JP6500083B2 - 不織布積層体、伸縮性不織布積層体、繊維製品、吸収性物品及び衛生マスク - Google Patents
不織布積層体、伸縮性不織布積層体、繊維製品、吸収性物品及び衛生マスク Download PDFInfo
- Publication number
- JP6500083B2 JP6500083B2 JP2017505384A JP2017505384A JP6500083B2 JP 6500083 B2 JP6500083 B2 JP 6500083B2 JP 2017505384 A JP2017505384 A JP 2017505384A JP 2017505384 A JP2017505384 A JP 2017505384A JP 6500083 B2 JP6500083 B2 JP 6500083B2
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- JP
- Japan
- Prior art keywords
- nonwoven fabric
- fabric laminate
- mass
- thermoplastic
- elastomer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 description 7
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- PBKONEOXTCPAFI-UHFFFAOYSA-N 1,2,4-trichlorobenzene Chemical compound ClC1=CC=C(Cl)C(Cl)=C1 PBKONEOXTCPAFI-UHFFFAOYSA-N 0.000 description 6
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- ZGEGCLOFRBLKSE-UHFFFAOYSA-N 1-Heptene Chemical compound CCCCCC=C ZGEGCLOFRBLKSE-UHFFFAOYSA-N 0.000 description 4
- AFFLGGQVNFXPEV-UHFFFAOYSA-N 1-decene Chemical compound CCCCCCCCC=C AFFLGGQVNFXPEV-UHFFFAOYSA-N 0.000 description 4
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 4
- 239000004970 Chain extender Substances 0.000 description 4
- RRHGJUQNOFWUDK-UHFFFAOYSA-N Isoprene Chemical compound CC(=C)C=C RRHGJUQNOFWUDK-UHFFFAOYSA-N 0.000 description 4
- 239000004721 Polyphenylene oxide Substances 0.000 description 4
- 239000012948 isocyanate Substances 0.000 description 4
- 239000000155 melt Substances 0.000 description 4
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 4
- 229920000570 polyether Polymers 0.000 description 4
- 229920005606 polypropylene copolymer Polymers 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 3
- IMNFDUFMRHMDMM-UHFFFAOYSA-N N-Heptane Chemical compound CCCCCCC IMNFDUFMRHMDMM-UHFFFAOYSA-N 0.000 description 3
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- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 description 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 2
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- 239000002216 antistatic agent Substances 0.000 description 2
- 125000003118 aryl group Chemical group 0.000 description 2
- WERYXYBDKMZEQL-UHFFFAOYSA-N butane-1,4-diol Chemical compound OCCCCO WERYXYBDKMZEQL-UHFFFAOYSA-N 0.000 description 2
- 238000001460 carbon-13 nuclear magnetic resonance spectrum Methods 0.000 description 2
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- RTZKZFJDLAIYFH-UHFFFAOYSA-N ether Substances CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 2
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- 238000010030 laminating Methods 0.000 description 2
- 239000000314 lubricant Substances 0.000 description 2
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- 239000004750 melt-blown nonwoven Substances 0.000 description 2
- 239000012299 nitrogen atmosphere Substances 0.000 description 2
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- MCULRUJILOGHCJ-UHFFFAOYSA-N triisobutylaluminium Chemical compound CC(C)C[Al](CC(C)C)CC(C)C MCULRUJILOGHCJ-UHFFFAOYSA-N 0.000 description 2
- 229920002554 vinyl polymer Polymers 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- PAPBSGBWRJIAAV-UHFFFAOYSA-N ε-Caprolactone Chemical compound O=C1CCCCCO1 PAPBSGBWRJIAAV-UHFFFAOYSA-N 0.000 description 2
- MXJJJAKXVVAHKI-WRBBJXAJSA-N (9z,29z)-octatriaconta-9,29-dienediamide Chemical compound NC(=O)CCCCCCC\C=C/CCCCCCCCCCCCCCCCCC\C=C/CCCCCCCC(N)=O MXJJJAKXVVAHKI-WRBBJXAJSA-N 0.000 description 1
- 238000001644 13C nuclear magnetic resonance spectroscopy Methods 0.000 description 1
- KGRVJHAUYBGFFP-UHFFFAOYSA-N 2,2'-Methylenebis(4-methyl-6-tert-butylphenol) Chemical compound CC(C)(C)C1=CC(C)=CC(CC=2C(=C(C=C(C)C=2)C(C)(C)C)O)=C1O KGRVJHAUYBGFFP-UHFFFAOYSA-N 0.000 description 1
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- 241000251468 Actinopterygii Species 0.000 description 1
- GVNWZKBFMFUVNX-UHFFFAOYSA-N Adipamide Chemical compound NC(=O)CCCCC(N)=O GVNWZKBFMFUVNX-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
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- MHABMANUFPZXEB-UHFFFAOYSA-N O-demethyl-aloesaponarin I Natural products O=C1C2=CC=CC(O)=C2C(=O)C2=C1C=C(O)C(C(O)=O)=C2C MHABMANUFPZXEB-UHFFFAOYSA-N 0.000 description 1
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- BGYHLZZASRKEJE-UHFFFAOYSA-N [3-[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyloxy]-2,2-bis[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyloxymethyl]propyl] 3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoate Chemical compound CC(C)(C)C1=C(O)C(C(C)(C)C)=CC(CCC(=O)OCC(COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)(COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)=C1 BGYHLZZASRKEJE-UHFFFAOYSA-N 0.000 description 1
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- RKISUIUJZGSLEV-UHFFFAOYSA-N n-[2-(octadecanoylamino)ethyl]octadecanamide Chemical compound CCCCCCCCCCCCCCCCCC(=O)NCCNC(=O)CCCCCCCCCCCCCCCCC RKISUIUJZGSLEV-UHFFFAOYSA-N 0.000 description 1
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Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D13/00—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
- A41D13/05—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches protecting only a particular body part
- A41D13/11—Protective face masks, e.g. for surgical use, or for use in foul atmospheres
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
-
- A—HUMAN NECESSITIES
- A62—LIFE-SAVING; FIRE-FIGHTING
- A62B—DEVICES, APPARATUS OR METHODS FOR LIFE-SAVING
- A62B18/00—Breathing masks or helmets, e.g. affording protection against chemical agents or for use at high altitudes or incorporating a pump or compressor for reducing the inhalation effort
- A62B18/02—Masks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/024—Woven fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/026—Knitted fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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Description
<1>下記(a)〜(f)を満たす低結晶性ポリプロピレンを含む弾性不織布と、前記弾性不織布の少なくとも片面側に配置され、熱可塑性エラストマー(A)の長繊維と、熱可塑性エラストマー以外の熱可塑性樹脂(B)の長繊維と、が10質量%〜90質量%:90質量%〜10質量%の割合(((A):(B)、但し(A)+(B)=100質量%とする)で含まれている混繊スパンボンド不織布と、を有する不織布積層体。
(a)[mmmm]=20〜60モル%
(b)[rrrr]/(1−[mmmm])≦0.1
(c)[rmrm]>2.5モル%
(d)[mm]×[rr]/[mr]2≦2.0
(e)重量平均分子量(Mw)=10,000〜200,000
(f)分子量分布(Mw/Mn)<4
(a)〜(d)中、[mmmm]はメソペンタッド分率であり、[rrrr]はラセミペンタッド分率であり、[rmrm]はラセミメソラセミメソペンタッド分率であり、[mm]、[rr]及び[mr]はそれぞれトリアッド分率である。
a/(a+b)≦0.8 (I)
(式中、aは、DSCにより測定される90℃〜140℃の範囲に存在する吸熱ピークから求められる融解熱量の総和を表し、bは、DSCにより測定される140℃を超えて220℃以下の範囲にある吸熱ピークから算出される融解熱の総和を表す。)
本発明の不織布積層体は、
下記(a)〜(f)を満たす低結晶性ポリプロピレンを(以下、単に「低結晶性ポリプロピレン」ともいう)含む弾性不織布と、前記弾性不織布の少なくとも片面側に配置され、熱可塑性エラストマー(A)の長繊維と、熱可塑性エラストマー以外の熱可塑性樹脂(B)の長繊維と、が10質量%〜90質量%:90質量%〜10質量%の割合((A):(B)、但し(A)+(B)=100質量%とする)で含まれている混繊スパンボンド不織布(以下、単に「混繊スパンボンド不織布」ともいう)と、を有する不織布積層体である。
(a)[mmmm]=20〜60モル%
(b)[rrrr]/(1−[mmmm])≦0.1
(c)[rmrm]>2.5モル%
(d)[mm]×[rr]/[mr]2≦2.0
(e)重量平均分子量(Mw)=10,000〜200,000
(f)分子量分布(Mw/Mn)<4
(a)〜(d)中、[mmmm]はメソペンタッド分率であり、[rrrr]はラセミペンタッド分率であり、[rmrm]はラセミメソラセミメソペンタッド分率であり、[mm]、[rr]及び[mr]はそれぞれトリアッド分率である。
本発明の不織布積層体を構成する弾性不織布は、後述する(a)〜(f)を満たす低結晶性ポリプロピレン(以下、単に低結晶性ポリプロピレンともいう)を含む。本発明の目的を効果的に達成する観点からは、弾性不織布中の低結晶性ポリプロピレンの割合は60質量%以上であることが好ましく、70質量%以上であることがより好ましく、80質量%以上であることが更に好ましい。
弾性不織布を構成する繊維は、通常、繊維径が50μm以下であり、好ましくは40μm以下であり、より好ましくは30μm以下である。
低結晶性ポリプロピレンは、下記(a)〜(f)の要件を満たす重合体である。
(a)[mmmm]=20〜60モル%:
低結晶性ポリプロピレンのメソペンタッド分率[mmmm]が20モル%以上であると、べたつきの発生が抑制され、60モル%以下であると、結晶化度が高くなりすぎることがないので、弾性回復性が良好となる。このメソペンタッド分率[mmmm]は、好ましくは30〜50モル%であり、より好ましくは40〜50モル%である。
方法:プロトン完全デカップリング法
濃度:220mg/ml
溶媒:1,2,4−トリクロロベンゼンと重ベンゼンの90:10(容量比)混合溶媒
温度:130℃
パルス幅:45°
パルス繰り返し時間:4秒
積算:10000回
M=m/S×100
R=γ/S×100
S=Pββ+Pαβ+Pαγ
S:全プロピレン単位の側鎖メチル炭素原子のシグナル強度
Pββ:19.8〜22.5ppm
Pαβ:18.0〜17.5ppm
Pαγ:17.5〜17.1ppm
γ:ラセミペンタッド連鎖:20.7〜20.3ppm
m:メソペンタッド連鎖:21.7〜22.5ppm
[rrrr]/[1−mmmm]の値は、上記のペンタッド単位の分率から求められ、低結晶性ポリプロピレンの規則性分布の均一さを示す指標である。この値が大きくなると、既存触媒系を用いて製造される従来のポリプロピレンのように高規則性ポリプロピレンとアタクチックポリプロピレンの混合物となり、べたつきの原因となる。
低結晶性ポリプロピレンにおいて、[rrrr]/(1−[mmmm])が0.1以下であると、得られる弾性不織布におけるべたつきが抑制される。このような観点から、[rrrr]/(1−[mmmm])は、好ましくは0.05以下であり、より好ましくは0.04以下である。
低結晶性ポリプロピレンのラセミメソラセミメソ分率[rmrm]が2.5モル%を超える値であると、該低結晶性ポリプロピレンのランダム性が増加し、弾性不織布の弾性回復性がさらに向上する。[rmrm]は、好ましくは2.6モル%以上であり、より好ましくは2.7モル%以上である。その上限は、通常10モル%程度である。
[mm]×[rr]/[mr]2は、低結晶性ポリプロピレンのランダム性の指標を示し、この値が2.0以下であると、弾性不織布は十分な弾性回復性が得られ、かつべたつきも抑制される。[mm]×[rr]/[mr]2は、0.25に近いほどランダム性が高くなる。上記十分な弾性回復性を得る観点から、[mm]×[rr]/[mr]2は、好ましくは0.25を超え1.8以下であり、より好ましくは0.5〜1.5である。
低結晶性ポリプロピレンにおいて重量平均分子量が10,000以上であると、該低結晶性ポリプロピレンの粘度が低すぎず適度のものとなるため、弾性不織布の製造時の糸切れが抑制される。また、重量平均分子量が200,000以下であると、上記低結晶性ポリプロピレンの粘度が高すぎず、紡糸性が向上する。この重量平均分子量は、好ましくは30,000〜150,000であり、より好ましくは50,000〜150,000である。この重量平均分子量の測定法については後述する。
低結晶性ポリプロピレンにおいて、分子量分布(Mw/Mn)が4未満であると、弾性不織布のべたつきの発生が抑制される。この分子量分布は、好ましくは3以下である。
上記重量平均分子量(Mw)は、ゲルパーミエイションクロマトグラフィ(GPC)法により、下記の装置及び条件で測定したポリスチレン換算の重量平均分子量であり、上記分子量分布(Mw/Mn)は、同様にして測定した数平均分子量(Mn)及び上記重量平均分子量(Mw)より算出した値である。
カラム :TOSO GMHHR−H(S)HT
検出器 :液体クロマトグラム用RI検出器 WATERS 150C
[測定条件]
溶媒 :1,2,4−トリクロロベンゼン
測定温度 :145℃
流速 :1.0ml/分
試料濃度 :2.2mg/ml
注入量 :160μl
検量線 :Universal Calibration
解析プログラム:HT−GPC(Ver.1.0)
(g)示差走査型熱量計(DSC)を用いて、窒素雰囲気下−10℃で5分間保持した後10℃/分で昇温させることにより得られた融解吸熱カーブの最も高温側に観測されるピークのピークトップとして定義される融点(Tm−D)が0℃〜120℃である。
本発明の不織布積層体を構成する混繊スパンボンド不織布は、熱可塑性エラストマー(A)の長繊維と、熱可塑性エラストマー以外の熱可塑性樹脂(B)の長繊維と、が10〜90質量%:90〜10質量%の割合(((A):(B)、但し(A)+(B)=100質量%とする)で含まれている混繊スパンボンド不織布である。
熱可塑性エラストマー(A)としては、種々公知の熱可塑性エラストマーを用いることができ、1種を単独で用いても、2種以上の熱可塑性エラストマーを併用してもよい。
熱可塑性ポリウレタン系エラストマーの中でも、凝固開始温度が65℃以上、好ましくは75℃以上、最も好ましくは85℃以上の熱可塑性ポリウレタン系エラストマーが好ましい。また、凝固開始温度は195℃以下であることが好ましい。ここで、凝固開始温度は、示差走査熱量計(DSC)を用いて測定される値であり、熱可塑性ポリウレタン系エラストマーを10℃/分で230℃まで昇温し、230℃で5分間保持した後、10℃/分で降温させる際に生じる熱可塑性ポリウレタン系エラストマーの凝固に由来する発熱ピークの開始温度である。凝固開始温度が65℃以上であると、混繊スパンボンド不織布を得る際に繊維同士の融着、糸切れ、樹脂塊などの成形不良を抑制することができるとともに、熱エンボス加工の際に成形された混繊スパンボンド不織布がエンボスローラーに巻きつくことを防止できる。また、得られる混繊スパンボンド不織布のベタツキが少なく、衣料、衛生材料、スポーツ材料等の肌と接触する材料として好適に用いられる。一方、凝固開始温度を195℃以下にすることにより、成形加工性を向上させることができる。なお、成形された繊維の凝固開始温度はこれに用いた熱可塑性ポリウレタン系エラストマーの凝固開始温度よりも高くなる傾向にある。
a/(a+b)≦0.8 (I)
a/(a+b)≦0.7 (II)
a/(a+b)≦0.55 (III)
ポリオレフィン系エラストマーの中でも、非晶性又は低結晶性のポリオレフィン系エラストマーが好ましく、非晶性又は低結晶性のエチレンとプロピレン、1−ブテン、1−ペンテン、1−ヘキセン、4−メチル−1−ペンテン、1−ヘプテン、1−オクテン、1−デセン等の炭素数が3〜20の1種以上のα−オレフィンとの共重合体であるエチレン・α−オレフィン共重合体、及び非晶性又は低結晶性のプロピレンとエチレン、1−ブテン、1−ペンテン、1−ヘキセン、4−メチル−1−ペンテン、1−ヘプテン、1−オクテン、1−デセン等の炭素数が2〜20(但し炭素数3を除く)の1種以上のα−オレフィンとの共重合体であるプロピレン・α−オレフィン共重合体がより好ましい。非晶性又は低結晶性のポリオレフィン系エラストマーとは、例えば、X線回折により測定される結晶化度が20%以下(0%を含む)であるポリオレフィン系エラストマーである。
熱可塑性樹脂(B)としては、熱可塑性エラストマー以外の種々公知の熱可塑性樹脂を用いることができ、1種を単独で用いても、2種以上の熱可塑性樹脂を併用してもよい。
必要に応じ、弾性不織布及び混繊スパンボンド不織布には耐熱安定剤、耐候安定剤等の各種安定剤、帯電防止剤、スリップ剤、防曇剤、滑剤、染料、顔料、天然油、合成油、ワックスなどを添加することができる。
本発明の不織布積層体は、用途に応じて弾性不織布及び混繊スパンボンド不織布以外の他の層を1又は2以上有していてもよい。
本発明の不織布積層体は、弾性不織布の原料となる低結晶性ポリプロピレン、混繊スパンボンド不織布の原料となる熱可塑性エラストマー(A)及び熱可塑性樹脂(B)、並びに必要に応じて用いられる添加剤を用いて、公知の不織布の製造方法により製造し得る。
まず、一列目の紡糸装置に備えられた押出機で熱可塑性エラストマー(A)及び熱可塑性樹脂(B)を溶融し、多数の紡糸孔(ノズル)を備えた口金(ダイ)、必要に応じて芯鞘構造を有する紡糸孔に導入し、吐出する。その後、溶融紡糸された熱可塑性エラストマー(A)からなる長繊維と熱可塑性樹脂(B)からなる長繊維を冷却室に導入し、冷却風により冷却した後、延伸エアにより長繊維を延伸(牽引)し、混繊スパンボンド不織布を移動捕集面上に堆積させる。
他方、二列目の紡糸装置に備えられた押出機で低結晶性ポリプロピレンを溶融し、多数の紡糸孔(ノズル)を備えた口金(ダイ)を有する紡糸孔に導入し、低結晶性ポリプロピレンを吐出する。その後、溶融紡糸された低結晶性ポリプロピレンからなる長繊維を冷却室に導入し、冷却風により冷却した後、延伸エアにより長繊維を延伸(牽引)し、混繊スパンボンド不織布上に堆積させて、弾性不織布を形成する。
必要に応じて、三列目の紡糸装置を用いて、混繊スパンボンド不織布を弾性不織布上に堆積させてもよい。
本発明の伸縮性不織布積層体は、前記不織布積層体を延伸することによって得られる、伸縮性を有する不織布積層体である。
本発明の繊維製品は、本発明の不織布積層体又は伸縮性不織布積層体を含む。繊維製品は特に制限されず、使い捨ておむつ、生理用品等の吸収性物品、衛生マスク等の衛生物品、包帯等の医療物品、衣料素材、包装材などが挙げられる。本発明の繊維製品は、本発明の不織布積層体又は伸縮性不織布積層体を伸縮部材として含むことが好ましい。
不織布単体又は不織布積層体から200mm(流れ方向:MD)×50mm(横方向:CD)の試験片を6点採取した。なお、採取場所はMD、CDともに任意の3箇所とした(計6箇所)。次いで、採取した各試験片について、上皿電子天秤(研精工業社製)を用いて、それぞれ質量(g)を測定した。各試験片の質量の平均値を求めた。求めた平均値から1m2当たりの質量(g)に換算し、小数点第2位を四捨五入して各サンプルの目付〔g/m2〕とした。
エンボス工程にてエンボスロールを5分間走行させ、不織布単体又は不織布積層体がエンボスロールを通過する際に生じる付着状態を確認した。
○:目視にて付着が全く確認されない状態。
△:目視にて付着が殆ど確認されない状態。
×:目視にて付着が確認される状態、またはエンボスロールに巻付く状態
不織布単体又は不織布積層体から50mm(MD)×200mm(CD)の試験片5枚を採取した。この試験片について、定速伸長型引張試験機を用いて、チャック間100mm、引張速度100mm/分の条件で引張試験を行い、試験片に掛かる荷重が最大になった時点における試験片の伸び率を測定した。5枚の試験片の平均値を求め、最大荷重伸度とした。
不織布単体又は不織布積層体から、250mm(MD)×50mm(CD)の試験片5枚を切り取った。この試験片を、チャック間30mm、引張速度30mm/分、延伸倍率100%の条件で延伸した。その後、直ちに同じ速度で原長まで回復させ、伸縮性不織布を得た。その際、引張荷重が0gfになった時点で、歪を測定した。5枚の不織布についての平均値を残留歪(単位:%)として評価した。
万能引張試験機(インテスコ社製、IM−201型)を用い、不織布単体又は不織布積層体から、25mm(MD)×200mm(CD)の試験片を5枚採取した。次いで、採取した各試験片をサンプル幅25mm、チャック間距離100mm、引張速度300mm/分の条件で試験片を100%伸長後、直ちに同じ速度で原長まで回復させた。この操作をもう1サイクル実施して、2サイクル目の伸長時に延伸倍率が50%となったときの応力を50%伸長時応力とし、2サイクル目の回復時に延伸倍率が50%となったときの応力を50%回復時応力とした。次いで、伸縮特性の尺度として〔50%伸長時応力÷50%回復時応力〕の値を測定し、5枚の試験片の平均値を伸縮特性として評価した。なお〔50%伸長時応力÷50%回復時応力〕の値が小さいほど伸縮特性が優れていることを意味する。
不織布単体又は不織布積層体を評価者10人が手で触り、そのベタツキを下記基準で評価した。
◎:10人のうち10人がベタツキ無く、手触りが良いと感じた場合。
○:10人のうち9〜7人がベタツキ無く、手触りが良いと感じた場合。
△:10人のうち6〜3人がベタツキ無く、手触りが良いと感じた場合。
×:10人のうち2〜0人がベタツキ無く、手触りが良いと感じた場合。
不織布積層体と、市販の紙おむつから剥した不織布を各1枚ずつ重ね合わせ、ヒートシーラーを用いて、温度90℃、圧力0.3Mpa、時間1秒の条件でヒートシールしたサンプルを作製した。作製したサンプルから250mm(MD)×50mm(CD)の試験片3枚を採取した。次いで、試験片の一部(MD方向の端から20mm)の両面にガムテープを貼付した。その後、ガムテープを試験片の両方向に手動で引っ張ることにより、不織布積層体の層間を100mm剥離させた。その後、剥離した各層を定速伸長型引張試験機にセットし、チャック間100mm、引張速度100mm/分の条件で引張試験を行い、試験片に掛かる荷重が最大になった時点における試験片の応力を測定した。3枚の試験片の平均値を、低温ヒートシール性として評価した。試験片が基材破壊を起こす程度に強固に固定されている場合は「材破」とした。
<熱可塑性ポリウレタンエラストマー(TPU)の調製>
数平均分子量が1932のポリエステルポリオール:71.7質量部、1,4−ブタンジオール(以下、「BD」と略す。):4.8質量部、ペンタエリスリトールテトラキス[3−(3,5−ジ−t−ブチル−4−ヒドロキシフェニル)プロピオネート](以下、「酸化防止剤‐1」と略す。):0.3質量部、ポリカルボンジイミド:0.3質量部を混合し、MDI:22.9質量部を加えて、十分に高速攪拌混合した。その後、160℃で1時間反応させた。この反応物を粉砕した後、当該粉砕物:100質量部に対して、エチレンビスステアリン酸アミド:0.8質量部、トリエチレングリコール−ビス−[3−(3,5−ジ−t−ブチル−4vヒドロキシフェニル)プロピオネート](以下、「酸化防止剤−2」と略す。):0.5質量部、エチレンビスオレイン酸アミド(以下、「EOA」と略す。):0.8質量部を混合した。その後、押出機(設定温度:210℃)で溶融混練して造粒し、熱可塑性ポリウレタンエラストマー〔TPU(A−1)〕を得た。
得られたTPU(A−1)の物性は、硬度:81、溶融粘度:1.1、流動開始温度155℃であった。
MFR(ASTM D1238に準拠し、温度230℃、荷重2.16kgで測定)60g/10分、密度0.91g/cm3、融点160℃のプロピレンホモポリマー(以下、「PP−1」と略す)92質量部と、MFR(ASTMD1238に準拠して、温度190℃、荷重2.16kgで測定)5g/10分、密度0.97g/cm3、融点134℃の高密度ポリエチレン(以下、「HDPE」と略す)8質量部とを混合し、熱可塑性樹脂組成物(B−1)を調製した。
撹拌機付き、内容積0.2m3のステンレス製反応器に、n−ヘプタンを20L/hで、トリイソブチルアルミニウムを15mmol/hで、さらに、ジメチルアニリニウムテトラキスペンタフルオロフェニルボレートと(1,2’−ジメチルシリレン)(2,1’−ジメチルシリレン)−ビス(3−トリメチルシリルメチルインデニル)ジルコニウムジクロライドとトリイソブチルアルミニウムとプロピレンを事前に接触させて得られた触媒成分をジルコニウムあたり6μmol/hで連続供給した。
得られた重合溶液に、SUMILIZER GP(住友化学社製)を1000ppmになるように添加し、溶媒を除去することにより、低結晶性プロピレン重合体を得た。
上記で調製したTPU(A−1)と熱可塑性樹脂組成物(B−1)とを、それぞれ独立に75mmφの押出機及び50mmφの押出機を用いて溶融した。その後、紡糸口金を有するスパンボンド不織布成形機(捕集面上の機械の流れ方向に垂直な方向の長さ:800mm)を用いて、樹脂温度とダイ温度がともに205℃、冷却風温度20℃、延伸エアー風速3200m/分の条件でスパンボンド法により溶融紡糸し、TPU(A−1)からなる長繊維Aと、熱可塑性樹脂組成物(B−1)からなる長繊維Bと、を含む混合長繊維からなるウェッブを捕集面上に堆積させた。
実施例1と同様にして、TPU(A−1)からなる長繊維Aと熱可塑性樹脂組成物(B−1)からなる長繊維Bとを含む混合長繊維からなるウエッブを捕集面上に第1層目として堆積させた。
実施例1の方法で製造したTPU(A−1)を、スクリュー径75mmφの単軸押出機を用いて溶融した。その後、紡糸口金を有するスパンボンド不織布成形機(捕集面上の機械の流れ方向に垂直な方向の長さ:800mm)を用いて、樹脂温度とダイ温度がともに205℃、冷却風温度20℃、延伸エアー風速3200m/分の条件でスパンボンド法により溶融紡糸し、TPU(A−1)からなる長繊維Aを捕集面上に堆積させた。この堆積物をエンボスロールで加熱加圧処理(エンボス面積率18%、エンボス温度107℃)したところ、堆積物がエンボスロールに付着してしまい、所望のTPU単体不織布を作製することができなかった。
実施例1で製造した低結晶性ポリプロピレンを、スクリュー径75mmφの単軸押出機を用いて溶融した。その後、紡糸口金(ダイ、孔数808ホール)を有するスパンボンド不織布成形機(捕集面上の機械の流れ方向に垂直な方向の長さ:800mm)を用いて、樹脂温度とダイ温度がともに215℃、冷却風温度20℃、延伸エアー風速3750m/分の条件でスパンボンド法により溶融紡糸し、低結晶性ポリプロピレン単体不織布を捕集面上に堆積させた。この堆積物をエンボスロールで加熱加圧処理(エンボス面積率18%、エンボス温度70℃)したところ、堆積物がエンボスロールに付着してしまい、所望の低結晶性ポリプロピレン単体不織布を作製することができなかった。
MFR(ASTM D1238に準拠して、温度230℃、荷重2.16kgで測定)8.5g/10分、密度0.91g/cm3、融点160℃のプロピレン単独重合体(以下「重合体IA」)を50mmφの押出機を用いて溶融し、それとは独立してMFR(ASTM D1238に準拠して、温度230℃、荷重2.16kgで測定)60g/10分、密度0.91g/cm3、融点160℃のプロピレン単独重合体(以下「重合体II」)を75mmφの押出機を用いて溶融した。その後、「重合体I」が芯、「重合体II」が鞘となるような同芯の芯鞘複合繊維の成形が可能な紡糸口金(ダイ、孔数2887ホール)を有するスパンボンド不織布成形機(捕集面上の機械の流れ方向に垂直な方向の長さ:800mm)を用いて、樹脂温度とダイ温度がともに250℃、冷却風温度20℃、延伸エアー風速3750m/分の条件でスパンボンド法により複合溶融紡糸を行い、芯部と鞘部の質量比が10/90の同芯の芯鞘型複合繊維からなるスパンボンド不織布(芯鞘スパンボンド不織布)を捕集面上に堆積させた。この堆積物をエンボスロールで加熱加圧処理(エンボス面積率18%、エンボス温度107℃)して、総目付量が60.0g/m2である芯鞘スパンボンド不織布単体を作製した。
実施例1で調製したTPU(A−1)と熱可塑性樹脂組成物(B−1)とを、それぞれ独立に75mmφの押出機及び50mmφの押出機を用いて溶融した。その後、紡糸口金を有するスパンボンド不織布成形機(捕集面上の機械の流れ方向に垂直な方向の長さ:800mm)を用いて、樹脂温度とダイ温度がとも205℃、冷却風温度20℃、延伸エアー風速3200m/分の条件でスパンボンド法により溶融紡糸し、TPU(A−1)からなる長繊維Aと熱可塑性樹脂組成物(B−1)からなる長繊維Bとを含む混合長繊維からなるウェッブを捕集面上に堆積させた。
目付が20.0g/m2となるようにした以外は比較例3と同様にして、芯鞘スパンボンド不織布を捕集面上に第1層目として堆積させた。
Claims (12)
- 下記(a)〜(f)を満たす低結晶性ポリプロピレンを含む弾性不織布と、前記弾性不織布の少なくとも片面側に配置され、熱可塑性エラストマー(A)の長繊維と、熱可塑性エラストマー以外の熱可塑性樹脂(B)の長繊維と、が10質量%〜90質量%:90質量%〜10質量%の割合(((A):(B)、但し(A)+(B)=100質量%とする)で含まれている混繊スパンボンド不織布と、を有し、前記熱可塑性エラストマー(A)が熱可塑性ポリウレタン系エラストマーを含む、不織布積層体。
(a)[mmmm]=20〜60モル%
(b)[rrrr]/(1−[mmmm])≦0.1
(c)[rmrm]>2.5モル%
(d)[mm]×[rr]/[mr]2≦2.0
(e)重量平均分子量(Mw)=10,000〜200,000
(f)分子量分布(Mw/Mn)<4
(a)〜(d)中、[mmmm]はメソペンタッド分率であり、[rrrr]はラセミペンタッド分率であり、[rmrm]はラセミメソラセミメソペンタッド分率であり、[mm]、[rr]及び[mr]はそれぞれトリアッド分率である。 - 熱可塑性樹脂(B)の長繊維が、スパンボンド不織布にした際の最大点伸度が50%以上である請求項1に記載の不織布積層体。
- 熱可塑性エラストマー(A)が、熱可塑性ポリウレタン系エラストマーである請求項1又は請求項2に記載の不織布積層体。
- 前記熱可塑性ポリウレタン系エラストマーが、示差走査熱量計(DSC)により測定される凝固開始温度が65℃以上であり、かつ細孔電気抵抗法に基づき100μmのアパーチャーを装着した粒度分布測定装置で測定されるジメチルアセトアミド溶媒不溶分の粒子数が300万個/g以下である請求項3に記載の不織布積層体。
- 前記熱可塑性ポリウレタン系エラストマーが、下記の関係式(I)を満たす熱可塑性ポリウレタン系エラストマーである請求項3又は請求項4に記載の不織布積層体。
a/(a+b)≦0.8 (I)
(式中、aは、DSCにより測定される90℃〜140℃の範囲に存在する吸熱ピークから求められる融解熱量の総和を表し、bは、DSCにより測定される140℃を超えて220℃以下の範囲にある吸熱ピークから算出される融解熱の総和を表す。) - 熱可塑性樹脂(B)が、ポリオレフィンである請求項1〜請求項5のいずれか1項に記載の不織布積層体。
- 熱可塑性樹脂(B)が、プロピレン系重合体である請求項1〜請求項6のいずれか1項に記載の不織布積層体。
- 熱可塑性樹脂(B)が、プロピレン系重合体99〜80質量%と高密度ポリエチレン1〜20質量%とからなる請求項1〜請求項7のいずれか1項に記載の不織布積層体。
- 請求項1〜請求項8のいずれか1項に記載の不織布積層体を延伸加工して得られる伸縮性不織布積層体。
- 請求項1〜請求項8のいずれか1項に記載の不織布積層体又は請求項9に記載の伸縮性不織布積層体を含む繊維製品。
- 請求項1〜請求項8のいずれか1項に記載の不織布積層体又は請求項9に記載の伸縮性不織布積層体を含む吸収性物品。
- 請求項1〜請求項8のいずれか1項に記載の不織布積層体又は請求項9に記載の伸縮性不織布積層体を含む衛生マスク。
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