JPH09105060A - Laminated nonwoven fabric and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a laminated nonwoven fabric having excellent feeling and strength and suitable as an absorbing material such as a diaper and a sanitary good by laminating and integrating a spun-bond nonwoven fabric to a melt-blow nonwoven fabric. SOLUTION: A spun-bond nonwoven fabric is produced by producing a sheath-core conjugate fiber by the conjugate spinning of a high-density polyethylene as a low- melting component to form the sheath and a polypropylene as a high-melting component to form the core, sucking the fibers with an air sucker, depositing the fibers on a net conveyor to form a web of conjugate fiber filaments having a fineness of 0.5-10de/f and heat-treating the web to effect the thermal welding of the fibers with each other. Separately, a melt-blow nonwoven fabric having an apparent density of 0.02-0.20g/cm<3> is produced from ultrafine fibers having fiber diameter of 0.1-10μm and composed of e.g. an ethylene-propylene-butene-1 terpolymer compatible with the low-melting component of the conjugate fiber filament. The melt-blow nonwoven fabric is laminated to the spun-bond nonwoven fabric and the laminate is heat-treated or interlocked by a needle-punching or spun-lacing method to obtain the objective laminated nonwoven fabric having a peeling strength of >=6g/5cm, containing <=10/m<2> of polymer lumps having a fiber diameter of >=0.1mm and a lateral strength of >=0.6kg/5cm reduced to the areal density of 40g/m<2> .

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated nonwoven fabric and a method for producing the same, and more particularly to a multilayer nonwoven fabric in which a composite spunbonded nonwoven fabric and a melt blown nonwoven fabric are laminated. This non-woven fabric is suitably used as a material such as a surface material for absorbent articles such as disposable diapers and sanitary napkins.

[0002]

2. Description of the Related Art Spunbonded nonwoven fabrics have been used as a surface material for absorbent articles such as disposable diapers because they have no fluffing and are excellent in pulling resistance. However, it is difficult to reduce the fineness of the long fibers that make up this spunbond nonwoven fabric,
It is difficult to obtain a soft texture like a non-woven fabric made of ultrafine fibers. Further, in the spunbonded non-woven fabric, there is a problem that as the fineness becomes finer, monofilament breakage occurs, the fine-fineness yarns are mixed, and the texture is further deteriorated.

On the other hand, JP-A-54-134177 discloses melt-blown nonwoven fabrics made of polypropylene ultrafine fibers, which are disclosed in JP-A-62-299501 and JP-A-3-75056.
Each of the publications discloses a paper diaper using a melt blown nonwoven fabric as a surface material. Such a melt-blown nonwoven fabric has an advantage that it has a soft texture because it has a small fiber diameter, but has problems such as low nonwoven fabric strength, fluffiness, and easy hair removal. Moreover, polymer beads are likely to be generated during spinning, and there is a problem that it has a feeling of roughness and irritates the skin, and it is particularly unsuitable for disposable diapers for newborns. For the purpose of increasing the strength of the meltblown nonwoven fabric and preventing hair removal, it is also possible to perform pressure bonding with a heat calendar roll or heat embossing roll, but conversely it is necessary to treat the temperature and pressure under severe heat pressure bonding conditions. However, there is an inconvenience that the apparent density of the nonwoven fabric is increased and the texture is deteriorated.

In addition, Japanese Examined Patent Publication No. 60-11148 and Japanese Patent Laid-Open No. 2-148.
No. 112458 and JP-A-2-234967 disclose a laminated nonwoven fabric in which a spunbonded nonwoven fabric and a meltblown nonwoven fabric are laminated and both layers are heat-sealed with a heat calendar roll, a hot embossing roll or the like. Although this non-woven fabric has improved strength as compared with conventional single-layer non-woven fabric, it uses regular fibers as long fibers constituting a spunbonded non-woven fabric, and has poor fusion-bonding property on its laminated surface and still has anti-pulling property. Is bad. Further, what is crimped with a hot embossing roll has the same severe thermocompression bonding conditions as described above, and there are problems such as increasing the apparent density and deteriorating the texture.

[0005]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a laminated non-woven fabric which has high strength, soft texture, good resistance to plucking, rough feeling and no skin irritation, and a method for producing the same. .

[0006]

In order to solve the above problems, the invention claimed in the present application is as follows. (1) A nonwoven fabric having a multi-layer structure in which a composite spunbonded nonwoven fabric and a melt blown nonwoven fabric having an average fiber diameter of 10 μm or less are laminated, and the composite spunbonded nonwoven fabric is a composite long fiber in which a low melting point resin component and a high melting point resin component are combined. The low-melting resin component forms part of the fiber surface and is heat-sealed via the low-melting resin component, the melt-blown nonwoven fabric is heat-sealed, and the composite spunbond The non-woven fabric and the melt-blown non-woven fabric are integrated by fusing the low melting point resin component of the composite spun-bonded non-woven fabric and / or the resin component of the melt-blown non-woven fabric, and the peel strength of both layers is 6 g / 5 cm or more and the fiber diameter is 0. 1mm or more polymers ball has 10 / m ² or less, a is layered nonwoven fabric. (2) The fineness of the composite spunbonded nonwoven fabric is 0.5 to 10 d / f
The melt-blown non-woven fabric is made of ultrafine fibers with a fiber diameter of 0.1-10 μm, and the fiber diameter is 0.1 mm.
The number of polymer balls is 10 or less / m ² , the apparent density of the melt-blown nonwoven fabric is 0.02 to 0.20 g / cm ³ , and the lateral strength of the laminated nonwoven fabric is 40 g / m ² when converted to a lateral strength of 0. The laminated non-woven fabric according to (1), which has a weight of 6 kg / 5 cm or more. (3) A method for producing a laminated non-woven fabric, in which a spun bond non-woven fabric and a melt blown non-woven fabric are laminated and heated to heat-bond both non-woven fabrics, wherein the spun bond non-woven fabric comprises a composite fiber composed of a low melting point component and a high melting point component. The meltblown nonwoven fabric is the same as the low melting point component of the composite fiber constituting the spunbonded nonwoven fabric, or is composed of a fiber containing a component having an affinity with the low melting point component, and the heating temperature is equal to or higher than the melting point of the low melting point component, and is high. A method for producing a laminated non-woven fabric, which is less than the melting point of the melting point component. (4) The method for producing a laminated non-woven fabric according to (3), which includes a step of intertwining both the non-woven fabrics with a needle bunch or a spun lace means before or after the heating. (5) An absorbent article using the laminated nonwoven fabric according to (1) or (2) as at least one member. (6) A non-woven fabric having a multilayer structure according to (1) and (2), which is a two-layer structure non-woven fabric of a melt blown non-woven fabric and a composite spun bond non-woven fabric, or a three-layer non-woven fabric of melt blown non-woven fabric / composite spun bond non-woven fabric / melt blown non-woven fabric.
The absorbent article according to (5), which is used as at least one member that constitutes the absorbent article, and is used in which the side of the meltblown nonwoven fabric layer is in contact with the skin. (7) A low melting point resin component and a high melting point resin component are spun by a composite spun bond method so that the low melting point resin component forms a part of the fiber surface to form a web, or the web is heat-melted. A non-woven fabric in which fibers are heat-sealed by heating to a bonding temperature or higher, while a micro-fiber non-woven fabric in which ultra-fine fibers having an average fiber diameter of 10 μm or less are heat-sealed by a melt blow method is formed, A method for producing a laminated non-woven fabric having a peel strength of 6 g / 5 cm or more, comprising laminating an adhesive non-woven fabric and the microfiber non-woven fabric in multiple layers, and heating both layers to a temperature at which they are heat-sealed or higher. (8) The method for producing a laminated non-woven fabric according to (7), wherein the non-woven fabric produced by the melt-blowing method is a non-woven fabric in which the intersections of the fibers are heat-sealed by self-heating during melt-blowing spinning. (9) The meltblown nonwoven fabric and the spunbonded nonwoven fabric are laminated in a multilayer structure so that at least one surface layer thereof forms a spunbonded nonwoven fabric, and the laminated nonwoven fabric is spun with hot air using a through-air type heater. The method for producing a laminated non-woven fabric according to (7) or (8), wherein both layers are heat-sealed so as to jet from the bonded non-woven fabric side to the meltblown non-woven fabric side. (10) The method for producing a laminated nonwoven fabric according to (7), wherein the heat-sealing is performed by thermocompression bonding with an embossing roll in a thermocompression bonding area of 5 to 25%.

The multi-layered nonwoven fabric of the present invention may have at least a two-layer structure in which a composite spunbonded nonwoven fabric and a melt blown nonwoven fabric are laminated. When the use is as a surface material of a disposable diaper, 2-3 layers are preferable. The composite spunbonded non-woven fabric used for the multilayer structured non-woven fabric of the present invention is a non-woven fabric in which at least two kinds of resin components having a melting point difference of 10 ° C. or more are spun by the composite spunbond method and heat-bonded. The composite spunbond method is a method in which a plurality of resin components are melt-extruded from a plurality of extruders, and a plurality of components are mixed from a spinneret for composite spinning so that the low-melting resin component forms at least a part of the fiber surface. The fiber is spun and the spun fiber is drawn by an airflow towing type device such as an air sucker, and the fiber is collected together with the airflow by a web collecting device such as a net conveyor, and then the web is heated with air, a heating roll, etc., if necessary. This is a method for producing a heat-bonded nonwoven fabric by performing a process such as fusion bonding using the heating device. This resin component is practically 2 to 4
Any kind of resin can be used, and the difference between the highest melting point and the lowest melting point is 10 ° C. or more. But for most applications, two are sufficient.

The resin used in the present invention is not particularly limited as long as it is a spinnable thermoplastic resin. For example, polypropylene, high-density polyethylene, medium-density polyethylene, low-density polyethylene, linear low-density polyethylene, polyolefins such as binary copolymers of propylene and other α-olefins, polyamides, polyethylene terephthalate, polybutylene terephthalate A low melting point polyester obtained by copolymerizing diol and terephthalic acid / isophthalic acid, polyesters such as polyester elastomer, fluororesin, a mixture of the above resins, and other spinnable resins can be used.

The combination of resin components in the composite spinning is, for example, high-density polyethylene / polypropylene, low-density polyethylene / propylene / ethylene / butene-1 crystalline copolymer, high-density polyethylene / polyethylene terephthalate, nylon-6 / Examples thereof include nylon 66, low melting point polyester / polyethylene terephthalate, polypropylene / polyethylene terephthalate, polyvinylidene fluoride / polyethylene terephthalate, a mixture of linear low density polyethylene and high density polyethylene / polypropylene, and the like.

The form of the composite fiber may be any of sheath-core type, parallel type, multi-layer type, hollow multi-layer type and the like. The melting point difference between the low-melting point resin component and the high-melting point resin component needs to be 10 ° C. or higher, but if it is lower than 10 ° C., it is difficult to control the temperature by heat treatment during the production of a laminated nonwoven fabric with the composite spunbonded nonwoven fabric or the meltblown nonwoven fabric, The degree of heat fusion is insufficient, a high-strength non-woven fabric cannot be obtained, wrinkles are generated by high temperature heating, or the whole non-woven fabric is melted to form a partially non-woven fabric. In addition, the obtained multi-layered non-woven fabric has insufficient plucking resistance and is easily peeled off on the laminated surface.

In the composite fiber, the composite ratio of the low melting point resin component and the high melting point resin component is 10 to 90% by weight of the low melting point resin component and 90 to 10% by weight of the high melting point resin component. More preferably, the low melting point resin component is 30 to 70% by weight and the high melting point resin component is 70 to 30% by weight. When the low melting point resin component is less than 10% by weight, the heat fusion of the composite spunbonded nonwoven fabric itself may be insufficient, or the heat fusion of the nonwoven fabric and the melt-blown nonwoven fabric described later may be insufficient. Therefore, it is not possible to obtain a product having high strength and excellent resistance to plucking.

The fineness of the composite fiber is not particularly limited,
In the case of the surface material of a disposable diaper, the range of about 0.2 to 10 d / f is preferable. The basis weight of the spunbonded nonwoven fabric is not particularly limited, but is preferably about 4 to 1000 g / m ² . As the composite spunbonded nonwoven fabric, a stronger one can be obtained by using a heating machine such as a hot air through heating machine, a hot calendar roll, or a hot embossing roll. In the present invention, the strength of the non-woven fabric alone is adjusted to 0.6 kg / 5 cm by controlling the heating conditions and the like using the above-mentioned heater.
It is preferable to make the above.

In the present invention, the melt-blown nonwoven fabric is obtained by melt-extruding a thermoplastic resin, blow-spinning fibers spun from a melt-blowing spinneret with a gas at high temperature and high speed as an ultrafine fiber stream, and producing an ultrafine fiber web with a collecting device, A non-woven fabric is obtained by heat fusion treatment if necessary. As the resin, various resins such as those used in the above composite spunbond can be used. Further, as the gas used in the blow spinning, an inert gas such as air or nitrogen gas is usually used. The temperature of the gas is about 200 to 500 ° C., preferably about 250 to 450 ° C., and the pressure is about 0.1 to 6 kg / cm ² , preferably about 0.2 to 5.5 kg / cm ³ .

This non-woven fabric is composed of ultrafine fibers having an average fiber diameter of 10 μm or less. The thickness is preferably 0.1 to 9 μm, more preferably 0.2 to 8 μm. Fiber diameter is 10 μm
If it exceeds, the texture deteriorates. Further, those having a thickness of 0.1 μm or less cannot be used for absorbent articles and the like because they are difficult to manufacture and are expensive. Further, in the present invention, it is preferable that the non-woven fabric has an average fiber diameter of 10 μm or less and polymer beads of 10 pieces / m ² or less. Here, the polymer beads are non-fibrous shapes having a diameter of 0.1 mm or more, such as a circle, an ellipse, and a teardrop shape. When the amount of polymer beads is large, it cannot be used in applications where it directly touches the skin, such as the surface material of a paper diaper or the base fabric of a napkin, even if it has a soft texture, because it has a rough feeling and is irritating to the skin.

The melt-blown nonwoven fabric used in the present invention has its fiber intersections thermally fused. The heat fusion may be performed by self-heating during spinning, and heat through air after spinning,
It may be heat-fused by using a heating device such as a hot calender roll or a hot embossing roll. Although the nonwoven fabric of basis weight is not particularly limited, about 3~1000g / m ^2, about 3~60g / m ² when the surface material of paper diapers is preferred. The apparent density of the non-woven fabric is not particularly limited, but considering the texture, it is preferably about 0.02 to 0.40 g / cm ³ .

The laminated nonwoven fabric of the present invention is obtained by laminating the composite spunbonded nonwoven fabric and the melt blown nonwoven fabric and heating them by using a heating device such as hot through air, a heat calender roll, a hot embossing roll, and a sonic bond. It can be manufactured by fusing. Further, when the heat fusion is performed by the embossing roll, the thermocompression bonding area is preferably 5 to 25%. If the thermocompression bonding area is less than 5%, the yarn removal resistance and the strength of the nonwoven fabric are poor. If it exceeds 25%, the texture becomes hard. In the case of hot through-air heating, a meltblown non-woven fabric is obtained which is relatively sublime.

In this case, heat treatment is carried out so that heat from the side of the spunbonded nonwoven fabric having a relatively large fineness penetrates from the side of the meltblown nonwoven fabric having a small fineness, whereby the bulkiness and the texture of the meltblown nonwoven fabric are maintained and the heat is evenly distributed in both layers. In addition, the peel strength of both layers can be further increased. On the other hand, when the melt blown nonwoven fabric side is placed facing the hot air jetting side and heated through air, the hot air pressure and the suction conditions are appropriately set, and the single fibers of the melt blown ultrafine fibers bite into the spunbonded nonwoven fabric layer, In addition, since the inside of the spunbonded nonwoven fabric and the both layers are heat-fused double, the peeling strength of both layers can be controlled. After laminating both nonwoven fabrics, a water column entanglement treatment or the like may be performed by a needle punching method or a spunlace method, and then heat treatment may be performed to obtain a material having a strong peeling strength. The heating temperature may be equal to or higher than the temperature at which the low melting point resin component of the composite fiber forming the composite spunbonded nonwoven fabric is softened and lower than the melting point of the high melting point component of the composite fiber forming the spunbonded nonwoven fabric. At the time of heating both layers, the fibers of the laminated non-woven fabrics or both of the non-woven fabrics can also serve as heat fusion. In the present invention, the peel strength is about 6 to 5000 g / 5 cm, preferably about 10 to 400.
It is 0 g / 5 cm. If the peeling strength is less than 6 g / 5 cm, both layers are easily peeled off by rubbing, so it cannot be used as a surface material for paper diapers and the like.

The laminated nonwoven fabric of the present invention utilizes the high tenacity of the composite spunbonded nonwoven fabric.
It is preferable that the lateral strength when converted to m ² is 0.6 kg / 5 cm or more. Here, the lateral strength means the so-called cross machine direction (CD) of the spunbonded nonwoven fabric layer. When the spunbonded nonwoven fabric layer is a multilayer, it means the lesser of the longitudinal or transverse strength. Also, the apparent density of the melt-blown nonwoven fabric after lamination is 0.02 to 0.20 g /
A cm ³ is particularly preferable because the soft texture of the ultrafine fibers constituting the meltblown nonwoven fabric can be used for various purposes, for example, as the surface material of a paper diaper.

The laminated nonwoven fabric of the present invention is used for various purposes by itself, or by laminating, sewing, heat-sealing with other members. For example, when it is used as one member of a pants-type disposable diaper, it can be used for a part that requires relatively water repellency, for example, an inner member near the trunk, an inner member near the legs, and the like. In the case where the vicinity of the leg portion is provided with a strip-shaped three-dimensional barrier for preventing liquid leakage inside thereof, the three-dimensional barrier material can be used, for example, by heat fusion with other members. Of course, when used in the diaper or the like, an elastic member or the like for tightly adhering the body and legs can be used in combination with the laminated nonwoven fabric. The laminated non-woven fabric can be used as a cover material for a pants-type disposable diaper or the like with its melt-blown non-woven fabric side facing outside or inside. In addition, since liquid or moisture can quickly pass through the nonwoven fabric of any one of the laminated nonwoven fabrics and / or the entire laminated nonwoven fabric, about 0.
By arranging a large number of transmission holes of 1 to 5 mm ² , it can be used as one member of the above surface material, back surface material and the like. In addition, the laminated nonwoven fabric may be coated with a water repellent material for controlling liquid permeability or an oil agent such as a hydrophilic material.

[0020]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail with reference to embodiments. In the following examples, evaluation of nonwoven fabrics and the like is as follows. Fiber diameter: Cut 10 small pieces from web or non-woven fabric,
A scanning electron microscope was used to take a photograph at a magnification of 100 to 5000 times, a total of 100 fiber diameters were measured, and the average value was taken as the fiber diameter (unit: μm).

Nonwoven fabric strength: Using a tensile strength tester,
The breaking strength (kg / 5 cm) in the transverse direction of a non-woven fabric having a width of 5 cm was determined. Texture: The texture of the non-woven fabric was evaluated by 5 panelists from the viewpoints of wrinkle, flexibility, roughness and the like, and judged according to the following criteria. If 3 or more people have no wrinkles, good flexibility, and no rough feeling, "good", 3 or more people have wrinkles, poor flexibility, rough feeling, or both When it was determined to be, it was determined to be “poor”.

Polymer beads: Randomly cut 10 non-woven fabrics with a size of 20 × 20 cm and use a magnifying glass to count the number of polymer beads having a fiber diameter of 0.1 mm or more per unit area (unit / m ² ). . Plucking: Cut a 20 × 20 cm size non-woven fabric and place it horizontally. Wet your hands with water and, while gently pressing, trace the surface of the non-woven fabric 5 times in a circular motion. After that, check if there is hair on your hand. When there was hair removal, it was determined to be "present", and when there was no hair removal, it was determined to be "none."

Peel strength: Cut the laminated non-woven fabric into a width of 5 cm. Cut both layers with a razor and use a tensile strength tester to determine the peel strength. Unit: g / 5cm. Example 1 A heat-bonded composite spunbonded non-woven fabric was produced using a composite spunbond spinning device equipped with a composite spinning machine, an air sucker, a net conveyor, a heating device and the like. The spinneret used was a sheath-core type composite spinneret having a pore diameter of 0.4 mm. As the first component, melting point 133 ° C, MFR22 (190 ° C, g / 10
Min) high-density polyethylene is used on the sheath side, and the second component has a melting point of 164 ° C, MFR60 (230 ° C, g / 10 min)
Of polypropylene is used for the core side, and the composite ratio is 50/50
(Wt%), spinning temperature first component 285 ° C., second component 30
The fibers were spun at 0 ° C., sucked with an air sucker at a speed of 3000 m / min, and the fibers were blown onto a net conveyor together with air. The blown air was sucked and removed by a suction / exhaust device provided under the net conveyor. The obtained web had a fineness of 1.5 d / f. The web was heated with a through air heater at a temperature of 145 ° C. to obtain a non-woven fabric in which fibers were heat-sealed. The non-woven fabric has a basis weight of 16
g / m ² , vertical strength is 2.65 kg / 5 cm, horizontal strength is 1.58
It was kg / 5 cm.

Melt blow spinneret with 0.3 mm pore size,
Use a melt blow spinning device equipped with a conveyor
A melt blown non-woven fabric was manufactured. Melting point 137 ° C, M
FR76 (230 ℃, g / 10min) Propylene ethyl
N-butene-1 terpolymer, spinning temperature 260
Spinning at ℃, heating air temperature 360 ℃, pressure 1.3kg / cm
^TwoBlow the heated air under the following conditions and blow it on the net conveyor.
I got stuck. The blown air is at the bottom of the net conveyor
It was suctioned and removed by the provided suction / exhaust device. The obtained wafer
The fiber diameter of the fiber was 2.8 μm. When the web is spun
The non-woven fabric was self-heated and had heat fusion between fiber intersections. Said
Woven fabric weight is 12g / m^Two, Vertical strength 0.62kg / 5cm, horizontal strength
Force 0.49kg / 5cm, apparent density 0.076g / cm^Threeso
there were.

The composite spunbonded non-woven fabric and the melt blown non-woven fabric were laminated and heated at a temperature of 145 ° C. using a through air type heater to obtain a laminated non-woven fabric having a two-layer structure in which both layers were heat-sealed. The weight of the laminated nonwoven fabric was slightly increased by heat treatment after lamination to be 29 g / m ² . The laminated nonwoven fabric has a longitudinal strength of 3.56 kg / 5 cm and a lateral strength of 2.
It was 14 kg / 5 cm. Further, the apparent density of the melt-blown nonwoven fabric obtained by cutting and peeling the laminated surface of the laminated nonwoven fabric with a razor slightly increases by 0.07 by heat treatment after lamination.
It was 8 g / cm ³ .

The laminated non-woven fabric has a good texture and has no hair loss,
The number of polymer balls was 0 / m ² , and the peel strength was 106 g / 5 cm. Example 2 A meltblown nonwoven fabric was manufactured by the same manufacturing method as in Example 1. However, the resin has a melting point of 165 ° C and MFR120.
Using polypropylene of (230 ° C., g / 10 minutes), spinning was performed at a spinning temperature of 270 ° C., heated air was blown under conditions of a heated air temperature of 380 ° C. and a pressure of 1.8 kg / cm ² , and was blown onto a net conveyor. The blown air was sucked and removed by a suction / exhaust device provided under the net conveyor.
The obtained web had a fiber diameter of 4.5 μm. The web was in the form of a non-woven fabric having heat fusion at the intersections between fibers due to self-heating during spinning. The non-woven fabric has a basis weight of 18 g / m ² and a longitudinal strength of 0.98.
kg / 5cm, lateral strength 0.90kg / 5cm, apparent density of 0.
It was 054 g / cm ³ .

The spunbonded nonwoven fabric obtained in Example 1 and the meltblown nonwoven fabric were laminated and heated at a temperature of 148 ° C. in the same manner as in Example 1 to obtain a laminated nonwoven fabric having a two-layer structure in which both layers were heat-sealed. . The weight of the laminated nonwoven fabric was slightly increased by the heat treatment of the laminate and was 38 g / m ² . The laminated nonwoven fabric had a longitudinal strength of 3.96 kg / 5 cm and a lateral strength of 2.76 kg / 5 cm. The apparent density of the meltblown nonwoven fabric measured by cutting and peeling the laminated surface of the laminated nonwoven fabric with a razor was slightly increased by the heat treatment after lamination to be 0.057 g / cm ³ .

The laminated non-woven fabric had a good texture, no plucking, 0 polymer balls / m ² , and a peeling strength of 81 g / 5 cm. Comparative Example 1 A meltblown nonwoven fabric was manufactured by the same manufacturing method as in Example 1. However, the resin has a melting point of 167 ° C and MFR21.
Using polypropylene (230 ° C., g / 10 minutes), spinning was performed at a spinning temperature of 300 ° C., and heated air was blown under the conditions of a heated air temperature of 360 ° C. and a pressure of 1.5 kg / cm ² to obtain an ultrafine fiber web. The obtained web had a fiber diameter of 8.9 μm. The web was in the form of a non-woven fabric in which fibers were heat-sealed by self-heating during spinning. The nonwoven fabric had a basis weight of 18 g / m ² . Further, it was confirmed that the nonwoven fabric had polymer beads visually and by touch. The non-woven fabric has a longitudinal strength of 0.88 kg /
5 cm, lateral strength 0.75 kg / 5 cm, apparent density 0.07
It was 0 g / cm ³ .

The composite spunbonded non-woven fabric obtained in Example 1 and the melt blown non-woven fabric were laminated to form the composite fabric of Example 1 above.
Similarly, a laminated nonwoven fabric having a two-layer structure in which both layers were heat-sealed by heating at a temperature of 145 ° C. was obtained. The weight of the laminated nonwoven fabric was slightly increased by the heat treatment of the laminate and was 35 g / m ² . The laminated nonwoven fabric had a longitudinal strength of 3.41 kg / 5 cm and a lateral strength of 2.28 kg / 5 cm. The apparent density of the meltblown nonwoven fabric measured by cutting and peeling the laminated surface of the laminated nonwoven fabric with a razor was slightly increased by the heat treatment after laminating to 0.073 g / cm ³ .

The laminated non-woven fabric did not have plucked hair. The laminated non-woven fabric had good flexibility, but had rough feeling due to polymer beads and skin irritation due to the beads, and was poor in texture. Also, 26 polymer balls / m ² , peel strength 79
It was g / 5 cm. Comparative Example 2 A meltblown nonwoven fabric was manufactured by the same manufacturing method as in Example 1. However, the resin has a melting point of 166 ° C. and MFR44 (2
30 ° C., g / 10 min) polypropylene, spinning at a spinning temperature of 290 ° C., heated air temperature of 260 ° C., pressure of 1.2
Heated air was blown under the condition of kg / cm ² to obtain an ultrafine fiber web. The obtained web had a fiber diameter of 14.6 μm. The web was in the form of a non-woven fabric having heat fusion between fiber intersections due to self-heating during spinning. The laminated nonwoven fabric had a basis weight of 18 g / m ² . The laminated nonwoven fabric had a longitudinal strength of 1.02 kg / 5 cm, a lateral strength of 0.95 kg / 5 cm and an apparent density of 0.060 g / cm ³ .

The spunbonded nonwoven fabric obtained in Example 1 and the meltblown nonwoven fabric were laminated and heated at a temperature of 150 ° C. in the same manner as in Example 1 to obtain a laminated nonwoven fabric having a two-layer structure in which both layers were heat-sealed. . The weight of the laminated nonwoven fabric was slightly increased by the heat treatment of the laminate and was 36 g / m ² . In addition, the nonwoven fabric has a vertical strength of 4.82 kg / 5 cm and a lateral strength of 3.36 kg.
/ 5 cm. Further, the apparent density of the meltblown nonwoven fabric measured by cutting and peeling the laminated surface of the laminated nonwoven fabric with a razor slightly increases due to the heat treatment after lamination,
It was 063 g / cm ³ .

The laminated non-woven fabric was free of plucking. The number of polymer balls was 0 / m ² , and the peel strength was 117 g / 5 cm. However, the texture of the laminated nonwoven fabric was hard and poor because the diameter of the fibers constituting the meltblown nonwoven fabric was large. Example 3 A composite spunbonded nonwoven fabric was produced in the same manner as in Example 1. However, as the first component, melting point 135 ° C, MFR7
6 (230 ° C., g / 10 min) propylene / ethylene / butene-1 terpolymer was used on the sheath side, and polyethylene terephthalate having a melting point of 257 was used on the core side as the second component.
Composite ratio 50/50 (wt%), spinning temperature first component 280
C., the second component was 295.degree. C., was spun under conditions of air sucker at a speed of 2647 m / min, and the fibers were blown together with air onto a net conveyor. The obtained web had a fineness of 1.7 d / f. The web was heated with a through air heater at a temperature of 152 ° C. to obtain a non-woven fabric in which fibers were heat-sealed. The nonwoven fabric had a basis weight of 23 g / m ² , a longitudinal strength of 4.26 kg / 5 cm, and a lateral strength of 3.81 kg / 5 cm.

As in Example 1, a melt-blown non-woven fabric was produced using a polypropylene / ethylene / butene-1 terpolymer. However, the fiber diameter is 2.9 μm, and the basis weight is 1
It was 8 g / m ² . Further, the non-woven fabric was one in which fibers were weakly heat-sealed by self-heating during spinning. The nonwoven fabric had a longitudinal strength of 0.10 kg / 5 cm, a lateral strength of 0.08 kg / 5 cm, and an apparent density of 0.071 g / cm ³ .

The spunbonded non-woven fabric and the melt blown non-woven fabric are laminated, and a spun lace device is used to apply a pressure of 80.
kg / cm ^2, 100kg / cm 2-stage water column entangling treatment with ² conditions, then the same manner as in Example 1 Temperature 0.99 ° C. The nonwoven fabric
To obtain a laminated nonwoven fabric having a two-layer structure in which both layers are heat-sealed. The laminated non-woven fabric has a slightly reduced basis weight due to either spunlace treatment or heat treatment of the laminate,
It was 40 g / m ² . The laminated nonwoven fabric has a longitudinal strength of 5.2.
The strength was 0 kg / 5 cm and the lateral strength was 4.33 kg / 5 cm. The apparent density of the meltblown nonwoven fabric measured by cutting and peeling the laminated surface of the laminated nonwoven fabric with a razor increases by spunlace treatment or heat treatment after laminating to 0.098 g / cm ³
Met.

The laminated nonwoven fabric had a good texture and had no hair removed. There are 0 polymer balls / m ² , peel strength 522g /
5 cm. Example 4 The laminated non-woven fabric having a two-layer structure in which both layers are heat-sealed in Example 2 is laminated again so that the spunbonded non-woven fabric layer is inside and the meltblown non-woven fabric layer is outside. A spunbonded non-woven fabric layer was heat-fused to obtain a four-layered non-woven fabric by heating at 150 ° C. using a heating machine. The laminated nonwoven fabric has a basis weight of 75 g / m ² and a longitudinal strength of 9.
It was 25 kg / 5 cm and the lateral strength was 6.03 kg / 5 cm. The apparent density of the meltblown nonwoven fabric measured by cutting and peeling the laminated surface with a razor was 0.058 g / cm ³ . The peel strength was 89 g / 5 cm.

The laminated nonwoven fabric had a good texture and had no hair removed. The number of polymer balls was 0 / m ² . The laminated nonwoven fabric could be used as a wiper for household use as it is or by adhering various lubricants or the like by a dipping method, a spray method or the like. Comparative Example 3 From a regular fiber spunbond spinneret having a pore size of 0.4 mm, a melting point of 165 ° C., MFR60 (230 ° C., g / 10 minutes)
Polypropylene was spun at a spinning temperature of 300 ° C., sucked with an air sucker at a speed of 3000 m / min, and the fibers were blown together with air onto a net conveyor. The blown air was sucked and removed by a suction / exhaust device provided under the net conveyor. The obtained web has a fineness of 1.5 d /
It was a regular fiber of f. The web was heated with a through air heater at a temperature of 162 ° C. to obtain a non-woven fabric in which fibers were heat-sealed. The non-woven fabric has a basis weight of 18 g / m ^2.
And the vertical strength is 2.10kg / 5cm, and the horizontal strength is 1.35kg /
5 cm. The non-woven fabric was heat-treated at a temperature slightly lower than the melting point. However, one side of the non-woven fabric was insufficiently fused, and wrinkles were generated due to heat shrinkage during heating.

The spunbonded non-woven fabric and the melt-blown non-woven fabric of Example 2 were laminated and heated at a temperature of 162 ° C. using a through air heater, and both layers were heat-sealed to form a two-layer fabric having a basis weight of 39 g / m ² . A non-woven fabric having a structure was obtained. The laminated nonwoven fabric has a longitudinal strength of 3.63 kg / 5 cm and a lateral strength of 2.68 kg / 5 cm.
Met. Further, the apparent density of the meltblown nonwoven fabric measured by cutting and peeling the laminated surface of the laminated nonwoven fabric with a razor is:
It increased by heat treatment after lamination and was 0.063 g / cm ³ .

The laminated non-woven fabric had no plucking. The number of polymer balls was 0 / m ² , and the peel strength was 81 g / 5 cm.
The nonwoven fabric had wrinkles and had a poor texture. Comparative Example 4 A meltblown nonwoven fabric was manufactured by the same manufacturing method as in Example 1. However, the resin used was polyethylene terephthalate having a melting point of 257 ° C., spinning was carried out at a spinning temperature of 300 ° C., and heated air was blown under the conditions of a heating air temperature of 360 ° C. and a pressure of 1.8 kg / cm ² to obtain an ultrafine fiber web. The obtained web had an average fiber diameter of 5.2 μm. The web had almost no heat fusion between fibers due to self-heating during spinning, and when the web was pushed by hand, fluff adhered to the hand. The web had a basis weight of 16 g / m ² . The non-woven fabric has a longitudinal strength of 0.03
kg / 5 cm, lateral strength 0.01 kg / 5 cm, apparent density of 0.1.
It was 070 g / cm ³ .

The composite spunbonded non-woven fabric obtained in Example 3 and the melt blown non-woven fabric were laminated and heated at a temperature of 140 ° C. using a through air heater, and both layers were heat-sealed to form a two-layer laminated non-woven fabric. Got The nonwoven fabric had a basis weight of 37 g / m ² . Also, the longitudinal strength of the non-woven fabric is 4.63 kg / 5.
cm, lateral strength was 3.92 kg / 5 cm. The apparent density of the meltblown nonwoven fabric measured by cutting and peeling the laminated surface of the laminated nonwoven fabric with a razor was 0.072 g / cm ³ . The peel strength was 5 g / 5 cm.

The laminated nonwoven fabric had a good texture and had 0 polymer beads / m ² . However, there was a lot of hair removal (poor hair removal). Example 5 The composite spunbonded nonwoven fabric obtained in Example 1 and the melt blown nonwoven fabric obtained in Example 1 were laminated and thermocompression bonded with a hot embossing roll. The roll used was a combination of a calender roll and an embossing roll having a convex area ratio of 15%, and the meltblown nonwoven fabric was brought into contact with the embossing roll side. Thermocompression bonding conditions are embossing roll temperature 12
The temperature was 0 ° C., the calender roll temperature was 120 ° C., and the linear pressure was 8 kg / cm.

The laminated nonwoven fabric had a basis weight of 29 g / m ² , a vertical strength of 9.8 kg / 5 cm, and a horizontal strength of 6.5 kg / 5 cm. The peel strength was 1300 g or more / 5 cm. The apparent density of the meltblown nonwoven fabric measured by cutting and laminating the laminated surface of the nonwoven fabric with a razor was 0.11 g / cm ³ . The laminated non-woven fabric has a good texture and has 0 polymer balls /
It was m ^2. There was no hair removal. Example 6 A meltblown nonwoven fabric was manufactured by the same manufacturing method as in Example 1. However, the resin has a melting point of 167 ° C. and MFR31 (2
(30 ° C., g / 10 min) polypropylene, spinning at a spinning temperature of 290 ° C., heated air temperature of 390 ° C., pressure of 2.4
Heated air was blown under the condition of kg / cm ² to obtain an ultrafine fiber web. The obtained web had a fiber diameter of 6.6 μm.
The web was in the form of a non-woven fabric in which fibers were heat-sealed by self-heating during spinning. The nonwoven fabric had a basis weight of 18 g / m ² . In addition, it was confirmed that the non-woven fabric had a few polymer beads by touch. The nonwoven fabric has a longitudinal strength of 0.80 kg / 5 cm,
Lateral strength 0.62kg / 5cm, apparent density 0.068g / cm
^{Was 3} .

The composite spunbonded non-woven fabric obtained in Example 1 and the melt blown non-woven fabric were laminated, and
Similarly, a laminated nonwoven fabric having a two-layer structure in which both layers were heat-sealed by heating at a temperature of 145 ° C. was obtained. The weight of the laminated nonwoven fabric was slightly increased by the heat treatment of the laminate and was 35 g / m ² . The laminated nonwoven fabric had a longitudinal strength of 3.01 kg / 5 cm and a lateral strength of 2.02 kg / 5 cm. The apparent density of the melt-blown nonwoven fabric measured by cutting and peeling the laminated surface of the laminated nonwoven fabric with a razor slightly increased by heat treatment after lamination to 0.069 g / cm ³ , and the peel strength was 81 g / 5 cm. It was

The laminated non-woven fabric did not have plucked hair. The polymer balls of the meltblown nonwoven fabric were 4.0 / m ² . The laminated non-woven fabric had good flexibility and had a good texture with almost no feeling of roughness due to polymer beads. This laminated nonwoven fabric can be used as a heat insulating material or a filter material. Example 7 A commercially available diaper having a substantially I-shaped cross section of a rail rail in a plane was used, and only the surface material near the legs of the diaper was replaced with the laminated nonwoven fabric of Example 1.

The commercially available disposable diaper uses polyethylene / polypropylene-based heat-fusible composite fiber staples, and a non-woven fabric in which the intersections of the fibers are heat-bonded is used as the surface material.
The water absorbent material was mainly composed of pulp and superabsorbent water resin, and the backing material was polyethylene film. Only the non-woven surface material near both legs was removed from the diaper with a knife. The laminated nonwoven fabric obtained in Example 1 was laminated in the vicinity of both legs so that the meltblown nonwoven fabric layer was on the skin side and the spunbond layer was on the polyethylene film side of the backing material. Further, three polyurethane elastic yarns are sandwiched between the surface material and the back material in a stretched state, the remaining non-woven fabric near the central portion and the laminated non-woven fabric are heat-sealed, and further laminated with the back material. The non-woven fabric was heat-sealed. The remaining laminated non-woven fabric near the legs was cut with scissors to obtain a paper diaper in which the melt-blown non-woven fabric was arranged on the skin side of the legs. This diaper was curved in an approximately bow shape by the elastic thread. This diaper had a soft texture on the legs, and was particularly suitable for a newborn baby.

[0045]

The non-woven fabric of the present invention is a laminated non-woven fabric of a composite spunbonded non-woven fabric and a melt blown non-woven fabric, and has a good texture and a high non-woven fabric strength. Further, since the melt-blown non-woven fabric is heat-sealed at the intersections of the ultrafine fibers and is heat-sealed to the low melting point component of the composite spun-bonded non-woven fabric, there is no hair removal, and since the melt-blown non-woven fabric has no polymer beads, it is rough. No feeling or skin irritation. The nonwoven fabric of the present invention is preferably used as an absorbent article such as a diaper or a sanitary napkin.

Claims (10)

[Claims] 1. A composite spunbonded nonwoven fabric and an average fiber diameter of 1.
A non-woven fabric having a multi-layer structure in which a melt blown non-woven fabric of 0 μm or less is laminated, and the composite spunbonded non-woven fabric is composed of a composite long fiber in which a low melting point resin component and a high melting point resin component are combined, and the low melting point resin component is the fiber surface. Which is part of, and is heat-sealed via the low melting point resin component,
The melt-blown non-woven fabric is heat-sealed, and the composite spun-bonded non-woven fabric and the melt-blown non-woven fabric are integrated by fusing the low-melting point resin component of the composite spun-bonded non-woven fabric and / or the resin component of the melt-blown non-woven fabric, and both peel strength is 6 g / 5 cm or more layers, the fiber diameter 0.1mm or more polymers ball has 10 / m ² or less is laminated nonwoven fabric. 2. The composite spunbonded non-woven fabric has a fineness of 0.5-.
The melt-blown nonwoven fabric is composed of 10 d / f composite long fibers, the melt-blown nonwoven fabric is composed of ultrafine fibers having a fiber diameter of 0.1 to 10 μm, and the number of polymer beads having a fiber diameter of 0.1 mm or more is 10 pieces / m ² or less. 0.02-0.20g / cm
^3. The laminated non-woven fabric according to claim 1, which has a lateral strength of 0.6 kg / 5 cm or more when converted to a basis weight of 40 g / m ² of the laminated non-woven fabric. 3. A method for producing a laminated non-woven fabric comprising laminating a spun bond non-woven fabric and a melt blown non-woven fabric, and heating the two to bond them together, wherein the spun bond non-woven fabric comprises a low melting point component and a high melting point component. The melt-blown non-woven fabric is the same as the low melting point component of the composite fiber constituting the spunbonded non-woven fabric, or is composed of a fiber containing a component having an affinity with the low melting point component, and the heating temperature is equal to or higher than the melting point of the low melting point component. A method for producing a laminated non-woven fabric, which is less than the melting point of the high-melting point component. 4. The method for producing a laminated non-woven fabric according to claim 3, which includes a step of entwining the two non-woven fabrics with a needle bunch or a spunlace means before or after the heating. 5. An absorbent article in which the laminated nonwoven fabric according to claim 1 or 2 is used as at least one member. 6. A two-layer structure nonwoven fabric comprising a melt blown nonwoven fabric and a composite spunbonded nonwoven fabric, or a meltblown nonwoven fabric /
The non-woven fabric having a multi-layer structure according to claim 1 or 2 which is a three-layered non-woven fabric of composite spunbonded non-woven fabric / melt-blown non-woven fabric is used as at least one member constituting an absorbent article, and the melt-blown non-woven fabric layer side is in contact with the skin. The absorbent article according to claim 5, which is used for. 7. A low-melting point resin component and a high-melting point resin component are spun by a composite spun bond method so that the low-melting point resin component forms a part of the fiber surface to form a web, or the web is formed. Non-woven fabric in which fibers are heat-fused by heating to a temperature higher than the heat-fusing temperature, while the average fiber diameter is 10 μm by the melt blow method
The following ultrafine fibers are heat-fused to form an ultrafine fiber non-woven fabric, and the composite spunbond method web or the heat-sealing non-woven fabric and the microfine fiber non-woven fabric are laminated in multiple layers, and both layers have a temperature of heat fusion or higher. A method for producing a laminated non-woven fabric, wherein the peel strength of both layers is 6 g / 5 cm or more, characterized by heating to a temperature. 8. The method for producing a laminated non-woven fabric according to claim 7, wherein the non-woven fabric produced by the melt-blowing method is a non-woven fabric in which the intersections of the fibers are heat-sealed by self-heating during melt-blowing spinning. 9. The melt-blown non-woven fabric and the spun-bonded non-woven fabric are laminated in a multilayer structure so that at least one surface layer thereof forms a spun-bonded non-woven fabric, and the laminated non-woven fabric is heated using a through-air type heater. 9. The method for producing a laminated non-woven fabric according to claim 7, wherein both layers are heat-sealed so as to jet from the spun bond non-woven fabric side to the melt blown non-woven fabric side. 10. The method for producing a laminated nonwoven fabric according to claim 7, wherein the heat-sealing is performed by thermocompression bonding with an embossing roll in a thermocompression bonding area of 5 to 25%.