JP4300006B2 - Production method and production apparatus for solid particle carrying fiber and solid particle carrying fiber sheet - Google Patents

Description

Ｅｐ：固体粒子の有効表面積率（％）
Ｓｅ：固体粒子のＢＥＴ法による露出表面積
Ｓｐ：固体粒子全体のＢＥＴ法による表面積
Ｓｃ：固体粒子担持繊維のＢＥＴ法による表面積
Ｓｆ：固体粒子担持前の繊維のＢＥＴ法による表面積
Ｓｃ＝Ｓｏｃ×Ｗｃ
Ｓｏｃ：固体粒子担持繊維のＢＥＴ法による比表面積（ｍ²／ｇ）
Ｗｃ：繊維１ｇからなる固体粒子担持繊維の質量（ｇ／ｇ）
［すなわち、繊維１ｇ当たりの固体粒子担持繊維の質量（ｇ／ｇ）］
Ｓｆ＝Ｓｏｆ×Ｗｆ
Ｓｏｆ：繊維のＢＥＴ法による比表面積（ｍ²／ｇ）
Ｗｆ：繊維１ｇに対する繊維の質量（ｇ／ｇ）
［すなわち、繊維１ｇ当たりの繊維の質量（ｇ／ｇ）］
＝１（ｇ／ｇ）
Ｓｐ＝Ｓｏｐ×Ｗｐ
Ｓｏｐ：固体粒子全体のＢＥＴ法による比表面積（ｍ²／ｇ）
Ｗｐ：繊維１ｇに対する固体粒子の担持量（ｇ／ｇ）
［すなわち、繊維１ｇ当たりの固体粒子の質量（ｇ／ｇ）］
＝（Ｗｃ−１）（ｇ／ｇ）
【００７９】
また、繊維の比表面積の算出方法については、繊維が多孔質でなく、しかも、繊維径／繊維長の値が０．０１以下である場合は、繊維の断面積がほぼ無視できる値となるので、繊維の側面積と繊維素材の密度との関係から、例えば、下記に示すように、繊維の比表面積を算出して、繊維のＢＥＴ法による比表面積に置き換えて用いることができる。

Ｆｆ：繊維長
Ｒｆ：繊維の平均径
Ｄｆ：繊維素材の密度
【００８０】
本発明の固体粒子担持繊維は、洗濯耐性試験後の固体粒子保持率が８０％以上であることが好ましく、９０％以上が更に好ましい。すなわち、固体粒子担持繊維又は固体粒子担持繊維シートの用途として、固体粒子の脱落が問題になるような用途の場合には、洗濯耐性試験後に繊維表面に固着した固体粒子が８０％以上、より好ましくは９０％以上保持されていることが好ましい。固体粒子保持率が８０％以下の場合、使用中に脱落が生じ、固体粒子を吸引することにより、人体に害を及ぼすことがある。また、フィルタのように気流を繊維又は繊維シートに接触させる用途の場合、繊維又は繊維シートから、担持した固体粒子由来の発塵が生じてしまう。また、研磨粒子を繊維又は繊維シートに担持して、研磨材として用いる場合、固体粒子の担持が弱すぎると、研磨能力が低く、必要な研磨力が得られない等の問題が生じる。このような用途に用いる場合、固体粒子保持率が８０％以上であることが好ましい。
【００８１】
本明細書において、固体粒子担持繊維の洗濯耐性試験は、例えば、以下に示す手順により実施することができる。
すなわち、固体粒子担持繊維を１０ｃｍ程度の長さにカットし、１００〜３００本を引き揃え、両端をクリップで固定して繊維束とする。次いで、その繊維束を縦方向及び横方向が１０ｃｍ×１０ｃｍの洗濯用ネットに入れ、試験体とする。固体粒子担持繊維が１０ｃｍ以下の長さである場合には、総長１０〜３０ｍの長さに相当する量の繊維塊を、繊維が抜け出ない程度の目の粗さの洗濯用ネットに入れ、試験体とする。
【００８２】
次に、家庭用二槽式洗濯機に約４０℃の水４０リットルを入れ、これに家庭用の洗濯用洗剤２０ｇを加え、よくかき混ぜて洗剤を溶解する。浴比が４０対１となるように、試験体１枚と負荷布として綿布を必要枚数加えて洗濯液に投入し、洗濯操作を行なう。洗濯操作は、正方向のみの回転方向で１５分間撹拌する。その後、水ですすぎ洗いを１５分間行ない、次に、洗濯機に付属の脱水機で３分間試験片を脱水し、次に、試験片を洗濯機より取り出し、取り出した試験片を室温で放置して、自然乾燥させる。次に、乾燥した試験片の質量を測定して、洗濯前の試験片の質量と比較して、担持された固体粒子が脱落する程度を調べ、残留した固体粒子の質量から固体粒子保持率を求める。
【００８３】
本発明の固体粒子担持繊維は、例えば、本発明による固体粒子担持繊維の製造方法において、固体粒子として、その平均粒子径が繊維の平均径の１／３以下である固体粒子を用いることにより製造することができる。
【００８４】
本発明の固体粒子担持繊維シートは、その繊維シート中に、本発明の固体粒子担持繊維を少なくとも含む限り、特に限定されるものではなく、本発明の固体粒子担持繊維のみを含むこともできるし、あるいは、本発明の固体粒子担持繊維以外の繊維を含むこともできる。固体粒子担持繊維以外の繊維としては、特に限定されず、少なくとも表面が熱可塑性樹脂から主としてなる繊維であっても、あるいは、表面が熱可塑性樹脂でない繊維、例えば、無機繊維、あるいは、融点を有せず分解温度を有する繊維などであることもできる。
【００８５】
繊維シートの構造としては、例えば、織物、編物、若しくは不織布、又はそれらの組合せを挙げることができる。織物又は編物の場合には、例えば、前記繊維を織機又は編機により加工することによって得られる。また、不織布の場合には、例えば、従来の不織布の製法である、乾式法、スパンボンド法、メルトブロー法、フラッシュ紡糸法、又は湿式法などによって繊維シートとすることができる。また、これらの製法によって形成される繊維ウエブに、接着性繊維及び／又は融点の異なる２種類以上の樹脂が複合された複合繊維などを予め混入させてから、加熱処理することにより、繊維間が接合された繊維シートとすることができる。また、前記繊維ウエブ間を機械的絡合処理（例えば、水流絡合又はニードルパンチなど）によって絡合させた繊維シートとすることもできる。また、前記繊維ウエブを、加熱した平滑なロールと加熱した凹凸のあるロールとの間に通して、部分的に結合された繊維シートとすることもできる。また、種類の異なる前記繊維シートを複数積層して更に一体化してなる繊維シートとすることもできる。
【００８６】
本発明の固体粒子担持繊維シートを得る方法としては、例えば、本発明の固体粒子担持繊維を含んだ繊維シートを前記のようにして形成することによって得る方法、あるいは、固体粒子担持繊維を含まない繊維シートを予め形成してから、本発明による固体粒子担持繊維シートの製造方法を用いて、固体粒子を担持させる方法等を挙げることができる。このように、本発明の固体粒子担持繊維シートは、繊維シート中に固体粒子担持繊維を有しているので、この繊維シートを濾過材、吸収材、又はカバー材等の様々な用途に適した形態とすることにより、固体粒子担持繊維が担持している固体粒子の表面機能を更に有効に発揮することができる。
【００８７】
本発明の固体粒子担持繊維シートの洗濯耐性試験は、例えば、以下に示す手順により実施することができる。
すなわち、家庭用二槽式洗濯機に約４０℃の水４０リットルを入れ、これに家庭用の洗濯用洗剤２０ｇを加え、よくかき混ぜて洗剤を溶解する。浴比が４０対１となるようにして、縦方向及び横方向が１０ｃｍ×１０ｃｍの試験片３枚と負荷布として綿布を必要枚数加えて洗濯液に投入し、洗濯操作を行なう。洗濯操作は、正方向のみの回転方向で１５分間撹拌する。その後、水ですすぎ洗いを１５分間行ない、次に、洗濯機に付属の脱水機で３分間試験片を脱水し、次に、試験片を洗濯機より取り出し、取り出した試験片を室温で放置して、自然乾燥させる。次に、乾燥した試験片の質量を測定して、洗濯前の試験片の質量と比較して、担持された固体粒子が脱落する程度を調べ、残留した固体粒子の質量から固体粒子保持率を求める。
【００８８】
【実施例】
以下、実施例によって本発明を具体的に説明するが、これらは本発明の範囲を限定するものではない。
【実施例１】
抄造装置により、芯成分がポリプロピレン樹脂であり、鞘成分が高密度ポリエチレン樹脂（融点＝１３２℃）からなる芯鞘型の複合繊維（繊度＝２．２デシテックス、繊維長＝１０ｍｍ）１００％からなる抄造シートを作成した。次に、この抄造シートを金網のコンベアーベルトの上に載置して、エアースルー型のドライヤーの中で、複合繊維の接着成分である高密度ポリエチレン繊維が溶融するように、１４０℃の温度で熱接着処理を行ない、湿式法不織布を得た。この湿式法不織布は、面密度が５２．８３ｇ／ｍ²であった。
【００８９】
次に、一次粒子の径が約２０ｎｍで二次粒子の径が０．１〜１μｍの酸化チタン粒子約１００ｇを、内径２０ｃｍのシャーレに入れ、１３５℃に加熱した。次に、このシャーレの中に、更に、前記湿式法不織布（縦＝１０ｃｍ、横＝１０ｃｍ、繊維質量＝０．５２８３ｇ）を入れ、シャーレに蓋をして、手に持ち、上下に５回振ってから、酸化チタン粒子が固着した繊維シートを素早く取り出した。次に、固着しなかった酸化チタン粒子を水で洗浄して、酸化チタン粒子が繊維表面に均一に担持された、固体粒子担持繊維からなる固体粒子担持繊維シートを得た。
【００９０】
この固体粒子担持繊維シートの質量は０．５９２６ｇであり、繊維質量１ｇ当たりの固体粒子担持繊維の質量は１．１２２ｇ／ｇ（＝０．５９２６ｇ／０．５２８３ｇ）であった。また、酸化チタン粒子の担持量は０．０６４３ｇ（＝０．５９２６−０．５２８３）であり、繊維質量１ｇ当たりに担持した酸化チタン粒子の質量は０．１２１７ｇ／ｇ（０．０６４３ｇ／０．５２８３ｇ）であった。この固体粒子担持繊維の比表面積をＢＥＴ法によって測定すると、７．２７ｍ²／ｇであった。また、酸化チタン粒子担持前の湿式法不織布の繊維の比表面積は０．３３２９ｍ²／ｇであり、酸化チタン粒子の担持前の比表面積、すなわち、酸化チタン粒子が本来有する比表面積は８９．５９ｍ²／ｇであった。これらの値より、この固体粒子担持繊維に担持されている酸化チタン粒子の比表面積の有効表面積率を、酸化チタン粒子が本来有する比表面積を基準として求めると、７１．８％であった。また、この固体粒子担持繊維シートは、酸化チタン粒子の担持処理中及び／又は処理後に、繊維の収縮や糸切れは生じなかった。
また、この固体粒子担持繊維シートに担持されている酸化チタン粒子の担持の強さを調べるため、この固体粒子担持繊維シートの洗濯耐性試験を行なった結果、洗濯耐性試験前の６．４３ｇ／ｍ²の酸化チタン粒子に対して、６．２４ｇ／ｍ²の酸化チタン粒子が保持されており、固体粒子保持率は９７．０％であった。
【００９１】
【実施例２】
抄造装置により、高密度ポリエチレン繊維（繊度＝２．２デシテックス、繊維長＝１０ｍｍ、融点＝１３２℃）１００％からなる抄紙シートを作成し、続いて、水流絡合法により抄紙シートの繊維を絡合させた抄造シートを作成した。次に、この抄造シートを金網のコンベアーベルトの上に載置して、エアースルー型のドライヤーの中で、１２５℃の温度で乾燥処理を行ない、湿式法不織布を得た。続いて、実施例１と同様の方法により、酸化チタン粒子が繊維表面に均一に担持された、固体粒子担持繊維からなる固体粒子担持繊維シートを得た。
【００９２】
前記湿式法不織布（すなわち、酸化チタン粒子担持前の不織布）の面密度は５１．２１ｇ／ｍ²（繊維質量＝０．５１２１ｇ）であった。固体粒子担持繊維シートの質量は０．５７６７ｇであり、繊維質量１ｇ当たりの固体粒子担持繊維の質量は１．１２６ｇ／ｇ（＝０．５７６７ｇ／０．５１２１ｇ）であった。また、酸化チタン粒子の担持量は０．０６４６ｇであり、繊維質量１ｇ当たりに担持した酸化チタン粒子の質量は０．１２６１ｇ／ｇ（＝０．０６４６ｇ／０．５１２１ｇ）であった。
【００９３】
この固体粒子担持繊維の比表面積をＢＥＴ法によって測定すると、７．１５ｍ²／ｇであった。また、酸化チタン粒子担持前の湿式法不織布の繊維の比表面積は０．３２４２ｍ²／ｇであり、酸化チタン粒子の担持前の比表面積、すなわち、酸化チタン粒子が本来有する比表面積は８９．５９ｍ²／ｇであった。これらの値より、この固体粒子担持繊維に担持されている酸化チタン粒子の比表面積の有効表面積率を、酸化チタン粒子が本来有する比表面積を基準として求めると、６８．４％であった。また、この固体粒子担持繊維シートは、酸化チタン粒子の担持処理中及び／又は処理後に、繊維の収縮や糸切れは生じなかった。
また、この固体粒子担持繊維シートに担持されている酸化チタン粒子の担持の強さを調べるため、この固体粒子担持繊維シートの洗濯耐性試験を行なった結果、洗濯耐性試験前の６．４６ｇ／ｍ²の酸化チタン粒子に対して、６．３５ｇ／ｍ²の酸化チタン粒子が保持されており、固体粒子保持率は９８．３％であった。
【００９４】
【実施例３】
高密度ポリエチレン樹脂（融点＝１３０℃）からなるモノフィラメント（繊度＝２０デシテックス）に、１３０℃に加熱した炭酸カルシウム粒子（粒子径＝５μｍ）を散布して、炭酸カルシウム粒子が繊維表面に均一に担持された固体粒子担持繊維を得た。この固体粒子担持繊維は、炭酸カルシウム粒子の担持処理中及び／又は処理後に前記モノフィラメントの収縮や糸切れは生じなかった。
【００９５】
【比較例１】
実施例１に記載の手順を繰り返すことにより、面密度が５１．４７ｇ／ｍ²である湿式法不織布を得た。
続いて、一次粒子の径が約２０ｎｍで二次粒子の径が０．１〜１μｍの酸化チタン粒子約１００ｇを、内径２０ｃｍのシャーレに入れ、２５℃に保った。次に、このシャーレの中に、更に、前記湿式法不織布（縦＝１０ｃｍ、横＝１０ｃｍ、繊維質量＝０．５１４７ｇ）を入れ、シャーレに蓋をして、手に持ち、上下に５回振った。次に、このシャーレを１３５℃のドライヤーに入れ、５分後にドライヤーからシャーレを取り出し、更に、素早くシャーレから酸化チタン粒子が固着した繊維シートを取り出した。次に、固着しなかった酸化チタン粒子を水で洗浄して、酸化チタン粒子が担持された繊維シートを得た。
【００９６】
この比較例では、酸化チタン粒子は繊維表面に均一に担持されておらず、部分的に凹凸があった。また、固体粒子担持繊維シートの質量は０．５７９６ｇであり、繊維質量１ｇ当たりの固体粒子担持繊維の質量は１．１２６ｇ／ｇ（＝０．５７９６ｇ／０．５１４７ｇ）であった。また、酸化チタン粒子の担持量は０．０６４９ｇであり、繊維質量１ｇ当たりに担持した酸化チタン粒子の質量は０．１２６１ｇ／ｇ（＝０．０６４９ｇ／０．５１４７ｇ）であった。
【００９７】
この固体粒子担持繊維の比表面積をＢＥＴ法によって測定すると、３．７３ｍ²／ｇであった。また、酸化チタン粒子担持前の湿式法不織布の繊維の比表面積は０．３３２９ｍ²／ｇであり、酸化チタン粒子の担持前の比表面積、すなわち、酸化チタン粒子が本来有する比表面積は８９．５９ｍ²／ｇであった。これらの値より、この固体粒子担持繊維に担持されている酸化チタン粒子の比表面積の有効表面積率を、酸化チタン粒子が本来有する比表面積を基準として求めると、３４．２％であった。また、この固体粒子担持繊維シートは、酸化チタン粒子の担持処理中及び／又は処理後に、繊維の糸切れが生じることはなかったものの、繊維の収縮が生じた。
また、この固体粒子担持繊維シートに担持されている酸化チタン粒子の担持の強さを調べるため、この固体粒子担持繊維シートの洗濯耐性試験を行なった結果、洗濯耐性試験前の６．４９ｇ／ｍ²の酸化チタン粒子に対して、６．２５ｇ／ｍ²の酸化チタン粒子が保持されており、固体粒子保持率は９６．３％であった。
【００９８】
【比較例２】
抄造装置により、高密度ポリエチレン繊維（繊度＝２．２デシテックス、繊維長＝１０ｍｍ、融点＝１３２℃）１００％からなる抄紙シートを作成し、続いて、水流絡合法により抄紙シートの繊維を絡合させた抄造シートを作成した。次に、この抄造シートを金網のコンベアーベルトの上に載置して、エアースルー型のドライヤーの中で、１２５℃の温度で乾燥処理を行ない、面密度が５１．２１ｇ／ｍ²である湿式法不織布を得た。
続いて、比較例１と同様の方法により、酸化チタン粒子が担持された繊維シートを得た。この固体粒子担持繊維シートでは、酸化チタン粒子は繊維表面に均一に担持されておらず、部分的に凹凸があった。この固体粒子担持繊維シートは、酸化チタン粒子の担持処理中及び／又は処理後に、不織布中の繊維の収縮が生じ、更に繊維の糸切れが多数生じた。
【００９９】
【比較例３】
高密度ポリエチレン樹脂（融点＝１３０℃）からなるモノフィラメント（繊度＝２０デシテックス）に、常温の炭酸カルシウム粒子（粒子の径＝５μｍ）を散布して、炭酸カルシウム粒子を繊維に接触させた後、１３５℃のドライヤーに１分間入れた。その結果、モノフィラメントが収縮して糸切れを生じてしまい、固体粒子担持繊維を得ることができなかった。
【０１００】
【評価結果】
表１に、実施例１及び２並びに比較例１についての結果を示す。実施例１及び２では、固体粒子の有効表面積率が５０％以上であり、固体粒子が繊維表面に担持された後も、固体粒子が本来有する表面機能を充分に発揮することができることを示している。これに対して、比較例１では、固体粒子の有効表面積率が５０％未満の値であり、固体粒子が繊維表面に担持された後は、固体粒子が本来有する表面機能を充分に発揮することができないことを示している。
また、実施例１〜３では、固体粒子を繊維表面に担持しても、繊維の収縮や糸切れが生じないのに対して、比較例１〜３では、繊維の収縮や糸切れが生じた。また、実施例１及び２の洗濯耐性試験では、比較例１と同様に固体粒子の脱落が少なく、固体粒子は繊維に強固に担持されていることを示している。
【０１０１】

【０１０２】
【発明の効果】
本発明の製造方法又は本発明の製造装置によれば、繊維の繊維表面又は繊維シートを構成する繊維の繊維表面に固体粒子を、その固体粒子の表面特性を有効に保持したまま、しかも均一に固着させることができる。
本発明の製造方法又は本発明の製造装置によれば、加熱した固体粒子を繊維表面に接触させることで、繊維表面に固体粒子が接触した部分のみが溶融して固体粒子が担持される。そのため、固体粒子の表面の内、接触部分以外又は固着部分以外の表面部分を溶融樹脂が覆ってしまうことが非常に少なくなっている。また、繊維表面の樹脂全体が溶融して流動化することにより、固体粒子が埋没してしまうことも非常に少なくなっている。
また、接触した固体粒子の隙間より溶融樹脂が沁み出し、その固体粒子の外側にある固体粒子をも固着して、繊維表面上で固体粒子が部分的に複層となってしまい、繊維表面に固体粒子が均一に担持されないという問題が発生しない。のみならず、場合によっては、均一な、単層の固着又は担持も可能である。
【０１０３】
また、本発明の製造方法又は本発明の製造装置によれば、固体粒子が繊維表面のみを溶融するので、繊維が単一の樹脂成分からなる繊維であっても、接触処理時又は固着処理時に繊維が収縮したり、繊維全体が溶融して糸切れが生じるようなことはない。また、繊維表面に固体粒子が接触された後、冷却されることによって繊維表面に強固に固体粒子が固着され担持されているので、例えば、洗濯耐性試験によって固体粒子が簡単に脱落することもない。
また、本発明の製造方法又は本発明の製造装置において、加熱固体粒子と繊維又は繊維シートとを接触させる方法として、加熱固体粒子含有気流を繊維又は繊維シート表面に吹き付ける方法を用いた場合には、加熱された固体粒子を含む気流を繊維表面に吹き付けて行なうため、固体粒子の慣性力により固体粒子が繊維表面に衝突して、固体粒子が繊維表面にしっかりと固着することができる。
【０１０４】
本発明の固体粒子担持繊維は、固体粒子の表面の内、担持部分以外の表面部分は溶融樹脂によって覆われることがなく、固体粒子が溶融樹脂中に埋没していない。更に、繊維表面に固体粒子が均一に担持されている。従って、固体粒子の有効表面積率をＢＥＴ法の比表面積測定により評価すると５０％以上となっている。すなわち、本発明の固体粒子担持繊維によれば、固体粒子が繊維表面に担持されていても、固体粒子が本来有する表面機能を充分に発揮することができる。
また、本発明の固体粒子担持繊維シートは、固体粒子担持繊維を有しているので、この繊維シートを、例えば、濾過材、吸収材、又はカバー材等の様々な用途に適した形態とすることにより、固体粒子担持繊維が担持している固体粒子の表面機能を更に有効に発揮することができる。
【図面の簡単な説明】
【図１】本発明による固体粒子担持繊維又は固体粒子担持繊維シートの製造装置の一態様を模式的に示す構成図である。
【図２】本発明による固体粒子担持繊維又は固体粒子担持繊維シートの製造装置の別の一態様を模式的に示す概略図である。
【図３】本発明による固体粒子担持繊維又は固体粒子担持繊維シートの製造装置の更に別の一態様を模式的に示す概略図である。
【符号の説明】
１０・・・気流発生手段；１１・・・ブロワー；１２・・・加熱管；
２０・・・粒子供給手段；２１・・・供給容器；２２・・・供給制御ロータ；
２３・・・供給管；２４・・・流動層型乾燥機；２９・・・固体粒子；
３０・・・粒子混合手段；４０・・・噴出手段；４１・・・ノズル；
５０，５１，５２，５３・・・加熱手段；
６０，６１，６２，６３・・・補助加熱手段；
７０・・・ロール又は繊維支持手段；
７０’・・・ロール又は繊維シート支持手段；
８０・・・繊維；８０’・・・繊維シート；
９０・・・固着処理室；９１・・・室内加熱手段；
９２・・・粒子回収ボックス；
９３・・・空気を吹き飛ばす方式の粒子回収手段。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a solid particle-carrying fiber, a method and apparatus for producing a solid particle-carrying fiber sheet, and a solid particle-carrying fiber and a solid particle-carrying fiber sheet.
[0002]
[Prior art]
As a method for supporting solid particles on the surface of the fiber, for example, in JP-A-6-341044 (Patent Document 1), fibers that are intertwined with each other are bonded together by a binder (binder liquid), and the binder is bonded to the surface of the fiber. Discloses a non-woven fabric to which a functional powder is fixed. Further, the publication uses hot-melt fibers having a core-sheath structure having a core made of a high-melting-point resin and a sheath made of a low-melting-point binder resin covering the core, and the aggregate of the hot-melt fibers is used as the binder. The binder resin is melted by heating to a temperature higher than the melting point of the resin, and the functional powder is supplied to the fibers and then cured by cooling. The fibers of the high melting point resin are mutually bonded by the binder resin. A non-woven fabric is disclosed in which the functional powder is bonded to a fiber while being bonded.
[0003]
However, according to the method in which the functional powder is fixed to the surface of the fiber by the binder, until the functional powder contacts the surface of the fiber several times, or until the binder is heated and cured after the functional powder contacts the surface of the fiber. Since the binder flows to the surface, the binder adheres to portions other than the portion where the functional powder contacts the fiber surface, and the surface of the functional powder is covered more than necessary, and the functional powder originally has. There was a problem that the function could not be used effectively.
In addition, according to the method of fixing the functional powder in a state where the binder resin in the sheath portion of the hot-melt fiber having the core-sheath structure is melted, the functional powder is fixed in a state where the binder resin is melted and fluidized. A large number of functional powders are buried in the binder resin layer, so that the surface of the functional powder is unnecessarily covered, and the function inherent to the functional powder cannot be effectively exhibited.
In addition, according to the method of the above publication, the binder or binder resin flows, squeezes out from the gap between the functional powders in contact with the binder or binder resin, and the functional powder outside the functional powder also adheres. There was a problem that the body partially overlapped with a plurality of layers, and the functional powder was not fixed uniformly on the fiber surface.
[0004]
Further, as a method other than the method using the binder or the core-sheath hot melt fiber as described in the above publication, there is also a method of fixing the functional powder by heating and melting a fiber made of a single resin component instead of the core-sheath structure. Though conceivable, in addition to the above problems, such a method has a further problem that the whole fiber is melted and the fiber contracts or the fiber breaks.
[0005]
[Patent Document 1]
JP-A-6-341044
[0006]
[Problems to be solved by the invention]
The object of the present invention is to solve the above-mentioned drawbacks of the prior art, and to fix solid particles on the fiber surface or the fiber surface constituting the fiber sheet, while maintaining the surface characteristics of the solid particles effectively, and solidly fixing the solid particles. An object of the present invention is to provide a method for producing a particle-supporting fiber and a solid particle-supporting fiber sheet, a manufacturing apparatus suitable for the method, and a novel solid particle-supporting fiber and a solid particle-supporting fiber sheet.
[0007]
[Means for Solving the Problems]
The subject is a method for producing fibers according to the present invention, in which solid particles are supported on the surface of fibers mainly comprising at least a surface of a thermoplastic resin,
Solid particles having a melting point or decomposition temperature higher than the melting point of the thermoplastic resin are heated to a temperature higher than the melting point of the thermoplastic resin, and the heated solid particles are maintained at a temperature higher than the melting point of the thermoplastic resin. The solid particles are fixed to the fiber surface by contacting the fibers, supporting the solid particles on the fiber surface by fusing the fiber surface, and cooling the solid particle fused fiber. This can be solved by the method for producing solid particle-supporting fibers.
[0008]
Further, the present invention is a method for producing a fiber sheet in which solid particles are supported on the surface of the fiber sheet, the fiber sheet comprising fibers mainly composed of a thermoplastic resin at least on the surface,
Solid particles having a melting point or decomposition temperature higher than the melting point of the thermoplastic resin are heated to a temperature higher than the melting point of the thermoplastic resin, and the heated solid particles are maintained at a temperature higher than the melting point of the thermoplastic resin. Contacting the fiber sheet, supporting the solid particles on the fiber surface by fusing the fiber surface, and cooling the solid particle fused fiber sheet to fix the solid particles to the fiber surface. The present invention relates to a method for producing a solid particle-supporting fiber sheet.
[0009]
Further, the present invention is a fiber production apparatus for carrying solid particles on the surface of a fiber mainly comprising at least a surface of a thermoplastic resin,
Particle forming means for forming an air flow containing solid particles,
Ejecting means for ejecting an air flow containing solid particles formed by the particle forming means;
A heating unit provided in the particle forming unit and / or the jetting unit, and capable of forming an air stream including heated solid particles heated to a temperature higher than the melting point of the thermoplastic resin; and
Fiber support means capable of holding the fiber at a position where the solid particle-containing air stream ejected from the ejection means can come into contact with the fiber surface.
The present invention relates to the manufacturing apparatus.
[0010]
Further, the present invention is a fiber sheet manufacturing apparatus for supporting solid particles on the surface of the fiber of a fiber sheet containing fibers mainly comprising a thermoplastic resin at least on the surface,
Particle forming means for forming an air flow containing solid particles,
Ejecting means for ejecting an air flow containing solid particles formed by the particle forming means;
A heating unit provided in the particle forming unit and / or the jetting unit, and capable of forming an air stream including heated solid particles heated to a temperature higher than the melting point of the thermoplastic resin; and
Fiber sheet support means capable of holding the fiber sheet at a position where the solid particle-containing air stream ejected from the ejection means can come into contact with the fiber sheet surface.
The present invention relates to the manufacturing apparatus.
[0011]
Further, the present invention is a fiber carrying solid particles on the surface of at least a fiber mainly composed of a thermoplastic resin, wherein the solid particles have a melting point or decomposition temperature higher than the melting point of the thermoplastic resin. The average particle diameter of the solid is less than 1/3 of the average diameter of the fiber, and the solid supported on the fiber surface with respect to the total surface area (Sp) of the solid particles before being supported on the fiber surface by the BET method The present invention relates to a solid particle-supporting fiber characterized in that an effective surface area ratio ((Se / Sp) × 100), which is a percentage of an exposed surface area (Se) of a particle by the BET method, is 50% or more.
Furthermore, this invention relates to the solid particle carrying | support fiber sheet containing the said solid particle carrying fiber.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
[1] Method for producing solid particle-carrying fiber or solid particle-carrying fiber sheet according to the present invention
According to the method for producing a solid particle-carrying fiber according to the present invention, it is possible to produce a fiber carrying solid particles on the surface of a fiber whose surface is mainly composed of a thermoplastic resin. In the method for producing solid particle-supporting fibers of the present invention, solid particles having a melting point or decomposition temperature higher than the melting point of the thermoplastic resin are heated to a temperature higher than the melting point of the thermoplastic resin, and the melting point of the thermoplastic resin is exceeded. The heated solid particles are brought into contact with the fibers while being maintained at a high temperature, the solid particles are supported on the fiber surfaces by fusing the fiber surfaces, and the solid particle fused fibers are cooled, thereby Solid particles are fixed on the fiber surface.
[0013]
In addition, according to the method for producing a solid particle-supporting fiber sheet according to the present invention, it is possible to produce a fiber sheet that supports solid particles on the surface of the fiber of a fiber sheet that includes fibers whose surface is mainly composed of a thermoplastic resin. it can. In the method for producing a solid particle-supporting fiber sheet of the present invention, solid particles having a melting point or decomposition temperature higher than the melting point of the thermoplastic resin are heated to a temperature higher than the melting point of the thermoplastic resin, and the melting point of the thermoplastic resin. Heated solid particles are brought into contact with the fiber sheet while being maintained at a higher temperature, the solid particles are supported on the fiber surface by fusing the fiber surface, and the solid particle fused fiber sheet is cooled. Thus, solid particles are fixed to the fiber surface.
[0014]
The fiber used in the method for producing a solid particle-carrying fiber of the present invention or the fiber contained in the fiber sheet used in the method for producing a solid particle-carrying fiber sheet of the present invention is a fiber whose surface is mainly composed of a thermoplastic resin. Yes, as long as the fiber surface melts by heating (for example, heating at 50 ° C. or higher, preferably heating at 80 ° C. or higher), the type of the fiber can be selected as appropriate. Examples of such fibers include synthetic fibers obtained by melt spinning, which is a conventional fiber production method, fibers obtained by a spunbond method, melt blow method, flash spinning method, etc., which are conventional nonwoven fabric production methods, or core portions. It can be appropriately selected from fibers made of natural fibers or inorganic fibers.
[0015]
As said fiber obtained by the manufacturing method of the said synthetic fiber or a nonwoven fabric, the synthetic fiber which consists of thermoplastic resins (for example, polyolefin fiber, polyester fiber, or polyamide fiber etc.) can be mentioned, for example, The said synthetic fiber is 1 Even if it is a synthetic fiber made of a kind of thermoplastic resin or a composite fiber in which two or more different kinds of resins are composited, it can be appropriately selected and used. Examples of such composite fibers include composite fibers in which two or more kinds of resins having different melting points are combined, such as copolymer polyester / polyester, copolymer polypropylene / polypropylene, polypropylene / polyamide, polyethylene / polypropylene, Mention may be made of composite fibers made of a combination of resins such as polypropylene / polyester or polyethylene / polyester. Also, when the composite fiber is a core-sheath type composite fiber having a high melting point resin in the core and a low melting point resin in the sheath, the solid particles are fixed to the fiber surface and contracted when supported. And thread breakage are further less likely to occur.
[0016]
In addition, the fibers are thermoplastic as a sheath portion on the surface of a fiber such as a rayon fiber, an acetate fiber, a wool fiber, or a carbon fiber whose core portion does not have a melting point and has a decomposition temperature. The resin may be a fiber formed by coating, for example. Moreover, the thermoplastic resin is used as a sheath part on the surface of a fiber such as a fiber having a high melting point, for example, a glass fiber, a ceramic fiber, or a metal fiber, the core part of which is an inorganic fiber. It can also be a fiber applied by coating or the like.
[0017]
Examples of the fiber mainly comprising at least a surface of a thermoplastic resin include, for example, a fiber having at least a surface made of one or more thermoplastic resins, a fiber having at least a surface substantially made of one or more thermoplastic resins, or Mention may be made of fibers mainly comprising at least one or more thermoplastic resins, at least one surface comprising fibers comprising one or more thermoplastic resins, or at least one surface comprising one or more thermoplastic resins. Substantially fibers are preferred. In this specification, “consisting mainly of” means that the target thermoplastic resin is 50 mass% or more (preferably 60 mass% or more, more preferably 70 mass% or more, particularly preferably 90 mass) with respect to the constituent resin on the fiber surface. % Or more). Moreover, the cross-sectional shape or surface shape of the fiber can be any shape. For example, a composite fiber made of a thermoplastic resin can be a fiber having a chrysanthemum-like cross-sectional shape divided by mechanical stress such as water flow, or a fiber divided into fibrils.
[0018]
The average diameter and length of the fibers are, for example, synthetic fibers obtained by melt spinning, which is a conventional fiber manufacturing method, fibers obtained by a spunbond method, melt blow method, flash spinning method, etc., which are conventional nonwoven fabric manufacturing methods, or A fiber having an average diameter and length of a fiber such as a fiber having a core part made of natural fiber or inorganic fiber can be appropriately selected. For example, the average diameter of the fibers can be a wide range of average diameters ranging from 0.1 μm to 3 mm. The average diameter of the fibers is preferably in the range of 0.1 μm to 500 μm, more preferably in the range of 0.1 μm to 100 μm. Here, when the cross-sectional shape of the fiber is other than a circle, the average diameter of the fiber is the diameter of a circle having the same area as the cross-sectional area of the fiber, and the number average fiber diameter by sampling from any 500 or more positions of the fiber And
[0019]
In addition, when it is difficult to measure the cross-sectional area of the fiber, the side surface of the fiber is enlarged and photographed with a scanning electron microscope or the like, and the fiber diameter that can be confirmed with the image of the fiber is measured from more than 500 arbitrary positions of the fiber. The number average fiber diameter obtained by sampling can be the fiber diameter of the fiber.
In the case of a commercially available fiber, when the number average fiber diameter is clearly shown in the catalog or specification, the value may be used as the average fiber diameter. Further, when the fiber diameter is clearly specified in the unit of denier or decitex in the catalog or specification, the value may be converted into the unit of length to obtain the average fiber diameter.
[0020]
The fiber sheet used in the method for producing a solid particle-carrying fiber sheet of the present invention is particularly limited as long as the fiber sheet has the above-described fibers, that is, fiber sheets having at least the surface mainly composed of a thermoplastic resin. Instead, the fiber sheet can include only the fibers or can include fibers other than the fibers. The fibers other than the above-described fibers (that is, fibers having at least the surface mainly composed of thermoplastic resin) are not particularly limited, and the surface is not a thermoplastic resin, such as inorganic fibers, or has no melting point, and has a decomposition temperature. The fiber which has can be used.
[0021]
Examples of the structure of the fiber sheet include a woven fabric, a knitted fabric, a non-woven fabric, or a combination thereof. In the case of a woven fabric or a knitted fabric, it can be obtained, for example, by processing the fibers with a loom or a knitting machine. Moreover, in the case of a nonwoven fabric, it can be made into a fiber sheet by, for example, a conventional nonwoven fabric manufacturing method such as a dry method, a spunbond method, a melt blow method, a flash spinning method, or a wet method. In addition, the fiber web formed by these manufacturing methods is premixed with adhesive fibers and / or composite fibers in which two or more types of resins having different melting points are combined, and then the heat treatment is performed. It can be a bonded fiber sheet. Moreover, it can also be set as the fiber sheet which entangled between the said fiber webs by a mechanical entanglement process (for example, water flow entanglement or a needle punch). Alternatively, the fiber web may be passed between a heated smooth roll and a heated uneven roll to form a partially bonded fiber sheet. Moreover, it can also be set as the fiber sheet formed by laminating | stacking the said fiber sheet from which a kind differs, and further integrating.
[0022]
Further, the shape of the fiber sheet is not particularly limited, and for example, a long fiber sheet (for example, a fiber sheet wound around a roll) or a non-long fiber sheet (that is, the long fiber sheet). And the like can be obtained by cutting the fiber sheet).
[0023]
The solid particles used in the method for producing a solid particle-carrying fiber or the method for producing a solid particle-carrying fiber sheet according to the present invention have a melting point higher than the melting point of the thermoplastic resin constituting the surface of the fiber used for fixing the solid particles, or As long as it is a solid particle having a decomposition temperature, it can be either inorganic or organic, and if it is a solid particle, one or more of such particles can be appropriately selected. The solid particles may be solid particles having functionalities such as deodorization, gas removal, catalyst, water absorption, ion exchange, electromagnetic radiation, ion generation, antibacterial, flame retardant, electromagnetic shielding, soundproofing, or water / oil repellency. Thus, the function can be effectively exhibited on the fiber surface. Examples of the material for such solid particles include various materials such as activated carbon, zeolite, titanium oxide, water-absorbing resin, ion exchange resin, metal particles, tourmaline, calcium carbonate, or water-repellent resin.
[0024]
The melting point or decomposition temperature of the solid particles needs to be higher than the melting point of the resin having the lowest melting point among the resins constituting the fiber surface, and the melting point or decomposition temperature of the solid particles is the melting point of the resin. When it is lower, the fiber surface is not melted by the heat of the heated solid particles, and the solid particles are not supported on the fiber surface. In other words, even if solid particles are not supported on the fiber surface, or even if solid particles are supported on the fiber surface, the form is such that the solid particles dissolve before the fiber surface and the solid particles become aggregates, The solid particles and the fiber surface are fused in a wide area, and the effective area of the supported solid particles is small.
[0025]
The average particle diameter of the solid particles is preferably equal to or less than the fiber diameter. When the average particle diameter of the solid particles exceeds the fiber diameter, the solid particles easily fall off from the fiber surface, and it may be difficult to keep the solid particles fixed on the fiber surface. Moreover, even if it is going to obtain the fiber which such a solid particle carry | supported, it may become difficult to fix a solid particle to the fiber surface. Further, the average particle size of the solid particles is preferably 0.01 μm or more, and more preferably 0.05 μm or more.
[0026]
In addition, the average particle diameter of solid particles shall represent the number average particle diameter of solid particles. In addition, as a method for calculating the number average particle diameter, the particles are enlarged and photographed with a scanning electron microscope or the like, and the particle diameters of arbitrary 500 or more particles are measured and divided by the measured number. . At this time, if the particles are not spherical, the diameter of the circumscribed circle of each particle that can be confirmed in the image of the photographed particle is defined as the individual particle diameter.
In the case of commercially available particles, when the number average particle size is clearly shown in catalogs or specifications, the value may be used as the average particle size of the solid particles.
[0027]
In the method for producing a solid particle-carrying fiber or the method for producing a solid particle-carrying fiber sheet according to the present invention, the solid particles heated to a predetermined temperature are brought into contact with the fiber or the fiber sheet while being maintained at the predetermined temperature. In the method of bringing the heated solid particles into contact with the fiber or the fiber sheet, the solid particles can be fused to the fiber surface by the contact, and further, the solid particle fused fiber is cooled to be solid on the fiber surface. As long as the particles can be fixed, it is not particularly limited, for example,
(1) A method of spraying an air stream containing heated solid particles on the surface of a fiber or fiber sheet;
(2) A method in which the heated solid particles are naturally dropped onto the fiber or fiber sheet;
(3) A method of shaking a heat-resistant container charged with heated solid particles and fibers or fiber sheets;
(4) A method of immersing fibers or fiber sheets in heated solid particles; or
(5) Method of exposing fiber or fiber sheet in fluidized bed of heated solid particles
And so on.
[0028]
As a method of bringing the heated solid particles into contact with the fibers contained in the fiber or the fiber sheet, when using the contact method (1), that is, a method of blowing an air flow containing the heated solid particles onto the surface of the fiber or the fiber sheet, As the heated solid particle-containing air flow, a mixed air flow in which solid particles heated above the melting point of the thermoplastic resin having the lowest melting point among the thermoplastic resins constituting the fiber surface and an air flow are used.
[0029]
To prepare such a mixed airflow, for example,
(A) A method of supplying solid particles heated to a melting point or higher of a thermoplastic resin in an air flow;
(B) a method of supplying solid particles in an air current heated to a temperature equal to or higher than the melting point of the thermoplastic resin; or
(C) A method in which solid particles are supplied in an air stream and heated above the melting point of the thermoplastic resin.
And so on. Among these, according to the mixed airflow preparation method (b) or (c), the solid particles are heated above the melting point of the thermoplastic resin through the airflow heated above the melting point of the thermoplastic resin.
[0030]
In the production method of the present invention, it is necessary to heat the solid particles above the melting point of the thermoplastic resin. However, if the solid particles at an excessively high temperature are fixed to the fiber, the fiber breaks or shrinks. When the problem arises, it is preferable to heat to a temperature not exceeding 100 ° C. higher than the melting point of the thermoplastic resin, more preferably to a temperature not exceeding 50 ° C. higher than the melting point of the thermoplastic resin. .
[0031]
In the mixed airflow preparation method (a), a method of supplying solid particles heated to a temperature equal to or higher than the melting point of the thermoplastic resin to an airflow heated to a temperature equal to or higher than 50 ° C. lower than the melting point of the thermoplastic resin is preferable. In this case, when the airflow and the solid particles are mixed, there is an effect of preheating so that the temperature of the solid particles does not become lower than the melting point of the thermoplastic resin. Further, there is an effect of keeping the temperature of the solid particles so that the temperature of the solid particles does not become lower than the melting point of the thermoplastic resin before the heated solid particles collide with the fiber. If there is a problem that when a mixed airflow of airflow and solid particles is blown onto the fiber, an excessively high temperature airflow hits the fiber, causing fiber breakage or shrinkage, the melting point of the thermoplastic resin It is preferable that the air flow is heated to a temperature equal to or higher than a temperature lower by 50 ° C., and the air flow is heated to a temperature lower than the temperature of the heated solid particles.
[0032]
In the mixed airflow preparation method (b), it is preferable to supply solid particles heated to a temperature of 50 ° C. lower than the melting point of the thermoplastic resin into the airflow heated to the melting point of the thermoplastic resin or higher. In this case, when the airflow and the solid particles are mixed, there is an effect of preheating so that the temperature of the solid particles does not become lower than the melting point of the thermoplastic resin.
[0033]
In each of the mixed airflow preparation methods (a), (b), or (c) described above, the mixed airflow after the airflow and the solid particles are mixed, if necessary, may be a thermoplastic resin. It is preferable to heat above the melting point. In this case, there is an effect of keeping the temperature so that the temperature of the solid particles does not become lower than the melting point of the thermoplastic resin before the solid particles collide with the fiber.
[0034]
In order to obtain a heated air flow, for example, an air flow is generated by an air flow generating means (for example, a blower or a compressor), and then a predetermined temperature (for example, a temperature lower than a melting point of the thermoplastic resin by 50 ° C. or more by a known heating means). Or a temperature equal to or higher than the melting point of the thermoplastic resin).
In order to obtain heated solid particles, for example, a heater is attached inside and outside the solid particle supply means (for example, a hopper or a supply container), and the solid particles in the solid particle supply means are heated to a predetermined temperature (for example, thermoplasticity). Use a method of heating to a temperature 50 ° C. or higher than the melting point of the resin, or a temperature higher than the melting point of the thermoplastic resin), or a device such as a fluidized bed dryer generally used as a powder dryer Then, a method of heating the solid particles to a predetermined temperature (for example, a temperature of 50 ° C. or more lower than the melting point of the thermoplastic resin or a temperature of the melting point of the thermoplastic resin or more) can be used.
[0035]
As a method for preparing a mixed air flow by supplying solid particles to an air flow, for example, a method of supplying solid particles from a solid particle supply means (for example, a hopper or a supply container) into the air flow in a certain amount, or a fluidized bed After heating the solid particles to a temperature above the melting point of the thermoplastic resin using an apparatus such as a mold dryer, the mixed gas in which the solid particles heated in the gas are dispersed and mixed is taken out from the fluidized bed dryer. And a method of supplying the mixed gas to the airflow.
[0036]
In addition to these methods, for example, as illustrated in FIG. 2, the particle mixing means 30 is an ejector, and the air flow A generated in the blower 11 and the heating tube 12 as the air flow generating means is used as the particle mixing means. 30, the particle mixing means 30 is connected to a funnel-shaped supply container 21 as a particle supply means, a rotary supply control rotor 22 and a supply pipe 23. It is also possible to use a method of sucking solid particles supplied from the supply means and supplying the solid particles into the airflow. In this case, in the particle mixing means 30, if the cross-sectional area of the air flow C in the part to which the particles are supplied is made smaller than the cross-sectional area before and after that to speed up the air flow, the suction force works strongly and the solid particles are dispersed and mixed. The effect can be increased.
[0037]
Further, for example, as illustrated in FIG. 3, the particle mixing unit 30 is an ejector, and the air flow A generated by the blower 11 and the heating tube 12 as the air flow generation unit is sent to the particle mixing unit 30 to mix the particles. The means 30 is supplied with a mixed gas in which solid particles are dispersed and mixed in a heated gas from a fluidized bed dryer 24 which is a particle supply means, and the mixed gas supplied from the particle supply means 24 by the suction force generated by the airflow A is supplied. A method of sucking and supplying solid particles in an air stream can also be used.
[0038]
In the method for producing a solid particle-carrying fiber or the method for producing a solid particle-carrying fiber sheet according to the present invention, as a method for bringing the heated solid particles into contact with the fiber or the fiber contained in the fiber sheet, the contact method (1), that is, heating When using a method in which an air flow containing solid particles is sprayed onto the surface of a fiber or fiber sheet, the mixed air flow obtained as described above (that is, the thermoplastic resin having the lowest melting point among the thermoplastic resins constituting the fiber surface). A mixed air stream containing solid particles heated to a temperature equal to or higher than the melting point of the resin is sprayed on the surface of the fiber or fiber sheet. Prior to spraying, the temperature of the fiber or fiber sheet surface is preferably less than the melting point of the thermoplastic resin.
[0039]
As a method of spraying on the surface of the fiber or the fiber sheet, for example, as shown in FIG. 2 or FIG. 3, when a mixed air stream containing solid particles is ejected from the nozzle 41 as the ejection means, the solid particles are given at the time of ejection. It collides with the fiber surface due to the inertial force caused by the kinetic energy. The ejection means can be connected directly to the particle mixing means 30 or can be connected via a connecting pipe, for example. The nozzle may have a shape suitable for ejecting fluid. For example, the flow path may be narrowed to increase the inertial force of the solid particles, or the tip of the nozzle may be widened to increase the ejection angle of the solid particles. It is also preferable to use a nozzle material that is less likely to be worn or the like depending on the solid particles ejected from the nozzle.
[0040]
When the method of spraying heated solid particle-containing airflow onto the fiber or fiber sheet surface is used as a method of contacting the heated solid particles and the fibers contained in the fiber or fiber sheet, by a movable fiber support means or fiber sheet support means It is preferable to spray an air stream containing heated solid particles on the supported fiber or fiber sheet. Such a supporting means is not particularly limited as long as it can be sprayed by a heated solid particle-containing air flow. Preferable examples include, for example, a rotating roll on which a fiber or fiber sheet is placed before and after a treatment region of spraying with a heated solid particle-containing air stream, and a tenter system that moves while gripping both sides of the fiber or fiber sheet with a pin or grip And an opening support (for example, a conveyor net or the like) that can be sprayed while placing the fiber or fiber sheet. In addition, according to a conveyor net etc., a some fiber can also be supported simultaneously.
[0041]
In addition, when the heated solid particle-containing air current is sprayed on the fiber or fiber sheet supported by the supporting means, a plurality of heating solid particle-containing air current ejecting means are installed in order to uniformly spray the fiber or fiber sheet in the width direction. It is also possible to provide a plurality of nozzle holes provided in the ejection means. Moreover, it is also possible to make the nozzle hole into a slit shape so that the tip of the nozzle is widened to the full width of the fiber sheet. Further, if the ejecting means is reciprocally movable substantially parallel to the width direction of the fiber sheet and at a right angle or an angle with respect to the traveling direction, the entire fiber sheet can be obtained even if the number of ejecting means is small. Can be processed.
[0042]
Furthermore, it is preferable that after the heated solid particle-containing air stream is sprayed on the fiber or fiber sheet, excess solid particles that have not adhered to the fiber or fiber sheet are recovered, and the recovered solid particles are reused. As such a recovery method, for example, as illustrated in FIG. 2 or FIG. 3, the atmosphere in which the heated solid particle-containing air flow is blown to the fiber 80 or the fiber sheet 80 ′ is surrounded by the fixing treatment chamber 90, and excess solids are contained. The particles are prevented from scattering out of the fixing processing chamber 90, and a particle recovery box 92 as a particle recovery means is connected to the fixing processing chamber 90, and excess solid particles are recovered by the particle recovery box 92. The method of doing can be mentioned. Also, in order to remove excess solid particles that did not adhere to the fiber or fiber sheet, for example, a method using particle recovery means 93 of a system in which the conveyor net is tilted and dropped by vibration or blown off by an air flow is used in combination. It is also possible to do.
[0043]
As a method of cooling the solid particle fusion fiber after bringing the solid particle into contact with the fiber surface to obtain a solid particle fusion fiber, as long as the solid particle can be cooled to a temperature at which the solid particle can be fixed to the fiber surface, Although not particularly limited, for example, a method of leaving at room temperature or a method of using an appropriate cooling means as required can be given.
[0044]
When any one of the contact methods (2) to (5) is used as a method for bringing the heated solid particles into contact with the fibers or the fibers contained in the fiber sheet, the solid particles are heated in advance, and then various It is made to contact with the fiber contained in a fiber or a fiber sheet by the contact method of this.
As a method for heating the solid particles, for example, the solid particles are put in a heat-resistant container and heated in an oven, or the solid particles are placed on a heat-resistant conveyor and the heater at the top of the conveyor is moved while moving the conveyor. The method of using and heating continuously etc. can be mentioned. As a method for heating the solid particles, any heating method can be used as long as the whole solid particles can be heated. The heating temperature at this time is the most among the thermoplastic resins constituting the fiber surface. It is necessary to heat higher than the melting point of the thermoplastic resin having a low melting point.
[0045]
Next, as a method for bringing the heated solid particles into contact with the fibers contained in the fibers or the fiber sheet, at least a fiber whose surface is mainly composed of a thermoplastic resin, or a fiber sheet having fibers whose surface is mainly composed of a thermoplastic resin. There is no particular limitation as long as the heated solid particles can be brought into contact with each other while maintaining the temperature at room temperature or lower than the melting point of the fiber surface as necessary, and any contact method can be used. As such a contact method, for example, a method in which fibers or fiber sheets are placed on a conveyor and solid particles are naturally dropped (for example, dispersed) from the upper part of the conveyor [that is, the contact method (2)], a fiber in a container is used. Alternatively, the fiber sheet is put together with solid particles and the container is shaken [that is, the contact method (3)], or the fiber or fiber sheet is immersed in a layer of solid particles [that is, the contact method (4)]. Alternatively, a method of exposing a fiber or a fiber sheet in a fluidized bed of solid particles [namely, the contact method (5)] can be exemplified.
[0046]
For example, in the contact method (2), that is, the method in which the heated solid particles are naturally dropped onto the fiber or fiber sheet, for example, it is placed on a heat-resistant conveyor that moves the fiber or fiber sheet, and then the upper part of the conveyor For example, by spraying the heated solid particles, for example, the heated solid particles come into contact with the fiber surface, and at the same time, the heated solid particles are held in a state where only the contact point of the thermoplastic resin on the fiber surface is dissolved. To do. Next, it is allowed to stand at room temperature or, if necessary, cooling means is blown from the upper part of the conveyor, for example, cooling air to cool the fiber or fiber sheet and solid particles, and the solid particles are fixed to the fiber surface. Let Next, the solid particles that have not adhered to the solid particle-supporting fiber or the solid particle-supporting fiber sheet are removed by an appropriate solid particle removing means, for example, by tilting the conveyor and dropping it by vibration or blowing it with an air current. To do.
[0047]
In the contact method (3), that is, a method of shaking a heat-resistant container charged with heated solid particles and fibers or fiber sheets, for example, the fibers or fiber sheets are placed in a heat-resistant container, Put the heated solid particles into the container, close the lid of the container, shake the entire container, and the heated solid particles come into contact with the fiber surface at the same time, the heated solid particles contact the thermoplastic resin on the fiber surface Make sure that only the points are melted. Next, the fiber or fiber sheet is taken out from the container quickly, and the fiber or fiber sheet is cooled to fix the solid particles to the fiber surface. Next, the solid particles not fixed to the solid particle-supporting fiber or the solid particle-supporting fiber sheet are removed by an appropriate removing means such as water washing.
[0048]
According to the production method of the present invention (including both the production method of the solid particle-carrying fiber according to the present invention and the production method of the solid particle-carrying fiber sheet according to the present invention), the heated solid particles are brought into contact with the fiber surface. Only the portion where the solid particles are in contact with the fiber surface is melted to carry the solid particles. Therefore, it is very rare that the molten resin covers the surface portion of the solid particles other than the contact portion or the surface portion other than the fixed portion. In addition, solid particles are rarely buried by melting and fluidizing the entire resin on the fiber surface.
In addition, the molten resin oozes out from the gaps between the contacted solid particles, the solid particles outside the solid particles are also fixed, and the solid particles partially become a multilayer on the fiber surface. There is no problem that the solid particles are not uniformly supported. Furthermore, in some cases, uniform, single-layer fixation or support is possible.
[0049]
Further, according to the production method of the present invention, since the solid particles melt only the fiber surface, even if the fiber is a fiber composed of a single resin component, the fiber shrinks during the contact treatment or the fixing treatment, The entire fiber melts and yarn breakage does not occur. In addition, there is an advantageous effect that thermal degradation of the entire fiber and thermal degradation of the fiber surface does not occur, or if it occurs, it can be reduced.
Furthermore, after the solid particles are brought into contact with the fiber surface and then cooled, the solid particles are firmly fixed and supported on the fiber surface. For example, the solid particles may easily fall off in a washing resistance test. Absent.
[0050]
Moreover, in the manufacturing method of this invention, as a method of contacting a heating solid particle and the fiber contained in a fiber or a fiber sheet, the said contact method (1), ie, a heating solid particle containing airflow, is sprayed on a fiber or a fiber sheet surface. When the method is used, the air flow containing heated solid particles is blown onto the fiber surface, so that the solid particles collide with the fiber surface due to the inertial force of the solid particles, and the solid particles firmly adhere to the fiber surface. can do.
[0051]
On the other hand, according to the conventional method, the solid particles are brought into contact with the binder or the heated and melted fiber, so that the binder or the molten resin covers the surface portion of the solid particles other than the contact portion or the fixed portion. Moreover, the binder and molten resin on the fiber surface are fluidized and the solid particles are buried. Also, the binder or molten resin oozes out from the gap between the contacted solid particles, and the solid particles outside the solid particles are also fixed, so that the solid particles partially become a multilayer on the fiber surface. This causes a problem that the solid particles are not fixed or supported uniformly. For this reason, in the conventional method, after the solid particles are fixed or supported on the fiber surface, the surface functions inherent to the solid particles cannot be sufficiently exhibited. In addition, according to the conventional method, the entire fiber is heated to melt the surface. Therefore, when the fiber is made of a single resin component, the fiber shrinks during the contact treatment or the fixing treatment, or the entire fiber melts. As a result, thread breakage occurs.
[0052]
[2] Apparatus for producing solid particle-carrying fiber or solid particle-carrying fiber sheet according to the present invention The apparatus for producing solid particle-carrying fiber according to the present invention includes at least particle forming means, ejection means, heating means, and fiber support means, The particle forming means includes, for example, an airflow generating means, a particle supplying means, and a particle mixing means.
The solid particle-supporting fiber sheet manufacturing apparatus according to the present invention includes at least particle forming means, jetting means, heating means, and fiber sheet supporting means, and the particle forming means includes, for example, an air flow generating means, a particle supplying means, And particle mixing means.
[0053]
FIG. 1 shows a basic configuration of a solid particle-carrying fiber manufacturing apparatus according to the present invention and a solid particle-carrying fiber sheet manufacturing apparatus according to the present invention.
The manufacturing apparatus of the present invention shown in FIG. 1 uses a fiber 80 as an object to be treated, and uses a fiber support means 70 capable of supporting the fiber 80 as an object to be treated support means. It can be used as an apparatus for producing particle-supporting fibers. Further, by using the fiber sheet 80 ′ as the object to be processed and the fiber sheet supporting means 70 ′ capable of supporting the fiber sheet 80 ′ as the object to be processed, the solid particle-supporting fiber according to the present invention is used. It can be used as a sheet manufacturing apparatus. Hereinafter, the manufacturing apparatus of the present invention will be described mainly using the case where the apparatus is used as a manufacturing apparatus for solid particle-supporting fibers.
[0054]
The solid particle-carrying fiber manufacturing apparatus according to the present invention shown in FIG. 1 includes an airflow generating means 10 for generating an airflow; a particle supplying means 20 for supplying solid particles; and the airflow generating means 10 and the particle supplying means 20. The airflow generated by the airflow generation means 10 is sent to each other, and the solid particles are supplied into the airflow sent by the particle supply means 20, whereby the airflow and the solid particles are A particle mixing means 30 capable of forming a mixed airflow by mixing; an ejection means 40 communicating with the particle mixing means 30 and ejecting a solid particle-containing airflow formed by the particle forming means 30; and the airflow generation The heating means 50 and 51 provided in the means 10, the particle supply means 20, the particle mixing means 30 and the ejection means 40, respectively. 52, 53 and; and a fiber support means 70 which can be solid particles containing stream ejected from the ejection means 40 is to hold the fibers 80 in the contactable position with the fiber surface.
[0055]
In the embodiment shown in FIG. 1, the heating means 50, 51, 52, 53 are provided on all of the airflow generation means 10, the particle supply means 20, the particle mixing means 30, and the ejection means 40, respectively. In the manufacturing apparatus of the invention, as long as an air stream containing heated solid particles heated to a temperature higher than the melting point of the thermoplastic resin on the fiber surface can be formed, the air flow generating means 10, the particle supplying means 20, the particle mixing means 30. , And at least one of the ejection means 40 may be provided with a heating means.
Further, instead of the fiber support means 70, a fiber sheet support means 70 ′ capable of holding the fiber sheet 80 ′ at a position where the solid particle-containing air stream ejected from the ejection means 40 can come into contact with the fiber sheet surface. By providing, the manufacturing apparatus shown in FIG. 1 can be made into the manufacturing apparatus of the solid particle carrying | support fiber sheet by this invention.
[0056]
The heating means 50, 51, 52 and 53 are heating means capable of controlling the temperature above the melting point of the thermoplastic resin so that the heating means 50, 51, 52 and 53 can be heated above the melting point of the thermoplastic resin. If there is a problem that excessively high temperature solid particles adhere to the fiber and cause fiber breakage or shrinkage, the temperature can be controlled within a temperature range that does not exceed 100 ° C above the melting point of the thermoplastic resin. It is preferable that the heating means be capable of heating, and it is more preferable that the heating means be capable of temperature control within a temperature range that does not exceed 50 ° C. higher than the melting point of the thermoplastic resin. By such heating means 50, 51, 52, 53, a mixed air stream in which solid particles heated above the melting point of the thermoplastic resin having the lowest melting point and the air stream are mixed among the thermoplastic resins constituting the fiber surface. It can be.
[0057]
For example, if the heating means 51 is attached to the particle supply means 20, solid particles heated to the melting point of the thermoplastic resin or more can be supplied into the airflow. Further, if the heating means 50 is attached to the airflow generation means 10, the solid particles are thermoplasticized via the heated airflow by supplying the solid particles into the airflow heated above the melting point of the thermoplastic resin. It can be heated above the melting point of the resin. Further, if the heating means 52 is attached to the particle mixing means 30 or the heating means 53 is attached to the ejection means 40, the mixed air stream supplied with solid particles in the air stream is converted into the melting point of the thermoplastic resin. By heating to the above, the solid particles can be heated to the melting point or higher of the thermoplastic resin through the heated airflow.
[0058]
The heating means 50, 51, 52, and 53 need to be attached to at least one of the airflow generation means 10, the particle supply means 20, the particle mixing means 30, and the ejection means 40. Attaching to two or more means is preferable because a preheating effect and a heat retaining effect can be obtained. For example, if the heating means 51 is attached to the particle supply means 20 and the heating means 50 is further attached to the airflow generation means 10, the temperature of the solid particles is increased when the airflow and the solid particles are mixed. There is an effect of preheating so as not to be lower than the melting point of the plastic resin. In addition, there is an effect of keeping the temperature of the solid particles so that the temperature of the solid particles does not become lower than the melting point of the thermoplastic resin before the heated solid particles collide with the fiber. Further, for example, if the heating means 51 is attached to the particle supply means 20 and the heating means 52 is further attached to the particle mixing means 30, the solid particles are heated before the heated solid particles collide with the fibers. There is an effect of keeping the temperature so that the temperature does not become lower than the melting point of the thermoplastic resin.
[0059]
Thus, when the said heating means 50, 51, 52, 53 are attached to two or more means, each heating means can be controlled by mutually different temperature in the temperature range more than melting | fusing point of a thermoplastic resin. It may be preferable. For example, in the case where the heating means 51 is attached to the particle supply means 20, if a mixed airflow of airflow and solid particles is blown onto the fibers, an excessively high temperature airflow hits the fibers and the fibers break or shrink. When the problem of causing the problem occurs, the heating means 51 is attached to the particle supply means 20, and the heating means 50 is further attached to the airflow generation means 10, and the temperature of the heating means 50 is set to the temperature of the heating means 51. The above problem can be solved by keeping it lower than the above.
[0060]
In the production apparatus of the present invention, at least one of the airflow generation means 10, the particle supply means 20, the particle mixing means 30, and the ejection means 40 has solid particles and / or airflow that is 50 ° C. lower than the melting point of the thermoplastic resin. Auxiliary heating means 60, 61, 62, 63 that can be controlled to a temperature that is equal to or higher than the temperature and lower than the melting point of the resin can be attached. By attaching such auxiliary heating means 60, 61, 62, 63 in addition to the heating means 50, 51, 52, 53, the above-mentioned preheating effect can be obtained. Further, for example, in the case where the heating means 51 is attached to the particle supply means 20, if a mixed airflow of airflow and solid particles is blown onto the fiber, the airflow of excessively high temperature hits the fiber and the fiber breaks. If the problem of causing shrinkage occurs, the heating means 51 is attached to the particle supply means 20, and the auxiliary heating means 60 is further attached to the airflow generation means 10 to solve the problem. it can.
[0061]
Another aspect of the production apparatus of the present invention is shown in FIGS. 2 and 3, respectively. Also in each aspect shown in FIG. 2 or FIG. 3, the fiber support means 70 which can use the fiber 80 as a to-be-processed object and can support the fiber 80 as a to-be-processed object support means similarly to the aspect shown in FIG. Can be used as an apparatus for producing a solid particle-supporting fiber according to the present invention. Further, by using the fiber sheet 80 ′ as the object to be processed and the fiber sheet supporting means 70 ′ capable of supporting the fiber sheet 80 ′ as the object to be processed, the solid particle-supporting fiber according to the present invention is used. It can be used as a sheet manufacturing apparatus.
[0062]
In the embodiment shown in FIG. 2, the airflow generated by the blower 11 as the airflow generation means is sent to the heating pipe 12 as the airflow generation means, and the fiber surface is constituted by the heating means 50 attached to the heating pipe 12. The thermoplastic resin is heated at a temperature a ° C. which is equal to or higher than the melting point of the thermoplastic resin having the lowest melting point. The heated airflow A is sent to the particle mixing means 30. The particle mixing means 30 is in communication with a particle supply means comprising a funnel-shaped supply container 21, a rotary supply control rotor 22, and a supply pipe 23. In addition, the particle supplying means is attached to the outside of the particle supplying means with a heating means 51 capable of heating the solid particles 29 to the melting point of the thermoplastic resin or higher. Thus, the solid particles 29 heated to a temperature b ° C. (b ° C. ≧ a ° C.) equal to or higher than the melting point of the thermoplastic resin are in the heated airflow flowing through the particle mixing means 30 from the supply pipe 23. In the particle mixing means 30, a mixed air stream is formed in which the air stream and the solid particles 29 heated to the melting point of the thermoplastic resin or more are mixed.
[0063]
In the embodiment shown in FIG. 2, the particle mixing means 30 has a structure for sucking the solid particles 29 supplied from the supply pipe 23 into the airflow C using the suction force generated by the airflow A. Further, the supply passage of the solid particles 29 is formed at a right angle or a certain angle with respect to the direction of the air flow C, and the cross-sectional area of the air flow C in the portion 31 intersecting with the supply passage is after or before and after that. It is smaller than the cross-sectional area. Therefore, the speed of the airflow is increased in this portion 31, the suction force works strongly, and the effect of dispersing and mixing solid particles can be increased. The solid particle flow B and the air flow C may be in the same direction.
[0064]
On the other hand, in the embodiment shown in FIG. 3, the air flow A generated by the blower 11 and the heating pipe 12 as the air flow generating means is fed into the particle mixing means 30, and at the same time from the fluidized bed dryer 24 as the particle supplying means. A mixed gas in which the solid particles 29 are dispersed and mixed in the heated gas is sent. At this time, the mixture gas supplied from the fluidized bed dryer 24 is sucked into the airflow C by using the suction force generated by the airflow A.
[0065]
In each aspect shown in FIG. 2 or FIG. 3, the mixed airflow is sent to a nozzle 41 as an ejection means connected to the particle mixing means 30 and ejected from the nozzle 41. At the tip of the nozzle 41, a roll 70 as a fiber support means, or a fiber 80 or a fiber sheet 80 'supported so as to be movable by a roll 70' as a fiber sheet support means is arranged. Solid particles ejected from the nozzle 41 as a mixed air current are sprayed onto the fiber surface of the fiber 80 or the fiber sheet 80 ′.
[0066]
In each aspect shown in FIG. 2 or FIG. 3, the atmosphere in which the solid particles 29 are sprayed on the fibers 80 or the fiber sheet 80 ′ is surrounded by the fixing processing chamber 90, and the excess solid particles 29 are not scattered outside the fixing processing chamber 90. I am doing so. In addition, a particle recovery box 92 that is a particle recovery means is connected to the fixing processing chamber 90, and the structure is such that excess solid particles 29 are recovered by the particle recovery box 92. Furthermore, in order to remove and collect excess solid particles 29 that have not adhered to the fiber or fiber sheet, a particle collecting means 93 of a system that blows away with an air current is provided. In each mode shown in FIG. 2 or FIG. 3, for example, it is also possible to use a method in which the fiber sheet support means is a conveyor net, the conveyor net is inclined and dropped by vibration.
[0067]
In each aspect shown in FIG. 2 or FIG. 3, the fixing processing chamber 90 is provided with an indoor heating means 91 for heating the gas in the chamber. By heating the indoor gas to a temperature not exceeding the melting point of the thermoplastic resin having the lowest melting point among the thermoplastic resins constituting the fiber surface of the fiber 80 or the fiber sheet 80 ′ by the indoor heating means 91, the fiber The solid particles 29 can be fixed to the 80 or the fiber sheet 80 ′.
[0068]
In the embodiment shown in FIG. 2, heating means 51 that can heat the solid particles 29 to the melting point of the resin or higher is attached to the supply container 21, the supply control rotor 22, and the supply pipe 23 as the particle supply means. . Moreover, in the aspect shown in FIG. 3, the heating means 50 is attached to the heating tube 12 as an airflow generation means. As described above, the heating means is attached to at least one of the particle supply means, the airflow generation means, the particle mixing means, and the ejection means, and the solid particles are directly heated or the airflow A or the airflow C is heated. Through this, it is possible to heat above the melting point of the thermoplastic resin. Further, in the embodiment shown in FIG. 2, by providing the auxiliary heating means 60, 61, 62, the supply container 21 as the particle supply means, the supply control rotor 22, the supply pipe 23, the heating pipe 12 as the airflow generating means, In addition, the particle mixing means 30 and the like can be set to a temperature equal to or higher than a temperature lower by 50 ° C. than the melting point of the thermoplastic resin.
[0069]
In the embodiment shown in FIG. 2, the particle mixing means 30 is connected to a particle supply means comprising a funnel-shaped supply container 20, a rotary supply control rotor 21, and a supply pipe 22. For example, as illustrated in FIG. 3, in the fluidized bed dryer 24, the thermoplastic resin constituting the fiber surface has a melting point equal to or higher than the melting point of the thermoplastic resin having the lowest melting point. After the solid particles 29 are heated to the temperature, the mixed gas in which the solid particles 29 are dispersed and mixed in the heated gas is taken out from the fluidized bed dryer 24, and this mixed gas is sent to the particle mixing means 30, and the solid particles 29 are flown through the air flow. The method of supplying to can also be used.
[0070]
In each mode shown in FIG. 2 or FIG. 3, the nozzle 41 having a narrowed tip as the ejection means is directly connected to the particle mixing means 30, but it can also be connected via a connecting pipe. In addition, the nozzle 41 has such a narrowed flow path in order to increase the inertial force of the solid particles 29, or a shape in which the tip of the nozzle is widened to widen the ejection angle of the solid particles 29. It can be set as the shape suitable for fluid ejecting. Further, it is also preferable to use a nozzle material that is less likely to be worn or the like according to the solid particles 29 ejected from the nozzle 41.
[0071]
2 or 3, when the solid particles 29 are sprayed on the fiber 80 or the fiber sheet 80 ′ supported by the roll 70 that is the fiber support means or the roll 70 ′ that is the fiber sheet support means, the fibers 80 or the fibers In order to uniformly spray the sheet 80 ′ in the width direction (with respect to the traveling direction E), a plurality of nozzles 41 as the ejection means for the solid particles 29 may be installed, or a plurality of nozzle holes provided in the ejection means may be provided. Is possible. Moreover, it is also possible to make the nozzle hole into a slit shape, and to make the tip of the nozzle 41 widen to the full width of the fiber sheet 80 ′. Further, if the ejecting means can be moved back and forth substantially parallel to the width direction of the fiber sheet 80 ′ and at a right angle or a certain angle with respect to the traveling direction E, the nozzle 41 as the ejecting means can be provided. Even with a small number, the entire fiber sheet 80 'can be processed.
[0072]
In each aspect shown in FIG. 2 or FIG. 3, the nozzle 41 is provided on the fiber surface of the fiber 80 or the fiber sheet 80 ′ that is movably supported by the roll 70 that is the fiber support means or the roll 70 ′ that is the fiber sheet support means. Solid particles 29 ejected as a mixed airflow are sprayed. Such a support means is not particularly limited as long as it can be sprayed with solid particles. Preferable examples include, for example, a tenter type apparatus that moves while holding both sides of a fiber or a fiber sheet with a pin or a grip before and after the treatment region of spraying with solid particles, and a counter roll that supports the fiber or the fiber sheet with a sandwich Alternatively, an opening support such as a conveyor net that can be sprayed while placing fibers or fiber sheets can be used.
[0073]
[3] Solid particle carrying fiber and solid particle carrying fiber sheet of the present invention
The solid particle-carrying fiber of the present invention is a fiber that carries solid particles on the surface of at least a fiber mainly composed of a thermoplastic resin, and the melting point or decomposition temperature of the solid particles is higher than the melting point of the thermoplastic resin. The average particle diameter of the solid particles is 1/3 or less of the average diameter of the fibers, and is supported on the fiber surface with respect to the total surface area (Sp) of the solid particles before being supported on the fiber surface by the BET method. The effective surface area ratio [(Se / Sp) × 100], which is a percentage of the exposed surface area (Se) of the solid particles by the BET method, is 50% or more.
The solid particle-carrying fiber of the present invention can be produced, for example, by the method for producing a solid particle-carrying fiber according to the present invention.
[0074]
The solid particle-supporting fiber of the present invention is a fiber that supports solid particles on the surface of a fiber whose surface is mainly composed of a thermoplastic resin. With regard to the “fibers mainly composed of thermoplastic resin at least on the surface”, the description regarding “fibers mainly composed of thermoplastic resin at least on the surface” described above in the production method of the present invention is applied as it is. That is, the type of fiber is not limited as long as it is a fiber whose surface is mainly composed of a thermoplastic resin and the fiber surface is melted by heating (for example, heating at 50 ° C. or higher, preferably 80 ° C. or higher). It can be selected appropriately. Examples of such fibers include synthetic fibers obtained by melt spinning, which is a conventional fiber production method, fibers obtained by a spunbond method, melt blow method, flash spinning method, etc., which are conventional nonwoven fabric production methods, or core portions. It can be appropriately selected from fibers made of natural fibers or inorganic fibers.
[0075]
As the solid particles supported on the solid particle-supporting fiber of the present invention, the solid particles used in the production method of the present invention can be used as they are except for the average particle diameter.
The average particle diameter of the solid particles supported on the solid particle-supporting fiber of the present invention needs to be 1/3 or less of the fiber diameter. When the average particle diameter of the solid particles exceeds 1/3 of the fiber diameter, the solid particles easily fall off from the fiber surface, and it is difficult to keep the solid particles fixed on the fiber surface. Moreover, even if it is intended to obtain a fiber carrying such solid particles, it is difficult to fix the solid particles to the fiber surface. The average particle size of the solid particles represents the number average particle size of the solid particles.
[0076]
The effective surface area ratio (Ep) of the solid particles in the solid particle-supporting fiber of the present invention is 50% or more when evaluated by specific surface area measurement by the BET (BRUNAURE EMMET TELLER) method. The effective surface area ratio is the surface area of the exposed surface of the solid particles supported on the fiber surface by the BET method [exposed surface area (Se)] and the surface area of the solid particles in the state before being supported on the fiber surface by the BET method [ The surface area (Sp) of the entire particle] is compared with the ratio of the former to the latter (Se / Sp) as a percentage. If the effective surface area ratio is 50% or more, even after the solid particles are supported on the fiber surface, the surface of the solid particles themselves is maintained to such an extent that the surface functions of the solid particles can be sufficiently exhibited. Is shown. On the other hand, if the effective surface area ratio is less than 50%, after the solid particles are supported on the fiber surface, the surface inherent to the solid particles themselves is maintained to such an extent that the surface functions of the solid particles can be sufficiently exhibited. It has not been shown.
[0077]
The BET method is a theoretical formula obtained by extending the Langmuir monomolecular adsorption layer to a multimolecular adsorption layer. The molecules are stacked and adsorbed infinitely. In this specification, the boiling point of liquid nitrogen − The specific surface area is determined from the adsorption isotherm of nitrogen gas or krypton gas at 195.8 ° C.
[0078]
The effective surface area ratio Ep (%) is calculated as follows. However, it is calculated on the assumption that there is no change in the surface area of the fiber before and after supporting the solid particles. In this calculation, the mass W (g / g) converted per 1 g of fiber mass is used as the mass of the solid particles and the solid particle-supporting fibers.

Ep: Effective surface area ratio of solid particles (%)
Se: exposed surface area of solid particles by BET method
Sp: Surface area of the entire solid particle by the BET method
Sc: Surface area of BET method of solid particle-supporting fiber
Sf: Surface area of fiber before carrying solid particles by BET method
Sc = Soc × Wc
Soc: specific surface area (m ² / G)
Wc: Mass of solid particle-supporting fiber composed of 1 g of fiber (g / g)
[In other words, the mass (g / g) of the solid particle-supporting fiber per 1 g of fiber]
Sf = Sof × Wf
Sof: specific surface area of fiber by BET method (m ² / G)
Wf: mass of fiber per g of fiber (g / g)
[I.e., mass of fiber per gram of fiber (g / g)]
= 1 (g / g)
Sp = Sop × Wp
Sop: specific surface area (m ² / G)
Wp: Amount of solid particles supported on 1 g of fiber (g / g)
[Ie, mass of solid particles per gram of fiber (g / g)]
= (Wc-1) (g / g)
[0079]
As for the calculation method of the specific surface area of the fiber, when the fiber is not porous and the value of the fiber diameter / fiber length is 0.01 or less, the cross-sectional area of the fiber is almost negligible. From the relationship between the side area of the fiber and the density of the fiber material, for example, as shown below, the specific surface area of the fiber can be calculated and replaced with the specific surface area of the fiber by the BET method.

Ff: Fiber length
Rf: average fiber diameter
Df: density of the fiber material
[0080]
The solid particle-supporting fiber of the present invention preferably has a solid particle retention rate of 80% or more after the washing resistance test, more preferably 90% or more. That is, as an application of the solid particle-supporting fiber or the solid particle-supporting fiber sheet, in the case where the solid particles fall off, the solid particles fixed to the fiber surface after the washing resistance test are more preferably 80% or more. Is preferably maintained at 90% or more. When the solid particle retention rate is 80% or less, dropping occurs during use, and the human body may be harmed by sucking the solid particles. Moreover, in the case of the use which makes an airflow contact a fiber or a fiber sheet like a filter, the dust generation derived from the supported solid particle will arise from a fiber or a fiber sheet. Further, when the abrasive particles are supported on fibers or fiber sheets and used as an abrasive, if the support of solid particles is too weak, there arises a problem that the polishing ability is low and the necessary polishing force cannot be obtained. When used in such applications, the solid particle retention is preferably 80% or more.
[0081]
In this specification, the washing | cleaning tolerance test of a solid particle carrying fiber can be implemented by the procedure shown below, for example.
That is, the solid particle-supporting fibers are cut into a length of about 10 cm, 100 to 300 are aligned, and both ends are fixed with clips to form a fiber bundle. Next, the fiber bundle is placed in a laundry net having a length and width of 10 cm × 10 cm to form a test specimen. When the solid particle-supporting fiber has a length of 10 cm or less, a fiber lump of an amount corresponding to a total length of 10 to 30 m is put in a laundry net having a degree of coarseness that does not allow the fiber to come out. Let it be the body.
[0082]
Next, 40 liters of water having a temperature of about 40 ° C. is placed in a two-tank washing machine for home use, and 20 g of household laundry detergent is added thereto, and the mixture is thoroughly stirred to dissolve the detergent. Washing operation is performed by adding one test piece and a necessary number of cotton cloths as load cloths to the washing liquid so that the bath ratio is 40: 1. In the washing operation, stirring is performed for 15 minutes in the rotation direction only in the positive direction. Then, rinse with water for 15 minutes, then dehydrate the test piece for 3 minutes with the dehydrator attached to the washing machine, then remove the test piece from the washing machine and leave the removed test piece at room temperature. Let dry naturally. Next, the mass of the dried test piece is measured, and compared with the mass of the test piece before washing, the degree to which the supported solid particles drop off is examined, and the solid particle retention rate is determined from the mass of the remaining solid particles. Ask.
[0083]
The solid particle-carrying fiber of the present invention is produced, for example, by using solid particles having an average particle diameter of 1/3 or less of the average diameter of the fiber as solid particles in the method for producing a solid particle-carrying fiber according to the present invention. can do.
[0084]
The solid particle-carrying fiber sheet of the present invention is not particularly limited as long as the fiber sheet includes at least the solid particle-carrying fiber of the present invention, and can include only the solid particle-carrying fiber of the present invention. Alternatively, fibers other than the solid particle-supporting fiber of the present invention can be included. The fiber other than the solid particle-supporting fiber is not particularly limited, and at least the surface is a fiber mainly composed of a thermoplastic resin, or the surface is not a thermoplastic resin, for example, an inorganic fiber or has a melting point. It can also be a fiber having a decomposition temperature.
[0085]
Examples of the structure of the fiber sheet include a woven fabric, a knitted fabric, a non-woven fabric, or a combination thereof. In the case of a woven fabric or a knitted fabric, it can be obtained, for example, by processing the fibers with a loom or a knitting machine. Moreover, in the case of a nonwoven fabric, it can be made into a fiber sheet by, for example, a conventional nonwoven fabric manufacturing method such as a dry method, a spunbond method, a melt blow method, a flash spinning method, or a wet method. In addition, the fiber web formed by these manufacturing methods is premixed with adhesive fibers and / or composite fibers in which two or more types of resins having different melting points are combined, and then the heat treatment is performed. It can be a bonded fiber sheet. Moreover, it can also be set as the fiber sheet which entangled between the said fiber webs by a mechanical entanglement process (for example, water flow entanglement or a needle punch). Alternatively, the fiber web may be passed between a heated smooth roll and a heated uneven roll to form a partially bonded fiber sheet. Moreover, it can also be set as the fiber sheet formed by laminating | stacking the said fiber sheet from which a kind differs, and further integrating.
[0086]
As a method for obtaining the solid particle-supporting fiber sheet of the present invention, for example, a method obtained by forming the fiber sheet containing the solid particle-supporting fiber of the present invention as described above, or no solid particle-supporting fiber is included. Examples thereof include a method of carrying solid particles by using the method for producing a solid particle-carrying fiber sheet according to the present invention after forming a fiber sheet in advance. Thus, since the solid particle carrying | support fiber sheet of this invention has a solid particle carrying fiber in a fiber sheet, this fiber sheet is suitable for various uses, such as a filter material, an absorber, or a cover material. By adopting the form, the surface function of the solid particles carried by the solid particle carrying fibers can be more effectively exhibited.
[0087]
The washing resistance test of the solid particle-supporting fiber sheet of the present invention can be carried out, for example, by the following procedure.
That is, 40 liters of water at about 40 ° C. is put into a household two-tank washing machine, 20 g of household laundry detergent is added thereto, and the mixture is stirred well to dissolve the detergent. Washing operation is performed by adding 3 sheets of test pieces of 10 cm × 10 cm in the vertical and horizontal directions and a necessary number of cotton cloths as load cloths to the washing liquid so that the bath ratio is 40: 1. In the washing operation, stirring is performed for 15 minutes in the rotation direction only in the positive direction. Then, rinse with water for 15 minutes, then dehydrate the test piece for 3 minutes with the dehydrator attached to the washing machine, then remove the test piece from the washing machine and leave the removed test piece at room temperature. Let dry naturally. Next, the mass of the dried test piece is measured, and compared with the mass of the test piece before washing, the degree to which the supported solid particles drop off is examined, and the solid particle retention rate is determined from the mass of the remaining solid particles. Ask.
[0088]
【Example】
EXAMPLES Hereinafter, the present invention will be specifically described by way of examples, but these do not limit the scope of the present invention.
[Example 1]
According to the paper making apparatus, the core component is made of polypropylene resin, and the sheath component is made of 100% core-sheath type composite fiber (fineness = 2.2 decitex, fiber length = 10 mm) made of high-density polyethylene resin (melting point = 132 ° C.). A paper sheet was prepared. Next, this paper sheet is placed on a metal mesh conveyor belt, and the high density polyethylene fiber, which is an adhesive component of the composite fiber, is melted in an air-through dryer at a temperature of 140 ° C. Thermal bonding treatment was performed to obtain a wet method nonwoven fabric. This wet method nonwoven fabric has a surface density of 52.83 g / m. ² Met.
[0089]
Next, about 100 g of titanium oxide particles having a primary particle diameter of about 20 nm and a secondary particle diameter of 0.1 to 1 μm were placed in a petri dish having an inner diameter of 20 cm and heated to 135 ° C. Next, the wet method nonwoven fabric (length = 10 cm, width = 10 cm, fiber mass = 0.5283 g) is further put into the petri dish, the petri dish is covered, held in the hand, and shaken up and down five times. Then, the fiber sheet to which the titanium oxide particles were fixed was quickly taken out. Next, the titanium oxide particles that did not adhere were washed with water to obtain a solid particle-supporting fiber sheet made of solid particle-supporting fibers in which the titanium oxide particles were uniformly supported on the fiber surface.
[0090]
The mass of the solid particle-carrying fiber sheet was 0.5926 g, and the mass of the solid particle-carrying fiber per 1 g of fiber mass was 1.122 g / g (= 0.5926 g / 0.5283 g). Further, the supported amount of titanium oxide particles is 0.0643 g (= 0.5926-0.5283), and the mass of titanium oxide particles supported per 1 g of fiber mass is 0.1217 g / g (0.0643 g / 0.0. 5283 g). When the specific surface area of the solid particle-supporting fiber was measured by the BET method, 7.27 m ² / G. Moreover, the specific surface area of the fiber of the wet method nonwoven fabric before carrying titanium oxide particles is 0.3329 m. ² / G, and the specific surface area before supporting the titanium oxide particles, that is, the specific surface area inherent to the titanium oxide particles is 89.59 m. ² / G. From these values, when the effective surface area ratio of the specific surface area of the titanium oxide particles supported on the solid particle-supporting fiber was determined based on the specific surface area inherent to the titanium oxide particles, it was 71.8%. In addition, the solid particle-carrying fiber sheet did not cause fiber shrinkage or yarn breakage during and / or after the treatment of supporting titanium oxide particles.
In addition, in order to investigate the strength of supporting the titanium oxide particles supported on the solid particle-supporting fiber sheet, a washing resistance test of the solid particle-supporting fiber sheet was performed. As a result, 6.43 g / m before the washing resistance test was performed. ² 6.24 g / m for titanium oxide particles of ² The titanium oxide particles were retained, and the solid particle retention rate was 97.0%.
[0091]
[Example 2]
A papermaking sheet made of 100% high-density polyethylene fiber (fineness = 2.2 decitex, fiber length = 10 mm, melting point = 132 ° C) is made by a papermaking apparatus, and then the papermaking sheet fibers are entangled by a hydroentanglement method. The papermaking sheet made was made. Next, this papermaking sheet was placed on a conveyor belt made of wire mesh, and dried at a temperature of 125 ° C. in an air-through dryer to obtain a wet process nonwoven fabric. Subsequently, a solid particle-carrying fiber sheet made of solid particle-carrying fibers in which titanium oxide particles were uniformly carried on the fiber surface was obtained by the same method as in Example 1.
[0092]
The surface density of the wet method nonwoven fabric (that is, the nonwoven fabric before supporting titanium oxide particles) is 51.21 g / m. ² (Fiber mass = 0.5121 g). The mass of the solid particle-carrying fiber sheet was 0.5767 g, and the mass of the solid particle-carrying fiber per 1 g of fiber mass was 1.126 g / g (= 0.5767 g / 0.5121 g). The amount of titanium oxide particles supported was 0.0646 g, and the mass of titanium oxide particles supported per 1 g of fiber mass was 0.1261 g / g (= 0.0646 g / 0.5121 g).
[0093]
When the specific surface area of the solid particle-supporting fiber was measured by the BET method, 7.15 m ² / G. Moreover, the specific surface area of the fiber of the wet method nonwoven fabric before carrying titanium oxide particles is 0.3242 m. ² / G, and the specific surface area before supporting the titanium oxide particles, that is, the specific surface area inherent to the titanium oxide particles is 89.59 m. ² / G. From these values, when the effective surface area ratio of the specific surface area of the titanium oxide particles supported on the solid particle-supporting fiber was determined on the basis of the specific surface area inherent to the titanium oxide particles, it was 68.4%. In addition, the solid particle-carrying fiber sheet did not cause fiber shrinkage or yarn breakage during and / or after the treatment of supporting titanium oxide particles.
Further, as a result of conducting a washing resistance test of the solid particle-carrying fiber sheet in order to examine the strength of carrying the titanium oxide particles carried on the solid particle-carrying fiber sheet, 6.46 g / m before the washing resistance test was conducted. ² 6.35 g / m with respect to titanium oxide particles ² The titanium oxide particles were retained, and the solid particle retention rate was 98.3%.
[0094]
[Example 3]
Calcium carbonate particles (particle size = 5 μm) heated to 130 ° C. are sprayed on a monofilament (fineness = 20 dtex) made of high-density polyethylene resin (melting point = 130 ° C.), and the calcium carbonate particles are uniformly supported on the fiber surface. A solid particle-supporting fiber was obtained. In the solid particle-supporting fiber, the monofilament contraction or yarn breakage did not occur during and / or after the calcium carbonate particle supporting treatment.
[0095]
[Comparative Example 1]
By repeating the procedure described in Example 1, the surface density was 51.47 g / m. ² A wet method nonwoven fabric was obtained.
Subsequently, about 100 g of titanium oxide particles having a primary particle diameter of about 20 nm and a secondary particle diameter of 0.1 to 1 μm were put in a petri dish having an inner diameter of 20 cm and kept at 25 ° C. Next, the wet method nonwoven fabric (length = 10 cm, width = 10 cm, fiber mass = 0.5147 g) is further put into the petri dish, the petri dish is covered, held in the hand, and shaken up and down five times. It was. Next, this petri dish was placed in a dryer at 135 ° C., and after 5 minutes, the petri dish was taken out from the drier, and further, a fiber sheet to which titanium oxide particles adhered was quickly taken out from the petri dish. Next, the titanium oxide particles that did not adhere were washed with water to obtain a fiber sheet carrying the titanium oxide particles.
[0096]
In this comparative example, the titanium oxide particles were not uniformly supported on the fiber surface and were partially uneven. The mass of the solid particle-carrying fiber sheet was 0.5796 g, and the mass of the solid particle-carrying fiber per 1 g of fiber mass was 1.126 g / g (= 0.5796 g / 0.5147 g). The amount of titanium oxide particles supported was 0.0649 g, and the mass of titanium oxide particles supported per 1 g of fiber mass was 0.1261 g / g (= 0.0649 g / 0.5147 g).
[0097]
When the specific surface area of the solid particle-supporting fiber was measured by the BET method, it was 3.73 m. ² / G. Moreover, the specific surface area of the fiber of the wet method nonwoven fabric before carrying titanium oxide particles is 0.3329 m. ² / G, and the specific surface area before supporting the titanium oxide particles, that is, the specific surface area inherent to the titanium oxide particles is 89.59 m. ² / G. From these values, the effective surface area ratio of the specific surface area of the titanium oxide particles supported on the solid particle-supporting fiber was found to be 34.2% based on the specific surface area inherent to the titanium oxide particles. Further, in this solid particle-supporting fiber sheet, fiber breakage occurred during and / or after the treatment of supporting titanium oxide particles, but fiber breakage occurred.
Further, as a result of conducting a washing resistance test of the solid particle-carrying fiber sheet in order to investigate the strength of carrying the titanium oxide particles carried on the solid particle-carrying fiber sheet, 6.49 g / m before the washing resistance test was conducted. ² 6.25 g / m with respect to titanium oxide particles ² Of titanium oxide particles were retained, and the solid particle retention rate was 96.3%.
[0098]
[Comparative Example 2]
A papermaking sheet made of 100% high-density polyethylene fiber (fineness = 2.2 decitex, fiber length = 10 mm, melting point = 132 ° C) is made by a papermaking apparatus, and then the papermaking sheet fibers are entangled by a hydroentanglement method. The papermaking sheet made was made. Next, this paper sheet is placed on a conveyor belt made of a wire mesh, and dried at a temperature of 125 ° C. in an air-through type dryer. The surface density is 51.21 g / m. ² A wet method nonwoven fabric was obtained.
Subsequently, a fiber sheet carrying titanium oxide particles was obtained by the same method as in Comparative Example 1. In the solid particle-supporting fiber sheet, the titanium oxide particles were not uniformly supported on the fiber surface, and were partially uneven. In the solid particle-supporting fiber sheet, the fibers in the nonwoven fabric contracted during and / or after the titanium oxide particles were supported, and many yarn breaks occurred.
[0099]
[Comparative Example 3]
After spraying normal temperature calcium carbonate particles (particle diameter = 5 μm) on monofilaments (fineness = 20 dtex) made of high-density polyethylene resin (melting point = 130 ° C.), the calcium carbonate particles are brought into contact with the fibers. Placed in a dryer at 0 ° C for 1 minute. As a result, the monofilament contracted to cause yarn breakage, and solid particle-supporting fibers could not be obtained.
[0100]
【Evaluation results】
Table 1 shows the results for Examples 1 and 2 and Comparative Example 1. In Examples 1 and 2, it is shown that the effective surface area ratio of the solid particles is 50% or more, and even after the solid particles are supported on the fiber surface, the surface functions inherent to the solid particles can be sufficiently exhibited. Yes. On the other hand, in Comparative Example 1, the effective surface area ratio of the solid particles is less than 50%, and after the solid particles are supported on the fiber surface, the surface functions inherent to the solid particles are sufficiently exhibited. Indicates that you cannot.
Further, in Examples 1 to 3, even when the solid particles were supported on the fiber surface, fiber shrinkage and thread breakage did not occur, whereas in Comparative Examples 1 to 3, fiber shrinkage and thread breakage occurred. . In addition, the washing resistance tests of Examples 1 and 2 show that solid particles are not easily dropped out as in Comparative Example 1, and the solid particles are firmly supported on the fibers.
[0101]

[0102]
【The invention's effect】
According to the production method of the present invention or the production apparatus of the present invention, the solid particles are uniformly applied to the fiber surface of the fiber or the fiber surface of the fiber constituting the fiber sheet while maintaining the surface characteristics of the solid particles effectively. Can be fixed.
According to the production method of the present invention or the production apparatus of the present invention, the heated solid particles are brought into contact with the fiber surface, whereby only the portion where the solid particles are in contact with the fiber surface is melted to carry the solid particles. Therefore, it is very rare that the molten resin covers the surface portion of the solid particles other than the contact portion or the surface portion other than the fixed portion. Further, the entire resin on the fiber surface is melted and fluidized, so that the solid particles are very rarely buried.
In addition, the molten resin oozes out from the gaps between the contacted solid particles, the solid particles outside the solid particles are also fixed, and the solid particles partially become a multilayer on the fiber surface. There is no problem that the solid particles are not uniformly supported. In addition, in some cases, uniform, single-layer fixation or support is possible.
[0103]
Further, according to the production method of the present invention or the production apparatus of the present invention, since the solid particles melt only the fiber surface, even when the fiber is a fiber composed of a single resin component, at the time of the contact treatment or the fixing treatment There is no case where the fiber shrinks or the whole fiber melts to cause yarn breakage. In addition, since the solid particles are firmly fixed and supported on the fiber surface by being cooled after the solid particles are brought into contact with the fiber surface, for example, the solid particles are not easily dropped by the washing resistance test. .
Further, in the production method of the present invention or the production apparatus of the present invention, as a method of bringing the heated solid particles into contact with the fiber or the fiber sheet, when a method of spraying the heated solid particle-containing airflow onto the fiber or fiber sheet surface is used. Since the air flow containing the heated solid particles is blown onto the fiber surface, the solid particles collide against the fiber surface by the inertial force of the solid particles, and the solid particles can be firmly fixed to the fiber surface.
[0104]
In the solid particle-carrying fiber of the present invention, the surface part other than the carrying part of the surface of the solid particle is not covered with the molten resin, and the solid particle is not buried in the molten resin. Furthermore, solid particles are uniformly supported on the fiber surface. Therefore, when the effective surface area ratio of the solid particles is evaluated by the specific surface area measurement by the BET method, it is 50% or more. That is, according to the solid particle-supporting fiber of the present invention, even if the solid particle is supported on the fiber surface, the surface function inherent to the solid particle can be sufficiently exhibited.
Moreover, since the solid particle carrying | support fiber sheet of this invention has a solid particle carrying | support fiber, let this fiber sheet be a form suitable for various uses, such as a filter material, an absorber, or a cover material, for example. As a result, the surface function of the solid particles carried by the solid particle carrying fibers can be more effectively exhibited.
[Brief description of the drawings]
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is a configuration diagram schematically showing one embodiment of an apparatus for producing solid particle-carrying fibers or solid particle-carrying fiber sheets according to the present invention.
FIG. 2 is a schematic view schematically showing another embodiment of the apparatus for producing a solid particle-carrying fiber or solid particle-carrying fiber sheet according to the present invention.
FIG. 3 is a schematic view schematically showing still another embodiment of the apparatus for producing a solid particle-carrying fiber or solid particle-carrying fiber sheet according to the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 ... Airflow generation means; 11 ... Blower; 12 ... Heating pipe;
20 ... Particle supply means; 21 ... Supply container; 22 ... Supply control rotor;
23 ... Supply pipe; 24 ... Fluidized bed dryer; 29 ... Solid particles;
30 ... Particle mixing means; 40 ... Ejecting means; 41 ... Nozzle;
50, 51, 52, 53 ... heating means;
60, 61, 62, 63 ... auxiliary heating means;
70 ... roll or fiber support means;
70 '... roll or fiber sheet support means;
80 ... fiber; 80 '... fiber sheet;
90: Adhesion treatment chamber; 91: Indoor heating means;
92 ... Particle recovery box;
93: Particle recovery means for blowing air away.

Claims (14)

A method for producing fibers in which solid particles are supported on the surface of fibers mainly comprising at least a surface of a thermoplastic resin,
By heating solid particles having a melting point or decomposition temperature higher than the melting point of the thermoplastic resin to a temperature higher than the melting point of the thermoplastic resin, and blowing an air flow containing the heated solid particles on the surface of the fiber, The heated solid particles are brought into contact with the fibers having a temperature lower than the melting point of the thermoplastic resin while being maintained at a temperature higher than the melting point of the thermoplastic resin, and the solid particles are bonded to the fiber surface by fusion of the fiber surface. A method for producing a solid particle-supporting fiber, wherein the solid particle is fixed to the surface of the fiber by cooling the solid particle fusion fiber.   The manufacturing method of Claim 1 whose average particle diameter of a solid particle is below the average fiber diameter of a fiber.   The heated solid particle-containing air flow is prepared by supplying the heated solid particles heated to a temperature higher than the melting point of the thermoplastic resin to an air flow heated to a temperature of 50 ° C. or lower than the melting point of the thermoplastic resin. The manufacturing method according to claim 1 or 2.   The manufacturing method according to any one of claims 1 to 3, wherein the heated solid particle-containing airflow is prepared by mixing solid particles in the airflow using suction force generated by the airflow. A method for producing a fiber sheet that carries solid particles on the surface of the fiber sheet, the fiber sheet comprising at least a fiber mainly composed of a thermoplastic resin,
By heating solid particles having a melting point or decomposition temperature higher than the melting point of the thermoplastic resin to a temperature higher than the melting point of the thermoplastic resin, and blowing an air flow containing the heated solid particles on the surface of the fiber sheet, Heated solid particles are brought into contact with the fiber sheet having a temperature lower than the melting point of the thermoplastic resin while being maintained at a temperature higher than the melting point of the thermoplastic resin, and the solid is obtained by fusing the fiber surface to the fiber surface. A method for producing a solid particle-supporting fiber sheet, comprising supporting particles and fixing the solid particles to the fiber surface by cooling the solid particle fusion fiber sheet.   The manufacturing method of Claim 5 whose average particle diameter of a solid particle is below the average fiber diameter of a fiber.   The heated solid particle-containing air flow is prepared by supplying the heated solid particles heated to a temperature higher than the melting point of the thermoplastic resin to an air flow heated to a temperature of 50 ° C. or lower than the melting point of the thermoplastic resin. The manufacturing method of Claim 5 or 6.   The manufacturing method according to any one of claims 5 to 7, wherein the heated solid particle-containing airflow is prepared by mixing solid particles in the airflow using suction force generated by the airflow. An apparatus for producing fibers in which at least the surface carries solid particles on the surface of fibers mainly composed of a thermoplastic resin,
Particle forming means for forming an air stream containing solid particles by mixing solid particles in the air stream using suction generated by the air stream;
Ejecting means for ejecting an air flow containing solid particles formed by the particle forming means;
It is provided in the particle forming means and / or the jetting means, and can be jetted from the heating means capable of forming an air stream containing heated solid particles heated to a temperature higher than the melting point of the thermoplastic resin, and the jetting means. Said manufacturing apparatus characterized by having a fiber support means which can hold | maintain the said fiber in the position which solid particle containing airflow can contact the said fiber surface. The particle forming means,
An airflow generating means for generating an airflow;
Particle supply means for supplying the solid particles;
The air flow generation means and the particle supply means are connected to each other, the air flow generated by the air flow generation means is sent in, and the solid particles are supplied into the sent air flow by the particle supply means. The particle mixing means for mixing the air flow and the solid particles to form a solid particle-containing air flow,
The manufacturing apparatus of Claim 9 containing.   The manufacturing apparatus according to claim 10, wherein the particle forming unit further includes the heating unit provided in at least one of the airflow generation unit, the particle supply unit, or the particle mixing unit. An apparatus for producing a fiber sheet that carries solid particles on the surface of the fiber sheet of a fiber sheet containing at least a surface mainly comprising a thermoplastic resin,
Particle forming means for forming an air stream containing solid particles by mixing solid particles in the air stream using suction generated by the air stream;
Ejecting means for ejecting an air flow containing solid particles formed by the particle forming means;
It is provided in the particle forming means and / or the ejection means, and is heated from the heating means capable of forming an air flow including heated solid particles heated to a temperature higher than the melting point of the thermoplastic resin, and ejected from the ejection means. Said manufacturing apparatus characterized by having a fiber sheet support means which can hold | maintain the said fiber sheet in the position which solid particle containing airflow can contact the said fiber sheet surface. The particle forming means,
An airflow generating means for generating an airflow;
Particle supply means for supplying the solid particles;
The air flow generation means and the particle supply means are connected to each other, the air flow generated by the air flow generation means is sent in, and the solid particles are supplied into the sent air flow by the particle supply means. The particle mixing means for mixing the air flow and the solid particles to form a solid particle-containing air flow,
The manufacturing apparatus of Claim 12 containing.   The manufacturing apparatus according to claim 13, wherein the particle forming unit further includes the heating unit provided in at least one of the airflow generation unit, the particle supply unit, or the particle mixing unit.

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