JP5154048B2 - Non-woven - Google Patents

Description

The present invention relates to a nonwoven fabric.

  Conventionally, non-woven fabrics are used in a wide range of fields such as sanitary products such as paper diapers and sanitary napkins, cleaning products such as wipers, and medical products such as masks. In this way, non-woven fabrics are used in various different fields, but when actually used in products in each field, they must be manufactured to have properties and structures suitable for the use of each product. It is.

  The nonwoven fabric is formed by, for example, forming a fiber layer (fiber web) by a dry method or a wet method and bonding fibers forming the fiber layer by a chemical bond method, a thermal bond method, or the like. In the step of bonding the fibers forming the fiber layer, there are also methods including applying a physical force from the outside to the fiber layer, such as a method of repeatedly piercing a large number of needles into this fiber layer and a method of jetting water flow. .

  However, these methods merely entangle the fibers, and do not adjust the orientation and arrangement of the fibers in the fiber layer, the shape of the fiber layer, and the like. That is, what was manufactured by these methods was a simple sheet-like nonwoven fabric.

Moreover, the nonwoven fabric provided with the opening is also proposed. In order to form the opening in the nonwoven fabric, the nonwoven fabric is sandwiched between a pressing die having a protrusion such as a needle protruding outward and the support on the receiving side that receives the protrusion, and the protruding portion is made to penetrate the nonwoven fabric. Discloses a method of opening three-dimensionally (see, for example, Patent Document 1).
JP-A-6-330443

  However, in such a nonwoven fabric, irregularities and openings are formed when the fiber assembly constituting the nonwoven fabric is bitten between the protruding portion and the receiving support. For this reason, for example, the fiber in the wall part of the convex part and the entire circumference of the opening is compressed to increase the fiber density, and further, heat may be applied to form a non-woven fabric.

  Therefore, for example, when such a nonwoven fabric is used for a surface sheet of an absorbent article, the fiber density of the wall portion of the convex portion and the entire circumference of the opening is high, and the external pressure is reduced by being formed into a film. Even if it is added, the valve (nonwoven fabric broken by the needle or the like) is unlikely to fall down and the opening is not easily crushed, but the liquid tends to be hardly transmitted downward. Then, when a large amount of liquid is brought to the convex part or the opening periphery, the liquid stays in the nonwoven fabric, and there is a possibility that the wearer's skin or the like is soiled or uncomfortable.

  The present invention provides a non-woven fabric in which irregularities and openings are formed, and the non-woven fabric is adjusted so that only a part of the periphery of the opening is densified without extremely increasing the fiber density in the convex portions and concave portions. The purpose is to do.

  The present inventors apply a gas from the upper surface side to a fiber web that is supported from the lower surface side by a predetermined mesh-like support member to move the fibers constituting the fiber web, thereby making the openings and the peripheral edge of the opening one. It has been found that only the part can be densified, and the present invention has been completed.

  (1) A nonwoven fabric having a longitudinal direction and a transverse direction, comprising a plurality of openings formed in the longitudinal direction, wherein one side edge in each of the plurality of openings is in the transverse direction A non-woven fabric having a fiber density higher than that of the other side edge.

  (2) The nonwoven fabric according to (1), wherein the one side edge portion has a higher basis weight than the other side edge portion.

  (3) a predetermined opening in the plurality of openings, and a first connecting portion formed between the predetermined opening and a first adjacent opening adjacent in the vertical direction, 1 connection part is a nonwoven fabric as described in (1) or (2) whose fiber density is higher than the said other side edge part in the said predetermined opening part.

  (4) The nonwoven fabric according to (3), wherein the one side edge portion in the first adjacent opening has a content of longitudinally oriented fibers higher than a content of horizontally oriented fibers.

  (5) The said 1st connection part is a nonwoven fabric as described in (3) or (4) whose content rate of a laterally oriented fiber is higher than the content rate of a longitudinally oriented fiber.

  (6) The nonwoven fabric according to any one of (3) to (5), wherein the first connecting portion has a higher basis weight than the other side edge portion in the predetermined opening.

  (7) a second connecting portion formed between the predetermined opening and the second adjacent opening adjacent to the side opposite to the first adjacent opening in the vertical direction in the predetermined opening; The nonwoven fabric according to any one of (3) to (6), wherein the second connecting portion has a fiber density higher than that of the other side edge portion in the predetermined opening.

  (8) The one side edge in the first adjacent opening is a side edge opposite to the one side edge in the predetermined opening in the lateral direction, and the second adjacent opening The one side edge of the predetermined opening is a side edge opposite to the one side edge of the predetermined opening in the lateral direction, and is more than the other side edge of the predetermined opening. The one side edge in the first adjacent opening, which is a region having a high fiber density, the first connecting part, the one side edge in the predetermined opening, and the second connecting part. The nonwoven fabric according to (7), wherein the one side edge portion in the second adjacent opening portion is continuous in a serpentine shape.

(9) The fiber density of the first connecting portion is 0.05 g / cm ³ or more, 1.1 times or more of the fiber density of the other side edge portion in the predetermined opening, The fiber density of the second connecting portion is 0.05 g / cm ³ or more, and is 1.1 times or more the fiber density of the other side edge portion in the predetermined opening (7) or The nonwoven fabric as described in (8).

  (10) The nonwoven fabric according to any one of (7) to (9), wherein the one side edge portion in the second adjacent opening has a content of longitudinally oriented fibers higher than a content of horizontally oriented fibers.

  (11) The non-woven fabric according to any one of (7) to (10), wherein the second connecting portion has a content of horizontally oriented fibers higher than a content of vertically oriented fibers.

  (12) The nonwoven fabric according to any one of (7) to (11), wherein the second connecting portion has a higher basis weight than the other side edge portion in the predetermined opening.

(13) The basis weight of the one side edge in the predetermined opening, the basis weight of the one side edge in the first adjacent opening, and the one side edge in the second adjacent opening The basis weight is 15 to 250 g / m ² , and the basis weight of the other side edge in the predetermined opening, the basis weight of the other side edge in the first adjacent opening, and the second The nonwoven fabric according to any one of (7) to (12), which is 1.1 times or more the basis weight of the other side edge in the adjacent opening.

  (14) A plurality of grooves formed on one surface side of the nonwoven fabric so as to extend in the longitudinal direction, and formed on the one surface side along the plurality of groove portions, respectively, so as to extend in the longitudinal direction. The nonwoven fabric according to any one of (1) to (13), wherein the plurality of openings are formed in each of the plurality of grooves.

  (15) The nonwoven fabric according to any one of (1) to (14), wherein each of the plurality of openings has a substantially circular shape or a substantially elliptical shape.

  (16) A nonwoven fabric having a longitudinal direction and a transverse direction, in which a high-density region is formed continuously or intermittently, wherein the high-density region comprises a plurality of longitudinal high-density regions extending in the longitudinal direction. .

  (17) The nonwoven fabric according to (16), wherein the high-density region includes a plurality of U-shaped high-density regions that are open on one side in the lateral direction.

  The “U-shape” includes a “reverse U-shape”. That is, the “U-shaped high-density region” includes “an inverted U-shaped high-density region”.

  (18) The non-woven fabric according to (16) or (17), wherein the high-density region includes a meandering high-density region extending in a meandering manner in the vertical direction.

  The present invention has been made in view of the problems as described above, and in a nonwoven fabric in which unevenness and openings are formed, the fiber density in the protrusions and recesses is not extremely high, and part of the periphery of the opening. It is possible to provide a non-woven fabric that has been adjusted to increase the density only.

  Moreover, the nonwoven fabric in which 1 or 2 or more of the predetermined groove part, opening part, or projection part was formed, the manufacturing method of this nonwoven fabric, and a nonwoven fabric manufacturing apparatus can be provided.

  The best mode for carrying out the present invention will be described below with reference to the drawings.

  Drawing 1 is a top view and a bottom view of a nonwoven fabric in a 1st embodiment. FIG. 2 is a perspective sectional view of the nonwoven fabric in the first embodiment. FIG. 3 is a plan view and a bottom view of the net-like support member in the first embodiment. FIG. 4 is a perspective view of the fiber web. FIG. 5 is a side view illustrating the nonwoven fabric manufacturing apparatus according to the first embodiment. FIG. 6 is a plan view illustrating the nonwoven fabric manufacturing apparatus of FIG. FIG. 7 is an enlarged perspective view of a region Z in FIG. FIG. 8 is a bottom view of the ejection portion in FIG. FIG. 9 is a plan view and a bottom view of the nonwoven fabric according to the second embodiment. FIG. 10 is a perspective sectional view of the nonwoven fabric in the second embodiment. Drawing 11 is a top view and a sectional view of a nonwoven fabric in a 3rd embodiment. FIG. 12 is a diagram showing an example of an application example of the nonwoven fabric in the present invention. FIG. 13 is a diagram showing an example of an application example of the nonwoven fabric in the present invention. FIG. 14 is a diagram illustrating an example of an application example of the nonwoven fabric in the present invention. FIG. 15 is a diagram showing an example of an application example of the nonwoven fabric in the present invention.

[1] Outline of Nonwoven Fabric of the Present Invention The nonwoven fabric of the present invention is a fiber assembly formed in a substantially sheet shape supported from one surface side by a predetermined net-like support member, and fibers constituting the fiber assembly A plurality of openings formed in the longitudinal direction, which is the longitudinal direction, are formed by spraying a fluid mainly composed of a gas on the fiber assembly in a state where has a degree of freedom. One side edge in the width direction that is the direction is a nonwoven fabric having a fiber density higher than that of the other side edge in the width direction in each of the plurality of openings.

[2] First Embodiment A first embodiment of the nonwoven fabric of the present invention will be described with reference to FIGS.

  In the following, as shown in FIGS. 1 and 2, the groove portions 1a and 1b are taken as an example of the groove portion 1 and the convex portions 2a and 2b are taken as an example of the convex portion 2 and adjacent to a predetermined opening 3a in the longitudinal direction. The first adjacent opening 3b (hereinafter, the opening 3a and the first adjacent opening 3b may be simply abbreviated as the openings 3a and 3b) will be described as an example of the plurality of openings 3.

[2.1] Shape As shown in FIG. 1A, FIG. 1B, or FIG. 2, the nonwoven fabric 116 in the present embodiment is a nonwoven fabric in which a plurality of units are formed in parallel with the grooves 1 a and 1 b as one unit. That is, the nonwoven fabric 116 has a plurality of grooves 1a and 1b formed on one surface side so as to extend in the longitudinal (vertical) direction. Further, convex portions 2a and 2b are alternately formed in parallel at substantially equal intervals between the groove portion 1a and the groove portion 1b. In other words, the nonwoven fabric 116 has a plurality of convex portions 2a and 2b formed on one surface side along the plurality of groove portions 1a and 1b and extending in the longitudinal direction.

  The nonwoven fabric 116 is a nonwoven fabric in which a plurality of openings 3a and 3b are alternately and continuously formed in the longitudinal direction, which is the longitudinal direction. In the present embodiment, the plurality of openings 3a, 3b are alternately and continuously formed, but may not be formed continuously.

  Here, the groove portions 1a and 1b support the fiber web 100 shown in FIG. 4 which is a fiber assembly from the lower surface side, for example, by the mesh support member 300 shown in FIG. It is formed by spraying and moving the fibers 101 constituting the fiber web 100.

  The movement of the fibers 101 constituting the fiber web 100 is performed by a fluid mainly composed of gas sprayed from the upper surface side of the fiber web 100.

  The convex portions 2a and 2b are regions in the fiber web 100 where a fluid mainly composed of gas is not sprayed, and the grooves 1a and 1b are formed to become relatively projecting regions. It is.

  Here, as shown in FIG. 3, the net-like support member 300 is formed so as to interweave a wire 301 arranged in the longitudinal direction and a wire 302 arranged in the width direction which is the lateral direction. 302 is woven in a zigzag shape so as to straddle the wire 301 in the thickness direction. The zigzag shape of the wire 302 is alternately woven in the longitudinal direction.

  Moreover, when the fiber web 100 which is a fiber assembly is supported from the lower surface side by the mesh-like support member 300 shown in FIG. 3 and the fluid mainly composed of gas is sprayed from the upper surface side, the fluid composed mainly of gas is The position where the fiber web 100 is sprayed is preferably substantially the center between the wires 301 arranged in the longitudinal direction. As a result, the fiber web 100 arranged on the wire 302 moves to form the openings 3a and 3b. The openings 3a and 3b are holes that penetrate through the nonwoven fabric 116 that is formed in the groove portion 1 at a predetermined interval, and are substantially circular or elliptical. Moreover, in this embodiment, although the opening parts 3a and 3b are formed at substantially equal intervals, it is not restricted to this and may be formed at different intervals.

  Further, the fiber web 100 is moved in the direction where the inclination of the wire 302 arranged in the width direction is lower, so that one side edge portions 14 and 16 in each of the openings 3a and 3b are formed. Further, the fiber web 100 is almost moved to the side edge portions of the openings 3a and 3b opposite to the side edges 14 and 16, that is, the other side edges 15 and 17 of the openings 3a and 3b. Not.

  Specifically, as shown in FIG. 1A, FIG. 1B, and FIG. 2, each of the convex portions 2a and 2b is formed with one side edge portion 14 and 16 in each of the openings 3a and 3b. . Here, the one side edge 16 in the first adjacent opening 3b is a side edge opposite to the one side edge 14 in the predetermined opening 3a in the lateral direction.

  On the other hand, the other side edges 15 and 17 in the openings 3a and 3b are formed in the convex portions 2b and 2a, respectively. However, the other side edge portions 15 and 17 are regions where the fibers 101 constituting the fiber web 100 are not moved as compared with the one side edge portions 14 and 16.

  In the present embodiment, the one side edge portions 14 and 16 and the other side edge portions 15 and 17 are formed in the convex portions 2a and 2b. However, the present invention is not limited thereto, and is formed in the groove portions 1a and 1b. May be.

  Further, the nonwoven fabric 116 has a first connecting portion 4a (hereinafter, the “first connecting portion 4a” may be simply abbreviated as the connecting portion 4a) between the predetermined opening 3a and the first adjacent opening 3b. It is a formed nonwoven fabric. That is, the 1st connection part 4a formed so that the adjacent convex-shaped parts 2a and 2b may be connected between the opening part 3a and the opening part 3b which adjoin in the groove part 1a or the groove part 1b. As will be described later, the first connecting portion 4a is a region having a higher fiber density and higher basis weight than the other side edge 15 in the predetermined opening 3a.

  The height in the thickness direction of the nonwoven fabric 116 of each of the convex portions 2a and 2b of the nonwoven fabric 116 in the present embodiment can be 0.3 to 15 mm, preferably 0.5 to 5 mm. Moreover, the length in the width direction of the nonwoven fabric 116 of each convex-shaped part 2a, 2b is 0.5-30 mm, Preferably it is 1.0-10 mm. Moreover, the distance between the vertexes of the adjacent convex portions 2a and 2b can be exemplified as 0.5 to 30 mm, preferably 3 to 10 mm.

  Moreover, the height in the thickness direction of the nonwoven fabric 116 in each of the groove portions 1a and 1b is 90% or less, preferably 0 to 50%, more preferably 1 to 20% of the height of each of the convex portions 2a and 2b. It is height. The length in the width direction of the nonwoven fabric 116 of each groove part 1a, 1b can be 0.1 to 30 mm, preferably 0.5 to 10 mm. The distance between the adjacent grooves 1a and 1b is 0.5 to 20 mm, preferably 3 to 10 mm. Here, the height in the thickness direction of 0% indicates that the region is the openings 3a and 3b.

  By adopting such a design, for example, when the nonwoven fabric 116 is used as a surface sheet of an absorbent article, the groove portion 1a suitable for preventing the surface from spreading widely even when a large amount of predetermined liquid is excreted. , 1b can be formed. Further, even if the convex portions 2a and 2b are crushed when excessive external pressure is applied, it becomes easy to maintain the space by the grooves 1a and 1b, and a predetermined liquid is applied in a state where external pressure is applied. Even when excreted, it can be difficult to spread widely on the surface. Furthermore, even when the predetermined liquid absorbed by the absorbent body or the like is reversed under an external pressure, since the unevenness is formed on the surface of the nonwoven fabric 116, the contact area with the skin is small, so that it is widely applied to the skin. It may be difficult to reattach.

  Here, the measuring method of the height, pitch, and width of the groove portions 1a and 1b or the convex portions 2a and 2b is as follows. For example, the non-woven fabric 116 is placed on a table in a non-pressurized state, and the cross-sectional photograph or cross-sectional image of the non-woven fabric 116 is measured with a microscope. In addition, the nonwoven fabric 116 used as a sample is cut so as to pass through the convex portions 2a and 2b and the groove portions 1a and 1b.

  When measuring the height (length in the thickness direction), the highest positions of the convex portions 2a and 2b and the groove portions 1a and 1b extending upward from the lowest position (that is, the table surface) of the nonwoven fabric 116 are set to the height. Measure as

  Moreover, the measurement of the pitch of convex-shaped part 2a, 2b measures the distance between the center positions of convex-shaped part 2a, 2b. Similarly, the pitch of the groove portions 1a and 1b is measured by measuring the distance between the center positions of the groove portions 1a and 1b.

  When measuring the widths of the convex portions 2a and 2b, the maximum width of the bottom surfaces of the convex portions 2a and 2b heading upward from the lowest position (that is, the table surface) of the nonwoven fabric 116 is measured, and similarly the groove portions 1a and 1b. Measure the maximum bottom width.

  Here, the cross-sectional shape of the convex portions 2a and 2b is not particularly limited. For example, a dome shape, a trapezoidal shape, a triangular shape, an Ω shape, a square shape, and the like can be given. In order to improve the touch, the vicinity of the top surfaces and the side surfaces of the convex portions 2a, 2b are preferably curved surfaces. Further, in order to allow the convex portions 2a and 2b to be crushed by the external pressure or to maintain the space by the groove portion 1, it is preferable that the width is narrowed from the bottom surface to the top surface of the convex portions 2a and 2b. As a preferable cross-sectional shape of the convex portions 2a and 2b, a curved shape (curved surface) such as a substantially dome shape can be mentioned.

  Moreover, the length (or length in the width direction) in the longitudinal direction of the nonwoven fabric 116 of each of the openings 3a and 3b can be 0.1 to 5 mm, preferably 0.5 to 4 mm. And the pitch of the opening part 3a and the opening part 3b which adjoin via the 1st connection part 4a can illustrate 0.5-30 mm, Preferably it is 1-10 mm.

  The height in the thickness direction of the nonwoven fabric 116 in the first connecting portion 4a is equal to or less than the height in the thickness direction of the nonwoven fabric 116 of the convex portions 2a and 2b, preferably 20 to 100%, more preferably 40 to 70%. It is.

  Further, the length in the longitudinal direction that is the longitudinal direction and the length in the width direction that is the lateral direction of the nonwoven fabric 116 of the first connecting portion 4a are both 0.1 to 5 mm, preferably 0.5 to 4 mm. be able to. And the pitch between the vertexes of adjacent 1st connection part 4a can be 0.5-30 mm, Preferably 1-10 mm can be illustrated.

  And in the 1st connection part 4a, the cross-sectional shape in the longitudinal direction of the nonwoven fabric 116 is substantially square shape. In addition, the cross-sectional shape in the longitudinal direction of the nonwoven fabric 116 of the 1st connection part 4a is not specifically limited, such as a dome shape, trapezoid shape, triangular shape, (omega | ohm) shape, not only substantially square shape. In order to suppress the spread of the predetermined liquid in the grooves 1a and 1b, it is preferable that the shape is a substantially square shape. In addition, the top surface of the first connecting portion 4a is preferably a flat surface or a curved surface so that the first connecting portion 4a does not come into contact with the skin or the like under excessive external pressure and does not give a sense of foreign matter.

[2.2] Fiber orientation, fiber density or basis weight [2.2.1] Fiber orientation As shown in FIG. 1A, FIG. 1B, or FIG. 2, the nonwoven fabric 116 has regions with different contents of longitudinally oriented fibers. Prepare. The different regions include, for example, the convex portions 2a including the groove portions 1a and 1b, one side edge portions 14 and 16 in the openings 3a and 3b, and the other side edge portions 15 and 17 in the openings 3a and 3b. , 2b and the like.

  Here, the fiber 101 being oriented in the longitudinal direction (longitudinal direction) means that the fiber 101 is oriented within a range of −45 degrees to +45 degrees with respect to the longitudinal direction, and is oriented in the longitudinal direction. The fibers are called longitudinally oriented fibers. In addition, the fiber 101 being oriented in the width direction (lateral direction) means that the fiber 101 is oriented within a range of −45 degrees to +45 degrees with respect to the width direction, and is oriented in the width direction. The fibers that are present are called laterally oriented fibers.

  The convex portions 2a and 2b are regions including one side edge portions 14 and 16 in the openings 3a and 3b and the other side edge portions 15 and 17 in the openings 3a and 3b. Except for one side edge part 14 and 16 in 3a and 3b, the fibers 101 in the convex parts 2a and 2b are substantially evenly along the longitudinal direction and the width direction of the nonwoven fabric 116 of the convex parts 2a and 2b. The region is oriented in the direction. In other words, except for the one side edge portions 14 and 16 in the openings 3a and 3b, the convex portions 2a and 2b are preferably mixed with longitudinally oriented fibers and laterally oriented fibers.

  On the other hand, the fibers 101 constituting one of the side edges 14 and 16 in the openings 3a and 3b are oriented in the direction along the longitudinal direction of the nonwoven fabric 116 of each of the convex portions 2a and 2b. For example, it is oriented in the longitudinal direction compared to the orientation of the fibers 101 in the convex portions 2a, 2b. That is, it can be said that 101 in one side edge portion 14 fiber in the predetermined opening 3 a has more longitudinally oriented fibers than laterally oriented fibers. Moreover, it can be said that the fiber 101 in the side edge part 16 in one side of the 1st adjacent opening part 3b has the number of longitudinally oriented fibers more than the number of laterally oriented fibers. For example, it can be exemplified that the content of the longitudinally oriented fibers in one of the side edges 14 and 16 in the openings 3a and 3b is 55% to 100%, more preferably 60 to 100%. That is, in one side edge portion 14 in the first adjacent opening, the content rate of the longitudinally oriented fibers is higher than the content rate of the laterally oriented fibers.

  As described above, the grooves 1a and 1b are regions in which the openings 3a and 3b and the first connecting portion 4a are formed by direct injection of a fluid mainly made of gas (for example, hot air). In the groove portions 1a and 1b, the fibers 101 (longitudinal orientation fibers) oriented in the longitudinal direction are jetted toward the side edges 14 and 16 of the openings 3a and 3b. Then, the fibers 101 (laterally oriented fibers) oriented in the width direction are sprayed toward the connecting portion 4a. In this way, the fibers 101 in the first connecting portions 4a of the groove portions 1a and 1b are oriented in the width (lateral) direction as a whole.

  Therefore, in the 1st connection part 4a of groove part 1a, 1b, the content rate of the longitudinally-oriented fiber in this nonwoven fabric 116 is the lowest. In other words, the 1st connection part 4a has the highest content rate of a laterally-oriented fiber. That is, as for the 1st connection part 4a, the content rate of a laterally oriented fiber is higher than the content rate of a longitudinally oriented fiber.

  Specifically, it is formed so that the content of the horizontally oriented fibers in the first connecting portion 4a is 55 to 100%, preferably 60 to 100%. When the content of the longitudinally oriented fibers is lower than 55%, it is difficult to increase the strength of the nonwoven fabric in the width direction because the basis weight of the groove portions 1a and 1b is low as described later. Then, for example, when the nonwoven fabric 116 is used as a surface sheet of an absorbent article, there is a risk that the absorbent article is distorted in the width direction or broken due to friction with the body while the absorbent article is used.

  The fiber orientation was measured using a digital microscope VHX-100 manufactured by Keyence Corporation, and the following measurement method was used. (1) Set the sample on the observation table so that the longitudinal direction is the vertical direction. (2) Focus the lens on the foremost fiber of the sample except for the irregularly protruding fiber. (3 ) Set the shooting depth (depth) and create a sample 3D image on the PC screen. Next, (4) the 3D image is converted into a 2D image, and (5) a plurality of parallel lines that equally divide the longitudinal direction in the measurement range are drawn on the screen. (6) In each cell subdivided by drawing parallel lines, it is observed whether the fiber orientation is the longitudinal direction or the width direction, and the number of fibers oriented in each direction is measured. And (7) Measure / calculate by calculating the ratio of the number of fibers oriented in the longitudinal direction and the ratio of the number of fibers oriented in the width direction relative to the total number of fibers in the set range. Can do.

[2.2.2] Fiber density The fiber density of the other side edge portions 15 and 17 in the openings 3a and 3b is, for example, 0.005 to 0.2 g / cm ³ , and further 0.007 to 0.07 g. / Cm ³ is preferred. When the fiber density of the convex portions 2a and 2b is lower than 0.005 g / cm ³ , the convex portions 2a and 2b are easily crushed by the weight of the liquid contained in the convex portions 2a and 2b and the external pressure. In addition, the liquid once absorbed may be easily returned under pressure. In addition, when the fiber density of the convex portions 2a and 2b is higher than 0.2 g / cm ³ , it becomes difficult for the predetermined liquid provided to the convex portions 2a and 2b to move downward. The liquid may stay in the portions 2a and 2b and give a user a wet feeling.

  The fiber density of one side edge 14, 16 in the openings 3 a, 3 b is 1.1 times or more the fiber density in the other side edge 15, 17.

Fiber density of the first connecting part 4a is, 0.05 g / cm ³ or more, preferably 0.1 to 0.5 g / cm ^3. When the fiber density of the first connecting portion 4a is smaller than 0.05 g / cm ³ , the first connecting portion 4a is also used when the convex portions 2a and 2b are crushed due to excessive external pressure. Similarly, it may be crushed. On the other hand, when the fiber density of the 1st connection part 4a is larger than 0.5 g / cm < ³ >, the predetermined | prescribed liquid dropped into the groove parts 1a and 1b accumulates in the 1st connection part 4a, and an excess external pressure is this said. When it is applied to the nonwoven fabric 116 and directly in contact with the skin, it may give a moist feeling.

  As described above, one side edge 14 in the predetermined opening 3a, one side edge 16 in the first adjacent opening 3b, and the first connecting portion 4a are at least the other in the predetermined opening 3a. It can be said that this is a high-density region in which the fiber density is higher than that of the other side edge 17 in the side edge 15 and the other side edge 17 in the first adjacent opening 3b.

  In particular, one side edge 14 in the predetermined opening 3a and one side edge 16 in the first adjacent opening 3b are defined as vertical high-density regions extending in the longitudinal direction (vertical direction). Can do. Since the plurality of openings 3a and 3b are alternately and intermittently formed in the grooves 1a and 1b, one side edge 14 in the predetermined opening 3a that is the vertical high-density region, and the first adjacent opening One side edge portion 16 in the portion 3b is also alternately and intermittently formed along the longitudinal direction. Therefore, the nonwoven fabric 116 includes a plurality of longitudinal high-density regions extending in the longitudinal direction.

  In addition, the nonwoven fabric 116 has a space area ratio measured from the surface side on which the groove portions 1 a and 1 b and the convex portions 2 a and 2 b are formed on one surface side in the thickness direction of the nonwoven fabric 116. It is formed to be lower than the space area ratio measured from the other surface side, which is the surface opposite to the surface on which the groove portions 1a, 1b and the convex portions 2a, 2b are formed.

  The fiber web 100 conveyed on the mesh-like support member 300 moves to the surface side opposite to the surface to which the fluid mainly composed of gas is sprayed by gravity, and is close to the surface side on the opposite side. There is a tendency that the distance between the fibers of the portion becomes narrow. On the other hand, the distance between the fibers tends to increase with increasing distance from the surface to which a fluid mainly composed of gas is sprayed.

  In addition, the fibers 101 on the side close to the mesh-like support member 300 are pressed against the mesh-like support member 300 by being mainly sprayed with a fluid made of gas, and some of the fibers 101 are oriented parallel to the plane of the mesh-like support member 300. is there. Thereby, the distance between fibers is further narrowed and the fibers are more likely to be densely packed. In such a state, the fibers are heat-sealed by a heat treatment such as an oven treatment, the degree of freedom of the fibers 101 is reduced, and the space area ratio between the fibers is reduced.

  On the other hand, the fibers are not excessively squeezed from the surface on the mesh-like support member 300 side toward the surface on which the fluid mainly composed of gas is sprayed, and the fibers are sprayed on the convex portions 2a and 2b. Some of the fibers 101 are directed so that the fibers 101 are partially perpendicular to the reticulated support member 300 when the fluid mainly composed of gas hits the reticulated support member 300 and is bounced back. In such a state, the fibers are thermally fused with each other, so that the space area ratio between the fibers is increased.

  Here, the space area ratio refers to the ratio of the space area where no fiber is present to the total area. Moreover, the measuring method of a space area ratio is as follows.

  First, a measuring instrument uses a digital microscope VHX-100 manufactured by Keyence Corporation. First, (1) the sample is set on a measuring instrument so that the direction along the groove portions 1a and 1b and the convex portions 2a and 2b is the vertical direction on the observation table, and (2) at the apex of the convex portions 2a and 2b. The following measurements are performed from the surface from which the convex portions 2a and 2b project and from the surface opposite to the surface from which the convex portions 2a and 2b project.

  (3) Set the lens magnification of the measuring device and the magnification on the PC screen appropriately, and focus the lens on the frontmost fiber of the sample (excluding fibers that have jumped out to the front). Then, (4) a shooting depth (depth) is appropriately set, and a sample 3D image is created.

  (5) The 3D image is converted into a 2D image, the set volume is planarized, and the space between the gaps in the range is specified. Further, (6) binarization processing is performed on the 2D image so that a portion where the fiber is present is white and a portion where the fiber is not present is black. Then, (7) the color is reversed to make the portion where the fiber does not exist white, and the whitened area or the like is measured.

  Here, in this case, the magnification was 300 times, the imaging depth was 220 μm (1 image was taken every 20 μm, 11 times in total), n = 10 measurements were taken, and the average value was taken.

The space area ratio is calculated as follows.
Space area ratio (%) = (total space area (mm ² ) / measurement range area (mm ² )) × 100
Here, the total space area is calculated by (total space area at measurement / magnification magnification at measurement), and the measurement area is calculated by (measurement area area at measurement / magnification magnification at measurement). be able to.

  It is agreed that the higher the space area ratio is, the wider and coarser the inter-fiber distance is, so that the fibers are easy to move and have a high degree of freedom. Furthermore, the non-woven fabric whose distance between fibers is partly wide due to the opening treatment or the like, and because the space area per space is high, the entire surface of the nonwoven fabric to which a fluid mainly composed of gas is sprayed The distance between them will be wide. For this reason, for example, when the nonwoven fabric is used for an absorbent article or the like, the resistance when a predetermined liquid such as excrement permeates the nonwoven fabric 116 can be lowered as a whole, and the liquid to the absorber or the like can be reduced. It is possible to make the transition easier.

Here, the space area per space refers to the ratio of the total area of the space where no fiber is present to the number of spaces where the fiber is not present within a predetermined range. It can be calculated by the following formula.
Space area (mm ² / piece) = (Total space area (mm ² ) / Number of spaces (pieces)) × 100

  The spatial area ratio measured from the surface of the convex portions 2a, 2b on the side from which the convex portions 2a, 2b project, and the spatial area measured from the surface on the opposite side to the surface from which the convex portions 2a, 2b project. The difference from the rate is 5% or more, preferably 5 to 80%, more preferably 15 to 40%.

  The space area ratio measured from the surface on which the convex portions 2a and 2b protrude is 50% or more, preferably 50 to 90%, more preferably 50 to 80%.

Furthermore, the space area of space one per measured from the surface on the side where the convex portions 2a, 2b protrudes is 3000 .mu.m ² or more, preferably exemplified that 30000Myuemu ^2, particularly preferably from 5000 20000μm ² from 3000.

[2.2.3] Weight per unit area The specific weight per unit area of the nonwoven fabric 116 is 10 to 200 g / m ² , preferably 20 to 100 g / m ² . For example, when the nonwoven fabric 116 is used for a top sheet of an absorbent article, if the basis weight is less than 10 g / m ² , the nonwoven fabric 116 may be easily broken during use. Moreover, when the fabric weight of this nonwoven fabric 116 is larger than 200 g / m < ² >, it may become difficult to perform smoothly the produced | generated liquid downward.

The basis weight of one side edge portion 14, 16 in the openings 3 a, 3 b is 1.1 times or more than the basis weight of the other side edge portion 15, 17, and the basis weight of one side edge portion 14, 16 is Can be 15 to 250 g / m ² , preferably 20 to 120 g / m ² . When the basis weight of one of the side edge portions 14 and 16 in the openings 3a and 3b is smaller than 15 g / m ² , the convex portions 2a and 2b are formed by the weight of the liquid contained in the convex portions 2a and 2b or external pressure. In addition to being easily crushed, there is a case where the liquid once absorbed is likely to return under pressure. Further, when the basis weight of one of the side edge portions 14 and 16 in the openings 3a and 3b is larger than 250 g / m ² , the predetermined liquid brought to the convex portions 2a and 2b is moved downward. In some cases, the liquid becomes stagnation in the convex portions 2a and 2b to give the user a wet feeling.

Other side edge portions 15 and 17 opening 3a, at 3b is a basis weight of ^{10g / m 2 ~200g / m 2} , preferably can be exemplified 20 to 100 g / ^{m 2.} When the basis weight of the other side edge portions 15 and 17 in the openings 3a and 3b is smaller than 10 g / m ² , the convex portions 2a and 2b are formed by the weight of the liquid contained in the convex portions 2a and 2b and the external pressure. In addition to being easily crushed, there is a case where the liquid once absorbed is likely to return under pressure. Further, when the basis weight of the other side edge portions 15 and 17 in the openings 3a and 3b is larger than 200 g / m ² , the predetermined liquid brought to the convex portions 2a and 2b is moved downward. In some cases, the liquid becomes stagnation in the convex portions 2a and 2b to give the user a wet feeling.

As for the fabric weight of the 1st connection part 4a, 15-250 g / m < ² >, Preferably 20-120 g / m < ² > can be mentioned. When the basis weight of the first connecting portion 4a is smaller than 15 g / m ² , the excessive amount of external pressure is applied to the first connecting portion 4a when the convex portions 2a and 2b are crushed. It may be crushed. Further, when the basis weight of the first connecting portion 4a is larger than 250 g / m ² , the predetermined liquid dropped into the groove portions 1a and 1b accumulates in the first connecting portion 4a, and an excessive external pressure is applied to the nonwoven fabric 116. When touched directly with the skin, it may give a moist feeling.

  From the above, it can be said that the one side edge 14 in the predetermined opening 3a has a higher basis weight than the other side edge 15 in the predetermined opening 3a. Similarly, it can be said that the one side edge 16 in the first adjacent opening 3b has a higher basis weight than the other side edge 17 in the first adjacent opening 3b. Furthermore, it can be said that the 1st connection part 4a is higher than the other side edge part 15 in the predetermined opening part 3a.

[2.3] Others When the nonwoven fabric of this embodiment is used for absorbing or transmitting a predetermined liquid, for example, the grooves 1a and 1b transmit the liquid, and the convex portions 2a and 2b hold the liquid. Porous to make it harder. Furthermore, the openings 3a and 3b formed in the grooves 1a and 1b can transmit a solid as well as a liquid.

  Since the plurality of openings 3a and 3b are formed in the grooves 1a and 1b, the grooves 1a and 1b are suitable for transmitting liquid and solid. Furthermore, since the fibers 101 at the bottoms of the grooves 1a and 1b are oriented in the width direction, it is possible to prevent the liquid from flowing too far in the longitudinal direction of the nonwoven fabric 116 of the grooves 1a and 1b and spreading widely. Although the groove portions 1a and 1b have a low basis weight, the fibers 101 are oriented (CD orientation) in the width direction of the groove portions 1a and 1b, so the strength (CD strength) in the width direction of the nonwoven fabric is increased.

[2.4] Manufacturing Method The nonwoven fabric manufacturing method of the present invention is mainly applied to a fiber assembly that is formed in a substantially sheet shape, and in which the fibers constituting the fiber assembly have a degree of freedom. A plurality of openings formed in the longitudinal direction that is the vertical direction is formed by spraying a fluid made of gas on the one side edge portion in the width direction that is the lateral direction in each of the plurality of openings, It is a manufacturing method which manufactures the nonwoven fabric whose fiber density is higher than the other side edge part in the said width direction in each of these opening parts.

  A method for manufacturing the nonwoven fabric 116 in the present embodiment will be described below with reference to FIGS. First, the fiber web 100 is placed on the upper surface side of the mesh support member 300. In other words, the fiber web 100 is supported from below by the mesh support member 300.

  Then, the net-like support member 300 in a state where the fiber web 100 is supported is moved in the longitudinal direction, which is the longitudinal direction, and the gas is continuously blown from the upper surface side of the moved fiber web 100 to perform this embodiment. A nonwoven fabric 116 in the form can be produced.

  As shown in FIGS. 5 to 8, the nonwoven fabric manufacturing apparatus 90 for manufacturing the nonwoven fabric 116 of the present embodiment includes a mesh-like support member 300 that supports a fiber web 100 that is a fiber assembly from one side, and a mesh-like support member. 300 is a spraying means for spraying a fluid mainly composed of gas from the other surface side of the fiber web 100 which is the fiber aggregate to the fiber web 100 which is a fiber aggregate supported by the one surface side by 300. An ejection unit 910 and an air supply unit (not shown), and a conveyor 930 that is a moving unit that moves the fiber web 100 that is a fiber assembly in a predetermined direction F are provided.

  As shown in FIG. 3, for example, the mesh-like support member 300 is configured such that a fluid mainly composed of gas sprayed from the upper surface side, which is the other surface side of the fiber web 100, is disposed in the mesh-like support member 300. A ventilation portion that can vent to the lower side opposite to the formed side, and a fluid mainly composed of gas blown from the upper surface side of the fiber web 100 cannot vent to the lower side of the mesh support member 300, and The fiber 101 constituting the fiber web 100 is a support member provided with a non-venting part that cannot move to the opposite side of the mesh support member 300.

  That is, the portion of the wire 301 and the wire 302 and the intersection portion 304 of the mesh-like support member 300 become a non-venting portion. On the other hand, as described above, the hole 303 which is a portion surrounded by the wire 301 and the wire 302 in the mesh-like support member 300 is a ventilation portion. The holes 303 in the mesh support member 300 allow the fibers 101 constituting the fiber web 100 to move to the opposite side of the mesh support member 300 from the side on which the fiber web 100 is placed. Thereby, the protrusion part which protrudes in the thickness direction can be formed. The protrusion will be described in detail in the third embodiment (see FIG. 11).

  As described above, the net-like support member 300 is formed so as to interweave the wire 301 arranged in the longitudinal direction and the wire 302 arranged in the width direction which is the lateral direction, and the wire 302 is formed in the thickness direction. Are woven in a zigzag shape so as to straddle the wire 301. The zigzag shape of the wire 302 is alternately woven in the longitudinal direction.

  Furthermore, in other words, the non-venting part is another one adjacent to one wire 301 so that the apex part in the upper direction of one wire 301 and the apex part in the lower direction of one wire 302 are connected. The wire 301 is woven so that the apex portion in the lower direction of the wire 301 and the upper apex portion of the other wire 302 adjacent to the one wire 302 are connected.

  Here, as described above, the fiber web 100 is supported from the lower surface side, which is one surface side, by the mesh-like support member 300 shown in FIG. 3, and ejected when a fluid mainly composed of gas is sprayed from the upper surface side. The positional relationship between the opening 913 and the wire 301 arranged in the longitudinal direction is that a fluid mainly composed of gas ejected from the ejection port 913 is sprayed to the substantial center between the wire 301 and the wire 301. preferable.

  As a result, the fiber web 100 disposed on the wire 302 moves by being sprayed with a fluid mainly composed of gas, thereby forming the openings 3a and 3b, and the fiber web 100 has a low inclination of the wire 302. The side edges 14 and 16 of the openings 3a and 3b are formed by being moved in the direction. Further, the fiber web 100 is hardly moved to the side edge opposite to the one side edge 14, 14 in the width direction of the openings 3a, 3b, that is, the other side edges 15, 17.

  Here, the height difference of the inclination of the wire 302 arranged in the longitudinal direction is 0.5 mm or more, preferably 0.5 to 10 mm, and more preferably 1.0 to 5.0 mm.

  In the case of such a support member, the air permeability can be partially changed by partially changing the weaving method, the yarn thickness, and the yarn shape.

  The net-like support member 300 can be made of, for example, a member made of resin such as polyester, polyphenylene sulfide, nylon, or conductive monofilament, or a member made of metal such as stainless steel, copper, or aluminum.

  The fluid mainly composed of gas blown from the upper surface side of the fiber web 100 is partially blocked by the wire 301, the wire 302, and the intersection portion 304 of the mesh support member 300, and partially meshed. The air flows downward without being blocked by the support member 300.

  However, the air permeability between the wire 301 and the wire 302 (especially the wire intersection 304) serving as the air-impermeable portion in such a case is 90% or less, preferably 0 to 50% with respect to the air permeability in the hole 303. More preferably, 0 to 20% can be exemplified. Here, 0% indicates that a fluid consisting essentially of gas cannot be vented.

The air permeability in the region such as the hole 303 serving as the ventilation portion can be, for example, 10,000 to 60000 cc / cm ² · min, preferably 20000 to 50000 cc / cm ² · min.

  It is preferable that the reticulated support member used has a higher surface slipperiness in the region serving as the air-impermeable portion than in the region forming the air-permeable portion. Since the slipperiness is high, the fiber 101 is easy to move in a region where a non-venting portion intersects with a region where a fluid mainly composed of gas is sprayed, so that the openings 3a and 3b and the first connecting portion 4a are formed. Can increase the sex.

  Here, as shown in FIGS. 5 and 6, the nonwoven fabric 115 (corresponding to the nonwoven fabric 116 in the present embodiment) is formed in the nonwoven fabric manufacturing apparatus 90 while the fiber web 100 is sequentially moved in a predetermined direction. The The moving means moves the fiber web 100, which is a fiber assembly in a state of being supported from one surface side by the above-described mesh-like support member 300, in a predetermined direction. Specifically, the fiber web 100 in a state where a fluid mainly composed of gas is sprayed is moved in a predetermined direction F. As the moving means, for example, a conveyor 930 can be exemplified. The conveyor 930 includes a breathable breathable belt portion 939 formed in a horizontally long ring shape on which the mesh support member 300 is placed, and a longitudinal direction inside the breathable belt portion 939 formed in a horizontally long ring shape. Rotating portions 931 and 933 that are arranged at both ends of the ring and rotate the ring-shaped breathable belt portion 939 in a predetermined direction.

  As described above, the conveyor 930 moves the mesh support member 300 in a state where the fiber web 100 is supported from the lower surface side in the predetermined direction F. Specifically, as shown in FIG. 7, the fiber web 100 is moved so as to pass below the ejection portion 910. Furthermore, the fiber web 100 is moved so as to pass through the inside of the heater portion 950 that is open on both side surfaces as heating means.

  The spraying means includes an air supply unit (not shown) and an ejection unit 910. An air supply unit (not shown) is connected to the ejection unit 910 via an air supply tube 920. The air supply pipe 920 is connected to the upper side of the ejection part 910 so as to allow ventilation. As shown in FIG. 8, a plurality of ejection ports 913 are formed at a predetermined interval in the ejection portion 910.

  As shown in FIG. 7, the gas supplied from an air supply unit (not shown) to the discharge unit 910 via the air supply pipe 920 is discharged from a plurality of discharge ports 913 formed in the discharge unit 910. The gas ejected from the plurality of ejection ports 913 is continuously ejected to the upper surface side of the fiber web 100 supported by the mesh-like support member 300 from the lower surface side. Specifically, the gas ejected from the plurality of ejection ports 913 is continuously ejected to the upper surface side of the fiber web 100 in a state where it is moved in the predetermined direction F by the conveyor 930.

  An intake portion 915 disposed below the ejection portion 910 and below the mesh-like support member 300 sucks in gas or the like ejected from the ejection portion 910 and ventilated through the mesh-like support member 300. Here, it is also possible to position the fiber web 100 so as to stick to the mesh-like support member 300 by the intake air by the intake portion 915. Furthermore, the air can be conveyed into the heater unit 950 in a state where the shape of the groove (unevenness) formed by the airflow is further maintained by intake air. In this case, it is preferable to convey while sucking up to the heater unit 950 simultaneously with the molding by the air flow.

  The temperature of the fluid mainly composed of gas ejected from each of the ejection ports 913 may be room temperature as in the first embodiment. For example, in order to improve the moldability of the groove (unevenness) and the opening. The temperature can be adjusted to at least the softening point of the thermoplastic fiber constituting the fiber assembly, preferably within the temperature range of + 50 ° C. to −50 ° C. of the melting point. When the fiber is softened, the repulsive force of the fiber itself is reduced. Therefore, it is easy to maintain the shape in which the fibers are rearranged by an air flow or the like, and when the temperature is further increased, heat fusion between the fibers is started. It becomes easy to maintain the shape of the unevenness. Thereby, it becomes easy to convey in the heater part 950 in the state which maintained shapes, such as a groove part (unevenness | corrugation).

  The heater unit 950, which is a heating unit, is open at both ends in the predetermined direction F. Thereby, the fiber web 100 mounted on the mesh support member 300 moved by the conveyor 930 is continuously moved in the heating space formed in the heater unit 950 with a predetermined time stay. For example, when thermoplastic fibers are included in the fibers 101 constituting the fiber web 100, the nonwoven fabric 115 in which the fibers 101 are bonded to each other by heating in the heater portion 950 can be obtained.

  In order to form the nonwoven fabric 116 having the openings 3a and 3b, a support member different from the mesh support member 300 may be used. The size and arrangement of the groove portions 1a and 1b, the convex portions 2a and 2b, the opening portions 3a and 3b, and the first connecting portion 4a can be changed depending on the support member used. For example, a sleeve made of a metal such as stainless steel, copper, or aluminum can be exemplified. The sleeve can be exemplified by the metal plate partially extracted in a predetermined pattern. The metal is hollowed out and a portion where the metal is not hollowed out is a non-vented portion. Further, in the same manner as described above, the non-venting portion preferably has a smooth surface in order to improve the slipperiness of the surface.

  In addition, at this time, it is preferable to include an intake portion 915 that draws in fluid mainly composed of gas sprayed on the nonwoven fabric 116 from below the mesh-like support member 300 or the support member of the sleeve. By sucking (inhaling) the fluid mainly composed of gas injected by the intake portion 915, the fluid composed mainly of gas that hits the mesh support member 300 is excessively rebounded and the shape of the fiber web 100 is disturbed. Can be prevented.

  The strength for drawing the fluid mainly composed of gas may be strong enough to press the fibers 101 in the region where the fluid composed mainly of gas is blown against the support member. Further, in order to maintain the state of being pressed against the support member, the temperature of the fluid mainly composed of gas sprayed is equal to or higher than the softening point of at least some of the constituent fibers of the fibers 101 constituting the nonwoven fabric 116, in particular, the softening point. The melting point is preferably not higher than the melting point.

  The convex portions 2a and 2b, the openings 3a and 3b, and the first connection can be adjusted by adjusting the air volume and temperature of the fluid mainly composed of gas, the drawing amount, the air permeability of the support member, the basis weight of the fiber web 100, and the like. The shape of the part 4a and the like can be changed. For example, the amount of fluid mainly composed of gas to be injected and the amount of fluid mainly composed of gas to be sucked (intake) are almost equal, or the amount of fluid mainly composed of gas to be sucked (intake) is larger. In this case, the back surfaces of the convex portions 2 a and 2 b in the nonwoven fabric 116 are formed so as to follow the shape of the net-like support member 300.

  Furthermore, since the fluid mainly composed of gas is drawn from the lower side of the mesh-like support member 300, the fibers in the region where the fluid made mainly of gas is sprayed are moved while being pressed against the mesh-like support member 300 side. Then, the fibers gather on the mesh support member 300 side. Moreover, in the convex-shaped parts 2a and 2b, the fluid which consists of the gas mainly injected collides with the mesh-shaped support member 300, and is moderately bounced, and it will be in the state where the fiber partially turned to the thickness direction. .

[3] Other Embodiments Hereinafter, other embodiments of the nonwoven fabric of the present invention will be described. In the following embodiments, parts that are not particularly described are the same as those in the above-described embodiments, and the same reference numerals are given to the numbers given in the drawings when they are the same as those in the above-described embodiments.

  A second embodiment and a third embodiment of the nonwoven fabric of the present invention will be described with reference to FIGS. 2nd Embodiment and 3rd Embodiment are other embodiment from which the shape of a nonwoven fabric differs.

[3.1] Second Embodiment A second embodiment of the nonwoven fabric of the present invention will be described with reference to FIGS.

[3.1.1] Nonwoven Fabric As shown in FIGS. 9 and 10, the nonwoven fabric 140 in the present embodiment is a second adjacent opening 3 c adjacent to the opposite side of the predetermined opening 3 a to the first adjacent opening 3 b. And the second connecting portion 4b formed between the two. Moreover, the nonwoven fabric 140 in this embodiment is the one side edge part 16 in the 1st adjacent opening part 3b, the 1st connection part 4a, the one side edge part 14 in the predetermined opening part 3a, and the 2nd connection part. 4b, the 2nd adjacent opening part 3c, and the one side edge part 18 in the 2nd adjacent opening part 3c differ from 1st Embodiment by the point which continues to meander shape. In addition, the nonwoven fabric 140 in this embodiment is the groove part 1a, 1b, convex part 2a, 2b, opening part 3a, 3b, one side edge part 14 and 16 in opening part 3a, 3b, and the other in opening part 3a, 3b. The side edge portions 15 and 17, the first connecting portion 4a, the fiber orientation, the fiber density, and the basis weight are the same as those in the above-described embodiment.

  Hereinafter, in addition to the predetermined opening 3a and the first adjacent opening 3b, a second adjacent opening 3c (hereinafter referred to as a second adjacent opening) adjacent to the opposite side of the predetermined opening 3a to the first adjacent opening 3b. The non-woven fabric 140 will be described with respect to differences from the above-described embodiment, with the portion 3c being simply abbreviated as the opening 3c) as an example of the plurality of openings 3.

[3.1.2] Outline of Nonwoven Fabric As shown in FIGS. 9 and 10, the nonwoven fabric 140 in the present embodiment is a nonwoven fabric in which an opening 3 c is formed in addition to the openings 3 a and 3 b as described above. . In other words, the nonwoven fabric 140 is a nonwoven fabric in which the openings 3a, 3b, and 3c are formed in the order of the opening 3c, the opening 3a, and the opening 3b from the front side in the drawing along the longitudinal (vertical) direction of the nonwoven fabric 140. .

  Moreover, the one side edge 18 in the width direction of the nonwoven fabric 140 in the opening part 3c is formed in the nonwoven fabric 140 similarly to the one side edge parts 14 and 16 in the opening parts 3a and 3b. Here, one side edge 18 in the second adjacent opening 3c is a side edge opposite to the one side edge 14 in the predetermined opening 3a in the width direction. On the other hand, the other side edge 19 in the width direction of the opening 3c is formed in the convex portions 2a and 2b.

  Moreover, the nonwoven fabric 140 is a nonwoven fabric in which the 2nd connection part 4b formed between the predetermined opening part 3a and the 2nd adjacent opening part 3c was formed. That is, between the predetermined opening 3a adjacent to the groove 1a or the groove 1b and the second adjacent opening 3c, the adjacent protrusions 2a and 2b are connected so as to sandwich the groove 1a or the groove 1b. A second connecting portion 4b is formed. In other words, it can be said that the plurality of second connecting portions 4b formed at a predetermined interval connect the convex portion 2a and the convex portion 2b adjacent thereto. As will be described later, the second connecting portion 4b is a region having a fiber density higher than that of the other side edge 15 in the predetermined opening 3a.

  The second adjacent opening 3c described above is the openings 3a, 3b, one side edge 18 is one side edge 14, 16, and the other side edge 19 is the other side edge 15, 17 and the 2nd connection part 4b are formed similarly to the 1st connection part 4a, and since size, thickness, fiber orientation, basis weight, space area ratio, etc. are the same, description is abbreviate | omitted.

[3.1.3] Fiber Density As shown in FIGS. 9 and 10, the second connecting portion 4b is more fiber than the other side edge portion 15 in the predetermined opening 3a, like the first connecting portion 4a. This is a high density area. Further, as described above, the first connecting portion 4a and the one side edge portion 14 in the predetermined opening 3a are similarly regions having a higher fiber density than the other side edge 15 in the predetermined opening 3a. .

  That is, the 1st connection part 4a, the one side edge part 14 in the predetermined opening part 3a, and the 2nd connection part 4b are high-density areas. Accordingly, the first connecting portion 4a, the one side edge 14 in the predetermined opening 3a, and the second connecting portion 4b are opposite to the one side edge 14 in the predetermined opening 3a in the width direction of the nonwoven fabric 140. Since the side (one side) is formed in an open U shape, it can be defined as a U-shaped high-density region as a whole.

  Since the plurality of openings 3a, 3b, 3c are alternately and continuously formed in the grooves 1a, 1b, the first connecting portion 4a, which is a U-shaped high-density region, and one of the predetermined openings 3a The side edge part 14 and the 2nd connection part 4b are also formed continuously along the longitudinal direction of the nonwoven fabric 140. FIG.

  Therefore, it can be said that the nonwoven fabric 140 which is this embodiment is a nonwoven fabric provided with two or more U-shaped high-density area | regions extended in a longitudinal direction. The U-shaped high-density region is an “inverted U-shaped” high-density region that is the opposite shape of the “U-shaped”, that is, a region including an inverted U-shaped high-density region. Further, as in the present embodiment, the groove portions 1a, “a”, “U-shaped” high density regions formed in the groove portion 1a, and “reverse U-shaped” high density regions formed in the groove portion 1b, A pair of “U-shaped” high-density regions may be formed in 1b, “U-shaped” high-density regions are formed in the grooves 1a, and “U-shaped” high-density regions are formed in the grooves 1b. As described above, “U-shaped” high-density regions having the same shape may be formed in the grooves 1a and 1b.

  As described above, in addition to the one side edge 14 in the predetermined opening 3a, the one side edge 16 in the first adjacent opening 3b, the first connection 4a, the second connection 4b, and The one side edge 18 in the second adjacent opening 3c is a high-density region having a higher fiber density than the other side edge 15 in the predetermined opening 3a.

  And as shown in FIG.9 and FIG.10, the nonwoven fabric 140 which is this embodiment is one side edge part 16 in the 1st adjacent opening part 3b, the 1st connection part 4a, and one side in the predetermined opening part 3a. The side edge portion 14, the second connecting portion 4b, and the one side edge portion 18 in the second adjacent opening 3c are nonwoven fabrics in which a high-density region is formed so as to be continuous in a serpentine shape as a whole. . One side edge 16 in the first adjacent opening 3b, the first connecting portion 4a, one side edge 14 in the predetermined opening 3a, the second connecting portion 4b, and one in the second adjacent opening 3c. The side edges 18 can be defined to be serpentine high density regions as a whole.

  And since several opening part 3a, 3b, 3c is formed in groove part 1a, 1b, one side edge part 16, 1st connection part 4a in the 1st adjacent opening part 3b which is a meandering high density area | region, predetermined | prescribed The one side edge 14 in the opening 3 a, the second connecting portion 4 b, and the one side edge 18 in the second adjacent opening 3 c are also formed along the longitudinal direction of the nonwoven fabric 140. Therefore, it can be said that the nonwoven fabric 140 which is this embodiment is a nonwoven fabric provided with two or more meandering high density area | regions extended in the longitudinal (vertical) direction of the groove parts 1a and 1b.

  The nonwoven fabric 140 in this embodiment can be manufactured with the nonwoven fabric manufacturing apparatus 90 mentioned above. The method for manufacturing the nonwoven fabric in the nonwoven fabric manufacturing apparatus 90 can be referred to the description of the method for manufacturing the nonwoven fabric 116 and the description of the nonwoven fabric manufacturing apparatus 90 described above. For example, in the present embodiment than in the first embodiment, when the fluid mainly composed of gas (for example, hot air) is strongly blown or when the amount of fluid mainly composed of gas blown is large, the fibrous web 100 When the line tension is hardly applied, or when the fiber web 100 is overfeeded just before a fluid mainly composed of gas (for example, hot air) is blown, the nonwoven fabric 140 is made by the nonwoven fabric manufacturing apparatus 90 described above. Can be manufactured.

[3.2] Third Embodiment A third embodiment of the nonwoven fabric of the present invention will be described with reference to FIG.

[3.2.1] Nonwoven Fabric As shown in FIG. 11, in the nonwoven fabric 150 in the present embodiment, on the other surface side (the other surface side), regions corresponding to the convex portions 2 a and 2 b are convex portions 2 a. , 2b is different from the protruding direction in that it protrudes in the same direction. Moreover, the nonwoven fabric 150 in this embodiment is different in that a plurality of protrusions 10 are formed on the other surface side. In addition, the nonwoven fabric 150 in this embodiment is groove part 1a, 1b, convex-shaped part 2a, 2b, opening part 3a, 3b, 3c, one side edge part 14,16,18 in opening part 3a, 3b, 3c, opening. The other side edge portions 15, 17, 19 in the portions 3a, 3b, 3c, the first connecting portion 4a, the second connecting portion 4b, their fiber orientation, fiber density, and basis weight are the same as those in the above-described embodiment. is there. Hereinafter, different points will be described.

[3.2.2] Overview of Non-woven Fabric As shown in FIGS. 11A and 11B, the non-woven fabric 150 in the present embodiment has the groove portions 1a and 1b alternately formed in parallel at substantially equal intervals, and the groove portions 1a and 1b. Between, convex-shaped parts 2a and 2b are alternately formed at substantially equal intervals. Further, in the non-woven fabric 150, on the other surface side, a region corresponding to the bottom surface of the convex portions 2a and 2b protrudes in the same direction as the convex portions 2a and 2b on one surface side (one surface side) along the longitudinal direction. It is formed to do. In other words, in the nonwoven fabric 150, on the other surface side of the nonwoven fabric 150, regions corresponding to the bottom surfaces of the convex portions 2a and 2b on the one surface side are recessed to form concave portions, and the bottom surfaces of the convex portions 2a and 2b on the one surface side. The corresponding area is convex.

  Moreover, as shown to FIG. 11A and FIG. 11B, the nonwoven fabric 150 is the other side, the one side edge part 14 in the predetermined opening part 3a, the one side edge part 16 in the 1st adjacent opening part 3b, 1st. The protrusion 10 having a predetermined length is a protrusion corresponding to one side edge 18 in the connecting part 4a, the second connecting part 4b, and the second adjacent opening 3c. A plurality of non-woven fabrics.

  The protrusion 10 is a high-density region, one side edge 14 in the predetermined opening 3a, one side edge 16 in the first adjacent opening 3b, the first connecting portion 4a, the second connecting portion 4b, And after the fiber 101 which comprises the fiber web 100 in the one side edge part 18 in the 2nd adjacent opening part 3c spaces apart from the mesh-shaped support member 300, it is formed protruding in the thickness direction. That is, the fibers 101 constituting the fiber web 100 to which a fluid mainly composed of gas is sprayed are subjected to the action of the wire 301 and the wire 302 of the net-like support member 300, and the plurality of protrusions 10 have a thickness in the fiber web 100. It is formed so as to protrude in the direction.

  As shown in FIG. 11B, the cross-sectional shape of the protrusion 10 in the longitudinal direction is a substantially square shape. In addition, the cross-sectional shape in the longitudinal direction of the protrusion 10 is not limited to a substantially square shape, and is not particularly limited to a dome shape, a trapezoidal shape, a triangular shape, an Ω shape, or the like. In order to suppress the spread of the predetermined liquid in the grooves 1a and 1b, it is preferable that the shape is a substantially square shape. Further, in order to prevent the protrusion 10 from coming into contact with the skin or the like under an excessive external pressure so as not to give a foreign object feeling, the top surface of the protrusion 10 is preferably a flat surface or a curved surface.

  In this embodiment, the cross-sectional shape in the longitudinal direction of the protrusion 10 is a substantially quadrangular shape. For example, the protrusion in the triangular shape (triangular prism shape), the triangular shape (on the triangular prism), and the top portion in the thickness direction. The protrusion may be a curved surface, a square (quadrangular columnar) protrusion, or a protrusion that is inclined with respect to the thickness direction.

  When the nonwoven fabric 150 is viewed from the one surface side, a plurality of protrusions 10, a plurality of flat portions that are substantially square formed between each of the plurality of protrusions 10, and a pair of each of the plurality of flat portions A plurality of openings 3a, 3b, 3c formed on the side are regularly formed.

[3.2.3] Manufacturing Method and Reticulated Support Member The manufacturing method of the nonwoven fabric 150 in the present embodiment is the same as that described above. However, as will be described later, the fluid mainly consists of gas as compared to the second embodiment. When there is much quantity etc., the nonwoven fabric 150 can be manufactured with the nonwoven fabric manufacturing apparatus 90 mentioned above. Further, the mesh support member 300 used in manufacturing the nonwoven fabric 150 is the same as the mesh support member 300 in the first embodiment described above.

  That is, the fiber web 100 which is a fiber aggregate is sprayed with a fluid mainly composed of gas in a state where the fiber web 100 is supported by the mesh support member 300 from the lower surface side. At this time, a fluid mainly composed of gas is sucked (intake) from below the reticulated support member 300. The amount of fluid mainly composed of gas sucked (intake) is smaller than the amount of fluid composed mainly of gas, that is, the fluid composed mainly of gas is sucked (intake). When the amount of fluid mainly composed of gas is larger than the amount of fluid mainly composed of gas, the bottom surface side (bottom surface side) of the convex portions 2a and 2b is convex by slightly repelling the fluid mainly composed of gas. It can be formed so as to protrude in the same direction as the convex portions 2a and 2b on the upper surface side of the portions 2a and 2b. Thereby, the area | region of the other surface side which is a bottom face in groove part 1a, 1b protrudes relatively, and the convex part which protrudes from a lower surface side is formed.

[4] Application example As a use of the nonwoven fabric in the present invention, for example, a surface sheet in an absorbent article such as a sanitary napkin, a liner, and a diaper can be exemplified. In this case, the convex portion may be on either the skin surface side or the back surface side. However, if the convex portion is on the skin surface side, the contact area with the skin is reduced, so that it may be difficult to give a moist feeling due to body fluids. Moreover, it can be used as an intermediate sheet between the surface sheet of the absorbent article and the absorbent body. Since the contact area with the surface sheet or the absorber is reduced, it may be difficult to reverse the absorber. In addition, side sheets of absorbent articles, outer surfaces such as diapers (outer backs), hook-and-loop fastener female materials, and the like can be used because of a reduction in contact area with the skin and a feeling of cushioning. In addition, it can be used in various fields such as wipers, masks, and breast milk pads for removing dust and dirt adhering to the floor and body.

[4.1] Surface sheet of absorbent article As an application of the nonwoven fabric in the present invention, as shown in FIGS. 12 and 13, for example, it has irregularities and a plurality of openings 3 a, recesses (grooves 1 a, 1 b). 3b and the first connecting portion 4a, the fiber density of one side edge 14 in the openings 3a and 3b is different from the fiber density of the other side edge 15 in the other portions, for example, the openings 3a and 3b. The case where a high nonwoven fabric is used as the surface sheets 401 and 402 of the absorbent article which has arrange | positioned convex-shaped part 2a, 2b to the skin surface side can be illustrated. In this case, it is preferable that the nonwoven fabric is disposed so that the surface on which the convex portions 2a and 2b are formed is on the skin side.

  One side edge 14 in the openings 3a and 3b has a relatively high fiber density, that is, a high rigidity. Accordingly, it is possible to prevent the openings 3a and 3b from being easily crushed even if a load is applied to one side edge portion 14. Further, the other side edge portion 15 in the openings 3a and 3b has a relatively low fiber density, that is, it can prevent the liquid around the openings 3a and 3b from staying.

  When the nonwoven fabric is used as the top sheets 401 and 402 of the absorbent article, when a predetermined liquid is excreted, the liquid is mainly dropped into the groove. In addition, since the opening is provided, for example, even a viscous liquid containing solids can be easily transferred to the absorber through the opening, and the liquid can be prevented from spreading widely on the surface. .

  Further, since most of the fibers in the first connecting portion 4a are oriented in the width direction, the tensile strength in the width direction is high, and a force such as friction in the width direction is applied during wearing of the absorbent article. It is possible to prevent the surface sheet from being damaged.

  As a result, even if the load applied to the topsheet changes due to changes in body posture, the contact area with the skin can be kept low, so that the tactile sensation can be maintained, and further, the absorbent is once absorbed by the absorber. Even if the liquid is reversed, it does not easily reattach to the skin.

[4.2] Intermediate Sheet of Absorbent Article As an application of the nonwoven fabric in the present invention, as shown in FIG. 14, for example, it has unevenness, and a plurality of openings 3a, 3b and second recesses (grooves 1a, 1b) Non-woven fabric having one connecting portion 4a and having a fiber density of one side edge 14 in the openings 3a and 3b higher than the fiber density of the other side edge 15 in the other portions, for example, the openings 3a and 3b Can be used as the intermediate sheet 311 of the absorbent article in which the convex portions 2a and 2b are arranged on the skin surface side. In this case, it is preferable that the nonwoven fabric is disposed so that the surface on which the convex portion is formed is on the surface sheet side.

  One side edge 14 in the openings 3a and 3b has a relatively high fiber density, that is, a high rigidity. Accordingly, it is possible to prevent the openings 3a and 3b from being easily crushed even if a load is applied to one side edge portion 14. Further, the other side edge portion 15 in the openings 3a and 3b has a relatively low fiber density, that is, it can prevent the liquid around the openings 3a and 3b from staying.

  A plurality of spaces can be provided between the top sheet 310 and the intermediate sheet 311 by arranging the nonwoven fabric as an intermediate sheet so that the surface on which the convex portions 2a and 2b are formed is on the top sheet 310 side. . Furthermore, since the openings 3a and 3b are provided in the intermediate sheet 311, even when a large amount of liquid is excreted in a short time, there are few liquid permeation inhibiting elements, and the liquid can be quickly transferred to the absorber. Can do. And it can prevent that this liquid returns to a surface sheet and spreads widely.

  Furthermore, even if the liquid that has once permeated through the intermediate sheet 311 and absorbed by the absorber is reversed, the contact ratio between the intermediate sheet 311 and the top sheet 310 is low, so that the liquid returns to the top sheet and spreads widely on the skin. It becomes difficult to reattach.

  Moreover, since the center part of convex-shaped part 2a, 2b contains many fibers orientated in the thickness direction compared with groove part 1a, 1b, since the vertex of convex-shaped part 2a, 2b and the surface sheet 310 are contacting, It becomes easy to draw the liquid remaining on the top sheet 310 in the thickness direction. This makes it difficult for the liquid to remain on the top sheet.

  Thus, the spot property on the top sheet and the low liquid residue can be obtained, and the liquid can be prevented from adhering to the skin for a long time. Furthermore, since one side edge 14 in the convex portions 2a and 2b has a high content of longitudinally oriented fibers oriented in the longitudinal direction, the liquid transferred from the top sheet 310 to the one side edge 14 is elongated. It can be guided in the direction. Thereby, even if the liquid diffuses in the width direction, it is possible to prevent leakage from the absorbent article and to increase the absorption efficiency of the absorbent body.

[4.3] Outer Back of Absorbent Article As an application of the nonwoven fabric in the present invention, as shown in FIG. 15, for example, it has unevenness, and a plurality of openings 3a, 3b and second openings are formed in the recesses (grooves 1a, 1b). Non-woven fabric having one connecting portion 4a and having a fiber density of one side edge 14 in the openings 3a and 3b higher than the fiber density of the other side edge 15 in the other portions, for example, the openings 3a and 3b Can be used as the outer back 320 of the absorbent article. In this case, it is preferable that the nonwoven fabric is arranged so that the surface on which the convex portions 2a and 2b are formed is outside the absorbent article.

  Since the surface on which the convex portions 2a and 2b are formed on the outer back 320 is arranged to be outside the absorbent article, the tactile sensation is improved when the hand is mainly touched when using the absorbent article. . Moreover, it is excellent in air permeability by opening part 3a, 3b in groove part 1a, 1b.

[5] Each component Each component is described in detail below.

[5.1] Non-woven fabric related [5.1.1] Fiber assembly The fiber assembly is a fiber assembly formed in a substantially sheet shape, and the fibers constituting the fiber assembly have a degree of freedom. There is something. In other words, the fiber assembly has a degree of freedom between fibers. Here, the degree of freedom between the fibers means that the fibers can move freely by a fluid composed mainly of a gas, which is a fiber assembly. This fiber assembly can be formed, for example, by ejecting mixed fibers obtained by mixing a plurality of fibers so as to form a fiber layer having a predetermined thickness. Moreover, for example, it can form by ejecting so that each of several different fiber may be laminated | stacked in multiple times, and a fiber layer may be formed.

  As the fiber assembly in the present invention, for example, a fiber web formed by a card method or a fiber web before heat fusion and solidification of heat fusion between fibers can be exemplified. Moreover, the web formed by the airlaid method, or the fiber web before heat-bonding and heat-bonding of fibers are solidified can be exemplified. Moreover, the fiber web before heat fusion embossed by the point bond method solidifies can be illustrated. Moreover, a fiber aggregate before being spun and embossed by the spunbond method, or a fiber aggregate before the embossed heat fusion is solidified can be exemplified. Moreover, the fiber web formed by the needle punch method and semi-entangled can be illustrated. Moreover, the fiber web formed by the spunlace method and semi-entangled can be illustrated. Moreover, the fiber aggregate before spinning | fiber-formation by the meltblown method and heat-bonding of fibers solidifying can be illustrated. Moreover, the fiber assembly before fiber solidifies with the solvent formed by the solvent adhesion method can be illustrated.

  Preferably, the fibers are easily rearranged by the air (gas) flow is a fiber web formed by a card method using relatively long fibers, and further, the degree of freedom between the fibers is high, and the fibers are formed only by entanglement. An example of the web before heat fusion is shown. Moreover, after forming a groove part (unevenness | corrugation) etc. by the several air (gas) flow mentioned later, in order to make it a nonwoven fabric with the shape maintained, it is fiber by carrying out oven processing (heating process) with a predetermined heating apparatus etc. The through-air method in which the thermoplastic fibers contained in the aggregate are thermally fused is preferable.

[5.1.2] Fiber As the fiber constituting the fiber assembly (for example, the fiber 101 constituting the fiber web 100 shown in FIG. 1), for example, low density polyethylene, high density polyethylene, linear polyethylene, polypropylene, Examples thereof include fibers made of a thermoplastic resin such as polyethylene terephthalate, modified polypropylene, modified polyethylene terephthalate, nylon, and polyamide, and each resin alone or in combination.

  Examples of the composite shape include a core-sheath type in which the melting point of the core component is higher than that of the sheath component, an eccentric type of the core-sheath, and a side-by-side type in which the melting points of the left and right components are different. Also mixed are hollow type, flat type, Y type, C type, etc., three-dimensional crimped fiber of latent crimp or actual crimp, split fiber divided by physical load such as water flow, heat, emboss, etc. It may be.

  Moreover, in order to form a tertiary crimp shape, a predetermined actual crimp fiber and a latent crimp fiber can be mix | blended. Here, the three-dimensional crimped shape is a spiral shape, zigzag shape, Ω shape, or the like, and even if the fiber orientation is mainly oriented in the plane direction, the fiber orientation is partially oriented in the thickness direction. Thereby, since the buckling strength of the fiber itself works in the thickness direction, the bulk is not easily crushed even when an external pressure is applied. Furthermore, among these, the spiral shape will return to its original shape when the external pressure is released, so even if the bulk is slightly crushed by excessive external pressure, it will return to its original thickness after the external pressure is released. It becomes easy.

  The manifested crimped fiber is a generic term for fibers that have been crimped in advance by shape imparting by mechanical crimping, a core-sheath structure is eccentric type, side-by-side, or the like. Latent crimped fibers are those that are crimped by applying heat.

  Mechanical crimping can be controlled by the difference in peripheral speed of the line speed, heat, and pressurization for continuous and linear fibers after spinning. The larger the number of crimps per unit length, the greater the buckling against external pressure. Strength can be increased. For example, the number of crimps is preferably in the range of 10 to 35 / inch, more preferably 15 to 30 / inch.

  Shape imparting by heat shrinkage is a fiber that is three-dimensionally crimped because it is made of two or more resins having different melting points, and when heat is applied, the heat shrinkage rate changes due to the difference in melting point. Examples of the resin configuration of the fiber cross section include an eccentric type with a core-sheath structure and a side-by-side type in which the melting points of the left and right components are different. The heat shrinkage rate of such a fiber can be exemplified as a preferable value in a range of 5 to 90%, and further 10 to 80%, for example.

  The method of measuring the heat shrinkage rate is as follows: (1) A web of 200 gsm (g / m2) is made with 100% of the fiber to be measured, (2) a sample cut to a size of 250 × 250 mm is made, and (3) this sample Can be left in an oven at 145 ° C. (418.15 K) for 5 minutes, (4) the length after shrinkage can be measured, and (5) it can be calculated from the difference in length before and after heat shrinkage.

  When using this nonwoven fabric as a surface sheet, the fineness is preferably in the range of 1.1 to 8.8 dtex in consideration of, for example, liquid penetration and touch.

  When using this non-woven fabric as a surface sheet, as fibers constituting the fiber assembly, for example, to absorb a small amount of menstrual blood or sweat remaining on the skin, pulp, chemical pulp, rayon, acetate, natural Cellulose-based liquid hydrophilic fibers such as cotton may be included. However, since it is difficult for the cellulosic fibers to discharge the liquid once absorbed, for example, a case where it is mixed in the range of 0.1 to 5% by mass with respect to the whole can be exemplified as a preferred embodiment.

  When this nonwoven fabric is used as a surface sheet, for example, in consideration of liquid penetration and rewet back, a hydrophilic agent or a water repellent is kneaded or coated on the hydrophobic synthetic fibers listed above. May be. Further, hydrophilicity may be imparted by corona treatment or plasma treatment.

  Moreover, in order to improve whitening property, inorganic fillers, such as a titanium oxide, barium sulfate, a calcium carbonate, may contain, for example. In the case of a core-sheath type composite fiber, it may be contained only in the core or in the sheath.

  In addition, as described above, it is a fiber web formed by a card method using relatively long fibers that easily rearranges the fibers by air flow, and grooves (unevenness) are formed by a plurality of air flows. In order to make a nonwoven fabric while maintaining its shape later, a through-air method in which thermoplastic fibers are thermally fused by oven treatment (heat treatment) is preferable. As a fiber suitable for this production method, it is preferable to use a fiber having a core-sheath structure or a side-by-side structure in order to heat-bond the intersections of the fibers. It is preferable that it is comprised with the fiber of this. In particular, it is preferable to use a core-sheath composite fiber made of polyethylene terephthalate and polyethylene or a core-sheath composite fiber made of polypropylene and polyethylene. These fibers can be used alone or in combination of two or more. The fiber length is preferably 20 to 100 mm, particularly 35 to 65 mm.

[5.2] Non-woven fabric manufacturing apparatus [5.2.1] Fluid mainly composed of gas The fluid mainly composed of gas in the present invention is, for example, a gas adjusted to room temperature or a predetermined temperature, or the gas. Examples include aerosols containing solid or liquid fine particles.

  Examples of the gas include air and nitrogen. The gas includes liquid vapor such as water vapor.

  An aerosol is a substance in which a liquid or solid is dispersed in a gas, and examples thereof are given below. For example, ink for coloring, softening agent such as silicon for enhancing flexibility, hydrophilic or water repellent activator for controlling antistatic property and wettability, and oxidation for enhancing fluid energy Inorganic fillers such as titanium and barium sulfate, powder bonds such as polyethylene for increasing the energy of fluids and enhancing unevenness molding maintenance in heat treatment, antihistamines such as diphenhydramine hydrochloride and isopropylmethylphenol for preventing itching, The thing which disperse | distributed the moisturizer, the disinfectant, etc. can be illustrated. Here, the solid includes a gel.

  The temperature of the fluid mainly composed of gas can be adjusted as appropriate. It can adjust suitably according to the property of the fiber which comprises a fiber assembly, and the shape of the nonwoven fabric which should be manufactured.

  Here, for example, in order to favorably move the fibers constituting the fiber assembly, the degree of freedom of the fibers constituting the fiber assembly increases when the temperature of the fluid mainly composed of gas is somewhat higher. preferable. In addition, when the fiber assembly includes thermoplastic fibers, the fluid mainly composed of gas was sprayed by setting the temperature of the fluid composed mainly of gas to a temperature at which the thermoplastic fiber can be softened. The thermoplastic fiber disposed in the region or the like can be configured to be softened or melted and cured again.

  Thereby, the shape of a nonwoven fabric is maintained by the fluid which consists mainly of gas being sprayed, for example. Further, for example, when the fiber assembly is moved by a predetermined moving means, a strength is given to such an extent that the fiber assembly (nonwoven fabric) is not scattered.

The flow rate of the fluid mainly composed of gas can be adjusted as appropriate. As a specific example of a fiber aggregate having a degree of freedom between fibers, for example, the sheath is made of high-density polyethylene and the core is made of polyethylene terephthalate, and the fiber length is 20 to 100 mm, preferably 35 to 65 mm, and the fineness is 1.1 to 8 .8 dtex, preferably 2.2 to 5.6 dtex core-sheath fiber, fiber length is 20 to 100 mm, preferably 35 to 65 mm for fiber opening by the card method, fiber for fiber opening by the airlaid method Examples thereof include a fiber web 100 using fibers having a length of 1 to 50 mm, preferably 3 to 20 mm, and adjusted to 10 to 1000 gsm, preferably 15 to 100 gsm. As a condition of the fluid mainly composed of gas, for example, an ejection portion 910 (a ejection port 913: a diameter of 0.1 to 30 mm, preferably 0.5 to 5) formed with a plurality of ejection ports 913 shown in FIG. 5 or FIG. 5 mm: pitch is 0.5 to 30 mm, preferably 0.1 to 10 mm: shape is perfect circle, ellipse or rectangle), temperature is 15 to 300 ° C. (288.15 K to 573.15 K), preferably 100 to 200 100 ° C. (373.15K to 473.15K) hot air at a flow rate of 3 to 50 [L / (minute / hole)], preferably 5 to 20 [L / (minute / hole)]. A case of spraying can be illustrated. For example, when a fluid composed mainly of gas is sprayed under the above conditions, a fiber assembly in which the position and orientation of the constituent fibers can be changed is one of the preferred ones in the fiber assembly in the present invention. is there. For example, the non-woven fabric shown in FIG. 9 can be formed by creating with such fibers and production conditions. The dimensions and basis weight of the groove portions 1a and 1b and the convex portions 2a and 2b can be obtained within the following ranges. In the groove part 1, the thickness is 0.05 to 10 mm, preferably 0.1 to 5 mm, the width is 0.1 to 30 mm, preferably 0.5 to 5 mm, and the basis weight is 2 to 900 g / m ² , preferably in the range of 90 g / ^{m 2} to 10. The convex portions 2a and 2b have a thickness of 0.1 to 15 mm, preferably 0.5 to 10 mm, a width of 0.5 to 30 mm, preferably 1.0 to 10 mm, and a basis weight of 5 to 1000 g / m. ² , preferably in the range of 10 to 100 gsm. Moreover, although a nonwoven fabric can be produced in the said numerical range approximately, it is not limited to this range.

[5.2.2] Blowing means By making it possible to change the direction of the fluid mainly composed of gas, for example, the gap between the concave portions (groove portions) in the formed irregularities, The height and the like can be adjusted as appropriate. Further, for example, by configuring the direction of the fluid to be automatically changeable, for example, the groove or the like can be appropriately adjusted to have a meandering shape (wave shape, zigzag shape) or other shapes. Moreover, the shape and formation pattern of a groove part and an opening part can be suitably adjusted by adjusting the ejection amount and ejection time of the fluid which mainly consist of gas. The jet angle of the fluid mainly composed of gas to the fiber web 100 may be vertical, and in the moving direction F of the fiber web 100, it is directed to the line flow direction which is the moving direction F by a predetermined angle. Alternatively, the direction may be opposite to the line flow direction by a predetermined angle.

[5.2.3] Heating means As a method of adhering the fibers 101 in the nonwoven fabric 116 in which the predetermined opening is formed, for example, adhesion by a needle punch method, a spunlace method, a solvent adhesion method, a point bond method, air The heat bonding by the through method can be exemplified, but the air through method is preferable in order to maintain the adjusted fiber orientation, fiber density or fiber weight, and the shape of the formed predetermined groove, opening or protrusion. For example, heat treatment in the air-through method using the heater unit 95 is preferable.

[5.2.4] Others The nonwoven fabric 115 manufactured by being heated by the heater unit 950 is, for example, a step of cutting the nonwoven fabric 115 into a predetermined shape or a winding step by the conveyor 940 continuous with the conveyor 930 in the predetermined direction F. Moved to. Similar to the conveyor 930, the conveyor 940 includes a belt portion 949, a rotating portion 941, and the like.

It is the top view and bottom view of the nonwoven fabric in 1st Embodiment. It is a perspective sectional view of the nonwoven fabric in a 1st embodiment. It is the top view and bottom view of a net-like support member in a 1st embodiment. It is a perspective view of a fiber web. It is a side view explaining the nonwoven fabric manufacturing apparatus of 1st Embodiment. It is a top view explaining the nonwoven fabric manufacturing apparatus of FIG. FIG. 6 is an enlarged perspective view of a region Z in FIG. 5. It is a bottom view of the ejection part in FIG. It is the top view and bottom view of the nonwoven fabric in 2nd Embodiment. It is a perspective sectional view of the nonwoven fabric in a 2nd embodiment. It is the top view and sectional drawing of the nonwoven fabric in 3rd Embodiment. It is a figure which shows an example of the usage example of the nonwoven fabric in this invention. It is a figure which shows an example of the usage example of the nonwoven fabric in this invention. It is a figure which shows an example of the usage example of the nonwoven fabric in this invention. It is a figure which shows an example of the usage example of the nonwoven fabric in this invention.

Explanation of symbols

1 (1a, 1b) Groove 2 (2a, 2b) Convex 3 (3a, 3b, 3c) Opening 4a First connection 4b Second connection 14, 16, 18 One side edge 15, 17, 19 Other side edge part 100 Fiber web 110 Nonwoven fabric 300 Reticulated support member 910 Blowing part 920 Air supply pipe 915 Suction part

Claims (17)

A non-woven fabric that is manufactured vertically in the machine flow direction ,
A plurality of openings which are formed continuously in a longitudinal direction parallel to the flow direction of the machine,
Said one side edge portion in the lateral direction orthogonal multiple flow direction of opening each of the machine, the fiber density than the other side edge portion in the lateral direction rather high,
A predetermined opening in the plurality of openings;
A first adjacent opening adjacent to the predetermined opening in the longitudinal direction;
A second adjacent opening adjacent to the predetermined opening in the vertical direction opposite to the first adjacent opening;
One side edge portion having a high fiber density in the first adjacent opening portion is a side edge portion on the opposite side to the one side edge portion having a high fiber density in the predetermined opening portion in the lateral direction,
The one side edge portion having a high fiber density in the second adjacent opening portion is a non-woven fabric that is a side edge portion on the opposite side in the lateral direction to the one side edge portion having a high fiber density in the predetermined opening portion .   The nonwoven fabric according to claim 1, wherein the one side edge portion has a higher basis weight than the other side edge portion. Before Symbol further comprising a first connecting portion formed between a predetermined opening and the front Symbol first adjacent opening,
The nonwoven fabric according to claim 1 or 2, wherein the first connecting portion has a fiber density higher than that of the other side edge portion in the predetermined opening.   The nonwoven fabric according to claim 3, wherein the one side edge portion in the first adjacent opening has a content of longitudinally oriented fibers higher than a content of horizontally oriented fibers.   The non-woven fabric according to claim 3 or 4, wherein the first connecting portion has a content of horizontally oriented fibers higher than a content of vertically oriented fibers.   The nonwoven fabric according to any one of claims 3 to 5, wherein the first connection portion has a higher basis weight than the other side edge portion in the predetermined opening. The apparatus further includes a second connecting portion formed between the predetermined opening and the second adjacent opening , and the second connecting portion has a fiber density higher than that of the other side edge portion of the predetermined opening. The nonwoven fabric in any one of Claim 3 to 6 with high. Before Symbol said one side edge portion of the first adjacent opening, said first connecting portion, said one side edge portion in the predetermined openings, and the second connecting portion, the second adjacent opening The non-woven fabric according to claim 7, wherein the one side edge portion in the meandering manner is continuous. The fiber density of the first connecting portion is 0.05 g / cm ³ or more, and 1.1 times or more the fiber density of the other side edge portion in the predetermined opening,
The fiber density of the second connection part is 0.05 g / cm ³ or more, and is 1.1 times or more with respect to the fiber density of the other side edge part in the predetermined opening. Or the nonwoven fabric of 8.   The nonwoven fabric according to any one of claims 7 to 9, wherein a content rate of longitudinally oriented fibers is higher than a content rate of laterally oriented fibers in the one side edge portion in the second adjacent opening.   The non-woven fabric according to any one of claims 7 to 10, wherein the second connecting portion has a content of horizontally oriented fibers higher than a content of vertically oriented fibers.   The non-woven fabric according to any one of claims 7 to 11, wherein the second connecting portion has a higher basis weight than the other side edge portion of the predetermined opening. The basis weight of the one side edge in the predetermined opening, the basis weight of the one side edge in the first adjacent opening, and the basis weight of the one side edge in the second adjacent opening are: 15 to 250 g / m ² , the basis weight of the other side edge portion in the predetermined opening portion, the basis weight of the other side edge portion in the first adjacent opening portion, and the second adjacent opening portion, respectively. The nonwoven fabric in any one of Claims 7-12 which is 1.1 times or more with respect to the fabric weight of the said other side edge part. A plurality of grooves formed to extend in the longitudinal direction on one side of the nonwoven fabric;
A plurality of convex portions formed on the one surface side along the plurality of groove portions and extending in the longitudinal direction;
The nonwoven fabric according to any one of claims 1 to 13, wherein the plurality of openings are formed in each of the plurality of grooves. The nonwoven fabric according to any one of claims 1 to 14, wherein each of the plurality of openings has a substantially circular shape or a substantially elliptical shape having a long side along the longitudinal direction . A non-woven fabric that is manufactured vertically in the machine flow direction,
A high density region is formed continuously or intermittently along a plurality of openings formed continuously in a longitudinal direction parallel to the machine flow direction ,
A predetermined opening in the plurality of openings;
A first adjacent opening that is adjacent to the predetermined opening in the vertical direction, and the high-density region is a core that is open on one side in the horizontal direction perpendicular to the vertical direction so as to surround the predetermined opening. And a high-density region
A plurality of U-shaped high-density regions opened on the other side in the lateral direction so as to surround the first adjacent opening ,
And the one side is a U-shaped high-density regions of the open, said the other side is a U-shaped high-density regions of the open, you continuously alternately in the longitudinal direction, the nonwoven fabric. The said high-density area | region is a nonwoven fabric of Claim 16 provided with the meandering high-density area | region extended in the meandering shape in the said vertical direction.

Images