# US 12,180,627 B2 · Method for producing fiber articles > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,180,627 B2 - Document ID: US12180627B2 - Status: Granted - Kind: B2 - Application number: 17/637,741 - Filed: 2020-08-28 - Published: 2022-09-08 - Granted: 2024-12-31 - Earliest claimed: 2019-08-30 - Assignees: Daicel Corporation - Applicants: Daicel Corporation - Inventors: Yoshitaka Ito; Masaya Omura; Junko Makino; Yuki Tsukamoto; Fuai Uehara; Hiroaki Shintani - Web page: https://patentgrep.com/patent/US12180627B2 ## CPC - D02G 1/12: using stuffer boxes - D04H 1/4382: Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather - D04H 1/72: the fibres being randomly arranged - D04H 5/08: characterised by the method of forming fleeces or layers, e.g. reorientation of fibres or yarns - D04H 1/4318: Fluorine series - D04H 1/43838: {Ultrafine fibres, e.g. microfibres} - D02G: CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS - D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B) ## Abstract A production method for a fiber article includes: a contact step of, while transferring a plurality of first fibers, bringing a plurality of resin particles formed of high molecules that can be fiberized into contact with the plurality of first fibers; a first processing step of applying an external force to the plurality of first fibers brought into contact with the plurality of resin particles and narrowing gaps between fibers; and a second processing step of, by relieving the external force applied to the plurality of first fibers brought into contact with the plurality of resin particles, forming second fibers from the plurality of resin particles, the second fibers each having an outer diameter that is smaller than each of the first fibers and is set to a value in a range of 30 nm or more to 1.0 μm or less, and forming a fiber composite including the first fibers and the second fibers. ## Claims ### Claim 1 A production method for a fiber article, comprising: a contact step of, while transferring a plurality of first fibers that are continuously spun, bringing a plurality of resin particles formed of polymers that can be fiberized into contact with the plurality of first fibers, the plurality of resin particles including lamellar structures; a first processing step of applying an external force to the plurality of first fibers brought into contact with the plurality of resin particles and continuously spun, and narrowing gaps between fibers; and a second processing step of, by relieving the external force applied to the plurality of first fibers brought into contact with the plurality of resin particles, forming second fibers from the plurality of resin particles, the second fibers each having an outer diameter that is smaller than each of the first fibers and is set to a value in a range of 30 nm or greater to 1.0 μm or less, so that a fiber composite including the first fibers and the second fibers is formed. ### Claim 2 (depends on 1) The production method for a fiber article according to claim 1, wherein, in the first processing step, a band is formed by applying the external force to the first fibers to which the plurality of resin particles is added and crimping the first fibers. ### Claim 3 (depends on 2) The production method for a fiber article according to claim 2, wherein, in the first processing step, while transferring the band, tensile force is applied as the external force in a transfer direction to the plurality of first fibers brought into contact with the plurality of resin particles in the band. ### Claim 4 (depends on 1) The production method for a fiber article according to claim 1, wherein, in the first processing step, the plurality of first fibers is inserted between a pair of nip rolls and pressed by the pair of nip rolls, whereby the external force is applied to the first fibers brought into contact with the plurality of resin particles. ### Claim 5 (depends on 1) The production method for a fiber article according to claim 1, wherein, in the contact step, a dispersion in which the plurality of resin particles are dispersed is used. ### Claim 6 (depends on 5) The production method for a fiber article according to claim 5, further comprising a drying step of, between the contact step and the first processing step, drying at least a portion of the dispersion applied to the first fibers. ### Claim 7 (depends on 5) The production method for a fiber article according to claim 5, wherein an aqueous dispersion obtained by dispersing the plurality of resin particles in water is used as the dispersion. ### Claim 8 (depends on 5) The production method for a fiber article according to claim 5, wherein, in the contact step, the dispersion separated from the first fibers in the first processing step is reused. ### Claim 9 (depends on 1) The production method for a fiber article according to claim 1, wherein, in the contact step, the plurality of resin particles in a powder form are directly brought into contact with the first fibers. ### Claim 10 (depends on 1) The production method for a fiber article according to claim 1, wherein, in the first processing step, nip pressure set to a value of 0.05 MPa or greater is applied as the external force to the plurality of first fibers brought into contact with the plurality of resin particles. ### Claim 11 (depends on 1) The production method for a fiber article according to claim 1, wherein, in the second processing step, the fiber composite is formed so that a weight ratio W1/W2 of a total weight W1 of the first fibers to a total weight W2 of the second fibers and resin particles adhered to the first fibers is within a range of 3.00 or greater to 200.00 or less. ### Claim 12 (depends on 1) The production method for a fiber article according to claim 1, wherein, in the second processing step, a length dimension of the first fibers forms the fiber composite that is longer than a length dimension of the second fibers. ### Claim 13 (depends on 1) The production method for a fiber article according to claim 1, wherein, in the contact step, the first fibers each having an outer diameter set to a value in a range of 5 μm or greater and 50 μm or less are used. ### Claim 14 (depends on 1) The production method for a fiber article according to claim 1, wherein, in the contact step, the first fibers formed of at least one of rayon, polypropylene, polyethylene terephthalate, polyethylene, or cellulose acetate are used. ### Claim 15 (depends on 1) The production method for a fiber article according to claim 1, wherein, in the contact step, the resin particles formed of at least one of polytetrafluoroethylene, polypropylene, polyethylene, or polyamide are used.