WO2004029349A1

WO2004029349A1 - Spun-bonded nonwoven fabric and sanitary supplies

Info

Publication number: WO2004029349A1
Application number: PCT/JP2003/012106
Authority: WO
Inventors: Masaru Ogo; Masaru Shimamura
Original assignee: Asahi Kasei Fibers Corporation
Priority date: 2002-09-26
Filing date: 2003-09-22
Publication date: 2004-04-08
Also published as: CN100575584C; AU2003266572A1; TWI238708B; CN1685099A; KR20050053696A; TW200406178A; KR100752979B1

Abstract

A spun-bonded nonwoven fabric constituted of a web of continuous filaments of thermoplastic synthetic fibers, the structure of which fabric is set by a pattern composed of areas which are produced by partially fusing the fibers by hot pressing and pierce through the fabric and concavely and convexly embossed patterns on the surfaces of the fabric which patterns are composed of high-density concave and convex areas of unbonded fibers respectively and the bulkiness of which fabric is 100 to 400 % in terms of the ratio of the thickness of the fabric inclusive of the convexly embossed pattern surface to the thickness of the low-density areas of the fabric. The application of a hydrophilic agent to the nonwoven fabric gives sanitary supplies such as disposable diaper.

Description

Description Spunbond nonwoven fabric and sanitary materials

Technical field

The present invention relates to a spunbonded nonwoven fabric, and in particular, a flexible and bulky nonwoven fabric structure fixed by a discontinuous pattern of partial hot-pressure fusion and a concave or convex emboss pattern in a high-density region of non-bonded fibers. The present invention relates to a disposable hygiene material and an improved nonwoven fabric useful for a disposable hygiene material. Conventional technology

Generally, sanitary materials used for sanitary towels and sanitary napkins include topsheets that allow urine and effluent to pass through, absorbent and waterproof backsheets, and three-dimensional gathers that make use of waterproofness. It is composed of a cuff for preventing leakage that is called. Nonwoven fabric is often used as a material for these sanitary materials because of its thinness, strength, soft touch for direct contact with the skin, and productivity and price. ing.

One of the sanitary materials, disposable ommop topsheet, is a material that comes into direct contact with the skin, so it has a soft touch and instantly transmits urine, etc., has little re-wetting, and repeatedly transmits urine several times For this purpose, durable liquid permeation performance and the like have been required.

At present, bulky fibers using composite short fibers or the like are joined by hot air or partial hot-pressure fusion. However, the non-woven fabric bonded by hot air has bulk and cushioning properties, but it is necessary to increase the basis weight of the non-woven fabric to obtain sufficient cushioning properties. It is composed of conjugate fibers and fixes the nonwoven fabric structure by fusing with hot air, resulting in a non-woven fabric with a rough and rugged touch.

In addition, the non-woven fabric of the point bond type, in which short fibers are partially hot-press fused, has low strength and thinness, and there is also a problem that the fiber ends of the short fibers irritate the skin.

On the other hand, nonwoven fabrics made by the spunbond method are manufactured by partially hot-filament bonding a filament web and subjecting them to a hydrophilic treatment as necessary, resulting in high productivity, high strength, and a soft touch. I have. However, due to the shape and arrangement of the fibers, they were generally flat and did not have sufficient performance such as liquid permeability and re-wetting properties as compared with nonwoven short fibers. As a method for improving the bulk of the spunbond nonwoven fabric, a topsheet consisting of an upper sheet and a lower sheet is laminated in contact with the absorbent core, and the upper sheet is used to form a liquid passage tube with a concave part. (Japanese Unexamined Patent Publication (Kokai) No. 6-304203), a method of forming and maintaining irregularities by hot embossing a web composed of a bicomponent fiber such as a core-sheath composite fiber or a side-by-side composite fiber. (Japanese Unexamined Patent Publication (Kokai) No. 11-1986-633), a web made of a bicomponent fiber such as a core-sheath type composite fiber or a side-by-side type composite fiber is subjected to hot-enbossing to form irregularities. In addition, there is known a method of forming a convex portion apex of the concavo-convex shape into a film (Japanese Patent Application Laid-Open No. 11-34762). However, these methods are perforated or shaped and fixed, so that the nonwoven fabric lacks flexibility.

The invention described in Japanese Patent Publication No. 63-179394, which is related to the inventor's invention, is composed of a filament web having a fineness of 0.5 d to 5 d, and has a partially bonded portion and a non-bonded irregular deformation. And a nonwoven fabric having: However, the present invention is a technique of bending the non-bonded portion of the fiber, shaping the unevenness, and kneading the fiber to make the fiber bulky and soft. No disclosure of characteristics. For three-dimensional gathers, which are another item of sanitary materials, especially for cuffs and backsheets for waterproofing, laminating a fiber web and a melt-blown fiber as a waterproof nonwoven fabric. A laminated non-woven fabric is used, which utilizes both the strength of the former and the fine covering and waterproof properties of the latter.

This laminated nonwoven fabric has better covering properties than the conventional single filament web, and therefore has a lower basis weight and its function. However, although there is a filament web, the paper form of the amenole and blow fiber webs is further strengthened, and furthermore, the adhesive properties of the melt and the mouth of the fiber are combined to provide a paper-like feel. There is a tendency for the nonwoven fabric to become hard and thin, especially as the basis weight decreases.

As a method of improving the bulk, a surface sheet composed of an upper surface sheet and a lower surface sheet is laminated in contact with the absorbent core portion, and the upper surface sheet is used to form a liquid passage pipe having a concave portion. Forming method (Japanese Unexamined Patent Publication No. Hei 6-304203) discloses a method in which a non-woven fabric made of a two-component fiber such as a core-sheath composite fiber or a side-by-side composite fiber is subjected to hot embossing to form irregularities. The holding method (Japanese Patent Application Laid-Open No. 11-288663) discloses that a nonwoven fabric composed of a bicomponent fiber such as a core-sheath type composite fiber or a side-by-side type composite fiber is subjected to a heat-enbossing process to remove irregularities. There is known a method of forming a film and forming the vertices of the convex portion of the irregular shape into a film (Japanese Patent Application Laid-Open No. 11-347602). However, these methods involve forming holes or forming. Nonwoven fabrics lack flexibility because they are fixed in shape.

A patent application publication (Japanese Patent Publication No. 63-179444) filed by the inventor of the present invention contains a filament web having a fineness of 0.5 d to 5 d, A nonwoven fabric having a bonded portion and a non-bonded uneven deformation is disclosed. However, the patent publication does not disclose melt blown fibers. There is no description about the use of a fibrous web, nor is the effect of improving the adhesiveness of the melt-blown fiber web shown in the present invention disclosed.

FIG. 1 (I) is a diagram schematically showing the planar structure of the spunbonded nonwoven fabric of the present invention, and FIG. 1 (Π) is a nonwoven fabric in which the nonwoven fabric structure is fixed only by the partial hot-press fusion fiber area pattern. FIG. 1 shows a cross-sectional view of a spunbonded nonwoven fabric in which the non-bonded fiber region of the surface is not subjected to unevenness processing. FIG. 1 (m) is a diagram schematically showing a cross-sectional structure of the spunbonded nonwoven fabric of the present invention.

FIG. 2 shows a lattice concave pattern in the high-density region of continuously connected non-bonded fibers in the spun-bonded nonwoven fabric of the present invention, that is, a lattice concave pattern particularly continuous on the first surface of the nonwoven fabric structure. FIG. 3 shows the provided embodiment without illustration of a partially hot-press fused fiber area pattern. FIG. 3 shows a spunbonded nonwoven fabric of the present invention in which the high-density region concave pattern of the non-bonded fiber is discontinuous. As in the example of FIG. Show.

Fig. 4 shows the spunbonded nonwoven fabric of the present invention in which high-density area turtle concaves of non-bonded fibers are continuously connected and provided. Are omitted from the illustration.

FIG. 5 is a diagram showing the relationship between the thickness of the spunbonded nonwoven fabric according to Example 1 of the present invention and Comparative Examples 1, 5, and 6 under various loads.

FIG. 6 is a diagram comparing the thickness under various loads of spunbonded nonwoven fabrics of Example 8 of the present invention and Comparative Example 8.

FIG. 7 (I) shows the structure of a spunbonded nonwoven fabric as an example of the present invention, and FIG. 7 (2) shows the spunbonded non-bonded fiber area shown in FIG. In an enlarged view of a micrograph showing the structure of is there.

Fig. 8 (I) shows the structure of the spunbonded nonwoven fabric of the present invention to which a melt-blown fiber web is added as another example, and Fig. 8 (Π) shows the unevenness in the unbonded fiber area in Fig. 8 (I). FIG. 3 is an enlarged photomicrograph showing the structure of a spunbond nonwoven fabric before processing is applied. Disclosure of the invention

An object of the present invention is to solve the above-mentioned problems and to provide an improved sanitary material having a bulky and soft touch feeling, high water permeability, low re-wetting, excellent strength, and useful for the production of disposable ommuts and the like. To provide spunbond nonwoven fabric.

Another object of the present invention is to provide an improved spunbond nonwoven fabric sanitary material by a spunbonding method which can be manufactured with high productivity.

The basic structure of the nonwoven fabric of the present invention is a nonwoven fabric mainly composed of a web of thermoplastic synthetic fiber continuous filament, and a partial nonwoven fabric penetrating between the front and back surfaces of the nonwoven fabric to be integrated. The structure of the nonwoven fabric is fixed on both sides of the hot-press fusion fiber area pattern and the nonwoven fabric structure by embossed concave or convex patterns consisting of high density areas of non-bonded fibers. A spunbonded nonwoven fabric characterized in that the bulkiness expressed by the ratio of the thickness of the nonwoven fabric occupied by the low-density non-bonded fiber region of the nonwoven fabric to the thickness is 100% or more. Adopting a nonwoven fabric structure in which a thermoplastic synthetic fiber filament layer is added to a melt fiber layer is also one of the preferred basic embodiments of the spunbonded nonwoven fabric of the present invention.

That is, at least one layer of continuous thermoplastic synthetic fiber web and at least one layer of melt-pro fiber web are laminated. A nonwoven fabric formed of a composite web consisting of: a partially hot-press-fused fiber area pattern penetrating between the front and back surfaces of the nonwoven fabric; and an embossed concave or convex pattern consisting of a high-density area of non-bonded fibers on one side of the nonwoven fabric structure. The structure of the nonwoven fabric is fixed by, and the bulkiness ratio, expressed as the ratio of the thickness of the nonwoven fabric occupied by the low-density region of the non-bonded fibers of the nonwoven fabric to the thickness of the nonwoven fabric including the surface of the convex embossed pattern of the nonwoven fabric, is 1 By using a spunbonded nonwoven fabric having a content of not less than 100%, basic performances such as bulkiness and flexibility desired as a sanitary material can be further enhanced.

The basic structure of the spunbonded nonwoven fabric (1) of the present invention is schematically shown in FIG. As shown in Fig. 1 (I) and Fig. 1 (Π), the non-woven fabric has (A) a partially hot-press-bonded fiber area embossed pattern (hereinafter sometimes simply referred to as a partially heat-bonded portion) and (B). ) It is fixed by embossed convex or concave pattern consisting of high density area of non-bonded fiber. The patterns (A) and (B) shown in FIG. 1 are patterns schematically shown, and the actual patterns of both (A) and (B) can be changed in both shape and pitch. Each of the patterns (A) and (B) is independently and discontinuously or continuously arranged on the front and back surfaces of the nonwoven fabric structure. Then, the nonwoven fabric structure includes the low-density region of the non-bonded fiber of (C) in contact with (A) and / or (B). Here, (A) the partial embossed fiber area embossed pattern is applied by hot embossing, and (B) the embossed convex or concave pattern consisting of the high density area of non-bonded fibers is Alternatively, it is an embossed pattern applied at a temperature at which the fibers are not fused, and is a pattern in which the upper surface (first surface) and the lower surface (second surface) of the nonwoven fabric are molded in opposite directions (Fig. 1 ( Ii), see Figures 2 to 4). One specific example of the spunbonded nonwoven fabric of the present invention is shown in FIG. In FIG. 7 (I), the nonwoven fabric structure in which the embossed patterns (A), (B) and (C) are formed can be seen. Fig. 8 (I) Is an example of a spunbonded nonwoven fabric of the present invention including a laminate of a melt-blown fiber web, and a nonwoven fabric structure in which the patterns of (A), (B) and (C) are formed as in the example of FIG. You can watch. As described above, the specific embodiments of the fixing structure of the nonwoven fabric structure of the present invention including the above (A), (B) and (C) will be clearly understood from FIGS. 7 and 8.

In the spunbonded nonwoven fabric of the present invention, the bulk ratio is determined by the thickness (a) of the nonwoven fabric occupied by the low-density region of the non-bonded fibers of the nonwoven fabric with respect to the thickness (b) of the nonwoven fabric including the surface of the convex-boss pattern of the nonwoven fabric. It is expressed by the ratio, that is, the value calculated by the following formula (see Fig. 1 (ΠΙ)).

Bulk factor (%) = (b / a) x 100

Here, the thickness (a) of the non-bonded fiber in the low-density region is the thickness before low-temperature uneven boss processing, and therefore the bulk ratio can be calculated based on the difference in thickness before and after uneven processing. Good. The bulk factor is important in determining the flexibility of the nonwoven fabric, which suggests that the unevenness processing at a low temperature has a kneading effect on the nonwoven fabric structure.

The spunbonded nonwoven fabric of the present invention further contains a hydrophilizing agent mainly in the high sitting area (B) of the non-bonded fiber, so that the desired performance, bulkiness, flexibility, and water permeability as a sanitary material are obtained. However, it can be modified into a nonwoven fabric that satisfies the four properties of rewetting simultaneously.

Hereinafter, the present invention will be described in detail.

As the fibers constituting the spunbonded nonwoven fabric of the present invention, polyolefin-based fibers such as propylene, polyethylene, and copolymers thereof are preferred because of their low water-retention property and rewetting properties. Polyester fibers such as terephthalate, polybutylene terephthalate, polytrimethylene terephthalate (PTT), or copolymers thereof are used to make nylon 6, 6, 6, 6 1 Polyamide fibers such as 0, 12 or copolymers thereof are preferred for obtaining a firm and flexible nonwoven fabric. If necessary, these composite fibers, blended fibers, and fibers having other special functions can be blended.

Nonwoven fabrics need to be strong enough to cope with the movement of the body when the surface is wet with urine and during use. From the viewpoint of productivity, continuous filaments (filaments) are used as webs. It is preferable to use a nonwoven fabric by a spunbond method formed by joining the nonwoven fabrics. Nonwoven fabrics made by the spunbond method have practical strength due to their long fiber length, have excellent air permeability, and, unlike the wet or dry methods, leave the fibers as they are without oil treatment. Because it is a sheet, the properties such as water repellency unique to the fiber can be utilized.

The bonding of the fibers and the fibers in the nonwoven fabric is preferably performed by a partial hot-pressure fusion method in order to impart the strength and flexibility of the nonwoven fabric and the feel of the fibers themselves. The area ratio of the hot press fusion in the partial hot press fusion is preferably from 5 to 40%, more preferably from 5 to 25%, from the viewpoint of maintaining strength and flexibility. Partial hot-pressure welding can be performed by using an ultrasonic welder, or by passing a web between hot embossing rolls that are heated to a temperature lower than the melting point of the constituent fibers, thereby integrating the front and back of the nonwoven fabric structure. For example, floating and sinking patterns such as pin points and rectangles are scattered all over the nonwoven fabric. Naturally, this hot-pressed fusion-bonded portion is pressed and is film-like, but the fibers around it have a unique feel to the fibers used.

The thickness of the nonwoven fabric formed only by the partial heat and pressure fusion varies depending on the fiber composition, the shape and the arrangement of the emboss, but it cannot be said that the thickness of the non-crimped fiber having a normal round cross section is large. In particular, in an ordinary web formed by the spunbond method, the arrangement of the fibers at the time of formation is flat and bulky. It should be noted that the partial heat and pressure fusion is a method of partially bonding by heat and pressure, and is formed by applying a partial pressure in an emboss pattern at a temperature lower than the melting point of the constituent fibers. This is a `` film-like '' part that adheres while retaining the fiber shape unlike a film that has been fused at a temperature equal to or higher than the melting point, and is distinguished from a high-density part formed by non-bonding unevenness processing Hot pressure welding was used.

As described above, the spunbonded nonwoven fabric of the present invention is a nonwoven fabric that is integrated front and back by a partial hot-press fusion part, and has a pattern different from the pattern of the hot-pressure fusion part on one side, in the high-density region of non-bonded fibers. Since the non-woven fabric structure has a concave portion and a convex portion in the high density region of the non-bonded fiber on the opposite surface, the non-woven fabric structure is integrated with the front and back by scattered partial hot-pressure fusion parts. The other part consists of a convex or concave embossed pattern in the high-density region of the non-bonded fiber, and two regions with different fiber densities in the low-density region of the non-bonded fiber, each of which is subjected to the rubbing effect of the low-temperature embossing process. As a result, a structure in which the fibers themselves are easy to move is formed, so that a soft and tactile yet bulky nonwoven structure is formed.

The high-density area of the non-bonded fiber is the area indicated by B in Fig. 1 to Fig. 3 and is the area where the fibers are not fused or adhered. By this, it refers to a dense fiber region where the fibers are compressed and densely packed. For example, it is in the range of 15 to 35% in terms of fiber volume fraction. And, in the present invention, the area ratio of the high-density region of the non-bonded fiber is 5 to 50%, preferably 5 to 25%. Here, the calculation of the partial heat-pressure welded portion is calculated from the shape of the embossed pattern that has been heat-pressure welded. The nonwoven fabric of the sample was magnified with a microscope, and the size and pitch were measured from the outline of the part that looks like a film when the two were fused together, the area was determined, and the area ratio to the area of the entire sample was calculated. The low-density area of the unbonded fiber is the area indicated by C in Fig. 1 and corresponds to the part where the fiber is not fused or adhered and which is not subjected to compression at the embossed opening for unevenness processing. Fibers are not densely packed compared to the high-density region of non-bonded fibers, and have a fiber aggregation density before roughening. Therefore, the fibers in the low-density region are bulky, have a freedom of movement, and have the original soft feel of the fibers. For example, the fiber volume fraction in the low-density region of unbonded fibers is in the range of 5 to 15%. The area of the high-density area of the non-bonded fiber is obtained by shaping the locus of the constituent fibers being crushed or partially deformed in the high-density area of the fiber formed by pressing the embossed pattern, and calculating the area. Calculate the area ratio to the area of the entire sample. As the fiber shape in the high-density region of the non-bonded fiber, a fiber in which the constriction is simply visible or the deformation is poor was included.

In the high-density region of the non-bonded fibers, the fibers are densely packed with a small thickness, and those treated with the hydrophilizing agent have good liquid permeability because the hydrophilizing agent is contained in the high-density region in a large amount. Is smooth and gives a smooth, soft feel.

The non-bonded low-density area is thicker than the high-density area, has a lower fiber aggregation density, is flexible and bulky, and has good liquid permeability, but is a barrier against liquid wetting back. It has good wet-back property (wet back).

The above operation will be described with reference to the cross-sectional views of FIGS. Fig. 1 Fig. 3 is a schematic diagram that makes it easy to understand the structural characteristics of the nonwoven fabric of the present invention.

(A) The partial heat and pressure welded portion is a region that acts to maintain the strength of the entire nonwoven fabric and has an appropriate area ratio.

(B) The non-bonding high-density area is the area of B and has a shape protruding from the surface of the nonwoven fabric, and therefore has the function of increasing the bulk of the nonwoven fabric. You. Further, since a large amount of the hydrophilizing agent is contained in the region B, the hydrophilicity of this portion is greatly improved, and the effect of improving the liquid permeability through the region B is obtained. .

(C) The non-bonded low-density region is a region of C, which has a high degree of freedom of fibers, has flexibility, and has a function of giving a soft touch. Further, the region C acts as a barrier against the return of the liquid from the absorber due to the bulky effect, and has an effect of improving the wet-return property.

Also, at the boundary with B, it has the effect of making it easy to bend. As described above, the feature of the present invention is that each of the regions (A), (B), and (C) has the above-described actions, and as a whole, has an action suitable for a sanitary material. It is.

The nonwoven fabric of the present invention uses the composite fiber shown in the prior art, and is completely different from a rough nonwoven fabric which is fused and hardened by bonding or hot air treatment.

According to the present invention, a fiber layer having a degree of freedom can be formed into a partially deformed (elongated) fiber layer by imparting non-bonding and uneven deformation to the fiber layer. It has good properties, and therefore has the property of not being easily compressed when a load is applied. Therefore, it is bulky and porous even under a load, so that the liquid easily permeates (the liquid permeation speed is high), and it can be said that the liquid once permeated and absorbed does not easily return to the wet state.

The uneven deformation imparted to the nonwoven fabric of the present invention is a concave or convex deformation of an arbitrary shape that does not partially match the pattern of the partially bonded joint portion, and the shape, size, and depth of the concave or convex portion. Is important for the flexibility effect in relation to the bonding pattern.

The shape of the concave or convex portion may be, for example, a straight line, a curved line, a corner, a round, a satin-like shape, or other continuous continuous or non-continuous shape. However, from the viewpoint of the flexibility effect, the depth of the concave or convex portion is

The effect increases as the depth increases from 0.2 to 5 mm. Further, the size of the discontinuous convex portion pressing surface is preferably 0.1 to 5 mm, and the pitch of the concave or convex portion is preferably 0.5 to 5 mm.

FIG. 1 schematically shows the overall structure of the nonwoven fabric of the present invention in plan view. 2 and 3 show examples in which a square non-woven fabric is embossed. FIGS. 2 and 3 show two examples of non-bonding unevenness processing patterns. In the drawings, the pattern of the heat-sealed portion and its distribution are omitted.

For example, by pressing an embossed pattern in which projections are scattered as shown in FIG. 3, depressions that are discontinuously scattered in a high-density region are formed. In addition, as shown in FIG. 2, the high-density region is continuously formed by pressing the embossed pattern having continuous projections, and the non-pressed portion is in a state in which the fiber layer is raised. The pitch of the deformation by the continuous pattern depends on the pattern, but is preferably 1 to 5 mm, and the size of the recess is preferably a line with a width of 0.02 to 3 mm or a dotted line.

By providing a high-density region, the thickness increases due to the bulkiness effect, the bulkiness of the nonwoven fabric is improved, and the change in the fabric thickness with respect to the load is small. The present inventors have found that when a hydrophilic agent is added to the nonwoven fabric, the concentration of the hydrophilic agent increases in the high-density region of the non-bonded fibers.

Nonwoven fabrics become more flexible as the apparent thickness increases, but the finer the texture, the finer the pitch of the unevenness and the size of the recesses, if the thickness is not too large.

The bulk ratio of the nonwoven fabric of the present invention is 100% or more, preferably 105 to 400%, more preferably 110 to 300%, particularly preferably 120 to 100%. ~ 200%. As the bulkiness increases, the decrease in thickness with respect to the load decreases, and the cushioning of the nonwoven fabric improves. FIGS. 5 and 6 show the change in thickness of the spunbond nonwoven fabric according to the present invention with respect to the load. It can be said that the spunbonded nonwoven fabric of the present invention has a large thickness and a large bulk under each load, and has good compression characteristics against loads. For this reason, when the spunbonded nonwoven fabric of the present invention is used, for example, as a top sheet of a disposable ommut, the decrease in thickness with the passage of time is small, and the flexibility during use of the ommut is reduced. This indicates that the effect of maintaining the bulkiness properties is great. In addition, even in the wet state, a good effect can be obtained because the thickness does not decrease much and the bulkiness of the liquid from returning from the absorber is large.

A method of providing a concave spunbonded nonwoven fabric or a non-bonded fiber convex embossed pattern is, for example, a method in which the surface has a concave, convex, or uneven pattern, between the rolls where both have just mated, or a concave on one surface. It is common to press between a roll with a convex pattern and a flexible roll, or to process between plates, but as a special method, a certain percentage of cloth is forced between rolls with a narrow gap. There is also a method of over-feeding and forming a small zigzag shape.

Fig. 4 shows an example in which unevenness is imparted by passing between two rolls each having a round-shaped uneven pattern on the surface and both of them just meshing with each other.

Of particular note in the concave and convex conditions are the processing temperature and the pressure applied to the nonwoven fabric. The temperature during the treatment may be room temperature, but if necessary, it is heated to a temperature within the range that does not cause fiber set-up for the purpose of plasticizing by heating and facilitating morphological stabilization, or for the purpose of imparting morphological stability. You may do it. For example, in the case of a polypropylene nonwoven fabric, the temperature is preferably in the range of 30 to 110 ° C. The embossing pressure varies depending on the temperature, but it is natural that the embossing pressure is set to a pressure at which the molding is sufficiently performed. In addition, this molding causes deformation of the fiber cross section of the compressed part. It is also effective to perform high-pressure treatment in order to obtain more flexibility due to the partial deformation effect. Of course, it is necessary to adopt conditions that do not cause temporary fixing between fibers in the compression section or heat and pressure fusion. For example, in the case of a polypropylene nonwoven fabric, the range is preferably 20 to 150 kgcm.

In the spunbond nonwoven fabric of the present invention, it is preferable that the high-density region concave portion of the non-bonded fiber formed on one side of the nonwoven fabric has a convex portion formed of the non-bonded high-density fiber on the opposite surface. . For example, when forming a high-density region in which concave portions are continuous on one surface, it is preferable that a convex shape protruding from other regions is formed so that the high-density region becomes a convex portion on the other surface. This is important not only in making the apparent thickness of the entire nonwoven fabric equal to or greater than the thickness of the web but also in imparting a hydrophilic agent to a specific site.

The hydrophilic treatment of the spunbonded nonwoven fabric of the present invention is carried out by a known method such as an immersion method, a spraying method, a coating method (roll coater, gravure coater, die, etc.) using a dilute hydrating agent solution. Can be adopted. The nonwoven fabric is dried using a drying means such as hot air or a hot roll after the application of the hydrophilizing agent.

In the hydrophilization treatment, it is considered that the adhesion distribution of the treatment agent is different between the high-density region previously applied and the other region. When the treatment liquid is applied, the liquid is apparently contained in the low-density, so-called rough portion of the fiber, but as the nonwoven fabric dries, the liquid moves to a portion that is easy to dry. For this reason, in the high-density region of the non-bonded fibers, it is considered that the treatment agent adheres to the nonwoven fabric in spite of the small thickness of the nonwoven fabric, so that the liquid can pass easily. Further, the liquid once permeated is hard to be compressed in the low-density region and is bulky, so that the liquid is separated from the absorbing layer and hardly wets back. As described above, a large amount of the hydrophilizing agent is contained mainly in the high-density region of the non-bonded fiber, and the liquid permeability unique to the spunbonded nonwoven fabric of the present invention is improved. Effects such as improvement of the etch back property and improvement of the liquid flow can be obtained.

It is also preferable to perform a corona treatment, a plasma treatment or the like prior to the hydrophilic treatment in order to improve the degree of hydrophilicity. The processing such as the corona processing may be a general processing used for improving the wetting characteristics as the pre-processing of printing. For example, high-frequency power is supplied between the discharge electrode and the processing roll by a high-frequency generating oscillator or the like. To discharge, and the nonwoven fabric is passed through and processed. Although it depends on the required wettability and treatment conditions, it is preferable to set the discharge conditions so that the surface tension of the treated surface is 37 to 4 OmN / m. When the corona discharge treatment is performed, the wettability of the nonwoven fabric itself is different, so that it is natural to adjust the amount of the hydrophilic agent to obtain the required performance. When the surface tension of the nonwoven fabric is in the range of 37 to 4 OmN / m, the affinity between the hydrophilicizing agent and the surface fibers of the nonwoven fabric is remarkably improved, and the hydrophilicizing agent is uniformly applied at a low concentration. be able to. In the present invention, the application of the hydrophilizing agent is preferably performed after the concavo-convex processing of the non-bonded fiber region, but there is no particular problem if applied before the concavo-convex processing.

When using the spunbonded nonwoven sanitary material of the present invention which has been treated with a hydrophilizing agent, it is natural to select the performance to be imparted and the method of use according to the target property level as the sanitary material. However, the difference in the tactile sensation of the front and back of the nonwoven fabric is also relevant. The high-density areas of the molded concave and convex patterns are not bonded to each other, but they are hardened compared to the others.Therefore, when used as a topsheet of Omut, the surface of the nonwoven fabric is used. In such cases, it is preferable to place the high-density region on the topsheet skin surface when placing it on the absorber side of the skin surface that does not directly touch the skin, or when emphasizing hydrophilicity.

The spunbonded nonwoven fabric of the present invention has at least one filament web and at least one melt blow web in the nonwoven structure. There is an embodiment in which a laminate of two or more layers is used.

In this case, the fiber material described above is effective as the fiber used for the nonwoven fabric. If necessary, blending with these composite fibers, blended fibers, and other fibers having special functions is also effective. It is effective to use different materials for the filament webs between layers, and the filament web and the melt-blown fiber web may be different materials. Materials that have an affinity for water, such as polyester fibers and polyamide fibers, are waterproof, water-repellent and, if necessary, silicone, fluorine, or wax-based waterproofing agents. However, it is necessary to improve by treatment with water repellent or addition.

Nonwoven fabrics need to be strong enough to cope with body movements during use.From the viewpoint of productivity, at least one filament web and at least more melt-blown fibers are required. It is preferable to use a nonwoven fabric formed by laminating two or more layers and laminating them continuously. This laminated structure may be simply a lamination of the filament web and the meltblown fiber web, but is usually between the filament web layers to compensate for the meltblown fiber webs with low surface strength. · A layer of blown web layers is used, and it is useful to make each layer a multilayer. Alternatively, the webs may be laminated after joining the webs.

The filament constituting the spunbonded nonwoven fabric is 0.5 to 5 dte X, has a practical strength due to a long fiber length, has excellent air permeability, and is obtained by a wet method or a dry method. In contrast, the fibers are made into a sheet without being treated with an oil agent or the like, so that the unique properties of the fibers, such as water repellency, are utilized.

Menolet blown fiber web is described in, for example, Japanese Patent Publication No. 56-3351, USP 3,978,185, USP 3,822,380, etc. As shown, it is formed of fine fibers of 1 to 6 _μm and has excellent force-barring properties. For example, a polypropylene material further contributes to water repellency and waterproof effect. Melt-blown fiber webs are thinner fibers and have a lower crystallographic orientation and are easier to join than filament webs. However, on the other hand, when used alone, the strength is weak even when joined, and it becomes hard due to the feeling of vapor-like (paper-like). For this reason, laminating the filament web and the melt-blown fiber web compensates for the drawbacks of each, resulting in excellent practical strength, covering properties, water repellency and waterproofness. .

In order to impart the strength and flexibility of the nonwoven fabric and the feel of the fiber itself, it is preferable to join and fix the webs by partial heat and pressure welding using a hot embossing roll. The area ratio of the hot press fusion in the partial heat press fusion is preferably from 5 to 40%, more preferably from 5 to 25%, from the viewpoint of strength retention and flexibility. Partial heat pressure welding can be performed by an ultrasonic method or by passing a web between heated embossing rolls, whereby the front and back surfaces are integrated, for example, a pinpoint shape, an elliptical shape, and the like. Floating and sinking patterns such as shape, diamond shape, and rectangular shape are scattered all over the nonwoven fabric. Naturally, the heat-pressure-welded part is pressed and formed into a film, but the fibers around it, especially the filament web, have a unique feel to the fibers used. Under the conditions for joining the filament web layer, the melt-blown fiber web layer is extremely fine, and due to its properties during fiber formation, etc., it becomes a paper-like (paper-like) touch due to heat. However, the entire nonwoven fabric has a paper-like hardness. In addition, the thickness of the non-woven fabric obtained by the partial heat and pressure fusion varies depending on the fiber structure, the shape and the arrangement of the emboss, but the adhesive effect peculiar to the melt-pro-fibrous web layer occurs, the thickness is reduced, and the bulk is reduced. Will not be. As a method for improving the bulk, there are methods such as making holes or shaping and fixing as described in the section of the prior art. However, as in the present invention, a laminate of at least one layer of at least one filament web and at least one layer of melt-pro-filament is mixed with a non-continuous It is not intended to obtain the bulk or softness of the nonwoven fabric which has been integrated by the partial hot-pressure fusion part by the non-bonding unevenness deformation. It does not improve the effect.

The point of the present invention in the design of laminating the melt-blown fiber web on the nonwoven structure is to laminate at least one filament web and at least one layer of melt-blown fiber web. The nonwoven fabric, which has two or more layers laminated on the front and back by non-continuous partial heat and pressure fusion parts scattered on the surface, is subjected to a process of giving non-bonding concave and convex deformation by embossing etc. As a result, the fibers of the scattered hot-pressure fusion parts are partially bonded and integrated into the front and back, but the fibers of the non-bonding irregularities in the other parts are soft touch feeling of the fibers themselves. The point is to have.

In the melt / pro-fiber web layer, even though it has a slight adhesive effect, it is considered to be in a temporarily fixed state, unlike the heat-pressure bonded part, and the composite fiber is fused by heat treatment for bonding. It is totally different from what is hard and rough. In addition, by giving non-bonding and uneven deformation force to the fiber with the degree of freedom, it is possible to make the fiber layer partially deformed (elongated) to have sufficient bulkiness. Is obtained. This means that when a load is applied, unlike the original fibrous layer, it has characteristics that are difficult to compress. In other words, the line is easy to bend, resulting in softness and bulk (thickness).

FIG. 6 shows a change curve of the thickness of the nonwoven fabric with respect to the load in Example 8 and Comparative Example 8. In the present invention, even if a load is applied, the material has a property that it is difficult to be compressed, and the bulkiness with respect to the load is reduced. It can be said that the nonwoven fabric has a small amount.

The concavo-convex embossed pattern in the high-density fiber region made of non-bonded fibers applied to the spunbonded nonwoven fabric of the present invention has a non-bonded concave or convex of an arbitrary shape that does not partially match the pattern of the bonded portion that is partially bonded. It is a deformation, and the shape, size, and depth of the concave or convex portions are important for the flexibility effect in relation to the bonding pattern. For example, the shape may be a straight line, a curve, a corner, a circle, a satin shape, or any other continuous or discontinuous shape.However, from the viewpoint of the flexibility effect, the depth of the concave or convex portion is 0. The thickness is preferably 2 to 5 mm, and the effect becomes larger as the unevenness becomes deeper.

The size of the pressure surface of the discontinuous pattern is preferably 0.1 to 5 mm, and the pitch of the concave or convex portions is preferably 0.5 to 5 mm. In the patterns of Fig. 1 (I) and Fig. 3, the embossed pattern with projections is pressed to form depressions that are discontinuously scattered in the high-density region. In addition, due to the pressing of the continuous embossed pattern of the convex pattern in Figs. 2 and 4, the fiber layer of the non-pressed portion rises while the concave portions in the high-density region continue. The deformation pitch of the continuous embossed pattern is preferably 1 to 5 mm, and the size of the concave portion is preferably a line having a width of 0.02 to 3 mm or a dotted line.

In the spunbonded nonwoven fabric provided with these embossed concavo-convex patterns, the partially hot-pressed and fused portion is a pattern that does not partially correspond to the embossed concavo-convex pattern, and the high-density region of non-bonded fibers and non-bonding It is located in the low-density region of the fiber (see C in Figs. 1 to 4).

The area ratio of the pressed portion of the unevenness in the high density region of the non-bonded fiber is preferably 5 to 40%, more preferably 5 to 25%, in order to obtain good flexibility and fiber feel. Considering practical aspects, the larger the apparent thickness is, of course, the more flexible, but if the pitch of the deformation and the size of the recess are not too large, a dense effect can be obtained and non-bonding deformation is imparted. With bulkiness before and after 1 It is preferably at least 100%, more preferably at least 105%, particularly preferably at least 130%.

In the method of providing a concave or convex pattern, a spunbonded nonwoven fabric provided with partial heat fusion by hot embossing has, for example, a concave, convex or irregular pattern on the surface, and both are just fitted together. between rolls, concave on one surface, b Nore and Bae over Nono ⁰ with convex pattern - b Nore, rubber Russia Nore, or pressed between the flexible port Lumpur such as a resin inlet Lumpur, or treated with plates It is common. As a special method, there is a method in which the cloth is forcibly over-fed at a fixed ratio between the rolls with a narrow gap to form a small zigzag shape.

The points to pay particular attention to in the concave and convex conditions are the temperature during processing and the pressure applied to the cloth. In particular, the aspect of the nonwoven fabric including the melt-blown fiber layer of the present invention is more susceptible to deformation effects than a nonwoven fabric having only a filament web. For this reason, it is preferable to set the processing temperature to be lower than that of the filament web alone in order to suppress the bonding effect of the menoret's blown fiber layer for softness. It can be set as appropriate. For example, in the case of using polypropylene as a material, it is preferable to set the temperature to 60 ° C or lower, more preferably to 50 ° C or lower, and to actively cool if necessary. Both are effective.

On the other hand, the temperature may be increased within a range that does not cause the set-up of the fibers to be plasticized to facilitate molding, or a treatment for imparting morphological stability may be performed. The pressure at the time of processing varies depending on the temperature, but can be set to a pressure at which deformation is sufficiently performed. It should be noted that the deformation gives rise to a deformation of the fiber cross section of the compressed portion, but it is also effective to perform a higher pressure treatment in order to provide more flexibility. Of course, great care must be taken to prevent temporary fixing of the fibers and hot-pressure fusion in the compression section. In a preferred embodiment of the present invention, the high density of the convex portion pressed on one side is provided. It is preferable that the opposite surface has a high-density concave portion. That is, for example, when a continuous concave portion (high-density region) is formed on one surface, it is preferable that the high-density region protrude from the other region so that the high-density region becomes a convex portion on the other surface. . It is important to make the apparent thickness of the entire nonwoven fabric equal to or greater than the thickness of Eb. Since the high-density to low-density region is formed without being joined in this way, the whole fabric is thick and easily bendable by bending force, so it is soft. It is thin, flat, and has a completely different feel to paper. In order to further enhance the processing effect, processing can be performed in multiple stages.

It is also effective that the nonwoven fabric of the present invention is provided with various treating agents such as an antistatic agent, a softening agent, a hydrophilizing agent, and a lubricant, if necessary.

When the spunbonded nonwoven fabric of the present invention is used as a sanitary material, the performance to be imparted and the method of use are selected depending on the target property level of the sanitary material. It is also necessary to consider the difference in the tactile sensation on the front and back of the nonwoven fabric. In other words, although the pressed high-density area is not bonded, it can be hardened compared to the other areas.For example, this surface is placed on the side that does not directly touch the skin, or placed in consideration of the use of convex parts. This is also a preferable mode.

In the present invention, it is economically preferable that the concave-convex processing at a low temperature is performed online in the process of manufacturing a spunbond nonwoven fabric. It can also be processed off-line. Example

Hereinafter, the present invention will be further described with reference to Examples and Comparative Examples.

First, the measurement method and the evaluation method will be described.

(1) Weight of non-woven fabric Several nonwoven fabrics measuring 10 cm square are collected, and the weight is indicated by the weight per 1 m ² .

(2) Thickness of non-woven fabric

Using a compression elasticity tester Model E-2 manufactured by Nakayama Electric Industry Co., Ltd., measuring 1.3, 10, 3, 7.5, 50, 100 g / cm ² at a measurement area of 4 cm ² Measured under each load.

(3) Non-woven fabric bulkiness

The rate of change before and after the non-woven fabric of a thickness which imparts a high density area of the unbonded fibers of the present invention (l O g Z cm ² under a load) was bulky rate.

(4) Strength of nonwoven fabric and stress at 5% elongation

A tensile test was performed on a test piece 3 cm wide and 20 cm long using a Shimadzu Corporation Tensilon at a grip width of 100 mm and a test speed of 300 m / min. The transverse strength and the stress at 5% elongation were measured.

(5) Flexibility of nonwoven fabric

As an index indicating flexibility, the flexural flexibility measured by the following method is expressed.

The measurement method is as follows: 1 cm of one end of the specimen in the measurement direction is left, and the scale is pressed across the entire width in the direction perpendicular to the specimen, and the other end of the specimen is not bent and the loop is formed. As it is formed, place it on the end pressed by the scale. While holding the end on the side held by the scale by hand, slide the scale over the specimen and move it into the loop.

The point at which the loop elongates due to the repulsive force of the sample is defined as the end point, and the length from this point to the end of the loop is defined as the critical length (mm). Shorter ones indicate more flexibility.

(6) Permeability measurement surface

Non-woven fabric is used as a top sheet of disposable sanitary materials for water permeability The side used for the skin surface was used as the surface for measuring water permeability. The “upper surface” or “lower surface” shown in the “Permeability measurement surface” column in Table 1 indicates the characteristics of the side used for the skin surface, respectively.

(7) Instantaneous water permeability

A measuring instrument (approximately 800 g, a 10 cm square hole with a diameter of 25 mm was provided at the center, and two electrodes were provided at the center, with 10 pieces of toy let paper as an absorber. Place the test cloth 10 cm square (or more) between the absorber and the measuring instrument, and drop one drop of physiological saline from the spot 15 mm above the cloth. (0. lcc Z drops) Drops. The time from dropping to the end of the cloth surface was measured with an electrode, and the instantaneous water permeation rate (seconds) was obtained.

(8) 5 cc water permeation rate (5 cc per second), amount of wetting back (g) As an absorber, use a specific filter paper (“93 9” 10 manufactured by Eton Dikeman) to stabilize the characteristics of the absorber. ：: Place an 11-corner three-piece stack under the measuring device (same as (6) Instantaneous water permeability measuring device). Place a test cloth (10 cm square) on this absorber. First, drip artificial urine of this upper 25 mm to 5 c c. The artificial urine was prepared by adding a non-ion activator to physiological saline to 45 ± 3 dyno cm (mN / m), and the drip rate was 3.3 seconds 25 cc. The time from the dropping to the end of passage through the cloth surface was measured with an electrode, and the water permeation rate was 5 cc (second / 5 cc).

Next, artificial urine is added as it is, and the total liquid volume is made approximately four times the weight of the absorber so that the amount of liquid contained in the absorber is constant. In this state, apply a load of 800 g / 100 cm square from the test cloth for 3 minutes to stabilize the liquid distribution in the absorber. Then, pre-weighed filter paper is placed on the test cloth

(Eaton Dikeman “631” 12.5 cm sq. X 2 sheets) are stacked on top of each other, and immediately squeeze 3600 g / 10 cm sq. (Equivalent to the load applied to infants' mummy) for 2 minutes. The weight increase is measured and the amount of re-wetting (g) Was.

(9) Liquid flow

Place 10 sheets of toylet paper as an absorber on a 45-degree inclined table, adhere the test cloth on it, and drop a drop of physiological saline from a spot 15 mm above the cloth ( 0. 1 c _{C / /} drops) is added dropwise. The length of the liquid flowing from the dropping part on the cloth surface to the end of the passage was measured and defined as the liquid flow (mm).

(10) Durable water permeability

Place 10 sheets of toilet paper as an absorber on a flat surface, and adhere the test cloth on it. Drop one drop of saline (0.1 cc Z drop) from the spot 15 mm above the cloth. Permeate the liquid that has been absorbed within 2 seconds. After the surface has dried, a drop is dropped again at the same position, and the test is repeated for the second time. Repeat for the third test. The same sample was tested at 10 to 40 locations, and the ratio of the number of passages to the number of drops was defined as the durable permeability (%).

(1 1) Fineness

The diameter of the fibers that make up the nonwoven fabric was measured with a microscope (Keyence Corporation high-power microscope VH-800) and the fineness (dtex: filament) calculated from the density of the fiber polymer as a fiber with a circular cross section (A weight of 1000 m). The fineness of the menoleto-blown fiber web was indicated by the fiber diameter.

(12) Softening rate of nonwoven fabric

The rate of change in the flexibility in the vertical direction before and after imparting the high-density region of the non-bonded fiber of the present invention (after treatment and before treatment) was defined as the softening rate. The smaller the value of this softening ratio, the greater the softening effect.

(13) Water pressure resistance

Water pressure is used as a measure of the denseness and waterproofness of the nonwoven fabric. Take a sample (20 cm square) and measure according to JIS-L-1092. Specified.

(Example 1, Example 2)

Polypropylene containing titanium oxide (MFR = 40 measured under the conditions in Table 1 of JIS-K7210) was used as a raw material, and a long fiber melt-extruded from a nozzle with a round cross section was spun. While being cooled from the side in the vicinity of, it was pulled off by a pulling and pulling device such as an air sucker. The yarn exiting the pulling and pulling device was passed through a charging device to spread the yarn, and then collected as a web on a moving wire mesh conveyor.

This web is passed between embossed flat rolls heated to 135 ° C, and a staggered pinpoint pattern with a diameter of 0.43mm and a diagonal pitch of 45 ° and a pitch of 1.5mm (area (Approximately 7%) to obtain a nonwoven fabric having a pinpoint dot pattern.

The constituent fibers of the obtained spunbonded nonwoven fabric were round cross-section yarns of 2.8 dte X (Example 1) and 2.0 dtex (Example 2), with a partial heat pressure fused area ratio of 7% and a basis weight of 2%. It was 0 gm ² .

This nonwoven fabric is a continuous honeycomb pattern with a side of 0.9 mm and a line width of 0.1 mm (concave pattern: see Fig. 4) (Pressing area ratio 12.5%, pattern pitch 2.8) mm, horizontal 3.2 mm, depth 0.7 mm) and a rubber roll with a surface hardness of 50 degrees (JIS-A hardness). The handle was pressed at a pressure of 100 kg / cm. The periphery of the tortoise shell was pressed, and a high-density area was obtained.

A hydrophilizing agent consisting of an activator mainly composed of a block copolymer of polyethylene glycol propylene glycol and a polyether-modified silicone is applied to this nonwoven fabric by a gravure method. wt% to give a nonwoven fabric for sanitary materials. Tables 1 and 2 show the performance evaluation results of the nonwoven fabric. The low-density area of the non-bonded fiber (the embossed concave surface), which is the surface of the nonwoven fabric, is placed on the skin side of the topsheet. However, the fiber layer was raised between the high-density regions and was soft, and had a good touch with the feel of a softer nonwoven fabric with improved wettability. Example 2 of fine decitex was smoother and more excellent in softness.

(Example 3, Example 4)

The non-bonding embossing pattern to be pressed is a non-continuous and scattered tortoiseshell pattern (0.45 mm per side, 25% pressing area ratio, 2.8 mm pattern pitch length, opposite to Example 1). The procedure of Example 1 was repeated except that the thickness was 3.2 mm and the depth was 0.6 mm) to obtain a nonwoven fabric of the present invention having 2.8 dtex and a basis weight of 20 g Zm ² . Tables 1 and 2 show the performance evaluation results of the nonwoven fabric.

This nonwoven fabric was used as a topsheet. In Example 3, the continuous convexity in the low-density region of the nonwoven fabric (the front surface of the nonwoven fabric) was used on the skin side of the topsheet, and in Example 4, the reverse nonwoven fabric was used. A non-continuous convex pattern in the high-density area on the back side of the top was used on the skin side of the topsheet to produce a disposable ommut. As in Example 1, the softness was excellent and the re-wetting performance was good as compared with the conventional nonwoven fabric. The top sheet of this non-woven fabric with the top and bottom reversed (Example 4) has a high-density area with a dot-like swelling, which adds to the smoothness of the surface. Was of a tactile feel

(Example 5)

The non-bonding embossing pattern to be pressed is assumed to be a non-continuously scattered lattice convex pattern (0.3 mm x 0.7 mm on one side, 22% pressing area ratio, 0.6 mm depth). A nonwoven fabric of the present invention having 2. O dtex and a basis weight of 18 g Zm ² was obtained in the same manner as in Example 1 except that the roll was passed while being combined with a roll having a lattice recessed pattern. Table 1 shows the performance evaluation results of the nonwoven fabric. See Figure 2.

A disposable ommut was manufactured by using the continuous convex surface of the low density region of this nonwoven fabric (the front surface of the nonwoven fabric) facing the skin of the top sheet. As in Example 1, the softness was superior to the conventional nonwoven fabric, and the wettability was also excellent.

(Examples 6 and 7)

Before applying the hydrophilizing agent, a corona treatment is performed. The corona treatment is performed at a discharge rate of 30 W · min ^/ m ² (discharge rate of 2.2 W / cm ² ) in an atmosphere at room temperature of 22 ° C. As a result, the surface tension of the nonwoven fabric was 37 mNZm, and Example 1 and Example 3 were performed except that the adhesion of the hydrophilizing agent was set to 0.3 wt% in consideration of the improvement in wettability by corona treatment. In the same manner as in the above, a nonwoven fabric for sanitary materials of the present invention was produced, and Examples 6 and 7 were obtained. The disposable sanitary material using the obtained nonwoven fabric as a topsheet is softer and less adherent with a hydrophilizing agent than the conventional nonwoven fabric, but is similar to Examples 1 and 3. Because of its excellent water permeability and few treatment agents, it had a good touch with a softer and more flexible nonwoven fabric.

(Comparative Examples 1, 2, 3, and 4)

In Examples 1, 2, 5, and 7, non-bonding pressing was not performed, and a lyophilic agent was applied, to Comparative Examples 1, 2, 3, and 4, respectively.

(Comparative Examples 5, 6)

As a preparative Ppushi one DOO comparison, commercially available short fibers Toppushi Have a single bets are for real Omu' Bointobon de nonwoven (1 9 g Zm ^2: Comparative Example 5), 2-component short fibers hot-air bonded nonwoven fabric (1 8 g Zm ² : The results are shown in Tables 1 and 2 using Comparative Example 6).

Table 2

Tensile strength of nonwoven fabric 5% elongation of nonwoven fabric Nonwoven fabric flexibility Water permeability

(N / 3cm width) Stress at time (N / 3cm width) (mm) Instantaneous water permeability 5 cc water permeability Wet return Liquid flow Durable water permeability (permeability) Remarks Vertical Horizontal Vertical Vertical Horizontal Vertical Vertical Horizontal (seconds) (seconds) (g) ( nun) 1 time 2 times 3 times Example 1 28.9 7.7 12.5 1.3 78 47 0.12 3.0 0.6 26 100 100 60

Example 2 28.5 7.2 12.0 1.3 76 50 0.12 3.1 0.8 28 100 100 60

Example 3 28.3 6.8 11.6 1.1 79 49 0.11 3.2 0.8 30 100 100 60

Example 4 28.8 7.5 11.5 1.3 77 46 0.11 3.2 0.8 27 100 100 60

Example 5 27.1 6.5 11.0 1.1 78 50 0.11 3.2 0.9 28 100 100 60

CD

Example 6------0.12 3.2 0.9 21 100 100 80

Example 7 0.11 3.5 0.7 27 100 100 60 Comparative Example 1 32.6 7.6 13.3 1.5 87 57 0.13 3.2 1.0 34 100 100 40

Comparative Example 2 31.9 7.4 15.3 1.5 85 52 0.13 3.2 1.3 36 100 100 40

Comparative Example 3 29.9 7.1 12.8 1.4 83 50 0.13 3.3 1.3 35 100 100 40

Comparative Example 4 0.11 3.2 1.7 22 100 100 70

Comparative Example 5 0.24 2.8 0.5 30 100 0 0 Short fiber hot water Comparative example 6 0.10 2.7 0.1 20 100 40 0 Short fiber hot air

From the results shown in Tables 1 and 2, the example is bulky, has less change in thickness under load, is flexible, has instantaneous water permeability, rewetting, It can be seen that it is excellent in water permeation performance such as liquid flowability and water permeation durability.

The nonwoven fabric for sanitary materials of the present invention shown in Tables 1 and 2 has good bulkiness, a bulkiness ratio of 110% or more, little change in thickness when a load is applied, and compressibility against a load. It is excellent in flexibility, and has good water permeability and durability.

(Example 8, Example 9)

Using polypropylene (MFR = 40 measured under the conditions shown in Table 1 of JIS-K720) as a raw material, a long fiber melt-extruded from a round cross-section nozzle is cooled from the side near the spinneret. While pulling it, it was picked up by a tow pulling device such as air soccer. After the yarn exiting the traction take-up device is passed through the charging device and spread, the filament web (2.8 dte X (Example 8) and 1.2) is placed on the moving wire mesh conveyor. dtex (Example 9), each of which was 6.5 g / m ² ).

Polypropylene (J15—1: MFR = 700 measured under the conditions in Table 1 of 710) was used as a raw material on this web, and a high pressure was applied from a slit near both the discharge nozzles. Two sheets of melt-blow fibers (diameter 1.8 μππ, 1 g / m ² ) spraying high-temperature air were laminated. Furthermore, the filament web prepared in the same manner as above was layered and collected to form a laminated web (15 g Zm ² ). The web threading between the embossing flat Bok rolls heated to 1 3 0, the major axis of about 0. 9 mm, shorter diameter of about 0. 5 mm, the area 0. 3 6 mm diagonal 3 elliptic shape Pattern ² 0 ° Through a heated embossing roll with a diagonal pattern (crimp area ratio of 15%) arranged in a zigzag pattern with a length of about 3 mm and a width of 1.7 m. A nonwoven fabric having an elliptical point-like dot pattern (oblique pattern) was obtained by partial heat-pressure fusion.

Embossed roll of this nonwoven fabric with a honeycomb pattern (concave pattern) with a continuous line shape of 0.9 mm on each side and a line width of 0.1 mm (press area ratio 12.5%, depth 0.7 mm) (40 ° C) and a surface hardness of 50 degrees (JIS-A hardness), and the handle was pressed at a linear pressure of 100 kg Z cm. A flexible non-woven fabric with a high density area pressed around the turtle pattern and a raised center was obtained. Tables 1 and 2 show the performance evaluation results of the nonwoven fabric. The nonwoven fabric whose filament web has a fineness of 1.2 dtex (Example 9) is a softer nonwoven fabric with a smooth feel of surface fibers.

The disposable ommut manufactured by using these nonwoven fabrics as three-dimensional gathers was softer and thicker than the conventional nonwoven fabrics that had not been subjected to a softening treatment. In addition, disposable materials that are made by laminating a microporous PE film on this nonwoven fabric and used as a backsheet are soft tactile materials that cannot be obtained with conventional nonwoven fabrics that have not been subjected to softening treatment. It had strength and surface strength to withstand heat.

(Example 10 and Example 11)

In order to obtain non-bonding unevenness deformation, the embossed pattern to be pressed was changed in a non-continuous and scattered turtle pattern (0.45 mm per side, pressing area 25%, depth 0. 6 mm), and nonwoven fabrics of the present invention having a basis weight of 15 g Zm ² (Example 10) and 17 _g m ² (Example 11) were obtained in the same manner as in Example 8. Tables 3 and 4 show the performance evaluation results of the nonwoven fabric.

A disposable ommut using this nonwoven fabric as a three-dimensional gather was produced. As in Example 8, it was made of a conventional non-woven fabric that had not been softened. It was more excellent in softness and thickness. The backsheet made by laminating a microporous PE film with the front and back of this nonwoven cloth turned over has a high-density area of non-bonded fibers that rises in a dot-like manner. It had a good tactile sensation with smoothness added.

(Example 12)

In order to obtain non-bonding uneven deformation, the embossed pattern to be pressed is non-continuously scattered with lattice convex patterns (0.3 mm X 0.7 mm on a side, pressing area ratio 22%, depth 0.6 mm). Then, the nonwoven fabric of the present invention having a basis weight of 15 gm ² was obtained in the same manner as in Example 8, except that the pattern was passed while being combined with a hole having a lattice concave pattern fitted with the pattern. Tables 3 and 4 show the performance evaluation results of the nonwoven fabric.

The nonwoven fabric was laminated with a microporous PE film to produce a disposable backpack. As in Example 8, the softness was excellent and the feeling of thickness was good as compared with the conventional nonwoven fabric.

(Example 13)

In order to obtain non-bonding uneven deformation, the embossed pattern to be pressed should be a continuous diagonal convex pattern (line width 0.2 mm, interval 0.5 mm, pressing area ratio 29%, depth 0.6 mm). the surface hardness of 6 0 degrees (JIS-a hardness), except through while in combination with rubber roll thickness 1 5 mm in the same manner as in example 8 to give the present invention a nonwoven fabric having a mass per unit area of 1 7 g Zm ² . Tables 3 and 4 show the performance evaluation results of the nonwoven fabric.

This nonwoven fabric had a diagonal bending habit, was superior in softness to the nonwoven fabric before softening treatment, and had a good thickness.

(Example 14)

The raw material polymer propylene (MFR = 40 measured under the conditions in Table 1 of JIS—K7 210) was replaced with a polypropylene random copolymer. (PE 3%, MFR = 35) Filament web (1.8 dtex, 6.5 g / m ² ) was used as in Example 8 except that the basis weight was 15 g / m ² . The nonwoven fabric of the present invention was obtained. Tables 3 and 4 show the performance evaluation results of the nonwoven fabric.

This nonwoven fabric had a polyethylene-like slimy feel on the surface, was more excellent in softness than the nonwoven fabric before softening treatment, and had a good thickness.

(Example 15)

Example 8 was repeated except that the filament layer on one side was 1.2 dtex (3.3 g / m ² ) on the outside and 2.8 dtex (3.3 g / m ² ) on the inside. In the same manner as in Example 8, a nonwoven fabric of the present invention having a basis weight of 15 g Zm ² was obtained. The obtained nonwoven fabric was a thick nonwoven fabric having a smooth surface layer.

(Example 16 and Example 17)

The raw materials for the filament tube are polyethylene terephthalate (viscosity 7? Sp / C = 0.75) and nylon 6 (relative viscosity Tjre 1 = 2.7). The polymer for one fiber is polyethylene terephthalate (viscosity jjspZc-O.42) and nylon 6 (relative viscosity r? Rel = 2.3), and the filament ゥWeb (2. Odtex, 8.3 g / m ² ), Menoleto 'fiber mouth fiber (PET = 2.4 μππ, 3.4 g Zm ² , N 6 = 1 6 m, 3.4 g Zm ² ) and a textured embossed pattern (0.5 mm square, crimping area ratio: 15%) Pass between the embossed flat mouth and polyethylene terephthalate film. The temperature of the web was 205 ° C, and that of the 6-filament filament was 186 ° C. The basis weight was 20 g Zm ^{2 in the same} manner as in Example 8 except that partial heat pressure welding was performed. Nonwoven fabric of the present invention Obtained. Tables 3 and 4 show the performance evaluation results of the nonwoven fabric. Each of these nonwoven fabrics is a nonwoven fabric which is excellent in softness and good in thickness as compared with the nonwoven fabric before the softening treatment, and the effect of the polyester nonwoven fabric of Example 16 is particularly remarkable.

These nonwoven fabrics were unprecedented soft nonwoven fabrics that can be used not only for sanitary materials but also for packaging materials, printing materials, simple clothing, and the like.

(Comparative Examples 8 to 14)

Nonwoven fabrics before non-bonding unevenness softening treatment corresponding to Examples 8, 9, 11, 14, 15, 16 and 17 were subjected to Comparative Examples 8, 9, 10, 0, 11 and 1 respectively. The characteristics are shown in Tables 3 and 4.

Three

Constituent fiber Non-woven fabric composition Thermo-compression Uneven processing Non-woven fabric Filament Meltoff 'F-F: Filament fenho * Shenbos pattern Upper surface (front) Lower surface (back) Material Fineness (d t ex) Material Fineness (m) M: Meltoff

Low density convex High density convex Example 8 ΡΡ 2.8 PP 1.8 F / M / M / F diagonal 亀

(Discontinuous) (Continuous) Low density convex High density convex Example 9 ΡΡ 1.2 PP 1.8 F / M / M / F Diagonal tillage

(Discontinuous) (Continuous) Low density convex High density convex Example 10 ΡΡ 2.8 PP 1.8 F / M / M / F

(Continuous) (Discontinuous) Low density convex High density convex Example 11 ΡΡ 2.8 PP 1.8 F / M / M / F diagonal 姘

(Continuous) (Discontinuous) Low density convex High density convex Example 12 ΡΡ 2.8 PP 1.8 F / M / M / F Oblique F Lattice convex pattern

(Continuous) (Discontinuous) Low density convex High density convex

ΡΡ 2.8 PP 1.8 / me M / M / h diagonal iff

(Continuous) (non-continuous) β / ,, low density convex high density convex Example 14 Ρ 1.8 PP 1.8 F / M / F レ^β ,, +

Hinohinoto Tortoiseshell concave pattern

(Discontinuous) (Continuous) Low density convex High density convex Fuka example lo r 丄.

(Discontinuous) (Continuous) Density convexity High density convexity Loss Rising PET 2.0 PET 2.4 M / r Jobard says Kaneda ππ ± κ Low

(Discontinuous) (Continuous) Low density convex High density convex Example 17 N6 2.0 N6 1.6 F / M / F texture

(Discontinuous) (Continuous) Comparative Example 8 PP 2.8 PP 1.8 F / M / M / F Angled

Comparative Example 9 PP 1.2 PP 1.8 F / M / M / F diagonal

Comparative Example 10 PP 2.8 PP 1.8 F / M / M / F Angled

Comparative Example 11 RCP 1.8 PP 1.8 F / M / F Pinpoint

Comparative Example 12 PP 1.2 / 2.8 PP 1.8 F / M / M / F Oblique

Comparative Example 13 PET 2.0 PET 2.4 F / M / F texture

Comparative Example 14 N6 2.0 N6 1.6 F / M / F texture

Table 4

Non-woven fabric Thickness of non-woven fabric under each load Non-woven fabric Non-woven fabric tensile strength 5% elongation of non-woven fabric Non-woven fabric non-woven fabric Flexibility Percentage (μm) Bulk (N / 3cmiH) Stress at time (N / 3cm width) Water pressure mm% (g / ni ² ) 1.3 g 37.5 g 50 g lOOg (%)

Vertical Horizontal Vertical Horizontal Vertical Vertical Horizontal

1 cm 1 cm 1 cm 1 cm

Example 8 15 268 189 149 138 119 119 12.2 7. 4 5.6 6.11 15 58 42 84 Example 9 15 266 178 140 131 112 115 18.2 7.7 6.1 2.1 15 57 41 76 Example 10 15 266 174 135 129 105 109 13.1 7.5 5 3.1.4 13 58 42 84 Example 11 17 184 115 22.8 7. 0 6.8 1.5 16 65 45 75 Example 12 15 241 173 131 130 109 109 13.0 7.7 5.9 1.8 14 59 43 86 Example 13 17 185 116 13.3 7.5 6.1 1.6 16 61 43 88 Example 14 16 188 121 12.0 5.3 4.4 1.3 13 59 40 87 Example 15 15 185 121 16.5 7.2 6.2 1.4 15 59 43 86 Example 16 20 162 157 48. 3 18.1 13.3 5.8 8-103 62 76 Example 17 20 159 135 53.0 14.1 8.1 1 2.4-54 35 87 Comparative Example 8 15 224 159 133 124 109 14. 9 9. 1 7.1 1 2. 7 18 69 44

Comparative Example 9 15 220 155 129 129 109 109 19.4 8.3 7.8 2.8 24 75 47

Comparative Example 10 17 160 19.8 7.8 8.5 1.8 16 87 49

Comparative Example 11 16 156 12.3 5.6 4.7 1.19 68 43

Comparative Example 12 15 153 17.4 8. 0 7. 5 2. 3 22 69 45

Comparative Example 13 20 103 53.0 19.0 28.8 11.3 135 87

Comparative Example 14 20 118 55.6 13.6 15.2 4.3 62 39

From the results shown in Tables 3 and 4, it can be seen that the example has superior bulkiness, tensile strength, stress at elongation, and flexibility as compared with the comparative example.

Industrial applicability

The spunbond nonwoven fabric of the present invention has excellent bulkiness, flexibility and strength, and is useful as a nonwoven fabric for sanitary materials. The spunbonded nonwoven fabric of the present invention further contains a hydrophilizing agent mainly in the region (B), so that the desired performance as a sanitary material such as a disposable omput topsheet or the like can be obtained. It satisfies the four characteristics of bulk, flexibility, water permeability and rewetting at the same time.

Claims

The scope of the claims

1. A non-woven fabric composed of a web of continuous thermoplastic synthetic filaments, and is formed on both sides of a partially hot-press-fused fiber area pattern and a non-woven fabric structure that penetrates between the front and back surfaces of the non-woven fabric and is integrated. The structure of the nonwoven fabric is fixed by the concave or convex pattern consisting of the high-density region of non-bonded fibers, and the low-density region of the nonwoven fabric occupies the thickness of the nonwoven fabric including the surface of the non-woven fiber including the convex-boss pattern. A spunbonded nonwoven fabric, characterized in that the bulkiness expressed by the ratio of the thickness of the nonwoven fabric is 100% or more.

2. The spunbond nonwoven fabric according to claim 1, wherein the high-density regions of the non-bonding fibers are continuously arranged.

3. The spunbonded nonwoven fabric according to claim 1, wherein the high-density regions of the non-bonded fibers are discontinuously scattered.

4. The spunbonded nonwoven fabric according to any one of claims 1 to 3, wherein the bulkiness ratio is 105 to 400%.

5. The area ratio of the partially hot-press fusion fiber area pattern is 5 to 40%, and the area ratio of the concave or convex pattern portion in the high-density area of the non-bonded fiber is 5 to 40%. The spunbonded nonwoven fabric according to any one of claims 1 to 4.

6. A nonwoven fabric formed of a composite web formed by laminating at least one layer of thermoplastic synthetic fiber continuous filament web and at least one layer of melt-blown fiber web. The structure of the nonwoven fabric is fixed by embossed concave or convex patterns consisting of a high-density region of non-bonded fibers on both sides of the partially hot-press fused fiber area pattern and the nonwoven fabric structure that penetrate through and intersect, A spunbond having a bulkiness ratio represented by a ratio of a thickness of the nonwoven fabric occupied by the low density region of the nonwoven fabric to a thickness of the nonwoven fabric including the surface of the convex embossed pattern of the nonwoven fabric of 100% or more. Non-woven fabric.

7. The spunbonded nonwoven fabric according to claim 6, wherein a high-density region of the non-bonded fibers is continuously arranged.

8. The spun-bonded nonwoven fabric according to claim 6, wherein high-density regions of the non-bonding fibers are discontinuously scattered.

9. The spunbonded nonwoven fabric according to any one of claims 6 to 8, wherein the bulkiness ratio is 105 to 400%.

10 0.The area ratio of the partial hot-press fusion bonding area pattern is 5 to 40%, and the area ratio of the concave or convex pattern in the high-density area of non-bonded fibers is 5 to 40%. The spunbonded nonwoven fabric according to any one of claims 6 to 9, characterized in that:

1 1. A non-woven fabric composed of a web of continuous thermoplastic synthetic filaments, and a non-woven fabric on both sides of the partially hot-press fused fiber area pattern and the non-woven fabric structure that penetrates between the front and back surfaces of the non-woven fabric and is integrated. The structure of the nonwoven fabric is fixed by an embossed concave or convex pattern consisting of a high density region of the bonding fiber.

The bulkiness expressed by the ratio of the thickness of the nonwoven fabric occupied by the low density region of the nonwoven fabric to the thickness of the nonwoven fabric including the surface of the convex embossed pattern of the nonwoven fabric is 100% or more, and a hydrophilic agent A spunbond nonwoven sanitary material characterized by being provided with a nonwoven fabric.

12. The spunbond nonwoven fabric for sanitary materials according to claim 11, wherein the hydrophilizing agent is mainly contained in a high-density region of the non-bonded fiber.

13. The spunbonded nonwoven sanitary material according to claim 11 or 12, wherein the bulkiness ratio is from 105 to 400%.

1 4. The area ratio of the partially hot-press fused fiber area pattern is 5 to 40%, and the area ratio of the pattern concave or convex portion in the high-density area of the non-bonded fiber is 5 to 40%. The method according to any one of claims 11 to 13, Spunbond nonwoven sanitary material.

15. The spunbond according to any one of claims 11 to 14, wherein the spunbond nonwoven sanitary material is subjected to a corona discharge treatment and then a hydrophilizing agent is applied thereto. Nonwoven sanitary material.

16 6. A nonwoven fabric formed of a composite web formed by laminating at least one thermoplastic synthetic fiber continuous filament web and at least one melt-blown fiber web. The non-woven fabric structure is fixed by embossed concave or convex patterns consisting of high-density areas of non-bonded fibers on both sides of the partially hot-press fused fiber area pattern penetrating between the back surfaces and the non-woven fabric structure. A spunbond having a bulkiness expressed as a ratio of the thickness of the nonwoven fabric occupied by the low-density region of the nonwoven fabric to the thickness of the nonwoven fabric including the pattern surface of 100% or more, and to which a hydrophilic agent is added. Nonwoven sanitary materials.

17. The spunbond nonwoven sanitary material according to claim 16, wherein the hydrophilizing agent is mainly contained in the high-density region of the non-bonded fiber.

18. The spunbonded nonwoven sanitary material according to claim 16 or 17, wherein the bulkiness ratio is from 105 to 400%.

19. The area ratio of the partial hot-press fusion fiber area pattern is 5 to 40%, and the area ratio of the pattern concave or convex portions in the high-density area of the non-bonded fiber is 5 to 40%. The spunbond nonwoven sanitary material according to any one of claims 16 to 18, characterized in that:

20. The spunbond nonwoven sanitary material according to any one of claims 16 to 19, wherein the nonwoven fabric is subjected to a corona discharge treatment and then a hydrophilizing agent is applied. The described spunbond nonwoven sanitary material.

21. The spunbond according to any one of claims 11 to 20 A spunbonded nonwoven disposable sanitary material characterized in that the surface of the nonwoven nonwoven sanitary material having a concave or convex pattern in the high-density region of the non-bonded fibers of the nonwoven is used for the skin surface of the topsheet.

22. The spunbond type sanitary material according to any one of claims 11 to 20 has a topsheet having a concave or convex pattern in a high-density region of non-bonded fibers of the nonwoven fabric of the nonwoven fabric. A disposable sanitary material characterized by being used as an anti-skin surface.

23. A disposable sanitary material characterized by using the spunbonded nonwoven fabric according to any one of claims 6 to 10 for a three-dimensional gather portion and a back or backsheet.