RU2569775C1 - Nonwoven fabric - Google Patents

Abstract

FIELD: textiles, paper.

SUBSTANCE: nonwoven fabric (1), according to the present invention, is provided with a set of fibres (11), where the long fibres (2) are secured in the areas (3) sealed by fusion. The nonwoven fabric (1) is provided with piled fibres (20) in which only one end parts (20a) are fixed in the areas (3) sealed by fusion, and other end sides are free end parts (20b). In the nonwoven fabric (1) the pile fibres (20) having a free end part, contain low pile fibres (21), where the height of the free end parts (20b) are smaller than the height of pile fibres (20) in their highest positions (20c).

EFFECT: improvement of the fabric.

16 cl, 1 tbl, 14 dwg

Description

Scope of technical application

The present invention relates to a nonwoven fabric containing long fibers.

BACKGROUND OF THE INVENTION

Non-woven “spunbond” material is often used in an absorbent product, for example, in a disposable diaper, as it has high tensile strength, is very suitable for processing, and is cost-effective. However, the non-woven material “spunbond” is completely unsuitable from the point of view of creating a feeling of fluffy, etc. because of the method of its manufacture, and it was difficult to improve its texture (perception by touch).

Patent Literature 1 describes, for example, a pile non-woven fabric obtained from a non-woven fabric containing continuous, long fibers that has been stretched and that delaminated and separated in the middle part in the direction of its thickness, and the fibers exfoliated from the parts in which they were bonded, the fibers were elongated to form loops, etc., and were mixed.

The present inventor previously proposed a non-woven material containing fibers that were formed by tearing parts of long fibers, where only one end part of the long fibers was fixed in areas fused together, and on the other end sides of the long fibers there were free end parts with a thickening ( see Patent Literature 2).

List of cited documents

Patent Literature

Patent Literature 1: JP 2002-302861 A

Patent Literature 2: JP 2012-092475 A

SUMMARY OF THE INVENTION

Technical problem

It was believed that the pile non-woven material described in Patent Literature 1 contains many fibers elongated in the form of loops or the like due to the method of its manufacture. Thus, when using the pile nonwoven fabric described in Patent Literature 1 in an absorbent article, for example, in a disposable diaper, the fibers in the form of loops cling to the skin of the consumer, resulting in poor perception during use. In addition, there is no description in Patent Literature 1 regarding the height or shape of the distal end parts of the constituent fibers.

As for the non-woven material described in Patent Literature 2, the number of loops is reduced and the non-woven material almost does not cling to the skin of the consumer, since the texture of the non-woven material is improved. In addition, although the tensile strength of the nonwoven material is high, a feeling of fluffiness is generally achieved, and its texture is improved. However, there is a need for further texture improvement.

Solution of problems

The present invention relates to a nonwoven material containing a complex of fibers, where a long fiber is fixed in the region bonded by fusion. The nonwoven material comprises a pile fiber formed by tearing a portion of a long fiber, where only one end portion is fixed in the fusion bonded region and the other end side is a free end portion. Pile fibers have the ability to form corrugations and include a low pile fiber, the height of the free end portion of which is less than the height of the pile fiber in its highest position.

Brief Description of the Drawings

In FIG. 1 is a perspective view of one embodiment of a nonwoven material according to the present invention.

In FIG. 2 illustrates schematically a method for measuring the height of the free end of a pile fiber and the height of a pile fiber having a free end in its highest position.

In FIG. 3 shows a linear section along a line approximately parallel to the direction of the Y axis and passing through a plurality of fusion bonded regions contained in the nonwoven fabric shown in FIG. one.

In FIG. 4 is a perspective view of a fiber having a thick free end contained in the nonwoven fabric shown in FIG. one.

In FIG. 5 illustrates schematically a method for measuring the diameter of the distal end of a nonwoven fiber according to the present invention.

In FIG. 6 illustrates schematically a methodology for determining the amount of pile fibers in a nonwoven material according to the present invention.

In FIG. 7 schematically shows the pre-treatment section that is provided with the corresponding apparatus for manufacturing the nonwoven fabric shown in FIG. one.

In FIG. 8 shows schematically a fiber teething section which is provided with an appropriate apparatus for manufacturing the nonwoven fabric shown in FIG. one.

In FIG. 9 shows a disposable diaper without fasteners for explaining an example of the use of a nonwoven material according to the present invention, and it is presented in plan, in expanded and stretched condition.

In FIG. 10 shows a section X1-X1 in FIG. 9.

Description of Embodiments

The nonwoven fabric of the present invention is described below with reference to preferred embodiments thereof (see FIGS. 1-8).

As shown in FIG. 1, the nonwoven fabric 1 according to this embodiment is a nonwoven fabric containing a complex of 11 fibers, where long fibers 2 are fixed in fusion bonded regions 3. The nonwoven fabric 1 contains pile fibers 20 (also called “pile fibers 20 having a free end portion”) formed by tearing apart pieces of long fibers 2, where only one end parts 20a are fixed in fusion bonded regions 3 and the other end sides are free end parts 20b. Pile fibers 20 having a free end portion include low pile fibers 21, the heights of the free end parts 20b of which are less than the heights of the pile fibers 20 having a free end portion at their highest positions 20c. In other words, when focusing on one pile fiber 20 having a free end portion, it should be understood that under the low pile fiber 21 is meant a fiber whose height of the free end portion 20b is less than the height of the pile fiber 20 having a free end portion in itself high position 20c. Pile fibers 20 of nonwoven fabric 1 having a free end portion include high pile fibers 22, the heights of the free end parts 20b of which are the heights of the pile fibers 20 having a free end portion at their highest positions 20c. Whether the fiber is low pile fiber 21 or high pile fiber is determined by observing the relationship between the distal end parts of ten pile fibers 20 having a free end portion, randomly selected from pile fibers 20 in images obtained using a scanning electron microscope (SEM) at approximately 50-fold increase, and comparison of the heights of the pile fibers 20, protruding from the fold 105, formed as a result of double addition of the sample by the method of measuring dia meter fiber described below. As shown in FIG. 1, the nonwoven fabric 1 (described in more detail below) has a longitudinal direction defined as the direction of the Y axis, and the width direction of the nonwoven fabric 1 is defined as the direction of the X axis. It should be noted that when considering the nonwoven fabric 1, in accordance with the direction of orientation of its constituent fibers , the longitudinal direction (Pr direction) along the fiber orientation direction is defined as the longitudinal direction (Y axis direction), and the transverse direction (Pop direction) perpendicular to the Pr direction is defined as width direction (X axis direction). Thus, in the following explanation, the longitudinal direction (Y axis direction) and the Pr direction mean the same direction, and the width direction (X axis direction) and the Pop direction mean the same direction.

In addition, in this description, the height of the free end and the height of the pile fiber having a free end portion in its highest position can be determined according to the following method.

Three relatively large [about 60-70 mm in the Pop direction (in the direction of width Y) and about 50 mm in the Pr direction (in the longitudinal direction)] specimens for viewing are cut so that they can be viewed in the viewing range of 10 mm wide.

The measurement sample 104 is formed by attaching the cut-out sample to the black support so that it is laid flat, as shown in FIG. 2, and so that it is bent outward relative to the bend line Z passing through a plurality of fusion regions 3 in the direction of the X axis. When folded in half, the sample is bent along the bend line in such a way that the viewing sample can be viewed transversely section. It is easy to observe the rise of the constituent fibers after lightly combing the half-folded portion of the specimen for viewing with a brush (conventional brush No. 812 with a size of 30 mm manufactured by KOMERI Co., Ltd.) in the direction of raising the pile fibers five times. In this case, combing with a brush is controlled so that the force (combing force) applied to the area of the object to be measured, during combing using a brush, falls into the range of 5 gs to 15 gs. The carding power can be measured by using a weighing tool, and adjustment can be made based on the measured value obtained with the weighing tool.

Outwardly curved specimen 104 described above is viewed at approximately 30 times magnification using a digital microscope (Model VHX-1000) manufactured by KEYENCE Corp. The measurement is carried out using the measurement mode along the vertical line of a digital microscope. When direct light is directed parallel to the bend line Z, the distance from the bend line Z to the position of a straight line parallel to the bend line Z, which intersects the pile fiber 20 and which is farthest from the bend line Z, is defined as the “most elevated position”. In addition, the distance from the inflection line Z to the free end is defined as the height of the free end part.

From the point of view that non-woven material 1 should be inexpensive, should give a pleasant feeling in contact with the texture, and the manufacturing process should be suitable for implementation, the surface density of non-woven material 1 should preferably be from 5 g / m ² to 100 g / m ² , more preferably from 5 g / m ² to 25 g / m ² .

From the point of view of the possibility of preventing tearing of the nonwoven material 1 during use and the suitability of the manufacturing process, the tensile strength of the nonwoven material 1 should be 5.00 N / 50 mm or more, more preferably 8 N / 50 mm or more and 30 N / 50 mm or less. It should be noted that, from the point of view of the possibility of achieving the tensile strength of the nonwoven material 1, the tensile strength of the original nonwoven material 10 (see Fig. 7) used according to the manufacturing method of the nonwoven material 1 described below should be 7 N / 50 mm or more, more preferably 10 N / 50 mm or more and 50 N / 50 mm or less. Thus, the manufacturing method of the nonwoven fabric 1 described below is a method according to which the decrease in tensile strength of the starting nonwoven fabric 10 is small in comparison with other methods of manufacturing the pile materials. Preferably, the tensile strength of the nonwoven fabric 1 and the original nonwoven fabric 10 satisfies the above ranges in the direction of the X axis (in the Pop direction). The ratio of the tensile strength of the nonwoven material 1 to the tensile strength of the original nonwoven material 10 (tensile strength of the nonwoven material 1 / tensile strength of the original nonwoven material 10) is 0.5 or more, preferably 0.7 or more and 1.0 or less, more specifically, preferably 0.5 or more and 1.0 or less, more preferably 0.7 or more and 1.0 or less. The tensile strength is determined using the following procedure.

Method of measuring tensile strength

Under ambient conditions: temperature 22 ° C, relative humidity (RH) 65%, cut a rectangular section for measurement, having dimensions: 200 mm in the direction of the X axis (in the width direction) and 50 mm in the direction of the Y axis (in the Pop direction) from nonwoven material 1 or from the original nonwoven material 10. A cut rectangular piece for measurement is used as a sample for measurement. The measurement sample is fixed in the clamps of the tensile testing machine (TENSILON tensile testing machine, model “RTA-100” manufactured by A&D Co., Ltd.) so that the direction of the X axis coincides with the direction of extension. The distance between the clamps is set equal to 150 mm. The measurement specimen is stretched at a speed of about 300 mm / min, and the maximum load until the specimen ruptures is determined as the tensile strength in the direction of the X axis. Next, cut a rectangular measurement segment having dimensions: 200 mm in the direction of the Y axis and 50 mm in the direction X axis, and the cut-out line is used as a sample for measurement. The measurement sample is fixed in the clamps of the tensile testing machine so that the direction of the Y axis coincides with the direction of extension. The tensile strength in the direction of the Y axis is determined according to the same procedure as when measuring the tensile strength in the direction of the X axis.

Non-woven material 1 is also characterized in that it has a pleasant to the touch texture.

Many characteristic values representing the texture are known, and, in particular, in general, the characteristic values presented in KES developed by KATO TECH CO., LDT are known. (Reference document: Standardization and Analysis of Sensation Assessment (Second Edition), Sueo KAWABATA Publishing House, published July 10, 1980). In particular, three characteristic values are known: LC (linearity of compressive load - compression deformation curve), WC (compression work) and RC (compression elasticity), called “compression characteristics”, among the characteristic values representing the texture to determine the feeling of fluffiness . Considering these compression characteristics, the characteristic value is calculated based on the strain caused by the application of a load of 0.49 cN / cm ² (0.50 g / cm ² ) or more and 49.0 cN / cm ² (50.0 gf / cm ² ) or less [0.49 cN / cm ² or more and 9.80 cN / cm ² or less (0.50 g / cm ² or more and 10.0 g / cm ² or less), highly sensitive measurements]. However, in a thin material, for example, a nonwoven material having a low surface density (from 5 g / m ² to 25 g / m ² ), a large difference may not be obtained, and thus, the correlation with the texture may be small. In addition, with such a consideration, in which a person feels a texture with a very light load, i.e. the load in contact with the absorbent product is about 0.98 cN / cm ² (1.00 g / cm ² ) and a characteristic value in the range less than the normal load is suitable for representing the original texture; a new characteristic value is calculated based on a load of 0.29 cN / cm ² (0.3 g / cm ² ) to 0.98 cN / cm ² (1 g / cm ² ) and the strain during loading.

Characteristic value of compression at light load

The measurement, which is the basis for calculating the characteristic compression values at light load, is carried out under ambient conditions: temperature 22 ° C, 65% RH, using a KES FB3-AUTO-A model (trademark) manufactured by KATO TECH Co., LDT . More specifically, the measurement samples are prepared by cutting the non-woven material 1 into three segments having dimensions: 20 × 20 cm. Then, one measurement sample from these measurement samples is placed on the test bench so that its pile surface is directed upwards (if pile fibers are absent in the sample for measurement or if pile fibers are present on both surfaces of the measurement sample, then measurements are made on both sides of the measurement sample and a smaller value is taken from the measured elichin). Then the sample for measurement is compressed between round, flat, steel plates with an area of 2 cm ² . The measurement is carried out at a compression speed of 20 μm / s and at a maximum compressive load of 9.80 cN / cm ² (10.0 g / cm ² ), and the measurement is also carried out at the same speed even during the recovery process. At this time, the displacement between the steel plates is represented as x (mm), the load is represented as y (cN / cm ² ), and the position of the point at which the load is determined is represented as x = 0, so that the measurement is carried out in the direction of compression. The value of x increases with increasing compression.

The characteristic value of compression at light load is calculated by isolating the magnitude of the change in thickness under light load from the measured values (x, y). More specifically, by isolating a value near the first load falling in the range from 0.29 cN / cm ² (0.30 g / cm ² ) to 0.98 cN / cm ² (1.00 g / cm ² ), which gets into the recovery process, and the strain values at this time, they get an approximating straight line characterizing the relationship between x and y according to the least squares method; the slope of the approximating line at this time is determined as the above characteristic value [unit (cN / cm ² ) / mm]. Three parts are measured on one piece for measurement. Measurements are made including a total amount of 9 parts in three samples. The characteristic values are calculated by considering the corresponding 9 parts, and the average value of these characteristic values is taken as the characteristic value of compression of the nonwoven material at light load.

The numerical value of the characteristic value of compression at a light load indicates that the smaller the numerical value, the easier it is for a measurement sample to flatten at a light load, and this can have a beneficial effect on the perception of a person who feels texture (especially, feeling fluffy). For example, the above-described characteristic compression value of the starting nonwoven material 10 having a normal surface density of 5 g / m ² to 25 g / m ² that was not subjected to the processing described below was 19.6 (cN / cm ² ) / mm [20.0 (gf / cm ² ) / mm] or more and 29.4 (cN / cm ² ) / mm or less [30.0 (gf / cm ² ) / mm] or less, whereas non-woven fabric 1 , which was not subjected to the treatment described below, became very brittle when viewed from its surface, and had the above characteristic compression value of 17.6 (cN / cm ² ) / mm [18.0 (g s / cm ² ) / mm] or less. This means that from the point of view of obtaining a quality texture, the above characteristic value of the compression of the nonwoven material 1 obtained by processing the original nonwoven material 10 with a surface density of 5 g / m ² to 25 g / m ² is 17.6 (cN / cm ² ) / mm [18.0 (g / cm ² ) / mm] or more, preferably 14.7 (cN / cm ² ) / mm [15.0 (g / cm ² ) / mm] or less and more preferably is 9.80 (cN / cm ² ) / mm [10.0 (gf / cm ² ) / mm] or less, from the point of view of obtaining a texture close to that of a breathable non-woven fabric with Clear to the touch texture. The lower limit of the above characteristic compression value of the nonwoven fabric 1 is not particularly limited, but should be 0.98 (cN / cm ² ) / mm [1.00 (gf / cm ² ) / mm] or about.

As described above, the nonwoven fabric 1 is provided with pile fibers 20, where only one end part 20a of the pile fibers 20 is fixed in fusion bonded regions 3, and the other end sides of the pile fibers 20 having free ends are free end parts 20b; and pile fibers 20 having free end portions have the ability to form corrugations, as shown in FIG. 1 and 3. Pile fibers 20 having free end parts include low pile fibers 21, where the heights of the free end parts 20b are less than the heights of the pile fibers themselves at their maximum positions 20c. Since the distal ends of the pile fibers do not directly come into contact with the skin of the consumer due to the presence of low pile fibers 21, a non-woven material 1 can be obtained that causes reduced skin stimulation. In the detailed description of the nonwoven fabric 1 shown in FIG. 1 and 3, it is said that the non-woven fabric 1 is provided with pile fibers 20 with a raised free end portion, where only one end parts 20a of the pile fibers 20 are fixed in fusion-bonded regions 3 and fibers in the form of loops 23 are teased in a loop-like shape between regions 3 and 3 fused together. Pile fibers 20 with free ends and fibers in the form of loops 23, collectively called “pile fibers”. The expression “pile fiber 20 having a free end part” indicates that the fiber, one end part 20a of which is fixed in the fusion bonded region 3, and the other end part is a free end part 20b where the pile fiber height is in position which is higher than the surface of the complex of 11 fibers by 0.2 mm or more, when viewing the image obtained using SEM at 50x magnification, the fibers, according to the method for determining the amount of pile fibers described below, as Zano FIG. 6 (c). As shown in FIG. 3, the low pile fibers 21 are composed of first, low, pile fibers 211 and second low, pile fibers 212. The free end portion 20b located on the other end side of the first, low pile fibers 211 is thick. The free end portion 20b located on the other end side of the second, low, pile fiber 212 is not thick. The first, low, nap fiber 211, the free end portion 20b of which is thick, preferably has a flat cross-sectional shape (oval or crushed shape) at its distal end portion. In addition, as described above, the pile fibers 20 having a free end portion contain, in addition to the low pile fibers 21, high pile fibers 22, as described above. The height of the free end portion 20b of the high pile fiber is the largest. High pile fibers 22 also include first, high, pile fibers 221 and second, high, pile fibers 222. The free end portion 20b of the first, high, pile fiber 221 is thick. The free end portion 20b of the second, high, pile fiber 222 is not thick. Here, the expression "free end part" means the "other end" of the pile fiber 20 having a free end part, only one end part 20a of which is fixed in the fusion bonded region 3; in other words, this expression means “distal end portion”. Whether or not the free end portion 20b is thick is determined by measuring the diameter of the fiber according to the following measurement procedure and calculating the increase (in percent) of the diameter of the distal end of the fiber. Since the free end portion 20b becomes thick, a pile fiber 20 with a soft, distant free end can be obtained, and thus non-woven material 1 can be obtained, causing reduced stimulation of the skin of the consumer.

Fiber Diameter Measurement Technique

Under ambient conditions: temperature 22 ° C, 65% RH, measuring section with dimensions of 2 cm in the direction of the X axis and 2 cm in the direction of the Y axis is first cut from the nonwoven fabric 1 to be measured using a sharp razor, as shown in FIG. . 5 (a), and the measurement sample bent outward along the bend line Z extending in the direction of the X axis and through a plurality of fusion bonded regions 3 is laid and fixed on a scanning type electron microscope (SEM) sample stand made of aluminum, where carbon tape is placed on the stand. Then, 10 pile fibers having free end parts, where only one end parts 20a of pile fibers are fixed in fusion-bonded regions 3, are randomly selected in SEM images at approximately 50 times magnification; close parts to the free end parts of these fibers are magnified 750 times for photographing. From the photographs taken (see FIG. 4), the diameter (diameter 20c of the pile fiber 20 having a free end portion in an area other than the free end portion 20b) of the pile fibers 20 having a free end portion at a position distant from the distal end of the free end is measured parts 20b at 120 μm, respectively. The inclined line during the measurement of the diameter 20c of the pile fiber 20 having a free end part in a region other than the free end part 20b is transferred plane-parallel to the free end part 20b and the diameter is measured (diameter 20d of the pile fiber 20 with a free end in the free end part 20b) a pile fiber 20 having a free end portion in a position in the thickest region located between the distal end of the free end portion 20b and a position remote from the distal end by 20 μm. It should be noted that when the distal end portion is flat, then the distal end portion cannot be seen as thick due to the viewing angle, but the measurement is carried out using a photograph taken in the state when it is visible.

A fiber having a thick, loose, end portion 20b (first, low, pile fiber 211, first, high, pile fiber 221) is understood to mean a fiber of randomly selected 10 pile fibers having a free end portion that satisfies the requirement that that the increase in the diameter of the distal end of the fiber is 15% or more. The increase in the diameter of the distal end of the fiber is calculated by the following formula (1), which is calculated by the diameter 20d of the pile fiber 20 in the free end portion 20b and the diameter 20c of the pile fiber 20 having a free end part in a region other than the free end part 20b; where both diameters are measured from the respective photographs 10 of the pile fibers 20 having a free end portion. From the point of view that the tearing of the fiber between the fusion bonded regions 3 (the portion in the form of a fiber except for the boundaries between the fusion bonded region 3 and the fiber) can be suppressed, a decrease in the tensile strength can be suppressed and the non-woven a material with a pleasant to the touch texture can be obtained, the increase in diameter is preferably 20% or more, more preferably 25% or more.

The increase in the diameter of the distant end of the fiber (%) = [((20d-20c) / 20c) × 100] ... (1)

The low pile fiber 21 and the high pile fiber 22 are practically distinguished using SEM images of approximately 50-fold magnification according to the aforementioned method for measuring fiber diameter so that the fiber, where the free end portion 20b is raised from the surface of region 3 bonded by fusion is located in the highest position and is defined as a high pile fiber 22, while a fiber in which the free end portion 20b hangs down to the surface of the fiber complex 11 It is defined as a low pile fiber 21.

In the nonwoven fabric 1, in terms of texture, the proportion of low pile fibers 21 among the pile fibers 20 having a free end portion (low pile fibers 21 and high pile fibers 22) is preferably 20% or more, more preferably 30% or more, even more preferably 40% or more. The proportion of low pile fibers 21 is determined according to the above method of measuring the diameter of the fiber, confirming the position of the heights of the free end parts 20b 10 of the pile fibers 20 having a free end part, randomly selected in the image obtained using SEM at approximately 50-fold magnification, determining the corresponding quantities low pile fibers 21 and high pile fibers 22, and calculating the shares of low pile fibers 21 and high pile fibers 22, respectively. In addition, in the nonwoven fabric 1, from the point of view of further improving smoothness, the proportion of the first, low, pile fibers 211 in the composition of the low pile fibers 21 (the first, low, pile fibers 211 having a thick, loose, end portion 20b, and the second pile fibers 212 having a non-thick free end portion 20b) is preferably 35% or more, more preferably 40% or more, even more preferably 50% or more. The fraction of the first, low, pile fibers 211 having a thick, loose, end portion 20b is determined by using the above method for measuring fiber diameter, calculating an increase in the fraction of the diameters of the distant ends of the fibers of 10 pile fibers 20 having free end parts selected randomly in the images obtained using SEM at approximately 750-fold magnification, respectively, and calculate the proportion of the first, low, pile fibers 211 with a thick free end portion 20b. The proportion of the first, low pile fibers 211 in the composition of the low pile fibers 21 is calculated by determining the number of fibers 211 having a thick, free, end portion, which are low pile fibers 21 when measuring the above low pile fibers 21 and measuring fibers having a thick free end (first, low, pile fibers 211 and first, high, pile fibers 221). It should be noted that the values in the above relevant measurements are calculated by determining the fractions from 9 images obtained using SEM, other areas in the same way and obtaining the average value of these 10 values (in percent).

As described above (see FIGS. 1 and 3), the nonwoven fabric 1 comprises a loop-shaped fiber 23 raised in the form of a loop between fusion bonded regions 3, 3. By a nap “loop-shaped fiber 23” is meant a fiber that does not have a free end portion 20b on the other end side, a portion of which is raised so that it is separated from the surface (inflection line Z) of the 11 fiber complex by 0.5 mm or more when browsing [see FIG. 5 (c)] according to the above method for measuring fiber diameter. From this point of view, that the nonwoven material 1 does not cling to the skin of the consumer, the discomfort is reduced and the texture is improved, the proportion of fibers in the form of loops 23 in the total number of pile fibers 20 having a free end part, only one end parts 20a of which are fixed in regions 3 fused together and fibers in the form of loops 23 are preferably less than 50%, more preferably 45% or less, even more preferably 40% or less. The proportion of fibers in the form of loops 23 is determined using the above method of measuring the diameter of the fiber, arbitrarily choosing 10 fibers in the image obtained using SEM at approximately 50-fold magnification, highlighting the pile fibers 20 having a free end [low pile fibers 21 (first , low, nap fibers 211 and second, low, nap fibers 212) and high nap fibers 22 (first, high, nap fibers 221 and second, high, nap fibers 222) and loop fibers 23] from 10 randomly selected fibers con, and calculate the proportion of fibers 23 (loop fibers) in the total number of low pile fibers 21, high pile fibers 22 and fibers 23. It should be noted that the measured values are also calculated by determining the percentage (percentage) of 9 images obtained from using SEM, other areas in the same way and determine the average value of these 10 values.

The complex of 11 fibers is described in more detail below. As shown in FIG. 1 and 3, the fiber complex 11 is formed by discrete fixing the webs containing the long fibers 2 by means of a plurality of fusion bonded regions 3. In this case, “long fibers” means fibers having a length of 30 mm or more, and it is preferable that the long fiber be the so-called continuous, long fiber having a length of 150 mm or more, from the point of view of obtaining a non-woven material having high tensile strength. In nonwoven fabric 1, long fiber 2 of a complex of 11 fibers has the ability to form corrugations. As described above, in nonwoven fabric 1, pile fibers 20 having a free end portion (low pile fibers 21 and high pile fibers 22) also have the ability to form corrugations, and loop-shaped fibers 23 also have the ability to form corrugations. This means that all the fibers that make up the nonwoven fabric 1 have the ability to form corrugations.

Pile fibers 20 having a free end portion (low pile fibers 21 and high pile fibers 22) are potentially corrugated fibers in a corrugated state, and, in nonwoven fabric 1, contain spiral (in the form of coils) three-dimensional corrugations. Since the pile fibers 20 having a free end portion (low pile fibers 21 and high pile fibers 22) are potentially corrugated fibers, the effect that the nonwoven fabric 1 easily becomes bulky and the sensation of fluffiness caused by it is enhanced and achieved its increased permeability to liquid. As a potentially corrugated fiber can be used, for example, a composite fiber of the eccentric type of “core-shell” or concentric type of “core-shell”, or type “side-by-side”, consisting of two types of components that differ in degree of shrinkage. More specifically, two types of components that differ in degree of shrinkage can be used (thermoplastic polymer, etc.): (1) a combination of a random copolymer of ethylene and propylene (a component with a high degree of shrinkage) and polypropylene (a component having a low degree of shrinkage); (2) a combination of polyethylene terephthalate (PET) (a component having a low degree of shrinkage) and a copolymer of polyethylene and terephthalate and isophthalic acid (CoPET) (a component having a high degree of shrinkage); etc. Preferably, the fiber thickness is 0.8 dtex or more and 2.8 dtex or less. Potentially corrugated fiber is not limited to one species having spiral corrugations (in the form of curls), but it can contain two-dimensional corrugations, for example, the fiber can be curved in a zigzag fashion. The same applies to fibers (including fibers in the form of loops 23 and long fibers 2 of a complex of 11 fibers) constituting the nonwoven fabric 1, different from the low pile fibers 21 and high pile fibers 22.

From the point of view of enhancing the feeling of fluffiness and increasing the degree of freedom in the plane direction, the number of corrugations in the pile fibers 20 having a free end portion (low pile fibers 21 and high pile fibers 22) is 15/25 mm or more, preferably 20/25 mm or more, and 50/25 mm or less, preferably 40/25 mm or less, and more particularly preferably 15/25 mm or more and 40/25 mm or less, more preferably 20/25 mm or more and 40/25 mm or less than 25 mm - the length at which the number of corrugations is determined. The number of corrugations is determined according to Japanese industrial standard JIS L1015 8.12.1. The same applies to fibers (including fibers in the form of loops 23 and long fibers 2 of a complex of 11 fibers), different from pile fibers 20 having a free end portion (low pile fibers 21 and high pile fibers 22). The diameter of the long fiber 2 before treatment is preferably from 5 μm to 30 μm, more preferably from 10 μm to 20 μm.

As described above, the pile fibers 20 having a free end portion are capable of forming corrugations, and the degree of corrugation of the pile fibers 20 having a free end portion (low pile fibers 21 and high pile fibers 22) is preferably 80% or less, more preferably 70% or less, preferably 20% or more, more preferably 30% or more, more specifically, the degree of corrugation is preferably 20% or more and 80% or less. The expression "fibers have the ability to form corrugations" in this description means that the degree of corrugation of the pile fibers 20 having a free end portion is 85% or less. The degree of corrugation is determined using the following procedure.

Method for determining the degree of corrugation

In the methodology for measuring the diameter of the fiber described above, for measuring the degree of corrugation of the pile fibers 20 having a free end portion, the shortest distance (L1) between the distal end of the free end portion 20b of the pile fiber 20 having a free end portion and the fusion bonded region 3 which fixed one end portion 20a, is measured in a natural state using an image obtained using SEM at approximately 50-fold magnification; the free end portion 20b of the nap fiber 20 having a free end portion is combed so that the nap fiber 20 is stretched straightly in a direction perpendicular to the bend line Z extending in the direction of the X axis and through regions 3 fused together using a brush [regular brush No. 812 manufactured by KOMERI CO., Ltd., where the width of the brush (the width of the entire part of the brush provided with bristles) is 30 mm]; and measuring the distance (L2) between the distal end of the free end portion 20b of the pile fiber 20 having a free end portion, in a state where the pile fiber 20 is stretched straightly and a fusion bonded region 3 in which one end portion 20a is fixed. The fraction (L1 x 100 / L2), which is the shortest distance (L1) from the distance (L2), is calculated, and the calculated value is taken as the degree of corrugation of the pile fiber 20 having a free end portion. It should be noted that the calculation is carried out by determining the degree of corrugation from 9 images obtained using SEM, other areas in the same way, and determine the average value of these 10 degrees of corrugation.

Considering the fusion bonded regions 3 obtained by embossing (see FIGS. 1 and 3) from the point of view of obtaining texture or processing suitability, it should be noted that the area of each of the fusion bonded regions 3 is preferably 0.05 mm ² or more and 10.0 mm ² or less, more preferably 0.1 mm ² or more and 1.0 mm ² or less. The number of regions 3 bonded by fusion is preferably 10 / cm ² or more and 250 / cm ² or less, more preferably 35 / cm ² or more and 65 / cm ² or less. The distance between the centers of the fusion bonded regions 3 adjacent to each other in the X axis direction is preferably 0.5 mm or more and 10 mm or less, more preferably 1 mm or more and 3 mm or less, and the distance between the centers the fusion bonded regions 3 adjacent to each other in the direction of the Y axis are preferably 0.5 mm or more and 10 mm or less, more preferably 1 mm or more and 3 mm or less.

As for the regions 3 bonded by fusion, they are discretely formed by thermal compression and bonding by embossing (by using an embossing shaft with protrusions and a shaft with a smooth surface or the like); by ultrasonic bonding; by partial bonding using discretely directed jets of hot air, etc. Among these methods, bonding by thermal compression is preferred in that the fibers can be easily torn. The shape of the region 3 bonded by fusion is not particularly limited, and it can be arbitrary, for example: round, in the form of a rhombus and a triangle. The fraction of the total area of the fusion bonded regions 3 from the surface area of one side of the nonwoven fabric 1 is preferably 5% or more and 30% or less, more preferably 7% or more and 20% or less, so that the pilling of the rolled fibers does not occur.

Since the nonwoven material 1 contains fibers having a relatively high degree of freedom, and the gaps between the fibers are filled, so that the surface roughness becomes small and the surface becomes smooth. From the point of view of improving texture, the wider the distribution range (degree of dispersion) of fiber diameters, the more preferable, but from the point of view of improving texture, with a distribution range (degree of dispersion) of 0.33 or more, a sufficiently satisfactory effect can be achieved and with a distribution range (degree of dispersion) of 0.35 or more, an additional satisfactory effect can be achieved. The upper limit of the distribution range (degree of dispersion) of the fiber diameters is not particularly clearly established, but the distribution range (degree of dispersion) of the fiber diameters is preferably 100 or more. The distribution range (degree of dispersion) of the fiber diameters is more preferably 0.33 or more and 0.9 or less. The term "distribution range (degree of dispersion) of fiber diameters" as used here means the distribution range (degree of dispersion) of all diameters of the fibers constituting the nonwoven material 1, and this is the distribution range of all pile fibers 20 having a free end portion, only one end portion 20a of which are fixed in fusion bonded regions 3 [low pile fibers 21 (first, low, pile fibers 211 having a thick, loose, end portion 20b, and second, low, pile fibers 212 having a free end portion 20b that is not thick) and high pile fibers 22 (first, high, pile fibers 221 having a thick, free, end portion 20b, and second, high, pile fibers 222 having a thick, free, end portion 20b, which is not thick], and fibers in the form of loops 23, as well as fibers, both ends of which are fixed in regions 3 fastened by fusion, not raised in the form of loops (fibers that were not affected by the processing described below). The distribution (degree of dispersion) of the fiber diameters is determined using the following procedure.

Fiber Diameter Measurement Technique

Methodology for determining the distribution (degree of dispersion) of fiber diameters

Under ambient conditions: temperature 22 ° C, 65% RH, measurement segment with dimensions: 2 cm in the direction of the X axis and 2 cm in the direction of the Y axis, first cut from the nonwoven fabric 1 to be measured using a sharp razor and cut the measuring section is laid and fixed on a scanning stand made of aluminum for samples of an electron microscope (SEM), where a carbon tape is laid on the stand without wrinkling in the initial state. Then, 10 fibers are randomly selected from the SEM images at approximately 750x magnification, and fiber diameters are measured in areas other than the free end portions 20b. The diameters of ten fibers are measured on a sample stand made of aluminum, as described above, and the average value d _{ave is} calculated from 10 diameters d ₁ -d ₁₀ fibers, and the distribution of fiber diameters over randomly selected 10 fibers obtained by measuring diameters d ₁ - d ₁₀ fibers, and the average value of d _{ave is} calculated according to the following formula (2). Measurements are made where the unit of measurement is microns and the resolution is 0.1 microns. To determine the distribution range of fiber diameters of 10 fibers, prepare 6 stands made of aluminum for samples in 6 places on one nonwoven material 1, and determine the average value of the distribution range of fiber diameters for 10 fibers obtained in each place [see the following formula (3)], and it is taken as the range of distribution of fiber diameters in non-woven material 1. It should be noted that to calculate the distribution of fiber diameters of 10 fibers, use the VARPA function in the Excel 2003 software spreadsheet created by Microsoft Corp.

The diameter distribution of the fibers of 10 fibers = [(d ₁ -d _ave ) ² + (d ₂ -d _ave ) ² + ... (d ₁₀ -d _ave ) ² )] / 10 ... (2)

Distribution (degree of dispersion) of fiber diameters in non-woven material 1 = (total sum of distributions of diameters of 10 fibers obtained by the above formula (2)) / 6 ... (3)

In the nonwoven fabric 1, from the point of view that the texture becomes good, the amount of pile fibers is preferably 8 / cm or more, more preferably 12 / cm or more. From such a point of view that sufficient tensile strength is obtained, the upper limit of the amount of pile fibers is 100 / cm or less, more preferably 40 / cm or less; from such a point of view that the nonwoven fabric 1 does not seem fluffy in appearance. The term “pile fibers” as used herein is understood to mean fibers consisting of pile fibers 20 having a free end portion [low pile fibers 21 (first, low, pile fibers 211 having a thick, loose, end portion 20b, and second, low , pile fibers 212 having a free end portion 20b which is not thick) and high pile fibers 22 (first, high, pile fibers 221 having a thick, loose, end portion 20b, and second, high, pile fibers 222 having a thick , free end portion 20b, not thick], and fibers in the form of loops 23. Pile fibers can be measured by the following method.

Method for measuring pile fibers

In FIG. 6 schematically illustrates the method for measuring the amount of pile fibers among the fibers constituting the nonwoven material 1, in ambient conditions: temperature 22 ° C, OV 65%. First, a measurement section with dimensions of 20 × 20 cm is cut out of the nonwoven material to be measured using a sharp razor, and a measurement sample 104 is formed by folding the pile surface of the measurement section outwardly relative to the bend line Z extending in the direction of the X axis and through many areas 3 fastened by fusion, as in the method for measuring fiber diameter, as shown in FIG. 6 (a). Then, the measurement sample 104 is laid on a black support of size A4, and a black support of size A4 containing an opening 107 with dimensions: 1 cm in the longitudinal direction × 1 cm in the transverse direction is additionally laid on it, as shown in FIG. 6 (b). At this time, as shown in FIG. 6 (b), the laying is carried out so that the fold 105 of the measurement sample 104 is visible in the hole 107 from the upper side of the rear support. For both supports, Kenran paper (a stack of paper of 500 sheets of 265 g) was used, manufactured by FUJIKYOWA SEISHI. Then, weights of 50 g are placed in places distant from both sides of the hole 107 of the upper support outward along the fold 105 by 5 cm, respectively, thereby forming a fully folded state of the sample 104 for measurements. Then, as shown in FIG. 6 (c), inside the aperture 107, the supports are viewed at 30x magnification using a microscope (Model VHX-900, manufactured by KEYENCE CORP.), And a fiber protruding above an imaginary line 108 formed in a position shifted plane-parallel upward on 0.2 mm from the fold 105 of the sample 104 for measurements, and parallel to the fold 105, is defined as a pile fiber, and the number of pile fibers per 1 cm is determined. The measurement is carried out in 9 positions, and the average value (rounded to the second decimal place) is taken as the number pile fibers.

In addition, when counting the number of pile fibers, for example, if there is a fiber crossing the imaginary line 108 twice, like the fiber 106a shown in FIG. 6 (c), then this fiber is counted as two fibers. More specifically, in the example shown in FIG. 6 (c), the number of fibers crossing the imaginary line 108 once is four; the number of fibers 106a crossing the imaginary line 108 two times is one, but the fiber 106a crossing the imaginary line 108 two times is read as two fibers, and the total number of pile fibers is six.

In addition, from the point of view of the fact that the pile fiber is difficult to turn into a rolled up ball (pilling), the pile is difficult to drop out and a soft-looking appearance is obtained, which is preferred; the pile fiber height is preferably 1.5 mm or less, more preferably 0.8 mm or less. When viewed from above, it turns out that the lower the height, the more preferable, but a nonwoven material having a sufficiently satisfactory texture can be obtained at a height of 0.2 mm or more. In addition, in addition to the above, for compatibility with tensile strength, the height of the pile fibers is more preferably 1.5 mm or less, and the number of pile fibers is 8 / cm or more. In addition, from the point of view that the non-woven material is slightly moved relative to the skin of the consumer, and the contact with it is pleasant, it is preferable that the height of the pile fiber is 0.5 mm or less, and the number of pile fibers is 15 / cm or more . In addition, if the height of the pile fiber exceeds 5 mm, a fluffy appearance is obtained, and when the pile fiber is rubbed during use, the fiber rolls into a ball (pilling) or the pile falls out, which is not desirable. The height of the pile fiber is different from the length of the fiber, and means the height of the fiber in its natural state when the fiber is not pulled during fiber measurement. If the length of the pile fiber is large or if the stiffness of the fiber is high, then there is a tendency for the height of the pile fiber to become larger. The pile fiber height is determined using the following procedure.

The height of the pile fibers is measured simultaneously with the measurement of the number of pile fibers. More specifically, as shown in FIG. 6 (c), the inside of the support hole 107 is viewed and lines parallel to the fold 105 are drawn at 0.05 mm intervals from the fold 105 to the part that the pile fibers do not cross. Then, a parallel line, where the number of fibers crossing the parallel lines becomes equal to half, compared with the number of pile fibers, determined as described above (definition obtained from an imaginary line 108, located 0.2 mm higher), and measure the distance from a parallel line to the crease. The measurement is made on three non-woven materials to be measured using the operations described above, and on three parts of each non-woven material, thus, in general, an average height of 9 parts of three non-woven materials is determined, thereby determining the height of the pile fibers (also called “ the height of the pile fiber ").

In addition to the height of the pile fibers and the pile fibers, it is preferable that the bulk softness of the nonwoven fabric 1 is 8.0 cN or less, since a soft nonwoven fabric is obtained and its texture is pleasant to the touch. In addition, it is preferable that the volume softness is 0.5 cN or more and 3.0 cN or less, since a pliable non-woven material similar to that for clothes for infants, for newborns or small children is obtained. Volume softness is determined using the following measurement procedure.

Method for measuring volumetric softness

Considering the volume softness of non-woven material 1, from non-woven material 1 at ambient conditions: temperature 22 ° C, 65% ОВ, cut a piece with dimensions: 150 mm in the Pr direction and 30 mm in the Pop direction and the end parts of the segment are fastened with a stapler from above and from below to its two places so that a ring is formed from the segment. At the same time, the staples installed by the stapler are positioned so that they pass in the Pr direction. A tensile testing machine (TENSILON tensile testing machine “RTA-100” manufactured by A&D Company, Ltd.) is used, where the ring is prepared so that it stands on the sample stand and the maximum compression load of the ring is measured at a compression speed of 10 mm / min, using a flat plate, which is placed on top approximately parallel to the stand; the maximum load is taken for volume softness in the Pop direction. Then the ring is formed so that the Pr direction and the Pop direction are mutually changed, and at the same time, volume softness is measured in the Pr direction. Two rings are formed for each of the directions (Pr direction and Pop direction) and measured to determine the average value in the Pop direction and in the Pr direction, and their accepted for the bulk softness of the non-woven material 1.

As described above, the fibers constituting the nonwoven fabric 1 [including: pile fibers 20 having a free end portion (low pile fibers 21 and high pile fibers 22) and long fibers 2 of the fiber complex 11] are potentially corrugated fibers, and potentially corrugated the fibers can be coated with small amounts of additives, for example: a fiber dye, an antistatic agent, a textile softener, or a hydrophilic substance. As a textile material softener, it is possible to use, for example, for example: a wax emulsion, a textile type softener that interacts, a silicone compound, a surfactant, and the like. It is preferable to use silicon containing an amino group, silicon containing an oxyalkene group or a surfactant. As the surfactant, an anionic surfactant can be used, for example: an anionic surfactant of a carboxylate group; anionic surfactant of the sulfonic acid group; anionic sulfate group surfactant; and an anionic surfactant based on phosphoric acid esters (especially alkyl phosphate); non-ionic surfactant, for example: ester of polyhydric alcohol and mono-fatty acid; for example, sorbitol fatty acid ester; diethylene glycol monostearate; diethylene glycol monooleate; glyceryl monostearate; glyceryl monooleate or propylene glycol monostearate; fatty acid amide, for example, oleic amide; stearic acid amide or erucic acid amide; N- (3-Oreirokishi-2-hydroxypropyl) diethanolamine; polyoxyethylene hydrogenated castor oil; polyoxyethylene sorbitol of beeswax; polyoxyethylene sorbitol one and a half stearate; polyoxyethylene monooleate, polyoxyethylene sorbitol of one and a half stearate; polyoxyethylene glyceryl monolaurate; polyoxyethylene monostearate; polyoxyethylene monolaurate; polyoxyethylene monooleate; cetyl polyoxyethylene ether or lauryl alcohol polyoxyethylene ether; a cationic surfactant, for example, a quaternary ammonium salt; amine salt or amine; or an amphoteric surfactant, for example, aliphatic derivatives of a secondary or tertiary amine containing carboxyl, sulfonate or saffate; or aliphatic derivatives of a heterocyclic secondary or tertiary amine. A known chemical substance can be added to the textile fabric softener according to the present invention as a secondary additive (small component) as necessary.

The following describes a preferred method of manufacturing a nonwoven fabric 1 according to the present invention with reference to FIG. 7 and 8. A manufacturing apparatus, preferably used for implementing the method of manufacturing a nonwoven fabric 1, approximately consists of a pretreatment section 4 and a fiber teething section 5 located downstream of the pretreatment section 4. The pretreatment section 4 is a partial stretch section in this manufacturing apparatus.

As shown in FIG. 7, the pre-treatment section 4 is provided with steel matched embossing shafts 43 consisting of a pair of shafts 41 and 42. As shown in FIG. 7, the steel, matched, embossing shafts 43 are metal cylindrical shafts made of aluminum alloy or steel, and one shaft 41 contains a plurality of protruding parts 411 on its circumferential surface, while the other shaft 42 contains recessed parts 422 into which protruding parts 411 and which are located in places corresponding to the locations of the protruding parts 411 of one shaft 41, on its circumferential surface. In addition, the other shaft 42 contains a plurality of protruding parts 421 on its circumferential surface, while one shaft 41 contains a recessed part 412, which should include the protruding parts 421 and which are located in places corresponding to the locations of the protruding parts 421 on the other shaft 42, on its circumferential surface. In a pair of shafts with recesses and protrusions 41 and 42, the protruding parts 411, 421 and the recessed parts 412, 422 are staggered, respectively. A pair of shafts 41 and 42 are rotated while they are engaged with each other by a drive force transmitted to the pin of one of the shafts from the drive means (not shown). In the apparatus for manufacturing according to this embodiment, one shaft 41 with recesses and protrusions and another shaft 42 with recesses and protrusions are the same shafts, except that mutually protruding parts 411, 421 are provided at locations corresponding to mutually recessed parts 422, 412. In the following explanation, thus, when considering the same parts, the protruding parts 411 of one shaft 41 with recesses and protrusions and the recessed parts 412 of another shaft 42 with recesses and protrusions are mainly described. In addition, the pre-treatment section 4 is provided with conveyor shafts 44 and 45 used to transport the original non-woven material 10, which are located upstream and downstream of the steel, matched, embossing shafts 43, for example, as shown in FIG. 7. The rotation speed of the steel matched embossing shafts 43 is controlled by a control unit (not shown) provided in the apparatus for manufacturing.

The height of each protruding part 411 of the shaft 41 from the circumferential surface of the shaft 41 to the top of the protruding part 411 is 1 mm or more, more preferably 2 mm or more, and is 10 mm or less, more preferably 7 mm or less. The distance (step) between the protruding parts 411 located next to each other in the direction of the axis of rotation is also 0.01 mm or more, more preferably 1.0 mm or more, and is 20 mm or less, more preferably 10 mm or less, and the distance (step) between the protruding parts 411 located adjacent to each other in the circumferential direction is also 0.01 mm or more, more preferably 1 mm or more, and is 20 mm or less, more preferably 10 mm or less. The shape of the upper surface of each protruding part 411 of the shaft 41 is not particularly limited, and a round shape, a polygonal shape, an oval shape or the like can be used, and the surface area of each protruding part 411 is 0.01 mm ² or more, more preferably 0, 1 mm ² or more and 500 mm ² or less, more preferably 10 mm ² or less. The engagement depth between each projecting part 411 of the shaft 41 and each recessed part 422 of the shaft 42 (overlap length of each projecting part 41 and each recessed part) is 0.1 mm or more, more preferably 1.0 mm or more, and is 10, 0 mm or less, more preferably 5.0 mm or less.

The fiber teasing section 5 comprises a protruding shaft 51 containing protruding parts 511 on its circumferential surface, and conveying shafts 52 and 53 used for conveying the pre-processed nonwoven fabric 10 ′, located upstream and downstream of the protruding shaft 51 . The shaft 51 with the protrusions is rotated using drive forces transmitted to the journal of the shaft 51 with the protrusions from the drive means (not shown). The rotational speed of the shaft 51 with protrusions is controlled by a control unit (not shown) provided in the apparatus for manufacturing.

The height of each protruding portion 511 of the shaft 51 with protrusions from the circumferential surface of the protruding shaft 51 is preferably 0.001 mm or more and 3.0 mm or less, more preferably 0.001 mm or more and 0.1 mm or less. Since the shaft 51 with protrusions of such a small height is also included, the so-called “matte shaft” is also sandblasted (the shaft is sandblasted). The distance (pitch) between the protruding parts 511 located adjacent to each other in the direction of the axis of rotation is preferably 0.1 mm or more and 50.0 mm or less, more preferably 0.1 mm or more and 3.0 mm or less, and the distance (pitch) between the protruding parts 511 located adjacent to each other in the circumferential direction is preferably 0.1 mm or more and 50.0 mm or less, more preferably 0.1 mm or more and 3.0 mm or less. The shape of the upper surface of each protruding portion 511 of the protruding shaft 51 is not particularly limited, and, for example, a circular shape, a polygonal shape, an oval shape or the like may be used, and the surface area of each protruding portion 511 is preferably 0.001 mm ² or more and 20 0 mm ² or less, more preferably 0.01 mm ² or more and 1.0 mm ² or less. It should be noted that if the shaft 51 with the protrusions is a sandblasted shaft, then the density of the protruding parts 511 is preferably 1000 / cm ² or more and 3000 / cm ² or less, more preferably 1200 / cm ² or more and 2500 / cm ² or less.

In a manufacturing apparatus provided with a pre-treatment section 4 and a nap section 5, fibers having such a configuration, for example, a continuous, starting, non-woven material 10, which is the starting material for making the non-woven material 1, are first wound from a roll of raw material (not shown ), and the original non-woven material 10 is transported between the shafts 41 and 42, representing a pair 43 of steel, matched, embossing shafts, using the conveyor shafts 44 and 45, as shown in FIG. 7.

As the source of nonwoven material 10, you can use the non-woven material "spunbond", with the ability to form corrugations, consisting, for example, of potentially corrugated fibers; or non-woven material, brought into a state in which the laminated non-woven material in the form of a layer of material "spunbond", consisting of potentially corrugated fibers and a layer of non-woven material obtained by blowing a polymer melt, consisting of potentially corrugated fibers, subjected to heat shrinkage to form corrugations, and etc. As a laminated non-woven material, you can use, for example: laminated non-woven material "spanbond" - "spanbond"; laminated non-woven material "spanbond" - "spanbond" - "spanbond"; laminated non-woven material "spunbond" - non-woven material obtained by blowing a polymer melt - "spunbond"; laminated non-woven material "spanbond" - "spanbond" - non-woven material obtained by blowing a polymer melt; etc.

In part 4 for pre-treatment, many parts of the original nonwoven material 10 are subjected to partial stretching, respectively. In more detail: in section 4 for preprocessing, as shown in FIG. 7, the starting nonwoven fabric 10 is clamped between a pair of shafts 41 and 42 so that the starting nonwoven fabric 10 is partially stretched and damaged. From the point of view of preventing bonding by fusion of the constituent fibers of the original nonwoven material 10 when the original nonwoven material 10 is damaged, it is preferable that the treatment with steel, matched, embossing shafts is carried out in a state in which the shafts 41 and 42 constituting a pair of 43 steel, matched, embossed shafts do not carry out direct heating, or they act at a temperature equal to or lower than the melting temperature of the component having the lowest melting temperature Ia, of the components constituting the raw nonwoven 10, in particular at a temperature below the melting point by 70 ° C or more.

Then, as shown in FIG. 8, the damaged starting nonwoven fabric 10 ′ is transported to the shaft 51 with protrusions using the transporting shafts 52 and 53. In the fiber picking section 5, parts of the long fibers 2 of the fiber complex 11 comprising the starting nonwoven fabric 10 ′ are torn using a shaft with protrusions containing protruding parts on its circumferential surface, thereby forming pile fibers 20 having a free end part (including low pile fibers 21 and high pile fibers 22), only one of which end parts 20a are fixed to 3, fusion-bonded, and other end sides are free end portions 20b. In this way, a nonwoven material 1 is formed containing pile fibers 20 having a free end portion (including low pile fibers 21 and high pile fibers 22), only one end parts of which 20a are fixed in the fusion bonded regions 3 of the spunbond nonwoven fabric (see Fig. 1). From the point of view of ensuring efficient formation of pile fibers 20 having a free end portion shown in FIG. 1, by tearing parts of the long fibers 2, it is preferable that the direction of rotation of the protruding shaft 51 is opposite to the conveying direction of the original nonwoven fabric 10 ′, and it is preferable that the protruding shaft 51 rotates at a speed 0.3-30.0 times different from the transportation speed of the original nonwoven material 10 ′. In addition, it is preferable that when the shaft 51 is rotated with protrusions in the circumferential direction (forward with respect to the conveying direction), its rotation speed differs by 1.5-50.0 times from the conveying speed of the initial nonwoven material 10 ′. In this case, the speed of the shaft 51 with protrusions is understood to mean the peripheral speed of the circumferential surface of the shaft 51 with protrusions.

From the point of view of ensuring a more efficient tearing of the parts of the long fibers 2 and a more efficient formation of pile fibers 20 having a free end part (see FIGS. 1 and 8), it is preferable that the conveying shaft 53 is mounted higher than the shaft 51 with protrusions, and the damaged starting nonwoven material 10 ′ was in contact with the contacting side of the shaft 51 with the protrusions at an angle of envelope α. From the point of view of suppressing a reduction in the width of the nonwoven material due to its narrowing, the envelope angle α is 10 ° or more, more preferably 30 ° or more, and 180 ° or less, more preferably 120 ° or less; more specifically, it is 10 ° or more and 180 ° or less, more preferably 30 ° or more and 120 ° or less.

It should be noted that if the pile fibers 20 having a free end part, where only one end parts 20a of the pile fibers 20 are fixed in the fusion bonded regions 3, are formed on both surfaces of the nonwoven fabric 1, then the formation of both surfaces can be carried out by additional surface treatment (back surface) of the original nonwoven material 10 ′, which is different from its surface machined by the shaft 51 with protrusions by using another shaft 51 with protrusions.

Pile fibers 20 having a free end portion contained in the nonwoven fabric 1 and formed by the above method are described in more detail below. As described above, since a non-woven material consisting of fibers having the ability to form corrugations in a corrugated state achieved by heat shrinking parts of the fibers is used as the starting nonwoven material 10, parts of the long fibers 2 are torn using the shaft 51 with protrusions for forming fibers 21, forming a low pile, the free end parts 20b of which hang down to the surface of the complex 11 fibers, and fibers 22, forming a high pile, the free end parts 20b of which are the most high. In addition, the original non-woven material 10 is pulled using steel, matched, embossing shafts 43; weakened points are formed in regions 3 bonded by fusion of the original nonwoven material 10; the long fibers 2 are then torn off from the weakened points of the upper surfaces of the fusion bonded regions 3 of the original non-woven material using a shaft 51 with protrusions; and fibers torn from fusion bonded regions 3 are fibers having a thick, loose, end portion 20b (first, low, pile fibers 211 and first, high, pile fibers 221). The adjustment of the weakened points can be accomplished by adjusting the amount of engagement between the upper and lower shafts 41 and 42 of the pair 43 of steel, matched, embossing shafts. In addition, if the surface of the initial nonwoven material 10 is treated with a shaft 51 with protrusions, then the long fibers 2 are torn between the fusion bonded regions 3 and 3, and fibers are formed having a free end portion 20b that is not thick (second, low , pile fibers 212 and second, high pile fibers 222). It should be noted that the long fibers 2 are released from the weakened points of the fusion bonded regions 3 under the action of the projection shaft 51, and the fibers released from the fusion bonded regions 3 form pile loops 23 between the fusion bonded regions 3. Since the non-woven fabric made using the corresponding manufacturing method described above, the fibers of the non-woven fabric 1 are bristled after weakening the dots in the fusion bonded areas 3 using steel matched embossing shafts 43, and it differs in that the proportion of fibers in the form loops 23 and fibers that have not become thick (second, low, pile fibers 212 and second, high, pile fibers 222) are smaller than in a nonwoven fabric made using a conventional teasing method. In addition, since napping is carried out after the formation of weakened points in the regions 3 fastened by fusion using steel, matched, embossing shafts 43, the formation of a so-called gap (breakthrough or hole) between the regions 3 fastened by fusion is unlikely, so that the strength the gap of the original nonwoven material 10 can be stored in its original condition.

In the above apparatus for manufacturing, a section for heat treatment is additionally provided for performing heat treatment at a temperature lower than the melting temperature of the fibers constituting the initial nonwoven material 10. The section for heat treatment is located up to the treatment zone by means of steel, matched, embossing rolls 43 of section 4 for pretreatment; before the processing carried out by means of the shaft 51 with the protrusions of the fiber teasing section 5, or after the processing carried out by the shaft 51 with the protrusions of the fiber teasing section 5; and in this section, the starting nonwoven material 10 can be treated with hot air at a temperature lower than the melting point of the fibers of the starting nonwoven material 10. By treating with hot air, the degree of corrugation can be further increased, and the proportion of low pile fibers 21 is increased or the bulk properties of the starting nonwoven material 10 are improved , and thus texture and absorption capacity can be further improved. In particular, from the point of view that it is possible to produce nonwoven material 1 with improved texture and increased absorption capacity, it is preferable that the heat treatment section be provided after processing carried out by the shaft 51 with protrusions in the fiber teasing section 5, and after of how many parts of the starting nonwoven material 10 were partially drawn in the pre-treatment section 4, respectively, and the pile fibers 20 having a free end part are formed in the 5 d section for nibbling the fiber by tearing parts of the long fibers 2 of the fiber complex 11 of the starting nonwoven material 10 ′, carried out by partial drawing using a shaft 51 with protrusions containing the protruding parts 511 on the circumferential surface; and pile fibers 20 having a free end portion are then heated in the heat treatment section.

The following describes the operation and the effect of its use when using the above nonwoven material 1 according to an embodiment of the present invention.

In the nonwoven fabric 1 according to an embodiment of the present invention, as shown in FIG. 1 and 3, pile fibers 20 are formed having a free end portion by tearing parts of long fibers 2, where only one end portion 20a is fixed in fusion bonded regions 3. Since such pile fibers 20 having a free end portion are in a corrugated state, all non-woven material 1 can cause a feeling of fluffiness. In particular, since the pile fibers 20 having a free end portion in the nonwoven fabric 1 include low-fiber corrugated fibers, the free end parts 20b of which hang down to the fiber complex 11 (first, low, pile fibers 211, free end parts 20b which are thick, and second, low, pile fibers 212, the free end parts of which are not thick 20b), the nonwoven fabric 1 is difficult to hold on the skin of the consumer and it has a high degree of freedom in the planar direction, which leads to results in smoothness, which improves the texture further. In addition, since only parts of the long fibers 2 are torn, the tensile strength can be kept high, similar to the strength of the original non-woven material 10. In addition, the non-woven material 1 according to this embodiment contains a reduced number of fibers in the form of loops, and it is difficult to hold on the skin of the consumer, as the texture is improved.

Spunbond nonwoven fabric or spunbond laminated nonwoven fabric usually causes a reduced feeling of fluffiness, and is worse in texture of the nonwoven fabric obtained by blowing hot air, but the nonwoven fabric 1 described above according to this embodiment, since the fluffiness property is added to smoothness such a Japanese paper texture improved to a large extent.

In particular, as shown in FIG. 1 and 3, since in the first low pile fibers 211 having a thick, loose, end portion 20b, their free end portions 20b are raised above the surface of the fiber complex 11, and they hang down to the fiber complex 11, the nonwoven fabric 1 causes a strong feeling of fluffiness so that the retention on the skin of the consumer can be weakened.

In addition, since all the fibers constituting the nonwoven fabric 1 have the ability to form corrugations, as shown in FIG. 3, the feeling of fluffiness can be additionally caused by all non-woven material 1.

Considering the range of use of the nonwoven fabric 1, it should be noted that the nonwoven fabric is mainly used appropriately as a constituent element in an absorbent article, for example, a disposable diaper or sanitary napkin. The nonwoven fabric 1 is suitable for use as a constituent element, for example, a topcoat, a lower coating, a web representing the outer coating of a disposable diaper, and the like, in particular, a nonwoven fabric 1 is suitable for use as a top coating of an absorbent article disposed facing the skin of the consumer. Considering the range of use of non-woven material 1, it should be noted that, among other things, non-woven material 1 is also suitable for use as a cloth for cleaning (cleaning). A disposable diaper using a nonwoven fabric 1 is described in more detail below.

As shown in FIG. 9, an article of clothing without fasteners, for example, a disposable diaper 100, is provided with an absorbent assembly 50 containing an absorbent component 40, and an outer cover 60 located on the side of the absorbent assembly 50 not applied to the skin of the consumer, where the absorbent assembly 50 is attached using this component. .

As shown in FIG. 10, the absorbent assembly 50 comprises: a liquid-permeable upper web 70; liquid impervious (containing hydrophobic material) back web 80; and a liquid retaining absorbent component 40 interposed between the webs 70, 80; where the assembly is essentially oblong in the longitudinal direction.

As shown in FIG. 9, the outer cover 60 comprises: a back A located on the back of the consumer; the front part B located on the front side of the consumer; the crotch part C, located between the rear part A and the front part B, and located in the crotch area of the consumer. Both side edge parts 6a, 6b of the rear part A and the front part B are fastened in such a way that a pair of side seals (not shown), a pair of leg openings (not shown) and a waist opening (not shown) are formed. In addition, the outer cover 60 includes: an outer canvas 62 forming the outer surface of the diaper, and an inner canvas 61 located on the side of the surface facing the skin of the consumer, the outer canvas 62, and partially attached to the outer canvas 62. Elastic elements 63 located in waist regions, and elastic elements 64 located in the leg region to form a joint are located between both webs 61 and 62 in the waist region and in the leg areas 6d to form a waist opening and leg openings.

As shown in FIG. 9, the absorbent assembly 50 is arranged so that it extends from the rear portion A of the outer cover 60 to the front portion B. Both longitudinal end parts of the absorbent assembly 50 are located in the longitudinal direction inside from both longitudinal end parts of the outer cover 60. As shown in FIG. 10, in the absorbent assembly 50, the surface not facing the skin of the consumer, the bottom cover 80 of the absorbent assembly 50, is attached to the surface facing the skin of the consumer, the inner web 61 of the outer coating 60 by a certain bonding method, for example, using adhesive, heat sealing or ultrasonic welding.

As shown in FIG. 9, lateral cuffs 55, 55, consisting of a liquid-impermeable or hydrophobic but breathable material, are provided in both lateral parts of the absorbent assembly 50 along a longitudinal direction. An elastic component 56 for forming the side cuffs is arranged and cuffs are stretched in the vicinity of the free edge portions of each side cuff 55. Using the side cuff 55, it is possible to prevent the outflows outward in the width direction of the absorbent assembly 50, since the free edge part rises while wearing the diaper . As shown in FIG. 10, a region 55a of a predetermined web width for forming a side collar 55 extending outwardly from the absorbent assembly 50 is bent from the side not facing the skin of the consumer, the absorbent member 40, and secured between the absorbent member 40 and the lower cover 80. It should be noted that a region 55a of a predetermined width can be fixed between the bottom cover 80 and the outer cover 60.

The nonwoven fabric 1 according to this embodiment is suitable for use as a top cover 70 of a disposable diaper 100 without fasteners in the form of a surface facing the skin of the consumer. In addition, the nonwoven fabric 1 can be used as the outer fabric 62 and the inner fabric 61 of the outer coating 60 and the lower coating 80, as well as the fabric for forming the side cuffs 55. As elements for the respective parts, if the nonwoven fabric 1 is not used, the elements commonly used in an absorbent article, such as a disposable diaper, can be used without limitation. For example, a liquid-permeable non-woven material, a perforated film or a laminate of these elements can be used as a top coating 70, and a polymer film, a polymer film laminate and non-woven material or the like can be used as the bottom coating 80. As the web for forming the side cuff 55, an extensible film, nonwoven fabric, fabric, or a limited list of these elements can be used. As the inner web 61 and the outer web 62, water-repellent non-woven material or the like can be used.

As the absorbent element 40, materials commonly used in an absorbent article, for example, a disposable diaper or the like, can be used without limitation. For example, as an absorbent element 40, an element obtained by wrapping a complex of fibers from a fibrous material from cellulose pulp or a similar material or a complex of fibers carrying polymers having a high absorbent ability with a wrapping material, for example, toilet paper or non-woven water-permeable, can be used material or similar means.

As the elastic element for forming the side cuff 56, the elastic element 63 in the waist region and the elastic element 64 in the leg region, elements commonly used in an absorbent article, for example, in a disposable diaper, can be used without limitation. For example, a tensile material consisting of natural rubber, polyurethane, a polystyrene and polyisoprene copolymer, a polystyrene-polybutadiene copolymer, a polyethylene-α-olefin copolymer, for example, an ethyl acrylate-ethylene copolymer, or the like, can be used.

The nonwoven fabric according to the present invention is not limited in any way to the nonwoven fabric 1 according to the above embodiment, and it can be modified appropriately.

For example, in this manufacturing apparatus used to implement the method of manufacturing non-woven material 1, a pair of shafts with teeth and grooves provided with teeth and grooves can be used as a shaft with protrusions in the fiber teasing section 5 together; knurled shaft; sprayed shaft; carding headset; sandblasted matte shaft (sandblasted shaft) or the like. In addition, it is possible to use a shaft with protrusions comprising a circumferential surface provided with protruding parts, where the shape of the upper surface of the protrusions of the shaft 51 with the protrusions has a circular shape, a polygonal shape, an oval shape or the like, arranged in a scattered order; or a rubber shaft provided with a rubber coating on its circumferential surface having friction resistance; or sandpaper. It is preferable to use a sandblasted shaft from these objects.

In addition, in this manufacturing apparatus used to carry out the method of manufacturing the nonwoven fabric 1, a pre-treatment section 4 is provided, which is a partial stretch section, in addition to a fiber tee section 5, but only a fiber tee section 5 can be provided .

Considering the embodiment described above, it should be noted that the following are further disclosed: nonwoven fabric, method for manufacturing nonwoven fabric, top coat of absorbent article, absorbent article and disposable diaper.

<1>

A nonwoven material comprising a complex of fibers, wherein the long fiber is fixed by means of a fusion bonded region; Where

- non-woven material contains a pile fiber formed by tearing part of a long fiber, and where only one end part is fixed in the area bonded by fusion, and the other end side is a free end part; and

- pile fibers have the ability to form corrugations and include low pile fibers, the height of the free end of which is less than the height of the pile fiber in its highest position.

<2>

The nonwoven fabric according to paragraph <1>, in which the low pile fibers include a pile fiber, in which the free end portion is thick.

<3>

The nonwoven fabric according to paragraph <1> or <2>, wherein the pile fibers include low pile fibers and high pile fibers.

<4>

The nonwoven fabric according to any one of paragraphs <1> to <3>, the tensile strength of which is preferably 5.0 N / 50 mm or more, more preferably 8.0 N / 50 mm or more and 30.0 N / 50 mm or less.

<5>

The nonwoven fabric according to any one of paragraphs <1> to <4>, wherein the tensile strength of the original nonwoven fabric for the manufacture of the nonwoven fabric (1) is preferably 7 N / 50 mm or more, more preferably 10 N / 50 mm or more, and 50 N / 50 mm or less.

<6>

Non-woven material according to paragraph <5>, where the ratio of the tensile strength of the non-woven material to the tensile strength of the original non-woven material (tensile strength of the non-woven material / tensile strength of the original non-woven material) is 0.5 or more, preferably 0.7 or more 1.0 or less, and is 0.5 or more and 1.0 or less, or 0.7 or more and 1.0 or less.

<7>

The nonwoven fabric according to any one of paragraphs <1> to <6>, wherein the characteristic value of compression of the nonwoven fabric under light load is preferably 0.98 (cN / cm ² ) / mm or more, preferably 17.6 (cN / cm ² ) / mm or less, preferably 14.7 (cN / cm ² ) / mm or less, more preferably 9.80 (cN / cm ² ) / mm or less.

<8>

The nonwoven material according to paragraph <2>, wherein the increase in the diameter of the distal end of the pile fiber having a thick free end portion is preferably 15% or more, more preferably 20% or more, even more preferably 25% or more.

<9>

The nonwoven fabric according to any one of paragraphs <1> to <8>, wherein the proportion of low pile fibers in the total number of pile fibers is 20% or more.

<10>

The nonwoven fabric according to paragraph <2>, wherein the proportion of pile fibers having a thick, free end portion in the total amount of low pile fibers is preferably 35% or more, more preferably 40% or more, even more preferably 50% or more .

<11>

The non-woven material according to any one of paragraphs <1> to <10>, comprising a loop-shaped fiber that represents a loop-shaped pile between regions fused together; and

- the proportion of fibers in the form of loops in the total number of pile fibers for which only one end part of the pile fibers is fixed in the areas bonded by fusion, and the proportion of fibers in the form of loops in the total number of fibers constituting the nonwoven material is less than 50%, 45%, or less, or 40% or less.

<12>

The nonwoven fabric according to any one of paragraphs <1> to <11>, in which long fibers other than the pile fibers of the fiber complex have the ability to form corrugations.

<13>

Non-woven material according to any one of paragraphs <1> to <12>, in which all the fibers making up the non-woven material have the ability to form corrugations.

<14>

The nonwoven fabric according to any one of paragraphs <1> to <13> in which the degree of corrugation of the pile fibers is 80% or less.

<15>

The nonwoven fabric according to paragraph <14>, wherein the degree of corrugation is preferably 80% or less, more preferably 70% or less, and preferably 20% or more, more preferably 30% or more, more specifically 20% or more and 80% or less.

<16>

Non-woven material according to any one of paragraphs <1> to <15>, in which the number of corrugations in the pile fibers is 15/25 mm or more, preferably 20/25 mm or more, and 50/25 mm or less, preferably 40 / 25 mm or less.

<17>

The non-woven fabric according to any one of paragraphs <1> to <16>, where the pile fiber having the ability to form corrugations is a self-freezing fiber.

<18>

The nonwoven fabric according to any one of paragraphs <1> to <17>, wherein the amount of pile fibers is preferably 8 / cm or more, more preferably 12 / cm or more, and 100 / cm or less, more preferably 40 / cm or less.

<19>

The nonwoven fabric according to any one of paragraphs <1> to <18>, wherein the pile fiber height is preferably 1.5 mm or less, more preferably 0.8 mm or less, and preferably 0.2 mm or more.

<20>

The nonwoven material according to any one of paragraphs <1> to <19>, the manufacturing process of which includes teasing fibers, comprising the step of tearing parts of long fibers of a fiber complex to form pile fibers by using a shaft with protrusions containing protruding parts on its circumferential surface, where the shaft with protrusions is a sandblasted shaft.

<21>

A method of manufacturing a nonwoven material according to any one of paragraphs <1> to <19>, comprising the step of nibbling the fiber to tear apart portions of the long fibers of the fiber complex, for forming the nap fibers by using a protruding shaft containing protruding portions on its circumferential surface.

<22>

The nonwoven fabric manufacturing method described in paragraph <21>, wherein the protrusion shaft is a sandblasted shaft, wherein the density of the protruding parts is preferably 1000 / cm ² or more and 3000 / cm ² or less, more preferably 1200 / cm ² or more and 2500 / cm ² or less.

<23>

A method of manufacturing a nonwoven fabric, as described in paragraph <21> or <22>, comprising the step of partially drawing to partially draw a plurality of regions of the original nonwoven fabric.

<24>

A method of manufacturing a non-woven material, presented in paragraph <23>, according to which the stage of partial drawing is carried out by using steel, matched, embossing shafts, consisting of a pair of shafts: the first shaft and the second shaft, where:

- the first shaft contains many protruding parts on its circumferential surface, and the second shaft contains on its circumferential surface recessed parts located in places corresponding to the locations of the protruding parts of the first shaft, which should include protruding parts; and

- the recesses are staggered on the circumferential surface of the first shaft and the recessed parts are staggered on the circumferential surface of the second shaft.

<25>

The method of manufacturing a nonwoven material presented in paragraph <24>, according to which the stage of partial drawing is carried out using a pair of shafts consisting of first and second shafts, which are steel, matched, embossing shafts, heated to a temperature equal to or lower than the melting temperature of the component constituting the fiber of which the starting nonwoven material consists and which has the lowest melting point, more specifically: to a temperature below the melting point of 70 ° C or more.

<26>

A method of manufacturing a non-woven material, presented in any one of paragraphs <21> - <25>, including the step of heat treatment for performing heat treatment at a temperature below the melting temperature of the constituent fibers of the original non-woven material.

<27>

A method of manufacturing a non-woven material, presented in paragraph <26>, according to which many areas of the original non-woven material are subjected to partial drawing at the stage of partial drawing, where

- parts of the long fibers of the fiber complex, which has been subjected to partial drawing, are torn by using a shaft with protrusions containing protruding parts on its circumferential surface, for the formation of pile fibers at the stage of fiber teasing; and then

- pile fibers are heated at the stage of heat treatment.

<28>

The top coating of an absorbent product, for the manufacture of which use the non-woven material presented in any one of paragraphs <1> - <20>, used as a surface facing the skin of the consumer.

<29>

An absorbent article in which a nonwoven fabric is used, as presented in any one of paragraphs <1> to <20>, as a constituent element.

<30>

A disposable diaper that uses non-woven material, presented in any one of paragraphs <1> - <20>, as a constituent element.

Examples

The present invention is further described below in more detail with reference to examples. However, the scope of the present invention is not limited to these examples.

Example 1

As the initial nonwoven material used non-woven material consisting of corrugated fibers, which were subjected to heat shrinkage and corrugation. Practically used laminated nonwoven "spunbond" - "spunbond" possessed an areal density of 17 g / m ² obtained by corrugating potentially gofriruemyh fibers had a diameter 13.7 microns, had an eccentric type structure "core-shell" consisting of a random copolymer ethylene and propylene, and a component of polypropylene. Then, the nonwoven fabric (in Example 1) was processed by feeding the spunbond nonwoven fabric into the sting of a pair of steel, matched, embossing rolls 43 shown in FIG. 7 and surface treated the non-woven spunbond material by means of the protrusion shaft 51 shown in FIG. 8 for performing two-stage processing. The height of each protruding part 411 of the used shaft 41 from a pair of steel, matched, embossing shafts 43 was 5.0 mm, and the engagement depth between each protruding part 411 of the shaft 41 and each recessed part 422 of the shaft 42 was 4.0 mm. In addition, the distance (step) between the protruding parts 411 located next to each other in the direction of the axis of rotation was 7 mm, and the distance (step) between the protruding parts 411 located next to each other in the circumferential direction was 7 mm. The same also applies to each protruding portion 421 on the shaft 42 of a pair of steel, matched, embossing shafts 43. In addition, the protruding portion of the protruding shaft 51 was at most 0.07 mm, and a sandblasted matte shaft (shaft subjected to sandblasted) with a density of protrusions of about 2000 / cm ² . The shaft 51 with the protrusions was rotated in a direction opposite to the direction of transportation of the nonwoven material, with a speed 4 times greater than the speed of transportation of the nonwoven material. The envelope angle was 60 °. The transport speed was 20 m / min.

Example 2

As the initial nonwoven material used non-woven material consisting of corrugated fibers, which were subjected to heat shrinkage and corrugation. Practically used laminated nonwoven "spunbond" - "spunbond" possessed an areal density of 17 g / m ² obtained by corrugating potentially gofriruemyh fibers had a diameter 13.7 microns, had an eccentric type structure "core-shell" consisting of a random copolymer ethylene and propylene, and a component made of polypropylene, as in Example 1. Then, the non-woven material in Example 2 was made by surface treatment of this non-woven material "spunbond" only with a shaft 51 with protrusions, shown in FIG. 8. The height of the protruding portion of the protruding portions 51 used was the largest 0.07 mm, and a sandblasted matte shaft with a protrusion density of about 2000 / cm ^{2 was used} . The shaft 51 with the protrusions was rotated in a direction opposite to the direction of transportation of the nonwoven material at a speed 30 times higher than the speed of transportation of the nonwoven material. The envelope angle was 60 °. The transport speed was 20 m / min.

Example 3

As the initial nonwoven material used non-woven material consisting of corrugated fibers, which were subjected to heat shrinkage and corrugation. Practically used laminated nonwoven "spunbond" - "spunbond" possessed an areal density of 17 g / m ² obtained by corrugating potentially gofriruemyh fibers had a diameter 13.7 microns, had an eccentric type structure "core-shell" consisting of a random copolymer ethylene and propylene, and a component made of polypropylene, as in Example 1. Then, the nonwoven fabric in Example 3 was made by surface treatment of this non-woven fabric "spunbond" only with a shaft 51 with protrusions grooves shown in FIG. 8, after which the heat treatment of the non-woven spunbond material subjected to surface treatment was carried out. The height of the protruding part of the 51 with protrusions used was at most 0.07 mm, and a sandblasted matte shaft with a protrusion density of about 2000 / cm ^{2 was used} . The used shaft 51 with protrusions was rotated in a direction opposite to the direction of transportation of the nonwoven material, at a speed 30 times higher than the speed of transportation of the nonwoven material. The envelope angle was 60 ° and the transport speed was 20 m / min. Then, heat treatment was carried out at a temperature of 120 ° C for one minute.

Comparative Example 1

Non-woven material in the form of a laminated non-woven material "spunbond" - "spunbond", having a surface density of 17 g / m ² , obtained by corrugating potentially corrugated fibers having a diameter of 13.7 μm, having an eccentric structure of the type of "core-shell", consisting of the random copolymer of ethylene and propylene, and the polypropylene component used in Example 1, which was used in Comparative Example 1. The nonwoven fabric in Comparative Example 1 was not particularly bristled a.

Reference Example 2

As the starting nonwoven material, a nonwoven material consisting of fibers that were not corrugated fibers was used. Practically used the laminated non-woven material "spanbond" - "spanbond", which had a surface density of 17 g / m², consisting of polypropylene fiber having a diameter of 14.6 μm. Then, the nonwoven material used in Comparative Example 2 was made by performing a two-stage processing of the spunbond nonwoven material under the same conditions as in Example 1.

Evaluation of the results of experiments

Considering the nonwoven materials obtained in Example 1 and Comparative Examples 1 and 2, the following were evaluated: the amount of pile fibers, the proportion of low pile fibers, the free end parts of which hung down, texture, absorption capacity and fluffy appearance according to the following methods, respectively. The assessment was made under ambient conditions: room temperature 20 ° C, RH 60%. These results are presented below in Table 1.

Number of pile fibers and pile height

Based on the aforementioned method for measuring pile fibers, the number of pile fibers and the height of the pile fibers in the nonwoven materials in Example 1 and Comparative Examples 1 and 2 were determined. It should be noted that, as described above, under the “pile fibers”, which were measured according to this method measurements, understood pile fibers 20 [low pile fibers 21 (first, low, pile fibers 211 and second, low, pile fibers 212) and high pile fibers 22 (first, high, pile fibers 221 and second, high, pile fibers and 222]) and pile fibers 23 in the form of loops.

The proportion of low pile fibers

Based on the above method for measuring fiber diameter, in the nonwoven materials in Examples 1-3 and in Comparative Examples 1 and 2, the relationship of the distant positions of the ends of ten randomly selected pile fibers 20 having free end parts was examined on images obtained using a scanning electron microscope (SEM) at an approximately 50-fold increase in fiber 20; pile fibers 20 are classified as low pile fibers and high pile fibers. Among the pile fibers 20 having free end portions [low pile fibers 21 (first, low, pile fibers 211 having a thick, loose, end portion 20b, and second, low, pile fibers 212 having a free end portion 20b that was not thick) and high pile fibers 22 (first, high, pile fibers 221 having a thick, loose, end portion 20b and second, high, pile fibers 222 having a loose end portion 20b that was not thick)], the proportion of low pile fibers was calculated 21 fibers (first, low, pile in olokon 211 and second, low, nap fibers 212). Next, the proportion of the first, low, pile fibers 211 having a thick, loose, end portion was calculated among the low pile fibers 21 (the first, low, pile fibers 211 having a thick, loose, end portion 20b, and the second, low, pile fibers 212 having a free end portion 20b that were not thick); calculation results are presented in Table 1.

Texture properties

Considering the nonwoven materials obtained in Examples 1-3 and in Comparative Examples 1 and 2, sensory assessments of the texture (smoothness) of the surfaces of nonwoven materials were carried out according to 10 categories (the closer the rating to category 10, the more pleasant to the touch texture), given by 10 specialists where the nonwoven fabric obtained in Comparative Example 1 was taken as a reference (category 5), and the average value of three webs, where each nonwoven fabric was evaluated in 10 categories, was calculated by rounding the score to an integer.

Absorbability

An overcoat was removed from a commercially available baby diaper (used a Merries product manufactured by Kao Corp. in 2012, size L), and the non-woven materials from Examples 1-3 and Comparative Examples 1 and 2 were used instead of the top coating; measured the ability to absorb. The diaper, from which the waist tightening means and the tightening means around the legs were removed, was fixed horizontally in the unfolded state so that the surface of its material was turned upward. An acrylic plate with a cylindrical spill portion was placed on the topcoat, and the weight was additionally laid on the acrylic plate so that the load was 2 kPa. A channel for a strait of cylindrical shape (53 mm high) with an inner diameter of 36 mm was formed in the acrylic plate, and through the hole with an inner diameter of 36 mm communicated between the inner cylindrical part for the strait and the surface of the acrylic plate facing the top coating was formed part located at a distance of 1/3 of the end of the acrylic plate in its longitudinal direction, so that the Central axis of the cylindrical part for the spill coincides with the Central axis of the acrylic plate in the width direction. The arrangement was carried out in such a way that the central axis of the spill cylindrical part in the acrylic plate was 125 mm from the distal end of the front part of the coating web, which covered the absorbent core of the diaper in the longitudinal direction, and the salt solution was spilled in an amount of 160 g. Time was measured that took place until the diaper completely absorbed the entire amount of the saline solution, and the average absorption time was determined from three webs from each nonwoven material, using your rounding to an integer. The case when the absorption time was within 85 seconds was marked as A, the case when the absorption time was more than 85 seconds but less than 100 seconds was marked as B, and the case when the absorption time was 100 seconds or more was marked as C; these indicators are presented in Table 1.

Fluffy appearance

Considering the nonwoven materials obtained in Examples 1-3 and in Comparative Examples 1 and 2, sensory evaluations were made in 3 categories (the closer the rating is to category 1, the more the consumer is worried about the pile, and the appearance is worse in many cases), where the nonwoven the material in Comparative Example 1 was adopted as a standard (category 3), which was given by 10 specialists; determined the average value of the categories for three canvases, considering each non-woven material, rounding off the estimates to an integer; the results are presented in Table 1.

Light load compression characteristics

Considering the nonwoven materials obtained in Examples 1-3 and Comparative Examples 1 and 2 according to the above method for measuring the characteristic value of compression under light load, the characteristic value of compression of the nonwoven material under light load was determined. In Table 1, the case where the obtained characteristic compression value was 18.0 (gf / cm ² ) / mm or less is shown as A; the case when it was more than 18.0 (gf / cm ² ) / mm is presented as B. The characteristic value of compression under light load is an index representing the sensation of fluffiness: the smaller the value, the greater the sensation of fluffiness, and if the value is 10.0 (gf / cm ² ) / mm or less, then the sensation of fluffiness is pleasant and characterizes the texture well, and a non-woven material similar in properties to a breathable non-woven material can be obtained.

Volume softness measurement

Considering the nonwoven materials obtained in Examples 1-3 and in Comparative Examples 1 and 2, according to the above procedure for measuring volume softness, the volume softness of the nonwoven material in the Pop direction was determined. In Table 1, the case where the volume softness value was 3.0 cN or less is shown as A; the case when it was more than 3.0 SN and 5.0 SN or less, is presented as B; and the case when it was more than 5.0 cN is presented as C.

Table 1 unit of measurement Example 1 Example 2 Example 3 Comparative Example 1 Reference Example 2 Number of pile fibers cm / cut 9 16 fifteen 0 9 Pile fiber height mm 0.8 0.8 0.7 0 1.3 The proportion of corrugated pile fibers having a free end portion % 69 64 62 - 90 Tensile strength N / 5 cm eleven 10 10 eleven 10 The proportion of low pile fibers % thirty 27 fifty 0 12 The ratio of the number of low pile fibers having a thick, loose, end part, and the number of low pile fibers % fifty 36 56 0 31 Characteristic value of compression under light load (caused by a feeling of fluffiness) (cN / cm ² ) / mm 9.6 6.4 6.1 24.5 13.7 Rating BUT BUT BUT AT BUT Volumetric softness in the transverse direction SN 2.2 3.3 2.7 5.3 2.7 Rating BUT AT BUT FROM BUT Texture Category 8 8 9 5 7 Absorption time Seconds 80 83 81 102 95 Rating BUT BUT BUT FROM AT Appearance (pile) Category 3 3 3 3 2

As is clear from the results presented in Table 1, since the non-woven materials in Examples 1-3 and the non-woven materials in Comparative Example 2 contain pile fibers, their texture was better than that of the non-woven materials in Comparative Example 1. As is clear from the results presented in Table 1, since the proportion of low pile fibers in non-woven materials in Examples 1-3 is higher than in non-woven material in Comparative example 2, the texture of the former is better. As is clear from the results presented in Table 1, since the non-woven materials in Examples 1-3 were formed from corrugated fibers, the absorption time was less than when using the non-woven material obtained in Comparative Example 2, and the ability to absorb non-woven materials according to the invention is enhanced.

Industrial Applicability

The nonwoven material according to the present invention, although its tensile strength is high, further has an increased ability to induce a feeling of fluffiness, and its texture is further improved.

Claims (16)

1. Non-woven material containing a complex of fibers, and the long fiber is fixed in the area bonded by fusion; moreover
- non-woven material contains a pile fiber formed by tearing part of a long fiber, while only one end part is fixed in the region bonded by fusion, and the other end side is a free end part;
- pile fiber has the ability to form corrugations and includes a low pile fiber, the height of the free end part of which is less than the height of the pile fiber in its highest position;
- the degree of corrugation of the pile fiber is 80% or less;
- the proportion of low pile fibers among pile fibers is 20% or more; and
- low pile fiber includes a pile fiber having a free end portion that is not thick. 2. The nonwoven fabric according to claim 1, wherein the low pile fibers include a pile fiber in which the free end portion is thick. 3. The nonwoven fabric of claim 1, wherein the pile fibers include low pile fiber and high pile fiber. 4. The nonwoven material according to claim 1, wherein the degree of corrugation is 80% or less and 20% or more. 5. The nonwoven material according to claim 1, wherein the degree of corrugation is 70% or less and 30% or more. 6. The nonwoven fabric according to claim 1, wherein the long fiber, other than the pile fibers of the fiber complex, is capable of forming corrugations. 7. The nonwoven material according to claim 1, wherein the pile fiber having the ability to form corrugations is a self-forming fiber. 8. The nonwoven material according to claim 1, which is a spunbond nonwoven material or a laminated nonwoven material containing a spunbond material layer. 9. A method of manufacturing a nonwoven material according to claim 1, including:
- a fiber teasing step for breaking apart parts of long fibers of the fiber complex to form pile fibers using a shaft with protrusions containing protruding parts on its circumferential surface; and
- a partial stretching step for partially stretching a plurality of regions of the original nonwoven material. 10. A method of manufacturing a nonwoven material according to claim 9, wherein the shaft with the protrusions is a sandblasted shaft, wherein the density of the protruding parts of the shaft with the protrusions is 1000 / cm ² or more and 3000 / cm ² or less. 11. A method of manufacturing a nonwoven material according to claim 9, according to which the stage of partial drawing is carried out by using a pair of steel, matched, embossing shafts containing a first shaft and a second shaft, where
- the first shaft contains many protruding parts on its circumferential surface, and the second shaft contains on its circumferential surface recessed parts located in places corresponding to the locations of the protruding parts of the first shaft, which should include protruding parts;
- a pair of shafts, consisting of a first shaft and a second shaft, contains on the circumferential surfaces recessed parts located in a checkerboard pattern, and deepened parts located in a checkerboard pattern; and
- the stage of partial drawing is carried out using a pair of shafts, consisting of a first shaft and a second shaft, representing steel, matched, embossing shafts, heated to a temperature equal to or lower than the melting temperature of the component of the component fiber constituting the initial non-woven material having the lowest melting point. 12. A method of manufacturing a nonwoven material according to claim 9, comprising a heat treatment step for performing heat treatment at a temperature below the melting temperature of the constituent fiber of the original nonwoven material. 13. A method of manufacturing a nonwoven material according to claim 12, whereby many regions of the initial nonwoven material are subjected to partial stretching in the partial stretching step, where
- parts of the long fibers of the fiber complex, subjected to partial drawing, are torn using a shaft with protrusions containing protruding parts on its circumferential surface, for the formation of pile fibers at the stage of fiber teasing, and then
- pile fibers are heated at the stage of heat treatment. 14. The upper coating of the absorbent product, for the manufacture of which use the non-woven material according to claim 1 in the surface facing the skin of the consumer. 15. An absorbent product that uses the non-woven material according to claim 1 as a constituent element. 16. A disposable diaper that uses the non-woven material according to claim 1 as a constituent element.

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