Melt blown nonwoven fabric, laminate using same, melt blown nonwoven fabric production method and melt blowing apparatus

Patent metadata

Field	Value
Publication number	US-11440289-B2
Application number	US-202016784537-A
Country	US
Kind code	B2
Filing date	Feb 7, 2020
Priority date	Aug 10, 2017
Publication date	Sep 13, 2022
Grant date	Sep 13, 2022

Abstract

Provided are a melt blown (MB) nonwoven fabric, a laminate using the same, a method of producing a melt blown nonwoven fabric as well as a melt blowing apparatus. A melt blowing apparatus 100 includes a die 10 configured to discharge a resin melt 42 with an accompanying jet to give fiber materials, a hollow cover 20, and a collector 60. The fiber materials 50 from the die 10 are heated to a temperature equal to or higher than a crystallization temperature of crystalline thermoplastic resin inside the hollow cover 20 and collected on a collecting surface 62 of the collector 60. The hollow cover 20 and the collector 60 are separated by a distance of 5 cm or longer between a lower edge 28 of the hollow cover 20 and the collecting surface 62 in a line extending downwardly from the nozzle holes 12 in a vertical direction.

First claim

What is claimed is:

1. A melt blown nonwoven fabric comprising a resin composition including a polyethylene terephthalate-series resin as a principal component, wherein
the melt blown nonwoven fabric has a surface shrinkage ratio at 200° C. of 20% or lower, a longitudinal 10% modulus (M MD ) at 30° C. of 22 N/5 cm or lower, and a longitudinal tensile strength (T MD ) of 20.3 N/5 cm or higher.

2. The melt blown nonwoven fabric according to claim 1 , wherein the melt blown nonwoven fabric has a ratio (T MD /T CD ) of the longitudinal tensile strength (T MD ) to a transverse tensile strength (T CD ) in a range from 1.00 to 1.40.

3. The melt blown nonwoven fabric according to claim 1 , wherein the melt blown nonwoven fabric has a longitudinal elongation ratio (E MD ) of 25% or higher and a ratio (E MD /E CD ) of the longitudinal elongation ratio (E MD ) to a transverse elongation ratio (E CD ) in a range from 0.80 to 1.20.

4. The melt blown nonwoven fabric according to claim 1 , wherein the melt blown nonwoven fabric has an air permeability of from 30 to 90 cm 3 /cm 2 ·s in accordance with JIS L 1906.

5. An acoustic material for a vehicle, comprising the melt blown nonwoven fabric according to claim 1 .

6. A laminate comprising a support and a melt blown nonwoven fabric that is thermocompression-bonded to at least one surface of the support, wherein the melt blown nonwoven fabric is a melt blown nonwoven fabric according to claim 1 .

7. The laminate according to claim 6 , wherein the laminate has a peeling strength (T-peel test) of 0.2 N/5 cm or higher in accordance with JIS K 6854-3 at a thermocompression-bonded surface between the melt blown nonwoven fabric and the support.

8. The laminate according to claim 6 , wherein the support is a nonwoven fabric or a felt.

9. An acoustic material for a vehicle, comprising a laminate according to claim 6 .

10. A method of producing the melt blown nonwoven fabric of claim 1 , the method comprising:
heating a resin composition comprising a polyethylene terephthalate-series resin to give a melt and discharging the melt with accompanying jet through nozzle holes to give fiber materials;
heating the fiber materials discharged through the nozzle holes in a heating zone;
exposing the heated fiber materials to outside air in an air gap zone to cool the fiber materials; and
collecting the cooled fiber materials on a collecting surface to obtain a web,
wherein at least a part of the heating zone is heated to a crystallization temperature of the polyethylene terephthalate-series resin or higher; and
the air gap zone is a space between a lower edge of the heating zone and the collecting surface, the space having a distance L of 5 cm or longer in a line extending downwardly from the nozzle holes in a vertical direction.

11. The method of producing a melt blown nonwoven fabric according to claim 10 , wherein the heating zone is a space between the nozzle holes and the lower edge of the heating zone, the space having a distance H of 10 cm or longer in the line extending downwardly from the nozzle holes in the vertical direction.

12. The method of producing a melt blown nonwoven fabric according to claim 10 , wherein the fiber materials have a temperature equal to or higher than the crystallization temperature (Tc)−25° C., at a position 10 cm below the nozzle holes in the vertical direction in the heating zone.

13. The method of producing a melt blown nonwoven fabric recited in claim 10 , wherein the crystalline thermoplastic resin is a polyethylene terephthalate-series resin.

14. A melt blowing apparatus to conduct the method of claim 10 , comprising:
an extruder configured to heat a resin composition including a polyethylene terephthalate-series resin to give a melt;
a die configured to discharge the melt with an accompanying jet to give fiber materials;
a hollow cover provided in a downstream side of the accompanying jet and configured to surround the fiber materials;
a heating unit configured to heat the fiber materials;
a collector having a collecting surface configured to collect the fiber materials flowing from the hollow cover in a downward direction of the accompanying jet,
wherein the hollow cover and the collector are separated by a distance of 5 cm or longer between a lower edge of the hollow cover and the collecting surface in a line extending downwardly from the nozzle holes in a vertical direction.

15. The melt blowing apparatus according to claim 14 , wherein the nozzle holes and the lower edge of the hollow cover are separated by a distance of 10 cm or longer in the line extending downwardly from the nozzle holes in the vertical direction.

16. The melt blowing apparatus according to claim 14 , wherein the hollow cover is formed with an air blowing port configured to introduce heated air.

Assignees

• Kuraray Co

Inventors

• Okamoto Tetsuya
• Shirotani Yasuhiro

Classifications

• D01D5/0985

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

• B32B2307/704

  Crystalline · CPC title

• B32B5/022

  Non-woven fabric · CPC title

• D04H3/16

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

• B32B37/26

  with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers · CPC title