CN102257199A - Non-woven fabric - Google Patents

Non-woven fabric Download PDF

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CN102257199A
CN102257199A CN2009801515021A CN200980151502A CN102257199A CN 102257199 A CN102257199 A CN 102257199A CN 2009801515021 A CN2009801515021 A CN 2009801515021A CN 200980151502 A CN200980151502 A CN 200980151502A CN 102257199 A CN102257199 A CN 102257199A
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nonwoven fabric
fiber
resin
protuberance
modulus
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CN102257199B (en
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舛木哲也
长岛启介
宫本孝信
坂涉
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Kao Corp
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Kao Corp
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Priority claimed from JP2009288324A external-priority patent/JP5021719B2/en
Priority claimed from JP2009293025A external-priority patent/JP4975091B2/en
Application filed by Kao Corp filed Critical Kao Corp
Priority to CN201410206154.6A priority Critical patent/CN103993428B/en
Priority claimed from PCT/JP2009/071552 external-priority patent/WO2010074208A1/en
Publication of CN102257199A publication Critical patent/CN102257199A/en
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Abstract

Disclosed is a non-woven fabric (10, 110) which comprises composite fibers each comprising a first component and a second component having different melting points from each other, and which has, formed therein, many thermally fused points produced by thermally fusing the intersection points of the composite fibers. When the state of the non-woven fabric (10, 110) is changed from dried state to wet state, the percentage of change in thickness of the non-woven fabric (10, 110) is 15% or more. In a non-woven fabric (10) which is an embodiment of the non-woven fabric, the composite fibers is fibers each comprising a polypropylene resin or a polyethylene terephthalate resin as the first component and a resin having a lower melting point from that of the first component as the second component and has a Young's modulus of 0.2 to 1.0 GPa.

Description

Nonwoven fabric
Technical field
The present invention relates to nonwoven fabric.Nonwoven fabric of the present invention is particularly suitable for for example using as the constituent material with the various absorbent commodities headed by menstrual hygiene towel and the disposable diaper.
Background technology
At present, as the face sheet of absorbent commodities such as menstrual hygiene towel and disposable diaper, be extensive use of nonwoven fabric.In such nonwoven fabric, require to make the liquid of supplying with on the surface move in the absorber as soon as possible, on the surface not the character of residual liquid (liquid residue) in case and make the liquid that is moved not adverse current to the character of nonwoven surface (against returning or getting damp).
If reduce the thickness of nonwoven fabric, generally speaking, then liquid residue tails off, but liquid countercurrent becomes many, if strengthen thickness, then can prevent liquid countercurrent, but liquid becomes at first and is difficult to move to absorber.In addition, be difficult to move to absorber, reduce liquid residue and have restriction at the residual liquid of the fiber intersection point of the sparse part of fibre density.Therefore, only merely controlling thickness can not make both with high-level realization.
As method corresponding to this requirement, known have at the thickness direction of continuous fibers make it the method (with reference to patent documentation 1) of possess hydrophilic property and fibre density gradient and make it the method (with reference to patent documentation 2) of the gradient of possess hydrophilic property at the thickness direction of nonwoven fabric.
But, in said method, have trouble in the processing make it to have gradient, be subjected to the restriction of auto levelizer, can't obtain sometimes the shortcoming of the performance that requires etc.
The prior art document
Patent documentation
Patent documentation 1: the spy opens the 2005-314825 communique
Patent documentation 2: the spy opens the 2005-87659 communique
Summary of the invention
Liquid residue according to can reduce the time and return the novel method of liquid measure as uses such as face sheets, by its use separately or with existing method and usefulness, can under condition widely, effectively prevent or alleviate liquid residue and liquid countercurrent.
The invention reside in provides a kind of nonwoven fabric, it contains and comprises the fusing point composite fibre of the 1st and the 2nd different compositions mutually, be formed with the hot melt contact that the intersection point thermal welding between a plurality of these composite fibres forms, thickness change is more than 15% when drying regime becomes moisture state.
In addition, the invention reside in provides a kind of absorbent commodity, and it possesses face sheet, back-sheet and the absorber between two sheet materials, and above-mentioned face sheet is above-mentioned nonwoven fabric.
In the nonwoven fabric as one embodiment of the present invention, as above-mentioned composite fibre, contain the 1st composition and be acrylic resin or pet resin and the 2nd composition and be the resin that is lower than the fusing point of the 1st composition, fiber that Young's modulus is 0.2～1.0GPa (following also this nonwoven fabric is called nonwoven fabric A).
In the nonwoven fabric as other embodiment of the present invention, as above-mentioned composite fibre, contain the thermally extensible fiber that its length is extended because of heating, have a plurality of protuberances and recess a face side, constitute the intersection point welding of this thermally extensible fiber of this protuberance at them, the heat seal strength on the top of protuberance is higher than the heat seal strength of bottom (following this nonwoven fabric is also referred to as nonwoven fabric B).
Description of drawings
Fig. 1 is the ideograph of the expression device for spinning that can use in the manufacturing of low Young's modulus fiber.
Fig. 2 is the stereogram of an embodiment of expression nonwoven fabric of the present invention.
Fig. 3 is a part of enlarged drawing along the cross section of nonwoven thickness direction shown in Figure 2.
Fig. 4 is that expression uses low Young's modulus fiber to make the ideograph of the operation of nonwoven fabric.
Fig. 5 is the figure (figure that is equivalent to Fig. 3) of other embodiment of expression nonwoven fabric of the present invention.
Fig. 6 (a)～6 (d) is the key diagram of the embodiment action effect of nonwoven fabric of the present invention.
Fig. 7 is the ideograph of device of representing to be used for suitably the manufacturing of nonwoven fabric 110.
Fig. 8 is the ideograph of blowing hot wind portion when the carriage direction of embossing WEB is seen.
The specific embodiment
Below, based on preferred implementation explanation the present invention of the present invention.
Nonwoven fabric of the present invention is the composite fibre that contains the 1st and the 2nd composition that comprises that fusing point is mutually different, be formed with the nonwoven fabric of the hot melt contact that the intersection point thermal welding between a plurality of these composite fibres forms, and the thickness change when drying regime is changed to moisture state is more than 15%.
Contain the fiber that Young's modulus is 0.2～1.0GPa (below be also referred to as low Young's modulus fiber) as the nonwoven fabric that constitutes fiber as the nonwoven fabric of an embodiment of the invention.
If nonwoven fabric soaks or form the state of dipping in liquid, then the surface tension effects of liquid is in nonwoven fabric.Its result applies the power that nonwoven thickness is reduced, and by containing low Young's modulus fiber, the thickness of this nonwoven fabric and the fiber spacing in the nonwoven fabric are from narrowing down.Thus, the power that absorb from the liquid of absorber is delivered to nonwoven fabric contact skin side more efficiently, and the liquid of nonwoven fabric face side successfully moves from another face side of face side direction of nonwoven fabric.When nonwoven fabric of the present invention was used as the face sheet of absorbent commodities such as menstrual hygiene towel, the face side that absorbs the side from this face side direction at the liquid of supplying with towards user's skin one side side was successfully carried out liquid and is moved.
The Young's modulus of low Young's modulus fiber be preferably 1.0GPa following, more preferably 0.8GPa following, be more preferably below the 0.65GPa.Young's modulus is 1.0GPa when following, and the fiber spacing that is easy to generate the nonwoven fabric when absorbing liquid obtains the effect that the liquid mobility improves easily from reducing with thickness.
In addition, the Young's modulus of low Young's modulus fiber be preferably 0.2GPa above, more preferably 0.4GPa, be more preferably more than the 0.5GPa.Young's modulus is 0.2GPa when above, and the thickness of drying regime is kept, and is difficult to cause liquid countercurrent.
In addition, in the nonwoven fabric of the present invention, be formed with the hot melt contact (diagram slightly) that the intersection point thermal welding between a plurality of fibers forms.Such hot melt contact can be by forming WEB and the nonwoven fabric enforcement heat treatment that contains the Thermoadhesive synthetic fiber.As heat treatment method, preferred hot blast is handled, and the hot blast of special optimizing breathing mode is handled.Constitute the hot melt contact between the fiber, preferred at least between low Young's modulus fiber mutual intersection point place contain the hot melt contact that thermal welding forms.In addition, the hot melt contact preferably disperses in nonwoven fabric usually three-dimensionally.
Nonwoven fabric forms the nonwoven fabric of the caliper recovery excellence of fiber spacing after the liquid that shortens takes out by having the hot melt contact that constitutes between the fiber outside nonwoven fabric.When nonwoven fabric of the present invention is used as the face sheet of absorbent commodities such as menstrual hygiene towel, because the caliper recovery excellence of nonwoven fabric, be difficult to be moved and return liquid phenomenon (getting damp) to the liquid countercurrent of absorber to the face sheet surface.
Nonwoven fabric of the present invention both can be that single-layer nonwoven also can be the nonwoven fabric of sandwich construction.All preferred at least one the face side of situation is that main body constitutes with low Young's modulus fiber arbitrarily.
For example, during for the nonwoven fabric of single layer structure, the ratio that nonwoven fabric all constitutes the low Young's modulus fiber in the fiber be preferably 50～100 quality %, more preferably 80～100 quality %, be more preferably 90～100 quality %.
On the other hand, during for the sandwich construction nonwoven fabric, the ratio that constitutes the low Young's modulus fiber in whole fibers of nonwoven fabric single face be preferably 50～100 quality %, more preferably 80～100 quality %, be more preferably 90～100 quality %.
The ratio of the low Young's modulus fiber in whole formation fibers of sandwich construction nonwoven fabric be preferably 50～100 quality %, more preferably 80～100 quality %, be more preferably 90～100 quality %.
Nonwoven fabric constitutes the Young's modulus of fiber can following operation and measure.
[assay method of Young's modulus]
The thermo-mechanical analysis device TMA/SS6000 that uses Seiko Instruments (strain) to produce.Measuring environment temperature is 25 ℃.As sample, the fibre length of preparing many collections is the above fiber of 10mm, and the total weight that makes every fibre length 10mm is 0.5mg, after this plurality of fibers is placed side by side abreast, in device, be that 10mm installs, load with certain load state of 0.73mN/dtex with distance between the chuck.After this, after obtaining stress-inflection curves under the condition of 240mN/min, be that the gradient of connecting line of 0.1% o'clock curve is a Young's modulus with deformation.
As low Young's modulus fiber,, can use so long as Young's modulus is 0.2～1.0GPa, gets final product by the fiber that can form the hot melt contact that thermal welding forms between the heat treatment of fibre such as hot blast processing with being not particularly limited.
As the preferred fiber of low Young's modulus fiber, can enumerate sheath portion and contain polyvinyl resin (PE), core and contain low core-sheath-type Thermoadhesive conjugate fiber of the degree of crystallinity of acrylic resin (PP), this acrylic resin (PP) etc.
As the preferred fiber of other low Young's modulus fiber, can enumerate sheath portion and contain polyvinyl resin (PE), core and contain low core-sheath-type Thermoadhesive conjugate fiber of the degree of crystallinity of pet resin (PET), this pet resin (PET) etc.
As the reason of in core, using these PP and PET, be owing to compare the cost cheapness with other resin, with the cause of the fusing point difference appropriateness of the PE that the feel of using in sheath portion is good, heat seal is good, aspect favourable in the manufacturing of fiber and in the manufacturing of nonwoven fabric, get a promotion.
At present, in this Thermoadhesive conjugate fiber, generally speaking, the effect of Thermoadhesive is expressed in the low-melting-point resin performance, and the effect of intensity is kept in the resin with high melting point performance as fiber.On the other hand, when the limit made the fibrous refinement limit carry out spinning from molten condition, the high-melting-point composition preferentially applied tension force by solidifying earlier, its result, and the oriented crystallineization of promotion resin with high melting point is fit in keeping intensity (Young's modulus).
But, if make the low fiber of Young's modulus, then must directly be the setting state low-tension of fusing with the resin with high melting point, can not stable creating conditions under such condition.In addition, if directly be that the state of fusing carries out spinning reluctantly with the resin with high melting point, then be created in the problem that the then silk thread fracture of small tension force is arranged in the spinning slightly, form the silk thread etc. of unstable rugosity, it is difficult stably carrying out spinning.In addition, when even the fiber that not at all easy use Young's modulus is low is made nonwoven fabric, if carry out nonwoven fabricization with existing condition, the less thick of nonwoven fabric then, form the many nonwoven fabric of liquid countercurrent, therefore, having the low rerum natura of Young's modulus is the existing notion of unfavorable rerum natura for fiber.Its result generally is the fiber with 1.5～6.0GPa left and right sides Young's modulus.
But we are according to method described later, have found the manufacture method of the fiber that Young's modulus is low and with its volume the earth nonwoven fabricization, the method that effectively utilizes.
In the low composite fibre of Young's modulus, the degree of crystallinity of resin with high melting point of preferably bearing the most of intensity of fiber is low.According to the kind of resin with high melting point, the degree of crystallinity that realizes above-mentioned Young's modulus is different naturally, but when be acrylic resin (PP), preferably degree of crystallinity be below 60%, more preferably below 50%, be more preferably below 45%.
When the resin that constitutes core was polyethylene terephthalate (PET), preferred degree of crystallinity was below 45%, more preferably below 30%, be more preferably below 15%.
In addition, the resin preferred orientation coefficient of formation core is low.For example, during for acrylic resin, the preferred orientation coefficient is below 60%, more preferably below 40%, be more preferably below 25%.During for pet resin (PET), orientation coefficient is preferably below 50%, more preferably below 20%, be more preferably below 10%.
The above-mentioned degree of crystallinity that constitutes the resin of core is obtained by following method.
[assay method of the degree of crystallinity of fiber]
Degree of crystallinity χ obtains from formula (1).
χ＝(1-(ρc-ρ)/(ρc-ρa))×100 (1)
Here, ρ c is the density of resin crystallization, is 0.936[g/cm among the PP 3], be 1.457[g/cm among the PET 3] (document 3).ρ a is the amorphous density of resin, is 0.850[g/cm among the PP 3], be 1.335[g/cm among the PET 3] (document 3).
In addition, (ρ c-ρ a) * (Lorentz density B-Lorentz density A)/(Lorentz density B-Lorentz density C) (2) for ρ=ρ c-
Here, Lorentz density A obtains from following formula (3).
Lorentz density A=(n 2-1)/(n 2+ 2) (3)
(3) n in the formula is a mean refractive index, uses the refractive index n of the parallel direction of said determination value ∥Refractive index n with vertical direction ⊥, obtain from formula (4).
n 2＝(n ∥ 2+2n ⊥ 2)/3 (4)
In addition, Lorentz density B can obtain the refractive index of different resins crystallization respectively as n substitution (3) formula, use n=1.52 in the PP resin, uses n=1.64 (reference literature 2, document 1 respectively) in the PET resin.In addition, Lorentz density C can obtain the amorphous refractive index of different resins respectively as n substitution (3) formula, use n=1.47 in the PP resin, uses n=1.58 (reference literature 2, document 1 respectively) in the PET resin.
[list of references 1] " Eat and Port リ エ ス テ Le Trees fat Ha Application De Block Star Network " (publishing house: the new Wen society of daily magazine industry, first edition, 1989)
[list of references 2] " POLYMER HANDBOOK " (A WILEY-INTERSCIENCE PUBLICATION, 1999)
In addition, degree of crystallinity is regarded the structure difference of crystallization as according to its assay method and condition, therefore, generally can't comment on its absolute value between different measuring methods, condition.
The above-mentioned orientation coefficient that constitutes the resin of core can be measured by following method.
[assay method of orientation coefficient]
With the birefringence value of the resin in the fiber be C, when being D with the intrinsic birefringence value of resin, orientation coefficient is represented with following formula (5).
Orientation coefficient (%)=(C/D) * 100 (5)
Intrinsic birefringence is meant the birefringence of macromolecular chain under complete state of orientation of resin, its value for example is documented in " processing To お け ゐ プ ラ ス チ Star Network material is shaped " first edition, subordinate list: shaping processing To is used in the な プ ラ ス チ Star Network material (プ ラ ス チ Star Network is shaped and processes association Knitting, シ グ マ publication, distribution on February 10th, 1998) of い ら れ ゐ representative.
Birefringence in the composite fibre is measured under the polarisation with respect to fiber axis parallel direction and vertical direction by Polarizer is installed in interference microscope.As maceration extract, the standard refraction liquid that uses Cargille company to produce.The refractive index of maceration extract is measured by Abbe refractometer.From utilizing the interference fringe of the composite fibre that interference microscope obtains, obtain refractive index n with respect to the parallel direction of fiber axis with the computational methods of record in below with reference to document 3 ∥Refractive index n with vertical direction ⊥, calculate birefringence as both differences.
[list of references 3] " プ ラ ス チ Star Network formed products high order Agencies makes and resolves Ru Door " (editor (society) プ ラ ス チ Star Network is shaped and processes association, first edition, 2006)
Can be as hanging down the Thermoadhesive conjugate fiber that the Young's modulus fiber preferably uses, for example, with vinyl (PE) and acrylic resin (PP) is raw material, making sheath portion is PE, core when being the core-sheath-type composite fibre of PP, and the crystallization of acrylic resin that can be by suppressing core is made.
In addition, can be as hanging down the Thermoadhesive conjugate fiber that the Young's modulus fiber preferably uses, for example, with vinyl (PE) and pet resin (PET) is raw material, making sheath portion is PE, core when being the core-sheath-type composite fibre of PET, and the crystallization of pet resin that can be by suppressing core is made.
Keep or improve tension force in the spinning for the limit suppresses the degree of crystallinity of resin with high melting point or degree of orientation limit, the curing of low-melting-point resin is accelerated with respect to resin with high melting point, make on the sheath resin and bear tension force.Here, solidify the state that is meant that viscosity rises rapidly on spinning threadling.As its method, can enumerate spinning temperature by making resin with high melting point and improve, improve spinning speed than the spinning temperature of low-melting-point resin and strengthen severing speed, thereby accelerate the crystallization speed of low-melting-point resin and the method accelerating to solidify; When sheath portion uses low-melting-point resin, improve all spinning temperatures and make the sheath method of cooling earlier; In the sheath resin, cooperate nucleator and promote the method etc. of crystallization.
The temperature that the extrusion temperature of low-melting-point resin composition (spinning temperature) is preferably high 80～250 ℃ with respect to the fusing point of this resin, more preferably high 130～170 ℃ temperature.
In addition, resin with high melting point preferably with more than the temperature of the same degree of spinning temperature of low-melting-point resin, preferably with high more than 30 ℃, more preferably carry out spinning with high temperature more than 50 ℃.
As the nucleator that promotes sheath resin crystallization, can preferably use 1,3:2,4-dibenzylidene sorbitol, 1,3:2, Arrcostab (preferred carbon number is 8～22 Arrcostabs) the class nucleator of the aliphatic polyacid of the Arrcostab of the ester ring type polyacid of diacetyl compounds class nucleator, tetrahydrophthalic acid and the hexahydrophthalic acid etc. of 4-two (to the methyl benzal) D-sorbite etc. (preferred carbon number is 8～22 Arrcostabs) class nucleator, adipic acid, decanedioic acid and azelaic acid etc., three (2-methylcyclohexyl acid amides) of tricarballylic acid etc.Add mineral-type pigment and also produce same effect.
Said method can use any one separately, also can be used in combination a plurality of methods.In addition, can make up and spin a hauling speed and be higher than method of existing general speed etc.
In addition, the hauling speed that spins silk be preferably more than 500m/ minute, more preferably more than 1000m/ minute, be more preferably more than 1500m/ minute.
Device for spinning shown in Figure 1 possesses the extrusion device 1,2 and the spinneret 3 of two systems that comprise extruder 1A, 2A and gear pump 1B, 2B.Spinneret 3, each resinous principle by extruder 1A, 2A and gear pump 1B, 2B fusion and metering collaborates in spinneret 3, discharges from nozzle.The shape of spinneret 3 is suitably selected according to the form of purpose composite fibre.In preferred embodiment, surround the resin state on every side that forms core with the resin that forms sheath portion, discharge two kinds of resinous principles from nozzle, such nozzle is formed with a plurality of with the state that disperses in border circular areas.Draw-gear 4 is set under spinneret 3, and the molten resin of discharging from nozzle draws downwards with the speed of regulation.In the embodiment shown in Figure 1, accommodate the low Young's modulus fibre bundle of traction in the part 6 in suitable accommodating.
Crispatura after spinning by the low Young's modulus fiber of said method manufacturing and to handle and heat treated, and preferably do not carry out stretch processing in fact.That is low Young's modulus fiber drawing of fiber not preferably.In addition, crispatura for example to handle and implement, then,, be cut to the length of regulation and form staple fibre with shearing device (not shown) through dried (not shown) with apparatus for crimping (not shown).
From making the viewpoint of the hot melt contact that the formation thermal welding forms between the fiber, the resinous principle that constitutes the sheath portion of the core-sheath-type composite fibre that uses as low Young's modulus is preferably polyvinyl resin.As polyvinyl resin, can use low density polyethylene (LDPE) (LDPE), high density polyethylene (HDPE) (HDPE), straight chain shape low density polyethylene (LDPE) (LLDPE) etc., but preferred density is 0.941g/cm 3Above high density polyethylene (HDPE).As the polyvinyl resin among the application,, also comprise the situation of mixing other resin except separately being the situation of polyvinyl resin.As other resin that mixes, can enumerate acrylic resin, ethylene-vinyl acetate copolymer (EVA), ETHYLENE-VINYL ALCOHOL COPOLYMER thing (EVOH) etc.Wherein, the resinous principle of formation sheath portion preferably is that polyvinyl resin, preferred especially 70～100 quality % are polyvinyl resin more than the 50 quality % in the resinous principle of sheath portion.
As the preferred example of the resinous principle that constitutes the core-sheath-type composite fibre core that hangs down the use of Young's modulus fiber, can enumerate acrylic resin.The low resin of the preferred aforesaid degree of crystallinity of acrylic resin, in addition, the resin that the preferred orientation coefficient is low.Acrylic resin in this application except separately being the situation of polyvinyl resin, also comprises the situation of mixing other resin.As other resin that mixes, can enumerate polyvinyl resin etc.Wherein, 70 quality % in the resinous principle of the preferred core of resinous principle of formation core are above is that acrylic resin, preferred especially 80～100 quality % are acrylic resin.
As other preferred example of the resinous principle that constitutes the core-sheath-type composite fibre core that hangs down the use of Young's modulus fiber, can enumerate pet resin.The low resin of the preferred aforesaid degree of crystallinity of pet resin, in addition, the resin that the preferred orientation coefficient is low.Pet resin among the application except separately being the situation of pet resin, also comprises the situation of mixing other resin.As other resin that mixes, can enumerate polyvinyl resin etc.Wherein, 70 quality % in the resinous principle of the preferred core of resinous principle of formation core are above is that pet resin, preferred especially 80～100 quality % are pet resin.
In addition, as the preferred core of core-sheath-type composite fibre of low Young's modulus fiber use and the sectional area ratio (core: sheath) be 2: 8～8: 2, more preferably 4: 6～7: 3 of sheath portion.
In addition, the rugosity (fiber number) of low Young's modulus fiber is selected suitable scope according to the concrete purposes of for example nonwoven fabric etc., but, be preferably 1.0～10.0dtex, 2.0～8.0dtex more preferably from the reduction that obtains Young's modulus really with by the viewpoint that it tells on.
Fig. 2 and Fig. 3 are the figure of the 1st embodiment nonwoven fabric 10 of expression nonwoven fabric of the present invention.Nonwoven fabric 10 is examples of above-mentioned nonwoven fabric A.
The nonwoven fabric 10 of the 1st embodiment, for example, as shown in Figure 4, be that staple fibre with low Young's modulus fiber is raw material, after using carding machine 11 to form WEB 12, this WEB 12 is imported the heat embossing device 13 that possesses pair of rolls 14,15 carry out embossing processing, utilize the hot blast treating apparatus 17 of ventilating mode to implement heat treatment to the WEB 16 after the ventilation processing again and obtain.
In the pair of rolls of using in embossing processing, one is to be formed with the knurling rolls 14 of the embossing of clathrate pattern with protuberance at side face, another be have level and smooth side face, with the smooth roller 15 of this knurling rolls subtend configuration.Embossing processing is by carrying out WEB pressurization compression between the level and smooth side face of the protuberance of knurling rolls 14 and smooth roller 15.Thus, can obtain having the nonwoven fabric of the thick part 19 of the part (embossed portion) 18 of the thin thickness that is processed to form by embossing and thickness in addition.
Nonwoven fabric 10 forms the male and fomale(M﹠F) 10b with concaveconvex shape in one side, forms smooth or littler than the concavo-convex degree of above-mentioned male and fomale(M﹠F) tabular surface 10a at another side.
The part 19 that thickness in the nonwoven fabric 10 is thick and the part 18 of thin thickness form protuberance 119 and recess 118 in the male and fomale(M﹠F) 10b of nonwoven fabric 10.Recess 118 has be parallel to each other the 1st 118a of wire portion that extends and the 2nd 118b of wire portion that is parallel to each other and extends, and the 1st 118a of wire portion and the 2nd 118b of wire portion form predetermined angular and intersect.Protuberance 119 is formed in the diamond shaped closed area of recess 118 encirclements.
(method of the nonwoven fabric of the low Young's modulus of volume the earth manufacturing)
In present vent method, wind speed is generally more than the 0.8m/sec, and for the nonwoven fabric volume that makes low Young's modulus is big, wind speed particular importance then is preferably with 0.1～0.8m/sec, more preferably the wind speed with 0.1～0.5m/sec carries out.By forming low wind speed, can not form the welding point by nonwoven fabric because of wind speed with damaging.
From forming the viewpoint of the hot melt contact between the fiber, the temperature that hot blast is handled is preferably more than the fusing point of the resinous principle that constitutes the sheath portion of hanging down the Young's modulus fiber, the preferred especially temperature high 5～15 ℃ with respect to this fusing point.
Fig. 5 is the figure of nonwoven fabric 10A of the 2nd embodiment of expression nonwoven fabric of the present invention.There is not the aspect of special instruction identical to the 2nd embodiment with the nonwoven fabric 10 of the 1st embodiment.
Following the obtaining of nonwoven fabric 10A of the 2nd embodiment: contain at present the Young's modulus commercially available with fiber as the nonwoven fabric manufacturing greater than 1.0GPa, the WEB of Thermoadhesive conjugate fiber below the 6.0GPa on, lamination contains the WEB of the staple fibre of 100% low Young's modulus fiber, they are implemented heat embossing processing integratedly, further implement to utilize the hot blast of ventilating mode to handle.
The nonwoven fabric 10A of the 2nd embodiment comprises the 1st layer 100 of containing commercially available general fiber and contains the 2nd layer 101 that hangs down the Young's modulus fiber.The fiber that layers 1 and 2 preferably constitutes each layer has the hot melt contact between the fiber, and in addition, the formation fiber of preferred the 1st layer formation fiber and the 2nd layer has the hot melt contact that thermal welding forms.When nonwoven fabric 10A is used as the face sheet of absorbent commodities such as menstrual hygiene towel, will contain the 2nd layer 101 of low Young's modulus fiber and use towards absorbing the side.
Shown in Fig. 6 (a), the face side that will contain low Young's modulus fiber is towards absorber 7 sides, when using nonwoven fabric 10, the 10A of the 1st and the 2nd embodiment as the face sheet of absorbent commodities such as menstrual hygiene towel, to supplying with liquid 20 such as menses towards the face side of user's skin one side, nonwoven fabric is soaked (or impregnated) by liquid, then shown in Fig. 6 (b), the surface tension effects of this liquid 20 is in the surface of non-woven skin contact surface side.Because surface tension inwardly acts at liquid surface, therefore, under this state, play a role and nonwoven thickness is reduced.Low Young's modulus fiber easy deformation in this nonwoven fabric is subjected to this power thus, the less thick of the thickness of this nonwoven fabric, part 19 that particularly thickness except embossed portion is big.When an end face capillaceous is exerted pressure with certain size, the pressure that on another end face, acts in length capillaceous, be that the thickness of nonwoven fabric hour approaches original pressure (loss is few) more more.According to this principle, less thick by nonwoven fabric, absorb the surface that acts on nonwoven fabric contact skin side from the power of the liquid of absorber, the effect efficiently in the integral body of nonwoven thickness direction or broad range that becomes of the strong wool tubule power of absorber with less reducing.In addition, from narrowing down, the capillary force of nonwoven fabric itself also has the effect that becomes big by fiber spacing.These results are shown in Fig. 6 (c) and Fig. 6 (d), and liquid 20 sees through nonwoven fabric smoothly, are absorbed body 7 and absorb.These thickness and fiber spacing from minimizing be the temporary phenomenon of liquid when passing through.Along with liquid moves to absorber 20, tail off owing to act on the amount of liquid of nonwoven surface, the surface tension of liquid reduces the power that nonwoven fabric applies.Its result shown in Fig. 6 (d), the caliper recovery of nonwoven fabric.Along with the liquid on surface disappears, thickness restores, therefore, residual liquid hardly in face material, thickness restores.Behind liquid, almost revert to original thickness.As a result, be difficult to take place the liquid countercurrent phenomenon (get damp) of liquid 20 from the absorber adverse current to the face sheet surface.
The rate of change of the drying regime of nonwoven fabric of the present invention and the nonwoven thickness of moisture state is preferably more than 15%, more preferably more than 20%, be more preferably more than 25%.The assay method of thickness and nonwoven thickness rate of change is narrated in an embodiment.
In addition, the nonwoven thickness recovery rate when moisture state is changed to drying regime again of nonwoven fabric of the present invention be preferably more than 70%, more preferably more than 80%, be more preferably more than 90%.The assay method of recovery rate is narrated in an embodiment.
In the nonwoven fabric 110 as other embodiment of the present invention, as comprising the 1st composition that fusing point is mutually different and the composite fibre of the 2nd composition, contain the thermally extensible fiber that its length is extended because of heating, have a plurality of protuberances 119 and recess 118 a face side, constitute the intersection point welding of this thermally extensible fiber of this protuberance 119 at them, the heat seal strength on the top of protuberance 119 is higher than the heat seal strength of bottom.
Nonwoven fabric 110 is aspect the form that has as shown in Figures 2 and 3, and is identical with above-mentioned nonwoven fabric 10.Therefore, with reference to the identical form of Fig. 2 and Fig. 3 explanation and nonwoven fabric 10.
Nonwoven fabric 110 forms single layer structure.Nonwoven fabric 110 is almost smooth in its one side (back side 10a among Fig. 2), and another side (the positive 10b among Fig. 2) forms the concaveconvex shape with a plurality of protuberances 119 and recess 118.That is, be the nonwoven fabric that is endowed three-dimensional shape.The formation fiber that recess 118 contains nonwoven fabric 110 is by densificationization, welding and the weld portion that forms.As the formation method of weld portion, can enumerate and follow hot embossing processing etc.On the other hand, protuberance 119 forms non-weld portion.The thickness of recess 118 is less than the thickness of protuberance 119.Protuberance 119 forms the shape of swelling towards the face side (upper face side among Fig. 3) of nonwoven fabric 110.Formation fiber with nonwoven fabric 110 in the protuberance 119 is full of.In protuberance 119, the formation fiber of nonwoven fabric 110 is in their intersection point welding.In protuberance 119, because thermal welding between the thermally extensible fiber, the fine hair in nonwoven fabric 110 surfaces is difficult to fluff.Whether thermal welding is observed nonwoven fabric 110 by scanning electron microscope between the fiber is judged.
Recess 118 has the 1st 118a of wire portion that extends to a direction in parallel to each other.In addition, recess 118 has the 2nd 118b of wire portion that extends to a direction in parallel to each other in the mode of intersecting with the 1st wire portion.Intersect to form close-shaped rhombus part by two 118a of wire portion, 118b.This diamond-shaped portion is divided formation protuberance 119.That is, protuberance 119 is surrounded and is formed by continuous close-shaped recess 118.
Constitute fiber as it, nonwoven fabric 110 contains the thermally extensible fiber of the fiber that extends because of heating as its length.As thermally extensible fiber, for example can enumerate the fiber that the crystalline state of resin is extended because of heating changes.Various thermally extensible fibers in nonwoven fabric 110 with the state that extended because of heating and/or can exist because of the state that heating is extended.That is, in nonwoven fabric 110, contain the thermally extensible fiber of the state that extends because of heating or contain and because of the thermally extensible fiber of heating elongation state or to contain this two kinds of fibers.Narrate the details of thermally extensible fiber in the back.
In each protuberance 119 of nonwoven fabric 110, constitute of the intersection point place welding of its thermally extensible fiber at them.Nonwoven fabric 110 has one of feature in this heat seal strength.Specifically, heat seal strength is that protuberance 119 tops are higher than the bottom.By the heat seal strength between the thermally extensible fiber in the protuberance 119 is formed like this, thickness reduces if nonwoven fabric 110 is soaked by liquid, the advantageous effects that realization can make this liquid effectively see through.Meanwhile, this liquid was difficult to the advantageous effects at remained on surface after nonwoven fabric 110 was implemented in liquid and sees through.Its reason is because the heat seal strength difference, the cause that the deflection when nonwoven fabric 110 is soaked by liquid creates a difference.The limit is elaborated to it with reference to Fig. 6 (a)～Fig. 6 (d) limit.
Shown in Fig. 6 (a), with nonwoven fabric 110 with the face that has protuberance and recess in this nonwoven fabric 110 towards the mode of user's skin be disposed on the absorber 7, when using as the face sheet of absorbent commodities such as menstrual hygiene towel, in face side towards user's skin, liquid such as menses 20 are drained, if nonwoven fabric 110 is soaked (or impregnated) by liquid 20, then as shown in Fig. 6 (b), the surface tension effects of liquid 20 is in the surface of the skin surface side of nonwoven fabric 110.Because surface tension upcountry acts on the surface of liquid 20, therefore, under this state, play a role to make and reduce nonwoven fabric 110 thickness.At this moment, and compare as the top at the high position of heat seal strength, in the protuberance 119 as the bottom at the low position of heat seal strength because thermally extensible fiber easy deformation and be subjected to the influence of this power easily.Its result, in protuberance 119, then the deformation extent of thermally extensible fiber is big more to the bottom more, and fiber spacing uprises from shortening fibre density.That is, with absorb liquid 20 before compare, in the protuberance 119, more to its underpart, fibre density is high more.
But, when an end face capillaceous is exerted pressure with certain size, the pressure that on another end face, acts in length capillaceous, be that the thickness of the nonwoven fabric 110 among Fig. 6 hour approaches original pressure (loss is few) more more.According to this principle, less thick by nonwoven fabric 110, absorb the surface that acts on the skin surface side of nonwoven fabric 110 from the power of the liquid of absorber 7, the effect efficiently in the integral body of the thickness direction of nonwoven fabric 110 or broad range of the strong wool tubule power of absorber 7 with less reducing.In addition, from narrowing down, also there are nonwoven fabric 110 capillary forces own to become big effect by fiber spacing.These results are shown in Fig. 6 (c) and Fig. 6 (d), and liquid 20 sees through nonwoven fabric 110 smoothly, are absorbed body 7 and absorb.
These thickness and fiber spacing from minimizing be liquid 20 by the time temporary phenomenon.Along with liquid 20 moves to absorber 7, owing to the quantitative change of the liquid 20 that acts on nonwoven fabric 110 surfaces is few, the surface tension effects of liquid 20 reduces in the power of nonwoven fabric 110.Its result is shown in Fig. 6 (d), and the thickness of nonwoven fabric 110 restores.Along with liquid in nonwoven fabric 110 surfaces 20 disappears, the thickness of nonwoven fabric 110 restores, and therefore, does not almost have residual liquid 20 on nonwoven fabric 110, and its thickness restores.Nonwoven fabric 110 after liquid 20 passes through almost recovers original thickness.Its result is difficult to produce liquid 20 from the absorber 7 contrary phenomenons of returning nonwoven fabric 110 surfaces.
From making the significant more viewpoint of above-mentioned favourable effect, the heat seal strength between the thermally extensible fiber in the preferred protuberance 119 from the top of protuberance 119 to bottom step-down slowly.For example, be preferably placed between the thermally extensible fiber of corresponding position B of the protuberance among top P1, midriff P2, recess adjacent portion P3 and the back side 10a of protuberance shown in Figure 3 119 heat seal strength from P1 to P3 gradually step-down, again from P3 to B step-down gradually.In order to control the heat seal strength between the thermally extensible fiber in this wise, for example, can make nonwoven fabric 110 according to manufacture method described later.
Heat seal strength between the thermally extensible fiber in the protuberance 119 of nonwoven fabric 110 is measured with following method.On rotating shaft, install rosette with polyurethane foam (the ウ レ タ Application Off オ one system モ Le ト Application MF30 that BRIDGESTONE (strain) produces, thickness 5mm) covering surfaces (diameter 70mm, 300g).The installation site is position of rotation with disc centre from the position that rotating shaft center departs from radius 20mm.Below nonwoven fabric, lay polyurethane foam same as described above.Then, with the mensuration face of nonwoven fabric with flatly as top and fixing on platform.On nonwoven fabric, carry above-mentioned disk.At this moment, the loading that applies on nonwoven fabric only is the deadweight of disk.Under this state, make the rotating shaft rotation, on nonwoven fabric, make the disk circumference motion.Circular motion with 2 weeks that turned clockwise, be rotated counterclockwise and 2 weeks be 1 group and carry out.The circular motion speed of this moment is that every 1 week of motion was 3 seconds.After carrying out 10 groups of these circular motion, be collected in the fiber of extracting of the polyurethane foam surface attachment that covers disk, measure number of fiber.The number of fiber of extracting is many more, and the expression heat seal strength is low more.According to this method, respectively and with the mensuration face (promptly as the protuberance corresponding position B among the back side 10a of bottom with the top P1 of protuberance, positive 10b side and rear side 10a with nonwoven fabric 110 are the mensuration face), respectively the radical of extracting of protuberance upper and lower is measured.If the radical of extracting on protuberance top is that the radical of extracting of a, protuberance bottom is b, then the gradient ratio of heat seal strength is represented with calculating formula a/b.If should represent then that the heat seal strength on protuberance top was higher than the heat seal strength of protuberance bottom than less than 1.
From further raising liquid permeability with further prevent the viewpoint of liquid countercurrent, the thermally extensible fiber preferred hydrophilic degree that constitutes protuberance 119 is that protuberance 119 tops are lower than the bottom.By forming such hydrophilicity, form the gradient that uprises to the bottom hydrophilicity from protuberance 119 tops.This gradient forms driving force, and liquid is absorbed to the bottom from the top of protuberance easily, and the permeability of liquid improves.In case liquid sees through, then this gradient forms the barrier to liquid countercurrent, therefore, prevents that the effect of liquid countercurrent from becoming remarkable.For example, the hydrophilicity that is preferably placed at top P1, the midriff P2 of protuberance shown in Figure 3 119, the protuberance corresponding position B in recess adjacent portion P3 and back side 10a uprises gradually, uprises gradually to B from P3 to P3 from P1.In order to control hydrophilic degree in this wise, for example, when making hydrophilizing agent be attached to thermally extensible fiber, can make nonwoven fabric 110 according to manufacture method described later.
Hydrophilizing agent adhere to the method by using hydrophilizing agent at fiber surface and in the resin that constitutes fiber, sneak into hydrophilizing agent in advance, the method for using this resin to carry out spinning realizes.Hydrophilizing agent is to make the hydrophily of fiber surface than the material that improves before hydrophilizing agent is adhered to.From improving hydrophilic viewpoint, with respect to the weight of thermally extensible fiber, the adhesion amount of hydrophilizing agent is preferably 0.1～0.6 weight %, 0.2～0.5 weight % more preferably.As hydrophilizing agent, can use with this technical field in the identical material of hydrophilizing agent that uses.As such hydrophilizing agent, various surfactants can be used as typical material and enumerate.
As surfactant, can use anion, CATION, amphion and non-ionic surfactant etc.As examples of anionic surfactants, can enumerate alkylphosphonic, alkyl ether phosphate, dialkyl group phosphate, dialkyl sulfosuccinates, alkylbenzenesulfonate, alkylsulfonate, alkyl sulfate, secondary alkyl sulfate etc. (all preferred carbon number of arbitrary alkyl is 6～22).As alkali metal salt, can enumerate sodium salt, sylvite etc.Example as cationic surfactant, can enumerate alkyl (or thiazolinyl) trimethyl-ammonium halide, dialkyl group (or thiazolinyl) dimethyl ammonium halide, alkyl (or thiazolinyl) halogenation pyridine etc., it is 6～18 alkyl or alkenyl that these compounds preferably have carbon number.As the halogen in the above-mentioned halide, can enumerate chlorine, bromine etc.As the example of zwitterionic surfactant, can enumerate alkyl (carbon number is 1～30) dimethyl betaine; alkyl (carbon number is 1～30) amido alkyl (carbon number is 1～4) dimethyl betaine; alkyl (carbon number is 1～30) dihydroxy alkyl (carbon number is 1～30) betaine; betaine type amphoteric ionic surface active agent and alanine type [alkyl (carbon number is 1～30) alanine types such as sulfobetaines type amphoteric surfactant; alkyl (carbon number is 1～30) imino-diacetic propionic acid type etc.] zwitterionic surfactant; amino acid type amphoteric ionic surface active agents such as glycine type [alkyl (carbon number is 1～30) amion acetic acid type etc.] zwitterionic surfactant; sulfamic acid amphoteric ionic surface active agents such as alkyl (carbon number is 1～30) taurine type.As the example of non-ionic surface active agent, can enumerate fatty acid glyceride, poly-(preferred n=2～10) fatty acid glyceride, polyol fatty acid esters such as sorbitan fatty acid esters (all the carbon number of preferred fatty acid is 8～22), the oxyalkylene addition product of above-mentioned polyol fatty acid ester (preferred addition molal quantity is 2～20 moles), polyoxyalkylene (the addition molal quantity is 2～20 moles) alkyl (carbon number is 8～22) acid amides, polyoxyalkylene (the addition molal quantity is 2～20 moles) alkyl (carbon number is 8～22) ether, the polyoxyalkylene modified polyorganosiloxane, amino modified polysiloxane etc.Special in the combination that is used to obtain desired hydrophilic preferred surfactant or surfactant, can enumerate alkyl phosphoric acid sylvite, polyoxyethylene alkylamide and alkyl betaine, alkyl phosphoric acid sylvite and mersolates, polyoxyethylene alkyl amine and polyglycereol one alkylates, polyoxyethylene alkylamide and stearoyl phosphate kalium salt, polyoxyethylene alkylamide and polyglycereol one alkylates, mersolates and stearoyl phosphate kalium salt, alkyl ether potassium phosphate and polyglyceryl fatty acid ester, polyoxyethylene alkylamide and dialkyl sodium sulfosuccinate salt, polyoxyethylene polyoxypropylene modified polyorganosiloxane and dialkyl sodium sulfosuccinate salt, polyglyceryl fatty acid ester and dialkyl sodium sulfosuccinate salt, sorbitan fatty acid esters and dialkyl sodium sulfosuccinate salt, polyoxyethylene alkylamide and polyglyceryl fatty acid ester, polyoxyethylene alkylamide and sorbitan fatty acid esters, polyoxyethylene alkyl amine and sorbitan fatty acid esters, polyoxyethylene polyoxypropylene modified polyorganosiloxane and polyoxyethylene alkyl ether, polyoxyethylene polyoxypropylene modified polyorganosiloxane and polyglyceryl fatty acid ester, polyoxyethylene polyoxypropylene modified polyorganosiloxane and sorbitan fatty acid esters, sorbitan fatty acid esters and polyoxyethylene alkyl ether, polyglyceryl fatty acid ester and sorbitan fatty acid esters, polyglyceryl fatty acid ester and polyoxyethylene alkyl ether etc.As long as these preferred surfactants and preferred surfactants combination contain these surfactants, also can contain other surfactant etc.
Hydrophilic degree can be estimated the contact angle of thermally extensible fiber by measuring water.The contact angle value is more little, and then to be evaluated as hydrophily high more.Contact angle is measured with following method.As determinator, the automatic contact angle meter MCA-J that uses consonance interface science Co., Ltd. to produce.In contact angle determination, use distilled water.To be set at 20 skin liters from the liquid measure that ink-jetting style water droplet discharge portion (CLUSTER TECHNOLOGY society produces, and the discharge portion aperture is the pulse ejector filler CTC-25 of 25 μ m) discharges, water droplet drips directly over fiber.Record the state that drips at the high speed recording apparatus that is connected with horizontally disposed camera.From after carry out the viewpoint that image is resolved and image is resolved, wish that recording apparatus is the personal computer that is assembled with the high speed trap setting.In this mensuration, picture is recorded a video with every 17msec.In the image of recording, (version of software is 2.6.2 to the initial image that water droplet is dripped on fiber with attached software FAMAS, analytic method is a sessile drop method, analytic method is θ/2 methods, image processing algorithm is an areflexia, the image processing image pattern is an animation, and threshold level is 200, does not carry out the radian correction.) carry out image and resolve, calculate the face that water droplet contacts with air and the angle of fiber formation, as contact angle.In addition, test sample (taking out the fiber obtain from nonwoven fabric) is the fiber that is arranged in the top P1 of protuberance shown in Figure 3 from top layer with fibre length 1mm severing and is positioned at the protuberance corresponding position B of back side 10a, this fiber of mounting on the sample stage of contact angle meter, keep level, 2 places different to this 1 fiber measure contact angle.In above-mentioned each position, with the contact angle to 1 calculating N=5 root below the decimal point, the value that the measured value that adds up to 10 places is average (following the 2nd of decimal point rounds up) is defined as contact angle separately.If the contact angle of protuberance top P1 is the contact angle of protuberance corresponding position B among α, the back side 10a when being β, if the hydrophilic gradient of representing with α/β represents then that than greater than 1 the hydrophily on protuberance top is lower than the hydrophily of protuberance bottom.
In protuberance 119, from further raising liquid permeability with further prevent the viewpoint of liquid countercurrent, preferably the fibre density on its top is lower than the fibre density of bottom.By in fibre density, forming such gradient, form the gradient that uprises to the bottom capillary force from the top of protuberance 119.This gradient forms driving force, and liquid is absorbed to the bottom from the top of protuberance easily, and the permeability of liquid improves.In case liquid sees through, this capillary force gradient forms the barrier to liquid countercurrent, therefore, prevents that the effect of liquid countercurrent from becoming remarkable.For such capillary force gradient is set, for example can make nonwoven fabric 110 according to manufacture method described later in nonwoven fabric 110.
Fibre density is measured with following method.Cutting nonwoven fabric 110 makes its summit of containing protuberance, and the length parallel with MD direction (mechanical flow direction) is 0.5～1.0mm greater than 1mm and CD direction (with the direction of above-mentioned MD direction quadrature) width.With the MD direction cross section of the nonwoven fabric of this cutting mounting on the black platform up, (KEYENCE of Co., Ltd. produces, and VHX-900) obtains the cross section enlarged photograph along the MD direction to use microscope.Use image analysis software (NexusNewQube) that the data (jpeg) of this enlarged photograph are carried out the pattern dissection process.Particularly, thickness direction carries out five equilibrium (protuberance upper side and protuberance lower side), the MD direction is carried out binary conversion treatment to the 1mm scope, and protuberance upper side and protuberance lower side are obtained the spacial area occupation ratio of fiber (%).As the fibre density X of protuberance upper side, the fibre density Y of protuberance lower side, the value that will calculate with calculating formula Y/X is as the fibre density gradient ratio with this area occupation ratio separately.Its 10 places to nonwoven fabric are carried out, try to achieve mean value.If this fibre density gradient ratio greater than 1, represents that then the fibre density on protuberance top is low, the fibre density height of protuberance bottom.
Nonwoven fabric 110 is the nonwoven fabric that contain thermally extensible fiber.The preferred especially thermally extensible fiber that uses be comprise the 1st resinous principle that contains resin with high melting point and contain have fusing point or softening point be lower than the 1st resinous principle fusing point low-melting-point resin the 2nd resinous principle composite fibre (below, this fiber is called " thermally extensible composite fibre "), the 2nd resinous principle is along the length direction continued presence of at least a portion of fiber surface.The 1st resinous principle in the thermally extensible composite fibre is that composition, the 2nd resinous principle of this fiber thermally extensible of expression is the composition of expressing this fiber thermal welding.The thermally extensible composite fibre generally is the binary class, but also can be the above multicomponent classes of three compositions.
The thermally extensible composite fibre can extend because of heat in the temperature of the fusing point that is lower than the 1st resinous principle.Like this, the thermally extensible composite fibre is preferably 0.5～20% in the temperature higher 10 ℃ than the 2nd resinous principle fusing point, thermal stretching rate when not having the resin of fusing point than the high 10 ℃ temperature of softening point the time, is preferably 3～20% especially, especially is preferably 5～20%.The nonwoven fabric 110 that contains such thermal stretching rate fiber is by this elongation of fiber, and volume becomes big or presents three-dimensional outward appearance.For example, the concaveconvex shape on nonwoven fabric 110 surfaces becomes remarkable.
The fusing point of the 1st resinous principle and the 2nd resinous principle, (Seiko Instruments Co., Ltd. produces to use differential scanning type calorimeter, DSC6200), carry out the heat analysis of the fiber sample (example weight 2mg) of very thin severing, measure the melting peak temperature of each resin with 10 ℃/min of programming rate.Fusing point is with this melting peak temperature definition.When the fusing point of the 2nd resinous principle can not clearly be measured with this method, this resin is defined as " resin that does not have fusing point ".At this moment, the temperature that begins to flow as the molecule of the 2nd resinous principle, with the temperature of the 2nd resinous principle welding when the degree of welding point intensity that can the instrumentation fiber as softening point.
[the thermal stretching rate of fiber]
The thermally extensible rate of fiber is measured with following method.The thermo-mechanical analysis device TMA/SS6000 that uses Seiko Instruments (strain) to produce.As sample, the fibre length of preparing many collections is the above fiber of 10mm, and the total weight that makes every fibre length 10mm is 0.5mg, after this plurality of fibers is placed side by side abreast, is that 10mm installs with distance between the chuck in device.Making and measuring initial temperature is 25 ℃, with certain load state of load 0.73mN/dtex, with the programming rate intensification of 5 ℃/min.Measure the elongate fiber amount of this moment, the elongation Cmm when reading than the high 10 ℃ of temperature of the 2nd resinous principle fusing point (when not having the resin of fusing point is softening point).The thermal stretching rate of fiber is from (C/10) * 100[%] calculate.Reason with above-mentioned temperature measuring thermal stretching rate is, and is as described later, when making nonwoven fabric 110 at the intersection point heat fusing that makes fiber, common with the fusing point of the 2nd resinous principle or more than the softening point and to making than the scope of these high 10 ℃ of left and right sides temperature.
When judging the thermally extensible of fiber, use following method from nonwoven fabric taking-up fiber.Collect 5 fibers that are positioned at each position shown in Figure 3 of nonwoven fabric at first, respectively.The fibre length of collecting is more than the 1mm, below the 5mm.The fiber of collecting is sandwiched in microscope with in the sample, measures the fiber total length that sandwiches.The microscope VHX-900, the camera lens VH-Z20R that use KEYENCE to produce observe above-mentioned fiber with 50～100 times multiplying power, use the instrumentation instrument that is assembled in device that this observation is looked like to measure.The length that obtains with said determination is as " the fiber total length of collecting from nonwoven fabric " Y.In the sample container (name of an article: robot container 52-023P, 15 μ L, aluminum) that the DSC6200 that SII NanoTechnology Co., Ltd. produces uses, put into the fiber of having measured total length.The container of putting into above-mentioned fiber is placed the sample mounting table that sets in advance to than the heating furnace of the DSC6200 of the low 10 ℃ of temperature of the fusing point of the 1st resinous principle.With the temperature of the thermocouple measurement that under the sample mounting table of DSC6200, is provided with (the expression title in the instrumentation software: specimen temperature) reach temperature range than low 10 ℃ ± 1 ℃ of the fusing point of the 1st resinous principle after, after this heating 60sec takes out rapidly.The sample container of fiber after the heat treated from DSC taken out, be sandwiched in microscope, measure the fiber total length that sandwiches with in the sample.In the mensuration, the microscope VHX-900, the camera lens VH-Z20R that use KEYENCE to produce observe above-mentioned fiber with 50～100 times multiplying power, use the instrumentation instrument that is assembled in device that this observation is looked like to measure.The length that obtains with said determination is as " the fiber total length after the heat treated " Z.Thermal stretching rate (%) is from calculating with following formula.
Thermal stretching rate (%)=(Z-Y) ÷ Y * 100[%]
It with this value defined the thermal stretching rate of the fiber that takes out from nonwoven fabric.This thermal stretching rate can judge that greater than 0 o'clock fiber is a thermally extensible fiber.
Kind to the 1st resinous principle and the 2nd resinous principle is not particularly limited, and gets final product so long as have the resin of fiber forming property power.Special aspect from carrying out the manufacturing of nonwoven fabric 110 easily by thermal welding, the difference of the softening point of the fusing point difference of preferred two kinds of resinous principles or the fusing point of the 1st resinous principle and the 2nd resinous principle is more than 20 ℃, is preferably more than 25 ℃ especially.When the thermally extensible composite fibre is core-sheath-type, use the fusing point of core composition to be higher than the fusing point of sheath composition or the resin of softening point.Especially preferably use and be lower than the core-sheath-type thermally extensible composite fibre of the resin of these fusing points as core, with fusing point as sheath with polypropylene (PP) or polyethylene terephthalate (PET).Preferred compositions as the 1st resinous principle and the 2nd resinous principle, the 2nd resinous principle when being PP with the 1st resinous principle can be enumerated high density polyethylene (HDPE) (HDPE), low density polyethylene (LDPE) (LDPE), straight chain shape low density polyethylene (LDPE) polyethylene such as (LLDPE), ethylene propylene copolymer, polystyrene etc.In addition, when using the polyester resin of PET, polybutylene terephthalate (PBT) (PBT) etc.,, except the example of above-mentioned the 2nd resinous principle, can enumerate PP, copolyester etc. as the 2nd resinous principle as the 1st resinous principle.In addition,, can also enumerate the copolymer more than 2 kinds of polyamide polymers and above-mentioned the 1st resinous principle, in addition,, also can enumerate the copolymer more than 2 kinds of above-mentioned the 2nd resinous principle etc. as the 2nd resinous principle as the 1st resinous principle.They can appropriate combination.
The fiber length of thermally extensible composite fibre can be used suitable length according to the manufacture method of nonwoven fabric 110.For example, during as described later with comb and parallel cotton fibers prior to spinning manufactured nonwoven fabric 110, optimum fiber length is about 30～70mm.Then the fibre length of the thermal welding composite fibre of narration also is same.
The fibre diameter of thermally extensible composite fibre can suitably be selected according to the concrete purposes of nonwoven fabric 10.When nonwoven fabric 110 is used as the component parts of the absorbent commodities such as face sheet of absorbent commodity, preferably use 10～35 μ m, especially preferably use the fibre diameter of 15～30 μ m.Then the fibre diameter of the thermal welding composite fibre of narration also is same.In addition, the fibre diameter of thermally extensible composite fibre is owing to elongation diminishes, and above-mentioned fibre diameter is meant the fibre diameter when using nonwoven fabric 110 in practice.
As thermally extensible fiber, for example, can use and open 2005-350836 communique, spy patent No. 4131852 communique, spy and open 2007-303035 communique, spy and open 2007-204899 communique, spy and open the fiber that 2007-204901 communique and Te Kai 2007-204902 communique, spy open record in the 2008-101285 communique etc.
Nonwoven fabric 110 both can only be made of thermally extensible fiber, perhaps also can contain other fiber beyond the thermally extensible fiber, for example contain the core-sheath-type thermal welding composite fibre that 2 kinds of different compositions of fusing point and stretched processing constitute the non-thermally extensible that its length in fact do not extend because of heating and constitute.In addition, also can additionally contain the fiber (for example natural fabric, artificial silk and the acetate fiber etc. of cotton and paper pulp etc.) that does not have thermal welding originally.When nonwoven fabric 110 also contains other fiber formation except thermally extensible fiber, the ratio of the thermally extensible fiber in this nonwoven fabric 110 is preferably more than the 30 weight %, is preferably more than the 50 weight % especially, and the ratio of other fiber is preferably below the 70 weight %, is preferably below the 50 weight % especially.
Then, the limit is with reference to the manufacture method that is fit to of Fig. 7 limit explanation nonwoven fabric 110.Device 120 shown in Figure 7 possesses WEB manufacturing department 130, embossing adds attached 150 of the Ministry of worker 140, blowing hot wind.In WEB manufacturing department 130, use fiber (i.e. the thermally extensible composite fibre of state before the elongation) to make WEB 110a as the raw material of nonwoven fabric 110.WEB 110a has the 1st 1101 and be positioned at its opposition side the 2nd 1102.The 1st 1101 is the face with smooth roller 142 butts in embossing described later processing part 140, and in blowing hot wind described later portion 150, is and 152 opposed of the conveyer belts that is made of aeration WEB shape thing.Adding in the Ministry of worker 140 in embossing for the 2nd 1102, is the face with pattern roller 141 butts, and in blowing hot wind portion 150, by the face of blowing hot-air.
As WEB manufacturing department 130, for example, can use carding machine 131 as shown in the figure.According to the concrete purposes of nonwoven fabric 110, also can use other WEB manufacturing installation, for example the air lay device replaces carding machine 131.By the WEB 110a that carding machine 131 is made, it constitutes the state that is in loose complexing between the fiber, does not obtain the shape stability as sheet yet.Therefore,, add in the Ministry of worker 140 in embossing this WEB 110a is handled, form embossing WEB 110b for WEB 110a being given shape stability as sheet material.
Embossing processing part 140 possesses the pair of rolls 141,142 of clamping WEB 110a and subtend configuration.Roller 141 constitutes by be formed with a plurality of concavo-convex metal pattern rollers at its side face.Relief pattern in this pattern roller can suitably be selected according to the concrete purposes of nonwoven fabric 110.For example, when forming the embossed pattern of diamond check shape shown in Figure 2, can on the side face of roller 141, form protuberance that should the diamond check shape.In addition, when wishing on nonwoven fabric 110, to form the embossed pattern (not shown) of point-like, can on the side face of roller 141, form putting the protuberance of shape.On the other hand, roller 142 is made of the level and smooth smooth roller of its periphery.Roller 142 is metal system, rubber system, made of paper etc.
Add in the Ministry of worker 140 in embossing, carry out embossing processing with two rollers, 141,142 cramping WEB 110a.Particularly,, will on this WEB 110a, form a plurality of embossed portion, make embossing WEB 110b as the thermally extensible fiber densificationization of the formation fiber of WEB 110a by following the densificationization of heat.In this manufacture method, roller 141 and roller 142 are the structures that can heat, and when embossing added the Ministry of worker's 140 runnings, pattern roller 141 was heated to set point of temperature at least.Smooth roller 142 both can be heated also and can not be heated.
Add in the Ministry of worker 140 in embossing, heating as with WEB 110a face in the pattern roller 141 of roller of the 2nd 1102 butts, its temperature is remained on more than the fusing point of the 2nd resinous principle in the thermally extensible fiber.Meanwhile, will as with WEB 110a face in the temperature of smooth roller 142 of roller of the 1st 1101 butts remain the fusing point that is lower than the 2nd resinous principle in the thermally extensible fiber.About smooth roller 142, both can not use with the state that is heated, its temperature is remained the fusing point that is lower than the 2nd resinous principle, perhaps also can exceed with the temperature that does not reach more than the 2nd resinous principle fusing point, use with the state that is heated.By the temperature of such setting two rollers 141,142, can reliably have been given the embossing WEB 110b of shape stability.
From giving reliable shape stability, expressing high strength, in addition, from giving the viewpoint of soft skin feel, the fusing point of establishing the 2nd resinous principle be Mp (℃), the heating-up temperature of pattern roller 141 is preferably more than the Mp, more preferably below above, the Mp+20 of Mp ℃.On the other hand, about smooth roller 142, preferably the temperature with smooth roller 142 remains from normal temperature to Mp, more preferably remains more than Mp-20 ℃, below the Mp-5 ℃.Be set in these temperature ranges by embossing being added the Ministry of worker, make thermally extensible fiber not express the essence elongation." essence is not expressed " is to get rid of to make thermally extensible fiber elongation consciously, is to allow to add the meaning that inevitable thermally extensible fiber that temperature fluctuation in the Ministry of worker 140 etc. causes extends a little by embossing.
The embossing WEB 110b that gives shape stability with the processing of embossing processing part 140 then is transported to blowing hot wind portion 150.With embossing WEB 110b when embossing adds the Ministry of worker 140 and is transported to blowing hot wind portion 150, preferably will to suppress with respect to the speed increasing ratio ((v2-v1)/v1 * 100) of the peripheral speed v2 of the conveyer belt 152 of the blowing hot wind part 150 of the peripheral speed v1 of pattern roller in the embossing processing part 140 and smooth roller be below 8%, be preferably below 6% especially.In common embossing processing, because the heating-up temperature of each roller is higher relatively, cause that thus embossing WEB 110b is attached at the roller side face easily, be attached at smooth roller 142 sides especially easily.At this moment, must improve speed increasing ratio, forcibly embossing WEB 110b be peeled from the roller side face.But, improve speed increasing ratio and be accompanied by embossing WEB 110b is applied excessive pressure, therefore, its result produces and is difficult to make nonwoven fabric 110 volumes to become big improper.With respect to this, in this manufacture method, as mentioned above, because the heating-up temperature of roller is relatively low, special because the temperature of smooth roller 142 is low, therefore, even reduce speed increasing ratio, embossing WEB 11b also peels from the roller periphery easily.Its result does not apply excessive pressure to embossing WEB 110b, can make nonwoven fabric 110 volumes become big.
Blowing hot wind portion 150 possesses cover 151.Embossing WEB 110b is by in this cover 151.In addition, blowing hot wind portion 150 possesses the conveyer belt 152 that is made of the aeration WEB.Conveyer belt 152 is rotation in cover 151.Embossing WEB 110b mounting is transported in the blowing hot wind portion 150 on conveyer belt 152.Conveyer belt 152 is formed by resins such as metal and polyethylene terephthalate.
The structure of expression blowing hot wind portion 150 when the carriage direction of embossing WEB 110b is seen among Fig. 8.Conveyer belt 152 and mounting embossing WEB 110b thereon moves with the direction of paper quadrature in Fig. 8.Space about being divided into by dividing plate 153 in the cover 151.Space, the left and right sides is communicated with in top and the bottom.In the space in space, the left and right sides, conveyer belt 152 and embossing WEB 110b pass through.At the parallel tabular air cleaner 154 of the downside setting of conveyer belt 152 and this conveyer belt 152.At embossing WEB 110b upside air cleaner 154 is set also.Heat exchanger 155 and circulating fan 156 are set in another space.Heat exchanger 155 can be used for the air in the heating mantles 151.If make heat exchanger 155 runnings, circulating fan 156 runnings, the air that then covers in 151 is heated, and the limit is by air cleaner 154, and the direction that the edge is represented with arrow among Fig. 8 circulates.Its result, 2nd 1102 side-blown of hot blast from the face of embossing WEB 110b sent.
By to embossing WEB 110b blowing hot-air, make the thermally extensible fiber elongation.At this moment, because the fiber that is arranged in embossing WEB 110b embossed portion is by densificationization, therefore, even blowing hot-air does not extend yet.Elongation is being present in embossed portion thermally extensible fiber generation in addition.That is, the part of thermally extensible fiber elongation is the part between the embossed portion.Like this, the part of thermally extensible fiber is fixed by embossed portion, and the elongated portion of the thermally extensible fiber of elongation loses to the action place of the in-plane of embossing WEB 110b and moves to the thickness direction of this embossing WEB 110b.Thus, form protuberance 119 between embossed portion, it is big that embossing WEB 110b volume becomes.In addition, formation has the three-dimensional outward appearance that is formed with a plurality of protuberances 119 formation.Like this, embossed portion forms recess 118.
In blowing hot wind, when making the thermally extensible fiber elongation, the intersection point between the welding thermally extensible fiber.In this welding, be present in the closer to fiber as the 2nd 1102 side positions of blowing hot wind face, the heat seal strength between the thermally extensible fiber is high more.On the contrary, in the face of embossing WEB 110b, be present in the closer to the fiber as the position of conveyer belt 152 opposed the 1st 1101 sides, the intensity of welding is low more between the thermally extensible fiber.In order to realize this purpose, the surface temperature that preferably makes blowing hot-air position in the conveyer belt 152 is below the fusing point of the 2nd resinous principle in the thermally extensible fiber.Thus, the temperature of thermally extensible fiber that suppresses to be positioned at the 1st 1,101 one sides of embossing WEB 110b rises, and is difficult to cause the welding between the thermally extensible fiber.
But, in conveyer belt 152, directly measure the surface temperature at blowing hot wind position and see it is very difficult technically.Therefore, in this manufacture method, index is instead measured the surface temperature (mensuration of this surface temperature is easy) of the conveyer belt 152 after blowing hot wind has just finished, the surface temperature of control conveyer belt 152, making this temperature is below the 2nd resinous principle fusing point in the thermally extensible fiber.Particularly, in Fig. 7, from cover 151 positions of coming out, measure the surface temperature of conveyer belt 152 at conveyer belt 152.If this is owing to be below the fusing point of the 2nd resinous principle in the surface temperature of the conveyer belt 152 of this position, can think reasonably that then the surface temperature of conveyer belt 152 at position (promptly covering in 151) of blowing hot-air also is below the fusing point of the 2nd resinous principle.
If with the fusing point of the 2nd resinous principle be Mp (℃), the surface temperature of the conveyer belt 152 after then blowing hot wind has just finished is preferably more than Mp-20 ℃, below the Mp, more preferably more than Mp-10 ℃, below the Mp.The surface temperature of conveyer belt 152 is measured by for example contact tehermometer ANRITSU DIGITAL THERMOMETER LC-1 SENSER 221K (translational surface is used).
For the surface temperature that makes conveyer belt 152 becomes above-mentioned scope, for example, can be set forth in and blow this conveyer belt 152 of the preceding cooling of attached hot blast on the conveyer belt 152, the surface temperature that makes this conveyer belt 152 is the following method of the 2nd resinous principle fusing point.In order to cool off, for example can face in the position that enters before covering in 151 at this conveyer belt 152 as shown in Figure 7, on this conveyer belt 152, make chill roll 157 butts.Chill roll 157 is portion circulation cooling fluid within it, is set to be lower than environment temperature.Therefore, be connected to conveyer belt 152, cool off this conveyer belt 152, enter in the cover 151 with the state of surface temperature step-down by chill roll 157.In the cooling of conveyer belt 152, can replace chill roll 157 or adopt coldblast etc. in addition.
Be present in the closer to high more as heat seal strength between the fiber thermally extensible fiber of the position of the 2nd 1102 sides of blowing hot wind face in order to make, making hot blast is that low wind speed also is effective.From this viewpoint, with the pressure reduction of the position (position of representing with B among Fig. 8) of the position (position of representing with A among Fig. 8) of conveyer belt 152 top 10cm and bottom 10cm be preferably 0.4～5Pa, the wind speed ground that is preferably 0.4～3.5Pa especially blows attached hot blast.Here so-called wind speed is meant in practice to the 2nd 1The fiber of 102 sides blows, at the 1st 1The wind speed of 101 sides by leaving away.Preferred wind speed is the ultra micro wind less than 0.4m/sec, and it is difficult directly calculating this wind speed of mensuration with airspeedometer.Therefore, use above-mentioned pressure reduction to represent and replace instrumentation, stipulate this ultra micro wind.In addition, the pressure representative negative pressure of the position of representing with A, the pressure representative negative pressure bigger of the position of representing with B than A position.In addition, on principle, should be the pressure of measuring the extremely near position of embossing WEB 110b, obtain pressure reduction.But, in reality, such be determined at technical to be unusual difficulty, therefore, in this manufacture method, to be the pressure of measuring in the position of leaving 10cm up and down.
The hot blast temperature that blows is the above temperature of the 2nd resinous principle fusing point in the thermally extensible fiber.Here so-called temperature is the hot blast temperature in embossing WEB 110b surface.But, in reality, because it is very difficult that the hot blast temperature in this position is determined at technical, therefore, in this manufacture method, mensuration is left the hot blast temperature of 10cm position on the embossing WEB 110b, if this temperature is the above temperature of fusing point of the 2nd resinous principle, it is the above temperature of fusing point of the 2nd resinous principle that the hot blast temperature in the then embossing WEB 110b surface also is considered as.
If with the fusing point of the 2nd resinous principle be Mp (℃), leave on embossing WEB 110b then that hot blast temperature the 10cm position is preferably more than the Mp, below the Mp+50 ℃, more preferably below above, the Mp+30 of Mp ℃.Hot blast temperature for example passes through thermocouple measurement.
Is condition with hot blast temperature and pressure reduction in above-mentioned scope inside, and the time of blowing hot wind is preferably 1～20 second, is preferably 3～15 seconds especially.
By adopting the above-mentioned condition that respectively blows, be present in the closer to the fiber of the 2nd 1102 sides, the intensity of welding becomes high more between the thermally extensible fiber.In addition, be present in the closer to the fiber of the 2nd 1102 sides, it is big more that the elongation degree of thermally extensible fiber becomes.That is, be present in the closer to the fiber of the 2nd 1102 sides, fiber spacing is from becoming big more.Say that on the contrary be present in the closer to the fiber of the 1st 1101 sides, fiber spacing is from becoming more little.Its result, in the protuberance 119 in the nonwoven fabric 110 that obtains, to top, fibre density is step-down slowly from its underpart.
The embossing WEB 110b that contains the thermally extensible fiber that is attached with hydrophilizing agent is in advance carried out blowing hot wind, and when making this thermally extensible fiber elongation, result's judgement of the present inventor's research obtains, and extends big more position hydrophily and descends more.Therefore, in this manufacture method, be positioned at the thermally extensible fiber that leans on the 2nd 1102 sides of blowing hot wind face more, it is big more that the degree of elongation becomes, and it is big more that hydrophilic decline becomes.Because the face of blowing hot wind is to be formed with the protuberance 119 in the nonwoven fabric 110 and the face of recess 118, therefore nonwoven fabric 110 for obtaining, more to the top of protuberance 119, it is big more that hydrophilic decline just becomes.Say that on the contrary more to the bottom of protuberance 119, it is high more that hydrophily just becomes.Therefore, in protuberance 119, from its top P1 to the back side of nonwoven fabric 110 10a side, promptly among Fig. 3 from P1 to P3 and from P3 to B, the hydrophily of this thermally extensible fiber uprises gradually.
In the blowing hot wind in this manufacture method, of course not all thermally extensible fibers are thoroughly elongation fully all.Therefore, nonwoven fabric 110 is to be the raw material manufacturing with the thermally extensible fiber and nonwoven fabric that contain thermally extensible fiber.
The nonwoven fabric A that the present invention is correlated with can apply in a flexible way and reduce the low interfibrous distance of Young's modulus when imbibition and improve logical fluidity and by the characteristic of removing caliper recovery behind the liquid etc. that has that the hot melt contact produces, use in various fields.
In addition, above-mentioned nonwoven fabric 110 can be applied in a flexible way and be reduced interfibrous distance and prevent that the effect of liquid countercurrent from uprising the characteristic that waits when improving dry after logical fluidity and the imbibition when imbibition, in the use of various fields.
For example, the various parts that can be used as in the absorbent commodity (particularly disposable hygienic article) that menstrual hygiene towel, women use from the liquid-absorbent that health is discharged with panty liner, disposable diaper, incontinence pad etc. use.As such parts, for example, can enumerate face sheet, secondary sheet material (being disposed at the sheet between face sheet and the absorber), back-sheet, leakproof sheet material etc.In addition, nonwoven fabric also can be used as human cleaning wipe sheet, skin care is used well with sheet material.Can also be as uses well such as the wipe sheet that thing is used.Particularly the nonwoven fabric face sheet that can be used as the absorbent commodity that uses from the liquid-absorbent that health is discharged uses well.
The weight per unit area of nonwoven fabric is suitably selected according to the concrete purposes as the nonwoven fabric of purpose.The weight per unit area of the nonwoven fabric when using as the face sheet of absorbent commodity is preferably 10～80g/m 2, be preferably 15～60g/m especially 2
Nonwoven fabric 10,10A, 110 are when for example using its face sheet as absorbent commodity, and the thickness of drying regime is preferably 0.5～3mm, is preferably 0.7～3mm especially.
Recess 118 in nonwoven fabric 10,10A, 110 and the area of protuberance 119 be than with embossing rate (the embossing area occupation ratio is promptly with respect to the total ratio of recess 118 areas of nonwoven fabric integral body) expression, and the volume size and the intensity of nonwoven fabric is exerted an influence.From these viewpoints, the embossing rate in nonwoven fabric is preferably 5～35%, is preferably 10～25% especially.Above-mentioned embossing rate is measured by following method.At first, (KEYENCE of Co., Ltd. produces to use microscope, VHX-900), obtain the surperficial enlarged photograph of nonwoven fabric, to the size of this nonwoven surface enlarged photograph, calculate the area aggregate value P of the recess 118 in the entire area Q that measures the position according to scale mensuration recess 118 (being embossed portion).The embossing rate can be calculated by calculating formula (P/Q) * 100.
The absorbent commodity that is used for the liquid-absorbent of discharging from health, the typical case possesses face sheet, back-sheet and is disposed at the absorber of the liquid retainability between two sheet materials.Absorber when using as face sheet as the nonwoven fabric of being correlated with the present invention and as back-sheet can use normally used material in this technical field with being not particularly limited.
For example, as absorber, can use with cladded sheet materials such as toilet paper or nonwoven fabric to coat the fiber assembly of forming by fibrous materials such as paper pulp fibers or keep the aggregate of absorbable polymer therein and the absorber that forms.As back-sheet, can use the liquid impermeability or the hydrophobic sheet material of the film of thermoplastic resin and the lamination sheet of this film and nonwoven fabric etc.Back-sheet also can have steam breathability.Absorbent commodity can also possess the various parts corresponding to the concrete purposes of this absorbent commodity.Such parts are known to this field practitioner.For example, in disposable diaper and sanitary napkin, be suitable for when using absorbent commodity, can or solid protection two pair or more a pair of in the configuration of the left and right sides portion on the face sheet.
More than, based on preferred implementation of the present invention the present invention has been described, but the present invention is not limited by above-mentioned embodiment.
For example, illustration with the fiber of Young's modulus 0.2～1.0GPa as constituting the example that fiber contains, but replace, also can use sheath portion resin is the fiber of elastic resin such as elastomer.In addition, the nonwoven fabric that also can use molten fusing point to reduce.
In addition, for example, in Fig. 4, as the manufacture method of nonwoven fabric, illustration implement heat treated example in embossing processing back, but replace, also can handle the back and implement embossing processing at hot blast.In addition, the embossed portion when nonwoven fabric forms embossed portion forms pattern, can replace clathrate and is made for the arbitrary graphic patterns such as striated, point-like, chessboard trellis, helical form of multiple row.Each point shape when being made for point-like can be made for shape arbitrarily such as circle, ellipse, triangle, quadrangle, hexagon, heart type.In addition, also can adopt the clathrate and the shape that is made for the tortoise plastron apperance of square or rectangular.
In addition, embossing processing also can replace heat embossing and use ultrasonic wave embossed, high frequency embossing, only compression and the embossing etc. that do not produce heat fusing.
In addition, according to the present invention, also can provide contain comprise fusing point mutually different the 1st and the 2nd composition, Young's moduluss be the nonwoven fabric (thickness change does not limit) that intersection point between 0.2～1.0GPa composite fibre, this composite fibre is formed with the hot melt contact of a plurality of heat fusings, wherein its 1st composition contains acrylic resin or polyethylene terephthalate, and the 2nd composition contains the resin that fusing point is lower than the 1st congruent melting point.
In addition, in the manufacture method of nonwoven fabric shown in Figure 7, in embossing processing part 140, allocation plan table roll 141, make the 1st 1101 butts of itself and WEB 110a, and dispose smooth roller 142, make itself and the 2nd 1102 butts, but replace, also can dispose smooth roller 142, make the 1st 1101 butts of itself and WEB 110a, and allocation plan table roll 141, make itself and the 2nd 1102 butts.At this moment, smooth roller is remained remain the fusing point that is lower than the low-melting-point resin in the thermally extensible fiber more than the fusing point of the low-melting-point resin in the thermally extensible fiber and with pattern roller.
In addition, nonwoven fabric of the present invention both can be a single layer structure, also can be the sandwich construction more than two layers.
Embodiment
Below, utilize embodiment to illustrate in greater detail the present invention.But scope of the present invention is not limited by such embodiment.
[embodiment 1]
(1) the 1st layer manufacturing
Use polypropylene in resin, use polyethylene in resin at core in sheath portion, with 325 ℃ of core melt temperatures, 280 ℃ in sheath portion, utilize melt spinning method, with spinning speed 1500m, the manufacturing fiber number is that 3.5dtex, Young's modulus are the concentric core-sheath-type composite fibre of 0.58GPa.The processing of crispaturaing, but do not carry out stretch processing especially.After crispaturaing, carry out high temperature drying, cut off the fiber obtain and obtain the staple fibre that fibre length is 51mm.The staple fibre that use obtains utilizes carding machine to form weight per unit area 20g/m 2WEB.
(2) the 2nd layers manufacturing
The core-sheath-type composite fibre that use is used in the 1st layer is operated equally with the WEB of the 1st layer of usefulness, makes the WEB of the 2nd layer of usefulness.
(3) nonwoven fabric processing
2 kinds of WEB that lamination such as above-mentioned operation are made are implemented ultrasonic wave embossed processing integratedly to this laminated body.Embossing processing is implemented in the mode of knurling rolls and the 1st layer of side butt, smooth roller and the 2nd layer of side butt, embossed pattern is continuous repetition rhombus (inclination grid), the long-diagonal of this non-embossed portion is the mechanical flow direction, short diagonal is perpendicular to above-mentioned flow direction, catercorner length is respectively 13mm, 8mm, embossed portion is a wire, uses the 0.5mm width.
Then, to the processing of ventilating of the laminated body after the embossing processing.The heat treatment temperature of ventilation processing is 136 ℃.The wind speed of hot blast is 0.4m/sec, and the processing time is 4sec.
The nonwoven fabric that obtains has the part (embossed portion) and the thick part of thickness in addition of thin thickness.In addition, weight per unit area is 40g/m 2
[embodiment 2]
Use polypropylene in resin, use polyethylene in resin at core similarly to Example 1 in sheath portion, in the WEB manufacturing of using in layers 1 and 2, use utilize fiber number that melt spinning method obtains as 3.5dtex, Young's modulus as 0.64GPa, the concentric core-sheath-type composite fibre of fibre length as 51mm, nonwoven fabric is made in operation similarly to Example 1.
[embodiment 3]
Use polyethylene terephthalate in resin, use polyethylene in resin at core in sheath portion, in the WEB manufacturing of layers 1 and 2, use and utilize fiber number that melt spinning method obtains to be 0.68GPa, fibre length concentric core-sheath-type composite fibre as 45mm as 4.3dtex, Young's modulus, in addition, nonwoven fabric is made in operation similarly to Example 1.
[embodiment 4]
Using core is poly commercially available core-sheath-type composite fibre as polyethylene terephthalate, sheath portion, utilizes carding machine manufactured weight per unit area to be 20g/m 2WEB.
The WEB of making is used as the WEB of the 2nd layer of usefulness, made to add up to 40g/m 2, and use with WEB as the 1st layer with the 1st layer of embodiment 1 WEB made from the same operation of WEB, in addition, nonwoven fabric is made in operation similarly to Example 1.
[embodiment 5]
Overlapping 2 pieces with the 1st layer of embodiment 1 WEB made from the same operation of WEB, then, laminated body is ventilated after the processing, implement ultrasonic wave embossed processing.The heat treatment temperature of ventilation processing is 136 ℃.Embossing processing is implemented in the mode of knurling rolls and the 1st layer of side butt, smooth roller and the 2nd layer of side butt, embossed pattern is continuous repetition rhombus (inclination grid), the long-diagonal of this non-embossed portion is the mechanical flow direction, short diagonal is perpendicular to above-mentioned flow direction, catercorner length is respectively 13mm, 8mm, embossed portion is a wire, uses the 0.5mm width.
[comparative example 1,2,3]
Except as using the WEB shown in the table 1 in the WEB of the WEB of the 1st layer of usefulness and the 2nd layer of usefulness, operate similarly to Example 1 and make nonwoven fabric.The WEB of the WEB of the 1st layer of usefulness and the 2nd layer of usefulness contains poly core-sheath-type composite fibre by the commercially available known portion of sheath arbitrarily that makes generally to create conditions and constitutes.
[evaluation]
Thickness when each nonwoven fabric that obtains in embodiment and the comparative example is determined at drying regime and moisture state and fiber spacing from.In addition, measure liquid residue and return liquid measure.These results of expression in table 1.
[table 1]
Figure BPA00001390085000311
Thickness and fiber spacing from assay method and liquid residue, return liquid measure assay method as follows.
[thickness and fiber spacing from assay method]
[thickness of drying regime and fiber spacing from]
(Kao Corp produces from commercially available menstrual hygiene towel, trade name " ロ リ エ さ ら さ ら Network Star シ ヨ Application flesh キ レ イ absorb plumage つ I ") take off face sheet after, absorber is cut to length direction 50mm * width (direction vertical with the length direction of sanitary napkin) 50mm of sanitary napkin, obtains sanitary napkin absorber (using the absorber of sanitary napkin middle body).The nonwoven fabric of determination object is cut to the length direction 50mm * width 50mm of sanitary napkin, makes the cut off machine of this nonwoven fabric.This cut off machine of mounting on above-mentioned sanitary napkin absorber is made the menstrual hygiene towel that the determination object nonwoven fabric is used as face sheet.
Above-mentioned nonwoven thickness in mounting under the state on the above-mentioned sanitary napkin absorber, with the mensuration of not pressurizeing.Measuring environment is 20 ± 2 ℃ of temperature, relative humidity 65 ± 5%, and (KEYENCE of Co., Ltd. produces, VHX-900) to use microscope in measuring machine.At first, obtain the enlarged photograph in above-mentioned nonwoven fabric cross section.In enlarged photograph, take the object of known dimensions simultaneously.The enlarged photograph in above-mentioned nonwoven fabric cross section is measured the thickness of nonwoven fabric according to scale.Carrying out operation more than 3 times, is the nonwoven thickness [mm] of drying regime with 3 times mean values.
Constitute the determination object nonwoven fabric fiber fiber spacing from by shown below, try to achieve based on the formula of the supposition of Wrotnowski.Based on the formula of the supposition of Wrotnowski generally the fiber spacing of obtaining the fiber that constitutes nonwoven fabric from the time use.According to formula based on the supposition of Wrotnowski, fiber spacing from A (μ m) by nonwoven thickness h (mm), weight per unit area e (g/m 2), constitute fibre diameter d (μ m), the fibre density ρ (g/cm of the fiber of nonwoven fabric 3), try to achieve with following formula (6).
Figure BPA00001390085000321
[thickness of moisture state and fiber spacing from]
Except the determination object thing is the nonwoven fabric of (moisture state) when soaking in liquid, with the same operation of the nonwoven thickness evaluation of drying regime and estimate.In addition, the nonwoven thickness when soaking in liquid from the disposable dropping 3.0g defiber horse blood in top (the 1st layer of side) of the nonwoven fabric of determination object, is measured and is flowed into the nonwoven thickness after 60 seconds behind the above-mentioned horse blood.Carry out operation more than 3 times, with the nonwoven thickness (mm) of 3 times mean values as moisture state.
The fiber spacing that fiber spacing can be used to calculate the drying regime nonwoven fabric with use from (μ m) from above-mentioned formula similarly obtain.
[thickness when moisture state is changed to drying regime again and fiber spacing from]
Thickness when moisture state is changed to drying regime again, after dripping liquid on the determination object thing after 3 minutes, promptly with from the thickness of mensuration after 2 minutes of above-mentioned moisture state as the thickness when moisture state is changed to drying regime again.
The nonwoven fabric after the determination object thing is dropping liquid after 3 minutes, operate and estimate with the nonwoven thickness evaluation of drying regime is same.In addition, the thickness when being changed to drying regime from the disposable dropping 3.0g defiber horse blood in top (the 1st layer of side) of the nonwoven fabric of determination object, is measured and is flowed into the nonwoven thickness after 3 minutes behind the above-mentioned horse blood.Carry out more than 3 times operation, with 3 times mean values as the nonwoven thickness [mm] when moisture state is changed to drying regime again.
The fiber spacing that fiber spacing can be used to calculate the drying regime nonwoven fabric with use from (μ m) from above-mentioned formula similarly obtain.
[rate of change of nonwoven thickness]
That use is measured with said method, the thickness A (mm) of drying regime and the thickness B (mm) of moisture state are with the thickness change (rate of change of nonwoven thickness) of following formula calculating when drying regime is changed to moisture state.
The rate of change of nonwoven thickness (%)=[(A-B)/A] * 100 (7)
This value is more than 15%, be in particular 20% when above, then can obtain good result.
[recovery rate of nonwoven thickness]
Use is with the thickness B (mm) of said method thickness A (mm) that measure, drying regime, moisture state and the thickness C (mm) when moisture state is changed to drying regime again, calculates caliper recovery rate (recovery rate of nonwoven thickness) when moisture state is changed to drying regime again with following formula.
The recovery rate of nonwoven thickness (%)=(C/A) * 100 (8)
This recovery rate is preferably more than 70%, more preferably more than 80%, be more preferably more than 90%.
Above-mentioned thickness change is more than 15% and above-mentioned recovery rate is more than 70%, after then liquid moves in absorber etc., can reduce the liquid residue in nonwoven fabric, can prevent more effectively that the liquid of this absorber etc. from turning back in the nonwoven fabric and the liquid countercurrent of nonwoven surface.
[mensuration of liquid residue (method 1)]
Take off face sheet from commercially available menstrual hygiene towel (Kao Corp produces, trade name " ロ リ エ (registration mark) さ ら さ ら Network Star シ ヨ Application flesh キ レ イ absorbs plumage つ I "), obtain the towel absorber.In addition, the nonwoven fabric with determination object is cut to MD50mm * CD50mm, the making cut off machine.Above-mentioned surface patch existence place in above-mentioned sanitary napkin absorber (on the sanitary napkin absorber skin contact) towards absorbing this cut off machine of ground, side configuration, is made the menstrual hygiene towel that the nonwoven fabric with determination object uses as face sheet with the 2nd layer of side.
State in the use on the surface of menstrual hygiene towel of nonwoven fabric of determination object, the overlapping cylindric propylene substrate that sees through the hole with diameter 10mm applies certain loading of 100Pa to this sanitary napkin.Under such loading, see through orifice flow from this propylene substrate and go into 3.0g defiber horse blood.After flowing into above-mentioned horse blood, take off the propylene substrate after 60 seconds, then, measure the weight (W2) of this nonwoven fabric, poor (W2-W1) of the nonwoven fabric weight (W1) before the inflow horse blood of calculating and measuring in advance.Carrying out the operation more than 3 times, is liquid residue (mg) with 3 times mean values, and liquid residue is estimated high more more at least.
[returning the mensuration (method 1) of liquid measure]
Operate equally with the assay method of above-mentioned [returning liquid measure], the nonwoven fabric of determination object is cut to MD150mm * CD50mm, obtain the menstrual hygiene towel that this nonwoven fabric is used as surface patch.
On the surface of the above-mentioned nonwoven fabric (face sheet) in above-mentioned menstrual hygiene towel, the overlapping propylene substrate that has cylindric through the hole applies 1.1g/cm to this sanitary napkin 2Loading.Under such loading, see through orifice flow from this propylene substrate and go into 3.0g defiber horse blood.After flowing into above-mentioned horse blood, take off the propylene substrate after 60 seconds, then, overlapping toilet paper on above-mentioned nonwoven surface, overlapping scheelite on this cotton paper applies the loading of 400Pa to this sanitary napkin again.After 5 seconds, take off this scheelite and toilet paper at overlapping scheelite, measure the weight (W2) of this toilet paper, poor (W2-W1) that calculate and measure in advance, the toilet paper weight (W1) on above-mentioned nonwoven surface before overlapping.Carry out the operation more than 3 times, for returning liquid measure (mg), return liquid measure and estimate high more more at least with 3 times mean values.
[embodiment 6～10 and comparative example 4 and 5]
Use is in the single-layer nonwoven 110 of Fig. 7 and device, shop drawings 2 and form shown in Figure 3 shown in Figure 8.Pattern roller 141 in the device shown in Figure 7 is to have the roller that live width is the diamond check shape protuberance of 0.5mm.Protuberance area occupation ratio in these knurling rolls 141 is 14%.As the thermally extensible composite fibre, using core to contain fiber number that polypropylene (161 ℃ of fusing points), sheath contain polyethylene (126 ℃ of fusing points) is 8% stable fibers as 4.2dtex, thermal stretching rate.Obtain nonwoven fabric with the condition manufacturing shown in the following table 2.In the nonwoven fabric that obtains among each embodiment, the intersection point welding between the thermally extensible composite fibre.In addition,, judge with the method for previous narration to have or not thermally extensible, confirm to have thermally extensible the fiber that contains in the nonwoven fabric that obtains among each embodiment.The weight per unit area of the nonwoven fabric that obtains in embodiment and the comparative example is represented in same table.To the nonwoven fabric that obtains in embodiment and the comparative example, measure every rerum natura with said method.In addition, carry out various evaluations with following method.These results of expression in table 2.
[feel: the harsh feeling that does not have nonwoven surface]
The mode that makes progress with protuberance on platform is placed nonwoven fabric.With 10 syndics is object, with 3 grades following judgment standard, estimates the sense of touch on palm.The result represents with 10 people's mean value.
Judgment standard
3: clearly do not have harsh feeling
2: harsh feeling is arranged slightly
1: harsh feeling is arranged
Evaluation result
Zero: judge that mean value is more than 2.5, below 3
△: judge that mean value is more than 1.5, less than 2.5
*: judge that mean value is more than 1, less than 1.5
[mensuration of liquid residue (method 2)]
The nonwoven fabric of determination object is cut to MD120mm * CD60mm, in addition, after flowing into 3.0g defiber horse blood, flow into 3.0g defiber horse blood again after 120 seconds, after adding up to inflow 6.0g horse blood, take off the propylene substrate after 60 seconds, in addition, with above-mentioned [mensuration of liquid residue (method 1)] same operation, measure liquid residue.
[returning liquid measure]
The nonwoven fabric of determination object is cut to MD120mm * CD60mm, in addition, after flowing into 3.0g defiber horse blood, flow into 3.0g defiber horse blood again after 60 seconds, after adding up to inflow 6.0g horse blood, take off the propylene substrate after 60 seconds, in addition, with above-mentioned [returning the mensuration (method 1) of liquid measure] same operation, measure and return liquid measure.
[table 2]
Figure BPA00001390085000361
*1: face enter conveyer belt before and after cover comes out, blow air immediately
It is few and to return liquid measure few to be judged as nonwoven fabric (the present invention's product) liquid residue that obtains the nonwoven fabric 1～5 of embodiment from the result shown in the table 1, at absorbency, prevent excellence aspect the liquid countercurrent.
As from the result shown in the table 2 as can be known, the nonwoven fabric that obtains among the embodiment 6～10 (the present invention's product) is judged as that liquid residue is few, liquid permeability height.In addition, be judged as and prevent liquid countercurrent, feel excellence.
Industrial utilizability
Nonwoven fabric of the present invention is if soaked by liquid then thickness reduces this liquid is seen through effectively, and this liquid is difficult to residual from the teeth outwards nonwoven fabric after liquid sees through.
According to absorbent commodity of the present invention, can provide and return the few absorbent commodity of liquid measure.

Claims (12)

1. nonwoven fabric is characterized in that:
Contain and comprise the 1st composition that fusing point is mutually different and the composite fibre of the 2nd composition, be formed with the hot melt contact that the intersection point thermal welding between a plurality of these composite fibres forms,
Thickness change when drying regime is changed to moisture state is more than 15%.
2. nonwoven fabric as claimed in claim 1 is characterized in that:
Caliper recovery rate when moisture state is changed to drying regime again is more than 70%.
3. nonwoven fabric as claimed in claim 1 or 2 is characterized in that:
As described composite fibre, containing the 1st composition and be acrylic resin or pet resin and the 2nd composition is that resin, the Young's modulus that fusing point is lower than the 1st composition is the fiber of 0.2～1.0GPa.
4. as each described nonwoven fabric in the claim 1～3, it is characterized in that:
The part of the thin thickness that existence is processed to form by embossing and the part thick than this segment thickness, the formation fiber of a face side of the part that described at least thickness is thick is that Young's modulus is the described fiber of 0.2～1.0GPa.
5. nonwoven fabric as claimed in claim 4 is characterized in that:
The formation fiber of another face side of the part that described thickness is thick is a Young's modulus greater than 1.0GPa, fiber below the 6.0GPa.
6. as each described nonwoven fabric in the claim 3～5, it is characterized in that:
Young's modulus is that the 1st composition is an acrylic resin in the described fiber of 0.2～1.0GPa, and degree of crystallinity is below 60%.
7. as each described nonwoven fabric in the claim 3～5, it is characterized in that:
Young's modulus is that the 1st composition is a pet resin in the described fiber of 0.2～1.0GPa, and degree of crystallinity is below 45%.
8. nonwoven fabric as claimed in claim 1 or 2 is characterized in that:
As described composite fibre, contain the thermally extensible fiber that its length is extended because of heating, have a plurality of protuberances and recess a face side, constitute the intersection point place welding of the thermally extensible fiber of this protuberance at them, the heat seal strength on the top of protuberance is higher than the heat seal strength of bottom.
9. nonwoven fabric as claimed in claim 8 is characterized in that:
In protuberance, the fibre density on the top of this protuberance is lower than the fibre density of bottom.
10. absorbent commodity is characterized in that:
It possesses face sheet, back-sheet and the absorber between two sheet materials, and described face sheet is each described nonwoven fabric in the claim 1～9.
11. absorbent commodity as claimed in claim 10 is characterized in that:
Described face sheet is made of each described nonwoven fabric in the claim 3～7, and in this nonwoven fabric, the face side towards this absorption side contains the described fiber that Young's modulus is 0.2～1.0GPa at least.
12. absorbent commodity as claimed in claim 10 is characterized in that:
Described face sheet is made of each described nonwoven fabric in the claim 8～9, and this nonwoven fabric disposes towards the mode of user's skin with the face that has protuberance and recess in this nonwoven fabric.
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US10195092B2 (en) 2014-03-06 2019-02-05 The Procter & Gamble Company Multi-component topsheets
US10206826B2 (en) 2014-03-06 2019-02-19 The Procter & Gamble Company Three-dimensional substrates
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