JP2002161466A - Thermoplastic composite nonwoven fabric and fiber product using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a thermoplastic composite nonwoven fabric which has a good texture, excellent fuzzing resistance and a sufficient nonwoven fabric strength and can be recycled, and to provide a fiber product using the same. SOLUTION: This thermoplastic composite nonwoven fabric produced by laminating nonwoven fiber aggregates (I) comprising a thermoplastic resin (A) as both outer layers to a nonwoven fiber aggregate (II) comprising a thermoplastic resin (A') produced from the same components as those of the thermoplastic resin (A) as an inner layer, is characterized in that the melt flow ratio of the nonwoven fiber aggregate (II)/nonwoven fiber aggregate (D is 1.1 to 5.0 after the fibers are formed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a thermoplastic composite nonwoven fabric and a fiber product using the same.

[0002]

2. Description of the Related Art Nonwoven fabrics using polyolefin-based heat-fusible fibers are preferred for properties such as soft texture and high strength of nonwoven fabrics, and are used for sanitary materials such as disposable diapers and sanitary products. Generally, a heat treatment method for forming a heat-fusible fiber into a nonwoven fabric includes a hot air bonding method using a suction band dryer or a suction dryer, and a heated embossing roll having a large number of convex portions and a flat roll (smooth roll). Introducing the web in between to obtain a nonwoven fabric,
It can be roughly classified into a so-called embossing point thermocompression bonding method. In particular, the latter point thermocompression bonding method is superior in productivity as compared with the hot air bonding method, and therefore is advantageous in terms of cost. However, as a recent trend, nonwoven fabrics obtained by point thermocompression bonding used for surface materials of sanitary materials are required to have a softer texture (feel). Therefore, a method of keeping the processing temperature low, a method of reducing the point thermocompression bonding area ratio, and the like are being studied.

[0003] In the method of keeping the processing temperature low, there is a problem that the adhesion of the nonwoven fabric is insufficient and the fibers are liable to be peeled off from the bonded portion, and this causes fluffing, thereby deteriorating the fuzzing resistance. Latent (reduced wear resistance).

On the other hand, in the method of reducing the area ratio of the point thermocompression bonding, the hand is improved, but the strength of the nonwoven fabric is insufficient. In addition, the degree of fiber freedom increases due to a decrease in the point thermocompression bonding area ratio, and the fuzz resistance tends to deteriorate.

[0005] In the method in which the point thermocompression bonding area ratio is reduced and the processing temperature is increased, the strength of the nonwoven fabric is improved, but the molten resin is fused to an embossing roll or a flat roll.
Problems such as coiling occurred, and there was a problem in long-term stable production (operability).

When a non-woven fabric made of a thermoplastic resin is used as a material of a disposable diaper top sheet, that is, a part of the child's buttocks that directly touches the non-woven fabric, the non-woven fabric having poor fuzz resistance is rubbed between the child's buttocks and the non-woven fabric. The tips of some of the constituent fibers protrude and irritate the skin, causing rash and the like. This is compared to a non-woven fabric made of long fibers.
This phenomenon is particularly common in nonwoven fabrics made of short fibers.

On the other hand, when a non-woven fabric is used as the back sheet of a disposable diaper, that is, the outermost portion of the so-called disposable diaper, which is a material for suppressing leakage of urine, etc. When the fibers come into contact with, for example, rubbing with a tatami mat, a carpet, or the like, the fibers are twisted and the basis weight of the nonwoven fabric becomes thin, which may lead to leakage of urine and the like. In addition, the twist of the fibers causes pills, and the pills may be put into the mouth by infants. As described above, improvement in the fuzz resistance of the nonwoven fabric is an important quality item together with the strength and texture of the nonwoven fabric, and various production methods have been proposed to supplement these.

For example, JP-A-5-33257 discloses that polyethylene terephthalate long fibers are interposed between layers composed of long fibers (sheath-core composite) having polyethylene terephthalate as a core component and high-density polyethylene as a sheath component. There has been proposed a laminated nonwoven fabric having a three-layer structure in which the constituted layers are present and in which the entire nonwoven fabric is partially subjected to point thermocompression bonding.
In this configuration, since the polyethylene terephthalate long fibers in the middle layer are made of a resin component having a higher melting point than the fibers in the upper and lower layers,
Even in the case of point thermocompression bonding, the middle layer has little adhesion between the fibers and the fibers move relatively freely. Further, in this configuration, since the fibers of the middle layer are not adhered, the flexibility of the nonwoven fabric is maintained, but the strength of the nonwoven fabric cannot be obtained, and the fibers of the upper and lower layers must be subjected to high temperature treatment. Fusion is a problem. In addition, since the adhesion between the laminations is insufficient, when the nonwoven fabrics are rubbed, peeling between the laminations occurs, and as a result, a problem remains in the fuzz resistance.

Further, Japanese Patent Application Laid-Open No. 8-41768 discloses that
In order to compensate for this drawback, between the part consisting only of the long fiber group A and the layer consisting of only the long fiber group B consisting of a polymer component having a melting point higher than that of the long fiber group A by 20 ° C. There has been proposed a laminated nonwoven fabric obtained by laminating long fiber groups C having portions where fiber groups B are mixed with each other and performing point thermocompression bonding.

In this method, since the fibers of the long fiber group A and the long fiber group B are mixed in the long fiber group C, the separation prevention between the lamination of the long fiber C and the long fiber group A and the long fiber group B is prevented. Can be expected to be effective. However, in this method, the long fiber group A
Since the melting point difference between the long fiber group B and the long fiber group B is different, it is necessary to set the processing temperature to the high melting point side or different processing temperatures for the high melting point side and the low melting point side. However, when the temperature is adjusted to the high melting point side, the amount of heat applied to the low melting point side becomes excessive, which causes a problem of fusing to a processing apparatus. Next, when different processing temperatures are set for the high melting point side and the low melting point side, respectively, the amount of heat applied to the long fiber group C, which is the middle layer, tends to be insufficient, and there has been a problem that separation between the layers occurs. In addition, since the long fiber group C has a structure in which the long fiber group A and the long fiber group B having different melting points are mixed, the long fiber group C has a fused portion sufficient for self-adhesion and adhesion between laminations. As a result, the degree of freedom of the fiber was increased, and the strength of the nonwoven fabric was insufficient, and there was a problem in the fuzz resistance.

As described above, various methods for producing a nonwoven fabric having both the texture of the nonwoven fabric and the strength of the nonwoven fabric have been proposed, but no nonwoven fabric satisfying the fuzz resistance has been developed. Hitherto, it has been known that as a means for improving the fuzz resistance, a method of increasing the point compression area ratio of the nonwoven fabric surface is most effective. However, if the point compression area ratio is increased and the processing temperature is increased at the same time, the texture of the nonwoven fabric is not only impaired, but also the nonwoven fabric is likely to be fused to the embossing roll. In addition, the fiber received greater damage at the edge of the crimping point, the fiber was more likely to be cut, and the fuzz resistance was poor. On the other hand, there is a method of keeping the processing temperature low, but the thermal bonding inside the nonwoven fabric becomes insufficient, leading to insufficient strength of the nonwoven fabric or delamination.

As described above, when the texture of the nonwoven fabric is emphasized,
The fuzz resistance and delamination are deteriorated, and when the fuzz resistance is emphasized, there is a dilemma that the operability is deteriorated due to the texture of the nonwoven fabric and the fusion and winding around the embossing roll.

Further, since the nonwoven fabric obtained by these methods is a fiber product obtained by combining several kinds of thermoplastic resins, it is difficult to recycle a defective lot product or the like generated during the manufacturing process as a resin. As a result, there is a problem of deterioration of the environment due to deterioration of the basic unit and increase of refuse, and a nonwoven fabric which has solved these problems has been demanded.

[0014]

SUMMARY OF THE INVENTION An object of the present invention is to provide a thermoplastic composite nonwoven fabric which has solved the above-mentioned problems and a fiber product such as an absorbent article using the same.

[0015]

Means for Solving the Problems The inventors of the present invention have made intensive studies to solve the above-mentioned problems, and as a result, have obtained a prospect that the intended purpose will be achieved by adopting the following structure.
The present invention has been completed. (1) Nonwoven fiber aggregate (I) composed of thermoplastic resin (A) as both outer layers, and nonwoven fiber aggregate (II) composed of thermoplastic resin (A ′) of the same type as thermoplastic resin (A) ) Is disposed in the middle layer of the nonwoven fiber aggregate (I), and is laminated, wherein the nonwoven fiber aggregate (I) after the fiber molding is formed.
I) / melt flow ratio of nonwoven fiber aggregate (I) is 1.1 to 1.1
5.0. A thermoplastic composite nonwoven fabric, which is 5.0. (2) The thermoplastic composite nonwoven fabric is joined by point thermocompression bonding, and the point thermocompression bonding area ratio is 4 to
The thermoplastic composite nonwoven fabric according to the above (1), wherein the content is 30%. (3) The heat as described in the above item (1) or (2), wherein the thermoplastic resins (A) and (A ′) are at least one kind of thermoplastic resin independently selected from polyolefin-based resins. Plastic composite non-woven fabric. (4) The thermoplastic resins (A) and (A ′) are each independently a low-density polyethylene, a linear low-density polyethylene, a high-density polyethylene, a polypropylene, a propylene-based binary copolymer, or a propylene-based ternary copolymer. The thermoplastic composite nonwoven fabric according to any one of the above items (1) to (3), wherein the thermoplastic composite nonwoven fabric is at least one type of thermoplastic resin selected from olefin resins that are polymers. (5) The thermoplastic composite nonwoven fabric according to any one of the above (1) to (4), wherein the nonwoven fiber aggregate (I) and / or the nonwoven fiber aggregate (II) is a long fiber. . (6) The thermoplastic composite nonwoven fabric according to any one of the above (1) to (5), and a nonwoven fabric other than the thermoplastic composite nonwoven fabric, a film, a pulp sheet, a knitted fabric, and a woven fabric. A laminated composite nonwoven fabric obtained by laminating at least one type of article obtained. (7) An absorbent article using the thermoplastic composite nonwoven fabric according to any one of the above (1) to (5) or the laminated composite nonwoven fabric according to the above (6). (8) A wiper using the thermoplastic composite nonwoven fabric according to any one of the above items (1) to (5) or the laminated composite nonwoven fabric according to the above item (6).

[0016]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in detail.
The thermoplastic composite nonwoven fabric of the present invention comprises a thermoplastic resin (A)
The nonwoven fiber aggregate (I) composed of the thermoplastic resin (A ′) and the nonwoven fiber aggregate (II) composed of the thermoplastic resin (A ′) of the same type as the thermoplastic resin (A) is used as both outer layers. I) A composite nonwoven fabric arranged and laminated in an intermediate layer, wherein the thermoplastic composite nonwoven fabric is joined by point thermocompression bonding of a thermoplastic resin (A ') of a nonwoven fiber aggregate (II). I have.
In other words, when subjected to point thermocompression bonding, the nonwoven fiber aggregate (I)
At the temperature at which the thermoplastic resin (A) softens and adheres, the thermoplastic resin (A ') of the nonwoven fiber aggregate (II) is sufficiently melt-bonded. Therefore, the nonwoven fiber aggregate (I) on the surface is less likely to be excessively damaged by heat, and does not impair the feel of the nonwoven fabric. In the present invention, the term “thermoplastic resin of the same type” refers to a thermoplastic resin containing the same monomer as a main component.

More specifically, in the thermoplastic composite nonwoven fabric of the present invention, the interlayer between the inner layer portion and the outer layer portion of the nonwoven fabric is bonded by the thermoplastic resin (A ') of the nonwoven fiber aggregate (II).
It has a sufficient strength of nonwoven fabric, can suppress the degree of freedom of fiber, and leads to improvement of fuzz resistance. It is also effective in preventing peeling between nonwoven fabric laminations.

The texture of the nonwoven fabric is greatly affected by the state of adhesion of the surface of the nonwoven fabric. In particular, in the case of the point thermocompression bonding using an embossing roll, the texture largely depends on the point thermocompression bonding area ratio (projection) and the processing temperature. With general-purpose technology, when the point thermocompression bonding area ratio is reduced, the degree of freedom of the fiber on the surface of the nonwoven fabric increases, and when the processing temperature is lowered, the degree of freedom of the fiber inside the nonwoven fabric increases. There was a tendency to decrease.

The thermoplastic composite nonwoven fabric of the present invention has a processing temperature that does not damage the surface of the nonwoven fabric because the middle layer between the three layers is composed of fibers having a higher melt flow rate than the upper and lower layers. Even if processing is carried out, since the inside of the nonwoven fabric is sufficiently adhered, the degree of freedom of the fiber can be controlled. For this reason, in the case of the same point thermocompression bonding area ratio, as compared with the conventional nonwoven fabric, the texture and the fuzz resistance are excellent, and the strength of the nonwoven fabric is sufficient. In addition, roll winding by the molten resin can be suppressed, and stable production (operability) can be achieved. Further, when the obtained nonwoven fabric is composed of the same raw material resin (this is one of the preferable embodiments of the present invention), the fibers or nonwoven fabric generated in the defective lot or the like are used again after re-pelleting. So-called recycling is possible.

In the production of the thermoplastic composite nonwoven fabric of the present invention, the nonwoven fiber aggregate (I) and the nonwoven fiber aggregate (II)
The reason why the point thermocompression bonding method is selected as an integrated method is that the point thermocompression bonding method is a processing method using heat and pressure compared to the hot air processing method, so that it can be processed at a temperature lower than the melting point of the thermoplastic resin to be welded There is. That is, when the nonwoven fiber aggregate (I) and the nonwoven fiber aggregate (II) are laminated and integrated by point thermocompression bonding, the point thermocompression bonding method uses a nonwoven fiber aggregate caused by heat during point thermocompression bonding. This is most preferable because damage to (I) can be suppressed and the adhesive strength of the nonwoven fiber aggregate (II) can be sufficiently exhibited. In addition, the area of the fusion zone for point thermocompression bonding (point thermocompression bonding area ratio) is
The range is preferably 4 to 30%, more preferably 5 to 25%.
%. If the area of the fusion zone is less than 4%, delamination between nonwoven fabric laminates is concerned, and if it exceeds 30%, the texture may be reduced.

As the shape of the convex portion of the embossing roll, those engraved in various shapes can be used. For example, various shapes such as circular, elliptical, square, rectangular, parallelogram, rhombic, triangular, and hexagonal can be used as the planar shape of the tip surface of the convex portion.

In the present invention, the melt flow rate (MF) of the thermoplastic resin (A) of the nonwoven fiber aggregate (I) and the thermoplastic resin (A ') of the nonwoven fiber aggregate (II) after fiber molding is used.
The reason why the melt flow ratio is required for R) is that fiber damage of the nonwoven fiber aggregate (I) is minimized during welding of the thermoplastic resin (A) by point thermocompression bonding, and the partial thermal bonding between the laminations is strong. Thereby, delamination is suppressed, and a composite nonwoven fabric having high nonwoven fabric strength is obtained. Conversely, when the MFR of the thermoplastic resin (A ') is lower than that of the thermoplastic resin (A), the fuzzing resistance deteriorates at low temperature processing, and a problem that may occur as a conventional problem such as roll winding occurs at high temperature processing. . Further, the melt flow ratio of the thermoplastic resin (A) and the thermoplastic resin (A ′) is as follows:
The melt flow ratio of the thermoplastic resin (A ′) (MFR of the thermoplastic resin (A ′) / MFR of the thermoplastic resin (A)) is preferably 1.1 to 5.0. Particularly preferably, it is 1.3 to 5.0. If the melt flow ratio is less than 1.1, a problem that may occur conventionally may occur. On the other hand, if the melt flow ratio is higher than 5.0, fusion of yarns and yarn breakage due to insufficient cooling during spinning are likely to occur, and there is a concern about stable production. For these reasons, the combination of the resins may be the same if the thermoplastic resin (A) and the thermoplastic resin (A ′) are the same type of thermoplastic resin and have the above-mentioned melt flow ratio. It is preferable to use a resin as a raw material. This combination is further effective in preventing peeling between the laminations, and is excellent in fuzz resistance. When obtaining non-woven fiber aggregates having different MFRs from the same raw material resin, a method of giving a difference in spinning temperature when producing each non-woven fiber aggregate can be used. That is, the nonwoven fiber aggregate (I) made of the thermoplastic resin (A ′) is set so that the melt flow ratio of both components falls within the above range.
What is necessary is just to make the spinning temperature of I) higher than the spinning temperature of the nonwoven fiber aggregate (I) consisting of a thermoplastic resin (A). Of course, instead of the same raw material, a thermoplastic resin of the same kind having a different MFR may be used as a raw material.

In the present invention, the resin used for the thermoplastic resin (A) and the thermoplastic resin (A ') is preferably a polyolefin resin such as a polyethylene resin or a polypropylene resin. As the polyethylene used for the thermoplastic resin (A) and the thermoplastic resin (A ′) in the present invention, a polyethylene resin that is generally used industrially is preferably used, for example, having a density of 0.910 to 0.92.
5 g / cm ³ low density polyethylene, density 0.926
-0.940 g / cm ³ linear low density polyethylene,
High-density polyethylene having a density of 0.941 to 0.980 g / cm ³ can be exemplified. The melt flow rate (M
I: JIS K 7210) is preferably in the range of 2 to 100 g / 10 minutes.

In the present invention, examples of the polypropylene used for the thermoplastic resin (A) and the thermoplastic resin (A ') include a homopolypropylene, a propylene-based binary copolymer and a propylene-based terpolymer. The melt flow rate (MFR: JIS K 721)
0 is a value measured according to condition 14 in Table 1)
Those having a melting point of 120 to 165 ° C. and a melting point of 50 g / 10 minutes are preferred.

In the present invention, the propylene-based binary copolymer and propylene-based terpolymer used for the thermoplastic resin (A) and the thermoplastic resin (A ') contain propylene as a main component and a small amount thereof. Of ethylene and butene
Examples thereof include a crystalline copolymer with an α-olefin such as 1, hexane-1, octene-1, or 4-methylpentene-1. Further, the copolymer has an MFR of 2 to 150 g / 10 min and a melting point of 120 to 158 ° C. Those in the range are preferably used.
As a specific example, a propylene / ethylene binary copolymer mainly composed of propylene containing 99 to 85% by weight of propylene units and 1 to 15% by weight of ethylene units, 99 to 50% by weight of propylene units and butene-1 Propylene / butene mainly composed of propylene containing 1 to 50% by weight of a unit
84 to 9 of the binary copolymer or propylene unit
8% by weight, 1 to 10% by weight of ethylene unit, butene-1
A terpolymer of propylene / ethylene / butene-1 containing 1 to 15% by weight of a unit is exemplified.

The thermoplastic resin used in the present invention may further contain an antioxidant, a light stabilizer, an ultraviolet absorber, a neutralizing agent, a nucleating agent, an epoxy stabilizer, a lubricant within a range not to impair the effects of the present invention. If necessary, antibacterial agents, flame retardants, antistatic agents, pigments, plasticizers, and hydrophilic agents may be added. In addition, the thermoplastic composite nonwoven fabric of the present invention may be subjected to a surface treatment such as a surfactant, if necessary.

Nonwoven fiber aggregate (I) used in the present invention
Short fibers or long fibers are used as the fibers of the nonwoven fiber aggregate (II). The method for producing the short fiber is not particularly limited, but using a spinneret, spinning is performed by a known spinning method to obtain an undrawn fiber, which is drawn, further crimped, and has an appropriate length. A method of cutting the fiber can be exemplified. In addition, a stretched fiber which is an intermediate for producing the short fiber is used, and a crimp is not applied to the stretched fiber, and a straight cut fiber (chop) or a melt-spun polymer stream is heated by a high-temperature high-pressure air stream. A method for producing fibers obtained by a known melt-blowing method, in which the web is blown, thinned, and collected and deposited on a moving collecting surface to form a web, is also a representative example of the method for producing short fibers. On the other hand, the method for producing a long fiber is not particularly limited, but it can be produced by a known spunbonding method using a spinneret.

The fineness of the fibers constituting the thermoplastic composite nonwoven fabric of the present invention is not particularly limited, but is preferably 0.01 to 11 dtex in terms of texture and flexibility. Also, the basis weight of the thermoplastic composite nonwoven is preferably from 5 to 40 g / m ^2, more preferably from 8~30g / m ^2. If the basis weight is less than 5 g / m ² , sufficient nonwoven fabric strength cannot be obtained, and
If it exceeds g / m ² , sufficient nonwoven fabric strength can be obtained, but when used for surface materials such as sanitary materials, the touch tends to be poor.

The lamination weight ratio of the nonwoven fiber aggregate (I) and the nonwoven fiber aggregate (II) constituting the thermoplastic composite nonwoven fabric of the present invention is determined by the weight ratio of the nonwoven fiber aggregate (II) ( The basis weight of the nonwoven fiber aggregate (I) / the basis weight of the nonwoven fiber aggregate (II)),
It is preferably 0.2 to 5. Particularly preferably, it is 0.
3-4. When the basis weight is more than 5, the nonwoven fabric has poor adhesion when heat-treated, and tends to cause problems in peeling between layers and fuzz resistance. The basis weight ratio of the upper and lower layers of the nonwoven fiber aggregate (I) is not limited to the same ratio, and can be arbitrarily selected according to the use.

In the thermoplastic composite nonwoven fabric of the present invention,
To the extent that the effect is not impaired, nonwoven fabrics other than the thermoplastic composite nonwoven fabric of the present invention, films, pulp sheets, knits, woven fabrics, and other articles can be laminated to form a laminated composite nonwoven fabric. In addition, the thermoplastic composite nonwoven fabric used at this time may be laminated alone, or may be laminated in combination of two or more. Further, the material constituting the article is not limited, and may be any material that can be used industrially, and may include a material that can be bonded to the base thermoplastic composite nonwoven fabric or a material that can be bonded. preferable.

The thermoplastic composite nonwoven fabric and laminated composite nonwoven fabric of the present invention can be preferably used for absorbent articles, textile products such as wipers and the like. As the absorbent article, for example, it can be particularly preferably used as a material for sanitary materials such as disposable diapers, napkins, sweat pads, sebum removing sheet materials, and hand wipes for infants and adults.

Further, as the wiper, for example, it can be preferably used as a part or the whole of a household disposable rag, a window wiping material, a floor wiping material, a tatami wiping material and the like. In addition, it can be used as a disposable seat cover for airplanes and passenger vehicles, a disposable toilet seat cover, a heat insulator for clothes, a molding base material, and the like.

[0033]

The present invention will be described below in detail with reference to examples and comparative examples, but the present invention is not limited to these examples. The terms used in the examples and comparative examples and methods for measuring physical properties are as follows.

(1) Melt flow rate of thermoplastic resin: MFR (after fiber molding) MFR: value measured according to condition 14 in JIS K7210 Table 1.

(2) Compression area ratio (emboss roll projection)%: The ratio of the projection to the total area of the compression roll. (3) Area ratio of point thermocompression bonding (embossed surface side of nonwoven fabric)%: ratio of area of fusion area for point thermocompression bonding to total area of nonwoven fabric.

(4) Hand feeling of nonwoven fabric A sensory test was conducted by five panelists. If all were judged to be soft, it was judged as excellent. Three to four persons were judged to be soft. When it was judged that the feeling was lacking, it was evaluated as "impossible".

(5) Non-woven fabric strength (CD) From thermoplastic composite non-woven fabric or laminated composite non-woven fabric, M
The test piece was placed 5 cm so that D was 2.5 cm and CD was 15 cm.
Collect one sheet. This test piece was gripped at a distance of 10 cm using an autograph AGS500D manufactured by Shimadzu Corporation.
Breaking strength (cN / 2.5 at a tensile speed of 10 cm / min)
cm) was measured, and the average value of the five sheets was regarded as the nonwoven fabric strength of the CD. The machine direction (length direction) of the nonwoven fabric was MD, and the direction perpendicular to the machine direction (lateral direction) was CD.

(6) Evaluation of Fuzzing Resistance A method for evaluating the fuzzing resistance (hardness of fluffing) of the obtained nonwoven fabric is described below. The evaluation method conforms to JIS L0849-1974. A non-woven fabric sample of 4 cm x 20 cm
・ Prepare 4 CDs each. 3.5cm x 20cm in the length direction of the nonwoven fabric sample
Paste long double-sided tape. At this time, two nonwoven fabric samples on the embossed roll treated surface side and the flat roll treated surface side are prepared for each of the MD and CD. A nonwoven fabric sample was stuck on a sample table of a friction tester (manufactured by Suga Test Instruments Co., Ltd.), and Kanakin No. 3 cloth (4 cm × 5
cm). Place the friction element on the non-woven fabric sample, and rub the surface of the non-woven fabric at 150 reciprocations (follicle generation and fluffing)
Is organoleptically evaluated. Judgment criteria (sensory index) A: Neither fluff nor fluff is observed. ：: Some fluffing is observed. Δ: Many fluffs and pills are observed. X: Many fluffs and multiple pills are observed.

Examples 1 and 2, Comparative Example 1 MFR10 crystalline polypropylene (homopolymer) was used as the basic resin for the thermoplastic resin, and the extrusion temperature was 250 ° C. as the thermoplastic resin (A) by a known spunbonding method.
The obtained fiber group is introduced into an air soccer and drawn and drawn to obtain a 2dtex long fiber,
Subsequently, after charging the long fiber group discharged from the air soccer by applying the same charge by a charging device,
The fibers are opened by colliding with a reflection plate, and the opened long fibers are collected as a long fiber web on an endless net-shaped conveyor provided with a suction device on the back surface, and this is collected as a nonwoven fiber aggregate (I). Using. Similarly, a crystalline polypropylene of MFR10 is discharged as a thermoplastic resin (A ′) from a spinneret at an extrusion temperature of 270 ° C. by a spun bond method, and the obtained fiber group is introduced into an air soccer and drawn and stretched. It is collected as a 2dtex long fiber web, and this is collected as a nonwoven fiber aggregate (I
I) (Example 1) and a nonwoven fiber aggregate (II) made of a 2dtex long fiber web, which was collected in the same manner as in Example 1 except that the extrusion temperature was 330 ° C. 2) Each was laminated so that the nonwoven fiber aggregate (II) was located in the middle layer and the nonwoven fiber aggregate (I) was located in the upper and lower layers. Next, the nonwoven fiber aggregate (I) is laminated on the middle layer, and the nonwoven fiber aggregate (II) of Example 2 is laminated on the upper and lower layers (Comparative Example 1), Examples 1, 2 and Comparative Example 1. Each laminated body was treated at a linear pressure of 20 N / mm, a compression bonding area ratio of 10%, and a processing temperature of emboss roll temperature / flat roll temperature = 140 ° C./140° C. to obtain a thermoplastic composite nonwoven fabric. Example 1
As shown in Table 1, was excellent in texture, nonwoven fabric strength, and fuzz resistance. Example 2 was excellent in texture, very strong in nonwoven fabric, and very excellent in fuzz resistance. In Comparative Example 1, the strength of the nonwoven fabric was low, and the fuzz resistance was poor.

Example 3 and Comparative Example 2 A high-density polyethylene having a density of 0.959 and an MI of 13 was used as a basic resin for the thermoplastic resin, and the thermoplastic resin (A) was prepared by the same spunbonding method as in Example 1. As a result, a 2dtex long fiber web discharged from a spinneret at an extrusion temperature of 230 ° C. was obtained, and this was used as a nonwoven fiber aggregate (I). Next, a 2dtex long fiber web discharged from a spinneret at an extrusion temperature of 300 ° C. was obtained as a thermoplastic resin (A ′) by the same spunbonding method as in Example 1, and this was used as a nonwoven fiber aggregate ( II) (Example 3) In addition, a 2dtex long fiber web discharged from a spinneret at an extrusion temperature of 200 ° C by the same spunbonding method was obtained, and this was used as a nonwoven fiber aggregate (II). Each (Comparative Example 2), the nonwoven fiber aggregate (II) was laminated on the middle layer so that the nonwoven fiber aggregate (I) was positioned on the upper and lower layers, and the linear pressure was 20 N / mm and the compression area ratio was 20%. Then, processing was performed at a processing temperature of emboss roll temperature / flat roll temperature = 120 ° C./120° C. to obtain a thermoplastic composite nonwoven fabric. As can be seen from Table 1, Example 3 was very excellent in texture, nonwoven fabric strength and fuzz resistance. Further, when the nonwoven fabric was used as a surface material of a disposable diaper for adults, it was very good as an absorbent article. Comparative Example 2 has a low strength of the nonwoven fabric,
The fluff resistance was poor.

Example 4 MFR16 in a thermoplastic resin, 5% by weight of ethylene unit,
A propylene / ethylene binary copolymer containing 95% by weight of propylene units was used as a basic resin, and a spun bond method was used as in Example 1 to obtain a thermoplastic resin (A) from a spinneret at an extrusion temperature of 250 ° C. A discharged 2dtex long fiber web was obtained and used as the nonwoven fiber aggregate (I). Next, as a thermoplastic resin (A ′), an undrawn yarn having a single-fiber fineness of 4.0 dtex, which was discharged from a spinneret at an extrusion temperature of 330 ° C., was obtained by a composite spinning device. Thereafter, the film is stretched 2.4 times with a hot roll, a surfactant is applied thereto, and a mechanical crimp is applied.
X 38 mm fibers were obtained. The fiber was carded with a roller card machine to obtain a web, which was used as a nonwoven fiber aggregate (II). The non-woven fiber aggregate (II) is laminated on the middle layer so that the non-woven fiber aggregate (I) is positioned on the upper and lower layers, and the linear pressure is 20 N / mm, the compression area ratio is 15%, the emboss roll temperature / the flat roll temperature = Processing was performed at a processing temperature of 130 ° C./130° C. to obtain a thermoplastic composite nonwoven fabric. As can be seen in Table 1, Example 4 was very excellent in texture, nonwoven fabric strength and fuzz resistance.

Comparative Examples 3 and 4 Using a high-density polyethylene having a density of 0.959 and an MI of 13, an extrusion temperature of 3 was obtained by the same spun bond method as in Example 1.
A 2dtex long fiber web discharged from the spinneret at 00 ° C. was obtained, and the linear pressure was 20 N / mm, the compression area ratio was 20%, and the emboss roll temperature / flat roll temperature = 110 ° C./1.
Processing was performed at a processing temperature of 10 ° C. to obtain a nonwoven fabric (Comparative Example 3). Further, using the same long fiber web, processing was performed at a processing temperature of emboss roll temperature / flat roll temperature = 130 ° C./130° C. to obtain a nonwoven fabric (Comparative Example 4). Comparative Example 3 was inferior in nonwoven fabric strength and fuzz resistance, and Comparative Example 4 was inferior in texture. During continuous operation, there was a problem that the resin was fused to the embossing roll and the nonwoven fabric was wound around the embossing roll.

COMPARATIVE EXAMPLE 5 2.0 dtex sampled at an extrusion temperature of 250 ° C. from a composite spinning apparatus in the same manner as in the nonwoven fiber aggregate (II) of Example 4.
A crystalline polypropylene (homopolymer) single fiber of MFR10 having a size of 38 mm is carded by a roller card machine, and the obtained web is used as an upper layer of a laminate, similar to the nonwoven fiber aggregate (II) of Example 4. From the composite spinning device,
2.0 dtex × 38, sampled at an extrusion temperature of 230 ° C.
A high density polyethylene single fiber having a density of 0.959 mm and an MI of 13 is carded with a roller card machine,
Using the obtained web as the lower layer of the laminate, a polypropylene single fiber and a high-density polyethylene single fiber similarly collected were mixed at a weight ratio of 50% / 50%, and carded with a roller card machine to obtain a web. The laminated web is used as a middle layer, and these layers are laminated and processed at a processing pressure of 20 N / mm linear pressure, 20% crimping area ratio, embossing roll temperature / flat roll temperature = 140 ° C./140° C. to obtain a thermoplastic composite. A nonwoven fabric was obtained. In Comparative Example 4, the polypropylene single fiber in the upper layer portion was insufficient in adhesion, and the fuzz resistance was poor. The nonwoven fabric strength was also low. Further, during continuous operation of the high-density polyethylene single fiber in the lower layer, the resin was fused to the flat roll, and the trouble that the nonwoven fabric was wound around the flat roll occurred.

Example 5 When the thermoplastic composite nonwoven fabric of the present invention obtained in Example 2 was used for a top sheet and / or a back sheet of a disposable diaper for children, there was no problem in fuzz resistance.
Further, it was excellent in tactile sensation and was sufficiently satisfactory.

Example 6 When the thermoplastic composite nonwoven fabric of the present invention obtained in Example 3 was used as a window-wiping wiper, it showed very good dust adsorbing properties.

Example 7 The laminated composite nonwoven fabric obtained by laminating the thermoplastic composite nonwoven fabric of the present invention obtained in Example 4 and another pulp sheet was used as a floor or table wiper. Good and excellent wiping properties.

As can be seen from the examples, the thermoplastic composite nonwoven fabric of the present invention has a nonwoven fiber aggregate (II) located in the middle layer.
Since the thermoplastic resin (A ') has a higher melt flow rate than the thermoplastic resin (A) of the nonwoven fiber aggregate (I) located in the upper and lower layers, the thermoplastic resin (A') At a temperature at which (A) is softened and adhered, the thermoplastic resin (A ') is sufficiently fused and adhered. Further, the non-woven fiber aggregate (I) located on the surface is hardly damaged by heat excessively, the fusion (winding) of the resin to the embossing roll is suppressed, and the strength of the non-woven fabric, the feeling and the fuzz resistance are reduced. Good and satisfactory.

[0048]

[Table 1]

[0049]

The thermoplastic composite nonwoven fabric of the present invention has excellent operability and has a good texture. In addition, it has excellent fuzz resistance and has practically sufficient nonwoven fabric strength.
Further, since the thermoplastic composite fibers are composed of the same component resin, it is possible to recycle fibers and nonwoven fabrics other than products as a resin again, which leads to an improvement in unit consumption and a reduction in dust.

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) A47L 1/15 A41B 13/02 E 13/16 F A61F 13/53 A61F 13/18 307G 13/15 B32B 5 / 02 F-term (reference) 3B029 BB02 BB03 BB07 BC02 BC07 3B074 AA02 AA08 AB01 AC03 4C003 AA07 AA28 4F100 AK01A AK01B AK01C AK01D AK03A AK03B AK03C AK05A AK05B AK05C AK06A AK06B AK06C AK07A AK07B AK07C AK07J AK63A AK63B AK63C AK80A AK80B AK80C AL01A AL01B AL01C BA03 BA04 BA06 BA07 BA10D BA13 BA32 DG02D DG04A DG04B DG04C DG06A DG06B DG06C DG12D DG13D DG15A DG15B DG15C DG15D GB66 GB72 JA06 JB16A JB16B JB16C JK01 JL00 JL01 JL47 AY14 AB03

Claims (8)

[Claims] 1. A nonwoven fiber aggregate comprising a thermoplastic resin (A ') having the same kind of components as the thermoplastic resin (A), wherein both outer layers comprise a nonwoven fiber aggregate (I) comprising a thermoplastic resin (A). (I
A composite nonwoven fabric obtained by laminating I) in the middle layer of the nonwoven fiber aggregate (I), wherein the nonwoven fiber aggregate (II) / nonwoven fiber aggregate (I) after fiber molding is formed. A thermoplastic composite nonwoven fabric having a melt flow ratio of 1.1 to 5.0. 2. The thermoplastic composite according to claim 1, wherein the thermoplastic composite nonwoven fabric is bonded by point thermocompression bonding, and a point thermocompression bonding area ratio is 4 to 30% based on the total area of the nonwoven fabric. Composite nonwoven fabric. 3. The thermoplastic resin (A) and (A ′)
The thermoplastic composite nonwoven fabric according to claim 1 or 2, wherein the thermoplastic composite nonwoven fabric is at least one type of thermoplastic resin independently selected from polyolefin resins. 4. The thermoplastic resin (A) and (A ′)
At least one type of heat independently selected from low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, propylene-based terpolymer, and propylene-based terpolymer; The thermoplastic composite nonwoven fabric according to any one of claims 1 to 3, which is a thermoplastic resin. 5. The thermoplastic composite nonwoven fabric according to claim 1, wherein the nonwoven fiber aggregate (I) and / or the nonwoven fiber aggregate (II) are long fibers. 6. The thermoplastic composite nonwoven fabric according to any one of claims 1 to 5, and a nonwoven fabric other than the thermoplastic composite nonwoven fabric, a film, a pulp sheet, a knitted fabric, and a woven fabric. A laminated composite nonwoven fabric in which at least one type of article is laminated. 7. An absorbent article using the thermoplastic composite nonwoven fabric according to any one of claims 1 to 5 or the laminated composite nonwoven fabric according to claim 6. 8. A wiper using the thermoplastic composite nonwoven fabric according to any one of claims 1 to 5 or the laminated composite nonwoven fabric according to claim 6.