WO2022004505A1 - Surface material for sanitary material and production method therefor - Google Patents

Surface material for sanitary material and production method therefor Download PDF

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Publication number
WO2022004505A1
WO2022004505A1 PCT/JP2021/023703 JP2021023703W WO2022004505A1 WO 2022004505 A1 WO2022004505 A1 WO 2022004505A1 JP 2021023703 W JP2021023703 W JP 2021023703W WO 2022004505 A1 WO2022004505 A1 WO 2022004505A1
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Prior art keywords
fiber
fibers
cotton
long
woven fabric
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PCT/JP2021/023703
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French (fr)
Japanese (ja)
Inventor
篤 松永
章太朗 森
大治 塚原
太郎 市川
規仁 佐座
Original Assignee
ユニチカ株式会社
三井化学株式会社
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Application filed by ユニチカ株式会社, 三井化学株式会社 filed Critical ユニチカ株式会社
Priority to CN202180045538.2A priority Critical patent/CN115917070A/en
Priority to JP2022533901A priority patent/JPWO2022004505A1/ja
Publication of WO2022004505A1 publication Critical patent/WO2022004505A1/en

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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/02—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
    • D04H5/03—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling by fluid jet

Definitions

  • the present invention relates to a method for manufacturing a surface material used for a portion of a sanitary material such as a sanitary napkin or a disposable diaper that comes into contact with the skin, and particularly to a method for manufacturing a surface material for a sanitary material that is soft to the touch and has excellent wear resistance. Is.
  • Patent Document 1 discloses a surface material of a sanitary material in which a long-fiber non-woven fabric and a specific short-fiber non-woven fabric are bonded.
  • Patent Document 1 As a specific short fiber non-woven fabric arranged on the skin side, a heat-fused composite short fiber having at least two kinds of thermoplastic resin components having a high melting point and a low melting point is fused with a low melting point component. It has been adopted (Patent Document 1, Claim 1). Further, as the long fiber non-woven fabric, one in which heat-fused composite long fibers having at least two kinds of thermoplastic resin components having a high melting point and a low melting point are fused with each other with a low melting point component is adopted (Patent Document). 1, claim 3).
  • the short fiber non-woven fabric made of short fibers made of a thermoplastic resin component is not as soft to the touch as the short fiber non-woven fabric made of natural fibers such as cotton fiber and silk fiber, and there is a risk of skin irritation. rice field. Therefore, as a short-fiber non-woven fabric, a non-woven fabric made of cotton fiber has been adopted, and a surface material in which the long fibers and the cotton fibers in the long-fiber non-woven fabric are entangled and integrated has been proposed (Patent Document 2, Claims). Item 1).
  • the present invention is an improved invention of the invention described in Patent Document 2, and an object of the present invention is to improve wear resistance without reducing the touch of the surface of the surface material in contact with the skin.
  • the present invention uses a meltblown nonwoven fabric (for example, Japanese Patent Application Laid-Open No. 2019-209121), which is often used as a leak-proof material for sanitary materials, as a surface material, and adopts a specific manufacturing method to achieve the above problems.
  • a meltblown nonwoven fabric for example, Japanese Patent Application Laid-Open No. 2019-209121
  • the present invention includes a cotton fiber web made of cotton fibers, a first long fiber non-woven fabric made of long fibers containing a propylene-based polymer, and a propylene-based polymer, the fiber diameter of which is the cotton fiber.
  • a high-pressure water stream is applied to the laminated body in which the second long fiber non-woven fabric composed of the ultra-fine fiber non-woven fabric containing the ultra-fine fiber finer than the fiber diameter of the long fiber and the long fiber containing the propylene-based polymer is laminated in this order.
  • the present invention relates to a method for producing a surface material of a sanitary material in which the web side of a cotton fiber comes into contact with the skin, which comprises breaking the ultrafine fiber non-woven fabric and entwining the ultrafine fiber with the cotton fiber.
  • the cotton fiber web region made of cotton fiber and the region containing long fiber containing a propylene-based polymer are included, and the cotton fiber and the ultrafine fiber having a fiber diameter smaller than the fiber diameter of the long fiber are the ultrafine fibers. It relates to a surface material of a sanitary material entwined with cotton fibers and the long fibers.
  • a high-pressure water stream is applied to a laminate containing an ultrafine fiber nonwoven fabric to break the ultrafine fiber nonwoven fabric, and most of the ultrafine fibers are discharged, and a part of the ultrafine fibers is formed into a confounding portion between cotton fibers. It is to stay and entangle. Therefore, the surface material obtained by the method according to the present invention has an effect that the bond between the cotton fibers is strong and the abrasion resistance of the cotton fiber web surface in contact with the skin is improved.
  • SMS non-woven fabric The surface of a laminate of first long fiber non-woven fabric / ultrafine fiber non-woven fabric / second long fiber non-woven fabric (hereinafter, this laminate may be referred to as “SMS non-woven fabric”) was photographed using an electron microscope at a magnification of 300 times. It is a photograph.
  • the cotton fiber web used in the present invention is mainly composed of cotton fiber.
  • hydrophilic fibers such as silk fibers or rayon fibers may be mixed.
  • Such a cotton fiber web can be obtained by opening and accumulating cotton fibers by a known card method.
  • the basis weight of the cotton fiber web is about 10 to 20 g / m 2.
  • As the cotton fiber it is preferable to use non-defatted cotton (non-defatted cotton), and further, it is preferable to use non-solvent degreased bleached cotton (non-defatted bleached cotton). In non-cotton wool, oil and fat (cotton wax, cottonseed oil, etc.
  • the numerical range represented by using "-" means a range including the numerical values before and after "-" as the lower limit value and the upper limit value.
  • the long fibers constituting the first long fiber non-woven fabric and the second long fiber non-woven fabric used in the present invention contain a polypropylene-based polymer. Since the surface material of the present invention contains a region derived from the first long fiber nonwoven fabric and the second long fiber nonwoven fabric, it tends to be superior in tensile strength.
  • the content of long fibers in the long fiber non-woven fabric is preferably 50% or more, more preferably 90% or more, still more preferably 99% or more, based on the number of fibers, from the viewpoint of further improving the tensile strength of the surface material.
  • the content of the propylene-based polymer in the long fibers is preferably 90% by mass or more, more preferably 99% by mass or more, from the viewpoint of spinnability.
  • the upper limit value or the lower limit value described in a certain numerical range is replaced with the upper limit value or the lower limit value of another numerical range described stepwise. You may. Further, in the numerical range described in the present specification, the upper limit value or the lower limit value described in a certain numerical range may be replaced with the value shown in the examples.
  • the polypropylene-based polymer a propylene homopolymer, a propylene / ⁇ -olefin random copolymer, a propylene / ⁇ -olefin block copolymer, or the like is used.
  • the ⁇ -olefin ⁇ -olefins other than propylene such as ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene and 4-methyl-1-pentene are used.
  • the copolymerization amount is preferably 1 to 10 mol%.
  • the fiber may contain one of these polymers alone or may contain two or more of them.
  • the propylene-based polymer means a polymer containing 50% by mass or more of a structural unit derived from propylene.
  • the melt flow rate (MFR, ASTM D1238, 230 ° C., load 2160 g) of the propylene-based polymer contained in the long fibers is not particularly limited as long as it can be melt-spun.
  • the MFR may be 1 g / 10 minutes to 1000 g / 10 minutes, preferably 5 g / 10 minutes to 500 g / 10 minutes, and more preferably 10 g / 10 minutes to 100 g / 10 minutes. ..
  • the MFR of the propylene-based polymer is within the above range, the tensile strength tends to improve, which is preferable.
  • the average fiber diameter of the long fibers is not particularly limited as long as the effect of the present invention is exhibited, but from the viewpoint of further improving the wear resistance and the tensile strength, 10 ⁇ m to 50 ⁇ m is preferable, and 11 ⁇ m to 30 ⁇ m is more preferable.
  • the average fiber diameter of the long fibers is calculated based on a photograph of the long fiber non-woven fabric, as will be described later in the item of the example.
  • the photograph taken may be a photograph of the long fiber non-woven fabric alone, a photograph of a laminate of the ultrafine fiber non-woven fabric and the long fiber non-woven fabric, or a photograph of the surface material. Note that FIG. 1 is a photograph of the surface of the SMS non-woven fabric.
  • the long fiber may be a long fiber composed of a single component, or may be a composite long fiber such as a core sheath type or a sea island type. From the viewpoint of further improving the strength of the surface material, long fibers composed of a single component are preferable.
  • the first long fiber non-woven fabric and the second long fiber non-woven fabric used in the present invention are generally manufactured by the so-called spunbond method. Further, it is preferable that the first long fiber non-woven fabric and the second long fiber non-woven fabric are partially hot pressed by heat embossing to further improve the morphological stability.
  • the basis weights of the first-long fiber nonwoven fabric and the second-long fiber nonwoven fabric are preferably 1 to 30 g / m 2 and 3 to 10 g from the viewpoint of further improving the tensile strength and facilitating the entanglement treatment by the high-pressure water flow described later. / M 2 is more preferable.
  • the ultrafine fibrous nonwoven fabric sandwiched between the first long fiber non-woven fabric and the second long fiber nonwoven fabric contains a propylene-based polymer and contains ultrafine fibers having an average fiber diameter of 0.5 to 7 ⁇ m.
  • the average fiber diameter of the ultrafine fibers is calculated based on a photograph of the ultrafine fiber non-woven fabric, as will be described later in the item of the example.
  • the photograph taken may be a photograph of the ultrafine fiber non-woven fabric alone, a photograph of a laminate of the ultrafine fiber non-woven fabric and the long fiber non-woven fabric, or a photograph of the surface material. Then, a fiber having a fiber diameter of 8 ⁇ m or less is selected and calculated. Therefore, the ultrafine fibers have a fiber diameter of 8 ⁇ m or less.
  • the monomers constituting the propylene-based polymer contained in the ultrafine fibers and their amounts thereof are the same as those of the propylene-based polymer contained in the above-mentioned long fibers.
  • the content of the ultrafine fibers in the ultrafine fiber non-woven fabric is preferably 50% or more, more preferably 90% or more, still more preferably 99% or more, based on the number of fibers, from the viewpoint of further improving the wear resistance.
  • the content of the propylene-based polymer in the ultrafine fibers is preferably 90% by mass or more, more preferably 99% by mass or more, from the viewpoint of spinnability.
  • the melt flow rate (MFR, ASTM D1238, 230 ° C., load 2160 g) of the propylene-based polymer contained in the ultrafine fibers is not particularly limited as long as it can be melt-spun.
  • the MFR may be 1 g / 10 min to 2000 g / 10 min, preferably 100 g / 10 min to 1500 g / 10 min, and more preferably 200 g / 10 min to 1000 g / 10 min. ..
  • the MFR of the propylene-based polymer is within the above range, the strength of the ultrafine fibers tends to be improved, which is preferable.
  • the average fiber diameter of the ultrafine fibers is preferably 1 ⁇ m to 5 ⁇ m from the viewpoint of facilitating the entanglement treatment with a high-pressure water flow.
  • Basis weight of the microfibrous non-woven fabric is to more easily subjected to entangling treatment by the high-pressure water stream, from the viewpoint of easier aspects and handling properties further improve the wear resistance, 0.1g / m 2 ⁇ 7g / m 2 is Preferably, 0.3 g / m 2 to 5 g / m 2 is more preferable.
  • the first long fiber non-woven fabric, the extra fine fiber non-woven fabric and the second long fiber non-woven fabric used in the present invention are antioxidants, heat-resistant stabilizers, weather-resistant stabilizers, antistatic agents, slip agents, antifogging agents, lubricants, dyes, pigments, etc. It may contain various known additives such as natural oils, synthetic oils, waxes and fatty acid amides. The content of these additives in each non-woven fabric is preferably 0.1% by mass or less, more preferably 0.05% by mass or less, still more preferably 0.01% by mass or less.
  • the first long fiber non-woven fabric, the extra fine fiber non-woven fabric and the second long fiber non-woven fabric can be obtained by laminating after each of them is manufactured separately, but it is generally preferable to obtain them by the following method. That is, the ultrafine fiber web obtained by the so-called melt blown method is laminated on the first long fiber web obtained by the so-called spunbond method, and the second long fiber obtained by the so-called spunbond method is further laminated on the ultrafine fiber web. Stack the web. Then, a method of partially hot pressing by hot embossing to fuse the fibers in each web to obtain an SMS nonwoven fabric in which the first long fiber non-woven fabric, the ultrafine fibrous nonwoven fabric, and the second long fiber nonwoven fabric are laminated in this order. Is preferable.
  • a laminated body is obtained by laminating the cotton fiber web, the first long fiber non-woven fabric, the ultrafine fiber non-woven fabric, and the second long fiber non-woven fabric in this order.
  • a high-pressure water flow is applied to this laminated body.
  • the high-pressure water flow may be applied from the cotton fiber web side, the second long fiber non-woven fabric side, or from both sides.
  • the cotton fibers and the long fibers are entangled, but the ultrafine fiber non-woven fabric is broken and the ultrafine fibers are cut or flow out together with the high pressure water flow.
  • some ultrafine fibers stay and entangle in the entangled portion between the cotton fibers and the entangled portion between the long fibers. That is, it is entangled with the entangled portion between the cotton fibers, and the bond between the cotton fibers becomes stronger.
  • the abrasion resistance of the cotton fiber web side that is, the surface of the surface material in contact with the skin is improved.
  • the ultrafine fiber non-woven fabric is destroyed, it no longer has a waterproof function and becomes a surface material having a body fluid permeability that allows the body fluid to pass through appropriately.
  • any other fiber web may be laminated on the second long fiber nonwoven fabric side.
  • a mixed fiber web composed of cotton fibers and heat-fusing short fibers may be laminated.
  • the texture of the mixed fiber web is about 10 to 20 g / m 2
  • the cotton fiber it is preferable to use the above-mentioned non-defatted cotton or non-defatted bleached cotton.
  • the heat-bondable short fibers those made of a thermoplastic resin having a melting point are adopted.
  • polypropylene fiber, polyester fiber, polyamide fiber and the like are used.
  • heat-sealing short fibers which are concentric sheath-type composite short fibers in which the melting point of the sheath component is lower than the melting point of the core component.
  • the fibers are fused and bonded to each other.
  • concentric sheath-type composite short fibers having a core component of polypropylene and a sheath component of polyethylene and concentric core-sheath-type composite short fibers having a core component of polyester and a sheath component of polyethylene are used.
  • the fineness and fiber length of the heat-bondable short fibers are arbitrary, but generally, the fineness is about 1 to 5 decitex and the fiber length is about 10 to 100 mm.
  • the laminate contains heat-bondable short fibers
  • the heat-bondable short fibers are softened or melted in this drying step or after drying to melt the fibers between the fibers. It is preferable to bond them.
  • a concentric sheath-type composite short fiber having a core component of polypropylene and a sheath component of polyethylene is used as the heat-sealing short fiber
  • the drying temperature is set to about 130 ° C.
  • the obtained surface material includes a cotton fiber web region composed of cotton fibers and a region containing long fibers containing a propylene-based polymer, and has a fiber diameter smaller than the fiber diameter of the cotton fibers and the long fibers.
  • the ultrafine fibers are the surface material of the sanitary material entwined with the cotton fibers and the long fibers.
  • the cotton fiber web region and the region containing long fibers cannot be clearly distinguished, and the fibers in each region invade other regions. That is, the region containing a relatively large amount of cotton fibers becomes the cotton fiber web region, and the region containing a relatively large amount of long fibers becomes a region containing long fibers.
  • the surface material of the sanitary material may be cut in the thickness direction, the cross section thereof may be observed with a microscope, and the number of each fiber may be counted.
  • the thickness of the surface material is preferably 0.50 mm or less.
  • the thickness is 0.50 mm or less, the entanglement of the cotton fibers and the ultrafine fibers that come into contact with the skin is further improved, and the wear resistance tends to be further improved.
  • a surface material of a sanitary material having such a thickness can be produced, for example, by the production method of the present invention.
  • the thickness is preferably 0.25 mm or more from the viewpoint of further improving the strength.
  • the basis weight of the surface material of the sanitary material is preferably 25 g / m 2 to 50 g / m 2. When the basis weight is 25 g / m 2 or more, the strength tends to be further improved. On the other hand, when the basis weight is 50 g / m 2 or less, the cotton fibers in the cotton fiber web region are entangled with the ultrafine fibers more often, and the wear resistance tends to be improved.
  • the tensile strength of the surface material of the sanitary material is preferably 15 N / 50 mm width to 100 N / 50 mm width, more preferably 25 N / 50 mm width to 90 N / 50 mm width, and 30 N / 50 mm. It is more preferably width to 85 N / 50 mm width. Further, it is preferable that the tensile strength in the direction orthogonal to the machine direction (width direction) is 10 N / 50 mm width to 50 N / 50 mm width. If the tensile strength is less than the lower limit, the handleability during manufacturing of sanitary materials tends to decrease. Further, if the tensile strength exceeds the upper limit value, the surface material becomes excessive quality, which is irrational.
  • the machine direction refers to the transport direction when manufacturing the nonwoven fabric. That is, it is the direction in which the long fibers in the non-woven fabric are arranged. Therefore, the tensile strength in the mechanical direction, which is the arrangement direction of the long fibers, is high, and the tensile strength in the width direction is low.
  • the surface material obtained as described above is used as a surface material for sanitary materials such as sanitary napkins, disposable diapers and face masks. And since the cotton fiber web side is used so as to be in contact with the skin, the touch is good.
  • the surface of the friction terminal was covered with a cloth adhesive tape, and a load of 300 g was applied to the friction terminal so that the cloth adhesive tape and the sample came into contact with each other. Then, the friction terminal was slid at a reciprocating speed of 30 times / min, and the number of reciprocating times when all 6 points of the sample were visually torn was measured. This measurement was performed 5 times, and the average value of these was taken as the wear resistance (times). Even if the number of round trips exceeded 500, if no tear was visually observed in all 6 points of the sample, the measurement was stopped and the number of round trips was set to 500. Therefore, the maximum value of wear resistance (times) is 500 times.
  • the diameters (widths) of all the fibers of the fibers having a fiber diameter of 9 ⁇ m or more located on the surface side of the ultrafine fibers were measured, and the arithmetic average value was measured as the long fibers in the long fiber non-woven fabric on the surface side.
  • the average fiber diameter of. Measure the back side in the same way.
  • Average fiber diameter of ultrafine fiber Measured based on an electron micrograph of the surface of the ultrafine fiber non-woven fabric. Specifically, a method of measuring the average fiber diameter of ultrafine fibers using an SMS nonwoven fabric will be described.
  • the diameters (widths) of all the fibers having a fiber diameter of 8 ⁇ m or less are measured, and the arithmetic mean value thereof is taken as the average fiber diameter of the ultrafine fibers in the ultrafine fiber nonwoven fabric.
  • the diameter (width) of the fiber may be measured at the position where the width of the fiber is the smallest in the photograph. Further, when the fibers are fused to each other, the measurement may be performed at the non-fused portion, and when the non-fused portion does not exist, the fiber may be excluded from the number.
  • Example 1 [Preparation of cotton fiber web] Undefatted bleached cotton with an average fiber length of 25 mm was opened and accumulated with a parallel card machine to obtain a cotton fiber web having a basis weight of 20 g / m 2.
  • SMS non-woven fabric A propylene homopolymer having a melting point of 162 ° C. and an MFR of 60 g / 10 minutes (MFR was measured at a temperature of 230 ° C. and a load of 2.16 kg according to ASTMD1238. Hereinafter, the measurement method of MFR is the same) was used, and the melting temperature was 230. Melt spinning was performed by a conventional spunbond method using a spun mouthpiece provided with a large number of spinning holes having a diameter of 0.6 mm at ° C., and long fibers were accumulated on the collection surface to obtain a first long fiber web.
  • the average fiber diameter of the long fibers in the first long fiber web was 12.8 ⁇ m, and the basis weight of the first long fiber web was 5.75 g / m 2 .
  • the melt melted at a melting temperature of 280 ° C. is discharged from a die equipped with a large number of 0.4 mm ⁇ discharge holes, and 280 at the discharge hole outlet.
  • the ultrafine fibers were accumulated on the first long fiber web by a conventional melt blown method in which heated air at ° C was blown to obtain an ultrafine fiber web.
  • the average fiber diameter of the ultrafine fibers in the ultrafine fiber web was 1.4 ⁇ m, and the basis weight of the ultrafine fiber web was 1.5 g / m 2 .
  • long fibers were accumulated on the ultrafine fiber web to obtain a second long fiber web.
  • the average fiber diameter of the long fibers in the second long fiber web was 12.8 ⁇ m, and the basis weight of the second long fiber web was 5.75 g / m 2 .
  • the temperature of the mirror roll is 145 ° C. with a thermal embossing roll so that the total pressure contact area is 18% on the web laminated in the order of the first long fiber web, the ultrafine fiber web and the second long fiber web.
  • the three layers were partially heat-pressed to obtain an SMS nonwoven fabric in which the first long fiber nonwoven fabric, the ultrafine fiber nonwoven fabric and the second long fiber nonwoven fabric were laminated in this order.
  • the basis weight of the SMS nonwoven fabric was 13 g / m 2 .
  • the laminated body in which the cotton fiber web and the SMS non-woven fabric prepared above are laminated is passed through a high-pressure water flow ejection device (a device in which ejection holes having a hole diameter of 0.1 mm are arranged in a horizontal row with a hole spacing of 0.6 mm).
  • a high-pressure water stream was applied from the web side at an ejection pressure of 3 MPa, and then a high-pressure water stream was applied at an ejection pressure of 6 MPa. Then, a high-pressure water stream was applied from the second long fiber nonwoven fabric side at an injection pressure of 6 MPa, and then dried at 120 ° C. to obtain a surface material.
  • Example 2 [Preparation of cotton fiber web and SMS non-woven fabric] The same cotton fiber web and SMS non-woven fabric used in Example 1 were obtained.
  • the laminate in which the cotton fiber web, the SMS non-woven fabric, and the mixed fiber web prepared above are laminated in this order is passed through the high-pressure water flow ejection device used in Example 1, and a high-pressure water flow is applied from the cotton fiber web side at an ejection pressure of 3 MPa. Then, a high-pressure water flow was applied at an ejection pressure of 6 MPa. Then, a high-pressure water stream was applied from the mixed fiber web side at an injection pressure of 6 MPa, and then dried to obtain a surface material.
  • the drying temperature was 135 ° C., only polyethylene, which was a concentric sheath-type composite short fiber, was softened or melted, and a surface material in which the fibers were fused and bonded to each other was obtained.
  • Example 3 In the SMS nonwoven fabric used in Example 1, the basis weights of the first long fiber web and the second long fiber web were changed to 6.25 g / m 2, and the basis weight of the ultrafine fiber web was changed to 0.5 g / m 2. Other than that, a surface material was obtained in the same manner as in Example 1. The basis weight was changed by adjusting the moving speed of the collecting surface and the discharge amount of the ultrafine fibers.
  • Comparative Example 1 A surface material having a basis weight of 35 g / m 2 was obtained by applying a high-pressure water stream under the same conditions as in Example 1 using only a cotton fiber web having a basis weight of 35 g / m 2 without using an SMS non-woven fabric.
  • Comparative Example 2 A surface material having a basis weight of 33 g / m 2 was obtained in the same manner as in Example 1 except that the long fiber web obtained by the following method was used instead of the SMS nonwoven fabric.
  • melt spinning was performed by a conventional spunbond method using a spinneret having a large number of spinning holes of 0.6 mm ⁇ at a melt temperature of 230 ° C. The fibers were accumulated on the collection surface to obtain a long fiber web.
  • the average fiber diameter of the long fibers in the long fiber web was 33.5 ⁇ m, and the basis weight of the long fiber web was 13.0 g / m 2 .

Abstract

[Problem] To provide a production method for a surface material for sanitary material, the surface material having improved wear resistance without reducing the feel of the surface that comes in contact with skin. [Solution] This production method for a surface material for sanitary material comprises the following steps. SMS nonwoven fabric and a cotton fiber web formed from cotton fibers are laminated to obtain a laminated body. The SMS nonwoven fabric herein is obtained by laminating first long fiber nonwoven fabric, ultrafine fiber nonwoven fabric, and second long fiber nonwoven fabric in this order. The laminated body is subjected to high pressure water processing to mutually interlace the cotton fibers and mutually interlace the long fibers. The ultrafine fiber nonwoven fabric is broken with high pressure water to drain off a large amount of the ultrafine fibers and to retain a part of the ultrafine fibers in the part at which cotton fibers are mutually interlaced, causing entanglement. A surface material in which bonding between cotton fibers is strengthened is obtained thereby. The surface on the cotton fiber web-side of the obtained surface material forms the surface that comes in contact with skin.

Description

衛生材料の表面材及びその製造方法Surface materials for sanitary materials and their manufacturing methods
　本発明は、生理用ナプキンや使い捨ておむつ等の衛生材料の肌に当接する箇所に用いる表面材の製造方法に関し、特に、肌触りが良く耐摩耗性に優れた衛生材料の表面材の製造方法に関するものである。 The present invention relates to a method for manufacturing a surface material used for a portion of a sanitary material such as a sanitary napkin or a disposable diaper that comes into contact with the skin, and particularly to a method for manufacturing a surface material for a sanitary material that is soft to the touch and has excellent wear resistance. Is.
　従来より、衛生材料の表面材として、短繊維不織布又は長繊維不織布が採用されている。短繊維不織布は、肌触りの点で優れているが破断強度が低いという欠点があった。一方、長繊維不織布は、高破断強度であるが肌触りが悪いという欠点があった。このため、特許文献１には、長繊維不織布と特定の短繊維不織布とを接合した衛生材料の表面材が開示されている。そして、肌側に配置される特定の短繊維不織布として、高融点と低融点の少なくとも２種の熱可塑性樹脂成分を有する熱融着性複合短繊維相互間を低融点成分で融着したものが採用されている（特許文献１、請求項１）。また、長繊維不織布としても、高融点と低融点の少なくとも２種の熱可塑性樹脂成分を有する熱融着性複合長繊維相互間を低融点成分で融着したものが採用されている（特許文献１、請求項３）。 Conventionally, a short fiber non-woven fabric or a long fiber non-woven fabric has been adopted as a surface material for sanitary materials. The short fiber non-woven fabric is excellent in terms of touch, but has a drawback of low breaking strength. On the other hand, the long-fiber non-woven fabric has a drawback that it has a high breaking strength but is not soft to the touch. Therefore, Patent Document 1 discloses a surface material of a sanitary material in which a long-fiber non-woven fabric and a specific short-fiber non-woven fabric are bonded. Then, as a specific short fiber non-woven fabric arranged on the skin side, a heat-fused composite short fiber having at least two kinds of thermoplastic resin components having a high melting point and a low melting point is fused with a low melting point component. It has been adopted (Patent Document 1, Claim 1). Further, as the long fiber non-woven fabric, one in which heat-fused composite long fibers having at least two kinds of thermoplastic resin components having a high melting point and a low melting point are fused with each other with a low melting point component is adopted (Patent Document). 1, claim 3).
　しかしながら、熱可塑性樹脂成分よりなる短繊維で構成される短繊維不織布は、コットン繊維や絹繊維等の天然繊維で構成される短繊維不織布に比べると、肌触りが悪く、しかも肌がかぶれる恐れもあった。このため、短繊維不織布として、コットン繊維よりなる不織布を採用し、長繊維不織布中の長繊維とコットン繊維とを絡合させて一体化させた表面材が提案されている（特許文献２、請求項１）。 However, the short fiber non-woven fabric made of short fibers made of a thermoplastic resin component is not as soft to the touch as the short fiber non-woven fabric made of natural fibers such as cotton fiber and silk fiber, and there is a risk of skin irritation. rice field. Therefore, as a short-fiber non-woven fabric, a non-woven fabric made of cotton fiber has been adopted, and a surface material in which the long fibers and the cotton fibers in the long-fiber non-woven fabric are entangled and integrated has been proposed (Patent Document 2, Claims). Item 1).
特開平９－１１７４７０号公報Japanese Unexamined Patent Publication No. 9-117470 実用新案登録第３２１８４１６号公報Utility Model Registration No. 3218416 Gazette
　本発明は、特許文献２記載の考案の改良発明であって、表面材の肌に当接する面の肌触りを低下させることなく、耐摩耗性を向上させることを課題とするものである。 The present invention is an improved invention of the invention described in Patent Document 2, and an object of the present invention is to improve wear resistance without reducing the touch of the surface of the surface material in contact with the skin.
　本発明は、衛生材料の防漏材として用いられることが多いメルトブローン不織布（たとえば、特開２０１９－２０９１２１号公報）を表面材の素材として用いると共に、特定の製造方法を採用することにより、上記課題を解決したものである。すなわち、本発明は、コットン繊維で構成されてなるコットン繊維ウェブ、プロピレン系重合体を含む長繊維で構成されてなる第一長繊維不織布、プロピレン系重合体を含み、その繊維径が該コットン繊維及び該長繊維の繊維径よりも細い極細繊維を含む極細繊維不織布及びプロピレン系重合体を含む長繊維で構成されてなる第二長繊維不織布の順に積層された積層体に高圧水流を施して、該極細繊維不織布を破壊すると共に、該コットン繊維に該極細繊維を絡合させることを特徴とする、コットン繊維ウェブ側が肌に当接する衛生材料の表面材の製造方法に関するものである。また、コットン繊維で構成されてなるコットン繊維ウェブ領域とプロピレン系重合体を含む長繊維を含む領域とを含み、該コットン繊維及び該長繊維の繊維径よりも細い繊維径の極細繊維が、該コットン繊維及び該長繊維と交絡している衛生材料の表面材に関するものである。 The present invention uses a meltblown nonwoven fabric (for example, Japanese Patent Application Laid-Open No. 2019-209121), which is often used as a leak-proof material for sanitary materials, as a surface material, and adopts a specific manufacturing method to achieve the above problems. Is the solution. That is, the present invention includes a cotton fiber web made of cotton fibers, a first long fiber non-woven fabric made of long fibers containing a propylene-based polymer, and a propylene-based polymer, the fiber diameter of which is the cotton fiber. A high-pressure water stream is applied to the laminated body in which the second long fiber non-woven fabric composed of the ultra-fine fiber non-woven fabric containing the ultra-fine fiber finer than the fiber diameter of the long fiber and the long fiber containing the propylene-based polymer is laminated in this order. The present invention relates to a method for producing a surface material of a sanitary material in which the web side of a cotton fiber comes into contact with the skin, which comprises breaking the ultrafine fiber non-woven fabric and entwining the ultrafine fiber with the cotton fiber. Further, the cotton fiber web region made of cotton fiber and the region containing long fiber containing a propylene-based polymer are included, and the cotton fiber and the ultrafine fiber having a fiber diameter smaller than the fiber diameter of the long fiber are the ultrafine fibers. It relates to a surface material of a sanitary material entwined with cotton fibers and the long fibers.
　本発明に係る方法は、極細繊維不織布を含む積層体に高圧水流を施し、極細繊維不織布を破壊し、極細繊維の多くを流出させると共に、極細繊維の一部をコットン繊維相互間の交絡部に滞留せしめて絡合させるというものである。したがって、本発明に係る方法で得られた表面材は、コットン繊維相互間の結合が強固になっており、肌に接するコットン繊維ウェブ面の耐摩耗性が向上するという効果を奏するものである。 In the method according to the present invention, a high-pressure water stream is applied to a laminate containing an ultrafine fiber nonwoven fabric to break the ultrafine fiber nonwoven fabric, and most of the ultrafine fibers are discharged, and a part of the ultrafine fibers is formed into a confounding portion between cotton fibers. It is to stay and entangle. Therefore, the surface material obtained by the method according to the present invention has an effect that the bond between the cotton fibers is strong and the abrasion resistance of the cotton fiber web surface in contact with the skin is improved.
電子顕微鏡を用いて倍率３００倍で、第一長繊維不織布／極細繊維不織布／第二長繊維不織布の積層物（以下、この積層物を「ＳＭＳ不織布」ということもある。）の表面を撮影した写真である。The surface of a laminate of first long fiber non-woven fabric / ultrafine fiber non-woven fabric / second long fiber non-woven fabric (hereinafter, this laminate may be referred to as “SMS non-woven fabric”) was photographed using an electron microscope at a magnification of 300 times. It is a photograph.
　本発明で用いるコットン繊維ウェブは、コットン繊維を主体として構成されてなる。コットン繊維の他に、絹繊維又はレーヨン繊維等の親水性繊維が混合されていてもよい。かかるコットン繊維ウェブは、公知のカード法でコットン繊維を開繊及び集積することにより、得ることができる。コットン繊維ウェブの目付は１０～２０ｇ／ｍ2程度である。コットン繊維としては、未脱脂のもの（未脱脂綿）を採用するのが好ましく、さらに未脱脂で漂白されたもの（未脱脂漂白綿）を採用するのが好ましい。未脱脂綿は、コットン繊維の表面に油脂分（原綿表面に付着しているコットンワックス及び綿実油等）が残存しているため、体液が表面材の面方向に拡散しにくい。したがって、使用時に肌に対してベタツキが生じにくいので好ましい。さらに、未脱脂漂白綿は白色に漂白されており、衛生材料に清潔感を与えるので好ましい。なお、本明細書中で、「～」を用いて表される数値範囲は、「～」の前後に記載される数値を下限値及び上限値として含む範囲を意味している。 The cotton fiber web used in the present invention is mainly composed of cotton fiber. In addition to cotton fibers, hydrophilic fibers such as silk fibers or rayon fibers may be mixed. Such a cotton fiber web can be obtained by opening and accumulating cotton fibers by a known card method. The basis weight of the cotton fiber web is about 10 to 20 g / m 2. As the cotton fiber, it is preferable to use non-defatted cotton (non-defatted cotton), and further, it is preferable to use non-solvent degreased bleached cotton (non-defatted bleached cotton). In non-cotton wool, oil and fat (cotton wax, cottonseed oil, etc. adhering to the surface of raw cotton) remain on the surface of the cotton fiber, so that the body fluid is difficult to diffuse in the surface direction of the surface material. Therefore, it is preferable because it is less likely to cause stickiness on the skin during use. Further, the non-defatted bleached cotton is bleached to white, which is preferable because it gives a clean feeling to the sanitary material. In the present specification, the numerical range represented by using "-" means a range including the numerical values before and after "-" as the lower limit value and the upper limit value.
　本発明で用いる第一長繊維不織布及び第二長繊維不織布を構成している長繊維は、ポリプロピレン系重合体を含む。本発明の表面材は、第一長繊維不織布及び第二長繊維不織布由来の領域を含むため、引張強度により優れる傾向がある。長繊維不織布における長繊維の含有率は、表面材の引張強度をより向上させる観点から、本数を基準として、５０％以上が好ましく、９０％以上がより好ましく、９９％以上がさらに好ましい。また、長繊維におけるプロピレン系重合体の含有率は、紡糸性の観点から、９０質量％以上が好ましく、９９質量％以上がより好ましい。なお、本明細書中で、段階的に記載されている数値範囲において、ある数値範囲で記載された上限値又は下限値は、他の段階的な記載の数値範囲の上限値又は下限値に置き換えてもよい。また、本明細書に記載されている数値範囲において、ある数値範囲で記載された上限値又は下限値は、実施例に示されている値に置き換えてもよい。 The long fibers constituting the first long fiber non-woven fabric and the second long fiber non-woven fabric used in the present invention contain a polypropylene-based polymer. Since the surface material of the present invention contains a region derived from the first long fiber nonwoven fabric and the second long fiber nonwoven fabric, it tends to be superior in tensile strength. The content of long fibers in the long fiber non-woven fabric is preferably 50% or more, more preferably 90% or more, still more preferably 99% or more, based on the number of fibers, from the viewpoint of further improving the tensile strength of the surface material. The content of the propylene-based polymer in the long fibers is preferably 90% by mass or more, more preferably 99% by mass or more, from the viewpoint of spinnability. In the present specification, in the numerical range described stepwise, the upper limit value or the lower limit value described in a certain numerical range is replaced with the upper limit value or the lower limit value of another numerical range described stepwise. You may. Further, in the numerical range described in the present specification, the upper limit value or the lower limit value described in a certain numerical range may be replaced with the value shown in the examples.
　ポリプロピレン系重合体としては、プロピレン単独重合体、プロピレン・α－オレフィンランダム共重合体又はプロピレン・α－オレフィンブロック共重合体等が用いられる。ここで、α－オレフィンとしては、エチレン、１－ブテン、１－ペンテン、１－ヘキセン、１－オクテン、４－メチル－１－ペンテン等のプロピレン以外のα－オレフィンが用いられる。なお、α－オレフィンを共重合する場合、その共重合量は、１～１０モル％が好ましい。繊維は、これらの重合体の１種を単独で含んでいてもよく、２種以上を含んでいても良い。なお、プロピレン系重合体は、プロピレンに由来する構成単位を５０質量％以上含む重合体を意味する。 As the polypropylene-based polymer, a propylene homopolymer, a propylene / α-olefin random copolymer, a propylene / α-olefin block copolymer, or the like is used. Here, as the α-olefin, α-olefins other than propylene such as ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene and 4-methyl-1-pentene are used. When the α-olefin is copolymerized, the copolymerization amount is preferably 1 to 10 mol%. The fiber may contain one of these polymers alone or may contain two or more of them. The propylene-based polymer means a polymer containing 50% by mass or more of a structural unit derived from propylene.
　長繊維が含むプロピレン系重合体のメルトフローレイト（ＭＦＲ、ＡＳＴＭ　Ｄ１２３８、２３０℃、荷重２１６０ｇ）は、溶融紡糸可能であれば特に制限されない。例えば、ＭＦＲは、１ｇ／１０分～１０００ｇ／１０分であってもよく、５ｇ／１０分～５００ｇ／１０分であることが好ましく、１０ｇ／１０分～１００ｇ／１０分であることがより好ましい。プロピレン系重合体のＭＦＲが上記範囲内であると、引張強度が向上する傾向にあり好ましい The melt flow rate (MFR, ASTM D1238, 230 ° C., load 2160 g) of the propylene-based polymer contained in the long fibers is not particularly limited as long as it can be melt-spun. For example, the MFR may be 1 g / 10 minutes to 1000 g / 10 minutes, preferably 5 g / 10 minutes to 500 g / 10 minutes, and more preferably 10 g / 10 minutes to 100 g / 10 minutes. .. When the MFR of the propylene-based polymer is within the above range, the tensile strength tends to improve, which is preferable.
　長繊維の平均繊維径は、本発明の効果を奏する限り特に制限されないが、耐摩耗性と引張強度をより向上させる観点から、１０μｍ～５０μｍが好ましく、１１μｍ～３０μｍがより好ましい。長繊維の平均繊維径は、実施例の項目中で後述するように、長繊維不織布を撮影した写真に基づいて算出されるものである。この撮影した写真は、長繊維不織布を単独で撮影した写真でもよく、極細繊維不織布と長繊維不織布の積層物を撮影した写真でもよく、表面材を撮影した写真であってもよい。なお、図１は、ＳＭＳ不織布の表面を撮影した写真である。 The average fiber diameter of the long fibers is not particularly limited as long as the effect of the present invention is exhibited, but from the viewpoint of further improving the wear resistance and the tensile strength, 10 μm to 50 μm is preferable, and 11 μm to 30 μm is more preferable. The average fiber diameter of the long fibers is calculated based on a photograph of the long fiber non-woven fabric, as will be described later in the item of the example. The photograph taken may be a photograph of the long fiber non-woven fabric alone, a photograph of a laminate of the ultrafine fiber non-woven fabric and the long fiber non-woven fabric, or a photograph of the surface material. Note that FIG. 1 is a photograph of the surface of the SMS non-woven fabric.
　長繊維は、単一の成分からなる長繊維であってもよく、芯鞘型や海島型などの複合長繊維であってもよい。表面材の強度をより向上させる観点から、単一の成分からなる長繊維であるのが好ましい。 The long fiber may be a long fiber composed of a single component, or may be a composite long fiber such as a core sheath type or a sea island type. From the viewpoint of further improving the strength of the surface material, long fibers composed of a single component are preferable.
　本発明で用いる第一長繊維不織布及び第二長繊維不織布は、いわゆるスパンボンド法により製造するのが一般的である。また、第一長繊維不織布及び第二長繊維不織布は、熱エンボス加工により部分的に熱圧接が施され、形態安定性がより向上されていることが好ましい。 The first long fiber non-woven fabric and the second long fiber non-woven fabric used in the present invention are generally manufactured by the so-called spunbond method. Further, it is preferable that the first long fiber non-woven fabric and the second long fiber non-woven fabric are partially hot pressed by heat embossing to further improve the morphological stability.
　第一長繊維不織布及び第二長繊維不織布のそれぞれの目付は、引張強度をより向上させつつ後述する高圧水流により交絡処理を施しやすくする観点から、１～３０ｇ／ｍ2が好ましく、３～１０ｇ／ｍ2がより好ましい。 The basis weights of the first-long fiber nonwoven fabric and the second-long fiber nonwoven fabric are preferably 1 to 30 g / m 2 and 3 to 10 g from the viewpoint of further improving the tensile strength and facilitating the entanglement treatment by the high-pressure water flow described later. / M 2 is more preferable.
　第一長繊維不織布及び第二長繊維不織布に挟まれている極細繊維不織布は、プロピレン系重合体を含み平均繊維径が０．５～７μｍの極細繊維を含む。極細繊維の平均繊維径は、実施例の項目中で後述するように、極細繊維不織布を撮影した写真に基づいて算出されるものである。この撮影した写真は、極細繊維不織布を単独で撮影した写真でもよく、極細繊維不織布と長繊維不織布の積層物を撮影した写真でもよく、表面材を撮影した写真であってもよい。そして、繊維径が８μｍ以下のものを選択して算出される。したがって、極細繊維は、その繊維径が８μｍ以下のものである。 The ultrafine fibrous nonwoven fabric sandwiched between the first long fiber non-woven fabric and the second long fiber nonwoven fabric contains a propylene-based polymer and contains ultrafine fibers having an average fiber diameter of 0.5 to 7 μm. The average fiber diameter of the ultrafine fibers is calculated based on a photograph of the ultrafine fiber non-woven fabric, as will be described later in the item of the example. The photograph taken may be a photograph of the ultrafine fiber non-woven fabric alone, a photograph of a laminate of the ultrafine fiber non-woven fabric and the long fiber non-woven fabric, or a photograph of the surface material. Then, a fiber having a fiber diameter of 8 μm or less is selected and calculated. Therefore, the ultrafine fibers have a fiber diameter of 8 μm or less.
　極細繊維が含むプロピレン系重合体を構成する単量体及びその量は、前述の長繊維に含まれるプロピレン系重合体と同様である。極細繊維不織布における極細繊維の含有率は、耐摩耗性をより向上させる観点から、本数を基準として、５０％以上が好ましく、９０％以上がより好ましく、９９％以上がさらに好ましい。また、極細繊維中のプロピレン系重合体の含有率は、紡糸性の観点から、９０質量％以上が好ましく、９９質量％以上がより好ましい。 The monomers constituting the propylene-based polymer contained in the ultrafine fibers and their amounts thereof are the same as those of the propylene-based polymer contained in the above-mentioned long fibers. The content of the ultrafine fibers in the ultrafine fiber non-woven fabric is preferably 50% or more, more preferably 90% or more, still more preferably 99% or more, based on the number of fibers, from the viewpoint of further improving the wear resistance. The content of the propylene-based polymer in the ultrafine fibers is preferably 90% by mass or more, more preferably 99% by mass or more, from the viewpoint of spinnability.
　極細繊維が含むプロピレン系重合体のメルトフローレイト（ＭＦＲ、ＡＳＴＭ　Ｄ１２３８、２３０℃、荷重２１６０ｇ）は、溶融紡糸可能であれば特に制限されない。例えば、ＭＦＲは、１ｇ／１０分～２０００ｇ／１０分であってもよく、１００ｇ／１０分～１５００ｇ／１０分であることが好ましく、２００ｇ／１０分～１０００ｇ／１０分であることがより好ましい。プロピレン系重合体のＭＦＲが上記範囲内であると、極細繊維の強度が向上する傾向にあり、好ましい。また、プロピレン系重合体のＭＦＲが上記範囲内であると、平均繊維径を所定範囲に調整しやすくなり、水流交絡による繊維同士の交絡がより適切に形成できる傾向にあるため、好ましい。なお、極細繊維の平均繊維径は、高圧水流による交絡処理をより施しやすくする観点から、１μｍ～５μｍであるのが好ましい。 The melt flow rate (MFR, ASTM D1238, 230 ° C., load 2160 g) of the propylene-based polymer contained in the ultrafine fibers is not particularly limited as long as it can be melt-spun. For example, the MFR may be 1 g / 10 min to 2000 g / 10 min, preferably 100 g / 10 min to 1500 g / 10 min, and more preferably 200 g / 10 min to 1000 g / 10 min. .. When the MFR of the propylene-based polymer is within the above range, the strength of the ultrafine fibers tends to be improved, which is preferable. Further, when the MFR of the propylene-based polymer is within the above range, the average fiber diameter can be easily adjusted to a predetermined range, and entanglement between fibers due to water flow entanglement tends to be more appropriately formed, which is preferable. The average fiber diameter of the ultrafine fibers is preferably 1 μm to 5 μm from the viewpoint of facilitating the entanglement treatment with a high-pressure water flow.
　極細繊維不織布の目付は、高圧水流による交絡処理をより施しやすくして、耐摩耗性をより向上させる観点及び取り扱い性をより容易にする観点から、０．１ｇ／ｍ2～７ｇ／ｍ2が好ましく、０．３ｇ／ｍ2～５ｇ／ｍ2がより好ましい。 Basis weight of the microfibrous non-woven fabric is to more easily subjected to entangling treatment by the high-pressure water stream, from the viewpoint of easier aspects and handling properties further improve the wear resistance, 0.1g / m 2 ~ 7g / m 2 is Preferably, 0.3 g / m 2 to 5 g / m 2 is more preferable.
　本発明で用いる第一長繊維不織布、極細繊維不織布及び第二長繊維不織布は、酸化防止剤、耐熱安定剤、耐候安定剤、帯電防止剤、スリップ剤、防曇剤，滑剤、染料、顔料、天然油、合成油、ワックス、脂肪酸アミド等の種々公知の添加剤を含んでいてもよい。各不織布中におけるこれらの添加剤の含有率は、０．１質量％以下が好ましく、０．０５質量％以下がより好ましく、０．０１質量％以下が更に好ましい。 The first long fiber non-woven fabric, the extra fine fiber non-woven fabric and the second long fiber non-woven fabric used in the present invention are antioxidants, heat-resistant stabilizers, weather-resistant stabilizers, antistatic agents, slip agents, antifogging agents, lubricants, dyes, pigments, etc. It may contain various known additives such as natural oils, synthetic oils, waxes and fatty acid amides. The content of these additives in each non-woven fabric is preferably 0.1% by mass or less, more preferably 0.05% by mass or less, still more preferably 0.01% by mass or less.
　第一長繊維不織布、極細繊維不織布及び第二長繊維不織布は、各々を別個に製造した後に、積層して得ることもできるが、一般的に、以下の方法で得るのが好ましい。すなわち、いわゆるスパンボンド法によって得られた第一長繊維ウェブ上に、いわゆるメルトブローン法で得られた極細繊維ウェブを積層し、さらに極細繊維ウェブ上にいわゆるスパンボンド法で得られた第二長繊維ウェブを積層する。その後、熱エンボス加工により部分的に熱圧接して各ウェブ中の繊維相互間を融着し、第一長繊維不織布、極細繊維不織布及び第二長繊維不織布の順に積層されたＳＭＳ不織布を得る方法が好ましい。 The first long fiber non-woven fabric, the extra fine fiber non-woven fabric and the second long fiber non-woven fabric can be obtained by laminating after each of them is manufactured separately, but it is generally preferable to obtain them by the following method. That is, the ultrafine fiber web obtained by the so-called melt blown method is laminated on the first long fiber web obtained by the so-called spunbond method, and the second long fiber obtained by the so-called spunbond method is further laminated on the ultrafine fiber web. Stack the web. Then, a method of partially hot pressing by hot embossing to fuse the fibers in each web to obtain an SMS nonwoven fabric in which the first long fiber non-woven fabric, the ultrafine fibrous nonwoven fabric, and the second long fiber nonwoven fabric are laminated in this order. Is preferable.
　コットン繊維ウェブ、第一長繊維不織布、極細繊維不織布及び第二長繊維不織布の順に積層して積層体を得る。この場合、コットン繊維ウェブにＳＭＳ不織布を積層して積層体を得るのが好ましい。極細繊維不織布単独で取り扱うよりも、高強度のＳＭＳ不織布として取り扱う方が、取り扱いやすいからである。そして、この積層体に高圧水流を施す。高圧水流はコットン繊維ウェブ側から施してもよいし、第二長繊維不織布側から施してもよいし、両側から施してもよい。高圧水流の作用により、コットン繊維及び長繊維は交絡するが、極細繊維不織布は破壊されて極細繊維が切断され或いは高圧水流と共に流出する。しかしながら、一部の極細繊維はコットン繊維相互間の交絡部や長繊維相互間の交絡部に滞留し絡合する。すなわち、コットン繊維相互間の交絡部に絡合して、コットン繊維相互間の結合がより強固になるのである。この作用により、コットン繊維ウェブ側、すなわち、表面材の肌に当接する面の耐摩耗性が向上するのである。また、極細繊維不織布が破壊されていることにより、もはや防水機能はなく、体液を適当に通過させうる体液透過性を持つ表面材となるのである。 A laminated body is obtained by laminating the cotton fiber web, the first long fiber non-woven fabric, the ultrafine fiber non-woven fabric, and the second long fiber non-woven fabric in this order. In this case, it is preferable to laminate the SMS non-woven fabric on the cotton fiber web to obtain a laminate. This is because it is easier to handle as a high-strength SMS non-woven fabric than to handle the ultrafine fiber non-woven fabric alone. Then, a high-pressure water flow is applied to this laminated body. The high-pressure water flow may be applied from the cotton fiber web side, the second long fiber non-woven fabric side, or from both sides. Due to the action of the high pressure water flow, the cotton fibers and the long fibers are entangled, but the ultrafine fiber non-woven fabric is broken and the ultrafine fibers are cut or flow out together with the high pressure water flow. However, some ultrafine fibers stay and entangle in the entangled portion between the cotton fibers and the entangled portion between the long fibers. That is, it is entangled with the entangled portion between the cotton fibers, and the bond between the cotton fibers becomes stronger. By this action, the abrasion resistance of the cotton fiber web side, that is, the surface of the surface material in contact with the skin is improved. In addition, since the ultrafine fiber non-woven fabric is destroyed, it no longer has a waterproof function and becomes a surface material having a body fluid permeability that allows the body fluid to pass through appropriately.
　第二長繊維不織布側には、他の任意の繊維ウェブが積層されていてもよい。たとえば、コットン繊維及び熱融着性短繊維で構成されてなる混合繊維ウェブが積層されていてもよい。混合繊維ウェブの目付は１０～２０ｇ／ｍ2程度であり、混合繊維ウェブ中におけるコットン繊維と熱融着性短繊維の混合割合は、コットン繊維：熱融着性短繊維＝１００：５０～１５０（質量比）であるのが好ましい。コットン繊維としては、上述した未脱脂綿や未脱脂漂白綿を採用するのが好ましい。熱融着性短繊維としては、融点を持つ熱可塑性樹脂で形成されてなるものが採用される。たとえば、ポリプロピレン繊維、ポリエステル繊維又はポリアミド繊維等が用いられる。本発明においては、同心芯鞘型複合短繊維であって、鞘成分の融点が芯成分の融点よりも低いものである熱融着性短繊維を用いるのが好ましい。かかる芯鞘型複合短繊維の鞘成分のみを軟化又は溶融せしめることにより、各繊維相互間が融着結合されるのである。鞘成分のみが軟化又は溶融する際に、複合短繊維が収縮しにくいように、同心芯鞘型にしておくのが好ましい。熱融着性短繊維が収縮すると、得られる表面材にシワ等が発生しやすくなる。具体的には、芯成分がポリプロピレンで鞘成分がポリエチレンである同心芯鞘型複合短繊維や、芯成分がポリエステルで鞘成分がポリエチレンである同心芯鞘型複合短繊維が用いられる。熱融着性短繊維の繊度及び繊維長は任意であるが、一般的に、繊度は１～５デシテックス程度で繊維長は１０～１００ｍｍ程度である。 Any other fiber web may be laminated on the second long fiber nonwoven fabric side. For example, a mixed fiber web composed of cotton fibers and heat-fusing short fibers may be laminated. The texture of the mixed fiber web is about 10 to 20 g / m 2 , and the mixing ratio of the cotton fiber and the heat-fused short fiber in the mixed fiber web is cotton fiber: heat-fused short fiber = 100: 50 to 150. (Mass ratio) is preferable. As the cotton fiber, it is preferable to use the above-mentioned non-defatted cotton or non-defatted bleached cotton. As the heat-bondable short fibers, those made of a thermoplastic resin having a melting point are adopted. For example, polypropylene fiber, polyester fiber, polyamide fiber and the like are used. In the present invention, it is preferable to use heat-sealing short fibers which are concentric sheath-type composite short fibers in which the melting point of the sheath component is lower than the melting point of the core component. By softening or melting only the sheath component of the core-sheath type composite short fiber, the fibers are fused and bonded to each other. It is preferable to make a concentric sheath type so that the composite short fibers do not easily shrink when only the sheath component is softened or melted. When the heat-bondable short fibers shrink, wrinkles and the like are likely to occur on the obtained surface material. Specifically, concentric sheath-type composite short fibers having a core component of polypropylene and a sheath component of polyethylene, and concentric core-sheath-type composite short fibers having a core component of polyester and a sheath component of polyethylene are used. The fineness and fiber length of the heat-bondable short fibers are arbitrary, but generally, the fineness is about 1 to 5 decitex and the fiber length is about 10 to 100 mm.
　高圧水流を施すことにより水を含有することになるので、乾燥させて水を蒸発する。これにより、衛生材料の表面材を得ることができる。積層体に熱融着性短繊維が含有されている場合には、この乾燥を行う工程で又は乾燥を行った後に、熱融着性短繊維を軟化又は溶融させて、各繊維相互間を融着結合するのが好ましい。たとえば、熱融着性短繊維として、芯成分がポリプロピレンで鞘成分がポリエチレンである同心芯鞘型複合短繊維を用いた場合、乾燥温度を１３０℃程度とすれば、水が蒸発すると共にポリエチレンが軟化又は溶融し、各繊維相互間が融着結合し、形態安定性に優れた表面材を得ることができる。 Since water is contained by applying a high-pressure water flow, dry it to evaporate the water. Thereby, a surface material of a sanitary material can be obtained. When the laminate contains heat-bondable short fibers, the heat-bondable short fibers are softened or melted in this drying step or after drying to melt the fibers between the fibers. It is preferable to bond them. For example, when a concentric sheath-type composite short fiber having a core component of polypropylene and a sheath component of polyethylene is used as the heat-sealing short fiber, if the drying temperature is set to about 130 ° C., water evaporates and polyethylene is formed. It is possible to obtain a surface material having excellent morphological stability by softening or melting and fusion-bonding between the fibers.
　得られた表面材は、コットン繊維で構成されてなるコットン繊維ウェブ領域とプロピレン系重合体を含む長繊維を含む領域とを含み、該コットン繊維及び該長繊維の繊維径よりも細い繊維径の極細繊維が、該コットン繊維及び該長繊維と交絡している衛生材料の表面材である。ここで、コットン繊維ウェブ領域と長繊維を含む領域とは明確に区別しうるものではなく、各領域の繊維は他の領域に侵入しているものである。すなわち、相対的にコットン繊維の多い領域がコットン繊維ウェブ領域となり、相対的に長繊維を多く含む領域が長繊維を含む領域となる。各領域における各繊維の多少は、衛生材料の表面材を厚み方向に切断し、その断面を顕微鏡で観察して、各繊維の本数を数えればよい。 The obtained surface material includes a cotton fiber web region composed of cotton fibers and a region containing long fibers containing a propylene-based polymer, and has a fiber diameter smaller than the fiber diameter of the cotton fibers and the long fibers. The ultrafine fibers are the surface material of the sanitary material entwined with the cotton fibers and the long fibers. Here, the cotton fiber web region and the region containing long fibers cannot be clearly distinguished, and the fibers in each region invade other regions. That is, the region containing a relatively large amount of cotton fibers becomes the cotton fiber web region, and the region containing a relatively large amount of long fibers becomes a region containing long fibers. For the amount of each fiber in each region, the surface material of the sanitary material may be cut in the thickness direction, the cross section thereof may be observed with a microscope, and the number of each fiber may be counted.
　表面材の厚みは、０．５０ｍｍ以下であるのが好ましい。厚みを０．５０ｍｍ以下にすると、肌に当接するコットン繊維と極細繊維の交絡がより向上して、耐摩耗性がより向上する傾向がある。このような厚みの衛生材料の表面材は、例えば、本発明の製造方法で製造することができる。厚みは、強度をより向上させる観点から、０．２５ｍｍ以上であるのが好ましい。衛生材料の表面材の目付は、２５ｇ／ｍ2～５０ｇ／ｍ2であるのが好ましい。目付が２５ｇ／ｍ2以上であると、強度がより向上する傾向にある。一方、目付が５０ｇ／ｍ2以下であると、コットン繊維ウェブ領域中のコットン繊維と極細繊維との交絡が多くなり、耐摩耗性が向上する傾向が生じる。 The thickness of the surface material is preferably 0.50 mm or less. When the thickness is 0.50 mm or less, the entanglement of the cotton fibers and the ultrafine fibers that come into contact with the skin is further improved, and the wear resistance tends to be further improved. A surface material of a sanitary material having such a thickness can be produced, for example, by the production method of the present invention. The thickness is preferably 0.25 mm or more from the viewpoint of further improving the strength. The basis weight of the surface material of the sanitary material is preferably 25 g / m 2 to 50 g / m 2. When the basis weight is 25 g / m 2 or more, the strength tends to be further improved. On the other hand, when the basis weight is 50 g / m 2 or less, the cotton fibers in the cotton fiber web region are entangled with the ultrafine fibers more often, and the wear resistance tends to be improved.
　衛生材料の表面材の引張強度は、機械方向の引張強度が１５Ｎ／５０ｍｍ幅～１００Ｎ／５０ｍｍ幅であるのが好ましく、２５Ｎ／５０ｍｍ幅～９０Ｎ／５０ｍｍ幅であるのがより好ましく、３０Ｎ／５０ｍｍ幅～８５Ｎ／５０ｍｍ幅であるのがさらに好ましい。また、機械方向と直交する方向（幅方向）の引張強度が１０Ｎ／５０ｍｍ幅～５０Ｎ／５０ｍｍ幅であるのが好ましい。引張強度が下限値未満であると、衛生材料製造時の取扱性が低下する傾向が生じる。また、引張強度が上限値を超えると、過剰品質の表面材となり、非合理的である。ここで、機械方向とは、不織布を製造する際の搬送方向のことをいう。すなわち、不織布中の長繊維が配列する方向のことである。したがって、長繊維の配列方向である機械方向の引張強度は高く、幅方向の引張強度は低い。 The tensile strength of the surface material of the sanitary material is preferably 15 N / 50 mm width to 100 N / 50 mm width, more preferably 25 N / 50 mm width to 90 N / 50 mm width, and 30 N / 50 mm. It is more preferably width to 85 N / 50 mm width. Further, it is preferable that the tensile strength in the direction orthogonal to the machine direction (width direction) is 10 N / 50 mm width to 50 N / 50 mm width. If the tensile strength is less than the lower limit, the handleability during manufacturing of sanitary materials tends to decrease. Further, if the tensile strength exceeds the upper limit value, the surface material becomes excessive quality, which is irrational. Here, the machine direction refers to the transport direction when manufacturing the nonwoven fabric. That is, it is the direction in which the long fibers in the non-woven fabric are arranged. Therefore, the tensile strength in the mechanical direction, which is the arrangement direction of the long fibers, is high, and the tensile strength in the width direction is low.
　以上のようにして得られた表面材は、生理用ナプキン、使い捨ておむつ及びフェイスマスク等の衛生材料の表面材として使用される。そして、コットン繊維ウェブ側が肌に当接するようにして使用されるので、肌触りが良好なのである。 The surface material obtained as described above is used as a surface material for sanitary materials such as sanitary napkins, disposable diapers and face masks. And since the cotton fiber web side is used so as to be in contact with the skin, the touch is good.
　以下、実施例に基づき本発明を説明するが、本発明は実施例によって何ら限定されるものではない。なお、本明細書で使用される下記の物性及び特性は、以下の測定方法によって測定されたものである。 Hereinafter, the present invention will be described based on examples, but the present invention is not limited to the examples. The following physical properties and properties used in the present specification are measured by the following measuring methods.
（１）目付（ｇ／ｍ2）
　表面材又は不織布から、機械方向１００ｍｍ×幅方向１００ｍｍの試料を１０点採取した。そして、各試料の質量を測定し、合計の質量を合計の面積で除して目付（ｇ／ｍ2）を算出した。
（２）厚み（ｍｍ）
　目付を測定した試料の中央及び四隅の５点の厚みを、厚み計（ＰＥＡＣＯＣＫ社製、品番「Ｒ１－２５０」、測定端子２５ｍｍφ）を用いて、荷重７ｇ／ｍ2で測定した。目付を測定した試料の１０点の試料につき、この方法で厚みを測定し、その平均値を厚み（ｍｍ）とした。 (1) Metsuke (g / m 2 )
Ten samples of 100 mm in the mechanical direction × 100 mm in the width direction were collected from the surface material or the non-woven fabric. Then, the mass of each sample was measured, and the total mass was divided by the total area to calculate the basis weight (g / m 2).
(2) Thickness (mm)
The thickness of the five points at the center and four corners of the sample whose basis weight was measured was measured with a load of 7 g / m 2 using a thickness gauge (manufactured by PEACOCK, product number "R1-250", measuring terminal 25 mmφ). The thickness of 10 samples whose basis weight was measured was measured by this method, and the average value was taken as the thickness (mm).
（３）機械方向の引張強度（Ｎ／５０ｍｍ幅）
　表面材から、機械方向２００ｍｍ×幅方向５０ｍｍの試料を５点採取した。そして、ＪＩＳ　Ｌ　１９１３に準拠し、引張試験機（島津製作所社製、オートグラフＡＧＳ－Ｊ）を用いて、チャック間距離１００ｍｍ及びヘッドスピード３００ｍｍ／ｍｉｎの条件で、各試料につき破断強度を測定した。５点の試料の破断強度の平均値を、機械方向の引張強度（Ｎ／５０ｍｍ幅）とした。
（４）幅方向の引張強度（Ｎ／５０ｍｍ幅）
　表面材から、機械方向５０ｍｍ×幅方向２００ｍｍの試料を５点採取した。そして、上記（３）と同様の方法で、各試料につき破断強度を測定した。５点の試料の破断強度の平均値を、幅方向の引張強度（Ｎ／５０ｍｍ幅）とした。 (3) Tensile strength in the machine direction (N / 50 mm width)
Five samples having a mechanical direction of 200 mm and a width direction of 50 mm were collected from the surface material. Then, in accordance with JIS L 1913, the breaking strength of each sample was measured using a tensile tester (manufactured by Shimadzu Corporation, Autograph AGS-J) under the conditions of a chuck distance of 100 mm and a head speed of 300 mm / min. .. The average value of the breaking strengths of the five samples was taken as the tensile strength in the mechanical direction (N / 50 mm width).
(4) Tensile strength in the width direction (N / 50 mm width)
Five samples having a mechanical direction of 50 mm and a width direction of 200 mm were collected from the surface material. Then, the breaking strength was measured for each sample by the same method as in (3) above. The average value of the breaking strengths of the five samples was taken as the tensile strength in the width direction (N / 50 mm width).
（５）耐摩耗性（回）
　表面材から、無作為の方向で長さ２９３ｍｍ×巾１６５ｍｍの試料を５０点採取した。この試料６点をＪＩＳ　Ｌ　０８４９に準拠し、学振型摩擦堅牢度試験機（大栄科学精器製作所社製、型式「ＲＴ－３００」）に、コットン繊維ウェブ面が摩擦端子側となるようにセットして、耐摩耗性を測定した。試料をセットする際には、試料の下に予めウレタンマットを敷き、シワが入らないように学振型摩擦堅牢度試験機備え付けの固定具に試料を固定した。また、摩擦端子表面を布粘着テープで覆い、摩擦端子に荷重３００ｇを掛けて、布粘着テープと試料が当接するようにした。そして、摩擦端子を３０回／ｍｉｎの往復速度で摺動し、試料６点の全てに破れが目視できたときの往復回数を測定した。この測定を５回行い、これらの平均値を耐摩耗性（回）とした。なお、往復回数が５００回を超えても、試料６点の全てに破れが目視できなかったときは測定を中止し、往復回数５００回とした。したがって、耐摩耗性（回）の値は、５００回が最大値となる。 (5) Wear resistance (times)
From the surface material, 50 samples having a length of 293 mm and a width of 165 mm were collected in a random direction. Based on JIS L 0849, 6 samples of this sample were used in a Gakushin type friction fastness tester (manufactured by Daiei Kagaku Seiki Seisakusho Co., Ltd., model "RT-300") so that the cotton fiber web surface was on the friction terminal side. It was set and the abrasion resistance was measured. When setting the sample, a urethane mat was laid under the sample in advance, and the sample was fixed to the fixture provided in the Gakushin type friction fastness tester so as not to cause wrinkles. Further, the surface of the friction terminal was covered with a cloth adhesive tape, and a load of 300 g was applied to the friction terminal so that the cloth adhesive tape and the sample came into contact with each other. Then, the friction terminal was slid at a reciprocating speed of 30 times / min, and the number of reciprocating times when all 6 points of the sample were visually torn was measured. This measurement was performed 5 times, and the average value of these was taken as the wear resistance (times). Even if the number of round trips exceeded 500, if no tear was visually observed in all 6 points of the sample, the measurement was stopped and the number of round trips was set to 500. Therefore, the maximum value of wear resistance (times) is 500 times.
（６）長繊維の平均繊維径
　長繊維不織布表面の電子顕微鏡写真に基づいて測定する。具体的には、ＳＭＳ不織布を用いて長繊維の平均繊維径を測定する方法を説明する。ＳＭＳ不織布の表面を、電子顕微鏡（日立製作所社製、型番；Ｓ－３５００Ｎ）を用いて、倍率３００倍の写真を撮影する。撮影された写真において、極細繊維より表面側に位置する繊維径が９μｍ以上の繊維の本数が合計で５０本（ｎ＝５０）以上になるまで撮影を繰り返す。得られた写真のうち、極細繊維の表面側に位置する繊維径が９μｍ以上の繊維の全ての繊維の直径（幅）を測定し、その算術平均値を、表面側の長繊維不織布における長繊維の平均繊維径とする。裏面側も同様にして測定する。
（７）極細繊維の平均繊維径
　極細繊維不織布表面の電子顕微鏡写真に基づいて測定する。具体的には、ＳＭＳ不織布を用いて極細繊維の平均繊維径を測定する方法を説明する。ＳＭＳ不織布の表面を、電子顕微鏡（日立製作所社製、型番；Ｓ－３５００Ｎ）を用いて、倍率２０００倍の写真を撮影する。撮影された写真において、繊維径が８μｍ以下の繊維の本数が合計で５０本（ｎ＝５０）以上になるまで撮影を繰り返す。得られた写真のうち、繊維径が８μｍ以下の繊維の全ての繊維の直径（幅）を測定し、その算術平均値を、極細繊維不織布における極細繊維の平均繊維径とする。
　なお、上記（６）及び（７）において、繊維の直径（幅）の測定は、写真の中で繊維の幅が最も小さい位置で測定すればよい。また、繊維同士が融着している場合には、融着していない部分で測定すればよく、融着していない部分が存在しない場合には本数から除外すればよい。 (6) Average fiber diameter of long fibers Measure based on an electron micrograph of the surface of the long fiber non-woven fabric. Specifically, a method of measuring the average fiber diameter of long fibers using an SMS nonwoven fabric will be described. The surface of the SMS non-woven fabric is photographed at a magnification of 300 times using an electron microscope (manufactured by Hitachi, Ltd., model number; S-3500N). In the photograph taken, the photography is repeated until the total number of fibers having a fiber diameter of 9 μm or more located on the surface side of the ultrafine fibers is 50 (n = 50) or more. Among the obtained photographs, the diameters (widths) of all the fibers of the fibers having a fiber diameter of 9 μm or more located on the surface side of the ultrafine fibers were measured, and the arithmetic average value was measured as the long fibers in the long fiber non-woven fabric on the surface side. The average fiber diameter of. Measure the back side in the same way.
(7) Average fiber diameter of ultrafine fiber Measured based on an electron micrograph of the surface of the ultrafine fiber non-woven fabric. Specifically, a method of measuring the average fiber diameter of ultrafine fibers using an SMS nonwoven fabric will be described. The surface of the SMS non-woven fabric is photographed at a magnification of 2000 times using an electron microscope (manufactured by Hitachi, Ltd., model number; S-3500N). In the photograph taken, the photography is repeated until the total number of fibers having a fiber diameter of 8 μm or less is 50 (n = 50) or more. Among the obtained photographs, the diameters (widths) of all the fibers having a fiber diameter of 8 μm or less are measured, and the arithmetic mean value thereof is taken as the average fiber diameter of the ultrafine fibers in the ultrafine fiber nonwoven fabric.
In the above (6) and (7), the diameter (width) of the fiber may be measured at the position where the width of the fiber is the smallest in the photograph. Further, when the fibers are fused to each other, the measurement may be performed at the non-fused portion, and when the non-fused portion does not exist, the fiber may be excluded from the number.
実施例１
［コットン繊維ウェブの準備］
　平均繊維長２５ｍｍの未脱脂漂白綿を、パラレルカード機で開繊及び集積し、目付２０ｇ／ｍ2のコットン繊維ウェブを得た。 Example 1
[Preparation of cotton fiber web]
Undefatted bleached cotton with an average fiber length of 25 mm was opened and accumulated with a parallel card machine to obtain a cotton fiber web having a basis weight of 20 g / m 2.
［ＳＭＳ不織布の準備］
　融点１６２℃でＭＦＲ６０ｇ／１０分（ＭＦＲは、ＡＳＴＭＤ１２３８に準拠し温度２３０℃荷重２．１６ｋｇで測定した。以下、ＭＦＲの測定法は同一である。）のプロピレン単独重合体を用い、溶融温度２３０℃で０．６ｍｍφの紡糸孔を多数備えた紡糸口金を用いて常法のスパンボンド法により溶融紡糸を行って、長繊維を捕集面に集積し、第一長繊維ウェブを得た。第一長繊維ウェブ中の長繊維の平均繊維径は１２．８μｍであり、第一長繊維ウェブの目付は５．７５ｇ／ｍ2であった。
　次いで、融点１６０℃でＭＦＲ４００ｇ／１０分のプロピレン単独重合体を用い、溶融温度２８０℃で溶融した溶融物を、０．４ｍｍφの吐出孔を多数備えたダイから吐出するとともに、吐出孔出口において２８０℃の加熱空気を吹き付ける常法のメルトブローン法により極細繊維を、上記第一長繊維ウェブ上に集積し、極細繊維ウェブを得た。極細繊維ウェブ中の極細繊維の平均繊維径は１．４μｍであり、極細繊維ウェブの目付は１．５ｇ／ｍ2であった。
　上記第一長繊維ウェブを得た方法と同様にして、極細繊維ウェブ上に長繊維を集積し、第二長繊維ウェブを得た。第二長繊維ウェブ中の長繊維の平均繊維径は１２．８μｍであり、第二長繊維ウェブの目付は５．７５ｇ／ｍ2であった。
　第一長繊維ウェブ、極細繊維ウェブ及び第二長繊維ウェブの順に積層されたウェブに、全圧接面積が１８％となるように、熱エンボスロールにてエンボスロールの温度１４５℃でミラーロールの温度１５０℃で、部分的に熱圧接し、３層を一体化して、第一長繊維不織布、極細繊維不織布及び第二長繊維不織布の順に積層されたＳＭＳ不織布を得た。なお、ＳＭＳ不織布の目付は１３ｇ／ｍ2であった。 [Preparation of SMS non-woven fabric]
A propylene homopolymer having a melting point of 162 ° C. and an MFR of 60 g / 10 minutes (MFR was measured at a temperature of 230 ° C. and a load of 2.16 kg according to ASTMD1238. Hereinafter, the measurement method of MFR is the same) was used, and the melting temperature was 230. Melt spinning was performed by a conventional spunbond method using a spun mouthpiece provided with a large number of spinning holes having a diameter of 0.6 mm at ° C., and long fibers were accumulated on the collection surface to obtain a first long fiber web. The average fiber diameter of the long fibers in the first long fiber web was 12.8 μm, and the basis weight of the first long fiber web was 5.75 g / m 2 .
Next, using a propylene homopolymer having a melting point of 160 ° C. and an MFR of 400 g / 10 min, the melt melted at a melting temperature of 280 ° C. is discharged from a die equipped with a large number of 0.4 mmφ discharge holes, and 280 at the discharge hole outlet. The ultrafine fibers were accumulated on the first long fiber web by a conventional melt blown method in which heated air at ° C was blown to obtain an ultrafine fiber web. The average fiber diameter of the ultrafine fibers in the ultrafine fiber web was 1.4 μm, and the basis weight of the ultrafine fiber web was 1.5 g / m 2 .
In the same manner as in the method for obtaining the first long fiber web, long fibers were accumulated on the ultrafine fiber web to obtain a second long fiber web. The average fiber diameter of the long fibers in the second long fiber web was 12.8 μm, and the basis weight of the second long fiber web was 5.75 g / m 2 .
The temperature of the mirror roll is 145 ° C. with a thermal embossing roll so that the total pressure contact area is 18% on the web laminated in the order of the first long fiber web, the ultrafine fiber web and the second long fiber web. At 150 ° C., the three layers were partially heat-pressed to obtain an SMS nonwoven fabric in which the first long fiber nonwoven fabric, the ultrafine fiber nonwoven fabric and the second long fiber nonwoven fabric were laminated in this order. The basis weight of the SMS nonwoven fabric was 13 g / m 2 .
　上記で準備したコットン繊維ウェブ及びＳＭＳ不織布を積層した積層体を、高圧水流噴出装置（孔径０．１ｍｍの噴出孔が孔間隔０．６ｍｍで横一列に配置されてなる装置）に通し、コットン繊維ウェブ側から３ＭＰａの噴出圧力で高圧水流を施し、次いで６ＭＰａの噴出圧力で高圧水流を施した。この後、第二長繊維不織布側から６ＭＰａの噴射圧力で高圧水流を施した後、１２０℃で乾燥して表面材を得た。 The laminated body in which the cotton fiber web and the SMS non-woven fabric prepared above are laminated is passed through a high-pressure water flow ejection device (a device in which ejection holes having a hole diameter of 0.1 mm are arranged in a horizontal row with a hole spacing of 0.6 mm). A high-pressure water stream was applied from the web side at an ejection pressure of 3 MPa, and then a high-pressure water stream was applied at an ejection pressure of 6 MPa. Then, a high-pressure water stream was applied from the second long fiber nonwoven fabric side at an injection pressure of 6 MPa, and then dried at 120 ° C. to obtain a surface material.
実施例２
［コットン繊維ウェブ及びＳＭＳ不織布の準備］
　実施例１で用いたのと同一のコットン繊維ウェブ及びＳＭＳ不織布を得た。 Example 2
[Preparation of cotton fiber web and SMS non-woven fabric]
The same cotton fiber web and SMS non-woven fabric used in Example 1 were obtained.
［混合繊維ウェブの準備］
　熱融着性短繊維として、鞘成分が融点１３０℃のポリエチレンで、芯成分が融点２６０℃のポリエチレンテレフタレートである同心芯鞘型複合短繊維（ユニチカ株式会社製、繊度２．２デシテックス、繊維長５１ｍｍ）を用いた。そして、平均繊維長２５ｍｍの未脱脂漂白綿５０質量％とこの熱融着性短繊維５０質量％とを均一に混合し、ランダムカード機で開繊及び集積し、目付１７ｇ／ｍ2の混合繊維ウェブを得た。 [Preparation of mixed fiber web]
Concentric sheath-type composite short fibers (manufactured by Unitika Ltd., fineness 2.2 decitex, fiber length) in which the sheath component is polyethylene having a melting point of 130 ° C and the core component is polyethylene terephthalate having a melting point of 260 ° C. 51 mm) was used. Then, 50% by mass of undgreased bleached cotton having an average fiber length of 25 mm and 50% by mass of this heat-fusing short fiber are uniformly mixed, and the fibers are opened and accumulated by a random card machine, and the mixed fiber having a grain size of 17 g / m 2 is used. Got the web.
　上記で準備したコットン繊維ウェブ、ＳＭＳ不織布及び混合繊維ウェブの順に積層した積層体を、実施例１で用いた高圧水流噴出装置に通し、コットン繊維ウェブ側から３ＭＰａの噴出圧力で高圧水流を施し、次いで６ＭＰａの噴出圧力で高圧水流を施した。この後、混合繊維ウェブ側から６ＭＰａの噴射圧力で高圧水流を施した後、乾燥して表面材を得た。なお、乾燥温度を１３５℃としたところ、同心芯鞘型複合短繊維のポリエチレンのみが軟化又は溶融し、各繊維相互間が融着結合した表面材を得た。 The laminate in which the cotton fiber web, the SMS non-woven fabric, and the mixed fiber web prepared above are laminated in this order is passed through the high-pressure water flow ejection device used in Example 1, and a high-pressure water flow is applied from the cotton fiber web side at an ejection pressure of 3 MPa. Then, a high-pressure water flow was applied at an ejection pressure of 6 MPa. Then, a high-pressure water stream was applied from the mixed fiber web side at an injection pressure of 6 MPa, and then dried to obtain a surface material. When the drying temperature was 135 ° C., only polyethylene, which was a concentric sheath-type composite short fiber, was softened or melted, and a surface material in which the fibers were fused and bonded to each other was obtained.
実施例３
　実施例１で用いたＳＭＳ不織布において、第一長繊維ウェブ及び第二長繊維ウェブの目付を６．２５ｇ／ｍ2に変更するとともに、極細繊維ウェブの目付を０．５ｇ／ｍ2に変更した他は、実施例１と同様にして表面材を得た。なお、目付の変更は、捕集面の移動速度と極細繊維の吐出量を調整することで行った。 Example 3
In the SMS nonwoven fabric used in Example 1, the basis weights of the first long fiber web and the second long fiber web were changed to 6.25 g / m 2, and the basis weight of the ultrafine fiber web was changed to 0.5 g / m 2. Other than that, a surface material was obtained in the same manner as in Example 1. The basis weight was changed by adjusting the moving speed of the collecting surface and the discharge amount of the ultrafine fibers.
比較例１
　ＳＭＳ不織布を用いずに、目付３５ｇ／ｍ2のコットン繊維ウェブのみを用いて、実施例１と同一の条件で高圧水流を施して、目付３５ｇ／ｍ2の表面材を得た。 Comparative Example 1
A surface material having a basis weight of 35 g / m 2 was obtained by applying a high-pressure water stream under the same conditions as in Example 1 using only a cotton fiber web having a basis weight of 35 g / m 2 without using an SMS non-woven fabric.
比較例２
　ＳＭＳ不織布に代えて、以下の方法で得られた長繊維ウェブを用いたことの他は、実施例１と同様にして、目付３３ｇ／ｍ2の表面材を得た。
［長繊維ウェブの製造］
　融点１６２℃でＭＦＲ６０ｇ／１０分のプロピレン単独重合体を用い、溶融温度２３０℃で０．６ｍｍΦの紡糸孔を多数備えた紡糸口金を用いて常法のスパンボンド法により溶融紡糸を行って、長繊維を捕集面に集積し、長繊維ウェブを得た。長繊維ウェブ中の長繊維の平均繊維径は３３．５μｍであり、長繊維ウェブの目付は１３．０ｇ／ｍ2であった。 Comparative Example 2
A surface material having a basis weight of 33 g / m 2 was obtained in the same manner as in Example 1 except that the long fiber web obtained by the following method was used instead of the SMS nonwoven fabric.
[Manufacturing of long fiber web]
Using a propylene homopolymer having a melting point of 162 ° C. and an MFR of 60 g / 10 min, melt spinning was performed by a conventional spunbond method using a spinneret having a large number of spinning holes of 0.6 mmΦ at a melt temperature of 230 ° C. The fibers were accumulated on the collection surface to obtain a long fiber web. The average fiber diameter of the long fibers in the long fiber web was 33.5 μm, and the basis weight of the long fiber web was 13.0 g / m 2 .
　実施例１～３、比較例１及び比較例２で得られた表面材のそれぞれについて、上述した方法で、その目付、厚み、機械方向の引張強度、幅方向の引張強度及び耐摩耗性を評価した。その結果を、表１に示した。表１の結果から、実施例で得られた表面材の肌に当接する面は、耐摩耗性に優れていることが分かる。 For each of the surface materials obtained in Examples 1 to 3, Comparative Example 1 and Comparative Example 2, the basis weight, thickness, tensile strength in the mechanical direction, tensile strength in the width direction and wear resistance are evaluated by the above-mentioned methods. did. The results are shown in Table 1. From the results in Table 1, it can be seen that the surface of the surface material obtained in the examples that comes into contact with the skin has excellent wear resistance.
［表１］
━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━
　　　　　　　　実施例１　実施例２　実施例３　比較例１　比較例２
━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━
　目付　　　　　　３３　　　４７　　　３３　　　３５　　　３３
（ｇ／ｍ2）
━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━
　厚み　　　　　０．３３　０．４３　０．３４　０．３２　０．３４
（ｍｍ）
━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━
　引張強度
（Ｎ／５０ｍｍ幅）
　───────────────────────────────
　　機械方向　　　３８　　　７３　　　３６　　　３０　　　３７
　───────────────────────────────
　　幅方向　　　　１７　　　２６　　　１５　　　１２　　　１６
━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━
　耐摩耗性　　　５００　　５００　　５００　　２００　　１５０
　（回）
━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ [Table 1]
━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━
Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2
━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━
Metsuke 33 47 33 35 33
(G / m 2 )
━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━
Thickness 0.33 0.43 0.34 0.32 0.34
(Mm)
━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━
Tensile strength (N / 50mm width)
──────────────────────────────
Machine direction 38 73 36 30 37
──────────────────────────────
Width direction 17 26 15 12 16
━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━
Abrasion resistance 500 500 500 200 200 150
(times)
━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━

Claims (4)

  1. 　コットン繊維で構成されてなるコットン繊維ウェブ、プロピレン系重合体を含む長繊維で構成されてなる第一長繊維不織布、プロピレン系重合体を含み、その繊維径が該コットン繊維及び該長繊維の繊維径よりも細い極細繊維を含む極細繊維不織布及びプロピレン系重合体を含む長繊維で構成されてなる第二長繊維不織布の順に積層された積層体に高圧水流を施して、該極細繊維不織布を破壊すると共に、該コットン繊維に該極細繊維を絡合させることを特徴とする、コットン繊維ウェブ側が肌に当接する衛生材料の表面材の製造方法。 It contains a cotton fiber web made of cotton fibers, a first long fiber non-woven fabric made of long fibers containing a propylene-based polymer, and a propylene-based polymer whose fiber diameters are the cotton fibers and the fibers of the long fibers. A high-pressure water stream is applied to a laminate in which a second long-fiber non-woven fabric composed of an ultra-fine fiber non-woven fabric containing ultra-fine fibers finer than the diameter and a long-fiber containing a propylene-based polymer is laminated in this order to destroy the ultra-fine fiber non-woven fabric. A method for producing a surface material of a sanitary material in which the web side of the cotton fiber comes into contact with the skin, which comprises entwining the ultrafine fiber with the cotton fiber.
  2. 　コットン繊維が未脱脂で漂白されたものである請求項１記載の衛生材料の表面材の製造方法。 The method for producing a surface material of a sanitary material according to claim 1, wherein the cotton fiber is bleached without degreasing.
  3. 　極細繊維不織布の目付が０．１ｇ／ｍ2～７ｇ／ｍ2である請求項１又は２記載の衛生材料の表面材の製造方法。 The method for producing a surface material of a sanitary material according to claim 1 or 2, wherein the ultrafine fiber nonwoven fabric has a basis weight of 0.1 g / m 2 to 7 g / m 2.
  4. 　コットン繊維で構成されてなるコットン繊維ウェブ領域とプロピレン系重合体を含む長繊維を含む領域とを含み、該コットン繊維及び該長繊維の繊維径よりも細い繊維径の極細繊維が、該コットン繊維及び該長繊維と交絡している衛生材料の表面材。 The cotton fiber includes a cotton fiber web region composed of cotton fibers and a region containing long fibers containing a propylene-based polymer, and the cotton fibers and ultrafine fibers having a fiber diameter smaller than the fiber diameter of the long fibers are the cotton fibers. And the surface material of the sanitary material entwined with the long fibers.
PCT/JP2021/023703 2020-07-02 2021-06-23 Surface material for sanitary material and production method therefor WO2022004505A1 (en)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0288058A (en) * 1988-09-26 1990-03-28 Oji Paper Co Ltd Surface material for sanitary good
JPH0768687A (en) * 1993-09-02 1995-03-14 Unitika Ltd Laminated nonwoven structure
JPH10251960A (en) * 1997-03-10 1998-09-22 Chisso Corp Laminated non-woven fabric
JP2001040564A (en) * 1999-07-23 2001-02-13 Mitsui Chemicals Inc Flexible nonwoven fabric and its nonwoven fabric laminate
JP3218416U (en) * 2018-08-02 2018-10-11 ユニチカ株式会社 Top sheet for absorbent articles

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0288058A (en) * 1988-09-26 1990-03-28 Oji Paper Co Ltd Surface material for sanitary good
JPH0768687A (en) * 1993-09-02 1995-03-14 Unitika Ltd Laminated nonwoven structure
JPH10251960A (en) * 1997-03-10 1998-09-22 Chisso Corp Laminated non-woven fabric
JP2001040564A (en) * 1999-07-23 2001-02-13 Mitsui Chemicals Inc Flexible nonwoven fabric and its nonwoven fabric laminate
JP3218416U (en) * 2018-08-02 2018-10-11 ユニチカ株式会社 Top sheet for absorbent articles

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