WO2012086766A1 - Procédé permettant de produire un non-tissé, non-tissé, dispositif de production d'un non-tissé, et support permettant de produire un non-tissé - Google Patents

Procédé permettant de produire un non-tissé, non-tissé, dispositif de production d'un non-tissé, et support permettant de produire un non-tissé Download PDF

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Publication number
WO2012086766A1
WO2012086766A1 PCT/JP2011/079840 JP2011079840W WO2012086766A1 WO 2012086766 A1 WO2012086766 A1 WO 2012086766A1 JP 2011079840 W JP2011079840 W JP 2011079840W WO 2012086766 A1 WO2012086766 A1 WO 2012086766A1
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WIPO (PCT)
Prior art keywords
web
hot air
support
nonwoven fabric
fibers
Prior art date
Application number
PCT/JP2011/079840
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English (en)
Japanese (ja)
Inventor
小森　康浩
宏子 川口
猛史 宮村
宮本　孝信
泰樹 内山
坂　渉
正洋 谷口
荘一 藤田
Original Assignee
花王株式会社
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
Priority claimed from JP2010287969A external-priority patent/JP5756627B2/ja
Priority claimed from JP2011267096A external-priority patent/JP5827555B2/ja
Application filed by 花王株式会社 filed Critical 花王株式会社
Priority to CN201180061168.8A priority Critical patent/CN103261503B/zh
Publication of WO2012086766A1 publication Critical patent/WO2012086766A1/fr

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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving

Definitions

  • the present invention relates to a method for producing a nonwoven fabric, a nonwoven fabric obtained from the method, a nonwoven fabric production apparatus, and a nonwoven fabric production support.
  • a fiber web containing thermoplastic fibers is passed between a pair of breathable conveyors having at least one unevenness, and the fiber web is conveyed between the conveyors.
  • This breathable conveyor with unevenness has a plurality of triangular helical wires, insert another triangular helical wire adjacent between the spirals of the triangular helical wire, and the adjacent triangular helical wires
  • a fluid mainly composed of a gas is sprayed on a fiber assembly formed in a substantially sheet shape with the fibers having a degree of freedom, and 1 or 2 of predetermined grooves, openings, or protrusions.
  • a predetermined spraying means sprays a fluid mainly composed of gas from the other surface side of the fiber assembly to move and separate the fibers, so that a groove, an opening, a protrusion, etc. Form.
  • the nonwoven fabric is formed by heat-sealing the thermoplastic fibers contained in the fiber assembly by heat treatment with a predetermined heating device while maintaining the uneven shape (see, for example, Patent Document 2).
  • Patent Document 3 discloses a method of pressing the tip of the fluff protruding from the web surface with a hot roll. In this production method, by adjusting the coefficient of friction of the surface of the nonwoven fabric by changing the temperature, rotation speed, and pressure of the heat roll, a nonwoven fabric with excellent liquid permeability, less irritation to the skin, and increased softness can be obtained.
  • Patent Document 4 discloses a technique for performing a so-called smoothing process in which a top sheet is sandwiched between two rollers and pressure is applied to the surface of the air-through nonwoven fabric so that fluffy fibers are laid down on the surface. Furthermore, a method for cutting and smoothing fuzzed fibers is also disclosed. Further, Patent Document 5 discloses a technique for pressing down a protruding fiber tip so as to lie down by applying pressure through an air-through non-woven fabric between heat rollers and thermally melting it.
  • fuzzed fibers on the surface of the nonwoven fabric are heated, but internal fibers are not heated. In this state, the fibers are not fused even if the fluff is pushed inside. Therefore, fluffing may occur again when external force is applied. Further, when the hot roll temperature is increased, the fusion strength is increased, but the voids are extremely reduced by heating, and the liquid permeability may be impaired. On the other hand, in the method of cutting fuzz, the fuzz is eliminated by the cut, but a fiber having no fused portion is generated, which may cause a problem of short fiber dropping.
  • a support for supporting a shaped fiber web used in a conventional method for producing a nonwoven fabric As a support for supporting a shaped fiber web used in a conventional method for producing a nonwoven fabric, a support having a large number of projections scattered on a continuous smooth surface and a plurality of small through holes in a plane between the projections. It is disclosed.
  • a fiber web is placed on the support, and a high-speed water stream is sprayed onto the fiber web to distribute the fibers on the protrusions and simultaneously provide openings.
  • a perforated nonwoven fabric is produced by entanglement of fibers on the smooth surface. (For example, refer to Patent Document 6).
  • the method for producing a nonwoven fabric disclosed in Patent Document 6 uses water as an energy to move and shape the fibers in the web, so that the portion corresponding to the protrusion of the support is opened. Although a non-woven fabric can be obtained, too much energy is applied, so that a non-woven fabric having a high fiber density, that is, a thin thickness can be obtained.
  • air is blown into the fiber web and pushed into the support used in the method described in Patent Document 1
  • the fibers of the fiber web contact on the back side through the small through holes of the support, and hot air is applied in that state.
  • the fibers are fused and entangled with the small through holes interposed therebetween. For this reason, it becomes difficult to peel off the fiber web from the support, and fluffing or poor appearance can be achieved.
  • each small through hole is as small as 1.0 mm to 2.0 mm and scattered in the flat portion, air hardly converges on the small through hole. For this reason, the air blown to the area
  • JP-A-2-229255 JP 2008-2034 A Japanese Patent Laid-Open No. 2003-235896 JP 2003-265520 A JP 2003-265528 A JP-A 62-69867
  • the fiber web is excellent in formability without disturbing the fibers of the fiber web and preventing fusion and entanglement of the fibers through the holes arranged in the support. It is an object of the present invention to provide a non-woven fabric production support and a method for producing a non-woven fabric using the support.
  • the present invention manufactures a nonwoven fabric that conveys a web containing thermoplastic fibers onto a support having an uneven shape, and blows hot air from the top of the web toward the support to shape the uneven shape on the web.
  • a method A step of temporarily fusing the web fibers with the first hot air so that the uneven shape is maintained, and a state where the second hot air having a temperature higher than the first is blown to maintain the uneven shape.
  • fixing the concavo-convex shape by fusing together the fibers of the web, and solving the above problems by a method of manufacturing a nonwoven fabric by shaping the concavo-convex shape on the web along the web It is.
  • the present invention relates to a method for producing a nonwoven fabric in which a fiber web containing thermoplastic fibers is conveyed on a breathable support having an uneven shape, and hot air is blown to shape the uneven shape on the fiber web.
  • air through refers to a state in which a fiber web is disposed on the surface of a breathable support, a gas is blown from the fiber web side, and the gas passes through the fiber web and the breathable support. The process which blows through to the back surface side of a breathable support body.
  • the present invention solves the above problems by the nonwoven fabric produced by the above-described method for producing a nonwoven fabric of the present invention.
  • the present invention includes a support having a projecting portion and a ventilation portion, and transporting a web containing thermoplastic fibers on the surface having the projecting portion, and the web is placed along the support.
  • a non-woven fabric manufacturing apparatus comprising a nozzle for blowing hot air, and forming a concavo-convex shape on the web, wherein the nozzle has a first nozzle for blowing the first hot air and a temperature higher than that of the first hot air.
  • the two nozzles solve the above problems by a manufacturing apparatus that fixes the uneven shape by fusing the fibers of the web with the uneven shape held by blowing the second hot air.
  • the present invention relates to an air-through type support that conveys a fiber web containing thermoplastic fibers on a surface having an uneven shape, and hot air is blown to the fiber web that is conveyed to the surface of the support.
  • a nozzle for shaping the web, a cooling section for cooling the shaped fiber web to a temperature lower than the melting point of the thermoplastic fiber, and fuzzed fibers and other fibers are fused to the cooled fiber web.
  • the present invention has a plate-like body, a plurality of protrusions arranged on the surface of the plate-like body, and a plurality of holes penetrating from the surface to the back surface facing the surface, the protrusions and the holes Are alternately arranged in a first direction on the surface and in a second direction perpendicular thereto, and the projections are arranged at a predetermined interval, and the projections have a first surface and a second surface facing each other.
  • the present invention is surrounded by a plurality of rod-shaped bodies arranged in parallel, a plurality of protrusions disposed between the rod-shaped bodies, and the protrusions adjacent to each other between the adjacent rod-shaped bodies and in the longitudinal direction of the rod-shaped body.
  • the projections and the holes are alternately arranged in a first direction and a second direction orthogonal thereto, and the projections are arranged at a predetermined interval, and the projections are opposed to each other.
  • a web containing thermoplastic fibers is conveyed onto a support having a plurality of protrusions and a plurality of holes, and hot air is blown to the fiber web along the support.
  • a plurality of holes penetrating the back surface wherein the protrusions and the holes are alternately arranged in a first direction on the surface and in a second direction perpendicular thereto, and the protrusions are arranged at a predetermined interval;
  • a fiber web containing thermoplastic fibers is transported onto a support having a plurality of protrusions and a plurality of holes, and hot air is blown to the fiber web along the support.
  • a method of manufacturing a shaped nonwoven fabric that forms a concavo-convex shape on a web wherein the support is provided with a plurality of rod-like bodies arranged in parallel, a plurality of protrusions arranged between the rod-like bodies, and the adjacent A hole existing in a region surrounded by the protrusions adjacent to each other in the longitudinal direction of the rod-shaped body, and the protrusion and the hole have a first direction and a second direction perpendicular thereto.
  • the projections are alternately arranged at predetermined intervals, and the projections solve the above problems by a method for manufacturing a shaped nonwoven fabric using a first surface and a second surface facing each other. .
  • the nonwoven fabric manufacturing method of the present invention shapes the fibers of the web into the concavo-convex shape of the support having the concavo-convex surface by spraying the first hot air, and performs the temporary fusion while maintaining the state. It is difficult for the fibers caught in the concave portions between the convex portions of the support to return. After the temporary fusing, the fibers are in this state and are fused and fixed by blowing the next second hot air, so that the web fibers are supported by the fact that the web fibers are softened by heat. It becomes easy to follow the shape of the convex part of the body, and the retainability of the uneven shape is improved. As a result, it is possible to obtain a low density and bulky nonwoven fabric with high formability.
  • the temporary fusion means that the fibers of the web are pressed to the concavo-convex portion of the support by blowing hot air as described above and the fibers pressed to the concave portion are hardly returned to each other.
  • the temporarily fused state of the fibers at that time is maintained up to a position where the second hot air is blown by the support. Accordingly, the temporary fusion is different from the fusion by blowing the second hot air in that the uneven shape is not fixed by fusing the fibers by fusing the fibers together.
  • the fibers in the method for producing a nonwoven fabric of the present invention, by cooling a fiber web formed by hot-air air-through blowing, the fibers can be firmly fused and the network structure of the fibers can be strengthened. In that state, the hot air is sufficiently blown and heated to the fluff fibers by air-through, so that the fluff fibers can be softened and brought into contact with other fibers (fibers of the network structure). Since the fibers are fused to each other, the fuzzed fibers can be fixed in a lying state. As a result, fluffing can be reduced, and even when an external force is applied to the surface of the nonwoven fabric, it becomes difficult to fluff, and a nonwoven fabric with a smooth feel can be obtained. Further, since the shaped shape is fixed when fuzzing fibers are fused, excessive fusion does not occur in other fibers, so that a non-woven fabric having a sufficient thickness and voids and excellent liquid permeability can be provided.
  • the nonwoven fabric of this invention is a nonwoven fabric manufactured by said special manufacturing process, it becomes a low density and bulky nonwoven fabric shape
  • the nonwoven fabric manufacturing apparatus of the present invention can temporarily fuse the fibers of the web so that the uneven shape is maintained by blowing the first hot air with the first nozzle. For this reason, it is difficult for the fibers of the web that are trapped between the protrusions of the support to return. In this state, the second hot air is blown by the second nozzle so that the fibers of the web can be fused together, so that the concavo-convex shape can be maintained and fixed. Further, since the hot air is blown, the fibers of the web are softened by heat, and it becomes easy to follow the shape of the protruding portion of the support, and the retention of the uneven shape is improved. As a result, a low-density and bulky nonwoven fabric excellent in formability as described above can be obtained.
  • the nonwoven fabric production apparatus of the present invention is a suitable apparatus for carrying out the above-described nonwoven fabric production method.
  • a cooling part that cools the shaped fiber web by blowing hot air with the air-through method By arranging a cooling part that cools the shaped fiber web by blowing hot air with the air-through method, the intersection of the fused fibers is firmly fixed, and the network structure of the fibers is solid Since it can do, the uneven
  • any of the nonwoven fabric production supports of the present invention and the method for producing a shaped nonwoven fabric using the support comprises disturbing the fibers of the fiber web by the blown air in the shaping treatment for forming irregularities on the fiber web. And there is no fusion or entanglement between the fibers through the holes in the support. Therefore, the three-dimensional uneven nonwoven fabric is excellent in formability of the fiber web and can be formed into a nonwoven fabric having a small weight per unit area (density) and an effective thickness (less liquid residue when used in an absorbent body). Enable production.
  • first embodiment of the nonwoven fabric production method and production apparatus according to the present invention, refer to the schematic configuration diagram of the nonwoven fabric production apparatus shown in FIG. 1 and the partially enlarged view of the support shown in FIG. However, it will be described below.
  • the nonwoven fabric manufacturing apparatus 1 preferably used for carrying out the nonwoven fabric manufacturing method according to the present invention will be described.
  • the nonwoven fabric manufacturing apparatus 1 has a support 10 that transports a web 60 (hereinafter also referred to as a fiber web) containing thermoplastic fibers.
  • the web 60 is supplied to the surface of the support 10 by a feed conveyor as the feed unit 21, and the shaped web 60 is fed from the support 10 by a guide roller as the guide unit 22 in a predetermined direction.
  • the support 10 has, for example, a drum shape, and has a plurality of protruding portions 10T that are concave and convex portions and a plurality of ventilation portions 10H that are concave portions on the surface thereof.
  • the protruding portions 10T and the ventilation portions 10H are alternately arranged in the longitudinal and lateral directions of the support 10.
  • the support body 10 is rotatable around the rotation shaft 10C.
  • a driving device (not shown) is connected to the rotating shaft 10C.
  • the protruding portion 10T has a shape that tapers toward the tip, and the tip has a round shape, for example, a plate shape, a spindle shape, or the like. The height varies depending on the use, standard, etc.
  • the protrusion pitch is 6 mm to 15 mm in the MD direction, and 4 mm to 8 mm in the CD direction. It is as follows.
  • the MD direction is the feeding direction of the web 60
  • the CD direction is a direction perpendicular to the MD direction on the surface of the support 10. If the height of the protrusion 10T is too low, sufficient unevenness cannot be formed on the web 60. If the height is too high, the protrusion 10T may penetrate the web 60 when hot air is blown. There is. Therefore, the protruding portion 10T is appropriately set within the above range.
  • it is formed at a height of 3 mm or more and 10 mm or less, is arranged in the MD direction at 6 mm or more and 10 mm or less, and is arranged in the CD direction at 4 mm or more and 6 mm or less.
  • the ventilation portion 10H is composed of a plurality of openings formed in the support 10, and the opening ratio is set to 20% or more and 45% or less with respect to the surface area of the support 10. If the opening ratio is less than 20%, it becomes difficult to form a sufficient uneven shape on the web 60. If the opening ratio exceeds 45%, the web 60 moves below the support 10 when hot air is blown. It becomes difficult to peel off from the support 10, and there is a possibility that the shaped shape is deteriorated and fluff is likely to be formed. Therefore, the aperture ratio is set.
  • the aperture ratio is preferably 10% to 50%, more preferably 15% to 40%, still more preferably 20% to 35%, and particularly preferably 30% to 35%.
  • the support 10 is rotated to convey the web 60 so that the web 60 is hooked by the protruding portion 10T on the surface side having the protruding portion 10T.
  • the first nozzle 11 that blows the first hot air W ⁇ b> 1 and the second hot air W ⁇ b> 2 that blows the second hot air W ⁇ b> 2 in order along the supply direction of the web 60 on the outside where the protruding portion 10 ⁇ / b> T of the support 10 is formed.
  • a nozzle 12 is provided.
  • the first nozzle 11 includes a heater 13, and the first hot air W1 heated by the heater 13 is passed through a ventilating conveyor 23 having air permeability to the surface of the support 10 on which the protruding portion 10T is disposed. For example, spray almost vertically.
  • the spray hole of the first nozzle 11 preferably has a length in the MD direction of 1 mm or more and 20 mm or less, and the length in the CD direction is a web width or more, or a width for shaping.
  • the spray holes have a single or multi-row slit shape, and a single or multi-row round hole, long hole, and square hole arranged in a staggered manner or in parallel.
  • the first hot air W1 has a slit shape in a row of 2 mm or more and 20 mm or less.
  • the first hot air W1 is blown at a uniform wind speed in the width direction of the surface of the web 60.
  • air, nitrogen or water vapor heated to a predetermined temperature by the heater 13 can be used.
  • air that does not cost is used.
  • the first hot air W ⁇ b> 1 blown from the first nozzle 11 is controlled by the heater 13 to a temperature at which the fibers of the web 60 are temporarily fused so that the uneven shape is maintained.
  • the first hot air W1 is 60 ° C. higher than the melting point of the low melting point component of the web 60 fiber.
  • the hot air is controlled to a temperature not lower than the low temperature and not higher than 15 ° C. higher than the melting point of the low melting point component.
  • the temperature is controlled to be not less than 50 ° C lower than the melting point of the low melting point component and not more than 10 ° C higher than the melting point of the low melting point component.
  • a preferable temperature range is from 82 ° C. to 142 ° C., more preferably from 132 ° C. to 142 ° C.
  • the temperature of the first hot air W1 is less than 60 ° C. lower than the melting point of the low melting point component of the fiber of the web 60, the fiber returns and the formability deteriorates.
  • the temperature exceeds 15 ° C. higher than the melting point of the low melting point component of the fiber of the web 60, the fibers are fused at once, and the formability is inferior due to a decrease in the degree of freedom.
  • the wind speed of the first hot air W1 is adjusted as appropriate, but is preferably controlled to a wind speed of 10 m / sec or more and 120 m / sec or less. If the wind speed of the first hot air W1 blown from the first nozzle 11 is too slow, the fibers do not sufficiently follow the support and the fibers are weakly fused so that they cannot be shaped, resulting in a bulky uneven shape. On the other hand, if the wind speed is too high, the fibers of the web 60 are sorted by the protruding portions 10T, and the fibers do not have a concavo-convex shape along the shape of the support or become a perforated nonwoven fabric. Therefore, the wind speed of the first hot air W1 is preferably in the above range. More preferably, it is 20 m / sec or more and 80 m / sec or less, and particularly preferably 40 m / sec or more and 60 m / sec or less.
  • the aeration conveyor 23 feeds the web 60 to the feed side along the surface of the support 10 while sandwiching the web 60 with the support 10.
  • a belt 24 having air permeability, a plurality of rollers 25 that support the belt 24, and a drive device (not shown) that drives the belt 24 via the rollers 25 are provided.
  • the plurality of rollers 25 at least two rollers 25 ⁇ / b> A and 25 ⁇ / b> B are arranged on the surface of the support 10 so that the belt 24 runs along the web 60.
  • the ventilation conveyor 23 can prevent the web 60 from being disturbed and scattered by the first hot air W ⁇ b> 1 of the first nozzle 11.
  • the second nozzle 12 includes a heater 14 and blows the second hot air W2 heated by the heater 14 to the surface of the support 10 on which the protruding portion 10T is formed, for example, substantially perpendicularly. It is desirable to use a punching metal that is regularly opened in the width direction and the flow direction as the blowing hole of the second nozzle 12.
  • the open area ratio is preferably 10% or more and 40% or less, and more preferably 20% or more and 30% or less.
  • the second hot air W2 is blown at a uniform wind speed in the width direction of the surface of the web 60.
  • air, nitrogen or water vapor heated by the heater 14 can be used.
  • air that does not cost is used.
  • the second hot air W2 is controlled by the heater 14 to a temperature at which the fibers 60 of the web 60 are fused together and the uneven shape is fixed while the uneven shape of the web 60 formed by the first hot air W1 is maintained. ing.
  • the second hot air W2 is higher than the melting point of the low melting point component of the web 60 fiber. It is controlled to be hot air at a temperature below the melting point of the high melting point component of 60 fibers, preferably 40 ° C. or higher than the melting point of the low melting point component.
  • the melting point of the low melting point component is controlled to a temperature not higher than 20 ° C. below this melting point, and the particularly preferable temperature is not less than the melting point of the low melting point component and not higher than 15 ° C. below this melting point.
  • a more preferable temperature range is from 132 ° C. to 152 ° C., particularly preferably from 132 ° C. to 147 ° C. Note that if the temperature of the second hot air W2 is lower than the melting point of the low melting point component of the fibers of the web 60, the uneven shape retainability is insufficient. On the other hand, if the temperature is higher than 180 ° C., the texture becomes worse.
  • the wind speed of the second hot air W2 blown from the second nozzle 12 is appropriately determined in consideration of its purpose, but is preferably controlled to a wind speed of 1 m / sec or more and 10 m / sec or less. If the wind speed of the second hot air W2 blown from the second nozzle 12 is too slow, heat cannot be transferred to the fibers, the fibers are not fused, and the uneven shape is insufficiently fixed. On the other hand, if the wind speed is too high, the fiber will be too hot and the texture will tend to be poor. Therefore, the wind speed of the second hot air W2 is preferably in the above range. More preferably, it is 1 m / sec or more and 8 m / sec or less, and particularly preferably 2 m / sec or more and 4 m / sec or less.
  • a suction unit 15 that sucks the first hot air W ⁇ b> 1 blown from the first nozzle 11 through the aeration conveyor 23, the web 60, and the support 10 is arranged.
  • An exhaust device 17 for exhausting the sucked first hot air W1 is connected to the suction portion 15.
  • a suction unit 16 that sucks the second hot air W ⁇ b> 2 blown from the second nozzle 12 through the web 60 and the support 10 is disposed.
  • the suction unit 16 is connected to an exhaust device 18 that exhausts the sucked second hot air W2.
  • any suction part can have a structure in which the length in the CD direction can be adjusted as appropriate.
  • suction portions 15 and 16 By arranging such suction portions 15 and 16, it is possible to prevent the web from being disturbed by the rebound of the air to be blown, and to stably shape the web into a desired shape. Further, it is possible to prevent the temperature around the drum from becoming too high and prevent the web 60 in contact with the drum from being excessively fused and hardened. Furthermore, it becomes easy to hold the web 60 on the support body 10, and the conveyance becomes easy. In consideration of the stabilization of hot air temperature and the running cost of utilities, it is desirable to circulate and use hot air.
  • the first hot air W1 can be blown by the first nozzle 11 to temporarily fuse the fibers of the web 60 to a state in which the uneven shape is maintained. For this reason, the fibers of the web 60 that are trapped between the protruding portions 10T of the support 10 are difficult to return. In this state, since the second hot air W2 is blown by the second nozzle 12, the fibers of the web 60 can be fused and fixed in a state where the uneven shape is maintained.
  • the fibers of the web 60 are softened by heat, so that it becomes easy to follow the surface shape of the protruding portion 10T of the support 10 and the unevenness. Good shape retention.
  • the web 60 can be more easily brought along the surface of the protruding portion 10T. As a result, a low density and bulky nonwoven fabric with good formability can be obtained.
  • the web 60 is deformed and weakly fixed between fibers by the first nozzle 11 so as to follow the uneven shape of the support 10, and is thermally fused by the second nozzle 12 to be a nonwoven fabric.
  • corrugated shape of the support body 10 should just be deform
  • the web 60 is too along the uneven shape of the support, not only the above-mentioned influence of the deformation of the shaped shape and the formation of fuzz at the time of separation from the support 10 but also the substantial thickness of the nonwoven fabric decreases, and the fiber melts.
  • the flexibility is impaired from the nonwoven fabric due to an increase in landing points, excessive fiber fusion due to contact with the support, and the like.
  • the tip of the projecting portion 10T of the support 10 having the plurality of projecting portions 10T and the plurality of ventilation portions 10H and the web 60 are in direct contact with each other from the viewpoint of improving the shapeability.
  • the web 60 is preferably spaced from the support 10 to form a gap from the viewpoint of flexibility of the nonwoven fabric and formation of a low density structure.
  • the gap is formed on the vent portion 10H side of the protruding portion 10T, the second hot air W2 is easily penetrated in the thickness direction of the web 60, so that the hot air blowing surface side and the support 10 side are provided. Differences in the fused state of the fibers are unlikely to occur, and the bulky structure is easily recovered against deformation such as compression and tension, resulting in a non-woven fabric that is less prone to fluff. From the same viewpoint, it is more preferable that a gap is formed between the ventilation portion 10H and the web 60.
  • the support 10 when the web 60 is in direct contact with the support 10, the support 10 is repeatedly warmed by each hot air, so that the fiber is excessively fused on the support 60 side surface of the web 60 and the surface becomes hard. As a result, the texture deteriorates, but the influence of the heat of the support 10 can be reduced by separating the web 60 and the support 10 by the gap.
  • the apparatus configuration can be reduced in size and the area occupied by the apparatus can be reduced.
  • the support body 10 is comprised in the drum shape, the fiber of the web 60 shaped rather than the conventional conveyor type support body becomes easy to peel from the protruding part 10T.
  • the nonwoven fabric production apparatus 2 is the one in which the aeration conveyor 23 is continuously arranged from the blowout side of the first nozzle 11 to the blowout side of the second nozzle 12 in the nonwoven fabric production apparatus 1 described above.
  • the web 60 is conveyed to the feed side along the surface of the support 10 while sandwiching the web 60 with the support 10.
  • a belt 24 having air permeability, a plurality of rollers 25 that support the belt 24, and a drive device (not shown) that drives the belt 24 via the rollers 25 are provided.
  • At least two rollers 25 ⁇ / b> A and 25 ⁇ / b> B of the plurality of rollers 25 are arranged such that the belt 24 passes along the web 60 on the surface of the support 10 from the blowing side of the first nozzle 11 to the blowing side of the second nozzle 12. It is arranged in.
  • the non-woven fabric manufacturing apparatus 2 includes a support 10, a rotating shaft 10 ⁇ / b> C, a protruding portion 10 ⁇ / b> T (see FIG. 2), a ventilation portion 10 ⁇ / b> H (see FIG. 2), and a first configuration other than the aeration conveyor 23.
  • 1 nozzle 11, 2nd nozzle 12, heater 13, heater 14, suction unit 15, suction unit 16, exhaust device 17, exhaust device 18, feeding unit 21, guide unit 22, etc. are the same as in the nonwoven fabric production apparatus 1. It has the composition of.
  • the nonwoven fabric manufacturing apparatus 2 of the second embodiment described above has the same operational effects as the nonwoven fabric manufacturing apparatus 1 described above, and the web 60 is disturbed by the first hot air W1 and the second hot air W2 by the aeration conveyor 23. , Can prevent scattering. Therefore, the texture and texture of the produced nonwoven fabric are improved, and fuzzing can be suppressed.
  • the nonwoven fabric manufacturing apparatus 3 sends the cooling nozzle 19 that cools the web 60 heated by the second hot air W ⁇ b> 2 from the support 10 in the nonwoven fabric manufacturing apparatus 1. It is for the side to be done.
  • the cooling nozzle 19 blows the cooling gas Wc toward the web 60.
  • air, nitrogen gas, water vapor, or the like can be used as the cooling gas Wc.
  • air is used.
  • the web 60 is preferably cooled to 100 ° C. or less, more preferably 90 ° C. or less by the cooling gas Wc. If the temperature of the web 60 after cooling is too high, the peelability of the web 60 from the support 10 is deteriorated and the formability is inferior.
  • the nonwoven fabric manufacturing apparatus 3 includes the support 10, the rotating shaft 10 ⁇ / b> C, the protruding portion 10 ⁇ / b> T, the ventilation portion 10 ⁇ / b> H, the first nozzle 11, the second nozzle 12, the heater 13, and the heater 14, which are components other than the cooling nozzle 19.
  • the suction unit 15, the suction unit 16, the exhaust device 17, the exhaust device 18, the feeding unit 21, the guide unit 22, and the like have the same configuration as that of the nonwoven fabric manufacturing apparatus 1.
  • the nonwoven fabric manufacturing apparatus 3 of the above-described third embodiment has the same effects as the nonwoven fabric manufacturing apparatus 1 described above, and the web 60 heated by the second hot air W2 blown by the cooling nozzle 19 is heated. Since it can cool, the shaped uneven
  • the example which installed the cooling nozzle 19 in the nonwoven fabric manufacturing apparatus 1 of 1st Embodiment was demonstrated in the above-mentioned description, the above-mentioned cooling nozzle 19 is similarly installed also in the nonwoven fabric manufacturing apparatus 2 of 2nd Embodiment. It comes out. Also in this case, the above-described effects can be obtained.
  • the cooling by the cooling nozzle 19 is preferably performed from the same surface as the first nozzle 11 and the second nozzle 12 for the purpose of cooling the web 60.
  • the support 10 is formed in a drum shape, so that the area occupied by the apparatus can be reduced.
  • the suction part 15 and the suction part 16 are arranged, the first and second hot air W1 and W2 that have passed through the web 60 and the ventilation holes of the support 10 can be sucked. No. 2 hot air W1 and W2 are not diffused to other regions, and temperature rise of the atmosphere around the apparatus can be prevented. Therefore, it is possible to ensure the safety of work by an operator or the like working around the apparatus.
  • the fiber material that can be used for the fibers of the web 60 is not particularly limited. Specific examples include the following fibers. There are polyolefin fibers such as polyethylene (PE) fibers and polypropylene (PP) fibers; fibers using a thermoplastic resin such as polyethylene terephthalate (PET) and polyamide alone. In addition, there are composite fibers having a structure such as a core-sheath type and a side-by-side type. In the present invention, it is preferable to use a composite fiber.
  • PE polyethylene
  • PP polypropylene
  • PET polyethylene terephthalate
  • composite fibers having a structure such as a core-sheath type and a side-by-side type. In the present invention, it is preferable to use a composite fiber.
  • the composite fiber includes a core-sheath fiber in which a high melting point component is a core part and a low melting point component is a sheath part, and a side-by-side fiber in which a high melting point component and a low melting point component are juxtaposed.
  • Preferred examples thereof include fibers having a core-sheath structure in which the sheath component (low-melting-point component) is polyethylene or low-melting-point polypropylene
  • typical examples of the fibers having the core / sheath structure include PET (core) / PE
  • Examples include fibers having a core-sheath structure such as a sheath), PP (core) / PE (sheath), polylactic acid (core) / PE (sheath), and PP (core) / low melting point PP (sheath).
  • the constituent fibers preferably include polyolefin fibers such as polyethylene fibers and polypropylene fibers, polyethylene composite fibers, and polypropylene composite fibers.
  • the composite composition of the polyethylene composite fiber is polyethylene terephthalate / polyethylene
  • the composite composition of the polypropylene composite fiber is preferably polyethylene terephthalate / low melting point polypropylene, and more specifically, PET (core). / PE (sheath), PET (core) / low melting point PP (sheath).
  • PET core
  • PE sheath
  • PET core
  • PP low melting point PP
  • the basis weight of the web 60 is not particularly limited, but is preferably 10 g / m 2 or more and 50 g / m 2 or less, and more preferably 20 g / m 2 or more and 40 g / m 2 or less.
  • the web 60 fed to the surface of the support 10 is fed so as to be further sandwiched between the aeration conveyor 23 and the support 10.
  • the first hot air W ⁇ b> 1 is blown from the first nozzle 11 and blown to the web 60 through the aeration conveyor 23. At this time, the first hot air W ⁇ b> 1 is blown from the direction perpendicular to the surface of the support 10.
  • the number of blowouts of the first nozzle 11 may be a plurality of locations along the feeding direction of the web 60.
  • the web 60 is shaped into a concavo-convex shape along the shape of the protruding portion 10T of the support 10.
  • the fusion of the fibers of the web 60 may be temporary fusion to such an extent that the uneven shape can be maintained.
  • the temperature of the hot air varies depending on the type of fiber, the processing speed, the wind speed of the hot air, etc., and thus cannot be uniquely determined.
  • the temperature of the first hot air W1 is the low melting point component of the fibers of the web 60.
  • the temperature is preferably 60 ° C. lower than the melting point, and is preferably controlled to a temperature not higher than 15 ° C. below the melting point. More preferably, the temperature is controlled to be 80 ° C. or higher and 140 ° C. or lower, and a more preferable temperature is 130 ° C. or higher and 140 ° C. or lower.
  • the fiber If the temperature of the first hot air W1 is too lower than the temperature 60 ° C. lower than the melting point of the low melting point component of the fiber of the web 60, the fiber is returned and the formability is deteriorated. On the other hand, if the temperature is higher than the temperature of 15 ° C. higher than the melting point of the low melting point component of the fiber of the web 60, the fibers are fused at once, and the formability is impaired due to a decrease in the degree of freedom.
  • the web 60 is conveyed to the spray position of the second hot air W2 of the second nozzle 12 along with the rotation of the support 10. Then, the second hot air W ⁇ b> 2 is blown by the second nozzle 12, and the fibers of the web 60 are fused together in a state where the uneven shape of the web 60 is maintained, thereby fixing the uneven shape. At this time, the second hot air W ⁇ b> 2 is blown from the direction perpendicular to the surface of the support 10.
  • the number of blowouts of the second nozzle 12 is preferably set at a plurality of locations along the feeding direction of the web 60.
  • the temperature of the second hot air W2 is controlled to be equal to or higher than the melting point of the low melting point component of the fiber of the web 60 and lower than the melting point of the high melting point component of the fiber of the web 60.
  • the temperature is preferably 135 ° C. or higher and 155 ° C. or lower, and more preferably 135 ° C. or higher and 145 ° C. or lower.
  • the shaped web 60 is sent out from the support 10 in a predetermined direction by a guide roller as the guide portion 22.
  • the first hot air W1 is blown to temporarily fuse the fibers of the web 60 so that the uneven shape is maintained.
  • the intervening fibers are less likely to return.
  • the fibers of the web 60 are fused together while the concavo-convex shape is maintained by blowing the second hot air W2, so that the concavo-convex shape can be fixed.
  • the fiber of the web 60 is softened by the heat of the first hot air W1, it becomes easy to follow the shape of the protruding portion 10T of the support 10 and the retention of the uneven shape is improved. As a result, a low density and bulky nonwoven fabric with good formability can be obtained.
  • the method for manufacturing the nonwoven fabric of the second embodiment is different from the method for manufacturing the nonwoven fabric of the first embodiment described above in that the feeding method of the aeration conveyor 23 is different from the blowing side of the first nozzle 11.
  • the web 60 is continuously conveyed to the feed side while sandwiching the web 60 between the support 10 and the aeration conveyor 23 over the blowing side of the second nozzle 12.
  • the first hot air W1 is temporarily unevenly bonded to the fibers of the web 60 by the first hot air W1 blown to the web 60 through the ventilating conveyor 23, so that the uneven shape along the shape of the protruding portion 10T of the support 10 is obtained.
  • the step of shaping the web 60 is the same as described above.
  • the second hot air W2 is blown onto the web 60 through the aeration conveyor 23, and the fibers of the web 60 are fused to fix the uneven shape.
  • the non-woven fabric manufacturing method of the second embodiment described above has the same effects as the non-woven fabric manufacturing method of the first embodiment described above, and the web 60 is disturbed or scattered by the second hot air W2 by the aeration conveyor 23. Can be prevented. Therefore, the texture and texture of the manufactured nonwoven fabric become better, and fuzzing can be suppressed. Thereby, since the fibers adhering to the aeration conveyor 23 are reduced, the durability of the aeration conveyor 23 is improved.
  • the nonwoven fabric manufacturing method of the third embodiment is the same as the nonwoven fabric manufacturing method of the first embodiment described above, in which the cooling gas Wc is sprayed onto the web 60 heated by the second hot air W2. And a cooling method. Therefore, the first hot air W1 before that is blown onto the web 60, the fibers of the web 60 are temporarily fused together, and the web 60 is shaped into an uneven shape along the shape of the protruding portion 10T of the support 10. The step of blowing the second hot air W2 to the web 60 and fusing the fibers together to fix the uneven shape is the same as described above.
  • the non-woven fabric manufacturing method of the third embodiment described above has the same effects as the non-woven fabric manufacturing method of the first embodiment described above, and the web 60 heated by blowing the second hot air W2 with a cooling gas. Can be cooled, so that the formed uneven shape is easily fixed. Cooling the heated web 60 in the manufacturing method of the third embodiment can also be applied to the manufacturing method of the second embodiment described above, and the same effects as described above can be obtained.
  • the first hot air W1 and the second hot air W2 are exhausted to the outside, so that they do not diffuse around the apparatus.
  • the temperature rise in the atmosphere around the apparatus can be prevented. Therefore, it is possible to ensure the safety of work by an operator or the like working around the apparatus.
  • Example 1 was manufactured under the following conditions by the manufacturing method of the first embodiment described above. That is, for the fiber of the web 60, a composite fiber having a core-sheath structure in which the core part is polyethylene terephthalate (melting point is 255 ° C.) and the sheath part is polyethylene (melting point is 132 ° C.).
  • the web 60 is transported by the support 10 and the aeration conveyor 23 disposed only on the blowing side of the first nozzle unit 11, and the first hot air W ⁇ b> 1 and the second hot air W ⁇ b> 2 are blown on the surface of the support 10. It was formed into an uneven shape.
  • the first hot air W1 was set to a temperature of 80 ° C. and the wind speed was set to 25 m / sec
  • the second hot air W2 was set to a temperature of 145 ° C. and a wind speed of 5.0 m / sec.
  • the processing speed for processing the irregular shape was 50 m / min.
  • the web 60 has a basis weight of 27 g / m 2 and a thickness of 3.1 mm. Nonwoven fabric specimens were produced under the above conditions.
  • Example 2 manufactures a nonwoven fabric specimen under the same conditions as in Example 1 except that the wind speed of the first hot air W1 is set to 50 m / sec and the thickness of the web 60 is 3.2 mm. did.
  • Example 3 a non-woven fabric specimen is manufactured under the same conditions as in Example 1 except that the wind speed of the first hot air W1 is set to 65 m / sec and the thickness of the web 60 is 3.4 mm. did.
  • the temperature of the first hot air W1 was set to 130 ° C., and a nonwoven fabric specimen was manufactured under the same conditions as in Example 1 except that the thickness of the web 60 was 3.2 mm. .
  • Example 5 the temperature of the first hot air W1 is set to 130 ° C., the wind speed is set to 50 m / sec, the temperature of the second hot air W2 is set to 135 ° C., and the thickness of the web 60 is 3.3 mm.
  • a non-woven fabric specimen was manufactured under the same conditions as in Example 1 described above.
  • Example 6 the temperature of the first hot air W1 is set to 130 ° C., the wind speed is set to 50 m / sec, and the thickness of the web 60 is 3.3 mm.
  • the test body was manufactured.
  • Example 7 the temperature of the first hot air W1 is set to 130 ° C., the wind speed is set to 50 m / sec, the temperature of the second hot air W2 is set to 155 ° C., and the thickness of the web 60 is 3.3 mm.
  • a non-woven fabric specimen was manufactured under the same conditions as in Example 1 described above.
  • the temperature of the first hot air W1 is set to 130 ° C., the wind speed is set to 65 m / sec, and the thickness of the web 60 is 3.5 mm.
  • the test body was manufactured.
  • Example 9 the temperature of the first hot air W1 was set to 140 ° C., and a nonwoven fabric specimen was manufactured under the same conditions as in Example 1 except that the thickness of the web 60 was 3.2 mm. .
  • Example 10 the temperature of the first hot air W1 was set to 140 ° C., the wind speed was set to 50 m / sec, and the thickness of the web 60 was 3.2 mm.
  • the test body was manufactured.
  • Example 11 the temperature of the first hot air W1 was set to 140 ° C., the wind speed was set to 65 m / sec, and the thickness of the web 60 was 3.4 mm.
  • the test body was manufactured.
  • Example 12 the temperature of the first hot air W1 is set to 140 ° C., the wind speed is set to 50 m / sec, and the thickness of the web 60 is 3.3 mm.
  • the nonwoven fabric is subjected to the same conditions as in Example 1 described above. The test body was manufactured.
  • Example 13 the temperature of the first hot air W1 was set to 140 ° C. and the wind speed was set to 65 m / sec by the manufacturing method of the second embodiment described above, and the web 60 together with the support 10 was blown out from the first nozzle 11. To the blowout side of the second nozzle 12, and a non-woven fabric specimen under the same conditions as in Example 1 except that the thickness of the web 60 is 3.4 mm. Manufactured.
  • Comparative Example 1 a nonwoven fabric specimen was manufactured under the same conditions as in Example 1 except that the temperature of the first hot air W1 was set to 36 ° C. and the thickness of the web 60 was 3.9 mm.
  • Comparative Example 2 is a nonwoven fabric under the same conditions as in Example 1 except that the temperature of the first hot air W1 is set to 36 ° C., the wind speed is set to 50 m / sec, and the thickness of the web 60 is 4.0 mm.
  • the test body was manufactured.
  • Comparative Example 3 the temperature of the first hot air W1 is set to 36 ° C., the wind speed is set to 65 m / sec, and the thickness of the web 60 is 3.7 mm.
  • the test body was manufactured.
  • the temperature of the first hot air W1 is set to 60 ° C., the wind speed is set to 50 m / sec, and the thickness of the web 60 is 3.6 mm.
  • the test body was manufactured.
  • the temperature of the first hot air W1 is set to 180 ° C., the wind speed is set to 50 m / sec, and the thickness of the web 60 is 2.1 mm.
  • the test body was manufactured.
  • the temperature of the first hot air W1 is set to 130 ° C.
  • the wind speed is set to 50 m / sec
  • the temperature of the second hot air W2 is set to 120 ° C.
  • the thickness of the web 60 is 3.2 mm.
  • a non-woven fabric specimen was manufactured under the same conditions as in Example 1 described above.
  • the temperature of the first hot air W1 is set to 130 ° C.
  • the wind speed is set to 50 m / sec
  • the second hot air W2 is not applied
  • the thickness of the web 60 is 3.2 mm.
  • Nonwoven fabric specimens were manufactured under the same conditions as in Example 1.
  • the temperature of the first hot air W1 is set to 180 ° C.
  • the wind speed is set to 50 m / sec
  • the second hot air W2 is not applied
  • the thickness of the web 60 is 2.2 mm.
  • Nonwoven fabric specimens were manufactured under the same conditions as in Example 1.
  • Comparative Example 9 the temperature of the first hot air W1 is set to 130 ° C., the wind speed is set to 50 m / sec, the temperature of the second hot air W2 is set to 120 ° C., and the thickness of the web 60 is not used.
  • a non-woven fabric specimen was produced under the same conditions as in Example 1 except that is 3.3 mm.
  • the temperature of the first hot air W1 is set to 140 ° C.
  • the wind speed is set to 50 m / sec
  • the temperature of the second hot air W2 is set to 190 ° C.
  • the thickness of the web 60 is 3.3 mm.
  • a non-woven fabric specimen was manufactured under the same conditions as in Example 1 described above.
  • the temperature of the first hot air W1 is measured directly under the blowout port of the first nozzle 11 by Anemo Master (manufactured by Nippon Kanomax Co., Ltd .: trade name), and the wind speed is directly under the blowout port of the first nozzle 11 through a Pitot tube.
  • the static pressure was pulled from the total pressure, the dynamic pressure was measured, and it was calculated from the flow velocity calculation formula using a Pitot tube.
  • the temperature and wind speed of the second hot air W2 were measured by the anemo master immediately below the outlet of the second nozzle 12.
  • the method for measuring the thickness of the nonwoven fabric was measured using a thickness measuring instrument with a load of 0.005 kPa applied to the nonwoven fabric. A laser displacement meter manufactured by OMRON Corporation was used as the thickness measuring instrument. The thickness was measured at 10 points, and the average value was calculated as the thickness.
  • the following methods evaluated the shaped shape, the state of wet back, the texture of the nonwoven fabric, and the texture of the nonwoven fabric. The results are shown in Tables 1 and 2.
  • the shaped shape is determined as the shape A when only the lower part of the web is shaped, and the shaped shape is good as shown in FIG. 5 (2).
  • Wet back was determined by the liquid return state. If there is no liquid return, it is indicated by ⁇ because the wetback is excellent. If there is almost no liquid return, it is indicated by ⁇ . Judgment was made.
  • the texture of the nonwoven fabric was judged by touch and suppleness for five monitors. The result was scored as 4 for a very soft and supple material, 3 for a soft and supple material, 2 for a soft, supple material, and 1 for a soft, supple material. Evaluated the average value of five people as follows. Evaluation result ⁇ : Judgment average 3.5 or more, 4 or less ⁇ : Judgment average 2.5 or more, less than 3.5 ⁇ : Judgment average 1.5 or more, less than 2.5 ⁇ : Judgment average 1 or more, less than 1.5 .
  • the texture was determined by homogeneity when the nonwoven fabric was visually observed. Those that look very homogeneous are indicated by ⁇ , those that appear almost homogeneous are indicated by ⁇ , and those that appear to be homogeneous but generally uniform are indicated by ⁇ . What is visible is indicated by a cross.
  • the fiber adhesion to the aeration conveyor was confirmed by visual observation of the adhesion of the fibers to the aeration conveyor after 30 minutes of operation under the processing conditions of each example and comparative example.
  • the case where there is no adhesion is indicated by ⁇
  • the case where some fibers are attached but there is no problem in continuous operation is indicated by ⁇
  • the case where there is a possibility of problems in continuous operation due to slightly more fiber attachment is indicated by x.
  • the temperature of the first hot air W1 is 60 ° C. lower than the melting point 132 ° C. of the low melting point component of the fiber of the web 60.
  • the temperature is 72 ° C. or higher, 147 ° C. or lower which is 15 ° C. higher than the melting point 132 ° C.
  • the temperature of the second hot air W2 is the melting point 132 ° C. or higher of the low melting point component of the web 60 fibers.
  • the high melting point component was shaped at a melting point of less than 255 ° C., the shaped shape was good, and the shape B was judged.
  • the thickness under pressure was 0.6 mm or more, the wet back was good, and the texture and texture were almost good.
  • the specimens of Example 3, Examples 6 to 8, and Examples 10 to 13 had a thickness under pressure of 0.7 mm or more and particularly good wetback. Further, the specimen of Example 5 was particularly excellent in texture. Further, in Examples 1 to 13 (except Example 12 in which no aeration conveyor is used), there is almost no fiber adhesion to the aeration conveyor 23, and in particular, from the blowing side of the first nozzle 11 to the blowing side of the second nozzle 12.
  • Example 13 in which the aeration conveyor 23 was continuously arranged over the period, it was confirmed that there was no fiber adhesion to the aeration conveyor 23 and there was no problem in continuous operation.
  • the specimens of Comparative Examples 1 to 10 in which the temperature of the first hot air W1 did not fall within the above temperature range were insufficiently shaped, and the shaped shape was judged as A.
  • the specimens of Comparative Examples 1 to 10 had poor wetback except for the specimens of Comparative Examples 5, 8, and 10.
  • the test bodies of Comparative Examples 5 and 8 had good wetback but poor texture.
  • the test body of Comparative Example 7 shaped only by the first hot air W1 had poor wetback, and the test body of Comparative Example 8 had poor texture.
  • all of Comparative Examples 1 to 10 except for Comparative Example 9 which does not use the aeration conveyor) had almost no fiber adhesion to the aeration conveyor 23 and there was no problem in continuous operation.
  • the shaped shape and the thickness under pressure are related to wetback. That is, the specimen determined as shape A had a thickness under pressure of 0.4 mm or less and a poor wetback.
  • the specimen determined as shape B had a thickness under pressure of 0.6 mm or more, and had good wetback. Therefore, it was found that the wetback is good when the shape is B and the thickness under pressure is 0.6 mm or more.
  • the shaping that blows the hot air of 2 degrees composed of the first hot air W1 and the second hot air W2 in the predetermined temperature range is excellent in the shaping shape, the wet back is good, the texture and the texture are almost the same. It has been found that a good nonwoven fabric can be obtained with almost no fiber adhesion to the breathable conveyor. Therefore, in the nonwoven fabric manufacturing method, the nonwoven fabric, and the nonwoven fabric manufacturing apparatus of the present invention, a low-density and bulky nonwoven fabric with good formability can be obtained.
  • the nonwoven fabric manufacturing apparatus 4 includes a support 30 that conveys a fiber web 60 containing thermoplastic fibers.
  • the fiber web 60 is supplied to the surface of the support 30, and is subjected to a shaping process and a process for reducing fluff by an air-through method while being placed on the surface of the support 30, and is sent out in a predetermined direction.
  • the support 30 is composed of a conveyor, and the conveyor belt 30B is supported and rotated by rotation support rollers 30R (30Ra, 30Rb, 30Rc, 30Rd) arranged at four locations on the upper and lower ends. It is configured.
  • the rotation support rollers 30R are not limited to four locations, and may be arranged so that the conveyor belt 30B rotates smoothly.
  • the conveyor belt 30B has a concavo-convex shape composed of a plurality of protruding portions 30T on its surface, and further has a plurality of ventilation portions (not shown).
  • the protruding portions 30T and the ventilation portions are alternately arranged in the longitudinal and lateral directions of the conveyor belt 30B.
  • the protruding portion 30T has a shape that tapers toward the tip, and the tip has a rounded shape, for example, the shape of one end of a spindle.
  • the height varies depending on the use, standard, etc. of the nonwoven fabric, and is not particularly limited. Usually, it is preferably formed to 2 mm to 10 mm, and the protrusion pitch is 6 mm to 10 mm in the MD direction, and in the CD direction. 4 mm or more and 6 mm or less.
  • the MD is the machine direction and the flow direction of the fiber web 60 during the production of the nonwoven fabric.
  • the CD is the width direction of the fiber web 60 and is the direction orthogonal to the machine direction.
  • the protruding portion 30T is appropriately set within the above range. More preferably, it is formed at a height of 3 mm or more and 8 mm or less, is arranged in the MD direction at 6 mm or more and 10 mm or less, and is arranged in the CD direction at 4 mm or more and 6 mm or less.
  • the ventilation portion (not shown) includes a plurality of openings arranged on the support 30, and the opening ratio is preferably set to 20% or more and 45% or less with respect to the surface area of the support 30. If the aperture ratio is too low, it becomes difficult to form a sufficient uneven shape on the fiber web 60. If the aperture ratio is too high, the fiber web 60 moves below the support 30 when hot air is blown, and the support It becomes difficult to peel from 30, and there is a possibility that the shaped shape is deteriorated and fluff is likely to be formed. Therefore, the aperture ratio is set.
  • the aperture ratio is more preferably 25% or more and 40% or less, and particularly preferably 30% or more and 35% or less.
  • the support 30 rotates the conveyor belt 30B supported by the rotation support roller 30R, so that the fiber web 60 is held by the protrusion 30T on the surface side having the protrusion 30T.
  • Transport A first nozzle 31 that performs the first air-through process by blowing the first hot air W1 in order along the supply direction of the fiber web 60 on the upper side where the protruding portion 30T of the support 30 is disposed,
  • the second nozzle 32 for blowing the second hot air W2 to perform the second air through process and the third nozzle 33 for blowing the third hot air W3 to perform the third air through process are arranged.
  • a cooling unit 34 for cooling the fiber web 60 is disposed between the three nozzles 33.
  • the first and second nozzles 31 and 32 perform front-stage air through, and the third nozzle 33 performs rear-stage air through.
  • the first nozzle 31 includes a first heater (not shown), and a support body on which the protruding portion 30T is arranged through the aeration conveyor 23 having air permeability to the first hot air W1 heated by the first heater.
  • the surface 30 is sprayed substantially perpendicularly.
  • the blowout hole of the first nozzle 31 preferably has a length in the MD direction of 1 mm or more and 20 mm or less, and a length in the CD direction is a web width or more, or a width for performing a shaping process.
  • the blow-out holes have a single or multi-row slit shape, and a form in which round holes, long holes, or square holes are arranged in a staggered manner or in parallel in a single row or multiple rows.
  • the first hot air W1 is blown at a uniform wind speed in the width direction of the surface of the fiber web 60.
  • air, nitrogen or water vapor heated to a predetermined temperature by the first heater can be used.
  • air that does not require drying or is low in cost is used.
  • the first hot air W1 blown out from the first nozzle 31 is controlled by the first heater to a temperature at which the fibers of the fiber web 60 are fused to maintain a concavo-convex shape.
  • the temperature of the first hot air W1 is preferably 80 ° C.
  • the temperature is controlled to 155 ° C. or lower, more preferably 130 ° C. to 135 ° C.
  • the first hot air W1 is preferably controlled to a wind speed of 20 m / sec or more and 120 m / sec or less. If the wind speed of the first hot air W1 blown out from the first nozzle 31 is too slow, it will not be sufficiently along the support and the fiber will be too fused, and shaping will be worsened. There is. On the other hand, if the wind speed is too high, the fibers of the fiber web 60 are selected by the protruding portions 30T, and sufficient shaping cannot be performed. Therefore, the wind speed of the 1st hot air W1 shall be said range, More preferably, you may be 40 m / sec or more and 80 m / sec or less.
  • the blowing time of the first hot air W1 is preferably controlled to 0.01 seconds or more and 0.5 seconds or less, more preferably 0.04 seconds or more and 0.08 seconds or less. If the spraying time is too short, the fiber web cannot be sufficiently shaped into a concavo-convex shape. On the other hand, if the spraying time is too long, the fibers of the fiber web 60 are selected by the protruding portions 30T and become too shaped. .
  • the second nozzle 32 blows the second hot air W2 heated by a second heater (not shown) to the surface of the conveyor belt 30B on which the protruding portions 30T are arranged, for example, substantially perpendicularly. It is desirable to use a punching metal that is regularly opened in the width direction and the flow direction for the blowing holes of the second nozzle 32.
  • the open area ratio is preferably 10% to 40%, more preferably 20% to 30%.
  • the second hot air W2 is blown at a uniform temperature in the width direction of the surface of the fiber web 60.
  • air nitrogen or water vapor heated by the second heater can be used.
  • air that does not require drying or is low in cost is used.
  • the second hot air W2 blown out from the second nozzle 32 fuses the fibers of the fiber web 60 with the second heater (not shown) holding the irregular shape of the shaped fiber web 60. Controlled by temperature.
  • the second hot air W1 is equal to or higher than the melting point of the low melting point component. The temperature is controlled below the melting point of the high melting point component.
  • the second hot air W1 is preferably at a temperature of 130 ° C. or higher and 155 ° C. or lower.
  • the hot air is more preferably controlled at 135 ° C. or higher and 150 ° C. or lower. If the temperature of the second hot air W2 is too low, the fibers cannot be fused together, and it becomes difficult to fix the fiber web 60 in an uneven shape. On the other hand, if the temperature of the second hot air W ⁇ b> 2 is too high, the texture of the nonwoven fabric becomes worse and the bulk becomes difficult.
  • the second hot air W2 is preferably controlled to a wind speed of 1 m / sec or more and 10 m / sec or less. If the wind speed of the second hot air W2 is too slow, the amount of heat is insufficient, and the nonwoven fabric strength is insufficient. On the other hand, if the wind speed is too high, the fiber web 60 becomes thin due to the wind pressure, and a large amount of heat is applied to the fiber web 60. Therefore, the fusion between the fibers increases, the thickness becomes thin, the texture becomes hard, and the liquid Poor permeability. Therefore, the wind speed of the 2nd hot air W2 shall be said range, More preferably, you may be 2 m / sec or more and 8 m / sec or less.
  • the blowing time of the second hot air W2 is preferably controlled to 0.03 seconds or more and 5 seconds or less, more preferably 0.1 seconds or more and 1 second or less. If the spraying time is too short, the fibers of the fiber web cannot be sufficiently fused together, and it becomes difficult to fix the uneven shape. On the other hand, if the spraying time is too long, the fibers of the fiber web 60 are too fused with each other, making it difficult to obtain liquid permeability.
  • the cooling unit 34 is a space arranged between the second nozzle 32 that performs the second air-through process and the third nozzle 33 that performs the third air-through process. By arranging this space, in other words, by not performing the second air-through process and the third air-through process continuously, the melting point of the fibers of the fiber web 60 after the second air-through process. Naturally cool to a lower temperature.
  • the cooling unit 34 can use means for forcibly cooling the fiber web 60.
  • the third nozzle 33 applies the third hot air W3 heated by a third heater (not shown) to the surface of the conveyor belt 30B on which the protruding portions 30T are arranged (the surface on which the uneven shape is arranged). For example, spray almost vertically.
  • the blowout holes of the third nozzle 33 preferably have a width of, for example, 200 mm or more and 10 mm or less, a length equal to or greater than the web width in the width direction of the fiber web 60, and a single or multiple rows of round holes, long holes, or square holes. It has a form that is arranged in parallel. Thus, since the blowing holes of the third nozzle 33 are arranged, the third hot air W3 is blown at a uniform temperature in the width direction of the surface of the fiber web 60.
  • the blowing holes can be arranged at a plurality of locations in the rotation direction of the conveyor belt 30B of the support 30.
  • the third hot air W3 can be air, nitrogen, or water vapor heated by the third heater. Preferably, air that does not require drying or is low in cost is used.
  • the 3rd hot air W3 which blows off from the 3rd nozzle 33 maintains the uneven
  • the temperature is controlled so as to fuse.
  • the fiber of the fiber web 60 is a composite fiber having a core-sheath structure in which the core portion is PET and the sheath portion is PE as described above
  • the third hot air W3 is hot air having a temperature of 130 ° C. or higher and 155 ° C. or lower. Is controlled.
  • the temperature is preferably controlled to 130 ° C. or higher and 145 ° C. or lower.
  • the fibers cannot be fused and it is difficult to reduce fuzz.
  • the temperature of the third hot air W3 is too high, fibers other than the fluffed fibers are fused together, and it is difficult to obtain liquid permeability.
  • the third hot air W3 is preferably controlled to a wind speed of 0.5 m / sec or more and 5 m / sec or less. If the wind speed of the third hot air W3 is too slow, the fuzzy fibers cannot be laid down, and the reduction of the fuzz becomes insufficient. On the other hand, if the wind speed is too high, the thickness of the nonwoven fabric becomes small due to the wind pressure, and since the fibers are heated in that state, fusion of fibers other than the fluffy fibers often occurs, resulting in a decrease in thickness, touch and liquid permeability becomes insufficient. Therefore, the wind speed of the 3rd hot air W3 shall be said range, More preferably, you may be 2 m / sec or more and 8 m / sec or less.
  • the blowing time of the third hot air W3 is preferably controlled to 0.3 seconds or more and 10 seconds or less, more preferably 2 seconds or more and 6 seconds or less. If the spraying time is too short, the fuzzy fiber and other fibers cannot be sufficiently fused together, and it becomes difficult to reduce the fuzz. On the other hand, if the spraying time is too long, fibers other than the fluffy fibers of the fiber web 60 are fused too much, and the thickness is reduced, making it difficult to obtain a texture and liquid permeability.
  • a suction portion 35 that exhausts the first hot air W ⁇ b> 1 blown from the first nozzle 31 and passed through the fiber web 60 and the support 30.
  • the suction unit 35 may be connected to an exhaust device (not shown) that discharges the sucked first hot air W1.
  • a suction portion 36 is arranged to exhaust the second hot air W2 blown from the second nozzle 32 and passed through the fiber web 60 and the support 30.
  • the suction unit 36 may be connected to an exhaust device (not shown) that discharges the sucked second hot air W2.
  • a suction part 37 that discharges the third hot air W ⁇ b> 3 blown out from the third nozzle 33 and passed through the fiber web 60 and the support 30 is arranged.
  • An exhaust device (not shown) for discharging the sucked third hot air W3 may be connected to the suction portion 37.
  • each exhaust apparatus may be connected to each suction part 35, 36, 37 as one exhaust apparatus.
  • the cooling unit 34 for cooling the shaped fiber web 60 is arranged, so that the intersection where the fibers are fused is strengthened to form a network structure of the fibers. Can be firmly fixed, so that the uneven shape formed on the fiber web 60 can be fixed. Since the third nozzle 33 for blowing the third hot air W3 to the cooled fluffed fiber is provided, the fluffy fiber is softened by the third hot air W3 blown from the third nozzle 33, and the fluff The fluffed portion of the fluffed fiber in the laid state and the non-fluffed portion of other fibers (fibers of the network structure) can be fused and fixed.
  • the first hot air W1 blown from the first nozzle 31 can keep the fibers of the fiber web 60 in an uneven shape. For this reason, the fibers of the fiber web 60 that are trapped between the protrusions 30T of the support 30 are difficult to return. In this state, the fibers of the fiber web 60 are fused together by the second hot air W2 blown from the second nozzle 32, and can be fixed in a state where the uneven shape is maintained. As described above, since the first and second hot air W1 and W2 are blown onto the fiber web 60, the fibers of the fiber web 60 are softened by heat and easily follow the surface shape of the protruding portion 30T of the support 30. The retention of the uneven shape is improved.
  • the fiber web 60 is more likely to follow along the surface of the protrusion 30T. As a result, a low density and bulky shaped non-woven fabric with good formability can be obtained.
  • a cooling nozzle that blows the cooling gas Wc onto the fiber web 60 between the second nozzle 32 and the third nozzle 33. 34N is distributed.
  • the temperature of the cooling gas Wc is lower than the melting point of the thermoplastic fibers of the fiber web 60, preferably lower than the melting point of the low melting point component of the fibers constituting the fiber web 60. More preferably, it is 100 degrees C or less, More preferably, it is 50 degrees C or less.
  • air, nitrogen gas, water vapor, or the like can be used as the cooling gas Wc.
  • air that does not require drying or is low in cost is used. If the temperature of the cooling gas Wc is too high, a sufficient cooling effect cannot be obtained.
  • the nonwoven fabric manufacturing apparatus 5 provided with the cooling nozzle 34N includes a support 30, a protrusion 30T, a vent (not shown), a first nozzle 31 and a second nozzle that are components other than the cooling nozzle 34N. 32, the 3rd nozzle 33, the suction part 35, the suction part 36, the suction part 37, etc. have the same structure as the manufacturing apparatus 4 of the said nonwoven fabric.
  • the fiber web 60 immediately after the second air-through process of blowing the second hot air W2 is forcibly cooled by blowing the cooling gas Wc blown from the cooling nozzle 34N. Therefore, the intersection of the fibers fused by the second hot air W2 can be more firmly fixed, and the fiber web 60 can be firmly fixed to the shaped uneven shape.
  • fluffing can be suppressed in the same manner as in the nonwoven fabric manufacturing apparatus 4 described above, and a soft shaped nonwoven fabric with a good touch feeling shaped into an uneven shape can be obtained.
  • cooling unit 34 a fiber web 60 between the second nozzle 32 and the third nozzle 33 is used as a conveyor belt of the support 30.
  • a cooling roller 34R is arranged to be pulled upward from the surface of 30B.
  • the cooling unit roller 34R is configured by a roller that is rotatable and has a smooth surface.
  • a round bar with a smooth surface or a bar-like body with a smooth curved surface on which the fiber web 60 slides may be configured.
  • a flow path through which, for example, a cooling gas or a cooling liquid can flow as a cooling medium may be disposed inside the cooling unit roller 34R.
  • a cooling medium By flowing a cooling medium through this flow path, the cooling efficiency of the fiber web 60 by the cooling section roller 34R is further enhanced.
  • the flow path can also be arranged inside the round bar or bar.
  • the nonwoven fabric manufacturing apparatus 6 provided with the cooling unit roller 34R includes a support body 30, a protruding portion 30T, a ventilation unit (not shown), a first nozzle 31, a first nozzle 31 and a first configuration, which are components other than the cooling unit roller 34R.
  • the 2 nozzle 32, the third nozzle 33, the suction part 35, the suction part 36, the suction part 37 and the like have the same configuration as that of the nonwoven fabric manufacturing apparatus 4.
  • the fiber web 60 immediately after the second air-through process of blowing the second hot air W2 is once separated from the surface of the conveyor belt 30B by the cooling roller 34R, so that it is efficiently cooled. Therefore, the intersection of the fibers fused by the second hot air W2 can be more firmly fixed, and the fiber web 60 can be firmly fixed to the shaped uneven shape. At the same time, fluffing can be suppressed in the same manner as in the nonwoven fabric manufacturing apparatus 4 described above, and a soft shaped nonwoven fabric with a good touch feeling shaped into an uneven shape can be obtained.
  • the nonwoven fabric manufacturing apparatus 7 of the fifth embodiment is a support (second support) 38 different from the support (first support) 30 in the nonwoven fabric manufacturing apparatus 4 described above. And a third air through step of blowing the third hot air W3 is performed by the second support 30.
  • the second support 38 is constituted by a conveyor that carries the fiber web 60 on the upper side and conveys it, and a rotation support roller 38R in which a conveyor belt 38B is arranged at four positions on both upper and lower ends. (38Ra, 38Rb, 38Rc, 38Rd) is configured to rotate while being supported, and the portion on which the fiber web 60 is transported is flat.
  • the rotation support rollers 38R are not limited to four places, and may be arranged so that the conveyor belt 38B rotates smoothly and a plane portion is formed.
  • the conveyor belt 38B is comprised by the mesh belt which has air permeability, for example, it is more preferable that it is comprised by the mesh belt of 12 meshes to 60 meshes.
  • the second support 38 is separated from the first support 30 so that the fiber web 60 subjected to the first and second air-through processes on the first support 30 is fed onto the conveyor belt 38B. Are arranged in series. Therefore, the space between the first support 30 and the second support 38 is the cooling unit 34.
  • the configuration of the cooling unit 34 may be the same as that of the natural cooling or forced cooling cooling unit 34 described with reference to FIGS.
  • a third nozzle 33 similar to that described above is disposed above the second support 38. Further, in the blowing direction of the third nozzle 33, a suction part 37 is arranged to exhaust the third hot air W ⁇ b> 3 blown out from the third nozzle 33 and passed through the fiber web 60 and the second support 38. An exhaust device (not shown) for discharging the sucked third hot air W3 may be connected to the suction portion 37.
  • the nonwoven fabric manufacturing apparatus 7 includes a first support 30, a protrusion 30 ⁇ / b> T, a vent (not shown), a first nozzle 31, a second nozzle 32, and a second structure other than the second support 38.
  • the three nozzles 33, the suction part 35, the suction part 36, the suction part 37, and the like have the same configuration as that of the non-woven fabric manufacturing apparatus 4 described above.
  • the nonwoven fabric manufacturing apparatus 7 of the above-described fifth embodiment has the same effects as the nonwoven fabric manufacturing apparatus 4 described above, and fibers from the first support 30 after the second air-through process of blowing the second hot air W2. Since the web 60 is peeled off, the fiber web 60 can be naturally cooled. Thereby, the fibers fused in the second air-through process can be firmly fixed, and the uneven shape formed on the fiber web 60 can be firmly fixed. Further, since the fiber web 60 is peeled off from the first support 30 and placed on the second support 38, the fiber web 60 is attached to the second support 38 by cooling the second support 38. The fiber web 60 can also be cooled when placed.
  • the retainability of the uneven shape of the fiber web 60 is further enhanced, so that the temperature of the third hot air W3 is increased within an allowable range, and the fuzzy fibers are securely fused to other fibers, thereby further improving the fuzziness. Can be reduced.
  • the use of a mesh belt as the air-permeable conveyor belt 38B for the second support 38 can eliminate fuzz on both sides of the fiber web 60. This is because, by using a support having air permeability such as a mesh belt, the fluff on the surface side of the fiber web 60 is softened by the third hot air W3 as described above. After lapping the existing part, the fuzzed part of the fluffy fiber and the non-fuzzy part of the other fiber are fused to reduce fuzzing. In addition, since the air-permeable support is used, the third hot air W3 easily blows through the fiber web 60 to the back surface side of the conveyor belt 38B, and the back surface side due to the weight of the web and the wind pressure applied to the web.
  • the fuzzed fibers are laid down and fused with other fibers. Also, by using a belt of 12 to 60 mesh as the mesh belt, the mesh area (vertical dimension ⁇ horizontal dimension) is 1.5 mm 2 or less at 12 mesh or more, and the fuzzy fibers are laid down. As a result, the fuzzing can be reduced. When the mesh is larger than 60 mesh, the cost for generating the hot air speed increases due to the increase in local resistance.
  • the nonwoven fabric manufacturing apparatus 8 is arranged on the surface side of the fiber web 60 to which another support (second support) 38 is fed in the nonwoven fabric manufacturing apparatus 7 described above.
  • the third air-through process described above is performed by the second support 38.
  • the configuration of the second support 38 is the same as that of the second support 38 of the second embodiment described above except that the top and bottom are reversed.
  • the second support 38 is fed so that the fiber web 60 subjected to the shaping process by blowing the first and second hot air W1, W2 on the first support 30 under the conveyor belt 38B is fed.
  • the first support 30 and the second support 38 are spaced apart.
  • the cooling unit 34 is between the first support 30 and the second support 38.
  • the configuration of the cooling unit 34 may be the same as that of the natural or forced cooling unit 34 described with reference to FIGS.
  • a third nozzle 33 similar to that described above is disposed below the second support 38. Further, in the blowing direction of the third nozzle 33, a suction part 37 is arranged to exhaust the third hot air W ⁇ b> 3 blown out from the third nozzle 33 and passed through the fiber web 60 and the second support 38. An exhaust device (not shown) for discharging the sucked third hot air W3 may be connected to the suction portion 37.
  • the nonwoven fabric manufacturing apparatus 8 is different from the arrangement of the second support 38, the third nozzle 33, and the suction part 37 in the first support 30, the protruding part 30T, the ventilation part (not shown), the first The 1 nozzle 31, the 2nd nozzle 32, the suction part 35, the suction part 36, etc. have the same structure as the manufacturing apparatus 7 of the said nonwoven fabric.
  • the nonwoven fabric manufacturing apparatus 8 of the above-described sixth embodiment can obtain a soft shaped nonwoven fabric with a good feel that is shaped into a concavo-convex shape, similar to the nonwoven fabric manufacturing apparatus 6 described above. In particular, fuzz on the back side of the fiber web 60 can be further reduced.
  • the manufacturing apparatus of the nonwoven fabric comprised with the conveyor as preferable embodiment, the preferable manufacturing apparatus of this application is not limited to a conveyor type, A drum type may be sufficient.
  • the nonwoven fabric manufacturing method of the fourth embodiment is realized by the above-described nonwoven fabric manufacturing apparatus 4.
  • the fiber web 60 is supplied to the upper surface side of the support 30 on which the protruding portions 30T are arranged.
  • the fiber material that can be used for the fibers of the fiber web 60 is not particularly limited. Specifically, the same ones as described above can be used.
  • the first hot air W 1 is supplied from the first nozzle 31 to the fiber web 60 fed to the surface of the support 30.
  • the 1st air through process which sprays is performed.
  • the first hot air W1 is blown from the direction perpendicular to the surface of the support 30 on which the fiber web 60 is placed.
  • the number of blowouts of the first nozzle 31 may be a plurality of locations along the feeding direction of the fiber web 60.
  • the fusion of the fibers of the fiber web 60 may be such that the uneven shape can be maintained.
  • the temperature of the first hot air W1 varies depending on the type of fiber, the processing speed, the wind speed of the hot air, etc., but is not uniquely determined.
  • the fiber of the fiber web 60 has a polyethylene terephthalate (PET) core.
  • PET polyethylene terephthalate
  • the sheath is a composite fiber having a core-sheath structure of polyethylene (PE)
  • the temperature is preferably 80 ° C. or higher and 155 ° C. or lower, more preferably 130 ° C. or higher and 135 ° C. or lower.
  • the first hot air W1 is preferably set to a wind speed of 20 m / sec or more and 120 m / sec or less.
  • the wind speed of the 1st hot air W1 is too slow, sufficient shaping cannot be performed and shaping property may be impaired.
  • the wind speed of the 1st hot air W1 shall be said range, More preferably, you may be 40 m / sec or more and 80 m / sec or less.
  • the blowing time of the first hot air W1 is preferably 0.01 seconds to 0.5 seconds, and more preferably 0.04 seconds to 0.08 seconds. If the spraying time is too short, the fibers of the fiber web 60 are not sufficiently fused to each other, and the uneven shape cannot be sufficiently shaped. On the other hand, if the spraying time is too long, the fusion of the fibers of the fiber web 60 proceeds too much, and the formability is impaired due to a decrease in the degree of freedom. And the 1st hot air W1 which passed the fiber web 60 is discharged
  • the fiber web 60 is conveyed to the blowing position of the second hot air W2 of the second nozzle 32 along with the rotation of the conveyor belt 30B of the support 30. Further, as a previous air-through process, a second hot air W2 is blown onto the fiber web 60 by the second nozzle 32, and the fibers are fused while the uneven shape of the fiber web 60 is maintained, thereby fixing the uneven shape. Perform an air-through process. At this time, the second hot air W ⁇ b> 2 is blown from the direction perpendicular to the surface of the fiber web 60.
  • the number of blowouts of the second nozzle 32 is preferably set at a plurality of locations along the feeding direction of the fiber web 60.
  • the temperature of the second hot air W2 varies depending on the type of fiber, the processing speed, the wind speed of the hot air, etc., and thus is not uniquely determined.
  • the melting point is not less than the melting point of the low melting point component of the fiber of the fiber web 60 and less than the melting point of the high melting point component of the fiber of the fiber web 60.
  • it is 135 degreeC or more and 155 degrees C or less, and more preferably is 135 degreeC or more and 150 degrees C or less.
  • the retainability of the uneven shape decreases, and when the temperature becomes equal to or higher than the melting point of the high melting point component of the fiber of the fiber web 60, Becomes worse and less bulky.
  • the second hot air W2 is preferably set slower than the wind speed of the first hot air W1, and is preferably set to 1 m / sec or more and 10 m / sec or less. If the wind speed of the second hot air W2 is too slow, the amount of heat is insufficient, and the nonwoven fabric strength is insufficient. On the other hand, if the wind speed is too high, the thickness of the fiber web 60 is reduced by the wind pressure, and if heated in that state, the fibers are fused more frequently, so the feel becomes harder, the thickness becomes thinner, and the liquid permeability is insufficient. become. Therefore, the wind speed of the 2nd hot air W2 shall be said range, More preferably, you may be 2 m / sec or more and 8 m / sec or less.
  • the blowing time of the second hot air W2 is preferably 0.03 seconds or more and 5 seconds or less, more preferably 0.1 seconds or more and 1 second or less. If the spraying time is too short, the fibers of the fiber web 60 cannot be sufficiently fused together, and it becomes difficult to fix the uneven shape. On the other hand, if the spraying time is too long, the fibers of the fiber web 60 are excessively fused with each other, making it difficult to obtain liquid permeability.
  • the fiber web 60 shaped by blowing the first and second hot air W1 and W2 in the first and second air-through processes described above is formed in a bulky state as shown in FIG. Fibers are fused together.
  • the surface is fuzzy.
  • the fiber web 60 shaped in the first and second air-through processes is cooled.
  • This cooling can be performed by natural cooling or forced cooling.
  • the cooling temperature is lower than the melting point of the thermoplastic fiber of the fiber web 60, preferably lower than the melting point of the low melting point component of the fiber constituting the fiber web 60.
  • the temperature is set to 100 ° C. or lower.
  • the shaped fiber web 60 is conveyed to the third hot air W3 blowing position of the third nozzle 33 along with the rotation of the conveyor belt 30B of the support 30. Meanwhile, the fiber web 60 is cooled to a temperature lower than the melting point of the thermoplastic fibers of the fiber web 60 by passing through the cooling unit 34.
  • This cooling may be natural cooling or forced cooling described with reference to FIGS. Preferably, it is cooled to 100 ° C. or lower by forced cooling.
  • the intersection portion where the fibers are fused by the blowing of the second hot air W ⁇ b> 2 is surely solidified (a fused network structure is configured). In particular, by cooling the fiber web 60 to 100 ° C.
  • the intersection of the fibers can be more firmly fixed, and the base of the fiber web 60 (the fusion fixing of the fiber web 60 excluding fuzzy fibers).
  • the thickness of the fiber part can be maintained.
  • the sheath resin is PE
  • the melting point is 125 ° C. to 135 ° C.
  • the softening point temperature is 100 ° C. to 130 ° C., so that the solidification is further ensured by cooling to 100 ° C. or lower.
  • the third hot air W3 is blown by the third nozzle 33 to the fiber web 60 conveyed to the position where the third hot air W3 is blown, and the fluffed fibers of the fiber web 60 are held in a state where the uneven shape of the fiber web 60 is maintained.
  • a third air-through process for fusing other fibers together is performed.
  • the temperature of the third hot air W3 at this time is not uniquely determined because it varies depending on the type of fiber, the processing speed, the wind speed of the hot air, etc.
  • the fibers of the fiber web 60 are made of PET and PE as described above. In the case of a composite fiber having a core-sheath structure, the temperature is preferably 130 ° C. or higher and 155 ° C.
  • the temperature of the third hot air W3 is too low, the fuzzy fibers cannot be fused with other fibers, and it becomes difficult to reduce the fuzz. On the other hand, if the temperature of the third hot air W3 is too high, fibers other than the fluffed fibers are fused together, and it is difficult to obtain liquid permeability.
  • the third hot air W3 is set to a wind speed slower than the wind speed of the first hot air W1 and a wind speed that causes the fluffed fibers of the fiber web 60 to lie down. Specifically, it is preferably 1.0 m / sec or more and 5 m / sec or less. If the wind speed of the third hot air W3 is too slow, the fuzzy fibers cannot be laid down, and the reduction of the fuzz becomes insufficient. On the other hand, if the wind speed is too high, the thickness of the nonwoven fabric becomes small due to the wind pressure, and since the fibers are heated in that state, fusion of fibers other than the fluffy fibers often occurs, resulting in a decrease in thickness, touch and liquid permeability Becomes insufficient.
  • the wind speed of the 3rd hot air W3 shall be said range, More preferably, you may be 1 m / sec or more and 2 m / sec or less. Furthermore, it is more preferable to select a fast wind speed within the range of the above wind speed, because the lapped fluff fibers can enter the base portion of the fiber web 60.
  • the blowing time of the third hot air W3 is preferably 0.3 seconds to 10 seconds, and more preferably 2 seconds to 6 seconds. If the spraying time is too short, the fuzzy fiber and other fibers cannot be sufficiently fused together, and it becomes difficult to reduce the fuzz. On the other hand, if the spraying time is too long, fibers other than the fluffy fibers of the fiber web 60 are excessively fused together, making it difficult to obtain liquid permeability.
  • the fluffed fibers are softened by the heat of the third hot air W3, and the fluffed portions are laid down by the wind pressure.
  • the fuzzed portion and the other non-fluffed portion of the other fibers are fused at a new fusing point.
  • melting point of fuzzy fiber and other fibers is solidified, and the shaping nonwoven fabric without fuzzing is manufactured.
  • the base of the shaped nonwoven fabric is firmly fixed, the thickness of the fiber web 60 is not reduced in the third air-through process, and a sufficient thickness is obtained.
  • FIG. 11 (5) even when an external force was applied to the surface of the shaped non-woven fabric to reproduce the use state, the fluffed fibers did not rise up and fluffed.
  • the fluffed fibers are softened and deformed by blowing the third hot air W3.
  • the fluffed fibers may be softened and deformed by blowing the second hot air W2.
  • the shaped fiber web 60 is formed into the fiber web 60 by firmly fixing the fiber network by cooling the intersection where the fibers are fused together.
  • the uneven shape is fixed. Since the third hot air W3 is blown onto the fluffed fibers in the fixed state, the fluffy fibers can be softened and laid down. At this time, since the fibers of the base portion of the fiber web 60 are firmly fixed, even if the third hot air W3 is blown, the thickness of the base portion is not reduced, and only the fluffy portion can be laid down.
  • the fluffed fibers in the laid state and the other fibers are fused to each other, so that the fuzzed fibers are fused and fixed to the other fibers in a loop shape, for example.
  • the fluffing is reduced, and the fluffed fibers that have been laid down are also reduced from returning to the original fluffing state, so that a soft shaped nonwoven fabric with a smooth feel that is shaped into an uneven shape is obtained. be able to. And since the base part of the fiber web 60 does not become thin, it becomes a low-density and bulky shaped nonwoven fabric. By using such a shaped nonwoven fabric for an absorbent article, it is possible to obtain an absorbent article having a good appearance and a good touch.
  • the nonwoven fabric manufacturing method of the fifth embodiment is realized by the above-described nonwoven fabric manufacturing apparatus 7.
  • the fiber web 60 is fed to the surface of the first support 30 and the first air through step and the second air through step are sequentially performed in the same manner as in the manufacturing method of the fourth embodiment described above.
  • the fiber web 60 is cooled by peeling the fiber web 60 from the first support 30 and supplying it to the second support 38 as another support.
  • This cooling may be natural cooling or forced cooling, but is preferably forced cooling using the cooling nozzle 34N and the cooling roller 34R described above.
  • the retainability of the uneven shape of the fiber web 60 is further enhanced, so that the temperature of the third hot air W3 is increased within an allowable range, and the fuzzy fibers are surely fused to other fibers, thereby fuzzing. It can be further reduced.
  • the fiber web 60 is supplied onto the conveyor belt 38B of the second support 38, the third hot air W3 blown from the third nozzle 33 is blown onto the fiber web 60, and the uneven shape of the fiber web 60 is maintained.
  • a third air-through process is performed in which the fluffed fiber and other fibers are fused.
  • Conditions such as the temperature, wind speed, and blowing time of the third hot air W3 are the same as those described in the manufacturing method of the fourth embodiment described above.
  • the manufacturing method of the nonwoven fabric of the above-described fifth embodiment can reduce the fluff on both sides of the fiber web 60 while exhibiting the same effects as the manufacturing method of the nonwoven fabric of the above-described fourth embodiment. This is because the fluffed fibers can be softened and laid down on the surface side of the fiber web 60 by the above-described action, and then the fuzzed fibers and other fibers can be fused and fixed. On the other hand, on the back side of the fiber web 60, since the third hot air W3 is easy to blow through the fiber web 60 to the back side of the conveyor belt 38B, the fluffed fibers are caused by the weight of the web and the wind pressure applied to the web.
  • the fluff fibers on the back side are laid down and fused with other fibers, the fluff fibers and other fibers can be fused and fixed. As a result, the fluffing on both sides of the fiber web 60 can be reduced, and the fluffed fiber that has been laid down is also reduced from returning to the original fluffing state. A shaped nonwoven fabric can be obtained. Further, since the fiber web 60 is fed to the upper surface side of the second support 38 and the third hot air W3 is blown from the surface side of the fiber web 60, the fluffing on the surface side of the fiber web 60 is further reduced. can do.
  • the nonwoven fabric manufacturing method of the sixth embodiment is realized by the above-described nonwoven fabric manufacturing apparatus 8.
  • the fiber web 60 is fed to the surface of the support (first support) 30 and the first air-through process and the second air-through process are sequentially performed in the same manner as in the manufacturing method of the fifth embodiment described above.
  • the fiber web 60 is cooled by peeling the fiber web 60 from the first support 30 and supplying it to the second support 38 as another support. This cooling is performed in the same manner as in the manufacturing method of the fifth embodiment described above.
  • the fiber web 60 is supplied to the lower surface side of the conveyor belt 38B of the second support 38, the third hot air W3 blown from the third nozzle 33 is blown from the back surface side of the fiber web 60, and the fiber web 60 A third air-through process is performed in which the fluffed fiber and other fibers are fused together while the uneven shape is maintained. Conditions such as the temperature, wind speed, and blowing time of the third hot air W3 are the same as those described in the manufacturing method of the fourth embodiment described above.
  • the manufacturing method of the nonwoven fabric of the above-described sixth embodiment has the same effects as the manufacturing method of the nonwoven fabric of the above-described fourth embodiment, and can reduce fuzz on both sides of the fiber web 60. This is because on the back side of the fiber web 60, the fluffed fibers and the other fibers can be fused and fixed after the fluffy fibers are softened and laid down. On the other hand, on the surface side of the fiber web 60, since the third hot air W3 easily blows through the fiber web 60 to the surface side of the conveyor belt 30B, the fluffed fibers are fluffed on the surface side by the wind pressure applied to the web. Since the fibers are laid down and fused with other fibers, the fuzzed fibers and other fibers can be fused and fixed.
  • the fluffing on both sides of the fiber web 60 can be reduced, and the fluffed fiber that has been laid down is also reduced from returning to the original fluffing state, so that a smooth feel that is shaped into a concavo-convex shape.
  • a good soft shaped nonwoven fabric can be obtained.
  • the 3rd hot air W3 is sprayed from the back surface side of the fiber web 60, especially the fluff on the back surface side of the fiber web 60 can be reduced further.
  • Example 21 to 29 described in Table 3 and Comparative Examples 21 to 23 described in Table 4 will be described.
  • Examples 21 to 24 were manufactured under the following conditions by the manufacturing method of the fourth embodiment described above. That is, in Example 21, a composite fiber having a core-sheath structure in which the core part is polyethylene terephthalate (melting point: 258 ° C.) and the sheath part is polyethylene (melting point: 130 ° C.) is used for the fiber of the fiber web 60. The mixing ratio was 100%, and the fineness was 2.2 dtex.
  • the fiber web 60 was conveyed by the support 30, and the first hot air W1 and the second hot air W2 were blown on the surface of the support 30 to form an uneven shape. Then, after naturally cooling the fiber web 60 on the surface of the support 30, third hot air W ⁇ b> 3 was blown on the surface of the support 30 to reduce fuzz.
  • the first hot air W1 had a temperature of 130 ° C., a wind speed of 50 m / sec, and a blowing time of 0.018 seconds.
  • the second hot air W2 had a temperature of 145 ° C., a wind speed of 5.0 m / sec, and a blowing time of 0.21 seconds.
  • the third hot air W3 had a temperature of 139 ° C., a wind speed of 1.5 m / sec, and a blowing time of 4.0 seconds.
  • a test specimen of shaped nonwoven fabric was produced under the above conditions.
  • Example 22 a shaped nonwoven fabric specimen was manufactured under the same conditions as in Example 21 except that cooling was performed to 100 ° C. or lower by forced cooling.
  • Example 23 is cooled to 100 ° C. or lower by forced cooling, the wind speed of the first hot air W1 is set to 20 m / sec, the blowing time is set to 0.050 seconds, and the wind speed of the third hot air W3 is set to 2.0 m / sec.
  • a shaped nonwoven fabric specimen was manufactured under the same conditions as in Example 21 except that the period was set to sec. In Example 24, cooling was performed to 100 ° C.
  • Example 25 A shaped nonwoven fabric specimen was manufactured under the same conditions as in Example 21 except that the period was set to sec.
  • the test of the shaped nonwoven fabric was performed under the same conditions as in Example 21 except that the second hot air W2 was set at a wind speed of 0.5 m / second and was cooled to 100 ° C. or lower by forced cooling. The body was manufactured.
  • Examples 25 to 29 were manufactured under the following conditions by the manufacturing method of the fifth embodiment described above. That is, in Example 25, after cooling to 100 ° C. or less by forced cooling, the shaped nonwoven fabric was formed under the same conditions as in Example 21 except that the third air-through process was performed on the second support 30. A test specimen was manufactured, In Example 26, after cooling to 100 ° C. or less by forced cooling, the third air through step was performed on the second support 30 and the temperature of the third hot air W3 was set to 130 ° C. A shaped nonwoven fabric specimen was produced under the same conditions as in No. 21, In Example 27, after cooling to 100 ° C.
  • Example 28 after cooling to 100 ° C. or less by forced cooling, the third air through step was performed on the second support 30 and the wind speed of the third hot air W3 was set to 1.0 m / sec.
  • Example 29 After cooling to 100 ° C. or less by forced cooling, the third air through step was performed on the second support 30 and the wind speed of the third hot air W3 was set to 2.0 m / sec.
  • a shaped nonwoven fabric specimen was manufactured under the same conditions as in Example 21.
  • Comparative Example 21 in the manufacturing method of the above-described fourth embodiment, the cooling after the second air-through process and the third air-through process were not performed, and the blowing time of the second hot air W2 was set to 1.0 second. Except for the above, a shaped nonwoven fabric specimen was produced under the same conditions as in Example 21 above. Comparative Example 22 produces a test specimen of shaped nonwoven fabric under the same conditions as in Example 21 except that the cooling after the second air-through step was not performed in the production method of the fourth embodiment. did.
  • Comparative Example 23 in the manufacturing method of the fourth embodiment described above, the temperature of the second hot air W2 was set to 139 ° C., the wind speed was set to 1.5 m / second, the blowing time was set to 5.0 seconds, and forced cooling was performed to 100. It is the same as that of the above-mentioned Example 21 except having performed the process (method of patent document 3) which cooled to below below ° C and passed through two hot rolls heated to 130 ° C instead of the subsequent third air-through process. A shaped nonwoven fabric specimen was manufactured under the conditions.
  • the temperature of the first hot air W1 is measured directly under the blowout port of the first nozzle 31 by an anemo master (manufactured by Nippon Kanomax Co., Ltd .: trade name), which is an anemometer, and the wind speed is measured by the pitot tube.
  • the static pressure was pulled from the total pressure just below the outlet of the tube, and the dynamic pressure was measured.
  • the temperature and wind speed of the second hot air W2 are measured immediately below the outlet of the second nozzle 32 by the anemo master, and the temperature and wind speed of the third hot air W3 are directly under the outlet of the third nozzle 33 by the anemo master.
  • the measuring method of the thickness of the shaped nonwoven fabric was measured using a thickness measuring instrument in a state where a load of 0.3 kPa was applied to the shaped nonwoven fabric.
  • a thickness measuring instrument for example, a thickness meter (for example, trade name: ABSOLUTE) manufactured by MITUTOYO was used. The thickness was measured, for example, at 10 points, and the average value was calculated as the thickness.
  • Appearance shapeability is ⁇ that the uneven shape is uniformly formed on the front side and the back side, ⁇ , that the uneven shape is formed almost uniformly on the front side and the back side, ⁇ ,
  • a case where there is a part that is not sufficiently shaped on at least one of the back side is represented by ⁇ , and a case where either one or both of the front side and the back side is not shaped is represented by x.
  • the thickness of the shaped non-woven fabric was represented by ⁇ , from 3.6 mm to ⁇ ⁇ , from 3.2 mm to less than 3.6 mm, 2.5 from 2.5 mm to less than 3.2 mm, and ⁇ from less than 2.5 mm.
  • the liquid permeability is ⁇ when the liquid dripped onto the shaped nonwoven fabric (for example, water) quickly permeates, ⁇ when the liquid dropped onto the shaped nonwoven fabric passes almost without permeation, and liquid dropped on the shaped nonwoven fabric
  • ⁇ when the liquid dropped onto the shaped nonwoven fabric passes almost without permeation
  • liquid dropped on the shaped nonwoven fabric The case where it takes a long time to blur and permeate is represented by ⁇ , and the case where the liquid dropped on the shaped nonwoven fabric does not permeate is represented by ⁇ .
  • the fluffing state of the top and bottom surfaces of the shaped nonwoven fabric was represented by ⁇ for the case where there was no fuzz, ⁇ for the case where there was little fuzz, ⁇ for the case where the fuzz was partially, and ⁇ where the fuzz was entirely present.
  • the strength of fusion of fibers at the convex portion of the shaped nonwoven fabric is measured by the following method.
  • a metal disk (diameter 70 mm, 300 g) whose surface is covered with urethane foam (Urethane foam Molton MF30 (trade name), thickness 5 mm) manufactured by Bridgestone Corporation is attached to the rotating shaft.
  • the attachment position is a position where the center of the disk rotates at a position shifted by 20 mm from the center of the rotation axis.
  • the same urethane foam as described above is laid on the lower surface of the shaped nonwoven fabric.
  • the measuring surface of the shaped non-woven fabric is fixed on a table with the horizontal and upper surfaces facing each other. The disk is placed on the shaped nonwoven fabric.
  • the load applied to the shaped nonwoven fabric is only the weight of the disk.
  • the rotating shaft is rotated to rotate the disk on the shaped nonwoven fabric.
  • the rotation is performed as one set of three clockwise rotations and three counterclockwise rotations.
  • the circumferential speed at this time is 3 seconds per round.
  • the fluffy fibers adhering to the surface of the urethane foam covering the disk are collected, and the number of fibers is measured.
  • the greater the number of fluffed fibers the lower the fusion strength.
  • Fluff due to friction between the upper surface and the lower surface of the shaped nonwoven fabric is measured by the above measurement method for each of the upper surface and the lower surface.
  • the feel of the upper surface and the lower surface of the shaped nonwoven fabric was determined based on the touch feeling. Those with a very soft touch were shown as ⁇ , those with a soft touch as ⁇ , those with a slightly soft touch as ⁇ , and those with a soft touch as ⁇ .
  • the basis weight of all the examples shown in Table 3 and the comparative examples shown in Table 4 was 27 g / m 2 .
  • the fiber web shaped by the first and second air-through processes was cooled to a temperature lower than the melting point of the thermoplastic fiber, and then hot air was blown onto the cooled fiber web.
  • a third air-through process was performed in which the fuzzy fibers and another fiber were fused together, and fuzzing was reduced in all of Examples 21 to 29 (judgment result is ⁇ or more).
  • the determination result was equal to or more than ⁇ in any evaluation item.
  • the appearance is good (judgment result is ⁇ or more), the thickness is 3.2 mm or more (judgment result is ⁇ or more), and the liquid permeability is excellent (the judgment result is ⁇ more than).
  • the second support 38 reduces fuzz.
  • the thickness of the third hot air W3 was 3.5 mm or more except for Example 28 where the wind speed was as slow as 1.0 m / sec. An excellent result was obtained with ⁇ .
  • all of the evaluation items other than the thickness were evaluated as ⁇ .
  • the temperature of the third hot air W3 is 139 ° C. and the wind speed is 1.5 m / second to 2.0 m / second or less.
  • the fuzzy fibers are sufficiently soft and laid down. It is considered that it is easy to fuse with other fibers.
  • the wind speed of the third hot air W3 is as high as 2.0 m / sec, the fluff fibers are likely to enter the base portion of the fiber web 60, so that it is considered that a sufficient fuzz reduction effect can be obtained. .
  • Examples 25 to 27 and 29 in which the fiber web 60 was fed to the second support 38 and the third air-through process was performed except for Example 28 were compared with Examples 21 to 24 in which the fiber A significant effect was observed in reducing the fluffing on the back side of the web 60.
  • the effect of reducing fluff on the back surface side was the same as that of the manufacturing method of the fourth embodiment in which the second support 38 was not used.
  • the wind speed of the third hot air W3 in the third air-through process Is considered to be 1.0 m / sec, which is slower than the wind speed of the other examples. That is, it can be said that the higher the wind speed of the third hot air W3, the more effective the suppression of fuzz on the back surface.
  • the wind speed is slower than the wind speed of the second hot air W2, and needs to be set to, for example, 5.0 m / second or less for the reason described above.
  • the wind speed of the third hot air W3 is 1.0 m / sec under the same conditions, all evaluations related to fuzz are ⁇ . Therefore, it was found that the wind speed of the third hot air W3 is required to be 0.5 m / second or more, preferably 1.0 m / second or more.
  • Comparative Example 2 in which the third air-through process was performed without cooling was insufficient in the fuzz reduction effect (evaluation ⁇ ).
  • Comparative Example 22 as shown in FIG. 12 (1), the first hot air W1 is blown onto the fiber web 60 in the first air-through process, and the fibers that can maintain the shaped shape are fused together. . The surface becomes fuzzy.
  • the 2nd hot air W2 is sprayed in a 2nd air through process, and the intersection of fibers is fusion-fixed. Even in this state, the surface is fuzzy.
  • the third hot air W3 is blown in the third air-through process following the second air-through process. In this state, as shown in (3) of FIG. 12, the fiber web 60 is thinly crushed, and the reduction of fuzz is insufficient.
  • the shaped nonwoven fabric produced in this way was fluffy and not bulky as shown in FIG. 12 (4).
  • Comparative Example 3 using a conventional heat roll the effect of reducing fuzz was insufficient (evaluation ⁇ ).
  • this comparative example 23 as shown in (1) of FIG. 13, the fiber web 60 before being processed through the hot roll was fuzzed, but as shown in (2) of FIG. 13, it was passed through the hot roll. As a result, the fluffy fibers are laid down. As a result, as shown in (3) of FIG. 13, a shaped nonwoven fabric without fuzz is produced. However, as shown in FIG. 13 (4), when an external force was applied to the surface of the shaped nonwoven fabric, the fluffed fibers rose again and fuzzed.
  • a preferred embodiment of a support for producing a nonwoven fabric (hereinafter referred to as a support) according to the present invention will be described below with reference to FIGS. 14 and 15.
  • the support body 40 of the present invention includes a plate-like body 41, a plurality of protrusions 42 arranged on a surface 41 ⁇ / b> S constituted by the plane of the plate-like body 41, and a surface 41 ⁇ / b> S.
  • a plurality of holes 43 penetrating the back surface 41B facing the front surface 41S are provided.
  • the protrusions 42 and the holes 43 are alternately arranged in a first direction (for example, the MD direction) on the surface 41S and a second direction (for example, the CD direction) perpendicular thereto, and the protrusions 42 are arranged at equal intervals with a predetermined interval. ing.
  • the protrusions 42 are arranged at equal intervals around the hole 43. That is, the hole 43 is arranged at the center position of the four protrusions 42 around the hole 43.
  • the surface 41S between the adjacent protrusions 42, between the adjacent holes 43, and between the protrusions 42 and the holes 43 is preferably a flat surface when configured with a conveyor, and when configured with a drum. It is preferable that a curved surface is formed.
  • the MD direction mentioned above is the machine direction and the feeding direction of the fiber web at the time of manufacturing the nonwoven fabric
  • the CD direction mentioned above is a direction orthogonal to the MD direction on the surface 41S of the support 40.
  • the plurality of protrusions 42 have a first surface 42SA and a second surface 42SB that face each other.
  • the first surface 42SA and the second surface 42SB may be flat surfaces or curved surfaces.
  • Each of the first surfaces 42SA is oriented in the same direction (CD direction), and each of the second surfaces 42SB is oriented in the same direction opposite to the first surface 42SA in the CD direction.
  • the protrusion 42 is long in the direction of the first and second surfaces 42SA and 42SB in plan view, and has a rectangular shape with rounded corners, for example.
  • the shape of the cross section of the protrusion 42 is preferably a rectangle or an ellipse with rounded corners except for the top.
  • the vertical cross section of the protrusion 42 is preferably a rectangle or a trapezoid whose tip or corner is a curved surface.
  • a third surface (side surface) 42SC connected to the periphery of each surface between the first surface 42SA and the second surface 42SB of the protrusion 42.
  • the outer peripheral edge of the third surface 42SC is inside the cycloid curve drawn so as to pass through the top portion and the surface 41S at the midpoint between the top portions when viewed from the normal direction (CD direction) of the first surface 42SA or the second surface 42SB. It is preferable to exist in.
  • At least one of the first surface 42SA, the second surface 42SB, and the third surface 42SC of the protrusion 42 is roughened. This surface roughness is appropriately selected depending on the fiber type, fiber diameter, and the like of the fiber web.
  • a preferable range of d1 is 0 mm ⁇ d1 in that the fiber web is shaped according to the shape of the support, has good peelability from the support after shaping, has a fine uneven pattern, and has a beautiful appearance.
  • ⁇ 10 mm a more preferable range is 1 mm ⁇ d1 ⁇ 3 mm, and a most preferable range is 1.5 mm ⁇ d1 ⁇ 2.5 mm.
  • the hole 43 preferably has the center of the hole 43 at the center between the adjacent protrusions 42 in both the MD direction and the CD direction. And when the said hole 43 is projected from MD direction, it is preferable to arrange
  • the opening ratio (area ratio) occupied by the holes 43 is preferably as large as possible so that the gas to be blown out is good, but the opening ratio is determined in consideration of the strength of the support 40.
  • the aperture ratio is preferably 10% to 50%, more preferably 15% to 40%, still more preferably 20% to 35%, and particularly preferably 30% to 35%.
  • the support 40 of the present invention has the substantially solid first surface 42SA and the substantially solid second surface 42SB, which the protrusions 42 face each other, the fibers enter the protrusions 42 and become entangled. There is no.
  • the term “substantially solid” as used herein refers to a state in which the fibers do not enter even if the structure is densely packed or there is a void to such an extent that the fibers do not enter.
  • the protrusions 42 and the holes 43 are alternately arranged at equal intervals in the MD direction and the CD direction orthogonal to the MD direction, the protrusions 42 and the holes 43 are orthogonal to each other around the hole 43 and at four locations around the hole 43.
  • the protrusions 42 are arranged at equal intervals.
  • the center of the hole 43 is arranged at the center of the protrusion 42 arranged at the four places. For this reason, since the hole 43 can be present in a sufficient size, the air blown to the support 40 hardly converges on the surface of the plate-like body 41 and is converged in the hole 43. Therefore, the fiber web can be efficiently shaped into a concavo-convex shape.
  • the support body 40 is not configured by knitting a wire, but is an integrated structure support body 40 in which the protrusions 42 and the holes 43 are arranged on the plate-like body 41, and the protrusions 42 are arranged at intervals. For this reason, the fibers do not get caught in a part of the support 40 such as between the protrusions. Further, since the protrusions 42 and the holes 43 are alternately arranged in the MD direction on the surface 41S and the CD direction perpendicular thereto, there is a sufficient distance between the adjacent holes 43. Will not get tangled.
  • the adjacent protrusion rows 44A and 44B are arranged at a distance d1, it is easy to peel the fiber web from the support 40 by setting the protrusion row 44 direction to the MD direction. Therefore, by using the support 40 of the present invention, the peelability of the shaped fiber web is improved, continuous production is possible, and productivity is improved.
  • the surface 41S between the adjacent protrusions 42, between the adjacent holes 43, and between the protrusions 42 and the holes 43 forms a flat surface. For this reason, when air is blown onto the fiber web when shaping the fiber web using the support 40, the fiber web is brought into surface contact with the flat surface 41S while being pushed into the hole 43. The finished non-woven fabric is less likely to fluff.
  • the projection 42 is configured to be long in the direction of the first and second surfaces 42SB and 42SA in plan view.
  • This fiber is oriented along the surface direction of the first and second surfaces 42SB and 42SA, so that the selection of the fibers becomes easy.
  • Wpm / Wpc is preferably 1.1 to 10, more preferably 2 to 4.
  • the width of the protrusion is narrow in the CD direction in that the selection is easy and a huge wind speed is not required at the time of shaping.
  • the base width Wpc to be described later is preferably as small as possible.
  • the base width Wpc is preferably 0.5 to 10 mm, more preferably as a dimension of a preferable protrusion. Is 1 to 5 mm, more preferably 1 to 2 mm.
  • the support 40 is particularly a drum-type nonwoven fabric manufacturing apparatus. When this is applied, the fiber web is smoothly separated from the side surface of the protrusion 42, so that the peelability of the fiber web from the support 40 is improved.
  • the fiber is protruded when the fiber web is shaped by blowing air. It becomes easy to get caught moderately on the roughened surface without sliding down the surface. For this reason, it becomes easy to shape the fiber web into an uneven shape along the surface of the protrusion 42.
  • the protrusion 42 may have a through hole (not shown) penetrating between the first surface 42SA and the second surface 42SB.
  • a through hole (not shown) penetrating between the first surface 42SA and the second surface 42SB.
  • a distance that does not allow the fibers of the fiber web to be entangled through the through hole is necessary. Since it has such a through-hole, the mass of the support body 40 can be made light.
  • the support 40 is made of metal, the effect of reducing the weight is great. As a result, the power for transporting the support can be reduced, and the constituent material of the support 40 can be reduced, thereby achieving energy and resource savings.
  • the shaped nonwoven fabric manufacturing apparatus 101 has a support 40 that transports a fiber web 60 containing thermoplastic fibers.
  • the fiber web 60 is supplied to the surface of the support 40, and is shaped and heat-treated by an air-through method while being placed on the surface of the support 40, and is sent out in a predetermined direction.
  • the support body 40 is constituted by a conveyor, and a conveyer belt 110B having air permeability is supported by rotation support rollers 110R (1100Ra, 110Rb, 110Rc, 110Rd) arranged at four places on both upper and lower ends. It is configured to rotate.
  • the rotation support rollers 110R are not limited to four places, and may be arranged so that the conveyor belt 110B rotates smoothly.
  • the above-described support 40 is arranged on the surface side of the conveyor belt 110B, and a plurality of protrusions 42 and a plurality of holes 43 are alternately arranged on the surface of the support 40 in the MD direction and the CD direction as described above. It is arranged at equal intervals.
  • the support 40 conveys the fiber web 60 so that the fiber web 60 is hooked by the protrusion 42 on the surface side having the protrusion 42 by rotating the conveyor belt 110B supported by the rotation support roller 110R.
  • a first air-through process for injecting high-speed gas (for example, high-speed air) W ⁇ b> 4 that performs shaping processing in order along the supply direction of the fiber web 60 is performed above the protrusions 42 of the support body 40.
  • 1 nozzle 111 and the 2nd nozzle 112 which performs the 2nd air through process which injects hot air W5 and performs heat processing are arranged.
  • the first nozzle 111 injects high-speed air W4, for example, substantially perpendicularly to the surface of the support body 40 on which the protrusions 42 are disposed. It is preferable that the high-speed air W ⁇ b> 4 ejected from the first nozzle 111 is uniformly blown in the width direction of the surface of the fiber web 60.
  • the second nozzle 42 injects hot air W5 heated by a second heater (not shown) onto the surface of the support 40 having the protrusions 42, for example, substantially perpendicularly.
  • the hot air W5 sprayed from the second nozzle 112 is preferably blown at a uniform temperature in the width direction of the surface of the fiber web 60.
  • air heated by the second heater nitrogen, or the like can be used.
  • air that is inexpensive and has high stability and safety when heated is used.
  • a suction unit for discharging high-speed air W4 ejected from the first nozzle 111 and passing through the fiber web 60, the support 40, and the like is disposed.
  • An exhaust device (not shown) for discharging the sucked high-speed air W4 may be connected to the suction portion.
  • a suction section (not shown) is provided for exhausting the hot air W5 ejected from the second nozzle 112 and passed through the fiber web 60, the support 40, and the like.
  • An exhaust device (not shown) for discharging the sucked hot air W5 may be connected to the suction portion. Further, each exhaust device may be connected to each suction unit as one exhaust device.
  • the method for manufacturing a shaped nonwoven fabric according to the seventh embodiment is realized by the aforementioned shaped nonwoven fabric manufacturing apparatus 101.
  • the fiber web 60 is supplied to the upper surface side on which the protrusions 42 of the support 40 are disposed.
  • the fiber material that can be used for the fibers of the fiber web 60 is not particularly limited. Specifically, the same ones as described above can be used.
  • a first air-through process is performed in which high-speed air W4 is blown onto the fiber web 60 to follow the breathable support 40.
  • the high-speed air W4 is blown from the vertical direction on the surface of the support 40 on which the fiber web 60 is placed.
  • the fiber web 60 is shaped into a concavo-convex shape along the shape of the protrusion 42 of the support 40.
  • the high-speed air W4 may be at a temperature at which the fibers of the fiber web 60 are fused to such a degree that the fibers are softened or the uneven shape can be maintained.
  • the temperature of the high-speed air W4 varies depending on the type of fiber, the processing speed, the speed of the hot air, etc., but is not uniquely determined.
  • the sheath is a composite fiber having a core-sheath structure of polyethylene (PE)
  • the temperature is 80 ° C. or higher and 155 ° C. or lower, preferably 120 ° C. or higher and 135 ° C. or lower.
  • the temperature of the high-speed air W4 is too low, the fiber returns and the formability is lowered.
  • the temperature is too high, the fibers are fused at a stretch, and the formability is impaired due to a decrease in the degree of freedom.
  • the high-speed air W4 has a wind speed of 20 m / sec or more and 120 m / sec or less, preferably 40 m / sec or more and 80 m / sec or less. If the wind speed of the high-speed air W4 is too slow, sufficient shaping cannot be performed and the shaping property may be impaired. On the other hand, if the wind speed is too high, the fibers of the fiber web 60 are sorted by the projections 42 and become too shaped. Therefore, the wind speed of the high-speed air W4 is set to the above range.
  • the blowing time of the high-speed air W4 is 0.01 seconds or more and 0.5 seconds or less, preferably 0.04 seconds or more and 0.08 seconds or less. If the spraying time is too short, the fibers of the fiber web 60 are not sufficiently fused to each other, and the uneven shape cannot be sufficiently shaped. On the other hand, if the spraying time is too long, the fusion of the fibers of the fiber web 60 proceeds too much, and the formability is impaired due to a decrease in the degree of freedom.
  • the high-speed air W4 that has passed through the fiber web 60 is discharged from the suction portion to the outside through the hole 43 of the support body 40.
  • the fiber web 60 is conveyed to the blowing position of the hot air W5 of the second nozzle 112 along with the rotation of the conveyor belt 40B of the support 40.
  • a second air through step is performed in which hot air W5 is sprayed from the second nozzle 112 and sprayed onto the fiber web 60, and the fibers are fused together to fix the uneven shape while maintaining the uneven shape of the fiber web 60.
  • the hot air W ⁇ b> 5 is blown from the direction perpendicular to the surface of the fiber web 60.
  • the number of blowouts of the second nozzle 112 is preferably set at a plurality of locations along the feeding direction of the fiber web 60.
  • the temperature of the hot air W5 varies depending on the type of fiber, the processing speed, the speed of the hot air, etc., so it is not uniquely determined.
  • the fiber of the fiber web 60 is a composite fiber having a core-sheath structure of PET and PE as described above.
  • the melting point is not less than the melting point of the low melting point component of the fiber of the fiber web 60 and less than the melting point of the high melting point component of the fiber of the fiber web 60.
  • the temperature is preferably 135 ° C. or higher and 155 ° C. or lower, and more preferably 135 ° C. or higher and 150 ° C. or lower.
  • the hot air W5 is preferably set slower than the wind speed of the high-speed air W4. Specifically, it is 1 m / sec or more and 10 m / sec or less, and more preferably 2 m / sec or more and 8 m / sec or less. If the wind speed of the hot air W5 is too slow, the hot air W5 does not reach the inside of the fiber web 60 and the fibers are not sufficiently fused together. On the other hand, if the wind speed is too high, the fibers of the fiber web 60 are disturbed and the shaped shape is disturbed. Therefore, the wind speed of the hot air W5 is set to the above range.
  • the blowing time of the hot air W5 is 0.03 seconds or more and 5 seconds or less, preferably 0.1 seconds or more and 1 second or less. If the spraying time is too short, the fibers of the fiber web 60 cannot be sufficiently fused together, and it becomes difficult to fix the uneven shape. On the other hand, if the spraying time is too long, the fibers of the fiber web 60 are excessively fused with each other, making it difficult to obtain liquid permeability.
  • the holes 43 disposed on the support 40 are not disturbed by the air blown and the fibers 40 are disturbed. There is no fusing or entanglement between the fibers. Therefore, when the shaped nonwoven fabric having three-dimensional unevenness is effectively used for an absorbent body having a small weight per unit area (density), the fiber web 60 can be shaped into a shaped nonwoven fabric with little liquid residue. In addition, it enables continuous production. By using such a shaped nonwoven fabric for an absorbent article, it is possible to obtain an absorbent article having a good appearance and a good touch.
  • the shaped nonwoven fabric manufacturing apparatus 201 has a support 40 that transports a fiber web 60 containing thermoplastic fibers.
  • the fiber web 60 is supplied to the surface of the support 40 by a feed conveyor (not shown), and the shaped fiber web 60 is fed from the support 40 in a predetermined direction by a guide roller (not shown).
  • the support 40 has a drum shape, and a plurality of protrusions 42 and a plurality of holes 43 are alternately arranged at equal intervals in the MD direction and the CD direction, respectively, on the surface as described above. Since the support body 40 has a drum shape, the surface of the support body 40 excluding the protrusions 42 and the holes 43 is a cylindrical surface, which is a curved surface having a curvature in the MD direction. On the outside where the protrusions 42 of the support body 40 are formed, there are a first nozzle 211 that injects high-speed air W4 and a second nozzle 212 that injects hot air W5 in order along the supply direction of the fiber web 60. It is provided.
  • the first nozzle 211 includes a heater (not shown), and jets high-speed air W4 heated by the heater to the surface of the support 40 on which the protrusions 42 are disposed, for example, substantially perpendicularly at a uniform temperature.
  • the high speed air W4 is 60 ° C. higher than the melting point of the low melting point component of the fiber web 60.
  • the hot air is controlled to a temperature not lower than the low temperature and not higher than 15 ° C. higher than the melting point of the low melting point component.
  • the temperature is controlled to be not less than 50 ° C lower than the melting point of the low melting point component and not more than 10 ° C higher than the melting point of the low melting point component.
  • a preferable temperature range is from 82 ° C. to 142 ° C., more preferably from 132 ° C. to 142 ° C.
  • the temperature of the high-speed air W4 is lower than the temperature lower by 60 ° C. than the melting point of the low melting point component of the fiber of the fiber web 60, the fiber returns and the formability deteriorates.
  • the temperature exceeds 15 ° C. higher than the melting point of the low melting point component of the fiber of the fiber web 60 the fibers are fused at once, and the formability is inferior due to a decrease in the degree of freedom.
  • the wind speed of the high-speed air W4 is appropriately adjusted, but is preferably controlled to a wind speed of 10 m / sec or more and 120 m / sec or less. If the wind speed of the high-speed air W4 blown from the first nozzle 211 is too slow, the fibers do not sufficiently follow the support 40 and the fibers are weakly fused so that they cannot be shaped, resulting in a bulky uneven shape. On the other hand, if the wind speed is too high, the fibers of the fiber web 60 are selected by the protrusions 42, and the fibers do not have an uneven shape along the shape of the support 40 or become a perforated nonwoven fabric. Therefore, the wind speed of the high-speed air W4 is preferably in the above range. More preferably, it is 20 m / sec or more and 80 m / sec or less, and particularly preferably 40 m / sec or more and 60 m / sec or less.
  • the nonwoven fabric manufacturing apparatus 1 described with reference to FIG. 1 can be used.
  • the second nozzle 212 includes a heater (not shown), and injects hot air W5 heated by the heater almost perpendicularly to the surface on which the protrusions 42 of the support 40 are disposed, for example, at a uniform temperature. It is desirable to use a punching metal that is regularly opened in the width direction and the flow direction as the blowing holes of the second nozzle 212.
  • the porosity is preferably 10% or more and 40% or less, more preferably 20% or more and 30% or less.
  • the hot air W5 is blown at a uniform wind speed in the width direction of the surface of the fiber web 60.
  • the hot air W5 air, nitrogen or water vapor heated by the heater (not shown) can be used.
  • air that does not cost is used.
  • the hot air W5 is controlled by a heater (not shown) to a temperature at which the unevenness of the fiber web 60 formed by the high-speed air W4 is held and the fibers of the fiber web 60 are fused to fix the unevenness.
  • a heater not shown
  • the hot air W5 is higher than the melting point of the low melting point component of the fiber of the fiber web 60. It is controlled to be hot air at a temperature below the melting point of the high melting point component of 60 fibers, preferably 40 ° C. or higher than the melting point of the low melting point component.
  • the melting point of the low melting point component is controlled to a temperature not higher than 20 ° C. below this melting point, and the particularly preferable temperature is not less than the melting point of the low melting point component and not higher than 15 ° C. below this melting point.
  • a more preferable temperature range is from 132 ° C. to 152 ° C., particularly preferably from 132 ° C. to 147 ° C. Note that if the temperature of the hot air W5 is lower than the melting point of the low melting point component of the fiber of the fiber web 60, the uneven shape retainability is insufficient. On the other hand, if the temperature is higher than 180 ° C., the texture becomes worse.
  • the wind speed of the hot air W5 blown from the second nozzle 212 is appropriately determined in consideration of its purpose, but is preferably controlled to a wind speed of 1 m / sec or more and 10 m / sec or less. If the wind speed of the hot air W5 blown from the second nozzle 212 is too slow, heat cannot be transferred to the fibers, the fibers will not be fused, and the uneven shape will be insufficiently fixed. On the other hand, if the wind speed is too high, the fiber will be too hot and the texture will tend to be poor. Therefore, the wind speed of the hot air W5 is preferably in the above range. More preferably, it is 1 m / sec or more and 8 m / sec or less, and particularly preferably 2 m / sec or more and 4 m / sec or less.
  • a suction unit (not shown) that sucks high-speed air W4 ejected from the first nozzle 211 through the fiber web 60 and the support 40 is disposed.
  • An exhaust device (not shown) that exhausts the sucked high-speed air W4 is connected to the suction portion.
  • a suction unit (not shown) that sucks hot air W5 ejected from the second nozzle 212 through the fiber web 60 and the support 40 is disposed.
  • An exhaust device (not shown) that exhausts the sucked hot air W5 is connected to the suction portion.
  • each exhaust device may be connected to each suction unit as one exhaust device.
  • the fiber web 60 is fed to the surface of the support 40 on which the protrusions 42 are formed by a feeding unit (not shown).
  • the fiber material that can be used for the fibers of the fiber web 60 is not particularly limited. Specifically, the fiber etc. which were demonstrated by the above-mentioned 7th Embodiment are mentioned.
  • high-speed air W4 is jetted from the first nozzle 211 and sprayed onto the fiber web 60 fed to the surface of the support 40. At this time, the high-speed air W4 is blown from the direction perpendicular to the surface of the support 40.
  • the temperature of the high-speed air W4 at that time may be a temperature at which the fibers are softened or a temporary fusion that allows the fibers of the fiber web 60 to be fused with each other so that the uneven shape can be maintained.
  • the temperature of the hot air varies depending on the type of fiber, the processing speed, the wind speed of the hot air, etc., and thus cannot be uniquely determined.
  • the temperature is preferably controlled around the melting point, preferably 80 ° C. or higher and 150 ° C. or lower, more preferably 120 ° C. or higher and 140 ° C. or lower.
  • the temperature of the high-speed air W4 is too low, the fibers are returned and the formability is deteriorated.
  • the temperature is too high, the fibers are fused at a stretch and the formability is impaired due to a decrease in the degree of freedom. It will be.
  • the wind speed of the high-speed air W4 is appropriately adjusted, but is preferably controlled to a wind speed of 10 m / sec or more and 120 m / sec or less. If the wind speed of the high-speed air W4 blown from the first nozzle 211 is too slow, the fibers do not sufficiently follow the support 40 and the fibers are weakly fused so that they cannot be shaped, resulting in a bulky uneven shape. On the other hand, if the wind speed is too high, the fibers of the web 60 are selected by the projections 42, and the fibers do not have an uneven shape along the shape of the support 40, or become a non-woven fabric with holes. Therefore, the wind speed of the high-speed air W4 is preferably in the above range. More preferably, it is 20 m / sec or more and 80 m / sec or less, and particularly preferably 40 m / sec or more and 60 m / sec or less.
  • the non-woven fabric manufacturing apparatus 1 described with reference to FIG. 1 may be used as the manufacturing apparatus.
  • the high-speed air W4 that has passed through the fiber web 60 is exhausted to the outside by the exhaust device from the suction portion through the hole 43 of the support 40.
  • the fiber web 60 is conveyed to the injection position of the hot air W5 of the second nozzle 212 as the support 40 rotates. And the hot air W5 is sprayed by the 2nd nozzle 212, the fiber of the fiber web 60 is fuse
  • the number of blowouts of the second nozzle 212 is preferably set at a plurality of locations along the feeding direction of the fiber web 60.
  • the open area ratio is preferably 10% or more and 40% or less, and more preferably 20% or more and 30% or less.
  • the hot air W5 is blown at a uniform wind speed in the width direction of the surface of the fiber web 60.
  • air, nitrogen or water vapor heated by the heater can be used.
  • air that does not cost is used.
  • the hot air W5 is controlled by a heater (not shown) to a temperature at which the unevenness of the fiber web 60 formed by the high-speed air W4 is held and the fibers of the fiber web 60 are fused to fix the unevenness.
  • a heater not shown
  • the temperature of the hot air W5 is equal to or higher than the melting point of the low melting point component of the fiber of the fiber web 60.
  • the temperature of the fiber web 60 is controlled to be hot air at a temperature lower than the melting point of the high melting point component of the fiber, preferably 40 ° C. higher than the melting point of the low melting point component.
  • the melting point of the low melting point component is controlled to a temperature not higher than 20 ° C. below this melting point, and the particularly preferable temperature is not less than the melting point of the low melting point component and not higher than 15 ° C. below this melting point.
  • the particularly preferable temperature is not less than the melting point of the low melting point component and not higher than 15 ° C. below this melting point.
  • a more preferable temperature range is controlled to 132 ° C. or more and 152 ° C. or less.
  • it is 132 ° C. or higher and 147 ° C. or lower. Note that if the temperature of the hot air W5 is lower than the melting point of the low melting point component of the fiber of the fiber web 60, the uneven shape retainability is insufficient.
  • the texture becomes worse.
  • the temperature of the hot air W5 is too low, the uneven shape retainability is deteriorated, and when it is too high, the texture is deteriorated and the bulk becomes difficult.
  • the wind speed of the hot air W5 blown from the second nozzle 212 is appropriately determined in consideration of its purpose, but is preferably controlled to a wind speed of 1 m / sec or more and 10 m / sec or less. If the wind speed of the hot air W5 blown from the second nozzle 212 is too slow, heat cannot be transferred to the fibers, the fibers will not be fused, and the uneven shape will be insufficiently fixed. On the other hand, if the wind speed is too high, the fiber will be too hot and the texture will tend to be poor. Therefore, the wind speed of the hot air W5 is preferably in the above range. More preferably, it is 1 m / sec or more and 8 m / sec or less, and particularly preferably 2 m / sec or more and 4 m / sec or less.
  • the shaped fiber web 60 is sent out in a predetermined direction from the support 40 by a guide roller (not shown) as a guide portion.
  • the thickness of the plate-like body 41 is T.
  • the MD direction pitch is Ppm
  • the CD direction pitch is Ppc
  • the protrusion 42 height is H
  • the MD direction protrusion 42 base width is Wpm
  • the CD direction protrusion 42 base width is Wpc.
  • the radius of roundness at the top of the side surface of the projection 42 projected from the CD direction is Rts
  • the radius of roundness at the top of the projection 42 projected from the MD direction is Rt.
  • the inclination angle of the side surface of the protrusion 42 (angle with respect to the normal to the surface 41S of the plate-like body 41) is ⁇ .
  • the pitch in the MD direction is Phm
  • the pitch in the CD direction is Phc
  • the diameter or length in the MD direction of the holes 43 is ⁇ m
  • the diameter or length in the CD direction of the holes 43 is ⁇ c.
  • Lm (hole diameter ⁇ c) ⁇ [(hole pitch Phc) / 2]
  • Lm is preferably ⁇ 0.1 or more and 8 or less, More preferably, it is 0 or more and 3 or less, and particularly preferably 0 or more and 1 or less.
  • the opening ratio R of the holes 43 was expressed as a percentage (%) obtained by dividing the total area of the holes 43 within a predetermined area on the surface 41S by the predetermined area.
  • the support body 40 of Example 31 is an integrally formed metal (for example, aluminum).
  • the protrusions 42 and the holes 43 are alternately arranged in the MD direction and the CD direction, the protrusions 42 are arranged at equal intervals, and the holes 43 are arranged at equal intervals.
  • the distance between the bases of the protrusions is 1.8 mm.
  • Example 43 Similar to Example 41.
  • the comparative example 31 is an integrally formed product made of aluminum.
  • a number of holes are arranged between the protrusions.
  • the support is disclosed in Patent Document 6.
  • the gap between the protrusions is 1.0 mm.
  • the arrangement pattern of the holes is a square.
  • Comparative Example 32 is a support disclosed in Patent Document 1.
  • a steel wire rod with a diameter of about 1.5 mm is provided in a net with a knuckle part (convex part).
  • the height (equivalent to H) from the tip of the convex part to the back side base part of the net is 5.0 mm
  • the opening is a parallelogram type
  • the base of the parallelogram in the CD direction is 1.5 mm
  • the height of the parallelogram in the MD direction is 1.5 mm.
  • the evaluation was performed by examining the shapeability of the nonwoven fabric as processability and the performance of the nonwoven fabric as sheet performance.
  • the fiber was evaluated using the PET / PE fiber of 2.2 dtex, 51 mm (ES fiber vision, ETC fiber) under the condition that the basis weight of the nonwoven fabric was 25 gsm ⁇ 1 gsm.
  • the processability “fiber blow-off”, “fiber entanglement”, “texture of shaped nonwoven fabric”, “peelability of nonwoven fabric from support”, “wind speed necessary for shaping” and the like were evaluated.
  • fibers do not blow off means the degree to which the fibers of the fiber web blow off when air is directly blown onto the fiber web placed on the support 40 to form the fiber. evaluated. If the fiber web fibers are not disturbed and shaped without blowing off at all, ⁇ , if the fiber web fibers are slightly disturbed but shaped without blowing, ⁇ , the fiber web fibers will not blow away The case where the fiber was disturbed was represented by ⁇ , and the case where the fiber of the fiber web was blown off was represented by x.
  • Fibers are entangled with parts means that the fibers are not entangled with the support 40 and are not fused, and the fibers are not entangled through the holes 43 and are not fused. The case where there was a problem in continuous production and peeling properties of the nonwoven fabric was shown as x.
  • the texture of the shaped nonwoven fabric was determined by homogeneity when the nonwoven fabric was visually observed. Those that appeared to be uniform with no unevenness and those that appeared to be almost homogeneous were indicated as ⁇ , those that were uneven but overall looked homogeneous were indicated by ⁇ , and those that were uneven and looked totally heterogeneous were indicated as ⁇ .
  • the “peelability of the shaped nonwoven fabric from the support” means that the fiber is not left on the support 40 easily and at a tension equal to or less than 10% elongation without air blowing from the back surface. When the shape can be released without breaking the shape of the non-woven fabric, air blowing from the back surface is necessary, but it is easy to form at a tension equal to or less than 10% without leaving any fibers on the support 40.
  • Wind speed required for shaping records the wind speed when the fiber web reaches the bottom surface of the support under various conditions of temperature of 120 ° C. and web transport speed of 10 / m. . It is preferable that the fiber can be shaped at the lowest possible wind speed in terms of preventing the fibers from being blown off and manufacturing costs.
  • the wind speed was 40 m / sec or less, ⁇ , when the wind speed was higher than 40, 60 m / sec, ⁇ , when larger than 60, 80 m / sec, ⁇ , when larger than 80 m / sec, x.
  • the mesh net of 60% of a hole area ratio was mounted on top, and it added and evaluated suitably so that a fiber might not blow off.
  • the sheet performance is "pattern (uneven shape pattern) sharpness", “longitudinal streaks”, “thickness”, “softness”, “beauty of appearance”, “easy to be crushed when loaded” “Fuzzing” was evaluated.
  • the sharpness of the pattern was evaluated based on the average score of 10 panelists. Five points are given when the irregular shape of the shaped nonwoven fabric is clearly known, four points when the irregular shape of the shaped nonwoven fabric is known, and three points when the irregular shape of the shaped nonwoven fabric is slightly known or partially blurred. And the case where the uneven shape of the shaped nonwoven fabric was unclear was taken as two points. At this time, the average score is 4.5 or more, ⁇ , 3.5 or more and less than 4.5, ⁇ , 2.5 or more and less than 3.5 as ⁇ , and less than 2.5 as x.
  • the “longitudinal streaks” were evaluated based on the average score of 10 panelists.
  • the case where longitudinal stripes are slightly recognized in the nonwoven fabric is three points, and vertical stripes are recognized in the shaped nonwoven fabric (the region where the thickness of the nonwoven fabric is thin is present in the MD direction).
  • the case was 2 points.
  • the average score is 4.5 or more, ⁇ , 3.5 or more and less than 4.5, ⁇ , 2.5 or more and less than 3.5 as ⁇ , and less than 2.5 as x.
  • a KES compression tester (KES FB-3, manufactured by Kato Tech Co., Ltd.) was used to evaluate the compression characteristics of the nonwoven fabric in a normal mode up to 5.0 ⁇ 10 3 Pa.
  • the thickness (T) of 0.05 ⁇ 10 3 Pa) was read from the chart.
  • ⁇ indicates a sufficient thickness (3.5 mm or more)
  • ⁇ indicates a necessary thickness (3.0 mm or more)
  • ⁇ indicates a thickness (2.0 mm or more)
  • thickness Is shown as x (less than 2.0 mm).
  • Softness was judged by touch and suppleness. An average score of 10 panelists was evaluated with 5 points for soft touch and suppleness, 3 points for soft touch, 3 points for softness, and 1 point for softness and lack of suppleness. In this case, the average score was expressed as ⁇ when 4 points or more, ⁇ when 2 points or more and less than 4 points, and ⁇ when less than 2 points.
  • the visual beauty” was evaluated by the average score of 10 panelists. 5 items with regular irregularities on the shaped non-woven fabric and good appearance, 4 items with regular appearance with irregular shapes regularly arranged on the shaped non-woven fabric 3 points where the irregular shape is partially irregularly arranged on the shaped nonwoven fabric and the appearance is slightly inferior, the irregular shape is partially blurred on the shaped nonwoven fabric, or a disordered arrangement It was expressed as two points that were inferior in appearance.
  • the average score is 4.5 or more, ⁇ , 3.5 or more and less than 4.5, ⁇ , 2.5 or more and less than 3.5, and ⁇ or less than 2.5.
  • “Easiness of crushing under load” was evaluated by a ratio of the above-mentioned “thickness” and “thickness under load” described later. “Thickness under load” / “thickness” is 0.5 or more, ⁇ , 0.4 or more and less than 0.5, ⁇ , 0.3 or more and less than 0.4, ⁇ , less than 0.3 It was set as x when it was.
  • the “thickness under load” was evaluated using a KES compression tester (KES FB-3 manufactured by Kato Tech Co., Ltd.) in a normal mode up to 5.0 ⁇ 10 3 Pa, and 3.5 ⁇ 10 3 The thickness at Pa pressurization was read from the chart. As measurement values, three points were measured and the average value was adopted.
  • “Fuzzing” was evaluated based on the average score of 10 panelists. The case where there was no fluffing was represented as 5 points, the case where there was almost no fluffing, 4 points, the case where there was partial fluffing, 3 points, and the case where fluffing was on the entire surface was represented as 2 points. At this time, the average score is 4.5 or more, ⁇ , 3.5 or more and less than 4.5, ⁇ , 2.5 or more and less than 3.5 as ⁇ , and less than 2.5 as x.
  • the unit of all the numerical values described in the table excluding the hole area ratio is mm.
  • the diameter in the CD direction is ⁇ c.
  • the statues overlapped.
  • Each support body 40 of Examples 31 to 45 can obtain the same effects as those of the above-described embodiment. Moreover, since it is an integrally molded product, there is no gap between parts. For this reason, the fibers are sandwiched in the gaps between the components, and the support 40 is soiled and the nonwoven fabric fibers are pulled out by continuous operation, which does not cause unclear patterns or stains.
  • the distance between the protrusion 42 and another adjacent protrusion 42 is 1.8 mm, so that no fibers are caught between the protrusions 42.
  • This distance is 0.5 mm or more, more preferably 1 mm or more, and further preferably 2 mm or more and 5 mm or less. Since the distance between the protrusions 42 pushes the fiber into a narrow place, it determines the ease of molding and the three-dimensional shape of the nonwoven fabric. For example, if the distance between the protrusions 42 is too short, the fibers are sandwiched between the protrusions 42 and are difficult to come off from the support 40.
  • the distance between the protrusions 42 is preferably in the above range. Also, if the height of the protrusion is too low, the shaped nonwoven fabric has poor unevenness, but if it is too high, the protrusion interferes when the shaped nonwoven fabric is peeled off from the support. Prone.
  • the height of the protrusions is preferably in the range of 2 mm to 6 mm, although it depends on the protrusion pitch.
  • the thickness of the nonwoven fabric was thin, the softness was slightly insufficient (evaluation ⁇ ), but fuzz was also noticeable (evaluation ⁇ ). Further, even if the web is held with a net or the like so that the fibers do not move, the air resistance increases due to the small holes through which the air escapes, and enormous wind speed is required for shaping. Moreover, since the overlap length Lm of the projection image of the hole 43 of the support body 40 is negative, the vertical stripe which is a low-density area
  • Comparative Example 32 after forming by blowing air to the fiber web, the fibers are sandwiched at the intersection of the wire rod and the wire rod as the support, or the fibers inside the knuckle portion and the fibers outside are mutually connected. In order to fuse to the substrate, the peelability of the shaped nonwoven fabric from the support is poor (evaluation x). As a result, the pattern was disordered, the appearance was poor (evaluation x), and fluff was produced (evaluation x). When industrial production was considered, continuous production was difficult.
  • the support 40 having the described dimensional shape is used to perform the process of forming irregularities on the fiber web 60. This prevents the fibers of the fiber web 60 from being disturbed, and prevents the fibers from being entangled or fused to the support 40 and the fibers 43 from being fused or entangled through the holes 43 provided in the support 40.
  • a shaped non-woven fabric that has a sufficient thickness, is soft and beautiful, has sufficient strength, does not crush the shaped projections when loaded, and has almost no fuzz.
  • support for producing nonwoven fabric (hereinafter referred to as support) according to the present invention will be described below with reference to FIGS. 19 and 20.
  • the support body 50 of the present invention has a plurality of rod-like bodies 51 arranged in parallel.
  • a plurality of protrusions 52 are arranged between the rod-shaped bodies 51, and lower portions on both sides of the protrusion 52 are connected to the rod-shaped body 51.
  • a rod-like body 51A which is one of the plurality of rod-like bodies 51, another rod-like body 51B adjacent to this rod-like body 51A, a protrusion 52A connected to the rod-like bodies 51A, 51B, and a rod-like shape adjacent to this protrusion 52A.
  • a hole 53 exists in a region surrounded by another protrusion 52B connected to the bodies 51A and 51B.
  • the shape of the hole 53 in plan view may be circular, oval, or polygonal. Preferably, it is circular or oval.
  • the protrusions 52 and the holes 53 are alternately arranged in a first direction (MD direction) orthogonal to the longitudinal direction of the rod-like body 51 and a second direction (CD direction) parallel to the longitudinal direction, and the protrusions 52 are predetermined. They are arranged at regular intervals as intervals. Accordingly, the protrusions 52 are arranged at equal intervals around the hole 53. That is, the hole 53 is disposed at the center position of the four protrusions 52 around the hole 53.
  • the MD direction mentioned above is the machine direction and the feeding direction of the fiber web during the production of the nonwoven fabric
  • the CD direction mentioned above is a direction orthogonal to the MD direction.
  • the plurality of protrusions 52 have a first surface 52SA and a second surface 52SB that face each other.
  • the first surface 52SA and the second surface 52SB may be flat surfaces or curved surfaces.
  • each of the first surfaces 52SA of the respective protrusions faces in the same direction
  • each of the second surfaces 52SB faces in the same direction opposite to the first surface 52SA.
  • the protrusion 52 is long in the direction of the first and second surfaces 52SA and 52SB in plan view, and has a rectangular shape with rounded corners, for example.
  • the shape of the cross section of the protrusion 52 is preferably a rectangle having rounded corners except for the top.
  • first surface 52SA and the second surface 52SB of the protrusion 52 there is a third surface (side surface) 52SC connected to the periphery of each surface, and the outer periphery of the third surface 52SC is the first surface. It is preferable that it exists inside a cycloid curve seeing from the normal line direction (MD direction) of 52SA or 2nd surface 52SB.
  • the protrusion 52 includes a protrusion row 54 (54A) of the protrusion 52 arranged in the surface direction of the first and second surfaces 52SA and 52SB, that is, the MD direction, and another protrusion adjacent in parallel to the protrusion row 54A. It is preferable to have a distance d2 between the row 54 (54B).
  • the fiber web 60 is shaped according to the shape of the support 50, and after the shaping, the peelability from the support 50 is good, the uneven pattern is fine, and the appearance is beautiful.
  • a more preferable range is 1 mm ⁇ d1 ⁇ 3 mm
  • a most preferable range is 1.5 mm ⁇ d1 ⁇ 2.5 mm.
  • the hole 53 preferably has the center of the hole 53 at the center between adjacent protrusions 52 in both the MD direction and the CD direction. And when the said hole 53 projects from MD direction, it is preferable to arrange
  • the value of [diameter ⁇ c of hole 43 or CD direction width] ⁇ [pitch Pcd / 2] is preferably as large as possible, but [pitch Pcd / 2] +0.2 ⁇ [The diameter ⁇ c of the hole 43 or the width in the CD direction] is preferably used.
  • the hole area ratio (area ratio) occupied by the holes 53 is preferably as large as possible so that the gas to be blown out is good, but the hole area ratio is determined in consideration of the strength of the support 50.
  • the aperture ratio is preferably 10% to 50%, more preferably 15% to 40%, still more preferably 20% to 35%, and particularly preferably 30% to 35%.
  • the rod-shaped body 51 of the support 50 is a flat surface.
  • the rod-shaped body 51 may be a round bar, or the rod-shaped body 51 may be a square bar as shown in FIG. Although not shown, it is preferable that the side corners of any rod-like body 51 are rounded.
  • the support 50 of the present invention has the substantially solid first surface 52SA and the substantially solid second surface 52SB facing each other, the fibers enter the protrusion 52 and become entangled. There is no.
  • the term “substantially solid” as used herein refers to a state in which the fibers do not enter even if the structure is densely packed or there is a void to such an extent that the fibers do not enter.
  • the protrusions 52 and the holes 53 are alternately arranged at equal intervals in the MD direction and the CD direction perpendicular to the MD direction, the protrusions 52 and the holes 53 are orthogonal to the hole 53 and at four locations around the hole 53.
  • the protrusions 52 are arranged at equal intervals.
  • the center of the hole 53 is disposed at the center of the protrusion 52 disposed at the four positions. For this reason, since the hole 53 can be present in a sufficient size, the air blown to the support 50 hardly converges on the surface of the support 50 and is converged in the hole 53. Therefore, the fiber web can be efficiently shaped into a concavo-convex shape.
  • the support body 50 is not configured by knitting a wire, but is an integrated structure support body 50 in which protrusions 52 and holes 53 are alternately arranged between rod-like bodies 51, and the protrusions 52 are arranged at intervals.
  • the fibers do not get caught in a part of the support 50 such as between the protrusions 52.
  • the connecting portion between the rod-like body 51 and the protrusion 52 on the hole 53 side is preferably provided with a corner. That is, the corners 53 ⁇ / b> R of the hole 53 in plan view are rounded so that the fibers are less likely to be pinched.
  • the protrusions 52 and the holes 53 are alternately arranged in the MD direction and the CD direction perpendicular to the MD direction, there is a sufficient distance between the adjacent holes 53, so that the fibers may be entangled through the adjacent holes 53. Absent.
  • the fiber web can be easily peeled from the support 50 by setting the protrusion row 54 direction to the MD direction. Therefore, by using the support 50 of the present invention for the production of a shaped nonwoven fabric, the fiber web after shaping is improved and continuous production becomes possible, so that productivity is improved.
  • the upper surface 51S of the rod-like body 51 between the adjacent protrusions 52, between the adjacent holes 53, and between the protrusions 52 and the holes 53 forms a flat surface. For this reason, when air is blown onto the fiber web when the fiber web is shaped using the support 50, the fiber web is brought into surface contact with the flat surface while being pushed into the hole 53. Non-woven fabric is less likely to fluff.
  • the protrusion 52 is configured to be long in the direction of the first and second surfaces 52SB and 52SA in plan view. These fibers are oriented along the surface direction of the first and second surfaces 52SB and 52SA, so that the fibers can be easily selected.
  • Wpm / Wpc is preferably 1.1 to 10, more preferably 2 to 4.
  • the width of the protrusion is narrow in the CD direction in that the selection is easy and a huge wind speed is not required at the time of shaping.
  • the base width Wpc is preferably as small as possible.
  • the base width Wpc is preferably 0.5 to 10 mm, more preferably 1 as a preferable projection size. It is ⁇ 5 mm, more preferably 1 to 2 mm.
  • the fiber web is smoothly separated from the side surface of the protrusion 52. Peelability is improved.
  • the fiber is protruded when the fiber web is shaped by blowing air. It becomes easy to get caught moderately on the roughened surface without sliding down the surface. For this reason, it becomes easy to shape the fiber web into an uneven shape along the surface of the protrusion 52.
  • the protrusion 52 may have a through hole (not shown) penetrating between the first surface 52SA and the second surface 52SB.
  • a through hole (not shown) penetrating between the first surface 52SA and the second surface 52SB.
  • a distance that does not allow the fibers of the fiber web to be entangled through the through hole is necessary. Since it has such a through-hole, the mass of the support body 50 can be lightened.
  • the support 50 is made of metal, the effect of reducing the weight is great. As a result, the power for transporting the support can be reduced, the constituent materials of the support 50 can be reduced, and energy and resource savings can be achieved.
  • the shaped nonwoven fabric manufacturing apparatus 101 has a support 50 that transports a fiber web 60 containing thermoplastic fibers.
  • the fiber web 60 is supplied to the surface of the support 50, and is shaped and heat-treated by an air-through method while being placed on the surface of the support 50, and is sent out in a predetermined direction.
  • the support 50 is constituted by a conveyor, and a conveyer belt 110B having air permeability is supported by rotation support rollers 110R (110Ra, 110Rb, 110Rc, 110Rd) arranged at four positions on both upper and lower ends. It is configured to rotate.
  • the rotation support rollers 110R are not limited to four places, and may be arranged so that the conveyor belt 110B rotates smoothly.
  • the support 50 described above is arranged on the surface side of the conveyor belt 110B, and a plurality of protrusions 52 and a plurality of holes 53 are alternately arranged on the surface of the support 50 in the MD direction and the CD direction as described above. And it is arranged at equal intervals.
  • the support body 50 conveys the fiber web 60 so that the fiber web 60 is latched by the protrusion 52 on the surface side having the protrusion 52 when the conveyor belt 110B is supported by the rotation support roller 110R and rotates.
  • a first air-through process for injecting high-speed gas (for example, high-speed air) W ⁇ b> 4 for shaping is sequentially performed along the supply direction of the fiber web 60 above the protrusions 52 of the support 50.
  • 1 nozzle 111 and the 2nd nozzle 112 which performs the 2nd air through process which injects hot air W5 and performs heat processing are arranged.
  • the first nozzle 111 injects high-speed air W4, for example, substantially perpendicularly to the surface of the support body 50 on which the protrusions 52 are arranged. It is preferable that the high-speed air W ⁇ b> 4 ejected from the first nozzle 111 is uniformly blown in the width direction of the surface of the fiber web 60.
  • the second nozzle 112 injects hot air W5 heated by a second heater (not shown) onto the surface of the support 50 having the protrusions 52, for example, substantially perpendicularly.
  • the hot air W5 sprayed from the second nozzle 112 is preferably blown at a uniform temperature in the width direction of the surface of the fiber web 60.
  • air heated by the second heater nitrogen, or the like can be used.
  • air that is inexpensive and has high stability and safety when heated is used.
  • a suction portion (not shown) that exhausts the high-speed air W4 ejected from the first nozzle 111 and passed through the fiber web 60, the support 50, and the like.
  • An exhaust device (not shown) for discharging the sucked high-speed air W4 may be connected to the suction portion.
  • a suction section (not shown) is provided for exhausting the hot air W5 ejected from the second nozzle 112 and passed through the fiber web 60, the support 50, and the like.
  • An exhaust device (not shown) for discharging the sucked hot air W5 may be connected to the suction portion. Further, each exhaust device may be connected to each suction unit as one exhaust device.
  • the fiber web 60 is supplied to the upper surface side where the protrusions 52 of the support 50 are disposed.
  • the fiber material that can be used for the fibers of the fiber web 60 is not particularly limited. Specifically, the same ones as described above can be used.
  • a first air-through process is performed in which high-speed air W4 is blown onto the fiber web 60 to follow the air-permeable support 50.
  • the high-speed air W4 is blown from the direction perpendicular to the surface of the support 50 on which the fiber web 60 is placed.
  • the fiber web 60 is shaped into a concavo-convex shape along the shape of the protrusion 52 of the support 50 by the high-speed air W4.
  • the high-speed air W4 may have a temperature at which the fibers are softened or a temperature at which the fibers of the fiber web 60 are fused to such an extent that the uneven shape can be maintained.
  • the temperature of the high-speed air W4 varies depending on the type of fiber, the processing speed, the speed of the hot air, etc., but is not uniquely determined.
  • the sheath is a composite fiber having a core-sheath structure of polyethylene (PE)
  • the temperature is 80 ° C. or higher and 155 ° C. or lower, preferably 120 ° C. or higher and 135 ° C. or lower.
  • the temperature of the high-speed air W4 is too low, the fiber returns and the formability is lowered.
  • the temperature is too high, the fibers are fused at a stretch, and the formability is impaired due to a decrease in the degree of freedom.
  • the high-speed air W4 has a wind speed of 20 m / sec or more and 120 m / sec or less, preferably 40 m / sec or more and 80 m / sec or less. If the wind speed of the high-speed air W4 is too slow, sufficient shaping cannot be performed and the shaping property may be impaired. On the other hand, if the wind speed is too high, the fibers of the fiber web 60 are sorted by the protrusions 52 and become too shaped. Therefore, the wind speed of the high-speed air W4 is set to the above range.
  • the blowing time of the high-speed air W4 is 0.01 seconds or more and 0.5 seconds or less, preferably 0.04 seconds or more and 0.08 seconds or less. If the spraying time is too short, the fibers of the fiber web 60 are not sufficiently fused to each other, and the uneven shape cannot be sufficiently shaped. On the other hand, if the spraying time is too long, the fusion of the fibers of the fiber web 60 proceeds too much, and the formability is impaired due to a decrease in the degree of freedom. Then, the high-speed air W4 that has passed through the fiber web 60 is discharged from the suction portion to the outside through the hole 53 of the support 50.
  • the fiber web 60 is conveyed to the blowing position of the hot air W5 of the second nozzle 112 along with the rotation of the conveyor belt 110B of the support 50.
  • a second air through step is performed in which hot air W5 is sprayed from the second nozzle 112 and sprayed onto the fiber web 60, and the fibers are fused together to fix the uneven shape while maintaining the uneven shape of the fiber web 60.
  • the hot air W ⁇ b> 5 is blown from the direction perpendicular to the surface of the fiber web 60.
  • the number of blowouts of the second nozzle 112 is preferably set at a plurality of locations along the feeding direction of the fiber web 60.
  • the temperature of the hot air W5 varies depending on the type of fiber, the processing speed, the speed of the hot air, etc., so it is not uniquely determined.
  • the fiber of the fiber web 60 is a composite fiber having a core-sheath structure of PET and PE as described above.
  • the melting point is not less than the melting point of the low melting point component of the fiber of the fiber web 60 and less than the melting point of the high melting point component of the fiber of the fiber web 60.
  • the temperature is preferably 135 ° C. or higher and 155 ° C. or lower, and more preferably 135 ° C. or higher and 150 ° C. or lower.
  • the hot air W5 is preferably set slower than the wind speed of the high-speed air W4. Specifically, it is 1 m / sec or more and 10 m / sec or less, and more preferably 2 m / sec or more and 8 m / sec or less. If the wind speed of the hot air W5 is too slow, the hot air W5 does not reach the inside of the fiber web 60 and the fibers are not sufficiently fused together. On the other hand, if the wind speed is too high, the fibers of the fiber web 60 are disturbed and the shaped shape is disturbed. Therefore, the wind speed of the hot air W5 is set to the above range.
  • the blowing time of the hot air W5 is 0.03 seconds or more and 5 seconds or less, preferably 0.1 seconds or more and 1 second or less. If the spraying time is too short, the fibers of the fiber web 60 cannot be sufficiently fused together, and it becomes difficult to fix the uneven shape. On the other hand, if the spraying time is too long, the fibers of the fiber web 60 are excessively fused with each other, making it difficult to obtain liquid permeability.
  • the shaped nonwoven fabric having three-dimensional unevenness can be formed into a shaped nonwoven fabric having a small weight per unit area (density) and effectively having a small thickness (less liquid residue when used in an absorbent body). Excellent shape and enables continuous production.
  • a shaped nonwoven fabric for an absorbent article it is possible to obtain an absorbent article having a good appearance and a good touch.
  • the shaped nonwoven fabric manufacturing apparatus 201 has a support 50 that transports a fiber web 60 containing thermoplastic fibers.
  • the fiber web 60 is supplied to the surface of the support 50 by a feed conveyor (not shown), and the shaped fiber web 60 is fed from the support 50 in a predetermined direction by a guide roller (not shown).
  • the support 50 has a drum shape, and a plurality of protrusions 52 and a plurality of holes 53 are alternately arranged at equal intervals in the MD direction and the CD direction on the surface thereof, as described above. Since the support body 50 has a drum shape, the surface of the support body 50 excluding the protrusions 52 and the holes 13 is a cylindrical surface, which is a curved surface having a curvature in the MD direction. On the outside where the protrusions 52 of the support 50 are formed, there are a first nozzle 211 that injects high-speed air W4 and a second nozzle 212 that injects hot air W5 in order along the direction in which the fiber web 60 is supplied. It is provided.
  • the first nozzle 211 includes a heater (not shown), and jets the high-speed air W4 heated by the heater to the surface of the support body 50 on which the protrusions 52 are disposed, for example, substantially perpendicularly at a uniform temperature.
  • the high speed air W4 is 60 ° C. higher than the melting point of the low melting point component of the fiber web 60.
  • the hot air is controlled to a temperature not lower than the low temperature and not higher than 15 ° C. higher than the melting point of the low melting point component.
  • the temperature is controlled to be not less than 50 ° C lower than the melting point of the low melting point component and not more than 10 ° C higher than the melting point of the low melting point component.
  • a preferable temperature range is from 82 ° C. to 142 ° C., more preferably from 132 ° C. to 142 ° C.
  • the temperature of the high-speed air W4 is lower than the temperature lower by 60 ° C. than the melting point of the low melting point component of the fiber of the fiber web 60, the fiber returns and the formability deteriorates.
  • the temperature exceeds 15 ° C. higher than the melting point of the low melting point component of the fiber of the fiber web 60 the fibers are fused at once, and the formability is inferior due to a decrease in the degree of freedom.
  • the wind speed of the high-speed air W4 is appropriately adjusted, but is preferably controlled to a wind speed of 10 m / sec or more and 120 m / sec or less. If the wind speed of the high-speed air W4 blown from the first nozzle 211 is too slow, the fibers do not sufficiently follow the support 50 and the fibers are weakly fused so that they cannot be shaped, resulting in a bulky uneven shape. On the other hand, if the wind speed is too high, the fibers of the fiber web 60 are selected by the protrusions 52, and the fibers do not have an uneven shape along the shape of the support 50 or become a perforated nonwoven fabric. Therefore, the wind speed of the high-speed air W4 is preferably in the above range. More preferably, it is 20 m / sec or more and 80 m / sec or less, and particularly preferably 40 m / sec or more and 60 m / sec or less.
  • the nonwoven fabric manufacturing apparatus 1 described with reference to FIG. 1 can be used.
  • the second nozzle 212 includes a heater (not shown), and injects hot air W5 heated by the heater almost perpendicularly to the surface on which the protrusions 52 of the support 50 are disposed, for example, at a uniform temperature. It is desirable to use a punching metal that is regularly opened in the width direction and the flow direction as the blowing holes of the second nozzle 212.
  • the porosity is preferably 10% or more and 40% or less, more preferably 20% or more and 30% or less.
  • the hot air W5 is blown at a uniform wind speed in the width direction of the surface of the fiber web 60.
  • air W5 air, nitrogen or water vapor heated by the heater (not shown) can be used.
  • air that does not cost is used.
  • the hot air W5 is controlled by a heater (not shown) to a temperature at which the unevenness of the fiber web 60 formed by the high-speed air W4 is held and the fibers of the fiber web 60 are fused to fix the unevenness.
  • a heater not shown
  • the hot air W5 is higher than the melting point of the low melting point component of the fiber of the fiber web 60. It is controlled to be hot air at a temperature below the melting point of the high melting point component of 60 fibers, preferably 40 ° C. or higher than the melting point of the low melting point component.
  • the melting point of the low melting point component is controlled to a temperature not higher than 20 ° C. below this melting point, and the particularly preferable temperature is not less than the melting point of the low melting point component and not higher than 15 ° C. below this melting point.
  • a more preferable temperature range is from 132 ° C. to 152 ° C., particularly preferably from 132 ° C. to 147 ° C. Note that if the temperature of the hot air W5 is lower than the melting point of the low melting point component of the fiber of the fiber web 60, the uneven shape retainability is insufficient. On the other hand, if the temperature is higher than 180 ° C., the texture becomes worse.
  • the wind speed of the hot air W5 blown from the second nozzle 212 is appropriately determined in consideration of its purpose, but is preferably controlled to a wind speed of 1 m / sec or more and 10 m / sec or less. If the wind speed of the hot air W5 blown from the second nozzle 212 is too slow, heat cannot be transferred to the fibers, the fibers will not be fused, and the uneven shape will be insufficiently fixed. On the other hand, if the wind speed is too high, the fiber will be too hot and the texture will tend to be poor. Therefore, the wind speed of the hot air W5 is preferably in the above range. More preferably, it is 1 m / sec or more and 8 m / sec or less, and particularly preferably 2 m / sec or more and 4 m / sec or less.
  • a suction unit (not shown) that sucks high-speed air W4 ejected from the first nozzle 211 through the fiber web 60 and the support 50 is arranged.
  • An exhaust device (not shown) that exhausts the sucked high-speed air W1 is connected to the suction portion.
  • a suction unit (not shown) that sucks hot air W5 ejected from the second nozzle 212 through the fiber web 60 and the support 50 is disposed.
  • An exhaust device (not shown) that exhausts the sucked hot air W5 is connected to the suction portion.
  • each exhaust device may be connected to each suction unit as one exhaust device.
  • the method for manufacturing a shaped nonwoven fabric according to the tenth embodiment is realized by the aforementioned shaped nonwoven fabric manufacturing apparatus 201.
  • the fiber web 60 is fed to the surface of the support 50 on which the protrusions 52 are formed by a feeding unit (not shown).
  • the fiber material that can be used for the fibers of the fiber web 60 is not particularly limited. Specifically, the fiber etc. which were demonstrated by the above-mentioned 9th Embodiment are mentioned.
  • high-speed air W4 is jetted from the first nozzle 211 and sprayed onto the fiber web 60 fed to the surface of the support 50.
  • the high-speed air W ⁇ b> 4 is blown from the direction perpendicular to the surface of the support 50.
  • the temperature of the high-speed air W4 at that time may be a temperature at which the fibers are softened or a temperature at which the fibers of the fiber web 60 can be temporarily fused so that the uneven shape can be maintained.
  • the temperature of the hot air varies depending on the type of fiber, the processing speed, the wind speed of the hot air, etc., and thus cannot be uniquely determined.
  • the temperature is preferably controlled around the melting point, preferably 80 ° C. or higher and 150 ° C. or lower, more preferably 120 ° C. or higher and 140 ° C. or lower.
  • the temperature of the high-speed air W4 is too low, the fibers are returned and the formability is deteriorated.
  • the temperature is too high, the fibers are fused at a stretch and the formability is impaired due to a decrease in the degree of freedom. It will be.
  • the wind speed of the high-speed air W4 is appropriately adjusted, but is preferably controlled to a wind speed of 10 m / sec or more and 120 m / sec or less. If the wind speed of the high-speed air W4 blown from the first nozzle 211 is too slow, the fibers do not sufficiently follow the support 50 and the fibers are weakly fused so that they cannot be shaped, resulting in a bulky uneven shape. On the other hand, if the wind speed is too high, the fibers of the fiber web 60 are selected by the protrusions 52, and the fibers do not have an uneven shape along the shape of the support 50 or become a perforated nonwoven fabric. Therefore, the wind speed of the high-speed air W4 is preferably in the above range. More preferably, it is 20 m / sec or more and 80 m / sec or less, and particularly preferably 40 m / sec or more and 60 m / sec or less.
  • the nonwoven fabric manufacturing apparatus 1 described with reference to FIG. 1 can be used.
  • the high-speed air W4 that has passed through the fiber web 60 is exhausted to the outside from the suction portion through the hole 53 of the support 50 by the exhaust device.
  • the fiber web 60 is conveyed to the injection position of the hot air W5 of the second nozzle 212 along with the rotation of the support 50. And the hot air W5 is sprayed by the 2nd nozzle 212, the fiber of the fiber web 60 is fuse
  • the number of blowouts of the second nozzle 212 is preferably set at a plurality of locations along the feeding direction of the fiber web 60.
  • the open area ratio is preferably 10% or more and 40% or less, and more preferably 20% or more and 30% or less.
  • the hot air W5 is blown at a uniform wind speed in the width direction of the surface of the web 60.
  • air, nitrogen or water vapor heated by the heater can be used.
  • air that does not cost is used.
  • the hot air W5 is controlled by a heater (not shown) to a temperature at which the unevenness of the fiber web 60 formed by the high-speed air W4 is held and the fibers of the fiber web 60 are fused to fix the unevenness.
  • a heater not shown
  • the temperature of the hot air W5 is equal to or higher than the melting point of the low melting point component of the fiber of the fiber web 60.
  • the temperature of the fiber web 60 is controlled to be hot air at a temperature lower than the melting point of the high melting point component of the fiber, preferably 40 ° C. higher than the melting point of the low melting point component.
  • the melting point of the low melting point component is controlled to a temperature not higher than 20 ° C. below this melting point, and the particularly preferable temperature is not less than the melting point of the low melting point component and not higher than 15 ° C. below this melting point.
  • the particularly preferable temperature is not less than the melting point of the low melting point component and not higher than 15 ° C. below this melting point.
  • a more preferable temperature range is controlled to 132 ° C. or more and 152 ° C. or less.
  • it is 132 ° C. or higher and 147 ° C. or lower. Note that if the temperature of the hot air W5 is lower than the melting point of the low melting point component of the fiber of the fiber web 60, the uneven shape retainability is insufficient.
  • the texture becomes worse.
  • the temperature of the hot air W5 is too low, the uneven shape retainability is deteriorated, and when it is too high, the texture is deteriorated and the bulk becomes difficult.
  • the wind speed of the hot air W5 blown from the second nozzle 212 is appropriately determined in consideration of its purpose, but is preferably controlled to a wind speed of 1 m / sec or more and 10 m / sec or less. If the wind speed of the hot air W5 blown from the second nozzle 212 is too slow, heat cannot be transferred to the fibers, the fibers will not be fused, and the uneven shape will be insufficiently fixed. On the other hand, if the wind speed is too high, the fiber will be too hot and the texture will tend to be poor. Therefore, the wind speed of the hot air W5 is preferably in the above range. More preferably, it is 1 m / sec or more and 8 m / sec or less, and particularly preferably 2 m / sec or more and 4 m / sec or less.
  • the shaped fiber web 60 is sent out in a predetermined direction from the support 50 by a guide roller (not shown) as a guide portion.
  • the present invention further discloses the following embodiments and manufacturing methods.
  • ⁇ 1> A method for producing a nonwoven fabric in which a web containing thermoplastic fibers is conveyed on a support having an uneven shape, and hot air is blown from the top of the web toward the support to shape the uneven shape on the web.
  • the fiber of the web is a composite fiber having a low melting point component and a high melting point component having a higher melting point than the low melting point component, The method for producing a nonwoven fabric according to ⁇ 1>, wherein the first hot air is hot air having a temperature not lower than 60 ° C.
  • the second hot air is hot air having a melting point equal to or higher than a low melting point component of the web fiber and lower than a melting point of the high melting point component.
  • the second hot air has a temperature not lower than the melting point of the low melting point component of the web fiber and lower than the melting point of the high melting point component of the web fiber, preferably 40 ° C. or higher than the melting point of the low melting point component. It is controlled by hot air.
  • the melting point is not less than the melting point of the low melting point component and not more than 20 ° C. above the melting point, and particularly preferably, the melting point is not less than the melting point of the low melting point component and not more than 15 ° C. below the melting point.
  • ⁇ 6> The method for producing a nonwoven fabric according to any one of ⁇ 2> to ⁇ 5>, wherein the composite fiber uses polyethylene as the low melting point component and uses polyethylene terephthalate or polylactic acid as the high melting point component.
  • the conjugate fiber uses a fiber having a core-sheath structure in which a core part is polyethylene terephthalate and a sheath part is polyethylene.
  • the first hot air preferably has a temperature range of 82 ° C. or higher and 142 ° C. or lower, more preferably 132 ° C.
  • the manufacturing method of the nonwoven fabric any one of ⁇ 7>. ⁇ 9>
  • the second hot air has a more preferable temperature range of 132 ° C. to 152 ° C., particularly preferably 132 ° C. to 147 ° C.
  • the manufacturing method of the nonwoven fabric any one of ⁇ 8>.
  • ⁇ 11> The method for producing a nonwoven fabric according to any one of ⁇ 1> to ⁇ 10>, wherein the support has a rotatable drum shape.
  • the web is a ventilated conveyor having air permeability arranged to face the support and the support surface when the first hot air is blown or when the first and second hot air is blown.
  • ⁇ 1> to ⁇ 11> wherein the first hot air or the first and second hot air is blown onto the web through the ventilation conveyor.
  • Manufacturing method of non-woven fabric ⁇ 13> The web according to any one of ⁇ 1> to ⁇ 12>, wherein a cooling gas is blown to the web after the second hot air is blown to cool the web, and the web is peeled off from the support.
  • the preceding air-through process is: A first air-through process in which a first hot air is blown onto the web while the web is transported along the surface of the support, and the web follows the uneven shape of the support; and A second air-through step of fusing the fibers of the web by blowing a second hot air in a state where the web is shaped into an uneven shape, In the subsequent air-through step, a third hot air having a wind speed slower than that of the first hot air and a wind speed at which the fluff fibers of the web are laid is blown onto the cooled web.
  • ⁇ 13> to ⁇ 15> The manufacturing method of the nonwoven fabric of any one.
  • ⁇ 17> The method for producing a nonwoven fabric according to any one of ⁇ 1> to ⁇ 16>, wherein the second hot air is slower than a wind speed of the first hot air.
  • ⁇ 18> The method for producing a nonwoven fabric according to any one of ⁇ 13> to ⁇ 18>, wherein after the second air-through step, the web is peeled from the support and then the latter air-through step is performed.
  • any one of ⁇ 15> to ⁇ 18> is performed, in which the web is peeled off from the support and then the subsequent air-through step is performed on a different support.
  • the manufacturing method of the nonwoven fabric as described in description.
  • ⁇ 20> The method for producing a nonwoven fabric according to any one of ⁇ 15> to ⁇ 19>, wherein the third hot air is blown onto a surface opposite to the surface of the web on which the second hot air is blown.
  • the fiber of the web is a composite fiber having a core-sheath structure in which a low melting point component is a sheath and a high melting point component is a core.
  • the temperature of said 3rd hot air is a manufacturing method of the nonwoven fabric any one of ⁇ 16> to ⁇ 20> set to the temperature more than melting
  • a web containing thermoplastic fibers is transported onto a support having a plurality of protrusions and a plurality of holes, and hot air is blown to form a concavo-convex shape on the web along the support.
  • a method for producing a nonwoven fabric comprising: For the support, A plate-like body, a plurality of protrusions arranged on the surface of the plate-like body, and a plurality of holes penetrating from the surface to the back surface facing the surface, The protrusions and the holes are alternately arranged in a first direction on the surface and a second direction orthogonal to the first direction, and the protrusions are spaced apart from each other, and the protrusions are opposed to the first surface and the second surface.
  • the manufacturing method of the nonwoven fabric using what has a surface.
  • a web containing thermoplastic fibers is transported onto a support having a plurality of protrusions and a plurality of holes and blown with hot air, and the web is shaped along the support to form an uneven shape.
  • a method for producing a nonwoven fabric comprising: For the support, In a region surrounded by a plurality of rod-shaped bodies arranged in parallel, a plurality of projections arranged between the rod-shaped bodies, and the projections adjacent between the adjacent rod-shaped bodies and in the longitudinal direction of the rod-shaped body Have existing holes, The protrusions and the holes are alternately arranged in a first direction and a second direction perpendicular thereto, and the protrusions are spaced apart from each other, and the protrusions have first and second surfaces facing each other.
  • the manufacturing method of the nonwoven fabric using a thing ⁇ 24> The method for producing a nonwoven fabric according to ⁇ 1> to ⁇ 23>, wherein the support has a plurality of protrusions that are concave and convex portions and a plurality of ventilation portions that are recesses on a surface thereof. ⁇ 25> The method for producing a nonwoven fabric according to any one of ⁇ 24>, wherein the protruding portions and the ventilation portions are alternately arranged in the longitudinal and lateral directions of the support. ⁇ 26> The method for producing a nonwoven fabric according to any one of ⁇ 24> or ⁇ 25>, wherein the protruding portion has a shape that tapers toward the tip, and the tip is rounded. .
  • ⁇ 27> The method for producing a nonwoven fabric according to any one of ⁇ 1> to ⁇ 26>, wherein the protruding portion has a plate shape or a spindle shape.
  • ⁇ 28> The method for manufacturing a nonwoven fabric according to any one of ⁇ 24> to ⁇ 27>, wherein the ventilation portion includes a plurality of openings formed in the support.
  • ⁇ 29> The method for producing a nonwoven fabric according to ⁇ 28>, wherein an opening ratio of the opening is set to 20% to 45% with respect to a surface area of the support.
  • the opening ratio is preferably 25% or more and 40% or less, and more preferably 30% or more and 35% or less.
  • ⁇ 31> The nonwoven fabric according to any one of ⁇ 1> to ⁇ 30>, which includes a step of blowing a first hot air and a step of blowing a second hot air in order along a supply direction of the web.
  • ⁇ 32> Any one of ⁇ 1> to ⁇ 33>, wherein a first nozzle that blows the first hot air and a second nozzle that blows the second hot air are provided in order along the web supply direction.
  • ⁇ 33> The method for producing a nonwoven fabric according to any one of ⁇ 1> to ⁇ 32>, wherein the first hot air is blown perpendicularly to the surface of the support.
  • the wind speed of the first hot air is preferably 10 m / sec or more and 120 m / sec or less, more preferably 20 m / sec or more and 80 m / sec or less, and particularly preferably 40 m / sec or more and 60 m / sec or less.
  • the manufacturing method of the nonwoven fabric any one of ⁇ 33>.
  • ⁇ 35> The method for producing a nonwoven fabric according to any one of ⁇ 1> to ⁇ 34>, wherein the second hot air is blown perpendicularly to the surface of the support.
  • ⁇ 36> The method for producing a nonwoven fabric according to any one of ⁇ 1> to ⁇ 35>, wherein the blowing holes of the second nozzle use punching metal that is regularly opened in the width direction and the flow direction.
  • the wind speed of the second hot air is 1 m / sec or more and 10 m / sec or less, more preferably 1 m / sec or more and 8 m / sec or less, and particularly preferably 2 m / sec or more and 4 m / sec or less.
  • ⁇ 38> The nonwoven fabric according to any one of ⁇ 1> to ⁇ 37>, wherein the basis weight of the web is preferably 10 g / m 2 or more and 50 g / m 2 or less, and 20 g / m 2 or more and 40 g / m 2 or less.
  • a support having a protruding portion and a ventilation portion, and carrying a web containing thermoplastic fibers on the surface having the protruding portion, and a nozzle for blowing hot air along the web to the support
  • the nozzle includes a first nozzle that blows first hot air, and a second nozzle that blows second hot air having a temperature higher than that of the first hot air,
  • the first nozzle temporarily fuses the fibers of the web to each other so that the uneven shape is maintained by blowing the first hot air
  • the said 2nd nozzle is a manufacturing apparatus of the nonwoven fabric which fuses the fibers of the said web and fixes the said uneven
  • ⁇ 41> a cooling unit that cools the shaped web to a temperature lower than the melting point of the thermoplastic fiber;
  • ⁇ 42> a plate-like body; A plurality of protrusions disposed on the surface of the plate-like body; A plurality of holes penetrating from the front surface to the back surface facing the surface; The protrusions and the holes are alternately arranged in a first direction on the surface and in a second direction perpendicular thereto, and the protrusions are arranged at a predetermined interval.
  • a support for producing a nonwoven fabric having two surfaces.
  • ⁇ 43> a plurality of rods arranged in parallel; A plurality of protrusions disposed between the rod-shaped bodies; A hole existing in a region surrounded by the protrusions adjacent to each other between the adjacent rod-shaped bodies and in the longitudinal direction of the rod-shaped bodies; The protrusions and the holes are alternately arranged in a first direction and a second direction perpendicular thereto, and the protrusions are arranged at a predetermined interval, and the protrusions have a first surface and a second surface facing each other.
  • the support body for nonwoven fabric manufacture which has.
  • ⁇ 44> The support for producing a nonwoven fabric according to ⁇ 43>, wherein the upper surface of the rod-shaped body is a flat surface.
  • ⁇ 45> The support for manufacturing a nonwoven fabric according to any one of ⁇ 42> to ⁇ 44>, wherein the protrusion is configured to be long in a plan view and the first and second surface directions.
  • ⁇ 46> ⁇ 42> to ⁇ 45> having a space between a protrusion row of the protrusions arranged in the surface direction of the first and second surfaces and another protrusion row adjacent in parallel to the protrusion row.
  • ⁇ 47> The support for nonwoven fabric production according to any one of ⁇ 42> to ⁇ 46>, wherein the surfaces between the protrusions, between the holes, and between the protrusions and the holes are flat.
  • the protrusion has a third surface connected to each surface between the first surface and the second surface,
  • the dimension of each part of the support body 50 is demonstrated below.
  • T be the thickness of the rod-shaped body 51.
  • the MD direction pitch is Ppm
  • the CD direction pitch is Ppc
  • the protrusion 52 height is H
  • the MD direction protrusion 52 base width is Wpm
  • the CD direction protrusion 52 base width is Wpc.
  • the round radius of the top of the side surface of the projection 52 projected from the CD direction is Rts
  • the round radius of the top of the projection 52 projected from the MD direction is Rt.
  • the shape of the side surface of the projection 52 projected from the MD direction is a curve.
  • the MD direction pitch is Phm
  • the CD direction pitch is Phc
  • the hole 53 MD direction length (or diameter) is ⁇ m
  • the hole 53 CD direction length (or diameter) is ⁇ c.
  • Lm is preferably ⁇ 0.1 or more and 8 or less, More preferably, it is 0 or more and 3 or less, and particularly preferably 0 or more and 1 or less.
  • the opening ratio R of the holes 53 was expressed as a percentage (%) obtained by dividing the total area of the holes 53 within a predetermined area in plan view by the predetermined area.
  • Examples 51-60 The support body 50 of Example 51 is integrally molded.
  • the protrusions 52 and the holes 53 are alternately arranged in the MD direction and the CD direction, the protrusions 52 are arranged at equal intervals, and the holes 53 are arranged at equal intervals.
  • the shape of the protrusion 52 as viewed from the CD direction is a generally triangular shape having a rounded end
  • the shape of the protrusion 52 as viewed from the MD direction is a generally rectangular shape having a rounded corner.
  • the outer shape excluding the top of the projection 52 projected from the CD direction is also a shape having a curvature.
  • the cross-sectional shape of the rod-shaped body 51 is a circular shape having a diameter of 3 mm.
  • the distance between the bases of the protrusions is 1.8 mm.
  • Comparative Example 51 is a support disclosed in Patent Document 6, and is the same as Comparative Example 31 described above.
  • Comparative Example 52 is a support disclosed in Patent Document 1, and is the same as Comparative Example 32 described above.
  • the evaluation was performed by examining the shapeability of the nonwoven fabric as processability and the performance of the nonwoven fabric as sheet performance.
  • the fibers used were 2.2 dtex PET / PE fibers and those having a fiber length of 51 mm (ES fiber vision, ETC fibers).
  • the nonwoven fabric was evaluated under the condition that the basis weight of the nonwoven fabric was 25 gsm ⁇ 1 gsm.
  • processability “fiber blow-off”, “fiber entanglement”, “texture of shaped nonwoven fabric”, “peelability of nonwoven fabric from support”, “wind speed necessary for shaping” and the like were evaluated.
  • the sheet performance is "pattern (uneven shape pattern) sharpness", “longitudinal streaks”, “thickness”, “softness”, “beauty of appearance”, “easy to be crushed when loaded” “Fuzzing” was evaluated.
  • Each evaluation item was evaluated by the same method as the above-described evaluation method, and the same criteria as the above-described evaluation criteria were used for the evaluation.
  • the respective supports 50 of Examples 51 to 56 obtained good results (evaluation of ⁇ or ⁇ ) in any evaluation item.
  • a non-woven fabric can be made.
  • the respective supports 50 in Examples 51 to 60 can obtain the same effects as those of the above-described embodiment.
  • it since it is an integrally molded product, there is no gap between parts, so fibers are caught in the gap between parts, the support 50 is soiled by continuous operation, the fibers of the shaped nonwoven fabric are pulled out, and the pattern is unclear. It will not cause dirt.
  • Comparative Example 52 after forming by blowing air on the fiber web, the fibers are sandwiched at the intersection of the wire rod and the wire rod as the support, or the fibers inside the knuckle portion and the fibers outside are mutually attached. As a result, the shaped nonwoven fabric peeled off from the support was poor (evaluation x). As a result, the pattern was disordered, the appearance was poor (evaluation x), and fluff was generated (evaluation x). When industrial production was considered, continuous production was difficult.
  • the fibers 50 of the fiber web 60 are disturbed by performing the process of forming irregularities on the fiber web 60 using the respective support bodies 50 having the dimensions and shapes described in the above-described Examples 51 to 60. Without losing the fiber through the holes 53 provided in the support 50 and preventing the fibers from being entangled and entangled, ensuring a uniform and sufficient thickness, being soft and beautiful, having sufficient strength, It is possible to produce a shaped nonwoven fabric in which the shape convex portions are hardly crushed and have almost no fuzz.
  • Nonwoven fabric manufacturing apparatus 10 30 Support (first support) 11, 31 1st nozzle 12, 32 2nd nozzle 13, 14 Heater 15, 16, 35, 36, 37 Suction part 17, 18 Exhaust device 19 Cooling nozzle 21 Feeding part 22 Guide part 23 Aeration conveyor 33 Third nozzle 34 Cooling unit 34N Cooling nozzle 34R Cooling unit roller 38
  • Another support (second support) 40 50 Support body 41 Plate-like body 41S Front surface 41B Back surface 42, 52, 53A, 52B Protrusion 42SA, 52SA First surface 42SB, 52SB Second surface 42SC, 52SC Third surface (side surface) 43, 53 hole 44, 44A, 44B, 54, 54A, 54B Projection row 51 Rod-like body 51S Upper surface 60 Web (fiber web) d1, d2 spacing (protrusion row spacing)

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

L'invention concerne un procédé permettant de produire des non-tissés, un voile contenant des fibres thermoplastiques étant porté sur un support de forme concavo-convexe (saillies et fentes) et de l'air chaud étant soufflé du dessus du voile vers le support de manière à créer la forme concavo-convexe sur le voile (5). Le soufflage à l'air chaud comprend : une étape consistant à souffler un premier air chaud, et à lier de façon temporaire par fusion les fibres du voile par le soufflage du premier air chaud de façon à maintenir la forme concavo-convexe ; et une étape consistant à souffler un second air chaud présentant une température supérieure au premier air chaud, et à fixer la forme concavo-convexe par liaison par fusion des fibres du voile pendant que la forme concavo-convexe est maintenue de sorte que la forme concavo-convexe est produite sur le voile alors que le voile suit la forme du support.
PCT/JP2011/079840 2010-12-24 2011-12-22 Procédé permettant de produire un non-tissé, non-tissé, dispositif de production d'un non-tissé, et support permettant de produire un non-tissé WO2012086766A1 (fr)

Priority Applications (1)

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CN201180061168.8A CN103261503B (zh) 2010-12-24 2011-12-22 无纺布及其制造方法和装置、以及无纺布制造用支承体

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JP2010287969A JP5756627B2 (ja) 2010-12-24 2010-12-24 賦形不織布の製造方法および賦形不織布の製造装置
JP2010-287968 2010-12-24
JP2010287968 2010-12-24
JP2010-287969 2010-12-24
JP2010291845 2010-12-28
JP2010-291844 2010-12-28
JP2010291844 2010-12-28
JP2010-291845 2010-12-28
JP2011-267096 2011-12-06
JP2011267096A JP5827555B2 (ja) 2010-12-24 2011-12-06 不織布の製造方法、不織布および不織布の製造装置

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20200100956A1 (en) * 2018-09-27 2020-04-02 The Procter & Gamble Company Nonwoven webs with visually discernible patterns
CN111705424A (zh) * 2020-06-30 2020-09-25 福建雷尔新材料有限公司 一种高吸液亲肤干爽型热风无纺布及其张力生产设备
US20200345563A1 (en) * 2019-05-03 2020-11-05 The Procter & Gamble Company Nonwoven webs with one or more repeat units

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0424262A (ja) * 1990-05-17 1992-01-28 Kao Corp 不織布及びその製造方法並びに吸収性物品
JP2008025082A (ja) * 2006-06-23 2008-02-07 Uni Charm Corp 不織布
JP2008284717A (ja) * 2007-05-15 2008-11-27 Kao Corp 伸縮性積層シート及びその製造方法
JP2009030218A (ja) * 2007-06-22 2009-02-12 Uni Charm Corp 不織布およびその製造方法
JP2010024573A (ja) * 2008-07-17 2010-02-04 Kao Corp 不織布

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0424262A (ja) * 1990-05-17 1992-01-28 Kao Corp 不織布及びその製造方法並びに吸収性物品
JP2008025082A (ja) * 2006-06-23 2008-02-07 Uni Charm Corp 不織布
JP2008284717A (ja) * 2007-05-15 2008-11-27 Kao Corp 伸縮性積層シート及びその製造方法
JP2009030218A (ja) * 2007-06-22 2009-02-12 Uni Charm Corp 不織布およびその製造方法
JP2010024573A (ja) * 2008-07-17 2010-02-04 Kao Corp 不織布

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20200100956A1 (en) * 2018-09-27 2020-04-02 The Procter & Gamble Company Nonwoven webs with visually discernible patterns
US11998427B2 (en) * 2018-09-27 2024-06-04 The Procter & Gamble Company Nonwoven webs with visually discernible patterns
US20200345563A1 (en) * 2019-05-03 2020-11-05 The Procter & Gamble Company Nonwoven webs with one or more repeat units
US11999150B2 (en) * 2019-05-03 2024-06-04 The Procter & Gamble Company Nonwoven webs with one or more repeat units
CN111705424A (zh) * 2020-06-30 2020-09-25 福建雷尔新材料有限公司 一种高吸液亲肤干爽型热风无纺布及其张力生产设备

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