Production method of nonwoven fabric

Patent metadata

Field	Value
Publication number	US-11174573-B2
Application number	US-201816489447-A
Country	US
Kind code	B2
Filing date	Feb 21, 2018
Priority date	Mar 3, 2017
Publication date	Nov 16, 2021
Grant date	Nov 16, 2021

Abstract

A method for producing a nonwoven fabric is provided. The method includes spinning a molten aromatic polysulfone resin from a nozzle and extending it with a high temperature fluid ejected at high speed, thereby obtaining the aromatic polysulfone resin in a fibrous form, and collecting the aromatic polysulfone resin obtained in a fibrous form on a moving collecting member. The aromatic polysulfone resin has a melt mass flow rate of 130 g/10 min or more under conditions of a test temperature of 400° C. and a nominal load of 2.16 kg, which is determined based on ASTM D 1238. A distance from the nozzle to the collecting member is set to 30 mm or less.

First claim

The invention claimed is:

1. A method for producing a nonwoven fabric, the method comprising:
spinning a molten aromatic polysulfone resin from a nozzle and extending it with a high temperature fluid ejected at high speed, thereby obtaining said aromatic polysulfone resin in a fibrous form; and
collecting said aromatic polysulfone resin obtained in a fibrous form on a moving collecting member;
wherein said aromatic polysulfone resin has a melt mass flow rate of 130 g/10 min or more under conditions of a test temperature of 400° C. and a nominal load of 2.16 kg, which is determined based on ASTM D 1238; and
a distance from said nozzle to said collecting member is set to 30 mm or less.

2. The method for producing a nonwoven fabric according to claim 1 , wherein a content of a repeating unit represented by the following formula (1) in said aromatic polysulfone resin is from 80 mol % to 100 mol % with respect to a total amount of all repeating units constituting said aromatic polysulfone resin:
-Ph 1 —SO 2 -Ph 2 —O—  (1)

wherein Ph 1 and Ph 2 represent a phenylene group; and at least one hydrogen atom in said phenylene group may each independently be substituted with an alkyl group having 1 to 10 carbon atoms, an aryl group having 6 to 20 carbon atoms or a halogen atom.

3. The method for producing a nonwoven fabric according to claim 1 , wherein the melt mass flow rate of the aromatic polysulfone resin is 400 g/10 min or less.

4. The method for producing a nonwoven fabric according to claim 1 , further comprising melting the aromatic polysulfone resin by an extruder, wherein a cylinder temperature of the extruder is from 330° C. to 410° C.

5. The method for producing a nonwoven fabric according to claim 4 , wherein the high temperature fluid is set to a temperature 20 to 50° C. higher than the cylinder temperature.

6. The method for producing a nonwoven fabric according to claim 1 , wherein the nonwoven fabric has a tensile strength of 4 N/3 cm or more and 8 N/3 cm or less.

7. The method for producing a nonwoven fabric according to claim 1 , wherein the nonwoven fabric has an average fiber diameter of 3 μm or more and 8 μm or less.

8. The method for producing a nonwoven fabric according to claim 1 , wherein the nonwoven fabric has a basis weight of 5 g/m 2 or more and 30 g/m 2 or less.

9. The method for producing a nonwoven fabric according to claim 1 , wherein the nonwoven fabric has a thickness of from 10 to 100 μm.

Assignees

• Sumitomo Chemical Co

Inventors

• Kohinata Yusaku

Classifications

• D01F6/765

  from polyarylene sulfides · CPC title

• D01F6/76 Primary

  from other polycondensation products · CPC title

• D04H3/16

  with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion · CPC title

• D04H3/009 Primary

  Condensation or reaction polymers · CPC title

• D01D5/0985

  by means of a flowing gas (e.g. melt-blowing) · CPC title