WO2010004895A1 - 吸水シート組成物 - Google Patents

吸水シート組成物 Download PDF

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Publication number
WO2010004895A1
WO2010004895A1 PCT/JP2009/061813 JP2009061813W WO2010004895A1 WO 2010004895 A1 WO2010004895 A1 WO 2010004895A1 JP 2009061813 W JP2009061813 W JP 2009061813W WO 2010004895 A1 WO2010004895 A1 WO 2010004895A1
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WO
WIPO (PCT)
Prior art keywords
water
liquid
absorbent
sheet composition
absorbing
Prior art date
Application number
PCT/JP2009/061813
Other languages
English (en)
French (fr)
Inventor
潤一 鷹取
昌良 半田
伸也 福留
暢浩 前田
Original Assignee
住友精化株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 住友精化株式会社 filed Critical 住友精化株式会社
Priority to US13/002,940 priority Critical patent/US20110111199A1/en
Priority to JP2010519737A priority patent/JP5345145B2/ja
Priority to AU2009269279A priority patent/AU2009269279B2/en
Priority to CN200980127033XA priority patent/CN102088939A/zh
Priority to EP09794341.9A priority patent/EP2301499B1/en
Priority to KR1020117002969A priority patent/KR101537137B1/ko
Publication of WO2010004895A1 publication Critical patent/WO2010004895A1/ja

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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T442/671—Multiple nonwoven fabric layers composed of the same polymeric strand or fiber material

Definitions

  • the present invention relates to a water absorbent sheet composition that can be used in the field of sanitary materials. Specifically, the present invention relates to a water-absorbent sheet composition that is thin and can be suitably used for absorbent articles such as sanitary napkins and incontinence pads. Furthermore, this invention relates to absorbent articles, such as a sanitary napkin and an incontinence pad which use this water absorbing sheet composition.
  • Body fluid absorbent articles used for sanitary materials such as sanitary napkins are flexible liquid-permeable surface sheets (top sheets) in which absorbents that absorb body fluids such as menstrual blood and urine are arranged on the side in contact with the body And a liquid-impermeable back sheet (back sheet) disposed on the opposite side in contact with the body.
  • top sheets flexible liquid-permeable surface sheets
  • back sheet liquid-impermeable back sheet
  • the absorbent body using a low ratio of hydrophilic fibers and using a large amount of water-absorbing resin reduces the bulky hydrophilic fibers, holds more liquid, and prevents liquid leakage. Is preferable for thinning.
  • gel blocking phenomenon Occurs, the liquid diffusibility is remarkably lowered, and the liquid permeation rate of the absorber is slow.
  • This “gel blocking phenomenon” means that when the absorbent body, which is rich in water-absorbing resin, absorbs the liquid, the water-absorbing resin existing near the surface layer absorbs the liquid, and the soft gel near the surface layer becomes more dense. As a result, the penetration of the liquid into the absorbent body is hindered, and the internal water-absorbing resin cannot efficiently absorb the liquid. Furthermore, an absorbent body with a reduced amount of hydrophilic nonwoven fabric that contributes to shape retention tends to cause deformation such as kinking and tearing before or after absorption of the liquid. Since the distorted absorbent body has a markedly reduced liquid diffusivity, the ability of the absorbent body cannot be exhibited, and the permeation rate becomes slow or liquid leakage occurs.
  • the ratio between the hydrophilic fiber and the water-absorbent resin is limited, and there is a limit to the reduction of the hydrophilic fiber and the thinning of the sanitary material.
  • Patent Document 1 a method of using two types of water-absorbing resins having different water absorption performance
  • Patent Document 2 a method using a water-absorbing resin having a high surface crosslink density
  • a method of fixing a water-absorbing resin to hydrophilic fibers has been studied.
  • a method in which a thermoplastic adhesive fiber is contained in an absorbent body composed of a water absorbent resin and a hydrophilic fiber and the absorbent body is heat-sealed see Patent Document 3
  • a water absorbent resin and a hydrophilic fiber using an emulsion adhesive for example, a method for fixing a hydrophilic fiber, a method for fixing a water-absorbent resin to a substrate using a hot melt adhesive (see Patent Document 4), and the like have been proposed.
  • the fiber base material enters the polymer particles and is firmly fixed.
  • An object of the present invention is to provide a water-absorbent sheet composition that has a sufficient liquid-absorbing ability and that can be suitably used for a sanitary napkin or an incontinence pad, even if it is thin, does not lose its shape after liquid absorption. is there. Furthermore, the objective of this invention is providing the absorptive articles, such as a sanitary napkin and an incontinence pad which use this water absorbing sheet composition.
  • the present invention [1] A water absorbent sheet composition having a structure in which a water absorbent resin and a hot melt adhesive are sandwiched between two or more hydrophilic nonwoven fabrics, wherein the basis weight of the hydrophilic nonwoven fabric is 30 g / m 2 or more, A water absorbent sheet composition having a water absorbent resin content of 10 to 150 g / m 2 and a hot melt adhesive content of 0.10 to 1.0 times the water absorbent resin content (mass basis); and [2 ] It is related with the absorptive article formed by holding the water-absorbing sheet composition of the above [1] with a liquid permeable sheet and a liquid impermeable sheet.
  • the water-absorbent sheet composition of the present invention Even if the water-absorbent sheet composition of the present invention is thin, it does not lose shape before and after liquid absorption, and exhibits sufficient absorption capacity not only for low-viscosity liquids but also for high-viscosity liquids. There is an effect that can be done. Therefore, by using the water-absorbent sheet composition of the present invention as an absorbent body such as a sanitary napkin or an incontinence pad, it is possible to provide a sanitary material that is thin and excellent in appearance and has no inconvenience such as liquid leakage. it can. Moreover, the water-absorbing sheet composition of the present invention can be used not only in the field of sanitary materials but also in the fields of agriculture and building materials.
  • the water-absorbent sheet composition of the present invention may be an aspect in which hydrophilic fibers such as pulp fibers are mixed with the water-absorbent resin between the nonwoven fabrics in such an amount that does not impair the effects of the present invention. From this point of view, it is preferable that the embodiment does not substantially contain hydrophilic fibers.
  • water-absorbing resins can be used as the type of water-absorbing resin.
  • starch-acrylonitrile graft copolymer hydrolyzate starch-acrylic acid graft polymer neutralized product, vinyl acetate-acrylic ester copolymer
  • saponified polymers and partially neutralized polyacrylic acid.
  • a partially neutralized polyacrylic acid is preferable from the viewpoint of production amount, production cost, water absorption performance, and the like.
  • the degree of neutralization of the partially neutralized polyacrylic acid is preferably 50 mol% or more, more preferably 70 to 90 mol%, from the viewpoint of increasing the osmotic pressure of the water absorbent resin and enhancing the water absorption capacity.
  • the content of the water-absorbent resin is 10 to 150 g / m 2 from the viewpoint of obtaining sufficient absorption capacity even when the water-absorbent sheet composition of the present invention is used for sanitary napkins and incontinence pads, preferably 20 ⁇ 120 g / m 2 , more preferably 30 to 100 g / m 2 . If the content of the water-absorbent resin is less than 10 g / m 2 , sufficient absorption capacity as an absorber cannot be obtained, and the amount of reversion tends to increase. On the other hand, if it exceeds 150 g / m 2 , a gel blocking phenomenon tends to occur, the liquid diffusing performance as an absorber is deteriorated, and the permeation rate tends to be slow.
  • the absorption capacity of the water absorbent sheet composition of the present invention is affected by the water absorption capacity of the water absorbent resin used. Therefore, the water-absorbent resin used in the present invention takes into consideration the structure of each component of the water-absorbent sheet composition, and the water-absorbing capacity (water retention capacity) of the water-absorbent resin, water absorption capacity under load, water absorption speed, etc. It is preferable to select one having a suitable performance range.
  • the physiological saline water retention capacity of the water-absorbent resin is preferably 30 g / g or more, more preferably 35 to 65 g / g, from the viewpoint of absorbing more liquid and keeping the gel strong during absorption to prevent gel blocking phenomenon. 40 to 60 g / g is more preferable.
  • the physiological saline water retention capacity of the water-absorbent resin is a value obtained by the measurement method described in Examples described later.
  • the physiological saline water absorption rate of the water absorbent resin is preferably less than 50 seconds, more preferably from the viewpoint of increasing the permeation rate of the water absorbent sheet composition of the present invention and preventing liquid leakage when used in sanitary materials. Is less than 40 seconds, more preferably 1 to 30 seconds.
  • the water absorption rate of the water absorbent resin is a value obtained by the measurement method described in Examples described later.
  • the weight-average particle diameter of the water-absorbent resin is a viewpoint of improving the texture by preventing the water-absorbent resin composition in the water-absorbent sheet composition and the gel-blocking phenomenon at the time of water absorption and reducing the jerky feel of the water-absorbent sheet composition. Therefore, the range of 20 to 800 ⁇ m is preferable, 60 to 500 ⁇ m is more preferable, and 100 to 400 ⁇ m is more preferable.
  • hot melt adhesive examples include rubber adhesives such as natural rubber, butyl rubber and polyisoprene; styrene-isoprene block copolymer (SIS), styrene-butadiene block copolymer (SBS).
  • rubber adhesives such as natural rubber, butyl rubber and polyisoprene
  • SIS styrene-isoprene block copolymer
  • SBS styrene-butadiene block copolymer
  • Styrene-isobutylene block copolymer SIBS
  • styrene elastomer adhesive such as styrene-ethylene-butylene-styrene block copolymer (SEBS); ethylene-vinyl acetate copolymer (EVA) adhesive; ethylene- Ethylene-acrylic acid derivative copolymer adhesives such as ethyl acrylate copolymer (EEA) and ethylene-butyl acrylate copolymer (EBA); Ethylene-acrylic acid copolymer (EAA) adhesive; Copolymer nylon , Polyamide-based adhesives such as dimer acid-based polyamide; polyethylene, polypropylene, atactic polypropylene, copolymer poly Polyolefin adhesives such as olefins; Polyethylene terephthalate (PET), Polybutylene terephthalate (PBT), polyester adhesives such as copolymer polyesters, and acrylic adhesives, and
  • an ethylene-vinyl acetate copolymer adhesive and a styrene elastomer adhesive are used from the viewpoint of strong adhesive strength and prevention of peeling of the hydrophilic nonwoven fabric and dissipation of the water absorbent resin in the water absorbent sheet composition. Is preferred.
  • the melting temperature or softening point of the hot melt adhesive is preferably 60 to 180 ° C. from the viewpoint of sufficiently fixing the water-absorbent resin to the nonwoven fabric and preventing thermal deterioration and deformation of the nonwoven fabric.
  • the hot melt adhesive is bonded to a non-woven fabric or a hydrophilic resin in a state of solidifying by cooling after melting in the production process of the water-absorbing sheet composition.
  • the content of the hot melt adhesive is 0.10 to 1.0 times the content (mass basis) of the water absorbent resin, preferably 0.15 to 0.75 times, more preferably 0.20 to 0.5 times.
  • content of the hot melt adhesive is less than 0.10 times, adhesion is insufficient, and there is a tendency that peeling between hydrophilic nonwoven fabrics, unevenness of water-absorbing resin, and dissipation increase. If it exceeds 1.0 times, the adhesion between the hydrophilic nonwoven fabrics becomes strong, and the swelling of the water-absorbent resin after water absorption is inhibited, so that the amount of reversion tends to increase.
  • the water-absorbent sheet composition of the present invention is also characterized in that two or more hydrophilic nonwoven fabrics are used.
  • the performance as a sanitary material such as the permeation rate and the amount of reversal is such as the hydrophilicity and strength of the nonwoven fabric on the liquid permeation side (forward side), etc. It is presumed that it is greatly influenced by the performance of Moreover, in the case of the nonwoven fabric on the opposite side, it is also inferred that performances other than strength and flexibility are not required as much as the forward side.
  • the hydrophilic non-woven fabric used in the present invention is not particularly limited as long as it is a non-woven fabric known in the technical field, but from the viewpoint of liquid permeability, flexibility and strength when used as a sheet composition, polyethylene (PE), Non-woven fabric made of polyolefin fibers such as polypropylene (PP), polyester fibers such as polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polyethylene naphthalate (PEN), polyamide fibers such as nylon, rayon fibers, and other synthetic fibers Examples thereof include a nonwoven fabric produced by mixing cotton, silk, hemp, pulp (cellulose) fibers, and the like, and may be a mixture of these two or more types of fibers.
  • PE polyethylene
  • Non-woven fabric made of polyolefin fibers such as polypropylene (PP)
  • polyester fibers such as polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polyethylene naphthalate (PEN)
  • the surface may be hydrophilized by a well-known method as needed.
  • synthetic fiber nonwoven fabrics are preferably used, and in particular, at least one selected from the group consisting of rayon fibers, polyolefin fibers, polyester fibers, and mixtures thereof. Is preferred.
  • the hydrophilic non-woven fabric of synthetic fibers may contain a small amount of pulp fibers to the extent that the thickness of the water absorbent sheet composition is not increased.
  • the hydrophilic nonwoven fabric is moderately bulky from the viewpoint of imparting good liquid permeability, flexibility, strength and cushioning properties to the water absorbent sheet composition of the present invention, and increasing the penetration speed of the water absorbent sheet composition.
  • a nonwoven fabric with a large basis weight is preferred.
  • the basis weight is 30 g / m 2 or more, preferably 40 to 250 g / m 2 , more preferably 50 to 150 g / m 2 .
  • the water-absorbent sheet composition of the present invention is, for example, a uniform dispersion of a water-absorbent resin and a mixed powder of a hot melt adhesive on a hydrophilic nonwoven fabric, and further overlaying the hydrophilic nonwoven fabric to form a hot melt adhesive. It can be manufactured by thermocompression bonding near the melting temperature.
  • the water-absorbing sheet composition of the present invention may be appropriately mixed with additives such as a deodorant, an antibacterial agent and a gel stabilizer.
  • the water-absorbent sheet composition of the present invention has a great feature in that it can be thinned, and considering its use for sanitary napkins and incontinence pads, the thickness is preferably 4 mm or less in a dry state. 3 mm or less is more preferable, 2 mm or less is more preferable, and 0.5 to 2 mm is still more preferable.
  • the absorbent article of the present invention comprises the water absorbent sheet composition of the present invention sandwiched between a liquid permeable sheet and a liquid impermeable sheet.
  • the absorbent article include an incontinence pad, a sanitary napkin, a pet sheet, a food drip sheet, a power cable water-stopping agent, and the like.
  • the liquid permeable sheet and the liquid impermeable sheet those known in the technical field of absorbent articles can be used without any particular limitation.
  • Such an absorbent article can be manufactured by a known method.
  • the performance of the water absorbent resin and the water absorbent sheet composition was measured by the following method.
  • ⁇ Mass average particle diameter of water absorbent resin> As a lubricant, 0.5 g of amorphous silica (Degussa Japan Co., Ltd., Sipernat 200) was mixed with 100 g of the water absorbent resin.
  • the water-absorbent resin particles are passed through a JIS standard sieve having a sieve opening of 250 ⁇ m.
  • a JIS standard sieve having a sieve opening of 250 ⁇ m.
  • the combination of sieves in (A) is used.
  • the mass average particle diameter was measured using the combination of sieves (B).
  • the above water-absorbing resin particles were put on the combined uppermost sieve and classified by shaking for 20 minutes using a low-tap shaker.
  • the mass of the water-absorbing resin remaining on each sieve is calculated as a percentage by mass with respect to the total amount, and the mass of the water-absorbing resin remaining on the sieve opening and the sieve is calculated by integrating in order from the larger particle size.
  • the relationship between percentage and integrated value was plotted on a logarithmic probability paper. By connecting the plots on the probability paper with a straight line, the particle diameter corresponding to an integrated mass percentage of 50 mass% was defined as the mass average particle diameter.
  • Test solution A low viscosity test solution
  • Saline 0.9 mass% sodium chloride aqueous solution
  • Test solution B high viscosity test solution: In a 10 L container, 60 g of sodium chloride, 24 g of sodium carbonate (anhydride), 60 g of glycerin and an appropriate amount of distilled water were added and completely dissolved. Distilled water was further added to adjust the total weight of the aqueous solution to 6000 g, and the resulting product was colored with a small amount of Blue No. 1.
  • sample (water-absorbing sheet composition) A On top of sample (water-absorbing sheet composition) A, a polyethylene air-through porous liquid permeable sheet B having the same size (8 ⁇ 20 cm) as the sample and a basis weight of 21 g / m 2 was placed. Moreover, the liquid impermeable sheet
  • seat B was set
  • a cylindrical cylinder 1 having an inner diameter of 2 cm is placed in the vicinity of the center of the body fluid absorbent article, and 20 mL of the test liquid 2 is poured at once, and the test liquid completely penetrates the body fluid absorbent article using a stopwatch.
  • the powder uniformly mixed with was uniformly sprayed.
  • a hydrophilic non-woven fabric forward side
  • a water-absorbent sheet composition was obtained by forming a sheet by pressure bonding.
  • Example 3 In Example 1, instead of “AQUAKEEP SA60N Type II” as the superabsorbent resin, “AQUAKEEP 10SH-P” (manufactured by Sumitomo Seika Co., Ltd., physiological saline water retention capacity: 41 g / g, physiological Except for using salt water absorption rate: 4 seconds, mass average particle size: 160 ⁇ m), a sheet was formed in the same manner as in Example 1 to obtain a water-absorbing sheet composition.
  • Example 4 In Example 1, a hydrophobic nonwoven fabric (hydrophobic polyethylene terephthalate (100%) with a basis weight of 40 g / m 2 ) instead of a hydrophilic nonwoven fabric as a nonwoven fabric (reverse side) to which a water-absorbing resin and a hot melt adhesive are dispersed. Except that was used, a sheet was formed in the same manner as in Example 1 to obtain a water absorbent sheet composition.
  • Table 1 shows the measurement results of the presence / absence of liquid leakage, the penetration rate, the amount of return, and the diffusion length when the test solution was added.
  • the water-absorbent sheet compositions of Examples 1 to 3 have a faster penetration rate than the Comparative Examples 1 to 3, and the amount of reversal is small regardless of the viscosity of the test solution, and the diffusion of the solution It turns out that it is also favorable. Further, in the water absorbent sheet composition of Comparative Example 4 using a hydrophobic nonwoven fabric on the opposite side, the test liquid was not absorbed by the absorbent sheet when the test liquid was added, and liquid leakage from the water absorbent sheet occurred. Therefore, comparative evaluation could not be performed.
  • the water-absorbent sheet composition of the present invention can be used in the sanitary material field, the agricultural field, the building material field, and the like, and in particular, can be suitably used for sanitary napkins and incontinence pads.

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Abstract

　吸水性樹脂及びホットメルト接着剤が、2枚以上の親水性不織布により挟持された構造を有する吸水シート組成物であって、前記親水性不織布の目付量が30g/m2以上、前記吸水性樹脂の含有量が10～150g/m2、前記ホットメルト接着剤の含有量が、吸水性樹脂の含有量（質量基準）の0.10～1.0倍である、吸水シート組成物。本発明の吸水シート組成物は、薄型であっても、液吸収前や液吸収後に型くずれを起こさず、しかも低粘度の液体だけでなく、高粘度の液体に対しても十分な吸収能力を発揮することができるという効果を奏する。従って、本発明の吸水シート組成物を生理用ナプキンや失禁パッド等の吸収体として使用することにより、薄くて外観の意匠性に優れると共に、液漏れ等の不都合のない衛生材料を提供することができる。

Description

吸水シート組成物
　本発明は、衛生材料分野等に使用し得る吸水シート組成物に関する。詳しくは、薄型で生理用ナプキンや失禁パッド等の吸収性物品に好適に使用し得る吸水シート組成物に関する。さらに本発明は、かかる吸水シート組成物を用いてなる生理用ナプキンや失禁パッド等の吸収性物品に関する。
　生理用ナプキン等の衛生材料に使用される体液吸収物品は、経血や尿等の体液を吸収する吸収体が、体に接する側に配された柔軟な液透過性の表面シート（トップシート）と、体と接する反対側に配された液不透過性の背面シート（バックシート）とにより挟持された構造を有する。
　近年、装着時の違和感の解消や持ち運びの便利さから、生理用ナプキン等の衛生材料の薄型化、軽量化に対する要求が強まっている。また、吸収体に対する吸収後の液漏れ防止への要求も強い。これに対し、従来の衛生材料において一般的に行われている薄型化のための方法としては、例えば、吸収体中の吸水性樹脂を固定する役割であるパルプ繊維等の親水性繊維を減らし、吸水性樹脂を増加させる方法がある。
　このように親水性繊維の比率を低くし、吸水性樹脂を多量に使用した吸収体は、嵩高い親水性繊維を減らして、より多くの液体を保持し、液漏れも防ぐことができるという観点からは、薄型化に好ましい。しかしながら、実際に生理用ナプキンや失禁パッド等の衛生材料に使用された際の液体の分配や拡散を考えた場合、多量の吸水性樹脂が吸収によって柔らかいゲル状になると、いわゆる「ゲルブロッキング現象」が発生し、液拡散性が格段に低下し、吸収体の液浸透速度が遅くなるという欠点を有する。この「ゲルブロッキング現象」とは、特に吸水性樹脂が多く密集した吸収体が液体を吸収する際、表層付近に存在する吸水性樹脂が液体を吸収し、表層付近で柔らかいゲルが、さらに密になることで、吸収体内部への液体の浸透が妨げられ、内部の吸水性樹脂が、効率良く液体を吸収できなくなる現象のことである。さらに、形態保持に寄与する親水性不織布を減らした吸収体は、液体の吸収前又は吸収後において、よじれや断裂などの型くずれを起こしやすくなる。型くずれをした吸収体は、液体の拡散性が格段に低下するため、吸収体の能力を発揮できずに、浸透速度が遅くなったり、液漏れが発生したりする。このような現象を避け、吸収体の吸収特性を維持するためには、親水性繊維と吸水性樹脂の比率が制限され、親水性繊維の減少や衛生材料の薄型化にも限界が生じる。
　そこで、これまでにも親水性繊維を減らし、吸水性樹脂を多量に使用した時に発生する「ゲルブロッキング現象」を防ぐ手段として、例えば、吸水性能の異なる2種類の吸水性樹脂を使用する方法（特許文献１参照）、表面の架橋密度が高い吸水性樹脂を用いる方法（特許文献２参照）等が提案されている。
　しかしながら、これらの方法では、吸水性樹脂を多量に使用した吸収体としての吸収特性は満足できるものではない。また、吸水性樹脂を固定する役割を担う親水性繊維が減少することより、吸水性樹脂が使用前に偏り、また使用中に移動するという問題が生じ、より「ゲルブロッキング現象」を引き起こしやすくなる傾向にある。
　これらの問題点を解決するために、親水性繊維に吸水性樹脂を固定する方法も検討されてきた。例えば、熱可塑性の接着性繊維を吸水性樹脂と親水性繊維からなる吸収体に含有させて吸収体を熱融着させる方法（特許文献３参照）、エマルション接着剤を用いて吸水性樹脂と親水性繊維を固定化する方法、ホットメルト接着剤を用いて吸水性樹脂を基材に固定化する方法（特許文献４参照）等が提案されている。
　しかし、このような方法で、接着剤を用いて吸水性樹脂を固定化する場合には、その接着剤の拘束により吸水性樹脂の膨潤が抑制される傾向にある。特に、吸水性樹脂と親水性繊維等を、熱可塑性接着剤やエマルションで固定した場合には、本来吸水性樹脂が持つ吸水能力が十分に発揮されず、また、「ゲルブロッキング現象」が生じやすいという問題もある。
　接着剤を用いずに基材に吸水性樹脂を固定化する方法もある。例えば、重合進行中の吸水性ポリマー粒子を繊維質基材に付着させ、繊維基材上で重合を行う方法（特許文献５参照）、アクリル酸及びアクリル酸塩を主成分とする単量体水性組成物を不織布基材上で電子線照射によって重合させる方法（特許文献６参照）等がある。
　これらの方法では、ポリマー粒子中に繊維基材が入り込んで堅固に固着されるが、基材中で重合反応を完結させることが難しく、未反応の残存モノマー等が多くなるという欠点を有する。
特開２００１－２５２３０７号公報 特開平０６－０５７０１０号公報 特開平１０－１１８１１４号公報 特開２０００－２３８１６１号公報 特開２００３－１１１１８号公報 特開平０２－０４８９４４号公報
　本発明の目的は、薄型であっても、液吸収後に型くずれを起こさず、十分な液吸収能力を有し、生理用ナプキンや失禁パッドに好適に使用しうる吸水シート組成物を提供することにある。さらに本発明の目的は、かかる吸水シート組成物を用いてなる生理用ナプキンや失禁パッド等の吸収性物品を提供することにある。
　本発明は、
〔１〕　　吸水性樹脂及びホットメルト接着剤が、2枚以上の親水性不織布により挟持された構造を有する吸水シート組成物であって、前記親水性不織布の目付量が30g/m2以上、前記吸水性樹脂の含有量が10～150g/m2、前記ホットメルト接着剤の含有量が、吸水性樹脂の含有量（質量基準）の0.10～1.0倍である、吸水シート組成物；並びに
〔２〕　　前記〔１〕記載の吸水シート組成物を、液体透過性シート及び液体不透過性シートで狭持してなる、吸収性物品、に関する。
　本発明の吸水シート組成物は、薄型であっても、液吸収前や液吸収後に型くずれを起こさず、しかも低粘度の液体だけでなく、高粘度の液体に対しても十分な吸収能力を発揮することができるという効果を奏する。従って、本発明の吸水シート組成物を生理用ナプキンや失禁パッド等の吸収体として使用することにより、薄くて外観の意匠性に優れると共に、液漏れ等の不都合のない衛生材料を提供することができる。また、本発明の吸水シート組成物は、衛生材料分野以外に、農業分野や建材分野等にも使用することができる。
吸収シート組成物の性能評価における、試験液投入時の模式図である。 吸収シート組成物の性能評価における、逆戻り量測定時の模式図である。 吸収シート組成物の性能評価における、拡散長の測定時の模式図である。
　吸水性樹脂及びホットメルト接着剤が、2枚以上の親水性不織布により挟持された構造を有する吸水シート組成物であり、吸水性樹脂の量と、吸水性樹脂に対するホットメルト接着剤の量を調整することにより、パルプ繊維等の親水性繊維を含まない薄型の吸水シート組成物を実現することができる。さらに、本発明の吸水シート組成物は、吸水性樹脂がホットメルト接着剤により不織布に固着しているため、パルプ繊維等の親水性繊維を含んでいなくても、吸水性樹脂の偏りや散逸を防止することができ、型くずれも防止される。また、吸水性樹脂の表面全体がホットメルト接着剤に覆われた状態ではなく、一部分が固着した状態であるため、吸水性樹脂の吸水性能が阻害されることがなく、吸水性樹脂が十分に膨潤することができると考えられる。
　本発明の吸水シート組成物は、パルプ繊維等の親水性繊維が本発明の効果を損なわない範囲の量で、不織布間に吸水性樹脂とともに混在している態様であってもよいが、薄型化の観点からは、実質的に親水性繊維を含まない態様であることが好ましい。
　吸水性樹脂の種類としては、市販の吸水性樹脂が使用でき、例えば、澱粉－アクリロニトリルグラフト共重合体の加水分解物、澱粉－アクリル酸グラフト重合体の中和物、酢酸ビニル－アクリル酸エステル共重合体のケン化物、ポリアクリル酸部分中和物等が挙げられる。これらのなかでは、生産量、製造コストや吸水性能等の点から、ポリアクリル酸部分中和物が好ましい。
　ポリアクリル酸部分中和物の中和度は、吸水性樹脂の浸透圧を高め、吸水能力を高める観点から、50モル％以上が好ましく、70～90モル％がさらに好ましい。
　吸水性樹脂の含有量は、本発明の吸水シート組成物が生理用ナプキンや失禁パッドに使用された際にも十分な吸収能力を得る観点から、10～150g/m2であり、好ましくは20～120g/m2、より好ましくは30～100g/m2である。吸水性樹脂の含有量が10g/m2未満であると、吸収体としての十分な吸収能力が得られず、逆戻り量が増加する傾向にある。また、150g/m2を超えると、ゲルブロッキング現象が生じやすくなり、吸収体として液体の拡散性能が悪くなり、また浸透速度も遅くなる傾向にある。
　本発明の吸水シート組成物の吸収能力は、使用される吸水性樹脂の吸水能力に影響をうける。よって本発明で使用される吸水性樹脂は、吸水シート組成物の各成分の構成等を考慮して、吸水性樹脂の吸水容量（保水能）、荷重下での吸水能、吸水速度等の吸水性能が好適な範囲のものを、選択することが好ましい。
　吸水性樹脂の生理食塩水保水能は、液体をより多く吸収し、かつ吸収時のゲルを強く保ちゲルブロッキング現象を防止する観点から、30g/g以上が好ましく、35～65g/gがより好ましく、40～60g/gがさらに好ましい。吸水性樹脂の生理食塩水保水能は、後述の実施例に記載の測定方法により得られる値である。
　吸水性樹脂の生理食塩水吸水速度は、本発明の吸水シート組成物の浸透速度を速め、衛生材料に使用される際の液漏れを防止する観点から、好ましくは50秒未満であり、より好ましくは40秒未満であり、さらに好ましくは、1～30秒である。吸水性樹脂の吸水速度は、後述の実施例に記載の測定方法により得られる値である。
　吸水性樹脂の質量平均粒径は、吸水シート組成物における吸水性樹脂の散逸及び吸水時のゲルブロッキング現象を防止するとともに、吸水シート組成物のゴツゴツする感触を低減して、風合いを向上する観点から、20～800μｍの範囲が好ましく、60～500μｍがさらに好ましく、100～400μｍがさらに好ましい。
　本発明に使用するホットメルト接着剤としては、例えば、天然ゴム系、ブチルゴム系、ポリイソプレン等のゴム系接着剤；スチレン－イソプレンブロック共重合体(SIS)、スチレン－ブタジエンブロック共重合体(SBS)、スチレン－イソブチレンブロック共重合体(SIBS)、スチレン－エチレン－ブチレン－スチレンブロック共重合体(SEBS)等のスチレン系エラストマー接着剤；エチレン－酢酸ビニル共重合体(EVA)接着剤；エチレン－アクリル酸エチル共重合体(EEA)、エチレン－アクリル酸ブチル共重合体(EBA)等のエチレン－アクリル酸誘導体共重合系接着剤；エチレン－アクリル酸共重合体(EAA)接着剤；共重合ナイロン、ダイマー酸ベースポリアミド等のポリアミド系接着剤；ポリエチレン、ポリプロピレン、アタクチックポリプロピレン、共重合ポリオレフィン等のポリオレフィン系接着剤；ポリエチレンテレフタレート(PET)、ポリブチレンテレフタレート(PBT)、共重合ポリエステル等のポリエステル系接着剤等、及びアクリル系接着剤が挙げられ、これらは２種以上が併用されていてもよい。本発明においては、接着力が強く、吸水シート組成物における親水性不織布の剥離や吸水性樹脂の散逸を防ぐことができるという観点から、エチレン－酢酸ビニル共重合体接着剤、スチレン系エラストマー接着剤が好ましい。
　ホットメルト接着剤の溶融温度または軟化点は、吸水性樹脂を不織布に十分に固定し、不織布の熱劣化や変形を防止する観点から、60～180℃が好ましい。なお、本発明の吸水シート組成物において、ホットメルト接着剤は、吸水シート組成物の製造過程において、溶融後、冷却によりそのまま固化した状態で不織布や親水性樹脂に接着したものである。
　ホットメルト接着剤の含有量は、吸水性樹脂の含有量（質量基準）の0.10～1.0倍であり、好ましくは0.15～0.75倍であり、より好ましくは0.20～0.5倍である。ホットメルト接着剤の含有量が0.10倍未満であると、接着が不十分となり、親水性不織布同士の剥離や吸水性樹脂の偏り、散逸が増加する傾向にある。1.0倍を超えると、親水性不織布同士の接着が強くなり、吸水後の吸水性樹脂の膨潤が阻害されるため、逆戻り量が増加する傾向にある。
　本発明の吸水シート組成物は、2枚以上の親水性不織布が用いられている点にも特徴を有する。一般的に吸水シート組成物が衛生材料に用いられる際、浸透速度や逆戻り量などの衛生材料としての性能は、吸水シート組成物において、液体浸透側（順側）の不織布の親水性や強度などの諸性能に大きく影響されると推察される。また、これとは逆側の不織布の場合、強度や柔軟性以外の性能は、順側ほど必要で無いことも推察される。しかしながら本検討に際し、逆側の不織布のみを疎水性としたところ、理由は明確でないものの、吸水時に不織布間から多大な液漏れを生じ、逆側の不織布も親水性が必須であることがわかった。すなわち本発明において、吸水性樹脂を挟持する不織布の両側に親水性不織布を用いることで、高い吸収性能を有する薄型の吸水シート組成物を得ることが可能となった。
　本発明に使用する親水性不織布としては、当該技術分野で公知の不織布であれば特に限定されないが、液浸透性、柔軟性及びシート組成物とした際の強度の観点から、ポリエチレン(PE)、ポリプロピレン(PP)等のポリオレフィン繊維、ポリエチレンテレフタレート(PET)、ポリトリメチレンテレフタレート(PTT)、ポリエチレンナフタレート(PEN)等のポリエステル繊維、ナイロン等のポリアミド繊維、レーヨン繊維、その他の合成繊維製の不織布や、綿、絹、麻、パルプ（セルロース）繊維等が混合されて製造された不織布等が挙げられ、これらの２種以上の繊維からなる混合体であってもよい。また、必要に応じて公知の方法で表面が親水化処理されていてもよい。吸水シート組成物の強度を高めるなどの観点から、合成繊維の不織布が好ましく用いられ、なかでもレーヨン繊維、ポリオレフィン繊維、ポリエステル繊維及びそれらの混合体からなる群より選ばれた少なくとも１種であることが好ましい。合成繊維の親水性不織布には、吸水シート組成物の厚みを増大させない程度に少量のパルプ繊維が含まれていてもよい。
　親水性不織布は、本発明の吸水シート組成物に、良好な液浸透性、柔軟性、強度やクッション性を付与すること、及び吸水シート組成物の浸透速度を速める観点から、適度に嵩高く、目付量が大きい不織布が好ましい。その目付量は、30g/m2以上であり、好ましくは40～250g/m2、より好ましくは50～150g/m2である。
　本発明の吸水シート組成物は、例えば、親水性不織布の上に、吸水性樹脂とホットメルト接着剤の混合粉末とを、均一に散布し、さらに親水性不織布を重ねて、ホットメルト接着剤の溶融温度付近で加熱圧着することにより、製造することができる。
　また、本発明の吸水シート組成物は、消臭剤、抗菌剤やゲル安定剤等の添加剤が適宜配合されていてもよい。
　本発明の吸水シート組成物は、薄型化が可能である点に大きな特徴を有しており、生理用ナプキンや失禁パッドへの使用を考慮すると、その厚みは、乾燥状態で、4mm以下が好ましく、3mm以下がより好ましく、2mm以下がさらに好ましく、0.5～2mmがよりさらに好ましい。
　さらに本発明の吸収性物品は、本発明の吸水シート組成物が、液体透過性シート及び液体不透過性シートで挟持されてなる。吸収性物品としては、例えば失禁パッド、生理用ナプキン、ペットシート、食品用ドリップシート、電力ケーブルの止水剤等が挙げられる。さらに、液体透過性シート及び液体不透過性シートとしては、吸収性物品の技術分野で公知のものを、特に制限なく用いることができる。かかる吸収性物品は、公知の方法によって製造することができる。
　以下に、本発明を実施例に基づいてさらに詳細に説明するが、本発明はかかる実施例のみに限定されるものではない。
　吸水性樹脂及び吸水シート組成物の性能は、以下の方法により測定した。
＜吸水性樹脂の生理食塩水保水能＞
　吸水性樹脂2.0gを、綿袋（メンブロード60番、横100mm×縦200mm）中に計り取り、500mL容のビーカーに入れた。綿袋に生理食塩水（0.9質量％塩化ナトリウム水溶液、以下同様）500gを一度に注ぎ込み、吸水性樹脂のママコが発生しないように生理食塩水を分散させた。綿袋の上部を輪ゴムで縛り、１時間放置して、吸水性樹脂を十分に膨潤させた。遠心力が167Gとなるよう設定した脱水機（国産遠心機株式会社製、品番：H-122）を用いて綿袋を1分間脱水し、脱水後の膨潤ゲルを含んだ綿袋の質量Ｗａ(g)を測定した。吸水性樹脂を添加せずに同様の操作を行い、綿袋の湿潤時空質量Ｗｂ(g)を測定し、次式により吸水性樹脂の生理食塩水保水能を求めた。
　吸水性樹脂の生理食塩水保水能(g/g)＝［Ｗａ－Ｗｂ］(g)／吸水性樹脂の質量(g)
＜吸水性樹脂の生理食塩水吸水速度＞
　本試験は、25℃±1℃に調節された室内で行なった。100mL容のビーカーに、生理食塩水50±0.1gを量りとり、マグネチックスターラーバー（8mmφ×30mmのリング無し）を投入し、ビーカーを恒温水槽に浸漬して、液温を25±0.2℃に調節した。次に、マグネチックスターラー上にビーカーを置いて、回転数600r/minとして、生理食塩水に渦を発生させた後、吸水性樹脂2.0±0.002gを、前記ビーカーに素早く添加し、ストップウォッチを用いて、吸水性樹脂の添加後から液面の渦が収束する時点までの時間（秒）を測定し、吸水性樹脂の吸水速度とした。
＜吸水性樹脂の質量平均粒径＞
　吸水性樹脂100gに、滑剤として、0.5gの非晶質シリカ（デグサジャパン（株）、Sipernat 200）を混合した。
　前記吸水性樹脂粒子を、JIS標準篩の目開き250μmの篩を用いて通過させ、その50質量％以上が通過する場合には（Ａ）の篩の組み合わせを、その50質量％以上が篩上に残る場合には（Ｂ）の篩の組み合わせを用いて質量平均粒子径を測定した。
（Ａ）JIS標準篩を上から、目開き425μmの篩、目開き250μmの篩、目開き180μmの篩、目開き150μmの篩、目開き106μmの篩、目開き75μmの篩、目開き45μmの篩及び受け皿の順に組み合わせた。
（Ｂ）JIS標準篩を上から、目開き850μmの篩、目開き600μmの篩、目開き500μmの篩、目開き425μmの篩、目開き300μmの篩、目開き250μmの篩、目開き150μmの篩及び受け皿の順に組み合わせた。
　組み合わせた最上の篩に、前記吸水性樹脂粒子を入れ、ロータップ式振とう器を用いて20分間振とうさせて分級した。
　分級後、各篩上に残った吸水性樹脂の質量を全量に対する質量百分率として計算し、粒子径の大きい方から順に積算することにより、篩の目開きと篩上に残った吸水性樹脂の質量百分率の積算値との関係を対数確率紙にプロットした。確率紙上のプロットを直線で結ぶことにより、積算質量百分率50質量％に相当する粒子径を質量平均粒子径とした。
＜吸収シート組成物の性能評価＞
　吸水シート組成物を8cm×20cmの短冊形に切断したものを、サンプルとして使用した。
　試験液として、下記試験液Ａ、Ｂを使用した。
試験液Ａ（低粘性試験液）：生理食塩水（0.9質量％塩化ナトリウム水溶液）を、少量の青色1号で着色した。
試験液Ｂ（高粘性試験液）：10Ｌ容の容器に、塩化ナトリウム60g、炭酸ナトリウム（無水物）24g、グリセリン60g及び適量の蒸留水を入れ、完全に溶解した。さらに蒸留水を添加して、水溶液全体の重量を6000gに調整した後、少量の青色1号で着色した。
　サンプル（吸水シート組成物）Ａの上部に、サンプルと同じ大きさ（8×20cm）、目付量21g/m2のポリエチレン製エアスルー型多孔質液体透過性シートＢを載せた。また、サンプルの下にシートＢと同じ大きさ、目付量のポリエチレン製液体不透過性シートＣを置き、体液吸収性物品を作製した。この体液吸収性物品の中心付近に、内径2cmの円筒型シリンダー１を置き、20mLの試験液２を一度に投入するとともに、ストップウォッチを用いて、試験液が完全に体液吸収性物品に浸透するまでの時間を測定し、浸透速度（秒）とした（図１）。5分後、液投入口付近に、あらかじめ質量（Ｗｃ(g)、約30g）を測定しておいた5×15cmの濾紙４を置き、その上に5cm×15cmの4.5kgの重り３を載せた（図２）。5分間の荷重後、濾紙４の質量（Ｗｄ(g)）を測定し、増加した質量を逆戻り量(g)とした。
　　逆戻り量(g)＝Ｗｄ－Ｗｃ
その後、試験液の拡散長Ｄ(cm)を測定した（図３）。
［実施例１、２及び比較例１～３］
　目付量60g/m2のレーヨン繊維とポリエチレンテレフタレート繊維の混合体（レーヨン繊維／ポリエチレンテレフタレート繊維＝65/35（質量比））からなる親水性不織布（逆側）の上に、ポリアクリル酸部分中和物（中和度：75モル％）からなる高吸水性樹脂「アクアキープSA60N Type II」（住友精化（株）社製、生理食塩水保水能：40g/g、生理食塩水吸水速度：28秒、質量平均粒径：300μm）とホットメルト接着剤としてエチレン－酢酸ビニル共重合体（溶融温度９５℃）とを、それぞれの量がシート面積に対して表１に示す含有量となるように均一に混合した粉末を、均一に散布した。上部から、目付量60g/m2のレーヨン繊維とポリエチレンテレフタレート繊維の混合体（レーヨン繊維／ポリエチレンテレフタレート繊維＝65/35（質量比））からなる親水性不織布（順側）を載せた後、加熱圧着によりシート化して、吸水シート組成物を得た。
［実施例３］
　実施例１において、高吸水性樹脂として、「アクアキープSA60N Type II」の代わりに、「アクアキープ10SH-P」（住友精化（株）社製、生理食塩水保水能：41g/g、生理食塩水吸水速度：4秒、質量平均粒径：160μm）を使用した以外は、実施例１と同じ方法でシート化し、吸水シート組成物を得た。
［比較例４］
　実施例１において、吸水性樹脂とホットメルト接着剤を散布する不織布（逆側）として、親水性不織布の代わりに、疎水性不織布（目付量40g/m2の疎水性ポリエチレンテレフタレート(100％)）を使用した以外は、実施例１と同じ方法でシート化し、吸水シート組成物を得た。
　実施例１～３及び比較例１～４で得られた吸水シート組成物の性能を上記の方法で測定した。試験液投入時の液漏れの有無、浸透速度、逆戻り量及び拡散長の測定結果を、表１に示す。
Figure JPOXMLDOC01-appb-T000001
　以上の結果より、実施例１～３の吸水シート組成物は、比較例１～３のものと対比して、浸透速度が速く、試験液の粘度にかかわらず、逆戻り量が少なく、液の拡散も良好であることが分かる。また、逆側に疎水性不織布を使用した比較例４の吸水シート組成物は、試験液投入時に、試験液が吸収シートに吸収されず、吸水シートからの液漏れが生じた。そのため、比較評価できなかった。
　本発明の吸水シート組成物は、衛生材料分野、農業分野、建材分野等に使用することができ、なかでも、生理用ナプキンや失禁パッドに好適に使用することができる。
１　　　円筒型シリンダー
２　　　試験液
３　　　重り
４　　　濾紙
Ａ　　　サンプル（吸水シート組成物）
Ｂ　　　液体透過性シート
Ｃ　　　液体不透過性シート
Ｄ　　　拡散長

Claims (5)

  1. 　吸水性樹脂及びホットメルト接着剤が、2枚以上の親水性不織布により挟持された構造を有する吸水シート組成物であって、前記親水性不織布の目付量が30g/m2以上、前記吸水性樹脂の含有量が10～150g/m2、前記ホットメルト接着剤の含有量が、吸水性樹脂の含有量（質量基準）の0.10～1.0倍である、吸水シート組成物。
  2. 　親水性不織布が、レーヨン繊維、ポリオレフィン繊維、ポリエステル繊維及びそれらの混合体からなる群より選ばれた少なくとも１種である、請求項１記載の吸水シート組成物。
  3. 　ホットメルト接着剤が、エチレン－酢酸ビニル共重合体接着剤及びスチレン系エラストマー接着剤より選ばれた少なくとも一種である、請求項１又は２記載の吸水シート組成物。
  4. 　吸水シート組成物の厚みが、乾燥状態で4mm以下である、請求項１～３いずれかに記載の吸水シート組成物。
  5. 　請求項１～４のいずれか１項に記載の吸水シート組成物を、液体透過性シート及び液体不透過性シートで狭持してなる、吸収性物品。
PCT/JP2009/061813 2008-07-11 2009-06-29 吸水シート組成物 WO2010004895A1 (ja)

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