JPH086241B2 - Stretchable composite fiber sheet and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial field of application) The present invention relates to a stretchable composite fiber sheet that can be used as a pad material, elastic tape, medical dressing, supporter, clothing interlining, pad for quilting clothing, and the like. And the manufacturing method thereof.

(Prior Art) Various types of stretchable composite fiber sheets are known. For example, Japanese Patent Publication No. 4-4309 and Japanese Patent Publication No. 47-10632.
Japanese Patent Laid-Open No. 51-147679 and the like disclose a non-stretchable non-woven fabric and a stretchable urethane foam sheet which are integrated by thermal bonding.

Further, in JP-A-51-7272, JP-A-56-53258, JP-A-57-149568, etc., stretchable binder fibers are used when producing a non-woven fabric made of non-elastomeric fibers. Is disclosed.

Further, JP-B-43-26592, JP-B-44-17591, JP-B-44-21508, JP-B-51-42675,
JP-A-59-211664 and JP-A-59-211666 disclose a method in which stretchable fibers and non-stretchable fibers are respectively wetted and bonded by heat bonding or adhesive bonding. There is.

Further, in JP-A-55-98956, JP-A-57-82553, JP-A-60-146004 and 60-171162, a stretchable nonwoven fabric composed of stretchable fibers and ordinary fibers are used. A non-stretchable non-woven fabric is bonded by needling.

(Problems to be Solved by the Invention) A composite sheet obtained by adhering a urethane foam sheet has low moisture permeability, is difficult to obtain a thin material, and has little stretchability, and is therefore suitable for use as a pad material or the like. Was inappropriate. Further, the one using a stretchable binder has insufficient stretchability, so that small unevenness is generated on the surface and the texture is bad, and there is a problem that the stretchability is low under low stress and lacks flexibility. It was In addition, the one obtained by adhering the web of stretchable fiber and the web of non-stretchable fiber,
It lacked flexibility and had insufficient stretchability under low stress.
Usually, in order to increase the stretchability, the stretchable fiber webs are laminated and joined under the stretch, and therefore, when the stretch is released, there is a problem that wrinkles are generated due to the shrinkage. Further, the one bonded by the needling has a problem that the fibers are damaged by the needling, so that the stretchability and the strength are reduced, the durability becomes insufficient, and the texture becomes hard. .

INDUSTRIAL APPLICABILITY The present invention has a soft texture, excellent moisture permeability and durability, has a large elongation under low stress, and is suitable for applications such as pad materials, elastic tapes, supporters, clothing interlinings, and quilting clothing pads. And a stretchable composite fiber sheet.

(Means for Solving Problems) The stretchable composite fiber sheet of the first invention is a polyester polyether elastomer fiber obtained by melt spinning a thermoplastic polyester polyether elastomer and pulling it with an aspirator to thin it. Stretchable non-woven fabric bonded by self-adhesion and non-elastomeric fiber,
A basis weight of 40 to 200 g / m ² and an extension load of 0.1 kg / c per unit width
A stretchable composite sheet comprising a fiber sheet such as a nonwoven fabric or a knitted fabric having an elongation rate of 5% or more with respect to m, wherein the stretchable nonwoven fabric and the fiber sheet are heat-bonded, and the stretchable nonwoven fabric is combined with the fiber sheet. The fiber sheet is partially buried by the plastic deformation in the semi-molten state at the interface of the interface and the peeling strength of the interface becomes 5 g / cm or more per unit width, and the elastic strain ε (%) of 100% in the elastic composite sheet Recovery rate R
(%) Is integrated so that R ≧ ⁷⁰⁻⁶ × e ^0.01ε .

A second invention relates to a method for producing the stretchable composite fiber sheet of the first invention, wherein a thermoplastic polyester polyether elastomer is melt-spun at a temperature 20 to 80 ° C. higher than the melting point, and a discharge filament of a nozzle is used. Downward 50-100c
The stretchable non-woven fabric in which the fibers are opened while being pulled and thinned by an aspirator installed in m, spun on the screen in a semi-molten state and partially bonded to each other by self-adhesion, has an elongation rate of 2% or less. It is made of non-elastomeric fibers under elongation and has a basis weight of 40 to 200 g / m ² and is laminated on a fiber sheet such as a non-woven fabric or knitted fabric having an elongation rate of 5% or more for an elongation load of 0.1 kg / cm per unit width, Then, this laminate is pressed and heated under the condition that the stretchability of the stretchable nonwoven fabric is 1% or less, whereby the stretchable nonwoven fabric is partially deformed by plastic deformation in a semi-molten state at the interface with the fiber sheet. It is characterized in that it is heat-bonded so that the area of this buried portion is 5% or more of the laminated surface of the elastic nonwoven fabric and the fiber sheet.

Polyester polyether elastomers used in the present invention include elastomers obtained from aromatic dicarboxylic acids, aliphatic diols and poly (alkylenedioxide) glycols, but terephthalic acid, 1,4-
An elastomer composed of butanediol and poly (alkylene oxide) glycol having a number average molecular weight of about 300 to 6000 is preferable, and if necessary, one or both of a dicarboxylic acid other than terephthalic acid and a lower molecular weight diol other than 1,4-butanediol are added. be able to. Examples of the dicarboxylic acid component other than terephthalic acid include isophthalic acid, phthalic acid, adipic acid and sebacic acid, and examples of the diol component other than 1,4-butanediol include ethylene glycol, trimethylene glycol and pentamethylene glycol. Are exemplified. Further, as the poly (alkylene oxide) glycol, there are polyethylene glycol, poly (tetramethylene oxide) glycol, poly (1,2-propylene oxide) glycol, and poly (1,3-propylene oxide) glycol. Methylene oxide) glycol is preferred. As a particularly preferable polyester polyether elastomer, a copolymer containing polybutylene terephthalate and poly (tetramethylene oxide) glycol as main components, as described in JP-B-53-19638 and JP-B-55-27697. Polyester is included, and the copolymerization ratio of this polybutylene terephthalate and poly (tetramethylene oxide) glycol is 30/70 to 6
0/40 is preferred. Various copolymerization components, colorants, light stabilizers, matting agents and the like can be added as the third component as long as the stretchability and hydrolysis resistance of the fibers are not impaired.

The stretchable non-woven fabric of the present invention is one in which the above-mentioned elastomer fibers are opened and laminated, and self-bonded by thermal fusion at the contact points of the elastomer fibers, for example, the above-mentioned elastomer is 20 to 80 ° C. higher than the melting point. It is melt-spun at a high temperature, the discharge filament is pulled by an aspirator below the nozzle to open while thinning, and it is shaken partially on the screen in a semi-molten state to be laminated and partially fused. The laminated body thus produced is further hot-pressed at a softening point or higher and a melting point or lower to produce it. When stacking the above,
It is necessary to properly select the positions of the aspirator and the screen so that fusion does not occur in the aspirator and partial fusion occurs on the screen, but polybutylene terephthalate and poly (tetramethylene oxide) glycol are In the case of an elastomer having a melting point of 170 ° C. copolymerized at a ratio of 40/60, the preferred positions of the aspirator and screen are 50 to 100 cm below the nozzle surface and 150 to 150 cm below the nozzle surface, respectively.
It is 200 cm.

On the other hand, fiber sheets made of non-elastomeric fibers include natural fibers such as cotton, silk and wool, synthetic fibers such as polyester, polyamide, polyolefin, polyacrylonitrile, semi-synthetic fibers such as acetate, regenerated fibers such as rayon, or the like. Needling non-woven fabric obtained by needling a card web made of mixed materials, spun-bonded non-woven fabric obtained by spinning, thinning, opening and laminating the above synthetic fibers, knitted with a yarn made of the above fibers It is a knitted fabric or the like, and the type of fiber, the fineness, the form of the sheet, the basis weight, etc. are set according to the application. For example, when a soft texture is required, a fiber having a fineness of 0.1 to 3 denier is preferable, and when a hard texture is required, a fiber having a denier of 1 to 5 is preferable. When sweat absorption and dry touch are required, cotton and rayon are used. Further, a needling non-woven fabric is preferable for the pad material and the like.
The basis weight is preferably 40 to 200 g / m ^{2 in} order to increase the elongation rate under low stress.

An embossing roller, a high-frequency welder, an ultrasonic welder, a rotary press, or the like can be used as a means for thermally adhering the elastic nonwoven fabric made of the elastomer fiber and the fiber sheet made of the non-elastomer fiber.

(Operation) In the second invention, the stretchable composite fiber sheet of the first invention having a smooth surface is obtained by laminating the stretchable nonwoven fabric with a fiber sheet made of non-elastomeric fibers under elongation of 2% or less and thermally adhering the stretched nonwoven fabric. That is, it is possible to obtain a stretchable composite fiber sheet having a recovery rate R (%) of ^70-6 × e ^0.01ε or more for 100% stretch strain ε (%). As shown in FIG. 1, when the expansion strain ε (%) is plotted on the horizontal axis and the recovery rate R (%) is plotted on the vertical axis, a graph of R = ⁷⁰⁻⁶ × e ^0.01ε is drawn. Is obtained. That is, the stretchable composite fiber sheet according to the first aspect of the invention has a recovery rate in the shaded area P in the figure. However, when the stretchable nonwoven fabric and the fiber sheet are laminated, if the stretchability of the stretchable nonwoven fabric exceeds 2%, the stretchable nonwoven fabric expands and recovers after heat bonding, resulting in unevenness on the fiber sheet surface of the non-elastomeric fiber. And make the appearance worse. By setting the elongation percentage of the stretchable nonwoven fabric at the time of lamination to 1% or less, wrinkles of the stretchable composite fiber sheet are suppressed and the appearance is further improved.

Then, as a fiber sheet made of non-elastomeric fibers, when using those having a basis weight of 40 to 200 g / m ² , the stretchable composite fiber sheet has a better balance of stretchability and texture, and the basis weight is 40 g. When it is less than / m ^{2, the} feeling and function of the fiber sheet made of non-elastomeric fibers are lost, and when it exceeds 200 g / m ² , the extension load becomes excessive. That is, when an extension load is applied to the above fiber sheet, the elongation at an extension load of 0.1 kg / cm per unit width is preferably 5% or more, particularly preferably 10% or more, and when the elongation is less than 5%, It becomes extremely difficult to satisfy the formula of the recovery rate R. In addition, the elastic nonwoven fabric and the fiber sheet are heat-bonded, and the elastic nonwoven fabric is plastically deformed in the semi-molten state at the interface with the fiber sheet, partially embedded in the fiber sheet, and integrated, so adhesive bonding The elasticity of the elastic cloth is not diminished as in the case of needling and the above-mentioned elasticity is fully utilized. The area of the heat-bonded portion, that is, the total area of the portions bonded by point bonding, embossing roller, or pattern bonding is 5% or more, especially 10% or more of the area of the laminated surface of the stretchable nonwoven fabric and the fiber sheet. In addition, the peel strength of the interface is per unit width
When bonded so that it is 5 g / cm or more, especially 10 g / cm, excellent stretch durability is obtained and the above peel strength is 5 g / cm.
If less than 100%, structural destruction occurs when 100% elongation is given. For example, when performing thermal bonding with a laminate welder, at a pressure of 50 to 500 g / cm ² , the temperature should be above and below the melting point 30
By setting the temperature within 0 ° C, the above desirable adhesion can be obtained.

Next, methods for measuring the stretching strain ε, the recovery rate R, and other physical properties will be described.

Stretching strain ε and recovery rate R A sheet was cut into a sample with a width of 5 cm and a length of 20 cm, and this sample was used as the initial tension on a Toyo Baldwin II type Tensilon.
8.3 × 10 ^-4 × W (g) (W is the sheet weight g / m
² ) Attach so that the effective sample length will be 15 cm under the load, stretch at a pulling speed of 15 cm / min to give a prescribed elongation strain (ε),
After left for 1 minute, the load is returned to 0 at the same speed as above and left for 1 minute, and then re-expansion and recovery are repeated, and the residual strain εi (where i = 1 to 10) is measured at each recovery, The recovery rate R is calculated by the following formula.

Elongation rate of fiber sheet A sample was prepared in the same manner as above and elongated in the same manner with the above tension, and a tension-elongation curve was drawn until the above sample broke, and the elongation strain (%) at a tension of 100 g was determined. , The average of 20 measurements is used.

Peeling strength A stretchable composite fiber sheet is cut into a sample with a width of 5 cm and a length of 20 cm, and a portion with a length of 5 cm on one end side is peeled off, and one and the other of the peeled ends are grasped with the tension chucks, respectively, and the same as above. Then, the whole is peeled off by pulling on the sheet, a tension-elongation curve at this time is drawn, the average strength is determined from the integrated value of this curve, and the average value of the 10 measurements is used.

Weight per unit area 20 cm wide, 30 cm long sample punched out, its weight W (g)
Is measured and multiplied by 100/6 to obtain a basis weight (g / m ² ), and the average of 5 measurements is used.

Tension of stretchable nonwoven fabric at 2% elongation The stretchable nonwoven fabric is similarly stretched by the above tension to draw a tension-elongation curve, and the tension at the elongation rate of 2% is obtained.
This tension is applied to the stretchable nonwoven that is laminated to the fiber sheet.

(Example) A copolymer of polybutylene terephthalate (PBT) and poly (tetramethylene oxide) glycol (PTMG) was prepared.
Using three kinds of polymers of 85/15, 60/40 and 45/55, 2
Melt at 20-250 ℃, spin from 4 nozzles with a hole diameter of 0.2 mm and 10 holes at a discharge speed of 20 g / min, index with an aspirator at a position of 30-120 cm below the nozzle, and 50-150 cm below the nozzle. A stretchable web was obtained by laminating the screen in a spread manner.
The fibers that make up this web are about 30
35% had self-adhesion, and its basis weight was 30 g / m ² . Next, this web was compression molded with a heating roll at 120 to 200 ° C. to obtain a stretchable nonwoven fabric. This performance is shown in Table 1. For comparison, the compression molding with a heating roll was omitted, and instead, the entangled sheet was manufactured by needling with a needle density of 10 needles / cm ² , and the performance thereof is also shown in Table 1 above.

On the other hand, 0.7 denier polyester tape and 1 denier rayon staple were mixed at a weight ratio of 50/50,
A sheet-shaped wet was obtained by caring, and then a needling with a needle density of 5 to 50 needles / cm ² was performed to manufacture a fiber sheet made of non-elastomeric fibers. The performance of this fiber sheet is shown in Table 2.

The self-adhesive stretchable non-woven fabric (Sample Nos. 1, 3, 5) and the entangled stretchable non-woven fabric (Sample Nos. 2, 4, 6) of Table 1 above and the fiber sheet of Table 2 (Sample Nos. 11, 1)
2, 13, 14, 15, 16) and were compounded by heat bonding or needling. At the time of this compounding, the stretchable nonwoven fabric was laminated on the fiber sheet with its tension adjusted by an auto rewinder. The performance of the obtained composite fiber sheet is shown in Table 3. However, in Table 3, the light fastness is the test result of irradiation with a fade meter for 500 hours, and the 60% water permeability is 20 ° C. for each of the sample (5 cm × 15 cm) and gauze (4 × 6 cm, 8 sheets stacked). The weight is measured by leaving it under constant temperature and humidity of 65% RH overnight, and then immersing the gauze in water to reduce the water content.
Squeeze it to 60%, put this gauze between the two folded samples, and put it on a plastic board for 2k.
A load of g is applied, and after 10 minutes, the sample is taken out, the weight is measured, and from this, the moisture content is obtained by calculation. Also, for 50% elongation stress, a 5 cm wide sample was attached to a constant speed extension type tensile tester with a self-recorder at a grip interval of 10 cm,
This is the stress read at a point of 50% elongation at a tensile rate of 10 cm / min until the sample breaks. In addition, the propane yellowing degree is ignited by propane gas in the gas yellowing tester, adjust the burner so that it is maintained at 60 ° C in the tester, hang the sample, take it out 10 hours later, and remove it with gray for discoloration. It is the result of class judgment using a scale. The recovery rate after 100 times means the recovery rate after 50% elongation was repeated 100 times. In the seventh embodiment, the embossing roller capable of pin bonding has the bonding areas set to 6% and 3%, respectively. The recovery rate curves of Examples 1 and 6 and Comparative Example 1 are shown in FIG.

As is clear from Tables 1 to 3 above, the stretchable composite sheets of Examples 1 to 7 were all made of a pad material,
It has been found to be extremely excellent as an elastic tape, medical dressing, mask, supporter, and batting for clothing. On the other hand, Comparative Examples 1, 2, 3 and 5 each having a low recovery rate R (%) at 100% elongation showed 10% elongation at 50%.
The recovery rate after repeating 0 times was low, and in particular, Comparative Example 5 was broken on the way. Then, Comparative Examples 3 and 5 were inferior in peeling tension, and Comparative Examples 2 and 3 were large in bending resistance and lacking in fittability. Further, Comparative Example 4, which was compounded by entanglement instead of thermal bonding, had a large bending resistance and lacked in fitting property, and also had a poor recovery rate after 100 times of 50% elongation.

Comparative Example 6 A melt-blown nonwoven fabric was produced using the elastomer of Example 4. That is, the spinning temperature is set to 260 ° C. and the heating air is set to 280 ° C., the average fineness is 1 denier, the basis weight is 25 g / m ² , the breaking elongation is 138%, and the recovery rate at 100% elongation is 64%. A melt-blown nonwoven fabric was obtained. Next, the above melt-blown non-woven fabric was laminated on a card web made of polyester staple having a fineness of 3 denier, a crimping degree of 26% and a fiber length of 51 mm and a basis weight of 100 g / m ² prepared by a conventional method, and needle punching was performed from the card web side. Apply with a needle density of 30 needles / cm ² ,
Furthermore, by performing relaxation heat treatment at a temperature of 180 ° C for 30 seconds,
A composite non-woven fabric (Comparative Example 6) having a basis weight of 140 g / m ² in which a bundle of staples constituting a card web penetrated the melt-blown non-woven fabric to form a loop was obtained. This composite non-woven fabric was inferior in elongation recovery as compared with the examples, and the recovery rate at 100% elongation was 58%.
%, The recovery rate after 100 times is 16%, and repeated extension causes breakage in the needle punch part, reducing durability, and because a ball-shaped loop is formed on the surface, surface uniformity Was inferior.

(Effects of the Invention) The first invention uses a stretchable nonwoven fabric made of polyester polyether elastomer fibers,
It is remarkably superior in chemical resistance, light resistance, embrittlement resistance, and heat resistance to those using polyurethane elastomer fibers. In addition, since this elastomeric fiber is self-adhered, the stretchable nonwoven fabric is superior in stretchability as compared with a needling one or a nonwoven fabric obtained by adhesive bonding. Since the above-mentioned stretchable nonwoven fabric is bonded to the fiber sheet made of non-elastomeric fibers by thermal bonding, the stretchable nonwoven fabric is partially plastically deformed in the semi-molten state at the interface with the fiber sheet. Since the fibrous sheet is embedded and integrated, the stretchability of the stretchable non-woven fabric is less likely to be impaired, and the stretchability is higher than that of the above-mentioned joining by needling or adhesive bonding. Are better. Moreover, when 100% or less of elongation strain is applied to the stretchable composite fiber sheet obtained by the above-mentioned joining, the recovery rate is equal to or more than the value of the formula (R), so that the stretchability is excellent. In addition to having excellent durability and flexibility, the surface is smooth and has a good appearance even under no load,
It is extremely useful for applications such as pad materials, elastic tapes, medical dressings, masks, supporters, and padded cotton. On the other hand, the second invention is to laminate the above-mentioned stretchable nonwoven fabric on a fiber sheet made of non-elastomeric fibers under the elongation of 2% or less and heat-bond it. Therefore, the stretchable composite fiber sheet of the above-mentioned first invention is used. It can be manufactured and is easy to manufacture.

[Brief description of drawings]

The drawing is a graph showing the relationship between elastic strain and recovery rate of the elastic composite fiber sheet of the present invention.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Hideaki Ishihara Inventor Hideaki Ishihara 2-1-1 Katata, Otsu City, Shiga Toyobo Co., Ltd. (72) Inventor Akira Hinata 4-Anyoji, Ritto-cho, Kurita-gun, Shiga Prefecture 1 (72) Inventor ▲ Ku ▼ Masahiro Sword 10-5-804 Nishioji-cho, Kusatsu City, Shiga Prefecture (56) Reference JP-A-60-17162 (JP, A)

Claims (7)

[Claims] 1. A stretchable non-woven fabric obtained by melt-spinning a thermoplastic polyester polyether elastomer, stretched by an aspirator to be thinned and bonded by self-adhesion of polyester polyether elastomer fibers, and a non-elastomeric fiber. And the basis weight is 40 to 200 g / m ² ,
A stretchable composite sheet comprising a fiber sheet such as a non-woven fabric or a knitted fabric having an elongation rate of 5% or more with respect to an extension load of 0.1 kg / cm per unit width. The stretchable non-woven fabric and the fiber sheet are heat-bonded to each other, and The elastic nonwoven fabric is partially embedded in the fiber sheet due to plastic deformation in a semi-molten state at the interface with the fiber sheet so that the peeling strength at the interface becomes 5 g / cm or more per unit width, and 100 in the elastic composite sheet. A stretchable composite sheet characterized by being integrated so that a recovery rate R (%) with respect to a stretching strain ε (%) of R is R ≧ ⁷⁰⁻⁶ × e ^0.01ε . 2. The stretchable composite sheet according to claim 1, wherein a recovery rate R (%) for a stretch strain ε (%) of 20 to 100% is R ≧ ⁷⁰⁻⁶ × e ^0.01ε . 3. The area of a portion where the stretchable nonwoven fabric is partially buried and heat-bonded at the interface with the fiber sheet is 10% or more of the area of the laminated surface of the stretchable nonwoven fabric and the fiber sheet. The stretchable composite sheet according to claim 1 or 2, wherein the peel strength of the interface is 10 g / cm or more per unit width. 4. The stretchable composite sheet according to any one of claims 1 to 3, wherein the fiber sheet made of non-elastomeric fibers is a needling nonwoven fabric. 5. A thermoplastic polyester polyether elastomer is melt-spun at a temperature 20 to 80 ° C. higher than the melting point, and the discharge filament is opened while being drawn and thinned by an aspirator installed 50 to 100 cm below the nozzle, Stretchable non-woven fabric composed of non-elastomeric fibers with a stretch ratio of 2% or less and a basis weight of 40-200g. Laminated on a fiber sheet such as a non-woven fabric or knitted fabric having an elongation of 5% or more per unit width of 0.1 kg / cm at an elongation of 1 / m ² and then this laminate is 1% or less of the elongation of the elastic non-woven fabric. By pressurizing and heating under the conditions described above, the elastic nonwoven fabric partially buries the fiber sheet due to plastic deformation in a semi-molten state at the interface with the fiber sheet, and the area of the buried portion is the elastic nonwoven fabric. Preparation of elastic composite sheet, characterized by heat-bonding the laminate to be 5% or more of the laminated surface of the fiber sheet and. 6. The method for producing a stretchable composite sheet according to claim 5, wherein the stretchable nonwoven fabric is heated and pressed at a softening point or higher and a melting point or lower after the fibers are bonded by partial self-adhesion. 7. The method for producing a stretchable composite sheet according to claim 5 or 6, wherein the fiber sheet is a needle felt.