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Spun Bonded Non Woven Fabric
Abstract: The purpose of the present invention is to provide a polypropylene spun- bonded non- woven fabric exhibiting excellent flexibility bending resistance, texture ,and strength. This spun- bonded non- woven fabric comprises a propylene polymer composition including a propylene polymer (A) having a melting point of at least 120°C, and a C15 -21 fatty acid amide. It is preferable that an oleic acid amide be used as the C15 -21 fatty acid amide. It is also preferable that the propylene polymer composition include a propylene polymer (B) having a melting point of less than 120°C.
Notices, Deadlines & Correspondence
Patent Information
Applicants
MITSUI CHEMICALS, INC.
Inventors
1. NAOSUKE KUNIMOTO
2. KENICHI SUZUKI
3. YOSHIHISA KAWAKAMI
4. KOSUKE OTA
Specification
DESCRIPTION
SPUNBOND NONWOVEN FABRIC
TECHNICAL FIELD
[0001]
5 The present invention relates to a spunbond nonwoven fabric
containing polypropylene, which is excellent in flexibility,
bending resistance, texture and strength, and particularly
relates to a polypropylene spunbond nonwoven fabric, which can
be suitably used for a wide variety of applications, especially
10 as a material for absorbent articles, such as a disposable diaper
and the like.
BACKGROUND ART
[0002]
Recently, nonwoven fabrics are used for a wide variety of
15 applications because of their excellent air permeability and
flexibility. Accordingly, nonwoven fabrics are required to have
a wide variety of properties in accordance with the applications
thereof and to improve the properties. For example, nonwoven
fabrics are broadly used as surface sheets for absorbent articles,
20 such as a paper diaper, a sanitary napkin and the like, which are
required to have the absorption ability that allows liquid such
as expelled or excreted menstrual blood or urine to be quickly
transferred to an absorbent body and/or a surface property that
gives a wearer a sense of flexibility and less stimulation at a
SF-2704 2
part of the skin in contact with any of those articles. Meanwhile,
nonwoven fabrics are also broadly used as back sheets, which are
required to have the water-resisting property that keeps a liquid
absorbed in an inner absorbent body from leaking outside as well
5 as the moisture permeation ability that allows the moisture inside
an absorbent article to permeate and to be dispersed outside in
order to prevent stuffiness due to the moisture generated on the
inward side of an absorbent article. Furthermore, because this
back sheet constitutes the surface of an absorbent article, the
10 back sheet is required to have excellent feeling and good texture.
[0003]
Thermoplastic resin-based filament nonwoven fabrics, such
as spunbond nonwoven fabrics, have been used in a variety of fields
because of their feasibility of continuous spinning, good
15 productivity as well as their excellent characteristics including
mechanical properties, such as high tensile strength; bending
resistance, air permeability, and the like. From the viewpoint
of the feasibility of melt spinning, fiber properties and the like,
polyamide resins, polyester resins or polyolefin resins are
20 employed as thermoplastic resins used in these filament nonwoven
fabrics and polyolefin resins are widely used especially for
absorbent articles, which polyolefin resins are inexpensive and
excellent in processability. Furthermore, resin compositions,
in which any other resin and/or a lubricant are added to a
SF-2704 3
polyolefin resin with the purpose of improving texture, have been
widely used.
[0004]
Spun-bonded nonwoven fabrics described in JP-A-2001-226865
5 (Patent Literature 1) and JP-A-2002-69820 (Patent Literature 2)
and the like are known as examples of a spunbond nonwoven fabric
produced by using a resin composition containing a polyolefin
resin and a lubricant. Patent Literature 1 has disclosed a
spunbond nonwoven fabric having a static friction coefficient in
10 a range of 0.1 to 0.4, which is produced from a polyolefin resin,
and particularly from a polypropylene resin. In addition, Patent
Literature 1 has disclosed that the nonwoven fabric contains a
fatty acid amide compound as a lubricant. Patent Literature 2
has also disclosed a polyolefin nonwoven fabric, in which a fatty
15 acid amide compound, particularly erucic acid amide, as a
lubricant is contained.
[0005]
Out of resin compositions each containing a polyolefin resin
and any other resin, a resin composition containing an a~olefin
20 polymer selected for the other resin is known to be used in spunbond
nonwoven fabrics described in JP-A-1993-194802 (Patent
Literature 3), JP-A-2002-146631 (Patent Literature 4),
JP-A-2005-126858 (Patent Literature 5) and JP-A-2008-524387
(Patent Literature 6).
SF-2704 4
[0006]
Moreover, the present applicant have disclosed a spunbond
nonwoven fabric in WO2012/07518 (Patent Literature 7) as well,
in which a resin composition containing a low-crystalline
5 polypropylene selected for the other resin was used out of the
above-described resin compositions.
[0007]
Recently, fabrics for use in hygiene materials and the like,
such as a paper diaper, a sanitary napkin and the like, are required
10 to improve the flexibility, in which less naps are raised and a
balance among their texture, sense of softness and sense of
smoothness is achieved, and the like. Thus, spunbond nonwoven
fabrics having excellent texture and strength as well as the
flexibility as described above are desired to appear.
15 CITATION LIST
PATENT LITERATURES
[0008]
Patent Literature 1: JP-A-2001-226865
Patent Literature 2: JP-A-2002-69820
20 Patent Literature 3: JP-A-1993-194802
Patent Literature 4: JP-A-2002-146631
Patent Literature 5: JP-A-2005-126858
Patent Literature 6: JP-A-2008-524387
Patent Literature 7: WO2012/07518
SF-2704 5
SUMMARY OF INVENTION
TECHNICAL PROBLEM
[0009]
In Patent Literatures 1 and 2, erucic acid amide is used
5 as a lubricant. However, when erucic acid amide was likewise used
as a lubricant, the flexibility of a nonwoven fabric was
insufficient and a problem associated with productivity arose,
in which problem the slipping property thereof was extremely
enhanced so that the nonwoven fabric could be hardly processed.
10 [0010]
In Patent Literatures 3, 4, 5 and 6, a resin composition
in which an a-olef in copolymer or a low-crystalline polypropylene
is added to a propylene polymer is used to improve the flexibility
of a nonwoven fabric. In this case, however, the added a-olefin
15 copolymer or low-crystalline polypropylene is separated from
fibers, which form a spunbond nonwoven fabric, and deposited on
the surface of the fibers, which causes a problem that impairs
the texture of the nonwoven fabric. Moreover, these literatures
describe the addition of a lubricant but not a specific lubricant
20 and do not suggest any specific effect of the addition thereof.
TECHNICAL SOLUTION
[0011]
The object of the present invention is to provide a spunbond
nonwoven fabric containing polypropylene, which achieves
SF-2704 6
excellent balance among its flexibility, texture, and strength.
[0012]
In such a background, the present inventors found that a
spunbond nonwoven fabric with desired properties could be obtained
5 by using a propylene polymer having a particular melting point
and a particular lubricant to produce the spunbond nonwoven fabric
and thereby completed the present invention:
[1] a spunbond nonwoven fabric made of a propylene polymer
composition containing a propylene polymer (A) having a melting
10 point of not less than 120°C and a fatty acid amide having not
less than 15 and not more than 21 carbon atoms;
[2] the spunbond nonwoven fabric according to [1], wherein the
fatty acid amide having not less than 15 and not more than 21 carbon
atoms is oleic acid amide;
15 [3] the spunbond nonwoven fabric according to [1] or [2], wherein
the propylene polymer composition further contains a propylene
polymer (B) having a melting point of less than 120°C;
[4] The spunbond nonwoven fabric according to claim 3, wherein
the propylene polymer composition contains, based on 100 parts
20 by weight of the total of the propylene polymer (A) having a melting
point of not less than 120°C and the propylene polymer (B) having
a melting point of less than 120°C,
the propylene polymer (A) having a melting point of not less
than 120°C in a range of 70 to 99.9 parts by weight,
SF-2704 7
the propylene polymer (B) having a melting point of less
than 120°C in a range of 30 to 0.1 parts by weight, and
the fatty acid amide having not less than 15 and not more
than 21 carbon atoms in a range of 0.01 to 1 part by weight;
5 [5] the spunbond nonwoven fabric according to any one of [1] to
[3], wherein the propylene polymer (B) having a melting point of
less than 120°C is a propylene homopolymer or a random copolymer
composed of propylene and an a-olefin having carbon atoms of 4
to 20;
10 [6] the spunbond nonwoven fabric according to [5], wherein the
propylene polymer (B) having a melting point of less than 120°C
is a copolymer composed of propylene and an a-olefin having carbon
atoms of 4 to 20;
[7] the spunbond nonwoven fabric according to [6], wherein the
15 content of the a-olefin in the copolymer is 0.1% by mole or more
and less than 90% by mole;
[8] the spunbond nonwoven fabric according to any one of [3] to
[7], wherein the propylene polymer (B) having a melting point of
less than 120°C is a low-crystalline polypropylene which satisfies
20 the following conditions (A) to (f):
(A) [mmmm] = 20-60% by mole,
(B) [rrrr]/{l-[mmmm]) < 0.1,
(c) [rmrm] > 2.5% by mole,
(d) [mm] x [rr]/[mr]2 < 2.0,
SF-2704 8
(e) mass-average molecular weight (Mw) = 10,000 to 200,000,
(f) molecular-weight distribution (Mw/Mn) < 4;
[9] the spunbond nonwoven fabric according to any one of [1] to
[4], wherein the propylene polymer (A) having a melting point of
5 not less than 120°C is a propylene homopolymer or a random
copolymer composed of propylene and an a-olefin;
[10] the spunbond nonwoven fabric according to any one of claims
1 to 4, containing a propylene homopolymer and a random copolymer
composed of propylene and an a-olefin as the propylene polymer
10 (A) having a melting point of not less than 120°C;
[11] a laminated nonwoven fabric material including the spunbond
nonwoven fabric according to any one of [1] to [10];
[12] an absorbent article using the spunbond nonwoven fabric
according to any one of [1] to [10] .
15 ADVANTAGEOUS EFFECTS OF INVENTION
[0013]
A spunbond nonwoven fabric of the present invention contains
a propylene polymer (A) having a melting point of not less than
120°C as well as a fatty acid amide having not less than 15 and
20 not more than 21 carbon atoms so that the spunbond nonwoven fabric
achieves a good balance among its texture, sense of softness and
sense of smoothness and has high flexibility. Furthermore, in
cases where a propylene polymer (B) having a melting point of less
than 120 °C is contained therein, the obtained nonwoven fabric has
SF-2704 9
high flexibility, high bending resistance, and good texture.
Additionally, the spunbond nonwoven fabric of the present
invention has characteristics, in addition to such flexibility,
such as difficulty in raising naps, high strength and excellent
5 workability, and is therefore suitable for use in a sanitary napkin,
a paper diaper and the like.
DESCRIPTION OF EMBODIMENT
[0014]
A propylene polymer (A) , which is a component of a spunbond
nonwoven fabric of the present invention, has a melting point of
not less than 120°C and preferably of 120-170°C, which melting
point is measured by a differential scanning calorimeter. The
15 propylene polymer (A) according to the present invention has
crystalline properties and a polypropylene whose isotactic index
(I.I.) (the insoluble fraction in boiling n-heptane) is preferably
not less than 75% by weight and more preferably 75-99% by weight
is preferred to be used as the propylene polymer (A).
20 [0015]
Moreover, the melt flow rate (measured at 230°C with a load
of 2160 g in accordance with ASTM D1238) of a propylene polymer
(A) is in a range of 1-300 g/10 min, and preferably of 2-200 g/10
min. The melt flow rate in this range enables melt spinning to
SF-2704 10
be performed.
[0016]
The propylene polymer (A) may be either a propylene
homopolymer or a random copolymer composed of propylene and an
5 a-olef in, or a combination of a propylene homopolymer and a random
copolymer composed of propylene and an a-olefin. The propylene
polymer (A) is preferably a propylene homopolymer from the
viewpoint of the strength of a nonwoven fabric to be obtained.
Moreover, the combinational use of a random copolymer composed
10 of propylene and an a-olefin with a propylene homopolymer allows
the texture to be improved. In this case, provided that the random
copolymer and the propylene homopolymer are considered to be 100%
by weight in total, the content of the random copolymer should
be in a range of 0.1 to 30% by weight.
15 [0017]
Moreover, a block polypropylene may be used as the polymer
(A) . A conventionally known propylene polymer may be used as such
a propylene polymer (A) and is easily available in the market.
Examples of a propylene homopolymer include, for example, "Prime
20 Polypro S119" {product name; produced by Prime Polymer Co., Ltd.)
and the like. Moreover, examples of a copolymer composed of
propylene and ethylene include Vistamaxx VM2125 {product name;
produced by Exxon Mobil Co.) and the like.
[0018]
SF-2704 11
The propylene polymer (A) can be produced by a known method,
using a solid titanium catalyst (Ziegler catalyst) component or
a metallocene compound catalyst component each of which is
conventionally known.
5 [0019]
In the present invention, the propylene polymer (A) may be
used alone but combinational use of the propylene polymer (A) and
a propylene polymer (B) shown below is preferred because the
flexibility, bending resistance, and texture of a nonwoven fabric
10 to be obtained are especially excellent.
A propylene polymer (B) used in the present invention is
a propylene polymer having a melting point of less than 120°C and
may be either a propylene homopolymer or a copolymer composed of
15 propylene and an a-olefin having two or 4-20 carbon atoms. Among
them, in the present invention, a propylene homopolymer or a
copolymer composed of propylene and an a-olefin having 4-20 carbon
atoms is preferred as the propylene polymer (B).
[0020]
20 The melting point (Tm) measured with a differential scanning
calorimeter is less than 120°C, preferably not more than 110°C,
more preferably 50-100°C, further preferably 55-85°C, and most
preferably 60-80°C.
[0021]
SF-2704 12
Moreover, the melt flow rate (measured at 230°C with a load
of 2160 g in accordance with ASTM D1238) of the propylene polymer
(B) is in a range of 1-1000 g/10 min, preferably of 2-500 g/10
min, further preferably of 2-250 g/10 min, and most preferably
5 of 2-150 g/10 min. The melt flow rate in this range allows a
nonwoven fabric obtained by combining the propylene polymer (B)
with the propylene polymer (A) to be excellent in flexibility,
bending resistance, and texture.
[0022]
10 In cases where a copolymer composed of propylene and an
ot-olefin having 4-20 carbon atoms is used as the propylene polymer
(B), examples of the a—olefin include, specifically, 1-butene,
1-pentene, 1-hexene, 1-heptene, 1-octene, 1-decene, 1-dodecene,
1-hexadecene, 4-methyl-l-pentene and the like. Among them,
15 1-butene is preferred.
[0023]
The content of the ot-olefin in the copolymer is not
particularly limited as long as the melting point (Tm) of a
propylene polymer to be obtained is within the above-described
20 range, and is typically in a range of 0.1% by mole or more and
less than 90% by mole, preferably in a range of 1-80% by mole,
further preferably in a range of 5-80% by mole, and most preferably
in a range of 15-75% by mole. Examples of such a propylene polymer
include TAFMER XM-7070 (product name; produced by Mitsui Chemicals,
SF-2704 13
Inc.) and the like.
[0024]
Moreover, in cases where a propylene homopolymer is used
as the propylene polymer (B) , the propylene homopolymer is
5 preferred to be a low-crystalline polypropylene satisfying the
following conditions (A) to (f).
[0025]
(A) [mmmm] - 20-60% by mole:
Generation of stickiness is reduced when the meso pentad
10 fraction [mmmm] of a low-crystalline polypropylene is not less
than 20% by mole. The crystallinity is not extremely increased
and therefore the elastic recovery property is enhanced when the
meso pentad fraction [mmmm] of a low-crystalline polypropylene
is not more than 60% by mole. The meso pentad fraction [mmmm]
15 is preferably 30-50% by mole and more preferably 40-50% by mole.
[0026]
The terms "meso pentad fraction" [mmmm] , "racemic pentad
fraction" [rrrr] and "racemic meso racemic meso pentad fraction"
[rmrm] , the latter two of which are recited below, refer to
20 fractions of pentads in the meso configuration, in the racemic
configuration and in the racemic meso racemic meso configuration
in a polypropylene molecular chain, respectively, which fractions
are determined based on signals of methyl groups in 13C-NMR spectra
in accordance with the method proposed by A. Zambelli et al. in
SF-2704 14
"Macromolecules, 1973, 6, 925". An increased meso pentad
fraction [mmmm] means increased tacticity. Moreover, the
below-described triad fractions in [mm] , [rr] and [mr] were also
calculated based on the above-described method.
5 [0027]
In addition, the determination of 13C-NMR spectrum can be
performed with reference to the identification of peaks proposed
by A. Zambelli et al. in "Macromolecules, 1975, 8, 687" and using
the following apparatus and conditions:
10 Apparatus: 13C-NMR spectrometer, type JNM-EX400, produced by JEOL
Ltd. ;
Method: the complete proton decoupling method;
Concentration: 220 mg/ml;
Solvent: a mixture solvent composed of 1,2, 4-trichlorobenzene and
15 deuterated benzene with a ratio of 90:10 (volume ratio);
Temperature: 130°C;
Pulse width: 45°;
Pulse repetition time: 4 seconds;
Scan number: 10000 times;
20
M = m/S x 100;
R = Y/S x 100;
S = Pf3[3 + Pa£ + Pay;
S: the sum of the signal strength from a carbon atom in a side-chain
SF-2704 15
methyl of every propylene unit;
P(5(3: 19.8-22.5 ppm;
Pap: 18.0-17.5 ppm;
Pay: 17.5-17.1 ppm;
5 y; racemic pentad chain: 20.7-20.3 ppm;
m: meso pentad chain: 21.7-22.5 ppm.
(B) [rrrr]/(l-[mmmm]) < 0.1:
The value of [rrrr]/[1-mmmm] is obtained based on the
fractions of the above-described pentad units and is an index
10 indicating the uniform distribution of regularity in a
low-crystalline polypropylene according to the present invention.
When this value is large, a mixture of stereochemically regular
polypropylene and atactic polypropylene has been produced, which
is observed likewise in a conventional polypropylene produced
15 using an existing catalyst system and causes a feeling of
stickiness.
[0028]
In cases where the value of [rrrr]/(1-[mmmm]) is not more
than 0.1 in a low-crystalline polypropylene, the feeling of
20 stickiness is reduced in an elastic nonwoven fabric to be obtained.
From such a viewpoint, the value of [rrrr] / (1-[mmmm] ) is
preferably not more than 0.05 and more preferably not more than
0.04.
(c) [rmrm] > 2.5% by mole:
SF-2704 16
The racemic meso racemic meso pentad fraction [rmrm] of a
low-crystalline polypropylene of more than 2.5% by mole results
in increased randomness in the low-crystalline polypropylene and
further improvement of the elastic recovery property of the
5 elastic nonwoven fabric. The fraction [rmrm] is preferably not
less than 2.6% by mole and more preferably not less than 2.7% by
mole. The upper limit of the fraction is typically around 10%
by mole.
(d) [mm] x [ r r ] / [ m r ] 2 < 2 . 0:
10 The value of [mm] x [rr] / [mr]2 represents an index indicating
the randomness of a low-crystalline polypropylene. When this
value is not more than 2.0, the elastic nonwoven fabric can have
sufficient elastic recovery and the feeling of stickiness is also
reduced. A value of [mm] x [rr]/[mr]2 closer to 0.25 means more
15 randomness. In order to gain the above-described sufficient
elastic recovery property, the value of [mm] x [rr]/[mr]2 is
preferably more than 0.25 and 1.8 or less and more preferably
0.5-1.5.
(e) Mass-average molecular weight (Mw) = 10,000 to 200,000:
20 When the mass-average molecular weight is not less than
10,000 in a low-crystalline polypropylene, the viscosity of the
low-crystalline polypropylene is not extremely low and is
appropriate and therefore yarn breakage during producing an
elastic nonwoven fabric is reduced. Moreover, when the
SF-2704 17
mass-average molecular weight is not more than 200,000, the
viscosity of the low-crystalline polypropylene is not extremely
high and therefore the spinning property is improved. The
mass-average molecular weight is preferably in a range of
5 30,000-150,000 and more preferably in a range of 50,000-150,000.
The method to determine the mass-average molecular weight will
be described below.
(f) Molecular-weight distribution (Mw/Mn) < 4:
When the molecular-weight distribution (Mw/Mn) is less than
10 4 in a low-crystalline polypropylene, generation of stickiness
is reduced in an elastic nonwoven fabric. The molecular-weight
distribution is preferably not more than 3. The mass-average
molecular weight (Mw) is a mass-average molecular weight in terms
of polystyrene equivalents, which is measured by the gel
15 permeation chromatography (GPC) method using the following
apparatus and conditions, and the molecular-weight distribution
(Mw/Mn) is a value calculated from the number-average molecular
weight (Mn) which is measured in the same manner and the
mass-average molecular weight (Mw):
20
Column: TOSO GMHHR-H(S)HT;
Detector: WATERS 150C, RI detector for liquid chromatograms;
Solvent: 1,2,4-trichlorobenzene;
SF-2704 18
Temperature during measurement: 145°C;
Flow rate: 1.0 ml/min;
Sample concentration: 2.2 mg/ml;
Injection volume: 160 ul;
5 Calibration curve: Universal Calibration;
Analysis program: HT-GPC (Ver. 1.0).
[0029]
A low-crystalline polypropylene used in the present
invention is preferred to further satisfy the condition (g) below:
10 (g) the melting point (Tm-D) is in a range of 0-120°C, wherein
the melting point is defined as a temperature corresponding to
a top of a peak observed at the highest temperature side of a
melting endothermic curve, which melting endothermic curve is
obtained by a measurement using a differential scanning
15 calorimeter (DSC), in which the temperature is raised at a rate
of 10°C/min after keeping the temperature at -10QC for 5 min under
nitrogen atmosphere.
[0030]
In cases where the melting point (Tm-D) of a low-crystalline
20 polypropylene is not less than 0°C, generation of stickiness is
reduced in the elastic nonwoven fabric. Meanwhile, in cases where
the melting point is not more than 120°C, sufficient elastic
recovery can be obtained. From such a viewpoint, the melting
point (Tm-D) is more preferably 0-100°C.
SF-2704 19
[0031]
In addition, the melting point (Tm-D) can be obtained as
a temperature corresponding to a top of a peak observed at the
highest temperature side of a melting endothermic curve, which
5 melting endothermic curve is obtained by a measurement using a
differential scanning calorimeter (DSC-7; produced by
PerkinElmer Inc.), in which the temperature of 10 mg of a sample
is raised at a rate of 10°C/min after keeping the temperature at
-10°C for 5 min under nitrogen atmosphere.
10 [0032]
Such a low-crystalline polypropylene can be synthesized
using a homogeneous catalyst referred to as a so-called
metallocene catalyst as described in, for example, WO2003/087172.
[0033]
15 Examples of the low-crystalline polypropylene as described
above include, for example, L-MODU S901 (product name; produced
by Idemitsu Kosan Co., Ltd. ) or L-MODU S600 (product name; produced
by Idemitsu Kosan Co., Ltd.) or the like.
Examples of a fatty acid amide having not less than 15 and
not more than 21 carbon atoms used in the present invention include
fatty acid monoamide compounds, fatty acid diamide compounds,
saturated fatty acid monoamide compounds, and unsaturated fatty
SF-2704 20
acid diamide compounds. In the present invention, the term
"carbon atom number" means the number of carbon atoms included
in a molecule, particularly, palmitic acid amide (carbon atom
number: 16), stearic acid amide (carbon atom number: 18), oleic
5 acid amide (carbon atom number: 18), and the like. Multiple
combinations of these amides can be used. The carbon atom in
"-CONH", which is contained in an amide, is also counted in the
number of carbon atoms of the amide. The carbon atom number of
the fatty acid amide is more preferably not less than 5 and not
10 more than 19 .
[0034]
In the present invention, oleic acid amide is-especially
preferred out of those fatty acid amide compounds. Using oleic
acid amide enables a nonwoven fabric excellent in flexibility,
15 texture, and strength to be obtained.
[0035]
As a lubricant, a known one may be contained in addition
to the above-described fatty acid amide. Examples of a known
lubricant include fatty acid compounds, paraffin and hydrocarbon
20 resins, silicon compounds, silicon polymers, fluorine compounds,
fluorine-containing polymers such as a copolymer of
tetrafluoroethylene and propylene and a copolymer of vinylidene
fluoride and hexafluoropropylene, and the like, or a mixture
thereof.
SF-2704 21
[0036]
A propylene polymer composition, which is a raw material
of a spunbond nonwoven fabric according-to the present invention,
5 contains a propylene polymer (A) having a melting point of not
less than 120°C and a fatty acid amide having not less than 15
and not more than 21 carbon atoms as essential components.
[0037]
In cases where a propylene polymer (B) having a melting point
10 of less than 120°C is contained, the propylene polymer composition
contains, based on 100 parts by weight of the total of the propylene
polymer (A) having a melting point of not less than 120°C and the
propylene polymer (B) having a melting point of less than 120°C,
70-99.9 parts by weight of the propylene polymer (A) having
15 a melting point of not less than 120°C and 0.1-30 parts by weight
of the propylene polymer (B) having a melting point of less than
120°C;
preferably 75-99 parts by weight of the propylene polymer
(A) having a melting point of not less than 120°C and 1-25 parts
20 by weight of the propylene polymer (B) having a melting point of
less than 120°C; and
more preferably 80-97 parts by weight of the propylene
polymer (A) having a melting point of not less than 120°C and 3-20
parts by weight of the propylene polymer (B) having a melting point
SF-2704 22
of less than 120°C.
[0038]
A propylene polymer composition containing the propylene
polymer (A) and the propylene polymer (B) in such a blending ratio,
5 v/hich further contains a particular fatty acid amide in
combination with them, allows a nonwoven fabric having excellent
flexibility, texture, and strength to be obtained.
[0039]
Moreover, based on 100 parts by weight of the total of the
10 propylene polymer (A) and the propylene polymer (B), the fatty
acid amide having not less than 15 and not more than 21 carbon
atoms is desired to be contained in a range of 0.01-1 part by weight,
preferably of 0.05-0.60 part by v/eight, and further preferably
of 0 .10-0 . 40 part by weight. Even if an excess amount of the fatty
15 acid amide is contained, reduction in strength and extreme
decrease in static friction coefficient could occur. Moreover,
in cases where the amount of the fatty acid amide is small, the
flexibility could be insufficient.
[0040]
20 The melt flow rate {MFR; measured at 190°C with a load of
2160 g in accordance with ASTM D-1238) of a composition prepared
according to the above conditions is typically in a range of 1-150
g/10 min, more preferably of 10-100 g/10 min, and further
preferably of 30-90 g/10 min.
SF-2704 23
Production of a propylene polymer composition
In manufacture of a nonwoven fabric of the present invention,
it is preferred that a propylene polymer (A) and a fatty acid amide
having not less than 15 and not more than 21 carbon atoms and,
5 as required, a propylene polymer (B) having a melting point of
less than 120°C are kneaded in advance to produce a propylene
polymer resin composition, followed by spinning of this propylene
polymer composition and formation of a nonwoven fabric. In this
step, the propylene polymer composition can be produced by
10 adopting a method, In which each component in the range as
described above is mixed by any of various known methods, such
as a multi-stage polymerization method and a mixing method using
a Henschel mixer, a V-blender, a ribbon blender, a tumble blender
or the like, or alternatively in which each component in the range
15 as described above is, after mixing them, melt kneaded with a
single screw extruder, a double screw extruder, a kneader, a
Banbury mixer or the like, followed by granulation or
pulverization.
[0041]
20 Moreover, an organic peroxide and the like as a degradation
promoter (degrading agent) may be added as required in accordance
with the production process of a nonwoven fabric in purpose of
ensuring the formability. Moreover, the fluidity according to
the production process of a nonwoven fabric to be selected may
SF-2704 24
be obtained in response to a degradation promoter (degrading
agent) added during the mixture.
[0042]
To the propylene polymer composition of the present
5 invention, additives including a weatherproof stabilizer, a
thermostabilizer, an anti-slip agent, an anti-blocking agent, an
anti-fogging agent, a pigment, a dye, aplasticizer, an anti-aging
agent, a hydrochloric acid absorbent, an antioxidant, a
hydrophilizing agent and the like may be combined as required in
10 such a range as not to impair the purpose of the present invention.
Moreover, any other polymer and the like can be combined in such
a range as not to impair the purpose of the present invention as
long as this does not depart from the spirit of the present
invention.
15 Production process of a nonwoven fabric formed of a propylene
polymer composition
From a propylene resin composition prepared as described
above, a nonwoven fabric is produced by a spun-bonding method.
The spun-bonding method is disclosed in JP-A-2007-46224,
20 JP-A-2002-317372, JP-A-2003-302862, and JP-A-2001-355172, all of
which belong to the present applicant.
[0043]
The diameter of fibers, which constitute a nonwoven fabric,
is normally selected to be around 0.1-100 urn. In a nonwoven fabric
SF-2704 25
of the present invention, a relatively thin fiber (for example,
of not more than 10 um) and a relatively thick fiber (for example,
of more than 10 um) may be used by either mixing them or layering
them. The diameter of fibers, which constitute a nonwoven fabric
5 of the present invention, is not particularly limited and the
fibers typically comprise continuous fibers in the spun-bonding
method.
[0044]
Fibers formed as described above can be entangled to produce
10 a nonwoven fabric. Entangling treatment by means of, for example,
needle punching, water jet treatment, ultrasonic sealing and the
like, or thermal fusion bonding treatment by a thermal embossing
roll can be carried out as a process for such entanglement.
Entangling process by thermal fusion bonding treatment using a
15 thermal embossing roll is particularly advantageous in the present
invention. In case of thermal fusion bonding treatment by a
thermal embossing roll, the area ratio of the embossing surface
of the embossing roll is appropriately determined and is typically
in a range of 5-30%.
20 Nonwoven fabric
Because a nonwoven fabric of the present invention obtained
as described above is composed of a particular composition, the
static friction coefficient thereof is in a range of 0.41-0.8.
[0045]
SF-2704 26
In cases where the static friction coefficient is less than
0.41, the slipping property is extremely enhanced so much as to
lose the productivity thereof. Moreover, in cases where the
static friction coefficient is more than 0.8, the flexibility of
5 a nonwoven fabric to be obtained could be insufficient. A
nonwoven fabric according to the present invention gives a greater
sense of softness as well as a greater sense of smoothness, hardly
raises naps, and has quite excellent flexibility.
[0046]
10 The bending resistance of the nonwoven fabric is typically
not more than 37, preferably not more than 35, and further
preferably not more than 31.
[0047]
The basis weight (the mass per unit area of a nonwoven
15 fabric) of the nonwoven fabric of the present invention is
typically in a range of 3-100 g/m2 and preferably of 7-60 g/m2.
[0048]
Fibers constituting the nonwoven fabric of the present
invention may be monocomponent type fibers or conjugate fibers,
20 such as sheath-core type, split type, sea-island type, and
side-by-side type conjugate fibers, and in case of the conjugate
fibers, a resin used to form a part of fibers may be a composition
according to the present invention. Moreover, the cross-section
of the fibers can take any of various known shapes, such as a
SF-2704 27
circular shape, a square shape and the like. Furthermore, a
nonwoven fabric of the present invention may be produced from a
mixture of two or more different fibers, and in this case at least
one fiber should be produced from a composition of the present
5 invention.
Laminated nonwoven fabric material
A nonwoven fabric of the present invention (hereinafter
sometimes referred to as "flexible nonwoven fabric" to
discriminate it from ordinary nonwoven fabrics) laminated with
10 various layers according to a usage is obtained.
[0049]
Specifically, examples of the layer can include, for example,
knitted fabrics, woven fabrics, nonwoven fabrics, films, and the
like. In order to laminate (stick) the flexible nonwoven fabric
15 on any other layer, any of various known methods can be adopted,
including, for example, thermal fusion bonding treatments such
as thermal embossing process, ultrasonic fusion bonding and the
like; mechanical entangling methods such as needle punching, water
jet treatment, and the like; methods using an adhesive agent such
20 as a hot melt adhesive, an urethane adhesive and the like;
extrusion lamination process; and the like.
[0050]
Examples of a nonwoven fabric laminated with the flexible
nonwoven fabric can include various known nonwoven fabrics, such
SF-2704 28
as a spunbond nonwoven fabric, a meltblown nonwoven fabric, a
wetlaid nonwoven fabric, a drylaid nonwoven fabric, an airlaid
pulp nonwoven fabric, a flash-spun nonwoven fabric, a split yarn
nonwoven fabric, and the like.
5 [0051]
Exemplary raw materials constituting such nonwoven fabrics
can include various known thermoplastic resins, for example, a
polyolefin such as a high pressure low density polyethylene, a
linear low density polyethylene (a so-called LLDPE), a high
10 density polyethylene, polypropylene, a polypropylene random
copolymer, poly(1-butene), poly(4-methyl-l-pentene), a random
copolymer of ethylene and propylene, a random copolymer of
ethylene and 1-butene, a random copolymer of propylene and
1-butene, and the like, all of which are homopolymers of an
15 a-olefin or copolymers of a-olefins, such as ethylene, propylene,
1-butene, 1-hexene, 4-methyl-l-pentene and 1-octene and the like;
polyester (polyethylene terephthalate, polybutylene
terephthalate, polyethylene naphthalate and the like), polyamide
(Nylon-6, Nylon-66, poly{m-xylene adipamide) and the like),
20 polyvinyl chloride, polyimide, a copolymer of ethylene and vinyl
acetate, polyacrylonitrile, polycarbonate, polystyrene, an
ionomer, a thermoplastic polyurethane or a mixture thereof, and
the like. Among these, a high pressure low density polyethylene,
a linear low density polyethylene (a so-called LLDPE), a high
SF-2704 29
density polyethylene, polypropylene, a polypropylene random
compolymer, polyethylene terephthalate, polyamide and the like
are preferred
[0052]
5 Preferred embodiments of a laminated material comprising
the flexible nonwoven fabric of the present invention include a
laminated material comprising the same with a spunbond nonwoven
fabric and/or a meltblown nonwoven fabric. Examples of the
laminated material include, specifically, laminated materials
10 comprising two layers composed of a spunbond nonwoven fabric/the
flexible nonwoven fabric, of a meltblown nonwoven fabric/the
flexible nonwoven fabric, and the like; laminated materials
comprising three layers composed of the flexible nonwoven fabric/a
spunbond nonwoven fabric/the flexible nonwoven fabric, of the
15 flexible nonwoven fabric/a spunbond nonwoven fabric/a meltblown
nonwoven fabric, of a spunbond nonwoven fabric/a meltblown
nonv/oven fabric/the flexible nonwoven fabric, of the flexible
nonwoven fabric/a meltblown nonwoven fabric/the flexible
nonwoven fabric, and the like; or laminated materials comprising
20 four or more layers composed of the flexible nonwoven fabric/a
spunbond nonwoven fabric/a meltblown nonwoven fabric/a spunbond
nonwoven fabric, of the flexible nonwoven fabric/a spunbond
nonwoven fabric/a meltblown nonwoven fabric/the flexible
nonwoven fabric, and the like. The basis weight of each layer
SF-2704 30
of nonwoven fabrics to be laminated is preferred to be in a range
of 2-25 g/m2. A spunbond nonwoven fabric comprising the
above-described ultra-fine fibers is obtained by controlling
(selecting) production conditions for spun-bonding. Such a
5 laminated nonwoven fabric material turns to be a laminated
material which makes good use of the flexibility of the flexible
nonwoven fabric of the present invention and has excellent surface
smoothness and an improved water-resisting property and/or
workability.
10 [0053]
Air permeating (moisture permeating) films are preferred
as films to be laminated with the flexible nonwoven fabric of the
present invention, which makes good use of the air permeability
characteristic of the flexible nonwoven fabric of the present
15 invention. Examples of such an air permeability film can include
various known air permeability films, for example, a film having
moisture permeability composed of a thermoplastic elastomer, such
as a polyurethane elastomer, a polyester elastomer, a polyamide
elastomer and the like; porous films produced by stretching a film
20 made of a thermoplastic resin containing inorganic or organic fine
particles to form multiple pores; and the like. A polyolefin such
as a high pressure low density polyethylene, a linear low density
polyethylene (a so-called LLDPE), a high density polyethylene,
polypropylene, a polypropylene random copolymer, or a composition
SF-2704 31
thereof and the like is preferred as thermoplastic resins used
for the porous films.
[0054]
A laminated material comprising an air permeability film
5 laminated with the flexible nonwoven fabric of the present
invention can turn to be a cloth-like composite material which
makes good use of the bulkiness and the flexibility of the flexible
nonwoven fabric and has a quite strong water-resisting property.
The nonwoven fabric of the present invention is rich in flexibility
10 so that it can be used for a wide variety of hygiene materials,
a disposable diaper, a sanitary napkin, absorbent articles, a
disposable mask, an adhesive bandage, a patch, a disposable gown
for surgery, a fire fighter suit, and the like, a variety of medical
films or sheets, a medical gown, a surgery cap, a disposable cap,
15 and the like.
[0055]
Now, specific applications of a nonwoven fabric of the
present invention will be described in detail below by way of
examples.
20 Absorbent articles
Absorbent articles, such as a disposable diaper or a
sanitary napkin, require excellent feeling and good texture.
Since the nonwoven fabric of the present invention has excellent
flexibility, utilizing this flexibility allows the nonwoven
SF-2704 32
fabric to be suitably used in parts including, specifically, the
topsheet, backsheet, waistband (elongation tape, side flaps),
fastening tape, three dimensional gather, leg cuff of a
development-type disposable diaper or a pants-type disposable
5 diaper, additionally the side panel of a pants-type disposable
diaper, and the like. Using the present invention for those parts
enables excellent texture to be obtained.
Disposable mask
A disposable mask is generally composed of a covering part,
10 which covers a mouth and the surrounding area thereof, and ear
loops, which extend from both sides of the covering part.
Excellent texture is required for a mask because especially ear
loops are in contact with the face of a wearer while he/she wears
the mask. Since the nonwoven fabric of the present invention has
15 excellent texture, the nonwoven fabric can meet those requirements
by using it in ear loops of a disposable mask.
Adhesive bandage and patch
Base materials used in an adhesive bandage and the like have
required sufficient air permeability, which prevents irritation
20 of skin, and flexibility, which does not give a sense of stiffness.
Since the nonwoven fabric of the present invention has air
permeability as well as flexibility, the nonwoven fabric is
suitably used as a base material for such an adhesive bandage and
the like.
SF-2704 33
Disposable gown for surgery and fire fighter suit
The movable joint parts of a disposable gown for surgery,
fire fighter suit or the like, such as the arm part, the elbow
part, the shoulder part and the sleeve, require air permeability
5 and flexibility. Since the nonwoven fabric of the present
invention is a nonwoven fabric as well as an ordinary nonwoven
fabric is and it has air permeability and also further excellent
flexibility, the nonwoven fabric of the present invention is
suitably used as a production material used in such a disposable
10 gown for surgery, fire fighter suit and the like.
[0056]
As described above, the nonwoven fabric of the present
invention is a polypropylene nonwoven fabric excellent in
flexibility and can be used as a nonwoven fabric for a wide variety
15 of applications including hygiene materials.
[0057]
The nonwoven fabric of the present invention has outstanding
sensory properties including especially excellent texture, a
greater sense of smoothness and softness, flexibility and the like,
20 and achieves a good balance among them and therefore a fitting
property which allows articles to follow the movement of the body
is obtained in a diaper and/or a sanitary napkin. Furthermore,
since the nonwoven fabric of the present invention is a nonwoven
fabric and therefore has good air permeability, it can impart
SF-2704 34
especially excellent performance to them.
EXAMPLES
[0058]
Now, the present invention will be described more
5 specifically with reference to Examples. However, the present
invention is not limited to these Examples.
[0059]
Physical properties and the like in Examples and Comparative
Examples were determined by the methods below.
10 [0060]
(1) Basis weight [g/m2]
Five pieces of samples in a size of 100 mm (MD) x 100 mm
(CD) were collected from a nonwoven fabric. Any five positions
on the fabric were selected to collect the samples. The mass (g)
15 of each collected sample piece was then measured using a scale
electronic balance {produced by Kensei Co., Ltd.). The average
mass of all sample pieces was obtained. The obtained average was
converted to a mass (g) per 1 m2 and the resulting value was rounded
to one decimal place to give the basis weight [g/m2] of each
20 nonwoven fabric sample.
[0061]
(2) Thickness [urn]
Five pieces of samples in a size of 100 mm (MD) x 100 mm
(CD) were collected from a nonwoven fabric. Any three positions
SF-2704 35
on the fabric were selected to collect the samples. The thickness
[urn] of each collected sample piece was then measured in accordance
with JIS L 1096 by using a load-applying type thickness gauge
(produced by Ozaki MFG Co., Ltd.) . The average thickness of all
5 sample pieces was obtained and rounded to the closest whole number
to give the thickness [um] of each nonwoven fabric sample.
[0062]
(3) Fiber diameter [um]
Five pieces of samples in a size of 10 mm (MD) x 10 mm (CD)
10 were collected from a nonwoven fabric. Any one position on the
fabric was selected to collect the samples. An image of each
sample piece was then captured at 20Ox magnification under an
optical microscope and the image was analyzed by image-based
dimensional measurement software (Pixs2000 Version 2.0; produced
15 by Inotech Co., Ltd.) . The diameter was measured in ten fibers
from each sample piece and the average fiber diameter of each
sample piece was obtained. The obtained average was rounded to
one decimal place to give the fiber diameter [um] of each nonwoven
fabric sample.
20 [0063]
(4) LC value
Two pieces of samples in a size of 150 mm (MD) x 150 mm (CD)
were collected from a nonwoven fabric. Any two positions on the
fabric were selected to collect the samples. The sample pieces
SF-2704 36
were then subjected to a compression test using a KES-FB system
produced by Kato Tech Co. , Ltd. to determine the LC value [-] under
measuring conditions suitable for analyzing a knitted fabric with
high sensitivity. The average LC value of all sample pieces was
5 obtained and rounded to two decimal places to give the LC value
[-] of each nonwoven fabric sample. The smaller LC value
represents the smaller work per thickness done by compression at
an early stage and more excellent flexibility.
[0064]
10 (5) Static friction coefficient [-]
Each three pieces of samples in a size of 300 mm (MD) x 100
mm (CD) and in a size of 100 mm (MD) x 100 mm (CD) were collected
from a nonwoven fabric. Any three positions (six positions in
15 total) on the fabric were selected to collect the samples. Then,
the static friction coefficient [-] was measured between the
embossed surfaces of the both types of the sample pieces in
accordance with JIS K 7125, in which a sample piece in a size of
100 mm (MD) x 100 mm (CD) was attached on a sliding piece to allow
20 its embossed surface to face outward and a sample piece in a size
of 300 mm (MD) x 100 mm (CD) was attached on a test bench to allow
its embossed surface to be rubbed. The average static friction
coefficient of all sample pieces was obtained and rounded to two
decimal places to give the static friction coefficient [-] of each
SF-2704 37
nonwoven fabric sample.
[0065]
(6) Strength in CD [N/25 mm]
Five pieces of CD samples in a size of 25 mm (MD) x 200 mm
5 (CD) were collected from each nonwoven fabric. Any five positions
on the fabric were selected to collect the samples. Each
collected sample piece was then stretched to determine the maximum
load [N] by using a universal tensile tester (type IM-201; produced
by INTESCO Co., Ltd.) under the following conditions: a chuck
10 distance of 100 mm, a tensile speed of 100 mm/min. The average
strength in CD of all sample pieces was obtained and rounded to
one decimal place to give the strength in CD [N/25 mm] of each
nonwoven fabric sample.
[0066]
15 (7) Raised nap [score]
Two pieces of CD samples in a size of 150 mm (MD) x 150 mm
(CD) were collected from each nonwoven fabric. Any two positions
on the fabric were selected to collect the samples. Each
collected sample piece was then subjected to a rubbing test using
20 a Gakushin-type rubbing tester for color fastness (a new type
product, NR-100; produced by Daiei Kagaku Seiki MFG Co., Ltd.)
in accordance with the test method for color fastness to rubbing
JIS L 0849. The non-embossed surface of each sample piece was
reciprocally rubbed 50 times in machine direction (MD) with a cloth
SF-2704 38
tape (No. 1532; produced by Teraoka Seisakusho Co., Ltd.) attached
to a rubbing member, while a load of 300 g was applied to the sample
piece. The appearance of the rubbed surface was ranked for raised
nap in each sample piece based on the following criteria and the
5 lesser rank was taken as the raised nap [score] of each nonwoven
fabric sample:
Grade 1: fibers are taken away so that a sample piece is
torn;
Grade 2: fibers are significantly taken away so that a sample
10 piece is worn off;
Grade 2.5: large pills of fibers are clearly observed and
some fibers start rising at multiple positions;
Grade 3: clear pills of fibers start to be formed and
multiple small pills are observed;
15 Grade 3.5: naps are raised at such an extent that a small
pill starts to be formed at one position;
Grade 4: no raised nap is observed.
[0067]
(8) Texture
20 The texture of each nonwoven fabric was identified by 20
panelists and evaluated based on the following criteria:
A: in cases where 20 out of the twenty panelists felt a sense
of flexibility;
B: in cases where 15 to 19 out of the twenty panelists felt
SF-2704 39
a sense of flexibility;
C: in cases where 10 to 14 out of the twenty panelists felt
a sense of flexibility;
D: in cases where 5 to 9 out of the twenty panelists felt
5 a sense of flexibility;
E: in cases where 0 to 4 out of the twenty panelists felt
a sense of flexibility.
(9) Bending resistance (Cantilever method)
Bending resistance test was in accordance with the method
10 8.19.1 A (45° cantilever method) in JIS1096.
[0068]
Five pieces of samples each in a size of 2 cm x 15 cm were
collected from each fabric sample both in its machine direction
and in its cross direction. A sample piece was placed on the smooth
15 surface of a horizontal stage having a downward slope at an angle
of 45 degree on one end, such that the short side of the sample
piece was aligned to the baseline of a scale on the stage. The
sample piece was then gently slid toward the slope by any suitable
way. When the central point of one end of the sample piece had
20 reached the slope, the position of the other end was determined
by reading the scale. The bending resistance of the sample piece
is represented by the distance {mm) along which the sample piece
has moved. Five sample pieces in each direction were used for
the measurement and the average distances were obtained in machine
SF-2704 40
direction (MD) and in cross direction (CD), respectively. The
value obtained by the following equation was rounded to one decimal
place to calculate the bending resistance of each sample fabric:
bending resistance = {([the average in MD]A2 + [the average in
5 CD]A2)/2]} ~ (1/2).
[Example 1]
A composition composed of 100 parts by weight of a
crystalline PP (product name: Prime Polypro S119; melting point:
156°C, MFR (measured at 230°C with a load of 2.16 kg in accordance
10 with ASTM D1238) : 62 g/10 min; produced by Prime Polymer Co. , Ltd. ;
hereinafter abbreviated to "Al") and 0.15 part by weight of oleic
acid amide (hereinafter abbreviated to "CI") added thereto was
used to perform melt spinning by spun-bonding method.
[0069]
15 A single screw extruder was used as an extruder and both
a resin temperature and a dye temperature were set at 220°C, and
a cooling air temperature was set at 20°C. At that time, the
spinning speed was 2750 m/min.
[0070]
20 Filaments obtained by melt spinning were deposited on a
collection surface to produce a nonwoven fabric, followed by
peeling off the produced nonwoven fabric from the collection
surface. The nonwoven fabric was thermal-bonded by hot embossing
technique using the following conditions to obtain a spunbond
SF-2704 41
nonwoven fabric: a ratio of area occupied by embossing patterns
of 6.7%, an area occupied by each embossed pattern of 0.19 mm2,
a heating temperature of 130°C, and a linear pressure of 60 kg/cm.
The basis weight of the spunbond nonwoven fabric was 13.8 g/m2.
5 The obtained spunbond nonwoven fabric was evaluated by the
above-described methods. The results of the evaluation are shown
in Table 1.
[0071]
[Example 2]
10 A spunbond nonwoven fabric was obtained by a similar method
to that in Example 1 except that 0.30 part by weight of CI was
used, and the obtained spunbond nonwoven fabric was evaluated by
the above-described methods. The results of the evaluation are
shown in Table 1.
15 [0072]
[Example 3]
After 90 parts by weight of Al and 10 parts by weight of
a propylene polymer (product name: L-MODU S901; melting point:
75°C, MFR {measured at 230°C with a load of 2.16 kg in accordance
20 with ASTM D1238): 80 g/10 min; produced by Idemitsu Kosan Co.,
Ltd.; hereinafter abbreviated to "Bl") were blended, a composition
composed of 100 parts by weight of the Al/Bl mixture and 0.30 part
by weight of CI added thereto was used to obtain a spunbond nonwoven
fabric by a similar method to that in Example 1 and the obtained
SF-2704 42
spunbond nonwoven fabric was evaluated by the above-described
methods. The results of the evaluation are shown in Table 1.
[0073]
[Example 4]
5 A spunbond nonwoven fabric was obtained by a similar method
to that in Example 3 except that the blending ratio of Al to Bl
was changed to a ratio of 80: 20 in parts by weight, and the obtained
spunbond nonwoven fabric was evaluated by the above-described
methods." The results of the evaluation are shown in Table 1.
10 [0074]
[Example 5]
After 90 parts by weight of-Al and 10 parts by weight of
a propylene polymer {product name: L-MODU S600; melting point:
70°C, MFR (measured at 230°C with a load of 2.16 kg in accordance
15 with ASTM D1238): 300 g/10 min; produced by Idemitsu Kosan Co.,
Ltd.; hereinafter abbreviated to WB2") were blended, a composition
composed of 100 parts by weight of the A1/B2 mixture and 0.30 part
by weight of CI added thereto was used to obtain a spunbond nonwoven
fabric by a similar method to that in Example 1 and the obtained
20 spunbond nonwoven fabric was evaluated by the above-described
methods. The results of the evaluation are shown in Table 1.
[0075]
[Example 6]
After 90 parts by weight of Al and 10 parts by weight of
SF-2704 43
a propylene polymer (product name: TAFMER XM-7070; melting point:
75°C/ MFR (measured at 230°C with a load of 2.16 kg in accordance
with ASTM D1238) : 7 g/10 min; produced by Mitsui Chemicals, Inc. ;
hereinafter abbreviated to WB3") were blended, a composition
5 composed of 100 parts by weight of the A1/B3 mixture and 0.30 part
by weight of CI added thereto was used to obtain a spunbond nonwoven
fabric by a similar method to that in Example 1 and the obtained
spunbond nonwoven fabric was evaluated by the above-described
methods. The results of the evaluation are shown in Table 2.
10 [0076]
[Example 7]
A spunbond nonwoven fabric was obtained by a similar method
to that in Example 6 except that the blending ratio of Al to B3
was changed to a ratio of 80: 20 in parts by weight, and the obtained
15 spunbond nonwoven fabric was evaluated by the above-described
methods. The results of the evaluation are shown in Table 2.
[0077]
[Example 8]
After 80 parts by weight of Al and 20 parts by weight of
20 a propylene polymer (product name: Vistamaxx VM2125; melting
point: 160°C, MFR (measured at 230°C with a load of 2.16 kg in
accordance with ASTM D1238) : 60 g/10 min; produced by Exxon Mobil
Co.; hereinafter abbreviated to XVA2") were blended, a composition
composed of 100 parts by weight of the A1/A2 mixture and 0.30 part
SF-2704 44
by weight of CI added thereto was used to obtain a spunbond nonwoven
fabric by a similar method to that in Example 1 and the obtained
spunbond nonwoven fabric was evaluated by the above-described
methods. The results of the evaluation are shown in Table 2.
5 [0078]
[Comparative Example 1]
A composition composed of 100 parts by weight of Al and 0.15
part by weight of erucic acid amide (hereinafter abbreviated to
"C2") added thereto was used to obtain a spunbond nonwoven fabric
10 by a similar method to that in Example 1, and the obtained spunbond
nonwoven fabric was evaluated by the above-described methods.
The results of the evaluation are shown in Table 3.
[0079]
[Comparative Example 2]
15 A spunbond nonwoven fabric was obtained by a similar method
to that in Comparative Example 1 except that 0.30 part by weight
of C2 was used, and the obtained spunbond nonwoven fabric was
evaluated by the above-described methods. The results of the
evaluation are shown in Table 3.
20 [0080]
[Comparative Example 3]
A spunbond nonwoven fabric was obtained by a similar method
to that in Comparative Example 1 except that 0.45 part by weight
of C2 was used, and the obtained spunbond nonwoven fabric was
SF-2704 45
evaluated by the above-described methods. The results of the
evaluation are shown in Table 3.
[0081]
[Comparative Example 4]
5 After 90 parts by weight of Al and 10 parts by weight of
Bl were blended, a composition composed of 100 parts by weight
of the Al/Bl mixture and 0.30 part by weight of C2 added thereto
was used to obtain a spunbond nonwoven fabric by a similar method
to that in Example 1, and the obtained spunbond nonwoven fabric
10 was evaluated by the above-described methods. The results of the
evaluation are shown in Table 3.
[0082]
[Comparative Example 5]
A spunbond nonwoven fabric was obtained by a similar method
15 to that in Comparative Example 4 except that Bl used in Comparative
Example 4 was changed to B2, and the obtained spunbond nonwoven
fabric was evaluated by the above-described methods. The results
of the evaluation are shown in Table 3.
[0083]
20 [Comparative Example 6]
A spunbond nonwoven fabric was obtained by a similar method
to that in Comparative Example 4 except that Bl used in Comparative
Example 4 was changed to B3, and the obtained spunbond nonwoven
fabric was evaluated by the above-described methods . The results
SF-2704 46
of the evaluation are shown in Table 3.
[0084]
[Table 1]
SF-2704 50
According to the above Examples, the nonwoven fabrics in
accordance with the present invention resulted in showing
excellent texture, causing less raised nap, achieving an excellent
balance between its static friction coefficient and strength, and
5 showing excellent flexibility and bending resistance as well.
INDUSTRIAL APPLICABILITY
[0087]
The spunbond nonwoven fabrics of the present invention are
suitably used for a wide variety of textile products, such as for
10 example disposable diapers, sanitary napkins, hygiene products,
clothing materials, surgical dressings, wrapping materials and
the like.
CLAIMS
1. A spunbond nonwoven fabric comprising a propylene polymer
composition comprising a propylene polymer (A) having a melting
5 point of not less than 120°C and a fatty acid amide having not
less than 15 and not more than 21 carbon atoms.
2. The spunbond nonwoven fabric according to claim 1, wherein
the fatty acid amide having not less than 15 and not more than
10 21 carbon atoms is oleic acid amide.
3. The spunbond nonwoven fabric according to claim 1 or 2,
wherein the propylene polymer composition further comprises a
propylene polymer (B) having a melting point of less than 120°C.
15
4. The spunbond nonwoven fabric according to claim 3, wherein
the propylene polymer composition comprises, based on 100 parts
by weight of the total of the propylene polymer (A) having a melting
point of not less than 120°C and the propylene polymer (B) having
20 a melting point of less than 120°C/
the propylene polymer (A) having a melting point of not less
than 120°C in a range of 70 to 99.9 parts by weight;
the propylene polymer (B) having a melting point of less
than 120°C in a range of 30 to 0.1 parts by weight; and
SF-2704 52
the fatty acid amide having not less than 15 and not more
than 21 carbon atoms in a range of 0.01 to 1 part by weight.
5. The spunbond nonwoven fabric according to any one of claims
5 1 to 3, wherein the propylene polymer (B) having a melting point
of less than 120°C is a propylene homopolymer or a random copolymer
composed of propylene and an a-olefin having carbon atoms of 4
to 20.
10 6. The spunbond nonwoven fabric according to claim 5, wherein
the propylene polymer (B) having a melting point of less than 120°C
is a copolymer composed of propylene and an a-olefin having carbon
atoms of 4 to 20.
15 7. The spunbond nonwoven fabric according to claim 6, wherein
the content of the a-olefin in the copolymer is 0.1% by mole or
more and less than 90% by mole.
8. The spunbond nonwoven fabric according to any one of claims
20 3 to 7, wherein the propylene polymer (B) having a melting point
of less than 120°C is a low-crystalline polypropylene which
satisfies the following conditions (a) to (f):
(a) [mmmm] - 20-60% by mole;
(b) [rrrr]/(l-[mmmm]) < 0.1;
SF-2704 53
(c) [rmrm] > 2.5% by mole;
(d) [mm] x '[xr]/[mr]2 < 2.0;
(e) mass-average molecular weight (Mw) = 10,000 to 200,000; ..
(f) molecular-weight distribution (Mw/Mn) < 4.
9. . The spunbond nonwoven fabric according to any one of claims
1 to 4, wherein the propylene polymer (A) having a melting point
of not less than 120°C is a propylene homopolymer or a random
copolymer composed of propylene and an a~olefin.
10. .The spunbond nonwoven fabric according to any one of claims
1 to 4, comprising a propylene homopolymer and a random copolymer
composed of propylene and an a-olefin as the propylene polymer
(A) having a melting point of not less than 120°C.
11. A laminated nonwoven fabric material comprising the
spunbond nonwoven fabric according to any one of claims 1 to 10.
12. An absorbent article using the spunbond nonwoven fabric
according to any one of claims 1 to 10.
Documents
Application Documents
| # | Name | Date |
|---|---|---|
| 1 | 3440-DELNP-2015-Response to office action [21-02-2025(online)].pdf | 2025-02-21 |
| 1 | Other relevant documents.pdf | 2015-04-30 |
| 2 | 3440-DELNP-2015-ASSIGNMENT WITH VERIFIED COPY [23-10-2024(online)].pdf | 2024-10-23 |
| 2 | GPA.pdf | 2015-04-30 |
| 3 | Form PCT-IB-304.pdf | 2015-04-30 |
| 3 | 3440-DELNP-2015-FORM-16 [23-10-2024(online)].pdf | 2024-10-23 |
| 4 | Form 3.pdf | 2015-04-30 |
| 4 | 3440-DELNP-2015-POWER OF AUTHORITY [23-10-2024(online)].pdf | 2024-10-23 |
| 5 | Form 2 + Specification.pdf | 2015-04-30 |
| 5 | 3440-DELNP-2015-PROOF OF ALTERATION [03-11-2023(online)].pdf | 2023-11-03 |
| 6 | 3440-DELNP-2015.pdf | 2015-05-05 |
| 6 | 3440-DELNP-2015-RELEVANT DOCUMENTS [11-09-2023(online)].pdf | 2023-09-11 |
| 7 | 3440-DELNP-2015-IntimationOfGrant18-01-2023.pdf | 2023-01-18 |
| 7 | 3440-delnp-2015-Form-1-(05-05-2015).pdf | 2015-05-05 |
| 8 | 3440-DELNP-2015-PatentCertificate18-01-2023.pdf | 2023-01-18 |
| 8 | 3440-delnp-2015-Correspondence Others-(05-05-2015).pdf | 2015-05-05 |
| 9 | 3440-DELNP-2015-FORM 3 [13-04-2021(online)].pdf | 2021-04-13 |
| 9 | 3440-marked.pdf | 2015-06-09 |
| 10 | 3440-DELNP-2015-FORM 3 [22-09-2020(online)].pdf | 2020-09-22 |
| 10 | 3440-form-13.pdf | 2015-06-09 |
| 11 | 3440-cont.pdf | 2015-06-09 |
| 11 | 3440-DELNP-2015-FORM 3 [22-11-2019(online)].pdf | 2019-11-22 |
| 12 | 3440-amended.pdf | 2015-06-09 |
| 12 | 3440-DELNP-2015-ABSTRACT [20-05-2019(online)].pdf | 2019-05-20 |
| 13 | 3440-DELNP-2015-CLAIMS [20-05-2019(online)].pdf | 2019-05-20 |
| 13 | 3440-delnp-2015-Form-3-(23-06-2015).pdf | 2015-06-23 |
| 14 | 3440-DELNP-2015-COMPLETE SPECIFICATION [20-05-2019(online)].pdf | 2019-05-20 |
| 14 | 3440-delnp-2015-Correspondence Other-(23-06-2015).pdf | 2015-06-23 |
| 15 | 3440-DELNP-2015-FER_SER_REPLY [20-05-2019(online)].pdf | 2019-05-20 |
| 15 | 3440-marked.pdf_4303.pdf | 2015-06-24 |
| 16 | 3440-DELNP-2015-OTHERS [20-05-2019(online)].pdf | 2019-05-20 |
| 16 | 3440-form-13.pdf_4301.pdf | 2015-06-24 |
| 17 | 3440-DELNP-2015-PETITION UNDER RULE 137 [17-05-2019(online)].pdf | 2019-05-17 |
| 17 | 3440-cont.pdf_4310.pdf | 2015-06-24 |
| 18 | 3440-amended.pdf_4302.pdf | 2015-06-24 |
| 18 | 3440-DELNP-2015-Verified English translation (MANDATORY) [30-01-2019(online)].pdf | 2019-01-30 |
| 19 | 3440-DELNP-2015-FER.pdf | 2018-12-19 |
| 19 | Form 3 [21-10-2016(online)].pdf | 2016-10-21 |
| 20 | 3440-DELNP-2015-FORM 3 [03-10-2017(online)].pdf | 2017-10-03 |
| 20 | 3440-DELNP-2015-FORM 3 [12-03-2018(online)].pdf | 2018-03-12 |
| 21 | 3440-DELNP-2015-FORM 3 [03-10-2017(online)].pdf | 2017-10-03 |
| 21 | 3440-DELNP-2015-FORM 3 [12-03-2018(online)].pdf | 2018-03-12 |
| 22 | 3440-DELNP-2015-FER.pdf | 2018-12-19 |
| 22 | Form 3 [21-10-2016(online)].pdf | 2016-10-21 |
| 23 | 3440-amended.pdf_4302.pdf | 2015-06-24 |
| 23 | 3440-DELNP-2015-Verified English translation (MANDATORY) [30-01-2019(online)].pdf | 2019-01-30 |
| 24 | 3440-DELNP-2015-PETITION UNDER RULE 137 [17-05-2019(online)].pdf | 2019-05-17 |
| 24 | 3440-cont.pdf_4310.pdf | 2015-06-24 |
| 25 | 3440-DELNP-2015-OTHERS [20-05-2019(online)].pdf | 2019-05-20 |
| 25 | 3440-form-13.pdf_4301.pdf | 2015-06-24 |
| 26 | 3440-DELNP-2015-FER_SER_REPLY [20-05-2019(online)].pdf | 2019-05-20 |
| 26 | 3440-marked.pdf_4303.pdf | 2015-06-24 |
| 27 | 3440-DELNP-2015-COMPLETE SPECIFICATION [20-05-2019(online)].pdf | 2019-05-20 |
| 27 | 3440-delnp-2015-Correspondence Other-(23-06-2015).pdf | 2015-06-23 |
| 28 | 3440-DELNP-2015-CLAIMS [20-05-2019(online)].pdf | 2019-05-20 |
| 28 | 3440-delnp-2015-Form-3-(23-06-2015).pdf | 2015-06-23 |
| 29 | 3440-amended.pdf | 2015-06-09 |
| 29 | 3440-DELNP-2015-ABSTRACT [20-05-2019(online)].pdf | 2019-05-20 |
| 30 | 3440-cont.pdf | 2015-06-09 |
| 30 | 3440-DELNP-2015-FORM 3 [22-11-2019(online)].pdf | 2019-11-22 |
| 31 | 3440-DELNP-2015-FORM 3 [22-09-2020(online)].pdf | 2020-09-22 |
| 31 | 3440-form-13.pdf | 2015-06-09 |
| 32 | 3440-DELNP-2015-FORM 3 [13-04-2021(online)].pdf | 2021-04-13 |
| 32 | 3440-marked.pdf | 2015-06-09 |
| 33 | 3440-delnp-2015-Correspondence Others-(05-05-2015).pdf | 2015-05-05 |
| 33 | 3440-DELNP-2015-PatentCertificate18-01-2023.pdf | 2023-01-18 |
| 34 | 3440-delnp-2015-Form-1-(05-05-2015).pdf | 2015-05-05 |
| 34 | 3440-DELNP-2015-IntimationOfGrant18-01-2023.pdf | 2023-01-18 |
| 35 | 3440-DELNP-2015-RELEVANT DOCUMENTS [11-09-2023(online)].pdf | 2023-09-11 |
| 35 | 3440-DELNP-2015.pdf | 2015-05-05 |
| 36 | 3440-DELNP-2015-PROOF OF ALTERATION [03-11-2023(online)].pdf | 2023-11-03 |
| 36 | Form 2 + Specification.pdf | 2015-04-30 |
| 37 | Form 3.pdf | 2015-04-30 |
| 37 | 3440-DELNP-2015-POWER OF AUTHORITY [23-10-2024(online)].pdf | 2024-10-23 |
| 38 | Form PCT-IB-304.pdf | 2015-04-30 |
| 38 | 3440-DELNP-2015-FORM-16 [23-10-2024(online)].pdf | 2024-10-23 |
| 39 | GPA.pdf | 2015-04-30 |
| 39 | 3440-DELNP-2015-ASSIGNMENT WITH VERIFIED COPY [23-10-2024(online)].pdf | 2024-10-23 |
| 40 | Other relevant documents.pdf | 2015-04-30 |
| 40 | 3440-DELNP-2015-Response to office action [21-02-2025(online)].pdf | 2025-02-21 |
Search Strategy
| 1 | 3440DELNP2015_SS_11-06-2018.pdf |