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Spunbonded Nonwoven Fabric And Production Method Therefor

Abstract: The present invention provides a spunbonded nonwoven fabric that: has a smooth surface; is highly unlikely to cause a widthwise curl due to a difference between the states of front and back surfaces; has a superior film forming property of not allowing at the time of casting of a resin solution a bleed-through of the resin solution due to excessive permeation a peel-off of a film material or any other defect such as nonuniform film or pin hole due to fluffing etc. of a base; and further exhibits film-adhesiveness that is strong enough to prevent the film material from peeling off after film formation.

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Notices, Deadlines & Correspondence

Patent Information

Application #
Filing Date
25 March 2019
Publication Number
19/2019
Publication Type
INA
Invention Field
TEXTILE
Status
Email
patent@depenning.com
Parent Application
Patent Number
Legal Status
Grant Date
2024-04-19
Renewal Date

Applicants

TORAY INDUSTRIES, INC.
1-1, Nihonbashi-Muromachi 2-chome, Chuo-ku, Tokyo 1038666

Inventors

1. SHIMADA, Daiki
c/o Shiga Plant, Toray Industries, Inc., 1-1, Sonoyama 1-chome, Otsu-shi, Shiga 5208558
2. IKEJIRI, Yuki
c/o Shiga Plant, Toray Industries, Inc., 1-1, Sonoyama 1-chome, Otsu-shi, Shiga 5208558
3. NAKANO, Yohei
c/o Shiga Plant, Toray Industries, Inc., 1-1, Sonoyama 1-chome, Otsu-shi, Shiga 5208558

Specification

WE CLAIM:
1. A spunbonded nonwoven fabric comprising thermoplastic
fibers, wherein the thermoplastic fiber is a conjugate
fiber in which a low-melting polymer having a melting point
lower by 10 to 140°C than that of a high-melting polymer is
provided around the high-melting polymer, an apparent
single fiber fineness of the conjugate fiber as viewed from
the surface of the spunbonded nonwoven fabric is 0.5 dtex
or more and 10 dtex or less, when the apparent single fiber
fineness of the conjugate fiber is 0.5 dtex or more and
less than 2 dtex, an apparent density is 0.50 to 0.70 g/cm ,
and air permeability satisfies [formula 1] described below,
and when the apparent single fiber fineness of the
conjugate fiber is 2 dtex or more and 10 dtex or less, the
apparent density is 0.50 to 0.80 g/cm , and the air
permeability satisfies [formula 2] described below,
(cc/cm -sec)]
3.8 × 10 × [basis weight (g/m )]- £ [air permeability
£ 6.0 × 10 × [basis weight (g/m )] ...
[formula 1], and
2.2 × 10 × [basis weight (g/m )]- £ [air permeability
(cc/cm -sec)] £ 4.6 × 10 × [basis weight (g/m )] - ...
[formula 2].
2. The spunbonded nonwoven fabric according to claim 1,
94

wherein the apparent single fiber fineness of the conjugate fiber as viewed from the surface of the spunbonded nonwoven fabric is 0.5 dtex or more and less than 2 dtex, and a Bekk smoothness of at least one surface of the spunbonded nonwoven fabric is 1 to 10 seconds.
3. The spunbonded nonwoven fabric according to claim 1, wherein the apparent single fiber fineness of the conjugate fiber as viewed from the surface of the spunbonded nonwoven fabric is 2 dtex or more and 10 dtex or less, and a Bekk smoothness of at least one surface of the spunbonded nonwoven fabric is 3 to 20 seconds.
4. The spunbonded nonwoven fabric according to any one of claims 1 to 3, wherein the basis weight of the spunbonded nonwoven fabric is 10 to 150 g/m2.
5. The spunbonded nonwoven fabric according to any one of claims 1 to 4, wherein the thermoplastic fiber is a polyester fiber.
6. The spunbonded nonwoven fabric according to any one of claims 1 to 5, wherein the thermoplastic fiber has a movable amorphous content of 35 to 50%.
95

7. A separation membrane support comprising the spunbonded nonwoven fabric according to any one of claims 1 to 6.
8. A production method for a spunbonded nonwoven fabric comprising the following steps (a) to (d) sequentially in this order:

(a) spinning, from a spinneret, a conjugate fiber in which a low-melting polymer having a melting point lower by 10 to 140°C than that of a high-melting polymer is provided around the high-melting polymer,
(b) stretching the spun conjugate fibers by suction flow using a high-speed suction gas and collecting the fibers on a moving net conveyor to form the collected fibers into a nonwoven web,
(c) thermally bonding the obtained nonwoven web with a pair of upper and lower flat rolls at a temperature lower by 65 to 95°C than the melting point of the low-melting polymer, and
(d) subsequently thermally bonding with the pair of upper and lower flat rolls at a temperature lower by 5 to 60°C than the melting point of the low-melting polymer.
9. The production method for a spunbonded nonwoven
fabric according to claim 8, wherein the spinneret of the
96

step (a) is a spinneret having a round discharge orifice.
10. The production method for a spunbonded nonwoven fabric according to claim 8, wherein the spinneret of the step (a) is a spinneret having a discharge orifice having an aspect ratio (long side length/short side length) of 1.6 to 8.
11. The production method for a spunbonded nonwoven fabric according to any one of claims 8 to 10, wherein the movable amorphous content of the spunbonded nonwoven fabric obtained in the step (c) is 40 to 55%.
12. The production method for a spunbonded nonwoven fabric according to any one of claims 8 to 11, wherein the movable amorphous content of the spunbonded nonwoven fabric obtained in the step (d) is 35 to 50%.
13. The production method for a spunbonded nonwoven fabric according to any one of claims 8 to 12, wherein the conjugate fiber of the step (a) is a polyester fiber.
97

Documents

Application Documents

# Name Date
1 201947011463.pdf 2019-03-25
2 201947011463-TRANSLATIOIN OF PRIOIRTY DOCUMENTS ETC. [25-03-2019(online)].pdf 2019-03-25
3 201947011463-STATEMENT OF UNDERTAKING (FORM 3) [25-03-2019(online)].pdf 2019-03-25
4 201947011463-PROOF OF RIGHT [25-03-2019(online)].pdf 2019-03-25
5 201947011463-PRIORITY DOCUMENTS [25-03-2019(online)].pdf 2019-03-25
6 201947011463-POWER OF AUTHORITY [25-03-2019(online)].pdf 2019-03-25
7 201947011463-FORM 1 [25-03-2019(online)].pdf 2019-03-25
8 201947011463-DECLARATION OF INVENTORSHIP (FORM 5) [25-03-2019(online)].pdf 2019-03-25
9 201947011463-COMPLETE SPECIFICATION [25-03-2019(online)].pdf 2019-03-25
10 201947011463-CLAIMS UNDER RULE 1 (PROVISIO) OF RULE 20 [25-03-2019(online)].pdf 2019-03-25
11 Correspondence by Agent_Form1_08-04-2019.pdf 2019-04-08
12 201947011463-FORM 3 [09-08-2019(online)].pdf 2019-08-09
13 201947011463-FORM 3 [19-06-2020(online)].pdf 2020-06-19
14 201947011463-FORM 18 [03-08-2020(online)].pdf 2020-08-03
15 201947011463-FORM 3 [02-06-2021(online)].pdf 2021-06-02
16 201947011463-FER.pdf 2021-12-20
17 201947011463-OTHERS [20-06-2022(online)].pdf 2022-06-20
18 201947011463-Information under section 8(2) [20-06-2022(online)].pdf 2022-06-20
19 201947011463-FORM 3 [20-06-2022(online)].pdf 2022-06-20
20 201947011463-FER_SER_REPLY [20-06-2022(online)].pdf 2022-06-20
21 201947011463-COMPLETE SPECIFICATION [20-06-2022(online)].pdf 2022-06-20
22 201947011463-CLAIMS [20-06-2022(online)].pdf 2022-06-20
23 201947011463-FORM 3 [03-07-2023(online)].pdf 2023-07-03
24 201947011463-US(14)-HearingNotice-(HearingDate-03-04-2024).pdf 2024-02-29
25 201947011463-Correspondence to notify the Controller [01-04-2024(online)].pdf 2024-04-01
26 201947011463-Written submissions and relevant documents [18-04-2024(online)].pdf 2024-04-18
27 201947011463-Retyped Pages under Rule 14(1) [18-04-2024(online)].pdf 2024-04-18
28 201947011463-2. Marked Copy under Rule 14(2) [18-04-2024(online)].pdf 2024-04-18
29 201947011463-PatentCertificate19-04-2024.pdf 2024-04-19
30 201947011463-IntimationOfGrant19-04-2024.pdf 2024-04-19

Search Strategy

1 SS201947011463E_17-12-2021.pdf

ERegister / Renewals

3rd: 08 Jul 2024

From 25/08/2019 - To 25/08/2020

4th: 08 Jul 2024

From 25/08/2020 - To 25/08/2021

5th: 08 Jul 2024

From 25/08/2021 - To 25/08/2022

6th: 08 Jul 2024

From 25/08/2022 - To 25/08/2023

7th: 08 Jul 2024

From 25/08/2023 - To 25/08/2024

8th: 08 Jul 2024

From 25/08/2024 - To 25/08/2025

9th: 06 Jul 2025

From 25/08/2025 - To 25/08/2026