JP4368297B2 - 3D sheet - Google Patents
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- JP4368297B2 JP4368297B2 JP2004370542A JP2004370542A JP4368297B2 JP 4368297 B2 JP4368297 B2 JP 4368297B2 JP 2004370542 A JP2004370542 A JP 2004370542A JP 2004370542 A JP2004370542 A JP 2004370542A JP 4368297 B2 JP4368297 B2 JP 4368297B2
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Description
本発明は、使い捨ておむつ、生理用ナプキン、パンティライナー（おりものシート）、失禁パッド等の吸収性物品の表面シート等に好ましく用いられる立体シートに関する。 The present invention relates to a three-dimensional sheet preferably used for a surface sheet of an absorbent article such as a disposable diaper, a sanitary napkin, a panty liner (corimono sheet), and an incontinence pad.
使い捨ておむつや生理用ナプキン等の吸収性物品の表面シートとして、着用者の肌に当接される面に凹凸を形成したものが知られている。
凹凸を有する表面シートによれば、凹凸の存在により着用者の肌との接触面積が低減するので、べたつき感やムレの低減を図ることができる。特に、積層された２枚のシートからなり、一方のシートによって凹凸形状を形成したものは、クッション感等に優れている。例えば、本出願人は、互いに積層された上層と下層と部分的に接合されて接合部が形成され、該上層が接合部以外の部分において着用者の肌側に向かって突出して、多数の凸部が形成されている表面シートを提案した（特許文献１参照）。
また、凹凸を有する表面シートとして、不織布製のシートに、吸収体に向かって延びる導液管を形成した表面シートが知られており（特許文献２参照）、また、本出願人は、２層の不織布からなり立体的な開孔を有する表面シートであって、該開孔の周縁部において両不織布が互いに接合されている表面シートを提案した（特許文献３参照）。
As a surface sheet of an absorbent article such as a disposable diaper or a sanitary napkin, there is known one having irregularities formed on a surface that comes into contact with a wearer's skin.
According to the surface sheet having unevenness, the contact area with the wearer's skin is reduced due to the presence of the unevenness, so that it is possible to reduce stickiness and stuffiness. In particular, a sheet composed of two laminated sheets and having a concavo-convex shape formed by one sheet is excellent in a cushion feeling and the like. For example, the applicant of the present invention has joined the upper layer and the lower layer, which are laminated to each other, to form a joint, and the upper layer protrudes toward the wearer's skin at a portion other than the joint, and has a large number of protrusions. The surface sheet in which the part was formed was proposed (refer to patent documents 1).
Further, as a surface sheet having irregularities, a surface sheet in which a liquid guide tube extending toward an absorbent body is formed on a non-woven sheet is known (see Patent Document 2). The surface sheet which consists of the nonwoven fabric of this, and has a three-dimensional opening, Comprising: Both the nonwoven fabrics were mutually joined in the peripheral part of this opening (refer patent document 3).
特許文献１に係る表面シートは、液流れ防止性やクッション等に優れたものであるが、接合部における上層と下層の接合状態によっては、接合部が液不透過性となるため、接合部上に残った液が、ムレや肌への付着等の原因となる恐れがあった。
また、特許文献２及び３記載の表面シートは、導液管や立体的な開孔によって、吸収性の向上が見受けされるが、凸部の形状を維持する又はクッション効果を一層高める工夫がなされていない。
The surface sheet according to Patent Document 1 is excellent in liquid flow prevention, cushioning, and the like. However, depending on the bonding state of the upper layer and the lower layer in the bonding portion, the bonding portion becomes liquid-impermeable, and thus on the bonding portion. The remaining liquid may cause stuffiness or adhesion to the skin.
In addition, the surface sheets described in Patent Documents 2 and 3 have improved absorbability due to liquid introduction pipes and three-dimensional openings, but are devised to maintain the shape of the convex portions or further increase the cushioning effect. Not.
従って、本発明の目的は、液流れ防止性やクッション性、肌触り等に優れ、更に液の引き込み性に優れた立体シートを提供することにある。 Accordingly, it is an object of the present invention to provide a three-dimensional sheet that is excellent in liquid flow preventing property, cushioning property, touch and the like, and further excellent in liquid drawability.
本発明は、互いに積層された第１繊維シート及び第２繊維シートが部分的に熱融着されて熱融着部が形成され、第１繊維シートが、前記熱融着部以外の部分において突出して多数の凸部を形成している立体シートであって、前記熱融着部は、開孔を有し、該開孔は、繊維状部分によって分断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。 In the present invention, the first fiber sheet and the second fiber sheet laminated to each other are partially heat-sealed to form a heat-sealing portion, and the first fiber sheet protrudes at a portion other than the heat-sealing portion. A plurality of convex portions, wherein the heat-sealed portion has an opening, and the opening is provided by providing a three-dimensional sheet that is divided by a fibrous portion. The goal has been achieved.
本発明の立体シートは、液流れ防止性やクッション性、肌触り等に優れ、更に液の引き込み性に優れており、特に、吸収性物品用の表面シートとして好ましく用いられる。 The three-dimensional sheet of the present invention is excellent in liquid flow preventing property, cushioning property, touch and the like, and further excellent in liquid drawability, and is particularly preferably used as a surface sheet for absorbent articles.
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、本発明の一実施形態としての立体シート１０が示されている。図１に示す立体シート１０は、吸収性物品用の表面シートであり、使い捨ておむつ、生理用ナプキン、パンティライナー（おりものシート）、失禁パッドなどの吸収性物品の肌当接面に用いられるものである。
立体シート１０は、互いに積層された第１不織布（第１繊維シート）１及び第２不織布（第２繊維シート）２とからなる。第１不織布１は、立体シート１０を吸収性物品の表面シートとして用いたときに、着用時に着用者の肌側に向けられる面（肌当接面）を形成し、第２不織布２は、着用時に吸収体側に向けられる面（非肌当接面）を形成する。
The present invention will be described below based on preferred embodiments with reference to the drawings.
FIG. 1 shows a three-dimensional sheet 10 as an embodiment of the present invention. The three-dimensional sheet 10 shown in FIG. 1 is a surface sheet for absorbent articles, and is used for skin contact surfaces of absorbent articles such as disposable diapers, sanitary napkins, panty liners (ororimono sheets), and incontinence pads. It is.
The three-dimensional sheet 10 includes a first non-woven fabric (first fiber sheet) 1 and a second non-woven fabric (second fiber sheet) 2 stacked on each other. When the three-dimensional sheet 10 is used as the top sheet of the absorbent article, the first nonwoven fabric 1 forms a surface (skin contact surface) that is directed to the wearer's skin when worn, and the second nonwoven fabric 2 is worn. A surface (non-skin contact surface) that is sometimes directed to the absorber side is formed.
第１不織布１と第２不織布２とは部分的に熱融着されており、それにより多数の熱融着部４が形成されている。第１不織布１は、熱融着部４以外の部分において、第２不織布２側とは反対向きに突出して、内部空洞の多数の凸部５を形成している。凸部５は、立体シート１０を吸収性物品の表面シートとして用いたときに、着用者の肌に向かう方向に突出する。 The 1st nonwoven fabric 1 and the 2nd nonwoven fabric 2 are partially heat-sealed, and, thereby, many heat-fusion parts 4 are formed. The 1st nonwoven fabric 1 protrudes in the direction opposite to the 2nd nonwoven fabric 2 side in parts other than the heat-fusion part 4, and forms many convex parts 5 of an internal cavity. The convex part 5 protrudes in the direction which goes to a wearer's skin, when the solid sheet 10 is used as a surface sheet of an absorbent article.
凸部５及び熱融着部４は、立体シート１０の面と平行な一方向（図１中Ｘ方向，以下、Ｘ方向という）に、交互に且つ一列をなすように配置されており、そのような列が、立体シート１０の面と平行で且つ前記一方向に直交する方向（図１中Ｙ方向，以下、Ｙ方向という）に、多列に形成されている。
互いに隣接する列における凸部５及び熱融着部４は、それぞれ、Ｘ方向にずれて配置されており、より具体的には、半ピッチずれて配置されている。
凸部５は、Ｘ方向及びＹ方向の両方向において不連続である。
The convex portions 5 and the heat fusion portions 4 are arranged alternately and in a line in one direction parallel to the surface of the three-dimensional sheet 10 (X direction in FIG. 1, hereinafter referred to as X direction). Such rows are formed in multiple rows in a direction parallel to the surface of the three-dimensional sheet 10 and perpendicular to the one direction (the Y direction in FIG. 1, hereinafter referred to as the Y direction).
The convex portions 5 and the heat fusion portions 4 in the rows adjacent to each other are each shifted in the X direction, and more specifically, are shifted by a half pitch.
The convex part 5 is discontinuous in both the X direction and the Y direction.
尚、本実施形態の立体シート１０におけるＸ方向は、立体シート１０の製造工程における流れ方向と一致し、また立体シート１０が表面シートとして吸収性物品に組み込まれたときの該吸収性物品の長手方向又はそれと直交する方向と一致する。また、立体シート１０におけるＸ方向は、第１及び第２不織布それぞれにおける繊維の配向方向とも一致している。また、立体シート１０は、全体として見ると、その第２不織布２側の面がほぼ平坦であり、第１不織布１側に起伏の大きな凹凸が形成されている。 In addition, the X direction in the three-dimensional sheet 10 of this embodiment corresponds to the flow direction in the manufacturing process of the three-dimensional sheet 10, and the length of the absorbent article when the three-dimensional sheet 10 is incorporated into the absorbent article as a surface sheet. It coincides with the direction or the direction orthogonal thereto. Further, the X direction in the three-dimensional sheet 10 also coincides with the fiber orientation directions in the first and second nonwoven fabrics. Further, when viewed as a whole, the three-dimensional sheet 10 has a substantially flat surface on the second nonwoven fabric 2 side, and has large unevenness on the first nonwoven fabric 1 side.
立体シート１０における熱融着部４には、図２及び３に示すように、開孔４１が形成されている。開孔４１は、熱融着部４を厚み方向に貫通しており、図２には、そのような開孔４１が複数（４個）形成された熱融着部４が示されている。熱融着部４は、積層した第１不織布及び第２不織布を部分的に加熱及び加圧して熱融着させる際に、第１及び／又は第２不織布の構成繊維に由来する熱融着性成分が溶融固化して形成されている。開孔４１部分を除く熱融着部４においては、第１及び第２不織布の構成繊維は溶融するか溶融した樹脂に埋没して、目視においては繊維状の形態を観察できない。即ち、熱融着部４は、外観状フィルム化した状態となっている。熱融着部４の、開孔４１部分を除く部分４３は、液不透過性となっており、また、上下面が平滑となっている。 As shown in FIGS. 2 and 3, an opening 41 is formed in the heat fusion part 4 in the three-dimensional sheet 10. The opening 41 penetrates the heat fusion part 4 in the thickness direction, and FIG. 2 shows the heat fusion part 4 in which a plurality (four) of such holes 41 are formed. When the heat-bonding part 4 heats and pressurizes the laminated first nonwoven fabric and second nonwoven fabric partially and heat-fuses them, the heat-fusibility derived from the constituent fibers of the first and / or second nonwoven fabrics. The component is formed by melting and solidifying. In the heat-sealing part 4 excluding the opening 41 portion, the constituent fibers of the first and second nonwoven fabrics are melted or buried in the melted resin, and the fibrous form cannot be visually observed. That is, the heat sealing | fusion part 4 is in the state made into the external appearance film. A portion 43 of the heat fusion portion 4 excluding the opening 41 portion is liquid-impermeable, and the upper and lower surfaces are smooth.
開孔４１は、図２に示すように、繊維状部分４２によって分断されている。図２には、繊維状部分４２として、開孔４１の開口周縁の一カ所から該開口周縁の他の箇所に亘っているもの（図２中符号４２ａで示す）と、開孔４１の開口周縁の一カ所から他の箇所に亘っていないが、開孔４１上において、他の繊維状部分と交差しているもの（図２中符号４２ｂで示す）とが示されている。開孔４１の形状は、個々の開孔４１毎に異なっている。 As shown in FIG. 2, the opening 41 is divided by a fibrous portion 42. In FIG. 2, as the fibrous portion 42, a portion extending from one position of the opening periphery of the opening 41 to another position of the opening periphery (indicated by reference numeral 42 a in FIG. 2), and the opening periphery of the opening 41. Although it does not extend from one place to another place, it is shown on the opening 41 that intersects with another fibrous portion (indicated by reference numeral 42b in FIG. 2). The shape of the opening 41 is different for each opening 41.
立体シート１０は、開孔の個数が異なる熱融着部４を有しており、開孔の数は、０〜５個の間で分散している。立体シート１０においては、少なくとも一個の開孔を有する熱融着部４の数が、熱融着部の総数の５％以上である。 The three-dimensional sheet 10 has the heat fusion part 4 in which the number of openings is different, and the number of openings is dispersed between 0 and 5. In the three-dimensional sheet 10, the number of the heat fusion parts 4 having at least one hole is 5% or more of the total number of the heat fusion parts.
立体シート１０における熱融着部４の開孔４１は、各熱融着部４について複数形成されており、液透過性に一層優れている。各熱融着部４について複数という場合には、総ての熱融着部について複数の開孔が形成されている場合に加え、複数の開孔を有する熱融着部４の数が、熱融着部の総数の６０％以上の場合も含まれる。 A plurality of openings 41 of the heat-sealing part 4 in the three-dimensional sheet 10 are formed for each heat-sealing part 4, and the liquid permeability is further improved. In the case where there are a plurality of heat fusion portions 4, in addition to the case where a plurality of holes are formed for all the heat fusion portions, the number of the heat fusion portions 4 having a plurality of openings is the heat The case of 60% or more of the total number of fused portions is also included.
繊維状部分４２は、主として第１及び／又は第２不織布の構成繊維に由来する非熱融着性成分からなる。
即ち、熱融着部４の開孔４１内には、積層した第１不織布及び第２不織布を熱融着させる際の加熱温度では溶融しない非熱融着性成分からなる繊維や、そのような非熱融着性成分を一成分とする複合繊維の該成分が、繊維状の形態を維持したまま存在している。「主として・・・非熱融着性成分からなる」としたのは、繊維状の形態を維持した非熱融着性成分に、多少の熱融着性成分が付着している場合が多いからである。非熱融着性成分は、第１不織布と第２不織布とを熱融着させる際の加熱温度では、溶融しない成分であり、熱融着性成分は、第１不織布と第２不織布とを熱融着させる際の加熱温度で溶融する成分である。非熱融着性成分は、少なくとも熱融着性成分の融点では溶融しない。
The fibrous portion 42 is mainly composed of a non-heat-fusible component derived from the constituent fibers of the first and / or second nonwoven fabric.
That is, in the opening 41 of the heat-sealing part 4, a fiber made of a non-heat-sealable component that does not melt at the heating temperature when the first nonwoven fabric and the second nonwoven fabric that are laminated are thermally fused, The component of the composite fiber containing the non-heat-fusible component as one component is present while maintaining the fibrous form. “Mainly composed of non-heat-sealable components” is because some heat-sealable components often adhere to non-heat-sealable components that maintain a fibrous form. It is. The non-heat-fusible component is a component that does not melt at the heating temperature when the first nonwoven fabric and the second nonwoven fabric are heat-sealed. The heat-fusible component heats the first nonwoven fabric and the second nonwoven fabric. It is a component that melts at the heating temperature at the time of fusing. The non-heat-fusible component does not melt at least at the melting point of the heat-fusible component.
非熱融着性成分からなる繊維や、非熱融着性成分を一成分とする複合繊維等、非熱融着性成分を含む繊維は、第１不織布（第１繊維シート）又は第２不織布（第２繊維シート）の何れか一方のみに含まれていても、双方に含まれていても良いが、熱融着部４の強度を高め、繊維状部分形成を容易にする点、および熱融着部４形成時の加工容易さの点から第１不織布（第１繊維シート）に含まれていることが好ましい。
また、熱融着性成分からなる繊維や、熱融着性成分からなる鞘部を有する複合繊維等、熱融着性成分を含む繊維は、第１不織布又は第２不織布の何れか一方のみに含まれていても、双方に含まれていても良いが、熱融着部４の強度を高める点、および熱融着部４形成時の加工性（主に融着性）の加工容易さの点から第２不織布（第２繊維シート）に含まれていることが好ましい。
A fiber comprising a non-heat-sealable component, such as a fiber made of a non-heat-sealable component or a composite fiber having a non-heat-sealable component as one component, is a first nonwoven fabric (first fiber sheet) or a second nonwoven fabric. (Second fiber sheet) may be included in either one or both of them, but may increase the strength of heat fusion part 4 and facilitate formation of a fibrous part, and heat It is preferable that it is contained in the 1st nonwoven fabric (1st fiber sheet) from the point of the ease of processing at the time of fusion-bonding part 4 formation.
Moreover, the fiber containing a heat-fusible component, such as a fiber made of a heat-fusible component or a composite fiber having a sheath portion made of a heat-fusible component, is only on either the first nonwoven fabric or the second nonwoven fabric. Although it may be included in both, it may be included in both, but the point of increasing the strength of the heat-fused portion 4 and the workability of the heat-fused portion 4 formation (mainly fusing property) It is preferable that it is contained in the 2nd nonwoven fabric (2nd fiber sheet) from a point.
また、熱融着性成分と非熱融着性成分とは、融点の温度差が３０℃以上、特に５０℃以上であることが、接合力の高い熱融着部を形成しつつ、繊維状部分４２を形成させる観点から好ましい。また、熱融着の条件設定の自由度等の観点から、熱融着性成分は、融点が９０〜１７０℃であることが好ましく、非熱融着性成分の融点は、１５０〜３００℃であることが好ましい。 In addition, the temperature difference between the melting points of the heat-fusible component and the non-heat-fusible component is 30 ° C. or higher, particularly 50 ° C. or higher, while forming a heat-bonding portion having a high bonding strength, This is preferable from the viewpoint of forming the portion 42. Further, from the viewpoint of the degree of freedom in setting the conditions for heat-sealing, the heat-fusible component preferably has a melting point of 90 to 170 ° C, and the non-heat-fusible component has a melting point of 150 to 300 ° C. Preferably there is.
第１不織布と第２不織布の好ましい組合せの例としては、下記(ａ)〜（ｃ）が挙げられる。
（ａ）第１不織布が、非熱融着性成分を一部に有する繊維（芯鞘型繊維、サイドバイサイド型繊維、単繊維）を５０〜１００％含む不織布で、第２不織布が、非熱融着性成分を有しないか非熱融着性成分が熱融着性成分に覆われている熱融着性成分からなる繊維を５０〜１００％含む不織布。
（ｂ）第１不織布が、非熱融着性成分と熱融着性成分からなる繊維（芯鞘型繊維、サイドバイサイド型繊維）を５０〜１００％含む不織布で、第２不織布が、非熱融着性成分と熱融着性成分からなる繊維（芯鞘型繊維、サイドバイサイド型繊維）を５０〜１００％含む不織布。
（ｃ）第１不織布が、融点の高い熱融着性成分からなる繊維を５０〜１００％含む不織布で、第２不織布が、非熱融着性成分と融点が低い熱融着性成分からなる繊維を５０〜１００％含む不織布。
Examples of preferred combinations of the first nonwoven fabric and the second nonwoven fabric include the following (a) to (c).
(A) The first non-woven fabric is a non-woven fabric containing 50 to 100% of fibers (core-sheath fiber, side-by-side fiber, single fiber) having a non-heat-sealable component in part, and the second non-woven fabric is non-heat-melting. A non-woven fabric containing 50 to 100% of a fiber comprising a heat-fusible component that has no adhesive component or a non-heat-fusible component covered with a heat-fusible component.
(B) The first nonwoven fabric is a nonwoven fabric containing 50 to 100% of fibers (core-sheath type fiber, side-by-side type fiber) composed of a non-heat-sealable component and a heat-sealable component, and the second nonwoven fabric is non-heat-sealable. A nonwoven fabric containing 50 to 100% of fibers (core-sheath type fibers, side-by-side type fibers) composed of an adhesive component and a heat-fusible component.
(C) The first nonwoven fabric is a nonwoven fabric containing 50 to 100% of a fiber having a high melting point, and the second nonwoven fabric is composed of a non-heat-fusible component and a heat-fusible component having a low melting point. Nonwoven fabric containing 50 to 100% fiber.
立体シート１０における熱融着部４は、図３（ａ）に示すように、中央部分４Ａの厚みより周縁近傍部４Ｂの厚みが大きくなされている。これにより、熱融着部４における接合強度を高めることができ、開孔４１を形成しても、充分な接合強度を確保できる。 As shown in FIG. 3A, the heat-sealed portion 4 in the three-dimensional sheet 10 has a peripheral portion 4 </ b> B that is thicker than the central portion 4 </ b> A. Thereby, the joining strength in the heat fusion part 4 can be raised, and even if the opening 41 is formed, sufficient joining strength can be ensured.
また、立体シート１０における開孔４１は、各熱融着部４に、異なる大きさ及び／又は配置で形成されている。即ち、開孔４１は、不規則な大きさ及び／又は配置に形成されている。熱融着部４は、上述したように、開孔４１部分を除く部分の上面が平滑である上に、開孔４１が不規則に形成されている部分は熱融着部４の厚みが薄くなった結果であるので、相対的に開孔４１は熱融着部の最も吸収体に近い部分となり、熱融着部４上を移動した液が、開孔４１からその下の吸収体に吸液され易い。また、熱融着部４に不規則に形成された開孔４１は、ほぼ均一に開孔された場合に比べ、微小な濃淡を作り出すことができるため、液遮蔽の印象を高めることができる。 Moreover, the opening 41 in the three-dimensional sheet 10 is formed in each heat fusion part 4 with a different magnitude | size and / or arrangement | positioning. That is, the opening 41 is formed in an irregular size and / or arrangement. As described above, the heat-sealed portion 4 has a smooth upper surface except the portion of the opening 41, and the portion where the openings 41 are irregularly formed has a small thickness of the heat-sealing portion 4. As a result, the opening 41 is relatively close to the absorber of the heat fusion part, and the liquid that has moved on the heat fusion part 4 is absorbed by the absorber below the hole 41. Easy to be liquefied. In addition, since the openings 41 irregularly formed in the heat-sealed portion 4 can produce a fine shade as compared to the case where the openings are formed almost uniformly, the impression of liquid shielding can be enhanced.
更に、熱融着部と開孔部の境界では、（空気が疎水性であるため）液が進み難い（開孔に導かれ難い）現象がおこるが、開孔４１に繊維状部分４２が形成されているため、熱融着部４が液となじまない性質（疎水性／撥水性）であっても繊維状部分４２によって液が開孔４１に導かれ吸収を促進する。熱融着部４および繊維状部分４２が液となじみ易く表面処理（親水処理）がなされていると、より開孔４１に液が導かれ易い。 In addition, a phenomenon occurs in which the liquid does not easily travel (because the air is hydrophobic) at the boundary between the heat-sealed portion and the opening portion (it is difficult to be guided to the opening), but the fibrous portion 42 is formed in the opening 41. Therefore, even if the heat-sealed portion 4 does not blend with the liquid (hydrophobic / water repellency), the liquid is guided to the opening 41 by the fibrous portion 42 to promote absorption. If the heat-sealed portion 4 and the fibrous portion 42 are easily mixed with the liquid and subjected to surface treatment (hydrophilic treatment), the liquid is more easily guided to the opening 41.
本実施形態の立体シート１０によれば、吸収性物品の表面シートとして用いた場合、凸部５により良好なクッション性や肌触りが得られると共に、凸部５と熱融着部４とが形成する凹凸により、優れた液流れ防止性が得られ、例えば軟便や経血等の液体がシート上を流れて拡がることを防止できる。また、熱融着部４上に排泄され又は到達した液は、繊維密度が高い凸部５の立ち上がり部分から吸液して吸収体に導く経路と、繊維状部分４２で開孔４１上に誘導し該開孔４１を介して吸収体に吸収させる経路とで、スムーズに吸収体に移行させることができる。
そのため、立体シート１０を用いた吸収性物品は、着用者の前後左右の何れの方向からも漏れが生じにくく、また、使用後の見た目も比較的きれいである。
また、立体シート１０は面方向の柔軟性に優れ、Ｘ方向及びＹ方向のいずれにおいても柔軟に曲がるため、着用者とのフィット性が向上し、また、柔軟性が要求される物品や部位にも使用できる。
According to the three-dimensional sheet 10 of the present embodiment, when used as a top sheet of an absorbent article, the convex portion 5 provides good cushioning properties and feel, and the convex portion 5 and the heat-sealed portion 4 are formed. Due to the unevenness, excellent liquid flow preventing property can be obtained, and for example, liquid such as soft stool and menstrual blood can be prevented from flowing and spreading on the sheet. Further, the liquid excreted or reached on the heat-sealing part 4 is guided to the opening 41 by the path leading to the absorbent by absorbing liquid from the rising part of the convex part 5 having a high fiber density and the fibrous part 42. And it can be made to transfer to an absorber smoothly with the course made to absorb to an absorber via this opening 41.
Therefore, the absorbent article using the three-dimensional sheet 10 is less likely to leak from any of the wearer's front, back, left and right directions, and the appearance after use is relatively clean.
Further, the three-dimensional sheet 10 is excellent in flexibility in the surface direction, and flexibly bends in both the X direction and the Y direction, so that the fit with the wearer is improved, and the article or part where flexibility is required. Can also be used.
上述した効果が一層確実に発現されるようにする観点等から、表面シート１０は以下の構成を有することが好ましい。
凸部５の高さＨ（図１参照）は１〜１０ｍｍ、特に３〜６ｍｍであることが好ましい。立体シート１０の単位面積（１ｃｍ2）当たりの凸部５の数は１〜２０、特に６〜１０個であることが好ましい。
From the viewpoint of ensuring that the above-described effects are more reliably exhibited, the topsheet 10 preferably has the following configuration.
The height H (see FIG. 1) of the convex portion 5 is preferably 1 to 10 mm, particularly preferably 3 to 6 mm. The number of convex portions 5 per unit area (1 cm 2 ) of the three-dimensional sheet 10 is preferably 1 to 20, particularly 6 to 10.
凸部５のＸ方向の底部寸法Ａ（図１参照）は０．５〜５．０ｍｍ、特に１．０〜４．０ｍｍであることが好ましい。凸部５のＹ方向の底部寸法Ｂ（図１参照）は１.０〜１０ｍｍ、特に２．０〜７．０ｍｍであることが好ましい。
Ｘ方向の底部寸法ＡとＹ方向の底部寸法Ｂとの比（底部寸法Ａ：底部寸法Ｂ）は１：１〜１：１０、特に１：２〜２：５であることが好ましい。凸部５の底部面積（底部寸法Ａ×底部寸法Ｂ）は０．５〜５０ｍｍ2、特に２〜２０ｍｍ2であることが好ましい。
The bottom dimension A (see FIG. 1) of the convex portion 5 in the X direction is preferably 0.5 to 5.0 mm, particularly preferably 1.0 to 4.0 mm. The bottom dimension B (see FIG. 1) of the convex part 5 in the Y direction is 1.0 to 10 mm, particularly preferably 2.0 to 7.0 mm.
The ratio of the bottom dimension A in the X direction to the bottom dimension B in the Y direction (bottom dimension A: bottom dimension B) is preferably 1: 1 to 1:10, particularly 1: 2 to 2: 5. The bottom area (bottom dimension A × bottom dimension B) of the convex portion 5 is preferably 0.5 to 50 mm 2 , particularly preferably 2 to 20 mm 2 .
熱融着部４は、Ｘ方向の寸法Ｃ（図１参照）が０．５〜２ｍｍ、特に０．８〜１．５ｍｍであることが好ましく、Ｙ方向の寸法Ｄ（図１参照）が１．０〜５.０ｍｍ、特に１．２〜３．０ｍｍであることが好ましい。Ｘ方向の寸法ＣとＹ方向の寸法Ｄとの比（寸法Ｃ：寸法Ｄ）は１：１〜１：３、特に２：３〜２：５であることが好ましい。熱融着部４の面積（寸法Ｃ×寸法Ｄ）は０．５〜１０ｍｍ2、特に０．８〜６ｍｍ2であることが好ましい。 The heat-sealed portion 4 preferably has a dimension C in the X direction (see FIG. 1) of 0.5 to 2 mm, particularly 0.8 to 1.5 mm, and a dimension D in the Y direction (see FIG. 1) of 1. It is preferable that it is 0.0-5.0 mm, especially 1.2-3.0 mm. The ratio of the dimension C in the X direction to the dimension D in the Y direction (dimension C: dimension D) is preferably 1: 1 to 1: 3, particularly 2: 3 to 2: 5. The area (dimension C × dimension D) of the heat fusion part 4 is preferably 0.5 to 10 mm 2 , particularly preferably 0.8 to 6 mm 2 .
個々の開孔４１の面積は、０．０５〜５ｍｍ2、特に０．２〜１．５ｍｍ2であることが好ましく、熱融着部４一つ当たりの開孔４１の総面積（複数存在する場合は各開孔面積の合計）は、０．２〜５ｍｍ2であることが好ましく、該総面積の熱融着部４の面積に対する比率（〔総面積／熱融着部面積〕×100）は１０〜８０％であることが好ましい。
また、繊維状部分４２は、概ねその太さが、第１不織布又は第２不織布に用いた非熱融着性成分を含む繊維の太さの０．５〜３倍であることが好ましい。
The area of each opening 41 is preferably 0.05 to 5 mm 2 , particularly preferably 0.2 to 1.5 mm 2 , and the total area (a plurality of openings 41 per one heat-sealing part 4 exists). In this case, the total area of the openings is preferably 0.2 to 5 mm 2 , and the ratio of the total area to the area of the heat-sealed portion 4 ([total area / heat-bonded portion area] × 100) Is preferably 10 to 80%.
Moreover, it is preferable that the thickness of the fibrous portion 42 is approximately 0.5 to 3 times the thickness of the fiber including the non-heat-fusible component used in the first nonwoven fabric or the second nonwoven fabric.
熱融着部４の形状は、実施形態では俵状（長方形の角を曲線処理）であるが、俵状のＸ方向やＹ方向中央部を膨らませた形状や狭くした形状であっても良い。この場合、上述したＸ方向の寸法ＣやＹ方向の寸法Ｄは、その最大部分で計測する。俵状の他矩形も使用可能であるが、立体シートの凸部成形性の観点から、俵状が好ましく、Ｘ方向を膨らませＹ方向を狭くした形状が、開孔性と熱融着部強度の点より好ましい。 Although the shape of the heat-sealing part 4 is a bowl shape (rectangular corner is curve-processed) in the embodiment, it may be a bowl-like shape in which the X direction or the Y direction center part is expanded or a narrow shape. In this case, the above-described dimension C in the X direction and dimension D in the Y direction are measured at the maximum portion. Although other ridge-like rectangles can be used, from the viewpoint of the convex formability of the three-dimensional sheet, the ridge-like shape is preferable, and the shape inflated in the X direction and narrowed in the Y direction has a good hole opening property and heat-bonding portion strength. It is more preferable than the point.
第１及び第２不織布としては、各種公知の不織布を用いることができ、例えば、カード法により製造された不織布、スパンボンド不織布、メルトブローン不織布、スパンレース不織布、ヒートロール不織布、ニードルパンチ不織布等の種々の不織布を用いることができる。第２繊維シートとしては、不織布化していない繊維ウエブ等を用いることもできる。本実施形態の立体シート１０においては、実質的に伸縮しない不織布を、第１及び第２不織布として用いている。
第１不織布としては、表面シートとして用いた場合の肌触りの観点から、カード法等により得た繊維ウエブにエアスルー法で繊維同士の熱融着点を形成したエアースルー不織布や、ヒートエンボス不織布、エアレイド不織布、スパンボンド不織布等が特に好ましく用いられる。第２不織布としては、凸部の形状を維持しクッション効果を高めるおよび吸収性の観点から、カード法等により得た繊維ウエブにヒートロール法で繊維同士の熱融着点を形成したヒートロール不織布やヒートエンボス不織布、スパンボンド不織布、メルトブロー不織布、スパンレース不織布等上層と比較して伸びの少ないシートが特に好ましく用いられる。
As the first and second nonwoven fabrics, various known nonwoven fabrics can be used. For example, various nonwoven fabrics manufactured by the card method, spunbond nonwoven fabrics, meltblown nonwoven fabrics, spunlace nonwoven fabrics, heat roll nonwoven fabrics, needle punched nonwoven fabrics, etc. Nonwoven fabrics can be used. As the second fiber sheet, a non-woven fiber web or the like can be used. In the three-dimensional sheet 10 of the present embodiment, a nonwoven fabric that does not substantially expand and contract is used as the first and second nonwoven fabrics.
As the first non-woven fabric, from the viewpoint of touch when used as a surface sheet, an air-through non-woven fabric, a heat-embossed non-woven fabric, an air-laid non-woven fabric in which heat-bonding points of fibers are formed on a fiber web obtained by a card method or the like by an air-through method. Nonwoven fabrics, spunbonded nonwoven fabrics and the like are particularly preferably used. As a 2nd nonwoven fabric, the heat roll nonwoven fabric which formed the heat-fusion point of fibers with the heat roll method on the fiber web obtained by the card | curd method etc. from the viewpoint of absorbing and maintaining the shape of a convex part and absorptivity In particular, a sheet with less elongation compared to the upper layer such as heat embossed nonwoven fabric, spunbond nonwoven fabric, melt blown nonwoven fabric, and spunlace nonwoven fabric is preferably used.
次に、本実施形態の立体シート１０の製造方法を図４及び図５を参照しながら説明する。図４に示すように、第１不織布１の原反１’から第１不織布１を繰り出す。また、これとは別の、第２不織布２の原反２’から第２不織布２を繰り出す。繰り出された第１不織布１を、周面が凹凸形状となっている第１のロール１１と第１のロールの凹凸形状と噛み合い形状となっている凹凸形状を周面に有する第２のロール１２との噛み合わせ部に噛み込ませて第１不織布１を凹凸賦形する。 Next, the manufacturing method of the three-dimensional sheet 10 of this embodiment is demonstrated, referring FIG.4 and FIG.5. As shown in FIG. 4, the first nonwoven fabric 1 is fed out from the raw fabric 1 ′ of the first nonwoven fabric 1. Separately, the second nonwoven fabric 2 is fed out from the raw fabric 2 'of the second nonwoven fabric 2. A first roll 11 having a concavo-convex shape on the peripheral surface, and a second roll 12 having a concavo-convex shape meshing with the concavo-convex shape of the first roll on the peripheral surface. The first nonwoven fabric 1 is unevenly shaped by being bitten by the meshing portion.
図５には、第１のロール１１の要部拡大図が示されている。第１のロール１１は、所定の歯幅を有する平歯車１１ａ，１１ｂ，・・を複数枚組み合わせてロール状に形成したものである。各歯車の歯幅は、表面シート１の凸部５におけるＹ方向の寸法を決定する。隣り合う歯車は、その歯のピッチが半ピッチずつずれるように組み合わされている。その結果、第１のロール１１は、その周面が凹凸形状となっている。 FIG. 5 shows an enlarged view of a main part of the first roll 11. The first roll 11 is formed by combining a plurality of spur gears 11a, 11b,... Having a predetermined tooth width into a roll shape. The tooth width of each gear determines the dimension in the Y direction of the convex portion 5 of the topsheet 1. Adjacent gears are combined such that the pitch of their teeth is shifted by half a pitch. As a result, the peripheral surface of the first roll 11 has an uneven shape.
第１のロール１１における各歯車の歯溝部には吸引孔１３が形成されている。この歯溝部は、第１のロール１１の周面における凹凸形状のうちの凹部に相当するものである。吸引孔１３は、ブロワや真空ポンプなどの吸引源（図示せず）に通じ、第１のロールと第２のロールとの噛み合い部から第１不織布１と第２不織布２との合流部までの間で吸引が行われる様に制御されている。従って、第１のロールと第２のロールとの噛み合いによって凹凸賦形された第１不織布１は、吸引孔１３による吸引力によって第１のロール周面に密着し、その凹凸賦形された状態が保持される。この場合、図５に示すように、隣り合う歯車間に所定の空隙Ｇを設けておくと、第１不織布１に無理な伸長力や、ロールの凹凸噛み合いによる切断効果を加えることなく第１不織布１を第１のロール１１の周面に密着させられる。 A suction hole 13 is formed in the tooth groove portion of each gear in the first roll 11. The tooth groove portion corresponds to a concave portion of the concave and convex shape on the peripheral surface of the first roll 11. The suction hole 13 communicates with a suction source (not shown) such as a blower or a vacuum pump, and extends from a meshing portion between the first roll and the second roll to a joining portion between the first nonwoven fabric 1 and the second nonwoven fabric 2. It is controlled so that suction is performed between them. Therefore, the 1st nonwoven fabric 1 unevenly shaped by meshing with the 1st roll and the 2nd roll closely_contact | adheres to the 1st roll surrounding surface with the suction force by the suction hole 13, and the uneven | corrugated shaped state Is retained. In this case, as shown in FIG. 5, if a predetermined gap G is provided between adjacent gears, the first nonwoven fabric 1 is not subjected to excessive stretching force or cutting effect due to uneven engagement of the rolls. 1 is brought into close contact with the peripheral surface of the first roll 11.
そして、第１不織布１を第１のロール１１の周面に引き続き吸引保持した状態下に、第２不織布２を重ね合わせ、その重ね合わせたものを、第１のロール１１と周面平滑なアンビルロール１５との間で挟圧する。このとき、第１のロール１１とアンビルロール１５の両方又はアンビルロール１５のみを所定温度に加熱しておく。これによって、第１のロール１１における凸部上、つまり各歯車の歯の上に位置する第１不織布と第２不織布２とが熱融着によって接合されて熱融着部４が形成される。 Then, the second nonwoven fabric 2 is overlapped in a state where the first nonwoven fabric 1 is continuously sucked and held on the peripheral surface of the first roll 11, and the overlapped one is the first roll 11 and the peripheral surface smooth anvil. A pressure is applied between the roll 15. At this time, both the first roll 11 and the anvil roll 15 or only the anvil roll 15 are heated to a predetermined temperature. Thereby, the 1st nonwoven fabric and the 2nd nonwoven fabric 2 which are located on the convex part in the 1st roll 11, ie, the tooth | gear of each gear, are joined by thermal fusion, and the thermal fusion part 4 is formed.
この様な製造工程は、特許文献１に開示された表面シートの製造方法とほぼ同様であるが、本実施形態の方法においては、アンビルロール１５の直径を、特許文献１におけるよりも小さくする、第１のロール１１の凸部１１ｃの先端部を若干Ｒ加工するなどして、積層された両不織布の、第１のロール１１の凸部先端面とアンビルロール１５の周面との間で挟まれる部分の内、両不織布の流れ方向における中央部付近がその前後に位置する部分より強く加熱及び加圧され、熱融着部４での繊維樹脂の移動と開孔形成が起こり易くなるようにし、また、第１及び／又は第２不織布の構成繊維として、その加熱及び加圧部分に、熱融着性成分及び非熱融着性成分の両者を存在させうる繊維を用いる。更に、その加熱及び加圧を、熱融着性成分が充分に溶融し、非熱融着性成分が溶融しない条件で行う。好ましくは、熱融着性成分の融点より５℃以上高く、非熱融着性成分の融点より２０℃以上低い温度で加熱する。
このような条件で熱融着することにより、第１のロール１１の凸部先端中央部における熱融着性成分が溶融して、その前後に移動することによって開孔４１が形成される一方、その条件では溶融しない非熱融着性成分が繊維状の形態を維持しながら開孔４１部分に残存して、上述した繊維状部分４２を形成する。
このようにして立体シート１０が得られる。
Such a manufacturing process is substantially the same as the manufacturing method of the surface sheet disclosed in Patent Document 1, but in the method of this embodiment, the diameter of the anvil roll 15 is made smaller than that in Patent Document 1. The tip of the convex portion 11c of the first roll 11 is slightly R-processed, for example, and sandwiched between the convex portion tip surface of the first roll 11 and the peripheral surface of the anvil roll 15 of the laminated nonwoven fabrics. The portion near the center in the flow direction of the two nonwoven fabrics is heated and pressurized more strongly than the portions located before and after it, so that the movement of the fiber resin and the formation of holes at the heat-sealed portion 4 are likely to occur. Moreover, as the constituent fiber of the first and / or second nonwoven fabric, a fiber capable of causing both a heat-fusible component and a non-heat-fusible component to exist in the heated and pressurized portions is used. Further, the heating and pressurization are performed under the condition that the heat-fusible component is sufficiently melted and the non-heat-fusible component is not melted. Preferably, heating is performed at a temperature 5 ° C. or more higher than the melting point of the heat-fusible component and 20 ° C. or lower than the melting point of the non-heat-fusible component.
By heat-sealing under such conditions, the heat-fusible component at the center of the convex tip end of the first roll 11 is melted and moved forward and backward to form the opening 41, The non-heat-fusible component that does not melt under the conditions remains in the opening 41 portion while maintaining the fibrous form to form the fibrous portion 42 described above.
In this way, the three-dimensional sheet 10 is obtained.
上述した立体シート１０の製造方法においては、張力が加えられた状態の第１不織布１が第２不織布２に熱融着される。そのため、熱融着部の中央部分は引き延ばされて低坪量化され、開孔が形成され易い。また、溶融した熱融着性成分が周辺部に移動し易いため、周縁近傍部の厚みが中央部分に比して厚い熱融着部が容易に形成できる。更に、不規則な大きさ及び配置の開孔を形成でき、熱融着部上における液の移動吸収がよりスムーズに進行する。 In the manufacturing method of the three-dimensional sheet 10 described above, the first nonwoven fabric 1 in a state where tension is applied is heat-sealed to the second nonwoven fabric 2. Therefore, the center part of the heat-sealed part is stretched to reduce the basis weight, and an opening is easily formed. In addition, since the melted heat-fusible component easily moves to the peripheral part, a heat-fused part having a thicker peripheral edge than the central part can be easily formed. Furthermore, irregularly sized and arranged openings can be formed, and the movement and absorption of the liquid on the heat-sealed portion proceed more smoothly.
次に、本発明の他の実施形態としての立体シート１０’について、図６及び図７を参照して説明する。立体シート１０’については、主として、上述した立体シート１０と異なる点について説明し、同様の点については、同一の符号を付して説明を省略する。特に言及しない点については、上述した立体シート１０に関する説明が適宜適用される。 Next, a three-dimensional sheet 10 ′ as another embodiment of the present invention will be described with reference to FIGS. 6 and 7. Regarding the three-dimensional sheet 10 ′, the points different from the three-dimensional sheet 10 described above are mainly described, and the same points are denoted by the same reference numerals and the description thereof is omitted. About the point which does not mention especially, the description regarding the three-dimensional sheet | seat 10 mentioned above is applied suitably.
立体シート１０’における各凸部５の内部には、短繊維が充填されている。短繊維は、繊維集合体３を形成している。短繊維からなる繊維集合体３は、立体シート１０’における凸部部分（凸部５を有する部分）における第１不織布１と第２不織布２との間に配されており、両不織布それぞれと密着している。 Short fibers are filled in the convex portions 5 of the three-dimensional sheet 10 ′. The short fibers form a fiber assembly 3. The fiber assembly 3 made of short fibers is disposed between the first nonwoven fabric 1 and the second nonwoven fabric 2 in the convex portion (portion having the convex portion 5) in the three-dimensional sheet 10 ′, and is in close contact with both nonwoven fabrics. is doing.
熱融着部４には、繊維集合体３を構成する短繊維が実質的に存在していない。「実質的に存在していない」とした理由は、立体シート１０’の製造工程において、短繊維を凸部部分のみに配するように工夫しても、少量の短繊維が熱融着部に配されてしまうことが多いことを考慮し、そのような少量の短繊維の存在を許容する趣旨である。但し、凸部部分の単位面積当たりの短繊維量に対する、熱融着部の単位面積当たりの短繊維量の割合（百分率）は２０重量％以下、好ましくは５重量％以下であることが好ましい。
また、短繊維に非融着性繊維を使用すると、熱融着部４の開孔４１に形成される繊維状部分４２に利用することもできる。この場合、上層および下層には、非融着性成分が含まれていなくても良い。
立体シート１０’の各凸部部分における繊維密度は、第１不織布１、短繊維（繊維集合体３としての短繊維）、第２不織布２の順に高くなっている。凸部部分に、このような繊維密度の勾配をつけることで、尿や経血等の排泄液を、凸部５表面から繊維集合体３にスムーズに移行させ、更にそれをスムーズに第２不織布２に移行させることができる。
In the heat fusion part 4, the short fiber which comprises the fiber assembly 3 does not exist substantially. The reason that “substantially does not exist” is that even in the manufacturing process of the three-dimensional sheet 10 ′, even if the short fibers are arranged only on the convex portions, a small amount of short fibers are formed in the heat-sealed portion. In consideration of the fact that it is often arranged, the purpose is to allow the presence of such a small amount of short fibers. However, the ratio (percentage) of the short fiber amount per unit area of the heat-sealed portion to the short fiber amount per unit area of the convex portion is 20% by weight or less, preferably 5% by weight or less.
In addition, when non-fusible fibers are used for the short fibers, they can be used for the fibrous portion 42 formed in the opening 41 of the heat-sealing portion 4. In this case, the non-fusible component may not be contained in the upper layer and the lower layer.
The fiber density in each convex portion of the three-dimensional sheet 10 ′ increases in the order of the first nonwoven fabric 1, the short fibers (short fibers as the fiber assembly 3), and the second nonwoven fabric 2. By imparting such a fiber density gradient to the convex portion, excretory fluid such as urine and menstrual blood can be smoothly transferred from the surface of the convex portion 5 to the fiber assembly 3, and then the second nonwoven fabric can be smoothly smoothed. 2 can be transferred.
また、熱融着部４に、繊維集合体３を構成する短繊維が実質的に存在していないことにより、熱融着部における熱融着性を考慮せずに、多様な繊維を、繊維集合体３を構成する短繊維として用いることができる。 Further, since the short fibers constituting the fiber assembly 3 are not substantially present in the heat-sealed portion 4, various fibers can be used without considering the heat-fusibility in the heat-fused portion. It can be used as a short fiber constituting the aggregate 3.
繊維集合体３を構成する短繊維（凸部５に充填される短繊維）としては、例えば、以下のようなものを用いることが好ましい。
（１）第１及び第２不織布それぞれの構成繊維よりも熱融着性に劣る繊維（以下、非熱融着性繊維ともいう）。
非熱融着性繊維を用いることにより、使用時の圧力変化に繊維の動きが自由に対応し、立体シート１０のクッション感を高める。
As short fibers (short fibers filled in the convex portions 5) constituting the fiber assembly 3, for example, the following are preferably used.
(1) Fibers that are inferior in heat-fusibility than the constituent fibers of the first and second nonwoven fabrics (hereinafter also referred to as non-heat-fusible fibers).
By using the non-heat-bondable fiber, the movement of the fiber freely corresponds to the pressure change during use, and the cushion feeling of the three-dimensional sheet 10 is enhanced.
第１（第２）不織布の構成繊維よりも熱融着性に劣る繊維とは、例えば第１（第２）不織布の構成繊維を構成する熱融着性樹脂の融点以下の温度では溶融しない繊維をいう。例えば、第１及び第２不織布がポリエチレン樹脂を主体とする繊維からなる場合には、繊維集合体を構成する短繊維として、それよりも融点の高いポリエチレンテレフタレート（ＰＥＴ）、ポリプロピレン（ＰＰ）、ナイロン、ポリアミド等の合成樹脂からなる繊維や、アセテート化されたレーヨンなど親水性調整がおこなわれた半天然繊維を用いることが好ましい。また、第１及び第２不織布がビスコースレーヨン、アセテート化されたレーヨン、パルプを主体とする繊維からなる場合には、繊維集合体を構成する短繊維として、コットン繊維、レーヨン繊維等を用いることが好ましい。
非熱着性繊維は、その太さが０．５〜６．６ｄｔｅｘ、特に１．１〜３．３ｄｔｅｘであることが好ましく、坪量が５〜５０ｇ／ｍ2、特に１０〜３０ｇ／ｍ2であることが好ましい。
The fiber that is inferior in heat fusibility to the constituent fibers of the first (second) non-woven fabric is, for example, a fiber that does not melt at a temperature lower than the melting point of the heat-fusible resin constituting the constituent fibers of the first (second) non-woven fabric. Say. For example, when the first and second non-woven fabrics are made of fibers mainly composed of polyethylene resin, as the short fibers constituting the fiber assembly, polyethylene terephthalate (PET), polypropylene (PP), nylon having a higher melting point. It is preferable to use a fiber made of a synthetic resin such as polyamide, or a semi-natural fiber that has been adjusted for hydrophilicity, such as acetate rayon. Further, when the first and second nonwoven fabrics are made of fibers mainly composed of viscose rayon, acetated rayon, and pulp, cotton fibers, rayon fibers, etc. are used as the short fibers constituting the fiber assembly. Is preferred.
The non-heat-bondable fiber preferably has a thickness of 0.5 to 6.6 dtex, particularly 1.1 to 3.3 dtex, and a basis weight of 5 to 50 g / m 2 , particularly 10 to 30 g / m 2. It is preferable that
（２）潜在捲縮性繊維
潜在捲縮性繊維を用いることにより、立体シート１０の製造段階又は立体シート１０を用いて吸収性物品を製造する段階における熱処理により、凸部５に所望の性状を付与することができる。例えば、捲縮の程度を高くして圧縮に対する弾性回復力に優れた凸部を形成したり、毛管径の小さな繊維構造体とすることで、液引き込み性に優れた短繊維・第２不織布を形成することができる。
(2) Latent crimpable fiber By using the latent crimpable fiber, the convex portion 5 has a desired property by heat treatment in the production step of the three-dimensional sheet 10 or in the step of producing an absorbent article using the three-dimensional sheet 10. Can be granted. For example, a short fiber / second non-woven fabric with excellent liquid drawability can be obtained by forming a convex portion having a high degree of crimping and forming an elastic recovery force against compression or a fiber structure having a small capillary diameter. Can be formed.
潜在捲縮性繊維は、加熱によって螺旋状の３次元捲縮が発現して収縮する性質を有する繊維である。本明細書では、螺旋状の捲縮を発現したものも、発現する前のものも共に潜在捲縮性繊維という。潜在捲縮性繊維は、例えば、収縮率の異なる２種類の成分からなる偏心芯鞘型若しくは同心芯鞘型の複合繊維又はサイド・バイ・サイド型の複合繊維からなる。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種類の成分（熱可塑性ポリマー等）としては、エチレン−プロピレンランダム共重合体（高収縮率成分）とポリプロピレン（低収縮率成分）との組み合わせ、ポリエチレンテレフタレート（ＰＥＴ，低収縮率成分）とポリエチレンテレフタレートとイソフタル酸（ＣｏＰＥＴ，高収縮率成分）との組み合わせが好ましい例として挙げられる。 The latent crimpable fiber is a fiber having a property that a helical three-dimensional crimp is developed and contracted by heating. In the present specification, both those that have developed a helical crimp and those that have been developed are referred to as latent crimpable fibers. The latent crimpable fiber includes, for example, an eccentric core-sheath type or concentric core-sheath type composite fiber or a side-by-side type composite fiber composed of two components having different shrinkage rates. Examples thereof include those described in JP-A-9-296325 and Japanese Patent No. 2759331. Two types of components (thermoplastic polymers, etc.) with different shrinkage rates include ethylene-propylene random copolymer (high shrinkage rate component) and polypropylene (low shrinkage rate component), polyethylene terephthalate (PET, low shrinkage rate) Component), a combination of polyethylene terephthalate and isophthalic acid (CoPET, high shrinkage component) is a preferred example.
繊維集合体３中の上記（１）又は（２）の繊維量は、例えば、繊維集合体３の重量に対して５０〜１００％、特に８０〜１００重量％とすることができる。潜在捲縮性繊維とともに含有させる繊維としては、例えば、上記（１）の繊維として例示したものを挙げることができる。 The amount of the fiber (1) or (2) in the fiber assembly 3 can be, for example, 50 to 100%, particularly 80 to 100% by weight with respect to the weight of the fiber assembly 3. Examples of the fiber to be included together with the latent crimpable fiber include those exemplified as the fiber of (1) above.
繊維集合体３を構成する繊維（凸部５に充填される繊維）は、短繊維、即ち、その平均繊維長が１００ｍｍ以下のものである。 The fibers constituting the fiber assembly 3 (fibers filling the convex portions 5) are short fibers, that is, the average fiber length is 100 mm or less.
立体シート１０’は、例えば、図７に示す工程で製造することができる。
即ち、上述した立体シート１０の製造方法と同様にして、第１のロール１１と第２のロール１２との噛み合いによって凹凸賦形された第１不織布１を、吸引孔１３による吸引力によって第１のロール周面に密着する。次いで、第１不織布１が密着した状態の、第１のロール１１の周面に対して、公知の繊維供給手段１４により、短繊維３１を飛散状態として供給する。短繊維３１は、第１のロール１１の一部を覆うダクト１４ａ内に生じた空気流にのって第１のロール１１の周面に向かって搬送され、吸引孔１３からの吸引により、該ロール１１の凹部内に選択的に堆積する。ダクト１４ａ内の空気流は、吸引孔１３からの吸引及び／又は他の送風手段（図示せず）により生じさせることができる。
The three-dimensional sheet 10 ′ can be manufactured, for example, by the process shown in FIG.
That is, in the same manner as the above-described manufacturing method of the three-dimensional sheet 10, the first nonwoven fabric 1 that has been concavo-convexly shaped by the meshing of the first roll 11 and the second roll 12 is applied to the first non-woven fabric 1 by the suction force of the suction holes 13. Adhering closely to the roll circumference. Next, the short fibers 31 are supplied in a scattered state by the known fiber supply means 14 to the peripheral surface of the first roll 11 in a state where the first nonwoven fabric 1 is in close contact. The short fibers 31 are conveyed toward the peripheral surface of the first roll 11 along the air flow generated in the duct 14 a covering a part of the first roll 11, and are sucked from the suction holes 13 to It selectively accumulates in the recesses of the roll 11. The air flow in the duct 14a can be generated by suction from the suction hole 13 and / or other blowing means (not shown).
そして、図７に示すように、第１不織布１及び堆積させた短繊維３１を第１のロール１１の周面に引き続き吸引保持した状態下に、第２不織布２を重ね合わせ、その重ね合わせたものを第１のロール１１の凸部とアンビルロール１５との間で部分的に加熱及び加圧して、第１不織布１と第２不織布２とを熱融着させる。このようにして、立体シート１０’を製造することができる。特に説明しない点は、上述した立体シート１０の製造方法と同様である。 And as shown in FIG. 7, the 2nd nonwoven fabric 2 was piled up in the state which sucked and held the 1st nonwoven fabric 1 and the accumulated short fiber 31 on the surrounding surface of the 1st roll 11, and the piled up. A thing is partially heated and pressurized between the convex part of the 1st roll 11, and the anvil roll 15, and the 1st nonwoven fabric 1 and the 2nd nonwoven fabric 2 are heat-sealed. In this way, the three-dimensional sheet 10 'can be manufactured. The points that are not particularly described are the same as in the method for manufacturing the three-dimensional sheet 10 described above.
上述した立体シート１０，１０’は、使い捨ておむつ、生理用ナプキン、パンティライナー、失禁パッドなどの吸収性物品の表面シートとして好適に用いられる。
また、吸収性物品の表面シート以外の用途に用いることもできる。
例えば、吸収性物品用のシートとして、表面シートと吸収体の間に配置されるシート、立体ギャザー（防漏壁）形成用のシート（特にギャザーの内壁を形成するシート）等に用いることができ、また、吸収性物品以外の用途として、清掃シート、特に液吸収を主とする清掃シートや、対人用の化粧シート等として用いることができる。清掃シートに用いる場合、凸部において、平滑でない被清掃面への追従性が良好であるため、第１不織布側を被清掃面に向けて使用することが好ましい。化粧シートとして用いる場合、凸部において対象者の肌に追従し、またマッサージ効果を発現するとともに、余分な化粧剤（別途使用）や汗の吸収を行うことができるため、第１不織布側を肌側に向けて使用することが好ましい。
The three-dimensional sheets 10 and 10 'described above are suitably used as a surface sheet for absorbent articles such as disposable diapers, sanitary napkins, panty liners, and incontinence pads.
Moreover, it can also be used for uses other than the surface sheet of an absorbent article.
For example, as a sheet for absorbent articles, it can be used as a sheet disposed between a top sheet and an absorbent body, a sheet for forming a three-dimensional gather (leakage barrier) (particularly a sheet for forming the inner wall of a gather), and the like. Moreover, as an application other than the absorbent article, it can be used as a cleaning sheet, particularly a cleaning sheet mainly for liquid absorption, a personal use decorative sheet, and the like. When using it for a cleaning sheet, in a convex part, since followability to a to-be-cleaned surface which is not smooth is good, it is preferred to use the 1st nonwoven fabric side toward a to-be-cleaned surface. When used as a decorative sheet, it can follow the skin of the subject at the convex part, express a massage effect, and can absorb excess cosmetic (used separately) and sweat, so the first nonwoven fabric side can be It is preferable to use it toward the side.
以上、本発明の立体シートの実施形態について説明したが、本発明は、上記の実施形態に何ら制限されるものではなく、適宜変更可能である。例えば、立体シート１０，１０’の凸部５は、四角錐台形状のものであったが、半球状のもの等であっても良い。また、互いに隣接する列における凸部５及び熱融着部４が、それぞれ、Ｘ方向にずれる程度は、１／２ピッチに代えて、１／３ピッチ、１／４ピッチ等であっても良く、更にＸ方向にずれていなくても良い。 As mentioned above, although embodiment of the three-dimensional sheet | seat of this invention was described, this invention is not restrict | limited to said embodiment at all and can be changed suitably. For example, the convex portions 5 of the three-dimensional sheets 10 and 10 ′ have a quadrangular pyramid shape, but may have a hemispherical shape or the like. In addition, the degree to which the convex portions 5 and the heat fusion portions 4 in the adjacent rows are displaced in the X direction may be 1/3 pitch, 1/4 pitch, or the like, instead of 1/2 pitch. Further, it does not have to be shifted in the X direction.
上述した実施形態では、開孔４１部分を除く熱融着部４においては、目視においては繊維状の形態を観察できない、即ち、外観状フィルム化されていたが、液不透過性または難透過性であれば、部分的に又が全体的に繊維状の形態が観察されてもよい。 In the above-described embodiment, in the heat-sealed portion 4 excluding the opening 41 portion, the fibrous form cannot be visually observed, that is, it has been formed into an appearance-like film, but is liquid-impermeable or hardly permeable. If so, a partially or wholly fibrous form may be observed.
１０，１０’ 立体シート
１ 第１不織布（第１繊維シート）
２ 第２不織布（第２繊維シート）
３ 短繊維からなる繊維集合体
４ 熱融着部
４１ 開孔
４２ 繊維状部分
５ 凸部
10, 10 'solid sheet 1 first nonwoven fabric (first fiber sheet)
2 Second nonwoven fabric (second fiber sheet)
DESCRIPTION OF SYMBOLS 3 The fiber assembly which consists of a short fiber 4 Heat-fusion part 41 Opening 42 Fiber-like part 5 Convex part
Claims (5)
第１繊維シート及び／又は第２繊維シートに、熱融着性成分を含む繊維と、該熱融着性成分の融点では溶融しない非熱融着性成分を含む繊維とを含んでおり、
前記熱融着部は、該熱融着部を厚み方向に貫通する開孔を有し、該開孔は、繊維状部分によって分断されており、
前記開孔は、前記熱融着部に不規則な大きさ及び配置で形成されている、立体シート。 The first fiber sheet and the second fiber sheet laminated to each other are partially heat-sealed to form a heat-sealing portion, and the first fiber sheet protrudes at a portion other than the heat-sealing portion and has a large number of protrusions. A three-dimensional sheet forming a part,
The first fiber sheet and / or the second fiber sheet includes a fiber containing a heat-fusible component and a fiber containing a non-heat-fusible component that does not melt at the melting point of the heat-fusible component,
The heat fusion part has an opening that penetrates the heat fusion part in the thickness direction, and the opening is divided by a fibrous part,
The said opening is a solid sheet | seat currently formed in the said heat-fusion part by the irregular magnitude | size and arrangement | positioning .
前記立体シートにおける前記第１繊維シート側を肌側に向けて用いられる吸収性物品の表面シート。 The solid sheet according to any one of claims 1 to 4 ,
A top sheet of an absorbent article that is used with the first fiber sheet side of the three-dimensional sheet facing the skin side.
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| KR101429932B1 (en) * | 2006-12-27 | 2014-08-13 | 가오 가부시키가이샤 | Topsheet for absorbent article and method for manufacturing the same |
| CN110248628A (en) * | 2017-01-31 | 2019-09-17 | 宝洁公司 | Molding supatex fabric and product including the fabric |
| US11214893B2 (en) | 2017-06-30 | 2022-01-04 | The Procter & Gamble Company | Shaped nonwoven |
| EP3645775B1 (en) | 2017-06-30 | 2021-07-21 | The Procter & Gamble Company | Method for making a shaped nonwoven |
| BR112020006876B1 (en) * | 2017-10-06 | 2023-03-14 | Zuiko Corporation | MANUFACTURING DEVICE AND MANUFACTURING METHOD OF COMPOSITE SHEET |
| JP6934405B2 (en) * | 2017-11-21 | 2021-09-15 | 花王株式会社 | Composite sheet manufacturing method and manufacturing equipment |
| MX2021005791A (en) * | 2018-11-30 | 2021-06-30 | Kimberly Clark Co | Three-dimensional nonwoven materials and methods of manufacturing thereof. |
| WO2021100832A1 (en) | 2019-11-19 | 2021-05-27 | 花王株式会社 | Method and device for producing composite sheet, composite sheet, and absorbent article |
| WO2022107770A1 (en) * | 2020-11-19 | 2022-05-27 | 花王株式会社 | Surface sheet for absorbent articles and absorbent article provided with same |
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