WO2017065204A1 - Absorbent article - Google Patents

Abstract

An absorbent article (10) is provided with a surface sheet (2), a reverse-surface sheet (3), and an absorbent body (4) interposed between these two sheets (2, 3). The surface sheet (2) has a plurality of skin-side convex portions (21) protruding toward the skin-facing side, and skin-side concave portions positioned between the skin-side convex portions (21). The surface sheet (2) comprises a nonwoven fabric (1) having concave-convex structures alternately and continuously disposed along two different directions where the skin-side convex portions (21) and the skin-side concave portions intersect each other. The nonwoven fabric (1) includes constituent fibers (11) having large-diameter portions (17) and small-diameter portions (16) that have different fiber diameters from each other.

Description

Absorbent articles

The present invention relates to absorbent articles such as light incontinence pads and sanitary napkins.

In order to reduce the contact area with the skin, reduce stuffiness, and improve the feeling of use, a surface sheet with a concavo-convex structure is used for absorbent articles. As an absorbent article provided with a concavo-convex surface sheet, for example, absorbent articles described in Patent Document 1 and Patent Document 2 are known.

Patent Document 1 describes an absorbent article including a top sheet in which a wave shape including a top region, a bottom region, and a wall region between the top region and the bottom region is continuously formed in the longitudinal direction. ing.

The absorbent article described in Patent Document 2 was previously proposed by the present applicant, and in Patent Document 2, the surface sheet has a plurality of convex portions and concave portions formed integrally in the thickness direction. The convex portions and the concave portions are alternately arranged adjacent to each other in different directions intersecting in plan view to form a concavo-convex shape, and a space portion is formed between the convex portion of the topsheet and the leak-proof layer. Absorbent articles are described.

JP 2008-1113866 A JP 2014-79291 A

The present invention comprises a liquid-permeable surface sheet that forms a skin-facing surface, a back sheet that forms a non-skin-facing surface, and an absorbent main body comprising an absorbent body interposed between these two sheets. The present invention relates to an absorbent article having a longitudinal direction corresponding to the front-rear direction and a transverse direction orthogonal to the longitudinal direction. The top sheet has a plurality of skin-side convex portions protruding to the skin facing surface side, and a skin-side concave portion positioned between the plurality of skin-side convex portions, and the plurality of skin-side convex portions and the skin The side recesses are formed of a nonwoven fabric having a concavo-convex structure arranged alternately and continuously along two different directions intersecting each other. The nonwoven fabric includes constituent fibers having a large diameter portion and a small diameter portion having different fiber diameters.

FIG. 1 is a plan view showing a skin facing surface side (surface sheet side) of an incontinence pad that is a preferred embodiment of the absorbent article of the present invention. FIG. 2 is an end view schematically showing a section taken along line II-II in FIG. FIG. 3 is an enlarged perspective view of a main part of the topsheet provided in the incontinence pad shown in FIG. 4 is an enlarged schematic cross-sectional view of a main part of the topsheet shown in FIG. FIG. 5 is a view for explaining a state in which the constituent fibers of the nonwoven fabric forming the top sheet shown in FIG. 3 are fixed at the heat fusion part. FIG. 6 is a schematic diagram showing a manufacturing apparatus suitably used for manufacturing the nonwoven fabric forming the top sheet shown in FIG. FIG. 7 is a schematic diagram illustrating an extending portion included in the manufacturing apparatus illustrated in FIG. 6. FIG. 8 is a schematic diagram illustrating a state in which the fiber sheet is stretched at the stretching portion illustrated in FIG. 7. FIG. 9A to FIG. 9C are explanatory views for explaining a state in which a plurality of small diameter portions and large diameter portions are formed in one constituent fiber between adjacent fused portions. FIG. 10 is a schematic diagram illustrating an embodiment of the first half of the extending portion included in the manufacturing apparatus illustrated in FIG. 6. FIG. 11 is a schematic diagram illustrating an embodiment of the latter half of the extending portion included in the manufacturing apparatus illustrated in FIG. 6.

Detailed Description of the Invention

Since the absorbent article described in Patent Document 1 includes a top sheet in which the wave shape is continuously formed in the longitudinal direction, the diffusion area of the body fluid in the width direction can be suppressed. However, in the absorbent article described in Patent Document 1, since the top sheet wave shape is continuously formed in the longitudinal direction, the top sheet can flexibly follow the movement in the width direction. It is difficult to follow movement flexibly.

On the other hand, in the absorbent article described in Patent Document 2, since the convex portions and the concave portions forming the concave-convex shape of the topsheet are alternately arranged in different directions intersecting in plan view, the absorbent article described in Patent Document 1 Compared with articles, the contact area with the skin can be further reduced, stuffiness can be further reduced, and the feeling of use can be further improved. Moreover, since the convex part and the recessed part are alternately arrange | positioned in the different direction which planar view cross | intersects the absorbent article of patent document 2, compared with the absorbent article of patent document 1, a convex part has it. It is possible to flexibly follow the movement in the width direction and to flexibly follow the movement in the longitudinal direction. However, there has been a need to make the convex portion of the topsheet follow the movement in the width direction more flexibly and more flexibly follow the movement in the longitudinal direction.

Therefore, an object of the present invention is to provide an absorbent article that can eliminate the above-mentioned drawbacks of the prior art.

Hereinafter, the absorbent article of the present invention will be described with reference to the drawings based on an incontinence pad 10 which is a preferred embodiment thereof. FIG. 1 shows a plan view of the incontinence pad 10 of the present embodiment as viewed from the surface sheet side, and FIG. 2 shows a cross-sectional view of the incontinence pad 10 of the present embodiment. As shown in FIGS. 1 and 2, the incontinence pad 10 of the present embodiment includes a liquid-permeable surface sheet 2 that forms a skin facing surface, a back sheet 3 that forms a non-skin facing surface, and both of these sheets 2. An absorber 4 interposed between the three is provided.

In the present specification, the skin facing surface is a surface of the incontinence pad 10 that is directed to the wearer's skin when the incontinence pad 10 is worn, and the non-skin facing surface is the surface of the incontinence pad 10 in the incontinence pad 10. It is a surface directed to the opposite side (clothing side) from the skin side when worn. Further, the vertical direction X coincides with the longitudinal direction of the incontinence pad 10, and the lateral direction Y coincides with the width direction (direction orthogonal to the longitudinal direction) of the incontinence pad 10.

In the incontinence pad 10, as shown in FIGS. 1 and 2, the topsheet 2 covers the entire area of the skin facing surface of the absorbent body 4, and from the side edges along the longitudinal direction X of the absorbent body 4 to the outside in the lateral direction Y. It extends to the direction. On the other hand, the back sheet 3 covers the entire area of the non-skin facing surface of the absorbent body 4 and further extends outward in the lateral direction Y from both side edges along the longitudinal direction X of the absorbent body 4 to be described later. 5 forms a side flap portion 10S. The non-skin contact surface on the back sheet 3 side of the incontinence pad 10 is provided with an adhesive portion (not shown) for fixing to underwear such as shorts. The back sheet 3 and the leak-proof cuff 5 are joined to each other by known joining means such as an adhesive, heat seal, ultrasonic seal, and the like at the extended portions from both side edges along the longitudinal direction X of the absorber 4. . In addition, between each of the top sheet 2 and the back sheet 3 and the absorbent body 4 may be joined by an adhesive.

As the forming material of the back sheet 3, various materials conventionally used for the back sheet of the absorbent article can be used without particular limitation. For example, a liquid-impermeable or water-repellent resin film, a resin film, A laminate sheet with a non-woven fabric can be used.

In the incontinence pad 10, the absorbent body 4 includes an absorbent core 40 and a core wrap sheet 41 that wraps the absorbent core 40 as shown in FIG. 2. The absorber 4 has a substantially rectangular shape with rounded corners in plan view.

The absorptive core 40 can be comprised from the laminated fiber body of liquid absorbing fibers, such as a pulp, for example, and the mixed fiber body of this liquid absorbing fiber and a water absorbing polymer. Examples of the liquid-absorbing fibers constituting the absorbent core 40 include cellulose-based hydrophilic fibers such as pulp fibers, rayon fibers, cotton fibers, and cellulose acetate. In addition to cellulose-based hydrophilic fibers, polyolefin fibers such as polyethylene and polypropylene, and condensation fibers such as polyester and polyamide may be included. Examples of water-absorbing polymers include sodium polyacrylate, (acrylic acid-vinyl alcohol) copolymer, cross-linked sodium polyacrylate, (starch-acrylic acid) graft copolymer, and (isobutylene-maleic anhydride) copolymer. Examples thereof include a polymer and a saponified product thereof, and polyaspartic acid. Each of the fibers and the water-absorbing polymer can be used alone or in combination of two or more.
As the core wrap sheet 41, a water-permeable fiber sheet such as tissue paper or nonwoven fabric is preferably used. Further, as shown in FIG. 2, the core wrap sheet 41 may wrap the entire absorbent core 40 with one sheet, or wrap the entire absorbent core 40 with two or more core wrap sheets. For example, the skin contact surface side and the non-skin contact surface side of the absorbent core 40 may be covered with separate sheets.

In the incontinence pad 10, the leak-proof cuff 5 is disposed on both sides along the vertical direction X on the skin facing surface of the topsheet 2 as shown in FIGS. 1 and 2. And the leak-proof cuff 5 is distribute | arranged over the full length of the vertical direction X of the surface sheet 2 so that it may overlap with the left-right both sides along the vertical direction X of the absorber 4 in planar view. The leak-proof cuff 5 has a free end and a fixed area that respectively extend in the longitudinal direction X. The fixing area is located on the surface sheet 2, and the leak-proof cuff 5 is fixed to the surface sheet 2 in the fixing area. Further, the fixing region of the leak-proof cuff 5 extends outward in the lateral direction Y, and the extending portion and the extending portion in the lateral direction Y of the back sheet 3 are joined to form the side flap portion 10S. ing. The leak-proof cuff 5 is attached with an elastic member extending along the longitudinal direction X in a stretched state at a position near the free end thereof. As the elastic member contracts, the position between the free end and the fixed end of the leak-proof cuff 5 rises in a substantially L shape toward the wearer's body. The leak-proof cuff 5 stands up during wearing and prevents the liquid from leaking sideways.

As the leak-proof cuff 5, various types conventionally used in the technical field can be used without particular limitation, for example, a liquid-impermeable or water-repellent resin film, a laminate of a resin film and a nonwoven fabric, or the like Can be used.

In the incontinence pad 10, the top sheet 2 and the back sheet 3 extend outward in the longitudinal direction X from the front end and the rear end in the longitudinal direction X of the absorbent body 4 as shown in FIG. Are joined to each other by a known joining means such as an adhesive, heat sealing, ultrasonic sealing or the like to form an end seal portion.
In the incontinence pad 10, as shown in FIGS. 1 and 2, the top sheet 2 and the absorbent body 4 are integrally recessed toward the back sheet 3 side on the skin facing surface (skin facing surface of the top sheet 2). A pair of linear pressing grooves 7 are formed. Each linear compressed groove 7 extends in the vertical direction X, and is formed so as to draw an arc toward the bisector extending in the vertical direction X of the incontinence pad 10. “Linear” in the linear compressed groove 7 means that the shape of the groove (concave portion) is not limited to a straight line in a plan view but includes a curved line. Each line may be a continuous line or a broken line. For example, the linear squeezing groove 7 may be composed of a row formed by a number of discontinuous point embosses. The linear squeezing grooves 7 formed in this way can suppress diffusion of body fluid in the planar direction of the absorbent body 4 and effectively prevent liquid leakage from the periphery of the incontinence pad 10.

The surface sheet 2 of the incontinence pad 10 will be described in detail. As shown in FIGS. 3 and 4, the surface sheet 2 protrudes toward the skin-facing surface and has a plurality of skin-side convex portions 21 having an internal space S1, and a plurality of skins. It has a skin-side recess located between the side projections 21. In the incontinence pad 10, when the surface sheet 2 is viewed in plan, the skin-side convex portions 21 and the skin-side concave portions are alternately and continuously arranged along two different directions intersecting each other. Here, the two different directions are preferably such that an arbitrary first direction in the plane and a second direction intersecting with the first direction intersect at an angle of 30 degrees or more and 90 degrees or less. Intersect at a degree. That is, for example, in the incontinence pad 10, one of the two directions is the horizontal direction Y, and the other of the two directions is the vertical direction X. Therefore, when the surface sheet 2 is viewed in plan, the skin-side convex portions 21 and the non-skin-side convex portions 22 are alternately and continuously arranged along the vertical direction X and the horizontal direction Y. More specifically, in the incontinence pad 10, as shown in FIG. 3 and FIG. 4, the top sheet 2 protrudes toward the non-skin facing surface and has a plurality of non-skin-side convex portions 22 having an internal space S 2, It has a skin-side recess located between the skin-side projections 22. In the form shown in FIG. 4, the convex portion viewed from the skin facing surface side is the skin side convex portion 21, and the skin side concave portion is the non-skin side convex portion 22. On the contrary, the convex part seen from the non-skin facing surface side is the non-skin side convex part 22, and the non-skin side concave part is the skin side convex part 21. Therefore, the skin-side convex portion 21 and the non-skin-side convex portion 22 are partially shared. The shared portion means a ring-shaped wall portion 21W to be described later and a ring-shaped wall portion 22W to be described later.

In the incontinence pad 10, with respect to the topsheet 2, as shown in FIGS. 3 and 4, the skin-side convex portion 21 has a wall portion 21W having an annular structure between the top portion 21T and the opening portion 21H of the internal space S1. Have. Moreover, the non-skin-side convex part 22 has the wall part 22W of the cyclic | annular structure between the top part 22T and the opening part 22H of the internal space S2. In the incontinence pad 10, the skin-side convex portion 21 and the non-skin-side convex portion 22 have a truncated cone shape or a hemispherical shape in which the top portion 21 </ b> T and the top portion 22 </ b> T are rounded. In addition, the protrusion shape of the skin side convex part 21 and the non-skin side convex part 22 is not limited to the said shape, What kind of protrusion shape may be sufficient. For example, it may have a cone shape such as a cone, a truncated cone, a pyramid, a truncated pyramid, or an oblique cone. In the incontinence pad 10, the skin-side convex portion 21 and the non-skin-side convex portion 22 hold a truncated cone-shaped or hemispherical internal space S1 and an internal space S2 that are round at the top similar to the outer diameter thereof.

In the incontinence pad 10, the wall portion 21 </ b> W of the skin-side convex portion 21 has an annular structure around the top portion 21 </ b> T of the skin-side convex portion 21 when the topsheet 2 is viewed in plan from the skin facing surface side. Further, when the top sheet 2 is viewed from the non-skin facing surface side, the wall portion 22W of the non-skin-side convex portion 22 has an annular structure with the top portion 22T of the non-skin-side convex portion 22 as the center. And the wall part 21W of the skin side convex part 21 shares the same site | part as the wall part 22W of the non-skin side convex part 22, as shown in FIG. Here, the “annular” is not particularly limited as long as it has an endless series of shapes in the plan view of the topsheet 2, and any shape such as a circle, an ellipse, a rectangle, or a polygon in the plan view of the topsheet 2 is used. Such a shape may be used. From the viewpoint of suitably maintaining the continuous state of the topsheet 2, a circular or elliptical annular structure is preferable. Furthermore, speaking of “annular” as a three-dimensional shape, a cylindrical shape, an oblique cylindrical shape, an elliptical columnar shape, a truncated cone shape, a truncated oblique cone shape, a truncated elliptical cone shape, a truncated rectangular pyramid shape, and a truncated oblique pyramid shape From the viewpoint of realizing a continuous sheet state, a cylindrical shape, an elliptic cylinder shape, a truncated cone shape, and a truncated elliptical cone shape are preferable.

In the incontinence pad 10, the topsheet 2 is composed of a nonwoven fabric 1 having a concavo-convex structure in which a plurality of skin-side convex portions 21 and non-skin-side convex portions 22 are arranged in the vertical direction X and the horizontal direction Y, as shown in FIG. Has been. Moreover, in the incontinence pad 10, as shown in FIG. 2, the surface sheet 2 is joined to the adjacent lower sheet 8 in the non-skin-side convex portion 22 which is a skin-side concave portion, An internal space S <b> 1 is formed between the lower sheet 8. In the incontinence pad 10, the lower sheet 8 is a second sheet made of a nonwoven fabric and disposed between the top sheet 2 and the absorbent body 4. Moreover, the nonwoven fabric 1 which comprises the surface sheet 2 contains the structure fiber 11 which has the large diameter part 17 and the small diameter parts 16 and 16 from which a fiber diameter mutually differs, as shown in FIG.

The second sheet is a sheet called a sublayer sheet in the technical field that is separate from the top sheet 2 and the absorber 4. The second sheet is a sheet that plays a role of improving the liquid permeability from the top sheet 2 to the absorber 4 or reducing the liquid return to the top sheet 2 absorbed by the absorber 4. The second sheet only needs to be disposed on the skin facing surface of the absorbent body 4, but the incontinence pad 10 covers the entire area of the skin facing surface of the absorbent body 4.

As the second sheet, various types conventionally used in the technical field can be used without particular limitation, and for example, a hydrophilic non-woven fabric or a hydrophilic fiber aggregate can be used. The second sheet has a basis weight of preferably 10 g / m ² or more and 50 g / m ² or less, more preferably 15 g / m ² or more and 25 g / m ² or less. The second sheet has a thickness of preferably 0.1 mm or more and 5 mm or less.

The joining of the top sheet 2 and the second sheet as the lower sheet 8 may be joined by thermal fusion, may be joined by an adhesive such as a hot-melt adhesive, or other joining means. It may be joined. When bonded by an adhesive, the adhesive can be applied using a known means such as a slot coat gun, a spiral spray gun, a spray gun, or a dot gun. As the adhesive to be applied, for example, a hot melt adhesive is preferably used. The application amount of the hot melt adhesive is preferably 3 g / m ² or more and 10 g / m ² or less.

The non-woven fabric 1 constituting the top sheet 2 will be described in more detail.
FIG. 3 shows a perspective view of the nonwoven fabric 1 (hereinafter also referred to as “nonwoven fabric 1”) used as the top sheet 2 in the incontinence pad 10 of the present embodiment. FIG. 4 is a schematic diagram showing a cross section in the thickness direction of the nonwoven fabric 1 shown in FIG. 3. FIG. 5 is an enlarged schematic view of the constituent fibers 11 of the nonwoven fabric 1 shown in FIG. In the incontinence pad 10, the nonwoven fabric 1 includes a plurality of fusion portions 12 formed by heat-sealing the intersections of the constituent fibers 11 as shown in FIG. 5. Moreover, in the nonwoven fabric 1 which comprises the surface sheet 2, "one direction" by which the skin side convex part 21 and the non-skin side convex part 22 were alternately arranged is the same direction as the vertical direction X of the incontinence pad 10, In the nonwoven fabric 1, “one direction” in which the skin-side convex portions 21 and the non-skin-side convex portions 22 are alternately arranged is also referred to as an X direction.

More specifically, as shown in FIG. 4, the nonwoven fabric 1 includes a plurality of skin-side convex portions 21 in which the cross-sectional shapes of the front and back surfaces a and b both protrude upward in the thickness direction (Z direction), and the front and back surfaces. Both cross-sectional shapes of both surfaces a and b have a non-skin-side convex portion 22 projecting downward in the thickness direction (Z direction) of the nonwoven fabric. The skin side convex portions 21 and the non-skin side convex portions 22 are alternately and continuously arranged along the X direction and the Y direction, respectively.

In the incontinence pad 10, the nonwoven fabric 1 is manufactured by applying uneven processing to the fiber sheet 1 a using a steel matching embossing roller including a pair of uneven rolls 401 and 402 meshing with each other. One direction (X direction) of the nonwoven fabric 1 described above is the same direction as the machine direction (MD, flow direction) when the nonwoven fabric 1 is manufactured by performing uneven processing on the fiber sheet 1a. The direction (Y direction) orthogonal to the direction (X direction) is the same direction as the orthogonal direction (CD, roll axis direction) orthogonal to the machine direction (MD, flow direction).

In the incontinence pad 10, the high-stretch fiber is included in the constituent fibers 11 of the nonwoven fabric 1. Here, the high elongation fiber included in the constituent fiber 11 means not only a fiber having a high elongation at the raw material fiber stage, but also a fiber having a high elongation at the stage of the produced nonwoven fabric 1. As the “high elongation fiber”, excluding stretchable fibers that have elasticity (elastomer) and expand and contract, for example, as described in paragraph [0033] of JP 2010-168715, melt spinning is performed at a low speed to form a composite After obtaining the fiber, the heat-extensible fiber, which is obtained by changing the crystal state of the resin by heating and / or crimping without stretching, or polypropylene or polyethylene Fibers manufactured using relatively low spinning speeds using a resin such as polyethylene, polypropylene-polypropylene copolymers with low crystallinity, or fibers manufactured by dry blending polyethylene into polypropylene and spinning, etc. Is mentioned. Among these fibers, the high elongation fiber is preferably a core-sheath type composite fiber having heat-fusibility. The core-sheath type composite fiber may be a concentric core-sheath type, an eccentric core-sheath type, a side-by-side type, or a deformed type, but is preferably a concentric core-sheath type. Whatever form the fiber takes, from the viewpoint of producing a nonwoven fabric that is soft and soft to the touch, the fineness of the high elongation fiber is 1.0 dtex or more and 10.0 dtex or less at the raw material stage. Is preferable, and more preferably 2.0 dtex or more and 8.0 dtex or less.

The constituent fibers 11 of the nonwoven fabric 1 may be configured to include other fibers in addition to the high elongation fibers, but are preferably configured only from the high elongation fibers. Other fibers include, for example, a non-heat-extensible core-sheath-type heat-fusible composite fiber containing two components having different melting points, or a fiber that does not inherently have heat-fusibility ( Examples thereof include natural fibers such as cotton and pulp, rayon and acetate fibers). When the nonwoven fabric 1 is configured to include other fibers in addition to the high elongation fibers, the proportion of the high elongation fibers in the nonwoven fabric 1 is preferably 50% by mass to 100% by mass, and more preferably It is 80 mass% or more and 100 mass% or less.

The heat-extensible fiber, which is a high-stretch fiber, is a composite fiber that has been subjected to unstretched or weakly stretched treatment at the raw material stage. For example, the first resin component that forms the core and the sheath And a second resin component containing a polyethylene resin, and the first resin component has a higher melting point than the second resin component. A 1st resin component is a component which expresses the heat | fever extensibility of this fiber, and a 2nd resin component is a component which expresses heat-fusibility. The melting points of the first resin component and the second resin component were determined by thermal analysis of a finely cut fiber sample (sample weight 2 mg) using a differential scanning calorimeter (DSC6200 manufactured by Seiko Instruments Inc.) at a heating rate of 10 ° C./min. The melting peak temperature of each resin is measured and defined by the melting peak temperature. When the melting point of the second resin component cannot be clearly measured by this method, the resin is defined as “resin having no melting point”. In this case, the temperature at which the second resin component is fused to such an extent that the strength of the fusion point of the fiber can be measured is used as the temperature at which the molecular flow of the second resin component begins, and this is used instead of the melting point.

As above-mentioned, as a 2nd resin component which comprises a sheath part, the polyethylene resin is included. Examples of the polyethylene resin include low density polyethylene (LDPE), high density polyethylene (HDPE), and linear low density polyethylene (LLDPE). In particular, a high density polyethylene having a density of 0.935 g / cm ³ or more and 0.965 g / cm ³ or less is preferable. The second resin component constituting the sheath is preferably a polyethylene resin alone, but other resins can also be blended. Other resins to be blended include polypropylene resin, ethylene-vinyl acetate copolymer (EVA), ethylene-vinyl alcohol copolymer (EVOH), and the like. However, as for the 2nd resin component which comprises a sheath part, it is preferable that 50 mass% or more in the resin component of a sheath part is 70 to 100 mass% especially polyethylene resin. The polyethylene resin preferably has a crystallite size of 10 nm or more and 20 nm or less, and more preferably 11.5 nm or more and 18 nm or less.

As the first resin component constituting the core portion, a resin component having a melting point higher than that of the polyethylene resin that is a constituent resin of the sheath portion can be used without any particular limitation. Examples of the resin component constituting the core include polyolefin resins such as polypropylene (PP) (excluding polyethylene resin), polyester resins such as polyethylene terephthalate (PET), and polybutylene terephthalate (PBT). Furthermore, polyamide-based polymers, copolymers having two or more resin components, and the like can also be used. A plurality of types of resins can be blended and used. In this case, the melting point of the core is the melting point of the resin having the highest melting point. Since the nonwoven fabric can be easily manufactured, the difference between the melting point of the first resin component constituting the core part and the melting point of the second resin component constituting the sheath part (the former-the latter) is 20 ° C. or higher. It is preferable that it is 150 degrees C or less.

The preferred orientation index of the first resin component in the heat-extensible fiber, which is a high elongation fiber, is naturally different depending on the resin used. For example, when the first resin component is a polypropylene resin, the orientation index may be 60% or less. Preferably, it is 40% or less, more preferably 25% or less. When the first resin component is polyester, the orientation index is preferably 25% or less, more preferably 20% or less, and still more preferably 10% or less. On the other hand, the second resin component preferably has an orientation index of 5% or more, more preferably 15% or more, and still more preferably 30% or more. The orientation index is an index of the degree of orientation of the polymer chain of the resin constituting the fiber.

The orientation index of the first resin component and the second resin component is determined by the method described in paragraphs [0027] to [0029] of JP 2010-168715 A. A method for achieving the orientation index as described above for each resin component in the thermally extensible composite fiber is described in paragraphs [0033] to [0036] of JP-A No. 2010-168715.

Further, the elongation of the high elongation fiber is preferably 100% or more and 800% or less, more preferably 200% or more and 500% or less, and further preferably 250% or more and 400% or less at the raw material stage. By using the high elongation fiber having the elongation in this range, the fiber is successfully stretched in the stretching apparatus, and the changing point from the small diameter portion to the large diameter portion described above is adjacent to the fusion portion. , The touch becomes good.

The elongation of the high elongation fiber conforms to JISL-1015, and the measurement is based on the measurement environment temperature and humidity of 20 ± 2 ° C, 65 ± 2% RH, the tensile tester gripping distance of 20mm, and the tensile speed of 20mm / min. And In addition, when collecting fibers from an already manufactured non-woven fabric and measuring the elongation, when the gripping interval cannot be 20 mm, that is, when the length of the fiber to be measured is less than 20 mm, the gripping interval is set. Measure by setting to 10 mm or 5 mm.

The ratio of the first resin component to the second resin component (mass ratio, the former: latter) in the high elongation fiber is 10:90 to 90:10, particularly 20:80 to 80:20, especially in the raw material stage. It is preferably 50:50 to 70:30. As the fiber length of the high elongation fiber, one having an appropriate length is used according to the method for producing the nonwoven fabric. For example, when the nonwoven fabric is manufactured by the card method as described later, the fiber length is preferably about 30 to 70 mm.

The fiber diameter of the high elongation fiber is appropriately selected according to the specific use of the nonwoven fabric at the raw material stage. When the nonwoven fabric is used as a constituent member of an absorbent article such as a surface sheet of the absorbent article, it is preferable to use a nonwoven fabric having a size of 10 μm to 35 μm, particularly 15 μm to 30 μm. The fiber diameter is measured by the following method.

[Measurement of fiber diameter]
The fiber diameter (μm) is measured by using a scanning electron microscope (JCM-5100 manufactured by JEOL Ltd.) and observing the cross section of the fiber at 200 to 800 times. The cross section of the fiber is obtained by cutting the fiber using a feather razor (product number FAS-10, manufactured by Feather Safety Razor Co., Ltd.). For each extracted fiber, the fiber diameter when approximated to a circle is measured at five locations, and the average value of the five measured values is taken as the fiber diameter.

In the raw material stage, the heat-extensible fibers that are high-stretch fibers include, in addition to the above-described heat-extensible fibers, Japanese Patent No. 4131852, Japanese Patent Laid-Open No. 2005-350836, Japanese Patent Laid-Open No. 2007-303035, The fibers described in JP 2007-204899 A, JP 2007-204901 A, and JP 2007-204902 A can also be used.

In the incontinence pad 10, as shown in FIG. 5, paying attention to one constituent fiber 11 among the constituent fibers 11 of the nonwoven fabric 1, the constituent fiber 11 is located between the adjacent fusion portions 12, 12. The large-diameter portion 17 having a large fiber diameter is sandwiched between two small- diameter portions 16 and 16 having a small fiber diameter. Specifically, as shown in FIG. 5, focusing on one constituent fiber 11 among the constituent fibers 11 of the nonwoven fabric 1, a fusion part formed by heat-sealing an intersection with another constituent fiber 11. 12, a small-diameter portion 16 having a small fiber diameter is formed to extend with substantially the same fiber diameter. Then, paying attention to the single constituent fiber 11, the large-diameter portion 17 having a fiber diameter larger than that of the small-diameter portion 16 between the small- diameter portions 16 and 16 extending from the adjacent fusion portions 12 and 12. Are extended with substantially the same fiber diameter. Specifically, the non-woven fabric 1 focuses on one constituent fiber 11 and moves from one fused part 12 to the other fused part 12 of the adjacent fused parts 12, 12. It has constituent fibers 11 arranged in the order of a small diameter portion 16 on the side of the attachment portion 12, one large diameter portion 17, and a small diameter portion 16 on the side of the other fusion portion 12.

As described above, the presence of the small-diameter portion 16 having a low rigidity so as to be adjacent to the fused portion 12 where the rigidity of the nonwoven fabric 1 is increased improves the flexibility of the nonwoven fabric 1 and improves the touch. Moreover, the softness | flexibility of the nonwoven fabric 1 improves further and the touch becomes still more favorable, so that the small diameter part 16 with low rigidity is provided in the component fiber 11 in multiple numbers.

As shown in FIG. 5, the nonwoven fabric 1 focuses on one constituent fiber 11 among the constituent fibers 11 of the nonwoven fabric 1, and includes a plurality of large-diameter portions 17 between the adjacent fusion portions 12, 12. (2 in the nonwoven fabric 1) It has the constituent fiber 11 provided. Specifically, the non-woven fabric 1 focuses on one constituent fiber 11 and moves from one fused part 12 to the other fused part 12 of the adjacent fused parts 12, 12. Constituent fibers arranged in the order of the small-diameter portion 16 on the bonding portion 12 side, the first large-diameter portion 17, the small-diameter portion 16, the second large-diameter portion 17, and the small-diameter portion 16 on the other fused portion 12 side. 11. The nonwoven fabric 1 pays attention to one constituent fiber 11, and preferably has one large-diameter portion 17 between adjacent fused portions 12, 12 from the viewpoint of improving the touch and reducing the strength of the nonwoven fabric. 5 or less, more preferably 1 or more and 3 or less.

The ratio (L ₁₆ / L ₁₇ ) of the fiber diameter (diameter L ₁₆ ) of the small diameter portion 16 to the fiber diameter (diameter L ₁₇ ) of the large diameter portion 17 is preferably 0.8 or less, more preferably from the viewpoint of improving the touch. Is 0.5 or more and 0.8 or less, particularly preferably 0.55 or more and 0.7 or less. Specifically, the fiber diameter (diameter L ₁₆ ) of the small-diameter portion 16 is preferably 5 μm or more and 28 μm or less, more preferably 6.5 μm or more and 20 μm or less, and particularly preferably 7.5 μm or more and 16 μm or less from the viewpoint of improving the touch. is there. The fiber diameter (diameter L ₁₇ ) of the large diameter portion 17 is preferably 10 μm or more and 35 μm or less, more preferably 13 μm or more and 25 μm or less, and particularly preferably 15 μm or more and 20 μm or less from the viewpoint of improving the touch.
The fiber diameters (diameters L ₁₆ and L ₁₇ ) of the small-diameter portion 16 and the large-diameter portion 17 are measured in the same manner as the fiber diameter measurement described above.

In the incontinence pad 10, as shown in FIG. 5, focusing on one constituent fiber 11 among the constituent fibers 11 of the nonwoven fabric 1, the small diameter portion 16 adjacent to the fused portion 12 is changed to the large diameter portion 17. The change point 18 is arranged within a range of ３ of the interval T between the fusion parts 12, 12 adjacent to the fusion part 12. Here, the transition point 18 of the nonwoven fabric gradually and gradually changes from the small diameter portion 16 extending with a small fiber diameter to the large diameter portion 17 extending with a fiber diameter larger than the small diameter portion 16. It does not include a part or a part that continuously changes over a plurality of stages, and means a part where the fiber diameter changes extremely in one step. Further, when the one constituent fiber 11 is a heat-extensible conjugate fiber, the change point 18 of the non-woven fabric is the first resin component constituting the core portion and the second resin component constituting the sheath portion. It does not include a state in which the fiber diameter is changed by peeling between them, and it means a portion where the fiber diameter is changed by stretching.

Further, the fact that the changing point 18 is arranged within a range of 1/3 of the interval T between the adjacent fused portions 12 and 12 from the fused portion 12 means that the constituent fibers 11 of the nonwoven fabric 1 are randomly extracted. As shown in FIG. 5, using JCM-5100 (trade name) manufactured by JEOL Co., Ltd. as a scanning electron microscope, the constituent fibers 11 are formed between adjacent fused portions 12 and 12 of the constituent fibers 11. Enlarge it so that it can be observed (100 to 300 times). Next, the interval T between the centers of the adjacent fused portions 12 and 12 is divided into three equal parts, and the region AT on the side of one fused portion 12, the region BT on the side of the other fused portion 12, and the center region CT Break down. This means that the change point 18 is arranged in the area AT or the area BT. Further, the non-woven fabric 1 in which the changing point 18 is disposed within a range of 1/3 of the interval T between the adjacent fused portions 12, 12 from the fused portion 12 is the number of the constituent fibers 11 of the non-woven fabric 1 20. When extracted randomly, the constituent fiber 11 in which the change point 18 is arranged in the region AT or the region BT means a nonwoven fabric in which at least one of the 20 constituent fibers 11 is present. Specifically, from the viewpoint of improving the touch, it is preferably 1 or more, more preferably 5 or more, and particularly preferably 10 or more.

The nonwoven fabric 1 is comprised from the top part area | region 13a, the bottom part area | region 13b, and the side part area | region 13c located among these, when the nonwoven fabric 1 is cross-sectional-viewed along the thickness direction Z, as shown in FIG. The top region 13a, the bottom region 13b, and the side region 13c, when the nonwoven fabric 1 is viewed in a cross-section along the thickness direction Z, divides the thickness of the nonwoven fabric 1 in the Z direction into three equal parts, The top region 13a is distinguished from the central region as the side region 13c and the lower region as the bottom region 13b. In the nonwoven fabric 1, the top of the skin-side convex portion 21 is formed from the top region 13a, and the top of the non-skin-side convex portion 22, that is, the skin-side concave portion is formed from the bottom region 13b.

In the incontinence pad 10, when the nonwoven fabric 1 is observed along the thickness direction Z, the fiber density of the side region 13c is preferably lower than the fiber density of the top region 13a or the fiber density of the bottom region 13b. In the incontinence pad 10, as shown in FIG. 4, the fiber density of the side region 13c is lower than the fiber density of the top region 13a and the fiber density of the bottom region 13b. Here, the fiber density is the number of fibers per unit area in the cross section of the nonwoven fabric 1. Therefore, the side area 13c is a sparse area in which the number of fibers is small (the distance between fibers is large) compared to the top area 13a and the bottom area 13b, and as a whole, the air permeability is improved. Liquid permeability is also improved. Furthermore, when the fiber density of the side region 13c is formed to be the smallest, the skin-side convex portion 21 can easily follow the movement of the wearer's skin, and good skin contact can be realized. In order to give such a fiber density to the side region 13c, the nonwoven fabric 1 may be manufactured according to the manufacturing method described later.

The ratio (D _13c / D _13a , D _13c / D _13a ) of the fiber density (D _13c ) of the side region 13c to the fiber density (D _13a ) in the top region 13a or the fiber density (D _13b ) in the bottom region 13b. ) Is preferably 0.15 or more and 0.9 or less, more preferably 0.2 or more and 0.8 or less. Specifically, the specific value of the fiber density of the nonwoven fabric 1 is such that the fiber density (D _13a ) in the top region 13a is preferably 90 fibers / mm ² or more and 200 fibers / mm ² or less, more preferably 100 fibers / mm ^2. mm ² or more and 180 pieces / mm ² or less. Also, the fiber density (D _13b) at the bottom area 13b is preferably 80 present / mm ² or more 200 present / mm ² or less, more preferably 90 present / mm ² or more 180 lines / mm ² or less. The fiber density of the side region 13c (D _13c) is preferably 30 lines / mm ² or more eighty / mm ² or less, more preferably 40 present / mm ² or more 70 yarns / mm ² or less. The method for measuring the fiber density is as follows.

[Measuring method of fiber density in top region 13a, bottom region 13b and side region 13c]
The nonwoven fabric is cut in the thickness direction Z along the transverse direction Y using a feather razor (product number FAS-10, manufactured by Feather Safety Razor Co., Ltd.). Regarding the fiber density in the top region 13a, the top region 13a, which is the upper part when the thickness of the cut surface of the nonwoven fabric is divided into three equal parts in the Z direction, is magnified using a scanning electron microscope (fiber cross section is 30 to 30%). adjust the magnification can measure about 60 present; 150-500 times), counting the number of cross sections of the fibers that are cut by the cutting surface per certain area ⁽² about 0.5 mm). Next, it is converted into the number of cross-sections of fibers per 1 mm ² and this is defined as the fiber density in the top region 13a. The measurement is performed at three locations, and the average is the fiber density of the sample. Similarly, the fiber density in the bottom region 13b is obtained by measuring the lower part when the thickness of the cut surface of the nonwoven fabric is divided into three equal parts in the Z direction. Similarly, the fiber density of the side region 13c is obtained by measuring the central portion when the thickness of the cut surface of the nonwoven fabric is divided into three equal parts in the Z direction. As a scanning electron microscope, JCM-5100 (trade name) manufactured by JEOL Ltd. is used.

Moreover, in the incontinence pad 10, as shown in FIG. 4, the nonwoven fabric 1 is a change point in the constituent fiber which comprises the top region 13a in the number of the fibers which have a change point in the constituent fiber which comprises the side region 13c. The number of fibers having 18 and the number of fibers having change points 18 in the constituent fibers constituting the bottom region 13b are formed. The side region 13c with respect to the number of fibers having the change point 18 in the constituent fibers constituting the top region 13a (N _13a ) or the number of fibers having the change point 18 in the component fibers constituting the bottom region 13b (N _13b ) The ratio (N _13c / N _13a , N _13c / N _13b ) of the number (N _13c ) of fibers having changing points in the constituent fibers to be formed is preferably 2 or more and 20 or less, more preferably 5 or more and 20 or less. Specifically, regarding the specific value of the number of fibers having the change point 18 of the nonwoven fabric 1, the number (N _13a ) of fibers having the change point 18 in the constituent fibers constituting the top region 13a is preferably one or more. 15 or less, more preferably 5 or more and 15 or less. The number (N _13b ) of fibers having the change point 18 in the constituent fibers constituting the bottom region 13b is preferably 1 or more and 15 or less, more preferably 5 or more and 15 or less. Further, the number (N _13c) of fibers having the change point 18 in the constituent fibers constituting the side region 13c is preferably 5 or more and 20 or less, and more preferably 10 or more and 20 or less. The method for measuring the number of fibers having the change point 18 is as follows.

[Measurement method of the number of fibers having the change point 18 in the constituent fibers constituting the top region 13a, the bottom region 13b, or the side region 13c]
With respect to the number of fibers having the change point 18 in the constituent fibers 11 constituting the top region 13a, scanning electrons are scanned near the apex of the top region 13a, which is the upper part when the thickness of the nonwoven fabric 1 is divided into three equal parts in the Z direction. Using a microscope, magnified observation (adjusted to a magnification capable of measuring about 30 to 60 fiber cross sections; 50 to 500 times), 20 constituent fibers 11 constituting the top region 13a were randomly extracted, and 20 constituent fibers were extracted. The number of fibers having the change point 18 in 11 is counted. This is the number of fibers having the change point 18 in the constituent fibers constituting the top region 13a. The measurement is performed at three places, and the average is the number of fibers having the change point 18 in the constituent fibers constituting the top region 13a of the sample. Similarly, regarding the number of fibers having the change point 18 in the constituent fibers 11 constituting the bottom region 13b, the vicinity of the bottom point of the bottom region 13b, which is a lower part when the thickness of the nonwoven fabric is equally divided into three in the Z direction, Determine by measuring. Similarly, the number of fibers having the change point 18 in the constituent fibers 11 constituting the side region 13c is obtained by measuring the central portion when the thickness of the nonwoven fabric is equally divided into three in the Z direction. As a scanning electron microscope, JCM-5100 (trade name) manufactured by JEOL Ltd. is used.

Regarding the thickness of the non-woven fabric 1, the total thickness when the non-woven fabric 1 is viewed from the side is the sheet thickness T _S, and the local thickness of the non-woven fabric 1 curved in the unevenness is the layer thickness T _L (FIG. 4). reference). Here, in the incontinence pad 10, the sheet thickness T _S is the same as the height of the skin-side convex portion 21 or the height of the non-skin-side convex portion 22. The sheet thickness T _S is preferably from 0.3 mm to 7 mm, and more preferably from 0.7 mm to 5 mm. By setting it as this range, the bodily fluid absorption speed | velocity at the time of use is quick, the liquid return from an absorber is suppressed, and also moderate cushioning property is realizable.

Layer thickness T _L may be different at each site in the non-woven fabric 1 is preferably a layer thickness T _L1 of the top region 13a is 0.1mm or more 3.0mm or less, 0.2 mm or more 2.0mm or less Is more preferable. The layer thickness T _L2 of the bottom region 13b is preferably 0.1 mm or greater and 3.0 mm or less, and more preferably 0.2 mm or greater and 2.0 mm or less. The layer thickness T _L3 of the side region 13c is preferably 0.1 mm or greater and 3.0 mm or less, and more preferably 0.2 mm or greater and 2.0 mm or less. The relationship between the layer thicknesses T _L1 , T _L2 , and T _L3 is within this range, so that the body fluid absorption speed during use is fast, the liquid return from the absorber is suppressed, and an appropriate cushioning property is realized. it can.

The sheet thickness T _S and the layer thickness T _L are measured by the following methods.
The sheet thickness T _S is measured using a thickness measuring instrument with a load of 0.05 kPa applied to the nonwoven fabric 1. A laser displacement meter manufactured by OMRON Corporation is used for the thickness measuring instrument. Thickness is measured at 10 points, and the average value is calculated as the thickness.
The layer thickness T _L is measured by enlarging the cross section of the sheet with a Keyence digital microscope VHX-900 at about 20 times, thereby measuring the thickness of each layer.

When the nonwoven fabric 1 forming the top sheet 2 is viewed in plan, the distance between the top of the skin-side convex portion 21 and the top of the non-skin-side convex portion 22 is preferably 1 mm or more and 15 mm or less. 10 mm or less is more preferable. Moreover, 2 mm or more and 30 mm or less are preferable, and, as for the space | interval L21 (refer FIG. 4) of the top parts of the skin side convex part 21 adjacent to the horizontal direction Y in the surface sheet 2, 2 mm or more and 15 mm or less are more preferable. Moreover, 2 mm or more and 30 mm or less are preferable, and, as for the space | interval of the top parts of the skin side convex part 21 adjacent to the vertical direction X in the surface sheet 2, 2 mm or more and 15 mm or less are more preferable.
In the incontinence pad 10, the height H of the internal space S <b> 1 (see FIG. 2) between the skin-side convex portion 21 and the lower sheet 8 when the topsheet 2 is viewed in cross section is determined while the incontinence pad 10 is being worn. From the viewpoint of improving the air permeability, it is preferable that the thickness is larger than the layer thickness T _L1 of the top region 13a. Specifically, the height H is preferably 0.1 mm or greater and 6 mm or less, and more preferably 0.6 mm or greater and 4 mm or less. The height H is measured under a no load by observing a cross section in the thickness direction Z of the nonwoven fabric 1 with a microscope.

The basis weight of the nonwoven fabric 1 may be appropriately selected depending on the use, and when used as a surface sheet for absorbent articles such as sanitary products, the average value of the entire sheet is preferably 15 g / m ² or more and 50 g / m ² or less. It is more preferably 20 g / m ² or more and 40 g / m ² or less.

Further, a small amount of fiber treatment agent such as fiber colorant, antistatic property agent, lubricant, hydrophilic agent may be adhered to the surface of the constituent fiber 11 of the nonwoven fabric 1 at the raw material stage.

As a method for attaching the fiber treatment agent to the surface of the constituent fibers 11, various known methods can be employed without any particular limitation. For example, application by spraying, application by a slot coater, application by roll transfer, immersion in a fiber treatment agent, and the like can be mentioned. These treatments may be performed on the fibers before being made into a web, or after the fibers are made into a web by various methods. However, it is necessary to perform the process before the hot air blowing process described later. The fiber having the fiber treatment agent attached to the surface is dried at a temperature sufficiently lower than the melting point of the polyethylene resin (for example, 120 ° C. or less) by, for example, a hot air blowing type dryer.

The non-woven fabric 1 used as the top sheet 2 in the incontinence pad 10 includes a fusing step of forming a fiber sheet by thermally fusing the intersections of the constituent fibers of the fiber web containing high elongation fibers at the fusing portion; It is manufactured by the manufacturing method of a nonwoven fabric provided with the extending process which extends | stretches a sheet | seat. One embodiment of a method for producing a nonwoven fabric used as the top sheet 2 will be described with reference to FIG. FIG. 6 schematically shows a preferable manufacturing apparatus 100 used in the method for manufacturing the nonwoven fabric 1. The manufacturing apparatus 100 is suitably used for manufacturing an air-through nonwoven fabric. The manufacturing apparatus 100 includes a web forming unit 200, a hot air processing unit 300, an extending unit 400, and a lower sheet joining unit 500 in this order from the upstream side to the downstream side of the manufacturing process. The lower sheet joining portion 500 is provided when joining the top sheet 2 (nonwoven fabric 1) and the second sheet, which is the lower sheet 8, by thermal fusion.

The web forming unit 200 is provided with a web forming apparatus 201 as shown in FIG. A card machine is used as the web forming apparatus 201. As a card machine, the thing normally used in the technical field of an absorbent article can be used without a restriction | limiting in particular. Depending on the specific use of the nonwoven fabric 1, another web manufacturing apparatus, such as an airlaid apparatus, can be used instead of the card machine.

The hot air processing unit 300 includes a hood 301 as shown in FIG. Inside the hood 301, hot air can be blown by an air-through method. The hot air processing unit 300 includes an endless conveyor belt 302 made of a breathable net. The conveyor belt 302 circulates in the hood 301. The conveyor belt 302 is made of a resin such as polyethylene terephthalate or a metal.

The temperature of the hot air blown in the hood 301 and the heat treatment time are preferably adjusted so that the intersections of the high elongation fibers included in the constituent fibers 11 of the fiber web 1b are heat-sealed. More specifically, the temperature of the hot air is preferably adjusted to a temperature higher by 0 ° C. to 30 ° C. than the melting point of the resin having the lowest melting point among the constituent fibers 11 of the fiber web 1b. The heat treatment time is preferably adjusted to 1 to 5 seconds depending on the temperature of the hot air. Further, from the viewpoint of encouraging further entanglement between the constituent fibers 11, the wind speed of the hot air is preferably about 0.3 m / sec to 1.5 m / sec. Further, the conveying speed is preferably about 5 m / min to 100 m / min.

As shown in FIGS. 6 and 7, the stretching unit 400 includes a steel matching embossing roller including a pair of concave and convex rolls 401 and 402 that can be engaged with each other. The steel matching embossing roller has a metallic cylindrical shape such as an aluminum alloy or steel, and the concavo- convex rolls 401 and 402 are formed to be heatable. One concavo-convex roll 401 has a plurality of columnar convex portions 401a uniformly distributed on the peripheral surface, and the other concavo-convex roll 402 has a columnar shape at a position corresponding to the columnar convex portion 401a of one concavo-convex roll 401 on the peripheral surface. It has a columnar concave portion 402b into which the convex portion 401a enters. Further, the other concavo-convex roll 402 has a plurality of columnar convex portions 402a that are uniformly distributed on the peripheral surface, and the one concavo-convex roll 401 corresponds to the columnar convex portion 402a of the other concavo-convex roll 402 on the peripheral surface. The columnar concave portion 401b into which the columnar convex portion 402a enters. The pair of concavo- convex rolls 401 and 402 are rotating rollers having a diameter of about 50 mm or more and 300 mm or less, respectively, and are rotated by being engaged with each other by transmitting a driving force from driving means (not shown) to at least one rotating shaft. As a material of the steel matching embossing roller, resin or the like can be used in addition to the above-mentioned metal, but it is preferable that the steel matching embossing roller is made of metal from the viewpoint of antistatic. In the steel matching embossing roller, the one concavo-convex roll 401 and the other concavo-convex roll 402 are the same roller except that the columnar convex portions 401a and 402a are provided at positions corresponding to the columnar concave portions 402b and 401b. It is. Therefore, in the following description, the columnar convex part 401a of one uneven | corrugated roll 401 is mainly demonstrated about the same part.

The uneven rolls 401 and 402 constituting the steel matching embossing roller may or may not be heated, but the heating temperature when the uneven rolls 401 and 402 are heated is a high stretch included in the constituent fibers 11 of the fiber sheet 1a described later. From the viewpoint of facilitating the drawing of the high-strength fiber, it is preferable to be not less than the glass transition point of the resin having the highest glass transition point in the high elongation fiber and not more than the melting point of the resin having the lowest melting point in the high elongation fiber. More preferably, the temperature is 10 ° C. higher than the glass transition point of the fiber and 10 ° C. lower than the melting point, more preferably 20 ° C. higher than the glass transition point of the fiber, and 20 ° C. lower than the melting point. is there. For example, when a fiber having a core / sheath structure of PET (core) having a glass transition point of 67 ° C. and a melting point of 258 ° C./PE (sheath) having a glass transition point of −20 ° C. and a melting point of 135 ° C. is used as the fiber. The temperature is preferably 67 ° C. or higher and 135 ° C. or lower, more preferably 77 ° C. or higher and 125 ° C. or lower, still more preferably 87 ° C. or higher and 115 ° C. or lower.

Moreover, in the manufacturing apparatus 100, the high elongation fiber included in the constituent fibers 11 of the fiber sheet 1a is successfully drawn in the drawing apparatus, and the change point 18 from the small diameter portion 16 to the large diameter portion 17 described above is obtained. From the viewpoint of being adjacent to the fused portion 12 and having a good feel, each columnar convex portion 401a of the concave-convex roll 401 has a height from the bottom of the concave-convex roll 401 to the apex of the columnar convex portion 401a of 0.5 mm or more and 10 mm. Or less, more preferably 1 mm or more and 7 mm or less. From the same viewpoint, the distance (pitch) between the columnar convex portions 401a adjacent in the rotation axis direction (X direction) is preferably 0.5 mm or more and 20 mm or less, more preferably 1 mm or more and 10 mm or less, The distance (pitch) between the columnar convex portions 401a adjacent to each other in the circumferential direction is preferably 0.5 mm or more and 20 mm or less, and more preferably 1 mm or more and 10 mm or less. Although there is no restriction | limiting in particular in the shape of the top part surface of each columnar convex part 401a of the uneven | corrugated roll 401, In the steel matching embossing roller, it is formed circularly. The depth of engagement between each columnar convex portion 401a of the concave-convex roll 401 and each columnar convex portion 402a of the concave-convex roll 402 (the length of the portion where each columnar convex portion 401a and each columnar convex portion 402a overlap) is the same. From such a viewpoint, it is preferably 0.5 mm or more, more preferably 1 mm or more, and preferably 10 mm or less, and more preferably 8 mm or less. Specifically, it is preferably 0.5 mm or more and 10 mm or less, and more preferably 1 mm or more and 8 mm or less. From the same viewpoint, the mechanical stretch ratio is preferably 1.2 times or more and 3.0 times or less, and particularly preferably 1.5 times or more and 2.8 times or less.

The lower sheet joining portion 500 includes a concavo-convex roll 402 and a flat roll 501 having a smooth surface, and a non-woven fabric having a concavo-convex shape between the columnar convex portion 402a of the concavo-convex roll 402 and the peripheral surface of the flat roll 501. It is a site | part which joins 1 and a lower sheet | seat by heating and pressurizing.

The manufacturing method of the nonwoven fabric 1 using the manufacturing apparatus 100 which has the above structure is demonstrated.
First, as shown in FIG. 6, in the web forming unit 200, the short fiber-shaped constituent fibers 11 having high elongation fibers are used as raw materials, and the fiber web 1b is formed by the web forming apparatus 201 which is a card machine ( Web forming step). The fiber web 1b manufactured by the web forming apparatus 201 is in a state where its constituent fibers 11 are loosely entangled with each other, and has not yet achieved shape retention as a sheet.

Next, as shown in FIG. 6, the fiber sheet 1a is formed by thermally fusing the intersections of the constituent fibers 11 of the fiber web 1b including the high elongation fibers at the fusion part 12 (fusing step). Specifically, the fiber web 1b is conveyed onto the conveyor belt 302, and hot air is blown by an air-through method while passing through the hood 301 by the hot air processing unit 300. When hot air is thus blown by the air-through method, the constituent fibers 11 of the fiber web 1b are further entangled, and at the same time, the intersection of the entangled fibers is thermally fused (see FIG. 9 (a)) to form a sheet. A fiber sheet 1a having a shape-retaining property is manufactured.

Next, as shown in FIGS. 6 to 8, the fused fiber sheet 1a is stretched (stretching step). Specifically, the fused fiber sheet 1a having a shape-retaining property as a sheet is conveyed between a pair of concavo- convex rolls 401 and 402, as shown in FIGS. 9 (a) to 9 (c). The nonwoven fabric 1 including the constituent fibers 11 having the small diameter portion 16 and the large diameter portion 17 having different fiber diameters is produced by stretching the fiber sheet 1a. Preferably, a large-diameter portion 17 having a large fiber diameter sandwiched between two small- diameter portions 16 and 16 having a small fiber diameter is formed in one constituent fiber 11 between adjacent fused portions 12 and 12. At the same time, the changing point 18 from the small diameter portion 16 to the large diameter portion 17 is formed within a range of ３ of the interval T between the fusion portions 12, 12 adjacent to the fusion portion 12.

Specifically, as shown in FIG. 9A, a fiber sheet 1a in which the intersections of the constituent fibers 11 are heat-sealed at the fusion part 12 as shown in FIG. , 402 between the columnar convex portion 401a of one concave-convex roll 401 and the columnar concave portion 402b of the other concave-convex roll 402, and the columnar convex portion 402a of the other concave-convex roll 402 and one concave-convex roll. Between the columnar recesses 401b 401, the fiber sheet 1a is stretched in the machine direction (MD, flow direction) and in the orthogonal direction (CD, roll axis direction). When the fiber sheet 1a is stretched, the region between the adjacent fused portions 12 and 12 fixing the constituent fibers 11 shown in FIG. 9A is positively stretched. In particular, as shown in FIG. 9B, local contraction is likely to occur first in the vicinity of each fusion part 12 that fixes the constituent fibers 11, and 1 between the adjacent fusion parts 12, 12. With respect to the constituent fiber 11, two small- diameter portions 16, 16 are formed at both ends, and a portion sandwiched between the two small- diameter portions 16, 16 becomes a large-diameter portion 17. A large-diameter portion 17 sandwiched between 16 is formed. In this way, local contraction is likely to occur in the vicinity of each fusion part 12, so that the change point 18 from the small diameter part 16 to the large diameter part 17 is adjacent to the fusion part 12 adjacent to the fusion part 12. It is formed within a range of 1/3 of the interval T between the twelve.

Then, with respect to one constituent fiber 11 between some adjacent fused portions 12 and 12, as shown in FIG. 9 (c), while leaving room for expansion (extension margin), Between the columnar convex portion 401a of the concave / convex roll 401 and the columnar concave portion 402b of the other concave / convex roll 402, and between the columnar convex portion 402a of the other concave / convex roll 402 and the columnar concave portion 401b of the one concave / convex roll 401, Further, the large diameter portion 17 between the adjacent fused portions 12 and 12 is stretched, and a plurality of small diameter portions 16 are formed in the large diameter portion 17.

As mentioned above, according to the manufacturing method of the nonwoven fabric 1 using the manufacturing apparatus 100, while providing the constituent fiber 11 shown in FIG. 5, the fiber density of the side region 13c is the fiber density of the top region 13a, or the bottom region 13b. It is possible to continuously and efficiently manufacture the concavo-convex structure nonwoven fabric 1 formed to be smaller than the fiber density. Moreover, the manufactured nonwoven fabric 1 is conveyed by the uneven | corrugated roll 402 to the sheet | seat junction part of the lower sheet | seat junction part 500 with the state deform | transformed into the uneven | corrugated shape. A belt-like lower sheet 8 for a second sheet unwound from the roll-shaped roll 8 ′ is supplied to the sheet joining portion, and the uneven nonwoven fabric 1 is overlapped with the belt-like lower sheet 8. The state is introduced between the uneven roll 402 and the flat roll 501. Between the concavo-convex roll 402 and the flat roll 501, the non-skin-side convex portion 22 and the belt-like lower sheet 8 in the concavo-convex nonwoven fabric 1 are arranged around each columnar convex portion 402 a of the concavo-convex roll 402 and the flat roll 501. It is heated and pressurized between the surfaces and joined. In this way, a band-shaped composite sheet in which the top sheet 2 made of the nonwoven fabric 1 is joined to the lower sheet 8 at each columnar convex portion 401a is obtained. The belt-shaped composite sheet is introduced into the incontinence pad 10 production line after being wound up, or is introduced into the incontinence pad 10 production line without being wound up.

The incontinence pad 10 described above is manufactured by disposing the absorbent body 4 between the strip-shaped composite sheet and the strip-shaped back sheet 3 and then cutting it into the shape of individual articles.

The operational effects of the incontinence pad 10 described above will be described.
In the incontinence pad 10, as shown in FIGS. 3 and 4, the topsheet 2 has a plurality of skin-side convex portions 21 protruding to the skin facing surface side and a skin side located between the plurality of skin-side convex portions 21. And a recess. Moreover, as shown in FIG. 3, the surface sheet 2 is comprised from the nonwoven fabric 1 of the uneven structure by which the several skin side convex part 21 and the skin side recessed part were alternately distribute | arranged alternately along two different directions which mutually cross | intersect. Has been. Therefore, during wearing of the incontinence pad 10, the contact area with the skin can be reduced, and stuffiness can be reduced. Moreover, the nonwoven fabric 1 which comprises the surface sheet 2 contains the structure fiber 11 which has the large diameter part 17 and the small diameter parts 16 and 16 from which a fiber diameter mutually differs, as shown in FIG. Therefore, while wearing the incontinence pad 10, it is easy to bend around the small diameter portion 16, and each skin-side convex portion 21 that comes into contact with the skin can flexibly follow the movement in the vertical direction X and the horizontal direction Y. Will improve. In particular, in the incontinence pad 10, the skin-side convex portions 21 and the skin-side concave portions are alternately and continuously arranged along the vertical direction X and the horizontal direction Y. Therefore, the contact area with the skin can be further reduced, and stuffiness can be further reduced.

Further, in the incontinence pad 10, as shown in FIG. 5, paying attention to one constituent fiber 11 among the constituent fibers 11 of the nonwoven fabric 1 forming the top sheet 2, the constituent fibers 11 are adjacent to each other. Between the parts 12 and 12, it has the large diameter part 17 with a large fiber diameter pinched | interposed into the two small diameter parts 16 and 16 with a small fiber diameter. Therefore, during wearing of the incontinence pad 10, each skin side convex part 21 which contacts skin can follow the movement to the vertical direction X and the horizontal direction Y more flexibly, and a usability improves. In particular, in the incontinence pad 10, in the nonwoven fabric 1 forming the topsheet 2, the change point 18 is arranged within a range of ３ of the interval T between the fusion parts 12, 12 adjacent to the fusion part 12. Yes. Therefore, during wearing of the incontinence pad 10, each skin-side convex portion 21 that comes into contact with the skin can follow the movement in the vertical direction X and the horizontal direction Y particularly flexibly, and the usability is further improved.

Moreover, in the incontinence pad 10, as shown in FIG. 4, the nonwoven fabric 1 forming the topsheet 2 has a fiber density in the side region 13 c of the skin-side convex portion 21, and the fibers in the top region 13 a of the skin-side convex portion 21. It is lower than the density or fiber density of the bottom region 13b. Therefore, it is easy to bend from the side area 13c of each skin side convex part 21 by the pressure at the time of wearing of the incontinence pad 10, and the top area 13a of each skin side convex part 21 that contacts the skin has the vertical direction X and the horizontal direction. It is possible to follow the movement in the direction Y more flexibly, and the usability is further improved.

Further, in the incontinence pad 10, the high-tensile fiber is included in the constituent fibers 11 of the nonwoven fabric 1. Therefore, since the fibers are not easily cut even after the stretching process, the top area 13a of each skin-side convex portion 21 is not easily crushed by the pressure when the incontinence pad 10 is worn, and the contact area with the skin can be further reduced. , Dripping can be further reduced.

Moreover, in the incontinence pad 10, as shown in FIG. 2, the surface sheet 2 is joined to the adjacent lower sheet 8 in the non-skin-side convex portion 22 which is a skin-side concave portion, An internal space S <b> 1 is formed between the lower sheet 8. Therefore, breathability can be improved while wearing the incontinence pad 10, and the feeling of use is further improved.

As mentioned above, although this invention was demonstrated based on the preferable embodiment, the absorbent article of this invention is not restrict | limited to the incontinence pad 10 of the said embodiment at all, and can be changed suitably.
For example, as shown in FIG. 3 and FIG. 4, the top sheet 2 of the incontinence pad 10 has a total thickness when the nonwoven fabric 1 is viewed from the side, the sheet thickness T _S (height of the skin-side convex portion 21, non- The height of the skin-side convex portion 22) is a constant height, but may be different from the viewpoint of reducing the contact area with the skin during wearing of the incontinence pad 10, for example, arranged in the vertical direction X The plurality of skin-side convex portions 21 may be alternately different in height from each skin-side convex portion 21. Thus, the nonwoven fabric 1 which forms the surface sheet 2 in which each skin side convex part 21 was arranged provided the columnar convex part 401a and the columnar recessed part 401b so that it might correspond to the position of this skin side convex part 21, for example. It can manufacture using the manufacturing apparatus 100 provided with the steel matching embossing roller which consists of the uneven | corrugated roll 401 and the uneven | corrugated roll 402 which arranged the columnar convex part 402a and the columnar recessed part 402b.

Moreover, as shown in FIG. 3, the surface sheet 2 of the incontinence pad 10 includes a plurality of skin-side convex portions 21 having an internal space S1 and a plurality of non-skin-side convex portions 22 having an internal space S2. And when the surface sheet 2 is viewed in plan, the skin-side convex portions 21 and the non-skin-side convex portions 22 are regularly and alternately arranged along the vertical direction X and the horizontal direction Y. It may be arranged at random. The nonwoven fabric 1 in which the skin-side convex portions 21 and the non-skin-side convex portions 22 are randomly arranged in this manner is, for example, columnar so as to correspond to the positions of the random skin-side convex portions 21 and the non-skin-side convex portions 22. It can be manufactured by using a manufacturing apparatus 100 including a steel matching embossing roller including a concavo-convex roll 401 provided with a convex portion 401a and a columnar concave portion 401b and a concavo-convex roll 402 provided with a columnar convex portion 402a and a columnar concave portion 402b.

Further, as shown in FIG. 4, the surface sheet 2 of the incontinence pad 10 has a fiber density in the wall portions 21 </ b> W and 22 </ b> W (side region 13 c) of the annular structure over the entire circumference of the skin-side convex portion 21. Although it is lower than the fiber density in the top part 21T (top part area 13a) and the fiber density of the top part 22T (bottom part area 13b) of the non-skin-side convex part 22, it is in a part of the wall parts 21W and 22W (side part area 13c). The fiber density may be lower than the fiber density of the top region 13a and the fiber density of the bottom region 13b. Such a nonwoven fabric 1 having a low fiber density in a part of the walls 21W and 22W (side regions 13c) can be manufactured as follows. Specifically, for example, as shown in FIG. 10, large-diameter convex portions 403 and 404 and small-diameter concave portions (not shown) extending over the entire rotation direction of the peripheral surface of the roll are in the roll axial direction. Using a pair of concavo- convex rolls 401 and 402 that are alternately arranged and meshed with each other, first, the fiber sheet 1a is conveyed between the pair of concavo- convex rolls 401 and 402, and the streaky ridges continuously extending in the X direction. A precursor 1c of the nonwoven fabric 1 having a concavo-convex structure in which the portions 23 and the concave stripe portions 24 are alternately arranged in the Y direction is manufactured. In the precursor 1c, the side region 13c corresponding to the wall portion between the protruding portion 23 and the recessed portion 24 extends continuously in the X direction, and the fiber density of the side region 13c is convex. It is lower than the fiber density of the top region 13 a of the strip 23 and the fiber density of the bottom region 13 b of the recess 24. Next, as shown in FIG. 11, a convex roll 406 and a flat roll 407 in which embossed convex portions 405 extending continuously in the roll axis direction on the peripheral surface of the roll are intermittently arranged in the rotation direction of the roll. The wall portions 21 </ b> W and 22 </ b> W (which are used to convey the precursor 1 c between the convex roll 406 and the flat roll 407 and have the streak-like embossed portions extending continuously in the Y direction intermittently arranged in the X direction. A nonwoven fabric 1 with a low fiber density in part of the side area 13c) can be produced.

Moreover, in the incontinence pad 10, as shown in FIG.2 and FIG.3, the surface sheet 2 has several skin side convex parts 21 which have internal space S1, and several non-skin side convex parts 22 which have internal space S2. Although it has, it does not need to have internal space S1, S2. That is, the surface sheet 2 of the incontinence pad 10 may be a sheet having a plurality of skin-side convex portions 21 and a plurality of non-skin-side convex portions 22 as shown in FIG.

In the incontinence pad 10, as shown in FIG. 2, the top sheet 2 is joined to the second sheet that is the adjacent lower sheet 8 at the non-skin-side convex portion 22, but the second sheet is arranged. It does not have to be. Instead of the second sheet, the top sheet 2 may be joined to the core wrap sheet 41 that is the adjacent lower sheet 8 at the non-skin-side convex portion 22.

Further, the absorbent article of the present invention may be a panty liner (origami sheet), a sanitary napkin, etc. in addition to an incontinence pad.

The following absorbent article is further disclosed regarding the embodiment described above.

<1>
It has a liquid-permeable surface sheet that forms a skin facing surface, a back sheet that forms a non-skin facing surface, and an absorbent main body having an absorbent body interposed between both sheets, and corresponds to the front and back direction of the wearer. An absorbent article having a longitudinal direction and a transverse direction perpendicular to the longitudinal direction,
The top sheet has a plurality of skin-side convex portions protruding to the skin facing surface side, and a skin-side concave portion positioned between the plurality of skin-side convex portions, and the plurality of skin-side convex portions and the skin It is formed from a non-woven fabric having a concavo-convex structure in which side recesses are alternately and continuously arranged along two different directions intersecting each other,
The said nonwoven fabric is an absorptive article containing the constituent fiber which has a large diameter part and a small diameter part from which fiber diameter differs mutually.

<2>
The non-woven fabric includes a plurality of fusion portions formed by heat-sealing the intersections of the constituent fibers,
Paying attention to one of the constituent fibers, the constituent fiber has the large-diameter portion sandwiched between two small-diameter portions between the adjacent fused portions. <1> Absorbent article as described in 1.
<3>
The absorbent article according to <1> or <2>, wherein the nonwoven fabric includes high elongation fibers in its constituent fibers.
<4>
The elongation of the high elongation fiber is preferably 100% or more and 800% or less, more preferably 200% or more and 500% or less, and further preferably 250% or more and 400% or less at the raw material stage. Absorbent article according to 3>.
<5>
The absorbent article according to any one of <1> to <4>, wherein the sheet thickness of the nonwoven fabric is 0.3 mm to 7 mm, preferably 0.7 mm to 5 mm.

<6>
The surface sheet is bonded to an adjacent lower sheet in the skin-side recess, and the internal space is formed between the lower sheet and the skin-side protrusion, <1> to <5 > Any one of>.
<7>
When the surface sheet is viewed in cross section, the height of the internal space between the lower sheet and the skin-side convex portion is greater than the layer thickness of the top portion of the skin-side convex portion. Absorbent article.
<8>
When the surface sheet is viewed in cross section, the height of the internal space between the skin-side convex portion and the lower sheet is 0.1 mm or more and 6 mm or less, preferably 0.6 mm or more and 4 mm or less. > Or <7>.
<9>
The absorptivity according to any one of <6> to <8>, wherein a second sheet made of a nonwoven fabric is disposed between the top sheet and the absorbent body, and the second sheet is the lower sheet. Goods.
<10>
The absorbent article according to <9>, wherein the second sheet has a basis weight of 10 g / m ^{2 to} 50 g / m ² , preferably 15 g / m ^{2 to} 25 g / m ² .
<11>
The absorbent sheet according to <9> or <10>, wherein the second sheet has a thickness of 0.1 mm to 5 mm.
<12>
The non-woven fabric has a plurality of non-skin-side convex portions protruding to the non-skin-facing surface side, and a non-skin-side concave portion positioned between the non-skin-side convex portions, as viewed from the skin-facing surface side. The absorptivity according to any one of <1> to <11>, wherein the skin-side concave portion is the non-skin-side convex portion, and the non-skin-side concave portion viewed from the non-skin facing surface side is the skin-side convex portion. Goods.
<13>
When the nonwoven fabric is viewed in plan, the distance between the top of the skin-side convex portion and the top of the non-skin-side convex portion at the closest position is 1 mm or more and 15 mm or less, preferably 1 mm or more and 10 mm or less. 12>.
<14>
The non-woven fabric has a top region, a bottom region, and a side region located therebetween,
The top part of the skin side convex part is formed from the top part area, the skin side concave part is formed from the bottom part area,
The absorbent article according to any one of <1> to <13>, wherein the fiber density in the side region is lower than the fiber density in the top region or the fiber density in the bottom region.
<15>
The absorbent article according to <14>, wherein the fiber density in the side region is lower than the fiber density in the top region and the fiber density in the bottom region.
<16>
The ratio (D13c / D13a, D13c / D13a) of the fiber density (D13c) in the side region to the fiber density (D13a) in the top region or the fiber density (D13b) in the bottom region is 0.15 or more. The absorbent article according to <14> or <15>, which is 0.9 or less, preferably 0.2 or more and 0.8 or less.
<17>
Fiber density at the bottom area (D13b) is 80 present / mm ² or more 200 present / mm ² or less, the <14> - a <16> is preferably 90 present / mm ² or more 180 lines / mm ² or less The absorbent article of any one.
<18>
Fiber density of the side region (D13C) provides 30 / mm ² or more eighty / mm ² or less, preferably said <14> - a <17> is forty / mm ² or more 70 yarns / mm ² or less The absorbent article of any one.

<19>
The number of fibers having a change point from the small diameter portion to the large diameter portion in the constituent fiber constituting the side region is a change point from the small diameter portion to the large diameter portion in the constituent fiber constituting the top region. Any of the above <14> to <18>, which is formed more than the number of fibers having a change point from the small diameter portion to the large diameter portion in the constituent fibers constituting the bottom region Or an absorbent article according to claim 1.
<20>
The number of fibers (N13a) having a change point from the small diameter portion to the large diameter portion in the constituent fibers constituting the top region, or from the small diameter portion to the large diameter portion in the constituent fibers constituting the bottom region. Ratio (N13c / N13a, N13c / N13c / N13c / N13c / N13c / N13c / N13c / N13c / N13c / N13c / N13c / N13c) The absorbent article according to any one of <14> to <19>, wherein N13b) is 2 or more and 20 or less, preferably 5 or more and 20 or less.
<21>
The number (N13a) of fibers having a change point from the small diameter portion to the large diameter portion in the constituent fibers constituting the top region is 1 or more and 15 or less, preferably 5 or more and 15 or less. 14. An absorbent article according to any one of 14> to <20>.
<22>
The number (N13b) of fibers having a change point from the small diameter portion to the large diameter portion in the constituent fibers constituting the bottom region is 1 or more and 15 or less, preferably 5 or more and 15 or less. 14. An absorbent article according to any one of 14> to <21>.
<23>
The number (N13c) of fibers having a change point from the small diameter portion to the large diameter portion in the constituent fibers constituting the side region is 5 or more and 20 or less, preferably 10 or more and 20 or less. The absorbent article according to any one of <14> to <22>.

<24>
The absorbent article according to any one of <1> to <23>, wherein the plurality of skin-side convex portions arranged in the vertical direction have different heights of the skin-side convex portions alternately. .
<25>
The absorbent article according to any one of <1> to <24>, wherein the ratio of the fiber diameter of the small diameter portion to the fiber diameter of the large diameter portion is 0.8 or less.
<26>
Any one of the above <1> to <25>, wherein the nonwoven fabric has a concavo-convex structure in which a plurality of the skin-side convex portions and the skin-side concave portions are alternately and continuously arranged along the vertical direction and the horizontal direction. 2. The absorbent article according to 1.
<27>
The interval between the top portions of the skin-side convex portions adjacent in the lateral direction in the topsheet is 2 mm or more and 30 mm or less, preferably 2 mm or more and 15 mm or less, according to any one of <1> to <26>. Absorbent article.
<28>
The absorption according to any one of <1> to <27>, wherein an interval between the top portions of the skin-side convex portions adjacent to each other in the longitudinal direction in the surface sheet is 2 mm or more and 30 mm or less, preferably 2 mm or more and 15 mm or less. Sex goods.

According to the present invention, the contact area with the skin can be reduced to reduce stuffiness, and the convex portion of the surface sheet can follow the movement in the vertical direction and the horizontal direction more flexibly, improving the usability.

Claims (28)

1. It has a liquid-permeable surface sheet that forms a skin facing surface, a back sheet that forms a non-skin facing surface, and an absorbent main body having an absorbent body interposed between both sheets, and corresponds to the front and back direction of the wearer. An absorbent article having a longitudinal direction and a transverse direction perpendicular to the longitudinal direction,
   The top sheet has a plurality of skin-side convex portions protruding to the skin facing surface side, and a skin-side concave portion positioned between the plurality of skin-side convex portions, and the plurality of skin-side convex portions and the skin It is formed from a non-woven fabric having a concavo-convex structure in which side recesses are alternately and continuously arranged along two different directions intersecting each other,
   The said nonwoven fabric is an absorptive article containing the constituent fiber which has a large diameter part and a small diameter part from which fiber diameter differs mutually.
2. The non-woven fabric includes a plurality of fusion portions formed by heat-sealing the intersections of the constituent fibers,
   Focusing on one said constituent fiber, this constituent fiber has the said large diameter part pinched | interposed into two said small diameter parts between the said adjacent fused parts. The absorbent article as described.
3. The absorbent article according to claim 1 or 2, wherein the nonwoven fabric includes high elongation fibers in its constituent fibers.
4. The absorbent article according to claim 3, wherein the elongation of the high elongation fiber is 100% or more and 800% or less at the raw material stage.
5. The absorbent article according to any one of claims 1 to 4, wherein the nonwoven fabric has a sheet thickness of 0.3 mm or more and 7 mm or less.
6. The surface sheet is joined to an adjacent lower sheet in the skin-side recess, and an internal space is formed between the lower sheet and the skin-side protrusion. The absorbent article of Claim 1.
7. The absorption according to claim 6, wherein the surface sheet is viewed in cross section, and the height of the internal space between the lower sheet and the skin-side convex portion is larger than the layer thickness of the top portion of the skin-side convex portion. Sex goods.
8. The absorbent article according to claim 6 or 7, wherein the height of the internal space between the skin-side convex portion and the lower sheet is 0.1 mm or more and 6 mm or less when the surface sheet is viewed in cross section.
9. The absorbent article according to any one of claims 6 to 8, wherein a second sheet made of a nonwoven fabric is disposed between the top sheet and the absorbent body, and the second sheet is the lower sheet.
10. The absorbent article according to claim 9, wherein the second sheet has a basis weight of 10 g / m ² or more and 50 g / m ² or less.
11. The absorbent article according to claim 9 or 10, wherein the second sheet has a thickness of 0.1 mm or more and 5 mm or less.
12. The non-woven fabric has a plurality of non-skin-side convex portions protruding to the non-skin-facing surface side, and a non-skin-side concave portion positioned between the non-skin-side convex portions, as viewed from the skin-facing surface side. The absorbent article according to any one of claims 1 to 11, wherein a skin-side concave portion becomes the non-skin-side convex portion, and the non-skin-side concave portion viewed from the non-skin facing surface side becomes the skin-side convex portion.
13. The absorbent article according to claim 12, wherein, when the nonwoven fabric is viewed in plan, a distance between a top portion of the skin-side convex portion and a top portion of the non-skin-side convex portion at a closest position is 1 mm or more and 15 mm or less. .
14. The non-woven fabric has a top region, a bottom region, and a side region located therebetween,
    The top part of the skin side convex part is formed from the top part area, the skin side concave part is formed from the bottom part area,
    The absorbent article according to any one of claims 1 to 13, wherein the fiber density in the side region is lower than the fiber density in the top region or the fiber density in the bottom region.
15. The absorbent article according to claim 14, wherein the fiber density of the side region is lower than the fiber density of the top region and the fiber density of the bottom region.
16. The ratio (D13c / D13a, D13c / D13a) of the fiber density (D13c) in the side region to the fiber density (D13a) in the top region or the fiber density (D13b) in the bottom region is 0.15 or more. The absorptive article according to claim 14 or 15 which is 0.9 or less.
17. Fiber density at the bottom area (D13b) The absorbent article according to any one of claims 14-16 and 80 present / mm ² or more 200 present / mm ² or less.
18. Fiber density of the side region (D13C) The absorbent article according to any one of claims 14-17 is 30 lines / mm ² or more eighty / mm ² or less.
19. The number of fibers having a change point from the small diameter portion to the large diameter portion in the constituent fiber constituting the side region is a change point from the small diameter portion to the large diameter portion in the constituent fiber constituting the top region. The number of fibers having a diameter and the number of fibers having a changing point from the small diameter portion to the large diameter portion in the constituent fibers constituting the bottom region are formed. Absorbent article as described in 1.
20. The number of fibers (N13a) having a change point from the small diameter portion to the large diameter portion in the constituent fibers constituting the top region, or from the small diameter portion to the large diameter portion in the constituent fibers constituting the bottom region. Ratio (N13c / N13a, N13c / N13c / N13c / N13c / N13c / N13c / N13c / N13c / N13c / N13c / N13c / N13c) The absorbent article according to any one of claims 14 to 19, wherein N13b) is 2 or more and 20 or less.
21. The number of fibers (N13a) having a change point from the small diameter portion to the large diameter portion in the constituent fibers constituting the top region is 1 or more and 15 or less. The absorbent article as described.
22. The number of fibers (N13b) having a change point from the small diameter portion to the large diameter portion in the constituent fibers constituting the bottom region is 1 or more and 15 or less. The absorbent article as described.
23. 23. The number (N13c) of fibers having a change point from the small diameter portion to the large diameter portion in the constituent fibers constituting the side region is 5 or more and 20 or less. Absorbent article as described in 1.
24. The absorbent article according to any one of claims 1 to 23, wherein the plurality of skin-side convex portions arranged in the longitudinal direction have different heights of the skin-side convex portions alternately.
25. The absorbent article according to any one of claims 1 to 24, wherein a ratio of a fiber diameter of the small diameter portion to a fiber diameter of the large diameter portion is 0.8 or less.
26. The nonwoven fabric according to any one of claims 1 to 25, wherein the nonwoven fabric has a concavo-convex structure in which a plurality of the skin-side convex portions and the skin-side concave portions are alternately and continuously arranged along the vertical direction and the horizontal direction. The absorbent article as described.
27. The absorbent article according to any one of claims 1 to 26, wherein an interval between the top portions of the skin-side convex portions adjacent in the lateral direction in the topsheet is 2 mm or more and 30 mm or less.
28. The absorbent article according to any one of claims 1 to 27, wherein an interval between the top portions of the skin-side convex portions adjacent to each other in the longitudinal direction in the top sheet is 2 mm or more and 30 mm or less.

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