WO2017145993A1 - Long fiber nonwoven fabric with superior tactile sense - Google Patents

Long fiber nonwoven fabric with superior tactile sense Download PDF

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Publication number
WO2017145993A1
WO2017145993A1 PCT/JP2017/006165 JP2017006165W WO2017145993A1 WO 2017145993 A1 WO2017145993 A1 WO 2017145993A1 JP 2017006165 W JP2017006165 W JP 2017006165W WO 2017145993 A1 WO2017145993 A1 WO 2017145993A1
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WO
WIPO (PCT)
Prior art keywords
nonwoven fabric
less
fiber
skin
friction
Prior art date
Application number
PCT/JP2017/006165
Other languages
French (fr)
Japanese (ja)
Inventor
登志子 中東
一哉 税所
矢放　正広
一史 加藤
Original Assignee
旭化成株式会社
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 旭化成株式会社 filed Critical 旭化成株式会社
Priority to CN201780011534.6A priority Critical patent/CN108699745B/en
Priority to JP2018501672A priority patent/JP6542974B2/en
Priority to MYPI2018702596A priority patent/MY184560A/en
Publication of WO2017145993A1 publication Critical patent/WO2017145993A1/en

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Classifications

    • 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
    • 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
    • A61F13/514—Backsheet, i.e. the impermeable cover or layer furthest from the skin
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L15/00—Chemical aspects of, or use of materials for, bandages, dressings or absorbent pads
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D04H3/147—Composite yarns or filaments

Definitions

  • the present invention relates to a partially thermocompression-bonded nonwoven fabric of composite long fibers made of two or more kinds of thermoplastic resins having good touch, little physical irritation to the skin, and bulky.
  • the materials used for the parts that come into contact with the skin such as top sheets for sanitary materials such as disposable diapers and sanitary napkins, have a soft texture and are free from itching, tingling, and pain due to fluff. It is important to be good. Above all, it is important that there is little physical irritation to the skin. Examples of the physical stimulation include stimulation by fluff generated from the end portion of the fiber and fibers, and abrasion stimulation resulting from the stimulation.
  • Nonwoven fabrics in which short fibers are heat-sealed by the heat-through air method to form a sheet are soft and the texture is soft. Since it is worn, there is little occurrence of fluff, and it has been used for many purposes. However, since this nonwoven fabric is composed of short fibers, the fiber ends are present on the surface, there is a tingling touch, and when the fiber ends rub against the skin, it causes scratching irritation. We were not satisfied with aspect.
  • a nonwoven fabric (hereinafter also referred to as “point-bonded nonwoven fabric”) in which short fibers are partially heat-sealed by an embossing roll or the like is sufficient in terms of physical stimulation because the fiber ends are present on the surface in the same manner as a through-air nonwoven fabric Not only that, but not all of the fiber intersections are bonded as compared to the through-air nonwoven fabric, and thus fuzzing is likely to occur and the texture is also inferior.
  • a long fiber nonwoven fabric obtained by thermocompression bonding of a long fiber nonwoven fabric with an embossing roll or the like does not cause the short fiber ends to come out on the surface and hardly causes physical irritation by the fiber ends, but excessive heat is used to prevent fluffing on the surface. Crimping is performed, so that the texture is hard and not only gives a rough feel, but also the periphery of the thermocompression bonding part causes physical irritation.
  • Patent Documents 1 and 2 disclose nonwoven fabrics made of thermoplastic composite fibers having good fuzz resistance and good texture.
  • the thermoplastic fiber is flattened by hot embossing and is subjected to point heat compression, there is a flattened heat fusion part, the bulkiness of the nonwoven fabric is impaired, and the texture is inferior Met.
  • the heat-sealed part was hard, physical stimulation due to friction was large.
  • Patent Document 3 discloses a polyolefin-based non-woven fabric in which a specific polyether compound and a specific polyether-modified silicon are used in combination with a long-fiber non-woven fabric partially thermocompression bonded in a specific thermocompression-bonding shape. .
  • the disclosed nonwoven fabric has good fuzz resistance and low physical irritation due to friction.
  • the polypropylene fibers are bonded only by heat embossing, in order to improve fuzz resistance, It is necessary to increase the number of fused portions, the bulk density is high, and it does not have a plump softness, which is not sufficient in these respects.
  • the problem to be solved by the present invention is a bulky property that is suitable for the top sheet or back sheet member of an absorbent article used for sanitary materials, has a soft touch, has a soft softness, and has little physical irritation to the skin. It is to provide a long fiber nonwoven fabric.
  • the inventors of the present invention are nonwoven fabrics composed of composite long fibers composed of two or more thermoplastic resins, and are non-woven before joining in the nonwoven fabric manufacturing process.
  • the web air permeability, hot air temperature and wind speed at the time of joining within a certain range, hot air can be penetrated while maintaining the bulk of the nonwoven web, and fuzz resistance is improved by adhering fiber intersection points,
  • the present inventors have found that the bulk density can be maintained, and have come to provide a nonwoven fabric that can be suitably used as a sanitary material with small physical irritation to the skin.
  • the said nonwoven fabric characterized by being 10 micrometers or less and an integrated abrasion depth of 80 micrometers or less.
  • a longitudinal and lateral average value of a variation value (MMD) of a friction coefficient of the nonwoven fabric is 0.015 or less.
  • thermoplastic resins are polyolefin resins.
  • nonwoven fabric according to any one of [1] to [7] wherein the nonwoven fabric contains a hydrophilizing agent.
  • a sanitary material comprising the non-woven fabric according to any one of [1] to [8].
  • the nonwoven fabric of the present invention is a nonwoven fabric composed of composite long fibers made of two or more kinds of thermoplastic resins, and the nonwoven fabric is configured so that the nonwoven fabric exhibits specific friction characteristics and thermocompression bonding portion shape index. It can be suitably used as a sanitary material having a low physical irritation to the skin, good fluff resistance, and soft texture achieved by adjusting the degree of fiber adhesion.
  • the composite long fiber constituting the nonwoven fabric of this embodiment is a combination of two or more thermoplastic resins.
  • the thermoplastic resin include polyolefin resins such as polyethylene, polypropylene, and copolymerized polypropylene, polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, and copolyester, nylon-6, nylon-66, and copolyester.
  • polyamide resins such as polymerized nylon
  • biodegradable resins such as polylactic acid, polybutylene succinate, and polyethylene succinate.
  • Any combination of the thermoplastic resins is possible as long as the desired effects are exhibited, but a combination of thermoplastic resins having a difference in melting point is preferable from the viewpoint of bonding properties between fibers.
  • polyolefin resins from the viewpoint of texture.
  • examples thereof include composite fibers obtained by combining resins such as polyethylene, polypropylene, and copolymers of these monomers with other ⁇ -olefins.
  • Other ⁇ -olefins are those having 3 to 10 carbon atoms, such as propylene, 1-butene, 1-pentene, 1-hexane, 4-methyl-1-pentene, and 1-octene. Can be mentioned.
  • the fiber shape of the thermoplastic conjugate fiber of this embodiment is preferably a side-by-side type (S / S) or an eccentric type (biased S / C) because a crimped yarn can be easily obtained.
  • the eccentric core portion may protrude from the fiber surface, and the area ratio of the core portion on the fiber surface is preferably 0 to 50%, more preferably 0 to 30%. The lower the ratio of the core part forming the fiber surface, the higher the ratio of the sheath part resulting from the adhesion, and the higher strength and fluff suppression can be obtained.
  • the weight ratio of the resin having the higher melting point in the combination of thermoplastic resins in the fiber is 20 wt% or more and 80 wt% or less, preferably 30 wt% or more and 80 wt% or less, more preferably It is 50 wt% or more and 70 wt% or less.
  • the fiber shape may be not only a normal circular fiber but also a specially shaped fiber such as a deformed fiber.
  • the first component is polypropylene and the second component is polyethylene.
  • the conjugate fiber is an eccentric type, it is preferable that the core portion is the first component and the sheath portion is the second component.
  • Polypropylene is preferred because it is strong and difficult to break during use, and is excellent in dimensional stability during the production of sanitary materials.
  • the polypropylene of the first component in the case of forming with the two types of thermoplastic resins may be a polymer synthesized by a general Ziegler Natta catalyst, or a polymer synthesized by a single site active catalyst typified by metallocene.
  • ethylene random copolymer polypropylene may be used. These may be a single type or a combination of two or more types. From the viewpoint of texture, strength, and dimensional stability, it is preferable that the main component is homopolypropylene.
  • the lower limit of the MFR of polypropylene can be 20 g / 10 minutes or more, preferably more than 30 g / 10 minutes, more preferably more than 40 g / 10 minutes, and most preferably more than 53 g / 10 minutes.
  • the upper limit can be 85 g / 10 min or less, preferably 70 g / 10 min or less, and most preferably 60 g / 10 min or less.
  • the measurement method of MFR is in accordance with JIS-K7210 “Testing methods for plastic-thermoplastic melt mass flow rate (MFR) and melt volume flow rate (MVR)”, test temperature 230 ° C., test load 2.16 kg. It is a thing.
  • the second component polyethylene has a high adhesive strength after joining the fibers and has a good texture as a non-woven fabric, and therefore can be suitably used as a sanitary material.
  • polyethylene may be a polymer synthesized by a general Ziegler Natta catalyst, or may be a polymer synthesized by a single site active catalyst typified by metallocene.
  • the polyethylene is preferably high-density polyethylene or linear low-density polyethylene, and the density is preferably 0.92 to 0.97 g / cm 3 , and preferably 0.925 to 0.96 g / cm 3. Is more preferable.
  • the lower limit of polyethylene MI can be 10 g / 10 min or more, preferably more than 15 g / 10 min.
  • the upper limit can be 100 g / 10 min or less, preferably 60 g / 10 min or less, and most preferably 40 g / 10 min or less.
  • the MI measurement method is in accordance with JIS-K7210 “Testing methods for plastics-thermoplastic melt mass flow rate (MFR) and melt volume flow rate (MVR)”, test temperature 190 ° C., test load 2.16 kg. It is a thing.
  • the nonwoven fabric of the present embodiment is preferably manufactured by forming a composite long fiber nonwoven web by a spunbond method from the viewpoint of strength and productivity.
  • composite long fibers are melt-extruded from two or more different extruders, respectively, and discharged as yarns in a state where two or more kinds of thermoplastic resins are combined from a spinneret having a large number of spinning holes. Is done.
  • the discharged yarn is pulled at a high speed by a traction device while being cooled by applying cold air controlled at 5 ° C. to 20 ° C.
  • the yarn coming out of the pulling device is deposited on a conveyor and conveyed as a nonwoven web.
  • the nonwoven web being conveyed may be laminated to form a multilayer laminated nonwoven web.
  • the joining means in the case of joining a nonwoven web composed of thermoplastic conjugate fibers to form a nonwoven fabric is not particularly limited as long as it is a method of heating above the temperature at which the intersections of the fibers melt and bond.
  • a heating method various heating methods such as a hot air circulation type, a hot air penetration type, an infrared heater type, a method of blowing hot air on both surfaces of a nonwoven fabric, and a method of introducing into a heated gas are used. From the viewpoint of obtaining more fiber adhesion points at the intersections of the fibers and increasing the breaking strength of the nonwoven fabric, heating with hot air is preferred, and hot air penetration type is particularly preferred.
  • the temperature of the hot air is preferably adjusted to a temperature suitable for the thermoplastic resin having a low melting point and contributing to bonding among the combined thermoplastic resins.
  • the temperature is 130 to 155 ° C. at which polyethylene melts and adheres, preferably 135 to 155 ° C., more preferably 140 ° C. to 150 ° C. If the bonding temperature is within this range, the bonding between the fibers appears at the intersection of the fibers, and the strength of the nonwoven fabric can be expressed.
  • the wind speed of the hot air is 0.5 to 3.0 m / s, preferably 0.7 to 2.5 m / s, and more preferably 2.0 m / s or less.
  • the air permeability of the nonwoven web greatly affects the joining state. If the air permeability of the nonwoven web is too low, the hot air is difficult to penetrate and uniform bonding as a nonwoven fabric is difficult to obtain. On the other hand, from the viewpoint of maintaining the strength of the resulting nonwoven fabric, it is not preferable that the air permeability is too high.
  • the air permeability of the finally obtained non-woven fabric is preferably from 300cm 3 / cm 2 / s or more 700cm 3 / cm 2 / s, 300cm 3 / cm 2 / s or more 650 cm 3 / More preferable is cm 2 / s or less.
  • thermocompression part shape index is a partial thermocompression bonding part formed on the nonwoven fabric surface by joining with an embossing roll or hot air treatment, that is, a fusion-bonded area ratio and a fixed area per unit area. This is defined by the fusion circumference.
  • the fused area ratio is the ratio of the area of the fused portion of the long-fiber nonwoven fabric to the total area of the nonwoven fabric
  • the fusion perimeter per fixed area is the fusion included per 20 square millimeters of the long-fiber nonwoven fabric. This is the sum of the circumferences of the department.
  • fusion at the fiber intersection occurs, but if the fusion at the fiber intersection is exposed on the surface in contact with the skin, it is fused as a filmed part including the fiber surface at the fiber intersection. It was included in the landing area and fusion circumference.
  • the part where the nonwoven fabric comes into contact with the skin and gives physical stimulation includes the short fiber ends of the contact surface of the nonwoven fabric and the surface fluff.
  • the short fiber end does not come out on the surface of the nonwoven fabric, and physical irritation due to the fiber end hardly occurs, but prevents fuzz on the surface. Therefore, when the thermocompression bonding area is excessive, or when the thermocompression bonding pressure is excessive and the unevenness of the peripheral part of the fusion part is deep, not only the texture is inferior, but also the peripheral part of the thermocompression bonding part is physically Causes irritation.
  • the nonwoven fabric becomes hard, and the frictional stimulus is large at the time of friction, and the skin is damaged.
  • the peripheral part of the heat-sealed part is a concave part in the heat-fused part and the convex part in the non-thermally-fused part, and the difference in unevenness is large. It will get caught and cause scratches. That is, the fusion area ratio and the circumferential length of the fusion part are closely related to the scratches at the time of friction.
  • the shape index of the non-woven fabric When the shape index of the non-woven fabric is large, the generation of fluff is suppressed in the non-woven fabric, and it is possible to prevent the feeling of touch such as itchiness and tingling by the fluff, but physical irritation is given to the skin by the hardened film. . On the other hand, if the thermocompression bonding portion shape index of the nonwoven fabric is small, physical irritation caused by the contact of the hard part formed into a film with the skin is reduced, and furthermore, the nonwoven fabric has a soft texture.
  • the “thermocompression bonding portion shape index” needs to be 0.05 or more and less than 1.9.
  • the thermocompression bonding portion shape index is less than 0.05, it is not preferable from the viewpoint of preventing fluff, and when it exceeds 1.9, the soft texture is impaired, and it is not preferable from the viewpoint of volume feeling and swelling feeling when compressed.
  • the “thermocompression bonding portion shape index” is more preferably 1.8 or less, and even more preferably 1.5 or less.
  • the “thermocompression bonding portion shape index” is more preferably 0.1 or more, and more preferably 0.3 or more.
  • the maximum scratch depth of the pseudo skin model is 0 ⁇ m or more and 10 ⁇ m or less, and the cumulative scratch depth is 0 ⁇ m or more and 80 ⁇ m or less. is necessary.
  • the maximum scratch depth and the total scratch depth of the pseudo skin model are the surface of the pseudo skin model when the non-woven fabric in contact with the skin is rubbed with the pseudo skin model having an initial compressive stress of 98 mN / cm 2 according to the measurement method described later. This refers to the maximum scratch depth of scratches and the cumulative scratch depth of scratches.
  • scratch refers to a change in the physical surface shape of the pseudo skin model caused by the non-woven fabric produced by rubbing the non-woven fabric and the pseudo skin model.
  • maximum scratch depth exceeds 10 ⁇ m, it is not preferable from the viewpoint of physical irritation to the skin, and more preferably 9 ⁇ m or less.
  • the integrated scratch depth exceeds 80 ⁇ m, more preferably 60 ⁇ m or less, and still more preferably 50 ⁇ m or less.
  • the frictional irritating property of the nonwoven fabric is expressed as the number of scratches, the depth of the scratches, and the width of the scratches on the simulated skin model, depending on the degree of physical stimulation caused by friction with the simulated skin model.
  • the surface of the pseudo skin model is adjusted so as to be flat, but fine irregularities on the surface before applying the frictional stimulus are not recognized as scratches.
  • the maximum flaw depth When the relationship between the maximum flaw depth and the cumulative flaw depth of scratches caused by friction between the nonwoven fabric and the pseudo skin model and the physical irritation due to friction between the nonwoven fabric and the actual skin is examined using a number of panelists, the maximum flaw depth It can be confirmed that the nonwoven fabric with a larger integrated scratch depth tends to feel stronger irritation when the skin is actually rubbed with the nonwoven fabric, and that the disappearance of the texture tends to be greater when observing the skin surface after friction . From this result, it is possible to evaluate the frictional irritation to the skin of the nonwoven fabric in contact with the skin by measuring the maximum scratch depth and the cumulative scratch depth caused by rubbing the pseudo skin model with the nonwoven fabric.
  • the “surface fluff index” of the nonwoven fabric is preferably 3 or more.
  • the surface fluff index is less than 3, fluff is generated on the surface of the nonwoven fabric due to friction with the skin and the like, resulting in a crisp feel and further friction causes physical irritation to the skin surface.
  • the average value of the variation value (MMD) of the friction coefficient of the nonwoven fabric is 0.015 or less.
  • MMD variation value
  • the friction with the skin is a combination of the friction in both the vertical direction and the horizontal direction, the coefficient of friction in both directions is low, smooth and low in resistance.
  • the stress of the frictional resistance is concentrated in the direction where the value of the friction coefficient in the vertical and horizontal directions is small.
  • the frictional resistance stress is averaged. Therefore, the average value of the variation value of the friction coefficient is important as a value indicating the load of physical stimulation on the skin. Differences in the size of the frictional resistance occur, and the frictional resistance stress is averaged because the frictional coefficient fluctuation value in the vertical and horizontal directions has a small friction coefficient fluctuation value and a large frictional value. When the ratio of the coefficient fluctuation value exceeds 20 times, the influence of the value in the larger direction becomes high, and even when the average value of the fluctuation value of the friction coefficient is 0.015 or less, the skin feels rough. Because.
  • the orientation index by X-ray CT of the nonwoven fabric of this embodiment is preferably 0.43 or less, more preferably 0.425 or less.
  • the lower limit is preferably as low as possible, but is preferably 0.30 or more, more preferably 0.33 or more.
  • the bulk density of the nonwoven fabric of this embodiment is preferably in the range of 0.01 g / cm 3 or more and 0.07 g / cm 3 or less, more preferably 0.03 g / cm 3 or more from the viewpoint of strength, and from the viewpoint of texture. More preferably, it is 0.07 g / cm 3 or less.
  • the compression work WC of the nonwoven fabric of the present embodiment is preferably 0.20 gf ⁇ cm / cm 2 or more and 1.00 gf ⁇ cm / cm 2 or less, more preferably 0.25 gf ⁇ cm / cm 2 or more and 0.0. 80 gf ⁇ cm ⁇ cm 2 or less. Holding the compression work WC within this range is preferable from the viewpoint of cushioning properties as a nonwoven fabric used for sanitary materials.
  • the average single yarn fineness of the composite long fibers constituting the nonwoven fabric of the present embodiment is preferably 0.5 dtex or more and 10.0 dtex or less, more preferably 0.7 dtex or more and 8.0 dtex or less, and further preferably 0.9 dtex. More than 5.0 dtex. From the viewpoint of spinning stability, it is preferably 0.5 dtex or more, and from the viewpoint of the texture of the nonwoven fabric used for the sanitary material, it is preferably 10.0 dtex or less.
  • the composite continuous fiber preferably has a helical crimp from the viewpoint of maintaining the texture and bulkiness of the nonwoven fabric.
  • the number of crimps of the fiber is preferably 5 pieces / inch or more and 45 pieces / inch or less, more preferably 10 pieces / inch or more and 40 pieces / inch or less.
  • the number of crimps is less than 5 pieces / inch, the resulting nonwoven fabric is insufficiently bulky.
  • the number of crimps exceeds 45 pieces / inch, the appearance of the nonwoven fabric is impaired due to uneven fiber dispersion.
  • the basis weight of the nonwoven fabric of the present embodiment is preferably 8 g / m 2 or more and 80 g / m 2 or less, more preferably 10 g / m 2 or more and 40 g / m 2 or less, and further preferably 10 g / m 2 or more and 30 g / m 2 or less. is there. If it is 8 g / m 2 or more, the non-woven fabric used in the sanitary material satisfies the strength, and if it is 80 g / m 2 or less, the non-woven fabric used in the sanitary material, which is the object of the present invention, is satisfied. Does not give a thick impression.
  • the nonwoven fabric of this embodiment may contain a hydrophilizing agent.
  • the hydrophilizing agent used is a nonionic active agent to which ethylene oxide such as higher alcohol, higher fatty acid, alkylphenol or the like is added in consideration of safety to the human body and safety in the process, alkyl phosphate salt, etc.
  • Anionic activators such as alkyl sulfates are preferably used alone or as a mixture.
  • an existing method such as a dipping method, a spraying method, or a coating (kiss coater, gravure coater, die coater) method can be generally used by using a diluted hydrophilizing agent, and if necessary, mixing is performed in advance.
  • the hydrophilizing agent diluted with a solvent such as water.
  • a drying step may be required.
  • a drying method at that time a known method using convective heat transfer, conduction heat transfer, radiant heat transfer, or the like can be employed, and a drying method using hot air or infrared rays, a drying method using heat contact, or the like can be used.
  • the adhesion amount of the hydrophilizing agent varies depending on the required performance, but usually it is preferably in the range of 0.05% by weight or more and 1.00% by weight or less, more preferably 0.15% by weight or more and 0%.
  • the adhesion amount is within this range, the hydrophilic performance as a sanitary material top sheet is satisfied, and the processing suitability is also good.
  • a hydrophilic agent is applied to the nonwoven fabric to improve its hydrophilicity and it is used as a sanitary material top sheet, urine and blood permeate the nonwoven fabric surface, so it does not remain on the skin and is chemically stimulated by ammonia and the like. Since the physical irritation to the skin is small and the skin is hardly damaged, inflammation such as dermatitis is less likely to occur against the chemical irritation.
  • the nonwoven fabric of the present embodiment is achieved by using a composite long fiber nonwoven fabric made of two or more thermoplastic resins and adjusting the fusion part on the surface in contact with the skin. Since a composite long fiber nonwoven fabric is used, the low melting point components of the composite fiber are bonded by heat fusion without completely forming a film at some fiber intersections. Since it is not damaged and stress concentration does not occur in the filmed portion, physical stimulation is reduced. Moreover, practical strength and fluff prevention are achieved by heat fusion bonding at the fiber intersection.
  • the degree of freedom of the constituent fibers of the long-fiber non-woven fabric is determined by the degree of thermal fusion bonding of the film-formed portion by thermocompression bonding or the like and the low melting point component of the composite fiber, and is indicated by the toughness index of the long-fiber non-woven fabric.
  • the toughness index is a value obtained by dividing the product of the breaking and breaking elongation of the nonwoven fabric by the basis weight of the nonwoven fabric, preferably 40 or more and 250 or less, more preferably 50 or more and 150 or less.
  • Weight per unit (g / m 2 ) According to JIS-L1906, 5 specimens measuring 20 cm in the MD direction ⁇ 5 cm in the CD direction were arbitrarily sampled and the mass was measured, and the average value was converted into the weight per unit area.
  • Air permeability (cm 3 / cm 2 / s) The measurement was performed according to the fragile method described in JIS L-1096. Ten points were collected and measured, and the average value of the measured values was calculated.
  • (D) Non-contact of the surface of the artificial skin model with a width of 1 cm caused by friction and a central portion of a friction trace of 2 cm in the friction direction, a maximum scratch depth of 1 cm width in a direction perpendicular to the friction direction, and an integrated scratch depth. Measure using a laser surveying instrument.
  • (E) Measure the maximum scratch depth and cumulative scratch depth on the surface of the pseudo skin model when rubbing about 10 locations at 1 cm intervals in the vertical and horizontal directions of the sample, and calculate the average length and width of the maximum scratch depth of the sample piece. The integrated scratch depth.
  • the maximum scratch depth and cumulative scratch depth of the sample are the average values of the above three points.
  • Thermocompression bonded portion shape index (a) A sample of 5 cm ⁇ 5 cm is taken from an arbitrary place of the nonwoven fabric. (B) 25 samples of 1 cm ⁇ 1 cm are prepared from the sample, and the surface is photographed with a microscope to obtain 25 magnified photographs of 25 times. (C) From the obtained photograph, the ratio of the fusion-bonded area of the nonwoven fabric to the nonwoven fabric surface area is determined. (D) From the obtained photograph, a value indicating the total sum of the circumferences of the fused and filmed portions included in a fixed area of 20 square millimeters is obtained.
  • Thermocompression bonding section shape index thermal fusion area ratio ⁇ fusion circumference per fixed area Formula (1) ⁇ In the formula, the fusion area ratio: the ratio of the fusion-bonded area of the long-fiber nonwoven fabric to the total area of the long-fiber nonwoven fabric; the fusion circumference per fixed area: the fusion-bonded portion contained per 20 square millimeters of the long-fiber nonwoven fabric Sum of perimeters of ⁇ To obtain the thermocompression bonding portion shape index.
  • the thermocompression bonding portion shape index is the average value of the 25 points.
  • X-ray target Cu X-ray tube voltage: 40 kV X-ray tube current: 30 mA Lens: 1.08 ⁇ m / pix Binning: 2 Rotation angle: 180 ° Number of projections: 1000 sheets Exposure time: 10 seconds / sheet Number of camera pixels: 3300 ⁇ 2500 Reconstruction: Feldkamp method A three-dimensional tomogram obtained by CT measurement was subjected to image analysis, and orientation indices Ix, Iy, Iz of three orthogonal axes (x, y, z) were obtained. The thickness direction of the sample to be mainly evaluated was matched with the z direction.
  • Toughness index breaking strength (N / 50 mm) ⁇ breaking elongation (%) / weight per unit (g / m 2 )
  • the second component is the second component
  • the first component discharge rate is 0.4 g / min ⁇ Hole
  • the second component discharge rate is 0.4 g /
  • the total single-hole discharge rate is 0.8 g / min ⁇ Hole in min ⁇ Hole
  • the fiber shape is an eccentric sheath core structure
  • the fiber in which the ratio of the first component to the second component is 50/50 is obtained by the spunbond method.
  • Extrusion was performed at a spinning temperature of 220 ° C., and this filament group was extruded toward a moving collection surface at a spinning speed of 3,000 m / min using a high-speed airflow traction device using an air jet, and a long fiber having an average single yarn fineness of 2.8 dtex.
  • a nonwoven web was prepared.
  • thermocompression-bonding roll in which an engraving roll and a smooth roll were combined.
  • thermocompression-bonding portion shape index the conveyance speed at the time of passing hot air, the temperature and pressure of the thermocompression-bonding roll, the speed of the conveyance conveyor and the winding device are adjusted.
  • a composite continuous fiber nonwoven fabric having an average single yarn fineness of 2.8 dtex crimped 30 pieces / inch and a basis weight of 20 g / m 2 was obtained.
  • Example 4 The composite long fiber nonwoven fabric obtained in the same manner as in Example 2 was applied to a corona discharge treatment machine under the condition of a discharge amount of 40 W ⁇ min / m 2 (discharge degree: 4.0 W / cm 2 ) in an atmosphere at room temperature of 22 ° C. A nonwoven fabric with a wetting tension of 39 mN / m was obtained. A polyether-based hydrophilizing agent was applied to the obtained non-woven fabric by a spraying method, followed by hot air drying at 110 ° C. for 30 seconds to obtain a long-fiber non-woven fabric having an agent concentration adhesion amount of 0.3% by weight. The obtained nonwoven fabric had satisfactory performance as a diaper top sheet.
  • Example 5 Polypropylene (PP) resin with an MFR of 40 g / 10 min (measured according to JIS-K7210, at a temperature of 230 ° C. and a load of 2.16 kg) is the first component, and MI is 26 g / 10 min (according to JIS-K7210, temperature High-density polyethylene (HDPE) resin (measured at 190 ° C.
  • PP polypropylene
  • MFR 40 g / 10 min
  • MI 26 g / 10 min
  • HDPE temperature High-density polyethylene
  • the second component is the second component
  • the first component discharge rate is 0.4 g / min ⁇ Hole
  • the second component discharge rate is 0.4 g /
  • the total single-hole discharge rate is 0.8 g / min ⁇ Hole in min ⁇ Hole
  • the fiber shape is an eccentric sheath core structure
  • the fiber in which the ratio of the first component to the second component is 50/50 is obtained by the spunbond method.
  • Extrusion was performed at a spinning temperature of 235 ° C., and this filament group was extruded toward a moving collection surface at a spinning speed of 2,500 m / min using a cold air push-type airflow traction device, and a long fiber having an average single yarn fineness of 2.8 dtex.
  • Woven web was prepared.
  • the nonwoven fabric was thermally bonded by passing hot air having a hot air temperature of 145 ° C. and a hot air speed of 1.0 m / s through the obtained nonwoven web.
  • the conveyance speed at the time of passing hot air and the speed of the winding device were adjusted to obtain a composite long fiber nonwoven fabric with a basis weight of 20 g / m 2 having a predetermined thermocompression bonding portion shape index.
  • Example 6 The composite long fiber nonwoven fabric obtained in the same manner as in Example 5 was applied to a corona discharge treatment machine under the condition of a discharge amount of 40 W ⁇ min / m 2 (discharge degree: 4.0 W / cm 2 ) in an atmosphere at room temperature of 25 ° C. A nonwoven fabric with a wetting tension of 39 mN / m was obtained. A polyether-based hydrophilizing agent was applied to the obtained non-woven fabric by a spraying method, followed by hot air drying at 120 ° C. to obtain a long-fiber non-woven fabric having an agent concentration adhesion amount of 0.35% by weight. The obtained nonwoven fabric had satisfactory performance as a diaper top sheet.
  • Polypropylene (PP) resin having an MFR of 55 g / 10 min (measured at a temperature of 230 ° C. and a load of 2.16 kg according to JIS-K7210) is extruded as a single component at a spinning temperature of 220 ° C. by a spunbond method.
  • a long-fiber nonwoven web having an average single yarn fineness of 2.8 dtex was prepared by extruding toward a moving collection surface at a spinning speed of 3,000 m / min using a high-speed airflow traction device using an air jet. Subsequently, the obtained nonwoven web was subjected to a flat roll and an embossing roll at 141 ° C.
  • the fibers are bonded to each other, a nonwoven fabric having a basis weight of 20 g / m 2 , an air permeability of 456 cm 3 / cm 2 / s, and a thermocompression bonding section shape index 1.9 in which the fibers are not crimped. Obtained.
  • the obtained nonwoven fabric had a high bulk density, had no cushioning properties, and had a hard texture.
  • the core component that is the first component is polypropylene having a melting point of 162 ° C.
  • the sheath component that is the second component is high-density polyethylene having a melting point of 130 ° C.
  • the short fibers having a fineness of 2.5 dtex and a cut length of 38 mm are used as the constituent fibers.
  • the nonwoven web was obtained by the card method. Next, the obtained nonwoven web was bonded to each other by hot air bonding at a hot air temperature of 140 ° C. and a hot air wind speed of 1.0 m / s, and the air permeability was 717 cm 3 / cm 2 / s with a basis weight of 18 g / m 2.
  • a composite short fiber nonwoven fabric of 5 / inch was obtained. The obtained nonwoven fabric had a low elongation, a low toughness index, and a hard texture.
  • the composite long fiber nonwoven fabric of the present invention has bulkiness and cushioning softness and high strength and elongation, it can be suitably used for the production of sanitary materials.
  • sanitary material it can be used suitably for disposable diapers, sanitary napkins or incontinence pads, and can be used as a top sheet on the surface and a back sheet on the outside.
  • Applications are not limited. For example, masks, body warmers, tape base fabrics, tarpaulin base fabrics, patch medicinal base fabrics, emergency bond base fabrics, packaging materials, wipe products, medical gowns, bandages, clothing, skin care It can also be used for sheets.

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Abstract

Provided is a long fiber nonwoven fabric that is suitable for top sheet and back sheet members of absorbent articles used as hygienic materials, and that has good tactile sense and fluffy softness and has little physical stimulation of the skin and high bulk. This nonwoven fabric is a partial thermocompressed nonwoven fabric of composite long fibers formed from two or more types of thermoplastic resin and is characterized in that the shape index of the thermocompressed part is greater than or equal to 0.05 and less than 1.9, the maximum abrasion depth is 10 µm or less, and the cumulative abrasion depth is 80 µm or less.

Description

肌触り感に優れた長繊維不織布Long fiber nonwoven fabric with excellent touch
　本発明は、肌触りが良く、皮膚に対する物理刺激が少なく、嵩高性の、２種以上の熱可塑性樹脂からなる複合長繊維の部分熱圧着不織布に関する。 The present invention relates to a partially thermocompression-bonded nonwoven fabric of composite long fibers made of two or more kinds of thermoplastic resins having good touch, little physical irritation to the skin, and bulky.
　一般に紙おむつや生理用ナプキン等の衛生材料用トップシートのように、肌に接する部分に使用される素材には、柔らかな風合いを有し、毛羽立ちによる痒み、ちくちく感、痛み等がなく、肌触り感がよいことが重要視される。中でも、肌に対する物理刺激が少ないことが重要である。物理刺激には、繊維の末端部や繊維から生ずる毛羽による刺激およびそれらに起因する擦過刺激等が挙げられる。 In general, the materials used for the parts that come into contact with the skin, such as top sheets for sanitary materials such as disposable diapers and sanitary napkins, have a soft texture and are free from itching, tingling, and pain due to fluff. It is important to be good. Above all, it is important that there is little physical irritation to the skin. Examples of the physical stimulation include stimulation by fluff generated from the end portion of the fiber and fibers, and abrasion stimulation resulting from the stimulation.
　短繊維を熱スルーエアー法にて繊維の交差部を熱融着してシート化した不織布（以下、「スルーエアー不織布」ともいう。）は、風合いがふんわりとして柔らかく、繊維の交差部が熱融着されているので毛羽の発生も少ないためにこれらの用途に多く用いられてきた。しかしながら、この不織布は短繊維で構成されているため、繊維端が表面に存在して、ちくちくした肌触り感があり、さらに繊維端が肌を摩擦したとき擦過刺激の原因となる等、物理刺激の面で満足なものではなかった。 Nonwoven fabrics (hereinafter also referred to as “through-air nonwoven fabrics”) in which short fibers are heat-sealed by the heat-through air method to form a sheet are soft and the texture is soft. Since it is worn, there is little occurrence of fluff, and it has been used for many purposes. However, since this nonwoven fabric is composed of short fibers, the fiber ends are present on the surface, there is a tingling touch, and when the fiber ends rub against the skin, it causes scratching irritation. We were not satisfied with aspect.
　短繊維をエンボスロール等によって部分的に熱融着された不織布（以下、「ポイントボンド不織布」ともいう。）は、スルーエアー不織布と同様に繊維端が表面に存在するため物理刺激の面で十分でないばかりでなく、スルーエアー不織布に比べて繊維交点全てが接着しているわけではないため、毛羽立ちが発生しやすく、風合いも劣るものであった。 A nonwoven fabric (hereinafter also referred to as “point-bonded nonwoven fabric”) in which short fibers are partially heat-sealed by an embossing roll or the like is sufficient in terms of physical stimulation because the fiber ends are present on the surface in the same manner as a through-air nonwoven fabric Not only that, but not all of the fiber intersections are bonded as compared to the through-air nonwoven fabric, and thus fuzzing is likely to occur and the texture is also inferior.
　他方、長繊維不織布をエンボスロール等によって熱圧着した長繊維不織布は、短繊維端が表面に出ることはなく、繊維端による物理刺激は起こりにくいが、表面の毛羽立ちを防止するために過剰な熱圧着が行われており、そのため風合いが硬く、ザラザラした肌触り感を与えるばかりでなく、熱圧着部の周辺部が物理刺激の原因となっていた。 On the other hand, a long fiber nonwoven fabric obtained by thermocompression bonding of a long fiber nonwoven fabric with an embossing roll or the like does not cause the short fiber ends to come out on the surface and hardly causes physical irritation by the fiber ends, but excessive heat is used to prevent fluffing on the surface. Crimping is performed, so that the texture is hard and not only gives a rough feel, but also the periphery of the thermocompression bonding part causes physical irritation.
　以下の特許文献１及び２には、耐毛羽立ち性が良好で風合いの良い熱可塑性複合繊維による不織布が開示されている。しかしながら、毛羽立ち性を向上させるために、熱エンボスによって熱可塑性繊維を扁平化して点熱圧着されており、扁平化した熱融着部が存在し、不織布の嵩高さが損なわれ、風合いの劣るものであった。更には熱融着部が硬いため、摩擦による物理刺激が大きなものであった。 The following Patent Documents 1 and 2 disclose nonwoven fabrics made of thermoplastic composite fibers having good fuzz resistance and good texture. However, in order to improve the fluffing property, the thermoplastic fiber is flattened by hot embossing and is subjected to point heat compression, there is a flattened heat fusion part, the bulkiness of the nonwoven fabric is impaired, and the texture is inferior Met. Furthermore, since the heat-sealed part was hard, physical stimulation due to friction was large.
　また、以下の特許文献３には、特定の熱圧着形状にて部分熱圧着された長繊維不織布に、特定のポリエーテル化合物と特定のポリエーテル変性シリコンを併用したポリオレフィン系不織布が開示されている。開示された不織布は、耐毛羽立ち性が良好で摩擦による物理刺激が低いものとなっているが、ポリプロピレン繊維を熱エンボスによってのみ接合されているため、耐毛羽性を良好とするためには、熱融着部を多くする必要があり、嵩密度が高く、ふっくらとした柔らかさを有しておらず、これらの点で充分ではなかった。 Patent Document 3 below discloses a polyolefin-based non-woven fabric in which a specific polyether compound and a specific polyether-modified silicon are used in combination with a long-fiber non-woven fabric partially thermocompression bonded in a specific thermocompression-bonding shape. . The disclosed nonwoven fabric has good fuzz resistance and low physical irritation due to friction. However, since the polypropylene fibers are bonded only by heat embossing, in order to improve fuzz resistance, It is necessary to increase the number of fused portions, the bulk density is high, and it does not have a plump softness, which is not sufficient in these respects.
特開２００１－３５５１７６号公報JP 2001-355176 A 特開２０００－２９０８６６号公報JP 2000-290866 A 特開２００３－５２７５２号公報JP 2003-52752 A
　本発明が解決しようとする課題は、衛生材料に用いられる吸収性物品のトップシート又はバックシート部材に適した、肌触りが良く、ふんわりとした柔らかさを有し、皮膚に対する物理刺激が少ない嵩高性の長繊維不織布を提供することである。 The problem to be solved by the present invention is a bulky property that is suitable for the top sheet or back sheet member of an absorbent article used for sanitary materials, has a soft touch, has a soft softness, and has little physical irritation to the skin. It is to provide a long fiber nonwoven fabric.
　本発明者らは、前記課題を解決すべく鋭意検討し実験を重ねた結果、２種以上の熱可塑性樹脂からなる複合長繊維で構成された不織布で、不織布の製造工程における接合前の不織ウェブの通気度、接合時の熱風温度と風速をある範囲とすることで熱風が不織ウェブの嵩を維持した状態で貫通することができ、繊維交点を接着させることにより耐毛羽性向上と、嵩密度を維持することができることを見出し、皮膚に対する物理刺激の小さい衛生材料として好適に使用することができる不織布を提供するに至ったものである。 As a result of intensive studies and repeated experiments to solve the above-mentioned problems, the inventors of the present invention are nonwoven fabrics composed of composite long fibers composed of two or more thermoplastic resins, and are non-woven before joining in the nonwoven fabric manufacturing process. By setting the web air permeability, hot air temperature and wind speed at the time of joining within a certain range, hot air can be penetrated while maintaining the bulk of the nonwoven web, and fuzz resistance is improved by adhering fiber intersection points, The present inventors have found that the bulk density can be maintained, and have come to provide a nonwoven fabric that can be suitably used as a sanitary material with small physical irritation to the skin.
　すなわち、本発明は下記の通りのものである。
　［１］２種以上の熱可塑性樹脂からなる複合長繊維の部分熱圧着不織布であって、熱圧着部形状指数が０．０５以上１．９未満であり、疑似皮膚モデルの最大擦過傷深さが１０μｍ以下であり、かつ、積算擦過傷深さが８０μｍ以下であることを特徴とする前記不織布。
　［２］前記不織布の表面毛羽指数が３以上である、前記［１］に記載の不織布。
　［３］前記不織布の摩擦係数の変動値（ＭＭＤ）の縦横平均値が０．０１５以下である、前記［１］又は［２］に記載の不織布。
　［４］前記不織布のＸ線ＣＴによる厚み方向の配向指標が０．４３以下であり、且つ嵩密度が０．０１以上０．０７ｇ／ｃｍ３以下である前記［１］～［３］のいずれかに記載の不織布。
　［５］前記不織布の圧縮仕事量ＷＣが０．２０以上１．００ｇｆ／ｃｍ／ｃｍ２以下である前記［１］～［４］のいずれかに記載の不織布。
　［６］前記複合長繊維はサイドバイサイド型又は偏芯型である、前記［１］～［５］のいずれかに記載の不織布。
　［７］前記２種の熱可塑性樹脂はいずれもポリオレフィン系樹脂である、前記［１］～［６］のいずれかに記載の不織布。
　［８］前記不織布は親水化剤を含有している、前記［１］～［７］のいずれかに記載の不織布。
　［９］前記［１］～［８］のいずれかに記載の不織布を含む衛生材料。 That is, the present invention is as follows.
[1] A partial thermocompression bonded nonwoven fabric of composite long fibers composed of two or more thermoplastic resins, having a thermocompression bonded portion shape index of 0.05 or more and less than 1.9, and having a maximum scratch depth of a pseudo skin model. The said nonwoven fabric characterized by being 10 micrometers or less and an integrated abrasion depth of 80 micrometers or less.
[2] The nonwoven fabric according to [1], wherein the nonwoven fabric has a surface fluff index of 3 or more.
[3] The nonwoven fabric according to [1] or [2], wherein a longitudinal and lateral average value of a variation value (MMD) of a friction coefficient of the nonwoven fabric is 0.015 or less.
[4] Any of [1] to [3] above, wherein the nonwoven fabric has an orientation index in the thickness direction by X-ray CT of 0.43 or less and a bulk density of 0.01 or more and 0.07 g / cm 3 or less. The non-woven fabric according to crab.
[5] The nonwoven fabric according to any one of [1] to [4], wherein the compression work WC of the nonwoven fabric is 0.20 or more and 1.00 gf / cm / cm 2 or less.
[6] The nonwoven fabric according to any one of [1] to [5], wherein the composite long fiber is a side-by-side type or an eccentric type.
[7] The nonwoven fabric according to any one of [1] to [6], wherein both of the two types of thermoplastic resins are polyolefin resins.
[8] The nonwoven fabric according to any one of [1] to [7], wherein the nonwoven fabric contains a hydrophilizing agent.
[9] A sanitary material comprising the non-woven fabric according to any one of [1] to [8].
　本発明の不織布は、２種以上の熱可塑性樹脂からなる複合長繊維で構成された不織布であって、該不織布が特定の摩擦特性と熱圧着部形状指数を示すように、該不織布を構成する繊維の接着程度を調整することで達成された、皮膚に対して物理刺激が小さく、耐毛羽性が良好で、風合いの柔らかい衛生材料として好適に使用することができるものである。 The nonwoven fabric of the present invention is a nonwoven fabric composed of composite long fibers made of two or more kinds of thermoplastic resins, and the nonwoven fabric is configured so that the nonwoven fabric exhibits specific friction characteristics and thermocompression bonding portion shape index. It can be suitably used as a sanitary material having a low physical irritation to the skin, good fluff resistance, and soft texture achieved by adjusting the degree of fiber adhesion.
　以下、本発明の実施形態について詳述する。
　本実施形態の不織布を構成する複合長繊維は、２種以上の熱可塑性樹脂の組み合わせからなる。熱可塑性樹脂としては、例えば、ポリエチレン、ポリプロピレン、共重合ポリプロピレンなどのポリオレフィン系樹脂、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリエチレンナフタレート、共重合ポリエステルなどのポリエステル系樹脂、ナイロン－６、ナイロン－６６、共重合ナイロンなどのポリアミド系樹脂、ポリ乳酸、ポリブチレンサクシネート、ポリエチレンサクシネートなどの生分解性樹脂などが挙げられる。所望の作用効果を奏する限り、前記熱可塑性樹脂の何れの組合せでも可能であるが、繊維同士の接合性の観点から、融点差のある熱可塑性樹脂の組合せが好ましい。 Hereinafter, embodiments of the present invention will be described in detail.
The composite long fiber constituting the nonwoven fabric of this embodiment is a combination of two or more thermoplastic resins. Examples of the thermoplastic resin include polyolefin resins such as polyethylene, polypropylene, and copolymerized polypropylene, polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, and copolyester, nylon-6, nylon-66, and copolyester. Examples thereof include polyamide resins such as polymerized nylon, and biodegradable resins such as polylactic acid, polybutylene succinate, and polyethylene succinate. Any combination of the thermoplastic resins is possible as long as the desired effects are exhibited, but a combination of thermoplastic resins having a difference in melting point is preferable from the viewpoint of bonding properties between fibers.
　なかでも風合いの観点から、ポリオレフィン系樹脂を組み合わせて用いることが好ましい。例えば、ポリエチレン、ポリプロピレン、それらのモノマーと他のα－オレフィンとの共重合体などの樹脂から組み合わせた複合繊維があげられる。他のα－オレフィンとしては、炭素数３～１０のものであり、具体的には、プロピレン、１－ブテン、１－ペンテン、１－ヘキサン、４－メチル－１－ペンテン、１－オクテンなどが挙げられる。 Among these, it is preferable to use a combination of polyolefin resins from the viewpoint of texture. Examples thereof include composite fibers obtained by combining resins such as polyethylene, polypropylene, and copolymers of these monomers with other α-olefins. Other α-olefins are those having 3 to 10 carbon atoms, such as propylene, 1-butene, 1-pentene, 1-hexane, 4-methyl-1-pentene, and 1-octene. Can be mentioned.
　本実施形態の熱可塑性複合繊維の繊維形状は、サイドバイサイド型（Ｓ／Ｓ）、偏芯型（偏Ｓ／Ｃ）であることが捲縮糸を容易に得られることから好ましい。偏芯型の芯部は繊維表面に出ていてもよく、繊維表面における芯部の占める面積率は０～５０％が好ましく、更に好ましくは０～３０％である。繊維表面を形成する芯部の比率が低い程、接着に起因する鞘部の比率が高くなり、高い強度と毛羽抑制性が得られるものとなる。また、繊維の強度の観点から、熱可塑性樹脂の組合せで融点の高い方の樹脂が繊維内に占める重量比率は２０ｗｔ％以上８０ｗｔ％以下であり、好ましくは３０ｗｔ％以上８０ｗｔ％以下、更に好ましくは５０ｗｔ％以上７０ｗｔ％以下である。 The fiber shape of the thermoplastic conjugate fiber of this embodiment is preferably a side-by-side type (S / S) or an eccentric type (biased S / C) because a crimped yarn can be easily obtained. The eccentric core portion may protrude from the fiber surface, and the area ratio of the core portion on the fiber surface is preferably 0 to 50%, more preferably 0 to 30%. The lower the ratio of the core part forming the fiber surface, the higher the ratio of the sheath part resulting from the adhesion, and the higher strength and fluff suppression can be obtained. From the viewpoint of fiber strength, the weight ratio of the resin having the higher melting point in the combination of thermoplastic resins in the fiber is 20 wt% or more and 80 wt% or less, preferably 30 wt% or more and 80 wt% or less, more preferably It is 50 wt% or more and 70 wt% or less.
　繊維形状は、通常の円形繊維のみでなく、異形繊維などの特殊形態の繊維であってもよい。
　２種の熱可塑性樹脂で複合長繊維を形成する場合、第１成分はポリプロピレン、第２成分はポリエチレンであることが好ましい。複合繊維が偏芯型の場合は、芯部を第１成分、鞘部を第２成分とすることが好ましい。ポリプロピレンは、強度が強く使用時において破断しにくく、衛生材料の生産時における寸法安定性に優れることから好ましい。 The fiber shape may be not only a normal circular fiber but also a specially shaped fiber such as a deformed fiber.
When forming a composite long fiber with two types of thermoplastic resins, it is preferable that the first component is polypropylene and the second component is polyethylene. When the conjugate fiber is an eccentric type, it is preferable that the core portion is the first component and the sheath portion is the second component. Polypropylene is preferred because it is strong and difficult to break during use, and is excellent in dimensional stability during the production of sanitary materials.
　前記２種の熱可塑性樹脂で形成する場合の第１成分のポリプロピレンは、一般的なチーグラナッタ触媒により合成されるポリマーでもよいし、メタロセンに代表されるシングルサイト活性触媒により合成されたポリマーであってもよく、また、エチレンランダム共重合ポリプロピレンでもよい。これらは、１種類単独であっても２種類以上を組み合わせたものでもよい。風合い、強度、寸法安定性の観点からは、ホモポリプロピレンを主成分とするものであることが好ましい。 The polypropylene of the first component in the case of forming with the two types of thermoplastic resins may be a polymer synthesized by a general Ziegler Natta catalyst, or a polymer synthesized by a single site active catalyst typified by metallocene. In addition, ethylene random copolymer polypropylene may be used. These may be a single type or a combination of two or more types. From the viewpoint of texture, strength, and dimensional stability, it is preferable that the main component is homopolypropylene.
　また、ポリプロピレンのＭＦＲの下限は、２０ｇ／１０分以上、好ましくは３０ｇ／１０分を超え、更に好ましくは４０ｇ／１０分を超え、最も好ましくは５３ｇ／１０分を超えるものであることができる。上限は、８５ｇ／１０分以下、好ましくは７０ｇ／１０分以下、最も好ましくは６０ｇ／１０分以下であることができる。ＭＦＲの測定方法は、ＪＩＳ－Ｋ７２１０「プラスチック－熱可塑性プラスチックのメルトマスフローレイト（ＭＦＲ）及びメルトボリュームフローレイト（ＭＶＲ）の試験方法」の表１、試験温度２３０℃、試験荷重２．１６ｋｇに準じたものである。 Also, the lower limit of the MFR of polypropylene can be 20 g / 10 minutes or more, preferably more than 30 g / 10 minutes, more preferably more than 40 g / 10 minutes, and most preferably more than 53 g / 10 minutes. The upper limit can be 85 g / 10 min or less, preferably 70 g / 10 min or less, and most preferably 60 g / 10 min or less. The measurement method of MFR is in accordance with JIS-K7210 “Testing methods for plastic-thermoplastic melt mass flow rate (MFR) and melt volume flow rate (MVR)”, test temperature 230 ° C., test load 2.16 kg. It is a thing.
　前記２種の熱可塑性樹脂で形成する場合の第２成分のポリエチレンは、繊維同士の接合後の接着強度が強く、不織布としての風合いが良いことから、衛生材料に好適に利用できる。また、ポリエチレンは、一般的なチーグラナッタ触媒により合成されるポリマーでもよいし、メタロセンに代表されるシングルサイト活性触媒により合成されたポリマーであってもよい。ポリエチレンは、高密度ポリエチレン、直鎖状低密度ポリエチレンであることが好ましく、密度は０．９２～０．９７ｇ／ｃｍ３であることが好ましく、０．９２５～０．９６ｇ／ｃｍ３であることが更に好ましい。 In the case of forming with the two types of thermoplastic resins, the second component polyethylene has a high adhesive strength after joining the fibers and has a good texture as a non-woven fabric, and therefore can be suitably used as a sanitary material. In addition, polyethylene may be a polymer synthesized by a general Ziegler Natta catalyst, or may be a polymer synthesized by a single site active catalyst typified by metallocene. The polyethylene is preferably high-density polyethylene or linear low-density polyethylene, and the density is preferably 0.92 to 0.97 g / cm 3 , and preferably 0.925 to 0.96 g / cm 3. Is more preferable.
　また、ポリエチレンのＭＩの下限は、１０ｇ／１０分以上、好ましくは１５ｇ／１０分を超えたものであることができる。上限は、１００ｇ／１０分以下、好ましくは６０ｇ／１０分以下、最も好ましくは４０ｇ／１０分以下であることができる。ＭＩの測定方法は、ＪＩＳ－Ｋ７２１０「プラスチック－熱可塑性プラスチックのメルトマスフローレイト（ＭＦＲ）及びメルトボリュームフローレイト（ＭＶＲ）の試験方法」の表１、試験温度１９０℃、試験荷重２．１６ｋｇに準じたものである。 Also, the lower limit of polyethylene MI can be 10 g / 10 min or more, preferably more than 15 g / 10 min. The upper limit can be 100 g / 10 min or less, preferably 60 g / 10 min or less, and most preferably 40 g / 10 min or less. The MI measurement method is in accordance with JIS-K7210 “Testing methods for plastics-thermoplastic melt mass flow rate (MFR) and melt volume flow rate (MVR)”, test temperature 190 ° C., test load 2.16 kg. It is a thing.
　本実施形態の不織布は、強度や生産性の観点から、スパンボンド法により複合長繊維不織ウェブを形成して製造されるものであることが好ましい。例えば、複合長繊維は、２つ以上の異なる押出機からそれぞれ異なる熱可塑性樹脂を溶融押出し、多数の紡糸孔を有する紡糸口金から２種以上の熱可塑性樹脂が複合された状態で糸条として吐出される。次いで、吐出された糸条を５℃～２０℃に制御した冷風をあて、冷却しながら牽引装置により高速牽引する。牽引装置より出た糸条は、搬送コンベア上に堆積され不織ウェブとして搬送される。搬送中の不織ウェブは積層され、多層積層の不織ウェブとしてもよい。 The nonwoven fabric of the present embodiment is preferably manufactured by forming a composite long fiber nonwoven web by a spunbond method from the viewpoint of strength and productivity. For example, composite long fibers are melt-extruded from two or more different extruders, respectively, and discharged as yarns in a state where two or more kinds of thermoplastic resins are combined from a spinneret having a large number of spinning holes. Is done. Next, the discharged yarn is pulled at a high speed by a traction device while being cooled by applying cold air controlled at 5 ° C. to 20 ° C. The yarn coming out of the pulling device is deposited on a conveyor and conveyed as a nonwoven web. The nonwoven web being conveyed may be laminated to form a multilayer laminated nonwoven web.
　熱可塑性複合繊維で構成された不織ウェブを接合して不織布となす場合の接合手段としては、繊維同士の交点が溶融し接着できる温度以上に加熱する方法であれば特に限定されるものではない。加熱する方法としては、熱風循環型、熱風貫通型、赤外線ヒーター型、不織布の両面に熱風を吹き付ける方法、加熱気体中に導入する方法等、各種の加熱する方法が用いられる。繊維同士の交点でより多くの繊維接着点が得られ且つ不織布の破断強度が高くなる観点から、熱風による加熱が好ましく、特に熱風貫通型が好ましい。 The joining means in the case of joining a nonwoven web composed of thermoplastic conjugate fibers to form a nonwoven fabric is not particularly limited as long as it is a method of heating above the temperature at which the intersections of the fibers melt and bond. . As a heating method, various heating methods such as a hot air circulation type, a hot air penetration type, an infrared heater type, a method of blowing hot air on both surfaces of a nonwoven fabric, and a method of introducing into a heated gas are used. From the viewpoint of obtaining more fiber adhesion points at the intersections of the fibers and increasing the breaking strength of the nonwoven fabric, heating with hot air is preferred, and hot air penetration type is particularly preferred.
　熱風の温度は、組み合わせた熱可塑性樹脂の中でも、融点が低く且つ接合に寄与する熱可塑性樹脂に適した温度に調整することが好ましい。例えば、該熱可塑性樹脂がポリエチレンの場合、ポリエチレンが溶融し接着する１３０～１５５℃であり、好ましくは１３５～１５５℃、更に好ましくは１４０℃～１５０℃である。接着温度がこの範囲であれば繊維同士の交点で繊維同士の接着が発現し、不織布としての強度を発現することが可能となる。 The temperature of the hot air is preferably adjusted to a temperature suitable for the thermoplastic resin having a low melting point and contributing to bonding among the combined thermoplastic resins. For example, when the thermoplastic resin is polyethylene, the temperature is 130 to 155 ° C. at which polyethylene melts and adheres, preferably 135 to 155 ° C., more preferably 140 ° C. to 150 ° C. If the bonding temperature is within this range, the bonding between the fibers appears at the intersection of the fibers, and the strength of the nonwoven fabric can be expressed.
　次いで、熱風の風速は０．５～３．０ｍ／ｓであり、好ましくは０．７～２．５ｍ／ｓ、更に好ましくは２．０ｍ／ｓ以下である。
　本実施形態の不織ウェブを熱風により接合する際、不織ウェブの通気度がその接合状態に大きく影響する。不織ウェブの通気度が低すぎると熱風は貫通しにくく、不織布としての均一な接合は得られにくい。他方、得られる不織布の強度保持の観点から、通気度は高すぎても好ましくない。接合強度を満足に保持できる、最終的に得られる不織布の通気度としては、３００ｃｍ３／ｃｍ２／ｓ以上７００ｃｍ３／ｃｍ２／ｓ以下が好ましく、３００ｃｍ３／ｃｍ２／ｓ以上６５０ｃｍ３／ｃｍ２／ｓ以下がより好ましい。 Next, the wind speed of the hot air is 0.5 to 3.0 m / s, preferably 0.7 to 2.5 m / s, and more preferably 2.0 m / s or less.
When joining the nonwoven web of this embodiment with hot air, the air permeability of the nonwoven web greatly affects the joining state. If the air permeability of the nonwoven web is too low, the hot air is difficult to penetrate and uniform bonding as a nonwoven fabric is difficult to obtain. On the other hand, from the viewpoint of maintaining the strength of the resulting nonwoven fabric, it is not preferable that the air permeability is too high. It can hold the bonding strength satisfactorily, as the air permeability of the finally obtained non-woven fabric, is preferably from 300cm 3 / cm 2 / s or more 700cm 3 / cm 2 / s, 300cm 3 / cm 2 / s or more 650 cm 3 / More preferable is cm 2 / s or less.
　本明細書中、「熱圧着部形状指数」とは、エンボスロールや熱風処理などにより接合されて不織布表面に形成される部分熱圧着部、すなわち熱融着された融着面積率と一定面積当たりの融着周長で規定されるものである。融着面積率とは、長繊維不織布の融着部面積が当該不織布の全体面積に占める割合であり、一定面積あたりの融着周長とは、長繊維不織布20平方ミリメートル当たりに含まれる融着部の周長の総和である。ここで、繊維交点の融着が発生するが、繊維交点の融着が肌に接する面に露出している場合は、繊維交点の繊維表面を含めて融着部としフィルム化している部分として融着面積及び融着周長に算入した。 In this specification, the “thermocompression part shape index” is a partial thermocompression bonding part formed on the nonwoven fabric surface by joining with an embossing roll or hot air treatment, that is, a fusion-bonded area ratio and a fixed area per unit area. This is defined by the fusion circumference. The fused area ratio is the ratio of the area of the fused portion of the long-fiber nonwoven fabric to the total area of the nonwoven fabric, and the fusion perimeter per fixed area is the fusion included per 20 square millimeters of the long-fiber nonwoven fabric. This is the sum of the circumferences of the department. Here, fusion at the fiber intersection occurs, but if the fusion at the fiber intersection is exposed on the surface in contact with the skin, it is fused as a filmed part including the fiber surface at the fiber intersection. It was included in the landing area and fusion circumference.
　不織布が肌と接触し物理刺激を与える部位としては、不織布の接触面の短繊維端や表面の毛羽があげられる。また、エンボスロール等によって熱圧着された長繊維不織布よりなる不織布に於いては、短繊維端が不織布の表面に出ることはなく、繊維端による物理刺激は起こりにくいが、表面の毛羽立ちを防止するため、熱圧着面積が過大である場合や、熱圧着圧力が過大で融着部の周辺部の凹凸が深い場合には、風合いが劣るものとなるばかりでなく、熱圧着部の周辺部が物理刺激の原因となる。すなわち、融着によってフィルム化した面積率が高いと不織布が硬くなり、摩擦時には擦過刺激が大きく、肌に傷を与えることになる。また、熱融着部の周辺部は熱融着部が凹部、非熱融着部が凸部となり、凹凸の差が大きく、摩擦時には不織布表面の融着部の周辺部が肌面に対してひっかかりとなり、傷の原因となる。すなわち、融着面積率と、融着部の周長の多さが、摩擦時の傷と密接に関係しているのである。不織布の熱圧着部形状指数が大きいと、該不織布は毛羽の発生が抑制され、毛羽による痒み、チクチク感といった手触り感の悪さは防止できるものの、フィルム化した硬い部分によって肌に物理刺激が与えられる。他方、不織布の熱圧着部形状指数が小さいと、フィルム化した硬い部分が肌に接触することによる物理刺激が小さくなり、更には、不織布はふんわりとした風合いの良いものとなる。しかしながら、熱圧着部形状指数が過少であると、該不織布は、実用上充分な強度が得られず、更に摩擦によって容易に毛羽が発生し、毛羽による物理刺激によって痒み、チクチク感等の手触り感が悪くなる。以上に鑑み、本実施形態において、「熱圧着部形状指数」は、０．０５以上１．９未満であることが必要である。熱圧着部形状指数が０．０５未満であると、毛羽防止の点から好ましくなく、１．９を超えるとふんわりとした風合いが損なわれ、圧縮した時のボリューム感、膨らみ感の点から好ましくない。「熱圧着部形状指数」は、より好ましくは１．８以下であり、より好ましくは１．５以下である。「熱圧着部形状指数」は、より好ましくは０．１以上であり、より好ましくは０．３以上である。 The part where the nonwoven fabric comes into contact with the skin and gives physical stimulation includes the short fiber ends of the contact surface of the nonwoven fabric and the surface fluff. In addition, in a nonwoven fabric made of a long-fiber nonwoven fabric that is thermocompression bonded by an embossing roll or the like, the short fiber end does not come out on the surface of the nonwoven fabric, and physical irritation due to the fiber end hardly occurs, but prevents fuzz on the surface. Therefore, when the thermocompression bonding area is excessive, or when the thermocompression bonding pressure is excessive and the unevenness of the peripheral part of the fusion part is deep, not only the texture is inferior, but also the peripheral part of the thermocompression bonding part is physically Causes irritation. That is, when the area ratio formed into a film by fusion is high, the nonwoven fabric becomes hard, and the frictional stimulus is large at the time of friction, and the skin is damaged. In addition, the peripheral part of the heat-sealed part is a concave part in the heat-fused part and the convex part in the non-thermally-fused part, and the difference in unevenness is large. It will get caught and cause scratches. That is, the fusion area ratio and the circumferential length of the fusion part are closely related to the scratches at the time of friction. When the shape index of the non-woven fabric is large, the generation of fluff is suppressed in the non-woven fabric, and it is possible to prevent the feeling of touch such as itchiness and tingling by the fluff, but physical irritation is given to the skin by the hardened film. . On the other hand, if the thermocompression bonding portion shape index of the nonwoven fabric is small, physical irritation caused by the contact of the hard part formed into a film with the skin is reduced, and furthermore, the nonwoven fabric has a soft texture. However, if the shape index of the thermocompression bonding part is too small, the nonwoven fabric cannot obtain a practically sufficient strength, and moreover, fluff is easily generated by friction, and it feels like a tingling sensation due to physical irritation caused by the fluff. Becomes worse. In view of the above, in the present embodiment, the “thermocompression bonding portion shape index” needs to be 0.05 or more and less than 1.9. When the thermocompression bonding portion shape index is less than 0.05, it is not preferable from the viewpoint of preventing fluff, and when it exceeds 1.9, the soft texture is impaired, and it is not preferable from the viewpoint of volume feeling and swelling feeling when compressed. . The “thermocompression bonding portion shape index” is more preferably 1.8 or less, and even more preferably 1.5 or less. The “thermocompression bonding portion shape index” is more preferably 0.1 or more, and more preferably 0.3 or more.
　衛生材料のトップシートとして使用する場合を想定した場合、本実施形態の不織布は、疑似皮膚モデルの最大擦過傷深さが０μｍ以上１０μｍ以下、かつ、積算擦過傷深さが０μｍ以上８０μｍ以下であることが必要である。疑似皮膚モデルの最大擦過傷深さ、及び積算擦過傷深さとは、後述する測定法にしたがい、初期圧縮応力が９８ｍＮ／ｃｍ２の疑似皮膚モデルで肌に接する不織布を摩擦したときに、疑似皮膚モデル表面にできる傷の最大擦過傷深さと傷の積算擦過傷深さをいう。ここでいう、傷とは、不織布と疑似皮膚モデルとを摩擦させて生じた不織布による疑似皮膚モデルの物理的な表面形状変化のことである。最大擦過傷深さが、１０μｍを超えると肌に対する物理刺激の点から好ましくなく、より好ましくは、９μｍ以下である。また、積算擦過傷深さが、８０μｍを超えると好ましくなく、より好ましくは６０μｍ以下、さらに好ましくは５０μｍ以下である。 Assuming that the nonwoven fabric of this embodiment is used as a top sheet of sanitary material, the maximum scratch depth of the pseudo skin model is 0 μm or more and 10 μm or less, and the cumulative scratch depth is 0 μm or more and 80 μm or less. is necessary. The maximum scratch depth and the total scratch depth of the pseudo skin model are the surface of the pseudo skin model when the non-woven fabric in contact with the skin is rubbed with the pseudo skin model having an initial compressive stress of 98 mN / cm 2 according to the measurement method described later. This refers to the maximum scratch depth of scratches and the cumulative scratch depth of scratches. The term “scratch” as used herein refers to a change in the physical surface shape of the pseudo skin model caused by the non-woven fabric produced by rubbing the non-woven fabric and the pseudo skin model. When the maximum scratch depth exceeds 10 μm, it is not preferable from the viewpoint of physical irritation to the skin, and more preferably 9 μm or less. Moreover, it is not preferable that the integrated scratch depth exceeds 80 μm, more preferably 60 μm or less, and still more preferably 50 μm or less.
　つまり不織布が持つ摩擦刺激性は、疑似皮膚モデルとの摩擦による物理的な刺激の程度によって、疑似皮膚モデル上に傷の数、傷の深さ、傷の幅となって表されるものである。疑似皮膚モデルの表面は平坦になるように調整して用いるが、摩擦刺激を与える前の表面の微細な凹凸は傷として認めない。同じ組成の疑似皮膚モデルを、この最大擦過傷深さと傷の積算擦過傷深さによって比較評価することにより、不織布の摩擦刺激の程度を比較することができる。
　不織布と疑似皮膚モデルとの摩擦で生じた傷の最大傷深さ及び積算擦過傷深さと、不織布と実際の肌との摩擦による物理刺激性との関係を、多数のパネラーにより検討すると、最大擦過傷深さと積算擦過傷深さが大きい不織布ほど、肌を実際に不織布で摩擦したときに刺激が強く感じる傾向があり、摩擦後の皮膚表面の様子を観察すると肌理の消失も大きい傾向にあることが確認できる。この結果から、不織布で疑似皮膚モデルを摩擦することにより生じる傷の最大擦過深さと積算擦過傷深さを測定することによって、肌に接する不織布の肌に対する摩擦刺激性を評価することが可能である。本発明者らの研究によると、この最大擦過傷深さが１０μｍ、積算擦過傷深さが８０μｍを超えると、肌に接する不織布は肌に対して摩擦刺激が大きく、肌を傷付け易くなることが判明した。 In other words, the frictional irritating property of the nonwoven fabric is expressed as the number of scratches, the depth of the scratches, and the width of the scratches on the simulated skin model, depending on the degree of physical stimulation caused by friction with the simulated skin model. . The surface of the pseudo skin model is adjusted so as to be flat, but fine irregularities on the surface before applying the frictional stimulus are not recognized as scratches. By comparing and evaluating the pseudo skin model having the same composition with the maximum scratch depth and the cumulative scratch depth of the scratch, the degree of frictional stimulation of the nonwoven fabric can be compared.
When the relationship between the maximum flaw depth and the cumulative flaw depth of scratches caused by friction between the nonwoven fabric and the pseudo skin model and the physical irritation due to friction between the nonwoven fabric and the actual skin is examined using a number of panelists, the maximum flaw depth It can be confirmed that the nonwoven fabric with a larger integrated scratch depth tends to feel stronger irritation when the skin is actually rubbed with the nonwoven fabric, and that the disappearance of the texture tends to be greater when observing the skin surface after friction . From this result, it is possible to evaluate the frictional irritation to the skin of the nonwoven fabric in contact with the skin by measuring the maximum scratch depth and the cumulative scratch depth caused by rubbing the pseudo skin model with the nonwoven fabric. According to the study by the present inventors, it has been found that when the maximum scratch depth is 10 μm and the cumulative scratch depth exceeds 80 μm, the nonwoven fabric in contact with the skin has a large frictional stimulus to the skin, and the skin is easily damaged. .
　本実施形態において、不織布の「表面毛羽指数」は、３以上であることが好ましい。表面毛羽指数が３未満であると、皮膚との摩擦等により、不織布表面に毛羽が発生し、ちくちくとした肌触りとなり、更に摩擦によって、皮膚表面に対して物理刺激となる。 In this embodiment, the “surface fluff index” of the nonwoven fabric is preferably 3 or more. When the surface fluff index is less than 3, fluff is generated on the surface of the nonwoven fabric due to friction with the skin and the like, resulting in a crisp feel and further friction causes physical irritation to the skin surface.
　本実施形態において、不織布の摩擦係数の変動値（ＭＭＤ）の縦横平均値は０．０１５以下であることが好ましい。０．０１５を超えると、肌触りの滑らかさ、物理刺激の小ささの点から好ましくなく、より好ましくは０．０１７以下、より好ましくは０．０１５以下である。
　皮膚との摩擦は、縦方向と横方向の両方向への摩擦が合わさっており、どちらの方向の摩擦係数も低く、滑らかで抵抗が少ないことが好ましい。然しながら、縦方向と横方向の摩擦抵抗の大きさに差異が発生する場合、縦方向と横方向の摩擦係数の値の小さい方向に摩擦抵抗の応力が集中し、その結果、縦方向と横方向の摩擦抵抗応力が平均化される。従って、摩擦係数の変動値の縦横平均値が皮膚に対する物理刺激の負荷を示す値として重要である。
　摩擦抵抗の大きさの差異が発生し、摩擦抵抗応力の平均化されるのは、摩擦係数の変動値の縦方向、横方向の値において、小さい方向の摩擦係数の変動値と大きい方向の摩擦係数の変動値の比率が２０倍を超えると、大きい方向の値の影響が高くなり、摩擦係数の変動値の縦横平均値が０．０１５以下であっても、肌触りはざらざらとした肌触りとなるからである。 In this embodiment, it is preferable that the average value of the variation value (MMD) of the friction coefficient of the nonwoven fabric is 0.015 or less. When it exceeds 0.015, it is not preferable from the point of the smoothness of the touch and the small physical stimulus, More preferably, it is 0.017 or less, More preferably, it is 0.015 or less.
It is preferable that the friction with the skin is a combination of the friction in both the vertical direction and the horizontal direction, the coefficient of friction in both directions is low, smooth and low in resistance. However, if there is a difference in the size of the frictional resistance between the vertical and horizontal directions, the stress of the frictional resistance is concentrated in the direction where the value of the friction coefficient in the vertical and horizontal directions is small. The frictional resistance stress is averaged. Therefore, the average value of the variation value of the friction coefficient is important as a value indicating the load of physical stimulation on the skin.
Differences in the size of the frictional resistance occur, and the frictional resistance stress is averaged because the frictional coefficient fluctuation value in the vertical and horizontal directions has a small friction coefficient fluctuation value and a large frictional value. When the ratio of the coefficient fluctuation value exceeds 20 times, the influence of the value in the larger direction becomes high, and even when the average value of the fluctuation value of the friction coefficient is 0.015 or less, the skin feels rough. Because.
　本実施形態の不織布のＸ線ＣＴによる配向指標は好ましくは０．４３以下であり、より好ましくは０．４２５以下である。Ｘ線ＣＴによる配向指数がこの範囲であると不織布の厚み方向を占有する繊維が多くなり、荷重下においても嵩が潰れることがなく、嵩高性を有する不織布となり、優れたクッション性を持つ不織布を得ることが可能となる。下限は低ければ低い方がよいが、好ましくは０．３０以上、より好ましくは０．３３以上である。 The orientation index by X-ray CT of the nonwoven fabric of this embodiment is preferably 0.43 or less, more preferably 0.425 or less. When the orientation index by X-ray CT is within this range, the number of fibers that occupy the thickness direction of the nonwoven fabric increases, and the bulk does not collapse even under load, resulting in a bulky nonwoven fabric that has excellent cushioning properties. Can be obtained. The lower limit is preferably as low as possible, but is preferably 0.30 or more, more preferably 0.33 or more.
　不織布の厚み方向の繊維配向を高くするためには、不織布の接合工程における熱風温度と風速、不織ウェブの通気度を制御することが重要である。熱風温度が高いと繊維表面の溶解度が非常に高くなり、風合いの硬いものとなる。熱風風速が速いと熱風は貫通するが、繊維も同時に潰れてしまい嵩の低い不織布となってしまう。更に不織ウェブの通気度が低過ぎると熱風は貫通せず、高過ぎると熱風が繊維交点へ充分に溶解する熱がかからなくなるため嵩と強度を両立する繊維接着点を形成することが困難となる。本実施形態の不織布の嵩密度は０．０１ｇ／ｃｍ３以上０．０７ｇ／ｃｍ３以下の範囲となるものが好ましく、強度の観点から０．０３ｇ／ｃｍ３以上がより好ましく、風合いの観点から０．０７ｇ／ｃｍ３以下とすることがさらに好ましい。 In order to increase the fiber orientation in the thickness direction of the nonwoven fabric, it is important to control the hot air temperature and wind speed and the air permeability of the nonwoven web in the joining process of the nonwoven fabric. When hot air temperature is high, the solubility of the fiber surface becomes very high and the texture becomes hard. When the hot air speed is high, the hot air penetrates, but the fibers are simultaneously crushed and become a non-woven fabric with low bulk. Furthermore, if the air permeability of the nonwoven web is too low, hot air will not penetrate, and if it is too high, it will be difficult to form a fiber bonding point that achieves both bulk and strength because the hot air will not be heated enough to dissolve at the fiber intersection. It becomes. The bulk density of the nonwoven fabric of this embodiment is preferably in the range of 0.01 g / cm 3 or more and 0.07 g / cm 3 or less, more preferably 0.03 g / cm 3 or more from the viewpoint of strength, and from the viewpoint of texture. More preferably, it is 0.07 g / cm 3 or less.
　本実施形態の不織布の圧縮仕事量ＷＣは０．２０ｇｆ・ｃｍ／ｃｍ２以上１．００ｇｆ・ｃｍ／ｃｍ２以下であることが好ましく、より好ましくは、０．２５ｇｆ・ｃｍ／ｃｍ２以上０．８０ｇｆ・ｃｍ・ｃｍ２以下である。この範囲の圧縮仕事量ＷＣを保持することは、衛生材料に使用される不織布としてのクッション性の観点から、好ましい。 The compression work WC of the nonwoven fabric of the present embodiment is preferably 0.20 gf · cm / cm 2 or more and 1.00 gf · cm / cm 2 or less, more preferably 0.25 gf · cm / cm 2 or more and 0.0. 80 gf · cm · cm 2 or less. Holding the compression work WC within this range is preferable from the viewpoint of cushioning properties as a nonwoven fabric used for sanitary materials.
　本実施形態の不織布を構成する複合長繊維の平均単糸繊度は、０．５ｄｔｅｘ以上１０．０ｄｔｅｘ以下であることが好ましく、より好ましくは０．７ｄｔｅｘ以上８．０ｄｔｅｘ以下、さらに好ましくは０．９ｄｔｅｘ以上５．０ｄｔｅｘ以下である。紡糸安定性の観点から、０．５ｄｔｅｘ以上であることが好ましく、衛生材料に使用される不織布の風合いの観点から１０．０ｄｔｅｘ以下であることが好ましい。 The average single yarn fineness of the composite long fibers constituting the nonwoven fabric of the present embodiment is preferably 0.5 dtex or more and 10.0 dtex or less, more preferably 0.7 dtex or more and 8.0 dtex or less, and further preferably 0.9 dtex. More than 5.0 dtex. From the viewpoint of spinning stability, it is preferably 0.5 dtex or more, and from the viewpoint of the texture of the nonwoven fabric used for the sanitary material, it is preferably 10.0 dtex or less.
　前記複合長繊維は不織布の風合いと嵩高を保持する観点から、らせん状の捲縮を有していることが好ましい。該繊維の捲縮数は５個／インチ以上４５個／インチ以下が好ましく、より好ましくは１０個／インチ以上４０個／インチ以下である。捲縮数が５個／インチ未満であると得られる不織布の嵩高が不足し、４５個／インチを超えると得られる不織布の繊維分散ムラにより見栄えを損なってしまう。 The composite continuous fiber preferably has a helical crimp from the viewpoint of maintaining the texture and bulkiness of the nonwoven fabric. The number of crimps of the fiber is preferably 5 pieces / inch or more and 45 pieces / inch or less, more preferably 10 pieces / inch or more and 40 pieces / inch or less. When the number of crimps is less than 5 pieces / inch, the resulting nonwoven fabric is insufficiently bulky. When the number of crimps exceeds 45 pieces / inch, the appearance of the nonwoven fabric is impaired due to uneven fiber dispersion.
　本実施形態の不織布の目付は、８ｇ／ｍ２以上８０ｇ／ｍ２以下が好ましく、より好ましくは１０ｇ／ｍ２以上４０ｇ／ｍ２以下、さらに好ましくは１０ｇ／ｍ２以上３０ｇ／ｍ２以下である。８ｇ／ｍ２以上であれば衛生材料に使用される不織布としては強力を満足し、８０ｇ／ｍ２以下であれば本願の目的である衛生材料に使用される不織布の柔軟性を満足し、外観的に厚ぼったい印象を与えない。 The basis weight of the nonwoven fabric of the present embodiment is preferably 8 g / m 2 or more and 80 g / m 2 or less, more preferably 10 g / m 2 or more and 40 g / m 2 or less, and further preferably 10 g / m 2 or more and 30 g / m 2 or less. is there. If it is 8 g / m 2 or more, the non-woven fabric used in the sanitary material satisfies the strength, and if it is 80 g / m 2 or less, the non-woven fabric used in the sanitary material, which is the object of the present invention, is satisfied. Does not give a thick impression.
　本実施形態の不織布には親水化剤が含有されていてもよい。使用される親水化剤としては、人体への安全性、工程での安全性等を考慮して、高級アルコール、高級脂肪酸、アルキルフェノール等のエチレンオキサイドを付加した非イオン系活性剤、アルキルフォスフェート塩、アルキル硫酸塩等のアニオン系活性剤等が単独又は混合物として好ましく用いられる。
　親水化剤を含有させる方法として、通常、希釈した親水化剤を用いて、浸漬法、噴霧法、コーティング（キスコーター、グラビアコーター、ダイコータ―）法等の既存の方法が採用でき、必要により予め混合した親水化剤を、水等の溶媒で希釈して塗布することが好ましい。
　親水化剤を水等の溶媒で希釈して塗布すると、乾燥工程を必要とする場合がある。その際の乾燥方法としては、対流伝熱、伝導伝熱、放射伝熱等を利用した既知の方法が採用でき、熱風や赤外線による乾燥あるいは熱接触による乾燥方法等を用いることができる。
　親水化剤の付着量は、要求される性能によって異なるが、通常は、繊維に対して０．０５重量％以上１．００重量％以下の範囲が好ましく、より好ましくは０．１５重量％以上０．８重量％以下、さらに好ましくは０．２重量％以上０．６重量％以下である。付着量がこの範囲にあると、衛生材料のトップシートとしての親水性能を満足し、加工適正も良好となる。
　不織布に、親水化剤を付与して親水性向上処理がなされて、衛生材料のトップシートとして用いた場合、尿や血液が不織布表面を透過するので、肌に残留せず、アンモニア等の化学刺激を低減させ、肌に対して物理刺激が小さく、かつ、肌を傷つけ難いので、化学刺激に対して皮膚炎等の炎症も発生し難くなる。 The nonwoven fabric of this embodiment may contain a hydrophilizing agent. The hydrophilizing agent used is a nonionic active agent to which ethylene oxide such as higher alcohol, higher fatty acid, alkylphenol or the like is added in consideration of safety to the human body and safety in the process, alkyl phosphate salt, etc. Anionic activators such as alkyl sulfates are preferably used alone or as a mixture.
As a method for adding a hydrophilizing agent, an existing method such as a dipping method, a spraying method, or a coating (kiss coater, gravure coater, die coater) method can be generally used by using a diluted hydrophilizing agent, and if necessary, mixing is performed in advance. It is preferable to apply the hydrophilizing agent diluted with a solvent such as water.
When the hydrophilizing agent is diluted with a solvent such as water and applied, a drying step may be required. As a drying method at that time, a known method using convective heat transfer, conduction heat transfer, radiant heat transfer, or the like can be employed, and a drying method using hot air or infrared rays, a drying method using heat contact, or the like can be used.
The adhesion amount of the hydrophilizing agent varies depending on the required performance, but usually it is preferably in the range of 0.05% by weight or more and 1.00% by weight or less, more preferably 0.15% by weight or more and 0%. 0.8 wt% or less, more preferably 0.2 wt% or more and 0.6 wt% or less. When the adhesion amount is within this range, the hydrophilic performance as a sanitary material top sheet is satisfied, and the processing suitability is also good.
When a hydrophilic agent is applied to the nonwoven fabric to improve its hydrophilicity and it is used as a sanitary material top sheet, urine and blood permeate the nonwoven fabric surface, so it does not remain on the skin and is chemically stimulated by ammonia and the like. Since the physical irritation to the skin is small and the skin is hardly damaged, inflammation such as dermatitis is less likely to occur against the chemical irritation.
　本実施形態の不織布は、２種以上の熱可塑性樹脂からなる複合長繊維不織布を用い、肌に接する面の融着部を調整することにより達成されたものである。複合長繊維不織布を用いているので、一部の繊維交点が完全にフィルム化することなく複合繊維の低融点成分が熱融着接合しているので、肌と接触した時に、繊維の自由度が損なわれることなく、かつフィルム化部分で応力集中することがないので、物理刺激が小さくなる。また、繊維交点の熱融着接合により、実用上の強度と毛羽防止が達成される。 The nonwoven fabric of the present embodiment is achieved by using a composite long fiber nonwoven fabric made of two or more thermoplastic resins and adjusting the fusion part on the surface in contact with the skin. Since a composite long fiber nonwoven fabric is used, the low melting point components of the composite fiber are bonded by heat fusion without completely forming a film at some fiber intersections. Since it is not damaged and stress concentration does not occur in the filmed portion, physical stimulation is reduced. Moreover, practical strength and fluff prevention are achieved by heat fusion bonding at the fiber intersection.
　長繊維不織布の構成繊維の自由度は、熱圧着等によるフィルム化部分と複合繊維の低融点成分の熱融着接合の程度によって定まり、長繊維不織布のタフネス指数で示される。タフネス指数とは、不織布の破断と破断伸度の積を不織布の目付で除した値であり、好ましくは４０以上２５０以下であり、より好ましくは５０以上１５０以下である。 The degree of freedom of the constituent fibers of the long-fiber non-woven fabric is determined by the degree of thermal fusion bonding of the film-formed portion by thermocompression bonding or the like and the low melting point component of the composite fiber, and is indicated by the toughness index of the long-fiber non-woven fabric. The toughness index is a value obtained by dividing the product of the breaking and breaking elongation of the nonwoven fabric by the basis weight of the nonwoven fabric, preferably 40 or more and 250 or less, more preferably 50 or more and 150 or less.
　本発明を実施例により具体的に説明するが、本発明はこれらの実施例に限定されるものではない。
　実施例における不織布の諸特性を以下の方法により測定した。
　各特性の評価方法は下記のとおりであり、得られた物性を以下の表１に示す。以下、製造ライン方向で繊維の流れ方向をＭＤ方向、繊維の流れ方向と直角方向で巾方向をＣＤ方向という。 EXAMPLES The present invention will be specifically described with reference to examples, but the present invention is not limited to these examples.
Various characteristics of the nonwoven fabric in the examples were measured by the following methods.
The evaluation method of each characteristic is as follows, and the obtained physical properties are shown in Table 1 below. Hereinafter, the fiber flow direction in the production line direction is referred to as MD direction, the fiber flow direction is perpendicular to the fiber flow direction, and the width direction is referred to as CD direction.
（１）平均単糸繊度（ｄｔｅｘ）
　１ｃｍ角の試験片をサンプリングし、キーエンス社製マイクロスコープＶＨＸ－７００Ｆで繊維の直径を各２０点ずつ測定し、その平均値から繊度を算出した。 (1) Average single yarn fineness (dtex)
A 1 cm square test piece was sampled, and the diameter of the fiber was measured at 20 points for each with a Microscope VHX-700F manufactured by Keyence, and the fineness was calculated from the average value.
（２）目付（ｇ／ｍ２）
　ＪＩＳ－Ｌ１９０６に準じ、ＭＤ方向２０ｃｍ×ＣＤ方向５ｃｍの試験片を任意に５枚採取して質量を測定し、その平均値を単位面積あたりの重量に換算して求めた。 (2) Weight per unit (g / m 2 )
According to JIS-L1906, 5 specimens measuring 20 cm in the MD direction × 5 cm in the CD direction were arbitrarily sampled and the mass was measured, and the average value was converted into the weight per unit area.
（３）通気度（ｃｍ３／ｃｍ２／ｓ）
　ＪＩＳ　Ｌ－１０９６に記載のフラジール法に準拠して測定した。１０点を採取して測定し、測定値の平均値を算出した。 (3) Air permeability (cm 3 / cm 2 / s)
The measurement was performed according to the fragile method described in JIS L-1096. Ten points were collected and measured, and the average value of the measured values was calculated.
（４）捲縮数
　ＣＤ方向に５点の５ｃｍ角の試験片をサンプリングし、キーエンス製マイクロスコープＶＨ－Ｚ４５０を用いて、試験片中の繊維に荷重がかからない状態で、１インチ（２．５４ｃｍ）あたりの捲縮数を測定し、その平均値より捲縮数を算出した。 (4) Number of crimps Samples of 5 cm squares at 5 points in the CD direction were sampled and 1 inch (2.54 cm) was applied using a Keyence microscope VH-Z450 with no load applied to the fibers in the test pieces. ) Was measured, and the number of crimps was calculated from the average value.
（５）最大擦過傷深さ、及び積算擦過傷深さ
　（イ）不織布の任意の場所より、５ｃｍ×５ｃｍの試料を３点作製する。
　（ロ）カトーテック（株）社製摩擦感テスター（ＫＥＳ－ＳＥ）の摩擦端子に試料を装着する。
　（ハ）試料と、後述する、初期圧縮応力９８ｍＮ／ｃｍ２の疑似皮膚モデルとを、接圧４．９×１０３Ｐａ、接触面積１ｃｍ２、摩擦距離２ｃｍの条件で上記摩擦感テスターを用いて１回摩擦する。
　（ニ）疑似皮膚モデル表面の、摩擦によって生じた幅１ｃｍ、摩擦方向２ｃｍの摩擦跡の中央部分、摩擦方向に対して直交する方向１ｃｍ幅の最大擦過傷深さ、積算擦過傷深さを、非接触式レーザー測量機を用いて測定する。
　（ホ）試料の縦および横方向各々１ｃｍ間隔で、１０箇所について摩擦した時の疑似皮膚モデル表面の最大擦過傷深さ、積算擦過傷深さを測定し、縦横平均を試料片の最大擦過傷深さ、積算擦過傷深さとする。サンプルの最大擦過傷深さ、積算擦過傷深さは、上記３点の平均値とする。
［疑似皮膚モデルの製造方法］
　寒天（ＡＧＡＲ　ＰＯＷＤＥＲ、和光純薬社製、試薬）１部、ゼラチン（ＧＩＦＣＯ社製、試薬）８部を水９１部を溶解後、冷蔵庫にて固化したものを用いる。表面は平坦になるように調整する。
　初期圧縮応力は、疑似皮膚モデルをハンディー圧縮試験機　ＫＥＳ－Ｇ５（カトーテック（株）社製）を用いて、圧縮面積２００ｍｍ２、圧縮速度０．１ｍｍ／秒で測定したときに、０．１ｍｍ変位した時の圧縮応力をいう。必要に応じて、加える水添加量を微調整して初期圧縮応力を合わせる。 (5) Maximum scratch depth and cumulative scratch depth (a) Three samples of 5 cm × 5 cm are prepared from any location of the nonwoven fabric.
(B) A sample is attached to the friction terminal of a friction tester (KES-SE) manufactured by Kato Tech Co., Ltd.
(C) A sample and a pseudo skin model having an initial compressive stress of 98 mN / cm 2 , which will be described later, are used with the friction tester under the conditions of a contact pressure of 4.9 × 10 3 Pa, a contact area of 1 cm 2 , and a friction distance of 2 cm. Rub once.
(D) Non-contact of the surface of the artificial skin model with a width of 1 cm caused by friction and a central portion of a friction trace of 2 cm in the friction direction, a maximum scratch depth of 1 cm width in a direction perpendicular to the friction direction, and an integrated scratch depth. Measure using a laser surveying instrument.
(E) Measure the maximum scratch depth and cumulative scratch depth on the surface of the pseudo skin model when rubbing about 10 locations at 1 cm intervals in the vertical and horizontal directions of the sample, and calculate the average length and width of the maximum scratch depth of the sample piece. The integrated scratch depth. The maximum scratch depth and cumulative scratch depth of the sample are the average values of the above three points.
[Method of manufacturing pseudo skin model]
1 part of agar (AGAR POWDER, manufactured by Wako Pure Chemical Industries, reagent) and 8 parts of gelatin (manufactured by GIFCO, reagent) are dissolved in 91 parts of water and solidified in a refrigerator. Adjust the surface to be flat.
The initial compressive stress is 0.1 mm when the pseudo skin model is measured using a handy compression tester KES-G5 (manufactured by Kato Tech Co., Ltd.) at a compression area of 200 mm 2 and a compression speed of 0.1 mm / second. This is the compressive stress when displaced. If necessary, adjust the initial compressive stress by finely adjusting the amount of water added.
（６）熱圧着部形状指数
　（イ）不織布の任意の場所より５ｃｍ×５ｃｍの試料を採取する。
　（ロ）前記試料より１ｃｍ×１ｃｍの試料を２５枚作製し、表面を顕微鏡で撮影し、２５倍の拡大写真２５枚を得る。
　（ハ）得られた写真から、不織布の融着部面積が不織布表面積に占める割合を求める。
　（ニ）得られた写真から、一定面積２０平方ミリメートルあたりに含まれる融着してフィルム化した部分の周長の総和を示す値を求める。
　（ホ）下記数式（１）：
　　　熱圧着部形状指数＝熱融着面積率×一定面積当たりの融着周長　　　式（１）
｛式中、融着面積率：長繊維不織布の融着部面積が長繊維不織布の全体面積に占める割合；一定面積あたりの融着周長：長繊維不織布20平方ミリメートル当たりに含まれる融着部の周長の総和。｝により熱圧着部形状指数を求める。熱圧着部形状指数は上記２５点の平均値とする。 (6) Thermocompression bonded portion shape index (a) A sample of 5 cm × 5 cm is taken from an arbitrary place of the nonwoven fabric.
(B) 25 samples of 1 cm × 1 cm are prepared from the sample, and the surface is photographed with a microscope to obtain 25 magnified photographs of 25 times.
(C) From the obtained photograph, the ratio of the fusion-bonded area of the nonwoven fabric to the nonwoven fabric surface area is determined.
(D) From the obtained photograph, a value indicating the total sum of the circumferences of the fused and filmed portions included in a fixed area of 20 square millimeters is obtained.
(E) The following mathematical formula (1):
Thermocompression bonding section shape index = thermal fusion area ratio × fusion circumference per fixed area Formula (1)
{In the formula, the fusion area ratio: the ratio of the fusion-bonded area of the long-fiber nonwoven fabric to the total area of the long-fiber nonwoven fabric; the fusion circumference per fixed area: the fusion-bonded portion contained per 20 square millimeters of the long-fiber nonwoven fabric Sum of perimeters of } To obtain the thermocompression bonding portion shape index. The thermocompression bonding portion shape index is the average value of the 25 points.
（７）摩擦係数の変動値
　（イ）不織布の任意の場所より、６ｃｍ×８ｃｍの試料を３点作製する。
　（ロ）カトーテック（株）社製摩擦感テスター（ＫＥＳ－ＳＥ）の測定台に試料を装着する。
　（ハ）試料と、摩擦感テスターの標準摩擦端子（１０ｍｍ角金属ワイヤー端子）を用いて、測定荷重２５ｇ／ｃｍ２にて摩擦係数の変動値（ＭＭＤ）を測定し、試料の縦横平均値を測定する。 (7) Fluctuation value of friction coefficient (a) Three samples of 6 cm × 8 cm are prepared from an arbitrary place of the nonwoven fabric.
(B) A sample is mounted on a measuring table of a friction tester (KES-SE) manufactured by Kato Tech Co., Ltd.
(C) Using the sample and the standard friction terminal (10 mm square metal wire terminal) of the friction tester, the fluctuation value (MMD) of the coefficient of friction was measured at a measurement load of 25 g / cm 2 , and the vertical and horizontal average values of the sample were calculated. taking measurement.
（８）表面毛羽指数
　ＪＩＳ　Ｐ　８１３６に準じて下記方法で実施する。
　（イ）不織布の任意の場所より、縦方向２５ｃｍ、横方向３ｃｍの試料を３点作製する。
　（ロ）耐摩耗試験機の試料台に試料を貼付け、摩擦子にカナキン３号（４ｃｍ×５ｃｍ）を装着する。
　（ハ）摩擦子（５００ｇ）を不織布の上に置き、往復カウント１００回の摩擦試験を実施する。
　（ニ）摩擦後の不織布表面の毛羽状態を、官能的に評価する。以下の判定基準で、３点の平均値にて示す。
［評価基準：表面毛羽指数］
　　　５点：摩擦による毛羽が観察されず、表面摩擦によって損傷が確認されない。
　　　４点：摩擦による表面形状変化は僅かに確認されるが、毛羽は確認されない。
　　　３点：摩擦による毛羽がやや観察されるが、剥離した繊維端は１０本以下である。
　　　２点：摩擦による毛羽が観察され、剥離した繊維端が１１本以上４９本以下確認される。
　　　１点：摩擦により、毛羽発生が多く、剥離した繊維端が５０本以上確認される。 (8) Surface fluff index It implements by the following method according to JISP8136.
(A) Three samples of 25 cm in the vertical direction and 3 cm in the horizontal direction are prepared from arbitrary locations of the nonwoven fabric.
(B) A sample is affixed to the sample stage of the abrasion resistance tester, and Kanakin No. 3 (4 cm × 5 cm) is attached to the friction element.
(C) A friction element (500 g) is placed on the nonwoven fabric, and a friction test with a reciprocating count of 100 is performed.
(D) The fluff state on the surface of the nonwoven fabric after friction is sensorially evaluated. The average value of 3 points is shown by the following criteria.
[Evaluation criteria: Surface fluff index]
5 points: Fluff due to friction is not observed, and damage is not confirmed due to surface friction.
4 points: A slight change in surface shape due to friction is confirmed, but no fluff is confirmed.
3 points: Fluff due to friction is somewhat observed, but the number of peeled fiber ends is 10 or less.
2 points: Fluff due to friction is observed, and 11 or more and 49 or less peeled fiber ends are confirmed.
1 point: Fuzz is often generated due to friction, and 50 or more separated fiber ends are confirmed.
（９）配向指数（Ｘ線ＣＴ）
　ＭＤ方向５ｍｍ×ＣＤ方向５ｍｍの試験片を任意にカットし、画像解析時の視野約３ｍｍ×３ｍｍで測定した。測定装置は高分解能３ＤＸ線顕微鏡ｎａｎｏ３ＤＸ（株式会社リガク製）を用い、軽元素でもコントラストが得られる低エネルギー高輝度Ｘ線によるＣＴ測定で行った。詳細な条件を以下に示す。
　　Ｘ線ターゲット：Ｃｕ
　　Ｘ線管電圧：４０ｋＶ
　　Ｘ線管電流：３０ｍＡ
　　レンズ：１．０８μｍ／ｐｉｘ
　　ビニング：２
　　回転角度：１８０°
　　投影数：１０００枚
　　露光時間：１０秒／枚
　　カメラ画素数：３３００×２５００
　　再構成：Ｆｅｌｄｋａｍｐ法
　ＣＴ測定により得られた３次元のトモグラムを画像解析し、直交する３軸（ｘ、ｙ、ｚ）の配向性指標Ｉｘ、Ｉｙ、Ｉｚを求めた。主に評価したいサンプルの厚み方向をｚ方向と一致させた。ここで、配向性指標Ｉｘ、Ｉｙ、Ｉｚとは、ｘ、ｙ、ｚの各方向から見た繊維表面の面積の和（各方向での繊維表面の延べ投影面積の和）をそれぞれＡｘ、Ａｙ、Ａｚとしたとき、
　　Ｉｘ＝Ａｘ／（Ａｘ＋Ａｙ＋Ａｚ）
　　Ｉｙ＝Ａｙ／（Ａｘ＋Ａｙ＋Ａｚ）
　　Ｉｚ＝Ａｚ／（Ａｘ＋Ａｙ＋Ａｚ）
で定義した。Ａｘ、Ａｙ、Ａｚはトモグラムから求めた。この指標においては、値の小さい方向に配向していることになる。また、等方的構造においてはすべて１／３となる。 (9) Orientation index (X-ray CT)
A test piece of 5 mm in the MD direction × 5 mm in the CD direction was arbitrarily cut and measured with a visual field of about 3 mm × 3 mm during image analysis. The measurement apparatus was a high-resolution 3DX-ray microscope nano3DX (manufactured by Rigaku Corporation), and was subjected to CT measurement using low-energy high-intensity X-rays that can provide contrast even with light elements. Detailed conditions are shown below.
X-ray target: Cu
X-ray tube voltage: 40 kV
X-ray tube current: 30 mA
Lens: 1.08 μm / pix
Binning: 2
Rotation angle: 180 °
Number of projections: 1000 sheets Exposure time: 10 seconds / sheet Number of camera pixels: 3300 × 2500
Reconstruction: Feldkamp method A three-dimensional tomogram obtained by CT measurement was subjected to image analysis, and orientation indices Ix, Iy, Iz of three orthogonal axes (x, y, z) were obtained. The thickness direction of the sample to be mainly evaluated was matched with the z direction. Here, the orientation indices Ix, Iy, and Iz are the sums of the fiber surface areas viewed from the x, y, and z directions (the sum of the total projected areas of the fiber surfaces in the respective directions), respectively, Ax, Ay. , Az,
Ix = Ax / (Ax + Ay + Az)
Iy = Ay / (Ax + Ay + Az)
Iz = Az / (Ax + Ay + Az)
Defined in Ax, Ay, and Az were obtained from tomograms. This index is oriented in the direction of smaller values. Further, in the isotropic structure, all are 1/3.
（１０）嵩密度（ｇ／ｃｍ３）
　不織布の布帛試料の両端１０ｃｍを除き、巾方向均等になる様にピーコック式厚み計（５ｇ／４ｃｍ２）で２０点測定し、平均の厚さを算出した。その平均値から以下の式を用い、嵩密度を算出した。
　嵩密度（ｇ／ｃｍ３）＝目付（ｇ／ｍ２）／厚み（ｍｍ）／１０００ (10) Bulk density (g / cm 3 )
The average thickness was calculated by measuring 20 points with a peacock thickness gauge (5 g / 4 cm 2 ) so that the width of the nonwoven fabric sample was 10 cm at both ends, and uniform in the width direction. The bulk density was calculated from the average value using the following formula.
Bulk density (g / cm 3 ) = weight per unit area (g / m 2 ) / thickness (mm) / 1000
（１１）圧縮仕事量（ＷＣ）
　ＣＤ方向に５点の５ｃｍ角の試験片を採取し、カトーテック社製圧縮試験装置（ＫＥＳ－Ｇ５）を用いて測定した。試験片を金属製試料台の上に設置し、加圧面積２ｃｍ２の円形平面を持つ鋼板間で圧縮した。圧縮速度は０．０６７ｍｍ／ｓで、圧縮最大荷重は３．４ｋＰａ（３５ｇｆ／ｃｍ２）とした。回復過程も同一速度で測定し、圧縮仕事量の平均値を算出した。 (11) Work of compression (WC)
Five 5 cm square test pieces were collected in the CD direction and measured using a compression test apparatus (KES-G5) manufactured by Kato Tech. The test piece was placed on a metal sample stage and compressed between steel plates having a circular plane with a pressure area of 2 cm 2 . The compression speed was 0.067 mm / s, and the maximum compression load was 3.4 kPa (35 gf / cm 2 ). The recovery process was also measured at the same speed, and the average value of the compression work was calculated.
（１２）風合い
　モニター５人による官能評価によって、サンプルの柔らかさを判定した。サンプルの風合いが、「硬い」又は「柔らかい」に分類し、５人の平均で判定した。 (12) Texture The softness of the sample was determined by sensory evaluation by five monitors. The texture of the sample was classified as “hard” or “soft” and judged by the average of five people.
（１３）タフネス指数
　ＪＩＳ　Ｌ－１９０６に準じ、ＭＤ方向２０ｃｍ、ＣＤ方向５ｃｍのサンプルを５点採取し、引張試験機で、つかみ間隔１００ｍｍ、引張速度３００ｍｍ／ｍｉｎで縦方向の引張試験を実施し、測定された破断強度と破断伸度より、タフネス指数を下記式にて算出した。
　タフネス指数＝破断強度（Ｎ／５０ｍｍ）×破断伸度（％）／目付（ｇ／ｍ２） (13) Toughness index In accordance with JIS L-1906, five samples of 20 cm in MD direction and 5 cm in CD direction were collected, and the tensile test in the longitudinal direction was carried out with a tensile tester at a grip interval of 100 mm and a pulling speed of 300 mm / min. From the measured breaking strength and breaking elongation, the toughness index was calculated by the following formula.
Toughness index = breaking strength (N / 50 mm) × breaking elongation (%) / weight per unit (g / m 2 )
［実施例１～３、比較例１、２］
　ＭＦＲが５５ｇ／１０分（ＪＩＳ－Ｋ７２１０に準じ、温度２３０℃、荷重２．１６ｋｇで測定）のポリプロピレン（ＰＰ）樹脂を第１成分とし、ＭＩが２６ｇ／１０分（ＪＩＳ－Ｋ７２１０に準じ、温度１９０℃、荷重２．１６ｋｇで測定）の高密度ポリエチレン（ＨＤＰＥ）樹脂を第２成分とし、第１成分の吐出量が０．４ｇ／分・Ｈｏｌｅ、第２成分の吐出量が０．４ｇ／分・Ｈｏｌｅで全単孔吐出量が０．８ｇ／分・Ｈｏｌｅであり、繊維形状を偏心鞘芯構造とし、第１成分と第２成分の比が５０／５０となる繊維をスパンボンド法により紡糸温度２２０℃で押出し、このフィラメント群をエアジェットによる高速気流牽引装置を使用して紡速３，０００ｍ／分で、移動捕集面に向けて押し出し、平均単糸繊度２．８ｄｔｅｘの長繊維不織ウェブを調製した。 [Examples 1 to 3, Comparative Examples 1 and 2]
Polypropylene (PP) resin having an MFR of 55 g / 10 min (measured according to JIS-K7210, at a temperature of 230 ° C. and a load of 2.16 kg) is the first component, and MI is 26 g / 10 min (according to JIS-K7210, temperature High-density polyethylene (HDPE) resin (measured at 190 ° C. and load 2.16 kg) is the second component, the first component discharge rate is 0.4 g / min · Hole, and the second component discharge rate is 0.4 g / The total single-hole discharge rate is 0.8 g / min · Hole in min · Hole, the fiber shape is an eccentric sheath core structure, and the fiber in which the ratio of the first component to the second component is 50/50 is obtained by the spunbond method. Extrusion was performed at a spinning temperature of 220 ° C., and this filament group was extruded toward a moving collection surface at a spinning speed of 3,000 m / min using a high-speed airflow traction device using an air jet, and a long fiber having an average single yarn fineness of 2.8 dtex. A nonwoven web was prepared.
　次いで、得られた不織ウェブに熱風温度１４２℃、熱風風速０．７ｍ／ｓの熱風を通過させて、更に彫刻ロールと平滑ロールを組合わせた熱圧着ロールにて圧着処理を行った。熱風を通過させる際の搬送速度、熱圧着ロールの温度、圧力、搬送コンベアと巻取り装置の速度を調整し、所定の熱圧着部形状指数を有する実施例１～３、比較例１、２の、平均単糸繊度２．８デシテックス捲縮数３０個／インチ、目付２０ｇ／ｍ２の複合長繊維不織布を得た。 Next, a hot air having a hot air temperature of 142 ° C. and a hot air wind speed of 0.7 m / s was passed through the obtained nonwoven web, and further subjected to pressure-bonding treatment with a thermocompression-bonding roll in which an engraving roll and a smooth roll were combined. In Examples 1 to 3 and Comparative Examples 1 and 2 having a predetermined thermocompression bonding portion shape index, the conveyance speed at the time of passing hot air, the temperature and pressure of the thermocompression-bonding roll, the speed of the conveyance conveyor and the winding device are adjusted. A composite continuous fiber nonwoven fabric having an average single yarn fineness of 2.8 dtex crimped 30 pieces / inch and a basis weight of 20 g / m 2 was obtained.
[実施例４]
　実施例２と同様にして得られた複合長繊維不織布を、室温２２℃の雰囲気下にて放電量４０Ｗ・ｍｉｎ／ｍ２（放電度４．０Ｗ／ｃｍ２）の条件でコロナ放電処理機に通し、濡れ張力３９ｍＮ／ｍの不織布を得た。得られた不織布にポリエーテル系の親水化剤を噴霧法により付与し、次いで、１１０℃で３０秒間熱風乾燥し、剤濃度付着量が０．３重量％となる長繊維不織布を得た。得られた不織布はオムツのトップシートとして満足できる性能であった。 [Example 4]
The composite long fiber nonwoven fabric obtained in the same manner as in Example 2 was applied to a corona discharge treatment machine under the condition of a discharge amount of 40 W · min / m 2 (discharge degree: 4.0 W / cm 2 ) in an atmosphere at room temperature of 22 ° C. A nonwoven fabric with a wetting tension of 39 mN / m was obtained. A polyether-based hydrophilizing agent was applied to the obtained non-woven fabric by a spraying method, followed by hot air drying at 110 ° C. for 30 seconds to obtain a long-fiber non-woven fabric having an agent concentration adhesion amount of 0.3% by weight. The obtained nonwoven fabric had satisfactory performance as a diaper top sheet.
［実施例５］
　ＭＦＲが４０ｇ／１０分（ＪＩＳ－Ｋ７２１０に準じ、温度２３０℃、荷重２．１６ｋｇで測定）のポリプロピレン（ＰＰ）樹脂を第１成分とし、ＭＩが２６ｇ／１０分（ＪＩＳ－Ｋ７２１０に準じ、温度１９０℃、荷重２．１６ｋｇで測定）の高密度ポリエチレン（ＨＤＰＥ）樹脂を第２成分とし、第１成分の吐出量が０．４ｇ／分・Ｈｏｌｅ、第２成分の吐出量が０．４ｇ／分・Ｈｏｌｅで全単孔吐出量が０．８ｇ／分・Ｈｏｌｅであり、繊維形状を偏心鞘芯構造とし、第１成分と第２成分の比が５０／５０となる繊維をスパンボンド法により紡糸温度２３５℃で押出し、このフィラメント群を冷風押し込みタイプの気流牽引装置を使用して紡速２，５００ｍ／分で、移動捕集面に向けて押し出し、平均単糸繊度２．８ｄｔｅｘの長繊維不織ウェブを調製した。 [Example 5]
Polypropylene (PP) resin with an MFR of 40 g / 10 min (measured according to JIS-K7210, at a temperature of 230 ° C. and a load of 2.16 kg) is the first component, and MI is 26 g / 10 min (according to JIS-K7210, temperature High-density polyethylene (HDPE) resin (measured at 190 ° C. and load 2.16 kg) is the second component, the first component discharge rate is 0.4 g / min · Hole, and the second component discharge rate is 0.4 g / The total single-hole discharge rate is 0.8 g / min · Hole in min · Hole, the fiber shape is an eccentric sheath core structure, and the fiber in which the ratio of the first component to the second component is 50/50 is obtained by the spunbond method. Extrusion was performed at a spinning temperature of 235 ° C., and this filament group was extruded toward a moving collection surface at a spinning speed of 2,500 m / min using a cold air push-type airflow traction device, and a long fiber having an average single yarn fineness of 2.8 dtex. Woven web was prepared.
　次いで、得られた不織ウェブに熱風温度１４５℃、熱風風速１．０ｍ／ｓの熱風を通過させて、不織布を熱接合した。熱風を通過させる際の搬送速度、巻取り装置の速度を調整し、所定の熱圧着部形状指数を有する目付２０ｇ／ｍ２の複合長繊維不織布を得た。 Next, the nonwoven fabric was thermally bonded by passing hot air having a hot air temperature of 145 ° C. and a hot air speed of 1.0 m / s through the obtained nonwoven web. The conveyance speed at the time of passing hot air and the speed of the winding device were adjusted to obtain a composite long fiber nonwoven fabric with a basis weight of 20 g / m 2 having a predetermined thermocompression bonding portion shape index.
［実施例６]
　実施例５と同様にして得られた複合長繊維不織布を、室温２５℃の雰囲気下にて放電量４０Ｗ・ｍｉｎ／ｍ２（放電度４．０Ｗ／ｃｍ２）の条件でコロナ放電処理機に通し、濡れ張力３９ｍＮ／ｍの不織布を得た。得られた不織布にポリエーテル系の親水化剤を噴霧法により付与し、次いで、１２０℃で熱風乾燥し、剤濃度付着量が０．３５重量％となる長繊維不織布を得た。得られた不織布はオムツのトップシートとして満足できる性能であった。 [Example 6]
The composite long fiber nonwoven fabric obtained in the same manner as in Example 5 was applied to a corona discharge treatment machine under the condition of a discharge amount of 40 W · min / m 2 (discharge degree: 4.0 W / cm 2 ) in an atmosphere at room temperature of 25 ° C. A nonwoven fabric with a wetting tension of 39 mN / m was obtained. A polyether-based hydrophilizing agent was applied to the obtained non-woven fabric by a spraying method, followed by hot air drying at 120 ° C. to obtain a long-fiber non-woven fabric having an agent concentration adhesion amount of 0.35% by weight. The obtained nonwoven fabric had satisfactory performance as a diaper top sheet.
［比較例３］
　ＭＦＲが５５ｇ／１０分（ＪＩＳ－Ｋ７２１０に準じ、温度２３０℃、荷重２．１６ｋｇで測定）のポリプロピレン（ＰＰ）樹脂を単成分にてスパンボンド法により紡糸温度２２０℃で押出し、このフィラメント群をエアジェットによる高速気流牽引装置を使用して紡速３，０００ｍ／分で、移動捕集面に向けて押し出し、平均単糸繊度２．８ｄｔｅｘの長繊維不織ウェブを調製した。
　次いで、得られた不織ウェブを、１４１℃のフラットロールとエンボスロール（パターン仕様：直径０．４２５ｍｍ円形、千鳥配列、横ピッチ２．１ｍｍ、縦ピッチ１．１ｍｍ、圧着面積率６．３％）の間に通して繊維同士を接着し、目付２０ｇ／ｍ２で通気度４５６ｃｍ３／ｃｍ２／ｓであり、繊維が捲縮していない熱圧着部形状指数１．９の長繊維不織布を得た。得られた不織布は嵩密度が高く、クッション性を有しておらず風合いの硬いものであった。 [Comparative Example 3]
Polypropylene (PP) resin having an MFR of 55 g / 10 min (measured at a temperature of 230 ° C. and a load of 2.16 kg according to JIS-K7210) is extruded as a single component at a spinning temperature of 220 ° C. by a spunbond method. A long-fiber nonwoven web having an average single yarn fineness of 2.8 dtex was prepared by extruding toward a moving collection surface at a spinning speed of 3,000 m / min using a high-speed airflow traction device using an air jet.
Subsequently, the obtained nonwoven web was subjected to a flat roll and an embossing roll at 141 ° C. (pattern specification: a circle having a diameter of 0.425 mm, a staggered arrangement, a horizontal pitch of 2.1 mm, a vertical pitch of 1.1 mm, and a crimping area ratio of 6.3%. ), The fibers are bonded to each other, a nonwoven fabric having a basis weight of 20 g / m 2 , an air permeability of 456 cm 3 / cm 2 / s, and a thermocompression bonding section shape index 1.9 in which the fibers are not crimped. Obtained. The obtained nonwoven fabric had a high bulk density, had no cushioning properties, and had a hard texture.
［比較例４］
　第１成分となる芯の成分が融点１６２℃のポリプロピレン、第２成分となる鞘の成分が融点１３０℃の高密度ポリエチレンであって、繊度２．５ｄｔｅｘ、カット長３８ｍｍの短繊維を構成繊維とし、カード法によって不織ウェブを得た。
　次いで、得られた不織ウェブを熱風温度１４０℃、熱風風速１．０ｍ／ｓの熱風ボンディングにより繊維同士を接着し、目付１８ｇ／ｍ２で通気度７１７ｃｍ３／ｃｍ２／ｓ、捲縮数５個／インチの複合短繊維不織布を得た。得られた不織布は伸度が低く、タフネス指標が低いく、風合いの硬いものであった。 [Comparative Example 4]
The core component that is the first component is polypropylene having a melting point of 162 ° C., the sheath component that is the second component is high-density polyethylene having a melting point of 130 ° C., and the short fibers having a fineness of 2.5 dtex and a cut length of 38 mm are used as the constituent fibers. The nonwoven web was obtained by the card method.
Next, the obtained nonwoven web was bonded to each other by hot air bonding at a hot air temperature of 140 ° C. and a hot air wind speed of 1.0 m / s, and the air permeability was 717 cm 3 / cm 2 / s with a basis weight of 18 g / m 2. A composite short fiber nonwoven fabric of 5 / inch was obtained. The obtained nonwoven fabric had a low elongation, a low toughness index, and a hard texture.
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
　本発明の複合長繊維不織布は、クッション性の柔らかさを有する嵩高性と高い強伸度を有するため、衛生材料の製造に好適に使用することができる。衛生材料としては使い捨てオムツ、生理用ナプキン又は失禁パットに好適に使用することができ、表面のトップシート、外側のバックシートとして使用することができる。また、用途は限定されず、例えば、マスク、カイロ、テープ基布、防水シート基布、貼布薬基布、救急絆基布、包装材、ワイプ製品、医療用ガウン、包帯、衣料、スキンケア用シートなどにも使用することができる。 Since the composite long fiber nonwoven fabric of the present invention has bulkiness and cushioning softness and high strength and elongation, it can be suitably used for the production of sanitary materials. As a sanitary material, it can be used suitably for disposable diapers, sanitary napkins or incontinence pads, and can be used as a top sheet on the surface and a back sheet on the outside. Applications are not limited. For example, masks, body warmers, tape base fabrics, tarpaulin base fabrics, patch medicinal base fabrics, emergency bond base fabrics, packaging materials, wipe products, medical gowns, bandages, clothing, skin care It can also be used for sheets.

Claims (9)

  1. 　２種以上の熱可塑性樹脂からなる複合長繊維の部分熱圧着不織布であって、熱圧着部形状指数が０．０５以上１．９未満であり、疑似皮膚モデルの最大擦過傷深さが１０μｍ以下であり、かつ、積算擦過傷深さが８０μｍ以下であることを特徴とする前記不織布。 It is a partial thermocompression bonded nonwoven fabric of composite long fibers made of two or more thermoplastic resins, and has a thermocompression bonded portion shape index of 0.05 or more and less than 1.9, and the maximum scratch depth of the pseudo skin model is 10 μm or less The nonwoven fabric is characterized by having an integrated scratch depth of 80 μm or less.
  2. 　前記不織布の表面毛羽指数が３以上である、請求項１に記載の不織布。 The nonwoven fabric according to claim 1, wherein the nonwoven fabric has a surface fluff index of 3 or more.
  3. 　前記不織布の摩擦係数の変動値（ＭＭＤ）の縦横平均値が０．０１５以下である、請求項１又は２に記載の不織布。 The nonwoven fabric according to claim 1 or 2, wherein a longitudinal and lateral average value of a variation value (MMD) of a friction coefficient of the nonwoven fabric is 0.015 or less.
  4. 　前記不織布のＸ線ＣＴによる厚み方向の配向指標が０．４３以下であり、且つ嵩密度が０．０１以上０．０７ｇ／ｃｍ３以下である、請求項１～３のいずれ１項に記載の不織布。 The orientation index in the thickness direction by X-ray CT of the nonwoven fabric is 0.43 or less, and the bulk density is 0.01 or more and 0.07 g / cm 3 or less, according to any one of claims 1 to 3. Non-woven fabric.
  5. 　前記不織布の圧縮仕事量ＷＣが０．２０以上１．００ｇｆ／ｃｍ／ｃｍ２以下である、請求項１～４のいずれか１項に記載の不織布。 The nonwoven fabric according to any one of claims 1 to 4, wherein a compression work WC of the nonwoven fabric is 0.20 or more and 1.00 gf / cm / cm 2 or less.
  6. 　前記複合長繊維はサイドバイサイド型又は偏芯型である、請求項１～５のいずれか１項に記載の不織布。 The nonwoven fabric according to any one of claims 1 to 5, wherein the composite long fiber is a side-by-side type or an eccentric type.
  7. 　前記２種の熱可塑性樹脂はいずれもポリオレフィン系樹脂である、請求項１～６のいずれか１項に記載の不織布。 The nonwoven fabric according to any one of claims 1 to 6, wherein both of the two types of thermoplastic resins are polyolefin resins.
  8. 　前記不織布は親水化剤を含有している、請求項１～７のいずれか１項に記載の不織布。 The nonwoven fabric according to any one of claims 1 to 7, wherein the nonwoven fabric contains a hydrophilizing agent.
  9. 　請求項１～８のいずれか１項に記載の不織布を含む衛生材料。 A sanitary material comprising the nonwoven fabric according to any one of claims 1 to 8.
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