JP6233778B2 - Non-woven - Google Patents

Description

  The present invention relates to a nonwoven fabric.

Nonwoven fabrics used for absorbent articles such as sanitary napkins, panty liners, disposable diapers, etc., depending on their functions, have been provided with a part that protrudes on one side of the sheet material, or a part that protrudes on both front and back sides Things have been developed.
In patent document 1, the 1st protrusion part which protrudes in the 1st surface side, and the 2nd protrusion part which protrudes in the 2nd surface side on the opposite side are the 1st direction and the 2nd direction in planar view of a nonwoven fabric And a nonwoven fabric spread alternately in a plurality of directions in the two directions.
In Patent Document 2, by providing embossing in a regular pattern, a large number of defined areas defined in a mesh shape are formed by embossed lines or embossed influence lines, and each defined area protrudes outward. The surface sheet which has the dent part which comprises the ridge part which does and is recessed inward in the approximate center part of each defined area | region is described.
In patent document 3, while projecting toward a wearer's skin side and forming many convex parts, between the adjacent convex parts, the joined part formed by joining the upper layer and the lower layer A sheet for an absorbent article in which the convex portions and the concave portions are alternately arranged in a row in one direction, and the rows are arranged in multiple rows. Have been described.

JP 2012-144835 A JP 2008-136561 A JP 2008-148807 A

  Since the nonwoven fabric described in Patent Document 1 has portions protruding on both sides, it exhibits a cushioning characteristic peculiar to its structure, but there is room for improving twist. Moreover, since the surface sheet of patent document 2 does not have a ridge part, a protruding part is easy to twist and is inferior to cushioning properties. Since the sheet for absorbent articles described in Patent Document 3 has no crimped portion on the wall and fiber orientation is not taken into consideration, the uneven shape with respect to external pressure is maintained, the twist is difficult, and the cushioning property is improved. There is room for improvement.

  The present invention relates to a nonwoven fabric that is difficult to twist and has high cushioning properties when the nonwoven fabric is used as a top sheet of an absorbent article.

  The present invention provides a first projecting portion projecting on the first surface side in plan view of the nonwoven fabric of the sheet body and having an inner space, and a second projecting projecting on the second surface side opposite to the first surface side and having an inner space. The first protrusions and the second protrusions are non-woven fabrics arranged alternately and continuously through wall portions in different directions intersecting in plan view of the non-woven fabric, The first projecting portion and the second projecting portion are integrated by a wall portion, and the wall portion connecting the first projecting portion and the second projecting portion has a pressure-bonded portion in which the wall portion is pressed. I will provide a.

  Since the nonwoven fabric of the present invention has a crimped portion in which the wall portion is pressed to the wall portion, the fiber structure of the wall portion becomes dense, and the elastic force at that portion is increased, so that it becomes difficult to twist. , Cushioning is improved.

It is the fragmentary sectional view which showed the preferable basic form of the nonwoven fabric which concerns on this invention. It is the arrangement | positioning top view which showed the preferable example of arrangement | positioning of the 1st, 2nd protrusion part in the nonwoven fabric of a basic form. It is the arrangement | positioning top view which showed the preferable example which has arrange | positioned the crimping | compression-bonding part to the wall part of the nonwoven fabric which is one Embodiment of the nonwoven fabric which concerns on this invention. It is the arrangement | positioning top view which showed the preferable example which has arrange | positioned the crimping | compression-bonding part to the ridge part of the nonwoven fabric of this embodiment. It is the arrangement | positioning top view which showed the preferable example which has arrange | positioned the crimping | compression-bonding part to the 2nd protrusion part of the nonwoven fabric of this embodiment. It is principal part sectional drawing which showed the preferable example of the web shaping process among the manufacturing methods of the nonwoven fabric of this invention, (a) is principal part sectional drawing which showed the state which sprayed the 1st hot air, ( (b) is a principal part sectional view showing after blowing the 1st hot air, (c) is a principal part sectional view showing the state where the 2nd hot air was blown. It is the schematic block diagram which showed a preferable example of the manufacturing process of a crimping | compression-bonding part among the manufacturing methods of the nonwoven fabric of this invention. It is the partially cutaway perspective view which showed typically the disposable diaper as one preferable embodiment of the absorbent article using the surface sheet which concerns on this invention.

A preferred embodiment of the nonwoven fabric according to the present invention will be described below with reference to FIGS. 1 to 5. First, the basic form of the nonwoven fabric of this invention is demonstrated with reference to FIG. 1 and FIG.
The nonwoven fabric 10 of the present invention is preferably applied to a surface sheet of an absorbent article such as a sanitary napkin, a disposable diaper, an incontinence pad, and the second surface 10 is used with the first surface side Z1 facing the skin surface of the wearer. The surface side Z2 is preferably used by being disposed on the absorber (not shown) side inside the 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.

As shown in FIG. 1 and FIG. 2, the basic form of the nonwoven fabric 10 of the present invention is a continuous uneven curved surface, which forms a seamless sheet surface. That is, the non-woven fabric of the sheet body is projected to the first surface side Z1 in plan view and has an internal space 11K, and the second surface side Z2 opposite to the first surface side Z1 is projected to project the internal space 12K. And a second projecting portion 12. The first protrusions 11 and the second protrusions 12 are alternately continuous in the first direction (X direction) and the second direction (Y direction), for example, as different directions intersecting in plan view over the entire surface of the nonwoven fabric 10. It is arranged. In the present embodiment, the first direction and the second direction are orthogonal to each other, but may not be orthogonal, and may intersect, for example, in the range of about 60 ° to 120 °.
The convex portion viewed from the first surface side Z <b> 1 is the first projecting portion 11, and the concave portion is the second projecting portion 12. Further, the convex portion viewed from the second surface side Z <b> 2 is the second projecting portion 12, and the concave portion is the first projecting portion 11. Therefore, the first protrusion 11 and the second protrusion 12 are partially shared.

  As described above, the first protrusions 1 and the second protrusions 2 that are arranged to extend in the first direction and the second direction in the surface, respectively, are continuous in a plane shape and constitute the nonwoven fabric 10. . Here, “continuous without contradiction” means that when a specific shape portion is continuous and becomes planar, it is not refracted or discontinuous, and the whole is continuous with a gentle curved surface. In addition, the arrangement | sequence form of the said 1st protrusion part and the 2nd protrusion part is not limited above, What is necessary is just a form which can be arrange | positioned by the arrangement | sequence which can be continued without contradiction, for example, a hexagonal shape centering on a 1st protrusion part. There may be an arrangement in which six second protrusions are arranged at the vertices and the pattern extends in the plane. In this case, since the number of the second protrusions exceeds the number of the first protrusions, the second protrusions are adjacent to each other. However, as long as a continuous sheet state is formed as a whole, this is the case. Such an arrangement is included in the meaning that the first protrusions and the second protrusions are arranged alternately.

Although there is no clear boundary between the first protrusion 11 and the second protrusion 12, in this specification, the space having the first protrusion 11 and the internal space 12 </ b> K of the second protrusion 12 is used as a reference. Is defined as follows. That is, the 1st protrusion part 11 is the part protruded to the 1st surface side Z1 of the nonwoven fabric 10 of the 1st surface side Z1 which covers the internal space 11K and this. The part which protruded to the 1st surface side Z1 of the nonwoven fabric 10 is a part which connected from the 1st protrusion part top part 11T to the bottom part of the surrounding internal space 12K through the wall part 13 (14). Moreover, the 2nd protrusion part 12 containing the internal space 12K is a part which protruded to the 2nd surface side Z2 of the nonwoven fabric 10 of the 2nd surface side Z2 which covers the internal space 12K and this. The portion recessed in the second surface side Z2 of the nonwoven fabric 10 is a portion connecting the bottom portion of the internal space 12K to the surrounding first protruding portion top portion 11T through the wall portion 13 (14). The first projecting portion 11T and the second projecting portion 12 are shared between the first projecting portion top portion 11T and the bottom portion of the internal space 12K, and the wall portion divides the two inner spaces 11K and the inner space 12K. 13 (14).
Furthermore, in order to clarify the 1st protrusion part 11, the 2nd protrusion part 12, and the wall part 13, the height of the thickness direction of the nonwoven fabric 10 is divided into 3 equal parts, the upper part is the 1st protrusion part 11, and the intermediate part is a wall. The part 13 (14) and the lower part are defined as the second projecting part 12. Moreover, although the part which connects the highest position in the 1st surface side Z1 direction which makes adjacent 1st protrusion parts 11 continue is a ridge part, when it sees with the 1st protrusion part 11 and the ridge part 15, it is 1st. A lower portion obtained by equally dividing the protrusion top portion 11T and the lowest position of the ridge portion 15 into two in the first surface side Z1 direction is referred to as a ridge portion 15.

  The adjacent first protrusions 11 are continuously connected in an oblique direction with respect to the first direction and the second direction via the ridge 15 in plan view. In other words, the 1st protrusion part 11 is connected like a mountain range via the ridge part 15 in the diagonal direction with respect to the 1st direction and the 2nd direction. When the first direction and the second direction are orthogonal to each other, the oblique direction is, for example, a 45 ° oblique direction with respect to each direction. Further, the adjacent second projecting portions 12 are continuously connected in an oblique direction like the first projecting portion 11 with respect to the first direction and the second direction through the ridge portion 15 when viewed from the second surface side Z2. ing.

  A height h1 (not shown) in the thickness direction of the first protrusion 11 is higher than a height h5 (not shown) in the thickness direction of the ridge portion 15. Each of the heights h1 and h5 is a height perpendicular to a plane (not shown) in contact with the apex 12T of the second protrusion top 12 and the height of the ridge 15 is between the first protrusions 11. This refers to the height of the lowest part of the ridge part 15. Since the height h1 in the thickness direction of the first protruding portion 11 is higher than the height h5 of the ridge portion 15 in this way, the liquid is poured into the internal space 12K of the second protruding portion 12 that is surrounded on all sides by the first protruding portion 11. Accumulated, the liquid flows over the ridge 15 in the direction of the internal space 12K of the adjacent second protrusion 12. In this case, the liquid flows also in the lower portion of the ridge portion 15, but does not leak to the first surface side Z1.

The fiber constituting the wall portion 13 has a fiber orientation along the direction connecting the first protruding portion 11 and the second protruding portion 12 at any location in the plane direction defined by the first direction and the second direction. Have sex.
Specifically, it has fiber orientation in the direction connecting the first protrusion top 11T and the edge of the opening 11H of the internal space 11K. In other words, it has fiber orientation in the direction in which the wall portion 13 stands. Therefore, it has the radial fiber orientation which goes to the 1st protrusion part top part 11T. In addition, the direction which ties the 1st protrusion part top part 11T and the edge part of the opening part 11H of the internal space 11K, and the direction where the wall part 13 stands up substantially correspond with the thickness direction in a nonwoven fabric.
The fibers constituting the wall 14 (13) of the second protrusion 12 have fiber orientation in the direction connecting the second protrusion top 12T and the edge of the opening 12H of the internal space 12K. The fiber orientation of the wall portion 14 is the same as the fiber orientation of the wall portion 13 in the common portion with the wall portion 13 described above. Note that the direction connecting the second projecting portion top 12T and the edge of the opening 12H of the internal space 12K and the direction in which the wall 13 rises substantially coincide with the thickness direction of the nonwoven fabric.

Thus, since the wall part 13 of the 1st protrusion part 11 has fiber orientation in the direction which ties the top part 11T of the 1st protrusion part 11, and the opening part 11H of the internal space 11K of the 1st protrusion part 11, it is a wearer. Since the first protrusion 11 and the second protrusion 12 are not easily crushed even under high pressure such as sleeping, the shape retention is excellent, and the problem of stuffiness is solved with high air permeability. In addition, a firm stiffness is born in the wall portion 13 and there is a moderate cushioning property that prevents the fibers from being crushed in the thickness direction. Furthermore, even if the nonwoven fabric 10 is crushed due to the pressing force due to the fiber orientation of the wall portion 13, 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 non-woven fabric 10 is excellent in shape retention even at the seating pressure of the wearer, the skin contact area is kept small even at the time of high pressurization, and the first and second protrusions are not easily crushed and are easily recovered even if deformation occurs. .
The fibers are smoothly transferred through the fibers by the fibers oriented in the thickness direction of the wall portion 13, thereby transferring to the absorbent body (not shown) disposed on the lower surface of the nonwoven fabric 10, and the fiber orientation of the wall portion 13. Because the liquid returns less depending on the nature, a smooth touch is realized. Moreover, it is useful for prevention of a blurring by being excellent in the air permeability of nonwoven fabric 10 itself by maintenance of the structure mentioned above.

  The first projecting portion 11 and the second projecting portion 12 have a truncated cone shape or a hemisphere with rounded top portions 11T and 12T. In more detail, the protruding shape of the first protruding portion 11 is rather a truncated cone shape, while the protruding shape of the second protruding portion 12 is a cone shape or a truncated cone shape having a round top. The first and second projecting portions 11 and 12 are not limited to the above shapes, and may have any projecting shape. For example, various cone shapes (in this specification, cone shapes are a cone and a truncated cone). In other words, it is practical to include a pyramid, a truncated pyramid, an oblique cone, etc.). The first projecting portion 11 holds a truncated cone-shaped internal space 11K having a rounded top portion similar to the outer diameter thereof. Moreover, the 2nd protrusion part 12 hold | maintains the truncated cone shape or hemispherical internal space 12K with the roundness in the top part similar to the outer diameter.

  A wall 13 is provided between the top of the first protrusion 11 (hereinafter also referred to as the first protrusion 11) 11T and the opening 11H. The wall portion 13 forms an annular structure in the first projecting portion 11. Moreover, it has the wall part 14 between the top part (henceforth the 2nd protrusion part top part) 12T of the 2nd protrusion part 12, and its opening part 12H. The wall portion 14 forms an annular structure in the second projecting portion 12. The wall portion 14 is shared with a part of the wall portion 13. 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, “annular” is a three-dimensional shape: cylinder, oblique cylinder, elliptical cylinder, truncated cone (truncated cone), oblique truncated cone (truncated truncated cone), oblique elliptical truncated cone (truncated elliptical cone), four Arbitrary ring structures composed of side surfaces such as truncated pyramid (truncated quadrangular pyramid), oblique quadrangular pyramid (truncated oblique pyramid), etc. are mentioned. A truncated cone and an elliptical truncated cone are preferable.

The nonwoven fabric 10 having the first and second projecting portions 11 and 12 arranged as described above does not have a bent portion, and is configured by a curved surface that is continuous as a whole.
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 can be defined, for example, as a hole having a diameter equivalent to a circle of 1.0 mm or more.

The operation based on the nonwoven fabric 10 of the basic form described above will now be described.
-Cushion property Since the nonwoven fabric 10 of the basic form has the 1st protrusion part 11 and the 2nd protrusion part 12 which protruded not only on the single side | surface of the front and back but on both surfaces, the cushioning characteristic peculiar to the structure is expressed. For example, the projection on one side will inevitably exhibit elasticity as a surface, but according to this embodiment, the three-dimensional cushioning that is well supported by points on both sides following a three-dimensional movement well Play. Further, the wall portion 13 has the orientation of fibers oriented in the direction in which the wall stands up. Therefore, a firm stiffness is born here, and an appropriate cushioning property is realized without the fibers being crushed in the thickness direction. Further, due to the fiber orientation of the wall portion 13 described above, even if the nonwoven fabric is crushed by receiving a pressing force, the shape restoring force is large, and even if the packing state and wearing are continued, the initial cushioning force is not easily lost.
-Touch The non-woven fabric 10 of the basic form has a first protrusion 11 and a first protrusion 12 in both directions, and the tops 11T and 12T are rounded. Therefore, whichever side is the skin side, a good feel that the nonwoven fabric 10 (for example, the surface sheet) softly contacts the skin with respect to the skin is realized. There also exists an effect | action resulting from said favorable cushioning property, and a unique favorable touch is obtained 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.
-Collectability of excrement In the nonwoven fabric 10 of a basic form, there exist the 1st protrusion part 11 and the 2nd protrusion part 12 which protrude on both surfaces. Each of them has a first internal space 11K and a second internal space 12K formed inside. Therefore, these can be collected and dealt with in various forms according to the physical properties of the excretion fluid and excrement. For example, assuming that the first surface side Z1 of the nonwoven fabric 10 of FIG. 1 is the skin surface side, if the excrement has a high viscosity and low permeability, without passing through the top sheet of the nonwoven fabric 10, The excrement is temporarily stored in the internal space 12K. On the other hand, if the excretory liquid has low viscosity and easily permeates, after passing through the surface sheet, if there is a lower layer sheet in the internal space 11K or below it, it is collected on it. In any of these cases, the portion that first hits the skin surface is the top portion 11T of the first protruding portion, and the collected excretory fluid or excrement is made difficult to contact the skin. As a result, after the excretion of urine, feces, menstrual blood, and spillage, a very good and smooth feeling can be sustained widely.

Next, the crimping part, which is a characteristic structure of the nonwoven fabric according to the embodiment of the present invention, will be described.
As shown in FIG. 3, the nonwoven fabric 10a of 1st Embodiment is the nonwoven fabric 10 of the said basic form, and the 1st protrusion part 11 and the 2nd protrusion part 12 are integrated by the wall part 13 (14), 1st. The wall portion 13 (14) that connects the protruding portion 11 and the second protruding portion 12 has a pressure-bonding portion (hereinafter also referred to as a wall-portion pressing portion) 16 to which the wall portion 13 (14) is pressed.
The shape of the wall crimping portion 16 in a plan view can take various shapes such as a circle, an ellipse, an oval, a rectangle, and the like, but a circle, an oval, and an ellipse are preferable. The area of the wall crimping portion 16 is preferably 0.25 mm ² or more, more preferably 1.0 mm ² or more, from the viewpoint of improving elasticity, suppressing twisting of the nonwoven fabric, and improving cushioning properties. From the viewpoint of having softness, it is preferably 5.0 mm ² or less, more preferably 3.0 mm ² or less. And preferably at 0.25 mm ² or more 5.0 mm ² or less, more preferably 1.0 mm ² or more 3.0 mm ² or less.
The thickness of the wall crimping part 16 is preferably 0.1 mm or more, and more preferably 0.2 mm or more, from the viewpoint of difficulty in twisting, improving elasticity, suppressing twisting of the wall part, and cushioning properties. From the viewpoint of improving, it is preferably 1.0 mm or less, more preferably 0.5 mm or less. And preferably they are 0.1 mm or more and 1.0 mm or less, More preferably, they are 0.2 mm or more and 0.5 mm or less.
In addition, the area ratio of the wall crimping portion 16 is preferably 5% or more, more preferably 15% or more, from the viewpoint of improving elasticity, suppressing twisting of the wall portion, and reducing the amount of remaining liquid. Preferably, it is 30% or more, and from the viewpoint of making it difficult to twist, it is preferably 70% or less, more preferably 60% or less, and even more preferably 55% or less. And preferably they are 5% or more and 70% or less, More preferably, they are 15% or more and 60% or less, More preferably, they are 30% or more and 55% or less.

  The nonwoven fabric 10a in which the crimping portion 16 is arranged on the wall portion 13 becomes dense with the crimping portion 16 so that the wall portion 13 becomes dense.

As shown in FIG. 4, in the nonwoven fabric 10 b of the second embodiment, the adjacent first protrusions 11 and the adjacent second protrusions 12 are each in the first direction (X direction) via the ridge part 15. And the second direction (Y direction) are continuously connected in an oblique direction of 45 ° in plan view, and the first projecting portion 11 and the second projecting portion 12 are integrated by the wall portion 13 (14). The ridge portion 15 that connects the adjacent first protrusions 11 includes a crimping portion 17 (hereinafter also referred to as a ridge portion crimping portion) 17 to which the ridge portion 15 is pressed.
The shape of the ridge portion crimping portion 17 in a plan view can take various shapes such as a circle, an ellipse, an oval, a rectangle, and the like, but a circle, an oval, and an ellipse are preferable. The area of the ridge portion crimping portion 17, increases density, from the viewpoint of reducing the liquid amount of remaining, preferably 0.25 mm ² or more, more preferably 1.0 mm ² or more, from the viewpoint for not harden, Preferably it is 5.0 mm ² or less, more preferably 3.0 mm ² or less. And preferably at 0.25 mm ² or more 5.0 mm ² or less, more preferably 1.0 mm ² or more 3.0 mm ² or less.
The thickness of the ridge portion crimping portion 17 is preferably 0.1 mm or more, more preferably 0.3 mm or more from the viewpoint of reducing the remaining amount of liquid, and from the viewpoint of improving the touch, preferably 1.0 mm or less, more Preferably it is 0.8 mm or less. And preferably they are 0.1 mm or more and 1.0 mm or less, More preferably, they are 0.3 mm or more and 0.8 mm or less.
Further, the area ratio of the ridge portion crimping portion 17 is preferably 5% or more, more preferably 10% or more, and further preferably 25% or more, from the viewpoint of increasing the density and reducing the remaining amount of liquid. From the viewpoint, it is preferably 50% or less, more preferably 40% or less, and still more preferably 35% or less. And preferably they are 5% or more and 50% or less, More preferably, they are 15% or more and 40% or less, More preferably, they are 25% or more and 35% or less.
Although not shown, it is more preferable to arrange the ridge crimping portion 17 together with the wall crimping portion 16.

  In the nonwoven fabric 10b having a configuration in which the crimping portion 17 is arranged on the ridge portion 15, since the ridge portion 15 becomes dense, the drawability of the liquid is increased and the nonwoven fabric is excellent in the liquid remaining property.

As shown in FIG. 5, the nonwoven fabric 10 of the third embodiment includes a crimped portion 19 (hereinafter also referred to as a second projecting portion crimping portion) 19 in which the second projecting portion 12 is pressed against the nonwoven fabric 10 of the basic form. Have.
The shape of the second projecting portion crimping portion 18 in a plan view can take various shapes such as a circle, an ellipse, an oval, and a rectangle, but a circle, an oval, and an ellipse are preferable. The area of the second projecting portion crimping portion 18 is preferably 0.25 mm ² or more, more preferably 1.0 mm ² or more, from the viewpoint of increasing the density of the first projecting portion or the wall portion and reducing the remaining liquid amount. From the viewpoint of softness, it is preferably 5.0 mm ² or less, more preferably 3.0 mm ² or less. And preferably at 0.25 mm ² or more 5.0 mm ² or less, more preferably 1.0 mm ² or more 3.0 mm ² or less.
The thickness of the second projecting portion crimping portion 18 is preferably 0.1 mm or more, more preferably 0.3 mm or more from the viewpoint of improving the density of the second projecting portion and drawing in the liquid. From the viewpoint of improving, it is preferably 1.0 mm or less, more preferably 0.8 mm or less. And preferably they are 0.1 mm or more and 1.0 mm or less, More preferably, they are 0.3 mm or more and 0.8 mm or less.
In addition, the area ratio of the second projecting portion crimping portion 18 is preferably 5% or more, more preferably 10% or more, from the viewpoint of improving the density of the second projecting portion and improving the drawability of the liquid. Preferably, it is 25% or more, and from the viewpoint of softness, it is preferably 50% or less, more preferably 45% or less, and still more preferably 40% or less. And preferably they are 5% or more and 50% or less, More preferably, they are 10% or more and 45% or less, More preferably, they are 25% or more and 40% or less.
Although not shown, it is more preferable to arrange the second projecting portion crimping portion 18 together with the wall crimping portion 16, and the second projecting portion crimping portion together with the wall crimping portion 16 and the ridge crimping portion 17. More preferably, 18 is arranged.

  In the configuration of the nonwoven fabric 10c in which the crimping portion 18 is disposed on the second protruding portion 12, the second protruding portion 12 becomes dense, so that the liquid drawability is increased and the nonwoven fabric is excellent in the liquid remaining property.

A method for calculating the area ratio will be described.
First, the area ratio of the wall crimping portion will be described. For the area S of a quadrilateral (rectangular shape) drawn by a line connecting the apexes (center point when viewed in plan) of four adjacent first protrusions 11, the total area Sa of the crimping portion 16 included in the quadrilateral. Is the area ratio. Therefore, the area ratio can be expressed as area ratio (%) = (Sa / S) × 100%.
The area ratio of the ridge portion crimping portion is within the square with respect to the area S of a quadrilateral (square) drawn by a line connecting the vertices of the four adjacent first protrusions 11 (center point in plan view). The ratio of the total area Sa of the included crimping part 17 is defined as the area ratio. Therefore, the area ratio can be expressed by area ratio (%) = (Sa / S) × 100% as described above.
The area ratio of the second projecting portion crimping portion is the total area Sa of the crimping portion 18 included in the square with respect to the area S of a quadrangle (square) having a diagonal between the centers of the adjacent second projecting portion crimping portions 18. The area ratio is defined as Therefore, the area ratio can be expressed by area ratio (%) = (Sa / S) × 100% as described above.

It is preferable that the area ratio of the wall crimping portion 16 is larger than the area ratio of the second protrusion crimping portion 17.
Since the pressure-bonding portion of the wall portion becomes elastic due to an increase in density, and the presence of a large amount makes it easy to maintain the concavo-convex shape, an effect that is difficult to twist is obtained.

  Each of the crimping parts 16, 17 and 18 is preferably formed by embossing. Since it is formed by embossing, it is easy to obtain a desired embossing pattern and area, and there is an advantage that it can be created at low cost.

  The fiber material that can be used for the nonwoven fabric 10 is not particularly limited. Specific examples include the following fibers. Polyolefin fibers such as polyethylene (PE) fibers and polypropylene (PP) fibers include fibers made of a single thermoplastic resin such as polyethylene terephthalate (PET) and polyamide, and have a core-sheath type, side-by-side type, etc. There is a composite fiber. 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. Preferable examples thereof include core-sheath fibers in which the sheath component (low melting point component) is polyethylene or low-melting polypropylene. Typical examples of the core-sheath fibers are PET (core) and PE (sheath). , PP (core) and PE (sheath), polylactic acid (core) and PE (sheath), PP (core) and low-melting point PP (sheath), etc. 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 and polyethylene, and the composite composition of the polypropylene composite fiber is preferably polyethylene terephthalate and low-melting polypropylene, and more specifically, PET (core). And PE (sheath), PET (core), and 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.

Next, the dimension specification in the said nonwoven fabric 10 is demonstrated below.
Regarding the thickness of the nonwoven fabric 10, the total thickness when the nonwoven fabric 10 is viewed from the side is the sheet thickness TS, and the local thickness of the sheet curved in the unevenness is the layer thickness TL. The sheet thickness TS may be appropriately adjusted depending on the application, but when used as a surface sheet for diapers, sanitary products, etc., it is preferably 1 mm or more and 7 mm or less, and more preferably 1.5 mm or more and 5 mm or less. By setting it as the range, the body fluid absorption speed at the time of use is high, the liquid return from an absorber is suppressed, and also moderate cushioning property is realizable. The layer thickness TL may be different in each part in the nonwoven fabric, and may be appropriately adjusted depending on the application. When used as a surface sheet for diapers, sanitary products, etc., the layer thickness TL1 of the first protrusion top 11T is preferably 0.1 mm or more and 3 mm or less, and more preferably 0.4 mm or more and 2 mm or less. The preferable range of the layer thickness is the same for the layer thickness TL2 of the second protrusion top 12T and the layer thickness TL3 of the wall 13. The relationship between the layer thicknesses TL1, TL2, and TL3 is preferably TL1>TL3> TL2. In addition, each layer thickness TL1, TL2, TL3 does not include the crimping parts 16, 17, and 18. Thereby, in the 1st protrusion part 11, especially on the skin surface side, fiber density is low and can implement | achieve favorable skin contact. On the other hand, the second protrusion 12 has a high fiber density, is not easily crushed, and can be made of a nonwoven fabric excellent in cushioning properties and liquid absorption speed without being deformed. And it becomes difficult to twist by arrange | positioning the crimping | compression-bonding part 16 to the wall part 13 (14), and also cushioning properties are excellent. Further, by arranging the crimping part 17 on the ridge part 15 or by arranging the crimping part 18 on the top part 12T of the second projecting part 12, the drawability of the liquid is further increased, and the liquid remaining ability is excellent.
The distance between the first projecting portion 11 and the second projecting portion 12 may be appropriately adjusted depending on the application, and when used as a surface sheet for diapers and sanitary products, it is preferably 1 mm or more and 15 mm or less, and more preferably 3 mm or more and 10 mm or less. preferable. The basis weight of the nonwoven fabric 10 is not particularly limited, but is preferably 15 g / ^{m 2} or more 50 g / ^{m 2} or less the average value of the entire sheet, 20 g / ^{m 2} or more 40 g / ^{m 2} or less is more preferable.

The nonwoven fabric 10 demonstrated by the said embodiment has the following effects.
The above-described nonwoven fabric 10 has increased elasticity by increasing the fiber density of the wall portion 13 (14) of the portion where the crimping portion 16 is arranged by arranging the wall crimping portion 16 on the wall portion 13 (14). As a result, the cushioning properties are further improved. Moreover, since the part of the crimping | compression-bonding part 16 becomes firm, it becomes difficult to twist.
Further, by arranging the ridge portion crimping portion 17 and the second projecting portion crimping portion 18 on the ridge portion 15 and the top portion 12T of the second projecting portion 12, the ridge portion 15 and the second projecting portion of the portion where the crimping portions 17 and 18 are arranged. When the fiber density of the top portion 12T of the portion 12 becomes dense, in other words, the distance between the fibers becomes short, the drawability of the liquid is enhanced by the capillary phenomenon, and the liquid remaining property is excellent.

Next, a preferred embodiment of the method for manufacturing the above-described nonwoven fabrics 10a to 10c 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.

As an example of a web-shaped support, a support 110 having the configuration shown in FIG. 6A is used. The support 110 has a large number of protrusions 111 corresponding to positions where the second protrusions 12 are shaped, and holes 112 are arranged corresponding to positions where the first protrusions 11 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 11 is shaped correspondingly, and the second protrusion 12 is shaped corresponding to the position of the protrusion 111. Accordingly, the first projecting portion 11 projecting to the first surface side Z1 on the side in plan view and having the internal space 11K, and the second projecting portion projecting to the second surface side Z2 opposite to the first surface side Z1 and having the internal space 12K. The protrusions 12 are alternately and continuously arranged in different X and Y directions intersecting in plan view, and the nonwoven fabric 10 of the basic form is shaped. In this case, the fiber density of the 1st protrusion part 11 shape | molded corresponding to the hole 112 becomes lower than the 2nd protrusion part 12 shape | molded corresponding to the processus | protrusion 111. FIG.
The arrows in the drawing schematically show the flow of the first hot air W1.

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. Subsequently, the 1st hot air W1 is sprayed on the web 50 on the support body 110 (state of Fig.6 (a)). Then, the web 50 is shaped so as to follow the shape of the support 110 (the state shown in FIG. 6B). 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 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 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 is set to 20 m / s or more and 150 m / s or less from a viewpoint of shaping property and texture, Preferably it is 30 m / s or more. 100 m / s or less. 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 at the top of the second projecting portion 12 and it will be easily crushed, and the cushioning properties, excrement stock properties and air permeability will not be fully exhibited. Further, when the opening is generated, the excrement easily returns through the opening.
Thus, it is set as the nonwoven fabric 10 shaped in the uneven | corrugated shape.

  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 or more and 10 mm or less, preferably 1.5 mm or more and 9 mm or less, more preferably 2 mm or more and 8 mm or less.

Next, as shown in FIG.6 (c), the 2nd hot air W2 of the temperature which each fiber of the web 50 can be fuse | melted moderately is blown, and fiber is fuse | melted. 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 second hot air W2 is set to 1 m / s or more and 10 m / s or less, preferably 3 m / s or more and 8 m / s or less. 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.
Moreover, after blowing the 2nd hot air W2, you may provide an air through process for the purpose of the further shape stabilization of the web 50, and reducing fluff.

  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. .

  Moreover, it is preferable that the web 50 contains 30 mass% or more and 100 mass% or less of thermoplastic fiber, More preferably, it is 40 mass% or more and 100 mass% or less. 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).

  In the said manufacturing method, the thickness of the nonwoven fabric 10 is suitably determined by the wind speed of the 1st hot air W1. For example, when the wind speed is increased, the thickness is increased, and when the wind speed is decreased, the thickness 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.

The nonwoven fabric 10 is produced as described above.
In the manufacturing method, considering continuous production, the manufacturing apparatus (not shown) is a conveyor type or drum type capable of transporting the support 110, and the transported nonwoven fabric 10 having a fixed uneven shape is fixed. The mode which winds with a roll (not shown) is mentioned.

Next, a crimping part is produced in the nonwoven fabric 10 released from the support. This process will be described with reference to FIG.
The arrangement of the wall portion 13 (14) is obtained from the arrangement of the first protrusion portion 11 and the second protrusion portion 12 in the design of the nonwoven fabric 10 so that the predetermined wall portion crimping portion 16 is formed on the wall portion 13 (14). The embossing roll 210 is rotatable in the direction of the arrow, and an embossing projection (hereinafter referred to as an embossing projection) 211 is disposed on the roll surface 210S. The emboss protrusions 211 are arranged corresponding to the positions where the crimping parts are produced on the nonwoven fabric 10. For example, as shown in FIG. 3, in the wall portion 13 (14) around the first protrusion 11 and the second protrusion 12, 16 crimping portions 16 surround a square with respect to one protrusion. It is arranged on the roll surface 210S so as to be arranged as described above. That is, the arrangement of the emboss projections 211 is transferred, and the crimping portion 16 is formed on the nonwoven fabric 10.

The roll surface temperature of the embossing roll 210 can be set to a temperature in the range of 40 ° C. or higher and 200 ° C. or lower.
The emboss protrusion 211 has a columnar shape, preferably a cylinder, an ellipse, an ellipse, or a prism, and more preferably a cylinder or a prism.
A receiving roll 220 that is rotatable in the direction of the arrow is disposed at a position facing the embossing roll 210. The receiving roll 220 preferably has a diameter equivalent to that of the embossing roll 210, but embossing is possible even if the diameter is larger or smaller than the embossing roll 210.

When forming the crimping portions 16 to 18 described with reference to FIGS. 3 to 5, the following setting is made.
When the wall crimping portion 16 is formed, the wall portion 13 (14) around the first projecting portion 11 and the second projecting portion 12 shown in FIG. The embossing protrusions 211 are arranged on the embossing roll surface 210S so as to correspond to positions where the respective crimping parts 16 are formed so that the crimping parts 16 are arranged in a dot-like and square shape. That is, the embossing protrusion 211 is arranged on the embossing roll surface 210S so that the arrangement of the embossing protrusion 211 is transferred and the crimping part 16 is formed.
The embossing protrusion 211 is a cylinder having an area of a cylinder end surface of 2 mm ² (diameter is 1.6 mm), for example. The roll surface temperature of the embossing roll is set to 130 ° C.

  The nonwoven fabric 10 shaped in the shaping process is conveyed between the embossing roll 210 and the receiving roll 220. At this time, the position of the nonwoven fabric 10 is adjusted so that the position where the crimping part of the wall part 13 (14) of the nonwoven fabric 10 is arranged corresponds to the position of the embossing projection 211. And the nonwoven fabric 10 is sent by rotation of the embossing roll 210 and the receiving roll 220, and the embossing protrusion 211 presses the nonwoven fabric 10 to the receiving roll 220, and a predetermined pressure is applied to the nonwoven fabric 10, and the crimping | compression-bonding part 16 is produced. . At this time, the roll interval is adjusted so that the pressure at the tip of the emboss projection 211 is 700 kPa. Thus, embossing is given to the nonwoven fabric 10 and the wall crimping | compression-bonding part 16 is produced.

When the ridge portion crimping portion 17 is formed, the four crimping portions 17 including the first projecting portions 11 between the first projecting portions 11 in the ridge portion 15 shown in FIG. The embossing protrusions 211 are arranged on the embossing roll surface 210 </ b> S so as to correspond to the positions where the respective crimping portions 17 are formed. That is, the embossing protrusion 211 is disposed on the embossing roll surface 210S so that the arrangement of the embossing protrusion 211 is transferred to form the crimping portion 17.
The emboss protrusion 211 is a cylinder having an area of a cylinder end surface of 1 mm ² (diameter is 1.1 mm), for example. The roll surface temperature of the embossing roll 210 is set to 130 ° C. A receiving roll 220 is disposed at a position facing the embossing roll 210.

  The nonwoven fabric 10 shaped in the shaping process is conveyed between the embossing roll 210 and the receiving roll 220. At this time, the position of the nonwoven fabric 10 is adjusted so that the position where the crimping part of the ridge part 15 of the nonwoven fabric 10 is arranged corresponds to the position of the embossing protrusion 211. And the nonwoven fabric 10 is sent by rotation of the embossing roll 210 and the receiving roll 220, and the embossing protrusion 211 presses the nonwoven fabric 10 to the receiving roll 220, and a predetermined pressure is applied to the nonwoven fabric 10, and the crimping | compression-bonding part 17 is produced. . At this time, the roll interval is adjusted so that the pressure at the tip of the emboss projection 211 is 700 kPa. In this way, the nonwoven fabric 10 is embossed to produce the ridge crimping portion 17.

When forming the second projecting portion crimping portion 18, the crimping portion 18 is formed so that, for example, one crimping portion 16 is arranged on the top portion 12 </ b> T of the second projecting portion 12 shown in FIG. 5. The embossing protrusion 211 is arranged on the embossing roll surface 210S corresponding to the position. That is, the embossing protrusion 211 is arranged on the embossing roll surface 210S so that the arrangement of the embossing protrusion 211 is transferred and the crimping part 18 is formed.
For example, the emboss protrusion 211 has an end surface area of 3 mm ² (2.0 mm in diameter) and a roll surface temperature of 130 ° C. A receiving roll 220 is disposed at a position facing the embossing roll 210.

  The nonwoven fabric 10 shaped in the shaping process is conveyed between the embossing roll 210 and the receiving roll 220. At this time, the position of the nonwoven fabric 10 is adjusted so that the position where the crimping portion of the top portion 12T of the second protruding portion 12 of the nonwoven fabric 10 corresponds to the position of the emboss projection 211. And the nonwoven fabric 10 is sent by rotation of the embossing roll 210 and the receiving roll 220, and the embossing protrusion 211 presses the nonwoven fabric 10 against the receiving roll 220, and a predetermined pressure is applied to the nonwoven fabric 10, and the crimping | compression-bonding part 18 is produced. . At this time, the roll interval is adjusted so that the pressure at the tip of the emboss projection 211 is 700 kPa. Thus, embossing is given to the nonwoven fabric 10, and the 2nd protrusion part crimping | compression-bonding part 18 is produced.

  The crimping portions 16 to 18 are preferably arranged in combination of the crimping portion 16 and the crimping portion 17 or 18. Or it is preferable to arrange the crimping portions 16 to 18 in combination. By combining in this way, the elasticity of the wall 13 (14) is improved, and the cushioning property is enhanced and the twist is made difficult. At the same time, the fiber density is increased by the pressure-bonding portions 17 and 18, whereby the drawability of the liquid is increased, and the nonwoven fabric 10 is further improved due to the liquid residue.

  The nonwoven fabrics 10a to 10c of the present invention can be used for various applications. For example, it can be suitably used as a surface sheet for 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.

  Next, an application example of the disposable diaper 100 to the main body 4 will be described below as a preferred embodiment of an absorbent article using the nonwoven fabric according to the present invention as a top sheet with reference to FIG. The disposable diaper shown in the figure is a tape-type disposable diaper for infants, and is shown in a state where the diaper developed in a plane is bent slightly and viewed from the inside (skin contact surface side).

As shown in FIG. 8, the disposable diaper 100 includes a liquid permeable top sheet 1 disposed on the skin contact surface side, a liquid poorly permeable back sheet 2 disposed on the non-skin contact surface side, and the aforementioned A liquid-retaining absorbent 3 is disposed between both sheets.
The nonwoven fabric 10 of the said embodiment is applied to the surface sheet 1, and the 1st protrusion part 11 side is made into the skin contact surface.

The back sheet 2 is in an unfolded state, and both side edges thereof have a shape confined to the inside in the longitudinal central portion C. Even if the back sheet 2 is composed of a single sheet, it is composed of a plurality of sheets. Also good.
The back sheet 2 is not particularly limited as long as it has waterproofness and moisture permeability. For example, a minute inorganic filler made of a hydrophobic thermoplastic resin and calcium carbonate, or an incompatible organic polymer. And the like, and a porous film obtained by uniaxially or biaxially stretching the film. Examples of the thermoplastic resin include polyolefin. Examples of the polyolefin include high-density to low-density polyethylene, linear low-density polyethylene, polypropylene, polybutene, and the like, and these can be used alone or in combination.

As the absorbent body 3, various forms used for this type of article can be widely adopted as long as they have liquid retention. For example, there are various types such as those in which pulp fibers are coated with a core wrap sheet, sheets in which an airlaid nonwoven is used, and sheets in which a superabsorbent polymer is sandwiched between fiber sheets. Examples of the pulp fiber include wood pulp such as softwood kraft pulp and hardwood kraft pulp, and natural cellulose fiber such as non-wood pulp such as cotton pulp and straw pulp. In addition, polyolefin resins such as polyethylene and polypropylene, polyester resins such as polyethylene terephthalate, single fibers made of synthetic resins such as polyvinyl alcohol resins, composite fibers containing two or more of these resins, semi-synthetic materials such as acetate and rayon Fibers may be included in part. Further, as the superabsorbent polymer, various polymer materials usually used for this type of article can be used. The water-absorbing polymer is preferably a superabsorbent polymer compound capable of absorbing and retaining water or saline more than 20 times its own weight.
In addition, the coated sheet is a hydrophilic member, for example, thin paper (thin paper) such as hydrophilic tissue paper, crepe paper, non-woven fabric made of hydrophilic fibers such as cotton and rayon, and synthetic resin fibers. A non-woven fabric formed by treatment, for example, an air-through non-woven fabric, a point bond non-woven fabric, a spunlace non-woven fabric, a spunbond non-woven fabric, a spunbond-meltblown-spunbond (SMS) non-woven fabric or the like can be used.

  The side sheet 5 is preferably a water-repellent non-woven fabric, and is water-repellent from among non-woven fabrics, spunbond nonwoven fabrics, meltblown nonwoven fabrics, spunlace nonwoven fabrics, heat roll nonwoven fabrics, needle punched nonwoven fabrics manufactured by the card method, Various non-woven fabrics treated with water can be used. Particularly preferably, for example, a spunbond nonwoven fabric, a spunbond-meltblown (SM) nonwoven fabric, a spunbond-meltblown-spunbond (SMS) nonwoven fabric, or the like is used.

  In this example, a side leakage prevention gather 7 formed by the side seats 5 is provided, whereby side leakage of liquid or the like in the hip joint portion due to movement of the infant can be effectively prevented. In the diaper of this embodiment, a functional structure part, a sheet material, etc. may be provided. In addition, in FIG. 5, the arrangement | positioning relationship and boundary of each member are not illustrated strictly, and if it is set as the general form of this kind of diaper, the structure will not be specifically limited.

  The diaper is shown as a tape type, and a fastening tape 6 is provided on the flap portion on the back side R. Fastening tape 6 can be affixed to a tape affixing part (not shown) provided in the flap part of ventral side F, and a diaper can be mounted and fixed. At this time, the center part C of the diaper is gently bent inward so that the absorbent body 3 is worn along the baby's buttocks and lower abdomen. As a result, excreta is absorbed and held in the absorber 3 accurately. By using in such a form, the skin contact surface even when a large amount of liquid is excreted or when it is under a high load, particularly by applying the nonwoven fabric 10 as the top sheet 1 It is possible to achieve both prevention of the liquid flow above and prevention of liquid return from the non-skin contact surface side. Further, higher air permeability is obtained by the space formed by the continuous internal space 11K, and a large amount of the captured liquid can be diffused in the continuous direction of the space, thereby preventing liquid leakage in the lateral direction. Furthermore, since the excreted fluid or excreted material that has been captured is made difficult to come into contact with the skin, after excretion of urine, menstrual blood, descending material, etc., a very good smooth feeling can be sustained widely.

  The absorbent article of the present invention is not limited to the disposable diaper of the above embodiment, and can be applied to, for example, sanitary napkins, panty liners, incontinence pads, urine collection pads, and the like. In addition to the top sheet 1, the back sheet 2, and the absorbent body 3, members may be incorporated as appropriate according to the purpose and function as constituent members of the absorbent article.

This invention discloses the following absorbent articles and its manufacturing method further regarding embodiment mentioned above.
<1>
A first protrusion that protrudes on the first surface side in plan view of the nonwoven fabric of the sheet body and has an internal space; and a second protrusion that protrudes on the second surface side opposite to the first surface side and has an internal space. The first protrusions and the second protrusions are non-woven fabrics arranged alternately and continuously through wall portions in different directions intersecting in plan view of the non-woven fabric, and the first protrusions And the second projecting portion are integrated with each other at the wall portion, and the wall portion connecting the first projecting portion and the second projecting portion is a non-woven fabric having a crimped portion to which the wall portion is pressed.
<2>
The nonwoven fabric as described in <1> which has a crimping | compression-bonding part to which the said 2nd protrusion part was pressed.
<3>
The non-woven fabric according to <2>, wherein the area ratio of the crimping portion existing in the second projecting portion is smaller than the area ratio of the crimping portion existing in the wall portion.
<4>
The area of the pressure-bonded portion where the wall portion is pressed is preferably 0.25 mm ² or more, more preferably 1.0 mm ² or more, preferably 5.0 mm ² or less, more preferably 3.0 mm ² or less. The nonwoven fabric according to any one of <1> to <3>.
<5>
The thickness of the pressure-bonded portion where the wall portion is pressed is preferably 0.1 mm or more, more preferably 0.2 mm or more, preferably 1.0 mm or less, more preferably 0.5 mm or less <1>. To <4>.
<6>
The area of the pressure-bonded portion where the second protrusion is pressed is preferably 0.25 mm ² or more, more preferably 1.0 mm ² or more, preferably 5.0 mm ² or less, more preferably 3.0 mm ^2. The nonwoven fabric according to any one of <2> to <5>, which is the following.
<7>
The thickness of the pressure-bonding part 18 to which the second protrusion is pressed is preferably 0.1 mm or more, more preferably 0.3 mm or more, preferably 1.0 mm or less, more preferably 0.8 mm or less < The nonwoven fabric as described in 2> or <6>.
<8>
The area ratio of the pressure-bonded portion where the second protrusion is pressed is preferably 5% or more, more preferably 10% or more, still more preferably 25% or more, preferably 50% or less, more preferably 45% or less. The nonwoven fabric according to any one of <2> to <7>, more preferably 40% or less.
<9>
The area ratio of the pressure-bonded portion where the wall portion is pressed is preferably 5% or more, more preferably 15% or more, still more preferably 30% or more, preferably 70% or less, more preferably 60% or less, More preferably, the nonwoven fabric according to any one of <1> to <8>, which is 55% or less.
<10>
The adjacent first protrusions are continuously connected in an oblique direction with respect to each of the different directions in plan view via the ridge parts, and the first protrusions and the second protrusions are connected to each other. The ridge part integrated with the wall part and connecting the adjacent first protrusions is a nonwoven fabric according to any one of <1> to <9>, wherein the ridge part has a pressure-bonded part to which the ridge part is pressed.
<11>
The area of the pressure-bonded portion where the ridge portion is pressed is preferably 0.25 mm ² or more, more preferably 1.0 mm ² or more, preferably 5.0 mm ² or less, more preferably 3.0 mm ² or less. The nonwoven fabric as described in <10>.
<12>
The thickness of the pressure-bonded portion to which the ridge portion is pressed is preferably 0.1 mm or more, more preferably 0.3 mm or more, preferably 1.0 mm or less, more preferably 0.8 mm or less <10> or <11>.
<13>
The area ratio of the pressure-bonded portion where the ridge portion is pressed is preferably 5% or more, more preferably 10% or more, still more preferably 25% or more, preferably 50% or less, more preferably 40% or less, More preferably, the nonwoven fabric according to any one of <10> to <12>, which is 35% or less.
<14>
The non-woven fabric according to any one of <1> to <13>, wherein the crimping portion is formed by embossing.
<15>
The wall portion has a fiber orientation along a direction connecting the first projecting portion and the second projecting portion at any location in the plane direction defined by the first direction and the second direction. The nonwoven fabric according to any one of <1> to <14>.
<16>
The nonwoven fabric according to any one of <1> to <15>, wherein the nonwoven fabric has fiber orientation in a direction connecting the top portion of the first projecting portion and the edge portion of the opening of the internal space.
<17>
The nonwoven fabric according to any one of <1> to <16>, which has fiber orientation in a direction in which the wall portion stands.
<18>
The nonwoven fabric according to any one of <1> to <17>, which has a radial fiber orientation toward the top of the first protrusion.
<19>
Any one of <1> to <18>, wherein the fibers constituting the wall of the second protrusion have fiber orientation in a direction connecting the top of the second protrusion and the edge of the opening of the internal space. The nonwoven fabric according to 1.

  EXAMPLES Hereinafter, although this invention is demonstrated further in detail based on an Example, this invention is limited and interpreted by these Examples.

[Example 1-3]
In Example 1, the core is made of polyethylene terephthalate (melting point: 258 ° C.), the sheath is made of polyethylene (melting point: 135 ° C.), and the core-sheath type composite fiber of 2.4 dtex × 51 mm is weighted from the card machine to a weight of 30 g / m ^2. 50 was supplied to the shaping apparatus. 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 3.5 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, switching to the second hot air W2 at a temperature of 145 ° C. and a wind speed of 5 m / s is performed to fuse the fibers of each core-sheath structure to fix the shape, and then the temperature is 139 ° C. and the wind speed is 1.5 m / s. s hot air was applied.
Next, the crimp part 16 was formed in the wall part 13 (14), the 2nd protrusion part 12, and the ridge part 15 of the nonwoven fabric 10. FIG. The crimping part 16 was a 2 mm ² circle, and the area ratio of the wall crimping part 16 was 50% (design value). The pressure for pressure bonding was set to 700 kPa, and the temperature for pressure bonding was set to 130 ° C. In this way, a nonwoven fabric 10 having a thickness of 2.1 mm and a basis weight of 30 g / m ² was produced.
In Example 2, the crimp part 17 was formed on the wall part 13 (14), the second projecting part 12, and the ridge part 15 of the nonwoven fabric 10 in Example 1 described above. The crimping part 17 was 1 mm ^{2 in} a circular shape, and the area ratio of the ridge crimping part 17 was 30% (design value). The pressure for pressure bonding was set to 700 kPa, and the temperature for pressure bonding was set to 130 ° C. Other than that, it produced similarly to Example 1. FIG. In this way, a nonwoven fabric 10 having a thickness of 2.5 mm and a basis weight of 33 g / m ² was produced.
In Example 3, the crimp part 18 was formed in the wall part 13 (14), the second protrusion part 12 T, and the ridge part 15 of the nonwoven fabric 10 in Example 1 described above. The crimping part 18 was made into a circle of 3 mm ² so that the area ratio of the second projecting part crimping part 18 was 19% (design value). The pressure for pressure bonding was set to 700 kPa, and the temperature for pressure bonding was set to 130 ° C. Other than that, it produced similarly to Example 1. FIG. In this way, a nonwoven fabric 10 having a thickness of 2.8 mm and a basis weight of 32 g / m ² was produced.

[Comparative Example 1]
Comparative Example 1 was produced in the same manner as in Example 1 except that the crimp portion was not formed in Example 1 above. The nonwoven fabric 10 had a thickness of 3.3 mm and a basis weight of 31 g / m ² .

  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.

<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, the orientation angle close to 90 ° indicates that the fibers are oriented in the central direction of the top portion 11T. If the orientation angle is 60 ° or more and 120 ° or less, the center direction of the top portion 11T It is determined that the fibers 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.

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 this 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 13 of the first protrusion 11. The orientation strength is preferably 1.05 or more, and more preferably 1.10 or more. The wall portion 14 of the second protrusion 12 is the same as the wall portion 13.
When the nonwoven fabric 10 is used as the top sheet of the absorbent article, the nonwoven fabric 10 has sufficient compression resistance even under high pressure due to the fiber orientation of each wall portion 13, and the first protrusion 11 of the nonwoven fabric 10, The crushing of the 2nd protrusion part 12 is prevented. 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.

<Measurement of cushioning properties>
Using a KES compression tester (KES FB-3, manufactured by Kato Tech Co., Ltd.), compression characteristics are evaluated up to 5.0 kPa in the normal mode, and a work WC value up to a maximum pressure of 5.0 kPa is read. As a measured value, three points in the nonwoven fabric 10 were measured to obtain an average value, which was repeated three times, and the average value was defined as compression recoverability. The compression area of the nonwoven fabric of the KES compression tester was 2 cm ² , the compression speed was 0.02 mm / sec, the direction of compression was reversed at a maximum pressure of 5.0 kPa, and the recovery process was started.
The evaluation criteria for the feeling of cushion is “A” as excellent when the WC value is 0.30 or less, and “B” as good when the WC value is greater than 0.30 and less than or equal to 0.50. When the WC value is greater than 0.50 and less than or equal to 0.80, it is represented as “C” because it is normal.

<Measurement of difficulty of twisting>
It was assumed that the nonwoven fabric 10 was bent into an arc shape using a KES bending tester (KES FB2-AUTO-A manufactured by Kato Tech Co., Ltd.). In the range of pure bending method curvature K = −2.5 to +2.5 (cm ⁻¹ ), the deformation rate was 0.50 cm ⁻¹ / sec.
The bending hysteresis 2HB was determined as a measured value. In the measurement, three points in the nonwoven fabric 10 were measured to obtain an average value, and this was repeated six times to make the average value difficult.
The evaluation standard for difficulty of twisting is expressed as “A” because it is excellent when the 2HB value is 0.23 or less, and “B” when the 2HB value is greater than 0.23 and 0.35 or less. When the 2HB value is greater than 0.36 and less than or equal to 0.50, it is represented as “C” as normal.

<Measurement of remaining liquid amount>
The diaper is placed on a horizontal table so that the top sheet faces upward. A rectangular frame with an inner dimension of 20 cm × 10 cm is placed on it. Trace the inside of the frame with an oil-based pen and copy the shape inside the frame onto the top sheet. Next, 200 g of physiological saline is uniformly injected into the frame. Leave for 10 minutes after injection. The frame is removed 1 minute after injection. After leaving for 10 minutes, the surface sheet is cut out along the shape of the frame written on the surface sheet, and its mass is measured. Next, the cut non-woven fabric is sandwiched between kitchen papers (Kim towel (trade name) manufactured by Nippon Paper Industries Co., Ltd.), and the artificial urine is absorbed into the kitchen paper by reciprocating between the mangles. This operation is performed twice. The mass of the nonwoven fabric after the artificial urine is absorbed is measured again, and the mass is subtracted from the mass of the nonwoven fabric measured first. The value was taken as the value of the liquid remaining amount of the nonwoven fabric.
The evaluation criteria for the remaining amount of liquid are expressed as “A” as being excellent when the remaining amount of liquid is 0.25 g or less, and being “good” when the remaining amount of liquid is larger than 0.25 g and not more than 0.30 g. “B”, and when the liquid remaining amount is larger than 0.27 g and equal to or smaller than 0.60 g, it is represented as “C”. In addition, when larger than 0.60g, it is set as D.

  The results of physical properties (orientation angle, orientation strength, thickness, basis weight) and performance (cushioning property (compression), difficulty of bending (bending), remaining liquid amount) of the nonwoven fabric 10 are shown in Table 1 below.

As shown in Table 1 above, Example 1 was excellent in cushioning properties and difficulty in twisting (Evaluation A), and liquid retentivity was also good (Evaluation B). In Examples 2 and 3, the remaining amount of liquid was small, the remaining liquid property was excellent (Evaluation A), and the cushioning property and the difficulty of twisting were good (Evaluation B).
On the other hand, Comparative Example 1 was normal (average) for cushioning properties, difficulty in twisting, and liquid residue (Evaluation C).
As described above, in Examples 1 to 3, the cushion feeling, the difficulty of twisting, and the remaining amount of liquid are all good or excellent, and it is possible to realize the simultaneous improvement of the three that cannot be achieved in Comparative Example 1. did it. Thereby, even if it wears for a long time, it is hard to twist, cushion property is maintained, and the absorbent article which can maintain the smooth touch excellent in the liquid residue property can be provided.

DESCRIPTION OF SYMBOLS 1 Top sheet 2 Back sheet 3 Absorber 4 Main body 5 Side sheet 6 Fastening tape 7 Side leakage prevention gather 10 Nonwoven fabric of basic form 10a, 10b, 10c Nonwoven fabric 11 First protruding portion 11K Internal space 11T First protruding portion top 12 Second Protrusion 12K Internal space 12T Second protrusion top 13, 14 Wall 15 Ridge 16 Crimp (wall crimp)
17 Crimping part (ridge crimping part)
18 Crimping part (second projecting part crimping part)
100 disposable diapers

Claims (6)

A first projecting portion projecting on the first surface side in plan view of the nonwoven fabric of the sheet body and having an internal space;
A second projecting portion projecting on the second surface side opposite to the first surface side and having an internal space;
The first protrusions and the second protrusions are non-woven fabrics that are alternately and continuously arranged through wall portions in each of the first direction and the second direction in different directions intersecting in plan view of the non-woven fabric. ,
The first projecting portion and the second projecting portion are integrated by a wall portion, and the wall portion connecting the first projecting portion and the second projecting portion has a pressure-bonding portion to which the wall portion is pressed. Non-woven fabric.   The adjacent first protrusions are continuously connected in an oblique direction with respect to each of the different directions in plan view via the ridge parts, and the first protrusions and the second protrusions are connected to each other. 2. The nonwoven fabric according to claim 1, wherein the ridge portion integrated with the wall portion and connecting the adjacent first projecting portions has a pressure-bonding portion to which the ridge portion is pressed.   The nonwoven fabric of Claim 1 or 2 which has a crimping | compression-bonding part to which the said 2nd protrusion part was pressed.   Each said crimping | compression-bonding part is the nonwoven fabric of any one of Claim 1 to 3 currently formed by the embossing.   The wall portion has a fiber orientation along a direction connecting the first projecting portion and the second projecting portion at any location in the plane direction defined by the first direction and the second direction. The nonwoven fabric according to any one of claims 1 to 4.   The nonwoven fabric according to any one of claims 3 to 5, wherein the area ratio of the crimping portion existing in the second projecting portion is smaller than the area ratio of the crimping portion existing in the wall portion.

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