U.S. patent application number 10/599774 was filed with the patent office on 2007-08-09 for nonwoven fabric sheet and method for producing same.
This patent application is currently assigned to MITSUI CHEMICALS, INC.. Invention is credited to Kazuya Okada, Yasuhiro Sudou.
Application Number | 20070184256 10/599774 |
Document ID | / |
Family ID | 35125115 |
Filed Date | 2007-08-09 |
United States Patent
Application |
20070184256 |
Kind Code |
A1 |
Okada; Kazuya ; et
al. |
August 9, 2007 |
Nonwoven fabric sheet and method for producing same
Abstract
The nonwoven fabric sheet of the present invention is
characterized by a porosity in the range of 0.3 to 0.7 and an
average pore size in the range of 0.5 .mu.m to 5.0 .mu.m. The
nonwoven fabric sheet of the present invention preferably has a
maximum pore size (.mu.m)/average pore size (.mu.m) ratio of 1.30
or lower. The nonwoven fabric sheet of the present invention is
obtained by press-molding a nonwoven fabric at a temperature lower
than the melting point of the thermoplastic resin which constitutes
the nonwoven fabric sheet. According to the present invention,
there is provided a nonwoven fabric sheet that has a high porosity,
small uniform pore sizes and excellent productivity, which can
suitably be used in various applications such as filters, light
diffusing material, liquid absorber and heat insulating materials;
and a method for producing the nonwoven fabric sheet.
Inventors: |
Okada; Kazuya; (Chiba,
JP) ; Sudou; Yasuhiro; (Chiba, JP) |
Correspondence
Address: |
AMIN, TUROCY & CALVIN, LLP
1900 EAST 9TH STREET, NATIONAL CITY CENTER
24TH FLOOR,
CLEVELAND
OH
44114
US
|
Assignee: |
MITSUI CHEMICALS, INC.
5-2, Higashi-Shimbashi 1-chome
Minato-ku, Tokyo
JP
|
Family ID: |
35125115 |
Appl. No.: |
10/599774 |
Filed: |
April 7, 2005 |
PCT Filed: |
April 7, 2005 |
PCT NO: |
PCT/JP05/06857 |
371 Date: |
October 9, 2006 |
Current U.S.
Class: |
428/304.4 ;
264/165; 442/327; 442/400 |
Current CPC
Class: |
B29C 2043/3652 20130101;
B29C 43/46 20130101; D04H 3/16 20130101; B29K 2105/0809 20130101;
D04H 3/14 20130101; Y10T 428/249953 20150401; D04H 3/08 20130101;
Y10T 442/60 20150401; Y10T 442/68 20150401; B29C 43/22
20130101 |
Class at
Publication: |
428/304.4 ;
442/327; 442/400; 264/165 |
International
Class: |
D04H 13/00 20060101
D04H013/00; D04H 1/56 20060101 D04H001/56; B32B 3/26 20060101
B32B003/26; B29C 41/24 20060101 B29C041/24 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 9, 2004 |
JP |
2004-116139 |
Claims
1. A nonwoven fabric sheet characterized by having a porosity in
the range of 0.3 to 0.7 and a maximum pore size in the range of 0.5
.mu.m to 5.0 .mu.m.
2. The nonwoven fabric sheet according to claim 1, wherein the
maximum pore size (.mu.m)/average pore size (.mu.m) ratio is 1.30
or lower.
3. The nonwoven fabric sheet according to claim 1, wherein the
fiber constituting the nonwoven fabric is a polyolefin fiber.
4. The nonwoven fabric sheet according to claim 3, wherein the
polyolefin is a polymer of 4-methyl-1-pentene.
5. A laminate comprising the nonwoven fabric sheet according to
claim 1 and a strength retention material laminated thereon.
6. A method of producing a nonwoven fabric sheet characterized by
molding a thermoplastic resin by a melt-blown method into a resin
molded article in nonwoven fabric form; and subsequently
press-molding said resin molded article in nonwoven fabric form
with an elastic pressing means having a Young's modulus of 20
kg/cm.sup.2 to 600 kg/cm.sup.2 at a temperature lower than the
melting point of the thermoplastic resin.
7. The method of producing the nonwoven fabric sheet according to
claim 6, wherein the pressing means has a Young's modulus of 20
kg/cm.sup.2 to 300 kg/cm.sup.2.
8. A filter, a light diffusion material, a liquid absorber, or a
heat insulating material comprising the nonwoven fabric according
to claim 1.
9. A laminate comprising the nonwoven fabric sheet according to
claim 2 and a strength retention material laminated thereon.
10. A laminate comprising the nonwoven fabric sheet according to
claim 3 and a strength retention material laminated thereon.
11. A laminate comprising the nonwoven fabric sheet according to
claim 4 and a strength retention material laminated thereon.
12. A filter, a light diffusion material, a liquid absorber, or a
heat insulating material comprising the laminate according to claim
5.
13. A filter, a light diffusion material, a liquid absorber, or a
heat insulating material comprising the laminate according to claim
9.
14. A filter, a light diffusion material, a liquid absorber, or a
heat insulating material comprising the laminate according to claim
10.
15. A filter, a light diffusion material, a liquid absorber, or a
heat insulating material comprising the laminate according to claim
11.
Description
TECHNICAL FIELD
[0001] The present invention relates to a nonwoven fabric sheet
with a high porosity and a small uniform pore size, and a method of
producing the same.
BACKGROUND ART
[0002] It has been known that a nonwoven fabric with fine openings
can be produced from fibers with a small fiber diameter. One of
such methods is calendering a nonwoven fabric using heated rollers,
wherein an opening size is decreased by reducing distances between
fibers. When a nonwoven fabric is subjected to calendering,
however, the thickness is reduced and the porosity of the nonwoven
fabric is lowered. Accordingly, when calendering is performed under
conditions to obtain a nonwoven fabric with sufficiently small
openings, an intrinsic property of nonwoven fabrics of having voids
therein is impaired. When heated rollers are used, fibers on the
surfaces of a nonwoven fabric are thermally fusion-bonded, and thus
the fibers may form a film or the pores may be squashed (for
example, see Japanese Patent Application Laid-Open No, 8-246309).
It has been pointed out that, when using a nonwoven fabric for
light diffusion materials, liquid absorbers, filter materials, heat
insulating materials and the like, if the nonwoven fabric has a low
porosity, a reduction in diffusion performance, liquid retention
performance, lifetime of filter material, heat insulation
performance, or the like, is caused. Accordingly, a nonwoven fabric
with some extent of high porosity and small uniform pore size has
been desired.
[0003] [Patent Document 1] Japanese Patent Application Laid-open
No. 8-246309
DISCLOSURE OF INVENTION
[0004] An object of the present invention is to provide a nonwoven
fabric sheet with a high porosity and small uniform pore size.
Another object of the present invention is to provide a high
productivity method of producing such a nonwoven fabric sheet.
[0005] With the above-mentioned circumstances in mind, the present
inventors pursued diligent research and, surprisingly, found that a
nonwoven fabric sheet with small uniform pore size could be
obtained, while maintaining a high porosity, by controlling
conditions of pressing. Thus, they attained the present
invention.
[0006] That is, the present invention provides a nonwoven fabric
sheet characterized by a porosity in the range of 0.3 to 0.7 and a
maximum pore size in the range of 0.5 .mu.m to 5.0 .mu.m.
EFFECTS OF THE INVENTION
[0007] The nonwoven fabric sheet according to the present invention
has a high porosity, relatively fine pore sizes, and a relatively
uniform pore size distribution, and thus can be suitably used in
various applications such as filters, light diffusion materials,
liquid absorbers, and heat insulating materials. The nonwoven
fabric sheet according to the present invention has a uniform pore
size and thus allows only substances having a certain size to pass
through.
BEST MODE FOR CARRYING OUT THE INVENTION
Raw Material Resins
[0008] The raw material resins of fibers that constitute the
nonwoven fabric according to the present invention are not
particularly limited, and various publicly known thermoplastic
resins may be utilized. Among these, there may be mentioned, for
example, polyolefins (polyethylene, polypropylene,
poly(4-methyl-1-pentene), polybutene, and the like), polyesters
(polyethylene terephthalate, polybutylene terephthalate,
polyethylene naphthalate, and the like), polyamides (nylon-6,
nylon-66, poly(meta-xylene adipamide), and the like), thermoplastic
elastomers (polyolefin elastomers, polyester elastomers, and the
like), and polyphenylene sulfite.
[0009] Among these thermoplastic resins, polyolefins are
preferable, and polypropylene-based polymers and
methylpentene-based polymers such as copolymers of a methylpentene
polymer or methylpentene and an .alpha.-olefin, are particularly
preferable for their excellent heat resistance.
[0010] Examples of the polypropylene-based polymers include
propylene homopolymers and copolymers of propylene and another
.alpha.-olefin (ethylene, butene, hexene, 4-methyl-1-pentene,
octene, or the like), an unsaturated carboxylic acid or a
derivative thereof (acrylic acid, maleic anhydride, or the like),
an aromatic vinyl monomer (styrene or the like), or the like.
Considering workability into nonwoven fabrics, mechanical strength
and other properties, it is preferable to use polypropylene having
a melt flow rate (MFR), measured at 230.degree. C. under 2.16 kg
load, of 10 g/10 min to 2000 g/10 min, preferably 800 g/10 min to
1500 g/10 min, and a melting point of 130.degree. C. to 165.degree.
C., preferably about 150.degree. C. to 163.degree. C. Such
polypropylene-based polymers can be obtained by various known
methods.
[0011] As the methylpentene-based polymers, preferred ones are
4-methyl-1-penetene homopolymers or random copolymers of
4-methyl-1-pentene and 0.1% by weight to 20% by weight, preferably
0.1% by weight to 10% by weight, of at least one kind of
.alpha.-olefin having 2 to 20 carbon atoms, preferably 10 to 20
carbon atoms, such as ethylene, propylene, 1-butene, 1-hexene,
1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene,
1-octadecene, and 1-eicocene. Considering workability into nonwoven
fabrics, mechanical strength, and other properties, it is
preferable to use a methylpentene-based polymer having a melt flow
rate, measured at 260.degree. C. under 5 kg load, of about 100 g/10
min to 1000 g/10 min, preferably about 150 g/10 min to 500 g/10
min, and a melting point of about 210.degree. C. to 280.degree. C.,
preferably about 230.degree. C. to 250.degree. C.
Methylpentene-based polymers having a Vicat softening point (ASTM D
1525) of 140.degree. C. or higher, preferably 160.degree. C. or
higher, more preferably 170.degree. C. or higher are desirable,
since the obtained nonwoven fabric sheet has excellent heat
resistance. These methylpentene-based polymers can be produced
using a stereospecific catalyst, and commercially available ones
may also be used as supplied.
Nonwoven Fabric
[0012] A nonwoven fabric used as a raw material of the nonwoven
fabric sheet of the present invention is not particularly limited
according to other requirements as long as it satisfies the
requirement that the nonwoven fabric has a porosity in the range of
0.3 to 0.7 and a maximum pore size in the range of 0.5 .mu.m to 5.0
.mu.m. The nonwoven fabric used as a raw material of the nonwoven
fabric sheet of the present invention may be a nonwoven fabric
produced by any publicly known method and may be produced, for
example, by a spun-bonding method, a melt-blown method, or a
flash-spinning method. Among these, nonwoven fabrics produced by a
melt-blown or a flash-spinning method is preferable since nonwoven
fabrics with a fine pore size can easily be obtained. Spinning and
producing nonwoven fabrics by the melt-blown method is particularly
preferable, since the process can be smoothly performed with good
productivity and nonwoven fabrics composed of homogeneous fibers
can easily be obtained.
Nonwoven Fabric Sheet
[0013] The nonwoven fabric sheet according to the present invention
is produced by press molding the above-described nonwoven fabric
and has a porosity in the range of 0.3 to 0.7 and a maximum pore
size in the range of 0.5 .mu.m to 5.0 .mu.m. Preferably, the
nonwoven fabric sheet according to the present invention further
has a "maximum pore size (.mu.m)/average pore size (.mu.m)" ratio
of 1.30 or lower.
[0014] Porosity is a ratio of a volume of voids to the total volume
of a nonwoven fabric composed of resin material and voids,
represented by the equation: porosity=1-basis weight
(g/m.sup.2)/[density of fiber (g/m.sup.3).times.thickness of
nonwoven fabric (.mu.m)]. A maximum pore size is the maximum value
of pore diameter in a nonwoven fabric sheet, and an average pore
size is an average of the diameters of all pores in a nonwoven
fabric sheet.
[0015] The maximum pore size and average pore size of the nonwoven
fabric sheet according to the present invention are determined by
measuring the pore size of the nonwoven fabric with a Coulter
Porometer (manufactured by Coulter Electronics Ltd.). Measurement
with the Coulter Porometer was performed in accordance with ASTM
E1294-89. A maximum pore size, an average pore size, and the like,
of a sheet sample can be determined by this method. The method is
specifically conducted as described below. A sample is wetted with
a standard liquid. The wetted sample, completely wetted with the
liquid having a low surface tension and a low vapor pressure, is
set in a sample holder and subjected to measurement. When pressure
is applied from one side of the sheet, the standard liquid in the
sheet is released by air pressure to empty the pores and air flow
is generated. As the pressure is continuously increased and the
pores in the sheet are continuously emptied, the air flow passing
through the sheet is recorded as a function of the pressure
supplied. A point where the first air flow with a certain volume is
generated is recognized as a bubble point (maximum pore size). The
operation is continued until the size of the pore size reaches the
smallest detectable level. Data thus obtained is compared with the
data of air flow rate versus air pressure obtained in a dried
sheet. A pore size distribution is obtained from the curve under
wet condition and the curve under dry condition, from which an
average pore size is obtained. POROFIL (trade name, manufactured by
Coulter Electronics Ltd.) or the like is used as the standard
liquid.
[0016] The porosity of the nonwoven fabric sheet according to the
present invention is in the range of 0.3 to 0.7, preferably 0.4 to
0.6, and the maximum pore size is in the range of 0.5 .mu.m to 5.0
.mu.m, preferably 0.5 .mu.m to 3.0 .mu.m, further preferably 0.5
.mu.m to 2.0 .mu.m. More preferably, in addition to the above
requirements, the ratio "maximum pore size/average pore size" is
1.30 or lower, more preferably in the range of 1.0 or higher and
1.25 or lower, particularly preferably in the range of 1.0 or
higher and 1.1 or lower. When a sheet has the above properties, the
pore sizes are small and the porosity is high, and thus the sheet
has good permeability, and further has a uniform pore size. Since
such a sheet therefore allows only a substance of a certain size to
pass through, the sheet can be used in various applications. As the
applications, there may be mentioned, for example, filters, light
dispersing materials, liquid absorbers, and heat insulating
materials. When the nonwoven fabric sheet according to the present
invention is used as a filter, the filter can selectively trap
particles of a particular size. Even if the sheet is used for a
long time, notwithstanding its high efficiency of trapping
particles of small particle sizes, the sheet is hardly clogged with
the particles, and the speed of treating a filtering liquid hardly
decreases. When the sheet is used as a filter, substances to be
filtered are not limited and may be in the form of either gasses or
liquids. When the nonwoven fabric sheet according to the present
invention is used as a light diff-using material, it is superior in
performances as a light diffusing plate since there are a large
number of boundary regions between fiber surfaces and voids where
light is diffused, and the areas of the boundary regions are large,
therefore the sheet exhibits a high light diffusivity. When the
nonwoven fabric sheet according to the present invention is used as
a liquid absorber, since there are a large number of small pores,
the permeability is excellent and the liquid retention ability is
better than that of a sheet with large pores, and when it is used
as a wiper, remaining after wiping hardly occurs and a large amount
of liquid can be treated through adsorption. When the nonwoven
fabric sheet according to the present invention is used as a heat
insulating material, it is highly effective in blocking
contaminants and excellent in heat insulation performance due to
its small pore size. A maximum pore size being too large is not
preferable, since small particles pass through the nonwoven fabric
sheet, and a porosity being too high is not preferable, since the
nonwoven fabric sheet may have uneven pore sizes.
[0017] Other properties of the nonwoven fabric sheet according to
the present invention are not particularly limited as long as the
above-described properties are satisfied. However, a nonwoven
fabric before being subjected to press-molding preferably has an
average fiber diameter of 0.5 .mu.m to 7 .mu.m more preferably 1
.mu.m to 3 .mu.m, and preferably a basis weight of 5 g/m.sup.2to 60
g/m.sup.2, more preferably 10 g/m.sup.2 to 20 g/m.sup.2.
[0018] A strength retention material may be laminated onto the
nonwoven fabric sheet according to the present invention. The
strength retention material is not particularly limited as long as
it increases the strength of the nonwoven fabric sheet according to
the present invention by being laminated thereon. For example,
there may be mentioned spun-bonded nonwoven fabrics, melt-blown
nonwoven fabrics, dry-laid nonwoven fabrics, woven fabrics, paper,
films, and the like, obtained by conventionally known methods. The
materials that do not impair the properties of the nonwoven fabric
according to the present invention and have favorable permeability
and a large pore size are preferably utilized. Various strength
retention materials to be laminated may be selected depending on
the application. In some cases, the strength retention material may
improve not only strength but also filtering property for trapping
fine particles or the like, liquid absorption property, light
diffusion property, gas retention property, or the like. For
example, a filter in which a spun-bonded nonwoven fabric obtained
by a conventionally known method is laminated on the nonwoven
fabric sheet according to the present invention can have an
increased external strength and, in addition, an improved filtering
property since the nonwoven fabric obtained by the conventional
method traps large particles, whereas small particles which have
passed through this nonwoven fabric are trapped by the nonwoven
fabric sheet according to the present invention. When laminating
such a strength retention material, one layer of the nonwoven
fabric sheet or two or more layers thereof may be laminated and
used.
Method for Producing a Nonwoven Fabric Sheet
[0019] The method for producing the nonwoven fabric sheet according
to the present invention comprises press-processing of a nonwoven
fabric, which is obtained by an ordinary known method, at a
particular temperature with a particular pressing means. As a
preferable method for producing the nonwoven fabric sheet according
to the present invention, there may be mentioned a method wherein a
thermoplastic resin is molded into a resin molded article in the
form of nonwoven fabric by a melt-blown method; and this resin
molded article in the form of nonwoven fabric is press-molded at a
temperature lower than the melting point of the thermoplastic resin
with a pressing means having a Young's modulus of 20 kg/cm.sup.2 to
600 kg/cm.sup.2.
[0020] The pressing means according to the present invention is
used to improve surface smoothness and strength of a nonwoven
fabric by applying a particular temperature and a particular
pressure on the nonwoven fabric obtained by an ordinary known
method. When this pressing means is used, the surface of the
pressing means deforms in compliance with microscopic variations in
thickness of a nonwoven fabric, and thus pressure is equally
applied. As a result, it is presumed that the porosity of the
nonwoven fabric is equalized and that the pore sizes become small
and uniform. The shape of the pressing means is not particularly
limited. For example, a pressing means having the above-mentioned
particular elastic modulus may be provided on one of the pressing
surfaces of a pressing machine while the other pressing surface
being made of a metal such as stainless steel. For a molding
machine composed of multiple rollers, the aforementioned pressing
means may be provided on the surface of one roller while the
surface of another roller being made of a hard substance such as a
metal, or the aforementioned pressing means may be provided on the
surfaces of both rollers. When production is performed by using a
molding machine composed of multiple rollers in which the
aforementioned pressing means is provided on the surface of one
roller and the surface of another roller is made of a hard
substance, it is industrially advantageous since the process is
easy and convenient and a long nonwoven fabric sheet can easily be
produced.
[0021] For the pressing means according to the present invention,
it is important to use an elastic material having a Young's modulus
of 20 kg/cm.sup.2to 600 kg/cm.sup.2, preferably 20 kg/cm.sup.2 to
300 kg/cm.sup.2. As such materials, there may be specifically
mentioned paper, cotton, felt, fabrics, wood, rubbers, foamed
plastics, and the like. Among these, rubbers and foamed plastics
with rubber elasticity are preferable since they have an
appropriate elastic modulus. As rubbers, there may be mentioned
materials such as urethane rubbers, styrene-butadiene rubbers,
olefinic elastomers, thermoplastic elastomers, and silicon rubbers.
As fabrics, there may be mentioned various materials such as
polyesters, silk, and polyurethanes. Such fabrics can appropriately
be made by selecting weaving or knitting methods, and when the
fabric is thin, it may be used as a laminate of a plurality of
pieces. When ordinary metal rollers are used, the pressing members
do not follow microscopic variations in the thickness of a nonwoven
fabric, and thus a higher pressure is applied on a thicker part
whereas pressure is hardly imposed on a thinner part. Consequently,
a porosity is drastically reduced and pores are clogged in the
thicker part, while a porosity remains high and pore sizes are
large in the thinner part. In such a case, the nonwoven fabric has
a large pore size and a wide pore size distribution, and a desired
nonwoven fabric sheet may not be obtained.
[0022] The pressing according to the present invention may be
performed on one or both surfaces of a nonwoven fabric, or may be
performed only in a part thereof.
[0023] The press-molding according to the present invention is
preferably performed at a temperature in the range from ordinary
temperature to a temperature not higher than the melting point of a
thermoplastic resin which constitutes a nonwoven fabric sheet. When
press-molding is performed at ordinary temperature or higher, it is
performed preferably at a temperature lower than the melting point
of the thermoplastic resin by 10.degree. C. or more, more
preferably at a temperature lower than the melting point of the
thermoplastic resin by 20.degree. C. or more. When press-molding is
performed at a temperature equal to or higher than the melting
point of the resin which constitutes the nonwoven fabric sheet,
fibers of the nonwoven fabric may fuse to clog the pores of the
nonwoven fabric sheet, or form a film. However, heating to some
degree facilitates shaping of the nonwoven fabrics. Heating
conditions at the time of press-molding may be selected as
appropriate depending on pressuring conditions and surface
materials of pressing means such as rollers, and may also be
selected depending on properties of a resin used as a raw material
of the nonwoven fabric.
[0024] For a nonwoven fabric made of polypropylene, for example,
conditions may be selected so that the temperature of the pressing
member that comes into contact with at least one surface of a
melt-blown nonwoven fabric is 30.degree. C. to 150.degree. C.,
preferably about 50.degree. C. to 130.degree. C. For example, when
using a pressing means wherein the pressing member that comes into
contact with one surface of a melt-blown nonwoven fabric is made of
metal, and the pressing member that comes into contact with the
other surface of the fabric is made of rubber, temperature
conditions may be selected so that the temperature of the
metal-made pressing member is about 80.degree. C. to 130.degree.
C., and that the temperature of the rubber-made pressing member is
about 50.degree. C. to 100.degree. C.
[0025] For nonwoven fabric made of a methylpentene-based polymer,
for example, conditions may be selected so that the temperature of
the pressing member that comes into contact with at least one
surface of a melt-blown nonwoven fabric is 80.degree. C. to
230.degree. C., preferably about 150.degree. C. to 200.degree. C.
For example, when using a pressing means wherein the pressing
member that comes into contact with one surface of a melt-blown
nonwoven fabric is made of metal, and the pressing member that
comes into contact with the other surface of the fabric is made of
rubber, temperature conditions may be selected so that the
temperature of the metal-made pressing member is about 120.degree.
C. to 200.degree. C. and that the temperature of the rubber-made
pressing member is about 90.degree. C. to 170.degree. C.
[0026] The press-molding according to the present invention is
preferably performed at a low pressure when the temperatures of the
pressing members are high, while at a high pressure when the
temperatures of the pressing members are low. In the above
temperature range, a linear pressure is usually 5 kg/cm to 50
kg/cm, preferably 10 kg/cm to 30 kg/cm. In this case, a nonwoven
fabric sheet having a large number of small pores is obtained. The
linear pressure is selected as appropriate depending on elastic
pressing means to be used, temperature at the time of pressing,
material of a nonwoven fabric sheet, and other conditions.
[0027] When the temperature and the pressure during press-molding
are too high, fibers fuse excessively to clog the pores, and thus
such conditions are not preferable. When the temperature and the
pressure are too low, sufficiently fine pores may not be formed in
the resultant sheet, and thus such conditions are not
preferable.
[0028] With the method for producing the nonwoven fabric sheet
according to the present invention, a nonwoven fabric sheet that
has small pore sizes, a small variation in pore size and a high
porosity, and is excellent in filtering property in trapping fine
particles or the like, liquid absorption property, light diffusing
property, gas retention property, and the like, can be produced
from inexpensive materials using an easy and convenient method.
Further, the nonwoven fabric sheet according to the present
invention, since it is molded by pressing a whole fabric uniformly,
has a reduced partial decrease in strength caused by occurrence of
uncompressed parts and is superior in mechanical strength as
compared with nonwoven fabric sheets produced by conventional
processing methods.
EXAMPLES
[0029] The present invention will be further specifically described
with reference to examples, but the present invention is not
limited to these examples.
[0030] Measurements and evaluations in examples and comparative
examples were performed as described below. The results obtained
are shown in Table 1. In the table, PP represents polypropylene and
4MP represents a 4-methyl-1-pentene copolymer.
(1) Fiber Diameter (.mu.m)
[0031] Fibers were photographed with an electron microscope,
diameters of 50 fibers were measured, and an average of the
diameters was calculated.
(2) Basis Weight (g/cm.sup.3)
[0032] A test specimen of 100 mm.times.100 mm was taken and
weighed, and the weight per m.sup.2 was calculated.
(3) Membrane Thickness (.mu.m)
[0033] Membrane thicknesses of nine samples that were used for the
measurement of basis weight were measured with a digital thickness
meter in accordance with JIS Z1702, and an average was
calculated.
(4) Porosity
[0034] Densities of fibers were determined in accordance with ASTM
D1505. Porosity was calculated from the following equation:
Porosity=1-basis weight/(density of fiber.times.thickness) (5)
Average Pore Size and Maximum Pore Size
[0035] Average pore sizes and maximum pore sizes were measured with
a Coulter Porometer manufactured by Coulter Electronics Ltd. by
procedures described below, under the following conditions.
Measurements were performed at ordinary temperature (20.degree.
C.).
[0036] Measurement Mode; PSA (pore size analysis)
[0037] Wetting Fluid: POROFIL (trade name, manufactured by Coulter
Electronics Ltd.)
[0038] Tourtuosity Factor: 1
[0039] Sample Holder: 25 mm
Procedures: A sample was wetted with the standard liquid, POROFIL
(trade name, manufactured by Coulter Electronics Ltd.) and set in a
sample holder. Measurement was then started.
[0040] Measurements were performed for a wet run and a dry run. An
average particle size and a maximum particle size were obtained
from the relationship between a difference in gas flow passing
through the sample between the wet run and dry run and a pore size,
a pore size vs. flow rate cumulative graph.
Example 1
[0041] Polypropylene (manufactured by Polymirae Co., Ltd.; melting
point: 150.degree. C.; melt flow rate measured at 230.degree. C.
under 2.16 kg load: 1000 g/10 min) was spun by a melt-blown method
at a resin temperature of 300.degree. C. and a spinning air flow of
25 Nm.sup.3/kg (air flow amount used for spinning 1 kg of a resin),
and fibers were collected with a web former to obtain a melt-blown
nonwoven original fabric with a basis weight of 12 g/m.sup.2. The
average fiber diameter of the nonwoven original fabric obtained was
2.7 .mu.m. The nonwoven original fabric obtained was pressed with a
roll machine having a rubber roller (Young modulus: 200
kg/cm.sup.2) at 100.degree. C. and a steel roller at 100.degree. C.
The linear pressure was set to 20 kg/cm and the processing speed
was set to 10 m/min. A nonwoven fabric sheet having properties
shown in Table 1 was obtained. The obtained nonwoven fabric sheet
had a large number of small pores and its appearance was white.
Example 2
[0042] Polypropylene (manufactured by Polymirae Co., Ltd.; melting
point: 150.degree. C.; melt flow rate at 230.degree. C. under 2.16
kg load: 1000 g/10 min) was spun by a melt-blown method at a resin
temperature of 300.degree. C. with a spinning air flow of 40
Nm.sup.3/kg (air flow amount used for spinning 1 kg of a resin),
and fibers were collected with a web former to obtain a melt-blown
nonwoven original fabric with a basis weight of 12 g/m.sup.2. The
average fiber diameter of the nonwoven original fabric obtained was
1.8 .mu.m. The nonwoven original fabric obtained was pressed with a
roll machine having a rubber roller at 100.degree. C. and a steel
roller at 100.degree. C. in the same manner as Example 1. The
linear pressure was set to 20 kg/cm and the processing speed was
set to 10 m/min. A nonwoven fabric sheet having properties shown in
Table 1 was obtained. The obtained nonwoven fabric sheet had a
large number of small pores and its appearance was white.
Example 3
[0043] Spinning was performed under the same spinning conditions as
Example 2 to obtain a melt-blown original fabric with a basis
weight of 20 g/m.sup.2. The nonwoven original fabric obtained was
pressed with a roll machine having a rubber roller at 100.degree.
C. and a steel roller at 100.degree. C. in the same manner as
Example 1. The linear pressure was set to 20 kg/cm and the
processing speed was set to 10 m/min. A nonwoven fabric sheet
having properties shown in Table 1 was obtained. The obtained
nonwoven fabric sheet had a large number of small pores and its
appearance was white.
Example 4
[0044] 4-Methyl-1-pentene copolymer (Mitsui Chemicals, Inc.;
melting point: 240.degree. C.; a melt flow rate at 260.degree. C.
under 5 kg load: 180 g/10 min) was spun by a melt-blown method at a
resin temperature of 360.degree. C. with a spinning air flow of 60
Nm.sup.3/kg (air flow amount used for spinning 1 kg of a resin),
and fibers were collected with a web former to obtain a melt-blown
nonwoven original fabric with a basis weight of 12 g/m.sup.2. The
average fiber diameter of the nonwoven original fabric obtained was
1.8 .mu.m. The nonwoven original fabric obtained was pressed with a
roll machine having a rubber roller at 160.degree. C. and a steel
roller at 160.degree. C. in the same manner as Example 1. The
linear pressure was set to 20 kg/cm and the processing speed was
set to 10 m/min. A nonwoven fabric sheet having properties shown in
Table 1 was obtained. The obtained nonwoven fabric sheet had a
large number of small pores and its appearance was white.
Example 5
[0045] 4-Methyl-1-pentene copolymer (Mitsui Chemicals, Inca;
melting point: 240.degree. C.; melt flow rate at 260.degree. C.
under 5 kg load: 180 g/10 min) was spun by a melt-blown method at a
resin temperature of 360.degree. C. with a spinning air flow of 90
Nm.sup.3/kg (air flow amount used for spinning 1 kg of a resin),
and fibers were collected with a web former to obtain a melt-blown
nonwoven original fabric with a basis weight of 12 g/m.sup.2. The
average fiber diameter of the nonwoven original fabric obtained was
1.2 .mu.m. The nonwoven original fabric obtained was pressed with a
roll machine having a rubber roller at 160.degree. C. and a steel
roller at 160.degree. C. in the same manner as Example 1. The
linear pressure was 20 kg/cm and the processing speed was 10 m/min.
A nonwoven fabric sheet having properties shown in Table 1 was
obtained. The obtained nonwoven fabric sheet had a large number of
small pores and its appearance was white.
Comparative Example 1
[0046] The nonwoven original fabric obtained in the same manner as
Example 1 was pressed with a roll machine having two steel rollers
at 70.degree. C. The linear pressure was set to 20 kg/cm and the
processing speed was set to 10 m/min. A nonwoven fabric sheet
having properties shown in Table 1 was obtained. Appearance of the
obtained nonwoven fabric sheet was such that a white sheet was
dotted with transparent parts.
Comparative Example 2
[0047] The nonwoven original fabric obtained in the same manner as
Example 1 was pressed with a roll machine having two steel rollers
at 100.degree. C. The linear pressure was set to 20 kg/cm and the
processing speed was set to 10 m/min. A nonwoven fabric sheet
having properties shown in Table 1 was obtained. Appearance of the
obtained nonwoven fabric sheet was such that a white sheet was
dotted with transparent parts.
Comparative Example 3
[0048] The nonwoven original fabric obtained in the same manner as
Example 2 was pressed with a roll machine having two steel rollers
at 70.degree. C. The linear pressure was set to 20 kg/cm and the
processing speed was set to 10 m/min. A nonwoven fabric sheet
having properties shown in Table 1 was obtained. Appearance of the
obtained nonwoven fabric sheet was such that a white sheet was
dotted with transparent parts.
Comparative Example 4
[0049] The nonwoven original fabric obtained in the same manner as
Example 4 was pressed with a roll machine having two steel rollers
at 90.degree. C. The linear pressure was set to 20 kg/cm and the
processing speed was set to 10 m/min. A nonwoven fabric sheet
having properties shown in Table 1 was obtained. Appearance of the
obtained nonwoven fabric sheet was such that a white sheet was
dotted with transparent parts.
Comparative Example 5
[0050] The nonwoven original fabric obtained in the same manner as
Example 4 was pressed with a roll machine having two steel rollers
at 160.degree. C. The linear pressure was set to 20 kg/cm and the
processing speed was set to 10 m/min. A nonwoven fabric sheet
having properties shown in Table 1 was obtained. Appearance of the
obtained nonwoven fabric sheet was such that a white sheet was
dotted with transparent parts. TABLE-US-00001 TABLE 1 Example
Comparative example 1 2 3 4 5 1 2 3 4 5 Raw PP PP PP 4MP 4MP PP PP
PP 4MP 4MP material Roller rubber/ rubber/ rubber/ rubber/ rubber/
steel/ steel/ steel/ steel/ steel/ materials steel steel steel
rubber steel steel steel steel steel steel Roller 100 100 100 160
160 70 100 70 90 160 temperature (.degree. C.) Density 0.91 0.91
0.91 0.83 0.83 0.91 0.91 0.91 0.83 0.83 (g/cm3) Fiber 2.7 1.8 1.8
1.8 1.2 2.7 2.7 1.8 1.8 1.8 diameter (.mu.m) Basis weight 12 12 20
12 12 12 12 12 12 12 (g/m2) Membrane 25 25 37 28 28 25 17 25 28 18
thickness (.mu.m) Porosity 0.47 0.47 0.41 0.48 0.48 0.47 0.22 0.47
0.48 0.20 Maximum 4.5 3.0 2.5 2.6 1.4 8.2 7.1 5.6 5.5 2.8 pore size
(.mu.m) Average 3.6 2.4 1.1 2.4 1.3 5.9 5.1 3.8 3.9 2 pore size
(.mu.m) Maximum 1.25 1.25 2.27 1.08 1.08 1.39 1.39 1.47 1.41 1.40
pore size/ average pore size
* * * * *