WO2022210047A1 - スパンボンド不織布及び衛生材料 - Google Patents

スパンボンド不織布及び衛生材料 Download PDF

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Publication number
WO2022210047A1
WO2022210047A1 PCT/JP2022/012798 JP2022012798W WO2022210047A1 WO 2022210047 A1 WO2022210047 A1 WO 2022210047A1 JP 2022012798 W JP2022012798 W JP 2022012798W WO 2022210047 A1 WO2022210047 A1 WO 2022210047A1
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Prior art keywords
nonwoven fabric
fibers
spunbond nonwoven
polymer
spunbond
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Ceased
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PCT/JP2022/012798
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English (en)
French (fr)
Japanese (ja)
Inventor
祥平 税田
泰一郎 市川
浩貴 金谷
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Mitsui Chemicals Inc
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Mitsui Chemicals Inc
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Filing date
Publication date
Application filed by Mitsui Chemicals Inc filed Critical Mitsui Chemicals Inc
Priority to KR1020237032802A priority Critical patent/KR20230150993A/ko
Priority to EP22780262.6A priority patent/EP4299805A4/en
Priority to US18/552,733 priority patent/US20240158966A1/en
Priority to CN202280024865.4A priority patent/CN117120681B/zh
Priority to JP2023510989A priority patent/JP7766082B2/ja
Publication of WO2022210047A1 publication Critical patent/WO2022210047A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/44—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds
    • D01F6/46—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds of polyolefins
    • 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
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/45—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 shape
    • A61F13/47—Sanitary towels, incontinence pads or napkins
    • 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
    • A61F13/45—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 shape
    • A61F13/49—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 shape specially adapted to be worn around the waist, e.g. diapers, nappies
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/10—Homopolymers or copolymers of propene
    • C08L23/12—Polypropene
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/06—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
    • 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
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/009—Condensation or reaction 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
    • D04H3/018—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
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2203/00—Applications
    • C08L2203/12—Applications used for fibers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/03—Polymer mixtures characterised by other features containing three or more polymers in a blend
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2207/00—Properties characterising the ingredient of the composition
    • C08L2207/02—Heterophasic composition
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43825—Composite fibres
    • D04H1/4383—Composite fibres sea-island
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
    • D10B2321/021—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polyethylene
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
    • D10B2321/022—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polypropylene
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/06—Load-responsive characteristics
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/06—Load-responsive characteristics
    • D10B2401/061—Load-responsive characteristics elastic
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2509/00—Medical; Hygiene
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2509/00—Medical; Hygiene
    • D10B2509/02—Bandages, dressings or absorbent pads

Definitions

  • the present disclosure relates to spunbond nonwoven fabrics and sanitary materials.
  • nonwoven fabrics have been widely used for various purposes because of their excellent air permeability and flexibility.
  • Typical uses of nonwoven fabrics include absorbent articles such as paper diapers and sanitary napkins, sanitary masks, medical gauze, and base fabrics for poultice materials.
  • Such nonwoven fabrics are required to have extensibility and the like from the viewpoint of ease of secondary processing, depending on where they are used.
  • Patent Document 1 discloses a spunbond nonwoven fabric that has good heat-sealability at low temperatures and aptitude for stretching.
  • the spunbond nonwoven fabric disclosed in Patent Document 1 is composed of a specific composition.
  • a specific composition comprises a propylene homopolymer having a melting point of 140° C. or higher, polyethylene, and at least one selected from a first polymer and a second polymer.
  • the first polymer is a random copolymer of propylene and at least one selected from ethylene and ⁇ -olefins having 4 to 20 carbon atoms.
  • the second polymer is a specific propylene homopolymer with a melting point of less than 120°C. The total content of the first polymer and the second polymer in the composition is within a specified range.
  • Patent Document 1 International Publication No. 2017/006972
  • the nonwoven fabric described in Patent Document 1 has excellent heat-sealing properties at low temperatures, but there are cases where it is required to further improve stretchability.
  • Elongated nonwoven fabrics which are required to have extensibility, are often subjected to a stretching process in order to impart flexibility and desired shaping treatment when used as nonwoven fabrics.
  • a stretching process may cause breakage depending on the properties of the nonwoven fabric to be stretched, making it impossible to perform desired processing. That is, in some cases, the suitability for stretching of the nonwoven fabric to be stretched is not necessarily sufficient.
  • the present disclosure aims to provide a spunbond nonwoven fabric with excellent stretchability and spinnability, and a sanitary material.
  • the means for solving the above problems include the following embodiments.
  • the fiber includes a fiber in which the proportion of island phases having a diameter of less than 0.32 ⁇ m is 60% or more based on the number of island phases in a cross section perpendicular to the axial direction of the fiber,
  • the ratio ( SMD / SCD ) of the tensile strength (SMD) in the machine direction ( MD ) to the tensile strength (SCD) in the direction ( CD ) perpendicular to the machine direction (MD) is 2.0 spunbond nonwoven fabrics with ⁇ 5.1.
  • ⁇ 2> The spunbond nonwoven fabric according to ⁇ 1>, wherein the propylene-based polymer (A) contains a propylene homopolymer.
  • the polymer (B) comprises an ⁇ -olefin homopolymer having 2 to 8 carbon atoms (excluding the propylene-based polymer (A)). Bond non-woven fabric.
  • the polymer (B) contains polyethylene.
  • the polyethylene has a density of 0.94 g/cm 3 to 0.97 g/cm 3 .
  • the sea phase included in the sea-island structure contains the propylene-based polymer (A), The spunbond nonwoven fabric according to any one of ⁇ 1> to ⁇ 5>, wherein the island phase contains the polymer (B).
  • ⁇ 9> Any one of ⁇ 1> to ⁇ 8>, wherein the content of the polymer (B) is 1.0% by mass to 10.0% by mass with respect to the total amount of the resin composition
  • the spunbond nonwoven fabric according to . ⁇ 10> The resin composition contains a low molecular weight olefin polymer having a weight average molecular weight of 500 to 30,000, Any one of ⁇ 1> to ⁇ 9>, wherein the content of the low-molecular-weight olefin polymer is 0.1% by mass to 5.0% by mass with respect to the total amount of the resin composition.
  • thermoplastic elastomer fiber including a thermoplastic elastomer fiber, A laminated nonwoven fabric or a mixed fiber nonwoven fabric, The laminated nonwoven fabric is formed by bonding a spunbond web containing the fibers and a resin layer containing the thermoplastic elastomer fibers laminated on at least one main surface of the spunbond web, The spunbond nonwoven fabric according to any one of ⁇ 1> to ⁇ 10>, wherein the mixed fiber nonwoven fabric is formed by mixing the fibers and the thermoplastic elastomer fibers.
  • thermoplastic elastomer fiber is a thermoplastic polyurethane elastomer fiber or a thermoplastic olefin elastomer fiber.
  • thermoplastic elastomer fiber is a thermoplastic polyurethane elastomer fiber or a thermoplastic olefin elastomer fiber.
  • thermoplastic elastomer fiber is a thermoplastic polyurethane elastomer fiber or a thermoplastic olefin
  • spunbond nonwoven fabrics and sanitary materials with excellent extensibility and spinnability are provided.
  • FIG. 1 is a transmission electron micrograph (magnification: 6000 times) of a cross section of fibers in the spunbond nonwoven fabric of Example 1.
  • FIG. 4 is a transmission electron micrograph (magnification: 6000 times) of a cross section of fibers in the spunbond nonwoven fabric of Comparative Example 1.
  • FIG. 1 is a transmission electron micrograph (magnification: 6000 times) of a cross section of fibers in the spunbond nonwoven fabric of Comparative Example 1.
  • the term "process” includes not only an independent process, but also a process that cannot be clearly distinguished from other processes as long as the purpose of the process is achieved.
  • the content of each component in the thermoplastic resin composition refers to the content of each component in the thermoplastic resin composition when there are multiple types of substances corresponding to each component in the thermoplastic resin composition, unless otherwise specified. means the total amount of the said multiple substances.
  • a numerical range represented using “to” means a range including the numerical values described before and after “to” as lower and upper limits.
  • the upper limit or lower limit described in one numerical range is the numerical range described in other stages may be replaced with the upper limit or lower limit of
  • the upper or lower limits of the numerical ranges may be replaced with the values shown in "Examples”.
  • the spunbond nonwoven fabric of the present disclosure is A fiber made of a resin composition containing a propylene-based polymer (A) and at least one polymer (B) selected from the group consisting of polyolefins (excluding the propylene-based polymer (A)) and polyesters including the fibers have a sea-island structure,
  • the fiber contains a fiber in which the proportion of island phases having a diameter of less than 0.32 ⁇ m among the island phases in the cross section perpendicular to the axial direction of the fiber is 60% or more on a number basis,
  • the ratio ( SMD / S CD ) is 2.0 to 5.1.
  • spunbond nonwoven fabric refers to a continuous fiber (filament) group spun from a spinneret by melting or dissolving a thermoplastic resin composition, and laminated on a moving collecting member (for example, a net conveyor). , indicates a nonwoven fabric made by one or more bonding methods.
  • spun-island structure means that a phase (island phase) containing one of at least two components is present (for example, dispersed) in a continuous phase (sea phase) consisting of the other component. A phase-separated structure is shown.
  • a fiber has a sea-island structure indicates that a cross section of the fiber cut in a direction orthogonal to the axial direction of the fiber has a sea-island structure.
  • machine direction (MD) refers to the direction parallel to the direction of travel of the moving collection member.
  • a direction (CD) perpendicular to the direction of machine flow (MD) indicates a direction perpendicular to the advancing direction of the moving collecting member among the surface directions of the moving collecting member.
  • a fiber having a sea-island structure may be referred to as a “sea-island fiber”.
  • ratio of island phases having a diameter of less than 0.32 ⁇ m among the island phases in the cross section orthogonal to the axial direction of the fiber may be simply referred to as “ratio of island phases”.
  • machine direction (MD) will be referred to as the “machine direction (MD)”
  • direction (CD) orthogonal to the machine direction (MD) will be referred to as the "transverse direction (CD)”.
  • ratio (S MD /S CD ) of the tensile strength (S MD ) in the machine direction (MD) to the tensile strength (S CD ) in the direction (CD) perpendicular to the machine direction (MD) is sometimes referred to as "tensile strength ratio ( SMD / SCD )".
  • the spunbond nonwoven fabric of the present disclosure has the above configuration, it is excellent in extensibility and spinnability.
  • “Excellent extensibility” indicates that the spunbond nonwoven fabric has the first property and the second property.
  • the "first property” indicates the property that the outer shape of the spunbond nonwoven fabric is stretched in one direction when an external force is applied to the spunbond nonwoven fabric.
  • “Secondary property” indicates the property that the outer shape of the spunbond nonwoven fabric is unlikely to return even if the external force applied to the spunbond nonwoven fabric is released.
  • a quantitative evaluation method for the extensibility of the spunbond nonwoven fabric is the same as the evaluation method described in Examples.
  • excellent in spinnability means that yarn breakage is unlikely to occur when the thermoplastic resin composition, which is the raw material of the spunbond nonwoven fabric, is discharged from the spinneret and during drawing of the continuous fiber group, and continuous fibers are not easily broken. It shows that no fusion occurs.
  • a quantitative evaluation method for the spinnability of the spunbond nonwoven fabric is the same as the evaluation method described in Examples.
  • the reason why the spunbond nonwoven fabric of the present disclosure is excellent in extensibility and spinnability is not clear, it is presumed as follows. If the island phase ratio of the fibers contained in the spunbond nonwoven fabric is within the above range, the oriented crystallization of the propylene-based polymer (A) is uniformly inhibited inside the sea-island fibers. This improves the extensibility and spinnability of the spunbond nonwoven fabric. Furthermore, if the tensile strength ratio (S MD /S CD ) of the spunbond nonwoven fabric is within the above range, the direction of dispersion of the fibers constituting the spunbond nonwoven fabric tends to be parallel to the machine direction (MD). Thereby, the extensibility of the obtained spunbond nonwoven fabric is excellent. It is presumed that the main reason why the spunbond nonwoven fabric of the present disclosure has excellent extensibility and spinnability is the synergistic effect of these combinations.
  • the tensile strength ratio (S MD /S CD ) of the spunbond nonwovens of the present disclosure is between 2.0 and 5.1. Since the tensile strength ratio (S MD /S CD ) is 2.0-5.1, there are more fibers oriented parallel to the machine direction (MD) than in the transverse direction (CD). Furthermore, the extensibility in the machine direction (MD) of spunbond nonwovens is better. Since the tensile strength ratio (S MD /S CD ) is 5.0 or less, the tensile strength of the spunbonded nonwoven fabric does not increase excessively, and cracking of the fibers constituting the spunbonded nonwoven fabric is suppressed.
  • the tensile strength ratio (S MD /S CD ) may be, for example, 2.0 to 5.0, preferably 2.5 to 5.1, more preferably 2.5 to 5.1, from the viewpoint of improving the extensibility of the spunbond nonwoven fabric. is 2.5 to 5.1, more preferably 3.0 to 5.0, particularly preferably 3.5 to 5.0.
  • the tensile strength ratio (SMD/ SCD ) of the spunbond nonwoven fabric is determined according to JIS L 1906 6.12.1 [method A] (transition to JIS L 1913:2010, It can be measured according to ISO 9073-3:1989).
  • the machine direction (MD) of a spunbond nonwoven can be determined from the spunbond nonwoven itself by measuring the tensile strength of the spunbond nonwoven.
  • the moving speed of the moving collecting member is set early from the viewpoint of productivity. Therefore, the continuous fiber group is likely to be oriented in a direction parallel to the machine direction (MD) when layered on the moving collection member.
  • the machine direction (MD) tensile strength of spunbond nonwovens is higher than the cross direction (CD) tensile strength of spunbond nonwovens. Therefore, by measuring the tensile strength of the spunbond nonwoven, the machine direction (MD) of the spunbond nonwoven can be determined from the spunbond nonwoven itself.
  • Fibers having a sea-island structure contain sea-island fibers.
  • the sea-island fiber is a resin composition containing a propylene-based polymer (A) and at least one polymer (B) selected from the group consisting of polyolefins (excluding the propylene-based polymer (A)) and polyesters. consists of
  • the propylene-based polymer (A) may be referred to as "specific polypropylene (A)".
  • the polymer (B) which is at least one selected from the group consisting of polyolefins (excluding propylene-based polymer (A)) and polyesters, may be referred to as "specific polymer (B)".
  • the sea-island structure has a sea phase and a plurality of island phases.
  • a plurality of island facies are present (eg, dispersed) in the sea facies.
  • the sea phase preferably contains the specific polypropylene (A), and each of the plurality of island phases preferably contains the specific polymer (B).
  • the fiber diameter of the sea-island fiber is preferably 4.0 d (denier) or less, more preferably 3.5 d or less, still more preferably 3.0 d or less.
  • the sea-island fiber may be a long fiber (staple) or a single fiber (filament). Furthermore, the cross-sectional shape of the sea-island fibers is not particularly limited, and examples thereof include circular, elliptical, and modified cross-sections.
  • the island phase ratio of sea-island fibers is 60% or more based on the number. Since the island phase ratio is 60% by number or more based on the number, the oriented crystallization of the specific polypropylene (A) is less likely to be unevenly inhibited inside the fiber. Thereby, the extensibility and spinnability of the spunbond nonwoven fabric are excellent. From the viewpoint of improving the extensibility of the spunbond nonwoven fabric, the island phase ratio is preferably 70 number % or more, more preferably 80 number % or more, and still more preferably 90 number % or more.
  • the method for adjusting the island phase ratio of the sea-island fibers to 60% by number or more on a number basis is not particularly limited, and examples thereof include a raw material adjustment method and a production facility adjustment method.
  • the raw material adjustment method raw materials for sea-island fibers are adjusted.
  • the island phase ratio can be increased to 60% by number or more on a number basis.
  • the manufacturing equipment adjustment method adjusts the manufacturing equipment for the spunbond nonwoven fabric.
  • the manufacturing equipment adjustment method includes a method of selecting a screw having a shape with improved kneading properties, a method of increasing the resin pressure of the die, a method of increasing the exit temperature of the die, and the like.
  • the island phase ratio can be increased to 60% by number or more.
  • the lower limit of the ratio of the island phase area to the total cross-sectional area of the sea-island fiber is preferably 1.0% or more.
  • the upper limit of the island phase area ratio is preferably 20% or less.
  • the oriented crystallization of the specific polypropylene (A) is less likely to be unevenly inhibited inside the sea-island fibers, and the spunbond nonwoven fabric has better extensibility and spinnability.
  • a method for adjusting the island phase area ratio is not particularly limited, and examples include a raw material adjustment method.
  • the sea-island fiber contained in the spunbond nonwoven fabric is made of a resin composition.
  • the presence of each of the above components in the resin composition can be appropriately confirmed by a known method.
  • Specific polypropylene (A) The resin composition of the sea-island fiber contains the specific polypropylene (A). Only one type of specific polypropylene (A) may be used, or two or more types having different melting points, molecular weights, crystal structures, and the like may be used.
  • the specific polypropylene (A) contains structural units derived from propylene.
  • the specific polypropylene (A) is a propylene homopolymer or a propylene copolymer.
  • the propylene copolymer is preferably a copolymer of propylene and a small amount of one or more ⁇ -olefins.
  • the ⁇ -olefin in the propylene copolymer has 2 or more carbon atoms (excluding 3 carbon atoms), preferably 2 to 8 carbon atoms (excluding 3 carbon atoms).
  • ⁇ -olefins in the propylene copolymer include ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 4-methyl-1-pentene and the like.
  • the specific polypropylene (A) preferably contains a propylene homopolymer, more preferably a propylene homopolymer.
  • the melting point of the specific polypropylene (A) is preferably 140°C or higher, more preferably 150°C or higher, still more preferably 155°C or higher, and particularly preferably 157°C or higher and 165°C or lower.
  • the melting point of the specific polypropylene (A) is obtained by using a differential scanning calorimeter (DSC) to hold the temperature at ⁇ 40° C. for 5 minutes in a nitrogen atmosphere and then raise the temperature at 10° C./min. It is defined as the peak top of the peak observed on the highest temperature side. Specifically, using a differential scanning calorimeter (manufactured by Perkin-Elmer, product name: DSC-7), 5 mg of the sample was held at -40 ° C. for 5 minutes in a nitrogen atmosphere, and then the temperature was raised at 10 ° C./min. It can be obtained as the peak top of the peak observed on the highest temperature side of the melting endothermic curve obtained by letting
  • the melt flow rate (MFR: Melt Flow Rate) of the specific polypropylene (A) is not particularly limited as long as the thermoplastic resin composition, which is the raw material of the spunbond nonwoven fabric, can be melt-spun, preferably 1 g / 10 minutes to 1000 g / 10 minutes. , more preferably 5 g/10 min to 500 g/10 min, and still more preferably 10 g/10 min to 100 g/10 min.
  • the melt flow rate of the specific polypropylene (A) is measured by a method according to ASTM Standard D-1238.
  • the conditions for measuring the melt flow rate of the specific polypropylene (A) are 230° C. and a load of 2.16 kg.
  • the content of the specific polypropylene (A) is preferably 55.0% by mass to 95.0% by mass, more preferably 65.0% by mass to 95.0% by mass, and still more preferably the total amount of the resin composition. is 75.0% by mass to 95.0% by mass, particularly preferably 85.0% by mass to 95.0% by mass.
  • the content of the specific polypropylene (A) is within the above range, the elongation of the spunbond nonwoven fabric is improved, and the tensile strength of the spunbond nonwoven fabric is maintained within a good range, while the spunbond nonwoven fabric has a low basis weight and is flexible. is.
  • the content of the specific polypropylene (A) is 85.0% by mass to 95.0% by mass, it is possible to suppress excessive aggregation of the island phase and achieve both elongation and spinnability of the spunbond nonwoven fabric. can.
  • the content of the specific polypropylene (A) is within the above range, the specific polypropylene (A) is included in the sea phase and the specific polymer (B) is included in the island phase.
  • a commercially available product may be used as long as it satisfies the specific polypropylene (A) of the present disclosure described above.
  • the sea-island fiber contains a specific polymer (B). Only one type of the specific polymer (B) may be used, or two or more types having different melting points, molecular weights, crystal structures, and the like may be used.
  • the specific polymer (B) is at least one selected from the group consisting of polyolefins (excluding propylene-based polymers (A)) and polyesters.
  • Polyolefins are homopolymers or copolymers of ⁇ -olefins.
  • the ⁇ -olefin is an ⁇ -olefin having 2 or more carbon atoms (excluding 3 carbon atoms), and preferably includes homopolymers of ⁇ -olefins having 2 to 8 carbon atoms (excluding 3 carbon atoms). , a homopolymer of an ⁇ -olefin having 2 to 8 carbon atoms (excluding 3 carbon atoms).
  • Specific examples of ⁇ -olefins include ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 4-methyl-1-pentene and the like.
  • the ⁇ -olefin is preferably ethylene.
  • polyolefins include polyethylene (ethylene homopolymer), ethylene/ ⁇ -olefin copolymer, propylene-based polymer, 1-butene-based polymer, poly 4 -methyl-1-pentene and the like.
  • polyethylene include high-pressure low-density polyethylene, linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), and the like.
  • ethylene/ ⁇ -olefin copolymers include ethylene/propylene random copolymers and ethylene/1-butene random copolymers.
  • propylene-based polymer examples include propylene/ethylene random copolymers, propylene/ethylene/1-butene random copolymers, propylene block copolymers, propylene/1-butene random copolymers, and the like.
  • 1-butene-based polymers examples include 1-butene homopolymers, 1-butene/ethylene copolymers, 1-butene/propylene copolymers, and the like.
  • the polyester is, for example, an aliphatic polyester or a polyester copolymer.
  • polyester copolymers include those obtained by polymerizing an aliphatic dicarboxylic acid alone or a mixture of an aliphatic dicarboxylic acid and an aromatic dicarboxylic acid with one or more diols.
  • the specific polymer (B) preferably contains polyethylene, more preferably polyethylene.
  • the density of polyethylene is preferably 0.94 g/cm 3 to 0.98 g/cm 3 , more preferably 0.94 g/cm 3 to 0.98 g/cm 3 , from the viewpoint of improving the tensile strength of the spunbond nonwoven fabric and from the viewpoint of the extensibility and flexibility of the spunbond nonwoven fabric. 94 g/cm 3 to 0.97 g/cm 3 .
  • the melting point of the specific polymer (B) is preferably 150°C or higher, more preferably 155°C or higher, even more preferably 155°C to 165°C.
  • the melt flow rate of the specific polymer (B) is not particularly limited as long as the melt of the thermoplastic resin composition which is the raw material of the spunbond nonwoven fabric can be spun, preferably 1 g/10 minutes to 1000 g/10 minutes or less, more preferably 2 g/10 minutes to 500 g/10 minutes, more preferably 3 g/10 minutes to 100 g/10 minutes.
  • the specific polymer (B) is polyethylene
  • the melt flow rate is measured according to ASTM D-1238.
  • the conditions for measuring the melt flow rate of polyethylene are 190° C. and a load of 2.16 kg.
  • the content of the specific polymer (B) is preferably 1.0% by mass to 10.0% by mass, more preferably 3.0% by mass to 8.0% by mass, and still more preferably the total amount of the resin composition. is 5.0% by mass to 7.0% by mass. If the content of the specific polymer (B) is within the above range, the extensibility of the spunbond nonwoven fabric is improved.
  • the resin composition contains a low-molecular-weight olefin-based polymer having a weight-average molecular weight of 500 to 30,000, and the content of the low-molecular-weight olefin-based polymer is , preferably 0.1% by mass to 5.0% by mass with respect to the total amount of the resin composition.
  • the low-molecular-weight olefin-based polymer may be of only one type, or two or more types having different melting points, molecular weights, crystal structures, etc. may be used.
  • the sea-island fibers contain the low-molecular-weight olefin-based polymer and the content of the low-molecular-weight olefin-based polymer is within the above range, the dispersibility of the specific polypropylene (A) and the specific polymer (B) is improved. As a result, the extensibility and spinnability of the spunbond nonwoven fabric are further improved.
  • the content of the low-molecular-weight olefinic polymer is preferably 0.1% by mass to 5.0% by mass relative to the total amount of the resin composition.
  • the lower limit of the content of the low-molecular-weight olefin-based polymer is determined by adding a sufficient amount of the low-molecular-weight olefin-based polymer to the interface between the sea phase and the island phase to improve the dispersibility of the specific polypropylene (A) and the specific polymer (B).
  • the resin composition from the viewpoint of being present in the resin composition, it is more preferably 0.2% by mass or more, still more preferably 1.0% by mass or more, and particularly preferably 1.5% by mass or less.
  • the upper limit of the content of the low-molecular-weight olefin-based polymer is more preferably 4.0% by mass or less, more preferably 3.0%, based on the total amount of the resin composition, from the viewpoint of not causing a significant decrease in strength of the sea-island fiber. % by mass or less, particularly preferably 2.5% by mass or less.
  • the low-molecular-weight olefin-based polymer may contain structural units derived from one type of olefin, or structural units derived from two or more types of olefins.
  • a low-molecular-weight olefin polymer is a waxy polymer.
  • the weight-average molecular weight (Mw) of the low-molecular-weight olefin polymer is lower than that of the specific polypropylene (A) and poly- ⁇ -olefin.
  • the weight average molecular weight (Mw) of the low molecular weight olefin polymer is 500-30,000.
  • the upper limit of the weight average molecular weight (Mw) of the low-molecular-weight olefin polymer is 30000 or less, preferably less than 15000, more preferably 10000 or less, still more preferably 6000 or less, particularly preferably less than 6000, still more preferably 5000 or less.
  • the lower limit of the weight average molecular weight (Mw) of the low molecular weight olefin polymer is 500 or more, preferably 700 or more, more preferably 1000 or more.
  • GPC Gel Permeation Chromatography
  • Mw weight average molecular weight of the low molecular weight olefin polymer.
  • GPC measurement conditions are preferably the first measurement conditions shown below.
  • the weight-average molecular weight (Mw) of the low-molecular-weight olefin polymer is measured, for example, by preparing a calibration curve using commercially available monodisperse standard polystyrene and using the following conversion method.
  • the softening point of the low-molecular-weight olefin polymer is preferably 90°C to 145°C, more preferably 90°C to 135°C, still more preferably 100°C to 125°C.
  • the softening point of the low molecular weight olefin polymer is measured according to JIS K2207.
  • the density of the low-molecular-weight olefin polymer is not particularly limited, and is preferably 0.890 g/cm 3 to 0.980 g/cm 3 . If the density of the low-molecular-weight olefin-based polymer is within the above range, the extensibility of the spunbond nonwoven fabric will be more excellent.
  • the lower limit of the density of the low-molecular-weight olefin polymer is more preferably 0.910 g/cm 3 or more, and still more preferably 0.920 g/cm 3 or more.
  • the upper limit of the density of the low-molecular-weight olefin polymer is more preferably 0.960 g/cm 3 or less, still more preferably 0.940 g/cm 3 or less.
  • the density of the low molecular weight olefin polymer is measured according to JIS K7112.
  • the difference between the density of the low-molecular-weight olefin-based polymer and the density of the specific polypropylene (A) is not particularly limited, and is preferably less than 0.35 g/cm 3 , more preferably less than 0.20 g/cm 3 , and even more preferably less than 0.20 g/cm 3 . is less than 0.15 g/cm 3 . If the difference between the density of the low-molecular-weight olefin-based polymer and the density of the specific polypropylene (A) is within the above range, the spunbond nonwoven fabric will have better extensibility. Although the reason is not clear, it is considered as follows.
  • the specific polymer (B) is formed in the specific polypropylene (A) via the low-molecular-weight olefin-based polymer. It is thought that it will be easier to disperse. That is, the low-molecular-weight olefin polymer effectively acts as a compatibilizer for the specific polypropylene (A) and the specific polymer (B). Therefore, the dispersibility of the specific polypropylene (A) and the specific polymer (B) is improved. As a result, the extensibility of the spunbond nonwoven fabric is considered to be improved.
  • the low-molecular-weight olefinic polymer is an olefinic homopolymer or an olefinic copolymer composed of two or more kinds of olefins.
  • the low-molecular-weight olefin polymer may be either an ethylene homopolymer or a copolymer of ethylene and an ⁇ -olefin having 3 to 20 carbon atoms.
  • the ⁇ -olefin preferably has 3 to 8 carbon atoms, more preferably 3 to 4 carbon atoms. If the number of carbon atoms in the ⁇ -olefin is within the above range, the extensibility and spinnability of the spunbonded nonwoven fabric are further improved.
  • the specific polymer (B) is easily dispersed in the specific polypropylene (A) via the low-molecular-weight olefin polymer. That is, the low-molecular-weight olefinic polymer acts as a compatibilizer for the specific polypropylene (A) and the poly- ⁇ -olefin. Therefore, the uniformity of the specific polypropylene (A) and the specific polymer (B) poly is improved. As a result, properties such as elongation of the spunbond nonwoven fabric are considered to be improved.
  • the low-molecular-weight olefin-based polymer may be used alone or as a mixture of two or more thereof.
  • the method for producing the low-molecular-weight olefin-based polymer is not particularly limited, and examples thereof include the first production method and the second production method.
  • the second production method is a method of reducing the molecular weight of a high-molecular-weight ethylene-based polymer by thermal degradation.
  • the low-molecular-weight olefinic polymer may be purified by a method such as solvent fractionation or distillation for fractionation based on the difference in solubility in a solvent.
  • the first production method include a production method using a Ziegler/Natta catalyst, a metallocene catalyst, or the like.
  • Examples of production methods using metallocene-based catalysts include the production methods described in JP-A-08-239414, International Publication No. 2007/114102, and the like.
  • the low-molecular-weight olefin-based polymer may be a commercial product.
  • Commercially available products of low-molecular-weight olefin polymers include "Hi-Wax (registered trademark) 320P", "Excelex (registered trademark) 30200B", “Hi-Wax (registered trademark) 100P” and “Hi-Wax (registered trademark) 100P” manufactured by Mitsui Chemicals, Inc. Hiwax (registered trademark) 110P” and the like.
  • the sea-island fiber contains a fatty acid amide having 15 to 22 carbon atoms, and the content of the fatty acid amide is 0.1% by mass to 5% with respect to the total amount of the resin composition. 0% by mass is preferred. Only one type of fatty acid amide may be used, or two or more types may be used. As a result, the fatty acid amide having 15 to 22 carbon atoms is adsorbed on the fiber surface of the spunbond nonwoven fabric, and the surface of the sea-island fiber is modified. In other words, the softness, tactile feel, blocking resistance, etc. of the spunbond nonwoven fabric are further improved.
  • the adhesion of the nonwoven fabric fibers to members such as various rotating devices in the apparatus used in the embossing process or the like is more effectively suppressed.
  • the extensibility and flexibility of the spunbond nonwoven fabric are further improved.
  • the number of carbon atoms in a fatty acid amide means the number of carbon atoms contained in the molecule, and the carbon atoms in —CONH constituting the amide are also included in the number of carbon atoms.
  • the number of carbon atoms in the fatty acid amide is preferably 18-22.
  • Fatty acid amides having 15 to 22 carbon atoms include fatty acid monoamide compounds, fatty acid diamide compounds, saturated fatty acid monoamide compounds, and unsaturated fatty acid diamide compounds. Among these, palmitic acid amide (carbon number: 16), stearin Acid amide (carbon number: 18), oleic acid amide (carbon number: 18), erucic acid amide (carbon number: 22) and the like are preferably mentioned.
  • the content of the fatty acid amide having 15 to 22 carbon atoms is preferably 0.1% by mass to 5.0% by mass, more preferably 0.1% by mass to 3.0% by mass, based on the total amount of the resin composition. , more preferably 0.1% by mass to 1.0% by mass.
  • Additives Sea-island fibers may contain additives as optional components within a range that does not impair the purpose of the present disclosure.
  • additives include antioxidants, heat stabilizers, weather stabilizers, antistatic agents, slip agents, hydrophilic agents, antifog agents, lubricants, dyes, pigments, natural oils, synthetic oils, waxes, fatty acid amides, and the like. be done.
  • the spunbonded nonwoven fabric may be composed only of sea-island fibers, or may be composed of sea-island fibers and fibers having no sea-island structure.
  • the content of the sea-island fibers is preferably based on the total amount of the spunbond nonwoven fabric from the viewpoint of expressing the above-described effects of the spunbond nonwoven fabric. is 5% to 95% by mass, more preferably 15% to 90% by mass, still more preferably 30% to 85% by mass, and particularly preferably 40% to 70% by mass.
  • the basis weight of the spunbond nonwoven fabric is preferably 30 g/m 2 or less, more preferably 28 g/m 2 from the viewpoint of achieving both flexibility and tensile strength of the spunbond nonwoven fabric. below, more preferably 25 g/m 2 or less, and particularly preferably 5 g/m 2 to 20 g/m 2 .
  • the spunbonded nonwoven fabric preferably has a basis weight in the range of 5 g/m 2 to 19 g/m 2 .
  • a spunbond nonwoven may or may not comprise elastic spunbond fibers.
  • the stretchable spunbond fibers are preferably fibers produced by extrusion molding a resin containing a specific thermoplastic polyurethane elastomer and using a spunbond method.
  • the specific thermoplastic polyurethane elastomer has a solidification onset temperature of at least 65° C. in differential scanning calorimeter (DSC) measurement, measured using a particle size distribution analyzer based on the electrical pore resistance method with an aperture of 100 microns.
  • the number of particles of the polar solvent-insoluble matter is 3,000,000/g or less.
  • Elastic spunbond fibers having the properties described above can be produced, for example, by the methods described in WO 2004/065680 and WO 2011/129433.
  • the spunbonded nonwoven fabric may be a laminated nonwoven fabric described below or a mixed fiber nonwoven fabric described below.
  • the spunbond nonwoven fabric may be a laminated nonwoven fabric or a mixed fiber nonwoven fabric depending on the purpose.
  • Laminated nonwoven fabric The laminated nonwoven fabric is formed by bonding a spunbond web and a resin layer. A resin layer is laminated onto at least one side of the spunbond web. A spunbond web includes islands-in-the-sea fibers. Any known bonding method may be used for bonding the spunbond web and the resin layer.
  • spunbond web refers to a product obtained by extruding a molten or melted thermoplastic resin composition from a spinneret and laminating continuous fibers (filaments) on a moving collection member (e.g., net conveyor). Shows a web made. Spunbond webs differ from spunbond nonwovens in that the fibers that make up the spunbond web are not bonded together.
  • the layer structure of the laminated nonwoven fabric is not particularly limited as long as each of the spunbond web and the resin layer is one layer.
  • the spunbond web may have one layer or two or more layers.
  • Laminated nonwoven fabric WHEREIN The resin layer may be one layer, and may be two or more layers.
  • the basis weight of the laminated nonwoven fabric is preferably 100 g/m 2 or less, more preferably 90 g/m 2 or less, still more preferably 80 g/m 2 or less, from the viewpoint of achieving both flexibility and tensile strength of the laminated nonwoven fabric.
  • the basis weight of the laminated nonwoven fabric is preferably in the range of 20 g/m 2 to 70 g/m 2 .
  • the raw material of the resin layer may be different from the thermoplastic resin composition that is the raw material of the sea-island fiber.
  • resin layers include knitted fabrics, woven fabrics, webs, nonwoven fabrics, and films.
  • Nonwoven fabrics, which are examples of the resin layer include spunbond nonwoven fabrics, meltblown nonwoven fabrics, wet nonwoven fabrics, dry nonwoven fabrics, dry pulp nonwoven fabrics, flash-spun nonwoven fabrics, and spread nonwoven fabrics. These nonwoven fabrics may be stretchable nonwoven fabrics or non-stretchable nonwoven fabrics.
  • the stretch nonwoven has a tertiary property and a quaternary property.
  • the term “tertiary property” refers to the property that the outer shape of the nonwoven fabric stretches in one direction when an external force is applied to the nonwoven fabric.
  • the “fourth property” indicates the property that the outer shape of the nonwoven fabric reverts when the external force applied to the nonwoven fabric is released.
  • Elastic nonwoven fabrics include elastic nonwoven fabrics using low-crystalline polypropylene described in WO 2012/070518.
  • Webs which are examples of the resin layer, include spunbond webs, meltblown webs, meltblown webs, wet webs, dry webs, dry pulp webs, flash spun webs, spread webs, and the like. These webs may be stretchable webs or non-stretchable webs.
  • the film which is an example of the resin layer, is preferably an air-permeable film or a moisture-permeable film when air permeability is required for the laminated nonwoven fabric.
  • the air-permeable film include a film made of a thermoplastic elastomer, a porous film, and the like.
  • Thermoplastic elastomers which are raw materials for films, include moisture-permeable polyurethane-based elastomers, polyester-based elastomers, polyamide-based elastomers, and the like.
  • the porous film is made porous by stretching a film made of a thermoplastic resin containing inorganic fine particles or organic fine particles.
  • thermoplastic resin such as high-pressure low-density polyethylene, linear low-density polyethylene (so-called LLDPE), high-density polyethylene, polypropylene, polypropylene random copolymer, and combinations thereof are preferred as the thermoplastic resin that is the raw material of the porous film.
  • LLDPE linear low-density polyethylene
  • polypropylene polypropylene random copolymer
  • combinations thereof are preferred as the thermoplastic resin that is the raw material of the porous film.
  • a thermoplastic resin made of one or more thermoplastic resins selected from polyethylene, polypropylene, etc. can be used as a raw material for a film, which is an example of the resin layer.
  • a part of the laminated nonwoven fabric is preferably heat-sealed.
  • the heat-sealing method for heat-sealing a part of the laminated nonwoven fabric include a method using means such as ultrasonic waves, heat embossing using an embossing roll, hot air through, and the like.
  • the heat-sealing method is preferably heat embossing because the long fibers are efficiently drawn when the nonwoven fabric laminate is drawn.
  • the embossed area ratio is usually preferably 5% to 30%, more preferably 5% to 20%.
  • stamped shapes include circles, ellipses, ellipses, squares, diamonds, rectangles, squares, and continuous shapes based on these shapes.
  • the embossing temperature in hot embossing is suitably adjusted by the line speed, crimping pressure, etc. during embossing, and is preferably 85°C to 150°C.
  • the resin layer When the resin layer is a knitted fabric, woven fabric, web or non-woven fabric, the resin layer preferably comprises thermoplastic elastomer fibers. By including thermoplastic elastomer fibers in the resin layer, it is possible to produce a stretchable nonwoven fabric that does not cause blocking.
  • thermoplastic elastomer fiber is not particularly limited as long as it is a thermoplastic elastomer.
  • a thermoplastic elastomer has a soft segment (soft phase) and a hard segment (hard phase).
  • the soft segment (soft phase) has elasticity in the molecule.
  • a hard segment (hard phase) has the property of preventing plastic deformation.
  • thermoplastic elastomer fibers include polyurethane thermoplastic elastomer fibers, olefin thermoplastic elastomer fibers, styrene thermoplastic elastomer fibers, polyester thermoplastic elastomer fibers, and polyamide thermoplastic elastomer fibers.
  • the thermoplastic elastomer fibers are preferably thermoplastic polyurethane fibers or olefin-based thermoplastic elastomer fibers from the viewpoint of the stretchability and spinning stability of the laminated nonwoven fabric.
  • Materials for polyurethane thermoplastic elastomer fibers include: (1) A method of reacting an isocyanate group-terminated prepolymer obtained by reacting a polyol and an isocyanate compound in advance with a chain extender, (2) Polyurethanes produced by mixing a polyol and a chain extender in advance and then reacting this mixture with an isocyanate compound.
  • Polyol which is one of the components constituting the thermoplastic polyurethane elastomer, includes polyoxyalkylene polyol, polytetramethylene ether glycol, polyester polyol, polycaprolactone polyol, and polycarbonate diol.
  • isocyanate compounds include compounds having two or more isocyanate groups in one molecule, such as aromatic ring, aliphatic or alicyclic compounds.
  • chain extender include aliphatic, aromatic, heterocyclic or alicyclic low-molecular-weight polyols having two or more hydroxyl groups in one molecule.
  • thermoplastic polyurethane elastomer fiber a thermoplastic polyurethane elastomer using 1,4-bis(2-hydroxyethoxy)benzene as a chain extender described in WO 2011/129433. is mentioned.
  • Examples of materials for olefin-based thermoplastic elastomer fibers include ethylene- ⁇ -olefin random copolymers and those obtained by copolymerizing dienes as a second component.
  • ethylene-propylene random copolymers examples thereof include ethylene-1-butene random copolymers and EPDM (ethylene-propylene-diene copolymers, the diene component of which is dicyclopentadiene or ethylidene norbornene) as soft segments and polyolefins as hard segments.
  • thermoplastic elastomer fiber materials include Tafmer (manufactured by Mitsui Chemicals, Inc.), Milastomer (manufactured by Mitsui Chemicals, Inc.), Evaflex-EEA (manufactured by Mitsui DuPont Polychemicals, Inc.), Vistamax (manufactured by Exxon Mobil Co., Ltd.), etc.
  • Raw materials for each of the thermoplastic styrene-based elastomer fiber, the thermoplastic polyester-based elastomer fiber, and the thermoplastic polyamide-based elastomer fiber are described in JP-A-2001-179867. What was done is mentioned.
  • the fiber diameter of the thermoplastic elastomer fiber is preferably 4.0d (denier) or less, more preferably 3.5d or less, and even more preferably 3.0d or less.
  • thermoplastic elastomer fiber may be a long fiber (staple) or a single fiber (filament). Furthermore, the cross-sectional shape of the thermoplastic elastomer fiber is not particularly limited, and examples thereof include circular, elliptical, irregular cross-sections, and the like.
  • the mixed fiber nonwoven fabric contains thermoplastic elastomer fibers.
  • the mixed fiber nonwoven fabric is obtained by mixing sea-island fibers and thermoplastic elastomer fibers.
  • the mixed fiber ratio of the sea-island fibers is not particularly limited, and is preferably 5% to 95% by mass, more preferably 25% to 75% by mass, and still more preferably 40% to 60% by mass.
  • the “mixed fiber ratio” indicates the ratio of a specific type of fiber contained in a nonwoven fabric made by mixing two or more types of fibers, or the mixing ratio of various types of fibers in the nonwoven fabric. That is, the “mixing ratio of sea-island fibers" in a mixed nonwoven fabric composed of sea-island fibers and thermoplastic elastomer fibers is ⁇ mass of sea-island fibers ⁇ (mass of sea-island fibers+mass of thermoplastic elastomer fibers) ⁇ .
  • the “mixing ratio of thermoplastic elastomer fibers” is ⁇ mass of thermoplastic elastomer fibers/(mass of sea-island fibers + mass of thermoplastic elastomer fibers) ⁇ .
  • the basis weight of the mixed fiber nonwoven fabric is preferably 100 g/m 2 or less, more preferably 90 g/m 2 or less, still more preferably 80 g/m 2 or less, from the viewpoint of achieving both softness and tensile strength of the mixed fiber nonwoven fabric.
  • the basis weight of the mixed fiber nonwoven fabric is preferably in the range of 20 g/m 2 to 70 g/m 2 .
  • thermoplastic elastomer fibers examples include those exemplified as the thermoplastic elastomer fibers that can be contained in the resin layer of the laminated nonwoven fabric.
  • Sanitary materials of the present disclosure include spunbond nonwoven fabrics of the present disclosure.
  • the spunbond nonwoven fabric of the present disclosure has excellent extensibility. Therefore, the sanitary material of the present disclosure has excellent extensibility.
  • Sanitary materials are suitably used for various sanitary material applications that require extensibility and flexibility.
  • the sanitary material is suitably used for absorbent articles such as disposable diapers and sanitary napkins, medical sanitary materials such as bandages, medical gauze and towels, and sanitary masks.
  • the spunbond nonwoven fabric of the present disclosure is produced by a conventional method using a thermoplastic resin composition as a raw material.
  • the spunbond nonwoven fabric of the present disclosure is produced, for example, as follows. That is, a thermoplastic resin composition is introduced into an extruder and melted. A melt of the thermoplastic resin composition is spun using a spunbond nonwoven fabric molding machine having multiple spinnerets. The obtained continuous fiber group is stretched by controlling the air volume with a blower or the like. At this time, the continuous fiber group is cooled as necessary. The continuous fibers are then deposited on the collecting surface of a spunbond nonwoven fabric forming machine to obtain a spunbond web. The resulting spunbond web is heat and pressure treated with an embossing roll. A spunbond nonwoven fabric is thus obtained.
  • thermoplastic resin composition is the same as that exemplified as the composition of the sea-island fiber described above.
  • FIG. 1 is a schematic diagram showing an example of a manufacturing apparatus used for closed spunbonding.
  • a group of continuous fibers melt-spun from a thermoplastic resin composition is stretched while being cooled in a closed space.
  • the spinning section 10 has an extruder 11 , a spinneret 12 , a cooling chamber 13 , a cooling air supply section 14 , a cooling air supply section 15 and a drawing section 16 .
  • Extruder 11 extrudes a thermoplastic polymer.
  • Spinneret 12 spins a melt of thermoplastic polymer.
  • the cooling chamber 13 cools the continuous fiber group 1 spun from the spinneret 12 .
  • the cooling air supply section 14 and the cooling air supply section 15 supply the cooling air A into the cooling chamber 13 and the extension section 16 .
  • the drawing section 16 draws the continuous fiber group 1 .
  • thermoplastic resin composition is introduced into the extruder 11 .
  • the thermoplastic resin composition introduced into the extruder 11 is melt-kneaded within the extruder 11 .
  • a melt of the thermoplastic resin composition is extruded from the extruder 11 .
  • a melt of the thermoplastic resin composition extruded from the extruder 11 is introduced into the spinneret 12 .
  • the melt of the thermoplastic resin composition introduced into the spinneret 12 is extruded from the spinneret 12 and spun.
  • the continuous fiber group 1 is formed.
  • the continuous fiber group 1 is introduced into the cooling chamber 13 .
  • the continuous fiber group 1 introduced into the cooling chamber 13 is cooled by the cooling air A.
  • the cooling air A is supplied from at least one of the cooling air supply section 14 and the cooling air supply section 15 into the cooling chamber 13 and the extending section 16 .
  • the cooled continuous fiber group 1 is introduced into the drawing section 16 arranged on the downstream side of the cooling chamber 13 .
  • the extension portion 16 has a bottleneck portion 16a and a tubular portion 16b.
  • the cylindrical portion 16b is formed at the end portion on the lower side (ie, the moving collection member 21 side) in the vertical direction (ie, the direction of gravity) of the bottleneck portion 16a.
  • the bottleneck portion 16a is bottleneck-shaped.
  • the cylindrical portion 16b is a cylindrical object. The hollow portion of the cylindrical portion 16b widens downward as shown in FIG.
  • the continuous fiber group 1 introduced into the stretching section 16 is stretched by increasing the speed of the cooling air at the bottleneck section 16a.
  • the continuous fiber group 1 that has been stretched and passed through the cylindrical portion 16b is dispersed and collected on the moving collecting member 21 .
  • the dispersed continuous fiber group 1 is efficiently collected on the moving collection member 21 by the suction unit 22 .
  • the suction unit 22 is arranged below the collection surface of the moving collection member 21 .
  • a spunbond web 2 is thus formed.
  • the fibers contained in the spunbond web 2 are then heat and pressure treated and bonded, for example by an embossing roll (not shown).
  • a spunbond nonwoven fabric is thus obtained.
  • the method for producing the spunbond nonwoven fabric of the present disclosure is not limited to the closed spunbond method.
  • the method of making the spunbond nonwoven fabric of the present disclosure may be an open spunbond process. In the open spunbond method, a group of continuous fibers melt-spun from a thermoplastic resin composition is cooled.
  • the melting temperature of the thermoplastic resin composition is not particularly limited as long as it is the softening temperature or the melting temperature of the thermoplastic resin composition or higher and is lower than the thermal decomposition temperature of the thermoplastic resin composition. It is appropriately set according to physical properties and the like.
  • the temperature of the spinneret 12 is appropriately adjusted according to the physical properties of the thermoplastic resin composition. Considering the physical properties of the specific polypropylene (A) contained in the thermoplastic resin composition, the temperature of the spinneret 12 is preferably 180° C. to 240° C., more preferably 190° C. to 230° C., and still more preferably 200° C. to 225° C. °C.
  • the pore diameter of the spinneret 12 is not particularly limited, and is preferably 0.05 mm to 1.00 mm from the viewpoint of the elongation of the spunbond nonwoven fabric.
  • the single hole discharge rate of the melt of the thermoplastic resin composition from the spinneret 12 is preferably 0.1 g/min to 3.0 g/min, more preferably 0.3 g. /min to 1.0 g/min.
  • the temperature of the cooling air that cools the continuous fiber group extruded from the spinneret is not particularly limited as long as it is a temperature at which the thermoplastic resin composition is solidified.
  • the temperature of the cooling air is preferably 5°C to 50°C, more preferably 10°C to 40°C, still more preferably 15°C to 30°C.
  • the fibers contained in the spunbond nonwoven fabric may be partially heat-sealed.
  • the fibers contained in the spunbond nonwoven fabric may be compressed using nip rolls before being heat-sealed.
  • the obtained test piece was subjected to a tensile test using a tensile tester (manufactured by Instron Japan Company Limited, Instron 5564 type) under the conditions of a temperature of 20 ⁇ 2 ° C., a chuck distance of 100 mm, and a tensile speed of 300 mm / min.
  • Tensile load was measured for each test piece, and the average value of the maximum values was taken as the tensile strength (maximum strength) [N/50 mm] in the machine direction (MD).
  • Elongation at tensile strength (maximum strength) was defined as maximum elongation [%] and used as an index for evaluating elongation.
  • the number of island phases with a diameter of 0.32 ⁇ m or more and the number of island phases with a diameter of less than 0.32 ⁇ m were counted.
  • the ratio (that is, the ratio of island phases) was calculated by dividing the number of island phases corresponding to each range by the number of island phases within the observation range (cross section).
  • a transmission electron microscope a transmission electron microscope model H-7650 manufactured by Hitachi High-Tech Co., Ltd. was used.
  • the observation magnification was 6000 times.
  • the diameter of the island phase was obtained by image analysis using Mac-View (Mountech Co., Ltd.). Specifically, the major axis and minor axis of the island phase were measured, and the average value was defined as the diameter.
  • the island phase area ratio was obtained by dividing the total area of the island phase by the total cross-sectional area of the sea-island fiber.
  • Example 1 ⁇ Production of spunbond nonwoven fabric> 92.7 parts by mass of a propylene homopolymer (1) having an MFR (measured according to ASTM D1238 at a temperature of 230°C and a load of 2.16 kg) of 60 g/10 minutes, a density of 0.91 g/cm 3 and a melting point of 160°C; High-density polyethylene (hereinafter referred to as "polyethylene") having an MFR (measured at a temperature of 190°C and a load of 2.16 kg according to ASTM D1238) of 5 g/10 minutes, a density of 0.95 g/cm 3 and a melting point of 134°C.
  • polyethylene High-density polyethylene
  • FIG. 2 shows an image of the cross section of the fibers in the spunbond nonwoven fabric obtained in Example 1, observed with a transmission electron microscope.
  • Example 2 91.7 parts by mass of a propylene homopolymer (1) having a melting point of 160° C., and 2.0 parts by mass of the product name “Hiwax (registered trademark) 320P” [density: 0.93 g/cm 3 , weight average molecular weight: 3000].
  • a spunbond nonwoven fabric was produced and evaluated in the same manner as in Example 1, except that the parts were changed. The number of yarn breakages during the test was zero.
  • Example 3 90.7 parts by mass of a propylene homopolymer (1) having a melting point of 160° C., and 3.0 parts by mass of the product name “Hiwax (registered trademark) 320P” [density: 0.93 g/cm 3 , weight average molecular weight: 3000].
  • a spunbond nonwoven fabric was produced and evaluated in the same manner as in Example 1, except that the parts were changed. The number of yarn breakages during the test was zero.
  • Example 4 87.7 parts by mass of propylene homopolymer (1) having a melting point of 160° C., 10.0 parts by mass of polyethylene, product name “Hiwax (registered trademark) 320P” [density: 0.93 g/cm 3 , weight average molecular weight : 3000] was changed to 2.0 parts by mass, a spunbond nonwoven fabric was produced and evaluated in the same manner as in Example 1. The number of yarn breakages during the test was zero.
  • Example 5 86.7 parts by mass of propylene homopolymer (1) having a melting point of 160° C., and 3.0 parts by mass of product name “Hiwax (registered trademark) 320P” [density: 0.93 g/cm 3 , weight average molecular weight: 3000].
  • a spunbond nonwoven fabric was produced and evaluated in the same manner as in Example 4, except that the parts were changed. The number of yarn breakages during the test was zero.
  • Example 6 The product name "High Wax (registered trademark) 320P” [density: 0.93 g/cm 3 , weight average molecular weight: 3000] is replaced with ethylene-butene copolymer wax [manufactured by Mitsui Chemicals, Inc., product name “Excelex (registered trademark) Trademark) 30200B", density: 0.92 g/cm 3 , weight average molecular weight: 2900]. The number of yarn breakages during the test was zero.
  • Example 7 The product name “Hiwax (registered trademark) 320P” [density: 0.93 g/cm 3 , weight average molecular weight: 3000] was mixed with ethylene polymer wax [manufactured by Mitsui Chemicals, Inc., product name “Hiwax (registered trademark) 100P”. , density: 0.95 g/cm 3 , weight average molecular weight: 900]. The number of yarn breakages during the test was zero.
  • Example 8 The product name "Hi-Wax (registered trademark) 320P" [density: 0.93 g/cm 3 , weight average molecular weight: 3000] is ethylene-propylene copolymer wax [manufactured by Mitsui Chemicals, Inc., product name "Hi-Wax (registered trademark) Trademark) 110P", density: 0.92 g/cm 3 , weight average molecular weight: 1000]. The number of yarn breakages during the test was zero.
  • Example 9 A spunbond nonwoven fabric was produced and evaluated in the same manner as in Example 8, except that 93.7 parts by mass of propylene homopolymer (1) having a melting point of 160°C was used and 5.0 parts by mass of polyethylene was used. The number of yarn breakages during the test was zero.
  • Example 10 A spunbond nonwoven fabric was produced and evaluated in the same manner as in Example 8, except that 94.7 parts by mass of propylene homopolymer (1) having a melting point of 160°C and 4.0 parts by mass of polyethylene were used. The number of yarn breakages during the test was zero.
  • Example 11 A spunbond nonwoven fabric was produced in the same manner as in Example 10, except that the propylene homopolymer (1) having a melting point of 160° C. was 93.0 parts by mass, the polyethylene was 6.0 parts by mass, and erucamide was not used. manufactured and evaluated. The number of yarn breakages during the test was zero.
  • (Comparative example 1) 92.7 parts by mass of a propylene homopolymer (1) having an MFR (measured according to ASTM D1238 at a temperature of 230°C and a load of 2.16 kg) of 60 g/10 minutes, a density of 0.91 g/cm 3 and a melting point of 160°C; MFR (measured at a temperature of 190°C and a load of 2.16 kg according to ASTM D1238) of 5 g/10 minutes, a density of 0.95 g/cm 3 , and a high-density polyethylene having a melting point of 134°C (3: hereinafter referred to as “polyethylene” .) 6 parts by mass; A mixture with 0.3 parts by mass of erucic acid amide was melted using an extruder of 75 mm ⁇ , and a spunbond nonwoven fabric molding machine having a spinneret with 1093 holes (direction perpendicular to the machine flow direction on the collection surface length: 320 mm, see FIG.
  • FIG. 3 shows an image of a cross section of fibers in the spunbonded nonwoven fabric obtained in Comparative Example 1 observed with a transmission electron microscope.
  • Comparative example 2 Except for adjusting the shape of the stretched portion so that the fibers are dispersed in the transverse direction (CD) (more specifically, the vertical length L (see FIG. 1) of the cylindrical portion 16b of the stretched portion 16 is increased by 50 times).
  • a spunbond nonwoven fabric prepared and evaluated a spunbond nonwoven fabric in the same manner as in Example 8. The number of yarn breakages during the test was zero. It should be noted that the cylindrical portion 16b of Comparative Example 2 was not in contact with the moving collection member 21 and the spunbond web 2 formed on the moving collection member 21 .
  • the spunbond nonwoven fabrics of Examples 1 to 11 contain sea-island fibers made of a resin composition containing a propylene homopolymer and polyethylene. All sea-island fibers were confirmed to have a sea-island structure. Sea-island fibers include fibers having an island phase ratio of 60% or more on a number basis.
  • the tensile strength ratio (S MD /S CD ) of the spunbond nonwoven fabrics of Examples 1 to 11 was 2.0 to 5.0. Therefore, the spunbond nonwoven fabrics of Examples 1 to 11 had a spinnability evaluation of "A" and a maximum elongation in the machine direction (MD) of more than 197%.
  • the spunbond nonwoven fabrics of Examples 1 to 11 were found to be excellent in extensibility and spinnability. From these evaluation results, it was found that the spunbond nonwoven fabric of the present disclosure has excellent productivity and is suitable for sanitary material applications that require various secondary workability.
  • the spunbond nonwoven fabrics of Comparative Examples 1 and 3 contain sea-island fibers made of a resin composition containing propylene homopolymer and polyethylene. All sea-island fibers were confirmed to have a sea-island structure. The sea-island fibers did not include fibers with an island phase ratio of 60% or more based on the number. Therefore, the spunbond nonwoven fabrics of Comparative Examples 1 and 3 had a maximum elongation in the machine direction (MD) of 197% or less. Furthermore, the spunbonded nonwoven fabric of Comparative Example 1 was evaluated as "B" in spinnability. As a result, it was found that the spunbond nonwoven fabrics of Comparative Examples 1 and 3 were not excellent in extensibility and spinnability.
  • the spunbond nonwoven fabrics of Comparative Examples 2 and 4 contain sea-island fibers made of a resin composition containing a propylene homopolymer and polyethylene.
  • the tensile strength ratios (S MD /S CD ) of the spunbond nonwoven fabrics of Comparative Examples 2 and 4 were not within the range of 2.0 to 5.0. Therefore, the spunbond nonwoven fabrics of Comparative Examples 2 and 4 had a maximum elongation in the machine direction (MD) of less than 197%. As a result, it was found that the spunbond nonwoven fabrics of Comparative Examples 2 and 4 were not excellent in extensibility and spinnability.

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