JP2013133579A - Nonwoven fabric laminate - Google Patents
Nonwoven fabric laminate Download PDFInfo
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- JP2013133579A JP2013133579A JP2011286167A JP2011286167A JP2013133579A JP 2013133579 A JP2013133579 A JP 2013133579A JP 2011286167 A JP2011286167 A JP 2011286167A JP 2011286167 A JP2011286167 A JP 2011286167A JP 2013133579 A JP2013133579 A JP 2013133579A
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- JP
- Japan
- Prior art keywords
- nonwoven fabric
- fabric laminate
- less
- fiber
- polyolefin
- 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
- 239000004745 nonwoven fabric Substances 0.000 title claims abstract description 194
- 239000000835 fiber Substances 0.000 claims abstract description 153
- 238000004519 manufacturing process Methods 0.000 claims abstract description 56
- 229920000098 polyolefin Polymers 0.000 claims abstract description 40
- 230000015572 biosynthetic process Effects 0.000 claims abstract description 29
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 21
- -1 polypropylene Polymers 0.000 claims description 43
- 238000000034 method Methods 0.000 claims description 33
- 238000002844 melting Methods 0.000 claims description 21
- 230000008018 melting Effects 0.000 claims description 21
- 230000035699 permeability Effects 0.000 claims description 21
- 239000000843 powder Substances 0.000 claims description 17
- 239000004743 Polypropylene Substances 0.000 claims description 15
- 238000005056 compaction Methods 0.000 claims description 15
- 229920001155 polypropylene Polymers 0.000 claims description 15
- 238000002788 crimping Methods 0.000 claims description 8
- 239000004902 Softening Agent Substances 0.000 claims description 7
- 238000003475 lamination Methods 0.000 claims description 7
- 238000000151 deposition Methods 0.000 claims description 4
- 206010021639 Incontinence Diseases 0.000 claims description 3
- 230000008569 process Effects 0.000 claims description 3
- 239000012943 hotmelt Substances 0.000 abstract description 9
- 239000010410 layer Substances 0.000 description 55
- 239000000306 component Substances 0.000 description 19
- 238000009987 spinning Methods 0.000 description 10
- 229920005989 resin Polymers 0.000 description 9
- 239000011347 resin Substances 0.000 description 9
- 238000012360 testing method Methods 0.000 description 9
- 238000005286 illumination Methods 0.000 description 8
- 230000000694 effects Effects 0.000 description 7
- 229920000247 superabsorbent polymer Polymers 0.000 description 7
- 239000004744 fabric Substances 0.000 description 6
- 229920005862 polyol Polymers 0.000 description 6
- 150000003077 polyols Chemical class 0.000 description 6
- 238000002834 transmittance Methods 0.000 description 6
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 5
- 239000005977 Ethylene Substances 0.000 description 5
- 238000005452 bending Methods 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 5
- 238000002835 absorbance Methods 0.000 description 4
- 230000002745 absorbent Effects 0.000 description 4
- 239000002250 absorbent Substances 0.000 description 4
- 230000005540 biological transmission Effects 0.000 description 4
- 238000001035 drying Methods 0.000 description 4
- 238000004049 embossing Methods 0.000 description 4
- 238000005259 measurement Methods 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 238000007639 printing Methods 0.000 description 4
- 239000004698 Polyethylene Substances 0.000 description 3
- 235000021355 Stearic acid Nutrition 0.000 description 3
- 239000002253 acid Substances 0.000 description 3
- 229920001577 copolymer Polymers 0.000 description 3
- 208000028659 discharge Diseases 0.000 description 3
- POULHZVOKOAJMA-UHFFFAOYSA-N dodecanoic acid Chemical compound CCCCCCCCCCCC(O)=O POULHZVOKOAJMA-UHFFFAOYSA-N 0.000 description 3
- 239000003925 fat Substances 0.000 description 3
- 230000002349 favourable effect Effects 0.000 description 3
- 238000005304 joining Methods 0.000 description 3
- 238000010030 laminating Methods 0.000 description 3
- 239000000155 melt Substances 0.000 description 3
- 150000002762 monocarboxylic acid derivatives Chemical class 0.000 description 3
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 description 3
- 239000003921 oil Substances 0.000 description 3
- 235000019198 oils Nutrition 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- 229920005672 polyolefin resin Polymers 0.000 description 3
- 239000002356 single layer Substances 0.000 description 3
- 238000012546 transfer Methods 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 239000004711 α-olefin Substances 0.000 description 3
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 2
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 2
- XDOFQFKRPWOURC-UHFFFAOYSA-N 16-methylheptadecanoic acid Chemical compound CC(C)CCCCCCCCCCCCCCC(O)=O XDOFQFKRPWOURC-UHFFFAOYSA-N 0.000 description 2
- WSSSPWUEQFSQQG-UHFFFAOYSA-N 4-methyl-1-pentene Chemical compound CC(C)CC=C WSSSPWUEQFSQQG-UHFFFAOYSA-N 0.000 description 2
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 2
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 description 2
- 229920001410 Microfiber Polymers 0.000 description 2
- WPYMKLBDIGXBTP-UHFFFAOYSA-N benzoic acid Chemical compound OC(=O)C1=CC=CC=C1 WPYMKLBDIGXBTP-UHFFFAOYSA-N 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- NZNMSOFKMUBTKW-UHFFFAOYSA-N cyclohexanecarboxylic acid Chemical compound OC(=O)C1CCCCC1 NZNMSOFKMUBTKW-UHFFFAOYSA-N 0.000 description 2
- 238000000354 decomposition reaction Methods 0.000 description 2
- UKMSUNONTOPOIO-UHFFFAOYSA-N docosanoic acid Chemical compound CCCCCCCCCCCCCCCCCCCCCC(O)=O UKMSUNONTOPOIO-UHFFFAOYSA-N 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 235000019197 fats Nutrition 0.000 description 2
- XMHIUKTWLZUKEX-UHFFFAOYSA-N hexacosanoic acid Chemical compound CCCCCCCCCCCCCCCCCCCCCCCCCC(O)=O XMHIUKTWLZUKEX-UHFFFAOYSA-N 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 229930014626 natural product Natural products 0.000 description 2
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 2
- YWAKXRMUMFPDSH-UHFFFAOYSA-N pentene Chemical compound CCCC=C YWAKXRMUMFPDSH-UHFFFAOYSA-N 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 229920005629 polypropylene homopolymer Polymers 0.000 description 2
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 2
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 2
- 229920005604 random copolymer Polymers 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- JNYAEWCLZODPBN-JGWLITMVSA-N (2r,3r,4s)-2-[(1r)-1,2-dihydroxyethyl]oxolane-3,4-diol Chemical compound OC[C@@H](O)[C@H]1OC[C@H](O)[C@H]1O JNYAEWCLZODPBN-JGWLITMVSA-N 0.000 description 1
- ATNNLHXCRAAGJS-QZQOTICOSA-N (e)-docos-2-enoic acid Chemical compound CCCCCCCCCCCCCCCCCCC\C=C\C(O)=O ATNNLHXCRAAGJS-QZQOTICOSA-N 0.000 description 1
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- KIHBGTRZFAVZRV-UHFFFAOYSA-N 2-Hydroxyoctadecanoic acid Natural products CCCCCCCCCCCCCCCCC(O)C(O)=O KIHBGTRZFAVZRV-UHFFFAOYSA-N 0.000 description 1
- TXBCBTDQIULDIA-UHFFFAOYSA-N 2-[[3-hydroxy-2,2-bis(hydroxymethyl)propoxy]methyl]-2-(hydroxymethyl)propane-1,3-diol Chemical compound OCC(CO)(CO)COCC(CO)(CO)CO TXBCBTDQIULDIA-UHFFFAOYSA-N 0.000 description 1
- JPUHAXBCXWSQMM-UHFFFAOYSA-N 2-hydroxyoctadec-2-enoic acid Chemical compound CCCCCCCCCCCCCCCC=C(O)C(O)=O JPUHAXBCXWSQMM-UHFFFAOYSA-N 0.000 description 1
- QLKSFCHONRVCOU-UHFFFAOYSA-N 3-[2-(2,3-dihydroxypropoxy)ethoxy]propane-1,2-diol Chemical compound OCC(O)COCCOCC(O)CO QLKSFCHONRVCOU-UHFFFAOYSA-N 0.000 description 1
- ALRHLSYJTWAHJZ-UHFFFAOYSA-N 3-hydroxypropionic acid Chemical compound OCCC(O)=O ALRHLSYJTWAHJZ-UHFFFAOYSA-N 0.000 description 1
- LXKCZUOSRQSRHW-UHFFFAOYSA-N 6-hydroxyoctadecanoic acid Chemical compound CCCCCCCCCCCCC(O)CCCCC(O)=O LXKCZUOSRQSRHW-UHFFFAOYSA-N 0.000 description 1
- 235000021357 Behenic acid Nutrition 0.000 description 1
- 239000005711 Benzoic acid Substances 0.000 description 1
- DPUOLQHDNGRHBS-UHFFFAOYSA-N Brassidinsaeure Natural products CCCCCCCCC=CCCCCCCCCCCCC(O)=O DPUOLQHDNGRHBS-UHFFFAOYSA-N 0.000 description 1
- 229920001634 Copolyester Polymers 0.000 description 1
- FBPFZTCFMRRESA-FSIIMWSLSA-N D-Glucitol Natural products OC[C@H](O)[C@H](O)[C@@H](O)[C@H](O)CO FBPFZTCFMRRESA-FSIIMWSLSA-N 0.000 description 1
- IAYPIBMASNFSPL-UHFFFAOYSA-N Ethylene oxide Chemical compound C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 description 1
- WQZGKKKJIJFFOK-GASJEMHNSA-N Glucose Natural products OC[C@H]1OC(O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-GASJEMHNSA-N 0.000 description 1
- 241000167880 Hirundinidae Species 0.000 description 1
- 241001465754 Metazoa Species 0.000 description 1
- TUNFSRHWOTWDNC-UHFFFAOYSA-N Myristic acid Natural products CCCCCCCCCCCCCC(O)=O TUNFSRHWOTWDNC-UHFFFAOYSA-N 0.000 description 1
- 229920002292 Nylon 6 Polymers 0.000 description 1
- 229920002302 Nylon 6,6 Polymers 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 206010042674 Swelling Diseases 0.000 description 1
- ZJCCRDAZUWHFQH-UHFFFAOYSA-N Trimethylolpropane Chemical compound CCC(CO)(CO)CO ZJCCRDAZUWHFQH-UHFFFAOYSA-N 0.000 description 1
- 239000011954 Ziegler–Natta catalyst Substances 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 150000001298 alcohols Chemical class 0.000 description 1
- 125000000217 alkyl group Chemical group 0.000 description 1
- 239000010775 animal oil Substances 0.000 description 1
- 239000003945 anionic surfactant Substances 0.000 description 1
- 239000002216 antistatic agent Substances 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 229940116226 behenic acid Drugs 0.000 description 1
- 235000010233 benzoic acid Nutrition 0.000 description 1
- WQZGKKKJIJFFOK-VFUOTHLCSA-N beta-D-glucose Chemical compound OC[C@H]1O[C@@H](O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-VFUOTHLCSA-N 0.000 description 1
- 229920006167 biodegradable resin Polymers 0.000 description 1
- 125000004432 carbon atom Chemical group C* 0.000 description 1
- 150000001732 carboxylic acid derivatives Chemical class 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 239000008358 core component Substances 0.000 description 1
- 238000003851 corona treatment Methods 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- VZFUCHSFHOYXIS-UHFFFAOYSA-N cycloheptane carboxylic acid Natural products OC(=O)C1CCCCCC1 VZFUCHSFHOYXIS-UHFFFAOYSA-N 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 229940105990 diglycerin Drugs 0.000 description 1
- GPLRAVKSCUXZTP-UHFFFAOYSA-N diglycerol Chemical compound OCC(O)COCC(O)CO GPLRAVKSCUXZTP-UHFFFAOYSA-N 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- KFEVDPWXEVUUMW-UHFFFAOYSA-N docosanoic acid Natural products CCCCCCCCCCCCCCCCCCCCCC(=O)OCCC1=CC=C(O)C=C1 KFEVDPWXEVUUMW-UHFFFAOYSA-N 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 238000007667 floating Methods 0.000 description 1
- 239000008103 glucose Substances 0.000 description 1
- 125000005456 glyceride group Chemical group 0.000 description 1
- 235000011187 glycerol Nutrition 0.000 description 1
- 239000012760 heat stabilizer Substances 0.000 description 1
- 239000008172 hydrogenated vegetable oil Substances 0.000 description 1
- 239000011256 inorganic filler Substances 0.000 description 1
- 229910003475 inorganic filler Inorganic materials 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 229920000092 linear low density polyethylene Polymers 0.000 description 1
- 239000004707 linear low-density polyethylene Substances 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 239000004750 melt-blown nonwoven Substances 0.000 description 1
- 150000002763 monocarboxylic acids Chemical class 0.000 description 1
- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical compound CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 1
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 1
- 239000002736 nonionic surfactant Substances 0.000 description 1
- 239000002667 nucleating agent Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- ZWLPBLYKEWSWPD-UHFFFAOYSA-N o-toluic acid Chemical compound CC1=CC=CC=C1C(O)=O ZWLPBLYKEWSWPD-UHFFFAOYSA-N 0.000 description 1
- 230000009965 odorless effect Effects 0.000 description 1
- 150000002894 organic compounds Chemical class 0.000 description 1
- 239000005022 packaging material Substances 0.000 description 1
- WXZMFSXDPGVJKK-UHFFFAOYSA-N pentaerythritol Chemical compound OCC(CO)(CO)CO WXZMFSXDPGVJKK-UHFFFAOYSA-N 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920003207 poly(ethylene-2,6-naphthalate) Polymers 0.000 description 1
- 229920000747 poly(lactic acid) Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 239000004631 polybutylene succinate Substances 0.000 description 1
- 229920002961 polybutylene succinate Polymers 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 239000004645 polyester resin Substances 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 239000011112 polyethylene naphthalate Substances 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 239000004626 polylactic acid Substances 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 239000000779 smoke Substances 0.000 description 1
- 239000000600 sorbitol Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 230000001629 suppression Effects 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 230000008961 swelling Effects 0.000 description 1
- 208000024891 symptom Diseases 0.000 description 1
- 229920003051 synthetic elastomer Polymers 0.000 description 1
- 239000005061 synthetic rubber Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- LKOVPWSSZFDYPG-WUKNDPDISA-N trans-octadec-2-enoic acid Chemical compound CCCCCCCCCCCCCCC\C=C\C(O)=O LKOVPWSSZFDYPG-WUKNDPDISA-N 0.000 description 1
- 150000004670 unsaturated fatty acids Chemical class 0.000 description 1
- 235000021122 unsaturated fatty acids Nutrition 0.000 description 1
- 235000015112 vegetable and seed oil Nutrition 0.000 description 1
- 235000019871 vegetable fat Nutrition 0.000 description 1
- 239000008158 vegetable oil Substances 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
Landscapes
- Laminated Bodies (AREA)
- Manufacturing Of Multi-Layer Textile Fabrics (AREA)
- Nonwoven Fabrics (AREA)
- Absorbent Articles And Supports Therefor (AREA)
- Orthopedics, Nursing, And Contraception (AREA)
Abstract
Description
本発明は、衛生製品の、トップシート、バックシート、サイドギャザー部等の吸収性部材において使用するのに特に適した不織布であって、加工性に優れるポリオレフィン系長繊維で構成された不織布に関する。 The present invention relates to a nonwoven fabric particularly suitable for use in absorbent members such as topsheets, backsheets, and side gather parts of sanitary products, and relates to a nonwoven fabric composed of polyolefin-based long fibers excellent in processability.
近年、使い捨てオムツ等の、不織布で構成された衛生製品の普及はめざましく、その生産量も急増してきている。このような環境下、例えば使い捨てオムツにおいて、その製造ラインでのロスの減少及び品質の安定性が重要である。オムツ製造ラインにおいて、素材となる不織布の地合が悪いと、吸収体であるＳＡＰ（超吸収性ポリマー）の漏れの問題、及びフィルムと不織布との貼り合わせ工程でホットメルト剤が不織布を抜けてしまうという問題等、様々な不具合が生じる。一方、バックシート用途においては、不織布の地合が悪い場合、不織布の厚みにムラがあり不織布の白色に濃淡があると、不織布の繊維が多く白色が濃い箇所では、バックシートの内側に一般的に使用しているキャラクター等が印刷されているフィルムの印刷が、最外層となる不織布側から見ると不鮮明になるという問題が生じ、また不織布の繊維が少なく白色が薄い箇所では排泄物が表面に見えてしまうという問題が生じる。 In recent years, sanitary products composed of nonwoven fabrics such as disposable diapers have been remarkably widespread, and their production volume has been rapidly increasing. Under such circumstances, for example, in disposable diapers, loss reduction and quality stability in the production line are important. In the diaper production line, if the nonwoven fabric used as the raw material is not well formed, the hot melt agent will pass through the nonwoven fabric in the bonding process between the film and the nonwoven fabric, as well as the SAP (super absorbent polymer) leakage. Various problems occur, such as the problem of end. On the other hand, in the backsheet application, if the nonwoven fabric is not well formed, the thickness of the nonwoven fabric is uneven, and the white color of the nonwoven fabric is generally dark inside. There is a problem that the printing of the film on which the characters etc. used for printing are printed becomes unclear when viewed from the non-woven fabric side which is the outermost layer. The problem of being visible arises.
従来、不織布の粉漏れ防止性及び地合を改善する手段としては、目付を上げる方法、繊度を細くする方法、２層のスパンボンド不織布の間に極細の繊維であるメルトブローン不織布をサンドウィッチしてなる積層不織布を用いる方法等がある。しかし、目付を上げる方法では、目付の増大に従って柔軟性が低下するため、衛生製品に用いる場合には厚ぼったい感触となる問題がある。繊度を細くする方法では、スパンボンド法において生産性を落とすことで繊度を細くすることが可能ではあるが、商業性を考慮するとスパンボンド法における細繊化には限界がある。また、メルトブローン層を入れて積層する方法では、隠蔽性が高くなり過ぎて通気性が悪くなり、ムレ等の症状が生じる。またメルトブローン層が入ると、バックシート内側のフィルムに印刷されたキャラクター等の印刷が極細の繊維により不鮮明となる問題がある。 Conventionally, as means for improving powder leakage prevention and formation of nonwoven fabric, a method of increasing the basis weight, a method of reducing the fineness, and sandwiching a meltblown nonwoven fabric, which is an ultrafine fiber, between two layers of spunbond nonwoven fabric There is a method using a laminated nonwoven fabric. However, in the method of raising the basis weight, the flexibility decreases with an increase in the basis weight, and therefore there is a problem that the touch becomes thick when used in a sanitary product. In the method of reducing the fineness, it is possible to reduce the fineness by reducing the productivity in the spunbond method, but there is a limit to the fineness in the spunbond method considering commerciality. Moreover, in the method of laminating with a meltblown layer, the concealability becomes too high, the air permeability becomes poor, and symptoms such as swelling occur. In addition, when a meltblown layer is inserted, there is a problem that printing of characters and the like printed on the film inside the backsheet becomes unclear due to ultrafine fibers.
スパンボンド不織布を積層する方法によれば、単層の不織布のムラが複数重なることで積層体としては均一性を向上させることができる。しかし、商業的な大量生産のためには生産ラインの高速化が必須となる。生産ラインの高速化は、繊維を積層する際にウェブが吹き飛んだり、コンベア上でメクレが発生したりするという問題を生じさせるため、３層以上の積層不織布を高速で得るのは非常に困難であった。 According to the method of laminating the spunbonded nonwoven fabric, the uniformity of the laminate can be improved by overlapping a plurality of unevenness of the single layer nonwoven fabric. However, high-speed production lines are essential for commercial mass production. Speeding up the production line causes problems that webs blow away when fibers are laminated, and melee occurs on the conveyor, so it is very difficult to obtain a laminated nonwoven fabric of three or more layers at high speed. there were.
特許文献１には、細デニール繊維のスパンボンド不織布を用いて高強力で濾過性能の良好なフィルター濾材を得る方法が開示されている。また、特許文献２には、連続長繊維群を高速気流牽引装置により牽引して細化延伸させ、連続長繊維群開繊用反射板に衝突させて、良好な地合のスパンボンド不織布を得る方法が開示されている。更に、特許文献３には、捲縮糸を用いた、嵩高性に富み地合の良好な積層不織布を得る方法が開示されている。 Patent Document 1 discloses a method for obtaining a filter medium having high strength and good filtration performance using a spunbond nonwoven fabric of fine denier fibers. Further, in Patent Document 2, a continuous long fiber group is pulled by a high-speed air current pulling device and is stretched and stretched, and is collided with a continuous long fiber group opening reflector to obtain a spunbond nonwoven fabric having a good formation. A method is disclosed. Furthermore, Patent Document 3 discloses a method for obtaining a laminated nonwoven fabric having a high bulkiness and good texture using crimped yarn.
しかし、特許文献１において使用されるポリエステル樹脂は剛軟度が高く、衛生製品に使用するには柔軟性に問題が生じる。また特許文献２の技術では、地合を良好にするための開繊用反射板の調整が煩雑である。またこの文献には積層に関する記載はない。更に、特許文献３における捲縮糸を用いたスパンボンド不織布では、耐毛羽性に問題があり、これを衛生製品に使用する場合、不織布から発生した毛羽を乳児が誤飲する等の問題が生じる。 However, the polyester resin used in Patent Document 1 has a high bending resistance, which causes a problem in flexibility when used in sanitary products. Moreover, in the technique of patent document 2, adjustment of the reflecting plate for fiber opening for making a formation favorable is complicated. In addition, this document has no description regarding lamination. Furthermore, the spunbonded nonwoven fabric using the crimped yarn in Patent Document 3 has a problem in the fluff resistance, and when this is used in a sanitary product, there arises a problem that an infant accidentally swallows the fluff generated from the nonwoven fabric. .
本発明が解決しようとする課題は、衛生製品における吸収性部材であるトップシート、バックシート又はサイドギャザー部を形成するのに特に適した、地合が良好で、隠蔽性に優れ、かつホットメルト剤及びＳＡＰの漏れが少ない不織布を提供することである。 The problem to be solved by the present invention is that it is particularly suitable for forming a top sheet, a back sheet or a side gather part, which is an absorbent member in a sanitary product, has good formation, excellent concealment, and hot melt It is to provide a non-woven fabric with less leakage of the agent and SAP.
本発明者らは、上記課題を解決すべく鋭意検討し実験を重ねた結果、特定範囲の平均単糸繊度を有する繊維を含む長繊維不織布層が３層以上積層されており、かつ特定の地合指数を有する不織布積層体によれば、良好な遮蔽性、並びにホットメルト剤及びＳＡＰの漏れの低減を実現できることを見出した。更に本発明者らは、上記の不織布積層体が、不織布積層体の生産工程におけるコンパクションロールの接圧及び温度を特定範囲とし、更に、繊維を堆積させるコンベアネットの通気度を特定範囲とすることで、良好かつ確実に製造されることを見出した。一般的に、生産能力を向上させ、低い目付の不織布を生産するためには、生産ラインの高速化が必要である。しかし生産ラインを高速化すると繊維の配向がタテ流れとなり、地合が悪くなりムラが生じる。本発明者らは、コンパクションロールの接圧及び温度を特定範囲とし、かつ繊維を堆積させるコンベアネットの通気度を制御することで、長繊維不織布層のウェブを積層する際のウェブの吹き飛び及びメクレ等を防止し、該ウェブを３層以上に積層することができ、地合が良好で高い隠蔽性を有する不織布積層体を得ることができることを見出した。すなわち、本発明は以下のとおりのものである。 As a result of intensive studies and repeated experiments to solve the above problems, the present inventors have found that three or more long-fiber nonwoven fabric layers containing fibers having an average single yarn fineness within a specific range are laminated, and a specific ground. It has been found that according to the nonwoven fabric laminate having a composite index, good shielding properties and reduction of leakage of the hot melt agent and SAP can be realized. Furthermore, the present inventors make the above-mentioned nonwoven fabric laminate a specific range of the contact pressure and temperature of the compaction roll in the production process of the nonwoven fabric laminate, and further make the air permeability of the conveyor net for depositing fibers a specific range. Thus, it was found that the product was manufactured reliably and reliably. Generally, in order to improve the production capacity and produce a nonwoven fabric with a low basis weight, it is necessary to speed up the production line. However, when the production line is speeded up, the orientation of the fibers becomes a vertical flow, the formation becomes worse and unevenness occurs. The present inventors set the contact pressure and temperature of the compaction roll within a specific range and control the air permeability of the conveyor net on which the fibers are deposited, so that the web blow-off and the meshing when laminating the webs of the long fiber nonwoven fabric layer are controlled. It was found that the web can be laminated into three or more layers, and a nonwoven fabric laminate having good formation and high concealability can be obtained. That is, the present invention is as follows.
［１］ ポリオレフィン系長繊維を含む長繊維不織布層を３層以上含む不織布積層体であって、
該不織布積層体の地合指数が５８以上８０以下であり、かつ
該ポリオレフィン系長繊維の平均単糸繊度が０．７ｄｔｅｘ以上３．５ｄｔｅｘ以下である、不織布積層体。
［２］ 分子配向度のＭＯＲ値で１．０５以上２．０以下である繊維配向を有する、上記［１］に記載の不織布積層体。
［３］ 粉漏れ率が３％以上５０％以下である、上記［１］又は［２］に記載の不織布積層体。
［４］ 目付が５ｇ／ｍ2以上３０ｇ／ｍ2以下である、上記［１］〜［３］のいずれかに記載の不織布積層体。
［５］ 通気度が１００ｃｍ3／ｃｍ2／秒以上８００ｃｍ3／ｃｍ2／秒以下である、上記［１］〜［４］のいずれかに記載の不織布積層体。
［６］ 嵩密度が０．０５ｇ／ｃｍ3以上０．２０ｇ／ｃｍ3以下である、上記［１］〜［５］のいずれかに記載の不織布積層体。
［７］ 該ポリオレフィン系長繊維がポリプロピレン系長繊維である、上記［１］〜［６］のいずれかに記載の不織布積層体。
［８］ スパンボンド不織布である、上記［１］〜「７」のいずれかに記載の不織布積層体。
［９］ 該長繊維不織布層を４層以上含む、上記［１］〜［８］のいずれかに記載の不織布積層体。
［１０］ 親水化剤を更に含む、上記［１］〜［９］のいずれかに記載の不織布積層体。
［１１］ 柔軟化剤を更に含む、上記［１］〜［９］のいずれかに記載の不織布積層体。
［１２］ 上記［１］〜［１１］のいずれかに記載の不織布積層体の製造方法であって、以下の工程：
ポリオレフィン系長繊維を含む繊維成分をコンベアネット上に堆積させることによって長繊維不織布層を形成する不織布層形成工程、及び
該不織布層形成工程で得た長繊維不織布層を３層以上重ねて圧着することによって不織布積層体を形成する圧着工程、
を含み、
生産速度が１７０ｍ／分以上であり、かつ
以下の関係式：繊維成分の繊度［ｄｔｅｘ］×生産速度［ｍ／分］≧２００を満足する、不織布積層体の製造方法。
［１３］ 上記コンベアネットの通気度が２００ｃｍ3／ｃｍ2／秒以上５００ｃｍ3／ｃｍ2／秒以下であり、
該圧着工程を、コンパクションロールを用いて接圧２ｋｇｆ／ｃｍ以上５ｋｇｆ／ｃｍ以下及び温度が該ポリオレフィン系長繊維の融点より０℃以上６０℃以下低い温度で行う、上記［１２］に記載の不織布積層体の製造方法。
［１４］ 上記［１］〜［１１］のいずれかに記載の不織布積層体を含む、衛生製品。
［１５］ 使い捨てオムツ、生理用ナプキン又は失禁パットである、上記［１４］に記載の衛生製品。
[1] A nonwoven fabric laminate comprising three or more long-fiber nonwoven fabric layers containing polyolefin-based long fibers,
A nonwoven fabric laminate in which the formation index of the nonwoven fabric laminate is 58 or more and 80 or less, and the average single yarn fineness of the polyolefin-based long fibers is 0.7 dtex or more and 3.5 dtex or less.
[2] The nonwoven fabric laminate according to the above [1], which has a fiber orientation of 1.05 or more and 2.0 or less in terms of MOR value of molecular orientation.
[3] The nonwoven fabric laminate according to the above [1] or [2], wherein the powder leakage rate is 3% or more and 50% or less.
[4] The nonwoven fabric laminate according to any one of [1] to [3], wherein the basis weight is 5 g / m 2 or more and 30 g / m 2 or less.
[5] The nonwoven fabric laminate according to any one of [1] to [4], wherein the air permeability is 100 cm 3 / cm 2 / second or more and 800 cm 3 / cm 2 / second or less.
[6] The bulk density is less than 0.05 g / cm 3 or more 0.20 g / cm 3, the above-mentioned [1] non-woven fabric laminate according to any one of to [5].
[7] The nonwoven fabric laminate according to any one of [1] to [6], wherein the polyolefin-based long fibers are polypropylene-based long fibers.
[8] The nonwoven fabric laminate according to any one of [1] to [7], which is a spunbonded nonwoven fabric.
[9] The nonwoven fabric laminate according to any one of the above [1] to [8], comprising 4 or more layers of the long fiber nonwoven fabric layer.
[10] The nonwoven fabric laminate according to any one of [1] to [9], further including a hydrophilizing agent.
[11] The nonwoven fabric laminate according to any one of [1] to [9], further including a softening agent.
[12] A method for producing a nonwoven fabric laminate according to any one of [1] to [11] above, wherein the following steps:
A non-woven fabric layer forming step for forming a long-fiber non-woven fabric layer by depositing fiber components including polyolefin-based long fibers on a conveyor net, and three or more long-fiber non-woven fabric layers obtained in the non-woven fabric layer forming step are stacked and pressure-bonded. A crimping step for forming a nonwoven fabric laminate,
Including
A method for producing a nonwoven fabric laminate, wherein the production rate is 170 m / min or more and the following relational expression: fineness [dtex] of fiber component × production rate [m / min] ≧ 200 is satisfied.
[13] The air permeability of the conveyor net is 200 cm 3 / cm 2 / second or more and 500 cm 3 / cm 2 / second or less,
The nonwoven fabric according to [12], wherein the crimping step is performed using a compaction roll at a contact pressure of 2 kgf / cm to 5 kgf / cm and a temperature lower by 0 ° C. or more and 60 ° C. or less than the melting point of the polyolefin long fiber. A manufacturing method of a layered product.
[14] A sanitary product comprising the nonwoven fabric laminate according to any one of [1] to [11].
[15] The sanitary product according to [14], which is a disposable diaper, a sanitary napkin or an incontinence pad.
本発明の不織布積層体は、ポリオレフィン系長繊維で構成される長繊維不織布層を含み、特定範囲の地合指数及び平均単糸繊度を有するため、衛生製品用途においてホットメルト剤及び吸収体であるＳＡＰの漏れを良好に抑制することができるとともに、良好な生産性で製造することが可能である。更に、本発明の不織布積層体は３層以上からなる積層不織布であるため、単層不織布のムラが均一化されており、極めて高い隠蔽性を有する。 The non-woven fabric laminate of the present invention includes a long-fiber non-woven fabric layer composed of polyolefin-based long fibers and has a specific range of formation index and average single yarn fineness, and is therefore a hot melt agent and an absorbent for hygiene products. It is possible to satisfactorily suppress SAP leakage and manufacture with good productivity. Furthermore, since the nonwoven fabric laminate of the present invention is a laminated nonwoven fabric composed of three or more layers, the unevenness of the single-layer nonwoven fabric is made uniform and has a very high concealing property.
更に、本発明の不織布積層体を例えばバックシート用途に適用する場合には、最外層となる不織布の地合が良好であるため、バックシートの内側に一般的に使用している、キャラクター等が印刷されているフィルムの印刷が鮮明にきれいに見えるという効果、及び不織布の厚みが極端に小さい箇所でも破断が抑制されるという効果が得られる。 Furthermore, when the nonwoven fabric laminate of the present invention is applied to, for example, a backsheet, since the formation of the nonwoven fabric that is the outermost layer is good, a character or the like that is generally used inside the backsheet The effect that the printing of the printed film looks clear and beautiful, and the effect that the breakage is suppressed even at a location where the thickness of the nonwoven fabric is extremely small are obtained.
本発明の不織布積層体は、上記の構成を有することにより、衛生製品において吸収性部材であるトップシート、バックシート又はサイドギャザー部に使用するのに特に適した加工性に優れる不織布である。 The nonwoven fabric laminate of the present invention is a nonwoven fabric excellent in processability particularly suitable for use in a top sheet, a back sheet or a side gather part, which is an absorbent member in a sanitary product, by having the above configuration.
以下、本発明について詳述する。 Hereinafter, the present invention will be described in detail.
＜不織布積層体＞
本発明の一態様は、ポリオレフィン系長繊維を含む長繊維不織布層を３層以上含む不織布積層体であって、該不織布積層体の地合指数が５８以上８０以下であり、かつ該ポリオレフィン系長繊維の平均単糸繊度が０．７ｄｔｅｘ以上３．５ｄｔｅｘ以下である、不織布積層体を提供する。
<Nonwoven fabric laminate>
One embodiment of the present invention is a nonwoven fabric laminate comprising three or more long-fiber nonwoven fabric layers containing polyolefin-based long fibers, wherein the nonwoven fabric laminate has a formation index of 58 or more and 80 or less, and the polyolefin-based length Provided is a nonwoven fabric laminate in which the average single yarn fineness of the fibers is 0.7 dtex or more and 3.5 dtex or less.
本発明の不織布積層体における各々の長繊維不織布層は、ポリオレフィン系長繊維で構成される。長繊維不織布層は、ポリオレフィン系長繊維のみで構成されてもよいし、本発明の効果を損なわない範囲（例えば全体の２０モル％以下、より好ましくは１０モル％以下）でポリオレフィン系長繊維以外の繊維を含んでもよい。ポリオレフィン系長繊維とは、主要構成成分（具体的には全体の５０モル％超）がポリオレフィンである長繊維を意味する。 Each long fiber nonwoven fabric layer in the nonwoven fabric laminate of the present invention is composed of polyolefin long fibers. The long-fiber non-woven fabric layer may be composed only of polyolefin-based long fibers, or other than polyolefin-based long fibers within a range that does not impair the effects of the present invention (for example, 20 mol% or less, more preferably 10 mol% or less of the whole). Of fibers may be included. The polyolefin-based long fiber means a long fiber whose main constituent component (specifically, more than 50 mol% of the whole) is polyolefin.
ポリオレフィン系長繊維としては、例えば、ポリエチレン繊維、ポリプロピレン繊維、並びに、エチレン及び／又はプロピレンと他のα−オレフィンとの共重合体等の樹脂から成る繊維が挙げられる。なかでも、強度が強く使用時において破断し難く、且つ衛生製品の生産時における寸法安定性に優れることから、ポリオレフィン系長繊維がポリプロピレン系繊維であることが好ましい。ポリプロピレンは、一般的なチーグラナッタ触媒により合成されるポリマーでもよいし、メタロセンに代表されるシングルサイト活性触媒により合成されたポリマーであってもよい。また、エチレンランダム共重合ポリプロピレンも使用できる。エチレンランダム共重合ポリプロピレンにおけるエチレン含有量は、衛生製品に好適に使用できる強度の観点から、２モル％未満、好ましくは１モル％未満であることが好ましい。他のα−オレフィンとしては、炭素数３〜１０のα−オレフィン、具体的には、プロピレン、１−ブテン、１−ペンテン、１−ヘキサン、４−メチル−１−ペンテン、１−オクテン等が挙げられる。これらは１種類単独でも２種類以上を組み合わせて用いてもよい。更に、ポリオレフィン系樹脂部分とポリオレフィン系樹脂以外の部分とからなる繊維、例えばポリオレフィン系樹脂を表面層とする芯鞘繊維等も使用できる。 Examples of the polyolefin-based long fibers include polyethylene fibers, polypropylene fibers, and fibers made of a resin such as a copolymer of ethylene and / or propylene and another α-olefin. Among these, the polyolefin-based long fibers are preferably polypropylene-based fibers because they are strong and difficult to break during use and have excellent dimensional stability during the production of sanitary products. Polypropylene may be a polymer synthesized by a general Ziegler-Natta catalyst or a polymer synthesized by a single site active catalyst typified by metallocene. Also, ethylene random copolymer polypropylene can be used. The ethylene content in the ethylene random copolymer polypropylene is preferably less than 2 mol%, preferably less than 1 mol%, from the viewpoint of strength that can be suitably used for sanitary products. Other α-olefins include α-olefins having 3 to 10 carbon atoms, specifically, propylene, 1-butene, 1-pentene, 1-hexane, 4-methyl-1-pentene, 1-octene, and the like. Can be mentioned. These may be used alone or in combination of two or more. Furthermore, a fiber composed of a polyolefin resin portion and a portion other than the polyolefin resin, for example, a core-sheath fiber having a polyolefin resin as a surface layer can be used.
長繊維不織布層が含有しうる、ポリオレフィン系長繊維以外の繊維としては、ポリエチレンテレフタレート繊維、ポリブチレンテレフタレート繊維、ポリエチレンナフタレート繊維、共重合ポリエステル繊維等のポリエステル系繊維；ナイロン−６繊維、ナイロン−６６繊維、共重合ナイロン繊維等のポリアミド系繊維；ポリ乳酸、ポリブチレンサクシネート、ポリエチレンサクシネート等の生分解性樹脂からなる繊維；等が挙げられる。これらの繊維は１種類又は２種類以上組み合わせて使用できる。紡糸安定性の観点から、好ましくは１種類単独で用いる。 Examples of fibers other than the polyolefin-based long fibers that can be contained in the long-fiber nonwoven fabric layer include polyester-based fibers such as polyethylene terephthalate fibers, polybutylene terephthalate fibers, polyethylene naphthalate fibers, and copolyester fibers; nylon-6 fibers, nylon- 66 fibers, polyamide fibers such as copolymer nylon fibers; fibers made of biodegradable resins such as polylactic acid, polybutylene succinate, polyethylene succinate; and the like. These fibers can be used alone or in combination of two or more. From the viewpoint of spinning stability, it is preferably used alone.
繊維形状は種々可能であり、円形断面を有する通常の繊維に加え、捲縮繊維、異形繊維等の特殊形態の繊維を使用可能である。 Various fiber shapes are possible, and in addition to ordinary fibers having a circular cross section, specially shaped fibers such as crimped fibers and deformed fibers can be used.
長繊維不織布層は、強度及び寸法安定性の観点から、ホモポリプロピレンであることが特に好ましい。この場合のホモポリプロピレンのＭＦＲ（メルトフローレイト）は、好ましくは２０ｇ／１０分以上、より好ましくは３０ｇ／１０分超、更に好ましくは４０ｇ／１０分超、特に好ましくは５３ｇ／１０分超であり、また、好ましくは１００ｇ／１０分以下、より好ましくは８５ｇ／１０分以下、更に好ましくは７０ｇ／１０分以下、特に好ましくは６５ｇ／１０分未満である。ＭＦＲがこの範囲にあると樹脂の流動性が良く、かつ曲げ柔軟度の良好な不織布を得ることができる。ＭＦＲは、ＪＩＳ−Ｋ７２１０「プラスチック−熱可塑性プラスチックのメルトマスフローレイト（ＭＦＲ）及びメルトボリュームフローレイト（ＭＶＲ）の試験方法」の表１、試験温度２３０℃、及び試験荷重２．１６ｋｇに準じて測定を行って求めることができる。 The long fiber nonwoven fabric layer is particularly preferably homopolypropylene from the viewpoint of strength and dimensional stability. The MFR (melt flow rate) of the homopolypropylene in this case is preferably 20 g / 10 minutes or more, more preferably more than 30 g / 10 minutes, still more preferably more than 40 g / 10 minutes, particularly preferably more than 53 g / 10 minutes. Also, it is preferably 100 g / 10 min or less, more preferably 85 g / 10 min or less, still more preferably 70 g / 10 min or less, particularly preferably less than 65 g / 10 min. When the MFR is within this range, a non-woven fabric having good resin fluidity and good bending flexibility can be obtained. MFR is measured in accordance with JIS-K7210 “Testing methods for plastics-thermoplastic melt mass flow rate (MFR) and melt volume flow rate (MVR)”, test temperature 230 ° C., and test load 2.16 kg. Can be obtained.
ポリオレフィン系長繊維は、核剤、難燃剤、無機充填剤、顔料、着色剤、耐熱安定剤、帯電防止剤等の各種添加剤を含有してもよい。 The polyolefin-based long fiber may contain various additives such as a nucleating agent, a flame retardant, an inorganic filler, a pigment, a colorant, a heat stabilizer, and an antistatic agent.
本発明の不織布積層体の地合指数は、５８以上８０以下であり、好ましくは５９以上７８以下、より好ましくは６０以上７５以下である。地合指数が８０以下であれば、粉漏れ率が良好となり、地合が５８以上であれば通気性が良好である。地合指数は、以下の方法で測定される値である。フォーメーションテスターを用い、試料台上に置いた試料に照射ランプの光を当てて透過像を二次元ＣＣＤカメラで撮影し、適切な画素数（例えばＡ４サイズ試料で３２０×３２０画素）に分解し、各画素が受ける光の強さを測定する。次に、各画素についての透過率（ｔ％）を下記式で算出する。
絶対透過率（ｔ％）＝（Ｖｔ−Ｖｒ）／（Ｖ１００−Ｖ０）×１００％
Ｖ１００：照射ランプ点灯の光度、Ｖ０：照射ランプの消灯の光度
Ｖｔ：試料をのせた状態の、照射ランプ点灯の光度
Ｖｒ：試料をのせた状態の、照射ランプ消灯の光度
絶対透過率（ｔ％）を、下記式：
吸光度（Ｅ）＝２−ｌｏｇｔ
に従って吸光度（Ｅ）に換算し、下記式：
地合指数＝吸光度（Ｅ）の変動係数×１０
に従って地合指数を算出する。
The formation index of the nonwoven fabric laminate of the present invention is from 58 to 80, preferably from 59 to 78, more preferably from 60 to 75. If the formation index is 80 or less, the powder leakage rate is good, and if the formation is 58 or more, the air permeability is good. The formation index is a value measured by the following method. Using a formation tester, irradiate the sample placed on the sample table with the light from the irradiation lamp and take a transmission image with a two-dimensional CCD camera, and decompose it into an appropriate number of pixels (for example, 320 × 320 pixels for an A4 size sample), The intensity of light received by each pixel is measured. Next, the transmittance (t%) for each pixel is calculated by the following equation.
Absolute transmittance (t%) = (Vt−Vr) / (V100−V0) × 100%
V100: intensity of illumination lamp on, V0: intensity of illumination lamp off Vt: intensity of illumination lamp on condition of sample Vr: intensity of illumination lamp off on condition of sample Absolute transmittance (t%) ) With the following formula:
Absorbance (E) = 2-logt
According to the following formula:
Formation index = coefficient of variation of absorbance (E) x 10
Calculate the formation index according to
ポリオレフィン系長繊維の平均単糸繊度は、０．７ｄｔｅｘ以上３．５ｄｔｅｘ以下である。該平均単糸繊度は、好ましくは０．８ｄｔｅｘ以上３．３ｄｔｅｘ以下、より好ましくは０．９ｄｔｅｘ以上３．０ｄｔｅｘ以下である。該平均単糸繊度は、紡糸安定性の観点から、０．７ｄｔｅｘ以上であり、不織布の強力（特に衛生製品において重要である）の観点から、３．５ｄｔｅｘ以下である。平均単糸繊度は、例えばマイクロスコープを用いて繊維直径を測定し、測定値の数平均を算出することにより得られる値である。測定点は、１本の長繊維全体での繊度の平均値が反映されるように選択すればよい。例として、長繊維の両端を除いた後、不織布積層体の幅方向にほぼ５等分して試料片を作製し、５つの繊維断面の各々で２０点ずつ繊維直径を測定し、全１００点の数平均を算出することによって平均単糸繊度を評価できる。 The average single yarn fineness of the polyolefin-based long fibers is 0.7 dtex or more and 3.5 dtex or less. The average single yarn fineness is preferably 0.8 dtex or more and 3.3 dtex or less, more preferably 0.9 dtex or more and 3.0 dtex or less. The average single yarn fineness is 0.7 dtex or more from the viewpoint of spinning stability, and 3.5 dtex or less from the viewpoint of the strength of the nonwoven fabric (especially important in sanitary products). The average single yarn fineness is a value obtained by measuring the fiber diameter using, for example, a microscope and calculating the number average of the measured values. What is necessary is just to select a measurement point so that the average value of the fineness in the whole one long fiber may be reflected. As an example, after removing both ends of the long fiber, a sample piece was prepared by dividing into approximately 5 equal parts in the width direction of the nonwoven fabric laminate, and the fiber diameter was measured at 20 points on each of the five fiber cross sections, and 100 points were obtained. The average single yarn fineness can be evaluated by calculating the number average.
ポリオレフィン系長繊維を含む繊維成分を接合して長繊維不織布層を製造する際の接合手段としては、部分熱圧着法、熱風法、溶融成分（ホットメルト剤）での接合法（ホットメルト法）、その他各種の方法が挙げられるが、強度の観点から、熱圧着法が好ましい。 Joining methods using a partial thermocompression bonding method, a hot air method, and a melted component (hot melt agent) (hot melt method) as a joining means for producing a long fiber nonwoven fabric layer by joining fiber components containing polyolefin-based long fibers. Although various other methods can be mentioned, the thermocompression bonding method is preferable from the viewpoint of strength.
上記部分熱圧着法における熱圧着面積率は、強度保持及び柔軟性の点から、好ましくは３％以上４０％以下であり、より好ましくは４％以上２５％以下であり、更に好ましくは４％以上２０％以下であり、特に好ましくは５％以上１５％以下である。 The thermocompression bonding area ratio in the partial thermocompression bonding method is preferably 3% or more and 40% or less, more preferably 4% or more and 25% or less, and further preferably 4% or more, from the viewpoint of strength retention and flexibility. It is 20% or less, and particularly preferably 5% or more and 15% or less.
部分熱圧着処理は、超音波法により、又は加熱エンボスロール間にウェブを通すことにより行うことができ、これにより、表裏一体化される。部分熱圧着処理により、例えば、ピンポイント状、楕円形状、ダイヤ形状、矩形状等の浮沈模様を不織布全面に散点させることができる。生産性の観点から、加熱エンボスロールを用いることが好ましい。 The partial thermocompression treatment can be performed by an ultrasonic method or by passing a web between heated embossing rolls, whereby the front and back surfaces are integrated. By the partial thermocompression treatment, for example, pinpoint, oval, diamond, rectangular and other floating patterns can be scattered on the entire surface of the nonwoven fabric. From the viewpoint of productivity, it is preferable to use a heated embossing roll.
不織布積層体の繊維配向の指標である分子配向度のＭＯＲ値は、好ましくは１．０５以上２．０以下であり、より好ましくは１．１以上２．０以下、更に好ましくは１．２以上１．７以下である。ＭＯＲ値が１．０５以上であれば、繊維配向が製造ラインの流れ方向となり、幅の寸法変化が非常に小さくなるため衛生製品の加工適性が良好となる。また、ＭＯＲ値が２．０以下であると、衛生製品に使用する際に不織布積層体の横強度が良好に得られる。ＭＯＲ値は、分子配向計を用いて測定される値である。 The MOR value of the degree of molecular orientation which is an index of fiber orientation of the nonwoven fabric laminate is preferably 1.05 or more and 2.0 or less, more preferably 1.1 or more and 2.0 or less, and further preferably 1.2 or more. 1.7 or less. If the MOR value is 1.05 or more, the fiber orientation becomes the flow direction of the production line and the dimensional change of the width becomes very small, so that the processability of the sanitary product becomes good. In addition, when the MOR value is 2.0 or less, the transverse strength of the nonwoven fabric laminate can be satisfactorily obtained when used in a sanitary product. The MOR value is a value measured using a molecular orientation meter.
不織布積層体の粉漏れ率は、好ましくは３％以上５０％以下であり、より好ましくは５％以上４５％以下、更に好ましくは７．５％以上４０％以下である。粉漏れ率がこの範囲にあれば、不織布積層体の通気性を良好に保持したままホットメルト剤及びＳＡＰの漏れの問題を防止できるため、不織布積層体を衛生製品に好適に使用することができる。粉漏れ率は以下の方法で測定される値である。不織布積層体からタテ１０ｃｍ×ヨコ１０ｃｍの試料片を採取する。試料片を二つ折りにして縁を１８０℃で１０秒間ヒートシールする。その中へＪＩＳ−Ｚ８９０１試験用粉体１種ダストを約１ｇ入れ、重量Ｗ１を正確に測定し、袋状にした試料の口を同様にヒートシールする。この袋状にした試料をポリエチレンの袋に入れ、１．５ｍの高さから自然落下にて１０回落下させる。その後試料袋から漏れた粉体の重量Ｗ２を測定し、下記式に従って算出した粉漏れ率を算出する。５回の測定による数平均値を採用する。
粉漏れ率（％）＝Ｗ２／Ｗ１×１００
The powder leakage rate of the nonwoven fabric laminate is preferably 3% to 50%, more preferably 5% to 45%, and still more preferably 7.5% to 40%. If the powder leakage rate is within this range, the problem of leakage of the hot melt agent and SAP can be prevented while maintaining the air permeability of the nonwoven fabric laminate, so that the nonwoven fabric laminate can be suitably used for sanitary products. . The powder leakage rate is a value measured by the following method. A sample piece of 10 cm in length and 10 cm in width is collected from the nonwoven fabric laminate. The sample piece is folded in half and the edges are heat sealed at 180 ° C. for 10 seconds. About 1 g of JIS-Z8901 test powder 1 type dust is put therein, the weight W1 is accurately measured, and the mouth of the bag-like sample is similarly heat-sealed. This bag-shaped sample is put in a polyethylene bag and dropped 10 times by natural fall from a height of 1.5 m. Thereafter, the weight W2 of the powder leaked from the sample bag is measured, and the powder leakage rate calculated according to the following formula is calculated. The number average value of five measurements is adopted.
Powder leakage rate (%) = W2 / W1 × 100
本発明の不織布の目付は、好ましくは５ｇ／ｍ2以上３０ｇ／ｍ2以下であり、より好ましくは８／ｍ2以上３０ｇ／ｍ2以下、更に好ましくは１０ｇ／ｍ2以上３０ｇ／ｍ2以下、更に好ましくは１０ｇ／ｍ2以上２５ｇ／ｍ2以下、特に好ましくは１０ｇ／ｍ2以上２３ｇ／ｍ2未満である。目付が５ｇ／ｍ2以上であれば、衛生製品に使用される不織布に要求される強力要件が良好であり、一方、３０ｇ／ｍ2以下であれば、衛生製品に使用される不織布の柔軟性が良好で、外観的に厚ぼったい印象を与えない点で有利である。目付は、ＪＩＳ−Ｌ１９０６に準拠して測定される値である。 The basis weight of the nonwoven fabric of the present invention is preferably 5 g / m 2 or more and 30 g / m 2 or less, more preferably 8 / m 2 or more and 30 g / m 2 or less, and further preferably 10 g / m 2 or more and 30 g / m 2 or less. More preferably, it is 10 g / m 2 or more and 25 g / m 2 or less, and particularly preferably 10 g / m 2 or more and less than 23 g / m 2 . If the basis weight is 5 g / m 2 or more, the strength requirement required for the nonwoven fabric used for sanitary products is good, while if it is 30 g / m 2 or less, the flexibility of the nonwoven fabric used for sanitary products is good. Is advantageous in that it does not give an impression of being thick in appearance. The basis weight is a value measured according to JIS-L1906.
不織布積層体の通気度は、好ましくは１００ｃｍ3／ｃｍ2／秒以上８００ｃｍ3／ｃｍ2／秒以下であり、より好ましくは１５０ｃｍ3／ｃｍ2／秒以上７００ｃｍ3／ｃｍ2／秒以下、更に好ましくは２００ｃｍ3／ｃｍ2／秒以上６００ｃｍ3／ｃｍ2／秒以下である。通気度が８００ｃｍ3／ｃｍ2／秒以下であれば、粉漏れの抑制性が良好であり、通気度が１００ｃｍ3／ｃｍ2／秒以上であれば、衛生製品に使用するのに適した良好な通気性が与えられる。通気度は、ＪＩＳ−Ｌ１０９６に準拠して測定される値である。 The air permeability of the nonwoven fabric laminate is preferably 100 cm 3 / cm 2 / second or more and 800 cm 3 / cm 2 / second or less, more preferably 150 cm 3 / cm 2 / second or more and 700 cm 3 / cm 2 / second or less, and Preferably, it is 200 cm 3 / cm 2 / second or more and 600 cm 3 / cm 2 / second or less. If the air permeability is 800 cm 3 / cm 2 / second or less, the powder leakage suppression property is good, and if the air permeability is 100 cm 3 / cm 2 / second or more, good suitable for use in sanitary products. Breathability is provided. The air permeability is a value measured according to JIS-L1096.
不織布積層体の嵩密度は、好ましくは０．０５ｇ／ｃｍ3以上０．２０ｇ／ｃｍ3以上であり、より好ましくは０．０６ｇ／ｃｍ3以上０．１９ｇ／ｃｍ3以下、更に好ましくは０．０７ｇ／ｃｍ3以上０．１８ｇ／ｃｍ3以下である。嵩密度が０．０５ｇ／ｃｍ3以上であれば衛生製品に好適に使用できる強度を得ることができる。０．２０ｇ／ｃｍ3以下であれば衛生製品に好適に使用できる通気性を得ることができる。嵩密度は、不織布積層体の上記の目付及び厚みから下記式に従って算出される値である。
嵩密度（ｇ／ｃｍ3）＝目付（ｇ／ｍ2）／厚み（ｍｍ）／１０００
The bulk density of the nonwoven fabric laminate, preferably at 0.05 g / cm 3 or more 0.20 g / cm 3 or more, more preferably 0.06 g / cm 3 or more 0.19 g / cm 3 or less, more preferably 0. 07g / cm 3 or more 0.18g / cm 3 or less. If the bulk density is 0.05 g / cm 3 or more, strength that can be suitably used for hygiene products can be obtained. If it is 0.20 g / cm 3 or less, air permeability that can be suitably used for sanitary products can be obtained. The bulk density is a value calculated according to the following formula from the basis weight and thickness of the nonwoven fabric laminate.
Bulk density (g / cm 3 ) = Weight (g / m 2 ) / Thickness (mm) / 1000
不織布積層体は、親水化剤を更に含んでもよい。親水化剤は、例えば、繊維中に含浸され、又は繊維表面に付着していることができる。親水化剤の使用は、例えば衛生製品のトップシート用途において不織布積層体に親水性を付与できる点で有利である。親水化剤としては、人体への安全性、工程での安全性等を考慮して、高級アルコール；高級脂肪酸；アルキルフェノール等のエチレンオキサイドを付加した非イオン系界面活性剤；アルキルフォスフェート塩、アルキル硫酸塩等のアニオン系界面活性剤；等が好適である。これらは単独で又は２種類以上の混合物として好ましく用いられる。 The nonwoven fabric laminate may further contain a hydrophilizing agent. The hydrophilizing agent can be impregnated in the fiber or attached to the fiber surface, for example. The use of a hydrophilizing agent is advantageous in that hydrophilicity can be imparted to the nonwoven fabric laminate in, for example, a top sheet application of sanitary products. As the hydrophilizing agent, considering the safety to the human body and the safety in the process, higher alcohols; higher fatty acids; nonionic surfactants added with ethylene oxide such as alkylphenols; alkyl phosphate salts, alkyls Anionic surfactants such as sulfates; etc. are preferred. These are preferably used alone or as a mixture of two or more.
親水化剤の使用量は、要求される性能によって異なるが、通常は、不織布積層体を構成している繊維１００質量％に対して０．１質量％以上１．０質量％以下が好ましく、より好ましくは０．１５質量％以上０．８質量％以下、更に好ましくは０．２質量％以上０．６質量％以下である。使用量がこの範囲にあると、例えば衛生製品のトップシートに要求される親水性能を良好に満足し、加工性も良好となる。 The amount of use of the hydrophilizing agent varies depending on the required performance, but is usually preferably 0.1% by mass or more and 1.0% by mass or less with respect to 100% by mass of the fibers constituting the nonwoven fabric laminate. Preferably they are 0.15 mass% or more and 0.8 mass% or less, More preferably, they are 0.2 mass% or more and 0.6 mass% or less. When the amount used is in this range, for example, the hydrophilic performance required for the top sheet of a sanitary product is satisfactorily satisfied, and the processability is also good.
親水化剤を含む不織布積層体を製造する方法としては、通常、希釈した親水化剤を用いた、浸漬法、噴霧法、コーティング（キスコーター又はグラビアコーターにより）法等の既存の方法を採用することができる。２種類以上を必要により予め混合した親水化剤を、水等の溶媒で希釈して繊維に塗布することも好ましい。 As a method for producing a nonwoven fabric laminate containing a hydrophilizing agent, an existing method such as a dipping method, a spraying method, or a coating (using a kiss coater or gravure coater) method using a diluted hydrophilizing agent is usually employed. Can do. It is also preferable to dilute a hydrophilic agent in which two or more kinds are mixed in advance as necessary with a solvent such as water and apply it to the fiber.
親水化剤を水等の溶媒で希釈して繊維に塗布する方法では、乾燥工程を必要とする場合がある。その際の乾燥方法としては、対流伝熱、伝導伝熱、放射伝熱等を利用した既知の方法を採用することができ、熱風又は赤外線による乾燥方法、熱接触による乾燥方法等を用いることができる。 In the method in which the hydrophilizing agent is diluted with a solvent such as water and applied to the fiber, a drying step may be required. As a drying method at that time, a known method using convective heat transfer, conduction heat transfer, radiant heat transfer, or the like can be adopted, and a drying method using hot air or infrared rays, a drying method using thermal contact, or the like can be used. it can.
不織布積層体は、柔軟化剤を更に含んでもよい。柔軟化剤としては、エステル化合物が好ましく、より好ましくは３〜６価のポリオールとモノカルボン酸とのエステル化合物が挙げられる。 The nonwoven fabric laminate may further contain a softening agent. As the softening agent, an ester compound is preferable, and an ester compound of a trivalent to hexavalent polyol and a monocarboxylic acid is more preferable.
３〜６価のポリオールとしては、例えば、グリセリン、トリメチロールプロパン等の３価のポリオール、ペンタエリスリトール、グルコース、ソルビタン、ジグリセリン、エチレングリコールジグリセリルエーテル等の４価のポリオール、トリグリセリン、トリメチロールプロパンジグリセリルエーテル等の５価のポリオール、ソルビトール、テトラグリセリン、ジペンタエリスリトール等の６価のポリオール等が挙げられる。 Examples of the trivalent to hexavalent polyol include trivalent polyols such as glycerin and trimethylolpropane, tetravalent polyols such as pentaerythritol, glucose, sorbitan, diglycerin, and ethylene glycol diglyceryl ether, triglycerin, and trimethylol. Examples include pentavalent polyols such as propanediglyceryl ether, hexavalent polyols such as sorbitol, tetraglycerin, and dipentaerythritol.
モノカルボン酸としては、例えば、オクタン酸、ドデカン酸、テトラデカン酸、オクタデカン酸、ドコサン酸、ヘキサコサン酸、オクタデセン酸、ドコセン酸、イソオクタデカン酸等のモノカルボン酸、シクロヘキサンカルボン酸等の脂環式モノカルボン酸、安息香酸、メチルベンゼンカルボン酸等の芳香族モノカルボン酸、ヒドロキシプロピオン酸、ヒドロキシオクタデカン酸、ヒドロキシオクタデセン酸等のヒドロキシ脂肪族モノカルボン酸、アルキルチオプロピオン酸等の含イオウ脂肪族モノカルボン酸等が挙げられる。 Examples of the monocarboxylic acid include alicyclic monocarboxylic acids such as octacarboxylic acid, dodecanoic acid, tetradecanoic acid, octadecanoic acid, docosanoic acid, hexacosanoic acid, octadecenoic acid, docosenoic acid, isooctadecanoic acid, and cyclohexanecarboxylic acid. Aromatic monocarboxylic acids such as carboxylic acid, benzoic acid and methylbenzenecarboxylic acid, hydroxyaliphatic monocarboxylic acids such as hydroxypropionic acid, hydroxyoctadecanoic acid and hydroxyoctadecenoic acid, and sulfur-containing aliphatic monocarboxylic acids such as alkylthiopropionic acid An acid etc. are mentioned.
エステル化合物は、単一成分である必要はなく、２種類以上の混合物であってもよい。また、エステル化合物は天然物由来の油脂類であってもよい。但し、不飽和脂肪酸を含むエステル化合物は酸化されやすく紡糸時に酸化劣化し易いため、飽和の脂肪族モノカルボン酸又は芳香族モノカルボン酸が好ましい。天然物由来の油脂類としては、原料油に比べて無臭で安定であるという観点から、水素添加されたエステル化合物が好ましく用いられる。 The ester compound need not be a single component and may be a mixture of two or more. The ester compound may be a natural product-derived oil or fat. However, saturated aliphatic monocarboxylic acids or aromatic monocarboxylic acids are preferable because ester compounds containing unsaturated fatty acids are easily oxidized and easily deteriorated during spinning. As the fats and oils derived from natural products, hydrogenated ester compounds are preferably used from the viewpoint of being odorless and stable as compared with raw material oils.
エステル化合物としては、モノカルボン酸の分子量が比較的大きく、親油性が高いものが好ましい。親油性が高いことにより、ポリオレフィン系長繊維の非晶部に入り込み、結晶化を阻害して非晶領域を増加させるため、曲げ柔軟度がより小さくなる効果が得られる。 As the ester compound, a monocarboxylic acid having a relatively large molecular weight and high lipophilicity is preferable. Due to the high lipophilicity, it enters into the amorphous part of the polyolefin-based long fiber and inhibits crystallization to increase the amorphous region, so that an effect of reducing the bending flexibility can be obtained.
かかる効果を得るためには、エステル化合物の融点は７０℃以上であることが好ましく、より好ましくは８０℃以上１５０℃以下である。融点は、示差走査熱量測定装置（ＤＳＣ）で測定される値である。ＤＳＣで測定されるエステル化合物の融解ピークがブロードで、ある範囲を有する場合には、該融点は、融解ピークの最も高い点（すなわちピークトップ）の温度を意味する。なお、融点７０℃以上のエステル化合物と、他の組成物、例えば融点が７０℃未満のエステル化合物、その他の有機化合物等との混合物も使用可能である。 In order to obtain such an effect, the melting point of the ester compound is preferably 70 ° C. or higher, more preferably 80 ° C. or higher and 150 ° C. or lower. The melting point is a value measured by a differential scanning calorimeter (DSC). When the melting peak of the ester compound measured by DSC is broad and has a certain range, the melting point means the temperature at the highest point (ie peak top) of the melting peak. A mixture of an ester compound having a melting point of 70 ° C. or higher and other compositions such as an ester compound having a melting point of less than 70 ° C. or other organic compounds can also be used.
柔軟化剤、特にエステル化合物の使用量は、不織布積層体を構成する繊維１００質量％に対し、０．３質量％以上５．０質量％以下であることが好ましい。柔軟化剤（特にエステル化合物）は、少量の使用でも曲げ柔軟度及び滑り易さを著しく向上させ、０．３質量％以上であれば良好な柔軟化効果が与えられる。一方、柔軟化剤は、使用量を大きく増やしても使用量に見合った性能向上は見られない。そのため、紡糸性及び発煙性を加味し、該使用量は５．０質量％以下であることが好ましく、より好ましくは０．５質量％以上３．５質量％以下、更に好ましくは０．５質量％以上２．０質量％以下である。 The use amount of the softening agent, particularly the ester compound, is preferably 0.3% by mass or more and 5.0% by mass or less with respect to 100% by mass of the fibers constituting the nonwoven fabric laminate. A softening agent (especially an ester compound) remarkably improves the bending flexibility and the slipperiness even when used in a small amount, and a good softening effect is given if it is 0.3% by mass or more. On the other hand, the softening agent does not improve the performance commensurate with the amount of use even if the amount of use is greatly increased. Therefore, in consideration of spinnability and smoke generation, the amount used is preferably 5.0% by mass or less, more preferably 0.5% by mass to 3.5% by mass, and still more preferably 0.5% by mass. % To 2.0% by mass.
不織布積層体は、強度（これは特に衛生製品において重要である）の観点から、スパンボンド不織布であることが好ましい。 The nonwoven fabric laminate is preferably a spunbonded nonwoven fabric from the viewpoint of strength (this is particularly important in sanitary products).
本発明の不織布積層体は、３層以上の長繊維不織布層を含むことによって不織布のムラが均一化されており、良好な地合を有する。不織布積層体は、４層以上の長繊維不織布層を含むことが好ましい。積層数が増えるほど、単層の不織布のムラの均一化効果が良好であり、地合は良好となる。 The nonwoven fabric laminate of the present invention includes three or more long-fiber nonwoven fabric layers so that the unevenness of the nonwoven fabric is made uniform and has a good texture. The nonwoven fabric laminate preferably includes four or more long fiber nonwoven fabric layers. As the number of layers increases, the effect of uniforming the unevenness of the single-layer nonwoven fabric becomes better, and the formation becomes better.
＜不織布積層体の製造＞
本発明の不織布積層体は、例えば、ポリオレフィン系長繊維を含む繊維成分を紡糸し、コンベアネット上に該繊維成分を堆積させて長繊維不織布層を形成し、そして該長繊維不織布層を３層以上重ねて圧着することにより製造できる。
<Manufacture of nonwoven fabric laminate>
The nonwoven fabric laminate of the present invention, for example, spins a fiber component containing polyolefin-based long fibers, deposits the fiber component on a conveyor net to form a long-fiber nonwoven fabric layer, and three layers of the long-fiber nonwoven fabric layer It can be manufactured by stacking and pressure-bonding.
本発明の別の態様は、上述した本発明の不織布積層体の製造方法であって、以下の工程：
ポリオレフィン系長繊維を含む繊維成分をコンベアネット上に堆積させることによって長繊維不織布層を形成する不織布層形成工程、及び
該不織布層形成工程で得た長繊維不織布層を３層以上重ねて圧着することによって不織布積層体を形成する圧着工程、
を含み、
生産速度が１７０ｍ／分以上であり、かつ
以下の関係式：繊維成分の繊度［ｄｔｅｘ］×生産速度［ｍ／分］≧２００を満足する、不織布積層体の製造方法を提供する。
Another aspect of the present invention is a method for producing the nonwoven fabric laminate of the present invention described above, and includes the following steps:
A non-woven fabric layer forming step for forming a long-fiber non-woven fabric layer by depositing fiber components including polyolefin-based long fibers on a conveyor net, and three or more long-fiber non-woven fabric layers obtained in the non-woven fabric layer forming step are stacked and pressure-bonded. A crimping step for forming a nonwoven fabric laminate,
Including
Provided is a method for producing a nonwoven fabric laminate, which has a production rate of 170 m / min or more and satisfies the following relational expression: fineness [dtex] of fiber component × production rate [m / min] ≧ 200.
不織布積層体の生産速度は好ましくは１７０ｍ／分以上であり、より好ましくは２５０ｍ／分以上、更に好ましくは３００ｍ／分以上、特に好ましくは３５０ｍ／分以上である。ここで生産速度とは、繊維成分を熱圧着する際の熱圧着ロール（エンボスロール、フラットロール等）の回転速度のことである。生産速度が１７０ｍ／分以上であれば商業的な費用対効果が良好である。不織布積層体の生産速度の上限は特に限定されるものではないが、不織布積層体の安定生産の観点から、好ましくは１５００ｍ／分以下、より好ましくは１２００ｍ／分以下、更に好ましくは１０００ｍ／分以下、特に好ましくは８００ｍ／分以下である。 The production rate of the nonwoven fabric laminate is preferably 170 m / min or more, more preferably 250 m / min or more, still more preferably 300 m / min or more, and particularly preferably 350 m / min or more. Here, the production speed is the rotational speed of a thermocompression-bonding roll (embossing roll, flat roll, etc.) when the fiber component is thermocompression bonded. If the production speed is 170 m / min or more, the commercial cost-effectiveness is good. The upper limit of the production rate of the nonwoven fabric laminate is not particularly limited, but from the viewpoint of stable production of the nonwoven fabric laminate, it is preferably 1500 m / min or less, more preferably 1200 m / min or less, and even more preferably 1000 m / min or less. Particularly preferably, it is 800 m / min or less.
不織布積層体を製造する際、用いる繊維成分の繊度と、生産速度とは地合に大きく影響し、一般的に繊維成分の繊度は細くなるほど地合は良好となり、生産速度は遅いほど地合は良好となる。しかし、生産性を落とさず繊度を細くするためには、繊維の延伸比を大きくすることが必要であり、糸切れの問題が発生する。また、生産性を落とさず、生産速度を遅くするためには目付を大きくすることが必要であり、衛生製品に使用する薄い不織布を得ることは困難である。地合が良好な不織布積層体を商業的に生産するためには繊度と生産速度とのバランスを保つことが必要である。 When producing a nonwoven fabric laminate, the fineness of the fiber component used and the production rate greatly affect the formation.Generally, the finer the fineness of the fiber component, the better the formation, and the slower the production rate, the better the formation. It becomes good. However, in order to reduce the fineness without reducing the productivity, it is necessary to increase the draw ratio of the fiber, which causes a problem of yarn breakage. Further, in order to slow down the production speed without reducing productivity, it is necessary to increase the basis weight, and it is difficult to obtain a thin nonwoven fabric used for sanitary products. In order to produce a nonwoven fabric laminate with a good texture commercially, it is necessary to maintain a balance between fineness and production speed.
上記観点から、繊維成分の繊度［ｄｔｅｘ］×生産速度［ｍ／分］の値は、好ましくは２００以上、より好ましくは３００以上、更に好ましくは３５０以上である。上限は特に限定されないが、衛生製品に適した柔軟性を得るため、また不織布を安定的に得るために、好ましくは３５００以下、より好ましくは３０００以下、更に好ましくは２５００以下、特に好ましくは１７００以下である。なお繊維成分の繊度は、繊度の異なる繊維を含む不織布の場合、最も多量に含まれている繊維についての繊度を意味する。 From the above viewpoint, the value of the fineness [dtex] × production rate [m / min] of the fiber component is preferably 200 or more, more preferably 300 or more, and still more preferably 350 or more. The upper limit is not particularly limited, but preferably 3500 or less, more preferably 3000 or less, still more preferably 2500 or less, particularly preferably 1700 or less, in order to obtain flexibility suitable for hygiene products and to obtain a nonwoven fabric stably. It is. In addition, the fineness of a fiber component means the fineness about the fiber contained most in the case of the nonwoven fabric containing the fiber from which fineness differs.
不織布積層体は、コンパクションロールの温度を、ポリオレフィン系長繊維の融点よりも、好ましくは０℃以上６０℃以下低く、より好ましくは１５℃以上５５℃以下低く、更に好ましくは３０℃以上５０℃以下低く設定して得られる。２種類以上のポリオレフィン系長繊維を組み合わせる場合、上記ポリオレフィン系長繊維の融点とは、主成分となるポリオレフィン系長繊維の融点を意味する。 In the nonwoven fabric laminate, the temperature of the compaction roll is preferably 0 ° C. or higher and 60 ° C. or lower, more preferably 15 ° C. or higher and 55 ° C. or lower, more preferably 30 ° C. or higher and 50 ° C. or lower, than the melting point of the polyolefin-based long fibers. Obtained by setting it low. When two or more types of polyolefin long fibers are combined, the melting point of the polyolefin long fibers means the melting point of the polyolefin long fibers as the main component.
例えば、ポリオレフィン系長繊維がポリプロピレン繊維であれば、コンパクションロールの温度は、好ましくは１００℃以上１６０℃以下、より好ましくは１０５℃以上１４５℃以下、更に好ましくは１１０℃以上１３０℃以下である。コンパクションロールの温度が１００℃以上であれば、不織布層の積層時の仮接着が良好となり、積層時のウェブの吹き飛び及びメクレを抑制することができる。またコンパクションロールの温度が１６０℃以下であれば、ポリプロピレンを溶融することなく繊維形状を維持したまま不織布積層体を形成することができる。 For example, when the polyolefin-based long fibers are polypropylene fibers, the temperature of the compaction roll is preferably 100 ° C. or higher and 160 ° C. or lower, more preferably 105 ° C. or higher and 145 ° C. or lower, and further preferably 110 ° C. or higher and 130 ° C. or lower. If the temperature of a compaction roll is 100 degreeC or more, temporary adhesion at the time of lamination | stacking of a nonwoven fabric layer will become favorable, and the blow-off of a web at the time of lamination | stacking and meklet can be suppressed. Moreover, if the temperature of a compaction roll is 160 degrees C or less, a nonwoven fabric laminated body can be formed, maintaining a fiber shape, without melting a polypropylene.
また、コンパクションロールの接圧は、好ましくは２ｋｇｆ／ｃｍ以上５ｋｇｆ／ｃｍ以下であり、より好ましくは３ｋｇｆ／ｃｍ以上４．７５ｋｇｆ／ｃｍ以下、更に好ましくは３．５ｋｇｆ／ｃｍ以上４．５ｋｇｆ／ｃｍ以下である。コンパクションロールの接圧がこの範囲であれば、例えば衛生製品に用いるのに好適な柔軟性を保持したまま繊維同士を十分に仮接着することができる。 The contact pressure of the compaction roll is preferably 2 kgf / cm or more and 5 kgf / cm or less, more preferably 3 kgf / cm or more and 4.75 kgf / cm or less, and further preferably 3.5 kgf / cm or more and 4.5 kgf / cm. It is as follows. If the contact pressure of the compaction roll is within this range, for example, the fibers can be sufficiently temporarily bonded together while maintaining flexibility suitable for use in sanitary products.
更に、不織布を形成するために繊維成分を堆積させるコンベアネットの通気度は、好ましくは２００ｃｍ3／ｃｍ2／秒以上５００ｃｍ3／ｃｍ2／秒以下であり、好ましくは２００ｃｍ3／ｃｍ2／秒以上４００ｃｍ3／ｃｍ2／秒以下、より好ましくは２５０ｃｍ3／ｃｍ2／秒以上３５０ｃｍ3／ｃｍ2／秒以下である。コンベアネットの通気度がこの範囲であれば、堆積した不織布ウェブが積層時に吹き飛んだり、メクレが発生したりすることがなく、コンベアから熱圧着ロールに乗り移る際にも不織布ウェブがコンベアに貼り付いたまま断布等することがなく、良好に生産することができる。 Further, the air permeability of the conveyor net on which the fiber component is deposited for forming the nonwoven fabric is preferably 200 cm 3 / cm 2 / second or more and 500 cm 3 / cm 2 / second or less, preferably 200 cm 3 / cm 2 / second. or 400cm 3 / cm 2 / sec or less, and more preferably not more than 250cm 3 / cm 2 / sec or more 350cm 3 / cm 2 / sec. If the air permeability of the conveyor net is within this range, the accumulated nonwoven web will not blow off during the lamination and no creaking will occur, and the nonwoven web adhered to the conveyor even when transferring from the conveyor to the thermocompression roll. It can be produced satisfactorily without cutting off.
好ましい態様においては、コンベアネットの通気度が２００ｃｍ3／ｃｍ2／秒以上５００ｃｍ3／ｃｍ2／秒以下であり、かつ圧着工程を、コンパクションロールを用いて接圧２ｋｇｆ／ｃｍ以上５ｋｇｆ／ｃｍ以下及び温度はポリオレフィン系長繊維の融点より０℃以上６０℃以下低い温度で行う。 In a preferred embodiment, the air permeability of the conveyor net is 200 cm 3 / cm 2 / second or more and 500 cm 3 / cm 2 / second or less, and the crimping step is performed using a compaction roll with a contact pressure of 2 kgf / cm or more and 5 kgf / cm or less. And the temperature is 0 to 60 ° C. lower than the melting point of the polyolefin-based long fibers.
特に好ましい態様においては、コンベアネットの通気度が２５０ｃｍ3／ｃｍ2／秒以上３５０ｃｍ3／ｃｍ2／秒以下であり、かつ圧着工程を、コンパクションロールを用いて接圧３．５ｋｇｆ／ｃｍ以上４．５ｋｇｆ／ｃｍ以下及び温度はポリオレフィン系長繊維の融点より３０℃以上５０℃以下低い温度で行う。 In a particularly preferable aspect, the air permeability of the conveyor net is 250 cm 3 / cm 2 / second or more and 350 cm 3 / cm 2 / second or less, and the pressure bonding step is performed using a compaction roll and a contact pressure of 3.5 kgf / cm or more 4 The temperature is 0.5 kgf / cm or less and the temperature is 30 ° C. or more and 50 ° C. or less lower than the melting point of the polyolefin-based long fibers.
ポリオレフィン系長繊維の紡糸温度は、好ましくは１９０℃以上２６０℃以下、より好ましくは２００℃以上２５５℃以下、更に好ましくは２０５℃以上２３０℃以下、特に好ましくは２１０℃以上２２５℃以下である。紡糸温度が２６０℃以下であれば、樹脂分解物による紡口表面の汚れが少なく、更に樹脂の粘度が低くなることによる糸切れの発生を抑制することができる。また、紡糸温度が高いと、作製した不織布は、樹脂分解物による影響のために、曲げ柔軟度が高くなるとともに不織布として硬い傾向を示す。紡糸温度が１９０℃以上であれば、樹脂の粘度が高くなることによる糸切れの発生を抑制し、更に紡糸時の紡口内圧力が高くなることによる樹脂漏れ等を抑制することができる。 The spinning temperature of the polyolefin-based long fibers is preferably 190 ° C or higher and 260 ° C or lower, more preferably 200 ° C or higher and 255 ° C or lower, still more preferably 205 ° C or higher and 230 ° C or lower, and particularly preferably 210 ° C or higher and 225 ° C or lower. When the spinning temperature is 260 ° C. or lower, the occurrence of yarn breakage due to less contamination of the spinneret surface due to the resin decomposition product and further lowering the viscosity of the resin can be suppressed. Moreover, when the spinning temperature is high, the produced nonwoven fabric tends to be hard as a nonwoven fabric with high bending flexibility due to the influence of the resin decomposition product. When the spinning temperature is 190 ° C. or higher, the occurrence of yarn breakage due to an increase in the viscosity of the resin can be suppressed, and further, resin leakage or the like due to an increase in the spinneret pressure during spinning can be suppressed.
＜不織布積層体の用途＞
本発明の不織布積層体は、地合が非常に良好なため衛生製品の製造に好適に使用することができる。本発明の別の態様は、上述した本発明の不織布積層体又は本発明の不織布積層体の製造方法によって得られた不織布積層体を含む、衛生製品を提供する。衛生製品としては、使い捨てオムツ、生理用ナプキン又は失禁パットが挙げられる。不織布積層体は、上記のような衛生製品における、表面のトップシート、外側のバックシート、足回りのサイドギャザー等に好適に使用される。
<Use of nonwoven fabric laminate>
Since the nonwoven fabric laminate of the present invention has a very good formation, it can be suitably used for the production of sanitary products. Another aspect of the present invention provides a sanitary product comprising the above-described nonwoven fabric laminate of the present invention or the nonwoven fabric laminate obtained by the method for producing the nonwoven fabric laminate of the present invention. Sanitary products include disposable diapers, sanitary napkins or incontinence pads. The nonwoven fabric laminate is suitably used for the top sheet on the surface, the outer back sheet, the side gathers of the undercarriage and the like in the sanitary product as described above.
また、本発明の不織布積層体の用途は上記用途に限られず、例えば、マスク、カイロ、テープ基布、防水シート基布、貼布薬基布、救急絆基布、包装材、ワイプ製品、医療用ガウン、包帯、衣料、スキンケア用シート等に使用することもできる。 In addition, the use of the nonwoven fabric laminate of the present invention is not limited to the above-mentioned uses. For example, masks, warmers, tape base fabrics, waterproof sheet base fabrics, patch medicinal base fabrics, first aid base fabrics, packaging materials, wipe products, medical care It can also be used for gowns, bandages, clothing, skin care sheets and the like.
以下、実施例及び比較例により本発明を具体的に説明するが、本発明は下記実施例のみに限定されるものではない。 EXAMPLES Hereinafter, although an Example and a comparative example demonstrate this invention concretely, this invention is not limited only to the following Example.
尚、実施例及び比較例において製造した不織布積層体の各種特性の評価方法は下記のとおりであり、得られた物性を以下の表１に示す。 In addition, the evaluation method of the various characteristics of the nonwoven fabric laminated body manufactured in the Example and the comparative example is as follows, and the obtained physical property is shown in the following Table 1.
１．平均単糸繊度（ｄｔｅｘ）
試料の両端１０ｃｍを除き、不織布積層体の幅方向にほぼ５等分して１ｃｍ角の試験片をサンプリングし、マイクロスコープで繊維の直径を各試験片につき２０点ずつ測定し、その数平均値を平均単糸繊度として算出した。
1. Average single yarn fineness (dtex)
Except 10 cm at both ends of the sample, sample the 1 cm square test piece by dividing it into 5 equal parts in the width direction of the nonwoven fabric laminate, measure the diameter of the fiber 20 points for each test piece with a microscope, and the number average value Was calculated as the average single yarn fineness.
２．目付（ｇ／ｍ2）
ＪＩＳ−Ｌ１９０６に準じ、タテ２０ｃｍ×ヨコ５ｃｍの試験片を任意に５枚採取して質量を測定し、その数平均値を単位面積当たりの質量に換算して求めた。
2. Weight per unit (g / m 2 )
According to JIS-L1906, 5 test specimens measuring 20 cm in length and 5 cm in width were arbitrarily collected and measured for mass, and the number average value was calculated by converting to mass per unit area.
３．厚み（ｍｍ）
プレッサーフートの大きさが直径９ｍｍ以上の適当な測定機を用いて、１００ｇｆ／ｃｍ2の荷重のもとで、厚さが落ち着くまでの適当な時間（１０秒程度）放置して、試料片を幅方向等間隔で５箇所測定し、その数平均値を厚みとした。
3. Thickness (mm)
Using a suitable measuring machine with a presser foot size of 9 mm or more in diameter, leave the sample piece under a load of 100 gf / cm 2 for a suitable time (about 10 seconds) until the thickness settles. Five locations were measured at equal intervals in the width direction, and the number average value was taken as the thickness.
４．嵩密度（ｇ／ｃｍ3）
目付と厚みとから下記式により算出した。
嵩密度（ｇ／ｃｍ3）＝目付（ｇ／ｍ2）／厚み（ｍｍ）／１０００
4). Bulk density (g / cm 3 )
It calculated by the following formula from the fabric weight and thickness.
Bulk density (g / cm 3 ) = Weight (g / m 2 ) / Thickness (mm) / 1000
５．地合指数
野村商事製フォーメーションテスター（ＦＭＴ−ＭＩＩＩ）測定器を用い、Ａ４サイズ（タテ２９．７ｃｍ×ヨコ２１ｃｍ）の試料を試料台の上に置き、二次元ＣＣＤカメラで照射ランプによる透過像を捕らえ、３２０×２３０画素に分解し、それぞれの画素が受ける光の強さを測定した。次いで画素それぞれに対する透過率（ｔ）を下記の式で算出した。
絶対透過率（ｔ％）＝（Ｖｔ−Ｖｒ）／（Ｖ１００−Ｖ０）×１００％
Ｖ１００：照射ランプ点灯の光度、Ｖ０：照射ランプの消灯の光度
Ｖｔ：試料をのせた状態の、照射ランプ点灯の光度
Ｖｒ：試料をのせた状態の、照射ランプ消灯の光度
絶対透過率（ｔ％）を、下記式：
吸光度（Ｅ）＝２−ｌｏｇｔ
に従って吸光度（Ｅ）に換算し、下記式：
地合指数＝吸光度（Ｅ）の変動係数×１０
に従って地合指数を算出した。
5. Geometric index Using a Nomura Corporation formation tester (FMT-MIII) measuring instrument, place a sample of A4 size (vertical 29.7 cm x horizontal 21 cm) on the sample table, and use a two-dimensional CCD camera to obtain a transmission image by an irradiation lamp. It was captured and decomposed into 320 × 230 pixels, and the intensity of light received by each pixel was measured. Next, the transmittance (t) for each pixel was calculated by the following equation.
Absolute transmittance (t%) = (Vt−Vr) / (V100−V0) × 100%
V100: intensity of illumination lamp on, V0: intensity of illumination lamp off Vt: intensity of illumination lamp on condition of sample Vr: intensity of illumination lamp off on condition of sample Absolute transmittance (t%) ) With the following formula:
Absorbance (E) = 2-logt
According to the following formula:
Formation index = coefficient of variation of absorbance (E) x 10
The formation index was calculated according to
６．分子配向度（ＭＯＲ値）
分子配向計（王子計測機器（株）製：ＭＯＡ−６００４）を用いて、試料に偏波したマイクロ波をあて、繊維の分子の双極子との相互作用により、その分子の主軸の配向を検知した。試料を回転することで異方性（配向性）を求め、ＴＤ方向及びＭＤ方向の透過マイクロ波強度を得た。下記式：
ＭＯＲ値＝透過マイクロ波強度の最大値／透過マイクロ波強度の最小値
に従ってＭＯＲ値を求めた。このＭＯＲ値はウェブ中の繊維の配列比に関連する値であり、値が１の場合は等方性を示し、１超であれば特定方向に繊維が配列されていることを示し、値が大きい程その配列の程度が強いことを示す。ただし、透過強度による測定のため配向の絶対値を示すものではない。
6). Molecular orientation (MOR value)
Using a molecular orientation meter (manufactured by Oji Scientific Instruments Co., Ltd .: MOA-6004), the polarized microwave is applied to the sample, and the orientation of the principal axis of the molecule is detected by the interaction with the dipole of the fiber molecule. did. Anisotropy (orientation) was obtained by rotating the sample, and transmission microwave intensity in the TD direction and MD direction was obtained. Following formula:
MOR value was determined according to MOR value = maximum value of transmitted microwave intensity / minimum value of transmitted microwave intensity. This MOR value is a value related to the arrangement ratio of fibers in the web. A value of 1 indicates isotropic, and if it exceeds 1, it indicates that the fibers are arranged in a specific direction. The larger the value, the stronger the arrangement. However, it does not indicate the absolute value of orientation because of measurement by transmission intensity.
７．粉漏れ率（％）
不織布積層体の端部を除いた後、幅方向に均等間隔をあけた５箇所からタテ１０ｃｍ×ヨコ１０ｃｍの試料片を採取した。試料片を二つ折りにして縁を１８０℃で１０秒間ヒートシールした。その中へＪＩＳ−Ｚ８９０１試験用粉体１種ダストを約１ｇ入れ、重量Ｗ１を正確に測定し、袋状にした試料の口を同様にヒートシールした。この袋状にした試料をポリエチレンの袋に入れ、１．５ｍの高さから自然落下にて１０回落下させた。その後試料袋から漏れた粉体の重量Ｗ２を測定し、下記式に従って粉漏れ率を算出した。５回の測定による数平均値を採用した。
粉漏れ率（％）＝Ｗ２／Ｗ１×１００
7). Powder leakage rate (%)
After removing the end portion of the nonwoven fabric laminate, sample pieces measuring 10 cm in length and 10 cm in width were collected from five locations spaced evenly in the width direction. The sample piece was folded in half and the edges were heat sealed at 180 ° C. for 10 seconds. About 1 g of JIS-Z8901 test powder 1 type dust was put therein, the weight W1 was accurately measured, and the mouth of the bag-like sample was similarly heat-sealed. This bag-like sample was put in a polyethylene bag and dropped from a height of 1.5 m 10 times by natural fall. Thereafter, the weight W2 of the powder leaked from the sample bag was measured, and the powder leakage rate was calculated according to the following formula. The number average value by five measurements was adopted.
Powder leakage rate (%) = W2 / W1 × 100
８．通気度（ｃｍ3／ｃｍ2／秒）
ＪＩＳ−Ｌ１０９６に準じ、タテ１５ｃｍ×ヨコ１５ｃｍの試験片を任意に５枚採取して、フラジール形試験機を用い、円筒の一端に試料を取り付けた後、加減抵抗器によって吸い込みファンを調整し、傾斜形気圧計が水柱１．２７ｃｍを示すように空気を吸い込ませ、そのときの垂直気圧計の示す圧力と、使用した空気孔の種類とから、試験機に付属する表によって、試料を通過する空気量を求め、その数平均値を通気度とした。
8). Air permeability (cm 3 / cm 2 / sec)
In accordance with JIS-L1096, 5 specimens of 15 cm x 15 cm are collected arbitrarily, and after using a Frazier type tester to attach the sample to one end of the cylinder, the suction fan is adjusted with an adjustable resistor, Air is sucked in so that the inclined barometer shows a water column of 1.27 cm, and the sample passes through the sample according to the table attached to the testing machine from the pressure indicated by the vertical barometer and the type of air hole used. The amount of air was determined, and the number average value was defined as the air permeability.
〔実施例１〕
ＭＦＲが６０ｇ／１０分（ＪＩＳ−Ｋ７２１０に準じ、温度２３０℃、荷重２．１６ｋｇで測定）のポリプロピレン（ＰＰ）樹脂（融点１６１℃）をスパンボンド法により、ノズル径φ０．４ｍｍ、紡糸温度２１５℃で押出し、このフィラメント群をエアジェットにより牽引し、コンベアネット（通気度：２７０ｃｍ3／ｃｍ2／秒）に平均単糸繊度１．１ｄｔｅｘの長繊維ウェブを堆積した。得られた長繊維ウェブを温度１２０℃のコンパクションロール（表面材質：ＨＣｒ、梨地模様）とバックアップロール（表面材質：硬度９０°合成ゴム）を用い、接圧４．２ｋｇｆ／ｃｍで仮圧着した。
[Example 1]
A polypropylene (PP) resin (melting point: 161 ° C.) having an MFR of 60 g / 10 minutes (measured at a temperature of 230 ° C. and a load of 2.16 kg in accordance with JIS-K7210) is obtained by a spunbond method with a nozzle diameter of 0.4 mm and a spinning temperature of 215. The filament group was extruded by air jet, pulled by an air jet, and a long fiber web having an average single yarn fineness of 1.1 dtex was deposited on a conveyor net (air permeability: 270 cm 3 / cm 2 / sec). The obtained long fiber web was temporarily press-bonded at a contact pressure of 4.2 kgf / cm using a compaction roll (surface material: HCr, satin pattern) having a temperature of 120 ° C. and a backup roll (surface material: hardness 90 ° synthetic rubber).
次いで、得られた長繊維ウェブに同様のスパンボンド法で得られた長繊維ウェブを吹きつけ堆積し、同様に仮接着した。 Next, the long fiber web obtained by the same spunbond method was sprayed and deposited on the obtained long fiber web, and temporarily bonded in the same manner.
更に、同様にもう１層積層し、計３層積層となる長繊維ウェブを得た。 Further, another layer was laminated in the same manner to obtain a long fiber web having a total of three layers.
次いで、得られた長繊維ウェブを、フラットロールとエンボスロール（パターン仕様：直径０．４２５ｍｍ円形、千鳥配列、横ピッチ２．１ｍｍ、縦ピッチ１．１ｍｍ、圧着面積率６．３％）の間に通して温度１３５℃及び線圧３５ｋｇｆ／ｃｍで繊維同士を接着し、生産速度３８０ｍ／分で目付１７ｇ／ｍ2の不織布積層体を得た。 Next, the obtained long fiber web was placed between a flat roll and an embossing roll (pattern specification: circular with a diameter of 0.425 mm, staggered arrangement, horizontal pitch 2.1 mm, vertical pitch 1.1 mm, crimping area ratio 6.3%). The fibers were bonded to each other at a temperature of 135 ° C. and a linear pressure of 35 kgf / cm to obtain a nonwoven fabric laminate having a basis weight of 17 g / m 2 at a production rate of 380 m / min.
〔実施例２〕
生産速度を４００ｍ／分とした他は実施例１と同様にして平均単糸繊度１．５ｄｔｅｘ、目付１３ｇ／ｍ2の不織布積層体を得た。得られた不織布積層体を、室温２２℃の雰囲気下にて放電量４０Ｗ・分／ｍ2（放電度４．０Ｗ／ｃｍ2）の条件でコロナ放電処理機に通し、濡れ張力３９ｍＮ／ｍの不織布積層体を得た。
[Example 2]
A nonwoven fabric laminate having an average single yarn fineness of 1.5 dtex and a basis weight of 13 g / m 2 was obtained in the same manner as in Example 1 except that the production rate was 400 m / min. The obtained nonwoven fabric laminate was passed through a corona discharge treatment machine under a discharge amount of 40 W · min / m 2 (discharge degree: 4.0 W / cm 2 ) in an atmosphere at a room temperature of 22 ° C., and a wetting tension of 39 mN / m. A nonwoven fabric laminate was obtained.
得られた不織布にポリエーテル系の親水化剤をグラビアコーターによるコーティング法により付与し、次いで１２０℃のシリンダードライヤーに通して乾燥し、親水化剤付着量が繊維１００質量％に対して０．３質量％である不織布積層体を得た。 A polyether-based hydrophilizing agent is applied to the obtained non-woven fabric by a coating method using a gravure coater, and then dried by passing through a 120 ° C. cylinder dryer. The nonwoven fabric laminated body which is the mass% was obtained.
〔実施例３〕
生産速度を６００ｍ／分とし、積層数を４層とした他は実施例１と同様にして平均単糸繊度２．８ｄｔｅｘ、目付１５ｇ／ｍ2の不織布積層体を得た。なお４層目は実施例１の３層目と同様にして形成した。
Example 3
A nonwoven fabric laminate having an average single yarn fineness of 2.8 dtex and a basis weight of 15 g / m 2 was obtained in the same manner as in Example 1 except that the production rate was 600 m / min and the number of laminations was four. The fourth layer was formed in the same manner as the third layer of Example 1.
〔実施例４〕
生産速度を８００ｍ／分とし、積層数を４層とした他は実施例２と同様にして、親水化剤付着量が繊維１００質量％に対して０．５質量％、平均単糸繊度１．３ｄｔｅｘ、目付１１ｇ／ｍ2の不織布積層体を得た。なお４層目は実施例２の３層目と同様にして形成した。
Example 4
In the same manner as in Example 2 except that the production rate was 800 m / min and the number of layers was four, the amount of hydrophilic agent attached was 0.5% by mass with respect to 100% by mass of fibers, and the average single yarn fineness was 1. A nonwoven fabric laminate having 3 dtex and a basis weight of 11 g / m 2 was obtained. The fourth layer was formed in the same manner as the third layer of Example 2.
〔実施例５〕
融点が８６〜９０℃（平均融点８８℃）のオクタデカン酸のグリセリド（水添動植物油脂）をポリオレフィン系長繊維１００質量％に対して１．２５質量％混合し、生産速度を５００ｍ／分とした他は実施例３と同様にして平均単糸繊度１．１ｄｔｅｘ、目付１７ｇ／ｍ2の不織布積層体を得た。
Example 5
Octadecanoic acid glycerides (hydrogenated animal and vegetable oils and fats) having a melting point of 86 to 90 ° C. (average melting point of 88 ° C.) were mixed in an amount of 1.25% by mass with respect to 100% by mass of polyolefin-based long fibers, and the production rate was 500 m / min. Other than that, a nonwoven fabric laminate having an average single yarn fineness of 1.1 dtex and a basis weight of 17 g / m 2 was obtained in the same manner as in Example 3.
〔実施例６〕
生産速度を１７５ｍ／分とし、積層数を５層とした他は実施例１と同様にして平均単糸繊度２．０ｄｔｅｘ、目付２５ｇ／ｍ2の不織布積層体を得た。なお４層目及び５層目は実施例１の３層目と同様にして形成した。
Example 6
A nonwoven fabric laminate having an average single yarn fineness of 2.0 dtex and a basis weight of 25 g / m 2 was obtained in the same manner as in Example 1 except that the production rate was 175 m / min and the number of laminated layers was 5. The fourth and fifth layers were formed in the same manner as the third layer in Example 1.
〔実施例７〕
生産速度を１０００ｍ／分とし、積層数を５層とした他は実施例５と同様にして、オクタデカン酸のグリセリド（水添動植物油脂）をポリオレフィン系長繊維１００質量％に対して３．５質量％混合し、平均単糸繊度２．８ｄｔｅｘ、目付１５ｇ／ｍ2の不織布積層体を得た。なお４層目及び５層目は実施例５の３層目と同様にして形成した。
Example 7
Except that the production rate was 1000 m / min and the number of layers was 5 layers, the glyceride (hydrogenated vegetable oil) of octadecanoic acid was 3.5% by mass with respect to 100% by mass of the polyolefin-based long fibers. % To obtain a nonwoven fabric laminate having an average single yarn fineness of 2.8 dtex and a basis weight of 15 g / m 2 . The fourth and fifth layers were formed in the same manner as the third layer of Example 5.
〔実施例８〕
エチレン成分含有率が４．３モル％、ＭＦＲが２４ｇ／１０分（ＪＩＳ−Ｋ７２１０に準じ、温度２３０℃、荷重２．１６ｋｇで測定）のエチレン・プロピレン共重合体（融点１２８℃）を使用し、コンパクションロールの温度を１１０℃、熱接着温度を１２０℃、生産速度を３３０ｍ／分とした以外は実施例３と同様にして平均単糸繊度１．１ｄｔｅｘ、目付１７ｇ／ｍ2の不織布積層体を得た。
Example 8
An ethylene / propylene copolymer (melting point: 128 ° C.) having an ethylene component content of 4.3 mol% and an MFR of 24 g / 10 min (measured at a temperature of 230 ° C. and a load of 2.16 kg according to JIS-K7210) is used. A nonwoven fabric laminate having an average single yarn fineness of 1.1 dtex and a basis weight of 17 g / m 2 in the same manner as in Example 3 except that the temperature of the compaction roll was 110 ° C., the thermal bonding temperature was 120 ° C., and the production rate was 330 m / min. Got.
〔実施例９〕
ＭＦＲが１７ｇ／１０分（ＪＩＳ−Ｋ７２１０に準じ、温度１９０℃、荷重２．１６ｋｇで測定）の線状低密度ポリエチレン（融点１２９℃）を鞘成分とし、ＭＦＲが６０ｇ／１０分（ＪＩＳ−Ｋ７２１０に準じ、温度２３０℃、荷重２．１６ｋｇで測定）のポリプロピレン（融点１６１℃）を芯成分とした鞘芯比１：９（質量比）の長繊維ウェブを得た。次いで、コンパクションロールの温度を１１０℃、熱接着温度を１２０℃として熱接着し、生産速度を６００ｍ／分とし、上記以外は実施例６と同様にして平均単糸繊度２．０ｄｔｅｘ、目付２０ｇ／ｍ2の不織布積層体を得た。
Example 9
A linear low density polyethylene (melting point: 129 ° C.) having an MFR of 17 g / 10 min (measured at a temperature of 190 ° C. and a load of 2.16 kg according to JIS-K7210) is used as a sheath component, and an MFR is 60 g / 10 min (JIS-K7210). According to the above, a long fiber web having a sheath-core ratio of 1: 9 (mass ratio) using polypropylene (melting point: 161 ° C.) having a temperature of 230 ° C. and a load of 2.16 kg as a core component was obtained. Subsequently, the compaction roll was heat-bonded at a temperature of 110 ° C. and a heat bonding temperature of 120 ° C., and the production rate was 600 m / min. Except for the above, the average single yarn fineness was 2.0 dtex, the basis weight was 20 g / min. An m 2 nonwoven fabric laminate was obtained.
〔実施例１０〕
生産速度を５０ｍ／分とした他は実施例１と同様にして平均単糸繊度２．８ｄｔｅｘ、目付１７ｇ／ｍ2の不織布積層体を得た。
Example 10
A nonwoven fabric laminate having an average single yarn fineness of 2.8 dtex and a basis weight of 17 g / m 2 was obtained in the same manner as in Example 1 except that the production rate was 50 m / min.
〔比較例１〕
生産速度を１００ｍ／分とし、積層数を２層とした（すなわち３層目を形成しなかった）他は実施例１と同様にして平均単糸繊度２．８ｄｔｅｘ、目付２０ｇ／ｍ2の不織布積層体を得た。得られた不織布の地合は８０を超え、更に生産性が非常に悪く、商業的に生産することは困難であった。
[Comparative Example 1]
A non-woven fabric having an average single yarn fineness of 2.8 dtex and a basis weight of 20 g / m 2 in the same manner as in Example 1 except that the production rate was 100 m / min and the number of layers was two (ie, the third layer was not formed). A laminate was obtained. The resulting nonwoven fabric has a texture exceeding 80, and the productivity is very poor, making it difficult to produce commercially.
〔比較例２〕
生産速度を６００ｍ／分とし、積層数を４層とした他は実施例１と同様にして平均単糸繊度５．８ｄｔｅｘ、目付１５ｇ／ｍ2の不織布積層体を得た。なお４層目は実施例１の３層目と同様にして形成した。
[Comparative Example 2]
A nonwoven fabric laminate having an average single yarn fineness of 5.8 dtex and a basis weight of 15 g / m 2 was obtained in the same manner as in Example 1 except that the production rate was 600 m / min and the number of laminations was four. The fourth layer was formed in the same manner as the third layer of Example 1.
〔比較例３〕
実施例１と同様にして平均単糸繊度１．８ｄｔｅｘとなる長繊維ウェブを調製した。次いで、ＭＦＲが１２００のポリプロピレン樹脂を紡糸温度２６０℃、加熱エア２８０℃、吐出エア６００Ｎｍ3／時／ｍの条件下で、メルトブローン法により紡糸して、平均繊維径１．８μｍ、平均単糸繊度０．０２３ｄｔｅｘのポリプロピレン繊維を、上記で調製された長繊維ウェブに向けて直に噴出させた。この際、メルトブローンノズルから長繊維ウェブの上面までの距離は、１００ｍｍとし、メルトブローンノズル直下の捕集面における吸引を０．２ｋＰａ、風速約７ｍ／秒に設定した。更に、実施例１と同様にして調製したポリプロピレン繊維を積層し、スパンボンド／メルトブローン／スパンボンドで構成された３層積層ウェブを得た。
[Comparative Example 3]
A long fiber web having an average single yarn fineness of 1.8 dtex was prepared in the same manner as in Example 1. Next, a polypropylene resin having an MFR of 1200 was spun by the melt blown method under the conditions of a spinning temperature of 260 ° C., heated air of 280 ° C., and discharge air of 600 Nm 3 / hour / m, an average fiber diameter of 1.8 μm, and an average single yarn fineness. 0.023 dtex polypropylene fibers were jetted directly towards the long fiber web prepared above. At this time, the distance from the melt blown nozzle to the upper surface of the long fiber web was set to 100 mm, and suction on the collecting surface immediately below the melt blown nozzle was set to 0.2 kPa and the wind speed was about 7 m / sec. Further, polypropylene fibers prepared in the same manner as in Example 1 were laminated to obtain a three-layer laminated web composed of spunbond / meltblown / spunbond.
次いで、スパンボンド／メルトブローン／スパンボンドの３層積層ウェブを、フラットロールとエンボスロール（パターン仕様：直径０．４２５ｍｍ円形、千鳥配列、横ピッチ２．１ｍｍ、縦ピッチ１．１ｍｍ、圧着面積率６．３％）の間に通して温度１３５℃及び線圧３５ｋｇｆ／ｃｍで繊維同士を接着し、生産速度４００ｍ／分で不織布積層体を得た。得られた不織布積層体は、トータル目付１５ｇ／ｍ2、メルトブローン繊維の比率が１３ｗｔ％であった。 Subsequently, a spunbond / meltblown / spunbond three-layer laminated web is formed by using a flat roll and an emboss roll (pattern specification: diameter 0.425 mm circular, staggered arrangement, horizontal pitch 2.1 mm, vertical pitch 1.1 mm, crimping area ratio 6 3%), the fibers were bonded at a temperature of 135 ° C. and a linear pressure of 35 kgf / cm, and a nonwoven fabric laminate was obtained at a production rate of 400 m / min. The obtained nonwoven fabric laminate had a total basis weight of 15 g / m 2 and a meltblown fiber ratio of 13 wt%.
本発明の不織布積層体は、地合が良好で、隠蔽性に優れ、かつホットメルト剤及びＳＡＰの漏れが少ない。また本発明の不織布積層体は良好な生産性で製造できるため商業的生産に有利である。本発明の不織布積層体は衛生製品のトップシート、バックシート、サイドギャザー等に好適に利用可能である。 The nonwoven fabric laminate of the present invention has a good formation, excellent concealability, and little leakage of hot melt agent and SAP. Moreover, since the nonwoven fabric laminated body of this invention can be manufactured with favorable productivity, it is advantageous for commercial production. The nonwoven fabric laminate of the present invention can be suitably used for sanitary product top sheets, back sheets, side gathers, and the like.
Claims (15)
前記不織布積層体の地合指数が５８以上８０以下であり、かつ
前記ポリオレフィン系長繊維の平均単糸繊度が０．７ｄｔｅｘ以上３．５ｄｔｅｘ以下である、不織布積層体。 A nonwoven fabric laminate comprising three or more long fiber nonwoven fabric layers containing polyolefin-based long fibers,
A nonwoven fabric laminate in which a formation index of the nonwoven fabric laminate is 58 or more and 80 or less, and an average single yarn fineness of the polyolefin-based long fibers is 0.7 dtex or more and 3.5 dtex or less.
ポリオレフィン系長繊維を含む繊維成分をコンベアネット上に堆積させることによって長繊維不織布層を形成する不織布層形成工程、及び
前記不織布層形成工程で得た長繊維不織布層を３層以上重ねて圧着することによって不織布積層体を形成する圧着工程、
を含み、
生産速度が１７０ｍ／分以上であり、かつ
以下の関係式：繊維成分の繊度［ｄｔｅｘ］×生産速度［ｍ／分］≧２００を満足する、不織布積層体の製造方法。 It is a manufacturing method of the nonwoven fabric laminated body of any one of Claims 1-11, Comprising: The following processes:
A non-woven fabric layer forming step for forming a long-fiber non-woven fabric layer by depositing a fiber component containing a polyolefin-based long fiber on a conveyor net, and three or more long-fiber non-woven fabric layers obtained in the non-woven fabric layer forming step are stacked and pressure-bonded. A crimping step for forming a nonwoven fabric laminate,
Including
A method for producing a nonwoven fabric laminate, wherein the production rate is 170 m / min or more and the following relational expression: fineness [dtex] of fiber component × production rate [m / min] ≧ 200 is satisfied.
前記圧着工程を、コンパクションロールを用いて接圧２ｋｇｆ／ｃｍ以上５ｋｇｆ／ｃｍ以下及び温度が前記ポリオレフィン系長繊維の融点より０℃以上６０℃以下低い温度で行う、請求項１２に記載の不織布積層体の製造方法。 The air permeability of the conveyor net is 200 cm 3 / cm 2 / second or more and 500 cm 3 / cm 2 / second or less,
The nonwoven fabric lamination according to claim 12, wherein the crimping step is performed using a compaction roll at a contact pressure of 2 kgf / cm or more and 5 kgf / cm or less and a temperature of 0 ° C or more and 60 ° C or less lower than the melting point of the polyolefin-based long fibers. Body manufacturing method.
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