WO2013183481A1

WO2013183481A1 - Nonwoven fabric

Info

Publication number: WO2013183481A1
Application number: PCT/JP2013/064651
Authority: WO
Inventors: 宏子川口; 正洋谷口; 泰樹内山
Original assignee: 花王株式会社
Priority date: 2012-06-07
Filing date: 2013-05-27
Publication date: 2013-12-12
Also published as: CN104246046B; JP2014012913A; JP6047428B2; CN104246046A; RU2617985C2; RU2014153855A

Abstract

Provided is nonwoven fabric which has first protrusions that protrude toward the first-surface side on which the nonwoven fabric sheet is viewed from a plan-view direction and recesses that are recessed toward the second-surface side which is opposite to the first-surface side, and in which the first protrusions and the recesses have been alternately and successively arranged, with wall parts interposed therebetween, in different directions that cross in the plan view of the nonwoven fabric, each wall part having fiber orientation in the direction that connects the top of the first protrusion and the bottom of the recess. In the nonwoven fabric, (Ta/T)×100 (%) is 50% or more, where Ta is the thickness of the first protrusions including the apexes thereof and T is the thickness of the entire nonwoven fabric viewed from a side-view direction. The nonwoven fabric comprises fibers differing in fineness.

Description

Non-woven

The present invention relates to a nonwoven fabric.

Absorbent articles such as sanitary napkins, panty liners, and disposable diapers have a two-layer sheet structure in which two-layer sheets are partially joined by a large number of joints according to their functions. The thing which arranged the part which raised in the shape is developed.
In Patent Document 1, a first fiber layer disposed on the skin side and a second fiber layer disposed on the absorber side are laminated and partially joined at a joint portion of a predetermined pattern. The portion other than the joint has a convex shape on the skin side, and the second fiber layer is made of a fiber assembly containing heat-shrinkable fibers, and heat-shrinkable heat-shrinkable portions and heat-shrinkage are suppressed. A topsheet for an absorbent article having a densified portion is disclosed.

Patent Document 2 discloses a multilayer nonwoven fabric in which one side of a sheet material is a protruding portion extending in a streak shape, and the cross-section thereof is a kamaboko (substantially semicircular) shape. The groove part in this nonwoven fabric is formed so that the basis weight is the lowest in the nonwoven fabric, the content of transversely oriented (CD oriented) fibers is high, and the content of longitudinally oriented (MD oriented) fibers is low. And the side part of a convex-shaped part has the highest fabric weight in a nonwoven fabric, and the content rate of the longitudinally-oriented (MD orientation) fiber is high.

Patent Document 3 has an upper layer and a lower layer made of a sheet-like material that does not substantially expand and contract, and both the layers are joined at a large number of joints, and the upper layer has a cavity between the two layers. A surface sheet in which a large number of convex portions are formed and the lower layer is flat is disclosed.

JP 2004-000466 A JP 2008-025081 A JP 2004-174234 A

The present invention has a first projecting portion projecting to the first surface side of the nonwoven fabric of the sheet in plan view, and a recessed portion recessed on the second surface side opposite to the first surface side, The first protrusions and the recesses are alternately arranged continuously through wall portions in different directions intersecting in plan view of the nonwoven fabric, and the wall portions are the top portions of the first protrusions and the recess portions. The thickness of the first protruding portion including the apex of the first protruding portion is Ta, and the thickness of the entire nonwoven fabric as viewed from the side is T. / T) × 100 (%) is 50% or more, and a nonwoven fabric in which fibers having different fineness are contained in the nonwoven fabric is provided.

The above and other features and advantages of the present invention will become more apparent from the following description with reference to the accompanying drawings as appropriate.

It is the fragmentary sectional perspective view which showed typically one Embodiment (1st Embodiment) of the nonwoven fabric which concerns on this invention typically. It is the fragmentary sectional view which showed typically the positional relationship of each component of a nonwoven fabric. It is the fragmentary sectional view which showed nonwoven fabric thickness T and 1st protrusion part thickness Ta typically, (a) figure is the figure which showed the case where the surface by the side of the 2nd surface of the 1st protrusion part of a nonwoven fabric becomes concave shape. Yes, (b) is a view showing a case where the second surface side of the nonwoven fabric is a flat surface, and (c) is a case where the second surface side surface of the first protruding portion of the nonwoven fabric is convex. FIG. It is the fragmentary sectional view which showed the modification of 1st Embodiment typically. (A) is a partial sectional view schematically showing a preferred example of the second embodiment, and (b) is a partial sectional view schematically showing a preferred example of the third embodiment. BRIEF DESCRIPTION OF THE DRAWINGS It is the fragmentary sectional view which showed typically an example of the preferable manufacturing method for manufacturing the nonwoven fabric which concerns on this invention, (a) A figure arrange | positions a web on a support body and sprays the 1st hot air, and the web (B) is a diagram showing a process of refilling the internal space of the first projecting portion to create a solid part, and (c) is a diagram showing a second process on the web. It is the figure which showed the process of blowing the hot air of and fuse | melting fibers.

The present invention relates to providing a nonwoven fabric having a high cushioning property and a high liquid drawing property.

A preferred embodiment (first embodiment) of the nonwoven fabric according to the present invention will be described below with reference to FIG.
The nonwoven fabric 10 of the present invention is preferably applied to a surface sheet of an absorbent article such as a sanitary napkin or a disposable diaper. The first surface side Z1 is used with the skin surface side of the wearer, and the second surface side Z2 is used. Is preferably arranged and used on the absorber (not shown) side inside the article. Hereinafter, although it demonstrates considering the embodiment which uses the 1st surface side Z1 of the nonwoven fabric 10 shown in drawing toward a wearer's skin surface, this invention is limited to this and is not interpreted.

As shown in FIG. 1, the nonwoven fabric 10 of 1st Embodiment of this invention is the 1st protrusion part 11 which protrudes to the 1st surface side Z1 of the side which planarly viewed the nonwoven fabric of the sheet | seat, and the 1st surface side Z1. It has the hollow part 12 dented in the 2nd surface side Z2 on the opposite side. The 1st protrusion part 11 and the hollow part 12 are alternately distribute | arranged via the wall part 13 alternately by each of the different direction which crosses planar view over the whole surface of the nonwoven fabric 10, for example. The different direction is, as a specific example, an x direction that is one direction (first direction) of the different direction and another one direction (second direction) that is different from the x direction and is different from the x direction. The y direction. Here, the convex portion viewed from the first surface side Z 1 is the first protruding portion 11, and the concave portion is the recessed portion 12.

In the structure of the nonwoven fabric 10 mentioned above, the nonwoven fabric 10 (10A) of the structure which has the 2nd protrusion part 12 which protrudes in the 2nd surface side Z2 and uses the internal space 12K of the hollow part 12 as a common internal space is demonstrated.
In the nonwoven fabric 10A, the 1st,

2nd protrusion parts

11 and 12 are distribute | arranged continuously via the wall part 13 by each in the different direction which planar view crosses of this nonwoven fabric 10A. That is, the top (hereinafter referred to as the first protrusion top) 11T of the first protrusion 11 and the top of the second protrusion 12 (hereinafter referred to as the recess bottom) 12T corresponding to the bottom (hereinafter also referred to as the recess bottom) 12T. , Which is also referred to as the second projecting portion top portion), and the wall portion 13 is arranged between the first projecting portion top portion 11T and the second projecting portion top portion (the bottom portion of the recess). It has fiber orientation in the direction connecting 12T. That is, the orientation direction of the fibers of the wall portion 13 is a direction converging on the first protrusion top portion 11T, in other words, a radial direction from the first protrusion top portion 11T toward the surrounding recess bottom portion 12T.

Here, as shown in FIG. 2, a layer portion having a predetermined thickness d1 above the first surface side Z1 of the first protrusion 11 is defined as a first protrusion top portion 11T, and the first surface side Z1 side of the first protrusion 11 is shown. The layer portion having a predetermined thickness d2 of the portion is defined as the wall portion 13, and the inside of the first protrusion portion 11 excluding the first protrusion portion top portion 11T and the wall portion 13 is defined as the solid portion 15. In addition, the solid part 15 may exist also between the hollow part top parts 12T as shown in figure. Further, since the above-described constituent members are continuous, for convenience of explanation, they are divided as described above. Although the said predetermined thickness d1, d2 changes with the specifications of the nonwoven fabric 10, as an example, it shall be equivalent to thickness Tb of the hollow part bottom part 12T.

Further, when viewed from the second surface side Z2, the convex portion is the second projecting portion (recessed portion) 12, and the second projecting portion 12 has a portion on the second surface side Z2 of the first projecting portion 11. The first protrusion 11 and the second protrusion 12 share the wall 13. In some cases, the first protrusion 11 has an internal space 11K that opens to the second surface side Z2. In the drawing, as indicated by a thick two-dot chain line, the second surface side Z2 of the nonwoven fabric 10 has an internal space 11K when it is closer to the top 11T than the opening 11H. Hereinafter, the internal space 11K includes the space between the second protrusion top portions 12T.

Next, the division of the first projecting portion top portion 11T, the wall portion 13, and the recess bottom portion (second projecting portion top portion) 12T will be described below (see FIG. 2).
As described above, the first protruding portion top portion 11T, the wall portion 13 and the hollow portion bottom portion (second protruding portion top portion) 12T are the first protruding portion 11 and the hollow portion 12 excluding the solid portion 15, and basically. The upper part P1 obtained by dividing the nonwoven fabric thickness T into three equal parts is the first protruding part top part 11T, the intermediate part P3 is the wall part 13, and the lower part P2 is the hollow part bottom part (second protruding part top part) 12T. Further, when the nonwoven fabric thickness T is thin and the nonwoven fabric 10 has a large layer thickness, or when the kurtosis or curvature of each apex is different, from the first protruding portion vertex 11Tp to the adjacent second protruding portion vertex 12Tp in the cross section. An orthogonal line on the first protrusion vertex 11Tp side with respect to this straight line at each position obtained by dividing the straight line into three equal parts is divided by curved surfaces obtained by rotating around a line parallel to the z-axis passing through the first protrusion vertex 11Tp. The upper portion of the non-woven fabric 10 is divided by a curved surface obtained by rotating an orthogonal line on the first protrusion top 11T and second protrusion apex 12Tp side around a line parallel to the z-axis passing through the second protrusion apex 12Tp. The lower portion of the nonwoven fabric 10 may be a recess bottom portion (second protrusion top portion) 12T, and the wall portion 13 may be between the first protrusion top portion 11T and the second protrusion top portion 12T. Alternatively, a straight portion in the cross section may be used as the wall portion 13, and a region that is curved and rounded from the wall portion 13 may be used as the protruding portion

top portions

11T and 12T.
And the 1st protrusion part 11 contains the 1st protrusion part top part 11T and the wall part 13, and the hollow part (2nd protrusion part) 12 contains the hollow part bottom part (2nd protrusion part top part) 12T and the wall part 13, and is a wall part. 13 is shared.

The arrangement of the first projecting portion 11 and the second projecting portion 12 (the recessed portion 12) will be described in detail (see FIG. 1).
In the nonwoven fabric 10 of the present embodiment, a large number of first protrusions 11 are arranged on the first surface side Z1 so as to obliquely intersect in two directions in the vertical and horizontal directions (hereinafter, this arrangement is referred to as an oblique lattice). Sometimes referred to as an array of shapes). The lattice arrangement may be orthogonal (90 °), and in this case, the lattice arrangement may be distinguished as an orthogonal lattice arrangement. In the present embodiment, it is preferable that the first direction (x direction) and the second direction (y direction) in the plane intersect at an angle of 30 ° to 90 °. Furthermore, in this embodiment, many 2nd protrusion parts 12 which protrude in the 2nd surface side Z2 of a nonwoven fabric are distribute | arranged. In other words, a large number of depressions 12 that are recessed from the first surface side Z1 to the second surface side Z2 of the nonwoven fabric are arranged. The second protrusions 12 are also arranged in an orthogonal grid pattern, but may be in an oblique grid pattern in accordance with the first protrusions 11. Since the preferable range of the crossing angle is determined along with the first protrusion 11, it is the same as described above. The first projecting portion 11 and the second projecting portion 12 project in opposite directions with respect to the sheet surface. The two are alternately arranged in the same position in the plan view and the side view, that is, in a non-overlapping relationship.

As described above, the first protrusions 11 and the second protrusions 12 arranged so as to extend in the first direction (x direction) and the second direction (y direction) in the surface are continuous in a plane shape without contradiction. Thus, the nonwoven fabric 10 is configured. “Continuous without contradiction” means that when a specific shape portion is connected to form a planar shape, the whole is continuous with a gentle curved surface without being refracted or discontinuous. In addition, the arrangement | sequence form of the said 1st protrusion part 11 and the 2nd protrusion part 12 is not limited above, What is necessary is just a form which can be arrange | positioned by the arrangement | sequence which can be continued without contradiction, for example, the 1st protrusion part 11 is centered. The second protrusions 12 may be arranged at each of the apexes of the hexagon, and the pattern may be spread in the plane. In this case, since the number of the second protrusions 12 exceeds the number of the first protrusions 11, a state in which the second protrusions 12 are adjacent to each other occurs. Such an arrangement is also included in the meaning that the first protrusions 11 and the second protrusions 12 are arranged alternately. Moreover, since it is the hollow part 12 which looked at the 2nd protrusion part 12 from the 1st surface side Z1, the arrangement | sequence of the above-mentioned arrangement | positioning of the 1st protrusion part 11 and the hollow part 12 is also the same.

The first projecting portion top portion 11T and the second projecting portion top portion 12T described above have a rounded truncated cone shape or a hemispherical shape. In the present embodiment, the first and second projecting

portions

11 and 12 are not limited to the above shape, and may be any projecting shape, for example, various cone shapes (in this specification, the cone shape is It is practical to include a cone, a truncated cone, a pyramid, a truncated pyramid, an oblique cone, etc.).
In the present embodiment, the second projecting portion 12 has a truncated cone-shaped or hemispherical internal space 12 K with a rounded top. This internal space 12K is equivalent to the internal space of the recess 12. In addition, the space between the 1st protrusion part top parts 11T is also included in the said internal space 12K.

The solid portion 15 is a portion where at least the top side or the whole inside the first projecting portion 11 is substantially solid with fibers. Here, “substantially solid by the fibers” means a state in which the fibers are densely gathered, and means that there are no intermittent portions or small holes. However, fine holes such as gaps between fibers are not included in the small holes. The small hole is defined as a hole having a diameter equivalent to a circle and having a diameter of 1 mm or more.

As shown in FIG. 2, when the first protrusion 11 has an internal space 11 K, the top of the first protrusion 11 (hereinafter also referred to as the first protrusion 11) 11 T and the first protrusion 11. The wall portion 13 (13a) is provided between the opening portion 11H and the solid portion 15 is provided inside the first projecting portion 11. That is, the solid part 15 is provided inside the first projecting part top part 11T and the wall part 13. The wall portion 13 a forms a ring structure in the first projecting portion 11. Moreover, it has the wall part 13 (13b) between the top part (henceforth the 2nd protrusion part top part) 12T of the 2nd protrusion part 12, and the opening part 12H. The wall portion 13b forms a ring structure at the second protrusion 12. The wall 13b is shared with the wall 13a.
The “ring structure” here is not particularly limited as long as it has an endless series of shapes in plan view, and may be any shape such as a circle, an ellipse, a rectangle, or a polygon in plan view. . In order to maintain the continuous state of the sheet suitably, a circle or an ellipse is preferable. Furthermore, the “ring structure” is a three-dimensional shape: cylinder, oblique cylinder, elliptical cylinder, truncated cone (conical frustum), truncated oblique cone (conical truncated cone), truncated elliptical cone (elliptical frustum), truncated Arbitrary ring structures such as a truncated quadrangular pyramid (square pyramid) and a truncated oblique pyramid (oblique quadrangular pyramid) can be mentioned, and in order to realize a continuous sheet state, a cylinder, an elliptical column, a truncated cone, a truncated cone An elliptical cone is preferred.

As described above, the non-woven fabric 10 having the first and second projecting

portions

11 and 12 does not have a bent portion, and is composed of a continuous curved surface as a whole. Thus, it is preferable that the said nonwoven fabric 10 has a structure continuous in the surface direction. This “continuous” means that there are no intermittent portions or small holes. However, fine holes such as gaps between fibers are not included in the small holes. The small hole is defined as a hole having a diameter equivalent to a circle of 1.0 mm or more, for example.

The thickness of the first protrusion 11 including the apex 11Tp of the first protrusion 11 (hereinafter also referred to as the first protrusion thickness) is Ta, and the thickness of the nonwoven fabric as viewed from the side (hereinafter also referred to as the nonwoven thickness). ) Is T, (Ta / T) × 100% is 50% or more. The first protrusion thickness Ta is larger than the thickness of the recess bottom 12T.
The nonwoven fabric thickness T is such that the vertex 12Tp of the second protrusion 12 is on the plane S, and the distance d1 between the plane S1 parallel to the plane S and passing through the vertex 11Tp of the first protrusion 11 and the plane S (See FIG. 3A).
In addition, since the 1st protrusion part thickness Ta does not become thicker than the nonwoven fabric thickness T, (Ta / T) * 100% is 100% or less.
Therefore, when (Ta / T) × 100% is 50% or more and less than 100%, the first protrusion 11 and the second protrusion 12 are provided as described above, and the first protrusion 11 is provided inside the first protrusion 11. It has a dent recessed in the surface side Z1 direction, and this dent serves as an internal space 11K of the first protrusion 11 (see FIG. 3A).
The first projecting portion thickness Ta is such that the apex 12Tp of the second projecting portion 12 is on the plane S, and the portion of the first projecting portion 11 located on the outermost side of the first surface side Z1 (the first projecting portion 11 of the first projecting portion 11). A plane S1 passing through the vertex 11Tp) and parallel to the plane S, and a portion of the first protrusion 11 located on the innermost side of the second surface side Z2 (the point 11Kp at the bottom of the internal space 11K viewed from the second surface side Z2) ) And parallel to the plane S, and the distance d2 between the plane S1 (see FIG. 3A).

On the other hand, when (Ta / T) × 100% is 100%, that is, when Ta = T, the nonwoven fabric thickness T (= first protruding portion thickness Ta) is the nonwoven fabric 10 positioned on the outermost side of the second surface side Z2. And the plane S passing through the outermost part of the first surface side Z1 (the vertex 11Tp of the first protrusion 11) and parallel to the plane S, and the plane S Distance d3 (see FIGS. 3B and 3C).
Although not shown, when (Ta / T) × 100% is less than 50%, the thickness of the solid portion 15 is not sufficient, and it is difficult to obtain a desired effect, particularly an improvement in cushioning properties. In addition, the value of (Ta / T) × 100% is preferably 65% or more, and more preferably 75% or more, from the viewpoint of cushioning properties and the remaining amount of surface liquid. Further, from the same viewpoint, it is preferably 90% or less, and more preferably 85% or less.

FIG. 3A shows a case where the second surface side Z2 surface of the first protrusion 11 of the nonwoven fabric 10 is concave, and FIG. 3B shows that the second surface side Z2 surface of the nonwoven fabric 10 is flat. FIG. 3C shows a case where the surface on the second surface side Z2 of the first protrusion 11 of the nonwoven fabric 10 is a convex surface. This convex portion is included in the solid portion 15.

The fiber constituting the wall portion 13 has a direction connecting the first protruding portion top portion 11T and the surrounding recess bottom portion (second protruding portion top portion) 12T, that is, the first protruding portion top portion 11T and the opening portion 11H. It has fiber orientation in the radial direction from the first protrusion top 11T in the tying direction. In other words, it has fiber orientation in the direction in which the wall portion 13 stands.
In general air-through non-woven fabric, when the non-woven fabric is usually produced, the fibers are oriented in the MD direction and fused as they are, so that the fibers in the wall section in the MD direction cross section are oriented in the standing direction. In the cross section in the CD direction, since the fibers are oriented in a direction orthogonal to the standing direction, such fiber orientation is not present.

Furthermore, the nonwoven fabric 10 contains fibers having different finenesses. Fibers with different finenesses are in a mixed state. Or it is the laminated structure of a fiber layer with a large fineness, and a fiber layer with a small fineness. In the laminated structure, a fiber layer having a large fineness may be disposed on the first surface side Z1, or a fiber layer having a small fineness may be disposed. In addition, fibers having different fineness may not be completely separated between fiber layers having different fineness, and fibers having different fineness may be mixed.

The fiber material that can be used for the nonwoven fabric 10 of the present invention is not particularly limited. Specific examples include the following fibers. Polyolefin fibers such as polyethylene (PE) fibers and polypropylene (PP) fibers; there are fibers using a thermoplastic resin such as polyethylene terephthalate (PET) and polyamide alone, and there are structures such as a core-sheath type and a side-by-side type. There are composite fibers. In the present invention, it is preferable to use a composite fiber. Examples of the composite fiber include a core-sheath fiber having a high melting point component as a core portion and a low melting point component as a sheath portion, and a side-by-side fiber in which a high melting point component and a low melting point component are arranged in parallel. 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). More specifically, the constituent fibers preferably include polyolefin fibers such as polyethylene fibers and polypropylene fibers, polyethylene composite fibers, and polypropylene composite fibers. Here, the composite composition of the polyethylene composite fiber is polyethylene terephthalate / polyethylene, and 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). These fibers may be used alone to form a nonwoven fabric, but can also be used as a mixed fiber in which two or more kinds are combined.

On the other hand, there is a nonwoven fabric 10 (10B) shown in FIG. 4 as a modification of the first embodiment. The non-woven fabric 10 (10B) has a configuration in which no internal space exists in the first projecting portion 11, that is, a configuration in which the entire interior of the first projecting portion 11 (including between the recessed portions 12) is substantially solid ((Ta / T) × 100 is 100%). In this configuration, the predetermined thickness portion of the surface layer of the first projecting portion 11 is the wall portion 13 and the top portion 11T, and the inside of the first projecting portion 11 excluding the wall portion 13 and the top portion 11T is the solid portion 15. Therefore, on the second surface side Z2, a portion corresponding to the second protrusion corresponding to the recess 12 is buried in the solid portion 15 and does not protrude.

The said nonwoven fabric 10 (10A, 10B) is a nonwoven fabric containing the fiber from which a fineness differs. The nonwoven fabric 10 contains two or more kinds of fibers having different finenesses. For example, it is preferable to contain fibers having a fineness of 4 dtex or more and 8 dtex or less, and it is more preferable to contain fibers having a fineness of 4 dtex or more and 6 dtex or less.
Also, the first fiber having a fineness of 1 dtex or more, more preferably 2 dtex or more, and preferably less than 4 dtex, more preferably 3.5 dtex or less, preferably a fineness of 4 dtex or more, and preferably a fineness of 8 dtex or less, more preferably It is preferable to contain the 2nd fiber of 7 dtex or less. More specifically, it preferably contains a first fiber having a fineness of 1 dtex or more and less than 4 dtex, and a second fiber having a fineness of 4 dtex or more and 8 dtex or less, a first fiber having a fineness of 2 dtex or more and 3.5 dtex or less, and a fineness of 4 dtex. It is more preferable that the second fiber is 7 dtex or less.
In addition, when the fineness exceeds 8 dtex, there is a concern that the texture of the nonwoven fabric 10 may be impaired. In addition, when fibers having a fineness of less than 1 dtex are included, the liquid drawing property is lowered, which is not preferable.

Moreover, the nonwoven fabric 10 (10A, 10B) demonstrated by the said 1st Embodiment (a modification is also included) is a nonwoven fabric with which the 1st fiber and 2nd fiber from which fineness differs are mixed. As described above, the first fiber is a fiber having a small fineness, and the second fiber is a fiber having a large fineness, both of which are in the above-described range.
Therefore, a fiber having a large fineness and a fiber having a small fineness are mixed and present throughout the first protrusion 11, and the fiber having a high fineness causes a firmness in the entire first protrusion 11 and a high pressure is applied. Even if it is done, cushioning properties are maintained. In addition, since fibers having a small fineness are present throughout the first protruding portion 11, unlike the case of only fibers having a high fineness, a decrease in the texture is suppressed, and a non-woven fabric having a good touch is obtained.

In the nonwoven fabric 10 demonstrated by the said 1st Embodiment, the nonwoven fabric 10 (10A, 10B) of 2nd, 3rd embodiment is a nonwoven fabric which has several layers from which a fineness differs. For example, at least one of the plurality of layers preferably has a fiber having a large fineness in the above-described range. Furthermore, it is more preferable to have the 1st fiber layer containing the 1st fiber with small fineness as mentioned above, and the 2nd fiber layer containing the 2nd fiber with big fineness as mentioned above. Further, the fiber layers having different finenesses may be three or more layers. Although not shown, for example, in order from the first surface side Z1, a first fiber layer having a fineness of 1 dtex or more and less than 4 dtex, a second fiber layer having a fineness of 4 dtex or more and 8 dtex or less, and a third fiber layer having a fineness of 4 dtex or more and 8 dtex or less. It may be laminated. In addition, each fiber layer does not need to be completely separated according to the fineness, and may be in a state where fibers having different fineness are mixed in the vicinity of the boundary between the fiber layers.
As described above, since the fiber layers having different finenesses are arranged in a plurality of layers, the thickness of the solid portion is increased, and a desired effect, in particular, an improvement in cushioning properties is easily obtained.

Moreover, as shown to Fig.5 (a), as for the nonwoven fabric 10 (10A, 10B) of 2nd Embodiment, the 1st fiber layer 16 with a large fineness is distribute | arranged to the 1st surface side Z1, and the fineness is arranged to the 2nd surface side Z2. 2nd fiber layer 17 with small is arranged. In the laminated structure of the fiber layers, the texture on the second surface side Z2 on which the second fiber layer 17 having a small fineness is arranged is superior to the first surface side Z1.

Moreover, as shown in FIG.5 (b), as for the nonwoven fabric 10 (10A, 10B) of 3rd Embodiment, the 2nd fiber layer 17 with a small fineness is distribute | arranged to the 1st surface side Z1, and the fineness is set to the 2nd surface side Z2. A large first fiber layer 16 is disposed. In the laminated structure of the fiber layers, the texture on the first surface side Z1 on which the second fiber layer 17 having a small fineness is arranged is superior to the second surface side Z2.

None of the nonwoven fabrics 10 of the second and third embodiments described above is bonded to the first fiber layer 16 and the second fiber layer 17 by embossing or bonding of the fiber layers by an adhesive. In the case of the second and third embodiments, when the web is shaped in an uneven state, part of the fibers of the second fiber layer 17 enters the first fiber layer 16 side, or conversely, When a part of the fibers enters the second fiber layer 17 side, the fibers between the fiber layers are entangled with each other and further bonded by thermally fusing the fibers together. Therefore, even if it is the hollow part bottom part 12T where thickness becomes the thinnest, the liquid drawing property is ensured.

In the nonwoven fabric 10 of each of the above embodiments, the fiber density of the first protrusion 11 (substantially the first protrusion top 11T) on the first surface side Z1 is the same as that of the depression 12 (substantially bottom 12T). It is preferably lower than the fiber density.
In the nonwoven fabric 10, since the fiber density of the first protrusion top 11T is lower than the fiber density of the recess bottom 12T, the liquid supplied from the first surface side Z1 passes through the first protrusion 11T. It becomes easy and is once held in the solid part 15. At this time, even if a large amount of liquid is supplied, the solid portion 15 can hold the liquid. And it transfers to the 2nd surface side Z2, and it can be made to absorb by the absorber (not shown) distribute | arranged to the 2nd surface side Z2. Therefore, the nonwoven fabric 10 of the present invention can significantly reduce the liquid residue and quickly absorb and process the liquid. Even if this liquid is urine or a highly viscous liquid such as loose stool or menstrual blood, the same effect can be obtained.

Specifically, in the nonwoven fabric 10, the first protruding portion in which the fiber density of the solid portion 15 that is the second surface side Z 2 of the first protruding portion 11 is the first surface side Z 1 of the first protruding portion 11. 11 (substantially the first protruding portion top portion 11T) is preferably higher than the fiber density of the recessed portion 12 (substantially the recessed portion bottom portion 12T). The fiber density here is a fiber density near the center of the thickness of each part, and was evaluated by measuring the number of fibers per 1 mm ² .
For example, the fiber density of the first protrusion top 11T is preferably 30 present / mm ² or more, more preferably 50 lines / mm ² or more, and preferably 180 lines / mm ² or less, more preferably 100 / mm ² Hereinafter, more specifically, 30 / mm ² or more and 130 / mm ² or less is preferable, and 50 / mm ² or more and 100 / mm ² or less is more preferable. Fiber density of the solid portion 15 is preferably 50 present / mm ² or more, more preferably 70 yarns / mm ² or more, and preferably 180 lines / mm ² or less, more preferably 150 present / mm ² or less, more specifically Specifically, it is preferably 50 / mm ² or more and 180 / mm ² or less, and more preferably 70 / mm ² or more and 150 / mm ² or less. Further, the fiber density of the recess bottom 12T is preferably 250 / mm ² or more, more preferably 270 / mm ² or more, and preferably 500 / mm ² or less, more preferably 480 / mm ² or less. Specifically, it is preferably 250 / mm ² or more and 500 / mm ² or less, and more preferably 270 / mm ² or more and 480 / mm ² or less.
In the said Embodiment 1 and Embodiment 2, it becomes the structure which has the said fiber density.

In such a nonwoven fabric 10, the fiber density of the 1st protrusion part top part 11T is lower than the fiber density of the hollow part bottom part 12T, and the fiber density of the 1st protrusion part top part 11T is lower than the fiber density of the solid part 15. Thus, the liquid supplied from the first surface side Z1 is more likely to pass through the first protruding portion top portion 11T, and the gradient density from the first protruding portion top portion 11T to the solid portion 15 (changes from coarse to dense). Therefore, it is easy to be guided to the solid part 15. Furthermore, since the fiber density of the solid portion 15 is lower than the fiber density of the recess bottom portion 12T, the liquid that has passed through the first protrusion top portion 11T without returning from the recess bottom portion 12T is caused by the solid portion 15. It becomes easy to hold once and it becomes easy to shift to the second surface side. Therefore, the liquid supplied to the nonwoven fabric 10 is discharged from the first protruding portion top portion 11T to the second surface side Z2 through the solid portion 15 and is disposed on the second surface side Z2 (not shown). ) Can be absorbed quickly. Therefore, since the drawability of liquid (menstrual blood, loose stool, etc.) becomes high, the remaining amount of liquid on the surface of the nonwoven fabric 10 is reduced, generation of stuffiness, itching and rash can be prevented, and comfortable wearing can be continued. Moreover, since it becomes difficult to see a liquid from the nonwoven fabric 10 surface, the concealment property of a liquid becomes high.

The nonwoven fabric 10 has a fiber density of the first protrusion 11 (substantially the first protrusion top 11T) which is the first surface side Z1 of the first protrusion 11 so that the second protrusion 10 has a second fiber density. It is preferable that the fiber density is higher than the fiber density of the solid portion 15 which is the surface side Z2 and lower than the fiber density of the recess portion 12 (substantially the recess portion bottom portion 12T).
For example, the fiber density of the first protrusion top 11T is preferably 50 present / mm ² or more, more preferably 70 yarns / mm ² or more, and preferably 180 lines / mm ² or less, more preferably 150 present / mm ² More specifically, it is preferably 50 / mm ² or more and 180 / mm ² or less, more preferably 70 / mm ² or more and 150 / mm ² or less. Fiber density of the solid portion 15 is preferably 30 present / mm ² or more, more preferably 50 lines / mm ² or more, and preferably 130 present / mm ² or less, more preferably 100 / mm ² or less, more specifically Specifically, it is preferably 30 / mm ² or more and 130 / mm ² or less, and more preferably 50 / mm ² or more and 100 / mm ² or less. Further, the fiber density of the recess bottom 12T is preferably 250 / mm ² or more, more preferably 270 / mm ² or more, and preferably 500 / mm ² or less, more preferably 480 / mm ² or less. Specifically, it is preferably 250 / mm ² or more and 500 / mm ² or less, and more preferably 270 / mm ² or more and 480 / mm ² or less.
In the said Embodiment 3, it becomes the structure which has the said fiber density.

In the nonwoven fabric 10, since the fiber density of the first protrusion top 11T is lower than the fiber density of the recess bottom 12T, the liquid supplied from the first surface side Z1 passes through the first protrusion 11T. Furthermore, since the fiber density of the solid portion 15 is lower than the fiber density of the first protruding portion top portion 11T, the liquid that has passed through the first protruding portion top portion 11T is more easily transferred to the solid portion 15. . Therefore, the liquid supplied to the nonwoven fabric 10 is discharged from the first protruding portion top portion 11T to the second surface side Z2 through the solid portion 15 and is disposed on the second surface side Z2 (not shown). ) Can be absorbed quickly. In this example, the drawability of the liquid is slightly inferior to the case where the fiber density of the solid part 15 is higher than the fiber density of the first protrusion top part 11T, but a sufficient liquid (menstrual blood, loose stool, etc.) is drawn. Therefore, it is difficult for the liquid to remain on the surface of the nonwoven fabric 10, and it is possible to prevent the occurrence of stuffiness, itchiness and rash, and to continue wearing comfortably. Moreover, since it becomes difficult to see a liquid from the nonwoven fabric 10 surface, the concealment property of a liquid is also acquired.
Furthermore, since the fiber with a small fineness exists in the skin surface side (1st surface side Z1) of the nonwoven fabric 10, it is excellent in a texture and excellent in a touch feeling.

Next, the dimension specification in the nonwoven fabric 10 of this embodiment is demonstrated below.
The nonwoven fabric thickness T may be adjusted as appropriate depending on the application, but when used as a top sheet for diapers, sanitary products, etc., it is preferably 1 mm or more and 7 mm or less, more preferably 1.5 mm or more and 5 mm or less. By setting it as the range, the body fluid absorption speed at the time of use is high, the liquid return from an absorber is suppressed, and also moderate cushioning property is realizable. The layer thickness of the sheet may be different at each site in the sheet, and may be appropriately adjusted depending on the application. When used as a surface sheet for diapers, sanitary products, etc., the first protrusion thickness Ta is preferably 0.5 mm or more, more preferably 0.8 mm or more, and preferably 7 mm or less, more preferably 5 mm or less, more specifically. Is preferably 0.5 mm or more and 7 mm or less, more preferably 0.8 mm or more and 5 mm or less. The layer thickness of the wall portion 13 of the first protrusion top portion 11T is preferably 0.3 mm or more, more preferably 0.6 mm or more, and preferably 2.0 mm or less, more preferably 1.5 mm or less, more specifically. Is preferably 0.3 mm or more and 2.0 mm or less, more preferably 0.6 mm or more and 1.5 mm or less. The layer thickness of the solid part 15 is preferably 0.2 mm or more, and preferably 5 mm or less, more preferably 3.5 mm or less, more specifically preferably 0.2 mm or more and 5 mm or less, preferably 0. .2 mm or more and 3.5 mm or less.
The interval between the first protrusions 11 may be appropriately adjusted depending on the application, and when used as a top sheet of a diaper, sanitary product, etc., it is 2 mm or more and 10 mm or less, preferably 3 mm or more and 7 mm or less. The basis weight of the nonwoven fabric 10 is not particularly limited, but the 15 g / ^{m 2} or more 70 g / ^{m 2} or less the average value of the entire sheet, preferably not 20 g / ^{m 2} or more 40 g / ^{m 2} or less.

The nonwoven fabric 10 demonstrated by the said embodiment has the following effects.
<Texture>
Since the nonwoven fabric 10 contains fibers with different finenesses, the deterioration of the texture due to the inclusion of fibers with high fineness due to the fibers with low fineness among fibers with different fineness is suppressed. Can be maintained. Moreover, the surface where many fibers with small fineness exist can raise the texture of the surface.
<Cushioning>
The fiber of the wall part 13 has fiber orientation in the direction connecting the first protrusion top part 11T and the bottom part of the hollow part 12, and satisfies (Ta / T) × 100 ≧ 50%, and the first protrusion vertex Since the thickness of the first projecting portion 11 including 11T is thick due to the solid portion 15, the ratio of the recovered energy to the energy at the time of compression is increased, and the elasticity is improved. Can be improved, and cushioning can be further enhanced.
<Liquid remaining amount and L value>
Furthermore, since the fiber density of the first projecting portion top portion 11T is lower than the fiber density of the recessed portion bottom portion 12T, the liquid drawability into the fiber layer is increased and the surface liquid remaining amount is increased. Can be reduced. Moreover, since L value (whiteness) becomes high, since the liquid absorbed by the nonwoven fabric 10 becomes difficult to see from the nonwoven fabric surface, the concealability of a liquid becomes high. Moreover, since there is little liquid residue on the surface, a feeling of cleanliness can be enhanced. Thereby, the nonwoven fabric which enables comfortable continuous wear can be provided.

The cushioning effect will be further described. In the nonwoven fabric 10 of the present embodiment, the first protruding portion 11 and the recessed portion 12 are continuously arranged through the wall portions 13 alternately in different directions intersecting in plan view over the entire surface of the nonwoven fabric 10, for example. 13 has fiber orientation in the direction connecting the first protrusion top portion 11T and the recess bottom portion 12T, and a substantially solid portion 15 having fibers with different fineness inside the first protrusion portion 11 is provided. Since it exists, the cushioning characteristic peculiar to this structure is expressed. For example, a single-sided protrusion having a streak-like protrusion or a hollow inside will exhibit elasticity as a line or surface, but according to this embodiment, it also follows a three-dimensional movement well. The three-dimensional cushion property supported by the point in the 1st protrusion part 11 is show | played. Moreover, the solid part 15 is distribute | arranged inside the 1st protrusion part 11, and it has the moderate cushioning property which the 1st protrusion part 11 does not collapse in the thickness direction of the nonwoven fabric 10. FIG. Furthermore, even if the nonwoven fabric 10 is crushed by the pressing force, the shape restoring force due to the fibers having different fineness among the fibers having different finenesses is large, and the initial cushioning force is easily maintained even if the packing state and wearing are continued. That is, the 1st protrusion part 11 is hard to be crushed and is easy to recover | recover even if a deformation | transformation occurs.
Moreover, since the nonwoven fabric 10 has a portion with low fiber density in the first protrusion 11, the first protrusion 11 easily dents even at low loads, so that cushioning properties are obtained even at low loads. There is an excellent effect of being able to.

Next, a preferable example of the method for manufacturing the nonwoven fabric 10 will be described below with reference to FIG.
As shown in FIG. 6A, a support 110 is used as an example of a support for shaping the web into a concavo-convex shape. The support 110 has a large number of protrusions 111 corresponding to the positions where the depressions 12 (second protrusions 12) are shaped, and the holes corresponding to the positions where the first protrusions 11 are shaped. 112 is arranged. That is, the support 110 has an uneven shape, and the protrusions 111 and the holes 112 are alternately arranged in different directions. For example, the protrusions 111 and the holes 112 are alternately arranged in the X direction and the Y direction, respectively. It is arranged.
A web (also referred to as a fiber web) 50 is disposed on the support 110 and the first hot air W 1 is blown toward the web 50. In this case, the first projecting portion 11 is shaped corresponding to the hole 112 of the support 110, and the recessed portion 12 is shaped corresponding to the position of the protrusion 111. Accordingly, the first projecting portion 11 projecting to the first surface side Z1 on the side in plan view and having the internal space 11K, and the second projecting portion projecting to the second surface side Z2 opposite to the first surface side Z1 and having the internal space 12K. The protrusions 12 are alternately and continuously arranged in different X and Y directions that intersect in plan view.
The arrows in the drawing schematically show the flow of the first hot air W1.

Specific examples of this production method include the following embodiments.
The web 50 containing fibers with different fineness before being fused is conveyed from a card machine (not shown) onto the support 110 of the apparatus for shaping the web so as to have a predetermined thickness and fixed.
The web 50 has a single-layer structure in which fibers having different finenesses are mixed, a laminated structure in which a fiber layer having a high fineness is used as an upper layer and a fiber layer having a low fineness is provided in a lower layer, and conversely, the fineness is low. A laminated structure having a fiber layer as an upper layer and a fiber layer having a high fineness as a lower layer is appropriately used.
Next, the first hot air W1 is blown onto the web 50 on the support 110, and the web 50 is shaped so as to conform to the shape of the support 110 (the state shown in FIG. 6A). At this time, the temperature of the first hot air W1 is preferably 0 ° C. to 70 ° C. lower than the melting point of the thermoplastic fiber constituting the web 50, and more preferably 5 ° C. to 50 ° C. lower. The wind speed of the first hot air W1 is set to 20 m / s or more and 50 m / s or less, preferably 30 m / s or more and 100 m / s or less, from the viewpoints of formability and texture. When the wind speed is slower than this lower limit, the film is not sufficiently shaped, and the effects such as cushioning properties, liquid drawability, and texture are not fully exhibited. If the wind speed exceeds this upper limit value, an opening is formed in the first projecting portion top portion 11T, and it becomes easy to be crushed. Thus, effects such as cushioning properties, liquid drawing property, and texture are not sufficiently exhibited. Furthermore, it becomes easy for excrement to go back through the opening.
In this way, the web 50 is shaped into an uneven shape.

Then, when the blowing of the first hot air W1 is stopped, as described above, among the fibers having different finenesses in the web 50, the shaping state is returned by the fibers having a higher fineness, and the internal space 11K of the first projecting portion 11 is restored. Is filled back to form the solid portion 15 (the state shown in FIG. 6B). The amount of fiber returned at this time varies depending on the fineness of the fiber, and the greater the fineness, the easier it is to return. In this case, the fiber density of the 1st protrusion part top part 11T shape | molded corresponding to the hole 112 becomes lower than the hollow part bottom part 12T (2nd protrusion part top part 12T) shape | molded corresponding to the protrusion 111. FIG.

Next, as shown in FIG. 6C, the second hot air W2 at a temperature at which each fiber of the web 50 can be appropriately fused is blown to fuse the fibers together. The temperature of the second hot air W 2 is preferably 0 ° C. to 70 ° C. higher than the melting point of the thermoplastic fiber constituting the web 50, preferably 5 ° C. to 50 ° C., considering the fiber material used for the nonwoven fabric 10. It is more preferable. The wind speed of the second hot air W2 is set to 1 m / s or more and 10 m / s or less, preferably 3 m / s or more and 8 m / s or less. If the wind speed of the second hot air W2 is too slow, heat cannot be transferred to the fibers, the fibers are not fused together, and the uneven shape is insufficiently fixed. On the other hand, when the wind speed is too high, heat is applied to the fiber too much and the texture becomes inferior.

The shaping apparatus (not shown) for carrying out the manufacturing method is a conveyor type or drum type capable of transporting the support 110 in consideration of continuous production, and the molded nonwoven fabric 10 that is transported, The mode which winds up with a roll is mentioned. In this way, the nonwoven fabric 10 of the present invention is obtained. In addition, you may face MD and CD in any direction about the nonwoven fabric 10 of this embodiment.
The MD is also referred to as a machine direction, which is a fiber web feeding direction when manufacturing a nonwoven fabric, and is an abbreviation for “Machine Direction”. The CD is a direction orthogonal to the MD and is an abbreviation of “Cross Direction”.

As the thermoplastic fiber, the fiber described above is used. For example, when a composite fiber containing a low melting point component and a high melting point component is used as the thermoplastic fiber, the temperature of the second hot air W2 sprayed on the web 50 is equal to or higher than the melting point of the low melting point component and lower than the melting point of the high melting point component. It is preferable. More preferably, the temperature is at least 10 ° C lower than the melting point of the high melting point component, more preferably at least 5 ° C higher than the melting point of the low melting point component, and more preferably at least 20 ° C lower than the melting point of the high melting point component. .

The web 50 includes fibers having different fineness as described above, and the containing form is the same as the embodiment of the nonwoven fabric 10 described above. Moreover, it is preferable that 30 mass% or more and 100 mass% or less of thermoplastic fibers are included, More preferably, they are 40 mass% or more and 100 mass% or less. The web 50 may include fibers that are not inherently heat-fusible (for example, natural fibers such as cotton and pulp, rayon and acetate fibers).

In the above manufacturing method, the thickness of the nonwoven fabric 10 is appropriately determined depending on the wind speed. For example, when the wind speed is increased, the thickness of the sheet is increased, and when it is decreased, the thickness of the sheet is decreased. Further, when the wind speed is increased, the fiber density difference between the first protrusion top 11T and the recess bottom 12T is increased, and when the wind speed is decreased, the fiber density difference between the first protrusion top 11T and the recess bottom 12T is decreased.

The nonwoven fabric 10 of the present invention can be used for various applications. For example, it can be suitably used as a surface sheet of absorbent articles such as disposable diapers, sanitary napkins, panty liners, urine absorption pads and the like. Furthermore, since the nonwoven fabric 10 is excellent in air permeability, liquid diffusibility, deformation characteristics at the time of pressing force, etc. due to the concavo-convex structure, it is interposed between a surface sheet such as a diaper or sanitary product and an absorbent body. It can also be used as a sublayer. In addition, the form utilized as a gather of an absorbent article, an exterior sheet, and a wing is also mentioned. Furthermore, the form utilized as a wiping wipe sheet | seat, a cleaning sheet | seat, and a filter is also mentioned.

The following nonwoven fabrics and the like are further disclosed with respect to the above-described embodiment.
<1> having a first projecting portion projecting to the first surface side of the nonwoven fabric in plan view, and a recessed portion recessed on the second surface side opposite to the first surface side, 1 protrusion part and the said hollow part are continuously arranged through the wall part alternately in each of the different directions which cross-sectional view of this nonwoven fabric,
The wall has fiber orientation in a direction connecting the top of the first protrusion and the bottom of the recess,
(Ta / T) × 100 (%) is 50% or more, where Ta is the thickness of the first protrusion including the apex of the first protrusion, and T is the thickness of the entire nonwoven fabric as viewed from the side. ,
A nonwoven fabric containing fibers having different finenesses in the nonwoven fabric.
<2> The nonwoven fabric according to <1>, wherein (Ta / T) × 100 (%) is 50% or more and 100% or less.
<3> The nonwoven fabric according to <1>, wherein (Ta / T) × 100 (%) is 50% or more and less than 100%.
<4> The nonwoven fabric according to <1>, wherein (Ta / T) × 100 (%) is 65% to 90%, preferably 75% to 85%.
<5> having a second protrusion that protrudes toward the second surface and shares the internal space of the recess,
The first and second protrusions are continuously arranged through the wall alternately in each of different directions intersecting in plan view of the nonwoven fabric,
The continuous wall is disposed between the top of the first protrusion and the top of the second protrusion, and the wall connects the top of the first protrusion and the top of the second protrusion. The nonwoven fabric according to any one of <1> to <4>, which has fiber orientation in a direction.
<6> The nonwoven fabric according to any one of <1> to <5>, wherein the fiber orientation of the wall portion is a radial direction from the top of the first projecting portion toward the bottom of the surrounding recess.
<7> The nonwoven fabric according to any one of <1> to <6>, wherein the fiber density at the top of the first protrusion is lower than the fiber density at the bottom of the recess.
<8> The nonwoven fabric according to any one of <1> to <7>, wherein the nonwoven fabric is a mixture of a plurality of types of fibers having different finenesses.
<9> The nonwoven fabric according to any one of <1> to <8>, wherein the nonwoven fabric has a plurality of layers having different finenesses.
<10> The non-woven fabric according to <9>, wherein a first fiber layer having a large fineness is disposed on the first surface side, and a second fiber layer having a small fineness is disposed on the second surface side. Non-woven fabric.
<11> The nonwoven fabric according to <9>, wherein the second fiber layer having a small fineness is disposed on the first surface side, and the first fiber layer having a large fineness is disposed on the second surface side.
<12> The nonwoven fabric according to any one of <1> to <11>, wherein the nonwoven fabric contains fibers having a fineness of 4 dtex or more and 8 dtex or less.
<13> The nonwoven fabric according to <12>, wherein the nonwoven fabric contains fibers having a fineness of 4 dtex or more and 7 dtex or less.
<14> The nonwoven fabric according to any one of <1> to <13>, wherein the nonwoven fabric includes a first fiber having a fineness of 1 dtex or more and less than 4 dtex and a second fiber having a fineness of 4 dtex or more and 8 dtex or less.
<15> The nonwoven fabric according to any one of <1> to <14>, wherein the nonwoven fabric includes a first fiber having a fineness of 2 dtex to 3.5 dtex and a second fiber having a fineness of 4 dtex to 6 dtex.
<16> Any one of <1> to <15>, wherein the fiber density of the solid portion of the first protrusion is higher than the fiber density of the first protrusion and lower than the fiber density of the bottom of the recess. The nonwoven fabric described in 1.
<17> Any one of <1> to <16>, wherein the fiber density of the first protrusion is higher than the fiber density of the solid part of the first protrusion and lower than the fiber density of the bottom of the recess. The nonwoven fabric described in 1.
<18> The nonwoven fabric according to any one of <1> to <17> is used with the first surface side facing the wearer's skin side, and the second surface side is disposed on the absorbent side inside the article. Absorbent article used as a surface sheet.
<19> Using the nonwoven fabric according to any one of <1> to <17>, the first surface side is directed toward the skin surface of the wearer, and the second surface side is disposed on the absorber side inside the article. Sanitary napkin used as a surface sheet.
<20> The method for producing a nonwoven fabric according to any one of <1> to <17>, wherein a web including a plurality of types of fibers having different fineness is alternately arranged in a direction in which a number of protrusions and holes are different from a card machine. A method for producing a nonwoven fabric, which is arranged on a support arranged in a shape, blows a first hot air from the second surface side of the nonwoven fabric, and then blows the second hot air to fuse the fibers together.

Hereinafter, the present invention will be described in more detail based on examples. The present invention is not construed as being limited by these examples.

[Example 1-6]
Example 1 is a non-woven fabric having the configuration of the first embodiment. The core-sheath type composite fibers of 2.4 dtex × 51 mm and 4.4 dtex × 51 mm whose core is made of polyethylene terephthalate and whose sheath is made of polyethylene have a basis weight ratio of 1: The web 50 was fed from two card machines to a device for shaping the web 50 so that the basis weight was 36 g / m ² . In this shaping apparatus, the web 50 was fixed on a support 110 having a large number of protrusions and having air permeability. The MD pitch in the plan view of the protrusion 111 of the support 110 was 8 mm, the CD pitch was 5 mm, and the protrusion height was 7.5 mm. Moreover, the hole diameter of the hole 112 in the support body 110 was 2.8 mm.
Next, the web 50 on the support 110 is shaped by blowing the first hot air W1 (temperature 130 ° C., wind speed 50 m / s), and the web 50 is shaped along the protrusions 111 on the support 110. At the same time, the fibers were switched to the second hot air W2 having a temperature of 145 ° C. and a wind speed of 5 m / s to fuse the fibers of each core-sheath structure. The line speed at this time was 100 m / min. Thus, the nonwoven fabric 10 was produced by heat-sealing to obtain a nonwoven fabric test body of Example 1. The nonwoven fabric thickness T of Example 1 was 3.3 mm, and the first protrusion thickness (Ta) was 1.9 mm.
Example 2 is a non-woven fabric having the configuration of the first embodiment. Example 1 except that a core-sheath type composite fiber of 6.7 dtex × 51 mm was used instead of the core-sheath type composite fiber of 4.4 dtex × 51 mm. A nonwoven fabric 10 was produced under the same conditions as those described above. The thickness T of the nonwoven fabric 10 of Example 2 was 3.4 mm, and the thickness of the first protrusion was 3.0 mm.

Example 3 is a nonwoven fabric having the configuration of the second embodiment, wherein the first surface side Z1 of the web 50 is a core-sheath type composite fiber layer of 4.4 dtex × 51 mm so that the basis weight is 18 g / m ² . A nonwoven fabric 10 was produced under the same conditions as in Example 1 except that the two-surface side Z2 was a core-sheath composite fiber layer of 2.4 dtex × 51 mm and the basis weight was 18 g / m ² . The nonwoven fabric 10 of Example 3 had a thickness T of 3.2 mm and a first protrusion thickness (Ta) of 2.5 mm.
Example 4 is a nonwoven fabric having the configuration of the second embodiment, wherein the first surface side Z1 of the web 50 is a core-sheath type composite fiber layer of 6.7 dtex × 51 mm, and the basis weight is 18 g / m ² . A nonwoven fabric 10 was produced under the same conditions as in Example 1 except that the two-surface side Z2 was a core-sheath composite fiber layer of 2.4 dtex × 51 mm and the basis weight was 18 g / m ² . The nonwoven fabric 10 of Example 4 had a thickness T of 3.2 mm and a first protrusion thickness (Ta) of 2.7 mm.

Example 5 is a nonwoven fabric having the configuration of the third embodiment. The first surface side Z1 of the web 50 is a core-sheath type composite fiber layer of 2.4 dtex × 51 mm so that the basis weight is 18 g / m ² . A nonwoven fabric 10 was produced under the same conditions as in Example 1 except that the two-surface side Z2 was a core-sheath composite fiber layer of 4.4 dtex × 51 mm and the basis weight was 18 g / m ² . The nonwoven fabric 10 of Example 5 had a thickness T of 3.2 mm and a first protrusion thickness (Ta) of 2.2 mm.
Example 6 is a nonwoven fabric having the configuration of the third embodiment. The first surface side Z1 of the web 50 is a core-sheath type composite fiber layer of 2.4 dtex × 51 mm so that the basis weight is 18 g / m ² . A nonwoven fabric 10 was produced under the same conditions as in Example 1 except that the two-surface side Z2 was a core-sheath type composite fiber layer of 6.7 dtex × 51 mm and the basis weight was 18 g / m ² . The nonwoven fabric 10 of Example 6 had a thickness T of 3.2 mm and a first protrusion thickness (Ta) of 3.2 mm.

[Comparative Example 1-3]
The comparative example 1 produced the nonwoven fabric test body on the conditions similar to the said Example 1 except having used the core-sheath-type composite fiber of 3.3 dtex * 51mm instead of the core-sheath-type composite fiber of 4.4 dtex * 51mm. . The nonwoven fabric of Comparative Example 1 had a thickness T of 3.2 mm and a first protrusion thickness (Ta) of 1.2 mm. Moreover, the comparative example 1 does not have a solid part.
Comparative Example 2 is a production method described in Japanese Patent Application Laid-Open No. 2004-174234 (Patent Document 3). A 2.4 dtex × 51 mm fiber and a 4.4 dtex × 51 mm fiber are mixed to obtain a basis weight of 18 g / m. The lower layer of the sheet having a basis weight of 18 g / m ² by mixing an upper layer having a large number of convex portions that are hollow inside ² and a fiber of 2.4 dtex × 51 mm and a fiber of 4.4 dtex × 51 mm Were bonded to each other to prepare a nonwoven fabric specimen. The thickness of the nonwoven fabric of Comparative Example 2 was 1.5 mm, and the layer thickness of the convex portion corresponding to the first protrusion thickness was 0.5 mm.
Comparative Example 3 is a nonwoven fabric specimen characterized by having a streak-like uneven shape having a solid part by the production method described in Example 1 of JP-A-2008-25081 (Patent Document 2). Was made. The thickness of the nonwoven fabric of Comparative Example 2 was 3.4 mm, and the thickness of the convex portion corresponding to the first protrusion thickness was 3.4 mm.

Next, the measurement method and evaluation method will be described. The following measurement tests were performed using the above-mentioned nonwoven fabric test specimens.

<Measurement of thickness>
Cut the non-woven fabric specimen into a cross section in the CD direction, and expand the cut surface to a size (10 times to 100 times) that can be measured by the Keyence digital microscope VHX-1000. The nonwoven fabric thickness T (mm) and the first protrusion thickness Ta (mm) were measured. The nonwoven fabric thickness T is the top surface of the first protrusion 11 located on the first surface side Z1 farthest from the second surface side Z2 and the second surface farthest from the first surface side Z1 in the nonwoven fabric 10 viewed from the side. It was set as the space | interval of the parallel plane which passes along the nonwoven fabric part located in the side Z2. The first protrusion thickness Ta is the thickness of the layer including the first protrusion top 11T and the solid portion 15. The measurement was performed five times for each in an environment of a temperature of 22 ° C. and a relative humidity (RH) of 65%, and the average values were defined as the nonwoven fabric thickness T and the first protrusion thickness Ta (see FIG. 2). .

<Measurement of orientation angle and orientation strength>
Measurement of fiber orientation (orientation angle, orientation strength) was performed as follows.
A surface on which the sample is measured using a scanning electron microscope JCM-5100 manufactured by JEOL Ltd. so that the direction connecting the top of the first protrusion and the bottom of the recess is up and down. An image (adjusted to a magnification capable of measuring 10 or more fibers to be measured: 100 to 300 times) was printed and traced on a transparent PET sheet. The said image was taken in in the personal computer and the said image was binarized using the NexusNew Inc. nextNewcube (stand-alone version) image processing software. Next, the binarized image is subjected to Fourier transform using Fiber Orientation Analysis 8.13 Single software manufactured by Nexus Co., Ltd., which is a fiber orientation analysis program, to obtain a power spectrum, and from an elliptical distribution map, An orientation angle and orientation strength were obtained.

The orientation angle indicates the angle at which the fibers are most oriented, and the orientation strength indicates the strength at the orientation angle. In the measurement of the wall portion, the orientation angle closer to 90 ° indicates that the fiber is oriented from the bottom portion 12T of the dent portion toward the first protrusion top portion 11T, and should be 50 ° or more and 130 ° or less. For example, it was determined that the fibers were oriented in a direction from the recess bottom 12T toward the first protrusion top 11T.
Moreover, it represents that the direction of a fiber has gathered, so that the value of orientation strength is large. The case where the orientation strength is 1.05 or more is regarded as being oriented.
The orientation angle and orientation strength were measured at three locations, and the average of these measured values was taken as the orientation angle and orientation strength of the test specimen. In the examples of the present application and the comparative example, the measurement of the orientation angle and orientation strength of the wall portion was performed on the CD direction cross section.

The fiber orientation described above is a concept consisting of the orientation angle and orientation strength of the fiber.
The fiber orientation angle is a concept that indicates in which direction a plurality of fibers having various directions are oriented as a whole, and the shape of the fiber aggregate is quantified. The orientation strength of the fiber is a concept indicating the amount of fibers exhibiting an orientation angle. The orientation strength is less than 1.05 and is hardly oriented, and it can be said that the orientation strength is 1.05 or more. However, in this embodiment, the fiber orientation changes depending on the part. That is, the orientation strength is changed during the transition from a part having a certain orientation angle to a part having a different orientation angle (while the fiber is changing from a state where the orientation strength is strong in one direction to a part showing a strong strength in a different orientation). It has various states such as a weak state and a high state due to reorientation. Therefore, it is preferable that the orientation angle of the fiber is changed between the part showing a strong orientation angle and the part showing a strong orientation angle in another direction even if the orientation strength of the fiber is weak, and the orientation strength is high. Is more preferable. An example of the orientation angle and the orientation strength is shown in the present embodiment. The orientation angle is preferably 50 ° or more and 130 ° or less, more preferably 70 ° or more and 110 ° with respect to the first surface side Z1 of the first protrusion 11. The orientation strength is preferably 1.05 or more, and more preferably 1.10 or more.
Since the orientation direction of the fibers of the wall portion 13 is the direction toward the top portion, the cushioning property is expressed. Moreover, when the nonwoven fabric 10 is used as a surface sheet, when the fiber strength of the wall portion 13 is different, for example, the first surface side Z1 of the first protrusion 11 has higher orientation strength than the second surface side Z2. Thereby, the 1st protrusion part 11 becomes difficult to be crushed, a contact area rate with skin is reduced even at the time of high pressurization, and the touch which is kind to skin can be given.

<Measurement of fiber density>
Cut the non-woven fabric into a cross section in the CD direction, and use a scanning electron microscope to magnify the cut surface (magnification (150 to 500 times) at which the number of fibers in the fiber cross section can be measured from 30 to 60 fibers) The cross-sectional area of the fiber cut by the cut surface per fixed area was measured and the observation site was the thickness (d1) of the first protrusion, solid The thickness of the first protrusion (d1) was set to the same value as the thickness (Tb) of the recess. The number of cross-sections of fibers per mm ² was converted into the fiber density (lines / mm ² ), measured at three locations, and averaged to obtain the fiber density of the sample. Use JCM-5100 (trade name) manufactured by JEOL Ltd. It was.

Next, the evaluation method will be described. Evaluation examined the performance of the nonwoven fabric test body as sheet performance. That is, “compression recovery”, “liquid remaining amount and L value” and the like were evaluated as cushioning properties.

<Evaluation of compression recovery>
For the compression recovery property, a KES compression tester (KES FB-3 manufactured by Kato Tech Co., Ltd.) was used to evaluate the compression characteristics up to 5.0 kPa in the normal mode, and the RC value was read. As measurement values, three points were measured and the average value was defined as compression recovery. This KES compression tester is a plate having a circular plane with an area of 2 cm ^{2 at} the compression site, the compression speed is 0.02 mm / s, the compression maximum pressure is 5.0 kPa, and the compression direction is reached when the compression maximum pressure is reached. Is reversed and the process proceeds to the recovery process. The RC value indicates the percentage of energy recovered relative to the energy during compression, and the greater the RC value, the better the resilience to compression and the greater the elasticity. The RC value in the compression characteristic evaluation is the time integral value of the pressure from the time T ₀ when the initial pressure applied to the nonwoven fabric specimen is 0.05 kPa to the time T _m when the maximum pressure is 5.0 kPa, up to the maximum pressure of 5.0 kPa. Divided by the amount of work and expressed in%.
When the RC value is 55% or more, it is expressed as “A” because the cushioning property is excellent,
When the RC value is 45% or more and less than 55%, the cushioning property is expressed as “B”,
When the RC value is less than 45%, the cushioning property is inferior and is expressed as “C”.

<Evaluation of remaining liquid amount and L value>
As an example of the absorbent article, the surface sheet is removed from a sanitary napkin (“Lorier Speed + Skin Clean Guard” manufactured by Kao Corporation 2011), and a non-woven fabric test specimen is laminated instead, and the periphery is fixed. The obtained sanitary napkin for evaluation was used. Then, an acrylic plate with a cylinder having a cross-sectional area of 1000 mm ² was placed on the sanitary napkin for evaluation including the nonwoven fabric test body so that a pressure of 0.1 kPa was applied. Next, 3 g of horse blood (manufactured by Nihon Biotech) was injected from the tube. After injecting the horse blood, it was left for 1 minute, and the acrylic plate was removed.

Next, the L value (whiteness) of the surface of the test body 100 that absorbed horse blood 105 was measured immediately. A color difference meter SZ-Σ80 (trade name) manufactured by Nippon Denshoku Co., Ltd. was used as a measuring instrument (not shown).

Immediately after that, a tissue paper (“Sophia Touch” manufactured by Masco Paper Co., Ltd.) folded in four is placed on the specimen, and a plate is placed on the tissue paper, and a pressure of 0.4 kPa is applied evenly over the whole specimen for 5 seconds. It was over. Immediately after releasing the pressure, the mass of the tissue paper in which horse blood was absorbed was measured. Then, a value (m1−m0) obtained by subtracting the mass m0 of the tissue paper before liquid absorption, which was measured in advance, from the mass m1 of the tissue paper after liquid absorption was used as the liquid remaining amount of the test specimen.
In the evaluation of the remaining amount of liquid, it can be determined that the smaller the value is, the higher the liquid drawability of the specimen is, and if it is less than 70 mg, it is good and does not give discomfort to the wearer.
Evaluation of L value (whiteness) can be judged that the higher the whiteness, the higher the liquid drawability of the test specimen, and if the L value is 55 or more, it is good and does not give the wearer discomfort.

About the nonwoven fabric 10, the result is shown about the physical property (fineness, basic weight, thickness, 1st protrusion part thickness, fiber orientation angle, fiber orientation degree, fiber density) and performance (compression recovery property, liquid residual amount, and L value). It is shown in 1.

As is clear from the results shown in Table 1, Examples 1 to 6 obtained good results in any of the evaluation items.
Each of the CD direction wall portion orientation angles had a high orientation angle of 68 ° to 81 °, and the orientation strength was as high as 1.1 to 1.3.
The fiber density, the first protrusion 11 is 45 present / mm ² or more 85 present / mm ² or less, the solid portion 15 is sixty / mm ² or more 144 / mm ² or less, recess 12 275 lines / mm ² or more 390 present / mm ² or less, both high recess 12, the first protrusion 11, solid portion 15 is lowered.
Further, the cushioning property was 57% or more in RC value, and the remaining amount of the surface material liquid was as small as 61 mg or less. Further, the L value was 56 or more, and the liquid concealability was excellent.

Comparative Example 1 has a CD orientation wall portion orientation angle as high as 80 ° and an orientation strength as high as 1.4, but does not have a solid portion, so it is compared with the Example. As a result, the cushioning property was slightly lowered, and the RC value was 53%. The fiber density, first protrusion 71 present / mm ^2, recess (projection of the second surface side) and 345 present / mm ^2, although the recess is higher than the first projecting portion Since it does not have a solid part, the liquid drawability of a highly viscous liquid such as blood is reduced compared to the example, so the remaining amount of the surface material liquid is slightly increased to 120 mg, and the L value is 53, and the concealability of the liquid was insufficient.
Comparative Example 2 has a high orientation strength of 1.19, a CD direction wall orientation angle of 172 °, and the fibers are oriented in a substantially lying state. The shape may be crushed, the cushioning property is low, and the RC value was 34%. In Comparative Example 2, since the fiber density of the convex portion is relatively high at 115 and does not have a solid portion, the liquid drawability of a highly viscous liquid such as blood is reduced as compared with the Example. Therefore, the remaining amount of the surface material liquid was as large as 378 mg, and the L value was 45, so that the liquid concealing property was insufficient.
In addition, although the orientation of Comparative Example 3 was not measured, the RC value was 53%, which was a result of slightly inferior cushioning properties compared to the Examples. The fiber density convex portions 65 present / mm ^2, the groove is 30 lines / mm ^2, the convex portion is higher than the groove, high viscosity liquids such as loose passage or menstrual blood is excreted At this time, since it is difficult for the liquid to move from the convex portion to the groove portion, the liquid drawability of the liquid is lower than that of the example, so the remaining amount of the surface material liquid is slightly increased to 71 mg, and the L value is 43. As a result, the concealability of the liquid was insufficient.

As described above, in the nonwoven fabric 10 of this embodiment used in Examples 1 to 6, the first protrusions 11 and the recesses 12 alternately pass through the wall portions 13 in different directions where the nonwoven fabric intersects in plan view. A favorable evaluation result was obtained by including fibers having a continuously arranged structure and different fineness. In particular, in the configuration having a fiber layer with a large fineness on the first surface side Z1, the remaining amount of the surface material liquid was very small, the L value (whiteness) was high, and the liquid concealing property was excellent. Further, among fibers having different finenesses, even if fibers having a fineness of 4.4 dtex or 6.7 dtex are included, fibers having a small fineness of 2.4 dtex are also included, so that deterioration of the texture is suppressed. It was. In particular, the structure in which fibers having different finenesses were mixed and the structure having a fiber layer with a small fineness on the first surface side Z1 were excellent in the texture on the first surface side Z1.
In addition, Examples 1 to 6 had an excellent effect that good cushioning properties were obtained. In other words, the wall portion has fiber orientation in the direction connecting the top portion of the first protrusion and the bottom portion of the hollow portion, and contains fibers having different fineness, so that the thickness including the apex of the first protrusion is (Ta / T) × 100 ≧ 50%, so that the ratio of energy recovered to the energy during compression increases, the recovery from compression is enhanced, and the elasticity is improved. More enhanced. Therefore, even if the nonwoven fabric 10 is crushed due to the pressing force, the shape restoring force is large, and it is difficult to lose the initial cushioning force even if the packing state and wearing are continued.
Furthermore, the nonwoven fabric 10 of the present embodiment has a three-dimensional cushioning property that is well supported by a three-dimensional movement and is supported at the vertex 11Tp of the first protrusion 11. On the other hand, streak-like projections and one-side projections inevitably exhibit elasticity as lines or surfaces, and lack three-dimensional followability.

Although the invention has been described in conjunction with the embodiments and examples, we do not intend to limit our invention in any detail of the description unless otherwise specified, and that the spirit and scope of the invention as set forth in the appended claims I think it should be interpreted broadly without violating the scope.

This application claims priority based on Japanese Patent Application No. 2012-130203 filed in Japan on June 7, 2012 and Japanese Patent Application No. 2013-045998 filed on March 7, 2013 in Japan. Which are hereby incorporated by reference herein as part of their description.

DESCRIPTION OF SYMBOLS 10 Nonwoven fabric 11 1st protrusion part 11K Internal space (of 1st protrusion part) 11T 1st protrusion part top part (the top part of a 1st protrusion part)
12 2nd protrusion part 12 hollow part, 2nd protrusion part 12K internal space (of hollow part), internal space (of 2nd protrusion part) 12T hollow part bottom part (bottom part of hollow part), 2nd protrusion part top part (2nd The top of the protrusion)
13 Wall portion 15 Solid portion 16 First fiber layer 17 Second fiber layer

Claims

A first projecting portion projecting to the first surface side of the nonwoven fabric of the sheet in plan view, and a recessed portion recessed on the second surface side opposite to the first surface side, the first projecting portion; And the depressions are continuously arranged through the wall alternately in each of the different directions intersecting the planar view of the nonwoven fabric,
The wall has fiber orientation in a direction connecting the top of the first protrusion and the bottom of the recess,
(Ta / T) × 100 (%) is 50% or more, where Ta is the thickness of the first protrusion including the apex of the first protrusion, and T is the thickness of the entire nonwoven fabric as viewed from the side. ,
A nonwoven fabric containing fibers having different finenesses in the nonwoven fabric.
The nonwoven fabric according to claim 1, wherein the (Ta / T) x 100 (%) is 50% or more and 100% or less.
The nonwoven fabric according to claim 1, wherein the (Ta / T) x 100 (%) is 50% or more and less than 100%.
The nonwoven fabric according to claim 1, wherein the (Ta / T) x 100 (%) is 75% or more and 85% or less.
A second protrusion that protrudes toward the second surface and shares the internal space of the recess,
The first and second protrusions are continuously arranged through the wall alternately in each of different directions intersecting in plan view of the nonwoven fabric,
The continuous wall is disposed between the top of the first protrusion and the top of the second protrusion, and the wall connects the top of the first protrusion and the top of the second protrusion. The nonwoven fabric of any one of Claim 1 to 4 which has fiber orientation in a direction.
The nonwoven fabric according to any one of claims 1 to 5, wherein the fiber orientation of the wall portion is in a radial direction from the top of the first projecting portion toward the bottom of the surrounding recess.
The nonwoven fabric according to any one of claims 1 to 6, wherein the fiber density at the top of the first protrusion is lower than the fiber density at the bottom of the recess.
The nonwoven fabric according to any one of claims 1 to 7, wherein the nonwoven fabric is a mixture of a plurality of types of fibers having different finenesses.
The nonwoven fabric according to any one of claims 1 to 8, wherein the nonwoven fabric has a plurality of layers having different finenesses.
The non-woven fabric according to claim 9, wherein the non-woven fabric is provided with a first fiber layer having a high fineness on the first surface side and a second fiber layer having a low fineness on the second surface side.
The non-woven fabric according to claim 9, wherein the non-woven fabric is provided with a second fiber layer having a small fineness on the first surface side and a first fiber layer having a high fineness on the second surface side.
The nonwoven fabric according to any one of claims 1 to 11, wherein the nonwoven fabric contains fibers having a fineness of 4 dtex or more and 8 dtex or less.
The nonwoven fabric according to claim 12, wherein the nonwoven fabric contains fibers having a fineness of 4 dtex or more and 7 dtex or less.
The nonwoven fabric according to any one of claims 1 to 13, wherein the nonwoven fabric contains a first fiber having a fineness of 1 dtex or more and less than 4 dtex and a second fiber having a fineness of 4 dtex or more and 8 dtex or less.
The non-woven fabric according to any one of claims 1 to 14, wherein the non-woven fabric contains first fibers having a fineness of 2 dtex or more and 3.5 dtex or less and second fibers having a fineness of 4 dtex or more and 6 dtex or less.
The nonwoven fabric according to any one of claims 1 to 15, wherein a fiber density of a solid part of the first protruding part is higher than a fiber density of the first protruding part and lower than a fiber density of a bottom part of the hollow part.
The nonwoven fabric according to any one of claims 1 to 16, wherein the fiber density of the first protrusion is higher than the fiber density of the solid part of the first protrusion and lower than the fiber density of the bottom of the recess.
The nonwoven fabric according to any one of claims 1 to 17, wherein the first surface side is directed toward the skin surface of the wearer, and the second surface side is disposed on the absorber side inside the article to form a surface sheet. Absorbent article to be used.
The nonwoven fabric according to any one of claims 1 to 17, wherein the first surface side is directed toward the skin surface of the wearer, and the second surface side is disposed on the absorber side inside the article to form a surface sheet. Sanitary napkin used.
18. The method for producing a nonwoven fabric according to claim 1, wherein a web including a plurality of types of fibers having different finenesses from a card machine is supported by a plurality of protrusions and holes alternately arranged in different directions. A method for producing a nonwoven fabric, which is disposed on a body, shaped by blowing a first hot air from the second surface side of the nonwoven fabric, and further fused the fibers by blowing a second hot air.