JP5139669B2 - Crimped composite fiber and method for producing the same - Google Patents
Crimped composite fiber and method for producing the same Download PDFInfo
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- JP5139669B2 JP5139669B2 JP2006322386A JP2006322386A JP5139669B2 JP 5139669 B2 JP5139669 B2 JP 5139669B2 JP 2006322386 A JP2006322386 A JP 2006322386A JP 2006322386 A JP2006322386 A JP 2006322386A JP 5139669 B2 JP5139669 B2 JP 5139669B2
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- 239000000835 fiber Substances 0.000 title claims description 102
- 239000002131 composite material Substances 0.000 title claims description 79
- 238000004519 manufacturing process Methods 0.000 title claims description 14
- 239000004745 nonwoven fabric Substances 0.000 claims description 108
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 claims description 25
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 claims description 24
- 238000002844 melting Methods 0.000 claims description 21
- 230000008018 melting Effects 0.000 claims description 19
- 229920000642 polymer Polymers 0.000 claims description 14
- 239000004711 α-olefin Substances 0.000 claims description 14
- 229920000089 Cyclic olefin copolymer Polymers 0.000 claims description 13
- 238000001816 cooling Methods 0.000 claims description 13
- 238000009987 spinning Methods 0.000 claims description 9
- 238000007599 discharging Methods 0.000 claims description 4
- 238000005507 spraying Methods 0.000 claims description 2
- 239000000306 component Substances 0.000 description 34
- 238000000034 method Methods 0.000 description 31
- 229920001155 polypropylene Polymers 0.000 description 23
- 239000010410 layer Substances 0.000 description 18
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 13
- -1 polypropylene Polymers 0.000 description 13
- 229920001410 Microfiber Polymers 0.000 description 11
- 239000004744 fabric Substances 0.000 description 10
- WSSSPWUEQFSQQG-UHFFFAOYSA-N 4-methyl-1-pentene Chemical compound CC(C)CC=C WSSSPWUEQFSQQG-UHFFFAOYSA-N 0.000 description 8
- 238000004049 embossing Methods 0.000 description 8
- 239000004743 Polypropylene Substances 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 description 6
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 6
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 6
- 239000005977 Ethylene Substances 0.000 description 6
- 239000000853 adhesive Substances 0.000 description 6
- 238000005452 bending Methods 0.000 description 6
- 229920000092 linear low density polyethylene Polymers 0.000 description 6
- 239000004707 linear low-density polyethylene Substances 0.000 description 6
- 239000000155 melt Substances 0.000 description 6
- 239000004750 melt-blown nonwoven Substances 0.000 description 6
- 239000000523 sample Substances 0.000 description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 6
- 230000001070 adhesive effect Effects 0.000 description 5
- 229920001577 copolymer Polymers 0.000 description 4
- 238000005227 gel permeation chromatography Methods 0.000 description 4
- YWAKXRMUMFPDSH-UHFFFAOYSA-N pentene Chemical compound CCCC=C YWAKXRMUMFPDSH-UHFFFAOYSA-N 0.000 description 4
- 229920005604 random copolymer Polymers 0.000 description 4
- 125000004432 carbon atom Chemical group C* 0.000 description 3
- 239000003795 chemical substances by application Substances 0.000 description 3
- 238000002788 crimping Methods 0.000 description 3
- 230000004927 fusion Effects 0.000 description 3
- 229920001903 high density polyethylene Polymers 0.000 description 3
- 239000004700 high-density polyethylene Substances 0.000 description 3
- 229920001684 low density polyethylene Polymers 0.000 description 3
- 239000004702 low-density polyethylene Substances 0.000 description 3
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 3
- 230000000704 physical effect Effects 0.000 description 3
- 229920005630 polypropylene random copolymer Polymers 0.000 description 3
- 229920001384 propylene homopolymer Polymers 0.000 description 3
- 229920005992 thermoplastic resin Polymers 0.000 description 3
- 239000004952 Polyamide Substances 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 239000003963 antioxidant agent Substances 0.000 description 2
- 239000002216 antistatic agent Substances 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 229920001971 elastomer Polymers 0.000 description 2
- 239000000806 elastomer Substances 0.000 description 2
- 229920005674 ethylene-propylene random copolymer Polymers 0.000 description 2
- 230000001771 impaired effect Effects 0.000 description 2
- 239000004611 light stabiliser Substances 0.000 description 2
- 239000000314 lubricant Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 239000002667 nucleating agent Substances 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 229920000139 polyethylene terephthalate Polymers 0.000 description 2
- 239000005020 polyethylene terephthalate Substances 0.000 description 2
- 229920000098 polyolefin Polymers 0.000 description 2
- 229920005672 polyolefin resin Polymers 0.000 description 2
- 229920005629 polypropylene homopolymer Polymers 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 239000003381 stabilizer Substances 0.000 description 2
- 229920001897 terpolymer Polymers 0.000 description 2
- GVNWZKBFMFUVNX-UHFFFAOYSA-N Adipamide Chemical compound NC(=O)CCCCC(N)=O GVNWZKBFMFUVNX-UHFFFAOYSA-N 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 229920002292 Nylon 6 Polymers 0.000 description 1
- 229920002302 Nylon 6,6 Polymers 0.000 description 1
- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 239000004433 Thermoplastic polyurethane Substances 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 230000003078 antioxidant effect Effects 0.000 description 1
- 239000002981 blocking agent Substances 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 239000008358 core component Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000001938 differential scanning calorimetry curve Methods 0.000 description 1
- HQQADJVZYDDRJT-UHFFFAOYSA-N ethene;prop-1-ene Chemical group C=C.CC=C HQQADJVZYDDRJT-UHFFFAOYSA-N 0.000 description 1
- 239000005038 ethylene vinyl acetate Substances 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 239000004751 flashspun nonwoven Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000012770 industrial material Substances 0.000 description 1
- 229920000554 ionomer Polymers 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 238000007500 overflow downdraw method Methods 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 229920003207 poly(ethylene-2,6-naphthalate) Polymers 0.000 description 1
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 1
- 229920002239 polyacrylonitrile Polymers 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 239000011112 polyethylene naphthalate Substances 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920003225 polyurethane elastomer Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- 230000035807 sensation Effects 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 229920002725 thermoplastic elastomer Polymers 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
- 239000008096 xylene Substances 0.000 description 1
Landscapes
- Absorbent Articles And Supports Therefor (AREA)
- Laminated Bodies (AREA)
- Multicomponent Fibers (AREA)
- Nonwoven Fabrics (AREA)
Description
本発明は、捲縮複合繊維からなる不織布、かかる不織布層を有する不織布積層体及びその用途に関する。 The present invention relates to a nonwoven fabric composed of crimped composite fibers, a nonwoven fabric laminate having such a nonwoven fabric layer, and uses thereof.
近年、不織布は通気性、柔軟性に優れることから各種用途に幅広く用いられている。そのため、不織布には、その用途に応じた各種の特性が求められるとともに、その特性の向上が要求されている。
例えば、紙おむつ、生理用ナプキン等の衛生材料、湿布材の基布等に用いられる不織布は、耐水性があり、且つ透湿性に優れることが要求される。また、使用される箇所によっては伸長性を有することも要求される。
不織布の風合いや触感を改良するためには、不織布を嵩高にすることが有効であり、その方法の一つとして、異種の重合体を用いた芯鞘型、あるいは並列型の複合繊維を用いることにより、不織布を構成する繊維に捲縮を起こさせる方法が多々提案されている。
In recent years, nonwoven fabrics are widely used for various applications because of their excellent breathability and flexibility. For this reason, the nonwoven fabric is required to have various properties according to its use and to improve the properties.
For example, non-woven fabrics used for sanitary materials such as disposable diapers and sanitary napkins, and base fabrics for poultices are required to have water resistance and excellent moisture permeability. Moreover, it is requested | required that it should be extensible depending on the location used.
In order to improve the texture and feel of the nonwoven fabric, it is effective to make the nonwoven fabric bulky, and one of the methods is to use a core-sheath type or parallel type composite fiber using different polymers. Thus, many methods for causing crimping to the fibers constituting the nonwoven fabric have been proposed.
例えば、ＭＦＲが異なる２種のポリオレフィン樹脂を用い、１０／９０〜２０／８０（重量比）の割合で紡糸した偏芯芯鞘型の捲縮複合繊維からなる不織布（特許文献１；特開平９−７８４３６号公報）、エチレン−プロピレンランダムコポリマーとポリプロピレンとを重量比２：９８〜１０：９０にて複合紡糸してなる並列型複合紡糸長繊維束を開繊し、これを嵩高ウェブ状とした層を有する長繊維積層スパンボンド不織布（特許文献２；特開平７−１９７３６７号公報）、エチレン含有率が２〜５％で且つ融解ピーク温度が１５５℃以下であるエチレン−プロピレンランダム共重合体より成る第一成分と、アイソタクチックポリプロピレンより成る第二成分とで形成された複合型長繊維を構成繊維とし、且つ第一成分が溶融固化することにより、複合型長繊維相互間が結合せしめられている不織布（特許文献３；特開平５−５２６１号公報）、モノマーの主成分がプロピレンである低融点共重合体を鞘成分とし、結晶性ポリプロピレンからなる高融点重合体を芯成分とする鞘芯型複合繊維からなり、かつ示差走査熱分析装置により得られるＤＳＣ曲線で前記低融点共重合体の融解ピークと前記高融点重合体の融解ピークとがダブルピークを示すことを特徴とする熱接着性繊維からなる不織布（特許文献４；特開平５−９８１０号公報）、ＭＦＲが１０の結晶性ポリプロピレン（ホモポリマー）とＭＦＲが１５のプロピレン／エチレン／ブテン−１三元共重合体（エチレン単位；３重量％、ブテン−１単位；５重量％、プロピレン単位；９２重量％）を用いてスパンボンド法でサイドバイサイド型紡糸口金を用い、紡糸口金から吐出した複合繊維群をエアーサッカーに導入して牽引延伸し、三元共重合体の捲率が５０％の長繊維からなる不織布層を有する伸縮性複合化不織布（特許文献５；特開２００１−１４０１５８号公報、〔００３３〕段落）等多数の方法が提案されている。 For example, a nonwoven fabric made of an eccentric core-sheathed crimped composite fiber that is spun at a ratio of 10/90 to 20/80 (weight ratio) using two types of polyolefin resins having different MFRs (Patent Document 1; No. -78436), a parallel composite spun continuous fiber bundle formed by composite spinning of ethylene-propylene random copolymer and polypropylene at a weight ratio of 2:98 to 10:90 was opened, and this was made into a bulky web shape A long fiber laminated spunbonded nonwoven fabric having a layer (Patent Document 2; Japanese Patent Laid-Open No. 7-197367), an ethylene-propylene random copolymer having an ethylene content of 2 to 5% and a melting peak temperature of 155 ° C. or lower A composite long fiber formed of a first component composed of a first component and a second component composed of isotactic polypropylene, and the first component is melted and solidified Further, a non-woven fabric in which composite long fibers are bonded to each other (Patent Document 3; Japanese Patent Laid-Open No. 5-5261), a low melting point copolymer whose main component is propylene is a sheath component, and crystalline polypropylene A melting peak of the low-melting copolymer and a melting peak of the high-melting polymer in a DSC curve obtained from a sheath-core type composite fiber having a high-melting-point polymer as a core component and obtained by a differential scanning calorimeter. A non-woven fabric made of heat-adhesive fibers characterized by a double peak (Patent Document 4; Japanese Patent Laid-Open No. Hei 5-9810), crystalline polypropylene (homopolymer) having an MFR of 10 and propylene / ethylene having an MFR of 15 / Butene-1 terpolymer (ethylene unit; 3 wt%, butene-1 unit; 5 wt%, propylene unit; 92 wt%) Using a Dubaiside spinneret, a composite fiber group discharged from the spinneret is introduced into an air soccer ball and pulled and stretched, and a stretchable composite having a non-woven fabric layer composed of long fibers with a terpolymer copolymer percentage of 50% Numerous methods such as modified nonwoven fabric (Patent Document 5; JP 2001-140158 A, paragraph [0033]) have been proposed.
しかしながら、特許文献１及び特許文献２に記載された不織布は２種のポリオレフィン樹脂がいずれもプロピレン単独重合体、あるいはポリプロピレン成分が９０重量％以上を占めるので柔軟性に欠け、特許文献３に記載の不織布は不織布を構成する複合型長繊維に捲縮が発生し難く、特許文献４に記載の熱接着性繊維は、紡糸した繊維を９０℃の温度で延伸ローラー等で延伸することで初めて捲縮が発生することから成形性に劣り、特許文献５に記載の不織布も、捲縮を発生させるためには、不織布を１２５℃で熱処理を行う必要があり、同じく成形性に劣る等、何れも不十分である。 However, the nonwoven fabrics described in Patent Document 1 and Patent Document 2 lack flexibility because both of the two polyolefin resins account for 90% by weight or more of the propylene homopolymer or the polypropylene component. Non-woven fabric is not easily crimped in the composite long fibers constituting the non-woven fabric, and the thermal adhesive fiber described in Patent Document 4 is crimped for the first time by stretching the spun fiber at a temperature of 90 ° C. with a stretching roller or the like. In order to generate crimp, the nonwoven fabric described in Patent Document 5 also needs to be heat treated at 125 ° C., and the moldability is also inferior. It is enough.
かかる欠点を解決する方法として、第２のプロピレン系重合体成分と第２のプロピレン系重合体より融点が２０℃以上高い第１のプロピレン系重合体からなり、第１のプロピレン系重合体／第２のプロピレン系重合体（重量比）が５０／５０〜５／９５である捲縮複合繊維からなる不織布が提案されている（特許文献６；国際公開番号 ＷＯ ０２/０６１１９２）。
しかしながら、かかる捲縮複合繊維も捲縮径が大きく、用途によってはその改良が求められている。
However, such crimped composite fibers also have a large crimp diameter, and there are demands for improvements depending on the application.
捲縮径が小さい捲縮複合繊維からなる不織布、好ましくは、嵩高性、柔軟性を有する不織布の製造方法、かかる製造方法から得られる不織布層を有する不織布積層体を開発することを目的とする。 It aims at developing the nonwoven fabric which consists of a crimped composite fiber with a small crimp diameter, Preferably the nonwoven fabric which has a bulkiness and a softness | flexibility, and the nonwoven fabric laminated body which has a nonwoven fabric layer obtained from this manufacturing method.
融点（Ｔｍ）が１５０℃以下のプロピレン・α−オレフィン共重合体（Ａ）からなる第１成分と融点（Ｔｍ）が１５５℃以上のプロピレン系重合体（Ｂ）からなる第２成分とを、それぞれ別個の押出機で溶融し、吐出された複合繊維の断面が、第１成分と第２成分との比（質量比）が４０／６０〜９５／５の範囲になるように第１成分と第２成分とが接合するように構成された複合紡糸ノズルを有する多数の紡糸口金から吐出させて、複合繊維群を紡出した後、当該紡出した複合繊維群が紡糸口金から５〜２００mmの範囲に達する間に冷却エアを当該紡出した複合繊維群に吹付けて冷却するとともに、引続き高速エアで複合繊維群を牽引細化して、捲縮させた後、捲縮複合繊維群を捕集ベルト上に捕集することを特徴とする不織布の製造方法かかる製造方法から得られ得る不織布層を有する不織布積層体及びその用途を提供するものである。 A first component composed of a propylene / α-olefin copolymer (A) having a melting point (Tm) of 150 ° C. or less and a second component composed of a propylene-based polymer (B) having a melting point (Tm) of 155 ° C. or more, The first component and the cross-section of the composite fiber melted and discharged by separate extruders are in a range of 40/60 to 95/5 between the first component and the second component (mass ratio). After spinning a composite fiber group by discharging from a plurality of spinnerets having a composite spinning nozzle configured to join the second component, the spun composite fiber group is 5 to 200 mm from the spinneret. While reaching the range, cooling air is blown onto the spun composite fiber group to cool it, and the composite fiber group is continuously pulled and crimped with high-speed air, and then the crimped composite fiber group is collected. Nonwoven fabric manufacturing method characterized by collecting on a belt The nonwoven fabric laminated body which has a nonwoven fabric layer which can be obtained from this manufacturing method, and its use are provided.
熱処理等の後処理をすることなく、捲縮数が多い捲縮複合繊維からなる嵩高性、柔軟性を有する不織布が容易に得られる。 Without post-treatment such as heat treatment, a nonwoven fabric having bulkiness and flexibility made of crimped composite fibers having a large number of crimps can be easily obtained.
＜プロピレン・α−オレフィン共重合体（Ａ）＞
捲縮複合繊維を構成する第1成分であるプロピレン・α−オレフィン共重合体（Ａ）は、融点（Ｔｍ）が１５０℃以下、好ましくは１２０〜１５０℃、さらに好ましくは１２５〜１４７℃の範囲にあるプロピレンとエチレン、１−ブテン、１−ペンテン、１−ヘキセン、１−オクテン、４−メチル−１−ペンテン等の炭素数２以上、好ましくは２〜８の１種または２種以上のα−オレフィンとの共重合体、好ましくはランダム共重合体である。
Ｔｍがかかる範囲のプロピレン・α−オレフィン共重合体（Ａ）を用いることにより、捲縮径が小さい捲縮複合繊維が得られるとともに、嵩高性及び柔軟性に富む不織布となる。Ｔｍが上記範囲を超える重合体は、捲縮の発現が十分でなく、得られる不織布の柔軟性が劣る傾向にあり、一方、Ｔｍが上記範囲に満たない重合体は、捲縮の発現が十分でなく、得られる不織布がべたつく虞がある。
<Propylene / α-olefin copolymer (A)>
The propylene / α-olefin copolymer (A) that is the first component constituting the crimped conjugate fiber has a melting point (Tm) of 150 ° C. or lower, preferably 120 to 150 ° C., more preferably 125 to 147 ° C. 1 or 2 or more types of α having 2 or more carbon atoms, preferably 2 to 8 carbon atoms such as propylene and ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 4-methyl-1-pentene, etc. -Copolymers with olefins, preferably random copolymers.
By using the propylene / α-olefin copolymer (A) having a Tm in such a range, a crimped composite fiber having a small crimp diameter is obtained, and a nonwoven fabric having high bulkiness and flexibility is obtained. A polymer having a Tm exceeding the above range does not exhibit sufficient crimp, and the resulting nonwoven fabric tends to have poor flexibility. On the other hand, a polymer having a Tm less than the above range has a sufficient expression of crimp. In addition, the obtained nonwoven fabric may be sticky.
プロピレン・α−オレフィン共重合体（Ａ）は、溶融紡糸し得る限り、メルトフローレート（ＭＦＲ：ＡＳＴＭ Ｄ−１２３８、２３０℃、荷重２１６０ｇ）は特に限定はされないが、通常、通常１〜１０００ｇ／１０分、好ましくは５〜５００ｇ／１０分、さらに好ましくは１０〜１００ｇ／１０分の範囲にある。また、プロピレン・α−オレフィン共重合体（Ａ）の重量平均分子量（Ｍｗ）と数平均分子量（Ｍｎ）の比Ｍｗ／Ｍｎは、通常１．５〜５．０である。紡糸性が良好で、かつ繊維強度が特に優れる複合繊維が得られる点で、さらには１．５〜３．０が好ましい。なお良好な紡糸性とは、紡糸ノズルからの吐き出し時および延伸中に糸切れを生じず、フィラメントの融着が生じないことをいい、ＭｗおよびＭｎは、ＧＰＣ（ゲルパーミエーションクロマトグラフィー）によって、公知の方法で測定することができる。 As long as the propylene / α-olefin copolymer (A) can be melt-spun, the melt flow rate (MFR: ASTM D-1238, 230 ° C., load 2160 g) is not particularly limited. The range is 10 minutes, preferably 5 to 500 g / 10 minutes, more preferably 10 to 100 g / 10 minutes. The ratio Mw / Mn of the weight average molecular weight (Mw) and the number average molecular weight (Mn) of the propylene / α-olefin copolymer (A) is usually 1.5 to 5.0. From the viewpoint of obtaining a composite fiber having good spinnability and particularly excellent fiber strength, 1.5 to 3.0 is more preferable. Good spinnability means that yarn breakage does not occur at the time of discharging from the spinning nozzle and during drawing, and filament fusion does not occur. Mw and Mn are determined by GPC (gel permeation chromatography), It can be measured by a known method.
プロピレン・α−オレフィン共重合体（Ａ）のＴｍは、示差走査熱量計（ＤＳＣ）を用い、昇温速度；１０℃／分で昇温したときの融解吸熱曲線の極値を与える温度より５０℃程度高い温度まで昇温して、この温度で１０分間保持した後、降温速度；１０℃／分で３０℃まで冷却し、再度、昇温速度；１０℃／分で所定の温度まで昇温したときの融解曲線を測定し、かかる融解曲線から、ＡＳＴＭ Ｄ３４１８−９９の方法に習い、融解吸熱曲線の極値を与える温度（Ｔｐ）を求め、かかるピーク温度の吸熱ピークをＴｍとした。
プロピレン・α−オレフィン共重合体（Ａ）には、物性を損なわない範囲で、通常用いられる酸化防止剤、耐候安定剤、耐光安定剤、帯電防止剤、防曇剤、ブロッキング防止剤、滑剤、核剤、顔料等の添加剤或いは他の重合体を必要に応じて配合することができる。
Tm of the propylene / α-olefin copolymer (A) is 50 from the temperature giving the extreme value of the melting endothermic curve when the temperature is increased at a rate of 10 ° C./min using a differential scanning calorimeter (DSC). The temperature is raised to a temperature as high as about 0 ° C., held at this temperature for 10 minutes, then cooled down to 30 ° C. at a rate of temperature decrease of 10 ° C./min, and again raised to a predetermined temperature at a rate of temperature increase of 10 ° C./min. The melting curve was measured, and the temperature (Tp) giving the extreme value of the melting endothermic curve was determined from the melting curve according to the method of ASTM D3418-99 , and the endothermic peak at this peak temperature was defined as Tm.
In the propylene / α-olefin copolymer (A), the antioxidant, weathering stabilizer, light stabilizer, antistatic agent, anti-fogging agent, anti-blocking agent, lubricant, and the like, as long as the physical properties are not impaired. Additives such as nucleating agents and pigments or other polymers can be blended as required.
＜プロピレン系重合体（Ｂ）＞
捲縮複合繊維を構成する第２成分であるプロピレン系重合体（Ｂ）は、融点（Ｔｍ）が１５５℃以上、好ましくは１５７〜１６５℃の範囲にあるプロピレンの単独重合体若しくはプロピレンと極少量のエチレン、１−ブテン、１−ペンテン、１−ヘキセン、１−オクテン、４−メチル−１−ペンテン等の炭素数２以上、好ましくは２〜８の１種または２種以上のα−オレフィンとの共重合体であり、プロピレン単独重合体が好ましい。
Ｔｍが上記範囲のプロピレン系重合体（Ｂ）を用いることにより、捲縮径が小さい捲縮複合繊維が得られるとともに、嵩高性及び柔軟性に富む不織布となる。Ｔｍが上記範囲に満たない重合体は、捲縮の発現が十分でない場合がある。
<Propylene polymer (B)>
The propylene polymer (B), which is the second component constituting the crimped conjugate fiber, has a melting point (Tm) of 155 ° C. or higher, preferably 157 to 165 ° C., or a very small amount with a propylene homopolymer or propylene. Of 1-butene, 1-pentene, 1-hexene, 1-octene, 4-methyl-1-pentene, and the like, preferably 1 or 2 or more α-olefins having 2 to 8 carbon atoms A propylene homopolymer is preferable.
By using the propylene polymer (B) having a Tm in the above range, a crimped composite fiber having a small crimp diameter is obtained, and a nonwoven fabric having high bulkiness and flexibility is obtained. A polymer whose Tm is less than the above range may not exhibit sufficient crimp.
プロピレン系重合体（Ｂ）は、溶融紡糸し得る限り、メルトフローレート（ＭＦＲ：ＡＳＴＭ Ｄ−１２３８、２３０℃、荷重２１６０ｇ）は特に限定はされないが、通常、通常１〜１０００ｇ／１０分、好ましくは５〜５００ｇ／１０分、さらに好ましくは１０〜１００ｇ／１０分の範囲にある。また、プロピレン系重合体（Ｂ）の重量平均分子量（Ｍｗ）と数平均分子量（Ｍｎ）の比Ｍｗ／Ｍｎは、通常１．５〜５．０である。紡糸性が良好で、かつ繊維強度が特に優れる複合繊維が得られる点で、さらには１．５〜３．０が好ましい。なお良好な紡糸性とは、紡糸ノズルからの吐き出し時および延伸中に糸切れを生じず、フィラメントの融着が生じないことをいい、ＭｗおよびＭｎは、ＧＰＣ（ゲルパーミエーションクロマトグラフィー）によって、公知の方法で測定することができる。 As long as the propylene polymer (B) can be melt-spun, the melt flow rate (MFR: ASTM D-1238, 230 ° C., load 2160 g) is not particularly limited, but usually 1 to 1000 g / 10 minutes, preferably Is in the range of 5 to 500 g / 10 min, more preferably 10 to 100 g / 10 min. The ratio Mw / Mn of the weight average molecular weight (Mw) and the number average molecular weight (Mn) of the propylene polymer (B) is usually 1.5 to 5.0. From the viewpoint of obtaining a composite fiber having good spinnability and particularly excellent fiber strength, 1.5 to 3.0 is more preferable. Good spinnability means that yarn breakage does not occur at the time of discharging from the spinning nozzle and during drawing, and filament fusion does not occur. Mw and Mn are determined by GPC (gel permeation chromatography), It can be measured by a known method.
プロピレン系重合体（Ｂ）のＴｍは、示差走査熱量計（ＤＳＣ）を用い、昇温速度；１０℃／分で昇温したときの融解吸熱曲線の極値を与える温度より５０℃程度高い温度まで昇温して、この温度で１０分間保持した後、降温速度；１０℃／分で３０℃まで冷却し、再度、昇温速度；１０℃／分で所定の温度まで昇温したときの融解曲線を測定し、かかる融解曲線から、ＡＳＴＭ Ｄ３４１８−９９の方法に習い、融解吸熱曲線の極値を与える温度（Ｔｐ）を求め、かかるピーク温度の吸熱ピークをＴｍとした。
プロピレン系重合体（Ｂ）には、物性を損なわない範囲で、通常用いられる酸化防止剤、耐候安定剤、耐光安定剤、帯電防止剤、防曇剤、ブロッキング防止剤、滑剤、核剤、顔料等の添加剤或いは他の重合体を必要に応じて配合することができる。
Tm of the propylene polymer (B) is a temperature about 50 ° C. higher than the temperature that gives the extreme value of the melting endothermic curve when the temperature is increased at a rate of temperature increase of 10 ° C./min using a differential scanning calorimeter (DSC). After the temperature is raised to 10 minutes and kept at this temperature for 10 minutes, it is cooled to 30 ° C. at a rate of temperature decrease of 10 ° C./minute, and then melted again when the temperature is raised to a predetermined temperature at a rate of temperature increase of 10 ° C./minute. A curve was measured, and from this melting curve, the temperature (Tp) giving the extreme value of the melting endothermic curve was determined by following the method of ASTM D3418-99 , and the endothermic peak at this peak temperature was defined as Tm.
For the propylene polymer (B), antioxidants, weather stabilizers, light stabilizers, antistatic agents, antifogging agents, antiblocking agents, lubricants, nucleating agents, pigments are used as long as the physical properties are not impaired. Such additives or other polymers can be blended as necessary.
＜不織布の製造方法＞
Ｔｍが１５０℃以下のプロピレン・α−オレフィン共重合体（Ａ）からなる第１成分とＴｍが１５５℃以上のプロピレン系重合体（Ｂ）からなる第２成分とを、それぞれ別個の押出機で、好ましくは１９０〜２５０℃、より好ましくは２００〜２２０℃で溶融し、吐出された複合繊維の断面が、第１成分と第２成分との比（質量比）が４０／６０〜９５／５、好ましくは６０／４０〜９０／１０の範囲になるように第１成分と第２成分とが接合するように構成された複合紡糸ノズルを有する、好ましくは１９０〜２５０℃、より好ましくは２００〜２２０℃に設定した多数の紡糸口金から、０．３ｇ/孔/分〜１ｇ/孔/分、好ましく０．５ｇ/孔/分〜０．７ｇ/孔/分で吐出させて、複合繊維群を紡出した後、当該紡出した複合繊維群が紡糸口金から２００ｍｍ、好ましくは１００ｍｍの距離に達する間に、好ましくは１０〜４０℃、より好ましくは２０〜３０℃の冷却エアを当該紡出した複合繊維群に、好ましくは２つあるいは２以上の異なる方向から吹付けて冷却するとともに、引続き、好ましくは１０００〜３０００ｍ／分、好ましくは１５００〜２５００ｍ／分の高速のエアで複合繊維群を牽引細化して、捲縮させた後、捲縮複合繊維群を捕集ベルト上に捕集することを特徴とする不織布の製造方法である。
紡出した複合繊維群に吹付ける冷却エアの位置が、紡糸口金から２００ｍｍを超える場合は得られる複合繊維の捲縮数が少なくなる虞がある。
<Nonwoven Fabric Manufacturing Method>
A first component composed of a propylene / α-olefin copolymer (A) having a Tm of 150 ° C. or less and a second component composed of a propylene-based polymer (B) having a Tm of 155 ° C. or more are separately used in separate extruders. The cross-section of the composite fiber melted and preferably discharged at 190 to 250 ° C., more preferably 200 to 220 ° C. has a ratio (mass ratio) of the first component to the second component of 40/60 to 95/5. Preferably having a composite spinning nozzle configured to join the first component and the second component so as to be in the range of 60/40 to 90/10, preferably 190 to 250 ° C., more preferably 200 to A composite fiber group is discharged from a number of spinnerets set at 220 ° C. at a rate of 0.3 g / hole / minute to 1 g / hole / minute, preferably 0.5 g / hole / minute to 0.7 g / hole / minute. After spinning, the spun composite fiber group is released from the spinneret. While reaching a distance of 200 mm, preferably 100 mm, cooling air of preferably 10 to 40 ° C., more preferably 20 to 30 ° C. is applied to the spun composite fiber group, preferably in two or more different directions. After spraying and cooling, the composite fiber group is continuously drawn and crimped with high-speed air, preferably 1000 to 3000 m / min, preferably 1500 to 2500 m / min. It is the manufacturing method of the nonwoven fabric characterized by collecting on a collection belt.
When the position of the cooling air sprayed onto the spun composite fiber group exceeds 200 mm from the spinneret, the number of crimps of the resulting composite fiber may be reduced.
重合体の溶融温度が２５０℃を超える場合は樹脂の溶融粘度の低下によるフィラメントの延伸切れの虞があり、一方、１９０℃未満の場合は溶融粘度が高く口金出口で糸切れの虞がある。また、紡糸口金の設定温度が２５０℃を超える場合は樹脂の溶融粘度の低下によるフィラメントの延伸切れの虞があり、一方、１９０℃未満の場合は溶融粘度が高く口金出口で糸切れの虞がある。吐出量が０．３ｇ/孔/分未満の場合は生産性が著しく低下する虞があり、一方、１ｇ/孔/分を超える場合は触感の良好な不織布が得られない虞がある。
また、冷却エアの温度が４０℃を超える場合は捲縮数が減少する虞があり、一方、１０℃未満の場合は冷却が効きすぎ糸切れをおこす虞がある。高速エアの速度が１０００ｍ／分未満では、複合繊維群の牽引細化が不十分で、捲縮数が減少したり、捲縮が発現しない虞があり、一方、３０００ｍ／分を超える場合は、複合繊維群が破断して良好な不織布が得られない虞がある。
When the melting temperature of the polymer exceeds 250 ° C., the filament may be stretched due to a decrease in the melt viscosity of the resin. On the other hand, when it is lower than 190 ° C., the melt viscosity is high and the yarn may break at the outlet of the die. In addition, when the set temperature of the spinneret exceeds 250 ° C., there is a possibility that the filament may be stretched due to a decrease in the melt viscosity of the resin. is there. When the discharge amount is less than 0.3 g / hole / minute, the productivity may be significantly reduced. On the other hand, when the discharge amount exceeds 1 g / hole / minute, a nonwoven fabric with good tactile sensation may not be obtained.
Further, when the temperature of the cooling air exceeds 40 ° C., the number of crimps may decrease. On the other hand, when the temperature is less than 10 ° C., cooling may be too effective and thread breakage may occur. When the speed of the high-speed air is less than 1000 m / min, the pulverization of the composite fiber group is insufficient, and the number of crimps may be reduced or crimp may not be expressed. On the other hand, if it exceeds 3000 m / min, There is a possibility that the composite fiber group is broken and a good nonwoven fabric cannot be obtained.
捲縮複合繊維群を捕集ベルト上に捕集した後は、通常、ニードルパンチ、ウォータージェット、超音波等の手段を用いる方法、あるいはエンボスロールを用いる熱エンボス加工またはホットエアースルーを用いることにより一部熱融着する方法等の交絡方法で交絡しておくことが好ましい。 After collecting the crimped composite fiber group on the collection belt, usually, by using a method such as needle punch, water jet, ultrasonic, or the like, or by using hot embossing using an embossing roll or hot air through It is preferable to entangle by a entanglement method such as a method of partially heat-sealing.
＜不織布＞
得られ得る不織布は、捲縮複合繊維からなる不織布であり、好ましくは目付が３〜１００ｇ／ｍ２、より好ましくは７〜３０ｇ／ｍ２の範囲にある。得られる捲縮複合繊維は長繊維であるので、使用時に捲縮複合繊維が不織布から脱落する虞が極めて小さく、嵩高性、柔軟性に富み、機械的強度に優れる不織布となる。
不織布は、用途により、前記した交絡方法、例えば、ニードルパンチ、ウォータージェット、超音波等の手段を用いる方法、あるいはエンボスロールを用いる熱エンボス加工またはホットエアースルーを用いることにより一部熱融着する方法により交絡しておいてもよい。かかる交絡方法は単独でも複数の交絡方法を組合わせて用いてもよい。
<Nonwoven fabric>
The non-woven fabric that can be obtained is a non-woven fabric composed of crimped composite fibers, and preferably has a basis weight of 3 to 100 g / m 2 , more preferably 7 to 30 g / m 2 . Since the crimped conjugate fiber obtained is a long fiber, there is very little possibility that the crimped conjugate fiber will fall off the nonwoven fabric during use, and the nonwoven fabric is excellent in bulkiness, flexibility and mechanical strength.
The non-woven fabric is partly heat-sealed by the entanglement method described above, for example, a method using a needle punch, a water jet, an ultrasonic wave, or the like, or hot embossing using an embossing roll or hot air through. It may be entangled by a method. Such entanglement methods may be used alone or in combination with a plurality of entanglement methods.
熱エンボス加工により熱融着する場合は、通常、エンボス面積率が５〜２０％、好ましくは５〜１０％、非エンボス単位面積が０．５ｍｍ２以上、好ましくは４〜４０ｍｍ２の範囲にある。非エンボス単位面積とは、四方をエンボス部で囲まれた最小単位の非エンボス部において、エンボスに内接する四角形の最大面積である。かかる範囲のエンボスを有することにより、嵩高性と柔軟性に優れ、毛羽の発生が押さえられ、高速処理が可能となる。
不織布は、種々用途により、単独でも他の層と積層して用いてもよい。また、不織布は、印刷を施すこともできる。
If heat sealing by the heat embossing is usually 5-20% embossed area ratio, preferably 5-10%, the non-embossed unit area is 0.5 mm 2 or more, preferably in the range of 4 to 40 mm 2 . The non-embossed unit area is the maximum area of a quadrilateral inscribed in the embossed portion in the smallest unit of the non-embossed portion surrounded on all four sides by the embossed portion. By having the embossing in such a range, it is excellent in bulkiness and flexibility, generation of fluff is suppressed, and high-speed processing becomes possible.
The nonwoven fabric may be used alone or laminated with other layers depending on various applications. The nonwoven fabric can also be printed.
＜捲縮複合繊維＞
不織布を構成する捲縮複合繊維は、前記プロピレン・α−オレフィン共重合体（Ａ）を第１成分、前記プロピレン系重合体（Ｂ）を第２成分とし、第１成分と第２成分との比（質量比）が４０／６０〜９５／５、好ましくは６０／４０〜９０／１０の範囲にあり、好ましくは捲縮数が５〜６０個／２５ｍｍ、より好ましくは１０〜５０個／２５ｍｍの範囲にある長繊維である。第１成分と第２成分との比が上記範囲にあることにより、捲縮性に富む複合繊維が得られる。
捲縮複合繊維の繊度は、通常、５デニール以下、好ましくは０．５〜３デニールの範囲にある。繊度がこの範囲にあることにより、より柔軟性に優れる不織布が得られる。
捲縮複合繊維は、第１成分からなる芯部及び第２成分からなる鞘部からなる偏芯芯鞘型複合繊維の構造あるいは第１成分及び第２成分が互いに接してなる並列型複合繊維の構造をとり得る。
複合繊維の構造が、同芯の芯鞘型複合繊維の場合は、捲縮が発生し難い。
<Crimp composite fiber>
The crimped composite fiber constituting the nonwoven fabric has the propylene / α-olefin copolymer (A) as the first component, the propylene polymer (B) as the second component, and the first component and the second component. The ratio (mass ratio) is in the range of 40/60 to 95/5, preferably 60/40 to 90/10, preferably the number of crimps is 5 to 60 pieces / 25 mm, more preferably 10 to 50 pieces / 25 mm. It is a long fiber in the range. When the ratio of the first component to the second component is in the above range, a conjugate fiber rich in crimpability can be obtained.
The fineness of the crimped conjugate fiber is usually 5 denier or less, preferably 0.5 to 3 denier. When the fineness is within this range, a non-woven fabric having more flexibility can be obtained.
A crimped conjugate fiber is a structure of an eccentric core-sheath type conjugate fiber composed of a core portion made of a first component and a sheath portion made of a second component, or a parallel type conjugate fiber formed by contacting the first component and the second component with each other. Can take a structure.
When the structure of the composite fiber is a concentric core-sheath type composite fiber, crimping is unlikely to occur.
偏芯芯鞘型複合繊維は、芯部を形成する前記プロピレン系重合体（Ｂ）の心（中心部）が、複合繊維の心と重ならない限り、特に限定はされないが、芯部を形成する前記プロピレン系重合体（Ｂ）の心と複合繊維の心がより離れる方が、捲縮が発生し易いので好ましい。また、偏芯芯鞘型複合繊維は、芯部を形成する前記プロピレン系重合体（Ｂ）が偏芯芯鞘型複合繊維の表面に１部出ていてもよい。 The eccentric core-sheath type composite fiber is not particularly limited as long as the core (center part) of the propylene polymer (B) forming the core part does not overlap with the core of the composite fiber, but forms the core part. It is preferable that the core of the propylene-based polymer (B) and the core of the composite fiber are further away from each other because crimps are likely to occur. Moreover, as for an eccentric core-sheath-type composite fiber, 1 part of the said propylene polymer (B) which forms a core part may protrude on the surface of the eccentric core-sheath type composite fiber.
並列型複合繊維は、第１成分を形成する前記プロピレン・α−オレフィン共重合体（Ａ）と第2成分を形成する前記プロピレン系重合体（Ｂ）の繊維断面の接合面は、直線であっても、弧状であってもよい。繊維断面の接合面が弧状の場合は、プロピレン系重合体（Ｂ）がプロピレン・α−オレフィン共重合体（Ａ）部に入り込んだ略円形状であっても、プロピレン系重合体（Ｂ）が凹んだ三日月状であってもよい。 In the side-by-side conjugate fiber, the joint surface of the fiber cross section of the propylene / α-olefin copolymer (A) forming the first component and the propylene polymer (B) forming the second component is a straight line. Or it may be arcuate. When the joint surface of the fiber cross section is arcuate, even if the propylene polymer (B) has a substantially circular shape that has entered the propylene / α-olefin copolymer (A), the propylene polymer (B) It may be a concave crescent.
＜不織布積層体＞
不織布積層体は、前記製造方法で得られ得る捲縮複合繊維からなる不織布からなる層と少なくとも１層の他の層からなる。不織布積層体を構成する他の層は、特に限定はされず、用途により種々の層が積層し得る。
具体的には、例えば、編布、織布、不織布、フィルム等を挙げることができる。前記捲縮複合繊維からなる不織布と他の層を積層する（貼り合せる）場合は、熱エンボス加工、超音波融着等の熱融着法、ニードルパンチ、ウォータージェット等の機械的交絡法、ホットメルト接着剤、ウレタン系接着剤等の接着剤による方法、押出しラミネート等をはじめ、種々公知の方法を採り得る。
不織布と積層される不織布としては、スパンボンド不織布、メルトブロー不織布、湿式不織布、乾式不織布、乾式パルプ不織布、フラッシュ紡糸不織布、開繊不織布等、種々公知の不織布を挙げることができる。
<Nonwoven fabric laminate>
A nonwoven fabric laminated body consists of the layer which consists of a nonwoven fabric which consists of a crimped composite fiber which can be obtained with the said manufacturing method, and at least one other layer. Other layers constituting the nonwoven fabric laminate are not particularly limited, and various layers may be laminated depending on the application.
Specifically, a knitted fabric, a woven fabric, a nonwoven fabric, a film, etc. can be mentioned, for example. When laminating the non-woven fabric composed of the crimped composite fibers and other layers (bonding), thermal embossing, thermal fusion methods such as ultrasonic fusion, mechanical entanglement methods such as needle punch and water jet, hot Various known methods such as a method using an adhesive such as a melt adhesive and a urethane-based adhesive, extrusion lamination, and the like can be adopted.
Examples of the nonwoven fabric laminated with the nonwoven fabric include various known nonwoven fabrics such as a spunbond nonwoven fabric, a melt blown nonwoven fabric, a wet nonwoven fabric, a dry nonwoven fabric, a dry pulp nonwoven fabric, a flash spun nonwoven fabric, and a spread nonwoven fabric.
かかる不織布を構成する材料としては、種々公知の熱可塑性樹脂、例えば、エチレン、プロピレン、１−ブテン、１−ヘキセン、４−メチル−１−ペンテンおよび１−オクテン等のα−オレフィンの単独若しくは共重合体である高圧法低密度ポリエチレン、線状低密度ポリエチレン（所謂ＬＬＤＰＥ）、高密度ポリエチレン、ポリプロピレン、ポリプロピレンランダム共重合体、ポリ１−ブテン、ポリ４−メチル−１−ペンテン、エチレン・プロピレンランダム共重合体、エチレン・１−ブテンランダム共重合体、プロピレン・１−ブテンランダム共重合体等のポリオレフィン、ポリエステル（ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリエチレンナフタレート等）、ポリアミド（ナイロン−６、ナイロン−６６、ポリメタキシレンアジパミド等）、ポリ塩化ビニル、ポリイミド、エチレン・酢酸ビニル共重合体、ポリアクリロニトリル、ポリカーボネート、ポリスチレン、アイオノマー、熱可塑性ポリウレタンあるいはこれらの混合物等を例示することができる。これらのうちでは、高圧法低密度ポリエチレン、線状低密度ポリエチレン（所謂ＬＬＤＰＥ）、高密度ポリエチレン、ポリプロピレン、ポリプロピレンランダム共重合体、ポリエチレンテレフタレート、ポリアミド等が好ましい。 Examples of the material constituting such a nonwoven fabric include various known thermoplastic resins such as ethylene, propylene, 1-butene, 1-hexene, 4-methyl-1-pentene, and 1-octene. High pressure low density polyethylene, linear low density polyethylene (so-called LLDPE), high density polyethylene, polypropylene, polypropylene random copolymer, poly 1-butene, poly 4-methyl-1-pentene, ethylene / propylene random Polyolefin such as copolymer, ethylene / 1-butene random copolymer, propylene / 1-butene random copolymer, polyester (polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, etc.), polyamide (nylon-6, nylon- 66, poly Data xylene adipamide, etc.), polyvinyl chloride, polyimide, ethylene-vinyl acetate copolymer, polyacrylonitrile, polycarbonate can be exemplified polystyrene, ionomers, thermoplastic polyurethane, or mixtures thereof. Among these, high pressure method low density polyethylene, linear low density polyethylene (so-called LLDPE), high density polyethylene, polypropylene, polypropylene random copolymer, polyethylene terephthalate, polyamide and the like are preferable.
不織布積層体の好ましい態様としては、スパンボンド法で製造した極細繊維（繊度；０．８〜２．５デニール、より好ましくは０．８〜１．５デニール）からなるスパンボンド不織布及び／又はメルトブローン不織布との積層体が挙げられる。具体的には、スパンボンド不織布（極細繊維）／スパンボンド不織布（捲縮複合繊維）、メルトブローン不織布／スパンボンド不織布（捲縮複合繊維）等の２層、スパンボンド不織布（極細繊維）／スパンボンド不織布（捲縮複合繊維）／スパンボンド不織布（極細繊維）、スパンボンド不織布（極細繊維）／スパンボンド不織布（捲縮複合繊維）／メルトブローン不織布、スパンボンド不織布（極細繊維）／メルトブローン不織布／スパンボンド不織布（捲縮複合繊維）等の３層、あるいはスパンボンド不織布（極細繊維）／スパンボンド不織布（捲縮複合繊維）／メルトブローン不織布／スパンボンド不織布（極細繊維）、スパンボンド不織布（極細繊維）／スパンボンド不織布（捲縮複合繊維）／メルトブローン不織布／スパンボンド不織布（捲縮複合繊維）／スパンボンド不織布（極細繊維）等の４層以上の積層体が挙げられる。積層される各層の不織布の目付は、２〜２５ｇ／ｍ２の範囲にあることが好ましい。上記極細繊維からなるスパンボンド不織布は、スパンボンド法の製造条件を制御（選択）することにより得られ得る。かかる不織布積層体は、前記捲縮複合繊維からなる不織布の嵩高性、柔軟性を生かすとともに、表面の滑らかさに優れ、耐水性が向上した積層体となる。 As a preferred embodiment of the nonwoven fabric laminate, a spunbond nonwoven fabric and / or a meltblown comprising ultrafine fibers (fineness: 0.8 to 2.5 denier, more preferably 0.8 to 1.5 denier) produced by a spunbond method A laminated body with a nonwoven fabric is mentioned. Specifically, two layers, such as spunbond nonwoven fabric (ultrafine fiber) / spunbond nonwoven fabric (crimped composite fiber), meltblown nonwoven fabric / spunbond nonwoven fabric (crimped composite fiber), spunbond nonwoven fabric (ultrafine fiber) / spunbond Nonwoven fabric (crimped composite fiber) / Spunbonded nonwoven fabric (ultrafine fiber), Spunbonded nonwoven fabric (ultrafine fiber) / Spunbonded nonwoven fabric (crimped composite fiber) / Meltblown nonwoven fabric, Spunbonded nonwoven fabric (ultrafine fiber) / Meltblown nonwoven fabric / Spunbond 3 layers such as nonwoven fabric (crimped composite fiber), or spunbond nonwoven fabric (ultrafine fiber) / spunbond nonwoven fabric (crimped composite fiber) / melt blown nonwoven fabric / spunbond nonwoven fabric (ultrafine fiber), spunbond nonwoven fabric (ultrafine fiber) / Spunbond nonwoven fabric (crimped composite fiber) / Meltblown nonwoven fabric / Spunbond Fabric (crimped conjugate fiber) / spunbonded nonwoven fabric (ultrafine fiber) four or more layers of the laminate of the like. The basis weight of the nonwoven fabric of each layer to be laminated is preferably in the range of 2 to 25 g / m 2 . The spunbond nonwoven fabric composed of the above ultrafine fibers can be obtained by controlling (selecting) the production conditions of the spunbond method. Such a nonwoven fabric laminate is a laminate in which the bulkiness and flexibility of the nonwoven fabric composed of the crimped composite fibers are utilized, the surface is excellent in smoothness, and the water resistance is improved.
不織布と積層されるフィルムとしては、不織布の特徴である通気性を生かす、通気性（透湿性）フィルムが好ましい。かかる通気性フィルムとしては、種々公知の通気性フィルム、例えば、透湿性を有するポリウレタン系エラストマー、ポリエステル系エラストマー、ポリアミド系エラストマー等の熱可塑性エラストマーからなるフィルム、無機あるいは有機微粒子を含む熱可塑性樹脂からなるフィルムを延伸して多孔化してなる多孔フィルム等を挙げることができる。多孔フィルムに用いる熱可塑性樹脂としては、高圧法低密度ポリエチレン、線状低密度ポリエチレン（所謂ＬＬＤＰＥ）、高密度ポリエチレン、ポリプロピレン、ポリプロピレンランダム共重合体あるいはそれらの組成物等のポリオレフィンが好ましい。
通気性フィルムとの積層体は、前記捲縮複合繊維からなる不織布の嵩高性、柔軟性を生かすとともに、極めて高い耐水性を有する、クロスライクな複合素材となり得る。
The film laminated with the nonwoven fabric is preferably a breathable (moisture permeable) film that takes advantage of the breathability characteristic of the nonwoven fabric. Examples of such a breathable film include various known breathable films, for example, films made of thermoplastic elastomers such as moisture-permeable polyurethane elastomers, polyester elastomers, polyamide elastomers, and thermoplastic resins containing inorganic or organic fine particles. Examples thereof include a porous film formed by stretching a film to be porous. The thermoplastic resin used for the porous film is preferably a polyolefin such as high-pressure method low-density polyethylene, linear low-density polyethylene (so-called LLDPE), high-density polyethylene, polypropylene, polypropylene random copolymer, or a composition thereof.
A laminate with a breathable film can be a cross-like composite material that takes advantage of the bulkiness and flexibility of the nonwoven fabric composed of the crimped composite fibers and has extremely high water resistance.
＜紙おむつ＞
前記不織布あるいは前記不織布積層体は、紙おむつの表面材、サイドギャザー、バックシート、トップシート、ウェスト部材等の部材となり得る。
<Paper diapers>
The said nonwoven fabric or the said nonwoven fabric laminated body can become members, such as the surface material of a paper diaper, a side gather, a back sheet, a top sheet, a waist member.
＜生理用ナプキン＞
前記不織布あるいは前記不織布積層体は、生理用ナプキンの表面材、サイドギャザー、バックシート、トップシート等の部材となり得る。
<Sanitary napkin>
The said nonwoven fabric or the said nonwoven fabric laminated body can become members, such as the surface material of a sanitary napkin, a side gather, a back sheet, a top sheet.
以下、実施例に基づいてさらに具体的に説明するが、本発明はこれらの実施例に限定されるものではない。
なお、実施例及び比較例における物性値等は、以下の方法により測定した。
Hereinafter, although it demonstrates more concretely based on an Example, this invention is not limited to these Examples.
In addition, the physical-property value in an Example and a comparative example was measured with the following method.
（１） 目付量
下記に示した手順以外は全てＪＩＳ Ｌ１９０６に準拠して測定した。
積層品を作成する前に、各層毎に個別に不織布成形し、単層品を作製した。この際、所定の目付け量になるように、成形条件を調整した。尚、目付け量は各層毎に１００ｍｍ×１００ｍｍの試験片を１０枚切り出し、ｇ/ｍ２に換算した値とした。
(1) Weight per unit area Except for the procedure shown below, all were measured in accordance with JIS L1906.
Before producing a laminated product, the nonwoven fabric was individually molded for each layer to produce a single-layer product. At this time, the molding conditions were adjusted so as to obtain a predetermined basis weight. The basis weight was a value obtained by cutting 10 test pieces of 100 mm × 100 mm for each layer and converting them to g / m 2 .
（２）捲縮数
以下の手順で捲縮数を測定した。なお、下記に示した手順以外は全てＪＩＳ Ｌ１０１５に準拠して測定した。
表面が滑らかで光沢のある紙片に空間距離２５ｍｍの区分線を作った。エンボスロールにより加熱加圧処理される前の不織布から、捲縮性が損なわれないように慎重に採取した繊維を１本ずつ、空間距離に対して２５±５％の緩みをもたせて、両端を接着剤で貼り付け固着させた。この試料を１本ずつ、捲縮試験機のつかみに取り付け、紙片を切断した後、試料に初荷重（０．１８ｍＮ×表示テックス数）をかけたときの、つかみ間の距離（空間距離）（ｍｍ）を読んだ。その時の捲縮数を数え、２５ｍｍ間当たりの捲縮数を求め、２０回の平均値とした。捲縮数は、山と谷を全部数え、２で割って求めた。
(2) Number of crimps The number of crimps was measured by the following procedure. In addition, it measured based on JISL1015 except the procedure shown below.
A dividing line having a spatial distance of 25 mm was made on a piece of paper having a smooth surface and gloss. Each fiber carefully picked from the nonwoven fabric before being heated and pressurized with an embossing roll so as not to impair the crimpability, with a looseness of 25 ± 5% relative to the spatial distance. It was stuck and fixed with an adhesive. One sample at a time, attached to the grip of the crimping tester, cut the piece of paper, and then the distance between the grips when the initial load (0.18 mN x number of tex) is applied to the sample (spatial distance) ( mm). The number of crimps at that time was counted, the number of crimps per 25 mm was obtained, and an average value of 20 times was obtained. The number of crimps was obtained by counting all peaks and valleys and dividing by two.
（３）剛軟度（カンチレバー法）
ＪＩＳ１０９６の８．１９．１[Ａ法（４５°カンチレバー法）]に準拠した。
試料から、２ｃｍ×１５ｃｍの試験片をたて方向及びよこ方向にそれぞれ３枚採取した。
一端が４５度の斜面をもつ表面の滑らかな水平台の上に試験片の短辺をスケール基線に合わせて置いた。次に、適当な方法によって試験片を斜面の方向に緩やかに滑らせて、試験片の一端の中央店が斜面と接したとき他端の位置をスケールによって読んだ。剛軟度は、試験片が移動した長さ（ｍｍ）で示され、それぞれ３枚を測り、たて方向（ＭＤ）及びよこ方向（ＣＤ）それぞれの平均値を小数点第一位を四捨五入して算出した。
(3) Bending softness (cantilever method)
This was in accordance with JIS 1096 8.19.1 [Method A (45 ° cantilever method)].
Three test pieces of 2 cm × 15 cm were collected from the sample in the vertical direction and the horizontal direction.
The short side of the test piece was placed on the scale base line on a smooth horizontal platform with a 45-degree slope at one end. Next, the specimen was gently slid in the direction of the slope by an appropriate method, and when the central store at one end of the specimen contacted the slope, the position of the other end was read on the scale. The bending resistance is indicated by the length (mm) that the test piece has moved. Measure three pieces each and round the average value in the vertical direction (MD) and horizontal direction (CD) to the first decimal place. Calculated.
（４）柔軟性（ＫＯＳＨＩ値）
カトーテック(株)製のＫＥＳ−ＦＢシステムにより、引張、せん断、圧縮、表面摩擦、曲げの各試験の測定を、測定条件をニット高感度条件にて行った。測定結果をニットアンダーウェアー（サマー）条件にて計測してＫＯＳＨＩ値とした。ＫＯＳＨＩ値はその値が小さいほど、柔軟性に優れることを示す。
(4) Flexibility (KOSHI value)
Using the KES-FB system manufactured by Kato Tech Co., Ltd., measurement of each test of tension, shear, compression, surface friction and bending was performed under the knit high sensitivity condition. The measurement result was measured under knit underwear (summer) conditions to obtain a KOSHI value. A KOSHI value indicates that the smaller the value, the better the flexibility.
（５）厚み（嵩高性）
試料から試験片（１００ｍｍ×１００ｍｍ）を５枚採取した。採取した各試験片の任意の３箇所の厚みを、定圧厚み測定器（（株）尾崎製作所製）を用いて測定した。このとき、測定子直径１６ｍｍ、荷重３．６ｇ／ｃｍ２とし、測定子が試験片に完全に接触してから３０秒±５秒後の指示値を読み取り、試験片５枚分の平均値を算出して、その値を厚み（嵩高性）とした。
(5) Thickness (bulkyness)
Five test pieces (100 mm × 100 mm) were collected from the sample. The thickness of arbitrary three places of each collected test piece was measured using a constant pressure thickness measuring instrument (manufactured by Ozaki Mfg. Co., Ltd.). At this time, the probe diameter is 16 mm, the load is 3.6 g / cm 2 , the indicated value is read 30 seconds ± 5 seconds after the probe comes into full contact with the test piece, and the average value for the five test pieces is obtained. Calculation was made and the value was defined as thickness (bulkyness).
[実施例１]
Ｔｍ＝１６２℃、ＭＦＲ＝６０ｇ／１０分（ＡＳＴＭ Ｄ１２３８に準拠し 温度２３０℃、荷重２．１６ｋｇで測定、以下特に限定しない限り同様）のポリプロピレン単独重合体と、Ｔｍ＝１４２℃、ＭＦＲ＝６０ｇ／１０分のプロピレン・エチレンランダム共重合体とを用い、スパンボンド法により、重量比２０／８０の並列型複合繊維（繊度３デニール）複合繊維群を紡出した後、当該紡出した複合繊維群が紡糸口金から１００ｍｍに達する間に冷却エアを当該紡出した複合繊維群に吹付けて冷却された不織布を得た。このとき、不織布の目付けが２０ｇ／ｍ２となるよう成形条件を調整した。得られた不織布について目付、捲縮数、剛軟度、柔軟性、厚みを測定して評価した。結果を表１に示す。
[Example 1]
Polypropylene homopolymer of Tm = 162 ° C., MFR = 60 g / 10 min (according to ASTM D1238, temperature 230 ° C., load 2.16 kg, the same unless otherwise specified), Tm = 142 ° C., MFR = 60 g / 10 min of propylene / ethylene random copolymer and spunbonded parallel fiber (fineness 3 denier) composite fiber group with a weight ratio of 20/80, and then the spun composite fiber While the group reached 100 mm from the spinneret, cooling air was sprayed onto the spun composite fiber group to obtain a cooled nonwoven fabric. At this time, the molding conditions were adjusted so that the basis weight of the nonwoven fabric was 20 g / m 2 . The obtained nonwoven fabric was evaluated by measuring basis weight, number of crimps, bending resistance, flexibility, and thickness. The results are shown in Table 1.
[実施例２]
実施例１において、当該紡出した複合繊維群が紡糸口金から２００ｍｍに達する間に冷却エアを当該紡出した複合繊維群に吹付けた以外は実施例１と同様にして不織布を得た。得られた不織布について目付、捲縮数、剛軟度、柔軟性、厚みを測定して評価した。結果を表１に示す。
[Example 2]
In Example 1, a nonwoven fabric was obtained in the same manner as in Example 1 except that cooling air was sprayed onto the spun composite fiber group while the spun composite fiber group reached 200 mm from the spinneret. The obtained nonwoven fabric was evaluated by measuring basis weight, number of crimps, bending resistance, flexibility, and thickness. The results are shown in Table 1.
[比較例１]
実施例１において、当該紡出した複合繊維群が紡糸口金から３００ｍｍを超えたところで冷却エアを当該紡出した複合繊維群に吹付けた以外は実施例１と同様にして不織布を得た。得られた不織布について目付、捲縮数、剛軟度、柔軟性、厚みを測定して評価した。結果を表１に示す。
[Comparative Example 1]
In Example 1, a nonwoven fabric was obtained in the same manner as in Example 1 except that when the spun composite fiber group exceeded 300 mm from the spinneret, cooling air was blown onto the spun composite fiber group. The obtained nonwoven fabric was evaluated by measuring basis weight, number of crimps, bending resistance, flexibility, and thickness. The results are shown in Table 1.
捲縮複合繊維からなる不織布は、嵩高性と柔軟性に優れるとともに、紡糸性に優れるので、紙おむつ、ナプキンなどの衛生材料等に好適に用いられる。
また、前記捲縮複合繊維からなる不織布を用いた不織布積層体は、積層する他の層によって各種の特性が付与できるので、前記衛生材のほか、生活資材、産業資材等にも好ましく応用できる。
Nonwoven fabrics made of crimped composite fibers are suitable for sanitary materials such as disposable diapers and napkins because they are excellent in bulkiness and flexibility and have excellent spinnability.
Moreover, since the nonwoven fabric laminated body using the nonwoven fabric which consists of the said crimped composite fiber can provide various characteristics with the other layer to laminate | stack, it can apply preferably to a living material, an industrial material, etc. besides the said sanitary material.
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| JP2017186728A (en) * | 2016-03-31 | 2017-10-12 | ダイワボウホールディングス株式会社 | Nonwoven fabric, absorbing article top sheet, and absorbing article comprising the same |
| EP3246443B1 (en) * | 2016-05-18 | 2020-06-17 | Fibertex Personal Care A/S | Nonwoven fabric comprising a high loft layer |
| MX2018014007A (en) * | 2016-05-18 | 2019-08-16 | Fibertex Personal Care As | Nonwoven laminate fabric comprising meltblown and spundbond layers. |
| JP2019136434A (en) * | 2018-02-15 | 2019-08-22 | 株式会社リブドゥコーポレーション | Laminated sheet, laminated sheet manufacturing method, and absorbent article |
| JP7168125B1 (en) * | 2021-03-18 | 2022-11-09 | 東レ株式会社 | Spunbond nonwovens and laminated nonwovens, their production methods and sanitary materials |
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| JPH01148862A (en) * | 1987-12-04 | 1989-06-12 | Asahi Chem Ind Co Ltd | Bulky spun bond nonwoven fabric made of crystalline thermoplastic resin |
| JPH01201567A (en) * | 1988-01-30 | 1989-08-14 | Asahi Chem Ind Co Ltd | Production of bulky spun-bond nonwoven fabric |
| JPH1136141A (en) * | 1997-07-14 | 1999-02-09 | Chisso Corp | Bulky conjugate fiber, and fibrous form using the same |
| US6454989B1 (en) * | 1998-11-12 | 2002-09-24 | Kimberly-Clark Worldwide, Inc. | Process of making a crimped multicomponent fiber web |
| JP4438181B2 (en) * | 1999-05-11 | 2010-03-24 | チッソ株式会社 | Latent crimpable conjugate fiber and nonwoven fabric using the same |
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