WO2022239838A1 - 衛生材料用不織布、sapシート用基材、及びsapシート - Google Patents
衛生材料用不織布、sapシート用基材、及びsapシート Download PDFInfo
- Publication number
- WO2022239838A1 WO2022239838A1 PCT/JP2022/020094 JP2022020094W WO2022239838A1 WO 2022239838 A1 WO2022239838 A1 WO 2022239838A1 JP 2022020094 W JP2022020094 W JP 2022020094W WO 2022239838 A1 WO2022239838 A1 WO 2022239838A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- nonwoven fabric
- sap
- less
- sanitary materials
- sanitary
- Prior art date
Links
- 239000004745 nonwoven fabric Substances 0.000 title claims abstract description 169
- 239000000463 material Substances 0.000 title claims abstract description 85
- 238000000034 method Methods 0.000 claims abstract description 54
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 25
- FJQXCDYVZAHXNS-UHFFFAOYSA-N methadone hydrochloride Chemical compound Cl.C=1C=CC=CC=1C(CC(C)N(C)C)(C(=O)CC)C1=CC=CC=C1 FJQXCDYVZAHXNS-UHFFFAOYSA-N 0.000 claims abstract description 21
- 239000000835 fiber Substances 0.000 claims description 80
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- 238000012360 testing method Methods 0.000 claims description 16
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- 230000003746 surface roughness Effects 0.000 claims description 3
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- 229930195729 fatty acid Natural products 0.000 description 6
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- 150000001875 compounds Chemical class 0.000 description 4
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- 239000002245 particle Substances 0.000 description 4
- 229920001296 polysiloxane Polymers 0.000 description 4
- 239000004711 α-olefin Substances 0.000 description 4
- 229920001903 high density polyethylene Polymers 0.000 description 3
- 239000004700 high-density polyethylene Substances 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
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- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
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- 229920000642 polymer Polymers 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- 239000007921 spray Substances 0.000 description 3
- 229910001220 stainless steel Inorganic materials 0.000 description 3
- 239000010935 stainless steel Substances 0.000 description 3
- 239000000758 substrate Substances 0.000 description 3
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 2
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 2
- WSSSPWUEQFSQQG-UHFFFAOYSA-N 4-methyl-1-pentene Chemical compound CC(C)CC=C WSSSPWUEQFSQQG-UHFFFAOYSA-N 0.000 description 2
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 2
- 239000005977 Ethylene Substances 0.000 description 2
- 229920003171 Poly (ethylene oxide) Polymers 0.000 description 2
- 229920005830 Polyurethane Foam Polymers 0.000 description 2
- 229920002125 Sokalan® Polymers 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 2
- 238000007664 blowing Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000012510 hollow fiber Substances 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- 230000007794 irritation Effects 0.000 description 2
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 2
- 239000010410 layer Substances 0.000 description 2
- 239000003595 mist Substances 0.000 description 2
- 239000005022 packaging material Substances 0.000 description 2
- YWAKXRMUMFPDSH-UHFFFAOYSA-N pentene Chemical compound CCCC=C YWAKXRMUMFPDSH-UHFFFAOYSA-N 0.000 description 2
- 239000002504 physiological saline solution Substances 0.000 description 2
- 239000004584 polyacrylic acid Substances 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 239000011496 polyurethane foam Substances 0.000 description 2
- 238000010998 test method Methods 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- NKFNBVMJTSYZDV-UHFFFAOYSA-N 2-[dodecyl(2-hydroxyethyl)amino]ethanol Chemical compound CCCCCCCCCCCCN(CCO)CCO NKFNBVMJTSYZDV-UHFFFAOYSA-N 0.000 description 1
- 201000004624 Dermatitis Diseases 0.000 description 1
- IAYPIBMASNFSPL-UHFFFAOYSA-N Ethylene oxide Chemical compound C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 description 1
- 208000010201 Exanthema Diseases 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
- 229910019142 PO4 Inorganic materials 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000002202 Polyethylene glycol Substances 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 230000002745 absorbent Effects 0.000 description 1
- 239000002250 absorbent Substances 0.000 description 1
- 239000006096 absorbing agent Substances 0.000 description 1
- 239000013543 active substance Substances 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 150000001298 alcohols Chemical class 0.000 description 1
- 150000005215 alkyl ethers Chemical class 0.000 description 1
- 125000000129 anionic group Chemical group 0.000 description 1
- 208000010668 atopic eczema Diseases 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 229920006167 biodegradable resin Polymers 0.000 description 1
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- 125000004432 carbon atom Chemical group C* 0.000 description 1
- 238000009960 carding Methods 0.000 description 1
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- 239000000470 constituent Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 235000019329 dioctyl sodium sulphosuccinate Nutrition 0.000 description 1
- YHAIUSTWZPMYGG-UHFFFAOYSA-L disodium;2,2-dioctyl-3-sulfobutanedioate Chemical compound [Na+].[Na+].CCCCCCCCC(C([O-])=O)(C(C([O-])=O)S(O)(=O)=O)CCCCCCCC YHAIUSTWZPMYGG-UHFFFAOYSA-L 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 201000005884 exanthem Diseases 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 238000007380 fibre production Methods 0.000 description 1
- 239000012943 hotmelt Substances 0.000 description 1
- 229920000092 linear low density polyethylene Polymers 0.000 description 1
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- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical compound CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 1
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 1
- 239000002736 nonionic surfactant Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000010452 phosphate Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920003207 poly(ethylene-2,6-naphthalate) Polymers 0.000 description 1
- 229920000747 poly(lactic acid) Polymers 0.000 description 1
- 229920001495 poly(sodium acrylate) polymer Polymers 0.000 description 1
- 229920002239 polyacrylonitrile Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 239000004631 polybutylene succinate Substances 0.000 description 1
- 229920002961 polybutylene succinate Polymers 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 239000011112 polyethylene naphthalate Substances 0.000 description 1
- 239000004626 polylactic acid Substances 0.000 description 1
- 229920005629 polypropylene homopolymer Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 1
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
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- 239000005060 rubber Substances 0.000 description 1
- 231100000046 skin rash Toxicity 0.000 description 1
- NNMHYFLPFNGQFZ-UHFFFAOYSA-M sodium polyacrylate Chemical compound [Na+].[O-]C(=O)C=C NNMHYFLPFNGQFZ-UHFFFAOYSA-M 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
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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
- A61F13/53—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 absorbing medium
-
- 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
- D04H1/413—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 containing granules other than absorbent substances
-
- 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
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
- D06M13/10—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing oxygen
- D06M13/224—Esters of carboxylic acids; Esters of carbonic acid
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
- D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D06M15/643—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds containing silicon in the main chain
- D06M15/647—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds containing silicon in the main chain containing polyether sequences
Definitions
- the present disclosure relates to nonwoven fabrics for sanitary materials, base materials for SAP sheets, and SAP sheets.
- a diaper basically consists of a top sheet, an absorbent body, a back sheet, and leg cuffs. Normally, a mixture of SAP (super absorbent polymer) and pulp wrapped in nonwoven fabric or tissue is used as an absorber. SAP sheet) is used in some cases. Substrates for SAP sheets are required to be able to support a large amount of SAP, not to inhibit water permeability to SAP, and to retain water by themselves.
- Patent Document 1 discloses an SAP sheet in which a planar web made of long fibers having hydrophilicity and crimps is used as a base material, and SAP is embedded and supported in the base material.
- the present disclosure aims to provide a nonwoven fabric for sanitary materials that is suitable as a base material for SAP sheets and has excellent liquid water retention, SAP carrying capacity, and water permeability.
- a nonwoven fabric for sanitary materials having a length-to-width ratio (length/width) of the variation value (MMD) of the mean coefficient of friction by the KES method of 0.5 or more and a fluff grade of grade 4 or less by the Martindale method.
- MMD variation value
- a nonwoven fabric for sanitary materials having a length-to-width ratio (length/width) of the variation value (MMD) of the average coefficient of friction according to the KES method of 0.5 or more, which is evaluated as a friction element in a friction test according to the Martindale method.
- MMD variation value
- An SAP sheet comprising the SAP sheet base material according to item [11] or [12] and SAP.
- a sanitary material comprising the SAP sheet according to item [13].
- the nonwoven fabric for sanitary materials of the present disclosure is excellent in liquid water retention, SAP carrying capacity, and water permeability, so it can be suitably used as a base material for SAP sheets.
- Nonwoven fabric for sanitary materials of the present disclosure has a length-to-width ratio of 0.5 or more in the variation value (MMD) of the average coefficient of friction measured by the KES (KAWABATA EVALUATION SYSTEM) method. be.
- the nonwoven fabric for sanitary materials of the present disclosure has a fluff grade of 4 or less by the Martindale method, or in a friction test by the Martindale method, the same nonwoven fabric as the nonwoven fabric for sanitary materials is used as a friction element, and the load is 9 kPa. , and one or more of surface roughness, pilling, holes, and tearing occurs when a friction test is performed with 16 times of friction.
- the nonwoven fabric may be either a long fiber nonwoven fabric or a short fiber nonwoven fabric. However, from the viewpoint of strength, productivity, reduction of irritation to the skin, etc., a long-fiber nonwoven fabric is preferred, and a spunbond nonwoven fabric is particularly preferred.
- long fibers refer to fibers having a fiber length of 50 mm or more. From the standpoint of fiber shedding, the longer the fiber length, the better.
- the nonwoven fabric is preferably composed of fibers having an average fiber length of 50 mm or longer, more preferably 80 mm or longer, even more preferably 100 mm or longer. The longer the average fiber length, the more difficult it is for the fibers to come off, and the more the liquid retains water.
- the nonwoven fabric is preferably composed of fibers made of thermoplastic resin.
- thermoplastic resins include, but are not limited to, polyolefin resins such as polyethylene, polypropylene, and copolymer polypropylene, polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, and copolymer polyester, and nylon-6. , nylon-66, and copolymer nylon; biodegradable resins such as polylactic acid, polybutylene succinate, and polyethylene succinate; and combinations thereof.
- the thermoplastic resin may be used singly or in combination of two or more. Polyolefin-based resins are preferred from the standpoint of texture of non-woven fabrics and from the standpoint of versatility and convenience of collection, since many of the uses are disposable materials.
- the fibers that make up the nonwoven fabric not only circular fibers but also special forms such as irregular cross-section fibers and hollow fibers may be used. From the viewpoint of imparting characteristics to the nonwoven fabric surface structure, it is preferable that the fibers are crimped.
- the lower limit of the number of crimps is preferably 3 crimps/2.5 cm or more, more preferably 5 crimps/2.5 cm or more.
- the cross section of the fibers is made into an irregular cross section, and the fibers are unevenly cooled during the spinning cooling.
- Composite fibers composed of two or more types of thermoplastic resins can also be crimped. , it is possible to easily develop crimps.
- the core may be exposed on the fiber surface, in which case the ratio of the core area to the fiber surface is preferably more than 0% and 50% or less, It is preferably more than 0% and 30% or less. If the ratio of the core area to the fiber surface is 50% or less, there is little effect on adhesion during bonding as a nonwoven fabric, and the fabric strength is sufficient.
- the fiber is a conjugate fiber composed of two or more types of thermoplastic resins
- any of the thermoplastic resins described above may be combined as long as the desired effect is achieved.
- a combination of thermoplastic resins having different melting points is preferred.
- the weight ratio of the resin with the higher melting point in the fiber is preferably 20 wt% or more and 80 wt% or less, more preferably 30 wt% or more and 80 wt% or less, still more preferably 50 wt% or more and 70 wt% or less.
- the conjugate fiber is preferably a combination of polyolefin resins, or preferably a combination of polyolefin resin and polyester resin.
- Composite fibers obtained by combining polyolefin resins include composite fibers obtained by combining resins such as polyethylene, polypropylene, and copolymers of these monomers with other ⁇ -olefins.
- Other ⁇ -olefins are preferably ⁇ -olefins having 3 to 10 carbon atoms, specifically propylene, 1-butene, 1-pentene, 1-hexane, 4-methyl-1-pentene and 1-octene. etc.
- polyethylene, polypropylene, and copolymers of these monomers and other ⁇ -olefins are used as the polyolefin resin
- polyethylene terephthalate is used as the polyester resin. It is preferable to use a single component or a copolymer containing isophthalic acid or the like as a monomer unit in polyethylene terephthalate.
- Polyethylene terephthalate may be modified by blending or the like, or may be added with additives or the like.
- thermoplastic resins a combination of polypropylene and polyethylene is preferable because it has high strength and is difficult to break during use, is excellent in processing suitability during production of sanitary materials, and has a good texture.
- the composite fiber is of the eccentric sheath-core type, it is preferable that the core is made of polypropylene and the sheath is made of polyethylene.
- polypropylene When polypropylene is used for the fiber, it may be polypropylene synthesized by a general Ziegranatta catalyst, polypropylene synthesized by a single-site active catalyst represented by metallocene, and ethylene random copolymer polypropylene. One type may be used alone, or two or more types may be combined. In terms of feel, strength and dimensional stability, it is preferable to use homopolypropylene as the main component.
- the lower limit of MFR of polypropylene is preferably 20 g/10 min or more, more preferably 30 g/10 min or more, still more preferably 40 g/10 min or more, and even more preferably 40 g/10 min or more. is greater than 53 g/10 min.
- the upper limit of MFR which can be arbitrarily combined with the above lower limit, is preferably 155 g/10 minutes or less, more preferably 70 g/10 minutes or less, and even more preferably 60 g/10 minutes or less.
- MFR is measured according to Table 1 of JIS-K7210 "Plastics - Test method for melt mass flow rate (MFR) and melt volume flow rate (MVR) of thermoplastics", test temperature 230 ° C., test load 2.16 kg. .
- polyethylene When polyethylene is used for the fiber, it may be either polyethylene synthesized with a general Ziegranatta catalyst or polyethylene synthesized with a single-site active catalyst typified by metallocene.
- the polyethylene is preferably high density polyethylene or linear low density polyethylene.
- the density of polyethylene is preferably 0.92 g/cm 3 or more and 0.97 g/cm 3 or less, more preferably 0.925 g/cm 3 or more and 0.96 g/cm 3 or less.
- Polyethylene may be used individually by 1 type, or may be used in combination of 2 or more types. From the viewpoint of fiber adhesion, it is preferable to add linear polyethylene to high-density polyethylene in an amount of 0.5 wt % or more and 25 wt % or less.
- the lower limit of the melt index (MI) of polyethylene is preferably 10 g/10 minutes or more, more preferably more than 15 g/10 minutes.
- the upper limit of MI which can be arbitrarily combined with the above lower limit, is preferably 100 g/10 min or less, more preferably 60 g/10 min or less, still more preferably 40 g/10 min or less.
- MI is measured according to Table 1 of JIS-K7210 "Plastics - Test method for melt mass flow rate (MFR) and melt volume flow rate (MVR) of thermoplastics", test temperature 190 ° C., test load 2.16 kg. .
- the lower limit of the solution viscosity ⁇ sp /c ( ⁇ sp is the specific viscosity and c is the unit concentration of the resin) is preferably 0.2 or more, more preferably 0.6 or more. is.
- the upper limit of the solution viscosity ⁇ sp /c that can be arbitrarily combined with the above lower limit is preferably 0.9 or less, more preferably 0.8 or less.
- the non-woven fabric has a length-to-width ratio (length/width) of the variation value (MMD) of the average coefficient of friction according to the KES method of 0.5 or more, preferably 0.55 or more, and more preferably 0.60 or more.
- “Longitudinal” means the machine direction (MD direction) in nonwoven fabric production
- “lateral” means the width direction (CD direction) perpendicular to the machine direction. If the length-to-width ratio of the average coefficient of friction is 0.5 or more, the dripped liquid is well diffused on the surface layer of the nonwoven fabric, so that the amount of liquid remaining after passing the liquid increases. Therefore, it can be suitably used as a base material for SAP sheets.
- the upper limit of the aspect ratio of the variation value (MMD) is preferably less than 1.00, more preferably less than 0.9.
- the absolute value of the average coefficient of friction according to the KES method is preferably 0.0010 or more and 0.0100 or less, more preferably 0.0020 or more and 0.0090 in the longitudinal direction (MD direction) from the viewpoint of reducing irritation to the skin.
- the non-woven fabric has a fluff grade of grade 4 or lower, preferably grade 3 or lower, according to the Martindale method. More specifically, the non-woven fabric was subjected to a friction test by the Martindale method, using the same non-woven fabric as the friction element, with a load of 9 kPa and a friction count of 16 times. , holes and tears, preferably pilling, holes and tears.
- the fluff grade according to Martindale is grade 4 or less, the adhesion between the fibers is not too strong, and the SAP can be easily carried inside the nonwoven fabric.
- the fluff grade is greater than grade 1.5. More specifically, it is preferable that the nonwoven fabric has no holes or tears in the above friction test. If the grade is higher than 1.5, the adhesion between the fibers will be sufficient, and the strength of the nonwoven fabric will be high, so that the nonwoven fabric will be less likely to break in the diaper manufacturing process.
- the average fiber diameter of the fibers of the nonwoven fabric is preferably 8.0 ⁇ m or more and 38.0 ⁇ m or less, more preferably 9.0 ⁇ m or more and 33.5 ⁇ m or less, and still more preferably 11.0 ⁇ m or more and 26.5 ⁇ m or less.
- the average fiber diameter is preferably 8.0 ⁇ m or more from the viewpoint of spinning stability, and preferably 38.0 ⁇ m or less from the viewpoint of texture as a nonwoven fabric used for sanitary materials.
- the basis weight of the nonwoven fabric is preferably 5 g/m 2 or more and 80 g/m 2 or less, more preferably 8 g/m 2 or more and 40 g/m 2 or less, and still more preferably 10 g/m 2 or more and 30 g/m 2 or less. If the basis weight is 5 g/m 2 or more, it has a preferable strength as a nonwoven fabric used for sanitary materials. If the basis weight is 80 g/m 2 or less, the nonwoven fabric used for sanitary materials has a sufficiently satisfying texture and is less likely to give an impression of thick appearance.
- the thickness of the nonwoven fabric under a load of 1.25 g/cm 2 is preferably 140 ⁇ m or more, more preferably 140 ⁇ m or more and 3000 ⁇ m or less, and even more preferably 140 ⁇ m or more and 2000 ⁇ m or less. If the thickness under a load of 1.25 g/cm 2 is 140 ⁇ m or more, the nonwoven fabric will be excellent in texture and water permeability. If the thickness is 3000 ⁇ m or less, the texture of the nonwoven fabric used for sanitary materials is sufficiently satisfied, and the appearance is less likely to give the impression of being thick.
- the nonwoven fabric may have a water permeable agent.
- the water permeable agent to be used is not particularly limited, but in consideration of safety to the human body, safety in the process, etc., higher alcohols, higher fatty acids, and nonionic surfactants added with ethylene oxide such as alkylphenol. , alkyl phosphate salts, and anionic active agents such as alkyl sulfate salts, and surfactants composed of these alone or mixtures.
- Preferred water-permeable agents include, for example, polyglycerin fatty acid esters, sorbitan fatty acid esters, polyether-polyester block copolymers, polyethylene ether-modified silicones, polyether-modified silicones, ethylene oxide-added polyhydric alcohols, and polyamide compounds. be done.
- the amount of the water permeable agent is generally preferably 0.10 wt% or more and 2.00 wt% or less, more preferably 0.15 wt% or more and 1.50 wt% or less, relative to the nonwoven fabric. If it is 0.10 wt % or more, sufficient water permeability can be obtained, while if it is 1.50 wt % or less, skin rashes and eczema are less likely to occur.
- the nonwoven fabric is preferably manufactured by a spunbond method from the viewpoint of strength and productivity. Details of the manufacturing method by the spunbond method are described below, but the nonwoven fabric of the present disclosure is not limited to the nonwoven fabric manufactured by the spunbond method.
- thermoplastic resin is melt extruded from an extruder and discharged from a spinneret with many spinning holes.
- a nonwoven fabric containing conjugate long fibers combined with two or more thermoplastic resins for example, different thermoplastic resins are melt extruded from two or more different extruders, and extruded from a spinneret having a large number of spinning holes. It can be produced by extruding a thread in a state in which two or more thermoplastic resins are combined.
- each layer may be formed of webs with different fiber diameters, or webs of special forms of fibers such as modified cross-section yarns, crimped fibers, and hollow fibers may be laminated.
- the web manufactured as described above is integrated by bonding to form a nonwoven fabric.
- Webs can be joined by using an adhesive, by using low-melting-point fibers or composite fibers, by sprinkling a hot-melt binder during web formation to melt and join, or by needle punching or water jets.
- a method such as entangling can be used, and there is no particular limitation.
- a method of heating and joining at a temperature above which the intersections of the fibers can be melted and bonded. is preferred.
- various heating methods such as a hot air circulation type, a hot air penetration type, an infrared heater type, a method of blowing hot air on both sides of the nonwoven fabric, and a method of introducing into a heated gas can be used. Heating with hot air is preferred, and the hot air penetration type is particularly preferred, from the viewpoint that more fiber bonding points are obtained at the intersections of the fibers, and as a result, the breaking strength of the nonwoven fabric increases.
- the time for heat treatment was short, and the temperature and wind speed during bonding were set high.
- the heat treatment time is preferably 0.5 seconds or more and 10 seconds or less, more preferably 0.5 seconds or more and 5 seconds or less, and still more preferably 1 second or more and 5 seconds in order to develop strength that can be used in the manufacturing process as a sanitary material. It is below. When the heat treatment time is 10 seconds or less, the adhesion between the fibers does not become too strong, and the texture becomes good.
- the wind speed of the hot air is preferably 0.1 m/s or more and 3.0 m/s or less, more preferably 0.5 m/s or more and 3.0 m/s or less, still more preferably 1.0 m/s or more and 3.0 m/s or more. It is below. If it is 0.5 m/s or more, the heat is transmitted firmly to the inside of the nonwoven fabric, so that the fibers are sufficiently bonded to each other. If it is 3.0 m/s or less, crushing of the nonwoven fabric due to wind speed can be suppressed, and the amount of SAP retained as a base material for an SAP sheet increases.
- Joining may be performed by embossing as long as the surface structure of the nonwoven fabric is not adversely affected.
- embossing is preferably a method of passing the web through a pair of rolls that are a combination of a metal embossing roll and a metal flat roll.
- the embossed area ratio that is, the ratio of the area of the embossed portion (bonded portion) to the area of the entire nonwoven fabric, is preferably 5% or more and 30% or less, more preferably. is 5% or more and 20% or less, more preferably 6% or more and 15% or less.
- the depth of the embossing becomes easier to maintain the thickness of the nonwoven fabric, and is preferably 0.5 mm or more and 2.0 mm or less, more preferably 0.7 mm or more and 1.5 mm or less.
- the embossed shape is not particularly limited, but circular, elliptical, diamond, rectangular, and combinations thereof are preferable.
- the water permeable agent may be diluted with a solvent such as water and applied as an aqueous solution.
- a solvent such as water
- the amount of the water-permeable agent aqueous solution applied is small.
- the amount (wt%) applied to the nonwoven fabric is preferably 1.0 wt% or more and 65 wt% or less, more preferably 3.0 wt% or more and 60 wt% or less, and still more preferably 5.0 wt% or more in any of the above coating methods. It is 50 wt% or less. If the coating amount is 1.0 wt% or more, it is easy to apply uniformly. Insufficient dryness is less likely to occur.
- the pattern of the gravure roll may be, for example, a lattice shape or a pyramid shape, but a slanted pattern is preferable because the water-permeable agent is less likely to remain on the bottom of the gravure cells.
- the cell volume is preferably 5 cm 3 /m 2 or more and 40 cm 3 /m 2 or less. If the cell volume is 5 cm 3 /m 2 or more, uniform application is easy, and if it is 40 cm 3 /m 2 or less, uneven adhesion of the water-permeable agent due to insufficient drying and migration during the drying process can be easily suppressed.
- the gravure cell depth is preferably 10 ⁇ m or more and 80 ⁇ m or less, and the cell spacing is preferably 80 mesh or more and 250 mesh or less.
- the water permeable agent aqueous solution can be applied by continuously supplying the water permeable agent aqueous solution to the bath and bringing a roller rotating in the bath into contact with the nonwoven fabric.
- the coating amount of the water-permeable agent can be easily adjusted by setting the rotation speed of the kiss roll per minute.
- the water permeable agent by spraying because it can be applied efficiently and can be applied at high speeds of equipment, and it is easy to maintain the thickness of the nonwoven fabric.
- a spraying method an air spray method in which compressed air is used to spray the aqueous solution of the water-permeable agent in the form of a fine mist, or a rotor dampening method in which the aqueous solution of the water-permeable agent is sprayed into mist using the centrifugal force of rotor rotation can be used.
- the direction of spraying may be to spray only one side of the nonwoven fabric or to both sides.
- a general drying method can be used for drying after applying the water-permeable agent aqueous solution, and there is no particular limitation, and a known method using convective heat transfer, conductive heat transfer, radiant heat transfer, etc. is adopted. can.
- various drying methods can be used, such as a hot air circulation type, a hot air penetration type, an infrared heater type, a method of blowing hot air on both sides of a nonwoven fabric, a method of introducing into a heated gas, and the like.
- the width in the longitudinal direction (MD direction) (the drop width from the outlet of the pulling device to the conveyor) is 30 mm or more.
- the fall width is preferably 500 mm or less, more preferably 300 mm or less, and even more preferably 200 mm or less.
- the machine direction (the direction in which the fibers are oriented) in manufacturing the nonwoven fabric is defined as the vertical direction, and the direction perpendicular to the machine direction in the plane of the nonwoven fabric is defined as the horizontal direction.
- the temperature of the hot air is preferably 160°C or less, more preferably 150°C or less, still more preferably 140°C or less, and most preferably 130°C. It is below. If the temperature is 160° C. or lower, the fluff grade according to the Martindale method is likely to be grade 4 or lower, and sufficient water retention is likely to be imparted.
- the bonding temperature is preferably 100° C. or higher from the viewpoint of sufficiently bonding the fibers together.
- the number of crimps is preferably more than 3/2.5 cm, more preferably 5/2.5 cm or more. Adjust the pulling speed. . The reason is not limited to theory, but it is believed that the number of crimps exceeding 3/2.5 cm increases the number of fiber loops present on the surface of the nonwoven fabric, and as a result, fluff tends to stand up. .
- the SAP sheet substrate of the present disclosure includes the nonwoven fabric for sanitary materials of the present disclosure, and may optionally be combined with other nonwoven fabrics for sanitary materials.
- the base material for SAP sheets preferably consists of the nonwoven fabric for sanitary materials of the present disclosure.
- SAP superabsorbent polymer
- SAP generally means a polymer compound capable of absorbing and retaining water several hundred to about one thousand times its own weight.
- SAP include, but are not limited to, polyvinyl alcohol, polyethylene glycol, polyacrylonitrile, polyacrylic acid-based polymer compounds, and the like.
- the SAP is preferably a polyacrylic acid-based polymer compound, more preferably sodium polyacrylate.
- the SAP sheet preferably has SAP carried on a SAP sheet substrate.
- the sanitary material of the present disclosure includes the SAP sheet of the present disclosure.
- Sanitary materials include, for example, diapers, masks, body warmers, tape base fabrics, patch base fabrics, bandage base fabrics, packaging materials, wipes, medical gowns, bandages, clothing, and skin care sheets.
- the sanitary material is preferably a diaper, because the nonwoven fabric for sanitary material of the present disclosure has excellent water retention, SAP carrying ability, and liquid permeability.
- the evaluation methods for each property are as follows, and the physical properties obtained are shown in Table 1 below.
- the machine direction in the production of nonwoven fabric is called the MD direction (longitudinal direction), and the width direction perpendicular to that direction is called the CD direction (lateral direction).
- ⁇ Average fiber diameter ( ⁇ m)> Divide 1 m in the CD direction of the nonwoven fabric into 5 equal parts, collect a 1 cm square sample from the center part of each sample divided into 5 equal parts, and measure the diameter of the fiber at 20 points each with a microscope VHX-700F manufactured by Keyence Corporation for each sample. It was measured and the average value was calculated.
- ⁇ Weight (g/m 2 )> According to JIS-L1906: 2000, 5 samples of 20 cm in the MD direction ⁇ 5 cm in the CD direction are collected so that the collection positions are even in the CD direction of the nonwoven fabric, the mass is measured, and the average value is the weight per unit area. was calculated as a basis weight (g/m 2 ).
- ⁇ Ratio of length to width of variation value (MMD) of mean friction coefficient by KES method> Five samples of 200 cm ⁇ 200 cm are taken by dividing 1 m of the nonwoven fabric into 5 equal parts in the CD direction. Each sample is mounted on the measurement table of an automated surface tester (KES-FB4A) manufactured by Kato Tech Co., Ltd. On the sample, a standard friction element (10 mm square metal wire friction element) is moved 30 mm at a measurement load of 50 gf, a tension of 400 gf/20 cm, and a moving speed of 1 mm/min. Calculate the value.
- KES-FB4A automated surface tester
- Measurements were taken in the machine direction (MD direction) and the cross direction (CD direction) of five samples, and the average value of each was taken as the variation value of the average friction coefficient in the longitudinal direction and the variation value of the average friction coefficient in the transverse direction. .
- the variation value of the average friction coefficient in the vertical direction was divided by the variation value of the average friction coefficient in the horizontal direction, and the ratio of the variation value of the average friction coefficient between the vertical and horizontal directions was obtained.
- the fluff condition of the sample after rubbing was observed, and the grade was determined visually. Measurements were taken on both sides of the sample with N 5, average values were taken, and the grade of the side with more fluff (lower fluff grade) was adopted.
- the grades and evaluation criteria described in the present disclosure are described in the reverse order of the grades described in the specification of Japanese Patent Application No. 2021-080917, which is the basic application of the priority of this application. There are no changes other than the order.
- the grading and evaluation criteria of the present disclosure and the basic application correspond as follows. Grade 5 (first grade in basic application): No change. Grade 4 (grade 2 in basic application): The surface is rough. Class 3 (class 3 in basic application): There is pilling. (less than 5) Grade 2 (Grade 4 in basic application): Pilling is observed on the entire surface. (5 or more) Grade 1 (Grade 5 in basic application): There are holes and tears.
- ⁇ Amount of water permeable agent (wt%)> Weight W1 (mg) of a nonwoven fabric sample to which a water-permeable agent adhered was conditioned at a temperature and humidity of 25° C. and 40% RH for 24 hours. The weight W2 (mg) of the obtained extract was measured, and the amount C (wt%) of the water-permeable agent was obtained from the following formula. C (wt%) [W2/W1] x 100 The nonwoven fabric samples were collected from 5 locations at 30 cm intervals in the MD direction, and from 5 locations at equal intervals within the width of the nonwoven fabric in the CD direction. A total of 10 samples are taken. A total of 10 samples were measured, and the average value was taken as the amount (wt%) of the water-permeable agent.
- ⁇ Number of crimps (pieces/2.5 cm)> The non-woven fabric was divided into 5 equal parts in the CD direction, and 5 cm squares in the center of each divided sample were collected. I took it out with care. The taken-out fibers were left unloaded, the number of crimps per length of 2.5 cm was measured, and the number of crimps (number/2.5 cm) was calculated from the average value.
- ⁇ Water retention (g)> The nonwoven fabric is sampled and weighed at 150 mm in the MD direction by 150 mm in the CD direction, and the sample is fixed to the mouth of a 300 mL beaker with a rubber band. Drop 100 mL of physiological saline from 25 mm above the center of the sample at a rate of 2 mL / s, hold the sample for 5 minutes after dropping, remove the sample, measure the weight of the sample, and measure the weight of the sample. The difference from the weight of was taken as water retention (g). Incidentally, if the water retention is 0.5 g or more, the water absorption is good, and the liquid hardly leaks when used as a diaper.
- the nonwoven fabric is sampled in an area of 150 mm in the MD direction and 150 mm in the CD direction, and the weight is measured (the weight at this time is defined as weight A (mg)).
- a nonwoven fabric sample is placed between a saucer and a sieve (inner diameter 75 mm x inner height 20 mm, opening 2.36 mm), and 10 g of SAP is dropped from above the sieve. Thereafter, the sieve containing the above tray, nonwoven fabric sample, and SAP is set in a sieve shaker (MICRO VIBRO SIFTER MODEL M-2), and the volume is set to 1 and shaken for 1 minute.
- the nonwoven fabric was taken out by holding one side of the nonwoven fabric so that the SAP on the surface of the nonwoven fabric fell off, and the nonwoven fabric was taken out in a vertical direction, and the weight was immediately measured with a balance (weight at this time B (mg)).
- the supported amount of SAP (%) was calculated by the following formula.
- SAP supported amount (%) [(weight B (mg) - weight A (mg)) / weight A (mg)] ⁇ 100
- the SAP used had the following particle size distribution.
- the prepared simple SAP sheet was sampled at 125 mm square, placed on a slightly larger plastic plate, and then placed on the detection plate of LISTER manufactured by LENZING INSTRUMENTS used in the STRIKE-THROUGH method according to the EDANA standard, and 20 mL from 30 mm above. Physiological saline is added dropwise, and this is the first time. The same operation was performed every 30 minutes, and the value displayed by LISTER after the third drop was taken as the third water flow rate.
- the first component is a polypropylene (PP) resin with an MFR of 55 g/10 minutes (according to JIS-K7210, measured at a temperature of 230 ° C and a load of 2.16 kg), and an MI of 26 g/10 minutes (according to JIS-K7210, temperature 190 ° C., a load of 2.16 kg) was used as the second component, a side-by-side type spinneret was used, and the total discharge rate was 0.8 g / min.
- the extruded filaments were drawn in a draw zone using the suction of the conveyor and then passed through a diffuser and deposited onto the conveyor surface to form a web. At this time, the distance (height) between the conveyor and the diffuser was adjusted so that the width of the fibers falling in the MD direction was 50 mm.
- the obtained web was subjected to hot air for 3 seconds at a temperature of 125° C. and an air velocity of 1.2 m/s to obtain a nonwoven fabric.
- a 5 wt% aqueous solution of a water-permeable agent consisting of polyoxyethylene fatty acid glyceryl and polyether-modified silicone (this water-permeable agent is denoted as A in the table) was applied to the obtained nonwoven fabric as an aqueous solution of the water-permeable agent at a liquid temperature of 20°C.
- Coating was carried out using a kiss coater while adjusting the embrace angle and rotation speed of a stainless steel applicator roll so that the coating amount was 10 wt %. Then, it was dried through a cylinder dryer at 125°C to obtain a nonwoven fabric.
- Example 2 A nonwoven fabric was obtained in the same manner as in Example 1, except that the distance (height) between the conveyor and the diffuser was adjusted so that the width of the fibers falling in the MD direction was 60 mm.
- Example 3 A nonwoven fabric was obtained in the same manner as in Example 1, except that the distance (height) between the conveyor and the diffuser was adjusted so that the width of the fiber falling in the MD direction was 70 mm.
- Example 4 A nonwoven fabric was obtained in the same manner as in Example 1, except that the distance (height) between the conveyor and the diffuser was adjusted so that the width of the fibers falling in the MD direction was 100 mm.
- Example 5 A nonwoven fabric was obtained in the same manner as in Example 1, except that the drop width of the fibers in the MD direction was 80 mm and the bonding temperature was 110°C.
- Example 6 A nonwoven fabric was obtained in the same manner as in Example 5, except that the bonding temperature was 120°C.
- Example 7 A nonwoven fabric was obtained in the same manner as in Example 5, except that the bonding temperature was 125°C.
- Example 8 A nonwoven fabric was obtained in the same manner as in Example 5, except that the bonding temperature was 130°C.
- Example 9 A nonwoven fabric was obtained in the same manner as in Example 5, except that the bonding temperature was 140°C.
- Example 10 In the coating of the water-permeable agent, a 5 wt% aqueous solution of the water-permeable agent is adjusted to a liquid temperature of 20 ° C by the rotor dampening method, applied so that the coating amount becomes 10 wt %, and dried by passing through a cylinder dryer at 120 ° C. A nonwoven fabric was obtained in the same manner as in Example 7, except that it was wound up.
- Example 11 A non-woven fabric was obtained in the same manner as in Example 7 except that the water-permeable agent was a mixture of polyoxyalkylene alkyl ether and polyether-modified silicone (this water-permeable agent is denoted by B in the table).
- the water-permeable agent was a mixture of polyoxyalkylene alkyl ether and polyether-modified silicone (this water-permeable agent is denoted by B in the table).
- Example 12 A nonwoven fabric was obtained in the same manner as in Example 7 except that the water-permeable agent was a mixture of polyoxyethylene fatty acid glyceryl, alkyl phosphate, and lauryl diethanolamine (this water-permeable agent is denoted as C in the table).
- the water-permeable agent was a mixture of polyoxyethylene fatty acid glyceryl, alkyl phosphate, and lauryl diethanolamine (this water-permeable agent is denoted as C in the table).
- Example 13 A nonwoven fabric was obtained in the same manner as in Example 7, except that the drawing speed was adjusted so that the number of crimps was 23/2.5 cm.
- Example 14 A nonwoven fabric was obtained in the same manner as in Example 7, except that the drawing speed was adjusted so that the number of crimps was 28/2.5 cm.
- Example 15 A polyethylene terephthalate (PET) resin having a solution viscosity ⁇ sp /c of 0.75 is used as the first component, a high-density polyethylene (PE) resin similar to that of Example 1 is used as the second component, and a side-by-side spinneret is used,
- PET polyethylene terephthalate
- PE high-density polyethylene
- the extruded filaments were drawn in a draw zone using the suction of the conveyor and then passed through a diffuser and deposited onto the conveyor surface to form a web.
- the distance (height) between the conveyor and the diffuser was adjusted so that the width of the fibers falling in the MD direction was 80 mm.
- the obtained web was exposed to hot air for 3 seconds at a temperature of 135° C. and a wind speed of 1.2 m/s to obtain a nonwoven fabric.
- a 5 wt% aqueous solution of a water-permeable agent composed of sorbitan fatty acid ester and sodium dioctylsulfosuccinate (this water-permeable agent is denoted as D in the table) was applied to the obtained nonwoven fabric as an aqueous solution of the water-permeable agent so that the liquid temperature reached 20°C. and coated with a kiss coater while adjusting the embrace angle and rotation speed of a stainless steel applicator roll so that the coating amount was 10 wt %. Then, it was dried through a cylinder dryer at 125°C to obtain a nonwoven fabric.
- a water-permeable agent composed of sorbitan fatty acid ester and sodium dioctylsulfosuccinate
- Example 16 A sheath -core composite fiber having a fiber length of 38 mm (fiber diameter: 2 0.5 dtex) and made into a web by the carding method. After applying hot air to the web at 135 ° C. and a wind speed of 1.2 m / s for 5 seconds to heat-seal the fibers to obtain a nonwoven fabric, the draw ratio of winding is adjusted so that the nonwoven fabric is stretched in the MD direction. After adjustment, a non-woven fabric was obtained.
- Example 1 A nonwoven fabric was obtained in the same manner as in Example 7, except that the drawing speed was adjusted so that the number of crimps was 32/2.5 cm.
- Example 2 A nonwoven fabric was obtained in the same manner as in Example 7, except that the distance (height) between the conveyor and the diffuser was adjusted so that the width of the fibers falling in the MD direction was 40 mm.
- Example 3 A nonwoven fabric was obtained in the same manner as in Example 7, except that the drawing speed was adjusted so that the number of crimps was 3/2.5 cm, and the bonding temperature was 145°C.
- the nonwoven fabric for sanitary materials of the present disclosure has excellent water retention, SAP supportability, and liquid permeability, so it can be suitably used as a base material for SAP sheets.
- the nonwoven fabric for sanitary materials of the present disclosure can also be used as constituent members for diapers such as top sheets and second sheets.
- nonwoven fabrics for sanitary materials of the present disclosure are, for example, masks, body warmers, tape base fabrics, medicinal patch fabrics, first aid fabrics, packaging materials, wipe products, medical gowns, bandages, clothing, skin care sheets, etc. can also be used for
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Abstract
Description
[1]KES法による平均摩擦係数の変動値(MMD)の縦横の比(縦/横)が0.5以上であり、マーチンデール法による毛羽等級が4級以下である、衛生材料用不織布。
[2]マーチンデール法による毛羽等級が3級以下である、項目[1]に記載の衛生材料用不織布。
[3]KES法による平均摩擦係数の変動値(MMD)の縦横の比(縦/横)が0.5以上である衛生材料用不織布であって、マーチンデール法による摩擦試験で、摩擦子として前記衛生材料用不織布と同一の不織布を用い、荷重9kPa、摩擦回数16回で摩擦試験を行ったときに、表面の荒れ、ピリング、穴、及び破れのいずれか1つ以上が生じる、衛生材料用不織布。
[4]マーチンデール法による摩擦試験で、摩擦子として前記衛生材料用不織布と同一の不織布を用い、荷重9kPa、摩擦回数16回で摩擦試験を行ったときに、ピリング、穴、及び破れのいずれか1つ以上が生じる、項目[3]に記載の衛生材料用不織布。
[5]目付が5g/m2以上80g/m2以下である、項目[1]~[4]のいずれかに記載の衛生材料不織布。
[6]繊維長が50mm以上の繊維で構成されている、項目[1]~[5]のいずれかに記載の衛生材料用不織布。
[7]スパンボンド不織布である、項目[1]~[6]のいずれかに記載の衛生材料用不織布。
[8]透水剤を含有する、項目[1]~[7]のいずれかに記載の衛生材料用不織布。
[9]捲縮数が3個/2.5cm以上45個/2.5cm以下の繊維を含む、項目[1]~[8]のいずれかに記載の衛生材料用不織布。
[10]ポリオレフィン系樹脂を含む、項目[1]~[8]のいずれかに記載の衛生材料用不織布。
[11]項目[1]~[10]のいずれかに記載の衛生材料用不織布を含む、SAPシート用基材。
[12]前記衛生材料用不織布が、マーチンデール法による毛羽等級が3級以下であり、スパンボンド不織布であり、ポリオレフィン系樹脂を含む、項目[11]に記載のSAPシート用基材。
[13]項目[11]又は[12]に記載のSAPシート用基材と、SAPとを含む、SAPシート。
[14]項目[13]に記載のSAPシートを含む、衛生材料。
本開示の衛生材料用不織布(以下、単に「不織布」ともいう。)は、KES(KAWABATA EVALUATION SYSTEM)法により測定される平均摩擦係数の変動値(MMD)の縦横の比が0.5以上である。本開示の衛生材料用不織布は、マーチンデール法による毛羽等級が4級以下であるか、あるいは、マーチンデール法による摩擦試験で、摩擦子として前記衛生材料用不織布と同一の不織布を用い、荷重9kPa、摩擦回数16回で摩擦試験を行ったときに、表面の荒れ、ピリング、穴、及び破れのいずれか1つ以上が生じることを特徴とする。
不織布は、強度、生産性の観点から、スパンボンド法により製造されることが好ましい。以下、スパンボンド法による製造方法の詳細を説明するが、本開示の不織布は、スパンボンド法により製造される不織布に限定されない。
本開示のSAPシート用基材は、本開示の衛生材料用不織布を含み、任意に、他の衛生材料用不織布と組み合わせても良い。SAPシート用基材は、好ましくは本開示の衛生材料用不織布からなる。
不織布のCD方向1mを5等分して、5等分した各サンプル中央部分の1cm角のサンプルを採取し、それぞれのサンプルについてキーエンス社製マイクロスコープVHX-700Fで繊維の直径を各20点ずつ測定し、その平均値算出した。
JIS-L1906:2000に準じ、MD方向20cm×CD方向5cmのサンプルを不織布のCD方向に採取位置が均等になるように5枚採取して質量を測定し、その平均値を単位面積あたりの重量に換算して目付(g/m2)として求めた。
不織布のCD方向1mを5等分して200cm×200cmのサンプルを5枚採取する。それぞれのサンプルについて、カトーテック(株)社自動化表面試験機(KES-FB4A)の測定台にサンプルを装着する。サンプル上で、測定荷重50gf、張力400gf/20cm、移動速度1mm/minで摩擦感標準摩擦子(10mm角金属ワイヤー摩擦子)を30mm移動させ、中心部の距離20mmのデータから平均摩擦係数の変動値を算出する。測定は5枚のサンプルの縦方向(MD方向)と横方向(CD方向)とで行い、それぞれの平均値を縦方向の平均摩擦係数の変動値及び横方向の平均摩擦係数の変動値とした。縦方向の平均摩擦係数の変動値を横方向の平均摩擦係数の変動値で除し、平均摩擦係数の変動値の縦横の比とした。
グロッツ・ベッケルト社製マーチンデール摩耗・ピリング試験機を用い、マーチンデール法(WSP20.5(05))に準拠して(ただし、不織布サンプルをフェルトではなく直径155mmのポリウレタンフォーム(型番HEA786-255、グロッツ・ベッケルト・ジャパン社より購入)の上に載せ、また、摩擦子には、サンプルと同一の不織布が摩擦面となるように、直径38mmのポリウレタンフォーム(同上)を摩擦子と不織布との間に挟んで、不織布を取り付けた。)、荷重9kPa、摩擦回数16回でサンプルを摩擦した。摩擦後のサンプルの毛羽の状態を観察し、目視で等級を判定した。測定は、サンプルの両面に対してそれぞれN=5で行い、平均値をとり、より毛羽が多い(毛羽等級が小さい)方の面の等級を採用した。なお、本開示に記載の等級及び評価基準は、本出願の優先権の基礎出願である日本特許出願第2021-080917号の明細書に記載の等級の順序とは逆順に記載されているが、順序以外に変更はない。本開示と基礎出願の等級及び評価基準は、以下のように対応する。
5級(基礎出願における1級):変化なし。
4級(基礎出願における2級):表面が荒れている。
3級(基礎出願における3級):ピリングがある。(5個未満)
2級(基礎出願における4級):全面にピリングが認められる。(5個以上)
1級(基礎出願における5級):穴や破れがある。
25℃×40%RHの温湿度で24時間調湿した透水剤が付着した不織布サンプルの重量W1(mg)、および、この不織布サンプルからメタノールを用いて、迅速抽出装置(インテック社製)によって抽出した抽出物の重量W2(mg)を測定し、透水剤の量C(wt%)を下記の式より求めた。
C(wt%)=[W2/W1]×100
尚、不織布サンプルの採取はMD方向に30cm間隔で5ヶ所、CD方向に不織布の巾内で等間隔に5ヶ所から、切取り巾が5cm~10cm範囲で不織布サンプルが約2gとなるような長さで切取り、合計10枚のサンプルを採取する。上記計10個のサンプルについて測定を行ない、それらの平均値を透水剤の量(wt%)とした。
不織布をCD方向に5等分し、5等分したサンプルの中央5cm角を採取し、それぞれのサンプルについて、実体顕微鏡で観察しながらピンセット、ハサミを用いて繊維5本を糸構造が変形しない様に注意して取り出した。取り出した繊維を荷重がかからない状態にしておき、長さ2.5cmあたりの捲縮数を測定し、その平均値から捲縮数(個/2.5cm)を算出した。
MD方向150mm×CD方向150mmに不織布をサンプリング及び重量測定し、該サンプルを輪ゴムで300mLビーカーの口に固定する。サンプルの中央部に対し、25mm上方から100mLの生理食塩水を速度2mL/sの速度で滴下し、滴下後5分間保持した後にサンプルの固定を外してサンプルの重量を測定し、予め測定したサンプルの重量との差を保水性(g)とした。尚、保水性が0.5g以上であれば吸水性が良好であり、おむつとして使用した時に液が漏れにくい。
不織布をMD方向150mm×CD方向150mmにサンプリングし、重量を測定する(このときの重量を重量A(mg)とする)。受け皿とふるい(内径75mm×内高20mm、目開き2.36mm)の間に不織布サンプルを置き、ふるいの上から10gのSAPを落とす。その後、上記受け皿、不織布サンプル、SAPが入ったふるいを、ふるい振とう機(MICRO VIBRO SIFTER MODEL M-2)にセットし、ボリュームを1にして、1分間振とうさせる。振とう後、不織布表面のSAPが落ちる様に不織布の一辺を持ち不織布が鉛直方向になる様にして取り出し、すぐに天秤で重量を測定した(このときの重量B(mg)とする)。SAP担持量(%)は以下の式により計算した。
SAP担持量(%)=[(重量B(mg)-重量A(mg))/重量A(mg)]×100
尚、SAPは、下記の粒子径分布を有するものを使用した。
0μm超200μm以下・・・1%
200μm超400μm以下・・・5%
400μm超600μm以下・・・24%
600μm超800μm以下・・・35%
800μm超1000μm以下・・・25%
1000μm超1200μm以下・・・10%
不織布をMD方向150mm×CD方向150mmになる様に2枚サンプリングし、1枚の上から1g/m2となる様にスプレータイプのホットメルトガンで不織布全面にホットメルトを均一に塗工した後、SAP5gを均一に振りかける。SAPを振りかけた後、もう1枚の不織布を重ね合わせ、不織布/SAP/不織布の3層構造の簡易SAPシートを作製する。作製した簡易SAPシートを125mm角でサンプリングし、一回り大きいプラスチック板に載せたのち、EDANA規格によるSTRIKE-THROUGH法で使用するLENZING INSTRUMENTS社製LISTERの検知プレートを上に乗せ、30mm上から20mLの生理食塩水を滴下し、これを1回目とする。30分おきに同じ操作を行い、3回目の滴下後、LISTERが表示する値を3回目通水速度とした。
JIS-L1913:2010に準じ、MD方向30cm×CD方向5cmのサンプルを不織布のCD方向にサンプル採取位置が均等になる様にして5枚採取して、引張強度を測定し、5枚の測定結果の平均値をMD引張強度とした。
[実施例1]
MFRが55g/10分(JIS-K7210に準じ、温度230℃、荷重2.16kgで測定)のポリプロピレン(PP)樹脂を第1成分とし、MIが26g/10分(JIS-K7210に準じ、温度190℃、荷重2.16kgで測定)の高密度ポリエチレン(HDPE)樹脂を第2成分とし、サイドバイサイド型の紡糸口金を用い、全吐出量を0.8g/分・hоleとして、第1成分と第2成分の比がPP/PE=3/2となるように紡糸温度220℃でフィラメントを押し出した。押し出されたフィラメントを、コンベアの吸引力を利用して牽引ゾーン内で延伸させた後、ディフューザーを通しコンベア面に堆積させて、ウェブを形成した。このとき、繊維のMD方向の落下巾が50mmになる様に、コンベアとディフューザーの距離(高さ)を調整した。得られたウェブは125℃、風速1.2m/sの条件で3秒間、熱風を当て不織布を得た。
繊維のMD方向の落下巾が60mmになる様に、コンベアとディフューザーの距離(高さ)を調整した以外は実施例1と同様の方法で調整し、不織布を得た。
繊維のMD方向の落下巾が70mmになる様に、コンベアとディフューザーの距離(高さ)を調整した以外は実施例1と同様の方法で調整し、不織布を得た。
繊維のMD方向の落下巾が100mmになる様に、コンベアとディフューザーの距離(高さ)を調整した以外は実施例1と同様の方法で調整し、不織布を得た。
繊維のMD方向の落下巾が80mm、ボンディング温度を110℃とした以外は実施例1と同様の方法で不織布を得た。
ボンディング温度を120℃とした以外は実施例5と同様の方法で不織布を得た。
ボンディング温度を125℃とした以外は実施例5と同様の方法で不織布を得た。
ボンディング温度を130℃とした以外は実施例5と同様の方法で不織布を得た。
ボンディング温度を140℃とした以外は実施例5と同様の方法で不織布を得た。
透水剤の塗工において、ローターダンプニング方式で透水剤の5wt%水溶液を、液温20℃に調整し、塗布量が10wt%となるように塗布し、120℃のシリンダードライヤーに通して乾燥させ巻き取った以外は実施例7と同様の方法で不織布を得た。
透水剤をポリオキシアルキレンアルキルエーテル、ポリエーテル変性シリコーンの混合物(この透水剤を表中ではBと表記する)にした以外は、実施例7と同様の方法で不織布を得た。
透水剤をポリオキシエチレン脂肪酸グリセリルとアルキルリン酸エステル、ラウリルジエタノールアミンとの混合物(この透水剤を表中ではCと表記する)にした以外は、実施例7と同様の方法で不織布を得た。
捲縮数を23個/2.5cmになる様に牽引速度を調整した以外は実施例7と同様の方法で不織布を得た。
捲縮数を28個/2.5cmになる様に牽引速度を調整した以外は実施例7と同様の方法で不織布を得た。
溶液粘度ηsp/cが0.75のポリエチレンテレフタレート(PET)樹脂を第1成分とし、実施例1と同様の高密度ポリエチレン(PE)樹脂を第2成分とし、サイドバイサイド型の紡糸口金を用い、全吐出量を0.8g/分・hоleとして、第1成分と第2成分の比がPPPET/PE=1/1となるように紡糸温度295℃でフィラメントを押し出した。押し出されたフィラメントを、コンベアの吸引力を利用して牽引ゾーン内で延伸させた後、ディフューザーを通しコンベア面に堆積させて、ウェブを形成した。このとき、繊維のMD方向の落下巾が80mmになる様に、コンベアとディフューザーの距離(高さ)を調整した。得られたウェブは135℃、風速1.2m/sの条件で3秒間、熱風を当て不織布を得た。
溶液粘度ηsp/cが0.75のポリエチレンテレフタレート(PET)を芯成分、実施例1と同様の高密度ポリエチレン(PE)を鞘成分とする、繊維長38mmの鞘芯複合繊維(繊維径2.5dtex)を用い、カーディング法でウェブとした。前記ウェブを135℃、風速1.2m/sの条件で5秒間、熱風を当て繊維同士を熱融着させ不織布を得た後、不織布がMD方向に延伸されるように巻き取りのドロー比を調整して、不織布を得た。
捲縮数を32個/2.5cmになる様に牽引速度を調整した以外は実施例7と同様の方法で不織布を得た。
繊維のMD方向の落下巾が40mmになる様に、コンベアとディフューザーの距離(高さ)を調整した以外は実施例7と同様の方法で不織布を得た。
捲縮数を3個/2.5cmになる様に牽引速度を調整し、ボンディング温度を145℃とした以外は実施例7と同様の方法で不織布を得た。
Claims (14)
- KES法による平均摩擦係数の変動値(MMD)の縦横の比(縦/横)が0.5以上であり、マーチンデール法による毛羽等級が4級以下である、衛生材料用不織布。
- マーチンデール法による毛羽等級が3級以下である、請求項1に記載の衛生材料用不織布。
- KES法による平均摩擦係数の変動値(MMD)の縦横の比(縦/横)が0.5以上である衛生材料用不織布であって、マーチンデール法による摩擦試験で、摩擦子として前記衛生材料用不織布と同一の不織布を用い、荷重9kPa、摩擦回数16回で摩擦試験を行ったときに、表面の荒れ、ピリング、穴、及び破れのいずれか1つ以上が生じる、衛生材料用不織布。
- マーチンデール法による摩擦試験で、摩擦子として前記衛生材料用不織布と同一の不織布を用い、荷重9kPa、摩擦回数16回で摩擦試験を行ったときに、ピリング、穴、及び破れのいずれか1つ以上が生じる、請求項3に記載の衛生材料用不織布。
- 目付が5g/m2以上80g/m2以下である、請求項1~4のいずれか1項に記載の衛生材料不織布。
- 繊維長が50mm以上の繊維で構成されている、請求項1~4のいずれか1項に記載の衛生材料用不織布。
- スパンボンド不織布である、請求項1~4のいずれか1項に記載の衛生材料用不織布。
- 透水剤を含有する、請求項1~4のいずれか1項に記載の衛生材料用不織布。
- 捲縮数が3個/2.5cm以上45個/2.5cm以下の繊維を含む、請求項1~4のいずれか1項に記載の衛生材料用不織布。
- ポリオレフィン系樹脂を含む、請求項1~4のいずれか1項に記載の衛生材料用不織布。
- 請求項1~4のいずれか1項に記載の衛生材料用不織布を含む、SAPシート用基材。
- 前記衛生材料用不織布が、マーチンデール法による毛羽等級が3級以下であり、スパンボンド不織布であり、ポリオレフィン系樹脂を含む、請求項11に記載のSAPシート用基材。
- 請求項11に記載のSAPシート用基材と、SAPとを含む、SAPシート。
- 請求項13に記載のSAPシートを含む、衛生材料。
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JP2005211135A (ja) * | 2004-01-27 | 2005-08-11 | Oji Nepia Kk | 吸収性物品 |
JP2013133579A (ja) * | 2011-12-27 | 2013-07-08 | Asahi Kasei Fibers Corp | 不織布積層体 |
WO2017145999A1 (ja) * | 2016-02-22 | 2017-08-31 | 旭化成株式会社 | 親水性嵩高不織布 |
WO2017145993A1 (ja) * | 2016-02-22 | 2017-08-31 | 旭化成株式会社 | 肌触り感に優れた長繊維不織布 |
JP2017222971A (ja) * | 2016-06-14 | 2017-12-21 | 王子ホールディングス株式会社 | 不織布および吸収性物品 |
US20180256772A1 (en) * | 2017-03-09 | 2018-09-13 | The Procter & Gamble Company | Absorbent core wrap with a low basis weight nonwoven in the bottom layer |
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JP2005211135A (ja) * | 2004-01-27 | 2005-08-11 | Oji Nepia Kk | 吸収性物品 |
JP2013133579A (ja) * | 2011-12-27 | 2013-07-08 | Asahi Kasei Fibers Corp | 不織布積層体 |
WO2017145999A1 (ja) * | 2016-02-22 | 2017-08-31 | 旭化成株式会社 | 親水性嵩高不織布 |
WO2017145993A1 (ja) * | 2016-02-22 | 2017-08-31 | 旭化成株式会社 | 肌触り感に優れた長繊維不織布 |
JP2017222971A (ja) * | 2016-06-14 | 2017-12-21 | 王子ホールディングス株式会社 | 不織布および吸収性物品 |
US20180256772A1 (en) * | 2017-03-09 | 2018-09-13 | The Procter & Gamble Company | Absorbent core wrap with a low basis weight nonwoven in the bottom layer |
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