JP3658271B2 - 複合シートの製造方法 - Google Patents

複合シートの製造方法 Download PDF

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Publication number
JP3658271B2
JP3658271B2 JP2000099888A JP2000099888A JP3658271B2 JP 3658271 B2 JP3658271 B2 JP 3658271B2 JP 2000099888 A JP2000099888 A JP 2000099888A JP 2000099888 A JP2000099888 A JP 2000099888A JP 3658271 B2 JP3658271 B2 JP 3658271B2
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Japan
Prior art keywords
composite sheet
stretchable
continuous fibers
web
conveyor
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Expired - Fee Related
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JP2000099888A
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English (en)
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JP2001288666A (ja
Inventor
悟 丹下
裕之 大幡
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Uni Charm Corp
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Uni Charm Corp
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Priority to JP2000099888A priority Critical patent/JP3658271B2/ja
Priority to CA002342291A priority patent/CA2342291C/en
Priority to AU31367/01A priority patent/AU782644B2/en
Priority to BR0101746-2A priority patent/BR0101746A/pt
Priority to US09/821,230 priority patent/US6995100B2/en
Priority to SG200101955A priority patent/SG85236A1/en
Priority to MYPI20011483A priority patent/MY128652A/en
Priority to CNB011173556A priority patent/CN1181969C/zh
Priority to TW090107617A priority patent/TW587994B/zh
Priority to IDP20010287D priority patent/ID29726A/id
Priority to KR1020010016713A priority patent/KR100666969B1/ko
Priority to AT01303149T priority patent/ATE542666T1/de
Priority to EP01303149A priority patent/EP1138475B1/en
Publication of JP2001288666A publication Critical patent/JP2001288666A/ja
Priority to US10/292,040 priority patent/US6998004B2/en
Application granted granted Critical
Publication of JP3658271B2 publication Critical patent/JP3658271B2/ja
Priority to US11/217,754 priority patent/US7563337B2/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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

Description

【０００１】
【発明の属する技術分野】
この発明は、伸縮性ウェブと伸長性の連続繊維からなる伸長性ウェブとによって形成される複合シートの製造方法に関する。
【０００２】
【従来の技術】
特開平６−１８４８９７号公報に開示された複合伸縮性材料は、引張ることによって首を付けた材料を引張った状態のままで、引張った伸縮性シートに対して非直線状に配列した少なくとも３点で接合し、しかる後に伸縮性シートを弛緩させることによって製造される。この製造方法によれば、首を付けた材料は、それが繊維からなるものであれば、伸縮性シートの弛緩に伴って多くのひだを形成し、伸縮性シートの伸縮性を損うことなく、このシートのゴムライクな表面を布様の肌触りのよいものに変えることができる。
【０００３】
【発明が解決しようとする課題】
前記公知技術によれば、首を付けた材料の一例は、熱可塑性合成繊維が互いに溶着してなるスパンボンド不織布を一方向へ引張ったものである。ランダムに分布してこの不織布を形成している繊維は、一方向へ引張られることによって、あるものはその一方向へ向かって塑性変形しながら伸長し、またあるものはその一方向へ向かって延びるように、その向きを変えるだけである。そうしたことの結果として、引張られた繊維は細くなる一方、向きを変えただけの繊維は太さが変らないから、得られる複合伸縮性材料は、繊維径のばらつきが大きく、肌触りが一様でないとか、外観が一様でないというものになることがある。
【０００４】
この発明では、前記公知技術の如く、伸縮層と伸長性の繊維からなる伸長層とで形成され、伸長層における繊維径のばらつきが小さい複合シートの製造方法の提供を課題にしている。
【０００５】
【課題を解決するための手段】
前記課題解決のために、この発明は新規な複合シートの製造方法を提案する。
【０００６】
【０００７】
【０００８】
かかる製造方法に関し、この発明が対象とするのは、上下面を有する弾性伸縮性ウェブの少なくとも片面に伸長性の連続繊維からなる伸長性ウェブを互いに直交する第１方向と第２方向とのうちの少なくとも前記第１方向において間欠的に接合することにより複合シートを製造する方法である。
【０００９】
かかる製造方法において、この発明が特徴とするところは、前記連続繊維は、互いに溶着することがないように、または前記第１方向へ配向するように引張られると容易に分離することができるように互いに溶着して重なり合うことによって前記伸長性ウェブを形成しているものであって、前記連続繊維を概ね前記第１方向へ配向させた後、前記伸長性ウェブを前記伸縮性ウェブに接合すること、にある。
【００１０】
この製造方法の好ましい実施態様において、溶融押出機から前記連続繊維を押出して一方向へ走行するコンベア上に捕集して前記伸長性ウェブを形成した後、前記連続繊維を概ね前記一方向へ配向させるように処理して前記伸縮性ウェブと重ね合わせ、しかる後にこれら両ウェブを前記一方向において間欠的に接合することにより前記複合シートを得る。
【００１１】
また、好ましい実施態様の他の１つにおいて、前記連続繊維を前記一方向へ配向させる工程が、速度Ｖ1 で走行する前記コンベアと、前記コンベアに続いて速度Ｖ２で走行する第２のコンベアとを含み、これらコンベアの走行速度比Ｖ２／Ｖ１が１．０５〜１０である。
好ましい実施態様のさらに他の一つにおいて、前記複合シートの前記一方向における引張強度Ｓ １ と前記一方向に直交する方向における引張強度Ｓ ２ との比Ｓ １ ／Ｓ ２ が３．０以上となるように前記連続繊維を前記一方向へ配向させる。
好ましい実施態様のさらにまた他の一つにおいて、前記複合シートの前記第１方向におけるストレッチ効率を６０〜９０％にする。
【００１２】
【発明の実施の形態】
添付の図面を参照し、この発明に係る複合シートとその製造方法の詳細を説明すると、以下のとおりである。
【００１３】
図１に斜視図で示された複合シート１０は、スチレン系エラストマーの連続繊維４０からなる弾性伸縮層３の上面に、伸長性のポリプロピレン連続繊維６からなる伸長層２が接合部４Ａで溶着することによって形成されている。複合シート１０は、Ｘ方向と、これに直交するＹ方向とを有し、伸縮層３がＸ，Ｙ方向のうちの少なくともＹ方向に弾性的に伸縮する。伸長層２の連続繊維６は、概ねＹ方向へ向かって延びるように配向している。伸縮層３の引張強度がＸ方向とＹ方向とで差がない場合、連続繊維６の配向の程度はＹ方向における引張強度Ｓ１とＸ方向における引張強度Ｓ２との比Ｓ１／Ｓ２で表わすことが可能であり、この発明の好ましい複合シート１０では、Ｓ１／Ｓ２が少なくとも３．０となるように連続繊維６が配向している。また、連続繊維６は接合部４Ａを除くと、溶着や接着によって互いに接合するということがなく、重なり合っているだけか、または複合シート１０がＹ方向へ僅かに引張られると互いに離れるように極めて弱く接合しており、実質的には重なり合っているだけの状態に等しい。
【００１４】
かかる複合シート１０は、これを両層２，３の破断伸度以下であって、かつ伸縮層３の弾性限界内でＹ方向へ伸長すると、伸縮層３が弾性的に伸長する一方、伸長層２が非弾性的に伸長し、連続繊維６が細く、長くなるように塑性変形する。伸長する力を解くと、複合シート１０は、伸縮層３の収縮力によって元の寸法近くにまで縮み、このときに、長く伸びた連続繊維６には多くのひだが形成され、伸長層２は伸長前の状態よりも嵩が高く、肌触りが柔軟になる。
【００１５】
図２は、最初に１５０％まで伸長した複合シート１０を再度伸長したときの荷重／伸度曲線であって、複合シート１０の構成は、次のとおりである。なお、複合シート１０を最初に伸長するときの割合は、初期伸長率ＥＩと定義される。
【００１６】
伸長層 伸長性連続繊維：ポリプロピレン／プロピレン、エチレン、ブテンの
ターポリマー＝６０／４０（重量比）
繊維径：１５．２μｍ
坪 量：１５ｇ／ｍ２
伸縮層 伸縮性連続繊維：スチレン系エラストマー
繊維径：１６．４μｍ
坪 量：６０ｇ／ｍ２
複合シート 強度比（Ｓ１／Ｓ２）：４．９
【００１７】
図２において、曲線はゆるく立上った後にほぼ一様な荷重で伸度１００％の変曲点Ｐにまで達し、そこから急に立ち上がる。複合シート１０では、まず伸長層２の連続繊維６のひだが伸び、それと同時に伸縮層３が弾性的に変曲点Ｐまで伸長する。変曲点Ｐ以降では、連続繊維６が塑性変形して、細く、長くなるように伸長し、伸縮層３が引き続き弾性的に伸長する。このように複合シート１０では、最初に１５０％まで伸長すると、２度目の伸長では、伸度１００％までの範囲において低い応力で伸縮する伸縮層３の特性が現われ、伸長層２はその特性に殆ど影響を与えることがない。複合シート１０を２度目に伸長したときに観察される変曲点Ｐまでの低い荷重を示す伸長率は、第２次伸長率ＥSと定義される。第２次伸長率ＥＳと初期伸長率ＥＩとの比ＥＳ／ＥＩはストレッチ効率ＳＥであり、図２の場合のストレッチ効率ＳＥは１００（％）／１５０（％）×１００＝６７（％）である。この発明に係る複合シート１０では、連続繊維６が概ねＹ方向へ配向しているから、これをＹ方向へ伸長するときには多くの連続繊維６もＹ方向へ伸長されて長くなるので、ストレッチ効率ＳＥが６０〜９０％程度の高い値になる。この複合シート１０に比べ、連続繊維６がランダムに分布している場合の複合シートでは、ストレッチ効率ＳＥが６０％以下である。
【００１８】
図３は、複合シート１０を製造するときの工程図である。図の左方には、連続繊維６を吐出する第１押出機３１と、第１コンベアベルト３２と、サクションボックス３３とがある。吐出された連続繊維６は、第１押出機のノズル側方から吐出される熱風（図示せず）やサクションの作用で第１コンベアベルト３２上に捕集され、伸長性ウェブ５２を形成する。連続繊維６は、互いに溶着することがないように、また、たとえ溶着しても極めて容易に分離することができるように、第１押出機３１の吐出条件、熱風やサクションの作用条件、連続繊維６の冷却条件、および第１コンベアベルト３２の速度Ｖ１が選ばれる。
【００１９】
伸長性ウェブ５２は、第２コンベアベルト３６へと進む。第２コンベアベルト３６は、速度Ｖ２で走行し、伸長性ウェブ５２を押さえるロール３７，３８は周速Ｖ２で回転している。速度Ｖ２とＶ１との比Ｖ２／Ｖ１は１．０５〜１０であって、伸長性ウェブ５２は、第１コンベアベルト３２から第２コンベアベルト３６へ移行する過程で進行方向へ引張られ、連続繊維６が進行方向へ向かって延びるように配向する。連続繊維６が互いに弱く溶着しているときには、第２コンベアベルト３６でばらばらになる。
【００２０】
伸長性ウェブ５２は、第２コンベアベルト３６から第３コンベアベルト４１へと進む。第２押出機４２からはエラストマーの連続繊維４０が吐出され、サクションボックス４３のサクションの作用を受けて伸長性ウェブ５２の上に堆積し、伸縮性ウェブ５３を形成する。両ウェブ５２，５３は、上下一対の熱エンボスロール４４，４４を通過するときに接合部４Ａを形成されて一体化し、複合シート１０となる。
【００２１】
かかる複合シート１０の製造工程では、第１コンベアベルト３２の速度Ｖ１第２コンベアベルト３６の速度Ｖ２との関係をＶ２／Ｖ１＝１．０５〜１０とすることによって連続繊維６を配向させると、その配向は、複合シート１０に６０〜９０％の高いストレッチ効率ＳＥをもたらすのに十分な程度となる。この配向が十分であるときの複合シート１０では、機械方向とそれに直交する方向の引張強度Ｓ１とＳ２との比Ｓ１／Ｓ２は、３．０以上になる。
【００２２】
この発明に係る複合シート１０は、図示例のものを、伸縮層３の上下面に伸長層２を有するものに代えることができる。また、それに合わせて、図３の工程に第３の押出機と、複数のコンベアベルトとを追加することができる。
【００２３】
【発明の効果】
この発明に係る方法によって得られる複合シートは、伸長性の連続繊維が概ね一方向に配向しているので、その一方向に伸長されると、多数の連続繊維がどれも一様に伸びるので伸長後の繊維径のばらつきが少なく、肌が触れたときの感触や外観にむらがない。
【００２４】
この発明に係る製造方法は、伸長性ウェブの連続繊維を概ね一方向へ配向させる工程を有するので、前記複合シートの製造が容易になる。
【図面の簡単な説明】
【図１】 複合シートの斜視図。
【図２】 荷重／伸度曲線。
【図３】 複合シートの製造工程図。
【符号の説明】
２ 伸長層
３ 伸縮層
６ 連続繊維
１０ 複合シート
３１ 押出機（第１押出機）
３２ コンベア（第１コンベアベルト）
３６ 第２のコンベア（第２コンベアベルト）
５２ 伸長性ウェブ
５３ 伸縮性ウェブ
Ｘ 第２方向
Ｙ 第１方向

Claims (5)

  1. 上下面を有する弾性伸縮性ウェブの少なくとも片面に伸長性の連続繊維からなる伸長性ウェブを互いに直交する第１方向と第２方向とのうちの少なくとも前記第１方向において間欠的に接合することにより複合シートを製造する方法において、
    前記連続繊維は、互いに溶着することがないように、または前記第１方向へ配向するように引張られると容易に分離することができるように互いに溶着して重なり合うことによって前記伸長性ウェブを形成しているものであって、前記連続繊維を概ね前記第１方向へ配向させた後、前記伸長性ウェブを前記伸縮性ウェブに接合することを特徴とする前記方法。
  2. 溶融押出機から前記連続繊維を押出して一方向へ走行するコンベア上に捕集して前記伸長性ウェブを形成した後、前記連続繊維を概ね前記一方向へ配向させるように処理して前記伸縮性ウェブと重ね合わせ、しかる後にこれら両ウェブを前記一方向において間欠的に接合することにより前記複合シートを得る請求項１記載の方法。
  3. 前記連続繊維を前記一方向へ配向させる工程が、速度Ｖ1 で走行する前記コンベアと、前記コンベアに続いて速度Ｖ２で走行する第２のコンベアとを含み、これらコンベアの走行速度比Ｖ２／Ｖ１が１．０５〜１０である請求項１または２記載の方法。
  4. 前記複合シートの前記一方向における引張強度Ｓ1 と前記一方向に直交する方向における引張強度Ｓ２との比Ｓ１／Ｓ２が３．０以上となるように前記連続繊維を前記一方向へ配向させる請求項１〜３のいずれかに記載の方法。
  5. 前記複合シートの前記第１方向におけるストレッチ効率を６０〜９０％にする請求項１〜４のいずれかに記載の方法。
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AU31367/01A AU782644B2 (en) 2000-03-31 2001-03-28 Composite sheet and process for making the same
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IDP20010287D ID29726A (id) 2000-03-31 2001-03-30 Lembar komposit dan proses pembuatannya
KR1020010016713A KR100666969B1 (ko) 2000-03-31 2001-03-30 복합 시이트의 제조 방법
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US10/292,040 US6998004B2 (en) 2000-03-31 2002-11-12 Composite sheet and process for making the same
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JP3658271B2 (ja) * 2000-03-31 2005-06-08 ユニ・チャーム株式会社 複合シートの製造方法
JP3734695B2 (ja) * 2000-09-01 2006-01-11 ユニ・チャーム株式会社 弾性伸縮性複合シートおよびその複合シートを使用した使い捨ての着用物品
US7078089B2 (en) * 2001-12-28 2006-07-18 Kimberly-Clark Worldwide, Inc. Low-cost elastic laminate material

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ATE542666T1 (de) 2012-02-15
AU782644B2 (en) 2005-08-18
TW587994B (en) 2004-05-21
BR0101746A (pt) 2001-12-04
CN1181969C (zh) 2004-12-29
SG85236A1 (en) 2001-12-19
US7563337B2 (en) 2009-07-21
KR100666969B1 (ko) 2007-01-12
MY128652A (en) 2007-02-28
EP1138475A2 (en) 2001-10-04
CN1322623A (zh) 2001-11-21
AU3136701A (en) 2001-10-04
ID29726A (id) 2001-10-04
EP1138475A3 (en) 2004-03-31
KR20010095125A (ko) 2001-11-03
US6995100B2 (en) 2006-02-07
US6998004B2 (en) 2006-02-14
US20010027074A1 (en) 2001-10-04
EP1138475B1 (en) 2012-01-25
JP2001288666A (ja) 2001-10-19
CA2342291A1 (en) 2001-09-30
US20060063450A1 (en) 2006-03-23
US20030070744A1 (en) 2003-04-17
CA2342291C (en) 2006-12-12

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