WO2004022831A1 - Nonwoven fabric - Google Patents

Nonwoven fabric Download PDF

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Publication number
WO2004022831A1
WO2004022831A1 PCT/JP2003/009178 JP0309178W WO2004022831A1 WO 2004022831 A1 WO2004022831 A1 WO 2004022831A1 JP 0309178 W JP0309178 W JP 0309178W WO 2004022831 A1 WO2004022831 A1 WO 2004022831A1
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WO
WIPO (PCT)
Prior art keywords
nonwoven fabric
layer
fiber
splittable conjugate
fibers
Prior art date
Application number
PCT/JP2003/009178
Other languages
French (fr)
Japanese (ja)
Inventor
Manabu Kaneda
Takanobu Miyamoto
Original Assignee
Kao Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kao Corporation filed Critical Kao Corporation
Priority to AU2003252662A priority Critical patent/AU2003252662A1/en
Publication of WO2004022831A1 publication Critical patent/WO2004022831A1/en

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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
    • D04H13/00—Other non-woven fabrics
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/51121—Topsheet, i.e. the permeable cover or layer facing the skin characterised by the material
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/5116—Topsheet, i.e. the permeable cover or layer facing the skin being formed of multiple layers
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/512—Topsheet, i.e. the permeable cover or layer facing the skin characterised by its apertures, e.g. perforations
    • A61F13/5123—Topsheet, i.e. the permeable cover or layer facing the skin characterised by its apertures, e.g. perforations the apertures being formed on a multilayer top sheet
    • 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

Definitions

  • the present invention relates to a bulky and flexible nonwoven fabric having excellent liquid permeability and a method for producing the same. Further, the present invention relates to an absorbent article using the nonwoven fabric. Background art
  • Nonwoven fabrics which are formed entirely or partially from splittable composite fibers and have fine fibers are known. Since this nonwoven fabric has an excellent tactile sensation and an excellent dust collecting power, it is used as a wiper for wiping glasses and various cleanings. Due to the structure of the composite fiber, the nonwoven fabric needs to separate and separate the composite fiber by a spunlace method. However, the nonwoven fabric manufactured by the spunless method has a problem that the manufacturing process is complicated and productivity is poor. Another problem is that the cost is high.
  • the present applicant has previously proposed a nonwoven fabric in which a part of the split fibers is separated and separated by heat treatment or pressurization by a roll in order to provide a soft and nonwoven fabric having a good feel (Japanese Unexamined Patent Publication No. Hei 9-2). No. 73061).
  • Japanese Unexamined Patent Publication No. Hei 9-2 Japanese Unexamined Patent Publication No. Hei 9-2). No. 73061).
  • fluffing may easily occur when repeated wear occurs, and strength may decrease when the amount of split fibers increases. Therefore, it is necessary to strengthen the bonding such as heat embossing.
  • the separation is generated using an embossing roll or a force render roll, the nonwoven fabric is pressed, and thus the nonwoven fabric is disadvantageously thinned.
  • the thickness can be maintained, but if heat is applied excessively, the entire nonwoven fabric becomes fine.
  • the fibers are separated and separated, making it easy for fluff and fluff to occur.
  • the number of fibers divided into the entire nonwoven fabric increases, and as a result, the surface area of the fibers increases, which results in an increase in the number of hydrophobic surfaces.
  • the increase in the number of hydrophobic surfaces becomes a hindrance to stably exhibiting liquid permeability when the nonwoven fabric is used as a surface sheet of an absorbent article. As described above, it was difficult to increase the liquid permeability by preventing the split fibers from fluffing and fluff while separating. Disclosure of the invention
  • an object of the present invention is to provide a strong nonwoven fabric which is excellent in liquid permeability and in which fluffing caused by friction is prevented.
  • Another object of the present invention is to provide a nonwoven fabric which is bulky, flexible and has a good texture.
  • the present invention has a multilayer structure having at least a first layer constituting one outer layer and a second layer constituting the other outer layer, wherein the splittable conjugate fiber is 5 to 40% by weight and heat-fusible.
  • the first layer contains not more than 20% by weight of the splittable conjugate fiber, and the second layer contains a larger amount of the splittable conjugate fiber,
  • the present invention also provides a preferable method for producing the nonwoven fabric, wherein a nonwoven fabric material having a multilayer structure having at least the first layer and the second layer includes a perforated pipe.
  • the present invention relates to an absorbent article having a liquid-permeable top sheet, a liquid-impermeable back sheet, and a liquid-retentive absorber interposed between the sheets, 4.
  • FIG. 1 is an enlarged perspective view showing a main part of a longitudinal section in one embodiment of the nonwoven fabric of the present invention.
  • FIG. 1 is an enlarged perspective view showing a main part of a longitudinal section in one embodiment of the nonwoven fabric of the present invention.
  • the nonwoven fabric 10 of the present embodiment has a two-layer structure including a first layer 1 constituting one outer layer and a second layer 2 constituting the other outer layer.
  • a large number of openings 3 are regularly formed on the entire surface.
  • the nonwoven fabric 10 contains splittable conjugate fibers and heat-fusible fibers.
  • the splittable conjugate fiber used in the present embodiment is composed of two or more different resins different from each other, and each resin is arranged continuously in the longitudinal direction of the fiber and alternately arranged in the circumferential direction of the fiber.
  • the fibers are separated and can be separated from each other by thermal action or mechanical action.
  • the opening 3 is formed by being surrounded by a nonwoven fabric extending from the first layer 1 toward the second layer 2.
  • the inner wall 4 of the opening 3 is formed by a continuous surface from the first layer 1. That is, the opening 3 is a three-dimensional opening.
  • the opening 3 has a circular shape in a plan view, and its diameter gradually decreases from the first layer 1 toward the second layer, thus forming a funnel shape.
  • the space 3 between the adjacent openings is convexly curved so as to have the top 5.
  • the plurality of tops 5 are connected substantially continuously to form a ridge.
  • the ridges 6 are formed in multiple rows, and a groove 7 is formed between the adjacent ridges 6,6.
  • the ridge portions 6 and the groove portions 7 are alternately arranged so as not to have a flat portion.
  • the ridges 6 are convexly curved and the grooves 7 are concavely curved, and the openings 3 are formed in the grooves 7.
  • the splittable conjugate fibers present at the periphery of the opening 3 are separated and separated between the constituent resins, and the degree of the separation is different from that of the other portions of the nonwoven fabric 10.
  • the nonwoven fabric 10 is given bulkiness and flexibility, and the texture of the nonwoven fabric 10 is improved. Also from this point, the nonwoven fabric 10 of the present embodiment is suitable as a surface sheet of an absorbent article, which is a member that directly contacts the skin.
  • a large "degree of separation between constituent resins in the splittable conjugate fiber” means that the apparent number of fibers is large and / or the distance between fibers is small.
  • Split The degree of separation between constituent resins in the conjugated fiber is, for example, the number of splittable conjugate fibers that are separated and separated, the length of the portion of the splittable conjugate fiber where the constituent resin is separated and separated, and the splitting.
  • the splittable conjugate fibers present in the peripheral portion of the opening 3 are separated and separated between the constituent resins, and the degree of the separation is larger than that of the splittable conjugate fibers present in other portions of the nonwoven fabric 10. It can be confirmed from the electron microscopic observation of the nonwoven fabric 10 whether or not it has been established.
  • the degree of separation between the constituent resins in the splittable conjugate fibers present at the peripheral portion of the opening 3 larger than that of the splittable conjugate fibers present in other portions of the nonwoven fabric 10.
  • a large number of openings 3 are formed using perforated pins, and a shear force is applied to the splittable conjugate fibers present at the periphery of the openings 3 to selectively form the splittable conjugate fibers.
  • the constituent resins may be divided and separated.
  • the first layer 1 of the nonwoven fabric 10 contains the splittable conjugate fiber in an amount of 20% by weight or less, preferably 10% by weight or less.
  • the second layer contains a larger amount of splittable composite fibers.
  • the amount of the splittable conjugate fiber in the first layer 1 may be zero. That is, the first layer 1 does not need to include the splittable conjugate fiber. If the first layer 1 contains more than 20% by weight of the splittable conjugate fiber, the nonwoven fabric 10 is used, for example, as a surface sheet of an absorbent article, and the first layer 1 is placed on the skin contact side. When arranged, fluffing due to friction with the wearer's skin is likely to occur. In addition, the area of the hydrophobic surface increases due to the separation and separation of the splittable conjugate fibers, and the liquid pull-in force decreases.
  • the amount of the splittable conjugate fiber in the second layer 2 is 10 to 80% by weight, particularly 20 to 60% by weight, which is sufficient for the effective expression of the capillary force gradient and the nonwoven fabric 10 described above. Bulkiness and flexibility Is preferred from the viewpoint of imparting When viewed as a nonwoven fabric 10 as a whole, the splittable conjugate fiber is contained in an amount of 5 to 40% by weight, preferably 10 to 30% by weight. When the amount of the splittable conjugate fiber is less than 5% by weight, the amount of the fiber separated and separated in the opening 3 is small, the liquid is not sufficiently drawn, and the flexibility is also insufficient.
  • the non-woven fabric 10 contains 60 to 95% by weight, preferably 70 to 90% by weight of the heat-fusible fiber. If the amount of the heat-fusible fiber is less than 60% by weight, the strength of the nonwoven fabric is insufficient and the nonwoven fabric is easily broken, and the suppression of fuzzing becomes insufficient. If the content is more than 95% by weight, fluffing is suppressed and the strength is high, but the liquid draw-in property at the opening 3 and the flexibility become insufficient. Regarding the content of the heat-fusible fibers in the first layer 1 and the second layer 2, the amount of the heat-fusible fibers in the first layer 1 is
  • the amount of the heat-fusible fiber in the second layer 2 is preferably from 20 to 90% by weight, particularly from 40 to 80% by weight, from the viewpoint of suppressing fluffing and fluffing out and developing flexibility of the nonwoven fabric. preferable.
  • the splittable conjugate fiber a fiber that can be divided into four to thirty-two parts is used, with a low-melting resin and a high-melting resin having a higher melting point than the low-melting resin as constituent resins. In particular, fibers that can be split into six to sixteen pieces are preferable in terms of cost, productivity, and splitting property.
  • the low melting point resin those having a melting point of about 100 to 150 are preferably used. Examples thereof include those described in paragraph [0113] of Japanese Patent Application Laid-Open No. 9 / 273,061.
  • the high melting point resin a resin having a melting point of about 160 to 260 ° C. is preferably used. Examples thereof include those described in paragraph [0114] of Japanese Patent Application Laid-open No. Hei 9-273601.
  • the melting point of the high melting point resin is preferably about 100 to 150 higher than the melting point of the low melting point resin.
  • the low melting point resin / the high melting point resin is a low melting point polypropylene (PP) polyethylene terephthalate (PET), polyethylene (PE) polyethylene terephthalate (PET) , Polyethylene (PE) / "polypropylene (PP), etc.
  • the splittable conjugate fiber has a fineness of 1 to 15 dte X, especially 3 to 8 dtex, and an excessively large capillary force. When the low melting point resin in the splittable conjugate fiber has heat shrinkage, the fibers can be separated and separated only by the thermal action.
  • the splittable conjugate fiber preferably has hydrophilicity by kneading a hydrophilic agent into at least one of the constituent resins, and becomes hydrophilic by kneading the hydrophilic agent.
  • the hydrophilicity is not easily reduced even when the liquid repeatedly permeates.
  • the hydrophilic agent kneaded into the constituent resin may be a compound having a hydrophilic group such as a hydroxyl group, a carboxy group, a carboxyl group, a sulfone group, etc.
  • a hydrophilic group such as a hydroxyl group, a carboxy group, a carboxyl group, a sulfone group, etc.
  • fatty acid glyceride, alkyloxyalkylphenol, polyalkylene fatty acid Examples include nonionic surfactants such as esters and fatty acid diethanolamide, etc.
  • examples of the hydrophilic agent applied to the surface of the splittable conjugate fiber include sulfuric acid and the like.
  • Ether base alkyl Berlin ester base C 8 ⁇ C 3
  • a fiber composed of a resin having a melting point similar to or lower than the melting point of the low-melting resin of the splittable conjugate fiber is used.
  • 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 be used.
  • a resin having a melting point similar to or lower than the melting point of the low-melting resin of the splittable conjugate fiber is used as the low-melting resin.
  • the surface thereof is provided with a hydrophilizing agent, similarly to the splittable conjugate fiber, from the viewpoint of imparting sufficient liquid permeability to the nonwoven fabric 10.
  • the heat-fused fiber has a fineness of 1.5 dtex to 5 dtex, especially 2.2 dtex to 4.4 dtex, which imparts liquid permeability to the nonwoven fabric and suppresses liquid residue. This is preferable from the viewpoint of maintaining the texture of, and the balance with the fineness of the splittable conjugate fiber.
  • the first layer 1 and / or the second layer 2 include natural fibers such as cotton and wool, and acrylic fibers in addition to the above-mentioned splittable composite fibers and heat-fusible fibers.
  • natural fibers such as cotton and wool
  • acrylic fibers in addition to the above-mentioned splittable composite fibers and heat-fusible fibers.
  • Polyolefin fiber Polyvinyl chloride Fiber, polyvinyl alcohol fiber, rayon, cuvula, acetate
  • the nonwoven fabric 10 of the present embodiment has a shape of the nonwoven fabric by fusion of the intersections of the heat-fusible fibers contained therein and the intersections of the heat-fusible fibers and the splittable conjugate fibers by applying heat. I keep it.
  • the means for applying heat include a method of blowing hot air as described below, a method of passing between heat rolls, and a method of radiating heat such as far infrared rays.
  • the nonwoven fabric 10 has a large number of openings 3 formed therein.
  • the diameter of the opening 3 at the opening end is 0.5 to 3 mm, particularly 0.7 to 2 mm, so that sufficient capillary force is exhibited, and the nonwoven fabric 10 is used as a surface sheet of the absorbent article. It is preferable from the viewpoint of preventing the liquid from returning when used.
  • the porosity that is, the ratio of the total area of the openings 3 to the total area of the nonwoven fabric 10 is preferably 2 to 30%, particularly preferably 5 to 18%.
  • the diameter and the opening ratio of the opening 3 are determined in accordance with the description in paragraphs [062] and [064] of Japanese Patent Application Laid-Open No. H8-246631, filed by the present applicant. Measured.
  • the distance between the openings 3 along the groove 7 is preferably 0.4 to 40 mm, particularly preferably 1.5 to 8 mm.
  • the distance between the adjacent grooves 7 is 1 to 6 mm, especially 1.7 to 3.7 mm, from the viewpoint of tightly forming the opening 3 and ensuring sufficient liquid permeability. preferable. It is preferable that the distance between adjacent ridges 6 is also the same.
  • Nonwoven fabric 10 has a basis weight of 10 to 50 g / m, especially 18 to 35 g / m m 2 is preferable from the viewpoints of securing an amount of fibers necessary for forming a void for drawing in the liquid, productivity, and cost.
  • the basis weight of the first layer is 5 to 30 g Zm 2 , particularly 8 to 20 g / m 2
  • the basis weight of the second layer 2 is 5 to 3 g / m 2.
  • 0 gZm 2 especially 8 to 2 O gZm 2 , is preferable from the viewpoints of liquid permeability and pull-in property, balance between suppression of fluff removal and feel, and cost.
  • the nonwoven fabric 10 preferably has a thickness of 0.4 to 3 mm, particularly 0.6 to 2 mm under a load of 0.5 g / cm 2, from the viewpoint of exhibiting a sufficient bulkiness.
  • the thickness under a load of 0.5 g / cm 2 is almost equivalent to the thickness when the nonwoven fabric 10 starts to touch lightly.
  • the thickness of the nonwoven fabric 10 under a load of 0.5 gZcm 2 is measured in accordance with the description in paragraph [063] of JP-A-8-246321.
  • a preferred method for producing the nonwoven fabric 10 of the present embodiment will be described. First, a fiber web constituting the first layer 1 and the second layer 2 is manufactured.
  • the fiber web can be formed by, for example, a card method using a card machine, a method in which a molten fiber spun from a spinning nozzle is drawn by an ejector and deposited on a compare belt, or an air laid method.
  • a card method using a card machine a method in which a molten fiber spun from a spinning nozzle is drawn by an ejector and deposited on a compare belt, or an air laid method.
  • the intersections of the constituent fibers are joined by a predetermined means to obtain an original nonwoven fabric.
  • fusion of hot melt fibers by application of heat, adhesion by a binder, etc. are used.
  • the obtained nonwoven fabric is subjected to a hole opening treatment.
  • the opening process heated or unheated drilling pins are used.
  • a shearing force can be selectively applied to the splittable conjugate fiber existing at the periphery of the opening at the same time as the formation of the opening.
  • the splittable conjugate fiber existing at the peripheral portion of the opening is divided and separated, and the splittable conjugate fiber having other portions is formed. It can be prevented from being separated and separated. That is, it becomes possible to selectively separate and separate the splittable conjugate fibers existing in the peripheral portion of the opening.
  • the method of forming an aperture using a perforated pin can be according to the method described in paragraphs [056] to [059] of JP-A-8-24631.
  • the nonwoven fabric 10 thus obtained may be, 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 and the surface sheet in the absorbent article, or It is suitably used as a wiper or the like that partially retains liquid in a sheet.
  • a nonwoven fabric 10 is used as the topsheet;
  • the side of the first layer 1 at 0 as the skin-facing side, it has good liquid permeability, little liquid residue, no sticky feeling that clings to the wearer's skin, and excellent dryness It becomes an article.
  • fibers that are partially peeled off and split are included, they are bulky and flexible.
  • there is little fluffing irritation to the wearer's skin is reduced, and an absorbent article with a good wearing feeling is obtained.
  • the present invention is not limited to the above embodiment.
  • the nonwoven fabric 10 of the above-described embodiment has a two-layer structure composed of the first layer 1 and the second layer 2, but instead of this, 1 or 1 is provided between the first layer and the second layer. It may have a multilayer structure of three or more layers having two or more layers.
  • the holes 3 formed in the nonwoven fabric 10 in the above embodiment have the same diameter, the holes 3 may have two or more different diameters instead.
  • an opening having a relatively large diameter is formed in a region of the nonwoven fabric 10 corresponding to a region along the longitudinal center line of the absorbent article, And the absorption
  • An opening having a relatively small diameter may be formed in a region of the nonwoven fabric 10 corresponding to both right and left sides of the non-woven article. This improves the liquid draw-in and liquid permeability at the central part, which is the drainage point, while the sides are relatively small in diameter, so the fibers do not split much, preventing fluffing and falling out This has the effect of being eliminated.
  • a first layer and a second layer fiber web were formed by a force method. Details of the fibers in Table 1 are as shown in Table 2. After the respective fibrous webs were superimposed on each other, a hot air heated to 140 T was blown to fuse the intersections of the constituent fibers to obtain a nonwoven fabric having a two-layer structure. Then, using a 1.5 mm diameter piercing pin heated to 125, a large number of holes were formed in the raw nonwoven fabric, and ridges and grooves were formed. Got. The diameter of the opening at the opening end of the obtained nonwoven fabric was about 1 mm, and the opening ratio was 10%.
  • the distance between the openings along the groove was 2.6 mm, and the distance between the groove and the ridge was 2.3 mm. Further, the thickness under a load of 0.5 gcm 2 was 0.6 to 0.5 mm.
  • the remaining amount of the dynamic liquid, the amount of fluff, and the CD strength were measured by the following methods. Table 1 shows the results. (Determination of dynamic liquid remaining amount)
  • urethane foam urethane foam maltoprene MF 30 manufactured by Priston Co., Ltd., thickness 5 mm
  • the mounting position shall be 20 mm from the center of the disk.
  • the same urethane foam as described above is laid on the lower surface of the nonwoven fabric in which the openings shown in FIG. 1 are formed downward.
  • the nonwoven fabric is fixed on a table with the upper surface side facing.
  • the disc is placed on the nonwoven fabric. At this time, the load applied to the nonwoven fabric is only the weight of the disc itself. Under this condition, the rotating shaft is rotated to make the disc circulate on the nonwoven fabric.
  • the rotation is performed 10 sets, with 2 rotations clockwise and 2 rotations counterclockwise as one set.
  • the orbiting speed at this time is about 3 seconds per orbit.
  • After the rotation of the 10 set, collect the fluffed fibers attached to the surface of the urethane foam covering the disk. This operation is performed for n 20 nonwoven fabrics.
  • the CD strength of the nonwoven fabric is measured using a tensile tester Tensilon manufactured by Orientec Co., Ltd .; TA-100. CD is applied to the obtained nonwoven fabric. Direction perpendicular to the flow direction.
  • the test piece shall be 200 mm in CD length and 50 mm in MD length.
  • the distance between the chucks is 150 mm and the pulling speed is 300 mm / min. Measure five test pieces and determine the average value as the CD strength.
  • Example 1 SCT Comparative Example 1 Core-sheath composite fiber 90 ⁇
  • Core-sheath composite fiber 703 ⁇ 4 Core-sheath composite fiber 703 ⁇ 4 Core-sheath composite fiber 703 ⁇ 4;
  • hydrophilic agent C8-C12 straight-chain alkyl phosphate or salt
  • Hydrophilic agent (C8-C12 straight-chain alkylphospho-to-potassium salt) is applied to the surface.
  • Heat shrinkable PP Knead a hydrophilizing agent e. W reserin fatty acid I stell
  • Hydrophilic agent (PO / EO-modified silicon, mixture of stearic acid, 'hetanol-lamite', and POE ', a mixture mainly composed of henic acid amide) is applied to the surface.
  • a hydrophilic agent (polyglycerin fatty acid J: ster) is kneaded into the PE component, and the split-type composite fiber is applied to the surface.
  • Watering agent (PO / EO-modified silicone, stearic acid mixture to ethalamide, and POE to henic acid amide) is applied.
  • the nonwoven fabric of the example (product of the present invention) has a smaller amount of liquid remaining, has higher strength and is less likely to fluff than the nonwoven fabric of the comparative example.
  • the nonwoven fabric of the example was bulky and flexible, and had a good texture.
  • the splittable conjugate fibers present at the periphery of the opening were separated and separated between the constituent resins. In addition, it was confirmed that the degree of the separation was larger than that of the split conjugate fiber present in the other part of the nonwoven fabric.
  • the nonwoven fabric which is excellent in liquid permeability, does not easily generate fluffing due to friction, and has sufficient strength can be obtained.
  • a nonwoven fabric which is bulky, flexible and has a good texture can be obtained.

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  • Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Biomedical Technology (AREA)
  • Heart & Thoracic Surgery (AREA)
  • Vascular Medicine (AREA)
  • Epidemiology (AREA)
  • Animal Behavior & Ethology (AREA)
  • General Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Veterinary Medicine (AREA)
  • Textile Engineering (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Nonwoven Fabrics (AREA)
  • Orthopedics, Nursing, And Contraception (AREA)

Abstract

Nonwoven fabric (10) having a multilayer structure including first layer (1) constituting one outer layer and second layer (2) constituting the other outer layer, which nonwoven fabric (10) is comprised of split type conjugate fibers and hot melt fibers. Split type conjugate fibers are contained in an amount of 20 wt.% or less in the first layer (1) and contained in greater amount in the second layer (2). The nonwoven fabric (10) is provided with a multiplicity of openings (3). The split type conjugate fibers lying at the periphery of openings (3) have constituent resins thereof split and spaced, and the extent of splitting and spacing thereof is greater than that of split type conjugate fibers at other parts of the nonwoven fabric (10)

Description

明 細 書 不 織 布 技術分野  Description Non-woven fabric Technical field
本発明は、 液の透過性に優れると共に嵩高で柔軟な不織布及びその 製造方法に関する。 また本発明は、 該不織布を用いた吸収性物品に関 する。 背景技術  TECHNICAL FIELD The present invention relates to a bulky and flexible nonwoven fabric having excellent liquid permeability and a method for producing the same. Further, the present invention relates to an absorbent article using the nonwoven fabric. Background art
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。 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 （特開平 9 - 2 7 3 0 6 1号公報参照） 。 しかし、 この不織布は、 分割繊維の分割離間が不織布全体に生ずるの で、 繰り返しの摩耗が起こると毛羽立ちが起こり易くなる場合がある, また、 分割繊維の量が増えると強度低下を起こすことがあるので、 熱 エンボス等の結合を強化する必要がある。 更に、 エンボスロールや力 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、 不織布が薄くなつてしまうという不都合がある。 ロール による加圧に代えてエアースルーなどの熱処理法を用いた場合には、 厚みは維持できるものの、 熱を過大に加えると不織布の全体に亘り繊 維が分割離間してしまい、 毛羽立ちや毛羽抜けが起こりやすくなる。 また不織布全体に分割した繊維の数が増え、 その結果繊維の表面積が 増えるので、 これに起因して疎水面が多くなつてしまう。 疎水面が多 くなることは、 前記不織布を吸収性物品の表面シ一トとして用いる場 合に、 通液性が安定して発現することの阻害要因となってしまう。 こ のように、 分割繊維を離間させつつ毛羽立ちや毛羽抜け防止して、 液 の通液性を高めることは難しかった。 発明の開示 2. Description of the Related Art Nonwoven fabrics which are formed entirely or partially from splittable composite fibers and have fine fibers are known. Since this nonwoven fabric has an excellent tactile sensation and an excellent dust collecting power, it is used as a wiper for wiping glasses and various cleanings. Due to the structure of the composite fiber, the nonwoven fabric needs to separate and separate the composite fiber by a spunlace method. However, the nonwoven fabric manufactured by the spunless method has a problem that the manufacturing process is complicated and productivity is poor. Another problem is that the cost is high. The present applicant has previously proposed a nonwoven fabric in which a part of the split fibers is separated and separated by heat treatment or pressurization by a roll in order to provide a soft and nonwoven fabric having a good feel (Japanese Unexamined Patent Publication No. Hei 9-2). No. 73061). However, in this nonwoven fabric, since the separation of the split fibers occurs in the entire nonwoven fabric, fluffing may easily occur when repeated wear occurs, and strength may decrease when the amount of split fibers increases. Therefore, it is necessary to strengthen the bonding such as heat embossing. Furthermore, if the separation is generated using an embossing roll or a force render roll, the nonwoven fabric is pressed, and thus the nonwoven fabric is disadvantageously thinned. When a heat treatment method such as air through is used instead of pressurization by a roll, the thickness can be maintained, but if heat is applied excessively, the entire nonwoven fabric becomes fine. The fibers are separated and separated, making it easy for fluff and fluff to occur. Also, the number of fibers divided into the entire nonwoven fabric increases, and as a result, the surface area of the fibers increases, which results in an increase in the number of hydrophobic surfaces. The increase in the number of hydrophobic surfaces becomes a hindrance to stably exhibiting liquid permeability when the nonwoven fabric is used as a surface sheet of an absorbent article. As described above, it was difficult to increase the liquid permeability by preventing the split fibers from fluffing and fluff while separating. Disclosure of the invention
従って、 本発明は、 通液性に優れ、 また摩擦に起因する毛羽立ちが 防止された強度の強い不織布を提供することを目的とする。  Accordingly, an object of the present invention is to provide a strong nonwoven fabric which is excellent in liquid permeability and in which fluffing caused by friction is prevented.
また本発明は、 嵩高く柔軟で風合いが良好な不織布を提供すること を目的とする。 本発明は、 少なく とも、 一方の外層を構成する第 1層と他方の外層 を構成する第 2層とを有する多層構造からなり、 分割型複合繊維を 5 〜 4 0重量％及び熱融着性繊維を 6 0〜 9 5重量％含有する不織布で あって、  Another object of the present invention is to provide a nonwoven fabric which is bulky, flexible and has a good texture. The present invention has a multilayer structure having at least a first layer constituting one outer layer and a second layer constituting the other outer layer, wherein the splittable conjugate fiber is 5 to 40% by weight and heat-fusible. A non-woven fabric containing 60 to 95% by weight of fibers,
前記第 1層には前記分割型複合繊維が 2 0重量％以下含まれている と共に前記第 2層にはそれよりも多量の前記分割型複合繊維が含まれ ており、  The first layer contains not more than 20% by weight of the splittable conjugate fiber, and the second layer contains a larger amount of the splittable conjugate fiber,
前記不織布には多数の開孔が形成されており、 該開孔の周縁部に存 する前記分割型複合繊維が構成樹脂間で分割離間しており、 且つその 分割離間の程度が、 該不織布における他の部分に存する該分割型複合 繊維のそれよりも大きい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。 また本発明は、 前記不織布の好ましい製造方法として、 少なくとも 前記第 1層及び前記第 2層を有する多層構造の不織布原反に、 穿孔ピ ンを用いて多数の前記開孔を形成すると共に、 該開孔の周縁部に存す る前記分割型複合繊維に剪断力を加えて選択的に該分割型複合繊維を その構成樹脂間で分割離間させる不織布の製造方法を提供するもので ある。 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、 前記表面シ一トとして請求項 1記載の不織布を用い且つ該不織 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。 図面の簡単な説明 A large number of openings are formed in the nonwoven fabric, and the splittable conjugate fibers present at the peripheral portion of the openings are separated and separated between the constituent resins, and the degree of the separation is determined in the nonwoven fabric. The above object has been achieved by providing a nonwoven fabric which is larger than that of the splittable conjugate fiber present in other portions. The present invention also provides a preferable method for producing the nonwoven fabric, wherein a nonwoven fabric material having a multilayer structure having at least the first layer and the second layer includes a perforated pipe. And forming a plurality of the openings by using a shearing force, and applying a shearing force to the splittable conjugate fibers present at the periphery of the openings to selectively split the splittable conjugate fibers among the constituent resins. It is intended to provide a method for producing a nonwoven fabric to be separated. Further, the present invention relates to an absorbent article having a liquid-permeable top sheet, a liquid-impermeable back sheet, and a liquid-retentive absorber interposed between the sheets, 4. An absorbent article using the nonwoven fabric according to item 1, wherein the side of the first layer in the nonwoven fabric is arranged as a skin-facing side. BRIEF DESCRIPTION OF THE FIGURES
図 1は、 本発明の不織布の一実施形態における縦断面の要部を拡大 して示す斜視図である。 発明を実施するための最良の形態  FIG. 1 is an enlarged perspective view showing a main part of a longitudinal section in one embodiment of the nonwoven fabric of the present invention. BEST MODE FOR CARRYING OUT THE INVENTION
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 には、 本発明の不織布の一実施形態における縦断面の 要部を拡大して示す斜視図が示されている。 図 1に示すように、 本実施形態の不織布 1 0は、 一方の外層を構成 する第 1層 1 と他方の外層を構成する第 2層 2 とを有する二層構造と なっている。 不織布 1 0には、 その全面に多数の開孔 3が規則的に形 成されている。 不織布 1 0は、 分割型複合繊維及び熱融着性繊維を含 有している。 本実施形態で用いられる分割型複合繊維は、 互いに異な る 2種類以上の樹脂から構成されており、 各樹脂が繊維の長手方向に 連続的に配されており且つ繊維の周方向に交互に配されている繊維で あって、 熱的作用又は機械的作用によって各樹脂間が分割離間可能に なっている。 図 1に示すように、 開孔 3は、 第 1層 1から第 2層 2に向かって延 出する不織布によって取り囲まれて形成されている。 そして、 開孔 3 の内壁 4は、 第 1層 1からの連続面で形成されている。 即ち開孔 3は 立体的な開孔である。 開孔 3は、 平面視して円形をしており、 その径 が第 1層 1から第 2層に向かって漸次減少しており漏斗状の形状とな つている。 隣り合う開孔間 3は、 頂部 5を有するように凸状に湾曲し ている。 複数の頂部 5は略連続的に連なっており畝部を形成している, 畝部 6は多列に形成されており、 隣り合う畝部 6， 6の間は溝部 7と なっている。 畝部 6と溝部 7とは平面部を有しないように交互に配列 されている。 畝部 6は凸状に湾曲し且つ溝部 7は凹状に湾曲している, 開孔 3は溝部 7に形成されている。 本実施形態の不織布 1 0においては、 開孔 3の周縁部に存する分割 型複合繊維が構成樹脂間で分割離間しており、 且つその分割離間の程 度が、 該不織布 1 0における他の部分に存する該分割型複合繊維のそ れよりも大きくなつている。 これによつて、 開孔 3の周縁部における 繊維の見掛け本数が、 その外側の領域におけるそれよりも多くなる。 その結果、 開孔 3の周縁部における繊維間距離が、 その外側の領域に おけるそれよりも小さくなり、 毛管力に勾配が生じる。 これによつて. 開孔 3の周縁部の外側の領域から該周縁部に向けて毛管力が大きくな り、 開孔 3の開孔端に向けて液の引き込み力が生じる。 従って、 本実 施形態の不織布 1 0を、 例えば後述するように吸収性物品の表面シー トとして用いると、 該表面シートに液残りが生じにく くなる。 更に、 分割型複合繊維が分割離間していることで、 不織布 1 0に嵩高さと柔 軟性が付与され、 不織布 1 0の風合いが良好になる。 この点からも、 本実施形態の不織布 1 0は、 肌に直接接触する部材である、 吸収性物 品の表面シートとして好適なものとなる。 尚、 「分割型複合繊維にお ける構成樹脂間での分割離間の程度」 が大きいとは、 繊維の見掛け本 数が多いこと及び/又は繊維間距離が小さいことを意味する。 「分割 型複合繊維における構成樹脂間での分割離間の程度」 は、 例えば分割 離間している分割型複合繊維の本数、 分割型複合繊維において構成樹 脂が分割離間している部分の長さ、 及び分割型複合繊維において分割 離間している構成樹脂間の距離などによって変化する。 開孔 3の周縁部に存する分割型複合繊維が構成樹脂間で分割離間し ており、 且つその分割離間の程度が、 不織布 1 0における他の部分に 存する該分割型複合繊維のそれよりも大きくなつているか否かは、 不 織布 1 0の電子顕微鏡観察から確認できる。 開孔 3の周縁部に存する分割型複合繊維における構成樹脂間での分 割離間の程度を、 該不織布 1 0における他の部分に存する該分割型複 合繊維のそれよりも大きくするには、 例えば後述するように、 穿孔ピ ンを用いて多数の開孔 3を形成すると共に、 開孔 3の周縁部に存する 該分割型複合繊維に剪断力を加えて選択的に該分割型複合繊維をその 構成樹脂間で分割離間させれば良い。 不織布 1 0における第 1層 1 には、 分割型複合繊維が 2 0重量％以 下、 好ましくは 1 0重量％以下含まれている。 これと共に第 2層には それよりも多量の分割型複合繊維が含まれている。 第 1層 1における 分割型複合繊維の量は 0でも良い。 つまり、 第 1層 1 には分割型複合 繊維が含まれていなくてもよい。 第 1層 1に分割型複合繊維が 2 0重 量％超含まれていると、 不織布 1 0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に、 着用 者の肌との摩擦に起因する毛羽立ちが起こり易くなつてしまう。 また 分割型複合繊維の分割離間によって疎水表面の面積が増大して、 液の 引き込み力が低下してしまう。 第 2層 2における分割型複合繊維の量 は 1 0〜 8 0重量％、 特に 2 0〜 6 0重量％であることが、 前述した 毛管力勾配の効果的な発現及び不織布 1 0に十分な嵩高性及び柔軟性 を付与する点から好ましい。 不織布 1 0全体としてみた場合、 分割型複合繊維は 5〜 4 0重量％. 好ましくは 1 0〜 3 0重量％含有されている。 分割型複合繊維の量が 5重量％未満では開孔 3において分割離間している繊維の量が少な く、 液の引き込みが不十分であり、 柔軟性も不十分となってしまう。Hereinafter, the present invention will be described based on preferred embodiments with reference to the drawings. FIG. 1 is an enlarged perspective view showing a main part of a longitudinal section in one embodiment of the nonwoven fabric of the present invention. As shown in FIG. 1, the nonwoven fabric 10 of the present embodiment has a two-layer structure including a first layer 1 constituting one outer layer and a second layer 2 constituting the other outer layer. In the nonwoven fabric 10, a large number of openings 3 are regularly formed on the entire surface. The nonwoven fabric 10 contains splittable conjugate fibers and heat-fusible fibers. The splittable conjugate fiber used in the present embodiment is composed of two or more different resins different from each other, and each resin is arranged continuously in the longitudinal direction of the fiber and alternately arranged in the circumferential direction of the fiber. The fibers are separated and can be separated from each other by thermal action or mechanical action. As shown in FIG. 1, the opening 3 is formed by being surrounded by a nonwoven fabric extending from the first layer 1 toward the second layer 2. The inner wall 4 of the opening 3 is formed by a continuous surface from the first layer 1. That is, the opening 3 is a three-dimensional opening. The opening 3 has a circular shape in a plan view, and its diameter gradually decreases from the first layer 1 toward the second layer, thus forming a funnel shape. The space 3 between the adjacent openings is convexly curved so as to have the top 5. The plurality of tops 5 are connected substantially continuously to form a ridge. The ridges 6 are formed in multiple rows, and a groove 7 is formed between the adjacent ridges 6,6. The ridge portions 6 and the groove portions 7 are alternately arranged so as not to have a flat portion. The ridges 6 are convexly curved and the grooves 7 are concavely curved, and the openings 3 are formed in the grooves 7. In the nonwoven fabric 10 of the present embodiment, the splittable conjugate fibers present at the periphery of the opening 3 are separated and separated between the constituent resins, and the degree of the separation is different from that of the other portions of the nonwoven fabric 10. Is larger than that of the splittable conjugate fiber. As a result, the apparent number of fibers in the peripheral portion of the opening 3 becomes larger than that in the outer region. As a result, the distance between the fibers at the peripheral portion of the opening 3 becomes smaller than that in the region outside the opening 3, and a gradient occurs in the capillary force. As a result, the capillary force increases from a region outside the peripheral edge of the opening 3 toward the peripheral portion, and a liquid drawing force is generated toward the opening end of the opening 3. Therefore, when the nonwoven fabric 10 of the present embodiment is used, for example, as a surface sheet of an absorbent article as described later, liquid residue hardly occurs on the surface sheet. Furthermore, since the splittable conjugate fibers are separated and separated, the nonwoven fabric 10 is given bulkiness and flexibility, and the texture of the nonwoven fabric 10 is improved. Also from this point, the nonwoven fabric 10 of the present embodiment is suitable as a surface sheet of an absorbent article, which is a member that directly contacts the skin. Note that a large "degree of separation between constituent resins in the splittable conjugate fiber" means that the apparent number of fibers is large and / or the distance between fibers is small. "Split The degree of separation between constituent resins in the conjugated fiber is, for example, the number of splittable conjugate fibers that are separated and separated, the length of the portion of the splittable conjugate fiber where the constituent resin is separated and separated, and the splitting. It changes depending on the distance between the constituent resins divided and separated in the type composite fiber. The splittable conjugate fibers present in the peripheral portion of the opening 3 are separated and separated between the constituent resins, and the degree of the separation is larger than that of the splittable conjugate fibers present in other portions of the nonwoven fabric 10. It can be confirmed from the electron microscopic observation of the nonwoven fabric 10 whether or not it has been established. In order to make the degree of separation between the constituent resins in the splittable conjugate fibers present at the peripheral portion of the opening 3 larger than that of the splittable conjugate fibers present in other portions of the nonwoven fabric 10, For example, as will be described later, a large number of openings 3 are formed using perforated pins, and a shear force is applied to the splittable conjugate fibers present at the periphery of the openings 3 to selectively form the splittable conjugate fibers. The constituent resins may be divided and separated. The first layer 1 of the nonwoven fabric 10 contains the splittable conjugate fiber in an amount of 20% by weight or less, preferably 10% by weight or less. At the same time, the second layer contains a larger amount of splittable composite fibers. The amount of the splittable conjugate fiber in the first layer 1 may be zero. That is, the first layer 1 does not need to include the splittable conjugate fiber. If the first layer 1 contains more than 20% by weight of the splittable conjugate fiber, the nonwoven fabric 10 is used, for example, as a surface sheet of an absorbent article, and the first layer 1 is placed on the skin contact side. When arranged, fluffing due to friction with the wearer's skin is likely to occur. In addition, the area of the hydrophobic surface increases due to the separation and separation of the splittable conjugate fibers, and the liquid pull-in force decreases. The amount of the splittable conjugate fiber in the second layer 2 is 10 to 80% by weight, particularly 20 to 60% by weight, which is sufficient for the effective expression of the capillary force gradient and the nonwoven fabric 10 described above. Bulkiness and flexibility Is preferred from the viewpoint of imparting When viewed as a nonwoven fabric 10 as a whole, the splittable conjugate fiber is contained in an amount of 5 to 40% by weight, preferably 10 to 30% by weight. When the amount of the splittable conjugate fiber is less than 5% by weight, the amount of the fiber separated and separated in the opening 3 is small, the liquid is not sufficiently drawn, and the flexibility is also insufficient.
4 0重量％超では分割繊維の量が多くなり、 摩擦に対する毛羽立ちや 毛羽抜けが起こりやすくなると共に、 開孔後の強度も低く、 破れやす ぃ不織布となってしまう。 一方、 不織布 1 0全体としてみた場合、 熱融着性繊維は 6 0〜 9 5 重量％、 好ましくは 7 0〜 9 0重量％含有されている。 熱融着性繊維 の量が 6 0重量％未満では不織布の強度が不十分で破れやすく、 また 毛羽立ちの抑制も不十分となってしまう。 9 5重量％超の場合には毛 羽立ちが抑制され強度も高いが、 開孔 3における液の引き込み性や、 柔軟性が不十分となってしまう。 第 1層 1及び第 2層 2における熱融 着性繊維の含有量に関しては、 第 1層 1 における熱融着性繊維の量はIf the content exceeds 40% by weight, the amount of split fibers increases, and fluffing and fuzzing due to friction tend to occur, and the strength after opening is low. On the other hand, as a whole, the non-woven fabric 10 contains 60 to 95% by weight, preferably 70 to 90% by weight of the heat-fusible fiber. If the amount of the heat-fusible fiber is less than 60% by weight, the strength of the nonwoven fabric is insufficient and the nonwoven fabric is easily broken, and the suppression of fuzzing becomes insufficient. If the content is more than 95% by weight, fluffing is suppressed and the strength is high, but the liquid draw-in property at the opening 3 and the flexibility become insufficient. Regarding the content of the heat-fusible fibers in the first layer 1 and the second layer 2, the amount of the heat-fusible fibers in the first layer 1 is
8 0〜 1 0 0重量％、 特に 9 0〜： 1 0 0重量％であることが、 毛羽立 ちゃ毛羽抜けの抑制および十分な強度発現の点から好ましい。 第 2層 2における熱融着性繊維の量は 2 0〜 9 0重量％、 特に 4 0〜 8 0重 量％であることが、 毛羽立ちや毛羽抜けの抑制、 不織布の柔軟性発現 の点から好ましい。 分割型複合繊維としては、 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、 4分割〜 3 2分割可能な繊維が 用いられる。 特に、 コスト、 生産性、 分割性の点で 6分割〜 1 6分割 可能な繊維が好ましい。 低融点樹脂としては、 その融点が 1 0 0〜 1 5 0 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 · 2 7 3 0 6 1号公報の段落 〔 0 0 1 3〕 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 1 6 0〜 2 6 0 °C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 2 7 3 0 6 1号公報の段 落 〔 0 0 1 4〕 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 1 0 0 ~ 1 5 0 程度高いことが好ましい。 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 （P P) ノポリエチレンテレフ タレート （P E T) 、 ポリエチレン （P E) ノポリエチレンテレフタ レート （P E T) 、 ポリエチレン （P E) /"ポリプロピレン （P P) 等が挙げられる。 分割型複合繊維は、 その繊度が 1〜 1 5 d t e X、 特に 3〜 8 d t e xであることが、 毛管力が過度に大きくなることを 防止し十分な液透過性を得る点及び製造コス 卜の点から好ましい。 分割型複合繊維における低融点樹脂が熱収縮性を有していると、 熱 的作用のみでも繊維を分割離間させることができる。 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、 不織布 1 0を、 吸収性物品の表面シートとして 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。 特に、 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。 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、 カルボ二ル基、 カル ポキシル基、 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エノール、 ポリ ォ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。 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、 C 8〜C 3 0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ァニオン系活性剤、 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ォレート、 ソルビタンモノォレートやポリオ 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ォキシアルキレン変性ォ 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ォ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 2 8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。 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 レ 熱融着繊維にも、 分割型複合繊維と同様に、 その表面に親水化剤 が施されていることが、 不織布 1 0に十分な通液性を付与する点から 好ましい。 熱融着繊維はその繊度が、 1. 5 d t e x〜 5 d t e x、 特に 2. 2 d t e x〜 4. 4 d t e xであることが、 不織布に通液性 を付与し、 また液残りを抑制する点、 不織布の風合いを維持する点、 及び分割型複合繊維の繊度とのバランスの点から好ましい。 本実施形態の不織布 1 0には、 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、 ポリオレフイン系繊維、 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、 キュブラ、 ァセテIt is preferably from 80 to 100% by weight, particularly from 90 to 100% by weight, from the viewpoints of suppression of fluffiness and fluffiness and sufficient strength. The amount of the heat-fusible fiber in the second layer 2 is preferably from 20 to 90% by weight, particularly from 40 to 80% by weight, from the viewpoint of suppressing fluffing and fluffing out and developing flexibility of the nonwoven fabric. preferable. As the splittable conjugate fiber, a fiber that can be divided into four to thirty-two parts is used, with a low-melting resin and a high-melting resin having a higher melting point than the low-melting resin as constituent resins. In particular, fibers that can be split into six to sixteen pieces are preferable in terms of cost, productivity, and splitting property. As the low melting point resin, those having a melting point of about 100 to 150 are preferably used. Examples thereof include those described in paragraph [0113] of Japanese Patent Application Laid-Open No. 9 / 273,061. As the high melting point resin, a resin having a melting point of about 160 to 260 ° C. is preferably used. Examples thereof include those described in paragraph [0114] of Japanese Patent Application Laid-open No. Hei 9-273601. The melting point of the high melting point resin is preferably about 100 to 150 higher than the melting point of the low melting point resin. As a preferred combination of the low melting point resin and the high melting point resin, the low melting point resin / the high melting point resin is a low melting point polypropylene (PP) polyethylene terephthalate (PET), polyethylene (PE) polyethylene terephthalate (PET) , Polyethylene (PE) / "polypropylene (PP), etc. The splittable conjugate fiber has a fineness of 1 to 15 dte X, especially 3 to 8 dtex, and an excessively large capillary force. When the low melting point resin in the splittable conjugate fiber has heat shrinkage, the fibers can be separated and separated only by the thermal action. In addition, the splittable conjugate fiber preferably has hydrophilicity by kneading a hydrophilic agent into at least one of the constituent resins, and becomes hydrophilic by kneading the hydrophilic agent. In the case where the nonwoven fabric 10 is used as a surface sheet of an absorbent article, the hydrophilicity is not easily reduced even when the liquid repeatedly permeates. By further mixing the hydrophilic agent into one and applying the same or different hydrophilic agent to the surface of the splittable conjugate fiber, more durability is imparted to the hydrophilicity. The hydrophilic agent kneaded into the constituent resin may be a compound having a hydrophilic group such as a hydroxyl group, a carboxy group, a carboxyl group, a sulfone group, etc. For example, fatty acid glyceride, alkyloxyalkylphenol, polyalkylene fatty acid Examples include nonionic surfactants such as esters and fatty acid diethanolamide, etc. On the other hand, examples of the hydrophilic agent applied to the surface of the splittable conjugate fiber include sulfuric acid and the like. Ether base, alkyl Berlin ester base C 8~C 3 0, Anion based activators containing sulfonate and the like, betaine active agent, polyoxyethylene alkyl ethers, polyoxy Ethylene sorbitan monoolate, sorbitan monoolate or polyoxyalkylene-modified organosiloxane, blend of alkylolamide-type compound and polyoxyalkylene-modified organosiloxane, polyglycerin fatty acid ester or polyoxyalkylene-modified with it Blends with organosiloxanes, blends of polyether polyester block copolymers or blends thereof with polyoxyalkylene-modified organosiloxanes, surfactants having a hydrocarbon group of at least 28 carbon atoms and polyoxygen Examples include blends with alkylene-modified organosiloxanes. As the heat-fusible fiber, a fiber composed of a resin having a melting point similar to or lower than the melting point of the low-melting resin of the splittable conjugate fiber is used. Is preferred. Examples of such fibers include polyethylene fibers, polypropylene fibers, polyethylene terephthalate fibers, and polyamide fibers. Also, a core-sheath type composite fiber or a side-by-side type composite fiber can be used. When these conjugate fibers are used, for the same reason as described above, a resin having a melting point similar to or lower than the melting point of the low-melting resin of the splittable conjugate fiber is used as the low-melting resin. It is also preferable for the heat-fused fiber that the surface thereof is provided with a hydrophilizing agent, similarly to the splittable conjugate fiber, from the viewpoint of imparting sufficient liquid permeability to the nonwoven fabric 10. The heat-fused fiber has a fineness of 1.5 dtex to 5 dtex, especially 2.2 dtex to 4.4 dtex, which imparts liquid permeability to the nonwoven fabric and suppresses liquid residue. This is preferable from the viewpoint of maintaining the texture of, and the balance with the fineness of the splittable conjugate fiber. In the nonwoven fabric 10 of the present embodiment, the first layer 1 and / or the second layer 2 include natural fibers such as cotton and wool, and acrylic fibers in addition to the above-mentioned splittable composite fibers and heat-fusible fibers. , Polyolefin fiber, Polyvinyl chloride Fiber, polyvinyl alcohol fiber, rayon, cuvula, acetate
—ト等の再生繊維、 ナイロン 6、 ナイロン 6 6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、 不織布 1 0の重量に対して 4 0重量％程度以下の量で含有させることができ る。 本実施形態の不織布 1 0は、 これに含まれる熱融着性繊維同士の交 点及び熱融着性繊維と分割型複合繊維との交点が熱の付与によって融 着することで不織布の形態を保っている。 熱を付与する手段としては、 後述するように熱風を吹き付ける方法、 ヒートロール間を通す方法、 遠赤外線等の幅射熱による方法が挙げられる。 嵩高で柔軟な不織布を 得る点からは、 熱風を吹き付ける方法、 即ちエアスルー法によって不 織布を形成することが好ましい。 前述の通り、 不織布 1 0には多数の開孔 3が形成されている。 開孔 3はその開孔端における径が 0. 5〜 3 mm、 特に 0. 7〜 2 mmで あることが、 十分な毛管力の発現、 及び不織布 1 0を吸収性物品の表 面シートとして用いた場合の液の逆戻り防止の点から好ましい。 また、 開孔率、 即ち不織布 1 0全体の面積に対する開孔 3の面積の総和の割 合は 2 ~ 3 0 %、 特に 5 ~ 1 8 %であることが好ましい。 開孔 3の径 及び開孔率は、 本出願人の先の出願に係る特開平 8 — 2 4 6 3 2 1号 公報の段落 〔 0 0 6 2〕 及び 〔 0 0 6 4〕 の記載に従い測定される。 溝部 7に沿う開孔 3間の距離は 0. 4 ~ 4 0 m m、 特に 1 . 5〜 8 m mであることが好ましい。 隣り合う溝部 7間の距離は 1 〜 6 mm、 特 に 1 . 7〜 3. 7 mmであることが、 開孔 3をしつかりと形成する点 及び液の十分な透過性を確保する点から好ましい。 隣り合う畝部 6間 の距離も同様であることが好ましい。 不織布 1 0は、 その坪量が 1 0〜 5 0 g/m 特に 1 8〜 3 5 g / m 2であることが、 液を引き込むための空隙を形成するのに必要な量の 繊維の確保、 生産性及びコストの点から好ましい。 また、 不織布 1 0 を構成する各層に関しては、 第 1層の坪量は 5〜 3 0 g Zm2、 特に 8 〜 2 0 g/m2であり、 第 2層 2の坪量は 5〜 3 0 gZm2、 特に 8〜 2 O gZm2であることが、 液の透過性及び引き込み性、 毛羽抜けの抑制 と肌触りとのバランス、 並びにコス 卜の点から好ましい。 不織布 1 0は、 その厚みが 0. 5 g / c m2荷重下において 0. 4 ~ 3 mm, 特に 0. 6〜 2 mm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. 5 g / c m2荷重下の厚みは、 不織布 1 0に軽く タツチし始めたときの厚みにほぼ相当する。 0. 5 gZ c m2荷重下の 不織布 1 0の厚みは、 特開平 8— 2 4 6 3 2 1号公報の段落 〔 0 0 6 3〕 の記載に従い測定される。 次に、 本実施形態の不織布 1 0の好ましい製造方法を説明する。 先 ず、 第 1層 1及び第 2層 2を構成する繊維ウェブを製造する。 該繊維 ウェブは、 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ィジェクタで延伸しコンペ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、 各層を構成する繊維ウェブを重ね合わせた後、 構成繊維の交点を所定 の手段によって結合させて不織布原反を得る。 結合には、 熱の付与に よる熱溶融繊維の融着、 バインダによる接着などが用いられ、 特に嵩 高さ及び柔軟性の付与が容易なことから、 熱風の吹き付けによる融着 を用いることが好ましい。 得られた不織布原反には、 開孔処理が施さ れる。 開孔処理には、 加熱されているか又は加熱されていない穿孔ピ ンが用いられる。 穿孔ピンを用いることによって、 開孔の形成と同時 に該開孔の周縁部に存する分割型複合繊維に選択的に剪断力を加える ことができる。 この操作によって、 開孔の周縁部に存する分割型複合 繊維を分割離間させ且つその他の部分の存する分割型複合繊維をなる ベく分割離間させないようにすることができる。 つまり、 開孔の周縁 部に存する分割型複合繊維を選択的に分割離間させることが可能とな る。 穿孔ピンを用いた開孔の形成方法は、 特開平 8— 2 4 6 3 2 1号 公報の段落 〔 0 0 5 6〕 〜 〔 0 0 5 9〕 に記載の方法に従うことがで さる。 このようにして得られた不織布 1 0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を持たせたワイパーなどとして好適に用いら 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不織布 1 0を用い、 且つ該不織布 1 0における 第 1層 1の側を肌対向側として配することで、 通液性が良好で液残り が少なく、 着用者の肌にまとわりつくようなベタツキ感がなく、 ドラ ィ感に優れた吸収性物品となる。 また、 部分的に剥離ノ分割した繊維 が含まれるので、 嵩高で柔軟性がある。 更に、 毛羽立ちが少ないので. 着用者の肌への刺激が低減し、 装着感の良好な吸収性物品となる。 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不織 布 1 0は第 1層 1及び第 2層 2から構成される二層構造であつたが、 これに代えて、 第 1層と第 2層との間に 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。 また前記実施形態における不織布 1 0に形成された開孔 3は、 その 径が何れも同じものであつたが、 これに代えて異なる 2種以上の径を 有する開孔を形成してもよい。 例えば、 不織布 1 0を吸収性物品の表 面シートとして用いる場合、 吸収性物品の縦中心線に沿った領域に対 応する不織布 1 0の領域に相対的に大径の開孔を形成し、 且つ該吸収 性物品の左右両側部に対応する不織布 1 0の領域に相対的に小径の開 孔を形成してもよい。 これによつて、 排液ポイントである中央部の液 の引き込み性及び液透過性が向上し、 一方、 両側部は相対的に径が小 さいので、 繊維があまり分割せず、 毛羽立ちや抜け抑制がされるとい う効果が奏される。 Other types of fibers such as recycled fibers such as nylon fibers and polyamide fibers such as nylon 6 and nylon 66 may be contained. These fibers can be contained in an amount of about 40% by weight or less based on the weight of the nonwoven fabric 10. The nonwoven fabric 10 of the present embodiment has a shape of the nonwoven fabric by fusion of the intersections of the heat-fusible fibers contained therein and the intersections of the heat-fusible fibers and the splittable conjugate fibers by applying heat. I keep it. Examples of the means for applying heat include a method of blowing hot air as described below, a method of passing between heat rolls, and a method of radiating heat such as far infrared rays. From the viewpoint of obtaining a bulky and flexible nonwoven fabric, it is preferable to form the nonwoven fabric by a method of blowing hot air, that is, an air-through method. As described above, the nonwoven fabric 10 has a large number of openings 3 formed therein. The diameter of the opening 3 at the opening end is 0.5 to 3 mm, particularly 0.7 to 2 mm, so that sufficient capillary force is exhibited, and the nonwoven fabric 10 is used as a surface sheet of the absorbent article. It is preferable from the viewpoint of preventing the liquid from returning when used. Further, the porosity, that is, the ratio of the total area of the openings 3 to the total area of the nonwoven fabric 10 is preferably 2 to 30%, particularly preferably 5 to 18%. The diameter and the opening ratio of the opening 3 are determined in accordance with the description in paragraphs [062] and [064] of Japanese Patent Application Laid-Open No. H8-246631, filed by the present applicant. Measured. The distance between the openings 3 along the groove 7 is preferably 0.4 to 40 mm, particularly preferably 1.5 to 8 mm. The distance between the adjacent grooves 7 is 1 to 6 mm, especially 1.7 to 3.7 mm, from the viewpoint of tightly forming the opening 3 and ensuring sufficient liquid permeability. preferable. It is preferable that the distance between adjacent ridges 6 is also the same. Nonwoven fabric 10 has a basis weight of 10 to 50 g / m, especially 18 to 35 g / m m 2 is preferable from the viewpoints of securing an amount of fibers necessary for forming a void for drawing in the liquid, productivity, and cost. In addition, with respect to each layer constituting the nonwoven fabric 10, the basis weight of the first layer is 5 to 30 g Zm 2 , particularly 8 to 20 g / m 2 , and the basis weight of the second layer 2 is 5 to 3 g / m 2. 0 gZm 2 , especially 8 to 2 O gZm 2 , is preferable from the viewpoints of liquid permeability and pull-in property, balance between suppression of fluff removal and feel, and cost. The nonwoven fabric 10 preferably has a thickness of 0.4 to 3 mm, particularly 0.6 to 2 mm under a load of 0.5 g / cm 2, from the viewpoint of exhibiting a sufficient bulkiness. The thickness under a load of 0.5 g / cm 2 is almost equivalent to the thickness when the nonwoven fabric 10 starts to touch lightly. The thickness of the nonwoven fabric 10 under a load of 0.5 gZcm 2 is measured in accordance with the description in paragraph [063] of JP-A-8-246321. Next, a preferred method for producing the nonwoven fabric 10 of the present embodiment will be described. First, a fiber web constituting the first layer 1 and the second layer 2 is manufactured. The fiber web can be formed by, for example, a card method using a card machine, a method in which a molten fiber spun from a spinning nozzle is drawn by an ejector and deposited on a compare belt, or an air laid method. Next, after superposing the fiber webs constituting the respective layers, the intersections of the constituent fibers are joined by a predetermined means to obtain an original nonwoven fabric. For the bonding, fusion of hot melt fibers by application of heat, adhesion by a binder, etc. are used. In particular, since the bulk and flexibility can be easily provided, it is preferable to use fusion by blowing hot air. . The obtained nonwoven fabric is subjected to a hole opening treatment. For the opening process, heated or unheated drilling pins are used. By using the perforated pin, a shearing force can be selectively applied to the splittable conjugate fiber existing at the periphery of the opening at the same time as the formation of the opening. By this operation, the splittable conjugate fiber existing at the peripheral portion of the opening is divided and separated, and the splittable conjugate fiber having other portions is formed. It can be prevented from being separated and separated. That is, it becomes possible to selectively separate and separate the splittable conjugate fibers existing in the peripheral portion of the opening. The method of forming an aperture using a perforated pin can be according to the method described in paragraphs [056] to [059] of JP-A-8-24631. The nonwoven fabric 10 thus obtained may be, 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 and the surface sheet in the absorbent article, or It is suitably used as a wiper or the like that partially retains liquid in a sheet. In particular, in the absorbent article having a liquid-permeable top sheet, a liquid-impermeable back sheet, and a liquid-retentive absorber interposed between the two sheets, a nonwoven fabric 10 is used as the topsheet; By arranging the side of the first layer 1 at 0 as the skin-facing side, it has good liquid permeability, little liquid residue, no sticky feeling that clings to the wearer's skin, and excellent dryness It becomes an article. In addition, since fibers that are partially peeled off and split are included, they are bulky and flexible. Furthermore, since there is little fluffing, irritation to the wearer's skin is reduced, and an absorbent article with a good wearing feeling is obtained. The present invention is not limited to the above embodiment. For example, the nonwoven fabric 10 of the above-described embodiment has a two-layer structure composed of the first layer 1 and the second layer 2, but instead of this, 1 or 1 is provided between the first layer and the second layer. It may have a multilayer structure of three or more layers having two or more layers. In addition, although the holes 3 formed in the nonwoven fabric 10 in the above embodiment have the same diameter, the holes 3 may have two or more different diameters instead. For example, when the nonwoven fabric 10 is used as a surface sheet of an absorbent article, an opening having a relatively large diameter is formed in a region of the nonwoven fabric 10 corresponding to a region along the longitudinal center line of the absorbent article, And the absorption An opening having a relatively small diameter may be formed in a region of the nonwoven fabric 10 corresponding to both right and left sides of the non-woven article. This improves the liquid draw-in and liquid permeability at the central part, which is the drainage point, while the sides are relatively small in diameter, so the fibers do not split much, preventing fluffing and falling out This has the effect of being eliminated.
〔実施例 1〜 3並びに比較例 1及び 2〕 (Examples 1-3 and Comparative Examples 1 and 2)
以下の表 1及び表 2に示す繊維を用いて、 力一ド法によって第 1層 及び第 2層の繊維ウェブを形成した。 表 1 における繊維の詳細は表 2 に示す通りである。 各繊維ウェブを互いに重ね合わせた後、 1 4 0 Tに 加熱された熱風を吹き付けて構成繊維の交点を融着させ二層構造の不 織布原反を得た。 その後、 1 2 5 に加熱された直径 1 . 5 m mの穿孔 ピンを用いて、 不織布原反に多数の開孔を形成すると共に畝部及び溝 部が形成された、 図 1に示す形態の不織布を得た。 得られた不織布に おける開孔の開孔端における径は約 1 m m、 開孔率は 1 0 %であった。 また、 溝部に沿う開孔間の距離は 2 . 6 m m , 溝部及び畝部間の距離 は何れも 2 . 3 m mであった。 更に 0 . 5 g c m 2荷重下における厚 みは 0 . 6〜； L . 0 m mであった。 得られた不織布について、 以下の方法で動的液残り量、 毛羽抜け量 及び C D強度を測定した。 結果を表 1 に示す。 〔動的液残り量の測定〕 Using the fibers shown in Tables 1 and 2 below, a first layer and a second layer fiber web were formed by a force method. Details of the fibers in Table 1 are as shown in Table 2. After the respective fibrous webs were superimposed on each other, a hot air heated to 140 T was blown to fuse the intersections of the constituent fibers to obtain a nonwoven fabric having a two-layer structure. Then, using a 1.5 mm diameter piercing pin heated to 125, a large number of holes were formed in the raw nonwoven fabric, and ridges and grooves were formed. Got. The diameter of the opening at the opening end of the obtained nonwoven fabric was about 1 mm, and the opening ratio was 10%. The distance between the openings along the groove was 2.6 mm, and the distance between the groove and the ridge was 2.3 mm. Further, the thickness under a load of 0.5 gcm 2 was 0.6 to 0.5 mm. With respect to the obtained nonwoven fabric, the remaining amount of the dynamic liquid, the amount of fluff, and the CD strength were measured by the following methods. Table 1 shows the results. (Determination of dynamic liquid remaining amount)
市販のナプキン 「ロリエさらさらクッション ウィ ングなし」 （商 品名、 花王製） から、 表面シー トの部分を取り除き、 ナプキン吸収体 を準備する。 実施例及び比較例でそれぞれ得られた不織布の重量 W 1 をあらかじめ測定しておく。 これらの不織布を表面シ一トとして用い、 先に準備したナプキン吸収体に巻いて固定し、 ナプキンを得る。 次に このナプキンを女性腰部モデルに装着させ、 更にその上にショーツを 装着後、 1 0 0歩 分 （ 5 0 m/"分） の歩行速度でモデルを歩行させ た。 歩行 1分間後に歩行させながら脱繊維馬血 1. 5 g (注入速度 8 g/分） をナプキン注入し、 歩行を続ける。 更に 3分間後、 歩行させ ながら脱繊維馬血を 1. 5 gをナプキンに注入し、 歩行を続ける。 1 分経過後歩行を停止し、 モデルからナプキンを取り外す。 ナプキンか ら不撒布のみを剥がし、 その重量 W2を測定する。 初めに測定した不 織布の重量 W 1 との差 （W2— W 1 ) を求める。 以上の操作を 3回行 い、 3回の平均値を動的液残り量とする。 Remove the surface sheet from the commercially available napkin “No Laurier Smooth Cushion Wing” (trade name, manufactured by Kao) and prepare a napkin absorber. The weight W 1 of the nonwoven fabric obtained in each of the examples and comparative examples is measured in advance. These non-woven fabrics are used as a surface sheet and wound and fixed on a napkin absorber prepared above to obtain a napkin. Next, attach this napkin to the female waist model, and then put shorts on it After wearing, the model was walked at a walking speed of 100 steps (50 m / "minute). While walking 1 minute after walking, 1.5 g of defibrillated horse blood (infusion speed of 8 g / minute) was applied. Inject napkin and continue walking After another 3 minutes, inject 1.5 g of defibrinated horse blood into napkin while walking, continue walking After 1 minute, stop walking and remove napkin from model. Peel off only the non-woven cloth from the napkin and measure its weight W2 Obtain the difference (W2-W 1) from the weight W 1 of the non-woven cloth measured first Perform the above operation 3 times and 3 times Is defined as the dynamic liquid remaining amount.
〔毛羽抜け量の測定方法〕 [Measurement method of fluff removal amount]
ウレタンフォーム （プリジストン (株) 製ウレタンフオーム モル トプレン MF 3 0、 厚さ 5 mm) で表面を覆った円盤 （直径 7 0 mm 3 5 0 g ) を、 回転軸に取り付ける。 取り付け位置は円盤中心から 2 0 mmずれた位置とする。 図 1に示す開孔が下方に向かって形成され ている不織布の下面に、 上記と同じウレタンフォームを敷く。 次いで. 不織布の上面側を表面にして、 台上に固定する。 不織布の上に前記円 盤を載せる。 このとき、 不織布に加わる荷重は円盤の自重のみとする, この状態下、 回転軸を回転させて、 円盤を不織布上で周動させる。 周 動は時計周りに 2回転、 反時計周りに 2回転を 1セッ トとして、 1 0 セッ ト行う。 このときの周動速度は 1周動あたり約 3秒である。 1 0 セッ トの周動後、 円盤を覆っているウレタンフォームの表面に付着し た毛羽抜けした繊維を集める。 この操作を n = 2 0枚の不織布につい て行う。 n = 2〜·5の不織布について毛羽抜けした繊維の重量を測定 し、 その重量を不織布 1枚につき毛羽抜けした繊維の重量に換算する, この値を毛羽抜け量とする。 〔 C D強度の測定方法〕  Attach a disk (diameter 70 mm 350 g) whose surface is covered with urethane foam (urethane foam maltoprene MF 30 manufactured by Priston Co., Ltd., thickness 5 mm) to the rotating shaft. The mounting position shall be 20 mm from the center of the disk. The same urethane foam as described above is laid on the lower surface of the nonwoven fabric in which the openings shown in FIG. 1 are formed downward. Then, the nonwoven fabric is fixed on a table with the upper surface side facing. The disc is placed on the nonwoven fabric. At this time, the load applied to the nonwoven fabric is only the weight of the disc itself. Under this condition, the rotating shaft is rotated to make the disc circulate on the nonwoven fabric. The rotation is performed 10 sets, with 2 rotations clockwise and 2 rotations counterclockwise as one set. The orbiting speed at this time is about 3 seconds per orbit. After the rotation of the 10 set, collect the fluffed fibers attached to the surface of the urethane foam covering the disk. This operation is performed for n = 20 nonwoven fabrics. The weight of the removed fibers is measured for the nonwoven fabric of n = 2 to 5 and the weight is converted into the weight of the removed fibers per nonwoven fabric. [Method of measuring CD strength]
株式会社オリエンテック製の引張試験機テンシロン； T A— 1 0 0 を用いて不織布の C D強度を測定する。 C Dは、 得られた不織布にお ける流れ方向に直交する方向とする。 試験片は CDの長さ 2 0 0 mm MDの長さ 5 0 mmとする。 チャック間距離は 1 5 0mm、 引張速度 は 3 0 0 mm/分とする。 5枚の試験片にっき測定を行いその平均値 を C D強度とする。 The CD strength of the nonwoven fabric is measured using a tensile tester Tensilon manufactured by Orientec Co., Ltd .; TA-100. CD is applied to the obtained nonwoven fabric. Direction perpendicular to the flow direction. The test piece shall be 200 mm in CD length and 50 mm in MD length. The distance between the chucks is 150 mm and the pulling speed is 300 mm / min. Measure five test pieces and determine the average value as the CD strength.
表 1 吳胭例 1 夹胭 夹 SCT 較例 1 芯鞘型複合繊維 90¾ Table 1 Example 1 Example 1 SCT Comparative Example 1 Core-sheath composite fiber 90 複合
芯鞘型複合繊維 100¾ 芯鞘型複合繊維 100SK 芯鞘型複合繊維 第 in 分割型複合繊維③ 10¾  Core-in-sheath composite fiber 100¾ Core-in-sheath composite fiber 100SK Core-in-sheath composite fiber No. 1 in split composite fiber③ 10¾
坪量 15g/m2 坪量 15g/m2 坪量 15g/ 坪量 15g/m2 Basis weight 15 g / m 2 basis weight 15 g / m 2 basis weight 15 g / basis weight 15 g / m 2
芯鞘型複合繊維 70¾ 芯鞘型複合繊維 70¾ 芯鞘型複合繊維 70¾  Core-sheath composite fiber 70¾ Core-sheath composite fiber 70¾ Core-sheath composite fiber 70¾
芯鞘型複合繊維 第 2層 分割型複合繊維① 30¾ 分割型複合繊維② 30¾ 分割型複合繊維③ 10¾  Core-sheath type composite fiber 2nd layer Split type composite fiber① 30¾ Split type composite fiber¾ 30¾ Split type composite fiber③ 10¾
坪量 15g/ 坪量 15g/m2 坪量 15g/m2 坪量 15g/m2 動的液残り量 Basis weight 15 g / basis weight 15 g / m 2 basis weight 15 g / m 2 basis weight 15 g / m 2 dynamic liquid remaining amount
21 14 25 34 (mg)  21 14 25 34 (mg)
毛羽抜け量  Fluff loss
1 13. 6 40 0. 8 (mg)  1 13.6 40 0.8 (mg)
CD強度  CD strength
800 753 654 877 (cN/50腿） 800 753 654 877 (cN / 50 thighs)
芯 PET/鞘 PE 2. 2d tex X 51mm Core PET / sheath PE 2.2d tex X 51mm
芯鞘型複合繊維  Core-sheath composite fiber
表面に親水化剤 （炭素数 8〜 1 2の直鎖アルキルフォスフエ-トか jゥム塩） を塗布。 Apply a hydrophilic agent (C8-C12 straight-chain alkyl phosphate or salt) to the surface.
PET/熱収縮性 PP 6. 7d tex X 51腿 8分割型 PET / heat shrinkable PP 6.7d tex X 51 thigh 8 split type
分割型複合繊維①  Splittable composite fiber①
表面に親水化剤 （炭素数 8〜 1 2の直鎖アルキルフォスフ 1-トカリウム塩） を塗布。 Hydrophilic agent (C8-C12 straight-chain alkylphospho-to-potassium salt) is applied to the surface.
PET/熱収縮性 PP 6. 7d tex X 51mm 8分割型 PET / heat-shrinkable PP 6.7d tex X 51mm 8 split type
熱収縮性 P P成分中に親水化剤 （ホ。 Wリセリン脂肪酸 Iステル） を練り込み、 分割型複合繊維②  Heat shrinkable PP Knead a hydrophilizing agent (e. W reserin fatty acid I stell) into the P component to obtain splittable composite fibers.
表面に親水化剤 （PO/EO変性シリコン、 ステアリン酸シ'ェタノ-ルァミト'、 POEへ'へニン酸アミ ドを主体成分とした混合物） を塗布。  Hydrophilic agent (PO / EO-modified silicon, mixture of stearic acid, 'hetanol-lamite', and POE ', a mixture mainly composed of henic acid amide) is applied to the surface.
PET/PE 6. 7d te X 51mm 8分割型  PET / PE 6.7d te X 51mm 8 split type
PE成分中に親水化剤 （ホ°リグリセリン脂肪酸 J:ステル） を練り込み、 表面に親 分割型複合繊維③  A hydrophilic agent (polyglycerin fatty acid J: ster) is kneaded into the PE component, and the split-type composite fiber is applied to the surface.
水化剤 （PO/EO変性シリコン、 ステアリン酸シ 'エタ ルアミド、 POEへ 'へニン酸アミドを主体 成分とした混合物） を塗布。  Watering agent (PO / EO-modified silicone, stearic acid mixture to ethalamide, and POE to henic acid amide) is applied.
表 1 に示す結果から明らかなように、 実施例の不織布 （本発明品） は、 比較例の不織布に比べて液残り量が少なく、 強度も高く また毛羽立ちし にく いことが判る。 また表には示していないが、 実施例の不織布は、 嵩 高く柔軟であり、 風合いの良好なものであった。 なお、 表には示してい ないが、 実施例 1 〜 3の不織布においては、 その電子顕微鏡観察の結果、 開孔の周縁部に存する分割型複合繊維が構成樹脂間で分割離間してお り、 且つその分割離間の程度が、 不織布における他の部分に存する該分 割型複合繊維のそれより も大きくなっている ことが確認された。 産業上の利用可能性 As is clear from the results shown in Table 1, the nonwoven fabric of the example (product of the present invention) has a smaller amount of liquid remaining, has higher strength and is less likely to fluff than the nonwoven fabric of the comparative example. Although not shown in the table, the nonwoven fabric of the example was bulky and flexible, and had a good texture. Although not shown in the table, in the nonwoven fabrics of Examples 1 to 3, as a result of observation with an electron microscope, the splittable conjugate fibers present at the periphery of the opening were separated and separated between the constituent resins. In addition, it was confirmed that the degree of the separation was larger than that of the split conjugate fiber present in the other part of the nonwoven fabric. Industrial applicability
本発明によれば、 通液性に優れ、 また摩擦に起因する毛羽立ちが起 りにく く、 十分な強度を有する不織布が得られる。  ADVANTAGE OF THE INVENTION According to this invention, the nonwoven fabric which is excellent in liquid permeability, does not easily generate fluffing due to friction, and has sufficient strength can be obtained.
また本発明によれば、 嵩高く柔軟で風合いが良好な不織布が得られ る。  Further, according to the present invention, a nonwoven fabric which is bulky, flexible and has a good texture can be obtained.

Claims

請 求 の 範 囲 The scope of the claims
1 . 少なく とも、 一方の外層を構成する第 1層と他方の外層を構成する 第 2層とを有する多層構造からなり、 分割型複合繊維を 5 ~ 4 0重量％ 及び熱融着性繊維を 6 0〜 9 5重量％含有する不織布であって、 前記第 1層には前記分割型複合繊維が 2 0重量％以下含まれていると 共に前記第 2層にはそれよりも多量の前記分割型複合繊維が含まれてお り、 1. At least a multilayer structure having a first layer constituting one outer layer and a second layer constituting the other outer layer, wherein the splittable composite fiber is 5 to 40% by weight and the heat-fusible fiber is A nonwoven fabric containing 60 to 95% by weight, wherein the first layer contains not more than 20% by weight of the splittable conjugate fiber, and the second layer has a larger amount of the splitting fiber. Type composite fiber,
前記不織布には多数の開孔が形成されており、 該開孔の周縁部に存す る前記分割型複合繊維が構成樹脂間で分割離間しており、 且つその分割 離間の程度が、 該不織布における他の部分に存する該分割型複合繊維の それよりも大きい不織布。  A large number of openings are formed in the nonwoven fabric, and the splittable conjugate fibers present at the periphery of the openings are separated and separated between constituent resins, and the degree of the separation is determined by the nonwoven fabric. A nonwoven fabric larger than that of the splittable conjugate fiber present in the other part of the nonwoven fabric.
2 . 前記分割型複合繊維として、 熱的作用又は機械的作用によって前記 構成樹脂間で分割離間が可能になっている繊維が用いられている請求の 範囲第 1項記載の不織布。 2. The nonwoven fabric according to claim 1, wherein the splittable conjugate fiber is a fiber that can be separated and separated between the constituent resins by a thermal action or a mechanical action.
3 . 前記分割型複合繊維の前記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の範囲第 1項記載の不織布。 3. The nonwoven fabric according to claim 1, wherein a hydrophilic agent is kneaded into at least one of the constituent resins of the splittable conjugate fiber.
4 . 前記分割型複合繊維の表面に親水化剤が施されている請求の範囲第 1項記載の不織布。 4. The nonwoven fabric according to claim 1, wherein a hydrophilizing agent is applied to the surface of the splittable conjugate fiber.
5 . 請求の範囲第 1項記載の不織布の製造方法であって、 5. The method for producing a nonwoven fabric according to claim 1, wherein
少なく とも前記第 1層及び前記第 2層を有する多層構造の不織布原反 に、 穿孔ピンを用いて多数の前記開孔を形成すると共に、 該開孔の周縁 部に存する前記分割型複合繊維に剪断力を加えて選択的に該分割型複合 繊維をその構成樹脂間で分割離間させる不織布の製造方法。  A multi-layered nonwoven fabric having at least the first layer and the second layer is provided with a large number of apertures using a piercing pin, and the split-type composite fiber present at the periphery of the apertures. A method for producing a nonwoven fabric, in which a shear force is applied to selectively divide the splittable conjugate fiber between its constituent resins.
6 . 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 ートとして請求の範囲第 1項記載の不織布を用い且つ該不織布における 前記第 1層の側を肌対向側として配した吸収性物品。 6. Liquid permeable top sheet, liquid impermeable back sheet and between both sheets An absorbent article having an intervening liquid-retaining absorbent, wherein the nonwoven fabric according to claim 1 is used as the surface sheet, and the first layer side of the nonwoven fabric is arranged as a skin-facing side. Absorbent articles.
PCT/JP2003/009178 2002-09-09 2003-07-18 Nonwoven fabric WO2004022831A1 (en)

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US7892622B2 (en) * 2007-02-12 2011-02-22 Carl Freudenberg Kg Method for manufacturing a tufted product, tufted product, and use thereof
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EP3437607A4 (en) * 2016-06-30 2019-05-08 Unicharm Corporation Absorbent article
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CN1681986A (en) 2005-10-12

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