WO2023195484A1 - リサイクル容易な吸収性物品、並びに再生原料、繊維及び繊維製品の製造方法 - Google Patents

リサイクル容易な吸収性物品、並びに再生原料、繊維及び繊維製品の製造方法 Download PDF

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Publication number
WO2023195484A1
WO2023195484A1 PCT/JP2023/014079 JP2023014079W WO2023195484A1 WO 2023195484 A1 WO2023195484 A1 WO 2023195484A1 JP 2023014079 W JP2023014079 W JP 2023014079W WO 2023195484 A1 WO2023195484 A1 WO 2023195484A1
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WO
WIPO (PCT)
Prior art keywords
absorbent article
melt
raw materials
exterior part
kneading
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2023/014079
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English (en)
French (fr)
Japanese (ja)
Inventor
祥吾 池田
圭一 豊田
孝正 森
凌平 人見
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Asahi Kasei Corp
Asahi Chemical Industry Co Ltd
Original Assignee
Asahi Kasei Corp
Asahi Chemical Industry Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Asahi Kasei Corp, Asahi Chemical Industry Co Ltd filed Critical Asahi Kasei Corp
Priority to JP2024514290A priority Critical patent/JPWO2023195484A1/ja
Priority to EP23784768.6A priority patent/EP4506401A4/en
Priority to CN202380031259.XA priority patent/CN119031896A/zh
Publication of WO2023195484A1 publication Critical patent/WO2023195484A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/0026—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers of the pads
    • A61F13/514—Backsheet, i.e. the impermeable cover or layer furthest from the skin
    • A61F13/51401—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by the material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J11/00—Recovery or working-up of waste materials
    • C08J11/04—Recovery or working-up of waste materials of polymers
    • C08J11/06—Recovery or working-up of waste materials of polymers without chemical reactions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/48—Wearing apparel
    • B29L2031/4871—Underwear
    • B29L2031/4878—Diapers, napkins
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2300/00—Characterised by the use of unspecified polymers
    • C08J2300/30—Polymeric waste or recycled polymer

Definitions

  • the present invention relates to easily recyclable absorbent articles, recycled raw materials, and methods for producing fibers and textile products.
  • Patent Document 1 describes a method for efficiently producing recycled pulp from used sanitary products that can be reused as sanitary products and has ash and antibacterial properties that meet sanitary product standards. It includes an ozonation process in which fibers are immersed in an ozone-containing aqueous solution to decompose superabsorbent polymers in used sanitary products or attached to pulp fibers, either before, simultaneously with, or A method is disclosed, characterized in that, after the treatment step, the used sanitary products or pulp fibers are treated with a cationic antimicrobial agent.
  • Patent Document 2 states that when manufacturing recycled products from the components of used absorbent articles, the components are separated and collected according to their characteristics, and reused according to their characteristics to manufacture recycled products.
  • the method includes a material separation step in which a plurality of used absorbent articles are separated into at least a plurality of films and an absorbent material, and a plurality of separated films are recycled into a plurality of types depending on the filler content.
  • a method comprising: a film sorting step of sorting into recyclable films; and a pellet forming step of forming a plurality of types of recycled resin pellets according to filler content using the separated plurality of types of recyclable films.
  • Absorbent articles generally consist of an interior material that includes a top sheet and an absorbent core, and an exterior material that includes a back sheet and gathers, and the mass of the exterior portion is approximately 30% of the total mass of the absorbent article. It is desirable that the exterior part be recycled as it occupies a large proportion.
  • Patent Document 1 only discloses a method of recovering heat by incinerating the exterior part as solid fuel (RPF), and does not disclose a technique for recycling the exterior part.
  • Patent Document 2 discloses a method of separating and recycling only the film that is part of the exterior part of the constituent members of the absorbent material, but a technique for recycling the entire exterior part without separating it. is not disclosed.
  • RPF solid fuel
  • Patent Document 2 discloses a method of separating and recycling only the film that is part of the exterior part of the constituent members of the absorbent material, but a technique for recycling the entire exterior part without separating it. is not disclosed.
  • absorbent article whose entire exterior can be easily recycled or a method for recycling the entire exterior.
  • the problems to be solved by the present invention are an absorbent article whose entire exterior can be easily recycled, a method for producing recycled raw materials or fibers from the absorbent article, and a method for producing recycled raw materials or fibers from the fibers.
  • the purpose is to provide a method for manufacturing a product.
  • the present inventors unexpectedly found that the above problem can be solved by including all the main members included in the exterior part of an absorbent article containing thermoplastic resin, and have completed the present invention. It is.
  • the present invention is as follows.
  • An interior section including a top sheet and an absorbent body; an exterior part that constitutes a part other than the interior part and includes a back sheet and gathers;
  • An absorbent article consisting of the back sheet includes a sheet material containing a thermoplastic resin, and
  • the thermoplastic elastic thread has an outflow start temperature of 160°C or more and 220°C or less.
  • the exterior part undergoes the following steps: Melt and knead the exterior part to obtain pellets; Leave the pellet in a capillary rheometer furnace set at 230°C for 30 minutes; Measure the melt viscosity at a shear rate of 1857/sec while maintaining the temperature at 230°C; Calculate the coefficient of variation of melt viscosity for any 3 minutes from 8 minutes after the start of measurement to the end of measurement;
  • the easily recyclable absorbent article according to any one of [1] to [5], wherein the coefficient of variation of the melt viscosity obtained by the method is 0.5 or less.
  • the exterior part is 200 to 220 when the pellets obtained by melt-kneading the exterior part are measured with a flow tester under the conditions of an extrusion load of 49 N, a starting temperature of 120 °C, and a temperature increase of 3 °C/min.
  • the value obtained by dividing the maximum value of melt viscosity at 200 to 220 °C by the maximum value of melt viscosity at 200 to 220 °C when pellets obtained by melt-kneading only the back sheet of the exterior part are measured in the same manner. , 5.0 or less, the easily recyclable absorbent article according to any one of [1] to [6] above.
  • a method for producing fibers comprising a step of fiberizing the recycled raw material produced by the production method described in any one of [8] to [13] above.
  • a method for producing a textile product comprising the step of producing a textile product using the fiber produced by the production method described in [14] above.
  • a method for producing fibers including: [17] The manufacturing method according to [16] above, wherein in the step (B), a virgin raw material is further added. [18] The production method according to [17], wherein in the step (B), 1 to 95% by mass of virgin raw material is added to the recycled raw material.
  • an absorbent article whose entire exterior can be easily recycled, a method for producing recycled raw materials or fibers from the absorbent article, and a method for producing textile products from the fibers.
  • thermoplastic means that it has the reversible property of being able to melt by heating below the decomposition temperature, exhibiting plastic flow while in a molten state, and solidifying upon cooling. do.
  • recycling refers to the effective use of products that are no longer needed in daily life or items obtained as a by-product of industrial activities, by reusing them as resources, or by collecting and recycling them. refers to material recycling or chemical recycling. For example, recycled raw materials can be obtained from used sanitary materials or sanitary materials whose quality was rejected during manufacturing.
  • One embodiment of the present invention is an absorbent article comprising an interior portion including a top sheet and an absorbent body, and an exterior portion that constitutes an area other than the interior portion and includes a back sheet and gathers, wherein the back sheet is , an easily recyclable absorbent article (hereinafter also simply referred to as an "absorbent article") comprising a sheet material containing a thermoplastic resin, and the gathers comprising a thermoplastic elastic yarn.
  • the absorbent article of this embodiment is mainly used for absorbing and retaining body fluids excreted from the body, such as urine, menstrual blood, and vaginal discharge.
  • Absorbent articles include, but are not limited to, disposable diapers, sanitary napkins, incontinence pads, panty liners, etc., and broadly include articles used to absorb fluids expelled from the human body. do.
  • the interior part is a part that constitutes the wearer's side of the absorbent article, and includes a top sheet and an absorbent core.
  • the interior portion may include three-dimensional gathers for the purpose of preventing leakage or the like.
  • the topsheet is a liquid-permeable sheet that initially receives excreted body fluids into the absorbent article, and conventionally known sheet materials such as spunbond nonwoven fabrics are used.
  • the absorber is a part that absorbs and retains bodily fluids excreted from the body, and is arranged between the top sheet and the back sheet.
  • Conventionally known absorbents can be used, but typically include pulp fibers, superabsorbent polymers (SAP), and absorbent paper.
  • the exterior part is a part other than the interior part, and includes a back sheet and gathers.
  • the absorbent article of this embodiment is characterized in that the back sheet includes a sheet material containing a thermoplastic resin, and the gathers include thermoplastic elastic threads. That is, the absorbent article of this embodiment is characterized in that all the main members included in the exterior part contain thermoplastic resin, and due to this feature, by thermoforming the entire exterior part, recycled raw materials and fibers can be used. Since it can be molded, it becomes an absorbent article that is easy to recycle.
  • the back sheet is a liquid-impermeable sheet that prevents leakage of body fluids held in the absorbent body, and includes a sheet material containing thermoplastic resin.
  • the back sheet includes a sheet material such as a nonwoven fabric, a synthetic resin film, or a composite sheet of a nonwoven fabric and a synthetic resin film.
  • the sheet material included in the back sheet includes, for example, polyolefin resins such as polyethylene and polypropylene, polyamide resins such as 6-nylon and 6,6-nylon, and polyesters such as polyethylene talephthalate (PET) and polybutylene terethalate (PBT). It can contain a resin, etc., and preferably contains a polyolefin resin.
  • the back sheet may contain an inorganic filler, a pigment, and the like.
  • inorganic fillers included in the back sheet include calcium carbonate, calcium oxide, zeolite, amorphous aluminosilicate, clay, synthetic silica, titanium oxide, alumina, barium sulfate, aluminum sulfate, magnesium hydroxide, etc.
  • calcium carbonate, zeolite, amorphous aluminosilicate, barium sulfate, synthetic silica, and magnesium hydroxide are preferred, and calcium carbonate and barium sulfate are particularly preferred.
  • the particle size of the inorganic filler is preferably 0.1 ⁇ m or more and 30 ⁇ m or less, more preferably 1 ⁇ m or more and 20 ⁇ m or less, and even more preferably 3 ⁇ m or more and 10 ⁇ m or less.
  • the content of the inorganic filler is preferably 20% by mass or less, more preferably 15% by mass or less, and 10% by mass or less based on the mass of the exterior part. It is more preferably 5% by mass or less, and most preferably 5% by mass or less.
  • the sheet material included in the back sheet has a thermoplastic resin content of 30% by mass with respect to the mass of the exterior part. % or less, more preferably 20% by mass or less, even more preferably 10% by mass or less, most preferably 5% by mass or less.
  • Gathers are stretchable members having a large number of pleats, expand and contract in at least one direction, and are arranged around the waist and legs of the absorbent article.
  • the gathers may be formed by joining a thermoplastic elastic thread to a part of the back sheet, or may be formed by joining a thermoplastic elastic thread to a sheet material different from the back sheet, and the gathers may be formed by joining a thermoplastic elastic thread to a part of the back sheet.
  • As the sheet material a sheet material containing a thermoplastic resin similar to that of the back sheet can be used.
  • the thermoplastic elastic yarn included in the gathers is a yarn that has thermoplasticity and elasticity.
  • thermoplastic elastic yarn for example, elastic yarn containing a styrene-based, olefin-based, polyester-based, or polyurethane-based thermoplastic elastomer can be used. (Also referred to as "thermoplastic polyurethane elastic yarn.”) is preferred.
  • the outflow start temperature of the thermoplastic elastic yarn is preferably 160°C or higher, 170°C or higher, or 180°C or higher, and preferably 220°C or lower, 215°C or lower, or 210°C or lower.
  • the outflow start temperature is 160° C. or higher, the heat resistance is sufficiently high, and fiber breakage due to heat such as when applying a hot melt adhesive during the manufacturing process of the absorbent article is unlikely to occur.
  • the outflow start temperature is 220° C. or lower, it is not necessary to melt the polyurethane at an excessively high temperature during recycling, so that thermal decomposition of the polyurethane is difficult to proceed.
  • the outflow start temperature was 49N using Shimadzu Flow Tester CFT-500D (manufactured by Shimadzu Corporation) under the conditions of a sample amount of 1.5g, a die (nozzle) diameter of 0.5mm, and thickness of 1.0mm. After applying an extrusion load of shall be.
  • thermoplastic polyurethane elastic thread is not particularly limited as long as it has thermoplasticity and contains polyurethane.
  • the thermoplastic polyurethane elastic thread comprises a polyurethane that is a polymer of, for example, a polymer polyol, a diisocyanate, and an active hydrogen-containing compound that reacts with the isocyanate group.
  • the polymer polyol used in polyurethane polymerization is preferably polyalkylene ether diol, polyester diol, or polycarbonate diol, which are commonly used in polyurethane polymerization, and particularly preferably polyalkylene ether diol, with a number average molecular weight of 900 to 3. ,000 is preferred.
  • polyalkylene ether diol examples include those in which the alkylene group is a tetramethylene group, and those in which the alkylene group is a tetramethylene group and a linear or branched alkylene group having 1 to 8 carbon atoms. That is, polytetramethylene ether diol, copolymerized poly(tetramethylene/neopentylene) ether diol, and copolymerized poly(tetramethylene/2-methylbutylene) ether diol are preferred.
  • diisocyanate used in the polymerization of polyurethane for example, all aliphatic, alicyclic, and aromatic diisocyanates that dissolve or are liquid under the reaction conditions can be used. Specifically, methylene-bis (4-phenylisocyanate), methylene-bis(3-methyl-4-phenylisocyanate), 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, m- and p-xylylene diisocyanate, ⁇ , ⁇ , ⁇ ', ⁇ '-Tetramethyl-xylylene diisocyanate, m- and p-phenylene diisocyanate, 4,4'-dimethyl-1,3-xylylene diisocyanate, 1-alkylphenylene-2,4- and 2,6- Diisocyanate, 3-( ⁇ -isocyanatoethyl) phenyl isocyanate, 2,6-diethylphenylene-1,4-d
  • the active hydrogen-containing compound used in the polymerization of polyurethane for example, low molecular weight glycols can be used, and specifically, ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 2,2-propylene glycol, etc. -dimethyl-1,3-propanediol, 1,4-butanediol, 1,3-butanediol, hexamethylene glycol, diethylene glycol, 1,10-decanediol, 1,3-dimethylolcyclohexane or 1,4-dimethyl Examples include methylolcyclohexanehydrazine, and 1,4-butanediol is particularly preferred. Furthermore, alkanolamines such as monoethanolamine can also be used as active hydrogen-containing compounds.
  • the thermoplastic polyurethane elastic thread preferably does not have chemical crosslinks, and particularly preferably does not have allophanate bonds in which isocyanate groups react and urethane bonds are crosslinked.
  • the thermoplastic polyurethane elastic thread may contain additives such as stabilizers and plasticizers, if necessary.
  • stabilizer include compounds commonly used in polyurethane resins, such as ultraviolet absorbers, antioxidants, light stabilizers, gas-resistant stabilizers, and antistatic agents.
  • the exterior part may contain a hot melt adhesive for the purpose of adhering each component.
  • Hot melt adhesives typically contain a base polymer, a tackifier, and a plasticizer.
  • the base polymer include acrylic, silicone, rubber, and olefin polymers.
  • the acrylic polymers include (co)polymers of vinyl monomers (ethylene-vinyl acetate copolymers, (combination, etc.).
  • silicone-based polymers include polydimethylsiloxane polymers.
  • Examples of the rubber-based polymer include natural rubber, polyisoprene, styrene-butadiene copolymer (SBR), styrene-isoprene-styrene block copolymer (SIS), and styrene-butadiene-styrene block copolymer (SBS). ), styrene-ethylene-butadiene-styrene block copolymer (SEBS), and styrene-ethylene-propylene-styrene block copolymer (SEPS).
  • SBR styrene-butadiene copolymer
  • SIS styrene-isoprene-styrene block copolymer
  • SBS styrene-butadiene-styrene block copolymer
  • SEBS styrene-ethylene-propylene-styrene block copolymer
  • SEPS s
  • the content of the hot melt adhesive is preferably 20% by mass or less based on the mass of the exterior part, and 15% by mass or less, from the viewpoint of suppressing the stickiness of the exterior part separated from the sanitary material in the recycling process and improving handling. % or less, more preferably 10% by mass or less, and most preferably 5% by mass or less.
  • the exterior part may include members such as fastening tape and adhesive material, and may be decorated with prints or other decorations, as long as recyclability is not inhibited.
  • the exterior part is constructed using the following steps: Melt and knead the exterior part to obtain pellets; Leave the pellet in a capillary rheometer furnace set at 230°C for 30 minutes; Measure the melt viscosity at a shear rate of 1857/sec while maintaining the temperature at 230°C; Measure the coefficient of variation of melt viscosity (hereinafter also simply referred to as "coefficient of variation of melt viscosity") for any 3 minutes from 8 minutes after the start of measurement until the end of measurement;
  • the coefficient of variation of the melt viscosity obtained is preferably 3% or less, more preferably 2% or less, even more preferably 1% or less, and most preferably 0.5% or less.
  • the exterior part was made by extruding pellets obtained by melt-kneading the exterior part using a flow tester at a load of 49N and a starting temperature of 120°C.
  • the maximum value of the melt viscosity at 200 to 220 °C when measured under the condition of temperature increase of 3 °C / min is 200 to 220 when the pellet obtained by melting and kneading only the back sheet of the exterior part is measured in the same manner.
  • melt viscosity ratio value The value divided by the maximum value of melt viscosity at °C (hereinafter also referred to as "melt viscosity ratio value”) is preferably 5.0 or less, more preferably 4.0 or less, and even more preferably 3.0 or less. It is.
  • the smaller the value of the melt viscosity ratio the smaller the fluctuation rate of the strands, the better the kneading state in the extruder, and the smaller the discharge fluctuation, so the shape when pelletized is stable and the recyclability is good. Furthermore, when recycled raw materials are used and remolded into fibers, there is little variation in viscosity and the moldability is good, so recyclability is good.
  • Another embodiment of the invention comprises the following steps: (1) At least a step of melt-kneading the outer package separated from the easily recyclable absorbent article; and (2) a step of pelletizing the product of step (1);
  • This is a method for producing recycled raw materials, including:
  • the exterior part used in this embodiment may be separated from the absorbent article by any means, and there is no particular limitation on the separation method, and any conventionally known method can be used.
  • the absorbent article may be either a pre-consumer product or a post-consumer product.
  • the exterior part may be washed, dried, sterilized, cut, and/or crushed before or after separation.
  • the outer package is preferably washed, dried, sterilized, cut, and/or crushed before being melt-kneaded.
  • melt-kneading method There are no particular limitations on the melt-kneading method, but examples include a method using a screw. During melt-kneading, virgin raw materials may be added for the purpose of stabilizing the quality of the recycled raw materials finally obtained.
  • constituent members of the absorbent article other than the exterior part including thermoplastic resin
  • constituent members other than the absorbent body of the absorbent article may be added. You can also add all of them.
  • the product produced by melt-kneading is pelletized using a conventionally known method such as a strand cut method, die face cut method, flat die method, ring die method, hot cut method, or screw method, and recycled raw materials are give.
  • Another embodiment of the invention comprises the following steps: (i) separating at least the outer packaging from the easily recyclable absorbent article; (ii) at least a step of melt-kneading the exterior part separated in the step (i); and (iii) a step of pelletizing the product of the step (ii);
  • This is a method for producing recycled raw materials, including:
  • the absorbent article may be either a pre-consumer product or a post-consumer product.
  • the exterior part may be washed, dried, sterilized, cut, and/or crushed before or after separation.
  • the outer package is preferably washed, dried, sterilized, cut, and/or crushed before being melt-kneaded.
  • melt-kneading method There are no particular limitations on the melt-kneading method, but examples include a method using a screw.
  • virgin raw materials may be added for the purpose of stabilizing the quality of the recycled raw materials finally obtained.
  • constituent members of the absorbent article other than the exterior part, including thermoplastic resin may be added to the extent that recyclability is not inhibited.
  • constituent members other than the absorbent body of the absorbent article may be added. You can also add all of them.
  • the product produced by melt-kneading is pelletized using a conventionally known method such as a strand cut method, die face cut method, flat die method, ring die method, hot cut method, or screw method, and recycled raw materials are give.
  • the pelletizing step may be performed via a strand.
  • the distance between the strand discharge holes is preferably 5 mm or more, more preferably 7 mm or more, and 10 mm or more from the viewpoint of preventing fusion or adhesion of the strands due to fluctuation or disturbance of the strands. is more preferable, and 15 mm or more is most preferable.
  • the lower limit of the outer diameter of the strand is preferably 2 mm or more, more preferably 4 mm or more, even more preferably 6 mm or more, and most preferably 8 mm or more.
  • the upper limit of the outer diameter is preferably 20 mm or less, more preferably 15 mm or less, even more preferably 12 mm or less, and most preferably 10 mm or less.
  • water cooling may be performed in the pelletizing step.
  • the water temperature is preferably kept at 50°C or lower, and 40°C or lower, from the viewpoint of reducing the stickiness of the polymer discharged after melt-kneading and improving cuttability during pelletization.
  • the temperature is more preferably 30°C or lower, even more preferably 20°C or lower.
  • a water cooling tank may be provided after melting and kneading.
  • the height fluctuation of the water surface be 100 mm or less, more preferably 80 mm or less, and 50 mm or less. More preferably, the length is 30 mm or less.
  • the height from the strand discharge hole to the water surface of the water cooling tank is 500 mm or less from the viewpoint of preventing fusion and adhesion of the strands due to fluctuation or disturbance of the strands. , more preferably 300 mm or less, further preferably 100 mm or less, and most preferably 50 mm or less.
  • the moisture content of the strands immediately before cutting is preferably 20% by mass or less, more preferably 10% by mass or less, and 5% by mass or less. is more preferable, and most preferably 3% by mass or less.
  • the pellet temperature during bagging is preferably 60°C or lower, more preferably 50°C or lower, and even more preferably 40°C or lower, from the viewpoint of preventing the recycled raw material from sticking.
  • the temperature is 30°C or less, most preferably.
  • the recycled raw materials produced by the above manufacturing method are suitable for products such as automobile parts, home appliance parts, packaging films, food containers, caps, trays, containers, pallets, clothing boxes, textiles, medical equipment, daily necessities, and garbage containers. used.
  • Another embodiment of the present invention is a method for producing fibers, which includes a step of fiberizing the recycled raw material produced by the above production method.
  • Conventionally known techniques can be used for the fiberization method, and any of wet spinning, dry spinning, and melt spinning may be used.
  • Another embodiment of the present invention is a method for manufacturing textile products using the fibers manufactured by the above manufacturing method.
  • “Textile products” here refers to products containing fibers, specifically woven fabrics, knitted fabrics, non-woven fabrics, clothing, bedding products, interior products, household goods, fishing nets, ropes, outdoor products, and industrial products. Examples include materials, reinforcing materials such as plastic and concrete, and absorbent articles. When an absorbent article is manufactured by the manufacturing method of this embodiment, so-called horizontal recycling is achieved.
  • Another embodiment of the invention comprises the following steps: (A) at least a step of melt-kneading the exterior part separated from the easily recyclable absorbent article; and (B) a step of melt-spinning the product of step (A);
  • a method for producing fibers including:
  • the exterior part used in this embodiment may be separated from the absorbent article by any means, and there is no particular limitation on the separation method, and any conventionally known method can be used.
  • the absorbent article may be either a pre-consumer product or a post-consumer product.
  • the exterior part may be washed, dried, sterilized, cut, and/or crushed before or after separation.
  • the outer package is preferably washed, dried, sterilized, cut, and/or crushed before being melt-kneaded.
  • melt-kneading method examples include a method using a screw.
  • a virgin raw material may be added for the purpose of stabilizing spinning in the next spinning process, stabilizing the quality of the finally obtained fiber, etc.
  • constituent members of the absorbent article other than the exterior part, including thermoplastic resin may be added to the extent that recyclability is not inhibited.
  • constituent members other than the absorbent body of the absorbent article may be added. You can also add all of them.
  • the product produced by melt-kneading is directly melt-spun to give fibers without pelletizing.
  • the melt spinning method a conventionally known method can be used.
  • the fibers produced in this manner are suitably used as clothing, bedding goods, interior goods, household goods, fishing nets, ropes, outdoor goods, industrial materials, reinforcing materials for plastics, concrete, etc.
  • Another embodiment of the invention comprises the following steps: (a) separating at least the outer packaging from the easily recyclable absorbent article; (b) at least a step of melt-kneading the exterior part separated in the step (a); and (c) a step of melt-spinning the product of the step (b);
  • a method for producing fibers including:
  • the absorbent article may be either a pre-consumer product or a post-consumer product.
  • the exterior part may be washed, dried, sterilized, cut, and/or crushed before or after separation, and, for example, all the constituent members of the absorbent article other than the absorbent body may be added thereto.
  • the outer package is preferably washed, dried, sterilized, cut, and/or crushed before being melt-kneaded.
  • melt-kneading method There are no particular limitations on the melt-kneading method, but examples include a method using a screw. During melt-kneading, a virgin raw material may be added for the purpose of stabilizing spinning in the next spinning process, stabilizing the quality of the finally obtained fiber, etc.
  • constituent members of the absorbent article other than the exterior part including thermoplastic resin, may be added within a range that does not impede recyclability.
  • the product produced by melt-kneading is directly melt-spun to give fibers without pelletizing.
  • the melt spinning method a conventionally known method can be used.
  • the fibers produced in this manner are suitably used as clothing, bedding goods, interior goods, household goods, fishing nets, ropes, outdoor goods, industrial materials, reinforcing materials for plastics, concrete, etc.
  • the addition rate is preferably 1% by mass or more, and 10% by mass or more based on the recycled raw materials or fibers that are finally produced. More preferably at least 20% by mass, even more preferably at least 20% by mass, particularly preferably at least 30% by mass, most preferably at most 40% by mass, and preferably at most 95% by mass, more preferably at most 80% by mass, and at most 70% by mass. is more preferred, 60% by mass or less is particularly preferred, and most preferably 50% by mass or less.
  • the addition rate of the virgin raw material is 1% by mass or more, even if the shape of the separated exterior part is uneven or the bulk density is low, the weight of the virgin raw material is The material is pressed by the material, making it less likely to get caught or clogged, and has good bite.
  • the addition rate of the virgin raw material is 95% by mass or less, the difference in melt viscosity between the exterior part and the virgin raw material will be small, so torque fluctuations during melt-kneading will be suppressed, and the kneading state and discharge will be stabilized.
  • a recycled raw material or fiber with a uniform shape is obtained.
  • the separated raw materials such as the exterior part to be subjected to melt-kneading are cooled in the melt-kneading step, specifically at 60°C or lower.
  • the temperature is preferably 50°C or lower, more preferably 40°C or lower, and most preferably 30°C or lower.
  • the raw material input section of the extruder etc. is cooled.
  • the temperature of the surface of the chute section is preferably 100°C or lower, more preferably 80°C or lower, and even more preferably 60°C or lower. , 40°C or less is most preferred.
  • the hot melt adhesive contained in the separated exterior section may cause the exterior section to stick to the equipment at the raw material input section, or cause the exterior sections to overlap each other. It is easy to prevent manufacturing problems caused by sticking and hardening and not being able to bite.
  • a lubricant may be added in the melt-kneading step.
  • the lubricant can be, for example, a metal salt of a fatty acid.
  • the number of carbon atoms in the fatty acid is preferably 8 to 30, more preferably 11 to 28, and even more preferably 12 to 22.
  • Specific examples of the fatty acid include stearic acid, palmitic acid, Examples include metal salts of lauric acid, behenic acid, 12-hydroxystearic acid, and the like.
  • metals that form salts with fatty acids include alkali metals such as lithium, potassium, and sodium, and alkaline earth metals such as magnesium, calcium, and barium.
  • Metal salts of fatty acids particularly suitable as lubricants include calcium stearate.
  • the lubricant is preferably more than 0% by mass, preferably 1% by mass or less, more preferably 0.7% by mass or less, even more preferably 0.5% by mass, and most preferably 0% by mass, based on the mass of the exterior part. It may be added in an amount of .3% by mass or less.
  • the bulk density of the raw material at the time of inputting into the raw material input section is 0.1 g/cm 3 or more. It is preferably 1.0 g/cm 3 or less, more preferably 0.2 g/cm 3 or more and 0.9 g/cm 3 or less, even more preferably 0.3 g/cm 3 or more and 0.8 g/cm 3 or less, and 0.4 g/cm 3 or less. cm 3 or more and 0.7 g/cm 3 or less is most preferable.
  • the exterior part was melt-kneaded and pelletized to prepare a sample for measurement.
  • a capillary rheometer Rheograf 20 manufactured by Goettfert
  • a 0.5 mm x 5.0 mm capillary die was attached to a barrel with a barrel diameter of 9.55 mm, and the temperature inside the furnace was heated to 230°C.
  • Approximately 5 g of sample was poured into the barrel from the top of the barrel by pushing it into the barrel little by little, taking care not to introduce any air bubbles.
  • the sample was left under a load for 30 minutes, and the melt viscosity was measured at a shear rate of 1857/sec while the temperature was maintained at 230°C.
  • the measurement ended 8 minutes after the start of the measurement (the sample was discharged). Calculate the coefficient of variation of the melt viscosity for any consecutive 3 minutes until no piston remains in the barrel, or the piston is pushed to the lower limit of the barrel and the equipment is stopped. Note that the arbitrary 3 minutes is selected within a range that does not include a sudden decrease in pressure that occurs when air bubbles are trapped, a sudden increase in pressure that occurs due to foreign matter getting caught in the capillary, etc.
  • the melt viscosity ⁇ is determined by solving the following simultaneous equations (1) to (4).
  • the coefficient of variation (%) is the value obtained by calculating the standard deviation and average value of the melt viscosity for any consecutive 3 minutes, and dividing the standard deviation by the average value.
  • Q is the flow rate of the molten resin (mm 3 /s)
  • A is the piston cross-sectional area (mm 2 )
  • ⁇ is the speed of the piston (mm/s)
  • ⁇ is is the apparent shear rate (s ⁇ 1 )
  • D is the capillary inner diameter (mm)
  • ⁇ is the apparent shear stress (Pa)
  • P is the barrel bottom pressure (Pa)
  • L is , the capillary length (mm)
  • ⁇ is the melt viscosity (Pa ⁇ sec).
  • ⁇ Outflow start temperature> The elastic thread was cut to an appropriate length to prepare a sample for measurement. Using a Shimadzu flow tester CFT-500D model (manufactured by Shimadzu Corporation), an extrusion load of 49 N was applied under conditions of a sample amount of 1.5 g, a die (nozzle) diameter of 0.5 mm, and a thickness of 1.0 mm. After preheating at an initial setting temperature of 120° C. for 240 seconds, the temperature was raised at a constant rate of 3° C./min, and the plunger stroke-temperature curve drawn at that time was determined. As the temperature increases at a constant rate, the sample gradually heats up and the polymer begins to flow out. The temperature at which this polymer begins to flow out is defined as the flow start temperature. The measurement is performed three times, and the average temperature is used as the outflow starting temperature.
  • ⁇ Value of melt viscosity ratio> The exterior part and only the back sheet of the exterior part were melt-kneaded and pelletized to prepare samples for measurement, and each was subjected to the following measurements. Using a Shimadzu flow tester CFT-500D model (manufactured by Shimadzu Corporation), an extrusion load of 49 N was applied under conditions of a sample amount of 1.5 g, a die (nozzle) diameter of 0.5 mm, and a thickness of 1.0 mm.
  • the value obtained by dividing the maximum value of the melt viscosity of the pellet obtained by melt-kneading the outer part by the maximum value of the melt viscosity of the pellet obtained by melt-kneading only the back sheet of the outer part is calculated as the ratio of melt viscosity. value.
  • FIG. 1 A commercially available diaper was used as the absorbent article.
  • the outer part of the diaper is made of a thermoplastic polypropylene nonwoven fabric laminated with a thermoplastic polyethylene film as the back sheet, and the gathers are made of dry spun spandex and styrene-based hot melt adhesive. It is formed by being adhered to the back sheet.
  • the exterior part was composed of 75% by mass of polypropylene nonwoven fabric, 16% by mass of polyethylene film, 4% by mass of dry spun spandex, and 5% by mass of hot melt adhesive, based on the mass of the exterior part. . Note that the dry spun spandex had an outflow start temperature of 235° C. and did not have thermoplasticity.
  • Exterior portions were separated by hand from a plurality of the diapers to obtain approximately 1.3 kg of exterior portions.
  • the separated outer package was heat-pressed at 150° C. for 20 seconds through heat-resistant paper, cooled to room temperature, and cut into pieces of about 5 to 10 mm square with a cutter to obtain cut pieces of the outer package.
  • the cut pieces of the exterior part are melt-kneaded at 160 to 180 °C using a twin-screw extruder, extruded into a water-cooling tank in the form of a strand through three discharge holes with an inter-hole distance of 5 mm, and after water-cooling, they are put into a pelletizer. It was cut into pellets.
  • Example 1 2400 g of polytetramethylene ether diol having a number average molecular weight of 1800 and 750.75 g of 4,4'-diphenylmethane diisocyanate were reacted with stirring at 60° C. for 3 hours in a dry nitrogen atmosphere to obtain a terminal capped product with isocyanate. A polyurethane prepolymer was obtained. After mixing 9 g of Adeka's AO-60 as an antioxidant and 9 g of Adeka's LA-36 as a UV absorber, 150.95 g of 1,4-butanediol was added to the reaction solution, and the mixture was stirred for 15 minutes.
  • a polyurethane having a viscosity of 200 Pa ⁇ s (30°C) was obtained. Thereafter, it was dispensed onto a Teflon (registered trademark) tray, and the polyurethane was annealed in a hot air oven at 110° C. for 19 hours while remaining in the tray to obtain a polyurethane resin.
  • the polyurethane resin thus obtained was pulverized into a powder of approximately 3 mm using a UG-280 type pulverizer manufactured by Horai. 0.35 parts by mass of dried ethylene bisstearamide was added to the polyurethane resin powder, charged through a hopper, and melted in an extruder.
  • the twist is propagated and the focusing position, which is the distance from the spinneret to the twist propagation position, is 1400mm, and then polydimethylsiloxane and mineral oil are the main components.
  • the yarn was wound at a speed of 500 m/min to obtain a thermoplastic polyurethane elastic yarn having a single yarn fineness of 10 dtex, a total fineness of 620 dtex, and an outflow start temperature of 182°C.
  • the application rate of the treatment agent to the polyurethane elastic yarn was 2 parts by mass.
  • Pellets, which are recycled raw materials, were produced in the same manner as in Comparative Example 1, except that the dry spun spandex of the diaper used in Comparative Example 1 was replaced with the thermoplastic polyurethane elastic yarn produced as described above.
  • Example 2 Example 1 except that the amount of 4,4'-diphenylmethane diisocyanate was 1134.47 g, the amount of 1,4-butanediol was 292.47 g, and the die temperature was 230°C. In the same manner, a polyurethane elastic thread having a starting temperature of 220° C. was obtained. Pellets, which are recycled raw materials, were produced in the same manner as in Comparative Example 1, except that the dry spun spandex of the diaper used in Comparative Example 1 was replaced with the thermoplastic polyurethane elastic yarn produced as described above.
  • Example 3 A recycled raw material was prepared in the same manner as in Example 1, except that 10 parts by mass of polypropylene pellets were added as a virgin raw material to 90 parts by mass of the shredded pieces of the exterior part before melt-kneading. A pellet was made.
  • Example 4 Pellets, which are recycled raw materials, were produced in the same manner as in Example 3, except that 50 parts by mass of virgin raw materials were added to 50 parts by mass of the shredded pieces of the exterior part.
  • Example 5 Pellets, which are recycled raw materials, were produced in the same manner as in Example 3, except that 80 parts by mass of virgin raw materials were added to 20 parts by mass of the shredded pieces of the exterior part.
  • Example 6 Pellets as a recycled raw material were produced in the same manner as in Example 3, except that the distance between the discharge holes of the strand was 10 mm.
  • Example 7 Pellets, which are recycled raw materials, were produced in the same manner as in Example 6, except that the inside of the water-cooled tank was maintained at 20 to 22° C. by pouring cooling water into the water-cooled tank.
  • Example 8 Pellets, which are recycled raw materials, were prepared in the same manner as in Example 7, except that the variation in water surface height was controlled to a maximum of 15 mm by installing a screen in the water cooling tank and adjusting the positions of water entry and drainage. was created.
  • Example 9 The same as in Example 8 except that the water content of the strands was reduced to 5% by mass immediately before cutting by blowing away the water adhering to the strands with compressed air from the time they left the water cooling tank until they entered the pelletizer. Then, pellets, which are recycled raw materials, were produced.
  • Example 10 Pellets as a recycled raw material were produced in the same manner as in Example 8, except that the outer package was cut without being pressed and the bulk density of the cut pieces of the outer package was 0.3 g/cm 3 .
  • melt spinning was performed under the same conditions by a known method. Specifically, the produced pellets are melted in an extruder at 200 to 230°C, weighed and pressurized by a gear pump attached to the head, and filters are made by stacking one layer each of 50 mesh, 200 mesh, and 400 mesh wire mesh. After filtration, the solution was discharged at a die temperature of 220° C. from a 12-hole nozzle with a diameter of 0.4 mm at a discharge rate of 15 g/min.
  • the spinning pack pressure was 0.1 MPa/hour or less, there was no sudden pressure increase, and there was no yarn breakage after 5 hours of spinning, resulting in stable spinning. It was possible to spin the yarn. From this, it can be seen that in the absorbent articles of Examples 1 to 10, in which all the main constituent members of the exterior part contain thermoplastic resin, the exterior part can be easily recycled.
  • the absorbent article of the present invention can be easily recycled after disposal, it can be suitably used as an environmentally friendly absorbent article. Further, the method for producing recycled raw materials and the method for producing fibers of the present invention can be suitably used as a method for obtaining recycled raw materials and fibers from waste materials of absorbent articles.

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PCT/JP2023/014079 2022-04-06 2023-04-05 リサイクル容易な吸収性物品、並びに再生原料、繊維及び繊維製品の製造方法 Ceased WO2023195484A1 (ja)

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EP23784768.6A EP4506401A4 (en) 2022-04-06 2023-04-05 EASILY RECYCLED ABSORBENT ARTICLE AND METHOD FOR MANUFACTURING A RECYCLED RAW MATERIAL, FIBER AND FIBER PRODUCT
CN202380031259.XA CN119031896A (zh) 2022-04-06 2023-04-05 容易再循环的吸收性物品、以及再生原料、纤维和纤维制品的制造方法

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EP4714651A1 (en) * 2024-09-23 2026-03-25 Ontex BV Post-consumer recycled material in flexible packages comprising absorbent articles

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JP2000014697A (ja) * 1998-06-30 2000-01-18 Uni Charm Corp パンツ型の使い捨ておむつ
JP2014151254A (ja) * 2013-02-06 2014-08-25 Fukuoka Univ 使用済み紙おむつの再資源化方法、土壌改良材、及び、使用済み紙おむつの再資源化システム
JP2016079525A (ja) 2014-10-15 2016-05-16 ユニ・チャーム株式会社 使用済み衛生用品からリサイクルパルプを製造する方法
JP2017036405A (ja) * 2015-08-11 2017-02-16 有限会社吉岡産業 合成樹脂混合成形品及びその製造方法
JP2018171780A (ja) 2017-03-31 2018-11-08 ユニ・チャーム株式会社 リサイクル製品を製造する方法、リサイクル樹脂ペレット、及びリサイクルフィルム
JP2021020437A (ja) * 2019-07-30 2021-02-18 花王株式会社 リサイクル資源の回収方法
WO2022054811A1 (ja) * 2020-09-11 2022-03-17 旭化成株式会社 ポリウレタン弾性繊維、並びにそれを含むギャザー部材、及び衛生材料

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TWI809315B (zh) * 2019-09-24 2023-07-21 日商旭化成股份有限公司 再生聚胺酯彈性纖維、其製法、含有該再生聚胺酯彈性纖維之纖維構造物、皺褶部件、及衛生材料

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JP2000014697A (ja) * 1998-06-30 2000-01-18 Uni Charm Corp パンツ型の使い捨ておむつ
JP2014151254A (ja) * 2013-02-06 2014-08-25 Fukuoka Univ 使用済み紙おむつの再資源化方法、土壌改良材、及び、使用済み紙おむつの再資源化システム
JP2016079525A (ja) 2014-10-15 2016-05-16 ユニ・チャーム株式会社 使用済み衛生用品からリサイクルパルプを製造する方法
JP2017036405A (ja) * 2015-08-11 2017-02-16 有限会社吉岡産業 合成樹脂混合成形品及びその製造方法
JP2018171780A (ja) 2017-03-31 2018-11-08 ユニ・チャーム株式会社 リサイクル製品を製造する方法、リサイクル樹脂ペレット、及びリサイクルフィルム
JP2021020437A (ja) * 2019-07-30 2021-02-18 花王株式会社 リサイクル資源の回収方法
WO2022054811A1 (ja) * 2020-09-11 2022-03-17 旭化成株式会社 ポリウレタン弾性繊維、並びにそれを含むギャザー部材、及び衛生材料

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Publication number Priority date Publication date Assignee Title
EP4714651A1 (en) * 2024-09-23 2026-03-25 Ontex BV Post-consumer recycled material in flexible packages comprising absorbent articles

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