Buffer substrate and use thereof

• US 9,200,390 B2
• Filed: 08/27/2008
• Issued: 12/01/2015
• Est. Priority Date: 08/31/2007
• Status: Active Grant

• Current Assignee: Kuraray Company Limited
• Original Assignee: Kuraray Company Limited
• Inventors: Kimura, Tomoaki, Ochiai, Toru, Kiyooka, Sumito, Koizumi, Satoshi, Muraki, Kazuhiro
• Primary Examiner(s): Pierce, Jeremy R
• Application Number:
  US12/675,536
• Publication Number:
  US 20100203788A1
• Time in Patent Office: 2,652 Days
• Field of Search: 442/352, 442/353, 442/356, 442/359, 442/361
• US Class Current: 1/1
• CPC Class Codes: D04H 1/005 Making three-dimensional articles by consolidation D04H1/22 takes precedence
• CPC Class Codes: D04H 1/02 Cotton wool; Wadding
• CPC Class Codes: D04H 1/5405 at spaced points or locations
• CPC Class Codes: D04H 1/5412 sheath-core
• CPC Class Codes: D04H 1/5414 side-by-side
• CPC Class Codes: D04H 1/5418 Mixed fibres, e.g. at least two chemically different fibres or fibre blends
• CPC Class Codes: D04H 1/544 Olefin series
• CPC Class Codes: D04H 1/545 Polyvinyl alcohol
• CPC Class Codes: D04H 1/55 Polyesters
• CPC Class Codes: D04H 1/558 in combination with mechanical or physical treatments other than embossing
• CPC Class Codes: D04H 1/74 the fibres being orientated, e.g. in parallel (anisotropic fleeces)
• CPC Class Codes: D04H 13/007 strengthened or consolidated by welding together the various components
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 442/60 Nonwoven fabric [i.e., nonwoven strand or fiber material]

Abstract

In a nonwoven fiber assembly which comprises a fiber comprising a thermal adhesive fiber under moisture and in which the fiber are entangled with each other, the fibers are bonded at contacting points of the fibers by melting the thermal adhesive fiber under moisture to distribute the bonded points approximately uniformly, thereby obtaining a buffer substrate. The buffer substrate may further comprises a conjugated fiber comprising a plurality of resins which are different in thermal shrinkage and form a phase separation structure, and the conjugated fibers may have an approximately uniform crimps having an average curvature radius of 20 to 200 μm and are entangled with the fibers constituting the nonwoven fiber assembly. The buffer substrate can be obtained by a method comprising the steps of: forming a web from the fiber comprising the thermal adhesive fiber under moisture; and subjecting the obtained fiber web to a heat and moisture treatment with a high-temperature water vapor to melt the thermal adhesive fiber under moisture for bonding the fibers. The buffer substrate has a high air-permeability, an excellent cushion property and softness.

Claims

1. A buffer substrate comprising a nonwoven fiber assembly which comprises a fiber comprising a moistenable-thermal adhesive fiber and a conjugated fiber comprising a plurality of resins which are different in thermal shrinkage and form a phase separation structure, in which the fibers constituting the nonwoven fiber assembly are entangled with each other and bonded at contacting points by melting the moistenable-thermal adhesive fiber to distribute the bonded points approximately uniformly,

wherein a bonded fiber ratio is from 3 to 30% in each of three areas and the proportion of the minimum value relative to the maximum value among the bonded fiber ratios in each of the three areas is not less than 50%,

providing that the three areas are obtained by cutting the buffer substrate in the thickness direction to give a cross section and dividing the cross section in a direction perpendicular to the thickness direction equally into three,

wherein the bonded fiber ratio represents the proportion of the number of cross sections of bonded fibers relative to the total number of cross sections of fibers as determined from a microphotograph of a cross section with respect to the thickness direction of the nonwoven fiber assembly,

wherein the bonded fibers means fibers which are still contacted with each other as observed on said microphotograph,

wherein a curved ratio of the conjugated fiber is not less than 1.3 in each of three areas and the proportion of the minimum value relative to the maximum value among the curved ratios in each of the three areas is not less than 75%,

providing that the three areas are obtained by cutting the buffer substrate in the thickness direction to give a cross section and dividing the cross section in a direction perpendicular to the thickness direction equally into three,

wherein the curved ratio represents a ratio (L2/L1) of a fiber length (L2) of the crimped fiber relative to a length between the both ends of the crimped fiber (L1).

2. A buffer substrate according to claim 1, wherein the conjugated fibers have approximately uniform crimps having an average curvature radius of 20 to 200 μ

m and are entangled with the fibers constituting the nonwoven fiber assembly.

3. A buffer substrate according to claim 1, wherein the moistenable-thermal adhesive fiber is a sheath-core structure conjugated fiber which comprises a sheath comprising an ethylene-vinyl alcohol-series copolymer and a core comprising a polyester-series resin.

4. A buffer substrate according to claim 2, wherein the conjugated fiber comprises a poly(alkylene arylate)-series resin and a modified poly(alkylene arylate)-series resin and has a side-by-side structure or an eccentric sheath-core structure.

5. A buffer substrate according to claim 2, wherein the mass ratio of the moistenable-thermal adhesive fiber relative to the conjugated fiber is 90/10 to 10/90.

6. A buffer substrate according to claim 1, wherein the apparent density is from 0.01 to 0.2 g/cm³.

7. A buffer substrate according to claim 1, wherein the air-permeability is from 0.1 to 300 cm³/(cm²·

second) in accordance with a Frazier tester method, and a cushion property is not less than 10%,

wherein the cushion property is represented by a ratio of a recovery stress (Y) relative to a compression stress (X) based on a hysteresis loop of a behavior in 50% compression and recovery after the compression (50% compression recovery behavior) in accordance with JIS K6400-2, and the compression stress (X) is a stress at 25% compression in an initial 50% compression behavior, and the recovery stress (Y) is a stress at 25% compression in returning (recovering) behavior after 50% compression.

8. A buffer substrate according to claim 1, which has a sheet or plate form and an approximately uniform thickness.

9. A buffer substrate according to claim 8, wherein the fibers constituting the nonwoven fiber assembly are oriented in a direction approximately parallel to a surface direction of the buffer substrate.

10. A buffer substrate according to claim 9, which has a plurality of areas comprising a large amount of the fibers oriented in the thickness direction of the buffer substrate,

wherein the plurality of areas are arranged regularly in the surface direction of the buffer substrate.

11. A cushion comprising a buffer substrate according to claim 1.

12. A cushion according to claim 11, wherein the apparent density of the buffer substrate is from 0.02 to 0.2 g/cm³.

13. A method for producing a buffer substrate recited in claim 1, comprising:

(a) forming a web from a fiber comprising a moistenable-thermal adhesive fiber; and

(b) subjecting the obtained fiber web to a heat and moisture treatment with a high-temperature water vapor to melt the moistenable-thermal adhesive fiber for bonding the fibers.

14. A method for producing a buffer substrate recited in claim 2, comprising:

(c) forming a web from a fiber comprising a moistenable-thermal adhesive fiber and a conjugated fiber comprising a plurality of resins which are different in thermal shrinkage and form a phase separation structure; and

(d) subjecting the obtained fiber web to a heat and moisture treatment with a high-temperature water vapor to melt the moistenable-thermal adhesive fiber for bonding the fibers and to develop a crimp of the conjugated fiber.

15. A method according to claim 13, further comprising subjecting a plurality of regularly arranged areas of a surface of the fiber web to a treatment to change the orientation directions of the fibers prior to conducting (b).

16. A method according to claim 14, further comprising subjecting a plurality of regularly arranged areas of a surface of the fiber web to a treatment to change the orientation directions of the fibers prior to conducting (d).