JP5590834B2 - 不織布およびその製造方法 - Google Patents
不織布およびその製造方法 Download PDFInfo
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- JP5590834B2 JP5590834B2 JP2009186885A JP2009186885A JP5590834B2 JP 5590834 B2 JP5590834 B2 JP 5590834B2 JP 2009186885 A JP2009186885 A JP 2009186885A JP 2009186885 A JP2009186885 A JP 2009186885A JP 5590834 B2 JP5590834 B2 JP 5590834B2
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- short fibers
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Description
この発明のうちの第2発明が対象とするのは、互いに溶着した短繊維によって形成されていて表面と裏面とを有し、前記表面には一方向へ互いに並行して延びる複数条の隆起部と前記隆起部どうしの間にあって前記一方向へ延びる複数条の谷部とが形成され、前記裏面の側を水平面に置いて前記一方向に直交する方向の断面を観察すると、前記隆起部における前記裏面と前記水平面との間に前記隆起部における前記短繊維どうしの間隙よりも大きな空隙である高空隙部が形成され、前記短繊維が前記隆起部のうちの少なくとも頂点付近においてその厚さ方向へ延びるように傾斜していて、少なくとも下記第1,第2工程を含む製造工程を経て製造されたものであることを特徴とする不織布である。
前記第1,第2工程は、以下のとおりである。
(1)前記不織布を形成するウエブを通気性の支持台に載せて前記支持台の下方から第1サクションを作用させながら機械方向へ走行させ、加熱されたジェットエアであって前記第1サクションの吸気量の3倍未満のエア量である第1ジェットエアを前記ウエブに対して前記表面から前記裏面に向かう方向へ吹き付けることにより、前記ウエブを厚さ方向において圧縮しながら前記短繊維どうしを溶着させる前記ウエブの予備処理工程である第1工程、および
(2)前記予備処理工程の後に、前記支持台の下方から第2サクションを作用させながら前記支持台に載せた前記ウエブを前記機械方向へ走行させ、前記機械方向に直交する交差方向に所要の間隔をあけて並ぶ複数のノズルから前記第2サクションの吸気量の3倍以上のエア量の第2ジェットエアを前記ウエブの前記表面から前記裏面に向かう方向へ吹き付けて前記第2ジェットエアの前記エア量の一部を前記支持台で反射させることにより前記機械方向へ互いに並行して延びる複数条の前記隆起部と、前記機械方向へ延びる複数条の前記谷部とを形成するとともに、前記隆起部における前記裏面と前記支持台との間に前記高空隙部を形成する第2工程。
(1)前記不織布を形成するウエブを通気性の支持台に載せて前記支持台の下方から第1サクションを作用させながら機械方向へ走行させ、加熱されたジェットエアであって前記第1サクションの吸気量の3倍未満のエア量である第1ジェットエアを前記ウエブに対して前記表面から前記裏面に向かう方向へ吹き付けることにより、前記ウエブを厚さ方向において圧縮しながら前記短繊維どうしを溶着させる前記ウエブの予備処理工程である第1工程、および
(2)前記予備処理工程の後に、前記支持台の下方から第2サクションを作用させながら前記支持台に載せた前記ウエブを前記機械方向へ走行させ、前記機械方向に直交する交差方向に所要の間隔をあけて並ぶ複数のノズルから前記第2サクションの吸気量の3倍以上のエア量の第2ジェットエアを前記ウエブの前記表面から前記裏面に向かう方向へ吹き付けて前記第2ジェットエアの前記エア量の一部を前記支持台で反射させることにより前記機械方向へ互いに並行して延びる複数条の前記隆起部と、前記機械方向へ延びる複数条の前記谷部とを形成するとともに、前記隆起部における前記裏面と前記支持台との間に前記高空隙部を形成する第2工程。
A.測定用試片の作成
(1)測定対象とする不織布をコクヨカッターナイフHA−7B(商品名)用の替え刃HA−100でカットして、不織布の交差方向CDの断面を有する試片を用意し、測定台の水平面Hに置く。
(2)試片の表面2にアクリル板(図示せず)を載せ、さらにウエイト(図示せず)を載せて、試片に0.6g/cm2の荷重を加える。
(3)キーエンスデジタルマイクロスコープVHX−100を使用して、試片の断面の50倍の写真を撮る(図2、図6のa参照)。
B.隆起部の断面積と空隙部面積率の測定
(1)画像解析ソフトUSB DEGIITAL SCALEを使用して、上記Aで作成した画像を読み込む。
(2)各画像を呼び出し、ヒストグラム値を80に設定して、画像を2値化する(図6のb)。
(3)画像の中で観察対象とする隆起部を指定し、図示の如く水平面Hを通る矩形の線Lで囲む(図6のc)。
(4)指定した隆起部において、画像解析により、短繊維が密集して白色を呈している部分の面積S1を求める。
(5)指定した隆起部において、画像解析により、水平面Hよりも上で黒色を呈している部分(短繊維が存在していない部分)の面積S2を求める。
(6)空隙部断面積と空隙部面積率とを次式によって求める。
空隙部断面積=S1+S2
空隙部面積率=S2/(S1+S2)
(1)測定対象とする不織布を100×100mmにカットして試片とする。
(2)2本の内径52mmの円筒を上下につなぎ、円筒と円筒との間に試片を置く。このときに、試片の下側には30メッシュ、厚さ0.3mmの合成樹脂性ネットをあてがい、試片のたわみを防ぐ。
(3)上側の円筒に40mlの人工軟便を5秒間で注入する。人工軟便の組成は、セルロース:ベントナイト:水=3.3:6.7:90とする。
(4)人工軟便を注入してから、人工軟便が試片への進入を開始した後に試片の上面に残って動かなくなるまでの時間を求め、軟便透過時間とする。
なお、軟便透過時間の測定の前後における試片の重量の差を求め、その差を試片における軟便残存量とするが、表1においての空隙部面積率が2.1〜6.3%である不織布についての軟便残存量は、いずれも4〜5gの範囲にあってほぼ一定しているとみなすことができた。
(1)測定対象とする不織布を100×100mmにカットして測定用試片として水平面の上に置く。
(2)試片の表面に厚さT0のアクリル板を載せ、アクリル板にはさらにウエイトを載せて試片に3g/cm2の荷重を加え、3分間静置する。
(3)次に、ダイアルゲージを使用してアクリル板の上から試片とアクリル板との厚さT1を測定する。
(4)次に、ウエイトを追加して試片に20g/cm2の荷重を加えて3分間静置し、その後にダイアルゲージを使用して試片とアクリル板との厚さT2を測定する。
(5)試片に対する荷重を3g/cm2に戻してから5分間静置し、その後にダイアルゲージを使用して試片とアクリル板との厚さT3測定する。
(6)次式によって、試片の嵩回復率を計算する。
嵩回復率(%)=(T3−T0)/(T1−T0)×100
(1)測定対象とする不織布、例えば図1の不織布1を100×100mmにカットして測定用試片30とし、その試片30を70℃で30分間加熱して、試片30の取り扱い過程で生じたしわや折り癖を消して、試片30をできるだけ平坦なものにする。
(2)コクヨカッターナイフHA−7B(商品名)用の標準替え刃HA−100を使用して、試片30を交差方向CDに切断して、観察用の切断面31(図7参照)を作り、その試片30を水平な面に載せる。
(3)切断面31を電子顕微鏡(キーエンス社製リアルサーフェースビュー顕微鏡 VE−7800)で観察し、切断面31の30倍の拡大写真(図7参照)を撮る。撮影では試片における隆起部6の高さ全体を視野に入れる。
(4)撮影した画像の拡大写真において、水平な面に一致する水平線Xと隆起部6における頂点を通り水平線Xに直交する垂直基準線Y 0 とを引く。
(5)さらに、画像に対して、垂直基準線Y0との平行間隔が100μmとなる垂直な補助線Y1,Y2を垂直基準線Y0の両側に引く。
(6)画像中の短繊維11それぞれについて、図8に示すように、2本の補助線Y1,Y2との交点にマークM1,M2をつける。
(7)2本の補助線Y1,Y2におけるマークM1,M2を直線Sで結び、その直線Sと垂直基準線Y0との交差角度α,βを求め、α,βのうちで値の小さい方の交差角度を繊維角度θとする。
(8)画像中で焦点が合っているすべての短繊維11について繊維角度θを求め、求めた繊維角度の算術平均値を平均繊維角度θmとする。
2 表面
3 裏面
6 隆起部
7 谷部
11 短繊維
21 高空隙部
100 ウエブ
200 支持台(ベルト)
901 予備処理工程(第1工程)
902 第2工程
911 第1ジェットエア
921 第2ジェットエア
A 長さ方向
B 幅方向
C 厚さ方向
MD 機械方向
CD 交差方向
θm 平均繊維角度
Claims (6)
- 互いに溶着した短繊維によって形成されていて表面と裏面とを有し、前記表面には一方向へ互いに並行して延びる複数条の隆起部と前記隆起部どうしの間にあって前記一方向へ延びる複数条の谷部とが形成されている不織布であって、
前記不織布は、前記裏面の側を水平面に置いて前記一方向に直交する方向の断面を観察すると、前記隆起部における前記裏面と前記水平面との間に前記隆起部における前記短繊維どうしの間隙よりも大きな空隙である高空隙部が形成されるものであって、前記短繊維が前記隆起部のうちの少なくとも頂点付近において前記不織布の厚さ方向へ延びるように傾斜し、
前記断面において、前記隆起部の断面積と前記高空隙部の断面積との合計断面積に対して、前記隆起部の断面積のうちで前記短繊維どうしの間隙が占める面積と前記高空隙部の断面積との和が占める割合である空隙部面積率が少なくとも3.5%であり、
前記表面に20g/cm 2 の荷重を3分間かけてから5分間静置した後の前記隆起部の高さの弾性的な回復率が少なくとも60%であることを特徴とする前記不織布。 - 前記断面においては、前記隆起部の頂点を通り前記水平面に対して垂直な基準線と前記短繊維との交差角度の平均値が75度以下である請求項1記載の不織布。
- 前記不織布は10〜80g/m2の単位質量を有するものであり、前記短繊維は1〜11dtexの繊度と20〜80mmの繊維長とを有する親水化処理されたものである請求項1または2に記載の不織布。
- 前記短繊維は、溶融温度の異なる二種類の熱可塑性合成樹脂で形成された複合繊維であって、前記二種類のうちで前記溶融温度の低い方の前記熱可塑性合成樹脂を介して互いに溶着している請求項1〜3のいずれかに記載の不織布。
- 互いに溶着した短繊維によって形成されていて表面と裏面とを有し、前記表面には一方向へ互いに並行して延びる複数条の隆起部と前記隆起部どうしの間にあって前記一方向へ延びる複数条の谷部とが形成され、
前記裏面の側を水平面に置いて前記一方向に直交する方向の断面を観察すると、前記隆起部における前記裏面と前記水平面との間に前記隆起部における前記短繊維どうしの間隙よりも大きな空隙である高空隙部が形成され、前記短繊維が前記隆起部のうちの少なくとも頂点付近においてその厚さ方向へ延びるように傾斜していて、少なくとも下記第1,第2工程を含む製造工程を経て製造されたものであることを特徴とする不織布:
(1)前記不織布を形成するウエブを通気性の支持台に載せて前記支持台の下方から第1サクションを作用させながら機械方向へ走行させ、加熱されたジェットエアであって前記第1サクションの吸気量の3倍未満のエア量である第1ジェットエアを前記ウエブに対して前記表面から前記裏面に向かう方向へ吹き付けることにより、前記ウエブを厚さ方向において圧縮しながら前記短繊維どうしを溶着させる前記ウエブの予備処理工程である第1工程、および
(2)前記予備処理工程の後に、前記支持台の下方から第2サクションを作用させながら前記支持台に載せた前記ウエブを前記機械方向へ走行させ、前記機械方向に直交する交差方向に所要の間隔をあけて並ぶ複数のノズルから前記第2サクションの吸気量の3倍以上のエア量の第2ジェットエアを前記ウエブの前記表面から前記裏面に向かう方向へ吹き付けて前記第2ジェットエアの前記エア量の一部を前記支持台で反射させることにより前記機械方向へ互いに並行して延びる複数条の前記隆起部と、前記機械方向へ延びる複数条の前記谷部とを形成するとともに、前記隆起部における前記裏面と前記支持台との間に前記高空隙部を形成する第2工程。 - 互いに溶着した短繊維によって形成されていて表面と裏面とを有し、前記表面には一方向へ互いに並行して延びる複数条の隆起部と前記隆起部どうしの間にあって前記一方向へ延びる複数条の谷部とが形成され、
前記裏面の側を水平面に置いて前記一方向に直交する方向の断面を観察すると、前記隆起部における前記裏面と前記水平面との間に前記隆起部における前記短繊維どうしの間隙よりも大きな空隙である高空隙部が形成され、前記短繊維が前記隆起部のうちの少なくとも頂点付近においてその厚さ方向へ延びるように傾斜している不織布の製造方法であって、
前記不織布を形成するウエブを通気性の支持台に載せて前記支持台の下方から第1サクションを作用させながら機械方向へ走行させ、加熱されたジェットエアであって前記第1サクションの吸気量の3倍未満のエア量である第1ジェットエアを前記ウエブに対して前記表面から前記裏面に向かう方向へ吹き付けることにより、前記ウエブを厚さ方向において圧縮しながら前記短繊維どうしを溶着させる前記ウエブの予備処理工程である第1工程、および
前記予備処理工程の後に、前記支持台の下方から第2サクションを作用させながら前記支持台に載せた前記ウエブを前記機械方向へ走行させ、前記機械方向に直交する交差方向に所要の間隔をあけて並ぶ複数のノズルから前記第2サクションの吸気量の3倍以上のエア量の第2ジェットエアを前記ウエブの前記表面から前記裏面に向かう方向へ吹き付けて前記第2ジェットエアの前記エア量の一部を前記支持台で反射させることにより前記機械方向へ互いに並行して延びる複数条の前記隆起部と、前記機械方向へ延びる複数条の前記谷部とを形成するとともに、前記隆起部における前記裏面と前記支持台との間に前記高空隙部を形成する第2工程を含むことを特徴とする前記不織布の製造方法。
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CN102575398A (zh) | 2012-07-11 |
MY157140A (en) | 2016-05-13 |
JP2011038211A (ja) | 2011-02-24 |
KR20120045044A (ko) | 2012-05-08 |
EP2465988A1 (en) | 2012-06-20 |
US9222206B2 (en) | 2015-12-29 |
EP2465988A4 (en) | 2014-01-01 |
US20120141742A1 (en) | 2012-06-07 |
KR101539831B1 (ko) | 2015-07-27 |
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