TWI492847B - 使用伸長性不織布的複合體 - Google Patents

使用伸長性不織布的複合體 Download PDF

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Publication number
TWI492847B
TWI492847B TW100109884A TW100109884A TWI492847B TW I492847 B TWI492847 B TW I492847B TW 100109884 A TW100109884 A TW 100109884A TW 100109884 A TW100109884 A TW 100109884A TW I492847 B TWI492847 B TW I492847B
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TW
Taiwan
Prior art keywords
composite
nonwoven fabric
spunbonded nonwoven
elongation
fiber
Prior art date
Application number
TW100109884A
Other languages
English (en)
Other versions
TW201134667A (en
Inventor
Toshikatsu Fujiwara
Taiju Terakawa
Original Assignee
Jnc Corp
Jnc Fibers Corp
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Filing date
Publication date
Application filed by Jnc Corp, Jnc Fibers Corp filed Critical Jnc Corp
Publication of TW201134667A publication Critical patent/TW201134667A/zh
Application granted granted Critical
Publication of TWI492847B publication Critical patent/TWI492847B/zh

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/04—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a layer being specifically extensible by reason of its structure or arrangement, e.g. by reason of the chemical nature of the fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
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    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
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Description

使用伸長性不織布的複合體
本發明關於一種將在一個方向上有低應力伸長性的不織布與伸縮性層積層成一體所成的複合體。特定的低應力伸長性不織布與伸縮性層積層成一體，有利於構成最適合作為如內衣或防塵口罩、拋棄式紙尿布等衛生用品等產品的材料，且加工容易，伸長或伸縮性、透氣性、柔軟性佳，觸感好且不易破裂(或斷裂、撕裂強度大)的薄片材料。
普通的紡黏不織布和熱軋不織布價格便宜，而被大量利用為使用方便的通用品不織布，但這些不織布幾乎不具有本發明所謂的低應力伸長性。另外，表現低應力伸長性的通用不織布有水刺(spunlace)不織布，但其未達到本發明所謂的低應力伸長性，且因製法特殊而價格相對高昂。另外，低應力伸長性的不織布也有長絲束近於平行的絲束開鬆不織布、以熔融擠出法而得的發泡網狀物等，但這些不織布的CD(Cross Direction，製造不織布時的寬度方向)強度極小，不適合於本發明的目的。記載了解決此問題的方法的文獻已知有以下的專利文獻。
專利文獻1記載了一種利用兩層的收縮差而在其中一面形成褶皺的積層體，但這種積層體的問題是，即使施加張力，褶皺也不會伸展。
專利文獻2記載了一種頸狀伸長的(neck-stretching)不織網布(nonwoven web)，但據其記載此不織網布的表 面為「平坦」。其並記載，在積層於此不織網布上的膜層的表面，伴隨不織網布的CD的收縮(以下將此種收縮稱為「縮幅」)而形成褶皺。
專利文獻3中使用齒輥(gear roll)對不織布賦予凹凸形狀，但是此凹凸結構是形成在不織布的整個面上，且高度為2~30mm，波長為2~50mm，相對較大。
[先前技術文獻]：[專利文獻]：
[專利文獻1]日本專利特開平7-54256
[專利文獻2]日本專利特開2004-521775
[專利文獻3]日本專利特開2004-76178
但是上述方法中，在不織布由多層構成時不能獲得柔軟性，或者不能獲得充分的伸長性或伸縮性，因此無法提供最適合用作內衣或衛生用品等產品的原材料的不織布。本發明提供一種積層了價格相對低廉且使用方便的低應力伸長性不織布的複合體。
本發明需要由包含低熔點成分與高熔點成分的複合纖維構成，且局部經過適度的熱壓接合加工的複合紡黏原料不織布。並且，藉由在規定條件下將此原料不織布沿著製造不織布時的長度方向(Machine Direction，以下簡稱MD)延伸，可以在熱壓接合部沿著製造不織布時的寬度方向(以下簡稱CD)形成由山部與谷部重複所成的微細折疊結構， 此原料不織布即藉由伸展此微細折疊結構而表現伸長性。由此，將此種原料不織布與伸縮性層積層成一體而成的本發明的複合體具有充分的伸縮性。
本發明的構成如下所述。
(1).一種複合體，包括積層成一體的複合紡黏不織布與伸縮性層，其中複合紡黏不織布包括含低熔點成分與高熔點成分的複合纖維，複合纖維彼此局部地熱壓接合，且熱壓接合部沿CD(製造不織布時的寬度方向)具有由山部與谷部重複所成的微細折疊結構，此折疊結構的相鄰山部間的平均距離在100~400μm範圍內，此複合紡黏不織布是藉由伸展此微細折疊結構而表現出伸長性。
(2).如(1)所述之複合體，其中複合紡黏不織布伸長5%時的CD強度在0.1N/5cm寬以下，伸長5%時的MD/CD強度比(「製造不織布時的長度方向/製造不織布時的寬度方向」的強度比)在200以上。
(3).如(1)所述之複合體，其中複合紡黏不織布伸長50%時的CD強度在5N/5cm寬以下。
(4).如(1)~(3)中任一項所述之複合體，其中伸縮性層是包含彈性體樹脂的長纖維層。
(5).如(4)所述之複合體，其中長纖維層是熔噴纖維層。
(6).如(1)~(5)中任一項所述之複合體，其中複合紡黏不織布與伸縮性層是藉由局部熱壓接合而積層成一體。
利用本發明可發揮以下效果，即能夠提供一種價格相 對低廉，最適合作為如內衣或防塵口罩、拋棄式紙尿布等衛生用品之類的產品的材料，而且加工容易，伸長性、透氣性、柔軟性佳，觸感良好的薄片材料狀的複合體，並且能夠提供一種使用這些複合體的物品。
要製造適用於本發明的複合體的具有優良的低應力伸長性的紡黏不織布，熱壓接合部形成折疊結構之前的原料不織布較佳是保有適度的MD乾熱收縮率，且熱壓接合部殘留有高熔點成分的纖維結構的複合紡黏不織布。此時，如果在熱壓接合部高熔點成分保持著纖維的形狀，則即便低熔點成分藉由熱熔融而遍及整個熱壓接合部地形成為一體也無妨。藉由對此原料不織布沿著MD進行加熱延伸(就可進行此種延伸的方面而言，原料不織布較佳使用複合紡黏不織布)，存在於非熱壓接合部的無規配置的複合長絲以沿MD配向的方式移動，但是其反作用會使不織布受到沿著CD內側的應力，而使不織布沿CD縮幅。此時，雖然熱壓接合部受到沿MD伸展的應力，但是非熱壓接合部的長絲的MD配向佔優勢，熱壓接合部不會延伸至要延伸的倍率，也不會被破壞。另外，雖然熱壓接合部也同樣受到沿著CD內側的應力，但因未沿著MD得到相應拉伸而殘留的應變應力會產生沿著CD表現出折疊結構的應力解除現象。而且，因為熱壓接合部中保持著熱收縮性的高熔點成分殘留成纖維狀，所以藉由與此高熔點成分的收縮功能的相乘效果，可以容易地形成微細的折疊結構。
相對於此，當原料不織布為由單一成分纖維構成的紡黏不織布時，要保持充分的強度，必須形成為熱壓接合部的纖維幾乎完全熔融固化的狀態。使用此紡黏不織布進行延伸時，雖然非熱壓接合部與前述同樣地進行作用，但熱壓接合部與本發明這樣的熱壓接合部相比較硬，因而即使延伸也不能獲得充分的折疊結構。另外，即使是複合紡黏不織布原料，如果熱壓接合部的高熔點成分也是熔融固化的狀態，則與前述情形同樣。
形成本發明的複合體的複合紡黏不織布的熱壓接合部的微細折疊結構示於圖1。此熱壓接合部10的微細折疊結構中，相鄰的折疊結構可以接觸也可以分開。相鄰折疊結構的相鄰的各山間或各谷間的距離依賴於原料不織布的物性或纖維的構成及延伸條件等，尤其較大程度地依賴於不織布的熱壓接合部10的狀態。本發明中，熱壓接合部10的折疊結構中相鄰各山間的目標距離較佳為100~400μm，特佳在100~300μm的範圍內。當相鄰各山間的距離為100~400μm時，可獲得足夠的伸長度，而且，即使不使用必要量以上的低基重(basis weight)原料不織布也可獲得充分的伸長度，容易均勻進行熱延伸，而可保持均勻的低應力伸長性。
本發明中使用的複合紡黏不織布沿著CD具有極低應力的伸長性。其指標如下：伸長5%時的CD強度在0.1N/5cm寬以下，較佳0.100N/5cm寬以下，更佳在0.050N/5cm寬以下，特佳0.010N/5cm寬以下。並且，伸長5%時的 MD/CD強度比在200以上，較佳300以上，更佳400以上。由於也有CD強度在拉伸試驗機測定極限(0.001N/5cm)以下的情況，所以限定MD/CD強度比的上限沒多大意義。但是，考慮到本發明的實例中MD強度的最大值為100N/5cm左右，可估算出MD/CD強度比的上限為100000左右，考慮MD強度更高(可假定上限為200N/5cm左右)的情況，則可估算出MD/CD強度比的上限為200000左右。為使本發明的效果更明確，伸長50%時的CD強度在5N/5cm寬以下，較佳在5.000N/5cm寬以下。此CD強度更佳在3.000N/5cm寬以下，特佳在1.000N/5cm寬以下。下限值是拉伸試驗機的測定極限(0.001N/5cm)。
接著說明複合紡黏不織布的樹脂成分的組合。低熔點成分及高熔點成分例如可以將作為普通熱塑性樹脂的聚乙烯(PE)、聚丙烯(PP)、聚酯(例如聚對苯二甲酸乙二酯(PET))、尼龍(nylon)組合使用。PE可使用高密度聚乙烯、低密度聚乙烯、線性低密度聚乙烯。複合纖維的形態可例舉鞘(sheath)側配置低熔點成分，芯(core)側配置高熔點成分的芯鞘型複合纖維，也可使用高熔點成分的一部分以50%以下的表面積露出纖維表面的複合形態。使用單一成分時，為使複合紡黏不織布具有可耐受延伸的MD強度，須將熱壓接合加工條件設得很嚴酷，因此不能在熱壓接合部殘留纖維結構至纖維本身所具熱收縮性殘留的程度，而難獲得本發明的不織布。使用鞘側配置高熔點成分，芯側配置低熔點成分的芯鞘型複合纖維時也同樣如此。本 發明的複合紡黏不織布的具體的熱塑性樹脂的組合較佳的是低熔點成分/高熔點成分為PE/PP、PE/尼龍、PE/PET、PP/尼龍、PP/PET、尼龍/PET，為在熱壓接合部殘留纖維結構至纖維本身所具熱收縮性殘留的程度，熔點差愈大則加工條件的限制愈少，特佳的是PE/PET的組合。
本發明的進一步的特徵在於：折疊結構形成前的原料不織布中，熱壓接合部10的總面積率較佳為7%~60%，特佳為10%~50%。藉由使熱壓接合部的總面積率在所述範圍內，可以在不損及不織布的柔軟性、透氣性的情況下，確保應表現微細折疊結構的熱壓接合部10的面積足夠。
另外，本發明使用的原料不織布中，連續散佈在MD上的熱壓接合部10相對於CD全寬的佔有率較佳在50%以上，更佳70%以上。以下將說明此連續散佈在MD上的熱壓接合部10相對於CD全寬的佔有率(下稱「CD佔有率」)。
本發明中使用的原料不織布的CD佔有率依賦予此原料不織布的熱壓接合部10的圖案的不同而變化，且關係到本發明的效果。因此，首先說明熱壓接合部10的圖案。
圖2(A)的熱壓接合部圖案是棋盤排列，熱壓接合部10沿著CD的排列(即CD行)與熱壓接合部10沿著MD的排列(即MD列)正交。各CD行及各MD列分別等間隔地排列。各CD行的間隔和各MD列的間隔可相同，亦可不同。可將所有熱壓接合部投影在CD軸20上而求出CD佔有率。關於圖2(A)的圖案的CD佔有率，因為CD軸與 各CD行平行，所以配置在每一行CD行的熱壓接合部的寬度(W1~Wn)的總和相對於CD全寬22所占的比例相同。
圖3(A)是使圖2的熱壓接合部圖案逆時針旋轉α角(α°)，各CD行相對於實際的CD有α°的角度。如圖3(B)所示，此時每一行的CD佔有率是：將一行中的各熱壓接合部10的寬度投影在CD軸20上時的W1~Wn的總和相對於CD全寬22所占的比例。
但是，由於此圖案有角度，所以如圖3(C)所示，兩行CD行的CD佔有率是2W1~2Wn的總和相對於CD全寬22所占的比例。實質上，因為CD行是第1行、第2行、第3行、......規則地逐漸錯開，所以將多行CD行投影在CD軸20上時的CD佔有率為100%。
圖4(A)是熱壓接合部的圖案交錯排列的示例(將此種各CD行的熱壓接合部10交錯排列的圖案稱為交錯排列)。各CD行間及各MD列間的距離相等，且熱壓接合部10以連續兩行及兩列為單位而重複排列。另外，各CD行的間隔和各MD列的間隔可相同，亦可不同。關於圖4(A)的圖案的CD佔有率，由於CD軸20與CD行平行，所以如圖4(B)所示，將任連續兩CD行的各熱壓接合部10的寬度投影在CD軸20上時的W1~Wn的總和相對於CD全寬22所佔的比例相同。
雖未圖示，但為此交錯排列時，也可以和圖3所示的棋盤格排列同樣地旋轉α°。此時，CD行是以連續的兩行 為單位而規則地逐漸錯開，所以和前述同樣，將多行CD行投影在CD軸20上時的CD佔有率為100%。
另外，當圖3(A)及圖4(A)的各CD行和MD列的間隔相同時，由CD行與MD列形成的四角形為正方形，所以如果將圖3(A)傾斜45°，則變成與圖4(A)相似的圖案；反之，如將圖4(A)傾斜45°，則變成與圖3(A)相似的圖案。
圖5(A)是熱壓接合部的形狀及排列不規則的示例。如圖5(B)所示，此時的CD佔有率是將從圖5(A)的靠近底邊的壓接部開始使壓接部一個一個地投影在CD軸上時的各熱壓接合部10的寬度設為W1、W2、W3、......Wn，W1~Wn的總和相對於CD全寬22所占的比例。
另外，由於原本就是不規則排列，所以即使將圖5(A)的圖案旋轉α°，也可用與前述相同的方式求出CD佔有率。
另外，本發明中使用的原料不織布的MD乾熱收縮率較佳為3.5%~23%，特佳為4%~20%。纖維的熱收縮在促進微細折疊結構的形成方面重要。特別是必須將熱壓接合部殘留的高熔點成分的纖維的收縮率保持在適當範圍內。當MD乾熱收縮率為3.5%~23%時，可容易形成折疊結構，且折疊的各山間的距離也足以保持在400μm以下，可不考慮在所製成的不織布上產生局部的抽縮或密集部(團塊)等問題而實施本發明。另外，不織布的質地亦可保持良好。
為得具有上述MD乾熱收縮率的不織布，重要的是適當地選擇紡絲速度或紡絲溫度等紡絲條件。所述紡絲條件可以藉由對高熔點成分側的結晶度或分子配向稍加抑制而 容易地設定。例如，如果是由PE/PET組合構成的不織布，則將紡絲速度設在2000~3000m/min的範圍內，紡絲溫度設在300~350℃的範圍內，即可較佳地獲得MD乾熱收縮率在3.5%~23%的範圍內的原料不織布。
關於對上述適當的原料不織布進行適度地延伸所得的不織布的縮幅，延伸後CD寬度相對於延伸前CD寬度的比較佳為0.1~0.7，更佳為0.2~0.6。當該比值為0.1~0.7時，可使本發明所說的低應力伸長性充分保持，且與前述MD乾熱收縮率的情況同樣，可不考慮在所製成的不織布上產生局部的抽縮或密集部(團塊)等問題而實施本發明。另外，不織布的質地亦可保持良好。
本發明中，雖然對於用來在原料不織布上設置熱壓接合部的熱壓接合加工條件不作特別限定，但重要的是設定成熱壓接合部殘留高熔點成分的纖維結構這樣的條件。如果是熱壓接合部的高熔點成分可以保持纖維的形狀這樣的加工條件，則即使低熔點成分藉由熱熔融而遍及整個熱壓接合部地形成為一體也無影響。為保持高熔點成分的纖維結構，特別重要的是適當選擇熱壓接合加工時的溫度、線壓等條件。此方法可利用已知方法，具代表性的是此技術領域中通常使用的，利用表面具有凹凸部的熱壓花輥進行熱壓接合的方法。上述用來設置熱壓接合部的熱壓花輥的壓接條件(溫度、線壓等)依所使用的樹脂的種類不同而有所不同，但是只要一邊觀察熱壓接合部的狀態一邊實施熱壓接合，就能夠容易地設定在通常進行的範圍內。
關於製造例如由PE/PET或PE/PP的組合構成的原料紡黏不織布時的熱壓接合條件，例如當使用Kuster公司製壓花輥/浮動輥(swimming roll)熱壓接合機時，理想的是輥溫度在115~140℃範圍內，線壓在20~70N/mm範圍內。
另外，本發明中延伸條件亦無特別限定。所謂延伸是指將原料不織布沿著MD的一方向延伸，可選擇輥延伸裝置或針板拉幅延伸裝置(pin tentering extension device)。延伸後的不織布寬度與延伸前原料不織布的寬度相比會收縮至0.1~0.7，所以理想的是對縮幅不產生阻力的裝置。使用輥延伸裝置時，可藉由調整傳送輥與拉伸輥的間隔而縮幅至規定寬度為止；使用針板拉幅延伸裝置時，可調整針板拉幅部以使原料不織布能延伸且縮幅至規定寬度為止。
接著說明用以使熱壓接合部表現出規定的微細折疊結構的溫度、倍率等延伸條件。
輥延伸時的加熱方式可以採用通常的加熱輥方式，或配置在傳送輥與拉伸輥之間的乾燥熱風、蒸汽、熱水腔室方式、加熱蒸汽腔室方式等的任一種，也可以將多種加熱方式組合。針板拉幅延伸時的加熱方式可以選擇乾燥熱風、遠紅外線加熱方式等。
關於延伸溫度，理想是在構成原料不織布的鞘側即低熔點成分不熔融，低熔點成分及高熔點成分可塑化且發揮適度的熱收縮的溫度下延伸。例如，如果是由PE/PET的組合構成的不織布，兼顧到低熔點成分PE的可塑化溫度及熔融溫度以及高熔點成分PET的可塑化溫度等，延伸溫 度較佳為50~120℃，考慮到確保延伸性以及使不織布的手感或低應力伸長性等物性穩定，更佳為80~100℃的範圍。
延伸倍率理想的是設定成非熱壓接合部的複合纖維沿著MD配向，即使進一步拉伸也不會斷裂，且原料不織布的熱壓接合部不受到破壞的適當的倍率。為了在本發明中所說的熱壓接合部獲得微細的折疊結構，在不會發生斷裂、破壞的範圍內將延伸倍率設定得越高，則所受到的沿著CD的反作用應力越增大，效果越佳。例如，如果是由PE/PET的組合構成的不織布，延伸倍率根據此原料不織布的壓接面積率、纖維直徑、基重、以及延伸溫度等而不同，可選擇1.3~2.0倍的範圍。
本發明使用的伸縮性層可例示包含由彈性體樹脂構成的纖維或含有彈性體樹脂的複合體的網狀物、不織布、膜，以及會因積層物的結構特徵而具伸縮性的材料，例如包含捲縮纖維的網狀物、乾式不織布、水刺不織布、網狀織物及針織物等。其中，以由彈性體樹脂構成的纖維或含彈性體樹脂的複合體作為原料的紡黏纖維、熔噴纖維所構成的纖維層及膜容易發揮高伸縮性。就使積層體的伸縮性良好方面而言，伸縮性層伸長80%時的伸長回復率較佳在60%以上，特佳在75%以上。伸縮性層較佳含有彈性體樹脂為構成成分，其以伸縮性層重量為基準來計算較佳在20wt%以上。當伸縮性層為纖維層時，就伸長回復率良好方面而言，較佳是構成纖維為長纖維，長纖維可例示紡黏纖維或閃蒸纖維、熔噴纖維、電紡纖維(electrospinning fiber)等， 就製造纖維的難度或經濟性方面而言，較佳是熔噴纖維。纖維的形態可為單一成分纖維，亦可為由含兩種以上樹脂成分的混合樹脂形成的纖維，還可為兩種以上樹脂成分各形成纖維截面的一部分的複合纖維。複合纖維的複合形態不限，可例示：芯鞘型或偏心芯鞘型、並列型、餡餅式節段(pie segment)、中空芯鞘型、中空偏心芯鞘型、中空並列型、中空餡餅式節段等。另亦可將這些纖維混合(混纖)。
彈性體樹脂可例舉聚苯乙烯彈性體、聚烯烴彈性體、聚酯彈性體、聚醯胺彈性體、聚氨酯彈性體。其中就可以回收再利用方面而言，較佳為聚苯乙烯彈性體、聚烯烴彈性體、聚酯彈性體、聚醯胺彈性體。
當伸縮性層由含有彈性體樹脂的纖維構成時，以此伸縮性層的重量為基準來計算，彈性體樹脂較佳佔20wt%以上，更佳佔50wt%以上。彈性體樹脂以外的樹脂可例示聚丙烯、聚乙烯、聚酯、聚醯胺、聚丙烯系共聚物、聚乙烯系共聚物、聚酯系共聚物等非彈性體樹脂。這些非彈性體樹脂能夠以與彈性體樹脂進行樹脂混合、構成複合纖維的複合成分，或者構成混合纖維中的一種纖維的樹脂成分的形式而包含於纖維中。特別是，如採用彈性體纖維與非彈性體纖維混合的混纖形態，則可調整各種纖維的混合量或纖維直徑等來調整成所需的手感或伸縮性。另外，將不同的彈性體樹脂彼此混纖，即可在更高的伸縮性水準下調整手感或伸縮性。這些不同彈性體樹脂彼此的組合可例舉：聚苯乙烯彈性體與其他聚苯乙烯彈性體、聚苯乙烯彈性體 與聚烯烴彈性體、聚苯乙烯彈性體與聚酯彈性體、聚苯乙烯彈性體與聚醯胺彈性體、聚苯乙烯彈性體與聚氨酯彈性體、聚烯烴彈性體與其他聚烯烴彈性體、聚烯烴彈性體與聚酯彈性體、聚烯烴彈性體與聚醯胺彈性體、聚烯烴彈性體與聚氨酯彈性體、聚酯彈性體與其他聚酯彈性體、聚酯彈性體與聚醯胺彈性體、聚酯彈性體與聚氨酯彈性體、聚醯胺彈性體與其他聚醯胺彈性體、聚醯胺彈性體與聚氨酯彈性體、聚氨酯彈性體與其他聚氨酯彈性體。
請參照圖6，本發明的複合體60是將至少一層複合紡黏不織布62與至少一層伸縮性層64積層成一體。另外，也可以在不妨礙本發明的效果的範圍內再積層其他層。各層可以交替地積層，也可以按照任意的順序積層。將伸縮性層作為中間層，使用複合紡黏不織布來形成複合體的兩表面層的形態也是本發明的複合體的較佳形態之一。
積層成一體(複合)的方法無特別限定，可例舉：按壓法、熱壓接合法、熱風貫通法、超聲波法、膠合法及熱熔樹脂固定法等。為有效發揮本發明的低應力伸長性或伸縮性，特別是以盡可能不會損傷複合紡黏不織布的折疊結構部的方法為佳，理想的是局部熱壓接合、超聲波黏接及熱熔黏接等。
就易得柔軟性或能價格相對低地製造方面而言，較佳進行局部熱壓接合。局部熱壓接合的條件較佳採用下述條件。溫度是依所使用的原材料來選擇，較佳是選擇伸縮性層與複合紡黏不織布不會容易剝離，即使反復地使本發明 的複合體伸長、回復所述局部熱壓接合也不會受到破壞的溫度。局部熱壓接合時較佳以10~100N/mm的範圍進行按壓。壓接面積率較佳4%~12%。局部熱壓接合部在CD上的間距(pitch)較佳的是，將本發明的複合體的局部熱壓接合部投影在CD上時，相鄰熱壓接合部間距離在0.6mm以上。MD方向上的間距無特別限制。局部熱壓接合部的形狀無特別限定，可例示：正圓或橢圓、正方形、長方形、圓角處理的長方形等。對於複合時所進行的熱壓接合，只要如圖6所示般不選擇其熱壓接合部與複合紡黏不織布本身的熱壓接合部10完全一致的圖案，即無任何特別限制，熱壓接合部66與10越不一致越好。
另外，當使用熔噴不織布作為伸縮性層時，亦可在熔噴不織布的生產工序中，直接將用彈性體樹脂等所得的熔噴纖維積層於本發明的複合紡黏不織布上而形成一體。複合後，可將本發明的複合體沿至少一方向延伸。藉此延伸，在複合紡黏不織布與伸縮性層的熱壓接合點間，複合紡黏不織布不能追隨伸縮性層的伸長回復性，而亦可在複合紡黏不織布的表面側形成突出成凸狀的表面結構。具有此結構，則在厚實感提高，觸感更接近布且設計性佳方面較佳。
本發明的製造設備包括原料不織布製造生產線和不織布延伸生產線，另外有時還包括積層生產線。這些生產線可以是各個分開的生產線即所謂離線(off line)，也可以是全部連續配置的生產線即所謂線內(in-line)。另外，還可以將其中兩條生產線設置成線內，另一條設置成離線。
另外，本發明中使用的複合紡黏不織布的特徵在於可以將伸長5%時的MD強度維持為與原料不織布相比幾乎無變化，因此在加工積層體或物品時，如果是沿著MD來反復搬送，則可以不對沿著CD所形成的微細的折疊結構造成破壞地進行操作。
[實例]
以下，藉由實例和比較例來進一步說明本發明。
另外，實例和比較例的測定方法、評價方法如下所述。
(1)伸長5%時的拉伸強度
依JIS L 1906「普通長纖維不織布試驗方法」的拉伸強度試驗方法，用自動繪圖裝置(拉伸試驗機)對MD及CD測定相對試片夾固長度100mm拉伸5mm時的強度。
(2)伸長50%時的拉伸強度
除了將試片拉伸50mm以外，以與所述伸長5%時的拉伸強度相同的方法進行測定。
(3)乾熱收縮率
依據JIS L 1906「普通長纖維不織布試驗方法」的乾熱收縮率試驗方法，求出MD的收縮率。
(4)熱壓接合部的微細的折疊結構的相鄰各山間的距離
使用KEYENCE公司製造數位顯微鏡(digital microscope)VHX-900，將從不織布中隨機選擇的20個熱黏接點放大200倍拍攝，分別測量所述20個熱黏接點的相鄰各山間的距離並求出它們的平均值。
(實例1)
準備下述複合紡黏不織布，即鞘側配置熔點129℃，密度為0.958g/cm3，190℃下測的熔體質量流動速率(melt mass-flow rate)為38dg/min的高密度聚乙烯，芯側配置特性黏度為0.640，熔點為254℃的聚酯，並於速度為2075m/min，聚乙烯紡絲溫度240℃，聚酯紡絲溫度320℃的條件下紡絲，於線壓45N/mm，溫度125℃的條件下進行熱壓接合加工所成的CD寬度1100mm，基重17g/m2的複合紡黏不織布。此不織布中熱壓接合部的總面積率為不織布的21%，CD佔有率為90%。使此複合紡黏不織布以約20m/min的速度通過在加熱輥間配置著蒸汽腔室的裝置，以在MD方向上延伸1.5倍。此時的輥及蒸汽溫度為100℃。寬度572mm，基重32g/m2。此複合紡黏不織布柔軟且極富CD伸長性。此複合紡黏不織布的物性如下。
‧熱壓接合部的微細的折疊結構的相鄰各山間的距離
233μm
‧伸長5%時的拉伸强度
MD：42.8N/5cm
CD：0.089N/5cm
MD/CD比：481
‧伸長50%時的拉伸强度
MD：斷裂
CD：2.89N/5cm
‧CD寬度的比
延伸後/延伸前：0.52
由此結果可知，所獲得的不織布在熱壓接合部表現出微細的折疊結構，與原料不織布相比較，CD方向的伸長5%及50%時的拉伸強度大幅下降，獲得了低應力伸長性。
在此熱壓接合部表現出微細的折疊結構的複合紡黏不織布上，使用混纖用紡絲噴嘴，將包含作為氫化苯乙烯系熱塑性彈性體的苯乙烯彈性體(旭化成化學公司製造的Tuftec H1031)的纖維，與包含作為乙烯-辛烯無規共聚物的聚乙烯彈性體(Dow Chemical公司製造的Engage 8402)的纖維混纖紡絲並形成為不織布而製成熔噴不織布，獲得複合紡黏不織布與混纖熔噴不織布的複合體。使用H1031的纖維平均直徑為10μm，使用Engage 8402的纖維平均直徑為11μm，混纖率以重量比來計算各為50%，此混纖熔噴不織布的基重為29gsm。製造混纖熔噴不織布時將紡絲溫度設為250℃，熱風溫度設為400℃並調整熱風壓力。
然後，在此複合紡黏不織布與混纖熔噴不織布的複合體的混纖熔噴不織布側，更積層前述在熱壓接合部表現出微細折疊結構的複合紡黏不織布，並在115℃下進行壓花處理，獲得包含複合紡黏不織布、混纖熔噴不織布及複合紡黏不織布的三層複合體。另外，壓花輥使用的是直徑0.65mm的突起在MD方向上以2.8mm，在CD方向上以2.84mm的間距交錯排列所成的面積率為8.3%的雕刻花紋。包含複合紡黏不織布、混纖熔噴不織布及複合紡黏不織布的三層複合體的基重為93gsm。此三層複合體的物性如下。
‧伸長80%時的CD拉伸强度
9.55N/5cm
‧伸長80%後的伸長回復率
72%
另關於伸長80%後的回復率，是使用自動繪圖裝置(拉伸試驗機)讀取在相對於試片的夾固長度100mm伸長80mm後恢復至100mm的夾固長度時，應力變成零的點並計算得出。
另外，伸長後的包含複合紡黏不織布、混纖熔噴不織布及複合紡黏不織布的三層複合體的表面形成以積層時的壓花點作為凹部的突出成凸狀的表面結構，設計性優良並顯示出像布一樣的觸感。
(參考例1)
除了線上壓為25N/mm的條件下進行熱壓接合加工以外，以和實例1相同的方式製作原料不織布並延伸而獲得寬度為274mm，基重為56g/m2的不織布。此不織布的物性如下所述。
‧熱壓接合部的微細的折疊結構的相鄰各山間的距離
108μm
‧伸長5%時的拉伸强度
MD：97.6N/5cm
CD：0.002N/5cm
MD/CD比：48800
‧伸長50%時的拉伸强度
MD：斷裂
CD：0.006N/5cm
‧CD寬度的比
延伸後/延伸前：0.25
(參考例2)
鞘側配置實例1使用的聚乙烯，芯側配置熔點162℃，密度0.961g/cm3，230℃下熔體質量流動速率為42dg/min的聚丙烯，在溫度240℃下紡絲，並於線壓60N/mm、溫度135℃條件下進行熱壓接合加工，除此以外，以和實例1相同的方式製作原料不織布並延伸而得寬度318mm，基重38g/m2的不織布。此不織布的物性如下。
‧熱壓接合部的微細的折疊結構的相鄰各山間的距離
243μm
‧伸長5%時的拉伸强度
MD：19.1N/5cm
CD：0.084N/5cm
MD/CD比：227
‧伸長50%時的拉伸强度
MD：斷裂
CD：4.33N/5cm
‧CD寬度的比
延伸後/延伸前：0.51
(參考例3)
除了熱壓接合部的總面積率為不織布的10%，CD佔有率為54%以外，以和實例1相同的方式製作原料不織布 並延伸而獲得寬度為421mm，基重為28g/m2的不織布。此不織布的物性如下所述。
‧熱壓接合部的微細的折疊結構的相鄰各山間的距離
122μm
‧伸長5%時的拉伸强度
MD：13.5N/5cm
CD：0.002N/5cm
MD/CD比：6750
‧伸長50%時的拉伸强度
MD：斷裂
CD：0.016N/5cm
‧CD寬度的比
延伸後/延伸前：0.57
(參考例4)
除了熱壓接合部的總面積率為不織布的47%，CD佔有率為100%以外，以和實例1相同的方式製作原料不織布，並延伸而得寬度205mm，基重32g/m2的不織布。此不織布的物性如下所述。
‧熱壓接合部的微細的折疊結構的相鄰各山間的距離
136μm
‧伸長5%時的拉伸强度
MD：69.1N/5cm
CD：0.003N/5cm
MD/CD比：23033
‧伸長50%時的拉伸强度
MD：斷裂
CD：0.133N/5cm
‧CD寬度的比
延伸後/延伸前：0.28
(比較例1)
將實例1所用的於熱壓接合部表現微細折疊結構的複合紡黏不織布的單層作為比較例1，評價其伸長80%時的CD拉伸強度及伸長80%後的伸長回復率。此比較例1的物性如下所述。
‧伸長80%時的CD拉伸强度
2.48N/5cm
‧伸長80%後的伸長回復率
51%
如上所述，如果僅使用經延伸的複合紡黏不織布，則雖可在低應力下高度伸長，但伸長後的回復性不夠好，而在此種經延伸的複合紡黏不織布上積層伸縮層，即可得到優良的伸長回復率，且伸長後的設計性及觸感良好。
[產業利用性]
本發明使用的複合紡黏不織布伸長性、柔軟性佳，因此與具伸縮性的伸縮性層積層即可適用於：一次性尿布用伸縮性構件、尿布用伸縮性構件、生理用品用伸縮性構件、尿布圍褲(diaper cover)用伸縮性構件等衛生材料的伸縮性構件，伸縮帶、絆創膏(adhesive plaster)、衣服用伸縮 性構件、衣料用襯布、衣料用絕緣材料或保溫材料、防護服、帽子、口罩、手套、護腿(supporter)、伸縮繃帶、敷布材料的底布、膏藥材料的底布、防滑底布、吸振材料、指墊，潔淨室用空氣濾清器、濾血器、油水分離過濾器等各種過濾器，經實施駐極體加工的駐極體過濾器(electret filter)、分離膜、隔熱材料、咖啡袋、食品包裝材料，汽車用頂棚外殼材料、隔聲材料、基材、緩衝材料、揚聲器防塵材料、空氣淨化器材料、絕緣體外殼、背襯材料、黏接不織布片材、門飾板(door trim)等各種汽車用構件，影印機的清潔材料等各種清潔材料，地毯的表面材料、背面材料，農業卷布、木材排水材料、運動鞋外皮等鞋用構件、手提包(handbag)用構件、工業用密封材料、擦拭材料、床單等物品。
10‧‧‧熱壓接合部(複合紡黏不織布本身的)
20‧‧‧CD軸
22‧‧‧CD全寬
60‧‧‧複合體
62‧‧‧複合紡黏不織布
64‧‧‧伸縮性層
66‧‧‧熱壓接合部(積層用的)
CD‧‧‧製造不織布時的寬度方向
MD‧‧‧製造不織布時的長度方向
W1、W2、W3、W4、W5、Wn‧‧‧寬度
圖1的(A)及(B)繪示本發明使用的紡黏不織布的熱壓接合部的微細折疊結構，其中(A)繪示沿MD延伸前的狀態，(B)繪示沿MD延伸後的狀態(放大圖)。
圖2的(A)及(B)繪示本發明使用的紡黏原料不織布的熱壓接合部圖案的示例(棋盤排列)及CD佔有率，其中(A)繪示排列圖案，(B)繪示1行的熱壓接合部的圖案。
圖3的(A)~(C)繪示本發明使用的紡黏原料不織布的熱壓接合部圖案的示例(將棋盤排列轉α°)及CD佔有率，其中(A)繪示排列圖案，(B)繪示1行的熱壓接合部的圖案，(C)繪示2行的熱壓接合部的圖案。
圖4的(A)及(B)繪示本發明使用的紡黏原料不織布的熱壓接合部圖案的示例(交錯排列)及CD佔有率，其中(A)繪示排列圖案，(B)繪示2行的熱壓接合部的圖案。
圖5的(A)及(B)繪示本發明使用的紡黏原料不織布的熱壓接合部圖案的示例(不規則形狀)及CD佔有率，其中(A)繪示排列圖案，(B)繪示熱壓接合部的圖案。
圖6繪示本發明一實施例之複合體，其是將複合紡黏不織布與伸縮性層積層為一體而得。
CD‧‧‧製造不織布時的寬度方向
MD‧‧‧製造不織布時的長度方向

Claims (8)

  1. 一種複合體，包括積層為一體的一複合紡黏不織布與一伸縮性層，其中該複合紡黏不織布包括包含低熔點成分與高熔點成分的複合纖維，該複合纖維為鞘側配置低熔點成分、芯側配置高熔點成分的芯鞘型態，或為高熔點成分的一部分以50%以下的表面積露出纖維表面的複合型態，其中該高熔點成分的熔點高於該低熔點成分的熔點，該複合紡黏不織布具有多個熱壓接合部，該些熱壓接合部是藉由第一局部熱壓接合步驟形成，且連續散佈在該複合紡黏不織布的長度方向(MD)上，其中各熱壓接合部沿著製造該複合紡黏不織布時的寬度方向(CD)具有由山部與谷部重複所成的微細折疊結構，該些微細折疊結構的相鄰山部間的平均距離在100~400μm範圍內，該複合紡黏不織布藉伸展該些微細折疊結構而表現出伸長性，且該複合紡黏不織布與該伸縮性層是藉由第二局部熱壓接合步驟而積層為一體，其中多個壓合部所佔面積的比例為4~12%，且所述多個壓合部的圖案與該複合紡黏不織布的所述多個熱壓接合部的圖案不完全一致。
  2. 如申請專利範圍第1項所述之複合體，其中該複合紡黏不織布在伸長5%時的CD方向拉伸強度在0.1N/5cm寬以下，伸長5%時的MD/CD拉伸強度比(MD方向拉伸強 度/CD方向拉伸強度)在200以上。
  3. 如申請專利範圍第1項所述之複合體，其中該複合紡黏不織布在伸長50%時的CD方向拉伸強度在5N/5cm寬以下。
  4. 如申請專利範圍第1~3項中任一項所述之複合體，其中該伸縮性層包括：包含彈性體樹脂的一長纖維層。
  5. 如申請專利範圍第4項所述之複合體，其中該長纖維層是一熔噴纖維層。
  6. 如申請專利範圍第1~3項中任一項之複合體，其中該伸縮性層在伸長80%時的伸長回復率在60%以上。
  7. 如申請專利範圍第1~3項中任一項所述之複合體，其中在該複合紡黏不織布中，該低熔點成分包括聚乙烯，且該高熔點成分包括聚酯。
  8. 如申請專利範圍第1~3項中任一項所述之複合體，其中相鄰之壓合部的在CD上的投影之間的距離在0.6mm以上。
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