CN101557929A - Stretchable sheet and process for producing the stretchable sheet - Google Patents
Stretchable sheet and process for producing the stretchable sheet Download PDFInfo
- Publication number
- CN101557929A CN101557929A CN200780045872.8A CN200780045872A CN101557929A CN 101557929 A CN101557929 A CN 101557929A CN 200780045872 A CN200780045872 A CN 200780045872A CN 101557929 A CN101557929 A CN 101557929A
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- China
- Prior art keywords
- elastic filament
- sheet material
- nonwoven
- flexible sheet
- elastic
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Images
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- Nonwoven Fabrics (AREA)
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Abstract
This invention provides a stretchable sheet (10) comprising a number of elastic filaments (13) arranged so as to extend in one direction without mutual crossing, the elastic filaments (13) having been bonded to stetchable nonwoven fabrics (11, 12) in a substantially nonstreched state over the whole length. The stretchable sheet (10) is produced by taking off a number of elastic filaments (13) in a molten state spun from a spinning nozzle (16) at a predetermined rate, fusing the elastic filaments (13) while stretching, before the solidification of the elastic filaments (13) while stretching, to the nonwoven fabrics (11, 12) so as to allow the elastic filaments (13) to arrange in one direction without mutual crossing, and then stretching a composite (19) comprising the fused elastic filaments (13) in a direction along which the elastic filaments (13) are extended, thereby imparting stretchability to the composite (19).
Description
Technical field
The present invention relates to flexible sheet material and manufacture method thereof that elastic filament and non-woven fabric compoundedization are formed.
Background technology
As the relevant prior art of flexible sheet material that rubber-like fiber and non-woven fabric compoundedization are formed, for example known technology that patent documentation 1 and 2 records are arranged.Shown in Figure 1 as these documents, the flexible sheet material of putting down in writing in these documents is made of the 1st nonwoven layer the 122, the 2nd nonwoven layer 126 and the elastomer layer between two nonwoven layer 124.Elastomer layer 124 by scrim (scrim), perforated films, elastomer weave cotton cloth, nonwoven constitutes.In Fig. 1 of these documents, to have put down in writing elastomer layer 124 and constituted by elastomer scrim 130, this elastomer scrim 130 is made of orthogonal big flow control 1 strand 125 and big flow control 2 strands 127.Because elastomer layer 124 forms such structure, so the flexible sheet materials of patent documentation 1 and 2 records, when making it along a certain direction elongation, the phenomenon that the sheet width with the prolonging direction vertical direction narrows down can appear, and the phenomenon that width reduces promptly appears.Therefore, when this flexible sheet material was for example used as the housing material of shorts type diaper, material was stretched along the waist direction, width takes place on the length direction of diaper reduce, so the diaper skew easily that becomes drops, or gauffer occurs on the diaper.In addition, consider the formation of diaper and user's action, it causes uneven elongation on width, so width reduces and becomes more obvious.In addition, strand 125,127 and nonwoven layer the 122, the 126th are bonded together by heat and pressure, and therefore, strand 125,127 is absorbed in the nonwoven layer 122,126, thereby diminish the loftiness of nonwoven layer 122,126.Strand 125,127 and nonwoven layer the 122, the 126th are bonded together by the heat that applies from nonwoven 122 or 126 sides and pressure, when therefore bonding, the temperature of the nonwoven side in the outside raises easily, becomes the temperature state lower than the temperature of nonwoven of strand side easily.Therefore, if go for sufficient joint strength, then there is nonwoven because heat and pressure ratio strand melt and the problem of filming earlier.In addition, owing to need and to melt with the resin of the contacted internal fiber of strand, therefore to apply higher temperature or pressure, thereby have the problem that makes the feel variation.If use the high nonwoven of fusing point, then non-woven fabrics fiber itself can not melt, but becomes and the elastomer scrim is difficult to melt bondedly, and the peel strength when therefore making sheet material descends.In addition, dystectic nonwoven is difficult to obtain the good sheet material of soft hand feeling.
As other technology of flexible sheet material, the also known technology that patent documentation 3 records are arranged.The flexible sheet material of putting down in writing in the document such as Fig. 1, Fig. 2 of the document and as shown in Figure 7, by waveform parts 20,21 with gear shape, on sheet material 12, form a large amount of arcuate parts 13, go up melt bonded flexible strand 16 at the top (bottom) of this arcuate part 13.Elastic strands 16 is to be extruded with molten condition from mouth mould 22, and melt bonded with the state and the sheet material 12 that do not stretch.Therefore, elastic strands 16 and sheet material 12 to be to contact joint, thus, improve bond strength and be not easy.In addition, the arcuate part 13 of the flexible sheet material of document record again can not extend after flattening, and the so-called elongation limit is arranged.And then, form arcuate part 13 and make the use quantitative change of sheet material 12 of the lax part of sheet material 12 many, and uneconomical, and gas permeability also reduces.In addition, in the document, put down in writing also and the sheet material 12 before engaging with elastic strands 16 can have been engaged with this elastic strands under the state that can extend with its blank volume state.But it is difficult will carrying out conveyance under the state that does not make its elongation along the tensile nonwoven of moving direction.And, with the flexible sheet material coiling tubular of patent documentation 3 record the time, stress relaxation can take place, promptly since the state that is stretched with the tension force when reeling when preserving for a long time convergent force reduce existing problems aspect keeping quality thus gradually.Add man-hour after different in addition places is implemented this sheet material, if consider operability and conveying property, sheet material coiling tubular then must will stretch.
The elastic sheet material shape composite of patent documentation 3 record is elastic strands not arranged according to the mode of not extending along a direction across mutually to form on a surface of the sheet material that is made of nonwoven etc., described elastic strands during by cooling rubber-like molten thermoplastic (for example elastic system polyester, polyurethane, polystyrene-poly isoprene-polystyrene, polystyrene-poly butadiene-polystyrene or polystyrene-poly (ethene-butylene)-polystyrene) constitute.This multiplicity of filaments does not mutually extend ground along a direction across and arranges the following manufacturing of flexible sheet material that forms: from extruding the long filament of molten condition in vertical with the conveyance direction of sheet material separating a large amount of spinning-nozzles that predetermined distance arranges, and make itself and described sheet material melt bonded.
But in the manufacture method of above-mentioned flexible sheet material, the long filament of extruding with molten condition from spinning-nozzle is before melt bonded with sheet material, and complications take place in the influence owing to wind or static etc. sometimes.Following problems appears in the result: should be in the final products upper edge long filament that directly directly extends of direction join on the sheet material with the state of complications, equally spaced arrange the flexible sheet material that forms thereby can't make a large amount of long filaments.The complications of long filament can be by the long filament that will extrude from spinning-nozzle to stipulate that above tension force carries out tractive and prevents, if will be applied on the long filament of molten condition to preventing the tortuous effectively tension force of degree, then this long filament can rupture (fracture of wire) sometimes, thereby can't carry out the spinning technique of long filament.When particularly the diameter of long filament was thin, the situation that fracture of wire takes place owing to tractive was a lot, and the productivity ratio reduction of flexible sheet material becomes serious.On the other hand, from improving the viewpoints such as feel of flexible sheet material, the diameter that the expectation long filament is arranged is than the commercially available thinner tendency of the employed elastic yarn of absorbent commodities such as diaper.
Put down in writing following method in the patent documentation 4: behind the shaped resilient strand, make this elastic strands, engage with nonwoven then, thereby obtain flexible sheet material with state elongation through cooling curing.Elongated portion by elastic strands is replied, and nonwoven is lax, thereby shows retractility in its length range.Since elastic strands with the curing that is cooled before nonwoven engages, so need carry out applying with nonwoven with bonding agent etc.Therefore, in order to obtain sufficient adhesion strength, need the bonding agent of more amount.If more ground coating adhesive then can be filled out the space between non-woven fabrics fiber, so gas permeability descends.In addition, because with bonding agent with the plurality of fibers bundle together, so rigidity improves.Thereby, be difficult to obtain the sheet material of softness and good permeability.In addition, the flexible sheet material of putting down in writing in the document with so that the common wire rubber elastomer that the state of elastic yarn elongation is fitted has same structure, therefore on flexible sheet material, form rivel, the skin sense of touch is poor, does not have the outward appearance as cloth.Under the state that has formed rivel, nonwoven will be elongated to original state, and elastomer is the state that has extended, thereby stress relaxation takes place, and promptly because convergent force descends gradually with long-time preservation of state of elongation, so contractility reduces during long preservation.In addition, with the operation of compoundization such as nonwoven in, use roller to make the elastic strands elongation or it be rolled in when carrying out conveyance on the roller, exist described elastic strands and be bonded on the described roller or problem such as fracture of wire takes place.
In addition, because this elastomeric strand all becomes thicker, therefore have hard sense of touch, feel is also bad.
Different with above technology, also proposed following elastic and expandable composite sheets: it is (referring to a patent documentation 5) that elastic sheet material that the continuous fiber by the film of elastic extension or elastic extension is constituted and the fiber assembly with stiff extensibility are laminated.Elastic sheet material and fiber assembly are bonded together by the junction surface of configuration discontinuously.The formation fiber of fiber assembly is a long fibre continuous between the junction surface.This long fibre is neither deposited not melt bonded between the junction surface yet, but fiber is separated from each other independence.In addition, this long fibre presents irregular curve-like between the junction surface.
According to patent documentation 5, in this elastic and expandable composite sheets, the long fibre of fiber assembly presents irregular curve-like between the junction surface, and therefore, when making this sheet material elongation, its elongation can not hindered by this fiber assembly.But because the long fibre of fiber assembly is separated from each other independence between the junction surface, so this elastic and expandable composite sheets is low to the intensity of tractive.And the peel strength between fiber assembly and the elastic sheet material is also low.In addition, be easy to generate between the junction surface and long stapledly float, sheet material has been the outward appearance of galley proof thus, and the impression of outward appearance is also bad.
Patent documentation 1:WO00/20206A1
Patent documentation 2:WO00/20207A1
Patent documentation 3:WO95/34264A1
Patent documentation 4:WO01/87214A1
Patent documentation 5:US6730390B1
Summary of the invention
The invention provides a kind of flexible sheet material, wherein, the great number of elastic long filament of arranging according to the mode of not extending along a direction across mutually engages with tensile nonwoven with the state that does not extend in fact on its whole length.
In addition, the invention provides a kind of manufacture method of flexible sheet material, wherein, will be from spinning-nozzle a large amount of elastic filament of spun molten condition with the fixing speed tractive and stretch, and before this elastic filament solidifies, the mode of mutually not arranging along a direction across according to described elastic filament makes this elastic filament and nonwoven melt bonded, then the bearing of trend of the melt bonded complex that this elastic filament arranged along this elastic filament stretched, thereby make this complex have retractility.
In addition, the present invention is a kind of manufacture method of flexible sheet material, it is that a large amount of elastic filament with spun molten condition from spinning-nozzle is with the fixing speed tractive and stretch, and before this elastic filament solidifies, the mode of mutually not arranging along a direction across according to described elastic filament makes elastic filament and nonwoven melt bonded, then the bearing of trend of the melt bonded complex that this elastic filament arranged along this elastic filament stretched, thereby make this complex have retractility, wherein, with before described nonwoven contacts, the displacement that this elastic filament is started at from the top of this spinning-nozzle is below the 600mm at spun described elastic filament from described spinning-nozzle.
Description of drawings
Fig. 1 is the partial cross-sectional perspective view of an embodiment of the flexible sheet material of demonstration the present invention.
Fig. 2 (a) and (b) be respectively elastic filament in the flexible sheet material shown in Figure 1 along the nature of bearing of trend and the longitdinal cross-section diagram under the elongation state.
Fig. 3 for the diameter (sectional area) of expression fiber with the SEM image of an example of the non-elastic fiber of the state of stepped variation roughly.
Fig. 4 is the key diagram of the assay method of fusion tension force.
Fig. 5 is the preferred schematic representation of apparatus of using in the manufacturing of expression flexible sheet material shown in Figure 1.
Fig. 6 is the side view of the major part of presentation graphs 5 shown devices schematically.
Fig. 7 is for representing that complex is by the schematic diagram of the state of device stretching shown in Figure 5.
Fig. 8 is for representing the schematic diagram of the state that non-elastic fiber is stretched.
Fig. 9 is the key diagram of the evaluation method of diaper skew dropping.
The specific embodiment
Below based on preferred implementation of the present invention, with reference to accompanying drawing the present invention will be described.The partial cross-sectional perspective view of an embodiment of flexible sheet material of the present invention has been shown among Fig. 1.
The flexible sheet material 10 of present embodiment amounts to 2 nonwoven by the 1st nonwoven 11 and the 2nd nonwoven 12 and the great number of elastic long filament 13 that is clamped between two nonwoven constitutes.Particularly, flexible sheet material 10 following formations: a large amount of elastic filament 13 of arranging according to the mode of not extending along a direction across mutually engages with the tensile nonwoven 11,12 that the state that does not extend in fact constitutes with containing non-elastic fiber.
The content of elastic resin is preferably above, 70～100 weight % more preferably of 40 weight % in the elastic filament.Thus, can improve the modification (formability improve, anti-oxidant, painted etc.) of elastic resin or improve bond strength between elastic filament and the nonwoven.The content of elastic resin is preferably 0～30 weight %, 0～10 weight % more preferably in the tensile nonwoven.By in nonwoven, containing elastic resin, not only can improve answer intensity, and can improve bond strength by the elastic resin that contains in the nonwoven and the compatibility between the elastic filament resin.In addition, the residual silk during from the sense of hardening, skin sense of touch, tearing, the viewpoints such as bond strength between answer intensity, elastic filament and the nonwoven, the weight per unit area of the elastic resin that is contained in the flexible sheet material of the present invention is preferably 1～25g/m
2, 4～15g/m more preferably
2This weight per unit area is tried to achieve by method described later.
Bond strength between elastic filament 13 and the nonwoven 11 is preferably above, the 20～200cN/25mm more preferably of 10cN/25mm.Bond strength between elastic filament 13 and the nonwoven 12 is also in above-mentioned scope.By making bond strength between elastic filament 13 and each nonwoven 11,12 more than 10cN/25mm, thereby the one sense of flexible sheet material 10 integral body is improved, stretching flexible sheet material 10 or when engaging, can prevent effectively that elastic filament 13 from unfavorable condition such as peeling off from each nonwoven 11,12 with other sheet material.On the other hand,, the expansion performance of flexible sheet material 10 is reduced, therefore preferably the upper limit of this bond strength is made as 200cN/25mm if the bond strength between elastic filament 13 and each nonwoven 11,12 surpasses 200cN/25mm.The following mensuration of above-mentioned bond strength.
The assay method of the bond strength between＜elastic filament and the nonwoven 〉
(1) nonwoven is 2 a situation
With flexible sheet material according on its flexible direction for 150mm, on the direction vertical with this flexible direction for the size of 25mm cut test film.This test film should flexible direction be peeled off about 3cm at a nonwoven and another nonwoven upper edge.At this moment, elastic filament is peeled off with the nonwoven that engages more firmly.The test film that so separates the part mode that is draw direction by its flexible direction is fixed between the chuck of distraction test machine (the system Autograph AG-1kNIS of Shimadzu Seisakusho Ltd.) (the chuck spacing is 25mm).Test film is carried out tractive with 300mm/ minute draw rate, reach 160mm, thereby on a nonwoven and another nonwoven, peel off, measure the peel strength of this moment until the chuck spacing.Following calculating between the measurement zone of peel strength: the chuck spacing is set at 35～150mm, and when peel strength is swung in the mode that shows minimax point in this mensuration interval, will be from 5 the bigger average peel strength of average conduct of maximal point (salient point).When not showing minimax point, calculate average peel strength.In addition, as preferred assay method of the present invention, the Autograph AG-1KNIS of use Shimadzu Seisakusho Ltd. system is as the distraction test machine and use the material testing machine software TRAPEZIUM2 of Shimadzu Seisakusho Ltd.'s system to measure, and is average by 5 of salient point maximums, calculates average peel strength.According to this method, no matter can calculate average peel strength showing minimax and do not show under the situation of minimax.Measurement is carried out 5 times, with their mean value as the bond strength between elastic filament and the nonwoven.
(2) nonwoven is 1 a situation
When test film being fixed between the chuck of distraction test machine, on a chuck, install and fix elastic filament, on another chuck, install and fix nonwoven, in addition, similarly carry out with above-mentioned (1).
25% of the per unit area weight of the elastic resin that is contained in＜flexible the sheet material is replied the assay method of intensity 〉
Try to achieve 25% of the sheet material that stretches by method described later and reply intensity,, try to achieve 25% answer intensity of the per unit area weight of the elastic resin in the flexible sheet material thus then divided by the weight per unit area of the elastic resin in the sheet material that should stretch of trying to achieve in addition.The weight per unit area of the elastic resin in the flexible sheet material is tried to achieve divided by the area of flexible sheet material by the addition of the elastic resin when making this flexible sheet material.In the time can from flexible sheet material, extracting elastic resin, can obtain the weight per unit area of the elastic resin of flexible sheet material with following method by using solvent etc.That is, utilize solvent etc. from flexible sheet material, to extract elastic resin, obtain the component ratio of this extraction composition with analyses such as NMR.Content by the elastic resin of calculating from this withdrawal ratio is tried to achieve the weight per unit area of elastic resin divided by the area of flexible sheet material.According to this method, can extract the elastic resin that contains in the elastic filament that constitutes flexible sheet material, and when in the tensile nonwoven that constitutes flexible sheet material, containing elastic resin, also can extract the described elastic resin that contains in the described nonwoven, thereby can measure the weight per unit area of the elastic resin that is contained in the flexible sheet material exactly.
Bond strength between elastic filament 13 and the nonwoven 11,12 is more than the 10cN/25mm and 25% answer intensity of the per unit area weight of the elastic resin in the flexible sheet material 10 is 1.0cN/{50mm (g/m
2) above flexible sheet material can make by manufacture method described later.Obtaining having aspect the flexible sheet material of the balance excellence between above-mentioned interlayer bond strength and the expansion performance particularly importantly, in its manufacturing process, " before the elastic filament of molten condition solidifies, make this elastic filament and nonwoven melt bonded ".That is, elastic filament 13 and nonwoven 11,12 are bonded together by melt bonded, help to show above-mentioned bond strength and 25% to a great extent and reply intensity.The flexible sheet material that engages by the engagement means beyond described elastic filament melt bonded between elastic filament and the nonwoven, for example heating pressurization with the two overlapping state by the elastic filament after will solidifying and nonwoven with them in the integrated flexible sheet material that forms, the formation fiber of nonwoven being absorbed in elastic filament is insufficient, therefore is difficult to take into account above-mentioned bond strength and 25% and replys intensity.
For 25% of the per unit area weight that makes bond strength between elastic filament 13 and the nonwoven 11,12 and the elastic resin in the flexible sheet material 10 is replied intensity respectively in above-mentioned specific scope, as concrete method, can list for example following method: in manufacture method described later, 1) grip strength when engaging elastic filament and nonwoven adjusts; Gap between the pair of rolls of using during 2) to joint elastic filament and nonwoven is adjusted; 3) top of this spinning-nozzle when the elastic filament with molten condition is spun by the spinning-nozzle distance till the kneading portion elastic filament and the nonwoven is adjusted etc.By carrying out above-mentioned 1)～3) in any, can remain in shape under the state to a certain degree elastic filament is engaged with nonwoven elastic filament.In general, when long filament that will be thinner as the present invention engages with nonwoven, compare with the situation that nonwoven engages,, sustain damage especially easily when therefore engaging because long filament is thinner with the film that will be wider than long filament far away.This damage is meant that the sectional area of elastic filament on the flexible direction of flexible sheet material reduces.Elastic filament is owing to be subjected to such damage, and the answer intensity that therefore flexible sheet material takes place reduces.But, according to above-mentioned 1)～3) method, can not produce above-mentioned unfavorable condition, can make above-mentioned bond strength and 25% reply intensity and be in respectively in the above-mentioned specific scope.
The bond strength of the flexible sheet material 10 of present embodiment between elastic filament 13 and each nonwoven 11,12 in above-mentioned scope and the per unit area weight of the elastic resin in the flexible sheet material 10 25% reply intensity in above-mentioned scope, further the average splice ratio between the fiber (nonwoven formation fiber) of preferred elastomeric long filament and the tensile nonwoven 11,12 of formation is 10～60%, more preferably 20～50%.The flexible sheet material of this average splice ratio in above-mentioned scope has sufficient peel strength, simultaneously by between elastic filament and the fiber that constitutes this nonwoven engage and the hard sense that produces can not become obviously, thereby the feel excellence.In addition, by this average splice ratio is set in the above-mentioned scope, can make the expansion performance of stretchable sheet material 10 approach the expansion performance of elastic filament 13 self.The weight per unit area that contains the elastic resin in the common flexible sheet material of elastic resin film is 30～80g/m
2(it is 0.6cN/{50mm (g/m that 25% of the per unit area weight of the elastic resin in the flexible sheet material 10 is replied intensity
2)), relative therewith, flexible sheet material of the present invention can be used the more 25% higher answer intensity and the bond strength of elastic resin acquisition of subsection area weight.
In order to make elastic filament and above-mentioned nonwoven constitute average splice ratio between the fiber in above-mentioned spy's scope, as concrete method, except above-mentioned 1)～3) method, also can list following method: the melt temperature (forming temperature) that 4) makes elastic resin than this fusing point that nonwoven constitutes the low melting point composition that fusing point is minimum in the fiber high 125 ℃～180 ℃; 5) fibre density of the fiber that constitutes nonwoven is compared with common fibre density low, is 0.05～0.12g/cm
3Deng.By as above-mentioned 5) reduce the fibre density of the fiber that constitutes nonwoven, can under the melt bonded and flexible situation that does not hinder elastic filament and nonwoven surface fiber, obtain replying the high sheet material of intensity.The following mensuration of average splice ratio between the fiber of elastic filament and formation nonwoven.
The assay method of the average splice ratio between the fiber of＜elastic filament and formation nonwoven 〉
Bonding part for 1 elastic filament and nonwoven, under 100～1000 times multiplying power SEM being carried out in the cross section of the flexible sheet material direction vertical with flexible direction observes, try to achieve bonding part that elastic filament and nonwoven constitute fiber length (unassembled girth) respectively, utilize following formula to obtain the joint ratio of 1 elastic filament along the disengaged part of the length (girth that is engaged) of the circumferencial direction of described elastic filament and elastic filament and nonwoven formation fiber along the circumferencial direction of described elastic filament.
The joint ratio (%) of 1 elastic filament={ girth that is engaged/(girth that is engaged+unassembled girth) } * 100
The mean value of n=10 in each SEM observation is constituted the average splice ratio of fiber as elastic filament and nonwoven.
Be back to Fig. 1, the flexible sheet material 10 of present embodiment amounts to 2 nonwoven by the 1st nonwoven 11 and the 2nd nonwoven 12 and a large amount of elastic filament 13 of being clamped between two nonwoven constitutes.Each elastic filament 13 engages with the 1st and the 2nd nonwoven 11,12.The 1st nonwoven 11 and the 2nd nonwoven 12 can be nonwoven of the same race, also can be nonwoven not of the same race.Here said nonwoven of the same race is meant that the manufacturing process, nonwoven of nonwoven constitute each all identical nonwoven such as the thickness of the kind of fiber, the fibre diameter that constitutes fiber or length, nonwoven or weight per unit area.In above-mentioned at least one is called nonwoven not of the same race when inequality.In addition, the elasticity among the present invention is meant following character: can extend, and from respect to the state of raw footage elongation 100% (length be raw footage 200%) release force the time, return back to the length of raw footage below 125%.
Each nonwoven 11,12 is all extending.Each nonwoven 11,12 can extend on the direction identical with the bearing of trend of elastic filament 13.The so-called extending following situation that comprises: the situation of the formation fiber of (1) nonwoven 11,12 self elongation; (2) do not extend even constitute fiber self, but be separated from each other or owing to fiber combination each other etc. makes the stereochemical structure recurring structure variation that is formed by plurality of fibers or constitutes that fiber is broken or the slack of fiber is stretched, thereby the situation of extending on the whole at nonwoven at the fiber of intersection point place combination.
Each nonwoven 11,12 also can with the state of blank volume before elastic filament 13 engages under be tensile.Perhaps can be following nonwoven: though with the state of blank volume before elastic filament 13 engages under be not tensile, according to after the tensile mode that becomes after elastic filament 13 engages is processed, thereby become tensile nonwoven.As being used to make the nonwoven tensile concrete grammar that becomes, can listing between heat treatment, roller the engaging-in stretching that stretches, utilize teeth groove or gear, utilizing the tractive stretching of stenter etc.Preferable production process in view of flexible sheet material 10 described later, the viewpoint that the conveyance of the described nonwoven 11,12 from will make elastic filament 13 and nonwoven 11,12 melt bonded the time becomes good, preferred nonwoven 11,12 is not extending under the state of blank volume.
Each nonwoven 11,12 is extending, and contains stiff in fact fiber, thereby comes down to stiff.
Each elastic filament 13 is continuous in fact on the total length of flexible sheet material 10.Elastic filament 13 contains elastic resin.Each elastic filament 13 is arranged according to the mode of not extending along a direction across mutually.But because the inevitable change of creating conditions of flexible sheet material 10, the situation that elastic filament 13 inadvertently takes place to intersect allows.Each elastic filament 13 then can extend with linearity as long as do not intersect mutually, also can extend circuitously.Long filament does not intersect mutually and is meant almost there is not intersection point.If intersection point is arranged, a large amount of fibers are then arranged between intersection point and the intersection point, but usually industrial, the situation of the length unanimity of the fiber that exists between intersection point is rarely found.If under the different state of the length of the fiber that exists between intersection point, extend, then only understand the short fiber stress application of length contained between antinode, even dispose a lot of fibers, also can produce the fiber that much has neither part nor lot in stretching.When the fiber of identical weight compared, the more convergent force of the intersection point of fiber was little.Therefore, wasted cost.Consider only flexible in the vertical situation, when having fiber in the horizontal as netted, it is useless that horizontal fiber not only becomes, and produce above-mentioned intersection point, similarly also producing useless part in the fiber longitudinally.The bearing of trend of elastic filament 13 can be consistent with the 1st and the 2nd nonwoven 11,12 moving direction during fabrication, also can be vertical with nonwoven 11,12 moving direction during fabrication.When making flexible sheet material 10 according to preferable production process described later, the bearing of trend of elastic filament 13 is consistent with the 1st and the 2nd nonwoven 11,12 moving direction during fabrication.
The molten resin that elastic filament 13 preferably will spray from nozzle stretches at spinning threadling and obtains.By stretching, the macromolecule that constitutes elastic filament 13 carries out molecularly oriented along the length direction of this elastic filament 13, and therefore, elongation/answers during 50% elongation described later is than raising, and hysteresis loss diminishes.In addition, by stretching, can obtain thin elastic filament.From this viewpoint, elastic filament 13 preferably is stretched to 1.1～400 times, especially preferably is stretched to 4～100 times long filament.Relative therewith, in the patent documentation 3 in front, the elastic strands of extruding with molten condition from the mouth mould engages with sheet material under the state that does not stretch, so the hysteresis loss of this elastic strands is inadequately little.In addition, in patent documentation 4, when stretching,, therefore there is the problem of elastic strands generation curling round the roll owing to the direct touch roll of adhering resin.
Particularly, elastic filament 13 preferably stretches elastic resin and forms under fusion or softening state.Thus, can obtain the long filament of abundant refinement, and because reason described later, feel improves.In addition, by elastic resin is stretched under fusion or softening state, behind applying nonwoven 11,12, the elastic filament 13 that reaches normal temperature does not show the power that desire is shunk, and becomes state same when elastic filament 13 is engaged with nonwoven 11,12 under the state that does not extend.As the concrete operations that stretch in the present embodiment, can list following operation: (1) will carry out melt spinning as the resin of elastic filament 13 raw materials, obtain undrawn yarn earlier, elastic filament with this undrawn yarn heats once more then, the operation that stretches under the state more than the softening temperature (glass transition temperature Tg of hard segment part (hard segment)); (2) will carry out melt spinning as the resin of the raw material of elastic filament 13, the operation that the fiber of gained molten condition is directly stretched.If make flexible sheet material 10 according to preferable production process described later, then elastic filament 13 can directly stretch by the fiber of the molten condition that will obtain behind the melt spinning and obtain.
The viewpoint that never produces above-mentioned difference in height is set out, and the diameter of elastic filament 13 on the thickness direction of flexible sheet material is preferably 1～30%, is preferably 5～12% especially with respect to the ratio of the thickness of flexible sheet material 10.
The cross section of elastic filament 13 can be circular, also can be the cross section of ellipse or flat pattern according to different situations.When for example making flexible sheet material 10 according to manufacture method described later, there is the tendency that is easy to become flat pattern in the cross section of elastic filament 13.At this moment, in flexible sheet material 10, elastic filament 13 is preferably as follows configuration: the in-plane of the major axis of flat pattern and flexible sheet material 10 is roughly equidirectional, and the thickness direction of minor axis and flexible sheet material 10 is roughly equidirectional.
When the cross section of elastic filament 13 is flat pattern, from the viewpoint that the masking function of bond strength between the formation fiber of expansion performance, elastic filament 13 and nonwoven 11,12 and flexible sheet material 10 increases, the ratio of major axis/minor axis (average flat ratio) is preferably 1.0～7.0, is preferably 1.1～3.0 especially.The cross section is that the elastic filament 13 of flat pattern disposes according to the roughly consistent mode of its long axis direction and the in-plane of flexible sheet material 10.In addition, when the cross section of elastic filament 13 was flat pattern, the diameter of elastic filament 13 was meant the average of major diameter and minor axis diameter.The major axis that has in the elastic filament 13 of flat pattern is meant, the length of long cross line in the periphery of the elastic filament of selecting by microscopic examination 13.Minor axis in the elastic filament 13 is meant, describes to have the both sides parallel with the major axis of as above determining and the length of the minor face during with the circumscribed rectangle of above-mentioned periphery.5 point elasticity long filaments are arbitrarily measured above-mentioned value, with the mean value of flat ratio as average flat ratio, with the mean value of diameter value diameter value as elastic filament.
From flexible sheet material 10 show sufficient retractility viewpoint, show as the viewpoint of the excellent handle of cloth and from showing the viewpoint of above-mentioned design effect as required, the spacing of adjacent elastic filament 13 (distance between the adjacent elastic filament 13), diameter with this elastic filament 13 is a condition in above-mentioned scope, is preferably 0.1～5mm, is preferably 0.4～1mm especially.
As the engage pattern of elastic filament 13, can list for example melt bonded etc. with the 1st and the 2nd nonwoven 11,12.If make flexible sheet material 10 according to preferable production process described later, then elastic filament 13 engages with each nonwoven 11,12 by melt bonded.So-called melt bonded, comprise elastic filament with the mutual fusion of fiber that constitutes nonwoven 11,12 bonding state, perhaps any one party fusion, the opposing party are absorbed in wherein and these two kinds of bonding states.According to this method, can each nonwoven 11,12 not applied under the situation of excessive heat, before the curing of the elastic filament 13 that obtains by melt spinning, make this elastic filament 13 melt bonded with nonwoven, therefore only be that the fiber that exists around this elastic filament 13 engages with this elastic filament 13, and keeping the feel of nonwoven 11,12 away from the fiber of this position, therefore have the advantage that the feel of flexible sheet material 10 is well kept.At this moment, at each nonwoven 11,12 with before elastic filament 13 engages, as auxiliary engagement means, can also coating adhesive.Perhaps, with after elastic filament 13 engages,, can also heat-treat (steam sprays, heat embossing) or machinery interweave (needle point method, jet net-spraying method) etc. at each nonwoven 11,12 as auxiliary engagement means.But these auxiliary engagement means are damaged the feel of the flexible sheet material 10 of gained sometimes, or elastic filament 13 is caused damage.Therefore, preferably that elastic filament 13 is melt bonded by its melting heat and nonwoven 11,12.But, as the assist in engagement means, when using when blowing the attached heat treatment that forms by the hot blast that utilizes the hot blast method, can under the situation of the feel of not damaging the flexible sheet material 10 of gained, still obtain the high sheet material of bond strength of nonwoven 11,12, be preferred from this point.
Different with the sheet material of record in aforementioned patent document 1 and 2, in the flexible sheet material 10 of present embodiment, do not exist with other elastic filament of the combinations of states vertical with elastic filament 13.Therefore, even the sheet material 10 that will stretch stretches on the direction identical with the bearing of trend of elastic filament 13, this flexible sheet material 10 also can extend under the situation that width reduces not taking place substantially.That is, flexible sheet material 10 is under its extended state, and width is much the same on its length direction.As a result, add man-hour at the sheet material 10 that will stretch with its elongation state conveyance and to it, it is good that operability becomes.In addition, when sheet material 10 housing material as for example shorts type diaper that will stretch uses, can prevent from effectively that diaper from taking place to be offset to drop or gauffer takes place in wearing with process.In addition, if consider the formation of diaper and user's action, though uneven elongation takes place on width, this moment width can not take place substantially yet and reduce, can prevent the diaper skew effectively or gauffer takes place.Width reduced scale when from this viewpoint, flexible sheet material 10 being elongated to 1.5 times be preferably width before the elongation 1%～10%, be preferably 1%～5% especially.Width reduces and can obtain with (width before the width ÷ elongation after the 1-elongation) * 100.The following mensuration of width after the elongation.Sample is roughly cut by width 50mm along the mode (differential seat angle is in 15 degree) of moving direction according to its length direction.Length surpasses 150mm.Remain at width under the state of 50mm, the length direction both ends of sample are spaced apart 150mm and control to control sample.At this moment, attention will make that sample is lax on its length direction not to be extended yet.From this state, will control at interval and be stretched to 1.5 times, measure the width of the length direction central portion of sample at this moment, this is worth as the width after the elongation.
Fig. 2 (a) and (b) showing in the flexible sheet material 10 of an embodiment of the invention along the longitdinal cross-section diagram of the bearing of trend of elastic filament 13.Fig. 2 (a) and (b) shown in embodiment be during elasticity performance in the manufacturing process of flexible sheet material 10 is handled, the form that significantly shows when using teeth groove to stretch.Fig. 2 (a) is the longitdinal cross-section diagram of the flexible sheet material 10 under the nature (relaxed state), and Fig. 2 (b) is the longitdinal cross-section diagram of the flexible sheet material 10 under the elongation state.Under nature, flexible sheet material 10 is top 14 ' and paddy portion 14 " wave-like of arranging alternately.Top 14 ' with paddy portion 14 " by crest line portion 15 ' link to each other.With respect to top 14 ' and paddy portion 14 " thickness, crest line portion 15 ' thickness smaller slightly, therefore than top 14 ' and paddy portion 14 " easier printing opacity.When overlooking flexible sheet material 10, top 14 ', crest line portion 15 ' and paddy portion 14 " extend towards the direction vertical with the prolonging direction of flexible sheet material 10.Therefore, in flexible sheet material 10, under its nature, by the crest line portion 15 of easy printing opacity ' and with the top 14 that is difficult to printing opacity than it ' and the travers style that paddy portion 14 produces indistinctly occur.This travers style can become more obvious owing to conditions such as flexible sheet material 10 elongations and elasticity described later performance processing.
That is, shown in Fig. 2 (b), in the flexible sheet material 10 of elongation state, along the bearing of trend of elastic filament 13, high weight per unit area part 14 and low weight per unit area part 15 are alternately arranged.Each several part 14,15 extends with band shape respectively on the direction vertical with the bearing of trend of elastic filament 13.High weight per unit area part 14 and low weight per unit area part 15 were alternately arranged with the constant cycle.For high weight per unit area part 14, to the last side-prominent part of sheet material 10 with to the following side-prominent part alternate configurations of sheet material 10.To the last side-prominent high weight per unit area part 14 of sheet material 10 come from top 14 in the sheet material 10 of the nature shown in Fig. 2 (a) '.And come from paddy portion 14 in the sheet material 10 of the nature shown in Fig. 2 (a) " to the following side-prominent high weight per unit area part 14 of sheet material 10.In addition, low weight per unit area part 15 come from crest line portion 15 in the sheet material 10 of the nature shown in Fig. 2 (a) '.In high weight per unit area part 14 and low weight per unit area part 15, on the printing opacity degree, there are differences owing to their weight per unit area difference.As a result, flexible sheet material 10 is presented on the upwardly extending travers style in the side vertical with the bearing of trend of elastic filament 13, design height.Particularly, as previously mentioned, flexible sheet material 10 also presents the striped style that is produced by elastic filament 13, therefore flexible sheet material 10 also presents the cancellate style that combines of this striped style and the striped style that is produced by high weight per unit area part 14 and low weight per unit area part 15, and design further improves.In addition, as Fig. 2 (a) with (b),, filling fiber in the outstanding part of the upside of sheet material 10 or downside as preferred implementation of the present invention.
High weight per unit area part 14 is compared with low weight per unit area part 15, and weight per unit area is big and thickness is also big.Thus, high weight per unit area part 14 is different with the printing opacity degree at low weight per unit area part 15 places, owing to this difference presents the striped style.Each high weight per unit area part 14 comes down to wait width to each other, and similarly, each low weight per unit area part 15 also comes down to wait width to each other.
The thickness of high weight per unit area part 14 is preferably 0.3～10mm, is preferably 0.5～1mm especially.From the viewpoint of expansion performance and gas permeability, the thickness of low weight per unit area part 15 is preferably 0.1～3mm, is preferably 0.2～0.6mm especially.Determination of thickness is that flexible sheet material 10 is placed more than 2 days under 20 ± 2 ℃, the environment of 65 ± 5%RH zero loadly, obtains with following method then.At first, the sheet material 10 that will stretch is stretched to 1.5 times to prolonging direction, under this state, with 0.5cN/cm
2Load be clipped between flat board.Under 50～200 times multiplying power, observe the cross section with microscope, obtain the average thickness in each visual field respectively, try to achieve above-mentioned thickness with the form of the average thickness value in three visuals field.High weight per unit area part 14 and low weight per unit area part 15 can easily form when making flexible sheet material 10 according to manufacture method described later.
Below, the 1st and the 2nd nonwoven 11,12 that constitutes flexible sheet material 10 and the constituent material of elastic filament 13 are described.Fiber as constituting each nonwoven 11,12 can use stiff in fact fiber.As its example, can list the fiber of formations such as polyethylene (PE), polypropylene (PP), polyester (PET or PBT), polyamide etc.The fiber that constitutes each nonwoven 11,12 can be that short fiber also can be a long fibre, can be hydrophilic also can be hydrophobic.In addition, can also use core-sheath-type or parallel type composite fibre, cut apart fiber, profiled fibre, crimped fibre, heat-shrinkable fibre etc.These fibers can be used alone, and also can make up two or more the use.Each nonwoven 11,12 can be the nonwoven of continuous filament yarn or short fiber.Particularly, make the viewpoint of the bulk sheet material of thickness from the sheet material 10 that will stretch, each nonwoven 11,12 is preferably the nonwoven of short fiber.When flexible sheet material 10 is used as the parts that contact with skin, can use the staple fiber nonwoven fabric of good hand touch, use the nonwoven of high-intensity continuous filament yarn at its opposing face at the skin contact side.
Each nonwoven 11,12 preferred its constitutes fiber and is made up of more than the composition low melting point composition and two of high-melting-point compositions.At this moment, bonding by the heat fusing of low melting point composition at least, it constitutes fiber and engages at fiber intersection point place each other.As the composite fibre by low melting point composition and two core-sheath-types that constitute more than the composition of high-melting-point composition, preferred core is dystectic PET, PP, and sheath is low-melting PET, PP, PE.Especially when using these composite fibres, with the melt bonded grow of elastic filament 13, be difficult to cause peeling off between the two, therefore preferred.
The thickness of each nonwoven 11,12 is preferably 0.05～5mm, more preferably 0.1～1.0mm, 0.15～0.5mm more preferably.Determination of thickness can followingly be carried out: with 0.5cN/cm
2Load be clipped between flat board, under 50～200 times multiplying power, observe the cross section of the sheet material 10 that stretches with microscope, obtain the average thickness in each visual field respectively, obtain above-mentioned thickness with the form of the average thickness value in three visuals field.The thickness of sheet material integral body can be tried to achieve by the distance of measuring between flat board.From viewpoints such as feel, thickness and design, the weight per unit area of each nonwoven 11,12 preferably is respectively 3～100g/m
2, be preferably 10～30g/m especially
2
From viewpoints such as feel, viscosity, each nonwoven 11,12 preferably is made of stiff in fact fiber.As the ratio of the non-elastic fiber in the nonwoven, can for more than the 70 weight %, be preferably more than the 90 weight %, 100 weight % more preferably.In addition, stiff in fact fiber also can contain elastic resin in non-resilient resin, the ratio of non-resilient resin can for more than the 70 weight %, be preferably more than the 90 weight %, 100 weight % more preferably.Especially, as stiff fiber, preferably use in the longitudinal direction the different fiber of fineness degree of fiber (following this fiber is called not sizing fiber).That is, the sizing fiber is not when its length direction is seen, (diameter) big part is amassed in existing fibre section, also has the fibre section to amass (diameter) little part.In sizing fiber not, its diameter (sectional area) can change to the best part continuously from the part of minimum.Perhaps, also can be as observed necking in the stretching process of undrawn yarn, the diameter of fiber (sectional area) is with roughly stepped variation.Diameter (sectional area) with fiber has been shown with an example of the non-elastic fiber of the state of stepped variation roughly among Fig. 3.
As raw material, this is preferred from the viewpoint that can obtain the high flexible sheet material 10 of maximum intensity to non-elastic fiber with the fiber of high elongation rate (for example the maximum elongation rate of fiber is 80～800%, is in particular 120～650%) with constant fibre diameter.The elongation of fiber rate is according to JIS L-1015, and with the benchmark that is determined as under the following condition: promptly measuring ambient temperature and humidity is 20 ± 2 ℃, 65 ± 5%RH, and the grip separation of distraction test machine is 20mm, and draw rate is 20mm/min.In addition, to measure percentage elongation be representative to gather fiber from the nonwoven of having made, when grip separation can not be located at 20mm, during the fibre length of promptly being measured is not enough 20mm, chuck is located at 10mm at interval or 5mm measures.
The fiber of above-mentioned high elongation rate is preferably the low non-elastic fiber that stretches.With the low non-elastic fiber that stretches is raw material, when making the flexible sheet material 10 of present embodiment according to manufacture method described later, in elasticity performance processing procedure, stretch, can in fiber, produce thinner part, thereby form above-mentioned not sizing fiber by the fiber that will hang down stretching.The result, in the elasticity performance processing procedure of the flexible sheet material of present embodiment, nonwoven becomes the form that structurally stretches easily, pass through drawing of fiber, whole nonwoven fabric construct all becomes and stretches easily, to be controlled at irreducible minimum to the destruction at the abutment of the interfibrous abutment of sizing, each nonwoven 11,12 and elastic filament 13 not, and can when keeping telescopicing performance, improve the intensity of flexible sheet material 10.Promptly can obtain having concurrently high elongation rate and high-intensity flexible sheet material 10.In addition, the interfibrous joint of above-mentioned not sizing also is difficult to destroyedly in elasticity performance processing procedure, and this also has the effect that makes each nonwoven 11,12 be difficult to fluff.This viewpoint from the outward appearance of the flexible sheet material 10 of raising present embodiment is favourable.Relative therewith, for the elastic and expandable composite sheets of patent documentation 5 records of describing in the background technology part, be difficult to extend owing in stretching process, constitute fiber, so fiber deposited or mechanical complexing each other can not realize.As a result, the intensity of sheet material reduces, and can not have high elongation rate and high strength concurrently.
In addition, be raw material by fiber with above-mentioned low stretching, and to compare before the tensile fiber, the radical of fine fibre (length) increases in fact.Thus, the opaqueness of the flexible sheet material 10 of present embodiment improves.Be difficult to see through the viewpoint that face sheet is seen the masking performance of the body fluid that is absorbed bulk absorption from raising, it is favourable that the opaqueness of flexible sheet material 10 improves when the face sheet of sheet material 10 as absorbent commodities such as sanitary napkin or disposable diapers that for example will stretch uses.
In addition, if the fineness degree of sizing fiber does not periodically change, then also have following additional effect: promptly the surface of each nonwoven 11,12 presents fine sinuous state, and its skin sense of touch becomes good.At this moment, the cycle of variation, be thicker part divide with the thicker part adjacent branch with it between distance be preferably 0.5～10mm, be preferably 2～5mm especially.This cycle can be measured from the microscopic examination of each nonwoven 11,12.Here, the mensuration of the diameter of sizing fiber can not measured according to the order of following (1)～(5).
(1) sampling nonwoven 11 or nonwoven 12 zone more than the lip-deep 5mm * 5mm of flexible sheet material 10.The sample of this moment can cut off nonwoven 11,12 and gather from elastic filament 13, also can gather flexible sheet material 10 integral body.
(2) sample of gathering is fixed on the observation of SEM with on the sample bench.At this moment, for easy observation sample, also can be under state with the degree of stretch sample that do not destroy structures of samples (up to the degree of the lax disappearance of nonwoven), sample is fixed on the sample bench with double faced adhesive tape.For the amount of tension of this moment, when for example in the manufacturing process of flexible sheet material 10, utilizing elasticity performance treatment process, be the following degree of stretching ratio of the precursor of the flexible sheet material 10 that stretches in the stretching process.
(3) SEM observes and carries out under 200 multiplying power.The visual field area that makes 1 place be about 0.4mm * 0.4mm more than, observe 5 places.
(4) extract fiber randomly out, being unit with 0.1 μ m upwards measures diameter every 10 μ m ground at fiber axis, measure altogether more than 20 places (fiber each other melt bonded point or the part of destruction be not included in the mensuration).Fiber is measured in each visual field more than 4, amounting to 20 and measure 5 visuals field.
(5) from these values, select the maximum gauge separately and the minimum diameter of 10 fibers.
The maximum gauge of 1 fiber and the difference of minimum diameter be 1 μ m, to fiber axis to position and the relation between diameter variation when mapping, greatly position or minimum position are that the above fiber in 2 places is called unsetting fiber.
From making the viewpoint of each above more remarkable effect, not the fineness degree of sizing fiber be preferably at the thinnest part place 2～15 μ m, more preferably 5～12 μ m, be preferably 10～40 μ m, 12～30 μ m more preferably at the thickest part place.The difference of the maximum gauge of sizing fiber and minimum diameter is not preferably more than the 3 μ m, is preferably more than the 5 μ m especially, especially is preferably more than the 10 μ m.In addition, the ratio with " maximum fiber diameter/minimum fiber diameter " defined fibre diameter is preferably 1～15, more preferably 1.2～10, more preferably 2～5.
Melt bonded intensity is not higher than this not intensity during 100% elongation of sizing fiber between preferred its fiber of sizing fiber.Thus, in the elasticity performance treatment process when sheet material 10 is stretched in manufacturing, when the flexible sheet material 10 before will stretching stretches with enforcement elasticity performance processing, be difficult to cause the destruction of the fiber melt bonded point each other of the flexible sheet material 10 before the elasticity performance is handled, the intensity that shows preceding flexible sheet material 10 with elasticity is compared, the intensity that shows the flexible sheet material 10 of treatment process acquisition through above-mentioned elasticity is difficult for reducing, and is preferred from this point.Melt bonded intensity can be measured according to the record of [0040] paragraph of formerly applying for TOHKEMY 2004-218183 communique of the applicant.Intensity during 100% elongation can be used the distraction test machine, measure under as 20mm, the condition of draw rate as 20mm/min between chuck.
The non-elastic fiber of above-mentioned low stretching comprises: fiber that is stretched with low stretching ratio after the spinning and the fiber that does not stretch, promptly not drawing of fiber the two.As the low fiber that stretches, preferably to use its percentage elongation be aforesaid 80～800% fiber, especially preferably use percentage elongation is 120～650% fiber.Have the fiber of low stretching of the percentage elongation of this scope by use, this fiber can successfully be stretched in stretching device shown in Figure 5 22 described later, can easily form not sizing fiber.The fibre diameter of the low fiber that stretches is preferably 10～35 μ m, is preferably 12～30 μ m especially.
As previously mentioned, the sizing fiber is not a raw material with the fiber of low stretching with constant fibre diameter preferably.At this moment, the low fiber that stretches can be the fiber that is made of single raw material, also can be to use the composite fibre of raw material, for example core-sheath-type composite fibre or parallel composite fiber more than 2 kinds.If consider the easiness that engages of easiness that sizing fiber not is engaged with each other, each nonwoven 11,12 and elastic filament 13, preferably use composite fibre.Under the situation of composite fibre that is core-sheath-type, preferred core is that polyester (PET or PBT), polypropylene (PP), sheath are low-melting polyester (PET or PBT), polypropylene (PP), polyethylene (PE).Especially, when using these composite fibres, contain under the elastomeric situation of polyolefin at elastic filament 13, the bonding enhancing of heat fusing between the formation fiber of elastic filament 13 and each nonwoven 11,12 is difficult to cause and layer peels off, and is preferred from this point.
The sizing fiber can not be the short fiber as staple fiber, can be the long fibre as continuous filament yarn yet.In view of the preferable production process of flexible sheet material 10 described later, preferably use short fiber.In addition, the sizing fiber can not be hydrophilic or hydrophobic.
Each nonwoven 11,12 can be only be made of sizing fiber not, also can be except also containing the non-elastic fiber of other constant diameter the sizing fiber not.As other non-elastic fiber, can list aforesaid fiber.Each nonwoven 11,12 is during except the non-elastic fiber of the constant diameter that also contains other the sizing fiber not, and the use level of other non-elastic fiber is preferably 1～30 weight %, is preferably 5～20 weight % especially.
The sizing fiber does not all contain in these two particularly preferably in two nonwoven 11,12, but can only contain among in two nonwoven 11,12 one yet.
Especially, as elastic filament 13, the preferred elastic filament that uses the resin combination that constitutes by containing A1-B-A2 type triblock copolymer to form, described A1-B-A2 type triblock copolymer is by forming based on the polymer blocks A1 of vinyl aromatic polymers and A2 with based on the polymer blocks B of polyolefin.
Polymer blocks A1 and A2 the adding up to of weight average molecular weight of passing through gel permeation chromatography (GPC) mensuration separately is preferably 14000～20000, more preferably 14000～18000, and the weight average molecular weight that polymer blocks B measures by the GPC method is preferably 40000～80000, more preferably 40000～70000.In this manual, the weight average molecular weight of measuring by the GPC method is measured under following condition determination: post: TSKgel G-2000H; Column temperature: 40 ℃; Phase flows: oxolane (THF); Flow: 1.0mL/min; Sample solution concentration: 10mg/5mL-THF; Injection rate: 500 μ L; Then with the value that obtains above-mentioned weight average molecular weight after the polystyrene conversion.As analytical sample, use and carried out the sample that following pre-treatment operation obtains: sample 10mg was dissolved 10 minutes in the oxolane of 5mL at normal temperatures, was the sintered filter filtration of 0.45 μ m then with the aperture.
When resin combination contained A1-B-A2 type triblock copolymer more than 2 kinds, for example the weighed average of the weight average molecular weight that above-mentioned " weight average molecular weight that polymer blocks A1 measures by the GPC method " measured by the GPC method as the A1-B-A2 type triblock copolymer polymer blocks A1 separately more than 2 kinds was tried to achieve.Promptly, for example resin combination contain (A1 '-B '-A2 ') and (A1 "-B '-A2 ") two kinds of A1-B-A2 type triblock copolymers as the percentage composition of A1-B-A2 type triblock copolymer and (A1 '-B '-A2 ') (A1 '-B '-A2 ' shared percentage composition in the total amount of the contained two or more A1-B-A2 type triblock copolymer of resin combination) be 80 weight %, (A1 "-B "-A2 ") percentage composition when being 20 weight %, above-mentioned " polymer blocks A1 is by the weight average molecular weight of GPC method mensuration " tries to achieve by following formula.
(weight average molecular weight that the GPC method of passing through of polymer blocks A1 ' is measured) * 0.8+ (polymer blocks A1 " the weight average molecular weight of the GPC method of pass through mensuration) * 0.2
When resin combination contains two or more A1-B-A2 type triblock copolymers, reach " weight average molecular weight that polymer blocks B measures by the GPC method " for above-mentioned " weight average molecular weight that polymer blocks A2 measures by the GPC method ", also try to achieve according to the above-mentioned example of polymer blocks A1 respectively.
In addition, when resin combination contained two or more A1-B-A2 type triblock copolymers, above-mentioned " total of the weight average molecular weight that polymer blocks A1 and A2 measure by the GPC method separately " was the total of the weighed average of the polymer blocks A1 that as above tries to achieve and A2 above-mentioned weight average molecular weight separately.
Polymer blocks A1 is that main body constitutes with the vinyl aromatic polymers.As the vinyl aromatic that constitutes this vinyl aromatic polymers, for example can list styrene, p-methylstyrene, a methyl styrene, to t-butyl styrene, AMS, chloro methyl styrene, to tert-butoxy styrene, dimethylaminomethyl styrene, dimethyl aminoethyl styrene, vinyltoluene, 1-vinyl naphthalene, 4-propylstyrene, 4-cyclohexyl benzene ethene, 4-dodecyl styrene, 2-ethyl-4-benzyl styrene, 4-(phenyl butyl) styrene etc.Vinyl aromatic polymers can be made of a kind in these vinyl aromatics, also can be by constituting more than 2 kinds.In these vinyl aromatics, from the easiness of polymerization and the viewpoint of versatility, optimization styrene.
The content of vinyl aromatic polymers is with respect to the total unit of polymer blocks A1 among the polymer blocks A1, is preferably 90～100 weight %, 95～100 weight % more preferably.
Polymer blocks A1 can also contain the conjugated diene compound polymer and constitutes except vinyl aromatic polymers.As the conjugated diene compound that constitutes this conjugated diene compound polymer, for example can list 1,3-butadiene, isoprene, 1,3-pentadiene, 2,3-dimethyl-1,3-butadiene, 2-methyl isophthalic acid, 3-pentadiene, 1,3-hexadiene, phenyl butadiene, 4,5-diethyl-1,3-octadiene, 3-butyl-1,3-octadiene etc.The conjugated diene compound polymer can be made of a kind in these conjugated diene compounds, also can be by constituting more than 2 kinds.
The content of conjugated diene compound polymer is among the polymer blocks A1, is preferably 0～10 weight %, 0～5 weight % more preferably with respect to the total unit of polymer blocks A1.
The weight average molecular weight that the GPC method of passing through of polymer blocks A1 is measured is preferably 7000～10000, and more preferably 7000～9000.
As polymer blocks A2, can use identical block with above-mentioned polymer blocks A1.The aspect that polymer blocks A2 is not had to specify can suitably be suitable for the explanation to polymer blocks A1.In A1-B-A2 type triblock copolymer, the structure of polymer blocks A1 and polymer blocks A2 can be the same or different.
Especially, polymer blocks A1 and A2 preferably are styrene.That is elastic filament 13 preferred following formations: only contain polystyrene as polymer blocks A1, and only contain polystyrene as polymer blocks A2.
The total content of polymer blocks A1 and A2 is with respect to the total unit of A1-B-A2 type triblock copolymer in the A1-B-A2 type triblock copolymer, is preferably 15～40 weight %, 18～30 weight % more preferably.
In addition, as mentioned above, when polymer blocks A1 and A2 were polystyrene, the ratio of polymer blocks A1 and polymer blocks A2 was preferably (A1/A2)=0.8～1.2, (A1/A2)=0.9～1.1 more preferably in weight ratio in the A1-B-A2 type triblock copolymer.
Polymer blocks B constitutes based on polyolefin.As constituting this polyolefinic alkene, can list for example isoprene, butadiene, ethene, propylene, butylene etc.The alkene that constitutes polymer blocks B can be made of a kind in these alkene, also can be by constituting more than 2 kinds.In these alkene, from the viewpoint of weatherability, expansion performance, optimal ethylene, propylene.
The content of said polyolefins is with respect to the total unit of polymer blocks B among the polymer blocks B, is preferably 90～100 weight %, 95～100 weight % more preferably.
Polymer blocks B can also contain by can constituting with other polymer of polyolefin polymerization that other polymerizable monomer is derived except said polyolefins.As this other polymerizable monomer, can list for example styrene.Constituting the above-mentioned of polymer blocks B can be made of a kind in these other the polymerizable monomer with other polymer of polyolefin polymerization, also can be by constituting more than 2 kinds.
Above-mentioned other the content of polymer is with respect to the total unit of polymer blocks B among the polymer blocks B, is preferably 0～10 weight %, 0～5 weight % more preferably.
As the object lesson of polymer blocks B, can list polyisoprene, polybutadiene, poly-(ethylene-propylene), poly-(ethene-butylene) etc.Wherein, poly-(ethylene-propylene) is preferred owing to the cause of weatherability, expansion performance.
The content of polymer blocks B is with respect to the total unit of A1-B-A2 type triblock copolymer in the A1-B-A2 type triblock copolymer, is preferably 60～85 weight %, 70～82 weight % more preferably.
As the object lesson of preferred A1-B-A2 type triblock copolymer, can list SBS (SBS), SIS (SIS), as the styrene-ethylene-butylene-styrene block copolymer (SEBS) of the hydride of SBS, as the styrene-ethylene-propylene-styrene block copolymer (SEPS) of the hydride of SIS, styrene-ethylene-ethylene-propylene-styrene block copolymer (SEEPS) etc.Wherein, SEBS, SEPS, SEEPS are preferred owing to the elastic filament 13 that can obtain heat endurance and have excellent weather resistance.
As A1-B-A2 type triblock copolymer, also can use commercially available product.As the commercially available product of the preferred A1-B-A2 type triblock copolymer that uses in the present invention, can list trade name " SEPTON " that the trade name " Tuftec " of the trade name of Kraton Polymers company " Kraton ", Asahi Chemical Corp for example reaches " TUFPRENE ", the Kuraray of Co., Ltd., " Hybrar " series etc.
A1-B-A2 type triblock copolymer can synthesize by for example following operation.At first, adding vinyl aromatic compounds in hydrocarbon solvents such as cyclohexane, is that initator carries out anionic polymerisation with organo-lithium compound or sodium metal etc., obtains polymer blocks A1.Then, add olefinic monomer and carry out polymerization, obtain polymer blocks A1-B.When olefinic monomer is conjugated diene,, obtain subject polymer block A1-B to the double-bond hydrogenation based on conjugated diene of this copolymer.From the viewpoint of hear resistance, weatherability, based on the hydrogenation ratio of two keys of conjugated diene be preferably conjugated diene more than 80% of two keys, be preferably more than 90% especially.Hydrogenation can use the composite catalyst of noble metal series catalysts, organic nickel compound, organic cobalt compound or these compounds and other organo-metallic compounds such as platinum, palladium to carry out.Hydrogenation ratio can utilize iodine number deter mination to calculate.Then, add vinyl aromatic compounds and carry out polymerization, thereby obtain polymer blocks A1-B-A2.
The above-mentioned resin combination of formation elastic filament 13 can only contain above-mentioned A1-B-A2 type triblock copolymer and constitute, also can be as required, in the scope of not damaging the object of the invention, except A1-B-A2 type triblock copolymer, also contain other the resin more than a kind or 2 kinds and constitute.When above-mentioned resin combination contained A1-B-A2 type triblock copolymer and other resin, the content of A1-B-A2 type triblock copolymer was preferably 90～100 weight %, 95～100 weight % more preferably in this resin combination.But from the viewpoint that spinning technique and retractility improve to greatest extent, above-mentioned resin combination preferably only contains A1-B-A2 type triblock copolymer and constitutes.
In addition, above-mentioned resin combination can contain a kind of A1-B-A2 type triblock copolymer and constitute, and also can contain the different A1-B-A2 type triblock copolymer more than 2 kinds of structure and constitutes.
When above-mentioned resin combination also contains other resin except A1-B-A2 type triblock copolymer, as described other resin, for example can use thermoplastic elastomer (TPE)s such as rubber or polyolefin elastomer, polyester based elastomers, polyurethane series elastomer etc.In addition, can use thermoplastic resins such as resin beyond the thermoplastic elastomer (TPE), for example polyethylene, polypropylene etc.They also can make up 2 kinds with on use.
Above-mentioned resin combination can obtain by A1-B-A2 type triblock copolymer or A1-B-A2 type triblock copolymer and above-mentioned other resin are carried out melting mixing with various known method.For example, with above-mentioned each composition side by side or in turn pack into mix in Henschel mixer, V-Mixer, rotary drum mixer, the ribbon blender etc. after, carry out melting mixing with kneading devices such as single screw extrusion machine, multi-screw extruder, kneader, closed mixing machines, thereby obtain above-mentioned resin combination.
In the above-mentioned resin combination except above-mentioned resinous principle (A1-B-A2 type triblock copolymer, other resin), can also be as required, contain plasticizer (for example paraffin series oil, paraffin series wax, cycloalkanes hydrocarbon system oil, ethene-alpha-olefin oligomer, low molecular weight polyethylene etc.), weather-proof stabilizing agent, heat-resisting stabilizing agent, antistatic agent, lubricant, slip agent, nucleator, fire retardant, pigment, dyestuff, inorganic or organic filler etc. in the scope of not damaging the object of the invention.
Above-mentioned resin combination is under the state with 245 ℃ temperature heating and melting, from internal diameter is that 0.45mm, length are the nozzle of drum of 4.5mm during with 8.4m/ minute spouting velocity ejection, and the maximum of fusion tension force is preferably 0.06～0.20cN, 0.07～0.15cN more preferably.The assay method of fusion tension force has been shown among Fig. 4.The power that makes progress that mensuration applies load sensor shown in Figure 4, with this measured value as fusion tension force.The maximum of the fusion tension force by making the resin combination that constitutes elastic filament 13 can make spinning technique become better in above-mentioned scope.The adjustment of fusion tension force can wait and carries out by for example adding plasticizer (paraffin etc.), rubber, thermoplastic resin.The fusion tension force of the resin combination of Gou Chenging is in above-mentioned scope as mentioned above.
Be configured in the viewpoint of the apparent weight per unit area of elastic filament between 2 nonwoven 11,12, that constitute by great number of elastic long filament 13, be preferably 4～30g/m from expansion performance, feel, thickness, cost
2, be preferably 6～15g/m especially
2
Below, with reference to Fig. 5 the preferable production process of the flexible sheet material 10 of present embodiment is described.In this manufacture method, will be from spinning-nozzle 16 the great number of elastic long filament 13 of spun molten condition with the fixing speed tractive and stretch, and before this elastic filament 13 solidifies, the modes of not arranging along a direction across mutually according to this this elastic filament 13 make this elastic filament and nonwoven 11,12 melt bonded, then the melt bonded complex 19 that this elastic filament 13 arranged is carried out the elasticity performance along the bearing of trend of this elastic filament 13 and handle, thereby make this non-woven fabric compounded body 19 have retractility.
Spinning-nozzle 16 is arranged on the spinneret 17.Spinneret 17 is connected with extruder.Also can supply with resin to spinneret 17 by gear pump.Utilize the elastic resin of this extruder melting mixing to be supplied to spinneret 17.On spinneret 17, a large amount of spinning-nozzles 16 are configured to row with linearity.Spinning-nozzle 16 is along the width configuration of the 1st and the 2nd nonwoven 11,12.The interval of adjacent spinning-nozzle 16 is equivalent to the interval of elastic filament 13 in the flexible sheet material 10 of target.It is circular that spinning-nozzle 16 is generally, and its diameter (internal diameter) can have influence on the diameter and the stretching ratio of elastic filament 13.From this viewpoint, the diameter of spinning-nozzle 16 (internal diameter) is preferably 0.1～2mm, is preferably 0.2～0.6mm especially.In order to improve and the bond strength of nonwoven 11,12, the expansion performance that improves the spinnability of elastic filament 13 and improve the sheet material 10 that stretches, also elastic filament 13 can be made complex morphological (parallel type, core sheath, island structure).Specifically, the preferably combination of the elastomer resin of the elastomer resin of PP system and polystyrene.
The elastic filament 13 of spun molten condition collaborates with spun the 1st nonwoven 11 of mutually the same speed and the 2nd nonwoven 12 respectively with from the blank volume, is clamped in then between two nonwoven 11,12 and with fixing speed and carries out tractive.The draw rate of elastic filament 13 is consistent with the speed that spins of two nonwoven 11,12.The draw rate of elastic filament 13 can have influence on the diameter and the stretching ratio of this elastic filament 13.The tension force that elastic filament 13 is produced by stretching can prevent flying away of this elastic filament 13 of being caused by wind or static when this elastic filament 13 is fitted with nonwoven 11,12.Thus, each elastic filament is not arranged each other across along a direction.From these viewpoints, the draw rate of elastic filament 13 preferably is adjusted into respect to the resin spouting velocity in the spinning-nozzle hole, and its stretching ratio is 1.1～400 times, be in particular 4～100 times, further be 10～80 times.
The elastic filament 13 of spun molten condition is with before nonwoven 11,12 contacts from spinning-nozzle 16, the displacement L that this elastic filament 13 is started at from the top 16a of this spinning-nozzle 16 (elastic filament 13 of spinning-nozzle top 16a and molten condition and nonwoven 11,12 be the beeline between its contact site 11a, the 12a when contact at first, referring to Fig. 6) is preferably below the 600mm, be preferably 100～500mm especially.The displacement L of the elastic filament 13 by making molten condition is below the 600mm, make this elastic filament and nonwoven melt bonded reliably before can solidifying at the elastic filament of molten condition, thereby can obtain the flexible sheet material of balance excellence between interlayer bond strength and the expansion performance more reliably, bond strength between promptly flexible being hit by a bullet property of sheet material long filament and the nonwoven is more than the 10cN/25mm, and 25% answer intensity of the per unit area weight of the elastic resin in the flexible sheet material is 1.0cN/{50mm (g/m
2) more than.In addition, the displacement L of the elastic filament 13 by making molten condition is more than the 100mm, by with fusion elastic filament 13 coolings improve the viscosity of elastic resin, thereby make elastic filament 13 between niproll 18a, 18b, be difficult to be damaged by pressure.Thus, can make elastic filament 13 and constitute average splice ratio between the fiber of tensile nonwoven 11,12 in aforementioned preferred range.On the other hand, the displacement L of the elastic filament 13 by making molten condition is below the 600mm, therefore long filament can be because of static or wind etc. fly away, and the occurrence frequency step-down of bonding, the overlapping or filament breakage between the long filament etc. preferably is made as 600mm with the upper limit of this displacement L.
The adjustment of displacement L can be by spinning-nozzle and/or niproll the adjustment of position carry out.In the present embodiment, elastic filament 13 and the melt bonded following of nonwoven 11,12 carry out: will be from spinning-nozzle 16 the described elastic filament 13 of spun molten condition and the described nonwoven in the conveyance 11,12 between a pair of niproll 18a, 18b, collaborate and pass through.In the flexible sheet material 10 of present embodiment, as mentioned above, elastic filament 13 engages with nonwoven 11,12 on its whole length, in this manufacture method, in order to realize such joint form, niproll 18a, 18b as a pair of use the roller that does not have concavo-convex drum on the roller periphery respectively.
In the process before spun elastic filament 13 and the 1st and the 2nd nonwoven 11,12 interflow, this elastic filament 13 is stretched, and molecule is orientated on draw direction.And diameter diminishes.By molecularly oriented, elongation/answer elastic filament 13 littler of intensity in the time of can obtaining 50% elongation than (aforesaid A/B).From the viewpoint and the viewpoint that prevents the fracture of wire of elastic filament 13 of abundant tensile elasticity long filament 13, also can blow the wind (hot blast, cold wind) of attached set point of temperature to adjust the temperature of this elastic filament 13 to spun elastic filament 13.
The stretching of elastic filament 13 also is not only the stretching (fusion drawn) of material resin under molten condition, also can be the stretching (the softening stretching) under the soft state in its cooling procedure.Molten condition is meant the state that resin can flow when applying external force.The melt temperature of resin is by determination of viscoelasticity (for example measuring being clipped in the vibration deformation that resin between circular parallel flat board applies direction of rotation), measure with the form of the peak temperature of Tan δ.For fracture of wire does not take place when elastic resin stretches, guarantee more longways to get final product between drawing zone.From this viewpoint, the melt temperature of elastic resin is preferably 130～300 ℃.In addition, from the stable on heating viewpoint of elastic resin, melt temperature is preferably below 220 ℃.In order to improve resin flow to optimize formability, the forming temperature of elastic filament 13 (temperature of mold) be preferably material resin melt temperature+more than 50 ℃, because hear resistance, above-mentioned forming temperature be preferably material resin melt temperature+below 110 ℃.Softening temperature is measured with the form of the Tg temperature in the viscoelastic property of the mensuration sample of the elastic resin of making sheet.Scope from the softening temperature to the melt temperature is called soft state.In addition, the state of temperature that will be lower than softening temperature is called solid state.The viewpoint that the expansion performance of the flexible sheet material 10 that crystal growth, the body temperature of elastic resin cause during from the preservation of flexible sheet material 10 reduces, softening temperature be preferably more than 60 ℃, more preferably 80 ℃～180 ℃.
Bonding in order to carry out fibers melt reliably, the temperature of elastic filament 13 was preferably more than 100 ℃ when elastic filament 13 engaged with nonwoven 11,12, more preferably more than 120 ℃, more preferably more than 140 ℃.In addition, to obtain the viewpoint of the good flexible sheet material 10 of expansion performance, the temperature of elastic filament is preferably below 180 ℃ from the shape that keeps elastic filament 13.The scope below 160 ℃ more preferably.Its synthesis result is: only long filament temperature is 120～160 ℃, 140～160 ℃ scope more preferably.Temperature during joint uses the film that is made of modified poly ethylene with fusing point different with the fusing point of the elastic resin that constitutes elastic filament or modified polypropene etc. as the laminated substrate that engages with elastic filament 13, and observes its engagement state and measure.At this moment, melt bonded if elastic filament and laminated substrate take place, then junction temperature is more than the fusing point of laminated substrate.
When elastic filament 13 engaged with nonwoven 11,12, elastic filament 13 was essentially not elongation state (non-shrinking state when removing external force).Under both engagement states, at least a portion of fiber that constitutes nonwoven 11,12 is preferably melt bonded with elastic filament, perhaps more preferably with elastic filament 13 and constitute nonwoven 11,12 fiber at least a portion these two all take place melt bonded.Because can obtain sufficient joint strength like this.The expansion performance of the flexible sheet material 10 of gained can be subjected to the influence of elastic filament 13 and the density at the abutment of nonwoven 11,12.In addition, expansion performance can be handled adjusting staggering of abutment of bringing by the elasticity performance of junction temperature, activating pressure, nonwoven described later 11,12.Melt bonded by the formation fiber and the elastic filament 13 that make nonwoven 11,12, the bond strength at abutment improves one by one.If reduce the density at abutment, then the flexible obstruction brought of nonwoven 11,12 reduces, and can obtain to have the flexible sheet material 10 of abundant bond strength, is preferred therefore.
When making elastic filament 13 and the 1st and the 2nd nonwoven 11,12 interflow, each elastic filament 13 is not arranged along a direction mutually across.Then, make elastic filament 13 and the 1st and the 2nd nonwoven 11,12 interflow and under the state of 11,12 these elastic filaments 13 of clamping of two nonwoven, this three is being carried out cramping with a pair of niproll 18,18.The condition of cramping can exert an influence to the feel of the flexible sheet material 10 of gained.If clamping force is excessive, then elastic filament 13 is absorbed in two nonwoven 11,12 easily, and the feel of the flexible sheet material 10 of gained is reduced.From this viewpoint, the clamping force that niproll 18,18 produces there is no need to apply too high clamping force so long as make elastic filament 13 just enough with the degree that two nonwoven 11,12 contact.
Make above-mentioned elastic filament 13 and the 1st and the 2nd nonwoven 11,12 interflow and under the state of 11,12 these elastic filaments 13 of clamping of two nonwoven, other the method for optimizing that this three carries out cramping is being had: elastic filament 13 and nonwoven 11,12 interflow, the method (with reference to Fig. 6) of interval W is being set between above-mentioned a pair of niproll 18a, 18b with a pair of nip roll 18,18.With above-mentioned same, from elastic filament not being brought damage and obtain the viewpoint of sufficient joint strength, the interval W that is provided with between 18a, 18b is preferably 0.05～1mm, is preferably 0.05～0.5mm especially.
With separately thickness of the nonwoven 11,12 before engaging, and elastic filament 13 aggregate value that is about to engage (clamping) preceding thickness (along the thickness of the thickness direction of nonwoven) when being made as T0, interval W between above-mentioned a pair of niproll 18a, 18b and the ratio W/T0 of T0 are preferably 0.05～0.8, are preferably 0.1～0.4 especially.The thickness of nonwoven can be tried to achieve by aforesaid method.The thickness of elastic filament (mm) with
Try to achieve.Wherein, G is that extrusion capacity (g/min), the n of the time per unit on the whole mechanical width are that long filament radical, v on the whole mechanical width is that niproll speed (m/min), ρ are the density (g/cm of long filament resin
3).By making W/T0 in above-mentioned scope, elastic filament and nonwoven constitute the abutment density of fiber and nonwoven and constitute between fiber being absorbed in elastic filament and obtain balance, can take into account thus the flexible sheet material of above-mentioned elastic filament and the bond strength between the nonwoven and unit formation resin weight per unit area 25% reply intensity.
As other condition of the cramping that utilizes niproll 18 to carry out, can list the temperature of niproll 18.The inventor's etc. result of study is: carry out cramping with it under the state of heating niproll 18, not as good as not heating (promptly letting matters aside) or carrying out cramping while cooling off, can obtain the good flexible sheet material 10 of feel.During niproll 18, preferably use cooling mediums such as cooling water in cooling, the surperficial design temperature of niproll 18 is adjusted to 10～50 ℃.
So obtain complex 19 at 11,12 flexible long filaments 13 of clamping of 2 nonwoven.Using the nonwoven that has extensibility originally as nonwoven 11,12 o'clock, this complex 19 is flexible sheet material 10 itself.On the other hand, using the nonwoven that do not have extensibility originally as nonwoven 11,12 o'clock, the complex 19 that will comprise this nonwoven 11,12 carries out the elasticity performance along the bearing of trend of elastic filament 13 to be handled, thus the operation that makes this complex 19 have retractility.In this manufacture method, this operation is following to be carried out: use the elasticity performance treating apparatus 22 possess a pair of tooth space roller 20,21 that alternately is formed with tooth and roller seating space respectively in a circumferential direction, with complex 19 along its conveyance direction, promptly carry out the elasticity performance and handle along the bearing of trend of elastic filament 13.
Elasticity performance treating apparatus 22 has the pivot branch known elevating mechanism (not shown) of displacement up and down that makes one or two tooth space roller 20,21, so the interval of 20,21 of tooth space rollers can be regulated.In this manufacture method, the compound mode of each tooth space roller 20,21 is between cog that the tooth of a tooth space roller 20 is inserted in another tooth space roller 21, and the tooth of another tooth space roller 21 is inserted in the between cog of a tooth space roller 20, complex 19 is inserted into 20,21 of two tooth space rollers of this state, then it is carried out the elasticity performance and handle.
In elasticity performance treating apparatus 22, the two can drive (corotation roller) by drive source a pair of tooth space roller 20,21, also only a side tooth space roller 20 or 21 drives (with transfer roller) by drive source, in this manufacture method, only the tooth space roller 21 of downside drives by drive source, the tooth space roller 20 of upside is not connected with drive source, but along with the rotation servo-actuated of tooth space roller 21 (with changeing).Make the striped style that clearly occurs high weight per unit area part 14 and low weight per unit area part 15 on the flexible sheet material 10 after the elasticity performance processing easily with the use of transfer roller, from the design that improves flexible sheet material 10 and viewpoints that weight per unit area is hanged down with the raising gas permeability than low weight per unit area portion 15, be preferred with the use of transfer roller.As the profile of tooth of tooth space roller 20,21, preferably use general gradually tooth punching shape, cycloidal tooth profile, the preferred especially profile of tooth of using the narrowed width of these teeth.
Schematically show the state that the performance of complex 19 elasticity is handled among Fig. 7.During by 20,21 of tooth space rollers, complex 19 is not stretched substantially in the zone (between P3-P2, between P1-P4) that contacts with the tooth 23,24 of tooth space roller 20,21 at complex 19.Relative therewith, by the flank of tooth as the tooth 24 of the tooth space roller 21 of driven roller, the zone (between P2-P1) being extruded towards the flank of tooth as the tooth 23 of the tooth space roller 20 of loose roll is stretched widely by two teeth 20,21.In addition, the top ends of the tooth 24 by tooth space roller 21, the zone (between P4-P3) in that the tooth 23 from tooth space roller 20 is pulled away from though do not reach the degree of above-mentioned zone (between P2-P1), is also stretched widely.
In addition, complex 19 is in the zone (between P3-P2, between P1-P4) that contacts with the top ends of the tooth 23,24 of tooth space roller 20,21, as mentioned above, substantially be not stretched, but top ends by tooth 23,24, on its diametric(al), promptly on the thickness direction of complex 19, pushed partly, therefore attenuation on thickness direction.But because the direction of being pushed partly between zone (between P3-P2) and zone (between P1-P4) in the opposite direction, so the direction of attenuation is also towards rightabout.
By above-mentioned drawing process, can prevent peeling off between elastic filament 13 and two nonwoven 11,12, and two nonwoven 11,12 in the complex 19 that can stretch effectively, thereby can make complex 19 have retractility.In addition, the zone that is stretched greatly (between P2-P1 and between P4-P3) becomes low weight per unit area part 15, and the zone that is not stretched substantially (between P3-P2, between P1-P4) becomes high weight per unit area part 14.
Particularly, when containing the fiber of low stretching in nonwoven 11,12, between above-mentioned (P2-P1) and (P4-P3), this fiber is stretched and attenuates, thereby forms the not sizing fiber of fiber thickness degree generating period variation.
The tensile force that tooth space roller 20,21 produces mainly acts on the stretching of low drawing of fiber, can not apply excessive power to the junction between nonwoven 11,12 and the elastic filament 13.Its result can prevent from the destruction of this junction to prevent nonwoven 11,12 and elastic filament 13 and peeling off, and the complex 19 that can stretch effectively.In addition, by this stretching, as shown in Figure 8, under the situation of not destroying interfibrous joint, nonwoven 11,12 extends fully, and thus, the degree that nonwoven 11,12 obstruction elastic filaments 13 freely stretch reduces greatly.Its result according to this manufacture method, can make high strength, high scalability and damaged and the good flexible sheet material 10 of few outward appearance of fluffing effectively.In addition, in Fig. 8, for convenience, the fineness degree of the non-elastic fiber that will produce by stretching is expressed as the same.
As mentioned above, when in nonwoven 11,12, containing the fiber of low stretching, because this fiber successfully can be carried out the elasticity performance handles, and these interfibrous joints can not be stretched destroy, so the elasticity performance intensity of handling the nonwoven 11,12 that brings reduce can be controlled as best one can.The ratio of the hot strength of the complex 19 before specifically, the performance of the hot strength of the flexible sheet material 10 that obtains after the stretching and elasticity is handled is 0.3～0.99, be 0.5～0.99 especially, further be 0.7～0.99 such near 1 value.Here said hot strength can be measured according to the assay method of following maximum intensity.
The mensuration of＜maximum intensity 〉
With flexible sheet material 10 by on its flexible direction for cut out the test film of rectangle on 200mm, the direction vertical for the size of 50mm with the direction of should stretching.Distance between chuck is set at 150mm.Test film is extended with 300mm/ minute speed to the flexible direction of flexible sheet material 10, measure the load of this moment.With the load of maximum point of this moment as maximum intensity.By same method, the complex 19 before also performance is handled to elasticity is measured maximum intensity.Measuring environment temperature is that 22 ℃, humidity are under the condition of 65%RH, preferably use the distraction test machine AG-1kNIS of Shimadzu Seisakusho Ltd.'s system to measure above-mentioned maximum intensity.
By above-mentioned elasticity performance processing, the thickness of the complex 19 of the thickness of flexible sheet material 10 before with respect to elasticity performance processing preferably is increased to 1.1 times～4 times, especially preferably is increased to 1.3 times～3 times.Thus, by the formation fiber generation plastic degeneration and the elongation of two nonwoven 11,12, thereby fiber attenuates.Meanwhile, two nonwoven 11,12 become more bulk, and the skin sense of touch is good, and elasticity (resiliency) becomes good.
From showing the viewpoint of sufficient expansion performance, the load A of the flexible sheet material 10 that so obtains during (below be also referred to as 50% reply intensity), be preferably more than 50%, be preferably more than 65% especially with the ratio (A/B) that extends 50% o'clock load B (below be also referred to as 50% elongation strengths) along the bearing of trend of elastic filament 13 along the bearing of trend elongation 100% of elastic filament 13 and from this replying state to 50%.
In addition, though according to the difference of concrete purposes and difference, the weight per unit area of the integral body of flexible sheet material 10 is preferably 10～150g/m
2, be preferably 25～60g/m especially
2About the thickness of flexible sheet material 10, be preferably 0.05～5mm, be preferably 0.5～2mm especially.The thickness of flexible sheet material 10 can be by measuring with the same method of the Determination of thickness of aforesaid each nonwoven 11,12.
The flexible sheet material 10 of present embodiment is preferably used as the housing material of Breeches type disposable diaper.At this moment, also can be with the flexible sheet material 10 of present embodiment as the sheet material that places the outside, use non-Stretchable sheet as placing inboard sheet material, the two sheet materials back of fitting is used as above-mentioned housing material.In addition, except this purposes, also can utilize advantages such as its good hand feeling, anti-fluffing property, retractility, gas permeability, be used as in the various purposes such as medical disposable garment, cleaning sheet material, eyeshade, facial mask, bandage.Be preferably used as the constituent material of absorbent commodities such as sanitary napkin or disposable diaper especially.As this constituent material, for example can list than absorber more by the sheet material (comprising face sheet, subgrade etc.) of the liquid permeability of skin side, constitute the outer surface of disposable diaper sheet material, be used to make waist portion or waist, leg perimembranous etc. to have the sheet material etc. of elastic extension.In addition, can be as the sheet material of the wing that forms sanitary napkin etc.In addition, though also can be used for be the position of wishing to have retractility, positions beyond these etc.The weight per unit area or the thickness of flexible sheet material 10 can suitably be adjusted according to its concrete purposes.For example when the constituent material as absorbent commodity used, weight per unit area was preferably 20～60g/m
2About, thickness is preferably about 0.5～1.5mm.
More than based on preferred embodiment describing the present invention, but the present invention is not limited to above-mentioned embodiment.In above-mentioned embodiment flexible, be the structure of a large amount of elastic filament 13 to be arranged for example, but also can replace, on 1 nonwoven surface, engage a large amount of elastic filaments and make flexible sheet material in 11,12 clampings of 2 nonwoven.At this moment, as the constituent material of elastic filament, can use the low resin of adhesiveness when solidifying, this is from preventing that the viewpoint that blocks from being preferred when the sheet material 10 that will stretch is preserved with the state that is rolled into the roller shape.
In addition, elastic filament 13 all is identical diameter in the above-mentioned embodiment, and with equidistant configuration, therefore concerning any part of flexible sheet material 10, elongation stress all is identical.But also can replace, according to constituting flexible sheet material by the mode that constitutes in the different zone more than 2 of elongation stress on the prolonging direction of elastic filament.Described zone more than 2 is roughly configuration side by side on described prolonging direction.At this moment, between each different zone of elongation stress, the spacing difference of adjacent elastic filament and/or the diameter difference of elastic filament.Thus, can make each interregional elongation stress difference.When sheet material is stretched in manufacturing, also resins different more than 2 kinds can be imported arbitrarily and carry out spinning in the spinning-nozzle, thereby make each interregional elongation stress difference.
Also can carry out embossing processing partly, perhaps elastic filament 13 partly be cut off or heat seal partly flexible sheet material 10.These operations are in order to form not flexible part or to improve intensity partly and carry out on flexible sheet material 10.Perhaps, in order to fit with other parts or to make it have design and carry out.
In addition, about elastic filament 13 is handled with the elasticity performance of carrying out after nonwoven 11,12 engages, draw direction not only can be the moving direction of nonwoven 11,12, can for example be oblique also.And, also can make up the elasticity performance processing method more than 2 kinds, improve stretching ratio perhaps interimly, perhaps partly carry out the elasticity performance and handle.It not only can be a direction that direction is handled in the elasticity performance, also can be vertical both direction.Also can will engage, thereby make flexible sheet material all have retractility on the directions along the flexible nonwoven of a direction with along the flexible nonwoven of perpendicular direction.
In addition, in the manufacture method of above-mentioned embodiment, in the elasticity performance processing of complex 19, used the elasticity performance treating apparatus that possesses a pair of tooth space roller 20,21, but also can replace, use the elasticity performance treating apparatus that possesses stenter to carry out elasticity performance processing.
In addition, in above-mentioned manufacture method,, also can on one nonwoven, directly extrude elastic filament 13 and do not carry out fusion drawn as other method that elastic filament 13 is engaged with nonwoven 11,12.The stretching ratio of this moment is 1 times.In addition, also can with elastic filament 13 with before nonwoven 11,12 engages, complementary ground coating adhesive on nonwoven or elastic filament is not in fact fitted under the state of elongation at elastic filament then.In addition, also coating adhesive not, but behind superposition elastic long filament 13 and nonwoven 11,12, carry out complementary heat treatment (utilize the hot blast of hot blast method blow attached, steam sprays, heat embossing), machinery interweave (needle point method, jet net-spraying method) etc.At this moment, also can on single face or two sides, use fleece to replace nonwoven.
Embodiment
Below, by embodiment the present invention is described in further detail.But scope of the present invention is not limited to these embodiment.
[embodiment 1-1]
Use device shown in Figure 5 to make the flexible nonwoven of Figure 1 and Figure 2 structure.As the 1st and the 2nd nonwoven 11,12, used weight per unit area to be 15g/m
2Hot blast method nonwoven.The formation fiber of this nonwoven is that diameter is that 19 μ m, maximum elongation rate are 180%, fibre length is the core-sheath-type composite fibre (core: PET of 44mm; Sheath: PE).As the material resin of elastic filament 13, used that (weight average molecular weight is 50,000, and MFR is the elastomer that 60g/10 minute (230 ℃, 2.16kg)) (JIS K7210:1999) constitutes by the SEPS resin.Spinning condition is: the temperature of spinneret 17 is 310 ℃, and the diameter of spinning-nozzle 16 is that the spacing of 400 μ m, spinning-nozzle 16 is 1mm.The diameter of elastic filament 13 is 120 μ m.The apparent weight per unit area of long filament (the long filament weight in the sample/sampling sheet material area) is 10g/m
2, stretching ratio is 11 times.Stretching ratio is used (fibre diameter before nozzle bore/flexible performance is handled)
2Define.The elasticity performance processing of complex 19 uses the elasticity performance treating apparatus 22 that possesses a pair of tooth space roller 20,21 that alternately is formed with tooth and roller seating space on the axial length direction to carry out.Spacing between between cog and roller seating space is respectively 2.0mm (the spacing P of the between cog under the engagement is 1.0mm).Adjust the amount of being pressed into of tooth space roller up and down, be 3.0 times with stretching ratio and complex 19 is carried out the elasticity performance handle on the bearing of trend of elastic filament 13.Obtaining along the flexible weight per unit area of the bearing of trend of elastic filament 13 thus is 40g/m
2Flexible sheet material 10.The flexible sheet material 10 of gained sees through nonwoven and presents the striped style that elastic filament 13 produces.Also present the striped style that high weight per unit area zone and low weight per unit area zone produce in addition.By these two kinds of striped styles, flexible sheet material also presents cancellate style.In addition, the elastic filament 13 in the flexible sheet material 10 has the plurality of stepped serrations of major axis at the in-plane of this sheet material 10, and the ratio of major axis/minor axis is 1.6.1.5 the width when doubly extending is 96% of a former width, it is 4% that width reduces.The formation fiber of having confirmed nonwoven 11,12 in the flexible sheet material 10 by microscope is different along the fineness degree of the length direction of fiber.The maximum fiber diameter of this formation fiber is that 26.1 μ m, minimum fiber diameter are that 6.8 μ m, fibre diameter ratio are 3.8.In addition, the fineness degree of fibre diameter changes on this scope intercycle ground.
[embodiment 1-2]
The spacing of spinning-nozzle 16 is set on the width of spinneret 17, is 1mm, thereby form the 1st nozzle rows.Then, since the 1st nozzle rows, on the position of leaving 1mm on the moving direction of spinneret 17, form the 2nd nozzle rows with the spacing identical with the 1st nozzle rows.The 1st nozzle rows and the 2nd nozzle rows configuration with staggering half pitch mutually.In addition, change the stretching ratio of elastic filament 13 into 25 times, the diameter that makes elastic filament 13 is 80 μ m, in addition, operates equally with embodiment 1-1, obtains flexible sheet material 10.Should stretch in the sheet material 10, the spacing of elastic filament 13 is 0.5mm.
[embodiment 1-3]
Form the 1st zone, wherein the nozzle diameter with spinning-nozzle 16 is set at 400 μ m, and the stretching ratio of elastic filament 13 is set at 11 times, and the diameter of elastic filament 13 is set at 120 μ m; With form the 2nd zone, wherein the nozzle diameter with spinning-nozzle 16 is set at 300 μ m, and the stretching ratio of elastic filament 13 is set at 18 times, and the diameter of elastic filament 13 is set at 70 μ m.In addition, operate equally, obtain flexible sheet material 10 with embodiment 1-1.The 1st zone and the 2nd zone are arranged side by side on the width of flexible sheet material 10.The diameter of the different 2 kinds of elastic filaments of fineness degree is measured respectively in should flexible sheet material.
[embodiment 1-4]
(PE is a resinous substrates to the color concentrate mixing material of the purple of dried mixed 1.5 weight % in the styrene series elastomer that embodiment 1-1 uses, pigment concentration is the product of 60 weight %), except the elastic filament 13 that uses purple, operate equally with embodiment 1-1, obtain flexible sheet material 10.In this flexible sheet material, see through nonwoven, the striped style that elastic filament 13 produces is more obvious.
[embodiment 1-5]
The complex 19 that uses among the embodiment 2 is blown attached having carried out after the heat treatment at the hot blast by use hot blast method, under condition similarly to Example 2, carry out stretch process, obtain flexible sheet material 10 thus.In this flexible sheet material, nonwoven 11,12 each fiber are melt bonded each other, and bond strength further improves.
[comparative example 1-1]
According to the flexible sheet material of the method manufacturing of patent documentation 1 record.That is (weight per unit area is 73g/m, to use the contractile fibre net of CONWED company
2), as the 1st and the 2nd nonwoven 11,12, the applying unit area weight is 20g/m
2Hot blast method nonwoven.The formation fiber of this nonwoven is that diameter is that 17 μ m, maximum elongation rate are 30%, fibre length is core-sheath-type composite fibre (the core PET of 44mm; Sheath: PE).With respect to the MD direction of nonwoven 11,12, the grid of contractile fibre net is roughly square (being 3.2mm on MD direction, the CD direction).Use and to be heated to about 120 ℃ and about 60 ℃ stamped metal machine respectively, to above-mentioned fleece and nonwoven with about 10kg/cm
2Pressure carry out the heat/pressure combination in 10 seconds.Using the stretching device (elasticity performance treating apparatus) that has a pair of concavo-convex roller that alternately is formed with large-diameter portion and minor diameter part on the axial length direction (the spacing P of the between cog under the engagement is 1.0mm) to carry out the elasticity performance resulting sheet handles.Because the formation fiber of nonwoven does not extend,, then can observe the phenomenon of perforate on the nonwoven if therefore elasticity shows the stretching ratio height of handling.Therefore, be to handle under 2.7 times the condition making stretching ratio on the MD direction.The degree that stretches is controlled by the amount of being pressed into of adjusting concavo-convex roller up and down.The flexible sheet material of gained is owing to be difficult to elongation, so width reduces and becomes big.In addition, feel the very hard sensation of elastic webs, relatively poor aspect feel.
[comparative example 1-2]
(weight per unit area is 55g/m similarly to use the contractile fibre net of CONWED company with comparative example 1
2) the flexible sheet material of acquisition.With respect to the MD direction of nonwoven 11,12, the grid of contractile fibre net is roughly rhombus (being 9.5mm on MD direction, the CD direction).Use and to be heated to about 120 ℃ and about 60 ℃ stamped metal machine respectively, to above-mentioned fleece and nonwoven with about 10kg/cm
2Pressure carry out the heat/pressure combination in 10 seconds.Resulting sheet is used the stretching device (elasticity performance treating apparatus) that has a pair of concavo-convex roller that alternately is formed with large-diameter portion and minor diameter part on the axial length direction (the spacing P of the between cog under the engagement is 1.0mm), on the MD direction, carry out 3.0 times of stretchings, carry out the elasticity performance and handle.On the flexible sheet material of gained, because non-woven fabrics fiber do not extend, so many holes have been opened in the elasticity performance when handling on nonwoven.Therefore, though sheet material integral body has thickness, the abutment of elastic webs and nonwoven is harder.The result is relatively poor aspect feel.
[evaluation]
To the flexible sheet material of gained in embodiment and the comparative example, measure, estimate 50% with following method and reply intensity/50% elongation strengths, feel.In addition, measure the thickness of flexible sheet material and nonwoven with said method.These be the results are shown in the following table 1.
[50% replys intensity/50% elongation strengths]
With flexible sheet material according on its flexible direction for 200mm, on the direction vertical, cut out test film for the size of 50mm with flexible direction.On the distraction test machine AG-1kNIS of Shimadzu Seisakusho Ltd.'s system by chuck between distance install and fix test film for 150mm.Test film speed with 300mm/ minute on its flexible direction is extended.At 50% o'clock record load of elongation, should be worth as 50% elongation strengths.Continue to make this test film to be stretched to 100%, it is shunk with identical speed to replying direction (shrinkage direction), form the state of elongation 50%.Record load is at this moment replied intensity as 50%.More than measure is to be that 20 ± 2 ℃, humidity are to carry out under the environment of 65 ± 5%RH in temperature.
[feel]
Allow women estimator 10 people in camera bellows that cannot see flexible sheet material, in temperature, be that 25 ℃, humidity are under 40% the environment feel of this flexible sheet material to be estimated.According to each estimator's evaluation, give a mark with following mark, then with estimator 10 people's average mark (rounding up below the decimal point) evaluation score as feel.
5 minutes: good hand touch.
4 minutes: feel was good slightly.
3 minutes: general.
2 minutes: feel was poor slightly.
1 minute: feel was poor.
By the result shown in the table 1 as can be known, the flexible sheet material of each embodiment is compared with the flexible sheet material of comparative example, and expansion performance is good.Thickness is in addition we know arranged and have good hand feeling.In addition, in the flexible sheet material of each embodiment, elastic filament does not intersect and separate configuration non-contiguously mutually mutually substantially.Relative therewith, the elastomer of the flexible sheet material of comparative example 1 is owing to compacting destroys, and fleece becomes obviously, and fibroreticulate gloss is arranged, and not talkative outward appearance is good.
[embodiment 2-1～2-5 and comparative example 2-1～2-3]
Use device shown in Figure 5 to obtain complex 19 (precursor of the flexible sheet material 10 of Figure 1 and Figure 2), with its sample as embodiment 2-1.Promptly, use is equipped with the device of the structure of spinneret 17 on single screw extrusion machine, above-mentioned spinneret 17 possesses spinning-nozzle 16, interval with 1mm on the described spinning-nozzle 16 is arranged with 250 nozzle bores point-blank, described nozzle bore is that internal diameter is 0.45mm, length is the hole of the drum of 4.5mm, to it be 290 ℃ with melt temperature as following triblock copolymer (1)～(8) of resin combination, spray volume is ejection from spinning-nozzle 16 in 0.3kg/ minute, acquisition is as the long filament of the precursor of elastic filament 13, this long filament is used hot blast method nonwoven 11 in the position of leaving 100mm from spinning-nozzle 16 downwards, 12 clamp and make their joints, thereby acquisition elastic filament 13 is clamped in the complex 19 between nonwoven 11 and the nonwoven 12, wherein said hot blast method nonwoven 11, the 12nd, the weight per unit area of sending with the speed of 150m/min is 20g/m
2, thickness is that 0.4mm, fibre diameter are the nonwoven of 3dtex.In addition, nonwoven 11 and 12 all is the nonwoven that do not have extensibility originally.
In following 8 kinds of A1-B-A2 type triblock copolymers (1)～(8), triblock copolymer (1)～(5) are the compounds in the scope of the invention, and triblock copolymer (6)～(8) are extraneous compounds of the present invention.
A1-B-A2 type triblock copolymer (1):
With A1 '-B '-A2 ' type triblock copolymer (SEPS triblock copolymer, styrene-content is 30 weight %, ethylene-propylene content is 70 weight %, A1 ', the weight average molecular weight of A2 ' is 7500, the weight average molecular weight of B1 is 35000) 80 weight %, and A1 "-B "-A2 " the type triblock copolymer (SEPS triblock copolymer; styrene-content is 18 weight %; ethylene-propylene content is 82 weight %; A1 ", A2 " weight average molecular weight be 8100; B " weight average molecular weight be 73800) 20 weight % mix with Henschel mixer, resulting polymers are used as triblock copolymer (1).The maximum of the above-mentioned fusion tension force of triblock copolymer (1) (under the state with 245 ℃ temperature heating and melting, being that 0.45mm, length are the maximum of the fusion tension force during with 8.4m/ minute spouting velocity ejection the nozzle bore of drum of 4.5mm from internal diameter) is 0.07cN.
The weight average molecular weight of polymer blocks A1 is in the triblock copolymer (1): [(weight average molecular weight of polymer blocks A1 ') * (this A1 '-B '-A2 ' is shared percentage composition in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)+(polymer blocks A1 " weight average molecular weight) * (and this A1 "-B "-A2 " shared percentage composition in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)=] 7620.
The weight average molecular weight of polymer blocks B is in the triblock copolymer (1): [(weight average molecular weight of polymer blocks B ') * (this A1 '-B '-A2 ' is shared percentage composition in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)+(polymer blocks B " weight average molecular weight) * (and this A1 "-B "-A2 " shared percentage composition in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)=] 42760.
The weight average molecular weight of polymer blocks A2 is in the triblock copolymer (1): [(weight average molecular weight of polymer blocks A2 ') * (this A1 '-B '-A2 ' is shared percentage composition in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)+(polymer blocks A2 " weight average molecular weight) * (and this A1 "-B "-A2 " shared percentage composition in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)=] 7620.
A1-B-A2 type triblock copolymer (2):
With A1-B-A2 type triblock copolymer (SEPS triblock copolymer, styrene-content is 18 weight %, ethylene-propylene content is 82 weight %, and the weight average molecular weight of A1, A2 is 8100, and the mean molecule quantity of B1 is 73800) 100 weight % use as triblock copolymer (2).The maximum of the above-mentioned fusion tension force of triblock copolymer (2) is 0.13cN.
A1-B-A2 type triblock copolymer (3):
(SEBS triblock copolymer, styrene-content are 20 weight % with A1-B-A2 type triblock copolymer, ethene-butene content is 80 weight %, the weight average molecular weight of A1, A2 is 9400, and the mean molecule quantity of B1 is 75200) 100 weight % use as triblock copolymer (3).The maximum of the above-mentioned fusion tension force of triblock copolymer (3) is 0.15cN.
A1-B-A2 type triblock copolymer (4):
With A1 '-B '-A2 ' type triblock copolymer (SEPS triblock copolymer, styrene-content is 30 weight %, ethylene-propylene content is 70 weight %, A1 ', the weight average molecular weight of A2 ' is 7500, the mean molecule quantity of B 1 is 35000) 60 weight %, and A1 "-B "-A2 " the type triblock copolymer (SEPS triblock copolymer; styrene-content is 18 weight %; ethylene-propylene content is 82 weight %; A1 ", A2 " weight average molecular weight be 8100; B " weight average molecular weight be 73800) 40 weight % mix with Henschel mixer, resulting polymers are used as triblock copolymer (4).The maximum of the above-mentioned fusion tension force of triblock copolymer (4) is 0.20cN.
The weight average molecular weight of polymer blocks A1 is in the triblock copolymer (4): [(weight average molecular weight of polymer blocks A1 ') * (this A1 '-B '-A2 ' is shared percentage composition in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)+(polymer blocks A1 " weight average molecular weight) * (and this A1 "-B "-A2 " shared percentage composition in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)=] 7740.
The weight average molecular weight of polymer blocks B is in the triblock copolymer (4): [(weight average molecular weight of polymer blocks B ') * (this A1 '-B '-A2 ' is shared percentage composition in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)+(polymer blocks B " weight average molecular weight) * (and this A1 "-B "-A2 " shared percentage composition in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)=] 50520.
The weight average molecular weight of polymer blocks A2 is in the triblock copolymer (4): [(weight average molecular weight of polymer blocks A2 ') * (this A1 '-B '-A2 ' is shared content in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)+(polymer blocks A2 " weight average molecular weight) * (and this A1 "-B "-A2 " shared percentage composition in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)=] 7740.
A1-B-A2 type triblock copolymer (5):
With A1 '-B '-A2 ' three block type copolymer (SEPS triblock copolymers, styrene-content is 30 weight %, ethylene-propylene content is 70 weight %, A1 ', the weight average molecular weight of A2 ' is 7500, the mean molecule quantity of B1 is 35000) 50 weight %, and A1 "-B "-A2 " the type triblock copolymer (SEPS triblock copolymer; styrene-content is 30 weight %; ethylene-propylene content is 70 weight %; A1 ", A2 " weight average molecular weight be 10500; B " weight average molecular weight be 49000) 50 weight % mix with Henschel mixer, resulting polymers are used as triblock copolymer (5).The maximum of the above-mentioned fusion tension force of triblock copolymer (5) is 0.07cN.
The weight average molecular weight of polymer blocks A1 is in the triblock copolymer (5): [(weight average molecular weight of polymer blocks A1 ') * (this A1 '-B '-A2 ' is shared percentage composition in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)+(polymer blocks A1 " weight average molecular weight) * (and this A1 "-B "-A2 " shared percentage composition in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)=] 9000.
The weight average molecular weight of polymer blocks B is in the triblock copolymer (5): [(weight average molecular weight of polymer blocks B ') * (this A1 '-B '-A2 ' is shared percentage composition in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)+(polymer blocks B " weight average molecular weight) * (and this A1 "-B "-A2 " shared percentage composition in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)=] 42000.
The weight average molecular weight of polymer blocks A2 is in the triblock copolymer (5): [(weight average molecular weight of polymer blocks A2 ') * (this A1 '-B '-A2 ' is shared percentage composition in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)+(polymer blocks A2 " weight average molecular weight) * (and this A1 "-B "-A2 " shared percentage composition in the total amount of the contained A1-B-A2 type triblock copolymer more than 2 kinds of resin combination)=] 9000.
A1-B-A2 type triblock copolymer (6):
With A1-B-A2 type triblock copolymer (SEPS triblock copolymer, styrene-content is 30 weight %, ethylene-propylene content is 70 weight %, and the weight average molecular weight of A1, A2 is 10500, and the mean molecule quantity of B1 is 49000) 100 weight % use as triblock copolymer (6).The maximum of the above-mentioned fusion tension force of triblock copolymer (6) is 0.08cN.
A1-B-A2 type triblock copolymer (7):
With A1-B-A2 type triblock copolymer (SEBS triblock copolymer, styrene-content is 20 weight %, ethene-butene content is 80 weight %, and the weight average molecular weight of A1, A2 is 4750, and the mean molecule quantity of B1 is 38000) 100 weight % use as triblock copolymer (7).The maximum of the above-mentioned fusion tension force of triblock copolymer (7) is 0.05cN.
A1-B-A2 type triblock copolymer (8):
With A1-B-A2 type triblock copolymer (SEBS triblock copolymer, styrene-content is 30 weight %, ethylene contents is 70 weight %, and the weight average molecular weight of A1, A2 is 22750, and the mean molecule quantity of B1 is 84500) 100 weight % use as triblock copolymer (8).Measured fusion tension force as shown in Figure 4, but, therefore failed to record because the viscosity height can't be extruded.
[evaluation]
The characteristic of the complex 19 (elastic filament 13) of gained in embodiment and the comparative example and the composition of resin combination (the formation material of elastic filament 13) are shown in following table 2 and the table 3 in the lump.The assay method of projects is as described below in table 2 and the table 3.
The spinning technique of＜elastic filament 〉
Will be under state with 245 ℃ temperature heating and melting as the resin combination (above-mentioned triblock copolymer (1)～(8)) of the formation material of elastic filament, from internal diameter is that 0.45mm, length are that the spouting velocity with 8.4m/ minute sprays as illustrated in fig. 4 the nozzle bore of drum of 4.5mm, make long filament, be arranged at from this nozzle bore downwards the corrosion resistant plate of the position of 100mm gather this long filament.Is that level and smooth average evaluation is zero (spinning technique is good) with the long filament of the being gathered ground that do not rupture continuously and with the side that microscope amplifies 200 times of long filaments when observing these long filaments, with filament breakage and discontinuous situation or long filament because die swelling and fineness degree become uneven average evaluation for *.
＜tortuous state 〉
From embodiment and comparative example, in the complex of gained,, see through the tortuous state of the nonwoven visual observations elastic filament that covers this elastic filament along mechanical moving direction (moving direction of this complex when MD direction, complex manufacturing) sampling 30cm.It is zero with interior average evaluation that the long filament that intersects in adjacent 100 elastic filaments or contact is 10, with the average evaluation that wherein intersects more than 11 or contact be *.
＜anti-diaper skew dropping 〉
Complex to gained in embodiment and the comparative example uses the stretching device that possesses a pair of tooth space roller shown in Figure 7 to implement stretch processing, make the flexible sheet material of Figure 1 and Figure 2, used as the housing material of diaper, the girth of making waist is the Breeches type disposable diaper of 35cm.As shown in Figure 9, this diaper is through on the propylene acid tube that girth is 44cm, the diaper bottom is fixed with crocodile mouth clamping, make this clip towards last side shifting, the propylene acid tube is placed on the jack.At this moment, the waist location of propylene acid tube subscript note diaper (will this moment position as initial position A), 50mm descends jack under the situation of fixing clip.Mensuration is with descend distance between waist location behind the 50mm (will this moment position as deviation post) and the initial position A of jack, with skew the drop amount of this distance as diaper.With this skew amount of dropping less than the situation of 10mm be judged to be ◎ (anti-diaper skew dropping is very good), with more than the 10mm but less than the situation of 20mm be judged to be zero (anti-diaper skew dropping is good), with more than the 20mm but less than the situation of 30mm be judged to be △ (in the practical application out of question level), the situation more than the 30mm be judged to be *.
By the result shown in table 2 and the table 3 as can be known, embodiment 2-1～2-5 is owing to the resin combination that has all used in the scope of the invention, so the spinning technique excellence of long filament, and long filament does not have complications in flexible sheet material, when the sheet material that will stretch is used for diaper, can obtain to be difficult to be offset the diaper that drops.Relative therewith, in comparative example 2-1, because die swelling makes the fineness degree of long filament become inhomogeneous, the part fracture of long filament from becoming very thin can't obtain continuous filament yarn.In comparative example 2-2, though fineness degree is even, fusion tension force is low, so filament breakage, can't obtain continuous filament yarn.Thereby, when the flexible sheet material that obtains is used for diaper,, therefore be offset the dropping variation because the fracture of long filament causes expansion performance to reduce in comparative example 2-1 and 2-2.In comparative example 2-3, because the viscosity height of triblock copolymer (8), can't spinning technique, therefore can't obtain long filament.
[embodiment 3-1]
Use device shown in Figure 5 to make the flexible sheet material of Figure 1 and Figure 2 structure.As the 1st and the 2nd nonwoven 11,12, the applying unit area weight is 20g/m
2, fibre density is 0.074g/cm
3Hot blast method nonwoven.The formation fiber of this nonwoven is that diameter is that 19 μ m, maximum elongation rate are 180%, fibre length is the core-sheath-type composite fibre (core: PET of 44mm; Sheath: PE).As the material resin of elastic filament 13, (weight average molecular weight is 50,000 by the SEPS resin in use; MFR is 60g/10 minute (230 ℃, 2.16kg)) elastomer that constitutes.Spinning condition is: the temperature of spinneret 17 is that 310 ℃, the diameter of spinning-nozzle 16 are that the spacing of 400 μ m, spinning-nozzle 16 is that 1mm, stretching ratio are 11 times.The diameter of elastic filament 13 is 107 μ m.The weight per unit area of long filament is 8g/m
2Interval W between niproll is set in the joint of elastic filament and nonwoven 11,12, and this is made as 0.2mm at interval.One is used the metal plain-barreled roll in the niproll, and another uses rubber rollers.The stretch process of complex 19 uses the stretching device 22 that possesses a pair of tooth space roller 20,21 that alternately is formed with tooth and roller seating space on the axial length direction to carry out.Spacing between between cog and roller seating space is respectively 2.0mm (the spacing P of the between cog under engagement is 1.0mm).Adjust the amount of being pressed into of tooth space roller up and down, be 3.0 times with stretching ratio complex 19 is stretched on the bearing of trend of elastic filament 13.Obtaining weight per unit area flexible on the bearing of trend of elastic filament 13 thus is 48g/m
2Flexible sheet material 10.The flexible sheet material 10 of gained sees through nonwoven and presents the striped style that elastic filament 13 produces.Also present the striped style that high weight per unit area zone and low weight per unit area zone produce in addition.By these two kinds of striped styles, flexible sheet material also presents cancellate style.In addition, the elastic filament 13 in the flexible sheet material 10 has the elliptic cross-section of major axis on the in-plane of this sheet material 10, and the ratio of major axis/minor axis is 1.5.1.5 it is 4% that the width when doubly extending reduces.
[embodiment 3-2～3-4]
Interval W between niproll is made as the value shown in table 4 and the table 5, in addition, operates equally, obtain flexible sheet material 10 with embodiment 3-1.
[embodiment 3-5～3-7]
To the distance before engage be made as a table 4 and table 5 indicating value from the top of spinning-nozzle, and the compartment of terrain that niproll is not set carries out whole extruding in joint, in addition, operate equally, obtain flexible sheet material 10 with embodiment 3-1.
[comparative example 3-1]
The elastic resin of the film shape that use is extruded from the T mould replaces elastic filament, and this film shape elastic resin and nonwoven is carried out stacked, in addition, operates equally with embodiment 3-1, obtains the sheet material that stretches.As this elastic resin, use G1657 (trade name, Kraton Polymers system).
[evaluation]
To the flexible sheet material that obtains in embodiment and the comparative example, measure and estimated the projects shown in table 4 and the table 5." interlaminar strength " in table 4 and the table 5 (bond strength between elastic filament and the nonwoven), " 25% answer intensity (cN/{50mm (g/m
2)) " (25% of the weight per unit area of contained elastic resin replys intensity in the flexible sheet material of unit), " the average splice ratio between elastic filament and the nonwoven formation fiber ", " width reduces (%) " (width the when sheet material that will stretch is elongated to 1.5 times reduces) and the thickness of flexible sheet material and nonwoven measures by above-mentioned method respectively.In addition, " 25% reply intensity (cN/50mm) ", " 25% replys intensity/25% elongation strengths (%) ", and " feel " measure and estimate by following method respectively.In addition, " intersection of elastic filament " undertaken by visual observations.The situation of intersection that does not almost observe elastic filament for high praise, have the situation of intersection to estimate for low.
[25% replys intensity/25% elongation strengths, 25% replys intensity]
With flexible sheet material by on its flexible direction for cutting out test film for the size of 50mm on 200mm, the direction vertical with the direction of should stretching.Distance (initial length) is that 150mm installs and fixes test film between distraction test machine (the system Autograph AG-1kNIS of Shimadzu Seisakusho Ltd.) is gone up with chuck.Test film speed with 300mm/ minute on its flexible direction is extended, and 25% o'clock load of record elongation should be worth as 25% elongation strengths.Continue to make test film to be elongated to 50%, it is shunk with identical speed to replying direction (shrinkage direction), 25% o'clock load of record elongation initial length is replied intensity with it as 25%.Use the value of 25% elongation strengths of trying to achieve thus respectively and the value of 25% answer intensity, calculate 25% and reply intensity/25% elongation strengths (%).More than measure is to be that 20 ± 2 ℃, humidity are to carry out under the environment of 65 ± 5%RH in temperature.
[feel]
Allow women estimator 10 people in camera bellows that cannot see flexible sheet material, in temperature, be that 25 ℃, humidity are under 40% the environment described feel that should flexible sheet material to be estimated.According to each estimator's evaluation, give a mark with following mark, then with estimator 10 people's average mark (rounding up below the decimal point) evaluation score as feel.
5 minutes: good hand touch.
4 minutes: feel was good slightly.
3 minutes: general.
2 minutes: feel was poor slightly.
1 minute: feel was poor.
Table 4
Table 5
By the result shown in table 4 and the table 5 as can be known, the flexible sheet material of each embodiment all shows desirable average splice ratio, has higher interlaminar strength (bond strength between elastic filament and the nonwoven) and higher 25% answer intensity (25% of the per unit area weight of the elastic resin in the flexible sheet material is replied intensity), width reduces little, substantially do not observe the intersection of elastic filament, feel is also excellent.In addition, the flexible sheet material of each embodiment has outward appearance shown in Figure 2, and outward appearance is also good.Relative therewith, 25% answer intensity of the per unit area weight of the elastic resin in the flexible sheet material of comparative example 3-1 is low, width reduces greatly, also do not have gas permeability.
As mentioned above, in flexible sheet material of the present invention, arrange, therefore can not take place to make of the bearing of trend elongation of this flexible sheet material under the situation that width reduces along this elastic filament because elastic filament extends ground along direction.In addition, the intensity height of flexible sheet material of the present invention when flexible sheet material is extended, is not easy to cause peeling off of elastic filament and nonwoven.
In addition, in flexible sheet material of the present invention, the tensile nonwoven that constitutes with respect to containing non-elastic fiber, a large amount of elastic filaments extends ground along a direction and arranges, and the bond strength between elastic filament and this nonwoven, 25% of the per unit area weight of the elastic resin in the flexible sheet material is replied intensity, and the average splice ratio between the fiber of elastic filament and this nonwoven of formation is respectively in above-mentioned specific scope, so balance excellence between interlayer bond strength and the expansion performance, can not take place to make of the bearing of trend elongation of this flexible sheet material under the situation that width reduces along this elastic filament, and, when flexible sheet material is extended, be not easy to cause peeling off of elastic filament and nonwoven.
In addition, the spinning technique excellence of elastic filament of the present invention even under the thinner situation of diameter, also can be carried out high-speed production fracture of wire not taking place and ejection shaping from spinning-nozzle under the tortuous situation not taking place.Contain of the present invention flexible sheet material that this elastic filament constitutes for example as be the various wearing clothings of representative with absorbent commodities such as disposable diapers, when other formation material that is worn on the various article on the human body uses, because the effect of this elastic filament, show excellent fit, can prevent effectively that the skew of dressing clothing from dropping.The absorbent commodity of the present invention that contains this flexible sheet material and constitute has the fit in the excellent wearing process, and is difficult to skew and drops.
Claims (19)
1, a kind of flexible sheet material, its for a large amount of elastic filament on its whole length with in fact not the state of elongation engages with tensile nonwoven and forms, described a large amount of elastic filament do not arrange along the mode of a direction extension across according to mutual.
2, flexible sheet material according to claim 1, wherein, described elastic filament engages by melt bonded with described nonwoven.
3, flexible sheet material according to claim 1 and 2, wherein, described elastic filament is to form by elastic resin is stretched under fusion or softening state.
4, flexible sheet material according to claim 3, wherein, described elastic filament by will be from spinning-nozzle spun elastic resin carry out fusion drawn and obtain.
5, according to claim 3 or 4 described flexible sheet materials, wherein, described elastic filament is stretched to 1.1～400 times with described elastic resin and obtains under fusion or softening state, and the diameter of described elastic filament is 10～200 μ m.
6, according to each described flexible sheet material in the claim 1～5, wherein, in described flexible sheet material, described elastic filament roughly disposes with respect to this prolonging direction side by side in the different zone more than 2 of the elongation stress on the prolonging direction, and between each zone, the diameter difference of the spacing of adjacent described elastic filament difference and/or described elastic filament.
7, according to each described flexible sheet material in the claim 1～6, wherein, described elastic filament is clamped between 2 identical or different nonwoven.
8, according to each described flexible sheet material in the claim 1～7, wherein, the average flat ratio of described elastic filament is 1.0～7.0 times.
9, according to each described flexible sheet material in the claim 1～8, wherein, tensile described nonwoven contains along the different non-elastic fiber of the fineness degree of fibre length direction.
10, flexible sheet material according to claim 9, wherein, the fineness degree of described non-elastic fiber is 2～15 μ m at its thinnest part place, is 10～40 μ m at its thickest part place.
11, according to claim 9 or 10 described flexible sheet materials, wherein, described non-elastic fiber is the short fiber that is made of composite fibre.
12, according to each described flexible sheet material in the claim 1～11, wherein, bond strength between described elastic filament and the described nonwoven is more than the 10cN/25mm, and 25% answer intensity is 1.0cN/{50mm (g/m with respect to the per unit area weight of the elastic resin that is contained in the described flexible sheet material
2) more than, and the average splice ratio between the fiber of described elastic filament and the described nonwoven of formation is 10～60%.
13, according to each described flexible sheet material in the claim 1～12, wherein, the resin combination that described elastic filament constitutes by containing A1-B-A2 type triblock copolymer forms, and described A1-B-A2 type triblock copolymer is by constituting based on the polymer blocks A1 of vinyl aromatic polymers and A2 with based on the polymer blocks B of polyolefin;
Described polymer blocks A1 and the A2 weight average molecular weight of passing through gel permeation chromatography separately add up to 14000～20000, and the weight average molecular weight of passing through gel permeation chromatography of described polymer blocks B is 40000～80000.
14, flexible sheet material according to claim 13, wherein, described resin combination is that 0.45mm, length are that the maximum of the fusion tension force during with 8.4m/ minute spouting velocity ejection the nozzle bore of drum of 4.5mm is 0.06～0.20cN from internal diameter under the state with 245 ℃ temperature heating and melting.
15, a kind of manufacture method of flexible sheet material, wherein, will be from spinning-nozzle a large amount of elastic filament of spun molten condition with the fixing speed tractive and stretch, and before this elastic filament solidifies, the mode of mutually not arranging along a direction across according to described elastic filament makes described elastic filament and nonwoven melt bonded, then the bearing of trend of the melt bonded complex that described elastic filament arranged along described elastic filament stretched, thereby make described complex have retractility.
16, the manufacture method of flexible sheet material according to claim 15, wherein, by making the described nonwoven in described elastic filament and the conveyance melt bonded, thereby with described elastic filament tractive and stretch.
17, according to the manufacture method of claim 16 or 17 described flexible sheet materials, wherein, described complex is passed through between a pair of tooth space roller along its moving direction, thereby the moving direction along described complex makes described complex have retractility, and described a pair of tooth space roller alternately is formed with tooth and roller seating space in a circumferential direction.
18, a kind of manufacture method of flexible sheet material; Its will be from spinning-nozzle a large amount of elastic filament of spun molten condition with the fixing speed tractive and stretch; And before described elastic filament solidifies; The mode of mutually not arranging along a direction across according to described elastic filament makes described elastic filament and nonwoven melt bonded; Then the bearing of trend of the melt bonded complex that described elastic filament arranged along described elastic filament stretched; Thereby make described complex have retractility
Wherein, with before described nonwoven contacts, the displacement that described elastic filament is started at from the top of described spinning-nozzle is below the 600mm at spun described elastic filament from described spinning-nozzle.
19, the manufacture method of flexible sheet material according to claim 18, wherein, the melt bonded of described elastic filament and described nonwoven is to collaborate to carry out between a pair of niproll by described elastic filament and the described nonwoven in the conveyance that makes spun molten condition from described spinning-nozzle, is spaced apart 0.05～1.0mm between the described a pair of niproll.
Applications Claiming Priority (7)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP356560/2006 | 2006-12-28 | ||
| JP2006356560 | 2006-12-28 | ||
| JP192665/2007 | 2007-07-24 | ||
| JP2007192665A JP5188117B2 (en) | 2007-07-24 | 2007-07-24 | Elastic filament and elastic sheet using the same |
| JP2007233410A JP4918002B2 (en) | 2007-09-07 | 2007-09-07 | Elastic sheet and method for producing the same |
| JP233410/2007 | 2007-09-07 | ||
| PCT/JP2007/072871 WO2008081662A1 (en) | 2006-12-28 | 2007-11-27 | Stretchable sheet and process for producing the stretchable sheet |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN101557929A true CN101557929A (en) | 2009-10-14 |
| CN101557929B CN101557929B (en) | 2012-09-05 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN200780045872.8A Expired - Fee Related CN101557929B (en) | 2006-12-28 | 2007-11-27 | Stretchable sheet and process for producing the stretchable sheet |
Country Status (2)
| Country | Link |
|---|---|
| JP (1) | JP5063315B2 (en) |
| CN (1) | CN101557929B (en) |
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| CN101557929B (en) | 2012-09-05 |
| JP2008179128A (en) | 2008-08-07 |
| JP5063315B2 (en) | 2012-10-31 |
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