JP2012504063A - ポリオレフィンを主成分とする弾性メルトブローン織物 - Google Patents
ポリオレフィンを主成分とする弾性メルトブローン織物 Download PDFInfo
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- JP2012504063A JP2012504063A JP2011529233A JP2011529233A JP2012504063A JP 2012504063 A JP2012504063 A JP 2012504063A JP 2011529233 A JP2011529233 A JP 2011529233A JP 2011529233 A JP2011529233 A JP 2011529233A JP 2012504063 A JP2012504063 A JP 2012504063A
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Abstract
Description
ここに記載する「ポリオレフィンポリマー」は、40%未満の結晶性を持つまたは75J/g未満の融解熱(Hf)を持つα-オレフィンのホモポリマーまたはコポリマーである。該ポリオレフィンポリマーのMFRは、幾つかの態様においては、90dg/分未満である。該ポリオレフィンポリマーは、プロピレン-α-オレフィンコポリマーを記載するのに使用されるようなパラメータによって様々に記載することができ、プロピレン-α-オレフィンコポリマーは、有用なポリオレフィンポリマーの特定の一態様である。好ましくは、該ポリオレフィンポリマーは、エチレンおよびC4〜C10α-オレフィン(プロピレンを主成分とするポリマー)およびC3〜C10α-オレフィン(エチレンを主成分とするポリマー)から選択されるコモノマー由来の単位を全く含まない(ホモポリマーの場合)か、または該ポリマーの質量基準で、0.1または1または2または5〜10または15または20または45質量%なる範囲の量で含む、プロピレンを主成分とするまたはエチレンを主成分とするホモポリマーまたはコポリマーである。ポリオレフィンポリマーの例は、プロピレンホモポリマー、エチレンホモポリマー、プロピレンコポリマーおよびエチレンコポリマー(例えば、LLDPE、HDPE、LDPE)を含み、これら各々は、本明細書に記載するように40%未満の結晶化度を持つ。
弾性メルトブローン織物の製造は、微細なデニールの繊維を紡ぐために、適当な溶融温度および圧力を取扱うことのできる少なくとも一つのダイを含む、溶融吹込成形装置を通して押し出すことにより、繊維を製造する必要がある。低い結晶化度を持つポリオレフィンポリマーに対する該押出し工程は、典型的には該繊維の空力的圧伸成形を伴う。ここに記載する該弾性メルトブローン織物は、90dg/分未満のMFRを持つポリオレフィンコポリマーを溶融吹込成形することのできる、当分野において公知の任意の技術によって製造することができる。該弾性メルトブローン織物は、3.45MPa(500psi)を越える溶融圧力および50〜300℃なる範囲の溶融温度にて動作でき、また平均径5μm程度の細い繊維を製造し得る装置から溶融吹込成形される。
・15%/10%未満または20%/10%未満または30%/10%未満または40%/10%未満または30%/20%未満の%残留歪(第一サイクル/第二サイクル);
・少なくとも約1.786kgw/m(0.1 lbf/in)または少なくとも約2.679kgw/m(0.15 lbf/in)または少なくとも約3.572kgw/m(0.2 lbf/in)または少なくとも約5.358kgw/m(0.3 lbf/in)または少なくとも約7.144kgw/m(0.4 lbf/in)または少なくとも約8.930kgw/m(0.5 lbf/in)なる、50%におけるにおける収縮力(lbf/in);
・0.5 lbs/in未満または1.0 lbs/in未満または2.0 lbs/in未満または3.0 lbs/in未満または3.5 lbs/in未満または3.75 lbs/in未満または4.0 lbs/in未満または4.25 lbs/in未満または4.5 lbs/in未満または4.75 lbs/in未満または5.0 lbs/in未満なるピーク負荷(lbs/in)(第一サイクル);
・少なくとも50または少なくとも70または少なくとも90または少なくとも110または少なくとも140または少なくとも145または少なくとも150または少なくとも155または少なくとも160または少なくとも170または少なくとも180または少なくとも200のピーク力MD(N);
・少なくとも60または少なくとも65または少なくとも70または少なくとも75または少なくとも80または少なくとも85または少なくとも90または少なくとも100なるピーク力CD(N);
・少なくとも90または少なくとも100または少なくとも110または少なくとも120または少なくとも130または少なくとも140の破断点伸びMD(%)(ASTM D412);
・少なくとも250または少なくとも275または少なくとも300または少なくとも325または少なくとも350または少なくとも375の破断点伸びCD(%)(ASTM D412)。
メルトブローン織物および多層構造物を、以下のような方法で、R. Zhaoによる、「ポリオキシメチレンコポリマーの溶融吹込成形(Melt Blowing Polyoxymethylene Copolymer)」と題する、INT’L NONWOVENS J., 19-24 (夏(summer) 2005)に掲載された論文に与えられているものと同様な装置および条件を用いて製造する。特に、6.89MPa(1200psi)〜10.34MPa(1700psi)なる範囲内の溶融圧力および200〜275℃なる範囲内の溶融温度にて作動され、また50〜150孔/2.54cm(1 in)なる範囲の紡糸口金孔密度を持つダイを使用する、バイアックス-ファイバーフィルム(Biax-FiberfilmTM)メルトブローンライン(WI州、グリーンビル(Greenville)のバイアックス-ファイバーフィルム社(Biax-Fiberfilm Corp))を使用して、該メルトブローン繊維、織物、および多層構造物を製造する。このラインは、押出機、ダイ-ブロックおよび紡糸口金、並びに34kPa〜138kPa(5〜20psi)なる範囲内の空気圧および220〜260℃なる範囲の空気温度を供給する、該紡糸口金用のエアマニホルドを含む。ビスタマックス(VistamaxxTM)6202特性エラストマー(18dg/分なるMFRおよび15質量%なるコモノマー:C2含有率を持つポリオレフィンポリマー、エクソンモービルケミカル社(ExxonMobil Chemical Co.)製)を、該バイアックス-ファイバーフィルムラインを用いて、上記条件下で溶融吹込成形して、該繊維、織物、および多層構造物を製造する。該ビスタマックスは、該押出機内で溶融混合され、該バイアックス-ファイバーフィルムアレイダイを介して、溶融吹込成形ビスタマックスの製造中の繊維の下方またはその上を通過する、スパンレース織物(50/50 PP/PET、30g/m2、ヤコブ-ホルムインダストリーズ社(Jacob-Holm Industries, Inc.)製)の延伸性構造物上で溶融吹込成形される。該繊維の平均径は、15〜45μmなる範囲内にある。該溶融温度および該紡糸口金と該通過するスパンレース織物との間の間隔は、該繊維が該スパンレース織物と接触した際に、該繊維が依然として溶融状態または部分的溶融状態にあるように調節される。
8種の多層構造体を製造し、その物性をテストした。公知のスパンレース外側層間に差込まれた、不織弾性手段としてのビスタマックス特性エラストマーで構成されるメルトブローン層、即ち中間層を用いて、各多層構造物を製造した。該8種の多層構造体は、表1に記載のようにして製造した:
・ハギーズ(Huggies)は、キンバリー-クラークワールドワイド社(Kimberly-Clark Worldwide Inc.)の登録商標である[ハギーズナチュラルアップ(Huggies Natural Ups);ハギーズナチュラルフィット(Huggies Natural Fit)] 。
・ホワイトクラウド(White Cloud)は、ウォルマート(Wal-Mart)社の登録商標である[ウォルマートホワイトクラウド(Wal-Mart White Cloud); ウォルマートアシュアランスアンダーウエア(Wal-Mart Assurance Underwear)]。
・テナ(Tena)は、SCAパーソナルケア(Personal Care)社の登録商標である[SCAテナセレニティーアンダーウエア(SCA Tena Serenity Underwear)]。
・アシュアランス(Assurance)は、コビディエン(Covidien)社の登録商標である[プレミアムアシュアランス(Premium Assurance)]。
・プリベイル(Prevail)は、ファーストクオリティープローダクツ(First Quality Products)社の登録商標である[プリベイルウルトラシィンアンダーウエア(Prevail Ultra Thin Underwear)]。
Claims (25)
- 90dg/分未満のMFRを持つ、1種またはそれ以上のポリオレフィンポリマーを含み、500%を越える極限伸び率を有する弾性メルトブローン織物の少なくとも一つの層、および
少なくとも一つの延伸性織物層
を含むことを特徴とする、多層構造。 - 90dg/分未満のMFRおよび75J/g未満のHf値を持つ、1種またはそれ以上のポリオレフィンポリマーを含む、少なくとも1層の弾性メルトブローン織物;および
少なくとも一つの延伸性織物層
を含むことを特徴とする、多層構造。 - 前記ポリオレフィンポリマーが、プロピレン-α-オレフィンコポリマーであり、該コポリマーが、その質量基準で5〜35質量%なる範囲内の、コモノマー-由来の単位の含有率を持つ、請求項1または2記載の多層構造。
- 100%伸び後の残留歪が<15%である、請求項1〜3の何れか1項に記載の多層構造。
- 前記ポリオレフィンポリマーが、30%までのプロピレンホモポリマーとブレンドされている、請求項1〜4の何れか1項に記載の多層構造。
- 前記ポリオレフィンポリマーが、2.0〜5.0なる範囲内の分子量分布を持つ、請求項1〜5の何れか1項に記載の多層構造。
- 前記ポリオレフィンポリマーの前記MFR値が、0.1〜50dg/分なる範囲内にある、請求項1〜6の何れか1項に記載の多層構造。
- 前記弾性メルトブローン織物が、5〜200μmなる範囲内の径を持つ繊維を含む、請求項1〜7の何れか1項に記載の多層構造。
- 前記弾性メルトブローン織物の6.45平方センチメートル(平方インチ)当たりの連続繊維数(繊維密度)が、20〜500繊維/6.45cm2(1in2)なる範囲内にある、請求項1〜8の何れか1項に記載の多層構造。
- 前記弾性メルトブローン織物が、100%未満のMD伸び率および100%を越えるCD伸び率を持つ、請求項1〜9の何れか1項に記載の多層構造。
- 前記延伸性織物が、スパンボンド、メルトブローン、カーディング、エアレイドまたはその他の手段により製造できる、請求項1〜10の何れか1項に記載の多層構造。
- 前記延伸性織物が、10〜150g/m2なる範囲の坪量を持ち、かつ該織物の質量基準で、10質量%を越えるまたは30質量%を越えるポリオレフィンを含む、少なくとも1層のスパンレース織物を含む、請求項1〜11の何れか1項に記載の多層構造。
- 前記延伸性織物が、セルロース、ナイロン、ポリオレフィン-テレフタレート、ポリエステル、ポリオレフィン、ビスコース、綿、アクリル樹脂またはこれらの組合せを含む、請求項1〜12の何れか1項に記載の多層構造。
- 前記多層構造またはその個々の層が、機械的に伸長されておらずまたは機械的に配向されていない、請求項1〜13の何れか1項に記載の多層構造。
- 前記多層構造またはその個々の層が、機械的に伸長されまたは配向されている、請求項1〜14の何れか1項に記載の多層構造。
- 織物層としてまたは織物層の成分としてのスチレン系ブロックコポリマーを、実質的に含まない、請求項1〜15の何れか1項に記載の多層構造。
- 接着剤を実質的に含まない、請求項1〜16の何れか1項に記載の多層構造。
- 請求項1〜17の何れか1項に記載の多層構造を含むことを特徴とする、吸収性物品。
- 前記物品が、幼児用オムツ、プルアップ、トレーニングパンツ、成人用失禁防止ブリーフおよびオムツ、パンティーライナー、生理用ナプキン、医療用被服および包帯から選択される、請求項18記載の吸収性物品。
- 90dg/分未満のMFR値を持つ1種またはそれ以上のポリオレフィンポリマーを、複数のノズルを備えた、少なくとも一つのダイを通して押し出して、複数の連続繊維を製造する工程、ここで該ダイの少なくとも一つを、3.45MPa(500psi)を越える溶融圧力にて動作させて、少なくとも一つの弾性メルトブローン織物を製造し;および
該少なくとも一つの弾性メルトブローン織物を、少なくとも一つの延伸性織物に接着する工程、
を含むことを特徴とする、多層構造の製造方法。 - 前記弾性メルトブローン織物を、10〜150g/m2なる範囲の坪量を持つスパンレース織物の少なくとも一方の面に接着する、請求項20記載の方法。
- 更に、前記多層構造を、水力学的絡み合わせ装置に通す工程を含む、請求項20または21記載の方法。
- 前記ダイが、280℃未満の溶融温度にて動作する、請求項20〜22の何れか1項に記載の方法。
- 90dg/分未満のMFRを持つ、1種またはそれ以上のポリオレフィンポリマーを含み、300%を越える極限伸び率を有する、弾性メルトブローン織物の少なくとも一つの層、および
少なくとも一つの追加の弾性層
を含むことを特徴とする、多層構造。 - 90dg/分未満のMFRおよび75J/g未満のHf値を持つ、1種またはそれ以上のポリオレフィンポリマーを含む、少なくとも1層の弾性メルトブローン織物;および
少なくとも一つの追加の弾性層
を含むことを特徴とする、多層構造。
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US12/271,526 US8664129B2 (en) | 2008-11-14 | 2008-11-14 | Extensible nonwoven facing layer for elastic multilayer fabrics |
US15607809P | 2009-02-27 | 2009-02-27 | |
US61/156,078 | 2009-02-27 | ||
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US61/157,524 | 2009-03-04 | ||
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US61/171,135 | 2009-04-21 | ||
PCT/US2009/058263 WO2010039583A1 (en) | 2008-09-30 | 2009-09-24 | Polyolefin-based elastic meltblown fabrics |
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KR20110059739A (ko) | 2011-06-03 |
AR073521A1 (es) | 2010-11-10 |
JP5221764B2 (ja) | 2013-06-26 |
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WO2010039579A1 (en) | 2010-04-08 |
MX2011003290A (es) | 2011-04-26 |
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TW201029840A (en) | 2010-08-16 |
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EP2342075B1 (en) | 2016-05-18 |
AR073705A1 (es) | 2010-11-24 |
EP2342075A1 (en) | 2011-07-13 |
BRPI0920473A2 (pt) | 2020-08-18 |
CN102171033A (zh) | 2011-08-31 |
DK2342075T3 (en) | 2016-08-29 |
KR101368522B1 (ko) | 2014-02-27 |
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Free format text: JAPANESE INTERMEDIATE CODE: R250 |
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R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
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