollers with a plurality of convex Areas on their surface and a lower roller with a smooth surface. The fineness of the filaments of this filament nonwoven fabric B is 2.22 dtex (2 denier), and the filament nonwoven fabric B obtained has a weight per unit area of 25 g / m ² and an average elongation at break of 22.5%. The filament nonwoven fabric B is layered on the staple nonwoven fabric A and then subjected to a treatment with a flowing water jet on the top of the filament nonwoven fabric B and on the underside of the staple fiber nonwoven fabric A to give a composite nonwoven fabric according to the invention. The water jet treatment is applied in three stages, if necessary by changing the pressure of the water jet. The pressure of the water jet is 1471 kPa (15 kg / cm ² ) in the first stage, 1471 kPa (15 kg / cm ² ) in the second stage and 2942 kPa (30 kg / cm ² ) in the third stage. In the case of the filament nonwoven B, the area ratio of the bonded areas produced by the embossing treatment is 10% of the total area of the filament nonwoven B.

Embodiments 2 to 4

In these exemplary embodiments 2 to 4, a staple fiber nonwoven fabric A is layered directly onto the same filament nonwoven fabric B used in example 1 using a paper processing method. Thereby, a polyethylene terephthalate staple fiber with a fineness of 0.111 dtex (0.1 denier) and a length of 5 mm and a viscose silk staple fiber with a fineness of 0.111 dtex (0.1 denier) and a length of 5 mm with the following three composition ratios dispersed in water and stirred to form a slurry with a concentration of 0.63%. The staple fiber nonwoven fabric A with a weight per unit area of 25 g / m ² is applied directly to the filament nonwoven fabric B by paper processing to give a layered body.

Composition of the staple fibers in the nonwoven fabric A

The layered body is subjected to the flowing water jet treatment using the same method as in Example 1 on the top and bottom thereof to give the composite nonwoven fabrics of Examples 2 to 4. Three water jet treatments with pressures of 1471 kPa (15 kg / cm ² ) in the first stage, 1471 kPa (15 kg / cm ² ) in the second stage and 2942 kPa (30 kg / cm ² ) in the third stage are carried out in succession made on both sides of the layered body.

Example 5

Five parts by weight of a polyethylene terephthalate stack 0.111 dtex (0.1 denier) and a length of 5 mm, 7 parts by weight of a viscose silk staple fiber with a fineness of 1.11 dtex (1 denier) and a length of 5 mm and 8 parts by weight a polyethylene terephthalate staple fiber with a Fineness of 0.444 dtex (0.4 denier) and a length of 5 mm are dispersed in water and stirred to give a Slurry with a concentration of 0.63% bil the. Using the in Examples 2 to 4 method is used from the slurry of Ver Bund nonwoven fabric produced in Example 5.  

Example 6

A staple fiber nonwoven fabric A having a basis weight of 15 g / m ² is obtained by paper processing a slurry with a concentration of 0.38%, which is produced by mixing 1 part by weight of an extra-fine polyester staple fiber with a fineness of 1.11 dtex (1 Denier) and a length of 5 mm and 3 parts by weight of a viscose silk staple fiber with a fineness of 1.11 dtex (1 denier) and a length of 5 mm in water and stirring. The staple fiber nonwoven fabric A obtained is layered on the same filament nonwoven fabric used in Example 1.

The layered body is subjected to the treatment with the flowing water jet in three stages on its top and bottom to give the composite nonwoven fabric of Example 6. Three water jet treatments with pressures of 981 kPa (10 kg / cm ² ) in the first stage, 981 kPa (10 kg / cm ² ) in the second stage and 1961 kPa (20 kg / cm ² ) in the third stage made on both sides of the layered body.

Example 7

A staple nonwoven fabric A having a basis weight of 40 g / m ² is obtained by paper processing the same slurry as used in Example 6 except that the concentration is changed to 1% and the staple nonwoven fabric A is made on the same filament nonwoven fabric used in Example 1 B is layered.

The layered body is subjected to the treatment with the flowing water jet in three stages on its top and bottom to give the composite nonwoven fabric of Example 7. Three water jet treatments with pressures of 1471 kPa (15 kg / cm ² ) in the first stage, 1961 kPa (20 kg / cm ² ) in the second stage and 2942 kPa (30 kg / cm ² ) in the third stage made on both sides of the layered body.

Examples 8-10

The composite nonwovens of Examples 8 to 10 are made using the same method as in Example 3, except that the following, using a Spunbonded Filament Nonwovens B be used.

Filament nonwoven fabric B in Example 8

Spunbonded polypropylene nonwoven fabric composed of filaments with a fineness of 3.33 dtex (3 denier), a basis weight of 25 g / m ² and an average elongation at break of 30%, obtained by melt spinning a polypropylene polymer into a web and embossing the web with heating using the same method as in Example 1.

Filament nonwoven fabric B in Example 9

Spunbond nylon 6 nonwoven fabric composed of filaments with a fineness of 2.22 dtex (2 denier), a basis weight of 25 g / m ² and an average elongation at break of 30%, obtained by melt spinning a nylon 6 polymer into one Web and embossing the web with heating using the same method as in Example 1.

Filament nonwoven fabric B in Example 10

Polyethylene terephthalate nonwoven fabric composed of filaments having a fineness of 2.22 dtex (2 denier), a basis weight of 30 g / m ² and an average elongation at break of 25%, obtained by using the same method as in Example 1.

Example 11

A part by weight of a polyethylene terephthalate stack 0.111 dtex (0.1 denier) and a length of 5 mm, 1 part by weight of a viscose silk sta pel fiber with a fineness of 1.11 dtex (1 denier) and a length of 5 mm and 2 parts by weight of a poly ethylene terephthalate staple fiber with a fineness of 1.11 dtex (1 denier) and a length of 5 mm are in Water dispersed and stirred to form a slurry with a concentration of 0.63%. Under An using the metho used in Examples 2 to 4 de becomes the composite nonwoven from Example 11 prepared.

Example 12

Two parts by weight of a polyethylene terephthalate stack 0.111 dtex (0.1 denier) and a length of 5 mm, 7 parts by weight of a viscose silk staple fiber with a fineness of 1.11 dtex (1 denier) and a length of 5 mm and 1 part by weight a fibrillated acrylic pulp obtained by application The following method are dispersed in water and stirred to form a slurry with a concentrate tion of 0.63%. Using the in the Examples 2 to 4 applied method is the composite Nonwoven fabric made from Example 12.  

The fibrillated acrylic pulp of Example 12 is included Made using the following method.

A polymer comprising 95.0% by weight acrylonitrile, 4.5% by weight of methyl acrylate and 0.5% by weight of meth allylsulfonic acid / soda, and a polyethylene oxide / poly propylene oxide / polyethylene oxide block copolymer with a Number average molecular weight of 10,000 and one Weight ratio of polyethylene oxide to polypropylene oxide from 70 to 30 are dissolved in dimethylformamide in order to to give a spinning solution containing 23% by weight of the acrylic polymer and contains 2.3% by weight of the block copolymer. This spinning solution is kept stationary for 6 hours and then to form an undrawn fiber by one Extruded spinneret into a precipitation bath at 35 ° C, which the dimethylformamide in a concentration of 75% ent holds. The undrawn fiber is washed, one Stretching operation with a 12-fold stretch ratio subjected and then in hot air at a temperature dried from 80 ° C to a fiber with a fineness of 1.67 dtex (1.5 denier). The received Fibers are cut into 5 mm pieces and 10 Parts by weight of the cut fibers are in 90 Ge most of the water dispersed. This fiber dispersion Solution is a disc refiner with a disc distance of 0.1 mm and knocked until the degree of filtration becomes zero. The knocked acrylic pulp has a number of fine beard-like fibrils which are obtained by separating them from the fiber around the surface of the part that the Shaft corresponds to the original fiber. Furthermore the shaft of the fiber is also partly in its longitudinal direction direction separately to give a fine fiber.  

As a result of measuring the properties of the Composite nonwoven fabric from Example 12 shows that Water resistance and tensile strength of the composite fleece fabric by using the fibrillated acrylic pulp can be easily improved without the air passage liquidity. Furthermore, when viewing one electron micrograph of the composite fleece Substance from Example 12 clearly shows that the middle orien Degree of zation of the staple fibers with a fineness of 0.333 dtex (0.3 denier) or less and that of the stacks fibers with a fineness of 0.556 dtex (0.5 denier) or more is kept at a high level and the fibers of the fibrillated acrylic pulp with the Staple fiber nonwoven fabric A and filament nonwoven fabric B are intertwined.

Example 13

57% by weight of a polyethylene terephthalate staple fiber with a fineness of 0.111 dtex (0.1 denier) and a length of 5 mm and 43% by weight of viscose silk staple fiber with a fineness of 1.11 dtex (1 denier) and a length of 5 mm are dispersed in water and stirred to form a slurry with a concentration of 0.63%. A staple nonwoven fabric A having a basis weight of 25 g / m ² is obtained by paper processing the slurry in a paper making machine in the manner of an inclined wire mesh. The same filament nonwoven fabric B used in Example 1 is layered on the staple nonwoven fabric A to give a layered body. The layered body is subjected to the treatment with the flowing water jet on its top and bottom in three stages to give the composite nonwoven fabric of Example 13. Three water jet treatments with pressures of 1471 kPa (15 kg / cm ² ) in the first stage, 1471 kPa (15 kg / cm ² ) in the second stage and 2942 kPa (30 kg / cm ² ) in the third stage made on both sides of the layered body.

Example 14

One part by weight of a polyethylene terephthalate staple fiber with a fineness of 0.28 dtex (0.25 denier) and a length of 5 mm and 3 parts by weight of a viscose silk staple fiber with a fineness of 1.11 dtex (1 denier) and a length of 5 mm are dispersed in water and stirred to form a slurry with a concentration of 0.63%. A staple fiber nonwoven fabric A having a basis weight of 25 g / m ² is obtained by paper processing the slurry in a paper making machine in the manner of an inclined wire mesh. The same filament nonwoven fabric B used in Example 1 is layered on the staple fiber nonwoven fabric A to give a layered body. The layered body is subjected to the treatment with the flowing water jet on its top and bottom three times to give the composite nonwoven fabric of Example 14. Three water jet treatments with pressures of 1471 kPa (15 kg / cm ² ) in the first stage, 1471 kPa (15 kg / cm ² ) in the second stage and 2942 kPa (30 kg / cm ² ) in the third stage are carried out in succession made on both sides of the layered body.

Example 15

One part by weight of a polyethylene terephthalate staple fiber with a fineness of 0.11 dtex (0.1 denier) and a length of 5 mm and 3 parts by weight of a viscose silk staple fiber with a fineness of 0.56 dtex (0.5 denier) and 5 mm in length are dispersed in water and stirred to form a slurry with a concentration of 0.63%. A staple fiber nonwoven fabric A having a basis weight of 25 g / m ² is obtained by paper processing the slurry in a paper making machine in the manner of an inclined wire mesh. The same filament nonwoven fabric B used in Example 1 is layered on the staple nonwoven fabric A to give a layered body. The layered body is subjected to the treatment with the flowing water jet on its top and bottom three times to give the composite nonwoven fabric of Example 15. Three water jet treatments with pressures of 1471 kPa (15 kg / cm ² ) in the first stage, 1471 kPa (15 kg / cm ² ) in the second stage and 2942 kPa (30 kg / cm ² ) in the third stage are carried out in succession made on both sides of the layered body.

Comparative Example 1

A part by weight of a polyethylene terephthalate staple fiber with a fineness of 0.11 dtex (0.1 denier) and a length of 5 mm, 1 part by weight of a viscose silk staple fiber with a fineness of 1.11 dtex (1 denier) and a length of 5 mm are dispersed in water and stirred to form a slurry with a concentration of 1%. A staple nonwoven fabric A having a basis weight of 40 g / m ² is obtained by paper processing the slurry in a paper making machine in the manner of an inclined wire mesh. A spunbond polypropylene nonwoven fabric B comprising filaments having a fineness of 3.33 dtex (3 denier), a basis weight of 30 g / m ² and an average elongation at break of 85% is produced using the same method as in Example 1, and this filament nonwoven B is in a spread state on the staple fiber nonwoven A layered to give a layered body. The layered body is subjected to the treatment with the flowing water jet on its top and bottom in three stages to give the composite nonwoven fabric of Comparative Example 1. Three water jet treatments with pressures of 1961 kPa (20 kg / cm ² ) in the first stage, 3922 kPa (40 kg / cm ² ) in the second stage and 3922 kPa (40 kg / cm ² ) in the third stage are carried out in succession made on both sides of the layered body.

Comparative Example 2

7 parts by weight of a polyethylene terephthalate staple fiber with a fineness of 0.11 dtex (0.1 denier) and a length of 5 mm and 3 parts by weight of a viscose silk staple fiber with a fineness of 1.11 dtex (1 denier) and a length of 5 mm are dispersed in water and stirred to form a slurry with a concentration of 0.63%. A staple fiber nonwoven fabric A having a basis weight of 25 g / m ² is obtained by paper processing the slurry in a paper making machine in the manner of an inclined wire mesh. The same filament nonwoven fabric B as used in Example 1 is spread out on the staple fiber nonwoven fabric A to give a layered body. The layered body is subjected to the treatment with the flowing water jet on its top and bottom in three stages to give the composite nonwoven fabric of Comparative Example 2. Three water jet treatments with pressures of 1471 kPa (15 kg / cm ² ) in the first stage, 1471 kPa (15 kg / cm ² ) in the second stage and 2942 kPa (30 kg / cm ² ) in the third stage are carried out in succession made on both sides of the layered body.

Comparative Example 3

The composite nonwoven fabric of Comparative Example 3 is included Using the same as in Comparative Example 2 applied method prepared, except that the content of poly ethylene terephthalate staple fiber and viscose silk stacks fiber is changed from 7 to 3 to 1 to 9.

Comparative Example 4

2 parts by weight of a pulp obtained by 5 min Tapping ALASKA PULP using a pulper, and 3 parts by weight of a polyethylene terephthalate stack fiber with a fineness of 1.11 dtex (1 denier) and a length of 5 mm are dispersed in water and stirred to a slurry with a concentration of 0.63%. The composite nonwoven from Ver same example 4 is made using the same as in Comparative Example 2 method used, except that the above slurry is used.

Comparative Example 5

1 part by weight of a polyethylene terephthalate staple fiber with a fineness of 0.11 dtex (0.1 denier) and a length of 5 mm and 3 parts by weight of a viscose silk staple fiber with a fineness of 1.11 dtex (1 denier) and a length of 5 mm are dispersed in water and stirred to form a slurry with a concentration of 0.18%. A staple nonwoven fabric A having a basis weight of 7 g / m ² is paper-processed directly from the above slurry on the same filament nonwoven fabric B used in Example 1 to give a layered body.

The layered body is subjected to the treatment with the flowing water jet on its top and bottom in three stages to give the composite nonwoven fabric of Comparative Example 5. Three water jet treatments with pressures of 981 kPa (10 kg / cm ² ) in the first stage, 981 kPa (10 kg / cm ² ) in the second stage and 1961 kPa (20 kg / cm ² ) in the third stage are carried out in succession made on both sides of the layered body.

Comparative Example 6

The same slurry as used in Comparative Example 5 is prepared, except that the concentration of the slurry is changed to 1.5%. A staple fiber nonwoven fabric A with a basis weight of 60 g / m ² is paper-processed directly from the above slurry on the same filament nonwoven fabric B used in Example 1 to give a layered body.

The layered body is subjected to the treatment with the flowing water jet on its top and bottom in three stages to give the composite nonwoven fabric of Comparative Example 6. Three water jet treatments with pressures of 1471 kPa (15 kg / cm ² ) in the first stage, 1471 kPa (15 kg / cm ² ) in the second stage and 2942 kPa (30 kg / cm ² ) in the third stage are carried out in succession made on both sides of the layered body.

Comparative Example 7

The composite nonwoven fabric of Comparative Example 7 is made by the same method as used in Comparative Example 6 except that the pressures of the first, second and third water jet treatments are 1961 kPa (20 kg / cm ² ), 3922 kPa (40 kg / cm ² ) or 3922 kPa (40 kg / cm ² ) can be changed.

Comparative Example 8

A spunbond polypropylene nonwoven fabric B comprising filaments having a fineness of 3.33 dtex (3 denier), a basis weight of 25 g / m ² and an average elongation at break of 55% is produced using the same method as in Example 1.

1 part by weight of a polyethylene terephthalate staple fiber with a fineness of 0.11 dtex (0.1 denier) and a length of 5 mm and 3 parts by weight of a viscose silk staple fiber with a fineness of 1.11 dtex (1 denier) and a length of 5 mm are dispersed in water and stirred to form a slurry with a concentration of 1.5%. A staple fiber nonwoven fabric A with a weight per unit area of 60 g / m ² is paper-processed directly from the above slurry onto the same filament nonwoven fabric B used in Example 1 and then composite-processed under the same conditions as used in Comparative Example 7.

Comparative Example 9

1 part by weight of a polyethylene terephthalate staple fiber with a fineness of 0.11 dtex (0.1 denier) and a length of 5 mm and 3 parts by weight of a viscose silk staple fiber with a fineness of 1.11 dtex (1 denier) and a length of 5 mm are dispersed in water and stirred to form a slurry with a concentration of 0.63%. A staple nonwoven fabric A having a basis weight of 25 g / m ² is paper processed directly from the above slurry onto the above filament nonwoven fabric B to give a layered body.

The layered body is subjected to the treatment with the flowing water jet on its top and bottom in three stages to give the composite nonwoven fabric of Comparative Example 9. Three water jet treatments with pressures of 1471 kPa (15 kg / cm ² ) in the first stage, 1471 kPa (15 kg / cm ² ) in the second stage and 2942 kPa (30 kg / cm ² ) in the third stage are carried out in succession made on both sides of the layered body.

Table 1 shows the construction characteristics of the composite nonwovens Examples 1 to 15 and Comparative Examples 1 to 9, and Table 2 shows properties of the composite nonwoven. As Table 2 shows, the composites have nonwovens of Examples 1 to 15 superior air through casualness, extraordinarily high water resistance and acceptable values, i. H. 60 min or more, in one Mason jug. The properties as rivers are also superior liquid barrier and bacterial barrier. Since the further Resistance to bending or com leakage of liquid caused by pressure forces is excellent, the composite nonwoven has the superior ability to prevent permeation of blood which is caused, for example, by the pressure exerted by an operator on Exercises operating table, is caused, and the Composite nonwoven collects due to its superior Air permeability no moisture, and also The strength and elasticity of the composite nonwoven are excellent.

The above characteristics of the composite nonwoven according to the invention can be made clear by using the Properties of the composite nonwovens of the comparison matches 1 to 9 compares. For example, the values high for N, but the values are for the middle orien Degree of tation in Comparative Examples 1, 4, 5, 7, 8 and 9 small. The proportion of staple fibers with a fine 0.333 dtex (0.3 denier) or less in the stack Nonwoven fabric A is high in Comparative Example 2 and low in comparative example 3; therefore shows first poor air permeability and the latter poor te water resistance. Furthermore, since the basis weight of the Staple fiber nonwoven A in the composite nonwoven from Ver same example 6 is excessively high, the air flow casualness bad, and the interconnection between  Staple fiber nonwoven A and filament nonwoven B is in this composite nonwoven is insufficient.

The apparent density of the staple nonwoven fabric A in Examples 1 to 15 is 0.1 g / cm ³ or less, while the staple fiber nonwoven fabric A with a lower value for the average degree of orientation Z in the comparative examples 1, 5 and 9 has an apparent density of below 0.1 g / cm ³ .

The composite nonwoven fabric according to the invention can be used are used in medical applications such as surgery clothing, sheets, curtains, masks or the like, and can still be used as top layer of a phy Siological napkin and a diaper, a filter, a wallpaper, as a base substrate for artificial leather or similar.

Claims (7)

1. A composite nonwoven fabric comprising a staple fiber nonwoven fabric (A) with the following structural features (1) to (3) and a filament nonwoven fabric (B) which is formed in such a way that the filaments are partially bonded to one another, with some of the staple fibers being build up the staple fiber nonwoven (A), inserted into the filament nonwoven (B) and intertwined with the filaments that build up the filament nonwoven (B), so that a layered body of staple fiber nonwoven (A) and filament nonwoven (B) is produced and the The number N of the staple fibers inserted to a depth of one to two or more times the thickness of the filament nonwoven fabric (B) in an area with a length of 500 µm in an optional cross section of the composite nonwoven fabric is 20 or less;

• 1) F + G 50% by weight
• 1/7 F / G 4/3

wherein
F is the ratio of the 0.333 dtex (0.3 denier) staple fiber or less to all the staple fibers;
G is the ratio of the staple fibers with a fineness of 0.556 dtex (0.5 denier) or more to all staple fibers;

• 2) basis weight of the staple fibers: 10 g / m ² to 40 g / m ² ;
• 3) average degree of orientation (Z) of the staple fibers:
• 2.0 to 10.

2. The composite nonwoven fabric according to claim 1, wherein the apparent density of the staple fiber nonwoven fabric (A) is 0.1 g / cm ³ or more. 3. The composite nonwoven fabric of claim 1, wherein the middle Elongation at break of the nonwoven filament (B) 40% or more ter, the mean elongation at break being a value which is obtained by averaging the elongations at break which measured in two mutually perpendicular directions will. 4. The composite nonwoven fabric of claim 1, wherein the stack nonwoven fabric (A) is composed of at least a fiber from the group of regenerated celluloses and the proportion of regenerated cellulose fibers Is 50% by weight or more and 80% by weight or less. 5. The composite nonwoven fabric of claim 1, wherein the stack nonwoven fabric (A) is composed of one fiber from the group of regenerated celluloses and one Fiber from the group of polyester and the ratio from polyester fiber to regenerated cellulose fiber is one in three or higher and one or lower. 6. The composite nonwoven fabric of claim 1, wherein the stack nonwoven fabric (A) is composed of at least a fibrillated acrylic pulp and the proportion of fibrillated acrylic pulp 5 wt% or more and Is 15% by weight or less.