WO2020085502A1 - 不織布積層体、並びに、伸縮性不織布積層体、繊維製品、吸収性物品及び衛生マスク - Google Patents
不織布積層体、並びに、伸縮性不織布積層体、繊維製品、吸収性物品及び衛生マスク Download PDFInfo
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- WO2020085502A1 WO2020085502A1 PCT/JP2019/041999 JP2019041999W WO2020085502A1 WO 2020085502 A1 WO2020085502 A1 WO 2020085502A1 JP 2019041999 W JP2019041999 W JP 2019041999W WO 2020085502 A1 WO2020085502 A1 WO 2020085502A1
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- WO
- WIPO (PCT)
- Prior art keywords
- nonwoven fabric
- stretchable
- laminate according
- fabric laminate
- elastic
- Prior art date
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Images
Classifications
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Definitions
- Patent Document 2 it is proposed to add a highly crystalline polypropylene or a release agent to the low crystalline polypropylene in order to improve the stickiness of the spunbonded nonwoven fabric.
- Patent Document 4 discloses a laminate of a nonwoven fabric containing low crystalline polypropylene, a mixed fiber spunbonded nonwoven fabric of thermoplastic elastomer filaments and thermoplastic resin filaments.
- an aspect of the present invention is to provide a nonwoven fabric laminate having excellent stretchability and excellent stress maintenance, and a stretchable nonwoven fabric laminate, a textile product, an absorbent article, and a sanitary mask.
- a stretchable nonwoven fabric laminate which is a stretched product of the nonwoven fabric laminate according to any one of [1] to [10].
- a fiber product comprising the nonwoven fabric laminate according to any one of [1] to [10] or the stretchable nonwoven fabric laminate according to [11].
- An absorbent article including the nonwoven fabric laminate according to any one of [1] to [10] or the stretchable nonwoven fabric laminate according to [11].
- a sanitary mask including the nonwoven fabric laminate according to any one of [1] to [10] or the stretchable nonwoven fabric laminate according to [11].
- the nonwoven fabric laminate includes an elastic nonwoven fabric containing an ⁇ -olefin copolymer having a ratio (E40 / E23) of the storage elastic modulus E40 at 40 ° C. to the storage elastic modulus E23 at 23 ° C. of 37% or more, A stretchable spunbonded nonwoven fabric arranged on at least one side of the elastic nonwoven fabric.
- the nonwoven fabric laminate may be configured to include other layers.
- the basis weight of the elastic nonwoven fabric is preferably 120 g / m 2 or less, more preferably 80 g / m 2 or less, further preferably 50 g / m 2 or less, and 40 g / m 2 to 2 g / m 2 Is particularly preferable, 30 g / m 2 to 5 g / m 2 is even more preferable, and 25 g / m 2 to 8 g / m 2 is extremely preferable.
- the fibers constituting the elastic nonwoven fabric preferably have a fiber diameter of 50 ⁇ m or less, more preferably 40 ⁇ m or less, and further preferably 30 ⁇ m or less.
- the fibers constituting the elastic nonwoven fabric may have a fiber diameter of 1.0 ⁇ m or more.
- the content ratio of the constituent unit derived from ethylene is preferably 1% by mass to 50% by mass, and 5% by mass to 25% by mass. % Is more preferable, 10% by mass to 20% by mass is further preferable, and 12% by mass to 18% by mass is particularly preferable.
- the ⁇ -olefin copolymer may be any of an alternating copolymer, a graft copolymer, a block copolymer and a random copolymer.
- the storage elastic modulus E23 of the ⁇ -olefin copolymer at 23 ° C. is preferably 30 MPa or less, more preferably 22 MPa or less, and 20 MPa from the viewpoint of making the nonwoven fabric laminate more excellent in stretchability.
- the pressure is more preferably below, and particularly preferably 18 MPa or below.
- the storage elastic modulus E40 at 40 ° C. of the ⁇ -olefin copolymer is preferably 10 MPa or less, and 9 MPa or less from the viewpoint of making the nonwoven fabric laminate to have lower stress and more excellent stretchability. Is more preferable.
- the storage elastic modulus E23 at 23 ° C. of the ⁇ -olefin copolymer may be 5 MPa or more, or 10 MPa or more.
- the storage elastic modulus E40 at 40 ° C. of the ⁇ -olefin copolymer may be 3 MPa or more, or 5 MPa or more.
- ⁇ - olefin copolymer density (ASTM D 1505) is preferably in the range of 0.850g / cm 3 ⁇ 0.950g / cm 3, of 0.855g / cm 3 ⁇ 0.900g / cm 3 more preferably in the range, more preferably in the range of 0.860g / cm 3 ⁇ 0.895g / cm 3.
- the density of the ⁇ -olefin copolymer is a value obtained by measurement according to the density gradient method of JIS K7112 (1999).
- the molecular weight distribution (Mw / Mn) of the ⁇ -olefin copolymer is preferably 1.5 to 5.0.
- the Mw / Mn is more preferably 1.5 to 4.5 from the viewpoint that fibers having excellent spinnability and particularly excellent fiber strength can be obtained.
- the mass average molecular weight (Mw) and number average molecular weight (Mn) of the ⁇ -olefin copolymer are values determined by GPC (gel permeation chromatography), and are values measured under the following conditions.
- the mass average molecular weight (Mw) is a polystyrene-equivalent mass average molecular weight
- the molecular weight distribution (Mw / Mn) is a value calculated from the number average molecular weight (Mn) and the mass average molecular weight (Mw) measured in the same manner. .
- the melting point of the ⁇ -olefin copolymer was obtained by using a differential scanning calorimeter (DSC) and holding it at ⁇ 100 ° C. for 5 minutes in a nitrogen atmosphere and then raising the temperature at 10 ° C./minute. Is defined as the peak top of the peak observed on the lowest temperature side of. Specifically, by using a differential scanning calorimeter (DSC-7 manufactured by Perkin Elmer Co., Ltd.), 5 mg of a sample was kept at ⁇ 100 ° C. for 5 minutes in a nitrogen atmosphere, and then heated at 10 ° C./minute. It can be determined as the peak top of the peak observed on the lowest temperature side of the obtained melting endothermic curve.
- DSC differential scanning calorimeter
- the MFR of the ethylene-based polymer is not particularly limited as long as it has spinnability, but from the viewpoint of exhibiting elongation, it is preferably 0.1 g / 10 min to 100 g / 10 min, and 0.5 g / 10. Minutes to 50 g / 10 minutes are more preferable, and 1 g / 10 minutes to 30 g / 10 minutes are still more preferable.
- a spunbonded non-woven fabric using a sea-island type composite fiber, a core-sheath type composite fiber, a side-by-side type composite fiber or a crimped composite fiber which is composed of an olefin polymer composition containing a propylene polymer and an ethylene polymer.
- the following compounds are preferable as the olefin polymer composition.
- An olefin polymer composition comprising 80% by mass to 99% by mass of a propylene homopolymer and 20% by mass to 1% by mass of high density polyethylene.
- a permeable (moisture permeable) film is preferable as a film when the nonwoven fabric laminate of the present disclosure has a film, from the viewpoint of retaining the breathability and hydrophilicity that are the characteristics of the nonwoven fabric laminate of the present disclosure.
- a polyurethane elastomer having moisture permeability a polyester elastomer, a film made of a thermoplastic elastomer such as a polyamide elastomer, a film made of a thermoplastic resin containing inorganic fine particles or organic fine particles is stretched to be porous.
- the elastic nonwoven fabric laminate of the present disclosure is an elastic nonwoven fabric laminate obtained by stretching the nonwoven fabric laminate.
- Example 4 The basis weight of the stretchable spunbonded nonwoven fabric in the first layer and the third layer was changed from 10.0 g / m 2 to 15.6 g / m 2, and the basis weight of the elastic nonwoven fabric in the second layer was 10.0 g / m 2.
- a nonwoven fabric laminate was obtained by the same operation as in Example 1 except that the amount was changed from 2 to 18.8 g / m 2 .
- Example 6 Except that the basis weight and the basis weight of the elastic nonwoven of the second layer of extensible spunbonded nonwoven fabric in the first layer and the third layer was changed from 10.0 g / m 2 to 20.0 g / m 2, Example 2 A non-woven fabric laminate was obtained by the same operation as above.
- Table 1 and Table 2 show the results of the storage elastic modulus at each temperature, the ratio of the storage elastic modulus, the maximum load elongation, and the basis weight of each nonwoven fabric measured by the above-described measuring method in each example.
Abstract
Description
[特許文献2]特開2009-62667号公報
[特許文献3]特開2009-79341号公報
[特許文献4]国際公開第2007/138733号
本発明の一形態は、上記課題に鑑み、伸縮特性に優れ、かつ、応力維持に優れる不織布積層体、並びに、伸縮性不織布積層体、繊維製品、吸収性物品及び衛生マスクを提供することを目的とする。
[1] 40℃における貯蔵弾性率E40と23℃における貯蔵弾性率E23との比(E40/E23)が37%以上であるα-オレフィン共重合体を含む弾性不織布と、
前記弾性不織布の少なくとも片面側に配置される伸長性スパンボンド不織布と、
を有する不織布積層体。
[12] 前記[1]~[10]のいずれか1項に記載の不織布積層体又は前記[11]に記載の伸縮性不織布積層体を含む繊維製品。
[13] 前記[1]~[10]のいずれか1項に記載の不織布積層体又は前記[11]に記載の伸縮性不織布積層体を含む吸収性物品。
[14] 前記[1]~[10]のいずれか1項に記載の不織布積層体又は前記[11]に記載の伸縮性不織布積層体を含む衛生マスク。
本開示に係る不織布積層体は、40℃における貯蔵弾性率E40と23℃における貯蔵弾性率E23との比(E40/E23)が37%以上であるα-オレフィン共重合体を含む弾性不織布と、前記弾性不織布の少なくとも片面側に配置される伸長性スパンボンド不織布と、を有する。不織布積層体は、その他の層を含んで構成されていてもよい。
また、前記α-オレフィン共重合体は、40℃における貯蔵弾性率E40と23℃における貯蔵弾性率E23との比(E40/E23)が37%以上である。すなわち、温度変化環境下(例えば、40℃~23℃)においても弾性不織布における弾性の低下が抑制され易い。そのため、応力維持に優れる不織布積層体が得られると考えられる。
弾性不織布の目付比が10以上であると、不織布積層体の伸縮性の低下が抑制される傾向にある。一方、弾性不織布の目付比が90以下であると、弾性不織布を構成する繊維が伸長性スパンボンド不織布層を超えて表面に露出する割合が減る傾向にある。そのため、成形性及び触感に優れた不織布積層体が得られ易くなる。
不織布積層体から流れ方向(MD)が200mm、横方向(CD)が50mmの試験片を6枚採取する。採取場所は、MD、CDともに任意の3箇所とする(計6箇所)。次いで、採取した各試験片の質量(g)を、上皿電子天秤(研精工業社製)を用いてそれぞれ測定し、各試験片の質量の算術平均値を求める。求めた算術平均値から、1m2当たりの質量(g)に換算し、小数点第1位を四捨五入して、これを目付〔g/m2〕とする。
不織布積層体から、流れ方向(MD)が200mm、横方向(CD)が50mmの試験片を5枚採取する。この試験片について、定速伸長型引張試験機を用いて、チャック間100mm、引張速度100mm/分の条件で引張試験を行う。試験片に掛かる最大の荷重〔N/50mm〕を測定し、前記最大荷重における試験片の伸び率〔%〕を測定する。5枚の試験片の算術平均値を求め、これを最大荷重伸度とする。
本開示に係る弾性不織布は、40℃における貯蔵弾性率E40と23℃における貯蔵弾性率E23との比(E40/E23)が37%以上であるα-オレフィン共重合体を含む。
弾性不織布を構成する繊維は、繊維径が50μm以下であることが好ましく、40μm以下であることがより好ましく、30μm以下であることがさらに好ましい。弾性不織布を構成する繊維は、繊維径が1.0μm以上であってもよい。
弾性不織布は、α-オレフィン共重合体を含む。
α-オレフィン共重合体は、2種以上のα-オレフィン骨格を有する共重合成分が共重合された共重合体を表す。
α-オレフィン骨格を有する共重合成分としては、例えば、エチレン、プロピレン、1-ブテン、1-ペンテン、3-メチル-1-ブテン、4-メチル-1-ペンテン、1-ヘキセン、1-オクテン、1-デセン、1-ドデセン、1-テトラデセン、1-ヘキサデセン、1-オクタデセン、1-エイコセン等のα-オレフィンが挙げられる。
上記の中でも、α-オレフィン共重合体は、不織布積層体を、より低応力であり、且つ、伸縮性により優れたものとする観点から、エチレン(下記表1及び表2中「C2」と表記する)及びプロピレン(下記表1及び表2中「C3」と表記する)を共重合成分とするエチレン及びプロピレンの共重合体を含むことが好ましい。
α-オレフィン共重合体の40℃における貯蔵弾性率E40は、不織布積層体を、より低応力であり、且つ、伸縮性により優れたものとする観点から、10MPa以下であることが好ましく、9MPa以下であることがより好ましい。
α-オレフィン共重合体の23℃における貯蔵弾性率E23は5MPa以上であってもよく、10MPa以上であってもよい。
α-オレフィン共重合体の40℃における貯蔵弾性率E40は3MPa以上であってもよく、5MPa以上であってもよい。
温度:23℃又は40℃
装置 :RSA-III(ティー・アイ・インスツルメント社製)
変形モード :引張りモード
温度範囲 :-20℃~120℃
昇温速度 :2℃/分
変形周波数 :10Hz
初期歪 :0.1%
測定温度感覚 :0.3℃
環境 :窒素雰囲気下
α-オレフィン共重合体の密度は、JIS K7112(1999)の密度勾配法に従って測定して得られた値である。
引張弾性率は、JIS K7161(2011)に準拠した方法で測定して得られた値である。
<GPC測定条件>
カラム:TOSO GMHHR-H(S)HT
検出器:液体クロマトグラム用RI検出器 WATERS 150C
溶媒:1,2,4-トリクロロベンゼン
測定温度:145℃
流速:1.0ml/分
試料濃度:2.2mg/ml
注入量:160μl
検量線:Universal Calibration
解析プログラム:HT-GPC(Ver.1.0)
α-オレフィン共重合体が合成品である場合、α-オレフィン共重合体は、チーグラー・ナッタ系触媒、メタロセン系触媒などの従来公知の触媒の存在下に、モノマーを気相法、バルク法、スラリー法、溶液法などの従来公知の重合法により重合あるいは共重合させることにより調製することができる。
α-オレフィン共重合体の市販品としては、例えば、タフマー(三井化学社製)、Vistamaxxシリーズ(エクソンモービルケミカル社製)等が挙げられる。
結晶化度=(ΔH/ΔH0)×100(%)
式中、ΔHはエチレンとプロピレンを含むα-オレフィン共重合体の主成分の融解に由来する融解熱カーブより求めた融解熱量(J/g)であり、ΔH0は主成分の完全結晶の融解熱量(J/g)である。つまり、主成分がエチレンの場合、ΔH0は293J/gであり、主成分がプロピレンの場合、ΔH0は210J/gである。
本開示に係る伸長性スパンボンド不織布は、少なくとも一方向の最大荷重伸度が45%以上であることが好ましく、70%以上であることがより好ましく、100%以上であることがさらに好ましく、150%以上であることが特に好ましい。伸長性スパンボンド不織布は、弾性回復が殆どない性質を有する不織布であることが好ましい。伸長性スパンボンド不織布の最大荷重伸度〔%〕は、不織布積層体の最大荷重伸度と同様の方法で求める。本開示に係る伸長性スパンボンド不織布は、少なくとも一方向の最大荷重伸度が600%以下であってもよく、500%以下であってもよい。
伸長性スパンボンド不織布は、オレフィン系重合体を含むことが好ましく、オレフィン系重合体を含むオレフィン系重合体組成物から形成されることが好ましい。オレフィン系重合体としては、ポリオレフィン系エラストマーであってもよい。
プロピレンを主成分とした共重合体としては、エチレン、1-ブテン、1-ペンテン、1-ヘキセン、1-オクテン、4-メチル-1-ペンテン等の炭素数2以上のα-オレフィン(好ましくは炭素数2~8のα-オレフィン)を共重合成分とする共重合体が挙げられる(但し炭素数3のアルケン、つまりプロピレンを除く)。なお、プロピレンを主成分とした共重合体は、ランダム共重合体、ブロック共重合体等のいずれであってもよい。
プロピレンを主成分とした共重合体の融点(Tm)は、130℃以上155℃未満であることが好ましく、130℃~150℃であることがより好ましい。
プロピレン系重合体のMFRは、溶融紡糸することができれば、特に限定されない。プロピレン系重合体のMFRは、例えば、1g/10分~1000g/10分であることが好ましく、5g/10分~500g/10分であることがより好ましく、10g/10分~100g/10分であることがさらに好ましい。
伸長性スパンボンド不織布としては、下記(1)~(3)の要件を満たす伸長性スパンボンド不織布を含むことが好ましい。
(2-1)プロピレン単独重合体80質量%~99質量%と、高密度ポリエチレン20質量%~1質量%とからなるオレフィン系重合体組成物。
(2-2)MFRが同一又は異なり、且つ、融点が157℃~165℃の範囲にある高融点のプロピレン系重合体を含むオレフィン系重合体組成物。
(A)芯部をMFRが10g/10分~200g/10分の範囲にあり、融点が157℃~165℃の範囲にある低MFRで高融点のプロピレン系重合体(好ましくはプロピレン単独重合体)とし、鞘部をMFRが10g/10分~200g/10分の範囲にあり、融点が130℃~150℃の範囲にある高MFRで低融点のプロピレン・α-オレフィンランダム共重合体とし、且つ、前記芯部のMFRと前記鞘部のMFRとの差が1g/10分以上である同芯の芯鞘型複合繊維からなる芯鞘型複合繊維、並列型複合繊維若しくは捲縮複合繊維を用いたスパンボンド不織布。
(B)芯部をMFRが1g/10分~200g/10分の範囲にある低MFRのプロピレン系重合体(好ましくはプロピレン単独重合体)とし、鞘部をMFRが31g/10分~230g/10分の範囲にある高MFRのプロピレン系重合体(好ましくはプロピレン単独重合体)とし、且つ、前記芯部のMFRと前記鞘部のMFRとの差が30g/10分以上である同芯の芯鞘型複合繊維からなるスパンボンド不織布。
前述の(B)にて、芯部をMFRが10g/10分~50g/10分の範囲にある低MFRのプロピレン系重合体とし、鞘部をMFRが50g/10分~100g/10分の範囲にある高MFRのプロピレン系重合体としてもよい。前記芯部のMFRと前記鞘部のMFRとの差は、30g/10分~100g/10分であってもよく、40g/10分~80g/10分以下であってもよい。
本開示の不織布積層体には種々用途により、他の層を積層してもよい。本開示の不織布積層体に積層する他の層は、特に限定はされず、用途により種々の層を積層し得る。
本開示の不織布積層体は、α-オレフィン共重合体を含む弾性不織布、伸長性スパンボンド不織布、及び、必要に応じて用いられる添加剤を用いて、公知の不織布の製造方法により製造し得る。
本開示の不織布積層体は、製造上の観点から、不織布製造装置に付随する回転機器に接触する側の面に、伸長性スパンボンド不織布が配置されている態様が好ましい。
まず、一列目の紡糸装置に備えられた押出機、必要に応じて二個以上の押出機でオレフィン系重合体、必要に応じて二種以上のオレフィン系重合体を溶融し、多数の紡糸孔(ノズル)を備えた口金(ダイ)、必要に応じて芯鞘構造を有する紡糸孔に導入し、吐出する。その後、溶融紡糸されたオレフィン系重合体を含む長繊維を冷却室に導入し、冷却風により冷却した後、延伸エアーにより長繊維を延伸(牽引)し、伸長性スパンボンド不織布を移動捕集面上に堆積させる。
他方、二列目の紡糸装置に備えられた押出機で本開示のα-オレフィン共重合体を含む樹脂組成物を溶融し、多数の紡糸孔(ノズル)を備えた口金(ダイ)を有する紡糸孔に導入し、樹脂組成物を吐出する。その後、溶融紡糸された樹脂組成物を含む長繊維を冷却室に導入し、冷却風により冷却した後、延伸エアーにより長繊維を延伸(牽引)し、伸長性スパンボンド不織布上に堆積させて、弾性不織布を形成する。
必要に応じて、三列目の紡糸装置を用いて、伸長性スパンボンド不織布を弾性不織布上に堆積させてもよい。
本開示の伸縮性不織布積層体は、前記不織布積層体を延伸することによって得られる、伸縮性を有する不織布積層体である。
不織布積層体を延伸した後、応力が解放されると、弾性不織布を形成する(長)繊維は弾性回復し、伸長性スパンボンド不織布を形成する長繊維は、弾性回復せずに褶曲し、不織布積層体に嵩高感が発現する。さらに、伸長性スパンボンド不織布を形成する長繊維は細くなる傾向にある。そのため、柔軟性及び触感が良くなるとともに、伸び止り機能を付与することができると考えられる。
本開示の繊維製品は、本開示の不織布積層体又は伸縮性不織布積層体を含む。繊維製品は特に制限されず、使い捨ておむつ、生理用品等の吸収性物品、衛生マスク等の衛生物品、包帯等の医療物品、衣料素材、包装材などが挙げられる。本開示の繊維製品は、本開示の不織布積層体又は伸縮性不織布積層体を伸縮部材として含むことが好ましい。
弾性不織布の原料として、以下の材料を準備した。
・α-オレフィン共重合体1A(プロピレン/エチレン共重合体)
ExxonMobil社製、製品名「VistamaxxTM6202」、MFR(230℃、荷重2.16kg):20g/10分、エチレン含量:15質量%、引張弾性率:9.8MPa。
・α-オレフィン共重合体1B(プロピレン/エチレン共重合体)
ExxonMobil社製、製品名「VistamaxxTM7050FL」、MFR(230℃、荷重2.16kg):48g/10分、エチレン含量:13質量%、引張弾性率:14.4MPa。
攪拌機付き、内容積0.2m3のステンレス製反応器に、n-ヘプタンを20L/hで、トリイソブチルアルミニウムを15mmol/hで、さらに、ジメチルアニリニウムテトラキスペンタフルオロフェニルボレートと(1,2’-ジメチルシリレン)(2,1’-ジメチルシリレン)-ビス(3-トリメチルシリルメチルインデニル)ジルコニウムジクロライドとトリイソブチルアルミニウムとプロピレンとを事前に接触させて得られた触媒成分をジルコニウムあたり6μmol/hで連続供給した。重合温度70℃で気相部水素濃度を8mol%、反応器内の全圧を0.7MPa・Gに保つようにして、プロピレンと水素を連続供給した。得られた重合溶液に、SUMILIZER GP(住友化学社製)を1000ppmになるように添加し、溶媒を除去することにより、プロピレン重合体を得た。
得られたプロピレン重合体の重量平均分子量(Mw)は1.2×104、Mw/Mn=2であった。また、NMR測定から求めた[mmmm]が46モル%、[rrrr]/(1-[mmmm])が0.038、[rmrm]が2.7モル%、[mm]×[rr]/[mr]2が1.5、引張弾性率が32.9MPaであった。
なお、[mmmm]はメソペンタッド分率であり、[rrrr]はラセミペンタッド分率であり、[rmrm]はラセミメソラセミメソペンタッド分率であり、[mm]、[rr]及び[mr]はそれぞれトリアッド分率である。これらの値は、例えば、国際公開第2016/143834号に記載の方法により求めることができる。
MFR(ASTM D1238に準拠して、温度230℃、荷重2.16kgで測定)8.5g/10分、密度0.91g/cm3、融点160℃のプロピレン単独重合体(以下「重合体2A」;表1及び表2中では「PP」)を50mmφの押出機を用い溶融し、それとは独立してMFR(ASTM D1238に準拠して、温度230℃、荷重2.16kgで測定)60g/10分、密度0.91g/cm3、融点160℃のプロピレン単独重合体(以下「重合体2B」;表1及び表2中では「PP」)を75mmφの押出機を用いて溶融した後、「重合体2A」が芯、「重合体2B」が鞘となるような同芯の芯鞘複合繊維の成形が可能な紡糸口金(ダイ、孔数2887ホール)を有するスパンボンド不織布成形機(捕集面上の機械の流れ方向に垂直な方向の長さ:800mm)を用いて、樹脂温度とダイ温度がともに250℃、冷却風温度20℃、延伸エアー風速3750m/分の条件でスパンボンド法により複合溶融紡糸を行い、芯部と鞘部の質量比が10/90の同芯の芯鞘型複合繊維からなる伸長性スパンボンド不織布を捕集面上に第1層目として堆積させた。
次いで、その堆積面上に、前記α-オレフィン共重合体1Aを、スクリュー径75mmφの単軸押出機を用いて溶融した後、紡糸口金(ダイ、孔数808ホール)を有するスパンボンド不織布成形機(捕集面上の機械の流れ方向に垂直な方向の長さ:800mm)を用いて、樹脂温度とダイ温度がともに215℃、冷却風温度20℃、延伸エアー風速3750m/分の条件でスパンボンド法により溶融紡糸し、第2層目として弾性不織布(弾性スパンボンド不織布)を堆積させた。この工程における、前記α-オレフィン共重合体1Aの紡糸性は非常に良好であった。
次いで、第3層目として、第1層目と同様の芯鞘型複合繊維を、同様の方法により堆積させ、3層堆積物とした。この堆積物をエンボスロールで加熱加圧処理(エンボス面積率18%、エンボス温度70℃)して総目付量が30.0g/m2、第1層目及び第3層目の目付量が10.0g/m2、2層目である弾性不織布層の目付量が10.0g/m2である不織布積層体を作製した(弾性不織布層が全体に対して占める質量分率が33.3%)。
上記のようにして得た不織布積層体は、エンボス工程における金属ロール表面への付着は殆どなく、成形性は良好であった。また、不織布積層体をロール状態に巻き取った際、ロールブロッキング(重なり合った不織布が相互に付着し合い、ロールが固まってしまう現象)も起こらず、容易に引き出すことができた。
弾性不織布の原料を、α-オレフィン共重合体1Aからα-オレフィン共重合体1Bへと変更する仕様とした以外は、実施例1と同様の操作により不織布積層体を得た。
弾性不織布の原料を、α-オレフィン共重合体1Aからα-オレフィン単独重合体1Cへと変更する仕様とした以外は、実施例1と同様の操作により不織布積層体を得た。
第1層目及び第3層目における伸長性スパンボンド不織布の目付並びに第2層目における弾性不織布の目付を10.0g/m2から16.7g/m2に変更した以外は、実施例1と同様の操作により不織布積層体を得た。
第1層目及び第3層目における伸長性スパンボンド不織布の目付を10.0g/m2から15.6g/m2に変更し、第2層目における弾性不織布の目付を10.0g/m2から18.8g/m2に変更した以外は、実施例1と同様の操作により不織布積層体を得た。
第1層目及び第3層目における伸長性スパンボンド不織布の目付並びに第2層目における弾性不織布の目付を10.0g/m2から20.0g/m2に変更した以外は、実施例1と同様の操作により不織布積層体を得た。
第1層目及び第3層目における伸長性スパンボンド不織布の目付並びに第2層目における弾性不織布の目付を10.0g/m2から20.0g/m2に変更した以外は、実施例2と同様の操作により不織布積層体を得た。
第1層目及び第3層目における伸長性スパンボンド不織布の目付並びに第2層目における弾性不織布の目付を10.0g/m2から20.0g/m2に変更した以外は、比較例1と同様の操作により不織布積層体を得た。
2層目における弾性不織布の目付を20.0g/m2から25.0g/m2に変更した以外は、比較例2と同様の操作により不織布積層体を得た。
(紡糸性)
各例の不織布について、製造の際に、スパンボンド不織布製造装置のノズル面近傍の紡糸状況を目視で観察し、5分あたりの糸切れ回数(単位:回/5分)を数えた。糸切れ回数が0回/5分であれば「A」、糸切れが発生し不織布採取に至らない場合は「B」と評価した(表1及び表2)。
万能引張試験機(インテスコ社製、IM-201型)を用い、各例の不織布積層体から、50mm(CD)×200mm(MD)の試験片を5枚採取した。次いで、採取した各試験片をサンプル幅50mm、チャック間距離100mm、引張速度100mm/分の条件で試験片を100%伸長後、直ちに同じ速度で原長まで回復させた。この操作をもう1サイクル実施して、2サイクル目の伸長時に延伸倍率が50%となったときの応力を50%伸長時応力とし、2サイクル目の回復時に延伸倍率が50%となったときの応力を50%回復時応力とした。次いで、伸縮特性の尺度として〔50%回復時応力÷50%伸長時応力〕の値を測定し、5枚の試験片の算術平均値を伸縮特性として評価した。なお〔50%回復時応力÷50%伸長時応力〕の値が大きいほど伸縮特性が優れていることを意味する(表1及び表2)。
本明細書に記載された全ての文献、特許出願、及び技術規格は、個々の文献、特許出願、及び技術規格が参照により取り込まれることが具体的かつ個々に記された場合と同程度に、本明細書中に参照により取り込まれる。
Claims (14)
- 40℃における貯蔵弾性率E40と23℃における貯蔵弾性率E23との比(E40/E23)が37%以上であるα-オレフィン共重合体を含む弾性不織布と、
前記弾性不織布の少なくとも片面側に配置される伸長性スパンボンド不織布と、
を有する不織布積層体。 - 前記α-オレフィン共重合体の前記23℃における貯蔵弾性率E23が30MPa以下である請求項1に記載の不織布積層体。
- 前記α-オレフィン共重合体がエチレン及びプロピレンの共重合体を含む請求項1又は請求項2に記載の不織布積層体。
- 前記α-オレフィン共重合体の引張弾性率が30MPa以下である請求項1~請求項3のいずれか1項に記載の不織布積層体。
- 前記弾性不織布の両面側に前記伸長性スパンボンド不織布が配置されている請求項1~請求項4のいずれか1項に記載の不織布積層体。
- 前記伸長性スパンボンド不織布は、少なくとも一方向の最大荷重伸度が45%以上である請求項1~請求項5のいずれか1項に記載の不織布積層体。
- 前記弾性不織布は、弾性スパンボンド不織布である請求項1~請求項6のいずれか1項に記載の不織布積層体。
- 前記伸長性スパンボンド不織布が、芯部をMFRが1g/10分~1000g/10分の範囲にある低MFRのオレフィン系重合体とし、鞘部をMFRが1g/10分~1000g/10分の範囲にある高MFRのオレフィン系重合体とし、且つ、前記低MFRのオレフィン系重合体と前記高MFRのオレフィン系重合体のMFRの差が1g/10分以上である、同芯の芯鞘型複合繊維からなる伸長性スパンボンド不織布である請求項1~請求項7のいずれか1項に記載の不織布積層体。
- 前記伸長性スパンボンド不織布が、80質量%~99質量%の結晶性プロピレン系重合体と、1質量%~20質量%の高密度ポリエチレンと、を含むオレフィン系重合体組成物を含有する請求項1~請求項8のいずれか1項に記載の不織布積層体。
- 前記弾性不織布と前記伸長性スパンボンド不織布との目付比(弾性不織布:伸長性スパンボンド不織布)が10:90~90:10の範囲にある請求項1~請求項9のいずれか1項に記載の不織布積層体。
- 請求項1~請求項10のいずれか1項に記載の不織布積層体の延伸加工物である伸縮性不織布積層体。
- 請求項1~請求項10のいずれか1項に記載の不織布積層体又は請求項11に記載の伸縮性不織布積層体を含む繊維製品。
- 請求項1~請求項10のいずれか1項に記載の不織布積層体又は請求項11に記載の伸縮性不織布積層体を含む吸収性物品。
- 請求項1~請求項10のいずれか1項に記載の不織布積層体又は請求項11に記載の伸縮性不織布積層体を含む衛生マスク。
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JP2018201247A (ja) | 2018-09-06 | 2018-12-20 | 株式会社バンダイナムコエンターテインメント | シミュレーションシステム |
Cited By (2)
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JPWO2019188134A1 (ja) * | 2018-03-30 | 2021-02-25 | 三井化学株式会社 | 不織布積層体、伸縮性不織布積層体、繊維製品、吸収性物品及び衛生マスク |
JP7034258B2 (ja) | 2018-03-30 | 2022-03-11 | 三井化学株式会社 | 不織布積層体、伸縮性不織布積層体、繊維製品、吸収性物品及び衛生マスク |
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KR102639889B1 (ko) | 2024-03-06 |
CN112805430B (zh) | 2023-09-15 |
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JP7308223B2 (ja) | 2023-07-13 |
EP3848492A1 (en) | 2021-07-14 |
KR20210045491A (ko) | 2021-04-26 |
JPWO2020085502A1 (ja) | 2021-09-24 |
EP3848492A4 (en) | 2022-06-08 |
KR20240033064A (ko) | 2024-03-12 |
CN117124672A (zh) | 2023-11-28 |
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US20210388548A1 (en) | 2021-12-16 |
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