CN102211426B - 使用伸长性无纺布的复合体 - Google Patents

使用伸长性无纺布的复合体 Download PDF

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Publication number
CN102211426B
CN102211426B CN201110068301.4A CN201110068301A CN102211426B CN 102211426 B CN102211426 B CN 102211426B CN 201110068301 A CN201110068301 A CN 201110068301A CN 102211426 B CN102211426 B CN 102211426B
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CN
China
Prior art keywords
woven fabrics
hot press
spunbonded nonwoven
retractility
press portion
Prior art date
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Expired - Fee Related
Application number
CN201110068301.4A
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English (en)
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CN102211426A (zh
Inventor
藤原寿克
寺川泰树
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JNC Corp
Original Assignee
JNC Corp
JNC Fibers Corp
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Publication of CN102211426A publication Critical patent/CN102211426A/zh
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Expired - Fee Related legal-status Critical Current
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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/04—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a layer being specifically extensible by reason of its structure or arrangement, e.g. by reason of the chemical nature of the fibres or filaments
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Abstract

本发明是有关于一种使用伸长性无纺布的复合体，作为薄片材料的复合体，其是将下述复合纺粘无纺布与伸缩性层积层而成，此复合纺粘无纺布由包含低熔点成分与高熔点成分的复合纤维构成，复合纤维彼此局部地热压接合，且热压接合部沿着CD(制造无纺布时的宽度方向)具有由山部与谷部重复所成的微细的折叠结构，所述折叠结构的相邻山部彼此间的距离的平均值在100μm～400μm的范围内，此复合纺粘无纺布通过伸展此微细的折叠结构而表现出伸长性，伸长5％时的CD强度小于等于0.1N/5cm宽，伸长5％时的MD/CD强度比(“制造无纺布时的长度方向/制造无纺布时的宽度方向”的强度比)大于等于200。

Description

使用伸长性无纺布的复合体
技术领域
本发明是有关于一种将在一方向上具有低应力伸长性的无纺布与伸缩性层积层成一体所成的复合体。本发明的复合体中，特定的低应力伸长性无纺布与伸缩性层积层成一体，有利于构成最适合作为像内衣或防尘口罩、一次性纸尿布等卫生用品之类的产品的材料，而且加工容易，伸长性或伸缩性、透气性、柔软性优异，触感良好且不容易破裂(或断裂、撕裂强度大)的薄片材料。
背景技术
普通的纺粘无纺布和热轧无纺布价格便宜，而被大量利用为使用方便的通用品无纺布，但是这些无纺布几乎不具有本发明中所说的低应力伸长性。另外，表现低应力伸长性的通用无纺布有水刺无纺布，但并未达到本发明中所说的低应力伸长性，并且由于制法的特征使得这种无纺布的价格相对高昂。另外，低应力伸长性的无纺布也有长丝束接近于平行的丝束开松无纺布、由熔融挤出法获得的发泡网状物等，但是这些无纺布的CD(CrossDirection，制造无纺布时的宽度方向)强度极小，不适合于本发明的目的。记载了解决此问题的方法的文献已知有以下的专利文献。
专利文献1记载了一种利用两层的收缩差而在其中一面形成褶皱的积层体，但是这种积层体存在即使施加张力褶皱也不伸展的问题。
专利文献2记载了一种颈状伸长的(neck-stretching)无纺网布(nonwoven web)，但据其记载此无纺网布的表面为“平坦”。其并记载，在积层于此无纺网布上的膜的表面，伴随无纺网布的CD的收缩(以下将这种收缩称为“缩幅”)而形成褶皱。
专利文献3中使用齿辊(gear roll)对无纺布赋予凹凸形状，但是此凹凸结构是形成在无纺布的整个面上的，且高度为2mm～30mm，波长为2mm～50mm，相对较大。
[先有技术文献]
[专利文献]
[专利文献1]日本专利特开平7-54256
[专利文献2]日本专利特开2004-521775
[专利文献3]日本专利特开2004-76178
发明内容
但是上述方法中，在无纺布由多层构成时不能获得柔软性，或者不能获得充分的伸长性或伸缩性，因此无法提供出最适合用作内衣或卫生用品等产品的原材料的无纺布。本发明提供一种积层了价格相对低廉且使用方便的低应力伸长性无纺布的复合体。
本发明需要由包含低熔点成分与高熔点成分的复合纤维构成，且局部经过适度的热压接合加工的复合纺粘原料无纺布。并且，通过在规定条件下将此原料无纺布沿着制造无纺布时的长度方向(Machine Direction，以下称为MD)延伸，可以在热压接合部沿着制造无纺布时的宽度方向(以下称为CD)，形成由山部与谷部重复所成的微细的折叠结构，所述原料无纺布通过伸展此微细的折叠结构而表现出伸长性，由此，将所述原料无纺布与伸缩性层积层成一体而成的本发明的复合体具有充分的伸缩性。
本发明的构成如下所述。
(1)一种复合体，其是将复合纺粘无纺布与伸缩性层积层成一体而成，此复合体的特征在于：复合纺粘无纺布由包含低熔点成分与高熔点成分的复合纤维构成，复合纤维彼此局部地热压接合，且热压接合部沿着CD(制造无纺布时的宽度方向)具有由山部与谷部重复所成的微细的折叠结构，所述折叠结构的相邻山部彼此间的距离的平均值在100μm～400μm的范围内，此复合纺粘无纺布通过伸展此微细的折叠结构而表现出伸长性。
(2)根据所述(1)记载的复合体，其特征在于：复合纺粘无纺布伸长5％时的CD强度小于等于0.1N/5cm宽，伸长5％时的MD/CD强度比(“制造无纺布时的长度方向/制造无纺布时的宽度方向”的强度比)大于等于200。
(3)根据所述(1)记载的复合体，其特征在于：复合纺粘无纺布伸长50％时的CD强度小于等于5N/5cm宽。
(4)根据所述(1)至(3)中任一项记载的复合体，其特征在于：伸缩性层是包含弹性体树脂的长纤维层。
(5)根据所述(4)记载的复合体，其特征在于：长纤维层是熔喷纤维层。
(6)根据所述(1)至(5)中任一项记载的复合体，其特征在于：通过将纺粘无纺布与伸缩性层局部热压接合而积层成一体。
[发明的效果]
利用本发明，可以发挥以下效果，即能够提供一种价格相对低廉，最适合作为像内衣或防尘口罩、一次性纸尿布等卫生用品之类的产品的材料，而且加工容易，伸长性、透气性、柔软性优异，触感良好的作为薄片材料的复合体，并且能够提供一种使用这些复合体的物品。
附图说明
图1A及图1B是表示本发明中使用的纺粘无纺布的热压接合部的微细的折叠结构的图。
图2A及图2B是表示本发明中使用的纺粘原料无纺布的热压接合部图案的示例(棋盘排列)及热压接合部图案的CD占有率的图。
图3A～图3C是表示本发明中使用的纺粘原料无纺布的热压接合部图案的示例(将棋盘排列旋转α°)及热压接合部图案的CD占有率的图。
图4A及图4B是表示本发明中使用的纺粘原料无纺布的热压接合部图案的示例(交错排列)及热压接合部图案的CD占有率的图。
图5A及图5B是表示本发明中使用的纺粘原料无纺布的热压接合部图案的示例(不规则形状)及热压接合部图案的CD占有率的图。
具体实施方式
要制造适用于本发明的复合体的具有优异的低应力伸长性的纺粘无纺布，热压接合部形成折叠结构之前的原料无纺布优选的是保有适度的MD干热收缩率，且热压接合部残留有高熔点成分的纤维结构的复合纺粘无纺布。此时，如果在热压接合部高熔点成分保持着纤维的形状，则不会妨碍低熔点成分通过热熔融而遍及整个热压接合部地形成为一体。通过对此原料无纺布沿着MD进行加热延伸(就可以进行这种延伸的方面而言，原料无纺布优选使用复合纺粘无纺布)，存在于非热压接合部的无规配置的复合长丝以沿MD配向的方式移动，但是其反作用会使无纺布受到沿着CD的内侧的应力，而使无纺布沿CD缩幅。此时，虽然热压接合部受到沿MD伸展的应力，但是非热压接合部的长丝的MD配向占优势，热压接合部不会延伸至要延伸的倍率，也不会被破坏。另外，虽然此热压接合部也同样受到沿着CD的内侧的应力，但因未沿着MD得到相应拉伸而残留的应变应力会产生沿着CD表现出折叠结构的应力解除现象。而且，因为热压接合部中保持着热收缩性的高熔点成分以纤维状而残留，所以通过与此高熔点成分的收缩功能的相乘效果，可以容易地形成微细的折叠结构。
相对于此，当原料无纺布为由单一成分纤维构成的纺粘无纺布时，要保持充分的强度，必须形成为热压接合部的纤维几乎完全熔融固化的状态。使用此纺粘无纺布进行延伸时，虽然非热压接合部与所述同样地进行作用，但热压接合部与像本发明这样的热压接合部相比较硬，因而即使延伸也不能获得充分的折叠结构。另外，即使是复合纺粘无纺布原料，如果热压接合部的高熔点成分也是熔融固化的状态则与所述同样。
形成本发明的复合体的复合纺粘无纺布的热压接合部的微细折叠结构示于图1A及图1B。此热压接合部的微细的折叠结构中，相邻的折叠结构可以接触也可以分开。相邻折叠结构的相邻的各山间或各谷间的距离依赖于原料无纺布的物性或纤维的构成及延伸条件等，尤其是较大程度地依赖于无纺布的热压接合部的状态。本发明中，热压接合部的折叠结构中相邻各山间的目标距离优选100μm～400μm，特别优选在100μm～300μm的范围内。当相邻各山间的距离为100μm～400μm时，可以获得充分的伸长度，而且，即使不使用必要量以上的低克重的原料无纺布也可以获得充分的伸长度，容易均匀地进行热延伸，而可以保持均匀的低应力伸长性。
本发明中使用的复合纺粘无纺布沿着CD具有极低应力的伸长性。其指标如下，伸长5％时的CD强度小于等于0.1N/5cm宽，优选小于等于0.100N/5cm宽，更优选小于等于0.050N/5cm宽，特别优选小于等于0.010N/5cm宽。并且，伸长5％时的MD/CD强度比大于等于200，优选大于等于300，更优选大于等于400。由于也存在CD强度在拉伸试验机的测定极限(0.001N/5cm)以下的情况，所以限定MD/CD强度比的上限并没有多大意义。但是，考虑到本发明的实例中MD强度的最大值为100N/5cm左右，则可以估算出MD/CD强度比的上限为100000左右，考虑MD强度更高(可以假定上限为200N/5cm左右)的情况，则可以估算出MD/CD强度比的上限为200000左右。为了使本发明的效果更加明确，伸长50％时的CD强度小于等于5N/5cm宽，优选小于等于5.000N/5cm宽。所述CD强度更优选小于等于3.000N/5cm宽，特别优选小于等于1.000N/5cm宽。下限值是拉伸试验机的测定极限(0.001N/5cm)。
对复合纺粘无纺布的树脂成分的组合进行说明。低熔点成分及高熔点成分例如可以将作为普通热塑性树脂的聚乙烯(PE)、聚丙烯(PP)、聚酯(例如聚对苯二甲酸乙二酯(PET))、尼龙(nylon)组合使用。PE可以使用高密度聚乙烯、低密度聚乙烯、线性低密度聚乙烯。复合纤维的形态可以列举鞘侧配置低熔点成分，芯侧配置高熔点成分的芯鞘型复合纤维，也可以使用高熔点成分的一部分以小于等于50％的表面积而露出至纤维表面的复合形态。使用单一成分时，为了使复合纺粘无纺布具有可以耐受延伸的MD强度，必须将热压接合加工条件设定得非常严酷，因此不能在热压接合部残留纤维结构至纤维本身所具有的热收缩性的性质残留的程度，难以获得本发明的无纺布。使用鞘侧配置高熔点成分，芯侧配置低熔点成分的芯鞘型复合纤维时也同样如此。本发明的复合纺粘无纺布的具体的热塑性树脂的组合优选的是低熔点成分/高熔点成分为PE/PP、PE/尼龙、PE/PET、PP/尼龙、PP/PET、尼龙/PET，为了在热压接合部残留纤维结构至纤维本身所具有的热收缩性的性质残留的程度，熔点差越大则加工条件的限制越少，特别优选的是PE/PET的组合。
本发明的进一步的特征在于：折叠结构形成前的原料无纺布中，热压接合部的总面积率优选7％～60％，特别优选10％～50％。通过使热压接合部的总面积率在所述范围内，可以在不损及无纺布的柔软性、透气性的情况下，确保应表现微细的折叠结构的热压接合部的面积足够。
另外，本发明中使用的原料无纺布中，连续散布在MD上的热压接合部相对于CD全宽的占有率优选大于等于50％，更优选大于等于70％。下面，对此连续散布在MD上的热压接合部相对于CD全宽的占有率(以下称为“CD占有率”)进行说明。
本发明中使用的原料无纺布的CD占有率根据赋予此原料无纺布的热压接合部的图案的不同而变化，并且关系到本发明的效果。因此，首先就热压接合部图案进行说明。
图2A的热压接合部图案是棋盘排列，热压接合部沿着CD的排列即CD行与热压接合部沿着MD的排列即MD列正交。各CD行及各MD列分别等间隔地排列着。各CD行的间隔和各MD列的间隔可以相同也可以不同。可以通过将全部热压接合部投影在CD轴上而求出CD占有率。关于图2A的图案的CD占有率，因为CD轴与各CD行平行，所以配置在每一行CD行的热压接合部的宽度(W1～Wn)的总和相对于CD全宽所占的比例相同。
图3A是使图2A及图2B的热压接合部图案逆时针旋转α角(α°)，各CD行相对于实际的CD具有α°的角度。像图3B所示，此时每一行的CD占有率是将一行中的各热压接合部的宽度投影在CD轴上时的W1～Wn的总和相对于CD全宽所占的比例。
但是，由于此图案具有角度，所以像图3C所示，两行CD行的CD占有率是2W1～2Wn的总和相对于CD全宽所占的比例。实质上，因为CD行是第1行、第2行、第3行、......规则地逐渐错开，所以将多行CD行投影在CD轴上时的CD占有率为100％。
图4A是热压接合部的图案交错排列的示例(将像这样各CD行的热压接合部交替排列的图案称为交错排列)。各CD行间及各MD列间的距离相等，并且热压接合部以各连续的两行及两列为单位而重复排列。另外，各CD行的间隔和各MD列的间隔可以相同也可以不同。关于图4A的图案的CD占有率，由于CD轴与CD行平行，所以像图4B所示，将连续的两行CD行的各热压接合部的宽度投影在CD轴上时的W1～Wn的总和相对于CD全宽所占的比例相同。
虽未图示，但为此交错排列时，也可以和图3A～图3C所示的棋盘格排列同样地旋转α°。此时，CD行是以连续的两行为单位而规则地逐渐错开，所以和前述同样，将多行CD行投影在CD轴上时的CD占有率为100％。
另外，当图3A及图4A的各CD行和MD列的间隔相同时，由CD行与MD列形成的四角形为正方形，所以如果将图3A倾斜45°，则变成与图4A相似的图案，相反地，如果将图4A倾斜45°，则变成与图3A相似的图案。
图5A是热压接合部的形状及排列不规则的示例。像图5B所示，此时的CD占有率是将从图5A的靠近底边的压接部开始使压接部一个一个地投影在CD轴上时的各热压接合部的宽度设为W1、W2、W3、......Wn，W1～Wn的总和相对于CD全宽所占的比例。
另外，由于原本就是不规则的排列，所以即使将图5A的图案旋转α°，也可以用与所述相同的方式求出CD占有率。
另外，本发明中使用的原料无纺布的MD干热收缩率优选3.5％～23％，特别优选4％～20％。纤维的热收缩在促进微细折叠结构的形成方面重要。特别是必须将热压接合部残留的高熔点成分的纤维的收缩率保持在适当的范围内。当所述MD干热收缩率为3.5％～23％时，可以容易地形成折叠结构，并且折叠的各山间的距离也足以保持在400μm以下，可以不考虑在所制成的无纺布上产生局部的抽缩或密集部(团块)等问题而实施本发明。另外，无纺布的质地也可以保持为良好。
为了获得具有上述MD干热收缩率的无纺布，重要的是适当地选择纺丝速度或纺丝温度等纺丝条件。所述纺丝条件可以通过对高熔点成分侧的结晶度或分子配向稍加抑制而容易地设定。例如，如果是由PE/PET的组合构成的无纺布，则通过将纺丝速度设定在2000m/min～3000m/min的范围内，将纺丝温度设定在300℃～350℃的范围内，可以较佳地获得MD干热收缩率在3.5％～23％的范围内的原料无纺布。
关于对上述的适当的原料无纺布进行适度地延伸所获得的无纺布的缩幅，延伸后的CD宽度相对于延伸前的CD宽度的比优选0.1～0.7，更优选0.2～0.6。当所述比值为0.1～0.7时，可以使本发明中所说的低应力伸长性充分保持，并且与所述MD干热收缩率的情况同样，可以不考虑在所制成的无纺布上产生局部的抽缩或密集部(团块)等问题而实施本发明。另外，无纺布的质地也可以保持为良好。
本发明中，虽然对于用来在原料无纺布上设置热压接合部的热压接合加工条件并不作特别限定，但重要的是设定成热压接合部残留高熔点成分的纤维结构这样的条件。如果是热压接合部的高熔点成分可以保持纤维的形状这样的加工条件，则即使低熔点成分通过热熔融而遍及整个热压接合部地形成为一体也无影响。为了保持高熔点成分的纤维结构，特别重要的是适当选择热压接合加工时的温度、线压等条件。此方法可以利用公知的方法，具有代表性的是此技术领域中通常使用的利用表面具有凹凸部的热压花辊进行热压接合的方法。如上所述的用来设置热压接合部的热压花辊的压接条件(温度、线压等)根据所使用的树脂的种类不同而有所不同，但是只要一边观察热压接合部的状态一边实施热压接合，就能够容易地设定在通常进行的范围内。
关于制造例如由PE/PET或PE/PP的组合所构成的原料纺粘无纺布时的热压接合条件，例如当使用Kuster公司制造的压花辊/浮动辊(swimmingroll)热压接合机时，理想的是辊温度在115℃～140℃的范围内，线压在20N/mm～70N/mm的范围内。
另外，本发明中延伸条件也并无特别限定。所谓延伸，是指将原料无纺布沿着MD的一方向延伸，可以选择辊延伸装置或针板拉幅延伸装置(pintentering extension device)。延伸后的无纺布宽度与延伸前的原料无纺布的宽度相比会收缩至0.1～0.7，所以理想的是对于缩幅不产生阻力的装置。使用辊延伸装置时，可以通过调整传送辊与拉伸辊的间隔而缩幅至规定的宽度为止，使用针板拉幅延伸装置时，可以调整针板拉幅部以使得原料无纺布能够延伸并且缩幅至规定的宽度为止。
下面，就用以使热压接合部表现出规定的微细折叠结构的温度、倍率等延伸条件进行说明。
辊延伸时的加热方式可以采用通常的加热辊方式，或配置在传送辊与拉伸辊之间的干燥热风、蒸汽、热水腔室方式、加热蒸汽腔室方式等的任一种，也可以将多种加热方式组合。针板拉幅延伸时的加热方式可以选择干燥热风、远红外线加热方式等。
关于延伸温度，理想的是在构成原料无纺布的鞘侧即低熔点成分不熔融，低熔点成分及高熔点成分可塑化且发挥适度的热收缩的温度下进行延伸。例如，如果是由PE/PET的组合构成的无纺布，兼顾到低熔点成分PE的可塑化温度及熔融温度以及高熔点成分PET的可塑化温度等，所述延伸温度优选50℃～120℃，考虑到确保延伸性以及使无纺布的手感或低应力伸长性等物性变得稳定，更优选80℃～100℃的范围。
延伸倍率理想的是设定成非热压接合部的复合纤维沿着MD配向，即使进一步拉伸也不会断裂，且原料无纺布的热压接合部不受到破坏的适当的倍率。为了在本发明中所说的热压接合部获得微细的折叠结构，在不会发生断裂、破坏的范围内将延伸倍率设定得越高，则所受到的沿着CD的反作用应力越增大，效果越佳。例如，如果是由PE/PET的组合构成的无纺布，延伸倍率根据此原料无纺布的压接面积率、纤维直径、克重、以及延伸温度等而不同，可选择1.3倍～2.0倍的范围。
本发明中使用的伸缩性层可以例示包含由弹性体树脂构成的纤维或含有弹性体树脂的复合体的网状物、无纺布、膜、以及会因积层物的结构特征而具有伸缩性能的材料，例如包含卷缩纤维的网状物、干式无纺布、水刺无纺布、网状织物及针织物等。其中，以由弹性体树脂构成的纤维或含有弹性体树脂的复合体作为原料的纺粘纤维、熔喷纤维所构成的纤维层及膜容易发挥高伸缩性能。就使积层体的伸缩性良好方面而言，优选伸缩性层伸长80％时的伸长回复率大于等于60％，特别优选大于等于75％。伸缩性层优选含有弹性体树脂作为构成成分，其以伸缩性层的重量为基准来计算优选大于等于20重量％。当伸缩性层为纤维层时，就伸长回复率良好方面而言，优选构成纤维为长纤维，长纤维可以例示纺粘纤维或闪蒸纤维、熔喷纤维、电纺纤维(electrospinning fiber)等，就制造纤维的难度或经济性方面而言，优选熔喷纤维。纤维的形态可以是单一成分纤维，也可以是由含有两种以上树脂成分的混合树脂形成的纤维，还可以是两种以上树脂成分各形成纤维截面的一部分的复合纤维。复合纤维的复合形态并无限制，可以例示：芯鞘型或偏心芯鞘型、并列型、馅饼式节段(pie segment)、中空芯鞘型、中空偏心芯鞘型、中空并列型、中空馅饼式节段等。另外，也可以将这些纤维混合(混纤)。
弹性体树脂可以列举聚苯乙烯弹性体、聚烯烃弹性体、聚酯弹性体、聚酰胺弹性体、聚氨酯弹性体。其中，就可以回收再利用方面而言，优选聚苯乙烯弹性体、聚烯烃弹性体、聚酯弹性体、聚酰胺弹性体。
当伸缩性层由含有弹性体树脂的纤维构成时，以此伸缩性层的重量为基准来计算，弹性体树脂优选占20重量％或20重量％以上，更优选占50重量％或50重量％以上。弹性体树脂以外的树脂可以例示聚丙烯、聚乙烯、聚酯、聚酰胺、聚丙烯系共聚物、聚乙烯系共聚物、聚酯系共聚物等非弹性体树脂。这些非弹性体树脂能够以与弹性体树脂进行树脂混合、构成复合纤维的复合成分、或者构成混合纤维中的一种纤维的树脂成分的形式而包含于纤维中。特别是，如果采用弹性体纤维与非弹性体纤维混合的混纤形态，则可以通过调整各种纤维的混合量或纤维直径等来调整成所需的手感或伸缩性。另外，通过将不同的弹性体树脂彼此混纤，可以在更高的伸缩性水平下调整手感或伸缩性。这些不同弹性体树脂彼此的组合例如可以列举：聚苯乙烯弹性体与其他聚苯乙烯弹性体、聚苯乙烯弹性体与聚烯烃弹性体、聚苯乙烯弹性体与聚酯弹性体、聚苯乙烯弹性体与聚酰胺弹性体、聚苯乙烯弹性体与聚氨酯弹性体、聚烯烃弹性体与其他聚烯烃弹性体、聚烯烃弹性体与聚酯弹性体、聚烯烃弹性体与聚酰胺弹性体、聚烯烃弹性体与聚氨酯弹性体、聚酯弹性体与其他聚酯弹性体、聚酯弹性体与聚酰胺弹性体、聚酯弹性体与聚氨酯弹性体、聚酰胺弹性体与其他聚酰胺弹性体、聚酰胺弹性体与聚氨酯弹性体、聚氨酯弹性体与其他聚氨酯弹性体。
本发明的复合体中将至少一层复合纺粘无纺布与至少一层伸缩性层积层成一体。另外，也可以在不阻碍本发明的效果的范围内再积层其他层。各层可以交替地积层，也可以按照任意的顺序积层。将伸缩性层作为中间层，使用复合纺粘无纺布来形成复合体的两表面层的形态也是本发明的复合体的优选形态之一。
积层成一体(复合)的方法并无特别限定，可以列举：按压法、热压接合法、热风贯通法、超声波法、糨糊粘合法以及热熔树脂固定法等。为了有效果地发挥本发明的低应力伸长性或伸缩性，特别是以尽可能地不对复合纺粘无纺布的折叠结构部造成损伤的方法为佳，理想的是局部热压接合、超声波粘接及热熔粘接等。
就容易获得柔软性或能够价格相对低廉地制造方面而言，优选进行局部热压接合。进行局部热压接合的条件优选采用如下所述的条件。温度是根据所使用的原材料来选择，优选的是选择伸缩性层与复合纺粘无纺布不会容易地剥离，即使反复地使本发明的复合体伸长、回复所述局部热压接合也不会受到破坏的温度。局部热压接合时优选以10N/mm～100N/mm的范围进行按压。压接面积率优选4％～12％。局部热压接合部在CD上的间距(pitch)优选的是，将本发明的复合体的局部热压接合部投影在CD上时，相邻热压接合部间的距离大于等于0.6mm。MD方向上的间距并没有特别限制。局部热压接合部的形状并无特别限定，可以例示：正圆或椭圆、正方形、长方形、经圆角处理的长方形等。对于复合时所进行的热压接合，只要不选择热压接合部与对纺粘无纺布进行的热压接合完全一致的图案即无任何特别限制，热压接合部越不一致越好。
另外，当使用熔喷无纺布来作为伸缩性层时，也可以通过在熔喷无纺布的生产工序中，直接将使用弹性体树脂等所获得的熔喷纤维积层于本发明的复合纺粘无纺布上而形成为一体。复合后，可以将本发明的复合体沿着至少一方向延伸。通过此延伸，在复合纺粘无纺布与伸缩性层的热压接合点间，复合纺粘无纺布不能追随伸缩性层的伸长回复性，从而也可以在复合纺粘无纺布的表面侧形成突出成凸状的表面结构。通过具有此结构，在厚实感提高，触感更接近布而且设计性优异方面优选。
本发明的制造设备包括原料无纺布制造生产线和无纺布延伸生产线，另外有时还包括积层生产线。这些生产线可以是各个分开的生产线即所谓离线(off line)，也可以是全部连续配置的生产线即所谓线内(in-line)。另外，还可以将其中两条生产线设置成线内，另一条设置成离线。
另外，本发明中使用的复合纺粘无纺布的特征在于可以将伸长5％时的MD强度维持为与原料无纺布相比几乎无变化，因此在加工积层体或物品时，如果是沿着MD来反复搬送，则可以不对沿着CD所形成的微细的折叠结构造成破坏地进行操作。
[实例]
以下，通过实例和比较例来进一步说明本发明。
另外，实例和比较例的测定方法、评价方法如下所述。
(1)伸长5％时的拉伸强度
依据JIS L 1906“普通长纤维无纺布试验方法”的拉伸强度试验方法，使用自动绘图装置(拉伸试验机)，对MD及CD测定相对于试片的夹固长度100mm拉伸5mm时的强度。
(2)伸长50％时的拉伸强度
除了将试片拉伸50mm以外，以与所述伸长5％时的拉伸强度相同的方法进行测定。
(3)干热收缩率
依据JIS L 1906“普通长纤维无纺布试验方法”的干热收缩率试验方法，求出MD的收缩率。
(4)热压接合部的微细的折叠结构的相邻各山间的距离
使用KEYENCE公司制造数码显微镜(digital microscope)VHX-900，将从无纺布中随机选择的20个热粘接点放大200倍拍摄，分别测量所述20个热粘接点的相邻各山间的距离并求出它们的平均值。
(实例1)
准备如下所述的复合纺粘无纺布，即鞘侧配置熔点为129℃，密度为0.958g/cm3，在190℃下测定的熔体质量流动速率(melt mass-flow rate)为38dg/min的高密度聚乙烯，芯侧配置特性粘度为0.640，熔点为254℃的聚酯，并于速度为2075m/min，聚乙烯的纺丝温度为240℃，聚酯的纺丝温度为320℃的条件下进行纺丝，于线压为45N/mm，温度为125℃的条件下进行热压接合加工所成的CD宽度为1100mm，克重为17g/m2的复合纺粘无纺布。此无纺布中，热压接合部的总面积率为无纺布的21％，CD占有率为90％。使此复合纺粘无纺布以约20m/min的速度通过在加热辊间配置着蒸汽腔室的装置，在MD方向上延伸1.5倍。此时的辊及蒸汽温度为100℃。宽度为572mm，克重为32g/m2。此复合纺粘无纺布柔软且极富CD伸长性。此复合纺粘无纺布的物性如下所述。
·热压接合部的微细的折叠结构的相邻各山间的距离
233μm
·伸长5％时的拉伸强度
MD：42.8N/5cm
CD：0.089N/5cm
MD/CD比：481
·伸长50％时的拉伸强度
MD：断裂
CD：2.89N/5cm
·CD宽度的比
延伸后/延伸前：0.52
根据此结果可知，所获得的无纺布在热压接合部表现出微细的折叠结构，与原料无纺布相比较，CD方向的伸长5％及50％时的拉伸强度大幅下降，获得了低应力伸长性。
在此热压接合部表现出微细的折叠结构的复合纺粘无纺布上，使用混纤用纺丝喷嘴，将包含作为氢化苯乙烯系热塑性弹性体的苯乙烯弹性体(旭化成化学(Asahi Kasei Chemicals)公司制造的Tuftec H1031)的纤维，与包含作为乙烯-辛烯无规共聚物的聚乙烯弹性体(陶氏化学(DowChemical)公司制造的Engage 8402)的纤维混纤纺丝并形成为无纺布而制成熔喷无纺布，获得复合纺粘无纺布与混纤熔喷无纺布的复合体。使用H1031的纤维的平均直径为10μm，使用Engage 8402的纤维的平均直径为11μm，混纤率以重量比来计算各为50％，此混纤熔喷无纺布的克重为29gsm。制造混纤熔喷无纺布时将纺丝温度设为250℃，热风温度设为400℃并调整热风压力。
然后，在此复合纺粘无纺布与混纤熔喷无纺布的复合体的混纤熔喷无纺布侧，更积层所述在热压接合部表现出微细的折叠结构的复合纺粘无纺布，并在115℃下进行压花处理，获得包含复合纺粘无纺布、混纤熔喷无纺布及复合纺粘无纺布的三层复合体。另外，压花辊使用的是φ0.65mm的突起在MD方向上以2.8mm，在CD方向上以2.84mm的间距交错排列所成的面积率为8.3％的雕刻花纹。包含复合纺粘无纺布、混纤熔喷无纺布及复合纺粘无纺布的三层复合体的克重为93gsm。此三层复合体的物性如下所述。
·伸长80％时的CD拉伸强度
9.55N/5cm
·伸长80％后的伸长回复率
72％
另外，关于伸长80％后的回复率，是使用自动绘图装置(拉伸试验机)，读取在相对于试片的夹固长度100mm伸长80mm后恢复至100mm的夹固长度时，应力变成零的点并计算得出。
另外，伸长后的包含复合纺粘无纺布、混纤熔喷无纺布及复合纺粘无纺布的三层复合体的表面形成以积层时的压花点作为凹部的突出成凸状的表面结构，设计性优异并显示出像布一样的触感。
(参考例1)
除了在线压为25N/mm的条件下进行热压接合加工以外，以和实例1相同的方式制作原料无纺布并延伸而获得宽度为274mm，克重为56g/m2的无纺布。此无纺布的物性如下所述。
·热压接合部的微细的折叠结构的相邻各山间的距离
108μm
·伸长5％时的拉伸强度
MD：97.6N/5cm
CD：0.002N/5cm
MD/CD比：48800
·伸长50％时的拉伸强度
MD：断裂
CD：0.006N/5cm
·CD宽度的比
延伸后/延伸前：0.25
(参考例2)
鞘侧配置实例1中使用的聚乙烯，芯侧配置熔点为162℃，密度为0.961g/cm3，230℃下所测定的熔体质量流动速率为42dg/min的聚丙烯，在温度240℃下进行纺丝，并于线压60N/mm、温度135℃的条件下进行热压接合加工，除此以外，以和实例1相同的方式制作原料无纺布并延伸而获得宽度为318mm，克重为38g/m2的无纺布。此无纺布的物性如下所述。
·热压接合部的微细的折叠结构的相邻各山间的距离
243μm
·伸长5％时的拉伸强度
MD：19.1N/5cm
CD：0.084N/5cm
MD/CD比：227
·伸长50％时的拉伸强度
MD：断裂
CD：4.33N/5cm
·CD宽度的比
延伸后/延伸前：0.51
(参考例3)
除了热压接合部的总面积率为无纺布的10％，CD占有率为54％以外，以和实例1相同的方式制作原料无纺布并延伸而获得宽度为421mm，克重为28g/m2的无纺布。此无纺布的物性如下所述。
·热压接合部的微细的折叠结构的相邻各山间的距离
122μm
·伸长5％时的拉伸强度
MD：13.5N/5cm
CD：0.002N/5cm
MD/CD比：6750
·伸长50％时的拉伸强度
MD：断裂
CD：0.016N/5cm
·CD宽度的比
延伸后/延伸前：0.57
(参考例4)
除了热压接合部的总面积率为无纺布的47％，CD占有率为100％以外，以和实例1相同的方式制作原料无纺布并延伸而获得宽度为205mm，克重为32g/m2的无纺布。此无纺布的物性如下所述。
·热压接合部的微细的折叠结构的相邻各山间的距离
136μm
·伸长5％时的拉伸强度
MD：69.1N/5cm
CD：0.003N/5cm
MD/CD比：23033
·伸长50％时的拉伸强度
MD：断裂
CD：0.133N/5cm
·CD宽度的比
延伸后/延伸前：0.28
(比较例1)
将实例1中所使用的热压接合部表现出微细的折叠结构的复合纺粘无纺布的单层作为比较例1，评价其伸长80％时的CD拉伸强度及伸长80％后的伸长回复率。此比较例1的物性如下所述。
·伸长80％时的CD拉伸强度
2.48N/5cm
·伸长80％后的伸长回复率
51％
如上所述，如果仅使用经过延伸的复合纺粘无纺布，则虽然可以在低应力下高度伸长，但是伸长后的回复性并不十分优异，而通过在此经过延伸的复合纺粘无纺布上积层伸缩层，可以发挥出优异的伸长回复率，而且伸长后的设计性及触感优异。
[产业上的可利用性]
本发明中使用的复合纺粘无纺布伸长性、柔软性优异，因此通过与具有伸缩性的伸缩性层积层，可以适宜地用于：一次性尿布用伸缩性构件、尿布用伸缩性构件、生理用品用伸缩性构件、尿布围裤(diaper cover)用伸缩性构件等卫生材料的伸缩性构件，伸缩性带、橡皮膏、衣服用伸缩性构件、衣料用衬布、衣料用绝缘材料或保温材料、防护服、帽子、口罩(mask)、手套、护腿(supporter)、伸缩性绷带、敷布材料的底布、膏药材料的底布、防滑底布、吸振材料、指垫(fingerstall)，洁净室用空气滤清器、血滤器(blood filter)、油水分离过滤器等各种过滤器，经实施驻极体加工的驻极体过滤器(electret filter)、分离膜(separator)、隔热材料、咖啡袋(coffee bag)、食品包装材料，汽车用顶棚外壳材料、隔声材料、基材、缓冲材料、扬声器防尘材料、空气净化器材料、绝缘体外壳、背衬材料(backing material)、粘接无纺布片材、门饰板(door trim)等各种汽车用构件，复印机的清洁材料等各种清洁材料，地毯的表面材料、背面材料，农业卷布、木材排水材料、运动鞋外皮等鞋用构件、手提包(handbag)用构件、工业用密封材料、擦拭材料、床单等物品。
以上所述，仅是本发明的较佳实施例而已，并非对本发明作任何形式上的限制，虽然本发明已以较佳实施例揭露如上，然而并非用以限定本发明，任何熟悉本专业的技术人员，在不脱离本发明技术方案范围内，当可利用上述揭示的技术内容作出些许更动或修饰为等同变化的等效实施例，但凡是未脱离本发明技术方案内容，依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与修饰，均仍属于本发明技术方案的范围内。

Claims (8)

1.一种复合体，其是将复合纺粘无纺布与伸缩性层积层成一体而成，其特征在于：所述复合纺粘无纺布由包含低熔点成分与高熔点成分的复合纤维构成，其中所述高熔点成分的熔点高于所述低熔点成分的熔点，而有熔点差，所述复合纤维彼此局部地热压接合，且热压接合部沿着CD即制造无纺布时的宽度方向具有由山部与谷部重复所成的微细的折叠结构，所述折叠结构的相邻山部彼此间的距离的平均值在100μm～400μm的范围内，此复合纺粘无纺布通过伸展此微细的折叠结构而表现出伸长性。
2.根据权利要求1所述的复合体，其特征在于：所述复合纺粘无纺布伸长5％时的CD强度小于等于0.1N/5cm宽，伸长5％时的MD/CD强度比即“制造无纺布时的长度方向/制造无纺布时的宽度方向”的强度比大于等于200。
3.根据权利要求1所述的复合体，其特征在于：所述复合纺粘无纺布伸长50％时的CD强度小于等于5N/5cm宽。
4.根据权利要求1至3中任一项所述的复合体，其特征在于：所述伸缩性层是包含弹性体树脂的长纤维层。
5.根据权利要求4所述的复合体，其特征在于：所述长纤维层是熔喷纤维层。
6.根据权利要求1至3中任一项所述的复合体，其特征在于：通过将所述复合纺粘无纺布与所述伸缩性层局部热压接合而积层成一体。
7.根据权利要求4所述的复合体，其特征在于：通过将所述复合纺粘无纺布与所述伸缩性层局部热压接合而积层成一体。
8.根据权利要求5所述的复合体，其特征在于：通过将所述复合纺粘无纺布与所述伸缩性层局部热压接合而积层成一体。
CN201110068301.4A 2010-04-06 2011-03-17 使用伸长性无纺布的复合体 Expired - Fee Related CN102211426B (zh)

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US8415263B2 (en) 2013-04-09
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US20110244749A1 (en) 2011-10-06
TWI492847B (zh) 2015-07-21
CN102211426A (zh) 2011-10-12
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JP2011231444A (ja) 2011-11-17

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