CN116981804A - Spun-bonded nonwoven fabric, laminated nonwoven fabric, method for producing same, and sanitary material - Google Patents
Spun-bonded nonwoven fabric, laminated nonwoven fabric, method for producing same, and sanitary material Download PDFInfo
- Publication number
- CN116981804A CN116981804A CN202280019012.1A CN202280019012A CN116981804A CN 116981804 A CN116981804 A CN 116981804A CN 202280019012 A CN202280019012 A CN 202280019012A CN 116981804 A CN116981804 A CN 116981804A
- Authority
- CN
- China
- Prior art keywords
- nonwoven fabric
- component
- spun
- fiber
- crimped
- 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.)
- Pending
Links
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- 239000002131 composite material Substances 0.000 claims abstract description 101
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- AFFLGGQVNFXPEV-UHFFFAOYSA-N 1-decene Chemical compound CCCCCCCCC=C AFFLGGQVNFXPEV-UHFFFAOYSA-N 0.000 description 4
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Classifications
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- A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
- A61F13/514—Backsheet, i.e. the impermeable cover or layer furthest from the skin
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
- A61F13/515—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 characterised by the interconnection of the topsheet and the backsheet
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
- D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
- D01F8/06—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/005—Synthetic yarns or filaments
- D04H3/007—Addition polymers
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- 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
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
- D10B2321/022—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polypropylene
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2509/00—Medical; Hygiene
- D10B2509/02—Bandages, dressings or absorbent pads
- D10B2509/026—Absorbent pads; Tampons; Laundry; Towels
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- Health & Medical Sciences (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Animal Behavior & Ethology (AREA)
- Vascular Medicine (AREA)
- Veterinary Medicine (AREA)
- Public Health (AREA)
- Epidemiology (AREA)
- Biomedical Technology (AREA)
- Heart & Thoracic Surgery (AREA)
- General Health & Medical Sciences (AREA)
- Life Sciences & Earth Sciences (AREA)
- Chemical & Material Sciences (AREA)
- General Chemical & Material Sciences (AREA)
- Dermatology (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Nonwoven Fabrics (AREA)
- Multicomponent Fibers (AREA)
- Laminated Bodies (AREA)
Abstract
In order to provide a spun-bonded nonwoven fabric and a laminated nonwoven fabric which can simultaneously realize excellent bending flexibility for use as a nonwoven fabric for sanitary materials without impairing mechanical strength, the spun-bonded nonwoven fabric of the present invention is a spun-bonded nonwoven fabric composed of a crimped composite fiber comprising a 1 st component composed mainly of a propylene-based polymer and a 2 nd component composed mainly of a propylene-based copolymer obtained by copolymerizing an alpha-olefin, wherein the 2 nd component is disposed at the innermost side of the crimp in the cross section of the crimped composite fiber, and the orientation parameter (I2) of the 2 nd component is 5.0 or more. The laminated nonwoven fabric of the present invention is formed by laminating at least one layer of elastomer with the spunbond nonwoven fabric.
Description
Technical Field
The present invention relates to a spun-bonded nonwoven fabric excellent in bending flexibility and particularly suitable for sanitary material applications, and a laminated nonwoven fabric obtained by laminating at least one elastomer layer thereon.
Background
In recent years, there has been an increasing demand for improvement in wearing comfort among sanitary materials such as disposable diapers and sanitary napkins. In particular, in members for covering the waist and the large buttocks, it is desired to conform to the shape of the body having irregularities, and thus, the nonwoven fabric member used is required to have improved flexibility in bending.
Conventionally, polypropylene spunbond nonwoven fabrics formed of linear fibers have been widely used in such locations. However, since the fibers constituting the polypropylene spunbonded nonwoven fabric do not have stretchability, the fibers are stretched between the hot-melt-bonding points when the sheet is bent, and thus the bending flexibility is insufficient.
To solve this problem, patent document 1 proposes a nonwoven fabric comprising crimped conjugate fibers of 2 propylene polymer components. In addition, patent document 2 proposes a method for producing a spunbond high-bulk nonwoven web, which comprises subjecting a nonwoven web comprising crimped multicomponent fibers formed of a polypropylene homopolymer and a copolymer of polypropylene and polyethylene to a specific pre-compaction treatment.
Patent document 3 proposes a nonwoven fabric in which a composite fiber having a phase structure of a plurality of resins having different heat shrinkage rates is formed by heat treatment to exhibit fine crimp.
Prior art literature
Patent literature
Patent document 1: japanese patent laid-open No. 2007-308868
Patent document 2: japanese patent laid-open publication No. 2018-024965
Patent document 3: japanese patent application laid-open No. 2012-012688
Disclosure of Invention
Problems to be solved by the invention
In the spunbond nonwoven fabric, when a curled structure such as a spring is formed in the fibers, the curled structure of the fibers can be gently stretched when the sheet is bent, and thus excellent bending flexibility can be obtained. Further, the finer the crimp structure of the fibers in the nonwoven fabric, that is, the smaller the interval between adjacent peaks of the crimp (Japanese: mountain), the more the elongation space of the fibers is sufficiently large, the greater the effect can be.
In the technique of patent document 1, the fiber is curled by setting the difference in melting point of 2 propylene polymer components and the ratio of the composite components within predetermined ranges. In the technique of patent document 2, a predetermined raw material is used, and a specific pre-compaction treatment is further performed, whereby the fiber is curled. However, in these techniques, the crimped structure of the fiber cannot be sufficiently thinned, and as a result, excellent bending flexibility cannot be obtained.
On the other hand, the technique of patent document 3 can obtain a fine curl because the curl presentation of the fibers is promoted by subjecting the nonwoven fabric to a heat treatment. However, since the heat treatment is indispensable for forming a desired curl pattern, uneven weight per unit area tends to be formed in the nonwoven fabric surface during the heat treatment, and the mechanical strength is deteriorated. In particular for use as sanitary material (approximately 100g/m 2 Hereinafter), the strength decrease due to the weight unevenness per unit area described above occurs more remarkably, and is not preferable. Further, the technology of patent document 3 is a polyester nonwoven fabric in essence, and therefore, the adhesion to a polypropylene spunbond nonwoven fabric widely used for sanitary materials is a major problem.
Accordingly, the present application has been made in view of the above circumstances, and an object of the present application is to provide a spun-bonded nonwoven fabric and a laminated nonwoven fabric which can realize excellent bending flexibility for use as a nonwoven fabric for sanitary materials without impairing mechanical strength.
Means for solving the problems
The inventors of the present application have conducted intensive studies to achieve the above object, and as a result, have obtained the following findings: in the crimped conjugate fiber constituting the spun-bonded nonwoven fabric, the use of specific raw materials and further the control of their molecular orientation result in the spun-bonded nonwoven fabric having excellent bending flexibility for use as a nonwoven fabric for sanitary materials without impairing mechanical strength.
The present application has been completed based on the above-described findings, and according to the present application, the following applications are provided.
The spun-bonded nonwoven fabric of the present application is a spun-bonded nonwoven fabric comprising a crimped composite fiber comprising a 1 st component comprising a propylene polymer as a main component and a 2 nd component comprising a propylene copolymer obtained by copolymerizing an alpha-olefin as a main component, wherein the 2 nd component is disposed at the innermost side of the crimp in the cross section of the crimped composite fiber, and the orientation parameter (I2) of the 2 nd component is 5.0 or more.
According to a preferred embodiment of the spunbonded nonwoven fabric of the present invention, the propylene polymer of the 1 st component is a propylene homopolymer, and the orientation parameter (I1) of the 1 st component is 6.0 or less.
According to a preferred embodiment of the spun-bonded nonwoven fabric of the present invention, the area ratio of the 2 nd component in the cross section of the crimped composite fiber is 1 to 80%.
According to a preferred embodiment of the spun-bonded nonwoven fabric of the present invention, the number of crimps of the crimped composite fibers observed on the surface of the nonwoven fabric is 50/25 mm or more.
The laminated nonwoven fabric of the present invention is formed by laminating at least one layer of an elastomer with a spunbond nonwoven fabric layer formed from the spunbond nonwoven fabric.
According to a preferred embodiment of the laminated nonwoven fabric of the present invention, the elastic layer is a layer formed of an elastic nonwoven fabric.
At least a part of the sanitary material of the present invention is composed of the spun-bonded nonwoven fabric or the laminated nonwoven fabric.
In the method for producing a spunbonded nonwoven fabric of the present invention, it is preferable that the 1 st component and the 2 nd component having a melt viscosity 1.20 times or more higher than the melt viscosity of the 1 st component are melted, a composite polymer stream is discharged from a composite spinneret and spun, and after that, the crimped composite fibers are formed by crimping the composite polymer stream from an air drawing unit to a collecting belt so that the 2 nd component is disposed at the innermost side of the crimp, and the crimped composite fibers are collected on the collecting belt.
According to a preferred embodiment of the method for producing a spunbonded nonwoven fabric of the present invention, the mass ratio of the 1 st component to the 2 nd component is 20: 80-99: 1, and the composite polymer stream is ejected.
The method for producing a laminated nonwoven fabric according to the present invention preferably includes: a step of forming a spun-bond nonwoven fabric layer by melting the 1 st component and the 2 nd component having a melt viscosity 1.20 times or more higher than the melt viscosity of the 1 st component, respectively, and discharging a composite polymer stream from a composite spinneret to spin the composite polymer stream, and then forming the crimped composite fiber by forming the crimped composite fiber while crimping the composite fiber so that the 2 nd component is disposed at the innermost side of crimping between an air drawing unit and a capturing belt, and capturing the crimped composite fiber on the capturing belt; and laminating at least one elastomer layer.
According to a preferred embodiment of the method for producing a laminated nonwoven fabric of the present invention, the elastomer layer is formed by a spunbond method.
According to a preferred embodiment of the method for producing a laminated nonwoven fabric of the present invention, the elastic layer is formed by a melt-blown method.
ADVANTAGEOUS EFFECTS OF INVENTION
According to the present invention, a spun-bonded nonwoven fabric capable of simultaneously realizing sufficient strength and excellent bending flexibility for use as a nonwoven fabric for sanitary materials, and a laminated nonwoven fabric obtained by laminating at least one elastomer layer thereon can be obtained.
Drawings
Fig. 1 is a schematic side view of a crimped composite fiber according to the present invention when the crimped composite fiber is observed by a Scanning Electron Microscope (SEM) or the like, fig. 1A is a schematic side view of a side by side composite fiber, and fig. 1B is a schematic side view of an eccentric core-sheath composite fiber.
FIG. 2 is a view for explaining a method of measuring a crimp diameter on a Scanning Electron Microscope (SEM) image obtained by observing the surface of an example of the spun-bonded nonwoven fabric according to the present invention.
Detailed Description
The spun-bonded nonwoven fabric of the present invention is a spun-bonded nonwoven fabric comprising a crimped composite fiber comprising a 1 st component comprising a propylene polymer as a main component and a 2 nd component comprising a propylene copolymer obtained by copolymerizing an alpha-olefin as a main component, wherein the 2 nd component is disposed at the innermost side of the crimp in the cross section of the crimped composite fiber, and the orientation parameter (I2) of the 2 nd component is 5.0 or more. The constituent elements will be described in detail below, but the present invention is not limited to the scope described below unless the gist thereof is exceeded.
[ propylene Polymer ]
First, the propylene-based polymer of the spunbonded nonwoven fabric of the present invention is a polymer containing propylene as a main constituent element. Examples of such propylene polymers include propylene homopolymers and copolymers of propylene as a main component and 1 or 2 or more kinds of α -olefins such as ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene, 3-methyl-1-butene, 3-methyl-1-pentene, 3-ethyl-1-pentene, 4-methyl-1-pentene, and 4-methyl-1-hexene. The term "propylene-based constituent unit component" as used herein is generally a main chain structure comprising 80 mass% or more of polypropylene in each polymer component constituting the crimped composite fiber. The propylene polymer may contain other propylene polymers and ethylene polymers. The propylene polymer may contain various additives such as inorganic substances such as titanium oxide, silica, and barium oxide, colorants such as carbon black, dyes, and pigments, flame retardants, fluorescent brighteners, antioxidants, and ultraviolet absorbers.
In the spun-bonded nonwoven fabric of the present invention, the crimped conjugate fiber containing the propylene polymer as the main component can improve the adhesion to other members when used as a sanitary material.
In the present invention, the "main component" is a component that occupies 80% by mass or more of each polymer component constituting the crimped composite fiber of each component.
In the propylene polymer according to the present invention, at least a part of the propylene polymer preferably contains a fatty acid amide compound. The content of the fatty acid amide compound is preferably 0.5 mass% or more, more preferably 0.7 mass% or more, and still more preferably 1.0 mass% or more, and the fatty acid amide compound acts as a lubricant on the fiber surface, so that a spun-bonded nonwoven fabric excellent in touch feeling can be formed. The upper limit of the content of the fatty acid amide compound in the present invention is not particularly limited, but is preferably 5.0 mass% or less from the viewpoints of cost and productivity.
When the propylene polymer according to the present invention contains the fatty acid amide compound, the number of carbon atoms of the fatty acid amide compound is preferably 15 to 50. Examples of the fatty acid amide compound having 15 to 50 carbon atoms include saturated fatty acid monoamide compounds, saturated fatty acid diamide compounds, unsaturated fatty acid monoamide compounds, and unsaturated fatty acid diamide compounds. The number of carbon atoms in the present invention refers to the number of carbon atoms contained in a molecule. Specific examples of the fatty acid amide compound include palmitoleic acid amide, stearic acid amide, oleic acid amide, elaidic acid amide, isooleic acid amide, linoleic acid amide, linolenic acid amide, terpineic acid amide, eleostearic acid amide, stearidonic acid amide, eicosapentaenoic acid amide, eicosatrienoic acid amide, arachidonic acid amide, eicosatetraenoic acid amide, eicosapentaenoic acid amide, heneicosenoic acid amide, behenic acid amide, erucic acid amide, docosadienoic acid amide, docosatetraenoic acid amide, docosapentaenoic acid amide docosapentaenoic acid amide, docosahexaenoic acid amide, tetracosanoic acid amide, ceramide acid amide, tetracosapentaenoic acid amide, tetracosahexenoic acid amide, cerotic acid amide, montanic acid amide, melissic acid amide, ethylenebisdecanoic acid amide, ethylenebislauric acid amide, ethylenebisstearic acid amide, ethylenebisoleic acid amide, ethylenebishydroxystearic acid amide, ethylenebisbehenic acid amide, ethylenebiserucic acid amide, hexamethylenebisstearic acid amide, hexamethylenebisbehenic acid amide, hexamethylenehydroxystearic acid amide, distearyl adipic acid amide, distearyl sebacic acid amide, hexamethylenebisoleic acid amide and the like, these may be used in combination of plural kinds. The fatty acid amide compound preferably has 15 or more, more preferably 23 or more, and still more preferably 30 or more carbon atoms, whereby excessive precipitation of the fatty acid amide compound on the fiber surface can be suppressed, and spinning properties and processing stability are excellent, thereby maintaining high productivity. Further, the fatty acid amide compound is preferably a laminate nonwoven fabric having a carbon number of 50 or less, more preferably 45 or less, and still more preferably 42 or less, because the fatty acid amide compound is moderately deposited on the fiber surface, the laminate nonwoven fabric is excellent in touch. The fatty acid amide compound has preferably 15 to 50 carbon atoms, more preferably 23 to 45 carbon atoms, and still more preferably 30 to 42 carbon atoms.
[ crimped composite fiber ]
The crimped composite fiber according to the present invention is a composite fiber having a certain crimp. Examples of such crimped conjugate fibers include side-by-side conjugate fibers and eccentric core-sheath conjugate fibers.
Since these composite fibers are separated at the center of gravity of each component in the cross section of the single fiber, when released from tension in the spinning process, the fibers bend according to the difference in the elastic recovery amount of each component, and they continue in the fiber axis direction, whereby the fibers can exhibit curl.
In the spun-bonded nonwoven fabric of the present invention, side-by-side conjugate fibers in which the distance between the center of gravity points for controlling the curl is set to be large are preferable from the viewpoint that the fibers can exhibit a fine curl and the flexibility in bending can be improved.
The crimped composite fiber according to the present invention comprises a 1 st component comprising a propylene polymer as a main component and a 2 nd component comprising a propylene copolymer obtained by copolymerizing an α -olefin as a main component, and the 2 nd component is disposed at the innermost side of the crimp in the cross section of the crimped composite fiber.
The "innermost portion of the crimp in the cross section of the crimped composite fiber" referred to herein means a portion shown below, and will be described with reference to fig. 1.
Fig. 1 is a schematic side view of a crimped composite fiber according to the present invention when the crimped composite fiber is observed by a Scanning Electron Microscope (SEM) or the like, fig. 1A is a schematic side view of a side-by-side composite fiber, and fig. 1B is a schematic side view of an eccentric core-sheath composite fiber. The crimped conjugate fiber of the present invention is bent by crimping, and the interface (B1) between the component (S1) and the component (S2) is observed in the fiber. In this case, the component (S2) at the innermost side of the crimp composite fiber, which is disposed at the inner side of the bent shape, is referred to as "at the innermost side of the crimp composite fiber in the cross section of the crimp composite fiber" (component 2), and the component (S1) at the outermost side of the crimp, which is disposed at the outer side of the bent shape, is referred to as "at the outermost side of the crimp composite fiber in the cross section of the crimp composite fiber" (component 1) in the present invention.
In the case where the core component is completely covered with the sheath component in the eccentric core-sheath type composite fiber, as shown in fig. 1B, 2 interfaces (B1, B1 '), that is, the interface between the component (S1) and the component (S2) and the interface between the component (S1') and the component (S2), may be observed in the fiber interior of the eccentric core-sheath type composite fiber. In this case, a thin component (S1 ') as a sheath component is present on the innermost surface of the curl, but the component (S2) as a core component is more contracted than the components (S1, S1') as a sheath component, and the component (S2) is curved inward to generate the curl, so that the component (S2) as a core component is set as the innermost component (2 nd component) of the curl.
In the crimped conjugate fiber according to the present invention, it is an important requirement that the 2 nd component composed mainly of a propylene copolymer obtained by copolymerizing an α -olefin is disposed at the innermost side of the crimp.
Since the propylene copolymer obtained by copolymerizing an α -olefin has lower crystallinity than a propylene homopolymer, the elastic recovery amount at the time of curl occurrence can be increased. Therefore, in the crimped conjugate fiber according to the present invention, the 2 nd component is disposed at the innermost side of the crimp, so that the radius of curvature of the crimped form can be reduced, and the crimp can be controlled to be thin, thereby improving the bending flexibility of the spun-bonded nonwoven fabric.
Examples of the α -olefin which can be suitably used in the present invention include ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene, 3-methyl-1-butene, 3-methyl-1-pentene, 3-ethyl-1-pentene, 4-methyl-1-pentene and 4-methyl-1-hexene. In addition, they may be used in combination. The copolymerization ratio of these α -olefins may be in the range of 0.5mol% or more. By setting the copolymerization ratio to this range, the elastic recovery amount can be increased. On the other hand, if the copolymerization ratio is increased, the elastic recovery amount becomes large, but if it is excessively increased, the crystallinity is significantly reduced, and the spun yarn becomes unstable, so that the copolymerization ratio is preferably 20.0mol% or less. More preferably 0.5 to 20.0mol%.
In the cross section of the crimped conjugate fiber according to the present invention, the state in which the 2 nd component is disposed at the innermost side of the crimp can be evaluated by, for example, micro raman spectroscopy. Since the component 2 according to the present invention is obtained by copolymerizing an α -olefin, no peak can be detected in the raman spectrum of the propylene homopolymer in the raman spectrum of the component 2. By utilizing this, the arrangement of the 2 nd component in the crimped composite fiber can be discriminated. For example, in the case of ethylene copolymerization, it is possible to use a copolymer of ethylene at 730cm -1 The raman band characteristic of ethylene units is observed nearby. An example of the measurement method is shown below.
First, crimped filaments (crimped conjugate fibers) are cut out of a spun-bonded nonwoven fabric and mounted on a glass slide so that the bending of the fibers can be discriminated. The fiber side was observed at a magnification at which 1 single fiber could be observed, and raman spectra were measured using a micro raman spectroscopy for the polymer component disposed at the innermost side of the curl. In this case, the beam spot (beam spot) diameter of the measurement light is preferably sufficiently small relative to the fiber diameter, and for example, is preferably 1 μm to 2 μm. The raman spectrum obtained in this manner is compared with the raman spectrum of the propylene homopolymer, and the composition inside the curl is discriminated.
In the crimped conjugated fiber according to the present invention, the orientation parameter (I2) of the 2 nd component is 5.0 or more. In this way, the elastic recovery amount of the 2 nd component can be made more remarkable.
The orientation parameter of the 2 nd component as referred to herein means a parameter measured by micro raman spectroscopy. In the case of propylene polymers, 810cm is known -1 And 840cm -1 The nearby raman band exhibits strong anisotropy with respect to the polarized light of the incident light. Thus, it can be according to 810cm -1 And 840cm -1 The intensity of the nearby raman band is used to evaluate molecular orientation.
The orientation parameter of the 2 nd component was measured by the method described below.
(1) Crimped composite fibers were collected from spun-bonded nonwoven fabrics and mounted on a glass slide so that the bending of the fibers could be discriminated.
(2) Raman spectra were measured on the innermost polymer component of the crimp disposed on the crimped conjugate fiber using incident light having a sufficiently small beam spot diameter relative to the fiber diameter and polarized parallel to the fiber axis.
(3) For the obtained Raman spectrum, at 750cm -1 ～900cm -1 Peak fitting was performed in the range of (2), and 800cm was calculated -1 ～815cm -1 Maximum intensity of peak having maximum point in between as I2 (810) Calculated 840-855 cm -1 Maximum intensity of peak having maximum point in between as I2 (840) 。
(4) Using the above values, I2 was obtained (810) Relative to I2 (840) Ratio (I2) (810) /I2 (840) )。
(5) The same operations as (1) to (4) were performed on the 10 different fibers, the arithmetic average of the obtained results was obtained, and the 2 nd bit after the decimal point was rounded. This value is the orientation parameter (I2) of component 2.
The higher the value of the orientation parameter (I2) of the 2 nd component, the higher the molecular orientation of the 2 nd component. Therefore, the higher the I2, the higher the orientation of the 2 nd component disposed inside the curl, and the more the amount of elastic recovery can be increased, so that finer curls can be formed, and a spunbond nonwoven fabric having excellent bending softness can be obtained. From such a viewpoint, I2 is more preferably 5.2 or more, and particularly preferably 5.5 or more. The upper limit of the orientation parameter is not limited, and is at most about 8.0 as a limit that can be produced from the propylene polymer fiber.
On the other hand, in the crimped conjugated fiber according to the present invention, the 1 st component is preferably a propylene homopolymer from the viewpoint of making the difference in the amounts of elastic recovery of the respective components significant. Since the propylene homopolymer has high crystallinity, the amount of elastic recovery in the spinning step can be reduced, and the strength can be improved.
In the crimped composite fiber according to the present invention, the orientation parameter of the 1 st component is preferably 6.0 or less in order to enlarge the difference in the elastic recovery amounts of the components. If the orientation parameter of the 1 st component is within this range, it means that the orientation of the 1 st component is sufficiently low, and the elastic recovery amount can be limited to be small. On the other hand, when the orientation parameter of the 1 st component is significantly reduced, the fiber strength is reduced, and thus it is more preferably 4.0 or more.
The orientation parameter of the 1 st component referred to herein means a parameter measured by a method described below.
(1) Crimped composite fibers were collected from spun-bonded nonwoven fabrics and mounted on a glass slide so that the bending of the fibers could be discriminated.
(2) Raman spectra were measured on the outermost polymer component of the crimp of the crimped conjugate fiber using incident light having a sufficiently small beam spot diameter relative to the fiber diameter and polarized parallel to the fiber axis.
(3) For the obtained Raman spectrum, at 750cm -1 ～900cm -1 Peak fitting was performed in the range of (2), and 800cm was calculated -1 ～815cm -1 Maximum intensity of peak having maximum point in between as I1 (810) Calculated 840-855 cm -1 Maximum intensity of peak having maximum point in between as I1 (840) 。
(4) Using the above values, I1 was obtained (810) Relative to I1 (840) Ratio (I1) (810) /I1 (840) )。
(5) The same operations as (1) to (4) were performed on the 10 different fibers, the arithmetic average of the obtained results was obtained, and the 2 nd bit after the decimal point was rounded. This value is the orientation parameter (I1) of the 1 st component.
In the crimped composite fiber according to the present invention, the area ratio of the 2 nd component in the cross section of the crimped composite fiber is preferably 1% to 80%. When the area ratio of the 2 nd component is within this range, the distance between the centers of gravity can be sufficiently ensured, and a thin curl can be formed. The area ratio of the 2 nd component is more preferably 50% or less, particularly preferably 40% or less, from the viewpoint of further expanding the distance between the centers of gravity. The lower limit is more preferably 10% or more, particularly preferably 20% or more.
The cross section of the fiber referred to herein means a cut surface when the fiber is cut at a plane perpendicular to the fiber length direction of the single fiber.
The area ratio of the 2 nd component in the cross section referred to herein means a ratio obtained in the following manner.
In the case of a spun-bonded nonwoven fabric (a laminated nonwoven fabric, a spun-bonded nonwoven fabric layer), a crimped filament (crimped composite fiber) is cut out from the spun-bonded nonwoven fabric, and the spun-bonded nonwoven fabric is subjected to an embedding treatment, cut into pieces by a dicing machine so that the cross section of the filament can be observed, and placed on a slide glass. Then, the fiber cross section was observed by a microscope incorporated in a raman spectroscopic device equipped with a 100-fold objective lens, and microscopic raman spectroscopic measurement was performed on 2 components constituting the fiber cross section. The obtained raman spectrum was compared with a previously measured raman spectrum of a propylene copolymer constituting the 2 nd component, and the component having the same spectrum was identified as the 2 nd component.
Then, for the section used in the above measurement, an image was taken with a transmission microscope at a magnification at which a cross section of 1 single fiber could be observed. From the SEM images thus captured, the cross-sectional area (Af) of the fiber and the area (A2) of the 2 nd component were measured using image analysis software (for example, "WinROOF2015", manufactured by san francisco, inc.) and the area ratio of the 2 nd component was calculated using equation 1.
(area ratio of the 2 nd component) =100×a2/Af formula (1)
The same operation was performed on the 20 different crimped composite fibers, and the arithmetic average of the obtained results was obtained, and the value obtained by rounding the 1 st position after the decimal point was the area ratio of the 2 nd component in the cross section referred to in the present invention.
In the crimped conjugate fiber according to the present invention, by realizing the above-described requirements, a fine crimp that has not been conventionally achieved can be formed. The spun-bonded nonwoven fabric comprising the fibers is extremely excellent in bending flexibility. In the crimped conjugated fiber according to the present invention, the number of crimps is preferably 50/25 mm or more.
The curl number referred to herein means a number obtained in the following manner.
An image was taken on the surface of the spun-bonded nonwoven fabric with a Scanning Electron Microscope (SEM) at a magnification at which 10 or more crimped composite fibers could be observed. Using the photographed image, the apparent length of the crimped composite fiber in the measurement range is measured. The total number of peaks and valleys of the crimped composite fibers present in the apparent length is counted and divided by 2. The total number is converted to a number per 25 mm. The same operations as described above were performed for the 20 fibers, and the number of crimps referred to in the present invention was obtained by rounding the 1 st position after the decimal point, which was the arithmetic average of the obtained results.
The larger the value of the crimp number, the higher the extensibility of the crimped conjugate fiber, and the tightness of the fiber between the thermosetting points can be suppressed when the spunbond nonwoven fabric is produced, so that the bending flexibility can be improved. From such a viewpoint, the number of curls is more preferably 80/25 mm or more, and 100/25 mm or more is particularly preferable. The upper limit of the number of crimps is not particularly limited, since the number of crimps varies depending on the fiber diameter of the crimped composite fiber, and is, for example, preferably 1000 pieces/25 mm or less, more preferably 750 pieces/25 mm or less.
In the crimped conjugated fiber according to the present invention, the crimp diameter is preferably 400 μm or less. The curl diameter referred to in the present invention can be obtained as follows, and will be described with reference to fig. 2.
Fig. 2 is a diagram illustrating a method of measuring crimp diameter on a Scanning Electron Microscope (SEM) image obtained by observing the surface of an example of the spun-bonded nonwoven fabric according to the present invention. An image of the surface of the spunbond nonwoven fabric was taken as in the measurement of the curl number described above. Using the SEM image thus captured, a tangent line (L) tangent to the adjacent 2 peaks (P1) of crimp and the peak (P2) of crimp was drawn for the crimped composite fiber within the measurement range. For the vertical distance (D) from the valley (V) between P1 and P2 to the tangent (L), the unit is set to μm and measured as an integer value. The same operations as described above were performed for the 20 fibers, and the arithmetic average of the obtained results was obtained, and the value obtained by rounding the 1 st position after the decimal point was the curl diameter referred to in the present invention.
By controlling the crimp diameter to be small, the thickness of the spun-bonded nonwoven fabric can be made small, and excellent flexibility can be obtained. From such a viewpoint, the curl diameter is more preferably 300 μm or less.
In the crimped conjugate fiber according to the present invention, the fiber diameter is not particularly limited, and the smaller the fiber diameter is, the smaller the radius of curvature of the crimp can be made, and the finer crimp is obtained, so that it is preferably 25.0 μm or less. On the other hand, if the fiber diameter is too small, there is a concern that the strength is lowered, so that it is more preferably 5.0 μm or more.
[ spun-bonded nonwoven fabrics ]
The spun-bonded nonwoven fabric of the present invention is composed of the characteristic crimped conjugate fiber described above, and therefore has excellent bending flexibility.
Therefore, the spunbond nonwoven fabric of the present invention is preferably set to have a stiffness of 0.50 mN.cm or less. When the stiffness is in this range, the sanitary material can have excellent bending flexibility suitable for the use of the sanitary material.
The stiffness in the present invention is based on JIS L1913:2010 "6.7.3.41.5℃cantilever method" of general nonwoven fabric test method ".
In addition, as a guardIn the case of using the nonwoven fabric for green material, the spunbond nonwoven fabric of the present invention preferably has a tensile strength per unit area weight of 0.40 (N/5 cm)/(g/m) 2 ) The above. When the nonwoven fabric strength is within this range, it is possible to provide an article which can withstand the process-passing properties in the production of a paper diaper or the like and is used as a product.
The strength in the present invention was obtained by following JIS L1913: the tensile test of 2010 "6.3 tensile strength and elongation (ISO method)" carried out at "6.3.1 standard time" of general nonwoven fabric test method "was carried out at a grip interval of at least 5cm, and the average of tensile strengths (strengths at break of samples) in the 2 orthogonal directions was divided by the weight per unit area.
The weight per unit area of the spunbonded nonwoven fabric of the invention is preferably 10g/m 2 150g/m above 2 The following is given. By making the weight per unit area 10g/m 2 As described above, the spunbond nonwoven fabric can be easily formed into a thickness suitable for sanitary material use, and the spunbond nonwoven fabric can be formed to have mechanical strength suitable for practical use. On the other hand, by making it 150g/m 2 Hereinafter, more preferably 120g/m 2 The following is more preferable to be 100g/m 2 In the following, a spun-bonded nonwoven fabric having excellent air permeability can be formed.
The weight per unit area (g/m) of the spunbonded nonwoven fabric in the present invention 2 ) Is based on JIS L1913:2010 "mass per unit area" of "6.2 of general nonwoven fabric test method".
The thickness of the spun-bonded nonwoven fabric of the present invention is preferably 2.00mm or less. By controlling the thickness within this range, good bending flexibility can be obtained. From such a viewpoint, the thickness is more preferably 1.50mm or less. On the other hand, the thickness is reduced to increase the fiber density, and the bending flexibility is impaired, so that it is preferably 0.01mm or more.
The thickness of the spun-bonded nonwoven fabric in the present invention is not particularly limited, and refers to, for example, the thickness under no load measured by a shape measuring machine (for example, "VR3050" manufactured by KEYENCE, inc.).
[ method for producing spun-bonded nonwoven Fabric ]
Next, a preferred mode for producing the spunbonded nonwoven fabric of the present invention will be specifically described.
The method for producing the spunbonded nonwoven fabric of the present invention is preferably the following method: after the 1 st component and the 2 nd component having a melt viscosity 1.20 times or more higher than the melt viscosity of the 1 st component are melted and spun out by discharging a composite polymer stream from a composite spinneret, the crimped composite fiber is formed by crimping the composite fiber so that the 2 nd component is disposed at the innermost side of the crimp between an air drawing unit and a collecting belt, and the crimped composite fiber is collected on the collecting belt.
The spunbonding method is generally a method for producing a nonwoven fabric as follows: after the thermoplastic resin as a raw material is melted and spun from a spinneret, the sliver obtained by cooling and solidifying is drawn and stretched by an air drawing unit such as a jet, and collected on a moving collecting belt to be formed into a nonwoven web, and then a thermal bonding step is required. In the spunbonded nonwoven fabric of the present invention, the molecular orientation is promoted by air traction by the spunbonding method, and the fibers are firmly fixed to each other by thermal bonding, so that a sufficient strength for use as a sanitary material can be obtained.
As a suitable composite spinneret used in the method for producing a spun-bonded nonwoven fabric of the present invention, a mechanism capable of forming a side-by-side composite cross section or an eccentric core-sheath composite cross section is preferably provided. The shape of the ejection hole of the nozzle may be freely selected as long as the effect of the present invention is not impaired, and is preferably a circular hole from the viewpoint of spinning stability.
In the method for producing a spunbonded nonwoven fabric of the present invention, it is preferable that the 1 st component and the 2 nd component having a melt viscosity 1.20 times or more higher than that of the 1 st component are melted, respectively, and are discharged from the composite spinneret as a composite polymer stream.
The melt viscosity referred to in the present invention means a shear rate of 31.4s at the spinning temperature -1 The melt viscosity at the time was measured by the method described below.
(1) A rotary rheometer (for example, "Rheosol-G3000" manufactured by UBM Co.) was used, and the temperature was raised to a temperature corresponding to the spinning temperature.
(2) At the position ofThe polymer was sandwiched between parallel plates, and after melting, the gap between the plates was set to 0.5mm.
(3) To be 31.4rad/s -1 Provides strain at the speed of (2).
(4) Under such conditions, the melt viscosity was measured with the unit being pa·s.
The spunbonding method is a production method in which the discharged polymer stream is deformed at a high speed while being cooled, and thus the molecular orientation of the produced fiber changes according to the melt viscosity at high shear. In particular, in the production of a composite fiber, when there is a difference in melt viscosity at high shear between the components, a high stress is applied to the components having high viscosity, and thus the molecular orientation can be improved. In the present invention, it was found that by comparing the shear rate of 31.4s -1 The melt viscosity at the time of this can be evaluated.
In the method for producing a spunbonded nonwoven fabric of the present invention, the ratio of the melt viscosity of the 2 nd component to that of the 1 st component is preferably 1.20 times or more, more preferably 1.30 times or more. By setting the ratio of the melt viscosities to this range, the 2 nd component can be highly molecularly oriented (a desired mode of the spun-bonded nonwoven fabric of the present invention), and finer curl can be formed. The larger the melt viscosity ratio is, the finer the curl becomes, so that it is preferable, but when the melt viscosity ratio is excessively large, a large difference occurs in deformation behavior between components, which causes yarn breakage, and thus it is more preferable to be 3.00 times or less.
In the method for producing a spunbonded nonwoven fabric of the present invention, in order to improve the orientation of the 2 nd component and to improve the ejection stability, it is preferable that the mass of the 1 st component and the 2 nd component be 20: 80-99: 1. In addition, from the viewpoint of making the ejection speed of each component equal and enabling stable ejection, the mass of the 1 st component and the 2 nd component is more preferably 50: 50-90: 10, particularly preferably 40: 60-80: 20.
in the present invention, when the melting temperature of one of the 1 st component and the 2 nd component, which has a higher melting temperature, is Tm, the spinning temperature is preferably (tm+10 ℃) or higher and (tm+100 ℃) or lower. By setting the spinning temperature within the above range, a stable molten state can be formed, and excellent spinning stability can be obtained.
The spun yarn is then cooled, and examples of the method of cooling the spun yarn include a method of forcibly blowing cold air to the yarn, a method of naturally cooling the yarn at an atmospheric temperature around the yarn, a method of adjusting a distance between the spinneret and the air drawing unit, and the like, or a method of combining these methods may be employed. The cooling conditions may be appropriately adjusted in consideration of the ejection amount per unit hole of the spinneret, the spinning temperature, the atmosphere temperature, and the like.
Then, the cooled and solidified sliver is drawn and stretched by the compressed air injected from the air drawing unit. The spinning speed is preferably 2000 m/min or more, more preferably 3000 m/min or more. By setting the spinning speed to 2000 m/min or more, the productivity is high, and the fiber is further oriented and crystallized, whereby a fiber having higher strength can be obtained.
The sliver stretched by the air-drawing is collected in the moving collection belt to be formed into a sheet, and then the sheet is subjected to a thermal bonding step.
In this case, in the method for producing a spun-bonded nonwoven fabric of the present invention, the crimped conjugate fiber is preferably formed by crimping the spun-bonded nonwoven fabric so that the 2 nd component is disposed at the innermost side of the crimp between the air-drawing means and the collecting belt. The distance between the air traction unit and the capturing belt is sufficiently large with respect to the curl size, and thus can exhibit curl without interference of the fibers with each other, thus facilitating formation of fine curl. Further, by completing the curl presentation before the sheet formation, the deformation amount of the sheet can be reduced, and the decrease in strength due to the weight unevenness per unit area can be prevented.
In the method for producing a spunbonded nonwoven fabric of the present invention, as a method for integrating the sheet captured by the capturing belt, there can be used: a method of bonding a sheet by heating and pressurizing various rolls such as a hot embossing roll having a pair of upper and lower roll surfaces and engraved (uneven) portions, a hot embossing roll having a combination of a roll having a flat (smooth) surface and a roll having an engraved (uneven) portion on a surface of the other roll, and a hot calendaring roll having a combination of a pair of upper and lower flat (smooth) rolls; a method of welding sheets by ultrasonic vibration of a horn (horn), and the like.
In particular, when the sheet is integrated by heating and pressing with such a roll, the nonwoven fabric layer is sufficiently bonded, and the mechanical strength of the spunbond nonwoven fabric is preferably increased.
On the other hand, as a method of integrating the above-described sheets, a method of welding the sheets by blowing heated air, nitrogen, or the like, that is, a so-called hot air method, may be mentioned.
When the spun-bonded nonwoven fabric of the present invention is produced by this hot air method, it is preferable because of excellent bulk and hand.
[ laminated nonwoven fabrics ]
The laminated nonwoven fabric of the present invention is preferably formed by laminating at least one layer of an elastomer with a spunbond nonwoven fabric layer formed from the spunbond nonwoven fabric described above. By using the spun-bonded nonwoven fabric as the spun-bonded nonwoven fabric layer and laminating at least one elastomer layer thereon, excellent bending flexibility can be achieved in combination with low rigidity peculiar to the elastomer.
First, the elastomer of the laminated nonwoven fabric of the present invention is a polymer compound having a hard segment and a soft segment at ordinary temperature. As the characteristics, deformation due to weak force is given, and in the present invention, the flexural modulus is preferably 500MPa or less as an index indicating the deformation. The flexural modulus of elasticity in the present invention is based on JIS K7171:2016 "determination of Plastic-Curve Properties", and the flexibility of the raw material itself was evaluated. In the laminated nonwoven fabric of the present invention, high bending flexibility can be obtained by laminating an elastomer layer using such an elastomer.
In addition, from the viewpoint of productivity, the elastomer is preferably a thermoplastic resin. By making the elastomer a thermoplastic resin, the fiber cross section and surface morphology can be easily controlled. The thermoplastic resin constituting the elastomer layer exhibits thermoplastic properties when heated to a temperature equal to or higher than the melting point, and is a polymer deformable by weak force at ordinary temperature. Specifically, the thermoplastic elastomer is a polyurethane elastomer, a polypropylene elastomer, a polyethylene elastomer, a polyester elastomer, a polystyrene elastomer, a polybutadiene elastomer, or the like.
Such thermoplastic resin may be 1 kind, or may contain a plurality of thermoplastic resins. The laminated nonwoven fabric of the present invention can be suitably selected from the above-mentioned materials in consideration of the adhesiveness to the spunbond nonwoven fabric layer and the constituent fibers thereof.
In the laminated nonwoven fabric of the present invention, the elastomer layer is a layer formed of the above-mentioned elastomer, and examples of the form include a film-like form, a fabric-like form such as a woven fabric, a knitted fabric, or a nonwoven fabric, a composite material in which the fabric is impregnated with an elastomer resin, and a sheet-like form such as a laminate of these. Among them, the form of nonwoven fabric is preferable. The nonwoven fabric layer formed by folding the fibers can greatly reduce the cross-sectional secondary moment of inertia compared with the film. Therefore, by laminating the elastic layer in the form of nonwoven fabric, the bending flexibility of the laminated nonwoven fabric can be improved.
The form of such nonwoven fabric may be selected from known nonwoven fabrics such as spunbond nonwoven fabrics, meltblown nonwoven fabrics and staple fiber nonwoven fabrics, and spunbond nonwoven fabrics and meltblown nonwoven fabrics are preferable from the viewpoint of productivity.
The laminated nonwoven fabric of the present invention is formed by laminating a spunbond nonwoven fabric layer with at least one elastomer layer as described above. That is, as the laminated structure, when the spunbond nonwoven fabric layer is represented by (S) and the elastomer layer is represented by (E), for example, when it is 2 layers, (S)/(E), when it is 3 layers, (S)/(E)/(S), etc., and when it is 4 layers, (S)/(E)/(S), etc., it is (S)/(E)/(S), etc. Among them, the form of the spunbonded nonwoven fabric layer laminated on both the front and back surfaces of the elastomer layer, that is, the form of (S)/(E)/(S), is more preferable. The lamination structure is selected according to the purpose of use and the like.
The laminated nonwoven fabric of the present invention is preferably formed by integrating these spunbond nonwoven fabric layers with an elastomer layer. The term "integrated" as used herein means that the layers are joined by interlacing fibers, fixing by an adhesive or other component, and welding thermoplastic resins constituting the layers.
[ method for producing laminated nonwoven fabric ]
The method for producing a laminated nonwoven fabric of the present invention comprises: a step of forming a spun-bond nonwoven fabric layer by melting the 1 st component and the 2 nd component having a melt viscosity 1.20 times or more higher than the melt viscosity of the 1 st component, respectively, and discharging a composite polymer stream from a composite spinneret, spinning the composite polymer stream, and then forming the crimped composite fiber by forming the crimped composite fiber while providing the 2 nd component at the innermost side of the crimp between an air drawing unit and a collecting belt, and collecting the crimped composite fiber on the collecting belt; and laminating at least one elastomer layer. The process for forming the spunbond nonwoven fabric layer is the same as the method for producing the spunbond nonwoven fabric.
Specifically, the step of laminating at least one elastomer layer may employ, for example: a method in which an elastomer layer is continuously collected in an on-line manner on a spun-bonded nonwoven fabric layer formed on a collecting belt as described above by a usual method including a known method, and is laminated and integrated by heating and pressurizing; and a method in which the spun-bonded nonwoven fabric layer and the elastic layer obtained separately are laminated off-line and integrated by heating, pressurizing, or the like. Among them, the following method is preferable in terms of excellent productivity: the elastic body layer is continuously collected in an in-line manner on the spun-bonded nonwoven fabric layer formed on the collecting belt, and thus laminated, and heat and pressure are applied to integrate the layers. The method of integrating may be a method of interlacing fibers with each other by a method such as needling, or a method of bonding with an adhesive or the like.
As a preferred embodiment of the method for producing a laminated nonwoven fabric of the present invention, the aforementioned elastomer layer is formed by a spunbond method. The use of the spunbonding method is preferable because a laminated nonwoven fabric having high strength can be obtained.
In addition, another preferable mode of the method for producing a laminated nonwoven fabric of the present invention is to form the aforementioned elastomer layer by a melt-blowing method. The reason for this is that by adopting the melt blowing method, a sheet can be stably formed as compared with the spunbond method. In addition, the fiber diameter can be reduced as compared with the spunbond method, and therefore, there is an advantage that the bending flexibility can be improved.
The method for producing a laminated nonwoven fabric of the present invention may be any method as long as the spunbond nonwoven fabric layer is laminated with at least one elastomer layer, and any composition may be used depending on the number and combination of layers.
[ sanitary Material ]
At least a part of the sanitary material of the present invention is composed of the spun-bonded nonwoven fabric or the laminated nonwoven fabric, and excellent bending flexibility can be obtained. The sanitary material of the present invention is mainly disposable for health-related purposes such as medical treatment and nursing, and includes disposable diapers, sanitary napkins, gauze, bandages, masks, gloves, hemostatic patches, and the like, and also includes constituent members thereof, such as topsheets, backsheets, side gathers, and the like of the disposable diapers.
Examples
The present invention will be specifically described below based on examples. However, the present invention is not limited to these examples. In the measurement of each physical property, items not specifically described are measured based on the above-described method.
[ measurement method ]
(1) Identification of the innermost component of the curl
The measurement device used was a raman spectroscopic device "inVia" manufactured by RENISHAW corporation. The measurement conditions were carried out as follows.
Beam spot diameter: 1 μm
Light source: 532nm
Laser power: 10mW
Diffraction lattice: single 1800gr/mm, 3000 (-1) gr/mm
Slit: 65 μm
The spun-bonded nonwoven fabric (spun-bonded nonwoven fabric layer in the case of laminated nonwoven fabric) is cut out of the spun-bonded nonwoven fabric, and the cut-out single fibers (crimped composite fibers) are placed on a glass slide so that the bending of the fibers can be discriminated. Then, 1 single fiber was observed from the fiber side using a microscope built in a raman spectroscopic device equipped with a 100-fold objective lens. Microscopic raman spectroscopy was performed on the components disposed on the inner side of the bend when viewed from the fiber side. The innermost component disposed in the curl was identified by comparing the obtained raman spectrum with a previously measured raman spectrum of a propylene homopolymer.
(2) Area ratio of the 2 nd component
From a spun-bonded nonwoven fabric (a spun-bonded nonwoven fabric layer in the case of a laminated nonwoven fabric), a crimped filament (crimped composite fiber) was cut out, and the cut filament was subjected to embedding treatment, and then cut into pieces by a dicing machine so that the cross section of the filament could be observed, and the cut filament was placed on a slide glass. Then, the fiber cross section was observed by a microscope built in a raman spectroscopic device equipped with a 100-fold objective lens. Microscopic raman spectroscopy was performed on 2 components constituting the fiber cross section. The obtained raman spectrum was compared with a previously measured raman spectrum of the propylene copolymer, and the component having the same spectrum was identified as the 2 nd component.
Then, for the section used in the above measurement, an image was taken with a transmission microscope at a magnification at which a cross section of 1 single fiber could be observed. From the SEM images thus captured, the cross-sectional area (Af) of the fiber and the area (A2) of the 2 nd component were measured using image analysis software (WinROOF 2015, division, inc.) and the area ratio of the 2 nd component was calculated using equation 1.
(area ratio of the 2 nd component) =100×a2/Af formula (1)
The same operation was performed on the 20 different crimped composite fibers, and the arithmetic average of the obtained results was obtained, and the value obtained by rounding the 1 st position after the decimal point was used as the area ratio of the 2 nd component in the cross section.
(3) Orientation parameters
The measurement device used was a raman spectroscopic device "inVia" manufactured by RENISHAW corporation. The measurement conditions were carried out as follows.
Measurement mode: micro Raman (polarization measurement)
Polarization direction: parallel direction relative to fibre axis
Beam spot diameter: 1 μm
Light source: 532nm
Laser power: 10mW
Diffraction lattice: single 800gr/mm, 3000 (-1) gr/mm
Slit: 65 μm
From the spun-bonded nonwoven fabric, crimped filaments were cut out and placed on a glass slide so that the bending of the filaments could be discriminated. Then, for the crimped composite fiber, observation was performed from the fiber side using a 50-fold objective lens. Raman spectrometry was performed on the polymer components disposed on the innermost and outermost sides of the bend when viewed from the fiber side. Based on the obtained raman spectra, the orientation parameters of the components were determined as described above.
(4) Number of curls
An image was taken on the surface of the spun-bonded nonwoven fabric with a scanning electron microscope (SEM, manufactured by KEYENCE corporation, "VHX 6000") at a magnification at which the peaks of the crimp of 10 to 50 structured crimped composite fibers could be observed. When fewer than 10 peaks of curl in a 10mm×10mm visual field were observed, the number of curls of the fiber was set to 0. The number of peaks and valleys per 25mm of the fiber was counted, the total divided by 2 was used as the curl number of the fiber, the same measurement was performed for 20 different fibers, and the number obtained by rounding the 1 st position after the decimal point of the arithmetic average was set as the curl number per 25 mm.
(5) Weight per unit area
Weight per unit area based on JIS L1913: the "mass per unit area" of "6.2 of 2010" general nonwoven fabric test method "was measured.
(6) Stiffness and rigidity
Stiffness is based on JIS L1913:2010 "general nonwoven fabric test method" was measured by the "6.7.341.5 ° cantilever method".
(7) Tensile Strength per weight unit area
Using a tensile tester (product of ORIENTEC, "TENSILON UCT-100"), JIS L1913: the "6.3.1 standard time" of "6.3 tensile strength and elongation (ISO method)" of 2010 "general nonwoven fabric test method" was measured. From the measured data, the average of the tensile strengths (strengths at which the sample breaks) in the orthogonal 2 directions was divided by the weight per unit area, thereby calculating the tensile strength per weight per unit area.
Example 1
As component 1, a shear rate of 31.4s was used -1 A homopolypropylene having a melt viscosity of 153 Pa.s (hereinafter, abbreviated as "homopolyPP" in some cases including Table 1) was used as the 2 nd component, and a shear rate of 31.4s was used -1 An ethylene-copolymerized polypropylene (hereinafter, abbreviated as "coPP" in some cases, including table 1, etc.) having a melt viscosity of 270pa·s and copolymerized with 2.7mol% ethylene. These were melted by a separate extruder, and the ejection amount per single hole was 0.55 g/(min. Hole) from a rectangular nozzle having a side-by-side composite cross section at a spinning temperature of 230℃to obtain a composition 1: component 2 = 50: 50. After the spun yarn was cooled and solidified, the yarn was drawn and stretched by compressed air having a pressure of 0.10MPa by a rectangular ejector and collected on a moving collecting belt, whereby a nonwoven web was obtained. At this time, the fibers in the nonwoven web have fine curls. For the nonwoven web obtained in this way, the upper roll was a metal embossing roll having circular protrusions arranged alternately at equal intervals in both the MD and CD directions, the lower roll was an embossing roll having a pair of upper and lower heating means and composed of a metal flat roll, and the embossing roll was integrated by heating and pressing at a temperature of 300N/cm in-line pressure and 125℃on the surface of the embossing roll The weight per unit area is 20g/m 2 Is a spun-bonded nonwoven fabric of (a). The obtained spun-bonded nonwoven fabric was evaluated for innermost component of curl, orientation parameter, number of curls, weight per unit area, stiffness, and tensile strength. The results are shown in Table 1.
Example 2
As component 1, a shear rate of 31.4s was used -1 A spunbond nonwoven fabric was obtained in the same manner as in example 1, except that the melt viscosity was a homopolymer PP of 220pa·s. The obtained spun-bonded nonwoven fabric was evaluated for innermost component of curl, orientation parameter, number of curls, weight per unit area, stiffness, and tensile strength. The results are shown in Table 1.
Example 3
The discharge mass ratio was set to component 1: component 2 = 80:20, and a spunbond nonwoven fabric was obtained in the same manner as in example 1. The obtained spun-bonded nonwoven fabric was evaluated for innermost component of curl, orientation parameter, number of curls, weight per unit area, stiffness, and tensile strength. The results are shown in Table 1.
Example 4
As component 2, a shear rate of 31.4s was used -1 A spunbond nonwoven fabric was obtained in the same manner as in example 1, except that the melt viscosity at the time was 280pa·s and 5.3mol% of ethylene was copolymerized with ethylene copolymerized polypropylene. The obtained spun-bonded nonwoven fabric was evaluated for innermost component of curl, orientation parameter, number of curls, weight per unit area, stiffness, and tensile strength. The results are shown in Table 1.
Example 5
The discharge mass ratio was set to component 1: component 2 = 99:1, a spunbond nonwoven fabric was obtained in the same manner as in example 1. The obtained spun-bonded nonwoven fabric was evaluated for innermost component of curl, orientation parameter, number of curls, weight per unit area, stiffness, and tensile strength. The results are shown in Table 1.
Comparative example 1
As component 1, a shear rate of 31.4s was used -1 The procedure of example 1 was repeated except that the melt viscosity of the homopolymer PP was 280 Pa.sAnd performing sample operation to obtain the spun-bonded non-woven fabric.
Comparative example 2
As component 2, a shear rate of 31.4s was used -1 A spunbond nonwoven fabric was obtained in the same manner as in example 1, except that the melt viscosity at the time was 270pa·s of homopolymerized PP.
TABLE 1
TABLE 1
As shown in table 1, the spunbond nonwoven fabrics of examples 1 to 4 were excellent in both bending flexibility and strength. In particular, examples 1, 3 and 4 showed excellent bending flexibility. On the other hand, the nonwoven fabrics of comparative examples 1 and 2 had the result that the fibers on the surface of the spunbond nonwoven fabric had relaxed crimp and low bending flexibility.
Example 6
(spunbond nonwoven layer)
Using a shear rate of 31.4s -1 As the 2 nd component, a homopolymer having a melt viscosity of 153 Pa.s was used at a shear rate of 31.4s -1 An ethylene copolymer polypropylene having a melt viscosity of 270 Pa.s and copolymerized with 2.7mol% of ethylene. These were melted by a separate extruder, and the ejection amount per single hole was 0.55 g/(min. Hole) from a rectangular nozzle having a side-by-side composite cross section at a spinning temperature of 230℃to obtain a composition 1: component 2 = 50: 50. The spun yarn was cooled and solidified, and then drawn and stretched in a rectangular ejector by compressed air having a pressure of 0.10MPa passing through the ejector, and collected on a moving collecting belt to obtain a yarn having a weight per unit area of 10g/m 2 Is referred to as "PP/coPP-SB" in Table 2. At this time, the fibers in the spunbond nonwoven layer have fine curls.
(elastomer layer)
Polypropylene elastomer comprising 15wt% of ethylene component copolymerized with melt viscosity 423 Pa.s and flexural modulus 13MPa(in Table 2, expressed as "PP system") an elastomer layer was formed by the spunbonding method. That is, the polypropylene elastomer having a melt viscosity of 423pa·s was melted by an extruder, and spun out from a rectangular nozzle at a spinning temperature of 230 ℃ under the condition that the ejection amount per single hole was 0.20 g/(min·hole). The spun yarn was cooled and solidified, and then drawn and stretched in a rectangular ejector by compressed air having a pressure of 0.10MPa passing through the ejector, and collected on a moving collecting belt to obtain a weight per unit area of 30g/m 2 Elastomer layer of (a) is produced (a spunbond process).
(laminated nonwoven fabric)
The elastomer layer was collected on the spun-bond nonwoven fabric layer obtained above by the above-mentioned method, and the spun-bond nonwoven fabric layer similar to the spun-bond nonwoven fabric layer was collected thereon, and the laminated nonwoven fabric layers were integrated under the same pressurizing and heating conditions as in example 1 to obtain a 3-layer structure of spun-bond nonwoven fabric layer-elastomer layer (spun-bond method) -spun-bond nonwoven fabric layer (regarding the lamination constitution, expressed as S/E in table 2 S1 The laminated nonwoven fabric of/S). The laminated nonwoven fabric obtained was evaluated for weight per unit area, stiffness, and tensile strength. The results are shown in Table 2.
Example 7
A3-layer structure of a spunbond nonwoven fabric layer-an elastomer layer (melt-blown method) -a spunbond nonwoven fabric layer (for the laminate constitution, expressed as S/E in Table 2) was obtained in the same manner as in example 6 except that an elastomer layer was produced by the melt-blown method as described below M and/S) laminating the nonwoven fabric. The laminated nonwoven fabric obtained was evaluated for weight per unit area, stiffness, and tensile strength. The results are shown in Table 2.
(elastomer layer)
Melting polypropylene elastomer with melt viscosity of 423 Pa.s and flexural modulus of 13MPa by using extruder, spinning at 255 deg.C and pore diameter Spinning under the conditions of 0.25mm, single hole ejection amount of 0.12 g/(min. Hole), and spraying air under the conditions of 275 deg.C and 0.15MPa to obtainTo a weight of 30g/m per unit area 2 Is described (melt blown).
Example 8
As the elastomer layer, 30g/m of the polypropylene-based elastomer used in example 6 was used 2 Except for the film of (a), a laminated nonwoven fabric (S/E in table 2 regarding the laminated structure F /S). The laminated nonwoven fabric obtained was evaluated for weight per unit area, stiffness, and tensile strength. The results are shown in Table 2.
Example 9
A laminated nonwoven fabric (S/E in table 2 for laminated structure) was obtained in the same manner as in example 6, except that a polyethylene-based elastomer (PE-based in table 2) having a melt viscosity of 252pa·s and a flexural elastic modulus of 23MPa was used in the elastomer layer S2 /S). The laminated nonwoven fabric obtained was evaluated for weight per unit area, stiffness, and tensile strength. The results are shown in Table 2.
Reference example 1
A laminated nonwoven fabric (the laminated structure is expressed as S/S in table 2) was obtained in the same manner as in example 6 except that the elastic layer was a normal spunbond nonwoven fabric layer (not an elastic layer) as shown below. The laminated nonwoven fabric obtained was evaluated for weight per unit area, stiffness, and tensile strength. The results are shown in Table 2.
(spunbond nonwoven layer)
The homo-polypropylene other than the elastomer having a melt viscosity of 290 pas and a flexural modulus of 1550MPa was melted by an extruder to obtain a yarn at a spinning temperature of 230℃and spun from a rectangular nozzle at a single-hole ejection amount of 0.45 g/(min. Hole). The spun yarn was cooled and solidified, and then drawn and stretched by compressed air having a pressure of 0.10MPa by a rectangular ejector, and collected on a moving collecting belt to obtain a weight per unit area of 30g/m 2 Is a spun-bonded nonwoven layer of (a).
TABLE 2
TABLE 2
As shown in table 2, the laminated nonwoven fabrics of examples 6 to 9 were excellent in bending flexibility and strength. On the other hand, the nonwoven fabric of reference example 1 had a result that the spunbond nonwoven fabric layers laminated between the spunbond nonwoven fabric layers were hard, and therefore the bending flexibility of the laminated nonwoven fabric was also low.
Description of the reference numerals
S1 component
S1' component
S2 component
B1 Interface(s)
B1' interface
Peaks of P1, P2 curls
Tangent to L tangent to P1 and P2
V is in the valley between P1 and P2
D perpendicular distance from valley V to tangent L between P1 and P2
Claims (12)
1. A spun-bonded nonwoven fabric comprising a crimped composite fiber comprising a 1 st component comprising a propylene polymer as a main component and a 2 nd component comprising a propylene copolymer obtained by copolymerizing an alpha-olefin as a main component,
In the cross section of the crimped composite fiber, the 2 nd component is disposed at the innermost side of the crimp, and the orientation parameter (I2) of the 2 nd component is 5.0 or more.
2. The spun-bonded nonwoven fabric of claim 1, wherein the propylene-based polymer of component 1 is a propylene homopolymer, and the orientation parameter (I1) of component 1 is 6.0 or less.
3. The spunbond nonwoven fabric according to claim 1 or 2, wherein the area ratio of the 2 nd component in the cross section of the crimped composite fiber is 1 to 80%.
4. The spun-bonded nonwoven fabric of any one of claims 1 to 3, wherein the crimped composite fibers have a crimp number of 50/25 mm or more as observed on the surface of the nonwoven fabric.
5. A laminated nonwoven fabric comprising a spunbond nonwoven fabric layer formed from the spunbond nonwoven fabric according to any one of claims 1 to 4 and at least one layer of an elastomer layer.
6. The laminated nonwoven fabric according to claim 5, wherein the elastomer layer is a layer formed of an elastomer nonwoven fabric.
7. A sanitary material comprising at least a part of the spunbonded nonwoven fabric according to any one of claims 1 to 4 or the laminated nonwoven fabric according to claim 5 or 6.
8. The method for producing a spunbonded nonwoven fabric according to any one of claims 1 to 4, wherein the 1 st component and the 2 nd component having a melt viscosity 1.20 times or more higher than the melt viscosity of the 1 st component are melted, and after the composite polymer stream is discharged from a composite spinneret and spun, the crimped composite fiber is formed by crimping the composite polymer stream so that the 2 nd component is disposed at the innermost side of the crimp from an air drawing unit to a collecting belt, and the crimped composite fiber is collected on the collecting belt.
9. The method for producing a spunbonded nonwoven fabric according to claim 8, wherein the mass of the 1 st component and the 2 nd component is 20: 80-99: 1, and the composite polymer stream is ejected.
10. The method for producing a laminated nonwoven fabric according to claim 5 or 6, comprising:
a step of forming a spun-bond nonwoven fabric layer by melting the 1 st component and the 2 nd component having a melt viscosity 1.20 times or more higher than the melt viscosity of the 1 st component, respectively, and discharging a composite polymer stream from a composite spinneret to spin the composite polymer stream, and then forming the crimped composite fiber by forming the crimped composite fiber while providing the 2 nd component at the innermost side of the crimp between an air drawing unit and a collecting belt, and collecting the crimped composite fiber on the collecting belt; and
and laminating at least one elastomer layer.
11. The method for producing a laminated nonwoven fabric according to claim 10, wherein the elastomer layer is formed by a spunbond method.
12. The method for producing a laminated nonwoven fabric according to claim 10, wherein the elastomer layer is formed by a melt-blowing method.
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| Application Number | Priority Date | Filing Date | Title |
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| JP2021-044293 | 2021-03-18 | ||
| JP2021044293 | 2021-03-18 | ||
| PCT/JP2022/010648 WO2022196527A1 (en) | 2021-03-18 | 2022-03-10 | Spunbond nonwoven fabric, laminate nonwoven fabric, manufacturing method of these and sanitary material |
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| CN116981804A true CN116981804A (en) | 2023-10-31 |
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| CN202280019012.1A Pending CN116981804A (en) | 2021-03-18 | 2022-03-10 | Spun-bonded nonwoven fabric, laminated nonwoven fabric, method for producing same, and sanitary material |
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| Country | Link |
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| JP (1) | JP7168125B1 (en) |
| KR (1) | KR20230156826A (en) |
| CN (1) | CN116981804A (en) |
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| WO2024089958A1 (en) * | 2022-10-27 | 2024-05-02 | Jnc株式会社 | Nonwoven fabric and surface sheet for absorbent article using same |
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| JPH07197367A (en) * | 1993-12-28 | 1995-08-01 | New Oji Paper Co Ltd | Filament-laminated spun-bonded nonwoven fabric |
| DK0846793T3 (en) * | 1996-04-25 | 2002-03-04 | Chisso Corp | Polyolene fin fibers and nonwoven fabrics made using them |
| JP4931700B2 (en) | 2001-01-29 | 2012-05-16 | 三井化学株式会社 | Crimped fiber nonwoven fabric and laminate thereof |
| JP5139669B2 (en) * | 2006-11-29 | 2013-02-06 | 三井化学株式会社 | Crimped composite fiber and method for producing the same |
| TW200934897A (en) * | 2007-12-14 | 2009-08-16 | Es Fiber Visions Co Ltd | Conjugate fiber having low-temperature processability, nonwoven fabric and formed article using the conjugate fiber |
| JP2012012758A (en) | 2010-06-04 | 2012-01-19 | Kuraray Kuraflex Co Ltd | Stretchable nonwoven fabric with high elongation |
| DK3246444T3 (en) | 2016-05-18 | 2020-06-02 | Reifenhaeuser Masch | Process for producing a high-volume non-woven web |
| JP6904260B2 (en) * | 2016-11-17 | 2021-07-14 | 東レ株式会社 | Spunbonded non-woven fabric and its manufacturing method |
| JP6935805B2 (en) * | 2017-09-28 | 2021-09-15 | 東レ株式会社 | Spun bond non-woven fabric |
-
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- 2022-03-10 JP JP2022516339A patent/JP7168125B1/en active Active
- 2022-03-10 KR KR1020237028428A patent/KR20230156826A/en unknown
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| JP7168125B1 (en) | 2022-11-09 |
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| TW202302948A (en) | 2023-01-16 |
| WO2022196527A1 (en) | 2022-09-22 |
| JPWO2022196527A1 (en) | 2022-09-22 |
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