WO2014030702A1 - 不織布積層体 - Google Patents
不織布積層体 Download PDFInfo
- Publication number
- WO2014030702A1 WO2014030702A1 PCT/JP2013/072421 JP2013072421W WO2014030702A1 WO 2014030702 A1 WO2014030702 A1 WO 2014030702A1 JP 2013072421 W JP2013072421 W JP 2013072421W WO 2014030702 A1 WO2014030702 A1 WO 2014030702A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- nonwoven fabric
- ethylene polymer
- fabric laminate
- laminate according
- ethylene
- Prior art date
Links
- 239000004745 nonwoven fabric Substances 0.000 title claims abstract description 162
- 229920000573 polyethylene Polymers 0.000 claims abstract description 137
- 239000000835 fiber Substances 0.000 claims abstract description 77
- 239000004744 fabric Substances 0.000 claims abstract description 62
- 239000004750 melt-blown nonwoven Substances 0.000 claims abstract description 55
- 229920000642 polymer Polymers 0.000 claims abstract description 37
- 239000000203 mixture Substances 0.000 claims abstract description 33
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 30
- 229920000728 polyester Polymers 0.000 claims abstract description 25
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 29
- 239000005977 Ethylene Substances 0.000 claims description 29
- 239000002131 composite material Substances 0.000 claims description 21
- 239000012968 metallocene catalyst Substances 0.000 claims description 12
- 239000000155 melt Substances 0.000 claims description 10
- 238000002425 crystallisation Methods 0.000 claims description 9
- 150000003623 transition metal compounds Chemical class 0.000 claims description 5
- 230000004927 fusion Effects 0.000 claims description 3
- 238000004049 embossing Methods 0.000 abstract description 18
- 230000004888 barrier function Effects 0.000 abstract description 15
- 239000002952 polymeric resin Substances 0.000 abstract description 2
- 238000000034 method Methods 0.000 description 78
- -1 Polyethylene Polymers 0.000 description 35
- 238000004519 manufacturing process Methods 0.000 description 23
- 239000004698 Polyethylene Substances 0.000 description 22
- 239000000463 material Substances 0.000 description 22
- 239000010410 layer Substances 0.000 description 20
- 239000003795 chemical substances by application Substances 0.000 description 16
- 238000012360 testing method Methods 0.000 description 15
- 239000000853 adhesive Substances 0.000 description 13
- 230000001070 adhesive effect Effects 0.000 description 12
- 239000000126 substance Substances 0.000 description 11
- 239000003054 catalyst Substances 0.000 description 10
- 230000000704 physical effect Effects 0.000 description 10
- 229920005989 resin Polymers 0.000 description 9
- 239000011347 resin Substances 0.000 description 9
- 230000000052 comparative effect Effects 0.000 description 8
- 238000005259 measurement Methods 0.000 description 8
- 230000002940 repellent Effects 0.000 description 8
- 239000005871 repellent Substances 0.000 description 8
- 238000010894 electron beam technology Methods 0.000 description 7
- 238000009987 spinning Methods 0.000 description 7
- 239000004711 α-olefin Substances 0.000 description 7
- 229920001577 copolymer Polymers 0.000 description 6
- 230000001954 sterilising effect Effects 0.000 description 6
- 238000004659 sterilization and disinfection Methods 0.000 description 6
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 5
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 description 5
- 230000008025 crystallization Effects 0.000 description 5
- 239000003381 stabilizer Substances 0.000 description 5
- AFFLGGQVNFXPEV-UHFFFAOYSA-N 1-decene Chemical compound CCCCCCCCC=C AFFLGGQVNFXPEV-UHFFFAOYSA-N 0.000 description 4
- CRSBERNSMYQZNG-UHFFFAOYSA-N 1-dodecene Chemical compound CCCCCCCCCCC=C CRSBERNSMYQZNG-UHFFFAOYSA-N 0.000 description 4
- GQEZCXVZFLOKMC-UHFFFAOYSA-N 1-hexadecene Chemical compound CCCCCCCCCCCCCCC=C GQEZCXVZFLOKMC-UHFFFAOYSA-N 0.000 description 4
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 4
- HFDVRLIODXPAHB-UHFFFAOYSA-N 1-tetradecene Chemical compound CCCCCCCCCCCCC=C HFDVRLIODXPAHB-UHFFFAOYSA-N 0.000 description 4
- WSSSPWUEQFSQQG-UHFFFAOYSA-N 4-methyl-1-pentene Chemical compound CC(C)CC=C WSSSPWUEQFSQQG-UHFFFAOYSA-N 0.000 description 4
- 238000005299 abrasion Methods 0.000 description 4
- 238000005452 bending Methods 0.000 description 4
- 238000001816 cooling Methods 0.000 description 4
- 235000014113 dietary fatty acids Nutrition 0.000 description 4
- 229920001038 ethylene copolymer Polymers 0.000 description 4
- 238000011156 evaluation Methods 0.000 description 4
- 239000000194 fatty acid Substances 0.000 description 4
- 229930195729 fatty acid Natural products 0.000 description 4
- 238000010030 laminating Methods 0.000 description 4
- 229920000092 linear low density polyethylene Polymers 0.000 description 4
- 239000004707 linear low-density polyethylene Substances 0.000 description 4
- CCCMONHAUSKTEQ-UHFFFAOYSA-N octadec-1-ene Chemical compound CCCCCCCCCCCCCCCCC=C CCCMONHAUSKTEQ-UHFFFAOYSA-N 0.000 description 4
- 239000003921 oil Substances 0.000 description 4
- YWAKXRMUMFPDSH-UHFFFAOYSA-N pentene Chemical compound CCCC=C YWAKXRMUMFPDSH-UHFFFAOYSA-N 0.000 description 4
- 238000012545 processing Methods 0.000 description 4
- 239000012748 slip agent Substances 0.000 description 4
- ROGIWVXWXZRRMZ-UHFFFAOYSA-N 2-methylbuta-1,3-diene;styrene Chemical compound CC(=C)C=C.C=CC1=CC=CC=C1 ROGIWVXWXZRRMZ-UHFFFAOYSA-N 0.000 description 3
- 229920000742 Cotton Polymers 0.000 description 3
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 3
- 239000004831 Hot glue Substances 0.000 description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 3
- 239000002174 Styrene-butadiene Substances 0.000 description 3
- 239000002390 adhesive tape Substances 0.000 description 3
- MTAZNLWOLGHBHU-UHFFFAOYSA-N butadiene-styrene rubber Chemical compound C=CC=C.C=CC1=CC=CC=C1 MTAZNLWOLGHBHU-UHFFFAOYSA-N 0.000 description 3
- 125000004432 carbon atom Chemical group C* 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- 229920001971 elastomer Polymers 0.000 description 3
- 229920001519 homopolymer Polymers 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 238000002074 melt spinning Methods 0.000 description 3
- 238000000465 moulding Methods 0.000 description 3
- 239000002667 nucleating agent Substances 0.000 description 3
- 238000004806 packaging method and process Methods 0.000 description 3
- 239000005020 polyethylene terephthalate Substances 0.000 description 3
- 229920000139 polyethylene terephthalate Polymers 0.000 description 3
- 239000002994 raw material Substances 0.000 description 3
- 239000005060 rubber Substances 0.000 description 3
- 239000002904 solvent Substances 0.000 description 3
- 239000011115 styrene butadiene Substances 0.000 description 3
- 229920003048 styrene butadiene rubber Polymers 0.000 description 3
- RFFLAFLAYFXFSW-UHFFFAOYSA-N 1,2-dichlorobenzene Chemical compound ClC1=CC=CC=C1Cl RFFLAFLAYFXFSW-UHFFFAOYSA-N 0.000 description 2
- VBICKXHEKHSIBG-UHFFFAOYSA-N 1-monostearoylglycerol Chemical compound CCCCCCCCCCCCCCCCCC(=O)OCC(O)CO VBICKXHEKHSIBG-UHFFFAOYSA-N 0.000 description 2
- 206010004542 Bezoar Diseases 0.000 description 2
- NLZUEZXRPGMBCV-UHFFFAOYSA-N Butylhydroxytoluene Chemical compound CC1=CC(C(C)(C)C)=C(O)C(C(C)(C)C)=C1 NLZUEZXRPGMBCV-UHFFFAOYSA-N 0.000 description 2
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 description 2
- 229920001410 Microfiber Polymers 0.000 description 2
- 229940123973 Oxygen scavenger Drugs 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 239000002216 antistatic agent Substances 0.000 description 2
- 239000012298 atmosphere Substances 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 2
- 239000003086 colorant Substances 0.000 description 2
- 238000013329 compounding Methods 0.000 description 2
- 238000000151 deposition Methods 0.000 description 2
- 229940069096 dodecene Drugs 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 239000000975 dye Substances 0.000 description 2
- 239000011737 fluorine Substances 0.000 description 2
- 229910052731 fluorine Inorganic materials 0.000 description 2
- 239000012760 heat stabilizer Substances 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 229920001903 high density polyethylene Polymers 0.000 description 2
- 239000004700 high-density polyethylene Substances 0.000 description 2
- 230000001771 impaired effect Effects 0.000 description 2
- 239000012770 industrial material Substances 0.000 description 2
- 229920001684 low density polyethylene Polymers 0.000 description 2
- 239000004702 low-density polyethylene Substances 0.000 description 2
- 239000000314 lubricant Substances 0.000 description 2
- 239000012567 medical material Substances 0.000 description 2
- 229920001179 medium density polyethylene Polymers 0.000 description 2
- 239000004701 medium-density polyethylene Substances 0.000 description 2
- 239000003658 microfiber Substances 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 2
- 239000002530 phenolic antioxidant Substances 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 239000006187 pill Substances 0.000 description 2
- 238000006116 polymerization reaction Methods 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 2
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 2
- 239000008262 pumice Substances 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- 229940095068 tetradecene Drugs 0.000 description 2
- 229910052719 titanium Inorganic materials 0.000 description 2
- 239000010936 titanium Substances 0.000 description 2
- 229910052723 transition metal Inorganic materials 0.000 description 2
- 150000003624 transition metals Chemical class 0.000 description 2
- WZUNUACWCJJERC-UHFFFAOYSA-N 2,2-bis(hydroxymethyl)butyl octadecanoate Chemical compound CCCCCCCCCCCCCCCCCC(=O)OCC(CC)(CO)CO WZUNUACWCJJERC-UHFFFAOYSA-N 0.000 description 1
- ROHFBIREHKPELA-UHFFFAOYSA-N 2-[(3,5-ditert-butyl-4-hydroxyphenyl)methyl]prop-2-enoic acid;methane Chemical compound C.CC(C)(C)C1=CC(CC(=C)C(O)=O)=CC(C(C)(C)C)=C1O.CC(C)(C)C1=CC(CC(=C)C(O)=O)=CC(C(C)(C)C)=C1O.CC(C)(C)C1=CC(CC(=C)C(O)=O)=CC(C(C)(C)C)=C1O.CC(C)(C)C1=CC(CC(=C)C(O)=O)=CC(C(C)(C)C)=C1O ROHFBIREHKPELA-UHFFFAOYSA-N 0.000 description 1
- KIHBGTRZFAVZRV-UHFFFAOYSA-N 2-hydroxyoctadecanoic acid Chemical class CCCCCCCCCCCCCCCCC(O)C(O)=O KIHBGTRZFAVZRV-UHFFFAOYSA-N 0.000 description 1
- 241000894006 Bacteria Species 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 239000005909 Kieselgur Substances 0.000 description 1
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- XBDQKXXYIPTUBI-UHFFFAOYSA-M Propionate Chemical compound CCC([O-])=O XBDQKXXYIPTUBI-UHFFFAOYSA-M 0.000 description 1
- 229920000297 Rayon Polymers 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- FSEJJKIPRNUIFL-UHFFFAOYSA-N [2,2-bis(hydroxymethyl)-3-octadecanoyloxypropyl] octadecanoate Chemical compound CCCCCCCCCCCCCCCCCC(=O)OCC(CO)(CO)COC(=O)CCCCCCCCCCCCCCCCC FSEJJKIPRNUIFL-UHFFFAOYSA-N 0.000 description 1
- FWCDLNRNBHJDQB-UHFFFAOYSA-N [2-(hydroxymethyl)-3-octadecanoyloxy-2-(octadecanoyloxymethyl)propyl] octadecanoate Chemical compound CCCCCCCCCCCCCCCCCC(=O)OCC(CO)(COC(=O)CCCCCCCCCCCCCCCCC)COC(=O)CCCCCCCCCCCCCCCCC FWCDLNRNBHJDQB-UHFFFAOYSA-N 0.000 description 1
- 230000002745 absorbent Effects 0.000 description 1
- 239000002250 absorbent Substances 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 230000003712 anti-aging effect Effects 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 239000010425 asbestos Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000008280 blood Substances 0.000 description 1
- 210000004369 blood Anatomy 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000000378 calcium silicate Substances 0.000 description 1
- 229910052918 calcium silicate Inorganic materials 0.000 description 1
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 description 1
- 239000008116 calcium stearate Substances 0.000 description 1
- 235000013539 calcium stearate Nutrition 0.000 description 1
- GBAOBIBJACZTNA-UHFFFAOYSA-L calcium sulfite Chemical compound [Ca+2].[O-]S([O-])=O GBAOBIBJACZTNA-UHFFFAOYSA-L 0.000 description 1
- 235000010261 calcium sulphite Nutrition 0.000 description 1
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
- 238000011088 calibration curve Methods 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 229910052570 clay Inorganic materials 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 239000012809 cooling fluid Substances 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- GUJOJGAPFQRJSV-UHFFFAOYSA-N dialuminum;dioxosilane;oxygen(2-);hydrate Chemical compound O.[O-2].[O-2].[O-2].[Al+3].[Al+3].O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O GUJOJGAPFQRJSV-UHFFFAOYSA-N 0.000 description 1
- 229940117389 dichlorobenzene Drugs 0.000 description 1
- NJLLQSBAHIKGKF-UHFFFAOYSA-N dipotassium dioxido(oxo)titanium Chemical compound [K+].[K+].[O-][Ti]([O-])=O NJLLQSBAHIKGKF-UHFFFAOYSA-N 0.000 description 1
- 239000010459 dolomite Substances 0.000 description 1
- 229910000514 dolomite Inorganic materials 0.000 description 1
- 239000000839 emulsion Substances 0.000 description 1
- UAUDZVJPLUQNMU-KTKRTIGZSA-N erucamide Chemical compound CCCCCCCC\C=C/CCCCCCCCCCCC(N)=O UAUDZVJPLUQNMU-KTKRTIGZSA-N 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 235000013305 food Nutrition 0.000 description 1
- 239000005003 food packaging material Substances 0.000 description 1
- 238000001879 gelation Methods 0.000 description 1
- YQEMORVAKMFKLG-UHFFFAOYSA-N glycerine monostearate Natural products CCCCCCCCCCCCCCCCCC(=O)OC(CO)CO YQEMORVAKMFKLG-UHFFFAOYSA-N 0.000 description 1
- SVUQHVRAGMNPLW-UHFFFAOYSA-N glycerol monostearate Natural products CCCCCCCCCCCCCCCCC(=O)OCC(O)CO SVUQHVRAGMNPLW-UHFFFAOYSA-N 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 150000002363 hafnium compounds Chemical class 0.000 description 1
- 238000001095 inductively coupled plasma mass spectrometry Methods 0.000 description 1
- 239000011229 interlayer Substances 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
- 239000001095 magnesium carbonate Substances 0.000 description 1
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 1
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 description 1
- 239000000347 magnesium hydroxide Substances 0.000 description 1
- 229910001862 magnesium hydroxide Inorganic materials 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 238000004949 mass spectrometry Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- CWQXQMHSOZUFJS-UHFFFAOYSA-N molybdenum disulfide Chemical compound S=[Mo]=S CWQXQMHSOZUFJS-UHFFFAOYSA-N 0.000 description 1
- 229910052901 montmorillonite Inorganic materials 0.000 description 1
- 229910017604 nitric acid Inorganic materials 0.000 description 1
- LYRFLYHAGKPMFH-UHFFFAOYSA-N octadecanamide Chemical compound CCCCCCCCCCCCCCCCCC(N)=O LYRFLYHAGKPMFH-UHFFFAOYSA-N 0.000 description 1
- UQDVHJGNIFVBLG-UHFFFAOYSA-N octadecanoic acid;propane-1,2,3-triol Chemical compound OCC(O)CO.CCCCCCCCCCCCCCCCCC(O)=O.CCCCCCCCCCCCCCCCCC(O)=O UQDVHJGNIFVBLG-UHFFFAOYSA-N 0.000 description 1
- FATBGEAMYMYZAF-KTKRTIGZSA-N oleamide Chemical compound CCCCCCCC\C=C/CCCCCCCC(N)=O FATBGEAMYMYZAF-KTKRTIGZSA-N 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 239000005022 packaging material Substances 0.000 description 1
- DOIRQSBPFJWKBE-UHFFFAOYSA-N phthalic acid di-n-butyl ester Natural products CCCCOC(=O)C1=CC=CC=C1C(=O)OCCCC DOIRQSBPFJWKBE-UHFFFAOYSA-N 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920002215 polytrimethylene terephthalate Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 150000003242 quaternary ammonium salts Chemical class 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 239000002964 rayon Substances 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 239000011342 resin composition Substances 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 230000035807 sensation Effects 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 238000009864 tensile test Methods 0.000 description 1
- 229920001897 terpolymer Polymers 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 239000003643 water by type Substances 0.000 description 1
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
- Y10T442/638—Side-by-side multicomponent strand or fiber material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T442/641—Sheath-core multicomponent strand or fiber material
Definitions
- the present invention relates to a nonwoven fabric laminate that can be sterilized by an electron beam or the like and is excellent in water resistance, low-temperature sealability and flexibility.
- Polyethylene non-woven fabric is softer and has better tactile sensation than polypropylene non-woven fabric, has excellent heat sealability, and has a low degree of deterioration even after irradiation with electron beam or radiation, etc. It is suitable for packaging, carrying and backing materials for various objects.
- polyethylene is generally inferior in melt spinnability compared to polypropylene
- polyethylene nonwoven fabrics obtained by the spunbond method or meltblown method are difficult to obtain thin fibers and have poor formation, so their use is very limited. ing.
- As an attempt to reduce the fiber diameter of the polyethylene fiber it is possible to raise the spinning temperature, but in this case, a part of the polyethylene may be cross-linked to cause gelation, which is not excellent in molding stability. .
- Patent Document 1 Japanese Patent Publication No. 2003-506582
- the nonwoven composite sheet material obtained by such a method is a so-called side-by-side type composite fiber in which the fibers forming the meltblown nonwoven fabric layer are joined by polyethylene and polyester, so that the polyester portion of the composite fiber is formed on the surface of the meltblown nonwoven fabric layer. Therefore, when laminated with a spunbond nonwoven fabric, embossing is poor and the fuzz resistance may be inferior.
- melt blown polyethylene nonwoven fabric having an average fiber diameter of 5 ⁇ m or less
- polyethylene having a weight average molecular weight of 21,000 to 45,000 and a melt flow rate of 15 to 250 g / 10 min and a weight average molecular weight of 6 are used.
- 2,000 to 12,000 polyethylene wax in a weight ratio of 70/30 to 30/70 is proposed (Patent Document 2: Japanese Patent No. 39958585).
- the melt blown polyethylene non-woven fabric obtained by such a method may be insufficient in strength, water resistance, and fuzz resistance when used as a medical gown, absorbent article, packaging / supporting / backing material for various objects in a single layer There is.
- Patent Document 2 in order to improve the abrasion resistance and fluff resistance of melt blown polyethylene nonwoven fabric, a resin composition in which polyethylene wax having a weight average molecular weight of 6000 to 12000 is blended with polyethylene is laminated with polyethylene spunbond nonwoven fabric. Have been proposed. However, the polyethylene nonwoven fabric laminate obtained by such a method is not sufficiently improved in water resistance.
- the present invention provides a nonwoven fabric laminate that is excellent in tensile strength and flexibility without being deteriorated in water resistance (barrier property) even if subjected to heat embossing treatment in order to maintain high abrasion resistance (fuzz resistance).
- the purpose is to obtain.
- the present invention relates to a fiber of an ethylene polymer resin composition
- a spunbonded nonwoven fabric made of fibers formed from an ethylene polymer (y) or an ethylene polymer (y) and a polyester polymer (x) is laminated on at least one surface of the meltblown nonwoven fabric (A).
- a nonwoven fabric laminate is provided.
- the nonwoven fabric laminate of the present invention is excellent in flexibility, water resistance (barrier property; barrier property for preventing permeation of water, blood, or an aqueous solution containing bacteria), abrasion resistance, and tensile strength. Moreover, the nonwoven fabric laminate of the present invention is excellent in low-temperature sealing properties and can be sterilized and sterilized with an electron beam or gamma rays.
- the ethylene polymer (a) which is one of the components of the ethylene polymer composition forming the melt blown nonwoven fabric (A) constituting the nonwoven fabric laminate of the present invention, is an ethylene homopolymer or ethylene and other components.
- Copolymer with ⁇ -olefin usually having a density of 0.870 to 0.980 g / cm 3 , preferably 0.900 to 0.980 g / cm 3 , more preferably 0.920 to 0.975 g. / Cm 3 , particularly preferably a polymer mainly composed of ethylene in the range of 0.940 to 0.970 g / cm 3 .
- the ethylene polymer (a) according to the present invention is usually produced and sold under the names of high-pressure low-density polyethylene, linear low-density polyethylene (so-called LLDPE), medium-density polyethylene, high-density polyethylene, and the like. Resin.
- ⁇ -olefins copolymerized with ethylene include propylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-octene, 1-decene, 1-dodecene, 1- Examples thereof include ⁇ -olefins having 3 to 20 carbon atoms such as tetradecene, 1-hexadecene, 1-octadecene and 1-eicocene. These ethylene polymers may be used alone or as a mixture of two or more.
- the resulting meltblown nonwoven fabric may be inferior in durability, heat resistance and strength, and stability over time.
- the resulting melt blown nonwoven fabric tends to be inferior in heat sealability and flexibility.
- the density of the ethylene-based polymer (a) is such that a strand obtained at the time of measurement of a melt flow rate (MFR) at 190 ° C. under a load of 2.16 kg is heat-treated at 120 ° C. for 1 hour and room temperature over 1 hour. It is a numerical value obtained by gradually cooling to a density gradient tube and measuring.
- MFR melt flow rate
- the ethylene polymer (a) according to the present invention is not particularly limited as long as it can be mixed with the later-described ethylene polymer wax (b) to produce a melt blown nonwoven fabric.
- the load is 2 according to MFR (ASTM D 1238). .16 kg, measured at 190 ° C.) is usually in the range of 10 to 250 g / 10 minutes, preferably 20 to 200 g / 10 minutes, more preferably 50 to 150 g / 10 minutes. Desirable from the viewpoint of spinnability.
- the ethylene polymer (a) according to the present invention may be a polymer obtained by various known production methods, for example, a high-pressure method, a medium-low pressure method obtained by using a Ziegler catalyst or a metallocene catalyst.
- a high-pressure method for example, a high-pressure method, a medium-low pressure method obtained by using a Ziegler catalyst or a metallocene catalyst.
- a metallocene catalyst a metallocene catalyst.
- the ethylene polymer wax (b) which is one of the components of the ethylene polymer composition forming the melt blown nonwoven fabric (A) constituting the nonwoven fabric laminate of the present invention has a weight average molecular weight (Mw) of 6,000. Less than, preferably 1,000 or more and less than 6,000.
- the ethylene polymer wax (b) according to the present invention is a wax-like polymer having a lower molecular weight than the ethylene polymer (a).
- the ethylene polymer wax (b) according to the present invention has a softening point measured in accordance with JIS K2207 of more than 110 ° C, preferably 115 ° C or more.
- the softening point is 110 ° C. or lower, the fiber is easily melted at the time of emboss thermocompression when the obtained meltblown nonwoven fabric is laminated with the spunbond nonwoven fabric, and as a result, the water resistance is inferior.
- the upper limit of the softening point is not particularly limited, but is usually 145 ° C. or lower.
- the ethylene polymer wax (b) according to the present invention is an ethylene homopolymer or ethylene and an ⁇ -olefin having 3 to 20 carbon atoms as long as the above weight average molecular weight and softening point range are satisfied. Any of these copolymers may be used. When an ethylene homopolymer is used, it is excellent in kneadability with the ethylene polymer (a) and excellent in spinnability.
- the ethylene polymer wax may be used alone or as a mixture of two or more thereof.
- the weight average molecular weight of the ethylene polymer wax (b) according to the present invention is a value obtained from GPC measurement, and is a value measured under the following conditions.
- the weight average molecular weight was determined based on the following conversion method by creating a calibration curve using commercially available monodisperse standard polystyrene.
- Apparatus Gel permeation chromatograph Alliance GPC2000 (manufactured by Waters) Solvent: o-dichlorobenzene Column: TSKgel column (manufactured by Tosoh Corporation) x 4 Flow rate: 1.0 ml / min Sample: 0.15 mg / mLo-dichlorobenzene solution Temperature: 140 ° C.
- Molecular weight conversion PE conversion / general-purpose calibration method The coefficient of the following Mark-Houwink viscosity equation was used for calculation of general-purpose calibration.
- the density of the ethylene polymer wax (b) according to the present invention measured according to JIS K6760 is not particularly limited, but is usually 0.890 to 0.980 g / cm 3 , preferably 0.910 to 0.00. It is 980 g / cm 3 , more preferably 0.920 to 0.980 g / cm 3 , and particularly preferably 0.940 to 0.980 g / cm 3 .
- the ethylene polymer wax (b) in such a density range is used, it is excellent in kneadability with the ethylene polymer (a), and excellent in spinnability and stability over time.
- the melt-blown nonwoven fabric is preferred because it is difficult for the fibers to melt during emboss thermocompression when laminating the spunbond nonwoven fabric.
- the ethylene polymer wax (b) according to the present invention can be produced by any method such as a production method by polymerization of a commonly used low molecular weight polymer or a method of reducing the molecular weight by heat degradation of a high molecular weight ethylene polymer. There is no particular limitation.
- the ethylene polymer composition for forming the melt blown nonwoven fabric (A) according to the present invention is a composition containing the ethylene polymer (a) and the ethylene polymer wax (b).
- the ethylene polymer composition according to the present invention can reduce the average fiber diameter of the resulting meltblown nonwoven fabric by including the ethylene polymer wax (b). If the amount is small, the average fiber diameter may not be reduced. On the other hand, if the amount of the ethylene polymer wax (b) is too large, spinning may be difficult, and the strength of the obtained fiber may be low.
- the ratio between the ethylene polymer (a) and the ethylene polymer wax (b) is preferably 20/80 to 80/20 by weight ratio (a) / (b). A ratio of 30/70 to 70/30 is particularly preferable.
- the half-crystallization time of the ethylene polymer composition according to the present invention is usually 87 seconds or longer, preferably 92 seconds or longer, more preferably 97 seconds or longer, more preferably 102 seconds or longer, particularly preferably 107 seconds or longer. Most preferably, it is 150 seconds or more.
- the upper limit of the half crystallization time of the ethylene polymer composition according to the present invention is not particularly limited.
- the half crystallization time in the present invention was measured by the following method. Using a differential scanning calorimeter (Perkin Elmer, DSC7), about 5 mg of the sample was set and allowed to stand at 200 ° C. for 5 minutes to completely melt the sample. Thereafter, isothermal crystallization was performed by rapidly cooling to 115 ° C. at a temperature lowering rate of 320 ° C./min. The time from the start of cooling until the heat of crystallization reached 1/2 of the total calorific value was defined as the half crystallization time.
- DSC7 differential scanning calorimeter
- the ethylene-based polymer composition satisfying the above-mentioned range for the half-crystallization time is a weight ratio of the ethylene-based polymer (a) and the ethylene-based polymer wax (b) in the ethylene-based polymer composition, an ethylene-based polymer wax ( Although it depends on the molecular weight of b), a polymer obtained by using a metallocene catalyst is used for at least one of the ethylene polymer (a) and the ethylene polymer wax (b) forming the ethylene polymer composition. Can be obtained.
- catalysts such as JP-A-57-63310, JP-A-58-83006, JP-A-3-706 and JP-A-3476793 are used.
- the metallocene catalyst described in JP-A No. 1993796 or JP-A No. 02-41303 can be suitably used.
- the ethylene-based polymer composition according to the present invention preferably comprises a transition metal compound.
- a transition metal compound a polymer obtained by using at least one of the ethylene polymer (a) and the ethylene polymer wax (b) forming the ethylene polymer composition by using a metallocene catalyst is used. Can be obtained.
- the transition metal compound include zirconium, titanium, and hafnium compounds contained in the metallocene catalyst.
- the total content of transition metals contained in the transition metal compound in the ethylene polymer composition is usually 2 ppm or less, preferably 1 ppm or less, more preferably 0.5 ppm or less, and most preferably 0.3 ppm or less.
- the total content of transition metals is calculated by ICP mass spectrometry (ICP-MS method) by collecting a sample in a fluororesin container, adding ultra-high purity nitric acid and then subjecting it to microwave decomposition.
- ethylene polymer composition in the ethylene polymer composition according to the present invention, other polymers, compounding agents such as colorants, stabilizers, nucleating agents, and the like are blended as necessary, as long as the object of the present invention is not impaired. May be.
- optional components for example, various conventionally known heat stabilizers, weather stabilizers and other stabilizers, antistatic agents, hydrophilic agents, water repellent agents, nucleating agents, slip agents, antiblocking agents , Antifogging agents, lubricants, dyes, pigments, natural oils, synthetic oils and the like.
- the stabilizer examples include anti-aging agents such as 2,6-di-t-butyl-4-methyl-phenol (BHT); tetrakis [methylene-3- (3,5-di-t-butyl-4- Hydroxyphenyl) propionate] methane, ⁇ - (3,5-di-t-butyl-4-hydroxyphenyl) propionic acid alkyl ester, 2,2′-oxamide bis [ethyl-3- (3,5-di-t- Butyl-4-hydroxyphenyl) propionate], Irganox® 1010 (hindered phenolic antioxidant: trade name) and other phenolic antioxidants; fatty acid metals such as zinc stearate, calcium stearate, calcium 1,2-hydroxystearate Salt: Glycerol monostearate, glycerin distearate, pentaerythritol monostearate, pentaerythritol distearate, pentaerythritol tristea
- silica diatomaceous earth, alumina, titanium oxide, magnesium oxide, pumice powder, pumice balloon, aluminum hydroxide, magnesium hydroxide, basic magnesium carbonate, dolomite, calcium sulfate, potassium titanate, barium sulfate, calcium sulfite,
- a filler such as talc, clay, mica, asbestos, calcium silicate, montmorillonite, pentonite, graphite, aluminum powder, molybdenum sulfide may be contained.
- the ethylene polymer composition according to the present invention comprises various known methods using an ethylene polymer (a), an ethylene polymer wax (b), and other optional components used as necessary. Can be mixed.
- the meltblown nonwoven fabric (A) constituting the nonwoven fabric laminate of the present invention is a meltblown nonwoven fabric obtained from the ethylene polymer composition, and the average fiber diameter of the fibers forming the meltblown nonwoven fabric is usually 10 ⁇ m or less, In order to obtain a melt-blown nonwoven fabric having a low basis weight and more excellent barrier properties, it is desirable to be in the range of 0.5 to 8 ⁇ m, more preferably 1 to 5 ⁇ m, still more preferably 1 to 4 ⁇ m, and particularly preferably 2 to 3.5 ⁇ m.
- the melt-blown nonwoven fabric obtained has good uniformity and excellent barrier properties.
- the melt blown nonwoven fabric (A) according to the present invention usually has a basis weight of 0.5 g / m 2 or more, preferably 10 to 50 g / m 2 , more preferably 15 to 45 g / m 2 , and still more preferably 20 to 40 g / m 2. It is in the range of 2 . If the basis weight is too low, the water-resistant pressure of the resulting nonwoven fabric laminate will be low, and the barrier properties may be poor. The upper limit of the basis weight is not particularly limited, but if the basis weight is too high, the resulting nonwoven fabric laminate tends to be less flexible.
- the basis weight range is 0.5 to 5 g / m 2 , more preferably in the range of 0.5 to 3 g / m 2 .
- the melt blown nonwoven fabric (A) according to the present invention can be produced using the ethylene polymer composition by a known melt blown nonwoven fabric production method. Specifically, for example, an ethylene polymer composition is melt-kneaded with an extruder or the like, and the melt is discharged from a spinneret having a spinning nozzle, and at the same time, high-speed and high-temperature air jetted from around the spinneret. It can be carried out by a melt blown method in which a web is produced by blowing away in a stream and depositing it on the collecting belt as a self-adhesive microfiber to a predetermined thickness. At this time, if necessary, the confounding process can be continued.
- Examples of the method of entanglement of the deposited web include a method of heat embossing using an embossing roll, a method of fusing by ultrasonic waves, a method of entanglement of fibers using a water jet, and fusing by hot air through Various methods such as a method and a method using a needle punch can be appropriately used.
- stacking is preferable.
- the ethylene polymer (y) which is one of the components of the fibers forming the spunbond nonwoven fabric constituting the nonwoven fabric laminate of the present invention, is the same resin as the ethylene polymer (a), and is a single ethylene.
- the ethylene-based polymer (y) according to the present invention is usually produced and sold under the names such as high-pressure method low-density polyethylene, linear low-density polyethylene (so-called LLDPE), medium-density polyethylene, and high-density polyethylene. Resin.
- ⁇ -olefins copolymerized with ethylene include propylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-octene, 1-decene, 1-dodecene, 1- Examples thereof include ⁇ -olefins having 3 to 20 carbon atoms such as tetradecene, 1-hexadecene, 1-octadecene and 1-eicocene. These ethylene polymers may be used alone or as a mixture of two or more.
- the ethylene-based polymer (y) according to the present invention is not particularly limited as long as a spunbond nonwoven fabric can be produced, but MFR (measured at 2.16 kg at 190 ° C. according to ASTM D1238) is usually 0. It is desirable from the viewpoint of spinnability to be in the range of 5 to 150 g / 10 minutes, preferably 10 to 150 g / 10 minutes.
- the ethylene polymer (y) according to the present invention is produced by various known production methods, for example, a high pressure method, a medium pressure method obtained using a Ziegler catalyst or a metallocene catalyst. The resulting polymer can be used.
- the ethylene polymer (y) according to the present invention may be blended with a slip agent composed of a fatty acid amide such as oleic acid amide, erucic acid amide, stearic acid amide in a proportion of 0.1 to 0.5% by weight. Good.
- a slip agent is blended with the ethylene polymer (y)
- the fuzz resistance and flexibility of the resulting spunbonded nonwoven fabric are further improved.
- Polyester (x) which is one of the components of the fibers forming the spunbond nonwoven fabric constituting the nonwoven fabric laminate of the present invention, is a known polyester used as a raw material for spunbond nonwoven fabric, specifically, Examples thereof include polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, and copolymers and terpolymers thereof.
- the molecular weight is not particularly limited, but is usually commercially available or industrially used. Of those, those that are commercially available and used particularly for fibers may be used. Specifically, those having an intrinsic viscosity in the range of 0.50 to 1.20 are preferred.
- the polyester (x) and / or ethylene-based polymer (y) according to the present invention has various stability such as other polymers, colorants, heat stabilizers, weathering stabilizers and the like as long as the object of the present invention is not impaired.
- Agents, antistatic agents, hydrophilic agents, water repellent agents, nucleating agents, slip agents, antiblocking agents, antifogging agents, lubricants, dyes, pigments, natural oils, synthetic oils, and the like may be blended.
- the spunbonded nonwoven fabric constituting the nonwoven fabric laminate of the present invention is a nonwoven fabric composed of an ethylene polymer (y) or fibers formed from an ethylene polymer (y) and a polyester polymer (x).
- a fiber formed from an ethylene polymer (y) as a spunbond nonwoven fabric according to the present invention, even a fiber (single fiber) formed from the ethylene polymer (y) alone, It may be a composite fiber in which at least the ethylene polymer (y) forms part of the fiber surface.
- the fibers forming the spunbonded nonwoven fabric include the polyester (x) and the ethylene polymer (y) in which at least the ethylene polymer (y) forms part of the fiber surface. From the viewpoint of flexibility and strength of the nonwoven fabric laminate obtained from the composite fiber.
- the basis weight of the spunbonded nonwoven fabric according to the present invention is usually in the range of 5 to 50 g / m 2 , preferably 10 to 25 g / m 2 .
- the average fiber diameter of the fibers forming the spunbonded nonwoven fabric according to the present invention is usually 5 to 30 ⁇ m (about 0.2 to 7 denier), preferably 10 to 20 ⁇ m.
- the shape of the composite fiber is not particularly limited as long as the ethylene polymer (y) is exposed on a part of the surface of the composite fiber. Since the ethylene polymer (y) is exposed on a part of the surface of the composite fiber, the adhesiveness with the melt blown nonwoven fabric (A) is excellent.
- the cross section of the composite fiber has a weight ratio [(x) / (y)] of the polyester (x) to the ethylene polymer (y) in the range of 5/95 to 95/5, particularly More preferably, it is in the range of 20/80 to 80/20.
- the ratio of the polyester polymer (x) and the ethylene polymer (y) is in this range, the obtained spunbonded nonwoven fabric is preferable because the balance between strength and flexibility is excellent.
- the spunbond nonwoven fabric according to the present invention can be produced by a known method for producing a spunbond nonwoven fabric. Specifically, for example, there is a method of producing a spunbonded nonwoven fabric by melt spinning the ethylene copolymer (y) alone. Moreover, when using the composite fiber by compounding the polyester (x) and the ethylene copolymer (y), the polyester (x) and the ethylene copolymer (y) are within a desired range. Long fibers by a melt spinning method in which each melt is melted by a separate extruder or the like, and each melt is spun by spinning from a spinneret having a spinning nozzle configured to eject a desired composite structure.
- the filaments are spun and then the spun filaments are cooled with a cooling fluid and tensioned to the filaments with drawn air to the desired fineness. Thereafter, the spun filaments are collected on a collecting belt and deposited to a predetermined thickness, and then entangled to obtain a spunbonded nonwoven fabric.
- the method for entanglement include the same methods as those for meltblown nonwoven fabrics. Among them, heat embossing is preferable.
- the embossed area ratio in the case of hot embossing is appropriately determined, but it is usually preferably 5 to 35%.
- the nonwoven fabric laminate of the present invention is formed by laminating a spunbond nonwoven fabric composed of the fibers on at least one surface of the melt blown nonwoven fabric (A).
- the meltblown nonwoven fabric (A) and the spunbond nonwoven fabric composed of the fibers are laminated to provide flexibility, barrier properties (a property having high water resistance), strength, durability, and uniformity.
- barrier properties a property having high water resistance
- strength a property having high water resistance
- durability a property having high water resistance
- uniformity A nonwoven fabric laminate having excellent properties, cloth-like appearance and texture can be obtained.
- the nonwoven fabric laminate of the present invention is not particularly limited as long as at least one surface layer is a layer composed of a spunbond nonwoven fabric, but preferably a spunbond nonwoven fabric layer / meltblown nonwoven fabric (A) layer, A) Layer / spunbond nonwoven fabric layer structure.
- the basis weight of the nonwoven fabric laminate of the present invention can be appropriately selected according to the use of the nonwoven fabric laminate, required quality, economy, etc., but is usually 6 to 150 g / m 2 , more preferably 11 to 120 g. / M 2 , more preferably 15 to 100 g / m 2 , most preferably 15 to 70 g / m 2 .
- the nonwoven fabric laminate of the present invention is formed by laminating a spunbond nonwoven fabric composed of the fibers on at least one surface of the meltblown nonwoven fabric (A), and any nonwoven fabric contains an ethylene polymer, so that the meltblown nonwoven fabric (A) and When bonded to a spunbonded nonwoven fabric by hot embossing or the like, it can be easily bonded, and the resulting nonwoven fabric laminate is excellent in interlayer adhesion strength.
- the nonwoven fabric laminate of the present invention is also excellent in stability to electron beams and gamma rays irradiated during sterilization and sterilization.
- the nonwoven fabric laminate of the present invention has good uniformity and excellent breathability, barrier properties and flexibility.
- the single-sided or double-sided surface layer is formed of a spunbonded nonwoven fabric layer, it is excellent in strength, durability, abrasion resistance, and fluff resistance.
- the nonwoven fabric laminate of the present invention has a cantilever value as an index of flexibility of usually 100 mm or less, preferably 90 mm or less, more preferably 80 mm or less, and water pressure resistance is usually 350 mmAq or more, preferably 500 mmAq or more. Preferably it is 600 mmAq or more, Most preferably, it is 650 mmAq or more.
- the nonwoven fabric laminate of the present invention can be subjected to water repellent treatment as necessary.
- the water repellent process can be performed by applying a water repellent such as a fluorine-based water repellent or by previously mixing a resin raw material with a water repellent as an additive to form a nonwoven fabric.
- the adhesion rate (addition rate) of the water repellent is suitably 0.5 to 5.0% by weight.
- a fluorine-based processing agent is adhered to the nonwoven fabric (b) at an adhesion rate of 0.01 to 3% by weight.
- the method of attaching the processing agent and the drying method are not particularly limited, and examples of the method of attaching the processing agent include a method of spraying with a spray, a method of immersing in a processing agent bath, squeezing with a mangle, and a method of coating.
- the drying method include a method using a hot air dryer, a method using a tenter, and a method of contacting a heating element.
- the nonwoven fabric laminate when used in a medical gown, water and alcohol do not penetrate, and even when the alcohol is sterilized, the barrier property is high.
- the nonwoven fabric laminate of the present invention may impart antistatic properties.
- the method for imparting antistatic properties include a method of applying an appropriate antistatic property imparting agent, for example, a fatty acid ester, a quaternary ammonium salt, or the like, or mixing with a resin raw material as an additive to form a nonwoven fabric. It is done.
- the degree of antistatic property is preferably 1000 V or less (the friction cloth is cotton cloth) by the method shown in the JIS L1094C method in an atmosphere of 20 ° C. and 40% RH.
- the degree of antistatic property is preferably 1000 V or less (the friction cloth is cotton cloth) by the method shown in the JIS L 1094C method in an atmosphere of 20 ° C. and 40% RH.
- the non-woven fabric laminate of the present invention may be further laminated with short fibers and long-fiber non-woven fabrics such as cotton, cupra, rayon, polyolefin fibers, polyamide fibers, and polyester fibers within a range that does not interfere with the object of the present invention. .
- the nonwoven fabric laminate of the present invention can be applied to sanitary materials, living materials, industrial materials, and medical materials in general.
- sanitary materials living materials, industrial materials, and medical materials in general.
- materials such as paper diapers, sanitary napkins, base materials such as poultices, and bed covers.
- polyethylene and polyester because it is composed of polyethylene and polyester, it is stable to electron beams and gamma rays irradiated during sterilization and sterilization, and is particularly suitable as a material for gowns, caps, masks, drapes, etc. used in hospitals.
- the method for producing the nonwoven fabric laminate of the present invention is not particularly limited as long as the melt blown nonwoven fabric (A) and the spunbond nonwoven fabric can be integrated to form a laminate.
- melt blown nonwoven fabric (A) After forming a melt blown nonwoven fabric (A) by directly depositing fibers obtained from an ethylene polymer composition obtained by a melt blown method on a previously obtained spun bond nonwoven fabric, A method of manufacturing a two-layer laminate by fusing the material with hot embossing, etc., (B) The fiber obtained from the ethylene polymer composition obtained by the melt blown method is directly deposited on the previously obtained spunbond nonwoven fabric to form the meltblown nonwoven fabric (A), and further formed by the spunbond method.
- a fiber is directly deposited on the meltblown nonwoven fabric (A) to form a spunbond nonwoven fabric, and the spunbond nonwoven fabric, the meltblown nonwoven fabric (A), and the spunbond nonwoven fabric are fused to produce a three-layer laminate.
- Method (C) A method of producing a laminate by superimposing a previously obtained spunbond nonwoven fabric and a separately produced melt blown nonwoven fabric (A), and fusing both nonwoven fabrics by heating and pressing, (D) Adopting a previously obtained spunbond nonwoven fabric and a separately prepared meltblown nonwoven fabric (A) with an adhesive such as a hot melt adhesive or a solvent-based adhesive to produce a laminate, etc.
- an adhesive such as a hot melt adhesive or a solvent-based adhesive
- the nonwoven fabric laminate of the present invention includes a method of thermally fusing the entire contact surface between the meltblown nonwoven fabric (A) and the spunbonded nonwoven fabric, and a method of thermally fusing a part of the contact surface.
- a part of the contact surface of each nonwoven fabric layer is fused, and in this case, the fused area (embossed area ratio: this corresponds to the embossed roll imprinted area) is 5 to 35% of the contact area. More preferably, it is 10 to 30%.
- the fused area is in the above range, a nonwoven fabric laminate having an excellent balance between adhesive strength and flexibility is obtained.
- the embossing temperature is generally in the range of 85 to 120 ° C., depending on the line speed and pressure during the embossing. If the embossing temperature is less than 85 ° C, the resulting non-woven fabric laminate may have poor fuzz resistance. If the embossing temperature exceeds 120 ° C, the resulting non-woven fabric laminate may have poor flexibility. As a result, it may be inferior in water resistance.
- the spunbonded nonwoven fabric and the melt blown nonwoven fabric (A) with an adhesive as a method other than fusing the nonwoven fabrics by heat fusion.
- the hot melt adhesive used in this method include resin adhesives such as vinyl acetate and polyvinyl alcohol, and rubber adhesives such as styrene-butadiene and styrene-isoprene.
- the solvent-based adhesive include rubber-based adhesives such as styrene-butadiene, styrene-isoprene, and urethane, resin-based organic solvents such as vinyl acetate and vinyl chloride, and aqueous emulsion adhesives. .
- rubber-based hot melt adhesives such as styrene-isoprene and styrene-butadiene are preferable because they do not impair the texture that is the characteristic of spunbonded nonwoven fabric.
- melt blown nonwoven fabrics, spunbond nonwoven fabrics, and nonwoven fabric laminates in the following examples and comparative examples were measured by the following methods.
- Average fiber diameter A sample piece was collected from the obtained nonwoven fabric, and observed with a scanning electron microscope at a magnification of 1000 times, and 30 fiber diameters ( ⁇ m) of the constituent fibers were measured and averaged. The value was determined.
- the test piece is manually slid gently in the direction of the slope, and when the central point of one end of the test piece comes into contact with the slope, the moving length of the other end is read on the scale.
- Bending softness was indicated by the length (mm) of the test piece moved, and was measured for each of the five front and back sides and expressed as an average value.
- 45 ° cantilever method it is determined that the nonwoven fabric is more flexible as the bending resistance is lower.
- the flexibility is good when the value of the bending resistance is 100 mm or less.
- the required flexibility varies depending on the purpose of use and the like, and is not necessarily limited to this value.
- the sandpaper “No. 400” is mounted on the table with the file surface facing up, and the test specimen is further placed so that the evaluation surface is up. Placed on the surface and mounted on the table of the measuring device. After attaching the test piece, the measurement surface of the test piece and the non-adhesive surface of the adhesive tape were rubbed back and forth 50 times. The friction surface of the test piece was observed, and the fluff resistance was evaluated by giving a score according to the following criteria.
- Example 1 ⁇ Manufacture of melt blown nonwoven fabric> 50 parts by weight of an ethylene / 1-hexene copolymer (manufactured by Prime Polymer Co., Ltd., product name: Evolu H SP50800P, density: 0.951 g / cm 3 , MFR: 135 g / 10 min) by metallocene catalyst, metallocene catalyst Using a mixture of 50 parts by weight of an ethylene polymer wax (manufactured by Mitsui Chemicals, Inc., product name Excellex 10500, density: 0.960 g / cm 3 , weight average molecular weight: 1,300, softening point 119 ° C.) From a spinneret having a nozzle of 0.4 mm ⁇ , 360 holes, a molten resin is discharged at a rate of 0.7 g / min per single hole, melt spinning is performed by a melt blown method, and microfibers are formed and deposited on a collecting surface.
- a melt blown
- the core ratio is 50% by weight by heat embossing after collection (core: sheath A spunbonded nonwoven fabric (SB) having a basis weight of 15 g / m 2 was obtained, which was composed of a concentric core-sheath composite fiber (PE-PET composite) having a weight ratio of 50 parts by weight.
- SB sheath A spunbonded nonwoven fabric
- Example 2 Instead of the ethylene polymer wax of the melt blown nonwoven fabric used in Example 1, an ethylene polymer wax using a metallocene catalyst [manufactured by Mitsui Chemicals, product name Excellex 20700, density: 0.970 g / cm 3 , weight The average molecular weight: 3,200, softening point: 124 ° C.] was used to obtain a nonwoven fabric laminate having a three-layer structure using the same production method as in Example 1. The physical properties of the obtained nonwoven fabric laminate were measured by the methods described above. The results are shown in Table 1.
- a metallocene catalyst manufactured by Mitsui Chemicals, product name Excellex 20700, density: 0.970 g / cm 3 , weight The average molecular weight: 3,200, softening point: 124 ° C.
- Example 3 Instead of the ethylene polymer wax of the melt blown nonwoven fabric used in Example 1, an ethylene polymer wax using a Ziegler catalyst [manufactured by Mitsui Chemicals, product name High Wax 100P, density: 0.950 g / cm 3 , weight The average molecular weight: 1,100, softening point: 116 ° C.] was used to obtain a nonwoven fabric laminate having a three-layer structure using the same production method as in Example 1. The physical properties of the obtained nonwoven fabric laminate were measured by the methods described above. The results are shown in Table 1.
- a Ziegler catalyst manufactured by Mitsui Chemicals, product name High Wax 100P, density: 0.950 g / cm 3 , weight The average molecular weight: 1,100, softening point: 116 ° C.
- Example 1 (Comparative Example 1) Instead of the ethylene polymer wax of the melt blown nonwoven fabric used in Example 1, an ethylene polymer wax using a metallocene catalyst [Mitsui Chemicals, product name Excellex 30200B, density: 0.915 g / cm 3 , weight The average molecular weight: 5,100, softening point: 102 ° C.] was used to obtain a nonwoven fabric laminate having a three-layer structure using the same production method as in Example 1. The physical properties of the obtained nonwoven fabric laminate were measured by the methods described above. The results are shown in Table 1.
- a metallocene catalyst Mitsubishi Chemicals, product name Excellex 30200B, density: 0.915 g / cm 3 , weight The average molecular weight: 5,100, softening point: 102 ° C.
- Example 2 (Comparative Example 2) Instead of the ethylene polymer wax of the melt blown nonwoven fabric used in Example 1, an ethylene polymer wax using a Ziegler catalyst [manufactured by Mitsui Chemicals, product name High Wax 110P, density: 0.920 g / cm 3 , weight The average molecular weight: 1,200, softening point: 109 ° C.] was used to obtain a nonwoven fabric laminate having a three-layer structure using the same production method as in Example 1. The physical properties of the obtained nonwoven fabric laminate were measured by the methods described above. The results are shown in Table 1.
- a Ziegler catalyst manufactured by Mitsui Chemicals, product name High Wax 110P, density: 0.920 g / cm 3 , weight The average molecular weight: 1,200, softening point: 109 ° C.
- Example 3 (Comparative Example 3) Instead of the ethylene polymer wax of the melt blown nonwoven fabric used in Example 1, an ethylene polymer wax using a Ziegler catalyst [manufactured by Mitsui Chemicals, product name High Wax 220P, density: 0.920 g / cm 3 , weight The average molecular weight: 3,000, softening point: 110 ° C.] was used to obtain a nonwoven fabric laminate having a three-layer structure using the same production method as in Example 1. The physical properties of the obtained nonwoven fabric laminate were measured by the methods described above. The results are shown in Table 1.
- a Ziegler catalyst manufactured by Mitsui Chemicals, product name High Wax 220P, density: 0.920 g / cm 3 , weight The average molecular weight: 3,000, softening point: 110 ° C.
- Example 4 (Comparative Example 4) Instead of the ethylene-based polymer wax of the melt blown nonwoven fabric used in Example 1, an ethylene-based polymer wax by Ziegler catalyst [manufactured by Mitsui Chemicals, product name High Wax 800P, density: 0.970 g / cm 3 , weight Average molecular weight: 12,700, softening point: 127 ° C.], and using the same production method as in Example 1, a nonwoven fabric laminate having a three-layer structure was obtained. The physical properties of the obtained nonwoven fabric laminate were measured by the methods described above. The results are shown in Table 1.
- Example 5 (Comparative Example 5) Instead of the ethylene polymer wax of the melt blown nonwoven fabric used in Example 1, an ethylene polymer wax using a Ziegler catalyst [manufactured by Mitsui Chemicals, product name High Wax 400P, density: 0.980 g / cm 3 , weight The average molecular weight: 6,800, softening point: 126 ° C.] was used to obtain a nonwoven fabric laminate having a three-layer structure using the same production method as in Example 1. The physical properties of the obtained nonwoven fabric laminate were measured by the methods described above. The results are shown in Table 1.
- a Ziegler catalyst manufactured by Mitsui Chemicals, product name High Wax 400P, density: 0.980 g / cm 3 , weight The average molecular weight: 6,800, softening point: 126 ° C.
- Example 6 (Comparative Example 6) Instead of the ethylene-based polymer wax of the melt blown nonwoven fabric used in Example 1, an ethylene-based polymer wax using a metallocene catalyst [Mitsui Chemicals, Inc., product name Excellex 40800, density: 0.980 g / cm 3, weight The average molecular weight: 6,900, softening point: 128 ° C.] was used to obtain a nonwoven fabric laminate having a three-layer structure using the same production method as in Example 1. The physical properties of the obtained nonwoven fabric laminate were measured by the methods described above. The results are shown in Table 1.
- a metallocene catalyst Mitsubishi Chemicals, Inc., product name Excellex 40800, density: 0.980 g / cm 3, weight The average molecular weight: 6,900, softening point: 128 ° C.
- the nonwoven fabric laminate of the present invention can be applied to sanitary materials, living materials, industrial materials, and medical materials in general.
- it since it is excellent in flexibility, breathability and barrier properties, it can be used for various clothing applications.
- materials such as paper diapers, sanitary napkins, base fabrics such as poultices, and bed covers. Because it can be sterilized and sterilized with electron beams and gamma rays, it is particularly stable against electron beams and gamma rays irradiated during sterilization and sterilization. Gowns, caps, drapes, masks, gauze, various protective clothing, etc. It can be particularly suitably used as a material for the above.
- it has excellent post-processability such as heat sealing, so it can be used to wrap oxygen scavengers, warmers, warm ships, masks, various powders, semi-solid, gel-like, liquid substances, CD (compact disc) bags, food It can be applied to general living materials such as packaging materials and clothes covers. For the same reason, it can be suitably used as an automobile interior material or various backing materials. Further, since it is composed of fine fibers, it can be widely applied as a liquid filter and air filter material.
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Abstract
Description
本発明の不織布積層体を構成するメルトブローン不織布(A)を形成するエチレン系重合体組成物の成分の一つであるエチレン系重合体(a)は、エチレンの単独重合体、あるいはエチレンと他のα-オレフィンとの共重合体であって、通常、密度が0.870~0.980g/cm3、好ましくは0.900~0.980g/cm3、より好ましくは0.920~0.975g/cm3、特に好ましくは0.940~0.970g/cm3範囲にあるエチレンを主体とする重合体である。
本発明の不織布積層体を構成するメルトブローン不織布(A)を形成するエチレン系重合体組成物の成分の一つであるエチレン系重合体ワックス(b)は、重量平均分子量(Mw)が6,000未満、好ましくは1,000以上、6,000未満の範囲にある。
溶剤:o-ジクロロベンゼン
カラム:TSKgelカラム(東ソー社製)×4
流速:1.0ml/分
試料:0.15mg/mLo-ジクロロベンゼン溶液
温度:140℃
分子量換算:PE換算/汎用較正法
なお、汎用較正の計算には、以下に示すMark-Houwink粘度式の係数を用いた。
ポリエチレン(PE)の係数:KPE=5.06×10-4,aPE=0.70
本発明に係るエチレン系重合体ワックス(b)のJIS K6760に従って測定した密度は特に限定されるものではないが、通常、0.890~0.980g/cm3、好ましくは0.910~0.980g/cm3、より好ましくは0.920~0.980g/cm3、特に好ましくは0.940~0.980g/cm3の範囲にある。このような密度範囲にあるエチレン系重合体ワックス(b)を用いると、前記エチレン系重合体(a)との混練性に優れ、且つ、紡糸性、経時での安定性に優れる上、得られたメルトブローン不織布をスパンボンド不織布と積層する際のエンボス熱圧着時に繊維が融解し難いので好ましい。
本発明に係るメルトブローン不織布(A)を形成するエチレン系重合体組成物は、前記エチレン系重合体(a)と前記エチレン系重合体ワックス(b)を含む組成物である。本発明に係るエチレン系重合体組成物は、エチレン系重合体ワックス(b)を含むことにより、得られるメルトブローン不織布の平均繊維径を細くすることができるが、エチレン系重合体ワックス(b)の量が少ない場合は、平均繊維径を細くできない虞があり、一方、エチレン系重合体ワックス(b)の量が多すぎると紡糸化が困難となる虞があり、また、得られる繊維の強度が低くなる虞あるので、エチレン系重合体(a)とエチレン系重合体ワックス(b)との割合は、(a)/(b)の重量比で20/80~80/20の割合が好ましく、特に30/70~70/30の割合が好ましい。
本発明の不織布積層体を構成するメルトブローン不織布(A)は、前記エチレン系重合体組成物から得られるメルトブローン不織布であり、メルトブローン不織布を形成する繊維の平均繊維径は、通常、10μm以下であり、低目付でよりバリア性に優れるメルトブローン不織布を得るには0.5~8μm、より好ましくは1~5μm、さらに好ましくは1~4μm、特に好ましくは2~3.5μmの範囲にあることが望ましい。
本発明に係るメルトブローン不織布(A)は、前記エチレン系重合体組成物を用いて、公知のメルトブローン不織布の製造方法を用いて製造し得る。具体的には、例えば、エチレン系重合体組成物を押出機等で溶融混練し、その溶融物を紡糸ノズルを有する紡糸口金から吐出するとともに、紡糸口金の周囲から噴射される高速・高温の空気流で吹き飛ばして、捕集ベルト上に自己接着性のマイクロファイバーとして所定の厚さに堆積させウェブを製造するメルトブローン法によって行うことができる。このとき、必要に応じて、引き続いて交絡処理することができる。
本発明の不織布積層体を構成するスパンボンド不織布を形成する繊維の成分の一つであるエチレン系重合体(y)は、前記エチレン系重合体(a)と同様の樹脂であり、エチレンの単独重合体、あるいはエチレンと他のα-オレフィンとの共重合体であって、通常、密度が0.870~0.990g/cm3、好ましくは0.900~0.980g/cm3、より好ましくは0.910~0.980g/cm3の範囲にあるエチレンを主体とする重合体である。
本発明の不織布積層体を構成するスパンボンド不織布を形成する繊維の成分の一つであるポリエステル(x)は、スパンボンド不織布の原料として用いられている公知のポリエステルであり、具体的には、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリトリメチレンテレフタレート、そしてそれらのコポリマー、ターポリマーなどを例示できる。
本発明の不織布積層体を構成するスパンボンド不織布は、エチレン系重合体(y)、または、エチレン系重合体(y)とポリエステル系重合体(x)から形成された繊維からなる不織布である。
本発明に係るスパンボンド不織布を形成する複合繊維は、複合繊維の表面の一部にエチレン系重合体(y)が露出している限り、複合繊維の形状は特に限定はされない。複合繊維の表面の一部にエチレン系重合体(y)が露出していることにより、前記メルトブローン不織布(A)との接着性が優れる。
本発明に係るスパンボンド不織布は、公知のスパンボンド不織布の製造方法により製造し得る。具体的には、例えば、前記エチレン系共重合体(y)を単独で溶融紡糸してスパンボンド不織布を製造する方法がある。また、前記ポリエステル(x)と前記エチレン系共重合体(y)とを複合化して複合繊維を用いる場合は、前記ポリエステル(x)と前記エチレン系共重合体(y)とを所望の範囲で、それぞれ、別の押出機等で溶融し、各溶融物を所望の複合構造を形成して吐出するように構成された紡糸ノズルを有する紡糸口金から吐出させて紡糸する溶融紡糸法によって、長繊維フィラメントを紡糸し、次に、紡出されたフィラメントを冷却流体により冷却し、延伸空気によってフィラメントに張力を加えて所望の繊度とする。その後、紡糸されたフィラメントを捕集ベルト上に捕集し所定の厚さに堆積させたのち、交絡処理を行ってスパンボンド不織布を得る。交絡処理をする方法としては、メルトブローン不織布と同様な方法が挙げられるが、それらのなかでも、熱エンボス処理が好ましい。熱エンボス処理する場合のエンボス面積率は適宜決められるが、通常5~35%が好ましい。
本発明の不織布積層体は、前記メルトブローン不織布(A)の少なくとも片面に、前記繊維からなるスパンボンド不織布が積層されてなる。
本発明の不織布積層体の製造方法は、メルトブローン不織布(A)とスパンボンド不織布とを一体化して積層体を形成できる方法であれば特に限定されない。
(イ)予め得られたスパンボンド不織布上に、メルトブローン法によって得られるエチレン系重合体組成物から得られる繊維を直接堆積させてメルトブローン不織布(A)を形成した後、スパンボンド不織布とメルトブローン不織布とを熱エンボスなどによって融着させて2層の積層体を製造する方法、
(ロ)メルトブローン法によって得られるエチレン系重合体組成物から得られる繊維を予め得られたスパンボンド不織布の上に直積堆積させてメルトブローン不織布(A)を形成し、さらにスパンボンド法により形成される繊維を前記メルトブローン不織布(A)の上に直接堆積させてスパンボンド不織布を形成した後、スパンボンド不織布とメルトブローン不織布(A)とスパンボンド不織布とを融着させて三層の積層体を製造する方法、
(ハ)予め得られたスパンボンド不織布と別途製造したメルトブローン不織布(A)とを重ね合わせ、加熱加圧により両不織布を融着させて積層体を製造する方法、
(ニ)予め得られたスパンボンド不織布と別途製造したメルトブローン不織布(A)とを、ホットメルト接着剤、溶剤系接着剤等の接着剤によって接着して積層体を製造する方法等を採用することができるが、これら方法に限定されるものではない。
得られた不織布から、試料片を採取して、走査型電子顕微鏡を用いて、倍率1000倍で観察し、構成繊維の30本の繊維径(μm)を測定し、平均値を求めた。
JIS L 1096‐1990の6.4.2項の「標準状態における単位面積当たりの質量」に従って測定した。得られた不織布から、100cm2の円形試験片を採取した。採取場所は、機械方向(MD)に対しては任意の場所とし、機械方向に直交する方向(CD)に対しては不織布サンプルの両端20cmを除き、直線上に均一間隔で20箇所とした。採取した各試験片につき、上皿電子天秤(島津製作所製、EB‐330型)を用いて、それぞれ質量(g)を測定し、各試験片の質量(g)の平均値を求めた。求めた平均値から1m2当たりの質量(g)に換算し、小数点第2位を四捨五入して各不織布サンプルの目付(g/m2)とした。
不織布積層体から、幅25mm×長さ250mmの試験片を採取し、チャック間距離50mm、引張速度100mm/分の条件で、機械方向(MD)及び機械方向に直交する方向(CD)の二方向の引張試験を行い、最大引張荷重を引張強度(N/25mm)とした。5回測定し5回の平均値を求めた。
JIS L 1096に規定されているA法(低水圧法)に準拠して、不織布積層体の耐水圧を測定し、耐水性(バリア性)の指標とした。
JIS L 1096(6.19.1 A法 項)に準拠して、JIS Z 8703(試験場所の標準状態)に規定する温度20±2℃、湿度65±2%の恒温室内で、不織布積層体から、幅20mm×長さ150mmの試験片を機械方向(MD)で5枚採取し、45°の斜面をもつ表面の滑らかな水平台の上に試験片の短辺をスケール基線に合わせて置く。次に、手動により試験片を斜面の方向に緩やかに滑らせて試験片の一端の中央点が斜面と接したとき他端の位置の移動長さをスケールによって読む。剛軟度(剛軟性)は試験片の移動した長さ(mm)で示され、それぞれ5枚の裏表について測定し、平均値で表した。このような、いわゆる45°カンチレバー法による測定では、剛軟度が低いほど不織布に柔軟性があると判断される。衣料用用途の場合、剛軟度の値が100mm以下の場合に、柔軟性が良好と判断される。但し、必要な柔軟性は使用目的等によっても異なるため、必ずしもこの数値に制限されるものではない。
不織布積層体から300mm(縦方向:MD)×25mm(横方向:CD)の試験片を40枚採取し、JIS L 0849-2004の5の5.1のbに記載の装置「摩擦試験器II形(学振形)」を用いて評価した。具体的には、該装置として大栄科学精器社製RT-100型を用い、摩擦子の荷重を200gとし、包装用粘着テープ(布)No.314(リンレイテープ社製)を用い、該粘着テープの粘着面と、試験片の測定面が摩擦できる様に設置した。この際、測定中に試験片がずれることを防止するために、紙やすり「400番」のやすり面を上にして装置の台上に取り付け、さらに試験片を評価面が上になる様にやすり面の上に置き、測定装置の台上に取り付けた。試験片を取り付けた後、試験片の測定面と粘着テープの非粘着面を50回往復摩擦させた。試験片の摩擦面を観察し、耐毛羽立ち性について、以下の基準で点数をつけて評価した。
<メルトブローン不織布の製造>
メタロセン触媒によるエチレン・1-ヘキセン共重合体〔(株)プライムポリマー社製、製品名:エボリューH SP50800P、密度:0.951g/cm3、MFR:135g/10分〕50重量部と、メタロセン触媒によるエチレン系重合体ワックス〔三井化学(株)製、製品名エクセレックス10500、密度:0.960g/cm3、重量平均分子量:1,300、軟化点119℃〕50重量部の混合物を用いて、0.4mmφ、360孔のノズルを有する紡糸口金から、単孔当たり0.7g/分で溶融樹脂を吐出させメルトブローン法による溶融紡糸を行ってマイクロファイバーを成形し、捕集面上に堆積させ、目付30g/m2のメルトブローン不織布(MB)を製造した。
鞘部を構成するエチレン系共重合体として、エチレン・1-ブテン共重合体〔(株)プライムポリマー社製、製品名:ネオゼックスNZ50301、密度0.950g/cm3、MFR(ASTM D 1238に準拠し温度190℃、荷重2.16kgで測定)30g/10分〕を用い、芯部を構成するポリエステル系重合体としてポリエチレンテレフタレート〔三井化学(株)製、製品名J125〕を用いて、単孔当たり吐出量0.5g/分/孔、樹脂温度270℃の紡糸条件で押出後、冷却、延伸してフィラメントの繊度2dとし、捕集後熱エンボスにより芯比率が50重量%(芯部:鞘部の重量比が50:50)である同芯の芯鞘複合繊維(PE系・PET複合)からなる、目付15g/m2のスパンボンド不織布(SB)を得た。
上記で得られたメルトブローン不織布の両面に、前記スパンボンド不織布を積層し、熱エンボス(刻印面積率18%)により90℃、線圧60kg/cmで熱融着を行って、三層構造からなる不織布積層体を得た。得られた不織布積層体の物性を前記記載の方法で測定した。結果を表1に示す。
実施例1で用いたメルトブローン不織布のエチレン系重合体ワックスに替えて、メタロセン触媒によるエチレン系重合体ワックス〔三井化学(株)製、製品名エクセレックス20700、密度:0.970g/cm3、重量平均分子量:3,200、軟化点:124℃〕を用いて、実施例1と同様の製造方法を用いて、三層構造からなる不織布積層体を得た。得られた不織布積層体の物性を前記記載の方法で測定した。結果を表1に示す。
実施例1で用いたメルトブローン不織布のエチレン系重合体ワックスに替えて、チーグラー触媒によるエチレン系重合体ワックス〔三井化学(株)製、製品名ハイワックス100P、密度:0.950g/cm3、重量平均分子量:1,100、軟化点:116℃〕を用いて、実施例1と同様の製造方法を用いて、三層構造からなる不織布積層体を得た。得られた不織布積層体の物性を前記記載の方法で測定した。結果を表1に示す。
実施例1で用いたメルトブローン不織布のエチレン系重合体ワックスに替えて、メタロセン触媒によるエチレン系重合体ワックス〔三井化学(株)製、製品名エクセレックス30200B、密度:0.915g/cm3、重量平均分子量:5,100、軟化点:102℃〕を用いて、実施例1と同様の製造方法を用いて、三層構造からなる不織布積層体を得た。得られた不織布積層体の物性を前記記載の方法で測定した。結果を表1に示す。
実施例1で用いたメルトブローン不織布のエチレン系重合体ワックスに替えて、チーグラー触媒によるエチレン系重合体ワックス〔三井化学(株)製、製品名ハイワックス110P、密度:0.920g/cm3、重量平均分子量:1,200、軟化点:109℃〕を用いて、実施例1と同様の製造方法を用いて、三層構造からなる不織布積層体を得た。得られた不織布積層体の物性を前記記載の方法で測定した。結果を表1に示す。
実施例1で用いたメルトブローン不織布のエチレン系重合体ワックスに替えて、チーグラー触媒によるエチレン系重合体ワックス〔三井化学(株)製、製品名ハイワックス220P、密度:0.920g/cm3、重量平均分子量:3,000、軟化点:110℃〕を用いて、実施例1と同様の製造方法を用いて、三層構造からなる不織布積層体を得た。得られた不織布積層体の物性を前記記載の方法で測定した。結果を表1に示す。
実施例1で用いたメルトブローン不織布のエチレン系重合体ワックスに替えて、チーグラー触媒によるエチレン系重合体ワックス〔三井化学(株)製、製品名ハイワックス800P、密度:0.970g/cm3、重量平均分子量:12,700、軟化点:127℃〕を用いて、実施例1と同様の製造方法を用いて、三層構造からなる不織布積層体を得た。得られた不織布積層体の物性を前記記載の方法で測定した。結果を表1に示す。
実施例1で用いたメルトブローン不織布のエチレン系重合体ワックスに替えて、チーグラー触媒によるエチレン系重合体ワックス〔三井化学(株)製、製品名ハイワックス400P、密度:0.980g/cm3、重量平均分子量:6,800、軟化点:126℃〕を用いて、実施例1と同様の製造方法を用いて、三層構造からなる不織布積層体を得た。得られた不織布積層体の物性を前記記載の方法で測定した。結果を表1に示す。
実施例1で用いたメルトブローン不織布のエチレン系重合体ワックスに替えて、メタロセン触媒によるエチレン系重合体ワックス〔三井化学(株)社製、製品名エクセレックス40800、密度:0.980g/cm3、重量平均分子量:6,900、軟化点:128℃〕を用いて、実施例1と同様の製造方法を用いて、三層構造からなる不織布積層体を得た。得られた不織布積層体の物性を前記記載の方法で測定した。結果を表1に示す。
Claims (15)
- エチレン系重合体(a)と重量平均分子量が1,000以上、6,000未満、および軟化点が110℃を超えるエチレン系重合体ワックス(b)とのエチレン系重合体組成物の繊維からなるメルトブローン不織布(A)の少なくとも片面に、エチレン系重合体(y)、またはエチレン系重合体(y)とポリエステル系重合体(x)から形成された繊維からなるスパンボンド不織布が積層されてなることを不織布積層体。
- エチレン系重合体組成物が、エチレン系重合体(a)と、エチレン系重合体ワックス(b)とを、(a)/(b)の重量比で80/20~20/80の割合で含んでなる請求項1記載の不織布積層体。
- エチレン系重合体組成物が、半結晶化時間が87秒以上である請求項1記載の不織布積層体。
- エチレン系重合体組成物が、遷移金属化合物を含んでなる請求項1記載の不織布積層体。
- エチレン系重合体(a)がメタロセン触媒を用いて重合されたエチレン系重合体を含むことを特徴とする請求項1記載の不織布積層体。
- エチレン系重合体(a)のメルトフローレートが50~150g/10分である請求項1記載の不織布積層体。
- スパンボンド不織布を形成する繊維が、ポリエステル(x)からなる芯部とエチレン系重合体(y)からなる鞘部とから形成される芯鞘型複合繊維、または、ポリエステル(x)とエチレン系重合体(y)とから形成されるサイドバイサイド型複合繊維の何れかである請求項1記載の不織布積層体。
- メルトブローン不織布(A)の目付けが10~50g/m2の範囲にある請求項1記載の不織布積層体。
- メルトブローン不織布(A)を形成する繊維の平均繊維径が0.5~3.5μmの範囲にある請求項1記載の不織布積層体。
- 不織布積層体が、耐水圧が650mmAq以上の不織布積層体である請求項1記載の不織布積層体。
- 不織布積層体が、熱融着により結合されている請求項1記載の不織布積層体。
- 不織布積層体の目付が、15~70g/m2の範囲にある請求項1記載の不織布積層体。
- 請求項1~12の何れか1項に記載の不織布積層体からなる医療用不織布積層体。
- 請求項1~12の何れか1項に記載の不織布積層体を含んでなる医療用衣料。
- 請求項1~12の何れか1項に記載の不織布積層体を含んでなるドレープ。
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US14/422,264 US20150210038A1 (en) | 2012-08-22 | 2013-08-22 | Nonwoven fabric laminates |
CN201380043430.5A CN104582948B (zh) | 2012-08-22 | 2013-08-22 | 非织造布叠层体 |
EP13830619.6A EP2889133B1 (en) | 2012-08-22 | 2013-08-22 | Nonwoven fabric laminate |
KR1020157003633A KR101720439B1 (ko) | 2012-08-22 | 2013-08-22 | 부직포 적층체 |
JP2014531667A JP5925322B2 (ja) | 2012-08-22 | 2013-08-22 | 不織布積層体 |
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EP (1) | EP2889133B1 (ja) |
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WO2017145993A1 (ja) * | 2016-02-22 | 2017-08-31 | 旭化成株式会社 | 肌触り感に優れた長繊維不織布 |
WO2021145049A1 (ja) | 2020-01-14 | 2021-07-22 | 株式会社Tbm | 無機物質粉末配合スパンボンド不織布 |
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WO2021145049A1 (ja) | 2020-01-14 | 2021-07-22 | 株式会社Tbm | 無機物質粉末配合スパンボンド不織布 |
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CN104582948B (zh) | 2016-12-28 |
EP2889133A4 (en) | 2016-03-16 |
KR20150036540A (ko) | 2015-04-07 |
KR101720439B1 (ko) | 2017-03-27 |
EP2889133B1 (en) | 2018-03-28 |
EP2889133A1 (en) | 2015-07-01 |
JPWO2014030702A1 (ja) | 2016-07-28 |
CN104582948A (zh) | 2015-04-29 |
JP5925322B2 (ja) | 2016-05-25 |
US20150210038A1 (en) | 2015-07-30 |
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