WO2018163879A1 - 賦形シートおよびその製造方法 - Google Patents
賦形シートおよびその製造方法 Download PDFInfo
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- WO2018163879A1 WO2018163879A1 PCT/JP2018/006908 JP2018006908W WO2018163879A1 WO 2018163879 A1 WO2018163879 A1 WO 2018163879A1 JP 2018006908 W JP2018006908 W JP 2018006908W WO 2018163879 A1 WO2018163879 A1 WO 2018163879A1
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- Prior art keywords
- sheet
- nonwoven fabric
- shaped sheet
- fusion
- convex
- Prior art date
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Classifications
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
- A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
- A61F13/51104—Topsheet, i.e. the permeable cover or layer facing the skin the top sheet having a three-dimensional cross-section, e.g. corrugations, embossments, recesses or projections
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
- A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/542—Adhesive fibres
- D04H1/55—Polyesters
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/558—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in combination with mechanical or physical treatments other than embossing
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2401/00—Physical properties
- D10B2401/06—Load-responsive characteristics
- D10B2401/061—Load-responsive characteristics elastic
Definitions
- the present invention relates to a shaped sheet formed from a single-layer nonwoven fabric sheet and a method for producing the same.
- a shaped sheet obtained by shaping a plurality of convex parts on a nonwoven fabric sheet and a flat sheet are intermittently joined around the convex parts, thereby forming the shaped convex parts. Hold the shape of.
- an object of the present invention is to provide a shaped sheet that can reduce the cost of the shaped sheet, suppress its bulk, and maintain the shape of the convex portion, and a method for producing the shaped sheet.
- the shaped sheet of the present invention is a shaped sheet 2 in which a plurality of rows of convex portions 21 are formed on the nonwoven fabric sheet 1 in the first direction D and the second direction F intersecting the first direction D, respectively.
- the shaped sheet 2 is easier to extend in the first direction D than the second direction F,
- the shaped sheet 2 is formed of a single-layer nonwoven fabric sheet 1, A part of or all of the periphery of each convex part 21 in the shaped sheet 2 extends intermittently or continuously in the first direction D, and is thinner than the convex part 21 due to a fusion structure.
- a portion 22 is provided.
- the method for manufacturing a shaped sheet according to the present invention is a method for manufacturing a shaped sheet 2 in which a plurality of rows of convex portions 21 are formed on the nonwoven fabric sheet 1 in a first direction D and a second direction F intersecting the first direction D.
- a method A step of transporting in the longitudinal direction a single-layer nonwoven fabric sheet 1 that is easier to extend in the width direction than in the longitudinal direction; A shaping step of shaping the plurality of rows of convex portions 21 on the nonwoven fabric sheet 1 being conveyed; In the single-layer nonwoven fabric sheet 1 or the shaped sheet 2, a fused portion 22 in which the fibers 11 constituting the single-layer nonwoven fabric sheet 1 are fused to each other partly or entirely around the convex portions 21. Forming a fusion process.
- the fibers 11 constituting the single-layer nonwoven fabric sheet 1 that is easier to extend in the width direction than in the longitudinal direction are fused together to form the fused portion 22.
- the fusion part 22 is formed by a fusion structure that is thinner than the convex part 21 of the shaped sheet 2.
- the fused part 22 is harder and more rigid than the convex part 21.
- the fusion part 22 will inhibit the extension of the shaped sheet 2 in the first direction D in which the shaped sheet 2 is easily extended around the convex part. Therefore, the convex portion is not easily crushed and the shape of the convex portion is maintained even in a single layer sheet. As a result, a low-cost shaped nonwoven fabric sheet can be obtained. Moreover, it can suppress that a shaping sheet becomes bulky.
- FIG. 1 is a super-enlarged perspective view of Example 1 showing a part of the shaped sheet of the present invention enlarged about 10 times.
- a ridge line is written in the convex portion to make it easy to grasp the convex shape.
- 2A is a super enlarged plan view of a part of the shaped sheet as seen from the surface
- FIG. 2B is a cross-sectional view taken along the line BB of FIG. 2A
- FIG. 2C is a cross-sectional view taken along the line CC of FIG.
- FIG. 3 is a super enlarged plan view of a part of the shaped sheet as seen from the back side.
- 4A and 4B are enlarged plan views each showing a pattern of the fused portion.
- FIG. 5A and FIG. 5B are enlarged plan views showing other patterns of the fused portion, respectively.
- the fused portion is colored in gray.
- Each of the convex portions in FIG. 2A and each concave portion in FIG. 3 is shaded so that light strikes from the upper left.
- FIG. 6 is a layout diagram showing an example of a manufacturing apparatus.
- FIG. 7A is an enlarged sectional view showing a part of the first roll and the second roll
- FIG. 7B is an enlarged sectional view showing a part of the second roll and the third roll.
- 8A, FIG. 8B, and FIG. 8C are a super-enlarged perspective view and a super-enlarged sectional view showing a manufacturing method, respectively.
- FIG. 9A is an enlarged plan view showing a part of a shaped sheet having a non-woven sheet portion at the edge as a digital photograph
- FIG. 9B is an enlarged perspective view showing a digital photograph of a part of the shaped sheet taken from the surface.
- FIG. 9C is an enlarged perspective view showing a digital photograph of a part of the shaped sheet taken from the back side.
- FIG. 10A is a super enlarged plan view showing a digital photograph of a part of the shaped sheet taken from the surface
- FIG. 10B is a super enlarged sectional view of the sliced shaped shaped sheet taken from the side
- FIG. 10C is one of the shaped sheets It is a super-enlarged back view shown by the digital photograph which imaged the part from the back surface.
- the fusion part 22 of the shaped sheet is formed by the fusion structure in which the fibers 11 constituting the single-layer nonwoven fabric sheet 1 are fused to each other. That the fibers 11 of the single-layer nonwoven fabric sheet 1 are fused to each other means that the fused portion 22 is not essentially fused to another nonwoven fabric. This also means that the double portions of the double-folded nonwoven fabric sheet 1 are not fused together.
- Such a fused part has higher hardness and rigidity than a non-fused part such as a convex part. Therefore, it is possible to inhibit the shaped sheet 2 from extending in the first direction around the convex portion.
- the fused part is defined by the thickness.
- the thickness may be measured by a method according to JIS L1913, but in general, the cut surface of the shaped sheet is enlarged with a digital camera or a microscope to increase the thickness of the fused portion and the convex portion. You can easily see the difference from the thickness.
- the fusion part 22 of the shaped sheet includes a central part 23 between the adjacent convex parts 21 in the first direction D, and the fusion part 22 is at least from the central part 23. It extends in one of the first directions D. In the central portion, adjacent convex portions are close to each other, so that the central portion is likely to be the most easily stretched portion. On the other hand, since the fusion part includes the central part and extends in the first direction, the shaped sheet 2 is difficult to extend in the first direction.
- the shaped sheet is related to the fiber density of the constituent fibers, and the fiber density of the constituent fibers of the fused portion 22 is higher than the fiber density of the constituent fibers of the convex portion 21.
- the fiber density is the mass of fibers per unit volume of the shaped sheet. High fiber density means that the amount of fibers present per unit volume of the sheet is large. Low fiber density means that the amount of fiber present per unit volume of the sheet is small.
- the cut surface of the sheet is enlarged and observed using a scanning electron microscope, and the number of cross sections of the fibers cut by the cut surface per certain area (about 0.5 mm 2 ) is counted. Also good.
- the fused part 22 is harder and more rigid than the convex part 21. Therefore, the fusion
- the shaped sheet in which the fused part 22 is made into a film close to transparency the presence of fibers cannot be clearly confirmed in the fused part 22, and the fiber density of the fused part 22 is higher than that of the convex part 21. May be smaller.
- the shaped sheet is related to the elongation rate when the shaped sheet is pulled in the first direction D, and the elongation rate of the fused portion 22 is greater than the elongation rate of the convex portion 21. small.
- elongation rate you may measure by the method according to JISL1913.
- the fused part 22 is harder and more rigid than the convex part 21. Therefore, the fusion
- each fusion part 22 of the shaped sheet 2 will be less likely to extend equally in the first direction D and the second direction F.
- each convex part 21 which is not fused easily extends in the first direction D. Therefore, the shaped sheet 2 as a whole is easier to extend in the first direction D than the second direction F.
- the shaped sheet 2 extends in the first direction D compared to the second direction F. It's easy. Therefore, “the shaped sheet 2 is easier to extend in the first direction D than the second direction F” means, for example, a shaped sheet having a size including a large number of the convex portions 21 and the fused portions 22.
- the shaped sheet 2 when comparing the case where the entire shaped sheet 2 is pulled in the first direction D and the case where the shaped sheet 2 is pulled in the second direction F, the shaped sheet 2 is compared with the second direction F in the first direction. It means that it is easy to extend in the direction D.
- the size of each of the convex portions 21 and the fused portions 22 is extremely small, and it is measured that the individual convex portions 21 and the fused portions 22 are easily extended in the first direction D. Therefore, it was defined by the ease of extension of the shaped sheet 2 including the convex portion 21 and the fused portion 22. That is, as a method for measuring whether or not the shaped sheet 2 is easier to extend in the first direction D than in the second direction F, it may be measured by a method according to JIS L1913.
- the first roll R1 and the second roll R2 are meshed so that the nonwoven sheet 1 is shaped.
- the first and / or second roll R1, R2 is heated to a temperature range lower than the melting point of the fibers 11 forming the nonwoven fabric sheet 1,
- the fusion process is performed when the heating device R3 contacts the second roll R2 via the fusion part 22 of the nonwoven fabric sheet 1.
- the convex portion 21 is easily formed on the nonwoven fabric sheet 1, and the formation of a through-hole in the shaped sheet at the fused portion 22 can be suppressed.
- adopt a heating roll as a heating apparatus, it is also possible to employ
- the shaping sheet 2 is composed of a single-layer nonwoven fabric sheet 1 and is used as, for example, a top sheet of a liquid absorption part of a disposable wearing article. Therefore, the shaped sheet 2 has the desired liquid permeability and air permeability.
- the shaping sheet 2 has a plurality of rows of convex portions 21 formed in the first direction D of the nonwoven fabric sheet 1, and a plurality of rows of projections in the second direction F intersecting the first direction D.
- the part 21 is formed in the nonwoven fabric sheet 1.
- many convex parts 21 may be formed over the full width of the said nonwoven fabric sheet 1, or as shown to FIG. 9A, about the side edge part of the said nonwoven fabric sheet 1, a convex part is formed without processing.
- the original non-woven fabric may be left as it is.
- the first direction D coincides with the width direction of the continuous nonwoven fabric sheet 1 in FIG. 8A, but the first direction D may be slightly inclined with respect to the width direction.
- Each fiber of the nonwoven fabric sheet 1 of this example is longer in the second direction F than in the first direction D. Therefore, the shaped sheet 2 is easier to extend in the first direction D than in the second direction F.
- the second direction F intersects the first direction D so as to be orthogonal, but the second direction F intersects the first direction D obliquely. You may do it.
- the shaped sheet 2 in FIG. 1 is provided with a fused portion 22.
- the fusion part 22 has a thickness T of FIG. That is, as shown in FIGS. 2B and 2C, in the single-layer shaped sheet 2, the convex portion 21 and the fused portion 22 having a thickness T smaller than the convex portion 21 are formed in the first direction D and the first direction. They are alternately arranged in two directions F. As shown in FIGS. 2B and 2C, the fusion part 22 may be higher than the convex part 21 with respect to the fiber density of the constituent fibers. Furthermore, regarding the elongation rate when the shaped sheet is pulled in the first direction D, the fused portion 22 may be smaller than the convex portion 21.
- the fused portion 22 in FIG. 1 is provided in a part of the periphery of each convex portion 21 in the shaped sheet 2.
- the fusion part 22 extends intermittently in the first direction D.
- the fused portion 22 may be provided on the entire periphery of each convex portion 21 in the shaped sheet 2.
- the fusion part 22 is continuously extended in the said 1st direction D and the 2nd direction F, and becomes loop shape.
- the fibers 11 constituting the single-layer nonwoven fabric sheet 1 are fused to each other at the fused portion 22 formed by the fused structure.
- the fusion part 22 of FIG. 1 formed by the fusion structure suppresses the extension of the shaped sheet 2 in the first direction D.
- the fused portion 22 to which the fibers 11 are fused is higher in transparency than the convex portion 21 and is translucent. In general, the transparency can be confirmed visually.
- the transparency is a scale representing the transparency of a substance or material.
- the degree of transparency may be displayed as a light transmittance.
- a measuring method of transparency it can measure using a haze meter etc.
- the test piece can be cut out and measured with reference to JIS K 7136 (Plastic—How to determine haze of transparent material).
- the shaped sheet 2 is formed of a single layer nonwoven fabric sheet 1.
- the nonwoven fabric formed with the air through nonwoven fabric (thermal bond nonwoven fabric) and the hydroentangled water punch nonwoven fabric may be used.
- the fibers 11 forming these non-woven fabrics are fused together to form the fused structure of the fused portion 22.
- the basis weight of the nonwoven fabric sheet 1 is preferably about 25 to 50 g / m 2 .
- Basis weight is 25 g / m 2 If it is smaller than this, it will be difficult to retain the shape of the convex portion 21 in the single-layer nonwoven fabric sheet 1.
- the basis weight is larger than 50 g / m 2 , even if the single-layer nonwoven fabric sheet 1 is used, the cost increases and the texture decreases. More preferably, the basis weight is about 30 to 40 g / m 2 .
- the fusion part 22 includes a central part 23 between the convex parts 21 adjacent to each other in the first direction D, and the fusion part 22 extends at least in the first direction D from the central part 23. It may extend to one side.
- the fusion part 22 is formed to be longer in the first direction D than in the second direction F. Further, the fused portion 22 may have a shape (bone shape, hourglass shape) constricted at the central portion 23.
- the fused portion 22 may be provided intermittently and intermittently along the first direction D around the convex portion 21. In these cases, the fused portion 22 is provided intermittently and intermittently also in the second direction F.
- the fusion part 22 may be provided over the entire width of the convex part 21 in the first direction D.
- fusion part 22 is provided in the 2nd direction F intermittently and intermittently.
- the fusion part 22 may be formed in the first direction D over an area of 60% or more of the width 21 ⁇ / b> D of the convex part 21.
- planar shape of the fused portion 22 various shapes such as the bone shape of FIG. 2A, the loop shape of FIG. 4A, the crescent shape of FIG. 4B, the rectangular shape of FIG. 5A, or the dot shape of FIG.
- a convex surface is formed on the surface of each convex portion 21 in FIG.
- a concave surface is formed on the back surface of each convex portion 21 as shown in FIGS. 2B, 2C and 3.
- the size of the convex portion is not particularly limited.
- the convex portion when used as a diaper top sheet, is generally set to about 6 mm 2 to 30 mm 2 , and the height of the convex portion is about 1 mm to 5 mm. It will be general.
- the manufacturing apparatus includes first to third rolls R1 to R3.
- the first and second rolls R1 and R2 in FIG. 6 mesh with each other and shape the nonwoven fabric sheet 1 introduced from the introduction roll R0.
- the first roll R1 is provided with a number of shaping convex portions 51.
- many recesses 52 are provided in the second roll R2.
- the convex portion 51 and the concave portion 52 mesh with each other to form the convex portion 21 on the nonwoven fabric sheet 1.
- a manifold 54 for adsorbing the nonwoven fabric sheet 1 communicates with the recess 52 of the second roll R2 in FIG. 7A.
- the non-woven fabric sheet 1 shaped in the recess 52 is adsorbed to retain the convex portion 21.
- the first and / or second rolls R1, R2 in FIG. 7A may have a first heater (not shown).
- the first heater may be a heater and / or a warm air heater built in the first and / or second rolls R1 and R2.
- the heater heats the first and / or second rolls R ⁇ b> 1 and R ⁇ b> 2 to a temperature range lower than the melting point of the fibers 11 forming the nonwoven fabric sheet 1.
- the second and third rolls R2 and R3 in FIG. 7B are in contact with each other via the shaped nonwoven fabric sheet 1.
- the second roll R ⁇ b> 2 has a large number of fusion protrusions 55 between the recesses 52.
- the convex portion 55 sandwiches the nonwoven fabric sheet 1 with the surface 53 of the third roll R3.
- the third roll (heating device) R3 is heated to a temperature range higher than the softening point or melting point of the fiber 11 by a heater (not shown). Accordingly, the temperature of the third roll R3 is higher than the temperatures of the first and second rolls R1, R2.
- a single-layer nonwoven fabric sheet 1 that is easier to extend in the width direction D than the longitudinal direction F in FIG. 8A is conveyed in the longitudinal direction F by the rolls R0 to R3 in FIG.
- the convex part 21 is shaped to the said nonwoven fabric sheet 1 currently conveyed by 1st and 2nd roll R1, R2 of the said FIG. 7A.
- the protrusions 21 are formed in a plurality of rows in the first direction D and the second direction F, respectively.
- the shaping step is introduced between the first roll R1 and the second roll R2 by engaging the convex portion 51 of the first roll R1 and the recess 52 of the second roll R2.
- the formed nonwoven fabric sheet 1 is shaped.
- the first and / or second rolls R1 and R2 are preferably heated in a temperature range lower than the melting point of the fibers 11 forming the nonwoven fabric sheet 1.
- a part of the shaped nonwoven fabric sheet 1 is formed between the fusion convex portion 55 of the second roll R2 and the surface 53 of the third roll R3.
- a fused portion 22 (FIG. 8C) is formed on the nonwoven fabric sheet 1 of FIG. 8B, and a fusion process is performed in which the shaped sheet 2 of FIG. 8C is obtained. That is, a fusion in which the fibers 11 constituting the nonwoven fabric sheet 1 are fused to each other (for example, FIG. 1) or all (FIG. 4) around each convex portion 21 in the single-layer shaped sheet 2.
- a landing portion 22 is formed.
- the thickness of the fusion part 22 is smaller than the thickness of the convex part 21.
- the third roll R3 may be heated to a temperature range higher than the softening point of the thermoplastic resin constituting the fiber 11 and about the melting point.
- the present invention can be used for various shaped sheets such as paper napkins in addition to the top sheet of disposable wearing articles.
- Nonwoven fabric sheet 11 Fiber 2: Shaped sheet 20: Concave surface 21: Convex part 22: Fusion part 23: Center part D: First direction (width direction) F: Second direction (longitudinal direction) V: Normal Direction R1, R2, R3: first to third rolls
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- Animal Behavior & Ethology (AREA)
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- Heart & Thoracic Surgery (AREA)
- Epidemiology (AREA)
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Abstract
Description
また、かかる2層の賦形シートは例えば使い捨てオムツや生理用品などの着用物品が嵩高くなる要因となる。
前記賦形シート2は前記第2方向Fに比べ前記第1方向Dに伸長し易く、
前記賦形シート2は単層の不織布シート1で形成され、
前記賦形シート2における前記各凸部21の周囲の一部または全部において、前記第1方向Dに断続的または連続的に延び、融着構造により前記凸部21に比べ厚さの薄い融着部22が設けられている。
長手方向よりも幅方向に伸長し易い単層の不織布シート1を前記長手方向に搬送する工程と、
前記搬送中の不織布シート1に前記複数列の凸部21を賦形する賦形工程と、
前記単層の不織布シート1又は賦形シート2における前記各凸部21の周囲の一部または全部に前記単層の不織布シート1を構成する繊維11同士が互いに融着された融着部22を形成する融着工程とを備える。
図2Aの各凸部および図3の各凹部について、それぞれ、左斜め上から光が当たっているように影付けされている。
単層の不織布シート1の繊維11同士が互いに融着されているとは、融着部22が他の不織布に本質的に融着されてないことを意味する。また、これは2重に折り畳んだ不織布シート1の2重の部分を互いに融着されたものでないことを意味する。
厚さの測定方法としては、JIS L1913に準じた方法で測定してもよいが、一般に、デジタルカメラやマイクロスコープなどで賦形シートの切断面を拡大して融着部の厚さと凸部の厚さとの違いを容易に確認できるだろう。
前記中央部は隣り合う凸部同士が互いに接近しており、そのため、最も伸び易い部位になり易い。これに対し、前記融着部が当該中央部を含み、かつ、前記第1方向に延びていることで、賦形シート2が前記第1方向に伸長しにくくなる。
繊維密度とは、賦形シートの単位体積当たりの繊維の質量のことである。繊維密度が高いとは、シートの単位体積当たりに存在する繊維の量が多いことを意味する。繊維密度が低いとは、シートの単位体積当たりに存在する繊維の量が少ないことを意味する。
繊維密度の測定方法としては、シートの切断面を、走査電子顕微鏡を用いて拡大観察し、一定面積当たり(0.5mm2程度)の前記切断面によって切断されている繊維の断面数を数えてもよい。
かかる融着部22は凸部21に比べ硬く剛性が大きい。そのため、融着部22は凸部の周囲において賦形シート2が伸長し易い第1方向の伸長を阻害するであろう。
なお、融着部22が透明に近い程度までフィルム化した賦形シートでは、融着部22に繊維の存在を明確に確認できず、融着部22の繊維密度が凸部21のそれよりも小さくなる場合があるかもしれない。
伸び率の測定方法としては、JIS L1913に準じた方法で測定してもよい。賦形シートを前記第1方向Dに低速度で引っ張った場合、凸部21が伸び、融着部22が殆ど伸びないことをマイクロスコープなどで観察することができるかもしれない。また、その場合、凸部21と融着部22との境界が破断することがあるだろう。
かかる融着部22は凸部21に比べ硬く剛性が大きい。そのため、融着部22は凸部の周囲において賦形シート2が伸長し易い第1方向Dの賦形シート2の伸長を阻害するであろう。
したがって、「賦形シート2が前記第2方向Fよりも前記第1方向Dに伸長し易い」とは、たとえば、多数の前記凸部21および前記融着部22を含む大きさの賦形シート2において、当該賦形シート2全体を前記第1方向Dに引っ張った場合と前記第2方向Fに引っ張った場合とを比べると、前記賦形シート2は前記第2方向Fに比べ前記第1方向Dに伸長し易いことを意味する。
すなわち、「賦形シート2が前記第2方向Fよりも前記第1方向Dに伸長し易い」か否かを測定する方法としては、前記JIS L1913に準じた方法で測定してもよい。
前記賦形工程において前記第1および/または第2ロールR1,R2が前記不織布シート1を形成する前記繊維11の融点よりも低い温度の範囲に加熱され、
前記融着工程は第2ロールR2に加熱装置R3が前記不織布シート1の前記融着部22を介して接することで実行される。
この場合、不織布シート1に凸部21が賦形され易くなると共に、融着部22において賦形シートに貫通孔が生じるのを抑制し得る。
なお、加熱装置は加熱ロールを採用するのが好ましいが、超音波加熱装置を採用することも可能である。
なお、前記不織布シート1の全幅にわたって多数の凸部21が形成されていてもよいし、あるいは、図9Aに示すように、前記不織布シート1の側縁部については加工せずに凸部が形成されていない元の不織布のままであってもよい。
また、図2Bおよび図2Cに示すように、構成繊維の繊維密度に関し、前記融着部22の方が前記凸部21よりも高くてもよい。更に、前記第1方向Dに前記賦形シートを引っ張った際の伸び率に関し、前記融着部22の方が前記凸部21よりも小さくてもよい。
透明度の測定方法としては、ヘーズメータなどを用いて測定することができる。具体的には、試験片を切り出し、JIS K 7136(プラスチック―透明材料のヘーズの求め方)を参考に測定することができる。
前記不織布シート1としては、エアスルー不織布(サーマルボンド不織布)や水流交絡ウォータパンチ不織布により形成された不織布が用いられてもよい。これらの不織布を形成する繊維11同士が互いに融着されて、前記融着部22の融着構造が形成される。
よりも小さいと、単層の不織布シート1では凸部21の保形が難しくなるであろう。一方、坪量が50g/m2よりも大きいと、単層の不織布シート1であっても、コストアップや風合いが低下する要因となる。より好ましくは前記坪量は30~40g/m2程度である。
凸部の大きさは特に限定されないが、たとえばオムツのトップシートとして用いられる場合、一般的には6mm2~30mm2程度に設定される場合が多く、凸部の高さは1mm~5mm程度が一般的であろう。
図6に示すように、製造装置は、第1~第3ロールR1~R3を備える。
2:賦形シート 20:凹面 21:凸部
22:融着部 23:中央部
D:第1方向(幅方向) F:第2方向(長手方向) V:法線方向
R1,R2,R3:第1~第3ロール
Claims (8)
- 第1方向Dおよび前記第1方向Dに交差する第2方向Fに各々複数列の凸部21が不織布シート1に形成された賦形シート2であって、
前記賦形シート2は前記第2方向Fに比べ前記第1方向Dに伸長し易く、
前記賦形シート2は単層の不織布シート1で形成され、
前記賦形シート2における前記各凸部21の周囲の一部または全部において、前記第1方向Dに断続的または連続的に延び、融着構造により前記凸部21に比べ厚さの薄い融着部22が設けられている、賦形シート。 - 請求項1において、前記融着部22は前記単層の不織布シート1を構成する繊維11同士が互いに融着された前記融着構造により形成されている、賦形シート。
- 請求項2において、前記融着部22は賦形シート2の第1方向Dの伸長を抑制する前記融着構造により形成されている、賦形シート。
- 請求項1において、前記融着部22は前記第1方向Dにおける互いに隣り合う凸部21同士の間の中央部23を含み、前記融着部22は前記中央部23から少なくとも前記第1方向Dの一方に延びる、賦形シート。
- 請求項1において、構成繊維の繊維密度に関し、前記融着部22の方が前記凸部21よりも高い、賦形シート。
- 請求項1において、前記第1方向Dに前記賦形シートを引っ張った際の伸び率に関し、前記融着部22の方が前記凸部21よりも小さい、賦形シート。
- 第1方向Dおよび前記第1方向Dに交差する第2方向Fに各々複数列の凸部21が不織布シート1に形成された賦形シート2の製造方法であって、
長手方向よりも幅方向に伸長し易い単層の不織布シート1を前記長手方向に搬送する工程と、
前記搬送中の不織布シート1に前記複数列の凸部21を賦形する賦形工程と、
前記単層の不織布シート1又は賦形シート2における前記各凸部21の周囲の一部または全部に前記単層の不織布シート1を構成する繊維11同士が互いに融着された融着部22を形成する融着工程とを備える、製造方法。 - 請求項7において、前記賦形工程は第1ロールR1と第2ロールR2とが噛み合うことで前記不織布シート1の賦形が実行され、
前記賦形工程において前記第1および/または第2ロールR1,R2が前記不織布シート1を形成する前記繊維11の融点よりも低い温度の範囲に加熱され、
前記融着工程は第2ロールR2に加熱装置R3が前記不織布シート1の前記融着部22を介して接することで実行される、製造方法。
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