JP2008213284A - Nonwoven fabric laminate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a nonwoven fabric laminate which is excellent in elasticity, flexibility, moisture permeability, and water resistance, prevents liquid oozing, and has good odor-barrier properties and high interlaminar adhesive strength. <P>SOLUTION: In the nonwoven fabric, a moisture permeable film is laminated on at least one side of a mixed fiber spun-bonded nonwoven fabric containing 10-90 wt.% of long fibers of a thermoplastic elastomer (A) and 90-10 wt.% of long fibers of a thermoplastic resin (B) [(A)+(B)=100 wt.%]. The nonwoven fabric laminate can appropriately be used in hygienic materials, medical materials, industrial materials, etc. Specifically, absorbent articles such as disposable diapers and sanitary items are included in the hygienic materials. In a development type disposable diaper or a brief-type disposable diaper, the laminate can appropriately be used in parts including a back sheet, a waist band (an extension tape and a side flap), a fastening tape, three-dimensional gathers, a leg cuff, and the side panel of a brief-type disposable diaper. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a nonwoven fabric laminate excellent in stretchability, flexibility, moisture permeability, water resistance, interlayer adhesion strength, and the like.

  In recent years, nonwoven fabrics are widely used for various applications because of their excellent breathability and flexibility. For this reason, the nonwoven fabric is required to have various properties according to its use and to improve the properties.

  For example, non-woven fabrics used for sanitary materials such as disposable diapers and sanitary napkins, and base fabrics for poultices are required to have water resistance and excellent moisture permeability. Moreover, it is requested | required to have a stretching property and bulkiness depending on the location used.

  As one of the methods for imparting stretchability to the nonwoven fabric, a method using a thermoplastic elastomer as a raw material for the spunbond nonwoven fabric (for example, Patent Document 1; JP 7-503502 A), thermoplastic as a fiber forming the nonwoven fabric. A method using a fiber made of polyurethane and a mixed fiber made of a thermoplastic polymer (for example, Patent Document 2; Japanese Patent Application Laid-Open No. 2004-247991), and the purpose is different from imparting stretchability, but a hydrogenated styrene block Various long-fiber nonwoven fabrics (for example, Patent Document 3; Japanese Patent Application Laid-Open No. 2004-197291) and the like obtained by mixing adhesive fibers composed of a copolymer or the like with non-adhesive fibers have been proposed.

On the other hand, as a method for imparting water resistance and waterproofness to a nonwoven fabric, a method of laminating a polyurethane nonwoven fabric having flexibility and a polyurethane film having moisture permeability and air permeability (for example, Patent Document 4; JP-A-8-10283) , A method of laminating a nonwoven fabric and a moisture-permeable thermoplastic polyester elastomer film (for example, Patent Document 5; Japanese Patent Laid-Open No. 2004-195833), a method of laminating a polyamide elastomer nonwoven fabric and a sheet having moisture permeability (for example, Patent Documents) 6; JP-A-2003-181995), a method of laminating a resin-coated thermoplastic elastomer nonwoven fabric and an elastomer film (for example, Patent Document 7; JP-A-2006-28695), and the like.
However, the demand for nonwoven fabric laminates with improved water resistance, moisture permeability, and stretchability is still strong.

JP 7-503502 A JP 2004-244791 A JP 2004-197291 A JP-A-8-10283 JP 2004-195833 A JP 2003-181995 A JP 2006-28695 A

  An object of the present invention is to develop a nonwoven fabric laminate having excellent stretchability, flexibility, moisture permeability, and water resistance, no liquid bleeding, good odor barrier properties, and high interlayer adhesion strength.

  In the present invention, the long fibers of the thermoplastic elastomer (A): 10 to 90% by weight and the long fibers of the thermoplastic resin (B): 90 to 10% by weight (provided that (A) + (B) = 100% by weight) A non-woven fabric laminate comprising a moisture-permeable film laminated on at least one surface of the mixed fiber spunbonded non-woven fabric.

  The nonwoven fabric laminate of the present invention is excellent in stretchability, flexibility, moisture permeability, and water resistance, has no liquid bleeding, has good odor barrier properties, and has high interlayer adhesion strength.

<Thermoplastic elastomer (A)>
As the thermoplastic elastomer (A) which is a raw material of the long fiber of the thermoplastic elastomer (A) which is one of the fiber components forming the mixed fiber spunbond nonwoven fabric constituting the nonwoven fabric laminate of the present invention, various known heat A plastic elastomer can be used, and two or more kinds of thermoplastic elastomers may be used in combination.

  Specifically, for example, polystyrene-polybutadiene-polystyrene block copolymer (referred to as SBS), polystyrene-polyisoprene-polystyrene block copolymer (referred to as SIS), and their hydrogenated polystyrene-polyethylene-butylene-polystyrene block copolymer. (Referred to as SEBS), and a polymer block composed of at least one aromatic vinyl compound such as styrene represented by polystyrene-polyethylene-propylene-polystyrene block copolymer (referred to as SEPS) and at least one butadiene or A block copolymer comprising a polymer block composed of a conjugated diene compound such as isoprene or a hydrogenated product thereof, a styrene elastomer, a highly crystalline aromatic polyester and a non-crystalline Polyester elastomers typified by block copolymers composed of crystalline aliphatic polyethers, composed of crystalline, high-melting polyamides and amorphous, low glass transition temperature (Tg) polyethers or polyesters. Heat represented by a block copolymer composed of a polyamide elastomer represented by a block copolymer, a hard segment made of polyurethane, and a soft segment made of polycarbonate polyol, ether polyol, caprolactone polyester or adipate polyester, etc. Plastic polyurethane elastomer, amorphous or low crystalline ethylene / α-olefin random copolymer, propylene / α-olefin random copolymer, propylene / ethylene / α-olefin random copolymer, etc. Or a mixture of the amorphous or low crystalline random copolymer and a propylene homopolymer, a copolymer of propylene and a small amount of α-olefin, a crystalline polyolefin such as high density polyethylene or medium density polyethylene. Examples thereof include polyolefin elastomers, polyvinyl chloride elastomers, fluorine elastomers, and the like.

  Styrenic elastomers include diblock and triblock copolymers based on polystyrene blocks and butadiene rubber blocks or isoprene rubber blocks. The rubber block may be unsaturated or completely hydrogenated. Specific examples of the styrene elastomer include KRATON polymer (trade name, manufactured by Shell Chemical Co., Ltd.), SEPTON (trade name, manufactured by Kuraray Co., Ltd.), and TUFTEC (trade name, manufactured by Asahi Kasei Kogyo Co., Ltd.). ), Rheostomer (trade name, manufactured by Riken Technos Co., Ltd.) and the like.

  Specifically, polyester-based elastomers are manufactured and sold under trade names such as HYTREL (trade name, manufactured by EI DuPont Co., Ltd.) and perprene (trade name, manufactured by Toyobo Co., Ltd.). Yes.

  Specifically, as the polyamide-based elastomer, for example, it is manufactured and sold under the trade name of PEBAX (trade name, Atofina Japan Co., Ltd.).

  Examples of polyolefin elastomers include ethylene / α-olefin copolymers and propylene / α-olefin copolymers. Specifically, for example, TAFMER (trade name, manufactured by Mitsui Chemicals, Inc.), Engage which is an ethylene-octene copolymer (trade name, manufactured by DuPontDow Elastomers), and CATALLOY (commercial product) containing a crystalline olefin copolymer. Name, manufactured by Montel Co., Ltd.), and Vistamaxx (trade name, manufactured by ExxonMobil Chemical Co., Ltd.).

  Specific examples of the vinyl chloride elastomer are manufactured and sold under trade names such as Leonil (trade name, manufactured by Riken Technos Co., Ltd.) and Posmir (trade name, manufactured by Shin-Etsu Polymer Co., Ltd.).

  Among these thermoplastic elastomers (A), the thermoplastic polyurethane elastomer (A1) and the olefin copolymer elastomer (A2) are preferable in terms of stretchability and workability when laminated.

  In the thermoplastic elastomer (A), the antioxidant, weathering stabilizer, antistatic agent, antifogging agent, antiblocking agent, lubricant, nucleating agent, pigment, etc. that are usually used are within the range not impairing the object of the present invention. Additives or other polymers can be blended as needed.

<Thermoplastic polyurethane-based elastomer (A1)>
Among the thermoplastic polyurethane elastomers (A1), a thermoplastic polyurethane elastomer having a solidification start temperature of 65 ° C. or higher, preferably 75 ° C. or higher, and most preferably 85 ° C. or higher is preferable. The upper limit of the solidification start temperature is preferably 195 ° C.

  Here, the solidification start temperature is a value measured using a differential scanning calorimeter (DSC), and the temperature of the thermoplastic polyurethane elastomer was increased to 230 ° C. at 10 ° C./min and held at 230 ° C. for 5 minutes. This is the starting temperature of the exothermic peak derived from the coagulation of the thermoplastic polyurethane elastomer that occurs when the temperature is subsequently lowered at 10 ° C./min. When the solidification start temperature is 65 ° C. or higher, it is possible to suppress molding defects such as fusion between fibers, yarn breakage, and resin lump when obtaining a mixed fiber spunbond nonwoven fabric. The formed mixed fiber spunbond nonwoven fabric can be prevented from being wound around the embossing roller. Moreover, the obtained mixed fiber spunbond nonwoven fabric has little stickiness, and is suitably used for materials that come into contact with the skin, such as clothing, sanitary materials, and sports materials. On the other hand, the moldability can be improved by setting the solidification start temperature to 195 ° C. or lower. The solidification start temperature of the formed fiber tends to be higher than the solidification start temperature of the thermoplastic polyurethane elastomer used for this.

  In order to adjust the solidification start temperature of such a thermoplastic polyurethane elastomer to 65 ° C. or higher, the polyol, isocyanate compound and chain extender used as raw materials for the thermoplastic polyurethane elastomer each have an optimal chemical structure. You need to select one and adjust the amount of hard segments. Here, the hard segment amount is a weight obtained by dividing the total weight of the isocyanate compound and the chain extender used for the production of the thermoplastic polyurethane elastomer by 100 and dividing the total amount of the polyol, the isocyanate compound and the chain extender by 100. Percent (% by weight) value. The amount of hard segment is preferably 20 to 60% by weight, more preferably 22 to 50% by weight, and most preferably 25 to 48% by weight.

  The thermoplastic polyurethane elastomer has a polar solvent-insoluble particle number of 3 million / g or less, preferably 2.5 million or less, and most preferably 2 million or less. Here, the polar solvent insoluble matter in the thermoplastic polyurethane elastomer is mainly a lump such as fish eye or gel generated during the production of the thermoplastic polyurethane elastomer, and the hard segment of the thermoplastic polyurethane elastomer. Components derived from agglomerates, and components generated by chemical reaction between raw materials constituting thermoplastic polyurethane elastomers, such as components in which hard segments and / or soft segments are crosslinked by allophanate bonds, burette bonds, etc. .

  The number of particles insoluble in the polar solvent is the particle size distribution measuring device using the pore electrical resistance method for the insoluble when the thermoplastic polyurethane elastomer is dissolved in the dimethylacetamide solvent (hereinafter abbreviated as “DMAC”). This is a value measured by attaching a 100 μm aperture to the surface. When a 100 μm aperture is attached, the number of particles having a size of 2 to 60 μm in terms of uncrosslinked polystyrene can be measured.

  By setting the number of particles insoluble in the polar solvent to 3 million or less with respect to 1 g of the thermoplastic polyurethane-based elastomer, the distribution of the fiber diameter is increased within the coagulation start temperature range of the thermoplastic polyurethane-based elastomer. Problems such as thread breakage can be avoided. In addition, the mixed fiber spunbond nonwoven fabric formed using such a thermoplastic polyurethane-based elastomer can have the same fiber diameter as the fiber diameter of the woven fabric, and is excellent in tactile sensation. Can be used. In addition, the filter installed inside the extruder for filtering impurities and the like is not easily clogged, and the frequency of adjustment and maintenance of the equipment is reduced, which is industrially preferable.

  The thermoplastic polyurethane-based elastomer having a small amount of insoluble polar solvent can be obtained by filtration after performing a polymerization reaction of a polyol, an isocyanate compound and a chain extender, as will be described later.

Such thermoplastic polyurethane-based elastomer has a total heat of fusion (a) determined from an endothermic peak having a peak temperature in the range of 90 to 140 ° C. and a peak temperature measured by a differential scanning calorimeter (DSC). The total amount of heat of fusion (b) obtained from the endothermic peak in the range of over 140 ° C. and below 220 ° C. is the following formula (1)
a / (a + b) × 100 ≦ 80 (1)
It is preferable to satisfy the relationship
Following formula (2)
a / (a + b) × 100 ≦ 70 (2)
It is more preferable to satisfy the relationship of
Following formula (3)
a / (a + b) × 100 ≦ 55 (3)
It is most preferable to satisfy this relationship.

  Here, “a / (a + b) × 100” means a heat of fusion ratio (unit:%) of hard domains of a thermoplastic polyurethane elastomer. When the ratio of heat of fusion of the hard domains of the thermoplastic polyurethane-based elastomer is 80% or less, the strength and stretchability of the fibers and particularly the fibers and the nonwoven fabrics in the mixed fiber spunbond nonwoven fabric are improved. In the present invention, the lower limit of the ratio of heat of fusion of the hard domains of the thermoplastic polyurethane elastomer is preferably about 0.1%.

The thermoplastic polyurethane elastomer preferably has a melt viscosity of 100 to 3000 Pa · s, more preferably 200 to 2000 Pa · s, and most preferably 1000 to 1500 Pa · s under the conditions of a temperature of 200 ° C. and a shear rate of 100 sec ^−1. . Here, the melt viscosity is a value measured by a capillograph (made by Toyo Seiki Co., Ltd., having a nozzle length of 30 mm and a diameter of 1 mm).

  The thermoplastic polyurethane elastomer preferably has a moisture value of 350 ppm or less, more preferably 300 ppm or less, and most preferably 150 ppm or less. By setting the moisture value to 350 ppm or less, it is possible to suppress the mixing of bubbles into the strands or the occurrence of yarn breakage in forming a nonwoven fabric with a large spunbond molding machine.

  A thermoplastic polyurethane-based elastomer having such characteristics can be obtained, for example, by a production method described in JP-A No. 2004-244791.

<Olefin copolymer elastomer (A2)>
Among the olefin copolymer elastomers (A2), ethylene and propylene, 1-butene, 1-butene having an amorphous or low crystallinity, preferably having a crystallinity of 20% by mass or less as measured by X-ray diffraction. Ethylene that is a copolymer with one or more α-olefins having 3 to 20 carbon atoms such as pentene, 1-hexene, 4-methyl-1-pentene, 1-heptene, 1-octene, 1-decene, etc. α-olefin copolymer elastomer, and propylene and ethylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-heptene, 1-octene, 1-decene and the like have 2 carbon atoms A propylene / α-olefin copolymer elastomer which is a copolymer with one or more α-olefins of ˜20 (excluding 3) is preferred. In addition to the α-olefin, the polyolefin-based elastomer is a small amount of norbornene, 5-methylnorbornene, 5-ethylnorbornene, cyclopentene, 3-methylcyclopentene, 4-methylcyclopentene or other cyclic olefin, 5-ethylidene-2 -Cyclic dienes such as norbornene, 5-methylene-2-norbornene, 1,3-cyclopentadiene, 1,3-cyclohexadiene, 1,4-cyclohexadiene, etc., or vinyl such as vinyl acetate and methacrylic acid ester It may contain a compound. (In the case where the polyolefin is a copolymer, the constituent unit composed of the monomer described first is the main component of the copolymer.)
Specific examples of such ethylene / α-olefin copolymer elastomers include ethylene / propylene random copolymer elastomers and ethylene / 1-butene random copolymer elastomers. Further, the melt flow rate (MFR) of the ethylene / α-olefin copolymer elastomer is not particularly limited as long as it has spinnability, but usually MFR (ASTM D1238 190 ° C., 2160 g load) is 1-1000 g / 10 min. More preferably, it exists in the range of 5-500 g / 10min, More preferably, it is the range of 10-100 g / 10min.

  Specific examples of the propylene / α-olefin copolymer elastomer include propylene / ethylene random copolymer elastomer, propylene / ethylene / 1-butene random copolymer elastomer, and propylene / 1-butene random copolymer elastomer. Can be illustrated. Further, the MFR of the propylene / α-olefin copolymer elastomer is not particularly limited as long as it has spinnability, but usually the MFR (ASTM D1238 230 ° C., 2160 g load) is 1-1000 g / 10 min, more preferably 5-5. It is in the range of 500 g / 10 min, more preferably 10-100 g / 10 min.

  Further, the olefin copolymer elastomer (A2) can be used as the amorphous or low crystalline polymer elastomer alone, but a propylene homopolymer or a copolymer of propylene and a small amount of α-olefin, It may be a composition in which crystalline polyolefin such as density polyethylene and medium density polyethylene is mixed in an amount of about 1 to 40% by mass.

  Particularly preferred olefin copolymer elastomers are olefin copolymers composed of a propylene homopolymer: 1 to 40% by mass and an amorphous or low crystalline propylene / ethylene random copolymer: 99 to 60% by mass. Copolymer elastomer, propylene homopolymer: 1 to 40% by mass and amorphous or low crystalline propylene / ethylene / α-olefin random copolymer [propylene: 45 to 89 mol%, ethylene: 10 to 25 mol % And C 4-20 α-olefins (however, the copolymerization amount of C 4-20 α-olefins does not exceed 30 mol%): 99 to 60% by mass of olefin copolymer A combined elastomer may be mentioned.

<Thermoplastic resin (B)>
As the thermoplastic resin (B) used as the raw material of the long fiber made of the thermoplastic resin which is one of the components forming the mixed fiber spunbond nonwoven fabric constituting the nonwoven fabric laminate of the present invention, the thermoplastic elastomer (A) Various known thermoplastic resins other than those may be used. For example, a crystalline polymer having a melting point (Tm) of 100 ° C. or higher, or an amorphous polymer having a glass transition temperature of 100 ° C. or higher can be used. A plastic resin is preferred.

  Further, among the thermoplastic resins (B), the maximum point elongation of a nonwoven fabric produced by a known method for producing a spunbonded nonwoven fabric is 50% or more, preferably 70% or more, more preferably 100 or more, A thermoplastic resin (extensible thermoplastic resin) having a property of little elastic recovery is laminated with a mixed fiber spunbond nonwoven fabric and a film obtained by blending with a long fiber of the thermoplastic elastomer (A) and laminated with a nonwoven fabric. When it is made into a body, it is preferable because a stretch feeling gives rise to a bulky feeling and improves the tactile sensation, and can impart a non-stretching function to the nonwoven fabric laminate. In addition, although the upper limit of the maximum point elongation of the spunbonded nonwoven fabric made of the thermoplastic resin (B) is not necessarily limited, it is usually 300% or less.

  Specific examples of the thermoplastic resin (B) include an α-olefin such as ethylene, propylene, 1-butene, 1-hexene, 4-methyl-1-pentene and 1-octene alone or in combination. Polyolefin (high pressure low density polyethylene, linear low density polyethylene (so-called LLDPE), high density polyethylene, ethylene / propylene random copolymer, ethylene homopolymer such as ethylene / 1-butene random copolymer, Ethylene polymers such as ethylene / α-olefin copolymers; propylene homopolymer (so-called polypropylene), propylene / ethylene random copolymer, propylene / ethylene / 1-butene random copolymer (so-called random polypropylene), Propylene block copolymer, propylene / 1-butene Propylene polymers such as random copolymers; 1-butene polymers such as 1-butene homopolymer, 1-butene / ethylene copolymer, 1-butene / propylene copolymer; poly-4-methyl-1 -Pentene, etc.], polyester (polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, etc.), polyamide (nylon-6, nylon-66, polymetaxylene adipamide, etc.), polyvinyl chloride, polyimide, ethylene / vinyl acetate Examples thereof include a polymer, polyacrylonitrile, polycarbonate, polystyrene, ionomer, and a mixture thereof. Among these, high pressure method low density polyethylene, linear low density polyethylene (so-called LLDPE), ethylene polymers such as high density polyethylene, propylene polymers such as polypropylene and polypropylene random copolymers, polyethylene terephthalate, polyamide, etc. Is preferred.

  For the thermoplastic resin (B), an antioxidant, a weather stabilizer, an antistatic agent, an antifogging agent, an antiblocking agent, a lubricant, a nucleating agent, a pigment, and a dye that are usually used within the range not impairing the object of the present invention. Additives such as natural oils, synthetic oils and waxes or other polymers can be blended as necessary.

<Propylene-based polymer (B1)>
Among the thermoplastic resins, the blended spunbonded nonwoven fabric from which the propylene-based polymer (B1) can be obtained is preferable in terms of processability and strength.
As such a propylene-based polymer, a homopolymer of propylene having a melting point (Tm) of 155 ° C. or more, preferably 157 to 165 ° C., or propylene and a very small amount of ethylene, 1-butene, 1-pentene, 1- One or more α-olefins having 2 or more carbon atoms (excluding 3), preferably 2 to 8 (excluding 3), such as hexene, 1-octene, 4-methyl-1-pentene A propylene homopolymer is preferable.

  As long as the propylene polymer can be melt-spun, the melt flow rate (MFR: ASTM D-1238, 230 ° C., load 2160 g) is not particularly limited, but is usually 1 to 100 g / 10 minutes, preferably 5 to It is in the range of 500 g / 10 min, more preferably 10-100 g / 10 min. The ratio Mw / Mn of the weight average molecular weight (Mw) and the number average molecular weight (Mn) of the propylene polymer according to the present invention is usually 1.5 to 5.0. From the viewpoint of obtaining a composite fiber having good spinnability and particularly excellent fiber strength, 1.5 to 3.0 is more preferable. In the present invention, good spinnability means that yarn breakage does not occur during discharge from the spinning nozzle and during drawing, and filament fusion does not occur. In the present invention, Mw and Mn can be measured by a known method by GPC (gel permeation chromatography).

<Mixed fiber spunbond nonwoven fabric>
The mixed fiber spunbond nonwoven fabric constituting the nonwoven fabric laminate of the present invention is also referred to as a thermoplastic elastomer (A) long fiber [hereinafter referred to as "thermoplastic elastomer (A) long fiber". ] And thermoplastic resin (B) long fibers [hereinafter also referred to as "thermoplastic resin (B) long fibers". ] Is a mixed fiber spunbonded nonwoven fabric in a ratio of 10 to 90% by weight: 90 to 10% by weight (provided that (A) + (B) = 100% by weight). As the mixed fiber spunbonded nonwoven fabric, from the viewpoint of stretchability and flexibility, the thermoplastic elastomer (A) long fibers are preferably 20% by weight or more, more preferably 30% by weight or more, and workability. From the viewpoint of (stickiness resistance), 70% by weight or less is preferable, and 60% by weight or less is more preferable.

  The fiber diameters (average values) of the thermoplastic elastomer (A) long fibers and the thermoplastic resin (B) long fibers forming the mixed fiber spunbond nonwoven fabric according to the present invention are usually 50 μm or less, 5 to 40 μm, more preferably, respectively. It exists in the range of 7-30 micrometers. The fiber diameters of the thermoplastic elastomer (A) long fiber and the thermoplastic resin (B) long fiber may be the same or different.

The mixed fiber spunbonded nonwoven fabric according to the present invention usually has a basis weight of 120 g / m ² or less, preferably 80 g / m ² or less, more preferably 50 g / m ² from the viewpoint of flexibility and breathability in hygiene materials such as diapers. m ² or less, more preferably in the range of 40 to 15 g / m ² .

  The mixed fiber spunbonded nonwoven fabric according to the present invention uses the thermoplastic elastomer (A) and the thermoplastic resin (B) to produce a known spunbonded nonwoven fabric, for example, Japanese Patent Application Laid-Open No. 2004-244791. It can be produced by the method described.

  Specifically, after the thermoplastic elastomer (A) and the thermoplastic resin (B) are melted by separate extruders, the melted polymer is individually divided into a die (die) having a large number of spinning holes (nozzles). ), The thermoplastic elastomer (A) and the thermoplastic resin (B) are discharged simultaneously from different spinning holes simultaneously, and then the melt-spun thermoplastic elastomer (A) long fibers and the thermoplastic resin ( After the long fibers of B) are introduced into a cooling chamber and cooled by cooling air, they can be produced by a method of drawing (pulling) the long fibers with drawing air and depositing them on the moving collection surface. The melting temperature of the polymer is not particularly limited as long as it is higher than the softening temperature or melting temperature of the polymer and lower than the thermal decomposition temperature, and can be determined depending on the polymer used. The die temperature depends on the polymer used. For example, a thermoplastic polyurethane elastomer or olefin copolymer elastomer is used as the thermoplastic elastomer (A), and a propylene polymer or propylene polymer is used as the thermoplastic resin (B). When using the olefin polymer composition of coalescence and HDPE, it can be set to a temperature of usually 180 to 240 ° C, preferably 190 to 230 ° C, more preferably 200 to 225 ° C.

  The temperature of the cooling air is not particularly limited as long as the temperature at which the polymer is solidified, but is usually in the range of 5 to 50 ° C, preferably 10 to 40 ° C, more preferably 15 to 30 ° C. The wind speed of the stretched air is usually in the range of 100 to 10,000 m / min, preferably 500 to 10,000 m / min.

  The mixed fiber spunbond nonwoven fabric according to the present invention may be subjected to various known entanglement methods, for example, a method using a needle punch, water jet, ultrasonic wave or the like, or hot embossing or hot air through using an embossing roll. By using it, it may be entangled by a method in which one part is heat-sealed. Such entanglement methods may be used alone or in combination with a plurality of entanglement methods.

If heat sealing by the heat embossing is usually 5-20% embossed area ratio, preferably 5-10%, the non-embossed unit area is 0.5 mm ² or more, preferably in the range of 4 to 40 mm ² . The non-embossed unit area is the maximum area of a quadrilateral inscribed in the embossed portion in the smallest unit of the non-embossed portion surrounded on all four sides by the embossed portion.

  By embossing a mixed fiber spunbonded nonwoven fabric or a nonwoven fabric laminate laminated with a moisture-permeable film described later in such a range, the flexibility, breathability, friction fastness, stretchability, etc. of the resulting nonwoven fabric laminate are balanced. Since it is excellent, it is preferable.

<Moisture permeable film>
The moisture-permeable film constituting the nonwoven fabric laminate of the present invention is from a thermoplastic elastomer (represented as a thermoplastic elastomer (C) to distinguish it from the thermoplastic elastomer (A) contained in the mixed fiber spunbond nonwoven fabric layer). The water vapor permeability according to JIS L1099 A-1 method (40 ° C., relative humidity 90%, conditions of CaCl ₂ method) is usually 2000 g / m ² · day or more, preferably 3000 g at a film thickness of 30 μm. / M ² · day More preferably, the film has a water vapor transmission rate of 4000 g / m ² · day or more.

  The moisture-permeable film according to the present invention can be appropriately selected depending on various applications, but usually has a thickness in the range of 10 to 50 μm, preferably 15 to 40 μm. In order to prevent pinholes at the time of nonwoven fabric and laminating, and to maintain mechanical strength and maintain appropriate water resistance, it is desirable to make the thickness 10 μm or more, in order to obtain good moisture permeability and flexibility The thickness is preferably 50 μm or less.

  The moisture-permeable film according to the present invention uses a thermoplastic elastomer (C) and is a film using a known film forming method, for example, a thermoplastic elastomer (C) is melted with an extruder, and then a T-die or an annular die is used. However, since moisture-permeable elastomers generally have large stickiness and blocking, they may be directly or indirectly extruded onto the mixed fiber spunbond nonwoven fabric layer to form a film layer. .

<Thermoplastic elastomer (C)>
As the thermoplastic elastomer (C) according to the present invention, various thermoplastic elastomers can be used as long as they have moisture permeability when a film is formed. In order to confirm that it has moisture permeability, for example, the moisture permeability can be confirmed by the water vapor permeability recognized by the measurement method according to JIS L1099 A-1 method (40 ° C., relative humidity 90%, conditions of CaCl ₂ method). It can have. In this case, preferably, according to the JIS L1099 A-1 method, a film having a thickness of 30 μm exhibits a water vapor transmission rate of 2000 g / m ² · day or more, preferably 3000 g / m ² · day or more. Preferably used.

Suitable examples of the thermoplastic elastomer (C) include a polyester elastomer (C1), a polyamide elastomer (C2), and a thermoplastic polyurethane elastomer (C3).
In the thermoplastic elastomer (C), the antioxidants, weathering stabilizers, antistatic agents, antifogging agents, antiblocking agents, lubricants, nucleating agents, pigments and the like that are usually used are within the range not impairing the object of the present invention. Additives or other polymers can be blended as needed.

<Polyester elastomer (C1)>
As the polyester elastomer (C1), a structural unit represented by the following formula (I) derived from an aromatic polyester is used as a hard segment, and a structural unit represented by the following formula (II) derived from an aliphatic polyether is used. Examples are block copolymers obtained by forming a soft segment and block copolymerizing them.

—O—D—O—CO—R—CO— (I)
-O-G-O-CO-R-CO- (II)
In the above formula, D is a divalent residue obtained by removing two hydroxyl groups from a diol having a molecular weight of about 250 or less, and R is a divalent residue obtained by removing two carboxyl groups from a dicarboxylic acid having a molecular weight of about 300 or less. G is a divalent residue obtained by removing hydroxyl groups at both ends from poly (alkylene oxide) glycol having an average molecular weight of about 400 to about 3500. Here, the amount of the ethylene oxide group inserted into the structural unit represented by the formula (II) which is a copolyether ester of poly (alkylene oxide) glycol is about 25 to 68% by mass with respect to the total mass of the copolyether ester. It is.

  In the present invention, it is particularly preferable that the aromatic polyester is tetramethylene terephthalate and the aliphatic polyether is alkylene ether terephthalate. Specific examples include polybutylene terephthalate / polytetramethylene ether glycol block copolymers. Specific examples of commercially available products are manufactured and sold under trade names such as HYTREL (trade name, manufactured by EI DuPont Co., Ltd.) and Perprene (trade name, manufactured by Toyobo Co., Ltd.). .

<Polyamide elastomer (C2)>
Examples of the polyamide-based elastomer (C2) include a multi-block copolymer using polyamide as a hard segment and polyester or polyol diol having a low glass transition temperature as a soft segment. Here, nylon 6, 66, 610, 11, 12, etc. are mention | raise | lifted as a polyamide component. Among these, nylon 6 and nylon 12 are preferable. Examples of the polyether diol include poly (oxytetramethylene) glycol, poly (oxypropylene) glycol, and the like, and examples of the polyester diol include poly (ethylene 1,4-adipate) glycol, poly (butylene 1,4- Adipate) glycol, polytetramethylene glycol and the like. Specific examples include nylon 12 / polytetramethylene glycol block copolymer. Specifically as a commercial item, it manufactures and sells by brand names, such as a diamide (made by Daicel Huls), PEBAX (made by Atochem) [all are brand names], for example.

<Thermoplastic polyurethane elastomer (C3)>
The thermoplastic polyurethane elastomer (C3) includes a polyurethane obtained by a reaction of a short chain polyol (molecular weight 60 to 600) and diisocyanate as a hard segment, and a long chain polyol (molecular weight 600 to 4000) and diisocyanate as a soft segment. Illustrative are block copolymers with polyurethanes obtained by the reaction of nate. Examples of the diisocyanate include toluene diisocyanate and diphenylmethane diisocyanate, and examples of the short-chain polyol include ethylene glycol, 1,3-propylene glycol, bisphenol A, and the like.

  The thermoplastic polyurethane elastomer (C3) is a polylactone ester polyol such as polycaprolactone glycol, which is obtained by addition polymerization of diisocyanate in the presence of a short-chain polyol (polyether polyurethane); poly (ethylene 1,4-adipate) ) Addition polymerization of diisocyanate in the presence of a short-chain polyol to adipic ester polyol such as glycol, poly (butylene, 1,4-adipate) glycol, etc. (polyester polyurethane); Examples include those obtained by addition polymerization of diisocyanate to methylene glycol in the presence of a short-chain polyol. Specific examples of commercially available products include trade names such as bulcolan (manufactured by Bayer), chemi gum SL (manufactured by Goodyear), adiprene (manufactured by DuPont), valcaprene (manufactured by ICI) [all trade names] Manufactured and sold in

  Among these, the polyester elastomer (C1) and the thermoplastic polyurethane elastomer (C3) are preferable from the viewpoint of excellent moisture permeability, and the thermoplastic polyurethane elastomer (C3) having particularly stretchability is particularly preferable.

<Nonwoven fabric laminate>
The nonwoven fabric laminate of the present invention is a mixed fiber spunbond nonwoven fabric layer in which 10 to 90% by mass of the long fibers of the thermoplastic elastomer (A) and 90 to 10% by mass of the long fibers of the thermoplastic resin (B) are mixed. And a moisture-permeable film made of the thermoplastic elastomer (C).

Since the nonwoven fabric laminate of the present invention uses the thermoplastic elastomer (C) as a moisture permeable film, it is superior in mechanical strength as compared to a nonwoven fabric laminate obtained by laminating a porous film or the like. Also typically, in 30μm of thickness JIS L1099 A-1 method (40 ° C., a relative humidity of 90%, CaCl ₂ of the conditions) moisture permeability by the 1000~15000g / m ² · day, preferably 2000~12000g / m ² · Day More preferably, it is 3000 to 10000 g / m ² · day. The water pressure resistance is 500 mmAq or more, preferably 800 mmAq or more.

  Furthermore, the nonwoven fabric laminate is excellent in extensibility and is 80% or more (1.8 times or more of the original length), preferably 100% or more (twice or more of the original length), more preferably 120%. It is characterized by having an elongation of not less than 2.2 times the original length, most preferably not less than 150% (more than 2.5 times the original length). Further, the stretch recovery property is usually 30% or less, preferably 25% or less, more preferably 20% or less, and most preferably 15% or less.

  In addition to the mixed fiber spunbond nonwoven fabric layer and the moisture-permeable film, other layers may be laminated on either side of the nonwoven fabric laminate of the present invention.

  The other layer which comprises the nonwoven fabric laminated body of this invention is not specifically limited, A various layer can be laminated | stacked by a use.

  Specifically, a knitted fabric, a woven fabric, a nonwoven fabric, a film, etc. can be mentioned, for example. When laminating (bonding) the nonwoven fabric laminate of the present invention to another layer, thermal embossing, thermal fusion methods such as ultrasonic fusion, mechanical entanglement methods such as needle punch and water jet, hot melt adhesion Various known methods such as a method using an adhesive such as an adhesive and a urethane-based adhesive, extrusion lamination, and the like can be adopted.

  As a nonwoven fabric laminated | stacked with the nonwoven fabric laminated body of this invention, various well-known nonwoven fabrics, such as a spun bond nonwoven fabric, a melt blown nonwoven fabric, a wet nonwoven fabric, a dry nonwoven fabric, a dry pulp nonwoven fabric, a flash spinning nonwoven fabric, and a spread nonwoven fabric, can be mentioned.

  As a method of laminating (bonding) the mixed fiber spunbond nonwoven fabric layer and the moisture permeable film, after obtaining the mixed fiber spunbond nonwoven fabric and the moisture permeable film in advance, the mixed fiber spunbond nonwoven fabric and the moisture permeable film are overlapped to emboss roll. Various known methods such as a method of pressure bonding by a method such as a method of extruding and laminating a thermoplastic elastomer (C) on a previously obtained mixed fiber spunbond nonwoven fabric layer can be employed. Moreover, after laminating a mixed fiber spunbond nonwoven fabric layer and a moisture permeable film, when pressure bonding with an embossing roll or the like, it is usually performed at a temperature of 60 to 150 ° C., preferably 70 to 140 (describe preferable conditions). obtain.

In the present invention, when the mixed fiber spunbonded nonwoven fabric and the moisture permeable film are both made of a thermoplastic elastomer having a close chemical composition, an adhesive or the like is not necessarily required for lamination. For example, as a specific example, as a thermoplastic elastomer (A) long fiber, a mixed fiber spunbond nonwoven fabric containing a thermoplastic elastomer (A) long fiber selected from thermoplastic polyurethane elastomer, polyester elastomer and polyamide elastomer, and By adhering a moisture-permeable film made of a thermoplastic polyurethane-based elastomer (C3), a polyester-based elastomer (C1) and a polyamide-based elastomer (C2) as the moisture-permeable film, good adhesiveness can be obtained.
Moreover, when laminating a mixed fiber spunbonded nonwoven fabric and a moisture permeable film, an adhesive or the like may be used in consideration of required moisture permeability and adhesive strength depending on various uses regardless of the chemical composition.

EXAMPLES Hereinafter, although this invention is demonstrated further more concretely based on an Example, this invention is not limited to these Examples.
The physical property values and the like in Examples and Comparative Examples were measured by the following methods.

(1) Weight per unit [g / m ² ]
-Six test pieces of 200 mm (MD) x 50 mm (CD) were collected from the nonwoven fabric and / or the nonwoven fabric laminate. In addition, the collection place was MD and CD arbitrary 3 places (a total of 6 places). Next, the mass (g) of each collected test piece was measured using an upper dish electronic balance (manufactured by Kensei Kogyo Co., Ltd.). The average value of the mass of each test piece was determined. It converted into the mass (g) per 1 m < ² > from the calculated | required average value, and rounded off the 2nd decimal place, and it was set as the fabric weight [g / m < ² >] of each nonwoven fabric sample.
· 200mm (MD) × 50mm converting the nonwoven fabric 1 cm ² at the punch in the case where the test piece (CD) can not be taken from an average of five points vent the mass 1 m ² per mass (g), the second decimal The weight was rounded to the basis weight [g / m ² ] of each nonwoven fabric sample.

(2) Maximum point elongation [%]
Six test pieces of 200 mm (MD) × 50 mm (CD) were collected from the nonwoven fabric and / or the nonwoven fabric laminate. Subsequently, each collected specimen was measured using a universal tensile testing machine (IM-201, manufactured by Intesco) with a span interval I ₀ = 100 mm and a tensile speed of 100 mm / min. A tensile test was conducted to obtain the elongation at the maximum strength point (maximum elongation at the point [%]). For the maximum point elongation, an average value was obtained for the above 6 points (3 points for each of MD and CD), and the second decimal place was rounded off.

(3) Residual strain [%]
Six test pieces of 200 mm (MD) × 50 mm (CD) were collected from the nonwoven fabric and / or the nonwoven fabric laminate. In addition, the collection place was MD and CD arbitrary 3 places (a total of 6 places). Subsequently, each collected test piece was measured using a universal tensile testing machine (IM-201, manufactured by Intesco) with a chuck distance of 100 mm and a tensile speed of 100 mm / min. After stretching at a stretch ratio of 100%, the film was immediately recovered to the original length at the same speed, and the strain at the time of recovery was measured to obtain the residual strain [%]. In addition, the residual strain calculated | required the average value about said 6 points | pieces (MD and CD each 3 points), and rounded off the 2nd decimal place.

(4) Moisture permeability According to the method prescribed in the JIS L1099 A-1 method, the moisture permeability was measured by the CaCl2 method at a temperature of 40 ° C. and a relative humidity of 90%. In addition, when the magnitude | size of a nonwoven fabric laminated body was not fully obtained, the cup which has an area according to it was prepared and measured.

(5) Water pressure resistance [mmH ₂ O]
The measurement was performed according to JIS L1092. Six test pieces of 150 mm (MD) × 150 mm (CD) were collected from the nonwoven fabric and / or the nonwoven fabric laminate. In addition, the collection place was made into arbitrary three places of the obtained nonwoven fabric. Next, each of the collected test pieces was attached using a water resistance test device (manufactured by Tester Sangyo) so that the surface of the test piece was exposed to water, and a level device containing normal temperature water was added at 60 ± 30 mm / min. Or 10 ± 5 mm / min. The water pressure was applied to the test piece by measuring the water level when water leaked from three places on the opposite side of the test piece, and the water pressure resistance [mmH ₂ O] was determined. In addition, when the water pressure resistance exceeds 1000 as the upper limit 1000, the average value was obtained for the above three points, and the first decimal place was rounded off.

(6) Adhesive evaluation A test piece of 200 mm (MD) × 50 mm (CD) was collected from the nonwoven fabric laminate, and then the collected test pieces were used using a universal tensile tester (IM-201, manufactured by Intesco). Span interval I ₀ = 100 mm, tensile speed 100 mm / min. The cycle of stretching to 100 mm and immediately returning at the same speed and returning to the origin was repeated 20 times as one cycle, and the presence or absence of delamination between layers was observed.

(7) Pinhole Cut out the nonwoven fabric laminate to a size of 20cm x 20cm, lay the laminate on the filter paper so that the moisture-permeable film surface is in contact with the filter paper, and use a commercially available edible salad oil mixed with an appropriate amount of food red as a brush The mixture fiber was coated so that the non-woven fabric was sufficiently wetted, and after 1 hour, the presence or absence of pinholes was examined based on whether or not the colored oil adhered to the filter paper.
Moreover, the analysis and evaluation of the thermoplastic polyurethane elastomer (TPU) used for the Example and the comparative example were performed in accordance with the following method.

(8) Solidification start temperature It measured with the differential scanning calorimeter (DSC220C) connected to the SSC5200H disk station by Seiko Denshi Kogyo Co., Ltd. As a sample, about 8 mg of ground TPU was collected in an aluminum pan, covered with a cover and crimped. Similarly, alumina was collected as a reference. After setting the sample and the reference at a predetermined position in the cell, the measurement was performed in a nitrogen stream at a flow rate of 40 Nml / min. The temperature was raised from room temperature to 230 ° C. at a temperature raising rate of 10 ° C./min, held at this temperature for 5 minutes, and then lowered to −75 ° C. at a temperature lowering rate of 10 ° C./min. The starting temperature of the exothermic peak derived from the solidification of TPU recorded at this time was measured and used as the solidification starting temperature (unit: ° C.).

(9) Number of particles in polar solvent insoluble The measurement was carried out using a multi-cerser II manufactured by Beckman Coulter as a particle size distribution measuring device based on the pore electrical resistance method. In a 5 liter separable flask, 3500 g of dimethylacetamide (special grade manufactured by Wako Pure Chemical Industries, Ltd.) and 145.83 g of ammonium thiocyanate (special grade manufactured by Junsei Chemical Co., Ltd.) are weighed and allowed to stand at room temperature for 24 hours. And dissolved.
Subsequently, it filtered under reduced pressure with a 1 micrometer membrane filter, and the reagent A was obtained. 180 g of reagent A and 2.37 g of TPU pellets were precisely weighed in a 200 cc glass bottle, and the soluble content in TPU was dissolved over 3 hours, which was used as a measurement sample. A 100 μm aperture tube was attached to Multisizer II, the solvent in the apparatus was replaced with reagent A, and the degree of vacuum was adjusted to about 3000 mmAq. 120 g of reagent A was weighed into a well-washed sample beaker, and it was confirmed that the amount of pulses generated by blank measurement was 50 or less. After setting the optimal Current value and Gain manually, calibration was performed using 10 μm uncrosslinked polystyrene standard particles. The measurement was performed for 210 seconds by weighing 120 g of reagent A and about 10 g of the measurement sample in a well-washed sample beaker. A value obtained by dividing the number of particles counted by this measurement by the weight of TPU sucked into the aperture tube was defined as the number of particles insoluble in the polar solvent (unit: number / g). The TPU weight was calculated by the following formula.
TPU weight = {(A / 100) × B / (B + C)} × D
In the formula, A: TPU concentration (% by weight) of measurement sample, B: Weight of measurement sample weighed in beaker (g), C: Weight of reagent A weighed in beaker (g), D: In measurement ( The amount of solution (g) sucked into the aperture tube during 210 seconds).

(10) Ratio of heat of fusion of hard domain Measured with a differential scanning calorimeter (DSC220C) connected to an SSC5200H disk station manufactured by Seiko Instruments Inc. As a sample, about 8 mg of ground TPU was collected in an aluminum pan, covered with a cover and crimped. Similarly, alumina was collected as a reference. After setting the sample and the reference at a predetermined position in the cell, the measurement was performed in a nitrogen stream at a flow rate of 40 Nml / min. The temperature was increased from room temperature to 230 ° C. at a rate of temperature increase of 10 ° C./min. At this time, it is calculated | required from the sum total (a) of the heat of fusion calculated | required from the endothermic peak in the range whose peak temperature is 90 degreeC or more and 140 degrees C or less, and the endothermic peak in which the peak temperature exceeds 140 degreeC and is 220 degrees C or less. The total amount of heat of fusion (b) was determined, and the ratio of heat of fusion of hard domains (unit:%) was determined by the following equation.
Hard domain melting heat ratio (%) = a / (a + b) × 100

(11) Melt viscosity at 200 ° C. (hereinafter simply referred to as “melt viscosity”)
Using a capillograph (Model 1C manufactured by Toyo Seiki Co., Ltd.), the melt viscosity (unit: unit: Pa · s) of TPU at a shear rate of 100 sec ⁻¹ at 200 ° C. was measured. A nozzle having a length of 30 mm and a diameter of 1 mm was used.

(12) Moisture value of TPU The moisture content (unit: ppm) of TPU is measured by combining a moisture content measuring device (AVQ-5S manufactured by Hiranuma Sangyo Co., Ltd.) and a water vaporizer (EV-6 manufactured by Hiranuma Sangyo Co., Ltd.). It was. About 2 g of TPU pellets weighed in a heated sample pan were put into a heating furnace at 250 ° C., and the evaporated water was introduced into a titration cell of a moisture measuring device from which residual moisture had been removed in advance and titrated with a Karl Fischer reagent. The titration was completed when no change in the potential of the titration electrode accompanying the change in the amount of water in the cell occurred for 20 seconds.

(13) Shore A hardness TPU hardness was measured by the method described in JIS K-7311 at 23 ° C. and 50% relative humidity. The durometer was type A.

<TPU production example 1>
Diphenylmethane diisocyanate (hereinafter referred to as MDI) was charged into tank A under a nitrogen atmosphere, and adjusted to 45 ° C. with stirring to such an extent that bubbles were not mixed.
628.6 parts by weight of a polyester polyol having a number average molecular weight of 2000 (manufactured by Mitsui Takeda Chemical Co., Ltd., trade name: Takelac U2024), 2.21 parts by weight of Irganox 1010, and 77.5 weights of 1,4-butanediol Were charged in tank B under a nitrogen atmosphere and adjusted to 95 ° C. with stirring. This mixture is referred to as polyol solution 1.
The hard segment amount calculated from these reaction raw materials is 37.1% by weight.
Next, a high-speed stirrer (SM40) adjusted to 120 ° C. with a flow rate of 17.6 kg / h for MDI and a flow rate of 42.4 kg / h for polyol solution 3 in a liquid feed line via a gear pump and a flow meter. The solution was quantitatively passed through, stirred and mixed at 2000 rpm for 2 minutes, and then passed through a static mixer. The static mixer unit was connected to the first to third static mixers (temperature 230 ° C.) in which three static mixers having a pipe length of 0.5 m and an inner diameter of 20 mmφ were connected, and three static mixers having a pipe length of 0.5 m and an inner diameter of 20 mmφ. Fourth to sixth static mixers (temperature 220 ° C.), pipe length 1.0 m, seventh to twelfth static mixers (temperature 210 ° C.) connected with six static mixers having an inner diameter of 34 mmφ, pipe length 0.5 m, A thirteenth to fifteenth static mixer (temperature 200 ° C.) connected with three static mixers having an inner diameter of 38 mmφ is connected in series.
The reaction product flowing out from the fifteenth static mixer was passed through a gear pump and a single screw extruder (diameter 65 mmφ, temperature 180 to 210) attached with a polymer filter (manufactured by Nagase Sangyo Co., Ltd., trade name: Dena filter) at the tip. And extruded from a strand die. After cooling with water, it was continuously pelletized with a pelletizer. Next, the obtained pellets were charged into a dryer and dried at 100 ° C. for 8 hours to obtain a thermoplastic polyurethane elastomer having a moisture value of 40 ppm. This thermoplastic polyurethane elastomer was continuously extruded with a single-screw extruder (diameter 50 mmφ, temperature 180 to 210 ° C.) and pelletized. It was again dried at 100 ° C. for 7 hours to obtain a thermoplastic polyurethane elastomer (A-1) having a moisture value of 57 ppm.
The solidification start temperature of A-1 is 103.7 ° C., the number of particles insoluble in the polar solvent is 1.5 million particles / g, the hardness by a test piece prepared by injection molding is 86 A, the melt viscosity at 200 ° C. is 1900 Pa · s, hard The heat of fusion ratio of the domain was 35.2%.

[Example 1]
<Preparation of thermoplastic resin composition for mixed fiber spunbond nonwoven fabric>
MFR (according to ASTM D1238, measured at a temperature of 230 ° C. and a load of 2.16 kg) 60 g / 10 min, a density of 0.91 g / cm ³ and a melting point of 160 ° C. (hereinafter abbreviated as “PP-1”) ) 96% by weight and MFR (measured according to ASTM D1238 at a temperature of 190 ° C. and a load of 2.16 kg) 5 g / 10 minutes, a density of 0.97 g / cm ³ , a melting point of 134 ° C. (hereinafter referred to as “HDPE”) And 4 wt% were mixed to prepare a thermoplastic resin composition (B-1).

<Manufacture of mixed fiber spunbond nonwoven fabric>
After forming the thermoplastic polyurethane elastomer (A-1) and the thermoplastic resin composition (B-1) independently using a 75 mmφ extruder and a 50 mmφ extruder, forming a spunbond nonwoven fabric having a spinneret Using a machine (length in the direction perpendicular to the machine flow direction on the collecting surface: 800 mm), the resin temperature and the die temperature are both 210 ° C., the cooling air temperature is 20 ° C., and the stretched air wind speed is 3750 m / min. Spun-bonded and melt spun to deposit a web of mixed fibers with a mixed fiber ratio of 41:59 (weight ratio) of A-1 long fibers A and B-1 long fibers B on the collection surface I let you. The spinneret has a nozzle pattern in which A-1 discharge holes and B-1 discharge holes are alternately arranged. A-1 (fiber A) has a nozzle diameter of 0.75 mmφ and B-1 (fiber B). ), The nozzle pitch is 8 mm in the vertical direction and 11 mm in the horizontal direction, and the ratio of the number of nozzles is nozzle for fiber A: nozzle for fiber B = 1: 1.45. The single hole discharge rate of the fiber A was 0.73 g / (minute / hole), and the single hole discharge amount of the fiber B was 0.73 g / (minute / hole).

The web composed of the mixed long fibers is prebonded at a linear pressure of 10 kg / cm with a nip roll coated with a non-adhesive material on the belt, the prebond web is peeled off from the moving belt, and the embossed pattern has an area ratio of 18%. The web was integrated by heating embossing with an embossed area of 0.41 mm ² , a heating temperature of 110 ° C., and a linear pressure of 30 kg / cm to obtain a mixed fiber spunbonded nonwoven fabric having a basis weight of 33 g / m ² . Moreover, the fiber diameter of the web which consists of the deposited mixed long fiber was 29.2 micrometers, the fiber diameter of the larger one, ie, the fiber diameter of the fiber A, 29.2 micrometers, and the smaller one.

<Manufacture of nonwoven fabric laminate>
After subjecting the surface of the mixed fiber spunbonded nonwoven fabric to corona treatment (30 W / m ² ), a polyester-based thermoplastic elastomer [E. I. DuPont Co., Ltd. product name HYTREL G3548L density: 1.15 g / cm ³ ] was melted at a molding temperature of 200 ° C. to 240 ° C. using a T-die film molding machine equipped with a T-die at the tip. Non-woven fabric laminate comprising a mixed fiber spunbond nonwoven fabric / moisture permeable film after being extruded and laminated in a film form so as to have a thickness of 20 μm at 240 ° C. and then supplied to a pair of roll gaps composed of a cooling roll and a nip roll. Got. The basis weight of the obtained nonwoven fabric laminate was 56 g / m ² .

The resulting nonwoven fabric laminate is uniaxially stretched in the machine direction at a stretching ratio of 2.0 times between a preheating roll heated to 70 ° C. and a stretching roll, and then the tension is released to laminate the nonwoven fabric with a basis weight of 47 g / m ² . Got the body. In addition, the distortion at the time of the extending | stretching process of a nonwoven fabric laminated body was 19%.
(Strain at the time of stretching) = {(Weight per layer before stretching) ÷ (Weight per layer after stretching) −1} × 100 (%)
The obtained nonwoven fabric laminate was evaluated by the method described above. The evaluation results are shown in Table 1.

[Example 2]
<Manufacture of mixed fiber spunbond nonwoven fabric>
In accordance with the method described in Example 1, a mixed fiber spunbonded nonwoven fabric having a mixed fiber ratio of long fibers A: long fibers B of 25:75 (weight ratio) and a basis weight of 38 g / m ² was obtained.

<Manufacture of nonwoven fabric laminate>
In accordance with the method described in Example 1, a nonwoven fabric laminate comprising a mixed fiber spunbond nonwoven fabric / moisture permeable film was obtained. The basis weight of the obtained nonwoven fabric laminate was 61 g / m ² .
In addition, the nonwoven fabric laminate was stretched according to the method described in Example 1. After releasing the tension, a nonwoven fabric laminate having a basis weight of 51 g / m ² was obtained. The strain during stretching was 20%.
The obtained nonwoven fabric laminate was evaluated by the method described above. The evaluation results are shown in Table 1.

[Example 3]
<Manufacture of mixed fiber nonwoven fabric>
According to the method described in Example 1, a mixed fiber spunbonded nonwoven fabric having a mixed fiber ratio of long fibers A: long fibers B of 60:40 (weight ratio) and a basis weight of 25 g / m ² was obtained.

<Manufacture of nonwoven fabric laminate>
In accordance with the method described in Example 1, a nonwoven fabric laminate comprising a mixed fiber spunbond nonwoven fabric / moisture permeable film was obtained. The basis weight of the obtained nonwoven fabric laminate was 48 g / m ² .
In addition, the nonwoven fabric laminate was stretched according to the method described in Example 1. After releasing the tension, a nonwoven fabric laminate having a basis weight of 41 g / m ² was obtained. The strain during stretching was 17%.
The obtained nonwoven fabric laminate was evaluated by the method described above. The evaluation results are shown in Table 1.

[Example 4]
<Manufacture of mixed fiber nonwoven fabric>
According to the method described in Example 1, a mixed fiber spunbonded nonwoven fabric having a mixed fiber ratio of long fibers A: long fibers B of 41:59 (weight ratio) and a basis weight of 33 g / m ² was obtained.

<Manufacture of nonwoven fabric laminate>
In place of the polyester thermoplastic elastomer used in Example 1, a polyester thermoplastic elastomer [E. I. It carried out like Example 1 except using Du Pont Co., Ltd. product HYTREL 8206 density 1.19 g / cm < ³ >], and obtained the nonwoven fabric laminated body which consists of a mixed fiber spunbond nonwoven fabric / moisture-permeable film. The basis weight of the obtained nonwoven fabric laminate was 57 g / m ² .
In addition, the nonwoven fabric laminate was stretched according to the method described in Example 1. After releasing the tension, a nonwoven fabric laminate having a basis weight of 47 g / m ² was obtained. The strain during stretching was 21%.
The obtained nonwoven fabric laminate was evaluated by the method described above. The evaluation results are shown in Table 1.

[Comparative Example 1]
Instead of the mixed fiber spunbond nonwoven fabric used in Example 4, a spunbond nonwoven fabric having a basis weight of 33 g / m ² consisting of only B-1 (stopping the discharge of A-1) was used, as in Example 4. And a nonwoven fabric laminate comprising a spunbond nonwoven fabric / a moisture permeable film was obtained. The basis weight of the obtained nonwoven fabric laminate was 56 g / m ² .
In addition, the nonwoven fabric laminate was stretched according to the method described in Example 1. After releasing the tension, a nonwoven fabric laminate having a basis weight of 41 g / m ² was obtained. The strain during stretching was 37%.
The obtained nonwoven fabric laminate was evaluated by the method described above. The evaluation results are shown in Table 1.

  The nonwoven fabric laminate of the present invention is excellent in stretchability, flexibility, moisture permeability, breathability, water resistance, deodorization, fuzz resistance, curl resistance, strength, and high interlayer adhesion strength. Thus, it can be suitably used for hygiene materials, medical materials, hygiene materials, industrial materials, and the like.

  Specifically, hygiene materials include absorbent articles such as disposable diapers and sanitary products. For unfoldable disposable diapers or pants-type disposable diapers, it is suitable for use in parts such as back sheets, waistbands (extension tape, side flaps), fastening tape, three-dimensional gathers, leg cuffs, and side panels of pants-type disposable diapers. it can. As a sanitary napkin, it can use suitably for parts, such as a back seat, a wing, and a side leak prevention cuff. By using the product of the present invention for these parts, it is possible to follow the movement of the wearer and fit the wearer's body, and a comfortable state is maintained even while wearing, and it is thin, light weight, Expected to be compact.

  As a ship base fabric, it is expected to be able to be used in various parts due to moderate stretchability, chemical transpiration control, good skin feel, follow-up to body movements, and skin care properties, and also lead to a healing effect. Similarly, the wound dressing base material has appropriate stretchability, high adhesion to the body, waterproofness, can prevent infection of wounds, and controls the humidity of the affected area with a ventilation film. Since it becomes possible, it can be expected to have an effect of accelerating wound recovery.

  Since the nonwoven fabric laminate of the present invention is a nonwoven fabric similar to a normal nonwoven fabric, it has excellent moisture permeability and stretchability, and can be expected to have better barrier properties and bacterial barrier properties. It is suitably used as a base material used for movable indirect parts such as disposable surgical gowns, rescue gowns, arms, elbows, and shoulders that require stretchability and infection prevention.

Claims (11)

  Long fiber of thermoplastic elastomer (A): 10 to 90% by weight and long fiber of thermoplastic resin (B): 90 to 10% by weight (provided that (A) + (B) = 100% by weight) A nonwoven fabric laminate, wherein a moisture permeable film is laminated on at least one side of a mixed fiber spunbond nonwoven fabric.   The nonwoven fabric laminate according to claim 1, wherein the long fibers of the thermoplastic elastomer (A) are long fibers of a thermoplastic polyurethane elastomer.   The nonwoven fabric laminate according to claim 1, wherein the long fibers of the thermoplastic elastomer (A) are long fibers of an olefin copolymer elastomer.   4. The nonwoven fabric according to claim 3, wherein the long fiber of the olefin copolymer elastomer is a long fiber of an ethylene / α-olefin copolymer elastomer or a long fiber of a propylene / α-olefin copolymer elastomer. Laminated body.   The nonwoven fabric laminate according to claim 1, wherein the long-point fiber of the thermoplastic resin (B) has a maximum point elongation of 50% or more when formed into a spunbonded nonwoven fabric.   The nonwoven fabric laminate according to claim 1, wherein the long fibers of the thermoplastic resin (B) are long fibers of a propylene-based polymer.   The nonwoven fabric laminate according to any one of claims 1 to 6, wherein the mixed fiber spunbond nonwoven fabric layer and the moisture-permeable film are directly bonded together.   The nonwoven fabric laminate according to claim 1, wherein the moisture-permeable film is made of a thermoplastic elastomer (C).   The nonwoven fabric laminate according to claim 8, wherein the thermoplastic elastomer (C) is a polyester elastomer.   The nonwoven fabric laminate according to claim 8, wherein the thermoplastic elastomer (C) is a polyamide-based elastomer.   The nonwoven fabric laminate according to claim 8, wherein the thermoplastic elastomer (C) is a thermoplastic polyurethane elastomer.