JP5956206B2 - Nonwoven fabric and method for producing the same - Google Patents

Nonwoven fabric and method for producing the same Download PDF

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JP5956206B2
JP5956206B2 JP2012060398A JP2012060398A JP5956206B2 JP 5956206 B2 JP5956206 B2 JP 5956206B2 JP 2012060398 A JP2012060398 A JP 2012060398A JP 2012060398 A JP2012060398 A JP 2012060398A JP 5956206 B2 JP5956206 B2 JP 5956206B2
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protrusion
sheet
nonwoven fabric
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JP2013194333A (en
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宏子 川口
宏子 川口
正洋 谷口
正洋 谷口
泰樹 内山
泰樹 内山
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Kao Corp
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本発明は不織布およびその製造方法に関する。   The present invention relates to a nonwoven fabric and a method for producing the same.

生理用ナプキン、パンティーライナー、および使い捨ておむつ等といった吸収性物品において、その機能に応じて、シート材の片面に突出した部分を配したものや、突出部を２段に配したもの、両面に断面波形のアーチ形状を配したものなどが開発されている。
吸収性物品は通常着用者の肌に直接当てて使用される。特に、肌荒れしやすいようなところに用いられることが多く、しかも長時間に亙って着用されることがある。そのため肌あたりのやさしいものが望まれる。他方、吸収性物品には基本的な機能として液体等の吸収液保持性が要求される。上記のような吸収性物品の肌触りと各機能とを高める表面シートの開発が試みられている。 Absorbent articles such as sanitary napkins, panty liners, disposable diapers, etc., depending on their functions, those with a protruding part on one side of the sheet material, those with protruding parts arranged in two steps, cross sections on both sides Products with corrugated arch shapes have been developed.
Absorbent articles are usually applied directly to the wearer's skin. In particular, it is often used in places that are prone to rough skin, and may be worn for a long time. Therefore, the gentle thing per skin is desired. On the other hand, absorbent articles such as liquids are required as a basic function for absorbent articles. Attempts have been made to develop a surface sheet that enhances the feel and functions of the absorbent article as described above.

特許文献１には、実質的に伸縮しないシート状物からなる上層と下層とを有し、この両層が多数の接合部で接合されており、両層の間に空洞を有して上層に多数の凸部を形成し、下層がフラットな表面シートが開示されている。この表面シートは、凸部の底面が矩形にされ、凸部が全体として直方体状又は截頭四角錐体状にされている。
特許文献１に開示された表面シートによれば、液漏れ防止性、特に軟便や経血などの高粘性液の漏れ防止性に優れているとされる。
しかし、特許文献１に記載の表面シートで例示されている構造では、多量の液が一度に供給された場合、上層と下層との間の空間が小さいため、その空間で液を十分に保持することができず、処理しきれない可能性がある。また、上層の凸部の空洞を塞ぐように下層が配されているため、通液性が不十分となる場合がある。さらに、壁部の繊維の配向性についての記述はないがＣＤ方向断面においては厚み方向に配向していないと考えられるため、高加圧下では凸部形状が潰れる場合がある。 Patent Document 1 has an upper layer and a lower layer made of a sheet-like material that does not substantially expand and contract, and both the layers are joined at a large number of joints, and the upper layer has a cavity between the two layers. A surface sheet in which a large number of convex portions are formed and the lower layer is flat is disclosed. In this surface sheet, the bottom surface of the convex portion is rectangular, and the convex portion as a whole has a rectangular parallelepiped shape or a truncated quadrangular pyramid shape.
According to the surface sheet disclosed in Patent Document 1, it is said that the liquid leakage prevention property, particularly the leakage prevention property of high viscosity liquid such as soft stool and menstrual blood is excellent.
However, in the structure illustrated in the surface sheet described in Patent Document 1, when a large amount of liquid is supplied at a time, the space between the upper layer and the lower layer is small, so that the liquid is sufficiently retained in that space. May not be able to be processed. In addition, since the lower layer is disposed so as to block the cavity of the convex portion of the upper layer, the liquid permeability may be insufficient. Furthermore, although there is no description about the orientation of the fibers in the wall portion, it is considered that the fibers are not oriented in the thickness direction in the cross section in the CD direction.

特許文献２には、不織布からなる第１層と第２層を有する表面シートが開示されている。表面シートは、第１層の一部が肌当接面側に突出して形成された多数の肌当接凸部と、第１層及び第２層それぞれの一部が非肌当接面側に突出して形成された多数の導液凹部とを有している。第１層及び第２層は、導液凹部の下端部において互いに接合されて接合部が形成され、第２層より第１層の方が相隣接する接合部間の長さが長く、第１層及び第２層は断面が波状をなしている。
この表面シートによれば、スポット吸収性や漏れ防止性に優れているとされる。また、肌や吸収体との間に離間部分が生じるため通気性に優れているとされる。さらに、形状保持効果が高く、潰れにくく、復元性が高いため、クッション性にも優れているとされる。
しかし、特許文献２に開示された表面シートでは、多量の液が一度に供給された場合、第１層と第２層との間に存在する空間が小さいため、その空間で液を十分に保持することができず、処理しきれない可能性がある。また、導液凹部の底部に開口部があるため、吸収体に移行した液（排泄物）がその開口部を通って逆戻りする場合がある。さらに、凸部の壁部の繊維の配向性についての記述はないがＣＤ方向断面においては厚み方向に配向していないと考えられるため、高加圧下では凸部の形状が潰れる場合がある。 Patent Document 2 discloses a surface sheet having a first layer and a second layer made of a nonwoven fabric. The surface sheet has a large number of skin contact convex portions formed by protruding a part of the first layer toward the skin contact surface side, and a part of each of the first layer and the second layer on the non-skin contact surface side. It has many liquid introduction recessed parts formed so that it may protrude. The first layer and the second layer are joined to each other at the lower end of the liquid introduction recess to form a joint, and the first layer is longer than the second layer between adjacent joints. The layers and the second layer are wavy in cross section.
According to this surface sheet, it is said that it is excellent in spot absorptivity and leakage prevention property. Moreover, since a separation | spacing part arises between skin and an absorber, it is supposed that it is excellent in air permeability. Furthermore, since the shape retention effect is high, it is difficult to be crushed, and the restoring property is high, it is said that the cushioning property is excellent.
However, in the surface sheet disclosed in Patent Document 2, when a large amount of liquid is supplied at a time, the space existing between the first layer and the second layer is small, so that the liquid is sufficiently retained in that space. May not be able to be processed. In addition, since there is an opening at the bottom of the liquid guide recess, the liquid (excrement) that has moved to the absorber may go back through the opening. Furthermore, although there is no description about the orientation of the fibers in the wall portion of the convex portion, it is considered that the fiber is not oriented in the thickness direction in the cross section in the CD direction, and thus the shape of the convex portion may be crushed under high pressure.

特許文献３には、液体透過性トップシートと、トップシートに接合されているバックシートと、トップシートとバックシートとの間に位置する、開放構造の大便管理部材とを備えたおむつであって、大便管理部材は、アーチ型部分のパターンを有し、間隔があけられた接着位置において、裏張りにアンカー留めされた第一繊維シートによって形成されて、前記第一繊維シートが、接着位置間においてアーチ型に前記裏張りから突出し、前記アーチ型部分が０．５ｍｍ以上の高さを有し、前記第一繊維シートは、１００ｇ/ｃｍ２の加えられた力の下で３０秒後に少なくとも５０％のレジリエンスを有し、前記トップシートが開口ウエブを含み、前記裏張りに対して前記第一繊維シートと反対側に、間隔が開けられた接着位置としてのアンカー部分を有するとともに、該接着位置との間で前記裏張りから突出するアーチ型部分を有する第二繊維シートをさらに備えた、おむつが開示されている。上述のおむつは、低粘度大便物質を装着者の皮膚から離間して保持することができるとされる。
しかし、特許文献３に開示されたおむつでは、アーチ型部分の壁部の繊維の配向性についてはＣＤ方向断面においては厚み方向に配向していないと推察できるため、高下ではアーチ型部分の形状が潰れやすくなり、その部分での肌接触面積が大きくなる。またアーチ型部分に裏張りがあるため、通液性に劣る。
なお、本明細書では、「ＭＤ」とは、機械方向ともいい、不織布製造時におけるウエブの送り方向であり、「Ｍａｃｈｉｎｅ Ｄｉｒｅｃｔｉｏｎ」の略語である。「ＣＤ」とはＭＤに対して直交する方向であり、「Ｃｒｏｓｓ Ｄｉｒｅｃｔｉｏｎ」の略語である。 Patent Document 3 discloses a diaper including a liquid-permeable top sheet, a back sheet bonded to the top sheet, and an open structure stool management member positioned between the top sheet and the back sheet. The stool management member has a pattern of arched portions and is formed by a first fiber sheet anchored to a backing at spaced adhesive positions, wherein the first fiber sheet is between the adhesive positions Projecting from the backing in an arcuate shape, the arched portion having a height of 0.5 mm or more, and the first fiber sheet is at least 50 seconds after 30 seconds under an applied force of 100 g / cm 2 % Of the resilience, the top sheet includes an open web, and the anchor as a spaced bond position opposite the first fiber sheet with respect to the backing Min and has a, further comprising a second fiber sheet having arched portions projecting from the backing between the adhesive position, the diaper is disclosed. The above-mentioned diaper is said to be able to hold the low-viscosity stool material away from the wearer's skin.
However, in the diaper disclosed in Patent Document 3, it can be inferred that the fiber orientation of the wall portion of the arch-shaped portion is not oriented in the thickness direction in the cross section in the CD direction. Will be crushed easily, and the skin contact area in the part will become large. Moreover, since the arch-shaped part has a backing, it is inferior in liquid permeability.
In the present specification, “MD” is also referred to as a machine direction, which is a web feeding direction at the time of manufacturing a nonwoven fabric, and is an abbreviation for “Machine Direction”. “CD” is a direction orthogonal to MD and is an abbreviation of “Cross Direction”.

特開２００４−１７４２３４号公報JP 2004-174234 A 特開２００９−８９９６５号公報JP 2009-89965 A 特許第４６３７３４９号公報Japanese Patent No. 4637349

本発明は、着用者が寝ているような高加圧下でも形状保持性に優れ、高い通気性を有して蒸れの問題を解決し、かつ排泄物が素早くシート間の空間に導かれることにより排泄物が肌に付き難くい不織布およびその製造方法を提供することを課題とする。   The present invention is excellent in shape retention even under high pressure such as when the wearer is sleeping, has high breathability, solves the problem of stuffiness, and excrement is quickly guided to the space between the sheets. It is an object of the present invention to provide a nonwoven fabric in which excrement is less likely to adhere to the skin and a method for producing the same.

本発明は、シート状の不織布を平面視した側の第１面側に突出し、前記第１面側とは反対側の第２面側に開口した内部空間を有する第１突出部と、前記第２面側に突出し内部空間を有する第２突出部とを有し、前記第１、第２突出部が該不織布の平面視交差する異なる方向のそれぞれに交互に連続して配された第１シートと、前記第２面側に突出し、前記第１面側に開口した内部空間を有する第３突出部と、前記第１面側に突出し内部空間を有する第４突出部とを有し、前記第３、第４突出部が該不織布の平面視交差する異なる方向のそれぞれに交互に連続して配された第２シートとを有し、前記第１突出部の頂部と前記第１突出部の前記第２面側に開口した開口部との間に環状構造の連続した壁部が配され、該壁部は前記第１突出部の頂部と開口部とを結ぶ方向に繊維配向性を有し、前記第１突出部と前記第３突出部とは突出方向が逆方向となるように対向する位置に配されて前記第２突出部と前記第４突出部とが接合されている不織布を提供する。   The present invention provides a first projecting portion that protrudes to the first surface side of the sheet-like nonwoven fabric when viewed in plan, and has an internal space that opens to the second surface side opposite to the first surface side, A first sheet having a second projecting portion projecting on the second surface side and having an internal space, wherein the first and second projecting portions are alternately and continuously arranged in different directions intersecting in plan view of the nonwoven fabric. And a third protrusion having an internal space protruding toward the second surface and opening toward the first surface, and a fourth protrusion having an internal space protruding toward the first surface. 3, the 4th protrusion part has the 2nd sheet | seat alternately and continuously distribute | arranged to each of the different direction which crosses planar view of this nonwoven fabric, The top part of the said 1st protrusion part, and the said 1st protrusion part A continuous wall portion having an annular structure is arranged between the opening portion opened on the second surface side, and the wall portion is a top portion of the first projecting portion. The first projecting portion and the third projecting portion are arranged at positions facing each other so that the projecting direction is opposite to the second projecting portion and the second projecting portion. Provided is a nonwoven fabric joined to a fourth protrusion.

本発明は、シート状の不織布を平面視した側の第１面側に突出し内部空間を有する第１突出部と、前記第１面側とは反対側の第２面側に突出し内部空間を有する第２突出部とを有し、前記第１、第２突出部は、該不織布の平面視交差する異なる方向のそれぞれに交互に連続して配された第１シートを作製する工程と、前記第２面側に突出し内部空間を有する第３突出部と、前記第１面側に突出し内部空間を有する第４突出部とを有し、前記第３、第４突出部は、該不織布の平面視交差する異なる方向のそれぞれに交互に連続して配された第２シートを作製する工程と、前記第１シートの第２面側と前記第２シートの第１面側とを向かい合わせにして前記第１シートの第２突出部と前記第２シートの第４突出部を接合する工程を有し、前記第１シートの作製工程および前記第２シートの作製工程は、それぞれ、凹凸形状を有する支持体上に熱可塑性繊維を含有するウエブを搬送し、第１の熱風の吹き付けにより前記ウエブの繊維同士を前記凹凸形状が保持される状態に賦形する工程と、前記第１の熱風よりも高温度の第２の熱風を前記賦形させたウエブに吹き付け、前記凹凸形状を保持した状態で前記ウエブの繊維同士を融着させて前記凹凸形状を固定する工程とを備えている不織布の製造方法を提供する。   The present invention has a first projecting portion projecting on the first surface side of the sheet-like nonwoven fabric in plan view and having an internal space, and projecting on the second surface side opposite to the first surface side and having an internal space. A first protrusion having a second protrusion, wherein the first and second protrusions are alternately and continuously arranged in different directions intersecting in plan view of the nonwoven fabric, A third projecting portion projecting on the second surface side and having an internal space; and a fourth projecting portion projecting on the first surface side and having the inner space, wherein the third and fourth projecting portions are planar views of the nonwoven fabric. The step of producing second sheets alternately and continuously arranged in different directions intersecting each other, the second surface side of the first sheet and the first surface side of the second sheet facing each other Joining the second protrusion of the first sheet and the fourth protrusion of the second sheet, the first In the sheet manufacturing process and the second sheet manufacturing process, a web containing thermoplastic fibers is conveyed onto a support having an uneven shape, and the fibers of the web are separated from each other by blowing a first hot air. The step of shaping the concavo-convex shape to be held, and the second hot air having a temperature higher than that of the first hot air is blown to the shaped web, and the web fiber is held in the state of holding the concavo-convex shape. The manufacturing method of the nonwoven fabric provided with the process of fuse | melting each other and fixing the said uneven | corrugated shape is provided.

本発明の不織布は、第１突出部の壁部が第１突出部の頂部と第１突出部の開口部とを結ぶ方向に、第３突出部の壁部が第３突出部の頂部と第３突出部の開口部とを結ぶ方向に繊維配向性を有することから、着用者が寝ているような高加圧下でも各突出部が潰れにくいため、形状保持性に優れ、高い通気性を有して蒸れの問題を解決することができる。それとともに、第１突出部の繊維密度が第２突出部の繊維密度より低く、第３突出部の繊維密度が第４突出部の繊維密度より低くなっていることから、不織布の第１面側から排泄物が供給された場合、その排泄物が素早くシート間の内部空間に導かれ、次いで吸収体に素早く移行するので、排泄物が肌に付き難くなる。よって、着用者の赤み、かぶれ、褥瘡等の発生を防止することができるため、快適な継続的着用が可能になる不織布を提供することができる。   In the nonwoven fabric of the present invention, the wall portion of the first protrusion portion connects the top portion of the first protrusion portion and the opening portion of the first protrusion portion in the direction in which the wall portion of the first protrusion portion is connected to the top portion of the third protrusion portion. 3.Because it has fiber orientation in the direction connecting the openings of the protrusions, each protrusion is not easily crushed even under high pressure, such as when the wearer is sleeping, so it has excellent shape retention and high air permeability. Then the problem of stuffiness can be solved. At the same time, the fiber density of the first protrusion is lower than the fiber density of the second protrusion, and the fiber density of the third protrusion is lower than the fiber density of the fourth protrusion. When the excrement is supplied from, the excrement is quickly guided to the internal space between the sheets, and then quickly transferred to the absorber, so that the excrement is difficult to adhere to the skin. Therefore, since the generation | occurrence | production of a wearer's redness, a rash, a pressure sore, etc. can be prevented, the nonwoven fabric which enables comfortable continuous wear can be provided.

本発明の不織布の製造方法は、着用者が寝ているような高加圧下でも各突出部が潰れにくく、形状保持性に優れ、高い通気性を有して蒸れの問題を解決する不織布を製造することができる。また凹凸形状を有する支持体上に搬送したウエブに第１の熱風を吹き付けることによってウエブを賦形することから、第１突出部の壁部が第１突出部の頂部と第１突出部の開口部とを結ぶ方向に、第３突出部の壁部が第３突出部の頂部と第３突出部の開口部とを結ぶ方向に繊維配向性を有する不織布を製造できる。この製造方法により作製された不織布は、排泄物が素早くシート間の内部空間に導かれることによって、着用者の赤み、かぶれ、褥瘡等の発生を防止することができ、快適な継続的着用が可能となる。   The method for producing a nonwoven fabric according to the present invention produces a nonwoven fabric that is resistant to crushing even under high pressure such as when the wearer is sleeping, has excellent shape retention, and has high breathability to solve the problem of stuffiness. can do. Further, since the web is shaped by blowing the first hot air onto the web transported on the support having an uneven shape, the wall portion of the first projecting portion is the top of the first projecting portion and the opening of the first projecting portion. The nonwoven fabric which has a fiber orientation can be manufactured in the direction which connects the top part of a 3rd protrusion part, and the opening part of a 3rd protrusion part in the direction which connects a part. Non-woven fabric produced by this manufacturing method can prevent the occurrence of redness, rash, pressure ulcers, etc. of the wearer by allowing the excrement to be quickly guided to the internal space between the sheets, enabling comfortable and continuous wear. It becomes.

本発明の不織布の好ましい一実施形態を示した部分断面図である。It is the fragmentary sectional view showing one desirable embodiment of the nonwoven fabric of the present invention. 本発明の不織布の第１シートの部分断面斜視図である。It is a partial section perspective view of the 1st sheet of the nonwoven fabric of the present invention. 本発明の不織布の第２シートの部分断面斜視図である。It is a partial section perspective view of the 2nd sheet of the nonwoven fabric of the present invention. 本発明の不織布の製造方法の好ましい一実施形態を示した部分断面図である。It is the fragmentary sectional view which showed preferable one Embodiment of the manufacturing method of the nonwoven fabric of this invention. ５ｋＰａ圧力時透気度の測定方法を説明した模式図である。It is the schematic diagram explaining the measuring method of the air permeability at the time of 5 kPa pressure.

本発明に係る不織布の好ましい一実施形態について、図１〜図３を参照しながら、以下に説明する。
本発明の不織布１０は、例えば生理用ナプキンや使い捨ておむつなどの吸収性物品の表面シートに適用することが好ましく、第１面側Ｚ１を着用者の肌面側に向けて用い、第２面側Ｚ２を吸収性物品内部の吸収体（図示せず）側に配置して用いることが好ましい。以下、図面に示した不織布１０の第１面側Ｚ１を着用者の肌面に向けて用いる実施態様を考慮して説明するが、本発明がこれにより限定して解釈されるものではない。 A preferred embodiment of the nonwoven fabric according to the present invention will be described below with reference to FIGS.
The nonwoven fabric 10 of the present invention is preferably applied to a surface sheet of an absorbent article such as a sanitary napkin or a disposable diaper, for example, and is used with the first surface side Z1 facing the skin side of the wearer, and the second surface side. It is preferable to use Z2 on the absorbent body (not shown) side inside the absorbent article. Hereinafter, although it demonstrates considering the embodiment which uses the 1st surface side Z1 of the nonwoven fabric 10 shown in drawing toward a wearer's skin surface, this invention is limited to this and is not interpreted.

図１ないし図３に示すように、本発明の不織布１０は、第１シート１１と第２シート１２とが接合してなる。   As shown in FIGS. 1 to 3, the nonwoven fabric 10 of the present invention is formed by joining a first sheet 11 and a second sheet 12.

第１シート１１は、シート状の不織布を平面視した側の第１面側Ｚ１に突出し、内側に第１面とは反対側の第２面側に開口した内部空間２１Ｋを有する第１突出部２１と、第１面側Ｚ１とは反対側の第２面側Ｚ２に突出し、内側に第２面側に開口した内部空間２２Ｋを有する第２突出部２２とを有している。第１突出部２１および第２突出部２２は、第１シート１１の全面にわたって、例えば平面視交差する異なる方向のそれぞれに交互に連続して配されている。上記異なる方向とは、具体的一例として、上記異なる方向の１方向であるｘ方向（ｘ軸方向）と、このｘ方向とは異なり、上記異なる方向の別の１方向であるｙ方向（ｙ軸方向）である。第１面側Ｚ１からみた凸部が第１突出部２１であり、凹部が第２突出部２２となる。また、第２面側Ｚ２からみた凸部が第２突出部２２であり、凹部が第１突出部２１となる。したがって、第１突出部２１と第２突出部２２とは一部が共有されている。上記ｘ軸とｙ軸の交差角度は、３０°以上９０°以下とすることが好ましく、本実施形態では９０°とした。また第１面側Ｚ１をｚ軸方向上方側とし、第２面側Ｚ２をｚ軸方向下方側とした。   The 1st sheet | seat 11 protrudes in the 1st surface side Z1 of the side which planarly viewed the sheet-like nonwoven fabric, and the 1st protrusion part which has the internal space 21K opened in the 2nd surface side on the opposite side to a 1st surface inside. 21 and the 2nd protrusion part 22 which protrudes in the 2nd surface side Z2 on the opposite side to the 1st surface side Z1, and has the internal space 22K opened to the 2nd surface side inside. The first protrusions 21 and the second protrusions 22 are arranged alternately and continuously over the entire surface of the first sheet 11, for example, in different directions intersecting in plan view. As a specific example, the different direction is an x direction (x-axis direction) that is one direction of the different directions, and a y direction (y-axis) that is different from the x direction and is another direction of the different direction. Direction). The convex portion viewed from the first surface side Z <b> 1 is the first projecting portion 21, and the concave portion is the second projecting portion 22. Further, the convex portion viewed from the second surface side Z <b> 2 is the second projecting portion 22, and the concave portion is the first projecting portion 21. Therefore, the first protrusion 21 and the second protrusion 22 are partially shared. The intersection angle between the x-axis and the y-axis is preferably 30 ° or more and 90 ° or less, and is 90 ° in this embodiment. Also, the first surface side Z1 is the upper side in the z-axis direction, and the second surface side Z2 is the lower side in the z-axis direction.

第１シート１１は、シートの全面に渡って０．０５ｋＰａの圧力がかかるように荷重がかけられたときの厚みＴ１が１ｍｍ〜１０ｍｍが好ましく、より好ましくは２ｍｍ〜６ｍｍであり、さらに好ましくは３ｍｍ〜５ｍｍである。また、シートの全面に渡って５ｋＰａの圧力がかかるように荷重がかけられたときの厚みＴｐ１が０．１ｍｍ〜６ｍｍが好ましく、より好ましくは０．２ｍｍ〜３．６ｍｍであり、さらに好ましくは０．３ｍｍ〜３ｍｍである。なお、上述の各厚みＴ１，Ｔｐ１は、ｚ軸方向でみた第１突出部２１の頂点から第２突出部２２の頂点までの高さの平均値をいう。   The first sheet 11 has a thickness T1 of preferably 1 mm to 10 mm, more preferably 2 mm to 6 mm, and even more preferably 3 mm when a load is applied so that a pressure of 0.05 kPa is applied over the entire surface of the sheet. ~ 5 mm. The thickness Tp1 when a load is applied so as to apply a pressure of 5 kPa over the entire surface of the sheet is preferably 0.1 mm to 6 mm, more preferably 0.2 mm to 3.6 mm, and still more preferably 0 .3 mm to 3 mm. In addition, each thickness T1 and Tp1 mentioned above mean the average value of the height from the vertex of the 1st protrusion part 21 to the vertex of the 2nd protrusion part 22 seeing in the z-axis direction.

さらに、第２シート１２は、シート状の不織布を平面視した側の第２面側Ｚ２に突出し、内側に第１面側に開口した内部空間２３Ｋを有する第３突出部２３と、第１面側Ｚ１に突出し、内側に第２面側に開口した内部空間２４Ｋを有する第４突出部２４とを有している。第３突出部２３および第４突出部２４は、第２シート１２の全面にわたって、例えば平面視交差する異なる方向のそれぞれに交互に連続して配されている。上記異なる方向とは、具体的一例として、上記ｘ方向とｙ方向である。第１面側Ｚ１からみた凸部が第３突出部２３であり、凹部が第４突出部２４となる。また、第２面側Ｚ２からみた凸部が第４突出部２４であり、凹部が第３突出部２３となる。したがって、第３突出部２３と第４突出部２４とは一部が共有されている。   Furthermore, the 2nd sheet | seat 12 protrudes in the 2nd surface side Z2 of the side which planarly viewed the sheet-like nonwoven fabric, the 3rd protrusion part 23 which has the internal space 23K opened to the 1st surface side inside, and 1st surface It has the 4th protrusion part 24 which has the internal space 24K which protrudes in the side Z1 and opened in the 2nd surface side inside. The third protrusions 23 and the fourth protrusions 24 are alternately and continuously arranged over the entire surface of the second sheet 12 in, for example, different directions intersecting in plan view. The different directions are the x direction and the y direction as a specific example. The convex portion viewed from the first surface side Z <b> 1 is the third projecting portion 23, and the concave portion is the fourth projecting portion 24. Further, the convex portion viewed from the second surface side Z <b> 2 is the fourth projecting portion 24, and the concave portion is the third projecting portion 23. Therefore, the third protrusion 23 and the fourth protrusion 24 are partially shared.

第２シート１２は、シートの全面に渡って０．０５ｋＰａの圧力がかかるように荷重がかけられたときの厚みＴ２は、１ｍｍ〜１０ｍｍが好ましく、より好ましくは２ｍｍ〜６ｍｍであり、さらに好ましくは３ｍｍ〜５ｍｍである。また、シートの全面に渡って５ｋＰａの圧力がかかるように荷重がかけられたときの厚みＴｐ２は、０．１ｍｍ〜６ｍｍが好ましく、より好ましくは０．２ｍｍ〜３．６ｍｍであり、さらに好ましくは０．３ｍｍ〜３ｍｍである。なお、上述の各厚みＴ２，Ｔｐ２は、ｚ軸方向でみた第３突出部２３の頂点から第４突出部２４の頂点までの高さの平均値をいう。   The thickness T2 of the second sheet 12 when a load is applied so that a pressure of 0.05 kPa is applied over the entire surface of the sheet is preferably 1 mm to 10 mm, more preferably 2 mm to 6 mm, and still more preferably. 3 mm to 5 mm. The thickness Tp2 when a load is applied so that a pressure of 5 kPa is applied over the entire surface of the sheet is preferably 0.1 mm to 6 mm, more preferably 0.2 mm to 3.6 mm, and still more preferably. 0.3 mm to 3 mm. The thicknesses T2 and Tp2 described above mean the average value of the height from the top of the third protrusion 23 to the top of the fourth protrusion 24 as viewed in the z-axis direction.

上記第１シート１１と第２シート１２とは、第１突出部２１と第２突出部２２の配置位置と第３突出部２３と第４突出部２４の配置位置が対向するように配されている。具体的には、第１突出部２１と第３突出部２３とを逆方向に突出するように対向し、また第２突出部２２と第４突出部２４が対向してそれぞれの頂部２２Ｔ，２４Ｔで接合されていることが好ましい。なお、頂部２２Ｔ，２４Ｔで接合していれば、それぞれの頂点が合致していない場合の接合も許容される。
上記接合は、接着剤（例えばホットメルト接着剤）を用いた接合、熱による融着接合、圧力をかけて接合する圧着接合等、種々の接合方法を採用することができる。 The first sheet 11 and the second sheet 12 are arranged such that the arrangement positions of the first protrusion 21 and the second protrusion 22 and the arrangement positions of the third protrusion 23 and the fourth protrusion 24 face each other. Yes. Specifically, the first projecting portion 21 and the third projecting portion 23 face each other so as to project in the opposite direction, and the second projecting portion 22 and the fourth projecting portion 24 face each other, and the respective top portions 22T and 24T. It is preferable that it is joined by. In addition, if it joins by the top parts 22T and 24T, joining when each vertex does not correspond is also accepted.
For the joining, various joining methods such as joining using an adhesive (for example, a hot-melt adhesive), fusion bonding by heat, and pressure-bonding joining by applying pressure can be adopted.

上述したように、第１シート１１と第２シート１２との接合は、第２突出部頂部２２Ｔと第４突出部頂部２４Ｔとの接合であるため、それらの頂部の周囲は接合されていない。したがって、第１突出部２１の内部空間２１Ｋと上記第３突出部２３の内部空間２３Ｋとは連続しているとともに、隣接する内部空間２１Ｋ、内部空間２３Ｋにも連続していて、一つの内部空間２５を構成している。   As described above, since the first sheet 11 and the second sheet 12 are joined to each other between the second projecting portion top portion 22T and the fourth projecting portion top portion 24T, the periphery of these top portions is not joined. Therefore, the internal space 21K of the first protrusion 21 and the internal space 23K of the third protrusion 23 are continuous, and are also connected to the adjacent internal space 21K and internal space 23K. 25.

本実施形態において第１突出部２１の頂部２１Ｔ、第２突出部２２の頂部２２Ｔ、第３突出部２３の頂部２３Ｔおよび第４突出部２４の頂部２４Ｔは、それぞれ、丸みをもった円錐台形状もしくは半球状にされている。なお、本実施形態において、第１突出部２１、第２突出部２２、第３突出部２３および第４突出部２４は上記形状に限定されず、どのような突出形態でもよく、例えば、様々な錐体形状（本明細書において錐体形状とは、円錐、円錐台、角錐、角錐台、斜円錐等を広く含む意味である。）であることが実際的である。
また本実施形態において、第１突出部２１、第２突出部２２、第３突出部２３および第４突出部２４は、それぞれにおいて、その外形と相似する頂部に丸みのある円錐台形状もしくは半球状の内部空間２１Ｋ、内部空間２２Ｋ、内部空間２３Ｋおよび内部空間２４Ｋを有している。 In the present embodiment, the top portion 21T of the first projecting portion 21, the top portion 22T of the second projecting portion 22, the top portion 23T of the third projecting portion 23, and the top portion 24T of the fourth projecting portion 24 are each rounded truncated cone shapes. Or hemispherical. In the present embodiment, the first projecting portion 21, the second projecting portion 22, the third projecting portion 23, and the fourth projecting portion 24 are not limited to the above shapes, and may have any projecting form, for example, various It is practical to have a pyramid shape (in this specification, the pyramid shape means widely including a cone, a truncated cone, a pyramid, a truncated pyramid, an oblique cone, etc.).
Moreover, in this embodiment, the 1st protrusion part 21, the 2nd protrusion part 22, the 3rd protrusion part 23, and the 4th protrusion part 24 are the truncated cone shape or hemispherical in which the top resembles the external shape, respectively. Internal space 21K, internal space 22K, internal space 23K, and internal space 24K.

上記第１突出部２１の頂部（以下、第１突出部頂部ともいう。）２１Ｔと第１突出部２１の第２面側Ｚ２に開口した開口部２１Ｈとの間に壁部２１Ｗを有する。開口部２１Ｈは、第２面側Ｚ２からみて第１突出部２１の壁部２１Ｗの第２面側Ｚ２の周縁をいう。この壁部２１Ｗは、第１突出部２１において環状構造を成している部分である。また第２突出部２２の頂部（以下、第２突出部頂部ともいう。）２２Ｔと第２突出部２２の第１面側Ｚ１に開口した開口部２２Ｈとの間に壁部２２Ｗを有する。開口部２２Ｈは、第１面側Ｚ１からみて第２突出部２２の壁部２２Ｗの第１面側Ｚ１の周縁をいう。この壁部２２Ｗは、第２突出部２２において環状構造を成している部分である。また壁部２２Ｗは上記壁部２１Ｗと一部を共有している。
さらに上記第３突出部２３の頂部（以下、第３突出部頂部ともいう。）２３Ｔと第３突出部２３の第１面側Ｚ１に開口した開口部２３Ｈとの間に壁部２３Ｗを有する。開口部２３Ｈは、第１面側Ｚ１からみて第３突出部２３の壁部２３Ｗの第１面側Ｚ１の周縁をいう。この壁部２３Ｗは、第３突出部２３において環状構造を成している部分である。また第４突出部２４の頂部（以下、第４突出部頂部ともいう。）２４Ｔと第４突出部２４の第２面側Ｚ２に開口した開口部２４Ｈとの間に壁部２４Ｗを有する。開口部２４Ｈは、第２面側Ｚ２からみて第４突出部２４の壁部２４Ｗの第２面側Ｚ２の周縁をいう。この壁部２４Ｗは、第４突出部２４において環状構造を成している部分である。また壁部２４Ｗは上記壁部２３Ｗと一部を共有している。
ここでいう「環状」とは、平面視において無端の一連の形状をなしていれば特に限定されず、平面視において円、楕円、矩形、多角形など、どのような形状であってもよい。シートの連続状態を好適に維持する上では円又は楕円が好ましい。さらに、「環状」を立体形状としていえば、円柱状、斜円柱状、楕円柱状、切頭円錐状、切頭斜円錐状、切頭楕円錐状、切頭四角錐状、切頭斜四角錐状など任意の環構造が挙げられ、連続したシート状態を実現する上では、円柱状、楕円柱状、切頭円錐状、切頭楕円錐状が好ましい。
なお、第１突出部頂部２１Ｔ、壁部２１Ｗ、第２突出部頂部２２は、基本的には、不織布厚みを３等分した上部Ｐ１を第１突出部頂部２１Ｔ、中間部Ｐ３を壁部２１Ｗ（２２Ｗ）、下部Ｐ２を第２突出部頂部２２Ｔとする（図２参照）。同様に、上部Ｐ１を第４突出部頂部２４Ｔ、中間部Ｐ３を壁部２４Ｗ（壁部２３Ｗ）、下部Ｐ２を第３突出部頂部２３Ｔとする（図３参照）。また側面視した不織布全体の厚みが薄く、不織布の層厚みが厚い場合や、それぞれの頂部の尖度ないし曲率が異なる場合には、断面において第１突出部頂点２１Ｔｐから隣接する第２突出部頂点２２Ｔｐまでの直線を３等分したそれぞれの位置での直線に対する第１突出部頂点２１Ｔｐ側の直交線が第１突出部頂点２１Ｔｐを通るｚ軸に平行な線周りに回転して得られる曲面で区分される不織布の上部を第１突出部頂部２１Ｔ、第２突出部頂点２２Ｔｐ側の直交線が第２突出部頂点２２Ｔｐを通るｚ軸に平行な線周りに回転して得られる曲面で区分される不織布の下部を第２突出部頂部２２Ｔ（第３突出部頂部２３Ｔ）、第１突出部頂部２１Ｔと第２突出部頂部２２Ｔとの間を壁部２１Ｗ（壁部２２Ｗ）としてもよい（図２参照）。なお、第２シート１２についても第１シート１１と同様に区分できる（図３参照）。もしくは、断面において直線状になった部分を壁部とし、そこから湾曲して丸みを帯びていく領域をそれぞれの突出部としてもよい。
さらに、第１突出部２１は第１突出部頂部２１Ｔと壁部２１Ｗを含み、第２突出部２２は第２突出部頂部２２Ｔと壁部２２Ｗを含み、壁部２１Ｗ，２２Ｗは一部が共有される。同様に、第３突出部２３は第３突出部頂部２３Ｔと壁部２３Ｗを含み、第４突出部２４は第４突出部頂部２４Ｔと壁部２４Ｗを含み、壁部２３Ｗ，２４Ｗは一部が共有される。 A wall portion 21 </ b> W is provided between a top portion (hereinafter also referred to as a first projection portion top portion) 21 </ b> T of the first projection portion 21 and an opening portion 21 </ b> H opened on the second surface side Z <b> 2 of the first projection portion 21. The opening 21H refers to the peripheral edge on the second surface side Z2 of the wall portion 21W of the first protruding portion 21 when viewed from the second surface side Z2. The wall portion 21 </ b> W is a portion that forms an annular structure in the first projecting portion 21. Further, a wall portion 22W is provided between the top portion of the second protrusion portion 22 (hereinafter also referred to as the second protrusion portion top portion) 22T and the opening portion 22H opened on the first surface side Z1 of the second protrusion portion 22. The opening 22H refers to the periphery of the first surface side Z1 of the wall 22W of the second protrusion 22 as viewed from the first surface side Z1. The wall portion 22 </ b> W is a portion that forms an annular structure in the second projecting portion 22. The wall 22W shares a part with the wall 21W.
Further, a wall portion 23W is provided between the top portion of the third protrusion portion 23 (hereinafter also referred to as a third protrusion portion top portion) 23T and the opening portion 23H opened on the first surface side Z1 of the third protrusion portion 23. The opening 23H refers to the periphery of the wall 23W of the third protrusion 23 on the first surface side Z1 when viewed from the first surface side Z1. This wall portion 23 </ b> W is a portion forming an annular structure in the third projecting portion 23. Further, a wall 24 </ b> W is provided between the top 24 </ b> T (hereinafter also referred to as a fourth protrusion top) 24 </ b> T of the fourth protrusion 24 and the opening 24 </ b> H opened on the second surface side Z <b> 2 of the fourth protrusion 24. The opening 24H refers to the peripheral edge of the second surface side Z2 of the wall 24W of the fourth protrusion 24 as viewed from the second surface side Z2. The wall portion 24 </ b> W is a portion that forms an annular structure in the fourth projecting portion 24. The wall portion 24W shares a part with the wall portion 23W.
The “annular” herein is not particularly limited as long as it has a series of endless shapes in plan view, and may be any shape such as a circle, an ellipse, a rectangle, or a polygon in plan view. In order to maintain the continuous state of the sheet suitably, a circle or an ellipse is preferable. Furthermore, if the "annular" is considered as a three-dimensional shape, a cylindrical shape, a slanted columnar shape, an elliptical columnar shape, a truncated cone shape, a truncated oblique cone shape, a truncated elliptical cone shape, a truncated quadrangular pyramid shape, a truncated oblique pyramid shape Arbitrary ring structures, such as a shape, are mentioned, In order to implement | achieve a continuous sheet | seat state, cylindrical shape, elliptic cylinder shape, truncated cone shape, and truncated elliptical cone shape are preferable.
The first protrusion top 21T, the wall 21W, and the second protrusion 22 basically have an upper part P1 obtained by dividing the nonwoven fabric thickness into three equal parts, the first protrusion top 21T, and the intermediate part P3 as the wall 21W. (22W), let the lower part P2 be the 2nd protrusion top part 22T (refer FIG. 2). Similarly, the upper portion P1 is a fourth protruding portion top portion 24T, the intermediate portion P3 is a wall portion 24W (wall portion 23W), and the lower portion P2 is a third protruding portion top portion 23T (see FIG. 3). In addition, when the thickness of the nonwoven fabric as viewed from the side is thin and the thickness of the nonwoven fabric is large, or when the kurtosis or curvature of the tops of the nonwoven fabrics is different, the vertex of the second protruding portion adjacent to the first protruding portion vertex 21Tp in the cross section A curved surface obtained by rotating an orthogonal line on the first protrusion vertex 21Tp side with respect to a straight line at each position obtained by dividing the straight line up to 22Tp into three equal parts around a line parallel to the z-axis passing through the first protrusion vertex 21Tp. The upper part of the divided nonwoven fabric is divided by a curved surface obtained by rotating an orthogonal line on the first protruding portion apex 21T, the second protruding portion apex 22Tp side around a line parallel to the z axis passing through the second protruding apex 22Tp. The lower portion of the non-woven fabric may be the second protrusion top 22T (third protrusion top 23T), and the wall 21W (wall 22W) between the first protrusion top 21T and the second protrusion top 22T (FIG. 2). The second sheet 12 can also be classified in the same manner as the first sheet 11 (see FIG. 3). Or it is good also considering the part which became linear in the cross section as a wall part, and each area | region which curves and rounds from there as each protrusion part.
Further, the first protrusion 21 includes a first protrusion top 21T and a wall 21W, the second protrusion 22 includes a second protrusion top 22T and a wall 22W, and the walls 21W and 22W are partially shared. Is done. Similarly, the third protrusion 23 includes a third protrusion top 23T and a wall 23W, the fourth protrusion 24 includes a fourth protrusion top 24T and a wall 24W, and the walls 23W and 24W are partly. Shared.

上述のように配設された第１，第２突出部２１，２２および第３，第４突出部２３，２４を有する不織布１０は、屈曲部を有さず、全体が連続した曲面で構成されている。
このように、上記不織布１０は面方向に連続した構造を有していることが好ましい。この「連続」とは、断続した部分や小孔がないことを意味する。ただし、繊維間の隙間のような微細孔は上記小孔に含めない。上記小孔とは、例えば、その孔径が円相当の直径で１ｍｍ以上のものと定義する。 The nonwoven fabric 10 having the first and second projecting portions 21 and 22 and the third and fourth projecting portions 23 and 24 arranged as described above does not have a bent portion, and is configured by a continuous curved surface as a whole. ing.
Thus, it is preferable that the said nonwoven fabric 10 has a structure continuous in the surface direction. This “continuous” means that there are no intermittent portions or small holes. However, fine holes such as gaps between fibers are not included in the small holes. The small hole is defined as, for example, a hole having a diameter equivalent to a circle of 1 mm or more.

上述の第１突出部２１の壁部２１Ｗを構成する繊維は、壁部２１Ｗの全周にわたって第１突出部頂部２１Ｔと開口部２１Ｈの縁部を結ぶ方向に繊維配向性を有する。言い換えれば、壁部２１Ｗを構成する繊維は、第１突出部頂部２１に向かって収束する様に配向し、その起立する方向に繊維配向性を有する。また上記第２突出部２２の壁部２２Ｗを構成する繊維は、壁部２２Ｗの全周にわたって第２突出部頂部２２Ｔと開口部２２Ｈの縁部を結ぶ方向に繊維配向性を有する。この壁部２２Ｗの繊維配向性は、上述の壁部２１Ｗと共通部分では、壁部２１Ｗの繊維配向性と同様になる。
さらに上述の第３突出部２３の壁部２３Ｗを構成する繊維は、壁部２３Ｗの全周にわたって第３突出部頂部２３Ｔと開口部２３Ｈの縁部を結ぶ方向に繊維配向性を有する。言い換えれば、壁部２３Ｗを構成する繊維は、第３突出部頂部２３に向かって収束する様に配向し、その起立する方向に繊維配向性を有する。また上記第４突出部２４の壁部２４Ｗを構成する繊維は、壁部２４Ｗの全周にわたって第４突出部頂部２４Ｔと開口部２４Ｈの縁部を結ぶ方向に繊維配向性を有する。この壁部２４Ｗの繊維配向性は、上述の壁部２３Ｗと共通部分では、壁部２３Ｗの繊維配向性と同様になる。
一般的なエアスルー不織布では、通常不織布を製造するときに、そのＭＤ方向に繊維が配向しそのまま融着されるため、ＭＤ方向断面における壁部の繊維はその起立方向に繊維が配向するものの、ＣＤ方向断面においては、起立方向とは直行する方向に繊維が配向することとなるため、このような繊維配向性は有さない。 The fibers constituting the wall portion 21W of the first protruding portion 21 have fiber orientation in the direction connecting the first protruding portion top portion 21T and the edge portion of the opening portion 21H over the entire circumference of the wall portion 21W. In other words, the fibers constituting the wall portion 21W are oriented so as to converge toward the first protruding portion top portion 21, and have fiber orientation in the standing direction. Moreover, the fiber which comprises the wall part 22W of the said 2nd protrusion part 22 has fiber orientation in the direction which ties the edge part of the 2nd protrusion part top part 22T and the opening part 22H over the perimeter of the wall part 22W. The fiber orientation of the wall portion 22W is the same as the fiber orientation of the wall portion 21W in the common portion with the above-described wall portion 21W.
Furthermore, the fiber which comprises the wall part 23W of the above-mentioned 3rd protrusion part 23 has fiber orientation in the direction which ties the edge part of the 3rd protrusion part top part 23T and the opening part 23H over the perimeter of the wall part 23W. In other words, the fibers constituting the wall portion 23W are oriented so as to converge toward the third protruding portion top portion 23, and have fiber orientation in the standing direction. The fibers constituting the wall 24W of the fourth protrusion 24 have fiber orientation in the direction connecting the fourth protrusion top 24T and the edge of the opening 24H over the entire circumference of the wall 24W. The fiber orientation of the wall 24W is the same as the fiber orientation of the wall 23W at the common part with the above-described wall 23W.
In general air-through non-woven fabric, when the non-woven fabric is usually produced, the fibers are oriented in the MD direction and are fused as they are. Therefore, the fibers in the wall portion in the MD direction cross section are oriented in the standing direction, but CD In the directional cross section, the fibers are oriented in a direction perpendicular to the standing direction, and thus do not have such fiber orientation.

本発明の不織布１０に用いることができる繊維材料は特に限定されない。具体的には、下記の繊維などが挙げられる。ポリエチレン（ＰＥ）繊維、ポリプロピレン（ＰＰ）繊維等のポリオレフィン繊維；ポリエチレンテレフタレート（ＰＥＴ）、ポリアミド等の熱可塑性樹脂を単独で用いてなる繊維があり、また、芯鞘型、サイドバイサイド型等の構造の複合繊維がある。本発明では複合繊維を用いるのが好ましい。ここでいう複合繊維とは、高融点成分が芯部分で低融点成分が鞘部分とする芯鞘繊維、また高融点成分と低融点成分とが並列するサイドバイサイド繊維が挙げられる。その好ましい例として、鞘成分（低融点成分）がポリエチレンまたは低融点ポリプロピレンである芯鞘構造の繊維が好ましく挙げられ、該芯／鞘構造の繊維の代表例としては、ＰＥＴ（芯）／ＰＥ（鞘）、ＰＰ（芯）／ＰＥ（鞘）、ポリ乳酸（芯）／ＰＥ（鞘）、ＰＰ（芯）／低融点ＰＰ（鞘）等の芯鞘構造の繊維があげられる。さらに具体的には、上記構成繊維は、ポリエチレン繊維、ポリプロピレン繊維等のポリオレフィン系繊維、ポリエチレン複合繊維、ポリプロピレン複合繊維を含むのが好ましい。ここで、該ポリエチレン複合繊維の複合組成は、ポリエチレンテレフタレート／ポリエチレンであり、該ポリプロピレン複合繊維の複合組成が、ポリエチレンテレフタレート／低融点ポリプロピレンであるのが好ましく、より具体的には、ＰＥＴ（芯）／ＰＥ（鞘）、ＰＥＴ（芯）／低融点ＰＰ（鞘）が挙げられる。また、これらの繊維は、単独で用いて不織布を構成してもよいが、２種以上を組み合わせた混繊として用いることもできる。   The fiber material that can be used for the nonwoven fabric 10 of the present invention is not particularly limited. Specific examples include the following fibers. Polyolefin fibers such as polyethylene (PE) fibers and polypropylene (PP) fibers; there are fibers that use a thermoplastic resin such as polyethylene terephthalate (PET) and polyamide alone, and there are structures of core-sheath type, side-by-side type, etc. There are composite fibers. In the present invention, it is preferable to use a composite fiber. Examples of the composite fiber include a core-sheath fiber having a high melting point component as a core portion and a low melting point component as a sheath portion, and a side-by-side fiber in which a high melting point component and a low melting point component are arranged in parallel. Preferred examples thereof include fibers having a core-sheath structure in which the sheath component (low-melting-point component) is polyethylene or low-melting-point polypropylene. Typical examples of the fibers having the core / sheath structure include PET (core) / PE ( Examples include fibers having a core-sheath structure such as a sheath), PP (core) / PE (sheath), polylactic acid (core) / PE (sheath), and PP (core) / low melting point PP (sheath). More specifically, the constituent fibers preferably include polyolefin fibers such as polyethylene fibers and polypropylene fibers, polyethylene composite fibers, and polypropylene composite fibers. Here, the composite composition of the polyethylene composite fiber is polyethylene terephthalate / polyethylene, and the composite composition of the polypropylene composite fiber is preferably polyethylene terephthalate / low melting point polypropylene, and more specifically, PET (core). / PE (sheath), PET (core) / low melting point PP (sheath). These fibers may be used alone to form a nonwoven fabric, but can also be used as a mixed fiber in which two or more kinds are combined.

上記不織布１０は、上記第１突出部２１の繊維密度が上記第２突出部２２の繊維密度より低く、上記第３突出部２３の繊維密度が上記第４突出部２４の繊維密度より低くなっている。これにより、不織布の第１面側Ｚ１から排泄物が供給された場合、その排泄物（図示せず）が素早くシート間の内部空間２５に導かれ、次いで吸収体（図示せず）に素早く移行するので、排泄物が肌に付き難くなる。よって、着用者の赤み、かぶれ、褥瘡等の発生を防止することができる。ここでいう繊維密度とは、各突出部の厚みの中心付近の繊維密度であり、１ｍｍ２辺りの繊維本数を計測することで評価した。例えば、上記第１突出部２１の繊維密度は３０〜１３０本／ｍｍ２であることが好ましく、５０〜１２０本／ｍｍ２がより好ましい。また上記第２突出部２２の繊維密度は２５０〜５００本／ｍｍ２であることが好ましく、２７０〜４８０本／ｍｍ２がより好ましい。また、第１突出部２１の繊維密度と第２突出部２２の繊維密度との差は、１５０本／ｍｍ２以上であることが好ましい。
上記第３突出部２３の繊維密度は３０〜１５０本／ｍｍ２であることが好ましく、５０〜１２０本／ｍｍ２がより好ましい。また上記第４突出部２４の繊維密度は２５０〜５００本／ｍｍ２であることが好ましく、２７０〜４８０本／ｍｍ２がより好ましい。また、第３突出部２３の繊維密度と第４突出部２４の繊維密度の差は、１５０本／ｍｍ２以上であることが好ましい。 In the nonwoven fabric 10, the fiber density of the first protrusion 21 is lower than the fiber density of the second protrusion 22, and the fiber density of the third protrusion 23 is lower than the fiber density of the fourth protrusion 24. Yes. Thereby, when excrement is supplied from the 1st surface side Z1 of a nonwoven fabric, the excrement (not shown) is led quickly to the internal space 25 between sheets, and then moves quickly to an absorber (not shown). As a result, it becomes difficult for the excrement to adhere to the skin. Therefore, generation | occurrence | production of a wearer's redness, a rash, a pressure sore, etc. can be prevented. The fiber density here is a fiber density near the center of the thickness of each protrusion, and was evaluated by measuring the number of fibers per 1 mm 2 . For example, the fiber density of the first protrusion 21 is preferably from 30 to 130 present / mm 2, more preferably from 50 to 120 present / mm 2. Also it is preferable that the fiber density of the second protrusion 22 is 250 to 500 present / mm 2, and more preferably 270 to 480 present / mm 2. Moreover, it is preferable that the difference between the fiber density of the 1st protrusion part 21 and the fiber density of the 2nd protrusion part 22 is 150 pieces / mm < 2 > or more.
Fiber density of the third protrusion 23 is preferably from 30 to 150 present / mm 2, and more preferably 50 to 120 present / mm 2. The fiber density of the fourth projecting portion 24 is preferably from 250 to 500 present / mm 2, and more preferably 270 to 480 present / mm 2. Moreover, it is preferable that the difference between the fiber density of the 3rd protrusion part 23 and the fiber density of the 4th protrusion part 24 is 150 pieces / mm < 2 > or more.

さらに、上記第１突出部２１の繊維密度が上記第３突出部２３の繊維密度と同等もしくは上記第３突出部２３の繊維密度より低くなっている。これにより、不織布の第１面側Ｚ１から排泄物（図示せず）が供給された場合、その排泄物が素早くシート間の内部空間２５に導かれ、ある程度の時間ストックされた後に、吸収体（図示せず）へ移行するので、吸収体での拡散を防ぎ、排泄物が漏れにくくなる。ここでいう繊維密度とは、各突出部の厚みの中心付近の繊維密度であり、１ｍｍ２辺りの繊維本数を計測することで評価した。また、第１突出部２１の繊維密度と第３突出部２３の繊維密度の差はなくてもよいが、第３突出部２３の方が第１突出部２１よりも、１０本／ｍｍ２以上高いことがより好ましく、２０本／ｍｍ２以上高いことがより好ましい。第１突出部２１の繊維密度が第３突出部２３の繊維密度よりも高いと吸収体での拡散を防ぎ、排泄物が漏れ難くなる効果がより高くなる。 Furthermore, the fiber density of the first protrusion 21 is equal to the fiber density of the third protrusion 23 or lower than the fiber density of the third protrusion 23. Thereby, when excrement (not shown) is supplied from the first surface side Z1 of the nonwoven fabric, the excrement is quickly guided to the internal space 25 between the sheets, and stocked for a certain period of time. (Not shown), diffusion in the absorber is prevented, and excrement is less likely to leak. The fiber density here is a fiber density near the center of the thickness of each protrusion, and was evaluated by measuring the number of fibers per 1 mm 2 . Further, there may be no difference between the fiber density of the first protrusion 21 and the fiber density of the third protrusion 23, but the third protrusion 23 is 10 pieces / mm 2 or more than the first protrusion 21. It is more preferable that the height is higher, and it is more preferable that the height is 20 lines / mm 2 or more. When the fiber density of the 1st protrusion part 21 is higher than the fiber density of the 3rd protrusion part 23, the spreading | diffusion in an absorber is prevented and the effect that excrement becomes difficult to leak becomes higher.

また上記第１シート１１および上記第２シート１２の所定の圧力下における厚みは前述のように規定される。
また第１シート１１に５ｋＰａの圧力となるように荷重をかけたときの厚みＴｐ１が上記厚みＴ１の値の１０〜６０％であることが好ましく、２０〜５０％がより好ましい。第２シート１２に５ｋＰａの圧力となるように荷重をかけたときの厚みＴｐ２が上記厚みＴ２の値の１０〜６０％であることが好ましく、２０〜５０％がより好ましい。 The thickness of the first sheet 11 and the second sheet 12 under a predetermined pressure is defined as described above.
Further, the thickness Tp1 when a load is applied to the first sheet 11 so as to be a pressure of 5 kPa is preferably 10 to 60% of the value of the thickness T1, and more preferably 20 to 50%. The thickness Tp2 when a load is applied to the second sheet 12 to a pressure of 5 kPa is preferably 10 to 60% of the value of the thickness T2, and more preferably 20 to 50%.

上記厚みＴ１は、第１シート１１に０．０５ｋＰａの圧力となるように荷重がかけられたときの第１突出部頂部２１Ｔの頂点を通るｘ−ｙ平面に平行な面と第２突出部頂部２２Ｔの頂点を通るｘ−ｙ平面に平行な面との間のｚ軸方向の距離である。
上記厚みＴ２は、第２シート１２に０．０５ｋＰａの圧力となるように荷重がかけられたときの第３突出部頂部２３Ｔの頂点を通るｘ−ｙ平面に平行な面と第４突出部頂部２４Ｔの頂点を通るｘ−ｙ平面に平行な面との間のｚ軸方向の距離である。
上記厚みＴｐ１は、第１シート１１に５ｋＰａの圧力となるように荷重がかけられたときの第１突出部頂部２１Ｔの頂点を通るｘ−ｙ平面に平行な面と第２突出部頂部２２Ｔの頂点を通るｘ−ｙ平面に平行な面との間のｚ軸方向の距離である。
上記厚みＴｐ２は、第２シート１２に５ｋＰａの圧力となるように荷重がかけられたときの第３突出部頂部２３Ｔの頂点を通るｘ−ｙ平面に平行な面と第４突出部頂部２４Ｔの頂点を通るｘ−ｙ平面に平行な面との間のｚ軸方向の距離である。 The thickness T1 includes a plane parallel to the xy plane passing through the apex of the first protrusion top 21T and the top of the second protrusion when the first sheet 11 is loaded to a pressure of 0.05 kPa. The distance in the z-axis direction between a plane parallel to the xy plane passing through the vertex of 22T.
The thickness T2 includes a plane parallel to the xy plane passing through the top of the third protrusion top 23T and the top of the fourth protrusion when the load is applied to the second sheet 12 to a pressure of 0.05 kPa. This is the distance in the z-axis direction between the plane parallel to the xy plane passing through the apex of 24T.
The thickness Tp1 is such that the surface parallel to the xy plane passing through the apex of the first protrusion top 21T when the load is applied to the first sheet 11 so as to have a pressure of 5 kPa and the second protrusion top 22T. This is the distance in the z-axis direction between the plane passing through the apex and parallel to the xy plane.
The thickness Tp2 is such that the surface parallel to the xy plane passing through the top of the third protrusion top 23T and the fourth protrusion top 24T when the load is applied to the second sheet 12 to have a pressure of 5 kPa. This is the distance in the z-axis direction between the plane passing through the apex and parallel to the xy plane.

上記厚みＴ１、厚みＴ２が上記範囲を採ることにより、着用者に適度なクッション性を与え、排泄物を十分に処理できる内部空間を確保することができる。また、上記厚みＴｐ１、厚みＴｐ２が上記範囲を採ることにより、着用者に硬さを感じさせることなく、寝ているような高加圧下でも各突出部が潰れにくいため、形状保持性に優れ、高い通気性を有して蒸れの問題を解決することができる。   When the thickness T1 and the thickness T2 are within the above ranges, an appropriate space can be given to the wearer, and an internal space where the excrement can be sufficiently processed can be secured. In addition, the thickness Tp1 and the thickness Tp2 are within the above ranges, so that the protrusions are not easily crushed even under high pressure such as sleeping without causing the wearer to feel the hardness. It has high breathability and can solve the problem of stuffiness.

上記実施形態で説明した不織布１０は、以下のような効果を奏する。
上記不織布１０は、第１突出部２１と第３突出部２３とが突出方向を逆にした状態に対向する位置に配されたことから、第１突出部２１と第３突出部２３との間には、第１突出部２１の内部空間２１Ｋと第３突出部２３の内部空間２３Ｋが連続して配された内部空間２５が存する。その内部空間２５は、第１突出部２１のみで構成された内部空間２１Ｋよりも第３突出部２３で構成された内部空間２３Ｋ分だけ広くなっている。また、第１突出部２１の繊維密度は第３突出部２３の繊維密度と同等もしくは低くなっている。さらに、第１突出部２１の繊維密度は第２突出部２２の繊維密度よりも低くなっている。このため、第１面側Ｚ１から供給された液体は、第１突出部２１を通液しやすくなり、一旦内部空間２５（２１Ｋ，２３Ｋ）内に保持される。このとき、供給される液体が多量であっても、内部空間２１Ｋ、２３Ｋによって液体を保持することができる。そして第３突出部２３を通液して第２面側Ｚ２に流出し、第２面側Ｚ２に配されている吸収体（図示せず）に吸収させることができる。したがって、本発明の不織布１０は多量の液体を吸収、処理することが可能になる。この効果は、液体が尿であっても、軟便、経血等の高粘性液体であっても同様の効果を奏する。 The nonwoven fabric 10 demonstrated by the said embodiment has the following effects.
The nonwoven fabric 10 is disposed at a position where the first protruding portion 21 and the third protruding portion 23 are opposed to each other in a state in which the protruding direction is reversed, and therefore, between the first protruding portion 21 and the third protruding portion 23. The internal space 25 in which the internal space 21K of the first protrusion 21 and the internal space 23K of the third protrusion 23 are continuously arranged exists. The internal space 25 is wider than the internal space 21 </ b> K configured by only the first projecting portion 21 by the internal space 23 </ b> K configured by the third projecting portion 23. Further, the fiber density of the first protrusion 21 is equal to or lower than the fiber density of the third protrusion 23. Further, the fiber density of the first protrusion 21 is lower than the fiber density of the second protrusion 22. For this reason, the liquid supplied from the first surface side Z1 becomes easy to pass through the first projecting portion 21, and is temporarily held in the internal space 25 (21K, 23K). At this time, even if a large amount of liquid is supplied, the liquid can be held by the internal spaces 21K and 23K. Then, the third protrusion 23 is passed through and flows out to the second surface side Z2, and can be absorbed by an absorber (not shown) disposed on the second surface side Z2. Therefore, the nonwoven fabric 10 of the present invention can absorb and process a large amount of liquid. This effect is the same regardless of whether the liquid is urine or a highly viscous liquid such as loose stool or menstrual blood.

さらに、第１シート１１と第２シート１２との接合が、対向する方向に突出された第２突出部頂部２２Ｔと第４突出部頂部２４Ｔ同士の接合であることから隣接する第３突出部２３の内部空間２３Ｋ同士が連通している。このため、一つの第３突出部２３の内部空間２３Ｋが液体で満たされて一杯になった状態で不織布１０に外部から圧力がかかっても、液戻りすることなく、隣接する第３突出部２３の内部空間２３Ｋに液体が流れ込める。これによって、第３突出部２３の内部空間２３Ｋによる液体の保持量が十分に確保できる。   Further, since the joining of the first sheet 11 and the second sheet 12 is the joining of the second projecting portion top portion 22T and the fourth projecting portion top portion 24T that project in the opposing direction, the adjacent third projecting portions 23 are adjacent to each other. The internal spaces 23K communicate with each other. For this reason, even if pressure is applied to the nonwoven fabric 10 from the outside in a state where the internal space 23K of one third projecting portion 23 is filled with the liquid, the adjacent third projecting portion 23 does not return to the liquid. The liquid can flow into the inner space 23K. Accordingly, a sufficient amount of liquid retained by the internal space 23K of the third protrusion 23 can be secured.

また、不織布１０は、第１面側Ｚ１に第１突出部２１が配され、第２面側Ｚ２に第３突出部２３が配されている。すなわち、不織布１０の両面に外方に突出する突出部が配されている。このため、肌当接面側と吸収体側との両方に空間（第１面側Ｚ１からみた第２突出部２２の内部空間２２Ｋと第２面側Ｚ２からみた第４突出部２４の内部空間２４Ｋに相当）が存することから、通気性が向上する。   Moreover, as for the nonwoven fabric 10, the 1st protrusion part 21 is distribute | arranged to the 1st surface side Z1, and the 3rd protrusion part 23 is distribute | arranged to the 2nd surface side Z2. That is, protruding portions that protrude outward are disposed on both surfaces of the nonwoven fabric 10. For this reason, there are spaces on both the skin contact surface side and the absorber side (internal space 22K of the second protrusion 22 viewed from the first surface side Z1 and internal space 24K of the fourth protrusion 24 viewed from the second surface side Z2). Therefore, air permeability is improved.

上記不織布１０は、各突出部がその頂部と開口部を結ぶ方向に繊維が配向している。このため、不織布１０を吸収性物品の表面シートに用いた場合、着用者が寝ているときのような高い圧力がかかる場合であっても各突出部が潰れにくくなる。このように各突出部が高加圧下においても形状保持性に優れているため、高い通気性を有して蒸れの問題を解決することができる。   In the nonwoven fabric 10, the fibers are oriented in the direction in which each protrusion connects the top and the opening. For this reason, when the nonwoven fabric 10 is used for the surface sheet of an absorbent article, even if it is a case where high pressure is applied like when a wearer is sleeping, each protrusion part becomes difficult to be crushed. Thus, since each protrusion is excellent in shape retention even under high pressure, it has high air permeability and can solve the problem of stuffiness.

また、第１突出部２１が第２突出部２２より繊維密度が低いことから、第１面側Ｚ１から供給された液は、第２突出部２２より繊維密度が低い第１突出部２１からその内側の第１突出部２１と第３突出部２３との間の内部空間２１Ｋ，２３Ｋに通液されやすくなる。そして第３突出部２３が第４突出部２４より繊維密度が低いことから、第４突出部２４より通液されやすくなり、一旦第３突出部２３の内側に溜まった液は外方に通液されやすくなっていて、第２面側Ｚ２に配される吸収体（図示せず）側にスムースに導かれる。これにより、排泄物が肌に付き難くなり、着用者の赤み、かぶれ、褥瘡等の発生を防止することができるため、継続的着用が快適になる不織布１０からなる表面シートを提供することができる。
さらに、第１突出部２１が第３突出部２３より繊維密度が低い場合には、第１突出部２１を通液した液は第３突出部２３の内側の内部空間２１Ｋで一旦保持されるので、液拡散の制御が行いやすくなる。すなわち、液の拡散を制御することができる。 Further, since the first projecting portion 21 has a fiber density lower than that of the second projecting portion 22, the liquid supplied from the first surface side Z <b> 1 has its fiber density lower than that of the second projecting portion 22 from the first projecting portion 21. The liquid is easily passed through the internal spaces 21K and 23K between the inner first protrusion 21 and the third protrusion 23. And since the 3rd protrusion part 23 has a fiber density lower than the 4th protrusion part 24, it becomes easy to let the liquid flow from the 4th protrusion part 24, and the liquid once collected inside the 3rd protrusion part 23 flows outward. It is easy to be done and is smoothly guided to the absorber (not shown) side arranged on the second surface side Z2. Thereby, since it becomes difficult for excrement to adhere to skin and generation | occurrence | production of a wearer's redness, a rash, a pressure sore, etc. can be prevented, the surface sheet which consists of the nonwoven fabric 10 which can be worn continuously can be provided. .
Furthermore, when the fiber density of the first protrusion 21 is lower than that of the third protrusion 23, the liquid that has passed through the first protrusion 21 is temporarily held in the internal space 21K inside the third protrusion 23. It becomes easier to control the liquid diffusion. That is, the diffusion of the liquid can be controlled.

上記不織布１０は、上記効果に加えて、以下のような効果を奏する。
不織布１０は優れたクッション性を有する。
本実施形態の不織布１０は表裏何れか一方の面（片面）だけではなく、両面において突出した部分（突出部）を有するため、その構造に特有のクッション性を発現する。例えば筋状の突起や片面の突起ではどうしても線ないし面としての弾力性を発現することとなるが、不織布１０によれば三次元的な動きに対してもよく追従して両面において点で支持された立体的なクッション性を奏する。また、第１突出部２１の頂部２１Ｔから放射状に開口部２１Ｈの縁部を結ぶ方向、すなわち、壁部２１Ｗ，２２Ｗを構成する繊維は、第１突出部頂部２１に向かって収束する様に配向し、その起立する方向に向けて配向した繊維配向性を有するため、壁部２１Ｗ、２２Ｗは、繊維が厚み方向に潰れてしまうことのない適度のクッション性を有する。さらに、壁部２１Ｗ、２２Ｗの繊維配向性により、押圧力を受けて不織布１０が潰されても、その形状復元力が大きく、梱包状態や着用が継続されても初期のクッション力が維持されやすい。すなわち、着用者の着座圧や寝た状態で掛かる圧力でも不織布１０は、形状保持性に優れ、高荷重下でも肌接触面積が少なく保たれ、第１、第２突出部２１、２２および第３、第４突出部２３、２４は、潰れ難く、変形が起こっても回復し易い。 The nonwoven fabric 10 has the following effects in addition to the effects described above.
The nonwoven fabric 10 has excellent cushioning properties.
Since the nonwoven fabric 10 of this embodiment has the part (projection part) which protruded in not only one side (one side) of the front and back but both surfaces, the cushioning characteristic peculiar to the structure is expressed. For example, streak-like projections or single-sided projections will inevitably exhibit elasticity as lines or surfaces, but the nonwoven fabric 10 is well supported by points on both sides following a three-dimensional movement well. Has a three-dimensional cushioning. Further, the direction of connecting the edges of the opening 21H radially from the top 21T of the first protrusion 21, that is, the fibers constituting the walls 21W and 22W are oriented so as to converge toward the first protrusion 21. And since it has the fiber orientation orientated toward the standing direction, wall part 21W, 22W has moderate cushioning property with which a fiber is not crushed in the thickness direction. Furthermore, due to the fiber orientation of the walls 21W and 22W, even if the nonwoven fabric 10 is crushed by receiving a pressing force, the shape restoring force is large, and the initial cushioning force is easily maintained even if the packing state and wearing are continued. . That is, the nonwoven fabric 10 is excellent in shape retention even under the seating pressure of the wearer or the pressure applied while lying down, and the skin contact area is kept small even under a high load, and the first, second protrusions 21, 22 and third The fourth protrusions 23 and 24 are not easily crushed and can be easily recovered even if deformation occurs.

上記不織布１０は肌触りに優れる。
本実施形態の不織布１０は、一方の面（第１面側Ｚ１）に第１突出部２１を突出した状態で有し、他方の面（第２面側Ｚ２）に第３突出部２３を突出した状態で有し、それらの頂部２１Ｔ、２３Ｔは丸みを帯びている。そのため、そのどちらの面を肌面側にしても、不織布１０が肌に対して点で柔らかく接触する良好な肌触りが実現される。また、装着時の圧力に対しても接触する面積が増減することで肌触りを良好としながら、圧力に対する不織布１０全体の形状変形を抑えることができ、また、圧力変形からの形状復元も容易にできる。上記の良好なクッション性に起因する作用もあり、点接触による動的な作用と相俟って、独特の良好な肌触り感が得られる。また、排泄等を受けたときにも、上述した点接触が効果を奏し、サラッとした肌触りが実現される。このサラッとした肌触り（吸収性の効果）について補足すると、壁部２１Ｗ，２２Ｗの起立する方向に向け配向した繊維配向性を有することから、その配向した繊維によって、液がスムースに繊維を伝い流れることによって、内部空間２１Ｋ，２３Ｋ、そして不織布１０の下面に配された吸収体に移行し、且つ、壁部２１Ｗ，２２Ｗの繊維配向性により液戻りが少なく、サラッとした肌触りが実現される。また、上述した構造の維持による不織布１０自体の通気性に優れ、点接触の効果により、カブレの防止にも役立つ。 The said nonwoven fabric 10 is excellent in the touch.
The nonwoven fabric 10 of this embodiment has the 1st protrusion part 21 in the state which protruded in one surface (1st surface side Z1), and protrudes the 3rd protrusion part 23 in the other surface (2nd surface side Z2). The tops 21T and 23T are rounded. Therefore, even if it makes which surface the skin side, the good touch which the nonwoven fabric 10 contacts softly with respect to skin is implement | achieved. In addition, the shape deformation of the entire nonwoven fabric 10 with respect to pressure can be suppressed and the shape restoration from pressure deformation can be easily performed while improving the touch area by increasing / decreasing the contact area with respect to the pressure at the time of wearing. . There also exists an effect | action resulting from said favorable cushioning properties, and a unique good feeling of touch is obtained combined with the dynamic effect | action by a point contact. Moreover, the point contact mentioned above has an effect also when excretion etc. are received, and the smooth touch is implement | achieved. Complementing this smooth touch (absorbing effect), since the fibers have a fiber orientation oriented in the direction in which the walls 21W and 22W stand up, the liquid flows smoothly through the fibers by the oriented fibers. Thus, the inner space 21K, 23K and the absorbent body disposed on the lower surface of the nonwoven fabric 10 are transferred, and the liquid orientation of the wall portions 21W, 22W is small, so that a smooth touch is realized. Further, the nonwoven fabric 10 itself is excellent in air permeability by maintaining the structure described above, and is also useful for preventing fog due to the point contact effect.

次に、上述の不織布１０の製造方法の好ましい一実施形態について、図４を参照しながら、以下に説明する。
上述の不織布１０の製造方法は、以下の製造方法を適宜採用すればよい。
まず、第１シート１１と第２シート１２を別々に製造する。なお、第１シート１１と第２シート１２の製造方法は同一であってもよく、または、いずれか一方のシートの突出部の高さを変えて製造してもよい。
この実施形態では、第１シート１１と第２シート１２とを同一の製造方法で製造する場合を説明する。したがって、代表して第１シート１１の製造方法を説明する。 Next, a preferred embodiment of the method for producing the nonwoven fabric 10 will be described below with reference to FIG.
The following manufacturing method should just be employ | adopted for the manufacturing method of the above-mentioned nonwoven fabric 10 suitably.
First, the 1st sheet | seat 11 and the 2nd sheet | seat 12 are manufactured separately. In addition, the manufacturing method of the 1st sheet | seat 11 and the 2nd sheet | seat 12 may be the same, or you may manufacture by changing the height of the protrusion part of any one sheet | seat.
This embodiment demonstrates the case where the 1st sheet | seat 11 and the 2nd sheet | seat 12 are manufactured with the same manufacturing method. Therefore, the manufacturing method of the 1st sheet | seat 11 is demonstrated as a representative.

ウエブ賦形の支持体の一例として、図４（１）に示した構成の支持体１１０を用いる。この支持体１１０は、第２突出部２２が賦形される位置に対応して多数の突起１１１を有し、第１突出部２１が賦形される位置に対応して孔１１２が配されている。すなわち、支持体１１０は凹凸形状を有しており、突起１１１と孔１１２とが異なる方向に交互に配されていて、例えば、Ｘ方向とＹ方向のそれぞれに突起１１１と孔１１２とが交互に配されている。
上記支持体１１０上にウエブ（繊維ウエブともいう）５０を配して、ウエブ５０に向けて第１の熱風Ｗ１を吹き付けた場合、図４（２）に示すように、支持体１１０の孔１１２に対応して第１突出部２１が賦形され、突起１１１の位置に対応して第２突出部２２が賦形される。したがって、平面視した側の第１面側Ｚ１に突出し内部空間２１Ｋを有する第１突出部２１と、第１面側Ｚ１とは反対側の第２面側Ｚ２に突出し内部空間２２Ｋを有する第２突出部２２とは、平面視交差する異なるＸ方向とＹ方向のそれぞれに交互に連続して配されて、第１シート１１が賦形される。この場合、突起１１１に対応して賦形された第２突出部２２より孔１１２に対応して賦形された第１突出部２１の繊維密度が低くなる。
なお、図面矢印は第１の熱風Ｗ１の流れを模式的に示している。 As an example of a web-shaped support, a support 110 having the configuration shown in FIG. 4A is used. The support 110 has a number of protrusions 111 corresponding to the positions where the second protrusions 22 are shaped, and the holes 112 are arranged corresponding to the positions where the first protrusions 21 are shaped. Yes. That is, the support 110 has an uneven shape, and the protrusions 111 and the holes 112 are alternately arranged in different directions. For example, the protrusions 111 and the holes 112 are alternately arranged in the X direction and the Y direction, respectively. It is arranged.
When a web (also referred to as a fiber web) 50 is arranged on the support 110 and the first hot air W1 is blown toward the web 50, as shown in FIG. The first protrusion 21 is shaped correspondingly, and the second protrusion 22 is shaped corresponding to the position of the protrusion 111. Accordingly, the first projecting portion 21 projecting to the first surface side Z1 on the side in plan view and having the inner space 21K, and the second projecting portion projecting to the second surface side Z2 opposite to the first surface side Z1 and having the inner space 22K. The protrusions 22 are alternately and continuously arranged in different X and Y directions intersecting in plan view, and the first sheet 11 is shaped. In this case, the fiber density of the first protrusion 21 shaped corresponding to the hole 112 is lower than the second protrusion 22 shaped corresponding to the protrusion 111.
The arrows in the drawing schematically show the flow of the first hot air W1.

この製造方法の具体的一例を挙げると、下記のような態様が挙げられる。
融着する前のウエブ５０を、所定の厚みとなるようカード機（図示せず）からウエブを賦形する装置に供給する。賦形装置では、まず上記支持体１１０上に上記ウエブ５０を搬送して定着させる。次いで、その支持体１１０上のウエブ５０に第１の熱風Ｗ１を吹きつける（図４（１）の状態。）。そしてウエブ５０を支持体１１０の形状に沿うように賦形する（図４（２）の状態。）。このときの第１の熱風Ｗ１の温度は、この種の製品に用いられる一般的な繊維材料を考慮すると、ウエブ５０を構成する熱可塑性繊維の融点に対して０℃〜７０℃低いことが好ましく、５℃〜５０℃低いことがより好ましい。第１の熱風Ｗ１の風速は、支持体１１０の突起１１１の高さにもよるが、賦形性と風合いの観点から、２０〜１５０ｍ／ｓに設定され、好ましくは３０〜１００ｍ／ｓである。風速がこの下限値より遅くなると、十分に賦形されなくなり、クッション性と排泄物のストック性と通気性の効果が十分に発揮されない。風速がこの上限値を超えると、第２突出部２２の頂部２２Ｔに開孔が生じることになり、潰れやすくなり、クッション性と排泄物のストック性と通気性の効果が十分に発揮されない。さらに、排泄物がその開孔部を通って逆戻りしやすくなる。
このようにして、第１シート１１を凹凸形状に賦形する。 Specific examples of this production method include the following embodiments.
The web 50 before being fused is supplied from a card machine (not shown) to a device for shaping the web so as to have a predetermined thickness. In the shaping apparatus, first, the web 50 is conveyed and fixed on the support 110. Next, the first hot air W1 is blown onto the web 50 on the support 110 (the state shown in FIG. 4 (1)). Then, the web 50 is shaped so as to follow the shape of the support 110 (the state shown in FIG. 4 (2)). The temperature of the first hot air W1 at this time is preferably 0 ° C. to 70 ° C. lower than the melting point of the thermoplastic fibers constituting the web 50 in consideration of a general fiber material used for this type of product. More preferably, the temperature is 5 to 50 ° C lower. Although the wind speed of the 1st hot air W1 is based also on the height of the processus | protrusion 111 of the support body 110, it sets to 20-150 m / s from a viewpoint of a shaping property and a texture, Preferably it is 30-100 m / s. . When the wind speed is slower than this lower limit, the film is not sufficiently shaped, and the effects of cushioning properties, excrement stock properties and breathability are not fully exhibited. If the wind speed exceeds this upper limit value, an opening will occur in the top portion 22T of the second protrusion 22 and it will be easily crushed, and the effects of cushioning, excrement stocking and breathability will not be fully exhibited. Furthermore, it becomes easy for excrement to go back through the opening.
In this way, the first sheet 11 is shaped into an uneven shape.

なお、支持体１１０の突起１１１の高さは、賦形されるシート全体の厚みやシートの層厚みによって適宜決定される。例えば、１ｍｍ〜１０ｍｍに設定され、好ましくは１．５ｍｍ〜９ｍｍに設定され、より好ましくは２ｍｍ〜８ｍｍに設定される。   In addition, the height of the protrusion 111 of the support 110 is appropriately determined depending on the thickness of the entire sheet to be shaped and the layer thickness of the sheet. For example, it is set to 1 mm to 10 mm, preferably set to 1.5 mm to 9 mm, and more preferably set to 2 mm to 8 mm.

次に、図４（３）に示すように、ウエブ５０の各繊維が適度に融着可能な温度の第２の熱風Ｗ２を吹きつけて、繊維同士を融着させる。このときの第２の熱風Ｗ２の温度は、この種の製品に用いられる一般的な繊維材料を考慮すると、ウエブ５０を構成する熱可塑性繊維の融点に対して０℃〜７０℃高いことが好ましく、５℃〜５０℃高いことがより好ましい。第２の熱風Ｗ２の風速は、１〜１０ｍ／ｓに設定され、好ましくは３〜８ｍ／ｓに設定される。この第２の熱風Ｗ２の風速は、遅すぎると繊維への熱伝達ができず、繊維同士が融着せず凹凸形状の固定が不十分になる。一方、風速が速すぎると、繊維へ熱が当たりすぎるため、風合いが悪くなる傾向となる。   Next, as shown in FIG. 4C, the second hot air W2 having a temperature at which each fiber of the web 50 can be appropriately fused is blown to fuse the fibers. The temperature of the second hot air W2 at this time is preferably 0 ° C. to 70 ° C. higher than the melting point of the thermoplastic fiber constituting the web 50 in consideration of a general fiber material used for this type of product. More preferably, the temperature is 5 to 50 ° C higher. The wind speed of the 2nd hot air W2 is set to 1-10 m / s, Preferably it is set to 3-8 m / s. If the wind speed of the second hot air W2 is too slow, heat cannot be transferred to the fibers, the fibers are not fused together, and the uneven shape is insufficiently fixed. On the other hand, if the wind speed is too high, the fiber will be too hot and the texture will tend to be poor.

熱可塑性繊維としては、前述した繊維が用いられる。例えば熱可塑性繊維として低融点成分および高融点成分を含む複合繊維を用いる場合、ウエブ５０に吹き付ける第２の熱風Ｗ２の温度は、低融点成分の融点以上で、かつ高融点成分の融点未満であることが好ましい。より好ましくは、低融点成分の融点以上高融点成分の融点より１０℃低い温度であり、さらに好ましくは、低融点成分の融点より５℃以上高く高融点成分の融点より２０℃以上低い温度である。   As the thermoplastic fiber, the fiber described above is used. For example, when a composite fiber containing a low melting point component and a high melting point component is used as the thermoplastic fiber, the temperature of the second hot air W2 sprayed on the web 50 is equal to or higher than the melting point of the low melting point component and lower than the melting point of the high melting point component. It is preferable. More preferably, the temperature is at least 10 ° C lower than the melting point of the high melting point component, more preferably at least 5 ° C higher than the melting point of the low melting point component, and more preferably at least 20 ° C lower than the melting point of the high melting point component. .

またウエブ５０は、熱可塑性繊維を、３０質量％〜１００質量％含んでいることが好ましく、より好ましくは４０質量％〜１００質量％である。ウエブ５０は、本来的に熱融着性を有さない繊維（例えばコットンやパルプ等の天然繊維、レーヨンやアセテート繊維など）を含んでいてもよい。   Moreover, it is preferable that the web 50 contains 30 mass%-100 mass% of thermoplastic fibers, More preferably, it is 40 mass%-100 mass%. The web 50 may include fibers that are not inherently heat-fusible (for example, natural fibers such as cotton and pulp, rayon and acetate fibers).

以上説明したようにして、第１シート１１が作製される。
上記製造方法は、連続生産を考慮すると、製造装置（図示せず）は、上記支持体１１０を搬送可能なコンベア式またはドラム式のものとし、搬送されてくる凹凸形状を固定された第１シート１１を、ロール（図示せず）で巻き取っていく態様が挙げられる。 As described above, the first sheet 11 is produced.
In the manufacturing method, in consideration of continuous production, the manufacturing apparatus (not shown) is a conveyor type or drum type capable of transporting the support 110, and the first sheet having the conveyed uneven shape fixed thereto. The aspect which winds 11 with a roll (not shown) is mentioned.

また、第２シート１２も第１シート１１と同様の製造方法によって作製される。第２シート１２の場合、第３突出部２３が第１シート１１の第１突出部２１に対応し、第４突出部２４が第１シート１１の第２突出部２２に対応する。
したがって、支持体１１０の孔１１２に対応して第３突出部２３が賦形され、突起１１１の位置に対応して第４突出部２４が賦形される。このように賦形されることによって、平面視した側の第１面側Ｚ１に突出し内部空間２３Ｋを有する第３突出部２３と、第２面側Ｚ２に突出し内部空間２４Ｋを有する第２突出部２４とが、平面視交差する異なるＸ方向とＹ方向のそれぞれに交互に連続して配される。この場合、突起１１１に対応して賦形された第４突出部２４より孔１１２に対応して賦形された第３突出部２３の繊維密度が低くなる。
次に、第１シート１１の製造方法と同様にして、第２の熱風Ｗ２を吹き付けて繊維同士を融着させて賦形形状を固定して、第２シート１２が作製される。 The second sheet 12 is also produced by the same manufacturing method as the first sheet 11. In the case of the second sheet 12, the third protrusion 23 corresponds to the first protrusion 21 of the first sheet 11, and the fourth protrusion 24 corresponds to the second protrusion 22 of the first sheet 11.
Therefore, the third protrusion 23 is shaped corresponding to the hole 112 of the support 110, and the fourth protrusion 24 is shaped corresponding to the position of the protrusion 111. By being shaped in this way, the third projecting portion 23 projecting to the first surface side Z1 on the plan view side and having the inner space 23K, and the second projecting portion projecting to the second surface side Z2 and having the inner space 24K. 24 are alternately and continuously arranged in each of the different X and Y directions intersecting in plan view. In this case, the fiber density of the third protrusion 23 shaped corresponding to the hole 112 is lower than the fourth protrusion 24 shaped corresponding to the protrusion 111.
Next, in the same manner as the manufacturing method of the first sheet 11, the second hot air W <b> 2 is blown to fuse the fibers together to fix the shaped shape, thereby producing the second sheet 12.

上記製造方法においては、各シートの厚みは、第１の熱風Ｗ１の風速によって、適宜決定される。例えば、風速を速くするとシートの厚みが厚くなり、遅くするとシートの厚みが薄くなる。また、風速を速くすると第１突出部と第２突出部の繊維密度差が大きくなり、風速を遅くすると第１突出部と第２突出部の繊維密度差が小さくなる。   In the said manufacturing method, the thickness of each sheet | seat is suitably determined by the wind speed of the 1st hot air W1. For example, when the wind speed is increased, the thickness of the sheet is increased, and when it is decreased, the thickness of the sheet is decreased. Further, when the wind speed is increased, the fiber density difference between the first protrusion and the second protrusion is increased, and when the wind speed is decreased, the fiber density difference between the first protrusion and the second protrusion is decreased.

次に、上記第１シート１１の第１突出部２１と上記第２シート１２の第３突出部２３とが反対方向に突出するようにそれぞれのシートを配し、上記第１シート１１の第２突出部２２と上記第２シート１２の第４突出部２４を対向させて接合する。この接合には、例えば、ホットメルト接着剤を用いて接合する。または熱融着によって接合してもよく、または圧着もしくは熱圧着によって接合してもよい。この接合では、第２突出部頂部２２Ｔの頂点と第４突出部頂部２４Ｔの頂点とが接合していることがより好ましいが、必ずしも頂点同士が接合していなくともよい。少なくとも、頂部同士が接合していればよい。したがって、第１シート１１と第２シート１２とを接合する際の両シートの位置合わせは、少なくとも頂部同士が接合するように行われ、より好ましくは頂点同士が接合するように行われる。
接合方法の具体的な一例としては、第１シート１１の第２面側Ｚ２を上面にした状態で、ホットメルトコーター（図示せず）を用いて、第２突出部２２側にホットメルト接着剤（図示せず）を塗工する。次いで、第２シート１２の第４突出部２４が第１シート１１の第２突出部２２と接合するように、第１シート１１に第２シート１２を貼り合わせる。 Next, the respective sheets are arranged so that the first projecting portion 21 of the first sheet 11 and the third projecting portion 23 of the second sheet 12 project in opposite directions. The protrusion 22 and the fourth protrusion 24 of the second sheet 12 are opposed to each other and joined. For this joining, for example, a hot melt adhesive is used. Alternatively, they may be joined by heat fusion, or may be joined by pressure bonding or thermocompression bonding. In this joining, it is more preferable that the apex of the second projecting portion top portion 22T and the apex of the fourth projecting portion top portion 24T are joined, but the apexes are not necessarily joined. It suffices that at least the tops are joined. Therefore, when the first sheet 11 and the second sheet 12 are joined, the sheets are aligned so that at least the tops are joined, and more preferably, the apexes are joined.
As a specific example of the bonding method, a hot melt adhesive is used on the second protrusion 22 side using a hot melt coater (not shown) with the second surface side Z2 of the first sheet 11 being the upper surface. Apply (not shown). Next, the second sheet 12 is bonded to the first sheet 11 such that the fourth protrusion 24 of the second sheet 12 is joined to the second protrusion 22 of the first sheet 11.

上記製造方法により、第１シート１１の第２突出部２２と第２シート１２の第４突出部２４とを接合させた不織布１０を作製することができる。したがって、着用者が寝ているような高加圧下でも各突出部が潰れにくく、形状保持性に優れ、高い通気性を有して蒸れの問題を解決する不織布１０を製造することができる。また凹凸形状を有する支持体１１０上に搬送したウエブ５０に第１の熱風を吹き付けることによってウエブ５０を賦形することから、壁部２１Ｗが第１突出部２１の頂部２１Ｔと開口部２１Ｈとを結ぶ方向に繊維配向性を有する不織布１０を製造できる。この不織布１０は、排泄物が素早くシート間の内部空間２１Ｋ，２３Ｋに導かれることによって、着用者に対する赤み、かぶれ、褥瘡等の発生を防止することができ、継続的に快適な着用が可能となる。   By the above manufacturing method, the nonwoven fabric 10 in which the second protrusion 22 of the first sheet 11 and the fourth protrusion 24 of the second sheet 12 are joined can be produced. Therefore, even when the wearer is sleeping, the protrusions are not easily crushed, and the nonwoven fabric 10 having excellent shape retention and high breathability can be produced. Further, since the web 50 is shaped by blowing the first hot air onto the web 50 conveyed on the support body 110 having an uneven shape, the wall 21W forms the top 21T and the opening 21H of the first protrusion 21. The nonwoven fabric 10 which has fiber orientation in the direction to tie can be manufactured. This non-woven fabric 10 can prevent the occurrence of redness, rash, pressure ulcer, etc. to the wearer by allowing the excrement to be quickly guided to the internal spaces 21K, 23K between the sheets, and can be worn comfortably continuously. Become.

本発明の不織布１０は、各種用途に用いることができる。例えば、使い捨ておむつ、生理用ナプキン、パンティーライナー、尿取りパッド等の吸収性物品の表面シートとして好適に使用することができる。さらに不織布１０の両面が凹凸構造であることに起因する通気性や液拡散性、押圧力時の変形特性、などに優れていることから、おむつや生理用品等の表面シートと吸収体との間に介在させるサブレイヤーとして用いることもできる。その他、吸収性物品のギャザー、外装シート、ウイングとして利用する形態も挙げられる。さらに、おしり拭きシート、清掃シート、フィルターとして利用する形態も挙げられる。   The nonwoven fabric 10 of the present invention can be used for various applications. For example, it can be suitably used as a surface sheet of absorbent articles such as disposable diapers, sanitary napkins, panty liners, urine absorption pads and the like. Furthermore, since the both surfaces of the nonwoven fabric 10 are excellent in air permeability, liquid diffusibility, deformation characteristics at the time of pressing force, etc. due to the concavo-convex structure, between the surface sheet such as diapers and sanitary products and the absorbent body It can also be used as a sub-layer interposed between. In addition, the form utilized as a gather of an absorbent article, an exterior sheet, and a wing is also mentioned. Furthermore, the form utilized as a wiping wipe sheet | seat, a cleaning sheet | seat, and a filter is also mentioned.

以下、実施例に基づき本発明を更に詳細に説明するが、本発明はこれらの実施例により限定して解釈されるものではない。   EXAMPLES Hereinafter, although this invention is demonstrated further in detail based on an Example, this invention is limited and interpreted by these Examples.

［実施例１−４］
実施例１は、芯がポリエチレンテレフタレートで鞘がポリエチレンからなる２．４ｄｔｅｘ×５１ｍｍの芯鞘型複合繊維を坪量３０ｇ／ｍ２となるようカード機からウエブ５０として賦形装置に供給した。賦形装置では、多数の突起を有し通気性を有する支持体１１０の上に上記ウエブ５０を定着させた。この支持体１１０の突起１１１の平面視におけるＭＤピッチを８ｍｍ、ＣＤピッチを５ｍｍとし、突起１１１の高さを７．５ｍｍとした。また支持体１１０における孔１１２の孔径を２．８ｍｍとした。
次いで、その支持体１１０上のウエブ５０に第１の熱風Ｗ１（温度１３０℃、風速５０ｍ／ｓ）を吹きつけて、支持体１１０上の突起１１１にそってウエブ５０を賦形する。次に、温度１４５℃、風速５ｍ／ｓの第２の熱風Ｗ２に切り替えて各芯鞘構造の繊維同士を融着させて賦形形状を固定した。このようにして第１シート１１を作製した。また、上記第１シート１１と同様の製造方法によって第２シート１２を作製した。さらに上記第１シート１１の第１突出部２１と上記第２シート１２の第３突出部２３とが反対方向に突出するようにそれぞれのシートを配し、上記第１シート１１の第２突出部２２と上記第２シート１２の第４突出部２４を対向させてホットメルト接着剤を用いて接合して、実施例１の不織布試験体とした。実施例１の不織布試験体の第１シート１１および第２シート１２の０．０５ｋＰａ圧力時の厚みＴ１，Ｔ２はともに３．６ｍｍ、５ｋＰａ圧力時の厚みＴｐ１，Ｔｐ２はともに１．６ｍｍであった。
実施例２は、第１シート１１および第２シート１２の融着条件としての第２の熱風Ｗ２を（温度１３６℃、風速４ｍ／ｓ）とした以外、上記実施例１と同様な条件で作製した。実施例２の不織布試験体の第１シート１１及び第２シート１２の０．０５ｋＰａ圧力時の厚みＴ１、Ｔ２は３．６ｍｍ、５ｋＰａ圧力時の厚みＴｐ１、Ｔｐ２は０．６ｍｍであった。
実施例３は、第１シート１１および第２シート１２の融着条件としての第２の熱風Ｗ２を（温度１６０℃、風速５ｍ／ｓ）とした以外、上記実施例１と同様な条件で作製した。実施例３の不織布試験体の第１シート１１及び２シート１２の０．０５ｋＰａ圧力時の厚みＴ１、Ｔ２は３．６ｍｍ、５ｋＰａ圧力時の厚みＴｐ１、Ｔｐ２は１．９ｍｍであった。
実施例４は、第２シート１２の賦形条件としての第１の熱風Ｗ１を（温度１３０℃、風速４５ｍ／ｓ）とした以外、上記実施例１と同様な条件で作製した。実施例４の不織布試験体の第２シート１２の０．０５ｋＰａ圧力時の厚みＴ１は３．６ｍｍ、厚みＴ２は３．５ｍｍであり、５ｋＰａ圧力時の厚みＴｐ１は１．６ｍｍであり、厚みＴｐ２は１．４ｍｍであった。 [Example 1-4]
In Example 1, a 2.4 dtex × 51 mm core-sheath composite fiber having a core of polyethylene terephthalate and a sheath of polyethylene was supplied as a web 50 from the card machine to the shaping apparatus so as to have a basis weight of 30 g / m 2 . In the shaping apparatus, the web 50 was fixed on the support 110 having a large number of protrusions and air permeability. The MD pitch in the plan view of the protrusion 111 of the support 110 was 8 mm, the CD pitch was 5 mm, and the height of the protrusion 111 was 7.5 mm. Moreover, the hole diameter of the hole 112 in the support body 110 was 2.8 mm.
Next, the first hot air W <b> 1 (temperature 130 ° C., wind speed 50 m / s) is blown onto the web 50 on the support 110, and the web 50 is shaped along the protrusions 111 on the support 110. Next, it switched to the 2nd hot air W2 of temperature 145 degreeC and the wind speed of 5 m / s, the fibers of each core-sheath structure were fused together, and the shaping shape was fixed. In this way, the first sheet 11 was produced. Further, the second sheet 12 was produced by the same production method as the first sheet 11. Further, the respective sheets are arranged so that the first protruding portion 21 of the first sheet 11 and the third protruding portion 23 of the second sheet 12 protrude in opposite directions, and the second protruding portion of the first sheet 11 is arranged. 22 and the 4th protrusion part 24 of the said 2nd sheet 12 were made to oppose, and it joined using the hot-melt-adhesive, and was set as the nonwoven fabric test body of Example 1. FIG. The thicknesses T1 and T2 at the time of 0.05 kPa pressure of the first sheet 11 and the second sheet 12 of the nonwoven fabric test body of Example 1 were both 3.6 mm, and the thicknesses Tp1 and Tp2 at the time of 5 kPa pressure were both 1.6 mm. .
Example 2 was produced under the same conditions as in Example 1 except that the second hot air W2 as the fusion condition of the first sheet 11 and the second sheet 12 was (temperature 136 ° C., wind speed 4 m / s). did. The thicknesses T1 and T2 of the first sheet 11 and the second sheet 12 of the nonwoven fabric test body of Example 2 at a pressure of 0.05 kPa were 3.6 mm, and the thicknesses Tp1 and Tp2 at a pressure of 5 kPa were 0.6 mm.
Example 3 was produced under the same conditions as in Example 1 above, except that the second hot air W2 as the fusing condition of the first sheet 11 and the second sheet 12 was (temperature 160 ° C., wind speed 5 m / s). did. The thicknesses T1 and T2 of the first sheet 11 and the second sheet 12 of the nonwoven fabric test body of Example 3 at a pressure of 0.05 kPa were 3.6 mm, and the thicknesses Tp1 and Tp2 at a pressure of 5 kPa were 1.9 mm.
Example 4 was produced under the same conditions as in Example 1 except that the first hot air W1 as the shaping condition of the second sheet 12 was (temperature 130 ° C., wind speed 45 m / s). The thickness T1 of the second sheet 12 of the nonwoven fabric test body of Example 4 at a pressure of 0.05 kPa is 3.6 mm, the thickness T2 is 3.5 mm, the thickness Tp1 at a pressure of 5 kPa is 1.6 mm, and the thickness Tp2 Was 1.4 mm.

［比較例１−３］
比較例１は、凹凸の無いフラットな不織布であり、０．０５ｋＰａ圧力時の厚みＴ１は０．９ｍｍ、５ｋＰａ圧力時の厚みＴｐ１は０．１ｍｍであった。
比較例２は、特開２００４−１７４２３４号公報（特許文献１）に記載された製造方法により製造したもので、０．０５ｋＰａ圧力時の上層の厚みＴ１は１．４ｍｍ、５ｋＰａ圧力時の上層の厚みＴｐ１は０．３ｍｍであった。
比較例３は、２枚の比較例２の不織布の凸部を対向させてホットメルト接着剤を用いて接合したものを不織布試験体とした。比較例３の不織布試験体の第１シート及び第２シートの０．０５ｋＰａ圧力時の厚みＴ１、Ｔ２は１．４ｍｍ、５ｋＰａ圧力時の厚みＴｐ１、Ｔｐ２は０．３ｍｍであった。 [Comparative Example 1-3]
Comparative Example 1 is a flat nonwoven fabric without unevenness, and the thickness T1 at a pressure of 0.05 kPa was 0.9 mm, and the thickness Tp1 at a pressure of 5 kPa was 0.1 mm.
Comparative Example 2 was manufactured by the manufacturing method described in Japanese Patent Application Laid-Open No. 2004-174234 (Patent Document 1), and the upper layer thickness T1 at a pressure of 0.05 kPa was 1.4 mm, and the upper layer at a pressure of 5 kPa. Thickness Tp1 was 0.3 mm.
The comparative example 3 made the nonwoven fabric test body what faced the convex part of the nonwoven fabric of the comparative example 2 of 2 sheets, and joined using the hot-melt-adhesive. The thicknesses T1 and T2 of the first and second sheets of the nonwoven fabric test body of Comparative Example 3 at a pressure of 0.05 kPa were 1.4 mm, and the thicknesses Tp1 and Tp2 at a pressure of 5 kPa were 0.3 mm.

次に、測定方法および評価方法について説明する。上述の各不織布試験体を用い、下記の測定試験を行った。   Next, a measurement method and an evaluation method will be described. The following measurement tests were performed using the above-mentioned nonwoven fabric test specimens.

＜繊維配向性（配向角、配向強度）の測定＞
日本電子（株）社製の走査電子顕微鏡ＪＣＭ−５１００（商品名）を使用し、図１におけるｚ軸方向が上下となるようにサンプルを静置し、サンプルの測定する面に対して垂直の方向から撮影した画像（測定する繊維が１０本以上計測できる倍率に調整；１００ないし３００倍）を印刷し、透明ＰＥＴ製シート上に繊維をなぞった。前記の画像をパソコン内に取り込み、株式会社ネクサス社製のｎｅｘｕｓＮｅｗＱｕｂｅ［商品名］（スタンドアロン版）画像処理ソフトウエアを使用し、前記画像を二値化した。次いで、前記二値化した画像を、繊維配向解析プログラムである、Ｆｉｂｅｒ Ｏｒｉｅｎｔａｔｉｏｎ Ａｎａｌｙｓｉｓ ８．１３ Ｓｉｎｇｌｅソフト（商品名）を用い、フーリエ変換し、パワースペクトルを得、楕円近似した分布図から、配向角と配向強度を得た。
配向角は繊維が最も配向している角度を示し、配向強度はその配向角における強度を示している。壁部中間部分の測定においては、配向角が９０°に近い値ほど、頂部２１Ｔの中心方向に繊維が配向していることを示し、６０〜１２０°であれば、頂部２１Ｔの中心方向に繊維が配向していると判断する。
また、配向強度の値が大きいほど繊維の向きがそろっていることを表す。配向強度が１．０５以上の場合を配向しているとする。
測定は３ヶ所行い、平均してそのサンプルの配向角と配向強度とした。 <Measurement of fiber orientation (orientation angle, orientation strength)>
Using a scanning electron microscope JCM-5100 (trade name) manufactured by JEOL Ltd., the sample is allowed to stand so that the z-axis direction in FIG. An image taken from the direction (adjusted to a magnification capable of measuring 10 or more fibers to be measured; 100 to 300 times) was printed, and the fibers were traced on a transparent PET sheet. The said image was taken in in the personal computer and the said image was binarized using the NexusNewQube [tradename] (stand-alone version) image processing software. Next, the binarized image was subjected to Fourier transform using Fiber Orientation Analysis 8.13 Single software (trade name), which is a fiber orientation analysis program, to obtain a power spectrum, and from an elliptical distribution map, an orientation angle was obtained. And the orientation strength was obtained.
The orientation angle indicates the angle at which the fibers are most oriented, and the orientation strength indicates the strength at the orientation angle. In the measurement of the middle portion of the wall portion, the closer the orientation angle is to 90 °, the more the fiber is oriented in the central direction of the top portion 21T, and if 60 to 120 °, the fiber in the central direction of the top portion 21T. Are oriented.
Moreover, it represents that the direction of a fiber has gathered, so that the value of orientation strength is large. The case where the orientation strength is 1.05 or more is assumed to be oriented.
Measurement was performed at three locations, and the average was taken as the orientation angle and orientation strength of the sample.

上述の繊維配向性は、繊維の配向角と配向強度からなる概念である。
繊維の配向角は、色々な方向性を有する複数の繊維が全体としてどの方向に配向しているかを示す概念で、繊維の集合体の形状を数値化している。繊維の配向強度は、配向角を示す繊維の量を示す概念であり、配向強度は、１．０５未満では、ほとんど配向しておらず、１．０５以上で配向を有しているといえる。しかしながら、本実施形態においては、繊維配向がその部位によって変化している。すなわち、ある配向角の状態の部位から異なる配向角の部位へと変化する間（繊維がある方向に配向強度が強い状態から異なる配向に強い強度を示す部位へ変化する間）に、配向強度が弱い状態や再配向することで高い状態へ至る等の様々な状態を有する。そのため、ある強い配向角を示す部位と別の方向に強い配向角を示す部位との間においては、繊維の配向強度が弱くとも繊維の配向角が変わっていることが好ましく、配向強度が高いことがより好ましい。配向角、配向強度について本実施形態において一例を示すと、第１突出部２１の壁部２１Ｗの曲面構造に対して配向角は、５０°以上１３０°以下が好ましく、より好ましくは６０°以上１２０°以下であり、配向強度は１．０５以上が好ましく、より好ましくは１．１０以上である。第３突出部２３の壁部２３Ｗの曲面構造に対して配向角は、５０°以上１３０°以下が好ましく、より好ましくは６０°以上１２０°以下であり、配向強度は１．０５以上が好ましく、より好ましくは１．２０以上である。
各々の壁部２１Ｗ，２３Ｗの繊維の配向方向が各頂部の中心に向かう方向であることから、クッション性を発現する。また、不織布１０を吸収性物品の表面シートとして用いた場合、各々の壁部２１Ｗ，２３Ｗの繊維配向性により高加圧下においても不織布１０は十分な耐圧縮性を有し、不織布１０の第１ないし第４突出部２１ないし２４の潰れを防ぐ。これにより十分な捕捉空間を確保でき、肌接触面積を小さくする効果、高い通気性、多量の液、固形分、高粘性液体等を十分に捕捉し、漏れを抑制する効果を十分に発揮する。 The fiber orientation described above is a concept consisting of the orientation angle and orientation strength of the fiber.
The fiber orientation angle is a concept that indicates in which direction a plurality of fibers having various directions are oriented as a whole, and the shape of the fiber aggregate is quantified. The orientation strength of the fiber is a concept indicating the amount of fibers exhibiting an orientation angle. The orientation strength is less than 1.05 and is hardly oriented, and it can be said that the orientation strength is 1.05 or more. However, in this embodiment, the fiber orientation changes depending on the part. That is, the orientation strength is changed during the transition from a part having a certain orientation angle to a part having a different orientation angle (while the fiber is changing from a state in which the orientation strength is strong in one direction to a part having a strong strength in a different orientation). It has various states such as a weak state and a high state due to reorientation. Therefore, it is preferable that the orientation angle of the fiber is changed between the part showing a strong orientation angle and the part showing a strong orientation angle in another direction even if the orientation strength of the fiber is weak, and the orientation strength is high. Is more preferable. An example of the orientation angle and orientation strength is shown in the present embodiment. The orientation angle is preferably 50 ° or more and 130 ° or less, more preferably 60 ° or more and 120 with respect to the curved surface structure of the wall portion 21W of the first protrusion 21. The orientation strength is preferably 1.05 or more, and more preferably 1.10 or more. The orientation angle with respect to the curved surface structure of the wall 23W of the third protrusion 23 is preferably 50 ° or more and 130 ° or less, more preferably 60 ° or more and 120 ° or less, and the orientation strength is preferably 1.05 or more, More preferably, it is 1.20 or more.
Since the orientation direction of the fibers of each of the wall portions 21W and 23W is the direction toward the center of each top portion, the cushioning property is expressed. Moreover, when the nonwoven fabric 10 is used as a surface sheet of an absorbent article, the nonwoven fabric 10 has sufficient compression resistance even under high pressure due to the fiber orientation of the respective wall portions 21W and 23W. In addition, the fourth protrusions 21 to 24 are prevented from being crushed. As a result, a sufficient capture space can be ensured, and the effect of reducing the skin contact area, high air permeability, a large amount of liquid, solid content, highly viscous liquid, etc. can be sufficiently captured and the effect of suppressing leakage can be sufficiently exhibited.

＜繊維密度の測定＞
不織布部分の切断面を、走査電子顕微鏡を用いて拡大観察（繊維断面が３０〜６０本程度計測できる倍率（１５０〜５００倍）に調整（本実施例では１００倍とした）し、一定面積あたりの前記切断面によって切断されている繊維の断面積を数えた。また、観察の中心は、各突出部の頂部の厚みの中心付近とした。次に１ｍｍ２あたりの繊維の断面数に換算し、これを繊維密度（本／ｍｍ２）とした。測定は３ヶ所行い、平均してそのサンプルの繊維密度とした。上記走査電子顕微鏡には、日本電子（株）社製のＪＣＭ−５１００（商品名）を用いた。 <Measurement of fiber density>
The cut surface of the non-woven fabric portion is enlarged and observed using a scanning electron microscope (adjusted to a magnification (150 to 500 times) at which the fiber cross section can be measured about 30 to 60 times (100 times in this example)) In addition, the cross-sectional area of the fibers cut by the cut surface was counted, and the center of observation was the vicinity of the center of the thickness of the top of each protrusion, and then converted into the number of cross-sections of the fiber per 1 mm 2 . This was taken as the fiber density (lines / mm 2 ), measured at three locations, and averaged to be the fiber density of the sample.The scanning electron microscope includes JCM-5100 (manufactured by JEOL Ltd.). Product name).

＜０．０５ｋＰａ圧力時の厚みの測定＞
第１シート１１および第２シート１２のそれぞれについて、０．０５ｋＰａの圧力がかかるように荷重を加えた状態で、厚み測定器を用いて測定した。厚み測定器にはオムロン社製のレーザー変位計を用いた。厚み測定は、１０点測定し、それらの平均値を算出して厚みとした。
＜５ｋＰａ圧力時の厚みの測定＞
第１シート１１および第２シート１２のそれぞれについて、５ｋＰａの圧力がかかるように荷重を加えた状態で、厚み測定器を用いて測定した。厚み測定器にはオムロン社製のレーザー変位計を用いた。厚み測定は、１０点測定し、それらの平均値を算出して厚みとした。 <Measurement of thickness at 0.05 kPa pressure>
About each of the 1st sheet | seat 11 and the 2nd sheet | seat 12, it measured using the thickness measuring device in the state which added the load so that the pressure of 0.05 kPa might be applied. A laser displacement meter manufactured by OMRON Corporation was used as the thickness measuring instrument. The thickness was measured at 10 points, and the average value was calculated as the thickness.
<Measurement of thickness at 5 kPa pressure>
About each of the 1st sheet | seat 11 and the 2nd sheet | seat 12, it measured using the thickness measuring device in the state which applied the load so that the pressure of 5 kPa might be applied. A laser displacement meter manufactured by OMRON Corporation was used as the thickness measuring instrument. The thickness was measured at 10 points, and the average value was calculated as the thickness.

＜５ｋＰａ圧力時通気度の測定方法＞
通気度測定には、ＫＥＳ圧縮試験機（カトーテック（株）製ＫＥＳ ＦＢ−３）を用い、不織布試験体について、通常モードで５ｋＰａまでの圧縮特性評価を行い、５ｋＰａ圧力時の不織布厚みをチャートから読み取った。次に、図５に示すように、チャートから読み取った５ｋＰａ圧力時の不織布厚みになるように、不織布１０の試験体（以下、不織布試験体２００という）をガーレー透気度Ｂ型試験機２１０に装着した。
このガーレー透気度Ｂ型試験機２１０は、底部を有する外筒２１１とその内部に昇降自在に配した底部を有する内筒２１２を有し、内筒２１２の内部には内筒２１２の底部および外筒２１１の底部を貫通して外部に連通する通気筒２１３が配されている。この通気筒２１３の下端には、試験体を挟み込んで固定する締付板２１４，２１５が配されている。締付板２１４，２１５には、通気筒２１３に連通する直径が１０ｍｍ（面積７８．４ｍｍ２）の円形の孔２１６，２１７が配されている。また、外筒２１１の内部には油２１８が供されている。
上記ガーレー透気度Ｂ型試験機２１０による通気度の測定方法を説明する。
測定は、ＪＩＳ Ｐ８１１７試験方法により行った。まず、締付板２１４，２１５に試験体としての不織布試験体２００が所定の厚さになるように固定した後、内筒２１２を降下させた。このとき内筒２１２は、外筒２１１内の油２１８によって内筒２１２の自重によりゆっくり降下（図面、太い矢印方向に降下）し、内筒２１２内の空気Ａ（図面では細い矢印で示す）が通気筒２１３を通して締付板２１４，２１５に固定されている不織布試験体２００を透気した。内筒２１２の降下量は１気圧において１００ｃｃに相当する空気が不織布試験体２００を通気する量とした。そしてストップウォッチを用いて、１００ｃｃの空気が不織布試験体２００を通過するのに要する時間（秒）を測定し、１秒あたりの透気量を算出して通気度とした。測定は３回行い、その測定値の平均値を不織布試験体２００の５ｋＰａ圧力時の通気度とした。 <Measurement method of air permeability at 5 kPa pressure>
For the measurement of air permeability, KES compression tester (KES FB-3 manufactured by Kato Tech Co., Ltd.) was used, and the non-woven fabric specimen was evaluated for compression characteristics up to 5 kPa in normal mode, and the nonwoven fabric thickness at 5 kPa pressure was charted. Read from. Next, as shown in FIG. 5, a test body of the nonwoven fabric 10 (hereinafter referred to as a nonwoven fabric test body 200) is placed in a Gurley air permeability B-type testing machine 210 so that the nonwoven fabric thickness at the time of 5 kPa pressure read from the chart is obtained. Installed.
This Gurley air permeability B-type testing machine 210 has an outer cylinder 211 having a bottom part and an inner cylinder 212 having a bottom part that can be moved up and down inside the inner cylinder 212. Inside the inner cylinder 212, the bottom part of the inner cylinder 212 and A through-cylinder 213 that passes through the bottom of the outer cylinder 211 and communicates with the outside is disposed. Clamping plates 214 and 215 for sandwiching and fixing the test body are disposed at the lower end of the through cylinder 213. The fastening plates 214 and 215 are provided with circular holes 216 and 217 having a diameter of 10 mm (area 78.4 mm 2 ) communicating with the through cylinder 213. In addition, oil 218 is provided inside the outer cylinder 211.
A method for measuring the air permeability by the Gurley air permeability B type tester 210 will be described.
The measurement was performed by the JIS P8117 test method. First, after fixing the nonwoven fabric test body 200 as a test body to the fastening plates 214 and 215 so as to have a predetermined thickness, the inner cylinder 212 was lowered. At this time, the inner cylinder 212 is slowly lowered by the weight of the inner cylinder 212 due to the oil 218 in the outer cylinder 211 (drawn in the direction of the thick arrow in the drawing), and the air A in the inner cylinder 212 (indicated by a thin arrow in the drawing) The nonwoven fabric test body 200 fixed to the fastening plates 214 and 215 through the through-cylinder 213 was permeable. The amount of descent of the inner cylinder 212 was an amount by which air equivalent to 100 cc passed through the nonwoven fabric test body 200 at 1 atmosphere. Then, using a stopwatch, the time (seconds) required for 100 cc of air to pass through the nonwoven fabric specimen 200 was measured, and the air permeability per second was calculated to obtain the air permeability. The measurement was performed three times, and the average value of the measured values was defined as the air permeability of the nonwoven fabric test body 200 at a pressure of 5 kPa.

＜５ｋＰａ圧力時便吸収時間および便付着量の測定方法＞
測定は、吸収性物品の一例として乳幼児用おむつ（花王株式会社製「メリーズさらさらエアスルー」（登録商標）Ｍサイズ）から表面シート、セカンドシートを取り除き、その代わりに、不織布試験体を積層し、その周囲を固定して得た評価用のベビー用おむつを用いた。
そして不織布試験体を含む評価用のベビー用おむつ上に５ｋＰａの圧力を均等にかけ、試験体のほぼ中央に設置した断面積１０００ｍｍ２の筒を当て、そこから擬似便を１０ｇ注入した。疑似便には、グリセリンに水を加えて粘度を調整したものを用いた。本試験では、粘度が３００ｍＰａ・ｓの疑似便を用いた。そして疑似便が表面から無くなる時間を測定し、５ｋＰａ圧力時便吸収時間とした。 <Measurement method of stool absorption time and stool adhesion amount at 5 kPa pressure>
As an example of the absorbent article, the surface sheet and the second sheet are removed from an infant diaper (“Merry's Sarah Air Through” (registered trademark) M size manufactured by Kao Corporation), and a non-woven fabric test specimen is laminated instead. A baby diaper for evaluation obtained by fixing the periphery was used.
And the pressure of 5 kPa was applied uniformly on the baby diaper for evaluation containing a nonwoven fabric test body, the cylinder with a cross-sectional area of 1000 mm < 2 > installed in the approximate center of the test body was applied, and 10 g of artificial stool was inject | poured there. The artificial stool was prepared by adjusting the viscosity by adding water to glycerin. In this test, artificial stool having a viscosity of 300 mPa · s was used. And the time when the artificial stool disappeared from the surface was measured, and it was defined as the stool absorption time at 5 kPa pressure.

その状態で５分静置した後、不織布試験体の上にフィルムを載せ、５ｋＰａの圧力がかかるように重り（図示せず）を載せて加圧し、さらに５分静置した。フィルムには、ＰＥＴフィルム（ＯＨＰシート）（例えば、ＫＯＫＵＹＯ社製ＶＦ−１４２０Ｎ（商品名））を用いた。
５分経過後に重りを取り除き、疑似便が付着したフィルムの質量を測定し、その測定値から予め測定しておいた疑似便の付着前のフィルムの質量を差し引いた値（フィルムの質量変化量）を５ｋＰａ圧力時便付着量とした。 After leaving still for 5 minutes in that state, a film was placed on the nonwoven fabric test specimen, a weight (not shown) was placed on the nonwoven fabric so as to apply a pressure of 5 kPa, and the mixture was further allowed to stand for 5 minutes. A PET film (OHP sheet) (for example, VF-1420N (trade name) manufactured by KOKYUYO) was used as the film.
Remove the weight after 5 minutes, measure the mass of the film to which the artificial stool adheres, and subtract the pre-measured film mass before the artificial stool from the measured value (the amount of change in the mass of the film) Was defined as the amount of stool attached at a pressure of 5 kPa.

上記各評価項目についての測定結果および評価結果を表１に示す。   Table 1 shows the measurement results and evaluation results for each of the above evaluation items.

Figure 0005956206
Figure 0005956206

表１に示した結果から明らかなように、各実施例１〜４のそれぞれの不織布１０の試験体は、いずれの評価項目においても良好な結果を得た。具体的には、壁部の配向角は、８５°〜１０９°であり、壁部に配向強度は１．１〜１．４であり、第１突出部２１の頂部２１Ｔから開口部２１Ｈ方向に放射状に繊維が配向しているので、圧力がかけられた場合であっても潰れにくくなり、さらに５ｋＰａ圧力時の通気度が１１０ｃｃ／ｓｅｃ以上となった。また、いずれの実施例１〜４も第１突出部の繊維密度が第２突出部の繊維密度より低く、第３突出部の繊維密度が第４突出部の繊維密度よりも低いため、供給された液体が軟便、経血等の高粘性液体であっても内部空間１１Ｋ内に流れ込みやすく、吸収体へ移行しやすくなるので、５ｋＰａ圧力時の便吸収時間が８１ｓｅｃ以下と速くなるという効果が得られた。さらに５ｋＰａ圧力時の便付着量は、１．８ｇ以下と少ない値になった。
以上の結果より、実施例１〜４の不織布を表面シートに用いた吸収性物品では、着用者が寝ているような高荷重下でも不織布１０の形状保持性に優れ、高い通気性を有して蒸れの問題が解決でき、かつ排泄物が素早くシート間の内部空間２５（２１Ｋ，２３Ｋ）に導かれることにより排泄物が肌に付き難くい不織布１０を提供できることがわかった。 As is clear from the results shown in Table 1, the test pieces of the nonwoven fabrics 10 of Examples 1 to 4 obtained good results in any evaluation item. Specifically, the orientation angle of the wall portion is 85 ° to 109 °, the orientation strength of the wall portion is 1.1 to 1.4, and the direction from the top portion 21T of the first protruding portion 21 toward the opening portion 21H. Since the fibers are oriented radially, they are not easily crushed even when pressure is applied, and the air permeability at a pressure of 5 kPa is 110 cc / sec or more. Also, any of Examples 1 to 4 is supplied because the fiber density of the first protrusion is lower than the fiber density of the second protrusion, and the fiber density of the third protrusion is lower than the fiber density of the fourth protrusion. Even if the liquid is a highly viscous liquid such as soft stool or menstrual blood, it easily flows into the internal space 11K and easily moves to the absorber, so that the stool absorption time at a pressure of 5 kPa is shortened to 81 sec or less. It was. Furthermore, the amount of feces adhering at a pressure of 5 kPa was as low as 1.8 g or less.
From the above results, the absorbent article using the nonwoven fabrics of Examples 1 to 4 as the top sheet has excellent shape retention of the nonwoven fabric 10 even under a high load such as the wearer sleeping, and has high air permeability. Thus, it was found that the problem of stuffiness can be solved and the non-woven fabric 10 in which the excrement is difficult to adhere to the skin can be provided by the excretion being quickly guided to the internal space 25 (21K, 23K) between sheets.

比較例１は、繊維配向性がないため、５ｋＰａ圧力時に潰れやすく、擬似便を保持するような空間を有さないため、５ｋＰａ圧力時の通気度が２１ｃｃ／ｓｅｃと低く、５ｋＰａ圧力時の便吸収時間が３００ｓｅｃ以上と遅く、５ｋＰａ圧力時の便付着量が５．２ｇとなり実施例の２．８倍以上多くなった。
比較例２は、配向強度は１．１９とあるものの配向角が１７２°と大きいため、実施例と比較して高加圧下で潰れやすく、擬似便を保持するような空間が小さいため、５ｋＰａ圧力時の通気度が３８ｃｃ／ｓｅｃとやや低く、５ｋＰａ圧力時の便吸収時間が２３４ｓｅｃ以上と遅く、５ｋＰａ圧力時の便付着量が３．２ｇとなり実施例の１．７倍以上多くなった。
比較例３は、比較例２と同様に高加圧下で潰れやすいものの、比較例２の不織布を２枚接合しているため、擬似便を保持するような空間が増加している。しかし、第１シートと第２シートの空間の間に裏張りが存在し、通気性、通液性が劣り、かつ第２シートの空間を有効利用できないため、５ｋＰａ圧力時の通気度が６５ｃｃ／ｓｅｃと実施例と比較して低く、５ｋＰａ圧力時の便吸収時間が２１１ｓｅｃ以上と遅く、５ｋＰａ圧力時の便付着量が３．０ｇとなり実施例の１．６倍以上多くなった。
したがって、比較例１〜３の不織布を吸収性物品の表面シートに用いた場合、不織布自体に十分な通気性が得られ難いため、蒸れやすくなり、着用者の肌に赤み、かぶれ、褥瘡等を発生させる可能性があり、また、排泄物が肌に付きやすくなり、快適な継続的着用が難しいことがわかった。 Since Comparative Example 1 does not have fiber orientation, it easily collapses at a pressure of 5 kPa and does not have a space for holding artificial stool. Therefore, the air permeability at a pressure of 5 kPa is as low as 21 cc / sec, and the stool at a pressure of 5 kPa is used. The absorption time was as slow as 300 sec or more, and the amount of stool adhering at a pressure of 5 kPa was 5.2 g, which was 2.8 times or more that of the example.
In Comparative Example 2, although the orientation strength is 1.19, the orientation angle is as large as 172 °. Therefore, compared to the Example, it is easily crushed under a high pressure, and the space for holding artificial stool is small. The air permeability at the time was slightly low at 38 cc / sec, the stool absorption time at a pressure of 5 kPa was slow as 234 sec or more, and the stool adhesion amount at a pressure of 5 kPa was 3.2 g, which was 1.7 times or more that of the example.
Although the comparative example 3 is easy to be crushed under high pressure like the comparative example 2, since the two nonwoven fabrics of the comparative example 2 are joined, the space which hold | maintains artificial stool is increasing. However, since there is a backing between the space of the first sheet and the second sheet, the air permeability and liquid permeability are inferior, and the space of the second sheet cannot be effectively used, the air permeability at a pressure of 5 kPa is 65 cc / The stool absorption time at 5 kPa pressure was as slow as 211 sec or more, and the stool adhesion amount at 5 kPa pressure was 3.0 g, which was 1.6 times greater than that of the example.
Therefore, when the nonwoven fabrics of Comparative Examples 1 to 3 are used for the surface sheet of the absorbent article, it is difficult to obtain sufficient breathability in the nonwoven fabric itself, so that it becomes easy to get stuffy, and the wearer's skin is reddish, rashed, acne, etc. It has been found that there is a possibility that it may occur, and excrement tends to adhere to the skin, and it is difficult to comfortably wear it continuously.

１０ 不織布
１１ 第１シート
１２ 第２シート
２１ 第１突出部
２１Ｈ 開口部
２１Ｋ 内部空間
２１Ｔ 第１突出部頂部
２１Ｗ 第１突出部の壁部
２２ 第２突出部
２２Ｈ 開口部
２２Ｋ 内部空間
２２Ｔ 第２突出部頂部
２２Ｗ 第２突出部の壁部
２３ 第３突出部
２３Ｈ 開口部
２３Ｋ 内部空間
２３Ｔ 第３突出部頂部
２３Ｗ 第３突出部の壁部
２４ 第４突出部
２４Ｈ 開口部
２４Ｋ 内部空間
２４Ｔ 第４突出部頂部
２４Ｗ 第４突出部の壁部
２５ 内部空間 DESCRIPTION OF SYMBOLS 10 Nonwoven fabric 11 1st sheet | seat 12 2nd sheet | seat 21 1st protrusion part 21H Opening part 21K Internal space 21T 1st protrusion part top part 21W Wall part of 1st protrusion part 22 2nd protrusion part 22H Opening part 22K Internal space 22T 2nd protrusion Top part 22W Wall part of second projecting part 23 Third projecting part 23H Opening part 23K Internal space 23T Third projecting part top part 23W Wall part of third projecting part 24 Fourth projecting part 24H Opening part 24K Internal space 24T Fourth projecting part Top part 24W Wall part of fourth protrusion 25 Internal space

Claims (6)

シート状の熱可塑性繊維からなる不織布を平面視した側の第１面側に突出し、前記第１面側とは反対側の第２面側に開口した内部空間を有する第１突出部と、前記第２面側に突出し内部空間を有する第２突出部とを有し、前記第１、第２突出部が該不織布の平面視交差する異なる方向のそれぞれに交互に連続して配された第１シートと、
前記第２面側に突出し、前記第１面側に開口した内部空間を有する第３突出部と、前記第１面側に突出し内部空間を有する第４突出部とを有し、前記第３、第４突出部が該不織布の平面視交差する異なる方向のそれぞれに交互に連続して配された第２シートとを有し、
前記第１突出部の頂部と前記第１突出部の前記第２面側に開口した開口部との間に環状構造の連続した壁部が配され、該壁部は前記第１突出部の頂部と開口部とを結ぶ方向の繊維配向が１．０５以上の配向強度を有し、
前記第１突出部と前記第３突出部とは突出方向が逆方向となるように対向する位置に配されて前記第２突出部と前記第４突出部とが接合されている不織布。 A first protrusion having an internal space that protrudes to the first surface side of the nonwoven fabric made of sheet-like thermoplastic fiber and that is open on the second surface side opposite to the first surface side; A second projecting portion projecting on the second surface side and having an internal space, wherein the first and second projecting portions are alternately and continuously arranged in different directions intersecting in plan view of the nonwoven fabric. Sheet,
A third protrusion having an internal space protruding toward the second surface and opening toward the first surface; and a fourth protrusion having an internal space protruding toward the first surface; The fourth protrusions have second sheets alternately and continuously arranged in different directions intersecting in plan view of the nonwoven fabric,
A continuous wall portion having an annular structure is disposed between a top portion of the first protrusion portion and an opening portion opened to the second surface side of the first protrusion portion, and the wall portion is a top portion of the first protrusion portion. The fiber orientation in the direction connecting the opening and the opening has an orientation strength of 1.05 or more ,
The non-woven fabric in which the first projecting portion and the third projecting portion are arranged at positions facing each other such that the projecting direction is opposite, and the second projecting portion and the fourth projecting portion are joined. 前記第３突出部の頂部と前記第３突出部の前記第１面側に開口した開口部との間に環状構造の連続した壁部が配され、該壁部は前記第３突出部の頂部と開口部とを結ぶ方向に繊維配向性を有している請求項１に記載の不織布。   A continuous wall portion having an annular structure is disposed between a top portion of the third protrusion portion and an opening portion opened to the first surface side of the third protrusion portion, and the wall portion is a top portion of the third protrusion portion. The nonwoven fabric of Claim 1 which has fiber orientation in the direction which ties an opening part. 前記第１突出部の繊維密度が前記第２突出部の繊維密度より低く、前記第３突出部の繊維密度が前記第４突出部の繊維密度より低い請求項１又は２に記載の不織布。   The nonwoven fabric according to claim 1 or 2, wherein the fiber density of the first protrusion is lower than the fiber density of the second protrusion, and the fiber density of the third protrusion is lower than the fiber density of the fourth protrusion. 前記第１突出部の繊維密度が前記第３突出部の繊維密度と同等もしくは前記第３突出部の繊維密度より低い請求項１〜３のいずれか１項に記載の不織布。   The nonwoven fabric according to any one of claims 1 to 3, wherein a fiber density of the first protrusion is equal to or lower than a fiber density of the third protrusion. 前記第１シートに０．０５ｋＰａの圧力をかけたときの厚みｔ１および前記第２シートに０．０５ｋＰａの圧力をかけたときの厚みｔ２のそれぞれが１ｍｍ以上１０ｍｍ以下であり、
前記第１シートに５ｋＰａの圧力をかけたときの厚みｔｐ１が前記厚みｔ１の値の１０％以上６０％以下であり、
前記第２シートに５ｋＰａの圧力をかけたときの厚みｔｐ２が前記厚みｔ２の値の１０％以上６０％以下である請求項１ないし４のいずれか１項に記載の不織布。 Each of the thickness t1 when a pressure of 0.05 kPa is applied to the first sheet and the thickness t2 when a pressure of 0.05 kPa is applied to the second sheet is 1 mm or more and 10 mm or less,
The thickness tp1 when a pressure of 5 kPa is applied to the first sheet is 10% to 60% of the value of the thickness t1,
The nonwoven fabric according to any one of claims 1 to 4, wherein a thickness tp2 when a pressure of 5 kPa is applied to the second sheet is 10% or more and 60% or less of a value of the thickness t2. シート状の不織布を平面視した側の第１面側に突出し内部空間を有する第１突出部と、前記第１面側とは反対側の第２面側に突出し内部空間を有する第２突出部とを有し、前記第１、第２突出部は、該不織布の平面視交差する異なる方向のそれぞれに交互に連続して配された第１シートを作製する工程と、
前記第２面側に突出し内部空間を有する第３突出部と、前記第１面側に突出し内部空間を有する第４突出部とを有し、前記第３、第４突出部は、該不織布の平面視交差する異なる方向のそれぞれに交互に連続して配された第２シートを作製する工程と、
前記第１シートの第２面側と前記第２シートの第１面側とを向かい合わせにして前記第１シートの第２突出部と前記第２シートの第４突出部を接着する工程を有し、
前記第１シートの作製工程および前記第２シートの作製工程は、それぞれ、凹凸形状を有する支持体上に熱可塑性繊維を含有するウエブを搬送し、第１の熱風の吹き付けにより前記ウエブの繊維同士を前記凹凸形状が保持される状態に賦形する工程と、
前記第１の熱風よりも高温度の第２の熱風を前記賦形させたウエブに吹き付け、前記凹凸形状を保持した状態で前記ウエブの繊維同士を融着させて前記凹凸形状を固定する工程とを備えている不織布の製造方法。 A first projecting portion projecting on the first surface side of the sheet-like nonwoven fabric in plan view and having an internal space, and a second projecting portion projecting on the second surface side opposite to the first surface side and having an internal space And the first and second protrusions produce a first sheet alternately and continuously arranged in different directions intersecting in plan view of the nonwoven fabric,
A third projecting portion projecting on the second surface side and having an inner space; and a fourth projecting portion projecting on the first surface side and having an inner space; and the third and fourth projecting portions are formed of the nonwoven fabric. Producing second sheets alternately and continuously arranged in different directions intersecting in plan view;
Bonding the second protrusion of the first sheet and the fourth protrusion of the second sheet with the second surface side of the first sheet facing the first surface side of the second sheet. And
In the first sheet production step and the second sheet production step, the webs containing thermoplastic fibers are conveyed onto a support having an uneven shape, and the fibers of the webs are blown by the first hot air. Forming the concavo-convex shape into a state where the concavo-convex shape is maintained,
Blowing the second hot air having a temperature higher than that of the first hot air to the shaped web, and fixing the uneven shape by fusing the fibers of the web while maintaining the uneven shape; A method for producing a nonwoven fabric comprising:
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