[0001] This invention relates to hot-melt-adhesive conjugate fibers and a non-woven fabric
using the conjugate fibers.
2. Description of the Related Prior Art
[0002] Non-woven fabrics having a basis weight of about 10 to 45 g/m have been used as the
surface materials for paper diaper, goods for menstruation, etc. Further, performances
required for non-woven fabrics have been highly elevated, accompanying the diversification
of the use applications of non-woven fabrics, and non-woven fabrics maintaining the
high strength thereof in a weight as small as possible and a soft feeling have been
required, and further, those abundant in the bulkiness depending upon the use applications
have been required.
[0003] In order to satisfy these requirements, it has been regarded as necessary conditions
that the non-woven fabrics are composed of hot-melt-adhesive conjugate fibers having
a small fineness, and the low melting component contributing to hot-melt-adhesion
of hot-melt-adhesive conjugate fibers displays a sufficient adhesion strength and
also has softness.
[0004] As examples of hot-melt-adhesive conjugate fibers, those of combinations of polypropylene/polyethylene,
polyethylene terephthalate/polyethylene, and polyethylene terephthalate/poly[(ethyleneterephthalate)-co-(ethyleneisophthalate)]
have been known. As polyethylene, high density polyethylene, low density polyethylene,
linear low density polyethylene, etc. have been used.
[0005] However, hot-melt-adhesive conjugate fibers using low density polyethylene or linear
low density polyethylene as the low melting component thereof have a merit that the
resulting non-woven fabric has a soft feeling, but in general, the fibers have a low
stiffness due to the low density so that the strength of the resulting nonwoven fabrics
have a low strength and are difficultly bulky. For example, Japanese patent application
laid-open No. Sho 63-92722 discloses hot-melt-adhesive conjugate fibers using a polyester
as the high melting component and a linear low density polyethylene having a low stiffness,
as the low melting component, and a hot-melt-adhesive non-woven fabric composed of
the conjugate fibers, but the non-woven fabric has a low strength and bulkiness; hence
the required performances aimed in the present invention are not satisfied.
[0006] On the other hand, hot-melt-adhesive conjugate fibers using a high density polyethylene
as the low melting component thereof, they usually have a higher density and a higher
stiffness than those of low density polyethylene or linear low density polyethylene,
to afford a non-woven fabric having a higher strength, but the high density polyethylene
as the low melting component has a higher melting point; hence in order to afford
a non-woven fabric having a high strength, it is necessary to elevate the processing
temperature of the fabric. Thus, when polypropylene is particularly used as the high
melting component, the bulkiness of the resulting nonwoven fabric is lowered due to
its heat yielding property. Further, there is a drawback that the feeling of the nonwoven
fabric is liable to become hard. Further, the processing temperature of the non-woven
fabric is preferred to be lower in the aspect of energy cost, but when the temperature
is insufficient, a non-woven fabric having a sufficient strength cannot be obtained.
SUMMARY OF THE INVENTION
Problem to be Solved:
[0007] The object of the present invention is to provide a non-woven fabric having overcome
the above drawbacks of the prior art, and having a high strength, a good bulkiness
and a soft feeling, and also to provide hot-melt-adhesive conjugate fibers enabling
to afford the above non-woven fabric.
Means for Solving the Problem:
[0008] The present inventors have made extensive research in order to solve the above problem,
and as a result, have found that when hot-melt-adhesive conjugate fibers obtained
by using a specified polyethylene as the low melting component of the fibers are processed
into a non-woven fabric, the resulting non-woven fabric has a high strength, a good
bulkiness and a soft feeling. Thus, we have found that the aimed object can be achieved
and have completed the present invention.
[0009] The present invention has the following compositions:
(1) In conjugate fibers of side-by-side type or sheath-and-core type, composed of
a high melting component of a polypropylene or a polyester and a low melting component
of a polyethylene, said polyethylene continuously forming at least one portion of
the fiber surface in the direction of the fibers,
hot-melt-adhesive conjugate fibers characterized in that said polyethylene has
0 to 1.5 methyl branch/ 1,000 C in the molecular chain, a density of 0.950 to 0.965
g/cm³ and a Q value (weight average molecular weight (Mw)/number average molecular
weight (Mn)) of 4.5 or less.
(2) Hot-melt-adhesive conjugate fibers according to item (1), wherein said polyethylene
is a homopolyethylene.
(3) Hot-melt-adhesive conjugate fibers according to item (1), wherein said polyethylene
is a copolymer of ethylene with an α-olefin of 4 or more carbon atoms.
(4) A non-woven fabric containing 20% by weight or more of the following hot-melt-adhesive
conjugate fibers and having the points of intersections of the fibers hot-melt-adhered
with the polyethylene as the low melting component in the conjugate fibers of the
hot-melt-adhesive conjugate fibers:
said hot-melt-adhesive conjugate fibers,
in conjugate fibers of side-by-side type or sheath-and-core type, composed of a
high melting component of a polypropylene or a polyester and a low melting component
of a polyethylene, said polyethylene continuously forming at least one portion of
the fiber surface in the direction of the fibers,
characterized in that said polyethylene has 0 to 1.5 methyl branch/1,000 C in the
molecular chain, a density of 0.950 to 0.965 g/cm³ and a Q value (weight average molecular
weight (Mw)/number average molecular weight (Mn)) of 4.5 or less.
(5) A non-woven fabric according to item (4), wherein said polyethylene is a copolymer
of ethylene with an α-olefin of 4 or more carbon atoms.
[0010] The present invention will be described in more detail.
[0011] The polypropylene used as a high melting component of the hot-melt-adhesive conjugate
fibers in the present invention is a crystalline polymer composed mainly of propylene
and may be propylene homopolymer or a copolymer of propylene with a small quantity
of another α-olefin (such as ethylene, butene-l, etc.), and is preferred to be those
having a melting point of 158°C or higher, and a melt flow rate (MFR: 230°C, ASTM
D1238 (L)) of 5 to 40. Such a polymer can be obtained by polymerizing propylene (and
another α-olefin) in the presence of Ziegler-Natta catalyst, Kaminski type catalyst
or the like, according to a production process such as slurry method, bulk method,
gas phase method, etc.
[0012] The polyester used as another of the high melting component of the hot-melt-adhesive
conjugate fibers in the present invention is a thermoplastic polyester generally used
as a raw material fibers. For example, it may be polyethylene terephthalate and besides,
copolymers such as poly[(ethyleneterephthalate)-co-(ethyleneisophthalate), and those
having a melting point of 250° to 260°C and an intrinsic viscosity of 0.5 to 1.2 (in
phenol/tetrachloroethane, at 30°C) are preferred.
[0013] As to the polyethylene used in the present invention, it is necessary to adjust its
density to 0.950 to 0.965 g/cm³. If the density exceeds 0.965 g/cm, the non-woven
fabric obtained from hot-melt-adhesive conjugate fibers has a high strength due to
the high stiffness of the low melting component, but since the melting point of the
low melting component is high, it is necessary to elevate the processing temperature
of the non-woven fabric.
[0014] In the case of conjugate fibers of polyethylene with polypropylene, since the softening
point of polypropylene is close to the melting point of the polyethylene, if the processing
temperature of the non-woven fabric is high, the influence upon polypropylene becomes
large; hence heat-yielding of the non-woven fabric occurs, so that a bulky non-woven
fabric cannot be obtained and also its feeling is liable to be hard. To the contrary,
if the desnity of the polyethylene is lower than 0.950 g/cm³, the non-woven fabric
obtained from the hot-melt-adhesive fibers has a soft feeling, but since the stiffness
of the low melting component is low, a high strength cannot be obtained; hence such
a polyethylene cannot be used. In both of the aspects of the strength and feeling
of the non-woven fabric, the density of the polyethylene is more preferably 0.955
to 0.961 g/cm³. In addition, the density referred to herein can be measured by preparing
a sample piece according to the pressing method of JIS K-6758 and measuring the piece
according to the density gradient tube method of JIS K-7112.
[0015] The Q value of the polyethylene used in the present invention is necessary to be
4.5 or less. A more preferable range is 3.7 or less. In the Q value exceeds 4.5, when
the fibers are heat-treated and adhered to obtain the non-woven fabric, since the
polyethylene which is a low melting component melted in the fibers has a broad molecular
weight distribution; the tensile strength of the fabric lowers, so that the melt adhesion
of the low melting component at the points of intersection of the fibers with each
other formed by the high melting component of the fibers is insufficient; hence a
non-woven fabric having a high strength cannot be obtained.
[0016] The Q value referred to herein means the ratio of the weight average molecular weight
to the number average molecular weight measured by way of gel permeation chromatography
in an o-dichlorobenzene solution at 140°C.
[0017] Further, the polyethylene used in the present invention has a methyl branch of 0
to 1.5/1000 C in the molecular chain, and a methyl branch as small as 0 to 0.5/1000
C is more preferable. The methyl branch referred to herein means a methyl group directly
branched from the main chain of the polyethylene, and methyl group directly bonded
to the main chain, like an end methyl group of ethyl branch is not included therein.
The number of methyl branches is represented by the number of methyl groups directly
bonded to the main chain, per 1000 carbon atoms of the main chain of the polyethylene.
Such methyl groups can be determined by way of nuclear magnetic resonance spectrum
of carbon atom having a mass number of 13.
[0018] The number of methyl branch of 0 in the present invention refers to, in the case
of copolymer polyethylene, a state where a long chain branch other than methyl branch,
such as ethyl branch, n-butyl branch, etc. is contained. Homopolyethylene, which is
not a copolymer, refers to ethylene homopolymer having substantially no branch, as
described below.
[0019] As seen from the linear low density polyethylene, the copolymer polyethylene is reduced
in the density if not only the number of methyl branch, but also the number of branch
increase. If it is intended to obtain the density range defined in the present invention,
by increasing only the number of methyl branch, then the point of branch increases
relative to the main chain of polyethylene, as compared with the case where a branch
longer than methyl branch is used. Further, if the length of branch is short, a structure
similar to a linear one is obtained, and the molecule is not compact and the viscosity
at the time of melting increases to make the fluidity inferior. When a non-woven fabric
is obtained by heat-treating and adhering hot-melt-adhesive fibers using a polyethylene
having a methyl branch of 1.5 or more/1000 C as the low melting point component, the
adhesion of the low melting component at the points of intersection of fibers with
each other, formed by the high melting component, is insufficient; hence a non-woven
fabric having a high strength cannot be obtained. As described above, in order to
lower the density of polyethylene while retaining the adhesion of non-woven fabric,
ethyl branch or branch longer than ethyl branch is preferred. Further, in the case
of conjugate fibers of polyethylene with polypropylene, since the softening point
of polypropylene is close to the melting point of polyethylene, if the fluidity of
polyethylene is inferior, the heat influence upon polypropylene enhances to cause
the heat yeidling of the non-woven fabric; hence a bulky non-woven fabric cannot be
obtained.
[0020] The copolymer polyethylene satisfying the above conditions can be obtained by copolymerizing
ethylene with a small quantity of an α-olefin in the presence of Ziegler-Natta catalyst,
chronium oxide system catalyst, molybdenum oxide system catalyst, Kaminski type catalyst
or the like, according to a production process such as conventional solution method
or gas phase method or high temperature and high pressure ionic polymerization method
or the like.
[0021] A small quantity of an α-olefin herein used as a comonomer refers to propylene forming
methyl branch, and 1-olefins of 4 carbon atoms or more forming a branch longer than
methyl branch such as butene-1, pentene-1, hexene-1, 4-methylpentene-1, heptene-1,
octene-1, nonene-1, decene-1, etc. Even if propylene is not used, other olefins may
be used within a range wherein the number of methyl branch of 1.5 or less/1000 C is
afforded, and as to other olefins, the polymer may be a multi-component consisting
of not only one kind but also two or more kinds of olefins and having a density and
a Q value falling within the respective ranges defined in the present invention.
[0022] Separately from the above, as a polyethylene of the present invention free from any
branch formed by comonomers, there is a homo-polyethylene which is an ethylene homopolymer.
In the case of such homopolyethylene having a melt flow rate (MFR at 190°C: 20) suitable
to fiber production, the density usually exceeds 0.965 g/cm³ and is usually close
to 0.970 g/cm³. However, when a homo-polyethylene having a density of 0.950 to 0.965
g/cm³ falling within the range of density of the present invention and a Q value of
4.5 or less is used as a low melting component and hot-melt-adhesive conjugate fibers
using the homo-polyethylene are heat-treated and adhered, the resulting non-woven
fabric has a high strength as in the case where a homo-polyethylene having a usual,
high density is used. Further, when the density and Q value thereof are made to fall
within the ranges of the present invention, the resulting nonwoven fabric was bulky
and had a good feeling. Although the reason is not well known, an example of the production
process of this polyethylene was as follows:
the polyethylene could be obtained by singly polymerizing ethylene according to
a process under polymerization conditions of high temperature and high pressure according
to a high concentration slurry process, in the presence of Ziegler-Natta catalyst
endurable to high temperature and high pressure and having a high activity, and for
a reaction retention time as very short as several minutes. If the density and Q value
fall within the ranges defined in the present invention, an ethylene homopolymer may
also be obtained using the above other catalysts and according to another polymerization
process. The thus prepared homopolyethylene having substantially no branch is particularly
preferred as a raw material for conjugate fibers of the present invention. In addition,
whether or not the polyethylene is homo-polyethylene can be judged according to nuclear
magnetic resonance spectrum of carbon atom having a mass number of 13.
[0023] As to the melt flow rate (MFR: 190°C, ASTM D1238 (E)) of the polyethylene used in
the present invention, those of about 5 to 45 are used, but those of 8 to 28 are preferably
used in the aspect of easy spinning. Further, in order to prevent deterioration at
the time of spinning and prevent discoloration of the resulting non-woven fabric,
etc., antioxydant, light-stabilizer, heat-stabilizer and besides, coloring agent,
slipping agents, surfactants, delustering agent, etc. added to usual polyolefins are
blended, if necessary.
[0024] The hot-melt-adhesive conjugate fibers of the present invention are obtained by conjugate-spinning
a polypropylene or a polyester as a high melting component and a polyethylene as a
low melting component into a side-by-side type or a sheath-and-core type in which
the polyethylene constitutes the sheath. In addition, the sheath-and-core type may
be either one of a concentric sheath-and-core type or an eccentric sheath-and-core
type. As to the component ratio of the high melting component to the low melting component,
those in the range of 30/70 to 70/30 by weight are preferred, and those in the range
of 40 / 60 to 65/35 are more preferred. Other spinning and stretching conditions may
be those of conjugate fibers consisting of usual combinations of polypropylene/polyethylene
or polyester/polyethylene. The fineness of single filament of fibers and the number
of crimps have no particular limitation, but in order that the strength and feeling
of the non-woven fabric are balanced, a fineness of single filament of 0.5 to 6.0
d and a number of crimps of 5 to 30 crimps/25 mm are preferred, and a fineness of
single filament of 1.0 to 3.0 d and a number of crimps of 10 to 20 crimps/25 mm are
more preferred.
[0025] The non-woven fabric of the present invention is obtained by making a fiber assembly
consisting only of hot-melt-adhesive conjugate fibers of the present invention or
a blended fiber assembly consisting of 20% by weight or more of the hot-melt-adhesive
conjugate fibers and other fibers, into a web, according to known carding process,
air-laying process, dry pulp process, wet paper-making process, tow-opening process,
etc., followed by heat-treating the web to hot-melt-adhere the contact points of the
hot-melt-adhesive conjugate fibers.
[0026] As the heat-treating method, any of a method using a dryer such as hot air dryer,
suction band dryer, yankee dryer, etc., and a method using press rolls such as flat
calender roll, emboss roll, etc. can be used. In order to obtain a more bulky non-woven
fabric, hot air dryer or suction band dryer are preferred. The heat-treatment temperature
is a temperature of melting point or higher of the low melting component of the conjugate
fibers and a melting point or lower of the high melting component thereof, and a range
of about 130° to 155°C is used.
[0027] The basis weight of the non-woven fabric has no particular limitation, and can be
varied according to use applications, but when the fabric is used as a surface material
of diaper or menstruation goods, 8 to 50 g/ m are preferred and 10 to 30 g/m are more
preferred.
[0028] As other fibers usable by blending with the hot-melt-adhesive conjugate fibers of
the present invention, those which do not cause change of properties due to the above
heat treatment and inhibit the object of the present invention can be optionally used,
and synthetic fibers of polyester, polyamide, polypropylene, polyethylene, etc., natural
fibers of cotton, wool, etc., rayon, etc. can be illustrated.
[0029] In the non-woven fabric of the present invention, since the low melting component
of the hot-melt-adhesive fibers functions as a binder, if the content of the hot-melt-adhesive
fibers in the fiber assembly is less than 20% by weight, the hot-melt-adhered points
in the points of intersection of fibers are reduced; hence a non-woven fabric having
a high strength cannot be obtained.
[0030] As to the use applications of the hot-melt-adhesive conjugate fibers and the non-woven
fabrics using the same, of the present invention, the conjugate fibers and the non-woven
fabrics are suitable to surface materials for paper diaper, menstruation goods, etc.
and besides, they can be broadly used as living-related materials, such as medical
materials such as surgical gown, civil materials such as drainage material, ground-improving
material, etc., industrial materials such as oil-adsorbing material, non-woven fabrics
for tray mat used for packaging fresh foods such as fibers, shellfishes, meats, etc.
Example
[0031] The present invention will be described in more detail by way of Examples and Comparative
examples. In addition, the methods for evaluating physical properties are as follows:
Strength of non-woven fabric:
[0032] According to JIS L1085 (a tesing method of an interlining cloth of non-woven fabric),
a test piece having a width of 5 cm cut off from a non-woven fabric in the fiber direction
(MD) and in the direction perpendicular thereto (CD) was prepared and its break strength
was measured at a gripping distance of 10 cm and at a tensile velocity of 30 ± 2 cm/min.
Unit: Kg/5 cm.
Bulkiness:
[0033] A load of 10 g/cm was applied to the test piece, and just thereafter its thickness
A (mm) was measured. The bulkiness refers to a specific volume (cm³/g) obtained from
the ratio of the thickness A to its basis weight B (g/m) (A/B) × C, wherein C represents
a unit amendment (C=1000).
[0034] The strength and bulkiness of the non-woven fabric are physical properties contrary
to each other, Namely, there is a tendency that when the strength is high, the bulkiness
is inferior, while when the bulkiness is good, the strength is low. Herein, evaluation
was made as follows:
[0035] In the case of a non-woven fabric composed totally (100%) of hot-melt-adhesive conjugate
fibers, when the strength of the non-woven fabric (CD) is 1.4 Kg or more/ 5 cm at
the time of a specific volume of 60 to 69 cm³/g, and when the strength of the non-woven
fabric (CD) is 1.1 Kg or more/5 cm at the time of a specific volume larger than 70
cm³/g, the non-woven fabrics in these cases were evaluated to be good. Further, in
the case where the non-woven fabric is composed of a blend of the hot-melt-adhesive
conjugate fibers with other fibers, when the specific volume is 60 cm³/g or more and
the strength of the non-woven fabric is 0.5 Kg/5 cm or higher, such a non-woven fabric
was evaluated to be good.
Feeling of non-woven fabric:
[0036] An organoleptic test was carried out by 5 panellers. When all members judged that
there was no rustling feeling due to wrinkles and the sample was soft, the fabric
was evaluated to be good (o), when three members or more judged as above, the fabric
was evaluated to be fairly good (Δ), and when three members or more judged that the
fabric had a rustling feeling due to wrinkles, etc. or was deficient in the softness,
the fabric was evaluated to be not good (×).
Examples 1 and 2 and Comparative examples 1 to 4
[0037] Conjugate fibers of a sheath-and-core type wherein a polypropylene constituted the
core and a polyethylene constituted the sheath and the ratio of sheath to core is
1:1, and having a single filament denier of 7.5 d/f, were obtained by spinning under
the following conditions:
a polypropylene (MFR: 16) as a high melting component, and its extrusion temperature:
280°C; a high density polyethylene (excluding Comparative example 2), or a linear
low density polyethylene (excluding Comparatige example 2) as a low melting component,
each indicated in Table 1; the total extrusion temperature of the high density polyethylene:
220°C; the total extruded quantity of both the components: 200 g/min; and
a sheath-and-core type spinning die having a nozzle diameter of 0.6 mm and a number
of nozzles of 350.
[0038] The resulting unstretched fibers were stretched to 3.75 times the original length,
followed by crimping, heat-treating at 100°C in order to prevent shrinkage, and cutting
the length to 51 mm to obtain a hot-melt-adhesive conjugate fiber staple. However,
stretching was carried out at 90°C only in Comparaitve example 2. The above staple
was passed through a carding machine, followed by heat-treating the resulting web
at 140°C by means of a suction band dryer, to obtain a non-woven fabric having the
points of intersection of the hot-melt-adhesive fibers hot-melt-adhered.
[0039] However, heat-treatment was carried out at 143°C in Comparative example 1 and at
130°C in Comparative example 2. The characteristics, of raw material polyethylene,
non-woven fabric-making conditions and characteristics of non-woven fabric are shown
in the following Table 1 and Table 2:
[0040] As seen from these results, the non-woven fabrics obtained by using conjugate fibers
of Example 1 and Example 2 of the present invention have high strengths in both of
the longitudinal direction (MD) and the lateral direction (CD), a good bulkiness and
a good feeling. Whereas, the non-woven fabrics obtained by using the conjugate fibers
of Comparaitve examples 1 to 4 have a weak strength in the lateral direction (CD)
or an inferior bulkiness or feeling.
Examples 3 and 4 and Comparative examples 5 to 7
[0041] Conjugate fibers of a sheath-and-core type wherein a polyester constituted the core
and a polyethylene constituted the sheath and the component ratio is 6:4, and having
a single filament denier of 6.7 d/f were obtained by spinning under the following
conditions:
a polyester (polyethylene terephthalate: PET, intrinsic viscosity: 0.65) as a high
melting point component, and its extrusion temperature: 300°C; a high density polyethylene
(excluding Comparative example 7) and a low density polyethylene (Comparative example
7), each as a low melting component, shown in Table 1; the total extrusion temperature
of the high density polyethylene: 200°C; the total extruded quantity of both the components:
282 g/min.; and a spinning die of sheath-and-core type having a nozzle diameter of
0.6 mm and a number of nozzles of 350.
[0042] The resulting unstretched fibers were stretched to 3.3 times the original length
at 90°C, followed by crimping, heat-treating at 80°C in order to prevent shrinkage
and cutting to a cut length of 51 mm to obtain a hot-melt-adhesive conjugate fiber
staple.
[0043] This staple was passed through a carding machine, followed by heat-treating the resulting
web at 140°C by means of a suction band dryer to obtain a non-woven fabric having
the points of intersection of the hot-melt-adhesive fibers hot-melt-adhered. However,
in the case of Comparative example 7, heat-treatment was carried out at 130°C. The
characteristics, non-woven fabric-making conditions of the raw material polyethylene
polymer, the characteristics of the resulting non-woven fabric, etc. are shown in
Table 1 and Table 2.
[0044] As seen from the results, the non-woven fabrics obtained by using the conjugate fibers
of Examples 3 and 4 according to the present invention had high strengths in both
of the longitudinal direction (MD) and the lateral direction (CD), a good bulkiness
and a good feeling. Whereas, the non-woven fabrics obtained by using the conjugate
fibers of Comparative examples 5 to 7 had a weak strength in the lateral direction
(CD) or an inferior bulkiness.
Examples 5 and 6 and Comparative examples 8 and 9
[0045] Conjugate fibers of a side-by-side type wherein the ratio of the components was 1:1,
and having a single filament denier of 12 d/f, were obtained by spinning under the
following conditions:
a polypropylene (MFR: 12) as a high melting component and its extrusion temperature:
300°C; a high density polyethylene shown in Table 1, as a low melting component and
its extrusion temperature of 200°C; the total extruded quantity of both the components:
200 g/min.; and a spinning die of side-by-side type having a nozzle diameter of 0.6
mm and a number of nozzles of 350.
[0046] The resulting unstretched filaments were stretched to 4 times the original length
at 110°C, followed by crimping, heat-treating at 100°C for 5 minutes in order to prevent
shrinkage and cutting to a cut length of 38 mm to obtain a hot-melt-adhesive conjugate
fiber staple.
[0047] The thus obtained hot-melt-adhesive conjugate fiber staple (12 to 25% by weight)
was optionally blended with a polyethylene terephthalate fiber staple having a single
filament denier of 6 d/f and a filament length of 51 mm (85 to 75% by weight), followed
by passing the blend through a carding machine and heat-treating the resulting web
at 140°C for 5 seconds by means of a suction band dryer to obtain a non-woven fabric
having the points of intersection of the hot-melt-adhesive fibers hot-melt-adhered.
The characteristics of the raw material polyethylene, the non-woven fabric-making
conditions and the characteristics of the non-woven fabric are shown in Table 1 and
Table 2.
[0048] As seen from the results, the hot-melt-adhesive non-woven fabrics containing 20%
by weight or more of the conjugate fibers of Examples 5 and 6 according to the present
invention are superior in the strength, bulkiness and feeling. However, even when
the non-woven fabric obtained by using the conjugate fibers of comparative example
8 and the hot-melt-adhesive non-woven fabric of Comparative example 9 which uses the
conjugate fibers of the present invention but does not contain 20% by weight or more
of the conjugate fibers, both have a weak, lateral strength (CD).
Examples 7 and 8 and Comparative examples 10 and 11
[0049] Conjugate fibers of sheath-and-core type wherein a polypropylene constitutes the
core and a polyethylene constitutes the sheath, and having a sheath to core ratio
of 1:1 and a single fiber denier of 7.5 d/f were obtained by spinning under the following
conditions:
a polypropylene (MFR: 14) as the high melting component, and its extrusion temperature:
280°C; a high density polyethylenes as a low melting component, respectively shown
in Table 3; the extrusion temperatures of the high density polyethylene: all 220°C;
the total extruded quantity of both the components: 200 g/min; and
spinning die of sheath-and-core type: nozzle diameter of 0.6 mm and number of nozzles
of 350.
[0051] As seen from the results, the non-woven fabrics obtained by using the conjugate fibers
of Examples 7 and 8 according to the present invention had a high strength of non-woven
fabric, both in the longitudinal direction (MD) and in the lateral direction (CD),
a good bulkiness and a good feeling. Whereas, the non-woven fabrics obtained by using
conjugate fibers of Comparative examples 10 and 11, had a weak strength in the lateral
direction (CD) or an inferior bulkiness or feeling.
Examples 9 and 10 and Comparative examples 12 and 13
[0052] Conjugate fibers of side-by-side type having a component ratio of 1:1 and a single
filament denier of 12 d/f were obtained by spinning under the following conditions:
polypropylenes (MFR: 9) as a high melting component and its extrusion temperature
of 300°C;
high density polyethylenes as a low melting component, indicated in Table 1 and
its extrusion temperature: 240°C; the total extrusion quantity of both the components:
200 g/min.; and
a spinning die having a nozzle diameter of 0.6 mm and a number of nozzles of 350.
[0053] The resulting unstretched filaments were stretched to 4 times the original length
at 110°C, followed by crimping, heat-treating at 100°C for 5 min. in order to prevent
shrinkage and cutting, to obtain a hot-melt-adhesive conjugate fiber staple.
[0054] The resulting hot-melt-adhesive fiber staple (15 to 25% by weight) was optionally
blended with a polyethylene terephthalate fiber staple (85 to 75% by weight) having
a single filament denier of 6 d/f and a fiber length of 51 mm, followed by passing
through a carding machine and heat-treating the resulting web at 140°C for 5 sec.
by means of a suction band dryer, to obtain a non-woven fabric having the points of
intersection of the hot-melt-adhesive fibers hot-melt-adhered. The characteristics
of the raw material polyethylene, the non-woven fabric-making conditions, the characteristics
of the non-woven fabrics, etc. are shown in Table 3 and Table 4.
[0055] As seen from the results, hot-melt-adhesive non-woven fabric containing 20% by weight
or more of the conjugate fibers of Examples 9 and 10 of the present invention had
a high strength of non-woven fabric, and a good bulkiness and feeling. Whereas, the
non-woven fabric obtained by using the conjugate fibers of Comparative example 12,
and the hot-melt-adhesive non-woven fabric obtained by using the conjugate fibers
of the present invention, but not containing the conjugate fibers in a quantity of
20% by weight or more, as in Comparative example 13, had a weak strength in the lateral
direction (CD).
(Effectiveness of the Invention)
[0056] As apparent from Examples, when the hot-melt-adhesive conjugate fibers of the present
invention obtained by using a specified polyethylene as the low-melting component
of conjugate fibers are processed into a non-woven fabric, a non-woven fabric having
a high strength, a good bulkiness and feeling is provided.