JP6994182B2 - Composite laminate - Google Patents

Description

The present invention relates to a composite laminate. More specifically, it is an elastic composite laminate for applications such as clothing that adheres to the skin, specifically underwear, sportswear, diapers for children and adults, and sanitary materials such as sanitary products. It relates to a composite laminate having elasticity that can be preferably used.

Conventionally, elastic materials have been used in order to improve the feeling of wearing and the stability of wearing in applications such as sanitary materials such as disposable diapers that are in close contact with the skin.

For example, in disposable diapers, a composite laminate in which elastic fibers are inserted into a laminated non-woven fabric is used to improve the fit with the body such as undercarriage, abdominal circumference, and waist circumference, or to prevent urine leakage. I came.

A composite laminate having such elasticity is often manufactured by stretching a plurality of elastic fibers into a predetermined draft and laminating them with a plurality of fabric sheets such as non-woven fabric while maintaining the state, and the composite laminate is manufactured. The morphology had a hot melt resin extending in a direction parallel to the elastic fibers in a fabric sheet such as a non-woven fabric. This type of composite laminate is often used for disposable diapers and is the mainstream of gather members.

Further, a composite laminate having a heat-fused fiber extending in a direction intersecting with an elastic fiber in a cloth sheet such as a non-woven fabric as in Patent Documents 1 to 3 has also been devised.

Japanese Unexamined Patent Publication No. 2013-202056 Japanese Unexamined Patent Publication No. 2005-320636 Japanese Unexamined Patent Publication No. 2014-076077

However, while all of these composite laminates have improved functions such as elasticity and feel in recent years, their appearance and aesthetics have not been sufficiently satisfactory. That is, it was insufficient to be used for advanced paper diaper products that can be used as underwear, let alone apparel products such as sportswear.

The main reason for the inadequate appearance is that the presence of elastic fibers in the composite laminate can be clearly visually identified. This point becomes even more remarkable by giving priority to the feel and the like and reducing the basis weight of the non-woven fabric. The main reason for poor aesthetics is that the folds of the composite laminate are irregular and exhibit the surface or contour morphology peculiar to disposable diapers.

The appearance and aesthetics of the composite laminate are one of the most important factors in developing advanced disposable diaper products and clothing applications. The biggest factor in recognizing a diaper from its looks is that the folds of the composite laminate are irregular and the presence of elastic fibers can be clearly visually identified. In particular, when the composite laminate is stretched, the elastic fibers at the time of stretching are exposed (peeling phenomenon) in the garment fabric, and the presence of the elastic fibers is further present at the time of wearing, that is, in the stretched state of the composite laminate. It stands out and makes its appearance unsatisfactory. Then, even if an attempt is made to impart design by dyeing or printing in order to improve this, the elastic fibers are raised in stripes or streaks, making it difficult to express the intended color or pattern.

Thus, the prior art does not neglect the appearance and aesthetics of the composite laminate, with excellent fit and feel when worn, a homogeneous appearance with inconspicuous elastic fibers and smooth, well-regular folds. It was not possible to obtain a composite laminate having the above. Even if such a technology is applied as it is, it is not possible to achieve both the functionality required for advanced disposable diaper products and clothing and the sophistication of appearance and aesthetics.

The present invention achieves both functionality, appearance and aesthetics required for obtaining advanced disposable diaper products and clothing, that is, excellent fit and feel when worn, and elastic fibers are conspicuous. It is an object of the present invention to provide a composite laminate having a uniform appearance and smooth and well-regular folds.

As a result of diligent studies to solve the above problems, the present inventors have found a form in which the presence of elastic fibers in the composite laminate is difficult to discriminate because of the high expansion and contraction function. That is,
Elastic fibers arranged in parallel in one direction between two fabrics,
A composite laminate having a plurality of resins arranged in a direction intersecting with elastic fibers and extending in one direction.
The two fabrics and the elastic fiber are separated from each other at the intersection of the resin extending in one direction and the elastic fiber adjacent to each other in the longitudinal direction of the elastic fiber.
The projected thickness X in the direction perpendicular to the length direction of the elastic fibers constituting the composite laminate measured by the scanning electron microscope and the direction perpendicular to the length direction of the fibers distributed on the surface of the fabric constituting the composite laminate. A composite laminate having a projected thickness ratio X / Y of 1 or more and 200 or less, which is obtained from the projected thickness Y of the above.

The color difference ΔE between the elastic fiber and the fabric is preferably 10 or less.

Further, the thickness at the intersection of the resin extending in one direction and the elastic fiber is 0.1 mm or more and 5.0 mm or less, and the maximum value of the thickness between the portions adjacent to each other in the longitudinal direction of the elastic fiber is It is preferably 1 mm or more and 20 mm or less.

Further, it is preferable that the width of the resin extending in one direction is 0.2 mm or more and 10 mm or less at the time of maximum extension, and the distance between the resins is 1 mm or more and 20 mm or less at the time of maximum extension.

Further, it is preferable that the heat softening point of the elastic fiber is 100 ° C. or higher and 240 ° C. or lower.

Further, it is preferable that the resin extending in one direction, which is arranged in a plurality of directions intersecting with the elastic fibers, contains a component of the cloth and / or the elastic fibers.

According to the present invention, it is possible to obtain a composite laminate having excellent elasticity and feel, and having a uniform appearance in which elastic fibers are inconspicuous and smooth and well-regular folds. By using such a composite laminate of the present invention, it is possible to achieve both the functionality, that is, the excellent fit and feel when worn, and the appearance and aesthetics required for clothing and advanced disposable diaper products. ..

Is an external photograph of the test piece of the composite laminate of Example 1 taken from a substantially plane direction. Is an external photograph of the test piece of the composite laminate of Example 1 taken from a substantially cross-sectional direction. A indicates the thickness at the intersection of the resin extending in one direction and the elastic fiber, and B indicates the measurement point of the maximum thickness between the intersections of the resin extending in one direction and the elastic fiber.

As a result of diligent studies to solve the above problems, the present inventors have found a form in which the presence of elastic fibers in the composite laminate is difficult to discriminate because of the high expansion and contraction function. That is,
Elastic fibers arranged in parallel in one direction between two fabrics,
A composite laminate having a plurality of resins arranged in a direction intersecting with elastic fibers and extending in one direction.
The elastic fibers are separated from each of the two fabrics facing each other with the elastic fibers sandwiched between the intersections of the resin extending in one direction and the elastic fibers adjacent to each other in the longitudinal direction of the elastic fibers.
The projected thickness X in the direction perpendicular to the length direction of the elastic fibers constituting the composite laminate and the surface of the fabric constituting the composite laminate, which are measured by a scanning electron microscope (hereinafter, may be abbreviated as SEM). It is a composite laminate in which the projected thickness Y in the direction perpendicular to the length direction of the fibers distributed in the above is obtained, and the projected thickness ratio X / Y is 1 or more and 200 or less.

By adopting such a configuration, the composite laminate of the present invention not only has an appearance as if it does not contain elastic fibers, but also expands and contracts for the hand under reflected light, and further, it is assumed that the composite laminate is stretched to the maximum extent. However, it has been found that it becomes difficult to determine that the composite laminate of the present invention contains elastic fibers, and that the elastic function originally possessed by the elastic fibers is also remarkably exhibited.

First, the form of this composite laminate will be described.

In the present invention, there are a plurality of elastic fibers arranged in parallel in one direction between two fabrics. The elastic fibers are arranged in a linear or curved shape or a combination thereof, and are sandwiched between fabrics.

In the present invention, the present invention has a plurality of resins arranged in a direction intersecting the elastic fibers and extending in one direction. That is, the resin is arranged in a direction intersecting the direction in which the elastic fiber is inserted. Here, extending in one direction means that the resin is linear and is arranged in one direction as a whole. The linear form may be linear, curved, or a combination thereof. Arranging in one direction as a whole means that the linear form is arranged so as to be within the range of parallel lines within a width of 10 mm, and the one-way direction means that the virtual parallel lines are arranged. Refers to the direction. The angle at which the elastic fiber and the resin extending in one direction intersect is not particularly limited, but is preferably 90 ± 20 °, more preferably 90 ± 10 °, and even more preferably 90 ± 5 °.

In the present invention, each cloth and the elastic fiber are separated from each other at the intersection of the resin extending in one direction and the elastic fiber adjacent to each other in the longitudinal direction of the elastic fiber.

The thickness between the intersections of the resin extending in one direction and the elastic fibers is preferably 0.1 mm or more and 5.0 mm or less, and more preferably 0.2 mm or more and 4.0 mm or less. If it is smaller than 0.1 mm, the presence of elastic fibers in the composite laminate may be visually discernible, and when the composite laminate is stretched, the presence of elastic fibers can be discriminated more prominently. The appearance and aesthetics of the composite laminate may be reduced. If it is larger than 5.0 mm, the formed folds may be easily deflated, and the fit when worn and the feel of smooth and regular folds may be unsatisfactory.

The maximum value of the thickness of the elastic fibers adjacent to each other in the longitudinal direction is preferably 1 mm or more and 20 mm or less, and more preferably 2 mm or more and 10 mm or less. If it is smaller than 1 mm, the presence of elastic fibers in the stretched composite laminate may be clearly visually discernible, and when the composite laminate is elongated, the presence of elastic fibers can be discriminated more prominently. , The appearance and aesthetics of the composite laminate may be reduced. If it is larger than 20 mm, the formed folds may be easily deflated, and the fit when worn and the feel of smooth and regular folds may be unsatisfactory.

The width of the resin extending in one direction is preferably 0.2 mm or more and 10 mm or less at the time of maximum elongation, and more preferably 0.4 mm or more and 6 mm or less. If it is smaller than 0.2 mm, the elastic fibers in the composite laminate are easy to move, and when the composite laminate is repeatedly expanded and contracted, the uniformity of the folds is lowered or the adjacent elastic fibers are in close proximity to each other, and the presence thereof can be visually identified. In some cases, the appearance and aesthetics of the composite laminate may be reduced. If it is larger than 10 mm, the presence of elastic fibers may be easily noticeable in streaks or stripes when the composite laminate is viewed with transmitted light. In addition, the elongation of the composite laminate may decrease and the placement size may increase, or the fit when worn and the feel of smooth and regular folds may be unsatisfactory.

The distance between the resins extending in one direction is preferably 1 mm or more and 20 mm or less at the time of maximum elongation, and more preferably 2 mm or more and 15 mm or less. The distance between the resins extending in one direction means the distance between the centers of the resins extending in one direction. When the interval is smaller than 1 mm, the presence of elastic fibers in the composite laminate may be clearly visually discernible, and when the composite laminate is elongated, it is more remarkable, and the appearance of the composite laminate and the appearance of the composite laminate are remarkably and. The aesthetics may be reduced. If it is larger than 20 mm, the formed folds may be easily deflated, and the fit when worn and the feel of smooth and regular folds may be unsatisfactory.

Next, the pitch between the elastic fibers is preferably 0.5 mm or more and 10 mm or less, and more preferably 1 mm or more and 8 mm or less. In particular, when the fineness range of the elastic fibers is 44 dtex to 250 dtex or less, the pitch between the elastic fibers is set to 2 mm or more and 6 mm or less, so that a composite laminated body having particularly excellent fold regularity can be obtained. The pitch between elastic fibers means the distance between the centers of two adjacent elastic fibers. If the pitch is smaller than 0.5 mm, the elastic fibers come into contact with each other and easily break the yarn when the composite laminate is formed. Further, if the pitch is larger than 10 mm, the regularity of the folds of the composite laminate is disturbed, and the appearance and feel and the fit when made into a disposable diaper may be impaired.

The cloth used for the composite laminate of the present invention is preferably a woven fabric, a knitted fabric, a non-woven fabric, or the like, and a particularly preferable cloth is a non-woven fabric, which is a wet non-woven fabric manufacturing method such as a papermaking method or a resin bond type, a thermal bond type, or a needle punch type. , Spunbond method, spunlace method, melt blow method, flash spinning method and other dry non-woven fabric manufacturing methods, which may be a single layer or a plurality of laminates. good.

The material of the fibers constituting the fabric is not particularly limited, but polyester, polyamide, polyacrylonitrile, polypropylene, polyethylene, various α-olefin copolymers such as propylene and ethylene, synthetic fibers such as polyurethane, and recycled fibers such as rayon and acetate, Semi-synthetic fibers, natural fibers such as wool and cotton are preferable.

The form of the fibers constituting the fabric may be either a long fiber filament or a short fiber spun yarn, and two or more kinds of fibers are blended or blended, crimped, or otherwise composite. A wide selection of fibers and the like can be made.

In the composite laminate of the present invention, elastic fibers are used at least in part.

The elastic fiber used in the present invention is a polyurethane-based elastic fiber, a polyether / ester-based elastic fiber, a polyamide-based elastic fiber, a thread-like so-called rubber thread made of natural rubber, synthetic rubber, or semi-synthetic rubber, and further. Fibers obtained by cutting an elastomer film into fibers, fibers obtained by combining or mixing with other organic synthetic resin bodies mainly composed of these, crimped fibers, etc. can be adopted, and the fibers themselves have enthalpy elasticity. More preferred. Polyurethane-based elastic fibers are most preferable from the viewpoint of better exhibiting elasticity as a composite laminate.

The elastic fiber used in the composite laminate of the present invention may be a bare yarn or may be coated (covered) with another elastic fiber or a non-elastic fiber. From the viewpoint of elasticity as a composite laminate, bare yarn is most preferable.

The polyurethane-based elastic fiber is a polyester mainly composed of a long-chain diol such as copolyesterdiol as a soft segment, a diisocyanate such as diphenylmethane-4,4 diisocyanate as a hard segment, and a bifunctional hydrogen compound as a chain extender. Polyester-based elastic fibers having polytetramethylene ether glycol as a soft segment, diphenylmethane-4,4 diisocyanate as a hard segment, and a low-molecular-weight bifunctional hydrogen compound as a chain extender are preferable.

Further, the polyether / ester-based elastic fiber preferably contains polytetramethylene ether glycol as a soft segment and polybutyl terephthalate or polybutyl isophthalate as a hard segment as main constituents.

In the present invention, it is preferable to use polyurethane-based elastic fibers from the viewpoint of imparting desired elasticity to the final product.

The polyurethane polymer used for the polyurethane-based elastic fiber that can be used in the present invention is a soft segment containing a long-chain polyether segment, a polyester segment, a polyether ester segment, or the like as a main constituent, an isocyanate, and a chain extender. It is preferably composed of a hard segment containing a diamine or a diol as a main component.

The raw materials constituting the soft segment of such a polyurethane polymer are 1) a polymer or a copolymer obtained from tetrahydrofuran, tetramethylene glycol, 3-methyl-1,5-pentanediol, tetrahydrofuran, 3-methyltetra and the like. A certain polyether segment, 2) a polyester segment obtained from a diol such as ethylene glycol, tetramethylene glycol, 2,2-dimethyl-1,3-propanediol and a dibasic acid such as adipic acid and succinic acid, 3) poly. Polyether ester segments obtained from-(pentan-1,5-carbonate) diols, poly- (hexane-1,6-carbonate) diols and the like can be used, among which the polyether segments obtained from tetramethylene glycol, That is, polytetramethylene ether glycol (hereinafter abbreviated as PTMG) is preferable.

In the elastic fiber used for the composite laminate of the present invention, the polyurethane polymer is a prepolymer product obtained by subjecting a hydroxyl-terminated soft segment precursor to a double addition reaction with an organic diisocyanate (capping reaction) to obtain an amine chain extender or an amine chain extender. It can be obtained by chain extension with a diol chain extender. Further, for the purpose of adjusting the thermal softening point, it is also preferable to further react the prepolymer product with an organic diisocyanate and then react with a chain extender.

Examples of the organic diisocyanate used for the polyurethane polymer in the present invention include bis- (p-isocyanatophenyl) -methane (hereinafter abbreviated as MDI), tolylene diisocyanate (hereinafter abbreviated as TDI), and bis- (4-). Isocyanatocyclohexyl) -methane (hereinafter abbreviated as PICM), hexamethylene diisocyanate, 3,3,5-trimethyl-5-methylenecyclohexyldiisocyanate and the like can be used, but MDI is particularly preferable.

Various diamines such as ethylenediamine, 1,3-cyclohexanediamine, 1,4-cyclohexanediamine and the like are preferably used as an amine chain extender for forming polyurethane urea.

The amine chain extender is not limited to only one type of diamine, and may be composed of a plurality of types of amines. The chain terminator can be included in the reaction mixture to help regulate the final molecular weight of the polyurethane urea. Usually, a monofunctional compound having active hydrogen, such as diethylamine, can be used as the chain terminator.

Further, the chain extender is not limited to the above amine, and may be a diol. In particular, it is suitable for obtaining elastic fibers having a thermal softening point of 100 ° C to 180 ° C. For example, ethylene glycol, 1,3-propanediol, 1,4-butanediol, neopentyl glycol, 1,2-propylene glycol, 1,4-cyclohexanedimethanol, 1,4-cyclohexanediol, 1,4-bis. (Β-Hydroxyethoxy) benzene, bis (β-hydroxyethyl) terephthalate, paraxylylene diol and the like can be used. The diol chain extender is not limited to only one type of diol, and may be composed of a plurality of types of diols. Further, it may be used in combination with a compound containing one hydroxyl group that reacts with an isocyanate group. In this case, various methods such as a melt polymerization method and a solution polymerization method can be adopted as the method for obtaining such polyurethane, and the method is not limited. The formulation of the polymerization is not particularly limited, and for example, a method of synthesizing polyurethane by simultaneously reacting a polyol, diisocyanate, and a chain extender composed of a diol can be adopted, and any method can be used. It may be a thing.

Further, it is also preferable to add a stabilizer, a thermal conductivity improver and a pigment within a range that does not impair the effects of the present invention.

For example, as light-resistant agents and antioxidants, hindered phenolic agents such as so-called BHT and "Smilizer (registered trademark)" GA-80 manufactured by Sumitomo Chemical Industries, Ltd., and "Chinubin (registered) manufactured by BASF" Benzoliazole-based, benzophenone-based agents, phosphorus-based agents, various hindered amine-based agents, fluororesin powders or silicone-based resin powders based on polyvinylidene fluoride, metal soaps such as magnesium stearate, etc. Also, various charges such as bactericides and deodorants containing silver, zinc and these compounds, lubricants such as silicone and mineral oil, barium sulfate, cerium oxide, betaine and phosphoric acid compounds, and phosphoric acid ester compounds. An inhibitor or the like may be added, or it may be present by reacting with a polymer. In particular, in order to further enhance the durability against light and various nitrogen oxides, nitrogen oxide scavengers such as HN-150 manufactured by Nippon Hydrazine Co., Ltd. and "Hostanox (registered trademark)" SE10 manufactured by Clariant Corporation can be used. It is preferable to contain a thermal oxidation stabilizer or the like.

Then, in order to promote melting and thermal softening, it is preferable to contain, for example, alumina, boron nitride, aluminum nitride, silica, silicon nitride, magnesium oxide, magnesium carbonate, silicon carbide and the like as a thermal conductivity improver.

For example, as the pigment, it is preferable to contain titanium oxide, zinc oxide, zirconium phosphate and the like. Of these, titanium oxide is preferable from the viewpoint of suppressing glare caused by peeling of elastic fibers and obtaining a composite laminate having a uniform appearance in which elastic fibers are inconspicuous. As long as it is titanium oxide, either rutile type or anatase type is preferably used. Further, from the viewpoint of suppressing light reflection and stably producing polyurethane-based elastic fibers, it is preferable that the average primary particle size is in the range of 0.15 μm to 0.3 μm. Further, the content in the polyurethane-based elastic fiber is preferably 0.3% by mass or more from the viewpoint of preventing glare, and from the viewpoint of preventing clogging of the base and stably spinning the polyurethane-based elastic fiber. It is preferably 3% by mass or less.

Then, in order to promote melting and thermal softening, it is preferable to contain, for example, alumina, boron nitride, aluminum nitride, silica, silicon nitride, magnesium oxide, magnesium carbonate, silicon carbide and the like as a thermal conductivity improver.

As the solvent used when the polyurethane polymer is used as a solution, N, N-dimethylacetamide (hereinafter abbreviated as DMAc), dimethylformamide, dimethyl sulfoxide, N-methylpyrrolidone and the like can be used, but DMAc is used. It is the most commonly used solvent.

As the solution concentration of the polyurethane polymer, a dry spinning method for obtaining filament yarns of polyurethane-based elastic fibers at a solution concentration of 30 to 50% by mass (based on the total mass of the solution) is preferable.

In the present invention, the method for spinning polyurethane-based elastic fibers from a polyurethane polymer is not particularly limited, but for example, 1) melt spinning as a method for spinning polyurethane-based elastic fibers using a diol as a chain extender. A method, a dry spinning method, a wet spinning method, or the like can be adopted. 2) As a method for spinning polyurethane elastic fibers using amine as a chain extender, a normal dry spinning method can be adopted.

In the present invention, it is preferable to use a polyurethane-based elastic fiber filament yarn from the viewpoint of high elasticity, particularly elastic recovery stress, but the elastic fiber itself tends to be conspicuous. Therefore, the following fiber specifications and combinations are preferable.

The fineness of the fibers and elastic fibers constituting the fabric can be appropriately selected depending on the intended use, but is preferably in the range of 0.1 to 5000 decitex.

The fineness of the fibers constituting the fabric is more preferably 0.1 to 500 decitex, and even more preferably 0.3 to 30 decitex.

The fineness of the elastic fiber is more preferably 1 to 3000 decitex, further preferably 10 to 200 decitex. In the present invention, the fineness of the elastic fiber is the apparent fineness measured according to ISO2060, and the measuring method is as follows. The elastic fiber sample used for measuring the apparent fineness is a sample that has been allowed to stand in an environment of 20 ° C. and 65% relative humidity for 24 hours. The elastic fiber is cut to a length d (unit: m) under no load, and the thread mass (g) × 10000 ÷ d of apparent fineness (decitex) = length d (m) is obtained up to one digit after the decimal point. Here, the length d is usually 0.1 m, but it does not have to be one continuous fiber, and the total length d'of a plurality of fibers may be 0.1 m. In this case, when the elastic fiber sample is taken out from the composite laminate, the elastic fibers arranged between the two fabrics may be sampled from a position separated from each fabric. For example, a composite laminate is cut with a scissors along a plurality of resins arranged in a direction intersecting the elastic fibers and extending in one direction, and elastic fiber pieces having a good linear shape have a total length. Measure the dimensions with an optical microscope until it reaches 0.1 ± 0.01 m, select a plurality of elastic fiber pieces, and obtain the total length d'. Next, a method of measuring the total mass of a plurality of elastic fiber pieces selected with a precision balance and calculating the total mass (g) × 10000 ÷ d'of the elastic fiber pieces to obtain the fineness of the elastic fibers can be mentioned.

When elastic fibers with a fineness of less than 10 decitex are used, the elastic fibers tend to be unable to withstand the running friction and yarn breakage tends to occur, and when elastic fibers exceeding 5000 decitex are used, the elastic fibers tend to be easily broken during production. , The sensor side cannot withstand the running friction and tends to be damaged.

In the composite laminate of the present invention, the color difference ΔE between the elastic fiber and the fabric is preferably 10 or less.

The color difference referred to here is a value calculated from each value of the L value, the a value, and the b value in the Lab color system described later by the formula described later. When the color difference ΔE is 10 or less, the elastic fibers are not conspicuous when the composite laminate is stretched, and the aesthetics when worn are maintained.

In the present invention, the elastic fiber may be a raw yarn, and it is also preferable to use a pre-colored fabric and fibers constituting the fabric. The method for coloring the fabric and the fibers constituting the fabric is not particularly limited, but from the viewpoint of coloring the fabric in the same color as the elastic fibers, it is also preferable to color the fabric by cheese dyeing or the like in which the color can be adjusted.

The L value, a value, and b value in the Lab color system are defined as values obtained by measuring as follows.

A 10 g card-shaped sample of the fiber to be measured is wound on a stainless steel plate and measured using a non-contact spectrocolorimeter (for example, a color master D25 DP-9000 type signal processor) (note that a will be described later). The value and b value are also obtained from this measurement).

Here, the L value in the Lab color system is an index representing the brightness as described above, the a value is an index representing the position between red and green, and the b value is an index representing the position between yellow and blue. Similar to the above L value, each of these values is a value obtained by winding 10 g of the fiber or fabric to be measured on a stainless steel plate as a card-shaped sample and measuring it using a non-contact spectrocolorimeter. Define.
When the color difference ΔE is larger than 10, the elastic fibers in the composite laminate can be visually confirmed regardless of the projected thickness ratio, and the aesthetics may be impaired.

The elastic fibers used in the present invention are preferably those having no practical problems including process passability and having excellent morphology at the intersection of the resin extending in one direction and the elastic fibers. From the viewpoint of obtaining, it is preferable that the thermal softening point is in the range of 100 ° C. or higher and 240 ° C. or lower. If the heat softening point is lower than 100 ° C, the morphology may be destroyed by the processing process such as dyeing or practically by tumbler drying, and if it is higher than 240 ° C, the resin extending in one direction and the elastic fiber intersect. The presence of elastic fibers at the site may be conspicuous, resulting in an unsatisfactory appearance, or the thickness of the laminate may become too large. The range of the thermal softening point is more preferably 110 ° C. or higher and 200 ° C. or lower, and further preferably 120 ° C. or higher and 160 ° C. Within this range, using known methods such as thermal rolls, ultrasonic welders, high-frequency welders, electromagnetic induction welders, and composite welders thereof, a plurality of fibers are arranged in a direction intersecting the elastic fibers and spread in one direction. It is suitable for the existing resin to be thermally softened or melted by the elastic fiber and / or the material constituting the cloth.

In the cloth used for the composite laminate of the present invention, there is a resin extending in one direction in which a plurality of fibers are arranged in a direction intersecting with the elastic fibers, and the resin is a hot melt adhesive, a solvent-based adhesive, or the like. Various adhesives, elastic fibers and / or materials constituting the fabric are heat-softened or melted.

When the material constituting the fabric is heat-softened or melted, various known methods such as heat embossing and ultrasonic fusion can be adopted.

It is also preferable that a mechanical entanglement method such as a needle punch or a water jet is added to the region of the resin extending in one direction.

Further, a resin preferable as a resin extending in one direction is a resin containing the same kind of material as the cloth or elastic fiber in order to enhance the effect of the present invention, and more preferably contains a component of the cloth or elastic fiber. preferable. When a resin containing a component of such a cloth or elastic fiber is used as the resin extending in one direction, it is also preferable to heat-soften or melt the cloth or elastic fiber to form a resin extending in one direction. It is more preferable that both the fabric and the elastic fiber are thermally softened or melted.

The composite laminate of the present invention is a stretchable composite laminate, which is clothing that adheres to the skin, specifically underwear, sportswear, or diapers for children and adults, menstrual products, masks, and medical wear. , Suitable for use in surgical gowns, bandages, sanitary materials such as supporters, medical materials, etc. Furthermore, because of its excellent aesthetics, interior products such as curtains and furniture, bedding, linings, girdles, brassieres, inti Applications include diaper products, clothing waistbands, stretch sportswear, stretch outerwear, etc.

Hereinafter, the present invention will be described with reference to examples.

[Projection thickness ratio]
The projection thickness X in the direction perpendicular to the length direction of the elastic fibers constituting the composite laminate and the projection thickness Y in the direction perpendicular to the length direction of the fibers distributed on the surface of the fabric constituting the composite laminate are scanning type. Measured with an electron microscope. In this example, the measurement was performed using the S-2380N type manufactured by Hitachi, Ltd.

In order to measure the projected thickness X (hereinafter abbreviated as elastic fiber thickness X) in the direction perpendicular to the length direction of the elastic fibers constituting the composite laminated body in the composite laminated layer, the composite laminated body is peeled off and elastic. The fibers were exposed and observed at 50 times with SEM, and the thickness X of the elastic fibers was measured. At this time, 5 points were randomly measured and the average value was calculated. Next, in order to measure the projected thickness Y (hereinafter abbreviated as the thickness Y of the fabric surface fibers) in the direction perpendicular to the length direction of the fibers distributed on the surface of the fabric constituting the composite laminate, the composite laminate The surface of the fabric was observed at a magnification of 50 times using SEM, and the thickness Y of the fabric surface fibers was measured. At this time, 5 points were randomly measured and the average value was calculated.
The projected thickness ratio was obtained from the measured X and Y by the following equation (1).

Projected thickness ratio Z = Elastic fiber thickness X / Fabric surface fiber thickness Y (1)
[Thermal softening point]
The thermal softening point was measured as one of the indexes of the heat resistance of the elastic fiber. For the elastic fibers, the temperature dispersion of the dynamic storage elastic modulus E'was measured at a heating rate of 10 ° C./min using a dynamic elastic modulus measuring machine RSAII manufactured by Leometric. The thermal softening point was determined from the intersection of the tangent line in the plate region where the E'curve is 80 ° C. or higher and 130 ° C. or lower and the tangent line of the E'curve where E'falls due to thermal softening at 160 ° C. or higher. The logarithmic axis was used for E', and the linear axis was used for the temperature.

[Color measurement]
A sample card was prepared by winding 10 g of the fiber to be measured on a stainless steel plate. The L value, a value, and b value in the Lab color system were measured using a color master (D25 DP-9000 type signal processor) as a non-contact spectrocolorimeter. Further, the color difference “ΔE” between the target fibers was calculated from the following formula.

ΔE = √ ((L2-L1) ² + (a2-a1) 2+ (b2-b1) ² )
(L1, a1, b1) is the measured value of the elastic fiber, and (L2, a2, b2) is the measured value of the cloth or the fiber constituting the cloth.

[Appearance evaluation of composite laminate]
A sensory evaluation was performed by 10 judges to visually observe and judge whether the elastic fibers inserted into the laminate were inconspicuous from above the laminate. In addition, the judgment results are displayed in the following categories.

◎: I felt that more than 8 people were inconspicuous.

○: Less than 8 people and 6 or more people felt that they were not noticeable.

Δ: Less than 6 people and 4 or more people felt that they were not noticeable.

×: Less than 4 people felt inconspicuous.

[Evaluation of fold regularity of composite laminate]
In the relaxed composite laminate, a sensory evaluation was performed in which 10 judges visually observed and determined whether the folds generated in the composite laminate had regularity. In addition, the judgment results are displayed in the following categories.

◎: More than 8 people felt that there was regularity.

○: Less than 8 people and 6 or more people felt that there was regularity.

Δ: Less than 6 people and 4 or more people felt that there was regularity.

×: Less than 4 people felt regularity.

[Feeling evaluation of laminated body]
The laminate was touched with bare hands, and a sensory evaluation was performed in which 10 judges judge the flexibility felt from the touch. In addition, the judgment results are displayed in the following categories.

◎: More than 8 people felt that they were flexible.

○: Less than 8 people 6 or more felt flexible.

Δ: Less than 6 people and 4 or more people felt that they were flexible.

×: Less than 4 people felt flexible.

[Evaluation of elasticity of laminated body]
The relaxed laminated body was expanded and contracted with bare hands, and a sensory evaluation was performed in which 10 judges determine the elasticity of the laminated body. In addition, the judgment results are displayed in the following categories.

◎: More than 8 people felt that the elasticity was excellent.

◯: Less than 8 people and 6 or more people felt that the elasticity was excellent.

Δ: Less than 6 people and 4 or more people felt that the elasticity was excellent.

×: Less than 4 people felt that the elasticity was excellent.

[Fitness: Degree of dispersion of tightening force of disposable diapers]
A sensory evaluation was performed in which 10 judges pressed the laminated body used for the gathered part of the disposable diaper against the skin to observe whether it felt difficult to get into the human skin. In addition, the judgment results are displayed in the following categories.

◎: I felt that it was difficult for 8 or more people to bite in.

○: Less than 8 people and 6 or more people felt that it was difficult to bite.

Δ: Less than 6 people and 4 or more people felt that it was difficult to bite.

×: I felt that it was difficult for less than 4 people to bite.

[Example 1]
Elastic fiber used: "Lycra® fiber" T-127C manufactured by Toray Operontex Co., Ltd.
The fineness of the elastic fiber: 78dtex
Number of elastic fibers constituting the elastic fiber beam: 76 Fiber length of elastic fiber wound on the bobbin as an elastic fiber beam: 20,000 m
Bobbin used: Aluminum collared bobbin (cylinder outer diameter 20 cmφ, winding width 22.5 cm, collar outer diameter 38.0 cmφ)
Tape used: Cloth adhesive tape (width 2.5 cm, length 24.5 cm)
Nonwoven fabric used: PP spunbond, fineness of fibers existing on the surface 2dtex, basis weight 16g / m ²
Projected thickness ratio Z = Elastic fiber thickness X / Fabric surface fiber thickness Y
= 930 μm / 21 μm
= 44
According to the method of JP-A-2005-320636, 38 elastic fiber wound fibers are arranged on a delivery roller and unwound and supplied at the same speed, and 76 elastic fibers are evenly arranged in parallel within a width of 20 cm. The elastic fiber beam winding body was prepared by winding it on the bobbin in a beam state and winding the elastic fiber having a fiber length of 20,000 m. Before winding on the bobbin, a cloth adhesive tape was attached over the beam width at a position 200 cm from the winding start end of the elastic fiber beam. Further, a cloth adhesive tape was attached over the beam width at a position 300 cm from the end of winding.

From the polyurethane-based elastic fiber beam winder, 76 polyurethane-based elastic fibers were unwound and supplied so that the fiber speed was 66.7 m / min. Two non-woven fabric winders were unwound and supplied so that the linear velocity of the non-woven fabric was 100 m / min. A polyurethane-based elastic fiber in which the pitch between the elastic fibers is divided into 2 mm by a fiber division guide is arranged between the two supplied non-woven fabrics so as to be arranged in parallel. According to the method, a composite laminate having a width of 2 mm for the resin coating strip-shaped coating surface in the direction orthogonal to the transfer direction of the laminate and a blank portion between the resin strip-shaped coating surfaces of 6 mm is produced using a design roller coating device. Then, ordinary paper diapers were manufactured.

The prepared composite laminate was soft to the touch and highly flexible, and elastic fibers could not be visually confirmed.
Table 1 shows the specifications of the composite laminate and the determination results of the composite laminate and the disposable diaper. In the table, the fineness of the fibers existing on the surface of the non-woven fabric is abbreviated as fineness. In addition, the measurement points for "the thickness at the intersection of the resin extending in one direction and the elastic fiber" and "the maximum value of the thickness between the intersection of the resin extending in one direction and the elastic fiber" are shown in FIG. As shown in.

[Example 2]
A composite laminate and a disposable diaper were produced in the same manner as in Example 1 except that the elastic fibers were changed to the following.
Elastic fiber used: "Lycra® fiber" T-127C manufactured by Toray Operontex Co., Ltd.
The fineness of the elastic fiber: 44dtex
Projected thickness ratio Z = Elastic fiber thickness X / Fabric surface fiber thickness Y
= 679 μm / 21 μm
= 32
The prepared composite laminate was soft to the touch and highly flexible, and elastic fibers could not be visually confirmed.

Table 1 shows the specifications of the composite laminate and the determination results of the composite laminate and the disposable diaper.

[Example 3]
The composite laminate and the disposable diaper were produced in the same manner except that the elastic fibers and the number of elastic fibers were changed to the following with respect to Example 1 and the pitch between the elastic fibers was changed by 4 mm.
Elastic fiber used: "Lycra® fiber" T-127C manufactured by Toray Operontex Co., Ltd.
The fineness of the elastic fiber: 156 dtex
Number of elastic fibers constituting the elastic fiber beam: 38 Projected thickness ratio Z = Elastic fiber thickness X / Fabric surface fiber thickness Y
= 1240 μm / 21 μm
= 59
The prepared composite laminate was soft to the touch and highly flexible, and it was difficult to visually confirm the elastic fibers.

Table 1 shows the specifications of the composite laminate and the determination results of the composite laminate and the disposable diaper.

[Example 4]
A composite laminate and a disposable diaper were produced in the same manner except that the elastic fibers and the number of elastic fibers were changed to the following with respect to Example 1.
Elastic fiber used: "Lycra® fiber" T-127 manufactured by Toray Operontex Co., Ltd.
The fineness of the elastic fiber: 78dtex
Number of elastic fibers constituting the elastic fiber beam: 76 Projected thickness ratio Z = Elastic fiber thickness X / Fabric surface fiber thickness Y
= 935 μm / 21 μm
= 45
The prepared composite laminate was soft to the touch and highly flexible, and it was difficult to visually confirm the elastic fibers.

Table 1 shows the specifications of the composite laminate and the determination results of the composite laminate and the disposable diaper.

[Example 5]
The elastic fibers were changed to the elastic fibers manufactured by the following method with respect to Example 1, and the composite laminate and the disposable diaper were manufactured in the same manner except that the ultrasonic welder was used from the design roller device when the composite laminate was produced.

MDI was charged in a container so as to be 1.6 mol with respect to 1 mol of PTMG having a number average molecular weight of 2000, reacted at 70 ° C., and the obtained reaction product was sufficiently stirred with N, N-dimethylacetamide (DMAc). , Dissolved to obtain a solution. Next, 0.4 mol of MDI was added to 1 mol of PTMG having a number average molecular weight of 2000, and the mixture was sufficiently stirred. Next, a DMAc solution containing 1,4-butanediol as a chain extender was added, and the mixture was sufficiently stirred. Further, a DMAc solution containing butanol as a terminal sequestering agent was added to prepare a polyurethane solution pu1 having a polymer solid content of 35% by mass. The resulting solution had a viscosity of about 3300 poise at 40 ° C. The polymer had an intrinsic viscosity of 0.88 as measured in DMAc at a solution concentration of 0.5 g / 100 ml at 25 ° C.

Next, as an antioxidant, a polyurethane solution ("Metachlor (registered trademark)" 2462D manufactured by DuPont) produced by the reaction of t-butyl diethanolamine and methylene-bis- (4-cyclohexyl isocyanate) was used. A condensation polymer of p-cresol and divinylbenzene ("Metachlor (registered trademark)" 2390D manufactured by Dupont Co., Ltd.) was mixed in a ratio of 2: 1 (mass ratio), and an antioxidant DMAc solution (concentration: 35% by mass) was mixed. Was adjusted, and 96 parts by mass of the polyurethane solution pu1 and 4 parts by mass of the antioxidant solution were mixed to obtain a polymer solution (A1). Next, as white pigments, titanium oxide "TIPAQUE (registered trademark)" PF-711 manufactured by Ishihara Sangyo Co., Ltd. and anhydrous magnesium carbonate "Magnesium (registered trademark)" manufactured by Kamishima Chemical Co., Ltd. were dispersed in DMAc at a mass ratio of 1: 1 to a concentration of 35. A mass% DMAc dispersion (B1) was prepared. Further, a 35% by mass DMAc dispersion (C1) composed of ferric oxide, iron oxyhydroxide, and carbon black was prepared as a coloring pigment.

The polymer solutions A1, B1 and C1 were mixed at a ratio of 98.7% by mass, 1.0% by mass and 0.3% by mass, respectively, to prepare a fiber stock solution push1. This push1 is discharged from a spinning fiber cap into an inert gas (nitrogen gas) at a high temperature (350 ° C.) with 5 filaments, dried by passing through the high temperature gas, and an air jet so that the fibers in the process of drying are twisted together. Five filaments were coalesced through a formula twisting fiber machine and wound at a speed of 600 m / min to produce 78 dtex polyurethane elastic fiber (PU1).

The thermal softening point of this polyurethane elastic fiber (PU1) was 151 ° C.
Projected thickness ratio Z = Elastic fiber thickness X / Fabric surface fiber thickness Y
= 930 μm / 21 μm
= 44
The prepared composite laminate was soft to the touch and highly flexible, and it was difficult to visually confirm the elastic fibers.

Table 1 shows the specifications of the composite laminate and the determination results of the composite laminate and the disposable diaper.

[Example 6]
Example 1 except that the resin coating strip-shaped coating surface in the direction orthogonal to the transfer direction of the composite laminate was set to 5 mm width and the blank portion between the resin strip-shaped coating surfaces was set to 8 mm by using the design roller coating device. The composite laminate was produced in the same manner as in the above, and then a normal disposable diaper was produced.
Projected thickness ratio Z = Elastic fiber thickness X / Fabric surface fiber thickness Y
= 933 μm / 21 μm
= 44
Table 1 shows the specifications of the composite laminate and the determination results of the composite laminate and the disposable diaper.

[Example 7]
A composite laminate and a disposable diaper were produced in the same manner except that the non-woven fabric was changed to the following non-woven fabric with respect to Example 3.
Nonwoven fabric used: PP spunbond, fineness of fibers present on the surface 0.7 dtex, basis weight 16 g / m ²
Projected thickness ratio Z = Elastic fiber thickness X / Fabric surface fiber thickness Y
= 1240 μm / 10 μm
= 124
Table 1 shows the specifications of the composite laminate and the determination results of the composite laminate and the disposable diaper.

[Example 8]
The composite laminate and the disposable diaper were produced in the same manner except that the elastic fibers and the number of elastic fibers were changed to the following with respect to Example 7 and the pitch between the elastic fibers was changed to 6 mm.
Elastic fiber used: "Lycra® fiber" T-127C manufactured by Toray Operontex Co., Ltd.
The fineness of the elastic fiber: 230dtex
Number of elastic fibers constituting the elastic fiber beam: 24 Projected thickness ratio Z = Elastic fiber thickness X / Fabric surface fiber thickness Y
= 1488 μm / 10 μm
= 149
Table 1 shows the specifications of the composite laminate and the determination results of the composite laminate and the disposable diaper.

[Example 9]
The composite laminate and the disposable diaper were produced in the same manner except that the elastic fibers and the number of elastic fibers were changed to the following with respect to Example 7 and the pitch between the elastic fibers was changed to 8 mm.
Elastic fiber used: "Lycra® fiber" T-127C manufactured by Toray Operontex Co., Ltd.
The fineness of the elastic fiber: 310dtex
Number of elastic fibers constituting the elastic fiber beam: 20 Projected thickness ratio Z = Elastic fiber thickness X / Fabric surface fiber thickness Y
= 1860 μm / 10 μm
= 186
Table 1 shows the specifications of the composite laminate and the determination results of the composite laminate and the disposable diaper.

[Comparative Example 1]
The composite laminate and the disposable diaper were produced in the same manner except that the elastic fibers and the number of elastic fibers were changed to the following with respect to Example 3 and the pitch between the elastic fibers was changed to 12 mm.
Elastic fiber used: "Lycra® fiber" T-127C manufactured by Toray Operontex Co., Ltd.
The fineness of the elastic fiber: 470dtex
Number of elastic fibers constituting the elastic fiber beam: In the prepared composite laminate, the elastic fibers were clearly confirmed from the appearance, and the fit of the paper diaper was inferior.
Table 1 shows the specifications of the composite laminate and the determination results of the composite laminate and the disposable diaper.

[Comparative Example 2]
The composite laminate and the disposable diaper were manufactured in the same manner as in Example 1 except that the resin coating method was changed to the curtain spray method and the resin coating amount was 5 g / m ² per fabric area.

Table 1 shows the specifications of the composite laminate and the determination results of the composite laminate and the disposable diaper.

[Comparative Example 3]
The composite laminate and the disposable diaper were manufactured in the same manner as in Example 5 except that the resin coating method was changed to the curtain spray method and the resin coating amount was 5 g / m ² per fabric area.

Table 1 shows the specifications of the composite laminate and the determination results of the composite laminate and the disposable diaper.

Claims (6)

Elastic fibers arranged in parallel in one direction between two fabrics,
A composite laminate having a plurality of resins arranged in a direction intersecting with elastic fibers and extending in one direction.
The two fabrics and the elastic fiber are separated from each other at the intersection of the resin extending in one direction adjacent to each other in the longitudinal direction of the elastic fiber and the elastic fiber.
The projected thickness X in the direction perpendicular to the length direction of the elastic fibers constituting the composite laminate measured by the scanning electron microscope and the direction perpendicular to the length direction of the fibers distributed on the surface of the fabric constituting the composite laminate. A composite laminate having a projected thickness ratio X / Y of 1 or more and 200 or less and a color difference ΔE between the elastic fiber and the fabric of 10 or less, which is obtained from the projected thickness Y of the above. Elastic fibers arranged in parallel in one direction between two fabrics,
It has a resin extending in one direction, which is arranged in a direction intersecting with the elastic fiber.
It is a composite laminate,
The two fabrics and the elastic fiber are separated from each other at the intersection of the resin extending in one direction adjacent to each other in the longitudinal direction of the elastic fiber and the elastic fiber.
The projected thickness X in the direction perpendicular to the length direction of the elastic fibers constituting the composite laminate measured by the scanning electron microscope and the direction perpendicular to the length direction of the fibers distributed on the surface of the fabric constituting the composite laminate. A composite laminate having a projected thickness ratio X / Y of 1 or more and 200 or less and a thermal softening point of elastic fibers of 100 ° C. or more and 240 ° C. or less, which is obtained from the projected thickness Y of the above. Elastic fibers arranged in parallel in one direction between two fabrics,
It has a resin extending in one direction, which is arranged in a direction intersecting with the elastic fiber.
It is a composite laminate,
The two fabrics and the elastic fiber are separated from each other at the intersection of the resin extending in one direction adjacent to each other in the longitudinal direction of the elastic fiber and the elastic fiber.
The projected thickness X in the direction perpendicular to the length direction of the elastic fibers constituting the composite laminate measured by a scanning electron microscope and the direction perpendicular to the length direction of the fibers distributed on the surface of the fabric constituting the composite laminate. The projected thickness ratio X / Y determined from the projected thickness Y of the above is 1 or more and 200 or less, and a plurality of resins arranged in a direction intersecting the elastic fibers and extending in one direction are made of cloth and / or elastic. A composite laminate that contains fiber components. The thickness at the intersection of the resin extending in one direction and the elastic fiber is 0.1 mm or more and 5.0 mm or less.
The composite laminate according to any one of claims 1 to 3 , wherein the maximum value of the thickness between the portions adjacent to each other in the longitudinal direction of the elastic fiber is 1 mm or more and 20 mm or less. The width of the resin extending in one direction is 0.2 mm or more and 10 mm or less at the maximum elongation.
The composite laminate according to any one of claims 1 to 4, wherein the resin spacing is 1 mm or more and 20 mm or less at the time of maximum elongation. The composite laminate according to any one of claims 1 to 5 , wherein the pitch between the elastic fibers is 0.5 mm or more and 10 mm or less.

Images