CN101219078B - Face sheet for absorption article and method for producing the same - Google Patents
Face sheet for absorption article and method for producing the same Download PDFInfo
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- CN101219078B CN101219078B CN 200710300198 CN200710300198A CN101219078B CN 101219078 B CN101219078 B CN 101219078B CN 200710300198 CN200710300198 CN 200710300198 CN 200710300198 A CN200710300198 A CN 200710300198A CN 101219078 B CN101219078 B CN 101219078B
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- woven fabrics
- roll
- fiber
- circumferential surface
- protuberance
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Abstract
A face sheeting is used as a skin contact surface for an absorbency object, and stacked first non-woven fabrics and second non-woven fabrics are partially melted and cohered to form a melted cohere part. Other parts of the first non-woven fabrics except the melted cohere part protrudes to the skin of the wearer to form a plurality of bulges. The bulge and the melted cohere part are disposed alternately to form an array arrangement with a plurality of arrays. At least part of bulges in a fiber orientation direction of the first non-woven fabrics have a fiber sparse part with a lower fibre density than that at a center part in the fiber orientation direction at one end or two ends.
Description
Technical field
The present invention relates to a kind of face sheet (stacked non-woven fabrics) and manufacture method thereof that is suitable for the skin contact face of the absorbent commodities such as disposable diaper, sanitary napkin, underwear back boxing (sanitary pad), incontinence pad.
Background technology
As the face sheet of disposable diaper and sanitary napkin etc., be widely used in and form irregular sheet material on the face that contacts the wearer skin.The irregular face sheet of tool because concavo-convex existence can reduce the contact area with the wearer skin, therefore can reduce the sense and airtight of being clamminess.
As the irregular face sheet of tool, for example known will have the sheet material of thickness and other sheet material by embossing processing and form integratedly, make the formed compression unit of embossing become recess, make other parts become the face sheet of protuberance.
In addition, in patent documentation 1, put down in writing and make 2 non-woven fabrics heat fusing is bonding partly, and the part beyond the heat fusing bonding part of a non-woven fabrics is formed with the face sheet of discontinuous protuberance.
As the irregular face sheet of surperficial tool, for example proposed following face sheet in patent documentation 2: the 1st non-woven fabrics and the 2nd non-woven fabrics partly heat fusing are bonding and formed the heat fusing bonding part, part beyond the heat fusing bonding part of the 1st non-woven fabrics forms towards the side-prominent protuberance of the skin of wearer, is filled with short fiber in the inside of this protuberance.
In addition, in patent documentation 3, proposed to be formed with at the single face of the base material of water penetration the face sheet of the continuous single fiber layer of ring-type.
Patent documentation 1: TOHKEMY 2004-174234
Patent documentation 2: TOHKEMY 2006-115974
Patent documentation 3: TOHKEMY 2002-065736
The above-mentioned formed compression unit of embossing that makes becomes recess, makes other parts become the face sheet of protuberance, and the performance of the protuberance that it can design is received the restriction of the characteristic of sheet material.
In addition, the face sheet that patent documentation 1 is put down in writing owing to be the cavity in the protuberance, therefore need to improve the liquid imbedibility, and makes the contour goo of menses or soft stool also have room for improvement rapidly aspect the wearer skin.
In addition, in the face sheet that patent documentation 2 is put down in writing, the fiber that is filled in protuberance inside is short fiber, and the anti-poor flexibility of the compression of protuberance also has room for improvement aspect resiliency.
In the face sheet that patent documentation 3 is put down in writing, because directly the face of contact wearer skin is formed by the few continuous single fiber layer that interweaves between the fiber, therefore when the directive effect of power edge and the differently-oriented directivity quadrature of fiber is on this single fiber layer, then fiber produces loose hair, and when stranding is twisted, be easy to become the ball top shape.This becomes part of ball top shape owing to be easy to keep liquid, and therefore roughly liquid residue or causes and is clamminess etc. at the near surface of face sheet and the degraded appearance after making imbibition.In addition since single fiber layer and below substrate layer between have the cavity with certain altitude, so the imbedibility of liquid is also relatively poor.
Summary of the invention
The present invention relates to a kind of face sheet that uses at the skin contact face of absorbent commodity.
In face sheet of the present invention, mutually heat fusing is bonding and formed the heat fusing bonding part partly for the 1st stacked non-woven fabrics and the 2nd non-woven fabrics.Part beyond the above-mentioned heat fusing bonding part of the 1st non-woven fabrics is side-prominent and form many protuberances to the skin of wearer.Raised part replaces with the heat fusing bonding part and becomes the row configuration, and is configured to multiple row.
The face general planar of the 2nd non-woven fabrics side of face sheet, the inside of raised part is made of the 1st non-woven fabrics or the long stapled aggregation different from the 1st non-woven fabrics.
In the preferred implementation of face sheet, at least a portion raised part in an end of the fiber orientation directions of the 1st non-woven fabrics or both ends have the sparse part of fiber of fibre density that fibre density is lower than the central part of this fiber orientation directions.The liquid imbedibility of the face sheet of this structure is good, and can make menses or the contour goo of soft stool promptly away from the skin of wearer.
In other preferred implementation of face sheet, in the internal configurations of raised part long stapled aggregation is arranged, many long fibres that consist of this aggregation form the curve-like that protrudes towards the projected direction of this protuberance.The resiliency of the face sheet of this structure and liquid imbedibility are good.
In addition, the present invention also provides the manufacture method of face sheet, it is to be manufactured on the method that forms the above-mentioned face sheet in cavity between the 1st non-woven fabrics of the part with protuberance and the 2nd non-woven fabrics, the method comprises: utilize hot blast to implement fluffy answer to the 1st non-woven fabrics that contains curling core shift core-sheath-type composite fibre and process, and make its bite into circumferential surface be the 1st roll and the circumferential surface of concaveconvex shape have with the concaveconvex shape of the 1st roll mutually in the bite of the 2nd roll of the concaveconvex shape of interlock to give its concaveconvex shape, then under the state on the circumferential surface that remains in the 1st roll, collaborate with the 2nd non-woven fabrics, and between the protuberance of the 1st roll and other roll, heat and pressurize with the 2nd non-woven fabrics, thereby form above-mentioned heat fusing bonding part.
In addition, the present invention also provides the manufacture method of face sheet, it is to be manufactured on the method that forms the above-mentioned face sheet in cavity between the 1st non-woven fabrics of the part with protuberance and the 2nd non-woven fabrics, the method comprises: utilize hot blast to implement fluffy answer to the 1st non-woven fabrics that contains curling core shift core-sheath-type composite fibre and process, making it be adsorbed in circumferential surface is concaveconvex shape, and recess has on the circumferential surface of the roll that attracts the hole, under the state that remains on the circumferential surface of this roll, collaborate with the 2nd non-woven fabrics, and between the protuberance of this roll and other roll, pressurize and heat with the 2nd non-woven fabrics, thereby form above-mentioned heat fusing bonding part.
In addition, the present invention also provides the manufacture method of face sheet, it is to be manufactured on the method that forms the above-mentioned face sheet in cavity between the 1st non-woven fabrics of the part with protuberance and the 2nd non-woven fabrics, the method comprises: make the 1st non-woven fabrics that contains thermally extensible fiber bite into circumferential surface be the 1st roll and the circumferential surface of concaveconvex shape have with the concaveconvex shape of the 1st roll mutually in the bite of the 2nd roll of the concaveconvex shape of interlock to give its concaveconvex shape, then under the state on the circumferential surface that remains in the 1st roll, collaborate with the 2nd non-woven fabrics, and between the protuberance of the 1st roll and other roll, heat and pressurize to form above-mentioned heat fusing bonding part with the 2nd non-woven fabrics, then implement heat treatment, make above-mentioned thermally extensible fiber elongation.
In addition, the present invention also provides the manufacture method of face sheet, it is to be manufactured on the method that forms the above-mentioned face sheet in cavity between the 1st non-woven fabrics of the part with protuberance and the 2nd non-woven fabrics, the method comprises: making the 1st non-woven fabrics that contains thermally extensible fiber be adsorbed on circumferential surface is concaveconvex shape, and recess has on the circumferential surface of the roll that attracts the hole, under the state that remains on the circumferential surface of this roll, collaborate with the 2nd non-woven fabrics, and between the protuberance of this roll and other roll, pressurize and heat to form above-mentioned heat fusing bonding part with the 2nd non-woven fabrics, then implement heat treatment, make above-mentioned thermally extensible fiber elongation.
Description of drawings
Fig. 1 is the axonometric chart of an embodiment of the face sheet used of expression absorbent commodity of the present invention.
Fig. 2 is the amplification sectional view in directions X cross section of the protuberance with the sparse part of fiber of face sheet shown in Figure 1.
Fig. 3 is the amplification sectional view in Y-direction cross section of the protuberance with the sparse part of fiber of face sheet shown in Figure 1.
Fig. 4 (a) and (b) be respectively explanation absorbent commodity of the present invention with the sketch map of the action effect of face sheet, Fig. 4 (a) is that sectional view, the Fig. 4 (b) corresponding to Fig. 2 is the sectional view corresponding to Fig. 3.
Fig. 5 is expression absorbent commodity of the present invention with the skeleton diagram of the 1st embodiment of the manufacture method of face sheet.
Fig. 6 be Fig. 5 the 1st roll want section's enlarged drawing.
Fig. 7 is expression absorbent commodity of the present invention with the skeleton diagram of the 2nd embodiment of the manufacture method of face sheet.
Fig. 8 is expression absorbent commodity of the present invention with the skeleton diagram of the 3rd embodiment of the manufacture method of face sheet.
Fig. 9 is the axonometric chart that expression absorbent commodity of the present invention is used the 4th embodiment of face sheet.
Figure 10 is the amplification sectional view in the directions X cross section of face sheet shown in Figure 9.
Figure 11 is the sketch map of an example of the manufacture method of expression face sheet shown in Figure 9.
Figure 12 be Figure 10 the 1st roll want section's enlarged drawing.
Figure 13 is the sectional view (Figure 10 corresponding diagram) that expression absorbent commodity of the present invention is used the 5th embodiment of face sheet.
The specific embodiment
Following according to preferred implementation of the present invention, the present invention will be described with reference to accompanying drawing.
Fig. 1 is the axonometric chart that expression absorbent commodity of the present invention is used an embodiment of face sheet.
Heat fusing is bonding partly for the 1st non-woven fabrics 1 and the 2nd non-woven fabrics 2, thus, has formed many heat fusing bonding parts 4 at face sheet 10.Part beyond the above-mentioned heat fusing bonding part 4 of the 1st non-woven fabrics 1 is side-prominent towards the skin of wearer, has formed many protuberances 5.
As shown in Figure 1, protuberance 5 and heat fusing bonding part 4 a direction parallel with the face of face sheet 10 be directions X alternately and become row to dispose, and be formed with multiple row in the Y-direction perpendicular to above-mentioned directions X.The configuration of on directions X, staggering respectively of the protuberance 5 of adjacent column and heat fusing bonding part 4, more particularly, the half pitch that staggers (pitch) configuration.
The directions X of the face sheet 10 of present embodiment is the direction identical with the differently-oriented directivity (fiber orientation directions) of the formation fiber of the 1st non-woven fabrics 1.Usually, the fiber of non-woven fabrics during fabrication fleece or the upper orientation of the moving direction (operating direction) of non-woven fabrics roughly.Fleece or the moving direction (operating direction) of non-woven fabrics of the fiber orientation directions of the 1st non-woven fabrics 1 grade during with its manufacturing is identical, but when the moving direction when making is not clear, with the direction of the more fibre orientation in bearing of trend that protuberance 5 and heat fusing bonding part 4 became to be listed as and the perpendicular direction as fiber orientation directions.
In the face sheet 10 of present embodiment, the differently-oriented directivity (fiber orientation directions) of the formation fiber of the 2nd non-woven fabrics 2 also is directions X, in addition, the 1st non-woven fabrics 1 and the 2nd non-woven fabrics 2 moving direction (with reference to Fig. 5) separately in the manufacturing process of the fiber orientation directions of the 1st non-woven fabrics (directions X) and face sheet 10 is also consistent.And, the fiber orientation directions of the 1st non-woven fabrics (directions X) is preferably when being assembled into face sheet 10 in the absorbent commodity, consistent, particularly preferably consistent with the length direction of absorbent commodity with any one direction in the length direction (fore-and-aft direction) of absorbent commodity and the perpendicular direction.
When the face sheet 10 of present embodiment was observed as a whole, the face general planar of its 2nd non-woven fabrics 2 sides had formed the concavo-convex of big rise and fall at the face of the 1st non-woven fabrics 1 side.
As shown in Figures 2 and 3, the inside of the protuberance 5 of face sheet 10 has been full of the formation fiber of the 1st non-woven fabrics 1.That is, between the 1st non-woven fabrics 1 of the part with protuberance 5 of face sheet 10 and the 2nd non-woven fabrics 2, form the cavity.Here said cavity refers between the 1st non-woven fabrics 1 and the 2nd non-woven fabrics 2 cavity that produces, the space that for example is not easy to confirm when the cross section of visualization face sheet 10 and and be present between fiber in the 1st non-woven fabrics 1 and the 2nd non-woven fabrics 2 space equal extent or the space of its several times size and be not included in here in the said cavity.
The face sheet 10 of present embodiment is owing to form the cavity between the 1st non-woven fabrics 1 of the part with protuberance 5 and the 2nd non-woven fabrics 2, so liquid is better to the mobility of the 2nd non-woven fabrics 2 from the 1st non-woven fabrics 1.
As shown in Figure 2, at least a portion protuberance 5 of face sheet 10 has the fibre density fiber sparse part 5b lower than the fibre density of the central part 5a of this fiber orientation directions (directions X) at an end XE or both ends XE, the XE of the fiber orientation directions (directions X) of the 1st non-woven fabrics 1.
Because protuberance 5 has the sparse part 5b of fiber, therefore in the sparse part 5b of the sparse fiber of fibre density and heat fusing bonding part 4 or near formation is larger between part it fibre density gradient, thus, be supplied to liquid on the face sheet 10, particularly flow in the recess between the protuberance 5 liquid by the path shown in Fig. 4 (a) swimmingly to the heat fusing bonding part 4 of the 1st non-woven fabrics 1 or near it part mobile.Then, flow to the liquid of heat fusing bonding part 4 or near its part swimmingly to the 2nd non-woven fabrics 2 and then mobile to configuration absorber (not shown) in its lower section.Particularly, fiber orientation directions (directions X) by making the 1st non-woven fabrics 1 is consistent with the length direction of absorbent commodity, the menses that flow along the product width direction promptly can be absorbed from the sparse part 5b of fiber, can prevent from the generation side leakage of product side.
In addition, the contour goo of the menses that viscosity is higher or soft stool also can enter into the sparse part 5b of the sparse fiber of fibre density, thereby promptly leaves the skin of wearer.
And because the fibre density of the central part 5a of the directions X of protuberance 5 is relatively high, so the top of protuberance 5 becomes smoother, become lower with the coefficient of friction of skin, so face sheet 10 has level and smooth sense of touch.
From reaching effectively the viewpoint of above-mentioned effect, one end XE of the fiber orientation directions of the 1st non-woven fabrics 1 (directions X) or the protuberance with the sparse part 5b of fiber 5 of both ends XE, XE are preferably more than 10% of protuberance 5 sums of face sheet 10, more preferably 20～50%, more preferably 30～50%.
Fig. 3 is the sectional view of the Y-direction of the protuberance identical with protuberance shown in Figure 25.
Contrast by Fig. 2 and Fig. 3 can be judged, in Fig. 2 and protuberance 5 shown in Figure 3, poor greater than perpendicular to the fibre density of the central part 5c of the direction (Y-direction) of this fiber orientation directions and both ends YE, YE of the difference of the central part 5a of the fiber orientation directions of the 1st non-woven fabrics 1 (directions X) and the fibre density of the sparse part 5b of fiber.
Thus, the liquid that is supplied on the face sheet 10 also enters in the face sheet 10 by the path shown in Fig. 4 (b), since near the top of protuberance 5 towards the heat fusing bonding part 4 of the 1st non-woven fabrics 1 or near it part have the fibre density gradient, so liquid swimmingly melt bonded 4 of thermotropism or near it part mobile.Then, flow to the liquid of heat fusing bonding part 4 or near its part swimmingly to the 2nd non-woven fabrics 2 and then mobile to configuration absorber (not shown) in its lower section.
Use the microscopic examination face sheet pass through to overlook the time the directions X of protuberance central point and the cross section of Y-direction, and observe directions X and Y-direction central part separately and the filling extent of the fiber of end, can judge an end XE or both ends XE at the protuberance 5 of the fiber orientation directions (directions X) of the 1st non-woven fabrics 1, whether have the sparse part 5b of fiber on the XE, and the difference of the fibre density of the central part 5a of the fiber orientation directions of the 1st non-woven fabrics 1 (directions X) and the sparse part 5b of fiber is whether greater than central part 5c and both ends YE perpendicular to the direction (Y-direction) of this fiber orientation directions, the difference of the fibre density of YE etc.Judge directions X and Y-direction separately central part and during the fiber filled degree of end, preferably with the classifying in three categories minute or 5 five equilibriums in directions X or Y-direction from short transverse upper end to about 2/3 part of protuberance, and judge by integrally observing its fiber filled degree central and two end portions.
In Fig. 2 and protuberance 5 shown in Figure 3, the fibre density of both ends YE, YE on the direction vertical with the fiber orientation directions of the 1st non-woven fabrics 1 (Y-direction) is more than or equal to the fibre density of the central part 5c of this direction.Therefore, utilize the liquid imbedibility in path shown in Fig. 4 (b) further to improve.
Refer to perpendicular to the fibre density of both ends YE, the YE of the direction (Y-direction) of the fiber orientation directions of the 1st non-woven fabrics 1 fibre density more than or equal to the central part 5a of this direction, the fibre density of these both ends YE, YE equates that with the fibre density of this central part 5a perhaps the fibre density of these both ends YE, YE is greater than the fibre density of this central part 5a.From the viewpoint of liquid entering, the fibre density of an above-mentioned end or both ends YE, YE is preferably greater than the fibre density of this central part 5c.
As the 1st and the 2nd non-woven fabrics 1,2, can use various known non-woven fabrics, such as using at the hot blast method non-woven fabrics that has formed the heat fusing bounding point of fiber and fiber on the fleece that utilizes combing method to obtain by the hot blast method, utilizing on the fleece of combing method acquisition the various non-woven fabrics such as hot roll non-woven fabrics, heat embossing non-woven fabrics, Nonwovens of spunbond, meltblown non-woven fabrics, jet net-spraying method non-woven fabrics, needle point method non-woven fabrics, air lay method non-woven fabrics, resin-bonded method non-woven fabrics that formed the heat fusing bounding point of fiber and fiber by the hot roll method.In the face sheet 10 of present embodiment, in fact flexible non-woven fabrics is used as the 1st and the 2nd non-woven fabrics.
As the 1st non-woven fabrics, there is not internally the viewpoint of the formative of empty protuberance 5 to set out, the preferred higher above-mentioned hot blast method non-woven fabrics of loft, jet net-spraying method non-woven fabrics, needle point method non-woven fabrics, air lay method non-woven fabrics, the resin-bonded method non-woven fabrics etc. of using, from good, good with the hot-melt-bondable of the 2nd non-woven fabrics viewpoint of skin sense of touch, particularly preferably use above-mentioned hot blast method non-woven fabrics.
As the 2nd non-woven fabrics, from improving fibre density, be easy to make liquid from the viewpoint that the 1st non-woven fabrics 1 flows into, particularly preferably use above-mentioned hot roll non-woven fabrics, heat embossing non-woven fabrics, Nonwovens of spunbond, meltblown non-woven fabrics, jet net-spraying method non-woven fabrics etc.
As the formation fiber of the 1st and the 2nd non-woven fabrics, the fiber that preferably use the hot-melt-bondable fiber, is particularly consisted of by thermoplastic, polymeric materials.As thermoplastic, polymeric materials, can enumerate the polyolefin such as polyethylene or polypropylene, the polyester such as polyethylene terephthalate, PTT, polybutylene terephthalate (PBT) and polyamide etc.Can also preferably use the core-sheath-type composite fibre or the parallel composite fiber that are combined by these thermoplastic, polymeric materials.The the 1st and the 2nd non-woven fabrics can also contain fiber with hot-melt-bondable (such as cotton fiber etc.) as consisting of fiber except containing the hot-melt-bondable fiber.
Do not have internally viewpoint and the liquid-absorbing rapidly of formative of the protuberance 5 in cavity, the viewpoint of flow direction the 2nd non-woven fabrics 2 is set out, the 1st non-woven fabrics 1 preferably has than high-loft, and its fibre density is preferably less than 0.075g/cm
2, 0.05g/cm more preferably
2Below.
In addition, be imbued with resiliency from forming softness, and the protuberance 5 that is easy to be out of shape along with the activity of skin, thereby and reduce viewpoint to the stimulation of skin from reducing friction with skin, the 1st non-woven fabrics 1 preferred average fineness that it consists of fiber is below the 4.4dtex, more preferably below the 3.3dtex.
From the viewpoint that needs utilize capillary force that liquid is drawn from the 1st non-woven fabrics 1, the fibre density of the 2nd non-woven fabrics 2 must be higher than the fibre density of the 1st non-woven fabrics 1.More particularly, its fibre density is preferably 0.075g/cm
2More than, 0.1g/cm more preferably
2More than.
In addition, the 2nd non-woven fabrics 2 is because when giving the face sheet resiliency, must make fibre density be higher than the fibre density of the 1st non-woven fabrics 1, so its average fineness that consists of fiber is preferably less than 3.3dtex, more preferably below the 2.2dtex.
From more conscientiously showing one of above-mentioned effect or the viewpoint more than two, face sheet 10 preferably has following formation.
The thickness H (with reference to Fig. 2) of the part with protuberance 5 of face sheet 10 is preferably more than the 0.6mm, is particularly preferably more than the 1.0mm.The thickness h of heat fusing bonding part 4 (with reference to Fig. 2) is preferably below the 0.3mm, is particularly preferably below the 0.2mm, and the ratio (H/h) of their thickness is preferably more than 2, is particularly preferably more than 3.
In addition, every 100cm of face sheet 10
2The number (no matter having or not the sparse part 5b of fiber) of protuberance 5 be preferably 250～2000, be particularly preferably 500～1500.In addition, the protuberance with the sparse part 5b of fiber preferably disperses to be present on the face sheet 10, every 100cm
2Number be preferably more than 250, be particularly preferably more than 500.
The bottom size A (with reference to Fig. 1) of the directions X of protuberance 5 is preferably 0.5～5.0mm, is particularly preferably 1.0～4.0mm.The bottom size B (with reference to Fig. 1) of the Y-direction of protuberance 5 is preferably 1.0～10mm, is particularly preferably 2.0～7.0mm.
Ratio (the bottom size A: bottom size B) be preferably 1: 1～1: 10, be particularly preferably 1: 2～2: 5 of the bottom size A of directions X and the bottom size B of Y-direction.The bottom area of protuberance 5 (bottom size A * bottom size B) is preferably 0.5～50mm
2, be particularly preferably 2～20mm
2
The size C of the directions X of heat fusing bonding part 4 (with reference to Fig. 1) is preferably 0.1～2mm, is particularly preferably 0.2～1.0mm, and the dimension D of Y-direction (with reference to Fig. 1) is preferably 0.2～5.0mm, is particularly preferably 0.5～3.0mm.
The preferable production process of above-mentioned face sheet 10 then, is described with reference to Fig. 5 and Fig. 6.
In the method for the 1st embodiment, as the 1st non-woven fabrics, use the non-woven fabrics that contains core shift core-sheath-type composite fibre.In above-mentioned core shift core-sheath-type composite fibre, core exists unevenly on the fibre section, when imposing when hot, occurs curling owing to the shrinkage factor of core and sheath material is different.Because curling core shift core-sheath-type composite fibre is three dimensional structure, therefore in the fleece that after the combing operation, forms, the probability that fiber contacts each other reduces, in addition, because the inhomogeneous existence of sheath material as the heat fusing adhesive composition, therefore form in the cross-wise direction of fiber and be easy to the many face of the bonding sheath composition of other fiber heat fusing and be difficult to the few face of the bonding sheath composition of heat fusing, so can reduce the heat fusing bounding point, utilize hot blast to carry out showing when fluffy answer is processed good fluffy recovery.Therefore, be suitable for forming the protuberance 5 that does not have the cavity.
As the non-woven fabrics that contains core shift core-sheath-type composite fibre, preferably use above-mentioned hot blast method non-woven fabrics, above-mentioned hot roll non-woven fabrics, heat embossing non-woven fabrics, air lay method non-woven fabrics, resin-bonded method non-woven fabrics etc.
As core shift core-sheath-type composite fibre, the preferred composite fibre that is consisted of by 2 kinds of thermoplastic, polymeric materials that uses.As thermoplastic, polymeric materials, can enumerate the polyolefin such as polyethylene or polypropylene, the polyester such as polyethylene terephthalate, PTT, polybutylene terephthalate (PBT) and polyamide etc.
Combination as the resin of core and sheath section, can enumerate core is the polyester such as polyethylene terephthalate, PTT, polybutylene terephthalate (PBT), sheath section is poly combination, core is polypropylene, sheath section is poly combination, core is ethylene-propylene random copolymer, and sheath section is poly combination etc.The ratio of the core shift core-sheath-type composite fibre in the 1st non-woven fabrics is preferably 50～100%, and more preferably 75～100%, more preferably 100%.As the fiber beyond the core shift core-sheath-type composite fibre, can mix and use the hot-melt-bondable fiber that consisted of by simple thermoplastic, polymeric materials or cotton etc.
In the method for the 1st embodiment, the 1st non-woven fabrics 1 for sending from the grey cloth (figure slightly) of drum as shown in Figure 5, uses the annealing device 6 of hot blast mode, utilizes hot blast to implement fluffy answer and processes.6 pairs of annealing devices shown in Figure 5 are wound on the non-woven fabrics that transports on the circumferential surface of cylinder 61 and utilize hot blast to implement heat treatment.The circumferential surface of cylinder 61 is made of poromeric materials such as punch metal or metal gauzes, and the top of cylinder 61 is covered by outer housing 62.In annealing device 6,61 blow hot blast from outer housing 62 to cylinder, and the hot blast that blows is attracted in the cylinder 61 after connecting non-woven fabrics 1.Utilizing the fluffy answer of this hot blast to process preferably carries out under the following conditions: with the hot blast mode to non-woven fabrics blow 0.3～3 second temperature less than the fusing point of core shift core-sheath-type composite fibre and more than or equal to the hot blast of this fusing point-50 ℃.Here the fusing point of said core shift core-sheath-type composite fibre is the fusing point of the polymer mesotheca composition resin of formation core and sheath section.For example, when the sheath composition of core shift core-sheath-type composite fibre is polyethylene, about 125 ℃ for this poly fusing point, preferably utilize 90～110 ℃ hot blast to reply processing.
Then, make and process the 1st non-woven fabrics 1 that makes loft increase (answer) by above-mentioned fluffy answer to bite into circumferential surface be that the 1st roll 11 and the circumferential surface of concaveconvex shape has in the bite with the 2nd roll 12 of the concaveconvex shape of the concaveconvex shape phase interlock of the 1st roll 11, give concaveconvex shape to this non-woven fabrics 1.
What Fig. 6 represented the 1st roll 11 wants section's enlarged drawing.The 1st roll 11 is combined to form the roll shape with a plurality of horizontal gear 11a, 11b... with regulation facewidth and obtains.The size of the Y-direction of the protuberance 5 of the facewidth decision face sheet 10 of each gear.Adjacent gear makes up according to the mode of each half tooth distance that staggers.Its result, the circumferential surface of the 1st roll 11 becomes concaveconvex shape.
Be formed with in the teeth groove section of each gear of the 1st roll 11 and attract hole 13.This teeth groove section is equivalent to the recess in the concaveconvex shape of circumferential surface of the 1st roll 11.Attract hole 13 to be communicated in the attraction sources (not shown) such as aerator or vacuum pump, according to from the bite of the 1st roll and the 2nd roll to and the interflow section of the 2nd non-woven fabrics 2 between the mode that attracts control.Therefore, be endowed the non-woven fabrics 1 of concaveconvex shape by the interlock of the 1st roll 11 and the 2nd roll 12 owing to the captivation that attracts hole 13 is sealed on the circumferential surface of the 1st roll, and kept this to give the state of concaveconvex shape.As shown in Figure 6, each half tooth distance that staggers of protuberance of the adjacent gear by making roll 11 produces the shearing force of broad ways tearing the 1st non-woven fabrics 1, thereby is easy to produce the sparse part 5b of above-mentioned fiber between each gear.By space G is set, and suitably set the width of this space G between protuberance, thereby can control the fibre density of the above-mentioned sparse part of fiber.That is, this space G is less then to produce larger shearing force, so the fibre density of the sparse part 5b of fiber diminishes; This space G is larger, and the shearing force that then produces is less, so the fibre density of the sparse part 5b of fiber becomes large.
Then, as shown in Figure 5, the 1st non-woven fabrics 1 is being continued attracting holding under the state on the circumferential surface of the 1st roll 11, making the 2nd non-woven fabrics 2 and the 1st non-woven fabrics 1 interflow, overlapping part is being clipped between the 1st roll 11 and the anvil roller 15.At this moment, with the 1st roll 11 and anvil roller 15 both or only anvil roller 15 is heated to set point of temperature in advance.Thus, will be positioned on the protuberance of the 1st roll 11, be the 1st non-woven fabrics 1 on the tooth of each gear and 2 heating of the 2nd non-woven fabrics and pressurization to form heat fusing bonding part 4, obtain the face sheet 10 of said structure.
According to the manufacture method of present embodiment, by utilizing hot blast the loft of the 1st non-woven fabrics is replied, can be manufactured on efficiently the face sheet 10 that forms the cavity between the 1st non-woven fabrics 1 of the part with protuberance 5 and the 2nd non-woven fabrics 2.In addition, when giving concaveconvex shape to the 1st non-woven fabrics 1, the 1st non-woven fabrics 1 is stretched in fiber orientation directions (moving direction) and perpendicular direction, but because the weak strength of this vertical direction etc., the part of the one or both sides, the left and right sides of the moving direction of this non-woven fabrics 1 of the protuberance that therefore forms at the 1st non-woven fabrics 1 produces the sparse part of fibre density.So acquisition has the face sheet 10 of the sparse sparse part 5b of fiber of fibre density.
Other manufacture method (method of the 2nd embodiment) of above-mentioned face sheet 10 then, is described with reference to Fig. 7.
For the method for the 2nd embodiment, the aspect different from the method for the 1st embodiment described, represent that with same-sign also description thereof is omitted for identical aspect.There is not the aspect that specifies, identical with the method for the 1st embodiment, can suitably be suitable for the related description of the method for the 1st embodiment.
In the method for the 2nd embodiment, make and utilize hot blast to implement the 1st non-woven fabrics 1 after fluffy answer is processed to be adsorbed to circumferential surface and to have on the circumferential surface of the roll 11 that attracts the hole for concaveconvex shape and recess, under the state on the circumferential surface of this roll 11, make the 1st non-woven fabrics 1 and the 2nd non-woven fabrics 2 interflow the 1st non-woven fabrics being continued attracting holding.Then, between the protuberance of roll 11 and anvil roller 15, its overlapping part is pressurizeed and heat to form heat fusing bonding part 4.So operation, the face sheet 10 of acquisition said structure.As the roll 11 in the method for the 2nd embodiment, can use the identical roll of the 1st roll 11 in the method with the 1st embodiment.
Other manufacture method (method of the 3rd embodiment) of above-mentioned face sheet 10 then, is described with reference to Fig. 8.
For the method for the 3rd embodiment, the aspect different from the 1st embodiment method described, represent that with same-sign also description thereof is omitted for identical aspect.There is not the aspect that specifies, identical with the method for the 1st embodiment, can suitably be suitable for the related description of the method for the 1st embodiment.
In the method for the 3rd embodiment, as the 1st non-woven fabrics, use the non-woven fabrics that contains thermally extensible fiber.As thermally extensible fiber, can use the fiber that is consisted of by different the 1st resinous principle of orientation index and the 2nd resinous principle.Wherein, the 1st resinous principle is the composition of keeping the intensity of this composite fibre, and the 2nd resinous principle is the composition of performance hot-melt-bondable.The orientation index of the 1st resinous principle is preferably more than 40%, more preferably more than 50%.On the other hand, the orientation index of the 2nd resinous principle is preferably below 25%, more preferably below 20%.Orientation index is the index of degree of orientation of the macromolecular chain of the expression resin that consists of fiber.And, be respectively above-mentioned value by the orientation index that makes the 1st resinous principle and the 2nd resinous principle, then the thermally extensible composite fibre is extending by heating.Particularly, this thermally extensible composite fibre is preferably made by the high speed melt-spinning method.
In addition, the non-woven fabrics that contains thermally extensible fiber is such as can be by obtaining with the heat fusing bounding point of hot blast method formation fiber and fiber etc. at the fleece that utilizes combing method to obtain.The ratio of the thermally extensible fiber in the 1st non-woven fabrics is preferably 50～100%, and more preferably 75～100%, more preferably 100%.
In the method for the 3rd embodiment, making the 1st non-woven fabrics 1 that contains the extensibility fiber bite into circumferential surface is that the 1st roll 11 and the circumferential surface of concaveconvex shape has with the concaveconvex shape of the 1st roll 11 and mutually in the bite of the 2nd roll 12 of the concaveconvex shape of interlock, give concaveconvex shape to this non-woven fabrics 1.Then, to be endowed the 1st non-woven fabrics 1 continuation attracting holding behind the concaveconvex shape under the state on the circumferential surface of the 1st roll 11, make the 1st non-woven fabrics 1 and the 2nd non-woven fabrics 2 interflow, the part that it is overlapping is clipped between the 1st roll 11 and the anvil roller 15, obtains to have formed the 1st non-woven fabrics 1 of heat fusing bonding part 4.In the 1st non-woven fabrics in this stage, between the 1st non-woven fabrics 1 of the part with protuberance 5 and the 2nd non-woven fabrics 2, produced the cavity.
Afterwards, the 1st non-woven fabrics 1 is implemented heat treatment, make the thermally extensible fiber elongation in the 1st non-woven fabrics 1, fill up above-mentioned cavity with the thermally extensible fiber that extends.So, obtain the face sheet 10 of said structure.
Fig. 9 is the axonometric chart that expression absorbent commodity of the present invention is used the 4th embodiment of face sheet.The face sheet 10A of the 4th embodiment is used for the skin contact face of the absorbent commodities such as disposable diaper, sanitary napkin, underwear back boxing (sanitary pad), incontinence pad.
Face sheet 10A is made of the 1st mutually stacked non-woven fabrics 1 and the 2nd non-woven fabrics 2 and the long stapled aggregation 3 that is configured between this two- layer nonwoven 1,2.
The 1st non-woven fabrics 1 forms the face towards wearer skin side (skin contact face) of face sheet 10A, and the 2nd non-woven fabrics 2 forms the face (non-skin contact face) towards the absorption side of face sheet 10A.
Heat fusing is bonding partly for the 1st non-woven fabrics and the 2nd non-woven fabrics, thus, has formed many heat fusing bonding parts 4 at face sheet 10A.Part beyond the above-mentioned heat fusing bonding part 4 of the 1st non-woven fabrics 1 is side-prominent towards the skin of wearer, has formed many protuberances 5.
As shown in Figure 9, protuberance 5 and heat fusing bonding part 4 a direction parallel with the face of face sheet 10A be directions X alternately and become row to dispose, and form multiple row in the Y-direction perpendicular to above-mentioned directions X.The configuration of on directions X, staggering respectively of the protuberance 5 of adjacent column and heat fusing bonding part 4, more particularly, the half pitch that staggers configuration.
In addition, the moving direction of the 1st non-woven fabrics 1, the 2nd non-woven fabrics 2 and long fibre aggregation 3 banded grey cloth 1A～3A (with reference to Figure 11) separately in the directions X of the face sheet 10A of present embodiment and the manufacturing process of face sheet 10A is consistent, the length direction of this absorbent commodity when in addition, being assembled in the absorbent commodity with face sheet 10A or perpendicular direction are consistent.In addition, the directions X of the face sheet 10A of present embodiment is also consistent with the 1st non-woven fabrics 1, the 2nd non-woven fabrics 2 and long fibre aggregation 3 fiber orientation directions separately.In addition, when face sheet 10A observed as a whole, the face general planar of its 2nd non-woven fabrics 2 sides had formed the concavo-convex of big rise and fall at the face of the 1st non-woven fabrics 1 side.
The internal configurations of the protuberance 5 of face sheet 10A has long stapled aggregation 3.Long stapled aggregation 3, when making face sheet 10A, the banded grey cloth 3A that is orientated in the longitudinal direction as long fibre, be introduced between the banded grey cloth 2A of the banded grey cloth 1A of the 1st non-woven fabrics and the 2nd non-woven fabrics 2, the long fibre 31 that consists of this aggregation 3 is seen along directions X above face sheet 10A and is orientated.Consist of the total length that each long fibre 31 of long stapled aggregation 3 spreads all over face sheet 10A at directions X, have the length of crossing over a plurality of heat fusing bonding parts 4 at the directions X of face sheet 10A.Long fibre 31 preferably has the length of crossing over 5 above heat fusing bonding parts 4 on directions X, more preferably have the length of crossing over 10 above heat fusing bonding parts 4.
Among the present invention, long fibre refers to measure the fiber long time by the long assay method of the average fiber of JIS L1015 (C method), be preferably more than the 70mm, and more preferably more than the 80mm, the above fiber of 100mm more preferably.But, the total length of the direction (directions X) of extending when the row of the protuberance 5 among the face sheet 10A and heat fusing bonding part 4 is during less than 100mm, be configured in nearly all fiber between the 1st non-woven fabrics 1 and the 2nd non-woven fabrics 2, for example the fiber more than 90% spreads all over the total length of face sheet and when extending, these fibers are long fibre.The long fibre that uses among the present invention is to be commonly referred to as continuous filamentary fiber.In addition, continuous filamentary bundle is commonly referred to as fibre bundle.Therefore, conceptive, the long fibre among the present invention is to comprise continuous filamentary fiber.In addition, long fibre of the present invention also comprises and being truncated near heat fusing bonding part 4 so that there is not the situation of long stapled aggregation 3 in face sheet 10B shown in Figure 13.
Long stapled aggregation 3 is fixed in the heat fusing bonding part 4 of directions X between the 1st non-woven fabrics 1 and the 2nd non-woven fabrics 2.The both ends of long stapled aggregation 3 are by making the 1st non-woven fabrics 1 and bonding being fixed of the 2nd non-woven fabrics 2 heat fusings under the state that this aggregation 3 is arranged in clamping.In the 1st non-woven fabrics 1 and the bonding heat fusing bonding part 4 that obtains of the 2nd non-woven fabrics 2 heat fusings, the constituent of the formation fiber of preferred the 1st non-woven fabrics 1 directly contacts with the constituent of the formation fiber of the 2nd non-woven fabrics 2 and heat fusing is bonding, but also can be the formation fiber of long stapled aggregation 3 heat fusing is bonding each other, and also can be that heat fusing is bonding respectively for the formation fiber of the 1st non-woven fabrics 1 and the formation fiber of the 2nd non-woven fabrics 2.
Long stapled aggregation 3 as shown in figure 10, between heat fusing bonding part 4,4 adjacent on the directions X of face sheet 10A, the 1st non-woven fabrics 1 and the 2nd non-woven fabrics 2 do not engage, and consist of the each other also not combination of long fibre 31 of aggregation 3.The many long fibres 31 that consist of aggregation 3 scatter and are present between the 1st non-woven fabrics 1 of the outer surface that forms protuberance 5 and flat condition the 2nd non-woven fabrics 2 in the formed roughly whole space.
Be positioned at protuberance 5 inside long fibre 31 as shown in figure 10, form the curve-like that protrudes towards the projected direction (top of Figure 10) of protuberance 5, more particularly, as shown in figure 10, when observing from Y-direction, formed the chevron shape with circular-arc top.The long fibre 31 of forming curves shape has part away from the 2nd non-woven fabrics 2 in heat fusing bonding part 4,4 substantial middle section on directions X, begin to reduce gradually towards two heat fusing bonding parts 4,4 respectively from this part with the distance of the 2nd non-woven fabrics 2.As shown in figure 10, in the long fibre 31 of forming curves shape, the protrusion degree that is configured near the long fibre 31a the 1st non-woven fabrics 1 is larger, the protrusion degree that is configured near the long fibre 31b the 2nd non-woven fabrics 2 is less, and therebetween long stapled protrusion degree diminishes towards the 2nd non-woven fabrics side gradually from the 1st non-woven fabrics 1 side.
As the 1st and the 2nd non-woven fabrics, can use the non-woven fabrics identical with the 1st and the 2nd non-woven fabrics of face sheet 10.Preferred non-woven fabrics is also identical.In the face sheet 10A of the 4th embodiment, also use not flexible in fact non-woven fabrics as the 1st and the 2nd non-woven fabrics.
As the 1st non-woven fabrics, from the viewpoint of skin sense of touch, can particularly preferably use above-mentioned hot blast method non-woven fabrics, heat embossing non-woven fabrics, air lay method non-woven fabrics, needle point method non-woven fabrics etc.
As the 2nd non-woven fabrics, from improving fibre density, make liquid be easy to the viewpoint that flows from the 1st non-woven fabrics 1 or long stapled aggregation 3, can particularly preferably use above-mentioned hot roll non-woven fabrics, heat embossing non-woven fabrics, Nonwovens of spunbond, meltblown non-woven fabrics, jet net-spraying method non-woven fabrics etc.
The 1st is identical with the face sheet 10 of the 1st embodiment with the formation fiber of the 2nd non-woven fabrics.
From making the limpen viewpoint of skin contact face, the 1st non-woven fabrics 1 preferred surface is level and smooth, preferably is made of the fiber number low fiber of trying one's best.On the other hand, from quick acquisition liquid, the viewpoint that prevents the leakage of exudates such as menses or urine is set out, the fibre density of the 1st non-woven fabrics 1 is preferably more sparse than the layer that long fibre 31 consists of, therefore, preferably its fiber number that consists of fiber greater than the fiber number that is clipped in the long fibre 31 between the 1st and the 2nd non-woven fabrics 1,2.
From the above point of view, the fiber number of the formation fiber of the 1st non-woven fabrics is preferably 1.0～8.0dtex, can make loft higher and reduce the viewpoint of fibre density from using lower fiber number, is more preferably formed by curling fiber.Mass area ratio is preferably 5～50g/m
2
The fiber number of long fibre 31 is preferably 0.3～3.0dtex.The fiber number of the formation fiber of the 2nd non-woven fabrics is preferably 1.0～5.0dtex, and mass area ratio is preferably 5～30g/m
2
As the long fibre 31 that consists of long stapled aggregation 3, can use in hot-melt-bondable fiber and the non-hot-melt-bondable fiber any, but when as the face sheet 10 of the 4th embodiment, accompanying long fibre 31 between the 1st and the 2nd non-woven fabrics at the heat fusing bonding part, from the viewpoint of the bond strength that improves the heat fusing bonding part, preferably can the bonding fiber of heat fusing.
Here so-called can the bonding fiber of heat fusing be at least the surface can be when heating melting or softening and be combined the fiber of perhaps being combined with the formation fiber of the 1st non-woven fabrics and/or the 2nd non-woven fabrics by melting or softening composition with the formation fiber of the 1st non-woven fabrics and/or the 2nd non-woven fabrics.
As can the bonding fiber of heat fusing, the preferred fiber that is consisted of by thermoplastic, polymeric materials that uses.As thermoplastic, polymeric materials, can enumerate the polyester such as the polyolefin such as cellulose acetate, polyethylene or polypropylene, polyethylene terephthalate and polyamide etc.In addition, go back the preferred core-sheath-type composite fibre or the parallel composite fiber that combine that uses by these thermoplastic, polymeric materials.
What long stapled aggregation 3 preferably contained 30～100 % by weight in this aggregation 3 can the bonding fiber of heat fusing, and what more preferably contain 50～100 % by weight can the bonding fiber of heat fusing.
In addition, long stapled aggregation 3 preferably consists of the little crispulate long fibre 31 of potentiality as main body.By curling long fibre 31, can make long fibre 31 be present in the inside of protuberance 5 and make this protuberance form solid state, can further improve resiliency and liquid imbedibility.In manufacturing equipment, with curling long fibre 31 be stretched to curling roughly fully the elongation after, its heat fusing is bonded on the 1st non-woven fabrics 1 and the 2nd non-woven fabrics 2, thus, in the inside of protuberance 5, so that the long fibre 31 of fully elongation shrinks, the effect of utilizing long stapled aggregation 3 to fill between the 1st non-woven fabrics 1 and the 2nd non-woven fabrics 2 can obtain solid protuberance 5 because potentiality is curling.
Long stapled aggregation 3 preferably consists of hydrophilic long fibre as main body.
As hydrophilic long fibre, comprise originally have hydrophilic fiber and originally do not have hydrophilic but by implement hydrophilicity-imparting treatment given hydrophilic fiber the two.Preferably originally had hydrophilic long fibre, such as enumerating cellulose acetate, artificial silk, Lyocell, Tencel etc.Particularly preferably not only had hydrophilic but also had the cellulose acetate of hot-melt-bondable.As cellulose acetate, preferably use Triafol T and/or cellulose diacetate.
The hydrophilic long fibre that contains 30～100 % by weight in long stapled aggregation 3 preferred these aggregations 3 more preferably contains the hydrophilic long fibre of 50～100 % by weight.
In the protuberance part (part with protuberance 5) of face sheet 10A, preferably the order hydrophiling degree by the 1st non-woven fabrics 1, long fibre aggregation 3, the 2nd non-woven fabrics 2 increases successively.By giving the hydrophiling degree with gradient, the discharged liquid such as urine or menses are flow to the long stapled aggregation 3 from protuberance 5 surfaces swimmingly, and then it is flow in the 2nd non-woven fabrics 2 swimmingly.
In addition, in the protuberance part (part with protuberance 5) of face sheet 10A, preferably by the 1st non-woven fabrics 1, long stapled aggregation 3, the 2nd non-woven fabrics 2 orders fibre density is increased successively.By giving fibre density with gradient, the discharged liquid such as urine or menses are flow to the long stapled aggregation 3 from protuberance 5 surfaces swimmingly, and then it is flow in the 2nd non-woven fabrics 2 swimmingly.
Face sheet 10A according to the 4th embodiment, because the internal configurations at protuberance 5 has the curvilinear long fibre 31 that protrudes towards the projected direction of protuberance 5, therefore for the pressurization of thickness direction, protuberance 5 demonstrates good resiliency, along with the activity of skin in the absorbent commodity use, protuberance can repeated compression and answer.Therefore, be difficult for bringing stimulation to skin, soft with the thoughts and feelings of skin contact.
In addition, protuberance 5 and heat fusing bonding part 4 are because therefore in the above described manner configuration is compared with the in the past situation that the top of protuberance forms in one direction continuously, and liquid is difficult for flowing to the surface, is conducive to prevent that liquid from leaking, and is also good with the time point absorbability.In addition, because the flexibility of the face direction of face sheet is good, all can be flexibly crooked on directions X and Y-direction, therefore the fit with wearer improves, and in addition, can also use in the article that require flexibility or position etc.
In addition, because consisting of the long fibre of long fibre aggregation is configured on the direction (directions X), therefore capillary force is from improving towards two heat fusing bonding parts 4,4 respectively near the central part of protuberance 5, so, the liquid that sees through the 1st non-woven fabrics 1 is mobile swimmingly along the long stapled differently-oriented directivity of long fibre aggregation 3, flows to the 2nd non-woven fabrics 2 swimmingly.Therefore, the some absorbability is more good.
From embodying more effectively one of above-mentioned effect or plural viewpoint, face sheet 10A preferably has following structure.
The thickness H (with reference to Figure 10) of the part with protuberance 5 of face sheet 10A is preferably more than the 0.6mm, be particularly preferably more than the 1.0mm, the thickness h of heat fusing bonding part 4 (with reference to Figure 10) is preferably below the 0.3mm, be particularly preferably below the 0.2mm, the ratio (H/h) of their thickness preferably is at least more than 2, is particularly preferably more than 3.The upper limit of the upper limit of thickness H, (H/h) ratio and the lower limit of thickness h are not particularly limited, and thickness H is preferably below the 3.0mm, and (H/h) than being preferably below 30, thickness h is preferably more than the 0.1mm.
In addition, every 100cm of face sheet 10A
2The number of protuberance 5 be preferably more than 250, be particularly preferably more than 500.
The bottom size A (with reference to Fig. 9) of the directions X of protuberance 5 is preferably 0.5～5.0mm, is particularly preferably 1.0～4.0mm.The bottom size B (with reference to Fig. 9) of the Y-direction of protuberance 5 is preferably 1.0～10mm, is particularly preferably 2.0～7.0mm.
Ratio (the bottom size A: bottom size B) be preferably 1: 1～1: 10, be particularly preferably 1: 2～2: 5 of the bottom size A of directions X and the bottom size B of Y-direction.The bottom area of protuberance 5 (bottom size A * bottom size B) is preferably 0.5～50mm
2, be particularly preferably 2～20mm
2
The size C of the directions X of heat fusing bonding part 4 (with reference to Fig. 9) is preferably 0.1～2mm, is particularly preferably 0.2～1.0mm, and the dimension D of Y-direction (with reference to Fig. 9) is preferably 0.2～5.0mm, is particularly preferably 0.5～3.0mm.
The preferable production process of above-mentioned face sheet 10A is described referring to Figure 11 and Figure 12.
At first, as shown in figure 11, banded grey cloth 3A at the long stapled aggregation 31 in the banded grey cloth 1A interflow of the 1st non-woven fabrics 1 of sending here continuously, they are bitten into circumferential surface is that the 1st roll 11 and the circumferential surface of concaveconvex shape has in the bite with the 2nd roll 12 of the concaveconvex shape of the concaveconvex shape phase interlock of the 1st roll, gives concaveconvex shape to the grey cloth 1A of the 1st non-woven fabrics 1.
What Figure 12 represented the 1st roll 11 wants section's enlarged drawing.The 1st roll 11 is combined to form the roll shape with a plurality of horizontal gear 11a, 11b... with regulation facewidth and obtains.The size of the Y-direction of the protuberance 5 of the facewidth decision face sheet 10A of each gear.Adjacent gear makes up according to the mode of each half tooth distance that staggers.Its result, the circumferential surface of the 1st roll 11 becomes concaveconvex shape.
Be formed with in the teeth groove section of each gear of the 1st roll 11 and attract hole 13.This teeth groove section is equivalent to the recess in the concaveconvex shape of circumferential surface of the 1st roll 11.Attract hole 13 to be communicated in the attraction sources (not shown) such as aerator or vacuum pump, according to from the bite of the 1st roll and the 2nd roll to and the interflow section of the 2nd non-woven fabrics 2 between the mode that attracts control.Therefore, the 1st non-woven fabrics 1 of having been given concaveconvex shape by the interlock of the 1st roll 11 and the 2nd roll 12 because of the captivation driving fit that attracts hole 13 on the circumferential surface of the 1st roll, and keep it to give the state of concaveconvex shape.At this moment, as shown in figure 12, after the space G of regulation is set between adjacent gear, can not be subject in the situation of the shear effect impact that the concave-convex clutch of undue extending force or roll produces the 1st non-woven fabrics 1 being sealed on the circumferential surface of the 1st roll 11 at the 1st non-woven fabrics 1.
Then, as shown in figure 11, continue attracting holding under the state on the 1st roll 11 circumferential surfaces at the grey cloth 1A with the 1st non-woven fabrics 1, the banded grey cloth 2A of overlapping the 2nd non-woven fabrics 2, the part that it is overlapping is clipped between the 1st roll 11 and the anvil roller 15.At this moment, with the 1st roll 11 and anvil roller 15 both or only anvil roller 15 is heated to set point of temperature in advance.Thus, by on the bonding protuberance that will be positioned at the 1st roll 11 of heat fusing, be that grey cloth 1A, the banded grey cloth 3A of long stapled aggregation 3 of the 1st non-woven fabrics 1 on the tooth of each gear and the grey cloth 2A of the 2nd non-woven fabrics 2 engage.
As the banded grey cloth 3A of long stapled aggregation, use will curling long fibre as the formation fiber, and the grey cloth that is orientated in the longitudinal direction of this long fibre.And, in the time of in the bite that grey cloth 3A is incorporated into the 1st roll 11 and the 2nd roll 12, in advance this grey cloth 3A is significantly extended on its length direction, and in the situation that keeps this state, between the 1st roll 11 and anvil roller 15, utilize the bonding joint that carries out the 1st non-woven fabrics 1 and the 2nd non-woven fabrics 2 of heat fusing.After the grey cloth 3A of the long stapled aggregation 3 of introducing with elongation state between the 1st non-woven fabrics 1 and the 2nd non-woven fabrics 2 is passing through between the 1st roll 11 and the anvil roller 15, elongation state is relaxed, thus, the long fibre that consists of this grey cloth 3a shrinks, and the long stapled loft that is present in the protuberance 5 increases.Thus, as shown in figure 10, can obtain the protuberance 5 interior face sheet 10A that are full of by long stapled aggregation 3.
The percentage elongation of long fibre 31 between the 1st non-woven fabrics 1 and the 2nd non-woven fabrics 2 during the fixed length fiber or the grey cloth 3A of its aggregation is preferably 105～130%, is particularly preferably 110～120%.
Here, the percentage elongation of the grey cloth 3A of long fibre or its aggregation is tried to achieve by following formula.
The percentage elongation of grey cloth 3A (%)=L
2/ L
1* 100
(L in the formula
1The length of the long fibre aggregation of the per unit weight of shearing out for the length of elongation before the grey cloth, operation from manufacturing equipment before the device of elongation grey cloth, L
2Length for the long fibre aggregation of the per unit weight sheared out of the later operation of device of elongation grey cloth from manufacturing equipment)
Face sheet of the present invention preferably uses as the face sheet of the absorbent commodities such as disposable diaper, sanitary napkin, underwear back boxing, incontinence pad as mentioned above.Absorbent commodity generally is configured the back-sheet of the difficult permeability of face sheet, liquid impermeability or liquid with liquid permeability and is clipped in the absorber of the liquid retainability that disposes between two sheet materials.
The embodiment of face sheet of the present invention and manufacture method thereof more than has been described, but each invention is not limited to above-mentioned embodiment, can carry out appropriate change.
For example, the protuberance 5 of Fig. 1 or face sheet shown in Figure 9 is quadrangular pyramid platform shape, but protuberance 5 also can be hemispherical other shape such as grade.In addition, the protuberance 5 of adjacent column and heat fusing bonding part 4 degree that staggers on directions X also can not be respectively 1/2 spacing, but the arbitrary sizes such as 1/3 spacing, 1/4 spacing.
In addition, Fig. 2 and protuberance shown in Figure 3 have the sparse part 5b of fiber at the both ends of the fiber orientation directions of the 1st non-woven fabrics 1, but also can only have the sparse part 5b of fiber an end, can also a face sheet 10 mix exist both ends have the protuberance of the sparse part 5b of fiber and only at one end section have the protuberance of the sparse part 5b of fiber.In addition, face sheet of the present invention can also only be configured in the skin contact face of absorbent commodity a part, for example be opposite on the part of excretory portion.In addition, the protuberance 5 that preferably has the sparse part 5b of fiber is distributed on the whole face sheet, but also can only be distributed with the protuberance with the sparse part 5b of fiber at the excretory portion opposing part.
In addition, the long fibre differently-oriented directivity of long fibre aggregation 3 can also be the Y-direction of face sheet 10A, in addition, can also mix existence with the long fibre that is orientated in Y-direction at the long fibre that directions X is orientated.
Claims (12)
1. face sheet, it is used for the skin contact face of absorbent commodity, and wherein, heat fusing is bonding and formed the heat fusing bonding part partly for the 1st stacked non-woven fabrics and the 2nd non-woven fabrics mutually; Part beyond the described heat fusing bonding part of the 1st non-woven fabrics is side-prominent and formed many protuberances to the skin of wearer; Described protuberance replaces with the heat fusing bonding part and becomes the row configuration, and described row are configured to multiple row; The face general planar of the 2nd non-woven fabrics one side of face sheet, the inside of described protuberance is made of the 1st non-woven fabrics,
The described protuberance of at least a portion has the sparse part of fiber that fibre density is lower than the fibre density of described fiber orientation directions central part at an end or the both ends of the fiber orientation directions of the 1st non-woven fabrics.
2. face sheet according to claim 1, wherein, in the described protuberance with the sparse part of described fiber, poor greater than perpendicular to the fibre density at the central part on the direction of described fiber orientation directions and both ends of the difference of the fibre density of the described central part on the fiber orientation directions of the 1st non-woven fabrics and the sparse part of described fiber.
3. face sheet according to claim 2, wherein, in the described protuberance with the sparse part of described fiber, the fibre density at the both ends on the direction vertical with the fiber orientation directions of the 1st non-woven fabrics is more than or equal to the fibre density of the central part of this direction.
4. face sheet according to claim 1, wherein, the 1st non-woven fabrics is to form the hot blast method non-woven fabrics that the heat fusing bounding point of fiber and fiber forms by the hot blast method on the fleece that utilizes combing method to obtain.
5. face sheet according to claim 4, it is formed by following method: utilize hot blast to implement fluffy answer to the 1st non-woven fabrics that contains curling core shift core-sheath-type composite fibre and process, make its bite into circumferential surface be the 1st roll and the circumferential surface of concaveconvex shape have with the concaveconvex shape of the 1st roll mutually in the bite of the 2nd roll of the concaveconvex shape of interlock to give its concaveconvex shape, then under the state on the circumferential surface that remains in the 1st roll, collaborate with the 2nd non-woven fabrics, and between the protuberance of the 1st roll and other roll, heat and pressurize with described the 2nd non-woven fabrics, thereby form described heat fusing bonding part.
6. face sheet according to claim 4, it is formed by following method: utilize hot blast to implement fluffy answer to the 1st non-woven fabrics that contains curling core shift core-sheath-type composite fibre and process, making it be adsorbed in circumferential surface is that concaveconvex shape and recess have on the circumferential surface of the roll that attracts the hole, under the state that remains on the circumferential surface of described roll, collaborate with the 2nd non-woven fabrics, and between the protuberance of described roll and other roll, pressurize and heat with described the 2nd non-woven fabrics, thereby form described heat fusing bonding part.
7. face sheet according to claim 4, it is formed by following method: make the 1st non-woven fabrics that contains thermally extensible fiber bite into circumferential surface be the 1st roll and the circumferential surface of concaveconvex shape have with the concaveconvex shape of the 1st roll mutually in the bite of the 2nd roll of the concaveconvex shape of interlock to give its concaveconvex shape, then under the state on the circumferential surface that remains in the 1st roll, collaborate with the 2nd non-woven fabrics, and between the protuberance of the 1st roll and other roll, heat and pressurize to form described heat fusing bonding part with described the 2nd non-woven fabrics, then implement heat treatment, make described thermally extensible fiber elongation.
8. face sheet according to claim 4, it is formed by following method: making the 1st non-woven fabrics that contains thermally extensible fiber be adsorbed in circumferential surface is that concaveconvex shape and recess have on the circumferential surface of the roll that attracts the hole, under the state that remains on the circumferential surface of described roll, collaborate with the 2nd non-woven fabrics, and between the protuberance of described roll and other roll, pressurize and heat to form described heat fusing bonding part with described the 2nd non-woven fabrics, then implement heat treatment, make described thermally extensible fiber elongation.
9. the manufacture method of a face sheet claimed in claim 1, it comprises: utilize hot blast to implement fluffy answer to the 1st non-woven fabrics that contains curling core shift core-sheath-type composite fibre and process, make its bite into circumferential surface be the 1st roll and the circumferential surface of concaveconvex shape have with the concaveconvex shape of the 1st roll mutually in the bite of the 2nd roll of the concaveconvex shape of interlock to give its concaveconvex shape, then under the state on the circumferential surface that remains in the 1st roll, collaborate with the 2nd non-woven fabrics, and between the protuberance of the 1st roll and other roll, heat and pressurize with described the 2nd non-woven fabrics, thereby form described heat fusing bonding part.
10. the manufacture method of a face sheet claimed in claim 1, it comprises: utilize hot blast to implement fluffy answer to the 1st non-woven fabrics that contains curling core shift core-sheath-type composite fibre and process, making it be adsorbed in circumferential surface is that concaveconvex shape and recess have on the circumferential surface of the roll that attracts the hole, under the state that remains on the circumferential surface of described roll, collaborate with the 2nd non-woven fabrics, and between the protuberance of described roll and other roll, pressurize and heat with described the 2nd non-woven fabrics, thereby form described heat fusing bonding part.
11. the manufacture method of a face sheet claimed in claim 1, it comprises: make the 1st non-woven fabrics that contains thermally extensible fiber bite into circumferential surface be the 1st roll and the circumferential surface of concaveconvex shape have with the concaveconvex shape of the 1st roll mutually in the bite of the 2nd roll of the concaveconvex shape of interlock to give its concaveconvex shape, then under the state on the circumferential surface that remains in the 1st roll, collaborate with the 2nd non-woven fabrics, and between the protuberance of the 1st roll and other roll, heat and pressurize to form described heat fusing bonding part with described the 2nd non-woven fabrics, then implement heat treatment, make described thermally extensible fiber elongation.
12. the manufacture method of a face sheet claimed in claim 1, it comprises: making the 1st non-woven fabrics that contains thermally extensible fiber be adsorbed in circumferential surface is that concaveconvex shape and recess have on the circumferential surface of the roll that attracts the hole, under the state that remains on the circumferential surface of described roll, collaborate with the 2nd non-woven fabrics, and between the protuberance of described roll and other roll, pressurize and heat to form described heat fusing bonding part with described the 2nd non-woven fabrics, then implement heat treatment, make described thermally extensible fiber elongation.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP352146/2006 | 2006-12-27 | ||
| JP2006352146A JP4804337B2 (en) | 2006-12-27 | 2006-12-27 | Top sheet for absorbent article and method for producing the same |
| JP2006355843A JP4931580B2 (en) | 2006-12-28 | 2006-12-28 | Top sheet for absorbent articles |
| JP355843/2006 | 2006-12-28 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN101219078A CN101219078A (en) | 2008-07-16 |
| CN101219078B true CN101219078B (en) | 2013-03-13 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN 200710300198 Expired - Fee Related CN101219078B (en) | 2006-12-27 | 2007-12-19 | Face sheet for absorption article and method for producing the same |
Country Status (2)
| Country | Link |
|---|---|
| JP (1) | JP4804337B2 (en) |
| CN (1) | CN101219078B (en) |
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| JP5374128B2 (en) * | 2008-12-08 | 2013-12-25 | 花王株式会社 | Solid shaped sheet |
| JP5021719B2 (en) * | 2009-12-18 | 2012-09-12 | 花王株式会社 | Non-woven |
| JP4975091B2 (en) * | 2008-12-25 | 2012-07-11 | 花王株式会社 | Non-woven |
| CN102257201B (en) * | 2008-12-25 | 2014-10-08 | 花王株式会社 | Non-woven fabric and process for producing same |
| CN103993428B (en) * | 2008-12-25 | 2017-10-24 | 花王株式会社 | The manufacture method of non-woven fabrics |
| WO2010074208A1 (en) * | 2008-12-25 | 2010-07-01 | 花王株式会社 | Non-woven fabric |
| JP2010148730A (en) * | 2008-12-25 | 2010-07-08 | Kao Corp | Surface sheet of absorbent article |
| JP5213695B2 (en) * | 2008-12-26 | 2013-06-19 | 花王株式会社 | Non-woven fabric bulk increase method |
| KR101212426B1 (en) * | 2009-08-25 | 2012-12-13 | 도레이첨단소재 주식회사 | Multilayer non-woven fabric having an improved property and manufacturing method thereof |
| JP5319512B2 (en) * | 2009-12-22 | 2013-10-16 | 花王株式会社 | Manufacturing method of uneven nonwoven fabric |
| JP5386341B2 (en) * | 2009-12-25 | 2014-01-15 | 花王株式会社 | Disposable diapers |
| JP5203349B2 (en) * | 2009-12-25 | 2013-06-05 | 花王株式会社 | Non-woven |
| JP5631035B2 (en) * | 2010-03-29 | 2014-11-26 | ユニ・チャーム株式会社 | Nonwoven sheet |
| JP5432823B2 (en) * | 2010-06-01 | 2014-03-05 | 花王株式会社 | Non-woven |
| CN102145565A (en) * | 2010-11-07 | 2011-08-10 | 金红叶纸业集团有限公司 | Surface sheet of absorption product and manufacturing method thereof |
| RU2598303C2 (en) * | 2010-12-24 | 2016-09-20 | Као Корпорейшн | Non-woven material and absorbent article using same |
| JP5717602B2 (en) * | 2011-09-30 | 2015-05-13 | ユニ・チャーム株式会社 | Laminated nonwoven fabric and method for producing the laminated nonwoven fabric |
| JP5743961B2 (en) * | 2011-12-09 | 2015-07-01 | ユニ・チャーム株式会社 | Liquid-permeable nonwoven fabric |
| US10070999B2 (en) | 2012-10-31 | 2018-09-11 | Kimberly-Clark Worldwide, Inc. | Absorbent article |
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| US9480609B2 (en) | 2012-10-31 | 2016-11-01 | Kimberly-Clark Worldwide, Inc. | Absorbent article with a fluid-entangled body facing material including a plurality of hollow projections |
| US9480608B2 (en) | 2012-10-31 | 2016-11-01 | Kimberly-Clark Worldwide, Inc. | Absorbent article with a fluid-entangled body facing material including a plurality of hollow projections |
| JP6024915B2 (en) * | 2013-03-28 | 2016-11-16 | Jnc株式会社 | Nonwoven fabric and products obtained using the same |
| CN103806222A (en) * | 2014-03-10 | 2014-05-21 | 宋志敏 | Multi-component integrally formed hot air non-woven fabric and manufacturing method thereof |
| JP5931131B2 (en) * | 2014-06-26 | 2016-06-08 | ユニ・チャーム株式会社 | Non-woven |
| CN104762755A (en) * | 2015-04-09 | 2015-07-08 | 希雅图（上海）新材料科技股份有限公司 | Steeped non-woven cloth and producing technique |
| CN105729898B (en) * | 2016-02-02 | 2018-03-13 | 安庆市恒昌机械制造有限责任公司 | A kind of composite nonwoven and its manufacture device |
| CN106038081B (en) * | 2016-07-07 | 2022-04-26 | 厦门延江新材料股份有限公司 | Three-dimensional non-woven fabrics of trompil |
| CN107889456B (en) * | 2016-07-29 | 2019-03-15 | 尤妮佳股份有限公司 | The manufacturing method of absorbent commodity |
| JP6946441B2 (en) * | 2017-01-31 | 2021-10-06 | ザ プロクター アンド ギャンブル カンパニーＴｈｅ Ｐｒｏｃｔｅｒ ＆ Ｇａｍｂｌｅ Ｃｏｍｐａｎｙ | Molded non-woven fabrics and articles containing molded non-woven fabrics |
| WO2018160161A1 (en) | 2017-02-28 | 2018-09-07 | Kimberly-Clark Worldwide, Inc. | Process for making fluid-entangled laminate webs with hollow projections and apertures |
| CN110312495A (en) | 2017-03-30 | 2019-10-08 | 金伯利-克拉克环球有限公司 | Opening area is combined in absorbent article |
| WO2019005906A1 (en) | 2017-06-30 | 2019-01-03 | The Procter & Gamble Company | Shaped nonwoven |
| EP3645775B1 (en) | 2017-06-30 | 2021-07-21 | The Procter & Gamble Company | Method for making a shaped nonwoven |
| JP6706646B2 (en) * | 2018-05-29 | 2020-06-10 | 花王株式会社 | Absorbent article |
| JP7271150B2 (en) * | 2018-11-30 | 2023-05-11 | ユニ・チャーム株式会社 | absorbent article |
| JP6934485B2 (en) * | 2019-04-02 | 2021-09-15 | 花王株式会社 | Sheet piece and method for manufacturing an absorber using it |
| CN110295404B (en) * | 2019-05-22 | 2021-08-10 | 武汉纺织大学 | Automatic production equipment and method for plane receiving type centrifugal spinning |
| DE102019115005A1 (en) * | 2019-06-04 | 2020-12-10 | Carl Freudenberg Kg | Skin pad |
| CN110341247A (en) * | 2019-08-13 | 2019-10-18 | 贵州卡布婴童用品有限责任公司 | A kind of fluffy fabric and its technique and the absorbent article with the fluffy fabric |
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Also Published As
| Publication number | Publication date |
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| JP2008161302A (en) | 2008-07-17 |
| CN101219078A (en) | 2008-07-16 |
| JP4804337B2 (en) | 2011-11-02 |
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