WO2016104795A1 - 自着性不織布 - Google Patents
自着性不織布 Download PDFInfo
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- WO2016104795A1 WO2016104795A1 PCT/JP2015/086422 JP2015086422W WO2016104795A1 WO 2016104795 A1 WO2016104795 A1 WO 2016104795A1 JP 2015086422 W JP2015086422 W JP 2015086422W WO 2016104795 A1 WO2016104795 A1 WO 2016104795A1
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- nonwoven fabric
- fiber
- length
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- fibers
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- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5414—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres side-by-side
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4391—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres
- D04H1/43914—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres hollow fibres
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5416—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sea-island
Definitions
- the present invention relates to a self-adhesive nonwoven fabric that can be suitably used as a bandage or the like.
- the bandage is not only used to wrap around the application site such as the affected area and directly protect the application site, or to fix other protective members (gauze etc.) to the application site, but when it has elasticity
- it is also used for performing hemostasis of a wound part by a compression force at the time of winding using the stretchability, and improving swelling by promoting blood flow.
- compression therapy in which treatment is performed by compressing the affected area, such as treatment or improvement of varicose veins.
- a non-woven fabric or the like is used for the elastic bandage.
- the bandage needs to be fixed at the tip after it is wrapped around the application site.
- fixing means a method of applying an adhesive to the bandage surface, a method of separately preparing a stopper for fixing the bandage tip, and the like are conventionally known.
- the former method has a problem that skin irritation or allergy may be induced by the adhesive, and the latter method has a problem that handling of the bandage becomes complicated.
- a self-adhesive dressing made of a nonwoven fabric has been proposed as a dressing that can solve the above problems [International Publication No. 2008/015972 (Patent Document 1)].
- Self-adhesive bandages are made by overlapping the bandages (for example, the tip after wrapping around the application site and the wrapped bandage directly under the tip) without using an adhesive or stopper. By combining, they refer to bandages that have the property of being engaged and fixed together.
- the self-adhesive bandage described in Patent Document 1 has a hand cutting property that can be broken (cut) by hand pulling without using cutting means such as scissors.
- Self-adhesive bandages are often used in environments where they are exposed to external forces, such as when wrapped around joints, and once wound around application sites, they tend to be used continuously for a long period of time. is there. Accordingly, the self-adhesive bandage is required to have excellent self-adhesive properties, and in particular, excellent self-adhesive properties are required for the tip portion formed by breaking by tension represented by hand cutting (cutting by hand). If the self-adhesiveness of the tip is insufficient, the tip tends to peel off due to external force or long-term use, etc., and the adhesion of other parts gradually begins from there, and the bandage finally comes off. It is because it becomes easy to end up.
- an object of the present invention is to provide a non-woven fabric with improved self-adhesiveness at the tip formed by breaking by tension, and a bandage using the same.
- the present invention provides the following nonwoven fabric and bandage.
- a breaking end portion formed by a tensile test in accordance with JIS L 1913, which is pulled and broken in one direction a point located on the innermost side with respect to the one direction is P in , and a point located on the outermost side when the P out, a distance D along said one direction from the point P in to the point P out is 50mm or less, a nonwoven fabric.
- the rectangular region includes three or more of the divided regions, Wherein the basis weight W i of the i-th divided area, the ratio is respectively 0.9 and 1.1 of the basis weight of the other divided regions, the nonwoven fabric according to [3] or [4].
- the crimped fiber is composed of a composite fiber in which a plurality of resins having different heat shrinkage rates form a phase structure, and is oriented substantially parallel to the surface direction, and has an average radius of curvature of 20 to The nonwoven fabric according to [8], which is crimped substantially uniformly in the thickness direction at 200 ⁇ m.
- the breaking strength is 5 to 30 N / 50 mm
- the breaking elongation is 50% or more
- the recovery rate after 50% elongation is 80% or more.
- the nonwoven fabric according to any one of [11].
- the fiber curvature rate in each of the three regions divided in the thickness direction is 1.3 or more, and the minimum value and the maximum value of the fiber curvature rate in the three regions.
- the present invention it is possible to provide a self-adhesive non-woven fabric that can be ruptured (cut) by tension and has excellent self-adhesiveness at the tip formed by the rupture.
- the nonwoven fabric according to the present invention is suitable for bandages and the like.
- the non-woven fabric according to the present invention is a non-woven fabric having a property that they are engaged and fixed by overlapping (contact) of fibers on the surface thereof, that is, self-adhesiveness.
- self-adhesiveness of the leading end portion hereinafter, also referred to as “breaking end portion” of the nonwoven fabric formed by breaking by pulling, as in the case of breaking (cutting) the nonwoven fabric by hand pulling.
- the nonwoven fabric according to the present invention has one characteristic at the broken end. The features of the broken end will be described with reference to FIGS.
- FIG. 1 shows an example of a broken end portion formed when the nonwoven fabric 100 is broken by tension.
- cilia fibers or aggregates (bundles) constituting the nonwoven fabric
- a plurality of such cilia can be formed at the broken end portion, but usually their protrusion (extension) lengths are different from each other and are distributed.
- a nonwoven fabric according to the present invention in the breaking edge portion formed by broken pull a certain one direction, a point located innermost with respect to said one direction P in, the outermost When the point located at P is P out , the distance D along the one direction from the point P in to the point P out (hereinafter also referred to as “breaking end portion length”) is 50 mm or less.
- the one direction is a breaking direction when the nonwoven fabric is pulled and broken, and this is synonymous with the pulling direction.
- the non-woven fabric of the present invention that can form a broken end having a broken end length D of 50 mm or less has relatively broken breaks (cuts) over a direction orthogonal to the break direction, Excellent part self-adhesion. In other words, even if it is self-attached in an environment exposed to external forces from various directions or is self-attached for a long period of time, the self-attached broken end portion is difficult to peel off. According to the nonwoven fabric of the present invention, it is possible to improve the resistance to peeling against external force from the outside to the inside of the nonwoven fabric in the breaking direction, and external force from other directions, for example, a direction orthogonal to the breaking direction (from the side The peel resistance against external force) can also be improved.
- the breaking end length D exceeds 50 mm, the self-adhesiveness of the breaking end is significantly lowered. Since the nonwoven fabric according to the present invention has good self-adhesiveness, it is preferable that the nonwoven fabric does not substantially contain an adhesive.
- the nonwoven fabric according to the present invention preferably has two or more locations at which a fracture end length D of 50 mm or less can be formed, more preferably 3 or more, and breaks at any position with respect to the fracture direction. Even if it makes it, it is still more preferable to show the fracture
- the broken end length D is preferably 45 mm or less, more preferably 40 mm or less.
- the fracture end portion tends to have poor self-adhesiveness. It is 1 mm or more, More preferably, it is 0.5 mm or more, More preferably, it is 1 mm or more.
- the non-woven fabric according to the present invention is typically a non-woven fabric having hand cutting properties, and is typically intended to improve the self-adhesiveness of the broken end portion caused by hand cutting (cutting by hand). is there. Therefore, the nonwoven fabric according to the present invention includes a cutting facilitating mechanism such as a cut line that is intermittently cut in advance along the line so that it can be easily cut along the line set in advance.
- the break end length D according to the present invention does not basically include the break end length when cut by this cutting facilitating mechanism. That is, when the nonwoven fabric which concerns on this invention has a cutting
- the break end length D is measured by pulling the nonwoven fabric in the above one direction to break, thereby creating a break end.
- a tensile test according to JIS L 1913 “General Nonwoven Test Method” is used.
- the fracture sample obtained by this measurement may be used as a sample for measuring the fracture end length D. it can.
- the point Pout when cilia extending in a direction not parallel to the breaking direction is present in the cilia exposed at the broken end, care is taken so that the protruding (extending) length itself does not change. However, the point Pout is specified by adjusting the direction so that the extending direction of the cilia is parallel to the breaking direction.
- the shape of the nonwoven fabric according to the present invention is usually a sheet shape, and a more specific shape can be selected according to the use, but preferably has a length direction and a width direction such as a tape shape or a strip shape (long shape). It is a rectangular sheet.
- the nonwoven fabric according to the present invention preferably forms a broken end portion having a broken end length D of 50 mm or less when at least the breaking direction is parallel to the length direction. More preferably, the nonwoven fabric according to the present invention has at least two or more locations where a break end length D is 50 mm or less when the break direction is parallel to the length direction.
- the length direction of the nonwoven fabric can be the flow direction (MD direction) of the nonwoven fabric in the manufacturing process, and the width direction of the nonwoven fabric is the direction (CD direction) orthogonal to the flow direction of the nonwoven fabric in the manufacturing process. Can do.
- the nonwoven fabric according to the present invention having a length direction and a width direction preferably includes a specific square region 200 having a length in the length direction of 5 cm and a length in the width direction being the entire width of the nonwoven fabric.
- the specific rectangular region 200 includes two or more divided regions included in the rectangular region 200 and having a length in the length direction of 5 cm and a length in the width direction of 1 cm.
- the basis weight W i of the i-th divided region from the one end in the width direction of the nonwoven fabric (where i is an integer of 1 or more, and the first divided region includes one end in the width direction of the nonwoven fabric); i + 1) A square area in which the ratio W i / W i + 1 to the basis weight W i + 1 of the divided area is 0.9 to 1.1.
- the nonwoven fabric 100 including the specific square region 200 has a length in the length direction of at least 5 cm and a length in the width direction of at least 2 cm.
- the first divided region is assigned so as to include one end of the nonwoven fabric 100 in the width direction (see FIG. 2).
- a blank area to which a divided area having a width of 1 cm cannot be allocated may be formed at the other end of the square area 200 in the width direction. That is, the full width of the nonwoven fabric according to the present invention is not limited to an integer multiple of 1 cm.
- the nonwoven fabric according to the present invention preferably has two or more of the specific rectangular regions 200, more preferably three or more, and substantially all or almost all of the nonwoven fabric has the specific rectangular region 200. More preferably, it is comprised. When the nonwoven fabric has two or more specific square regions 200, these square regions 200 may be continuous or may be spaced apart.
- the density (bulk density) of the nonwoven fabric according to the present invention is, for example, 0.03 to 0.5 g / cm 3 , preferably 0.05 to 0.2 g / cm 3 , more preferably 0.06 to 0.18 g. / Cm 3 .
- the thickness of the nonwoven fabric is, for example, 0.2 to 5 mm, preferably 0.3 to 3 mm, and more preferably 0.4 to 2 mm.
- the fabric weight as a whole nonwoven fabric that is, the average fabric weight of the nonwoven fabric is preferably 30 g / m 2 or more, more preferably 50 g / m 2 or more.
- the weight per unit area and the thickness are in this range, the balance between the stretchability and flexibility of the nonwoven fabric, the texture, and the cushioning property becomes good.
- the nonwoven fabric according to the present invention preferably includes a plurality of low-density portions and a plurality of high-density portions arranged along a certain in-plane direction (for example, the length direction). More preferably, they are arranged alternately alternately.
- the arrangement pattern of the low density portion and the high density portion is not particularly limited, but when the nonwoven fabric has a length direction and a width direction, a striped pattern in which the low density portion and the high density portion are alternately arranged along the length direction.
- the area ratios of the low density portion and the high density portion may be different or the same.
- the area ratio of the low density portion / high density portion is, for example, 90/10 to 10/90, and preferably 70/30 to 30/70.
- the average width of the low density portion and the high density portion is, for example, 0.1 to 10 mm, preferably 0.5 to 5 mm, and more preferably 1 to 3 mm.
- the compressive stress of the nonwoven fabric according to the present invention is preferably 0.2 to 10 kPa, more preferably 0.5 to 5 kPa, and still more preferably 0.6 to 4 kPa.
- the compressive stress of the non-woven fabric is within this range, the non-woven fabric has an appropriate cushioning property and the integrity when the fibers are brought into contact with each other increases. Can be improved.
- the compressive stress of the nonwoven fabric is measured according to the method described in the Examples section.
- the nonwoven fabric according to the present invention has a breaking strength in at least one direction in the plane direction of, for example, 5 to 30 N / 50 mm, preferably 6 to 25 N / 50 mm, more preferably 7 to 20 N / 50 mm.
- the breaking strength is related to the hand cutting property of the nonwoven fabric.
- the nonwoven fabric according to the present invention preferably has a good hand cutting property that can be broken (cut) relatively easily by hand. However, if the breaking strength is too high, the hand cutting property is insufficient. For example, the nonwoven fabric is cut with one hand. It becomes difficult. On the other hand, if the breaking strength is too small, the strength of the non-woven fabric is insufficient and breaks easily, resulting in poor handling.
- the breaking strength is measured by a tensile test according to JIS L 1913 “General nonwoven fabric test method”.
- the above “at least one direction in the plane direction” can be the flow direction (MD direction) of the nonwoven fabric in the production process, and when the nonwoven fabric has a length direction and a width direction like a bandage, for example, The length direction is preferable.
- the nonwoven fabric according to the present invention preferably satisfies the range of the breaking strength in the length direction.
- the breaking strength is in the above range in the length direction of the nonwoven fabric also from the viewpoint of ensuring good productivity.
- breakage in a direction other than at least one direction in the plane direction for example, a direction perpendicular to the flow direction of the manufacturing process (CD direction) or a width direction when the nonwoven fabric has a length direction and a width direction like a bandage.
- the strength may be relatively small, for example 0.05 to 20 N / 50 mm, preferably 0.1 to 15 N / 50 mm, more preferably 0.5 to 10 N / 50 mm.
- the nonwoven fabric according to the present invention usually has anisotropy between the MD direction and the CD direction. That is, the nonwoven fabric of the present invention is not limited in that the axial direction of the coiled crimped fiber is substantially parallel to the surface direction in the course of production, but also the axial core of the coiled crimped fiber oriented substantially parallel to the surface direction. The direction tends to be substantially parallel to the MD direction. As a result, when a nonwoven fabric having a length direction and a width direction is produced, the stretch properties and the rupture properties, particularly the rupture strength, are anisotropic between the MD direction and the CD direction.
- the nonwoven fabric which has the breaking strength of the length direction in the said range can be obtained by making MD direction into the length direction of a nonwoven fabric.
- the breaking strength in the length direction (MD direction) of the nonwoven fabric is, for example, 1.5 to 50 times, preferably 2 to 40 times, more preferably 3 times the breaking strength in the width direction. ⁇ 30 times.
- the elongation at break in at least one direction in the plane direction is, for example, 50% or more, preferably 60% or more, and more preferably 80% or more. It is advantageous to increase the stretchability of the nonwoven fabric that the breaking elongation is in the above range. Moreover, when using a nonwoven fabric as a bandage, followable
- the elongation at break in at least one direction in the plane direction is usually 300% or less, preferably 250% or less.
- the breaking elongation is also measured by a tensile test according to JIS L 1913 “General Nonwoven Test Method”.
- the above “at least one direction in the plane direction” can be the MD direction, and when the nonwoven fabric has a length direction and a width direction as in a bandage, for example, the length direction of the nonwoven fabric is preferable.
- the elongation at break in the direction other than at least one of the plane directions, for example, the CD direction, and the width direction when the nonwoven fabric has a length direction and a width direction like a bandage is, for example, 50 to 500%, preferably 100 to 350%.
- the recovery rate after 50% elongation (recovery rate after 50% elongation) in at least one direction in the plane direction is preferably 70% or more (100% or less), more preferably 80% or more, 90 % Or more is more preferable.
- the 50% elongation recovery rate is in this range, the followability to elongation is improved.
- it sufficiently follows the shape of the place of use and is self-adhesive due to friction between the laminated nonwoven fabrics. It is advantageous for improvement.
- the fixing force due to friction corresponds to the recovery stress as a whole and exhibits a behavior similar to that of increasing the basis weight.
- the above “at least one direction in the plane direction” can be the MD direction, and when the nonwoven fabric has a length direction and a width direction as in a bandage, for example, the length direction of the nonwoven fabric is preferable.
- the recovery rate after 50% elongation is the residual strain (%) after the test when the load was removed immediately after the elongation rate reached 50% in the tensile test according to JIS L 1913 "General nonwoven fabric test method".
- the recovery rate after 50% elongation in a direction other than at least one direction in the plane direction, for example, the CD direction or the width direction when the nonwoven fabric has a length direction and a width direction like a bandage is, for example, 70% or more (100% Or less), preferably 80% or more.
- the stress at 50% elongation in at least one direction in the plane direction is preferably 3 to 50 N / 50 mm, more preferably 4 to 40 N / 50 mm, and further preferably 5 to 30 N / 50 mm. preferable. When the stress at 50% elongation is in this range, it is advantageous for followability to elongation.
- the stress at 50% elongation is also measured by a tensile test according to JIS L 1913 “General Nonwoven Test Method”.
- the above “at least one direction in the plane direction” can be the MD direction, and when the nonwoven fabric has a length direction and a width direction as in a bandage, for example, the length direction of the nonwoven fabric is preferable.
- the stress at 50% elongation in a direction other than at least one of the plane directions, for example, the CD direction, or the width direction when the nonwoven fabric has a length direction and a width direction like a bandage is, for example, 0.5 to 50 N / 50 mm And preferably 1 to 30 N / 50 mm.
- the non-woven fabric according to the present invention is excellent in self-adhesive property, particularly in the self-adhesive property at the broken end. With this self-adhesive property, one nonwoven fabric portion can be hooked and fixed to the other nonwoven fabric portion by joining or entanglement when the nonwoven fabrics are in contact with each other without using an adhesive or a stopper.
- the self-adhesion property of the nonwoven fabric can be evaluated by curved surface sliding stress.
- the curved surface slip stress in the portion other than the fracture end is, for example, 0.5 N / 50 mm or more, preferably 1 N / 50 mm or more, more preferably 3 N / 50 mm or more.
- the curved surface sliding stress at the fracture end can be set to 5 N / 50 mm or more, further can be set to 7 N / 50 mm or more, and further can be set to 10 N / 50 mm or more. It is.
- curved surface slip stress (self-adhesion) at the break end can be increased.
- the curved slip stress at the portion other than the fracture end and the curved slip stress at the fracture end are measured using a tensile tester according to the method described in the example section (FIGS. 3 to 5).
- the air permeability of the nonwoven fabric according to the present invention is 0.1 cm 3 / cm 2 ⁇ sec or more as measured by the Frazier method, for example, 1 to 500 cm 3 / cm 2 ⁇ sec, preferably 5 to 300 cm 3 / cm 2. Seconds, more preferably 10 to 200 cm 3 / cm 2 ⁇ seconds. When the air permeability is within this range, the air permeability is good and the hair is not easily peeled off.
- the non-woven fabric according to the present invention preferably includes crimped fibers crimped into a coil shape, as will be described in detail later.
- the nonwoven fabric according to the present invention has a structure in which crimped fibers are mainly entangled and constrained by their crimped coil portions without substantially fusing each fiber constituting the nonwoven fabric. It is preferable.
- most (most) crimped fibers (axial direction of the crimped fibers) constituting this are oriented substantially parallel to the nonwoven fabric surface (sheet surface). preferable.
- orientated substantially parallel to the plane direction means that a number of crimped fibers (axial direction of the crimped fibers) are locally in the thickness direction, for example, entangled by a needle punch. This means a state in which the portion oriented along the line does not exist repeatedly.
- the nonwoven fabric according to the present invention preferably includes crimped fibers oriented in the plane direction (longitudinal direction) and crimped in a coil shape, and adjacent or intersecting crimped fibers are their crimped coil portions. Are entangled with each other.
- the crimped fibers are preferably slightly entangled even in the thickness direction (or oblique direction) of the nonwoven fabric. Particularly, in the fiber web, the fibers are entangled in the process of contracting into a coil shape, and the crimped fibers are restrained by the entangled crimped coil portion.
- the nonwoven fabric according to the present invention can be a stretchable nonwoven fabric that can be greatly stretched in the plane direction (longitudinal direction) by the entangled crimped coil portion rather than in the width direction or thickness direction.
- the crimped fibers are preferably oriented in the surface direction and the length direction. Therefore, when tension is applied in the length direction, the entangled crimped coil portion is expanded and is in the original coil shape. In order to return, high elasticity can be shown in the surface direction and the length direction.
- the cushioning property and flexibility in the thickness direction can be expressed by the slight entanglement between the crimped fibers in the thickness direction of the nonwoven fabric, whereby the nonwoven fabric can have a good touch and texture.
- the crimped coil part is easily entangled with other crimped coil parts by contact with a certain pressure. Self-adhesion can be expressed by the entanglement of the crimped coil portions.
- the crimped fibers are preferably oriented in the plane direction and the length direction. Therefore, when tension is applied in the length direction, the entangled crimped coil portion is extended by elastic deformation, and finally, when tension is further applied, finally Since it can be dissolved, it has good cutting properties (hand cutting properties).
- the nonwoven fabric which concerns on this invention can be equipped with self-adhesion property, hand cutting property, and a stretching property with sufficient balance.
- the coil-shaped crimped fibers are oriented substantially parallel to the surface direction of the nonwoven fabric, whereby the nonwoven fabric according to the present invention can have stretchability in the surface direction.
- the fiber when the fiber is stretched in the thickness direction, the fiber is relatively easily unwound, and thus does not exhibit stretchability (shrinkage) as seen in the surface direction.
- stretchability shrinkage
- the orientation of the fibers can be easily confirmed by observing the stretchability.
- the nonwoven fabric according to the present invention preferably includes crimped fibers crimped into a coil shape.
- the crimped fibers are preferably oriented mainly in the surface direction of the nonwoven fabric, and preferably crimped substantially uniformly in the thickness direction.
- the crimped fiber can be composed of a composite fiber in which a plurality of resins having different thermal shrinkage rates (or thermal expansion rates) form a phase structure.
- the composite fiber constituting the crimped fiber is a fiber having an asymmetric or layered (so-called bimetal) structure that causes crimping by heating due to the difference in thermal shrinkage rate (or thermal expansion rate) of a plurality of resins Crimped fiber).
- a plurality of resins usually have different softening points or melting points.
- the plurality of resins include, for example, polyolefin resins (low density, medium density or high density polyethylene, poly C 2-4 olefin resins such as polypropylene); acrylic resins (such as acrylonitrile-vinyl chloride copolymer) Acrylonitrile resins having acrylonitrile units); polyvinyl acetal resins (polyvinyl acetal resins, etc.); polyvinyl chloride resins (polyvinyl chloride, vinyl chloride-vinyl acetate copolymers, vinyl chloride-acrylonitrile copolymers, etc.); Polyvinylidene chloride resin (vinylidene chloride-vinyl chloride copolymer, vinylidene chloride-vinyl acetate copolymer, etc.); Styrene resin (heat resistant polystyrene, etc.); Polyester resin (polyethylene terephthalate resin, polytrimethylene terephthalate resin, poly Butylene TV
- the plurality of resins are non-wet heat adhesive resins (or heat-resistant hydrophobic resins having a softening point or melting point of 100 ° C. or higher because the fibers do not melt and soften even when heat-treated with high-temperature steam.
- non-aqueous resins for example, polypropylene resins, polyester resins, and polyamide resins are preferred, and aromatic polyester resins and polyamide resins are particularly preferred from the viewpoint of excellent balance of heat resistance and fiber-forming properties.
- at least the resin exposed on the surface of the composite fiber is a non-wet heat adhesive fiber so that the fiber does not melt even when the composite fiber (latently crimped fiber) constituting the nonwoven fabric is treated with high-temperature steam.
- the plurality of resins constituting the composite fiber may have different heat shrinkage rates, and may be a combination of resins of the same system or a combination of different resins.
- the plurality of resins constituting the composite fiber are preferably a combination of resins of the same system.
- a combination of a component (A) that forms a homopolymer (essential component) and a component (B) that forms a modified polymer (copolymer) is usually used.
- the homopolymer which is an essential component, is crystallized more than the homopolymer by, for example, copolymerizing and modifying a copolymerizable monomer that lowers the crystallinity, melting point, or softening point. The melting point or the softening point may be lowered as compared with the homopolymer.
- a difference can be provided in the heat shrinkage rate by changing the crystallinity, the melting point or the softening point.
- the difference in melting point or softening point can be, for example, 5 to 150 ° C., preferably 40 to 130 ° C., more preferably 60 to 120 ° C.
- the ratio of the copolymerizable monomer used for modification is, for example, 1 to 50 mol%, preferably 2 to 40 mol%, more preferably 3 to 30 mol% (particularly 5 to 20 mol%).
- the mass ratio of the component forming the homopolymer and the component forming the modified polymer can be selected according to the structure of the fiber.
- the homopolymer component (A) / modified polymer component (B) 90/10 to 10/90, preferably 70/30 to 30/70, more preferably 60/40 to 40/60.
- the conjugate fiber is a combination of an aromatic polyester resin, in particular, a combination of a polyalkylene arylate resin (a) and a modified polyalkylene arylate resin (b).
- the polyalkylene arylate resin (a) comprises an aromatic dicarboxylic acid (such as a symmetric aromatic dicarboxylic acid such as terephthalic acid or naphthalene-2,6-dicarboxylic acid) and an alkanediol component (such as ethylene glycol or butylene glycol). C 2-6 alkanediol and the like).
- poly C 2-4 alkylene terephthalate resins such as polyethylene terephthalate (PET) and polybutylene terephthalate (PBT) are used, and general PET having an intrinsic viscosity of 0.6 to 0.7 is usually used. PET used for fibers is used.
- the copolymer component that lowers the melting point or softening point and crystallinity of the polyalkylene arylate resin (a), which is an essential component is, for example, an asymmetric aromatic dicarboxylic acid.
- examples include dicarboxylic acid components such as acids, alicyclic dicarboxylic acids, and aliphatic dicarboxylic acids, and alkanediol components and / or ether bond-containing diol components having a chain length longer than the alkanediol of the polyalkylene arylate resin (a). It is done.
- a copolymerization component can be used individually or in combination of 2 or more types.
- dicarboxylic acid components asymmetric aromatic dicarboxylic acids (isophthalic acid, phthalic acid, 5-sodium sulfoisophthalic acid, etc.), aliphatic dicarboxylic acids (C 6-12 aliphatic dicarboxylic acids such as adipic acid) Acid) and the like, and as a diol component, alkanediol (C 3-6 alkanediol such as 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, etc.), Polyoxyalkylene glycols (polyoxy C 2-4 alkylene glycols such as diethylene glycol, triethylene glycol, polyethylene glycol, and polytetramethylene glycol) are widely used.
- alkanediol C 3-6 alkanediol such as 1,3-propanediol, 1,4-butanedio
- modified polyalkylene arylate resin (b) may be an elastomer having a C 2-4 alkylene arylate (ethylene terephthalate, butylene terephthalate, etc.) as a hard segment and (poly) oxyalkylene glycol or the like as a soft segment. .
- the proportion of the dicarboxylic acid component (such as isophthalic acid) for decreasing the melting point or softening point is the same as that of the dicarboxylic acid component constituting the modified polyalkylene arylate resin (b).
- the proportion of the dicarboxylic acid component (such as isophthalic acid) for decreasing the melting point or softening point is the same as that of the dicarboxylic acid component constituting the modified polyalkylene arylate resin (b).
- it is 1 to 50 mol%, preferably 5 to 50 mol%, more preferably 15 to 40 mol%, based on the total amount.
- the ratio of the diol component (for example, diethylene glycol etc.) for lowering the melting point or the softening point is, for example, 30 mol% or less with respect to the total amount of the diol component constituting the modified polyalkylene arylate resin (b), Preferably, it is 10 mol% or less (for example, 0.1 to 10 mol%). If the ratio of the copolymer component is too low, sufficient crimps are not expressed, and the form stability and stretchability of the nonwoven fabric after crimps are reduced. On the other hand, if the proportion of the copolymer component is too high, the crimping performance will be high, but it will be difficult to spin stably.
- the ratio of the copolymer component for example, diethylene glycol etc.
- the modified polyalkylene arylate resin (b) is a polyvalent carboxylic acid component such as trimellitic acid or pyromellitic acid, a polyol component such as glycerin, trimethylolpropane, trimethylolethane, or pentaerythritol, if necessary. May be included as a monomer component.
- the cross-sectional shape (cross-sectional shape perpendicular to the longitudinal direction of the fiber) of the composite fiber is a general solid cross-sectional shape, such as a round cross-section or an irregular cross-section (flat, elliptical, polygonal, 3-14 leaf, T Shape, H-shape, V-shape, dogbone (I-shape), etc.], and may be a hollow cross-section, but is usually a round cross-section.
- phase structure formed of a plurality of resins, for example, a core-sheath type, a sea-island type, a blend type, a parallel type (side-by-side type or multilayer bonding type), a radial type (radial bonding type) ), Hollow radiation type, block type, random composite type and the like.
- a structure in which the phase portions are adjacent is adjacent (so-called bimetal structure) or a structure in which the phase structure is asymmetric, for example, an eccentric core-sheath type or a parallel type structure is preferable because it is easy to cause spontaneous crimping by heating.
- the core part Is a wet heat adhesive resin (for example, a vinyl alcohol polymer such as ethylene-vinyl alcohol copolymer or polyvinyl alcohol) or a thermoplastic resin having a low melting point or softening point (for example, polystyrene or low density polyethylene). It may be comprised.
- a wet heat adhesive resin for example, a vinyl alcohol polymer such as ethylene-vinyl alcohol copolymer or polyvinyl alcohol
- a thermoplastic resin having a low melting point or softening point for example, polystyrene or low density polyethylene
- the average fineness of the composite fiber can be selected from the range of, for example, 0.1 to 50 dtex, preferably 0.5 to 10 dtex, more preferably 1 to 5 dtex (particularly 1.5 to 3 dtex). If the fineness is too small, it is difficult to produce the fiber itself, and it is difficult to secure the fiber strength. Moreover, it becomes difficult to express a beautiful coiled crimp in the step of expressing crimp. On the other hand, if the fineness is too large, the fiber becomes stiff and it is difficult to express sufficient crimp.
- the average fiber length of the composite fiber can be selected, for example, from a range of 10 to 100 mm, preferably 20 to 80 mm, more preferably 25 to 75 mm (particularly 40 to 60 mm). If the average fiber length is too short, formation of the fiber web becomes difficult, and when crimps are expressed, the entanglement between the crimped fibers becomes insufficient, and it is difficult to ensure the strength and stretchability of the nonwoven fabric. Become. In addition, if the average fiber length is too long, it becomes difficult to form a fiber web with a uniform basis weight, and a lot of fibers are entangled at the time of web formation, and they interfere with each other when crimping occurs. This makes it difficult to develop stretchability.
- the average fiber length is in the above range, a part of the fibers crimped on the nonwoven fabric surface is appropriately exposed on the nonwoven fabric surface, so that the self-adhesiveness of the nonwoven fabric can be improved. Furthermore, the average fiber length in the above range is advantageous for obtaining good hand cutting properties.
- the above-mentioned composite fiber is a latent crimped fiber, and when subjected to heat treatment, the crimp is expressed (or becomes manifest) and becomes a fiber having a substantially coiled (spiral or helical spring-like) three-dimensional crimp.
- the number of crimps before heating is, for example, 0 to 30 pieces / 25 mm, preferably 1 to 25 pieces / 25 mm, and more preferably 5 to 20 pieces / 25 mm.
- the number of crimps after heating is, for example, 30 pieces / 25 mm or more (for example, 30 to 200 pieces / 25 mm), preferably 35 to 150 pieces / 25 mm, and more preferably about 40 to 120 pieces / 25 mm. It may be ⁇ 120 pieces / 25 mm (especially 50 to 100 pieces / 25 mm).
- the crimped fibers are preferably crimped substantially uniformly in the thickness direction, that is, the crimps of the composite fiber are preferably expressed substantially uniformly in the thickness direction.
- the number of fibers forming one or more coil crimps in the central portion (inner layer) of each region divided in three in the thickness direction is preferably 5 -50 pieces / 5 mm (length in the surface direction) .0.2 mm (thickness), more preferably 10-50 pieces / 5 mm (face direction) .0.2 mm (thickness), more preferably 20-50 pieces / 5 mm. (Surface direction) ⁇ 0.2 mm (thickness).
- region divided into three equal to the thickness direction means each area
- the fact that crimps are uniform in the thickness direction can also be evaluated by the uniform fiber curvature.
- the fiber curvature is the ratio (L2 / L1) of the fiber length (L2) to the distance (L1) at both ends of the crimped fiber, and the fiber curvature (particularly the fiber curvature in the central region in the thickness direction) is: For example, it is 1.3 or more (for example, 1.35 to 20), preferably 2 to 10 (for example, 2.1 to 9.5), more preferably 4 to 8 (particularly 4.5 to 7.5).
- the fiber bending rate is measured based on an electron micrograph of a cross section of the nonwoven fabric. Therefore, the fiber length (L2) is a fiber length (stretched three-dimensionally and linearized). It means not the actual length), but the length of the two-dimensionally crimped fibers shown in the photograph, which is drawn into a straight line (the fiber length on the photograph). Therefore, the fiber length (L2) is measured shorter than the actual fiber length.
- the fiber curvature is uniform in the thickness direction.
- the uniformity of the fiber curvature can be evaluated by comparing the fiber curvature in each layer divided in three in the thickness direction in the cross section in the thickness direction. That is, in the cross section in the thickness direction, the fiber curvature rate in each region divided in three in the thickness direction is in the above range, and the ratio of the minimum value to the maximum value of the fiber curvature rate in each region (the fiber curvature rate is the maximum).
- the ratio of the minimum area to the above area is, for example, about 75% or more (for example, 75 to 100%), preferably about 80 to 99%, more preferably about 82 to 98% (especially 85 to 97%).
- a method for measuring the fiber curvature and its uniformity a method is used in which a cross section of the nonwoven fabric is taken with an electron micrograph and the fiber curvature is measured for a region selected from each region divided into three equal parts in the thickness direction. It is done.
- the area to be measured is an area of 2 mm or more in the length direction for each of the surface layer (surface area), inner layer (center area), and back layer (back area) divided into three.
- the thickness direction of each measurement region is set so that each measurement region has the same thickness width in the vicinity of the center of each layer.
- Each measurement region includes 100 or more (preferably about 300 or more, more preferably about 500 to 1000) fiber pieces that are parallel in the thickness direction and capable of measuring the fiber curvature in each measurement region.
- the crimped fiber constituting the nonwoven fabric has a substantially coil-shaped crimp after the crimp is developed.
- the average radius of curvature of the circle formed by the coil of crimped fibers can be selected from the range of, for example, 10 to 250 ⁇ m, preferably 20 to 200 ⁇ m (for example, 50 to 200 ⁇ m), more preferably 50 to 160 ⁇ m (for example, 60 to 150 ⁇ m). ), More preferably 70 to 130 ⁇ m.
- the average radius of curvature is an index that represents the average size of a circle formed by a coil of crimped fibers. If this value is large, the formed coil has a loose shape, in other words, the number of crimps. It means that it has a shape with few.
- the entanglement between the crimped fibers also decreases, and it becomes difficult to recover the shape with respect to the deformation of the coil shape. If the average radius of curvature is too small, the crimped fibers will not be sufficiently entangled and it will be difficult to ensure the web strength, and the stress at the time of deformation of the coil will be too great and the breaking strength will be excessive. It becomes large and it becomes difficult to obtain moderate elasticity.
- the average coil pitch (average crimped pitch) is, for example, 0.03 to 0.5 mm, preferably 0.03 to 0.3 mm, and more preferably 0.05 to 0.2 mm.
- the average pitch is excessively large, the number of coil crimps that can be expressed per fiber is reduced, and sufficient stretchability cannot be exhibited.
- the average pitch is excessively small, the entangled crimped fibers are not sufficiently entangled, making it difficult to ensure the strength of the nonwoven fabric.
- the nonwoven fabric (fiber web) may contain other fibers (non-composite fibers) in addition to the composite fibers.
- Non-composite fibers include, for example, cellulosic fibers [for example, natural fibers (cotton, wool, silk, hemp, etc.), semi-synthetic fibers, in addition to the above-described non-wet heat adhesive resins or fibers composed of wet heat adhesive resins.
- Fiber acetate fiber such as triacetate fiber
- regenerated fiber rayon, polynosic, cupra, lyocell (for example, registered trademark name: “Tencel” etc.)] and the like.
- the average fineness and average fiber length of the non-composite fibers are the same as those of the composite fibers.
- Non-composite fibers can be used alone or in combination of two or more.
- recycled fibers such as rayon, semi-synthetic fibers such as acetate, polyolefin fibers such as polypropylene fibers and polyethylene fibers, polyester fibers, polyamide fibers, and the like are preferable.
- the same type of fiber as the composite fiber is preferable.
- the non-composite fiber can also be a polyester fiber.
- the balance between strength and stretchability or flexibility of the nonwoven fabric can be adjusted.
- the ratio of the composite fiber is too small, when the composite fiber expands and contracts after the crimp is developed, particularly when the composite fiber contracts after expansion, the non-composite fiber becomes a resistance to the contraction, so that the shape recovery of the nonwoven fabric becomes difficult. .
- Nonwoven fabrics are made of conventional additives such as stabilizers (heat stabilizers such as copper compounds, UV absorbers, light stabilizers, antioxidants, etc.), antibacterial agents, deodorants, perfumes, and coloring.
- stabilizers heat stabilizers such as copper compounds, UV absorbers, light stabilizers, antioxidants, etc.
- An agent dieing pigment, etc.
- a filler an antistatic agent, a flame retardant, a plasticizer, a lubricant, a crystallization rate retarder and the like may be contained.
- An additive can be used individually or in combination of 2 or more types. The additive may be supported on the fiber surface or may be contained in the fiber.
- the nonwoven fabric according to the present invention comprises a step of forming a fiber containing the above composite fiber (latent crimped fiber) (web forming step) and a step of heating the fiber web to crimp the composite fiber (heating step). It can manufacture suitably by the method of including.
- a conventional method for example, a spunbond method, a direct method such as a melt blow method, a card method using melt blow fibers or staple fibers, a dry method such as an air lay method, etc.
- a card method using melt blown fibers or staple fibers particularly a card method using staple fibers is widely used.
- webs obtained using staple fibers include random webs, semi-random webs, parallel webs, and cross-wrap webs.
- an entanglement step in which at least some of the fibers in the fiber web are entangled may be performed.
- the entanglement method may be a method of mechanical entanglement, but a method of entanglement by spraying or spraying (spraying) water is preferable. Entangling the fibers with a water stream is advantageous in increasing the density of entanglement due to crimping in the heating process.
- the water to be sprayed or sprayed may be sprayed from one side of the fiber web or may be sprayed from both sides, but it is preferable to spray from both sides in order to efficiently perform strong entanglement.
- the water ejection pressure in the entanglement step is, for example, 2 MPa or more (for example, 2 to 15 MPa), preferably 3 to 12 MPa, more preferably 4 to 10 MPa (particularly 5 to 8 MPa) so that the fiber entanglement is in an appropriate range. It is.
- the temperature of water sprayed or jetted is, for example, 5 to 50 ° C., preferably 10 to 40 ° C., for example 15 to 35 ° C. (normal temperature).
- a method of injecting water using a nozzle having a regular spray area or a spray pattern is preferable from the viewpoint of simplicity and the like.
- water can be sprayed on the fiber web transported by the belt conveyor while being placed on the conveyor belt.
- the conveyor belt may be water-permeable, and water may be sprayed onto the fiber web by passing the water-permeable conveyor belt from the back side of the fiber web.
- the fiber web may be wetted with a small amount of water in advance.
- the nozzle for spraying or spraying water may be a plate or die in which predetermined orifices are continuously arranged in the width direction, and the orifices may be arranged in the width direction of the fiber web to be supplied. There may be one or more orifice rows, and a plurality of rows may be arranged in parallel. A plurality of nozzle dies having one orifice row may be installed in parallel.
- the thickness of the plate can be 0.5 to 1.0 mm, for example.
- the diameter of the orifice is usually 0.01 to 2 mm, preferably 0.05 to 1.5 mm, more preferably 0.1 to 1.0 mm.
- the pitch of the orifices is usually 0.1 to 2 mm, preferably 0.2 to 1.5 mm, more preferably 0.3 to 1 mm.
- the belt conveyor to be used is not particularly limited as long as it can be transported without disturbing the form of the fiber web, but an endless conveyor is preferably used. Only one belt conveyor may be used alone, or another belt conveyor may be combined as necessary, and the belt may be transported with a fiber web sandwiched between both belts. In particular, in the next heating step of fixing the fiber web in the final form, the fiber web may be sandwiched using a set of belts to adjust the density of the fiber web. By carrying in this way, when the fiber web is processed, the form of the carried web is prevented from being deformed by external forces such as water for entanglement, high-temperature steam in the heating process, vibration of the conveyor, etc. it can.
- the distance between the belts may be appropriately selected depending on the desired basis weight and density of the fiber web, and is, for example, 1 to 10 mm, preferably 1 to 8 mm, more preferably 1 to 5 mm. .
- the endless belt used for the conveyor is not particularly limited as long as it does not interfere with the water for transporting and entanglement of the fiber web, and the high-temperature steam treatment in the heating process.
- a net of about 10 to 80 mesh is preferable.
- a fine net with a mesh larger than this has low air permeability, and it becomes difficult for water for entanglement and water vapor in the next process to pass through.
- the material of the belt is not particularly limited, but the material of the belt used in the heating process is a metal, a heat-treated polyester resin, a polyphenylene sulfide resin, a polyarylate resin (totally aromatic resin) Heat-resistant resins such as aromatic polyester resins).
- the belt used for the conveyor may be the same for the entanglement process using a water flow or the like and the heating process using high-temperature steam. However, since adjustment is required for each process, a separate conveyor is usually used.
- a step of unevenly distributing the fibers in the fiber web in the plane may be provided prior to the above-described entanglement step.
- a region where the fiber density is sparse is formed in the fiber web, so that when the entanglement step is hydroentanglement, the water flow is efficiently injected into the fiber web. This makes it easy to achieve moderate entanglement not only on the surface of the fiber web but also on the inside.
- the uneven distribution process can be performed by spraying or jetting low-pressure water onto the fiber web.
- Spraying or spraying low pressure water onto the fibrous web may be continuous, but is preferably sprayed intermittently or periodically.
- By spraying water on the fiber web intermittently or periodically, a plurality of low density portions and a plurality of high density portions can be alternately formed periodically.
- the water ejection pressure in this uneven distribution step is desirably as low as possible, for example, about 0.1 to 1.5 MPa, preferably about 0.3 to 1.2 MPa, and more preferably about 0.6 to 1.0 MPa.
- the temperature of water sprayed or sprayed is, for example, 5 to 50 ° C., preferably 10 to 40 ° C., for example, 15 to 35 ° C. (normal temperature).
- the method for spraying or spraying water intermittently or periodically is not particularly limited as long as it is a method capable of alternately and periodically forming a density gradient on the fiber web.
- a method of injecting water through the formed plate-like material (perforated plate or the like) having a regular spray area or spray pattern is preferable.
- the fiber web obtained in the web forming step is sent to the next step by a belt conveyor, and then placed on the conveyor belt, and a drum (perforated plate drum) configured with a perforated plate You may pass between belts.
- the conveyor belt may be water permeable, and when the fiber web passes between the perforated plate drum and the belt, the water is sprayed at the above pressure so that it passes through the fiber web from the inside of the drum and the conveyor belt. Can be ejected.
- the fiber which comprises the fiber web on a conveyor belt can be moved to the non-spraying area
- the arrangement or arrangement structure of the holes in the perforated plate is not particularly limited.
- a structure in which the holes are alternately arranged in a mesh shape or a lattice shape (staggered shape) may be used.
- the hole diameters of the respective holes are usually formed in the same size, for example, 1 to 10 mm, preferably 1.5 to 5 mm.
- the pitch of adjacent holes is also usually the same length, for example 1-5 mm, preferably 1.5-3 mm.
- the pore diameter is too small, the amount of flowing water is reduced, and thus the fibers of the fiber web may not be moved.
- the hole diameter is too large, it is necessary to widen the pitch in order to secure the form of the drum, resulting in a portion where the fiber web does not come into contact with water, resulting in uneven quality and difficult uniform processing. It becomes.
- the pitch of the holes is too small, it is inevitably necessary to reduce the hole diameter, and the amount of water cannot be secured.
- the pitch is too wide, a portion where water does not come into contact with the fiber web is formed, and quality unevenness is likely to occur.
- the fiber web is sent to the next process by a belt conveyor, heated with high-temperature steam and crimped.
- the fiber web sent by the belt conveyor is exposed to a high-temperature or superheated steam (high-pressure steam) stream, thereby causing coil crimp in the composite fiber (latent crimped fiber).
- high-pressure steam superheated steam
- the composite fiber moves while changing its shape into a coil shape due to the appearance of crimps, and the three-dimensional entanglement between the fibers appears. Since the fiber web is breathable, high-temperature water vapor penetrates into the inside even if it is processed from one direction, and a substantially uniform crimp is developed in the thickness direction, and the fibers are entangled uniformly. To do.
- the fiber web is subjected to high temperature steam treatment by a belt conveyor, but the fiber web shrinks simultaneously with the high temperature steam treatment. Therefore, it is desirable that the fibrous web to be supplied is over-feed according to the area shrinkage rate of the target nonwoven fabric immediately before being exposed to high-temperature steam.
- the overfeed ratio is 110 to 300%, preferably 120 to 250%, based on the length of the target nonwoven fabric.
- a conventional water vapor jet apparatus In order to supply water vapor to the fiber web, a conventional water vapor jet apparatus is used.
- this water vapor spraying device a device capable of spraying water vapor almost uniformly over the entire width of the fiber web at a desired pressure and amount is preferable.
- a steam spraying device is installed in one conveyor, and steam is supplied to the fiber web through a water-permeable conveyor belt or a conveyor net placed on the conveyor.
- a suction box may be attached to the other conveyor. Excess water vapor that has passed through the fiber web may be sucked and discharged by the suction box, but in order to bring the water vapor into sufficient contact with the fiber web and more efficiently develop the fiber crimp that is generated by this heat.
- the fiber in the fiber web that is the object to be processed enters the fiber web without largely moving. It is considered that the water vapor flow effectively covers the surface of each fiber existing in the fiber web and allows uniform heat crimping by the invasion action of the water vapor flow into the fiber web. Moreover, since heat can be sufficiently conducted to the inside of the fiber web as compared with the dry heat treatment, the degree of crimping in the surface direction and the thickness direction becomes substantially uniform.
- the nozzle for injecting high-temperature water vapor is a plate or die in which predetermined orifices are continuously arranged in the width direction, as in the case of the water-entangled nozzle, and this plate or die is used for the fiber web to be supplied. What is necessary is just to arrange
- the thickness of the plate may be about 0.5 to 1.0 mm.
- the orifice diameter and pitch are not particularly limited as long as the desired crimp expression and the fiber entanglement associated with the expression can be efficiently realized, but the orifice diameter is usually 0.05 to 2 mm, preferably Is about 0.1 to 1 mm, more preferably about 0.2 to 0.5 mm.
- the pitch of the orifices is usually about 0.5 to 5 mm, preferably about 1 to 4 mm, more preferably about 1 to 3 mm. If the diameter of the orifice is too small, an operational problem that clogging is likely to occur is likely to occur.
- the high-temperature steam used is not particularly limited as long as the desired fiber crimp expression and appropriate fiber entanglement associated therewith can be realized, and may be set according to the material and form of the fiber used. .1 to 2 MPa, preferably 0.2 to 1.5 MPa, more preferably 0.3 to 1 MPa.
- the pressure of the water vapor is too high, the fibers forming the fiber web may move more than necessary to cause formation disturbance or the fibers may be entangled more than necessary. In extreme cases, the fibers are fused together, making it difficult to ensure stretchability.
- the temperature of the high-temperature steam is, for example, 70 to 150 ° C., preferably 80 to 120 ° C., more preferably 90 to 110 ° C.
- the processing speed of the high-temperature steam is, for example, 200 m / min or less, preferably 0.1 to 100 m / min, and more preferably 1 to 50 m / min.
- the nonwoven fabric may be dried as necessary.
- drying it is necessary that the fibers on the surface of the nonwoven fabric in contact with the heating element for drying are not fused by the heat of drying to reduce the stretchability, and a conventional method can be used as long as the stretchability can be maintained.
- a large dryer such as a cylinder dryer or tenter used for drying nonwoven fabrics may be used, but the remaining moisture is very small and can be dried by a relatively light drying means. Therefore, a non-contact method such as far-infrared irradiation, microwave irradiation, or electron beam irradiation, a method of blowing hot air, or a method of passing through hot air is preferable.
- the obtained non-woven fabric is wetted with water in the production process and exposed to a high-temperature steam atmosphere. That is, since the nonwoven fabric of the present invention is subjected to the same treatment as that of washing, the adhering matter to the fibers such as spinning oil is washed. Therefore, the stretchable nonwoven fabric of the present invention is hygienic and exhibits high water repellency.
- a crimped fiber (composite fiber) is extracted from a non-woven fabric with care not to stretch the coil crimp, and in the same manner as the measurement of the number of mechanical crimps, JIS L 1015 “Chemical fiber staple test method” According to (8.12.1), the average number of coil crimps (pieces / mm) was measured. In addition, this measurement was performed only about the fiber in which the coiled crimp was expressed.
- the major axis and minor axis of the ellipse Only the ellipse whose ratio is in the range of 0.8 to 1.2 was measured.
- Fiber bending rate and uniformity of crimped fibers Take an electron micrograph (magnification x 100 times) in an arbitrary cross section of the nonwoven fabric, and in the portion where the photographed fibers are projected, the thickness direction , The measurement area is set so that it is divided into three equal parts, the surface layer, the inner layer, and the back layer, and 500 or more crimped fibers that are 2 mm or longer in the length direction and measurable are included near the center of each layer. did. For these regions, the distance between the ends of the crimped fiber and the other end (the shortest distance) is measured, and the fiber length of the crimped fiber (fiber length on the photograph) is further determined. It was measured.
- the end of the crimped fiber when the end of the crimped fiber is exposed on the nonwoven fabric surface, the end is used as it is as an end for measuring the distance between the ends, and when the end is embedded in the nonwoven fabric,
- the boundary part (end part on the photograph) embedded in the nonwoven fabric was used as the end part for measuring the distance between the end parts.
- a fiber image that cannot be confirmed to be continuous over 100 ⁇ m or more was excluded from measurement.
- the fiber curvature was calculated as the ratio (L2 / L1) of the fiber length (L2) of the composite fiber to the end-to-end distance (L1).
- the average value of fiber curvature is calculated for each of the surface layer, inner layer, and back layer divided into three equal parts in the thickness direction, and the fiber curvature ratio is calculated from the ratio of the minimum value to the maximum value (minimum value / maximum value).
- the uniformity in the thickness direction was calculated.
- FIG. 6 shows a schematic diagram of a method for measuring the fiber curvature of the photographed crimped fiber.
- FIG. 6A shows a crimped fiber having one end exposed on the surface and the other end buried in the nonwoven fabric.
- the end-to-end distance L1 is the end of the crimped fiber. This is the distance from the part to the boundary part embedded in the nonwoven fabric.
- the fiber length L2 is a length obtained by two-dimensionally stretching the fiber of the portion where the crimped fiber can be observed (the portion from the end of the crimped fiber to being embedded in the nonwoven fabric).
- FIG. 6B shows a composite fiber having both ends embedded in the nonwoven fabric.
- the end-to-end distance L1 is the distance between both ends (both ends on the photograph) of the portion exposed on the nonwoven fabric surface. become.
- the fiber length L2 is a length obtained by two-dimensionally stretching the crimped fibers exposed on the nonwoven fabric surface on the photograph.
- Breaking strength, breaking elongation, and stress at 50% elongation Measured according to JIS L 1913 “General Nonwoven Testing Method”.
- the breaking strength (N / 50 mm), breaking elongation (%) and 50% elongation stress (N / 50 mm) were measured in the flow (MD) direction and width (CD) direction of the nonwoven fabric.
- Compressive stress Five non-woven fabrics were stacked and the stress when compressed in the thickness direction by 20% was measured, and this was defined as compressive stress (kPa).
- a precision universal testing machine (“Autograph AG-IS” manufactured by Shimadzu Corporation) was used for the measurement.
- a cylindrical compressor having a diameter of 29 mm was used, and compression was performed at a head speed of 10 mm / min.
- the breaking direction is the MD direction, which is the length direction of the nonwoven fabric having the obtained length direction and width direction.
- the basis weight ratio of the divided region For the obtained nonwoven fabric having the length direction and the width direction, select a rectangular region having a length in the length direction of 5 cm and a length in the width direction being the full width of the nonwoven fabric, this rectangular region, the basis weight W i of the i-th divided area was first the (i + 1) th divided ratio W i / W i + 1 of the basis weight W i + 1 of the area was measured (Fig. as described in the aforementioned 2). The basis weight ratio W i / W i + 1 was determined by cutting each divided area (length in the length direction: 5 cm, length in the width direction: 1 cm) included in the square area with scissors and measuring the weight thereof. It was determined by calculating the ratio.
- Table 2 three square regions selected from each of three types of nonwoven fabrics having different overall widths are defined as square regions 1, 2, and 3, respectively.
- Table 2 describes the maximum value and the minimum value of the basis weight ratio W i / W i + 1 in each of the square regions 1 to 3, and the basis weight ratio W i / W i + 1 is 0.9 for all i.
- a case where the weight ratio is between 1.1 and 1.1 is referred to as “Evaluation A”
- a case where the basis weight ratio W i / W i + 1 is not 0.9 to 1.1 at any one or more i is referred to as “Evaluation B”.
- a non-woven fabric having a total width of 5 cm has five divided regions in each of the rectangular regions 1 to 3, and the total number of i is 4.
- the total number of i in each rectangular area is the total number of divided areas -1.
- Tables 3 to 5 show the weights of the respective divided regions measured in calculating the basis weight ratio W i / W i + 1 .
- the outermost peripheral part of the sample 1 is cut with a razor blade so as not to damage the inner layer sample at the point 7 half-turned (180 °) along the sample 1 wound around the core 3 from the base point 6, A cut 8 was provided (see FIG. 4).
- the curved slip stress between the outermost layer portion in Sample 1 and the inner layer portion wound around the pipe roll 3 below (inner layer) was measured.
- a tensile tester (“Autograph” manufactured by Shimadzu Corporation) was used for this measurement.
- the core 3 is fixed to a jig 9 installed on the fixed side chuck base of the tensile tester (see FIG. 5), and the end portion of the sample 1 (the end portion to which the alligator clip 4 is attached) is attached to the chuck 10 on the load cell side.
- the sample 1 wound around the core 3 is pulled out by hand together with the alligator clip 4 and the weight 5 in the state shown in FIG. Only one sample 1 in the inner layer was cut with a razor blade.
- the core 3 is fixed to the jig 9 installed on the fixed side chuck base of the tensile tester (see FIG. 5), and the end of the sample 1 that is not the broken part is held by the chuck 10 on the load cell side, and the tensile speed is 200 mm.
- the tensile strength was measured when the sample 1 was detached (separated), and this was defined as the curved sliding stress (N / 50 mm) at the fracture end.
- a polyethylene terephthalate resin [component (A)] having an intrinsic viscosity of 0.65 and a modified polyethylene terephthalate resin [component (B)] obtained by copolymerizing 20 mol% of isophthalic acid and 5 mol% of diethylene glycol are used.
- Constructed side-by-side type composite staple fiber [manufactured by Kuraray Co., Ltd., “Sophit PN780”, 1.7 dtex ⁇ 51 mm length, mechanical crimp number of 12/25 mm, 130 ° C. ⁇ 62 min. 25 mm] was prepared.
- a card web having a basis weight of about 30 g / m 2 was obtained by a card method.
- This card web is moved on a conveyor net, passed between a perforated plate drum with holes (circular shape) in a zigzag pattern with a diameter of 2 mm ⁇ and a pitch of 2 mm, and from the inside of the perforated plate drum toward the web and the conveyor net. Then, a water flow was sprayed at 0.8 MPa in the form of a spray to carry out an uneven distribution step of periodically forming low density regions and high density regions of fibers.
- this card web was transferred to the heating step while overfeeding the web to about 200% so as not to inhibit the shrinkage in the heating step with the next steam.
- the card web is introduced into the water vapor jetting device provided in the belt conveyor, 0.5 MPa water vapor is jetted perpendicularly to the card web from the water vapor jetting device, and the water vapor treatment is performed, so that a coil of latent crimped fibers is obtained. While producing crimps, the fibers were entangled to obtain a nonwoven fabric.
- this steam spraying device nozzles are installed in one conveyor so as to spray steam toward the card web via a conveyor belt.
- the hole diameter of the steam spray nozzle is 0.3 mm, and an apparatus in which the nozzles are arranged in a line at a pitch of 2 mm along the conveyor width direction was used.
- the processing speed was 8.5 m / min, and the distance between the nozzle and the conveyor belt on the suction side was 7.5 mm.
- each fiber was oriented substantially parallel to the surface direction of the nonwoven fabric and crimped substantially uniformly in the thickness direction. It was.
- a card web having a weight per unit area of about 10 g / m 2 was obtained by a card method using 100% by mass of polyethylene terephthalate fiber (“Tetron” manufactured by Toray Industries, Inc., 1.6 dtex ⁇ 51 mm length, 15 mechanical crimps / 25 mm). Six layers of this card web were cross-laid and overlapped, and the fibers were entangled by the needle punch method to obtain a nonwoven fabric. The processing speed was 2.5 m / min, and the needle density (number of punches) was 1000 times / cm 2 in total from both sides.
- Tetron polyethylene terephthalate fiber
- Example 3 The card web used in Example 1 was introduced into a water vapor jet apparatus, the water vapor jet pressure was 0.8 MPa, the processing speed was 5.0 m / min, and the distance between the nozzle and the conveyor belt on the suction side was 5.5 mm. Except for this, a nonwoven fabric was obtained in the same manner as in Example 1. When the surface of the obtained nonwoven fabric and the cross section in the thickness direction were observed with an electron microscope (100 times), each fiber was oriented substantially parallel to the surface direction of the nonwoven fabric and crimped substantially uniformly in the thickness direction. It was.
- ⁇ Comparative Example 1> While transferring the card web used in Example 2 to a belt conveyor equipped with a 76 mesh, 500 mm wide resin endless belt, orifices having a diameter of 0.1 mm are provided in a row at 0.6 mm intervals in the width direction of the web.
- the obtained nozzles were used in two stages on the front and back sides, and water was sprayed from the nozzles, and the fibers were entangled at a processing speed of 30 m / min to obtain a nonwoven fabric.
- the jet water pressure was 3 MPa for both the front and back sides of the front nozzle row, and 5 MPa for both the front and back sides of the rear nozzle row.
- Example 2 A nonwoven fabric was obtained in the same manner as in Example 2 except that the needle density (the number of punches) was 250 times / cm 2 in total from both sides.
- Example 3 The card web used in Example 2 was subjected to hot air treatment at 130 ° C. with a hot air circulation processor to develop coiled crimps of latent crimped fibers, and the fibers were entangled to obtain a nonwoven fabric.
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Abstract
Description
[1]1つの方向に引張って破断させるJIS L 1913に準拠する引張試験によって形成される破断端部において、前記1つの方向に関して最も内側に位置する点をPin、最も外側に位置する点をPoutとするとき、点Pinから点Poutまでの前記1つの方向に沿った距離Dが50mm以下である、不織布。
前記1つの方向は、前記長さ方向と平行である、[1]に記載の不織布。
前記方形領域に含まれる、長さ方向の長さが5cmであり、幅方向の長さが1cmである2以上の分割領域において、前記不織布の幅方向の一端から第i番目の分割領域(ただし、iは1以上の整数であり、第1番目の分割領域は前記幅方向の一端を含む。)の目付Wiと、第(i+1)番目の分割領域の目付Wi+1との比Wi/Wi+1が0.9~1.1である、[2]に記載の不織布。
[5]前記方形領域は、前記分割領域を3以上含み、
前記第i番目の分割領域の目付Wiと、それ以外の分割領域の目付との比がそれぞれ0.9~1.1である、[3]又は[4]に記載の不織布。
[9]前記捲縮繊維は、熱収縮率の異なる複数の樹脂が相構造を形成した複合繊維で構成されており、面方向に対して略平行に配向しているとともに、平均曲率半径20~200μmで厚み方向において略均一に捲縮している、[8]に記載の不織布。
(1)不織布の特性
本発明に係る不織布は、その表面の繊維同士の重ね合わせ(接触)によってこれらが互いに係合して固定される性質、すなわち自着性を有する不織布である。とりわけ本発明では、手で引張って不織布を破断(切断)する場合のように、引張による破断によって形成される不織布の先端部(以下、「破断端部」ともいう。)の自着性に着目しており、本発明に係る不織布は、この破断端部に1つの特徴を有している。この破断端部の特徴について図1及び図2を参照しながら説明する。
50%伸長後回復率(%)=100-X
で定義される。
本発明に係る不織布は、後で詳述するように、コイル状に捲縮した捲縮繊維を含んで構成されることが好ましい。また本発明に係る不織布は、これを構成する各繊維が実質的に融着することなく、主として、捲縮繊維が互いにそれらの捲縮コイル部で絡み合って拘束又は掛止された構造を有していることが好ましい。また本発明に係る不織布において、これを構成する殆ど(大部分)の捲縮繊維(捲縮繊維の軸芯方向)は、不織布面(シート面)に対して略平行に配向していることが好ましい。本願明細書において「面方向に対して略平行に配向している」とは、例えばニードルパンチによる交絡のように、局部的に多数の捲縮繊維(捲縮繊維の軸芯方向)が厚み方向に沿って配向している部分が繰り返し存在しない状態を意味する。
本発明に係る不織布は、上記複合繊維(潜在捲縮繊維)を含む繊維をウェブ化する工程(ウェブ化工程)と、繊維ウェブを加熱して複合繊維を捲縮させる工程(加熱工程)とを含む方法によって好適に製造することができる。
JIS L 1015「化学繊維ステープル試験方法」(8.12.1)に準じて、機械捲縮数(個/25mm)を測定した。
不織布から捲縮繊維(複合繊維)を、コイル捲縮を引き伸ばさないよう注意しながら抜き取り、機械捲縮数の測定と同様に、JIS L 1015「化学繊維ステープル試験方法」(8.12.1)に準じて、平均コイル捲縮数(個/mm)を測定した。なお、本測定はコイル状の捲縮が発現している繊維のみについて行った。
平均コイル捲縮数の測定時に、連続して隣り合うコイル間の距離を測定し、n数=100の平均値として、平均捲縮ピッチ(μm)を測定した。
走査型電子顕微鏡(SEM)を用いて、不織布の任意の断面を100倍に拡大した写真を撮影した。撮影した不織布断面写真に写っている繊維の中で、1周以上の螺旋(コイル)を形成している繊維について、その螺旋に沿って円を描いたときの円の半径(コイル軸方向から捲縮繊維を観察したときの円の半径)を求め、これを曲率半径(μm)とした。なお、繊維が楕円状に螺旋を描いている場合は、楕円の長径と短径との和の1/2を曲率半径とした。ただし、捲縮繊維が充分なコイル捲縮を発現していない場合や、繊維の螺旋形状が斜めから観察されることにより楕円として写っている場合を排除するために、楕円の長径と短径との比が0.8~1.2の範囲に入る楕円だけを測定対象とした。平均曲率半径(μm)は、n数=100の平均値として求めた。
不織布の任意の断面における電子顕微鏡写真(倍率×100倍)を撮影し、撮影された繊維の映し出された部分において、厚み方向において、表層、内層、裏層の3つの領域に三等分し、各層の中心付近において、長さ方向2mm以上で、かつ測定可能な捲縮繊維が500本以上含まれるように測定領域を設定した。これらの領域について、その捲縮繊維の一方の端部ともう一方の端部との端部間距離(最短距離)を測定し、さらにその捲縮繊維の繊維長(写真上の繊維長)を測定した。すなわち、捲縮繊維の端部が不織布表面に露出している場合は、その端部をそのまま端部間距離を測定するための端部とし、端部が不織布内部に埋没している場合は、不織布内部に埋没する境界部分(写真上の端部)を端部間距離を測定するための端部とした。このとき、撮影された捲縮繊維のうち、100μm以上にわたって連続していることが確認できない繊維像に関しては測定の対象外とした。そして、端部間距離(L1)に対するその複合繊維の繊維長(L2)の比(L2/L1)として繊維湾曲率を算出した。厚み方向に三等分した表層、内層、裏層ごとに繊維湾曲率の平均値を算出し、さらに、それらのうちの最大値に対する最小値の割合(最小値/最大値)から繊維湾曲率の厚み方向における均一性を算出した。
JIS L 1913「一般不織布試験方法」に準じて、不織布全体としての目付、すなわち不織布の平均目付(g/m2)を測定した。
JIS L 1913「一般不織布試験方法」に準じて不織布の厚み(mm)を測定し、この値と〔6〕の方法で測定した目付とから不織布の密度(g/cm2)を算出した。
JIS L 1913「一般不織布試験方法」に準じて測定した。破断強度(N/50mm)、破断伸度(%)及び50%伸長時応力(N/50mm)は、不織布の流れ(MD)方向及び幅(CD)方向について測定した。
JIS L 1913「一般不織布試験方法」に準拠する引張試験を実施し、下記式:
50%伸長後回復率(%)=100-X
に基づいて50%伸長後回復率を求めた。式中、Xは、引張試験において、伸び率が50%に到達した後すぐに荷重を除去したときの、試験後の残留歪み(%)である。50%伸長後回復率は、MD方向及びCD方向について測定した。
不織布を5枚重ね、厚み方向に20%圧縮したときの応力を測定し、これを圧縮応力(kPa)とした。測定には精密万能試験機((株)島津製作所製の「オートグラフAG-IS」)を用いた。圧縮には直径29mmの円柱状の圧縮子を用い、ヘッドスピード10mm/分で圧縮した。
上記〔8〕の破断強度の測定によって得られた破断サンプルについて、前述の測定方法に従って破断端部長さD(mm)を求めた(図1参照)。破断方向はMD方向であり、得られた長さ方向及び幅方向を有する不織布の長さ方向である。
得られた長さ方向及び幅方向を有する不織布について、長さ方向の長さが5cmであり、幅方向の長さが不織布の全幅である方形領域を選択し、この方形領域について、前述の記載に従って第i番目の分割領域の目付Wiと、第(i+1)番目の分割領域の目付Wi+1との比Wi/Wi+1を測定した(図2参照)。目付比Wi/Wi+1は、方形領域に含まれる各分割領域(長さ方向の長さ:5cm、幅方向の長さ:1cm)をハサミで切り取ってその重量を測定し、それらの比を算出することにより求めた。
まず不織布を、MD方向が長さ方向となるように50mm幅×600mm長の大きさにカットし、サンプル1とした。次に、図3(a)に示すように、サンプル1の一方の端部を片面粘着テープ2で巻芯3(外径30mm×長さ150mmのポリプロピレン樹脂製パイプロール)に固定した後、このサンプル1のもう一方の端部にワニ口クリップ4(掴み幅50mm、使用にあたり口部内側に0.5mm厚のゴムシートを両面テープで固定した)を使用して、サンプル1の全幅に対し均一に加重が掛かるように150gの錘5を取り付けた。
潜在捲縮性繊維として、固有粘度0.65のポリエチレンテレフタレート樹脂〔成分(A)〕と、イソフタル酸20モル%及びジエチレングリコール5モル%を共重合した変性ポリエチレンテレフタレート樹脂〔成分(B)〕とで構成されたサイドバイサイド型複合ステープル繊維〔(株)クラレ製、「ソフィットPN780」、1.7dtex×51mm長、機械捲縮数12個/25mm、130℃×1分熱処理後における捲縮数62個/25mm〕を準備した。このサイドバイサイド型複合ステープル繊維を100質量%用いて、カード法により目付約30g/m2のカードウェブとした。
ポリエチレンテレフタレート繊維〔東レ株式会社製「テトロン」、1.6dtex×51mm長、機械捲縮数15個/25mm〕を100質量%用いて、カード法により目付約10g/m2のカードウェブとした。このカードウェブを6層クロスレイドさせて重ね合わせ、ニードルパンチ法によって繊維を交絡させて、不織布を得た。加工速度は2.5m/分であり、針密度(パンチ数)は両面側から合計で1000回/cm2とした。
実施例1で用いたカードウェブを水蒸気噴射装置へ導入し、水蒸気の噴射圧力を0.8MPa、加工速度を5.0m/分、ノズルとサクション側のコンベアベルトとの距離を5.5mmとしたこと以外は、実施例1と同じ方法で不織布を得た。得られた不織布の表面及び厚み方向断面を電子顕微鏡(100倍)で観察したところ、各繊維は不織布の面方向に対して略平行に配向しており、厚み方向において略均一に捲縮していた。
実施例2で用いたカードウェブを76メッシュ、幅500mmの樹脂製エンドレスベルトを装備したベルトコンベアに移送しながら、直径0.1mmのオリフィスがウェブの幅方向に0.6mm間隔で1列に設けられたノズルを表裏2段ずつ用いて、ノズルから水を噴射し、加工速度30m/分で繊維を交絡させ不織布を得た。噴射水圧は、前段のノズル列では、表と裏の両面ともに3MPaとし、後段のノズル列では、表と裏の両面ともに5MPaとした。
針密度(パンチ数)は両面側から合計で250回/cm2としたこと以外は、実施例2と同様にして不織布を得た。
実施例2で用いたカードウェブを、熱風循環処理機によって130℃で熱風処理を施して、潜在捲縮繊維のコイル状捲縮を発現させるとともに、繊維を交絡させ不織布を得た。
Claims (16)
- 1つの方向に引張って破断させるJIS L 1913に準拠する引張試験によって形成される破断端部において、前記1つの方向に関して最も内側に位置する点をPin、最も外側に位置する点をPoutとするとき、点Pinから点Poutまでの前記1つの方向に沿った距離Dが50mm以下である、不織布。
- 長さ方向及び幅方向を有し、
前記1つの方向は、前記長さ方向と平行である、請求項1に記載の不織布。 - 長さ方向の長さが5cmであり、幅方向の長さが前記不織布の全幅である方形領域を含み、
前記方形領域に含まれる、長さ方向の長さが5cmであり、幅方向の長さが1cmである2以上の分割領域において、前記不織布の幅方向の一端から第i番目の分割領域(ただし、iは1以上の整数であり、第1番目の分割領域は前記幅方向の一端を含む。)の目付Wiと、第(i+1)番目の分割領域の目付Wi+1との比Wi/Wi+1が0.9~1.1である、請求項2に記載の不織布。 - 前記方形領域を2以上含む、請求項3に記載の不織布。
- 前記方形領域は、前記分割領域を3以上含み、
前記第i番目の分割領域の目付Wiと、それ以外の分割領域の目付との比がそれぞれ0.9~1.1である、請求項3又は4に記載の不織布。 - 密度が0.05~0.2g/cm3である、請求項1~5のいずれか1項に記載の不織布。
- 圧縮応力が0.2~10kPaである、請求項1~6のいずれか1項に記載の不織布。
- 捲縮繊維を含む、請求項1~7のいずれか1項に記載の不織布。
- 前記捲縮繊維は、熱収縮率の異なる複数の樹脂が相構造を形成した複合繊維で構成されており、面方向に対して略平行に配向しているとともに、平均曲率半径20~200μmで厚み方向において略均一に捲縮している、請求項8に記載の不織布。
- 前記不織布を構成する全繊維における前記複合繊維の含有率が80質量%以上である、請求項9に記載の不織布。
- 粘着剤を実質的に含有せず、かつ、前記不織布を構成する各繊維が実質的に融着していない、請求項1~10のいずれか1項に記載の不織布。
- 少なくとも1つの面方向において、破断強度が5~30N/50mmであり、破断伸度が50%以上であり、50%伸長後の回復率が80%以上である、請求項1~11のいずれか1項に記載の不織布。
- 前記破断端部における曲面滑り応力が5N/50mm以上である、請求項1~12のいずれか1項に記載の不織布。
- 長さ方向の破断強度と幅方向の破断強度との比が1.5~50である、請求項2~5のいずれか1項に記載の不織布。
- 厚み方向の断面において、厚み方向に三等分した各々の領域における繊維湾曲率がいずれも1.3以上であり、かつ、該3つの領域についての繊維湾曲率の最小値と最大値との比が75%以上である、請求項1~14のいずれか1項に記載の不織布。
- 包帯である、請求項1~15のいずれか1項に記載の不織布。
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