WO2018230013A1

WO2018230013A1 - Absorber complex

Info

Publication number: WO2018230013A1
Application number: PCT/JP2017/044620
Authority: WO
Inventors: 神野　文夫; 暁師徐
Original assignee: 王子ホールディングス株式会社
Priority date: 2017-06-14
Filing date: 2017-12-12
Publication date: 2018-12-20
Also published as: CN110770381A

Abstract

Provided is an absorber complex including an absorber (13) and one or a plurality of sheets (12, 13B, 14) provided in a position covering at least part of the absorber (13), wherein the absorber complex has depressions (21) that are formed by compression molding and are recessed toward the side of the absorber (13) from the sheet side (12, 13B, 14), and at least one of the sheets (12, 13N, 14) forming the depressions (21) is configured such that a region including the depressions is constituted by a crimped nonwoven fabric.

Description

Absorber complex

The present invention relates to an absorbent composite, and more particularly to an absorbent composite that can be used for absorbent articles.

Sanitary ware, wiping composed of a substance (properly expressed as “absorbent”) having the property of taking in liquids such as body fluids, water, and moisture (expressed as “absorbent” as appropriate) Absorbent articles such as sheets, humidity control sheets, hygroscopic materials, and joinery are known.

As an element of an absorbent article, an absorber complex including an absorber and a sheet that covers at least a part of the absorber is generally known. The absorbent composite may be subjected to partial pressing treatment such as embossing for various purposes.

For example, in Patent Document 1, in a disposable diaper, an absorbent core (absorber) formed by laminating pulp fibers and an absorbent polymer (SAP) is provided as an upper layer (skin side) and a lower layer (non-skin) which are liquid permeable sheets. The structure which pinches | interposes with the core wrap of the skin side), and also this is pinched | interposed with a top sheet member and a back sheet member is disclosed. Patent Document 1 discloses a technique for embossing an absorbent body from the skin side, attaching an emboss line, and forming an absorbent body corresponding to the crotch portion into a cup shape to create a space for storing excrement. Is disclosed.

JP 2016-123836 A

When a dent from the sheet side to the absorber side is formed in the absorbent composite by embossing, the sheet is pulled toward the dent, so that the sheet may be torn. In addition, if there is a relatively hard material such as SAP particles under the sheet, the material may break through the sheet and leak in the vicinity of the portion compressed to form the dent.
Also, sanitary products (absorbent articles) such as diapers, sanitary products, armpit sweat pads, and non-woven fabrics used in the field of disposable clothing are displaced and twisted with the movement of the user during use. It may become wrinkled while being kinked. When these wrinkles are in contact with body parts such as the crotch and armpits, users of hygiene products and disposable clothing may feel uncomfortable or, in some cases, irritate the skin where they come into contact. Sometimes. Therefore, there is a demand for a non-woven fabric that does not easily wrinkle when deformed.

An object of this invention is to provide the novel absorber composite body which a sheet | seat tear does not produce easily at the time of manufacture and use.
Another object of the present invention is to provide a non-woven fabric that does not easily wrinkle even when deformed, and an absorbent article using the same.
In addition, an object of the present invention is to provide a composite fiber capable of providing a bulky nonwoven fabric having a good touch.

The absorbent body composite according to the present embodiment for solving the above problems includes an absorbent body, and an absorbent body composite including one or a plurality of sheets provided at a position covering at least a part of the absorbent body. And the said absorber composite_body | complex has the recessed part formed by pressing toward the said absorber side from the said sheet | seat side, At least 1 sheet of the said sheet | seat which makes the said recessed part contains the said recessed part. Is made of a crimped nonwoven fabric.
Moreover, the 2nd embodiment of this invention is related with the nonwoven fabric which has the following aspects.
A nonwoven fabric mainly composed of a composite fiber containing a first component and a second component that are fiber-forming components, wherein the first component and the second component are each composed mainly of a thermoplastic resin, The first component includes a long-chain branched polyolefin resin, and the nonwoven fabric has a rate of change in shear force per angle centered on a shear angle of 0 ° in the measurement of shear force by a tensile / shear measurement device. A non-woven fabric characterized by satisfying the relationship of 1 ≦ D0 / Dmax ≦ 5, where Dmax is the rate of change of shear force per angle, where the maximum shearing angle at which the maximum shearing force is obtained is taken as Dmax.
Furthermore, the third embodiment of the present invention relates to a composite fiber having the following aspects.
A composite fiber comprising a first component and a second component which are fiber-forming components, wherein the first component and the second component are each composed mainly of a thermoplastic resin, and the first component Includes a long-chain branched polyolefin resin, and the long-chain branched polyolefin resin has a melt flow rate (MFR) of 4 g / 10 min or more measured at a load of 2.16 kg and a temperature of 230 ° C. according to ASTM D1238. A composite fiber characterized by being.
Moreover, the 4th embodiment of this invention is related with the nonwoven fabric which has the following suns.
A nonwoven fabric mainly composed of a composite fiber containing a first component and a second component that are fiber-forming components, wherein the first component and the second component are each composed mainly of a thermoplastic resin, The first component includes a low crystalline polyolefin resin satisfying the following a) to g) in an amount of 80% by mass or more and 100% by mass or less based on the total solid content of the first component:
a) Mesopentad fraction [mmmm] is 30 mol% or more and 80 mol% or less,
b) The racemic pentad fraction [rrrr] and [1-mmmm] satisfy the relationship [rrrr] / [1-mmmm] ≦ 0.1;
c) the racemic meso racemic meso pentad fraction [rmrm] is greater than 2.5 mol%,
d) Mesotriad fraction [mm], racemic triad fraction [rr], and triad fraction [mr] satisfy the relationship [mm] × [rr] / [mr] ² ≦ 2.0,
e) The weight average molecular weight [Mw] is 10,000 or more and 200,000 or less,
f) The weight average molecular weight [Mw] and the number average molecular weight [Mn] satisfy the relationship of molecular weight distribution [Mw] / [Mn] ≦ 4,
g) The amount of the extract by boiling diethyl ether is 0% by mass or more and 10% by mass or less based on the total solid content of the low crystalline polyolefin resin,
The nonwoven fabric is, in the measurement of the shear force by the tensile-shear measurement device, an angle of a maximum angle of shear angle the maximum shear force can be obtained by the rate of change of the shear force per angle around the shear angle of 0 ° and D ₀ A nonwoven fabric characterized by satisfying a relationship of 1 ≦ D ₀ / Dmax ≦ 5, where Dmax is the rate of change in the shearing force per unit.

According to the above, it is possible to provide an absorbent body composite that is less likely to be broken during production and use. Furthermore, it is possible to provide a non-woven fabric that is difficult to wrinkle when subjected to shear deformation. The non-woven fabric according to the present embodiment is suitable for sanitary goods such as diapers, medical uses, other mat-like and sheet-like uses, and particularly for top sheets of absorbent articles and core wrap sheets for core wrap type absorbers. Can be used.
Moreover, since the nonwoven fabric by this Embodiment is hard to sway, especially when it is used for the sheet | seat which comprises a water absorptive article, there can exist the following effects.
(1) In the manufacture of an absorbent article containing a superabsorbent polymer (SAP), the sealing process for encapsulating the SAP can be performed in a state where the nonwoven fabric is not twisted. Thereby, sealing failure is prevented and SAP leakage from the absorbent article due to sealing failure can be prevented.
(2) In manufacture of an absorbent article, the pressing process for forming a pressing groove can be performed in the state in which the nonwoven fabric is not called. Therefore, it is possible to prevent the occurrence of a situation in which the groove cannot be formed or the shape of the formed groove is not fixed, which can be caused by squeezing the twisted portion. Thereby, it is prevented that the location which does not exhibit the effect of a groove | channel in an absorbent article comes out.
(3) In the manufacture of an absorbent article containing a superabsorbent polymer (SAP), the pressing process for forming the pressing groove can be performed in a state in which the nonwoven fabric is not twisted. Therefore, generation | occurrence | production of the sheet | seat tear by the load (tensile | tensile_strength) at the time of squeezing which can arise by squeezing the scramble part can be prevented. Thereby, SAP leakage from the absorbent article can be prevented.
(4) In the manufacture of an absorbent article containing a superabsorbent polymer (SAP), the pressing process for forming the pressing groove can be performed in a state where the nonwoven fabric is not twisted. Therefore, the manufactured absorbent article does not have a sheet portion subjected to an unexpected load that may occur in an absorbent article having a groove formed in a state in which the nonwoven fabric is twisted. Therefore, the risk of sheet tearing due to an external impact (load) is reduced, thereby preventing SAP leakage from the absorbent article.

It is a figure which shows the example of the diaper using the absorber composite_body | complex by this Embodiment. It is the figure which looked at the lower half body which wore the diaper shown in FIG. 1 from the back side. It is the stereographic projection figure which expand | deploys the diaper shown in FIG. 1, and shows in a decomposition | disassembly state. It is the top view which looked at the absorber of the diaper shown in FIG. 1 from the near side of the top sheet. FIG. 5 is a cross-sectional view of the diaper shown in FIG. 1 cut along line VV. It is a fragmentary sectional view of the diaper which shows the modification of the composition of the absorber complex by this embodiment. It is a fragmentary sectional view of the diaper which shows the modification of the composition of the absorber complex by this embodiment. It is a fragmentary sectional view of the diaper which shows the modification of the composition of the absorber complex by this embodiment. It is a cross-sectional view of the example of the composite fiber applicable to the sheet | seat of this Embodiment. It is a cross-sectional view of the example of the composite fiber applicable to the sheet | seat of this Embodiment. It is a figure which shows the example of the manufacturing apparatus which can be used for manufacture of the sheet | seat of this Embodiment. It is a figure which illustrates the shear angle-shear force curve of a nonwoven fabric. It is a table | surface which shows the constituent material of the composite fiber in an Example and a comparative example. It is a table | surface which shows the constituent material of the composite fiber in an Example and a comparative example. It is a table | surface which shows the compounding ratio of the structural material of the composite fiber in an Example and a comparative example. It is a table | surface which shows the layer structure of the nonwoven fabric in an Example and a comparative example. It is a table | surface which shows the result of the evaluation test about the nonwoven fabric of an Example and a comparative example. It is a table | surface which shows the result of the evaluation test about the diaper of an Example and a comparative example. It is a figure which illustrates the shear angle-shear force curve of a nonwoven fabric. It is a table | surface which shows the constituent material of the composite fiber in an Example and a comparative example. It is a table | surface which shows the constituent material of the composite fiber in an Example and a comparative example. It is a table | surface which shows the compounding ratio of the structural material of the composite fiber in an Example and a comparative example. It is a table | surface which shows the layer structure of the nonwoven fabric in an Example and a comparative example, spinnability, etc. It is a table | surface which shows the layer structure of the nonwoven fabric in an Example and a comparative example, spinnability, etc. It is a table | surface which shows the result of the evaluation test about an Example and a comparative example (fiber, nonwoven fabric). It is a table | surface which shows the result of the evaluation test about an Example and a comparative example (nonwoven fabric, a diaper). It is a table | surface which shows the constituent material of the composite fiber in an Example and a comparative example. It is a table | surface which shows the constituent material of the composite fiber in an Example and a comparative example. It is a table | surface which shows the compounding ratio of the structural material of the composite fiber in an Example and a comparative example. It is a table | surface which shows the structure of the nonwoven fabric in an Example and a comparative example, and the spinnability of a composite fiber. It is a table | surface which shows the structure of the nonwoven fabric in an Example and a comparative example, and the spinnability of a composite fiber. It is a table | surface which shows the result of the test about an Example and a comparative example. It is a figure which illustrates the shear angle-shear force curve of a nonwoven fabric. It is a table | surface which shows the constituent material of the composite fiber in an Example and a comparative example. It is a table | surface which shows the constituent material of the composite fiber in an Example and a comparative example. It is a table | surface which shows the compounding ratio of the structural material of the composite fiber in an Example and a comparative example. It is a table | surface which shows the result of the laminated constitution and evaluation test of the nonwoven fabric in an Example and a comparative example. It is a table | surface which shows the result of the laminated constitution and evaluation test of the nonwoven fabric in an Example and a comparative example. It is a table | surface which shows the result of the evaluation test about an Example and a comparative example (nonwoven fabric, a diaper).

Hereinafter, preferred embodiments will be described. The following embodiments are for illustrative purposes and are not limited thereto, and appropriate design changes, improvements, and the like are added based on ordinary knowledge of those skilled in the art without departing from the spirit of the present invention. It should be understood.

<Absorber complex>
In the present specification, the “absorber complex” is a complex having liquid absorbency including an absorber and a sheet covering at least a part of the absorber. The absorbent composite can itself be used as an absorbent article or as a component of an absorbent article. For example, in a diaper, a structure including only an absorber and a core wrap, and a structure obtained by adding a top sheet member and further a back sheet member to the structure are each an absorber complex. That is, the absorbent composite refers to an article including an absorbent and a sheet stacked so as to cover at least a part of the absorbent, and includes not only the final product but also an intermediate.

<Absorbent article>
In the present specification, the “absorbent article” refers to an article having a property (absorbability) for taking in body fluids such as urine, blood, sweat, and breast milk, and liquids such as water and moisture. Examples of absorbent articles include diapers, sanitary products, sweat-absorbing sheets (for face, side, neck, feet, etc.), breast pads, anti-condensation sheets, humidity control sheets, hygroscopic materials, for illustrative purposes and not for limited purposes. Articles such as wiping sheets, joinery, wallpaper, cushions, bedding are included. The absorbent body composite according to the present embodiment can be preferably used particularly for diapers for infants, diapers for adults, urine leak pads, diapers for pets, pet toilet mats and the like. Accordingly, the absorbent article is an absorbent composite (final product), and also includes an absorbent composite as an intermediate.

<Embodiment>
The absorbent body composite according to the present embodiment will be described using an example of a pants-type disposable diaper shown in FIG. FIG. 1 is a three-dimensional projection view showing the appearance of a pants-type disposable diaper using the absorbent composite according to the present embodiment. 2 is a three-dimensional projection of the lower body wearing the diaper shown in FIG. 1 as seen from the back side. FIG. 3 is a three-dimensional projection view showing the diaper shown in FIG. 1 in an exploded state. FIG. 4 is a top view of the diaper absorbent body shown in FIG. 1 as viewed from the front side of the top sheet. FIG. 5 is a cross-sectional view showing a central portion of the diaper shown in FIG. 1 cut along line VV.

A pants-type disposable diaper (hereinafter also simply referred to as a diaper) 10 according to the present embodiment includes a front body region 10F, a back body region 10R, and a crotch region 10C that connects the front body region 10F and the back body region 10R. . Moreover, the waist periphery opening part 10W which surrounds a wearer's waist part with the front body area | region 10F and the back body area | region 10R at the time of wear is formed. Similarly, a pair of left and right leg openings 10L that surround the thigh portions of both legs of the wearer are formed by the lower end crotch region 10C of the front body region 10F and the back body region 10R.

As shown in FIG. 2, the front body region 10F is positioned on the wearer's ventral side and the back body region 10R is positioned on the wearer's back side when worn. The crotch region 10 C covers the wearer's crotch, and the leg of the wearer is passed through the pair of left and right leg openings 10 L. Therefore, the leg periphery opening 10L is located at any position around the thigh from the base of the wearer's legs.

In the rear body region 10R of the diaper, a disposal tape 10T is provided to be rolled up and stopped when the diaper is discarded.

The imaginary line P extends through the crotch part from the abdominal side to the back side in the central part of the diaper. Specifically, the imaginary line P extends, for example, along the diaper surface and in the vertical direction when the waist side of the diaper is up and the crotch side is down. It extends in the vertical direction. In other words, the vertical direction is a direction along the center axis of the body from the wearer's head to the crotch, and the virtual line P extends along the center axis of the body.

As shown in FIGS. 3 to 5, the diaper 10 using the absorbent body composite according to the present embodiment touches the cover sheet 11, the back sheet 12, the absorbent body 13, and the wearer's skin in order from the outside. The top sheet 14 is laminated and joined in order. The left and right side edges of the cover sheet 11 that define the front body region 10F and the back body region 10R of the diaper 10 together with the crotch region 10C are joined together to form a closing portion 10J. As a result, a waist opening 10W and a pair of left and right leg openings 10L surrounding the thighs of both legs are defined, and the leg openings 10L are respectively provided on the left and right sides of the crotch region 10C of the cover sheet 11. A pair of cutout portions 11A having a semicircular arc shape is formed. The liquid-impermeable back sheet 12 is joined to the inner cover sheet 11 B, and the absorber 13 is disposed between the back sheet 12 and the liquid-permeable top sheet 14, and the top sheet 14 is interposed via the absorber 13. Is bonded to the backsheet 12. Between the outer cover sheet 11C and the inner cover sheet 11B, which are formed of a thin non-woven fabric in order to obtain a good touch, the rubber thread 15 for forming the leg gathers and the waist gathers are formed. The rubber thread 17 is joined in an extended state.

<Absorber>
In the present specification, the “absorber” includes, for example, a body fluid such as urine, blood, sweat, and breast milk, and a material having a property (absorbability) for taking in water, moisture, and the like. Say what you indicate. As an example of an absorptive material, a pulp, rayon, a superabsorbent polymer, etc. are mentioned, for example.

As the absorber 13 of the present embodiment, any absorber known in the field of absorbent articles can be used. A combination of cotton-like pulp and a superabsorbent polymer can be preferably used.

<Cotton pulp>
As the cotton-like pulp, for example, a fiber sheet having a fiber length of 5 mm or less can be suitably used by defibrating a pulp sheet with a pulverizer. The pulp sheet used at this time may be a chemical pulp sheet or a mechanical pulp sheet, and the pulp raw material is not particularly limited as long as it is used as a normal pulp raw material, such as softwood, hardwood, straw, bamboo, kenaf, waste paper, etc. Can be used. The use amount of the cotton-like pulp varies depending on the application and the structure of the absorbent body, but generally the basis weight is 50 to 400 g / m ² .

<Superabsorbent polymer>
As a super absorbent polymer (hereinafter also referred to as SAP), starch-based, cellulose-based, and synthetic resin-based SAPs are known, and any one of these may be used alone or in combination. It may also be used by containing other substances. Specifically, starch-acrylic acid (salt) graft copolymer, saponified starch-ethyl acrylate graft copolymer, saponified starch-methyl methacrylate graft copolymer, starch-acrylonitrile graft copolymer Saponified product of starch, acrylamide saponified copolymer, polyacrylic acid (salt), polyethylene oxide cross-linked with acrylic acid, cross-linked product of sodium carboxymethyl cellulose, cross-linked product of polyvinyl alcohol-maleic anhydride reaction product, etc. Can be used. Among them, sodium polyacrylate having a high absorption performance capable of absorbing water 20 times or more of its own weight is preferably used.

There is no limitation on the shape of the SAP, and particles, fibers, sheets, and the like can be used. When used for absorbent articles such as sanitary products that touch the user's skin, it is preferable that the user does not feel the presence or shape of the SAP, and particulate SAP can be preferably used. The particle size of the particulate SAP is, for example, 1000 μm or less, and preferably, for example, 400 μm or less. Moreover, since it will be easy to leak from an absorber when a particle size is too small, it is preferable that the particle size of SAP is 150 micrometers or more, for example.

<Configuration of absorber>
In the absorber 13 of the present embodiment, the absorbent material is usually used in a single-layer or multi-layer mat shape. As for an absorptive material, 1 type may be used independently and 2 or more types may be used together.

Of these, a combination of cotton-like pulp and particulate SAP is preferable. The SAP may be uniformly mixed in a cotton-like pulp mat, or may be arranged in layers between layers of a multi-layered cotton-like pulp.

The amount of SAP is preferably 10 to 500 parts by mass, and more preferably 15 to 300 parts by mass with respect to 100 parts by mass of the dried cotton-like pulp. By setting such an amount, mutual interference between SAP particles is stopped. For this reason, SAP particles that have absorbed and gelled liquid rarely form a permeation barrier against the liquid to be absorbed, and urine and body fluid can permeate in the absorbent body in a three-dimensional direction and be absorbed.

Generally, when the amount of liquid to be absorbed in the absorber is large, a phenomenon that the liquid that could not be absorbed leaks (so-called liquid leakage) may occur. By mix | blending SAP with the absorber 13, the liquid absorbable amount can be increased, without increasing the pulp amount. Therefore, it is possible to realize an absorbent body having a good absorbability that is less likely to cause liquid leakage while being thin.

As the absorbent body 13 of the present embodiment, an absorbent material in which an absorbent material is held by a hydrophilic sheet can be used. For example, a hydrophilic sheet provided with a hydrophilic layer on the surface of an absorbent material such as a SAP sheet provided on one side and a SAP sheet sandwiched between two hydrophilic sheets can do. In particular, the so-called “core wrap type absorber”, in which the water-absorbing material is the core and the whole is wrapped with the core wrap of a hydrophilic sheet like tissue, prevents the water-absorbing material that is the core from being exposed or leaked. ,preferable.

Examples of the hydrophilic sheet include tissue, absorbent paper, and non-woven fabric subjected to hydrophilic treatment. Those having a basis weight in the range of 5 to 40 g / m ² , and particularly those having a basis weight in the range of 10 to 30 g / m ² can be preferably used. It is preferable to use a crimped nonwoven fabric as the hydrophilic sheet. According to this, when an absorber receives external force, such as squeezing, a hydrophilic sheet | seat is torn and possibility that absorbent materials, such as SAP currently hold | maintained, will be exposed or leaked will be reduced. Moreover, if a crimped nonwoven fabric is used, it becomes bulky and can improve cushioning properties, and it is possible to reduce the problem of skin irritation caused by contact with a hard part that is comfortable to the touch / skin. Details of the crimped nonwoven fabric will be described later.

<Shape and size of absorber>
Any size and shape of the absorber can be used depending on the application. For example, the absorber may have an hourglass shape in a plan view, and may be a rectangle, an ellipse, a semicircle, or the like. The hourglass shape is preferable because it easily fits the user's body when the absorbent body is applied to a sanitary product.

<Top sheet>
The top sheet generally refers to a sheet constituting a surface intended to absorb a liquid that is an object to be absorbed (hereinafter also referred to as a “liquid absorbing surface”). In particular, when the absorbent composite is used in a sanitary product, the top sheet is a sheet that constitutes a surface (hereinafter also referred to as a skin contact surface) that faces the user and can contact the user's skin. Say. That is, the skin contact surface is a kind of liquid absorption surface. The top sheet is preferably a sheet having liquid permeability.

According to the configuration in which the top sheet 14 having liquid permeability covers the absorber 13, the liquid that is the object of absorption can be guided to the absorber through the top sheet while diffusing in the surface direction of the top sheet. it can. As a result, effects such as shortening the absorption time and increasing the amount of absorption by the absorber can be obtained.

As the top sheet, a sheet having liquid permeability and a bulky shape formed by hot air through (hot air ventilation method) processing is preferably used. As a sheet that realizes this performance, for example, a porous or non-porous nonwoven fabric can be used.

The material of the nonwoven fabric is not particularly limited. For example, synthetic fibers such as olefins such as polyethylene and polypropylene, polyesters and polyamides, recycled fibers such as rayon and cupra, natural fibers such as cotton, etc., mixed fibers in which two or more of these are used, A composite fiber etc. can be illustrated. In particular, a nonwoven fabric composed of long fibers is preferable, and the top sheet according to the present embodiment is preferably crimped.

The top sheet may be a single sheet or a laminated sheet obtained by bonding two or more sheets. Similarly, the top sheet may be composed of one sheet or two or more sheets with respect to the planar direction. When the top sheet is composed of a plurality of sheets, it is preferable that at least one of them is a crimped nonwoven fabric.

In addition, the thickness (mm) when a pressure of 0.5 g / cm ² is applied to the nonwoven fabric to be measured by a 2 cm ² circular pressure plate using an automated compression tester “KES FB-3A” manufactured by Kato Tech Co., Ltd. Is called the initial thickness (TO), and the initial thickness of the top sheet 14 in this example is preferably in the range of 0.1 to 2 mm.

<Back sheet>
The back sheet 12 generally refers to a sheet that forms a surface different from the liquid absorption surface, particularly a surface opposite to the liquid absorption surface (hereinafter also referred to as “non-liquid absorption surface”) with respect to the absorber. . The back sheet is preferably a sheet having liquid impermeability. According to the liquid-impermeable back sheet, the liquid absorbed by the absorber from the liquid absorption surface is difficult to penetrate through the non-liquid absorption surface side. The backsheet as the absorbent composite is preferably a crimped nonwoven fabric as will be described later. In particular, when a pressing groove is provided from the back sheet side, a crimped nonwoven fabric is also preferably used for the back sheet. When the back sheet has a multi-layer structure, at least one layer is preferably a crimped nonwoven fabric. Application of the crimped nonwoven fabric to the absorbent composite will be described later.

<Reverse prevention sheet>
In addition, between the top sheet and the absorbent body, an anti-return sheet (not shown) can be provided to prevent the liquid taken in from the top sheet from returning. The anti-reverse sheet is preferably a sheet having a liquid permeation rate higher than that of the top sheet. According to this, the liquid absorbed from the top sheet side can be promptly transferred to the absorbent body to improve the absorption performance. The anti-reverse sheet may be called an intermediate sheet or a second sheet.

<Back-through prevention sheet>
Moreover, a back-through prevention sheet (not shown) for preventing the back-through of the liquid can be provided between the absorber and the back sheet.

Crimped non-woven fabric can also be used for the back-through prevention sheet and the back-turn prevention sheet. These will also be described later.

FIG. 4 is a top view of the absorber 13 as seen from the front side of the top sheet 14, and FIG. 5 is a cross-sectional view taken along line VV of FIG.

In the absorber composite according to the present embodiment, at least a part of the absorber is covered with a sheet. The sheet only needs to be positioned so that the sheet covers at least a part of the absorber when the sheet and the absorber are viewed from the front side of the sheet. For example, in the plan view, as in the example of FIG. The sheet area may be larger than the absorber area. Moreover, the sheet | seat and the absorber do not necessarily need to contact directly. The sheet may cover the entirety of the absorber, i.e., it may wrap around the absorber. When the absorbent body has a shape having a relatively large area front and back surfaces and side surfaces surrounding the front and back surfaces, such as a sheet shape, a flat plate shape, or a mat shape, the sheet is formed on the front and back surfaces of the absorber. It is preferable to arrange on at least one surface. At this time, the sheet may entirely cover or partially cover at least one surface. The sheet | seat may be arrange | positioned at both the front and back of an absorber, and may be arrange | positioned further at the side surface. One sheet may be arranged, or a plurality of sheets may be laminated. When laminated, the plurality of sheets may or may not be bonded to each other. The sheet may be composed of a single sheet or a plurality of sheets in the planar direction. In the case of a plurality of sheets, the plurality of sheets may or may not be joined to each other.

As shown in FIGS. 4 and 5, the top sheet 14 covers the entire top surface of the absorbent body 13, and both are integrated by a hot melt adhesive to form the absorbent body composite of the present embodiment. is doing. The top sheet 14 and the absorber 13 are provided with a groove-like recess 21 (hereinafter also referred to as a groove 21 or a recess 21) that extends in an oblique lattice shape. As FIG. 5 shows, the groove | channel 21 is dented toward the absorber 13 side from the top sheet 14 side. The groove 21 functions as a passage for guiding urine, functions to reduce the humidity in the diaper by circulating air inside and outside the diaper, and when the absorber 13 absorbs urine, the wearer side (cross-sectional view of FIG. 5) In the above, a function of relaxing the pressure on the wearer by inflating only on the upper side in the vertical direction defined by the direction of the written code is provided.

As shown in FIG. 4, the groove 21 is inclined in one specific direction with respect to an imaginary line P that is assumed to extend along the central axis of the body of the diaper wearer on the upper surface of the top sheet 14. The plurality of first grooves 21a extending in the direction and the plurality of second grooves 21b extending in a direction different from the first groove 21a. That is, with the imaginary line P as an axis, the first groove 21a is inclined at an angle α on one side, and the second groove 21b is inclined at an angle β on the other side. The angle α and the angle β may be the same or different.

In FIG. 4, the plurality of first grooves 21a are inclined at the same angle, and are arranged at regular intervals. That is, although each 1st groove | channel 21a is arrange | positioned in parallel and fixed space | interval, this Embodiment is not restricted to this, The thing where the space | interval of a groove | channel is not constant and the inclination angle of each groove | channel differs. The same applies to the second groove 21b.

In FIG. 4, a plurality of first grooves 21 a and second grooves 21 b are formed, but this embodiment is not limited to this, and one groove extending in an oblique direction is formed on each side. It may be what you have. Although it is preferable that the two intersect, this embodiment is not limited to this, and includes those in which the two do not intersect directly and the extending directions of the grooves intersect. Furthermore, a configuration in which all the grooves are oriented in the same direction (parallel) such as 21a and 21b may be employed, or a configuration having only one groove (only one) may be employed. Of course, it may be a groove provided with a curved portion, and may be constituted by two or more kinds of grooves. These groove patterns can be appropriately designed in consideration of performance for guiding urine from the urination position, air permeability, and contact properties with the skin (per skin / feel, etc.).

The groove 21 is a member in which a predetermined groove pattern is formed from the upper surface of the top sheet 14, and is formed by pressing the top sheet 14 and the absorber 13 together from the top sheet 14 side. That is, in this embodiment, as shown in FIG. 5, the absorber 13 has a recess formed on the top sheet 14 side and no recess formed on the back sheet 12 side. The width and depth of each groove 21 may be uniform, or may vary depending on the distance between adjacent grooves, the position of the groove, and the like. Further, the side wall of the groove 21 may extend substantially perpendicularly from the absorber surface as shown in FIG. 5, or may have a V-shape inclined obliquely as shown in FIG.

By the squeezing for forming the groove 21, the groove 21 portion of the absorbent body 13 is compressed as compared with other portions, and the density of the absorbent body 13 is increased. The porosity of the pressed portion is, for example, 20% or less, preferably 5% or less. Moreover, the absorber density of the squeezed part is set to be twice or more as compared with the non-squeezed part. The absorber density is mainly the density of the pulp.

In the present embodiment, if the direction opposite to the direction indicated by the phantom line P is the width direction, the absorber 13 has a groove forming region N1 at the center in the width direction, and groove non-forming regions N2 on both sides thereof. have. In FIG. 4, both end portions in the width direction of the absorber 13 are groove non-formation regions N2, and the groove formation region N1 extends in a band shape from one end in the direction indicated by the phantom line P toward the other end in the center. . As described above, the groove 21 portion of the absorbent body 13 is formed by pressing the absorbent body 13. Therefore, in the groove 21 portion, the absorber 13 is compressed and harder than the other portions of the absorber 13. By not providing the grooves 21 at both ends in the width direction of the absorbent body where the inner crotch of the leg contacts, the texture is improved and the wearing feeling is improved. However, it goes without saying that the groove 21 may also be provided at the end in the width direction depending on the position and size of the absorber. That is, it can be appropriately modified to a configuration in which the groove non-forming region N2 is not provided, or a configuration in which the groove non-forming region is provided in the central portion in the width direction of the diaper (left-right direction in FIG. 4).

By the way, people walk with their legs alternately forward and left. As for high and high, the movement of the base of the crotch is the same as when walking, and it is put forward alternately. Since the diaper in the vicinity of the leg that is put forward is pulled in the forward direction, the crotch portion of the diaper is pulled in an oblique direction. That is, when the right foot comes forward, the diaper is pulled in an oblique direction from the lower left of the crotch to the upper right. On the other hand, when the left foot comes forward, the diaper is pulled in an oblique direction from the lower right of the crotch to the upper left. The diaper of the present embodiment has rigidity against the tensile force in the oblique direction due to walking because the oblique groove 21 is formed in the absorber 13. Since the crotch portion M2 of the absorbent body 13, that is, the large and slanted groove 21 extends in the center portion, the first groove 21a and the second groove 21b alternate with respect to the pulling force due to the back and forth movement of both feet. Exhibits rigidity and prevents the absorber 13 from being twisted or deformed.

The deformation prevention part 22 is difficult to deform because the outer periphery of the absorber in the restriction part 22 is pressed by the groove 21. Therefore, even if a tensile force is generated in the oblique direction, the absorber 13 is more difficult to be wrinkled obliquely due to the rigidity of the groove 21 and the deformation preventing portion 22 is difficult to deform. As a result, deformation in the oblique direction is suppressed. Will be. Therefore, the absorber 13 is not greatly deformed and deformed by the longitudinal movement of the legs. Since the absorbent body 13 does not move, the fit between the crotch can be maintained, and body fluid leakage hardly occurs. Moreover, since it can also suppress that the absorber 13 cuts by deformation | transformation, absorption performance can be maintained.

In order to suppress the deformation of the absorber 13 due to the movement of the legs, a preferable arrangement of the grooves 21 is as follows. That is, the inclination angle of the groove 21 with respect to the longitudinal direction is 10 degrees or more and less than 80 degrees, and preferably 45 degrees or more and 60 degrees or less. And it is better for the groove | channel 21 to incline symmetrically. Moreover, the groove | channel inclined in the same direction, ie, the space | interval of the some 1st groove | channel 21a, and the space | interval of the some 2nd groove | channel 21b are 10 mm or more and less than 100 mm, and 10 mm or more and 30 mm or less are especially preferable.

In the present embodiment, the groove forming region N1 extends from the front body portion M1 to the back body portion M3 of the absorber 13, but the present invention is not limited to this. That is, the groove forming region N1 may be formed only in the crotch portion M2. Moreover, even if it is formed in the front body part M1 and the back body part M3, a longitudinal direction edge part may not be formed. Since the portion close to the waist portion is brought into close contact with the skin by waist gathers, the feeling of wearing is improved by preventing the hard portion of the groove 21 from contacting the skin.

The liquid-impermeable side sheets 18 are joined to the left and right side edges of the liquid-permeable top sheet 14 in the present embodiment, and three-dimensional gathers are formed at the inner edge of the left and right side sheets 18. The rubber thread 19 is joined in an extended state.

(Modification)
6 and 7 show another configuration example of the absorber complex according to the present embodiment.

As shown in FIG. 6, in this example, the upper and lower surfaces of the absorber 13 are covered with a sheet 13B (core wrap sheet). In this example, the sheet 13 B that covers the upper and lower surfaces is connected at a place not shown. That is, in this example, the sheet 13B wraps around the absorber 13, and forms a single core wrap type absorber by taking the relationship between the so-called core wrap sheet and the absorber core. However, the present embodiment is not limited to this, and the upper and lower surfaces 13B may be separate sheets. Further, the sheet 13B may cover only a part of the absorber 13, and in this case, the sheet 13B is configured to cover at least one groove portion 21. As for the some sheet | seat which covers the groove part 21, at least 1 is comprised with a crimped nonwoven fabric. “Constituted of crimped nonwoven fabric” includes not only the configuration of the crimped nonwoven fabric in the region but also the configuration in which one of the regions is a crimped nonwoven fabric in a multi-layer structure, for example. The absorber 13 and the sheet 13B are integrally joined. The sheet 13B on the surface (upper surface) of the absorbent body 13 on the top sheet 14 side, together with the absorbent body 13, forms a recess 21 that is recessed from the upper surface sheet 13B side toward the absorbent body 13 side. Thus, in the example of the present embodiment shown in FIG. 6, the absorber 13 and the sheet 13 B covering it constitute an absorber complex. This absorbent body composite is disposed between the top sheet 14 and the back sheet 12 and joined thereto, and can be used for a diaper.

In the example shown in FIG. 7, the surface (upper surface) on the top sheet 14 side of the sheet 13 B of the core wrap type absorber described in FIG. 6 is covered with the top sheet 14, and the top sheet 14 and the top of the absorber 13 are covered. A sheet 13 B on the sheet 14 side surface (upper surface, that is, a liquid absorption surface), together with the absorber 13, forms a recess 21 that is recessed from the top sheet 14 side toward the absorber 13 side. In this example, the absorbent body 13 and the sheet 13B and the top sheet 14 covering the absorbent body 13 constitute an absorbent body composite. This absorber complex can be used alone, or can be arranged on the back sheet 12 and joined to a diaper or the like.

Alternatively, one in which the top sheet 14, the sheet 13B, and the absorber 13 are joined together with the back sheet 12 can also be used as the absorber composite according to the present embodiment.

An example of the layer configuration that the absorbent composite according to this embodiment can take is shown below for illustrative purposes and not for limitation purposes.
(1) Top sheet / absorber (2) Absorber / back sheet (3) Top sheet / absorber / back sheet (4) Top sheet / reverse prevention sheet / absorber (5) Absorber / back-through prevention sheet / Back sheet (6) Top sheet / Reverse prevention sheet / Absorber / Back sheet (7) Top sheet / Absorber / Back-through prevention sheet / Back sheet (8) Top sheet / Reverse prevention sheet / Absorber / Back-through prevention sheet / Back sheet (9) Core wrap type absorber The "absorber" in the above layer configuration example is an absorbent core (hereinafter also referred to as "absorber core") and a sheet (hereinafter referred to as "core wrap sheet"). Or a so-called “core wrap type absorber”. In the case of the core wrap type absorbent body, since it itself includes the absorbent body and a sheet (core wrap sheet) covering at least a part, the configuration not including other sheets as shown in (9) It is an absorber complex according to the present embodiment.

Moreover, the structure which provided the cover sheet in the outermost layer of the surface (non-liquid absorption surface) on the opposite side to a liquid absorption surface with respect to an absorber with respect to the structure of (1) to (9) also depends on this embodiment. It can be an absorber complex.

<Recess>
The absorbent body composite according to the present embodiment has a concave portion 21 that is recessed from the sheet side (including the core wrap sheet) toward the absorbent core side. This concave portion is formed from the sheet side with respect to the absorbent composite. It is the pressing recessed part provided by the pressing of. The recess can be provided by any pressing means known in the field of absorbent articles, such as an embossing method and an embossing device. Specifically, for example, by rotating an embossing roll having an uneven surface on the sheet side and rotating while applying pressure to a laminate including an absorbent body and a sheet constituting the absorbent composite, And the absorber can be squeezed together to form a recess on the sheet side.

The shape of the recess is not limited, and the recess may be, for example, a dot formed by an emboss pattern such as a dot, a line formed by connecting dots, or a groove. May be. The point may be a circle (including a true circle or an ellipse), a polygon (such as a triangle or a quadrangle), or a character type.

In the above configuration example, the concave portion is provided on the liquid absorption surface (skin contact surface) side, but the concave portion may be provided on the non-liquid absorption surface side depending on the purpose and effect. For example, there may be a purpose such as aesthetic appearance such as designability or imparting rigidity by improving density.

In the absorbent body composite according to the present embodiment, the sheet that forms the concave portion that is recessed from the sheet side toward the absorbent side is a sheet that is formed of a crimped nonwoven fabric.

<Crimped nonwoven fabric>
The second embodiment of the present invention relates to a nonwoven fabric. Specifically, the crimped nonwoven fabric used in the absorbent composite according to the present embodiment. In this specification, “crimped nonwoven fabric” refers to a nonwoven fabric containing crimped fibers as a constituent material.

<Crimped fiber>
In this specification, “crimped fiber” refers to a fiber having a crimped form. The “crimped form” of the crimped fiber is a form that is not straight, and refers to a crimped form such as a spiral or a crimp.
The degree of crimping of the fiber can be indicated by the number of crimps of the fiber measured in accordance with, for example, Japanese Industrial Standard JIS L1015. The number of crimps of the composite fiber of the present embodiment can be appropriately set depending on the blending ratio of the components, but is preferably 18 or more per 25 mm of fiber, more preferably 20 to 50, and the visibility and formation of the resulting nonwoven fabric In view of the above, 20 to 40 is more preferable.

In the absorbent composite, when the concave portion is provided by squeezing from the sheet side, if the sheet is pulled and cut, the sheet covering the absorber is also torn, and contents such as SAP leak out. Sometimes. In this region, when the SAP is squeezed out, the sheet may be torn by protruding to the squeezing side, and the contents may leak out. On the other hand, the absorbent body composite according to the present embodiment is such that the sheet is stretched when being squeezed so that the sheet is torn or easily broken at the time of forming a recess by squeezing. It is intended to prevent leakage of the contents.

That is, if attention is paid at the time of forming the recess, at least one or a plurality of the side where the compressed groove is provided in the portion where the compressed groove is formed and the periphery thereof (these ranges are appropriately referred to as “recess formed portion”). In particular, it is preferable that all the sheets are made of crimped nonwoven fabric. In this case, a non-crimped non-woven fabric other than the recessed portion forming portion may not be used. For example, a combination in which a crimped nonwoven fabric is used for the sheet in the recess forming portion and other than the crimpable nonwoven fabric is used for other portions is also possible. If comprised in this way, the sheet | seat cutting | disconnection problem can be prevented in a recessed part formation part, the sheet | seat excellent in the other function can be used in another area | region, and the performance of a diaper as a whole can be made high.

In addition, if the above configuration is adopted, even when a load is applied from the outside after forming the recess, at least a portion of the sheet having crimpability is stretched so that it is difficult to break, and leakage of the contents of the absorber is prevented. be able to. Therefore, it can be said that it is preferable that a portion other than the concave portion forming portion is also made of a crimped nonwoven fabric in consideration of a load other than when the compressed groove is formed.

From the viewpoint of preventing leakage of the contents, at least one sheet of the portion covering at least the recess forming portion may be a crimped nonwoven fabric as described above, but if the core wrap directly covering the absorbent core is not torn, Since leakage does not occur, it can be said that it is preferable that the recessed portion forming portion of the core wrap is more preferably made of a crimped nonwoven fabric. Since the leakage of the contents does not occur unless the outermost sheet (the top sheet in the above embodiment) where the compressed groove is provided is broken, it is preferable that the entire area of the sheet is made of a crimped nonwoven fabric.

When a groove having a groove-like intersection (as in the embodiment) as shown in the embodiment is provided as a concave portion, the absorbent body contents accumulate at the intersection at the time of pressing, so that the sheet (core wrap, top sheet, etc.) is easily torn. However, if a crimped nonwoven fabric is used for one or more (including all) sheets in a position (position in the thickness direction of the absorber) that overlaps the part, the problem of sheet tearing can be prevented very effectively. Moreover, although the absorber is compressed and hardened at the position, softness can be realized by using the crimped nonwoven fabric at this position, and the touch of the diaper can be made extremely good.

A sheet using a crimped nonwoven fabric not only has the above-described content leakage prevention function (breakage prevention function), but also becomes bulky compared to a non-crimped sheet having the same basis weight. In other words, a “fluffy” cushioning height can be realized. The portion where the compressed groove is provided has a higher density and becomes harder, the skin feel becomes worse, and a load may be applied to the skin. On the other hand, if a sheet having crimpability is used, cushioning is also provided, so that the hardness of the squeezing groove can be reduced. Paying attention to such a function, at least one sheet in the recess forming part can be not only a crimped nonwoven fabric but also a crimped nonwoven fabric over the entire region, or a plurality of sheets can be crimped nonwoven fabric. It can be said that it is preferable. From the viewpoint of touch, it is preferable that the sheet that contacts the skin (the top sheet in the above embodiment) is a crimped nonwoven fabric.

When using a crimped nonwoven fabric as the outermost surface-side sheet when providing the compressed grooves, wrinkles generated on the surface-side sheet can be prevented. For example, in the case where the compressed groove is provided from the top sheet side of the composite of the top sheet and the absorbent body, the top sheet can extend toward the groove portion, so that the generation of wrinkles on the top sheet can be reduced. Moreover, even if it uses for a sheet | seat (for example, core wrap) inside a surface side sheet | seat, generation | occurrence | production of a wrinkle can be reduced similarly, and it can suppress that a wrinkle appears on the surface side by this.

In order to solve this, the absorbent body composite according to the present embodiment can use a non-woven sheet using fibers as described below.

<Composite fiber>
The third embodiment of the present invention relates to a composite fiber. In detail, it is related with the composite fiber mentioned below used as a crimped fiber of this Embodiment.
The composite fiber includes a first component and a second component. The conjugate fiber applicable to this embodiment includes the first component in an amount of 10% by mass or more and 40% by mass or less based on the total solid content of the conjugate fiber.

(First ingredient)
The first component is mainly composed of a thermoplastic resin. In the present specification, the term “main component” means that the component is contained in an amount of 90% by mass or more. That is, the first component contains the thermoplastic resin in an amount of 90% by mass or more and 100% by mass or less based on the total solid content of the first component. Examples of the thermoplastic resin applicable to the first component include polyolefin resins such as polypropylene (PP) and polyethylene (PE). From the viewpoint of spinnability and strength of the composite fiber, polypropylene (PP) is preferably used as the thermoplastic resin.

In the present embodiment, the first component includes a long-chain branched structure polyolefin resin as one kind of thermoplastic resin. The first component contains the long-chain branched polyolefin resin in an amount of 0.5% by mass or more, more preferably 1% by mass or more based on the total solid content of the first component. The first component is a long chain branched structure polyolefin resin in an amount of 10% by mass or less, more preferably 5% by mass or less, more preferably 3% by mass or less, based on the total solid content of the first component. Including. That is, the first component includes at least two types of thermoplastic resins, that is, a long-chain branched structure polyolefin resin and a thermoplastic resin that is not a long-chain branched structure polyolefin resin. Three or more types of thermoplastic resins as the first component can be used in combination. When the long-chain branched structure polyolefin in the first component is less than 0.5% by mass, the effect of increasing the degree of crimping of the composite fiber is reduced, and when it is more than 10% by mass, the spinnability is lowered. .

In this specification, “long-chain branched structure polyolefin resin” refers to a polyolefin resin having a structure in which a long side chain is branched from a linear polymer. In this specification, the “long side chain” means a carbon chain having 12 or more carbon atoms constituting one side chain. The long-chain branched polyolefin resin has a structure in which long side chains are branched, so that fluidity in a molten state is lowered. Therefore, if spinning is performed using a thermoplastic resin containing a long-chain branched polyolefin resin as a raw material, when the yarn extruded from the spinning die is drawn by drawing air, the molecular orientation of the yarn tends to advance and the crystal Is promoted. The crystallization of one of the fiber-forming components of the composite fiber is accelerated and hardened, so that the difference in elasticity with the other increases, so that the composite fiber containing the long-chain branched structure polyolefin resin is crimpable. The degree becomes higher. Moreover, the nonwoven fabric using this is easily bulky and has excellent cushioning properties, and is less likely to wrinkle even when subjected to shear deformation.

Here, the higher the blending ratio of the long-chain branched structure polyolefin resin in the first component, the greater the degree of crimpability of the resulting composite fiber, and the nonwoven fabric using this tends to be highly cushioning and less likely to wrinkle. It becomes. On the other hand, the higher the compounding ratio of the long-chain branched polyolefin resin in the first component, the lower the spinnability of the produced composite fiber. Therefore, the blending ratio of the long-chain branched structure polyolefin resin can be set in consideration of the effect of the nonwoven fabric of the present invention and the spinnability of the composite fiber used therefor.

The long-chain branched structure polyolefin resin applicable to the first component preferably has a melt flow rate (MFR) measured at a load of 2.16 kg and a temperature of 230 ° C. in accordance with ASTM D1238 of 4 g / 10 min or more. . As a long-chain branched polyolefin resin applicable to the first component, commercially available products (for example, a long-chain branched polyolefin resin having a melting point of 162 ° C. and MFR of 8 g / 10 minutes, and a long-chain branched polyolefin resin having a melting point of 162 ° C. and MFR of 4 g / 10 minutes) (Structural polyolefin resin) can be preferably used. If the MFR of the long-chain branched polyolefin resin is lower than 4 g / 10 min, the spinnability of the yarn made from a thermoplastic resin containing this as a raw material is significantly lowered. When a polypropylene resin is used as the long-chain branched polyolefin resin, it is preferable to use a polypropylene resin as the first component thermoplastic resin from the viewpoint of compatibility and the like.

A low crystalline polyolefin resin can be used in combination as the thermoplastic resin of the first component. For example, the low crystalline polyolefin resin satisfying the following a) to g) can be contained in an amount of 5% by mass or more and 50% by mass or less based on the total solid content of the first component.
a) Mesopentad fraction [mmmm] is 30 mol% or more and 80 mol% or less.
b) The racemic pentad fraction [rrrr] and [1-mmmm] satisfy the relationship [rrrr] / [1-mmmm] ≦ 0.1.
c) Racemic meso racemic meso pentad fraction [rmrm] exceeds 2.5 mol%.
d) Mesotriad fraction [mm], racemic triad fraction [rr], and triad fraction [mr] satisfy the relationship [mm] × [rr] / [mr] ² ≦ 2.0.
e) The weight average molecular weight [Mw] is 10,000 or more and 200,000 or less.
f) The weight average molecular weight [Mw] and the number average molecular weight [Mn] satisfy the relationship of molecular weight distribution [Mw] / [Mn] ≦ 4.
g) The amount of the extract by boiling diethyl ether is 0% by mass or more and 10% by mass or less based on the total solid content of the low crystalline polyolefin resin.

As the low crystalline polyolefin resin applicable to the first component, commercially available polypropylene (for example, polypropylene having a melting point of 52 ° C. and an MFR of 50 g / 10 min) can be suitably used.

The low crystalline polyolefin resin is difficult to make crystals because of the uneven direction of side chain protrusions, and fibers and nonwoven fabrics using this tend to be soft and less rugged.

(Second component)
The second component is mainly composed of a thermoplastic resin. Specifically, the second component includes the thermoplastic resin in an amount of 90% by mass or more and 100% by mass or less based on the total solid content of the second component.

Examples of the thermoplastic resin applicable to the main component of the second component include polyolefin resins such as polypropylene (PP) and polyethylene (PE). One type of thermoplastic resin may be used, or two or more types may be used in combination. From the viewpoint of spinnability and strength of the composite fiber, polypropylene (PP) can be preferably used as the thermoplastic resin.

As the second component thermoplastic resin, a low crystalline polyolefin resin can be used in combination. For example, the low crystalline polyolefin resin satisfying the following a) to g) can be contained in an amount of 5% by mass or more and 50% by mass or less based on the total solid content of the second component.
a) Mesopentad fraction [mmmm] is 30 mol% or more and 80 mol% or less.
b) The racemic pentad fraction [rrrr] and [1-mmmm] satisfy the relationship [rrrr] / [1-mmmm] ≦ 0.1.
c) Racemic meso racemic meso pentad fraction [rmrm] exceeds 2.5 mol%.
d) Mesotriad fraction [mm], racemic triad fraction [rr], and triad fraction [mr] satisfy the relationship [mm] × [rr] / [mr] ² ≦ 2.0.
e) The weight average molecular weight [Mw] is 10,000 or more and 200,000 or less.
f) The weight average molecular weight [Mw] and the number average molecular weight [Mn] satisfy the relationship of molecular weight distribution [Mw] / [Mn] ≦ 4.
g) The amount of the extract by boiling diethyl ether is 0% by mass or more and 10% by mass or less based on the total solid content of the low crystalline polyolefin resin.

As the low crystalline polyolefin resin applicable to the second component, commercially available polypropylene (for example, polypropylene having a melting point of 52 ° C. and an MFR of 50 g / 10 min) can be suitably used.

The low crystalline polyolefin resin is not easy to produce crystals because the direction of the side chain is not uniform, and the fibers and nonwoven fabrics using this tend to be soft and less rugged.

(Other ingredients)
In each of the first component and the second component, the composite fiber may contain other components as necessary in addition to the thermoplastic resin as long as the object of the present invention is not impaired.

Examples of other components include various stabilizers such as known heat stabilizers and weather stabilizers, antistatic agents, slip agents, antiblocking agents, antifogging agents, lubricants, dyes, pigments, natural oils, and synthetic oils. And wax.

Examples of stabilizers include anti-aging agents such as 2,6-di-t-butyl-4-methylphenol (BHT); tetrakis [methylene-3- (3,5-di-t-butyl-4-hydroxy Phenyl) propionate] methane, β- (3,5-di-t-butyl-4-hydroxyphenyl) propionic acid alkyl ester, 2,2′-oxamide bis [ethyl-3- (3,5-di-t-butyl) Phenolic antioxidants such as -4-hydroxyphenyl) propionate; fatty acid metal salts such as zinc stearate, calcium stearate, calcium 1,2-hydroxystearate; glycerol monostearate, glycerol distearate, pentaerythritol monostearate , Pentaerythritol distearate, pentaerythritol tristearate , And the like polyhydric alcohol fatty acid esters and the like. Moreover, these can also be used in combination.

Examples of the lubricant include oleic amide, erucic acid amide, stearic acid amide, and the like.

Also, silica, diatomaceous earth, alumina, titanium oxide, magnesium oxide, pumice powder, pumice balloon, aluminum hydroxide, magnesium hydroxide, basic magnesium carbonate, dolomite, calcium sulfate, potassium titanate, barium sulfate, calcium sulfite, A filler such as talc, clay, mica, asbestos, calcium silicate, montmorillonite, bentonite, graphite, aluminum powder, molybdenum sulfide may be contained.

FIG. 9 is a cross-sectional view showing the configuration of the composite fiber according to the present embodiment for the purpose of illustration and not for the purpose of limitation. In the cross section, that is, the cross section perpendicular to the longitudinal direction of the composite fiber, the fiber-forming component is divided into two zones. The first component 10 is disposed in one zone, and the second component 20 is disposed in the other zone.

FIG. 9A shows a core-sheath type composite fiber in which the first component 10 is a core component and the second component 20 is a sheath component surrounding the first component 10. In this figure, an eccentric core-sheath type composite fiber having a core component shifted from the center of the fiber is particularly shown. FIG. 9B shows a side-by-side type composite fiber in which the first component 10 and the second component 20 come close to each other.

In the conjugate fiber of the present embodiment, the first component containing the long-chain branched structure polyolefin resin and the second component different from the first component are asymmetrical in a cross section perpendicular to the longitudinal direction of the conjugate fiber. Is arranged. Compared with the second component, the first component tends to advance the molecular orientation when it is spun and stretched, and the crystallization is easily promoted. Therefore, the conjugate fiber according to the present embodiment exhibits high crimpability, and the nonwoven fabric using this conjugate fiber has good stretchability and is not easily wrinkled even when subjected to shear deformation.

In FIG. 9, although the composite fiber formed from the two fiber forming components of the first component and the second component is illustrated, the composite fiber applicable to the present invention is not limited to this, It may be a composite fiber formed from three or more types of fiber-forming components including the first component and the second component as long as the material and the arrangement in the fiber do not hinder the crimpability.

The fineness of the composite fiber according to the present embodiment can be appropriately set depending on the use of the nonwoven fabric and the like, but is 0.1 denier or more and less than 10 denier, preferably 0.3 denier or more and less than 5 denier, more preferably 0.5 or more and 3 denier. Is less than. If it is less than 0.1 denier, the rigidity of the fiber becomes low and the crimped structure cannot be maintained. If it exceeds 10 denier, the feeling of touch becomes worse.

<Nonwoven fabric>
The fourth embodiment of the present invention relates to a non-woven fabric mainly composed of the above-mentioned composite fiber (crimped fiber). In the present specification, the term “main body” means that the component is contained in an amount of 50% by mass or more. That is, the nonwoven fabric according to the present embodiment includes the above-described composite fiber in an amount of 50% by mass or more, preferably 60% by mass or more, more preferably 70% by mass, based on the total solid content of the nonwoven fabric. It is preferably contained in an amount of 80% by mass or more, more preferably 90% by mass or more. The nonwoven fabric according to the present embodiment may have a single-layer configuration composed of one layer, or may have a multilayer configuration composed of a plurality of layers. When a nonwoven fabric is a laminated body which has a multilayer structure, it is preferable that a nonwoven fabric contains the above-mentioned composite fiber in the quantity of 60 mass% or more on the basis of the total solid of the whole nonwoven fabric.

(Layer structure)
As described above, the nonwoven fabric according to the present embodiment may have a single-layer configuration composed of one layer, or may have a multilayer configuration composed of a plurality of layers. Each of the plurality of layers of the nonwoven fabric having the multilayer configuration of the present embodiment may be a separately formed nonwoven fabric.

For example, the nonwoven fabric having the multilayer structure of the present embodiment has a single-layered nonwoven fabric of the present embodiment as one layer, and a spunbond made of non-crimped fibers manufactured by, for example, a spun band method. You may have the structure which laminated the nonwoven fabric as a surface layer. At this time, the fineness of the non-crimped fiber is, for example, preferably 0.5 denier or more and less than 2.5 denier, more preferably 0.5 denier or more and less than 1.5 denier. According to this configuration, it is possible to obtain a nonwoven fabric in the form of a laminate that is not only difficult to wrinkle but also has excellent surface smoothness and improved water resistance. In addition, the non-woven fabric according to the present embodiment can be laminated separately to improve the surface properties and to provide functionality to the non-woven fabric according to the present embodiment having a single layer configuration. .

The following are mentioned as a non-limiting example of the structure of the nonwoven fabric of such a laminated body. In the following examples, the spunbonded nonwoven fabric described as “mainly composed of crimped composite fibers” is intended to be a single-layered nonwoven fabric according to this embodiment. In addition, a spunband nonwoven fabric having a description “consisting mainly of non-crimped fibers” can be obtained by controlling the production conditions of the spunband method.
(A) A non-woven fabric having a two-layer structure of spun band non-woven fabric (mainly composed of non-crimped fibers) / spun band non-woven fabric (mainly composed of crimped composite fibers).
(B) Three-layer structure of spunband nonwoven fabric (mainly composed of non-crimped fibers) / spunband nonwoven fabric (mainly composed of crimped composite fibers) / spunband nonwoven fabric (mainly composed of non-crimped fibers) Non-woven fabric.
(C) A non-woven fabric having a three-layer structure of spunband nonwoven fabric (mainly composed of non-crimped fibers) / spunband nonwoven fabric (mainly composed of crimped composite fibers) / melt blown nonwoven fabric.
(D) Spunband nonwoven fabric (mainly composed of non-crimped fibers) / spunband nonwoven fabric (mainly composed of crimped composite fibers) / melt blown nonwoven fabric / spunband nonwoven fabric (mainly composed of non-crimped fibers) A layered nonwoven fabric.
(E) Spunband nonwoven fabric (mainly non-crimped fiber) / spunband nonwoven fabric (mainly crimped conjugate fiber) / melt blown nonwoven fabric / spunband nonwoven fabric (mainly crimped conjugate fiber) / spanband A non-woven fabric (mainly non-crimped fibers), which has a five-layer structure.

The basis weight of the nonwoven fabric constituting each layer to be laminated is preferably in the range of 2.0 to 25 g / m ² . If the basis weight is too large, the nonwoven fabric constituting the layer may inhibit the function of the nonwoven fabric constituting the other layer. If the basis weight is too small, the nonwoven fabric constituting the layer may have a small effect of imparting a function to the multilayer nonwoven fabric of the present embodiment.

(Nonwoven fabric manufacturing method and apparatus)
The nonwoven fabric containing the composite fiber of the present embodiment can be obtained by a normal composite melt spinning method and apparatus without using a special apparatus. Of these, the spunbond method having excellent productivity is preferably used.

FIG. 10 shows a manufacturing apparatus that can be used to manufacture the nonwoven fabric according to the present embodiment for the purpose of illustration rather than limitation. In the production of a nonwoven fabric, first, a mixture (first component) 110 of a polypropylene resin and a long-chain branched polyolefin resin for forming one zone of a composite fiber, and a propylene resin for forming another zone, The mixture of additives (second component) 120 is melted separately in the

extruders

130 and 140 to obtain respective melts. Next, each melt is discharged from a spinneret 150 having a composite spinning nozzle configured to discharge in a desired fiber structure, and a composite in which the first component and the second component are combined. Spins long fibers. The spun composite long fiber is cooled by cooling air 160, and further tensioned by drawing air 170 to a predetermined fineness, collected as it is on the collecting belt of the collecting conveyor 180, Deposit to thickness. Next, heat and pressure are applied to the deposited composite long fibers by the hot embossing roll 190 to melt some fibers, and the fibers are entangled. Thereby, the nonwoven fabric by this Embodiment can be obtained. This entanglement method is also called a heat embossing method, and an embossed pattern appears on the surface of the nonwoven fabric obtained by this method.

For the nonwoven fabric according to the present embodiment, in addition to the heat embossing method, a method using a means such as needle punch, water jet, ultrasonic wave, or a method of heat-sealing by hot air through is employed as a method of fiber entanglement treatment. can do. The needle punching means is a method in which a needle is inserted into a nonwoven fabric and entangled. The water jet means is a method in which high-pressure water is jetted onto the fiber assembly and entangled. The ultrasonic means is a method in which some fibers are melted and entangled using ultrasonic waves. Hot air through is a method in which hot air is blown into fibers to melt some fibers and entangle them.

(Physical properties of non-woven fabric)
The nonwoven fabric according to the present embodiment having the above-described configuration is difficult to wrinkle when subjected to shear deformation, and even if the shear angle is changed, the change in shear force per angle is small.

In Fig. 11, the non-woven fabric is cut into a 20 cm square shape, set in a tensile / shear tester (KES-FB1-AUTO-A, manufactured by Kato Tech Co., Ltd.), and the shear force is measured under standard measurement conditions. 2 illustrates an example of a shear angle-shear force curve when performing. The graph in a figure shows the test result about Example 4, Example 5, and the comparative example 1 by this Embodiment mentioned later. The graph plots the shear force (gf / m) against the shear angle (°) by shearing the sample in the positive direction, negative direction, and positive direction within a predetermined angle range with a shear angle of 0 °. is there. The change rate DO + of the shear force in the positive direction near the shear angle 0 °, the change rate Dmax + of the shear force in the vicinity of the maximum shear angle, and the change rate DO− of the shear force in the negative direction near the shear angle 0 ° Then, the change rate Dmax− of the shearing force in the vicinity of the minimum shearing angle is obtained. These change rates correspond to the slopes of the portions indicated by straight lines with the same reference numerals in the figure.

The average value of the change rate DO + and the change rate DO− is DO. Hereinafter, in this specification, DO is also referred to as “the rate of change in shear force per angle centered on a shear angle of 0 °”. Further, an average value of the change rate Dmax + and the change rate Dmax− is Dmax. Hereinafter, in the present specification, Dmax is also referred to as “the rate of change of shear force per angle with the maximum shear angle at which the maximum shear force is obtained”.

The closer the change rate ratio DO / Dmax is to 1, the smaller the change in shear force per angle. A non-woven fabric having a change rate ratio DO / Dmax close to 1 is preferable because it is difficult to wrinkle when subjected to shear deformation.

The nonwoven fabric according to the present embodiment has a shear force change rate DO per angle centered at a shear angle of 0 degree and shear that provides the maximum shear force in the measurement of the shear force using the tension / shear measurement device as described above. The change rate Dmax of the shearing force per angle with the angle being the maximum angle satisfies the relationship of 1 ≦ DO / Dmax ≦ 5.

(Function and effect)
The nonwoven fabric sheet according to the present embodiment is mainly composed of a composite fiber containing a first component and a second component. The first component contains a long-chain branched structure polyolefin resin, and can provide high crimpability to the composite fiber blended therewith. Moreover, bulkiness and cushioning properties can be provided for a nonwoven fabric mainly composed of this composite fiber. Therefore, the nonwoven fabric according to the present embodiment has an effect that wrinkles are difficult to enter even when subjected to deformation.

(Method for producing absorbent composite)
The absorber composite (diaper 10) of this Embodiment is manufactured by the manufacturing method including the following processes, for example.
(1) An absorbent body (absorber core) 13 composed of pulp and SAP is wrapped with a core wrap 13B, which is a liquid-permeable sheet, to produce a continuous mat-shaped core wrap type absorbent body.
(2) The continuous mat-shaped core wrap type absorber is narrowed through the nip while rotating a pair of embossing rolls having a convex embossing pattern on the surface, and embossed. By this embossing, a recess 21 corresponding to the shape of the emboss pattern is formed on the surface of the continuous absorber 13.
(3) The continuous mat-shaped core wrap type absorbent body after embossing is cut into a length required for one diaper by a cutting device, and a liquid-permeable top sheet 14 and a liquid-impermeable back sheet 12 are obtained. Then, it is joined to the cover sheet 11 having a soft touch and processed into a diaper shape. Thereby, the diaper 10 is manufactured.

In the above manufacturing method, the recess 21 is formed by squeezing the absorbent core and the core wrap, but the embodiment of the present invention is not limited to this. For example, you may form the recessed part 21 by pressing what laminated | stacked the absorber core and the core wrap, and the top sheet. Moreover, when pressing what laminated | stacked the absorber 13 and the top sheet | seat 14, the absorber 13 and the top sheet | seat 14 which were previously divided into the predetermined dimension (for example, cut | disconnected) are joined, and it squeezes with respect to this May be applied. In addition, appropriate changes and modifications are possible.

(Use of absorbent composite)
Below, the use of the absorber composite_body | complex by this Embodiment is illustrated.

Applications of the absorbent composite according to the present embodiment include (1) for clothing, (2) for medical use, (3) for building materials, (4) for hygiene, (5) for furniture and interior, and (6) for sleeping Wearing, (7) industrial materials, and the like.

(1) Examples of clothing include clothing members, disposable clothing (also referred to as disposable clothing), shoes, emblems, gloves, slippers, and hats. Specific examples of the clothing member include interlining, adhesive interlining, filling cotton, bra pad, shoulder pad, jumper liner, and the like. Specific examples of the disposable clothing include event jumpers and travel underwear. Specific examples of the shoe include an insole material and a fishing leather sole.

(2) For medical use, for example, gauze, surgical clothes, covering cloth set, bat for birth, cap, mask, sheets, antibacterial mat, poultice base cloth, poultice base cloth, cast material, artificial skin, etc. Can be mentioned.

(3) For building materials, for example, roofing, tufts, carpet base fabrics, anti-condensation sheets, temperature control sheets, humidity control sheets, wall coverings, heat insulating materials, moisture absorption materials, soundproof materials, sound absorption materials, vibration isolation materials, Wood materials, curing sheets, etc. are listed.

(4) Examples of hygiene include diapers, sanitary products, first aid products, cleaning products, towels, masks, and the like. Specific examples of the diaper include a paper diaper and a diaper cover. A specific example of the sanitary product is a napkin. Specific examples of the emergency supplies include gauze, first-aid plasters, and swabs. Specific examples of the cleansing products include breast milk pads, wiping sheets, sweat absorption sheets (for face, side, neck, feet, etc.), antibacterial / antibacterial sheets, antiviral sheets, antiallergen sheets, antibacterial deodorants There are sheets. Specific examples of the mask include a disposable three-dimensional mask.

(5) Examples of furniture / interior use include carpets, flooring, curtains, furniture parts, joinery, wallpaper, and ornaments. Specific examples of the carpet include carpets, carpet base fabrics, tile carpets, electric carpets, mat base fabrics, and under carpets. Specific examples of the furniture parts include a cushion material and a filling cotton in a reception chair. Specific examples of the joinery include shoji paper, folds, tatami mats, blinds, and the like. Specific examples of the ornament include a pennant, a roll screen, and artificial flowers.

(6) Examples of bedding include futons, pillow covers, and sheets. Specific examples of the futon include futon batting and futon bags.

(7) Examples of industrial materials include industrial materials, electrical materials, batteries, product materials, OA equipment, AV equipment, rolls, musical instruments, packaging materials, and the like. Specific examples of the industrial material include an abrasive, an oil absorbing material, a papermaking felt, a heat resistant cushion, a draining material, a heat insulating material, a soundproofing material, and a vibration proofing material. Specific examples of the electrical material include an electrical insulating material, a printed circuit board base material, an electromagnetic wave shielding material, a static electricity removal sheet, and a wire holding tape. Specific examples of the battery include a separator. Specific examples of the product material include FRP (fiber reinforced plastic) base material, tape, printing base fabric, synthetic paper, electrostatic recording paper, adhesive tape, thermal transfer sheet, radiation shielding mat, and the like. Specific examples of the OA device include a disk liner and a packaging material. Specific examples of the AV device include a speaker diaphragm and a sound absorbing plate. Specific examples of the roll include a buffalo, a coating roll, and a squeezed roll. Specific examples of the musical instrument include a piano key cushion and a hammer rail. Specific examples of the packaging material include dry ice packaging material and packing.

Also, the absorbent composite according to the present embodiment can be used in various fields and applications without being limited to the above classification. In particular, the absorbent composite according to the present embodiment can be suitably used for absorbent articles.

Hereinafter, the present embodiment will be specifically described by way of examples of sheets applicable to the absorbent composite according to the present embodiment, but the present embodiment is not limited to the following examples.

[Example 1]
<Manufacture of non-woven fabric>
As a first component, polypropylene resin PP (melting point: 162 ° C., MFR: 40 g / 10 minutes) and long-chain branched polypropylene resin PP1 (melting point: 162 ° C., MFR: 8 g / 10 minutes) are 99% by mass in terms of solid content: 1 A mixture mixed at a blending ratio of mass% was prepared. As the second component, polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min), low crystalline polyolefin resin PP (melting point 52 ° C., MFR 50 g / 10 min), and organic additive (erucamide 5 % PP masterbatch (based on polypropylene resin and containing 5% by mass of active ingredient erucamide) and inorganic pigment (50% titanium oxide PP masterbatch (based on polypropylene resin and containing active ingredient titanium oxide) In a quantity of 50% by mass) and a mixture of 74% by mass: 20% by mass: 4% by mass: 2% by mass in terms of solid content.

Using the apparatus shown in Fig. 10, spinning of the composite fiber and production of the nonwoven fabric were performed. Specifically, first, the first component and the second component were separately melted by the

extruders

130 and 140, respectively, to obtain respective melts. Next, each melt is discharged from a spinneret 150 having a composite spinning nozzle configured to discharge by forming a side-by-side type composite fiber structure, so that the first component and the second component are 30. A side-by-side type composite fiber that was compounded so as to have a blending ratio of 70% by mass was spun.

The spun composite fiber is cooled by cooling air 160 and further tensioned by drawing air 170 to a predetermined fineness (1.5 denier) and collected as it is on the collecting belt of the collecting conveyor 180. And it was deposited so that it might become a predetermined weight per unit area (15 g / m < ² >). Next, heat and pressure were applied to the deposited composite fiber with a hot embossing roll 190 to melt some fibers and entangle the fibers. Thereby, the nonwoven fabric of Example 1 was obtained. The nonwoven fabric of Example 1 is a single-layered nonwoven fabric composed of a nonwoven fabric mainly composed of composite fibers.

<Manufacture of absorbent composite (diaper)>
The diaper was manufactured with the following manufacturing methods using the nonwoven fabric of Example 1 as a core wrap.

First, an absorbent body (absorber core) having a basis weight of 100 g / m ² composed of cotton-like pulp having a dry mass ratio of 100 to 100 and SAP is wrapped with a liquid-permeable core wrap, and a mat-shaped core wrap type absorbent body. Was generated. Next, by laminating a liquid-permeable top sheet on one surface of this mat-shaped core wrap type absorber, and by narrowing it through its nip while rotating an embossing roll pair having a convex embossing pattern on the surface, Embossed. By this embossing, a recess recessed from the top sheet side to the absorber side was formed on the top sheet side surface of the laminate of the core wrap type absorber and the top sheet, corresponding to the shape of the emboss pattern.

The formed recesses were the lattice-like grooves 21 composed of the

grooves

21a and 21b shown in FIG. The groove 21a and the groove 21b are formed in a single continuous groove structure that extends with an inclination (α, β) of 45 degrees with respect to the longitudinal direction of the absorber 13, respectively. The interval between the grooves 21b was 30 mm. The width of the opening of the groove 21 was 1.5 mm, and the depth of the groove 21 was 2 mm.

Next, the embossed laminate is cut into a length required for one diaper using a cutting device, joined to a liquid-impermeable back sheet and a cover sheet excellent in touch, and processed into a diaper shape. Thus, the diaper of Example 1 was obtained.

[Example 2]
<Manufacturing of non-woven fabric>
The blending ratio of the polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min) and the long-chain branched polypropylene resin PP1 (melting point 162 ° C., MFR 8 g / 10 min) in the first component is 95% by mass in terms of solid content: A nonwoven fabric of Example 2 was obtained in the same manner as Example 1 except that the amount was 5% by mass. The nonwoven fabric of Example 2 is a single-layer nonwoven fabric composed of a nonwoven fabric mainly composed of composite fibers.

<Manufacture of absorber complex>
The diaper of Example 2 is used in the same manner as in Example 1 except that the nonwoven fabric of Example 2 is used as a top sheet and tissue paper having a basis weight of 12 g / m ² is used for the core wrap instead of the nonwoven fabric of Example 1. Obtained.

[Example 3]
<Manufacturing of non-woven fabric>
Except that the long-chain branched polypropylene resin PP1 (melting point 162 ° C., MFR 8 g / 10 min) in the first component was changed to the long-chain branched polypropylene resin PP2 (melting point 162 ° C., MFR 4 g / 10 min), the same as in Example 2. The nonwoven fabric of Example 3 was obtained. The nonwoven fabric of Example 3 is a single-layered nonwoven fabric composed of a nonwoven fabric mainly composed of composite fibers.

<Manufacture of absorber complex>
A diaper of Example 3 was obtained in the same manner as in Example 1 except that the nonwoven fabric of Example 3 was used as a core wrap and a top sheet.

[Example 4]
<Manufacturing of non-woven fabric>
The blending ratio of the polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min) and the long-chain branched polypropylene resin PP1 (melting point 162 ° C., MFR 8 g / 10 min) in the first component is 97% by mass in terms of solid content: The nonwoven fabric of Example 4 was obtained in the same manner as in Example 1 except that the composition was 3% by mass, and the first component and the second component were combined so as to have a blending ratio of 10% by mass to 90% by mass. . The nonwoven fabric of Example 4 is a single-layered nonwoven fabric composed of a nonwoven fabric mainly composed of composite fibers.

<Manufacture of absorber complex>
A diaper of Example 3 was obtained in the same manner as in Example 1 except that the nonwoven fabric of Example 4 was used as a core wrap.

[Example 5]
<Manufacturing of non-woven fabric>
A nonwoven fabric (hereinafter simply referred to as “nonwoven fabric”) mainly composed of a composite fiber in the same manner as in Example 4 except that the first component and the second component are combined so as to have a blending ratio of 40% by mass to 60% by mass. Also referred to as “composite fiber nonwoven fabric”.

As the third component, polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min) and organic additive (erucic acid amide 5% PP master batch (based on polypropylene resin, 5% by mass of active ingredient erucic acid amide) And a mixture of 97% by mass and 3% by mass in terms of solid content. The third component was melted with an extruder to obtain a melt. Next, the melt of the third component is discharged from a spinneret having a spinning nozzle configured to discharge a single-structured fiber, and the third component has a blending ratio of 100% by mass. A single structure fiber was spun.

The spun single structure fiber is cooled with cooling air, and further tension is applied with drawing air to a predetermined fineness (1.4 denier). It was collected and deposited so as to have a predetermined basis weight (5 g / m ² ). Next, heat and pressure were applied to the deposited composite fiber with a hot embossing roll 190 to melt some fibers and entangle the fibers. Thereby, the nonwoven fabric of Example 5 was obtained. The non-woven fabric of Example 5 is a non-woven fabric having a two-layer structure in which a non-woven fabric mainly composed of a single structure fiber (hereinafter also simply referred to as “single structure fiber non-woven fabric”) is laminated on a composite fiber non-woven fabric.

<Manufacture of absorber complex>
The diaper of Example 5 is used in the same manner as in Example 1 except that the nonwoven fabric of Example 5 is used as a top sheet and tissue paper having a basis weight of 12 g / m ² is used for the core wrap instead of the nonwoven fabric of Example 1. Obtained.

[Example 6]
<Manufacturing of non-woven fabric>
A composite fiber nonwoven fabric was obtained in the same manner as in Example 5 except that the first component and the second component in the composite fiber nonwoven fabric were combined so as to have a blending ratio of 30% by mass to 70% by mass.

In addition, a single-structure fiber having a blending ratio of 100% by mass of the third component is spun on both sides as well as on one side of the composite fiber nonwoven fabric so as to obtain a predetermined basis weight (4 g / m ² ). A nonwoven fabric of Example 6 was obtained in the same manner as in Example 5 except that a monostructural fiber nonwoven fabric was laminated. The nonwoven fabric of Example 6 is a nonwoven fabric having a three-layer structure in which one single-structure fiber nonwoven fabric is laminated on both surfaces of the composite fiber nonwoven fabric.

<Manufacture of absorber complex>
A diaper of Example 6 was obtained in the same manner as in Example 1 except that the nonwoven fabric of Example 6 was used for the core wrap.

[Example 7]
<Manufacturing of non-woven fabric>
As the second component, polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min), low crystalline polyolefin resin PP (melting point 52 ° C., MFR 50 g / 10 min), and organic additive (Daiichi Seika Kogyo Co., Ltd.) Erucic acid amide 5% PP masterbatch (based on polypropylene resin and containing 5% by mass of active ingredient erucamide) and inorganic pigment (titanium oxide 50% PP masterbatch (based on polypropylene resin) And an active ingredient titanium oxide in an amount of 50% by mass), and a mixture of 89% by mass, 5% by mass, 4% by mass and 2% by mass in terms of solid content, and a composite fiber. The nonwoven fabric of Example 7 is the same as Example 5 except that the first component and the second component in the nonwoven fabric are combined so as to have a blending ratio of 30% by mass to 70% by mass. Obtained. Example 7 of the nonwoven fabric has, on the composite fiber nonwoven fabric, a laminate of unitary fiber nonwoven fabric, a nonwoven fabric of two-layer structure.

<Manufacture of absorber complex>
A diaper of Example 7 was obtained in the same manner as Example 1 except that the nonwoven fabric of Example 7 was used for the core wrap.

[Example 8]
<Manufacturing of non-woven fabric>
As the second component, polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min), low crystalline polyolefin resin PP (melting point 52 ° C., MFR 50 g / 10 min), and organic additive (erucamide 5% PP) Masterbatch (based on polypropylene resin and containing 5% by mass of active ingredient erucamide) and inorganic pigment (50% titanium oxide PP masterbatch (based on polypropylene resin and 50% of active ingredient titanium oxide) In the same manner as in Example 7 except that a mixture was prepared at a blending ratio of 44% by mass: 50% by mass: 4% by mass: 2% by mass in terms of solid content. The nonwoven fabric of Example 8 was obtained The nonwoven fabric of Example 8 is a nonwoven fabric having a two-layer structure in which a single structure fiber nonwoven fabric is laminated on a composite fiber nonwoven fabric.

<Manufacture of absorber complex>
A diaper of Example 8 was obtained in the same manner as Example 1 except that the nonwoven fabric of Example 8 was used for the core wrap and the top sheet.

[Comparative Example 1]
<Manufacturing of non-woven fabric>
Polypropylene resin PP (melting point: 162 ° C., MFR: 40 g / 10 min) was melted by the

extruders

130 and 140 to obtain respective melts. Next, each melt was discharged from a spinneret 150 having a single-hole nozzle to spin polypropylene fibers. The spun composite fiber is cooled by cooling air 160 and further tensioned by drawing air 170 to a predetermined fineness (1.5 denier) and collected as it is on the collecting belt of the collecting conveyor 180. And it was deposited so that it might become a predetermined weight per unit area (15 g / m < ² >). Next, heat and pressure were applied to the deposited composite fiber with a hot embossing roll 190 to melt some fibers and entangle the fibers. This obtained the nonwoven fabric sheet of the comparative example 1.

<Manufacture of absorber complex>
A diaper of Comparative Example 1 was obtained in the same manner as in Example 1 except that the nonwoven fabric of Comparative Example 1 was used for the core wrap.

[Example 1A]
<Manufacture of non-woven fabric>
As a first component, polypropylene resin PP (melting point: 162 ° C., MFR: 40 g / 10 minutes) and long-chain branched polypropylene resin PP1 (melting point: 162 ° C., MFR: 8 g / 10 minutes) are 99% by mass in terms of solid content: 1 A mixture mixed at a blending ratio of mass% was prepared. As the second component, polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min), low crystalline polyolefin resin PP (melting point 52 ° C., MFR 50 g / 10 min), and organic additive (erucamide 5 % PP masterbatch (based on polypropylene resin and containing 5% by mass of active ingredient erucamide) and inorganic pigment (50% titanium oxide PP masterbatch (based on polypropylene resin and containing active ingredient titanium oxide) In a quantity of 50% by mass) and a mixture of 74% by mass: 20% by mass: 4% by mass: 2% by mass in terms of solid content.

extruders

The spun composite fiber is cooled by cooling air 160 and further tensioned by drawing air 170 to a predetermined fineness (1.5 denier) and collected as it is on the collecting belt of the collecting conveyor 180. And it was deposited so that it might become a predetermined weight per unit area (15 g / m < ² >). Next, heat and pressure were applied to the deposited composite fiber with a hot embossing roll 190 to melt some fibers and entangle the fibers. This obtained the nonwoven fabric of Example 1A. The nonwoven fabric of Example 1A is a nonwoven fabric having a single layer structure composed of a nonwoven fabric mainly composed of composite fibers.

<Manufacture of absorbent articles (diapers)>
A diaper was manufactured by the following manufacturing method using the nonwoven fabric of Example 1A as a top sheet.

The formed recesses were the lattice-like grooves 21 composed of the

grooves

Next, the embossed laminate is cut into a length required for one diaper using a cutting device, joined to a liquid-impermeable back sheet and a cover sheet excellent in touch, and processed into a diaper shape. Thus, the diaper of Example 1A was obtained.

[Example 2A]
<Manufacture of non-woven fabric>
The blending ratio of the polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min) and the long-chain branched polypropylene resin PP1 (melting point 162 ° C., MFR 8 g / 10 min) in the first component is 95% by mass in terms of solid content: A nonwoven fabric of Example 2A was obtained in the same manner as Example 1 except that the content was 5% by mass. The nonwoven fabric of Example 2 is a single-layer nonwoven fabric composed of a nonwoven fabric mainly composed of composite fibers.

<Manufacture of absorbent articles (diapers)>
A diaper of Example 2 was obtained in the same manner as Example 1A, except that the nonwoven fabric of Example 2A was used instead of the nonwoven fabric of Example 1 as the top sheet.

[Example 3A]
<Manufacture of non-woven fabric>
Except that the long-chain branched polypropylene resin PP1 (melting point 162 ° C., MFR 8 g / 10 min) in the first component was changed to the long-chain branched polypropylene resin PP2 (melting point 162 ° C., MFR 4 g / 10 min), the same as Example 2A The nonwoven fabric of Example 3A was obtained. The nonwoven fabric of Example 3A is a single-layered nonwoven fabric composed of a nonwoven fabric mainly composed of composite fibers.

<Manufacture of absorbent articles (diapers)>
A diaper of Example 2A was obtained in the same manner as Example 1A except that the nonwoven fabric of Example 3A was used instead of the nonwoven fabric of Example 1A as the top sheet.

[Example 4A]
<Manufacture of non-woven fabric>
The blending ratio of the polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min) and the long-chain branched polypropylene resin PP1 (melting point 162 ° C., MFR 8 g / 10 min) in the first component is 97% by mass in terms of solid content: The nonwoven fabric of Example 4A was obtained in the same manner as in Example 1A except that the composition was 3% by mass, and the first component and the second component were combined so that the mixing ratio was 10% by mass: 90% by mass. . The nonwoven fabric of Example 4A is a nonwoven fabric having a single layer structure composed of a nonwoven fabric mainly composed of composite fibers.

<Manufacture of absorbent articles (diapers)>
A diaper of Example 2 was obtained in the same manner as Example 1A, except that the nonwoven fabric of Example 4A was used instead of the nonwoven fabric of Example 1A as the top sheet.

[Example 5A]
<Manufacture of non-woven fabric>
A non-woven fabric mainly composed of a composite fiber (hereinafter simply referred to as “a”) except that the first component and the second component are combined so as to have a blending ratio of 40% by mass to 60% by mass. Also referred to as “composite fiber nonwoven fabric”.

The spun single structure fiber is cooled with cooling air, and further tension is applied with drawing air to a predetermined fineness (1.4 denier). It was collected and deposited so as to have a predetermined basis weight (5 g / m ² ). Next, heat and pressure were applied to the deposited composite fiber with a hot embossing roll 190 to melt some fibers and entangle the fibers. This obtained the nonwoven fabric of Example 5A. The nonwoven fabric of Example 5A is a nonwoven fabric having a two-layer structure in which a nonwoven fabric mainly composed of a single structure fiber (hereinafter, also simply referred to as “single structure fiber nonwoven fabric”) is laminated on a composite fiber nonwoven fabric.

<Manufacture of absorbent articles (diapers)>
A diaper of Example 5A was obtained in the same manner as Example 1A except that the nonwoven fabric of Example 5A was used instead of the nonwoven fabric of Example 1A as the top sheet.

[Example 6A]
<Manufacture of non-woven fabric>
A composite fiber nonwoven fabric was obtained in the same manner as in Example 5A, except that the first component and the second component in the composite fiber nonwoven fabric were combined so as to have a blending ratio of 30% by mass to 70% by mass.

In addition, a single-structure fiber having a blending ratio of 100% by mass of the third component is spun on both sides as well as on one side of the composite fiber nonwoven fabric so as to obtain a predetermined basis weight (4 g / m ² ). A nonwoven fabric of Example 6A was obtained in the same manner as Example 5A, except that a monostructural fiber nonwoven fabric was laminated. The nonwoven fabric of Example 6A is a nonwoven fabric having a three-layer structure in which one single-structure fiber nonwoven fabric is laminated on both surfaces of the composite fiber nonwoven fabric.

<Manufacture of absorbent articles (diapers)>
A diaper of Example 6A was obtained in the same manner as Example 1A, except that the nonwoven fabric of Example 6A was used instead of the nonwoven fabric of Example 1A as the top sheet.

[Example 7A]
<Manufacture of non-woven fabric>
As the second component, polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min), low crystalline polyolefin resin PP (melting point 52 ° C., MFR 50 g / 10 min), and organic additive (Daiichi Seika Kogyo Co., Ltd.) Erucic acid amide 5% PP masterbatch (based on polypropylene resin and containing 5% by mass of active ingredient erucamide) and inorganic pigment (titanium oxide 50% PP masterbatch (based on polypropylene resin) And an active ingredient titanium oxide in an amount of 50% by mass), and a mixture of 89% by mass, 5% by mass, 4% by mass and 2% by mass in terms of solid content, and a composite fiber. Example 7A is the same as Example 5A except that the first component and the second component in the nonwoven fabric were combined so as to have a blending ratio of 30% by mass to 70% by mass. To obtain a fabric. Example 7A nonwoven fabric on a conjugate fiber nonwoven fabric, a laminate of unitary fiber nonwoven fabric, a nonwoven fabric of two-layer structure.

<Manufacture of absorbent articles (diapers)>
A diaper of Example 7A was obtained in the same manner as Example 1A except that the nonwoven fabric of Example 7A was used instead of the nonwoven fabric of Example 1A as the top sheet.

[Example 8A]
<Manufacture of non-woven fabric>
As the second component, polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min), low crystalline polyolefin resin PP (melting point 52 ° C., MFR 50 g / 10 min), and organic additive (erucamide 5% PP) Masterbatch (based on polypropylene resin and containing 5% by mass of active ingredient erucamide) and inorganic pigment (50% titanium oxide PP masterbatch (based on polypropylene resin and 50% of active ingredient titanium oxide) In the same manner as in Example 7A, except that a mixture was mixed in a mixing ratio of 44% by mass: 50% by mass: 4% by mass: 2% by mass in terms of solid content. The nonwoven fabric of Example 8A was obtained, and the nonwoven fabric of Example 8A is a nonwoven fabric having a two-layer structure in which a single structure fiber nonwoven fabric is laminated on a composite fiber nonwoven fabric.

[Comparative Example 1A]
<Manufacture of non-woven fabric>
A nonwoven fabric of Comparative Example 1A was obtained in the same manner as Example 1A, except that long-chain branched polypropylene resin PP1 (melting point 162 ° C., MFR 8 g / 10 min) was not blended with the first component.

<Manufacture of absorbent articles (diapers)>
A diaper of Comparative Example 1A was obtained in the same manner as Example 1A except that the nonwoven fabric of Comparative Example 1A was used as the top sheet instead of the nonwoven fabric of Example 1A.

[Comparative Example 2A]
<Manufacture of non-woven fabric>
Except that the long-chain branched polypropylene resin PP1 (melting point 162 ° C., MFR 8 g / 10 min) in the first component was changed to the long-chain branched polypropylene resin PP3 (melting point 162 ° C., MFR 2 g / 10 min), the same as Example 2A The composite fiber was spun. The nonwoven fabric of Comparative Example 2A was not obtained due to poor spinning.

[Comparative Example 3A]
<Manufacture of non-woven fabric>
The blending ratio of the polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min) and the long-chain branched polypropylene resin PP1 (melting point 162 ° C., MFR 8 g / 10 min) in the first component is 85% by mass in terms of solid content: The composite fiber was spun in the same manner as in Example 1A except that the content was 15% by mass. The nonwoven fabric of Comparative Example 3A was not obtained due to poor spinning.

[Comparative Example 4A]
<Manufacture of non-woven fabric>
A nonwoven fabric of Comparative Example 4A was obtained in the same manner as in Example 5 except that the first component and the second component were combined so as to have a blending ratio of 5% by mass to 95% by mass. The nonwoven fabric of Comparative Example 4A is a nonwoven fabric having a two-layer structure in which a single-structure fiber nonwoven fabric is laminated on a composite fiber nonwoven fabric.

<Manufacture of absorbent articles (diapers)>
A diaper of Comparative Example 4A was obtained in the same manner as Example 1A except that the nonwoven fabric of Comparative Example 4A was used instead of the nonwoven fabric of Example 1A as the top sheet.

[Comparative Example 5A]
<Manufacture of non-woven fabric>
A nonwoven fabric of Comparative Example 5A was obtained in the same manner as Example 5A, except that the first component and the second component were combined so as to have a blending ratio of 50% by mass to 50% by mass. The nonwoven fabric of Comparative Example 5A is a nonwoven fabric having a two-layer structure in which a single structure fiber nonwoven fabric is laminated on a composite fiber nonwoven fabric.

<Manufacture of absorbent articles (diapers)>
A diaper of Comparative Example 5A was obtained in the same manner as Example 1A, except that the nonwoven fabric of Comparative Example 5A was used instead of the nonwoven fabric of Example 1A as the top sheet.

[Comparative Example 6A]
<Manufacture of non-woven fabric>
Polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min), low crystalline polyolefin resin PP (melting point 52 ° C., MFR 50 g / 10 min) and organic additive (erucamide 5% PP master) in the second component Batch (based on polypropylene resin and containing 5% by mass of active ingredient erucamide) and inorganic pigment (50% titanium oxide PP masterbatch (based on polypropylene resin and 50% by mass of active ingredient titanium oxide) The composite fiber was spun in the same manner as in Example 6A except that the blending ratio was 56 mass%: 20 mass%: 4 mass%: 20 mass% in terms of solid content. The nonwoven fabric of Comparative Example 6A was not obtained due to poor spinning.

[Comparative Example 7]
<Manufacture of non-woven fabric>
A nonwoven fabric of Comparative Example 7A was obtained in the same manner as Example 6A, except that the predetermined total basis weight of the single structure fiber nonwoven fabric was changed from 8 g / m ² to 13 g / m ² . The nonwoven fabric of Comparative Example 7A is a nonwoven fabric having a three-layer structure in which one single-structure fiber nonwoven fabric is laminated on each side of the composite fiber nonwoven fabric.

<Manufacture of absorbent articles (diapers)>
A diaper of Comparative Example 7A was obtained in the same manner as Example 1A, except that the nonwoven fabric of Comparative Example 7A was used instead of the nonwoven fabric of Example 1A as the top sheet.

[Comparative Example 8A]
<Manufacture of non-woven fabric>
Polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min), low crystalline polyolefin resin PP (melting point 52 ° C., MFR 50 g / 10 min) and organic additive (erucamide 5% PP master) in the second component Batch (based on polypropylene resin and containing 5% by mass of active ingredient erucamide) and inorganic pigment (50% titanium oxide PP masterbatch (based on polypropylene resin and 50% by mass of active ingredient titanium oxide) The nonwoven fabric of Comparative Example 8A is obtained in the same manner as in Example 7A except that the blending ratio is 94% by mass: 0% by mass: 4% by mass: 2% by mass in terms of solid content. The nonwoven fabric of Comparative Example 8 is a two-layered nonwoven fabric in which a single structure fiber nonwoven fabric is laminated on a composite fiber nonwoven fabric.

<Manufacture of absorbent articles (diapers)>
A diaper of Comparative Example 8A was obtained in the same manner as Example 1A, except that the nonwoven fabric of Comparative Example 8A was used instead of the nonwoven fabric of Example 1A as the top sheet.

[Comparative Example 9A]
<Manufacture of non-woven fabric>
Polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min), low crystalline polyolefin resin PP (melting point 52 ° C., MFR 50 g / 10 min) and organic additive (erucamide 5% PP master) in the second component Batch (based on polypropylene resin and containing 5% by mass of active ingredient erucamide) and inorganic pigment (50% titanium oxide PP masterbatch (based on polypropylene resin and 50% by mass of active ingredient titanium oxide) The composite fiber was spun in the same manner as in Example 6A except that the blending ratio was 34% by mass: 60% by mass: 4% by mass: 2% by mass in terms of solid content. Although the spinning was possible, the production of the nonwoven fabric was stopped because of the poor texture of the laminated composite fibers.

[Example 1B]
<Manufacture of composite fiber and nonwoven fabric>
As a first component, polypropylene resin PP (melting point: 162 ° C., MFR: 40 g / 10 minutes) and long-chain branched polypropylene resin PP1 (melting point: 162 ° C., MFR: 8 g / 10 minutes) are 99% by mass in terms of solid content: 1 A mixture mixed at a blending ratio of mass% was prepared. As the second component, polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min), low crystalline polyolefin resin PP (melting point 52 ° C., MFR 50 g / 10 min), and organic additive (erucamide 5 % PP masterbatch (based on polypropylene resin and containing 5% by mass of active ingredient erucamide) and inorganic pigment (50% titanium oxide PP masterbatch (based on polypropylene resin and containing active ingredient titanium oxide) In the amount of 50% by mass) and a mixture ratio of 74% by mass: 20% by mass: 4% by mass: 2% by mass in terms of solid content.

extruders

130 and 140, respectively, to obtain respective melts. Next, each melt is discharged from a spinneret 150 having a composite spinning nozzle configured to form and discharge an eccentric core-sheath type composite fiber structure, and the first component and the second component are discharged. An eccentric core-sheath type composite fiber that was compounded so as to have a blending ratio of 30% by mass to 70% by mass was spun.

The spun composite fiber is cooled by cooling air 160 and further tensioned by drawing air 170 to a predetermined fineness (1.5 denier) and collected as it is on the collecting belt of the collecting conveyor 180. And it was deposited so that it might become a predetermined weight per unit area (15 g / m < ² >). Next, heat and pressure were applied to the deposited composite fiber with a hot embossing roll 190 to melt some fibers and entangle the fibers. This obtained the nonwoven fabric of Example 1B. The nonwoven fabric of Example 1B is a nonwoven fabric having a single layer structure composed of a nonwoven fabric mainly composed of an eccentric core-sheath type composite fiber.

<Manufacture of absorbent articles (diapers)>
The diaper was manufactured with the following manufacturing methods using the nonwoven fabric of Example 1 as a core wrap sheet.

First, an absorbent body (absorbent core) having a basis weight of 100 g / m ² composed of cotton-like pulp having a dry mass ratio of 100 to 100 and SAP is wrapped with a liquid-permeable core wrap sheet, and a mat-shaped core wrap type Absorber was produced. Next, by laminating a liquid-permeable top sheet on one surface of this mat-shaped core wrap type absorber, and by narrowing it through its nip while rotating an embossing roll pair having a convex embossing pattern on the surface, Embossed. By this embossing, a recess recessed from the top sheet side to the absorber side was formed on the top sheet side surface of the laminate of the core wrap type absorber and the top sheet, corresponding to the shape of the emboss pattern.

The formed recesses were the lattice-like grooves 21 composed of the

grooves

Next, the embossed laminate is cut into a length required for one diaper using a cutting device, joined to a liquid-impermeable back sheet and a cover sheet excellent in touch, and processed into a diaper shape. Thus, a diaper of Example 1B was obtained.

[Example 2B]
<Manufacture of composite fiber and nonwoven fabric>
The blending ratio of the polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min) and the long-chain branched polypropylene resin PP1 (melting point 162 ° C., MFR 8 g / 10 min) in the first component is 95% by mass in terms of solid content: A nonwoven fabric of Example 2 was obtained in the same manner as Example 1 except that the amount was 5% by mass. The nonwoven fabric of Example 2B is a single-layered nonwoven fabric composed of a nonwoven fabric mainly composed of an eccentric core-sheath type composite fiber.

<Manufacture of absorbent articles (diapers)>
The nonwoven fabric of Example 2B was used as the top sheet, and the core wrap sheet was similar to Example 1B except that tissue paper having a basis weight of 12 g / m ² was used instead of the nonwoven fabric of Example 1B. I got a diaper.

[Example 3B]
<Manufacture of composite fiber and nonwoven fabric>
The blending ratio of the polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min) and the long-chain branched polypropylene resin PP1 (melting point 162 ° C., MFR 8 g / 10 min) in the first component is 97% by mass in terms of solid content: 3% by mass, the first component and the second component are compounded so as to have a blending ratio of 10% by mass: 90% by mass, and a side-by-side type composite fiber structure is formed and discharged as a spinneret. A nonwoven fabric of Example 3B was obtained in the same manner as Example 1B, except that a die having a constructed composite spinning nozzle was used. The nonwoven fabric of Example 3B is a nonwoven fabric having a single layer structure composed of a nonwoven fabric mainly composed of side-by-side type composite fibers.

<Manufacture of absorbent articles (diapers)>
A diaper of Example 3B was obtained in the same manner as Example 1B, except that the nonwoven fabric of Example 3B was used as a top sheet and a core wrap sheet, and the nonwoven fabric of Example 1 was not used.

[Example 4B]
<Manufacture of composite fiber and nonwoven fabric>
The first component and the second component are combined so as to have a blending ratio of 40% by mass: 60% by mass, and an eccentric core-sheath composite type composite fiber structure is formed and discharged as a spinneret. A nonwoven fabric made of an eccentric core-sheath type composite fiber was obtained in the same manner as in Example 3B, except that a die having a composite spinning nozzle was used.

As the third component, polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min) and organic additive (erucic amide 5% PP masterbatch made by Dainichi Seika Kogyo Co., Ltd. based on polypropylene resin) The component erucic acid amide is contained in an amount of 5% by mass))) and a mixture of 97% by mass and 3% by mass in terms of solid content. The third component was melted with an extruder to obtain a melt. Next, the melt of the third component is discharged from a spinneret having a spinning nozzle configured to discharge by forming a single structure fiber, and the third component has a blending ratio of 100% by mass. Single structure fibers were spun. In addition, in this specification, a single structure fiber means the fiber comprised with the same and uniform material in the cross section perpendicular | vertical to a longitudinal direction.

The spun single structure fiber is cooled with cooling air, and further tensioned with drawing air to a predetermined fineness (1.4 denier). It was collected on top and deposited so as to have a predetermined basis weight (5 g / m ² ). Next, heat and pressure were applied to the deposited composite fiber with a hot embossing roll 190 to melt some fibers and entangle the fibers. Thereby, the nonwoven fabric of Example 4 was obtained. The nonwoven fabric of Example 4B is a nonwoven fabric having a two-layer structure in which a nonwoven fabric mainly composed of a single structure fiber (hereinafter, also simply referred to as “single structure fiber nonwoven fabric”) is laminated on a composite fiber nonwoven fabric.

<Manufacture of absorbent articles (diapers)>
The nonwoven fabric of Example 4B was used as the top sheet, and the core wrap sheet was similar to Example 1B except that tissue paper having a basis weight of 12 g / m ² was used instead of the nonwoven fabric of Example 1B. I got a diaper.

[Example 5B]
<Manufacture of composite fiber and nonwoven fabric>
The long-chain branched polypropylene resin PP1 (melting point 162 ° C., MFR 8 g / 10 min) in the first component was changed to the long-chain branched polypropylene resin PP2 (melting point 162 ° C., MFR 4 g / 10 min), and the polypropylene resin in the first component Implemented except that the blending ratio of PP (melting point 162 ° C., MFR 40 g / 10 min) and long chain branched polypropylene resin PP2 (melting point 162 ° C., MFR 8 g / 10 min) was 97% by mass: 3% by mass in terms of solid content. In the same manner as in Example 1B, a nonwoven fabric made of an eccentric core-sheath type composite fiber was obtained.

In addition, a single structure fiber having a blending ratio of 100% by mass of the third component is spun on both sides as well as on one side of the composite fiber nonwoven fabric so that a predetermined basis weight (5 g / m ² ) is obtained. A nonwoven fabric of Example 5 was obtained in the same manner as Example 4B, except that a monostructural fiber nonwoven fabric was laminated. The nonwoven fabric of Example 5B is a three-layered nonwoven fabric in which one single-structure fiber nonwoven fabric is laminated on each side of a nonwoven fabric composed of an eccentric core-sheath type composite fiber.

<Manufacture of absorbent articles (diapers)>
A diaper of Example 5B was obtained in the same manner as Example 1B, except that the nonwoven fabric of Example 5B was used as a top sheet and a core wrap sheet, and the nonwoven fabric of Example 1B was not used.

[Comparative Example 1B]
<Manufacture of composite fiber and nonwoven fabric>
A nonwoven fabric of Comparative Example 1B was obtained in the same manner as Example 1B, except that long-chain branched polypropylene resin PP1 (melting point: 162 ° C., MFR: 8 g / 10 min) was not blended with the first component. The nonwoven fabric of Comparative Example 1B is a nonwoven fabric having a single layer structure made of a nonwoven fabric mainly composed of an eccentric core-sheath type composite fiber.

<Manufacture of absorbent articles (diapers)>
The non-woven fabric of Comparative Example 1B was used as the top sheet, and the core wrap sheet was the same as Example 1B except that tissue paper having a basis weight of 12 g / m ² was used instead of the non-woven fabric of Example 1B. I got a diaper.

[Comparative Example 2B]
<Manufacture of composite fiber and nonwoven fabric>
Except that the long chain branched polypropylene resin PP1 (melting point 162 ° C., MFR 8 g / 10 min) in the first component was changed to the long chain branched polypropylene resin PP3 (melting point 162 ° C., MFR 2 g / 10 min), the same as Example 2B The composite fiber was spun. Due to spinning failure, the nonwoven fabric of Comparative Example 2B was not obtained.

[Comparative Example 3B]
<Manufacture of composite fiber and nonwoven fabric>
The blending ratio of the polypropylene resin PP (melting point 162 ° C., MFR 4 g / 10 min) and the long-chain branched polypropylene resin PP1 (melting point 162 ° C., MFR 8 g / 10 min) in the first component is 85% by mass in terms of solid content: The conjugate fiber was spun in the same manner as in Example 1B except that the content was 15% by mass. The nonwoven fabric of Comparative Example 3B was not obtained due to poor spinning.

[Comparative Example 4B]
<Manufacture of composite fiber and nonwoven fabric>
A nonwoven fabric of Comparative Example 4B was obtained in the same manner as in Example 4B except that the first component and the second component were combined so as to have a blending ratio of 5% by mass to 95% by mass. The nonwoven fabric of Comparative Example 4B is a nonwoven fabric having a single layer structure made of a nonwoven fabric mainly composed of an eccentric core-sheath type composite fiber.

<Manufacture of absorbent articles (diapers)>
A diaper of Comparative Example 4B was obtained in the same manner as Example 1B, except that the nonwoven fabric of Comparative Example 4B was used as the top sheet and core wrap sheet, and the nonwoven fabric of Example 1B was not used.

[Comparative Example 5B]
<Manufacture of composite fiber and nonwoven fabric>
A nonwoven fabric of Comparative Example 5B was obtained in the same manner as in Example 4B except that the first component and the second component were combined so as to have a blending ratio of 50% by mass to 50% by mass. The nonwoven fabric of Comparative Example 5B is a nonwoven fabric having a single layer structure composed of a nonwoven fabric mainly composed of an eccentric core-sheath type composite fiber.

[Comparative Example 6B]
<Manufacture of composite fiber and nonwoven fabric>
Polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min), low crystalline polyolefin resin PP1 (melting point 52 ° C., MFR 50 g / 10 min) and organic additive (erucamide 5% PP master) in the second component Batch (based on polypropylene resin and containing 5% by mass of active ingredient erucamide) and inorganic pigment (50% titanium oxide PP masterbatch (based on polypropylene resin and 50% by mass of active ingredient titanium oxide) The composite fiber was spun in the same manner as in Example 4B except that the blending ratio was 56 mass%: 20 mass%: 4 mass%: 20 mass% in terms of solid content. Due to poor spinning, the nonwoven fabric of Comparative Example 6B was not obtained.

[Comparative Example 7B]
<Manufacture of composite fiber and nonwoven fabric>
Other than changing the predetermined basis weight of the nonwoven fabric made of composite fiber from 15 g / m ² to 46 g / m ² and changing the predetermined basis weight of the nonwoven fabric made of single structure fiber from 5 g / m ² to 13 g / m ² Produced a nonwoven fabric of Comparative Example 7B in the same manner as Example 5B. The nonwoven fabric of Comparative Example 7B is a nonwoven fabric having a three-layer structure in which one single-structure fiber nonwoven fabric is laminated on each side of a nonwoven fabric composed of an eccentric core-sheath type composite fiber.

<Manufacture of absorbent articles (diapers)>
A diaper of Comparative Example 7B was obtained in the same manner as Example 1B, except that the nonwoven fabric of Comparative Example 7B was used as the core wrap sheet and the nonwoven fabric of Example 1B was not used.

[Comparative Example 8B]
<Manufacture of composite fiber and nonwoven fabric>
Polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min), low crystalline polyolefin resin PP1 (melting point 52 ° C., MFR 50 g / 10 min) and organic additive (erucamide 5% PP master) in the second component Batch (based on polypropylene resin and containing 5% by mass of active ingredient erucamide) and inorganic pigment (50% titanium oxide PP masterbatch (based on polypropylene resin and 50% by mass of active ingredient titanium oxide) The non-woven fabric of Comparative Example 8B is obtained in the same manner as in Example 4B except that the blending ratio is 94% by mass: 0% by mass: 4% by mass: 2% by mass in terms of solid content. The nonwoven fabric of Comparative Example 8B is a two-layered nonwoven fabric in which a single-structure fiber nonwoven fabric is laminated on a composite fiber nonwoven fabric.

<Manufacture of absorbent articles (diapers)>
The nonwoven fabric of Comparative Example 8B was used as the top sheet, and the core wrap sheet was the same as Example 1B except that tissue paper having a basis weight of 12 g / m ² was used instead of the nonwoven fabric of Example 1B. I got a diaper.

[Comparative Example 9B]
<Manufacture of composite fiber and nonwoven fabric>
Polypropylene resin PP (melting point 162 ° C., MFR 40 g / 10 min), low crystalline polyolefin resin PP1 (melting point 52 ° C., MFR 50 g / 10 min) and organic additive (erucamide 5% PP master) in the second component Batch (based on polypropylene resin and containing 5% by mass of active ingredient erucamide) and inorganic pigment (50% titanium oxide PP masterbatch (based on polypropylene resin and 50% by mass of active ingredient titanium oxide) The mixing ratio is 34% by mass: 60% by mass: 4% by mass: 2% by mass in terms of solid content, and the first component and the second component are 30% by mass: 70% by mass. The composite fiber was spun in the same manner as in Example 4B, except that the composite fiber was compounded so that the blending ratio was equal to 50%. Because was discontinued production of nonwovens.

[Example 1C]
<Manufacture of a nonwoven fabric> As a 1st component, low crystalline polypropylene resin (melting | fusing point 52 degreeC, MFR50g / 10min) and polypropylene resin (melting point 162 degreeC, MFR40g / 10min) are 80 mass% in conversion of solid content. : A mixture mixed at a blending ratio of 20% by mass was prepared. As the second component, polypropylene resin (melting point: 162 ° C., MFR: 40 g / 10 min), low crystalline polypropylene resin (melting point: 52 ° C., MFR: 50 g / 10 min), and organic additive (erucamide 5% PP) Masterbatch (based on polypropylene resin and containing 5% by mass of active ingredient erucamide) and inorganic pigment (50% titanium oxide PP masterbatch (based on polypropylene resin and 50% of active ingredient titanium oxide) %))) Was mixed at a blending ratio of 50% by mass: 44% by mass: 4% by mass: 2% by mass in terms of solid content.

extruders

130 and 140, respectively, to obtain respective melts. Next, each melt is discharged from a spinneret 150 having a composite spinning nozzle configured to discharge by forming a core-sheath type composite fiber structure, and the first component and the second component are discharged. A core-sheath composite fiber composited so as to have a blending ratio of 70% by mass to 30% by mass was spun.

The spun composite fiber is cooled by cooling air 160 and further tensioned by drawing air 170 to a predetermined fineness (1.5 denier) and collected as it is on the collecting belt of the collecting conveyor 180. And it was deposited so that it might become a predetermined weight per unit area (15 g / m < ² >). Next, heat and pressure were applied to the deposited composite fiber with a hot embossing roll 190 to melt some fibers and entangle the fibers. This obtained the nonwoven fabric of Example 1C. The nonwoven fabric of Example 1C is a single-layered nonwoven fabric composed of a nonwoven fabric mainly composed of core-sheath composite fibers.

<Manufacture of absorbent articles (diapers)>
The diaper was manufactured with the following manufacturing methods using the nonwoven fabric of Example 1C as a top sheet.

The formed recesses were the lattice-like grooves 21 composed of the

grooves

Next, the embossed laminate is cut into a length required for one diaper using a cutting device, joined to a liquid-impermeable back sheet and a cover sheet excellent in touch, and processed into a diaper shape. Thus, a diaper of Example 1C was obtained.

[Example 2C]
<Manufacture of non-woven fabric>
The blending ratio of the low crystalline polypropylene resin (melting point 52 ° C., MFR 50 g / 10 min) and the polypropylene resin (melting point 162 ° C., MFR 40 g / 10 min) in the first component is 100% by mass: 0% by mass in terms of solid content. A nonwoven fabric of Example 2C was obtained in the same manner as Example 1C except that. The nonwoven fabric of Example 2C is a single-layered nonwoven fabric composed of a nonwoven fabric mainly composed of core-sheath composite fibers.

<Manufacture of absorbent articles (diapers)>
A diaper of Example 2C was obtained in the same manner as Example 1C except that the nonwoven fabric of Example 2C was used instead of the nonwoven fabric of Example 1C as the top sheet.

[Example 3C]
<Manufacture of non-woven fabric>
The blend ratio of the low crystalline polypropylene resin PP (melting point 52 ° C., MFR 50 g / 10 min) and the polypropylene resin (melting point 162 ° C., MFR 40 g / 10 min) in the first component is 90% by mass: 10% in terms of solid content. The nonwoven fabric of Example 3C was obtained in the same manner as Example 1C except that the first component and the second component were combined so as to have a blending ratio of 50% by mass to 50% by mass. The nonwoven fabric of Example 3C is a single-layered nonwoven fabric composed of a nonwoven fabric mainly composed of core-sheath composite fibers.

<Manufacture of absorbent articles (diapers)>
A diaper of Example 3C was obtained in the same manner as Example 1C except that the nonwoven fabric of Example 3C was used instead of the nonwoven fabric of Example 1C as the top sheet.

[Example 4C]
<Manufacture of non-woven fabric>
As the second component, linear low density polyethylene (melting point 129 ° C., MFR 17 g / 10 min), octane modified polyethylene (melting point 80 ° C., MFR 30 g / 10 min), and organic additive (erucamide 5% PP masterbatch) (Based on polypropylene resin and containing 5% by mass of active ingredient erucamide) and inorganic pigment (50% titanium oxide PP masterbatch (based on polypropylene resin and 50% by mass of active ingredient titanium oxide) Are included at a blending ratio of 50% by mass: 44% by mass: 4% by mass: 2% by mass in terms of solid content, and the first component and the second component are 90% by mass: 10% by mass. A core-sheath composite fiber nonwoven fabric was obtained in the same manner as in Example 3C except that the composite was made so as to have a mixing ratio of%.

As a third component, polypropylene resin (melting point 162 ° C., MFR 40 g / 10 min) and organic additive (erucic acid amide 5% PP masterbatch (based on polypropylene resin, active ingredient erucic acid amide 5% by mass) And a mixture of 97 mass% and 3 mass% in terms of solid content. The third component was melted with an extruder to obtain a melt. Next, the melt of the third component is discharged from a spinneret having a spinning nozzle configured to discharge by forming a single structure fiber, and the third component has a blending ratio of 100% by mass. Single structure fibers were spun. In addition, in this specification, a single structure fiber means the fiber comprised with the same and uniform material in the cross section perpendicular | vertical to a longitudinal direction.

The spun single structure fiber is cooled with cooling air, and further tension is applied with drawing air to a predetermined fineness (1.4 denier). It was collected on top and deposited so as to have a predetermined basis weight (5 g / m ² ). Next, heat and pressure were applied to the deposited composite fiber with a hot embossing roll 190 to melt some fibers and entangle the fibers. Thereby, the nonwoven fabric of Example 4 was obtained. The nonwoven fabric of Example 4C is a nonwoven fabric having a two-layer structure in which a nonwoven fabric mainly composed of a single structure fiber (hereinafter, also simply referred to as “single structure fiber nonwoven fabric”) is laminated on a composite fiber nonwoven fabric.

<Manufacture of absorbent articles (diapers)>
A diaper of Example 4C was obtained in the same manner as Example 1C except that the nonwoven fabric of Example 4C was used instead of the nonwoven fabric of Example 1C as the top sheet.

[Example 5]
<Manufacture of non-woven fabric>
A composite fiber nonwoven fabric is obtained by combining the first component and the second component so as to have a blending ratio of 70% by mass: 30% by mass. A nonwoven fabric of Example 5C was obtained in the same manner as Example 4C except that each layer was laminated at 4 g / m ² . The nonwoven fabric of Example 5C is a nonwoven fabric having a three-layer structure in which a single-structure fiber nonwoven fabric is laminated on both surfaces of a composite fiber nonwoven fabric.

<Manufacture of absorbent articles (diapers)>
A diaper of Example 5C was obtained in the same manner as Example 1C except that the nonwoven fabric of Example 5C was used instead of the nonwoven fabric of Example 1C as the top sheet.

[Comparative Example 1C]
<Manufacture of non-woven fabric>
The blending ratio of the low crystalline polypropylene resin (melting point 52 ° C., MFR 50 g / 10 min) and the polypropylene resin (melting point 162 ° C., MFR 40 g / 10 min) in the first component is 70% by mass: 30% by mass in terms of solid content. A nonwoven fabric of Comparative Example 1C was obtained in the same manner as Example 1C except that.
<Manufacture of absorbent articles (diapers)>
A diaper of Comparative Example 1C was obtained in the same manner as Example 1C except that the nonwoven fabric of Comparative Example 1C was used instead of the nonwoven fabric of Example 1C as the top sheet.

[Comparative Example 2C]
<Manufacture of non-woven fabric>
Linear low density polyethylene (melting point: 129 ° C., MFR: 20 g / 10 min), octane modified polyethylene (melting point: 80 ° C., MFR: 30 g / 10 min) in the second component, and organic additive (erucamide 5% PP master batch ( An active ingredient erucic acid amide based on a polypropylene resin in an amount of 5% by mass) and an inorganic pigment (titanium oxide 50% PP master batch (based on a polypropylene resin and an active ingredient titanium oxide in an amount of 50% by mass) The mixing ratio is 44% by mass: 50% by mass: 4% by mass: 2% by mass in terms of solid content, and the first component and the second component are 40% by mass: 60% by mass. The composite fiber was spun in the same manner as in Example 4C except that it was combined so as to have a blending ratio, and the nonwoven fabric of Comparative Example 2C was not obtained due to poor spinnability.

[Comparative Example 3C]
<Manufacture of non-woven fabric>
The composite fiber was spun in the same manner as in Comparative Example 2 and C except that the first component and the second component were combined so as to have a blending ratio of 95% by mass to 5% by mass. Although spinning was possible, the production of the nonwoven fabric was stopped because the texture of the laminated composite fibers was poor.

[Comparative Example 4C]
<Manufacture of non-woven fabric>
Linear low density polyethylene (melting point: 129 ° C., MFR: 20 g / 10 min), octane modified polyethylene (melting point: 80 ° C., MFR: 30 g / 10 min) in the second component, and organic additive (erucamide 5% PP master batch ( An active ingredient erucic acid amide based on a polypropylene resin in an amount of 5% by mass) and an inorganic pigment (titanium oxide 50% PP master batch (based on a polypropylene resin and an active ingredient titanium oxide in an amount of 50% by mass) The mixing ratio is 44% by mass: 32% by mass: 4% by mass: 20% by mass in terms of solid content, and the first component and the second component are 70% by mass: 30% by mass. The composite fiber was spun in the same manner as in Comparative Example 3C except that the blending ratio was changed, because the nonwoven fabric of Comparative Example 4C was not obtained due to poor spinnability.

[Comparative Example 5C]
<Manufacture of non-woven fabric>
As the second component, polypropylene resin (melting point 162 ° C., MFR 40 g / 10 min), low crystalline polypropylene resin (melting point 52 ° C., MFR 50 g / 10 min), and organic additive (erucamide 5% PP master batch) (Based on polypropylene resin and containing 5% by mass of active ingredient erucamide) and inorganic pigment (50% titanium oxide PP masterbatch (based on polypropylene resin and 50% by mass of active ingredient titanium oxide) Is used in the same manner as in Example 5C, except that a non-woven fabric of Comparative Example 5C is obtained. The nonwoven fabric of Comparative Example 5C is a nonwoven fabric having a three-layer structure in which one single-structure fiber nonwoven fabric is laminated on each side of the composite fiber nonwoven fabric with a basis weight of 4 g / m ² .

<Manufacture of absorbent articles (diapers)>
A diaper of Comparative Example 5C was obtained in the same manner as Example 1C except that the nonwoven fabric of Comparative Example 5C was used instead of the nonwoven fabric of Example 1C as the top sheet.

<Evaluation>
The following items were evaluated for crimped fibers, crimped nonwoven fabrics, and diapers according to Examples and Comparative Examples.

I. The number of crimps of the fiber The number of crimps of the fiber was determined according to Japanese Industrial Standard JIS L1015.

II. Average fiber diameter of non-woven fabric (denier: denier)
Using an electron microscope (S-3500N manufactured by Hitachi, Ltd.), a photograph of the fiber nonwoven fabric at a magnification of 1000 times was taken. Arbitrary 100 fibers were selected from the fibers constituting the fiber nonwoven fabric, and the width (diameter) of the selected fibers was measured. The average of the measurement results was taken as the average fiber diameter. If it is less than 0.1 denier, the rigidity of the fiber becomes low and the crimped structure cannot be maintained. If it exceeds 10 denier, the feeling of touch becomes worse.

III. Non-woven fabric weight (g / m ² )
Three samples each having a length of 50 cm and a width of 50 cm were taken, the weight of each sample was measured, the average value of the obtained values was converted per unit area, and the first decimal place was rounded off.
In addition, let the flow direction at the time of nonwoven fabric preparation be the vertical direction, and let the direction orthogonal to the vertical direction be the horizontal direction. When the nonwoven fabric was a laminate (multi-layered product) containing a plurality of nonwoven fabrics, the basis weight was measured for each layer.

IV. Nonwoven fabric porosity (%)
About the arbitrary location of the fiber nonwoven fabric, based on JIS1096, thickness was measured under 0.7 kPa for 10 seconds using the thickness measuring device. From the result, the basis weight of the nonwoven fabric, and the raw material density used for the nonwoven fabric, the porosity was calculated by rounding off the first decimal place of the numerical value obtained by the following formula. However, when the obtained nonwoven fabric was a laminate (multi-layered product), a single-layer nonwoven fabric obtained by removing the spunbond nonwoven fabric was measured.
Porosity (%) = [1- (Weight / Thickness / Density)] × 100
In the nonwoven fabric according to the present embodiment, the porosity of the nonwoven fabric is 80% or more, preferably 90% or more. If it is less than 80%, the stretchability to prevent wrinkles is insufficient.
In the nonwoven fabric according to the present embodiment, the porosity of the nonwoven fabric is 80% or more, preferably 90% or more. If it is less than 80%, the stretchability to prevent wrinkles is insufficient.
The nonwoven fabric according to the present embodiment having the above-described configuration is difficult to wrinkle when subjected to shear deformation, and even if the shear angle is changed, the change in shear force per angle is small.

V. Elongation rate of nonwoven fabric (longitudinal direction, lateral direction)
The elongation (%) in both the vertical and horizontal directions was evaluated for the sheets of Examples and Comparative Examples using a general tensile tester based on Japanese Industrial Standard JIS P 8113: 2006.

The flow direction during production of the nonwoven fabric was defined as the vertical direction, and the direction perpendicular to the vertical direction was defined as the horizontal direction. The test piece was cut out so that the sheet width was 50 mm and the length exceeded the chuck-to-chuck distance of 100 mm and could be held by the chuck. The tensile speed was 300 mm / min, and the elongation at the time when the tensile stress reached the maximum was divided by the original length to obtain a percentage.

As is clear from the results shown in Table 1, the elongation percentage of the sheet of the example according to the present embodiment was higher than that of the comparative example in both the vertical direction and the horizontal direction.

The longitudinal elongation was 57.4% to 88.2%, both of which were 50% or more. Moreover, the elongation in the horizontal direction was 90.9% to 122.1%, and all were 85% or more.

In contrast, the longitudinal elongation of the comparative sheet was 45% or less, and the lateral elongation was 80% or less.

VI. Evaluation of rate of change of shear force (DO, Dmax) of non-woven fabric Cut a non-woven fabric sample into a 20cm square shape, and set one piece on a tensile / shear tester (KES-FB1-AUTO-A, manufactured by Kato Tech Co., Ltd.). The shear force was measured under standard measurement conditions. Regarding the obtained shear angle-shear force data, the change rate DO + of the straight line portion near the shear angle 0 ° in the positive direction, the change rate Dmax + near the maximum shear angle, and the shear angle 0 in the negative direction
The rate of change DO− of the straight line portion near ° and the rate of change Dmax− near the minimum shear angle were determined.

The average value of the change rate DO + and the change rate DO− is DO, and the change rate Dmax + and the change rate Dmax
The ratio DO / Dmax of the change rate was calculated with the average value of − as Dmax.

VII. Wrinkles of non-woven fabric When the above-mentioned Dmax was evaluated, the state of wrinkles near the maximum shear angle was visually confirmed. The evaluation criteria were the following four-level evaluation (indicated by the symbols ◎, ○, Δ, × in order from the highest evaluation). The most applicable evaluation was adopted with a parameter (N) of 30.
◎: No wrinkles ○: Wrinkles with slight undulation are visible on the surface △: Wrinkles with a wide pitch are observed ×: Wrinkles with a fine pitch are observed

VIII. Diaper feel (feel)
The non-woven fabric created in this example is processed into a paper diaper as a cover sheet, and 50 subjects are given a sense of touch with a sensory evaluation on a five-point scale (shown as one of the numbers 1 to 5 where 5 is the best). The average value of 50 persons was used as the evaluation value of the touch feeling.

IX. Number of diapers that were torn The diaper was held with one hand and was swung up and down to reciprocate at a distance of 30 cm in 1 second. This was repeated 10 times. Subsequently, the appearance was visually confirmed, and a case where there was a tear or a content (SAP) leaked out was determined to be “has been torn”. Fifty test subjects were asked to perform this test, and the number determined to be broken was counted. The smaller the number, the harder it is to tear and the better the performance.

The sheet made of the crimped nonwoven fabric of the example according to the present embodiment thus exhibits excellent elongation in both the vertical direction and the horizontal direction.

When this sheet is used as a sheet covering at least a part of the absorbent body of the absorbent body composite according to the present embodiment, when forming a dent from the sheet side to the absorbent body side in the absorbent body body by embossing. Even if the sheet is pulled toward the dent, the sheet is hardly broken. In addition, even when there is a relatively hard material such as SAP particles under the sheet, the material can be prevented from leaking through the sheet in the vicinity of the portion squeezed to form the dent or in the vicinity thereof.

As is clear from the above examples and comparative examples, it has been found that the diaper using the crimped nonwoven fabric for the core wrap and / or the top sheet has improved the tearing problem compared to the diaper not using the diaper. It was.

In particular, it was found that when the crimped nonwoven fabric was used for the top sheet (sheet located on the surface layer side), the tactile sensation was good. It was found that even when a crimped nonwoven fabric was used for the core wrap, the tactile sensation was better than when no crimped nonwoven fabric was used for any of the sheets.

In particular, it was found that when a crimped nonwoven fabric was used for the top sheet (sheet located on the surface layer side), generation of wrinkles was well prevented. It was found that the generation of wrinkles was also prevented when a crimped nonwoven fabric was used for the core wrap.

Hereinafter, examples of preferred embodiments of the absorber complex according to the present embodiment will be shown.

[1] An absorber complex including an absorber and one or a plurality of sheets provided at a position covering at least a part of the absorber, the absorber complex from the sheet side An absorbent body composite having a depression formed by squeezing toward the absorber side, wherein at least one of the sheets forming the depression is formed of a crimped nonwoven fabric.

This configuration includes a configuration in which a top sheet is disposed directly on the absorber. Moreover, after holding an absorber with a hydrophilic sheet | seat, the structure which distribute | arranged the top sheet | seat is contained. That is, this aspect includes a configuration of an absorber complex including a so-called core wrap type absorber and a top sheet covering the so-called core wrap type absorber. The following [2] and [3] represent this.

[2] In the above [1], the sheet is a core wrap that wraps an absorbent body, and one or more (including all) one or more layers constituting the core wrap is formed of a crimped nonwoven fabric. The absorbent complex as described.

[3] The sheet is a sheet provided at a position covering the absorber, and one or a plurality (including all) of one or a plurality of layers constituting the sheet is formed of a crimped nonwoven fabric. , [1] or [2].

The hydrophilic sheet may be attached so as to enclose the absorbent body, or may be simply placed on the front and back without wrapping the end of the absorbent body. Moreover, you may provide the liquid diffusion sheet which improves liquid diffusibility between a top sheet and a hydrophilic sheet, or between a hydrophilic sheet and an absorber. This sheet makes it easier for body fluid to diffuse.

In this embodiment, the sheet having the concave portion formed by compression is composed of a crimped nonwoven fabric. Therefore, the sheet exhibits a high elongation rate, and the sheet is not easily torn when the concave portion is compressed and formed or thereafter.

[4] The absorber complex includes a plurality of groove-shaped recesses, and at least some of the plurality of groove-shaped recesses intersect with each other or extend in directions. [1] To [3].

When the concave part to be pressed is groove-shaped, when the concave part is pressed into the sheet, the sheet is pushed down with a larger area than in the case of the dot-like concave part, so that the end is easily broken. In addition, when there are a plurality of groove-like recesses, the recesses are squeezed in duplicate, or pressure tends to be easily applied to the recesses.

On the other hand, the absorbent body composite according to the present embodiment is not easily torn when being squeezed because the sheet forming the recess is made of a crimped nonwoven fabric.

[5] The absorbent composite according to any one of [1] to [4], wherein the sheet forming the concave portion is provided on a liquid absorption surface of the absorbent composite.

[6] The absorbent body according to any one of [1] to [5], wherein the longitudinal elongation of the sheet is 50% or more as measured by a tensile test based on Japanese Industrial Standard JIS P 8113. Complex.

[7] The absorbent body according to any one of [1] to [6], wherein the lateral elongation of the sheet is 85% or more as measured by a tensile test based on Japanese Industrial Standard JIS P 8113. Complex.

[8] The absorbent composite according to any one of [1] to [7], wherein the concave is a concave formed by embossing from the sheet side to the absorbent composite.

According to these aspects, since the sheet is composed of a crimped nonwoven fabric having a high elongation rate, the sheet is not easily torn, and internal materials (such as SAP) covered with the sheet are difficult to leak.

10 Disposable Diaper 10F Front Body Area 10R Back Body Area 10C Inseam Area 10W Waist Around Opening 10L Leg Around Opening 10J Closure 10T Waste Tape 11 Cover Sheet 11A Notch 11B Inner Cover Sheet 11C Outer Cover Sheet 12 Back Sheet ( Back sheet)
13 Absorber 13B Hydrophilic sheet 14 Top sheet (surface sheet)
15, 17 Thread rubber 18 Side sheet 19 Thread rubber 21 Recess (groove)
21a 1st groove | channel 21b 2nd groove | channel 22 Squeeze part 24 Flat part

Claims

An absorber complex including an absorber and one or more sheets provided at a position covering at least a part of the absorber,
The absorber complex has a depression formed by squeezing from the sheet side toward the absorber side,
At least one of the sheets forming the recess is an absorbent composite in which a region including the recess is formed of a crimped nonwoven fabric.
The sheet is a core wrap that wraps the absorbent body,
The absorbent core composite according to claim 1, wherein one or a plurality (including all) of one or a plurality of layers constituting the core wrap is formed of a crimped nonwoven fabric.
The sheet is a sheet provided at a position covering the absorber,
The absorbent composite according to claim 1 or 2, wherein one or a plurality (including all) of one or a plurality of layers constituting the sheet is formed of a crimped nonwoven fabric.
The absorbent body complex includes a plurality of groove-shaped recesses, and at least some of the plurality of groove-shaped recesses intersect with each other or extend in directions. The absorber complex according to any one of the above.
The absorbent composite according to any one of claims 1 to 4, wherein the sheet forming the recess is provided on a liquid absorption surface of the absorbent composite.
The absorbent composite according to any one of claims 1 to 5, wherein an elongation percentage in the longitudinal direction of the sheet is 50% or more as measured by a tensile test based on Japanese Industrial Standard JIS P 8113.
The absorbent composite according to any one of claims 1 to 6, wherein an elongation percentage in the transverse direction of the sheet is 85% or more as measured by a tensile test based on Japanese Industrial Standard JIS P 8113.
The absorbent composite according to any one of claims 1 to 7, wherein the concave is a concave formed by embossing from the sheet side to the absorbent composite.
A nonwoven fabric mainly composed of a composite fiber containing a first component and a second component which are fiber-forming components,
Each of the first component and the second component is mainly composed of a thermoplastic resin,
The first component includes a long-chain branched structure polyolefin resin,
In the measurement of the shearing force with a tensile / shear measuring device, the nonwoven fabric has a change rate of the shearing force per angle centered at a shearing angle of 0 ° as DO and a maximum shearing angle at which the maximum shearing force is obtained. A nonwoven fabric characterized by satisfying a relationship of 1≤DO / Dmax≤5, where Dmax is the rate of change in the shearing force.
The long chain branched structure polyolefin resin according to claim 9, wherein the melt flow rate (MFR) measured at a load of 2.16 kg and a temperature of 230 ° C in accordance with ASTM D1238 is 4 g / 10 min or more. The nonwoven fabric described.
The first component includes the long-chain branched structure polyolefin resin in an amount of 0.5% by mass or more and 10% by mass or less based on the total solid content of the first component. The nonwoven fabric according to claim 9 or 10.
12. The composite fiber according to claim 9, wherein the composite fiber includes the first component in an amount of 10% by mass or more and 40% by mass or less based on the total solid content of the composite fiber. The nonwoven fabric described in 1.
The first component and the second component each include a thermoplastic resin in an amount of 90% by mass or more and 100% by mass or less based on the total solid content of each component. The nonwoven fabric according to any one of 12 above.
The nonwoven fabric according to any one of claims 9 to 13, wherein each of the first component and the second component is mainly composed of polypropylene.
The nonwoven fabric according to any one of claims 9 to 13, wherein the first component is mainly composed of polypropylene, and the long-chain branched structure polyolefin resin is a long-chain branched structure polypropylene.
The composite fiber according to any one of claims 9 to 15, wherein the composite fiber is a core-sheath type composite fiber in which the first component is a core component and the second component is a sheath component. Non-woven fabric.
The nonwoven fabric according to claim 16, wherein the core-sheath type composite fiber is an eccentric core-sheath type composite fiber.
The nonwoven fabric according to any one of claims 9 to 15, wherein the conjugate fiber is a side-by-side type conjugate fiber.
At least one of the first component and the second component includes the following a) to g):
a) Mesopentad fraction [mmmm] is 30 mol% or more and 80 mol% or less,
b) The racemic pentad fraction [rrrr] and [1-mmmm] satisfy the relationship [rrrr] / [1-mmmm] ≦ 0.1;
c) the racemic meso racemic meso pentad fraction [rmrm] is greater than 2.5 mol%,
d) Mesotriad fraction [mm], racemic triad fraction [rr], and triad fraction [mr] satisfy the relationship [mm] × [rr] / [mr] 2 ≦ 2.0,
e) The weight average molecular weight [Mw] is 10,000 or more and 200,000 or less,
f) The weight average molecular weight [Mw] and the number average molecular weight [Mn] satisfy the relationship of molecular weight distribution [Mw] / [Mn] ≦ 4,
g) The amount of the extract by boiling diethyl ether is 0% by mass or more and 10% by mass or less based on the total solid content of the low crystalline polyolefin resin.
The non-woven fabric according to any one of claims 9 to 18, comprising a low crystalline polyolefin resin satisfying the above condition in an amount of 5% by mass or more and 50% by mass or less based on the total solid content.
The nonwoven fabric according to any one of claims 9 to 19, wherein the nonwoven fabric contains the composite fiber in an amount of 60% by mass or more based on the total solid content of the nonwoven fabric.
21. An absorbent article, wherein the crimped nonwoven fabric is the nonwoven fabric according to any one of claims 9 to 20.
A composite fiber comprising a first component and a second component which are fiber-forming components,
The first component and the second component are each composed mainly of a thermoplastic resin,
The first component includes a long-chain branched structure polyolefin resin,
The long-chain branched polyolefin resin is a composite fiber having a melt flow rate measured at a load of 2.16 kg and a temperature of 230 ° C. in accordance with ASTM D1238 of 4 g / 10 min or more.
The first component includes the long-chain branched structure polyolefin resin in an amount of 0.5% by mass or more and 10% by mass or less based on the total solid content of the first component. The composite fiber according to claim 22.
The composite fiber according to claim 22 or 23, wherein the composite fiber contains the first component in an amount of 10 mass% or more and 40 mass% or less based on the total solid content of the composite fiber. .
The first component and the second component each include a thermoplastic resin in an amount of 90% by mass or more and 100% by mass or less based on the total solid content of each component. 25. The composite fiber according to any one of 24.
The composite fiber according to any one of claims 22 to 25, wherein each of the first component and the second component is mainly composed of polypropylene.
The composite fiber according to any one of claims 22 to 26, wherein the first component is mainly composed of polypropylene, and the long-chain branched structure polyolefin resin is a long-chain branched structure polypropylene.
28. The composite fiber according to any one of claims 22 to 27, wherein the composite fiber is a core-sheath type composite fiber having the first component as a core component and the second component as a sheath component. Composite fiber.
The composite fiber according to claim 28, wherein the core-sheath type composite fiber is an eccentric core-sheath type composite fiber.
28. The composite fiber according to any one of claims 22 to 27, wherein the composite fiber is a side-by-side type composite fiber.
At least one of the first component and the second component includes the following a) to g):
a) Mesopentad fraction [mmmm] is 30 mol% or more and 80 mol% or less,
b) The racemic pentad fraction [rrrr] and [1-mmmm] satisfy the relationship [rrrr] / [1-mmmm] ≦ 0.1;
c) the racemic meso racemic meso pentad fraction [rmrm] is greater than 2.5 mol%,
d) Mesotriad fraction [mm], racemic triad fraction [rr], and triad fraction [mr] satisfy the relationship [mm] × [rr] / [mr] 2 ≦ 2.0,
e) The weight average molecular weight [Mw] is 10,000 or more and 200,000 or less,
f) The weight average molecular weight [Mw] and the number average molecular weight [Mn] satisfy the relationship of molecular weight distribution [Mw] / [Mn] ≦ 4,
g) The amount of the extract by boiling diethyl ether is 0% by mass or more and 10% by mass or less based on the total solid content of the low crystalline polyolefin resin.
The composite fiber according to any one of claims 22 to 30, wherein the low crystalline polyolefin resin satisfying the above condition is contained in an amount of 5% by mass or more and 50% by mass or less based on the total solid content.
A non-woven fabric mainly comprising the conjugate fiber according to claim 31,
The nonwoven fabric is, in the measurement of the shear force by the tensile-shear measurement device, an angle of a maximum angle of shear angle the maximum shear force can be obtained by the rate of change of the shear force per angle around the shear angle of 0 ° and D 0 A nonwoven fabric characterized by satisfying a relationship of 1 ≦ D 0 / Dmax ≦ 5, where Dmax is the rate of change in the shearing force per unit.
The nonwoven fabric according to claim 32, wherein the composite fiber contains the first component in an amount of 50 mass% or more and 90 mass% or less based on the total solid content of the composite fiber.
The first component and the second component each include a thermoplastic resin in an amount of 90% by mass or more and 100% by mass or less based on the total solid content of each component. 33. The nonwoven fabric according to 33.
The low crystalline polyolefin resin is a low crystalline polypropylene, and the first component includes the low crystalline polypropylene and a polypropylene different from the low crystalline polypropylene. 35. The nonwoven fabric according to any one of 34 to 34.
The nonwoven fabric according to any one of claims 32 to 35, wherein the nonwoven fabric contains the composite fiber in an amount of 60% by mass or more based on the total solid content of the nonwoven fabric.