JP2008025084A - 不織布 - Google Patents
不織布 Download PDFInfo
- Publication number
- JP2008025084A JP2008025084A JP2006270110A JP2006270110A JP2008025084A JP 2008025084 A JP2008025084 A JP 2008025084A JP 2006270110 A JP2006270110 A JP 2006270110A JP 2006270110 A JP2006270110 A JP 2006270110A JP 2008025084 A JP2008025084 A JP 2008025084A
- Authority
- JP
- Japan
- Prior art keywords
- nonwoven fabric
- fiber
- fibers
- support member
- openings
- 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
Links
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Images
Classifications
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Abstract
【解決手段】所定の支持部材220により下面側から支持される繊維ウェブ100に、該繊維ウェブ100の上面側から主に気体からなる流体を噴きあてて該繊維ウェブ100を構成する繊維101を移動させ、少なくとも複数の開口部3を形成する。該不織布170には、所定の方向に沿うように、所定の間隔で連続的に形成される複数の開口部3と、所定の方向において隣り合う開口部3との間に形成される複数の連結部4と、が形成される。
【選択図】図2
Description
図1(A)、図1(B)、図2、図4により、本発明の不織布における第1実施形態について説明する。
図1(A)、図1(B)、図2に示すように、本実施形態における不織布180は、該不織布180の一方の面側に縦方向である長手方向に沿って複数の溝部1が略等間隔で並列的に形成され、該溝部1において略等間隔で開口部3及び連結部4が交互に形成された不織布である。この複数の開口部3それぞれは、略円形状又は略楕円状に形成される。ここで、本実施形態において、溝部1は略等間隔で並列的に形成されているがこれに限定されず、例えば、異なる間隔ごとに形成されてもよく、また、溝部1同士の間隔が変化するように形成されていてもよい。
図1(A)、図1(B)又は図2に示すように該不織布180は、繊維101が主に気体からなる流体が噴きあてられた領域に沿って配向する縦配向繊維が含まれる含有率がそれぞれ異なる領域が形成される。それぞれ異なる領域とは、例えば、凸状部2及び連結部4等を例示することができる。
図1(A)、図1(B)に示すように、連結部4は、繊維密度が凸状部2より高くなるように調整されている。
空間面積率(%)=(空間総面積(mm2)/測定範囲面積(mm2))×100
ここで、空間総面積は、(測定時の空間総面積/測定時の拡大倍率)で算出し、また、測定範囲面積は(測定時の測定範囲面積/測定時の拡大倍率)で算出することができる。
空間面積(mm2/個)=(空間総面積(mm2)/空間個数(個))×100
不織布180全体の平均目付は、具体的には、10から200g/m2、好ましくは20から100g/m2を例示することができる。該不織布180を例えば吸収性物品の表面シートに使用する場合、平均目付が10g/m2より小さい場合には、使用中に容易に破損する場合がある。また、該不織布180の平均目付が200g/m2より大きい場合には、もたらされた液体を下方に移行させることが円滑に行われにくくなる場合がある。
本実施形態の不織布180を、例えば、所定の液体を吸収又は透過させるために使用した場合、溝部1は液体を透過させ、凸状部2はポーラス構造であるので液体を保持しにくい。さらには、溝部1に形成された開口部3は、液体に加え固体も透過させることができる。
図3から図9により、以下に、本実施形態における不織布180を製造する方法について説明する。まず、繊維ウェブ100を通気性支持部材である支持部材240の上面側に載置する。言い換えると、繊維ウェブ100を支持部材240により下側から支持する。
以下に、本発明の不織布における実施形態の変形形態について説明する。なお、以下の変形形態において、特に説明しない部分は、第1実施形態と同様であり、図面に付した番号も第1実施形態と同様である場合は、同じ番号を付している。
図10により、本発明の不織布における第2実施形態について説明する。
本実施形態における不織布182は、その一方の面側に、溝部1及び凸状部2が交互に並列的に形成されている。そして、不織布182の他方の面側においては、凸状部2の底面にあたる領域が、該凸状部2が突出する側に突出するよう形成されている。言い換えると、不織布182は、該不織布182の他方の面側において、該一方の面側における凸状部2の底面にあたる領域が窪んで凹部を形成している。該一方の面側の溝部1のにおける底面にあたる他方の面側の領域が、一方の面側の凸状部と反対方向に突出し、凸状部を形成している。
本実施形態における不織布182の製造方法は第1実施形態の記載と同様である。また、該不織布182を製造するにあたり使用される支持部材は、第1実施形態における支持部材240と同様のものを用いることができる。
図11及び図12により、本発明の不織布における第3実施形態について説明する。
図11に示すように、本実施形態における不織布184は、該不織布184の全体が波状に起伏する点で第1実施形態と異なる。以下、第1実施形態と異なる点を中心に説明する。
本実施形態における不織布184を製造する方法については第1実施形態と同様であるが、通気性支持部材である支持部材の形態が異なる。本実施形態における支持部材280は、図12に示すように、網状支持部材260の上面に複数の細長状部材285を所定間隔で略平行に配置した支持部材である。
図13により、本発明の不織布における第4実施形態について説明する。
該不織布186の一方の面側に複数の溝部1が並列的に形成された不織布である。そして、複数の溝部1それぞれの間に複数の凸状部2及び複数の第2凸状部22が交互にそれぞれ形成されている。この凸状部2及び第2凸状部22は、複数の溝部1と同様に並列的に形成されている。また、溝部1それぞれには開口部3及び連結部4が形成される。
本実施形態における不織布186の製造方法は第1実施形態の記載と同様であるが、不織布186の製造に用いられる不織布製造装置90の噴き出し口913の態様が異なる。
<繊維構成>
高密度ポリエチレンとポリエチレンテレフタレートの芯鞘構造で、平均繊度3.3dtex、平均繊維長51mm、親水油剤がコーティングされた繊維Aと、繊維Aとは撥水油剤のコーティングがされた点で異なる繊維Bとの混綿を使用する。繊維Aと繊維Bとの混合比は、70:30であり、目付は40g/m2に調整された繊維集合体を使用した。
図9における噴き出し口913の形状は横長の長方形で、噴き出し口913の断面形状は角柱型である。噴き出し口913は、縦1.0mm、横6.0mm、噴き出し口913間のピッチが14mmで複数形成される。また、噴き出し部910の幅は500mmである。温度が105℃、風量が1000l/分の条件で熱風を噴きあてた。
・凸状部:目付は52g/m2、厚みが3.8mm、繊維密度が0.01g/cm3であり、該凸状部一つ当たりの幅は8.5mm、ピッチが14mmであった。
・溝部:平均目付は11g/m2、厚みが1.8mm、繊維密度が0.007g/cm3であり、該溝部一つ当たりの幅5.5mm、ピッチが14mmであった。
・連結部:目付は30g/m2、厚みが1.8mm、繊維密度が0.02g/cm3であり、該連結部一つ当たりの幅は5.5mm、連結部一つ当たりの長さは2.1mm、MD方向へのピッチが15.0mm、CD方向へのピッチは14.0mmであった。
・開口部:該開口部一つ当たりの幅は5.3mm、開口部一つ当たりの長さは11.5mm、MD方向へのピッチが15.0mm、CD方向へのピッチは14.0mmであった。
・形状:凸状部、溝部、開口部及び連結部がそれぞれ形成され、凸状部の裏面が凸状部と同じ方向に隆起し、該不織布の最裏面を形成しない形状となった。また、溝部では、該溝部が延びる方向に沿って連結部と開口部とが交互に複数形成された。該開口部の面積は61.0mm2の縦長長方形状であって、角が丸い形状となった。
本発明における不織布の用途として、例えば、生理用ナプキン、ライナー、おむつ等の吸収性物品における表面シート等を例示できる。この場合、凸状部は肌面側、裏面側のどちらであってもよいが、肌面側にすることによって、肌との接触面積が低下するため体液による湿り感を与えにくい場合がある。また、吸収性物品の表面シートと吸収体との間の中間シートとしても使用できる。表面シートもしくは吸収体との接触面積が低下するため、吸収体からの逆戻りがしにくい場合がある。また、吸収性物品のサイドシートや、おむつ等の外面(アウターバック)、面ファスナー雌材等でも、肌との接触面積の低下やクッション感があることから用いることができる。また、床や身体に付着したゴミや垢等を除去するためのワイパー、マスク、母乳パッド等多方面に使用することができる。
本発明における不織布の用途として、図14,図15に示すように、例えば、凹凸を有し、凹部に複数の開口部と凸状部より相対的に繊維密度が高い連結部が設けられた不織布を吸収性物品の表面シート301、302として使用した場合を例示できる。この場合、凸状部が形成された面が肌側になるように該不織布が配置されることが好ましい。
本発明における不織布の用途として、図16に示すように、例えば、凹凸を有し、凹部に複数の開口部と、凸状部より相対的に繊維密度が高い連結部が設けられた該不織布を吸収性物品の中間シート311として使用した場合を例示できる。この場合、凸状部が形成された面が表面シート310側になるように該不織布が配置されることが好ましい。
本発明における不織布の用途として、図17に示すように、例えば、凹凸を有し、凹部に複数の開口部と凸状部より相対的に繊維密度が高い連結部が設けられた不織布を吸収性物品のアウターバック321として使用した場合を例示できる。この場合、凸状部が形成された面が該吸収性物品の外側になるように該不織布が配置されることが好ましい。
以下に、各構成物について詳述する。
[5.1.1]繊維集合体
繊維集合体は、略シート状に形成された繊維集合体であって該繊維集合体を構成する繊維が自由度を有する状態であるものである。言い換えると、繊維同士の自由度を有する繊維集合体である。ここで、繊維同士の自由度とは、繊維集合体である繊維ウェブが主に気体からなる流体によって繊維が自由に移動することが可能な程度のことをいう。この繊維集合体は、例えば、複数の繊維を混合した混合繊維を所定厚さの繊維層を形成するように噴き出すことで形成することができる。また、例えば、複数の異なる繊維それぞれを、複数回に分けて積層させて繊維層を形成するように噴出することで形成することができる。度
繊維集合体を構成する繊維(例えば、繊維ウェブ100を構成する繊維101)として、例えば、低密度ポリエチレン、高密度ポリエチレン、直鎖状ポリエチレン、ポリプロピレン、ポリエチレンテレフタレート、変性ポリプロピレン、変性ポリエチレンテレフタレート、ナイロン、ポリアミド等の熱可塑性樹脂で構成し、各樹脂を単独、もしくは複合した繊維が挙げられる。
[5.2.1]主に気体からなる流体
本発明にける主に気体からなる流体は、例えば、常温もしくは所定温度に調整された気体、又は、該気体に固体もしくは液体の微粒子が含まれるエーロゾルを例示できる。
通気性支持部材200として、繊維ウェブ100を支持する側が略平面状又は略曲面状であると共に、略平面状又は略曲面状における表面は略平坦である支持部材を例示できる。略平面状又は略曲面状として、例えば、板状や円筒状を例示できる。また、略平坦状とは、例えば、支持部材における繊維ウェブ100を載置する面自体が凹凸状等に形成されていないことをいう。具体的には、網状支持部材210における網が凹凸状等に形成されていない支持部材を例示することができる。
噴き出し部910を、主に気体からなる流体の向きを変更可能にすることで、例えば、形成される凹凸における凹部(溝部)の間隔や、凸状部の高さ等を適宜調整することができる。また、例えば、上記流体の向きを自動的に変更可能に構成することで、例えば、溝部等を蛇行状(波状、ジグザグ状)や他の形状となるよう適宜調整することができる。また、主に気体からなる流体の噴き出し量や噴き出し時間を調整することで、溝部や開口部の形状や形成パターンを適宜調整することができる。主に気体からなる流体の繊維ウェブ100に対する噴きあて角度は、垂直であってもよく、また、繊維ウェブ100の移動方向Fにおいて、該移動方向Fであるライン流れ方向へ所定角度だけ向いていても、ライン流れ方向とは逆へ所定角度だけ向いていてもよい。
所定の開口部が形成された不織布180における繊維101を接着させる方法として、例えば、ニードルパンチ法、スパンレース法、溶剤接着法による接着や、ポイントボンド法やエアースルー法による熱接着が例示できるが、形成された所定の開口部の形状を維持するためは、エアースルー法が好ましい。そして、例えば、ヒータ部950によるエアースルー法における熱処理が好ましい。
ヒータ部950により加熱されて製造された不織布115は、コンベア930と所定方向Fにおいて連続するコンベア940により、例えば、不織布115を所定形状に切断する工程や巻き取る工程に移動される。コンベア940は、コンベア930と同様に、ベルト部949と、回転部941等を備えてもよい。
2 凸状部
100 繊維ウェブ
110 不織布
210 網状支持部材
910 噴き出し部
920 送気管
915 吸引部
Claims (17)
- 縦方向と横方向とを有する不織布であって、
前記縦方向に沿って形成される複数の開口部と、
前記複数の開口部における所定の開口部と、前記縦方向において隣り合う開口部との間に形成される複数の連結部と、を有し、
前記複数の連結部それぞれは、前記横方向に配向する横配向繊維の含有率が、前記縦方向に配向する縦配向繊維の含有率よりも高いと共に、
該所定の連結部における繊維密度が、前記複数の開口部及び前記複数の連結部が形成される領域に沿って隣接する複数の領域それぞれの繊維密度より高い不織布。 - 前記複数の連結部それぞれは、前記横方向の長さと、前記縦方向の長さとの比が0.7以下である請求項1に記載の不織布。
- 前記複数の開口部それぞれは、該複数の開口部それぞれの周縁における繊維が該複数の開口部それぞれの周縁に沿って配向する請求項1又は2に記載の不織布。
- 前記複数の開口部それぞれは、略円形又は略楕円形状である請求項1から3のいずれかに記載の不織布。
- 前記複数の開口部それぞれは、前記縦方向における径と、前記横方向における径との比率が1未満である請求項1から4のいずれかに記載の不織布。
- 前記複数の開口部それぞれは、前記横方向の長さが4から30mmである請求項1から5のいずれかに記載の不織布。
- 前記複数の開口部及び複数の連結部が形成される領域は、該不織布の一方の面側において厚さ方向に窪む複数の溝部に形成され、
前記複数の溝部における所定の溝部に沿うように隣接し、前記一方の面側において厚さ方向に突出する複数の凸状部をさらに有する請求項1から6のいずれかに記載の不織布。 - 前記複数の溝部それぞれは、該不織布の厚さ方向の高さが、前記複数の凸状部それぞれの前記高さの90%以下である請求項7に記載の不織布。
- 前記複数の凸状部における所定の凸状部は、前記複数の溝部における所定の溝部を挟んで隣り合う凸状部と前記高さが異なる、請求項7又は8に記載の不織布。
- 前記複数の凸状部それぞれは、頂部が略扁平状である、請求項7から9のいずれかに記載の不織布。
- 該不織布における前記複数の溝部及び前記複数の凸状部が形成される面とは反対側の面である他方の面側には、前記凸状部における突出方向とは反対側に突出する複数の領域が形成される請求項7から10のいずれかに記載の不織布。
- 前記縦方向において波状に起伏する、請求項7から11のいずれかに記載の不織布。
- 該不織布における前記複数の溝部及び前記複数の凸状部が形成される面とは反対側の面である他方の面側は略平坦である請求項1から10のいずれかに記載の不織布。
- 前記複数の凸状部それぞれにおける側部それぞれは、前記縦配向繊維の含有率が、前記横配向繊維の含有率より高い請求項7から13のいずれかに記載の不織布。
- 前記複数の凸状部それぞれは、前記一方の面側から測定した空間面積率が、該不織布における他方の面側から測定した空間面積率より大きい請求項7から14のいずれかに記載の不織布。
- 前記複数の連結部それぞれにおける繊維密度は0.05g/cm3以上である、請求項1から15のいずれかに記載の不織布。
- 該不織布を構成する繊維は、撥水性の繊維を混合している、請求項1から16のいずれかに記載の不織布。
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KR101423792B1 (ko) | 2014-07-25 |
US7897240B2 (en) | 2011-03-01 |
US20070298213A1 (en) | 2007-12-27 |
TW200804641A (en) | 2008-01-16 |
MY148083A (en) | 2013-02-28 |
TWI343429B (ja) | 2011-06-11 |
EP2034071A4 (en) | 2010-05-05 |
EP2034071B1 (en) | 2013-10-02 |
EP2034071A1 (en) | 2009-03-11 |
KR20090023342A (ko) | 2009-03-04 |
JP5123512B2 (ja) | 2013-01-23 |
WO2007148502A1 (ja) | 2007-12-27 |
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