WO2013094474A1 - Nonwoven fabric, manufacturing method therefor and manufacturing equipment therefor - Google Patents

Nonwoven fabric, manufacturing method therefor and manufacturing equipment therefor Download PDF

Info

Publication number
WO2013094474A1
WO2013094474A1 PCT/JP2012/082062 JP2012082062W WO2013094474A1 WO 2013094474 A1 WO2013094474 A1 WO 2013094474A1 JP 2012082062 W JP2012082062 W JP 2012082062W WO 2013094474 A1 WO2013094474 A1 WO 2013094474A1
Authority
WO
WIPO (PCT)
Prior art keywords
nonwoven fabric
support
convex
hot air
fiber web
Prior art date
Application number
PCT/JP2012/082062
Other languages
French (fr)
Japanese (ja)
Inventor
小森　康浩
Original Assignee
花王株式会社
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 花王株式会社 filed Critical 花王株式会社
Publication of WO2013094474A1 publication Critical patent/WO2013094474A1/en

Links

Images

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
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/736—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged characterised by the apparatus for arranging fibres
    • 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
    • A61F13/51104—Topsheet, i.e. the permeable cover or layer facing the skin the top sheet having a three-dimensional cross-section, e.g. corrugations, embossments, recesses or projections

Definitions

  • the present invention relates to a nonwoven fabric, a production method thereof, a production apparatus thereof, and an absorbent article using the nonwoven fabric.
  • U.S. Patent No. 6,053,836 discloses a method and apparatus for roughening and perforating a substantially continuous web of a substantially flat polymer film to conform to the shape of one or more three-dimensional shaped structures. It is disclosed.
  • This web forming structure has a large-diameter second opening, and the bottom of the large-diameter second opening is closed by a perforated wall.
  • the perforated wall includes a number of small-diameter first openings. The first opening having a small diameter is a perforation, which is formed by breaking the web with a high-pressure liquid.
  • a fluid mainly composed of gas is sprayed on a fiber assembly formed in a substantially sheet shape in a state where the fibers have a degree of freedom, and one of predetermined grooves, openings, or protrusions or
  • a technique for manufacturing a nonwoven fabric in which two or more are formed is disclosed.
  • the fibers are moved and separated by spraying a fluid mainly composed of gas from the other surface side of the fiber assembly by a predetermined spraying means, so that the grooves, openings, protrusions, etc. Form.
  • the nonwoven fabric is formed by heat-sealing the thermoplastic fibers contained in the fiber assembly by heat treatment with a predetermined heating device while maintaining the uneven shape.
  • the breathable support member that supports the fiber assembly has a substantially planar or substantially curved surface on the side that supports the fiber assembly in the breathable support member, and the surface of the substantially planar or substantially curved surface is substantially the same. It is said to be flat.
  • Patent Document 3 has a central portion and both end portions adjacent to the central portion and higher in height than the central portion, and a convex portion and a concave portion are dispersed and formed in the entire central portion.
  • a nonwoven fabric is disclosed in which the fiber assembly density in the recesses is lower than the protrusions, and the fiber assembly density at both ends is uniform.
  • a fiber web containing thermoplastic fibers is placed on a breathable conveyor having irregularities, and discontinuously in the width direction on the surface of the fiber web while being transported in a state where the fiber web is placed.
  • the fiber web After jetting gas, the fiber web is made to follow the concave part of the breathable conveyor to form the irregular part on the fiber web only at the part where the substrate is jetted, and then the fiber web is heated to fuse the thermoplastic fibers.
  • a manufacturing method of integration is disclosed.
  • the nonwoven fabric of the present invention is a first concavo-convex structure in which a first convex portion projecting to the first surface side of the sheet-shaped nonwoven fabric in plan view and a first concave portion surrounded by the first convex portion are arranged.
  • the second convex portion includes a second convex portion projecting to the first surface side and a second concave portion projecting to the second surface side opposite to the first surface side.
  • a second concavo-convex structure whose height is lower than that of the first convex portion, and the second convex portion provides a non-woven fabric (hereinafter referred to as a first non-woven fabric) having a lower density than the second concave portion.
  • the nonwoven fabric of the present invention includes a first convex portion projecting to the first surface side of the sheet-shaped nonwoven fabric in plan view, a first concave-convex structure in which a first concave portion surrounding the first convex portion is disposed,
  • the upper surface of the first convex portion has a second concavo-convex structure in which a second convex portion protruding to the first surface side and a second concave portion protruding to the second surface side opposite to the first surface side are arranged,
  • the second concave portion provides a non-woven fabric (hereinafter referred to as a second non-woven fabric) having a lower density than the first convex portion.
  • a fiber web containing thermoplastic fibers is conveyed on a support in which a plurality of support parts having a plurality of protrusions and a plurality of holes are arranged at a predetermined interval.
  • first hot air and second hot air are blown to form a first concavo-convex structure in which a first convex portion and a first concave portion surrounded by the first convex portion are arranged, and the bottom surface of the first concave portion is A second convex portion and a second concave portion are arranged, and the second convex portion has a step of forming a second concave-convex structure having a height lower than that of the first convex portion, and the fiber web includes fibers of the fiber web.
  • the first hot air having a temperature of 60 ° C.
  • a plurality of support portions each having a plurality of protrusions and a plurality of holes are arranged at a predetermined interval and the height between the support portions is higher than the support.
  • a support body portion is disposed, a fiber web containing thermoplastic fibers is conveyed onto the support body on which both support body portions are disposed, and a first hot air and a second hot air are blown to the first recess and the first
  • the second hot air having a temperature higher than that of the first hot air is blown to maintain the temporarily fused shape and the fibers are retained.
  • the first nonwoven fabric manufacturing apparatus of the present invention includes a support body in which a plurality of support body portions provided with a plurality of protrusions and a plurality of holes are arranged at predetermined intervals, and a thermoplastic fiber conveyed on the support body.
  • a first concavo-convex structure in which a first convex part and a first concave part are formed on the fiber web by the support and the interval having a low height is produced, and the protrusion and the hole of the support part are provided on the fiber web.
  • a nonwoven fabric manufacturing apparatus in which a second concavo-convex structure in which a second convex portion and a second concave portion having a height lower than that of a first convex portion are formed is produced.
  • a plurality of support portions having a plurality of protrusions and a plurality of holes are arranged at predetermined intervals, and the height between the support portions is higher than that of the support.
  • a second nozzle that blows high-temperature second hot air, and the first convex portion is formed on the fiber web by the support body portion and another support body portion having a height higher than the second nozzle portion.
  • the first concavo-convex structure in which the first convex portion is formed on the fiber web is manufactured by the support portion, and the height of the fiber web is higher than that of the first convex portion by the protrusion and the hole of the support portion.
  • a second concavo-convex structure in which a low second convex portion and a second concave portion are shaped is produced. Providing a nonwoven manufacturing apparatus.
  • the present invention is a nonwoven fabric that suppresses leakage of highly viscous liquid such as soft stool when used as a surface material for absorbent articles.
  • the nonwoven fabric 10 of the present invention is preferably applied to a top sheet of an absorbent article such as a disposable diaper, and the first side Z1 is used with the skin side of the wearer, and the second side Z2 is used inside the article. It is preferable to arrange and use on the absorber (not shown) side.
  • the absorber (not shown) side it demonstrates considering the embodiment which uses the 1st surface side Z1 of the nonwoven fabric 10 shown in drawing toward a wearer's skin surface, this invention is limited to this and is not interpreted.
  • the first nonwoven fabric 10A as the nonwoven fabric 10 of the present invention includes a first convex portion 11 projecting to the first surface side Z1 on the side of the sheet-like nonwoven fabric in plan view, and the first surface side.
  • a plurality of first recesses 12 are recessed in the second surface side Z2 opposite to Z1.
  • Each first recess 12 is arranged, for example, vertically and horizontally over the entire surface of the first nonwoven fabric 10 ⁇ / b> A, and the first protrusion 11 is arranged so as to surround each first recess 12. Therefore, it is preferable that the 1st convex part 11 is distribute
  • the first concavo-convex structure 13 is formed by the first convex portion 11 and the first concave portion 12.
  • the bottom surface portion of the first concave portion 12 includes a second convex portion 21 having a height H2 lower than the height H1 of the first convex portion 11 with respect to the lowermost surface SB of the first concave portion 12, and a second concave portion 22.
  • the second concavo-convex structure 23 is arranged.
  • the second concavo-convex structure 23 is a nonwoven fabric structure in which the second convex portions 21 are lower in density and bulky than the second concave portions 22.
  • the second convex portions 21 and the second concave portions 22 are alternately arranged in different directions within the bottom surface of the first concave portion 12.
  • the 2nd convex part 21 seen from the 1st surface side Z1 is 21 A of 1st protrusion parts
  • the 2nd recessed part 22 seen from the 2nd surface side Z2 becomes 22 A of 2nd protrusion parts. Therefore, a part is shared by the 1st protrusion part 21A and the 2nd protrusion part 22A.
  • a wall 21W is provided between the top of the first protrusion 21A (hereinafter also referred to as the first protrusion top) 21T and the opening 21H.
  • the wall portion 21W forms an annular structure at the first protruding portion 21A.
  • a wall 22W is provided between the top of the second protrusion 22A (hereinafter also referred to as the second protrusion top) 22T and the opening 22H.
  • the wall 22W has an annular structure in the second protrusion 22A.
  • the wall 21W and the wall 22W share at least a part.
  • the “annular” here is not particularly limited as long as it has a series of endless shapes in plan view, and may be any shape such as a circle, an ellipse, a rectangle, or a polygon in plan view. . In order to maintain the continuous state of the sheet suitably, a circle or an ellipse is preferable.
  • any ring structure such as a cylinder, a slanted cylinder, an elliptical column, a truncated cone, a truncated cone, a truncated elliptical cone, a truncated quadrangular pyramid, a truncated oblique pyramid can be mentioned.
  • a cylinder, an elliptical column, a truncated cone, and a truncated elliptical cone are preferable.
  • the first nonwoven fabric 10A having the first and second projecting portions 21A and 22A arranged as in the above-described example does not have a bent portion, and is configured by a continuous curved surface as a whole.
  • the first nonwoven fabric 10A preferably has a continuous structure in the surface direction. This “continuous” means that there are no intermittent portions or small holes. However, fine holes such as gaps between fibers are not included in the small holes.
  • the small hole can be defined, for example, as a hole having a diameter equivalent to a circle of 1 mm or more.
  • the height of the first convex portion 11 is 3 mm or more and 10 mm or less, preferably 4 mm or more and 9 mm or less, more preferably 6 mm or more and 8 mm or less.
  • the 2nd convex part 21 is 2 mm or more lower than the 1st convex part 11, Preferably it is 3 mm or more lower, More preferably, it is 4 mm or more lower height, and the height H2 of the 2nd convex part 21 is 1 mm. Above, preferably 2 mm or more, more preferably 3 mm or more. By setting it as these dimensions, the touch feeling is favorable and leakage of liquids with high viscosity such as loose stool can be prevented.
  • the above-described highly viscous liquid refers to a highly viscous liquid such as soft stool or menstrual blood (for example, a liquid having a viscosity of 10 mPa ⁇ s to 350 mPa ⁇ s).
  • the fiber material that can be used for the first nonwoven fabric 10A of the present invention is not particularly limited. Specific examples include the following fibers. There are polyolefin fibers such as polyethylene (PE) fibers, polypropylene (PP) fibers, etc., and there are fibers that use a thermoplastic resin such as polyethylene terephthalate (PET) and polyamide alone, and core-sheath type, side-by-side type, etc. There is a composite fiber of structure. In the present invention, it is preferable to use a composite fiber.
  • the composite fiber examples include a core-sheath fiber having a high melting point component as a core portion and a low melting point component as a sheath portion, and a side-by-side fiber in which a high melting point component and a low melting point component are arranged in parallel.
  • Preferred examples thereof include fibers having a core-sheath structure in which the sheath component (low-melting-point component) is polyethylene or low-melting-point polypropylene.
  • the fibers having the core / sheath structure include PET (core) / PE ( Examples include fibers having a core-sheath structure such as (sheath), PP (core) / PE (sheath), polylactic acid (core) / PE (sheath), and PP (core) / low melting point PP (sheath). More specifically, the constituent fibers preferably include polyolefin fibers such as polyethylene fibers and polypropylene fibers, polyethylene composite fibers, and polypropylene composite fibers.
  • the composite composition of the polyethylene composite fiber is polyethylene terephthalate / polyethylene
  • the composite composition of the polypropylene composite fiber is preferably polyethylene terephthalate / low-melting polypropylene, and more specifically, PET (core). / PE (sheath), PET (core) / low melting point PP (sheath).
  • PET core
  • PE sheath
  • PET core
  • low melting point PP sheath
  • the fiber density of 21 A of 1st protrusion parts and 22 A of 2nd protrusion parts differs. Specifically, the fiber density of the first protrusion 21A is lower than the fiber density of the second protrusion 22A. Preferably 30 present / mm 2 or more 130 present / mm 2 or less in the measurement method the fiber density of the first protrusion (second protrusion) 21A is described below, and more preferably 50 lines / mm 2 or more 100 / mm 2 or less .
  • the fiber density in the second projecting portion (second recess) 22A is described later, 300 lines / mm 2 or more 450 present / mm 2 or less being more preferred.
  • the difference of the fiber density in 21 A of 1st protrusion parts (2nd convex part) and the fiber density in 22 A of 2nd protrusion parts (2nd recessed part) is 150 pieces / mm ⁇ 2 > or more. Since the difference in fiber density occurs in this way, when the first nonwoven fabric 10A is used as the top sheet of the absorbent article, the liquid is supplied from the first surface side Z1 of the first nonwoven fabric 10A.
  • the local thickness of the sheet curved in the unevenness is the layer thickness TL.
  • the sheet thickness TS may be appropriately adjusted depending on the application, but when used as a surface sheet for diapers, sanitary products, etc., it is preferably 1 mm or more and 7 mm or less, and more preferably 1.5 mm or more and 5 mm or less. By setting it as the range, the body fluid absorption speed at the time of use is high, the liquid return from an absorber is suppressed, and also moderate cushioning property is realizable.
  • the layer thickness TL may be different in each part in the sheet, and may be appropriately adjusted depending on the application.
  • the layer thickness TL1 of the first protrusion top 21T is preferably 0.1 mm or more and 3 mm or less, and more preferably 0.4 mm or more and 2 mm or less.
  • the preferable range of the layer thickness is the same for the layer thickness TL2 of the second protrusion top 22T and the layer thickness TL3 of the wall 21W.
  • the relationship between the layer thicknesses TL1, TL2, and TL3 is preferably TL1>TL3> TL2.
  • the second protruding portion 22A has a high fiber density, is not easily crushed, and can be a nonwoven fabric excellent in cushioning properties and liquid absorption speed without being deformed.
  • the distance between the first protrusion 21A and the second protrusion 22A in plan view may be adjusted as appropriate depending on the application. When used as a top sheet for diapers, sanitary products, etc., it is preferably 1 mm to 15 mm, preferably 3 mm to 10 mm. The following is more preferable.
  • the above basis weight of the first nonwoven 10A is not particularly limited, but is preferably 15 g / m 2 or more 50 g / m 2 or less the average value of the entire sheet, 20 g / m 2 or more 40 g / m 2 or less is more preferable.
  • a part of the second surface side Z2 opposite to the first surface side Z1 of the first convex portion 11 is a flat surface 11S. It is preferable that the surface 11S is on the same plane as the virtual plane S with which the second concavo-convex structure 23 contacts on the second plane side Z2, or on the second plane side Z2 from the virtual plane S. With this configuration, the contact area with the absorbent body 3 can be secured at the portion of the flat surface 11 ⁇ / b> S of the first convex portion 11, so that a sufficient adhesion area with respect to the absorbent body 3 can be secured.
  • the fixability of the first nonwoven fabric 10A as the surface material with respect to the absorbent body 3 can be improved, and the first nonwoven fabric 10A can be prevented from being swung and lifted to improve the absorbability.
  • first recess 22 in which the second uneven structure 23 is arranged will be described with reference to FIG.
  • vertically long rectangular first recesses 12 are arranged at equal intervals vertically and horizontally over the entire surface of the nonwoven fabric 10 in plan view.
  • the 1st convex part 11 is distribute
  • the 1st convex part 11 is continuous means that the 1st convex part 11 is the state which forms the sheet of nonwoven fabric continued in the state except each 1st recessed part 12. As shown in FIG. The same applies hereinafter.
  • Such an arrangement of the first recesses 12 can suppress liquid spreading in the vertical and horizontal directions, particularly in the horizontal direction.
  • the first rectangular recesses 12 that are vertically long in the drawing are arranged at equal intervals vertically and horizontally and shifted by, for example, 1 ⁇ 2 pitch in the longitudinal direction over the entire planar view of the nonwoven fabric 10.
  • the first recesses 12 may be shifted in the lateral direction by, for example, 1 ⁇ 2 pitch.
  • the 1st convex part 11 is continuously distribute
  • first recesses 12 are arranged vertically and horizontally at equal intervals over the entire surface of the nonwoven fabric 10 in plan view.
  • the first recesses 12 may be shifted in the vertical direction or the horizontal direction by, for example, 1 ⁇ 2 pitch.
  • the 1st convex part 11 is continuously distribute
  • circular first recesses 12 are arranged vertically and horizontally at equal intervals over the entire planar view of the nonwoven fabric 10.
  • an ellipse or an ellipse may be used instead of a circle.
  • the arrangement in the vertical direction or the horizontal direction may be shifted by, for example, 1 ⁇ 2 pitch.
  • the 1st convex part 11 is continuously distribute
  • the heart-shaped first recesses 12 are arranged in the lateral direction at equal intervals over the entire planar view of the nonwoven fabric 10, and the heart-shaped first recesses 12 arranged in the lateral direction are arranged in the horizontal direction.
  • One group is arranged in a staggered manner in the vertical direction. That is, it is arranged so that the pointed portions of each heart shape of another first group enter between the heart shapes of the first group on the sharp side of each heart shape.
  • the rounded side of each heart-shaped member of the first group is arranged so as to face the rounded part of each heart-shaped member of another first group.
  • the 1st convex part 11 is distribute
  • Such an arrangement of the first recesses 12 can improve the appearance design. Moreover, liquid spreading in the vertical and horizontal directions can be suppressed.
  • the first recesses 12 are arranged in stripes at equal intervals in the longitudinal direction of the drawing over the entire surface of the nonwoven fabric 10 in plan view. Moreover, the 1st convex part 11 is distribute
  • the pattern shape and the arrangement example of the first recess 12 described above are merely examples, and are not limited to the above shape and arrangement example, and can be changed as appropriate. For example, various shapes such as a cross shape and an H shape may be used. Further, different shapes such as a combination of a heart shape and a diamond shape, a combination of a cross shape and a square shape, and the like may be combined.
  • the first nonwoven fabric 10A of the first embodiment of the present invention has the following effects.
  • the first non-woven fabric 10A (see FIG. 1) is excellent in trapping of excrement, particularly liquid with high viscosity such as loose stool.
  • a liquid such as soft stool is supplied to the second uneven structure 23.
  • a highly viscous liquid such as soft stool spreads in the second concavo-convex structure 23, but the spread of the liquid is blocked by the first convex portion 11, so that further spread can be suppressed.
  • the second convex portion 21 has a lower density than the second concave portion 22 (fiber density of the first protruding portion 21A ⁇ fiber density of the second protruding portion 22A) and is bulky, the second uneven structure 23 When a liquid such as soft stool is supplied, the second convex portion 21 guides it to the internal space. Furthermore, since the fiber density of the 1st convex part 11 is uniform, it does not leak partially.
  • the first nonwoven fabric 10A (see FIG. 1) has an excellent cushioning property. Since the first nonwoven fabric 10A of the present embodiment has not only one side of the front and back sides but also protruding portions on both sides, the first nonwoven fabric 10A expresses a cushioning characteristic peculiar to the structure. For example, streak-like projections or single-sided projections will inevitably exhibit elasticity as lines or surfaces. However, according to this embodiment, the two-dimensional movement is well followed and supported by points on both sides. Has a three-dimensional cushioning. Moreover, the moderate cushioning property which a fiber does not collapse in the thickness direction by the wall part 21W can be expressed, and even if a packing state and wearing are continued, the initial cushion force is maintained by the shape restoring force. It becomes easy. That is, the first and second projecting portions 21A and 22A are not easily crushed and can be easily recovered even if deformation occurs.
  • the first nonwoven fabric 10A (see FIG. 1) is excellent in touch.
  • the first nonwoven fabric 10A of the present embodiment has first and second projecting portions 11A and 21A in both directions, and the top portions 11T and 21T are rounded. Therefore, whichever surface is the skin side, a good touch that the top sheet softly contacts the skin with respect to the skin is realized.
  • the point of contact with the pressure at the time of wearing increases and decreases in a planar shape, and the shape deformation of the entire topsheet against pressure can be suppressed while improving the touch, and shape restoration from pressure deformation can also be achieved Easy to do.
  • action resulting from said favorable cushioning property and a unique favorable touch is obtained with the dynamic effect
  • the point contact mentioned above has an effect also when excretion etc. are received, and the smooth touch is implement
  • the first nonwoven fabric 10 ⁇ / b> A (see FIG. 2) is excellent in fixability to the absorbent body 3. Since the contact area with the absorber 3 can be ensured at the portion of the flat surface 11S of the first convex portion 11, sufficient adhesion to the absorber 3 is possible, and the fixability as a surface material is improved. . For this reason, it is possible to prevent the first nonwoven fabric 10 ⁇ / b> A from being lifted or lifted from the absorber 3.
  • the 2nd nonwoven fabric 10B as the nonwoven fabric 10 of this invention is the 1st convex part 11 which protrudes to the 1st surface side Z1 of the side which planarly viewed the nonwoven fabric of the sheet
  • Each 1st convex part 11 is distribute
  • the first concavo-convex structure 13 is formed by the first convex portion 11 and the first concave portion 12.
  • the upper surface of the first convex portion 11 forms a second concavo-convex structure 23 in which the second convex portion 21 and the second concave portion 22 are arranged.
  • the second concavo-convex structure 23 is a web shaping in which the second convex portions 21 are lower in density and bulky than the second concave portions 22.
  • the second convex portions 21 and the second concave portions 22 are alternately arranged in different directions in the upper surface of the first convex portion 11.
  • the second uneven structure 23 is the same as the first nonwoven fabric 10A. That is, the 2nd convex part 21 seen from the 1st surface side Z1 is the 1st protrusion part 21A, and the 2nd recessed part 22 seen from the 2nd surface side Z2 is the 2nd protrusion part 22A. Further, the first projecting portion 21A has an annular structure wall portion 21W, and the second projecting portion 22A has an annular structure wall portion 22W, and the wall portion 21W and the wall portion 22W share a part.
  • the second nonwoven fabric 10B having the first and second protruding portions 21A and 22A arranged as in the above example does not have a bent portion, and is configured by a continuous curved surface as a whole.
  • the depth of the first recess 12 is 1 mm or more and 10 mm or less, preferably 2 mm or more and 10 mm or less, more preferably 3 mm or more and 10 mm or less, thereby preventing leakage of highly viscous liquid such as soft stool. .
  • the depth is 10 mm or less, it is preferable that the three-dimensional shape is not easily crushed.
  • the second convex portion 21 has a height of 1 mm or more, preferably 2 mm or more, more preferably 3 mm or more, so that the cushioning property is good and the touch feeling is good.
  • the bottom surface of the first recess 12 is a flat surface 12S.
  • the flat surface 12S facilitates adhesion between the bottom surface of the first recess 12 and the absorbent body 3 and improves the fixability of the second nonwoven fabric 10B as the surface material, so that the second nonwoven fabric 10B can be warped or lifted. Can be prevented.
  • the fiber material that can be used for the second nonwoven fabric 10B of the present invention is not particularly limited. Specifically, the same fibers as the first nonwoven fabric 10A can be mentioned.
  • the fiber density of the 1st protrusion part 21B and the 2nd protrusion part 22B differs. Specifically, the fiber density of the first protrusion 21B is lower than the fiber density of the second protrusion 22B. Preferably 30 present / mm 2 or more 130 present / mm 2 or less in the measurement method the fiber density of the first protrusion (second protrusion) 21B is described below, and more preferably 50 lines / mm 2 or more 100 / mm 2 or less .
  • the fiber density in the second protrusion (second recess) 22B is preferably 250 / mm 2 or more and 500 / mm 2 or less, more preferably 300 / mm 2 or more and 450 / mm 2 or less in the measurement method described later. Moreover, it is preferable that the difference of the fiber density in the 1st protrusion part (2nd convex part) 21B and the fiber density in the 2nd protrusion part (2nd recessed part) 22B is 150 pieces / mm ⁇ 2 > or more. Since the difference in fiber density occurs in this way, when the second nonwoven fabric 10B is used as the top sheet of the absorbent article, the liquid is supplied from the first surface side Z1 of the second nonwoven fabric 10B.
  • the local thickness of the sheet curved in the unevenness is the layer thickness TL.
  • the sheet thickness TS may be appropriately adjusted depending on the application, but when used as a surface sheet for diapers, sanitary products, etc., it is preferably 1 mm or more and 7 mm or less, and more preferably 1.5 mm or more and 5 mm or less. By setting it as the range, the body fluid absorption speed at the time of use is high, the liquid return from an absorber is suppressed, and also moderate cushioning property is realizable.
  • the layer thickness TL is the same as that of the above-described first nonwoven fabric 10A (first embodiment), may be different in each part in the sheet, and may be appropriately adjusted depending on the application. Moreover, the space
  • the pattern example applicable to the second uneven structure 23 of the second nonwoven fabric 10B can be the same pattern as the second uneven structure 23 that can be used for the first nonwoven fabric 10A.
  • the second nonwoven fabric 10B has the following effects.
  • the second non-woven fabric 10B is excellent in the trapping property of highly viscous liquid such as excrement, particularly soft stool.
  • the second concavo-convex structure 23 is formed on the upper surface of the first convex portion 11, when a liquid such as soft stool is supplied to the second concavo-convex structure 23,
  • the liquid having high viscosity such as soft stool spreads in the first convex portion 11, but the spread of the liquid is blocked by the side wall portion of the first convex portion 11, that is, the outer side of the first concave portion 12, and so on. Can be suppressed.
  • a highly viscous liquid such as soft stool that has flowed through the surface of the second concavo-convex structure 23 flows into the first recess 12 and can prevent further spread.
  • the second convex portion 21 has a lower density than the second concave portion 22 (fiber density of the first protruding portion 21A ⁇ fiber density of the second protruding portion 22A) and is bulky, the second uneven structure 23 When liquid such as soft stool is supplied to the first convex portion 11, the second convex portion 21 guides the liquid into the internal space of the first convex portion 11 and stores it. Furthermore, since the fiber density of the 1st convex part 11 is uniform, it does not leak partially.
  • the second non-woven fabric 10B has an excellent cushioning property as in the case of the first non-woven fabric 10A, and is excellent in the touch.
  • the nonwoven fabric manufacturing apparatus 100 includes a support 110 that conveys a fiber web 50 containing thermoplastic fibers and imparts a shaping shape.
  • the support 110 has a drum 111 that is rotated by a driving device (not shown) and a support portion 112 that is disposed on the surface of the drum 111.
  • the first nonwoven fabric 10 ⁇ / b> A and the second nonwoven fabric 10 ⁇ / b> B described above are produced by the uneven shape of the support body portion 112.
  • the drum 111 is provided with a ventilation portion (not shown) over the entire surface.
  • the fiber web 50 is supplied to the surface of the support 110 by a transfer conveyor as the transfer unit 131, and the shaped fiber web 50 is sent out from the support 110 by a guide roller as the guide unit 132 in a predetermined direction.
  • the support body 110 (110 ⁇ / b> A) used when the above-described nonwoven fabric 10 ⁇ / b> A is manufactured has the support body portion 112 arranged on the surface of the drum 111 at a predetermined interval.
  • the support body portion 112 for example, protrusions 114 and holes 115 are alternately arranged in the longitudinal and lateral directions of the support base portion 113.
  • the height of the surface of the support base 113 is higher than the surface of the drum 111 by a height ⁇ h1. By having this height ⁇ h1, the height of the first convex portion 11 when the first nonwoven fabric 10A is produced becomes higher than the height of the second convex portion 21.
  • the ventilation portion 117 of the drum 111 is disposed so as to communicate with the hole 115 when the support body portion 112 is disposed on the surface of the drum 111.
  • the predetermined interval between the support portions 112 creates the first protrusions 11 of the first nonwoven fabric 10A, and the support portions 112 are the second recesses 12 of the first nonwoven fabric 10A, that is, the second uneven structure 23.
  • the second convex portion 21 and the second concave portion 22 are created.
  • the support 110 (110B) used when producing the second nonwoven fabric 10B described above has the support 112 placed on the surface of the drum 111 at a predetermined interval.
  • the support body portion 112 for example, protrusions 114 and holes 115 are alternately arranged in the longitudinal and lateral directions of the support base portion 113.
  • the ventilation portion 117 of the drum 111 is disposed so as to communicate with the hole 115 when the support body portion 112 is disposed on the surface of the drum 111.
  • another support 116 is disposed at the predetermined interval. This other support 116 is higher than the height of the support 112 by ⁇ h2.
  • the first concave portion 12 is formed around the first convex portion 11 when the second nonwoven fabric 10B is produced.
  • the support body 112 creates the first protrusions 11 of the second nonwoven fabric 10B, that is, the second protrusions 21 and the second recesses 22 of the second uneven structure 23.
  • the support 116 is adapted to create the first recess 12 of the second nonwoven fabric 10B.
  • the protrusion 114 has a shape that tapers toward the tip, and the tip has a round shape, for example, a spindle shape.
  • the height varies depending on the use, standard, etc. of the nonwoven fabric, and is not particularly limited, but is usually formed to 3 mm to 30 mm, the protrusion pitch is 6 mm to 15 mm in the MD direction, and 4 mm to 8 mm in the CD direction. It is as follows.
  • the MD direction is the conveyance direction of the fiber web 50
  • the CD direction is a direction perpendicular to the MD direction on the surface of the support 110. If the height of the projection 114 is too low, sufficient unevenness cannot be formed on the fiber web 50.
  • the protrusion 114 is appropriately set within the above range. And preferably, it is formed at a height of 3 mm or more and 10 mm or less, is arranged in the MD direction at 6 mm or more and 10 mm or less, and is arranged in the CD direction at 4 mm or more and 6 mm or less.
  • the hole 115 is composed of a plurality of openings disposed in the support 110, and the opening ratio is set to 20% or more and 45% or less with respect to the surface area of the support 110. This aperture ratio is preferably set to 25% or more and 40% or less, more preferably 30% or more and 35% or less. If the opening ratio is less than 20%, it is difficult to form a sufficient uneven shape on the fiber web 50. If the opening ratio exceeds 45%, the fiber web 50 is under the support 110 when hot air is blown. It may become difficult to peel off from the support 110, and the shaped shape may be deteriorated or fluff may be easily formed.
  • the fiber web 50 is transported so that the fiber web 50 is hooked by the protrusions 114 arranged on the support 112.
  • a first nozzle 121 that blows the first hot air W1 and a second nozzle 122 that blows the second hot air W2 are provided outside the support 110 in order along the supply direction of the fiber web 50. .
  • the first nozzle 121 includes a heater 123, and blows the first hot air W ⁇ b> 1 heated by the heater 123 to the surface of the support 110 through the air-permeable conveyor 133 having air permeability, for example, substantially perpendicularly.
  • the spray holes of the first nozzle 121 preferably have a length in the MD direction of 1 mm or more and 20 mm or less, and the length in the CD direction is a web width or more, or a width for shaping.
  • the spray holes have a shape in which one or more rows of slit holes are formed, and round holes, long holes or square holes are arranged in a staggered manner or in series in one or more rows.
  • the first hot air W1 is blown at a uniform wind speed in the width direction of the surface of the fiber web 50.
  • air, nitrogen, or water vapor heated to a predetermined temperature by the heater 123 can be used.
  • air that does not cost is used.
  • the temperature of the first hot air W ⁇ b> 1 blown from the first nozzle 121 is controlled by the heater 123 to a temperature at which the fibers of the fiber web 50 are temporarily fused so that the uneven shape is maintained.
  • the wind speed of the 1st hot air W1 is suitably adjusted so that the uneven
  • the aeration conveyor 133 holds the fiber web 50 along the surface of the support 110 while sandwiching the fiber web 50 with the support 110 until it passes the position where the first hot air W1 is blown before the position where it is blown. 50 is conveyed to the sending side. Disturbance and scattering of the fiber web 50 due to the first hot air W ⁇ b> 1 blown from the first nozzle 121 by the aeration conveyor 133 can be prevented.
  • the second nozzle 122 includes a heater 124, and blows the second hot air W2 heated by the heater 124 to the surface of the support 110, for example, substantially perpendicularly. It is desirable to use a punching metal that is regularly opened in the width direction and the flow direction as the spray hole of the second nozzle 122.
  • the open area ratio is preferably 10% or more and 40% or less, and more preferably 20% or more and 30% or less.
  • the blowing holes of the second nozzle 122 are formed, the second hot air W2 is blown at a uniform wind speed in the width direction of the surface of the fiber web 50.
  • the second hot air W2 air, nitrogen or water vapor heated by the heater 124 can be used. Preferably, air that does not cost is used.
  • the temperature of the second hot air W2 blown from the second nozzle 122 is such that the fibers of the fiber web 50 are melted by the heater 124 while the uneven shape of the fiber web 50 temporarily fused with the first hot air W1 is maintained.
  • the temperature is controlled to fix the uneven shape by wearing.
  • the wind speed of the second hot air W2 is appropriately determined in consideration of its purpose. However, if the wind speed is too slow, heat cannot be transferred to the fibers, the fibers are not fused, and the uneven shape is insufficiently fixed. . On the other hand, when the wind speed is too high, heat is applied to the fiber too much, so that the texture tends to deteriorate.
  • a suction part 125 for sucking the first hot air W1 blown from the first nozzle 121 through the aeration conveyor 133, the fiber web 50, and the support 110 is disposed.
  • the suction unit 125 is connected to an exhaust device 127 that exhausts the sucked first hot air W1.
  • a suction portion 126 that sucks the second hot air W2 blown from the second nozzle 122 through the fiber web 50 and the support 110 is disposed.
  • the suction unit 126 is connected to an exhaust device 128 that exhausts the sucked second hot air W2.
  • any suction part can have a structure in which the length in the CD direction can be adjusted as appropriate.
  • a suction portion 126 By arranging such a suction portion 126, it is possible to prevent the web from being disturbed by the rebound of hot air to be blown or the like, and to stably shape the web into a desired shape.
  • the temperature around the drum can be prevented from becoming too high, and the web in contact with the drum can be prevented from being excessively fused and hardened. Furthermore, it becomes easy to hold the web on the support and the conveyance becomes easy. Considering the stabilization of hot air temperature and the running cost of utilities, it is desirable to circulate and use hot air.
  • the first hot air W1 can be blown by the first nozzle 121 to temporarily fuse the fibers of the fiber web 50 so that the uneven shape is maintained.
  • the second hot air W ⁇ b> 2 is blown by the second nozzle 122, the fibers of the fiber web 50 can be fused and fixed while maintaining the uneven shape.
  • the fibers of the fiber web 50 are softened by heat, so that it becomes easier to follow the surface shape of the support 112, and the irregular shape Retention is improved.
  • the fiber web 50 is more likely to follow along the surface of the protrusion 114. As a result, a low density and bulky nonwoven fabric with good formability can be obtained.
  • the fiber web 50 is deformed and weakly fixed between the fibers by the first hot air W1 blown from the first nozzle 121 so as to follow the uneven shape of the support 110, and is thermally fused by the second hot air W2 blown from the second nozzle 122. And non-woven fabric.
  • the deformation so as to conform to the uneven shape of the support 110 is not limited as long as it is deformed so as to be along a part of the support 110 and may not be completely in contact with the shape of the support 110T.
  • the fiber web 50 is too along the uneven shape of the support 110, not only the influence of the shape deformation and the formation of fluff at the time of separation from the support 110 described above, but also the substantial thickness of the nonwoven fabric is reduced.
  • the flexibility of the nonwoven fabric is impaired due to an increase in the fusion point of the fiber and excessive fiber fusion caused by contact with the support 110. For this reason, it is preferable that the tip of the protrusion 114 of the support 112 and the fiber web 50 are in direct contact with each other from the viewpoint of improving the shapeability, and the fiber web 50 is separated from the support 112 at the hole 115 side of the protrusion 114. It is preferable from the viewpoint of the flexibility of the nonwoven fabric and the formation of a low density structure.
  • the second hot air W2 can easily penetrate in the thickness direction of the fiber web 50, so that the fibers on the hot air blowing surface side and the support 110 side are Thus, a non-woven fabric that does not easily become fluff is obtained. From the same viewpoint, it is more preferable that a gap is formed between the fiber 115 and the hole 115.
  • the support 110 when the support 110 is in direct contact with the gap, the support 110 is repeatedly warmed by each hot air, so that the fiber fusion is excessively advanced on the surface of the fiber web 50 on the support 110 side.
  • the surface becomes hard and as a result, the texture deteriorates.
  • the influence of the heat of the support 110 can be reduced by separating from the support 110.
  • the apparatus configuration can be reduced in size and the area occupied by the apparatus can be reduced. Further, since the support body 110 is formed in a drum shape, the fibers of the shaped fiber web 50 are more easily separated from the support body portion 112 than the conventional conveyor-type support body.
  • the nonwoven fabric manufacturing apparatus 200 is different from the nonwoven fabric manufacturing apparatus 100 in the arrangement of the aeration conveyor 133, and other components are the same as those of the nonwoven fabric manufacturing apparatus 100. It is the same. That is, the ventilation conveyor 133 supports the support 110 while sandwiching the fiber web 50 between the support 110 and the position before the position where the second hot air W2 is blown before the position where the first hot air W1 is blown. The fiber web 50 is conveyed to the feed side along the surface. Disturbance and scattering of the fiber web 50 due to the first hot air W1 blown from the first nozzle 121 and the second hot air W2 blown from the second nozzle 122 by the aeration conveyor 133 can be prevented. Furthermore, the nonwoven fabric manufacturing apparatus 200 can obtain the same effects as the nonwoven fabric manufacturing apparatus 100 described above.
  • the manufacturing method of the nonwoven fabric of 1st Embodiment is implement
  • the case where the manufacturing apparatus 100 of a nonwoven fabric is used as an example is demonstrated.
  • the same manufacturing method is used when the nonwoven fabric manufacturing apparatus 200 is used.
  • the fiber web 50 is transported by the transport unit 131 to the surface of the support 110 on which the protrusions 114 are formed.
  • the fiber material that can be used for the fibers of the fiber web 50 is not particularly limited. Specifically, the above-mentioned fibers and the like can be mentioned.
  • the basis weight of the fiber web 50 is not particularly limited, but is preferably 10 g / m 2 or more and 50 g / m 2 or less, more preferably 20 g / m 2 or more and 40 g / m 2 or less.
  • the fiber web 50 conveyed to the surface of the support 110 is further conveyed so as to be sandwiched between the aeration conveyor 133 and the support 110.
  • the 1st hot air W1 is sprayed from the 1st nozzle 121, and it sprays on the fiber web 50 through the ventilation conveyor 133.
  • the first hot air W ⁇ b> 1 is blown from the direction perpendicular to the surface of the support 110.
  • the number of blowouts of the first nozzle 121 may be a plurality of locations along the conveying direction of the fiber web 50.
  • the fiber web 50 is shaped into a concavo-convex shape along the shape of the protrusion 114 of the support 110.
  • the fusion of the fibers of the fiber web 50 may be a temporary fusion that can maintain the uneven shape.
  • the temperature of the first hot air W1 varies depending on the type of fiber, the processing speed, the wind speed of the hot air, etc., and thus cannot be uniquely determined, but is 60 ° C. lower than the melting point of the low melting point component of the fiber of the fiber web 50. It is preferable to set the temperature to be equal to or higher than the temperature, and it is preferable to control the temperature to be equal to or lower than 15 ° C. higher than the melting point. More preferably, the temperature is controlled to a temperature that is 50 ° C. lower than the melting point of the low-melting point component or more and 10 ° C. lower than this melting point. For example, when polyethylene having a melting point of 132 ° C.
  • a preferable temperature range is 72 ° C. or higher and 147 ° C. or lower, more preferably 82 ° C. or higher and 142 ° C. or lower.
  • a fiber will return and shaping property will worsen.
  • the temperature is higher than the melting point of the low melting point component of the fiber of the fiber web 50 by 15 ° C., the fibers are fused at a stretch, and the formability is impaired due to a decrease in the degree of freedom.
  • the wind speed of the first hot air W1 is appropriately adjusted, but is preferably controlled to a wind speed of 10 m / sec or more and 120 m / sec or less. If the wind speed of the first hot air W1 blown from the first nozzle 121 is too slow, the fibers do not sufficiently follow the support and the fibers are weakly fused and cannot be shaped, resulting in a bulky uneven shape. On the other hand, if the wind speed is too high, the fibers of the fiber web 50 are selected by the protrusions 114 of the support body 112, and the fibers do not have an uneven shape along the shape of the support, and become a non-woven fabric with holes. Therefore, the wind speed of the first hot air W1 is preferably in the above range. More preferably, it is 20 m / sec or more and 80 m / sec or less, and particularly preferably 40 m / sec or more and 60 m / sec or less.
  • the first hot air W1 that has passed through the fiber web 50 is exhausted to the outside by the exhaust device 127 from the suction portion 125 through the hole 115 of the support 110.
  • the fiber web 50 is conveyed to the position where the second hot air W2 is blown from the second nozzle 122 as the support 110 rotates. Then, the second hot air W ⁇ b> 2 is blown by the second nozzle 122, and the fibers of the fiber web 50 are fused together while the uneven shape of the fiber web 50 is maintained, thereby fixing the uneven shape.
  • the second hot air W2 is blown from the direction perpendicular to the surface of the support 110.
  • the number of blowouts of the second nozzle 122 is preferably set at a plurality of locations along the direction in which the fiber web 50 is conveyed.
  • the temperature of the second hot air W2 varies depending on the type of fiber, the processing speed, the wind speed of the hot air, etc., it cannot be uniquely determined.
  • the fiber web 50 temporarily fused with the first hot air W1 by the heater 124. It is preferable to control the temperature to fix the uneven shape by fusing the fibers of the fiber web 50 while maintaining the uneven shape.
  • the fiber of the fiber web 50 is a composite fiber having a low melting point component and a high melting point component having a higher melting point than the low melting point component
  • the second hot air W2 is equal to or higher than the melting point of the low melting point component of the fiber of the fiber web 50.
  • the hot air at a temperature lower than the melting point of the high melting point component of the fiber of the fiber web 50, preferably 40 ° C. or higher than the melting point of the low melting point component. More preferably, the melting point is not less than the melting point of the low melting point component and not more than 20 ° C. above this melting point, and more preferably the temperature is not less than the melting point of the low melting point component and not more than 15 ° C. above this melting point. For example, when polyethylene having a melting point of 132 ° C. is used as the low melting point component, a more preferable temperature range is 132 ° C. to 152 ° C., more preferably 132 ° C. to 147 ° C. If the temperature of the second hot air W2 is lower than the melting point of the low melting point component of the fiber of the fiber web 50, the uneven shape retainability is insufficient. On the other hand, if the temperature is higher than 180 ° C., the texture becomes worse.
  • the wind speed of the second hot air W2 blown from the second nozzle 122 is appropriately determined in consideration of the purpose, but is preferably controlled to a wind speed of 1 m / sec or more and 10 m / sec or less. If the wind speed of the second hot air W2 blown from the second nozzle 122 is too slow, heat cannot be transferred to the fibers, the fibers will not be fused, and the uneven shape will be insufficiently fixed. On the other hand, if the wind speed is too high, the fiber will be too hot and the texture will tend to be poor. Therefore, the wind speed of the second hot air W2 is preferably in the above range. More preferably, it is 1 m / sec or more and 8 m / sec or less, and particularly preferably 2 m / sec or more and 6 m / sec or less.
  • the shaped fiber web 50 is sent out in a predetermined direction from the support 110 by a guide roller as the guide portion 132.
  • the first hot air W1 is sprayed to temporarily bond the fibers of the fiber web 50 so that the uneven shape is maintained, and then the second hot air W2 is sprayed.
  • the fibers of the fiber web 50 are fused together in a state where the concavo-convex shape is maintained, so that the concavo-convex shape can be fixed.
  • the fiber of the fiber web 50 is softened by the heat of the first hot air W1, it becomes easy to follow the shape of the protrusion 114 of the support 110, and the uneven shape retainability is improved. As a result, a low density and bulky nonwoven fabric with good formability can be obtained.
  • the first hot air W1 and the second hot air W2 are blown onto the fiber web 50, so that the first concavo-convex structure 13 formed into the first convex portion 11 and the first concave portion 12 surrounded by the first hot air W1 can be produced.
  • the bottom surface of the first concave portion 12 can be formed into the second concave-convex structure 23 shaped into the first convex portion 11 and the second convex portion 21 having a lower height. Therefore, when a highly viscous liquid such as soft stool is supplied to the second uneven structure 23, the liquid spreads in the first recess 12 where the second uneven structure 23 is located, but the liquid is expanded by the first protrusion 11. Can be produced, and a nonwoven fabric 10A that can suppress further spreading can be manufactured.
  • the first hot air W1 is blown onto the fiber web 50, and the fibers of the fiber web 50 are temporarily fused together to form an uneven shape along the shapes of the support body portion 112 of the support body 110 and another support body portion 116.
  • the step of shaping the fiber web 50 and the step of blowing the second hot air W2 onto the fiber web 50 and fusing the fibers together to fix the uneven shape are the same as described above.
  • the nonwoven fabric manufacturing method of the second embodiment has the same effects as the nonwoven fabric manufacturing method of the first embodiment described above.
  • the first hot air W1 and the second hot air W2 are blown onto the fiber web 50 to form the first concave portion 12 and the first convex portion 11 surrounded by the first concave portion 12 as shown in FIG.
  • the first uneven structure 13 can be produced.
  • the upper surface of the first convex portion 11 can be formed into the second concavo-convex structure 23 in which the second convex portion 21 and the second concave portion 22 are shaped.
  • the first hot air W1 and the second hot air W2 are exhausted to the outside, so that they do not diffuse around the apparatus.
  • the temperature rise in the atmosphere around the apparatus can be prevented. Therefore, it is possible to ensure the safety of work by an operator or the like working around the apparatus.
  • the illustrated absorbent article is, for example, a tape-type disposable diaper for infants, and is shown in a state where the disposable diaper developed in a plane is slightly bent and viewed from the inside (skin contact surface side).
  • the absorbent main body 4 used for the disposable diaper 5 of the present invention has the following basic configuration. That is, a liquid-permeable top sheet 1 disposed on the skin contact surface side, a liquid-impermeable back sheet 2 disposed on the non-skin contact surface side, and between the top sheet 1 and the back sheet 2 And an absorbent body 3 having liquid retention properties interposed between the two.
  • the non-woven fabric 10 of the above embodiment is applied to the top sheet 1.
  • the back sheet 2 is in an unfolded state, and both side edges thereof have a shape confined to the inside in the longitudinal central portion C. Even if the back sheet 2 is composed of a single sheet, it is composed of a plurality of sheets. Also good.
  • a side leakage prevention gather 7 formed by the side seat 6 is provided, and thereby side leakage of liquid or the like in the hip joint part due to the wearer's exercise or the like can be effectively prevented.
  • FIG. 12 the arrangement
  • the disposable diaper 5 is shown as a tape type, and a fastening tape 8 is provided on the flap portion on the back side R.
  • Fastening tape 8 can be affixed to a tape application part (not shown) provided in the flap part of ventral side F, and a diaper can be mounted and fixed.
  • the center part C of the diaper is gently bent inward and worn so that the absorbent body 3 runs along the lower abdomen from the buttocks.
  • excreta is absorbed and held in the absorber 3 accurately.
  • the non-woven fabric 10 is applied as the top sheet 1 in particular, so that the liquid flow of highly viscous liquid such as loose stool can be stopped at a predetermined position, and the touch is soft and supple.
  • the shape of the absorbent main body 4 is a vertically long shape having a longitudinal direction that is arranged from the lower abdomen side to the buttocks side through the wearer's crotch portion and a width direction perpendicular thereto.
  • the side in contact with the human body is referred to as the skin contact surface side or the surface side
  • the opposite side is referred to as the non-skin contact surface side or the back surface side.
  • a direction having a relatively long length in a plan view of the absorbent main body 4 is referred to as a longitudinal direction
  • a direction orthogonal to the longitudinal direction is referred to as a width direction.
  • the longitudinal direction typically coincides with the front-rear direction of the human body in a worn state.
  • the topsheet 1 is preferably a hydrophilic nonwoven fabric composed of the above-described nonwoven fabric 10 of the present invention.
  • the hydrophilic non-woven fabric fibers that have been subjected to a hydrophilic treatment with a composite fiber of polypropylene and polyethylene, a composite fiber of polyethylene terephthalate and polyethylene, or the like can be preferably used.
  • the back sheet 2 is not particularly limited as long as it is waterproof and moisture permeable.
  • a film is formed by melt-kneading a hydrophobic thermoplastic resin, a fine inorganic filler made of calcium carbonate or the like or an incompatible organic polymer, and the film is obtained by uniaxial or biaxial stretching.
  • a porous film is mentioned.
  • the thermoplastic resin include polyolefin.
  • the polyolefin include high-density to low-density polyethylene, linear low-density polyethylene, polypropylene, polybutene, and the like, and these can be used alone or in combination.
  • the absorbent body 3 for example, a fiber aggregate or a combination of this and an absorbent polymer can be used.
  • the fibers constituting the fiber assembly hydrophilic natural fibers such as pulp fibers, synthetic fibers (preferably subjected to hydrophilic treatment), and the like can be used.
  • the basis weight is not particularly limited, but is preferably 150 g / m 2 or more 500 g / m 2 or less.
  • covers the absorber 3 can also be used.
  • This coated sheet includes thin paper (thin paper) such as hydrophilic tissue paper, non-woven fabric made of hydrophilic fibers such as cotton and rayon, and non-woven fabric (spunbond-meltblown) obtained by subjecting synthetic resin fibers to hydrophilic treatment. Spunbond (SMS), spunbond-meltblown-meltblown-spunbond (SMMS), spunbond-spunbond-meltblown-spunbond (SSMS), etc.) can be used.
  • the disposable diaper 5 according to the present invention is a liquid that is provided by the first convex portion 11 (see FIG. 1) of the nonwoven fabric 10 according to the present invention as the top sheet 1 even when a highly viscous liquid such as soft stool is supplied. Flow can be prevented.
  • ⁇ 1> a first concavo-convex structure in which a first convex portion protruding to the first surface side on the side of the sheet-like nonwoven fabric in plan view and a first concave portion surrounded by the first convex portion are arranged;
  • the bottom surface of the first concave portion includes a second convex portion projecting to the first surface side and a second concave portion projecting to the second surface side opposite to the first surface side, and the second convex portion is Forming a second concavo-convex structure having a height lower than that of the first convex portion;
  • the said 2nd convex part is a nonwoven fabric whose density is lower than the said 2nd recessed part.
  • ⁇ 2> The nonwoven fabric according to ⁇ 1>, wherein in the second concavo-convex structure, the second convex portions and the second concave portions are alternately arranged in different directions within the bottom surface of the first concave portion.
  • ⁇ 3> The nonwoven fabric according to ⁇ 1> or ⁇ 2>, wherein the second convex portion is 2 mm or more lower than the first convex portion.
  • ⁇ 4> The nonwoven fabric according to any one of ⁇ 1> to ⁇ 3>, wherein the density of the second protrusions is 150 pieces / mm 2 or more higher than the density of the second recesses.
  • the first convex portion has a flat part on the second surface side opposite to the first surface side,
  • the flat surface is the non-woven fabric according to any one of ⁇ 1> to ⁇ 4>, wherein the second uneven structure is on the same plane as the virtual plane with which the second surface structure contacts on the second surface side or on the second surface side with respect to the virtual plane.
  • the vertically long rectangular first concave portions are arranged at equal intervals across the entire surface of the nonwoven fabric in plan view, and the first convex portions are continuously formed around the first concave portions so as to surround them.
  • the nonwoven fabric according to any one of ⁇ 1> to ⁇ 5> which is arranged.
  • the vertically long rectangular first recesses are arranged at equal intervals vertically and horizontally and shifted by 1/2 pitch in the longitudinal direction over the entire surface of the nonwoven fabric in plan view, and surround each of the first recesses.
  • the circular first recesses are arranged vertically and horizontally at equal intervals over the entire planar view of the nonwoven fabric, and the first protrusions are continuously arranged around each first recess so as to surround them.
  • the first concave portions are arranged at equal intervals in the vertical direction over the entire surface of the nonwoven fabric in plan view, and the first convex portions are continuously formed around the first concave portions so as to surround them.
  • the nonwoven fabric according to any one of ⁇ 1> to ⁇ 5>, which is arranged.
  • a first protrusion projecting toward the first surface on the side of the sheet-like nonwoven fabric in plan view, and a first uneven structure in which a first recess surrounding the first protrusion is disposed;
  • the upper surface of the first convex portion has a second concavo-convex structure in which a second convex portion protruding to the first surface side and a second concave portion protruding to the second surface side opposite to the first surface side are arranged.
  • the second recess is a nonwoven fabric having a lower density than the first protrusion.
  • ⁇ 11> The nonwoven fabric according to ⁇ 10>, wherein a difference between the fiber density in the second convex portion and the fiber density in the second concave portion is 150 pieces / mm 2 or more.
  • said 1st recessed part is a nonwoven fabric as described in ⁇ 10> or ⁇ 11> whose at least one part of the 2nd surface side opposite to the said 1st surface side is a flat surface.
  • a fiber web containing thermoplastic fibers is transported onto a support body in which a plurality of support body portions having a plurality of protrusions and a plurality of holes are arranged at predetermined intervals, and the first hot air and the second hot air are conveyed.
  • the second convex part is shaped into a second concavo-convex structure having a height lower than that of the first convex part,
  • the first hot air having a temperature 60 ° C. or more lower than the melting point of the low melting point component of the fiber of the fiber web is blown onto the fiber web so that the fiber web conforms to the shape of the support and the fibers are temporarily fused together.
  • the manufacturing method of the nonwoven fabric which fixes the shape by fuse
  • the fiber web is conveyed onto the support, and the first hot air is blown to temporarily fuse the first and second concavo-convex structures and the shapes of the second concavo-convex structures,
  • ⁇ 15> The nonwoven fabric according to ⁇ 13> or ⁇ 14>, wherein the first protrusion is formed by the predetermined interval of the support, and the first recess having a second uneven structure is formed by the support base.
  • a plurality of support portions each having a plurality of protrusions and a plurality of holes are arranged at a predetermined interval, and another support portion having a height higher than that of the support is disposed between the support portions.
  • the first convex portion surrounded by the first concave portion and the first concave portion by conveying the fiber web containing the thermoplastic fiber onto the support body on which the body portion is arranged, and blowing the first hot air and the second hot air. And forming the upper surface of the first convex portion with the first concave-convex structure arranged with the second convex-concave structure with the second convex portion and the second concave portion,
  • the first hot air having a temperature of 60 ° C. lower than the melting point of the low melting point component of the fiber of the fiber web is blown onto the fiber web so that the fiber web conforms to the shape of the support and the fibers are temporarily fused together.
  • the manufacturing method of the nonwoven fabric which fuses the fibers of the said fiber web and fixes the shape in the state which sprayed the said 2nd hot air of higher temperature than the said 1st hot air, and hold
  • the fiber web is transported onto the support, and the first hot air is blown to temporarily bond the first concavo-convex structure and the second concavo-convex structure into a state in which the shape is maintained,
  • ⁇ 19> The method for producing a nonwoven fabric according to any one of ⁇ 13> to ⁇ 18>, wherein the support has a drum shape.
  • the manufacturing method of the nonwoven fabric any one of ⁇ 18>from>.
  • the temperature of the first hot air is preferably 60 ° C.
  • the nonwoven fabric according to any one of ⁇ 13> to ⁇ 20>, which is preferably controlled to a temperature not higher than 15 ° C above the melting point, and more preferably controlled to a temperature not higher than 10 ° C higher than the melting point.
  • the temperature of the second hot air is preferably equal to or higher than the melting point of the low melting point component of the fiber of the fiber web, less than the melting point of the high melting point component of the fiber of the fiber web 50, and preferably 40 ° C. higher than the melting point of the low melting point component.
  • the temperature is controlled below the temperature, more preferably above the melting point of the low melting point component and below 20 ° C. below the melting point, and more preferably below the melting point of the low melting point component and below 15 ° C. above the melting point.
  • the manufacturing method of the nonwoven fabric any one of these.
  • a first hot air is applied to a support body in which a plurality of support portions provided with a plurality of protrusions and a plurality of holes are arranged at predetermined intervals, and a fiber web containing thermoplastic fibers conveyed on the support body.
  • a first nozzle for blowing, and a second nozzle for blowing a second hot air having a temperature higher than that of the first hot air to the fiber web A first concavo-convex structure in which a first convex portion and a first concave portion are formed on the fiber web by the spacing between the support portion and the support lower in height than the support portion, and the protrusion of the support portion is formed.
  • a non-woven fabric manufacturing apparatus in which a second concavo-convex structure in which a second convex portion and a second concave portion having a height lower than that of the first convex portion are formed on the fiber web is produced by the holes.
  • a support in which a plurality of support parts having a plurality of protrusions and a plurality of holes are arranged at predetermined intervals, and another support part having a height higher than the support is arranged between the support parts.
  • a body a first nozzle that blows first hot air onto a fiber web containing thermoplastic fibers conveyed on the support, and a second hot air that is hotter than the first hot air is blown onto the fiber web.
  • a second nozzle A first convex portion is formed on the fiber web by the support portion and another support portion having a height higher than the support portion, and a first concave portion is formed on the fiber web by the another support portion.
  • Nonwoven fabric manufacturing apparatus for producing ⁇ 25> A liquid-permeable front sheet disposed on the skin contact surface side, a liquid-impermeable back sheet disposed on the non-skin contact surface side, and an absorber interposed between the two sheets.
  • Have The said surface sheet is an absorbent article which consists of a nonwoven fabric any one of ⁇ 1> to ⁇ 12>.
  • the top sheet is a disposable diaper made of the nonwoven fabric according to any one of ⁇ 1> to ⁇ 12>.
  • Example 1 was manufactured under the following conditions by the manufacturing method of the first embodiment described above. That is, for the fiber of the fiber web 50, a composite fiber having a core-sheath structure in which the core part is polyethylene terephthalate (melting point is 255 ° C.) and the sheath part is polyethylene (melting point is 132 ° C.).
  • the fiber web 50 was conveyed by the support body 110 and the aeration conveyor 133, and the first hot air W1 and the second hot air W2 were blown on the surface of the support body 110 to form an uneven shape.
  • the first hot air W1 blown from the first nozzle is set to a temperature of 130 ° C.
  • Example 2 was produced by the same method as Example 1 except that ⁇ h1 was 1.5 mm.
  • Example 3 was produced by the same method as Example 1 except that ⁇ h1 was 4.5 mm.
  • Example 4 was manufactured by the manufacturing method of the second embodiment described above under the following conditions. That is, for the fiber of the fiber web 50, a composite fiber having a core-sheath structure in which the core part is polyethylene terephthalate (melting point is 255 ° C.) and the sheath part is polyethylene (melting point is 132 ° C.).
  • the fiber web 50 was conveyed by the support body 110 and the aeration conveyor 133, and the first hot air W1 and the second hot air W2 were blown on the surface of the support body 110 to form an uneven shape.
  • the first hot air W1 was set to a temperature of 130 ° C.
  • Example 5 was produced by the same method as Example 1 except that ⁇ h2 was 1.5 mm.
  • Example 6 was produced by the same method as in Example 1 except that ⁇ h2 was 4.5 mm.
  • the comparative example 1 manufactured the test body of the nonwoven fabric with the manufacturing method of the nonwoven fabric disclosed by the above-mentioned patent document 2.
  • a nonwoven fabric test body was manufactured by using the same thermoplastic fiber as in Example 1 and the nonwoven fabric manufacturing method disclosed in Patent Document 3 described above.
  • a non-woven fabric specimen was manufactured under the same conditions as in Example 1 above, except that the support 112 was placed without any gap.
  • the temperature of the first hot air W1 is measured directly under the outlet of the first nozzle 111 by the Anemo Master (manufactured by Nippon Kanomax Co., Ltd .: trade name), and the wind speed of the first hot air W1 is measured by the Pitot tube.
  • the static pressure was drawn from the total pressure just below the 111 outlet, and the dynamic pressure was measured, and was calculated from the flow velocity calculation formula using a Pitot tube.
  • the temperature of the second hot air W2 was measured immediately below the outlet of the second nozzle 112 by the anemo master.
  • the measurement method of the thickness of the nonwoven fabric was measured using a thickness measuring instrument in a state where a load of 0.05 kPa was applied to the nonwoven fabric.
  • a laser displacement meter manufactured by OMRON Corporation was used as the thickness measuring instrument.
  • the thickness was measured at 10 points, and the average value was calculated as the thickness.
  • the thickness of the first concavo-convex structure 13 is substantially the height H1 of the first convex portion 11
  • the thickness of the second concavo-convex structure 23 is the height of the second convex portion 21. H2.
  • the thickness of the first uneven structure 13 is substantially the height of the first protrusion 11 and the second uneven structure 23, and the second uneven structure 23 The thickness is the height of the first protrusion 11 as in the case of the nonwoven fabric 10A.
  • the step was obtained by subtracting the thickness of the second uneven structure 23 from the thickness of the first uneven structure 13.
  • the method for measuring the fiber density is to adjust the cut surface of the nonwoven fabric portion to a magnification (150 to 500 times) that can be measured with a scanning electron microscope (fiber cross section is 30 to 60) (this example And the number of the sections where the cross-sectional area of the fiber cut by the cut surface per fixed area appears was converted into the number of cross-sections of the fiber per 1 mm 2 , and The fiber density (lines / mm 2 ) was measured at three locations and averaged to be the fiber density of the sample.
  • the JEM-5100 (trade name) manufactured by JEOL Ltd. was used for the scanning electron microscope. ) was used.
  • the measuring method of the liquid flow of the loose stool is the absorbent body 3 (Marys (trademark registration) manufactured by Kao Corporation) on a 30 ° flat inclined surface. Put the absorber manufactured in 2011). Further, a nonwoven fabric test body 30A (nonwoven fabric 10A) is placed thereon. Then, 10 g of pseudo-soft stool 60 was supplied from 1 cm above the nonwoven fabric test body 30A, and the distance flowing over the nonwoven fabric test body 30A was measured. In the case of the nonwoven fabric test sample of Example 1, pseudo soft stool was supplied from the first convex portion 11 to a position 150 mm obliquely upward.
  • the absorbent body 3 (the absorbent body of Marys (trademark) manufactured by Kao Corporation) is placed on a flat inclined surface of 30 °. Further, a nonwoven fabric test body 30B (nonwoven fabric 10B) is placed thereon. Then, 10 g of pseudo-soft stool 60 was supplied from 1 cm above the nonwoven fabric test body 30A, and the distance flowing over the nonwoven fabric test body 30A was measured. In the case of the nonwoven fabric specimen of Example 1, pseudo soft stool was supplied to a position 150 mm obliquely upward from the upper end in the width direction of the first recess 12. The length of the first recess 12 in the width direction is 15 mm.
  • the distance from the supply position of the pseudo soft stool 60 to the lower end in the width direction of the first recess 12 is 165 mm.
  • the simulated soft stool 60 was prepared by adjusting the viscosity to 300 mPa ⁇ s by adding ion exchange water to 100% glycerin in an environment of room temperature 20 ° C. and humidity 60%. In addition, the flow of the soft stool fluid was also measured in the same environment.
  • the texture of the nonwoven fabric was judged by touch and suppleness for five monitors. The result was scored as 4 for a very soft and supple material, 3 for a soft and supple material, 2 for a soft, supple material, and 1 for a soft, supple material. Evaluated the average value of five people as follows. Evaluation result A: Judgment average 2.5 or more and less than 3.5 B: Judgment average 1.5 or more and less than 2.5 The liquid flow of the loose stool was measured by measuring the distance from the position where the artificial stool was supplied. As shown in FIG.
  • the method for evaluating the adhesiveness with the absorbent body is to place the absorbent body 3 (absorbent manufactured by Marys (trademark registered) 2011 manufactured by Kao Corporation) on a 30 ° flat inclined surface.
  • a hot melt adhesive (not shown) was spirally applied to the surface of the absorbent body 3
  • a nonwoven fabric test body 30 was bonded to the absorbent body 3 via the hot melt adhesive.
  • the application amount of the hot melt adhesive was 10 g / cm 2 .
  • the end portion of the nonwoven fabric test body 30 on the upper end side of the inclined surface was peeled downward along the inclined surface and evaluated as follows.
  • B Adhesion is easy to peel off
  • the basis weight of the fiber web 50 is 30 g / m 2
  • the thickness of the first uneven structure 13 is 6.75 mm
  • the second uneven structure 23 The thickness was 3.09 mm, and thus the step was 3.66 mm.
  • the fiber density of the 1st convex part 11 was 84 pieces / mm ⁇ 2 >
  • the fiber density of the 2nd convex part 21 was 82 pieces / mm ⁇ 2 >
  • the fiber density of the 2nd recessed part 22 was 435 pieces / mm ⁇ 2 >.
  • the touch was soft and supple
  • the texture was good
  • the evaluation result was "A". As shown in FIG.
  • the liquid flow of the pseudo soft stool 60 is 150 mm, and the pseudo soft stool 60 that could not be absorbed by the nonwoven fabric 10A or the absorbent body 3 flows on the surface of the nonwoven fabric 10A. 11 was able to stop the flow. Moreover, the adhesiveness with an absorber was firmly peeled off because the non-woven fabric test specimen was firmly adhered, and the evaluation result was “A”.
  • the basis weight of the fiber web 50 is 30 g / m 2
  • the thickness of the first uneven structure 13 is 5.16 mm
  • the thickness of the second uneven structure 23 is 3.02 mm
  • the level difference is 2. 14 mm.
  • the fiber density of the 1st convex part 11 was 82 pieces / mm ⁇ 2 >
  • the fiber density of the 2nd convex part 21 was 82 pieces / mm ⁇ 2 >
  • the fiber density of the 2nd recessed part 22 was 442 pieces / mm ⁇ 2 >.
  • the same evaluation results as in Example 1 were obtained for the texture, the flow of soft stool, and the adhesiveness with the absorber.
  • the basis weight of the fiber web 50 is 30 g / m 2
  • the thickness of the first uneven structure 13 is 8.11 mm
  • the thickness of the second uneven structure 23 is 3.03 mm
  • the step is 5. It was 08 mm.
  • the fiber density of the 1st convex part 11 was 85 pieces / mm ⁇ 2 >
  • the fiber density of the 2nd convex part 21 was 84 pieces / mm ⁇ 2 >
  • the fiber density of the 2nd recessed part 22 was 446 pieces / mm ⁇ 2 >.
  • the basis weight of the fiber web 50 is 30 g / m 2
  • the thickness of the first uneven structure 13 is 6.54 mm
  • the thickness of the second uneven structure 23 is 3.27 mm
  • the step is 3. It was 27 mm.
  • the fiber density of the 1st recessed part 12 was 82 pieces / mm ⁇ 2 >
  • the fiber density of the 2nd convex part 21 was 80 pieces / mm ⁇ 2 >
  • the fiber density of the 2nd recessed part 22 was 442 pieces / mm ⁇ 2 >.
  • the touch was soft and supple
  • the texture was good
  • the evaluation result was "A". As shown in FIG.
  • the liquid flow of the pseudo soft stool 60 is 165 mm, and the pseudo soft stool 60 that could not be absorbed by the nonwoven fabric 10B or the absorbent body 3 flows on the surface of the nonwoven fabric 10B. I was able to stop the flow. Moreover, the adhesiveness with an absorber became the same evaluation result as Example 1.
  • the basis weight of the fiber web 50 is 30 g / m 2
  • the thickness of the first uneven structure 13 is 4.99 mm
  • the thickness of the second uneven structure 23 is 3.11 mm
  • the level difference is 1. It was 88 mm.
  • the fiber density of the 1st recessed part 12 was 88 pieces / mm ⁇ 2 >
  • the fiber density of the 2nd convex part 21 was 84 pieces / mm ⁇ 2 >
  • the fiber density of the 2nd recessed part 22 was 455 pieces / mm ⁇ 2 >.
  • the same evaluation results as in Example 4 were obtained for the texture, the liquid flow of soft stool, and the adhesiveness with the absorber.
  • the basis weight of the fiber web 50 is 30 g / m 2
  • the thickness of the first uneven structure 13 is 8.11 mm
  • the thickness of the second uneven structure 23 is 3.05 mm
  • the step is 5. It was 06 mm.
  • the fiber density of the 1st recessed part 12 was 83 pieces / mm ⁇ 2 >
  • the fiber density of the 2nd convex part 21 was 84 pieces / mm ⁇ 2 >
  • the fiber density of the 2nd recessed part 22 was 460 pieces / mm ⁇ 2 >.
  • the same evaluation results as in Example 4 were obtained for the texture, the liquid flow of soft stool, and the adhesiveness with the absorber.
  • the basis weight of the fiber web was 27 g / m 2 , and the thickness of the first uneven structure was 1.3 mm.
  • the fiber density of the 1st convex part was 65 pieces / mm ⁇ 2 >, and the fiber density of the 2nd convex part was 0 piece / mm ⁇ 2 >.
  • evaluation of the texture was "B” and evaluation of adhesiveness with an absorber was "A”
  • the liquid flow of soft stool was 350 mm or more, and the liquid flow could not be stopped.
  • the basis weight of the fiber web was 27 g / m 2
  • the thickness of the first concavo-convex structure was 5.5 mm.
  • the fiber density of the 1st convex part was 80 piece / mm ⁇ 2 >, and the fiber density of the 2nd convex part was 0 piece / mm ⁇ 2 >.
  • evaluation of the texture was "A” and evaluation of adhesiveness with an absorber was "A”
  • the liquid flow of the soft stool was 350 mm or more, and the liquid flow could not be stopped.
  • the basis weight of the fiber web 50 was 30 g / m 2
  • the thickness of the nonwoven fabric (corresponding to the second uneven structure 23 of Example 1) was 3.14 mm.
  • the texture was good as in Example 1, and the evaluation result was “A”, but the adhesion to the absorber was easy to peel off, and the evaluation result was “B”.
  • the liquid flow of the soft stool was 220 mm, and the liquid flow could not be stopped in the middle of the nonwoven fabric.
  • the present invention can stop a liquid flow of a highly viscous liquid such as soft stool at a predetermined position, and can obtain a nonwoven fabric having a soft touch and a supple texture.

Landscapes

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

Abstract

Provided is a nonwoven fabric, wherein first contoured structures and second contoured structures are formed. In the first contoured structure, first protrusions that protrude toward the first surface, which is the side of the nonwoven fabric sheet that is seen in top view, and first recesses that are surrounded by the first protrusions are disposed. In the second contoured structure, second protrusions that protrude toward the first surface and second recesses that protrude toward the second surface, which is on the side opposite to the first surface, are disposed on the bottom surfaces of the first recesses and the height of the second protrusions is lower than the first protrusions. The second protrusions are less dense than the second recesses.

Description

不織布、その製造方法およびその製造装置Nonwoven fabric, manufacturing method thereof and manufacturing apparatus thereof
　本発明は不織布、その製造方法、その製造装置およびその不織布を用いた吸収性物品に関する。 The present invention relates to a nonwoven fabric, a production method thereof, a production apparatus thereof, and an absorbent article using the nonwoven fabric.
　使い捨ておむつ、パンティーライナー、及び生理用ナプキン等といった吸収性物品において、その機能に応じて、シート材の片面に突出した部分を配したものや、筋状に***した部分を配したもの、多数の小さな孔をあけたものなどが開発されている。
　特許文献１には、１種または複数の３次元成形構造の形状に一致するように実質的に平坦な重合体フィルムの実質的に連続的なウエブを凹凸加工および穿孔するための方法および装置が開示されている。このウエブの成形構造は、大径第二開口を有し、その大径第二開口の底部は有孔壁によって閉鎖されているものである。この有孔壁は多数の小径第一開口を含むものである。この小径第一開口は穿孔であり高圧液体によりウエブを破断し穿孔されたものである。 Absorbent articles such as disposable diapers, panty liners, sanitary napkins, etc., depending on the function, those with a protruding part on one side of the sheet material, those with a protruding part, etc. Products with small holes have been developed.
U.S. Patent No. 6,053,836 discloses a method and apparatus for roughening and perforating a substantially continuous web of a substantially flat polymer film to conform to the shape of one or more three-dimensional shaped structures. It is disclosed. This web forming structure has a large-diameter second opening, and the bottom of the large-diameter second opening is closed by a perforated wall. The perforated wall includes a number of small-diameter first openings. The first opening having a small diameter is a perforation, which is formed by breaking the web with a high-pressure liquid.
　また特許文献２には、繊維が自由度を有する状態で略シート状に形成された繊維集合体に、主に気体からなる流体を噴きあてて、所定の溝部、開口部または突起部の１または２以上が形成された不織布を製造する技術が開示されている。この製造方法では、所定の噴きあて手段により、繊維集合体の他の面側から主に気体からなる流体を噴きあてることで、繊維を移動、より分けて、溝部、開口部、突起部等を形成する。その後、凹凸形状を保持したまま所定の加熱装置により加熱処理することで繊維集合体に含まれる熱可塑性繊維を熱融着させて不織布を形成するものである。また、繊維集合体を支持する通気性支持部材は、該通気性支持部材における繊維集合体を支持する側が略平面状又は略曲面状であると共に、該略平面状又は略曲面状における表面は略平坦であるとされている。 Further, in Patent Document 2, a fluid mainly composed of gas is sprayed on a fiber assembly formed in a substantially sheet shape in a state where the fibers have a degree of freedom, and one of predetermined grooves, openings, or protrusions or A technique for manufacturing a nonwoven fabric in which two or more are formed is disclosed. In this manufacturing method, the fibers are moved and separated by spraying a fluid mainly composed of gas from the other surface side of the fiber assembly by a predetermined spraying means, so that the grooves, openings, protrusions, etc. Form. Thereafter, the nonwoven fabric is formed by heat-sealing the thermoplastic fibers contained in the fiber assembly by heat treatment with a predetermined heating device while maintaining the uneven shape. Further, the breathable support member that supports the fiber assembly has a substantially planar or substantially curved surface on the side that supports the fiber assembly in the breathable support member, and the surface of the substantially planar or substantially curved surface is substantially the same. It is said to be flat.
　さらに特許文献３には、中央部と中央部に隣接し、中央部より高さが高い両端部を有し、その中央部の全体には凸部と凹部とが分散されて形成されていて、凸部より凹部の繊維集合密度が低く、両端部の繊維集合密度が均一である不織布が開示されている。また、この製造方法として、凹凸を有する通気性コンベアに熱可塑性繊維を含有する繊維ウエブを載置し、繊維ウエブを載置した状態で搬送する間に繊維ウエブ表面に幅方向において不連続的に気体を噴射して、通気性コンベアの凹状部に繊維ウエブを追随させて基体を噴射した部位においてのみ繊維ウエブに凹凸状部を形成した後、繊維ウエブを加熱して熱可塑性繊維を融着し一体化するという製造方法が開示されている。 Furthermore, Patent Document 3 has a central portion and both end portions adjacent to the central portion and higher in height than the central portion, and a convex portion and a concave portion are dispersed and formed in the entire central portion. A nonwoven fabric is disclosed in which the fiber assembly density in the recesses is lower than the protrusions, and the fiber assembly density at both ends is uniform. In addition, as a manufacturing method, a fiber web containing thermoplastic fibers is placed on a breathable conveyor having irregularities, and discontinuously in the width direction on the surface of the fiber web while being transported in a state where the fiber web is placed. After jetting gas, the fiber web is made to follow the concave part of the breathable conveyor to form the irregular part on the fiber web only at the part where the substrate is jetted, and then the fiber web is heated to fuse the thermoplastic fibers. A manufacturing method of integration is disclosed.
特開平０８－２２６０６５号公報Japanese Patent Laid-Open No. 08-226065 特開２００８－００２０３４号公報JP 2008-002034 A 特開平０４－０２４２６１号公報Japanese Patent Laid-Open No. 04-024261
　本発明の不織布は、シート状の不織布を平面視した側の第１面側に突出する第１凸部と、前記第１凸部に囲まれた第１凹部とが配された第１凹凸構造と、前記第１凹部底面は前記第１面側に突出する第２凸部と前記第１面側とは反対側の第２面側に突出する第２凹部とが配され該第２凸部が前記第１凸部より高さが低い第２凹凸構造を成し、前記第２凸部は前記第２凹部より低密度である不織布（以下、第１の不織布という。）を提供する。 The nonwoven fabric of the present invention is a first concavo-convex structure in which a first convex portion projecting to the first surface side of the sheet-shaped nonwoven fabric in plan view and a first concave portion surrounded by the first convex portion are arranged. And the second convex portion includes a second convex portion projecting to the first surface side and a second concave portion projecting to the second surface side opposite to the first surface side. Forms a second concavo-convex structure whose height is lower than that of the first convex portion, and the second convex portion provides a non-woven fabric (hereinafter referred to as a first non-woven fabric) having a lower density than the second concave portion.
　本発明の不織布は、シート状の不織布を平面視した側の第１面側に突出する第１凸部と、前記第１凸部を囲む第１凹部が配された第１凹凸構造と、前記第１凸部上面が前記第１面側に突出する第２凸部と前記第１面側とは反対側の第２面側に突出する第２凹部を配した第２凹凸構造を成し、前記第２凹部は前記第１凸部より低密度である不織布（以下、第２の不織布という。）を提供する。 The nonwoven fabric of the present invention includes a first convex portion projecting to the first surface side of the sheet-shaped nonwoven fabric in plan view, a first concave-convex structure in which a first concave portion surrounding the first convex portion is disposed, The upper surface of the first convex portion has a second concavo-convex structure in which a second convex portion protruding to the first surface side and a second concave portion protruding to the second surface side opposite to the first surface side are arranged, The second concave portion provides a non-woven fabric (hereinafter referred to as a second non-woven fabric) having a lower density than the first convex portion.
　本発明の第１の不織布の製造方法は、複数の突起と複数の孔を配した複数の支持体部を所定間隔に配置した支持体上に熱可塑性繊維を含有する繊維ウエブを搬送し、第１の熱風および第２の熱風を吹き付けて、第１凸部と該第１凸部に囲まれた第１凹部とが配された第１凹凸構造に賦形するとともに、前記第１凹部底面が第２凸部と第２凹部とが配され該第２凸部が前記第１凸部より高さが低い第２凹凸構造に賦形する工程を有し、前記繊維ウエブに前記繊維ウエブの繊維の低融点成分の融点より６０℃低い温度以上の前記第１の熱風を吹き付けて前記繊維ウエブを前記支持体の形状に沿わせて繊維同士を仮融着し、前記第１の熱風よりも高温の前記第２の熱風を吹き付けて前記仮融着させた形状を保持した状態で前記繊維ウエブの繊維同士を融着させて形状を固定する不織布の製造方法を提供する。 In the first method for producing a nonwoven fabric of the present invention, a fiber web containing thermoplastic fibers is conveyed on a support in which a plurality of support parts having a plurality of protrusions and a plurality of holes are arranged at a predetermined interval. 1 hot air and second hot air are blown to form a first concavo-convex structure in which a first convex portion and a first concave portion surrounded by the first convex portion are arranged, and the bottom surface of the first concave portion is A second convex portion and a second concave portion are arranged, and the second convex portion has a step of forming a second concave-convex structure having a height lower than that of the first convex portion, and the fiber web includes fibers of the fiber web. The first hot air having a temperature of 60 ° C. or more lower than the melting point of the low melting point component is blown so that the fibers are temporarily fused with each other along the shape of the support, and the temperature is higher than that of the first hot air. In the state where the second hot air is blown and the temporarily fused shape is maintained, the fibers of the fiber web are kept the same. The provides a method for producing a nonwoven fabric for fixing the shape by fusion.
　本発明の第２の不織布の製造方法は、複数の突起と複数の孔を配した複数の支持体部を所定間隔に配置するとともに該支持体部間に該支持体より高さが高い別の支持体部を配し、両支持体部を配した支持体上に熱可塑性繊維を含有する繊維ウエブを搬送し、第１の熱風および第２の熱風を吹き付けて、第１凹部と該第１凹部に囲まれた第１凸部とが配された第１凹凸構造とともに前記第１凸部上面を第２凸部と第２凹部が配された第２凹凸構造に賦形する工程を有し、前記繊維ウエブの繊維の低融点成分の融点より６０℃低い温度以上の前記第１の熱風を吹き付けて前記繊維ウエブを前記支持体の形状に沿わせて繊維同士を仮融着し、前記第１の熱風よりも高温の前記第２の熱風を吹き付けて前記仮融着させた形状を保持した状態で前記繊維ウエブの繊維同士を融着させて形状を固定する不織布の製造方法を提供する。 According to the second method for producing a nonwoven fabric of the present invention, a plurality of support portions each having a plurality of protrusions and a plurality of holes are arranged at a predetermined interval and the height between the support portions is higher than the support. A support body portion is disposed, a fiber web containing thermoplastic fibers is conveyed onto the support body on which both support body portions are disposed, and a first hot air and a second hot air are blown to the first recess and the first A step of shaping the upper surface of the first convex part into a second concave-convex structure in which the second convex part and the second concave part are arranged together with the first concave-convex structure in which the first convex part surrounded by the concave part is arranged. Blowing the first hot air at a temperature 60 ° C. lower than the melting point of the low melting point component of the fiber of the fiber web to temporarily fuse the fibers along the shape of the support, The second hot air having a temperature higher than that of the first hot air is blown to maintain the temporarily fused shape and the fibers are retained. To provide a manufacturing method of the nonwoven fabric for fixing the shape by fusing a web of fibers.
　本発明の第１の不織布の製造装置は、複数の突起と複数の孔を配した複数の支持体部を所定間隔に配置した支持体と、前記支持体上に搬送された熱可塑性繊維を含有する繊維ウエブに第１の熱風を吹き付ける第１ノズルと、前記繊維ウエブに前記第１の熱風よりも高温の第２の熱風を吹き付ける第２ノズルとを有し、前記支持体部とこれより高さの低い前記支持体と間隔によって前記繊維ウエブに第１凸部と第１凹部が賦形された第１凹凸構造が作製され、前記支持体部の前記突起と前記孔によって前記繊維ウエブに前記第１凸部より高さが低い第２凸部と第２凹部が賦形された第２凹凸構造が作製される不織布の製造装置を提供する。 The first nonwoven fabric manufacturing apparatus of the present invention includes a support body in which a plurality of support body portions provided with a plurality of protrusions and a plurality of holes are arranged at predetermined intervals, and a thermoplastic fiber conveyed on the support body. A first nozzle that blows a first hot air on the fiber web that is to be blown, and a second nozzle that blows a second hot air that is hotter than the first hot air on the fiber web. A first concavo-convex structure in which a first convex part and a first concave part are formed on the fiber web by the support and the interval having a low height is produced, and the protrusion and the hole of the support part are provided on the fiber web. Provided is a nonwoven fabric manufacturing apparatus in which a second concavo-convex structure in which a second convex portion and a second concave portion having a height lower than that of a first convex portion are formed is produced.
　本発明の第２の不織布の製造装置は、複数の突起と複数の孔を配した複数の支持体部を所定間隔に配置するとともに、前記支持体部間に前記支持体よりも高さの高い別の支持体部を配置した支持体と、前記支持体上に搬送された熱可塑性繊維を含有する繊維ウエブに第１の熱風を吹き付ける第１ノズルと、前記繊維ウエブに前記第１の熱風よりも高温の第２の熱風を吹き付ける第２ノズルとを有し、前記支持体部とこれよりも高さの高い別の支持体部によって前記繊維ウエブに第１凸部が賦形され、前記別の支持体部によって前記繊維ウエブに第１凸部が賦形された第１凹凸構造が作製され、前記支持体部の前記突起と前記孔によって前記繊維ウエブに前記第１凸部より高さが低い第２凸部と第２凹部が賦形された第２凹凸構造が作製される不織布の製造装置を提供する。 In the second nonwoven fabric manufacturing apparatus of the present invention, a plurality of support portions having a plurality of protrusions and a plurality of holes are arranged at predetermined intervals, and the height between the support portions is higher than that of the support. A support body in which another support body portion is disposed, a first nozzle that blows a first hot air on a fiber web containing thermoplastic fibers conveyed on the support body, and the first hot air on the fiber web A second nozzle that blows high-temperature second hot air, and the first convex portion is formed on the fiber web by the support body portion and another support body portion having a height higher than the second nozzle portion. The first concavo-convex structure in which the first convex portion is formed on the fiber web is manufactured by the support portion, and the height of the fiber web is higher than that of the first convex portion by the protrusion and the hole of the support portion. A second concavo-convex structure in which a low second convex portion and a second concave portion are shaped is produced. Providing a nonwoven manufacturing apparatus.
　本発明の上記及び他の特徴及び利点は、適宜添付の図面を参照して、下記の記載からより明らかになるであろう。 The above and other features and advantages of the present invention will become more apparent from the following description with reference to the accompanying drawings as appropriate.
本発明に係る不織布の好ましい一実施形態（第１実施形態）を示した図であり、（１）は平面図、（２）は第２凹凸構造の断面図、（３）は第２凹凸構造の部分斜視拡大図である。It is the figure which showed preferable one Embodiment (1st Embodiment) of the nonwoven fabric which concerns on this invention, (1) is a top view, (2) is sectional drawing of a 2nd uneven structure, (3) is a 2nd uneven structure. FIG. 第１実施形態の不織布の変形例を示した断面図である。It is sectional drawing which showed the modification of the nonwoven fabric of 1st Embodiment. 第２凹凸構造が配される第１凹部のパターン例を示した平面図である。It is the top view which showed the example of a pattern of the 1st recessed part by which a 2nd uneven structure is arranged. 本発明に係る不織布の第２実施形態を示した図であり、（１）は平面図、（２）は第２凹凸構造の部分斜視図である。It is the figure which showed 2nd Embodiment of the nonwoven fabric which concerns on this invention, (1) is a top view, (2) is the fragmentary perspective view of a 2nd uneven structure. 本発明の不織布の製造装置の好ましい一実施形態（第１実施形態）を示した図面であり、（１）は概略構成図、（２）は支持体の拡大斜視図である。It is drawing which showed preferable one Embodiment (1st Embodiment) of the manufacturing apparatus of the nonwoven fabric of this invention, (1) is a schematic block diagram, (2) is an expansion perspective view of a support body. 第１実施形態の不織布を製造する支持体部を示した図面であり、（１）は支持体に配される支持体部を示した斜視図、（２）は支持体に取り付けた支持体部の拡大断面図である。It is drawing which showed the support body part which manufactures the nonwoven fabric of 1st Embodiment, (1) is the perspective view which showed the support body part distribute | arranged to a support body, (2) is the support body part attached to the support body FIG. 第２実施形態の不織布を製造する支持体部を示した図面であり、（１）は支持体に配される支持体部を示した斜視図、（２）は支持体に取り付けた支持体部の拡大断面図である。It is drawing which showed the support body part which manufactures the nonwoven fabric of 2nd Embodiment, (1) is the perspective view which showed the support body part distribute | arranged to a support body, (2) is the support body part attached to the support body FIG. 本発明の不織布の製造装置の第２実施形態を示した概略構成図である。It is the schematic block diagram which showed 2nd Embodiment of the manufacturing apparatus of the nonwoven fabric of this invention. 液流れの評価方法を示した部分断面図であり、（１）は第１実施形態の不織布の評価方法を示した図面であり、（２）は第２実施形態の不織布の評価方法を示した図面である。It is the fragmentary sectional view which showed the evaluation method of a liquid flow, (1) was drawing which showed the evaluation method of the nonwoven fabric of 1st Embodiment, (2) showed the evaluation method of the nonwoven fabric of 2nd Embodiment. It is a drawing. 不織布と吸収体との接着性の評価方法を示した部分断面図である。It is the fragmentary sectional view which showed the evaluation method of the adhesiveness of a nonwoven fabric and an absorber. 液流れの評価結果を示した部分断面図であり、（１）は第１実施形態の不織布の評価結果を示した図面であり、（２）は第２実施形態の不織布の評価結果を示した図面である。It is the fragmentary sectional view which showed the evaluation result of the liquid flow, (1) is drawing which showed the evaluation result of the nonwoven fabric of 1st Embodiment, (2) showed the evaluation result of the nonwoven fabric of 2nd Embodiment. It is a drawing. 本発明の吸収性物品としての使い捨ておむつの一例を示した部分切欠き図である。It is the partial notch figure which showed an example of the disposable diaper as an absorbent article of this invention.
　本発明は、吸収性物品の表面材として用いたときの軟便等の粘性の高い液体の漏れを抑制する不織布である。 The present invention is a nonwoven fabric that suppresses leakage of highly viscous liquid such as soft stool when used as a surface material for absorbent articles.
　本発明に係る不織布の好ましい一実施形態（第１実施形態）について、図１を参照しながら、以下に説明する。
　本発明の不織布１０は例えば使い捨ておむつなどの吸収性物品の表面シートに適用することが好ましく、第１面側Ｚ１を着用者の肌面側に向けて用い、第２面側Ｚ２を物品内部の吸収体（図示せず）側に配置して用いることが好ましい。以下、図面に示した不織布１０の第１面側Ｚ１を着用者の肌面に向けて用いる実施態様を考慮して説明するが、本発明がこれにより限定して解釈されるものではない。 A preferred embodiment (first embodiment) of the nonwoven fabric according to the present invention will be described below with reference to FIG.
The nonwoven fabric 10 of the present invention is preferably applied to a top sheet of an absorbent article such as a disposable diaper, and the first side Z1 is used with the skin side of the wearer, and the second side Z2 is used inside the article. It is preferable to arrange and use on the absorber (not shown) side. Hereinafter, although it demonstrates considering the embodiment which uses the 1st surface side Z1 of the nonwoven fabric 10 shown in drawing toward a wearer's skin surface, this invention is limited to this and is not interpreted.
　図１に示すように、本発明の不織布１０としての第１の不織布１０Ａは、シート状の不織布を平面視した側の第１面側Ｚ１に突出する第１凸部１１と、第１面側Ｚ１とは反対側の第２面側Ｚ２にへこむ複数の第１凹部１２とを有している。各第１凹部１２は、第１の不織布１０Ａの全面にわたって、例えば縦横に配されていて、各第１凹部１２を囲むように第１凸部１１が配されている。したがって、第１凸部１１は連続して配されていることが好ましい。このように、第１凸部１１と第１凹部１２とで第１凹凸構造１３が成されている。 As shown in FIG. 1, the first nonwoven fabric 10A as the nonwoven fabric 10 of the present invention includes a first convex portion 11 projecting to the first surface side Z1 on the side of the sheet-like nonwoven fabric in plan view, and the first surface side. A plurality of first recesses 12 are recessed in the second surface side Z2 opposite to Z1. Each first recess 12 is arranged, for example, vertically and horizontally over the entire surface of the first nonwoven fabric 10 </ b> A, and the first protrusion 11 is arranged so as to surround each first recess 12. Therefore, it is preferable that the 1st convex part 11 is distribute | arranged continuously. As described above, the first concavo-convex structure 13 is formed by the first convex portion 11 and the first concave portion 12.
　また、第１凹部１２の底面部は、第１凹部１２の最下面ＳＢを基準にして第１凸部１１の高さＨ１より低い高さＨ２の第２凸部２１と、第２凹部２２とが配された第２凹凸構造２３を成している。第２凹凸構造２３は第２凹部２２より第２凸部２１が低密度で嵩高な不織布構造である。この第２凹凸構造２３は、上記第１凹部１２の底面内において、第２凸部２１と第２凹部２２とが異なる方向に交互に配列されているものである。 Further, the bottom surface portion of the first concave portion 12 includes a second convex portion 21 having a height H2 lower than the height H1 of the first convex portion 11 with respect to the lowermost surface SB of the first concave portion 12, and a second concave portion 22. The second concavo-convex structure 23 is arranged. The second concavo-convex structure 23 is a nonwoven fabric structure in which the second convex portions 21 are lower in density and bulky than the second concave portions 22. In the second concavo-convex structure 23, the second convex portions 21 and the second concave portions 22 are alternately arranged in different directions within the bottom surface of the first concave portion 12.
　ここでは、第１面側Ｚ１からみた第２凸部２１が第１突出部２１Ａであり、また第２面側Ｚ２からみた第２凹部２２が第２突出部２２Ａとなる。したがって、第１突出部２１Ａと第２突出部２２Ａとは一部が共有されている。
　上記第１突出部２１Ａの頂部（以下、第１突出部頂部ともいう。）２１Ｔとその開口部２１Ｈとの間に壁部２１Ｗを有する。この壁部２１Ｗは、第１突出部２１Ａにおいて環状構造を成している。
　また第２突出部２２Ａの頂部（以下、第２突出部頂部ともいう。）２２Ｔとその開口部２２Ｈとの間に壁部２２Ｗを有する。この壁部２２Ｗは、第２突出部２２Ａにおいて環状構造を成している。
　そして、壁部２１Ｗと壁部２２Ｗは少なくとも一部分を共有している。
　ここでいう「環状」とは、平面視において無端の一連の形状をなしていれば特に限定されず、平面視において、円、楕円、矩形、多角形など、どのような形状であってもよい。シートの連続状態を好適に維持する上では円又は楕円が好ましい。さらに、「環状」を立体としていえば、円柱、斜円柱、楕円柱、切頭円錐、切頭斜円錐、切頭楕円錐、切頭四角錐、切頭斜四角錐など任意の環構造が挙げられ、連続したシート状態を実現する上では、円柱、楕円柱、切頭円錐、切頭楕円錐が好ましい。 Here, the 2nd convex part 21 seen from the 1st surface side Z1 is 21 A of 1st protrusion parts, and the 2nd recessed part 22 seen from the 2nd surface side Z2 becomes 22 A of 2nd protrusion parts. Therefore, a part is shared by the 1st protrusion part 21A and the 2nd protrusion part 22A.
A wall 21W is provided between the top of the first protrusion 21A (hereinafter also referred to as the first protrusion top) 21T and the opening 21H. The wall portion 21W forms an annular structure at the first protruding portion 21A.
A wall 22W is provided between the top of the second protrusion 22A (hereinafter also referred to as the second protrusion top) 22T and the opening 22H. The wall 22W has an annular structure in the second protrusion 22A.
The wall 21W and the wall 22W share at least a part.
The “annular” here is not particularly limited as long as it has a series of endless shapes in plan view, and may be any shape such as a circle, an ellipse, a rectangle, or a polygon in plan view. . In order to maintain the continuous state of the sheet suitably, a circle or an ellipse is preferable. Furthermore, speaking of “circular” as a solid, any ring structure such as a cylinder, a slanted cylinder, an elliptical column, a truncated cone, a truncated cone, a truncated elliptical cone, a truncated quadrangular pyramid, a truncated oblique pyramid can be mentioned. In order to realize a continuous sheet state, a cylinder, an elliptical column, a truncated cone, and a truncated elliptical cone are preferable.
　上述の例のように配設された第１、第２突出部２１Ａ、２２Ａを有する第１の不織布１０Ａは、屈曲部を有さず、全体が連続した曲面で構成されている。
　このように上記第１の不織布１０Ａは、面方向に連続した構造を有していることが好ましい。この「連続」とは、断続した部分や小孔がないことを意味する。ただし、繊維間の隙間のような微細孔は上記小孔に含めない。上記小孔とは、例えば、その孔径が円相当の直径で１ｍｍ以上のものと定義することができる。 The first nonwoven fabric 10A having the first and second projecting portions 21A and 22A arranged as in the above-described example does not have a bent portion, and is configured by a continuous curved surface as a whole.
As described above, the first nonwoven fabric 10A preferably has a continuous structure in the surface direction. This “continuous” means that there are no intermittent portions or small holes. However, fine holes such as gaps between fibers are not included in the small holes. The small hole can be defined, for example, as a hole having a diameter equivalent to a circle of 1 mm or more.
　さらに、第１凸部１１の高さは、３ｍｍ以上１０ｍｍ以下、好ましくは４ｍｍ以上９ｍｍ以下、より好ましくは６ｍｍ以上８ｍｍ以下とする。また、第２凸部２１は、第１凸部１１よりも２ｍｍ以上低く、好ましくは３ｍｍ以上低く、より好ましくは４ｍｍ以上低い高さであり、且つ、第２凸部２１の高さＨ２が１ｍｍ以上、好ましくは２ｍｍ以上、より好ましくは３ｍｍ以上を有する。これらの寸法とすることによって、肌触り感が良好で、軟便等の粘性の高い液の漏れを防止することができる。なお、上述の粘性の高い液とは、軟便、経血等の粘性の高い液（例えば、粘度が１０ｍＰａ・ｓ以上３５０ｍＰａ・ｓ以下の液）をいう。 Furthermore, the height of the first convex portion 11 is 3 mm or more and 10 mm or less, preferably 4 mm or more and 9 mm or less, more preferably 6 mm or more and 8 mm or less. Moreover, the 2nd convex part 21 is 2 mm or more lower than the 1st convex part 11, Preferably it is 3 mm or more lower, More preferably, it is 4 mm or more lower height, and the height H2 of the 2nd convex part 21 is 1 mm. Above, preferably 2 mm or more, more preferably 3 mm or more. By setting it as these dimensions, the touch feeling is favorable and leakage of liquids with high viscosity such as loose stool can be prevented. The above-described highly viscous liquid refers to a highly viscous liquid such as soft stool or menstrual blood (for example, a liquid having a viscosity of 10 mPa · s to 350 mPa · s).
　本発明の第１の不織布１０Ａに用いることができる繊維材料は特に限定されない。具体的には、下記の繊維などが挙げられる。ポリエチレン（ＰＥ）繊維、ポリプロピレン（ＰＰ）繊維等のポリオレフィン繊維があり、ポリエチレンテレフタレート（ＰＥＴ）、ポリアミド等の熱可塑性樹脂を単独で用いてなる繊維があり、また、芯鞘型、サイドバイサイド型等の構造の複合繊維がある。本発明では複合繊維を用いるのが好ましい。ここでいう複合繊維とは、高融点成分が芯部分で低融点成分が鞘部分とする芯鞘繊維、また高融点成分と低融点成分とが並列するサイドバイサイド繊維が挙げられる。その好ましい例として、鞘成分（低融点成分）がポリエチレンまたは低融点ポリプロピレンである芯鞘構造の繊維が好ましく挙げられ、該芯／鞘構造の繊維の代表例としては、ＰＥＴ（芯）／ＰＥ（鞘）、ＰＰ（芯）／ＰＥ（鞘）、ポリ乳酸（芯）／ＰＥ（鞘）、ＰＰ（芯）／低融点ＰＰ（鞘）等の芯鞘構造の繊維が挙げられる。さらに具体的には、上記構成繊維は、ポリエチレン繊維、ポリプロピレン繊維等のポリオレフィン系繊維、ポリエチレン複合繊維、ポリプロピレン複合繊維を含むのが好ましい。ここで、該ポリエチレン複合繊維の複合組成は、ポリエチレンテレフタレート／ポリエチレンであり、該ポリプロピレン複合繊維の複合組成は、ポリエチレンテレフタレート／低融点ポリプロピレンであるのが好ましく、より具体的には、ＰＥＴ（芯）／ＰＥ（鞘）、ＰＥＴ（芯）／低融点ＰＰ（鞘）が挙げられる。また、これらの繊維は、単独で用いて不織布を構成してもよいが、２種以上を組み合わせた混繊として用いることもできる。 The fiber material that can be used for the first nonwoven fabric 10A of the present invention is not particularly limited. Specific examples include the following fibers. There are polyolefin fibers such as polyethylene (PE) fibers, polypropylene (PP) fibers, etc., and there are fibers that use a thermoplastic resin such as polyethylene terephthalate (PET) and polyamide alone, and core-sheath type, side-by-side type, etc. There is a composite fiber of structure. In the present invention, it is preferable to use a composite fiber. Examples of the composite fiber include a core-sheath fiber having a high melting point component as a core portion and a low melting point component as a sheath portion, and a side-by-side fiber in which a high melting point component and a low melting point component are arranged in parallel. Preferred examples thereof include fibers having a core-sheath structure in which the sheath component (low-melting-point component) is polyethylene or low-melting-point polypropylene. Typical examples of the fibers having the core / sheath structure include PET (core) / PE ( Examples include fibers having a core-sheath structure such as (sheath), PP (core) / PE (sheath), polylactic acid (core) / PE (sheath), and PP (core) / low melting point PP (sheath). More specifically, the constituent fibers preferably include polyolefin fibers such as polyethylene fibers and polypropylene fibers, polyethylene composite fibers, and polypropylene composite fibers. Here, the composite composition of the polyethylene composite fiber is polyethylene terephthalate / polyethylene, and the composite composition of the polypropylene composite fiber is preferably polyethylene terephthalate / low-melting polypropylene, and more specifically, PET (core). / PE (sheath), PET (core) / low melting point PP (sheath). These fibers may be used alone to form a nonwoven fabric, but can also be used as a mixed fiber in which two or more kinds are combined.
　また、第１突出部２１Ａと第２突出部２２Ａとの繊維密度が異なっている。具体的には、第１突出部２１Ａの繊維密度が第２突出部２２Ａの繊維密度より低くなっている。
　第１突出部（第２凸部）２１Ａにおける繊維密度は後述する測定方法において３０本／ｍｍ２以上１３０本／ｍｍ２以下が好ましく、５０本／ｍｍ２以上１００本／ｍｍ２以下がより好ましい。第２突出部（第２凹部）２２Ａにおける繊維密度は後述する測定方法において２５０本／ｍｍ２以上５００本／ｍｍ２以下が好ましく、３００本／ｍｍ２以上４５０本／ｍｍ２以下がより好ましい。また、第１突出部（第２凸部）２１Ａにおける繊維密度と第２突出部（第２凹部）２２Ａにおける繊維密度の差は、１５０本／ｍｍ２以上であることが好ましい。
　このように繊維密度に差が生じていることから、第１の不織布１０Ａを吸収性物品の表面シートに用いた場合において、第１の不織布１０Ａの第１面側Ｚ１から液体が供給された場合、肌に接触する第１突出部２１Ａへの液移行を防ぎ、毛管現象により吸収体に近い第２突出部２２Ａへの液移行を進めることになる。このため、第１の不織布１０Ａの表面側（第１面側Ｚ１）の液残りが少なくなる。 Moreover, the fiber density of 21 A of 1st protrusion parts and 22 A of 2nd protrusion parts differs. Specifically, the fiber density of the first protrusion 21A is lower than the fiber density of the second protrusion 22A.
Preferably 30 present / mm 2 or more 130 present / mm 2 or less in the measurement method the fiber density of the first protrusion (second protrusion) 21A is described below, and more preferably 50 lines / mm 2 or more 100 / mm 2 or less . Preferably 250 lines / mm 2 or more 500 / mm 2 or less in the measurement method the fiber density in the second projecting portion (second recess) 22A is described later, 300 lines / mm 2 or more 450 present / mm 2 or less being more preferred. Moreover, it is preferable that the difference of the fiber density in 21 A of 1st protrusion parts (2nd convex part) and the fiber density in 22 A of 2nd protrusion parts (2nd recessed part) is 150 pieces / mm < 2 > or more.
Since the difference in fiber density occurs in this way, when the first nonwoven fabric 10A is used as the top sheet of the absorbent article, the liquid is supplied from the first surface side Z1 of the first nonwoven fabric 10A. Then, the liquid transfer to the first protrusion 21A that contacts the skin is prevented, and the liquid transfer to the second protrusion 22A close to the absorber is promoted by capillary action. For this reason, the liquid residue of the surface side (1st surface side Z1) of 10 A of 1st nonwoven fabrics decreases.
　次に、本実施形態の第１の不織布１０Ａにおける寸法諸元について以下に説明する。
　シートの厚さについては、第１の不織布１０Ａの側面視としてみたときの全体の厚さをシート厚みＴＳ（＝Ｈ１）とし、その凹凸に湾曲したシートの局部的な厚さを層厚みＴＬとする。シート厚みＴＳは、用途によって適宜調節すればよいが、おむつや生理用品等の表面シートとして用いる場合、１ｍｍ以上７ｍｍ以下が好ましく、１．５ｍｍ以上５ｍｍ以下がより好ましい。その範囲とすることにより、使用時の体液吸収速度が速く、吸収体からの液戻りを抑え、さらには、適度なクッション性を実現することができる。層厚みＴＬは、シート内の各部位において異なっていてよく、用途によって適宜調節すればよい。おむつや生理用品等の表面シートとして用いる場合、第１突出部頂部２１Ｔの層厚みＴＬ１は０．１ｍｍ以上３ｍｍ以下であることが好ましく、０．４ｍｍ以上２ｍｍ以下がより好ましい。好ましい層厚みの範囲としては第２突出部頂部２２Ｔの層厚みＴＬ２および壁部２１Ｗの層厚みＴＬ３も同様である。各層厚みＴＬ１、ＴＬ２、ＴＬ３の関係は、ＴＬ１＞ＴＬ３＞ＴＬ２であることが好ましい。これにより、第１突出部２１Ａにおいて、特に肌面側では、繊維密度が低く、良好な肌当たりを実現することができる。一方、第２突出部２２Ａは繊維密度が高くなり、潰れにくく、型崩れせずに良好なクッション性と液体の吸収速度に優れた不織布とすることができる。
　平面視した上記第１突出部２１Ａと第２突出部２２Ａとの間隔は、用途によって適宜調節すればよく、おむつや生理用品等の表面シートとして用いる場合、１ｍｍ以上１５ｍｍ以下が好ましく、３ｍｍ以上１０ｍｍ以下がより好ましい。また上記第１の不織布１０Ａの坪量は特に限定されないが、シート全体の平均値で１５ｇ／ｍ２以上５０ｇ／ｍ２以下が好ましく、２０ｇ／ｍ２以上４０ｇ／ｍ２以下がより好ましい。 Next, the dimension specification in 10 A of 1st nonwoven fabrics of this embodiment is demonstrated below.
Regarding the thickness of the sheet, the total thickness when viewed from the side of the first nonwoven fabric 10A is the sheet thickness TS (= H1), and the local thickness of the sheet curved in the unevenness is the layer thickness TL. To do. The sheet thickness TS may be appropriately adjusted depending on the application, but when used as a surface sheet for diapers, sanitary products, etc., it is preferably 1 mm or more and 7 mm or less, and more preferably 1.5 mm or more and 5 mm or less. By setting it as the range, the body fluid absorption speed at the time of use is high, the liquid return from an absorber is suppressed, and also moderate cushioning property is realizable. The layer thickness TL may be different in each part in the sheet, and may be appropriately adjusted depending on the application. When used as a surface sheet for diapers, sanitary products, etc., the layer thickness TL1 of the first protrusion top 21T is preferably 0.1 mm or more and 3 mm or less, and more preferably 0.4 mm or more and 2 mm or less. The preferable range of the layer thickness is the same for the layer thickness TL2 of the second protrusion top 22T and the layer thickness TL3 of the wall 21W. The relationship between the layer thicknesses TL1, TL2, and TL3 is preferably TL1>TL3> TL2. Thereby, in the 1st protrusion part 21A, especially in the skin surface side, fiber density is low and can implement | achieve favorable skin contact. On the other hand, the second protruding portion 22A has a high fiber density, is not easily crushed, and can be a nonwoven fabric excellent in cushioning properties and liquid absorption speed without being deformed.
The distance between the first protrusion 21A and the second protrusion 22A in plan view may be adjusted as appropriate depending on the application. When used as a top sheet for diapers, sanitary products, etc., it is preferably 1 mm to 15 mm, preferably 3 mm to 10 mm. The following is more preferable. The above basis weight of the first nonwoven 10A is not particularly limited, but is preferably 15 g / m 2 or more 50 g / m 2 or less the average value of the entire sheet, 20 g / m 2 or more 40 g / m 2 or less is more preferable.
　また図２に示すように、上記第１の不織布１０Ａにおいては、第１凸部１１は、第１面側Ｚ１とは反対の第２面側Ｚ２の一部が平坦面１１Ｓであり、該平坦面１１Ｓは、上記第２凹凸構造２３が第２面側Ｚ２で接する仮想平面Ｓと同一平面または該仮想平面Ｓより第２面側Ｚ２に存することが好ましい。
　この構成により、第１凸部１１の平坦面１１Ｓの部分で吸収体３との接触面積を確保することができるので、吸収体３に対して十分な接着面積の確保が可能になる。よって、吸収体３に対する表面材としての第１の不織布１０Ａの固定性を向上させることができ、第１の不織布１０Ａのよれや浮き上がりを防止して吸収性を向上させることができる。なお、吸収体３に第１の不織布１０Ａをしっかりと固定するために、第１の不織布１０Ａの端部にサイド不織布６を貼り付けることも好ましい。 As shown in FIG. 2, in the first nonwoven fabric 10A, a part of the second surface side Z2 opposite to the first surface side Z1 of the first convex portion 11 is a flat surface 11S. It is preferable that the surface 11S is on the same plane as the virtual plane S with which the second concavo-convex structure 23 contacts on the second plane side Z2, or on the second plane side Z2 from the virtual plane S.
With this configuration, the contact area with the absorbent body 3 can be secured at the portion of the flat surface 11 </ b> S of the first convex portion 11, so that a sufficient adhesion area with respect to the absorbent body 3 can be secured. Therefore, the fixability of the first nonwoven fabric 10A as the surface material with respect to the absorbent body 3 can be improved, and the first nonwoven fabric 10A can be prevented from being swung and lifted to improve the absorbability. In addition, in order to fix the 1st nonwoven fabric 10A to the absorber 3 firmly, it is also preferable to affix the side nonwoven fabric 6 to the edge part of the 1st nonwoven fabric 10A.
　次に、第２凹凸構造２３が配される第１凹部２２のパターン例を、図３を参照して説明する。
　図３（１）に示すように、不織布１０の平面視全面にわたって図面上縦長の長方形の第１凹部１２が等間隔に縦横に配されている。また各第１凹部１２の周囲にはそれらを囲むように第１凸部１１が連続的に配されている。なお、「第１凸部１１が連続的」とは、第１凸部１１が各第１凹部１２を除いた状態において連なった１枚の不織布を形成している状態であることをいう。以下、同様である。
　このような第１凹部１２の配列では、縦横方向、特に横方向への液拡がりを抑制することができる。 Next, a pattern example of the first recess 22 in which the second uneven structure 23 is arranged will be described with reference to FIG.
As shown in FIG. 3 (1), vertically long rectangular first recesses 12 are arranged at equal intervals vertically and horizontally over the entire surface of the nonwoven fabric 10 in plan view. Moreover, the 1st convex part 11 is distribute | arranged continuously around each 1st recessed part 12 so that they may be enclosed. In addition, "the 1st convex part 11 is continuous" means that the 1st convex part 11 is the state which forms the sheet of nonwoven fabric continued in the state except each 1st recessed part 12. As shown in FIG. The same applies hereinafter.
Such an arrangement of the first recesses 12 can suppress liquid spreading in the vertical and horizontal directions, particularly in the horizontal direction.
　図３（２）に示すように、不織布１０の平面視全面にわたって図面上縦長の長方形の第１凹部１２が等間隔に縦横にかつ縦方向に例えば１／２ピッチずつずらして配されている。また図示はしないが、第１凹部１２を横方向に例えば１／２ピッチずつずらして配してもよい。さらに各第１凹部１２の周囲にはそれらを囲むように第１凸部１１が連続的に配されている。
　このような第１凹部１２の配列では、縦横方向、特に横方向への液拡がりは図３（１）に示したパターンよりも抑制効果は大きい。 As shown in FIG. 3 (2), the first rectangular recesses 12 that are vertically long in the drawing are arranged at equal intervals vertically and horizontally and shifted by, for example, ½ pitch in the longitudinal direction over the entire planar view of the nonwoven fabric 10. Although not shown, the first recesses 12 may be shifted in the lateral direction by, for example, ½ pitch. Furthermore, the 1st convex part 11 is continuously distribute | arranged around each 1st recessed part 12 so that they may be enclosed.
In such an arrangement of the first recesses 12, the liquid spreading in the vertical and horizontal directions, particularly in the horizontal direction, has a greater suppression effect than the pattern shown in FIG.
　図３（３）に示すように、不織布１０の平面視全面にわたって図面上横長の長方形の第１凹部１２が等間隔に縦横に配されている。また図示はしないが、第１凹部１２を縦方向または横方向に例えば１／２ピッチずつずらして配してもよい。さらに各第１凹部１２の周囲にはそれらを囲むように第１凸部１１が連続的に配されている。
　このような第１凹部１２の配列では、縦横方向、特に縦方向への液拡がりを抑制することができる。 As shown in FIG. 3 (3), horizontally long rectangular first recesses 12 are arranged vertically and horizontally at equal intervals over the entire surface of the nonwoven fabric 10 in plan view. Although not shown, the first recesses 12 may be shifted in the vertical direction or the horizontal direction by, for example, ½ pitch. Furthermore, the 1st convex part 11 is continuously distribute | arranged around each 1st recessed part 12 so that they may be enclosed.
Such an arrangement of the first recesses 12 can suppress liquid spreading in the vertical and horizontal directions, particularly in the vertical direction.
　図３（４）に示すように、不織布１０の平面視全面にわたって円形の第１凹部１２が等間隔に縦横に配されている。図示はしないが、円形の代わりに長円形もしくは楕円形であってもよい。また縦方向もしくは横方向の配置は、例えば１／２ピッチずらして配してもよい。さらに各第１凹部１２の周囲にはそれらを囲むように第１凸部１１が連続的に配されている。
　このような第１凹部１２の配列では、縦横方向均等な液拡がりを抑制することができる。 As shown in FIG. 3 (4), circular first recesses 12 are arranged vertically and horizontally at equal intervals over the entire planar view of the nonwoven fabric 10. Although not shown, an ellipse or an ellipse may be used instead of a circle. Further, the arrangement in the vertical direction or the horizontal direction may be shifted by, for example, ½ pitch. Furthermore, the 1st convex part 11 is continuously distribute | arranged around each 1st recessed part 12 so that they may be enclosed.
With such an arrangement of the first recesses 12, it is possible to suppress liquid spreading even in the vertical and horizontal directions.
　図３（５）に示すように、不織布１０の平面視全面にわたってハート形の第１凹部１２が等間隔に横方向に配列され、その横方向に配列されたハート形の第１凹部１２の第１群が縦方向に上下互い違いにして配されている。すなわち、各ハート形の尖った側の第１群の各ハート形間に、別の第１群の各ハート形の尖った部分が入り込むように配されている。さらに、第１群の各ハート形の丸い側が別の第１群の各ハート形の丸い部分と対向するように配されている。また各第１凹部１２の周囲にはそれらを囲むように第１凸部１１が連続的に配されている。
　このような第１凹部１２の配列では、見た目のデザイン性を高めることができる。また、縦横方向への液拡がりを抑制することができる。 As shown in FIG. 3 (5), the heart-shaped first recesses 12 are arranged in the lateral direction at equal intervals over the entire planar view of the nonwoven fabric 10, and the heart-shaped first recesses 12 arranged in the lateral direction are arranged in the horizontal direction. One group is arranged in a staggered manner in the vertical direction. That is, it is arranged so that the pointed portions of each heart shape of another first group enter between the heart shapes of the first group on the sharp side of each heart shape. Further, the rounded side of each heart-shaped member of the first group is arranged so as to face the rounded part of each heart-shaped member of another first group. Moreover, the 1st convex part 11 is distribute | arranged continuously around each 1st recessed part 12 so that they may be enclosed.
Such an arrangement of the first recesses 12 can improve the appearance design. Moreover, liquid spreading in the vertical and horizontal directions can be suppressed.
　図３（６）に示すように、不織布１０の平面視全面にわたって図面縦方向に第１凹部１２が縞状に等間隔に配されている。また各第１凹部１２の周囲にはそれらを囲むように第１凸部１１が連続的に配されている。
　このような第１凹部１２の配列では、横方向への液拡がりを抑制することができる。
　上述した第１凹部１２のパターン形状およびその配置例は一例であって、上記形状、配置例に限定されることはなく、適宜変更可能である。例えば、十字形、Ｈ字形、等、種々の形状であってもよい。さらには、ハート形とダイヤ形の組み合わせ、十字形と四角形の組み合わせ、等の異種形状を組み合わせてもよい。 As shown in FIG. 3 (6), the first recesses 12 are arranged in stripes at equal intervals in the longitudinal direction of the drawing over the entire surface of the nonwoven fabric 10 in plan view. Moreover, the 1st convex part 11 is distribute | arranged continuously around each 1st recessed part 12 so that they may be enclosed.
With such an arrangement of the first recesses 12, it is possible to suppress liquid spreading in the lateral direction.
The pattern shape and the arrangement example of the first recess 12 described above are merely examples, and are not limited to the above shape and arrangement example, and can be changed as appropriate. For example, various shapes such as a cross shape and an H shape may be used. Further, different shapes such as a combination of a heart shape and a diamond shape, a combination of a cross shape and a square shape, and the like may be combined.
　本発明の上記第１実施形態の第１の不織布１０Ａは、以下のような効果を奏する。
　上記第１の不織布１０Ａ（前記図１参照）は***物、特に軟便等の粘性の高い液の捕捉性に優れる。
　本発明の第１の不織布１０Ａは、第１凸部１１の高さＨ１より第２凸部２１の高さＨ２の高さが低いことから、第２凹凸構造２３に軟便等の液が供給された場合、第２凹凸構造２３内に軟便等の粘性の高い液が拡がるが、第１凸部１１によって、その液の拡がりは堰き止められるので、それ以上の拡がりを抑えることができる。
　また第２凸部２１は第２凹部２２よりも低密度（第１突出部２１Ａの繊維密度＜第２突出部２２Ａの繊維密度）で嵩高なウエブ賦形であることから、第２凹凸構造２３に軟便等の液体が供給されると、第２凸部２１よりその内部空間に導かれる。
　さらに第１凸部１１の繊維密度が均一であることから、部分的に液漏れすることがない。 The first nonwoven fabric 10A of the first embodiment of the present invention has the following effects.
The first non-woven fabric 10A (see FIG. 1) is excellent in trapping of excrement, particularly liquid with high viscosity such as loose stool.
In the first nonwoven fabric 10A of the present invention, since the height H2 of the second protrusion 21 is lower than the height H1 of the first protrusion 11, a liquid such as soft stool is supplied to the second uneven structure 23. In such a case, a highly viscous liquid such as soft stool spreads in the second concavo-convex structure 23, but the spread of the liquid is blocked by the first convex portion 11, so that further spread can be suppressed.
Further, since the second convex portion 21 has a lower density than the second concave portion 22 (fiber density of the first protruding portion 21A <fiber density of the second protruding portion 22A) and is bulky, the second uneven structure 23 When a liquid such as soft stool is supplied, the second convex portion 21 guides it to the internal space.
Furthermore, since the fiber density of the 1st convex part 11 is uniform, it does not leak partially.
　上記第１の不織布１０Ａ（前記図１参照）は、優れたクッション性を有する。
　本実施形態の第１の不織布１０Ａは表裏の片面だけではなく、両面において突出した部分を有するため、その構造に特有のクッション性を発現する。例えば筋状の突起や片面の突起ではどうしても線ないし面としての弾力性を発現することとなるが、本実施形態によれば三次元的な動きに対してもよく追従して両面において点で支持された立体的なクッション性を奏する。また、壁部２１Ｗによって繊維が厚み方向に潰れてしまうことのない適度のクッション性を発現することができ、その形状復元力によって、梱包状態や着用が継続されても初期のクッション力が維持されやすくなる。すなわち、第１、第２突出部２１Ａ、２２Ａは、潰れ難く、変形が起こっても回復し易い。 The first nonwoven fabric 10A (see FIG. 1) has an excellent cushioning property.
Since the first nonwoven fabric 10A of the present embodiment has not only one side of the front and back sides but also protruding portions on both sides, the first nonwoven fabric 10A expresses a cushioning characteristic peculiar to the structure. For example, streak-like projections or single-sided projections will inevitably exhibit elasticity as lines or surfaces. However, according to this embodiment, the two-dimensional movement is well followed and supported by points on both sides. Has a three-dimensional cushioning. Moreover, the moderate cushioning property which a fiber does not collapse in the thickness direction by the wall part 21W can be expressed, and even if a packing state and wearing are continued, the initial cushion force is maintained by the shape restoring force. It becomes easy. That is, the first and second projecting portions 21A and 22A are not easily crushed and can be easily recovered even if deformation occurs.
　上記第１の不織布１０Ａ（前記図１参照）は、肌触りに優れる。
　本実施形態の第１の不織布１０Ａには両面方向に第１、第２突出部１１Ａ、２１Ａを有し、その頂部１１Ｔ、２１Ｔは丸みを帯びている。そのため、そのどちらの面を肌面側にしても、表面シートが肌に対して点で柔らかく接触する良好な肌触りが実現される。また、装着時の圧力に対しても接触する点が面状に増減することで肌触りを良好としながら、圧力に対する表面シート全体の形状変形を抑えることができ、また、圧力変形からの形状復元も容易にできる。上記の良好なクッション性に起因する作用もあり、点接触による動的な作用と相俟って、独特の良好な肌触りが得られる。また、***等を受けたときにも、上述した点接触が効果を奏し、サラッとした肌触りが実現される。 The first nonwoven fabric 10A (see FIG. 1) is excellent in touch.
The first nonwoven fabric 10A of the present embodiment has first and second projecting portions 11A and 21A in both directions, and the top portions 11T and 21T are rounded. Therefore, whichever surface is the skin side, a good touch that the top sheet softly contacts the skin with respect to the skin is realized. In addition, the point of contact with the pressure at the time of wearing increases and decreases in a planar shape, and the shape deformation of the entire topsheet against pressure can be suppressed while improving the touch, and shape restoration from pressure deformation can also be achieved Easy to do. There also exists an effect | action resulting from said favorable cushioning property, and a unique favorable touch is obtained with the dynamic effect | action by a point contact. Moreover, the point contact mentioned above has an effect also when excretion etc. are received, and the smooth touch is implement | achieved.
　上記第１の不織布１０Ａ（前記図２参照）は、吸収体３に対する固定性に優れる。
　第１凸部１１の平坦面１１Ｓの部分で吸収体３との接触面積を確保することができるので、吸収体３に対して十分な接着が可能になり、表面材としての固定性が向上する。このため、第１の不織布１０Ａのよれや吸収体３からの浮き上がりを防止することができる。 The first nonwoven fabric 10 </ b> A (see FIG. 2) is excellent in fixability to the absorbent body 3.
Since the contact area with the absorber 3 can be ensured at the portion of the flat surface 11S of the first convex portion 11, sufficient adhesion to the absorber 3 is possible, and the fixability as a surface material is improved. . For this reason, it is possible to prevent the first nonwoven fabric 10 </ b> A from being lifted or lifted from the absorber 3.
　次に本発明に係る不織布の好ましい一実施形態（第２実施形態）について、図４を参照しながら、以下に説明する。
　図４に示すように、本発明の不織布１０としての第２の不織布１０Ｂは、シートの不織布を平面視した側の第１面側Ｚ１に突出する第１凸部１１と、第１面側Ｚ１とは反対側の第２面側Ｚ２にへこむ複数の第１凹部１２とを有している。各第１凸部１１は、第２の不織布１０Ｂの全面にわたって、例えば縦横に配されていて、各第１凸部１１を囲むように第１凹部１２が配されている。したがって、第１凹部１２は連続して配されていることが好ましい。このように、第１凸部１１と第１凹部１２とで第１凹凸構造１３が成されている。 Next, a preferred embodiment (second embodiment) of the nonwoven fabric according to the present invention will be described below with reference to FIG.
As shown in FIG. 4, the 2nd nonwoven fabric 10B as the nonwoven fabric 10 of this invention is the 1st convex part 11 which protrudes to the 1st surface side Z1 of the side which planarly viewed the nonwoven fabric of the sheet | seat, and 1st surface side Z1. And a plurality of first recesses 12 recessed in the second surface side Z2 opposite to the first side. Each 1st convex part 11 is distribute | arranged over the whole surface of the 2nd nonwoven fabric 10B, for example vertically and horizontally, and the 1st recessed part 12 is distribute | arranged so that each 1st convex part 11 may be enclosed. Therefore, it is preferable that the 1st recessed part 12 is distribute | arranged continuously. As described above, the first concavo-convex structure 13 is formed by the first convex portion 11 and the first concave portion 12.
　また、第１凸部１１の上面は、第２凸部２１と第２凹部２２が配された第２凹凸構造２３を成している。第２凹凸構造２３は第２凹部２２より第２凸部２１が低密度で嵩高なウエブ賦形である。この第２凹凸構造２３は、上記第１凸部１１の上面内において、第２凸部２１と第２凹部２２とが異なる方向に交互に配列されているものである。 Further, the upper surface of the first convex portion 11 forms a second concavo-convex structure 23 in which the second convex portion 21 and the second concave portion 22 are arranged. The second concavo-convex structure 23 is a web shaping in which the second convex portions 21 are lower in density and bulky than the second concave portions 22. In the second concavo-convex structure 23, the second convex portions 21 and the second concave portions 22 are alternately arranged in different directions in the upper surface of the first convex portion 11.
　上記第２凹凸構造２３は前述の第１の不織布１０Ａと同様である。すなわち、第１面側Ｚ１からみた第２凸部２１が第１突出部２１Ａであり、また第２面側Ｚ２からみた第２凹部２２が第２突出部２２Ａとなっている。さらに第１突出部２１Ａにおいて環状構造の壁部２１Ｗを有し、第２突出部２２Ａにおいて環状構造の壁部２２Ｗを有し、壁部２１Ｗと壁部２２Ｗは一部分を共有している。 The second uneven structure 23 is the same as the first nonwoven fabric 10A. That is, the 2nd convex part 21 seen from the 1st surface side Z1 is the 1st protrusion part 21A, and the 2nd recessed part 22 seen from the 2nd surface side Z2 is the 2nd protrusion part 22A. Further, the first projecting portion 21A has an annular structure wall portion 21W, and the second projecting portion 22A has an annular structure wall portion 22W, and the wall portion 21W and the wall portion 22W share a part.
　上述の例のように配設された第１、第２突出部２１Ａ、２２Ａを有する第２の不織布１０Ｂは、屈曲部を有さず、全体が連続した曲面で構成されている。 The second nonwoven fabric 10B having the first and second protruding portions 21A and 22A arranged as in the above example does not have a bent portion, and is configured by a continuous curved surface as a whole.
　さらに、第１凹部１２の深さは、１ｍｍ以上１０ｍｍ以下、好ましくは２ｍｍ以上１０ｍｍ以下、より好ましくは３ｍｍ以上１０ｍｍ以下とすることにより、軟便等の粘性の高い液の漏れを防止することができる。また、深さが１０ｍｍ以下であることにより、立体形状が潰れにくく好ましい。また、第２凸部２１は、１ｍｍ以上、好ましくは２ｍｍ以上、より好ましくは３ｍｍ以上の高さを有することにより、クッション性が良く肌触り感が良好になる。 Further, the depth of the first recess 12 is 1 mm or more and 10 mm or less, preferably 2 mm or more and 10 mm or less, more preferably 3 mm or more and 10 mm or less, thereby preventing leakage of highly viscous liquid such as soft stool. . Moreover, when the depth is 10 mm or less, it is preferable that the three-dimensional shape is not easily crushed. Further, the second convex portion 21 has a height of 1 mm or more, preferably 2 mm or more, more preferably 3 mm or more, so that the cushioning property is good and the touch feeling is good.
　また、第１凹部１２の底面は、少なくともその一部が平坦面１２Ｓとなっている。この平坦面１２Ｓによって、第１凹部１２の底面と吸収体３とが接着しやすくなり、表面材としての第２の不織布１０Ｂの固定性が向上するので、第２の不織布１０Ｂのよれや浮き上がりを防止することができる。なお、吸収体３に第２の不織布１０Ｂをしっかりと固定するために、第２の不織布１０Ｂの端部にサイド不織布６を貼り付けることも好ましい。 Further, at least a part of the bottom surface of the first recess 12 is a flat surface 12S. The flat surface 12S facilitates adhesion between the bottom surface of the first recess 12 and the absorbent body 3 and improves the fixability of the second nonwoven fabric 10B as the surface material, so that the second nonwoven fabric 10B can be warped or lifted. Can be prevented. In addition, in order to fix the 2nd nonwoven fabric 10B to the absorber 3, it is also preferable to affix the side nonwoven fabric 6 to the edge part of the 2nd nonwoven fabric 10B.
　本発明の第２の不織布１０Ｂに用いることができる繊維材料は特に限定されない。具体的には、前記第１の不織布１０Ａと同様の繊維が挙げられる。 The fiber material that can be used for the second nonwoven fabric 10B of the present invention is not particularly limited. Specifically, the same fibers as the first nonwoven fabric 10A can be mentioned.
　また、第１突出部２１Ｂと第２突出部２２Ｂとの繊維密度が異なっている。具体的には、第１突出部２１Ｂの繊維密度が第２突出部２２Ｂの繊維密度より低くなっている。
　第１突出部（第２凸部）２１Ｂにおける繊維密度は後述する測定方法において３０本／ｍｍ２以上１３０本／ｍｍ２以下が好ましく、５０本／ｍｍ２以上１００本／ｍｍ２以下がより好ましい。第２突出部（第２凹部）２２Ｂにおける繊維密度は後述する測定方法において２５０本／ｍｍ２以上５００本／ｍｍ２以下が好ましく、３００本／ｍｍ２以上４５０本／ｍｍ２以下がより好ましい。また、第１突出部（第２凸部）２１Ｂにおける繊維密度と第２突出部（第２凹部）２２Ｂにおける繊維密度の差は、１５０本／ｍｍ２以上であることが好ましい。
　このように繊維密度に差が生じていることから、第２の不織布１０Ｂを吸収性物品の表面シートに用いた場合において、第２の不織布１０Ｂの第１面側Ｚ１から液体が供給された場合、肌に接触する第１突出部２１Ａへの液移行を防ぎ、毛管現象により吸収体に近い第２突出部２２Ａへの液移行を進めることになる。このため、第２の不織布１０Ｂの表面側（第１面側Ｚ１）の液残りが少なくなる。 Moreover, the fiber density of the 1st protrusion part 21B and the 2nd protrusion part 22B differs. Specifically, the fiber density of the first protrusion 21B is lower than the fiber density of the second protrusion 22B.
Preferably 30 present / mm 2 or more 130 present / mm 2 or less in the measurement method the fiber density of the first protrusion (second protrusion) 21B is described below, and more preferably 50 lines / mm 2 or more 100 / mm 2 or less . The fiber density in the second protrusion (second recess) 22B is preferably 250 / mm 2 or more and 500 / mm 2 or less, more preferably 300 / mm 2 or more and 450 / mm 2 or less in the measurement method described later. Moreover, it is preferable that the difference of the fiber density in the 1st protrusion part (2nd convex part) 21B and the fiber density in the 2nd protrusion part (2nd recessed part) 22B is 150 pieces / mm < 2 > or more.
Since the difference in fiber density occurs in this way, when the second nonwoven fabric 10B is used as the top sheet of the absorbent article, the liquid is supplied from the first surface side Z1 of the second nonwoven fabric 10B. Then, the liquid transfer to the first protrusion 21A that contacts the skin is prevented, and the liquid transfer to the second protrusion 22A close to the absorber is promoted by capillary action. For this reason, the liquid residue of the surface side (1st surface side Z1) of the 2nd nonwoven fabric 10B decreases.
　次に、本実施形態の第２の不織布１０Ｂにおける寸法諸元について以下に説明する。
　シートの厚さについては、第２の不織布１０Ｂの側面視としてみたときの全体の厚さをシート厚みＴＳ（＝Ｈ１）とし、その凹凸に湾曲したシートの局部的な厚さを層厚みＴＬとする。シート厚みＴＳは、用途によって適宜調節すればよいが、おむつや生理用品等の表面シートとして用いる場合、１ｍｍ以上７ｍｍ以下が好ましく、１．５ｍｍ以上５ｍｍ以下がより好ましい。その範囲とすることにより、使用時の体液吸収速度が速く、吸収体からの液戻りを抑え、さらには、適度なクッション性を実現することができる。層厚みＴＬは、前述の第１の不織布１０Ａ（第１実施形態）と同様であり、シート内の各部位において異なっていてよく、用途によって適宜調節すればよい。
　また、平面視した上記第１突出部２１Ａと第２突出部２２Ａとの間隔も前述の第１の不織布１０Ａ（第１実施形態）と同様である。 Next, the dimension specification in the 2nd nonwoven fabric 10B of this embodiment is demonstrated below.
Regarding the thickness of the sheet, the total thickness when viewed from the side of the second nonwoven fabric 10B is the sheet thickness TS (= H1), and the local thickness of the sheet curved in the unevenness is the layer thickness TL. To do. The sheet thickness TS may be appropriately adjusted depending on the application, but when used as a surface sheet for diapers, sanitary products, etc., it is preferably 1 mm or more and 7 mm or less, and more preferably 1.5 mm or more and 5 mm or less. By setting it as the range, the body fluid absorption speed at the time of use is high, the liquid return from an absorber is suppressed, and also moderate cushioning property is realizable. The layer thickness TL is the same as that of the above-described first nonwoven fabric 10A (first embodiment), may be different in each part in the sheet, and may be appropriately adjusted depending on the application.
Moreover, the space | interval of the said 1st protrusion part 21A and 22 A of 2nd protrusions which were planarly viewed is the same as that of the above-mentioned 1st nonwoven fabric 10A (1st Embodiment).
　上記第２の不織布１０Ｂの第２凹凸構造２３に適用できるパターン例は、前記第１の不織布１０Ａに用いることができる第２凹凸構造２３と同様なパターンを用いることができる。 The pattern example applicable to the second uneven structure 23 of the second nonwoven fabric 10B can be the same pattern as the second uneven structure 23 that can be used for the first nonwoven fabric 10A.
　上記第２の不織布１０Ｂは、以下のような効果を奏する。
　上記第２の不織布１０Ｂは、***物、特に軟便等の粘性の高い液の捕捉性に優れる。
　第２の不織布１０Ｂは、第１凸部１１の上面で第２凹凸構造２３が作製されていることから、第２凹凸構造２３に軟便等の液が供給された場合、第２凹凸構造２３内である第１凸部１１内に軟便等の粘性の高い液が拡がるが、第１凸部１１の側壁部、すなわち第１凹部１２の外側によって、その液の拡がりは堰き止められるので、それ以上の拡がりを抑えることができる。また、第２凹凸構造２３の表面を流れた軟便等の粘性の高い液は第１凹部１２内に流れ込み、それ以上の拡がりを防止することができる。 The second nonwoven fabric 10B has the following effects.
The second non-woven fabric 10B is excellent in the trapping property of highly viscous liquid such as excrement, particularly soft stool.
In the second nonwoven fabric 10B, since the second concavo-convex structure 23 is formed on the upper surface of the first convex portion 11, when a liquid such as soft stool is supplied to the second concavo-convex structure 23, The liquid having high viscosity such as soft stool spreads in the first convex portion 11, but the spread of the liquid is blocked by the side wall portion of the first convex portion 11, that is, the outer side of the first concave portion 12, and so on. Can be suppressed. In addition, a highly viscous liquid such as soft stool that has flowed through the surface of the second concavo-convex structure 23 flows into the first recess 12 and can prevent further spread.
　また第２凸部２１は第２凹部２２よりも低密度（第１突出部２１Ａの繊維密度＜第２突出部２２Ａの繊維密度）で嵩高なウエブ賦形であることから、第２凹凸構造２３に軟便等の液体が供給されると、第２凸部２１より第１凸部１１の内部空間に導かれ、貯えられる。
　さらに第１凸部１１の繊維密度が均一であることから、部分的に液漏れすることがない。 Further, since the second convex portion 21 has a lower density than the second concave portion 22 (fiber density of the first protruding portion 21A <fiber density of the second protruding portion 22A) and is bulky, the second uneven structure 23 When liquid such as soft stool is supplied to the first convex portion 11, the second convex portion 21 guides the liquid into the internal space of the first convex portion 11 and stores it.
Furthermore, since the fiber density of the 1st convex part 11 is uniform, it does not leak partially.
　上記第２の不織布１０Ｂは、前記第１の不織布１０Ａと同様に優れたクッション性を有し、肌触りに優れる。 The second non-woven fabric 10B has an excellent cushioning property as in the case of the first non-woven fabric 10A, and is excellent in the touch.
　次に、本発明に係る不織布の製造方法および製造装置の好ましい一実施形態（第１実施形態）について、図５から図８に示した不織布の製造装置の概略構成図を参照しながら、以下に説明する。 Next, a preferred embodiment (first embodiment) of the nonwoven fabric production method and production apparatus according to the present invention will be described below with reference to the schematic configuration diagrams of the nonwoven fabric production apparatus shown in FIGS. explain.
　まず、図５から図７を参照して、本発明に係る不織布の製造方法の実施に好ましく用いられる不織布の製造装置１００について説明する。 First, with reference to FIG. 5 to FIG. 7, a nonwoven fabric manufacturing apparatus 100 that is preferably used for carrying out the nonwoven fabric manufacturing method according to the present invention will be described.
　図５から図７に示すように、不織布の製造装置１００は、熱可塑性繊維を含有する繊維ウエブ５０を搬送するとともに賦形形状を付与する支持体１１０を有する。
　この支持体１１０は、図示していない駆動装置によって回転されるドラム１１１とその表面に配された支持体部１１２を有している。この支持体部１１２の凹凸形状によって、前述の第１の不織布１０Ａ、第２の不織布１０Ｂが作製される。また、ドラム１１１には表面全域にわたって通気部（図示せず）が配されている。
　上記繊維ウエブ５０は搬送部１３１としての搬送コンベアによって支持体１１０の表面に供給され、賦形された繊維ウエブ５０は支持体１１０より案内部１３２としての案内ローラよって所定の方向に送り出される。 As shown in FIGS. 5 to 7, the nonwoven fabric manufacturing apparatus 100 includes a support 110 that conveys a fiber web 50 containing thermoplastic fibers and imparts a shaping shape.
The support 110 has a drum 111 that is rotated by a driving device (not shown) and a support portion 112 that is disposed on the surface of the drum 111. The first nonwoven fabric 10 </ b> A and the second nonwoven fabric 10 </ b> B described above are produced by the uneven shape of the support body portion 112. The drum 111 is provided with a ventilation portion (not shown) over the entire surface.
The fiber web 50 is supplied to the surface of the support 110 by a transfer conveyor as the transfer unit 131, and the shaped fiber web 50 is sent out from the support 110 by a guide roller as the guide unit 132 in a predetermined direction.
　ここで支持体１１０について詳細に説明する。
　図６に示すように、前述の不織布１０Ａを作製する際に用いる支持体１１０（１１０Ａ）は、ドラム１１１の表面に、所定間隔を置いて支持体部１１２が配置されている。支持体部１１２には、例えば、支持体基部１１３の面内縦横に突起１１４と孔１１５とが交互に配されている。この支持体基部１１３の表面の高さは、ドラム１１１の表面より高さΔｈ１だけ高くなっている。この高さΔｈ１が存することによって、第１の不織布１０Ａを作製した際の第１凸部１１の高さが第２凸部２１の高さより高くなる。
　また、ドラム１１１の通気部１１７は、ドラム１１１表面に支持体部１１２を配したときに上記孔１１５と連通するように配されている。
　上記支持体１１０Ａでは、支持体部１１２の所定間隔が第１の不織布１０Ａの第１凸部１１を作り出し、支持体部１１２が第１の不織布１０Ａの第２凹部１２、すなわち第２凹凸構造２３の第２凸部２１と第２凹部２２を作り出すようになっている。 Here, the support 110 will be described in detail.
As shown in FIG. 6, the support body 110 (110 </ b> A) used when the above-described nonwoven fabric 10 </ b> A is manufactured has the support body portion 112 arranged on the surface of the drum 111 at a predetermined interval. In the support body portion 112, for example, protrusions 114 and holes 115 are alternately arranged in the longitudinal and lateral directions of the support base portion 113. The height of the surface of the support base 113 is higher than the surface of the drum 111 by a height Δh1. By having this height Δh1, the height of the first convex portion 11 when the first nonwoven fabric 10A is produced becomes higher than the height of the second convex portion 21.
The ventilation portion 117 of the drum 111 is disposed so as to communicate with the hole 115 when the support body portion 112 is disposed on the surface of the drum 111.
In the support 110A, the predetermined interval between the support portions 112 creates the first protrusions 11 of the first nonwoven fabric 10A, and the support portions 112 are the second recesses 12 of the first nonwoven fabric 10A, that is, the second uneven structure 23. The second convex portion 21 and the second concave portion 22 are created.
　また図７に示すように、前述の第２の不織布１０Ｂを作製する際に用いる支持体１１０（１１０Ｂ）は、ドラム１１１の表面に、所定間隔を置いて支持体部１１２が配置されている。支持体部１１２には、例えば、支持体基部１１３の面内縦横に突起１１４と孔１１５とが交互に配されている。また、ドラム１１１の通気部１１７は、ドラム１１１表面に支持体部１１２を配したときに上記孔１１５と連通するように配されている。さらに上記所定間隔の部分に、別の支持体１１６が配されている。この別の支持体１１６は、支持体１１２の高さよりΔｈ２だけ高くなっている。この高さΔｈ２が存することによって、第２の不織布１０Ｂを作製した際に第１凸部１１の周囲に第１凹部１２が作られることになる。また支持体部１１２が第２の不織布１０Ｂの第１凸部１１、すなわち、第２凹凸構造２３の第２凸部２１と第２凹部２２を作り出し、支持体部１１２の所定間隔に存する別の支持体１１６が第２の不織布１０Ｂの第１凹部１２を作り出すようになっている。 Further, as shown in FIG. 7, the support 110 (110B) used when producing the second nonwoven fabric 10B described above has the support 112 placed on the surface of the drum 111 at a predetermined interval. In the support body portion 112, for example, protrusions 114 and holes 115 are alternately arranged in the longitudinal and lateral directions of the support base portion 113. The ventilation portion 117 of the drum 111 is disposed so as to communicate with the hole 115 when the support body portion 112 is disposed on the surface of the drum 111. Further, another support 116 is disposed at the predetermined interval. This other support 116 is higher than the height of the support 112 by Δh2. By having this height Δh2, the first concave portion 12 is formed around the first convex portion 11 when the second nonwoven fabric 10B is produced. In addition, the support body 112 creates the first protrusions 11 of the second nonwoven fabric 10B, that is, the second protrusions 21 and the second recesses 22 of the second uneven structure 23. The support 116 is adapted to create the first recess 12 of the second nonwoven fabric 10B.
　上記いずれの場合も突起１１４は、先端に向かうにしたがって先細りになる形状を有し、その先端部は丸みが形成されている、例えば紡錘形状を成す。その高さは不織布の用途、規格等により変わり、特に制限するものではないが、通常、３ｍｍ以上３０ｍｍ以下に形成され、突起ピッチはＭＤ方向に６ｍｍ以上１５ｍｍ以下であり、ＣＤ方向に４ｍｍ以上８ｍｍ以下になっている。ＭＤ方向とは、繊維ウエブ５０の搬送方向であり、ＣＤ方向とは支持体１１０の表面におけるＭＤ方向に対して直行する方向をいう。この突起１１４は、その高さが低すぎては繊維ウエブ５０に十分な凹凸を賦形することができず、高すぎると熱風を吹き付けたときに突起１１４が繊維ウエブ５０を突き抜ける可能性がある。よって、突起１１４は、上記範囲の高さで適宜設定される。そして好ましくは、３ｍｍ以上１０ｍｍ以下の高さに形成され、ＭＤ方向に６ｍｍ以上１０ｍｍ以下に配され、ＣＤ方向に４ｍｍ以上６ｍｍ以下に配されている。 In any of the above cases, the protrusion 114 has a shape that tapers toward the tip, and the tip has a round shape, for example, a spindle shape. The height varies depending on the use, standard, etc. of the nonwoven fabric, and is not particularly limited, but is usually formed to 3 mm to 30 mm, the protrusion pitch is 6 mm to 15 mm in the MD direction, and 4 mm to 8 mm in the CD direction. It is as follows. The MD direction is the conveyance direction of the fiber web 50, and the CD direction is a direction perpendicular to the MD direction on the surface of the support 110. If the height of the projection 114 is too low, sufficient unevenness cannot be formed on the fiber web 50. If the height is too high, the projection 114 may penetrate the fiber web 50 when hot air is blown. . Therefore, the protrusion 114 is appropriately set within the above range. And preferably, it is formed at a height of 3 mm or more and 10 mm or less, is arranged in the MD direction at 6 mm or more and 10 mm or less, and is arranged in the CD direction at 4 mm or more and 6 mm or less.
　また上記孔１１５は、支持体１１０に配された複数の開口部からなり、その開口率が支持体１１０の表面積に対して２０％以上４５％以下に設定されている。この開口率は好ましくは２５％以上４０％以下に設定され、より好ましくは３０％以上３５％以下に設定される。開口率が２０％未満では、繊維ウエブ５０に十分な凹凸形状を賦形することが難しくなり、開口率が４５％を超えると、熱風を吹き付けた際に繊維ウエブ５０が支持体１１０の下に移行して支持体１１０から剥離しにくくなり、賦形形状の悪化や毛羽が形成されやすくなる可能性がある。 The hole 115 is composed of a plurality of openings disposed in the support 110, and the opening ratio is set to 20% or more and 45% or less with respect to the surface area of the support 110. This aperture ratio is preferably set to 25% or more and 40% or less, more preferably 30% or more and 35% or less. If the opening ratio is less than 20%, it is difficult to form a sufficient uneven shape on the fiber web 50. If the opening ratio exceeds 45%, the fiber web 50 is under the support 110 when hot air is blown. It may become difficult to peel off from the support 110, and the shaped shape may be deteriorated or fluff may be easily formed.
　再び図５を参照する。上記支持体１１０は、回転することにより、支持体部１１２に配された突起１１４で繊維ウエブ５０を掛け止めるようにして繊維ウエブ５０を搬送する。支持体１１０の外方には、繊維ウエブ５０の供給方向にそって順に、第１の熱風Ｗ１を吹き付ける第１ノズル１２１と、第２の熱風Ｗ２を吹き付ける第２ノズル１２２とが備られている。 Refer to FIG. 5 again. By rotating the support 110, the fiber web 50 is transported so that the fiber web 50 is hooked by the protrusions 114 arranged on the support 112. A first nozzle 121 that blows the first hot air W1 and a second nozzle 122 that blows the second hot air W2 are provided outside the support 110 in order along the supply direction of the fiber web 50. .
　第１ノズル１２１は、ヒータ１２３を備え、ヒータ１２３で加熱された第１の熱風Ｗ１を、通気性を有する通気コンベア１３３を通して支持体１１０の表面に対して、例えばほぼ垂直に吹き付ける。第１ノズル１２１の吹き付け孔は、好ましくは、ＭＤ方向における長さが１ｍｍ以上２０ｍｍ以下で、ＣＤ方向における長さはウエブ幅以上、または賦形加工を行う幅である。吹き付け孔は、一列または多列のスリット形状、一列または多列に丸孔、長孔もしくは角孔が千鳥もしくは直列に配置した形状を有している。より好ましくは、ＭＤ方向における長さが２ｍｍ以上２０ｍｍ以下の一列のスリット形状を有している。このように、第１ノズル１２１の吹き付け孔が形成されていることから、第１の熱風Ｗ１が繊維ウエブ５０の表面の幅方向に均一な風速で吹き付けられる。この第１の熱風Ｗ１には、上記ヒータ１２３によって所定温度に加熱された空気、窒素または水蒸気を用いることができる。好ましくは、コストがかからない空気を用いる。
　第１ノズル１２１から吹き付ける第１の熱風Ｗ１の温度は、繊維ウエブ５０の繊維同士を凹凸形状が保持される状態に仮融着させる温度にヒータ１２３によって制御されている。また第１の熱風Ｗ１の風速は、支持体１１０の凹凸形状に沿うように適宜に調節される。 The first nozzle 121 includes a heater 123, and blows the first hot air W <b> 1 heated by the heater 123 to the surface of the support 110 through the air-permeable conveyor 133 having air permeability, for example, substantially perpendicularly. The spray holes of the first nozzle 121 preferably have a length in the MD direction of 1 mm or more and 20 mm or less, and the length in the CD direction is a web width or more, or a width for shaping. The spray holes have a shape in which one or more rows of slit holes are formed, and round holes, long holes or square holes are arranged in a staggered manner or in series in one or more rows. More preferably, it has a slit shape with a length in the MD direction of 2 mm or more and 20 mm or less. Thus, since the blowing hole of the first nozzle 121 is formed, the first hot air W1 is blown at a uniform wind speed in the width direction of the surface of the fiber web 50. As the first hot air W1, air, nitrogen, or water vapor heated to a predetermined temperature by the heater 123 can be used. Preferably, air that does not cost is used.
The temperature of the first hot air W <b> 1 blown from the first nozzle 121 is controlled by the heater 123 to a temperature at which the fibers of the fiber web 50 are temporarily fused so that the uneven shape is maintained. Moreover, the wind speed of the 1st hot air W1 is suitably adjusted so that the uneven | corrugated shape of the support body 110 may be followed.
　上記通気コンベア１３３は、第１の熱風Ｗ１が吹き付けられる位置の手前から吹き付けられた位置を過ぎるまで、繊維ウエブ５０を支持体１１０との間で挟みつつ、支持体１１０の表面にそって繊維ウエブ５０を送り側に搬送する。この通気コンベア１３３によって第１ノズル１２１から吹きつける第１の熱風Ｗ１による繊維ウエブ５０の乱れ、飛散が防止できる。 The aeration conveyor 133 holds the fiber web 50 along the surface of the support 110 while sandwiching the fiber web 50 with the support 110 until it passes the position where the first hot air W1 is blown before the position where it is blown. 50 is conveyed to the sending side. Disturbance and scattering of the fiber web 50 due to the first hot air W <b> 1 blown from the first nozzle 121 by the aeration conveyor 133 can be prevented.
　第２ノズル１２２は、ヒータ１２４を備え、ヒータ１２４で加熱された第２の熱風Ｗ２を、支持体１１０の表面に対して、例えばほぼ垂直に吹き付ける。第２ノズル１２２の吹き付け孔は、幅方向、流れ方向に規則的に開孔しているパンチングメタルを使用することが望ましい。開孔率は、好ましくは１０％以上４０％以下であり、より好ましくは２０％以上３０％以下である。このように、第２ノズル１２２の吹き付け孔が形成されていることから、第２の熱風Ｗ２が繊維ウエブ５０の表面の幅方向に均一な風速で吹き付けられる。この第２の熱風Ｗ２には、上記ヒータ１２４によって加熱された空気、窒素または水蒸気を用いることができる。好ましくは、コストがかからない空気を用いる。
　第２ノズル１２２から吹きつける第２の熱風Ｗ２の温度は、ヒータ１２４によって、第１の熱風Ｗ１で仮融着された繊維ウエブ５０の凹凸形状を保持した状態で繊維ウエブ５０の繊維同士を融着させてその凹凸形状を固定する温度に制御されている。また第２の熱風Ｗ２の風速は、その目的を考慮して適宜に定められるが、風速が遅すぎると繊維への熱伝達ができず、繊維が融着せず凹凸形状の固定が不十分になる。一方、風速が速すぎると、繊維へ熱が当たりすぎるため、風合いが悪くなる傾向となることを考慮して決定される。 The second nozzle 122 includes a heater 124, and blows the second hot air W2 heated by the heater 124 to the surface of the support 110, for example, substantially perpendicularly. It is desirable to use a punching metal that is regularly opened in the width direction and the flow direction as the spray hole of the second nozzle 122. The open area ratio is preferably 10% or more and 40% or less, and more preferably 20% or more and 30% or less. Thus, since the blowing holes of the second nozzle 122 are formed, the second hot air W2 is blown at a uniform wind speed in the width direction of the surface of the fiber web 50. As the second hot air W2, air, nitrogen or water vapor heated by the heater 124 can be used. Preferably, air that does not cost is used.
The temperature of the second hot air W2 blown from the second nozzle 122 is such that the fibers of the fiber web 50 are melted by the heater 124 while the uneven shape of the fiber web 50 temporarily fused with the first hot air W1 is maintained. The temperature is controlled to fix the uneven shape by wearing. The wind speed of the second hot air W2 is appropriately determined in consideration of its purpose. However, if the wind speed is too slow, heat cannot be transferred to the fibers, the fibers are not fused, and the uneven shape is insufficiently fixed. . On the other hand, when the wind speed is too high, heat is applied to the fiber too much, so that the texture tends to deteriorate.
　さらに、第１ノズル１２１の吹き出し方向には、第１ノズル１２１から通気コンベア１３３、繊維ウエブ５０、支持体１１０を通して吹き付けられた第１の熱風Ｗ１を吸引する吸引部１２５が配されている。この吸引部１２５には、吸引された第１の熱風Ｗ１を排気する排気装置１２７が接続されている。またさらに、第２ノズル１２２の吹き出し方向には、第２ノズル１２２から繊維ウエブ５０、支持体１１０を通して吹き付けられた第２の熱風Ｗ２を吸引する吸引部１２６が配されている。この吸引部１２６には、吸引された第２の熱風Ｗ２を排気する排気装置１２８が接続されている。また、何れの吸引部もＣＤ方向の長さが適宜調整可能な構造とすることができる。このような吸引部１２６を配することにより、吹き付ける熱風の跳ね返り等によりウエブが乱れることを防止し、所望の形状に安定して賦形することができる。また、ドラム周りが高温になりすぎることを防止し、これと接するウエブが過度に融着して硬くなることを防止できる。さらに、ウエブを支持体に保持しやすくなり、搬送が容易になる。熱風温度の安定化、ユーティリティーのランニングコストを考えると熱風は循環して使用することが望ましい。 Further, in the blowing direction of the first nozzle 121, a suction part 125 for sucking the first hot air W1 blown from the first nozzle 121 through the aeration conveyor 133, the fiber web 50, and the support 110 is disposed. The suction unit 125 is connected to an exhaust device 127 that exhausts the sucked first hot air W1. Furthermore, in the blowing direction of the second nozzle 122, a suction portion 126 that sucks the second hot air W2 blown from the second nozzle 122 through the fiber web 50 and the support 110 is disposed. The suction unit 126 is connected to an exhaust device 128 that exhausts the sucked second hot air W2. In addition, any suction part can have a structure in which the length in the CD direction can be adjusted as appropriate. By arranging such a suction portion 126, it is possible to prevent the web from being disturbed by the rebound of hot air to be blown or the like, and to stably shape the web into a desired shape. In addition, the temperature around the drum can be prevented from becoming too high, and the web in contact with the drum can be prevented from being excessively fused and hardened. Furthermore, it becomes easy to hold the web on the support and the conveyance becomes easy. Considering the stabilization of hot air temperature and the running cost of utilities, it is desirable to circulate and use hot air.
　上述の第１実施形態の不織布の製造装置１００では、第１ノズル１２１で第１の熱風Ｗ１を吹き付けて繊維ウエブ５０の繊維同士を凹凸形状が保持される状態に仮融着させることができる。この状態で、第２ノズル１２２によって第２の熱風Ｗ２を吹き付けることから、繊維ウエブ５０の繊維同士が融着され、凹凸形状を維持した状態で固定することができる。さらに、繊維ウエブ５０に第１、第２の熱風Ｗ１、Ｗ２を吹き付けることから、熱により繊維ウエブ５０の繊維が柔軟化されるので、支持体部１１２の表面形状に沿いやすくなり、凹凸形状の保持性がよくなる。その際、第１、第２の熱風Ｗ１、Ｗ２は、支持体部に形成された通気孔を通過することから、繊維ウエブ５０を突起１１４の表面により沿わせ易くなる。その結果、賦形性のよい低密度で嵩高な不織布が得られる。 In the nonwoven fabric manufacturing apparatus 100 of the first embodiment described above, the first hot air W1 can be blown by the first nozzle 121 to temporarily fuse the fibers of the fiber web 50 so that the uneven shape is maintained. In this state, since the second hot air W <b> 2 is blown by the second nozzle 122, the fibers of the fiber web 50 can be fused and fixed while maintaining the uneven shape. Furthermore, since the first and second hot air W1 and W2 are blown onto the fiber web 50, the fibers of the fiber web 50 are softened by heat, so that it becomes easier to follow the surface shape of the support 112, and the irregular shape Retention is improved. At this time, since the first and second hot air W1 and W2 pass through the air holes formed in the support portion, the fiber web 50 is more likely to follow along the surface of the protrusion 114. As a result, a low density and bulky nonwoven fabric with good formability can be obtained.
　繊維ウエブ５０は、第１ノズル１２１から吹き付ける第１の熱風Ｗ１により支持体１１０の凹凸形状に沿うよう変形かつ弱く繊維間固着され、第２ノズル１２２から吹き付ける第２の熱風Ｗ２によって熱融着して不織布とされる。ここで、支持体１１０の凹凸形状に沿うよう変形とは、支持体１１０の一部分において沿うように変形されていればよく、完全に支持体１１０Ｔの形状に接触していなくてもよい。繊維ウエブ５０が支持体１１０の凹凸形状に沿いすぎた場合、前述した支持体１１０からの離間時に賦形形状の崩れや毛羽形成等の影響だけでなく、不織布の実質的な厚みが低下し繊維の融着点が増加する、支持体１１０との接触による過度な繊維融着が起こる等により、不織布から柔軟性が損なわれてしまう。そのため、支持体部１１２の突起１１４の先端と繊維ウエブ５０は直接接触することが賦形性を良好とする点から好ましく、突起１１４の孔１１５側では繊維ウエブ５０は支持体部１１２と離間して隙間を形成していることが不織布の柔軟性や低密度構造形成の点から好ましい。また、突起１１４の孔１１５側に該隙間を形成していることにより、第２の熱風Ｗ２が繊維ウエブ５０の厚み方向に貫通し易くなることで、熱風吹き付け面側と支持体１１０側の繊維の融着状態に差が生じにくくなり、嵩高な構造が圧縮や引張等の変形に対しても回復され易く、毛羽となりにくい不織布となる。同様の観点から、さらに、孔１１５においても繊維ウエブ５０との間に隙間を形成していることがより好ましい。 The fiber web 50 is deformed and weakly fixed between the fibers by the first hot air W1 blown from the first nozzle 121 so as to follow the uneven shape of the support 110, and is thermally fused by the second hot air W2 blown from the second nozzle 122. And non-woven fabric. Here, the deformation so as to conform to the uneven shape of the support 110 is not limited as long as it is deformed so as to be along a part of the support 110 and may not be completely in contact with the shape of the support 110T. When the fiber web 50 is too along the uneven shape of the support 110, not only the influence of the shape deformation and the formation of fluff at the time of separation from the support 110 described above, but also the substantial thickness of the nonwoven fabric is reduced. The flexibility of the nonwoven fabric is impaired due to an increase in the fusion point of the fiber and excessive fiber fusion caused by contact with the support 110. For this reason, it is preferable that the tip of the protrusion 114 of the support 112 and the fiber web 50 are in direct contact with each other from the viewpoint of improving the shapeability, and the fiber web 50 is separated from the support 112 at the hole 115 side of the protrusion 114. It is preferable from the viewpoint of the flexibility of the nonwoven fabric and the formation of a low density structure. Further, by forming the gap on the hole 115 side of the protrusion 114, the second hot air W2 can easily penetrate in the thickness direction of the fiber web 50, so that the fibers on the hot air blowing surface side and the support 110 side are Thus, a non-woven fabric that does not easily become fluff is obtained. From the same viewpoint, it is more preferable that a gap is formed between the fiber 115 and the hole 115.
　さらに、該隙間によって支持体１１０と直接接触した場合には、支持体１１０が各熱風によって繰り返し暖められているため、繊維ウエブ５０の支持体１１０側の面で繊維の融着が過度に進んで表面が硬くなり、その結果風合いが悪化する。しかし、支持体１１０と離間させることで支持体１１０の熱による影響を低減できる。 Further, when the support 110 is in direct contact with the gap, the support 110 is repeatedly warmed by each hot air, so that the fiber fusion is excessively advanced on the surface of the fiber web 50 on the support 110 side. The surface becomes hard and as a result, the texture deteriorates. However, the influence of the heat of the support 110 can be reduced by separating from the support 110.
　また、支持体１１０がドラム状に形成されているので、装置構成を小型化でき、装置の占有面積を縮小化できる。また、支持体１１０がドラム形状に構成されているため、従来のコンベア式の支持体よりも賦形した繊維ウエブ５０の繊維が支持体部１１２より剥離しやすくなる。 Further, since the support 110 is formed in a drum shape, the apparatus configuration can be reduced in size and the area occupied by the apparatus can be reduced. Further, since the support body 110 is formed in a drum shape, the fibers of the shaped fiber web 50 are more easily separated from the support body portion 112 than the conventional conveyor-type support body.
　次に、本発明の不織布１０の製造方法の実施に好ましく用いられる製造装置の別の一例について、図８を参照して説明する。 Next, another example of a production apparatus preferably used for carrying out the method for producing the nonwoven fabric 10 of the present invention will be described with reference to FIG.
　図８に示すように、不織布の製造装置２００は、前述の不織布の製造装置１００において、通気コンベア１３３の配置が異なるものであり、その他の構成部品は前述の不織布の製造装置１００の構成部品と同様である。すなわち、通気コンベア１３３は、第１の熱風Ｗ１が吹き付けられる位置の手前から第２の熱風Ｗ２が吹き付けられた位置を過ぎるまで、繊維ウエブ５０を支持体１１０との間で挟みつつ、支持体１１０の表面にそって繊維ウエブ５０を送り側に搬送するものである。この通気コンベア１３３によって第１ノズル１２１から吹きつける第１の熱風Ｗ１および第２ノズル１２２か吹きつける第２の熱風Ｗ２による繊維ウエブ５０の乱れ、飛散が防止できる。さらに不織布の製造装置２００は、前述の不織布の製造装置１００と同様な作用効果が得られる。 As shown in FIG. 8, the nonwoven fabric manufacturing apparatus 200 is different from the nonwoven fabric manufacturing apparatus 100 in the arrangement of the aeration conveyor 133, and other components are the same as those of the nonwoven fabric manufacturing apparatus 100. It is the same. That is, the ventilation conveyor 133 supports the support 110 while sandwiching the fiber web 50 between the support 110 and the position before the position where the second hot air W2 is blown before the position where the first hot air W1 is blown. The fiber web 50 is conveyed to the feed side along the surface. Disturbance and scattering of the fiber web 50 due to the first hot air W1 blown from the first nozzle 121 and the second hot air W2 blown from the second nozzle 122 by the aeration conveyor 133 can be prevented. Furthermore, the nonwoven fabric manufacturing apparatus 200 can obtain the same effects as the nonwoven fabric manufacturing apparatus 100 described above.
　次に、本発明に係る不織布の製造方法の好ましい一実施形態（第１実施形態）について、前述の図５および図６を参照しながら、以下に説明する。
　第１実施形態の不織布の製造方法は、前述の不織布の製造装置１００または２００によって実現される。ここでは、一例として不織布の製造装置１００を用いた場合を説明する。なお、不織布の製造装置２００を用いた場合も同様の製造方法になる。 Next, a preferred embodiment (first embodiment) of the method for producing a nonwoven fabric according to the present invention will be described below with reference to FIGS. 5 and 6 described above.
The manufacturing method of the nonwoven fabric of 1st Embodiment is implement | achieved by the manufacturing apparatus 100 or 200 of the above-mentioned nonwoven fabric. Here, the case where the manufacturing apparatus 100 of a nonwoven fabric is used as an example is demonstrated. The same manufacturing method is used when the nonwoven fabric manufacturing apparatus 200 is used.
　まず、搬送部１３１によって繊維ウエブ５０を支持体１１０の突起１１４が形成された表面に搬送する。
　繊維ウエブ５０の繊維に用いることができる繊維材料は特に限定されない。具体的には、前述の繊維などが挙げられる。また繊維ウエブ５０の坪量は、特に限定されないが、１０ｇ／ｍ２以上５０ｇ／ｍ２以下が好ましく、２０ｇ／ｍ２以上４０ｇ／ｍ２以下であることがより好ましい。 First, the fiber web 50 is transported by the transport unit 131 to the surface of the support 110 on which the protrusions 114 are formed.
The fiber material that can be used for the fibers of the fiber web 50 is not particularly limited. Specifically, the above-mentioned fibers and the like can be mentioned. The basis weight of the fiber web 50 is not particularly limited, but is preferably 10 g / m 2 or more and 50 g / m 2 or less, more preferably 20 g / m 2 or more and 40 g / m 2 or less.
　そして支持体１１０表面に搬送された繊維ウエブ５０をさらに通気コンベア１３３と支持体１１０とによって挟むようにして搬送する。このとき、支持体１１０の回転時の周速度と通気コンベア１３３の搬送速度とが一致するように、双方を制御することが好ましい。 Then, the fiber web 50 conveyed to the surface of the support 110 is further conveyed so as to be sandwiched between the aeration conveyor 133 and the support 110. At this time, it is preferable to control both so that the peripheral speed at the time of rotation of the support body 110 and the conveyance speed of the ventilation conveyor 133 coincide.
　次に第１ノズル１２１より第１の熱風Ｗ１を吹き付け、通気コンベア１３３を通して繊維ウエブ５０に吹き付ける。このとき、第１の熱風Ｗ１は、支持体１１０の表面に対して垂直方向から吹き付ける。また第１ノズル１２１の吹き出し数は繊維ウエブ５０の搬送方向にそって複数個所としてもよい。この第１の熱風Ｗ１によって、支持体１１０の突起１１４の形状に沿った凹凸形状に繊維ウエブ５０が賦形される。繊維ウエブ５０の繊維同士の融着は、その凹凸形状が維持できる程度の仮融着でよい。
　このとき、第１の熱風Ｗ１の温度は、繊維の種類、加工速度、熱風の風速などによって変わるので一義的に定めることはできないが、繊維ウエブ５０の繊維の低融点成分の融点より６０℃低い温度以上とすることが好ましく、この融点より１５℃高い温度以下の温度に制御することが好ましい。より好ましくは低融点成分の融点より５０℃低い温度以上この融点より１０℃高い温度以下に制御する。例えば低融点成分として融点１３２℃のポリエチレンを用いた場合には、好ましい温度範囲は、７２℃以上１４７℃以下、より好ましくは８２℃以上１４２℃以下となる。
　なお、第１の熱風Ｗ１の温度が繊維ウエブ５０の繊維の低融点成分の融点より６０℃低い温度より低すぎる場合、繊維の戻りが生じ賦形性が悪くなる。他方、繊維ウエブ５０の繊維の低融点成分の融点より１５℃高い温度より高すぎると、繊維同士が一気に融着し、自由度の低下により賦形性が損なわれることとなる。 Next, the 1st hot air W1 is sprayed from the 1st nozzle 121, and it sprays on the fiber web 50 through the ventilation conveyor 133. FIG. At this time, the first hot air W <b> 1 is blown from the direction perpendicular to the surface of the support 110. Further, the number of blowouts of the first nozzle 121 may be a plurality of locations along the conveying direction of the fiber web 50. By this first hot air W1, the fiber web 50 is shaped into a concavo-convex shape along the shape of the protrusion 114 of the support 110. The fusion of the fibers of the fiber web 50 may be a temporary fusion that can maintain the uneven shape.
At this time, the temperature of the first hot air W1 varies depending on the type of fiber, the processing speed, the wind speed of the hot air, etc., and thus cannot be uniquely determined, but is 60 ° C. lower than the melting point of the low melting point component of the fiber of the fiber web 50. It is preferable to set the temperature to be equal to or higher than the temperature, and it is preferable to control the temperature to be equal to or lower than 15 ° C. higher than the melting point. More preferably, the temperature is controlled to a temperature that is 50 ° C. lower than the melting point of the low-melting point component or more and 10 ° C. lower than this melting point. For example, when polyethylene having a melting point of 132 ° C. is used as the low melting point component, a preferable temperature range is 72 ° C. or higher and 147 ° C. or lower, more preferably 82 ° C. or higher and 142 ° C. or lower.
In addition, when the temperature of the 1st hot air W1 is too lower than the temperature 60 degreeC lower than the melting | fusing point of the low melting point component of the fiber of the fiber web 50, a fiber will return and shaping property will worsen. On the other hand, if the temperature is higher than the melting point of the low melting point component of the fiber of the fiber web 50 by 15 ° C., the fibers are fused at a stretch, and the formability is impaired due to a decrease in the degree of freedom.
　また第１の熱風Ｗ１の風速は適宜に調節されるが、好ましくは、１０ｍ／ｓｅｃ以上１２０ｍ／ｓｅｃ以下の風速に制御する。第１ノズル１２１から吹き付ける第１の熱風Ｗ１の風速が遅すぎると繊維が十分に支持体に沿わないことおよび繊維の融着が弱く賦形ができず、嵩高な凹凸形状とならない。一方、風速が速すぎると、繊維ウエブ５０の繊維が支持体部１１２の突起１１４により選り分けられ、繊維が支持体の形状に沿った凹凸形状にならず、また開孔した不織布となる。よって、第１の熱風Ｗ１の風速は上記の範囲とするのが好ましい。またより好ましくは、２０ｍ／ｓｅｃ以上８０ｍ／ｓｅｃ以下とし、特に好ましくは４０ｍ／ｓｅｃ以上６０ｍ／ｓｅｃ以下とする。 Further, the wind speed of the first hot air W1 is appropriately adjusted, but is preferably controlled to a wind speed of 10 m / sec or more and 120 m / sec or less. If the wind speed of the first hot air W1 blown from the first nozzle 121 is too slow, the fibers do not sufficiently follow the support and the fibers are weakly fused and cannot be shaped, resulting in a bulky uneven shape. On the other hand, if the wind speed is too high, the fibers of the fiber web 50 are selected by the protrusions 114 of the support body 112, and the fibers do not have an uneven shape along the shape of the support, and become a non-woven fabric with holes. Therefore, the wind speed of the first hot air W1 is preferably in the above range. More preferably, it is 20 m / sec or more and 80 m / sec or less, and particularly preferably 40 m / sec or more and 60 m / sec or less.
　そして繊維ウエブ５０を通過した第１の熱風Ｗ１は、支持体１１０の孔１１５を通して吸引部１２５より排気装置１２７によって外部に排気される。 Then, the first hot air W1 that has passed through the fiber web 50 is exhausted to the outside by the exhaust device 127 from the suction portion 125 through the hole 115 of the support 110.
　次に、繊維ウエブ５０を支持体１１０の回転とともに第２ノズル１２２の第２の熱風Ｗ２の吹き付け位置まで搬送する。そして、第２ノズル１２２によって第２の熱風Ｗ２を吹き付け、繊維ウエブ５０の凹凸形状を保持した状態で繊維ウエブ５０の繊維同士を融着させて凹凸形状を固定する。この第２の熱風Ｗ２は、支持体１１０の表面に対して垂直方向から吹き付ける。また第２ノズル１２２の吹き出し数は繊維ウエブ５０の搬送方向にそって複数個所とすることが好ましい。
　第２の熱風Ｗ２の温度は、繊維の種類、加工速度、熱風の風速などによって変わるので一義的に定めることはできないが、ヒータ１２４によって、第１の熱風Ｗ１で仮融着された繊維ウエブ５０の凹凸形状を保持した状態で繊維ウエブ５０の繊維同士を融着させてその凹凸形状を固定する温度に制御することが好ましい。例えば、繊維ウエブ５０の繊維は低融点成分とこの低融点成分より融点の高い高融点成分を有する複合繊維である場合、第２の熱風Ｗ２は、繊維ウエブ５０の繊維の低融点成分の融点以上、繊維ウエブ５０の繊維の高融点成分の融点未満、好ましくは低融点成分の融点より４０℃高い温度以下の温度の熱風に制御することが好ましい。より好ましくは低融点成分の融点以上この融点より２０℃高い温度以下、さらに好ましい温度として低融点成分の融点以上この融点より１５℃高い温度以下に制御する。例えば低融点成分として融点１３２℃のポリエチレンを用いた場合には、より好ましい温度範囲は１３２℃以上１５２℃以下、さらに好ましくは１３２℃以上１４７℃以下となる。
　なお、第２の熱風Ｗ２の温度が繊維ウエブ５０の繊維の低融点成分の融点未満であると、凹凸形状の保持性が不十分になる。他方、１８０℃を超える温度であると、風合いが悪くなる。 Next, the fiber web 50 is conveyed to the position where the second hot air W2 is blown from the second nozzle 122 as the support 110 rotates. Then, the second hot air W <b> 2 is blown by the second nozzle 122, and the fibers of the fiber web 50 are fused together while the uneven shape of the fiber web 50 is maintained, thereby fixing the uneven shape. The second hot air W2 is blown from the direction perpendicular to the surface of the support 110. The number of blowouts of the second nozzle 122 is preferably set at a plurality of locations along the direction in which the fiber web 50 is conveyed.
Although the temperature of the second hot air W2 varies depending on the type of fiber, the processing speed, the wind speed of the hot air, etc., it cannot be uniquely determined. However, the fiber web 50 temporarily fused with the first hot air W1 by the heater 124. It is preferable to control the temperature to fix the uneven shape by fusing the fibers of the fiber web 50 while maintaining the uneven shape. For example, when the fiber of the fiber web 50 is a composite fiber having a low melting point component and a high melting point component having a higher melting point than the low melting point component, the second hot air W2 is equal to or higher than the melting point of the low melting point component of the fiber of the fiber web 50. It is preferable to control the hot air at a temperature lower than the melting point of the high melting point component of the fiber of the fiber web 50, preferably 40 ° C. or higher than the melting point of the low melting point component. More preferably, the melting point is not less than the melting point of the low melting point component and not more than 20 ° C. above this melting point, and more preferably the temperature is not less than the melting point of the low melting point component and not more than 15 ° C. above this melting point. For example, when polyethylene having a melting point of 132 ° C. is used as the low melting point component, a more preferable temperature range is 132 ° C. to 152 ° C., more preferably 132 ° C. to 147 ° C.
If the temperature of the second hot air W2 is lower than the melting point of the low melting point component of the fiber of the fiber web 50, the uneven shape retainability is insufficient. On the other hand, if the temperature is higher than 180 ° C., the texture becomes worse.
　また第２ノズル１２２から吹き付けられる第２の熱風Ｗ２の風速もその目的を考慮して適宜に定められるが、好ましくは、１ｍ／ｓｅｃ以上１０ｍ／ｓｅｃ以下の風速に制御される。第２ノズル１２２から吹き付ける第２の熱風Ｗ２の風速が遅すぎると繊維への熱伝達ができず、繊維が融着せず凹凸形状の固定が不十分になる。一方、風速が速すぎると、繊維へ熱が当たりすぎるため、風合いが悪くなる傾向となる。よって、第２の熱風Ｗ２の風速は上記の範囲とするのが好ましい。より好ましくは、１ｍ／ｓｅｃ以上８ｍ／ｓｅｃ以下とし、特に好ましくは２ｍ／ｓｅｃ以上６ｍ／ｓｅｃ以下とする。 Also, the wind speed of the second hot air W2 blown from the second nozzle 122 is appropriately determined in consideration of the purpose, but is preferably controlled to a wind speed of 1 m / sec or more and 10 m / sec or less. If the wind speed of the second hot air W2 blown from the second nozzle 122 is too slow, heat cannot be transferred to the fibers, the fibers will not be fused, and the uneven shape will be insufficiently fixed. On the other hand, if the wind speed is too high, the fiber will be too hot and the texture will tend to be poor. Therefore, the wind speed of the second hot air W2 is preferably in the above range. More preferably, it is 1 m / sec or more and 8 m / sec or less, and particularly preferably 2 m / sec or more and 6 m / sec or less.
　その後、賦形された繊維ウエブ５０は支持体１１０より案内部１３２としての案内ローラよって所定の方向に送り出される。 Thereafter, the shaped fiber web 50 is sent out in a predetermined direction from the support 110 by a guide roller as the guide portion 132.
　上述の第１実施形態の不織布の製造方法では、第１の熱風Ｗ１の吹き付けにより繊維ウエブ５０の繊維同士を凹凸形状が保持される状態に仮融着させてから、第２の熱風Ｗ２の吹き付けにより凹凸形状を保持した状態で繊維ウエブ５０の繊維同士を融着させるので、その凹凸形状に固定することができる。また、第１の熱風Ｗ１による熱により繊維ウエブ５０の繊維が柔軟化されるので支持体１１０の突起１１４の形状に沿いやすくなり、凹凸形状の保持性がよくなる。その結果、賦形性のよい低密度で嵩高な不織布が得られる。 In the method for manufacturing the nonwoven fabric of the first embodiment described above, the first hot air W1 is sprayed to temporarily bond the fibers of the fiber web 50 so that the uneven shape is maintained, and then the second hot air W2 is sprayed. Thus, the fibers of the fiber web 50 are fused together in a state where the concavo-convex shape is maintained, so that the concavo-convex shape can be fixed. Moreover, since the fiber of the fiber web 50 is softened by the heat of the first hot air W1, it becomes easy to follow the shape of the protrusion 114 of the support 110, and the uneven shape retainability is improved. As a result, a low density and bulky nonwoven fabric with good formability can be obtained.
　すなわち、繊維ウエブ５０に第１の熱風Ｗ１および第２の熱風Ｗ２を吹き付けて、第１凸部１１とそれに囲まれた第１凹部１２とに賦形された第１凹凸構造１３に作製できる。それとともに、第１凹部１２底面を第１凸部１１とそれより高さが低い第２凸部２１とに賦形された第２凹凸構造２３に作製できる。よって、第２凹凸構造２３に軟便等の粘性の高い液が供給された場合、第２凹凸構造２３がある第１凹部１２内にその液が拡がるが、第１凸部１１によってその液の拡がりは堰き止められ、それ以上の拡がりを抑えることができる不織布１０Ａを製造できる。 In other words, the first hot air W1 and the second hot air W2 are blown onto the fiber web 50, so that the first concavo-convex structure 13 formed into the first convex portion 11 and the first concave portion 12 surrounded by the first hot air W1 can be produced. At the same time, the bottom surface of the first concave portion 12 can be formed into the second concave-convex structure 23 shaped into the first convex portion 11 and the second convex portion 21 having a lower height. Therefore, when a highly viscous liquid such as soft stool is supplied to the second uneven structure 23, the liquid spreads in the first recess 12 where the second uneven structure 23 is located, but the liquid is expanded by the first protrusion 11. Can be produced, and a nonwoven fabric 10A that can suppress further spreading can be manufactured.
　次に、本発明に係る不織布の製造方法の第２実施形態については、前述の図７に示した支持体１１０Ｂを用いること以外、上述の第１実施形態の不織布の製造方法と同様である。したがって、第１の熱風Ｗ１を繊維ウエブ５０に吹き付けて、繊維ウエブ５０の繊維同士を仮融着し、支持体１１０の支持体部１１２および別の支持体部１１６の形状に沿った凹凸形状に繊維ウエブ５０を賦形する工程、第２の熱風Ｗ２を繊維ウエブ５０に吹き付け、繊維同士を融着させて凹凸形状を固定する工程は、前述と同様である。
　この第２実施形態の不織布の製造方法は、前述の第１実施形態の不織布の製造方法と同様な作用が得られ、同様の効果を奏する。 Next, about the 2nd Embodiment of the manufacturing method of the nonwoven fabric which concerns on this invention, it is the same as that of the manufacturing method of the nonwoven fabric of the above-mentioned 1st Embodiment except using the support body 110B shown in the above-mentioned FIG. Therefore, the first hot air W1 is blown onto the fiber web 50, and the fibers of the fiber web 50 are temporarily fused together to form an uneven shape along the shapes of the support body portion 112 of the support body 110 and another support body portion 116. The step of shaping the fiber web 50 and the step of blowing the second hot air W2 onto the fiber web 50 and fusing the fibers together to fix the uneven shape are the same as described above.
The nonwoven fabric manufacturing method of the second embodiment has the same effects as the nonwoven fabric manufacturing method of the first embodiment described above.
　すなわち、繊維ウエブ５０に第１の熱風Ｗ１および第２の熱風Ｗ２を吹き付けて、前記図４に示したように、第１凹部１２とこれに囲まれた第１凸部１１とが賦形された第１凹凸構造１３を作製できる。それとともに、第１凸部１１上面を第２凸部２１と第２凹部２２が賦形された第２凹凸構造２３に作製することができる。よって、第２凹凸構造２３に軟便等の粘性の高い液が供給された場合、第２凹凸構造２３を通過して第１凸部１１内にその液が拡がるが、第１凸部１１の側壁部によってその液の拡がりは堰き止められるので、それ以上の拡がりを抑えることができる。それとともに、第２凹凸構造２３の表面を流れた軟便等の粘性の高い液は第１凹部１２内に流れ込み、それ以上の拡がりを防止することができる不織布１０Ｂを製造できる。 That is, the first hot air W1 and the second hot air W2 are blown onto the fiber web 50 to form the first concave portion 12 and the first convex portion 11 surrounded by the first concave portion 12 as shown in FIG. In addition, the first uneven structure 13 can be produced. At the same time, the upper surface of the first convex portion 11 can be formed into the second concavo-convex structure 23 in which the second convex portion 21 and the second concave portion 22 are shaped. Therefore, when a highly viscous liquid such as soft stool is supplied to the second concavo-convex structure 23, the liquid passes through the second concavo-convex structure 23 and spreads into the first convex portion 11, but the side wall of the first convex portion 11 Since the spread of the liquid is blocked by the portion, the further spread can be suppressed. At the same time, a highly viscous liquid such as soft stool that flows on the surface of the second concavo-convex structure 23 flows into the first recess 12, and the nonwoven fabric 10 </ b> B that can prevent further spreading can be manufactured.
　上記第１および第２実施形態の不織布の製造方法では、上記作用効果の他に、第１の熱風Ｗ１および第２の熱風Ｗ２が外部に排気されることから装置周囲に拡散することがないので、装置周囲の雰囲気の温度上昇を防止することができる。よって、装置周辺で作業するオペレータ等の作業の安全が確保できる。 In the manufacturing method of the nonwoven fabric according to the first and second embodiments, in addition to the above effects, the first hot air W1 and the second hot air W2 are exhausted to the outside, so that they do not diffuse around the apparatus. The temperature rise in the atmosphere around the apparatus can be prevented. Therefore, it is possible to ensure the safety of work by an operator or the like working around the apparatus.
　次に、本発明に係る吸収性物品の好ましい一実施形態について、図１２を参照しながら、以下に説明する。なお、図示した吸収性物品は、一例としてテープ型の乳幼児用使い捨ておむつであり、平面に展開した状態の使い捨ておむつを多少曲げて内側（肌当接面側）からみた状態で示している。 Next, a preferred embodiment of the absorbent article according to the present invention will be described below with reference to FIG. The illustrated absorbent article is, for example, a tape-type disposable diaper for infants, and is shown in a state where the disposable diaper developed in a plane is slightly bent and viewed from the inside (skin contact surface side).
　図１２に示すように、本発明の使い捨ておむつ５に使用される吸収性本体４は以下の基本構成を有する。すなわち、肌当接面側に配置される液透過性の表面シート１と、非肌当接面側に配置される液不透過性の裏面シート２と、表面シート１と裏面シート２との間に介在される液保持性を有する吸収体３とを有する。 As shown in FIG. 12, the absorbent main body 4 used for the disposable diaper 5 of the present invention has the following basic configuration. That is, a liquid-permeable top sheet 1 disposed on the skin contact surface side, a liquid-impermeable back sheet 2 disposed on the non-skin contact surface side, and between the top sheet 1 and the back sheet 2 And an absorbent body 3 having liquid retention properties interposed between the two.
　表面シート１には上記実施形態の不織布１０が適用されている。裏面シート２は展開状態で、その両側縁が長手方向中央部Ｃにおいて内側に括れた形状を有しており、１枚のシートからなるものであっても、複数のシートからなるものであってもよい。本例においては、サイドシート６がなす横漏れ防止ギャザー７が設けられており、これにより着用者の運動等による股関節部分における液体等の横漏れを効果的に防止しうる。なお、図１２においては各部材の配置関係や境界を厳密には図示しておらず、この種のおむつの一般的な形態とされていれば特にその構造は限定されない。 The non-woven fabric 10 of the above embodiment is applied to the top sheet 1. The back sheet 2 is in an unfolded state, and both side edges thereof have a shape confined to the inside in the longitudinal central portion C. Even if the back sheet 2 is composed of a single sheet, it is composed of a plurality of sheets. Also good. In this example, a side leakage prevention gather 7 formed by the side seat 6 is provided, and thereby side leakage of liquid or the like in the hip joint part due to the wearer's exercise or the like can be effectively prevented. In addition, in FIG. 12, the arrangement | positioning relationship and boundary of each member are not illustrated strictly, and if it is set as the general form of this kind of diaper, the structure will not be specifically limited.
　上記使い捨ておむつ５はテープ型のものとして示しており、背側Ｒのフラップ部にはファスニングテープ８が設けられている。ファスニングテープ８を腹側Ｆのフラップ部に設けたテープ貼付部（図示せず）に貼付して、おむつを装着固定することができる。このとき、おむつ中央部Ｃを緩やかに内側に折り曲げて、吸収体３が臀部から下腹部にわたって沿わされるように着用する。これにより***物が的確に吸収体３に吸収保持される。このような形態で用いることにより、特に不織布１０を表面シート１として適用したことにより、軟便等の粘性の高い液の液流れを所定の位置で止めることができ、しかも肌触りが柔らかでしなやかな風合いの良さを示す。 The disposable diaper 5 is shown as a tape type, and a fastening tape 8 is provided on the flap portion on the back side R. Fastening tape 8 can be affixed to a tape application part (not shown) provided in the flap part of ventral side F, and a diaper can be mounted and fixed. At this time, the center part C of the diaper is gently bent inward and worn so that the absorbent body 3 runs along the lower abdomen from the buttocks. As a result, excreta is absorbed and held in the absorber 3 accurately. By using in such a form, the non-woven fabric 10 is applied as the top sheet 1 in particular, so that the liquid flow of highly viscous liquid such as loose stool can be stopped at a predetermined position, and the touch is soft and supple. The goodness of
　吸収性本体４の形状は、装着時に着用者の股下部分を介して下腹部側から臀部側へと配される長手方向とこれと直交する幅方向とを有する縦長の形状である。本発明においては、特に断らない限り、人体に接触する側を肌当接面側または表面側といい、その反対側を非肌当接面側または裏面側という。さらに吸収性本体４の平面視において相対的に長さのある方向を長手方向といい、この長手方向と直交する方向を幅方向という。上記長手方向は典型的には装着状態において人体の前後方向と一致する。 The shape of the absorbent main body 4 is a vertically long shape having a longitudinal direction that is arranged from the lower abdomen side to the buttocks side through the wearer's crotch portion and a width direction perpendicular thereto. In the present invention, unless otherwise specified, the side in contact with the human body is referred to as the skin contact surface side or the surface side, and the opposite side is referred to as the non-skin contact surface side or the back surface side. Further, a direction having a relatively long length in a plan view of the absorbent main body 4 is referred to as a longitudinal direction, and a direction orthogonal to the longitudinal direction is referred to as a width direction. The longitudinal direction typically coincides with the front-rear direction of the human body in a worn state.
　表面シート１は、前述の本発明の不織布１０で構成される、親水性不織布であることが好ましい。親水性不織布としては、その繊維がポリプロピレンとポリエチレンの複合繊維、ポリエチレンテレフタレートとポリエチレンの複合繊維等で親水化処理が施された繊維が好ましく使用できる。 The topsheet 1 is preferably a hydrophilic nonwoven fabric composed of the above-described nonwoven fabric 10 of the present invention. As the hydrophilic non-woven fabric, fibers that have been subjected to a hydrophilic treatment with a composite fiber of polypropylene and polyethylene, a composite fiber of polyethylene terephthalate and polyethylene, or the like can be preferably used.
　上記裏面シート２は、防水性があり透湿性を有していれば特に限定されない。例えば疎水性の熱可塑性樹脂と、炭酸カルシウム等からなる微小な無機フィラーまたは相溶性のない有機高分子等とを溶融混練してフィルムを形成し、該フィルムを一軸または二軸延伸して得られる多孔性フィルムが挙げられる。熱可塑性樹脂としては、ポリオレフィンが挙げられる。該ポリオレフィンとしては、高密度ないし低密度ポリエチレン、線状低密度ポリエチレン、ポリプロピレン、ポリブテン等が挙げられ、これらを単独でまたは混合して用いることができる。 The back sheet 2 is not particularly limited as long as it is waterproof and moisture permeable. For example, a film is formed by melt-kneading a hydrophobic thermoplastic resin, a fine inorganic filler made of calcium carbonate or the like or an incompatible organic polymer, and the film is obtained by uniaxial or biaxial stretching. A porous film is mentioned. Examples of the thermoplastic resin include polyolefin. Examples of the polyolefin include high-density to low-density polyethylene, linear low-density polyethylene, polypropylene, polybutene, and the like, and these can be used alone or in combination.
　吸収体３には、例えば、繊維集合体またはこれと吸収性ポリマーとを併用させたもの等を用いることができる。繊維集合体を構成する繊維としては、パルプ繊維等の親水性天然繊維や、合成繊維（好ましくは親水化処理を施したもの）等を用いることができる。坪量は特に限定されないが、１５０ｇ／ｍ２以上５００ｇ／ｍ２以下が好ましい。また吸収体３を被覆する被覆シートを用いることもできる。この被覆シートには、親水性のティッシュペーパー等の薄手の紙（薄葉紙）、コットンやレーヨンなどの親水性繊維からなる不織布、合成樹脂の繊維に親水化処理を施してなる不織布（スパンボンド－メルトブローン－スパンボンド（ＳＭＳ）、スパンボンド－メルトブローン－メルトブローン－スパンボンド（ＳＭＭＳ）、スパンボンド－スパンボンド－メルトブローン－スパンボンド（ＳＳＭＳ）等の複合不織布）等を用いることができる。 As the absorbent body 3, for example, a fiber aggregate or a combination of this and an absorbent polymer can be used. As the fibers constituting the fiber assembly, hydrophilic natural fibers such as pulp fibers, synthetic fibers (preferably subjected to hydrophilic treatment), and the like can be used. Although the basis weight is not particularly limited, but is preferably 150 g / m 2 or more 500 g / m 2 or less. Moreover, the coating sheet which coat | covers the absorber 3 can also be used. This coated sheet includes thin paper (thin paper) such as hydrophilic tissue paper, non-woven fabric made of hydrophilic fibers such as cotton and rayon, and non-woven fabric (spunbond-meltblown) obtained by subjecting synthetic resin fibers to hydrophilic treatment. Spunbond (SMS), spunbond-meltblown-meltblown-spunbond (SMMS), spunbond-spunbond-meltblown-spunbond (SSMS), etc.) can be used.
　本発明の使い捨ておむつ５は、軟便等の粘性の高い液が供給された場合であっても、表面シート１としての本発明の不織布１０の第１凸部１１（前記図１参照）によって、液流れを防止することができる。 The disposable diaper 5 according to the present invention is a liquid that is provided by the first convex portion 11 (see FIG. 1) of the nonwoven fabric 10 according to the present invention as the top sheet 1 even when a highly viscous liquid such as soft stool is supplied. Flow can be prevented.
　上述した実施形態に関し、さらに以下の付記（不織布、不織布の製造方法、吸収性物品および使い捨ておむつ）を開示する。 The following additional notes (nonwoven fabric, nonwoven fabric manufacturing method, absorbent article, and disposable diaper) are further disclosed with respect to the above-described embodiment.
＜１＞シート状の不織布を平面視した側の第１面側に突出する第１凸部と、前記第１凸部に囲まれた第１凹部とが配された第１凹凸構造と、
　前記第１凹部底面は前記第１面側に突出する第２凸部と前記第１面側とは反対側の第２面側に突出する第２凹部とが配され該第２凸部が前記第１凸部より高さが低い第２凹凸構造を成し、
　前記第２凸部は前記第２凹部より低密度である不織布。
＜２＞前記第２凹凸構造は、前記第１凹部の底面内において、第２凸部と第２凹部とが異なる方向に交互に配列されている＜１＞に記載の不織布。
＜３＞前記第２凸部は、前記第１凸部よりも２ｍｍ以上低い＜１＞又は＜２＞に記載の不織布。
＜４＞前記第２凸部の密度は前記第２凹部の密度より１５０本／ｍｍ２以上高い＜１＞から＜３＞のいずれか１に記載の不織布。
＜５＞前記第１凸部は、前記第１面側とは反対の第２面側の一部が平坦面であり、
　前記平坦面は、前記第２凹凸構造が前記第２面側で接する仮想平面と同一平面または前記仮想平面より第２面側に存する＜１＞から＜４＞のいずれか１に記載の不織布。
＜６＞前記不織布の平面視全面にわたって縦長の長方形の前記第１凹部が等間隔に縦横に配され、前記各第１凹部の周囲にはそれらを囲むように前記第１凸部が連続的に配されている＜１＞から＜５＞のいずれか１に記載の不織布。
＜７＞前記不織布の平面視全面にわたって縦長の長方形の前記第１凹部が等間隔に縦横にかつ縦方向に１／２ピッチずつずらして配され、前記各第１凹部の周囲にはそれらを囲むように前記第１凸部が連続的に配されている＜１＞から＜５＞のいずれか１に記載の不織布。
＜８＞前記不織布の平面視全面にわたって円形の前記第１凹部が等間隔に縦横に配され、前記各第１凹部の周囲にはそれらを囲むように前記第１凸部が連続的に配されている＜１＞から＜５＞のいずれか１に記載の不織布。
＜９＞前記不織布の平面視全面にわたって縦方向に前記第１凹部が縞状に等間隔に配され、前記各第１凹部の周囲にはそれらを囲むように前記第１凸部が連続的に配されている＜１＞から＜５＞のいずれか１に記載の不織布。
＜１０＞シート状の不織布を平面視した側の第１面側に突出する第１凸部と、前記第１凸部を囲む第１凹部が配された第１凹凸構造と、
　前記第１凸部上面が前記第１面側に突出する第２凸部と前記第１面側とは反対側の第２面側に突出する第２凹部を配した第２凹凸構造を成し、
　前記第２凹部は前記第１凸部より低密度である不織布。
＜１１＞前記第２凸部における繊維密度と前記第２凹部における繊維密度の差は、１５０本／ｍｍ２以上である＜１０＞に記載の不織布。
＜１２＞前記第１凹部は、前記第１面側とは反対の第２面側の少なくとも一部が平坦面である＜１０＞または＜１１＞に記載の不織布。
＜１３＞複数の突起と複数の孔を配した複数の支持体部を所定間隔に配置した支持体上に熱可塑性繊維を含有する繊維ウエブを搬送し、第１の熱風および第２の熱風を吹き付けて、第１凸部と該第１凸部に囲まれた第１凹部とが配された第１凹凸構造に賦形するとともに、前記第１凹部底面を第２凸部と第２凹部とが配され該第２凸部が前記第１凸部より高さが低い第２凹凸構造に賦形する工程を有し、
　前記繊維ウエブに前記繊維ウエブの繊維の低融点成分の融点より６０℃低い温度以上の前記第１の熱風を吹き付けて前記繊維ウエブを前記支持体の形状に沿わせて繊維同士を仮融着し、前記第１の熱風よりも高温の前記第２の熱風を吹き付けて前記仮融着させた形状を保持した状態で前記繊維ウエブの繊維同士を融着させて形状を固定する不織布の製造方法。
＜１４＞前記支持体上に前記繊維ウエブを搬送し、前記第１の熱風を吹きつけることにより、前記第１凹凸構造及び第２凹凸構造の形状が保持される状態に仮融着し、前記第２の熱風により、繊維ウエブの繊維同士を融着させて形状を固定する、＜１３＞に記載の不織布の製造方法。
＜１５＞前記支持体の前記所定間隔により前記第１凸部を形成し、前記支持体基部により、第２凹凸構造を有する第１凹部を形成する、＜１３＞又は＜１４＞に記載の不織布の製造方法。
＜１６＞前記孔の開孔率が好ましくは２０％以上４５％以下、より好ましくは２５％以上４０％以下、さらに好ましくは３０％以上３５％以下である＜１３＞から＜１５＞のいずれか１に記載の不織布の製造方法。
＜１７＞複数の突起と複数の孔を配した複数の支持体部を所定間隔に配置するとともに該支持体部間に該支持体より高さが高い別の支持体部を配し、両支持体部を配した支持体上に熱可塑性繊維を含有する繊維ウエブを搬送し、第１の熱風および第２の熱風を吹き付けて、第１凹部と該第１凹部に囲まれた第１凸部とが配された第１凹凸構造とともに前記第１凸部上面を第２凸部と第２凹部が配された第２凹凸構造に賦形する工程を有し、
　前記繊維ウエブに、前記繊維ウエブの繊維の低融点成分の融点より６０℃低い温度以上の前記第１の熱風を吹き付けて前記繊維ウエブを前記支持体の形状に沿わせて繊維同士を仮融着し、前記第１の熱風よりも高温の前記第２の熱風を吹き付けて前記仮融着させた形状を保持した状態で前記繊維ウエブの繊維同士を融着させて形状を固定する不織布の製造方法。
＜１８＞前記支持体上に前記繊維ウエブを搬送し、前記第１の熱風を吹きつけることにより、前記第１凹凸構造及び第２凹凸構造の形状が保持される状態に仮融着し、前記第２の熱風により、繊維ウエブの繊維同士を融着させて形状を固定する、＜１７＞に記載の不織布の製造方法。
＜１９＞前記支持体はドラム形状を有する＜１３＞から＜１８＞のいうちのいずれか１に記載の不織布の製造方法。
＜２０＞前記第１の熱風を吹き出す第１ノズルと前記第２の熱風を吹き出す第２ノズルを有し、前記第１ノズルと前記支持体との間で、通気性を有するベルトで前記繊維ウエブを前記支持体側に押さえつける、または前記第１ノズルと前記支持体との間および前記第２ノズルと前記支持体との間で、通気性を有するベルトで前記繊維ウエブを前記支持体側に押さえつける＜１３＞から＜１８＞のいずれか１に記載の不織布の製造方法。
＜２１＞前記第１の熱風の温度は、繊維ウエブの繊維の低融点成分の融点より６０℃低い温度以上とすることが好ましく、低融点成分の融点より５０℃低い温度以上とすることがより好ましく、この融点より１５℃高い温度以下に制御することが好ましく、この融点より１０℃高い温度以下の温度に制御することがより好ましい＜１３＞から＜２０＞のいずれか１に記載の不織布の製造方法。
＜２２＞前記第２の熱風の温度は、好ましくは繊維ウエブの繊維の低融点成分の融点以上、繊維ウエブ５０の繊維の高融点成分の融点未満、好ましくは低融点成分の融点より４０℃高い温度以下、より好ましくは低融点成分の融点以上この融点より２０℃高い温度以下、さらに好ましい温度として低融点成分の融点以上この融点より１５℃高い温度以下に制御する、＜１３＞から＜２１＞のいずれか１に記載の不織布の製造方法。
＜２３＞複数の突起と複数の孔を配した複数の支持体部を所定間隔に配置した支持体と、前記支持体上に搬送された熱可塑性繊維を含有する繊維ウエブに第１の熱風を吹き付ける第１ノズルと、前記繊維ウエブに前記第１の熱風よりも高温の第２の熱風を吹き付ける第２ノズルとを有し、
　前記支持体部とこれより高さの低い前記支持体と間隔によって前記繊維ウエブに第１凸部と第１凹部が賦形された第１凹凸構造が作製され、前記支持体部の前記突起と前記孔によって前記繊維ウエブに前記第１凸部より高さが低い第２凸部と第２凹部が賦形された第２凹凸構造が作製される不織布の製造装置。
＜２４＞複数の突起と複数の孔を配した複数の支持体部を所定間隔に配置するとともに、前記支持体部間に前記支持体よりも高さの高い別の支持体部を配置した支持体と、前記支持体上に搬送された熱可塑性繊維を含有する繊維ウエブに第１の熱風を吹き付ける第１ノズルと、前記繊維ウエブに前記第１の熱風よりも高温の第２の熱風を吹き付ける第２ノズルとを有し、
　前記支持体部とこれよりも高さの高い別の支持体部によって前記繊維ウエブに第１凸部が賦形され、前記別の支持体部によって前記繊維ウエブに第１凹部が賦形された第１凹凸構造が作製され、前記支持体部の前記突起と前記孔によって前記繊維ウエブに前記第１凸部より高さが低い第２凸部と第２凹部が賦形された第２凹凸構造が作製される不織布の製造装置。
＜２５＞肌当接面側に配置される液透過性の表面シートと、非肌当接面側に配置される液不透過性の裏面シートと、前記両シート間に介在される吸収体とを有し、
　前記表面シートは、＜１＞から＜１２＞のいずれか１に記載の不織布からなる吸収性物品。
＜２６＞肌当接面側に配置される液透過性の表面シートと、非肌当接面側に配置される液不透過性の裏面シートと、前記両シート間に介在される吸収体とを有し、
　前記表面シートは、＜１＞から＜１２＞のいずれか１に記載の不織布からなる使い捨ておむつ。 <1> a first concavo-convex structure in which a first convex portion protruding to the first surface side on the side of the sheet-like nonwoven fabric in plan view and a first concave portion surrounded by the first convex portion are arranged;
The bottom surface of the first concave portion includes a second convex portion projecting to the first surface side and a second concave portion projecting to the second surface side opposite to the first surface side, and the second convex portion is Forming a second concavo-convex structure having a height lower than that of the first convex portion;
The said 2nd convex part is a nonwoven fabric whose density is lower than the said 2nd recessed part.
<2> The nonwoven fabric according to <1>, wherein in the second concavo-convex structure, the second convex portions and the second concave portions are alternately arranged in different directions within the bottom surface of the first concave portion.
<3> The nonwoven fabric according to <1> or <2>, wherein the second convex portion is 2 mm or more lower than the first convex portion.
<4> The nonwoven fabric according to any one of <1> to <3>, wherein the density of the second protrusions is 150 pieces / mm 2 or more higher than the density of the second recesses.
<5> The first convex portion has a flat part on the second surface side opposite to the first surface side,
The flat surface is the non-woven fabric according to any one of <1> to <4>, wherein the second uneven structure is on the same plane as the virtual plane with which the second surface structure contacts on the second surface side or on the second surface side with respect to the virtual plane.
<6> The vertically long rectangular first concave portions are arranged at equal intervals across the entire surface of the nonwoven fabric in plan view, and the first convex portions are continuously formed around the first concave portions so as to surround them. The nonwoven fabric according to any one of <1> to <5>, which is arranged.
<7> The vertically long rectangular first recesses are arranged at equal intervals vertically and horizontally and shifted by 1/2 pitch in the longitudinal direction over the entire surface of the nonwoven fabric in plan view, and surround each of the first recesses. The nonwoven fabric according to any one of <1> to <5>, wherein the first convex portions are continuously arranged.
<8> The circular first recesses are arranged vertically and horizontally at equal intervals over the entire planar view of the nonwoven fabric, and the first protrusions are continuously arranged around each first recess so as to surround them. The nonwoven fabric according to any one of <1> to <5>.
<9> The first concave portions are arranged at equal intervals in the vertical direction over the entire surface of the nonwoven fabric in plan view, and the first convex portions are continuously formed around the first concave portions so as to surround them. The nonwoven fabric according to any one of <1> to <5>, which is arranged.
<10> a first protrusion projecting toward the first surface on the side of the sheet-like nonwoven fabric in plan view, and a first uneven structure in which a first recess surrounding the first protrusion is disposed;
The upper surface of the first convex portion has a second concavo-convex structure in which a second convex portion protruding to the first surface side and a second concave portion protruding to the second surface side opposite to the first surface side are arranged. ,
The second recess is a nonwoven fabric having a lower density than the first protrusion.
<11> The nonwoven fabric according to <10>, wherein a difference between the fiber density in the second convex portion and the fiber density in the second concave portion is 150 pieces / mm 2 or more.
The <12> said 1st recessed part is a nonwoven fabric as described in <10> or <11> whose at least one part of the 2nd surface side opposite to the said 1st surface side is a flat surface.
<13> A fiber web containing thermoplastic fibers is transported onto a support body in which a plurality of support body portions having a plurality of protrusions and a plurality of holes are arranged at predetermined intervals, and the first hot air and the second hot air are conveyed. Spraying to shape the first concavo-convex structure in which the first convex portion and the first concave portion surrounded by the first convex portion are arranged, and forming the bottom surface of the first concave portion with the second convex portion and the second concave portion. And the second convex part is shaped into a second concavo-convex structure having a height lower than that of the first convex part,
The first hot air having a temperature 60 ° C. or more lower than the melting point of the low melting point component of the fiber of the fiber web is blown onto the fiber web so that the fiber web conforms to the shape of the support and the fibers are temporarily fused together. The manufacturing method of the nonwoven fabric which fixes the shape by fuse | melting the fibers of the said fiber web in the state which sprayed the said 2nd hot air of higher temperature than the said 1st hot air, and hold | maintained the said temporarily fused shape.
<14> The fiber web is conveyed onto the support, and the first hot air is blown to temporarily fuse the first and second concavo-convex structures and the shapes of the second concavo-convex structures, The method for producing a nonwoven fabric according to <13>, wherein the shape of the fiber web is fixed by fusing the fibers of the fiber web with the second hot air.
<15> The nonwoven fabric according to <13> or <14>, wherein the first protrusion is formed by the predetermined interval of the support, and the first recess having a second uneven structure is formed by the support base. Manufacturing method.
<16> Any one of <13> to <15>, wherein an opening ratio of the holes is preferably 20% to 45%, more preferably 25% to 40%, and further preferably 30% to 35%. The manufacturing method of the nonwoven fabric of 1.
<17> A plurality of support portions each having a plurality of protrusions and a plurality of holes are arranged at a predetermined interval, and another support portion having a height higher than that of the support is disposed between the support portions. The first convex portion surrounded by the first concave portion and the first concave portion by conveying the fiber web containing the thermoplastic fiber onto the support body on which the body portion is arranged, and blowing the first hot air and the second hot air. And forming the upper surface of the first convex portion with the first concave-convex structure arranged with the second convex-concave structure with the second convex portion and the second concave portion,
The first hot air having a temperature of 60 ° C. lower than the melting point of the low melting point component of the fiber of the fiber web is blown onto the fiber web so that the fiber web conforms to the shape of the support and the fibers are temporarily fused together. And the manufacturing method of the nonwoven fabric which fuses the fibers of the said fiber web and fixes the shape in the state which sprayed the said 2nd hot air of higher temperature than the said 1st hot air, and hold | maintained the said shape temporarily bonded. .
<18> The fiber web is transported onto the support, and the first hot air is blown to temporarily bond the first concavo-convex structure and the second concavo-convex structure into a state in which the shape is maintained, The method for producing a nonwoven fabric according to <17>, wherein the fibers of the fiber web are fused together with the second hot air to fix the shape.
<19> The method for producing a nonwoven fabric according to any one of <13> to <18>, wherein the support has a drum shape.
<20> A fiber belt having a first nozzle that blows out the first hot air and a second nozzle that blows out the second hot air, and a breathable belt between the first nozzle and the support. Is pressed against the support side, or the fiber web is pressed against the support side with a belt having air permeability between the first nozzle and the support and between the second nozzle and the support <13. The manufacturing method of the nonwoven fabric any one of <18>from>.
<21> The temperature of the first hot air is preferably 60 ° C. lower than the melting point of the low melting point component of the fiber of the fiber web, and more preferably 50 ° C. lower than the melting point of the low melting point component. Preferably, the nonwoven fabric according to any one of <13> to <20>, which is preferably controlled to a temperature not higher than 15 ° C above the melting point, and more preferably controlled to a temperature not higher than 10 ° C higher than the melting point. Production method.
<22> The temperature of the second hot air is preferably equal to or higher than the melting point of the low melting point component of the fiber of the fiber web, less than the melting point of the high melting point component of the fiber of the fiber web 50, and preferably 40 ° C. higher than the melting point of the low melting point component. <13> to <21> The temperature is controlled below the temperature, more preferably above the melting point of the low melting point component and below 20 ° C. below the melting point, and more preferably below the melting point of the low melting point component and below 15 ° C. above the melting point. The manufacturing method of the nonwoven fabric any one of these.
<23> A first hot air is applied to a support body in which a plurality of support portions provided with a plurality of protrusions and a plurality of holes are arranged at predetermined intervals, and a fiber web containing thermoplastic fibers conveyed on the support body. A first nozzle for blowing, and a second nozzle for blowing a second hot air having a temperature higher than that of the first hot air to the fiber web,
A first concavo-convex structure in which a first convex portion and a first concave portion are formed on the fiber web by the spacing between the support portion and the support lower in height than the support portion, and the protrusion of the support portion is formed. A non-woven fabric manufacturing apparatus in which a second concavo-convex structure in which a second convex portion and a second concave portion having a height lower than that of the first convex portion are formed on the fiber web is produced by the holes.
<24> A support in which a plurality of support parts having a plurality of protrusions and a plurality of holes are arranged at predetermined intervals, and another support part having a height higher than the support is arranged between the support parts. A body, a first nozzle that blows first hot air onto a fiber web containing thermoplastic fibers conveyed on the support, and a second hot air that is hotter than the first hot air is blown onto the fiber web. A second nozzle,
A first convex portion is formed on the fiber web by the support portion and another support portion having a height higher than the support portion, and a first concave portion is formed on the fiber web by the another support portion. A second concavo-convex structure in which a first concavo-convex structure is formed, and the second convex portion and the second concave portion having a height lower than the first convex portion are formed on the fiber web by the protrusions and the holes of the support portion. Nonwoven fabric manufacturing apparatus for producing
<25> A liquid-permeable front sheet disposed on the skin contact surface side, a liquid-impermeable back sheet disposed on the non-skin contact surface side, and an absorber interposed between the two sheets. Have
The said surface sheet is an absorbent article which consists of a nonwoven fabric any one of <1> to <12>.
<26> A liquid-permeable top sheet disposed on the skin contact surface side, a liquid-impermeable back sheet disposed on the non-skin contact surface side, and an absorber interposed between the two sheets. Have
The top sheet is a disposable diaper made of the nonwoven fabric according to any one of <1> to <12>.
　以下に、不織布の実施例および比較例を説明する。
　実施例１は、前述の第１実施形態の製造方法により以下の条件で製造した。すなわち、繊維ウエブ５０の繊維には、芯部がポリエチレンテレフタレート（融点が２５５℃）で、鞘部がポリエチレン（融点が１３２℃）の芯鞘構造の複合繊維を用いた。その繊維ウエブ５０を支持体１１０と通気コンベア１３３とにより搬送し、支持体１１０の表面で第１の熱風Ｗ１、第２の熱風Ｗ２を吹き付けることによって凹凸形状に賦形させた。第１ノズルから吹き出す第１の熱風Ｗ１は、温度を１３０℃、風速を５０ｍ／ｓｅｃに設定し、第２ノズルから吹き出す第２の熱風Ｗ２は、温度を１４５℃、風速を５．０ｍ／ｓｅｃに設定した。凹凸形状に加工する加工速度は５０ｍ／ｍｉｎとした。また支持体部１１２は所定間隔（１５ｍｍ）に配置されている。ドラム１１１の表面からの支持体基部１１３の表面の高さΔｈ１を３ｍｍとした。上記条件にて不織布の試験体を製造した。
　実施例２は、Δｈ１を１．５ｍｍとした以外、実施例１と同様の方法により製造した。
　実施例３は、Δｈ１を４．５ｍｍとした以外、実施例１と同様の方法により製造した。 Below, the Example and comparative example of a nonwoven fabric are demonstrated.
Example 1 was manufactured under the following conditions by the manufacturing method of the first embodiment described above. That is, for the fiber of the fiber web 50, a composite fiber having a core-sheath structure in which the core part is polyethylene terephthalate (melting point is 255 ° C.) and the sheath part is polyethylene (melting point is 132 ° C.). The fiber web 50 was conveyed by the support body 110 and the aeration conveyor 133, and the first hot air W1 and the second hot air W2 were blown on the surface of the support body 110 to form an uneven shape. The first hot air W1 blown from the first nozzle is set to a temperature of 130 ° C. and the wind speed is set to 50 m / sec, and the second hot air W2 blown from the second nozzle is set to a temperature of 145 ° C. and the wind speed of 5.0 m / sec. Set to. The processing speed for processing the irregular shape was 50 m / min. The support portions 112 are arranged at a predetermined interval (15 mm). The height Δh1 of the surface of the support base 113 from the surface of the drum 111 was 3 mm. Nonwoven fabric specimens were produced under the above conditions.
Example 2 was produced by the same method as Example 1 except that Δh1 was 1.5 mm.
Example 3 was produced by the same method as Example 1 except that Δh1 was 4.5 mm.
　実施例４は、前述の第２実施形態の製造方法により以下の条件で製造した。すなわち、繊維ウエブ５０の繊維には、芯部がポリエチレンテレフタレート（融点が２５５℃）で、鞘部がポリエチレン（融点が１３２℃）の芯鞘構造の複合繊維を用いた。その繊維ウエブ５０を支持体１１０と通気コンベア１３３とにより搬送し、支持体１１０の表面で第１の熱風Ｗ１、第２の熱風Ｗ２を吹き付けることによって凹凸形状に賦形させた。第１の熱風Ｗ１は、温度を１３０℃、風速を５０ｍ／ｓｅｃに設定し、第２の熱風Ｗ２は、温度を１４５℃、風速を５．０ｍ／ｓｅｃに設定した。凹凸形状に加工する加工速度は５０ｍ／ｍｉｎとした。また支持体部１１２は所定間隔（１５ｍｍ）に配置され、その間に別の支持体１１６が配されている。別の支持体１１６の高さと支持体１１２の高さとの差Δｈ２を３ｍｍとした。上記条件にて不織布の試験体を製造した。
　実施例５は、Δｈ２を１．５ｍｍとした以外、実施例１と同様の方法により製造した。
　実施例６は、Δｈ２を４．５ｍｍとした以外、実施例１と同様の方法により製造した。 Example 4 was manufactured by the manufacturing method of the second embodiment described above under the following conditions. That is, for the fiber of the fiber web 50, a composite fiber having a core-sheath structure in which the core part is polyethylene terephthalate (melting point is 255 ° C.) and the sheath part is polyethylene (melting point is 132 ° C.). The fiber web 50 was conveyed by the support body 110 and the aeration conveyor 133, and the first hot air W1 and the second hot air W2 were blown on the surface of the support body 110 to form an uneven shape. The first hot air W1 was set to a temperature of 130 ° C. and the wind speed was set to 50 m / sec, and the second hot air W2 was set to a temperature of 145 ° C. and the wind speed was set to 5.0 m / sec. The processing speed for processing the irregular shape was 50 m / min. Moreover, the support body part 112 is arrange | positioned at predetermined spacing (15 mm), and another support body 116 is distribute | arranged among them. The difference Δh2 between the height of another support 116 and the height of the support 112 was 3 mm. Nonwoven fabric specimens were produced under the above conditions.
Example 5 was produced by the same method as Example 1 except that Δh2 was 1.5 mm.
Example 6 was produced by the same method as in Example 1 except that Δh2 was 4.5 mm.
　比較例１は、前述の特許文献２に開示された不織布の製造方法により不織布の試験体を製造した。
　比較例２は、実施例１と同様の熱可塑性繊維を用い、前述の特許文献３に開示された不織布の製造方法により不織布の試験体を製造した。 The comparative example 1 manufactured the test body of the nonwoven fabric with the manufacturing method of the nonwoven fabric disclosed by the above-mentioned patent document 2.
In Comparative Example 2, a nonwoven fabric test body was manufactured by using the same thermoplastic fiber as in Example 1 and the nonwoven fabric manufacturing method disclosed in Patent Document 3 described above.
　参考例は、支持体部１１２を配置する際に間隔を開けずに配置した以外、前述の実施例１と同様の条件にて不織布の試験体を製造した。 In the reference example, a non-woven fabric specimen was manufactured under the same conditions as in Example 1 above, except that the support 112 was placed without any gap.
　次に測定方法について説明する。
　第１の熱風Ｗ１の温度は、アネモマスター(日本カノマックス株式会社製：商品名)により第１ノズル１１１の吹き出し口の直下で測定し、第１の熱風Ｗ１の風速は、ピトー管により第１ノズル１１１の吹き出し口の直下で総圧から静圧を引き動圧を測定し、ピトー管による流速計算式より求めた。第２の熱風Ｗ２の温度は、上記アネモマスターにより第２ノズル１１２の吹き出し口直下で測定した。 Next, the measurement method will be described.
The temperature of the first hot air W1 is measured directly under the outlet of the first nozzle 111 by the Anemo Master (manufactured by Nippon Kanomax Co., Ltd .: trade name), and the wind speed of the first hot air W1 is measured by the Pitot tube. The static pressure was drawn from the total pressure just below the 111 outlet, and the dynamic pressure was measured, and was calculated from the flow velocity calculation formula using a Pitot tube. The temperature of the second hot air W2 was measured immediately below the outlet of the second nozzle 112 by the anemo master.
　不織布の厚みの測定方法は、不織布に０．０５ｋＰａの荷重を加えた状態で、厚み測定器を用いて測定した。厚み測定器にはオムロン社製のレーザー変位計を用いた。厚み測定は、１０点測定し、それらの平均値を算出して厚みとした。
　第１実施形態の不織布１０Ａの場合、実質的に、第１凹凸構造１３の厚みは第１凸部１１の高さＨ１になり、第２凹凸構造２３の厚みは第２凸部２１の高さＨ２になる。また、第２実施例の不織布１０Ｂの場合、実質的に、第１凹凸構造１３の厚みは第１凸部１１と第２凹凸構造２３とを合わせた高さになり、第２凹凸構造２３の厚みは不織布１０Ａと同様に第１凸部１１の高さになる。
　段差は、第１凹凸構造１３の厚みから第２凹凸構造２３の厚みを引いて求めた。 The measurement method of the thickness of the nonwoven fabric was measured using a thickness measuring instrument in a state where a load of 0.05 kPa was applied to the nonwoven fabric. A laser displacement meter manufactured by OMRON Corporation was used as the thickness measuring instrument. The thickness was measured at 10 points, and the average value was calculated as the thickness.
In the case of the nonwoven fabric 10A of the first embodiment, the thickness of the first concavo-convex structure 13 is substantially the height H1 of the first convex portion 11, and the thickness of the second concavo-convex structure 23 is the height of the second convex portion 21. H2. Further, in the case of the nonwoven fabric 10B of the second example, the thickness of the first uneven structure 13 is substantially the height of the first protrusion 11 and the second uneven structure 23, and the second uneven structure 23 The thickness is the height of the first protrusion 11 as in the case of the nonwoven fabric 10A.
The step was obtained by subtracting the thickness of the second uneven structure 23 from the thickness of the first uneven structure 13.
　繊維密度の測定方法は、不織布部分の切断面を、走査電子顕微鏡を用いて拡大観察（繊維断面が３０本以上６０本以下の計測できる倍率（１５０倍以上５００倍以下）に調整（本実施例については４００倍とした）し、一定面積あたりの前記切断面によって切断されている繊維の断面積が表れている箇所を数えた。次に１ｍｍ２あたりの繊維の断面数に換算し、これを繊維密度（本／ｍｍ２）とした。測定は３ヶ所行い、平均してそのサンプルの繊維密度とした。なお、走査電子顕微鏡には、日本電子（株）社製のＪＣＭ－５１００（商品名）を用いた。 The method for measuring the fiber density is to adjust the cut surface of the nonwoven fabric portion to a magnification (150 to 500 times) that can be measured with a scanning electron microscope (fiber cross section is 30 to 60) (this example And the number of the sections where the cross-sectional area of the fiber cut by the cut surface per fixed area appears was converted into the number of cross-sections of the fiber per 1 mm 2 , and The fiber density (lines / mm 2 ) was measured at three locations and averaged to be the fiber density of the sample.The JEM-5100 (trade name) manufactured by JEOL Ltd. was used for the scanning electron microscope. ) Was used.
　賦形された不織布について、不織布の風合い、軟便の液流れ、吸収体との接着性について、以下の方法で評価した。その結果を表１に示す。 About the shaped nonwoven fabric, the texture of the nonwoven fabric, the flow of soft stool, and the adhesiveness with the absorber were evaluated by the following methods. The results are shown in Table 1.
　軟便の液流れの測定方法は、第１実施形態の不織布１０Ａの場合、図９（１）に示すように、３０°の平坦な傾斜面に吸収体３（花王株式会社製メリーズ（商標登録）２０１１年製造の吸収体）を置く。さらにその上に不織布の試験体３０Ａ（不織布１０Ａ）を置く。そして不織布の試験体３０Ａの上方１ｃｍから１０ｇの疑似軟便６０を供給し、不織布の試験体３０Ａ上を流れた距離を測定した。なお、実施例１の不織布の試験体の場合、第１凸部１１から斜め上方１５０ｍｍの位置に疑似軟便が供給されるようにした。
　第２実施形態の不織布１０Ｂの場合は、図９（２）に示すように、３０°の平坦な傾斜面に吸収体３（花王株式会社製メリーズ（商標登録）の吸収体）を置く。さらにその上に不織布の試験体３０Ｂ（不織布１０Ｂ）を置く。そして不織布の試験体３０Ａの上方１ｃｍから１０ｇの疑似軟便６０を供給し、不織布の試験体３０Ａ上を流れた距離を測定した。なお、実施例１の不織布の試験体の場合、第１凹部１２の幅方向上端から斜め上方１５０ｍｍの位置に疑似軟便が供給されるようにした。第１凹部１２の幅方向の長さは１５ｍｍである。したがって、疑似軟便６０の供給位置から第１凹部１２の幅方向下端までの距離は１６５ｍｍである。
　疑似軟便６０は、室温２０℃、湿度６０％の環境下において、グリセリン１００％にイオン交換水を添加することにより粘度を３００ｍＰａ・ｓに調整したものを用いた。
　また、軟便液流れの測定も同環境下にて行った。
　　 In the case of the nonwoven fabric 10A of the first embodiment, as shown in FIG. 9 (1), the measuring method of the liquid flow of the loose stool is the absorbent body 3 (Marys (trademark registration) manufactured by Kao Corporation) on a 30 ° flat inclined surface. Put the absorber manufactured in 2011). Further, a nonwoven fabric test body 30A (nonwoven fabric 10A) is placed thereon. Then, 10 g of pseudo-soft stool 60 was supplied from 1 cm above the nonwoven fabric test body 30A, and the distance flowing over the nonwoven fabric test body 30A was measured. In the case of the nonwoven fabric test sample of Example 1, pseudo soft stool was supplied from the first convex portion 11 to a position 150 mm obliquely upward.
In the case of the nonwoven fabric 10B of the second embodiment, as shown in FIG. 9 (2), the absorbent body 3 (the absorbent body of Marys (trademark) manufactured by Kao Corporation) is placed on a flat inclined surface of 30 °. Further, a nonwoven fabric test body 30B (nonwoven fabric 10B) is placed thereon. Then, 10 g of pseudo-soft stool 60 was supplied from 1 cm above the nonwoven fabric test body 30A, and the distance flowing over the nonwoven fabric test body 30A was measured. In the case of the nonwoven fabric specimen of Example 1, pseudo soft stool was supplied to a position 150 mm obliquely upward from the upper end in the width direction of the first recess 12. The length of the first recess 12 in the width direction is 15 mm. Therefore, the distance from the supply position of the pseudo soft stool 60 to the lower end in the width direction of the first recess 12 is 165 mm.
The simulated soft stool 60 was prepared by adjusting the viscosity to 300 mPa · s by adding ion exchange water to 100% glycerin in an environment of room temperature 20 ° C. and humidity 60%.
In addition, the flow of the soft stool fluid was also measured in the same environment.
　不織布の風合いは、５人のモニターを対象として、肌触りとしなやかさで判定した。肌触りが非常に柔らかく、しなやかのものを４、肌触りが柔らかく、しなやかのものを３、肌触りがふつうで、しなやかのものを２、肌触りが堅く、しなやかさに欠けるものを１として点数付けし、結果は、５人の平均値を下記のように評価した。
評価結果
　Ａ：判定平均２．５以上３．５未満
　Ｂ：判定平均１．５以上２．５未満
　軟便の液流れは、疑似軟便を供給した位置から流れ落ちた距離を測定した。
　吸収体との接着性の評価方法は、図１０に示すように、３０°の平坦な傾斜面に吸収体３（花王株式会社製メリーズ（商標登録）２０１１年製造の吸収体）を置く。この吸収体３の表面に、ホットメルト接着剤（図示せず）をスパイラル状に塗布した直後にこのホットメルト接着剤を介して不織布の試験体３０を貼り合わせた。ホットメルト接着剤の塗布量は１０ｇ／ｃｍ２とした。貼り合わせた状態で３０分放置した後、傾斜面上端側の不織布の試験体３０の端部を傾斜面にそって下方に向かって剥がし、以下のように評価した。
評価結果
　Ａ：しっかり接着していて剥がれ難い
　Ｂ：接着があまく剥がし易い The texture of the nonwoven fabric was judged by touch and suppleness for five monitors. The result was scored as 4 for a very soft and supple material, 3 for a soft and supple material, 2 for a soft, supple material, and 1 for a soft, supple material. Evaluated the average value of five people as follows.
Evaluation result A: Judgment average 2.5 or more and less than 3.5 B: Judgment average 1.5 or more and less than 2.5 The liquid flow of the loose stool was measured by measuring the distance from the position where the artificial stool was supplied.
As shown in FIG. 10, the method for evaluating the adhesiveness with the absorbent body is to place the absorbent body 3 (absorbent manufactured by Marys (trademark registered) 2011 manufactured by Kao Corporation) on a 30 ° flat inclined surface. Immediately after a hot melt adhesive (not shown) was spirally applied to the surface of the absorbent body 3, a nonwoven fabric test body 30 was bonded to the absorbent body 3 via the hot melt adhesive. The application amount of the hot melt adhesive was 10 g / cm 2 . After leaving for 30 minutes in the bonded state, the end portion of the nonwoven fabric test body 30 on the upper end side of the inclined surface was peeled downward along the inclined surface and evaluated as follows.
Evaluation result A: Adhering firmly and difficult to peel off B: Adhesion is easy to peel off
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
　表１に示した結果から明らかなように、実施例１の試験体は、繊維ウエブ５０の坪量は３０ｇ／ｍ２、第１凹凸構造１３の厚みは６．７５ｍｍ、第２凹凸構造２３の厚みは３．０９ｍｍ、したがって、段差は３．６６ｍｍであった。また、第１凸部１１の繊維密度は８４本／ｍｍ２、第２凸部２１の繊維密度は８２本／ｍｍ２、第２凹部２２の繊維密度は４３５本／ｍｍ２であった。また肌触りが柔らかく、しなやかであり、風合いが良く、評価結果は「Ａ」であった。図１１（１）に示すように、疑似軟便６０の液流れは、１５０ｍｍであり、不織布１０Ａや吸収体３で吸収しきれなかった疑似軟便６０が不織布１０Ａの表面を流れるが、第１凸部１１で流れを止めることができた。また、吸収体との接着性は、不織布の試験体がしっかり接着していて剥がれ難く、評価結果は「Ａ」であった。
　実施例２の試験体は、繊維ウエブ５０の坪量は３０ｇ／ｍ２、第１凹凸構造１３の厚みは５．１６ｍｍ、第２凹凸構造２３の厚みは３．０２ｍｍ、したがって、段差は２．１４ｍｍであった。また、第１凸部１１の繊維密度は８２本／ｍｍ２、第２凸部２１の繊維密度は８２本／ｍｍ２、第２凹部２２の繊維密度は４４２本／ｍｍ２であった。また、風合い、軟便の液流れおよび吸収体との接着性は、実施例１と同じ評価結果となった。
　実施例３の試験体は、繊維ウエブ５０の坪量は３０ｇ／ｍ２、第１凹凸構造１３の厚みは８．１１ｍｍ、第２凹凸構造２３の厚みは３．０３ｍｍ、したがって、段差は５．０８ｍｍであった。また、第１凸部１１の繊維密度は８５本／ｍｍ２、第２凸部２１の繊維密度は８４本／ｍｍ２、第２凹部２２の繊維密度は４４６本／ｍｍ２であった。また、風合い、軟便の液流れ、および吸収体との接着性は、実施例１と同じ評価結果となった。 As is apparent from the results shown in Table 1, in the test body of Example 1, the basis weight of the fiber web 50 is 30 g / m 2 , the thickness of the first uneven structure 13 is 6.75 mm, and the second uneven structure 23 The thickness was 3.09 mm, and thus the step was 3.66 mm. Moreover, the fiber density of the 1st convex part 11 was 84 pieces / mm < 2 >, the fiber density of the 2nd convex part 21 was 82 pieces / mm < 2 >, and the fiber density of the 2nd recessed part 22 was 435 pieces / mm < 2 >. Moreover, the touch was soft and supple, the texture was good, and the evaluation result was "A". As shown in FIG. 11 (1), the liquid flow of the pseudo soft stool 60 is 150 mm, and the pseudo soft stool 60 that could not be absorbed by the nonwoven fabric 10A or the absorbent body 3 flows on the surface of the nonwoven fabric 10A. 11 was able to stop the flow. Moreover, the adhesiveness with an absorber was firmly peeled off because the non-woven fabric test specimen was firmly adhered, and the evaluation result was “A”.
In the test body of Example 2, the basis weight of the fiber web 50 is 30 g / m 2 , the thickness of the first uneven structure 13 is 5.16 mm, the thickness of the second uneven structure 23 is 3.02 mm, and thus the level difference is 2. 14 mm. Moreover, the fiber density of the 1st convex part 11 was 82 pieces / mm < 2 >, the fiber density of the 2nd convex part 21 was 82 pieces / mm < 2 >, and the fiber density of the 2nd recessed part 22 was 442 pieces / mm < 2 >. In addition, the same evaluation results as in Example 1 were obtained for the texture, the flow of soft stool, and the adhesiveness with the absorber.
In the test body of Example 3, the basis weight of the fiber web 50 is 30 g / m 2 , the thickness of the first uneven structure 13 is 8.11 mm, the thickness of the second uneven structure 23 is 3.03 mm, and thus the step is 5. It was 08 mm. Moreover, the fiber density of the 1st convex part 11 was 85 pieces / mm < 2 >, the fiber density of the 2nd convex part 21 was 84 pieces / mm < 2 >, and the fiber density of the 2nd recessed part 22 was 446 pieces / mm < 2 >. In addition, the same evaluation results as in Example 1 were obtained for the texture, the flow of soft stool, and the adhesion to the absorber.
　実施例４の試験体は、繊維ウエブ５０の坪量は３０ｇ／ｍ２、第１凹凸構造１３の厚みは６．５４ｍｍ、第２凹凸構造２３の厚みは３．２７ｍｍ、したがって、段差は３．２７ｍｍであった。また、第１凹部１２の繊維密度は８２本／ｍｍ２、第２凸部２１の繊維密度は８０本／ｍｍ２、第２凹部２２の繊維密度は４４２本／ｍｍ２であった。また肌触りが柔らかく、しなやかであり、風合いが良く、評価結果は「Ａ」であった。図１１（２）に示すように、疑似軟便６０の液流れは、１６５ｍｍであり、不織布１０Ｂや吸収体３で吸収しきれなかった疑似軟便６０が不織布１０Ｂの表面を流れるが、第２凹部２２で流れを止めることができた。また、吸収体との接着性は、実施例１と同じ評価結果となった。
　実施例５の試験体は、繊維ウエブ５０の坪量は３０ｇ／ｍ２、第１凹凸構造１３の厚みは４．９９ｍｍ、第２凹凸構造２３の厚みは３．１１ｍｍ、したがって、段差は１．８８ｍｍであった。また、第１凹部１２の繊維密度は８８本／ｍｍ２、第２凸部２１の繊維密度は８４本／ｍｍ２、第２凹部２２の繊維密度は４５５本／ｍｍ２であった。また、風合い、軟便の液流れおよび吸収体との接着性は、実施例４と同じ評価結果となった。
　実施例６の試験体は、繊維ウエブ５０の坪量は３０ｇ／ｍ２、第１凹凸構造１３の厚みは８．１１ｍｍ、第２凹凸構造２３の厚みは３．０５ｍｍ、したがって、段差は５．０６ｍｍであった。また、第１凹部１２の繊維密度は８３本／ｍｍ２、第２凸部２１の繊維密度は８４本／ｍｍ２、第２凹部２２の繊維密度は４６０本／ｍｍ２であった。また、風合い、軟便の液流れおよび吸収体との接着性は、実施例４と同じ評価結果となった。 In the test body of Example 4, the basis weight of the fiber web 50 is 30 g / m 2 , the thickness of the first uneven structure 13 is 6.54 mm, the thickness of the second uneven structure 23 is 3.27 mm, and thus the step is 3. It was 27 mm. Moreover, the fiber density of the 1st recessed part 12 was 82 pieces / mm < 2 >, the fiber density of the 2nd convex part 21 was 80 pieces / mm < 2 >, and the fiber density of the 2nd recessed part 22 was 442 pieces / mm < 2 >. Moreover, the touch was soft and supple, the texture was good, and the evaluation result was "A". As shown in FIG. 11 (2), the liquid flow of the pseudo soft stool 60 is 165 mm, and the pseudo soft stool 60 that could not be absorbed by the nonwoven fabric 10B or the absorbent body 3 flows on the surface of the nonwoven fabric 10B. I was able to stop the flow. Moreover, the adhesiveness with an absorber became the same evaluation result as Example 1.
In the test body of Example 5, the basis weight of the fiber web 50 is 30 g / m 2 , the thickness of the first uneven structure 13 is 4.99 mm, the thickness of the second uneven structure 23 is 3.11 mm, and thus the level difference is 1. It was 88 mm. Moreover, the fiber density of the 1st recessed part 12 was 88 pieces / mm < 2 >, the fiber density of the 2nd convex part 21 was 84 pieces / mm < 2 >, and the fiber density of the 2nd recessed part 22 was 455 pieces / mm < 2 >. Moreover, the same evaluation results as in Example 4 were obtained for the texture, the liquid flow of soft stool, and the adhesiveness with the absorber.
In the test body of Example 6, the basis weight of the fiber web 50 is 30 g / m 2 , the thickness of the first uneven structure 13 is 8.11 mm, the thickness of the second uneven structure 23 is 3.05 mm, and thus the step is 5. It was 06 mm. Moreover, the fiber density of the 1st recessed part 12 was 83 pieces / mm < 2 >, the fiber density of the 2nd convex part 21 was 84 pieces / mm < 2 >, and the fiber density of the 2nd recessed part 22 was 460 pieces / mm < 2 >. Moreover, the same evaluation results as in Example 4 were obtained for the texture, the liquid flow of soft stool, and the adhesiveness with the absorber.
　比較例１の試験体は、繊維ウエブの坪量は２７ｇ／ｍ２、第１凹凸構造の厚みは１．３ｍｍであった。また、第１凸部の繊維密度は６５本／ｍｍ２、第２凸部の繊維密度は０本／ｍｍ２であった。また、風合いの評価は「Ｂ」であり、吸収体との接着性の評価は「Ａ」であったが、軟便の液流れは３５０ｍｍ以上であり、液流れを止めることができなかった。
　比較例２の試験体は、繊維ウエブの坪量は２７ｇ／ｍ２、第１凹凸構造の厚みは５．５ｍｍであった。また、第１凸部の繊維密度は８０本／ｍｍ２、第２凸部の繊維密度は０本／ｍｍ２であった。また、風合いの評価は「Ａ」であり、吸収体との接着性の評価は「Ａ」であったが、軟便の液流れは３５０ｍｍ以上であり、液流れを止めることができなかった。 In the test body of Comparative Example 1, the basis weight of the fiber web was 27 g / m 2 , and the thickness of the first uneven structure was 1.3 mm. Moreover, the fiber density of the 1st convex part was 65 pieces / mm < 2 >, and the fiber density of the 2nd convex part was 0 piece / mm < 2 >. Moreover, although evaluation of the texture was "B" and evaluation of adhesiveness with an absorber was "A", the liquid flow of soft stool was 350 mm or more, and the liquid flow could not be stopped.
In the test body of Comparative Example 2, the basis weight of the fiber web was 27 g / m 2 , and the thickness of the first concavo-convex structure was 5.5 mm. Moreover, the fiber density of the 1st convex part was 80 piece / mm < 2 >, and the fiber density of the 2nd convex part was 0 piece / mm < 2 >. Moreover, although evaluation of the texture was "A" and evaluation of adhesiveness with an absorber was "A", the liquid flow of the soft stool was 350 mm or more, and the liquid flow could not be stopped.
　参考例の試験体は、繊維ウエブ５０の坪量は３０ｇ／ｍ２、不織布（実施例１の第２凹凸構造２３に相当）の厚みは３．１４ｍｍであった。また実施例１と同様に風合いは良く、評価結果は「Ａ」となったが、吸収体との接着性は、接着があまく剥がし易く、評価結果は「Ｂ」となった。さらに軟便の液流れが２２０ｍｍであり、不織布の途中で液流れを止めることができなかった。 In the test sample of the reference example, the basis weight of the fiber web 50 was 30 g / m 2 , and the thickness of the nonwoven fabric (corresponding to the second uneven structure 23 of Example 1) was 3.14 mm. In addition, the texture was good as in Example 1, and the evaluation result was “A”, but the adhesion to the absorber was easy to peel off, and the evaluation result was “B”. Furthermore, the liquid flow of the soft stool was 220 mm, and the liquid flow could not be stopped in the middle of the nonwoven fabric.
　以上説明したように、本発明は、軟便等の粘性の高い液の液流れを所定の位置で止めることができ、しかも肌触りが柔らかでしなやかな風合いの良い不織布を得ることができる。 As described above, the present invention can stop a liquid flow of a highly viscous liquid such as soft stool at a predetermined position, and can obtain a nonwoven fabric having a soft touch and a supple texture.
　本発明をその実施態様とともに説明したが、我々は特に指定しない限り我々の発明を説明のどの細部においても限定しようとするものではなく、添付の請求の範囲に示した発明の精神と範囲に反することなく幅広く解釈されるべきであると考える。 While this invention has been described in conjunction with its embodiments, we do not intend to limit our invention in any detail of the description unless otherwise specified and are contrary to the spirit and scope of the invention as set forth in the appended claims. I think it should be interpreted widely.
　本願は、２０１１年１２月２１日に日本国で特許出願された特願２０１１－２８０４９６、２０１２年１２月１０日に日本国で特許出願された特願２０１２－２６９４７１に基づく優先権を主張するものであり、これらはここに参照してその内容を本明細書の記載の一部として取り込む。 This application claims priority based on Japanese Patent Application No. 2011-280496 filed in Japan on December 21, 2011 and Japanese Patent Application No. 2012-269471 filed in Japan on December 10, 2012 Which are hereby incorporated by reference herein as part of their description.
　１　表面シート
　２　裏面シート
　３　吸収体
　４　吸収性本体
　５　使い捨ておむつ
　６　サイドシート
　７　横漏れ防止ギャザー
　８　ファスニングテープ
　１０　不織布
　１０Ａ　第１の不織布
　１０Ｂ　第２の不織布
　１１　第１凸部
　１２　第１凹部
　１３　第１凹凸構造
　２１　第２凸部
　２２　第２凹部
　２３　第２凹凸構造
　５０　繊維ウエブ
　１００，２００　不織布の製造装置
　１１０　支持体
　１１１　ドラム
　１１２　支持体部
　１１３　支持体基部
　１１４　突起
　１１５　孔
　１１６　別の支持体部
　１１７　通気部
　１２１　第１ノズル
　１２２　第２ノズル
　１２３　第１ヒータ
　１２４　第２ヒータ
　１２５，１２６　吸引部
　１２７，１２８　排気装置
　１２８　排気装置
　１３１　搬送部
　１３２　案内部
　１３３　通気コンベア
　Ｗ１　第１の熱風
　Ｗ２　第２の熱風
　Ｚ１　第１面側
　Ｚ２　第２面側
  DESCRIPTION OF SYMBOLS 1 Top sheet 2 Back sheet 3 Absorber 4 Absorbent main body 5 Disposable diaper 6 Side sheet 7 Side leakage prevention gather 8 Fastening tape 10 Non-woven fabric 10A 1st nonwoven fabric 10B 2nd nonwoven fabric 11 1st convex part 12 1st recessed part 13 1st DESCRIPTION OF SYMBOLS 1 Uneven structure 21 2nd convex part 22 2nd recessed part 23 2nd uneven structure 50 Fiber web 100,200 The manufacturing apparatus of a nonwoven fabric 110 Support body 111 Drum 112 Support body part 113 Support body base 114 Projection 115 Hole 116 Another support body part 117 Ventilation part 121 1st nozzle 122 2nd nozzle 123 1st heater 124 2nd heater 125,126 Suction part 127,128 Exhaust device 128 Exhaust device 131 Conveying part 132 Guide part 133 Ventilation conveyor W1 1st hot air W2 2nd Hot air Z1 1st surface side Z2 2nd surface side

Claims (26)

  1. 　シート状の不織布を平面視した側の第１面側に突出する第１凸部と、前記第１凸部に囲まれた第１凹部とが配された第１凹凸構造と、
    　前記第１凹部底面は前記第１面側に突出する第２凸部と前記第１面側とは反対側の第２面側に突出する第２凹部とが配され該第２凸部が前記第１凸部より高さが低い第２凹凸構造を成し、
    　前記第２凸部は前記第２凹部より低密度である不織布。     A first concavo-convex structure in which a first convex portion protruding to the first surface side of the sheet-like nonwoven fabric in plan view and a first concave portion surrounded by the first convex portion are disposed;
    The bottom surface of the first concave portion includes a second convex portion projecting to the first surface side and a second concave portion projecting to the second surface side opposite to the first surface side, and the second convex portion is Forming a second concavo-convex structure having a height lower than that of the first convex portion;
    The said 2nd convex part is a nonwoven fabric whose density is lower than the said 2nd recessed part.
  2. 前記第２凹凸構造は、前記第１凹部の底面内において、第２凸部と第２凹部とが異なる方向に交互に配列されている請求項１に記載の不織布。 2. The nonwoven fabric according to claim 1, wherein in the second concavo-convex structure, the second convex portions and the second concave portions are alternately arranged in different directions within the bottom surface of the first concave portion.
  3. 　前記第２凸部は、前記第１凸部よりも２ｍｍ以上低い請求項１または２に記載の不織布。 The said 2nd convex part is a nonwoven fabric of Claim 1 or 2 lower than the said 1st convex part by 2 mm or more.
  4. 　前記第２凸部の密度は前記第２凹部の密度より１５０本／ｍｍ２以上高い請求項１から３のいずれか１項に記載の不織布。 The density of the said 2nd convex part is a nonwoven fabric of any one of Claim 1 to 3 higher than the density of the said 2nd recessed part 150 pieces / mm < 2 > or more.
  5. 　前記第１凸部は、前記第１面側とは反対の第２面側の一部が平坦面であり、
    　前記平坦面は、前記第２凹凸構造が前記第２面側で接する仮想平面と同一平面または前記仮想平面より第２面側に存する請求項１から４のいずれか１項に記載の不織布。     The first convex portion is a flat surface part of the second surface opposite to the first surface.
    The said flat surface is a nonwoven fabric of any one of Claim 1 to 4 which exists in the 2nd surface side from the same plane or the said virtual plane with which the said 2nd uneven structure contacts the said 2nd surface side.
  6. 　前記不織布の平面視全面にわたって縦長の長方形の前記第１凹部が等間隔に縦横に配され、前記各第１凹部の周囲にはそれらを囲むように前記第１凸部が連続的に配されている請求項１から５のいずれか１項に記載の不織布。 The vertically elongated rectangular first recesses are arranged at equal intervals across the entire surface of the nonwoven fabric in plan view, and the first projections are continuously arranged around each first recess so as to surround them. The nonwoven fabric according to any one of claims 1 to 5.
  7. 　前記不織布の平面視全面にわたって縦長の長方形の前記第１凹部が等間隔に縦横にかつ縦方向に１／２ピッチずつずらして配され、前記各第１凹部の周囲にはそれらを囲むように前記第１凸部が連続的に配されている請求項１から５のいずれか１項に記載の不織布。 The vertically long rectangular first recesses are arranged at regular intervals vertically and horizontally and shifted by 1/2 pitch over the entire surface of the nonwoven fabric in plan view, and the first recesses surround the first recesses so as to surround them. The nonwoven fabric according to any one of claims 1 to 5, wherein the first convex portions are continuously arranged.
  8. 　前記不織布の平面視全面にわたって円形の前記第１凹部が等間隔に縦横に配され、前記各第１凹部の周囲にはそれらを囲むように前記第１凸部が連続的に配されている請求項１から５のいずれか１項に記載の不織布。 The circular first recesses are arranged vertically and horizontally at equal intervals over the entire surface of the nonwoven fabric in plan view, and the first protrusions are continuously arranged around each first recess so as to surround them. Item 6. The nonwoven fabric according to any one of Items 1 to 5.
  9. 　前記不織布の平面視全面にわたって縦方向に前記第１凹部が縞に等間隔に配され、前記各第１凹部の周囲にはそれらを囲むように前記第１凸部が連続的に配されている請求項１から５のいずれか１項に記載の不織布。 The first recesses are arranged in stripes at equal intervals in the longitudinal direction over the entire planar view of the nonwoven fabric, and the first projections are continuously arranged around each first recess so as to surround them. The nonwoven fabric according to any one of claims 1 to 5.
  10. 　シート状の不織布を平面視した側の第１面側に突出する第１凸部と、前記第１凸部を囲む第１凹部が配された第１凹凸構造と、
    　前記第１凸部上面が前記第１面側に突出する第２凸部と前記第１面側とは反対側の第２面側に突出する第２凹部を配した第２凹凸構造を成し、
    　前記第２凹部は前記第１凸部より低密度である不織布。     A first convex part projecting to the first surface side of the sheet-like nonwoven fabric in plan view, and a first concave-convex structure in which a first concave part surrounding the first convex part is arranged,
    The upper surface of the first convex portion has a second concavo-convex structure in which a second convex portion protruding to the first surface side and a second concave portion protruding to the second surface side opposite to the first surface side are arranged. ,
    The second recess is a nonwoven fabric having a lower density than the first protrusion.
  11. 　前記第２凸部における繊維密度と前記第２凹部における繊維密度の差は、１５０本／ｍｍ２以上である請求項１０に記載の不織布。 The nonwoven fabric according to claim 10, wherein a difference between a fiber density in the second convex portion and a fiber density in the second concave portion is 150 pieces / mm 2 or more.
  12. 　前記第１凹部は、前記第１面側とは反対の第２面側の少なくとも一部が平坦面である請求項１０または１１に記載の不織布。 The nonwoven fabric according to claim 10 or 11, wherein at least a part of the first concave portion on the second surface side opposite to the first surface side is a flat surface.
  13. 　複数の突起と複数の孔を配した複数の支持体部を所定間隔に配置した支持体上に熱可塑性繊維を含有する繊維ウエブを搬送し、第１の熱風および第２の熱風を吹き付けて、第１凸部と該第１凸部に囲まれた第１凹部とが配された第１凹凸構造に賦形するとともに、前記第１凹部底面を第２凸部と第２凹部とが配され該第２凸部が前記第１凸部より高さが低い第２凹凸構造に賦形する工程を有し、
    　前記繊維ウエブに前記繊維ウエブの繊維の低融点成分の融点より６０℃低い温度以上の前記第１の熱風を吹き付けて前記繊維ウエブを前記支持体の形状に沿わせて繊維同士を仮融着し、前記第１の熱風よりも高温の前記第２の熱風を吹き付けて前記仮融着させた形状を保持した状態で前記繊維ウエブの繊維同士を融着させて形状を固定する不織布の製造方法。     A fiber web containing thermoplastic fibers is transported onto a support in which a plurality of support portions having a plurality of protrusions and a plurality of holes are arranged at predetermined intervals, and the first hot air and the second hot air are blown, The first convex part and the first concave part surrounded by the first convex part are shaped into a first concave-convex structure, and the bottom surface of the first concave part is arranged with the second convex part and the second concave part. The second convex portion has a step of forming a second concave-convex structure having a lower height than the first convex portion,
    The first hot air having a temperature 60 ° C. or more lower than the melting point of the low melting point component of the fiber of the fiber web is blown onto the fiber web so that the fiber web conforms to the shape of the support and the fibers are temporarily fused together. The manufacturing method of the nonwoven fabric which fixes the shape by fuse | melting the fibers of the said fiber web in the state which sprayed the said 2nd hot air of higher temperature than the said 1st hot air, and hold | maintained the said temporarily fused shape.
  14. 前記支持体上に前記繊維ウエブを搬送し、前記第１の熱風を吹きつけることにより、前記第１凹凸構造及び第２凹凸構造の形状が保持される状態に仮融着し、前記第２の熱風により、繊維ウエブの繊維同士を融着させて形状を固定する、請求項１３に記載の不織布の製造方法。 By transporting the fiber web onto the support and blowing the first hot air, the first and second concavo-convex structures and the second concavo-convex structure are preliminarily fused so as to maintain the shape. The manufacturing method of the nonwoven fabric of Claim 13 which fuses the fibers of a fiber web with hot air and fixes a shape.
  15. 前記支持体の前記所定間隔により前記第１凸部を形成し、前記支持体基部により、第２凹凸構造を有する第１凹部を形成する、請求項１３または１４に記載の不織布の製造方法。 The manufacturing method of the nonwoven fabric according to claim 13 or 14, wherein the first protrusion is formed by the predetermined interval of the support, and the first recess having a second uneven structure is formed by the support base.
  16. 　前記孔の開孔率が２０％以上４５％以下である請求項１３記載の不織布の製造方法。 The method for producing a nonwoven fabric according to claim 13, wherein the hole area ratio is 20% or more and 45% or less.
  17. 　複数の突起と複数の孔を配した複数の支持体部を所定間隔に配置するとともに該支持体部間に該支持体より高さが高い別の支持体部を配し、両支持体部を配した支持体上に熱可塑性繊維を含有する繊維ウエブを搬送し、第１の熱風および第２の熱風を吹き付けて、第１凹部と該第１凹部に囲まれた第１凸部とが配された第１凹凸構造とともに前記第１凸部上面を第２凸部と第２凹部が配された第２凹凸構造に賦形する工程を有し、
    　前記繊維ウエブに、前記繊維ウエブの繊維の低融点成分の融点より６０℃低い温度以上の前記第１の熱風を吹き付けて前記繊維ウエブを前記支持体の形状に沿わせて繊維同士を仮融着し、前記第１の熱風よりも高温の前記第２の熱風を吹き付けて前記仮融着させた形状を保持した状態で前記繊維ウエブの繊維同士を融着させて形状を固定する不織布の製造方法。     A plurality of support parts having a plurality of protrusions and a plurality of holes are arranged at a predetermined interval, and another support part having a height higher than the support is provided between the support parts. A fiber web containing thermoplastic fibers is transported onto the disposed support, and the first hot air and the second hot air are blown to arrange the first concave portion and the first convex portion surrounded by the first concave portion. Forming the upper surface of the first convex portion together with the first concave-convex structure formed into a second concave-convex structure in which a second convex portion and a second concave portion are arranged,
    The first hot air having a temperature of 60 ° C. lower than the melting point of the low melting point component of the fiber of the fiber web is blown onto the fiber web so that the fiber web conforms to the shape of the support and the fibers are temporarily fused together. And the manufacturing method of the nonwoven fabric which fuses the fibers of the said fiber web and fixes the shape in the state which sprayed the said 2nd hot air of higher temperature than the said 1st hot air, and hold | maintained the said shape temporarily bonded. .
  18. 前記支持体上に前記繊維ウエブを搬送し、前記第１の熱風を吹きつけることにより、前記第１凹凸構造及び第２凹凸構造の形状が保持される状態に仮融着し、前記第２の熱風により、繊維ウエブの繊維同士を融着させて形状を固定する、請求項１７に記載の不織布の製造方法。 By transporting the fiber web onto the support and blowing the first hot air, the first and second concavo-convex structures and the second concavo-convex structure are preliminarily fused so as to maintain the shape. The manufacturing method of the nonwoven fabric of Claim 17 which fuses the fibers of a fiber web with hot air and fixes a shape.
  19. 　前記支持体はドラム形状を有する請求項１３から１８のいうちのいずれか１項に記載の不織布の製造方法。 The method for producing a nonwoven fabric according to any one of claims 13 to 18, wherein the support has a drum shape.
  20. 　前記第１の熱風を吹き出す第１ノズルと前記第２の熱風を吹き出す第２ノズルを有し、前記第１ノズルと前記支持体との間で、通気性を有するベルトで前記繊維ウエブを前記支持体側に押さえつける、または前記第１ノズルと前記支持体との間および前記第２ノズルと前記支持体との間で、通気性を有するベルトで前記繊維ウエブを前記支持体側に押さえつける請求項１３から１８のいずれか１項に記載の不織布の製造方法。 A first nozzle that blows the first hot air and a second nozzle that blows the second hot air, and the fiber web is supported by a belt having air permeability between the first nozzle and the support. 19. The fiber web is pressed against the support side by a belt having air permeability between the first nozzle and the support and between the second nozzle and the support. The manufacturing method of the nonwoven fabric of any one of these.
  21. 前記第１の熱風の温度は、繊維ウエブの繊維の低融点成分の融点より６０℃低い温度以上であり、該低融点成分の融点より１５℃高い温度以下に制御する請求項１３から２０のいずれか１項に記載の不織布の製造方法。 21. The temperature of the first hot air is controlled to be not less than 60 ° C. lower than the melting point of the low melting point component of the fiber of the fiber web and controlled to be not more than 15 ° C. higher than the melting point of the low melting point component. The manufacturing method of the nonwoven fabric of Claim 1.
  22. 前記第２の熱風の温度は、前記繊維ウエブの繊維の低融点成分の融点以上、前記繊維ウエブの繊維の高融点成分の融点未満に制御する、請求項１３から２１のいずれか１項に記載の不織布の製造方法。 The temperature of the second hot air is controlled to be not less than the melting point of the low melting point component of the fiber of the fiber web and less than the melting point of the high melting point component of the fiber of the fiber web. Manufacturing method of non-woven fabric.
  23. 　複数の突起と複数の孔を配した複数の支持体部を所定間隔に配置した支持体と、前記支持体上に搬送された熱可塑性繊維を含有する繊維ウエブに第１の熱風を吹き付ける第１ノズルと、前記繊維ウエブに前記第１の熱風よりも高温の第２の熱風を吹き付ける第２ノズルとを有し、
    　前記支持体部とこれより高さの低い前記支持体と間隔によって前記繊維ウエブに第１凸部と第１凹部が賦形された第１凹凸構造が作製され、前記支持体部の前記突起と前記孔によって前記繊維ウエブに前記第１凸部より高さが低い第２凸部と第２凹部が賦形された第２凹凸構造が作製される不織布の製造装置。     A first support body in which a plurality of support portions provided with a plurality of protrusions and a plurality of holes are arranged at predetermined intervals, and a first hot air is blown onto a fiber web containing thermoplastic fibers conveyed on the support body. A nozzle, and a second nozzle that blows a second hot air higher in temperature than the first hot air onto the fiber web,
    A first concavo-convex structure in which a first convex portion and a first concave portion are formed on the fiber web by the spacing between the support portion and the support lower in height than the support portion, and the protrusion of the support portion is formed. A non-woven fabric manufacturing apparatus in which a second concavo-convex structure in which a second convex portion and a second concave portion having a height lower than that of the first convex portion are formed on the fiber web is produced by the holes.
  24. 　複数の突起と複数の孔を配した複数の支持体部を所定間隔に配置するとともに、前記支持体部間に前記支持体よりも高さの高い別の支持体部を配置した支持体と、前記支持体上に搬送された熱可塑性繊維を含有する繊維ウエブに第１の熱風を吹き付ける第１ノズルと、前記繊維ウエブに前記第１の熱風よりも高温の第２の熱風を吹き付ける第２ノズルとを有し、
    　前記支持体部とこれよりも高さの高い別の支持体部によって前記繊維ウエブに第１凸部が賦形され、前記別の支持体部によって前記繊維ウエブに第１凹部が賦形された第１凹凸構造が作製され、前記支持体部の前記突起と前記孔によって前記繊維ウエブに前記第１凸部より高さが低い第２凸部と第２凹部が賦形された第２凹凸構造が作製される不織布の製造装置。     A plurality of support portions arranged with a plurality of protrusions and a plurality of holes are arranged at predetermined intervals, and a support body in which another support portion having a height higher than the support is disposed between the support portions, A first nozzle that blows first hot air on a fiber web containing thermoplastic fibers conveyed on the support, and a second nozzle that blows second hot air higher in temperature than the first hot air on the fiber web. And
    A first convex portion is formed on the fiber web by the support portion and another support portion having a height higher than the support portion, and a first concave portion is formed on the fiber web by the another support portion. A second concavo-convex structure in which a first concavo-convex structure is formed, and the second convex portion and the second concave portion having a height lower than the first convex portion are formed on the fiber web by the protrusions and the holes of the support portion. Nonwoven fabric manufacturing apparatus for producing
  25. 　肌当接面側に配置される液透過性の表面シートと、非肌当接面側に配置される液不透過性の裏面シートと、前記両シート間に介在される吸収体とを有し、
    　前記表面シートは、請求項１から１２のいずれか１項に記載の不織布からなる吸収性物品。     A liquid-permeable surface sheet disposed on the skin contact surface side, a liquid-impermeable back sheet disposed on the non-skin contact surface side, and an absorber interposed between the two sheets. ,
    The said surface sheet is an absorptive article which consists of a nonwoven fabric given in any 1 paragraph of Claims 1-12.
  26. 　肌当接面側に配置される液透過性の表面シートと、非肌当接面側に配置される液不透過性の裏面シートと、前記両シート間に介在される吸収体とを有し、
    　前記表面シートは、請求項１から１２のいずれか１項に記載の不織布からなる使い捨ておむつ。
     
          A liquid-permeable surface sheet disposed on the skin contact surface side, a liquid-impermeable back sheet disposed on the non-skin contact surface side, and an absorber interposed between the two sheets. ,
    The said surface sheet is a disposable diaper which consists of a nonwoven fabric of any one of Claim 1 to 12.

PCT/JP2012/082062 2011-12-21 2012-12-11 Nonwoven fabric, manufacturing method therefor and manufacturing equipment therefor WO2013094474A1 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
JP2011280496 2011-12-21
JP2011-280496 2011-12-21
JP2012269471A JP5498562B2 (en) 2011-12-21 2012-12-10 Nonwoven manufacturing method
JP2012-269471 2012-12-10

Publications (1)

Publication Number Publication Date
WO2013094474A1 true WO2013094474A1 (en) 2013-06-27

Family

ID=48668368

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/JP2012/082062 WO2013094474A1 (en) 2011-12-21 2012-12-11 Nonwoven fabric, manufacturing method therefor and manufacturing equipment therefor

Country Status (2)

Country Link
JP (1) JP5498562B2 (en)
WO (1) WO2013094474A1 (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107613925A (en) * 2015-05-29 2018-01-19 尤妮佳股份有限公司 Absorbent commodity
CN107613924A (en) * 2015-05-29 2018-01-19 尤妮佳股份有限公司 Absorbent commodity non-woven fabrics
CN109234912A (en) * 2018-11-15 2019-01-18 佛山市南海必得福无纺布有限公司 A kind of ventilative rotary drum with anaglyph
CN109328050A (en) * 2016-06-30 2019-02-12 尤妮佳股份有限公司 Absorbent commodity

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP6190260B2 (en) * 2013-12-09 2017-08-30 花王株式会社 Nonwoven manufacturing method
JP5634632B1 (en) * 2014-05-09 2014-12-03 ユニ・チャーム株式会社 Absorbent articles
WO2016084251A1 (en) 2014-11-28 2016-06-02 ユニ・チャーム株式会社 Method for forming crimped parts in continuous body of web member having fiber bundles, and formation device
WO2016084250A1 (en) * 2014-11-28 2016-06-02 ユニ・チャーム株式会社 Method for forming crimped parts on continuous body of web member having fiber bundles, and formation device
JP6087462B1 (en) * 2016-05-13 2017-03-01 ユニ・チャーム株式会社 Absorbent articles
JP7091754B2 (en) * 2018-03-22 2022-06-28 王子ホールディングス株式会社 Absorbent article
JP7446712B2 (en) * 2018-12-28 2024-03-11 ユニ・チャーム株式会社 Sheet member manufacturing method and sheet member manufacturing device
KR102134865B1 (en) * 2019-12-24 2020-07-22 (주) 신우피앤씨 Apparatus for producing the hygiene absorbent article

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002020957A (en) * 2000-07-06 2002-01-23 Nippon Kyushutai Gijutsu Kenkyusho:Kk Nonwoven fabric with double phase structure and method for producing the same
JP2009072398A (en) * 2007-09-21 2009-04-09 Daio Paper Corp Absorbent article
JP2011080178A (en) * 2009-10-09 2011-04-21 Unicharm Corp Nonwoven fabric
JP2011127242A (en) * 2009-12-16 2011-06-30 Kao Corp Method and apparatus for producing nonwoven fabric

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002020957A (en) * 2000-07-06 2002-01-23 Nippon Kyushutai Gijutsu Kenkyusho:Kk Nonwoven fabric with double phase structure and method for producing the same
JP2009072398A (en) * 2007-09-21 2009-04-09 Daio Paper Corp Absorbent article
JP2011080178A (en) * 2009-10-09 2011-04-21 Unicharm Corp Nonwoven fabric
JP2011127242A (en) * 2009-12-16 2011-06-30 Kao Corp Method and apparatus for producing nonwoven fabric

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107613925A (en) * 2015-05-29 2018-01-19 尤妮佳股份有限公司 Absorbent commodity
CN107613924A (en) * 2015-05-29 2018-01-19 尤妮佳股份有限公司 Absorbent commodity non-woven fabrics
CN110478133A (en) * 2015-05-29 2019-11-22 尤妮佳股份有限公司 Absorbent commodity
CN109328050A (en) * 2016-06-30 2019-02-12 尤妮佳股份有限公司 Absorbent commodity
CN109328050B (en) * 2016-06-30 2020-03-06 尤妮佳股份有限公司 Absorbent article
CN109234912A (en) * 2018-11-15 2019-01-18 佛山市南海必得福无纺布有限公司 A kind of ventilative rotary drum with anaglyph

Also Published As

Publication number Publication date
JP5498562B2 (en) 2014-05-21
JP2013147784A (en) 2013-08-01

Similar Documents

Publication Publication Date Title
JP5498562B2 (en) Nonwoven manufacturing method
US11903805B2 (en) Method of making an absorbent composite and absorbent articles employing the same
KR102493090B1 (en) Method of making an absorbent composite and absorbent articles employing the same
AU2015285607B2 (en) Absorbent article and wearable article including absorbent article
JP6271313B2 (en) Absorber manufacturing apparatus and manufacturing method
JP6193328B2 (en) Sheet material and method for producing sheet material
TWI684435B (en) Absorbent article and wearing article provided with the absorbent article
WO2015151727A1 (en) Nonwoven fabric
BR112015010854B1 (en) ABSORBENT ARTICLE
TW200803802A (en) Absorbent product
JP2017213360A (en) Absorbent article
JP6170978B2 (en) Absorbent article and manufacturing method thereof
JP2013124428A (en) Laminated nonwoven fabric and method for producing the same
JP2011136077A (en) Absorbent article
JP6408194B1 (en) LAMINATED NONWOVEN, PROCESS FOR PRODUCING THE SAME, ABSORBENT ARTICLE, AND SEAT ABSORBING SHEET
BR112018074135B1 (en) ABSORBENT ARTICLE
JP6321505B2 (en) Uneven fabric
CN108024889B (en) Absorbent commodity
ES2464144T3 (en) Printed absorbent article
JP2009279098A (en) Absorbent article
WO2015151757A1 (en) Absorbent article
WO2017061565A1 (en) Absorbent article
JP2019042005A (en) High-absorbent sheet and absorbent article with the same
WO2017208775A1 (en) Absorbent article
JP6972470B2 (en) Highly absorbent sheet and absorbent article comprising the highly absorbent sheet

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 12860058

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 12860058

Country of ref document: EP

Kind code of ref document: A1