JP2006002303A - Three-dimensional nonwoven fabric - Google Patents

Three-dimensional nonwoven fabric Download PDF

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JP2006002303A
JP2006002303A JP2004181814A JP2004181814A JP2006002303A JP 2006002303 A JP2006002303 A JP 2006002303A JP 2004181814 A JP2004181814 A JP 2004181814A JP 2004181814 A JP2004181814 A JP 2004181814A JP 2006002303 A JP2006002303 A JP 2006002303A
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nonwoven fabric
split
fibers
fiber
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JP4318597B2 (en
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Manabu Kaneda
学 金田
Koji Asano
浩司 浅野
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Kao Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a three-dimensional nonwoven fabric in which good touch and good hiding property of color of menstrual blood, etc., are developed even when the basis weight of the nonwoven fabric is relatively low. <P>SOLUTION: The three-dimensional nonwoven fabric 10 has at least first layer 1 and second layer 2 and the first layer 1 is partially joined to the second layer 2 by a joining part 3 having a prescribed pattern and a splittable conjugated fiber in an amount of 20-100 mass% is contained in the first layer 1. In the first layer 1, a part other than the joining part 3 is raised by contraction of the second layer 2 to form a protruded part 4. Parts in which the spaces between component resins are split and separated are formed in the splittable conjugated fiber. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

本発明は、立体不織布及びその製造方法並びに該立体不織布を用いた吸収性物品に関する。   The present invention relates to a three-dimensional nonwoven fabric, a method for producing the same, and an absorbent article using the three-dimensional nonwoven fabric.

全部又は一部が分割可能な複合繊維から形成され、微細な繊維を有してなる不織布が知られている。この不織布は触感に優れており更に集塵力に優れるので、眼鏡拭きや各種清掃用のワイパーとして用いられている。前記不織布は、前記複合繊維の構造上、スパンレース法によって前記複合繊維を分割離間させる必要がある。しかし、スパンレース法により製造される前記不織布は、製造工程が煩雑であり、生産性が悪いという問題がある。更にコストも高いという問題もある。   Nonwoven fabrics are known that are formed of composite fibers that can be divided in whole or in part and that have fine fibers. Since this nonwoven fabric has excellent tactile sensation and excellent dust collecting power, it is used as a wiper for wiping glasses and various cleanings. The nonwoven fabric needs to be separated and separated by the spunlace method due to the structure of the conjugate fiber. However, the nonwoven fabric produced by the spunlace method has a problem that the production process is complicated and the productivity is poor. There is also the problem of high costs.

本出願人は先に、柔軟で感触に優れた不織布を提供することを目的として、熱処理やロールによる加圧によって分割繊維の一部を分割離間させた不織布を提案した（特許文献１参照）。しかし、エンボスロールやカレンダーロールを用いて分割離間を生じさせると、不織布を加圧してしまうため、不織布が薄くなってしまうという不都合がある。また、ロールによる加圧に代えてエアースルーなどの熱処理のみで分割離間を生じさせた場合には、分割離間をさせるためにかける熱がより高温で長時間の熱処理になり、加熱のし過ぎにからくる溶融繊維溶融ムラや玉が発生し、良好な感触が得られにくい。また、加工そのものも煩雑になり好ましくない。   The present applicant has previously proposed a non-woven fabric in which a part of the split fibers is separated and separated by heat treatment or pressurization with a roll for the purpose of providing a non-woven fabric that is flexible and excellent in touch (see Patent Document 1). However, when the separation and separation are caused by using an embossing roll or a calender roll, the nonwoven fabric is pressurized, so that the nonwoven fabric becomes thin. In addition, when split separation is caused only by heat treatment such as air-through instead of pressurization with a roll, the heat applied to cause separation and separation becomes a heat treatment for a long time at a higher temperature, and overheating Unevenness of melted fibers and balls are generated, making it difficult to obtain a good feel. Further, the processing itself becomes complicated, which is not preferable.

また、出願人は、平面方向へ伸張させた場合の回復性及び厚み方向へ圧縮させたときの圧縮変形性が充分な立体シートを提供することを目的として、第１層とこれに隣接する第２層とを有し、第１層と第２層とが所定パターンの接合部によって部分的に接合されており、該接合部間で第１層が３次元的立体形状をなしており、第２層がエラストマー的挙動を示す材料で構成され、シート全体がエラストマー的挙動を示すと共に通気性を有する立体シート材料を提案した（特許文献２参照）。しかし、この立体シート材料も、良好な感触を得るためには目付を比較的大きくしなければならなかった。   In addition, the applicant intends to provide a three-dimensional sheet having sufficient recoverability when stretched in the plane direction and sufficient compressive deformation when compressed in the thickness direction. Two layers, the first layer and the second layer are partially joined by a joint of a predetermined pattern, the first layer has a three-dimensional shape between the joints, A three-dimensional sheet material has been proposed in which two layers are made of a material exhibiting an elastomeric behavior, and the entire sheet exhibits an elastomeric behavior and has air permeability (see Patent Document 2). However, this three-dimensional sheet material also has to have a relatively large basis weight in order to obtain a good feel.

特開平９−２７３０６１号公報JP-A-9-273061 特開２００２−１８７２２８号公報JP 2002-187228 A

本発明の目的は、比較的低い目付でも良好な感触及び良好な経血等の色の隠蔽性が発現される立体不織布を提供することにある。   An object of the present invention is to provide a three-dimensional nonwoven fabric that exhibits good touch and good color hiding properties such as menstrual blood even with a relatively low basis weight.

本発明は、少なくとも第１層と第２層とを有し、第１層と第２層とが所定パターンの接合部によって部分的に接合されており、第１層に、分割型複合繊維が２０質量％以上含まれており、第１層は、第２層の収縮により前記接合部以外の部分が***して凸部を形成しており、該分割型複合繊維には、構成樹脂間が分割離間した部分が生じている立体不織布を提供することにより前記目的を達成したものである。   The present invention has at least a first layer and a second layer, and the first layer and the second layer are partially joined by a joint portion having a predetermined pattern. 20% by mass or more is contained, and the first layer has a convex portion formed by protruding the portion other than the joint portion due to the contraction of the second layer. The object is achieved by providing a three-dimensional non-woven fabric in which divided and separated portions are generated.

また本発明は、前記立体不織布の好ましい製造方法として、分割型複合繊維を含む第１層用の不織布を形成し、第１層用の不織布とは別に形成した第２層用の不織布又は繊維ウエブと第１層用の不織布とを重ね合わせ、両者を所定パターンで部分的に接合して積層不織布とした後、該積層不織布の第２層部分を収縮させる立体不織布の製造方法を提供するものである。   The present invention also provides a second layer nonwoven fabric or fiber web formed separately from the first layer nonwoven fabric by forming a first layer nonwoven fabric containing split-type conjugate fibers as a preferred method for producing the three-dimensional nonwoven fabric. And a non-woven fabric for the first layer are overlapped, and the two layers are partially joined together in a predetermined pattern to form a laminated nonwoven fabric, and then a method for producing a three-dimensional nonwoven fabric that shrinks the second layer portion of the laminated nonwoven fabric is provided. is there.

更に本発明は、液透過性の表面シート、液不透過性の裏面シート及び両シート間に介在された液保持性の吸収体を有する吸収性物品において、前記表面シートとして請求項１記載の立体不織布を用い且つ該立体不織布における前記第１層の側を肌対向側として配した吸収性物品を提供するものである。   Furthermore, the present invention provides a solid article according to claim 1 as the top sheet in an absorbent article having a liquid-permeable top sheet, a liquid-impermeable back sheet, and a liquid-retaining absorbent interposed between the two sheets. The present invention provides an absorbent article using a non-woven fabric and having the first layer side of the three-dimensional non-woven fabric as the skin facing side.

本発明によれば、比較的低い目付でも良好な感触が発現される立体不織布が得られる。
また本発明によれば、良好な感触及び良好な経血等の色の隠蔽性が発現される吸収性物品が得られる。 According to the present invention, it is possible to obtain a three-dimensional nonwoven fabric that exhibits a good feel even with a relatively low basis weight.
Furthermore, according to the present invention, an absorbent article that exhibits good touch and good color hiding properties such as menstrual blood can be obtained.

以下本発明を、その好ましい実施形態に基づき図面を参照しながら説明する。
図１及び図２に示すように、本実施形態の立体不織布１０は、第１層１及びこれに隣接する第２層２とを有している。第１層１及び第２層２は、互いに積層されて所定パターンの接合部３で部分的に接合されている。 The present invention will be described below based on preferred embodiments with reference to the drawings.
As shown in FIG.1 and FIG.2, the three-dimensional nonwoven fabric 10 of this embodiment has the 1st layer 1 and the 2nd layer 2 adjacent to this. The first layer 1 and the second layer 2 are stacked on each other and are partially bonded by a bonding portion 3 having a predetermined pattern.

本実施形態における接合部３は、いわゆる千鳥状のパターン〔図４（ａ）参照〕で散点状に配されており、個々の接合部３は、それぞれ平面視円形で不連続に形成されている。接合部３は、図２に示すように、圧密化されており、立体不織布１０における他の部位に比して厚みが小さく且つ密度が高くなっている。   The joints 3 in the present embodiment are arranged in a dotted pattern in a so-called staggered pattern [see FIG. 4A], and each joint 3 is formed discontinuously in a circular shape in plan view. Yes. As shown in FIG. 2, the joint portion 3 is consolidated and has a smaller thickness and a higher density than other portions of the three-dimensional nonwoven fabric 10.

接合部３は、例えば熱エンボス、超音波エンボス、高周波エンボス、接着剤による接着などの各種接合手段によって形成される。本実施形態における接合部３は円形のものであるが、接合部３の形状は、円形の他、楕円形、三角形、矩形又はこれらの組み合わせ等であってもよい。また接合部３を、連続した形状、例えば直線や曲線などの線状、格子状等に形成してもよい。接合部３の形成パターンの他の例を図４（ｂ）〜図４（ｄ）に示した。   The joining portion 3 is formed by various joining means such as heat embossing, ultrasonic embossing, high frequency embossing, and adhesion using an adhesive. The joint 3 in the present embodiment is circular, but the shape of the joint 3 may be an ellipse, a triangle, a rectangle, or a combination thereof in addition to a circle. Moreover, you may form the junction part 3 in the continuous shape, for example, linear shapes, such as a straight line and a curve, a grid | lattice shape. The other example of the formation pattern of the junction part 3 was shown in FIG.4 (b)-FIG.4 (d).

第１層１は、第２層２との接合部３以外の部分が、立体不織布１の第１層１側の面側に***して凸部４を形成している。即ち、図１及び図２に示すように、第１層１における、接合部３同士間に位置する部分（詳細には、四隅部に接合部３を有する矩形状部分）が凸状をなしている。各凸部４の内部は、第１層１を構成する繊維で満たされている。   In the first layer 1, a portion other than the joint portion 3 with the second layer 2 is raised on the surface side of the three-dimensional nonwoven fabric 1 on the first layer 1 side to form a convex portion 4. That is, as shown in FIG.1 and FIG.2, the part (specifically, the rectangular-shaped part which has the junction part 3 in the four corners) located between the junction parts 3 in the 1st layer 1 makes convex shape. Yes. The inside of each convex portion 4 is filled with fibers constituting the first layer 1.

凸部４は、接合部３を形成するための処理（熱エンボス、超音波エンボス、高周波エンボス等）のみによって生じたものではなく、後述する第２層２の収縮により接合部３間が***して生じたものである。換言すれば、第２層２を収縮させることにより、接合部３を形成した後の積層不織布（製造中間体）に比較して、接合部３部分の厚みｔに対する凸部４部分の厚みＴの比（Ｔ／ｔ）が増大している。***には、***の程度が増大することも含まれる。   The convex portions 4 are not generated only by the processing (thermal embossing, ultrasonic embossing, high-frequency embossing, etc.) for forming the joint portions 3, but the joint portions 3 are raised by contraction of the second layer 2 described later. This is what happened. In other words, by shrinking the second layer 2, the thickness T of the convex portion 4 with respect to the thickness t of the joint 3 portion compared to the laminated nonwoven fabric (production intermediate) after forming the joint 3. The ratio (T / t) is increasing. Raising includes increasing the degree of bulging.

第２層２を収縮させて第１層１の一部を***させてあることは、第１層中に含まれる分割型複合繊維には曲げ応力が加わっていることを意味しており、その曲げ応力により第１層中の分割型複合繊維には、構成繊維間の分割離間が良好に生じている。また、第２層２が熱により収縮する場合、第１層１にも熱がかかり分割繊維を構成する樹脂成分の熱特性（軟化・溶融）により、さらに構成繊維間の分離を進めることができる。これにより、不織布中の繊維充填密度としては変わらないが、見かけの繊維本数が増大するため、比較的低い目付にしても良好な感触及び良好な経血等の色の隠蔽性を達成することができる。
経血等の色の隠蔽性とは、一面側から他面側に色の付いた液を透過させた後に、該一面側から見てその液の色を見えにくくできる性質である。 The fact that the second layer 2 is contracted and a part of the first layer 1 is raised means that the split type composite fiber contained in the first layer is subjected to bending stress, Due to the bending stress, the split type composite fibers in the first layer have good splitting between the constituent fibers. Further, when the second layer 2 contracts due to heat, the first layer 1 is also heated, and the separation between the constituent fibers can be further promoted by the thermal characteristics (softening / melting) of the resin component constituting the split fibers. . As a result, the fiber packing density in the nonwoven fabric does not change, but the apparent number of fibers increases, so that even with a relatively low basis weight, it is possible to achieve good touch and good color hiding properties such as menstrual blood. it can.
Color concealment such as menstrual blood is a property that makes it difficult to see the color of the liquid when viewed from the one surface side after allowing the colored liquid to pass from the one surface side to the other surface side.

立体不織布１０は、接合部３部分の厚みｔに対する凸部４部分の厚みＴの比（Ｔ／ｔ）が、液の吸収性（液引込み性や表面液残り）、隠蔽性、風合い、触感、毛羽立ちの観点から３０〜１５０、特に４０〜１００であることが好ましい。   The three-dimensional non-woven fabric 10 has a ratio (T / t) of the thickness T of the convex portion 4 to the thickness t of the joint 3 portion, the liquid absorbency (liquid drawability and surface liquid residue), concealability, texture, touch, From the viewpoint of fluffing, it is preferably 30 to 150, particularly 40 to 100.

第１層１及び第２層２は、それぞれ繊維集合体から構成されている。本明細書において、繊維集合体は、不織布化していない繊維ウエブや、不織布を含む概念である。
第１層１には、分割型複合繊維が２０質量％以上、好ましくは３０質量％以上含まれている。
第１層１中の分割型複合繊維の含有量が２０質量％未満であると、分割型複合繊維の構成樹脂間を分割離間させることによる見掛けの繊維量の増大効果が充分に得られず、低目付で良好な感触及び／又は隠蔽性を実現することが困難となる。 The first layer 1 and the second layer 2 are each composed of a fiber assembly. In this specification, the fiber assembly is a concept including a fiber web that is not made into a nonwoven fabric and a nonwoven fabric.
The first layer 1 contains 20% by mass or more, preferably 30% by mass or more of split-type composite fibers.
When the content of the split-type conjugate fiber in the first layer 1 is less than 20% by mass, the effect of increasing the apparent fiber amount by dividing and separating the constituent resins of the split-type conjugate fiber cannot be sufficiently obtained, It becomes difficult to achieve a good feel and / or concealment with a low basis weight.

第１層１は、分割型複合繊維１００％からなるものでも良いが、第１層１中の分割型複合繊維の含有量は８０質量％以下、特に７０質量％以下であることが、第１層１側の表面を摩擦することによる毛羽立ちや毛羽抜けを効果的に防止できるので好ましい。例えば、立体不織布１０を例えば吸収性物品の表面シートとして用い、且つ第１層１の側を肌当接側にして配した場合等に、着用者との摩擦に起因する毛羽立ちや毛羽抜けを防止することができる。   The first layer 1 may be composed of 100% split-type conjugate fiber, but the content of the split-type conjugate fiber in the first layer 1 is 80% by mass or less, particularly 70% by mass or less. Fluffing and fluffing due to friction on the surface on the layer 1 side can be effectively prevented, which is preferable. For example, when the three-dimensional nonwoven fabric 10 is used as a top sheet of an absorbent article, for example, and the first layer 1 side is disposed on the skin contact side, fluff and fluff due to friction with the wearer are prevented. can do.

本実施形態で用いた分割型複合繊維５は、図３（ａ）に示すように、互いに異なる２種類以上の樹脂５１，５２から構成され、各樹脂５１，５２が、繊維５の長手方向に連続的に配されており且つ繊維５の周方向に交互に配されている繊維であり、熱的作用及び／又は機械的作用によって各樹脂間が分割離間可能なものである。   As shown in FIG. 3A, the split-type conjugate fiber 5 used in the present embodiment is composed of two or more kinds of resins 51 and 52 that are different from each other, and each resin 51 and 52 is in the longitudinal direction of the fiber 5. The fibers are continuously arranged and alternately arranged in the circumferential direction of the fibers 5, and the resins can be separated and separated by a thermal action and / or a mechanical action.

分割型複合繊維５は、低融点樹脂５１と、該低融点樹脂５１よりも融点の高い高融点樹脂５２とを構成樹脂とし、４分割〜３２分割可能な繊維であることが好ましく、特にコスト、生産性、分割性の点で６分割〜１６分割可能な繊維であることが好ましい。   The split-type composite fiber 5 is preferably a fiber that can be divided into four to 32 parts, with the low-melting resin 51 and the high-melting resin 52 having a higher melting point than the low-melting resin 51 as a constituent resin. A fiber that can be divided into 6 to 16 parts is preferable in terms of productivity and division.

低融点樹脂としては、その融点が１００〜１５０℃程度のものが好ましく用いられる。その例としては、特開平９−２７３０６１号公報の段落〔００１３〕に記載のものが挙げられる。高融点樹脂としては、その融点が１５０〜２６０℃程度のものが好ましく用いられる。その例としては、特開平９−２７３０６１号公報の段落〔００１４〕に記載のものが挙げられる。高融点樹脂の融点は、低融点樹脂の融点よりも１００〜１５０℃程度高いことが好ましい。   As the low melting point resin, those having a melting point of about 100 to 150 ° C. are preferably used. Examples thereof include those described in paragraph [0013] of JP-A-9-273061. As the high melting point resin, those having a melting point of about 150 to 260 ° C. are preferably used. Examples thereof include those described in paragraph [0014] of JP-A-9-273061. The melting point of the high melting point resin is preferably about 100 to 150 ° C. higher than the melting point of the low melting point resin.

低融点樹脂と高融点樹脂との好ましい組み合わせとしては、低融点樹脂／高融点樹脂が、低融点ポリプロピレン（ＰＰ）／ポリエチレンテレフタレート（ＰＥＴ）、ポリエチレン（ＰＥ）／ポリエチレンテレフタレート（ＰＥＴ）、ポリエチレン（ＰＥ）／ポリプロピレン（ＰＰ）等が挙げられる。
分割型複合繊維は、その繊度が１〜１５ｄｔｅｘ、特に２〜８ｄｔｅｘであることが、不織布製造時の開繊性やカード性が良好であるため、これら加工性の点から好ましい。 Preferred combinations of the low melting point resin and the high melting point resin include low melting point resin / high melting point resin, low melting point polypropylene (PP) / polyethylene terephthalate (PET), polyethylene (PE) / polyethylene terephthalate (PET), polyethylene (PE ) / Polypropylene (PP).
The split-type conjugate fiber preferably has a fineness of 1 to 15 dtex, particularly 2 to 8 dtex, from the viewpoint of these processability because the fiber-opening property and cardability during the production of the nonwoven fabric are good.

第１層１中の分割型複合繊維は、立体不織布を低目付としても充分な強度が得られるようにする観点及び／又は毛羽立ちや毛羽抜けを防止する観点から、繊維の交点において熱融着していることが好ましい。繊維の交点は、分割型複合繊維同士の交点と、他の繊維を含有させる場合における、分割型複合繊維と他の繊維との交点とがあるが、何れかの交点において熱融着していることが好ましい。   The split-type conjugate fiber in the first layer 1 is heat-sealed at the intersection of the fibers from the viewpoint of obtaining sufficient strength even if the solid nonwoven fabric has a low basis weight and / or preventing fluffing and fluffing. It is preferable. The intersection of the fibers includes the intersection of the split-type composite fibers and the cross-point of the split-type composite fibers and other fibers in the case where other fibers are contained. It is preferable.

低融点樹脂及び高融点樹脂からなる分割型複合繊維は、低融点樹脂が熱収縮性を有するものであることが好ましい。その場合、立体不織布の状態では、低融点樹脂が繊維の長手方向に熱収縮している。   In the split-type composite fiber made of a low-melting resin and a high-melting resin, it is preferable that the low-melting resin has heat shrinkability. In that case, in the state of the three-dimensional nonwoven fabric, the low melting point resin is thermally contracted in the longitudinal direction of the fiber.

低融点樹脂が熱収縮性を有していると、立体不織布の製造工程において、分割型複合繊維の構成樹脂を分割離間させ易く、前述のように熱融着の工程と同時に行なえるため設備的に簡易な手段で、容易に見掛けの繊維量を増大させることができる。
また、低融点樹脂が熱収縮性を有していると、図３（ｂ）に示すように、熱処理により、熱収縮して凝集した低融点樹脂５１によって高融点樹脂５２が覆われ、それによって構成樹脂間が完全に分割離間するのを抑制された部分５３と、低融点樹脂の存在量が低下して構成樹脂間の分割離間が促進された部分５４とを、分割型複合繊維の長手方向に混在状態に生じさせることができる。そして、分割離間が抑制された部分５３同士又は該部分５３と他の熱融着性繊維との強固に熱融着された熱融着点５５が生じることによって、毛羽立ちや毛羽抜けの発生を防止することができる。また、分割離間が促進された部分５４によって見掛けの繊維量が増大する。そのため、低目付であっても、感触及び／又は色の隠蔽性の良好な立体不織布が得られる。 When the low melting point resin has heat shrinkability, it is easy to divide and separate the constituent resin of the split type composite fiber in the manufacturing process of the three-dimensional nonwoven fabric, and can be performed simultaneously with the heat sealing process as described above. The apparent fiber amount can be easily increased by simple means.
Further, if the low melting point resin has heat shrinkability, as shown in FIG. 3B, the high melting point resin 52 is covered with the low melting point resin 51 which is heat shrunk and aggregated by heat treatment, thereby The longitudinal direction of the split-type composite fiber includes a portion 53 in which the constituent resins are prevented from being completely separated and separated, and a portion 54 in which the abundance of the low-melting-point resin is reduced to promote the separation and separation between the constituent resins. Can occur in a mixed state. Then, the occurrence of fluffing and fluffing is prevented by the generation of the heat fusion points 55 that are firmly heat-sealed between the portions 53 in which the separation and separation are suppressed or between the portions 53 and other heat-fusible fibers. can do. Further, the apparent fiber amount is increased by the portion 54 in which the separation and separation are promoted. Therefore, a three-dimensional non-woven fabric with good feel and / or color hiding properties can be obtained even with a low basis weight.

また分割型複合繊維は、その構成樹脂の少なくとも一つに親水化剤が練り込まれて親水性を有していることが好ましい。親水化剤を練り込むことで親水性に耐久性が付与され、立体不織布１０を、吸収性物品の表面シートや表面シートと吸収体との間に配置するセカンドシートとして用いる場合に、液が繰り返し透過しても親水性が低下しにくくなる。これにより、通液性を安定して発現させることができる。   Moreover, it is preferable that the split type composite fiber has hydrophilicity by kneading a hydrophilizing agent into at least one of the constituent resins. Durability is imparted to the hydrophilicity by kneading a hydrophilizing agent, and the liquid is repeatedly used when the three-dimensional nonwoven fabric 10 is used as a second sheet disposed between the surface sheet of the absorbent article or the surface sheet and the absorbent body. Even if it permeates, the hydrophilicity is unlikely to decrease. Thereby, liquid permeability can be expressed stably.

特に、分割型複合繊維は、その構成樹脂の少なくとも一つに親水化剤を練り込むと共に分割型複合繊維の表面に該親水化剤と同一又は異なる親水化剤を施すことで、親水性に一層の耐久性が付与される。   In particular, the split-type conjugate fiber is made more hydrophilic by kneading a hydrophilizing agent into at least one of its constituent resins and applying the same or different hydrophilizing agent to the surface of the split-type conjugate fiber. Is provided with durability.

分割型複合繊維の構成樹脂に練り込む親水化剤は、水酸基、カルボニル基、カルボキシル基、スルホン基などの親水基を有する化合物であればよい。例えば脂肪酸グリセリド、アルキコキシ化アルキルフェノール、ポリオキシアルキレン脂肪酸エステル、脂肪酸ジエタノールアミド等の非イオン界面活性剤が挙げられる。   The hydrophilizing agent kneaded into the constituent resin of the split composite fiber may be a compound having a hydrophilic group such as a hydroxyl group, a carbonyl group, a carboxyl group, or a sulfone group. Examples thereof include nonionic surfactants such as fatty acid glycerides, alkyloxylated alkylphenols, polyoxyalkylene fatty acid esters, and fatty acid diethanolamides.

一方、分割型複合繊維の表面に施す親水化剤としては、例えば硫酸エステル塩基、Ｃ８〜Ｃ３０のアルキルリン酸エステル塩基、スルホン酸塩基等を含むアニオン系活性剤、ベタイン活性剤、ポリオキシエチレンアルキルエーテル、ポリオキシエチレンソルビタンモノオレート、ソルビタンモノオレートやポリオキシアルキレン変性オルガノシロキサン、アルキロールアミド型化合物とポリオキシアルキレン変性オルガノシロキサンとの配合物、ポリグリセリン脂肪酸エステル或いはこれとポリオキシアルキレン変性オルガノシロキサンとの配合物、ポリエーテルポリエステルブロック共重合体或いはこれとポリオキシアルキレン変性オルガノシロキサンとの配合物、炭素数２８以上の炭化水素基を疎水基とする界面活性剤とポリオキシアルキレン変性オルガノシロキサンとの配合物が挙げられる。   On the other hand, as the hydrophilizing agent applied to the surface of the split type composite fiber, for example, an anionic activator containing a sulfate ester base, a C8-C30 alkyl phosphate ester base, a sulfonate base, etc., a betaine activator, a polyoxyethylene alkyl Ether, polyoxyethylene sorbitan monooleate, sorbitan monooleate, polyoxyalkylene modified organosiloxane, blend of alkylolamide type compound and polyoxyalkylene modified organosiloxane, polyglycerin fatty acid ester or polyoxyalkylene modified organosiloxane , A polyether polyester block copolymer or a blend of this with a polyoxyalkylene-modified organosiloxane, a surfactant having a hydrocarbon group having 28 or more carbon atoms as a hydrophobic group, and a polyoxyal Blend of polyalkylene-modified organosiloxanes.

また分割型複合繊維は、その構成樹脂の少なくとも一つが親水性の樹脂であることが好ましい。構成樹脂の少なくとも一つ、好ましくは全部に、親水性の樹脂を用いることで、親水化剤を練り込んだ場合と同様又はそれ以上に、親水性に耐久性を付与でき、親水化剤を練り込んだ場合と同様に、通液性を安定して発現させることができる。親水性樹脂を用いた分割型複合繊維も同様に、繊維の表面に該親水化剤と同一又は異なる親水化剤を施すこともできる。   Moreover, it is preferable that at least one of the constituent resins of the split-type conjugate fiber is a hydrophilic resin. By using a hydrophilic resin for at least one, preferably all of the constituent resins, durability can be imparted to the hydrophilicity in the same manner as or more than when the hydrophilic agent is kneaded. In the same manner as in the case of filling, liquid permeability can be stably expressed. Similarly, the split type composite fiber using a hydrophilic resin can be subjected to the same or different hydrophilizing agent as the hydrophilizing agent on the surface of the fiber.

親水性の樹脂としては、例えばエチレン・ビニルアルコール共重合体などのポリビニルアルコール系樹脂。ポリエチレングリコール、ポリオキシアルキレングリコール、親水性ビニルモノマー等の共重合による物やスルホン酸金属塩含有などの親水性ＰＥＴ樹脂類。改質アクリレートやアクリル系樹脂。例えば酢酸ビニルをグラフト重合したナイロンなどポリアミド系樹脂。また、前述の親水化剤を練り込んだ親水ポリオレフィン系樹脂、酢酸セルロース樹脂、ポリ乳酸樹脂、ポリカプロラクトン樹脂等が挙げられる。これらの中でもポリビニルアルコール系樹脂や親水ＰＥＴ系樹脂等が好ましい。   Examples of the hydrophilic resin include polyvinyl alcohol resins such as ethylene / vinyl alcohol copolymer. Hydrophilic PET resins such as polyethylene glycol, polyoxyalkylene glycol, hydrophilic vinyl monomers and the like, and sulfonic acid metal salt-containing products. Modified acrylate and acrylic resin. For example, polyamide resins such as nylon grafted with vinyl acetate. Further, hydrophilic polyolefin resins, cellulose acetate resins, polylactic acid resins, polycaprolactone resins and the like in which the aforementioned hydrophilizing agent is kneaded can be mentioned. Of these, polyvinyl alcohol resins and hydrophilic PET resins are preferable.

尚、低融点樹脂と高融点樹脂とからなる分割型複合繊維の場合、高融点樹脂が、親水性の樹脂であることが熱処理後に繊維形状が維持されるため、液の引込みや吸収性の安定性、繰り返しの吸収性発現の観点から好ましい。低融点樹脂が親水性の樹脂である場合、熱によって溶融、軟化させながら分割剥離すると、樹脂が収縮や凝集するため、不織布内の低融点親水樹脂と液との接触面積が減少するため、高点融点樹脂の場合より低下するが、表面ドライ感を重視する設計の場合は有効である。   In the case of split-type composite fibers composed of a low-melting resin and a high-melting resin, the fiber shape is maintained after the heat treatment if the high-melting resin is a hydrophilic resin. From the viewpoint of the property and the repetitive absorbency expression. When the low melting point resin is a hydrophilic resin, if it is divided and peeled while being melted and softened by heat, the resin shrinks and aggregates, so the contact area between the low melting point hydrophilic resin and the liquid in the nonwoven fabric is reduced. Although it is lower than the case of a point melting point resin, it is effective in the case of a design that emphasizes the surface dry feeling.

本実施形態の立体不織布１０は、その製造工程に第２層２を収縮させる工程を有しており、第２層２を収縮させる手段として、第２層２中に、熱収縮性繊維を含有させてある。立体不織布１０の状態では、熱収縮性繊維はその多くが収縮した状態であるが、充分に収縮していない状態のもの等が残っていても良い。本明細書においては、収縮しているか否かを問わずに、熱収縮性繊維という。
熱収縮性繊維としては、熱可塑性ポリマー材料からなり且つ熱収縮性を有するものが好ましく用いられる。特に潜在捲縮性繊維が、不織布のやわらかさや風合い、伸縮性や弾性発現の観点から好ましい。 The three-dimensional nonwoven fabric 10 of this embodiment has a step of shrinking the second layer 2 in its production process, and contains heat-shrinkable fibers in the second layer 2 as means for shrinking the second layer 2. I'm allowed. In the state of the three-dimensional nonwoven fabric 10, most of the heat-shrinkable fibers are in a contracted state, but those that are not sufficiently contracted may remain. In this specification, it is called heat-shrinkable fiber regardless of whether or not it is contracted.
As the heat-shrinkable fibers, those made of a thermoplastic polymer material and having heat-shrinkability are preferably used. In particular, latent crimpable fibers are preferable from the viewpoint of the softness and texture of the nonwoven fabric, the stretchability and the development of elasticity.

潜在捲縮性繊維は、加熱される前は、従来の不織布用の繊維と同様に取り扱うことができ、且つ所定温度での加熱によって螺旋状の捲縮が発現して収縮する性質を有する繊維である。潜在捲縮性繊維は、例えば収縮率の異なる２種類の熱可塑性ポリマー材料を成分とする偏心芯鞘型複合繊維又はサイド・バイ・サイド型複合繊維からなる。その例としては、特開平９−２９６３２５号公報や特許２７５９３３１号明細書に記載のものが挙げられる。   The latent crimpable fiber is a fiber that can be handled in the same manner as a conventional nonwoven fabric fiber before being heated, and has a property that a helical crimp is developed and contracted by heating at a predetermined temperature. is there. The latent crimpable fiber includes, for example, an eccentric core-sheath type composite fiber or a side-by-side type composite fiber containing two types of thermoplastic polymer materials having different shrinkage rates as components. Examples thereof include those described in JP-A-9-296325 and Japanese Patent No. 2759331.

第２層２中の熱収縮性繊維（特に潜在捲縮性繊維）の含有量は、立体形状の成形性や伸縮性、弾性、不織布生産性や加工性の観点から、５０〜１００質量％、特に７０〜１００質量％であることが好ましい。   The content of the heat-shrinkable fibers (particularly latent crimpable fibers) in the second layer 2 is 50 to 100% by mass from the viewpoints of three-dimensional formability and stretchability, elasticity, nonwoven fabric productivity, and processability. In particular, the content is preferably 70 to 100% by mass.

第１層１中には、分割型複合繊維以外の繊維が含まれていても良い。第１層１中に含有させる分割型複合繊維以外の繊維としては、熱可塑性ポリマー材料からなる熱融着繊維が挙げられる。このような熱融着繊維としては、分割型複合繊維の低融点樹脂の融点と同程度又はそれよりも低い融点を有する樹脂もしくは同種の樹脂から構成されるものを用いることが、分割型複合繊維との融着の点から好ましい。そのような繊維としては、例えばポリエチレン系繊維やポリプロピレン系繊維、ポリエチレンテレフタレート系繊維、ポリアミド系繊維が挙げられる。また、芯鞘型複合繊維やサイドバイサイド型複合繊維を用いることもできる。これらの複合繊維を用いる場合には、その低融点樹脂として、分割型複合繊維の低融点樹脂の融点と同程度又はそれよりも低い融点を有する樹脂もしくは同種の樹脂が用いられることが前述した理由と同様の理由から好ましい。   The first layer 1 may contain fibers other than the split composite fibers. Examples of fibers other than the split-type composite fibers contained in the first layer 1 include heat-sealed fibers made of a thermoplastic polymer material. As such a heat-bonding fiber, it is possible to use a split composite fiber that is composed of a resin having the same or lower melting point as that of the low melting point resin of the split composite fiber or a resin of the same type. It is preferable from the viewpoint of fusion. Examples of such fibers include polyethylene fibers, polypropylene fibers, polyethylene terephthalate fibers, and polyamide fibers. A core-sheath type composite fiber or a side-by-side type composite fiber can also be used. When these composite fibers are used, the low melting point resin is a resin having the same or lower melting point than the melting point of the low melting point resin of the split type composite fiber or the same type of resin as described above. It is preferable for the same reason.

熱可塑性ポリマー材料からなる熱融着性繊維（分割型複合繊維を除く）の第１層１中の含有量は０〜８０質量％、特に２０％〜７０質量％であることが好ましい。
第１層１を構成する繊維は、実質的に熱収縮性を有しないか、又は収縮性がある場合上述した第２層２中の熱収縮性繊維の収縮開始温度以下では前記熱収縮性繊維よりも収縮率が低いものであることが好ましい。 The content in the first layer 1 of heat-fusible fibers (excluding split-type composite fibers) made of a thermoplastic polymer material is preferably 0 to 80% by mass, particularly preferably 20% to 70% by mass.
If the fibers constituting the first layer 1 are substantially not heat-shrinkable or are shrinkable, the heat-shrinkable fibers are below the shrinkage start temperature of the heat-shrinkable fibers in the second layer 2 described above. It is preferable that the shrinkage rate is lower than that.

第２層２中には、熱収縮性繊維以外の繊維が含まれていても良い。第２層２中に含有させる熱収縮性繊維以外の繊維としては、上述した熱可塑性ポリマー材料からなる熱融着性繊維や、第１層１中に含有させた分割型複合繊維と同様の分割型複合繊維が挙げられる。
第２層中に分割型複合繊維を含有させる場合その含有量は、第１層中の分割型複合繊維の含有率よりも低いことが好ましく、特に第２層中の含有量が５〜６０質量％、特に１０〜４０質量％であることが収縮による立体形状の形成性と不織布の液の引込み性や拡散性を向上する点と、見かけの繊維量が上がるため隠蔽性を上げられる点から好ましい。
第２層中の熱可塑性ポリマー材料からなる熱融着性繊維（分割型複合繊維を除く）の含有量は５〜５０質量％、特に１０〜３０質量％であることが不織布の強度や伸びをある程度抑制できるのでハンドリング性や加工性の点から好ましい。 The second layer 2 may contain fibers other than heat-shrinkable fibers. Examples of fibers other than the heat-shrinkable fibers contained in the second layer 2 include the above-described heat-fusible fibers made of the thermoplastic polymer material and the same split fibers as the split-type conjugate fibers contained in the first layer 1. Type composite fiber.
When the split-type conjugate fiber is contained in the second layer, the content is preferably lower than the content of the split-type conjugate fiber in the first layer, and the content in the second layer is particularly 5 to 60 mass. %, Especially 10 to 40% by mass is preferable from the viewpoint of improving the formability of the three-dimensional shape by shrinkage, the drawability and diffusibility of the liquid of the nonwoven fabric, and the concealability can be increased because the apparent fiber amount increases. .
The content of the heat-fusible fiber (excluding the split-type composite fiber) made of the thermoplastic polymer material in the second layer is 5 to 50% by mass, particularly 10 to 30% by mass, which increases the strength and elongation of the nonwoven fabric. Since it can suppress to some extent, it is preferable from the point of handling property or workability.

立体不織布全体として見た場合、分割型複合繊維の含有量は、立体不織布中５〜８０質量％、特に１０〜６０質量％であることが収縮による立体構造の形成や液の引込み、吸収性、拡散性及び風合いの各特性や機能を最適に発現する点から好ましい。また、その他の熱融着性繊維（分割型複合繊維を除く）の含有量は、立体不織布中５〜７０質量％、特に１０〜５５質量％であることが立体構造の形成性を妨げず、風合いと強度バランスの点から好ましい。   When viewed as the whole of the three-dimensional nonwoven fabric, the content of the split-type conjugate fiber is 5 to 80% by mass, particularly 10 to 60% by mass in the three-dimensional nonwoven fabric. It is preferable from the viewpoint of optimal expression of each characteristic and function of diffusibility and texture. In addition, the content of other heat-fusible fibers (excluding split-type composite fibers) is 5 to 70% by mass, particularly 10 to 55% by mass in the three-dimensional nonwoven fabric, without disturbing the formation of the three-dimensional structure, It is preferable from the viewpoint of texture and strength balance.

本実施形態の立体不織布１０においては、第１層１及び／又は第２層２に、前述した分割型複合繊維、熱収縮性繊維及び熱融着繊維に加えて、コットン、羊毛などの天然繊維、アクリル系繊維、ポリオレフィン系繊維、ポリ塩化ビニル系繊維、ポリビニルアルコール繊維、レーヨン、キュプラ、アセテート等の再生繊維、ナイロン６、ナイロン６６等のポリアミド系繊維などの他の種の繊維を含有させてもよい。これらの繊維は、立体不織布１０の重量に対して３０質量％程度以下、好ましくは２０質量％程度以下の量で含有させることができる。   In the three-dimensional nonwoven fabric 10 of the present embodiment, the first layer 1 and / or the second layer 2 are made of natural fibers such as cotton and wool in addition to the above-described split type composite fiber, heat-shrinkable fiber and heat-bonded fiber. Other fibers such as acrylic fiber, polyolefin fiber, polyvinyl chloride fiber, polyvinyl alcohol fiber, regenerated fiber such as rayon, cupra and acetate, and polyamide fiber such as nylon 6 and nylon 66. Also good. These fibers can be contained in an amount of about 30% by mass or less, preferably about 20% by mass or less, based on the weight of the three-dimensional nonwoven fabric 10.

本実施形態の立体不織布１０は、上述した構成を有するため、比較的低い目付でも良好な感触及び良好な経血等の色の隠蔽性が発現される。
本発明の立体不織布は、その目付が３０〜１００ｇ／ｍ2、特に４０〜８０ｇ／ｍ2であることが、吸収性物品の表面材として用いたときの液の吸収性と透過性のバランスが良く、また、コストの点からも好ましい。 Since the three-dimensional nonwoven fabric 10 of the present embodiment has the above-described configuration, a good touch and good color concealing properties such as menstrual blood are expressed even with a relatively low basis weight.
The three-dimensional nonwoven fabric of the present invention has a basis weight of 30 to 100 g / m 2 , particularly 40 to 80 g / m 2 , and the balance between liquid absorbency and permeability when used as a surface material for absorbent articles. It is also preferable from the viewpoint of cost.

また、立体不織布１０は、ＫＥＳの圧縮特性において、圧縮仕事量の値が、1〜２（ｇｆ・ｃｍ／ｃｍ2）、特に１．２〜１．８（ｇｆ・ｃｍ／ｃｍ2）であることが、吸収性物品の表面材として、肌への負荷が小さく柔らかい。また、適度な反発性を維持するため、表面材としての液の透過性、液戻りの抑制など吸収性と前記風合いのバランスの点から好ましい。 The three-dimensional nonwoven fabric 10 has a compression work value of 1 to 2 (gf · cm / cm 2 ), particularly 1.2 to 1.8 (gf · cm / cm 2 ) in the compression characteristics of KES. However, as a surface material of an absorbent article, the load on the skin is small and soft. Moreover, in order to maintain moderate resilience, it is preferable from the viewpoint of the balance between the absorbability and the texture such as the permeability of the liquid as the surface material and the suppression of liquid return.

ＫＥＳ圧縮特性の圧縮仕事量の値は、以下のようにして測定される。
ＫＥＳＦＢ３（カトーテック株式会社製）を用いた。長さ２．５ｃｍ×幅２．０ｃｍ以上の試料を準備し測定台にのせ、面積２ｃｍ2の円形平面をもつ鋼板の圧縮子で圧縮速度２０μｍ／ｓｅｃにて、圧縮最大荷重５０ｇｆ／ｃｍ2まで圧縮した。試料は第１層が上面になるように置き圧縮した。この時、圧縮荷重０．５ｇｆ／ｃｍ2から最大荷重時までの圧縮荷重の変化を積分することにより、圧縮仕事量が求められる。測定は３回行ない平均値を求めた。 The value of the compression work amount of the KES compression characteristic is measured as follows.
KESFB3 (manufactured by Kato Tech Co., Ltd.) was used. Placed on Prepare length 2.5 cm × width 2.0cm or more sample measurement stage, in the compression rate 20 [mu] m / sec in the compression element of the steel plate with a circular plane area 2 cm 2, to the compression maximum load 50 gf / cm 2 Compressed. The sample was placed and compressed with the first layer on top. At this time, the work of compression is obtained by integrating the change of the compression load from the compression load of 0.5 gf / cm 2 to the maximum load. The measurement was performed 3 times and the average value was obtained.

また、立体不織布１０は、単位坪量当たりの隠蔽率が１．２０〜１．７０、特に１．２５〜１．６０であることが、液の透過性と隠蔽性のバランスが良好で、吸液後のドライ感の点から好ましい。   Further, the three-dimensional nonwoven fabric 10 has a concealment rate per unit basis weight of 1.20 to 1.70, particularly 1.25 to 1.60, which has a good balance between liquid permeability and concealment, and absorbs water. It is preferable from the viewpoint of dry feeling after liquid.

単位坪量当たりの隠蔽率は、以下のようにして測定される。
簡易型分光色差計ＮＦ３３３（日本電色工業株式会社製）を用い、Ｌ値、ａ値、ｂ値を測定した。測定の設定は、視野角２°、光源Ｃで、赤色の基準版を用い、その上に、第１層側を上にして試料を置き測定した。測定は３回行ない、平均値を求めた。この中で、白さをあらわすＬ値を隠蔽率とした。一方、試料の坪量を測定し、前記隠蔽率の値を坪量で割り算し、単位坪量当たりの隠蔽率を算出した。 The concealment rate per unit basis weight is measured as follows.
The L value, a value, and b value were measured using a simple spectral color difference meter NF333 (manufactured by Nippon Denshoku Industries Co., Ltd.). The measurement was set by using a red reference plate with a viewing angle of 2 ° and a light source C, and placing a sample with the first layer side up, and measuring. The measurement was performed 3 times, and the average value was obtained. Among these, the L value representing whiteness was defined as the concealment rate. On the other hand, the basis weight of the sample was measured, and the value of the concealment rate was divided by the basis weight to calculate the concealment rate per unit basis weight.

また、立体不織布１０は、その厚みが０．５ｇ／ｃｍ2荷重下において１．０〜４．０ｍｍ、特に１．５〜３．０ｍｍであることが、十分な嵩高さが発現する点から好ましい。０．５ｇ／ｃｍ2荷重下の厚みは、立体不織布１０に軽くタッチし始めたときの厚みにほぼ相当する。０．５ｇ／ｃｍ2荷重下の立体不織布１０の厚みは、特開平８−２４６３２１号公報の段落〔００６３〕の記載に従い測定される。 The three-dimensional nonwoven fabric 10 preferably has a thickness of 1.0 to 4.0 mm, particularly 1.5 to 3.0 mm under a load of 0.5 g / cm 2 , in view of sufficient bulkiness. . The thickness under a load of 0.5 g / cm 2 substantially corresponds to the thickness when the three-dimensional nonwoven fabric 10 starts to be lightly touched. The thickness of the three-dimensional nonwoven fabric 10 under a load of 0.5 g / cm 2 is measured according to the description in paragraph [0063] of JP-A-8-246321.

次に、本実施形態の立体不織布１０の好ましい製造方法について説明する。
先ず、第１層１及び第２層２を構成する繊維ウエブを製造する。両繊維ウエブは、それぞれ、例えばカード機を用いたカード法、紡糸ノズルから紡出された溶融状態の繊維をイジェクタで延伸しコンベアベルト上に堆積させる方法、エアレイド法などによって形成することができる。
次いで、第１層用の繊維ウエブに、熱処理を施し、構成繊維の交点を熱融着させて不織布化する。熱処理は、ドットや線状の各種パターンを持ったヒートエンボスロールやスムースロールで熱や超音波により繊維同士を圧着する方法、熱風を透過させて繊維同士を融着するエアスルー法等を用いることもできるが、熱風を透過させる方法、即ちエアースルー法が好ましい。エアースルー法によれば、分割型複合繊維に、低融点樹脂の熱収縮による凝集が生じやすく、高融点樹脂と低融点樹脂が離間しやすくなり、繊維の分割が促進する。 Next, the preferable manufacturing method of the three-dimensional nonwoven fabric 10 of this embodiment is demonstrated.
First, the fiber web which comprises the 1st layer 1 and the 2nd layer 2 is manufactured. Both fiber webs can be formed by, for example, a card method using a carding machine, a method in which melted fibers spun from a spinning nozzle are drawn by an ejector and deposited on a conveyor belt, an airlaid method, and the like.
Next, the fiber web for the first layer is subjected to heat treatment, and the intersections of the constituent fibers are thermally fused to form a nonwoven fabric. For heat treatment, heat embossing rolls and smooth rolls with various patterns such as dots and lines can be used to press the fibers together with heat or ultrasonic waves, or air-through methods can be used to fuse the fibers by passing hot air. Although possible, a method of transmitting hot air, that is, an air-through method is preferable. According to the air-through method, the split-type composite fiber is likely to aggregate due to thermal contraction of the low-melting resin, and the high-melting resin and the low-melting resin are easily separated from each other, thereby promoting the fiber splitting.

次いで、得られた第１層用の不織布を、上述した第２層用の繊維ウエブ又はこれに不織布化処理を施して得た第２層用の不織布と重ね合わせ、凹凸ロールと平滑ロールとの組み合わせからなる熱エンボスロール装置等を用いて、これらを所定のパターンで部分的に接合させる。これにより、所定パターンの接合部３が形成された積層不織布が得られる。
得られた積層不織布に対して、第２層２部分（第２層となる部分）に含まれた熱収縮性繊維が熱収縮を開始する温度以上の熱処理を施して、該積層不織布の第２層部分を熱収縮させる。
この熱収縮により、積層不織布の第１層部分（第１層となる部分）の接合部３間に位置する部分が、第１層側に***して凸部４を形成する。また、それと同時に、第１層部分に含まれていた分割型複合繊維に再び熱がかかり低融点樹脂が軟化又は再凝集や収縮が起こると共に、分割繊維に曲げ応力も発生し、分割型複合繊維の構成樹脂間の分割離間がより一層生じやすくなりる。特に熱融着した繊維の交点以外の部分に構成繊維間の分割離間が生じる
第２層を熱収縮させるための熱処理の温度は、収縮繊維の収縮開始温度より高く、収縮繊維の融着温度より低いことが、立体不織布の風合いの点から好ましい。また、分割型複合繊維を構成する低融点樹脂の融点は収縮繊維の融着温度より低い場合、分割離間が促進するので好ましい。
第２層を収縮させるには、例えば卓上型の恒温乾燥機や、熱接着不織布を製造する際に用いられるエアスルー熱処理機などが用いられる。 Next, the obtained nonwoven fabric for the first layer is overlapped with the above-described fiber web for the second layer or the nonwoven fabric for the second layer obtained by subjecting this to the nonwoven fabric, and the uneven roll and the smooth roll These are partially joined in a predetermined pattern using a hot embossing roll device or the like made of a combination. Thereby, the laminated nonwoven fabric in which the junction part 3 of the predetermined pattern was formed is obtained.
The laminated nonwoven fabric obtained is subjected to a heat treatment at a temperature equal to or higher than the temperature at which the heat-shrinkable fibers contained in the second layer 2 portion (portion to be the second layer) start thermal shrinkage. Heat shrink the layer part.
Due to this heat shrinkage, the portion located between the joint portions 3 of the first layer portion (portion serving as the first layer) of the laminated nonwoven fabric bulges toward the first layer side to form the convex portion 4. At the same time, the split type composite fiber contained in the first layer portion is heated again, and the low melting point resin softens or re-aggregates and shrinks, and the split fiber also generates bending stress. The separation and separation between the constituent resins is more likely to occur. In particular, the separation and separation between the constituent fibers occurs at a portion other than the intersection of the heat-fused fibers. The temperature of the heat treatment for thermally shrinking the second layer is higher than the shrinkage start temperature of the shrink fibers, and higher than the fusion temperature of the shrink fibers. Low is preferable from the viewpoint of the texture of the three-dimensional nonwoven fabric. Moreover, when the melting point of the low melting point resin constituting the split type composite fiber is lower than the fusion temperature of the shrink fiber, it is preferable because the split separation is promoted.
In order to shrink the second layer, for example, a desktop type thermostatic dryer or an air-through heat treatment machine used when manufacturing a heat-bonding nonwoven fabric is used.

本実施形態の立体不織布の製造方法によれば、分割繊維に加わる熱工程が多く、しかも変形する応力を工程の中で与えられるため、繊維の分割離間が促進し易い。このため、比較的簡易な方法で分割離間させることができると共に、柔らかく、風合いの良い、不織布を製造することができる。また、繊維に酸化チタンなどの無機粒子を多く含有しなくとも隠蔽性の高い不織布を製造できる。   According to the manufacturing method of the three-dimensional nonwoven fabric of the present embodiment, there are many thermal processes applied to the split fibers, and further, the stress to be deformed is given in the process, so that the splitting and separation of the fibers are easily promoted. For this reason, while being able to divide | separate and separate by a comparatively simple method, the soft nonwoven fabric which is soft and can be manufactured can be manufactured. In addition, a nonwoven fabric with high concealability can be produced even if the fiber does not contain many inorganic particles such as titanium oxide.

第２層を熱収縮させる際の第２層の熱収縮率は、熱収縮のコントロール、風合い、加工性、コストなどの点から、２０〜９０％、特に４０〜８０％とすることが好ましい。熱収縮率は面積収縮率であり、収縮前の基準面積Ｓ0 、基準面積の収縮後の面積Ｓ1 から下記の式（１）にて求められる。
収縮率＝（Ｓ0 −Ｓ1 ）／Ｓ0 ×１００ （１） The thermal contraction rate of the second layer when the second layer is thermally contracted is preferably 20 to 90%, particularly 40 to 80% from the viewpoints of thermal contraction control, texture, workability, cost, and the like. The thermal shrinkage rate is an area shrinkage rate, and is obtained by the following formula (1) from the reference area S 0 before shrinkage and the area S 1 after shrinkage of the reference area.
Shrinkage rate = (S 0 −S 1 ) / S 0 × 100 (1)

立体不織布１０は、例えば生理用ナプキンや使い捨ておむつなどの吸収性物品の表面シート、該吸収性物品における吸収体と表面シートの間に配置されるセカンドシート、あるいはシートの中に部分的に保液性や徐放性を持たせたスキンケアシートや清掃シートなどとして好適に用いられる。清掃シートとして用いた場合には汚れのかきとり性が優れている。また、スキンケアシートとして用いた場合には、肌への良好な感触が得られる。特に、液透過性の表面シート、液不透過性の裏面シート及び両シート間に介在された液保持性の吸収体を有する吸収性物品における前記表面シートとして立体不織布１０を用い、且つ該立体不織布１０における第１層１の側を肌対向側として配することで、良好な感触及び良好な経血等の色の隠蔽性が発現され、しかも、違和感の少ない、使用感、ドライ感に優れた吸収性物品が得られる。   The three-dimensional nonwoven fabric 10 is, for example, a surface sheet of an absorbent article such as a sanitary napkin or a disposable diaper, a second sheet disposed between the absorbent body and the surface sheet in the absorbent article, or a liquid retaining solution partially in the sheet It is suitably used as a skin care sheet or a cleaning sheet that has the property and sustained release property. When used as a cleaning sheet, it has excellent dirt scraping properties. Moreover, when used as a skin care sheet, a good feel to the skin can be obtained. In particular, the three-dimensional nonwoven fabric 10 is used as the surface sheet in an absorbent article having a liquid-permeable top sheet, a liquid-impermeable back sheet, and a liquid-retaining absorbent interposed between the two sheets. By arranging the side of the first layer 1 in 10 as the skin facing side, a good touch and a good color concealing property such as menstrual blood are expressed, and there is little discomfort, excellent use feeling and dry feeling. An absorbent article is obtained.

本発明は前記実施形態に制限されない。例えば前記実施形態の立体不織布１０は第１層１及び第２層２から構成される二層構造であったが、これに代えて、第２層の第１層とは反対側の面側に１又は２以上の層を備えた三層構造以上の多層構造であってもよい。   The present invention is not limited to the embodiment. For example, although the three-dimensional nonwoven fabric 10 of the said embodiment was a two-layer structure comprised from the 1st layer 1 and the 2nd layer 2, it replaced with this and the surface side on the opposite side to the 1st layer of a 2nd layer was carried out. It may be a multilayer structure of three or more layers provided with one or more layers.

図１は、本発明の立体不織布の一実施形態として立体不織布を示す斜視図である。FIG. 1 is a perspective view showing a three-dimensional nonwoven fabric as an embodiment of the three-dimensional nonwoven fabric of the present invention. 図２は、図１の立体不織布における、複数の凸部の各頂部を通る縦方向断面（Ｉ−Ｉ断面）が模式的に示されている。FIG. 2 schematically shows a longitudinal section (II section) passing through the tops of the plurality of convex portions in the three-dimensional nonwoven fabric of FIG. 図３は、分割型複合繊維を示す図で、図３（ａ）は構成繊維間が分割離間していない繊維単独の状態を示し、図３（ｂ）は図１の立体不織布中における状態を模式的に示す説明図である。FIG. 3 is a diagram showing a split type composite fiber, FIG. 3 (a) shows a state of a single fiber in which constituent fibers are not split apart, and FIG. 3 (b) shows a state in the three-dimensional nonwoven fabric of FIG. It is explanatory drawing shown typically. 図４は、立体不織布の接合部の形成パターンを示す平面図であり、図４（ａ）は、図１に示す立体不織布のパターンであり、図４（ｂ）〜図４（ｄ）は、他の例を示す図である。FIG. 4 is a plan view showing the formation pattern of the joint portion of the three-dimensional nonwoven fabric, FIG. 4 (a) is the pattern of the three-dimensional nonwoven fabric shown in FIG. 1, and FIG. 4 (b) to FIG. It is a figure which shows another example.

符号の説明Explanation of symbols

１ 第１層
２ 第２層
３ 接合部
４ 凸部
５ 分割型複合繊維
５１，５２ 構成樹脂
１０ 立体不織布


DESCRIPTION OF SYMBOLS 1 1st layer 2 2nd layer 3 Joining part 4 Convex part 5 Splitting type composite fiber 51,52 Component resin 10 Three-dimensional nonwoven fabric


Claims (9)

少なくとも第１層と第２層とを有し、第１層と第２層とが所定パターンの接合部によって部分的に接合されており、第１層に、分割型複合繊維が２０質量％以上含まれており、第１層は、第２層の収縮により前記接合部以外の部分が***して凸部を形成しており、該分割型複合繊維には、その構成樹脂間が分割離間した部分が生じている立体不織布。 It has at least a first layer and a second layer, and the first layer and the second layer are partially bonded by a predetermined pattern of joints, and the split composite fiber is 20% by mass or more in the first layer. In the first layer, the portion other than the joint portion is raised by contraction of the second layer to form a convex portion, and the constituent resin is divided and separated in the split type composite fiber. A three-dimensional non-woven fabric with parts. 第２層には、潜在捲縮性繊維が含まれており、第２層は、該潜在捲縮性繊維が捲縮を発現して収縮したものである請求項１記載の立体不織布。 The three-dimensional nonwoven fabric according to claim 1, wherein the second layer contains latent crimpable fibers, and the second layer is one in which the latent crimpable fibers are contracted to develop crimps. 前記分割型複合繊維が、繊維の交点において熱融着している請求項１又は２記載の立体不織布。 The three-dimensional nonwoven fabric according to claim 1 or 2, wherein the split type composite fibers are heat-sealed at the intersections of the fibers. 前記分割型複合繊維の構成樹脂の少なくとも一つに親水化剤が練り込まれている請求項１〜３の何れかに記載の立体不織布。 The three-dimensional nonwoven fabric according to any one of claims 1 to 3, wherein a hydrophilizing agent is kneaded into at least one of the constituent resins of the split composite fibers. 前記分割型複合繊維の構成樹脂の少なくとも一つが親水性の樹脂である請求項１〜３の何れかに記載の立体不織布。 The three-dimensional nonwoven fabric according to any one of claims 1 to 3, wherein at least one of the constituent resins of the split-type conjugate fiber is a hydrophilic resin. 前記分割型複合繊維が、低融点樹脂と、該低融点樹脂よりも融点の高い高融点樹脂とを構成樹脂とし、低融点樹脂が該繊維の長手方向に熱収縮している１〜５の何れかに記載の立体不織布。 Any one of 1 to 5 in which the split-type conjugate fiber is composed of a low melting point resin and a high melting point resin having a higher melting point than the low melting point resin, and the low melting point resin is thermally contracted in the longitudinal direction of the fiber. The three-dimensional nonwoven fabric of crab. 請求項１記載の立体不織布の製造方法であって、
分割型複合繊維を含む第１層用の不織布を形成し、第１層用の不織布とは別に形成した第２層用の不織布又は繊維ウエブと第１層用の不織布とを重ね合わせ、両者を所定パターンで部分的に接合して積層不織布とした後、該積層不織布の第２層部分を収縮させる立体不織布の製造方法。 It is a manufacturing method of the solid nonwoven fabric according to claim 1,
A non-woven fabric for the first layer containing the split-type conjugate fibers is formed, and the non-woven fabric for the second layer or the fiber web formed separately from the non-woven fabric for the first layer is overlapped with the non-woven fabric for the first layer. A method for producing a three-dimensional nonwoven fabric in which a second layer portion of the laminated nonwoven fabric is contracted after partially joining in a predetermined pattern to form a laminated nonwoven fabric. 前記第１層用の不織布を、分割型複合繊維を含む繊維ウエブにエアースルー法による熱処理を施して形成する請求項７記載の立体不織布の製造方法。 The manufacturing method of the three-dimensional nonwoven fabric of Claim 7 which forms the nonwoven fabric for said 1st layers by heat-processing by the air through method to the fiber web containing a split type composite fiber. 液透過性の表面シート、液不透過性の裏面シート及び両シート間に介在された液保持性の吸収体を有する吸収性物品において、前記表面シートとして請求項１記載の立体不織布を用い且つ該立体不織布における前記第１層の側を肌対向側として配した吸収性物品。

In an absorbent article having a liquid-permeable top sheet, a liquid-impermeable back sheet, and a liquid-retaining absorbent interposed between the two sheets, the three-dimensional nonwoven fabric according to claim 1 is used as the top sheet, and The absorptive article which arranged the 1st layer side in a solid nonwoven fabric as the skin opposing side.

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JP2011137248A (en) * 2009-12-25 2011-07-14 Kao Corp Raised nonwoven fabric and method for producing the same
JP2013102885A (en) * 2011-11-11 2013-05-30 Kao Corp Wearing article
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CN107604534A (en) * 2017-09-27 2018-01-19 江苏盛纺纳米材料科技股份有限公司 A kind of pearl powder is modified hot blast non-woven material and preparation method thereof
CN113858867A (en) * 2020-06-30 2021-12-31 尤妮佳股份有限公司 Method for manufacturing decorative sheet and decorative sheet
CN113858867B (en) * 2020-06-30 2023-11-14 尤妮佳股份有限公司 Method for manufacturing decorative sheet and decorative sheet
CN116323176A (en) * 2020-12-17 2023-06-23 花王株式会社 Package and method for manufacturing the same
CN116323176B (en) * 2020-12-17 2024-02-06 花王株式会社 Package and method for manufacturing the same
CN115214219A (en) * 2022-07-12 2022-10-21 李华 Three-dimensional texture forming sandwich fabric and anti-fouling after-finishing processing technology thereof
CN115214219B (en) * 2022-07-12 2023-12-08 厦门品达工贸有限公司 Three-dimensional texture forming sandwich fabric and anti-fouling post-finishing processing technology thereof

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