JP3883460B2 - 3D sheet - Google Patents

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Publication number
JP3883460B2
JP3883460B2 JP2002084397A JP2002084397A JP3883460B2 JP 3883460 B2 JP3883460 B2 JP 3883460B2 JP 2002084397 A JP2002084397 A JP 2002084397A JP 2002084397 A JP2002084397 A JP 2002084397A JP 3883460 B2 JP3883460 B2 JP 3883460B2
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heat
fiber
fiber layer
fusible
dimensional sheet
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JP2003286642A (en
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渉 坂
祥一 種市
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Kao Corp
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Kao Corp
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Priority to JP2002084397A priority Critical patent/JP3883460B2/en
Priority to PCT/JP2002/013538 priority patent/WO2003080912A1/en
Priority to AU2002360034A priority patent/AU2002360034A1/en
Priority to CNB028286510A priority patent/CN100347369C/en
Priority to TW092100424A priority patent/TWI263715B/en
Publication of JP2003286642A publication Critical patent/JP2003286642A/en
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A61F13/539—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium characterised by the connection of the absorbent layers with each other or with the outer layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/5116—Topsheet, i.e. the permeable cover or layer facing the skin being formed of multiple layers
    • A61F2013/51182—Topsheet, i.e. the permeable cover or layer facing the skin being formed of multiple layers with non-continuous bonding

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  • Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • General Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Heart & Thoracic Surgery (AREA)
  • Vascular Medicine (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • Epidemiology (AREA)
  • Biomedical Technology (AREA)
  • Veterinary Medicine (AREA)
  • Textile Engineering (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Orthopedics, Nursing, And Contraception (AREA)

Description

【０００１】
【発明の属する技術分野】
本発明は、表面に所望の凹凸を有し嵩高な構造を有する立体シートに関する。
【０００２】
【従来の技術及び発明が解決しようとする課題】
特許３１３１５５７号明細書には、熱収縮性繊維及び該熱収縮性繊維の熱収縮開始温度よりも融点の低い樹脂からなる熱融着繊維を含む第一繊維層の片面に、非熱収縮性繊維からなる第二繊維層が積層されてなる多皺性不織布が記載されている。両繊維層は、線状熱融着により厚さ方向に一体化され、熱融着部が凹部、該熱融着部間が凸部になっており、第二繊維層に筋状の多数の皺が形成されている。この多皺性不織布は、第一繊維層と第二繊維層とを重ね合わせ、前記熱収縮性繊維の熱収縮開始温度よりも低い温度で、両繊維層を熱融着によって一体化させた後、前記熱収縮温度以上の熱風を吹き付けて前記熱収縮性繊維を熱収縮させることで得られる。しかし、この不織布では、第一繊維層と第二繊維層との熱融着は、第一繊維層に３０〜５０重量％以上含まれる熱融着繊維に依存しているので、両繊維層の接合力に限りがある。従って第一繊維層の熱収縮時並びに不織布の後加工時及び使用時に前記熱融着部が剥離し易く、その結果凹凸模様が不鮮明になったり、所望の凹凸形状が得られない場合がある。また、前記熱収縮性繊維の収縮温度が熱融着繊維の融点よりも高いため、収縮の際に熱融着繊維が溶けて風合いが悪くなり、肌に直接触れるシートには不向きである。
両繊維層の接合力を高めるには、第１繊維層に含有させる熱融着性繊維の比率を高めたり、熱融着加工の際の温度や圧力を高めることが考えられるが、前者では、熱収縮性繊維の比率が低下して第１繊維層の収縮性が不充分となって、所望の凹凸形状が得られい恐れがある。また、後者では、熱融着部が硬くなる結果、シート全体の柔軟性が低下し、風合いが悪化する。
また、上述した多皺性不織布を他の材料等に固定して用いる場合、第１繊維層側の面を他の材料等に向けて固定することになるが、第１繊維層には、収縮力確保の為に熱融着繊維を多量に用いることができず、また、熱エンボス等の熱圧着は熱収縮繊維の収縮温度以下で行われるから熱収縮性繊維は溶かすことはできず、熱エンボス等の熱圧着により固定しようとしても、十分な接合強度が得られない。
【０００３】
従って、本発明の目的は、風合いが良く、他の材料等に対する熱圧着性に優れ、また、製造時に所望の凹凸を形成させることのできる立体シートを提供することにある。
【０００４】
【課題を解決するための手段】
本発明は、熱収縮した熱収縮性繊維を含む第１繊維層の片面に、非熱収縮性繊維を主体とし且つ熱融着性繊維を含む第２繊維層が積層され、第１繊維層の他面に、熱融着性繊維を含む第３繊維層が積層された立体シートであって、第１〜第３繊維層が、前記立体シートに所定パターンの熱融着部を形成しており、前記熱融着部は、第２繊維層から第３繊維層に亘っており且つ該熱融着部が形成されている部分における前記立体シートの厚み方向の全域に亘っており、第２繊維層は、前記熱融着部以外の部分が凸状をなしており、第１繊維層に含まれる熱収縮性繊維の量が、第１繊維層の重量に対して７０〜１００重量％であり、第２繊維層に含まれる熱融着性繊維の量が、第２繊維層の重量に対して７０〜１００重量％であり、第３繊維層に含まれる熱融着性繊維の量が、第３繊維層の重量に対して７０〜１００重量％であり、第２及び第３繊維層に含まれる熱融着性繊維は、前記熱収縮性繊維の融点よりも融点の低い熱融着樹脂を含み、前記熱融着部は、第２繊維層に含まれる熱融着性繊維の熱融着樹脂と第３繊維層に含まれる熱融着性繊維の熱融着樹脂とが、それぞれ第１繊維層中に溶融して浸透し、互いに接着して形成されている、立体シートを提供することにより前記目的を達成したものである。尚、熱融着性繊維と熱融着繊維とは同じ意味である。
【０００６】
【発明の実施の形態】
以下本発明を、その好ましい実施形態に基づき図面を参照しながら説明する。
図１には、本発明（第１発明）の一実施形態としての立体シート１０の断面図が模式的に示されている。立体シート１０は、熱収縮性繊維を含む第１繊維層１の片面に、第２繊維層２が積層され、第１繊維層１の他面に、第３繊維層３が積層された３層構造を有している。第１繊維層１は、繊維の集合体から構成されている。他方、第２繊維層２及び第３繊維層３は、それぞれ、第１繊維層１を構成する繊維と異なる種類及び／又は配合の繊維の集合体から構成されている。第２繊維層２と第３繊維層３とは、同一種類及び配合の繊維の集合体、又は、異なる種類及び／又は配合の繊維の集合体から構成されている。
【０００７】
立体シート１０を平面視した場合、該立体シート１０には、図２（ａ）に示す菱形格子状パターンの熱融着部４が形成されている。熱融着部４は、積層状態における第１〜第３繊維層を部分的に熱圧着して形成されている。
熱融着部４は、第２繊維層２から第３繊維層３に亘っている。第２繊維層と第１繊維層との接合箇所、及び第１繊維層と第３繊維層との接合箇所は、それぞれ立体シート１０を平面視した状態において完全に重なっている。熱融着部４は、熱融着樹脂の溶融固化によって形成されている。後述するように、熱融着樹脂は、これを含む熱融着性繊維の形態で、第２繊維層２及び第３繊維層３に含まれており、これら両繊維層の熱融着樹脂が、第１繊維層の樹脂が全く溶けていなくとも、溶融浸透し、お互いが接着して３層の接着を可能にしている。更に所望により第１繊維層にも含まれていることが好ましい。熱融着部４は、立体シート１０の個々の熱融着部の総てにおいて第２繊維層から第３繊維層に亘っていることが好ましく、また、個々の熱融着部は、該部分における立体シートの厚み方向の全域に亘っている。
尚、本実施形態における個々の熱融着部は、円形のものであるが、個々の熱融着部の形状は、楕円形、三角形若しくは矩形又はこれらの組み合わせ等であってもよい。また接合部を連続した形状、例えば直線や曲線などの線状に形成してもよい。熱融着部４の形成パターンは、例えば図２（ｂ）及び図２（ｃ）に示すようなパターンとすることもできる。
【０００８】
立体シート１０の面積に対する熱融着部４の面積率（立体シート１０単位面積当りの熱融着部４の面積）は、立体シート１０の具体的な用途等にもよるが、第１〜第３の繊維層の接合強度を十分に高くする点、及び第２繊維層の変形により凸状の立体的な形状を十分に形成して嵩高さを発現させる点から、熱融着部４の形成後且つ第１繊維層１の熱収縮前においては３〜５０％、特に５〜３５％であり、熱収縮後においては６〜９０％、特に１０〜７０％であることが好ましい。
【０００９】
立体シート１０は、積層状態における第１〜第３繊維層を部分的に熱圧着して一体化させた後、第１繊維層１に含まれる熱収縮性繊維の収縮開始温度以上で熱処理して製造されたものであり、第１繊維層の熱収縮によって、第２繊維層２の前記熱融着４部以外の部分が凸状をなしている。本実施形態においては、立体シート１０は、図２（ａ）に示すように、菱形格子状のパターンからなる熱融着部４によって取り囲まれた閉じた領域を多数有しており、この閉じた各領域において第２繊維層２がドーム状の凸状に変形している。他方、熱融着部４は、第２繊維層２が凸状をなす部分（凸部５ともいう）と比べて相対的に凹んでおり、それにより、立体シート１０の第２繊維層側の表面には、多数の凸部及び凹部からなる凹凸形状が形成されている。本実施形態においては、第１繊維層１の収縮により、第３繊維層３側にも同様の凹凸形状が形成されている。
【００１０】
第１繊維層１は、熱収縮性繊維を含んでいる。この熱収縮性繊維は、立体シート１０中において、熱収縮した状態となっている。熱収縮性繊維としては、公知のものを特に制限なく用いることができる。熱収縮性繊維として潜在捲縮性繊維を用いると、第１繊維層１にエラストマー的な性質が付与され、立体シート１０全体としてもエラストマー的な性質が発現することから好ましい。立体シート１０がエラストマー的な性質を有すると、立体シート１０を例えば後述する使い捨て吸収性物品の構成部材として用いた場合に、着用者の動作に対する追従性が良好となり、該吸収性物品のフィット性が向上し、液漏れが効果的に防止されることから好ましい。
【００１１】
潜在捲縮性繊維は、例えば収縮率の異なる２種類の熱可塑性ポリマー材料を成分とする偏心芯鞘型複合繊維又はサイド・バイ・サイド型複合繊維からなる。その例としては、特開平９−２９６３２５号公報や特許２７５９３３１号明細書に記載のものが挙げられる。収縮率の異なる２種類の熱可塑性ポリマー材料の例としては、例えばエチレン−プロピレンランダム共重合体（ＥＰ）とポリプロピレン（ＰＰ）との組み合わせ、ポリエチレンテレフタレート（ＰＥＴ）と、ポリエチレンテレフタレートとポリエチレンイソフタレートとの共重合体（ＣｏＰＥＴ）との組み合わせが挙げられる。熱収縮性繊維は、短繊維ステープルファイバでもよく或いは長繊維フィラメントでもよい。その太さは１〜７ｄｔｅｘ程度が好適である。
熱収縮性繊維の熱収縮開始温度は例えば９０〜１１０℃とすることができる。熱収縮開始温度とは、昇温可能な炉にその繊維を置き、一定速度で昇温したとき、その繊維が実質的に収縮開始した時の実測温度を言う。
【００１２】
第１繊維層１は熱収縮性繊維１００％からなるものでも、或いは他の繊維を含んでいるものでも良い。第１繊維層１に含ませる他の繊維としては、後述する熱融着性繊維、例えば、第２及び／又は第３繊維層に含まれる熱融着性繊維が挙げられる。
第１繊維層１に他の繊維が含まれる場合であっても、立体シートの製造時に、熱収縮性繊維の収縮が阻害されないようにする観点から、熱収縮性繊維の量は、第１繊維層１の重量に対して７０重量％以上であり、好ましくは９０〜１００重量％である。
【００１３】
熱収縮する前の第１繊維層１の形態としては、構成繊維が未接合状態にあるウエブ、又は不織布が挙げられる。ウエブの形態である第１繊維層１としては、熱収縮性繊維を含み且つカード法によって形成されたウエブが挙げられる。不織布の形態である第１繊維層１としては、熱収縮性繊維を含む、各種不織布製造法で製造された不織布が挙げられる。不織布製造法としては、熱融着法、水流交絡法、ニードルパンチ法、溶剤接着法、スパンボンド法、メルトブローン法が挙げられる。
【００１４】
第２繊維層２は、非熱収縮性繊維を主体として構成されている。本明細書において非熱収縮性繊維とは、熱収縮性を示さない繊維、及び熱収縮性は示すが、第１繊維層に含まれる熱収縮性繊維の熱収縮開始温度以下で実質的に熱収縮しない繊維の双方を含む。
第２繊維層２中の非熱収縮性繊維の量は、第２繊維層１の重量に対して少なくとも ７０重量％以上であり、好ましくは９０重量％以上、特に１００重量％であることが、第１繊維層がより立体的になる点から好ましい。
尚、立体性および収縮性の調整を行う観点から、第２繊維層中には、第１繊維層中の熱収縮性繊維と同様の熱収縮性繊維を１０〜３０重量％程度含ませることが好ましい。
【００１５】
第２繊維層２及び第３繊維層３は、それぞれ、熱融着性繊維を含んでいる。熱融着性繊維は、熱融着樹脂を含み、該樹脂の溶融固化により繊維同士が融着し得るものである。
第２繊維層２及び第３繊維層３に含まれる熱融着性繊維は、それぞれ、第１繊維層１に含まれる熱収縮性繊維の融点よりも融点の低い熱融着樹脂を含んでいる。これにより、熱融着部の接合強度を一層向上させることができる。第１繊維層中の熱収縮性繊維が、芯鞘型（偏心又は同心型）の複合繊維又はサイド・バイ・サイド型の複合繊維である場合には、第２及び第３繊維層に含まれる熱融着性繊維は、芯鞘型複合繊維の鞘成分又はサイド・バイ・サイド型の複合繊維の両方の熱融着成分の融点よりも融点の低い樹脂を含む。
ここで、熱収縮性繊維の融点は、ＤＳＣ（示差走査熱量計）により融解熱測定を行ったときのピーク値をいう。
【００１６】
第２繊維層２及び第３繊維層３に含まれる熱融着性繊維中の熱融着樹脂の融点は、第１繊維層の熱収縮性繊維の融点より１０℃以上、特に２０℃以上低いことが肌にあたる第１繊維層を収縮させずに、第２繊維層に含まれる熱融着繊維を溶かして接着できる点から好ましい。熱融着性繊維が多成分系の複合繊維である場合には、その内の最も融点の低い熱融着樹脂が第１繊維層の熱収縮性繊維の融点よりも低いことが好ましい。
また、第２繊維層２及び第３繊維層３に含まれる熱融着性繊維中の熱融着樹脂の融点は、第１繊維層の熱収縮性繊維の熱収縮温度よりも３０℃以上、特に４０℃以上低いことが、第１繊維層を収縮させずに、第２繊維層に含まれる熱融着繊維を溶かして充分に接着強度のある接着ができる点から好ましい。
【００１７】
更に、第２繊維層２に含まれる熱融着繊維中の熱融着樹脂の融点と、第３繊維層３に含まれる熱融着繊維中の熱融着樹脂の融点とは同じであるか、又はこれら２つの熱融着樹脂の融点の差が２０℃以内、特に１０℃以内であることが、第１〜第３繊維層の接合強度を一層向上させることができ、また、これらを一体化するための熱処理の温度条件を比較的低温で行うことができ、立体シートの風合いを一層良好なものとすることができる点から好ましい。
【００１８】
熱融着部４における繊維層同士の接合強度を向上させると共に立体シートの風合いを良好にする点から、第２繊維層に含まれる熱融着性繊維の量は、第２繊維層２の重量に対して７０〜１００重量％であり、好ましくは９０〜１００重量％である。
第３繊維層に含まれる熱融着性繊維の量は、熱融着部４における繊維層同士の接合強度を向上させると共に立体シートの風合いを良好にする点、及び他の材料等、特に繊維材料に対する熱圧着性を高める点から、第３繊維層２の重量に対して７０〜１００重量％であり、好ましくは９０〜１００重量％である。
【００１９】
第２繊維層２及び第３繊維層３に含まれる熱融着繊維の例としては、ポリエチレン（ＰＥ）、ポリプロピレン（ＰＰ）、ポリエチレンープロピレン共重合体、ポリエチレンテレフタレート（ＰＥＴ）、ポリブチレンテレフタレート等のポリエステル、ポリエチレンテレフタレートーエチレンイソフタレート共重合体、ポリアミドエチレンアクリル酸共重合体、エチレン―アクリル酸メチル共重合体、エチレンーメタクリル酸共重合体、エチレンーメタクリル酸メチル共重合体、エチレンーメタクリル酸エチル共重合体、エチレンーアクリル酸メチルーアクリル３元共重合体、等からなる繊維が挙げられる。またこれらの熱可塑性ポリマー材料の組み合わせからなる芯鞘型複合繊維やサイド・バイ・サイド型複合繊維も用いることができる。これらの繊維は短繊維ステープルファイバでもよく或いは長繊維フィラメントでもよい。その太さは１〜７ｄｔｅｘ程度が好適である。第１繊維層１に熱融着繊維を含ませる場合の熱融着繊維は、これらと同様のものを用いることができる。
【００２０】
第１繊維層１が熱収縮する前の第２及び第３繊維層２の形態としては、構成繊維が未接合状態にあるウエブ又は不織布が挙げられる。熱収縮する前の第２繊維層及び第３繊維層２の形態は同一でも又は異なるものでも良い。
第２繊維層の形態が、特にウエブの形態であると、収縮によって第２繊維層２の面積ないし形状を変化させることが容易となり、第２繊維層２を厚み方向に凸状に盛り上げることが容易になるので好ましい。また盛り上がった凸部の中が繊維で満たされるので、クッション性に富み柔らかな風合いを有するシートが得られるので好ましい。第２繊維層２及び／又は第３繊維層３がウエブの形態である場合、該ウエブは例えばカード法によって形成することができる。第２繊維層２が、斯かるウエブから形成された立体シート１０には、嵩高で且つ該ウェブを構成する繊維で満たされた凸部５が形成され、また繊維が凸部５に沿うように配向する。特に、第２繊維層２が、カード法によって形成されたウエブの形態であると、第２繊維層２が極めて疎な構造となり、本発明の立体シート１０は、粘度の高い液の透過や保持が可能となる。また立体シート１０を厚み方向へ圧縮させたときの圧縮変形性も高くなる。粘度の高い液としては、軟便若しくは経血、対人用の清浄剤若しくは保湿剤、又は対物用の清浄剤が挙げられる。
一方、第２繊維層の形態が接合及び収縮前に不織布であると、搬送性が良好及び強度が大きい利点がある。また、第１繊維層との接合後に第２繊維層の構成繊維同士を融着させる必要がないので、収縮温度の選択範囲が広い利点もある。
【００２１】
本実施形態の立体シート１０は、例えば、公知の方法を用いて第１〜第３繊維層をそれぞれ製造し、第２繊維層２と第３繊維層３との間に第１繊維層１を挟むようにして、これらを重ね合わせた後、凹凸ロール同士又は凹凸ロールと平滑ロールとからなる熱エンボスロール装置によって、積層された第１〜第３繊維層を所定パターンで部分的に熱圧着し、次いで、第１繊維層１に含まれる熱収縮性繊維の熱収縮開始温度以上の熱処理により該熱収縮性繊維を収縮させることにより得られる。熱処理の方法は、積層一体化された第１〜第３繊維層に熱風を通したり吹き付けたりする方法の他、マイクロウェーブ、蒸気、赤外線、ヒートロールの接触等の方法を用いることもできる。
【００２２】
本実施形態の立体シート１０によれば、該立体シート１０を平面視した状態において、所定パターンの熱融着部４が、第２繊維層から第３繊維層に亘るように形成されているため、熱融着部４における第２繊維層から第３繊維層までの接合強度を向上させることができる。そのため、第１繊維層の十分な収縮性及び第２繊維層から第３繊維層に亘る接合強度を十分に維持しながら、例えば、製造時における熱圧着を比較的低温の条件で行うことができる。そのため、柔軟で肌触りの良好な風合いを有する立体シートを得ることが可能である。
【００２３】
また、第３繊維層側を、立体シート１０を固定しようとする他の材料等（被固定物６ともいう）側に向けて熱圧着（熱エンボス等）することにより、該立体シート１０を、該他の材料等に強固に熱圧着させることができ、立体シート１０と被固定物との間に剥離が生じにくい。
【００２４】
図３には、上記構成の立体シート１０を、熱エンボス加工により、繊維材料からなる被固定物６としての、生理用ナプキン（吸収性物品）の吸収体６１及び防漏シート６２に、第３繊維層側を該被固定物側にして固定した状態が示されている。
即ち、立体シート１０は、生理用ナプキンの中央領域において、ヒートシール装置による熱エンボス加工により、吸収体６１の肌当接面側の表面に熱圧着されており、この熱圧着部７１により、生理用ナプキンの肌当接面に環状の中央防漏溝が形成されている。また、立体シート１０は、生理用ナプキンの長手方向の両側部において、同様にヒートシール装置による熱エンボス加工により、吸収体６１上に配された防漏シート上に熱圧着されており、この熱圧着部７２により、生理用ナプキンの肌当接面の前記中央防漏溝の両側に、一対のサイド防漏溝が形成されている。尚、熱圧着部７１における吸収体の表面は、セルロース系の繊維材料からなる台紙によって形成されており、熱圧着部７２における防漏シート６２は、セルロース系の繊維材料にポリエチレンをラミネートしたものから構成されている。尚、防漏シート６２は、接着性がより良好であるため、ラミネート（ポリエチレン）側を表面シート側に向けて使用した（後述する実施例及び比較例においても同様）。
【００２５】
両熱圧着部７１，７２においては、ヒートシール装置による熱エンボス加工時に、第３繊維層中の熱融着樹脂が被固定物６の構成繊維間に食い込んだ状態で溶融固化するため、立体シート１０とこれらの被固定物６との間に剥離が生じにくい。
尚、ヒートシール装置としては、生理用ナプキン、使い捨ておむつ等において、従来用いられている溝形成用のヒートシール装置あるいはエンドシール部形成用のヒートシール装置等を用いることができる。尚、図３においては、立体シート１０の表面に形成された凹凸等の図示を省略してある。図３に示す生理用ナプキンにおいては、立体シート１０を、液透過性の表面材（表面シート）として用いており、該立体シート１０と液不透過性の裏面材（裏面シート）８との間に、液保持性の吸収体６１が介在している。立体シート１０は、吸収体６１の両側部近傍において、ホットメルト接着剤９１により防漏シート６２及び裏面材８に固定されており、防漏シート６２は、ホットメルト接着剤９２により裏面材８に固定されている。
【００２８】
本発明は前記実施形態に制限されない。
本発明の立体シートは、例えば１回あるいは数回の使用で廃棄される使い捨て物品の構成部材として好適に使用される。また面ファスナの雌材（ループ材）やパップ材としても使用することができる。特に、生理用ナプキンや使い捨ておむつなどの使い捨て吸収性物品、掃除用ワイパーや対人ワイパーなどの使い捨てワイパーの構成部材として好適である。使い捨て吸収性物品、例えば液透過性の表面材と、液不透過性の裏面材と、両シート間に介在された吸収体とを有する吸収性物品の構成部材として用いる場合には、その構成部材の一部、例えば表面材、裏面材又はサイド立体ガードの何れかの部材の一部として使用することができる。
【００２９】
本発明の立体シートを熱エンボス加工により他の材料等（被固定物）に固定して用いる場合及び立体シートの固定方法において立体シートを固定する被固定物としては、使い捨てワイパーの基材シート等が挙げられる。但し、特に繊維材料からなる被固定物の場合、とりわけ上述した生理用ナプキンや使い捨ておむつ等の使い捨て吸収性物品の吸収体等、圧縮により変形する柔軟な被固定物の場合に本発明の効果が特に顕著に発現される。
【００３０】
以下実施例により本発明を更に詳細に説明する。しかし、本発明の範囲は斯かる実施例に制限されない。
【００３１】
〔実施例〕
（１）第１繊維層の製造
熱収縮性繊維としてダイワボウポリテック社製の潜在捲縮性の芯鞘型複合繊維（商品名ＣＰＰ、芯；ポリプロピレン（融点１６５〜１７０℃）、鞘；エチレン・プロピレンコポリマー（融点１４５〜１４７℃）、芯／鞘重量比＝５／５、繊度２．２ｄｔｅｘ、繊維長５１ｍｍ、熱収縮開始温度９０℃）を用いた。この繊維を原料として、ウェブをローラーカードにより形成した上で、エンボスロール（エンボス率２８％、温度条件：パターン１４５℃、スピード８０m/min）を通し、冷却ロールを通過させて、坪量２０ｇ／ｍ2の第１繊維層のヒートロール不織布を形成した。
【００３２】
（２）第２繊維層の製造
熱融着繊維としてダイワボウポリテック社製の芯鞘型複合繊維（商品名ＳＨＷ６、芯；ポリエチレンテレフタレート（融点２５０〜２５５℃）、鞘；ポリエチレン（融点１２８〜１３０℃）、芯／鞘重量比＝５／５、繊度２．２ｄｔｅｘ、繊維長５１ｍｍ）を用いた。この繊維を原料として、ウェブをローラーカードにより形成した上で、エアースルー熱処理機（温度１３８ｍ／ｍｉｎ、貫通風速1m/sec、処理時間約１０秒）を通し、坪量１２ｇ／ｍ2の第２繊維層のエアースルー不織布を形成した。
【００３３】
（３）第３繊維層の製造
上記の第２繊維層の製造と同様にして得たエアースルー不織布を第３繊維層とした。
【００３４】
（４）立体シートの製造
上記第１〜第３繊維層を重ね、エンボスロール（パターンロール１４５℃、フラットロール１３５℃、エンボス柄図２のＣ ドット径１．５ｍｍ、面積率７．４％）で張り合わせた。その後、速やかに、ピンテンターで熱収縮処理（上下風風速約４．２ｍ、温度１１０℃〜１１６℃、処理時間約１４秒）を行い、機械設定で処理前寸法の縦７０％、横７０％に収縮させた。得られた不織布の坪量は、約８４g/m2だった。
【００３５】
〔比較例〕
実施例における立体シートの製造において、第３繊維層を用いずに張り合わせ後、収縮させた以外は、実施例と同様にして立体シートを得た。
【００３６】
〔性能評価〕
得られた各立体シートを、吸収性物品用の表面材として用いて、図３に示す断面構成の生理用ナプキンを各シートについて１００個以上連続生産した。各立体シートは、温度１９０℃のヒートシール（熱エンボス加工）により、吸収体６１（坪量約２５０g/m2）における台紙（坪量約１６g/m2）からなる表面上に固定すると共に、温度２００℃のヒートシール（熱エンボス加工）により撥水性のポリエチレンシートをラミネートした紙（ラミネート坪量約７g/m2、紙坪量１６g/m2）からなる防漏シート６２上に固定した。
製造した生理用ナプキンのそれぞれについて、吸収体６１上に固定した熱圧着部７１及び防漏シート６２上に固定した熱圧着部７２におけるシール性を、パターン部の浮きの有無を目視により観察し、下記評価基準により熱圧着部の外観に問題がない（外観良好）と判定されたナプキンの個数を表１に示した（Ｎ＝１００）。
【００３７】
＜評価基準＞
外観良好；シールブロックの型どおり鮮明に基材と接着しており、浮きが全くない
外観不良；シールブロックの型の一部がわずかでも不鮮明または、一部または全部に浮きがある
【００３８】
【表１】

Figure 0003883460
【００３９】
表１に示す結果から明らかなように、実施例の立体シート（本発明品）は、吸収体及び防漏シートに対する熱圧着性に優れており、他の材料等、特に繊維材料からなる被固定物に対する熱圧着性に優れていることが判る。
これに対して、比較例の立体シートは、シールブロックの型の一部がわずかでも不鮮明または、一部または全部に浮きがあるものが存在し、製品性能上問題がある。
【００４０】
【発明の効果】
本発明の立体シートは、風合いが良く、他の材料に対する熱圧着性に優れ、また、製造時に所望の凹凸を形成させることのできるものである。
【図面の簡単な説明】
【図１】本発明（第１発明）の立体シートの一実施形態としての立体シートを、それを固定して用いる場合の被固定物と共に示す模式断面図である。
【図２】立体シートに形成された熱融着部の形成パターンの例を示す平面図である。
【図３】立体シートを用いて製造された生理用ナプキン（吸収性物品）の幅方向の断面を示す模式断面図である。
【符号の説明】
１０ 立体シート
１ 第１繊維層
２ 第２繊維層
３ 第３繊維層
４ 熱融着部
５ 凸部[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a three-dimensional sheet having desired irregularities on its surface and a bulky structure.
[0002]
[Prior art and problems to be solved by the invention]
In Japanese Patent No. 3131557, a non-heat-shrinkable fiber is provided on one side of a first fiber layer containing a heat-shrinkable fiber and a heat-fusible fiber made of a resin having a melting point lower than the heat-shrink start temperature of the heat-shrinkable fiber. A multi-layered nonwoven fabric in which a second fiber layer made of is laminated is described. Both fiber layers are integrated in the thickness direction by linear heat fusion, the heat fusion part is a concave part, and the space between the heat fusion parts is a convex part. A cocoon is formed. This multi-layered nonwoven fabric is obtained by laminating the first fiber layer and the second fiber layer and integrating the two fiber layers by heat fusion at a temperature lower than the heat shrink start temperature of the heat shrinkable fiber. The heat-shrinkable fiber is obtained by heat-shrinking the heat-shrinkable fiber by blowing hot air having a temperature equal to or higher than the heat-shrink temperature. However, in this nonwoven fabric, the thermal fusion between the first fiber layer and the second fiber layer depends on the thermal fusion fibers contained in the first fiber layer in an amount of 30 to 50% by weight. There is a limit to the bonding force. Therefore, when the first fiber layer is thermally contracted and when the nonwoven fabric is post-processed and used, the heat-sealed portion is easily peeled off. As a result, the uneven pattern may become unclear or a desired uneven shape may not be obtained. Further, since the shrinkage temperature of the heat-shrinkable fiber is higher than the melting point of the heat-fusible fiber, the heat-fusible fiber melts during shrinkage and the texture is poor, and is not suitable for a sheet that directly touches the skin.
In order to increase the bonding strength of both fiber layers, it is conceivable to increase the ratio of heat-fusible fibers to be contained in the first fiber layer, or to increase the temperature and pressure at the time of heat-sealing, There is a risk that the ratio of the heat-shrinkable fibers is lowered and the shrinkability of the first fiber layer is insufficient, and a desired uneven shape cannot be obtained. Moreover, in the latter, as a result of the heat-sealed portion becoming hard, the flexibility of the entire sheet is lowered and the texture is deteriorated.
In addition, when the above-mentioned multi-layered nonwoven fabric is used while being fixed to another material or the like, the surface on the first fiber layer side is fixed to the other material or the like, but the first fiber layer is contracted. Heat securing fibers cannot be used in large quantities to ensure strength, and heat-shrinking such as heat embossing is performed at a temperature lower than the shrinkage temperature of heat-shrinkable fibers, so heat-shrinkable fibers cannot be melted. Even if it is fixed by thermocompression bonding such as embossing, sufficient bonding strength cannot be obtained.
[0003]
  Accordingly, an object of the present invention is to provide a three-dimensional sheet that has a good texture, is excellent in thermocompression bonding to other materials, and can form desired irregularities during production.
[0004]
[Means for Solving the Problems]
  In the present invention, a second fiber layer mainly comprising non-heat-shrinkable fibers and containing heat-fusible fibers is laminated on one side of the first fiber layer containing heat-shrinkable fibers, It is a three-dimensional sheet in which a third fiber layer containing heat-fusible fibers is laminated on the other surface, and the first to third fiber layers form a heat-sealed portion of a predetermined pattern on the three-dimensional sheet. The heat fusion part extends from the second fiber layer to the third fiber layer and extends in the thickness direction of the three-dimensional sheet in the part where the heat fusion part is formed, and the second fiber In the layer, a portion other than the heat fusion part is convex, and the amount of heat-shrinkable fibers contained in the first fiber layer is 70 to 100% by weight with respect to the weight of the first fiber layer. The amount of heat-fusible fiber contained in the second fiber layer is 70 to 100% by weight with respect to the weight of the second fiber layer, The amount of Murrell heat-fusible fibers is 70 to 100% by weight relative to the weight of the third fiber layer,The heat-fusible fiber included in the second and third fiber layers includes a heat-fusion resin having a melting point lower than the melting point of the heat-shrinkable fiber, and the heat-fusion part is included in the second fiber layer. The heat-fusible resin of the heat-fusible fiber and the heat-fusible resin of the heat-fusible fiber contained in the third fiber layer are formed by melting and penetrating into the first fiber layer and adhering to each other. ing,The object is achieved by providing a three-dimensional sheet. Note that the heat-fusible fiber and the heat-fusible fiber have the same meaning.
[0006]
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described below based on preferred embodiments with reference to the drawings.
FIG. 1 schematically shows a cross-sectional view of a three-dimensional sheet 10 as an embodiment of the present invention (first invention). The three-dimensional sheet 10 has three layers in which the second fiber layer 2 is laminated on one side of the first fiber layer 1 containing heat-shrinkable fibers and the third fiber layer 3 is laminated on the other side of the first fiber layer 1. It has a structure. The first fiber layer 1 is composed of an aggregate of fibers. On the other hand, the 2nd fiber layer 2 and the 3rd fiber layer 3 are comprised from the aggregate | assembly of the fiber of a kind and / or a compound which are different from the fiber which comprises the 1st fiber layer 1, respectively. The 2nd fiber layer 2 and the 3rd fiber layer 3 are comprised from the aggregate | assembly of the fiber of the same kind and a mixing | blending, or the aggregate of the fiber of a different kind and / or a mixing | blending.
[0007]
  When the three-dimensional sheet 10 is viewed in plan, the three-dimensional sheet 10 is formed with a heat-sealed portion 4 having a rhombic lattice pattern shown in FIG. The heat fusion part 4 is formed by partially thermocompression bonding the first to third fiber layers in the laminated state.
  The heat fusion part 4 extends from the second fiber layer 2 to the third fiber layer 3. The joint portion between the second fiber layer and the first fiber layer and the joint portion between the first fiber layer and the third fiber layer are completely overlapped in a state in which the three-dimensional sheet 10 is viewed in plan. The heat fusion part 4 is formed by melting and solidifying the heat fusion resin. As will be described later, the heat-sealing resin isThisIn the form of a heat-fusible fiber containing these, it is contained in the second fiber layer 2 and the third fiber layer 3, and the heat-fusion resin of these two fiber layers is completely dissolved in the resin of the first fiber layer. Even if not, it melts and permeates and adheres to each other, allowing three layers to be bonded. Further, it is preferably contained in the first fiber layer as desired. It is preferable that the heat fusion part 4 extends from the second fiber layer to the third fiber layer in all of the individual heat fusion parts of the three-dimensional sheet 10, Over the whole area in the thickness direction of the three-dimensional sheet.
  In addition, although each heat-fusion part in this embodiment is circular, the shape of each heat-fusion part may be an ellipse, a triangle, a rectangle, or a combination thereof. Moreover, you may form a junction part in continuous shape, for example, linear form, such as a straight line and a curve. The formation pattern of the heat fusion part 4 can also be made into a pattern as shown, for example in FIG.2 (b) and FIG.2 (c).
[0008]
The area ratio of the heat-sealed part 4 to the area of the three-dimensional sheet 10 (the area of the heat-fused part 4 per unit area of the three-dimensional sheet 10) depends on the specific application of the three-dimensional sheet 10, but the first to first Formation of the heat-sealed portion 4 from the point of sufficiently increasing the bonding strength of the fiber layer 3 and the formation of a bulky shape by sufficiently forming a convex three-dimensional shape by deformation of the second fiber layer. It is preferably 3 to 50%, particularly 5 to 35% before and after heat shrinkage of the first fiber layer 1, and 6 to 90%, particularly 10 to 70% after heat shrinkage.
[0009]
The three-dimensional sheet 10 is heat-treated at a temperature equal to or higher than the shrinkage start temperature of the heat-shrinkable fibers contained in the first fiber layer 1 after the first to third fiber layers in the laminated state are partially thermocompressed and integrated. It is manufactured, and the portions other than the heat-sealed 4 parts of the second fiber layer 2 are convex due to the thermal contraction of the first fiber layer. In the present embodiment, as shown in FIG. 2A, the three-dimensional sheet 10 has a large number of closed regions surrounded by the heat-sealed portions 4 each having a rhombus lattice pattern. In each region, the second fiber layer 2 is deformed into a dome-like convex shape. On the other hand, the heat-sealing part 4 is relatively recessed as compared with the part (also referred to as the convex part 5) in which the second fiber layer 2 has a convex shape, whereby the second fiber layer side of the three-dimensional sheet 10 is The surface is formed with a concavo-convex shape including a large number of convex portions and concave portions. In this embodiment, the same uneven | corrugated shape is formed also in the 3rd fiber layer 3 side by shrinkage | contraction of the 1st fiber layer 1. FIG.
[0010]
The first fiber layer 1 includes heat-shrinkable fibers. This heat-shrinkable fiber is in a heat-shrinked state in the three-dimensional sheet 10. Known heat-shrinkable fibers can be used without particular limitation. It is preferable to use latent crimpable fibers as the heat-shrinkable fibers because the first fiber layer 1 is imparted with elastomeric properties, and the three-dimensional sheet 10 as a whole also exhibits elastomeric properties. When the three-dimensional sheet 10 has an elastomeric property, when the three-dimensional sheet 10 is used as a constituent member of a disposable absorbent article, which will be described later, for example, the followability to the wearer's movement becomes good, and the fit of the absorbent article Is improved, and liquid leakage is effectively prevented.
[0011]
The latent crimpable fiber includes, for example, an eccentric core-sheath type composite fiber or a side-by-side type composite fiber containing two types of thermoplastic polymer materials having different shrinkage rates as components. Examples thereof include those described in JP-A-9-296325 and Japanese Patent No. 2759331. Examples of two thermoplastic polymer materials having different shrinkage rates include, for example, a combination of ethylene-propylene random copolymer (EP) and polypropylene (PP), polyethylene terephthalate (PET), polyethylene terephthalate and polyethylene isophthalate. And a combination with a copolymer (CoPET). The heat-shrinkable fibers may be short fiber staple fibers or long fiber filaments. The thickness is preferably about 1 to 7 dtex.
The heat shrink start temperature of the heat shrinkable fiber can be set to 90 to 110 ° C., for example. The heat shrinkage start temperature is an actually measured temperature when the fiber starts to shrink substantially when the fiber is placed in a furnace capable of raising the temperature and heated at a constant speed.
[0012]
  The first fiber layer 1 may be made of 100% heat-shrinkable fibers or may contain other fibers. As other fibers to be included in the first fiber layer 1, heat fusion to be described latersexHeat fusion contained in fibers, eg second and / or third fiber layerssexFiber.
  Even if the first fiber layer 1 contains other fibers, the amount of the heat-shrinkable fibers is the first fiber from the viewpoint of preventing the shrinkage of the heat-shrinkable fibers from being inhibited during the production of the three-dimensional sheet. 70% by weight or more based on the weight of layer 1And preferably90-100% by weight.
[0013]
As a form of the 1st fiber layer 1 before heat-shrinking, the web in which a constituent fiber is in an unjoined state, or a nonwoven fabric is mentioned. As the 1st fiber layer 1 which is the form of a web, the web containing the heat-shrinkable fiber and formed by the card | curd method is mentioned. As the 1st fiber layer 1 which is a form of a nonwoven fabric, the nonwoven fabric manufactured with the various nonwoven fabric manufacturing methods containing a heat-shrinkable fiber is mentioned. Examples of the nonwoven fabric production method include a thermal fusion method, a hydroentanglement method, a needle punch method, a solvent adhesion method, a spun bond method, and a melt blown method.
[0014]
The second fiber layer 2 is mainly composed of non-heat-shrinkable fibers. In the present specification, the non-heat-shrinkable fiber means a fiber that does not exhibit heat-shrinkability, and heat-shrinkability, but substantially does not heat at a temperature lower than the heat-shrink start temperature of the heat-shrinkable fiber contained in the first fiber layer. Includes both non-shrinkable fibers.
The amount of non-heat-shrinkable fiber in the second fiber layer 2 is at least 70% by weight, preferably 90% by weight or more, particularly 100% by weight, based on the weight of the second fiber layer 1. It is preferable from the point that the first fiber layer becomes more three-dimensional.
From the viewpoint of adjusting stericity and shrinkage, the second fiber layer may contain about 10 to 30% by weight of heat-shrinkable fibers similar to the heat-shrinkable fibers in the first fiber layer. preferable.
[0015]
  The second fiber layer 2 and the third fiber layer 3 each include a heat-fusible fiber. The heat-fusible fiber includes a heat-sealing resin, and the fibers can be fused together by melting and solidifying the resin.
  The heat-fusible fibers contained in the second fiber layer 2 and the third fiber layer 3 each contain a heat-fusible resin having a melting point lower than that of the heat-shrinkable fibers contained in the first fiber layer 1.It is out. ThisFurther improve the bonding strength of the heat-sealed partbe able to. When the heat-shrinkable fiber in the first fiber layer is a core-sheath type (eccentric or concentric type) composite fiber or a side-by-side type composite fiber, it is included in the second and third fiber layers. The heat-fusible fiber is made of a resin having a melting point lower than the melting point of both the sheath component of the core-sheath type composite fiber or the side-by-side type composite fiber.Including.
Here, the melting point of the heat-shrinkable fiber refers to a peak value when the heat of fusion is measured by DSC (differential scanning calorimeter).
[0016]
The melting point of the heat-sealing resin in the heat-fusible fiber contained in the second fiber layer 2 and the third fiber layer 3 is 10 ° C. or more, particularly 20 ° C. or more lower than the melting point of the heat-shrinkable fiber of the first fiber layer. This is preferable from the viewpoint that the heat-fusible fibers contained in the second fiber layer can be melted and bonded without shrinking the first fiber layer that touches the skin. When the heat-fusible fiber is a multicomponent composite fiber, it is preferable that the heat-fusible resin having the lowest melting point is lower than the melting point of the heat-shrinkable fiber of the first fiber layer.
Further, the melting point of the heat-sealing resin in the heat-fusible fiber contained in the second fiber layer 2 and the third fiber layer 3 is 30 ° C. or higher than the heat shrink temperature of the heat-shrinkable fiber of the first fiber layer, In particular, a temperature lower by 40 ° C. or more is preferable from the viewpoint that the heat-sealable fiber contained in the second fiber layer can be melted and bonded with sufficient adhesive strength without contracting the first fiber layer.
[0017]
Furthermore, the melting point of the heat-sealing resin in the heat-sealing fiber contained in the second fiber layer 2 is the same as the melting point of the heat-sealing resin in the heat-sealing fiber contained in the third fiber layer 3. Or the difference in melting point between these two heat-sealing resins is within 20 ° C., particularly within 10 ° C., can further improve the bonding strength of the first to third fiber layers, It is preferable from the point that the temperature condition of the heat treatment for converting to a low temperature can be performed at a relatively low temperature and the texture of the three-dimensional sheet can be further improved.
[0018]
  The heat fusion contained in the second fiber layer from the viewpoint of improving the bonding strength between the fiber layers in the heat fusion part 4 and improving the texture of the three-dimensional sheet.sexThe amount of the fiber is 70 to 100% by weight with respect to the weight of the second fiber layer 2And preferably90-100% by weight.
  Thermal fusion contained in the third fiber layersexThe amount of the fibers is from the point of improving the bonding strength between the fiber layers in the heat-sealing part 4 and improving the texture of the three-dimensional sheet, and improving the thermocompression bonding property to other materials, particularly the fiber material. 70 to 100% by weight based on the weight of the three fiber layers 2And preferably90-100% by weight.
[0019]
Examples of heat-fusible fibers contained in the second fiber layer 2 and the third fiber layer 3 include polyethylene (PE), polypropylene (PP), polyethylene-propylene copolymer, polyethylene terephthalate (PET), polybutylene terephthalate, and the like. Polyester, polyethylene terephthalate-ethylene isophthalate copolymer, polyamide ethylene acrylic acid copolymer, ethylene-methyl acrylate copolymer, ethylene-methacrylic acid copolymer, ethylene-methyl methacrylate copolymer, ethylene-methacrylic acid Examples thereof include fibers composed of an acid ethyl copolymer, an ethylene-methyl acrylate-acrylic terpolymer, and the like. A core-sheath type composite fiber or a side-by-side type composite fiber made of a combination of these thermoplastic polymer materials can also be used. These fibers may be staple fiber staples or filament filaments. The thickness is preferably about 1 to 7 dtex. The same thing as these can be used for the heat-fusion fiber in the case of including the heat-fusion fiber in the first fiber layer 1.
[0020]
As a form of the 2nd and 3rd fiber layer 2 before the 1st fiber layer 1 heat-shrinks, the web or nonwoven fabric in which a constituent fiber is in an unjoined state is mentioned. The form of the second fiber layer and the third fiber layer 2 before heat shrinking may be the same or different.
When the form of the second fiber layer is a web form in particular, it becomes easy to change the area or shape of the second fiber layer 2 by shrinkage, and the second fiber layer 2 can be raised in a convex shape in the thickness direction. Since it becomes easy, it is preferable. Moreover, since the inside of the raised convex part is satisfy | filled with a fiber, since the sheet | seat which is rich in cushioning and has a soft texture is obtained, it is preferable. When the second fiber layer 2 and / or the third fiber layer 3 is in the form of a web, the web can be formed by, for example, a card method. The three-dimensional sheet 10 in which the second fiber layer 2 is formed from such a web is formed with a convex portion 5 that is bulky and filled with fibers constituting the web, and the fibers are along the convex portion 5. Orient. In particular, when the second fiber layer 2 is in the form of a web formed by a card method, the second fiber layer 2 has a very sparse structure, and the three-dimensional sheet 10 of the present invention can transmit and retain a liquid having a high viscosity. Is possible. Moreover, the compression deformability when the three-dimensional sheet 10 is compressed in the thickness direction is also increased. Examples of the liquid having a high viscosity include soft stool or menstrual blood, anti-personal detergent or humectant, or objective detergent.
On the other hand, when the form of the second fiber layer is a non-woven fabric before joining and shrinking, there are advantages of good transportability and high strength. Moreover, since it is not necessary to fuse the constituent fibers of the second fiber layer after joining with the first fiber layer, there is also an advantage that the selection range of the shrinkage temperature is wide.
[0021]
The three-dimensional sheet 10 of this embodiment manufactures a 1st-3rd fiber layer, respectively using a well-known method, for example, and the 1st fiber layer 1 is provided between the 2nd fiber layer 2 and the 3rd fiber layer 3. After superposing these layers so as to be sandwiched, the laminated first to third fiber layers are partially thermocompression-bonded in a predetermined pattern by a hot embossing roll device composed of concavo-convex rolls or concavo-convex rolls and smooth rolls, and then The heat-shrinkable fiber is obtained by shrinking the heat-shrinkable fiber by heat treatment at a temperature equal to or higher than the heat shrinkage start temperature of the heat-shrinkable fiber contained in the first fiber layer 1. As a method for the heat treatment, a method of passing microwaves, steam, infrared rays, a heat roll, or the like can be used in addition to a method in which hot air is passed or blown through the first and third laminated fiber layers.
[0022]
According to the three-dimensional sheet 10 of the present embodiment, the heat-sealed portion 4 having a predetermined pattern is formed so as to extend from the second fiber layer to the third fiber layer in a state in which the three-dimensional sheet 10 is viewed in plan. In addition, the bonding strength from the second fiber layer to the third fiber layer in the heat-sealing part 4 can be improved. Therefore, for example, thermocompression bonding at the time of manufacture can be performed under relatively low temperature conditions while maintaining sufficient contractility of the first fiber layer and sufficient bonding strength from the second fiber layer to the third fiber layer. . Therefore, it is possible to obtain a three-dimensional sheet having a soft and soft texture.
[0023]
In addition, the third fiber layer side is subjected to thermocompression bonding (thermal embossing or the like) toward another material or the like (also referred to as an object to be fixed 6) to fix the three-dimensional sheet 10, thereby the three-dimensional sheet 10 is The other material or the like can be strongly thermocompression bonded, and separation between the three-dimensional sheet 10 and the fixed object is unlikely to occur.
[0024]
In FIG. 3, the three-dimensional sheet 10 having the above-described configuration is attached to an absorbent body 61 and a leak-proof sheet 62 of a sanitary napkin (absorbent article) as a fixed object 6 made of a fiber material by heat embossing. A state in which the fiber layer side is fixed with the fixed object side is shown.
That is, the three-dimensional sheet 10 is thermocompression bonded to the surface of the absorbent body 61 on the skin contact surface side by heat embossing by a heat seal device in the central region of the sanitary napkin. An annular central leakage prevention groove is formed on the skin contact surface of the napkin for use. Further, the three-dimensional sheet 10 is thermocompression-bonded on a leak-proof sheet disposed on the absorbent body 61 by heat embossing by a heat seal device at both sides in the longitudinal direction of the sanitary napkin. A pair of side leakage preventing grooves are formed on both sides of the central leakage preventing groove on the skin contact surface of the sanitary napkin by the crimping portion 72. The surface of the absorber in the thermocompression bonding part 71 is formed by a mount made of a cellulosic fiber material, and the leak-proof sheet 62 in the thermocompression bonding part 72 is obtained by laminating polyethylene on a cellulosic fiber material. It is configured. In addition, since the leak-proof sheet 62 has better adhesiveness, the laminate (polyethylene) side was used with the surface sheet side facing (the same applies to Examples and Comparative Examples described later).
[0025]
In both the thermocompression bonding parts 71 and 72, since the heat-sealing resin in the third fiber layer is melted and solidified in a state where the heat-bonding resin in the third fiber layer is caught between the constituent fibers of the fixed object 6 during the heat embossing by the heat seal device, Peeling is unlikely to occur between 10 and these fixed objects 6.
In addition, as a heat seal apparatus, a sanitary napkin, a disposable diaper, etc. can use the heat seal apparatus for groove | channel formation conventionally used, the heat seal apparatus for end seal part formation, etc. In addition, in FIG. 3, illustration of the unevenness | corrugation etc. which were formed in the surface of the solid sheet 10 is abbreviate | omitted. In the sanitary napkin shown in FIG. 3, the three-dimensional sheet 10 is used as a liquid-permeable surface material (surface sheet), and between the three-dimensional sheet 10 and the liquid-impermeable back material (back surface sheet) 8. In addition, a liquid-retaining absorbent 61 is interposed. The three-dimensional sheet 10 is fixed to the leak-proof sheet 62 and the back material 8 with a hot melt adhesive 91 in the vicinity of both sides of the absorber 61, and the leak-proof sheet 62 is attached to the back material 8 with a hot melt adhesive 92. It is fixed.
[0028]
The present invention is not limited to the embodiment.
The three-dimensional sheet of the present invention is suitably used as a component of a disposable article that is discarded, for example, once or several times. It can also be used as a female material (loop material) or a poultice material for hook and loop fasteners. In particular, it is suitable as a component of disposable absorbent articles such as sanitary napkins and disposable diapers, and disposable wipers such as cleaning wipers and interpersonal wipers. When used as a component member of a disposable absorbent article, for example, an absorbent article having a liquid-permeable surface material, a liquid-impermeable back material, and an absorbent body interposed between both sheets, the component member It can be used as a part of any of the members, for example, any member of the front surface material, the back surface material, or the side solid guard.
[0029]
When the solid sheet of the present invention is used by being fixed to another material or the like (fixed object) by hot embossing, and as the fixed object for fixing the three-dimensional sheet in the fixing method of the three-dimensional sheet, a base sheet of a disposable wiper, etc. Is mentioned. However, the effect of the present invention is particularly effective in the case of an object to be fixed made of a fiber material, in particular, in the case of a flexible object to be fixed that is deformed by compression, such as an absorbent body of a disposable absorbent article such as a sanitary napkin or a disposable diaper described above. It is particularly prominently expressed.
[0030]
Hereinafter, the present invention will be described in more detail with reference to examples. However, the scope of the present invention is not limited to such embodiments.
[0031]
〔Example〕
(1) Production of the first fiber layer
Latent crimped core-sheath type composite fiber (trade name CPP, core: polypropylene (melting point: 165 to 170 ° C.), sheath: ethylene / propylene copolymer (melting point: 145 to 147 ° C.) manufactured by Daiwabo Polytech Co., Ltd. as heat shrinkable fiber The core / sheath weight ratio was 5/5, the fineness was 2.2 dtex, the fiber length was 51 mm, and the thermal shrinkage starting temperature was 90 ° C.). Using this fiber as a raw material, a web was formed by a roller card, and then passed through an embossing roll (embossing rate 28%, temperature condition: pattern 145 ° C., speed 80 m / min), passing through a cooling roll, and a basis weight of 20 g / m2A heat roll nonwoven fabric of the first fiber layer was formed.
[0032]
(2) Production of second fiber layer
Core-sheath type composite fiber (trade name SHW6, core: polyethylene terephthalate (melting point: 250-255 ° C.), sheath: polyethylene (melting point: 128-130 ° C.), core / sheath weight ratio = 5 manufactured by Daiwabo Polytech Co., Ltd. / 5, fineness 2.2 dtex, fiber length 51 mm). Using this fiber as a raw material, a web was formed by a roller card, and then passed through an air-through heat treatment machine (temperature: 138 m / min, through-air speed: 1 m / sec, treatment time: about 10 seconds), basis weight of 12 g / m2An air-through nonwoven fabric of the second fiber layer was formed.
[0033]
(3) Production of third fiber layer
An air-through nonwoven fabric obtained in the same manner as in the production of the second fiber layer was used as the third fiber layer.
[0034]
(4) Production of solid sheet
The said 1st-3rd fiber layer was piled up, and it bonded together with the embossing roll (Pattern roll 145 degreeC, flat roll 135 degreeC, C dot diameter 1.5mm of embossing pattern figure 2, area ratio 7.4%). After that, heat shrinkage processing (up and down wind speed of about 4.2m, temperature of 110 ° C to 116 ° C, processing time of about 14 seconds) is quickly performed with a pin tenter, and the machine setting is set to 70% length and 70% width before processing. Shrink. The basis weight of the obtained nonwoven fabric is about 84 g / m.2was.
[0035]
[Comparative Example]
In the manufacture of the three-dimensional sheet in the example, a three-dimensional sheet was obtained in the same manner as in the example, except that the third fiber layer was not used and then bonded together and then contracted.
[0036]
[Performance evaluation]
Using each of the obtained three-dimensional sheets as a surface material for absorbent articles, 100 or more sanitary napkins having a cross-sectional configuration shown in FIG. 3 were continuously produced for each sheet. Each three-dimensional sheet has an absorbent body 61 (basis weight of about 250 g / m) by heat sealing (heat embossing) at a temperature of 190 ° C.2) Mount (basis weight about 16g / m)2) And a water-repellent polyethylene sheet laminated by heat sealing (heat embossing) at a temperature of 200 ° C. (lamination basis weight of about 7 g / m)2Paper basis weight 16g / m2).
For each of the manufactured sanitary napkins, the sealability in the thermocompression bonding part 71 fixed on the absorbent body 61 and the thermocompression bonding part 72 fixed on the leak-proof sheet 62 is observed by visual observation of the presence or absence of lifting of the pattern part, The number of napkins determined to have no problem in the appearance of the thermocompression bonding part according to the following evaluation criteria (good appearance) is shown in Table 1 (N = 100).
[0037]
<Evaluation criteria>
Appearance is good; adheres clearly to the base material as the seal block is shaped and does not float at all
Appearance failure; even a small part of the seal block mold may be blurred or partially or completely floating
[0038]
[Table 1]
Figure 0003883460
[0039]
As is clear from the results shown in Table 1, the three-dimensional sheet of the example (product of the present invention) is excellent in thermocompression bonding to the absorbent body and the leak-proof sheet, and is fixed to other materials, particularly fiber materials. It turns out that it is excellent in the thermocompression bonding property.
On the other hand, the three-dimensional sheet of the comparative example has a problem in product performance because a part of the seal block mold is slightly blurred or partially or entirely floated.
[0040]
【The invention's effect】
  The three-dimensional sheet of the present invention has a good texture, is excellent in thermocompression with respect to other materials, and can form desired irregularities during production.
[Brief description of the drawings]
FIG. 1 is a schematic cross-sectional view showing a three-dimensional sheet as an embodiment of the three-dimensional sheet of the present invention (first invention) together with an object to be fixed when used.
FIG. 2 is a plan view illustrating an example of a formation pattern of a heat-sealed portion formed on a three-dimensional sheet.
FIG. 3 is a schematic cross-sectional view showing a cross-section in the width direction of a sanitary napkin (absorbent article) manufactured using a three-dimensional sheet.
[Explanation of symbols]
  10 Solid sheet
  1 First fiber layer
  2 Second fiber layer
  3 Third fiber layer
  4 heat fusion part
  5 Convex

Claims (4)

熱収縮した熱収縮性繊維を含む第１繊維層の片面に、非熱収縮性繊維を主体とし且つ熱融着性繊維を含む第２繊維層が積層され、第１繊維層の他面に、熱融着性繊維を含む第３繊維層が積層された立体シートであって、
第１〜第３繊維層が、前記立体シートに所定パターンの熱融着部を形成しており、
前記熱融着部は、第２繊維層から第３繊維層に亘っており且つ該熱融着部が形成されている部分における前記立体シートの厚み方向の全域に亘っており、
第２繊維層は、前記熱融着部以外の部分が凸状をなしており、
第１繊維層に含まれる熱収縮性繊維の量が、第１繊維層の重量に対して７０〜１００重量％であり、
第２繊維層に含まれる熱融着性繊維の量が、第２繊維層の重量に対して７０〜１００重量％であり、第３繊維層に含まれる熱融着性繊維の量が、第３繊維層の重量に対して７０〜１００重量％であり、
第２及び第３繊維層に含まれる熱融着性繊維は、前記熱収縮性繊維の融点よりも融点の低い熱融着樹脂を含み、前記熱融着部は、第２繊維層に含まれる熱融着性繊維の熱融着樹脂と第３繊維層に含まれる熱融着性繊維の熱融着樹脂とが、それぞれ第１繊維層中に溶融して浸透し、互いに接着して形成されている、立体シート。A second fiber layer mainly comprising non-heat-shrinkable fibers and containing heat-fusible fibers is laminated on one side of the first fiber layer containing heat-shrinkable fibers, and on the other side of the first fiber layer, A three-dimensional sheet in which a third fiber layer containing heat-fusible fibers is laminated,
The first to third fiber layers form a heat-sealed portion of a predetermined pattern on the three-dimensional sheet,
The heat fusion part extends from the second fiber layer to the third fiber layer and extends in the entire thickness direction of the three-dimensional sheet in the part where the heat fusion part is formed,
The second fiber layer has a convex portion other than the heat fusion part,
The amount of heat-shrinkable fibers contained in the first fiber layer is 70 to 100% by weight with respect to the weight of the first fiber layer,
The amount of heat-fusible fiber contained in the second fiber layer is 70 to 100% by weight with respect to the weight of the second fiber layer, and the amount of heat-fusible fiber contained in the third fiber layer is 70 to 100% by weight based on the weight of the three fiber layers,
The heat-fusible fiber included in the second and third fiber layers includes a heat-fusion resin having a melting point lower than the melting point of the heat-shrinkable fiber, and the heat-fusion part is included in the second fiber layer. The heat-fusible resin of the heat-fusible fiber and the heat-fusible resin of the heat-fusible fiber contained in the third fiber layer are respectively melted and penetrated into the first fiber layer and bonded to each other. A solid sheet. 第２繊維層が、第１繊維層中に含まれる熱収縮性繊維と同様の熱収縮性繊維を１０〜３０重量％含有している、請求項１記載の立体シート。  The three-dimensional sheet according to claim 1, wherein the second fiber layer contains 10 to 30 wt% of heat-shrinkable fibers similar to the heat-shrinkable fibers contained in the first fiber layer. 第２繊維層に含まれる熱融着性繊維中の熱融着樹脂の融点と、第３繊維層に含まれる熱融着性繊維中の熱融着樹脂の融点とが同じであるか、又はこれら２つの熱融着樹脂の融点の差が２０℃以内である請求項１又は２記載の立体シート。The melting point of the heat-sealing resin in the heat-fusible fiber contained in the second fiber layer and the melting point of the heat-sealing resin in the heat-fusible fiber contained in the third fiber layer are the same, or The three-dimensional sheet according to claim 1 or 2, wherein the difference between the melting points of these two heat-sealing resins is within 20 ° C. 繊維材料からなる被固定物に、熱エンボス加工により、第３繊維層側を被固定物側にして固定されている請求項１〜３の何れか記載の立体シート。The three-dimensional sheet according to any one of claims 1 to 3 , wherein the three-dimensional sheet is fixed to a fixed object made of a fiber material by heat embossing so that the third fiber layer side is the fixed object side.
JP2002084397A 2002-03-25 2002-03-25 3D sheet Expired - Fee Related JP3883460B2 (en)

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