JPH02229252A - Surface-material for sanitary goods and production thereof - Google Patents

Abstract

PURPOSE:To obtain the subject surface-material having high strength and high permeability of urine, etc., while preventing the deterioration of feeling by interlocking a fiber group constituting a melt-blow nonwoven fabric with a continuous fiber group constituting a spun-bond nonwoven fabric in a specific manner. CONSTITUTION:A melt-flow nonwoven fabric 2 is laminated to a spun-bond nonwoven fabric 1. The laminate is place on a porous sheet 8 and blasted with high-pressure fluid flow 9 to exhaust the fluid flow through the pores of the porous sheet 8. The ultrafine fiber group 4 and continuous fiber group existing at the position corresponding to the pore of the porous sheet 8 are interlocked with each other by the pressure of the fluid flow 9 in the course of moving toward the non-porous part of the porous sheet 8.

Description

[Detailed description of the invention] [Industrial application field]

The present invention relates to a surface material for sanitary products such as sanitary belts for women and disposable diapers used for urinating and defecating for infants or sick people, and which has particularly high strength, good texture and overall texture, and is suitable for use in urination and defecation. The present invention relates to surface materials for sanitary products that have good permeability.

[Conventional technology]

In recent years, spunbond nonwoven fabrics and meltblown nonwoven fabrics have been used as surface materials for sanitary products such as disposable diapers. An example of using a spunbond non-woven fabric is described in Japanese Utility Model Publication No. 59-9620, and an example of using a melt-blown non-woven fabric is described in JP-A-62-29.
It is described in Publication No. 9501. Spunbond ant-free fabric is obtained by directly assembling continuous fibers that are spun from a polymer stock solution and then drawn. Methods for producing spunbond nonwoven fabrics are known, for example, as described in Japanese Patent Publication No. 37-4993. It is described in Japanese Patent Publication No. 49-30861. The continuous fibers that make up the spunbond nonwoven fabric are drawn, and the polymer chains are oriented and have a high degree of crystallinity, so they exhibit high strength. Therefore, the spunbond nonwoven fabric itself has the advantage of being high in strength. Taking advantage of this advantage, it is used as a surface material for sanitary products, but on the other hand, it has the disadvantage of being unpleasant to the touch. This is because it is difficult to obtain ultrafine fibers in the production of spunbond nonwoven fabrics, and the surface cannot be finished smoothly. On the other hand, melt-blown nonwoven fabric is made by blowing a polymer stock solution through pores with a high-speed gas (for example, heated air) and collecting the resulting ultrafine fibers. Methods for producing melt-blown nonwoven fabrics are also known, for example, as disclosed in Japanese Patent Publication No. 56-335.
1.1 and Japanese Patent Publication No. 62-2062. The fibers constituting the melt-blown nonwoven fabric generally have a very thin fiber diameter. Therefore, the surface of the melt-blown nonwoven fabric has the advantage of being excellent in smoothness and having a good texture. However, the ultrafine fibers constituting the melt-blown nonwoven fabric are not sufficiently drawn during manufacture and have low strength, and therefore the melt-blown nonwoven fabric itself has a disadvantage of having low strength. That is, when a spunbond nonwoven fabric is used as a surface material for sanitary products, it has the disadvantage of being uncomfortable to the touch, and when a meltblown nonwoven fabric is used as a surface material for sanitary products, it has a disadvantage of low strength.

[Problem to be solved by the invention]

In order to eliminate these drawbacks, it is thought that by laminating spunbond nonwoven fabrics and meltblown nonwoven fabrics, a surface material with good texture and high strength can be obtained (for example,
(See Japanese Patent Publication No. 60-11148). However, when a melt-blown nonwoven fabric and a spunbond nonwoven fabric are bonded together using an adhesive, the resulting surface material is hardened as a whole due to the presence of the adhesive, resulting in a decrease in texture and poor texture. there were. It is also possible to obtain a surface material by softening or melting either the melt-blown nonwoven fabric or the spunbond nonwoven fabric, and then thermocompressing the two completely or partially, but the softened or melted nonwoven fabric hardens. In some cases, the texture deteriorates and the texture becomes worse. Furthermore, because melt-blown nonwoven fabrics are made up of a collection of ultrafine fibers, the fiber gaps are very small, and although they feel good against the skin, they have the disadvantage of being difficult for urine, etc. to pass through. Therefore, the present invention involves entangling the continuous fibers constituting the spunbond nonwoven fabric and the fibers constituting the melt-blown nonwoven fabric in a specific manner, using an adhesive or softening or melting the constituent fibers. By bonding the two and providing small holes at the same time, we aim to avoid deterioration in texture, provide a surface material for sanitary products that is strong, feels good on the skin, and has good permeability to urine, etc. It is something.

Means and Effects for Solving the Problems That is, the present invention provides a laminate of a spunbond nonwoven fabric made up of a group of continuous fibers and a meltblown nonwoven fabric made of a group of ultrafine fibers, the laminate comprising: has many small pore areas where the continuous fiber group and the ultra-fine fiber group are not substantially present, and the small pore area has the continuous fiber group and the ultra-fine fiber group densely packed together and tightly entwined with each other. The present invention relates to a surface material for sanitary products, characterized in that it is surrounded by joined connecting areas, and a method for producing this surface material. The surface material of the sanitary product according to the present invention has a form as schematically shown in FIGS. 1 and 2. The first is a plan view of this surface material, and the second is a central cross-sectional end view thereof. The surface material of the sanitary product according to the present invention includes a spunbond nonwoven fabric (1) in which continuous fibers (3) are accumulated and ultrafine fibers (4).
) are laminated together with the melt-blown nonwoven fabric (2). As the continuous fibers (3), polyolefin fibers, polyester fibers, polyamide fibers, etc. are used. Further, as the ultrafine fiber (4), polyolefin fiber, polyester fiber. Polyamide fibers and the like are used. Spunbond nonwoven fabric (1) and meltblown nonwoven fabric (2)
The laminate (7) has a large number of pore areas (5). This pore area (5) is substantially free of continuous fibers (3) and ultrafine fibers (4). Here, "substantially absent" does not mean that continuous fibers (3) or ultrafine fibers (4) are not present at all, but rather that continuous fibers (
Compared to the connected area (6) where groups of 3) and ultrafine fibers (4) are densely packed, there is a very small amount of continuous fibers (3) or ultrafine fibers (3) or ultrafine fibers (4).
This means that only 4) exists. The shape of the small hole area (5) is a long side shape. Any shape such as an ellipse, a circle, a polygon, etc. can be adopted. The size of this small hole area (5) is preferably about 0.1 to 11. When the size of the small pore area (5) is less than 0.1, it tends to be difficult for urine etc. to pass through this area (5). Also,
If the size of the small pore area (5) exceeds 1-, the permeability of urine, etc. will be good, but there is a risk that the urine, etc. that has once passed through will flow back. The density or number of pore areas (5) is 50
About 200 pieces/cd is preferable. When the number of small pore areas (5) is less than 50/cti, urine etc. tend to be difficult to pass through. Also, the pore area (
5) tends to be difficult to produce in excess of 200 pieces/cd due to the manufacturing method. This stoma area (5) is surrounded by a connecting area (6). The connected area (6) is an area where the continuous fiber (3) group and the ultrafine fiber (4) group are densely packed, and the continuous fiber (3) group and the ultrafine fiber (4) group are closely entwined with each other. It matches. Due to this entanglement, the spunbond nonwoven fabric (1) and the meltblown nonwoven fabric (2), which are laminates, are firmly integrated and become difficult to separate. Connected area (6)
may have any shape, for example, it may be a regular lattice shape as shown in FIG. 1, or it may be an oblique lattice shape (not shown). Note that a surfactant may be added to the surface material of the sanitary product according to the present invention. This is because the surfactant improves the wettability of the surface material and improves the permeability of urine and the like. Such a surface material for sanitary products according to the present invention is manufactured, for example, by the method shown below. First, a spunbond nonwoven fabric (1) is prepared. As the continuous fibers (3) constituting this spunbond nonwoven fabric (1), it is preferable to use polyolefin continuous fibers of 1 to 4 deniers. If the polyolefin continuous fiber is less than 1 denier, the fiber tends to be easily cut. In addition, if the polyolefin continuous fiber exceeds 4 denier,
The stiffness of the fibers increases, which tends to lead to a decrease in texture. Furthermore, the basis weight of the spunpond nonwoven fabric (1) is 8 to 2.
Preferably it is 8 g/%. When the basis weight is less than 8 g/rrf, the spunbond nonwoven fabric (1) tends to become thinner and its strength decreases. Moreover, when the basis weight exceeds 28 g/nf, there is a tendency for excessive quality to occur. A melt-blown nonwoven fabric (2) is laminated on the surface of this spunbond nonwoven fabric (1) to obtain a laminate. As the ultrafine TA fibers (4) constituting the melt-blown nonwoven fabric (2), it is preferable to use polyolefin ultrafine fibers, and the fiber diameter is preferably less than 1 denier. If the fiber diameter of the ultrafine fibers (4) is 1 denier or more, the surface smoothness of the melt-blown nonwoven fabric (2) obtained by accumulating the ultrafine fibers (4) tends to decrease. In addition, melt-blown nonwoven fabric (
The basis weight of 2) is preferably 0.2 to 10 g/bo.
If the basis weight is less than 0.2 g/rd, the nonwoven fabric will be too thin,
There is a tendency for the poor surface smoothness of the spunbond nonwoven fabric ( ) to manifest as it is. On the other hand, the basis weight is 10g/
Exceeding rrf tends to result in excessive quality. Spunbond nonwoven fabric (1) and meltblown nonwoven fabric (2)
As for the method of laminating the spunbond nonwoven fabric (1), the melt-blown nonwoven fabric (2) obtained in advance may simply be laminated on the surface of the spunbond nonwoven fabric (1). Alternatively, as shown in FIG. 3, a melt-blown non-woven fabric (2) may be laminated by blowing and accumulating ultrafine fibers (4) obtained by a melt-blowing method on the surface of a spun-bonded non-woven fabric (1). Furthermore, in the latter method, while the ultrafine fibers (4) obtained by the melt-in-place method are still sticky, the ultrafine fibers (4) are sprayed onto the surface of the spunbond nonwoven fabric (1), Continuous fiber (
3) is preferable. This is ultrafine fiber (
4) adheres to the continuous fibers (3) of the spunbond nonwoven fabric (1) due to its adhesiveness, and the ultrafine fibers (4) are accumulated on the surface of the spunbond nonwoven fabric (1) to become a meltblown nonwoven fabric (2), This is because the melt-blown nonwoven fabric (2) is laminated and bonded to the spunbond nonwoven fabric (1). In particular, if both the continuous fibers (3) and the ultrafine fibers (4) are made of polyolefin, the affinity will be good and the adhesive strength between them will be high. (2
) because the bonding strength of the two is increased. The thus obtained laminate of the spunbond nonwoven fabric (1) and the melt-blown nonwoven fabric (2) is a porous sheet (8
) is placed on top. The porous sheet (8) is a metal plate having predetermined holes, Kisaka. A plastic plate or the like may be used, and a mesh-like plastic sheet, a plastic net, a mesh knitted fabric, or the like, in which the mesh portions are holes, may be used. Note that this porous sheet (8) has non-porous areas outside the pores. Since small pore areas (5) are formed in the laminate at positions corresponding to the pores, the size of the pores is preferably about 0.1 to 11, and the density of the pores, i.e. The number is preferably about 50 to 200 pieces/c1A. After the laminate is placed on the perforated sheet (8), the laminate is impinged with a high pressure fluid stream (9). High pressure fluid flow (9)
is obtained by ejecting a fluid such as water at high pressure through a nozzle hole with a fine diameter. Specifically, using a nozzle with a nozzle hole diameter of about 0.001 to 0.1 cm, the pressure is 5 to 400 kg/cd, preferably 5 to 80 kg/cd.
This can be obtained by spouting water at a certain level. and,
Immediately after the high-pressure fluid stream (9) impinges on the laminate, this fluid stream (9) is discharged from the pores of the porous sheet (8). The high-pressure fluid stream (9) may impinge on any surface of the laminate, but it is preferable to impinge on the melt-blown nonwoven fabric (2) surface. When a high-pressure fluid stream (9) collides with the surface of the spunbond nonwoven fabric (2), the fluid stream (9) is discharged from the surface of the meltblown nonwoven fabric (2), and the ultrafine fibers constituting the meltblown nonwoven fabric (2) This is because since (4) is discontinuous, there is a risk that it will flow out together with the fluid flow (9). In this way, a high pressure fluid stream (9) is impinged on the laminate;
When immediately discharged from the pores of the porous sheet (8), the ultrafine fibers (4) and continuous fibers (3) in the laminate located at positions corresponding to the pores of the porous sheet (8) are removed by the fluid flow. (
It moves to the non-porous part of the porous sheet (8) under the pressure of 9).
That is, the ultrafine fiber (4) group and the continuous fiber (3) group are gathered in the non-porous portion of the porous sheet (8). This high-pressure fluid flow (9) causes the ultrafine fibers (4) to
The groups and continuous fibers (3) move together and become tightly entangled with each other. In addition, in the method shown in FIG. 3, a high-pressure fluid flow (9
) is directly collided with the laminate, and then the fluid flow (9) is discharged from the opposite side of the collided through the pores of the porous sheet (8). High pressure fluid flow (9) passes through the pores of the sandwiched and porous sheet (8).
) may be impinged on the laminate and the fluid stream (9) may be discharged through the pores of the porous sheet (8) from the same side as the impingement. By the above method, a large number of small pore areas (5) are formed at positions corresponding to the holes of the porous sheet (8).
A laminate (7) of a spunbond nonwoven fabric (1) and a meltblown nonwoven fabric (2) is obtained, consisting of a connecting zone (6) surrounding a Finishing is performed to make the surface material for sanitary products.For finishing, a surfactant may be added to the product (7) to improve its permeability to urine, etc., and it may also be made flexible. A softener may be applied to the laminate (7) in order to improve the laminate (7).Also, a small amount of adhesive may be applied to suppress fuzz on the surface of the laminate (7). The surface material of the sanitary product according to the above is used so that the melt-blown nonwoven fabric (2) side is in contact with the skin.

【Example】

28% polypropylene resin (melt index 30)
The fibers are heated and melted at 0°C, extruded using an extruder, spun and stretched to obtain continuous fibers of a predetermined denier, which are assembled on a collector wire to form sheets into various spunbond nonwoven fabrics as shown in Table 1. I got it. In addition, the unit of basis weight is g
/rd. Next, polypropylene resin (melt index 130
) is heated and melted at 290°C, extruded with an extruder, passed through a spinneret, and the resin is blown away with high-temperature, high-velocity hot air to obtain ultrafine fibers of a predetermined denier. Various melt-blown nonwoven fabrics were obtained as shown in Table 1. Note that the distance from the spinneret to the surface of the spunbond nonwoven fabric was 15 cm. Next, a laminate consisting of spunbond nonwoven fabric and meltblown nonwoven fabric was coated with 40 mesh (pore size is approximately 0.4-mesh).
) was placed on a plastic net. Then, nozzles with a nozzle diameter of 0.1 amφ are arranged in parallel,
From a nozzle die with a distance between nozzles of 2aI1, a pressure of 30
Water was ejected at a rate of kg/d, and a high-pressure fluid stream impinged on the melt-blown nonwoven fabric surface of the laminate. Then, the fluid stream was immediately discharged from the holes in the plastic net. This treatment was performed using a high-pressure fluid flow, and Table 1 shows those treated (with treatment) and those without treatment (no treatment). Table 1: The fluff, overall flexibility, and water permeability of the surface materials of these Examples and Comparative Examples were measured. The results are shown in Table 2. In addition, fuzz etc. were measured using the following test method. - Fluffing: The surface was rubbed several times by hand, and then the degree of surface fluffing was visually examined. ◎...Very good, 0-...Good, Δ...Slightly bad. ×...Poor - Surface flexibility of the entire surface material; tested by sensory test by touch. ◎...Very good, 0-...Good. Δ...Slightly poor, ×...Poor/Water permeability; The surface material, etc. according to the example was immersed in a surfactant solution (manufactured by Sanyo Chemical Industries, trade name: Sunsilicant 84, concentration 0.3%). , dehydrated and dried to prepare a sample. This sample was placed on a water-absorbent sheet, 20 pieces of artificial urine were dropped onto the sample, and the time until the artificial urine was absorbed was measured. As is clear from these test results, it can be seen that the surface materials according to Examples have excellent water permeability, whereas the surface materials according to Comparative Examples have poor water permeability.

【Effect of the invention】

As explained above, the surface material of the sanitary product according to the present invention is made of a laminate of a spunbond nonwoven fabric and a meltblown nonwoven fabric. It imparts surface flexibility and good texture and texture. Therefore, if melt-blown nonwoven fabric is placed on the side that comes into contact with the skin and used as a surface material for sanitary products, it has the effect of being resistant to tearing and having a good texture. Also, what are spunbond nonwoven fabrics and meltblown nonwoven fabrics?
Without using adhesives or softening or melting the constituent fibers, the constituent fibers of both nonwoven fabrics, that is, the continuous fibers and the thin fibers, are tightly entangled with each other in the connection area, thereby making it possible to form a material. As a result, it exhibits drape properties similar to those of knitted fabrics, has excellent overall flexibility, and has a good texture. Furthermore, the surface material of the sanitary product according to the present invention is provided with small pore areas, through which excrement such as urine can pass through.
The effect is that urine etc. are quickly absorbed into the internal absorbent body.

[Brief explanation of the drawing]

FIG. 1 is a plan view of a surface material of a sanitary product according to an example of the present invention, and FIG. 2 is a cross-sectional end view of the same. FIG. 3 is a schematic diagram showing an example of an apparatus for producing a surface material for sanitary products according to the present invention. (1) - Subanbond nonwoven fabric, (2) Hemeltblown nonwoven fabric. (3) 1 continuous fiber, (4) 6 ultrafine fibers, 5 1 pore area, (6
) A series of connected areas, (7)・One laminate. (8)...One porous sheet, (9)...High pressure fluid flow

Claims (2)

[Claims] (1) A laminate of a spunbond nonwoven fabric in which a group of continuous fibers is accumulated and a melt-blown nonwoven fabric in which a group of ultrafine fibers is accumulated, wherein the laminate contains substantially the continuous fiber group and the ultrafine fiber group. It has a large number of small pore areas that do not exist in the fibers, and the small pore areas are surrounded by a connected area in which the continuous fiber group and the ultrafine fiber group are densely packed together and tightly entangled with each other. surface material for sanitary products. (2) A laminate is obtained by laminating a spunbond nonwoven fabric made of a group of continuous fibers and a melt-blown nonwoven fabric made of a group of ultrafine fibers, and the laminate is placed on a porous sheet and then subjected to high pressure. By impinging a fluid stream on the laminate and then discharging the fluid stream from the pores of the porous sheet, the continuous fibers in the laminate present at positions corresponding to the pores of the porous sheet and A method for manufacturing a surface material for sanitary products, characterized in that the ultrafine fiber group is gathered in a non-porous portion of the porous sheet, and the continuous fiber group and the ultrafine fiber group are tightly entangled with each other.