JP4543196B2 - Non-woven fabric having a multiphase structure and method for producing the same - Google Patents
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Description
【０００１】
【発明の属する技術分野】
一方の表面が親水性で、他方の表面が疎水性であり、しかも透気性の優れた不織布、およびこの不織布を製造する方法に関する。さらに本発明は、このような不織布を利用した子供用・大人用オムツ、女性用生理用品、メディカルケア用品等の吸収体製品に関する。
【０００２】
【従来の技術】
本発明は、吸収体製品において、液体を吸収および固定する機能を発現するための基本的な考え方は、液体透過性に優れたトップシートと、液体を一時的に拡散、貯留するアクイジション層と、液体を吸収して安定的に固定する吸収層とを適切に組み合わせるとういう概念から成り立っている。
【０００３】
従来技術においては、トップシートとして親水性もしくは親水化処理された比較的薄い多孔性の不織布が、アクイジション層としては嵩高な圧縮抵抗の高い不織布が、また吸収層としては高吸水性樹脂（ＳＡＰ）／パルプの混合体が、それぞれ分離、独立した要素として組み合わされて使用されている。
【０００４】
【発明が解決しようとする課題】
したがって、吸収体製品を工業的規模で連続的に製造するためには、吸収の主体をなすトップシート、アクイジション層、およびＳＡＰ／パルプの混合体の各要素に対応する他種類の素材をそれぞれ別個に供給することが必要であり、しかもこれら他種類の素材を一体化するためには、数段階の工程の各々でホットメルト等の結合材を多量に使用することが必要である等、プロセスとしてきわめて複雑となる。
【０００５】
また、例えばトップシートに要求される表面ドライ感の維持と高い水透過性とは互いに矛盾する条件であり、従来の技術はここにも大きな問題が存在する。
上述のような従来の技術が抱えている、表面ドライ感の維持と高い水透過性という矛盾を解決し、さらにアクイジション機能を効果的に発揮させるなどの機能面での改善を達成するためには、疎水性繊維層と親水性繊維層とを効果的に配置し、通気性と水透過性とをより安定に保つ必要がある。このような課題の解決は、個々の機能を兼ね備えた要素を複合して複合構造化することによりはじめて可能になる。
【０００６】
本発明は、このような多機能を兼ね備えた、複相構造を持った不織布とその製造法を提供する。
【０００７】
【課題を解決するための手段】
本発明によれば、嵩高で見掛け密度の小さい水難透過性の部分（Ａ相）と、このＡ相と密着し、Ａ相よりも大きい見掛け密度の水易透過性の部分（Ｂ相）とから構成されている、透気性の優れた不織布において、Ａ相は疎水性繊維層と親水性繊維層とが層状に重なった構造を有し、Ｂ相は疎水性繊維と親水性繊維とが混在した状態で水流交絡により圧縮された構造を有していることを特徴とする複相構造を持った不織布が提供される。
【０００８】
好ましくは、Ａ相の見掛け密度は、0.10g/cm3 以下であり、Ｂ相の見掛け密度は0.15g/cm3 以上である。
Ａ相の占める面積Ａと、Ｂ相の占める面積Ｂとの比は、広い範囲で選択可能であるが、好ましい範囲は、
Ｂ／（Ａ＋Ｂ）×１００＝１０〜６０（％）
である。
Ｂ相は、Ａ相内に複数の帯状に分布しており、各帯状Ｂ相の幅は、１mm以上、好ましくは２mm〜２０mmである。この帯は、連続する１本の帯であることが望ましいが、不連続な帯からなっていてもよい。
【０００９】
不織布は、好ましくは疎水性の化合繊繊維からなるカードウェブと、親水性繊維からなるカードウェブとを重ね合わせ、低圧力水流で予備交絡させたたＡ相に密着する帯状Ｂ相として、その各々が、さらに複数本の高圧水流によって水流交絡処理することにより形成されているものである。
水流交絡処理することにより形成された帯状Ｂ相の間隔は、好ましくは１０mm以上である。
【００１０】
あるいは、不織布として、疎水性の熱融着性繊維を主成分とするカードウェブと、親水性繊維を主成分とするカードウェブとを重ね合わせ、ついで熱風処理を施すことにより全体を結合させて形成した不織布を用い、熱グリッドロールにより加熱圧着させることにより帯状のＢ層を設けることもできる。
【００１１】
本発明はまた、嵩高で見掛け密度の小さい水難透過性の部分（Ａ相）と、このＡ相と密着し、Ａ相よりも大きい見掛け密度の水易透過性の部分（Ｂ相）とから構成されている、透気性の優れた不織布の製造法において、疎水性の化合繊繊維からなるカードウェブと、親水性繊維からなるカードウェブとを重ね合わせ、両者を低圧力水流で予備交絡させてウェブを形成する工程と、ウェブに、所定間隔で高圧水流を当てる水流交絡処理により、Ａ相と、このＡ相内に帯状の複数のＢ相を形成する水流交絡処理工程と、を備えていることを特徴とする複相構造を持った不織布の製造法を提供する。
【００１２】
水流交絡処理工程は、各帯状Ｂ相について複数本の近接する高圧水流により行うことができる。
さらに本発明は、嵩高で見掛け密度の小さい水難透過性の部分（Ａ相）と、このＡ相と密着し、Ａ相よりも大きい見掛け密度の水易透過性の部分（Ｂ相）とから構成されている、透気性の優れた不織布の製造法において、疎水性の熱融着性繊維を主成分とするカードウェブと、親水性繊維を主成分とするカードウェブとを重ね合わせ、ついで熱風処理を施すことにより熱融着性繊維の一部を溶融させてウェブを形成する工程と、ウェブに、２〜２０mmの間隔で複数の環状突起部を設けた熱グリッドロールを圧着させて加熱圧着させることにより、Ａ相と、このＡ相内に帯状の複数のＢ相を形成する加熱圧着処理工程と、を備えていることを特徴とする複相構造を持った不織布の製造法を提供する。
【００１３】
本発明の複相構造を持った不織布は、嵩高なＡ相部分を主体に、高吸水性樹脂を固定することにより、複合吸収体として利用することが可能である。このような複合吸収体は、吸収体製品の吸収要素として有用である。
【００１４】
また本発明の複相構造を持った不織布は、吸収体製品のトップシート、またはバックシートとして利用することが可能である。
【００１５】
【発明の実施の形態】
本発明の複相構造を持った不織布の基本的な構成について図面を参照して説明する。
図１は、本発明の複相構造を持った不織布を構成するのに適用される、カードウェブからなる疎水性繊維層Ｐと、これに重ね合わされた、同じくカードウェブからなる親水性繊維層Ｑとからなるウェブを示している。このウェブは、複数の列状に延びる部分で、疎水性繊維層Ｐと親水性繊維層Ｑとを相互に部分的に交絡もしくは融着により圧縮させることにより、図２に示すような、本発明の複相構造を持った不織布を構成する。
【００１６】
図２において、疎水性繊維層Ｐと親水性繊維層Ｑとが単に重なり合ったままの状態を保っている領域をＡ相、両層を部分的に交絡もしくは融着させることにより、疎水性繊維層Ｐの構成繊維と、親水性繊維層Ｑの構成繊維とが相互に混ざり合って圧縮され、厚みを低下させた領域をＢ相として示している。
この圧縮は、疎水性繊維層Ｐと親水性繊維層Ｑとを重ね合わせ、両者を低圧力水流で予備交絡させたのち、所定間隔で高圧水流を当てる水流交絡処理により、Ａ相と、このＡ相内に帯状の複数のＢ相を形成することにより行うことができる。
【００１７】
あるいは、疎水性の熱融着性繊維を主成分とするカードウェブと、親水性繊維を主成分とするカードウェブとを重ね合わせ、ついで熱風処理を施すことにより熱融着性繊維の一部を溶融させたのち、２〜２０mmの間隔で複数の環状突起部を設けた熱グリッドロールを圧着させて加熱圧着させることにより、Ａ相と、このＡ相内に帯状の複数のＢ相を形成することができる。
Ａ相とＢ相は、その層構成、物性および機能において、表１に示すように相互に異なっている。
【００１８】
【表１】
表１に示すように、Ａ相は、Ｂ相に対比すると厚さが大きく、見掛け密度が低くバルキーであるが、強度は低い。一方、Ｂ相は薄いが強度が高く、いわば強度の支持体となっていることが分かる。
【００２０】
Ａ相の厚さは、７g/cm2 の圧力下での測定値で0.5mm 〜１０mmの範囲である。
見掛け密度でいえば、0.10g/cm3 以下、多くの例では0.08g/cm3 〜0.02g/cm3 である。
一方、Ｂ相の厚さは、同一条件での測定値で0.1mm 〜１mmの範囲である。見掛け密度でいえば、0.15g/cm3 以上、多くの例では0.17g/cm3 〜0.5g/cm 3 である。
Ａ相とＢ相との強度の比較は容易ではないが、Ａ相が1.0 〜５kg/ ５０mmであるのに対して、Ｂ相は４kg/ ５０mm〜２０kg/ ５０mmである。
上記の層構成、強度および見掛け密度におけるＡ相およびＢ相間の相違を倍率で示すと、Ａ相とＢ相との間には下記の範囲で示すような差があることが分かる。
厚さ： Ａ／Ｂ＝1.5 倍〜30倍 （通常は３〜10倍）
強度： Ｂ／Ａ＝2.0 倍〜20倍 （通常は2.5 〜10倍）
見掛け密度： Ｂ／Ａ＝1.5 倍〜10倍 （通常は2.0 〜5.0 倍）
【００２１】
疎水性繊維層Ｐの構成繊維としては、
ＰＰ繊維、ＰＥＴ繊維、ＰＥ繊維等の合成繊維類、またはこれらの複合繊維、あるいはその混合体が挙げられるが、Ｂ相の形成に融着を適用する場合には、融着成分として、易熱融着成分を含むものがよい。易熱融着性繊維の例としては、易溶融性ＰＥＴコポリマー、ＰＥ／ＰＥＴ複合繊維、ＰＥ／ＰＰ複合繊維、易溶融性ＰＰコポリマー／ＰＰ複合繊維等が挙げられる。
親水性繊維層Ｑの構成繊維としては、レーヨン、コットン、アセテート等のセルロース系繊維、あるいは上記合成繊維の親水性加工繊維が用いられ、Ｐ：Ｑの割合は、Ｑの含有量で表すと、全体の１０〜９０％以上、好ましくは２０〜６０％が好ましい。
【００２２】
Ａ相とＢ相との間で最も重要な相違点は、水透過性である。
すなわちＡ相は、疎水性繊維層と親水性繊維とが互いにほとんど混ざり合うことがなく重なった状態であるため、疎水性の表面側に水性液体が接触させても、圧力を掛けない限り透過させることは難しい。一方、Ｂ相は、疎水性繊維面から見ると、疎水性繊維の中に親水性繊維が混ざり込み、多数の親水性繊維が先端を表面に露出している構造を持っている。しかも親水性繊維の存在割合は、通常のＢ層作成方法では下層（親水性層側）が明らかに多いので、厚さ方向に関して親水性の勾配を持つことになる。
【００２３】
このような構造のため、Ｂ相に水性液体が接触すると、このＢ相を通じて液体は素早く浸透し、Ｂ相を透過することになる。
このような特性を有する本発明の複相構造を持った不織布を、例えば吸収体製品において、疎水性表面を着用者の皮膚側に位置するような配置でトップシート（皮膚接触シート）として利用すると、着用者から排出された液体は、Ｂ相を通じて素早く吸収されるが、Ａ相の表面は濡れず、しかも水分は残存しないので、皮膚の乾燥状態が保たれる。
さらに、例えばシート状吸収体の基布として利用し、バルキーな疎水性面のＡ相に部分に高吸水性樹脂（ＳＡＰ）のスラリーをコーティングして、ＳＡＰ粒子を繊維間に包蔵させた構造とした場合には、Ｂ相は液体を分配、拡散させるためのチャンネルとして働き、吸収体の面積利用効率の向上に寄与する。
【００２４】
このようなＡ相およびＢ相の互いに異なる機能を有効に、かつ効率的に発揮させるためには、Ｂ相の存在状態が重要である。第１はＢ相の幅であり、第２はＢ相の存在面積である。
【００２５】
本発明の一つの形態では、Ｂ相はＡ相の中に複数の帯状に分布している。このＢ相の帯は、連続する１本の帯であっても、不連続な複数の帯であってもよいが、ある程度の幅を持つ帯であることが重要である。きわめて幅の狭い線状である場合には、排出される液体の表面張力の程度にもよるが、液体が線をまたぐ粒状を形成し、スムースな浸透が行われない。
【００２６】
帯状のＢ相の幅は、疎水性表面の性状等の条件によっても異なるが、通常は１mmもしくはそれ以上が好ましく、さらに好ましくは２mm〜２０mmであることが望ましい。
【００２７】
このような幅を持つＢ相を形成するためには、グリッドロールを用いて熱で溶融させた状態で圧着する場合には、使用するグリッドロールのグリッド幅を規定すればよい。また高圧水流による水流交絡を適用する場合には、連続に配置されたノズルを持つ１本のノズルビームを用いたのでは上記の好ましい範囲の幅の帯状を形成することが難しいので、２〜５個のノズル群を一定間隔で配置したノズルビームを使用するのが望ましい。この場合に形成されるＢ相の帯は、微視的には複数列の交絡線の集合であるが、全体としては所望の幅の帯として機能する。
なお、ノズルビームを使用する場合、吐出孔の数が多すぎると、高圧水流がフラッディングを起こし、好ましい交絡パターンが得られないことがあるので注意が必要である。
疎水性繊維層と親水性繊維層とを低圧力の水流で予備交絡させたウェブを使用する場合、この予備水流交絡は細かいピッチのノズルを用い、例えば２０kg/cm2 程度の低い圧力で水流交絡を行い、Ｂ相形成のための水流交絡はそれよりも著しく高い、例えば５０kg/cm 2 もしくはそれ以上の高圧で行うことが望ましい。
【００２８】
【実施例】
（実施例１）
＜複相構造を持った不織布の製造＞
下記の組成の疎水性繊維層Ｐおよび親水性繊維層Ｑからなる２層のカードウェブを用意した。
ついで第二段処理として、ノズル径0.15mmφ、ノズル間隔１mmで配置された３個のノズルからなるノズル群を、相互に１５mmの間隔で設けたノズルビームを用いて、８０kg/cm 2 の水流圧で部分的な強度の交絡処理を行った後、乾燥させて、Ａ相内にＢ相が複数の帯状に分布する複相構造を持った水流交絡不織布を得た。
【００２９】
得られた不織布は、図３に示すように、嵩高なＡ相と、低密度のＢ相とを持ち、Ｂ相の割合（Ｂ／（Ａ＋Ｂ）×１００）は約１５％、Ａ相の見掛け密度は0.07g/cm3 、Ｂ相の見掛け密度は0.2g/cm 3 であった。
【００３０】
＜高吸水性樹脂（ＳＡＰ）のコーティング基材としての利用＞
ＰＥＯ（製紙用粘材、住友精化製）の0.5 ％水溶液に、EtOHをEtOH／水＝６０／４０になるように添加して、一部ゲル状になった高粘度液に、ＳＡＰ（住友精化製、商品名「SA-60S」）を約２０％になるように添加してＳＡＰのスラリーを調製した。
この粘稠なスラリーを上記の不織布の疎水性繊維層Ｐ表面にアプリケータを用いて、ＳＡＰ目付で200g/m2 になるように塗布し、脱溶媒、乾燥させて、シート状の吸収体を得た。
得られた吸収体を観察すると、ＳＡＰのほとんどはＡ相の部分に存在し、Ｂ相の部分にはほとんど存在しなかった。Ａ相のＳＡＰがウェブに安定に捕捉され、乾燥後に振動処理してもほとんどＳＡＰの脱落は生じなかった。
【００３１】
（実施例２）
下記の組成の疎水性繊維層Ｐおよび親水性繊維層Ｑからなる２層のカードウェブを用意した。
得られたウェブの表面に、周面に幅３mmの環状突起が１０mm間隔で形成され、表面がテフロン加工された鉄製のグリッドロールを表面温度１８０℃に加熱し、４０kg/cmの圧力で圧着させながら、２０m/minの速度で移動させた。
【００３２】
これにより得られた不織布は、図４に示すように、嵩高なＡ相と、圧縮および融着されたＢ相を有するもので、Ｂ相の割合（Ｂ／Ａ＋Ｂ×１００）は約３０％、Ａ相の見掛け密度は0.06g/cm3 、Ｂ相の見掛け密度は0.3g/cm 3 であった。
【００３３】
＜吸収体の表面材としての利用＞
市販オムツ（ユニチャーム社製、商品名「マミーポコパワースリム」）の表面材を取り除き、上記の不織布に差し替えて生理食塩水を注入して吸収テストを行ったところ、液はＢ相からのみ急速に吸収され、吸収分は逆戻りも吸収残りも認められず、きわめてドライな状態を保っていた。
【００３４】
【発明の効果】
以上に説明したように本発明の複相構造を持った不織布は、嵩高で見掛け密度の小さい水難透過性の部分（Ａ相）と、このＡ相と密着し、Ａ相よりも大きい見掛け密度の水易透過性の部分（Ｂ相）とから構成されている、透気性の優れた不織布において、Ａ相は疎水性繊維層と親水性繊維層とが層状に重なった構造を有し、Ｂ相は疎水性繊維と親水性繊維とが混在した状態で圧縮された構造を有している。これにより、表面ドライ感の維持と高い水透過性という矛盾を解決し、さらにアクイジション機能を効果的に発揮させるなどの機能面での改善を達成することができる。したがって、この複相構造を持った不織布を吸収体製品に、疎水性表面を着用者の皮膚側に位置するような配置でトップシートに利用した場合、着用者から排出された液体は、Ｂ相を通じて素早く吸収されるが、Ａ相の表面は濡れず、しかも水分は残存しないので、皮膚の乾燥状態が保たれるという顕著な効果が得られる。
【図面の簡単な説明】
【図１】本発明の複相構造を持った不織布を構成するのに適用される疎水性繊維層と親水性繊維層からなるウェブを模式的に示す断面図。
【図２】本発明の複相構造を持った不織布を模式的に示す断面図。
【図３】本発明の実施例１で得られた複相構造を持った不織布を模式的に示す断面図。
【図４】本発明の実施例２で得られた複相構造を持った不織布を模式的に示す断面図。
【符号の説明】
Ｐ 疎水性繊維層
Ｑ 親水性繊維層
ＷＪ ウォータージェットシールライン
ＨＺ ヒートシールゾーン[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a nonwoven fabric in which one surface is hydrophilic and the other surface is hydrophobic and excellent in air permeability, and a method for producing the nonwoven fabric. Furthermore, the present invention relates to absorbent products such as diapers for children and adults, sanitary products for women, medical care products and the like using such nonwoven fabric.
[0002]
[Prior art]
In the absorbent product, the basic idea for expressing the function of absorbing and fixing the liquid is a top sheet excellent in liquid permeability, an acquisition layer for temporarily diffusing and storing the liquid, It consists of the concept of appropriately combining an absorption layer that absorbs liquid and stably fixes it.
[0003]
In the prior art, a relatively thin porous nonwoven fabric that is hydrophilic or hydrophilized as the top sheet, a bulky nonwoven fabric with high compression resistance as the acquisition layer, and a highly water absorbent resin (SAP) as the absorption layer / Pulp mixtures are used in combination as separate and independent elements.
[0004]
[Problems to be solved by the invention]
Therefore, in order to continuously manufacture absorbent products on an industrial scale, separate types of materials corresponding to each element of the top sheet, the acquisition layer, and the SAP / pulp mixture that form the main component of absorption are separately provided. In order to integrate these other types of materials, it is necessary to use a large amount of a binder such as hot melt in each of several steps. It becomes extremely complicated.
[0005]
Further, for example, maintaining the surface dry feeling required for the top sheet and high water permeability are mutually contradictory conditions, and the conventional technology also has a big problem here.
In order to resolve the contradiction of maintaining the dryness of the surface and high water permeability that the conventional technologies mentioned above have, and to achieve functional improvements such as making the acquisition function effective. It is necessary to effectively arrange the hydrophobic fiber layer and the hydrophilic fiber layer to keep the air permeability and water permeability more stable. Such a problem can be solved only by combining elements having individual functions into a composite structure.
[0006]
The present invention provides a nonwoven fabric having such a multi-function and having a multiphase structure and a method for producing the same.
[0007]
[Means for Solving the Problems]
According to the present invention, a water-permeable portion (A phase) that is bulky and has a small apparent density, and a water-permeable portion (B phase) that is in close contact with the A phase and has an apparent density that is larger than the A phase. In the non-woven fabric with excellent air permeability, the A phase has a structure in which the hydrophobic fiber layer and the hydrophilic fiber layer overlap each other in a layered state, and the B phase includes a mixture of hydrophobic fibers and hydrophilic fibers. A nonwoven fabric having a multiphase structure characterized by having a structure compressed by hydroentanglement in a state is provided.
[0008]
Preferably, the apparent density of the A phase is 0.10 g / cm 3 or less, and the apparent density of the B phase is 0.15 g / cm 3 or more.
The ratio of the area A occupied by the A phase and the area B occupied by the B phase can be selected in a wide range, but the preferred range is:
B / (A + B) × 100 = 10 to 60 (%)
It is.
The B phase is distributed in a plurality of strips within the A phase, and the width of each strip B phase is 1 mm or more, preferably 2 mm to 20 mm. This band is preferably a single continuous band, but may be a discontinuous band.
[0009]
The non-woven fabric is preferably a belt-like B phase in which a card web made of hydrophobic synthetic fiber and a card web made of hydrophilic fiber are superposed and closely adhered to the A phase preliminarily entangled with a low-pressure water flow. However, it is formed by carrying out the hydroentanglement process with a plurality of high-pressure water streams.
The interval between the belt-like B phases formed by the hydroentanglement treatment is preferably 10 mm or more.
[0010]
Alternatively, as a non-woven fabric, a card web mainly composed of hydrophobic heat-fusible fibers and a card web mainly composed of hydrophilic fibers are overlapped and then subjected to hot air treatment to form the whole. The belt-like B layer can be provided by using the non-woven fabric and heat-pressing with a hot grid roll.
[0011]
The present invention also comprises a hardly water-permeable portion (A phase) that is bulky and has a small apparent density, and a readily water-permeable portion (B phase) that is in close contact with the A phase and has an apparent density that is larger than the A phase. In a method for producing a nonwoven fabric with excellent air permeability, a card web made of hydrophobic synthetic fibers and a card web made of hydrophilic fibers are overlapped, and the web is pre-entangled with a low-pressure water flow. And a hydroentanglement treatment step of forming a plurality of strip-like B phases in the A phase by hydroentanglement treatment in which a high-pressure water stream is applied to the web at predetermined intervals. A method for producing a nonwoven fabric having a multiphase structure characterized by the following:
[0012]
The hydroentanglement process step can be performed by a plurality of adjacent high-pressure water streams for each strip B phase.
Furthermore, the present invention is composed of a water-permeable portion (A phase) that is bulky and has a small apparent density, and a water-permeable portion (B phase) that is in close contact with the A phase and has an apparent density that is larger than the A phase. In a method for producing a nonwoven fabric having excellent air permeability, a card web mainly composed of hydrophobic heat-fusible fibers and a card web mainly composed of hydrophilic fibers are overlapped, and then hot air treatment is performed. And a step of melting a part of the heat-fusible fiber to form a web, and a heat grid roll provided with a plurality of annular projections at intervals of 2 to 20 mm is heat-bonded to the web. By this, the manufacturing method of the nonwoven fabric with a multiphase structure characterized by including the A phase and the thermocompression-bonding process process which forms several strip | belt-shaped B phases in this A phase is provided.
[0013]
The nonwoven fabric having a multiphase structure of the present invention can be used as a composite absorbent body by fixing a superabsorbent resin mainly with a bulky A phase portion. Such a composite absorbent is useful as an absorbent element of an absorbent product.
[0014]
Moreover, the nonwoven fabric having a multiphase structure of the present invention can be used as a top sheet or a back sheet of an absorbent product.
[0015]
DETAILED DESCRIPTION OF THE INVENTION
A basic configuration of the nonwoven fabric having a multiphase structure of the present invention will be described with reference to the drawings.
FIG. 1 shows a hydrophobic fiber layer P made of a card web and a hydrophilic fiber layer Q made of a card web, which is superimposed on the hydrophobic fiber layer P, which is applied to construct the nonwoven fabric having a multiphase structure of the present invention. A web consisting of This web is a portion extending in a plurality of rows, and the hydrophobic fiber layer P and the hydrophilic fiber layer Q are partially compressed with each other by entanglement or fusion, so that the present invention as shown in FIG. A non-woven fabric having a multiphase structure is constructed.
[0016]
In FIG. 2, the region in which the hydrophobic fiber layer P and the hydrophilic fiber layer Q are simply kept in an overlapping state is the A phase, and the two layers are partially entangled or fused together to form the hydrophobic fiber layer. A region where the constituent fibers of P and the constituent fibers of the hydrophilic fiber layer Q are mixed and compressed to reduce the thickness is shown as a B phase.
In this compression, the hydrophobic fiber layer P and the hydrophilic fiber layer Q are overlapped, and both are pre-entangled with a low-pressure water flow, and then subjected to a hydro-entanglement process in which a high-pressure water flow is applied at a predetermined interval, and the A phase This can be done by forming a plurality of strip-like B phases in the phase.
[0017]
Alternatively, a card web mainly composed of hydrophobic heat-fusible fibers and a card web mainly composed of hydrophilic fibers are overlapped, and then subjected to hot air treatment to partially remove the heat-fusible fibers. After melting, a thermal grid roll provided with a plurality of annular projections at intervals of 2 to 20 mm is crimped and thermocompression bonded, thereby forming an A phase and a plurality of strip-like B phases within the A phase. be able to.
As shown in Table 1, the A phase and the B phase are different from each other in the layer configuration, physical properties, and functions.
[0018]
[Table 1]
As shown in Table 1, the A phase is thicker than the B phase, has a low apparent density and is bulky, but has a low strength. On the other hand, although the B phase is thin, the strength is high, so that it can be seen that it is a strong support.
[0020]
The thickness of the A phase is in the range of 0.5 mm to 10 mm as measured under a pressure of 7 g / cm 2 .
In terms of apparent density, 0.10 g / cm 3 or less, in many instances it is 0.08g / cm 3 ~0.02g / cm 3 .
On the other hand, the thickness of the B phase is in the range of 0.1 mm to 1 mm as measured under the same conditions. In terms of apparent density, 0.15 g / cm 3 or more, in many instances it is 0.17g / cm 3 ~0.5g / cm 3 .
Although it is not easy to compare the strength of the A phase and the B phase, the A phase is 1.0 to 5 kg / 50 mm, whereas the B phase is 4 kg / 50 mm to 20 kg / 50 mm.
When the difference between the A phase and the B phase in the layer configuration, strength, and apparent density is shown in terms of magnification, it can be seen that there is a difference between the A phase and the B phase as shown in the following range.
Thickness: A / B = 1.5 to 30 times (usually 3 to 10 times)
Strength: B / A = 2.0 times to 20 times (usually 2.5 to 10 times)
Apparent density: B / A = 1.5 to 10 times (usually 2.0 to 5.0 times)
[0021]
As constituent fibers of the hydrophobic fiber layer P,
Synthetic fibers such as PP fiber, PET fiber, PE fiber, etc., or composite fibers thereof, or a mixture thereof may be mentioned. When fusion is applied to the formation of the B phase, as a fusion component, Those containing a fusing component are preferred. Examples of the easily heat-fusible fiber include easily meltable PET copolymer, PE / PET composite fiber, PE / PP composite fiber, and easily meltable PP copolymer / PP composite fiber.
As the constituent fibers of the hydrophilic fiber layer Q, cellulosic fibers such as rayon, cotton, acetate, or the hydrophilic processed fibers of the above synthetic fibers are used, and the ratio of P: Q is expressed by the content of Q. 10 to 90% or more of the whole, preferably 20 to 60% is preferable.
[0022]
The most important difference between the A phase and the B phase is water permeability.
That is, the A phase is in a state where the hydrophobic fiber layer and the hydrophilic fiber are almost not mixed with each other and are overlapped with each other. It ’s difficult. On the other hand, when viewed from the surface of the hydrophobic fiber, the B phase has a structure in which hydrophilic fibers are mixed in the hydrophobic fibers and a large number of hydrophilic fibers are exposed on the surface. Moreover, since the lower layer (hydrophilic layer side) is clearly present in the ordinary B layer preparation method, the existing ratio of hydrophilic fibers has a hydrophilic gradient in the thickness direction.
[0023]
Due to such a structure, when an aqueous liquid comes into contact with the B phase, the liquid quickly permeates through the B phase and permeates the B phase.
When the non-woven fabric having the multi-phase structure of the present invention having such characteristics is used as a top sheet (skin contact sheet), for example, in an absorbent product, in such an arrangement that the hydrophobic surface is located on the skin side of the wearer. The liquid discharged from the wearer is quickly absorbed through the B phase, but the surface of the A phase does not get wet and moisture does not remain, so that the skin is kept dry.
Furthermore, for example, it is used as a base fabric of a sheet-like absorbent body, and a structure in which a slurry of a highly water-absorbent resin (SAP) is coated on a part of the bulky hydrophobic surface A phase and SAP particles are embedded between fibers. In this case, the B phase functions as a channel for distributing and diffusing the liquid, and contributes to improvement of the area utilization efficiency of the absorber.
[0024]
In order to effectively and efficiently exhibit such different functions of the A phase and the B phase, the existence state of the B phase is important. The first is the width of the B phase, and the second is the existing area of the B phase.
[0025]
In one form of the present invention, the B phase is distributed in a plurality of strips within the A phase. The B-phase band may be one continuous band or a plurality of discontinuous bands, but it is important that the band has a certain width. In the case of a very narrow line shape, depending on the surface tension of the liquid to be discharged, the liquid forms a grain that crosses the line, and smooth permeation is not performed.
[0026]
The width of the band-like B phase varies depending on conditions such as the properties of the hydrophobic surface, but is usually preferably 1 mm or more, more preferably 2 mm to 20 mm.
[0027]
In order to form the B phase having such a width, the grid width of the grid roll to be used may be specified in the case of pressure bonding in a state where the grid roll is melted by heat. In addition, in the case of applying hydroentanglement by high-pressure water flow, it is difficult to form a band with a width in the above preferred range by using a single nozzle beam having nozzles arranged continuously. It is desirable to use a nozzle beam in which a group of nozzles are arranged at regular intervals. The B-phase band formed in this case is a set of confounding lines of a plurality of rows microscopically, but functions as a band having a desired width as a whole.
It should be noted that when using a nozzle beam, if the number of discharge holes is too large, the high-pressure water flow causes flooding, and a preferable entanglement pattern may not be obtained.
When a web in which a hydrophobic fiber layer and a hydrophilic fiber layer are pre-entangled with a low-pressure water flow is used, this pre-water flow entanglement uses a fine pitch nozzle, for example, water entanglement at a low pressure of about 20 kg / cm 2. It is desirable that the hydroentanglement for forming the B phase is significantly higher than that, for example, at a high pressure of 50 kg / cm 2 or more.
[0028]
【Example】
Example 1
<Manufacture of non-woven fabric with multiphase structure>
A two-layer card web comprising a hydrophobic fiber layer P and a hydrophilic fiber layer Q having the following composition was prepared.
Next, as a second stage treatment, a water flow pressure of 80 kg / cm 2 was obtained using a nozzle beam consisting of three nozzles arranged at a nozzle diameter of 0.15 mmφ and a nozzle interval of 1 mm at intervals of 15 mm. After the partial entanglement treatment was performed, the water entangled nonwoven fabric having a multiphase structure in which the B phase was distributed in a plurality of strips in the A phase was obtained.
[0029]
As shown in FIG. 3, the obtained nonwoven fabric has a bulky A phase and a low density B phase, and the ratio of the B phase (B / (A + B) × 100) is about 15%. The density was 0.07 g / cm 3 and the apparent density of the B phase was 0.2 g / cm 3 .
[0030]
<Utilization of superabsorbent resin (SAP) as a coating substrate>
EtOH is added to a 0.5% aqueous solution of PEO (Paper adhesive, manufactured by Sumitomo Seika) so that EtOH / water = 60/40, and SAP (Sumitomo) is added to the partially viscous gelled liquid. A slurry of SAP was prepared by adding Seiko Seisaku, trade name “SA-60S”) to about 20%.
The viscous slurry is applied to the surface of the hydrophobic fiber layer P of the above nonwoven fabric using an applicator so that the SAP basis weight is 200 g / m 2 , and the solvent is removed and dried. Obtained.
When the obtained absorber was observed, most of the SAP was present in the A-phase portion and hardly present in the B-phase portion. The A-phase SAP was stably captured on the web, and almost no SAP was dropped even when subjected to vibration treatment after drying.
[0031]
(Example 2)
A two-layer card web comprising a hydrophobic fiber layer P and a hydrophilic fiber layer Q having the following composition was prepared.
On the surface of the obtained web, an iron grid roll with 3 mm wide annular protrusions formed on the peripheral surface at 10 mm intervals and a Teflon-processed surface is heated to a surface temperature of 180 ° C. and pressed at a pressure of 40 kg / cm. However, it was moved at a speed of 20 m / min.
[0032]
As shown in FIG. 4, the nonwoven fabric obtained by this has a bulky A phase and a compressed and fused B phase, and the ratio of B phase (B / A + B × 100) is about 30%, The apparent density of the A phase was 0.06 g / cm 3 and the apparent density of the B phase was 0.3 g / cm 3 .
[0033]
<Utilization of absorber as surface material>
The surface material of a commercial diaper (made by Unicharm, trade name “Mummy Poko Power Slim”) was removed, replaced with the above non-woven fabric and injected with physiological saline. Absorbed, no reversal or absorption remaining was observed, and it was kept very dry.
[0034]
【The invention's effect】
As described above, the nonwoven fabric having a multiphase structure according to the present invention has a bulky and hardly water-permeability portion (A phase), which is in close contact with the A phase and has an apparent density larger than that of the A phase. In the nonwoven fabric excellent in air permeability, which is composed of a water-permeable portion (B phase), the A phase has a structure in which a hydrophobic fiber layer and a hydrophilic fiber layer are layered, and the B phase Has a structure compressed with a mixture of hydrophobic fibers and hydrophilic fibers. Thereby, the contradiction between the maintenance of the surface dry feeling and the high water permeability can be solved, and further, the improvement in the functional aspect such as the effective acquisition function can be achieved. Therefore, when the non-woven fabric having this multiphase structure is used for the absorbent product and the top sheet is arranged such that the hydrophobic surface is located on the skin side of the wearer, the liquid discharged from the wearer is the B phase. However, since the surface of the A phase is not wetted and moisture does not remain, a remarkable effect is obtained in that the skin is kept dry.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view schematically showing a web composed of a hydrophobic fiber layer and a hydrophilic fiber layer applied to construct a nonwoven fabric having a multiphase structure of the present invention.
FIG. 2 is a cross-sectional view schematically showing a nonwoven fabric having a multiphase structure according to the present invention.
FIG. 3 is a cross-sectional view schematically showing a nonwoven fabric having a multiphase structure obtained in Example 1 of the present invention.
FIG. 4 is a cross-sectional view schematically showing a nonwoven fabric having a multiphase structure obtained in Example 2 of the present invention.
[Explanation of symbols]
P Hydrophobic fiber layer Q Hydrophilic fiber layer WJ Water jet seal line HZ Heat seal zone
Claims (12)
前記Ａ相は疎水性繊維層と親水性繊維層とが層状に重なった構造を有し、前記Ｂ相は疎水性繊維と親水性繊維とが混在した状態で水流交絡により圧縮された構造を有していることを特徴とする複相構造を持った不織布。It is composed of a water-impermeable portion (A phase) that is bulky and has a small apparent density, and a water-permeable portion (B phase) that is in close contact with the A phase and has an apparent density that is larger than the A phase. In the nonwoven fabric with excellent air permeability,
The A phase has a structure in which a hydrophobic fiber layer and a hydrophilic fiber layer overlap each other, and the B phase has a structure compressed by hydroentanglement with a mixture of hydrophobic fibers and hydrophilic fibers. Nonwoven fabric with a multiphase structure characterized by
Ｂ／（Ａ＋Ｂ）×１００＝１０〜６０（％）
である請求項１または２に記載の複相構造を持った不織布。The ratio of the area A occupied by the A phase and the area B occupied by the B phase is
B / (A + B) × 100 = 10 to 60 (%)
The nonwoven fabric having a multiphase structure according to claim 1 or 2.
疎水性の化合繊繊維からなるカードウェブと、親水性繊維からなるカードウェブとを重ね合わせ、両者を低圧力水流で予備交絡させてウェブを形成する工程と、
前記ウェブに、所定間隔で高圧水流を当てる水流交絡処理により、Ａ相と、このＡ相内に帯状の複数のＢ相を形成する水流交絡処理工程と、
を備えていることを特徴とする複相構造を持った不織布の製造法。It is composed of a water-impermeable portion (A phase) that is bulky and has a small apparent density, and a water-permeable portion (B phase) that is in close contact with the A phase and has an apparent density that is larger than the A phase. In the manufacturing method of non-woven fabric with excellent air permeability,
A step of superposing a card web made of hydrophobic synthetic fiber and a card web made of hydrophilic fiber to form a web by pre-entanglement of both with a low-pressure water flow;
A hydroentanglement treatment step of forming a plurality of strip-like B phases in the A phase by hydroentanglement treatment in which a high-pressure water flow is applied to the web at a predetermined interval;
A process for producing a non-woven fabric having a multiphase structure characterized by comprising:
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| JP2000205294A JP4543196B2 (en) | 2000-07-06 | 2000-07-06 | Non-woven fabric having a multiphase structure and method for producing the same |
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| JP2000205294A JP4543196B2 (en) | 2000-07-06 | 2000-07-06 | Non-woven fabric having a multiphase structure and method for producing the same |
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| JP4543196B2 true JP4543196B2 (en) | 2010-09-15 |
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| GB2554651A (en) * | 2016-09-30 | 2018-04-11 | Adv Med Solutions Ltd | Nonwoven fabric |
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| WO2017208775A1 (en) | 2016-05-30 | 2017-12-07 | 花王株式会社 | Absorbent article |
| JP7017886B2 (en) * | 2017-09-06 | 2022-02-09 | 花王株式会社 | Sheet for absorbent articles |
| JP7390970B2 (en) * | 2020-05-14 | 2023-12-04 | ユニ・チャーム株式会社 | absorbent articles |
| JP2022046325A (en) * | 2020-09-10 | 2022-03-23 | ユニ・チャーム株式会社 | Body fluid absorption sheet |
| CN113786287B (en) * | 2021-08-31 | 2022-07-05 | 福建恒安集团有限公司 | Paper diaper and preparation method thereof |
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| JPH08216310A (en) * | 1995-02-17 | 1996-08-27 | Nippon Kyushutai Gijutsu Kenkyusho:Kk | Porous welded composite material sheet and its production |
| JPH0931821A (en) * | 1995-05-18 | 1997-02-04 | Unitika Ltd | Elastic conjugate nonwoven fabric and its production |
| JPH0976388A (en) * | 1995-09-19 | 1997-03-25 | Nippon Kyushutai Gijutsu Kenkyusho:Kk | Water-permeable composite sheet |
| JPH11350322A (en) * | 1998-06-11 | 1999-12-21 | Daiwabo Co Ltd | Absorber base, its production and absorber using the same |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2554651A (en) * | 2016-09-30 | 2018-04-11 | Adv Med Solutions Ltd | Nonwoven fabric |
| GB2554651B (en) * | 2016-09-30 | 2019-08-28 | Adv Med Solutions Ltd | Nonwoven Fabric Comprising Gelling Fibres |
| US11459679B2 (en) | 2016-09-30 | 2022-10-04 | Advanced Medical Solutions Limited | Nonwoven fabric |
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|---|---|
| JP2002020957A (en) | 2002-01-23 |
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