WO2020049747A1 - Air-through nonwoven fabric for absorbent article - Google Patents
Air-through nonwoven fabric for absorbent article Download PDFInfo
- Publication number
- WO2020049747A1 WO2020049747A1 PCT/JP2018/033325 JP2018033325W WO2020049747A1 WO 2020049747 A1 WO2020049747 A1 WO 2020049747A1 JP 2018033325 W JP2018033325 W JP 2018033325W WO 2020049747 A1 WO2020049747 A1 WO 2020049747A1
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- WIPO (PCT)
- Prior art keywords
- air
- fiber
- nonwoven fabric
- less
- absorbent article
- Prior art date
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- 239000004745 nonwoven fabric Substances 0.000 title claims abstract description 375
- 230000002745 absorbent Effects 0.000 title claims abstract description 181
- 239000002250 absorbent Substances 0.000 title claims abstract description 181
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- 238000003892 spreading Methods 0.000 claims description 17
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- 229920005989 resin Polymers 0.000 claims description 16
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Images
Classifications
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Definitions
- the present invention relates to an air-through nonwoven fabric for absorbent articles.
- the air-through nonwoven fabric is formed by blowing hot air by an air-through method to thermally fuse the intersections of the fibers, so that the air-through nonwoven fabric can be relatively thick and feel good. Therefore, it is often used as a constituent member of an absorbent article.
- Various proposals have been made on this air-through nonwoven fabric for absorbent articles.
- Patent Literature 1 from the viewpoint of imparting aesthetics by a pattern without impairing the feel, the difference between the thickness of a portion with a small fiber mass and the thickness of a portion without a small fiber mass under a pressure of 7.64 kPa is set to 1 mm or less.
- An air-through nonwoven is described.
- Patent Document 2 discloses an absorbent article provided with a nonwoven fabric having thermoplastic synthetic fibers and organic cotton fibers. In the nonwoven fabric, organic cotton fibers are arranged in a plurality of fiber masses. The organic cotton fibers are not heat-sealed, but are retained in the nonwoven fabric by the entanglement of the fibers.
- Patent Literature 3 describes that a completed nonwoven fabric is subjected to pressure treatment between a pair of rolls at a specific linear pressure and temperature from the viewpoint of improving the texture of the nonwoven fabric.
- Patent Literature 4 describes a processing method in which a fiber sheet wound in a roll shape is fed, hot air is blown by an air-through method, and calendering is performed at a specific linear pressure.
- JP 2013-151774 A JP, 2017-202265, A JP-A-60-126365 JP 2006-299480 A
- the present invention provides an air-through nonwoven fabric for an absorbent article, which is an air-through nonwoven fabric in which two or more fiber layers are laminated, and includes at least one fiber layer containing thermoplastic fibers and having a fiber lump. .
- the present invention also provides a fiber-spreading step of performing a fiber-spreading process on thermoplastic fibers a plurality of times to form a web, and laminating a plurality of single-layer webs obtained in the fiber-spreading step to form a laminated web. Subjecting the laminated web to air-through processing with hot air to obtain an air-through nonwoven fabric, and calendering the one or more selected from the single-layer web, the laminated web and the air-through nonwoven fabric using a pair of calender rolls. And a method for producing an air-through nonwoven fabric for an absorbent article.
- the present invention relates to the provision of a patterned air-through nonwoven fabric for an absorbent article which is excellent in bulkiness and soft touch.
- the fibers In the manufacturing process of the air-through nonwoven fabric, when the fibers are spread and formed into a web, the fibers may be entangled with each other to form a fiber mass partially. In particular, the smaller the fiber diameter, the more easily the fiber mass is generated.
- the fiber mass is subjected to an air-through processing step using hot air as it is, the fiber mass is cured by heat fusion between the fibers.
- calendering is performed on the completed nonwoven fabric to reduce the hardness.
- calendering is a process in which the air-through nonwoven fabric is pressed between a pair of rolls, and the air-through nonwoven fabric after the pressurization becomes thinner, so that there is room for improvement in bulkiness.
- Patent Document 3 Even if non-woven fabrics described in Patent Documents 1, 3 and 4 are subjected to hot air treatment after calendering, there is a limit to the recovery of the thickness of the non-woven fabric once collapsed, and there is room for further improvement. was there. In this respect, there is no suggestion in Patent Document 3 regarding the restoration of bulkiness. In air-through nonwoven fabrics for absorbent articles, it is strongly desired that both the bulkiness and the soft touch be further improved, from the viewpoints of the absorbency and cushioning properties of the absorbent articles.
- the air-through nonwoven fabric for absorbent articles of the present invention is excellent in bulkiness and soft touch, and has a pattern. Further, according to the production method of the present invention, the air-through nonwoven fabric for absorbent articles can be produced with high accuracy.
- the air-through nonwoven fabric for an absorbent article of the present invention can be applied to various absorbent articles that are attached to a body and absorb body fluid, and can be applied to various constituent members such as a surface sheet in the absorbent article.
- the side in contact with the human body is referred to as the skin side or the skin contact side or the front side, and the opposite side is referred to as the non-skin side or the non-skin contact side or the back side.
- the “air-through nonwoven fabric” is one in which heat-fusible fibers are heat-sealed at intersections and integrated.
- the air-through method is used for manufacturing this nonwoven fabric.
- the air-through method refers to a method in which hot air is blown onto a fibrous web containing heat-fusible fibers in a penetrating manner to fuse intersections of the webs to form a nonwoven fabric.
- the air-through nonwoven fabric for absorbent articles of the present invention is an air-through nonwoven fabric in which two or more fiber layers are laminated.
- the number of the fiber layers to be laminated may be two or three or more. Since the air-through nonwoven fabric for an absorbent article of the present invention has two or more layers, it becomes possible to obtain a bulky nonwoven fabric that exceeds manufacturing restrictions as compared with a case where a nonwoven fabric is formed with one layer.
- FIG. 1 shows an air-through nonwoven fabric 10 for an absorbent article (hereinafter simply referred to as a nonwoven fabric 10) in which two fiber layers (fiber layers 1 and 2) are laminated as a preferred embodiment of the air-through nonwoven fabric for an absorbent article of the present invention. ).
- the fiber layer 1 and the fiber layer 2 contain heat-fusible fibers, and the contact surfaces of both layers are joined over the entire area by fusion of the heat-fusible fibers. Therefore, the nonwoven fabric 10 does not have a region where the fiber layer 1 and the fiber layer 2 are separated from each other. That is, the nonwoven fabric 10 is a single sheet body in which the two layers are integrated.
- the nonwoven fabric of the present invention may have various surface shapes such as an uneven surface, like the nonwoven fabric 10 of the present embodiment shown in FIG. 1, both sides 10A and 10B (the surface of the fiber layer 1 and the fiber layer 2 Is preferably flat.
- the nonwoven fabric 10 is a laminate of a plurality of fiber layers and has a flat shape on both sides, so that both the smoothness of the surface and the cushioning feel are excellent, and the nonwoven fabric 10 is excellent.
- the flat shape refers to a material having a thickness difference of 1 mm or less between the concave portion and the convex portion on the surface of the nonwoven fabric.
- the nonwoven fabric is cut in the thickness direction with a razor blade, and a photograph of a cross section is taken using a microscope (VHX-900, manufactured by Keyence Corporation).
- VHX-900 the thickness of the portion where the upper surface of the nonwoven fabric is located at the uppermost position, ie, the convex portion, and the portion where the upper surface of the nonwoven fabric is located at the lowermost position, ie, the thickness of the concave portion, are obtained by calculating the thickness difference.
- the nonwoven fabric 10 has at least one fiber layer 8 having the fiber mass 7.
- the fiber layer 8 having the fiber lump 7 is referred to as a fiber lump layer 8.
- the fiber lump layer 8 is arranged on the fiber layer 1.
- the term “fiber lump” refers to a knot (yarn lump) formed by entanglement of fibers in a fiber layer.
- the density of the fiber is higher than that of the peripheral portion in the same fiber layer, and the density (brightness) of the color (mainly white) of the fiber is higher than that of the peripheral portion (granularity). ).
- the shape of the fiber mass is not particularly limited.
- the fiber mass has a flat shape crushed in the thickness direction of the nonwoven fabric in a cross section in the thickness direction of the nonwoven fabric, and preferably has a structure in which the surface of the fiber mass portion on the surface side of the nonwoven fabric is smooth. Thereby, the surface of the nonwoven fabric corresponding to the position where the fiber mass 7 is present becomes smooth, and the surface feel of the nonwoven fabric 10 is felt to be more excellent.
- the “fiber lump layer 8” refers to a layer having one or more fiber lump portions.
- the fiber lump layer 8 does not need to be filled with the fiber lump 7 and is preferably dispersed.
- the fiber mass layer 8 is not limited to the case where the fiber mass layer 8 is provided only in the fiber layer 1 as shown in FIG. 1, but may be provided in the fiber layer 2 instead of the fiber layer 1 or in both layers. From the viewpoint of soft touch, it is preferable that any one layer be present. From the viewpoint of enhancing the visual effect of the pattern of the fiber lump 7 when the nonwoven fabric 10 is viewed in a plan view, it is preferable that both layers have the fiber lump layer 8. As a result, the pattern formed by the fiber clumps 7 appears to be dispersed not only in the plane direction but also in the thickness direction of the nonwoven fabric 10, and the concentration of the fiber clumps 7 seen in the thickness direction changes thinly as it is located on the lower layer side. You can see and see deeper patterns.
- the fiber lump layer 8 When the fiber lump layer 8 is provided in both the fiber layer 1 and the fiber layer 2, it is preferable that the fiber lump 7 of the fiber layer 1 and the fiber lump 7 of the fiber layer 2 are arranged so as not to overlap in the thickness direction.
- the fiber lump layer 8 may be disposed on the entire fiber layer (fiber layer 1 or fiber layer 2) on which the fiber lump layer 8 is disposed, or may be disposed on a part thereof.
- the nonwoven fabric 10 is formed by fusing fibers at the layer interface in an entire region where the fiber layer 1 and the fiber layer 2 are in contact with each other and integrated. Therefore, even when the nonwoven fabric 10 includes the fiber lump layer 8 having the fiber lump 7, the entire nonwoven fabric 10 in which a plurality of fiber layers are integrated at the entire layer interface is felt to be thick, and the bulk and soft touch are felt. And it will be excellent. Then, when the nonwoven fabric 10 is viewed in a plan view, a pattern is provided by the difference in the shade of color between a portion having a fiber lump and a portion having no fiber lump. The nonwoven fabric 10 is provided with aesthetics by the pattern of the fiber lump 7, particularly the pattern of the fiber lump 7 having a flattened thickness.
- the nonwoven fabric 10 of the present embodiment preferably has fine fibers having a fiber diameter of 1 dtex or more and 2.2 dtex or less, and thick fibers having a fiber diameter larger than the fine fibers.
- fine fibers having a fiber diameter of 1 dtex or more and 2.2 dtex or less
- thick fibers having a fiber diameter larger than the fine fibers.
- the fiber lump layer 8 contains the fine fibers.
- the fine fibers may be contained in the fiber lump 7 or may be contained in a portion other than the fiber lump 7. Thereby, the hardness around the fiber mass 7 felt when the nonwoven fabric 10 is touched is reduced by the presence of the fine fibers.
- the fiber layer 1 having the fiber lump layer 8 containing the fine fibers is preferably arranged toward the skin contact surface side of the absorbent article.
- the fiber diameter of the fine fibers is more preferably 2 dtex or less, and further preferably 1.5 dtex or less.
- the fiber diameter of the fine fibers is more preferably 1 dtex or more, and further preferably 1.2 dtex or more, from the viewpoint of the spinning property of the card machine in the production of the nonwoven fabric.
- the fiber diameter of the fine fiber is preferably from 1 dtex to 2 dtex, more preferably from 1.2 dtex to 1.5 dtex.
- the content of the fine fibers in the fiber mass layer 8 is preferably 50% by mass or more, more preferably 80% by mass or more, and still more preferably 100% by mass, from the viewpoint of improving the soft touch of the nonwoven fabric 10 as a mass ratio.
- the nonwoven fabric 10 of the present embodiment preferably has at least one fiber layer 9 having no fiber clump portion 7 (hereinafter, referred to as a non-fiber clump layer 9) in addition to the fiber clump layer 8 described above.
- a non-fiber clump layer 9 having no fiber clump portion 7
- FIG. 1 there is a form in which the fiber layer 1 is a fiber lump layer 8 and the fiber layer 2 is a non-fiber lump layer 9.
- the nonwoven fabric 10 When the nonwoven fabric 10 has the fiber lump layer 8 and the non-fiber lump layer 9, it may have a thick fiber having a fiber diameter of more than 2.2 dtex and 7 dtex or less and a fine fiber having a smaller fiber diameter than the thick fiber.
- the fiber diameter of the fine fiber is preferably in the above range.
- the non-fiber lump layer 9 includes the thick fibers.
- the nonwoven fabric 10 is preferably such that the fiber layer 2 having the non-fiber lump layer 9 containing thick fibers is arranged toward the non-skin contact surface side of the absorbent article.
- the fiber diameter of the thick fiber is more preferably more than 2.2 dtex, and more preferably 4.4 dtex or more, from the viewpoint of improving the bulkiness and compression recovery of the nonwoven fabric 10. Further, the fiber diameter of the thick fiber is preferably 5.5 dtex or less, more preferably 5 dtex or less, from the viewpoint of the feeling from the fiber lump layer side. Specifically, the fiber diameter of the thick fiber is preferably more than 2.2 dtex and 5.5 dtex or less, more preferably 4.4 dtex or more and 5 dtex or less.
- the content of the thick fiber in the non-fiber lump layer 9 is preferably 50% by mass or more, more preferably 80% by mass or more, and more preferably 100% by mass, from the viewpoint of improving the bulkiness and compression recovery of the nonwoven fabric 10 as a mass ratio. % Is more preferred.
- the content of the thick fibers in the fiber lump layer 8 is preferably 50% by mass or less, more preferably 30% by mass or less, and more preferably 10% by mass or less in terms of mass ratio, from the viewpoint of improving the soft touch of the nonwoven fabric 10. Is more preferred.
- the fluctuation width of the fiber diameter in the nonwoven fabric for an absorbent article is usually such a small difference that it is difficult to confirm even when observed with the above-mentioned scanning electron microscope.
- the fluctuation width of the fiber diameter is about 6% according to the fiber standard. Therefore, each fiber diameter can be used as long as the average value is obtained by measuring 20 points as described above.
- Fiber content An OHP film is placed on a photograph within 1 mm 2 enlarged and observed previously, and blacked out according to fiber diameter. This sheet is subjected to image analysis processing using image analysis software (NexusNewQube). Binarization processing is performed to determine the area. The area of each fiber is measured, and the ratio is defined as the content of each fiber.
- the average fiber diameter of the non-fiber lump layer 9 is preferably larger than that of the fiber lump layer 8.
- the fiber lump layer 8 becomes a layer for improving the soft touch of the nonwoven fabric 10
- the non-fiber lump layer 9 becomes a layer for improving the bulkiness and the thickness recovery of the nonwoven fabric 10.
- the fiber lump layer 8 and the non-fiber lump layer 9 can share the function of the non-woven cloth 10 in units of layers, and both layers cooperate in the thickness direction to improve the texture of the entire non-woven cloth 10. It can be.
- the nonwoven fabric 10 has the fine fibers and the thick fibers, and the fiber lump layer 8 includes the fine fibers, since the action can be more clearly exhibited.
- the non-fiber lump layer 9 contains the thick fiber from the same viewpoint.
- the difference V3 is preferably 5.6 dtex or less, more preferably 4 dtex or less, and still more preferably 3.5 dtex or less, from the same viewpoint as described above.
- the difference V3 is preferably more than 0 dtex and not more than 5.6 dtex, more preferably not less than 2.2 dtex and not more than 4 dtex, further preferably not less than 3 dtex and not more than 3.5 dtex.
- the basis weight of the non-fiber clump layer 9 is preferably larger than that of the fibrous clump layer 8.
- the non-fiber lump layer 9 becomes bulkier than the fiber lump layer 8, and the hardness of the fiber lump 7 becomes more difficult to perceive.
- the bulkiness of the non-fiber lump layer 9 acts to enhance the cushioning property of the entire nonwoven fabric 10, and further reduces the stress applied to the skin by the fiber lump 7 when the fibrous lump layer 8 is crushed in the thickness direction. As a result, good texture can be further improved.
- the nonwoven fabric 10 has the fine fibers and the thick fibers, and that the fiber lump layer 8 contains the fine fibers, since the above-mentioned action can be more clearly exhibited.
- the non-fiber lump layer 9 contains the thick fiber from the same viewpoint.
- the nonwoven fabric 10 preferably has a larger average fiber diameter in the non-fiber clump layer 9 than in the fibrous clump layer 8.
- the difference Y3 is preferably more than 0 g / m 2 and 20 g / m 2 or less, more preferably 3 g / m 2 or more and 15 g / m 2 or less, and further preferably 5 g / m 2 or more and 10 g / m 2 or less. preferable.
- Basis weight of each layer Each layer of the nonwoven fabric to be measured is carefully peeled off, and the value obtained by converting the mass per 1 m 2 is defined as the basis weight of each layer. [Unit: Number of digits] g / m 2 : Calculate to the first decimal place by rounding off the second decimal place. [Number of Measurements] Three points are measured, and the average value is defined as each grammage.
- the basis weight of the entire nonwoven fabric 10 is preferably 15 g / m 2 or more from the viewpoint of having excellent bulkiness and soft touch and having good texture in a structure in which two or more fiber layers are laminated and integrated. Preferably, it is 18 g / m 2 or more, more preferably 20 / m 2 or more.
- the basis weight of the entire nonwoven fabric 10 specifically, preferably from 15 g / m 2 or more 40 g / m 2 or less, 18 g / m, more preferably 2 or more 30 g / m 2 or less, 20 / m 2 or more 25 g / m 2 or less Is more preferred.
- the basis weight of the entire nonwoven fabric 10 is measured according to the above-mentioned (method of measuring the basis weight of the fiber lump layer 8 and the non-fiber lump layer 9).
- the thickness of the nonwoven fabric 10 measured at a pressure of 7.64 kpa at the position where the fiber lump 7 is disposed is defined as T1, and at the position where the fiber lump 7 is not disposed under the same pressure.
- T2 the thickness of the nonwoven fabric 10 measured in the above
- T3 T1 ⁇ T2
- a cushion feeling accompanying bulkiness due to the lamination of a plurality of fiber layers is easily felt, and soft touch is easily perceived.
- the thickness difference T3 is preferably equal to or less than 0.4 mm, more preferably equal to or less than 0.3 mm, still more preferably equal to or less than 0.2 mm, and most preferably 0 (zero) mm.
- the “position where the fiber mass portion is disposed” refers to the position of the fiber mass portion 7 on the surface of the nonwoven fabric 10 when viewed in plan from the surface on the pressing side of the front and back surfaces of the nonwoven fabric 10. Refers to a position at which the presence can be confirmed (hereinafter, the meaning is the same in the present specification). Further, the “position where the fiber lump portion is not arranged” means a position where the presence of the fiber lump portion 7 cannot be visually confirmed on the plane viewed from above (hereinafter, the same meaning in the present specification). ).
- the soft touch of the nonwoven fabric 10 is indicated by the value of the average friction coefficient, and the smaller the value, the better the touch.
- the value of the average friction coefficient is smaller in a portion where the fiber mass 7 is not arranged than in a portion where the fiber mass 7 is arranged.
- the nonwoven fabric 10 of the present embodiment is formed by laminating a plurality of fiber layers in the thickness direction and integrating them, and the average friction coefficient is reduced at the position where the fiber mass 7 is disposed.
- the average coefficient of friction (Q1) at the position where the fiber mass 7 of the nonwoven fabric 10 is arranged is preferably 2.5 or less, more preferably 2.4 or less, and further preferably 2.3 or less, from the viewpoint of maintaining soft touch. Preferably, 1.6 or more is realistic.
- the average friction coefficient (Q1) at the position where the fiber mass 7 of the nonwoven fabric 10 is arranged is preferably 1.6 or more and 2.5 or less, more preferably 1.6 or more and 2.4 or less. More preferably, it is from 0.6 to 2.3.
- the MIU value at the set position and at the position where the fiber mass portion is not arranged is measured.
- the measurement is performed at five or more points in each of two orthogonal directions (typically, the MD direction and the CD direction), and the average value is obtained.
- the MIU value is an average friction coefficient. The larger the value, the worse the surface is rough and the texture is poor. The smaller the MIU value, the smoother the texture and the better the texture.
- the above-mentioned fiber lump layer 8 is preferably the outermost layer of the nonwoven fabric 10.
- the fiber lump layer 8 may be provided only on one of the front and back surfaces of the nonwoven fabric 10 or the fiber lump layer 8 may be provided on both the front and back surfaces of the nonwoven fabric 10. Since the fiber mass layer 8 is the outermost layer of the nonwoven fabric 10, the visual effect is maximized.
- the number of the fiber mass portions 7 disposed on the nonwoven fabric 10 is 10 cm square when the front and back surfaces of the nonwoven fabric 10 are viewed in plan (in a plan view in a state where the respective fiber layers are stacked). Is preferably 50 or less, more preferably 40 or less, and even more preferably 30 or less.
- the number of fiber lump portions 7 arranged on the nonwoven fabric 10 is a 10 cm square area when the front and back surfaces of the nonwoven fabric 10 are viewed in a plan view (in a plan view in a state where the respective fiber layers are stacked).
- the average for each is preferably 5 or more, more preferably 10 or more, and even more preferably 20 or more.
- the number of the fiber mass portions 7 is, specifically, an average of 5 or more and 50 or less for each 10 cm square area when the front and back surfaces of the nonwoven fabric 10 are viewed in a plan view (in a plan view in a state where the respective fiber layers are stacked). It is preferably from 10 to 40, more preferably from 20 to 30.
- the number of the fiber lump 7 in the fiber layer on the skin side of the absorbent article in the laminated fiber layers is The average of each side of the fiber layer on a 10 cm square area in plan view is preferably 30 or less, more preferably 20 or less, and even more preferably 10 or less.
- the number of fiber lump portions 7 in the fiber layer on the skin side of the absorbent article is preferably one or more.
- the number of fiber clumps 7 in the fiber layer on the skin surface side of the absorbent article is, specifically, an average of 1 to 30 or less as an average for each area of 10 cm square in a plan view of the fiber layer on the skin surface side.
- the number of fiber clumps 7 arranged in the fiber layer on the non-skin surface side of the absorbent article is the non-skin surface side of the two laminated layers.
- 3 or more is preferable, 8 or more is more preferable, and 15 or more is further preferable.
- Individual fiber agglomerations portion 7 of the nonwoven fabric 10 when viewed in plan size (area), from the viewpoint of maintaining the soft touch of the nonwoven fabric 10 is preferably 10 mm 2 or less, 8 mm 2 or less, more preferably, is 6 mm 2 or less More preferred.
- the magnitude of the time of the nonwoven fabric 10 of the individual fiber agglomerations unit 7 viewed from above, from the viewpoint of imparting a pattern preferably 1 mm 2 or more, more preferably 2.5 mm 2 or more, 4 mm 2 or more is more preferable.
- the size of the time of the nonwoven fabric 10 of the fiber mass portion 7 disposed in the fiber layer to be a skin face side of the absorbent article is viewed in plane is preferably 9 mm 2 or less, more preferably 7 mm 2 or less, 5 mm 2 or less Is more preferred.
- the size of the nonwoven fabric 10 of the fiber lump 7 arranged in the fiber layer on the non-skin side of the absorbent article among the two laminated layers when viewed in plan Saga, 2 mm 2 or more, more preferably 3 mm 2 or more, 5 mm 2 or more is more preferable.
- the size (thickness) of the individual fiber mass portions 7 in the thickness direction of the nonwoven fabric 10 is preferably 50% or less, more preferably 40% or less, as a percentage of the thickness of the nonwoven fabric 10 from the viewpoint of maintaining the soft touch of the nonwoven fabric 10. It is preferably at most 30%.
- the size (thickness) of the individual fiber mass portions 7 in the thickness direction of the nonwoven fabric 10 is preferably as small as possible within a range of more than 0% as a percentage of the thickness of the nonwoven fabric 10 from the viewpoint of the feeling.
- the size (thickness) of the individual fiber mass portions 7 in the thickness direction of the nonwoven fabric 10 is preferably more than 0% and not more than 50%, more preferably more than 0% and not more than 40% as a ratio to the thickness of the nonwoven fabric 10. Is more preferable, and more than 0% and 30% or less is still more preferable.
- the fiber of the two layers laminated on the skin surface side of the absorbent article is preferably 50% or less, more preferably 40% or less, and still more preferably 30% or less, as a percentage of the thickness of the nonwoven fabric 10.
- the size (thickness) of the individual fiber mass portions 7 in the thickness direction of the nonwoven fabric 10 is preferably 1 mm or less, more preferably 0.8 mm or less, still more preferably 0.5 mm or less, from the same viewpoint as described above. Further, it is more preferable that the diameter is smaller than 0 mm.
- the size (thickness) of the individual fiber mass portions 7 in the thickness direction of the nonwoven fabric 10 is preferably greater than 0 mm and 1 mm or less, more preferably greater than 0 mm and 0.8 mm or less, and further preferably greater than 0 mm and 0.5 mm or less. preferable.
- a photograph is taken using a microscope (VHX-900, manufactured by KEYENCE CORPORATION) from the observation target surface of the nonwoven fabric cut into a 10 cm square (for example, the surface 10A of the nonwoven fabric 10).
- the image data (jpeg) is subjected to image analysis processing using image analysis software (NexusNewQube).
- a binarization process is performed to determine the number and area of the lumps. Further, the entire lump is cut in the thickness direction with a razor blade, and the cross section is observed with the microscope to measure the thickness of the nonwoven fabric and the thickness of the fiber lump.
- the air-through nonwoven fabric for an absorbent article of the present invention is used as a component of an absorbent article.
- the absorbent articles include various articles having a function of absorbing and retaining human excreted liquid, such as diapers, sanitary napkins, urine absorbing pads, and panty liners.
- the air-through nonwoven fabric for an absorbent article of the present invention is used as various members of the absorbent article according to its function, and is incorporated into the absorbent article. For example, when it has liquid permeability, it is incorporated as a topsheet, and when it has water repellency, it is incorporated as a sidesheet.
- the air-through non-woven fabric for absorbent articles of the present invention has an absorption property from the viewpoint of facilitating the feel of the non-woven fabric excellent in bulk and soft touch with the skin, and facilitating visual recognition of the pattern of the non-woven fabric. It is preferable to arrange the outermost layer on the skin side of the sexual article and arrange the fiber lump layer 8 toward the skin side.
- a surface sheet and a side sheet are mentioned, and it is particularly preferable to arrange the air-through nonwoven fabric for an absorbent article of the present invention on the absorbent article as the surface sheet.
- the fiber layers to be laminated are not limited to two layers (the fiber layer 1 and the fiber layer 2), and may be a layer in which three or more fiber layers are laminated.
- the manufacturing method of this embodiment includes the following steps 501 and 502.
- Step 501 a fiber-spreading step of performing a fiber-spreading process on thermoplastic fibers a plurality of times to form a web.
- Step 502 a step of laminating a plurality of single-layer webs obtained in the opening step to form a laminated web, and subjecting the laminated web to air-through processing with hot air to obtain an air-through nonwoven fabric.
- the manufacturing method of the present embodiment includes the following step 503.
- Step 503 a calendering step of using one pair of calender rolls for one or more selected from the single-layer web, the laminated web, and the air-through nonwoven fabric.
- Step 503 is performed after step 501, before step 502, during step 502, and / or after step 502.
- FIG. 2 shows a manufacturing apparatus 100 suitably used in the method for manufacturing the nonwoven fabric 10 of the present embodiment.
- the production apparatus 100 is obtained by carding, from the upstream side to the downstream side, the fiber-spreading units 101 and 102 of the fiber material amount used as the raw material of the nonwoven fabric, the carding units 103 and 104 forming the fiber web.
- the apparatus includes a laminated web forming section 105 for conveying and laminating a single-layer web, a web calender section 106 for performing a pressure treatment on the laminated web, and a heat treatment section (air through processing section) 107.
- the step 501 is performed in the opening units 101 and 102 and the carding units 103 and 104.
- the step 502 is performed in the laminated web forming unit 105 and the heat treatment unit 107.
- the step 503 is performed in the web calender unit 106.
- the web calender section 106 is disposed between the laminated web forming section 105 and the heat treatment section 107, and performs the step 503 as web calendering of the laminated web in the middle of the step 502.
- the opening units 101 and 102 each have a device for opening the thermoplastic fibers which are the raw materials of the fiber layers 1 and 2 and sending them to the next carding units 103 and 104, respectively.
- a raw fiber (thin fiber) 71 is input to the opening unit 101 to open the fiber (arrow 171)
- a raw fiber (thick fiber) 72 is input to the opening unit 102 to open the fiber (arrow). 172).
- thermoplastic fibers used for the air-through nonwoven fabric can be used.
- a composite fiber having a core-sheath structure in which the resin component of the sheath has a lower melting point than that of the resin component of the core may be used.
- the carding units 103 and 104 receive the fibers spread in the opening units 101 and 102 (arrows 173 and 174), and form single-layer webs 81 and 82. Specifically, the aggregate of the fibers spread in the fiber-spreading units 101 and 102 is combed and further spread to form a sheet-like web.
- the carding section 103 forms a single layer web 81 based on the raw fibers (fine fibers) 71, and the carding section 104 forms a single layer web 82 based on the raw fibers (thick fibers) 72.
- various card machines usually used for manufacturing an air-through nonwoven fabric can be used without any particular limitation.
- a parallel card machine, a semi-random card machine, a random card machine, a parallel card machine combined with a cross layer and a drafter, and the like can be mentioned.
- the card machine includes one provided with three types of rolls of a main cylinder roll, a worker roll, and a stripper roll covered with a saw-toothed metallic wire.
- the fiber aggregate can be broken between the main cylinder roll, the worker roll, and the stripper roll to perform fiber opening.
- both the opening units 101 and 102 and the carding units 103 and 104 perform the opening operation a plurality of times.
- a spreading step of forming a web by applying a plurality of spreading processes to the thermoplastic fibers in the above-described opening sections 101 and 102 and carding sections 103 and 104 step 501. I do.
- the laminated web 90 is formed by laminating the single-layer web 82 formed in the carding section 104 on the single-layer web 81 formed in the carding section 103.
- the single-layer web 81 is carried out from the carding section 103 along the carry-out belt 103A and is placed on the carrying belt 105A.
- the transport belt 105A transports the single-layer web 81 downstream.
- the single-layer web 82 is carried out from the carding along the carry-out belt 104A, guided to the transport belt 105A, and stacked on the single-layer web 81 being transported.
- the laminated web 90 thus formed is transported further downstream along the transport belt 105A.
- portions corresponding to the single-layer webs 81 and 82 are simply referred to as webs 81 and 82.
- the web 82 is formed from the raw fibers (thick fibers) 72, and the web 81 is formed from the raw fibers (fine fibers) 71. Therefore, the average fiber diameter of the web 82 is larger than the average fiber diameter of the web 81. From this, the web 81 becomes the fiber mass layer 8 containing the fine fibers having the specific fiber diameter in the completed nonwoven fabric 10.
- the web 82 can be the non-fiber lump layer 9 containing the thick fibers having the specific fiber diameter in the completed nonwoven fabric 10.
- increasing the basis weight of the non-fibrous lump layer 9 in the completed nonwoven fabric 10 compared to the fibrous lump layer 8 can reduce the supply mass of the fiber from the spreader 102 to the carding unit 104 from the spreader 101. This can be realized by increasing the supply mass of the fiber to the carding portion 103.
- the manufacturing method of the present embodiment it is preferable to form a laminated web using a plurality of types of fibers having different fiber diameters.
- the fibers having different fiber diameters it is preferable that the above-mentioned fine fibers having a fiber diameter of 1 dtex or more and 2.2 dtex or less are used. Further, the fiber diameter of the fine fiber is more preferably in the range of the fiber diameter described above.
- the web calender 106 performs web calendering by pressing the conveyed laminated web 90 between a pair of calender rolls 106A and 106B (hereinafter, may be simply referred to as “calendering”). This makes it possible to smooth the web surface at a certain portion of the fiber lump 7 and reduce the hardness of the fiber lump 7.
- the fibers are not yet fixed by fusion, and the fibers can be largely moved. . That is, in the calendering according to the present embodiment, there is no possibility that the fibers are separated or broken at the fused portion of the fibers, and the fibers gathering in the fiber lump 7 are preferably separated while maintaining the state of the fibers in a good state. (The distance between the fibers is widened), and the fiber lump 7 can be satisfactorily crushed. Thereby, the effect of reducing the hardness of the fiber mass 7 is enhanced.
- the fibers of the fiber lump 7 are easily separated from each other in any of the laminated webs 81 and 82 before forming the nonwoven fabric, and the fiber lump 7 (Hereinafter, a laminated web subjected to web calendering may be referred to as a laminated web 95).
- a laminated web subjected to web calendering may be referred to as a laminated web 95.
- the air-through process can be used as a process for recovering the thickness of the nonwoven fabric. That is, in the present embodiment, the processing steps performed in this order are significant for recovering the thickness of the laminated web 95, forming a bulkier and softer touch, and forming a pattern.
- the laminated web 95 subjected to the web calendering is subjected to air through processing by hot air.
- the heat treatment section 107 has a hood 107A and a conveyor belt 107B provided with a gas permeable net that circulates in the hood 107A.
- hot air is blown from above toward the conveyor belt 107B (arrow F shown in FIG. 2).
- the conveyor belt 107B the blown hot air blows through the air permeable net.
- the web 95 subjected to web calendering is extruded to the heat treatment unit 107 by the rotation of the roll of the web calender unit 106.
- the laminated web 95 is transported into the hood 107A by the conveyor belt 107B. Hot air heated to a predetermined temperature is blown from above the laminated web 95 (that is, from above the web 82) to the laminated web 95 in the hood 107A by a penetration method. That is, air through processing is performed on the laminated web 95. Thereby, in the laminated web 95, the interval between the fibers in the fiber lump 7 is widened by the web calendering process described above, and the intersection of the fibers is blown by blowing hot air in a fiber state in which the hardness of the fiber lump 7 is relaxed. Are fused. Thereby, the air-through nonwoven fabric 10 for an absorbent article of the present embodiment is obtained.
- the single-layer webs 81 and 82 obtained through the opening step of the step 501 are subjected to the laminating web forming section 105, the web calender section 106, and the heat treatment section 107.
- Step 502 and Step 503 are performed. Specifically, a process 502 by the laminated web forming unit 105 and the heat treatment unit 107 and a calendering process (process 503) by the web calender unit 106 on the way are performed.
- the air-through nonwoven fabric 10 for an absorbent article having a pattern that is excellent in bulkiness and soft touch and has a pattern can be manufactured with high accuracy.
- the manufactured air-through nonwoven fabric 10 for an absorbent article is wound into a roll as required.
- the calendering step (step 503) is performed on the laminated web 90 before the air-through processing.
- the present invention is not limited thereto, and the single-layer web 81 and the single-layer web 82 before lamination may be individually calendered, or the air-through nonwoven fabric after the air-through processing may be calendered.
- the air-through nonwoven fabric to be processed is a raw material air-through nonwoven fabric before becoming the air-through nonwoven fabric 10 for an absorbent article of the present embodiment.
- the fiber lump 7 is crushed by the calender, and portions other than the fiber lump 7 are smoothed and smoothed by calendering. . Since the nonwoven fabric 10 having a smooth surface is integrated while maintaining the thickness of the plurality of fiber layers, the thickness and the cushion are such that the feeling of foreign matter (discomfort) that touches the skin of the fiber mass 7 is reduced. It will have the nature.
- the fiber mass can be crushed in a consistent manufacturing process of the nonwoven fabric. Therefore, it is not necessary to introduce a fiber lump inspection device after the production of the nonwoven fabric, and the production cost can be reduced. Further, since the post-manufacturing inspection process, the post-calendering process, and the hot-air recovery process are not required, the production efficiency of the nonwoven fabric can be improved.
- the above calendering is preferably a web calendering performed on one or a plurality of webs selected from a single-layer web or a laminated web.
- the calendering process is not limited to being performed in only one stage among the single-layer web stage, the laminated web stage, and the air-through nonwoven fabric stage, and may be performed in two or more stages.
- the calendar processing is not limited to being performed once in each stage, but may be performed two or more times.
- the present invention is not limited to the case where the calendar processing is performed only once on the laminated web 90, and may be performed two or more times.
- the linear pressure in the calendering process that is, the linear pressure applied to the laminated web 90, the single-layer webs 81 and 82, and the air-through nonwoven fabric (raw air-through nonwoven fabric) sandwiched by the calender rolls 106A and 106B increases the single-layer web in all processes.
- all rolls as used herein means all rolls used in all manufacturing steps, in addition to the above-described calender rolls 106A and 106B. For example, a nip roll for conveying the nonwoven fabric after the heat treatment, a nip roll and a press roll for winding, and a press roll for slitting thereafter are applicable.
- the linear pressure (P) applied to the single-layer webs 81 and 82 and the laminated web 90 is set to 20 N / p from the point of effectively reducing the hardness of the fiber mass 7 before heat fusion. cm or more, more preferably 100 N / cm or more, even more preferably 180 N / cm or more.
- the linear pressure (P) is preferably 700 N / cm or less, more preferably 500 N / cm or less, and further preferably 250 N / cm or less, from the viewpoint of the recovery of the thickness after pressing.
- the linear pressure (P) is preferably from 20 N / cm to 700 N / cm, more preferably from 100 N / cm to 500 N / cm, even more preferably from 180 N / cm to 250 N / cm.
- a pair of calender rolls 106A and 106B used in the web calender unit 106 are smooth rolls.
- Various materials used for calendering can be used as the material.
- the material of the calendar roll 106A and the material of the calendar roll 106B may be the same or different.
- the calender roll used for calendering is preferably a combination of a resin roll and a steel roll from the viewpoint of further increasing the effect of reducing the hardness of the fiber mass 7.
- the calender roll 106 ⁇ / b> A is assumed to be in contact with the web 82 including the thick fiber of the laminated web 90, and the steel roll is used as the calender roll 106 ⁇ / b> B.
- a resin roll is used to abut on 81.
- the arrangement of the resin roll and the steel roll is not limited to this, and may be a reverse combination.
- the hardness of the resin roll is preferably 20 degrees or more, more preferably 50 degrees or more, and still more preferably 80 degrees or more in D hardness (JIS # K6253-3) from the viewpoint of further enhancing the effect of reducing the hardness of the fiber mass 7. .
- the hardness of the resin roll is preferably 100 degrees or less, more preferably 95 degrees or less, and further preferably 90 degrees or less in D hardness (JIS # K6253-3).
- the hardness of the resin roll is preferably from 20 to 100 degrees, more preferably from 50 to 95 degrees, and still more preferably from 80 to 90 degrees.
- the air-through processing preferably includes a plurality of air-through processings.
- FIG. 3 shows an aspect of a heat treatment section (air through processing section) having a first air through processing section 117 and a second air through processing section 127.
- the air through processing is performed twice, that is, the first air through processing and the second air through processing.
- the number of air-through processes is not limited to two in FIG. 3, but may be three or more.
- the “post-stage air-through processing” with respect to the “first air-through processing” means the second and subsequent air-through processings. In the two air-through processings shown in FIG.
- first air-through processing is a first air-through processing
- subsequent air-through processing means a second air-through processing.
- air-through process two air-through processes
- hot air is blown on the hood 107C of the first air-through processing unit 117 (arrow F1)
- hot air is blown on the hood 107D of the second air-through processing unit 127 (arrow).
- F2 the laminated web 95 subjected to the web calendering is continuously conveyed from the first air-through processing section 117 to the second air-through processing section 127 by the conveyor belt 107B.
- the first air-through processing and the second air-through processing are continuously performed on the laminated web 95.
- the subsequent air-through process has a higher velocity of the hot air than the first air-through process, that is, the first air-through process is performed at a low wind speed.
- the collapse of the bulk due to the wind pressure in the air-through processing section is suppressed, the hot air recovery effect is exhibited, and the web becomes bulky.
- the above-described processing in the subsequent air-through processing is effective.
- the wind speed S1 of the hot air in the first air-through processing is preferably 0.2 m / sec or more, more preferably 0.25 m / sec or more, and even more preferably 0.4 m / sec or more.
- the wind speed S1 of the hot air in the first air-through processing is preferably 1.2 m / sec or less, more preferably 0.8 m / sec or less, and even more preferably 0.5 m / sec or less.
- the wind speed S1 is preferably from 0.2 m / sec to 1.2 m / sec, more preferably from 0.25 m / sec to 0.8 m / sec, and more preferably from 0.4 m / sec to 0.5 m / sec. / Sec or less is more preferable. Thereby, the collapse of the web is suppressed, and the effect of recovering the thickness is exhibited.
- the wind speed S2 of the hot air in the subsequent air-through processing is preferably 0.8 m / sec or more, more preferably 0.9 m / sec or more, and further preferably 1.2 m / sec or more.
- the wind speed S2 of the hot air in the subsequent air-through processing is preferably 1.6 m / sec or less, more preferably 1.4 m / sec or less, and still more preferably 1.3 m / sec or less.
- the wind speed S2 is preferably 0.8 m / sec or more and 1.6 m / sec or less, more preferably 0.9 m / sec or more and 1.4 m / sec or less, and 1.2 m / sec or more and 1.3 m or less.
- / Sec or less is more preferable. This allows air to penetrate the web evenly, effectively providing thermal energy, resulting in a nonwoven fabric structure.
- both the recovery of the bulk and the nonwoven fabric can be effectively realized.
- the temperature of the hot air is higher in the later-stage air-through process than in the first air-through process.
- the fusion of the fibers proceeds in a stepwise manner, whereby the recovery of the web in the air-through processing portion is effectively exhibited.
- the above-described effect in the subsequent air-through processing is higher.
- the temperature P1 of the hot air in the first air-through treatment is preferably 85 ° C. or higher, more preferably 90 ° C. or higher, and even more preferably 100 ° C. or higher.
- the temperature P1 of the hot air in the first air-through treatment is preferably 134 ° C. or lower, more preferably 115 ° C. or lower, and further preferably 105 ° C. or lower.
- the temperature P1 of the hot air in the first air-through treatment is preferably from 85 ° C to 134 ° C, more preferably from 90 ° C to 115 ° C, and still more preferably from 100 ° C to 105 ° C.
- the temperature P2 of the hot air in the subsequent air-through treatment is equal to or higher than the melting point of the component of the fiber surface used (for example, the sheath portion in the core-sheath composite fiber), preferably 145 ° C or lower, more preferably 137 ° C or lower, and 134. C. or lower is more preferable. More specifically, the temperature P2 of the hot air in the subsequent air-through treatment is preferably from the melting point of the component on the fiber surface to be used to 145 ° C or less, more preferably from the melting point of the component on the fiber surface to be used to 137 ° C or less. The temperature is more preferably from the melting point of the surface component to 134 ° C. As a result, it is possible to produce a nonwoven fabric having a good texture and a soft touch.
- the temperature is more preferably 30 ° C or more and 35 ° C or less. This makes it possible to produce a bulky nonwoven fabric having a good texture.
- step 504 it is preferable to temporarily collect unnecessary portions such as cut pieces generated in the manufacturing process and return to the fiber opening process again (step 504). ).
- step 504 a step of recovering the widthwise end of the web in the carding machine used in the opening step, and a step of partially collecting the air-through nonwoven fabric and cutting and opening the collected air-through nonwoven portion And one or both of fibering steps.
- the collected web and the portion of the air-through nonwoven fabric cut and opened are subjected to the opening step.
- the portion of the air-through nonwoven fabric to be cut and opened includes a cut portion at an end in the width direction, and is not limited to this, and refers to a processed condition-adjusted product or a nonstandard product generated in the nonwoven fabric manufacturing process.
- FIG. 2 shows a specific example of the step 504.
- the ends (not shown) in the width direction are collected by suction (arrows 181 and 182).
- the air-through nonwoven fabric 10 obtained by performing the air-through processing in the heat treatment unit 107 is partially collected (arrow 183).
- the collected air-through nonwoven fabric cannot be reused as it is, it is cut at the cutting / spreading unit 108 and spread to return to a fibrous state.
- the collected web and the portion of the air-through nonwoven fabric cut and opened are returned to the opening section 101, opened again, and used as a material for forming a web (arrow 184).
- FIG. 2 shows that the fiber is returned to the fiber opening unit 101.
- a new raw material fiber fine fiber
- the ratio of the fine fiber in the formed web 81 is maintained at a certain level or more and the content of the thick fiber is kept within several% (for example, within 5%). It is preferable to appropriately adjust the input amount of the (fiber) 71.
- the web 81 contains a large amount of fine fibers while forming the fiber mass portion 7, and a soft touch on the surface 10 ⁇ / b> A side of the nonwoven fabric 10 can be realized. Further, the return of the material is not limited to the embodiment shown in FIG.
- a mode in which the material collected from the carding unit 103 is returned to the opening unit 101 and the material collected from the carding 104 is returned to the opening unit 102 may be adopted. At that time, it is preferable to return the cut-off and opened air-through nonwoven fabric portion to the opening portion 102.
- the patterned nonwoven fabric 10 having excellent bulkiness and soft touch and having a pattern can be suitably manufactured.
- the nonwoven fabric 10 is provided with aesthetics due to the pattern of the fiber lump 7, particularly the pattern of the flat fiber lump 7.
- the obtained air-through nonwoven fabric for an absorbent article of the present invention is incorporated as a predetermined constituent member in the absorbent article according to the purpose in the manufacturing process of the absorbent article (incorporation step).
- the incorporation step is preferably, for example, the following step. That is, the obtained air-through nonwoven fabric for an absorbent article of the present invention is prepared by cutting it into a size or a shape according to the purpose, and is placed at a predetermined position with respect to other constituent members. Next, if necessary, the member is rotated and folded together with other members, and is joined and incorporated into an absorbent article.
- the target absorbent article is manufactured through the step of incorporating the air-through nonwoven fabric for the absorbent article of the present invention in the manufacturing step of the absorbent article.
- the air-through nonwoven fabric for absorbent articles of the present invention achieves both bulkiness and soft touch, and has a pattern that can be visually appealed to the user. It is preferably a step of incorporating the outermost layer member (for example, a topsheet or a sidesheet) on the skin side.
- the absorbent article into the absorbent article as a surface sheet that touches the skin and is most noticeable.
- the air-through nonwoven fabric for an absorbent article of the present invention has a configuration in which the fiber layer having the fiber lump is the outermost layer of the nonwoven fabric. It is more preferable that the air-through nonwoven fabric for an absorbent article of the present invention is arranged on the outermost layer on the skin side of the absorbent article, and the fiber layer having the fiber mass is arranged toward the skin side of the absorbent article. .
- the present invention further discloses the following air-through nonwoven fabric for absorbent articles and a method for producing the air-through nonwoven fabric for absorbent articles.
- An air-through nonwoven fabric for an absorbent article which is an air-through nonwoven fabric in which two or more fiber layers are laminated, wherein the air-through nonwoven fabric contains thermoplastic fibers and has at least one fiber layer having a fiber mass portion.
- the air-through nonwoven fabric for absorbent articles has a fiber diameter of 1 dtex or more and 2.2 dtex or less, preferably 1 dtex or more, more preferably 1.2 dtex or more, preferably 2 dtex or less, more preferably 1.5 dtex or less, Having a thick fiber with a larger fiber diameter than the fine fiber,
- the content of the fine fibers in the fiber layer having the fiber mass portion is 50% by mass or more, preferably 80% by mass or more, and more preferably 100% by mass.
- the air-through nonwoven fabric for absorbent articles has a fiber diameter of more than 2.2 dtex and 7 dtex or less, preferably more than 2.2 dtex, more preferably 4.4 dtex or more, preferably 5.5 dtex or less, more preferably 5 dtex or less. And, having a fine fiber having a smaller fiber diameter than the thick fiber,
- ⁇ 6> The absorbent article according to ⁇ 5>, wherein the content of the thick fiber in the fiber layer having no fiber mass portion is 50% by mass or more, preferably 80% by mass or more, and more preferably 100% by mass.
- the content of the thick fiber in the layer having the fiber mass portion is 50% by mass or less, preferably 30% by mass or less, more preferably 10% by mass or less.
- Air-through nonwoven fabric for absorbent articles. ⁇ 8> The air-through nonwoven fabric for an absorbent article according to any one of ⁇ 4> to ⁇ 7>, wherein the average fiber diameter of the fiber layer having no fiber lump is greater than the fiber layer having the fiber lump.
- the difference between the average fiber diameter of the fiber layer having no fiber lump and the average fiber diameter of the fiber layer having the fiber lump is more than 0 dtex and 5.6 dtex or less, preferably 2.2 dtex or more, more preferably
- the difference between the basis weight of the fiber layer having no fiber lump and the basis weight of the fiber layer having the fiber lump is more than 0 g / m 2 and 20 g / m 2 or less, preferably 3 g / m 2 or more,
- the basis weight of the whole air-through nonwoven fabric for absorbent articles is 15 g / m 2 or more and 40 g / m 2 or less, preferably 18 g / m 2 or more, more preferably 20 / m 2 or more, and preferably 30 g / m 2 or less.
- T1-T2 The thickness of the air-through nonwoven fabric for an absorbent article measured at a pressure of 7.64 kPa at the position where the fiber lump is disposed is T1, and the thickness is measured at the position where the fiber lump is not disposed at the same pressure.
- the average friction coefficient of the air-through nonwoven fabric for the absorbent article at the position where the fiber mass is disposed is 1.6 or more and 2.5 or less, preferably 1.6 or more, preferably 2.4 or less, more preferably.
- the difference between the average friction coefficient of the air-through nonwoven fabric for the absorbent article at the position where the fiber lump is arranged and the average friction coefficient at the position where the fiber lump is not arranged is 0.7 or less, preferably 0 or less.
- ⁇ 17> The air-through nonwoven fabric for an absorbent article according to any one of ⁇ 1> to ⁇ 16>, wherein the fiber layer having the fiber lump portion is an outermost layer of the air-through nonwoven fabric for the absorbent article.
- An absorbent article comprising the air-through nonwoven fabric for an absorbent article according to any one of ⁇ 1> to ⁇ 17>.
- a method for producing an air-through nonwoven fabric for an absorbent article comprising: a calendering step of applying one or more of the single-layer web, the laminated web and the air-through nonwoven fabric using a pair of calender rolls.
- a linear pressure applied to the single-layer web or the laminated web is 20 N / cm or more and 700 N / cm or less, preferably 100 N / cm or more, more preferably 180 N / cm or more, and preferably 500 N / cm.
- the wind speed of the hot air in the first air-through treatment is 0.2 m / sec or more and 1.2 m / sec or less, preferably 0.25 m / sec or more, more preferably 0.4 m / sec or more, and preferably 0.8 m / sec or more.
- the method for producing an air-through nonwoven fabric for absorbent articles according to ⁇ 27> wherein the air-through nonwoven fabric is not more than 0.5 sec / sec, more preferably not more than 0.5 m / sec. ⁇ 29>
- the wind velocity of the hot air in the latter air-through treatment is 0.8 m / sec or more and 1.6 m / sec or less, preferably 0.9 m / sec or more, more preferably 1.2 m / sec or more, and preferably 1.4 m / sec or more.
- the difference between the wind speed of the hot air in the first air-through process and the wind speed of the hot air in the subsequent air-through process is more than 0 m / sec and 1.4 m / sec or less, preferably 0.4 m / sec or more, and more preferably 0.1 m / sec or more.
- the temperature of the hot air in the first air-through treatment is 85 ° C. or more and 134 ° C. or less, preferably 90 ° C. or more, more preferably 100 ° C. or more, preferably 115 ° C. or less, and more preferably 105 ° C. or less.
- the temperature of the hot air in the subsequent air-through treatment is not less than the melting point of the component on the fiber surface used and not more than 145 ° C., preferably not less than the melting point of the component on the fiber surface used, preferably not more than 137 ° C., more preferably not more than 134 ° C.
- the method for producing an air-through nonwoven fabric for an absorbent article according to ⁇ 31> or ⁇ 32>, wherein ⁇ 34> The difference between the temperature of the hot air in the first air through process and the temperature of the hot air in the subsequent air through process is more than 0 ° C. and 60 ° C. or less, preferably 20 ° C. or more, more preferably 30 ° C. or more, and preferably 40 ° C. or less.
- ⁇ 35> A step of collecting the width direction end of the web in the carding machine used in the opening step, and a step of partially collecting the air-through nonwoven fabric and cutting and opening the collected air-through nonwoven portion.
- ⁇ 36> The method for producing an air-through nonwoven fabric for absorbent articles according to any one of the above items ⁇ 21> to ⁇ 35>, wherein the laminated web has a plurality of types of fibers having different fiber diameters.
- the laminated web has fine fibers having a fiber diameter of 1 dtex or more and 2.2 dtex or less, preferably 1 dtex or more, more preferably 1.2 dtex or more, preferably 2 dtex or less, more preferably 1.5 dtex or less.
- a method for producing an absorbent article comprising a step of incorporating the air-through nonwoven fabric for an absorbent article produced by the production method according to any one of ⁇ 21> to ⁇ 37> into the absorbent article.
- the method for producing an absorbent article according to ⁇ 38> further comprising a step of incorporating the air-through nonwoven fabric for an absorbent article as a surface sheet into the absorbent article.
- Example 1 Using the manufacturing apparatus shown in FIG. 2, a nonwoven fabric sample of Example 1 was produced as shown below at a processing speed of 10 m / min.
- a raw material fiber (fine fiber) 71 forming the fiber layer 1 a core-sheath type thermoplastic fiber having a fiber diameter of 1.4 dtex (core is polyethylene terephthalate resin, sheath is polyethylene resin) was used.
- the fiber opening processing was performed a plurality of times in the fiber opening part 101 and the carding part 103 to produce a single-layer web 81 having a basis weight of 10 g / m 2 .
- the raw material fiber (thick fiber) 72 forming the fiber layer 2 a thermoplastic fiber of a core-sheath type having a fiber diameter of 4.4 dtex (core is polyethylene terephthalate resin, sheath is polyethylene resin) was used.
- the raw fiber 72 was subjected to multiple opening processing in the opening section 102 and the carding section 104 to produce a single-layer web 82 having a basis weight of 15 g / m 2 .
- the laminated web forming unit 105 the laminated web 90 was formed by laminating the single-layer web 82 on the single-layer web 81.
- the web calender section 106 the laminated web 90 was subjected to web calendering.
- the linear pressure was set to 200 N / cm using a calender roll 106A of a steel body on the upper layer side and a resin roll 106B (D hardness: 90 degrees) of the lower layer side.
- the laminated web 95 subjected to the web calendering was subjected to the air-through processing in which the air-through processing shown in FIG.
- the wind speed and temperature of the first air-through process and the second air-through process were as shown in Table 1.
- a nonwoven fabric sample of Example 1 was produced.
- the widthwise end of the formed web and a part of the nonwoven fabric were not recovered and returned to the fiber opening step. Therefore, the fiber diameter of the raw fiber (fine fiber) 71 was the average fiber diameter of the fiber layer 1, and the fiber diameter of the raw fiber (thick fiber) 72 was the average fiber diameter of the fiber layer 2.
- Example 2 to 7 Nonwoven fabric samples of Examples 2 to 7 were produced in the same manner as in Example 1 except that the temperature and the wind speed of the first air-through treatment were as shown in Table 1.
- Example 8 A nonwoven fabric sample of Example 8 was produced in the same manner as in Example 1 except that the nonwoven fabric after air-through processing was subjected to the nonwoven fabric calendering processing shown in Table 1 without performing web calendering.
- Example 1 was repeated in the same manner as in Example 1 except that the fiber diameter of the raw material fibers (fine fibers) forming the fiber layer 1 was 2.0 dtex, and the temperature and wind speed of the first air-through treatment were as shown in Table 1. Nine nonwoven fabric samples were prepared.
- Example 10 A nonwoven fabric sample of Example 10 was produced in the same manner as in Example 9, except that the fiber diameter of the raw material fiber 72 forming the fiber layer 2 was 2.0 dtex.
- Example 11 The same procedure as in Example 10 was carried out except that the fiber diameter of the raw fibers (fine fibers) forming the fiber layer 1 and the fiber diameter of the raw fibers 71 forming the fiber layer 2 (lower layer) were 1.4 dtex. Eleven nonwoven fabric samples were prepared.
- Example 12 A nonwoven fabric sample of Example 12 was produced in the same manner as in Example 11, except that the temperature and the wind speed of the first air-through treatment were as shown in Table 2.
- Example 13 A nonwoven fabric sample of Example 13 was prepared in the same manner as in Example 12, except that the nonwoven fabric after air-through processing was subjected to the nonwoven fabric calendaring shown in Table 2 without performing web calendering.
- Comparative Example 1 A nonwoven fabric sample of Comparative Example 1 was prepared in the same manner as in Example 1 except that the calendering was not performed.
- Comparative Example 2 A nonwoven fabric sample of Comparative Example 2 was produced in the same manner as in Comparative Example 1, except that the fiber diameter of the raw material fiber 71 forming the fiber layer 2 (lower layer) was 1.4 dtex.
- Thickness of nonwoven fabric sample under 0.05 kPa load Measured using a laser sensor (model number ZS-LD80) and a controller (model number ZS-LDC11) manufactured by OMRON Corporation as a laser thickness gauge. When measuring the thickness, a weight (0.05 kpa) was placed between the tip of the laser sensor and the nonwoven fabric sample to be measured, and the thickness in such a pressurized state was measured. The measurement was performed at five or more points, and the average value was obtained. Note that 0.05 kPa is a load assuming the apparent thickness of the nonwoven fabric so as not to crush the thickness as much as possible.
- Example 1 to 13 compared to Comparative Examples 1 and 2, the thickness T1 at the position where the fiber lump was disposed under the pressure of 7.64 kPa and the fiber lump were not disposed.
- the difference T3 from the thickness T2 at the position was small, and the bulkiness of the entire nonwoven fabric was excellent.
- the non-woven fabric subjected to the heat treatment after the web calender was thicker than the non-woven fabric calendered after the non-woven fabric, and had a good texture of the fiber mass portion.
- the average friction coefficient Q1 at the position where the fiber lump was arranged and the position where the fiber lump was not arranged were compared with Comparative Examples 1 and 2 while the pattern of the fiber lump was confirmed.
- the average friction coefficient Q2 and the difference Q3 between the two were small, and soft touch was realized in the entire nonwoven fabric.
- Examples 1 to 13 were excellent in bulkiness and soft touch, were provided with patterns, and were excellent in aesthetics.
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Abstract
Description
例えば、特許文献1には、肌触りを損なわず、模様による審美性を付与する観点から、7.64kPa加圧下における小繊維塊のある部位の厚みと無い部位の厚みとの差を1mm以下とするエアスルー不織布が記載されている。このエアスルー不織布の製造方法として、熱風吹き付け処理によって得られた予備不織布に対してカレンダー加工を施すことが記載されている。また、特許文献2には、熱可塑性の合成繊維とオーガニックコットン繊維とを有する不織布を備えた吸収性物品が記載されている。前記不織布において、オーガニックコットン繊維が複数の繊維塊を形成して配されている。このオーガニックコットン繊維は熱融着されず、繊維同士の絡み合いによって不織布内に留められている。
特許文献3には、不織布の風合いを改良する観点から、完成された不織布に対し、一対のロール間で特定の線圧及び温度にて加圧処理することが記載されている。
特許文献4には、ロール状に巻きまわされた繊維シートを繰り出してエアスルー方式で熱風を吹き付け、特定の線圧でカレンダー加工を施す加工方法が記載されている。 The air-through nonwoven fabric is formed by blowing hot air by an air-through method to thermally fuse the intersections of the fibers, so that the air-through nonwoven fabric can be relatively thick and feel good. Therefore, it is often used as a constituent member of an absorbent article. Various proposals have been made on this air-through nonwoven fabric for absorbent articles.
For example, in
Patent Literature 3 describes that a completed nonwoven fabric is subjected to pressure treatment between a pair of rolls at a specific linear pressure and temperature from the viewpoint of improving the texture of the nonwoven fabric.
Patent Literature 4 describes a processing method in which a fiber sheet wound in a roll shape is fed, hot air is blown by an air-through method, and calendering is performed at a specific linear pressure.
これに対し、従来は、前記特許文献1、3及び4に記載されているように、完成された不織布に対してカレンダー加工を行って、硬さを低減するようにしていた。しかし、カレンダー加工が一対のロール間にエアスルー不織布を挟んで加圧する処理であり、加圧後のエアスルー不織布は、厚みが薄くなるため、嵩高さに改善の余地があった。仮に、前記特許文献1、3及び4に記載されるような不織布について、カレンダー加工の後に熱風処理を行ったとしても、一度潰れた不織布の厚みの回復には限度があり、更なる改善の余地があった。この点、前記特許文献3には嵩高さの回復に関する示唆はない。
吸収性物品用エアスルー不織布において、嵩高さと柔らかな肌触りとをいずれも更に優れたものとして両立させることは、吸収性物品の吸収性及びクッション性等の観点から、強く望まれている。 In the manufacturing process of the air-through nonwoven fabric, when the fibers are spread and formed into a web, the fibers may be entangled with each other to form a fiber mass partially. In particular, the smaller the fiber diameter, the more easily the fiber mass is generated. When the fiber mass is subjected to an air-through processing step using hot air as it is, the fiber mass is cured by heat fusion between the fibers.
On the other hand, conventionally, as described in
In air-through nonwoven fabrics for absorbent articles, it is strongly desired that both the bulkiness and the soft touch be further improved, from the viewpoints of the absorbency and cushioning properties of the absorbent articles.
本発明の吸収性物品用エアスルー不織布は、体に装着して体液を吸収する様々な吸収性物品に適用でき、該吸収性物品における表面シートなど種々の構成部材に適用することができる。 Hereinafter, the air-through nonwoven fabric for absorbent articles of the present invention will be described with reference to the drawings.
The air-through nonwoven fabric for an absorbent article of the present invention can be applied to various absorbent articles that are attached to a body and absorb body fluid, and can be applied to various constituent members such as a surface sheet in the absorbent article.
また、本発明において「エアスルー不織布」とは、熱融着性繊維同士が交点において熱融着して一体化されたものである。この不織布の製造にはエアスルー法が用いられる。該エアスルー法は、熱融着性繊維を含む繊維ウェブに熱風を貫通方式で吹き付けて、該ウェブ同士の交点を融着させて不織布を形成する方法を言う。 In the present invention, unless otherwise specified, the side in contact with the human body is referred to as the skin side or the skin contact side or the front side, and the opposite side is referred to as the non-skin side or the non-skin contact side or the back side. .
In the present invention, the “air-through nonwoven fabric” is one in which heat-fusible fibers are heat-sealed at intersections and integrated. The air-through method is used for manufacturing this nonwoven fabric. The air-through method refers to a method in which hot air is blown onto a fibrous web containing heat-fusible fibers in a penetrating manner to fuse intersections of the webs to form a nonwoven fabric.
不織布の任意の場所から、繊維塊層側、及び非繊維塊層の表面側を、走査電子顕微鏡(日本電子株式会社製のJCM-5100)を用いて100倍率にて3か所拡大観察する。
繊維径:1mm2面積範囲内の繊維直径を測定する。繊維径の測定は1か所につき各異なる繊維につき20点測定し平均値を各繊維径とする。なお、吸収性物品用不織布における繊維径の振れ幅は、上記走査電子顕微鏡で観察しても確認し難いほどの微差であることが通常である。例えば一般的には、繊維径の振れ幅としては繊維の規格からすれば6%程度のものである。したがって、上記のように20点測定し平均した値であれば、各繊維径とすることができる。
繊維含有率:先に拡大観察した1mm2内の写真の上にOHPフィルムを載置し繊維径別に黒く塗りつぶす。このシートを、画像解析ソフト(NexusNewQube)を用いて、画像解析処理を行う。二値化処理を行い、面積を求める。各繊維面積を計測しその割合を各繊維の含有率とする。 (Method of measuring fiber diameter of fine fiber and thick fiber, method of measuring content of fine fiber in
From arbitrary positions of the nonwoven fabric, the fiber lump layer side and the surface side of the non-fiber lump layer are observed with a scanning electron microscope (JCM-5100 manufactured by JEOL Ltd.) at three magnifications at 100 magnifications.
Fiber diameter: 1 mm Measure the fiber diameter within a 2 area range. The fiber diameter is measured at 20 points for each different fiber at one location, and the average value is defined as each fiber diameter. In addition, the fluctuation width of the fiber diameter in the nonwoven fabric for an absorbent article is usually such a small difference that it is difficult to confirm even when observed with the above-mentioned scanning electron microscope. For example, generally, the fluctuation width of the fiber diameter is about 6% according to the fiber standard. Therefore, each fiber diameter can be used as long as the average value is obtained by measuring 20 points as described above.
Fiber content: An OHP film is placed on a photograph within 1 mm 2 enlarged and observed previously, and blacked out according to fiber diameter. This sheet is subjected to image analysis processing using image analysis software (NexusNewQube). Binarization processing is performed to determine the area. The area of each fiber is measured, and the ratio is defined as the content of each fiber.
上記の測定に際して、吸収性物品から測定対象の構成部材(例えば表面材)を取り出して評価測定する場合においては下記の方法によって取得する。すなわち、その構成部材が、接着剤などによって他の構成部材に固定されている場合には、液体窒素により接着剤を冷やして構成部材を剥がしやすくする。構成部材が、融着などによって他の構成部材に固定されている場合には、構成部材を手で剥がすか、融着部分をカッターナイフなどで切り取って剥がして行う。この方法は、他の測定方法においても同様に用いられる。 (Measurement member sampling method)
In the above measurement, when a constituent member (for example, a surface material) to be measured is taken out from the absorbent article and evaluated and measured, it is obtained by the following method. That is, when the constituent member is fixed to another constituent member with an adhesive or the like, the adhesive is cooled by liquid nitrogen to facilitate peeling of the constituent member. When the component is fixed to another component by fusion or the like, the component is peeled off by hand, or the fusion portion is cut off with a cutter knife or the like and peeled off. This method is similarly used in other measurement methods.
前記(細繊維及び太繊維の繊維径の測定方法、繊維塊層8における細繊維の含有量の測定方法、非繊維塊層9における太繊維の含有量の測定方法)に基づいて求めた、繊維径と含有率を掛け合わせ、その和を各層の平均繊維径とする。 (Measurement method of average fiber diameter of
The fiber obtained based on the above (method of measuring the fiber diameter of the fine fiber and the thick fiber, method of measuring the content of the fine fiber in the
1)測定対象の不織布の質量を1m2当たりに換算した値を全体の坪量とする。
測定対象の不織布の質量(w)を計り、次式により計算された値を全体の坪量(W)とする。
W=(1000000/LMD/LCD)w=25w
LMD:測定対象の不織布のMD方向の長さ 250mm
LCD:測定対象の不織布のCD方向の長さ 160mm
製品よりサンプルを採取する際前記サイズで採取できない場合は採取できる範囲でカットし、1m2あたりに換算する。
2)各層の坪量:測定対象の不織布の各層を丁寧に剥し、その質量を1m2当たりに換算した値を各層の坪量とする。
[単位:桁数] g/m2:小数第2位を四捨五入して、小数第1位まで算出する。
[測定数] 3点を測定しその平均値を各坪量とする。 (Method of measuring basis weight of
1) The value obtained by converting the mass of the nonwoven fabric to be measured per 1 m 2 is defined as the total basis weight.
The mass (w) of the nonwoven fabric to be measured is measured, and the value calculated by the following equation is defined as the total basis weight (W).
W = (1,000,000 / LMD / LCD) w = 25w
LMD: length in the MD direction of the nonwoven fabric to be measured 250 mm
LCD: 160mm in the CD direction of the nonwoven fabric to be measured
If you can not collect in the size when taking samples from the product cuts within the range that can be harvested and converted per 1 m 2.
2) Basis weight of each layer: Each layer of the nonwoven fabric to be measured is carefully peeled off, and the value obtained by converting the mass per 1 m 2 is defined as the basis weight of each layer.
[Unit: Number of digits] g / m 2 : Calculate to the first decimal place by rounding off the second decimal place.
[Number of Measurements] Three points are measured, and the average value is defined as each grammage.
なお、ここで言う「繊維塊部が配置された位置」とは、不織布10の表裏面のうち加圧する側の面から平面視した際に、該平面視した面において目視で繊維塊部7の存在が確認できる位置を言う(以下、本明細書において同様の意味である。)。また、「繊維塊部が配置されていない位置」とは、上記の平面視した面において目視で繊維塊部7の存在が確認できない位置を言う(以下、本明細書において同様の意味である。)。 With respect to such a
Here, the “position where the fiber mass portion is disposed” refers to the position of the
ダイヤルゲージ式厚み計(JIS B 7503(1997)、PEACOCK社製UPRIGHT DIAL GAUGE 7.64kPa圧力 測定子の先端はΦ5mmの平型円盤)を用いて、不織布における繊維塊部が配置された位置の厚みT1、不織布における繊維塊部が配置されていない位置の同圧力下での厚みT2を測定し、T3=T1-T2で定義される厚みの差を求める。測定は、T1及びT2についてそれぞれ5点以上行う。そして、T1の平均値及びT2の平均値を算出し、それらの差をT3とする。なお、荷重7.64kpaは、繊維塊部の存在を明確にするために設定された測定条件である。 (Method of measuring thickness of nonwoven fabric under 7.64 kPa pressure)
Using a dial gauge thickness gauge (JIS B7503 (1997), UPAIGHT DIAL GAUGE 7.64 kPa pressure manufactured by PEACOCK Co., Ltd.) The thickness of the nonwoven fabric at the position where the fiber mass is arranged is measured using a flat disk with a Φ5 mm tip. At T1, the thickness T2 at the position where the fiber lump portion is not arranged in the nonwoven fabric under the same pressure is measured, and the thickness difference defined by T3 = T1-T2 is obtained. The measurement is performed at five or more points for T1 and T2. Then, the average value of T1 and the average value of T2 are calculated, and the difference between them is defined as T3. The load of 7.64 kpa is a measurement condition set in order to clarify the existence of the fiber mass.
また、不織布10の繊維塊部7が配置された位置における平均摩擦係数Q1と不織布10の繊維塊部7が配置されていない位置における平均摩擦係数Q2との差Q3(=Q1-Q2)は、柔らかい肌触りを保持する観点から、0.7以下が好ましく、0.5以下がより好ましく、0.32以下が更に好ましく、0.3以下が特に好ましく、0(ゼロ)が最も好ましい。 The soft touch of the
The difference Q3 (= Q1-Q2) between the average friction coefficient Q1 at the position where the
カトーテック株式会社製、KES-FB4表面試験機を用い、測定対象の不織布を15cm角にカットし、その測定面についてSENS:2×5、荷重4.9kPaの条件にて、繊維塊部が配置された位置及び繊維塊部が配置されていない位置におけるMIU値を測定する。測定はそれぞれ直交する2方向(典型的にはMD方向とCD方向)に各5点以上行い、それらの平均値とする。MIU値は、平均摩擦係数であり、値が大きいほど表面はざらざらして風合いが悪く、小さい方がなめらかであり風合いが良いと評価される。 (Method of measuring average friction coefficient)
Using a KES-FB4 surface tester manufactured by Kato Tech Co., Ltd., the nonwoven fabric to be measured is cut into a 15 cm square, and the fiber mass portion is arranged on the measurement surface under the conditions of SENS: 2 × 5, load 4.9 kPa. The MIU value at the set position and at the position where the fiber mass portion is not arranged is measured. The measurement is performed at five or more points in each of two orthogonal directions (typically, the MD direction and the CD direction), and the average value is obtained. The MIU value is an average friction coefficient. The larger the value, the worse the surface is rough and the texture is poor. The smaller the MIU value, the smoother the texture and the better the texture.
また、肌と繊維塊部7との接触の機会を低減する観点から、積層された繊維層のうち、吸収性物品の肌面側となる繊維層における繊維塊部7の数が、該肌面側となる繊維層を平面視した10cm四方の領域毎の平均として、30以下が好ましく、20以下がより好ましく、10以下が更に好ましい。吸収性物品の肌面側となる繊維層における繊維塊部7の数は、1以上であることが好ましい。吸収性物品の肌面側となる繊維層における繊維塊部7の数は、具体的には、前記肌面側となる繊維層を平面視した10cm四方の領域毎の平均として、1以上30以下が好ましく、1以上20以下がより好ましく、1以上10以下が更に好ましい。
さらに、深みのある模様を形成する観点から、積層された2層のうち、吸収性物品の非肌面側となる繊維層に配される繊維塊部7の数が、該非肌面側となる繊維層を平面視した10cm四方の領域毎の平均として、3以上が好ましく、8以上がより好ましく、15以上が更に好ましい。 From the viewpoint of maintaining the soft touch of the
In addition, from the viewpoint of reducing the chance of contact between the skin and the
Further, from the viewpoint of forming a deep pattern, the number of
また、吸収性物品の肌面側となる繊維層に配される繊維塊部7の不織布10を平面視した際の大きさが、9mm2以下が好ましく、7mm2以下がより好ましく、5mm2以下が更に好ましい。
さらに、深みのある模様を形成する観点から、積層された2層のうち、吸収性物品の非肌面側となる繊維層に配される繊維塊部7の不織布10を平面視した際の大きさが、2mm2以上が好ましく、3mm2以上がより好ましく、5mm2以上が更に好ましい。 Individual
The size of the time of the
Further, from the viewpoint of forming a deep pattern, the size of the
また、繊維塊部7に肌が触れた際に感じる硬さを積層一体化された複数の繊維層によって緩和させる観点から、積層された2層のうち、吸収性物品の肌面側となる繊維層に配される繊維塊部7の不織布10の厚み方向における大きさが、不織布10の厚みに対する割合として、50%以下が好ましく、40%以下がより好ましく、30%以下が更に好ましい。
さらに、個々の繊維塊部7の不織布10の厚み方向における大きさ(厚み)は、上記と同様の観点から、1mm以下が好ましく、0.8mm以下がより好ましく、0.5mm以下が更に好ましく、また、0mm超の範囲で小さければ小さいほど好ましい。個々の繊維塊部7の不織布10の厚み方向における大きさ(厚み)は、具体的には、0mm超1mm以下が好ましく、0mm超0.8mm以下がより好ましく、0mm超0.5mm以下が更に好ましい。 The size (thickness) of the individual
In addition, from the viewpoint of reducing the hardness felt when the skin touches the
Furthermore, the size (thickness) of the individual
10cm角にカットした不織布の観測対象面(例えば不織布10における面10A)から、マイクロスコープ(株式会社キーエンス製、VHX-900)を用い写真を撮る。この写真のデータ(jpeg)を、画像解析ソフト(NexusNewQube)を用いて画像解析処理を行う。二値化処理を行い、繊塊部の数、及び面積を求める。また、全塊部を剃刀刃で厚み方向にカットし、前記マイクロスコープで断面を観察し不織布厚み及び繊維塊部の厚みを測定する。 (Method of measuring the number, area and thickness of fiber mass)
A photograph is taken using a microscope (VHX-900, manufactured by KEYENCE CORPORATION) from the observation target surface of the nonwoven fabric cut into a 10 cm square (for example, the
本発明の吸収性物品用エアスルー不織布は、その機能に合わせて吸収性物品の様々な部材として用いられ、吸収性物品に組み込まれる。例えば、液透過性を有する場合、表面シートとして組み込まれ、撥水性を有する場合サイドシートとして組み込まれる。また、より薄く柔らかいものにして、おむつ等の吸収性物品の外側(着衣側)の肌触りを向上させる外装材として組み込まれる。
その中でも、嵩高さと柔らかい肌触りとに優れた不織布の風合いを肌で感知させやすくし、かつ、不織布が有する模様を目視で認識させやすくする観点から、本発明の吸収性物品用エアスルー不織布は、吸収性物品の肌面側の最外層に配置し、繊維塊層8を肌面側に向けて配することが好ましい。例えば表面シートやサイドシートが挙げられ、特に表面シートとして本発明の吸収性物品用エアスルー不織布を吸収性物品に配置することが好ましい。 The air-through nonwoven fabric for an absorbent article of the present invention is used as a component of an absorbent article. Examples of the absorbent articles include various articles having a function of absorbing and retaining human excreted liquid, such as diapers, sanitary napkins, urine absorbing pads, and panty liners.
The air-through nonwoven fabric for an absorbent article of the present invention is used as various members of the absorbent article according to its function, and is incorporated into the absorbent article. For example, when it has liquid permeability, it is incorporated as a topsheet, and when it has water repellency, it is incorporated as a sidesheet. Moreover, it is made thinner and softer, and is incorporated as an exterior material for improving the feel on the outside (clothing side) of an absorbent article such as a diaper.
Among them, the air-through non-woven fabric for absorbent articles of the present invention has an absorption property from the viewpoint of facilitating the feel of the non-woven fabric excellent in bulk and soft touch with the skin, and facilitating visual recognition of the pattern of the non-woven fabric. It is preferable to arrange the outermost layer on the skin side of the sexual article and arrange the
工程501:熱可塑性繊維に複数回の開繊処理を施してウェブを形成する開繊工程。
工程502:前記開繊工程にて得た複数の単層ウェブを積層して積層ウェブを形成し、前記積層ウェブに熱風によるエアスルー加工を施してエアスルー不織布を得る工程。 The manufacturing method of this embodiment includes the following
Step 501: a fiber-spreading step of performing a fiber-spreading process on thermoplastic fibers a plurality of times to form a web.
Step 502: a step of laminating a plurality of single-layer webs obtained in the opening step to form a laminated web, and subjecting the laminated web to air-through processing with hot air to obtain an air-through nonwoven fabric.
工程503:前記単層ウェブ、前記積層ウェブ及び前記エアスルー不織布から選ばれる一又は複数に対して一対のカレンダーロールを用いて施すカレンダー加工工程。
工程503は、工程501の後であって工程502の前、工程502の途中、及び、工程502の後のいずれか又は複数において行われる。 In addition, the manufacturing method of the present embodiment includes the following
Step 503: a calendering step of using one pair of calender rolls for one or more selected from the single-layer web, the laminated web, and the air-through nonwoven fabric.
Step 503 is performed after
製造装置100において、前記工程501は、開繊部101及び102並びにカーディング部103及び104において行われる。前記工程502は、積層ウェブ形成部105及び熱処理部107において行われる。
製造装置100では、前記工程503は、ウェブカレンダー部106において行われる。ウェブカレンダー部106は積層ウェブ形成部105と熱処理部107との間に配置されており、前記工程503を、前記工程502の途中の積層ウェブに対するウェブカレンダー加工として実施する。 FIG. 2 shows a manufacturing apparatus 100 suitably used in the method for manufacturing the
In the manufacturing apparatus 100, the
In the manufacturing apparatus 100, the
具体的には、カーディング部103から搬出ベルト103Aに沿って単層ウェブ81を搬出し搬送ベルト105A上に載置する。搬送ベルト105Aは、単層ウェブ81を下流へと搬送する。また、カーディングから搬出ベルト104Aに沿って単層ウェブ82を搬出して搬送ベルト105Aへと導き、搬送中の単層ウェブ81上に積層する。これにより形成された積層ウェブ90を搬送ベルト105Aに沿って更に下流へと搬送する。なお、積層ウェブ90においては、単層ウェブ81及び82に相当する部分を、単にウェブ81及び82と呼ぶ。 Next, in the laminated
Specifically, the single-
異なる繊維径の繊維には、前述した繊維径が1dtex以上2.2dtex以下である細繊維が用いられていることが好ましい。また、該細繊維の繊維径は、前述した繊維径の範囲にあることがより好ましい。 Thus, in the manufacturing method of the present embodiment, it is preferable to form a laminated web using a plurality of types of fibers having different fiber diameters. In particular, it is more preferable to use different fiber diameters for the
As the fibers having different fiber diameters, it is preferable that the above-mentioned fine fibers having a fiber diameter of 1 dtex or more and 2.2 dtex or less are used. Further, the fiber diameter of the fine fiber is more preferably in the range of the fiber diameter described above.
具体的には、熱処理部107は、フード107Aと、該フード107A内を周回する通気性ネットを備えたコンベアベルト107Bとを有する。フード107A内において、上方からコンベアベルト107Bに向けて熱風が吹き付けられるようになっている(図2に示す矢印F)。コンベアベルト107Bでは前記通気性ネットによって、吹き付けされた熱風が吹き抜けるようにされている。ウェブカレンダー加工された積層ウェブ95は、ウェブカレンダー部106のロール回転によって、熱処理部107へと押し出される。熱処理部107では、積層ウェブ95をコンベアベルト107Bによってフード107A内へと搬送する。フード内107A内の積層ウェブ95に対して、積層ウェブ95の上方(すなわちウェブ82の上方)から厚み方向に、所定温度に加熱された熱風が貫通方式によって吹き付ける。すなわち、積層ウェブ95に対してエアスルー加工が施される。これにより、積層ウェブ95においては、前述のウェブカレンダー加工によって繊維塊部7における繊維間の間隔を広げ、繊維塊部7の硬さを緩和した繊維状態のまま、熱風の吹き付けによって繊維同士の交点が融着される。これにより、本実施形態の吸収性物品用エアスルー不織布10が得られる。 In the
Specifically, the
これらの工程501、工程502及び工程503を実行することによって、前述した本実施形態の吸収性物品用エアスルー不織布10を精度よく製造することができる。すなわち、繊維塊部7を有する繊維層8を含んでいても、嵩高さと柔らかい肌触りとに優れ、模様を有する吸収性物品用エアスルー不織布10を精度よく製造することができる。製造された吸収性物品用エアスルー不織布10は、必要によりロール状に巻き取られる。 As described above, in the manufacturing method of the present embodiment, the single-
By performing these
加えて、本実施形態の製造方法においては、不織布の一貫した製造工程において繊維塊を潰すことができる。そのため、不織布の製造後の繊維塊検査装置の導入を不要とし、製造コストの低減化を可能にする。さらに、製造後の検査処理や事後的なカレンダー処理及び熱風回復処理を不要とするため、不織布の製造効率の向上を実現できる。 In the manufacturing method of the present embodiment, when the calendering step (step 503) is performed, the
In addition, in the manufacturing method of the present embodiment, the fiber mass can be crushed in a consistent manufacturing process of the nonwoven fabric. Therefore, it is not necessary to introduce a fiber lump inspection device after the production of the nonwoven fabric, and the production cost can be reduced. Further, since the post-manufacturing inspection process, the post-calendering process, and the hot-air recovery process are not required, the production efficiency of the nonwoven fabric can be improved.
その中でも、カレンダー加工に用いるカレンダーロールは、繊維塊部7の硬さ低減効果をより高める観点から、樹脂ロールと鋼体ロールとの組み合わせであることが好ましい。本実施形態のウェブカレンダー加工においては、カレンダーロール106Aは、積層ウェブ90の太繊維を含むウェブ82に当接するものとして、鋼体ロールを、カレンダーロール106Bは、積層ウェブ90の細繊維を含むウェブ81に当接するものとして、樹脂ロールを使用している。ただし、樹脂ロールと鋼体ロールとの配置は、これに限定されず、逆の組み合わせであってもよい。 A pair of calender rolls 106A and 106B used in the
Among them, the calender roll used for calendering is preferably a combination of a resin roll and a steel roll from the viewpoint of further increasing the effect of reducing the hardness of the
図3は、第1エアスルー処理部117と第2エアスルー処理部127とを有する熱処理部(エアスルー加工部)の態様を示している。この態様では、エアスルー加工を、第1エアスルー処理と第2エアスルー処理の2回行う。ただし、エアスルー処理の回数は、図3の2回に限らず、3回以上であってもよい。エアスルー加工が3回以上のエアスルー処理を有する場合、「最初のエアスルー処理」に対する「後段のエアスルー処理」は、2回目以降のエアスルー処理を意味する。図3の2回のエアスルー処理において、「最初のエアスルー処理」とは第1エアスルー処理であり、「後段のエアスルー処理」とは第2エアスルー処理を意味する。図3に示すエアスルー工程(2回のエアスルー処理)では、第1エアスルー処理部117のフード107Cにおいて熱風吹き付けを行い(矢印F1)、第2エアスルー処理部127のフード107Dにおいて熱風吹き付けを行う(矢印F2)。このとき、コンベアベルト107Bによって、ウェブカレンダー加工された積層ウェブ95を第1エアスルー処理部117から第2エアスルー処理部127へと連続的に搬送する。これにより、第1エアスルー処理と第2エアスルー処理とを積層ウェブ95に対して連続的に施す。 Further, the air-through processing preferably includes a plurality of air-through processings.
FIG. 3 shows an aspect of a heat treatment section (air through processing section) having a first air through
この工程504においては、前記開繊工程にて用いられるカード機内においてウェブの幅方向端部を回収する工程、及び、前記エアスルー不織布を部分的に回収し該回収したエアスルー不織布の部分を裁断し開繊する工程、の一方又は両方を有する。回収した前記ウェブ、及び裁断し開繊したエアスルー不織布の部分を前記開繊工程に供する。なお、裁断し開繊するエアスルー不織布の部分とは、幅方向端部の端切れ部分を含み、これに限らず、不織布製造工程内で生じた加工条件調整品や規格外品などを言う。 Furthermore, in the method for manufacturing an air-through nonwoven fabric for absorbent articles according to the present embodiment, as described below, it is preferable to temporarily collect unnecessary portions such as cut pieces generated in the manufacturing process and return to the fiber opening process again (step 504). ).
In this
回収したウェブ及び裁断し開繊したエアスルー不織布の部分を開繊部101へと戻して、再度開繊を行いウェブ形成のための材料として使用する(矢印184)。このとき、開繊部101及び開繊部102のいずれに戻すことも可能である。図2は、開繊部101に戻すものとして示している。開繊部101に戻す場合、形成されるウェブ81における細繊維の割合を一定以上に保持し、太繊維の含有量を数%以内(例えば、5%以内)に抑えるよう、新しい原料繊維(細繊維)71の投入量を適宜調製することが好ましい。これにより、ウェブ81に繊維塊部7を形成しながら細繊維を多く含み、不織布10の面10A側における柔らかい肌触りを実現できる。
また、上記の材料の戻しは、図2に示す態様に限定されるものではない。例えば、カーディング部103から回収した材料は開繊部101に戻し、カーディング104から回収した材料は開繊部102に戻す態様でもよい。その際、裁断し開繊したエアスルー不織布の部分は開繊部102に戻すことが好ましい。 FIG. 2 shows a specific example of the
The collected web and the portion of the air-through nonwoven fabric cut and opened are returned to the
Further, the return of the material is not limited to the embodiment shown in FIG. For example, a mode in which the material collected from the
その中でも、本発明の吸収性物品用エアスルー不織布は、嵩高さと柔らかな肌触りの両立を実現し、かつ、視覚的に使用者に訴求できる模様を備えることから、前記組み込み工程が、吸収性物品の肌面側の最外層の部材(例えば表面シートやサイドシート)に組み込む工程であることが好ましい。特に、肌に触れ最も目にとまる表面シートとして吸収性物品に組み込む工程であることが好ましい。その際、本発明の吸収性物品用エアスルー不織布は、繊維塊部を有する繊維層を不織布の最外層とする構成を備えていることが好ましい。この本発明の吸収性物品用エアスルー不織布を吸収性物品の肌面側の最外層に配し、前記繊維塊部を有する繊維層を吸収性物品の肌面側に向けて配することがより好ましい。 The obtained air-through nonwoven fabric for an absorbent article of the present invention is incorporated as a predetermined constituent member in the absorbent article according to the purpose in the manufacturing process of the absorbent article (incorporation step). The incorporation step is preferably, for example, the following step. That is, the obtained air-through nonwoven fabric for an absorbent article of the present invention is prepared by cutting it into a size or a shape according to the purpose, and is placed at a predetermined position with respect to other constituent members. Next, if necessary, the member is rotated and folded together with other members, and is joined and incorporated into an absorbent article. As described above, the target absorbent article is manufactured through the step of incorporating the air-through nonwoven fabric for the absorbent article of the present invention in the manufacturing step of the absorbent article.
Above all, the air-through nonwoven fabric for absorbent articles of the present invention achieves both bulkiness and soft touch, and has a pattern that can be visually appealed to the user. It is preferably a step of incorporating the outermost layer member (for example, a topsheet or a sidesheet) on the skin side. In particular, it is preferable to incorporate the absorbent article into the absorbent article as a surface sheet that touches the skin and is most noticeable. In that case, it is preferable that the air-through nonwoven fabric for an absorbent article of the present invention has a configuration in which the fiber layer having the fiber lump is the outermost layer of the nonwoven fabric. It is more preferable that the air-through nonwoven fabric for an absorbent article of the present invention is arranged on the outermost layer on the skin side of the absorbent article, and the fiber layer having the fiber mass is arranged toward the skin side of the absorbent article. .
2層以上の繊維層が積層されたエアスルー不織布であって、熱可塑性繊維を含み、かつ、繊維塊部を有する繊維層を少なくとも1層有する、吸収性物品用エアスルー不織布。 <1>
An air-through nonwoven fabric for an absorbent article, which is an air-through nonwoven fabric in which two or more fiber layers are laminated, wherein the air-through nonwoven fabric contains thermoplastic fibers and has at least one fiber layer having a fiber mass portion.
前記吸収性物品用エアスルー不織布は、繊維径が1dtex以上2.2dtex以下、好ましくは1dtex以上、より好ましくは1.2dtex以上、好ましくは2dtex以下、より好ましくは1.5dtex以下である細繊維と、該細繊維よりも繊維径が太い太繊維とを有しており、
前記繊維塊部を有する繊維層が前記細繊維を含む、前記<1>に記載の吸収性物品用エアスルー不織布。
<3>
前記繊維塊部を有する繊維層における前記細繊維の含有量が、50質量%以上であり、好ましく80質量%以上、より好ましくは100質量%である前記<2>に記載の吸収性物品用エアスルー不織布。 <2>
The air-through nonwoven fabric for absorbent articles has a fiber diameter of 1 dtex or more and 2.2 dtex or less, preferably 1 dtex or more, more preferably 1.2 dtex or more, preferably 2 dtex or less, more preferably 1.5 dtex or less, Having a thick fiber with a larger fiber diameter than the fine fiber,
The air-through nonwoven fabric for an absorbent article according to <1>, wherein the fiber layer having the fiber mass portion includes the fine fibers.
<3>
The air-through for an absorbent article according to <2>, wherein the content of the fine fibers in the fiber layer having the fiber mass portion is 50% by mass or more, preferably 80% by mass or more, and more preferably 100% by mass. Non-woven fabric.
前記繊維塊部を有しない繊維層を少なくとも1層有する、前記<1>~<3>のいずれか1に記載の吸収性物品用エアスルー不織布。
<5>
前記吸収性物品用エアスルー不織布は、繊維径が2.2dtex超7dtex以下、好ましくは2.2dtex超、より好ましくは4.4dtex以上、好ましくは5.5dtex以下、より好ましくは5dtex以下である太繊維と、該太繊維よりも繊維径が細い細繊維とを有しており、
前記繊維塊部を有しない繊維層が前記太繊維を含む、前記<4>に記載の吸収性物品用エアスルー不織布。
<6>
前記繊維塊部を有しない繊維層における前記太繊維の含有量が、50質量%以上であり、好ましくは80質量%以上、より好ましくは100質量%である前記<5>に記載の吸収性物品用エアスルー不織布。
<7>
前記繊維塊部を有する層における前記太繊維の含有量が、50質量%以下であり、好ましくは30質量%以下、より好ましくは10質量%以下である前記<5>又は<6>に記載の吸収性物品用エアスルー不織布。
<8>
前記繊維塊部を有する繊維層よりも前記繊維塊部を有しない繊維層の平均繊維径が大きい、前記<4>~<7>のいずれか1に記載の吸収性物品用エアスルー不織布。
<9>
前記繊維塊部を有しない繊維層の平均繊維径と前記繊維塊部を有する繊維層の平均繊維径との差が、0dtex超5.6dtex以下であり、好ましくは2.2dtex以上、より好ましくは3dtex以上、好ましくは4dtex以下、より好ましくは3.5dtex以下である、前記<8>に記載の吸収性物品用エアスルー不織布。
<10>
前記繊維塊部を有する繊維層よりも前記繊維塊部を有しない繊維層の坪量が大きい、前記<4>~<9>のいずれか1に記載の吸収性物品用エアスルー不織布。
<11>
前記繊維塊部を有しない繊維層の坪量と前記繊維塊部を有する繊維層の坪量との差が、0g/m2超20g/m2以下であり、好ましくは3g/m2以上、より好ましくは5g/m2以上、好ましくは15g/m2以下、より好ましくは10g/m2以下である、前記<10>に記載の吸収性物品用エアスルー不織布。
<12>
前記吸収性物品用エアスルー不織布全体の坪量が、15g/m2以上40g/m2以下であり、好ましくは18g/m2以上、より好ましくは20/m2以上、好ましくは30g/m2以下、より好ましくは25g/m2以下である、前記<1>~<11>のいずれか1に記載の吸収性物品用エアスルー不織布。 <4>
The air-through nonwoven fabric for an absorbent article according to any one of <1> to <3>, wherein the air-through nonwoven fabric has at least one fiber layer having no fiber lump portion.
<5>
The air-through nonwoven fabric for absorbent articles has a fiber diameter of more than 2.2 dtex and 7 dtex or less, preferably more than 2.2 dtex, more preferably 4.4 dtex or more, preferably 5.5 dtex or less, more preferably 5 dtex or less. And, having a fine fiber having a smaller fiber diameter than the thick fiber,
The air-through nonwoven fabric for an absorbent article according to <4>, wherein the fiber layer having no fiber mass portion includes the thick fiber.
<6>
The absorbent article according to <5>, wherein the content of the thick fiber in the fiber layer having no fiber mass portion is 50% by mass or more, preferably 80% by mass or more, and more preferably 100% by mass. For air-through non-woven fabric.
<7>
<5> or <6>, wherein the content of the thick fiber in the layer having the fiber mass portion is 50% by mass or less, preferably 30% by mass or less, more preferably 10% by mass or less. Air-through nonwoven fabric for absorbent articles.
<8>
The air-through nonwoven fabric for an absorbent article according to any one of <4> to <7>, wherein the average fiber diameter of the fiber layer having no fiber lump is greater than the fiber layer having the fiber lump.
<9>
The difference between the average fiber diameter of the fiber layer having no fiber lump and the average fiber diameter of the fiber layer having the fiber lump is more than 0 dtex and 5.6 dtex or less, preferably 2.2 dtex or more, more preferably The air-through nonwoven fabric for an absorbent article according to <8>, wherein the air-through nonwoven fabric is 3 dtex or more, preferably 4 dtex or less, more preferably 3.5 dtex or less.
<10>
The air-through nonwoven fabric for an absorbent article according to any one of <4> to <9>, wherein the basis weight of the fiber layer having no fiber lump is greater than the fiber layer having the fiber lump.
<11>
The difference between the basis weight of the fiber layer having no fiber lump and the basis weight of the fiber layer having the fiber lump is more than 0 g / m 2 and 20 g / m 2 or less, preferably 3 g / m 2 or more, The air-through nonwoven fabric for an absorbent article according to <10>, wherein the air-through nonwoven fabric is more preferably 5 g / m 2 or more, preferably 15 g / m 2 or less, more preferably 10 g / m 2 or less.
<12>
The basis weight of the whole air-through nonwoven fabric for absorbent articles is 15 g / m 2 or more and 40 g / m 2 or less, preferably 18 g / m 2 or more, more preferably 20 / m 2 or more, and preferably 30 g / m 2 or less. Air-through nonwoven fabric for an absorbent article according to any one of the above items <1> to <11>, more preferably 25 g / m 2 or less.
前記繊維塊部が配置された位置において、7.64kPa圧力下で測定された前記吸収性物品用エアスルー不織布の厚みをT1とし、前記繊維塊部が配置されていない位置において、同圧力下で測定された前記吸収性物品用エアスルー不織布の厚みをT2としたとき、T3=T1-T2で定義される厚みの差T3が0.4mm以下であり、好ましくは0.3mm以下、より好ましくは0.2mm以下であり、更に好ましくは0(ゼロ)mmである、前記<1>~<12>のいずれか1に記載の吸収性物品用エアスルー不織布。
<14>
前記吸収性物品用エアスルー不織布の前記繊維塊部が配置された位置における平均摩擦係数が1.6以上2.5以下であり、好ましくは1.6以上、好ましくは2.4以下、より好ましくは2.3以下である、前記<1>~<13>のいずれか1に記載の吸収性物品用エアスルー不織布。
<15>
前記吸収性物品用エアスルー不織布の前記繊維塊部が配置された位置における平均摩擦係数と前記繊維塊部が配置されていない位置における平均摩擦係数との差が0.7以下であり、好ましくは0.5以下、より好ましくは0.32以下、更に好ましくは0.3以下、特に好ましくは0(ゼロ)である、前記<14>に記載の吸収性物品用エアスルー不織布。 <13>
The thickness of the air-through nonwoven fabric for an absorbent article measured at a pressure of 7.64 kPa at the position where the fiber lump is disposed is T1, and the thickness is measured at the position where the fiber lump is not disposed at the same pressure. Assuming that the thickness of the air-through nonwoven fabric for an absorbent article thus obtained is T2, the difference T3 in thickness defined by T3 = T1-T2 is 0.4 mm or less, preferably 0.3 mm or less, more preferably 0.1 mm or less. The air-through nonwoven fabric for absorbent articles according to any one of the above items <1> to <12>, which is not more than 2 mm, and more preferably 0 (zero) mm.
<14>
The average friction coefficient of the air-through nonwoven fabric for the absorbent article at the position where the fiber mass is disposed is 1.6 or more and 2.5 or less, preferably 1.6 or more, preferably 2.4 or less, more preferably. The air-through nonwoven fabric for absorbent articles according to any one of <1> to <13>, which is 2.3 or less.
<15>
The difference between the average friction coefficient of the air-through nonwoven fabric for the absorbent article at the position where the fiber lump is arranged and the average friction coefficient at the position where the fiber lump is not arranged is 0.7 or less, preferably 0 or less. The air-through nonwoven fabric for absorbent articles according to <14>, wherein the air-through nonwoven fabric is at most 0.5, more preferably at most 0.32, still more preferably at most 0.3, particularly preferably 0 (zero).
前記繊維塊部が、不織布の厚み方向の断面において、不織布厚み方向に潰された扁平形状となっており、不織布表面側の繊維塊部表面が滑らかな構造を有する、前記<1>~<15>のいずれか1に記載の吸収性物品用エアスルー不織布。 <16>
<1> to <15, wherein the fiber lump has a flat shape crushed in the thickness direction of the nonwoven fabric in a cross section in the thickness direction of the nonwoven fabric, and the surface of the fiber lump on the nonwoven fabric surface side has a smooth structure. > The air-through nonwoven fabric for absorbent articles according to any one of <1> to <3>.
前記繊維塊部を有する繊維層が、前記吸収性物品用エアスルー不織布の最も外側の層である、前記<1>~<16>のいずれか1に記載の吸収性物品用エアスルー不織布。
<18>
前記<1>~<17>のいずれか1に記載の吸収性物品用エアスルー不織布を有する吸収性物品。
<19>
前記<17>に記載の前記吸収性物品用エアスルー不織布を吸収性物品の肌面側の最外層に配置し、前記繊維塊部を有する繊維層を肌面側に向けて配した吸収性物品。
<20>
前記吸収性物品用エアスルー不織布を表面シートとして有する、前記<18>又は<19>に記載の吸収性物品。 <17>
The air-through nonwoven fabric for an absorbent article according to any one of <1> to <16>, wherein the fiber layer having the fiber lump portion is an outermost layer of the air-through nonwoven fabric for the absorbent article.
<18>
An absorbent article comprising the air-through nonwoven fabric for an absorbent article according to any one of <1> to <17>.
<19>
An absorbent article in which the air-through nonwoven fabric for an absorbent article according to <17> is arranged on the outermost layer on the skin side of the absorbent article, and the fiber layer having the fiber lump is arranged toward the skin side.
<20>
The absorbent article according to <18> or <19>, having the air-through nonwoven fabric for absorbent article as a surface sheet.
熱可塑性繊維に複数回の開繊処理を施してウェブを形成する開繊工程と、
前記開繊工程にて得た複数の単層ウェブを積層して積層ウェブを形成し、前記積層ウェブに熱風によるエアスルー加工を施してエアスルー不織布を得る工程と、
前記単層ウェブ、前記積層ウェブ及び前記エアスルー不織布から選ばれる一又は複数に対して一対のカレンダーロールを用いて施すカレンダー加工工程と
を有する吸収性物品用エアスルー不織布の製造方法。
<22>
吸収性物品用エアスルー不織布の製造方法の全工程において、
前記単層ウェブ、前記積層ウェブ及び前記エアスルー不織布にかかる線圧のうち、前記カレンダー加工工程における線圧が最も高い、前記<21>に記載の吸収性物品用エアスルー不織布の製造方法。
<23>
前記カレンダー加工工程が、前記単層ウェブ及び前記積層ウェブから選ばれる一又は複数に対して行うウェブカレンダー加工工程である、前記<21>又は<22>記載の吸収性物品用エアスルー不織布の製造方法。
<24>
前記ウェブカレンダー加工工程において前記単層ウェブ又は前記積層ウェブに加える線圧が20N/cm以上700N/cm以下であり、好ましくは100N/cm以上、より好ましくは180N/cm以上、好ましくは500N/cm以下、より好ましくは250N/cm以下である、前記<23>に記載の吸収性物品用エアスルー不織布の製造方法。
<25>
前記前記カレンダー加工工程にて用いる一対のカレンダーロールが樹脂ロールと鋼体ロールの組み合わせである、前記<21>~<24>のいずれか1に記載の吸収性物品用エアスルー不織布の製造方法。
<26>
前記樹脂ロールの硬度がD硬度において20以上100以下であり、好ましくは50度以上、より好ましくは80度以上、好ましくは95度以下、より好ましくは90度以下である、前記<25>に記載の吸収性物品用エアスルー不織布の製造方法。 <21>
A fiber-spreading step of performing a web-spreading process on the thermoplastic fibers a plurality of times to form a web,
Laminating a plurality of single-layer webs obtained in the fiber opening step to form a laminated web, and performing an air-through process by hot air on the laminated web to obtain an air-through nonwoven fabric,
A method for producing an air-through nonwoven fabric for an absorbent article, comprising: a calendering step of applying one or more of the single-layer web, the laminated web and the air-through nonwoven fabric using a pair of calender rolls.
<22>
In all steps of the manufacturing method of the air-through nonwoven fabric for absorbent articles,
The method for producing an air-through nonwoven fabric for absorbent articles according to <21>, wherein the linear pressure in the calendering step is the highest among the linear pressures applied to the single-layer web, the laminated web, and the air-through nonwoven fabric.
<23>
The method for producing an air-through nonwoven fabric for absorbent articles according to <21> or <22>, wherein the calendering step is a web calendering step performed on one or more selected from the single-layer web and the laminated web. .
<24>
In the web calendering step, a linear pressure applied to the single-layer web or the laminated web is 20 N / cm or more and 700 N / cm or less, preferably 100 N / cm or more, more preferably 180 N / cm or more, and preferably 500 N / cm. The method for producing an air-through nonwoven fabric for an absorbent article according to <23>, wherein the non-woven fabric is at most 250 N / cm or less.
<25>
The method for producing an air-through nonwoven fabric for absorbent articles according to any one of <21> to <24>, wherein the pair of calender rolls used in the calendering step is a combination of a resin roll and a steel roll.
<26>
<25> The resin roll according to <25>, wherein the resin roll has a D hardness of 20 or more and 100 or less, preferably 50 or more, more preferably 80 or more, preferably 95 or less, and more preferably 90 or less. A method for producing an air-through nonwoven fabric for absorbent articles.
前記エアスルー加工が複数のエアスルー処理を有し、最初のエアスルー処理よりも後段のエアスルー処理の方が熱風の風速が速い、前記<21>~<26>のいずれか1に記載の吸収性物品用エアスルー不織布の製造方法。
<28>
前記最初のエアスルー処理における熱風の風速が0.2m/sec以上1.2m/sec以下であり、好ましくは0.25m/sec以上、より好ましくは0.4m/sec以上、好ましくは0.8m/sec以下、より好ましくは0.5m/sec以下である、前記<27>に記載の吸収性物品用エアスルー不織布の製造方法。
<29>
前記後段のエアスルー処理における熱風の風速が0.8m/sec以上1.6m/sec以下であり、好ましくは0.9m/sec以上、より好ましくは1.2m/sec以上、好ましくは1.4m/sec以下、より好ましくは1.3m/sec以下である、前記<27>又は<28>に記載の吸収性物品用エアスルー不織布の製造方法。
<30>
前記最初のエアスルー処理における熱風の風速と前記後段のエアスルー処理における熱風の風速の差が、0m/sec超1.4m/sec以下であり、好ましくは0.4m/sec以上、より好ましくは0.8m/sec以上、好ましくは1.2m/sec以下、より好ましくは1m/sec以下である、前記<27>~<29>のいずれか1に記載の吸収性物品用エアスルー不織布の製造方法。
<31>
前記エアスルー加工が複数のエアスルー処理を有し、最初のエアスルー処理よりも後段のエアスルー処理の方が熱風の温度が高い、前記<21>~<30>のいずれか1に記載の吸収性物品用エアスルー不織布の製造方法。
<32>
前記最初のエアスルー処理における熱風の温度が85℃以上134℃以下であり、好ましくは90℃以上、より好ましくは100℃以上、好ましくは115℃以下、より好ましくは105℃以下である、前記<31>に記載の吸収性物品用エアスルー不織布の製造方法。
<33>
前記後段のエアスルー処理における熱風の温度が、使用する繊維表面の成分の融点以上145℃以下であり、好ましくは使用する繊維表面の成分の融点以上、好ましくは137℃以下、より好ましくは134℃以下である、前記<31>又は<32>記載の吸収性物品用エアスルー不織布の製造方法。
<34>
前記最初のエアスルー処理における熱風の温度と後段のエアスルー処理における熱風の温度の差は0℃超60℃以下であり、好ましくは20℃以上、より好ましくは30℃以上、好ましくは40℃以下、より好ましくは35℃以下である、前記<31>~<33>のいずれか1に記載の吸収性物品用エアスルー不織布の製造方法。 <27>
The absorbent article according to any one of the items <21> to <26>, wherein the air-through processing has a plurality of air-through processings, and a subsequent-stage air-through processing has a higher velocity of hot air than an initial air-through processing. Manufacturing method of air-through nonwoven fabric.
<28>
The wind speed of the hot air in the first air-through treatment is 0.2 m / sec or more and 1.2 m / sec or less, preferably 0.25 m / sec or more, more preferably 0.4 m / sec or more, and preferably 0.8 m / sec or more. The method for producing an air-through nonwoven fabric for absorbent articles according to <27>, wherein the air-through nonwoven fabric is not more than 0.5 sec / sec, more preferably not more than 0.5 m / sec.
<29>
The wind velocity of the hot air in the latter air-through treatment is 0.8 m / sec or more and 1.6 m / sec or less, preferably 0.9 m / sec or more, more preferably 1.2 m / sec or more, and preferably 1.4 m / sec or more. The method for producing an air-through nonwoven fabric for absorbent articles according to the item <27> or <28>, wherein the air-through nonwoven fabric is not more than sec, more preferably not more than 1.3 m / sec.
<30>
The difference between the wind speed of the hot air in the first air-through process and the wind speed of the hot air in the subsequent air-through process is more than 0 m / sec and 1.4 m / sec or less, preferably 0.4 m / sec or more, and more preferably 0.1 m / sec or more. The method for producing an air-through nonwoven fabric for absorbent articles according to any one of the above items <27> to <29>, which is at least 8 m / sec, preferably at most 1.2 m / sec, more preferably at most 1 m / sec.
<31>
The absorbent article according to any one of <21> to <30>, wherein the air-through processing has a plurality of air-through processings, and a temperature of hot air is higher in a later-stage air-through processing than in an initial air-through processing. Manufacturing method of air-through nonwoven fabric.
<32>
The temperature of the hot air in the first air-through treatment is 85 ° C. or more and 134 ° C. or less, preferably 90 ° C. or more, more preferably 100 ° C. or more, preferably 115 ° C. or less, and more preferably 105 ° C. or less. The method for producing an air-through nonwoven fabric for absorbent articles according to <1>.
<33>
The temperature of the hot air in the subsequent air-through treatment is not less than the melting point of the component on the fiber surface used and not more than 145 ° C., preferably not less than the melting point of the component on the fiber surface used, preferably not more than 137 ° C., more preferably not more than 134 ° C. The method for producing an air-through nonwoven fabric for an absorbent article according to <31> or <32>, wherein
<34>
The difference between the temperature of the hot air in the first air through process and the temperature of the hot air in the subsequent air through process is more than 0 ° C. and 60 ° C. or less, preferably 20 ° C. or more, more preferably 30 ° C. or more, and preferably 40 ° C. or less. The method for producing an air-through nonwoven fabric for absorbent articles according to any one of the above <31> to <33>, which is preferably at most 35 ° C.
前記開繊工程にて用いられるカード機内においてウェブの幅方向端部を回収する工程、及び、前記エアスルー不織布を部分的に回収し該回収した前記エアスルー不織布の部分を裁断し開繊する工程、の一方又は両方を有し、
回収した前記ウェブ、及び裁断し開繊した前記エアスルー不織布の部分を前記開繊工程に供する、前記<21>~<34>のいずれか1に記載の吸収性物品用エアスルー不織布の製造方法。 <35>
A step of collecting the width direction end of the web in the carding machine used in the opening step, and a step of partially collecting the air-through nonwoven fabric and cutting and opening the collected air-through nonwoven portion. Have one or both,
The method for producing an air-through nonwoven fabric for absorbent articles according to any one of <21> to <34>, wherein the collected web and a portion of the cut-opened air-through nonwoven fabric are subjected to the opening process.
前記積層ウェブは繊維径が異なる複数種類の繊維を有している、前記<21>~<35>のいずれか1に記載の吸収性物品用エアスルー不織布の製造方法。
<37>
前記積層ウェブは、繊維径が1dtex以上2.2dtex以下、好ましくは1dtex以上、より好ましくは1.2dtex以上、好ましくは2dtex以下、より好ましくは1.5dtex以下である細繊維を有している、前記<21>~<36>のいずれか1に記載の吸収性物品用エアスルー不織布の製造方法。 <36>
The method for producing an air-through nonwoven fabric for absorbent articles according to any one of the above items <21> to <35>, wherein the laminated web has a plurality of types of fibers having different fiber diameters.
<37>
The laminated web has fine fibers having a fiber diameter of 1 dtex or more and 2.2 dtex or less, preferably 1 dtex or more, more preferably 1.2 dtex or more, preferably 2 dtex or less, more preferably 1.5 dtex or less. The method for producing an air-through nonwoven fabric for an absorbent article according to any one of <21> to <36>.
前記<21>~<37>のいずれか1に記載の製造方法により製造された吸収性物品用エアスルー不織布を吸収性物品に組み込む工程を有する、吸収性物品の製造方法。
<39>
前記吸収性物品用エアスルー不織布を表面シートとして吸収性物品に組み込む工程を有する、前記<38>に記載の吸収性物品の製造方法。 <38>
A method for producing an absorbent article, comprising a step of incorporating the air-through nonwoven fabric for an absorbent article produced by the production method according to any one of <21> to <37> into the absorbent article.
<39>
The method for producing an absorbent article according to <38>, further comprising a step of incorporating the air-through nonwoven fabric for an absorbent article as a surface sheet into the absorbent article.
図2に示す製造装置を用い、加工速度10m/minにて、下記に示すとおり実施例1の不織布試料を作製した。
まず、繊維層1を形成する原料繊維(細繊維)71として、繊維径1.4dtexの芯鞘型(芯がポリエチレンテレフタレート樹脂、鞘がポリエチレン樹脂)の熱可塑性繊維を用いた。この原料繊維71を用いて、開繊部101及びカーディング部103において複数回の開繊処理を施し、坪量10g/m2の単層ウェブ81を作製した。
また、繊維層2を形成する原料繊維(太繊維)72として、繊維径4.4dtexの芯鞘型(芯がポリエチレンテレフタレート樹脂、鞘がポリエチレン樹脂)の熱可塑性繊維を用いた。この原料繊維72を用いて、開繊部102及びカーディング部104において複数回の開繊処理を施し、坪量15g/m2の単層ウェブ82を作製した。
次いで、積層ウェブ形成部105において、単層ウェブ81上に単層ウェブ82を積層して積層ウェブ90を形成した。ウェブカレンダー部106において、積層ウェブ90に対してウェブカレンダー加工を施した。ウェブカレンダー部106では、上層側の鋼体のカレンダーロール106A、下層側の樹脂ロール106B(D硬度:90度)を用い、線圧を200N/cmとした。
ウェブカレンダー加工を施した積層ウェブ95に対し、熱処理部107において、図3に示す2回のエアスルー処理を施すエアスルー加工を行った。第1エアスルー処理と第2エアスルー処理の風速及び温度は表1に示すものとした。これにより、実施例1の不織布試料を作製した。
なお、上記の製造方法においては、形成したウェブの幅方向端部や不織布の一部を回収して開繊工程に戻すことは行わなかった。そのため、原料繊維(細繊維)71の繊維径が繊維層1の平均繊維径となり、原料繊維(太繊維)72の繊維径が繊維層2の平均繊維径となった。 (Example 1)
Using the manufacturing apparatus shown in FIG. 2, a nonwoven fabric sample of Example 1 was produced as shown below at a processing speed of 10 m / min.
First, as a raw material fiber (fine fiber) 71 forming the
As the raw material fiber (thick fiber) 72 forming the
Next, in the laminated
The
In the above-described production method, the widthwise end of the formed web and a part of the nonwoven fabric were not recovered and returned to the fiber opening step. Therefore, the fiber diameter of the raw fiber (fine fiber) 71 was the average fiber diameter of the
第1エアスルー処理の温度及び風速を表1に示すとおりとした以外は、実施例1と同様にして、実施例2~7の不織布試料をそれぞれ作製した。 (Examples 2 to 7)
Nonwoven fabric samples of Examples 2 to 7 were produced in the same manner as in Example 1 except that the temperature and the wind speed of the first air-through treatment were as shown in Table 1.
ウェブカレンダー加工を行わず、エアスルー加工後の不織布に対して、表1に示す不織布カレンダー加工を行った以外は、実施例1と同様にして、実施例8の不織布試料を作製した。 (Example 8)
A nonwoven fabric sample of Example 8 was produced in the same manner as in Example 1 except that the nonwoven fabric after air-through processing was subjected to the nonwoven fabric calendering processing shown in Table 1 without performing web calendering.
繊維層1を形成する原料繊維(細繊維)の繊維径を2.0dtexとし、第1エアスルー処理の温度及び風速を表1に示すとおりとした以外は、実施例1と同様にして、実施例9の不織布試料を作製した。 (Example 9)
Example 1 was repeated in the same manner as in Example 1 except that the fiber diameter of the raw material fibers (fine fibers) forming the
繊維層2を形成する原料繊維72の繊維径を2.0dtexとした以外は、実施例9と同様にして、実施例10の不織布試料を作製した。 (Example 10)
A nonwoven fabric sample of Example 10 was produced in the same manner as in Example 9, except that the fiber diameter of the
繊維層1を形成する原料繊維(細繊維)の繊維径及び繊維層2(下層)を形成する原料繊維71の繊維径を1.4dtexとした以外は、実施例10と同様にして、実施例11の不織布試料を作製した。 (Example 11)
The same procedure as in Example 10 was carried out except that the fiber diameter of the raw fibers (fine fibers) forming the
第1エアスルー処理の温度及び風速を表2に示すとおりとした以外は、実施例11と同様にして、実施例12の不織布試料を作製した。 (Example 12)
A nonwoven fabric sample of Example 12 was produced in the same manner as in Example 11, except that the temperature and the wind speed of the first air-through treatment were as shown in Table 2.
ウェブカレンダー加工を行わず、エアスルー加工後の不織布に対して、表2に示す不織布カレンダー加工を行った以外は、実施例12と同様にして、実施例13の不織布試料を作製した。 (Example 13)
A nonwoven fabric sample of Example 13 was prepared in the same manner as in Example 12, except that the nonwoven fabric after air-through processing was subjected to the nonwoven fabric calendaring shown in Table 2 without performing web calendering.
カレンダー加工を行わなかった以外は、実施例1と同様にして、比較例1の不織布試料を作製した。 (Comparative Example 1)
A nonwoven fabric sample of Comparative Example 1 was prepared in the same manner as in Example 1 except that the calendering was not performed.
繊維層2(下層)を形成する原料繊維71の繊維径を1.4dtexとした以外は、比較例1と同様にして、比較例2の不織布試料を作製した。 (Comparative Example 2)
A nonwoven fabric sample of Comparative Example 2 was produced in the same manner as in Comparative Example 1, except that the fiber diameter of the
[1]嵩高性
(1)0.05kPa荷重下の不織布試料の厚み
レーザー式厚み計としてオムロン株式会社製のレーザーセンサ(型番ZS-LD80)及びコントローラー(型番ZS-LDC11)を用いて測定した。
厚み測定の際には、レーザーセンサの先端部と測定対象の不織布試料との間に錘(0.05kpa)を配置して、斯かる加圧状態の厚みを測定した。測定は、それぞれ5点以上行い、それらの平均値とした。なお、0.05kPaは、できるだけ厚みを潰さないように不織布の見掛け厚みを想定した荷重である。
(2)7.64kPa圧力下の不織布試料の厚み
前述の(7.64kPa圧力下における不織布の厚みの測定方法)に記載された方法に基づき、各不織布試料の繊維塊部が配置された位置の厚み(T1)、繊維塊部が配置されていない位置の厚み(T2)をそれぞれ測定した。さらに、厚みの差(T3=T1-T2)を算出した。
[2]摩擦
前述の(平均摩擦係数の測定方法)に記載された方法に基づき、各不織布試料の繊維塊部が配置された位置におけるMIU値(Q1)、繊維塊部が配置されていない位置におけるMIU値(Q2)をそれぞれ測定した。さらに、MIU値の差Q3(=Q1-Q2)を算出した。
[3]模様
各不織布試料について、目視で繊維塊部の有無を確認した。 (test)
[1] Bulkiness (1) Thickness of nonwoven fabric sample under 0.05 kPa load Measured using a laser sensor (model number ZS-LD80) and a controller (model number ZS-LDC11) manufactured by OMRON Corporation as a laser thickness gauge.
When measuring the thickness, a weight (0.05 kpa) was placed between the tip of the laser sensor and the nonwoven fabric sample to be measured, and the thickness in such a pressurized state was measured. The measurement was performed at five or more points, and the average value was obtained. Note that 0.05 kPa is a load assuming the apparent thickness of the nonwoven fabric so as not to crush the thickness as much as possible.
(2) Thickness of nonwoven fabric sample under 7.64 kPa pressure Based on the method described in (Method of measuring thickness of nonwoven fabric under 7.64 kPa pressure), the position of the fiber mass portion of each nonwoven fabric sample was determined. The thickness (T1) and the thickness (T2) at the position where the fiber lump was not arranged were measured. Further, the difference in thickness (T3 = T1-T2) was calculated.
[2] Friction Based on the method described in the above (Method for measuring average friction coefficient), MIU value (Q1) at the position where the fiber lump portion of each nonwoven fabric sample was placed, the position where the fiber lump portion was not placed , And the MIU value (Q2) was measured. Further, the MIU value difference Q3 (= Q1-Q2) was calculated.
[3] Pattern For each nonwoven fabric sample, the presence or absence of a fiber lump was visually confirmed.
また、実施例1~13は、繊維塊の模様が確認されながら、比較例1及び2に比べて、繊維塊部が配置された位置における平均摩擦係数Q1、繊維塊部が配置されていない位置における平均摩擦係数Q2、及び両者の差Q3のいずれもが小さく、不織布全体における柔らかい肌触りが実現されていた。
以上のとおり、実施例1~13は、嵩高さと柔らかい肌触りとに優れ、模様を備え審美性に優れたものとなっていた。 As shown in Tables 1 and 2, in Examples 1 to 13, compared to Comparative Examples 1 and 2, the thickness T1 at the position where the fiber lump was disposed under the pressure of 7.64 kPa and the fiber lump were not disposed. The difference T3 from the thickness T2 at the position was small, and the bulkiness of the entire nonwoven fabric was excellent. In particular, among the examples, the non-woven fabric subjected to the heat treatment after the web calender was thicker than the non-woven fabric calendered after the non-woven fabric, and had a good texture of the fiber mass portion.
In Examples 1 to 13, the average friction coefficient Q1 at the position where the fiber lump was arranged and the position where the fiber lump was not arranged were compared with Comparative Examples 1 and 2 while the pattern of the fiber lump was confirmed. , The average friction coefficient Q2 and the difference Q3 between the two were small, and soft touch was realized in the entire nonwoven fabric.
As described above, Examples 1 to 13 were excellent in bulkiness and soft touch, were provided with patterns, and were excellent in aesthetics.
2 繊維層
7 繊維塊部
8 繊維塊層(繊維塊部を有する層)
9 非繊維塊層(繊維塊部を有しない層)
10 吸収性物品用エアスルー不織布
100 吸収性物品用エアスルー不織布の製造装置
101、102 開繊部
103、104 カーディング部
105 積層ウェブ形成部
106 ウェブカレンダー部
106A、106B カレンダーロール
107 熱処理部(エアスルー加工部)
117 第1エアスルー処理部
127 第2エアスルー処理部
108 裁断・開繊部
71、72 原料繊維
81、82 単層ウェブ(又はウェブ)
90 積層ウェブ
95 ウェブカレンダー加工された積層ウェブ
9 Non-fiber lump layer (layer without fiber lump)
117 First air-through
90
Claims (39)
- 2層以上の繊維層が積層されたエアスルー不織布であって、熱可塑性繊維を含み、かつ、繊維塊部を有する繊維層を少なくとも1層有する、吸収性物品用エアスルー不織布。 (4) An air-through nonwoven fabric for an absorbent article, which is an air-through nonwoven fabric in which two or more fiber layers are laminated, and includes at least one fiber layer containing thermoplastic fibers and having a fiber mass portion.
- 前記吸収性物品用エアスルー不織布は、繊維径が1dtex以上2.2dtex以下、好ましくは1dtex以上、より好ましくは1.2dtex以上、好ましくは2dtex以下、より好ましくは1.5dtex以下である細繊維と、該細繊維よりも繊維径が太い太繊維とを有しており、
前記繊維塊部を有する繊維層が前記細繊維を含む、請求項1記載の吸収性物品用エアスルー不織布。 The air-through nonwoven fabric for absorbent articles has a fiber diameter of 1 dtex or more and 2.2 dtex or less, preferably 1 dtex or more, more preferably 1.2 dtex or more, preferably 2 dtex or less, more preferably 1.5 dtex or less, Having a thick fiber with a larger fiber diameter than the fine fiber,
The air-through nonwoven fabric for an absorbent article according to claim 1, wherein the fiber layer having the fiber mass portion includes the fine fibers. - 前記繊維塊部を有する繊維層における前記細繊維の含有量が、50質量%以上であり、好ましく80質量%以上、より好ましくは100質量%である請求項2記載の吸収性物品用エアスルー不織布。 The air-through nonwoven fabric for absorbent articles according to claim 2, wherein the content of the fine fibers in the fiber layer having the fiber mass is 50% by mass or more, preferably 80% by mass or more, more preferably 100% by mass.
- 前記繊維塊部を有しない繊維層を少なくとも1層有する、請求項1~3のいずれか1項に記載の吸収性物品用エアスルー不織布。 The air-through nonwoven fabric for absorbent articles according to any one of claims 1 to 3, wherein the air-through nonwoven fabric has at least one fiber layer not having the fiber mass portion.
- 前記吸収性物品用エアスルー不織布は、繊維径が2.2dtex超7dtex以下、好ましくは2.2dtex超、より好ましくは4.4dtex以上、好ましくは5.5dtex以下、より好ましくは5dtex以下である太繊維と、該太繊維よりも繊維径が細い細繊維とを有しており、
前記繊維塊部を有しない繊維層が前記太繊維を含む、請求項4記載の吸収性物品用エアスルー不織布。 The air-through nonwoven fabric for absorbent articles has a fiber diameter of more than 2.2 dtex and 7 dtex or less, preferably more than 2.2 dtex, more preferably 4.4 dtex or more, preferably 5.5 dtex or less, more preferably 5 dtex or less. And, having a fine fiber having a smaller fiber diameter than the thick fiber,
The air-through nonwoven fabric for an absorbent article according to claim 4, wherein the fiber layer having no fiber lump includes the thick fiber. - 前記繊維塊部を有しない繊維層における前記太繊維の含有量が、50質量%以上であり、好ましくは80質量%以上、より好ましくは100質量%である請求項5記載の吸収性物品用エアスルー不織布。 The air-through for an absorbent article according to claim 5, wherein the content of the thick fiber in the fiber layer having no fiber mass portion is 50% by mass or more, preferably 80% by mass or more, and more preferably 100% by mass. Non-woven fabric.
- 前記繊維塊部を有する層における前記太繊維の含有量が、50質量%以下であり、好ましくは30質量%以下、より好ましくは10質量%以下である請求項5又は6記載の吸収性物品用エアスルー不織布。 7. The absorbent article according to claim 5, wherein the content of the thick fiber in the layer having the fiber mass portion is 50% by mass or less, preferably 30% by mass or less, more preferably 10% by mass or less. Air-through non-woven fabric.
- 前記繊維塊部を有する繊維層よりも前記繊維塊部を有しない繊維層の平均繊維径が大きい、請求項4~7のいずれか1項に記載の吸収性物品用エアスルー不織布。 The air-through nonwoven fabric for an absorbent article according to any one of claims 4 to 7, wherein the average fiber diameter of the fiber layer having no fiber lump is larger than that of the fiber layer having the fiber lump.
- 前記繊維塊部を有しない繊維層の平均繊維径と前記繊維塊部を有する繊維層の平均繊維径との差が、0dtex超5.6dtex以下であり、好ましくは2.2dtex以上、より好ましくは3dtex以上、好ましくは4dtex以下、より好ましくは3.5dtex以下である、請求項8記載の吸収性物品用エアスルー不織布。 The difference between the average fiber diameter of the fiber layer having no fiber lump and the average fiber diameter of the fiber layer having the fiber lump is more than 0 dtex and 5.6 dtex or less, preferably 2.2 dtex or more, more preferably The air-through nonwoven fabric for absorbent articles according to claim 8, wherein the air-through nonwoven fabric for an absorbent article has a dtex of 3 dtex or more, preferably 4 dtex or less, more preferably 3.5 dtex or less.
- 前記繊維塊部を有する繊維層よりも前記繊維塊部を有しない繊維層の坪量が大きい、請求項4~9のいずれか1項に記載の吸収性物品用エアスルー不織布。 The air-through nonwoven fabric for an absorbent article according to any one of claims 4 to 9, wherein the basis weight of the fiber layer having no fiber lump is larger than that of the fiber layer having the fiber lump.
- 前記繊維塊部を有しない繊維層の坪量と前記繊維塊部を有する繊維層の坪量との差が、0g/m2超20g/m2以下であり、好ましくは3g/m2以上、より好ましくは5g/m2以上、好ましくは15g/m2以下、より好ましくは10g/m2以下である、請求項10記載の吸収性物品用エアスルー不織布。 The difference between the basis weight of the fiber layer having no fiber mass portion and the basis weight of the fiber layer having the fiber mass portion is more than 0 g / m 2 and 20 g / m 2 or less, preferably 3 g / m 2 or more, more preferably 5 g / m 2 or more, preferably 15 g / m 2 or less, and more preferably not more than 10 g / m 2, claim 10 for an absorbent article air-through nonwoven fabric according.
- 前記吸収性物品用エアスルー不織布全体の坪量が、15g/m2以上40g/m2以下であり、好ましくは18g/m2以上、より好ましくは20/m2以上、好ましくは30g/m2以下、より好ましくは25g/m2以下である、請求項1~11のいずれか1項に記載の吸収性物品用エアスルー不織布。 The basis weight of the air-through nonwoven fabric for absorbent articles is 15 g / m 2 or more and 40 g / m 2 or less, preferably 18 g / m 2 or more, more preferably 20 / m 2 or more, and preferably 30 g / m 2 or less. The air-through nonwoven fabric for absorbent articles according to any one of claims 1 to 11, wherein the air-through nonwoven fabric is at most 25 g / m 2 or less.
- 前記繊維塊部が配置された位置において、7.64kPa圧力下で測定された前記吸収性物品用エアスルー不織布の厚みをT1とし、前記繊維塊部が配置されていない位置において、同圧力下で測定された前記吸収性物品用エアスルー不織布の厚みをT2としたとき、T3=T1-T2で定義される厚みの差T3が0.4mm以下であり、好ましくは0.3mm以下、より好ましくは0.2mm以下であり、更に好ましくは0(ゼロ)mmである、請求項1~12のいずれか1項に記載の吸収性物品用エアスルー不織布。 The thickness of the air-through nonwoven fabric for an absorbent article measured at a pressure of 7.64 kPa at the position where the fiber lump is disposed is T1, and the thickness is measured at the position where the fiber lump is not disposed at the same pressure. Assuming that the thickness of the air-through nonwoven fabric for an absorbent article thus obtained is T2, the difference T3 in thickness defined by T3 = T1-T2 is 0.4 mm or less, preferably 0.3 mm or less, more preferably 0.1 mm or less. The air-through nonwoven fabric for absorbent articles according to any one of claims 1 to 12, wherein the thickness is 2 mm or less, more preferably 0 (zero) mm.
- 前記吸収性物品用エアスルー不織布の前記繊維塊部が配置された位置における平均摩擦係数が1.6以上2.5以下であり、好ましくは1.6以上、好ましくは2.4以下、より好ましくは2.3以下である、請求項1~13のいずれか1項に記載の吸収性物品用エアスルー不織布。 The average friction coefficient of the air-through nonwoven fabric for the absorbent article at the position where the fiber mass is disposed is 1.6 or more and 2.5 or less, preferably 1.6 or more, preferably 2.4 or less, more preferably. The air-through nonwoven fabric for an absorbent article according to any one of claims 1 to 13, which is 2.3 or less.
- 前記吸収性物品用エアスルー不織布の前記繊維塊部が配置された位置における平均摩擦係数と前記繊維塊部が配置されていない位置における平均摩擦係数との差が0.7以下であり、好ましくは0.5以下、より好ましくは0.32以下、更に好ましくは0.3以下、特に好ましくは0(ゼロ)である、請求項14記載の吸収性物品用エアスルー不織布。 The difference between the average friction coefficient of the air-through nonwoven fabric for the absorbent article at the position where the fiber lump is arranged and the average friction coefficient at the position where the fiber lump is not arranged is 0.7 or less, preferably 0 or less. 15. The air-through nonwoven fabric for absorbent articles according to claim 14, wherein the air-through nonwoven fabric is at most 0.5, more preferably at most 0.32, even more preferably at most 0.3, particularly preferably 0 (zero).
- 前記繊維塊部が、不織布の厚み方向の断面において、不織布厚み方向に潰された扁平形状となっており、不織布表面側の繊維塊部表面が滑らかな構造を有する、請求項1~15のいずれか1項に記載の吸収性物品用エアスルー不織布。 16. The fiber lump according to any one of claims 1 to 15, wherein, in a cross section in the thickness direction of the nonwoven fabric, the fiber lump has a flat shape crushed in the thickness direction of the nonwoven fabric, and the surface of the fiber lump on the nonwoven fabric surface side has a smooth structure. The air-through nonwoven fabric for an absorbent article according to claim 1 or 2.
- 前記繊維塊部を有する繊維層が、前記吸収性物品用エアスルー不織布の最も外側の層である、請求項1~16のいずれか1項に記載の吸収性物品用エアスルー不織布。 The air-through nonwoven fabric for an absorbent article according to any one of claims 1 to 16, wherein the fiber layer having the fiber mass portion is the outermost layer of the air-through nonwoven fabric for the absorbent article.
- 請求項1~17のいずれか1項に記載の吸収性物品用エアスルー不織布を有する吸収性物品。 An absorbent article having the air-through nonwoven fabric for an absorbent article according to any one of claims 1 to 17.
- 請求項17記載の前記吸収性物品用エアスルー不織布を吸収性物品の肌面側の最外層に配置し、前記繊維塊部を有する繊維層を肌面側に向けて配した吸収性物品。 18. An absorbent article, wherein the air-through nonwoven fabric for an absorbent article according to claim 17 is disposed on the outermost layer on the skin side of the absorbent article, and the fiber layer having the fiber mass is disposed toward the skin side.
- 前記吸収性物品用エアスルー不織布を表面シートとして有する、請求項18又は19記載の吸収性物品。 20. The absorbent article according to claim 18 or 19, wherein the air-through nonwoven fabric for the absorbent article has a surface sheet.
- 熱可塑性繊維に複数回の開繊処理を施してウェブを形成する開繊工程と、
前記開繊工程にて得た複数の単層ウェブを積層して積層ウェブを形成し、前記積層ウェブに熱風によるエアスルー加工を施してエアスルー不織布を得る工程と、
前記単層ウェブ、前記積層ウェブ及び前記エアスルー不織布から選ばれる一又は複数に対して一対のカレンダーロールを用いて施すカレンダー加工工程と
を有する吸収性物品用エアスルー不織布の製造方法。 A fiber-spreading step of performing a web-spreading process on the thermoplastic fibers a plurality of times to form a web,
Laminating a plurality of single-layer webs obtained in the fiber opening step to form a laminated web, and performing an air-through process by hot air on the laminated web to obtain an air-through nonwoven fabric,
A method for producing an air-through nonwoven fabric for an absorbent article, comprising: a calendering step of applying one or more of the single-layer web, the laminated web and the air-through nonwoven fabric using a pair of calender rolls. - 吸収性物品用エアスルー不織布の製造方法の全工程において、
前記単層ウェブ、前記積層ウェブ及び前記エアスルー不織布にかかる線圧のうち、前記カレンダー加工工程における線圧が最も高い、請求項21記載の吸収性物品用エアスルー不織布の製造方法。 In all steps of the manufacturing method of the air-through nonwoven fabric for absorbent articles,
The method for producing an air-through nonwoven fabric for absorbent articles according to claim 21, wherein the linear pressure in the calendering step is the highest among the linear pressures applied to the single-layer web, the laminated web, and the air-through nonwoven fabric. - 前記カレンダー加工工程が、前記単層ウェブ及び前記積層ウェブから選ばれる一又は複数に対して行うウェブカレンダー加工工程である、請求項21又は22記載の吸収性物品用エアスルー不織布の製造方法。 23. The method for producing an air-through nonwoven fabric for absorbent articles according to claim 21 or 22, wherein the calendering step is a web calendering step performed on one or more selected from the single-layer web and the laminated web.
- 前記ウェブカレンダー加工工程において前記単層ウェブ又は前記積層ウェブに加える線圧が20N/cm以上700N/cm以下であり、好ましくは100N/cm以上、より好ましくは180N/cm以上、好ましくは500N/cm以下、より好ましくは250N/cm以下である、請求項23記載の吸収性物品用エアスルー不織布の製造方法。 In the web calendering step, a linear pressure applied to the single-layer web or the laminated web is 20 N / cm or more and 700 N / cm or less, preferably 100 N / cm or more, more preferably 180 N / cm or more, and preferably 500 N / cm. The method for producing an air-through nonwoven fabric for absorbent articles according to claim 23, wherein the non-woven fabric is at most 250 N / cm or less.
- 前記前記カレンダー加工工程にて用いる一対のカレンダーロールが樹脂ロールと鋼体ロールの組み合わせである、請求項21~24のいずれか1項に記載の吸収性物品用エアスルー不織布の製造方法。 The method for producing an air-through nonwoven fabric for absorbent articles according to any one of claims 21 to 24, wherein the pair of calender rolls used in the calendering step are a combination of a resin roll and a steel roll.
- 前記樹脂ロールの硬度がD硬度において20以上100以下であり、好ましくは50度以上、より好ましくは80度以上、好ましくは95度以下、より好ましくは90度以下である、請求項25記載の吸収性物品用エアスルー不織布の製造方法。 The absorption according to claim 25, wherein the hardness of the resin roll is 20 or more and 100 or less in D hardness, preferably 50 or more, more preferably 80 or more, preferably 95 or less, more preferably 90 or less. A method for producing an air-through nonwoven fabric for non-woven articles.
- 前記エアスルー加工が複数のエアスルー処理を有し、最初のエアスルー処理よりも後段のエアスルー処理の方が熱風の風速が速い、請求項21~26のいずれか1項に記載の吸収性物品用エアスルー不織布の製造方法。 27. The air-through nonwoven fabric for absorbent articles according to any one of claims 21 to 26, wherein the air-through processing has a plurality of air-through processings, and a later-stage air-through processing has a higher velocity of hot air than a first air-through processing. Manufacturing method.
- 前記最初のエアスルー処理における熱風の風速が0.2m/sec以上1.2m/sec以下であり、好ましくは0.25m/sec以上、より好ましくは0.4m/sec以上、好ましくは0.8m/sec以下、より好ましくは0.5m/sec以下である、請求項27記載の吸収性物品用エアスルー不織布の製造方法。 The wind speed of the hot air in the first air-through treatment is 0.2 m / sec or more and 1.2 m / sec or less, preferably 0.25 m / sec or more, more preferably 0.4 m / sec or more, and preferably 0.8 m / sec or more. 28. The method for producing an air-through nonwoven fabric for absorbent articles according to claim 27, which is at most 0.5 sec / sec, more preferably at most 0.5 m / sec.
- 前記後段のエアスルー処理における熱風の風速が0.8m/sec以上1.6m/sec以下であり、好ましくは0.9m/sec以上、より好ましくは1.2m/sec以上、好ましくは1.4m/sec以下、より好ましくは1.3m/sec以下である、請求項27又は28記載の吸収性物品用エアスルー不織布の製造方法。 The wind velocity of the hot air in the latter air-through treatment is 0.8 m / sec or more and 1.6 m / sec or less, preferably 0.9 m / sec or more, more preferably 1.2 m / sec or more, and preferably 1.4 m / sec or more. 29. The method for producing an air-through nonwoven fabric for absorbent articles according to claim 27 or 28, wherein the air-through nonwoven fabric is at most 1.3 m / sec or less.
- 前記最初のエアスルー処理における熱風の風速と前記後段のエアスルー処理における熱風の風速の差が、0m/sec超1.4m/sec以下であり、好ましくは0.4m/sec以上、より好ましくは0.8m/sec以上、好ましくは1.2m/sec以下、より好ましくは1m/sec以下である、請求項27~29のいずれか1項に記載の吸収性物品用エアスルー不織布の製造方法。 The difference between the wind speed of the hot air in the first air-through process and the wind speed of the hot air in the subsequent air-through process is more than 0 m / sec and 1.4 m / sec or less, preferably 0.4 m / sec or more, and more preferably 0.1 m / sec or more. The method for producing an air-through nonwoven fabric for an absorbent article according to any one of claims 27 to 29, wherein the non-woven fabric is at least 8 m / sec, preferably at most 1.2 m / sec, more preferably at most 1 m / sec.
- 前記エアスルー加工が複数のエアスルー処理を有し、最初のエアスルー処理よりも後段のエアスルー処理の方が熱風の温度が高い、請求項21~30のいずれか1項に記載の吸収性物品用エアスルー不織布の製造方法。 The air-through nonwoven fabric for absorbent articles according to any one of claims 21 to 30, wherein the air-through processing includes a plurality of air-through processings, and the temperature of hot air is higher in a later-stage air-through processing than in an initial air-through processing. Manufacturing method.
- 前記最初のエアスルー処理における熱風の温度が85℃以上134℃以下であり、好ましくは90℃以上、より好ましくは100℃以上、好ましくは115℃以下、より好ましくは105℃以下である、請求項31記載の吸収性物品用エアスルー不織布の製造方法。 32. The temperature of the hot air in the first air-through treatment is 85 ° C or more and 134 ° C or less, preferably 90 ° C or more, more preferably 100 ° C or more, preferably 115 ° C or less, more preferably 105 ° C or less. A method for producing the air-through nonwoven fabric for an absorbent article according to the above.
- 前記後段のエアスルー処理における熱風の温度が、使用する繊維表面の成分の融点以上145℃以下であり、好ましくは使用する繊維表面の成分の融点以上、好ましくは137℃以下、より好ましくは134℃以下である、請求項31又は32記載の吸収性物品用エアスルー不織布の製造方法。 The temperature of the hot air in the subsequent air-through treatment is not less than the melting point of the component on the fiber surface used and not more than 145 ° C., preferably not less than the melting point of the component on the fiber surface used, preferably not more than 137 ° C., more preferably not more than 134 ° C. The method for producing an air-through nonwoven fabric for an absorbent article according to claim 31 or 32, wherein
- 前記最初のエアスルー処理における熱風の温度と後段のエアスルー処理における熱風の温度の差は0℃超60℃以下であり、好ましくは20℃以上、より好ましくは30℃以上、好ましくは40℃以下、より好ましくは35℃以下である、請求項31~33のいずれか1項に記載の吸収性物品用エアスルー不織布の製造方法。 The difference between the temperature of the hot air in the first air through process and the temperature of the hot air in the subsequent air through process is more than 0 ° C. and 60 ° C. or less, preferably 20 ° C. or more, more preferably 30 ° C. or more, and preferably 40 ° C. or less. The method for producing an air-through nonwoven fabric for absorbent articles according to any one of claims 31 to 33, wherein the temperature is preferably 35 ° C or lower.
- 前記開繊工程にて用いられるカード機内においてウェブの幅方向端部を回収する工程、及び、前記エアスルー不織布を部分的に回収し該回収した前記エアスルー不織布の部分を裁断し開繊する工程、の一方又は両方を有し、
回収した前記ウェブ、及び裁断し開繊した前記エアスルー不織布の部分を前記開繊工程に供する、請求項21~34のいずれか1項に記載の吸収性物品用エアスルー不織布の製造方法。 A step of collecting the width direction end of the web in the carding machine used in the opening step, and a step of partially collecting the air-through nonwoven fabric and cutting and opening the collected air-through nonwoven portion. Have one or both,
The method for producing an air-through nonwoven fabric for an absorbent article according to any one of claims 21 to 34, wherein the collected web and a portion of the air-through nonwoven fabric that has been cut and spread are subjected to the fiber-spreading step. - 前記積層ウェブは繊維径が異なる複数種類の繊維を有している、請求項21~35のいずれか1項に記載の吸収性物品用エアスルー不織布の製造方法。 The method for producing an air-through nonwoven fabric for an absorbent article according to any one of claims 21 to 35, wherein the laminated web has a plurality of types of fibers having different fiber diameters.
- 前記積層ウェブは、繊維径が1dtex以上2.2dtex以下、好ましくは1dtex以上、より好ましくは1.2dtex以上、好ましくは2dtex以下、より好ましくは1.5dtex以下である細繊維を有している、請求項21~36のいずれか1項に記載の吸収性物品用エアスルー不織布の製造方法。 The laminated web has fine fibers having a fiber diameter of 1 dtex or more and 2.2 dtex or less, preferably 1 dtex or more, more preferably 1.2 dtex or more, preferably 2 dtex or less, more preferably 1.5 dtex or less. The method for producing an air-through nonwoven fabric for an absorbent article according to any one of claims 21 to 36.
- 請求項21~37のいずれか1項に記載の製造方法により製造された吸収性物品用エアスルー不織布を吸収性物品に組み込む工程を有する、吸収性物品の製造方法。 A method for producing an absorbent article, comprising a step of incorporating the air-through nonwoven fabric for an absorbent article produced by the production method according to any one of claims 21 to 37 into the absorbent article.
- 前記吸収性物品用エアスルー不織布を表面シートとして吸収性物品に組み込む工程を有する、請求項38記載の吸収性物品の製造方法。
The method for producing an absorbent article according to claim 38, further comprising a step of incorporating the air-through nonwoven fabric for the absorbent article into the absorbent article as a topsheet.
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GB1918330.0A GB2581560B (en) | 2018-09-07 | 2018-09-07 | Air-through nonwoven fabric for absorbent article |
JP2019500600A JP6667047B1 (en) | 2018-09-07 | 2018-09-07 | Air-through nonwoven fabric for absorbent articles |
DE112018003388.0T DE112018003388T5 (en) | 2018-09-07 | 2018-09-07 | Air-through fleece for absorbent articles |
PCT/JP2018/033325 WO2020049747A1 (en) | 2018-09-07 | 2018-09-07 | Air-through nonwoven fabric for absorbent article |
CN201890001448.7U CN215689118U (en) | 2018-09-07 | 2018-09-07 | Hot-air nonwoven fabric for absorbent article |
RU2020104033A RU2733362C1 (en) | 2018-09-07 | 2018-09-07 | Hot air-bonded non-woven material for absorbent product |
KR1020207001004A KR102177357B1 (en) | 2018-09-07 | 2018-09-07 | Air-through nonwoven fabric for absorbent articles |
TW108132173A TWI711437B (en) | 2018-09-07 | 2019-09-06 | Hot-air non-woven fabric for absorbent article and its manufacturing method, and absorbent article |
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RU2796016C1 (en) * | 2020-08-25 | 2023-05-16 | Као Корпорейшн | Absorbing product |
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KR102505451B1 (en) * | 2022-11-22 | 2023-03-06 | 임영배 | Non-woven fabric manufacturing equipment |
KR102608132B1 (en) * | 2023-07-27 | 2023-11-30 | 남양부직포 주식회사 | Double-faced adhesive cleaner fabric and Manufacturing method thereof |
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