Title of the invention: Non-woven fabric laminate, elastic non-woven fabric laminate, textile product, absorbent article and sanitary mask
Technical field
[0001]
The present invention relates to a non-woven fabric laminate, an elastic non-woven fabric laminate, a textile product, an absorbent article, and a sanitary mask.
Background technology
[0002]
In recent years, 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 characteristics according to its use, and is also required to improve the characteristics.
[0003]
For example, non-woven fabrics used for sanitary materials such as disposable diapers and sanitary napkins, and base cloths for poultices are required to have water resistance and excellent moisture permeability. It is also required to have elasticity and bulkiness depending on the place where it is used.
[0004]
As one of the methods for imparting elasticity to the nonwoven fabric, a method using a thermoplastic elastomer as a raw material for the spunbonded nonwoven fabric (see, for example, Patent Document 1) and a method using low crystalline polypropylene (for example, Patent Document 2 and Patent Document 1). 3) etc. have been proposed.
[0005]
Patent Document 2 or Patent Document 3 proposes adding a highly crystalline polypropylene or a mold release agent to low crystalline polypropylene in order to improve the stickiness of the spunbonded nonwoven fabric. Patent Document 4 discloses a laminate of a nonwoven fabric containing low crystalline polypropylene and a mixed fiber spunbonded nonwoven fabric of thermoplastic elastomer long fibers and thermoplastic resin long fibers.
[0006]
[Patent Document 1] Japanese Patent Publication No. 7-503502
[Patent Document 2] Japanese Unexamined Patent Publication No. 2009-62667
[Patent Document 3] Japanese Unexamined Patent Publication No. 2009-79341
[Patent Document 4] International Publication No. 2007/138733
Outline of the invention
Problems to be solved by the invention
[0007]
In the method described in Patent Document 2 or Patent Document 3, in order to prevent adhesion to each rotating device or other non-woven fabric in the apparatus when the non-woven fabric is produced, low crystalline polypropylene or high crystalline polypropylene or It is necessary to increase the amount of the release agent added, and as a result, the residual strain of the obtained spunbonded nonwoven fabric becomes large, and the elasticity tends to be inferior. In the method described in Patent Document 4, the stretchability is maintained by laminating a non-woven fabric containing low crystalline polypropylene and a mixed fiber spunbonded non-woven fabric, but further improvement in stretchability is strongly required.
[0008]
In addition, for sanitary materials such as disposable diapers and sanitary napkins, and base cloths for poultices, it is required that the stress during elongation is small so that it can be worn with a weak force, and the stress during recovery is high so that it does not shift when worn. It is required to be large. That is, in the above application, it is required to increase the value of the expansion / contraction characteristic (ratio of stress during recovery / stress during elongation).
[0009]
Furthermore, in applications such as disposable diapers, sanitary materials such as sanitary napkins, and base fabrics for poultices, the stress during recovery does not decrease in the range of room temperature (23 ° C) to body temperature (for example, the range of 23 ° C to 40 ° C). That is, it is required to have excellent stress maintenance. As a result, even if sanitary materials such as disposable diapers and sanitary napkins rise to body temperature when worn, they will not easily shift.
In view of the above problems, one aspect of the present invention is to provide a nonwoven fabric laminate having excellent stretchability and stress maintenance, as well as a stretchable nonwoven fabric laminate, a textile product, an absorbent article, and a sanitary mask. And.
Means to solve problems
[0010]
Specific means for solving the above problems include the following aspects.
[1] An elastic nonwoven fabric containing an α-olefin copolymer having a ratio (E40 / E23) of a storage elastic modulus E40 at 40 ° C. and a storage elastic modulus E23 at 23 ° C. of 37% or more.
Extensible spunbonded non-woven fabric arranged on at least one side of the elastic non-woven fabric,
Non-woven fabric laminate with.
[0011]
[2] The nonwoven fabric laminate according to the above [1], wherein the storage elastic modulus E23 of the α-olefin copolymer at 23 ° C. is 30 MPa or less.
[0012]
[3] The nonwoven fabric laminate according to the above [1] or [2], wherein the α-olefin copolymer contains a copolymer of ethylene and propylene.
[0013]
[4] The nonwoven fabric laminate according to any one of the above [1] to [3], wherein the α-olefin copolymer has a tensile elastic modulus of 30 MPa or less.
[0014]
[5] The nonwoven fabric laminate according to any one of the above [1] to [4], wherein the stretchable spunbonded nonwoven fabric is arranged on both sides of the elastic nonwoven fabric.
[0015]
[6] The nonwoven fabric laminate according to any one of the above [1] to [5], wherein the extensible spunbonded nonwoven fabric has a maximum load elongation of 45% or more in at least one direction.
[0016]
[7] The nonwoven fabric laminate according to any one of the above [1] to [6], wherein the elastic nonwoven fabric is an elastic spunbonded nonwoven fabric.
[0017]
[8] In the extensible spunbonded non-woven fabric, the core portion is a low MFR olefin polymer having an MFR in the range of 1 g / 10 min to 1000 g / 10 min, and the sheath portion is MFR 1 g / 10 min to 1000 g / g. A concentric olefin polymer having a high MFR in the range of 10 minutes and having a difference in MFR between the low MFR olefin polymer and the high MFR olefin polymer of 1 g / 10 minutes or more. The nonwoven fabric laminate according to any one of [1] to [7] above, which is an extensible spunbonded nonwoven fabric made of a core-sheath type composite fiber.
[0018]
[9] The extensible spunbonded non-woven fabric contains an olefin-based polymer composition containing 80% by mass to 99% by mass of a crystalline propylene-based polymer and 1% by mass to 20% by mass of high-density polyethylene. The non-woven fabric laminate according to any one of the above [1] to [8].
[0019]
[10] Any of the above [1] to [9] in which the basis weight ratio (elastic nonwoven fabric: extensible nonwoven fabric) between the elastic nonwoven fabric and the extensible nonwoven fabric is in the range of 10:90 to 90:10. The nonwoven fabric laminate according to item 1.
[0020]
[11] A stretchable nonwoven fabric laminate that is a stretched product of the nonwoven fabric laminate according to any one of the above [1] to [10].
[12] A textile product containing the nonwoven fabric laminate according to any one of the above [1] to [10] or the stretchable nonwoven fabric laminate according to the above [11].
[13] An absorbent article containing the nonwoven fabric laminate according to any one of the above [1] to [10] or the stretchable nonwoven fabric laminate according to the above [11].
[14] A sanitary mask containing the nonwoven fabric laminate according to any one of the above [1] to [10] or the stretchable nonwoven fabric laminate according to the above [11].
The invention's effect
[0021]
According to one embodiment of the present invention, a nonwoven fabric laminate having excellent stretchability and stress maintenance, as well as a stretchable nonwoven fabric laminate, a textile product, an absorbent article, and a sanitary mask are provided.
A brief description of the drawing
[0022]
FIG. 1 is a schematic view of a gear stretching device.
Embodiment for carrying out the invention
[0023]
Hereinafter, embodiments of the present disclosure will be described. These explanations and examples are examples of embodiments and do not limit the scope of the embodiments.
[0024]
In the numerical range described stepwise in the present disclosure, the upper limit value or the lower limit value described in one numerical range may be replaced with the upper limit value or the lower limit value of the numerical range described in another stepwise description. .. Further, in the numerical range described in the present disclosure, the upper limit value or the lower limit value of the numerical range may be replaced with the value shown in the examples.
[0025]
In this disclosure, each component may contain a plurality of applicable substances. When referring to the amount of each component in the composition in the present disclosure, if a plurality of substances corresponding to each component are present in the composition, unless otherwise specified, the plurality of species present in the composition. It means the total amount of substances.
[0026]
In the present disclosure, 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. Further, 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. Further, in the present disclosure, the content of each component in the composition refers to the content of each component in the composition when a plurality of substances corresponding to each component are present in the composition, unless otherwise specified. Means the total amount.
[0027]
-Non-woven fabric laminate-
The nonwoven fabric laminate according to the present disclosure includes an elastic nonwoven fabric containing an α-olefin copolymer having a ratio (E40 / E23) of a storage elastic modulus E40 at 40 ° C. and a storage elastic modulus E23 at 23 ° C. of 37% or more. It has an extensible spunbonded nonwoven fabric arranged on at least one side of the elastic nonwoven fabric. The non-woven fabric laminate may be composed of other layers.
[0028]
The nonwoven fabric laminate according to the present disclosure contains an α-olefin copolymer as an elastic nonwoven fabric. Therefore, it is considered that a nonwoven fabric laminate having excellent expansion and contraction characteristics and excellent stress maintenance can be obtained as compared with the case of using an elastic nonwoven fabric containing no α-olefin copolymer, for example, an elastic nonwoven fabric made of a polypropylene homopolymer. Be done.
Further, the α-olefin copolymer has a storage elastic modulus E40 at 40 ° C. and a storage elastic modulus E23 at 23 ° C. (E40 / E23) of 37% or more. That is, even in a temperature change environment (for example, 40 ° C to 23 ° C), the decrease in elasticity of the elastic nonwoven fabric is likely to be suppressed. Therefore, it is considered that a nonwoven fabric laminate excellent in stress maintenance can be obtained.
[0029]
In the nonwoven fabric laminate of the present disclosure, an stretchable spunbonded nonwoven fabric is arranged on at least one side of the elastic nonwoven fabric. As a result, it is easy to prevent the non-woven fabric laminate from adhering to members such as various rotating devices in the device used in the embossing process, and it is considered that the moldability and productivity are excellent. Further, since the stretchable spunbonded nonwoven fabric has extensibility, the elasticity of the elastic nonwoven fabric due to its excellent elasticity can be easily maintained.
[0030]
As the nonwoven fabric laminate, it is preferable that the stretchable spunbonded nonwoven fabric is arranged on both sides of the elastic nonwoven fabric from the viewpoint of obtaining a nonwoven fabric laminate having excellent expansion and contraction characteristics and excellent stress maintenance.
[0031]
The non-woven laminate of the present disclosure preferably has a texture of 360 g / m 2 or less, more preferably 240 g / m 2 or less, further preferably 150 g / m 2 or less, and 120 g / m 2 to 120 g / m 2. It is particularly preferably 15 g / m 2, even more preferably 80 g / m 2 to 20 g / m 2, and extremely preferably 70 g / m 2 to 25 g / m 2.
[0032]
The basis weight ratio (composition ratio) between the elastic nonwoven fabric and the stretchable spunbonded nonwoven fabric may be appropriately set according to various uses. For example, the basis weight ratio of the elastic nonwoven fabric and the extensible nonwoven fabric (elastic nonwoven fabric: extensible nonwoven fabric) is preferably in the range of 10:90 to 90:10, and is in the range of 20:80 to 80:20. It is more preferable that it is in the range of 40:60 to 60:40.
When the basis weight ratio of the elastic nonwoven fabric is 10 or more, the decrease in elasticity of the nonwoven fabric laminate tends to be suppressed. On the other hand, when the basis weight ratio of the elastic nonwoven fabric is 90 or less, the ratio of the fibers constituting the elastic nonwoven fabric exceeding the stretchable spunbonded nonwoven fabric layer and being exposed on the surface tends to decrease. Therefore, it becomes easy to obtain a nonwoven fabric laminate having excellent moldability and tactile sensation.
[0033]
When there are two or more elastic non-woven fabrics (or extensible non-woven fabrics), the basis weight of the elastic non-woven fabrics (or extensible non-woven fabrics) is a total of two or more.
[0034]
The basis weight (g / m 2) of the non-woven fabric laminate shall be the value obtained by measuring as follows. The basis weights of the elastic non-woven fabric and the extensible spunbonded non-woven fabric are also obtained by the same method.
Collect 6 test pieces with a flow direction (MD) of 200 mm and a lateral direction (CD) of 50 mm from the non-woven fabric laminate. The collection locations are arbitrary 3 locations for both MD and CD (6 locations in total). Next, the mass (g) of each of the collected test pieces is measured using a precision electronic balance (manufactured by Kensei Kogyo Co., Ltd.), and the arithmetic mean value of the mass of each test piece is obtained. Request Convert the calculated arithmetic mean value into mass (g) per 1 m 2, round off to the first decimal place, and use this as the basis weight [g / m 2].
[0035]
The nonwoven fabric laminate preferably has a maximum load elongation of 100% or more in at least one direction, more preferably 150% or more, and further preferably 220% or more.
[0036]
The maximum load elongation (%) of the non-woven fabric laminate shall be the value obtained by measuring as follows.
From the non-woven fabric laminate, 5 test pieces with a flow direction (MD) of 200 mm and a lateral direction (CD) of 50 mm are collected. This test piece is subjected to a tensile test using a constant-speed extension type tensile tester under the conditions of a chuck distance of 100 mm and a tensile speed of 100 mm / min. The maximum load [N / 50 mm] applied to the test piece is measured, and the elongation rate [%] of the test piece at the maximum load is measured. Obtain the arithmetic mean value of the five test pieces, and use this as the maximum load elongation.
[0037]
[Elastic non-woven fabric]
The elastic nonwoven fabric according to the present disclosure contains an α-olefin copolymer having a ratio (E40 / E23) of a storage elastic modulus E40 at 40 ° C. and a storage elastic modulus E23 at 23 ° C. of 37% or more.
[0038]
The texture of the elastic non-woven fabric is preferably 120 g / m 2 or less, more preferably 80 g / m 2 or less, further preferably 50 g / m 2 or less, and 40 g / m 2 to 2 g / m 2. Is particularly preferable, 30 g / m 2 to 5 g / m 2 is even more preferable, and 25 g / m 2 to 8 g / m 2 is extremely preferable.
The fibers constituting the elastic nonwoven fabric preferably have a fiber diameter of 50 μm or less, more preferably 40 μm or less, and further preferably 30 μm or less. The fibers constituting the elastic nonwoven fabric may have a fiber diameter of 1.0 μm or more.
[0039]
The method for producing the elastic nonwoven fabric is not particularly limited, and various known methods may be applied. For example, the elastic nonwoven fabric may be an elastic nonwoven fabric manufactured by a method such as a spunbond method, a melt blow method, or a flash spinning method. Among the above, the elastic nonwoven fabric is preferably an elastic nonwoven fabric produced by the spunbond method from the viewpoint that the fibers forming the nonwoven fabric are long fibers.
[0040]
(Α-olefin copolymer)
The elastic non-woven fabric contains an α-olefin copolymer.
The α-olefin copolymer represents a copolymer obtained by copolymerizing a copolymerization component having two or more kinds of α-olefin skeletons.
Examples of the copolymerization component having an α-olefin skeleton include ethylene, propylene, 1-butene, 1-pentene, 3-methyl-1-butene, 4-methyl-1-pentene, 1-hexene and 1-octene. Examples thereof include α-olefins such as 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene and 1-eicosene.
Among the above, the α-olefin copolymer is represented by ethylene (referred to as “C2” in Tables 1 and 2 below) from the viewpoint of making the non-woven laminate a lower stress and more excellent in elasticity. It is preferable to contain a copolymer of ethylene and propylene containing propylene (referred to as "C3" in Tables 1 and 2 below) as a copolymerization component.
[0041]
The content of the building blocks derived from ethylene in the ethylene and propylene copolymer (hereinafter, also simply referred to as “ethylene content”) is preferably 1% by mass to 50% by mass, preferably 5% by mass to 25% by mass. %, More preferably 10% by mass to 20% by mass, and particularly preferably 12% by mass to 18% by mass.
[0042]
The α-olefin copolymer may be any of an alternating copolymer, a graft copolymer, a block copolymer and a random copolymer.
[0043]
The ratio (E40 / E23) of the storage elastic modulus E40 at 40 ° C. and the storage elastic modulus E23 at 23 ° C. of the α-olefin copolymer is 37% or more from the viewpoint of obtaining a nonwoven fabric laminate excellent in stress maintenance. be. The larger the value, the more preferably the ratio (E40 / E23) is, more preferably 40% or more, further preferably 45% or more, and particularly preferably 50% or more. The upper limit of the ratio (E40 / E23) is not particularly limited, and may be 100% or less, 95% or less, or 90% or less.
[0044]
Examples of the method for setting the storage elastic modulus ratio E40 / E23 of the α-olefin copolymer in the above-mentioned specific range include a method in which the α-olefin copolymer is a copolymer of ethylene and propylene. Be done.
[0045]
The storage elastic modulus E23 of the α-olefin copolymer at 23 ° C. is preferably 30 MPa or less, more preferably 22 MPa or less, and more preferably 20 MPa, from the viewpoint of making the nonwoven fabric laminate more excellent in elasticity. It is more preferably 18 MPa or less, and particularly preferably 18 MPa or less.
The storage elastic modulus E40 of the α-olefin copolymer at 40 ° C. is preferably 10 MPa or less, preferably 9 MPa or less, from the viewpoint of making the nonwoven fabric laminate less stressful and more excellent in elasticity. Is more preferable.
The storage elastic modulus E23 of the α-olefin copolymer at 23 ° C. may be 5 MPa or more, or 10 MPa or more.
The storage elastic modulus E40 of the α-olefin copolymer at 40 ° C. may be 3 MPa or more, or 5 MPa or more.
[0046]
Each storage elastic modulus of the α-olefin copolymer shall be a value measured by the following equipment and conditions.
Temperature: 23 ° C or 40 ° C
Equipment: RSA-III (manufactured by TI Instruments)
Deformation mode: Pulling mode
Temperature range: -20 ° C to 120 ° C
Temperature rise rate: 2 ° C / min
Deformation frequency: 10Hz
Initial distortion: 0.1%
Measurement temperature sensation: 0.3 ° C
Environment: Under a nitrogen atmosphere
[0047]
The density of the α-olefin copolymer (ASTM D1505) is preferably in the range of 0.850 g / cm 3 to 0.950 g / cm 3, preferably 0.855 g / cm 3 to 0.900 g / cm 3. It is more preferably in the range, and even more preferably in the range of 0.860 g / cm 3 to 0.895 g / cm 3.
The density of the α-olefin copolymer is a value obtained by measuring according to the density gradient method of JIS K7112 (1999).
[0048]
The tensile elastic modulus of the α-olefin copolymer is preferably 30 MPa or less, more preferably 20 MPa or less, and more preferably 15 MPa or less, from the viewpoint of making the nonwoven fabric laminate more excellent in elasticity. Is even more preferable. The upper limit of the tensile elastic modulus of the α-olefin copolymer is not particularly limited, and may be, for example, 5 MPa or more.
The tensile elastic modulus is a value obtained by measuring by a method conforming to JIS K7161 (2011).
[0049]
The molecular weight distribution (Mw / Mn) of the α-olefin copolymer is preferably 1.5 to 5.0. The Mw / Mn is more preferably 1.5 to 4.5 in that a fiber having good spinnability and particularly excellent fiber strength can be obtained.
[0050]
The mass average molecular weight (Mw) and the number average molecular weight (Mn) of the α-olefin copolymer are values ​​obtained by GPC (gel permeation chromatography) and are measured under the following conditions. The mass average molecular weight (Mw) is the mass average molecular weight in terms of polystyrene, and the molecular weight distribution (Mw / Mn) is a value calculated from the number average molecular weight (Mn) and the mass average molecular weight (Mw) measured in the same manner. ..

Column: TOSO GMHHR-H (S) HT
Detector: RI detector for liquid chromatogram WATERS 150C
Solvent: 1,2,4-trichlorobenzene
Measurement temperature: 145 ° C
Flow velocity: 1.0 ml / min
Sample concentration: 2.2 mg / ml
Injection amount: 160 μl
Calibration curve: Universal Calibration
Analysis program: HT-GPC (Ver.1.0)
[0051]
The melt flow rate (MFR) of the α-olefin copolymer is not particularly limited, and is preferably, for example, 1 g / 10 minutes to 100 g / 10 minutes, and is preferably 10 g / 10 minutes to 80 g / 10 minutes. It is more preferably 15 g / 10 minutes to 70 g / 10 minutes, and particularly preferably 15 g / 10 minutes to 50 g / 10 minutes.
[0052]
The melt flow rate of the α-olefin copolymer is measured under the conditions of ASTM D-1238, 230 ° C., and a load of 2.16 kg.
[0053]
The α-olefin copolymer may be a synthetic product or a commercially available product.
When the α-olefin copolymer is a synthetic product, the α-olefin copolymer can be prepared by using a vapor phase method, a bulk method, or the like in the presence of a conventionally known catalyst such as a Cheegler-Natta catalyst or a metallocene catalyst. It can be prepared by polymerizing or copolymerizing by a conventionally known polymerization method such as a slurry method or a solution method.
Examples of commercially available α-olefin copolymers include Tuffmer (manufactured by Mitsui Chemicals), Vistamaxx series (manufactured by ExxonMobil Chemicals), and the like.
[0054]
The composition of the α-olefin copolymer can be obtained by using a conventionally known method (for example, IR analysis, NMR analysis, trace analysis, etc.).
[0055]
The ratio of the α-olefin copolymer to the total amount of the elastic nonwoven fabric is preferably 90% by mass to 100% by mass, more preferably 98% by mass to 100% by mass.
[0056]
When the α-olefin copolymer contains a copolymer of ethylene and propylene, the ratio of the copolymer of ethylene and propylene to the total amount of the elastic non-woven fabric is 80% by mass to 100% by mass from the viewpoint of the expansion and contraction characteristics of the non-woven laminate. %, More preferably 90% by mass to 100% by mass.
[0057]
When the α-olefin copolymer is a copolymer of ethylene and propylene, the crystallinity of the α-olefin copolymer is preferably 1% to 15% from the viewpoint of expansion and contraction characteristics in the non-woven laminate. It is more preferably 1% to 13%, further preferably 2% to 10%, and particularly preferably 4% to 10%.
[0058]
The crystallinity of the α-olefin copolymer was obtained by using a differential scanning calorimeter (DSC) to hold the α-olefin copolymer at −100 ° C. for 5 minutes and then raising the temperature at 10 ° C./min. It is calculated from the heat of fusion curve derived from the melting of the main component of the heat absorption curve. Specifically, using a differential scanning calorimeter (DSC-7, manufactured by PerkinElmer), 5 mg of the sample was held at −100 ° C. for 5 minutes in a nitrogen atmosphere, and then the temperature was raised at 10 ° C./min. Of the obtained heat absorption curves for melting, it can be calculated using the following formula from the heat of fusion curve derived from the melting of the main component.
Crystallinity = (ΔH / ΔH0) × 100 (%)
In the formula, ΔH is the heat of fusion (J / g) obtained from the heat of fusion curve derived from the melting of the main component of the α-olefin copolymer containing ethylene and propylene, and ΔH0 is the heat of fusion of the perfect crystal of the main component. (J / g). That is, when the main component is ethylene, ΔH0 is 293 J / g, and when the main component is propylene, ΔH0 is 210 J / g.
[0059]
When the α-olefin copolymer is a copolymer of ethylene and propylene, the melting point of the α-olefin may be 130 ° C. or lower, 115 ° C. or lower, or 100 ° C. or lower. It may be 40 ° C. to 85 ° C., or 40 ° C. to 60 ° C.
[0060]
The melting point of the α-olefin copolymer is a melting endothermic curve obtained by holding the α-olefin copolymer at -100 ° C for 5 minutes under a differential scanning calorimeter (DSC) and then raising the temperature at 10 ° C / min. It is defined as the peak top of the peak observed on the coldest side of. Specifically, the differential scanning calorimeter (Parkin) Observed on the lowest temperature side of the melting endothermic curve obtained by holding 5 mg of the sample in a nitrogen atmosphere at -100 ° C for 5 minutes and then raising the temperature at 10 ° C / min using DSC-7) manufactured by Elmer. It can be obtained as the peak top of the peak.
[0061]
[Extensible spunbonded non-woven fabric]
The extensible spunbonded nonwoven fabric according to the present disclosure preferably has a maximum load elongation of 45% or more in at least one direction, more preferably 70% or more, further preferably 100% or more, and more preferably 150. % Or more is particularly preferable. The extensible spunbonded non-woven fabric is preferably a non-woven fabric having a property of having almost no elastic recovery. The maximum load elongation [%] of the extensible spunbonded nonwoven fabric is obtained by the same method as the maximum load elongation of the nonwoven fabric laminate. The extensible spunbonded nonwoven fabric according to the present disclosure may have a maximum load elongation in at least one direction of 600% or less, or may be 500% or less.
[0062]
The extensibility spunbonded non-woven fabric preferably has a texture of 120 g / m 2 or less, more preferably 80 g / m 2 or less, further preferably 50 g / m 2 or less, and 40 g / m 2 to 5 g. / M 2 is particularly preferable, 30 g / m 2 to 5 g / m 2 is even more preferable, and 25 g / m 2 to 8 g / m 2 is extremely preferable.
[0063]
The fibers constituting the extensible spunbonded nonwoven fabric preferably have a fiber diameter of 50 μm or less, more preferably 40 μm or less, and further preferably 30 μm or less. The fibers constituting the extensible spunbonded nonwoven fabric may have a fiber diameter of 1.0 μm or more.
[0064]
The extensible spunbonded non-woven fabric is any of a concentric core-sheath type composite fiber having a core part and a sheath part, a sea-island type composite fiber having a sea part and an island part, a parallel type composite fiber, and a crimped composite fiber. There may be. The extensible spunbonded non-woven fabric is preferably a concentric core-sheath type composite fiber or a sea-island type composite fiber.
[0065]
In the stretchable spunbonded nonwoven fabric containing the concentric core-sheath type composite fiber, the core is a low MFR olefin polymer having an MFR in the range of 1 g / 10 min to 1000 g / 10 min, and the sheath is MFR. A high MFR olefin polymer in the range of 1 g / 10 min to 1000 g / 10 min, and the difference in MFR between the low MFR olefin polymer and the high MFR olefin polymer is 1 g / 10 min. The above is preferable. The difference in MFR is more preferably 15 g / 10 minutes or more, further preferably 30 g / 10 minutes or more, and particularly preferably 40 g / 10 minutes or more. The difference in MFR may be 100 g / 10 minutes or less, or 70 g / 10 minutes or less.
[0066]
In the stretchable spunbonded nonwoven fabric containing the sea-island type composite fiber, the sea part is a propylene-based polymer (preferably a homopolymer of propylene) and the island part is an ethylene-based polymer (preferably high-density polyethylene). It may be a composite fiber.
[0067]
Examples of the extensible spunbonded nonwoven fabric include nonwoven fabrics using one or more of the olefin-based polymer compositions described below.
[0068]
(Olefin-based polymer composition)
The extensible spunbonded nonwoven fabric preferably contains an olefin-based polymer, and is preferably formed from an olefin-based polymer composition containing the olefin-based polymer. The olefin-based polymer may be a polyolefin-based elastomer.
[0069]
The olefin-based polymer composition has, as an optional component, an antioxidant, a heat-resistant stabilizer, a weather-resistant stabilizer, an antistatic agent, a slip agent, an antifogging agent, a lubricant, a dye, and a pigment, as long as the object of the present disclosure is not impaired. , Natural oils, synthetic oils, waxes, hydrophilic agents and the like may be included.
[0070]
The olefin-based polymer is preferably a polymer having crystallinity. Examples of the crystalline component in the polymerization having crystallinity include poly1-butene and poly4-methyl-1-pentene. The olefin-based polymer may be used alone or in combination of two or more.
[0071]
Examples of the olefin polymer include homopolymers or copolymers of α-olefins such as ethylene, propylene, 1-butene, 1-hexene, 4-methyl-1-pentene and 1-octene. Examples of the α-olefin copolymer include an ethylene-based polymer and a propylene-based polymer.
[0072]
Examples of the ethylene-based polymer include high-pressure low-density polyethylene, linear low-density polyethylene (so-called LLDPE), high-density polyethylene (so-called HDPE) and other ethylene homopolymers, and random copolymers or blocks of ethylene and α-olefin. Examples include copolymers.
[0073]
The density of the ethylene-based polymer is not particularly limited, but is preferably 0.94 g / cm 3 to 0.97 g / cm 3, preferably 0.95 g / cm 3 to 0.97 g / cm 3. Is more preferable, and 0.96 g / cm 3 to 0.97 g / cm 3 is even more preferable.
[0074]
The MFR of the ethylene polymer is not particularly limited as long as it has spinnability, but for example, from the viewpoint of exhibiting extensibility, it is preferably 0.1 g / 10 min to 100 g / 10 min, and 0.5 g / 10 min. It is more preferably minutes to 50 g / 10 minutes, and even more preferably 1 g / 10 minutes to 30 g / 10 minutes.
[0075]
Propylene-based polymer generally refers to a crystalline resin manufactured and sold under the name of polypropylene. The propylene-based polymer is preferably a homopolymer of propylene or a copolymer containing propylene as a main component.
Examples of the propylene-based copolymer include α-olefins having 2 or more carbon atoms such as ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, and 4-methyl-1-pentene (preferably). Examples thereof include copolymers containing (α-olefins having 2 to 8 carbon atoms) as a copolymerization component (however, alkene having 3 carbon atoms, that is, propylene is excluded). The copolymer containing propylene as a main component may be either a random copolymer, a block copolymer, or the like.
[0076]
The melting point (Tm) of the homopolymer of propylene is preferably 155 ° C or higher, more preferably 157 ° C to 165 ° C.
The melting point (Tm) of the copolymer containing propylene as a main component is preferably 130 ° C. or higher and lower than 155 ° C., and more preferably 130 ° C. to 150 ° C.
The MFR of the propylene-based polymer is not particularly limited as long as it can be melt-spun. The MFR of the propylene-based polymer is, for example, preferably 1 g / 10 minutes to 1000 g / 10 minutes, more preferably 5 g / 10 minutes to 500 g / 10 minutes, and 10 g / 10 minutes to 100 g / 10 minutes. Is more preferable.
[0077]
The extensible spunbonded nonwoven fabric may contain a polymer other than the olefin polymer (hereinafter, also referred to as “other polymer”), and may not contain any other polymer. Examples of other polymers include thermoplastic resins other than thermoplastic elastomers and olefin polymers.
[0078]
Specific examples of the thermoplastic elastomer include styrene-based elastomers, polyester-based elastomers, polyamide-based elastomers, thermoplastic polyurethane-based elastomers, vinyl chloride-based elastomers, and fluoroelastomers.
[0079]
Specific examples of the thermoplastic resin other than the olefin polymer include polyester (polyester terephthalate, polybutylene terephthalate, polyethylene naphthalate, etc.) and polyamide (nylon-6, nylon-66, polymethoxylen adipamide, etc.). , Polyvinyl chloride, polyimide, ethylene / vinyl acetate copolymer, ethylene / vinyl acetate / vinyl alcohol copolymer, ethylene / (meth) acrylic acid copolymer, ethylene-acrylic acid ester-carbon monoxide copolymer, Examples thereof include polyacrylonitrile, polycarbonate, and polystyrene.
[0080] [0080]
The content of the olefin polymer in the extensible spunbonded non-woven fabric is more than 90% by mass and 100% by mass with respect to the total of the olefin polymer and other polymers (thermoplastic elastomer and thermoplastic resin other than the olefin polymer). % Or less, more preferably 95% by mass to 100% by mass.
[0081]
The extensible spunbonded polymer does not contain other polymers, or the content of other polymers (thermoplastic elastomers and thermoplastic resins other than olefinic polymers) in the extensible spunbonded polymer is an olefinic polymer. It is preferably more than 0% and less than 10% by mass, and more preferably more than 0% and 5% by mass or less with respect to the total of the and other polymers.
[0082]
When the olefin-based polymer composition contains the propylene-based polymer and the ethylene-based polymer, the content of the propylene-based polymer is 80% by mass to 99% by mass with respect to the total amount of the olefin-based polymer composition. It is preferably 84% by mass to 96% by mass, and more preferably 84% by mass to 96% by mass. On the other hand, the content of the ethylene-based polymer is preferably 20% by mass to 1% by mass, more preferably 16% by mass to 4% by mass, based on the total amount of the olefin-based polymer composition. However, propylene-based polymer + ethylene-based polymer = 100% by mass).
[0083]
(Specific example of extensible spunbonded non-woven fabric)
The extensible spunbonded non-woven fabric preferably contains an extensible spunbonded nonwoven fabric that satisfies the following requirements (1) to (3).
[0084]
(1) Core-sheath type composite fiber and parallel type composite fiber (side-by-side type composite) composed of two or more kinds of olefin-based polymers having a difference in crystallization induction time of 100 seconds or more in flow-induced phase separation. Spunbonded non-woven fabric using fiber) or crimped composite fiber.
[0085]
The two or more kinds of olefin-based polymers may be, for example, a propylene-based polymer having a high melting point and a propylene-based polymer having a low melting point.
[0086]
(2) A spunbonded non-woven fabric using a sea-island type composite fiber, a core-sheath type composite fiber, a parallel type composite fiber, or a crimped composite fiber, which comprises an olefin-based polymer composition containing a propylene-based polymer and an ethylene-based polymer. .. In particular, as the olefin-based polymer composition, those shown below are preferable.
(2-1) An olefin-based polymer composition comprising 80% by mass to 99% by mass of a propylene homopolymer and 20% by mass to 1% by mass of high-density polyethylene.
(2-2) An olefin polymer composition containing a high melting point propylene polymer having the same or different MFR and a melting point in the range of 157 ° C to 165 ° C.
[0087]
The propylene-based polymer is, for example, a propylene-based polymer obtained by copolymerizing a propylene homopolymer and a random copolymer of propylene and α-olefin having a low melting point in the range of 130 ° C. to 150 ° C. May be.
[0088]
(3) The core is a low MFR propylene-based polymer having an MFR in the range of 1 g / 10 min to 200 g / 10 min, and the sheath is a high MFR having an MFR in the range of 16 g / 10 min to 215 g / 10 min. A spunbonded non-woven fabric using a concentric core-sheath composite fiber, which is a propylene-based polymer of the above and has a difference between the MFR of the core portion and the MFR of the sheath portion of 15 g / 10 minutes or more.
[0089]
Examples of the extensible spunbonded non-woven fabric satisfying the above requirements (1) to (3) include the following (A) and (B) extensible spunbonded non-woven fabrics.
(A) A low MFR and high melting point propylene-based polymer (preferably a propylene homopolymer) having an MFR in the range of 10 g / 10 min to 200 g / 10 min and a melting point in the range of 157 ° C to 165 ° C. ), And the sheath portion is a propylene / α-olefin random copolymer having a high MFR and a low melting point in the range of 10 g / 10 min to 200 g / 10 min and a melting point in the range of 130 ° C to 150 ° C. Moreover, the difference between the MFR of the core portion and the MFR of the sheath portion is A spunbonded non-woven fabric using a core-sheath type composite fiber, a parallel type composite fiber, or a crimped composite fiber composed of a core-sheath type composite fiber having a concentric core of 1 g / 10 minutes or more.
(B) The core portion is a low MFR propylene-based polymer (preferably a propylene homopolymer) having an MFR in the range of 1 g / 10 min to 200 g / 10 min, and the sheath portion is an MFR of 31 g / 10 min to 230 g / g. A propylene-based polymer with a high MFR in the range of 10 minutes (preferably a propylene homopolymer), and a concentric polymer in which the difference between the MFR of the core portion and the MFR of the sheath portion is 30 g / 10 minutes or more. A spunbonded non-woven fabric made of core-sheath type composite fiber.
In (B) above, the core portion is a low MFR propylene-based polymer having an MFR in the range of 10 g / 10 min to 50 g / 10 min, and the sheath portion is an MFR of 50 g / 10 min to 100 g / 10 min. It may be a propylene-based polymer having a high MFR in the range. The difference between the MFR of the core portion and the MFR of the sheath portion may be 30 g / 10 minutes to 100 g / 10 minutes, or may be 40 g / 10 minutes to 80 g / 10 minutes or less.
[0090]
[Other layers]
Other layers may be laminated on the nonwoven fabric laminate of the present disclosure depending on various uses. The other layers to be laminated on the nonwoven fabric laminate of the present disclosure are not particularly limited, and various layers can be laminated depending on the application.
[0091]
Specific examples of the other layer include knitted fabrics, woven fabrics, non-woven fabrics other than elastic non-woven fabrics and extensible spunbonded non-woven fabrics, films and the like. The method of further laminating (bonding) other layers to the nonwoven fabric laminate of the present disclosure is not particularly limited, and thermal embossing, thermal fusion methods such as ultrasonic fusion, mechanical entanglement such as needle punching and water jet are not particularly limited. Various methods such as a method, a method using an adhesive such as a hot melt adhesive and a urethane adhesive, and an extruded laminate can be adopted.
[0092]
When the non-woven fabric laminate of the present disclosure has a non-woven fabric other than the elastic non-woven fabric and the stretchable spunbond non-woven fabric, the non-woven fabric includes 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, and spread fiber non-woven fabric. Various known non-woven fabrics such as, etc. can be mentioned. These non-woven fabrics may be stretchable non-woven fabrics or non-stretchable non-woven fabrics. Here, the non-stretchable non-woven fabric means a non-woven fabric that does not generate a return stress after being stretched in MD (flow direction of the non-woven fabric, vertical direction) or CD (direction perpendicular to the flow direction of the non-woven fabric, horizontal direction).
[0093]
As the film when the nonwoven fabric laminate of the present disclosure has a film, a breathable (moisture permeable) film is preferable from the viewpoint of maintaining the breathability and hydrophilicity characteristic of the nonwoven fabric laminate of the present disclosure. As the breathable film, a film made of a thermoplastic elastomer such as a moisture-permeable polyurethane elastomer, a polyester elastomer, or a polyamide elastomer, or a film made of a thermoplastic resin containing inorganic fine particles or organic fine particles is stretched and made porous. Examples thereof include various known breathable films such as a porous film. As the thermoplastic resin used for the porous film, 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 are preferable. However, if it is not necessary to maintain the breathability and hydrophilicity of the nonwoven fabric laminate, a thermoplastic resin film such as polyethylene, polypropylene, or a combination thereof may be used.
[0094]
[Manufacturing method of non-woven fabric laminate]
The nonwoven fabric laminate of the present disclosure can be produced by a known method for producing a nonwoven fabric using an elastic nonwoven fabric containing an α-olefin copolymer, an extensible spunbonded nonwoven fabric, and an additive used as necessary.
[0095]
As an example of a method for manufacturing a nonwoven fabric laminate, a method using a nonwoven fabric manufacturing apparatus equipped with at least two rows of spinning apparatus will be described below. The following example is an example of a method for producing a nonwoven fabric laminate using an olefin polymer as an extensible spunbonded nonwoven fabric and an α-olefin copolymer as an elastic nonwoven fabric.
From the viewpoint of manufacturing, the nonwoven fabric laminate of the present disclosure preferably has an extensible spunbonded nonwoven fabric arranged on the surface of the nonwoven fabric manufacturing apparatus on the side in contact with the rotating device.
First, an extruder provided in the first row spinning apparatus, an olefin polymer as needed, and two or more olefin polymers melted with two or more extruders, and a large number of spinning holes are formed. It is introduced into a mouthpiece (die) provided with a (nozzle) and, if necessary, a spinning hole having a core-sheath structure, and discharged. After that, the long fibers containing the melt-spun olefin polymer are introduced into the cooling chamber, cooled by the cooling air, and then the long fibers are drawn (drawn) by the stretched air to move the extensible spunbonded non-woven fabric to the moving collection surface. Deposit on top.
On the other hand, the resin composition containing the α-olefin copolymer of the present disclosure is melted by an extruder provided in the second row spinning apparatus, and spinning having a die having a large number of spinning holes (nozzles). It is introduced into the pores and the resin composition is discharged. Then, the long fibers containing the melt-spun resin composition are introduced into the cooling chamber, cooled by the cooling air, and then the long fibers are drawn (drawn) by the stretched air and deposited on the extensible spunbonded nonwoven fabric. Form an elastic non-woven fabric.
If necessary, the stretchable spunbonded non-woven fabric may be deposited on the elastic non-woven fabric using a spinning device in the third row.
[0096]
The melting temperature of each polymer in the elastic nonwoven fabric and the extensible spunbonded nonwoven fabric is not particularly limited as long as it is equal to or higher than the softening temperature or melting temperature of each polymer and lower than the thermal decomposition temperature. The temperature of the base depends on the type of polymer used, but for example, when a copolymer of ethylene and propylene is used as the α-olefin copolymer, the temperature of the base may be 180 ° C to 240 ° C. It is preferably 190 ° C. to 230 ° C., more preferably 200 ° C. to 225 ° C.
[0097]
The temperature of the cooling air is not particularly limited as long as it is the temperature at which the polymer solidifies, preferably 5 ° C to 50 ° C, more preferably 10 ° C to 40 ° C, and 15 ° C to 30 ° C. Is even more preferable. The wind speed of the stretched air is preferably 100 m / min to 10,000 m / min, more preferably 500 m / min to 10,000 m / min.
[0098]
The nonwoven fabric laminate of the present disclosure preferably has a structure in which at least a part of an elastic nonwoven fabric and at least a part of an extensible spunbonded nonwoven fabric are heat-sealed. At this time, before heat-sealing at least a part of the elastic nonwoven fabric and at least a part of the extensible spunbonded nonwoven fabric, it may be compacted by using a nip roll.
[0099]
The heat fusion method is not particularly limited and can be selected from various known methods. For example, a method using means such as ultrasonic waves, a heat embossing process using embossing rolls, a method using hot air through, and the like can be mentioned as prebonding. Above all, thermal embossing is preferable from the viewpoint that the long fibers are efficiently drawn when drawn, and the temperature range thereof is preferably 40 ° C to 115 ° C.
[0100]
When a part of the laminated body is heat-sealed by heat embossing, the embossing area ratio is preferably 5% to 30%, more preferably 5% to 20%. The non-embossed unit area is preferably 0.5 mm 2 or more, and more preferably 4 mm 2 to 40 mm 2. The non-embossed unit area represents the maximum area of ​​a quadrangle inscribed in embossing in the smallest non-embossed portion surrounded by embossed portions on all sides. Examples of the shape of the engraving include a circle, an ellipse, an ellipse, a square, a rhombus, a rectangular shape, a square, and a continuous shape based on these shapes.
[0101]

The stretchable nonwoven fabric laminate of the present disclosure is a nonwoven fabric laminate having elasticity obtained by stretching the nonwoven fabric laminate.
[0102]
The stretchable nonwoven fabric laminate of the present disclosure is a stretched product of the nonwoven fabric laminate obtained by stretching the nonwoven fabric laminate. The method of stretching is not particularly limited, and a conventionally known method can be applied. The method of stretching may be a method of partially stretching or a method of totally stretching. Further, it may be a method of uniaxial stretching or a method of biaxial stretching. Examples of the method of stretching in the flow direction (MD) of the machine include a method of passing mixed fibers partially fused to two or more nip rolls. At this time, the partially fused nonwoven fabric laminate can be stretched by increasing the rotation speed of the nip roll in the order of the flow direction of the machine. Further, the gear stretching process can also be performed using the gear stretching device shown in FIG.
[0103]
The lower limit of the draw ratio is preferably 50% or more, more preferably 100% or more, and further preferably 200% or more. On the other hand, the upper limit of the draw ratio is preferably 1000% or less, more preferably 500% or less.
[0104]
In the case of uniaxial stretching, it is preferable that either the stretching ratio in the flow direction (MD) of the machine or the direction perpendicular to the stretching ratio (CD) satisfies the stretching ratio. In the case of biaxial stretching, it is preferable that at least one of the flow direction (MD) of the machine and the direction perpendicular to the flow direction (CD) satisfies the stretching ratio.
[0105]
By stretching at the draw ratio as described above, both the elastic non-woven fabric and the (long) fibers forming the extensible spunbonded non-woven fabric are stretched. The long fibers forming the extensible spunbonded non-woven fabric layer are plastically deformed and elongated (that is, lengthened) according to the draw ratio.
When the stress is released after stretching the non-woven fabric laminate, the (long) fibers forming the elastic non-woven fabric recover elastically, and the long fibers forming the extensible spunbonded non-woven fabric bend without elastic recovery and the non-woven fabric. A feeling of bulkiness appears in the laminated fabric. Further, the long fibers forming the extensible spunbonded non-woven fabric tend to be thin. Therefore, it is considered that the flexibility and the tactile sensation are improved, and the stretch-stopping function can be imparted.
[0106]

The textile products of the present disclosure include the nonwoven fabric laminate or the stretchable nonwoven fabric laminate of the present disclosure. Textile products are not particularly limited, and examples thereof include disposable diapers, absorbent articles such as sanitary products, sanitary articles such as sanitary masks, medical articles such as bandages, clothing materials, and packaging materials. The textile product of the present disclosure preferably contains the nonwoven fabric laminate or the stretchable nonwoven fabric laminate of the present disclosure as an elastic member.
Example
[0107]
Hereinafter, the present invention will be described in more detail based on Examples, but the present invention is not limited to the following Examples. The materials, amounts, ratios, treatment procedures, etc. shown in the following examples may be appropriately changed as long as they do not deviate from the gist of the present disclosure. Unless otherwise specified, "part" means "part by mass".
[0108]
-Preparation of materials-
The following materials were prepared as raw materials for elastic non-woven fabric.
-Α-olefin copolymer 1A (propylene / ethylene copolymer)
ExxonMobil, product name "Vistamaxx TM6202", MFR (230 ° C, load 2.16 kg): 20 g / 10 minutes, ethylene content: 15% by mass, tensile modulus: 9.8 MPa.
-Α-olefin copolymer 1B (propylene / ethylene copolymer)
ExxonMobil, product name "Vistamaxx TM7050FL", MFR (230 ° C, load 2.16 kg): 48 g / 10 minutes, ethylene content: 13% by mass, tensile modulus: 14.4 MPa.
[0109]
-Synthesis of α-olefin homopolymer 1C (low crystalline polypropylene)
In a stainless steel reactor with an internal volume of 0.2 m 3 with a stirrer, n-heptane at 20 L / h, triisobutylaluminum at 15 mmol / h, and dimethylanilinium tetrakispentafluorophenylborate (1,2' -Dimethylsilylene) (2,1'-dimethylsilylene) -bis (3-trimethylsilylmethylindenyl) Zirconium Dichloride, triisobutylaluminum and propylene were previously contacted to obtain a catalytic component at 6 μmol / h per zirconium. Continuously supplied. Hydrogen concentration in the gas phase at a polymerization temperature of 70 ° C Propylene and hydrogen were continuously supplied while keeping the degree at 8 mol% and the total pressure in the reactor at 0.7 MPa · G. A propylene polymer was obtained by adding SUMILIZER GP (manufactured by Sumitomo Chemical Co., Ltd.) to the obtained polymerization solution so as to have a concentration of 1000 ppm and removing the solvent.
The weight average molecular weight (Mw) of the obtained propylene polymer was 1.2 × 104 and Mw / Mn = 2. Further, [mmmm] obtained from NMR measurement was 46 mol%, [rrrr] / (1- [mmmm]) was 0.038, [rmrm] was 2.7 mol%, and [mm] × [rr] / [. mr] 2 was 1.5 and the tensile modulus was 32.9 MPa.
In addition, [mmmm] is a mesopentad fraction, [rrrr] is a racemic pentad fraction, and [rmrm] is a racemic mesolas semimespentad fraction, [mm], [rr] and [mr]. Are triad fractions, respectively. These values ​​can be determined, for example, by the method described in International Publication No. 2016/143834.
[0110]
[Example 1]
MFR (measured at 230 ° C. and 2.16 kg load according to ASTM D1238) 8.5 g / 10 minutes, density 0.91 g / cm 3, melting point 160 ° C. propylene homopolymer (hereinafter referred to as "polymer 2A") ; "PP" in Tables 1 and 2) is melted using a 50 mmφ extruder, and independently MFR (measured at a temperature of 230 ° C. and a load of 2.16 kg according to ASM D1238) 60 g / 10 After melting a propylene homopolymer (hereinafter referred to as "polymer 2B"; "PP" in Tables 1 and 2) having a density of 0.91 g / cm 3 and a melting point of 160 ° C. using a 75 mmφ extruder, " A spunbonded non-woven fabric molding machine (collection) having a spinneret (die, 2887 holes) capable of forming a concentric core-sheath composite fiber in which "polymer 2A" is the core and "polymer 2B" is the sheath. Using the spunbond method under the conditions of a resin temperature and a die temperature of 250 ° C., a cooling air temperature of 20 ° C., and a stretched air air velocity of 3750 m / min, using a length (800 mm) in the direction perpendicular to the flow direction of the machine on the surface. Composite melt spinning was performed, and an extensible spunbonded non-woven fabric composed of concentric core-sheath type composite fibers having a core-sheath mass ratio of 10/90 was deposited as the first layer on the collection surface.
Next, the α-olefin copolymer 1A is melted on the deposited surface using a single-screw extruder having a screw diameter of 75 mmφ, and then a spunbonded nonwoven fabric molding machine having a spinneret (die, number of holes 808 holes). Using (length in the direction perpendicular to the flow direction of the machine on the collection surface: 800 mm), span under the conditions that both the resin temperature and the die temperature are 215 ° C, the cooling air temperature is 20 ° C, and the stretching air air speed is 3750 m / min. It was melt-spun by the bond method, and an elastic nonwoven fabric (elastic spunbonded nonwoven fabric) was deposited as the second layer. The spinnability of the α-olefin copolymer 1A in this step was very good.
Next, as the third layer, core-sheath type composite fibers similar to those in the first layer were deposited by the same method to form a three-layer deposit. This deposit is heat-pressurized with an embossed roll (embossed area ratio 18%, embossed temperature 70 ° C.), and the total grain size is 30.0 g / m 2, and the grain size of the first and third layers is 10. A non-woven fabric laminate having a grain size of 10.0 g / m 2 and the second elastic nonwoven fabric layer of 10.0 g / m 2 was produced (the mass fraction of the elastic nonwoven fabric layer to the whole is 33.3%). ).
The non-woven fabric laminate obtained as described above had almost no adhesion to the surface of the metal roll in the embossing process, and had good moldability. Further, when the nonwoven fabric laminate was wound into a roll state, roll blocking (a phenomenon in which the overlapping nonwoven fabrics adhered to each other and the rolls solidified) did not occur and could be easily pulled out.
[0111]
[Example 2]
A nonwoven fabric laminate was obtained by the same operation as in Example 1 except that the raw material of the elastic nonwoven fabric was changed from α-olefin copolymer 1A to α-olefin copolymer 1B.
[0112]
[Comparative Example 1]
A nonwoven fabric laminate was obtained by the same operation as in Example 1 except that the raw material of the elastic nonwoven fabric was changed from the α-olefin copolymer 1A to the α-olefin homopolymer 1C.
[0113]
[Example 3]
Example 1 except that the basis weight of the stretchable spunbonded nonwoven fabric in the first layer and the third layer and the basis weight of the elastic nonwoven fabric in the second layer were changed from 10.0 g / m 2 to 16.7 g / m 2. A non-woven fabric laminate was obtained by the same operation as in the above.
[0114]
[Example 4]
The texture of the stretchable spunbonded non-woven fabric in the first and third layers was changed from 10.0 g / m 2 to 15.6 g / m 2, and the texture of the elastic nonwoven fabric in the second layer was 10.0 g / m. A nonwoven fabric laminate was obtained by the same operation as in Example 1 except that the value was changed from 2 to 18.8 g / m 2.
[0115]
[Example 5]
Example 1 except that the basis weight of the stretchable spunbonded nonwoven fabric in the first layer and the third layer and the basis weight of the elastic nonwoven fabric in the second layer were changed from 10.0 g / m 2 to 20.0 g / m 2. A non-woven fabric laminate was obtained by the same operation as in the above.
[0116]
[Example 6]
Example 2 except that the basis weight of the stretchable spunbonded nonwoven fabric in the first layer and the third layer and the basis weight of the elastic nonwoven fabric in the second layer were changed from 10.0 g / m 2 to 20.0 g / m 2. A non-woven fabric laminate was obtained by the same operation as in the above.
[0117]
[Comparative Example 2]
Comparative Example 1 except that the basis weight of the stretchable spunbonded nonwoven fabric in the first layer and the third layer and the basis weight of the elastic nonwoven fabric in the second layer were changed from 10.0 g / m 2 to 20.0 g / m 2. A non-woven fabric laminate was obtained by the same operation as in the above.
[0118]
[Comparative Example 3]
A nonwoven fabric laminate was obtained by the same operation as in Comparative Example 2 except that the basis weight of the elastic nonwoven fabric in the second layer was changed from 20.0 g / m 2 to 25.0 g / m 2.
[0119]
-evaluation-
(Spinability)
For the non-woven fabrics of each example, the spinning condition near the nozzle surface of the spunbonded non-woven fabric manufacturing apparatus was visually observed during manufacturing, and the number of yarn breaks per 5 minutes (unit: times / 5 minutes) was counted. When the number of yarn breaks was 0 times / 5 minutes, it was evaluated as "A", and when the yarn breakage occurred and the non-woven fabric could not be collected, it was evaluated as "B" (Tables 1 and 2).
[0120]
-Evaluation of expansion and contraction characteristics (50% elongation stress, 50% recovery stress)-
Using a universal tensile tester (IM-201 type manufactured by Intesco), 5 test pieces of 50 mm (CD) × 200 mm (MD) were collected from the nonwoven fabric laminates of each example. Then, each of the collected test pieces was stretched 100% under the conditions of a sample width of 50 mm, a distance between chucks of 100 mm, and a tensile speed of 100 mm / min, and then immediately restored to the original length at the same speed. When this operation is performed for another cycle, the stress when the draw ratio becomes 50% at the time of extension in the second cycle is set as the stress at the time of 50% elongation, and when the draw ratio becomes 50% at the time of recovery in the second cycle. The stress of 50% was set as the stress at the time of recovery. Next, the value of [50% recovery stress ÷ 50% elongation stress] was measured as a measure of the expansion and contraction characteristics, and the arithmetic mean value of the five test pieces was evaluated as the expansion and contraction characteristics. The larger the value of [50% recovery stress ÷ 50% elongation stress], the better the expansion / contraction characteristics (Tables 1 and 2).
[0121]
In addition, Tables 1 and 2 show the results of measuring the storage elastic modulus at each temperature, the ratio of the storage elastic modulus, the maximum load elongation, and the texture of each non-woven fabric in each example by the above-mentioned measuring method.
[0122]
[table 1]

[0123]
[Table 2]

[0124]
As shown in Tables 1 and 2, it was found that the nonwoven fabric laminates of Examples were superior in stretching characteristics and stress maintenance as compared with the nonwoven fabric laminates of Comparative Examples.
[0125]
The entire disclosure of Japanese Patent Application No. 2018-201247 filed on October 25, 2018 is incorporated herein by reference in its entirety.
All documents, patent applications, and technical standards described herein are to the same extent as if the individual documents, patent applications, and technical standards were specifically and individually stated to be incorporated by reference. Incorporated by reference herein.
The scope of the claims
[Claim 1]
An elastic nonwoven fabric containing an α-olefin copolymer having a ratio (E40 / E23) of a storage elastic modulus E40 at 40 ° C. and a storage elastic modulus E23 at 23 ° C. of 37% or more.
Extensible spunbonded non-woven fabric arranged on at least one side of the elastic non-woven fabric,
Non-woven fabric laminate with.
[Claim 2]
The nonwoven fabric laminate according to claim 1, wherein the storage elastic modulus E23 of the α-olefin copolymer at 23 ° C. is 30 MPa or less.
[Claim 3]
The non-woven laminate according to claim 1 or 2, wherein the α-olefin copolymer contains a copolymer of ethylene and propylene.
[Claim 4]
The nonwoven fabric laminate according to any one of claims 1 to 3, wherein the α-olefin copolymer has a tensile elastic modulus of 30 MPa or less.
[Claim 5]
The nonwoven fabric laminate according to any one of claims 1 to 4, wherein the stretchable spunbonded nonwoven fabric is arranged on both sides of the elastic nonwoven fabric.
[Claim 6]
The nonwoven fabric laminate according to any one of claims 1 to 5, wherein the stretchable spunbonded nonwoven fabric has a maximum load elongation of 45% or more in at least one direction.
[Claim 7]
The nonwoven fabric laminate according to any one of claims 1 to 6, wherein the elastic nonwoven fabric is an elastic spunbonded nonwoven fabric.
[Claim 8]
The extensible spunbonded non-woven fabric has a core made of a low MFR olefin polymer having an MFR in the range of 1 g / 10 min to 1000 g / 10 min, and a sheath portion having an MFR of 1 g / 10 min to 1000 g / 10 min. A concentric core-sheath type polymer having a high MFR in the range and having an MFR difference of 1 g / 10 minutes or more between the low MFR olefin polymer and the high MFR olefin polymer. The nonwoven fabric laminate according to any one of claims 1 to 7, which is an extensible spunbonded nonwoven fabric made of composite fibers.
[Claim 9]
Claimed that the extensible spunbonded nonwoven fabric contains an olefin polymer composition containing 80% by mass to 99% by mass of a crystalline propylene-based polymer and 1% by mass to 20% by mass of high-density polyethylene. The nonwoven fabric laminate according to any one of claims 1 to 8.
[Claim 10]
6. Non-woven fabric laminate.
[Claim 11]
A stretchable nonwoven fabric laminate that is a stretched product of the nonwoven fabric laminate according to any one of claims 1 to 10.
[Claim 12]
A textile product containing the nonwoven fabric laminate according to any one of claims 1 to 10 or the stretchable nonwoven fabric laminate according to claim 11.
[Claim 13]
An absorbent article containing the nonwoven fabric laminate according to any one of claims 1 to 10 or the stretchable nonwoven fabric laminate according to claim 11.
[Claim 14]
A sanitary mask containing the nonwoven fabric laminate according to any one of claims 1 to 10 or the stretchable nonwoven fabric laminate according to claim 11.