WO2020196663A1 - 不織布積層体及び衛生用品 - Google Patents
不織布積層体及び衛生用品 Download PDFInfo
- Publication number
- WO2020196663A1 WO2020196663A1 PCT/JP2020/013446 JP2020013446W WO2020196663A1 WO 2020196663 A1 WO2020196663 A1 WO 2020196663A1 JP 2020013446 W JP2020013446 W JP 2020013446W WO 2020196663 A1 WO2020196663 A1 WO 2020196663A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- woven fabric
- olefin
- layer
- based polymer
- fabric laminate
- Prior art date
Links
- 239000000835 fiber Substances 0.000 claims abstract description 195
- 239000002131 composite material Substances 0.000 claims abstract description 119
- 239000004745 nonwoven fabric Substances 0.000 claims description 242
- 229920000642 polymer Polymers 0.000 claims description 156
- 150000001336 alkenes Chemical class 0.000 claims description 93
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 claims description 93
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 claims description 64
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 claims description 62
- 229920001410 Microfiber Polymers 0.000 claims description 44
- 238000002844 melting Methods 0.000 claims description 41
- 230000008018 melting Effects 0.000 claims description 41
- 239000004744 fabric Substances 0.000 claims description 20
- 238000004049 embossing Methods 0.000 claims description 16
- 239000004750 melt-blown nonwoven Substances 0.000 claims description 16
- 238000000034 method Methods 0.000 description 62
- 229920000098 polyolefin Polymers 0.000 description 37
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 31
- 239000005977 Ethylene Substances 0.000 description 31
- 239000004711 α-olefin Substances 0.000 description 31
- 229920005604 random copolymer Polymers 0.000 description 25
- 230000000052 comparative effect Effects 0.000 description 20
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 19
- 238000012360 testing method Methods 0.000 description 16
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 13
- 238000004519 manufacturing process Methods 0.000 description 11
- 229920001384 propylene homopolymer Polymers 0.000 description 10
- 230000014759 maintenance of location Effects 0.000 description 9
- 239000000203 mixture Substances 0.000 description 9
- AFFLGGQVNFXPEV-UHFFFAOYSA-N 1-decene Chemical compound CCCCCCCCC=C AFFLGGQVNFXPEV-UHFFFAOYSA-N 0.000 description 8
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 description 8
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 8
- 229920001577 copolymer Polymers 0.000 description 8
- 238000006116 polymerization reaction Methods 0.000 description 8
- 238000005227 gel permeation chromatography Methods 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- YWAKXRMUMFPDSH-UHFFFAOYSA-N pentene Chemical compound CCCC=C YWAKXRMUMFPDSH-UHFFFAOYSA-N 0.000 description 7
- 229920001155 polypropylene Polymers 0.000 description 7
- -1 polypropylene Polymers 0.000 description 7
- WSSSPWUEQFSQQG-UHFFFAOYSA-N 4-methyl-1-pentene Chemical compound CC(C)CC=C WSSSPWUEQFSQQG-UHFFFAOYSA-N 0.000 description 6
- 239000004743 Polypropylene Substances 0.000 description 6
- 125000004432 carbon atom Chemical group C* 0.000 description 6
- 238000009826 distribution Methods 0.000 description 6
- 238000006243 chemical reaction Methods 0.000 description 5
- 238000011156 evaluation Methods 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- RFFLAFLAYFXFSW-UHFFFAOYSA-N 1,2-dichlorobenzene Chemical compound ClC1=CC=CC=C1Cl RFFLAFLAYFXFSW-UHFFFAOYSA-N 0.000 description 4
- YPVPQMCSLFDIKA-UHFFFAOYSA-N 3-ethylpent-1-ene Chemical compound CCC(CC)C=C YPVPQMCSLFDIKA-UHFFFAOYSA-N 0.000 description 4
- LDTAOIUHUHHCMU-UHFFFAOYSA-N 3-methylpent-1-ene Chemical compound CCC(C)C=C LDTAOIUHUHHCMU-UHFFFAOYSA-N 0.000 description 4
- SUWJESCICIOQHO-UHFFFAOYSA-N 4-methylhex-1-ene Chemical compound CCC(C)CC=C SUWJESCICIOQHO-UHFFFAOYSA-N 0.000 description 4
- 239000004793 Polystyrene Substances 0.000 description 4
- 238000005452 bending Methods 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 4
- 229920001519 homopolymer Polymers 0.000 description 4
- 239000000155 melt Substances 0.000 description 4
- 238000002156 mixing Methods 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 4
- 239000002994 raw material Substances 0.000 description 4
- 229920005989 resin Polymers 0.000 description 4
- 239000011347 resin Substances 0.000 description 4
- YHQXBTXEYZIYOV-UHFFFAOYSA-N 3-methylbut-1-ene Chemical compound CC(C)C=C YHQXBTXEYZIYOV-UHFFFAOYSA-N 0.000 description 3
- 229920000089 Cyclic olefin copolymer Polymers 0.000 description 3
- 239000003054 catalyst Substances 0.000 description 3
- 239000004751 flashspun nonwoven Substances 0.000 description 3
- 229920005606 polypropylene copolymer Polymers 0.000 description 3
- 229920002223 polystyrene Polymers 0.000 description 3
- 238000004677 spark ionization mass spectrometry Methods 0.000 description 3
- RYPKRALMXUUNKS-UHFFFAOYSA-N 2-Hexene Natural products CCCC=CC RYPKRALMXUUNKS-UHFFFAOYSA-N 0.000 description 2
- 239000004322 Butylated hydroxytoluene Substances 0.000 description 2
- NLZUEZXRPGMBCV-UHFFFAOYSA-N Butylhydroxytoluene Chemical compound CC1=CC(C(C)(C)C)=C(O)C(C(C)(C)C)=C1 NLZUEZXRPGMBCV-UHFFFAOYSA-N 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 239000003963 antioxidant agent Substances 0.000 description 2
- 239000002216 antistatic agent Substances 0.000 description 2
- IYYGCUZHHGZXGJ-UHFFFAOYSA-N but-1-ene;ethene;prop-1-ene Chemical compound C=C.CC=C.CCC=C IYYGCUZHHGZXGJ-UHFFFAOYSA-N 0.000 description 2
- 235000010354 butylated hydroxytoluene Nutrition 0.000 description 2
- 238000004581 coalescence Methods 0.000 description 2
- 239000000470 constituent Substances 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 238000002425 crystallisation Methods 0.000 description 2
- 230000008025 crystallization Effects 0.000 description 2
- HQQADJVZYDDRJT-UHFFFAOYSA-N ethene;prop-1-ene Chemical group C=C.CC=C HQQADJVZYDDRJT-UHFFFAOYSA-N 0.000 description 2
- 230000001747 exhibiting effect Effects 0.000 description 2
- 230000001771 impaired effect Effects 0.000 description 2
- 239000004611 light stabiliser Substances 0.000 description 2
- 229920000092 linear low density polyethylene Polymers 0.000 description 2
- 239000004707 linear low-density polyethylene Substances 0.000 description 2
- 239000000314 lubricant Substances 0.000 description 2
- 238000002074 melt spinning Methods 0.000 description 2
- 239000002667 nucleating agent Substances 0.000 description 2
- 150000002978 peroxides Chemical class 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 239000004417 polycarbonate Substances 0.000 description 2
- 229920000515 polycarbonate Polymers 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 238000009987 spinning Methods 0.000 description 2
- 239000003381 stabilizer Substances 0.000 description 2
- 229920005992 thermoplastic resin Polymers 0.000 description 2
- 239000003643 water by type Substances 0.000 description 2
- GVNWZKBFMFUVNX-UHFFFAOYSA-N Adipamide Chemical compound NC(=O)CCCCC(N)=O GVNWZKBFMFUVNX-UHFFFAOYSA-N 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 239000004831 Hot glue Substances 0.000 description 1
- 229920003355 Novatec® Polymers 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 229920002292 Nylon 6 Polymers 0.000 description 1
- 229920002302 Nylon 6,6 Polymers 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- 239000004433 Thermoplastic polyurethane Substances 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 238000012662 bulk polymerization Methods 0.000 description 1
- IAQRGUVFOMOMEM-UHFFFAOYSA-N butene Natural products CC=CC IAQRGUVFOMOMEM-UHFFFAOYSA-N 0.000 description 1
- 229940095259 butylated hydroxytoluene Drugs 0.000 description 1
- RGIBXDHONMXTLI-UHFFFAOYSA-N chavicol Chemical group OC1=CC=C(CC=C)C=C1 RGIBXDHONMXTLI-UHFFFAOYSA-N 0.000 description 1
- 239000003426 co-catalyst Substances 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 125000000058 cyclopentadienyl group Chemical group C1(=CC=CC1)* 0.000 description 1
- 238000000113 differential scanning calorimetry Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000010408 film Substances 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 229920000554 ionomer Polymers 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- RLAWWYSOJDYHDC-BZSNNMDCSA-N lisinopril Chemical compound C([C@H](N[C@@H](CCCCN)C(=O)N1[C@@H](CCC1)C(O)=O)C(O)=O)CC1=CC=CC=C1 RLAWWYSOJDYHDC-BZSNNMDCSA-N 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000012968 metallocene catalyst Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 125000002524 organometallic group Chemical group 0.000 description 1
- 238000007500 overflow downdraw method Methods 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 239000012071 phase Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920003207 poly(ethylene-2,6-naphthalate) Polymers 0.000 description 1
- 229920002239 polyacrylonitrile Polymers 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 239000011112 polyethylene naphthalate Substances 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 229920005629 polypropylene homopolymer Polymers 0.000 description 1
- 229920005630 polypropylene random copolymer Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052723 transition metal Inorganic materials 0.000 description 1
- 150000003623 transition metal compounds Chemical class 0.000 description 1
- 150000003624 transition metals Chemical class 0.000 description 1
- 239000012808 vapor phase Substances 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Images
Classifications
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
- A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
- A61F13/51121—Topsheet, i.e. the permeable cover or layer facing the skin characterised by the material
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
- A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
- A61F13/5116—Topsheet, i.e. the permeable cover or layer facing the skin being formed of multiple layers
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
- A61F13/514—Backsheet, i.e. the impermeable cover or layer furthest from the skin
- A61F13/51401—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by the material
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
- A61F13/514—Backsheet, i.e. the impermeable cover or layer furthest from the skin
- A61F13/51474—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its structure
- A61F13/51478—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its structure being a laminate, e.g. multi-layered or with several layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
- B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/14—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
- B32B5/142—Variation across the area of the layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/05—Interconnection of layers the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/005—Synthetic yarns or filaments
- D04H3/007—Addition polymers
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/016—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the fineness
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/018—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the shape
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
- D04H3/147—Composite yarns or filaments
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/02—Adhesive bandages or dressings
- A61F13/0276—Apparatus or processes for manufacturing adhesive dressings or bandages
- A61F13/0289—Apparatus or processes for manufacturing adhesive dressings or bandages manufacturing of adhesive dressings
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/15577—Apparatus or processes for manufacturing
- A61F2013/15821—Apparatus or processes for manufacturing characterized by the apparatus for manufacturing
- A61F2013/15934—Apparatus or processes for manufacturing characterized by the apparatus for manufacturing for making non-woven
- A61F2013/15991—Apparatus or processes for manufacturing characterized by the apparatus for manufacturing for making non-woven in making composite multi-layered product
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
- A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
- A61F13/5116—Topsheet, i.e. the permeable cover or layer facing the skin being formed of multiple layers
- A61F2013/51178—Topsheet, i.e. the permeable cover or layer facing the skin being formed of multiple layers with the combination of nonwoven webs
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
- A61F13/514—Backsheet, i.e. the impermeable cover or layer furthest from the skin
- A61F13/51401—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by the material
- A61F2013/51441—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by the material being a fibrous material
- A61F2013/51452—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by the material being a fibrous material being nonwovens
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/02—2 layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/20—All layers being fibrous or filamentary
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0253—Polyolefin fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/12—Conjugate fibres, e.g. core/sheath or side-by-side
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/14—Mixture of at least two fibres made of different materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/54—Yield strength; Tensile strength
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/718—Weight, e.g. weight per square meter
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
- B32B2307/734—Dimensional stability
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2432/00—Cleaning articles, e.g. mops, wipes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2555/00—Personal care
Definitions
- This disclosure relates to a non-woven fabric laminate and hygiene products.
- Nonwoven fabrics using polyolefins are used as sanitary materials for disposable diapers, sanitary napkins, etc. because they have excellent breathability, but further improvement in characteristics is required.
- polyolefins for example, polypropylene
- a non-woven fabric using polypropylene with further improved flexibility, bulkiness, and mechanical strength.
- Patent Document 2 and Patent Document 3 describe a composite in which melt blown fibers are laminated on an intermediate layer of a crimped composite fiber laminate.
- Patent Document 1 International Publication No. 2011-129211 Patent Document 2: US Patent Application Publication No. 2017/0335498 Patent Document 3: International Publication No. 2017/198336
- neck-in means, for example, the length of the non-woven fabric in the CD direction (direction orthogonal to the fiber flow direction) due to expansion and contraction of the fibers when the non-woven fabric is pulled in the MD direction (fiber flow direction). Means the phenomenon that becomes shorter.
- An object to be solved by the embodiment of the present disclosure is to provide a non-woven fabric laminate and a sanitary product which show good flexibility by suppressing the flexural rigidity to be low and have excellent neck-in resistance. ..
- the means for solving the above problems include the following aspects.
- a non-woven fabric layer A containing crimped composite fibers and a non-woven fabric layer B containing ultrafine fibers having an average fiber diameter of less than 1.35 ⁇ m are provided, and the ratio of the non-woven fabric layer B to the total non-woven fabric laminated body is A non-woven fabric laminate of 2.0% to 8.0%.
- ⁇ 3> The nonwoven fabric laminate according to ⁇ 1> or ⁇ 2>, wherein the ratio of the basis weight of the nonwoven fabric layer B to the total basis weight of the nonwoven fabric laminate is 5.0% to 8.0%.
- ⁇ 4> The non-woven fabric laminate according to any one of ⁇ 1> to ⁇ 3>, wherein the non-woven fabric layer A is a layer of spunbonded non-woven fabric, and the non-woven fabric layer B is a layer of melt blown non-woven fabric.
- the crimped composite fiber has at least two regions, a portion (a) composed of the olefin-based polymer (A) and a portion (b) composed of the olefin-based polymer (B).
- the mass ratio [(a): (b)] of the part (a) to the part (b) is 10: 90 to 60:40, and the melting point of the olefin polymer (A) is the above. It satisfies at least one of being higher than the melting point of the olefin-based polymer (B) and having Mz / Mw of the olefin-based polymer (A) larger than Mz / Mw of the olefin-based polymer (B).
- the non-woven polymer according to any one of ⁇ 1> to ⁇ 4>.
- ⁇ 6> The nonwoven fabric laminate according to ⁇ 5>, wherein the olefin-based polymer (A) and the olefin-based polymer (B) are propylene-based polymers.
- the crimped composite fiber has an eccentric core sheath structure in which the (a) portion is the core portion (a') and the (b) portion is the sheath portion (b'). 6> The non-woven fabric laminate.
- ⁇ 8> The nonwoven fabric laminate according to any one of ⁇ 1> to ⁇ 7>, which is heat-sealed by embossing.
- ⁇ 9> The nonwoven fabric laminate according to ⁇ 8>, wherein the embossed area ratio by the embossing is 5% to 20%.
- the numerical range represented by using “-” means a range including the numerical values before and after "-" as the lower limit value and the upper limit value.
- the upper limit value or the lower limit value described in a certain numerical range may be replaced with the upper limit value or the lower limit value of another numerical range described stepwise.
- the upper limit value or the lower limit value described in a certain numerical range may be replaced with the value shown in the examples.
- the term "process” is included in this term not only as an independent process but also as long as the purpose of the process is achieved even if it cannot be clearly distinguished from other processes.
- the content of each component in the composition is the total amount of the plurality of substances present in the composition unless otherwise specified, when a plurality of substances corresponding to each component are present in the composition.
- the "MD" (Machine Direction) direction refers to the traveling direction of the non-woven web in the nonwoven fabric manufacturing apparatus.
- the "CD” (Cross Direction) direction refers to a direction perpendicular to the MD direction and parallel to the main surface (a surface orthogonal to the thickness direction of the non-woven fabric).
- the plurality of substances present in the composition Means the total amount.
- the term "layer" is used not only when the area where the layer exists is observed, but also when the layer is formed in the entire area or only a part of the area. included.
- the non-woven fabric laminate of the present disclosure includes a non-woven fabric layer A containing crimped composite fibers and a non-woven fabric layer B containing ultrafine fibers having an average fiber diameter of less than 1.35 ⁇ m, and the non-woven fabric layer B with respect to the total texture of the non-woven fabric laminate.
- the ratio of the non-woven fabric is 2.0% to 8.0%.
- a laminate using only the non-woven fabric layer containing the crimp composite fiber tends to be inferior in neck-in resistance because the shrink width of the neck-in is large. Further, the non-woven fabric layer B containing the ultrafine fibers can improve the neck-in resistance, but can be a factor of increasing the bending rigidity and lowering the flexibility.
- the non-woven fabric laminate of the present disclosure exhibits good flexibility and is excellent in neck-in resistance because the bending rigidity is suppressed to be low by providing the above structure.
- the ultrafine fibers are finer than the crimped composite fibers. Therefore, in the non-woven fabric laminate, the ultrafine fibers can be more uniformly dispersed as compared with the crimped composite fibers.
- the non-woven fabric laminate contains the ultrafine fibers, so that the non-woven fabric laminate shrinks in the vertical and horizontal directions when it is pulled in the horizontal and vertical directions. That is, it is presumed that the neck-in phenomenon) is suppressed.
- the "flexibility" in the present disclosure means the flexibility of the non-woven fabric laminate itself due to the fact that the flexural rigidity is suppressed to a low level and the drapeability is excellent.
- the non-woven fabric laminate of the present disclosure includes a non-woven fabric layer A containing crimped composite fibers.
- the crimp composite fiber is preferably a spunbond fiber produced by the spunbond method from the viewpoint of reducing the flexural rigidity of the nonwoven fabric laminate and improving the flexibility.
- the non-woven fabric layer A includes spunbonded non-woven fabric, card-type air-through non-woven fabric, air-laid non-woven fabric, needle-punched spunbonded non-woven fabric, wet non-woven fabric, dry non-woven fabric, dry pulp non-woven fabric, flash-spun non-woven fabric, spread non-woven fabric, and various other materials.
- it may contain a known non-woven fabric or the like, it preferably contains only crimped composite fibers.
- the crimped composite fiber can be formed, for example, by having the composite fiber have a crimpable cross-sectional shape.
- the crimped composite fiber can be composed of a plurality of types of polymers by the spunbond method, and examples of the polymer include an olefin-based polymer, a polyester-based polymer, and nylon.
- the polymer is preferably an olefin-based polymer from the viewpoint of flexibility, strength and water resistance of the non-woven fabric laminate itself.
- the crimped composite fiber in the present disclosure includes, for example, at least two parts (a) composed of a specific polymer and (b) part composed of another polymer different from the specific polymer. It may have a region. Further, the crimped composite fiber in the nonwoven fabric laminate of the present disclosure is at least a part (a) composed of the olefin polymer (A) and a part (b) composed of the olefin polymer (B). It is preferable to have two regions.
- Olefin-based polymer (A) examples include an ethylene polymer and a propylene polymer. Among the above, the olefin-based polymer (A) is preferably a propylene-based polymer.
- the olefin-based polymer (A) may be composed of one type of polymer, or may be a mixture of two or more types of polymers, that is, two or more types of polymers.
- the ethylene-based polymer is a polymer mainly composed of a structural unit derived from ethylene, and is a concept including an ethylene homopolymer and a copolymer of ethylene and an ⁇ -olefin other than ethylene.
- it may be either an ethylene homopolymer or a copolymer of ethylene and an ⁇ -olefin other than ethylene (ethylene / ⁇ -olefin random copolymer).
- the ethylene / ⁇ -olefin random copolymer is preferably, for example, a random copolymer of ethylene and one or more ⁇ -olefins having 2 to 10 carbon atoms other than ethylene.
- Examples of the ethylene / ⁇ -olefin random copolymer include an ethylene / propylene random copolymer and an ethylene / 1-butene random copolymer.
- the ethylene-based polymer may contain two or more different ethylene-based polymers.
- the propylene-based polymer used as the olefin-based polymer (A) is a polymer mainly composed of a structural unit derived from propylene, and is a propylene homopolymer and a copolymer of propylene and ⁇ -olefin other than propylene (propylene). / ⁇ -Olefin random copolymer).
- the propylene-based polymer may be a propylene homopolymer, a copolymer of propylene and an ⁇ -olefin other than propylene, a propylene homopolymer, and ⁇ - propylene and other than propylene. It may contain both a copolymer with olefin.
- the propylene / ⁇ -olefin random copolymer is preferably a random copolymer of propylene and one or more ⁇ -olefins having 2 to 10 carbon atoms other than propylene.
- ⁇ -olefin copolymerized with propylene examples include ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene, and 3-methyl-1-.
- examples thereof include butene, 3-methyl-1-pentene, 3-ethyl-1-pentene, 4-methyl-1-pentene, 4-methyl-1-hexene and the like.
- propylene / ⁇ -olefin random copolymer examples include a propylene / ethylene random copolymer and a propylene / ethylene / 1-butene random copolymer.
- the content of ⁇ -olefin in the propylene / ⁇ -olefin random copolymer is not particularly limited, and is, for example, preferably 10 mol% or less, more preferably 5 mol% or less, and 2 mol% or less. It is more preferably present, and particularly preferably 1 mol% or less.
- the propylene-based polymer may contain two or more different propylene-based polymers, or may contain a propylene-based polymer and an ethylene-based polymer.
- the olefin-based polymer (A) is preferably a homopolymer of propylene.
- the melt flow rate (MFR) (ASTM D-1238, 230 ° C., load 2,160 g) of the olefin polymer (A) is preferably 20 g / 10 min to 100 g / 10 min from the viewpoint of spinnability. , 30 g / 10 min to 80 g / 10 min, more preferably.
- MFR melt flow rate
- the MFR is 100 g / 10 minutes or less, the tensile strength and the like of the obtained non-woven fabric laminate can be improved.
- the olefin-based polymer (A) in the present disclosure preferably has a higher melting point than the olefin-based polymer (B), and the difference preferably exceeds 10 ° C., and the difference is 12 ° C. to 40 ° C. More preferably in the range.
- a crimped composite fiber can be obtained from a composite fiber having more excellent crimpability.
- the olefin-based polymer (A) in the present disclosure preferably has a melting point of 155 ° C. or higher, and more preferably 157 ° C. to 165 ° C.
- the difference between the melting point of the olefin polymer (A) and the melting point of the olefin polymer (B) is set to exceed 10 ° C.
- the crimped composite fiber can be obtained from the composite fiber having excellent crimpability.
- the ratio [Mz / Mw (A)] of the Z average molecular weight (Mz) to the weight average molecular weight (Mw) of the olefin polymer (A) in the present disclosure is 2.0 from the viewpoint of exhibiting good crimpability.
- Mz / Mw (A) is preferably 4.5 or less from the viewpoint of spinnability.
- the Mz / Mw (A) of the olefin polymer (A) is more preferably 2.1 to 4.5, and even more preferably 2.1 to 3.0.
- the olefin-based polymer (A) in the present disclosure preferably has an Mw of 150,000 to 250,000 and a Mz of 300,000 to 600,000.
- the olefin-based polymer (A) in the present disclosure has a ratio [Mw / Mn (A)] of a weight average molecular weight (Mw) defined as a molecular weight distribution to a number average molecular weight (Mn) of 2.0 to 4.0. Is preferable, and 2.2 to 3.5 is more preferable.
- Mz, Mw, Mn, Mz / Mw (A) and Mw / Mn (A) of the olefin polymer (A) are measured by GPC (gel permeation chromatography) by the method described later. be able to.
- the olefin-based polymer (A) in the present disclosure is usually a Ziegler-Natta type catalyst in which a so-called titanium-containing solid transition metal component and an organometallic component are combined, or a periodic table number having at least one cyclopentadienyl skeleton.
- a metallocene catalyst composed of Group 4 to Group 6 transition metal compounds and co-catalyst components, in slurry polymerization, vapor phase polymerization, bulk polymerization, for example, propylene is homopolymerized, or propylene and a small amount of ⁇ -olefin are used. Is obtained by copolymerizing.
- a small amount of a propylene-based polymer having a different MFR, particularly a propylene-based polymer having a smaller MFR than the propylene-based polymer, is added so that Mz, Mw and Mz / Mw are within the above ranges. It can be produced by mixing or multi-stage polymerization, or can be obtained by direct polymerization.
- Mw / Mn (A) and Mz / Mw (A) of the olefin-based polymer (A) are prepared by a method of adjusting according to the polymerization conditions using a specific catalyst, and the polymer is decomposed by a peroxide or the like. It can be adjusted by a method of adjusting, a method of mixing and adjusting two or more kinds of polymers having different molecular weights, and the like.
- olefin-based polymer (A) in the present disclosure it is also possible to use a commercially available applicable product, for example, a propylene-based polymer manufactured and sold by Nippon Polypropylene Corporation under the trade name Novatec PP SA06A. is there.
- the olefin polymer (A) in the present disclosure includes antioxidants, weather stabilizers, light stabilizers, antistatic agents, antifogging agents, antiblocking agents, which are usually used, as long as the object of the present disclosure is not impaired. Additives such as lubricants, nucleating agents and pigments or other polymers can be added as needed.
- Olefin-based polymer (B) examples include ethylene-based polymers and propylene-based polymers.
- the ethylene-based polymer in the olefin-based polymer (B) is the same as the ethylene-based polymer described in the above-mentioned item of the olefin-based polymer (A), and the same applies to the preferred embodiment.
- the propylene-based polymer in the olefin-based polymer (B) is the same as the propylene-based polymer described in the above-mentioned item of the olefin-based polymer (A), and the same applies to the preferred embodiment. Further, as the propylene-based polymer in the olefin-based polymer (B), the following aspects are also preferable.
- the propylene-based polymer used as the olefin-based polymer (B) may be a homopolymer of propylene, and propylene listed in the above-mentioned olefin-based polymer (A) section and a small amount of one or more ⁇ .
- -It may be a copolymer with olefin (excluding propylene).
- the propylene-based polymer used as the olefin-based polymer (B) includes a copolymer of propylene and a small amount of one or more ⁇ -olefins.
- the coalescence is more preferable, and among them, a propylene / ⁇ -olefin random copolymer such as a propylene / ethylene random copolymer and a propylene / ethylene / 1-butene random copolymer is further preferable.
- melt flow rate (MFR) (ASTM D-1238, 230 ° C., load 2,160 g) of the olefin polymer (B) is in the same range from the same viewpoint as the MFR in the olefin polymer (A) described above. Is preferable.
- the olefin polymer (B) preferably has a melting point of 120 ° C. to 155 ° C., and more preferably 125 ° C. to 150 ° C. When the melting point of the olefin polymer (B) is 120 ° C. or higher, the heat resistance can be well maintained.
- the ratio [Mz / Mw (B)] of the Z average molecular weight (Mz) to the weight average molecular weight (Mw) of the olefin polymer (B) is preferably 2.5 or less, preferably 2.3 or less. More preferably.
- the olefin-based polymer (B) preferably has an Mw of 150,000 to 250,000, and preferably has an Mz of 300,000 to 600,000.
- the olefin polymer (B) has a ratio [Mw / Mn (B)] of the weight average molecular weight (Mw) defined as the molecular weight distribution to the number average molecular weight (Mn) of 2.0 to 4.0. Is preferable, and more preferably in the range of 2.2 to 3.5.
- Mz, Mw, Mn, Mz / Mw (B) and Mw / Mn (B) of the olefin polymer (B) are measured by GPC (gel permeation chromatography) by the method described later. be able to.
- the olefin-based polymer (B) in the present disclosure can be produced by the same polymerization method as the above-mentioned olefin-based polymer (A), and for example, a propylene / ⁇ -olefin random copolymer is used as the olefin-based polymer (B).
- a propylene / ⁇ -olefin random copolymer is used as the olefin-based polymer (B).
- it may be produced by mixing a small amount of propylene / ⁇ -olefin random copolymers having different MFRs or multistage polymerization so that Mz, Mw and Mz / Mw are in the above range, or directly polymerizing. It may be manufactured by.
- a method for adjusting Mw / Mn (B) and Mz / Mw (B) of the olefin-based polymer (B) a method of adjusting according to the polymerization conditions using a specific catalyst, a method of adjusting the polymer by a peroxide or the like, etc. Examples thereof include a method of decomposing and adjusting, a method of mixing and adjusting two or more kinds of polymers having different molecular weights, and the like.
- olefin-based polymer (B) it is also possible to use a commercially available applicable product, for example, a propylene-based polymer manufactured and sold under the trade name Prime Polypro S119 from Prime Polymer Co., Ltd.
- the olefin polymer (B) in the present disclosure includes antioxidants, weather stabilizers, light stabilizers, antistatic agents, antifogging agents, antiblocking agents, which are usually used, as long as the object of the present disclosure is not impaired. Additives such as lubricants, nucleating agents and pigments or other polymers can be added as needed.
- the olefin-based polymer (A) and the olefin-based polymer (B) are propylene-based polymers from the viewpoint of excellent balance between mechanical strength, neck-in resistance and flexibility of the obtained non-woven laminate.
- the olefin-based polymer (A) is preferably a propylene homopolymer
- the olefin-based polymer (B) is preferably a propylene / ⁇ -olefin random copolymer.
- the melting point of the olefin-based polymer (A) is higher than the melting point of the olefin-based polymer (B), and the Mz / Mw of the olefin-based polymer (A) is the olefin-based polymer. It is preferable to satisfy at least one of being larger than Mz / Mw of (B). Thereby, the crimpability of the crimp composite fiber can be improved. Further, it is more preferable that the melting points (Tm), Mz / Mw and MFR of the olefin-based polymer (A) and the olefin-based polymer (B) satisfy the following relationships.
- the melting point of the olefin-based polymer (A) is preferably higher than the melting point of the olefin-based polymer (B).
- the crimped composite fiber can be obtained from the composite fiber having more excellent crimpability.
- the melting point of the olefin-based polymer (A) constituting the part (a) and the olefin-based polymer constituting the part (b) of the present disclosure preferably exceeds 10 ° C., and the difference is more preferably 12 ° C. to 40 ° C. Further, when the melting point of the olefin polymer (B) is 155 ° C. or lower, it becomes easier to make the melting point difference from the olefin polymer (A) more than 10 ° C.
- ⁇ Tm is calculated by determining the melting points of the olefin-based polymer (A) and the olefin-based polymer (B), which are the raw materials of the parts (a) and (b), and the difference between them.
- the melting point is measured as follows. 1) The olefin polymer is set in a measuring pan for differential scanning calorimetry (DSC) manufactured by PerkinElmer, the temperature is raised from 30 ° C. to 200 ° C. at 10 ° C./min, and the temperature is maintained at 200 ° C. for 10 minutes. , The temperature is lowered to 30 ° C. at 10 ° C./min. 2) Next, the temperature is raised again from 30 ° C. to 200 ° C. at 10 ° C./min, and the melting point is obtained from the peaks observed during that period.
- DSC differential scanning calorimetry
- the Mz / Mw of the olefin-based polymer (A) is larger than the Mz / Mw of the olefin-based polymer (B).
- the crimped composite fiber can be obtained from the composite fiber having excellent crimpability.
- ⁇ Mz / Mw] is preferably 0.01 to 2.0, more preferably 0.03 to 1.0. It is more preferably 0.05 to 0.40.
- ⁇ Mz / Mw is 0.01 or more, the crimped composite fiber can be obtained from the composite fiber having excellent crimpability.
- ⁇ Mz / Mw is 2.0 or less, the spinnability can be well maintained.
- Mz is called Z average molecular weight, is known, and is defined by the following formula (1).
- Mi is a polymer [olefin-based polymer (A) and olefin-based polymer (B): hereinafter, when combined, it is referred to as "olefin-based polymer”. ]
- Ni is the number of moles of the polymer (olefin-based polymer).
- Mz is considered to have a molecular weight that more reflects the high molecular weight component of the polymer. Therefore, Mz / Mw represents a molecular weight distribution that reflects a higher molecular weight component than Mw / Mn, which is an index of a general molecular weight distribution. This value affects the crimpability of the fiber.
- the Mz / Mw of each of the olefin-based polymer (A) and the olefin-based polymer (B) constituting the parts (a) and (b) was obtained by GPC analysis, and the absolute value of the difference was obtained. Is calculated by.
- the GPC analysis is performed under the following conditions. 1) Completely dissolve 30 mg of the propylene polymer in 20 mL of o-dichlorobenzene at 145 ° C. 2) The solution is filtered through a sintered filter having a pore size of 1.0 ⁇ m to prepare a sample. 3) The sample is analyzed by GPC and converted into polystyrene (PS) to obtain an average molecular weight and a molecular weight distribution curve.
- PS polystyrene
- the measuring equipment and measurement conditions are as follows. Measuring device Gel osmosis chromatograph Alliance GPC2000 type (manufactured by Waters) Analyst data processing software Emper2 (manufactured by Waters) Column TSKgel GMH6-HT x 2 + TSKgel GMH6-HTL x 2 (both 7.5 mm I.D.
- MFR ratio The ratio of the MFR of the olefin-based polymer (A) constituting the part (a) of the present disclosure to the MFR of the olefin-based polymer (B) constituting the part (b) (hereinafter, also referred to as “MFR ratio”) is particularly high. Although not limited, it is preferably 0.8 to 1.2.
- the MFR of the olefin-based polymer (A) and the olefin-based polymer (B) in the present disclosure is preferably 20 g / 10 minutes to 100 g / 10 minutes.
- the MFR is determined at a load of 2,160 g and a temperature of 230 ° C. in accordance with ASTM D1238.
- the mass ratio [(a): (b)] of the part (a) and the part (b) in the crimped composite fiber of the present disclosure is preferably 10:90 to 60:40.
- the mass ratio of the part (a) and the part (b) is within the above range, the crimpability of the composite fiber used for forming the crimped composite fiber can be improved, and the non-woven fabric laminate can be made more comfortable. The flexibility can be further improved.
- the mass ratio of the part (a) to the part (b) [(a): (b)] is more preferably 10:90 to 50:50, further preferably 20:80 to 40:60. ..
- the crimped composite fiber in the present disclosure has at least two regions, a portion (a) composed of the olefin polymer (A) and a portion (b) composed of the olefin polymer (B).
- the mass ratio [(a): (b)] of the part (a) to the part (b) is 10: 90 to 60:40, and the olefin-based polymer (A) and the olefin-based weight.
- the coalescence (B) preferably has a mode in which at least one of Mz / Mw, melting point and MFR is different.
- Has an area of The mass ratio of part (a) to part (b) [(a): (b)] is 10:90 to 60:40.
- the melting point of the olefin-based polymer (A) is higher than the melting point of the olefin-based polymer (B), and the Mz / Mw of the olefin-based polymer (A) is higher than the Mz / Mw of the olefin-based polymer (B). It is preferable to satisfy at least one of the large ones.
- the crimped composite fiber of the present disclosure is a crimped composite fiber composed of the olefin-based polymer (A) and the olefin-based polymer (B), and has cross sections of parts (a) and (b).
- a crimped composite fiber having at least two regions.
- the mass ratio [(a): (b)] of the part (a) to the part (b) is 10: 90 to 60:40, and the part (a) is derived from the olefin polymer (A).
- the part (b) is composed of the olefin polymer (B), respectively, and is composed of Mz / Mw (A) of the olefin polymer (A) and Mz / Mw (B) of the olefin polymer (B).
- the average fiber diameter of the crimped composite fiber in the present disclosure is preferably 8 ⁇ m or more, preferably 10 ⁇ m or more, from the viewpoints of excellent yarn property, crimped property, neck-in resistance and mechanical strength when formed into a non-woven fabric laminate. It is more preferably 14 ⁇ m or more, and further preferably 14 ⁇ m or more. Further, the average fiber diameter of the crimped composite fibers in the present disclosure is preferably 23 ⁇ m or less, more preferably 20 ⁇ m or less, from the viewpoint of excellent flexibility of the nonwoven fabric laminate itself when it is made into a nonwoven fabric laminate. , 17 ⁇ m or less, and particularly preferably 16.6 ⁇ m or less. In the present disclosure, the average fiber diameter is measured by the method described in the section of Examples.
- FIG. 1 is a perspective view showing an example of the crimped composite fiber of the present disclosure.
- 10 is a part (a) and 20 is a part (b).
- the ratio of the (a) part in the cross section of the crimped composite fiber is the (b) part.
- the proportion is 10:90 to 60:40, preferably 10:90 to 50:50, more preferably 20:80 to 40: 40 in terms of mass ratio [(a): (b)]. It is 60.
- the crimped composite fiber having such a structure is not particularly limited and may take various known shapes. Specifically, for example, a side-by-side type (parallel type) crimp composite fiber in which the (a) portion and the (b) portion are in contact with each other, or the (a) portion is the core portion (a').
- a core-sheath type crimped composite fiber whose part (b) is formed of a sheath part (b') can be mentioned.
- the core-sheath type crimped composite fiber is composed of a core portion and a sheath portion, and refers to a crimped fiber.
- the core portion (a') is a portion within the cross section of the fiber that is arranged so as to be at least partially surrounded by a polymer different from the core portion (a') and extends in the length direction of the fiber.
- the sheath portion (b') is a portion that is arranged so as to surround at least a part of the core portion (a') in the cross section of the fiber and extends in the length direction of the fiber.
- the crimped composite fibers having an eccentric core-sheath structure are the crimped composite fibers having an eccentric core-sheath structure. It is also called an eccentric core sheath type crimped composite fiber).
- the crimped composite fiber has an eccentric core sheath structure in which the (a) portion is the core portion (a') and the (b) portion is the sheath portion (b'). Is preferable.
- the crimped composite fiber has the eccentric core sheath structure, the crimpability of the composite fiber used for forming the crimped composite fiber can be improved, and the flexibility of the non-woven fabric laminate can be further improved. Can be done.
- the eccentric core sheath structure is, for example, from the olefin polymer (B) having a smaller Mz / Mw, with the portion (a) composed of the olefin polymer (A) having a larger Mz / Mw as the core.
- the configured portion (b) may be used for the sheath portion.
- the eccentric core-sheath type crimped composite fiber includes an "exposed type” in which the side surface of the core portion (a') is exposed and a "non-exposed type” in which the side surface of the core portion (a') is not exposed. ..
- the eccentric core-sheath type crimp composite fiber is preferably an exposed type eccentric core-sheath type crimp composite fiber. This is because it can be an eccentric core-sheath type crimped composite fiber having excellent crimpability.
- the cross section in which the core portion (a') and the sheath portion (b') are in contact with each other may be a straight line or a curved line, and the cross section of the core portion may be circular, elliptical or square.
- a composite fiber in which the joint surface between the core portion and the sheath portion is straight and a part of the core portion is exposed on the surface of the crimped composite fiber is also called a side-by-side type.
- 3 to 8 show another example of the cross-sectional view of the crimped composite fiber in the present disclosure.
- a known method can be used as a method for producing the crimped composite fiber.
- the mode of the crimped composite fiber such as the core-sheath type crimped composite fiber is formed. be able to.
- the crimped composite fiber of the present disclosure may be a short fiber or a long fiber, but the long fiber does not cause the crimped composite fiber to fall off from the non-woven fabric when it is made into a non-woven fabric. It is preferable because it has excellent fluff resistance.
- the number of crimps of the crimp composite fiber is not particularly limited, and examples thereof include 5 fibers / 25 mm or more. From the viewpoint of producing a spunbonded non-woven fabric that is bulky and has excellent flexibility, the number of crimps is preferably 20 pieces / 25 mm or more, and more preferably 25 pieces / 25 mm or more.
- non-woven fabric using the crimped composite fiber examples include a manifest crimped spunbonded non-woven fabric in which the fiber is distorted during cooling and crimped.
- the long fibers of the actual crimped spunbonded non-woven fabric include eccentric core-sheath type composite long fibers in which different types of thermoplastic resins having different crystallization temperature, melting point, softening point, crystallization rate, melt viscosity, etc. are composited, parallel type. (Side-by-side type) Composite long fibers, eccentric hollow composite long fibers and the like can be mentioned.
- the nonwoven fabric laminate of the present disclosure includes a nonwoven fabric layer B containing ultrafine fibers having an average fiber diameter of less than 1.35 ⁇ m.
- the neck-in resistance of the nonwoven fabric laminate can be improved.
- the ultrafine fibers are preferably melt-blown non-woven fabrics produced by the melt-blown method from the viewpoint of further improving the neck-in property of the non-woven fabric laminate.
- the non-woven fabric layer B includes melt blown non-woven fabric, card-type air-through non-woven fabric, air-laid non-woven fabric, needle-punched spunbond non-woven fabric, wet non-woven fabric, dry non-woven fabric, dry pulp non-woven fabric, flash-spun non-woven fabric, spread non-woven fabric, and various known non-woven fabrics. Etc. may be contained, but it is preferable to contain only ultrafine fibers.
- the average fiber diameter of the ultrafine fibers is less than 1.35 ⁇ m.
- the average fiber diameter of the ultrafine fibers is preferably 1.34 ⁇ m or less.
- the average fiber diameter of the ultrafine fibers is preferably 1.00 ⁇ m or more from the viewpoint of obtaining a non-woven fabric laminate having high single yarn strength and sufficient mechanical properties.
- 1.20 ⁇ m from the viewpoint that a non-woven fabric laminate exhibiting sufficient mechanical properties can be obtained, and further, a non-woven fabric laminate having excellent uniformity and a good texture can be obtained, and a nonwoven fabric laminate having excellent neck-in resistance can be obtained. It is more preferably 1.30 ⁇ m or more, and further preferably 1.30 ⁇ m or more.
- the method for measuring the average fiber diameter of the ultrafine fibers is as described in the section of Examples.
- the ratio of the basis weight of the nonwoven fabric layer B to the total basis weight of the nonwoven fabric laminate is 2.0% to 8.0%.
- the ratio of the basis weight of the nonwoven fabric layer B to the total basis weight of the nonwoven fabric laminate is 2.0% or more, the nonwoven fabric has excellent uniformity and a good texture, and a nonwoven fabric laminate having excellent neck-in resistance can be obtained. it can.
- the ratio of the basis weight of the nonwoven fabric layer B to the total basis weight of the nonwoven fabric laminate is preferably 5.0% or more, more preferably 6.0% or more, and 6.3% or more. It is more preferable to have.
- the ratio of the basis weight of the nonwoven fabric layer B to the total basis weight of the nonwoven fabric laminate is 8.0% or less, it is possible to obtain a nonwoven fabric laminate having low bending rigidity and excellent flexibility of the nonwoven fabric laminate itself.
- the ratio of the basis weight of the nonwoven fabric layer B to the total basis weight of the nonwoven fabric laminate is preferably 8.0% or less, more preferably 7.0% or less, and 6.8% or less. It is more preferable to have.
- the "neck-in coefficient" in the present disclosure is a value calculated by the width retention rate (%) / basis weight (g / m 2 ).
- the "width retention rate (%)” and “weighting (g / m 2 )” are values calculated by the method described in the section of Examples.
- "Percentage of mass per unit area of the ultrafine fibers to the total basis weight of the laminate” in the present disclosure is a value calculated by the non-woven fabric layer B having a basis weight (g / m 2) / nonwoven fabric laminate of the basis weight (g / m 2) ..
- the method for measuring the width retention rate is as described in the section of Examples.
- the ratio of the basis weight of the non-woven fabric layer B to the total basis weight of the non-woven fabric laminate can be calculated by using the basis weight of the ultrafine fibers estimated from the value of the water pressure resistance using the above conversion formula.
- thermoplastic resins for example, Ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene, 3-methyl-1-butene, 3-methyl-1-pentene, 3-ethyl-1-pentene, 4- High-pressure low-density polyethylene, which is a single or copolymer of ⁇ -olefins of methyl-1-pentene and 4-methyl-1-hexene, linear low-density polyethylene (so-called LLDPE), high-density polyethylene, and propylene-based polymers ( (Propylene homopolymer, polypropylene random copolymer, propylene / ⁇ -olefin copolymer, etc.), poly1-butene, poly4-methyl-1-pentene, ethylene / propylene random copolymer, ethylene / 1-butene random Olefin-based polymers
- Polycarbonate-based polymers polyvinyl chloride, polyimide, ethylene / vinyl acetate copolymer, polyacrylonitrile, polycarbonate, polystyrene, ionomer, thermoplastic polyurethane, or a mixture thereof can be exemplified.
- the material constituting the ultrafine fibers is preferably an olefin-based polymer, and more preferably a propylene-based polymer.
- the ultrafine fibers are preferably propylene-based polymers from the viewpoint of chemical resistance.
- a propylene-based polymer include a propylene homopolymer having a melting point (Tm) of 155 ° C. or higher, preferably 157 ° C. to 165 ° C., and propylene and one or more of propylene having two or more carbon atoms. It is preferably a propylene / ⁇ -olefin copolymer which is a copolymer of ⁇ -olefin (excluding propylene).
- one or more ⁇ -olefins (excluding propylene) having two or more carbon atoms
- one or two or more ⁇ -olefins having 2 to 10 carbon atoms for example, ethylene, 1-butene, 1-) Penten, 1-hexene, 1-octene, 1-decene, 3-methyl-1-butene, 3-methyl-1-pentene, 3-ethyl-1-pentene, 4-methyl-1-pentene, 4-methyl- 1-Hexene, etc.
- the propylene homopolymer is more preferable.
- the content of the constituent units derived from the ⁇ -olefin of the propylene / ⁇ -olefin copolymer is preferably 0.5% by mass to 25% by mass, and 1.0% by mass to 20% by mass, based on the total constituent units. More preferably, it is by mass.
- the melt flow rate (MFR: ASTM D 1238, 230 ° C., load 2,160 g) of the propylene-based polymer is not particularly limited as long as it can be melt-spun, but is, for example, 1 g / 10 minutes to 3,000 g / 10 minutes. It may be, preferably 500 g / 10 minutes to 2,000 g / 10 minutes, and more preferably 700 g / 10 minutes to 1,600 g / 10 minutes.
- the texture of the nonwoven fabric layer B is preferably in the range of 0.5 g / m 2 to 1.5 g / m 2 , and preferably in the range of 0.7 g / m 2 to 1.5 g / m 2 . Is more preferable.
- the non-woven fabric layer B has a basis weight of 0.5 g / m 2 to 1.5 g / m 2 , it has an excellent balance between neck-in resistance and flexibility, and a thin crimped non-woven fabric can be obtained.
- the method of measuring the basis weight in the present disclosure is as described in the section of Examples.
- the non-woven fabric laminate of the present disclosure has a neck-in coefficient of 5.0 or more when stretched at 100 N / m.
- the neck-in coefficient of the nonwoven fabric laminate of the present disclosure is 5.0 or more, the basis weight of the nonwoven fabric laminate can be suppressed and the neck-in phenomenon can be satisfactorily suppressed.
- the non-woven fabric laminate preferably has a neck-in coefficient of 5.2 or more when stretched at 100 N / m, and more preferably 5.4 or more.
- a method of adjusting the neck-in coefficient for example, the following method can be mentioned.
- a method of adjusting the neck-in coefficient by selecting a resin having an appropriate unit structure and a binding pattern of the above unit structure as the resin contained in the crimp composite fiber and the ultrafine fiber.
- a method of adjusting the neck-in coefficient by selecting a resin having appropriate physical properties (for example, molecular weight distribution, crystallinity, etc.) as the resin contained in the crimped composite fiber and the ultrafine fiber.
- a method of adjusting the neck-in coefficient by changing the basis weight ratio of each layer in the laminated body.
- the non-woven fabric layer A is a layer of spunbonded non-woven fabric and the non-woven fabric layer B is a layer of melt blown non-woven fabric.
- the non-woven fabric laminate of the present disclosure may include a layer containing other fibers in addition to the above-mentioned non-woven fabric layer A and non-woven fabric layer B.
- the layer containing other fibers include a layer containing a spunbonded non-woven fabric that does not correspond to the non-woven fabric layer A, a layer containing a melt blown non-woven fabric that does not correspond to the non-woven fabric layer B, a layer containing a wet non-woven fabric, a layer containing a dry non-woven fabric, and a dry pulp non-woven fabric.
- the non-woven fabric layer B corresponds to the layer containing other fibers from the viewpoint of maintaining the cushioning property and flexibility required for sanitary materials in recent years at a high level while improving the neck-in resistance. It is preferable that the layer contains a melt blown non-woven fabric that does not.
- Basis weight of the nonwoven fabric laminate of the present disclosure is preferably from the viewpoint of suppressing a neck-in phenomenon is 8g / m 2 ⁇ 25g / m 2, 10g / m 2 ⁇ 23g / more preferably m is 2, more preferably from 12 g / m 2 ⁇ 18 g / m 2, and particularly preferably 12 g / m 2 ⁇ 15 g / m 2.
- the non-woven fabric laminate of the present disclosure is preferably heat-sealed by embossing.
- Non-woven fabric laminate The crimped composite fibers are heat-sealed to each other by embossing, so that the stability and strength of the fibers can be maintained satisfactorily.
- the non-woven fabric laminate of the present disclosure preferably has an embossed area ratio of 5% to 20% by the above embossing process. Within the above range, both the mechanical strength and flexibility required for sanitary materials can be achieved. From the same viewpoint as described above, it is more preferable that the embossed area ratio of the embossing is 7% to 15%.
- a method of embossing a known method can be used, and for example, the method described in JP-A-2017-153901 may be used.
- the non-woven fabric laminate of the present disclosure can be laminated with various layers and applied to various uses. Specific examples thereof include knitted fabrics, woven fabrics, non-woven fabrics, films, sanitary goods and the like. Among the above, since the nonwoven fabric laminate of the present disclosure exhibits good cushioning property, flexibility and neck-in resistance, the use of the nonwoven fabric laminate is preferably a sanitary product having the nonwoven fabric laminate of the present disclosure. ..
- embossing or super-adhesion when laminating (bonding) a non-woven fabric layer A containing crimped composite fibers, a non-woven fabric layer B containing ultrafine fibers, and a layer containing other fibers contained as necessary, embossing or super-adhesion is performed.
- thermal fusion methods such as ultrasonic fusion
- mechanical entanglement methods such as needle punching and water jets
- hot melt adhesives and adhesives such as urethane adhesives
- non-woven fabric laminate As a preferred embodiment of the non-woven fabric laminate of the present disclosure, a spunbonded non-woven fabric (crimped) made of a crimped composite fiber produced by a spunbond method and a melt-blown non-woven fabric (ultrafine fiber) made of a melt-blown fiber are laminated as needed. Examples thereof include a laminate with other non-woven fabrics.
- the nonwoven fabric laminate of the present disclosure is preferably a laminate having a three-layer structure and a four-layer structure, and has a four-layer structure. Laminates are more preferred.
- the non-woven fabric laminate of the present disclosure is a spunbonded nonwoven fabric (crimp) / melt blown nonwoven fabric (ultrafine fiber) / spunbonded nonwoven fabric.
- a structure of (crimp) / spunbonded non-woven fabric (crimp) is more preferable.
- the method for producing the nonwoven fabric laminate is not particularly limited, and a known method can be used.
- the non-woven fabric manufacturing apparatus shown in FIG. 9 can be used.
- the above-mentioned non-woven fabric manufacturing apparatus includes extruders 1 and 1'that extrude the olefin polymer (A) and the olefin polymer (B), a spinning base 2 that spins the extruded raw material into fibers 3, and fibers.
- the collector device 6 is provided with a suction unit 7 for efficiently collecting fibers by suction under the surface (collecting surface) for collecting fibers.
- the fibers 3 obtained by the spinning base 2 are cooled by air (quenching air) for cooling the fibers.
- the basis weight (g / m 2 ) was measured by the following method.
- Ten test pieces of 100 mm (fiber flow direction: MD) ⁇ 100 mm (direction orthogonal to the fiber flow direction: CD) are collected from the non-woven fabric to be measured.
- the test pieces shall be collected at 10 locations in the CD direction.
- the mass [g] of each of the collected test pieces is measured using a precision electronic balance (manufactured by Kensei Kogyo Co., Ltd.) to obtain the average value of the mass of each test piece.
- the average value obtained above is converted into the mass [g] per 1 m 2 to obtain the basis weight [g / m 2 ] of each non-woven fabric.
- the average fiber diameter is measured by the following method. First, using an electron microscope, the magnification is appropriately adjusted (for example, 200 times), a photograph of the fibrous nonwoven fabric is taken, 50 arbitrary fibers are selected from the fibers constituting the fibrous nonwoven fabric, and the width of the selected fibers ( Diameter) is measured. Then, the value calculated as the average value of the measured fiber widths (diameters) is taken as the average fiber diameter.
- the average fiber diameter of ultrafine fibers is also measured by appropriately adjusting the magnification of the electron microscope (for example, 1,000 times) and using the above-mentioned method for measuring the average fiber diameter.
- Water pressure resistance JIS L1072A method (low water pressure method) was followed. Take four test pieces of about 15 x 15 cm each, attach them to a water resistance test device (manufactured by Tester Sangyo Co., Ltd.) so that the surface of the test pieces is exposed to water, and attach a level device containing room temperature water to 60. Raise at a speed of ⁇ 3 cm / min or 10 ⁇ 0.5 cm / min, apply water pressure to the test piece, measure the water level when water leaks from three points on the opposite side of the test piece, and measure the pressure at that time. The water pressure resistance was calculated from.
- the flexibility was evaluated by the so-called cantilever method in accordance with JIS L1096. Specifically, it was carried out by the following method. 1) A 2 cm ⁇ 15 cm test piece 30 was prepared and placed on a test table 40 as shown in FIG. 2) The test piece 30 was slowly extruded in the direction of the arrow, and the distance 50 moved until the test piece was bent was measured. 3) The case where the MD of the test piece was parallel to the moving direction and the case where the CD of the test piece was parallel to the moving direction were measured. The higher the value measured above, the more the non-woven fabric laminate is more rigid, and the lower the value, the more flexible the non-woven fabric laminate is.
- the width retention rate is measured by the method described above, and the measured width retention rate is used as a value calculated by the width retention rate (%) / basis weight (g / m 2 ).
- the neck-in coefficient was calculated. The higher the neck-in coefficient, the better the neck-in resistance.
- Example 1 Composite melt spinning is performed by the spunbond method using the following IA component and the following IB component, and is formed from side-by-side type crimp composite fibers (hereinafter referred to as "crimp composite fibers I").
- the non-woven web was deposited on the mobile collection surface to prepare the first layer.
- the crimped composite fiber I had a mass ratio of IA component / IB component of 40/60.
- the average fiber diameter of the crimped composite fiber I in the first layer and the basis weight in the first layer are shown in Table 1.
- -Olefin-based polymer (A) (IA component) of crimped composite fiber I- Polypropylene homopolymer (h) having a melting point of 162 ° C., Mz / Mw2.24, MFR: 60 g / 10 minutes (measured at a temperature of 230 ° C. and a load of 2,160 g according to ASTM D1238. The same shall apply hereinafter unless otherwise specified).
- -PP) -Olefin-based polymer (B) (IB component) of crimped composite fiber I- Propylene / ethylene random copolymer (r-PP) having a melting point of 142 ° C., Mz / Mw2.19, and MFR60 g / 10 min.
- (2nd layer) A second layer was prepared on the non-woven web of the first layer by the same method and component as the method and component described in the first layer to prepare a non-woven web having a laminated structure.
- the average fiber diameter of the crimped composite fiber I in the second layer and the basis weight in the second layer are shown in Table 1.
- a propylene homopolymer having a melting point of 159 ° C. and an MFR of 850 g / 10 min was supplied to a die of a melt-blown non-woven fabric manufacturing apparatus, and a melt-blown nozzle (diameter 0.32 mm, diameter 0.32 mm) was introduced from the die heated to the molding temperature shown in Table 1. 41 hole / inch) is used to eject the air from both sides of the nozzle together with the high-temperature, high-speed air at the molding temperature shown in Table 1, and the DCD (distance from the surface of the spinneret to the collector) shown in Table 1 is used.
- the fibers (non-crimp composite fibers I) were deposited in-line on the non-woven webs of the first layer and the second layer to prepare a third layer, and a non-woven web having a laminated structure was prepared.
- the average fiber diameter of the non-crimped composite fiber I in the third layer and the basis weight in the third layer are shown in Table 1.
- the fourth layer was prepared on the non-woven web of the third layer by the same method and component as the method and component described in the first layer, and a non-woven web having a laminated structure was prepared.
- Table 1 shows the average fiber diameter of the crimped composite fiber I in the fourth layer and the basis weight in the fourth layer.
- the non-woven web having a laminated structure was heat-sealed with the following embossing roll under the following embossing conditions to obtain an SQL Server nonwoven fabric laminate.
- the embossed area ratio of the crimped portion was 11%.
- Table 1 shows the total basis weight of the entire non-woven fabric laminate.
- -Embossed roll- Embossed area ratio 11% Embossed aspect ratio: 4.1 mm / mm 2
- Rockwell hardness of embossed base material 37HRC -Embossing conditions
- Embossed temperature 142 ° C Embossed line pressure: 784 N / cm
- Example 2 Example 3, Comparative Example 1, and Comparative Example 2>
- the average fiber diameters of the first layer, the second layer, and the fourth layer are adjusted as shown in Table 1
- the average fiber diameters of the third layer are adjusted as shown in Table 1
- the basis weights of the first to fourth layers are adjusted.
- An SSMS non-woven fabric laminate having the total basis weights shown in Table 1 was obtained in the same manner as in Example 1 except that the changes were made as described in Table 1.
- (2nd layer) Composite melt spinning is performed by the spunbond method using the following IIA component and the following IIB component, and is formed from side-by-side type crimped composite fibers (hereinafter referred to as "crimped composite fibers II").
- the non-woven web was deposited in-line on the non-woven web of the first layer to prepare a second layer, and a non-woven web having a laminated structure was prepared.
- the crimped composite fiber II had a mass ratio of IIA component / IIB component of 40/60. Table 1 shows the average fiber diameter of the crimped composite fiber II in the second layer and the basis weight in the second layer.
- the third layer was prepared by using the same method as that described in the section (third layer) of Example 1 except that the molding temperature was the temperature shown in Table 1 and the DCD was the DCD shown in Table 1. Made. The average fiber diameter of the non-crimped composite fiber I in the third layer and the basis weight in the third layer are shown in Table 1.
- the fourth layer was prepared on the non-woven web of the third layer by the same method and component as the method and component described in the second layer, and a non-woven web having a laminated structure was prepared.
- Table 1 shows the average fiber diameter of the crimped composite fiber II in the fourth layer and the basis weight in the fourth layer.
- Example 2 Under the same method and embossing conditions as in Example 1, a non-woven web having a laminated structure was heat-sealed with an embossing roll to obtain an SSMS non-woven fabric laminate.
- the embossed area ratio of the crimped portion was 11%.
- Table 1 shows the total basis weight of the entire non-woven fabric laminate.
- ⁇ Comparative Example 4 and Comparative Example 5> The average fiber diameters of the first layer, the second layer, and the fourth layer are adjusted as shown in Table 1, the average fiber diameters of the third layer are adjusted as shown in Table 1, and the basis weights of the first to fourth layers are adjusted.
- An SSMS non-woven fabric laminate having the total basis weights shown in Table 1 was obtained in the same manner as in Comparative Example 3 except that the changes were made as shown in Table 1.
- the non-woven fabric layer A (first, second and fourth layers) containing crimped composite fibers and the non-woven fabric layer B (third layer) containing ultrafine fibers having an average fiber diameter of less than 1.35 ⁇ m.
- the ratio of the non-woven fabric layer B to the total non-woven fabric laminate is 2.0% to 8.0%, in Examples 1 to 3 were excellent in flexibility and neck-in resistance. ..
- Comparative Example 1 in which the ratio of the basis weight of the nonwoven fabric layer B (third layer) to the total basis weight of the nonwoven fabric laminate was more than 8.0%, the value of the cantilever was high and the flexibility was inferior.
- Comparative Example 2 in which the ratio of the basis weight of the nonwoven fabric layer B (third layer) to the total basis weight of the nonwoven fabric laminate was less than 2.0%, the value of the neck-in coefficient was low and the neck-in resistance was inferior.
- Comparative Examples 3 to 5 in which the average fiber diameter of the ultrafine fibers in the non-woven fabric layer B is 1.35 ⁇ m or more, Comparative Examples 3 and 5 are inferior in both flexibility and neck-in resistance, and Comparative Example 4 was inferior in neck-in resistance.
- Comparative Example 6 and Comparative Example 7 which do not have the nonwoven fabric layer B containing the ultrafine fibers having an average fiber diameter of less than 1.35 ⁇ m, Comparative Example 6 is inferior in neck-in resistance, and Comparative Example 7 is a nonwoven fabric laminate. could not be collected.
Landscapes
- Health & Medical Sciences (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Epidemiology (AREA)
- Biomedical Technology (AREA)
- Heart & Thoracic Surgery (AREA)
- Vascular Medicine (AREA)
- Animal Behavior & Ethology (AREA)
- General Health & Medical Sciences (AREA)
- Public Health (AREA)
- Veterinary Medicine (AREA)
- Dermatology (AREA)
- Nonwoven Fabrics (AREA)
- Absorbent Articles And Supports Therefor (AREA)
- Laminated Bodies (AREA)
Abstract
Description
例えば、特許文献1には、融点が異なる二種類のプロピレン系重合体を用いた偏芯芯鞘構造を有する複合繊維とした場合に、鞘部に用いる低融点のプロピレン系重合体よりMz/Mwが大きい高融点のプロピレン系重合体を芯部に用いて複合繊維とすると、より高度に捲縮した捲縮複合繊維が得られることが記載されている。
特許文献2:米国特許出願公開第2017/0335498号明細書
特許文献3:国際公開第2017/198336号
なお、本開示においてネックインとは、例えば、不織布をMD方向(繊維の流れ方向)に引っ張られた場合に、繊維の伸縮により不織布のCD方向(繊維の流れ方向と直交する方向)の長さが短くなる現象を意味する。
<1> 捲縮複合繊維を含む不織布層A、及び、平均繊維径1.35μm未満である極細繊維を含む不織布層Bを備え、不織布積層体の総目付に対する前記不織布層Bの目付の割合が2.0%~8.0%である不織布積層体。
<2> 前記極細繊維の平均繊維径が、1.00μm以上1.35μm未満である<1>に記載の不織布積層体。
<3> 不織布積層体の総目付に対する前記不織布層Bの目付の割合が、5.0%~8.0%である<1>又は<2>に記載の不織布積層体。
<4> 前記不織布層Aはスパンボンド不織布の層であり、前記不織布層Bはメルトブローン不織布の層である<1>~<3>のいずれか1つに記載の不織布積層体。
<5> 前記捲縮複合繊維は、オレフィン系重合体(A)から構成される(a)部、及び、オレフィン系重合体(B)から構成される(b)部の少なくとも2の領域を有し、前記(a)部と前記(b)部との質量比〔(a):(b)〕が、10:90~60:40であり、前記オレフィン系重合体(A)の融点が前記オレフィン系重合体(B)の融点よりも高いこと、及び、前記オレフィン系重合体(A)のMz/Mwが前記オレフィン系重合体(B)のMz/Mwよりも大きいことの少なくとも一方を満たす<1>~<4>のいずれか1つに記載の不織布積層体。
<6> 前記オレフィン系重合体(A)及び前記オレフィン系重合体(B)は、プロピレン系重合体である<5>に記載の不織布積層体。
<7> 前記捲縮複合繊維は、前記(a)部が芯部(a’)であり前記(b)部が鞘部(b’)である偏芯芯鞘構造を有する<5>又は<6>に記載の不織布積層体。
<8> エンボス加工により熱融着されている<1>~<7>のいずれか1つに記載の不織布積層体。
<9> 前記エンボス加工によるエンボス面積率が、5%~20%である<8>に記載の不織布積層体。
<10> <1>~<9>のいずれか1つに記載の不織布積層体を有する衛生用品。
本開示において「工程」との語は、独立した工程だけではなく、他の工程と明確に区別できない場合であってもその工程の目的が達成されれば、本用語に含まれる。
本開示において組成物中の各成分の含有量は、組成物中に各成分に該当する物質が複数種存在する場合、特に断らない限り、組成物中に存在する当該複数種の物質の合計量を意味する。
本開示において、「MD」(Machine Direction)方向とは、不織布製造装置における不織ウェブの進行方向を指す。「CD」(Cross Direction)方向とは、MD方向に垂直で、主面(不織布の厚さ方向に直交する面)に平行な方向を指す。
本開示において、組成物中の各成分の量について言及する場合、組成物中に各成分に該当する物質が複数存在する場合には、特に断らない限り、組成物中に存在する複数の物質の合計量を意味する。
本開示において「層」との語には、当該層が存在する領域を観察したときに、当該領域の全体に形成されている場合に加え、当該領域の一部にのみ形成されている場合も含まれる。
本開示の不織布積層体は、捲縮複合繊維を含む不織布層A、及び、平均繊維径1.35μm未満である極細繊維を含む不織布層Bを備え、不織布積層体の総目付に対する不織布層Bの目付の割合が2.0%~8.0%である。
また、極細繊維を含む不織布層Bは、耐ネックイン性を向上させ得るものの、曲げ剛性を増加させ、柔軟性を低下させる要因となり得る。
極細繊維は捲縮複合繊維よりも細い繊維である。そのため、不織布積層体中において、極細繊維は、捲縮複合繊維と比較して、より均一に分散され得る。
また、極細繊維は不織布積層体の形状を保持することに寄与し得るため、不織布積層体に極細繊維が含まれることで、不織布積層体が横縦方向に引っ張られた場合の縦横方向の収縮(即ちネックイン現象)が抑制されると推測される。
なお、本開示における「柔軟性」は、曲げ剛性が低く抑えられており、ドレープ性に優れていることによる不織布積層体自体の柔軟性を意味する。
本開示の不織布積層体は、捲縮複合繊維を含む不織布層Aを備える。
本開示の不織布積層体が捲縮複合繊維を含む不織布層Aを備えることで、不織布積層体の曲げ剛性を低下させることができ、柔軟性を向上させることができる。
捲縮複合繊維としては、不織布積層体の曲げ剛性を低下させて柔軟性を向上させる観点から、スパンボンド法により製造されたスパンボンド繊維であることが好ましい。
捲縮複合繊維は、例えば複合繊維が捲縮可能な断面形状を有することで形成することができる。
上記の中でも、不織布積層体自体の柔軟性、強度及び耐水性の観点から、上記重合体はオレフィン系重合体であることが好ましい。
また、本開示の不織布積層体における捲縮複合繊維は、オレフィン系重合体(A)から構成される(a)部、及び、オレフィン系重合体(B)から構成される(b)部の少なくとも2の領域を有することが好ましい。
オレフィン系重合体(A)としては、エチレン系重合体、プロピレン系重合体等が挙げられる。上記の中でも、オレフィン系重合体(A)としては、プロピレン系重合体であることが好ましい。
なお、オレフィン系重合体(A)は、1種類の重合体で構成されてもよく、2種類以上の重合体、即ち2種類以上の重合体の混合体であってもよい。
例えば、エチレン単独重合体、及びエチレンとエチレン以外のα-オレフィンとの共重合体(エチレン/α-オレフィンランダム共重合体)のいずれでもよい。
エチレン系重合体は、異なるエチレン系重合体を2種以上含んでもよい。
例えば、プロピレン系重合体は、プロピレン単独重合体であってもよく、プロピレンとプロピレン以外のα-オレフィンとの共重合体であってもよく、プロピレン単独重合体、及びプロピレンとプロピレン以外のα-オレフィンとの共重合体の両方を含んでいてもよい。
一方、MFRが100g/10分以下であることで、得られる不織布積層体の引張強度等を向上させることができる。
オレフィン系重合体(A)とオレフィン系重合体(B)との融点差を大きくすることにより、より捲縮性に優れる複合繊維から捲縮複合繊維を得ることができる。
オレフィン系重合体(A)の融点が155℃以上であることで、オレフィン系重合体(A)の融点とオレフィン系重合体(B)の融点との差を、10℃を超える差にすることがより容易となるため、捲縮性に優れる複合繊維から捲縮複合繊維を得ることができる。
上記同様の観点から、オレフィン系重合体(A)のMz/Mw(A)は、2.1~4.5がより好ましく、2.1~3.0がさらに好ましい。
オレフィン系重合体(B)としては、エチレン系重合体、プロピレン系重合体等が挙げられる。
オレフィン系重合体(B)におけるエチレン系重合体は、上述のオレフィン系重合体(A)の項に記載されるエチレン系重合体と同様であり、好ましい態様についても同様である。
また、オレフィン系重合体(B)におけるプロピレン系重合体としては、以下の態様も好ましい。
上記の中でも、耐ネックイン性と柔軟性とのバランスに優れる観点から、オレフィン系重合体(B)として用いられるプロピレン系重合体としては、プロピレンと少量の一種以上のα-オレフィンとの共重合体がより好ましく、中でも、プロピレン・エチレンランダム共重合体、プロピレン・エチレン・1-ブテンランダム共重合体などのプロピレン・α-オレフィンランダム共重合体がさらに好ましい。
オレフィン系重合体(B)の融点が120℃以上であることで、耐熱性を良好に保持することができる。
また、オレフィン系重合体(A)及びオレフィン系重合体(B)の、融点(Tm)、Mz/Mw及びMFRが、以下の関係を満たすことがより好ましい。
本開示において、オレフィン系重合体(A)の融点はオレフィン系重合体(B)の融点よりも高いことが好ましい。
これによって、より捲縮性に優れる複合繊維から捲縮複合繊維を得ることができる。
また、オレフィン系重合体(B)の融点が155℃以下であることで、オレフィン系重合体(A)との融点差を、10℃を超える差にすることがより容易となる。
1)オレフィン系重合体をパーキンエルマー社製示差走査熱量分析(DSC)の測定用パンにセットし、30℃から200℃まで、10℃/分で昇温し、200℃で10分間保持した後、30℃まで10℃/分で降温する。
2)次に、再び、30℃から200℃まで10℃/分で昇温し、その間に観測されたピークから融点を求める。
本開示において、オレフィン系重合体(A)のMz/Mwはオレフィン系重合体(B)のMz/Mwよりも大きいことが好ましい。
これによって、捲縮性に優れる複合繊維から捲縮複合繊維を得ることができる。
△Mz/Mwが0.01以上であることで、捲縮性に優れる複合繊維から捲縮複合繊維が得られる。一方、△Mz/Mwが2.0以下であることで、紡糸性を良好に保持できる。
なお、MzはZ平均分子量と呼ばれ、公知であり、以下の式(1)で定義される。
1)プロピレン重合体30mgをo-ジクロロベンゼン20mLに145℃で完全に溶解させる。
2)当該溶液を孔径が1.0μmの焼結フィルターで濾過し、試料とする。
3)当該試料をGPCにより分析し、ポリスチレン(PS)換算して、平均分子量及び分子量分布曲線を求める。
測定装置 ゲル浸透クロマトグラフAlliance GPC2000型(Waters社製)
解析装置 データ処理ソフトEmpower2(Waters社製)
カラム TSKgel GMH6-HT×2+TSKgel GMH6-HTL×2(いずれも7.5mmI.D.×30cm、東ソー社製)
カラム温度 140℃
移動相 o-ジクロロベンゼン (0.025%butylated hydroxytoluene BHT含有)
検出器 示差屈折率計
流速 1mL/min
試料濃度 30mg/20mL
注入量 500μL
サンプリング時間間隔 1s
カラム校正 単分散ポリスチレン(東ソー社製)
分子量換算 PS換算/標準換算法
本開示の(a)部を構成するオレフィン系重合体(A)のMFRと(b)部を構成するオレフィン系重合体(B)のMFRの比(以下「MFR比」ともいう)は、特に限定はされないが、0.8~1.2であることが好ましい。
本開示におけるオレフィン系重合体(A)及びオレフィン系重合体(B)のMFRは、20g/10分~100g/10分であることが好ましい。
本開示の捲縮複合繊維における(a)部と(b)部との質量比〔(a):(b)〕は、10:90~60:40であることが好ましい。
(a)部と(b)部との質量比が上記の範囲内であることで、捲縮複合繊維の形成に用いる複合繊維の捲縮性をより良好にすることができ、不織布積層体の柔軟性をより向上させることができる。
上記の観点から、(a)部と(b)部との質量比〔(a):(b)〕は、10:90~50:50がより好ましく、20:80~40:60がさらに好ましい。
(a)部と(b)部との質量比〔(a):(b)〕が、10:90~60:40であり、
オレフィン系重合体(A)の融点がオレフィン系重合体(B)の融点よりも高いこと、及び、オレフィン系重合体(A)のMz/Mwがオレフィン系重合体(B)のMz/Mwよりも大きいことの少なくとも一方を満たすことが好ましい。
上記(a)部と上記(b)部の質量比〔(a):(b)〕が、10:90~60:40であり、上記(a)部はオレフィン系重合体(A)から、上記(b)部はオレフィン系重合体(B)からそれぞれ構成され、上記オレフィン系重合体(A)のMz/Mw(A)と上記オレフィン系重合体(B)のMz/Mw(B)の差〔Mz/Mw(A)-Mz/Mw(B):△Mz/Mw〕が、0.10~2.2であり、上記オレフィン系重合体(A)の融点〔Tm(A)〕と上記オレフィン系重合体(B)の融点〔Tm(B)〕の差〔△Tm=Tm(A)-Tm(B)〕が10℃を超える、捲縮複合繊維であってもよい。
また、本開示における捲縮複合繊維の平均繊維径は、不織布積層体とした場合の不織布積層体自体の柔軟性に優れる観点から、23μm以下であることが好ましく、20μm以下であることがより好ましく、17μm以下であることがさらに好ましく、16.6μm以下であることが特に好ましい。
なお、本開示において平均繊維径は、実施例の項に記載の方法で測定する。
鞘部(b’)は、繊維の断面内において芯部(a’)の少なくとも一部を取り囲むように配列され、かつ繊維の長さ方向に延びる部分をいう。芯鞘型捲縮複合繊維のうち、繊維の断面内における繊維の芯部(a’)の中心と鞘部(b’)の中心が同一でないものを偏芯芯鞘構造の捲縮複合繊維(偏芯芯鞘型捲縮複合繊維とも称する。)という。
本開示の不織布積層体において、捲縮複合繊維は、上記(a)部が芯部(a’)であり上記(b)部が鞘部(b’)である偏芯芯鞘構造を有することが好ましい。
捲縮複合繊維が上記偏芯芯鞘構造を有することで、捲縮複合繊維の形成に用いる複合繊維の捲縮性をより良好にすることができ、不織布積層体の柔軟性をより向上させることができる。
上記偏芯芯鞘構造は、例えば、Mz/Mwがより大きいオレフィン系重合体(A)から構成される(a)部を芯部に、Mz/Mwがより小さいオレフィン系重合体(B)から構成される(b)部を鞘部に用いてもよい。
偏芯芯鞘型捲縮複合繊維としては、露出型の偏芯芯鞘型捲縮複合繊維であることが好ましい。捲縮性に優れた偏芯芯鞘型捲縮複合繊維となり得るからである。また、芯部(a’)と鞘部(b’)が接する断面は、直線であっても曲線であってもよく、芯部の断面は円形であっても、楕円あるいは方形であってもよい。
芯部と鞘部の接合面が直線で、芯部の一部が捲縮複合繊維の表面に露出した複合繊維は、サイド・バイ・サイド型とも呼ばれる。
図3~図8に、本開示における捲縮複合繊維の断面図の他の例を示す。
本開示の不織布積層体は、平均繊維径1.35μm未満である極細繊維を含む不織布層Bを備える。
本開示の不織布積層体が不織布層Bを備えることで、不織布積層体の耐ネックイン性を向上させることができる。
これによって均一性に優れ地合いの良い積層体になり、耐ネックイン性が優れる不織布積層体を得ることができる。
上記同様の観点から、極細繊維の平均繊維径は1.34μm以下であることが好ましい。
また、極細繊維の平均繊維径は、単糸強度が高く、充分な機械特性を示す不織布積層体が得られる観点から、1.00μm以上であることが好ましい。
充分な機械特性を示す不織布積層体が得られることに加えてさらに、均一性に優れ地合いの良い積層体になり、耐ネックイン性が優れる不織布積層体を得ることができる観点から、1.20μm以上であることがより好ましく、1.30μm以上であることがさらに好ましい。
極細繊維の平均繊維径の測定方法は、実施例の項に記載の通りである。
不織布積層体の総目付に対する不織布層Bの目付の割合が2.0%以上であることで、均一性に優れ地合いの良い積層体になり、耐ネックイン性が優れる不織布積層体を得ることができる。
上記同様の観点から、不織布積層体の総目付に対する不織布層Bの目付の割合が5.0%以上であることが好ましく、6.0%以上であることがより好ましく、6.3%以上であることがさらに好ましい。
上記同様の観点から、不織布積層体の総目付に対する不織布層Bの目付の割合が8.0%以下であることが好ましく、7.0%以下であることがより好ましく、6.8%以下であることがさらに好ましい。
また「幅保持率(%)」、「目付(g/m2)」は、実施例の項に記載の方法で算出される値である。
本開示における「積層体の総目付に占める極細繊維の目付の割合」は、不織布層Bの目付(g/m2)/不織布積層体の目付(g/m2)で算出される値である。
幅保持率の測定方法は、実施例の項に記載の通りである。
本開示の不織布積層体において、耐水圧の値と極細繊維の目付との間には正の相関があることが知られている。そのため、耐水圧の値から極細繊維の目付を見積もることが可能である。
これによって、耐水圧の値より見積もられた極細繊維の目付を用いて、不織布層Bの目付比率を概算することができる。
耐水圧の値から極細繊維の目付を見積もるための換算式は、以下の式1で表される。
なお、式1は、国際公開第2017/198336号の実験例におけるSMS不織布積層体、及び、本開示における実験例のデータから算出した式である。
耐水圧[mmH2O]=55.7×極細繊維の目付[g/m2]+97.0 式1
エチレン、プロピレン、1-ブテン、1-ペンテン、1-ヘキセン、1-オクテン、1-デセン、3-メチル-1-ブテン、3-メチル-1-ペンテン、3-エチル-1-ペンテン、4-メチル-1-ペンテン、4-メチル-1-ヘキセンのα-オレフィンの単独若しくは共重合体である高圧法低密度ポリエチレン、線状低密度ポリエチレン(所謂LLDPE)、高密度ポリエチレン、プロピレン系重合体(プロピレン単独重合体、ポリプロピレンランダム共重合体、プロピレン・α-オレフィン共重合体等)、ポリ1-ブテン、ポリ4-メチル-1-ペンテン、エチレン・プロピレンランダム共重合体、エチレン・1-ブテンランダム共重合体、プロピレン・1-ブテンランダム共重合体等のオレフィン系重合体;ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリエチレンナフタレート等のポリエステル;ナイロン-6、ナイロン-66、ポリメタキシレンアジパミド等のポリアミド系重合体;ポリ塩化ビニル、ポリイミド、エチレン・酢酸ビニル共重合体、ポリアクリロニトリル、ポリカーボネート、ポリスチレン、アイオノマー、熱可塑性ポリウレタンあるいはこれらの混合物等を例示することができる。
上記の中でも、極細繊維を構成する材料としては、オレフィン系重合体であることが好ましく、プロピレン系重合体であることがより好ましい。
極細繊維としては、上記オレフィン系重合体の中でも、耐薬品性の観点からプロピレン系重合体であることが好ましい。
かかるプロピレン系重合体としては、融点(Tm)が155℃以上、好ましくは157℃~165℃の範囲にあるプロピレンの単独重合体、及び、プロピレンと、炭素数2以上の1種又は2種以上のα-オレフィン(プロピレンは除く)と、の共重合体であるプロピレン・α-オレフィン共重合体であることが好ましい。
炭素数2以上の1種又は2種以上のα-オレフィン(プロピレンは除く)としては、炭素数2~10の1種又は2種以上のα-オレフィン(例えば、エチレン、1-ブテン、1-ペンテン、1-ヘキセン、1-オクテン、1-デセン、3-メチル-1-ブテン、3-メチル-1-ペンテン、3-エチル-1-ペンテン、4-メチル-1-ペンテン、4-メチル-1-ヘキセン等)が好ましく、炭素数2~8の1種又は2種以上のα-オレフィンがより好ましい。これらの中でもプロピレン単独重合体がより好ましい。プロピレン・α-オレフィン共重合体のα-オレフィンに由来する構成単位の含有量は、全構成単位に対し、0.5質量%~25質量%であることが好ましく、1.0質量%~20質量%であることがより好ましい。
プロピレン系重合体は、溶融紡糸し得る限り、メルトフローレート(MFR:ASTM D 1238、230℃、荷重2,160g)は特に限定はされないが、例えば1g/10分~3,000g/10分であってもよく、好ましくは500g/10分~2,000g/10分であり、さらに好ましくは700g/10分~1,600g/10分である。
なお、本開示における目付の測定方法は、実施例の項に記載した通りである。
本開示の不織布積層体は、100N/mで伸展させた場合のネックイン係数が5.0以上である。
本開示の不織布積層体のネックイン係数が5.0以上であることで、不織布積層体の目付を抑制し、ネックイン現象を良好に抑制することができる。
上記同様の観点から、不織布積層体は100N/mで伸展させた場合のネックイン係数が5.2以上であることが好ましく、5.4以上であることがより好ましい。
捲縮複合繊維及び極細繊維に含まれる樹脂として、適切な単位構造及び上記単位構造の結合パターンを有する樹脂を選択することによりネックイン係数を調整する方法。
捲縮複合繊維及び極細繊維に含まれる樹脂として、適切な物性(例えば、分子量分布、結晶性等)を有する樹脂を選択することによりネックイン係数を調整する方法。
積層体における各層の目付比率を変更することによりネックイン係数を調整する方法。
本開示の不織布積層体は、上述の不織布層A及び不織布層B以外に、他の繊維を含む層を備えていてもよい。
他の繊維を含む層としては、不織布層Aに該当しないスパンボンド不織布を含む層、不織布層Bに該当しないメルトブローン不織布を含む層、湿式不織布を含む層、乾式不織布を含む層、乾式パルプ不織布を含む層、フラッシュ紡糸不織布を含む層、開繊不織布を含む層等、種々公知の不織布を含む層を挙げることができる。
上記の中でも、耐ネックイン性を向上させつつ、近年の衛生材料に求められているクッション性及び柔軟性を高い水準で維持する観点から、他の繊維を含む層としては、不織布層Bに該当しないメルトブローン不織布を含む層であることが好ましい。
本開示の不織布積層体の目付(不織布積層体の単位面積当たりの質量)は、ネックイン現象を抑制する観点から8g/m2~25g/m2であることが好ましく、10g/m2~23g/m2であることがより好ましく、12g/m2~18g/m2であることがさらに好ましく、12g/m2~15g/m2であることが特に好ましい。
不織布積層体上記捲縮複合繊維がエンボス加工により互いに熱融着されていることで、繊維の安定性及び強度を良好に維持できる。
上記同様の観点から、エンボス加工のエンボス面積率が7%~15%であることがより好ましい。
エンボス加工の方法については、公知の方法を用いることができ、例えば特開2017-153901号公報に記載の方法を用いてもよい。
本開示の不織布積層体は、種々の層と積層して様々な用途に適用することができる。
具体的には、例えば、編布、織布、不織布、フィルム、衛生用品等を挙げることができる。上記の中でも、本開示の不織布積層体が良好なクッション性、柔軟性及び耐ネックイン性を示すことから、不織布積層体の用途は、本開示の不織布積層体を有する衛生用品であることが好ましい。
本開示において、捲縮複合繊維を含む不織布層A、極細繊維を含む不織布層B、及び、必要に応じて含まれる他の繊維を含む層を積層する(貼り合せる)場合は、エンボス加工、超音波融着等の熱融着法、ニードルパンチ、ウォータージェット等の機械的交絡法、ホットメルト接着剤、ウレタン系接着剤等の接着剤による方法、押出しラミネート等をはじめ、種々公知の方法を採り得る。
本開示の不織布積層体の好ましい態様としては、スパンボンド法で製造した捲縮複合繊維からなるスパンボンド不織布(捲縮)及びメルトブローン繊維からなるメルトブローン不織布(極細繊維)と、必要に応じて積層されるその他の不織布と、の積層体が挙げられる。
具体的には、スパンボンド不織布(捲縮)/メルトブローン不織布(極細繊維)/スパンボンド不織布(捲縮)/スパンボンド不織布(捲縮)、スパンボンド不織布(非捲縮)/メルトブローン不織布(極細繊維)/スパンボンド不織布(捲縮)/スパンボンド不織布(捲縮)、スパンボンド不織布(非捲縮)/メルトブローン不織布(極細繊維)/スパンボンド不織布(非捲縮)/スパンボンド不織布(捲縮)等の4層構造の積層体;
スパンボンド不織布(捲縮)/メルトブローン不織布(極細繊維)/スパンボンド不織布(捲縮)、スパンボンド不織布(非捲縮)/メルトブローン不織布(極細繊維)/スパンボンド不織布(捲縮)等の3層構造の積層体;
メルトブローン不織布(極細繊維)/スパンボンド不織布(捲縮)等の2層構造の積層体などが挙げられる。
上記の中でも、不織布積層体の柔軟性と耐ネックイン性とを両立させる観点から、本開示の不織布積層体は、上記3層構造及び4層構造の積層体であることが好ましく、4層構造の積層体がより好ましい。
不織布積層体の製造方法としては、特に制限はなく、公知の方法を用いることができる。
例えば、図9に示す不織布製造装置を用いることができる。
上記不織布製造装置は、オレフィン系重合体(A)及びオレフィン系重合体(B)を押し出す押出機1及び1’と、押し出された原料を紡糸して繊維3とする紡糸用口金2と、繊維3を延伸するエジェクター5と、延伸後の繊維を捕集することにより不織布8とするコレクター装置6と、不織布8の少なくとも一部を熱融着するボンディングユニット9と、熱融着後の不織布を巻き取るワインダーと、を備える。コレクター装置6は、繊維を捕集する面(補集面)の下部に、吸引によって繊維を効率良く補集するためのサクションユニット7を備える。この不織布製造装置において、紡糸用口金2によって得られた繊維3は、繊維を冷却するための空気(クエンチエアー)によって冷却される。
測定対象の不織布から100mm(繊維の流れ方向:MD)×100mm(繊維の流れ方向と直交する方向:CD)の試験片を10点採取する。試験片の採取場所は、CD方向にわたって10箇所とする。次いで、採取した各試験片に対して上皿電子天秤(研精工業社製)を用いて、それぞれ質量〔g〕を測定して各試験片の質量の平均値を求める。
上記で求めた平均値から1m2当たりの質量〔g〕に換算し、各不織布の目付〔g/m2〕とする。
まず、電子顕微鏡を用いて、倍率を適宜調整して(例えば200倍)繊維不織布の写真を撮影し、繊維不織布を構成する繊維のうち、任意の繊維50本を選び、選択した繊維の幅(直径)を測定する。そして、測定した繊維の幅(直径)の平均値として算出した値を平均繊維径とする。
なお、極細繊維(メルトブローン繊維を含む)の平均繊維径についても、電子顕微鏡の倍率を適宜調整(例えば1,000倍)して、上述の平均繊維径の測定方法を用いて測定する。
まず、冶具を用い、冶具間の距離は350mmとして、幅200mm×長さ450mmの不織布積層体の長さ方向の両端を挟む。次に引張試験機に上記不織布積層体をセットして100N/mの張力で引っ張った後、幅を測定する。そして以下の式にて幅保持率を算出する。
幅保持率(%)=(引張時の幅(mm)/初期の幅(mm))×100
各実施例及び比較例について、以下の各評価を行い、各評価結果を表2に示した。
(引張強度)
不織布積層体について、JIS L 1906に準拠して測定した。不織布積層体から、幅25mm×長さ200mmの試験片を採取し、引張試験機を用いてチャック間距離100mm、ヘッドスピード100mm/minで、MD(繊維の流れ方向):5点、及びCD(繊維の流れ方向と直交する方向):5点を測定し、それぞれ平均値を算出して引張強度(N/25mm)を求めた。
耐水圧JIS L1072A法(低水圧法)に準じて行った。約15×15cmの試験片を4枚ずつ採取し、耐水度試験装置(テスター産業(株)製)に試験片の表面が水に当てられるように取り付け、常温水が入れられた水準装置を60±3cm/分又は10±0.5cm/分の速さで上昇させて試験片に水圧をかけて試験片の反対側の3箇所から水が漏れたときの水位を測定し、その際の圧力から耐水圧を求めた。
JIS L1096準拠し、いわゆるカンチレバー法により柔軟性を評価した。具体的には、以下の方法で行った。
1)2cm×15cmの試験片30を準備し、図2に示すような試験台40の上に静置した。
2)試験片30をゆっくり矢印方向へ押出し、試験片が折れ曲がるまでに移動させた距離50を測定した。
3)試験片のMDが移動方向に平行である場合と、試験片のCDが移動方向に平行である場合について測定した。
なお、上記で測定される数値が高いほど不織布積層体は剛性に優れ、低いほど不織布積層体は柔軟性に優れる。
耐ネックイン性の指標として、既述の方法により幅保持率を測定して、測定した幅保持率を用いて、幅保持率(%)/目付(g/m2)で算出される値としてネックイン係数を算出した。
なお、ネックイン係数が高い程耐ネックイン性が良好である。
各実施例又は比較例において、各層を構成する重合体を紡糸した際の糸切れ回数を測定し、以下の評価基準に従って評価した。
A:糸切れなし
B:糸切れが1回以上発生した。
エンボス加工において、エンボスロールを5分間走行させ、不織布積層体がエンボスロールを通過する際に生じる付着状態を確認し、下記評価基準に従って評価した。
A:目視にて付着が全く確認されない状態。
B:目視にて付着が確認される状態、又はエンボスロールに巻付く状態
(第1層)
下記のIA成分と下記のIB成分とを用いて、スパンボンド法により複合溶融紡糸を行い、サイド・バイ・サイド型の捲縮複合繊維(以下「捲縮複合繊維I」とする)から形成される不織ウェブを移動捕集面上に堆積させて、第1層を作製した。上記捲縮複合繊維Iは、IA成分/IB成分の質量比が40/60であった。
第1層における捲縮複合繊維Iの平均繊維径、及び、第1層における目付は表1に示す。
-捲縮複合繊維Iのオレフィン系重合体(A)(IA成分)-
融点162℃、Mz/Mw2.24、MFR:60g/10分(ASTM D1238に準拠して温度230℃、荷重2,160gで測定。以下、特に特定しない限り同様。)のプロピレン単独重合体(h-PP)
-捲縮複合繊維Iのオレフィン系重合体(B)(IB成分)-
融点142℃、Mz/Mw2.19、MFR60g/10分のプロピレン・エチレンランダム共重合体(r-PP)
上記第1層に記載の方法及び成分と同様の方法及び成分にて、上記第1層の不織ウェブ上に第2層を作製し、積層構造の不織ウェブを作製した。
第2層における捲縮複合繊維Iの平均繊維径、及び、第2層における目付は表1に示す。
融点159℃、MFRが850g/10分のプロピレン単独重合体を、メルトブローン不織布製造装置のダイに供給し、表1に記載の成形温度に加熱されたダイから、メルトブローン用ノズル(直径0.32mm、41hole/inch)を用いて、ノズルの両側から吹き出す表1に記載の成形温度の高温高速空気と伴に吐出し、表1に記載のDCD(紡糸口金の表面からコレクターまでの距離)で吐出される繊維(非捲縮複合繊維I)をインラインで第1層及び第2層の不織ウェブ上に堆積させて第3層を作製し、積層構造の不織ウェブを作製した。
第3層における非捲縮複合繊維Iの平均繊維径、及び、第3層における目付は表1に示す。
第1層に記載の方法及び成分と同様の方法及び成分にて、第3層の不織ウェブ上に第4層を作製し、積層構造の不織ウェブを作製した。
第4層における捲縮複合繊維Iの平均繊維径、及び、第4層における目付は表1に示す。
-エンボスロール-
エンボス面積率:11%
エンボスアスペクト比:4.1mm/mm2
エンボス母材のロックウェル硬度:37HRC
-エンボス条件-
エンボス温度:142℃
エンボス線圧:784N/cm
第1層、第2層及び第4層の平均繊維径を表1の通りに調整し、第3層の平均繊維径を表1の通りに調整し、第1層~第4層の目付を表1に記載の通りに変更した以外は、実施例1と同様にして、表1に記載の総目付を有するSSMS不織布積層体を得た。
(第1層)
実施例1の(第1層)の項に記載の方法と同様の方法を用いて、第1層を作製した。
第1層における捲縮複合繊維Iの平均繊維径、及び、第1層における目付は表1に示す。
下記のIIA成分と下記のIIB成分とを用いて、スパンボンド法により複合溶融紡糸を行い、サイド・バイ・サイド型の捲縮複合繊維(以下「捲縮複合繊維II」とする)から形成される不織ウェブを、インラインで、第1層の不織ウェブ上に堆積させて第2層を作製し、積層構造の不織ウェブを作製した。捲縮複合繊維IIは、IIA成分/IIB成分の質量比が40/60であった。
第2層における捲縮複合繊維IIの平均繊維径、及び、第2層における目付は表1に示す。
-捲縮複合繊維IIのオレフィン系重合体(A)(IIA成分)-
融点142℃、MFR60g/10分のプロピレン・エチレンランダム共重合体と融点162℃、MFR3g/10分のプロピレン単独重合体との質量比(プロピレン・エチレンランダム共重合体/プロピレン単独重合体)が96対4の混合体(Mz/Mw2.54)。
-捲縮複合繊維IIのオレフィン系重合体(B)(IIB成分)-
融点142℃、Mz/Mw2.19、MFR60g/10分のプロピレン・エチレンランダム共重合体
成形温度を表1に記載の温度とし、DCDを表1に記載のDCDとした以外は、実施例1の(第3層)の項に記載の方法と同様の方法を用いて第3層を作製した。
第3層における非捲縮複合繊維Iの平均繊維径、及び、第3層における目付は表1に示す。
第2層に記載の方法及び成分と同様の方法及び成分にて、第3層の不織ウェブ上に第4層を作製し、積層構造の不織ウェブを作製した。
第4層における捲縮複合繊維IIの平均繊維径、及び、第4層における目付は表1に示す。
<比較例4及び比較例5>
第1層、第2層及び第4層の平均繊維径を表1の通りに調整し、第3層の平均繊維径を表1の通りに調整し、第1層~第4層の目付を表1に記載の通りに変更した以外は、比較例3と同様にして、表1に記載の総目付を有するSSMS不織布積層体を得た。
第1層、第2層及び第4層の平均繊維径を表1の通りに調整し、第1層、第2層及び第4層の目付を表1に記載の通りに変更し、第3層を作製しなかった以外は、比較例3と同様にして、表1に記載の総目付を有する不織布積層体を得た。
一方、不織布積層体の総目付に対する不織布層B(第3層)の目付の割合が8.0%超である比較例1はカンチレバーの値が高く柔軟性に劣っていた。
不織布積層体の総目付に対する不織布層B(第3層)の目付の割合が2.0%未満である比較例2は、ネックイン係数の値が低く、耐ネックイン性に劣っていた。
不織布層B中の極細繊維の平均繊維径が1.35μm以上である比較例3~比較例5について、比較例3及び5は柔軟性及び耐ネックイン性の両方に劣っており、比較例4は耐ネックイン性に劣っていた。
平均繊維径1.35μm未満である極細繊維を含む不織布層Bを備えていない比較例6及び比較例7について、比較例6は耐ネックイン性に劣っており、比較例7は不織布積層体を採取できなかった。
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、本明細書に参照により取り込まれる。
Claims (10)
- 捲縮複合繊維を含む不織布層A、及び、
平均繊維径1.35μm未満である極細繊維を含む不織布層Bを備え、
不織布積層体の総目付に対する前記不織布層Bの目付の割合が2.0%~8.0%である不織布積層体。 - 前記極細繊維の平均繊維径が、1.00μm以上1.35μm未満である請求項1に記載の不織布積層体。
- 不織布積層体の総目付に対する前記不織布層Bの目付の割合が、5.0%~8.0%である請求項1又は請求項2に記載の不織布積層体。
- 前記不織布層Aはスパンボンド不織布の層であり、
前記不織布層Bはメルトブローン不織布の層である請求項1~請求項3のいずれか1項に記載の不織布積層体。 - 前記捲縮複合繊維は、オレフィン系重合体(A)から構成される(a)部、及び、オレフィン系重合体(B)から構成される(b)部の少なくとも2の領域を有し、
前記(a)部と前記(b)部との質量比〔(a):(b)〕が、10:90~60:40であり、
前記オレフィン系重合体(A)の融点が前記オレフィン系重合体(B)の融点よりも高いこと、及び、前記オレフィン系重合体(A)のMz/Mwが前記オレフィン系重合体(B)のMz/Mwよりも大きいことの少なくとも一方を満たす請求項1~請求項4のいずれか1項に記載の不織布積層体。 - 前記オレフィン系重合体(A)及び前記オレフィン系重合体(B)は、プロピレン系重合体である請求項5に記載の不織布積層体。
- 前記捲縮複合繊維は、前記(a)部が芯部(a’)であり前記(b)部が鞘部(b’)である偏芯芯鞘構造を有する請求項5又は請求項6に記載の不織布積層体。
- エンボス加工により熱融着されている請求項1~請求項7のいずれか1項に記載の不織布積層体。
- 前記エンボス加工によるエンボス面積率が、5%~20%である請求項8に記載の不織布積層体。
- 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を有する衛生用品。
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
KR1020217029718A KR102564088B1 (ko) | 2019-03-27 | 2020-03-25 | 부직포 적층체 및 위생 용품 |
JP2021509537A JP7182693B2 (ja) | 2019-03-27 | 2020-03-25 | 不織布積層体及び衛生用品 |
CN202080024357.7A CN113677516B (zh) | 2019-03-27 | 2020-03-25 | 无纺布层叠体及卫生用品 |
EP20779484.3A EP3950303A4 (en) | 2019-03-27 | 2020-03-25 | LAMINATED NONWOVEN BODY AND HYGIENE PRODUCT |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2019061595 | 2019-03-27 | ||
JP2019-061595 | 2019-03-27 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2020196663A1 true WO2020196663A1 (ja) | 2020-10-01 |
Family
ID=72612029
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/JP2020/013446 WO2020196663A1 (ja) | 2019-03-27 | 2020-03-25 | 不織布積層体及び衛生用品 |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP3950303A4 (ja) |
JP (1) | JP7182693B2 (ja) |
KR (1) | KR102564088B1 (ja) |
CN (1) | CN113677516B (ja) |
WO (1) | WO2020196663A1 (ja) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3715519A4 (en) * | 2019-01-25 | 2021-04-07 | Mitsui Chemicals, Inc. | SPINNED FABRIC, PROCESS FOR MANUFACTURING A SPINNED NONWOVEN FABRIC, AND EMBOSSING ROLLER |
WO2023234224A1 (ja) * | 2022-06-03 | 2023-12-07 | エム・エーライフマテリアルズ株式会社 | 不織布積層体 |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2023229570A1 (en) * | 2022-05-23 | 2023-11-30 | Kimberly-Clark Worldwide, Inc. | A lofty nonwoven fabric |
Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2004003096A (ja) * | 2002-04-26 | 2004-01-08 | Asahi Kasei Corp | 耐水性不織布 |
WO2011129211A1 (ja) | 2010-04-16 | 2011-10-20 | 三井化学株式会社 | 捲縮複合繊維、及び当該繊維からなる不織布 |
WO2012111723A1 (ja) * | 2011-02-15 | 2012-08-23 | 三井化学株式会社 | スパンボンド不織布 |
JP2017153901A (ja) | 2016-03-04 | 2017-09-07 | 三井化学株式会社 | 吸収体及び衛生用品 |
WO2017150728A1 (ja) * | 2016-03-04 | 2017-09-08 | 三井化学株式会社 | 吸収体及び衛生用品 |
US20170335498A1 (en) | 2016-05-18 | 2017-11-23 | Fibertex Personal Care A/S | Nonwoven Fabric Comprising A High Loft Spunbond Layer |
WO2017198336A1 (en) | 2016-05-18 | 2017-11-23 | Fibertex Personal Care A/S | Nonwoven laminate fabric comprising meltblown and spundbond layers |
JP2019061595A (ja) | 2017-09-28 | 2019-04-18 | 株式会社 バイオミメティクスシンパシーズ | 報知システム |
Family Cites Families (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO1999049120A1 (fr) * | 1998-03-24 | 1999-09-30 | Mitsui Chemicals, Inc. | Stratifie de non-tisse flexible |
EP1039007A4 (en) * | 1998-10-09 | 2003-04-23 | Mitsui Chemicals Inc | NON-WOVEN POLYETHYLENE FABRIC AND LAMINATE OF NON-WOVEN FABRIC CONTAINING THE SAME |
KR100701553B1 (ko) * | 2001-01-29 | 2007-03-30 | 미쯔이가가꾸가부시끼가이샤 | 권축 섬유 부직포 및 그의 적층체 |
WO2007088828A1 (ja) * | 2006-02-03 | 2007-08-09 | Mitsui Chemicals, Inc. | 不織布積層体、不織布積層体を用いた透湿性不織布積層シートおよびそれらを用いた衛生用品 |
DK2022879T3 (da) * | 2006-05-31 | 2013-09-16 | Mitsui Chemicals Inc | Nonwoven-stoflaminat og fremgangsmåde til fremstilling deraf |
KR101551554B1 (ko) * | 2011-02-15 | 2015-09-08 | 미쓰이 가가쿠 가부시키가이샤 | 부직포 적층체 |
MY165729A (en) * | 2011-05-11 | 2018-04-20 | Mitsui Chemicals Inc | Crimped Conjugated Fiber and Non-Woven Fabric Comprising the Fiber |
JP6034022B2 (ja) * | 2011-12-27 | 2016-11-30 | 旭化成株式会社 | 不織布積層体 |
CN104582948B (zh) * | 2012-08-22 | 2016-12-28 | 三井化学株式会社 | 非织造布叠层体 |
EP3255191B1 (en) * | 2015-03-09 | 2020-01-15 | Mitsui Chemicals, Inc. | Nonwoven fabric laminate, stretchable nonwoven fabric laminate, fiber product, absorbent article and hygienic mask |
-
2020
- 2020-03-25 CN CN202080024357.7A patent/CN113677516B/zh active Active
- 2020-03-25 KR KR1020217029718A patent/KR102564088B1/ko active IP Right Grant
- 2020-03-25 JP JP2021509537A patent/JP7182693B2/ja active Active
- 2020-03-25 WO PCT/JP2020/013446 patent/WO2020196663A1/ja unknown
- 2020-03-25 EP EP20779484.3A patent/EP3950303A4/en active Pending
Patent Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2004003096A (ja) * | 2002-04-26 | 2004-01-08 | Asahi Kasei Corp | 耐水性不織布 |
WO2011129211A1 (ja) | 2010-04-16 | 2011-10-20 | 三井化学株式会社 | 捲縮複合繊維、及び当該繊維からなる不織布 |
WO2012111723A1 (ja) * | 2011-02-15 | 2012-08-23 | 三井化学株式会社 | スパンボンド不織布 |
JP2017153901A (ja) | 2016-03-04 | 2017-09-07 | 三井化学株式会社 | 吸収体及び衛生用品 |
WO2017150728A1 (ja) * | 2016-03-04 | 2017-09-08 | 三井化学株式会社 | 吸収体及び衛生用品 |
US20170335498A1 (en) | 2016-05-18 | 2017-11-23 | Fibertex Personal Care A/S | Nonwoven Fabric Comprising A High Loft Spunbond Layer |
WO2017198336A1 (en) | 2016-05-18 | 2017-11-23 | Fibertex Personal Care A/S | Nonwoven laminate fabric comprising meltblown and spundbond layers |
JP2019061595A (ja) | 2017-09-28 | 2019-04-18 | 株式会社 バイオミメティクスシンパシーズ | 報知システム |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3715519A4 (en) * | 2019-01-25 | 2021-04-07 | Mitsui Chemicals, Inc. | SPINNED FABRIC, PROCESS FOR MANUFACTURING A SPINNED NONWOVEN FABRIC, AND EMBOSSING ROLLER |
WO2023234224A1 (ja) * | 2022-06-03 | 2023-12-07 | エム・エーライフマテリアルズ株式会社 | 不織布積層体 |
Also Published As
Publication number | Publication date |
---|---|
KR102564088B1 (ko) | 2023-08-07 |
JP7182693B2 (ja) | 2022-12-02 |
EP3950303A1 (en) | 2022-02-09 |
CN113677516A (zh) | 2021-11-19 |
JPWO2020196663A1 (ja) | 2021-11-04 |
KR20210128457A (ko) | 2021-10-26 |
EP3950303A4 (en) | 2022-12-14 |
CN113677516B (zh) | 2023-07-11 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US10077518B2 (en) | Crimped conjugated fiber and nonwoven fabric comprising the same | |
KR101354331B1 (ko) | 권축 복합 섬유, 및 당해 섬유로 이루어지는 부직포 | |
US9611568B2 (en) | Crimped conjugated fiber and non-woven fabric comprising the fiber | |
KR101533167B1 (ko) | 스펀본드 부직포 적층체 | |
WO2020196663A1 (ja) | 不織布積層体及び衛生用品 | |
JP2023126282A (ja) | 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 | |
KR102552774B1 (ko) | 스펀본드 부직포, 스펀본드 부직포의 제조 방법, 엠보스 롤 | |
JP7461460B2 (ja) | 不織布積層体、被覆シート及び吸収性物品 | |
JP2022135776A (ja) | 不織布、不織布積層体及び吸収性物品 |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 20779484 Country of ref document: EP Kind code of ref document: A1 |
|
ENP | Entry into the national phase |
Ref document number: 2021509537 Country of ref document: JP Kind code of ref document: A |
|
ENP | Entry into the national phase |
Ref document number: 20217029718 Country of ref document: KR Kind code of ref document: A |
|
NENP | Non-entry into the national phase |
Ref country code: DE |
|
ENP | Entry into the national phase |
Ref document number: 2020779484 Country of ref document: EP Effective date: 20211027 |