JP2001288666A - 複合シートおよびその製造方法 - Google Patents

複合シートおよびその製造方法

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Publication number
JP2001288666A
JP2001288666A JP2000099888A JP2000099888A JP2001288666A JP 2001288666 A JP2001288666 A JP 2001288666A JP 2000099888 A JP2000099888 A JP 2000099888A JP 2000099888 A JP2000099888 A JP 2000099888A JP 2001288666 A JP2001288666 A JP 2001288666A
Authority
JP
Japan
Prior art keywords
composite sheet
continuous fibers
web
stretchable
elastic
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
JP2000099888A
Other languages
English (en)
Other versions
JP3658271B2 (ja
Inventor
Satoru Tange
悟 丹下
Hiroyuki Ohata
裕之 大幡
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Unicharm Corp
Original Assignee
Unicharm Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Unicharm Corp filed Critical Unicharm Corp
Priority to JP2000099888A priority Critical patent/JP3658271B2/ja
Priority to CA002342291A priority patent/CA2342291C/en
Priority to AU31367/01A priority patent/AU782644B2/en
Priority to US09/821,230 priority patent/US6995100B2/en
Priority to SG200101955A priority patent/SG85236A1/en
Priority to MYPI20011483A priority patent/MY128652A/en
Priority to BR0101746-2A priority patent/BR0101746A/pt
Priority to TW090107617A priority patent/TW587994B/zh
Priority to CNB011173556A priority patent/CN1181969C/zh
Priority to KR1020010016713A priority patent/KR100666969B1/ko
Priority to IDP20010287D priority patent/ID29726A/id
Priority to AT01303149T priority patent/ATE542666T1/de
Priority to EP01303149A priority patent/EP1138475B1/en
Publication of JP2001288666A publication Critical patent/JP2001288666A/ja
Priority to US10/292,040 priority patent/US6998004B2/en
Application granted granted Critical
Publication of JP3658271B2 publication Critical patent/JP3658271B2/ja
Priority to US11/217,754 priority patent/US7563337B2/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

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    • 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
    • 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
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • 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
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    • B32B7/04—Interconnection of layers
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    • 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
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Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Diaphragms For Electromechanical Transducers (AREA)
  • Manufacturing Of Multi-Layer Textile Fabrics (AREA)

Abstract

(57)【要約】 【課題】 径のばらつきが小さい伸長性の連続繊維から
なる層を形成することができる複合シートの提供。 【解決手段】 弾性伸縮層３の少なくとも片面に伸長性
の連続繊維６からなる伸長層２が一方向へ間欠的に接合
して複合シート１０を形成する。連続繊維６は、概ねそ
の一方向に配向し、その一方向とそれに直交する方向と
における引張強度の比Ｓ1 ／Ｓ2 が３．０以上となる。

Description

【発明の詳細な説明】
【０００１】
【発明の属する技術分野】この発明は、伸縮性ウェブと
伸長性の連続繊維からなる伸長性ウェブとによって形成
される複合シートおよびその製造方法に関する。
【０００２】
【従来の技術】特開平６−１８４８９７号公報に開示さ
れた複合伸縮性材料は、引張ることによって首を付けた
材料を引張った状態のままで、引張った伸縮性シートに
対して非直線状に配列した少なくとも３点で接合し、し
かる後に伸縮性シートを弛緩させることによって製造さ
れる。この製造方法によれば、首を付けた材料は、それ
が繊維からなるものであれば、伸縮性シートの弛緩に伴
って多くのひだを形成し、伸縮性シートの伸縮性を損う
ことなく、このシートのゴムライクな表面を布様の肌触
りのよいものに変えることができる。
【０００３】
【発明が解決しようとする課題】前記公知技術によれ
ば、首を付けた材料の一例は、熱可塑性合成繊維が互い
に溶着してなるスパンボンド不織布を一方向へ引張った
ものである。ランダムに分布してこの不織布を形成して
いる繊維は、一方向へ引張られることによって、あるも
のはその一方向へ向かって塑性変形しながら伸長し、ま
たあるものはその一方向へ向かって延びるように、その
向きを変えるだけである。そうしたことの結果として、
引張られた繊維は細くなる一方、向きを変えただけの繊
維は太さが変らないから、得られる複合伸縮性材料は、
繊維径のばらつきが大きく、肌触りが一様でないとか、
外観が一様でないというものになることがある。
【０００４】この発明では、前記公知技術の如く、伸縮
層と伸長性の繊維からなる伸長層とで形成され、伸長層
における繊維径のばらつきが小さい複合シートとその製
造方法の提供とを課題にしている。
【０００５】
【課題を解決するための手段】前記課題解決のために、
この発明は新規な複合シートとその製造方法とを提案す
る。
【０００６】前記複合シートに関し、この発明が対象と
するのは、上下面を有する弾性伸縮層の少なくとも片面
に伸長性の連続繊維からなる伸長層が互いに直交する第
１方向と第２方向とのうちの少なくとも前記第１方向に
おいて間欠的に接合することにより形成された複合シー
トである。
【０００７】かかる複合シートにおいて、この発明が特
徴とするところは、前記連続繊維が概ね前記第１方向へ
配向し、前記複合シートの前記第１方向における引張強
度Ｓ 1 と前記第２方向における引張強度Ｓ2 との比Ｓ1
／Ｓ2 が３．０以上であること、にある。
【０００８】また、前記製造方法に関し、この発明が対
象とするのは、上下面を有する弾性伸縮性ウェブの少な
くとも片面に伸長性の連続繊維からなる伸長性ウェブを
互いに直交する第１方向と第２方向とのうちの少なくと
も前記第１方向において間欠的に接合することにより複
合シートを製造する方法である。
【０００９】かかる製造方法において、この発明が特徴
とするところは、前記連続繊維が、実質的に非結合の状
態で重なり合うことによって前記伸長性ウェブを形成し
ているものであって、前記連続繊維を概ね前記一方向へ
配向させた後、前記伸長性ウェブを前記伸縮性ウェブに
接合すること、にある。
【００１０】この製造方法の好ましい実施態様におい
て、溶融押出機から前記連続繊維を押出して一方向へ走
行するコンベア上に捕集して前記伸長性ウェブを形成し
た後、前記連続繊維を概ね前記一方向へ配向させるよう
に処理して前記伸縮性ウェブと重ね合わせ、しかる後に
これら両ウェブを前記一方向において間欠的に接合する
ことにより前記複合シートを得る。
【００１１】また、好ましい実施態様の他の１つにおい
て、前記連続繊維を前記一方向へ配向させる工程が、速
度Ｖ1 で走行する前記コンベアと、前記コンベアに続い
て速度Ｖ2 で走行する第２のコンベアとを含み、これら
コンベアの走行速度比Ｖ2 ／Ｖ1 が１．０５〜１０であ
る。
【００１２】
【発明の実施の形態】添付の図面を参照し、この発明に
係る複合シートとその製造方法の詳細を説明すると、以
下のとおりである。
【００１３】図１に斜視図で示された複合シート１０
は、スチレン系エラストマーの連続繊維４０からなる弾
性伸縮層３の上面に、伸長性のポリプロピレン連続繊維
６からなる伸長層２が接合部４Ａで溶着することによっ
て形成されている。複合シート１０は、Ｘ方向と、これ
に直交するＹ方向とを有し、伸縮層３がＸ，Ｙ方向のう
ちの少なくともＹ方向に弾性的に伸縮する。伸長層２の
連続繊維６は、概ねＹ方向へ向かって延びるように配向
している。伸縮層３の引張強度がＸ方向とＹ方向とで差
がない場合、連続繊維６の配向の程度はＹ方向における
引張強度Ｓ１ とＸ方向における引張強度Ｓ２ との比Ｓ
１ ／Ｓ２ で表わすことが可能であり、この発明の好ま
しい複合シート１０では、Ｓ１ ／Ｓ２ が少なくとも
３．０となるように連続繊維６が配向している。また、
連続繊維６は接合部４Ａを除くと、溶着や接着によって
互いに接合するということがなく、重なり合っているだ
けか、または複合シート１０がＹ方向へ僅かに引張られ
ると互いに離れるように極めて弱く接合しており、実質
的には重なり合っているだけの状態に等しい。
【００１４】かかる複合シート１０は、これを両層２，
３の破断伸度以下であって、かつ伸縮層３の弾性限界内
でＹ方向へ伸長すると、伸縮層３が弾性的に伸長する一
方、伸長層２が非弾性的に伸長し、連続繊維６が細く、
長くなるように塑性変形する。伸長する力を解くと、複
合シート１０は、伸縮層３の収縮力によって元の寸法近
くにまで縮み、このときに、長く伸びた連続繊維６には
多くのひだが形成され、伸長層２は伸長前の状態よりも
嵩が高く、肌触りが柔軟になる。
【００１５】図２は、最初に１５０％まで伸長した複合
シート１０を再度伸長したときの荷重／伸度曲線であっ
て、複合シート１０の構成は、次のとおりである。な
お、複合シート１０を最初に伸長するときの割合は、初
期伸長率ＥI と定義される。
【００１６】 伸長層 伸長性連続繊維：ポリプロピレン／プロピレン、エチレン、ブテンの ターポリマー＝６０／４０（重量比） 繊維径：１５．２μｍ 坪 量：１５ｇ／ｍ２ 伸縮層 伸縮性連続繊維：スチレン系エラストマー 繊維径：１６．４μｍ 坪 量：６０ｇ／ｍ２ 複合シート 強度比（Ｓ１ ／Ｓ２ ）：４．９
【００１７】図２において、曲線はゆるく立上った後に
ほぼ一様な荷重で伸度１００％の変曲点Ｐにまで達し、
そこから急に立ち上がる。複合シート１０では、まず伸
長層２の連続繊維６のひだが伸び、それと同時に伸縮層
３が弾性的に変曲点Ｐまで伸長する。変曲点Ｐ以降で
は、連続繊維６が塑性変形して、細く、長くなるように
伸長し、伸縮層３が引き続き弾性的に伸長する。このよ
うに複合シート１０では、最初に１５０％まで伸長する
と、２度目の伸長では、伸度１００％までの範囲におい
て低い応力で伸縮する伸縮層３の特性が現われ、伸長層
２はその特性に殆ど影響を与えることがない。複合シー
ト１０を２度目に伸長したときに観察される変曲点Ｐま
での低い荷重を示す伸長率は、第２次伸長率ＥSと定義
される。第２次伸長率ＥS と初期伸長率ＥＩ との比Ｅ
S ／ＥI はストレッチ効率ＳE であり、図２の場合のス
トレッチ効率ＳE は１００（％）／１５０（％）×１０
０＝６７（％）である。この発明に係る複合シート１０
では、連続繊維６が概ねＹ方向へ配向しているから、こ
れをＹ方向へ伸長するときには多くの連続繊維６もＹ方
向へ伸長されて長くなるので、ストレッチ効率ＳＥが６
０〜９０％程度の高い値になる。この複合シート１０に
比べ、連続繊維６がランダムに分布している場合の複合
シートでは、ストレッチ効率ＳＥが６０％以下である。
【００１８】図３は、複合シート１０を製造するときの
工程図である。図の左方には、連続繊維６を吐出する第
１押出機３１と、第１コンベアベルト３２と、サクショ
ンボックス３３とがある。吐出された連続繊維６は、第
１押出機のノズル側方から吐出される熱風（図示せず）
やサクションの作用で第１コンベアベルト３２上に捕集
され、伸長性ウェブ５２を形成する。連続繊維６は、互
いに溶着することがないように、また、たとえ溶着して
も極めて容易に分離することができるように、第１押出
機３１の吐出条件、熱風やサクションの作用条件、連続
繊維６の冷却条件、および第１コンベアベルト３２の速
度Ｖ1 が選ばれる。
【００１９】伸長性ウェブ５２は、第２コンベアベルト
３６へと進む。第２コンベアベルト３６は、速度Ｖ2 で
走行し、伸長性ウェブ５２を押さえるロール３７，３８
は周速Ｖ2 で回転している。速度Ｖ2 とＶ1 との比Ｖ2
／Ｖ1 は１．０５〜１０であって、伸長性ウェブ５２
は、第１コンベアベルト３２から第２コンベアベルト３
６へ移行する過程で進行方向へ引張られ、連続繊維６が
進行方向へ向かって延びるように配向する。連続繊維６
が互いに弱く溶着しているときには、第２コンベアベル
ト３６でばらばらになる。
【００２０】伸長性ウェブ５２は、第２コンベアベルト
３６から第３コンベアベルト４１へと進む。第２押出機
４２からはエラストマーの連続繊維４０が吐出され、サ
クションボックス４３のサクションの作用を受けて伸長
性ウェブ５２の上に堆積し、伸縮性ウェブ５３を形成す
る。両ウェブ５２，５３は、上下一対の熱エンボスロー
ル４４，４４を通過するときに接合部４Ａを形成されて
一体化し、複合シート１０となる。
【００２１】かかる複合シート１０の製造工程では、第
１コンベアベルト３２の速度Ｖ1と第２コンベアベルト
３６の速度Ｖ2 との関係をＶ2 ／Ｖ1 ＝１．０５〜１０
とすることによって連続繊維６を配向させると、その配
向は、複合シート１０に６０〜９０％の高いストレッチ
効率ＳＥをもたらすのに十分な程度となる。この配向が
十分であるときの複合シート１０では、機械方向とそれ
に直交する方向の引張強度Ｓ１ とＳ２ との比Ｓ１ ／
Ｓ２ は、３．０以上になる。
【００２２】この発明に係る複合シート１０は、図示例
のものを、伸縮層３の上下面に伸長層２を有するものに
代えることができる。また、それに合わせて、図３の工
程に第３の押出機と、複数のコンベアベルトとを追加す
ることができる。
【００２３】
【発明の効果】この発明に係る複合シートは、伸長性の
連続繊維が概ね一方向に配向しているので、その一方向
に伸長されると、多数の連続繊維がどれも一様に伸びる
ので伸長後の繊維径のばらつきが少なく、肌が触れたと
きの感触や外観にむらがない。
【００２４】この発明に係る製造方法は、伸長性ウェブ
の連続繊維を概ね一方向へ配向させる工程を有するの
で、前記複合シートの製造が容易になる。
【図面の簡単な説明】
【図１】複合シートの斜視図。
【図２】荷重／伸度曲線。
【図３】複合シートの製造工程図。
【符号の説明】
２ 伸長層 ３ 伸縮層 ６ 連続繊維 １０ 複合シート ３１ 押出機（第１押出機） ３２ コンベア（第１コンベアベルト） ３６ 第２のコンベア（第２コンベアベルト） ５２ 伸長性ウェブ ５３ 伸縮性ウェブ Ｘ 第２方向 Ｙ 第１方向
───────────────────────────────────────────────────── フロントページの続き Ｆターム(参考） 4F100 BA13 BA22A BA22B BA32 DG01A DG01B DG06A DG06B EA061 EC032 EJ402 JA20A JK02A JK02B JK08A JK08B JL00 YY00A YY00B 4L032 AA05 AB04 AC01 BD01 BD03 DA01 EA06 4L047 AA14 AA18 AB03 AB07 AB10 BD02 CA02 CB01 CB02 CB10 CC01

Claims (6)

    【特許請求の範囲】
  1. 【請求項１】 上下面を有する弾性伸縮層の少なくとも
    片面に伸長性の連続繊維からなる伸長層が互いに直交す
    る第１方向と第２方向とのうちの少なくとも前記第１方
    向において間欠的に接合することにより形成された複合
    シートにおいて、 前記連続繊維が概ね前記第１方向へ配向し、前記複合シ
    ートの前記第１方向における引張強度Ｓ1 と前記第２方
    向における引張強度Ｓ2 との比Ｓ1 ／Ｓ2 が３．０以上
    であることを特徴とする前記複合シート。
  2. 【請求項２】 前記第１方向におけるストレッチ効率が
    ６０〜９０％である請求項１記載の複合シート。
  3. 【請求項３】 上下面を有する弾性伸縮性ウェブの少な
    くとも片面に伸長性の連続繊維からなる伸長性ウェブを
    互いに直交する第１方向と第２方向とのうちの少なくと
    も前記第１方向において間欠的に接合することにより複
    合シートを製造する方法において、 前記連続繊維は、実質的に非結合の状態で重なり合うこ
    とによって前記伸長性ウェブを形成しているものであっ
    て、前記連続繊維を概ね前記一方向へ配向させた後、前
    記伸長性ウェブを前記伸縮性ウェブに接合することを特
    徴とする前記方法。
  4. 【請求項４】 溶融押出機から前記連続繊維を押出して
    一方向へ走行するコンベア上に捕集して前記伸長性ウェ
    ブを形成した後、前記連続繊維を概ね前記一方向へ配向
    させるように処理して前記伸縮性ウェブと重ね合わせ、
    しかる後にこれら両ウェブを前記一方向において間欠的
    に接合することにより前記複合シートを得る請求項３記
    載の方法。
  5. 【請求項５】 前記連続繊維を前記一方向へ配向させる
    工程が、速度Ｖ1 で走行する前記コンベアと、前記コン
    ベアに続いて速度Ｖ2 で走行する第２のコンベアとを含
    み、これらコンベアの走行速度比Ｖ2 ／Ｖ1 が１．０５
    〜１０である請求項３または４記載の方法。
  6. 【請求項６】 前記複合シートの前記一方向における引
    張強度Ｓ1 と前記一方向に直交する方向における引張強
    度Ｓ2 との比Ｓ1 ／Ｓ2 が３．０以上となるように前記
    連続繊維を前記一方向へ配向させる請求項３〜５のいず
    れかに記載の方法。
JP2000099888A 2000-03-31 2000-03-31 複合シートの製造方法 Expired - Fee Related JP3658271B2 (ja)

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JP2000099888A JP3658271B2 (ja) 2000-03-31 2000-03-31 複合シートの製造方法
CA002342291A CA2342291C (en) 2000-03-31 2001-03-27 Composite sheet and process for making the same
AU31367/01A AU782644B2 (en) 2000-03-31 2001-03-28 Composite sheet and process for making the same
SG200101955A SG85236A1 (en) 2000-03-31 2001-03-29 Composite sheet and process for making the same
MYPI20011483A MY128652A (en) 2000-03-31 2001-03-29 Composite sheet and process for making the same
BR0101746-2A BR0101746A (pt) 2000-03-31 2001-03-29 Folha composta e processo para sua fabricação
US09/821,230 US6995100B2 (en) 2000-03-31 2001-03-29 Composite sheet and process for making the same
CNB011173556A CN1181969C (zh) 2000-03-31 2001-03-30 复合片及其制造方法
TW090107617A TW587994B (en) 2000-03-31 2001-03-30 Composite sheet and process for making the same
KR1020010016713A KR100666969B1 (ko) 2000-03-31 2001-03-30 복합 시이트의 제조 방법
IDP20010287D ID29726A (id) 2000-03-31 2001-03-30 Lembar komposit dan proses pembuatannya
AT01303149T ATE542666T1 (de) 2000-03-31 2001-04-02 Verfahren zur herstellung eines verbundstoffes
EP01303149A EP1138475B1 (en) 2000-03-31 2001-04-02 Process for making a composite sheet
US10/292,040 US6998004B2 (en) 2000-03-31 2002-11-12 Composite sheet and process for making the same
US11/217,754 US7563337B2 (en) 2000-03-31 2005-09-01 Composite sheet and process for making the same

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AT (1) ATE542666T1 (ja)
AU (1) AU782644B2 (ja)
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CA (1) CA2342291C (ja)
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US6998004B2 (en) 2006-02-14
SG85236A1 (en) 2001-12-19
EP1138475A2 (en) 2001-10-04
JP3658271B2 (ja) 2005-06-08
AU782644B2 (en) 2005-08-18
US20030070744A1 (en) 2003-04-17
ATE542666T1 (de) 2012-02-15
ID29726A (id) 2001-10-04
EP1138475B1 (en) 2012-01-25
TW587994B (en) 2004-05-21
CA2342291A1 (en) 2001-09-30
CN1322623A (zh) 2001-11-21
CN1181969C (zh) 2004-12-29
MY128652A (en) 2007-02-28
AU3136701A (en) 2001-10-04
US7563337B2 (en) 2009-07-21
US20060063450A1 (en) 2006-03-23
EP1138475A3 (en) 2004-03-31
BR0101746A (pt) 2001-12-04
KR20010095125A (ko) 2001-11-03
US6995100B2 (en) 2006-02-07
US20010027074A1 (en) 2001-10-04
CA2342291C (en) 2006-12-12

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