CN111771021A - Laminated nonwoven fabric - Google Patents

Laminated nonwoven fabric Download PDF

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Publication number
CN111771021A
CN111771021A CN201980015565.8A CN201980015565A CN111771021A CN 111771021 A CN111771021 A CN 111771021A CN 201980015565 A CN201980015565 A CN 201980015565A CN 111771021 A CN111771021 A CN 111771021A
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China
Prior art keywords
nonwoven fabric
laminated nonwoven
laminated
polyolefin resin
layer
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Granted
Application number
CN201980015565.8A
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Chinese (zh)
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CN111771021B (en
Inventor
西村�一
阪上好
中野洋平
羽根亮一
西村诚
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Toray Industries Inc
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Toray Industries Inc
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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/593—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives to layered webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/007—Addition polymers
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A40/00—Adaptation technologies in agriculture, forestry, livestock or agroalimentary production
    • Y02A40/10—Adaptation technologies in agriculture, forestry, livestock or agroalimentary production in agriculture
    • Y02A40/25—Greenhouse technology, e.g. cooling systems therefor

Abstract

The invention provides a nonwoven fabric having both water resistance and flexibility and excellent processability, the nonwoven fabric being composed of fibers containing a polyolefin resin. The present invention relates to a laminated nonwoven fabricA fabric comprising a laminated nonwoven fabric obtained by laminating a spunbonded nonwoven fabric comprising fibers of a polyolefin resin (A) and a meltblown nonwoven fabric comprising fibers of a polyolefin resin (B), wherein the melt flow rate of the laminated nonwoven fabric is 80 to 850g/10 min, the surface roughness (SMD) of at least one side by the KES method is 1.0 to 2.6 [ mu ] m, and the water pressure resistance per unit area weight is 15mmH2O/(g/m2) The above.

Description

Laminated nonwoven fabric
Technical Field
The present invention relates to a laminated nonwoven fabric which is composed of fibers containing a polyolefin resin, has excellent water resistance and flexibility, and has excellent moldability for use as a building material.
Background
In recent years, nonwoven fabrics are used in various applications, and are expected to grow in the future. The nonwoven fabric is used in a wide range of applications such as industrial materials, civil engineering materials, construction materials, living materials, agricultural materials, sanitary materials, and medical materials.
As the use of nonwoven fabrics, the use of building materials is attracting attention. In recent buildings such as wooden houses, a ventilation layer process is becoming popular in which a ventilation layer is provided between an outer wall material and a heat insulating material, and moisture penetrating into the wall body is discharged to the outside through the ventilation layer. In this breathable layer process, a spunbond nonwoven fabric is used as a house wrapping material for a moisture-permeable waterproof sheet (which has both waterproofness for preventing rainwater from penetrating from the outside of a building and moisture permeability for allowing moisture generated in a wall to escape to the outside).
The spunbond nonwoven fabric has a characteristic of excellent moisture permeability due to its structure, but has a problem of poor water resistance. Therefore, a moisture-permeable waterproof sheet is produced by laminating a spunbond nonwoven fabric and a film having excellent water resistance and is used as a house packaging material.
House packaging materials are constructed by fixing them to a base with a staple (also referred to as a nail gun pin or a staple), and are required to have excellent long-term durability, weather resistance under high-temperature and low-temperature conditions, durability (hydrolysis resistance) capable of withstanding long-term use, and excellent moldability during construction.
In order to achieve a good balance between moisture permeability and water resistance, a moisture-permeable waterproof sheet for use in such house packaging materials has been proposed, which uses a single fiber having a diameter of 3 to 28 μm and a weight per unit area of 5 to 50g/m2And a film having a thickness of 7 to 60 μm formed of a block copolyester having a hard segment and a soft segment is laminated on the nonwoven fabric (see patent document 1).
Documents of the prior art
Patent document
Patent document 1: japanese patent No. 3656837
Disclosure of Invention
Problems to be solved by the invention
However, since the conventional house wrap material is a laminate of a nonwoven fabric and a film, there is a problem that the sheet is hard and has poor moldability. The sheet hardness is due to the film, and it is effective to reduce the ratio of the film to be bonded, but there is a limit to reduce the ratio of the film from the viewpoint of water resistance.
The present invention has been made in view of the above circumstances, and an object thereof is to provide a nonwoven fabric having both water resistance and flexibility without using a film conventionally used, and having excellent moldability.
Means for solving the problems
The inventors of the present application have made intensive studies to achieve the above object, and as a result, have obtained the following findings: the mechanical properties of the laminated nonwoven fabric can be improved by using a laminated nonwoven fabric in which a spunbond nonwoven fabric layer composed of fibers containing a polyolefin resin and a meltblown nonwoven fabric layer composed of fibers containing a polyolefin resin are laminated, and by appropriately controlling the flowability of the fibers constituting each nonwoven fabric layer. It has also been found that the laminated nonwoven fabric can have a targeted high level of water resistance, flexibility, and processability.
The present invention has been made based on the above-described findings, and the present invention provides the following inventions.
The laminated nonwoven fabric of the present invention is a laminated nonwoven fabric in which a spunbond nonwoven fabric layer composed of fibers containing a polyolefin resin (A) and a meltblown nonwoven fabric layer composed of fibers containing a polyolefin resin (B) are laminated, and has a melt flow rate of 80 to 850g/10 min, a surface roughness SMD of 1.0 to 2.6 [ mu ] m by the KES method on at least one side, and a water pressure resistance of 15mmH per unit area weight2O/(g/m2) The above.
According to a preferred embodiment of the laminated nonwoven fabric of the present invention, the average filament diameter of the fibers comprising the polyolefin resin (a) constituting the spunbond nonwoven fabric layer is 6.5 to 11.9 μm.
According to a preferred embodiment of the laminated nonwoven fabric of the present invention, the content of the meltblown nonwoven fabric layer is 1 mass% or more and 15 mass% or less with respect to the mass of the laminated nonwoven fabric.
In a preferred embodiment of the laminated nonwoven fabric of the present invention, the average friction coefficient MIU of at least one surface of the laminated nonwoven fabric by the KES method is 0.1 to 0.5.
According to a preferred embodiment of the laminated nonwoven fabric of the present invention, the variation MMD of the average friction coefficient by the KES method on at least one side is 0.008 or less.
According to a preferred embodiment of the laminated nonwoven fabric of the present invention, the polyolefin resin (a) contains a fatty acid amide compound having 23 to 50 carbon atoms.
According to a preferred embodiment of the laminated nonwoven fabric of the present invention, the amount of the fatty acid amide compound added is 0.01 to 5.0% by mass.
According to a preferred embodiment of the laminated nonwoven fabric of the present invention, the fatty acid amide compound is ethylene bisstearamide.
Effects of the invention
According to the present invention, a laminated nonwoven fabric composed of fibers containing a polyolefin resin, having excellent water resistance and flexibility, and having excellent processability can be obtained. Due to these characteristics, the laminated nonwoven fabric of the present invention can be suitably used for building materials such as moisture-permeable waterproof sheets.
The laminated nonwoven fabric of the present invention has excellent water resistance, and therefore, when used as a moisture-permeable waterproof sheet, can realize a lower unit area weight than a conventional laminated nonwoven fabric.
In addition, the present invention can be used for applications requiring high water resistance, for which conventional laminated nonwoven fabrics are difficult to apply, in addition to reducing the weight of the film to be bonded for the purpose of water resistance.
Further, since the flexibility is excellent, when the composition is used for building materials, wrinkles are not easily generated particularly in a bonding step, and the moldability is good.
Detailed Description
The laminated nonwoven fabric is a laminated nonwoven fabric in which a spunbonded nonwoven fabric layer composed of fibers containing a polyolefin resin (A) and a meltblown nonwoven fabric layer composed of fibers containing a polyolefin resin (B) are laminated, the melt flow rate of the laminated nonwoven fabric is 80-850 g/10 min, the surface roughness SMD of at least one surface by the KES method (Kawabata Evaluation System) is 1.0-2.6 [ mu ] m, and the water pressure resistance per unit area weight is 15mmH2O/(g/m2) The above. The details thereof will be described below.
[ polyolefin resin (A) and polyolefin resin (B) ]
The melt flow rate (abbreviated as MFR in some cases) indicating the flow characteristics of the polyolefin resin (a) constituting the fibers of the spunbond nonwoven fabric layer and the polyolefin resin (B) constituting the fibers of the meltblown nonwoven fabric layer according to the present invention is a value measured by ASTM D1238 (method a).
In addition, according to the above specification, for example: the polypropylene was measured under a load of 2.16kg at a temperature of 230 ℃ and the polyethylene was measured under a load of 2.16kg at a temperature of 190 ℃.
First, the polyolefin resin (A) constituting the fibers of the spunbonded nonwoven fabric layer preferably has an MFR of 75 to 850g/10 min. By setting the MFR to 75 to 850g/10 min, more preferably 120 to 600g/10 min, and still more preferably 155 to 400g/10 min, the fiber thinning behavior when spinning the spunbond nonwoven fabric layer is stabilized, and even if the fiber is drawn at a high spinning speed for improving productivity, stable spinning can be achieved. Further, by stabilizing the thinning behavior, the yarn chattering is suppressed, and unevenness in collecting the yarn into a sheet shape is less likely to occur. Further, since the drawing can be stably performed at a high spinning speed, the oriented crystallization of the fiber can be performed to produce a fiber having high mechanical strength.
The polyolefin resin (B) constituting the fibers of the meltblown nonwoven fabric layer preferably has an MFR of 200 to 2500g/10 min. By setting the MFR to preferably 200 to 2500g/10 min, more preferably 400 to 2000g/10 min, and even more preferably 600 to 1500g/10 min, stable spinning is facilitated, and a fiber containing the polyolefin resin (B) at a level of several μm can be obtained.
Examples of the polyolefin resins (a) and (B) used in the present invention include polyethylene resins and polypropylene resins.
Examples of the polyethylene resin include homopolymers of ethylene and copolymers of ethylene and various α -olefins.
The polypropylene resin includes, for example, homopolymers of propylene and copolymers of propylene and various α -olefins, and is particularly preferably used from the viewpoint of spinning property and strength characteristics.
The proportion of the propylene homopolymer in the polyolefin-based resin used in the present invention is preferably 60% by mass or more, more preferably 70% by mass or more, and still more preferably 80% by mass or more. By setting the above range, the strength can be improved while maintaining good spinning properties.
The polyolefin resin used in the present invention may be a mixture of two or more kinds, and a resin composition containing another polyolefin resin, a thermoplastic elastomer, or the like may be used. It is needless to say that the MFR of the polyolefin resin (a) and/or the polyolefin resin (B) can be adjusted by mixing two or more resins having different MFRs at an arbitrary ratio. In this case, the MFR of the resin mixed with the main polyolefin resin is preferably 10 to 1000g/10 min, more preferably 20 to 800g/10 min, and still more preferably 30 to 600g/10 min. By setting in this way, local occurrence of viscosity unevenness, unevenness in fineness, and deterioration in spinning property in the polyolefin resin to be mixed can be prevented.
In the laminated nonwoven fabric of the present invention, the ratio of MFR (MFR) of the polyolefin resin (a) and the polyolefin resin (B) constituting the spunbond nonwoven fabric and the meltblown nonwoven fabric, respectivelyB/MFRA) Preferably 1 to 13, and more preferably 1.5 to 12. By making the ratio of MFR (MFR)B/MFRA) In the above range, the meltblown nonwoven fabric can be easily bonded to the spunbond nonwoven fabric when laminated, and the effect of improving physical properties such as peel strength can be obtained.
Additives such as antioxidants, weather stabilizers, light stabilizers, antistatic agents, antifogging agents, antiblocking agents, lubricants, nucleating agents, and pigments, or other polymers, which are generally used, may be added to the polyolefin resin used in the present invention as needed within a range not to impair the effects of the present invention.
In spinning fibers described later, in order to prevent local viscosity unevenness from occurring, to make the fineness of the fibers uniform, and to further refine the fiber diameter as described later, it is also considered to decompose the resin used to adjust MFR. However, it is preferable that, for example, a peroxide, particularly a radical agent such as a dialkyl peroxide, is not added. When this method is used, viscosity unevenness locally occurs, the fineness becomes uneven, and it is difficult to sufficiently reduce the fiber diameter, and in addition, the spinnability may be deteriorated due to the viscosity unevenness and bubbles generated by the decomposed gas.
The melting point of the polyolefin resin used in the present invention is preferably 80 to 200 ℃, more preferably 100 to 180 ℃, and still more preferably 120 to 180 ℃. By setting the melting point to preferably 80 ℃ or higher, more preferably 100 ℃ or higher, and further preferably 120 ℃ or higher, practical heat resistance can be easily obtained. Further, by setting the melting point to preferably 200 ℃ or lower, more preferably 180 ℃ or lower, the yarn discharged from the spinneret is easily cooled, and fusion of fibers is suppressed, and stable spinning is easily performed.
In order to improve the sliding property and flexibility of the laminated nonwoven fabric of the present invention, it is preferable that the polyolefin resin (a) constituting the spunbond nonwoven fabric contains a fatty acid amide compound having 23 to 50 carbon atoms.
By making the number of carbon atoms of the fatty acid amide compound be preferably 23 or more, more preferably 30 or more, excessive exposure of the fatty acid amide compound to the fiber surface can be suppressed, and excellent spinning properties and processing stability can be achieved, and high productivity can be maintained. On the other hand, when the number of carbon atoms of the fatty acid amide compound is preferably 50 or less, more preferably 42 or less, the fatty acid amide compound is easily transferred to the fiber surface, and the non-woven laminate fabric can be provided with slidability and flexibility.
Examples of the fatty acid amide compound having 23 to 50 carbon atoms used in the present invention include saturated fatty acid monoamide compounds, saturated fatty acid diamide compounds, unsaturated fatty acid monoamide compounds, and unsaturated fatty acid diamide compounds.
Specifically, examples of the fatty acid amide compound having 23 to 50 carbon atoms include tetracosanoic acid amide, hexacosanoic acid amide, octacosanoic acid amide, eicosenoic acid amide, tetracosanoic acid amide, ethylene bis-lauric acid amide, methylene bis-lauric acid amide, ethylene bis-stearic acid amide, ethylene bis-hydroxystearic acid amide, ethylene bis-behenic acid amide, hexamethylene bis-stearic acid amide, hexamethylene bis-behenic acid amide, hexamethylene hydroxy stearic acid amide, distearyl adipic acid amide, distearyl sebacic acid amide, ethylene bis-oleic acid amide, ethylene bis-erucic acid amide, and hexamethylene bis-oleic acid amide, and a plurality of these may be used in combination.
In the present invention, among these fatty acid amide compounds, ethylene bisstearic acid amide which is a saturated fatty acid diamide compound is particularly preferably used. The ethylene bis stearamide has excellent thermal stability, and therefore can be melt-spun, and the polyolefin resin (a) containing the ethylene bis stearamide can maintain high productivity. Further, the slippage of the fibers is improved, and the fibers can be uniformly dispersed at the time of collection, which contributes to the improvement of the smoothness of the nonwoven fabric. Therefore, when a nonwoven fabric is produced, the pore diameter of the nonwoven fabric can be reduced, and a laminated nonwoven fabric having excellent water resistance and flexibility can be obtained.
In the present invention, the amount of the fatty acid amide compound added to the polyolefin resin (a) is preferably 0.01 to 5.0 mass%. The amount of the fatty acid amide compound added is preferably 0.01 to 5.0% by mass, more preferably 0.1 to 3.0% by mass, and even more preferably 0.1 to 1.0% by mass, whereby appropriate slidability and flexibility can be imparted while maintaining the spinning property.
The amount added here means: the mass percentage of the fatty acid amide compound added to the whole polyolefin resin (a) constituting the spunbonded nonwoven fabric layer constituting the laminated nonwoven fabric of the present invention. For example, when a fatty acid amide compound is added to a sheath component constituting a core-sheath composite fiber as described later, the addition ratio with respect to the total amount of the core-sheath component is also calculated.
Examples of a method for measuring the amount of the fatty acid amide compound added to the polyolefin resin-containing fibers include a method in which the additive is extracted from the fibers with a solvent and then quantitatively analyzed by liquid chromatography mass spectrometry (LS/MS) or the like. In this case, the extraction solvent is a solvent appropriately selected depending on the type of the fatty acid amide compound, and for example, in the case of ethylene bis-stearamide, a chloroform-methanol mixed solution or the like is used as an example.
[ fibers ]
The average filament diameter of the fibers comprising the polyolefin resin (A) constituting the spunbonded nonwoven fabric layer according to the present invention is preferably 6.5 to 11.9. mu.m. By setting the average single fiber diameter to preferably 6.5 μm or more, more preferably 7.5 μm or more, and further preferably 8.4 μm or more, it is possible to prevent a decrease in spinnability and stably form a nonwoven fabric layer having good quality. On the other hand, by setting the average filament diameter to preferably 11.9 μm or less, more preferably 11.2 μm or less, and further preferably 10.6 μm or less, it is possible to obtain a laminated nonwoven fabric having excellent water resistance which is high in flexibility and uniformity and can withstand practical use even when the content ratio of the meltblown nonwoven fabric layer is reduced.
In the present invention, the average single fiber diameter (μm) of the fibers including the polyolefin resin (a) constituting the spunbond nonwoven fabric layer described above is calculated by the following procedure.
(1) The polyolefin resin (a) was melt-spun, drawn and stretched by an ejector, and the nonwoven fabric layer was collected on a web.
(2) 10 small samples (100X 100mm) were taken randomly.
(3) A surface photograph was taken 500 to 1000 times by microscope, and the width of 10 polyolefin fibers each and 100 polyolefin fibers in total was measured from each sample.
(4) The average single fiber diameter (. mu.m) was calculated from the average of the measured values of 100 fibers.
On the other hand, the average filament diameter of the fibers comprising the polyolefin resin (B) constituting the melt-blown nonwoven fabric according to the present invention is preferably in the range of 0.1 to 8.0 μm, and more preferably in the range of 0.4 to 7.0 μm.
In the present invention, the average filament diameter (μm) of the fibers including the polyolefin resin (B) constituting the meltblown nonwoven fabric layer is calculated by the following procedure.
(1) The polyolefin resin (B) was melt-spun, and after the polyolefin resin (B) was thinned with hot air, the nonwoven fabric layer was collected on a net.
(2) 10 small samples (100X 100mm) were taken randomly.
(3) A surface photograph was taken 500 to 2000 times with a microscope, and the width of 10 fibers was measured for each sample, and the total of 100 fibers was measured.
(4) The average single fiber diameter (. mu.m) was calculated from the average of the measured values of 100 fibers.
In the present invention, the polyolefin-based resin may be combined with a composite fiber. Examples of the composite form of the composite fiber include a concentric core-sheath type, an eccentric core-sheath type, and a sea-island type. Among them, a concentric core-sheath type composite form is preferable in terms of excellent spinnability and the ability to uniformly bond the fibers to each other by thermal bonding because a low-melting component is blended in the sheath component.
[ non-woven fabrics layer ]
The water resistance of the laminated nonwoven fabric of the present invention can be controlled by utilizing the properties of the spunbond nonwoven fabric layer and the meltblown nonwoven fabric layer constituting the laminated nonwoven fabric. The water resistance of the spunbond nonwoven fabric layer can be controlled by the average fiber diameter of the constituent fibers and the dispersibility of the fibers on the surface of the nonwoven fabric layer. The water resistance of the meltblown nonwoven fabric layer can be controlled by the average fiber diameter of the constituent fibers, the mass ratio of the constituent fibers in the laminated nonwoven fabric, and the degree of fusion between the fibers constituting the meltblown nonwoven fabric layer.
[ laminated nonwoven Fabric ]
In the laminated nonwoven fabric of the present invention, it is important to laminate a spunbond nonwoven fabric layer and a meltblown nonwoven fabric layer. With such a configuration, water resistance of a level or more required as a nonwoven fabric for house wrap can be provided.
The laminated nonwoven fabric of the present invention has an MFR of 80 to 850g/10 min. By setting the MFR to 80 to 850g/10 min, preferably 120 to 600g/10 min, and more preferably 155 to 400g/10 min, the thinning behavior of the fibers when the spunbond nonwoven fabric layer is spun is stabilized, and even if the fiber is drawn at a high spinning speed for improving productivity, stable spinning can be achieved. Further, by stabilizing the thinning behavior of the spunbond fibers, the yarn-shaking is suppressed, and unevenness in collecting the spunbond fibers into a sheet shape is less likely to occur. Further, the ratio of MFR (MFR) of the spunbonded nonwoven fabric to MFR of the meltblown nonwoven fabricB/MFRA) Reduced in size on spunbonded non-woven fabricsThe melt-blown nonwoven fabric is easily bonded when laminated, and the effect of improving physical properties such as peel strength can be obtained.
The MFR of the laminated nonwoven fabric of the present invention is measured by ASTM D1238 (method a). According to this standard, for example, there are defined: the polypropylene was measured under a load of 2.16kg at a temperature of 230 ℃ and the polyethylene was measured under a load of 2.16kg at a temperature of 190 ℃. In the case where a plurality of resins are used, such as a polyolefin resin constituting the spunbond nonwoven fabric and a polyolefin resin constituting the meltblown nonwoven fabric, the measurement is performed at the highest temperature among the measurement temperatures of the respective polyolefin resins.
The laminated nonwoven fabric of the present invention has a water pressure resistance of 15mmH per unit area weight2O/(g/m2) The above is important. By setting the water pressure resistance per unit area weight to 15mmH2O/(g/m2) Above, more preferably 17mmH2O/(g/m2) As described above, a laminated nonwoven fabric having excellent flexibility while maintaining practical water resistance can be obtained, and a low unit area weight of the laminated nonwoven fabric can be realized. The upper limit of the water pressure resistance is not particularly limited, but the upper limit of the water pressure resistance can be up to 30mmH while maintaining the structure of the nonwoven fabric2O/(g/m2)。
The water pressure resistance per unit weight of the laminated nonwoven fabric of the present invention is measured according to JISL1092 (2009) "7.1.1A method (low water pressure method)" in the following procedure.
(1) From the laminated nonwoven fabric, 5 test pieces of 150mm × 150mm width were sampled at equal intervals in the width direction of the laminated nonwoven fabric.
(2) The test piece was set in a jig of a measuring apparatus (the portion of the test piece contacting water was 100 cm)2Size of (d).
(3) The water level was raised at a rate of 600 mm/min. + -. 30mm/min by using a leveling device filled with water, and the water level at the time of discharging water from 3 on the back side of the test piece was measured in mm units.
(4) The above measurement was carried out using 5 test pieces, and the average value thereof was set as the water pressure resistance.
In the present invention, the smoothness of the surface and the degree of touch of the skin of the laminated nonwoven fabric are evaluated by the surface roughness SMD by the KES method, the average friction coefficient MIU by the KES method, and the variation MMD of the average friction coefficient by the KES method.
It is important that the surface roughness SMD of at least one surface of the laminated nonwoven fabric of the present invention by the KES method is 1.0 to 2.6 μm. By setting the surface roughness SMD by the KES method to 1.0 μm or more, preferably 1.3 μm or more, more preferably 1.6 μm or more, and further preferably 2.0 μm or more, it is possible to prevent deterioration of hand and deterioration of flexibility due to excessive densification of the fiber.
On the other hand, by setting the surface roughness SMD by the KES method to 2.6 μm or less, preferably 2.5 μm or less, more preferably 2.4 μm or less, and further preferably 2.3 μm or less, it is possible to produce a laminated nonwoven fabric having a smooth surface, a small rough feeling, and an excellent skin touch. The surface roughness SMD based on the KES method can be controlled by appropriately adjusting the average single fiber diameter, the MFR of the laminated nonwoven fabric, and the like.
In the present invention, the surface roughness SMD based on the KES method uses a value measured in the following manner.
(1) 3 test pieces of 200mm × 200mm width were collected from the laminated nonwoven fabric at equal intervals in the width direction of the laminated nonwoven fabric.
(2) The test piece was set on a sample table.
(3) The surface of the test piece was scanned with a contact (raw material: 0.5mm piano wire, contact length: 5mm) for measuring surface roughness to which a load of 10gf was applied, and the average variation of the uneven shape of the surface was measured.
(4) The above measurements were performed in the longitudinal direction (longitudinal direction of nonwoven fabric) and the transverse direction (width direction of nonwoven fabric) of all the test pieces, and the average deviations at 6 points in total were averaged, and the second decimal place was rounded off to obtain the surface roughness SMD (μm).
The laminated nonwoven fabric of the present invention preferably has an average friction coefficient MIU of 0.1 to 0.5 on at least one surface thereof by a KES method. By setting the average friction coefficient MIU to be preferably 0.5 or less, more preferably 0.45 or less, and further preferably 0.4 or less, the slidability of the nonwoven fabric surface is improved, and a laminated nonwoven fabric having a more satisfactory texture can be produced.
On the other hand, by setting the average friction coefficient MIU to be preferably 0.1 or more, more preferably 0.15 or more, and further preferably 0.2 or more, it is possible to prevent deterioration of spinnability due to excessive addition of a lubricant or deterioration of texture due to slippage of a yarn when the yarn is collected on a web. The average friction coefficient MIU by the KES method can be controlled by appropriately adjusting the average single fiber diameter or MFR of the laminated nonwoven fabric, or the like, or can be controlled by adding a lubricant to the polyolefin-based resin.
The variation MMD of the average friction coefficient by the KES method in at least one surface of the laminated nonwoven fabric of the present invention is preferably 0.008 or less. The variation MMD of the average friction coefficient is preferably 0.008 or less, more preferably 0.0075 or less, and further preferably 0.0070 or less, whereby the roughness of the surface of the laminated nonwoven fabric can be further reduced.
The variation MMD of the average friction coefficient by the KES method can be controlled by appropriately adjusting the average single fiber diameter, the MFR of the laminated nonwoven fabric, or the like, or can be controlled by adding a lubricant to the polyolefin resin.
In the present invention, the average friction coefficient MIU and the variation MMD of the average friction coefficient by the KES method are values measured as follows.
(1) 3 test pieces of 200mm × 200mm width were collected from the laminated nonwoven fabric at equal intervals in the width direction of the laminated nonwoven fabric.
(2) The test piece was set on a sample table.
(3) A contact friction head (raw material: 0.5mm diameter piano wire (20 parallel) and contact area: 1 cm) to which a load of 50gf was applied was used2) The surface of the test piece was scanned to determine the average coefficient of friction.
(4) The above measurements were performed in the longitudinal direction (longitudinal direction of nonwoven fabric) and the transverse direction (width direction of nonwoven fabric) of all the test pieces, and the average deviation of 6 points in total was averaged, and the fourth decimal place was rounded off to obtain the average friction coefficient MIU. Further, the variation of the average friction coefficient at the total of 6 points described above was further averaged, and the fourth place after the decimal point was rounded off to be the variation MMD of the average friction coefficient.
In the present invention, the flexibility of the laminated nonwoven fabric was evaluated by the air permeability and the sensory test.
The laminated nonwoven fabric of the present invention preferably has an air permeability per unit area weight of 0.2 to 10cc/cm2Second/(g/m)2). By making the air permeability per unit area weight preferably 8cc/cm2Second/(g/m)2) Less, more preferably 6cc/cm2Second/(g/m)2) The lower, more preferably 4cc/cm2Second/(g/m)2) As described below, the air permeability required for house packaging applications and the like can be sufficiently satisfied.
On the other hand, the air permeability per unit area weight is preferably set to 0.2cc/cm2Second/(g/m)2) Above, more preferably 0.4cc/cm2Second/(g/m)2) Above, more preferably 0.6cc/cm2Second/(g/m)2) This can prevent the spunbond nonwoven fabric from being excessively densified and from deteriorating flexibility. The air permeability can be adjusted by the weight per unit area, the fineness of single fibers, the weight per unit area of the meltblown layer, and the thermal compression bonding conditions (compression bonding ratio, temperature, and line pressure).
In the present invention, the air permeability per unit area weight of the laminated nonwoven fabric is measured by the following procedure in accordance with "6.8.1 Frazir type (Frazir) method" of JIS L1913 (2010).
(1) A test piece of 80 cm. times.100 cm was cut out from the laminated nonwoven fabric.
(2) The measurement was performed at any 20 points in the test piece under a pressure of 125Pa by a barometer.
(3) The average value at 20 points is calculated by rounding the second decimal place.
(4) The calculated air permeation volume (cc/cm)2Second) divided byWeight per unit area (g/m)2)。
The laminated nonwoven fabric of the present invention is in the following form: the content of the meltblown nonwoven fabric layer is preferably 1 mass% or more and 15 mass% or less, and more preferably 2 mass% or more and 10 mass% or less, based on the mass of the laminated nonwoven fabric. By making the content of the meltblown nonwoven fabric layer preferably 1 mass% or more, more preferably 2 mass% or more, practical water resistance can be provided. Further, by making the content of the meltblown nonwoven fabric layer preferably 5 mass% or less, more preferably 10 mass% or less, the specific hardness of the meltblown nonwoven fabric can be reduced.
Further, by making the content of the spunbond nonwoven layer in the laminated nonwoven fabric preferably more than 85 mass% and less than 99 mass%, a laminated nonwoven fabric excellent in flexibility and processability can be obtained.
In the present invention, the content ratio of the meltblown nonwoven fabric layer is a value measured by the following procedure.
(1) 3 test pieces 100mm × 100mm in width were sampled at equal intervals in the width direction of the laminated nonwoven fabric.
(2) Only the non-crimped portions of the laminated nonwoven fabric were collected.
(3) The quality of the collected test piece and the quality of the melt-blown nonwoven fabric collected from the test piece were measured.
(4) The content ratio of the meltblown nonwoven fabric in the laminated nonwoven fabric was calculated.
The weight per unit area of the laminated nonwoven fabric of the present invention is preferably 10 to 100g/m2. By making the weight per unit area preferably 10g/m2Above, more preferably 13g/m2More preferably 15g/m or more2As described above, a laminated nonwoven fabric having a practical mechanical strength can be obtained.
On the other hand, the weight per unit area is preferably 100g/m2Below, more preferably 50g/m2The lower, more preferably 30g/m2When used as a house packing material, the weight of the material is suitable for a worker to handle the material during construction, and the material can be used during constructionThe laminated nonwoven fabric has excellent handleability. Further, when used for other applications, a laminated nonwoven fabric having excellent handleability can be obtained.
In the present invention, the weight per unit area of the laminated nonwoven fabric is a value measured by the following procedure in accordance with "mass per unit area of 6.2" of JIS L1913 (2010).
(1) 3 test pieces of 20 cm. times.25 cm were collected from each 1m width of the specimen.
(2) The respective masses (g) in the standard state were weighed.
(3) At a rate of 1m2Mass (g/m) of2) The average value thereof is shown.
The thickness of the laminated nonwoven fabric of the present invention is preferably 0.05 to 1.5 mm. By making the thickness of the nonwoven fabric preferably 0.05 to 1.5mm, more preferably 0.08 to 1.0mm, and even more preferably 0.10 to 0.8mm, the nonwoven fabric has flexibility and appropriate cushioning properties, and when used as a house packaging material, the nonwoven fabric becomes a weight suitable for a worker to handle during construction, and the nonwoven fabric does not have too strong rigidity, and a laminated nonwoven fabric having excellent workability during construction can be produced.
In the present invention, the thickness (mm) of the laminated nonwoven fabric is a value measured by the following procedure in accordance with JIS L1906 (2000) "5.1".
(1) The thickness of the nonwoven fabric was measured at 10 points per 1m at 0.01mm intervals in the width direction under a load of 10kPa using a 10 mm-diameter pressure head.
(2) The third position after the decimal point of the average value at 10 above is rounded.
The apparent density of the laminated nonwoven fabric is preferably 0.05 to 0.3g/cm3. By making the apparent density preferably 0.3g/cm3Less than, more preferably 0.25g/cm3The concentration is preferably 0.20g/cm or less3As described below, the fibers are densely packed, and the flexibility of the laminated nonwoven fabric can be prevented from being impaired.
On the other hand, the apparent density is preferably set to 0.05g/cm3Above, more preferably 0.08g/cm3The aboveMore preferably 0.10g/cm3As described above, the occurrence of fuzz and delamination is suppressed, and a laminated nonwoven fabric having practical strength, flexibility, and handleability can be obtained.
In the present invention, the apparent density (g/cm)3) The weight per unit area and the thickness before rounding described above were calculated based on the following formulas, and the third digit after the decimal point was rounded.
Apparent density (g/cm)3) Weight per unit area (g/m)2)]/[ thickness (mm)]×10-3。
The laminated nonwoven fabric of the present invention preferably has a stress at 5% elongation per unit weight (hereinafter, sometimes referred to as a 5% modulus per unit weight) of 0.06 to 0.33(N/25 mm)/(g/m)2) More preferably 0.13 to 0.30(N/25 mm)/(g/m)2) More preferably 0.20 to 0.27(N/25 mm)/(g/m)2). By setting the above range, a spun-bonded nonwoven fabric having softness and excellent touch feeling can be obtained while maintaining strength that can be used practically.
In the present invention, the stress at 5% elongation of the weight per unit area of the laminated nonwoven fabric is measured by the following procedure in accordance with "6.3 tensile strength and elongation (ISO method)" of JIS L1913 (2010).
(1) 3 test pieces of 25mm × 300mm were taken per 1m width of the nonwoven fabric in each of the longitudinal direction (longitudinal direction of the nonwoven fabric) and the transverse direction (width direction of the nonwoven fabric).
(2) The test pieces were set in a tensile testing machine at a clamping interval of 200 mm.
(3) A tensile test was conducted at a tensile rate of 100 mm/min, and the stress at 5% elongation (5% modulus) was measured.
(4) The average value of the 5% modulus in the machine direction and the transverse direction measured from each test piece was obtained, the 5% modulus per unit area weight was calculated based on the following formula, and the third decimal place was rounded.
5% modulus per weight of area ((N/25 mm)/(g/m)2) Not [ < 5% modulus mean value (N/25mm) ]]Weight per unit area (g/m)2)。
[ method for producing laminated nonwoven Fabric ]
Next, preferred embodiments of the method for producing the laminated nonwoven fabric of the present invention will be specifically described.
The laminated nonwoven fabric of the present invention is a laminated nonwoven fabric including nonwoven fabrics produced by a spunbond (S) method and a meltblown (M) method. The method for producing the laminated nonwoven fabric of the present invention may be carried out by any method as long as the spunbond nonwoven fabric layer and the meltblown nonwoven fabric layer can be laminated. For example, it is possible to employ: a method in which a spunbond nonwoven fabric layer and a meltblown nonwoven fabric layer are fused together after fibers formed by a meltblowing method are directly deposited on the nonwoven fabric layer obtained by a spunbonding method to form a meltblown nonwoven fabric layer; a method of superposing a spunbonded nonwoven fabric layer and a meltblown nonwoven fabric layer and fusing the two nonwoven fabric layers by heating and pressurizing; a method of bonding a spunbond nonwoven fabric layer and a meltblown nonwoven fabric layer with an adhesive such as a hot melt adhesive or a solvent-based adhesive; and so on. From the viewpoint of productivity, a preferred embodiment is a method of directly forming a meltblown nonwoven fabric layer on a spunbond nonwoven fabric layer.
In addition, the spunbonded nonwoven fabric layer (S) and the meltblown nonwoven fabric layer (M) may be laminated to form a structure of SM, SMs, SMMS, SSMMS, and SMSMS according to the purpose.
In the case of a spunbond nonwoven fabric layer, first, a molten thermoplastic resin (polyolefin resin) is spun as long fibers from a spinneret, and the spun filaments are drawn and stretched by compressed air through an ejector, and then the fibers are collected on a moving web to produce a nonwoven fabric layer.
The shape of the spinneret and the ejector is not particularly limited, and various shapes such as a circle and a rectangle can be used. Among them, a combination of a rectangular spinneret and a rectangular ejector is preferably used in view of a small amount of compressed air, excellent energy cost, less possibility of fusion or friction between yarns, and easy opening of yarns.
In the present invention, a polyolefin resin is melted in an extruder, metered, and supplied to a spinneret, and spun as a long fiber. The spinning temperature when melting and spinning the polyolefin resin is preferably 200 to 270 ℃, more preferably 210 to 260 ℃, and still more preferably 220 to 250 ℃. By setting the spinning temperature within the above range, a stable molten state is formed, and excellent spinning stability can be obtained.
The spun sliver of long fibers is then cooled. Examples of methods for cooling the spun sliver include: a method of forcibly blowing cold air to a sliver; a method of natural cooling by using the ambient temperature around the sliver; and a method of adjusting the distance between the spinneret and the ejector; etc., or a combination of these methods can be employed. The cooling conditions may be appropriately adjusted and used in consideration of the discharge amount per one hole of the spinneret, the spinning temperature, the atmospheric temperature, and the like.
Then, the cooled and solidified sliver is drawn and stretched by compressed air injected from an injector. The spinning speed is preferably 3,000 to 6,500 m/min, more preferably 3,500 to 6,500 m/min, and still more preferably 4,000 to 6,500 m/min. By setting the spinning speed to 3,000 to 6,500 m/min, the productivity is high, and the oriented crystallization of the fiber advances, so that a long fiber having high strength can be obtained. In general, when the spinning speed is increased, the spinnability is deteriorated and a stable yarn cannot be produced, but by using a polyolefin resin having an MFR within a specific range as described above, a desired polyolefin fiber can be stably spun.
Then, the long fibers obtained were collected on a moving web to prepare a nonwoven fabric layer. In the present invention, it is also preferable that the nonwoven fabric layer is temporarily bonded to the web by contacting the web with a hot flat roll from one side thereof. This prevents the surface layer of the nonwoven fabric layer from being turned over or blown off during the web conveyance, thereby preventing deterioration of the texture and improving the conveyance performance from the collection of the sliver to the thermocompression bonding.
Next, the meltblown nonwoven fabric can be formed by a conventionally known method. First, a polyolefin resin is melted in an extruder and supplied to a spinneret, and a nonwoven fabric layer is formed on a collecting web after a yarn extruded from the spinneret is thinned by blowing hot air to the yarn. In the melt blowing method, fine fibers of several μm can be easily obtained without requiring a complicated process, and high water resistance can be easily achieved.
Next, the obtained spunbond nonwoven fabric layer and meltblown nonwoven fabric layer are laminated and thermally bonded to each other, thereby obtaining a desired laminated nonwoven fabric.
The method for thermally bonding the nonwoven fabric layer is not particularly limited, and examples thereof include: a method of performing thermal bonding by various rollers such as a hot embossing roller having engraved (uneven) portions on the upper and lower pair of roller surfaces, a hot embossing roller having a combination of a roller having a flat (smooth) one roller surface and a roller having engraved (uneven) portions on the other roller surface, and a hot calender roller having a combination of a pair of upper and lower flat (smooth) rollers; ultrasonic bonding in which the heat is thermally welded by ultrasonic vibration of a horn (horn).
Among them, from the viewpoint of excellent productivity, the ability to impart strength to a part of the thermally-bonded part, and the maintenance of the texture and the touch of the nonwoven fabric at the non-bonded part, it is preferable to use a heat embossing roll in which engraving (uneven portions) is performed on the upper and lower pair of roll surfaces, or a heat embossing roll formed by a combination of a roll having a flat (smooth) roll surface and a roll having engraving (uneven portions) performed on the other roll surface.
As a surface material of the heat embossing roll, in order to obtain a sufficient thermocompression bonding effect and prevent the engraved portions (uneven portions) of one embossing roll from being transferred to the surface of the other embossing roll, it is preferable to pair a metal roll and a metal roll.
The embossing bonding area ratio obtained by the hot embossing roller is preferably 5 to 30%. By setting the bonding area to 5% or more, more preferably 8% or more, and still more preferably 10% or more, it is possible to obtain strength that can be practically used as a laminated nonwoven fabric. On the other hand, by setting the bonding area to be preferably 30% or less, more preferably 25% or less, and further preferably 20% or less, appropriate flexibility suitable for use particularly in building material applications can be obtained. In the case of using ultrasonic bonding, the bonding area ratio is preferably in the same range.
The bonding area here means a ratio of the bonded portion to the whole laminated nonwoven fabric. Specifically, the thermal bonding by a pair of rollers having concave and convex portions means a ratio of a portion (bonded portion) where the convex portion of the upper roller overlaps with the convex portion of the lower roller and contacts the nonwoven fabric layer to the whole laminated nonwoven fabric. In the case of thermal bonding between a roll having irregularities and a flat roll, the ratio of the portion (bonded portion) where the irregularities of the roll having irregularities are in contact with the nonwoven fabric layer is the ratio of the entire laminated nonwoven fabric. In the case of ultrasonic bonding, the ratio of the portion thermally welded by ultrasonic processing (bonded portion) to the whole laminated nonwoven fabric is referred to.
The shape of the bonded portion obtained by the heat embossing roll or the ultrasonic bonding is not particularly limited, and for example, a circle, an ellipse, a square, a rectangle, a parallelogram, a rhombus, a regular hexagon, a regular octagon, or the like can be used. The bonding portions are preferably uniformly present at regular intervals in the longitudinal direction (conveying direction) and the width direction of the laminated nonwoven fabric. This can reduce variation in strength of the laminated nonwoven fabric.
The surface temperature of the hot embossing roll at the time of thermal bonding is preferably from-50 to-15 ℃ relative to the melting point of the polyolefin resin used. By setting the surface temperature of the heat roll to preferably-50 ℃ or higher, more preferably-45 ℃ or higher, relative to the melting point of the polyolefin resin, it is possible to obtain a laminated nonwoven fabric having a practical strength by appropriately thermally bonding the heat roll. Further, by setting the surface temperature of the heat embossing roll to preferably-15 ℃ or lower, more preferably-20 ℃ or lower, with respect to the melting point of the polyolefin-based resin, excessive thermal bonding can be suppressed, and appropriate flexibility and processability suitable for use in building material applications can be obtained as the laminated nonwoven fabric.
The linear pressure of the hot embossing roller during thermal bonding is preferably 50 to 500N/cm. By setting the linear pressure of the roller to preferably 50N/cm or more, more preferably 100N/cm or more, and further preferably 150N/cm or more, it is possible to obtain a laminated nonwoven fabric having a practical strength by appropriately thermally bonding the rollers.
On the other hand, by setting the linear pressure of the heat embossing roll to preferably 500N/cm or less, more preferably 400N/cm or less, and further preferably 300N/cm or less, appropriate flexibility and processability can be obtained as a laminated nonwoven fabric which is particularly suitable for use in building material applications.
In the present invention, for the purpose of adjusting the thickness of the laminated nonwoven fabric, the thermal compression bonding can be performed by a pair of upper and lower flat rolls before and/or after the thermal bonding by the above-described hot embossing roll. The pair of upper and lower flat rolls are metal rolls or elastic rolls having no unevenness on the roll surface, and the metal rolls can be used in pairs or the metal rolls and the elastic rolls can be used in pairs.
Here, the elastic roller is a roller made of a material more elastic than the metal roller. Examples of the elastic roll include a so-called paper roll such as paper, cotton, and aramid paper, and a resin roll made of urethane resin, epoxy resin, silicone resin, polyester resin, and hard rubber, and a mixture thereof.
Examples
Next, a laminated nonwoven fabric of the present invention will be specifically described based on examples. In the measurement of each physical property, the measurement is not particularly described based on the above-described method.
(1) MFR (g/10 min) of the polyolefin resin:
the MFR of the polyolefin resin (A) and that of the polyolefin resin (B) were measured under a load of 2.16kg and at a temperature of 230 ℃.
(2) MFR (g/10 min) of the laminated nonwoven fabric:
the MFR of the laminated nonwoven fabric was measured under the conditions of a load of 2.16kg and a temperature of 230 ℃.
(3) Spinning speed (m/min):
the average single fiber diameter and the solid density of the polyolefin resin (a) or the polyolefin resin (B) used were calculated by rounding off the second decimal place with respect to the mass per 10,000m length as the average single fiber fineness (dtex). The spinning speed was calculated from the average single fiber fineness and the discharge amount of the resin discharged from the single hole of the spinneret (hereinafter, simply referred to as the discharge amount per single hole) (g/min) set under each condition based on the following formula.
Spinning speed (m/min) × (10000 × [ single hole discharge amount (g/min) ])/[ average single fiber fineness (dtex) ].
(4) Water pressure resistance (mmH) of laminated nonwoven fabric2O)：
A hydrostatic tester "Hydrotester" (FX-3000-IV) from TEXTEST, Switzerland was used.
(5) Air permeability per unit area weight ((cc/cm) of laminated nonwoven fabric2Second)/(g/m2))：
The measurement of the air permeability was performed based on the method described above. The air permeability (cc/(cm))2Second)) and the weight per unit area (g/m) determined by the method described above2) And the second decimal place is rounded off by the following formula to calculate the air permeability per unit area weight.
Air permeability (cc/(cm) — air permeability per unit area weight2Seconds))/weight per unit area (g/m)2)。
(6) Surface roughness SMD (μm) based on KES method of laminated nonwoven fabric:
in the measurement, an automated surface testing machine "KES-FB 4-AUTO-A" manufactured by KatoTech was used. The surface roughness SMD was measured on both sides of the laminated nonwoven fabric, and the smaller value of these was shown in table 1.
(7) Average coefficient of friction MIU by KES method of laminated nonwoven fabric, variation MMD of average coefficient of friction by KES method of laminated nonwoven fabric:
in the measurement, an automated surface testing machine "KES-FB 4-AUTO-A" manufactured by KatoTech was used. The average friction coefficient MIU was measured on both sides of the laminated nonwoven fabric, and the smaller value of these was shown in the table.
(8) Softness (processability) of nonwoven fabric:
as a sensory evaluation of the nonwoven fabric feel, softness was evaluated according to the following criteria. The evaluation was made by 10 persons, and the average of the evaluation was evaluated as the touch of the nonwoven fabric. The higher the respective scores, the more excellent the flexibility and the better the workability in various working processes, and the score of 4.0 or more was regarded as acceptable.
< flexibility (processability) >
And 5, dividing: soft (good processability)
And 4, dividing: between 5 and 3 points
And 3, dividing: general purpose
And 2, dividing: intermediate between 3 and 1
1 minute: hard (poor processability).
[ example 1]
(spunbonded nonwoven Fabric layer (lower layer))
A polypropylene resin comprising a homopolymer having an MFR of 200g/10 min and a melting point of 163 ℃ was melted in an extruder and spun through a rectangular spinneret having an orifice diameter of 0.30mm and a hole depth of 2mm at a spinning temperature of 235 ℃ and a discharge amount per hole of 0.32 g/min. After the spun sliver was cooled and solidified, it was drawn and stretched by compressed air with an ejector pressure of 0.35MPa in a rectangular ejector and collected on a moving web. Thereby forming a polypropylene long fiber-containing fiber having a weight per unit area of 8.2g/m2A spunbond nonwoven layer. Regarding the characteristics of the fibers constituting the formed spunbond nonwoven fabric layer, the average filament diameter was 10.1 μm, and the spinning speed was 4,400 m/min in terms of the average filament diameter. With respect to spinnability, no yarn breakage was observed in 1 hour of spinning, and the spinnability was good.
(meltblown nonwoven layer)
Next, a polypropylene resin containing a homopolymer and having an MFR of 1100 g/min was melted in an extruder and spun from a spinneret having an orifice diameter of 0.25mm at a spinning temperature of 260 ℃ and a discharge amount per one hole of 0.10 g/min. Then, air was jetted to the sliver at an air temperature of 290 ℃ and an air pressure of 0.10MPa, and the air was collected on the spunbond nonwoven fabric layer to form a meltblown nonwoven fabric layer. At this time, the weight per unit area of the meltblown nonwoven fabric layer additionally collected onto the collecting web under these conditions was 1.6g/m2The average fiber diameter was 1.5. mu.m.
(spunbonded nonwoven Fabric layer (Upper layer))
Further, the spunbond nonwoven fabric layer was formed by collecting the polypropylene long fibers on the meltblown nonwoven fabric layer under the same conditions as those for forming the lower spunbond nonwoven fabric layer. Thus, a total basis weight of 18g/m was obtained2Spunbond-meltblown-spunbond laminated webs.
(laminated nonwoven Fabric)
Then, the obtained laminated web was thermally bonded using an engraved embossing roll having a 16% bonding area ratio in which a metal pattern of Borkard dots (polka dots) was engraved on the upper roll and an upper and lower pair of heat embossing rolls each of which was constituted by a metal flat roll on the lower roll under conditions of a line pressure of 300N/cm and a thermal bonding temperature of 130 ℃ to obtain a weight per unit area of 18g/m2The laminated nonwoven fabric of (1). The obtained laminated nonwoven fabric was measured for thickness, apparent density, water pressure resistance, air permeability per unit area weight, surface roughness SMD, average friction coefficient MIU, and variation in average friction coefficient MMD, and the flexibility of the laminated nonwoven fabric was also evaluated. The results are shown in Table 1.
[ example 2]
(spunbonded nonwoven Fabric layer (lower layer) · (upper layer))
A spunbond nonwoven fabric layer containing polypropylene long fibers was formed in the same manner as in example 1, except that the discharge amount per hole was 0.21 g/min and the pressure of the ejector was 0.50 MPa. Regarding the characteristics of the long fibers constituting the spunbond nonwoven fabric layer formed, the average single fiber diameter was 7.2 μm, and the spinning speed was 5,700 m/min in terms of the average single fiber diameter. With respect to spinnability, no yarn breakage was observed in 1 hour of spinning, and the spinnability was good.
(meltblown nonwoven layer)
A meltblown nonwoven fabric layer was formed in the same manner as in example 1, except that the air pressure was set to 0.20 MPa. With respect to the characteristics of the fibers constituting the formed meltblown nonwoven fabric layer, the average fiber diameter was 1.0 μm.
(laminated nonwoven Fabric)
A laminated nonwoven fabric was obtained in the same manner as in example 1. The obtained laminated nonwoven fabric was measured for thickness, apparent density, water pressure resistance, air permeability per unit area weight, surface roughness SMD, average friction coefficient MIU, and variation in average friction coefficient MMD, and the flexibility of the laminated nonwoven fabric was also evaluated. The results are shown in Table 1.
[ example 3]
(spunbonded nonwoven Fabric layer (lower layer) · (upper layer))
A spunbond nonwoven fabric layer containing polypropylene long fibers was formed in the same manner as in example 1, except that the ejector pressure was set to 0.50 MPa. Regarding the characteristics of the long fibers constituting the spunbond nonwoven fabric layer formed, the average single fiber diameter was 8.9 μm, and the spinning speed was 5,600 m/min in terms of the average single fiber diameter. With respect to spinnability, no yarn breakage was observed in 1 hour of spinning, and the spinnability was good.
(meltblown nonwoven layer)
A meltblown nonwoven fabric layer was formed in the same manner as in example 2.
(laminated nonwoven Fabric)
A laminated nonwoven fabric was obtained in the same manner as in example 1. The obtained laminated nonwoven fabric was measured for thickness, apparent density, water pressure resistance, air permeability per unit area weight, surface roughness SMD, average friction coefficient MIU, and variation in average friction coefficient MMD, and the flexibility of the laminated nonwoven fabric was also evaluated. The results are shown in Table 1.
[ example 4]
(spunbonded nonwoven Fabric layer (lower layer) · (upper layer))
A spunbond nonwoven fabric layer was obtained in the same manner as in example 1.
(meltblown nonwoven layer)
A meltblown nonwoven fabric layer web was obtained in the same manner as in example 2.
(laminated nonwoven Fabric)
A laminated nonwoven fabric was obtained in the same manner as in example 1. The obtained laminated nonwoven fabric was measured for thickness, apparent density, water pressure resistance, air permeability per unit area weight, surface roughness SMD, average friction coefficient MIU, and variation in average friction coefficient MMD, and the flexibility of the laminated nonwoven fabric was also evaluated. The results are shown in Table 1.
[ example 5]
(spunbonded nonwoven Fabric layer (lower layer) · (upper layer))
Except that the unit area weight was set to 8.5g/m2Except for this, a spunbond nonwoven fabric layer was obtained in the same manner as in example 2.
(meltblown nonwoven layer)
Except that the unit area weight was set to 1.0g/m2Except for this, a meltblown nonwoven fabric layer was obtained in the same manner as in example 2.
(laminated nonwoven Fabric)
A laminated nonwoven fabric was obtained in the same manner as in example 1. The obtained laminated nonwoven fabric was measured for thickness, apparent density, water pressure resistance, air permeability per unit area weight, surface roughness SMD, average friction coefficient MIU, and variation in average friction coefficient MMD, and the flexibility of the laminated nonwoven fabric was also evaluated. The results are shown in Table 1.
[ example 6]
(spunbonded nonwoven Fabric layer (lower layer) · (upper layer))
Except that the unit area weight was set to 8.5g/m2Except for this, a spunbond nonwoven fabric layer was obtained in the same manner as in example 3.
(meltblown nonwoven layer)
A meltblown nonwoven fabric layer was obtained in the same manner as in example 5.
(laminated nonwoven Fabric)
A laminated nonwoven fabric was obtained in the same manner as in example 1. The obtained laminated nonwoven fabric was measured for thickness, apparent density, water pressure resistance, air permeability per unit area weight, surface roughness SMD, average friction coefficient MIU, and variation in average friction coefficient MMD, and the flexibility of the laminated nonwoven fabric was also evaluated. The results are shown in Table 1.
[ example 7]
(spunbonded nonwoven Fabric layer (lower layer) · (upper layer))
A spunbond nonwoven fabric layer was obtained in the same manner as in example 1, except that 1.0 mass% of ethylene bisstearamide was added as a fatty acid amide compound to a polypropylene resin containing a homopolymer.
(meltblown nonwoven layer)
A meltblown nonwoven fabric layer was obtained in the same manner as in example 1.
(laminated nonwoven Fabric)
A laminated nonwoven fabric was obtained in the same manner as in example 1. The obtained laminated nonwoven fabric was measured for thickness, apparent density, water pressure resistance, air permeability per unit area weight, surface roughness SMD, average friction coefficient MIU, and variation in average friction coefficient MMD, and the flexibility of the laminated nonwoven fabric was also evaluated. The results are shown in Table 1.
[ example 8]
(spunbonded nonwoven Fabric layer (lower layer) · (upper layer))
Except that the unit area weight was set to 13.6g/m2Except for this, a spunbond nonwoven fabric layer was obtained in the same manner as in example 1.
(meltblown nonwoven layer)
Except that the unit area weight was set to 2.8g/m2Except for this, a meltblown nonwoven fabric layer was obtained in the same manner as in example 1.
(laminated nonwoven Fabric)
A laminated nonwoven fabric was obtained in the same manner as in example 1. The obtained laminated nonwoven fabric was measured for thickness, apparent density, water pressure resistance, air permeability per unit area weight, surface roughness SMD, average friction coefficient MIU, and variation in average friction coefficient MMD, and the flexibility of the laminated nonwoven fabric was also evaluated. The results are shown in Table 1.
Comparative example 1
(spunbonded nonwoven Fabric layer (lower layer) · (upper layer))
A spunbond nonwoven fabric layer was obtained in the same manner as in example 1, except that a homopolypropylene resin having an MFR of 60g/10 min and a melting point of 163 ℃ was used and the ejector pressure was set to 0.20 MPa. Regarding the characteristics of the long fibers constituting the obtained spunbond nonwoven fabric layer, the average single fiber diameter was 11.8 μm, and the spinning speed was 3,200 m/min in terms of the average single fiber diameter. With respect to spinnability, no yarn breakage was observed in 1 hour of spinning, and the spinnability was good. When the ejector pressure was set to 0.35MPa under the same conditions, yarn breakage occurred frequently, and spinning was not possible.
(meltblown nonwoven layer)
A meltblown nonwoven fabric layer was obtained in the same manner as in example 2.
(laminated nonwoven Fabric)
A laminated nonwoven fabric was obtained in the same manner as in example 1. The obtained laminated nonwoven fabric was measured for thickness, apparent density, water pressure resistance, air permeability per unit area weight, surface roughness SMD, average friction coefficient MIU, and variation in average friction coefficient MMD, and the flexibility of the laminated nonwoven fabric was also evaluated. The results are shown in Table 1.
Comparative example 2
(spunbonded nonwoven Fabric layer (lower layer) · (upper layer))
A spunbond nonwoven fabric layer was obtained in the same manner as in comparative example 1.
(meltblown nonwoven layer)
Except that the unit area weight was set to 2.0g/m2Except for this, a meltblown nonwoven fabric layer was obtained in the same manner as in example 2.
(laminated nonwoven Fabric)
A laminated nonwoven fabric was obtained in the same manner as in example 1. The obtained laminated nonwoven fabric was measured for thickness, apparent density, water pressure resistance, air permeability per unit area weight, surface roughness SMD, average friction coefficient MIU, and variation in average friction coefficient MMD, and the flexibility of the laminated nonwoven fabric was also evaluated. The results are shown in Table 1.
Comparative example 3
(spunbonded nonwoven Fabric layer (lower layer) · (upper layer))
A spunbonded nonwoven fabric layer was obtained in the same manner as in example 1, except that a homopolypropylene resin having an MFR of 35g/10 min and a melting point of 163 ℃ was used, and the discharge rate per cell was 0.5 g/min and the ejector pressure was 0.20 MPa. Regarding the characteristics of the long fibers constituting the obtained spunbond nonwoven fabric layer, the average single fiber diameter was 14.5 μm, and the spinning speed was 3,300 m/min in terms of the average single fiber diameter. When the ejector pressure was set to 0.35MPa under the same conditions, yarn breakage occurred frequently, and spinning was not possible.
(meltblown nonwoven layer)
A meltblown nonwoven fabric layer was obtained in the same manner as in example 2.
(laminated nonwoven Fabric)
A laminated nonwoven fabric was obtained in the same manner as in example 1. The obtained laminated nonwoven fabric was measured for thickness, apparent density, water pressure resistance, air permeability per unit area weight, surface roughness SMD, average friction coefficient MIU, and variation in average friction coefficient MMD, and the flexibility of the laminated nonwoven fabric was also evaluated. The results are shown in Table 1.
[ Table 1]
Figure BDA0002651031670000281
In examples 1 to 8, the surface roughness SMD by the KES method was 1.0 to 2.6 μm, and the water pressure resistance per unit weight was 15mmH2O/(g/m2) Thereby having excellent water resistance. In particular, in examples 1 to 7, the content of the fibers constituting the meltblown nonwoven fabric layer was 1 to 10 mass% based on the mass of the laminated nonwoven fabric, and therefore the nonwoven fabric was excellent in flexibility (processability). The laminated nonwoven fabric of example 7, in which ethylene bis stearamide was added to the fibers constituting the spunbond nonwoven fabric layer, had a reduced average friction coefficient, increased flexibility and excellent processability, and was particularly suitable as a nonwoven fabric for house wrap.
On the other hand, the laminated nonwoven fabrics of comparative examples 1 to 3 had a surface roughness SMD of 2.7 μm or more, poor water resistance and low flexibility.
The present invention has been described in detail with reference to specific embodiments, but it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention. It should be noted that the present application is based on japanese patent application filed on 28.2.2018 (japanese patent application 2018-.
Industrial applicability
The laminated nonwoven fabric of the present invention has high productivity, uniform texture, smooth surface, excellent hand and skin touch, and high water resistance, and therefore can be suitably used as a moisture-permeable waterproof sheet for building materials.
The applications of the laminated nonwoven fabric of the present invention are not limited to the above, and examples thereof include industrial materials such as filters, filter substrates, and wire wrapping materials, building materials such as wall papers, roof underlayments, sound insulating materials, heat insulating materials, and sound absorbing materials, living materials such as packaging materials, bag materials, billboard materials, and printing substrates, civil engineering materials such as grass-proof sheets, drainage materials, foundation reinforcing materials, sound insulating materials, and sound absorbing materials, agricultural materials such as covering materials (japanese: べた zhi け), agricultural materials such as light-shielding sheets, and vehicle materials such as ceiling materials and spare tire covers.

Claims (8)

1. A laminated nonwoven fabric comprising a spunbonded nonwoven fabric layer comprising fibers comprising a polyolefin resin (A) and a meltblown nonwoven fabric layer comprising fibers comprising a polyolefin resin (B), wherein the melt flow rate of the laminated nonwoven fabric is 80-850 g/10 min, the surface roughness (SMD) of at least one surface by the KES method is 1.0-2.6 [ mu ] m, and the water pressure resistance per unit area weight is 15mmH2O/(g/m2) The above.
2. The laminated nonwoven fabric according to claim 1, wherein the average filament diameter of the fibers comprising the polyolefin resin (A) constituting the spunbond nonwoven fabric layer is 6.5 to 11.9 μm.
3. The laminated nonwoven fabric according to claim 1 or 2, wherein the content of the meltblown nonwoven fabric layer is 1 mass% or more and 15 mass% or less with respect to the mass of the laminated nonwoven fabric.
4. A laminated nonwoven fabric according to any one of claims 1 to 3, at least one side of which has an average coefficient of friction MIU based on the KES method of 0.1 to 0.5.
5. The laminated nonwoven fabric according to any one of claims 1 to 4, wherein the variation MMD of the average friction coefficient based on the KES method of at least one surface is 0.008 or less.
6. The laminated nonwoven fabric according to any one of claims 1 to 5, which is obtained by adding a fatty acid amide compound having 23 to 50 carbon atoms to the polyolefin resin (A).
7. The laminated nonwoven fabric according to claim 6, wherein the fatty acid amide compound is added in an amount of 0.01 to 5.0 mass%.
8. The laminated nonwoven fabric according to claim 6 or 7, wherein the fatty acid amide compound is ethylene bisstearamide.
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