WO2020184335A1 - 不織布積層体、複合積層体、及び被覆シート - Google Patents
不織布積層体、複合積層体、及び被覆シート Download PDFInfo
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- WO2020184335A1 WO2020184335A1 PCT/JP2020/009186 JP2020009186W WO2020184335A1 WO 2020184335 A1 WO2020184335 A1 WO 2020184335A1 JP 2020009186 W JP2020009186 W JP 2020009186W WO 2020184335 A1 WO2020184335 A1 WO 2020184335A1
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- Prior art keywords
- woven fabric
- layer
- fabric layer
- propylene
- fiber
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Classifications
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/28—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D01F6/30—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds comprising olefins as the major constituent
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
- D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
- D01F8/06—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/005—Synthetic yarns or filaments
- D04H3/007—Addition polymers
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/018—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the shape
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
- D04H3/147—Composite yarns or filaments
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M2200/00—Functionality of the treatment composition and/or properties imparted to the textile material
- D06M2200/10—Repellency against liquids
- D06M2200/11—Oleophobic properties
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M2200/00—Functionality of the treatment composition and/or properties imparted to the textile material
- D06M2200/50—Modified hand or grip properties; Softening compositions
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
- D10B2321/021—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polyethylene
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
- D10B2321/022—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polypropylene
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2401/00—Physical properties
- D10B2401/06—Load-responsive characteristics
- D10B2401/063—Load-responsive characteristics high strength
Definitions
- the present invention relates to a non-woven fabric laminate, a composite laminate, and a covering sheet.
- non-woven fabrics have been widely used in various applications due to their excellent breathability and flexibility. Therefore, the non-woven fabric is required to have various properties according to its use, and to improve the properties.
- a non-woven fabric (such as a top sheet of an absorbent article) used for a member that comes into direct contact with the skin is required to have excellent flexibility and hydrophilicity.
- Patent Document 1 proposes a specific hydrophilic bulky non-woven fabric made of a thermoplastic fiber.
- specific crimp fibers are applied to this hydrophilic bulky non-woven fabric.
- Patent Document 1 discloses that a hydrophilic bulky nonwoven fabric contains or is coated with a water permeable agent.
- Patent Document 2 discloses a non-woven fabric web, which comprises a plurality of continuous spunbond crimped fibers and has a plurality of openings extending through the non-woven fabric web. Is disclosed to include additives for flexibility, hydrophilic additives, hydrophobic additives and the like.
- Patent Document 1 International Publication No. 2017/145999
- Patent Document 2 US Patent Application Publication No. 2016/0166443
- a kneading method and a coating method are known as a method of imparting hydrophilicity to a non-woven fabric.
- a non-woven fabric is formed by forming a non-woven fabric with fibers of a thermoplastic polymer in which a drug for imparting hydrophilicity (hereinafter, the drug for imparting hydrophilicity is referred to as a hydrophilic agent) is kneaded.
- a hydrophilic agent a drug for imparting hydrophilicity
- the coating method is a method of imparting hydrophilicity to the non-woven fabric by adhering a hydrophilic agent to the fiber surface.
- the hydrophilic agent may migrate to a member (gather, etc.) that comes into contact with the diaper top sheet. For example, if the gathers are hydrophilized due to the transfer of the hydrophilizing agent to the gathers, liquid leakage may occur in the diaper.
- the hydrophilic agent may be transferred to the processing machine. If the hydrophilic agent continues to move to the processing machine for a long period of time, it is considered that corrosion due to the transfer of the hydrophilic agent occurs.
- An object of the present disclosure is to provide a non-woven fabric laminate having excellent hydrophilicity and capable of suppressing the migration of a hydrophilic agent when in contact with another member.
- An object of the present disclosure is to provide a composite laminate having a nonwoven fabric laminate having excellent hydrophilicity and capable of suppressing the migration of a hydrophilic agent when in contact with another member.
- This disclosure relates to the following aspects.
- the first non-woven fabric layer is the outermost layer.
- the thermoplastic polymer contains an olefin polymer.
- thermoplastic polymer contains at least one selected from the group consisting of a propylene polymer and an ethylene polymer as an olefin polymer.
- thermoplastic polymer contains at least one selected from the group consisting of a propylene polymer and an ethylene polymer as an olefin polymer.
- ⁇ 5> The non-woven fabric according to any one of ⁇ 1> to ⁇ 4>, wherein the width retention rate when a tensile stress of 0.1 N / mm is applied in the MD direction of the non-woven fabric laminate is 75% or more.
- Laminated body ⁇ 6> The nonwoven fabric laminate according to any one of ⁇ 1> to ⁇ 5>, wherein the tensile strength of the nonwoven fabric laminate at 5% stretching in the MD direction is 2.2 N / 50 mm or more.
- the hydrophilizing agent comprises at least one selected from the group consisting of polyhydric alcohol fatty acid ester, polyoxyalkylene fatty acid ester, and alkylene oxide adduct of polyhydric alcohol fatty acid ester, ⁇ 1> to ⁇ 8>.
- the non-woven laminate according to any one of the above. ⁇ 10> A crimped fiber (B) which is a fiber of a thermoplastic polymer, has an average crimped diameter different from the average crimped diameter of the crimped fiber (A), and has an average crimped diameter of 500 ⁇ m or more.
- the non-woven fabric laminate according to any one of ⁇ 1> to ⁇ 9> further comprising a second non-woven fabric layer containing the non-crimped fiber (C).
- the fibers of the thermoplastic polymer contained in the first non-woven fabric layer and the second non-woven fabric layer are fibers containing a propylene-based polymer.
- the propylene-based polymer is exposed on the surface of the crimped fiber (A) contained in the first non-woven fabric layer.
- the propylene-based polymer is exposed on the surface of the crimped fibers (B) or non-crimped fibers (C) contained in the second non-woven fabric layer.
- the non-woven fabric laminate according to ⁇ 12> wherein is a propylene / ⁇ -olefin copolymer, a mixture of a propylene homopolymer and a propylene / ⁇ -olefin copolymer, or a combination thereof.
- the first non-woven fabric layer is a layer of spunbonded non-woven fabric
- the second non-woven fabric layer is a layer of spunbonded non-woven fabric, has a crimped portion and a non-crimped portion, and has an area ratio of the crimped portion.
- the thermoplastic polymer in the melt-blown non-woven fabric layer is a propylene homopolymer having a melt flow rate of 800 g / 10 minutes or more, and the average fiber diameter of the fibers in the melt-blown non-woven fabric layer is less than 3 ⁇ m.
- thermoplastic polymer in the melt blown non-woven layer is a propylene / ⁇ -olefin copolymer having a melt flow rate of 200 g / 10 minutes or more, or a propylene polymer containing a propylene / ⁇ -olefin copolymer.
- the non-woven polymer according to ⁇ 15> or ⁇ 16> which is a mixture and has a texture of the melt blown non-woven layer of less than 5 g / m 2 .
- ⁇ 18> A composite laminate having the nonwoven fabric laminate according to any one of ⁇ 1> to ⁇ 17>.
- ⁇ 19> A covering sheet containing the nonwoven fabric laminate according to any one of ⁇ 14> to ⁇ 17> or the composite laminate according to ⁇ 18>.
- a non-woven fabric laminate having excellent hydrophilicity and capable of suppressing the migration of a hydrophilic agent when in contact with another member (sometimes referred to as a migration suppressing effect).
- a composite laminate having a nonwoven fabric laminate having excellent hydrophilicity and capable of suppressing the migration of a hydrophilic agent when in contact with another member.
- the numerical range indicated by using “-” in the present disclosure indicates a range including the numerical values before and after "-” as the minimum value and the maximum value, respectively.
- the term “process” is included in this term not only as an independent process but also as long as the purpose of the process is achieved even if it cannot be clearly distinguished from other processes.
- the content of each component in the composition is the total amount of the plurality of substances present in the composition when a plurality of substances corresponding to the respective components are present in the composition, unless otherwise specified. Means.
- the "MD" (Machine Direction) direction refers to the traveling direction of the non-woven web in the nonwoven fabric manufacturing apparatus.
- CD Cross Direction
- Cross Direction refers to a direction perpendicular to the MD direction and parallel to the main surface (a surface orthogonal to the thickness direction of the non-woven fabric).
- the term "included as a subject” means that the substance of interest is contained in the largest amount as a whole. For example, as a ratio to the whole, it shows that the content ratio of the target substance is 50% by mass or more.
- the non-woven fabric laminate of the present disclosure is a fiber of a thermoplastic polymer, includes a first non-woven fabric layer containing a crimp fiber (A) having an average crimp diameter of 800 ⁇ m or less, and contains a hydrophilic agent.
- A crimp fiber
- a large average crimp diameter of the crimped fiber (A) indicates that the degree of crimped fiber is small.
- the present inventors have found that by making the average crimp diameter of the crimp fiber (A) smaller than a specific value, the effect of suppressing the migration of the hydrophilic agent contained in the non-woven fabric laminate is preferably exhibited. It was. The reason why this migration suppressing effect is preferably exhibited is presumed as follows. If the average crimp diameter is too large, the degree of crimping of the fibers is small, so that the effect of suppressing the migration of the hydrophilic agent contained in the non-woven fabric laminate is low. On the other hand, when the average crimp diameter is small, the degree of crimping of the fiber is large, so that the effect of suppressing the migration of the hydrophilic agent is exhibited.
- the first non-woven fabric layer contains crimped fibers (A), which are fibers of a thermoplastic polymer.
- the average crimp diameter of the crimped fiber (A) is 800 ⁇ m or less, preferably 700 ⁇ m or less, more preferably 600 ⁇ m or less, further preferably 550 ⁇ m or less, and 500 ⁇ m or less. Is particularly preferable, and 400 ⁇ m or less is extremely preferable.
- the average crimp diameter of the crimp fibers (A) is 800 ⁇ m or less, a non-woven fabric laminate having excellent hydrophilicity and capable of suppressing the migration of the hydrophilic agent when in contact with other members can be obtained.
- the average crimped diameter of the crimped fiber (A) is preferably 200 ⁇ m or more, more preferably 220 ⁇ m or more, and 250 ⁇ m or more. It is more preferably 270 ⁇ m or more, and particularly preferably 270 ⁇ m or more.
- the crimp diameter represents the size of the crimp in the crimp fibers forming one or more crimps
- the average crimp diameter represents the average value of the crimp size.
- the average crimp diameter is measured as follows.
- a measurement sample is collected from the non-woven fabric layer to be measured.
- the measurement sample is placed on the microscope stage of an optical microscope (“ECLIPSE E400” manufactured by Nikon Corporation).
- the surface (flat surface) of the non-woven fabric was observed at a magnification of 4 times, and among the crimped fibers, the crimped fibers having a crimp shape of a semicircle or more were randomly selected. Select 50 points for.
- the diameter of the selected crimped fiber is measured by the image analysis software "Pixs2000" attached to the optical microscope. The diameter of the crimped fiber is measured by selecting three points on the circumference by the diameter measuring function of the image analysis software. The diameter of the crimped fiber is measured at 50 points, and the average value is calculated to obtain the average crimped diameter.
- the non-woven fabric laminate of the present disclosure may include a second non-woven fabric layer.
- the second non-woven fabric layer is preferably a non-woven fabric layer containing fibers of a thermoplastic polymer.
- the second non-woven fabric layer is not particularly limited, and may be, for example, a conventionally known non-woven fabric layer.
- the second non-woven fabric layer is a non-woven fabric layer including spunbonded non-woven fabric, melt blown non-woven fabric, card type air-through non-woven fabric, air-laid non-woven fabric, needle punch type spunbond non-woven fabric, wet non-woven fabric, dry pulp non-woven fabric, flash spun non-woven fabric, spread non-woven fabric and the like. There may be.
- the second non-woven fabric layer has an average crimp diameter different from the average crimp diameter of the crimp fiber (A), and the crimp fiber (B) or non-crimp fiber (B) having an average crimp diameter of 500 ⁇ m or more. It is preferable that the crimp fiber (C) is contained.
- a hydrophilic agent is added to a non-woven fabric composed of crimped fibers in order to obtain a non-woven fabric having both flexibility and hydrophilicity, the non-woven fabric tends to shrink in the CD direction.
- the nonwoven fabric laminate of the present disclosure contains the above-mentioned crimped fibers (B) or non-crimped fibers (C), shrinkage in the CD direction is suppressed when the nonwoven fabric laminate of the present disclosure is produced. Stable production is possible. Therefore, the non-woven fabric laminate provided with the second non-woven fabric layer tends to have excellent dimensional stability.
- the second non-woven fabric layer may be a non-woven fabric layer mainly containing non-crimped fibers (C) which are fibers of a thermoplastic polymer.
- the average crimped diameter of the crimped fibers (A) is 700 ⁇ m or less. It is more preferably 600 ⁇ m or less, further preferably 550 ⁇ m or less, and particularly preferably 500 ⁇ m or less.
- the first non-woven fabric layer may be the outermost layer.
- the average crimping diameter of the crimped fiber (A) is preferably 600 ⁇ m or less, more preferably 550 ⁇ m or less, and further preferably 500 ⁇ m or less.
- the non-woven fabric laminate of the present disclosure has an excellent hydrophilicity when it has such a layer structure, and has excellent dimensional stability while suppressing the migration of the hydrophilic agent when it comes into contact with other members. It becomes easier to obtain a laminate.
- the second non-woven fabric layer may contain other fibers other than the non-curly fibers (C).
- other fibers include crimped fibers (B) and crimped fibers other than the crimped fibers (B) described above.
- the other fibers may be long fibers or short fibers.
- short fiber generally means a fiber having an average fiber length of 200 mm or less.
- the second non-woven fabric layer is a non-woven fabric layer containing non-woven fabric (C) and other fibers other than non-woven fabric (C), such as spunbonded non-woven fabric, melt-blown non-woven fabric, card-type air-through non-woven fabric, and air-laid non-woven fabric. , Needle punch type spunbonded non-woven fabric, wet non-woven fabric, dry pulp non-woven fabric, flash spun non-woven fabric, spread non-woven fabric and the like.
- the second non-woven fabric layer may be a non-woven fabric layer mainly containing the above-mentioned crimped fibers (B) which are fibers of a thermoplastic polymer.
- the second non-woven fabric layer is a non-woven fabric layer mainly containing crimped fibers (B) which are fibers of a thermoplastic polymer, it is rolled from the viewpoint of achieving both excellent flexibility and excellent dimensional stability.
- the average crimp diameter of the crimped fiber (B) is preferably 500 ⁇ m or more, more preferably 550 ⁇ m or more, further preferably 600 ⁇ m or more, and particularly preferably 650 ⁇ m or more.
- the average crimp diameter of the crimp fiber (B) is preferably 1,500 ⁇ m or less, and more preferably 1,000 ⁇ m or less.
- the average crimp diameters of the crimp fibers (A) and the crimp fibers (B) are different from each other, and the average crimp diameters of the crimp fibers (A) and the crimp fibers (B) are in the above range. It becomes easier to obtain a non-woven fabric laminate having excellent hydrophilicity and excellent dimensional stability while suppressing the migration of the hydrophilic agent when it comes into contact with other members.
- the difference in the average crimp diameter between the crimp fiber (A) and the crimp fiber (B) is not particularly limited, and is, for example, 100 ⁇ m or more. It may be.
- the second non-woven fabric layer may contain other fibers other than the crimped fibers (B).
- other fibers include crimped fibers other than crimped fibers (B), the above-mentioned non-crimped fibers (C), and the like.
- the other fibers may be long fibers or short fibers.
- the second non-woven fabric layer is a non-woven fabric layer containing the crimped fiber (B) and other fibers other than the crimped fiber (B), and is a spunbonded non-woven fabric, a melt-blown non-woven fabric, a card-type air-through non-woven fabric, an air-laid non-woven fabric, and a needle. It may be a layer of a non-woven fabric including a punch-type spunbond non-woven fabric, a wet non-woven fabric, a dry-type pulp non-woven fabric, a flash-spun non-woven fabric, an open fiber non-woven fabric, and the like.
- the first non-woven fabric layer may be the outermost layer in the non-woven fabric laminate.
- the average crimping diameter of the crimped fibers (A) contained in the first non-woven fabric layer is preferably 600 ⁇ m or less, more preferably 550 ⁇ m or less, further preferably 500 ⁇ m or less, and 400 ⁇ m. The following is particularly preferable.
- the non-woven fabric laminate of the present disclosure may have a plurality of first non-woven fabric layers, or may have a plurality of second non-woven fabric layers.
- it may have a layer structure of a first non-woven fabric layer / a first non-woven fabric layer / a second non-woven fabric layer, or a layer structure of a first non-woven fabric layer / a second non-woven fabric layer / a first non-woven fabric layer.
- It may have a layer structure of a first non-woven fabric layer / a second non-woven fabric layer / a second non-woven fabric layer, a first non-woven fabric layer / a first non-woven fabric layer / a first non-woven fabric layer / a second.
- the non-woven fabric layer may have a layer structure of the first non-woven fabric layer / first non-woven fabric layer / second non-woven fabric layer / second non-woven fabric layer. It may have a layer structure of a first non-woven fabric layer / a second non-woven fabric layer / a first non-woven fabric layer, and may be a first non-woven fabric layer / a second non-woven fabric layer / a first non-woven fabric layer / a second non-woven fabric layer. It may have a layer structure, a first non-woven fabric layer / a second non-woven fabric layer / a second non-woven fabric layer / a second non-woven fabric layer, or a first non-woven fabric layer / a second non-woven fabric.
- the layer structure may be a layer / a second non-woven fabric layer / a first non-woven fabric layer.
- the non-woven fabric laminate of the present disclosure may include a melt-blown non-woven fabric layer described later, for example, on the first non-woven fabric layer, on the second non-woven fabric layer, and between the two first non-woven fabric layers, 2 A melt blown non-woven fabric layer may be provided between the second non-woven fabric layer of the layer, between the first non-woven fabric layer and the second non-woven fabric layer, and the like.
- the non-woven fabric laminate of the present disclosure may have a plurality of melt blown non-woven fabric layers described later.
- the first non-woven fabric layer is preferably a spunbonded non-woven fabric layer, and when the above-mentioned non-woven fabric laminate includes a second non-woven fabric layer, the first non-woven fabric layer is a spunbonded non-woven fabric. It is a layer, and it is preferable that the second non-woven fabric layer is a layer of spunbonded non-woven fabric.
- the fibers of the thermoplastic polymer contained in the first non-woven layer and the second non-woven layer (that is, the crimped fibers (A) contained in the first non-woven layer, and the crimped fibers contained in the second non-woven layer).
- the (B) or non-crimped fiber (C)) is not particularly limited as long as it is a fiber capable of forming a non-woven fabric.
- the thermoplastic polymer constituting the fiber include an olefin polymer and a polyester polymer. Examples thereof include polymers, polyamide-based polymers, and thermoplastic polymer compositions containing a plurality of these polymers.
- the thermoplastic polymer is a concept including a thermoplastic polymer composition.
- thermoplastic polymer constituting the other fiber include, for example, an olefin polymer, a polyester polymer, a polyamide polymer, and a thermoplastic polymer composition containing a plurality of these polymers independently. Things etc. can be mentioned.
- the olefin-based polymer is a polymer containing a structural unit derived from olefin as a main component
- the polyester-based polymer is a polymer containing polyester as a structural unit
- the polyamide-based polymer is a weight containing polyamide as a structural unit. It is a coalescence.
- the thermoplastic polymer preferably contains an olefin-based polymer, and more preferably contains at least one selected from the group consisting of a propylene-based polymer and an ethylene-based polymer as the olefin-based polymer.
- the propylene-based polymer is a polymer mainly composed of a structural unit derived from propylene, and is a propylene homopolymer and a copolymer of propylene and ⁇ -olefin other than propylene (propylene / ⁇ -olefin random copolymer). It is a concept that includes. For example, it may be either a propylene homopolymer or a copolymer of propylene and an ⁇ -olefin other than propylene, or both may be contained.
- the propylene / ⁇ -olefin random copolymer is preferably, for example, a random copolymer of propylene and one or more ⁇ -olefins having 2 to 10 carbon atoms other than propylene, and is other than propylene and propylene. Random copolymers with one or more ⁇ -olefins having 2 to 8 carbon atoms are more preferable. Specific examples of preferable ⁇ -olefins that copolymerize with propylene from the viewpoint of excellent flexibility include ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene, and 3-methyl-1.
- Examples thereof include -butene, 3-methyl-1-pentene, 3-ethyl-1-pentene, 4-methyl-1-pentene and 4-methyl-1-hexene.
- Examples of the propylene / ⁇ -olefin random copolymer include a propylene / ethylene random copolymer and a propylene / ethylene / 1-butene random copolymer.
- the content of the structural unit derived from ⁇ -olefin in the propylene / ⁇ -olefin random copolymer is not particularly limited, and is preferably 1 mol% to 10 mol%, for example, 1 mol% to 5 mol%. More preferably.
- the propylene-based polymer may contain two or more different propylene-based polymers, or may contain a propylene-based polymer and an ethylene-based polymer.
- a copolymer of propylene and an ⁇ -olefin other than propylene such a copolymer is used when the content of the structural unit derived from propylene and the content of the structural unit derived from ethylene are equal. Is classified as a propylene-based polymer.
- the ethylene-based polymer is a polymer mainly composed of a structural unit derived from ethylene, and is a concept including an ethylene homopolymer and a copolymer of ethylene and an ⁇ -olefin other than ethylene.
- it may be either an ethylene homopolymer or a copolymer of ethylene and an ⁇ -olefin other than ethylene (ethylene / ⁇ -olefin random copolymer).
- the ethylene / ⁇ -olefin random copolymer is preferably, for example, a random copolymer of ethylene and one or more ⁇ -olefins having 2 to 10 carbon atoms other than ethylene.
- the ethylene / ⁇ -olefin random copolymer include an ethylene / propylene random copolymer and an ethylene / 1-butene random copolymer.
- the ethylene-based polymer may contain two or more different ethylene-based polymers, or may contain an ethylene-based polymer and a propylene-based polymer.
- the density of the ethylene / alpha-olefin random copolymer is preferably 900kg / m 3 ⁇ 980kg / m 3, from the viewpoint of spinnability, more preferably from 910kg / m 3 ⁇ 980kg / m 3, It is more preferably 950 kg / m 3 to 980 kg / m 3 .
- the above-mentioned density is preferably 900 kg / m 3 to 960 kg / m 3 , and more preferably 900 kg / m 3 to 940 kg / m 3 .
- Density of the foregoing it is preferable from the viewpoint of the balance between spinning property and Mekuchijimi ⁇ is 910kg / m 3 ⁇ 940kg / m 3.
- the melting point and density of the ethylene / ⁇ -olefin random copolymer can be adjusted within the above ranges. It is known that there is a correlation between the density and the melting point of the ethylene / ⁇ -olefin random copolymer.
- the melting point (Tm) of the propylene-based polymer is preferably 125 ° C. or higher, and more preferably 125 ° C. to 165 ° C.
- the melt flow rate (MFR) (ASTM D-1238, 230 ° C., load 2,160 g) of the propylene-based polymer is preferably 10 g / 10 min to 100 g / 10 min, preferably 20 g / min, from the viewpoint of spinnability. More preferably, it is 10 minutes to 70 g / 10 minutes.
- the melt flow rate (MFR) (ASTM D-1238, 190 ° C., load 2,160 g) of the ethylene polymer is preferably 1 g / 10 min to 100 g / 10 min, from the viewpoint of spinnability, and is 20 g / min. More preferably, it is 10 minutes to 70 g / 10 minutes.
- the non-crimp fiber (C) may be a fiber containing one kind of thermoplastic polymer. It may be a fiber containing two or more kinds of thermoplastic polymers.
- the non-crimped fiber (C) preferably contains a propylene-based polymer.
- the crimp fibers (A) and crimp fibers of the thermoplastic polymer contained in the first non-woven layer (B) may be a fiber containing one kind of thermoplastic polymer, or may be a composite fiber containing two or more kinds of thermoplastic polymers.
- the composite fiber is For example, it may be a side-by-side type, a concentric core sheath type, or an eccentric core sheath type.
- the eccentric core sheath type composite fiber may be an exposed type in which the core portion is exposed on the surface, or a non-exposed type in which the core portion is not exposed on the surface.
- the crimp fibers (A) of the thermoplastic polymer contained in the first non-woven fabric layer and the crimp fibers (B) of the thermoplastic polymer contained in the second non-woven fabric layer are composite fibers containing a propylene-based polymer. It is more preferable that the crimped composite fiber contains a propylene-based polymer, and more preferably an eccentric core-sheath type crimped composite fiber containing a propylene-based polymer.
- a composite fiber containing a propylene-based polymer it is a non-woven fabric laminate that has excellent hydrophilicity and that achieves both dimensional stability and flexibility while suppressing the migration of the hydrophilic agent when it comes into contact with other members. Is easy to obtain.
- the fibers of the thermoplastic polymer contained in the first non-woven fabric layer and the second non-woven fabric layer are fibers containing a propylene-based polymer, and are on the surface of the crimped fibers (A) contained in the first non-woven fabric layer.
- the propylene-based polymer is exposed, and the propylene-based polymer is exposed on the surface of the crimped fiber (B) or the non-crimped fiber (C) contained in the second non-woven layer, and the crimped fiber.
- the melting point difference between the propylene-based polymer exposed on the surface of (A) and the propylene-based polymer exposed on the surface of the crimped fiber (B) or the non-crimped fiber (C) is ⁇ 15 ° C. It is preferably within.
- the polymer portion on the low melting point side becomes relatively soft when embossed at a high temperature
- the polymer portion on the high melting point side is preferably thermally entangled when embossed at a low temperature, which is sufficient.
- the propylene-based polymer exposed on the surface of the crimped fiber (A) contained in the first non-woven fabric layer and the crimped fiber (B) contained in the second non-woven fabric layer is preferable to reduce the difference in melting point from the propylene-based polymer exposed on the surface of the non-crimped fiber (C).
- the propylene-based polymer on the side exposed on the surface of the crimped fiber (A) contained in the first non-woven fabric layer and the second non-woven fabric layer are contained.
- the crimped fiber (B) or the propylene-based polymer on the exposed side of the non-crimped fiber (C) is a propylene / ⁇ -olefin copolymer, a propylene homopolymer and a propylene / ⁇ -olefin. It may be a mixture of copolymers or a combination thereof.
- the melting point (Tm) of the propylene / ⁇ -olefin random copolymer as the propylene / ⁇ -olefin copolymer can be measured using a differential scanning calorimeter (DSC). With a differential scanning calorimeter (DSC), raise the temperature to a temperature about 50 ° C higher than the temperature that gives the extreme value of the melting endothermic curve when the temperature is raised at a heating rate of 10 ° C / min, and hold at this temperature for 10 minutes. .. Then, the temperature is cooled to 30 ° C.
- DSC differential scanning calorimeter
- the melting curve is measured again when the temperature is raised to a predetermined temperature at a heating rate of 10 ° C./min.
- the temperature (Tp) that gives the extreme value of the endothermic curve of melting can be obtained according to the method of ASTM D3418, and the endothermic peak of the peak temperature can be obtained as the melting point (Tm).
- the exposure to the surface of the crimped fiber means the side where many parts are exposed on the surface of the composite fiber.
- the side with a large amount of exposed portion on the surface represents the side of the composite fiber in which the thermoplastic polymer is more exposed.
- the side having many exposed parts on the surface is collectively referred to as a sheath part.
- the side where the portion exposed on the surface is small is collectively referred to as a core portion.
- the composite fiber having the largest amount of exposed portion on the surface (that is, the composite fiber having the largest sheath portion) is a non-exposed type composite fiber because the exposure of the core portion is the smallest.
- the mass ratio (core / sheath) between the sheath and the core is preferably, for example, 95/5 to 5/95, and 90/10 to 10 /. It is more preferably 90, and even more preferably 90/10 to 40/60.
- the mass ratio between the sheath and the core can be selected according to the type of resin used for the sheath and the core and the target average crimp diameter.
- the average fiber diameter of the fibers of the thermoplastic polymer contained in the first non-woven fabric layer and the second non-woven fabric layer is preferably 5 ⁇ m or more, and more preferably 7 ⁇ m or more. Further, the above-mentioned average fiber diameter is preferably 25 ⁇ m or less, and more preferably 20 ⁇ m or less. In the present disclosure, the average fiber diameter is determined as follows. From the obtained non-woven fabric laminate, 10 test pieces of 10 mm ⁇ 10 mm are sampled, and the diameter of the fiber is read to the first decimal place at a magnification of 20 times using an ECLIPSE E400 microscope manufactured by Nikon Corporation. Measure the diameters of 20 arbitrary points for each test piece, and calculate the average value. This is done with each non-woven fabric layer, for example, a spunbonded non-woven fabric layer, a melt blown non-woven fabric layer, or the like.
- the non-woven fabric laminate of the present disclosure further includes a melt blown non-woven fabric layer containing fibers of a thermoplastic polymer.
- the average fiber diameter of the fibers in the meltblown non-woven fabric layer is preferably less than 3.0 ⁇ m, more preferably 2.8 ⁇ m or less, and further preferably 2.6 ⁇ m or less.
- the lower limit of the average fiber diameter of the fibers in the melt blown non-woven fabric layer is not particularly limited, and may be more than 0 ⁇ m, preferably 0.5 ⁇ m or more.
- the method for measuring the average fiber diameter of the melt blown fiber is as described above except that the magnification of the microscope is appropriately adjusted (for example, set to 1,000 times and observed with a scanning electron microscope).
- thermoplastic polymer constituting the melt blown non-woven layer examples include ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene, 3-methyl-1-butene and 3-methyl.
- High-pressure low-density polyethylene, linear low which is a single or copolymer of ⁇ -olefins such as -1-pentene, 3-ethyl-1-pentene, 4-methyl-1-pentene, and 4-methyl-1-hexene.
- Dense polyethylene (so-called LLDPE), high-density polyethylene, propylene-based polymer (propylene homopolymer, polypropylene random copolymer, propylene / ⁇ -olefin copolymer, etc.), poly1-butene, poly4-methyl-1- Olefin-based polymers such as penten, ethylene / propylene random copolymer, ethylene / 1-butene random copolymer, propylene / 1-butene random copolymer; polyesters such as polyethylene terephthalate, polybutylene terephthalate, and polyethylene naphthalate; Polyamide-based polymers such as nylon-6, nylon-66, and polymethoxylen adipamide; polyvinyl chloride, polyimide, ethylene / vinyl acetate copolymer, polyacrylonitrile, polycarbonate, polystyrene, ionomer, thermoplastic polyurethane or these. Examples include a
- the propylene-based polymer constituting the melt blown non-woven layer is a propylene homopolymer and a copolymer of propylene and one or two or more ⁇ -olefins having two or more carbon atoms (excluding propylene).
- a certain propylene / ⁇ -olefin copolymer is preferable.
- one or more ⁇ -olefins (excluding propylene) having two or more carbon atoms
- one or two or more ⁇ -olefins having 2 to 10 carbon atoms for example, ethylene, 1-butene, 1-) Penten, 1-hexene, 1-octene, 1-decene, 3-methyl-1-butene, 3-methyl-1-pentene, 3-ethyl-1-pentene, 4-methyl-1-pentene, 4-methyl- 1-Hexene, etc.
- one or more ⁇ -olefins having 2 to 8 carbon atoms are more preferable.
- the melting point (Tm) of the propylene homopolymer is preferably 155 ° C. or higher, and more preferably 157 ° C. to 165 ° C.
- the content of the structural unit derived from the ⁇ -olefin of the propylene / ⁇ -olefin copolymer is preferably 0.5% by mass to 25% by mass, and 1.0% by mass to 20% by mass, based on the total structural unit. More preferably, it is by mass.
- the thermoplastic polymer may be a mixture of a plurality of propylene-based polymers.
- examples of the above-mentioned mixture include a mixture of a propylene / ⁇ -olefin copolymer and a propylene homopolymer, a mixture of a propylene / ⁇ -olefin copolymer and a propylene-based polymer wax, and a propylene / ⁇ -olefin common weight.
- examples thereof include a mixture of three types of a combination, a propylene homopolymer and a propylene-based polymer wax.
- the propylene-based polymer wax is a propylene-based polymer having a relatively low molecular weight, that is, a wax-like propylene-based polymer.
- the weight average molecular weight (Mw) of the propylene-based polymer wax is preferably 400 to 30,000, more preferably 400 to 25,000, and even more preferably 1,000 to 10,000.
- the molecular weight and molecular weight distribution of wax are measured by using the GPC method. The measurement is carried out under the following conditions using commercially available monodisperse standard polystyrene as a standard.
- the propylene-based polymer wax preferably has a softening point of 90 ° C. or higher, more preferably 100 ° C. or higher, as measured according to JIS K2207: 1996.
- the softening point is 90 ° C. or higher, the heat resistance stability during heat treatment, use, etc. can be further improved, and as a result, the heat resistance of the melt blown non-woven fabric can be further improved.
- the upper limit of the softening point is not particularly limited, and examples thereof include 168 ° C. or lower.
- propylene-based polymer wax examples include a propylene homopolymer, a copolymer of propylene and an ⁇ -olefin having 2 carbon atoms or 4 to 20 carbon atoms, and the like.
- the melt flow rate (MFR: ASTM D 1238, 230 ° C., load 2,160 g) of the propylene-based polymer constituting the melt blown non-woven fabric layer is 200 g / 10 from the viewpoint of obtaining a flexible non-woven fabric laminate by thinning fibers, for example. It is preferably minutes or more, and more preferably 800 g / 10 minutes or more. Further, the above-mentioned melt flow rate is preferably 2,000 g / 10 minutes or less, and more preferably 1,600 g / 10 minutes or less from the viewpoint of spinning stability.
- Basis weight of the meltblown nonwoven fabric layer, from the viewpoint of flexibility after the nonwoven laminate is preferably less than 5 g / m 2, more preferably less than 3 g / m 2.
- the lower limit of the melt blown non-woven fabric layer is not particularly limited, and is preferably 0.2 g / m 2 or more, more preferably 0.5 g / m 2 or more, for example, from the viewpoint of barrier properties. It is more preferably 7 g / m 2 or more.
- the method of measuring the basis weight in the present disclosure is as described in Examples described later.
- the thermoplastic polymer in the meltblown nonwoven fabric layer is a propylene homopolymer having a melt flow rate of 800 g / 10 minutes or more, and the average fiber diameter of the fibers in the meltblown nonwoven fabric layer is less than 3 ⁇ m.
- the texture of the melt blown non-woven fabric layer is preferably less than 3 g / m 2 . As a result, the flexibility after forming the non-woven fabric laminate tends to be excellent.
- the thermoplastic polymer in the melt blown non-woven layer is a propylene-based weight containing a propylene / ⁇ -olefin copolymer or a propylene / ⁇ -olefin copolymer having a melt flow rate of 200 g / 10 minutes or more. It is a coalesced mixture, and the texture of the melt blown non-woven layer is preferably less than 5 g / m 2 . As a result, the flexibility after forming the non-woven fabric laminate tends to be excellent.
- the first non-woven fabric layer is preferably a layer of spunbonded non-woven fabric.
- the non-woven fabric laminate of the present disclosure may include a second non-woven fabric layer, which is a layer of spunbonded non-woven fabric, a melt-blown non-woven fabric layer, and the like.
- preferred forms of the non-woven fabric laminate include, for example, a first non-woven fabric layer / first non-woven fabric layer / melt blown non-woven fabric layer / first non-woven fabric layer, first non-woven fabric layer / melt blown non-woven fabric layer / first non-woven fabric.
- the non-woven fabric laminate contains the melt blown non-woven fabric layer, the air permeability is lowered and the barrier property (particle trapping property) is improved, so that it is used for filters and for wrapping fine particles (diapers, packaging materials for pet sheet absorbers). ) Etc. can also be suitably used.
- the flexibility, particularly the cantilever value tends to be deteriorated as compared with the non-woven fabric laminate not containing the melt-blown non-woven fabric layer.
- the above-mentioned deterioration of flexibility can be suitably suppressed, and further, the melt-blown non-woven fabric layer has a texture and fibers.
- the melt-blown non-woven fabric layer has a texture and fibers.
- the fibers of the thermoplastic polymer contained in the first non-woven fabric layer, the second non-woven fabric layer, and the melt blown non-woven fabric layer may contain commonly used additives, if necessary.
- additives include various known additives such as antioxidants, weather stabilizers, heat stabilizers, light stabilizers, antistatic agents, antifogging agents, lubricants, dyes, pigments, natural oils, synthetic oils, and waxes. Agents can be mentioned.
- the non-woven fabric laminate of the present disclosure contains a hydrophilic agent. Hydrophilizing agents can be further classified into penetrants and wetting agents.
- the non-woven fabric laminate of the present disclosure may contain both a penetrant and a wetting agent, may not contain a penetrant, and may contain a wetting agent. From the viewpoint of excellent hydrophilicity and further exerting the effect of suppressing migration of the hydrophilic agent, it is preferable to include both a penetrant and a wetting agent as the hydrophilic agent.
- the hydrophilizing agent preferably contains at least one of a sulfonate and a sulfate ester salt as a penetrant.
- the sulfonate include alkylbenzene sulfonate, alkylnaphthalene sulfonate, ⁇ -olefin sulfonate, alkylsulfosuccinate and the like.
- Alkali metal salts are preferable as these sulfonates.
- the sulfate ester salt include higher alcohol sulfate ester salts and alkyl sulfate ester salts. Alkali metal salts are preferable as these sulfate ester salts.
- the hydrophilic agent preferably contains a sulfonate as a penetrant, and more preferably contains an alkali metal salt of a sulfonic acid.
- the sulfonate as a penetrant is preferably an alkyl sulfosuccinate from the viewpoint of suppressing the migration of the hydrophilizing agent when it comes into contact with other members.
- the alkyl sulfosuccinate is preferably an alkali metal salt of dialkyl sulfosuccinic acid, more preferably an alkali metal salt of dialkyl sulfosuccinic acid having two alkyl groups having 8 to 16 carbon atoms.
- Examples of the alkali metal salt of dialkylsulfosuccinic acid include a lithium salt thereof, a sodium salt thereof, a potassium salt thereof and the like, and the sodium salt thereof is preferable.
- alkali metal salt of dialkyl sulfosuccinic acid having two alkyl groups having 8 to 16 carbon atoms include dioctyl sulfosuccinate sodium salt, di (2-ethylhexyl) sulfosuccinate sodium salt, and didecyl.
- examples thereof include sodium sulfosuccinate salt, didodecyl sulfosuccinate sodium salt, ditetradecyl sulfosuccinate lithium (Li) salt, dihexadecyl sulfosuccinate potassium (K) salt and the like.
- a di (2-ethylhexyl) sodium sulfosuccinate salt is preferable from the viewpoint of suppressing the transfer of the hydrophilizing agent when it comes into contact with other members.
- the hydrophilizing agent may contain any of a cationic surfactant, an anionic surfactant, an amphoteric surfactant, and a nonionic surfactant as the wetting agent, and the wetting agent is not particularly limited.
- Examples of the cationic surfactant include alkyl (or alkenyl) trimethylammonium halides, quaternary ammonium salts typified by dialkyl (or alkenyl) dimethylammonium halides, and alkylamine salts, and alkylene oxide adducts thereof. ..
- Examples of the anionic surfactant include a phosphate ester salt typified by sodium lauryl phosphate and a fatty acid salt typified by sodium laurate.
- Examples of the amphoteric surfactant include salts of these cationic surfactants and anionic surfactants.
- the wetting agent is preferably a nonionic surfactant from the viewpoint of imparting excellent hydrophilicity.
- the nonionic surfactant which is a wetting agent include polyhydric alcohol fatty acid ester, polyoxyalkylene fatty acid ester, alkylpolyoxyethylene alcohol, alkylene oxide adduct of polyhydric alcohol fatty acid ester, alkoxylated alkylphenol, fatty acid amide, and the like.
- nonionic surfactants such as alkyldiethanolamide and polyoxyalkylene.
- the hydrophilic agent is selected from the group consisting of polyhydric alcohol fatty acid ester, polyoxyalkylene fatty acid ester, and alkylene oxide adduct of polyhydric alcohol fatty acid ester as a wetting agent. It is preferable to include at least one selected.
- the polyhydric alcohol fatty acid ester, the polyoxyalkylene fatty acid ester, and the alkylene oxide adduct of the polyhydric alcohol fatty acid ester may be any of monoester, diester, and triester, respectively.
- the polyhydric alcohol fatty acid ester, the polyoxyalkylene fatty acid ester, and the alkylene oxide adduct of the polyhydric alcohol fatty acid ester may contain one of a monoester, a diester, and a triester, respectively. It may contain more than a seed.
- polyhydric alcohol fatty acid ester examples include glycerin fatty acid ester and sorbitan fatty acid ester.
- glycerin fatty acid ester and sorbitan fatty acid ester examples include an ester of glycerin or sorbitan and a fatty acid having 10 to 20 carbon atoms.
- Specific examples thereof include glycerin lauric acid monoester, glycerin oleic acid diester, glycerin oleic acid triester, sorbitan lauric acid monoester, sorbitan lauric acid diester, and sorbitan lauric acid triester.
- polyoxyalkylene fatty acid ester examples include polyoxyethylene fatty acid ester and polyoxypropylene fatty acid ester. Among these, polyoxyethylene fatty acid ester is preferable.
- the polyoxyethylene fatty acid ester preferably has 10 to 20 carbon atoms of the fatty acid and 5 to 20 additional moles of the ethylene oxide chain (also referred to as EO chain). Specific examples thereof include polyoxyethylene stearic acid monoester, polyoxyethylene lauric acid monoester, polyoxyethylene lauric acid diester, polyoxyethylene oleic acid monoester, and polyoxyethylene oleic acid diester.
- alkylene oxide adduct of the polyhydric alcohol fatty acid ester examples include ethylene oxide adduct of the polyhydric alcohol fatty acid ester and propylene oxide adduct of the polyhydric alcohol fatty acid ester.
- the alkylene oxide adduct of the polyhydric alcohol fatty acid ester is an ester of glycerin and a fatty acid having 10 to 20 carbon atoms, and the addition molar number of ethylene oxide is preferably 5 to 20.
- Specific examples thereof include polyoxyethylene glycerin lauric acid monoester, polyoxyethylene glycerin lauric acid diester, and polyoxyethylene glycerin lauric acid triester.
- the wetting agent is preferably contained in combination with a polyhydric alcohol fatty acid ester, an alkylene oxide adduct of the polyhydric alcohol fatty acid ester, and a polyoxyalkylene fatty acid ester from the viewpoint of imparting excellent hydrophilicity.
- the wetting agent is also preferably contained in combination with a polyhydric alcohol fatty acid ester and a polyoxyalkylene fatty acid ester.
- the combination of the polyhydric alcohol fatty acid ester, the alkylene oxide adduct of the polyhydric alcohol fatty acid ester, and the polyoxyalkylene fatty acid ester includes glycerin fatty acid ester, the ethylene oxide adduct of the polyhydric alcohol fatty acid ester, and the polyoxyethylene fatty acid. More preferably, it is a combination with an ester. More preferably, it is a combination of a glycerin oleic acid diester, a polyoxyethylene glycerin lauric acid diester and a triester, and a polyoxyethylene lauric acid diester.
- the combination of the polyhydric alcohol fatty acid ester and the alkylene oxide adduct of the polyhydric alcohol fatty acid ester is preferably a combination of the glycerin fatty acid ester and the alkylene oxide adduct of the polyhydric alcohol fatty acid ester, and glycerin oleic acid. More preferably, it is a combination of a diester and a glycerin oleic acid triester and a polyoxyethylene oleic acid monoester and a polyoxyethylene oleic acid diester.
- the combination of the polyhydric alcohol fatty acid ester and the polyoxyalkylene fatty acid ester is preferably a combination of a sorbitan lauric acid monoester, a diester and a triester, and a polyoxyethylene lauric acid monoester and a diester.
- a sorbitan lauric acid monoester a diester and a triester
- polyoxyethylene lauric acid monoester and a diester it is also preferable to combine polyoxyethylene sorbitan oleic acid monoesters, polyoxyethylene sorbitan oleic acid diesters and polyoxyethylene sorbitan oleic acid triesters.
- the ratio of the penetrant to the wetting agent is preferably 1/99 to 60/40, more preferably 5/95 to 50/50 in terms of mass ratio, and is 10/90. It is more preferably to 40/60.
- mass ratio of the wetting agent / penetrant is in this range, the hydrophilicity is excellent, and the transfer of the hydrophilicizing agent when it comes into contact with other members is likely to be suppressed.
- hydrophilic agent separation test is considered to be an index of the affinity of water or the thermoplastic polymer for fibers as a whole of the hydrophilic agent.
- the hydrophilicity tends to be further improved by using the hydrophilic agent that separates by the above separation test.
- the hydrophilizing agent exhibiting such properties preferably has a penetrant / wetting agent mass ratio of 1/99 to 60/40, and more preferably 10/90 to 40/60.
- the separation test of the hydrophilic agent when analyzing from the non-woven fabric to be measured, for example, it may be measured as follows. First, a non-woven fabric of 100 g or more is prepared. Next, the prepared non-woven fabric is immersed in ethanol and allowed to stand at 25 ° C. for 24 hours to obtain an extract A. The non-woven fabric is immersed in another ethanol and allowed to stand at 25 ° C. for 24 hours to obtain an extract B. The extract A and the extract B are degassed and heated to 80 ° C. to sufficiently remove ethanol to obtain a residue. The residue is then mixed and the residue is subjected to a separation test of the hydrophilic agent.
- the amount of the hydrophilizing agent applied is preferably 0.1% by mass to 2.0% by mass, more preferably 0.2% by mass to 1.5% by mass, and 0.3% by mass to 1%. It is more preferably .2% by mass.
- the amount of the hydrophilic agent applied is obtained by subtracting the mass of the non-woven fabric before applying the hydrophilic agent from the mass of the non-woven fabric after applying the hydrophilic agent, and subtracting the mass of the non-woven fabric after applying the hydrophilic agent. It is expressed as a percentage divided by.
- the coating amount of the hydrophilic agent is a concept that is included as the coating amount even in the case of the kneading method.
- the non-woven fabric laminate of the present disclosure may contain other components, if necessary.
- Other components include, for example, antioxidants, heat stabilizers, weather stabilizers, antistatic agents, slip agents, antifogging agents, lubricants, dyes, pigments, light stabilizers, antiblocking agents, dispersants, nucleating agents.
- These other components may be contained inside the fibers constituting the non-woven fabric, or may be attached to the surface of the fibers.
- the transfer amount (hereinafter, also referred to as the transfer amount) of the hydrophilic agent from the non-woven fabric laminate to the non-woven fabric to be transferred is preferably 0.015 g / m 2 or less, preferably 0.013 g. / more preferably m is 2 or less, and more preferably 0.011 g / m 2 or less.
- the transfer amount is in the above range, the non-woven fabric laminate is excellent in hydrophilicity, and the transfer of the hydrophilic agent when it comes into contact with other members is suppressed.
- the method for measuring the transfer amount will be described in Examples described later.
- the above range of the transfer amount can be satisfied by adjusting the production conditions such as the type and amount of the hydrophilic agent contained in the non-woven fabric laminate and the coating method.
- the non-woven fabric laminate of the present disclosure is not particularly limited as long as the transfer amount of the hydrophilic agent from the non-woven fabric laminate to the non-woven fabric to be transferred is 0 g / m 2 or more, and is, for example, 0.001 g / m 2 or more. There may be.
- the non-woven laminate of the present disclosure is the ratio of the surface water vapor adsorption area in the water vapor adsorption test obtained by the water vapor adsorption isotherm BET formula to the surface nitrogen adsorption area in the nitrogen adsorption test obtained by the BET formula of the nitrogen adsorption isotherm (surface water vapor).
- the adsorption area / surface nitrogen adsorption area (hereinafter, also referred to as an area ratio) is preferably 1.5 or more, more preferably 3.0 or more, and further preferably 5.0 or more.
- the area ratio is preferably 9.0 or less, and more preferably 8.5 or less.
- the area ratio is an index of the balance between hydrophilicity and hydrophobicity per surface area of the non-woven fabric.
- the non-woven fabric is excellent in hydrophilicity, and the migration of the hydrophilic agent when it comes into contact with other members is suppressed.
- the measuring method of the water vapor adsorption test obtained by the BET method of the water vapor adsorption isotherm and the measuring method of the surface nitrogen adsorption area in the nitrogen adsorption test obtained by the BET method of the nitrogen adsorption isotherm will be described in Examples described later.
- the above range of the ratio of the surface water vapor adsorption area to the surface nitrogen adsorption area can be satisfied by adjusting the production conditions such as the type and amount of the hydrophilic agent contained in the non-woven fabric laminate and the coating method. Is.
- the nonwoven fabric laminate of the present disclosure preferably has a width retention rate of 75% or more, more preferably 77% or more, when a tensile stress of 0.1 N / mm is applied in the MD direction of the nonwoven fabric laminate. preferable.
- the width retention rate when a tensile stress of 0.1 N / mm is applied is 75% or more, the dimensional stability is excellent.
- the nonwoven fabric laminate of the present disclosure preferably has a tensile strength of 2.2 N / 50 mm or more, more preferably 2.5 N / 50 mm or more, when the nonwoven fabric laminate is stretched by 5% in the MD direction.
- the nonwoven fabric laminate of the present disclosure may have a crimped portion and a non-crimped portion from the viewpoint of excellent flexibility.
- the area ratio of the pressure-bonded portion is preferably 7% to 20%, more preferably 8% to 18%.
- the area ratio of the pressure-bonded portion is a test in which a test piece having a size of 10 mm ⁇ 10 mm is collected from the non-woven fabric laminate, and the contact surface of the test piece with the embossed roll is observed with an electron microscope (magnification: 100 times). The ratio of the area of the thermocompression-bonded portion to the piece.
- the nonwoven fabric laminate of the present disclosure preferably has the following characteristics.
- the compression work WC measured by the KES method is preferably 0.15 or more.
- the KES (Kawabata Evaluation System) method is one of the methods for measuring the texture of a non-woven fabric and objectively evaluating it.
- the sample was compressed from 0 gf / cm 2 up to the maximum pressure 50 gf / cm 2, based on Make measurements while returning to.
- Compression work WC represents the compression work in the compression test by the KES method. From the viewpoint of flexibility of the nonwoven fabric laminate is excellent, the amount of compression work WC is preferably at 0.15gf ⁇ cm / cm 2 or more, and more preferably 0.17gf ⁇ cm / cm 2 or more.
- the upper limit of the compression work amount WC is not particularly limited, and is preferably 1.00 gf ⁇ cm / cm 2 or less, for example.
- Thickness TO at a pressure 0.5 gf / cm 2 is the thickness at a pressure 0.5 gf / cm 2 in a compression test according to KES method, it represents the initial thickness.
- the TO is preferably 0.40 mm or more, and more preferably 0.50 mm or more.
- the thickness TM of the pressure 50 gf / cm 2 is the thickness at a pressure 50 gf / cm 2 in a compression test according to KES method, represents the thickness at the time of maximum compression.
- the TM is preferably 0.10 mm or more, and more preferably 0.15 mm or more.
- TO-TM is the difference between the TO and the TM. The larger the TO-TM, the better the bulkiness.
- the TO-TM is preferably 0.20 mm or more, and more preferably 0.25 mm or more.
- the upper limit of TO-TM is not particularly limited, and is preferably 1.00 mm or less, for example.
- the non-woven fabric laminate of the present disclosure preferably has an air permeability of 500 cm 3 / cm 2 / sec or less measured under the condition of a flow rate with a pressure difference of 125 Pa by a Frazier air permeability measuring machine according to JIS L 1096: 2010. 400 cm 3 / cm 2 / sec or less is more preferable, and 300 cm 3 / cm 2 / sec or less is further preferable.
- the lower limit of the air permeability is not particularly limited, and may be 20 cm 3 / cm 2 / sec or more, or 50 cm 3 / cm 2 / sec or more.
- the air permeability of the non-woven fabric laminate is within the above range, appropriate air permeability and barrier properties can be obtained. Further, the obtained non-woven fabric laminate is excellent in strength.
- the nonwoven fabric laminate of the present disclosure includes a melt blown layer, the air permeability in the above range can be easily obtained.
- the method for producing the nonwoven fabric laminate of the present disclosure is not particularly limited.
- a method of incorporating the hydrophilic agent into the nonwoven fabric laminate for example, the following method can be mentioned.
- Method 1 (kneading method): A method including a step of mixing a hydrophilic agent with a raw material of a thermoplastic polymer and a step of forming a nonwoven fabric laminate containing fibers of the thermoplastic polymer containing the hydrophilic agent.
- Method 2 (Coating method): A method comprising a step of forming a non-woven fabric containing fibers of a thermoplastic polymer and a step of adhering a hydrophilic agent to the non-woven fabric.
- a non-woven fabric laminate may be formed by a known method for producing a long-fiber non-woven fabric or a known method for producing a short-fiber non-woven fabric.
- the nonwoven fabric laminate of the present disclosure is a first nonwoven fabric layer made of spunbonded nonwoven fabric and a second nonwoven fabric layer made of spunbonded nonwoven fabric, as an example of the method for producing the nonwoven fabric laminate of the present disclosure.
- the method for producing the nonwoven fabric laminate of the present disclosure Preferably has the following steps.
- a step of melt-spinning a first thermoplastic polymer to form a first continuous fiber (first spinning step).
- a step of depositing a first continuous fiber on a mobile collecting member to form a first non-woven web (non-woven web forming step).
- a step of melt-spinning the second thermoplastic polymer to form a second continuous fiber (second spinning step).
- Process of entwining laminated webs (entanglement process)
- Method 1 has a step of mixing a hydrophilic agent with at least one of the first thermoplastic polymer and the second thermoplastic polymer.
- a hydrophilic agent may be mixed with at least one of the spinning stock solutions of the first thermoplastic polymer and the second thermoplastic polymer.
- the first spinning step includes a known process of cooling and stretching until the first continuous fiber is deposited on the mobile collecting member.
- the second spinning step also includes a known process of cooling and stretching before depositing the second continuous fiber on the first non-woven web.
- the entanglement process is not particularly limited, and a known entanglement process can be mentioned.
- the entanglement treatment is preferably thermocompression bonding with an embossed roll. It is preferable to apply an embossed roll having a convex area ratio of 7% to 20%.
- Method 2 has a step of adhering a hydrophilic agent to the non-woven fabric on the non-woven fabric laminate after the entanglement treatment. Further, if necessary, a drawing step and a drying step may be provided.
- the method of attaching the hydrophilic agent is not particularly limited.
- the hydrophilic agent is preferably attached by applying a solution of the hydrophilic agent in a solvent (for example, a volatile organic solvent such as methanol, ethanol, isopropyl alcohol, or water) to the non-woven fabric. ..
- a solvent for example, a volatile organic solvent such as methanol, ethanol, isopropyl alcohol, or water
- Examples of the method for adhering the hydrophilic agent to the non-woven fabric include known methods such as dipping (immersion), roll coating (gravure coating, kiss coating), spray coating, and die coating.
- dipping immersion
- roll coating gravure coating, kiss coating
- spray coating and die coating.
- coating is a concept including “dipping (immersion)”.
- the hydrophilizing agent solution should contain a penetrant and a wetting agent as active ingredients, and the total amount of the active ingredients should be 0.1% by mass to 30% by mass. Is preferable.
- the solution of the hydrophilic agent may contain additives such as an antibacterial agent, an antioxidant, a preservative, a matting agent, a pigment, a rust preventive, a fragrance, and a defoaming agent, depending on the purpose.
- melt spinning is performed by the melt blown method to form a melt blown web on the first non-woven web, and a second continuous fiber is deposited on the melt blown web.
- a second non-woven web may be formed to form a laminated non-woven web.
- a hydrophilic agent may be mixed with the thermoplastic polymer constituting the melt-blown non-woven fabric layer.
- the composite laminate of the present disclosure may include the nonwoven fabric laminate of the present disclosure.
- the composite laminate of the present disclosure may have a composite structure in which the nonwoven fabric laminate of the present disclosure and other layers other than the nonwoven fabric laminate of the present disclosure are laminated.
- the other layer may be one layer or two or more layers.
- a laminate provided with layers other than the nonwoven fabric laminate of the present disclosure is referred to as a "composite laminate".
- Examples of other layers include fiber aggregates such as knitted fabrics, woven fabrics, and non-woven fabrics (short-fiber non-woven fabrics, long-fiber non-woven fabrics) other than the non-woven fabric laminates of the present disclosure.
- Examples of the non-woven fabric other than the non-woven fabric laminate of the present disclosure include various known non-woven fabrics (spunbond non-woven fabric, melt blown non-woven fabric, wet non-woven fabric, dry non-woven fabric, dry pulp non-woven fabric, flash-spun non-woven fabric, spread fiber non-woven fabric, etc.).
- the fiber aggregate may be a sheet-like material of natural fibers such as cotton.
- the term "long fiber” refers to "continuous filament” generally used in the art, such as the Nonwoven Fabric Handbook (edited by the American Nonwoven Fabric Industry Association, Nonwoven Fabric Information Co., Ltd., 1996). ..
- examples of the other layer include resin films such as polyolefin, polyester, and polyamide. These may be combined and laminated.
- the non-woven fabric laminate of the present disclosure, the resin film, and the fiber aggregate of natural fibers such as cotton may be laminated in this order.
- a breathable film and a moisture-permeable film are preferable when the laminate requires breathability.
- the breathable film include various known breathable films. Examples thereof include a film of a thermoplastic elastomer such as a moisture-permeable polyurethane elastomer, a polyester elastomer, and a polyamide elastomer, and a porous film obtained by stretching a thermoplastic resin film containing inorganic particles or organic particles to make it porous. ..
- thermoplastic resin used for the porous film examples include polyolefins such as high-pressure low-density polyethylene, linear low-density polyethylene (so-called LLDPE), high-density polyethylene, polypropylene, polypropylene random copolymer, and a combination thereof.
- polyolefins such as high-pressure low-density polyethylene, linear low-density polyethylene (so-called LLDPE), high-density polyethylene, polypropylene, polypropylene random copolymer, and a combination thereof.
- LLDPE linear low-density polyethylene
- polypropylene polypropylene random copolymer
- polyamide polyamide
- the method of further laminating (bonding) other layers to the non-woven fabric laminate of the present disclosure is not particularly limited, and thermal embossing, a thermal fusion method such as ultrasonic fusion, mechanical entanglement such as needle punching and water jet, etc. Examples thereof include a method using an adhesive such as a hot melt adhesive and a urethane adhesive, and various methods such as extrusion laminating.
- the coating sheet of the present disclosure includes the non-woven fabric laminate of the present disclosure. Further, the coating sheet of the present disclosure is not particularly limited as long as it contains the non-woven fabric laminate or the composite laminate of the present disclosure.
- the covering sheet of the present disclosure refers to a sheet for covering at least a part of a target object.
- the coating sheet is not particularly limited, and various uses can be mentioned. Specifically, absorbent articles (disposable diapers, disposable pants, sanitary napkins, urine absorbing pads, top sheets such as pet sheets, second sheets, and absorbents (pulp / high) are used as applications to which the coating sheet is applied.
- Packaging material for molecular absorber particles
- Cosmetic materials face mask, etc.
- Sanitary materials wet cloth materials, sheets, towels, industrial masks, sanitary masks, hair caps, gauze, disposable underwear, etc.
- Packaging materials oxygen scavenger, cairo, warm ship, food packaging material
- it can be applied to all living materials such as clothes covers. It can also be suitably used as an automobile interior material and various backing materials. It can be widely applied as a filter material such as a liquid filter and an air filter.
- a compression test was performed at a compression deformation rate of 0.020 mm / sec and a maximum pressure of 50 gf / cm 2 using a pressure plate), and TO [mm] and TM [mm] were measured.
- the average values of TO [mm] and TM [mm] of each test piece were obtained, and the third decimal place was rounded off to obtain TO [mm] and TM [mm] of each non-woven fabric sample.
- the TO-TM [mm] of each non-woven fabric sample was calculated.
- Width retention rate [%]
- the non-woven fabric on which the weight was placed was left in an environment of 60 ° C. and a relative humidity of 80% for 1 week.
- the non-woven fabric to be transferred was taken out, 0.2 ml of water was added dropwise, and the infiltration of water was evaluated.
- C hydrophilicity
- B the expression of hydrophilicity
- Ratio of surface water vapor adsorption area to surface nitrogen adsorption area Measured using Microtrac Bell Co., Ltd. equipment BELSORP-max. Specifically, it was carried out as follows. First, a sample of about 0.50 g to 1.0 g was taken from the non-woven fabric and set in the apparatus. Then, a drying treatment by vacuum exhaust was performed at room temperature (25 ° C.) for 8 hours. Then, water vapor was adsorbed at 25 ° C. by changing the introduction pressure, and the water vapor adsorption isotherm was measured by plotting the amount of water vapor adsorbed for each introduction pressure.
- the following BET formula was applied to determine the specific surface area [m 2 / g] as the surface water vapor adsorption area.
- the test was carried out from sample collection in the same procedure as the water vapor adsorption test except that nitrogen was used instead of water vapor, and the nitrogen adsorption isotherm was measured.
- the specific surface area as the surface nitrogen adsorption area was determined by the following BET formula. From the specific surface area as the surface water vapor adsorption area obtained above and the specific surface area as the surface nitrogen adsorption area obtained above, the ratio is calculated by "(specific surface area with water vapor) ⁇ (specific surface area with nitrogen)". I asked.
- the BET equation is an equation expressing the relationship between the adsorption equilibrium pressure P and the adsorption amount V at that pressure when the adsorption equilibrium state is reached at a constant temperature.
- P / (V (P 0- P)) 1 / (Vm ⁇ C) + ⁇ ((C-1) / (Vm ⁇ C)) ⁇ (P / P 0 ) ⁇
- P 0 saturated water vapor pressure (Pa)
- Vm monolayer adsorption amount (mg / g)
- C parameters related to heat of adsorption, etc. ( ⁇ ) ⁇ 0.
- Example 1 (1st and 2nd layers)
- the following thermoplastic polymer as a core component and the following thermoplastic polymer as a sheath component were subjected to composite melt spinning by a spunbond method. Then, from the eccentric core-sheath type crimp composite fiber (hereinafter referred to as "crimp fiber (C1)") in which the mass ratio of the core component / sheath component is 40/60, the first non-woven web (1 layer). The eyes) and the second non-woven web (second layer) were formed, and the laminated non-woven web provided with the second non-woven web on the first non-woven web was deposited on the moving collection surface.
- the crimped composite fiber had an average fiber diameter of 14.2 ⁇ m.
- -Core component- MFR 60 g / 10 min, propylene homopolymer (hPP1) having a melting point of 162 ° C.
- hPP1 propylene homopolymer having a melting point of 162 ° C.
- sheath component- MFR 60 g / 10 min, melting point 142 ° C., ethylene content 4% by mass propylene / ethylene random copolymer (rPP1)
- non-crimped fiber (hereinafter, “non-crimped fiber (NC1)”.
- the third non-woven web (third layer) formed from)) was laminated on the second non-woven web to form a laminated web having a three-layer structure.
- the basis weight of the laminated web having a three-layer structure was 17 g / m 2 , and the basis weight of each layer was almost uniform.
- the laminated web having a three-layer structure is thermocompression bonded at 125 ° C. so that the embossed roll contacts the first non-woven fabric layer side and the mirror surface roll contacts the third non-woven fabric layer side.
- a non-woven fabric laminate was obtained.
- the total basis weight of the spunbonded non-woven fabric laminate was 17 g / m 2 , and the area ratio of the pressure-bonded portion was 11%.
- the first and second layers correspond to the first non-woven fabric layer
- the third layer corresponds to the second non-woven fabric layer.
- the following hydrophilizing agent A was dissolved in an aqueous solution to obtain an aqueous solution in which the total amount of the active ingredient was diluted by 5%.
- the obtained spunbonded non-woven fabric laminate was immersed in an aqueous solution of the following hydrophilic agent A, and then the spunbonded nonwoven fabric laminate was squeezed. Then, it was dried in a drying oven at 100 ° C. for 1 minute under a tension of 5 N / m in the MD direction.
- the physical properties of the spunbonded non-woven fabric laminated body (hereinafter referred to as hydrophilized non-woven fabric laminated body) obtained by adhering the hydrophilizing agent were measured according to the method described above.
- the mass of the hydrophilizing agent adhering to the hydrophilic non-woven fabric laminate was determined from the mass difference before and after drying and the concentration of the hydrophilizing agent according to the measurement of the coating amount, and the coating amount was 0.5% by mass. ..
- Example 2 A hydrophilized nonwoven fabric laminate was obtained in the same manner as in Example 1 except that the amount of the hydrophilizing agent A applied was 1.0% by mass.
- the first layer and the second layer correspond to the first non-woven fabric layer
- the third layer corresponds to the second non-woven fabric layer.
- Example 3 A hydrophilic non-woven fabric laminate was obtained in the same manner as in Example 2 except that the total basis weight was 20 g / m 2 .
- the first layer and the second layer correspond to the first non-woven fabric layer
- the third layer corresponds to the second non-woven fabric layer.
- Example 4 A hydrophilic non-woven fabric laminate was obtained in the same manner as in Example 1 except that the third non-woven fabric layer was changed as follows and the amount of the hydrophilic agent A applied was 0.9%.
- the first layer and the second layer correspond to the first non-woven fabric layer
- the third layer corresponds to the second non-woven fabric layer.
- thermoplastic polymer as a core component and the following thermoplastic polymer as a sheath component were subjected to composite melt spinning by a spunbond method. Then, from the eccentric core-sheath type crimp composite fiber (hereinafter referred to as "crimp fiber (C2)") in which the mass ratio of the core component / sheath component is 85/15, the third non-woven web (third layer). ) was laminated on the second non-woven web (second layer) to form a laminated web having a three-layer structure.
- the crimped composite fiber had an average fiber diameter of 14.7 ⁇ m.
- -Core component- MFR 60 g / 10 min, propylene homopolymer (hPP1) having a melting point of 162 ° C.
- hPP1 propylene homopolymer having a melting point of 162 ° C.
- sheath component- MFR 60 g / 10 min, melting point 142 ° C., ethylene content 4% by mass propylene / ethylene random copolymer (rPP1)
- Example 5 A spunbonded nonwoven fabric laminate was obtained in the same manner as in Example 2 except that the second nonwoven fabric layer in Example 1 was not provided. That is, the spunbonded non-woven fabric is the same as in Example 1 except that the second non-woven web (second layer) is laminated on the first non-woven web (first layer) to form a two-layer structure laminated web. A laminate was prepared, and a hydrophilizing agent was applied in the same manner as in Example 1 to obtain a hydrophilic non-woven fabric laminate. In the non-woven fabric laminate of Example 5, the first layer corresponds to the first non-woven fabric layer, and the second layer corresponds to the second non-woven fabric layer.
- Example 6> The same as in Example 1 except that the fiber for forming the second non-woven fabric layer was changed to a non-crimped fiber (NC1) and the amount of the hydrophilic agent A applied was 0.9% by mass. A hydrophilic non-woven fabric laminate was obtained.
- the first layer corresponds to the first non-woven fabric layer
- the second and third layers correspond to the second non-woven fabric layer.
- Example 7 The fibers for forming the second non-woven fabric layer are changed to non-crimped fibers (NC1), the fibers for forming the third non-woven fabric layer are changed to crimped fibers (C1), and further, hydrophilic.
- a hydrophilic non-woven fabric laminate was obtained in the same manner as in Example 1 except that the coating amount of the agent A was 1.1% by mass.
- the first layer and the third layer correspond to the first non-woven fabric layer
- the second layer corresponds to the second non-woven fabric layer.
- Example 8> The first and second non-woven fabric layers are changed as follows, the fibers for forming the third non-woven fabric layer are changed to crimp fibers (C2), the average crimp diameter is changed, and further.
- a spunbonded non-woven fabric laminate was obtained in the same manner as in Example 1 except that the coating amount of the hydrophilizing agent A was 0.8%.
- the first and second layers correspond to the first non-woven fabric layer
- the third layer corresponds to the second non-woven fabric layer.
- thermoplastic polymer as a core component and the following thermoplastic polymer as a sheath component were subjected to composite melt spinning by a spunbond method. Then, from the eccentric core-sheath type crimp composite fiber (hereinafter referred to as "crimp fiber (C3)") in which the mass ratio of the core component / sheath component is 60/40, the first non-woven web (1 layer). The eyes) and the second non-woven web (second layer) were formed, and the laminated non-woven web provided with the second non-woven web on the first non-woven web was deposited on the moving collection surface.
- the crimped composite fiber had an average fiber diameter of 14.5 ⁇ m.
- -Core component- MFR 60 g / 10 min, propylene homopolymer (hPP1) having a melting point of 162 ° C.
- hPP1 propylene homopolymer having a melting point of 162 ° C.
- sheath component- MFR 60 g / 10 min, melting point 142 ° C., ethylene content 4% by mass propylene / ethylene random copolymer (rPP1)
- Example 9 The same as in Example 8 except that the fiber for forming the third non-woven fabric layer was changed to crimped fiber (C4) and the amount of the hydrophilic agent A applied was 1.0%. A spunbonded non-woven fabric laminate was obtained.
- the first and second layers correspond to the first non-woven fabric layer
- the third layer corresponds to the second non-woven fabric layer.
- thermoplastic polymer as a core component and the following thermoplastic polymer as a sheath component were subjected to composite melt spinning by a spunbond method. Then, from the eccentric core-sheath type crimp composite fiber (hereinafter referred to as "crimp fiber (C4)") having a mass ratio of core component / sheath component of 80/20, a third non-woven web (3). The layer) was laminated on the second non-woven web (second layer) to form a laminated web having a three-layer structure.
- the crimped composite fiber had an average fiber diameter of 14.3 ⁇ m.
- -Core component- MFR 60 g / 10 min, propylene homopolymer (hPP1) having a melting point of 162 ° C.
- hPP1 propylene homopolymer having a melting point of 162 ° C.
- sheath component- MFR 60 g / 10 min, melting point 142 ° C., ethylene content 4% by mass propylene / ethylene random copolymer (rPP1)
- Example 10 A hydrophilic non-woven fabric laminate was obtained in the same manner as in Example 1 except that the area ratio of the pressure-bonded portion was 18%, which was thermocompression-bonded by embossing.
- the first layer corresponds to the first non-woven fabric layer
- the third layer corresponds to the second non-woven fabric layer.
- Example 11 A hydrophilic non-woven fabric laminate was obtained in the same manner as in Example 1 except that the first layer and the second layer were changed as follows.
- the first and second layers correspond to the first non-woven fabric layer
- the third layer corresponds to the second non-woven fabric layer.
- thermoplastic polymer as a core component and the following thermoplastic polymer as a sheath component were subjected to composite melt spinning by a spunbond method. Then, from the eccentric core-sheath type crimp composite fiber (hereinafter referred to as "crimp fiber (C5)") in which the mass ratio of the core component / sheath component is 40/60, the first non-woven web (1 layer). The eyes) and the second non-woven web (second layer) were formed, and the laminated non-woven web provided with the second non-woven web on the first non-woven web was deposited on the moving collection surface.
- the crimped composite fiber had an average fiber diameter of 14.3 ⁇ m.
- -Core component- MFR 35 g / 10 min, propylene homopolymer (hPP2) with a melting point of 160 ° C.
- hPP2 propylene homopolymer
- rPP2 propylene / ethylene random copolymer
- Example 12 A hydrophilized nonwoven fabric laminate was obtained in the same manner as in Example 1 except that the hydrophilizing agent A was changed to the following hydrophilizing agent B and the coating amount of the hydrophilizing agent B was 0.8% by mass.
- the first and second layers correspond to the first non-woven fabric layer
- the third layer corresponds to the second non-woven fabric layer.
- (Hydrophilic agent B) Di (2-ethylhexyl) sodium sulfosuccinate: 20% by mass Glycerin oleic acid diester: 30% by mass Polyoxyethylene glycerin dilauric acid ester / polyoxyethylene glycerin trilauric acid ester 4: 6 (mass ratio) (EO chain 8 mol adduct): 20% by mass Polyoxyethylene dilauric acid ester (8 mol adduct of EO chain): 30% by mass
- the above-mentioned compounding ratio (% by mass) is the ratio of each component to the total mass of the active ingredient in the hydrophilic agent B, that is, in the aqueous solution of the hydrophilic agent B.
- Example 13 A hydrophilized nonwoven fabric laminate was obtained in the same manner as in Example 12 except that the amount of the hydrophilizing agent B applied was 1.1% by mass.
- the first and second layers correspond to the first non-woven fabric layer
- the third layer corresponds to the second non-woven fabric layer.
- Example 14 A hydrophilized nonwoven fabric laminate was obtained in the same manner as in Example 1 except that the hydrophilizing agent A was changed to the following hydrophilizing agent C and the coating amount of the hydrophilizing agent C was 1.0% by mass.
- the first layer and the second layer correspond to the first non-woven fabric layer
- the third layer corresponds to the second non-woven fabric layer.
- Example 15 The hydrophilic agent A was changed to the following hydrophilic agent D, and the hydrophilic agent D was mixed and spun at a ratio of 1.1% by mass with respect to 100% of the raw material component of the spinning stock solution of the crimped composite fiber C1. Obtained a spunbonded non-woven fabric laminate in the same manner as in Example 1. That is, the hydrophilic agent A is not applied to the spunbonded non-woven fabric laminate of Example 15.
- the first and second layers correspond to the first non-woven fabric layer
- the third layer corresponds to the second non-woven fabric layer.
- the above-mentioned compounding ratio (mass%) is the ratio of each component to the total mass of the active ingredient in the hydrophilic agent D.
- Example 16 A hydrophilic non-woven fabric laminate was obtained in the same manner as in Example 1 except that the third non-woven fabric layer was changed as follows and the amount of the hydrophilic agent A applied was 0.9% by mass.
- the first layer and the second layer correspond to the first non-woven fabric layer
- the third layer corresponds to the second non-woven fabric layer.
- a propylene homopolymer (hPP1) having an MFR: 60 g / 10 minutes and a melting point of 162 ° C. is melt-spun by the spunbond method to be a non-crimped fiber (hereinafter referred to as “non-crimped fiber (NC2)”).
- non-crimped fiber (NC2) non-crimped fiber
- the third non-woven web (third layer) formed from the above was laminated on the second non-woven web to form a laminated web having a three-layer structure.
- the hydrophilic non-woven fabric laminate of the example 16 is within the permissible range, but the entanglement due to the embossing of the third layer is weaker than that of the examples 1 to 15. There was concern that the non-woven fabric was prone to fraying.
- Example 17 A hydrophilic non-woven fabric laminate was obtained in the same manner as in Example 16 except that the embossed thermocompression bonding temperature was 130 ° C. and the coating amount of the hydrophilizing agent A was 1.0% by mass.
- the first and second layers correspond to the first non-woven fabric layer
- the third layer corresponds to the second non-woven fabric layer.
- the hydrophilic non-woven fabric laminate of the example 17 is within the permissible range, but as compared with the examples 1 to 15, the first layer and the second layer are entangled by embossing. The embossed part of the eyes became harder, and the feel became harder.
- thermoplastic polymer as a core component and the following thermoplastic polymer as a sheath component were subjected to composite melt spinning by a spunbond method. Then, a laminated non-woven web having a three-layer structure is formed from an eccentric core-sheath type crimp composite fiber (hereinafter referred to as "crimp fiber (C6)") having a mass ratio of core component / sheath component of 90/10. Formed.
- crimped composite fiber had an average fiber diameter of 14.2 ⁇ m.
- -Core component- MFR 60 g / 10 min, propylene homopolymer (hPP1) having a melting point of 162 ° C.
- hPP1 propylene homopolymer having a melting point of 162 ° C.
- sheath component- MFR 60 g / 10 min, melting point 142 ° C., ethylene content 4% by mass propylene / ethylene random copolymer (rPP1)
- Example 18 A hydrophilic non-woven fabric laminate was obtained in the same manner as in Comparative Example 2 except that the fibers for forming all the layers of the first to third non-woven fabric layers were changed to crimped fibers (C1).
- Example 19 (1st layer)
- the following thermoplastic polymer as a core component and the following thermoplastic polymer as a sheath component were subjected to composite melt spinning by a spunbond method. Then, from the eccentric core-sheath type crimp composite fiber (hereinafter referred to as "crimp fiber (C7)") in which the mass ratio of the core component / sheath component is 60/40, the first non-woven web (1 layer). The eyes) and the second non-woven web (second layer) were formed, and the laminated non-woven web provided with the second non-woven web on the first non-woven web was deposited on the moving collection surface.
- the crimped composite fiber had an average fiber diameter of 16.2 ⁇ m.
- -Core component- MFR 60 g / 10 min, propylene homopolymer (hPP1) with melting point 162 ° C.
- a propylene homopolymer (hPP1) as a core component and an ethylene / 1-butene random copolymer (PE1) as a sheath component were subjected to composite melt spinning by a spunbond method.
- non-crimped fiber (hereinafter referred to as "non-crimped fiber (NC3)") having a concentric core-sheath type having a mass ratio of core component / sheath component of 75/25 is formed.
- the woven web (second layer) and the third non-woven web (third layer) were laminated on the first non-woven web to form a laminated web having a three-layer structure.
- the basis weight of the laminated web having a three-layer structure was 18 g / m 2 , and the basis weight of each layer was almost uniform.
- the laminated web having a three-layer structure is thermocompression bonded at 90 ° C.
- a non-woven fabric laminate was obtained.
- the total basis weight of the spunbonded non-woven fabric laminate was 18 g / m 2 , and the area ratio of the pressure-bonded portion was 11%.
- the first layer corresponds to the first non-woven fabric layer
- the second and third layers correspond to the second non-woven fabric layer.
- the coating amount of the hydrophilic agent A obtained in the same manner as in Example 1 was 1.0% by mass.
- Example 20 Except that the mass ratio of the core component / sheath component of the eccentric core-sheath type crimp composite fiber (hereinafter referred to as "crimp fiber (C8)") of the first layer non-woven fabric in Example 19 was set to 40/60. Obtained a spunbonded non-woven fabric laminate in the same manner as in Example 19.
- crimp fiber (C8) the mass ratio of the core component / sheath component of the eccentric core-sheath type crimp composite fiber (hereinafter referred to as "crimp fiber (C8)) of the first layer non-woven fabric in Example 19 was set to 40/60. Obtained a spunbonded non-woven fabric laminate in the same manner as in Example 19.
- Example 21 Except that the fibers for forming the first, second, and third non-woven fabric layers were changed to crimp fibers (C2), and the amount of the hydrophilic agent A applied was 1.0%. Obtained a spunbonded non-woven fabric laminate in the same manner as in Example 1.
- Example 22 The fibers for forming the first and second non-woven fabric layers are changed to crimp fibers (C4), and the fibers for forming the third non-woven fabric layer are changed to crimp fibers (C2). Further, a spunbonded non-woven fabric laminate was obtained in the same manner as in Example 1 except that the coating amount of the hydrophilizing agent A was 1.0%.
- the nonwoven fabric laminate of the example is superior in hydrophilicity to the nonwoven fabric laminate of the comparative example, and suppresses the migration of the hydrophilic agent when it comes into contact with other members. However, it was confirmed that it has excellent dimensional stability.
- Examples 23 to 33 (1st and 2nd layers)
- a laminated non-woven fabric in which a second non-woven web (second layer, a layer of a spunbonded non-woven fabric) is provided on a first non-woven web (first layer, a layer of a spunbonded non-woven fabric) in the same manner as in Example 1.
- the web was deposited on the mobile collection surface.
- melt blown webs (third layer, MB) having the basis weights shown in Table 5 were formed on the second non-woven web (second layer, layer of spunbonded non-woven fabric).
- Example 30 a polymer obtained by mixing MB3, MB2 and MB4 in a mass ratio of 40/20/40 (MB3 / MB2 / MB4) was used, and in Example 31, MB3 and MB2 were mixed in a mass ratio of 60/40 (MB3).
- a polymer mixed at / MB2) was used, and in Example 32, a polymer in which MB2 and MB4 were mixed at a mass ratio of 60/40 (MB2 / MB4) was used.
- the spinning temperature in each example was 245 ° C. for MB1 of Examples 23 to 26 and 250 ° C. for the polymer obtained by mixing MB1 and MB2 of Examples 27 and 28.
- the temperature was 290 ° C. in the polymer in which MB3, MB2 and MB4 of Example 30 were mixed, 300 ° C. in the polymer in which MB3 and MB2 of Example 31 were mixed, and the temperature of the polymer in which MB2 and MB4 of Example 32 were mixed. It was 300 ° C., and it was 300 ° C. in MB5 of Example 33.
- MB1 Polypropylene homopolymer (MFR: 1,100 g / 10 minutes, weight average molecular weight (Mw): 97,000)
- MB2 Propylene / ethylene copolymer [manufactured by ExxonMobil: product name "Vistamaxx TM 6202", MFR (230 ° C, 2,160 g load): 20 g / 10 minutes, ethylene content: 15% by mass]
- MB3 Propylene homopolymer [MFR: 1,500 g / 10 minutes, weight average molecular weight (Mw): 54000]
- MB4 Propylene polymer wax [Density: 0.900 g / cm 3 , Weight average molecular weight: 7,800, Softening point 148 ° C., Ethylene content: 1.7% by mass]
- MB5 Propylene-ethylene random copolymer (rPP1) according to Example 1.
- the third non-woven web (third layer, layer of spunbonded non-woven fabric) was laminated on the melt blown web in the same manner as in Example 1 to form a laminated web having a four-layer structure.
- the basis weight of the four-layered laminated web excluding the third layer is 17 g / m 2 .
- the laminated web having a four-layer structure is thermocompression-bonded at 125 ° C. so that the embossed roll is in contact with the non-woven fabric layer side of the first layer and the mirror surface roll is in contact with the non-woven fabric layer side of the fourth layer. I got a body.
- the area ratio of the crimped portion was 11%.
- the first and second layers correspond to the first non-woven fabric layer
- the fourth layer corresponds to the second non-woven fabric layer.
- a hydrophilic agent was attached to the non-woven fabric laminate.
- the mass of the hydrophilic agent adhering to the non-woven fabric laminate was determined from the mass difference before and after drying and the concentration of the hydrophilic agent according to the measurement of the coating amount, and the coating amount was 0.5% by mass.
- the non-woven fabric laminate of the example is excellent in hydrophilicity and has excellent dimensional stability while suppressing the migration of the hydrophilic agent when it comes into contact with other members. confirmed. Further, as shown in Table 5, flexibility was ensured even in the embodiment in which the spunbonded nonwoven fabric layer and the meltblown nonwoven fabric layer were laminated.
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Abstract
Description
[特許文献1]国際公開第2017/145999号
[特許文献2]米国特許出願公開第2016/0166443号明細書
親水化剤を含有する不織布積層体。
<2> 前記第1の不織布層が、最外層であり、
前記捲縮繊維(A)の平均捲縮径が600μm以下である、<1>に記載の不織布積層体。
<3> 前記熱可塑性重合体がオレフィン系重合体を含む、<1>又は<2>に記載の不織布積層体。
<4> 前記熱可塑性重合体がオレフィン系重合体としてプロピレン系重合体及びエチレン系重合体からなる群より選ばれる少なくとも一種を含む、<3>に記載の不織布積層体。
<5> 不織布積層体のMD方向に、0.1N/mmの引張応力を加えた場合の幅保持率が75%以上である、<1>~<4>のいずれか1つに記載の不織布積層体。
<6> 不織布積層体のMD方向の5%延伸時の引張強度が2.2N/50mm以上である、<1>~<5>のいずれか1つに記載の不織布積層体。
<7> 不織布積層体から被転写不織布への親水化剤の転写量が0.015g/m2以下である、<1>~<6>のいずれか1つに記載の不織布積層体。
<8> 窒素吸着等温線のBET式より得られる窒素吸着試験における表面窒素吸着面積に対する水蒸気吸着等温線のBET式により得られる水蒸気吸着試験における表面水蒸気吸着面積の比(表面水蒸気吸着面積/表面窒素吸着面積)が1.5~9.0である、<1>~<7>のいずれか1つに記載の不織布積層体。
<9> 前記親水化剤は、多価アルコール脂肪酸エステル、ポリオキシアルキレン脂肪酸エステル、及び多価アルコール脂肪酸エステルのアルキレンオキシド付加物からなる群より選ばれる少なくとも一種を含む、<1>~<8>のいずれか1つに記載の不織布積層体。
<10> 熱可塑性重合体の繊維であり、前記捲縮繊維(A)の平均捲縮径とは異なる平均捲縮径を有し、平均捲縮径が500μm以上である捲縮繊維(B)、又は非捲縮繊維(C)を含む第2の不織布層をさらに備える<1>~<9>のいずれか1つに記載の不織布積層体。
<11> 前記第2の不織布層に含まれる前記繊維が、前記非捲縮繊維(C)である、<10>に記載の不織布積層体。
<12> 前記第1の不織布層及び前記第2の不織布層に含まれる前記熱可塑性重合体の繊維が、プロピレン系重合体を含む繊維であり、
前記第1の不織布層に含まれる前記捲縮繊維(A)の表面に、プロピレン系重合体が露出しており、
前記第2の不織布層に含まれる前記捲縮繊維(B)又は非捲縮繊維(C)の表面に、プロピレン系重合体が露出しており、
前記捲縮繊維(A)の表面に露出しているプロピレン系重合体と、前記捲縮繊維(B)又は前記非捲縮繊維(C)の表面に露出しているプロピレン系重合体との融点差が、±15℃以内である、<10>又は<11>に記載の不織布積層体。
<13> 前記捲縮繊維(A)の表面に露出しているプロピレン系重合体と、前記捲縮繊維(B)又は前記非捲縮繊維(C)の表面に露出しているプロピレン系重合体とが、それぞれプロピレン/α-オレフィン共重合体、プロピレン単独重合体とプロピレン/α-オレフィン共重合体との混合物、又はその組み合わせである<12>に記載の不織布積層体。
<14> 前記第1の不織布層がスパンボンド不織布の層であり、前記第2の不織布層がスパンボンド不織布の層であり、圧着部と非圧着部とを有し、前記圧着部の面積率が7%~20%である、<10>~<13>のいずれか1つに記載の不織布積層体。
<15> 熱可塑性重合体の繊維を含むメルトブローン不織布層をさらに備える、<1>~<14>のいずれか1つに記載の不織布積層体。
<16> 前記メルトブローン不織布層における前記熱可塑性重合体は、メルトフローレートが800g/10分以上のプロピレン単独重合体であり、前記メルトブローン不織布層における前記繊維の平均繊維径は、3μm未満であり、前記メルトブローン不織布層の目付は、3g/m2未満である<15>に記載の不織布積層体。
<17> 前記メルトブローン不織布層における前記熱可塑性重合体は、メルトフローレートが200g/10分以上のプロピレン/α-オレフィン共重合体、又はプロピレン・α-オレフィン共重合体を含むプロピレン系重合体の混合物であり、前記メルトブローン不織布層の目付は、5g/m2未満である<15>又は<16>に記載の不織布積層体。
<18> <1>~<17>のいずれか1つに記載の不織布積層体を有する、複合積層体。
<19> <14>~<17>のいずれか1つに記載の不織布積層体、又は<18>に記載の複合積層体を含む、被覆シート。
本開示において「工程」との語は、独立した工程だけではなく、他の工程と明確に区別できない場合であってもその工程の目的が達成されれば、本用語に含まれる。
本開示において組成物中の各成分の含有量は、組成物中に各成分に該当する物質が複数種存在する場合、特に断らない限り、組成物中に存在する当該複数種の物質の合計量を意味する。
本開示において、「MD」(Machine Direction)方向とは、不織布製造装置における不織ウェブの進行方向を指す。「CD」(Cross Direction)方向とは、MD方向に垂直で、主面(不織布の厚さ方向に直交する面)に平行な方向を指す。
本開示において、主体として含むとは、対象となる物質が、全体に対して最も多く含まれることを表す。例えば、全体に占める割合として、対象となる物質の含有割合が50質量%以上であることを示す。
本開示の不織布積層体は、熱可塑性重合体の繊維であり、平均捲縮径が800μm以下である捲縮繊維(A)を含む第1の不織布層を備え、親水化剤を含有する。
なお、本開示において「短繊維」とは、おおむね平均繊維長200mm以下の繊維を意味する。
第2の不織布層は、非捲縮繊維(C)及び非捲縮繊維(C)以外のその他の繊維を含む不織布の層であって、スパンボンド不織布、メルトブロー不織布、カード式エアスルー不織布、エアレイド不織布、ニードルパンチ式スパンボンド不織布、湿式不織布、乾式パルプ不織布、フラッシュ紡糸不織布、開繊不織布等を含む不織布の層であってもよい。
第2の不織布層は、捲縮繊維(B)及び捲縮繊維(B)以外のその他の繊維を含む不織布の層であって、スパンボンド不織布、メルトブロー不織布、カード式エアスルー不織布、エアレイド不織布、ニードルパンチ式スパンボンド不織布、湿式不織布、乾式パルプ不織布、フラッシュ紡糸不織布、開繊不織布等を含む不織布の層であってもよい。
なお、本開示では、プロピレンとプロピレン以外のα-オレフィンとの共重合体について、プロピレン由来の構造単位の含有量と、エチレン由来の構造単位の含有量とが等しい場合、このような共重合体はプロピレン系重合体に分類する。
示差走査熱量計(DSC)で、昇温速度10℃/分で昇温したときの融解吸熱曲線の極値を与える温度より50℃程度高い温度まで昇温して、この温度で10分間保持する。その後、降温速度10℃/分で30℃まで冷却し、再度、昇温速度10℃/分で所定の温度まで昇温したときの融解曲線を測定する。かかる融解曲線から、ASTM D3418の方法にならい、融解吸熱曲線の極値を与える温度(Tp)を求め、かかるピーク温度の吸熱ピークを融点(Tm)として求めることができる。
メルトブローン繊維の平均繊維径の測定方法は、顕微鏡の倍率を適宜調整(例えば1,000倍とし、走査型電子顕微鏡で観察)すること以外は既述の通りである。
上記の中でも、メルトブローン不織布層を構成する熱可塑性重合体としては、オレフィン系重合体が好ましく、プロピレン系重合体がより好ましい。
ワックスの分子量及び分子量分布の測定は、GPC法を用いて行う。
測定は、市販の単分散標準ポリスチレンを標準とし、以下の条件で行う。
装置:ゲル浸透クロマトグラフAlliance GPC2000型(Waters社製)
溶剤:o-ジクロルベンゼン
カラム:TSKgelカラム(東ソー社製)×4
流速:1.0ml/分
試料:0.3%o-ジクロルベンゼン溶液
温度:140℃
プロピレン系重合体ワックスのMwが上記範囲にあることで、メルトブローン不織布を構成する繊維をより細くし易くなり、また溶融繊維吐出時のショットの発生をより抑制することができる。
上記軟化点が90℃以上であると、熱処理時、使用時等における耐熱安定性をより向上させ、結果としてメルトブローン不織布の耐熱性をより向上させることができる。
上記軟化点の上限は、特に限定されず、例えば168℃以下が挙げられる。
なお、本開示における目付の測定方法は後述の実施例に記載の通りである。
一方で、メルトブローン不織布層を含む不織布積層体とする場合、メルトブローン不織布層を含まない不織布積層体に比べて柔軟性、特にカンチレバー値が悪化する傾向にある。第1の不織布層と、第2の不織布層と、メルトブローン不織布層と、を組み合わせることにより、前述の柔軟性の悪化を好適に抑制することができ、さらにはメルトブローン不織布層にて、目付、繊維の平均繊維径等を前述の範囲にすること、前述の熱可塑性重合体を使用すること等で、前述の柔軟性の悪化をより好適に抑制することができる。
また、多価アルコール脂肪酸エステルと、ポリオキシアルキレン脂肪酸エステルとの組み合わせとしては、ソルビタンラウリン酸モノエステル、ジエステル及びトリエステルと、ポリオキシエチレンラウリン酸モノエステル及びジエステルとの組み合わせであることが好ましく、これらのソルビタンラウリン酸エステル、及びポリオキシエチレンラウリン酸エステルに加えて、ポリオキシエチレンソルビタンオレイン酸モノエステル、ポリオキシエチレンソルビタンオレイン酸ジエステル及びポリオキシエチレンソルビタンオレイン酸トリエステルを組み合わせることも好ましい。
また、本開示の不織布積層体は、不織布積層体から被転写不織布への親水化剤の転写量が、0g/m2以上であれば特に限定されず、例えば、0.001g/m2以上であってもよい。
KES法で測定した圧縮仕事量WCが0.15以上であることが好ましい。また、KES法で測定した圧縮特性試験における圧力0.5gf/cm2における厚みTOと、KES法で測定した圧力50gf/cm2における厚みTMとの差(TO-TM)が0.2以上であることが好ましい。
圧縮仕事量WC、圧力0.5gf/cm2における厚みTO、及び圧力50gf/cm2における厚みTMは、カトーテック株式会社製の試験機KES-FB3-Aにより測定する。具体的には、圧縮面積2cm2の円形平面をもつ鋼製加圧板間で、圧縮変形速度0.020mm/secにて、0gf/cm2から最大圧力50gf/cm2まで試料を圧縮し、元に戻す間で測定を行う。
圧力50gf/cm2における厚みTMは、KES法による圧縮試験における圧力50gf/cm2での厚みであり、最大圧縮時の厚みを表す。TMは、0.10mm以上であることが好ましく、0.15mm以上であることがより好ましい。
TO-TMは、上記TOと上記TMとの差である。TO-TMが大きいほど、嵩高さに優れる。TO-TMは、0.20mm以上であることが好ましく、0.25mm以上であることがより好ましい。TO-TMの上限値は、特に限定されず、例えば、1.00mm以下であることが好ましい。
不織布積層体の通気度が上記範囲であると、適度な通気性及びバリア性が得られる。また、得られた不織布積層体は強度に優れる。本開示の不織布積層体がメルトブローン層を備える場合に、上記範囲の通気度が得られやすい。
ここで、不織布積層体に、親水化剤を含ませる方法は、例えば、下記の方法が挙げられる。
(1):親水化剤を練り込んだ熱可塑性重合体の繊維で不織布を形成することにより、不織布に親水性を付与する方法(練り込み法)。
(2):親水化剤を繊維表面に付着させて不織布に親水性を付与する方法(塗布法)。
方法1(練り込み法):熱可塑性重合体の原料に親水化剤を混合する工程と、親水化剤を含む熱可塑性重合体の繊維を含む不織布積層体を形成する工程と、を有する方法。
方法2(塗布法):熱可塑性重合体の繊維を含む不織布を形成する工程と、前記不織布に、親水化剤を付着させる工程と、を有する方法。
移動捕集部材上に、第1の連続繊維を堆積させて第1の不織ウェブを形成する工程(不織ウェブ形成工程)
第2の熱可塑性重合体を溶融紡糸して第2の連続繊維を形成する工程(第2紡糸工程)
第1の不織ウェブ上に、第2の連続繊維を堆積させて第2の不織ウェブを形成して積層不織ウェブを形成する工程(積層不織ウェブ形成工程)
積層ウェブを交絡する工程(交絡工程)
本開示の複合積層体は、本開示の不織布積層体を備えていればよい。本開示の複合積層体は、本開示の不織布積層体と、本開示の不織布積層体以外の他の層が積層された複合構造であってもよい。他の層は、1層であってもよく、2層以上であってもよい。なお、本開示において、本開示の不織布積層体以外の他の層が設けられた積層体を、「複合積層体」と称する。
通気性フィルムとしては、種々の公知の通気性フィルムが挙げられる。例えば、透湿性を有するポリウレタン系エラストマー、ポリエステル系エラストマー、ポリアミド系エラストマー等の熱可塑性エラストマーのフィルム、無機粒子又は有機粒子を含む熱可塑性樹脂フィルムを延伸して多孔化してなる多孔フィルム等が挙げられる。多孔フィルムに用いる熱可塑性樹脂としては、高圧法低密度ポリエチレン、線状低密度ポリエチレン(所謂LLDPE)、高密度ポリエチレン、ポリプロピレン、ポリプロピレンランダム共重合体、これらの組み合わせ等のポリオレフィンが挙げられる。
不織布積層体が通気性を必要としない場合には、ポリオレフィン(ポリエチレン、ポリプロピレン等)、ポリエステル、ポリアミドから選ばれる1種以上の多孔化されていない熱可塑性樹脂フィルムを用いてもよい。
本開示の被覆シートは、本開示の不織布積層体を含む。また、本開示の被覆シートは、本開示の不織布積層体又は複合積層体を含んでいれば特に限定されるものではない。本開示の被覆シートは、対象となる物体の少なくとも一部を被覆するためのシートを指す。被覆シートは、特に限定されず、各種用途が挙げられる。被覆シートが適用される用途としては、具体的には、吸収性物品(使い捨ておむつ、使い捨てパンツ、生理用品、尿取りパッド、ペット用シートなどのトップシート、セカンドシート、吸収体用(パルプ・高分子吸収体粒子)の包装材(コアラップ)等);化粧用材料(フェイスマスク等);衛生材料(湿布材、シーツ、タオル、産業用マスク、衛生用マスク、ヘアキャップ、ガーゼ、使い捨て下着等);包装用材料(脱酸素剤、カイロ、温シップ、食品包装材)などが挙げられる。さらに、衣服カバーなどの生活資材全般に適用可能である。自動車内装材や各種バッキング材としても好適に使用できる。液体フィルター、エアフィルターなどのフィルター資材としても広く適用可能である。
なお、以下の実施例において、「%」は質量%を表す。
得られた不織布積層体から、100mm(流れ方向:MD)×100mm(流れ方向と直交する方向:CD)の試験片を10点採取した。試験片の採取場所は、CD方向にわたって10箇所とした。次いで、23℃、相対湿度50%RH環境下で、採取した各試験片に対して上皿電子天秤(研精工業社製)を用いて、それぞれ質量〔g〕を測定した。各試験片の質量の平均値を求めた。求めた平均値から1m2当たりの質量〔g〕に換算し、小数点第2位を四捨五入して各不織布サンプルの目付〔g/m2〕とした。
得られた不織布積層体から、100mm(MD)×100mm(CD)の試験片を10点採取した。試験片の採取場所は、目付け測定用の試験片と同様の場所とした。次いで、採取した各試験片に対して荷重型厚み計(尾崎製作所社製)を用いて、JIS L 1096:2010に記載の方法で厚み〔mm〕を測定した。各試験片の厚みの平均値を求め、小数点第2位を四捨五入して各不織布サンプルの厚み〔mm〕とした。
(3)WC値(圧縮仕事量)〔gf・cm/cm2〕
得られた不織布積層体から、150mm(MD)×150mm(CD)の試験片を2点採取した。なお、採取場所はCD方向にわたって2箇所とした。次いで、試験片をカトーテック(株)製のKES-FB3-Aにより、測定条件として、20℃、相対湿度50%RH環境下で、圧縮子(圧縮面積2cm2の円形平面をもつ鋼製加圧板)を用い、圧縮変形速度0.020mm/sec、最大圧力50gf/cm2にて圧縮試験を行い、小数点第3位を四捨五入して各不織布サンプルのWC値〔gf・cm/cm2〕とした。
(4)TO(圧力0.5gf/cm2における厚み)-TM(圧力50gf/cm2における厚み)〔mm〕
得られた不織布積層体から、150mm(MD)×150mm(CD)の試験片を2点採取した。なお、採取場所はCD方向にわたって2箇所とした。次いで、試験片をカトーテック(株)製のKES-FB3-Aにより、測定条件として、20℃、相対湿度50%RH環境下で、圧縮子(圧縮面積2cm2の円形平面をもつ鋼製加圧板)を用い、圧縮変形速度0.020mm/sec、最大圧力50gf/cm2にて圧縮試験を行い、TO〔mm〕及びTM〔mm〕を測定した。
各試験片のTO〔mm〕及びTM〔mm〕の平均値を求め、小数点第3位を四捨五入して各不織布サンプルのTO〔mm〕及びTM〔mm〕とした。各不織布サンプルのTO―TM〔mm〕を計算した。
得られた不織布積層体について、JIS L 1913:2010のカンチレバー法(ISO法)に準拠して、MD方向及びCD方向のそれぞれについて、剛軟度を測定した。
(6)引張強度、及び5%延伸時の強度〔N/50mm〕
得られた不織布積層体について、JIS L 1906に準拠して測定した。不織布から、幅50mm×長さ200mmの試験片を採取し、引張試験機を用いてチャック間距離100mm、ヘッドスピード100mm/minでMD:5点を測定し、平均値を算出し、引張強度(N/50mm)を求めた。また測定プログラムにて、5%延伸時(チャック間:105mm)時に記録された強度を5%延伸時の強度とした。
(7)幅保持率〔%〕
得られた不織布積層体について、幅200mm×長さ450mm(採取できない場合は、幅100mm×長さ450mm)の試験片を採取し、均一に近い状態で引っ張ることが可能な冶具により幅方向の両端を挟む。なお、冶具間の距離は350mmとする。引張試験機にセットし、0.1N/mmの張力で引っ張り、その際の幅を測定する。そして、以下の式により、幅保持率(%)を求める
幅保持率(%) = {引張時の幅(mm)/初期の幅(mm)}×100
幅保持率が75%未満の場合は、乾燥炉適性不良と判断した(表中「B」と表記)。幅保持率が75%以上の場合は、乾燥炉適性良好と判断した(表中「A」と表記)。
(9)液流れ距離〔mm〕
得られた不織布積層体を100mm×200mmのサイズにカットし、試料とした。水平方向に対して45度に傾斜させて固定した板上に、濾紙(No.2、アドバンテック社製)を5枚重ねて置き、濾紙の上に試料を置いて、試料の長手方向の両端を濾紙と一緒に板上に固定した。25℃の環境下で、試料面に対して垂直方向に約10mmの高さから、スポイトにて人工尿を0.1ml落下させ、液滴の落下点から液滴が完全に吸収された点までの距離を計測し、液流れ距離(mm)とした。
液流れ距離は、下記の評価基準に基づき評価した。結果を表1に示す。
なお、上記人工尿は、表面張力が70±2mN/mである塩化ナトリウムの水溶液(9g/リットル)を用いた。
EDANA(欧州不織布工業会)規格 NWSP 070.8.R0(15)に準拠して測定した。そのうち1回目の結果と、3回目の結果を記録した。
(11)移行性評価
各例で得られた不織布積層体を、100mm×100mmのサイズにカットした。また目付25g/m2のホモポリプロピレンからなる親水化剤が含まれていない不織布(被転写不織布)を100mm×100mmのサイズにカットした。2つの不織布を合わせ、さらに断面積100mm×100mmの4kgの錘を乗せた。なお、錘及び床面に対する親水化剤の転移を防ぐため、フィルムで包んでもよい。錘を乗せた不織布を60℃、相対湿度80%の環境下に1週間放置した。被転写不織布を取り出し、水を0.2ml滴下し、水の浸み込みを評価した。浸み込んだ場合は、親水性が強く発現しており、親水化剤移行性不良と判断した(表中「C」と表記)。浸み込んでいるが、親水性の発現が弱い場合は、親水化剤移行性不良と判断した(表中「B」と表記)。浸み込まなかった場合は、親水性が発現しておらず、親水化剤移行性良好と判断した(表中「A」と表記)。
上記の通り作製した被転写不織布を、メタノールを用いて、迅速残脂抽出装置OC-1型(インテック株式会社製)で抽出し、抽出液から完全に溶剤を留去させ、転写した親水化剤の質量を求めた。そして下記の式より、親水化剤付着率C%、及び不織布積層体から被転写不織布へ転写した親水化剤量W3(g/m2)を求めた。なお、本測定に最適な不織布質量は2g前後であることから、上記被転写不織布を8~10枚作製し、測定を行った。
C(%)=(W2/W1)×100
W1:被転写不織布の不織布質量(g)
W2:抽出液中の親水化剤(=転写した親水化剤)の質量(g)
W3(g/m2):不織布積層体から被転写不織布への親水化剤の転写量(C(%)×25(g/m2)×100)
マイクロトラック・ベル株式会社製装置・BELSORP-maxを用いて測定した。
具体的には、以下のようにして行った。まず、不織布から0.50g~1.0g程度のサンプルを採取して、装置にセットした。次いで、室温(25℃)にて真空排気による乾燥処理を8時間行った。その後、水蒸気を25℃にて、導入圧力を変えて吸着させて、導入圧力ごとの水蒸気吸着量をプロットした水蒸気吸着等温線を測定した。そして、下記BET式を適用し、表面水蒸気吸着面積としての比表面積〔m2/g〕を求めた。
次いで、水蒸気のかわりに窒素を用いた以外は、水蒸気吸着試験と同様の手順で、サンプル採取から試験を行い、窒素吸着等温線を測定した。そして、下記BET式により、表面窒素吸着面積としての比表面積を求めた。上記で得られた表面水蒸気吸着面積としての比表面積と、得られた表面窒素吸着面積としての比表面積から、「(水蒸気での比表面積)÷(窒素での比表面積)」により、その比を求めた。
(BET式) : P/(V(P0-P))=1/(Vm×C)+{((C-1)/(Vm×C))×(P/P0)}
式中、P0:飽和水蒸気圧(Pa)、Vm:単分子層吸着量(mg/g)、C:吸着熱などに関するパラメーター(-)<0である。本関係式は、特にP/P0=0.05~0.35の範囲で良く成り立つ。
不織布から、150mm(MD)×150mm(CD)の試験片を採取し、JIS L 1096:2010に準じたフラジール通気度測定機によって圧力差125Paでの流量の条件で行った。n=5の平均値を測定値とした。
親水化剤を塗布する前の不織布の質量(塗布前質量)と、親水化剤を塗布・乾燥した後の不織布の質量(塗布後質量)とを測定し、親水化剤の塗布量を下記式より算出した。
塗布量(%)=[(塗布後質量-塗布前質量)/塗布後質量]×100
平均捲縮径は、既述の測定方法にしたがって、光学式顕微鏡に付属の画像解析ソフト「Pixs2000」により測定した。
(1層目及び2層目)
下記の芯成分としての熱可塑性重合体と下記の鞘成分としての熱可塑性重合体とを、スパンボンド法により複合溶融紡糸を行った。そして、芯成分/鞘成分の質量比が40/60である偏芯芯鞘型の捲縮複合繊維(以下、「捲縮繊維(C1)」とする)から、第1不織ウェブ(1層目)及び第2不織ウェブ(2層目)を形成し、第1不織ウェブ上に第2不織ウェブが設けられた積層不織ウェブを移動捕集面上に堆積させた。この捲縮複合繊維は、平均繊維径が14.2μmであった。
MFR:60g/10分、融点162℃、のプロピレン単独重合体(hPP1)
-鞘成分-
MFR:60g/10分、融点142℃、エチレン含量4質量%のプロピレン・エチレンランダム共重合体(rPP1)
MFR60g/10分、融点142℃、エチレン含量4質量%のプロピレン・エチレンランダム共重合体(rPP1)をスパンボンド法により溶融紡糸を行い、非捲縮型繊維(以下、「非捲縮繊維(NC1)」とする))から形成される第3不織ウェブ(3層目)を、第2の不織ウェブ上に積層し、3層構造の積層ウェブを形成した。
ジ(2-エチルヘキシル)スルホコハク酸Na : 20質量%
ソルビタンラウリン酸モノエステル/ソルビタンラウリン酸ジエステル/ソルビタンラウリン酸トリエステル=2:3:5(質量比) : 20質量%
ポリオキシエチレンモノラウリン酸エステル(EO鎖8モル付加物)/ポリオキシエチレンラウリン酸ジエステル(EO鎖8モル付加物)=4:6(質量比) : 30質量%
ポリオキシエチレンソルビタンオレイン酸モノエステル(EO鎖8モル付加物)/ポリオキシエチレンソルビタンオレイン酸ジエステル(EO鎖8モル付加物)/ポリオキシエチレンソルビタンオレイン酸トリエステル(EO鎖8モル付加物)=1:6:3(質量比): 30質量%
なお、上記の配合割合(質量%)は、親水化剤A中の、すなわち親水化剤Aの水溶液における有効成分全質量に対する各成分の割合である。
親水化剤Aの塗布量を、1.0質量%とした以外は、実施例1と同様にして親水化不織布積層体を得た。実施例2の親水化不織布積層体は、1層目及び2層目が第1の不織布層に相当し、3層目が第2の不織布層に相当する。
総目付を20g/m2とした他は、実施例2と同様にして親水化不織布積層体を得た。実施例3の親水化不織布積層体は、1層目及び2層目が第1の不織布層に相当し、3層目が第2の不織布層に相当する。
3層目の不織布層を下記のように変更し、さらに、親水化剤Aの塗布量を、0.9%とした以外は、実施例1と同様にして親水化不織布積層体を得た。実施例4の親水化不織布積層体は、1層目及び2層目が第1の不織布層に相当し、3層目が第2の不織布層に相当する。
下記の芯成分としての熱可塑性重合体と下記の鞘成分としての熱可塑性重合体とを、スパンボンド法により複合溶融紡糸を行った。そして、芯成分/鞘成分の質量比が85/15である偏芯芯鞘型の捲縮複合繊維(以下、「捲縮繊維(C2)」とする)から第3不織ウェブ(3層目)を、第2不織ウェブ(2層目)上に積層し、3層構造の積層ウェブを形成した。この捲縮複合繊維は、平均繊維径が14.7μmであった。
MFR:60g/10分、融点162℃、のプロピレン単独重合体(hPP1)
-鞘成分-
MFR:60g/10分、融点142℃、エチレン含量4質量%のプロピレン・エチレンランダム共重合体(rPP1)
実施例1における2層目の不織布層を設けない以外は、実施例2と同様にして、スパンボンド不織布積層体を得た。すなわち、第1不織ウェブ(1層目)上に、第2不織ウェブ(2層目)を積層した2層構造の積層ウェブとした以外は、実施例1と同様にして、スパンボンド不織布積層体を作製し、実施例1と同様にして親水化剤を塗布して、親水化不織布積層体を得た。実施例5の不織布積層体は、1層目が第1の不織布層、2層目が第2の不織布層に相当する。
2層目の不織布層を形成するための繊維を非捲縮繊維(NC1)に変更し、さらに、親水化剤Aの塗布量を、0.9質量%とした以外は、実施例1と同様にして親水化不織布積層体を得た。実施例6の親水化不織布積層体は、1層目が第1の不織布層に相当し、2層目及び3層目が第2の不織布層に相当する。
2層目の不織布層を形成するための繊維を非捲縮繊維(NC1)に変更し、3層目の不織布層を形成するための繊維を捲縮繊維(C1)に変更し、さらに、親水化剤Aの塗布量を、1.1質量%とした以外は、実施例1と同様にして親水化不織布積層体を得た。実施例7の親水化不織布積層体は、1層目及び3層目が第1の不織布層に相当し、2層目が第2の不織布層に相当する。
1層目及び2層目の不織布層を下記のように変更し、3層目の不織布層を形成するための繊維を捲縮繊維(C2)に変更し、平均捲縮径を変更し、さらに、親水化剤Aの塗布量を、0.8%とした以外は、実施例1と同様にしてスパンボンド不織布積層体を得た。実施例8の不織布積層体は、1層目及び2層目が第1の不織布層、3層目が第2の不織布層に相当する。
下記の芯成分としての熱可塑性重合体と下記の鞘成分としての熱可塑性重合体とを、スパンボンド法により複合溶融紡糸を行った。そして、芯成分/鞘成分の質量比が60/40である偏芯芯鞘型の捲縮複合繊維(以下、「捲縮繊維(C3)」とする)から、第1不織ウェブ(1層目)及び第2不織ウェブ(2層目)を形成し、第1不織ウェブ上に第2不織ウェブが設けられた積層不織ウェブを移動捕集面上に堆積させた。この捲縮複合繊維は、平均繊維径が14.5μmであった。
MFR:60g/10分、融点162℃、のプロピレン単独重合体(hPP1)
-鞘成分-
MFR:60g/10分、融点142℃、エチレン含量4質量%のプロピレン・エチレンランダム共重合体(rPP1)
3層目の不織布層を形成するための繊維を捲縮繊維(C4)に変更し、さらに、親水化剤Aの塗布量を、1.0%とした以外は、実施例8と同様にしてスパンボンド不織布積層体を得た。実施例9の不織布積層体は、1層目及び2層目が第1の不織布層、3層目が第2の不織布層に相当する。
下記の芯成分としての熱可塑性重合体と下記の鞘成分としての熱可塑性重合体とを、スパンボンド法により複合溶融紡糸を行った。そして、芯成分/鞘成分の質量比が80/20である偏芯芯鞘型の捲縮複合繊維(以下、「捲縮繊維(C4)」とする)から、第3の不織ウェブ(3層目)を、第2の不織ウェブ(2層目)上に積層し、3層構造の積層ウェブを形成した。この捲縮複合繊維は、平均繊維径が14.3μmであった。
MFR:60g/10分、融点162℃、のプロピレン単独重合体(hPP1)
-鞘成分-
MFR:60g/10分、融点142℃、エチレン含量4質量%のプロピレン・エチレンランダム共重合体(rPP1)
圧着部の面積率を18%となるように、エンボスで熱圧着した以外は、実施例1と同様にして親水化不織布積層体を得た。実施例10の親水化不織布積層体は、1層目が第1の不織布層、3層目が第2の不織布層に相当する。
1層目及び2層目を下記のように変更した以外は、実施例1と同様にして親水化不織布積層体を得た。実施例11の親水化不織布積層体は、1層目及び2層目が第1の不織布層、3層目が第2の不織布層に相当する。
下記の芯成分としての熱可塑性重合体と下記の鞘成分としての熱可塑性重合体とを、スパンボンド法により複合溶融紡糸を行った。そして、芯成分/鞘成分の質量比が40/60である偏芯芯鞘型の捲縮複合繊維(以下、「捲縮繊維(C5)」とする)から、第1不織ウェブ(1層目)及び第2不織ウェブ(2層目)を形成し、第1不織ウェブ上に第2不織ウェブが設けられた積層不織ウェブを移動捕集面上に堆積させた。この捲縮複合繊維は、平均繊維径が14.3μmであった。
MFR:35g/10分、融点160℃のプロピレン単独重合体(hPP2)
-鞘成分-
MFR:35g/10分、融点160℃のプロピレン単独重合体(hPP2)を60%と、MFR20g/10分、エチレン含量15質量%のプロピレン・エチレンランダム共重合体(rPP2)とを40%含む混合物
親水化剤Aを、下記親水化剤Bに変更し、親水化剤Bの塗布量を0.8質量%とした以外は、実施例1と同様にして親水化不織布積層体を得た。実施例12の親水化不織布積層体は、1層目及び2層目が第1の不織布層、3層目が第2の不織布層に相当する。
ジ(2-エチルヘキシル)スルホコハク酸Na : 20質量%
グリセリンオレイン酸ジエステル : 30質量%
ポリオキシエチレングリセリンジラウリン酸エステル/ポリオキシエチレングリセリントリラウリン酸エステル=4:6(質量比)(EO鎖8モル付加物): 20質量%
ポリオキシエチレンジラウリン酸エステル(EO鎖8モル付加物) : 30質量%
なお、上記の配合割合(質量%)は、親水化剤B中の、すなわち親水化剤Bの水溶液における有効成分全質量に対する各成分の割合である。
親水化剤Bの塗布量を1.1質量%とした以外は、実施例12と同様にして親水化不織布積層体を得た。実施例13の親水化不織布積層体は、1層目及び2層目が第1の不織布層、3層目が第2の不織布層に相当する。
親水化剤Aを、下記親水化剤Cに変更し、親水化剤Cの塗布量を1.0質量%とした以外は、実施例1と同様にして親水化不織布積層体を得た。実施例14の親水化不織布積層体は、1層目及び2層目が第1の不織布層、3層目が第2の不織布層に相当する。
ジ(2-エチルヘキシル)スルホコハク酸Na : 20質量%
グリセリンオレイン酸ジエステル/グリセリンオレイン酸トリエステル=5:5(質量比) : 50質量%
ポリオキシエチレンオレイン酸モノエステル(EO鎖10モル付加物)/ポリオキシエチレンオレイン酸ジエステル(EO鎖10モル付加物)=6:4(質量比) : 30質量%
なお、上記の配合割合(質量%)は、親水化剤C中の、すなわち親水化剤Cの水溶液における有効成分全質量に対する各成分の割合である。
親水化剤Aを下記親水化剤Dに変更し、捲縮複合繊維C1の紡糸原液の原料成分100%に対し、1.1質量%の割合で、親水化剤Dを混合して紡糸した以外は、実施例1と同様にしてスパンボンド不織布積層体を得た。すなわち、実施例15のスパンボンド不織布積層体では、親水化剤Aは塗布されていない。実施例14の不織布積層体は、1層目及び2層目が第1の不織布層、3層目が第2の不織布層に相当する。
ポリオキシエチレン(5モル)ステアリン酸エーテル : 50質量%
ポリオキシエチレン(10モル)ステアリン酸アミド : 25質量%
グリセリンモノステアリン酸エステル : 25質量%
なお、上記の配合割合(質量%)は、親水化剤D中における有効成分全質量に対する各成分の割合である。
3層目の不織布層を下記のように変更し、さらに、親水化剤Aの塗布量を0.9質量%とした以外は、実施例1と同様にして親水化不織布積層体を得た。実施例16の親水化不織布積層体は、1層目及び2層目が第1の不織布層に相当し、3層目が第2の不織布層に相当する。
MFR:60g/10分、融点162℃、のプロピレン単独重合体(hPP1)をスパンボンド法により溶融紡糸を行い、非捲縮型繊維(以下、「非捲縮繊維(NC2)」とする))から形成される第3不織ウェブ(3層目)を、第2不織ウェブ上に積層し、3層構造の積層ウェブを形成した。
エンボス熱圧着温度を130℃とし、親水化剤Aの塗布量を1.0質量%とした以外は、実施例16と同様にして親水化不織布積層体を得た。実施例17の親水化不織布積層体は、1層目及び2層目が第1の不織布層、3層目が第2の不織布層に相当する。
1層目~3層目の全ての層を形成するための繊維を、hPP1を使用した非捲縮繊維(NC2)に変更し、総目付けを15g/m2に変更し、熱圧着の温度を135℃に変更し、親水化剤Aの塗布量を1.0質量%とした以外は、実施例1と同様にして、親水化不織布積層体を得た。
1層目~3層目の不織布層の全ての層を下記のように変更し、総目付けを17g/m2に変更し、エンボス熱圧着温度を125℃に変更した以外は、比較例1と同様にして、親水化不織布積層体を得た。
下記の芯成分としての熱可塑性重合体と下記の鞘成分としての熱可塑性重合体とを、スパンボンド法により複合溶融紡糸を行った。そして、芯成分/鞘成分の質量比が90/10である偏芯芯鞘型の捲縮複合繊維(以下、「捲縮繊維(C6)」とする)から3層構造の積層不織ウェブを形成した。この捲縮複合繊維は、平均繊維径が14.2μmであった。
MFR:60g/10分、融点162℃、のプロピレン単独重合体(hPP1)
-鞘成分-
MFR:60g/10分、融点142℃、エチレン含量4質量%のプロピレン・エチレンランダム共重合体(rPP1)
親水化剤Aの塗布量を1.5質量%とした以外は、比較例2と同様にして、親水化不織布積層体を得た。
3層目を実施例1と同様に非捲縮繊維(NC1)に変更した以外は、比較例2と同様にして、親水化不織布積層体を得た。
1層目~3層目の不織布層の全ての層を形成するための繊維を捲縮繊維(C1)に変更した以外は、比較例2と同様にして、親水化不織布積層体を得た。
親水化剤Aを親水化剤Bに変更し、親水化剤Bの塗布量を1.1質量%とした以外は、比較例1と同様にして親水化不織布積層体を得た。
(1層目)
下記の芯成分としての熱可塑性重合体と下記の鞘成分としての熱可塑性重合体とを、スパンボンド法により複合溶融紡糸を行った。そして、芯成分/鞘成分の質量比が60/40である偏芯芯鞘型の捲縮複合繊維(以下、「捲縮繊維(C7)」とする)から、第1不織ウェブ(1層目)及び第2不織ウェブ(2層目)を形成し、第1不織ウェブ上に第2不織ウェブが設けられた積層不織ウェブを移動捕集面上に堆積させた。この捲縮複合繊維は、平均繊維径が16.2μmであった。
-芯成分-
MFR:60g/10分、融点162℃、のプロピレン単独重合体(hPP1)
-鞘成分-
MFR25g/10分、融点115℃、密度915kg/m3のエチレン・1-ブテンランダム共重合体(PE1)
(2層目及び3層目)
芯成分としてプロピレン単独重合体(hPP1)、鞘成分としてエチレン・1-ブテンランダム共重合体(PE1)を、スパンボンド法により複合溶融紡糸を行った。そして、芯成分/鞘成分の質量比が75/25である同芯芯鞘型の非捲縮複合繊維(以下、「非捲縮繊維(NC3)」とする)から形成される、第2不織ウェブ(2層目)及び第3不織ウェブ(3層目)を、第1の不織ウェブ上に積層し、3層構造の積層ウェブを形成した。
3層構造の積層ウェブの目付は18g/m2であり、各層の目付はほぼ均等であった。次に、3層構造の積層ウェブを、1層目の不織布層側にエンボスロールが接触し、3層目の不織布層側に鏡面ロールを接触するように、90℃で熱圧着し、スパンボンド不織布積層体を得た。スパンボンド不織布積層体の総目付は18g/m2であり、圧着部の面積率は、11%であった。実施例1の不織布積層体は、1層目が第1の不織布層に相当し、2層目及び3層目が第2の不織布層に相当する。
実施例1と同様にして求めた親水化剤Aの塗布量は1.0質量%であった。
実施例19における1層目の不織布の偏芯芯鞘型の捲縮複合繊維(以下、「捲縮繊維(C8)」とする)の芯成分/鞘成分の質量比が40/60とした以外は実施例19と同様にして、スパンボンド不織布積層体を得た。
1層目、2層目、及び3層目の不織布層を形成するための繊維を捲縮繊維(C2)に変更し、さらに、親水化剤Aの塗布量を、1.0%とした以外は、実施例1と同様にしてスパンボンド不織布積層体を得た。
1層目、及び2層目の不織布層を形成するための繊維を捲縮繊維(C4)に変更し、3層目の不織布層を形成するための繊維を捲縮繊維(C2)に変更し、さらに、親水化剤Aの塗布量を、1.0%とした以外は、実施例1と同様にしてスパンボンド不織布積層体を得た。
(1層目及び2層目)
まず、実施例1と同様にして第1不織ウェブ(1層目、スパンボンド不織布の層)上に第2不織ウェブ(2層目、スパンボンド不織布の層)が設けられた積層不織ウェブを移動捕集面上に堆積させた。
次に、以下に示すMB1~MB5の重合体を用いて、0.38mmφのノズルを有する紡糸口金から、溶融した重合体を吐出させメルトブローン法による溶融紡糸を行い、繊維を前述の積層不織ウェブにおける第2不織ウェブに堆積させた。これにより、それぞれ表5に示す目付を有するメルトブローンウェブ(3層目、MB)が第2不織ウェブ(2層目、スパンボンド不織布の層)上に設けられた積層ウェブを形成した。なお、表5に示すように、実施例27及び実施例28では、MB1及びMB2を質量比で90/10又は80/20(MB1/MB2)で混合した重合体を用い、実施例29及び実施例30では、MB3、MB2及びMB4を質量比で40/20/40(MB3/MB2/MB4)で混合した重合体を用い、実施例31では、MB3及びMB2を質量比で60/40(MB3/MB2)で混合した重合体を用い、実施例32では、MB2及びMB4を質量比で60/40(MB2/MB4)で混合した重合体を用いた。また、各実施例における紡糸温度は、実施例23~26のMB1では245℃であり、実施例27及び実施例28のMB1及びMB2を混合した重合体では250℃であり、実施例29及び実施例30のMB3、MB2及びMB4を混合した重合体では290℃であり、実施例31のMB3及びMB2を混合した重合体では300℃であり、実施例32のMB2及びMB4を混合した重合体では300℃であり、実施例33のMB5では300℃であった。
MB1:ポリプロピレン単独重合体(MFR:1,100g/10分、重量平均分子量(Mw):97,000)
MB2:プロピレン・エチレン共重合体〔ExxonMobil社製:製品名「VistamaxxTM6202」、MFR(230℃、2,160g荷重):20g/10分、エチレン含量:15質量%〕
MB3:プロピレン単独重合体〔MFR:1,500g/10分、重量平均分子量(Mw):54000〕
MB4:プロピレン系重合体ワックス〔密度:0.900g/cm3、重量平均分子量:7,800、軟化点148℃、エチレン含量:1.7質量%〕
MB5:実施例1に記載のプロピレン-エチレンランダム共重合体(rPP1)
次に、実施例1と同様にして第3不織ウェブ(3層目、スパンボンド不織布の層)を、メルトブローンウェブ上に積層し、4層構造の積層ウェブを形成した。
本明細書に記載された全ての文献、特許出願、および技術規格は、個々の文献、特許出願、および技術規格が参照により取り込まれることが具体的かつ個々に記された場合と同程度に、本明細書中に参照により取り込まれる。
Claims (19)
- 熱可塑性重合体の繊維であり、平均捲縮径が800μm以下である捲縮繊維(A)を含む第1の不織布層を備え、
親水化剤を含有する不織布積層体。 - 前記第1の不織布層が、最外層であり、
前記捲縮繊維(A)の平均捲縮径が600μm以下である、請求項1に記載の不織布積層体。 - 前記熱可塑性重合体がオレフィン系重合体を含む、請求項1又は請求項2に記載の不織布積層体。
- 前記熱可塑性重合体がオレフィン系重合体としてプロピレン系重合体及びエチレン系重合体からなる群より選ばれる少なくとも一種を含む、請求項3に記載の不織布積層体。
- 不織布積層体のMD方向に、0.1N/mmの引張応力を加えた場合の幅保持率が75%以上である、請求項1~請求項4のいずれか1項に記載の不織布積層体。
- 不織布積層体のMD方向の5%延伸時の引張強度が2.2N/50mm以上である、請求項1~請求項5のいずれか1項に記載の不織布積層体。
- 不織布積層体から被転写不織布への親水化剤の転写量が0.015g/m2以下である、請求項1~請求項6のいずれか1項に記載の不織布積層体。
- 窒素吸着等温線のBET式より得られる窒素吸着試験における表面窒素吸着面積に対する水蒸気吸着等温線のBET式により得られる水蒸気吸着試験における表面水蒸気吸着面積の比(表面水蒸気吸着面積/表面窒素吸着面積)が1.5~9.0である、請求項1~請求項7のいずれか1項に記載の不織布積層体。
- 前記親水化剤は、多価アルコール脂肪酸エステル、ポリオキシアルキレン脂肪酸エステル、及び多価アルコール脂肪酸エステルのアルキレンオキシド付加物からなる群より選ばれる少なくとも一種を含む、請求項1~請求項8のいずれか1項に記載の不織布積層体。
- 熱可塑性重合体の繊維であり、前記捲縮繊維(A)の平均捲縮径とは異なる平均捲縮径を有し、平均捲縮径が500μm以上である捲縮繊維(B)、又は非捲縮繊維(C)を含む第2の不織布層をさらに備える請求項1~請求項9のいずれか1項に記載の不織布積層体。
- 前記第2の不織布層に含まれる前記繊維が、前記非捲縮繊維(C)である、請求項10に記載の不織布積層体。
- 前記第1の不織布層及び前記第2の不織布層に含まれる前記熱可塑性重合体の繊維が、プロピレン系重合体を含む繊維であり、
前記第1の不織布層に含まれる前記捲縮繊維(A)の表面に、プロピレン系重合体が露出しており、
前記第2の不織布層に含まれる前記捲縮繊維(B)又は非捲縮繊維(C)の表面に、プロピレン系重合体が露出しており、
前記捲縮繊維(A)の表面に露出しているプロピレン系重合体と、前記捲縮繊維(B)又は前記非捲縮繊維(C)の表面に露出しているプロピレン系重合体との融点差が、±15℃以内である、請求項10又は請求項11に記載の不織布積層体。 - 前記捲縮繊維(A)の表面に露出しているプロピレン系重合体と、前記捲縮繊維(B)又は前記非捲縮繊維(C)の表面に露出しているプロピレン系重合体とが、それぞれプロピレン/α-オレフィン共重合体、プロピレン単独重合体とプロピレン/α-オレフィン共重合体との混合物、又はその組み合わせである請求項12に記載の不織布積層体。
- 前記第1の不織布層がスパンボンド不織布の層であり、前記第2の不織布層がスパンボンド不織布の層であり、圧着部と非圧着部とを有し、前記圧着部の面積率が7%~20%である、請求項10~請求項13のいずれか1項に記載の不織布積層体。
- 熱可塑性重合体の繊維を含むメルトブローン不織布層をさらに備える、請求項1~請求項14のいずれか1項に記載の不織布積層体。
- 前記メルトブローン不織布層における前記熱可塑性重合体は、メルトフローレートが800g/10分以上のプロピレン単独重合体であり、前記メルトブローン不織布層における前記繊維の平均繊維径は、3μm未満であり、前記メルトブローン不織布層の目付は、3g/m2未満である請求項15に記載の不織布積層体。
- 前記メルトブローン不織布層における前記熱可塑性重合体は、メルトフローレートが200g/10分以上のプロピレン/α-オレフィン共重合体、又はプロピレン・α-オレフィン共重合体を含むプロピレン系重合体の混合物であり、前記メルトブローン不織布層の目付は、5g/m2未満である請求項15又は請求項16に記載の不織布積層体。
- 請求項1~請求項17のいずれか1項に記載の不織布積層体を有する、複合積層体。
- 請求項14~請求項17のいずれか1項に記載の不織布積層体、又は請求項18に記載の複合積層体を含む、被覆シート。
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JP2021504971A JP7233519B2 (ja) | 2019-03-08 | 2020-03-04 | 不織布積層体、複合積層体、及び被覆シート |
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Cited By (3)
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WO2022163716A1 (ja) * | 2021-01-27 | 2022-08-04 | 旭化成株式会社 | 繊維用親水剤及び不織布 |
WO2023234224A1 (ja) * | 2022-06-03 | 2023-12-07 | エム・エーライフマテリアルズ株式会社 | 不織布積層体 |
JP7518682B2 (ja) | 2019-07-30 | 2024-07-18 | ライフェンホイザー・ゲゼルシャフト・ミト・ベシュレンクテル・ハフツング・ウント・コンパニー・コマンデイトゲゼルシャフト・マシイネンファブリーク | スパンボンド不織布積層体、およびスパンボンド不織布積層体の製造方法 |
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Also Published As
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JP7233519B2 (ja) | 2023-03-06 |
EP3915777A4 (en) | 2022-11-02 |
CN113543966A (zh) | 2021-10-22 |
KR102565496B1 (ko) | 2023-08-09 |
EP3915777A1 (en) | 2021-12-01 |
CN113543966B (zh) | 2024-02-09 |
US20220119998A1 (en) | 2022-04-21 |
KR20210122825A (ko) | 2021-10-12 |
US12012679B2 (en) | 2024-06-18 |
JPWO2020184335A1 (ja) | 2020-09-17 |
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