Patent Application
20190110529
The present invention relates to a composite textile sheet, a disposable textile product that uses the composite textile sheet, a glove, a raincoat, and a method for manufacturing a disposable textile product.
Ordinarily, a so-called disposable product that is used once or multiple times and then discarded is widely used in clothing such as an undergarment, a shirt, a diaper, a glove, and a raincoat, and these products are growing in widespread popularity for use in areas such as for home use and medical care. Fabrics used in the disposable product are often fabrics which use a nonwoven fabric or a synthetic resin sheet as a main material, and these fabrics exhibit merits of being lightweight and easy to process. However, on the other hand, disposable products that use these fabrics are inferior in terms of the moisture transpiration property, and are also inferior in terms of comfort when worn including causing a stuffiness when used for an extended period of time, or causing stickiness on the skin by sweat and other body fluids. While there have been many technical proposals relating to improving the air permeability of fabrics for disposable products, currently, moisture transpiration property is not being sufficiently examined.
In the related art, several clothing goods have been proposed that use a composite formed by laminating a nonwoven fabric, a porous film, and staple fibers using an adhesive, and thus are imparted with air permeability and resistance to liquid. For example, the Patent Document 1 describes a composite sheet formed by laminating a surface web made from a nonwoven fabric, a microporous film, and an internal web made from cotton. In addition, several pants-type disposable diapers have also been proposed as a disposable textile product. For example, the Patent Document 2 describes a pants-type disposable diaper made from an exterior member and an absorbent body, with the absorbent body connected in a detachable manner to a crotch part of the exterior member.
While the composite sheet described by Patent Document 1 has a microporous film, the composite sheet does not exhibit a sufficient moisture transpiration property. In addition, with respect to the pants-type disposable diaper described in Patent Document 2, the exterior member is formed from a nonwoven fabric, and is therefore inferior in terms of the moisture transpiration property, and has problems such as causing stuffiness or stickiness to the skin due to sweat and other body fluids. Patent Document 2 also discloses that a stretchable material is disposed around the waist, abdomen, and legs of the pants-type disposable diaper, and the fit feeling on the wearer is thereby improved. However, a significant amount of stretchable material is used, and the stretchable material around the legs in particular is disposed in a curved manner, leading to problems of the manufacturing not being easy and costs being incurred.
The present invention was developed in order to realize a disposable textile product that exhibits an excellent moisture transpiration property and does not cause a stuffiness or sticky feeling when worn, and an object of the present invention is to provide a composite textile sheet that can be used as a fabric for manufacturing a disposable textile product that does not cause a stuffiness or a stickiness. Another object of the present invention is to provide a disposable textile product that uses the composite textile sheet and exhibits an excellent moisture transpiration property. Yet another object of the present invention is to provide a glove and a raincoat as a disposable textile product having an excellent moisture transpiration property. In addition, another object of the present invention is to provide a manufacturing method that can be used to easily and inexpensively manufacture a disposable textile product.
The present invention provides the following to solve the problems above.
(1) A composite textile sheet including a multi-ply sheet that is formed by laminating a textile sheet having air permeability and a textile material sheet having liquid diffusibility; wherein the textile sheet and the textile material sheet are in mutual contact; in a plane of mutual contact, a bonded region in which the textile sheet and the textile material sheet are bonded, and a non-bonded region in which the textile sheet and the textile material sheet are not bonded, are formed; the non-bonded region includes a space section; and a moisture transpiration path is formed, and through the moisture transpiration path, the space section, a textile gap of the textile sheet, and a textile gap of the textile material sheet mutually communicate.
(2) A disposable textile product formed using the composite textile sheet described in (1).
(3) A glove as the disposable textile product described in (2), wherein the glove is formed by bonding: a first composite textile sheet for a glove, formed by laminating a first textile sheet, the textile material sheet, an elastic member, and a second textile sheet; and a second composite textile sheet for a glove, formed by laminating the first textile sheet, the textile material sheet, and the second textile sheet.
(4) A raincoat as the disposable textile product described in (2), wherein the raincoat is formed by bonding: a first composite textile sheet for a raincoat, formed by laminating the first textile sheet, the elastic member, the textile material sheet, and a moisture permeable film; and a second composite textile sheet for a raincoat, obtained by laminating the first textile sheet, the textile material sheet, and the moisture permeable film.
(5) A method for manufacturing a disposable textile product, the method including the steps of: manufacturing a first composite textile sheet by supplying each of a textile sheet having air permeability and a textile material sheet having liquid diffusibility, and partially bonding the sheets through a bonding means to form a multi-ply sheet; manufacturing a second composite textile sheet by a similar step as described above; bonding the first composite textile sheet and the second composite textile sheet; and cutting to a prescribed shape at the same time as bonding or after bonding.
The composite textile sheet according to an embodiment of the present invention has an excellent moisture transpiration property, and can be favorably used as a fabric for a disposable textile product. In addition, a disposable textile product that uses the composite textile sheet according to an embodiment of the present invention exhibits an advantageous effect of providing a comfortable wear feeling without causing stuffiness or stickiness during use. Furthermore, the glove and raincoat according to an embodiment of the present invention do not lead to sweaty skin or heat accumulation even when worn for an extended period of time, and have an advantageous effect of being able to improve product value as a disposable glove and as a disposable raincoat. Moreover, the method for manufacturing a disposable textile product according to an embodiment of the present invention provides an advantageous effect of enabling the easy and economical manufacture of a disposable textile product provided with an unprecedented characteristic of having an excellent moisture transpiration property.
Embodiments of the present invention will be explained below with reference to the drawings. However, the embodiments described herein are merely examples of the implementation of the present invention, and the present invention is not restricted in any way by the matters described in the following embodiments. A composite textile sheet 1 of the present embodiment can be applied as a fabric for various disposable textile products. Examples of disposable textile products that can use the composite textile sheet 1 include gloves 310, 310a (see
The composite textile sheet 1 according to a first embodiment of the present invention is described.
The composite textile sheet 1 illustrated in
In the composite textile sheet 1, the moisture permeable film 70 is preferably layered at a position directly facing the textile material sheet 4. With such a configuration, the escape of liquid outwardly from the textile material sheet 4 can be more effectively suppressed while ensuring that a moisture transpiration function is exhibited by the multi-layered structure of the first textile sheet 2 and the textile material sheet 4. At this time, from the perspective of ensuring that the moisture transpiration function is exhibited by the multi-layered structure of the first textile sheet 2 and the textile material sheet 4, the moisture permeable film 70 is preferably layered to avoid a position directly facing the first textile sheet 2, which is slated to be positioned at the skin surface side. Therefore, in a case where the composite textile sheet 1 has three layers including the first and second textile sheets 2, 3 and the textile material sheet 4, the composite textile sheet 1 preferably has the moisture permeable film 70 interposed between the second textile sheet 3 and the textile material sheet 4 as illustrated in
Furthermore, in a composite textile sheet 1 having a two-layer configuration of the first textile sheet 2 or the second textile sheet 3, and the textile material sheet 4, in a case where the moisture permeable film 70 is layered, as illustrated in
In
In an embodiment in which the composite textile sheet 1 is configured as a composite textile sheet made from two layers including the first textile sheet 2 or the second textile sheet 3, and the textile material sheet 4, the first textile sheet 2 or the second textile sheet 3 and the textile material sheet 4 are in mutual contact. In this type of plane of mutual contact between the textile sheet and the textile material sheet, the first or second textile sheet 2 or 3 and the textile material sheet 4 are partially bonded by an adhesive. At this time, a bonded region in which the first textile sheet 2 or the second textile sheet 3 and the textile material sheet 4 are bonded, and a non-bonded region in which these are not bonded are formed, and the non-bonded region includes a space section.
For example, in a case where the first textile sheet 2 and the textile material sheet 4 illustrated in
Note that cases in which the “first textile sheet 2 or the second textile sheet 3” and the textile material sheet 4 are in contact include both a case where the “first textile sheet 2 or the second textile sheet 3” and the textile material sheet 4 are in contact directly, and a case where the “first textile sheet 2 or the second textile sheet 3” and the textile material sheet 4 are in contact indirectly with an adhesive interposed therebetween.
In an embodiment in which the moisture permeable film 70 is provided so as to face the textile material sheet 4, the bonding of the moisture permeable film 70 is also partial bonding, and in the plane of mutual contact between the textile material sheet 4 and the moisture permeable film 70, a bonded region 30 where the textile material sheet 4 and the moisture permeable film 70 are bonded, and a non-bonded region 8 where these are not bonded are formed, and the non-bonded region 8 includes a space section 9. Similar to the formation of the bonded region 30 between the first textile sheet 2 or the second textile sheet 3 and the textile material sheet 4, the bonded region 30 where the textile material sheet 4 and the moisture permeable film 70 are bonded can be formed using the adhesive 7.
As illustrated in
Furthermore, in the composite textile sheet 1 configured in this manner, a moisture transpiration path is formed, and through the moisture transpiration path, the space section 9 formed in the non-bonded region 8 in the plane of mutual contact between the first textile sheet 2 and the textile material sheet 4, the space section 9 formed in the non-bonded region 8 in the plane of mutual contact between the second textile sheet 3 and the textile material sheet 4, the textile gap of the first textile sheet 2, the textile gap of the second textile sheet 3, and textile gap of the textile material sheet 4 mutually communicate. In an embodiment in which the moisture permeable film 70 is provided so as to face the textile material sheet 4, a portion of the moisture permeable film 70 through which water vapor passes is further added to the moisture transpiration path.
The above-described moisture transpiration path is formed in the composite textile sheet 1, and therefore the composite textile sheet 1 can exhibit an excellent moisture transpiration property through the action of these moisture transpiration paths. In addition, heat dissipation and moisture permeability of the composite textile sheet 1 can also be improved by the formation of the moisture transpiration path. In an embodiment in which the moisture permeable film is layered to the outer surface side, the moisture permeable film does not allow the passage of liquid such as water, but does allow the passage of water vapor, and therefore in embodiments provided with the moisture permeable film as well, the moisture transpiration property can likewise be improved. In addition, forming the above-described moisture transpiration path can also improve the heat dissipation and moisture permeability of the composite textile sheet 1.
The composite textile sheet 1 is suitable as a fabric for manufacturing a disposable textile product (for example, a glove, raincoat, underpants, and sheet). For a case where sweat or other such body fluids are emanated from the body when a disposable textile product is worn on the body, the body fluids pass from the first textile sheet 2 side that is in contact with the skin surface and through the moisture transpiration path of the composite textile sheet 1, and are transpired externally while being diffused within the textile material sheet 4. For a case where the composite textile sheet 1 is a multi-ply sheet of the first textile sheet 2, the textile material sheet 4, and the second textile sheet 3, as illustrated by the arrows of
The composite textile sheet 1 has moisture transpiration path in this manner, and therefore can exhibit excellent moisture transpiration property, and can improve comfort during use of a disposable textile product when the product is worn, without causing a stuffiness or stickiness due to sweat or other such body fluids. As will be described below, in the present embodiment, the first textile sheet 2 and the second textile sheet 3 include a nonwoven fabric material, and the textile material sheet 4 include a paper material. A paper material excels in liquid diffusibility and in moisture transpiration property, but if a fabric for a disposable textile product is formed from only a paper material, the disposable textile product cannot be provided for practical use. This is because when configured only of a paper material, the product easily disintegrates when moisture is absorbed. However, an effect of the present embodiment can be exhibited when laminating a paper material to a nonwoven fabric material. Note that in the present specification, the term paper material refers to a material that is manufactured by agglutinating or using a binder to bind plant fibers containing a cellulose-based component or fibers other than plant fibers. More specifically, examples of paper materials include tissue paper, crepe paper and airlaid nonwoven fabrics. The paper material may also contain other materials in addition to the fiber material, and materials containing these types of additional materials are also included in the concept of paper materials.
According to an embodiment in which the moisture permeable film is layered to the outer surface side of the second textile sheet 3 in a case where the disposable textile product is underpants, upon occurrence of incontinence during wearing the underpants, the moisture permeable film does not allow the passage of liquid, and therefore urine leakage to the outside can be prevented.
In the example illustrated in
A nonwoven fabric can be used as the first textile sheet 2, and a two-layer or a three-layer spunbond nonwoven fabric can be used as this nonwoven fabric. In a case where the first textile sheet 2 is used at the skin surface side of an exterior sheet 11 of disposable underpants 10 (
A nonwoven fabric can be used as the second textile sheet 3, and a two-layer or a three-layer spunbond nonwoven fabric can be used as this nonwoven fabric. In a case where the second textile sheet 3 is used at the non-skin surface side of the exterior sheet 11 of the disposable underpants 10, a water repellent nonwoven fabric is preferably used as the second textile sheet 3. A three-layer spunbond nonwoven fabric can be used as the water repellent nonwoven fabric, and a water repellent treatment in which a silicone-based, fluorine-based, paraffin metal-based, or alkyl chromic chloride-based water repellent agent is coated thereon is preferably performed. The basis weight of the water repellent nonwoven fabric is preferably, as one example, from 10 to 50 g/m2, and from the perspective of manufacturing costs, the basis weight thereof is more preferably from 10 to 20 g/m2, but is not limited to these ranges. In addition, the first textile sheet 2 and the second textile sheet 3 may be the same basis weight.
A paper material containing cellulose fibers can be used as the textile material sheet 4, and in this case, a paper material formed from a material using pulp paper or pulp as a principal raw material can be used. Pulp such as wood pulp, synthetic pulp, and waste paper pulp can be used as the raw material pulp. Additionally, the raw material pulp is not limited to natural fibers such as pulp, and regenerated fibers such as rayon can be used. The basis weight of the textile material sheet 4 is preferably, as one example, from 10 to 50 g/m2, and is preferably smaller than the basis weight of the first textile sheet 2 and the basis weight of the second textile sheet 3. As an example, the basis weight of the textile material sheet 4 is preferably from 5% to 25% smaller than the basis weight of the first textile sheet 2. Likewise, the basis weight of the textile material sheet 4 is preferably from 5% to 25% smaller than the basis weight of the second textile sheet 3. However, the present embodiment does not exclude cases in which the basis weight of the textile material sheet 4 is greater than the basis weight of the first textile sheet 2.
Moreover, in a case where a paper material is used as the textile material sheet 4, the textile material sheet 4 is preferably subjected to embossing in order to impart softness. Furthermore, if the composite textile sheet 1 is used in the exterior sheet 11 of the disposable underpants 10, various printing may be applied in advance on this paper material to form a printed layer. The surface of this printed layer may be subjected to color proofing through varnishing and the addition of a binder. Examples of the binder include known materials such as PVA, CMC, EVA, acrylic, and lacquer. An ink subjected to a color proofing treatment can be also used.
As the moisture permeable film, moisture permeable films such as those that include a polyolefin-based resin and an inorganic filler, and those that include a polyethylene resin composition and an inorganic filler can be used. More specifically, a polyethylene-based microporous film can be used as the moisture permeable film, but the moisture permeable film is not limited thereto. In this case, a paper material may be used as the textile material sheet 4, which excels in transpiration performance and heat dissipation, and therefore heat within the body is transferred to outside the body through the textile material sheet 4 and the moisture permeable film. In a case where a composite textile sheet 1 including a moisture permeable film provided on the outer surface side of the second textile sheet 3 is used, for example, in the fabric of the gloves 310, 310a, the raincoat 311, and the underpants 10, 312, the composite textile sheet 1 excels in transpiration performance and heat dissipation as described above, and therefore gloves, raincoats, underpants, and sheets that do not cause stuffiness when used can be provided. In addition, design aspect can be improved by applying various printing to the textile material sheet 4 and moisture permeable film.
In the present embodiment, the space 9 present in the non-bonded region 8 is also a part of the multi-ply sheet 15. In addition, the first textile sheet 2, the second textile sheet 3, and the textile material sheet 4 of the approximately same areas are layered in the present embodiment. However, these sheets are not required to have the same area, and the areas may differ by a few % to around 10%. As described below, the textile material sheet 4 may be softened by pressing with embossing rollers 202a depicted in
As described above, in the present embodiment, the textile material sheet 4 is subjected to a mechanical softening treatment through embossing, and through this mechanical softening treatment, the textile material sheet 4 can be imparted with flexibility that resembles flexibility achieved by hand-rubbing the textile material sheet 4. As a result, the entire composite textile sheet 1 exhibits softness, and becomes soft to the touch. Also, during embossing by the embossing rollers 202a, minute holes can be formed in the textile material sheet 4. In a case where minute holes are formed in this manner, during bonding the first and second textile sheets 2, 3 by an adhesive (a bonding step in the manufacturing process), the adhesive penetrates the holes, and as a result, the adhesion between the first and second textile sheets 2, 3 and the textile material sheet 4 is improved, and the bonding strength between the first and second textile sheets 2, 3 and the textile material sheet 4 is increased. Note that the holes formed through embossing are dependent on the embossing pattern, and can be various shapes such as round, square, hexagonal, and a break-off shape.
The amount of the adhesive 7 for bonding the first textile sheet 2 and the textile material sheet 4, and the amount of the adhesive 7 for bonding the second textile sheet 3 and the textile material sheet 4 can be determined as appropriate. However, a larger amount of the adhesive reduces the area of the non-bonded region 8 between the first textile sheet 2 and the textile material sheet 4, and the area of the non-bonded region 8 between the second textile sheet 3 and the textile material sheet 4. Thus, the area of the space section 9 in each of the non-bonded regions 8 is also reduced. As a result, the area of the moisture transpiration path, through which the space sections 9, 9 in each of the non-bonded regions 8, 8, the textile gap of the first textile sheet 2, the textile gap of the second textile sheet 3, and the textile gap of the textile material sheet 4 mutually communicate, is also reduced overall, resulting in a decrease in the moisture transpiration property and air permeability. In addition, the larger amount of the adhesive reduces the softness of the composite textile sheet 1 (the sheet becomes hard), and degrades the feel when worn in a case where the composite textile sheet 1 is used as the fabric for a disposable product. The bonding area between the first textile sheet 2 and the textile material sheet 4 and the bonding area between the second textile sheet 3 and the textile material sheet 4 are both preferably from 50% to 90%, and more preferably from 70% to 90% of the area of the first textile sheet 2 or the second textile sheet 3.
From the above-described perspective, the application amount of the adhesive when bonding 1 m2 of the first textile sheet 2 and the textile material sheet 4, and the application amount of adhesive when bonding 1 m2 of the second textile sheet 3 and the textile material sheet 4 are both preferably from 0.8 to 5.0 g/m2. When the application amount is less than 0.8 g/m2, the bonding strength between the first and second textile sheets 2,3 and the textile material sheet 4 is reduced, and peeling between each of the sheets easily occurs. When the application amount exceeds 5.0 g/m2, the area of the moisture transpiration path becomes small, the moisture transpiration property and air permeability decrease, and the softness of the composite textile sheet 1 is lost. The adhesive application amount is more preferably from 1.0 to 3.5 g/m2. Furthermore, in order to provide a composite textile sheet 1 with further improved softness, the upper limit value of the adhesive application amount is preferably set to 1.5 g/m2.
Note that bonding between the first textile sheet 2 and the textile material sheet 4, and bonding between the second textile sheet 3 and the textile material sheet 4 can be performed through various bonding methods that are ordinarily used such as using an adhesive, ultrasonic welding, and heat sealing. When an adhesive is used, an adhesive such as a hot-melt adhesive and a solvent-based adhesive can be used. When bonding, the space sections 9 may be arranged so as to be mutually opposing, or the space sections 9 may be arranged so as to be mutually shifted, with the textile material sheet 4 interposed therebetween.
The method for manufacturing the composite textile sheet 1 of the present embodiment is described below using, as an example, a case of manufacturing the disposable underpants 10 that use the composite textile sheet 1.
The textile material sheet 4 wound on a sheet roll 201 is conveyed to the negative side in the X-direction of
The textile material sheet 4 that has passed through the embossing roller 202a is coated with an adhesive by an adhesive application device 203a. In the present embodiment, hot-melt adhesive is used as the adhesive, but the adhesive is not limited thereto.
The functional material is applied to the textile material sheet 4. Examples of the functional material include deodorants, insect repellents, fragrances, waterproofing agents, antifouling agents, and antibacterial agents. In the present embodiment, a case where a deodorant, a fragrance, and a softener are applied as functional materials is described, but the present invention is not limited thereto.
A functional material application device 150 has a nozzle, and is configured to apply (spray) a functional material onto the first surface of the textile material sheet 4. The functional material application device 150 may also be a device that is configured to apply a functional material onto a second surface (bonding surface with the first textile sheet 2) of the textile material sheet 4, and the device may be configured to apply a functional material onto a sheet other than the textile material sheet 4 as long as the sheet thereof is not contacted by the wearer. A plurality of functional material application devices 150 may be provided according to the number of functional materials. Alternatively, a plurality of functional materials may be mixed and then applied by the functional material application device 150 onto the textile material sheet 4.
As the deodorant, which is a functional material, catechin, epigallocatechin, gallocatechin, epicatechin gallate, epigallocatechin gallate, gallotannin, and ellagitannin, which are extracts from plants such as catechins and tannins; iron-ascorbic acid chelate compounds; hydroxides of zirconium;
hydroxides of lanthanoid; and salts of metals such as Zn, Cu, and Fe (for example, ZnSO4) can be used. In the present embodiment, an alum (potassium alum) or a polyphenol is applied by the functional material application device 150. There are cases in which a liquid in which a metal is dissolved is used for the functional material such as alum, and therefore application to a portion that does not directly contact the skin (for example, a sheet other than on the skin surface side) is preferable. The textile material sheet 4 of the present embodiment is not at the skin surface side, and therefore the metal substance does not contact the wearer.
As the fragrance, which is a functional material, essential oils of fruits such as oranges, lemons, limes, and peaches; of flowers such as rose and lavender; and of mint and sandalwood (plants) can be used, and fragrances other than those mentioned above can also be used. This fragrance may be applied (sprayed) using the functional material application device 150. Note that fragrances may be selectively used according to gender, use by an adult or use by a child, and region.
As the softener, which is a functional material, a polyol (glycerin for example), which is a polyhydric alcohol and which softens the textile material sheet 4, can be used. In the present embodiment, the functional material is applied before bonding the second textile sheet 3 and the textile material sheet 4, but application after passing through the embossing rollers 202a is preferable. This is because when the functional material (glycerin for example) is applied before passage through the embossing rollers 202a, there is a concern that the textile material sheet 4 could easily tear, and the torn end of the textile material sheet 4 could adhere to the embossing rollers 202a, and thereby hinder the manufacturing of the composite textile sheet 1. The functional material may also be applied to the textile material sheet 4 or the second textile sheet 3 after bonding of the second textile sheet 3 and the textile material sheet 4. Furthermore, the functional material may be applied before the step of manufacturing the textile material sheet 4.
The second textile sheet 3 wound on a sheet roll 207 is conveyed to the negative side (downward) in the Z-direction by a conveyance roller 208a, and is bonded to the textile material sheet 4 onto which the adhesive 7 was applied, by a pressing roller 209a. In the present embodiment, the above-described bonding area between the second textile sheet 3 and the textile material sheet 4 is the area after passing the pressing roller 209a. Furthermore, the bonded second textile sheet 3 and textile material sheet 4 are conveyed to the positive side (upward) in the Z-direction by conveyance rollers 208b, 208c.
Step S3: Bonding with the First Textile Sheet 2
The second surface of the textile material sheet 4 is coated with the adhesive 7 by an adhesive application device 203b to bond the bonded second textile sheet 3 and textile material sheet 4 with the first textile sheet 2. In the present embodiment, a hot-melt adhesive is used as the adhesive 7, but the adhesive is not limited thereto. Note that the adhesive 7 is heated to a prescribed temperature (60° C. to 150° C. for example) by the second adhesive application device 203b, and the application amount is as described above.
The first textile sheet 2 wound on a sheet roll 206 is conveyed to the negative side (downward) in the Z-direction by a conveyance roller 208d. A pair of pressing rollers 209b press and bond the first textile sheet 2 and the bonded body of the bonded second textile sheet 3 and textile material sheet 4, and thereby the multi-ply sheet 15 (composite textile sheet 1) is manufactured. In the present embodiment, the above-described bonding area between the first textile sheet 2 and the textile material sheet 4 is the area after passage through the pair of pressing rollers 209b.
The multi-ply sheet 15 is formed by laminating in order from the positive side (top side) in the Z-direction, the first textile sheet 2, the textile material sheet 4, and the second textile sheet 3. When the first textile sheet 2, the textile material sheet 4, and the second textile sheet 3 are layered by the pair of pressing rollers 209b, the first textile sheet 2, the textile material sheet 4, and the second textile sheet 3 may have the same area and the same shape. Alternatively, after a cutting step (cutting by a below-described cutting device 221 for example), the first textile sheet 2, the textile material sheet 4, and the second textile sheet 3 may have the same area and the same shape. In the present embodiment, the textile material sheet 4 is positioned between the first textile sheet 2 and the second textile sheet 3, and because the textile material sheet 4 is embossed by the pair of embossing rollers 202a, the dimension in the sheet width direction of each of the first textile sheet 2 and the second textile sheet 3 set in the sheet rolls may be larger than the dimension in the width direction of the textile material sheet 4. The multi-ply sheet 15 is embossed, or in other words, is subjected to a mechanical softening treatment by a pair of embossing rollers 202b. Note that embossing of the multi-ply sheet 15 by the embossing rollers 202b may be omitted.
A nonwoven fabric can be used as the first textile sheet 2 and the second textile sheet 3, and the nonwoven fabric is a material that does not easily wrinkle. On the other hand, a paper material containing cellulose fibers can be used as the textile material sheet 4, but the paper material is a material that easily wrinkles. Here, the multi-ply sheet 15 (composite textile sheet 1) may be formed after subjecting the textile material sheet 4 to deep embossing by the embossing rollers 202a such that a plurality of minute holes are formed in the textile material sheet 4, then wrinkles may not be easily formed in the multi-ply sheet 15 (composite textile sheet 1). Furthermore, the multi-ply sheet 15 (composite textile sheet 1) may be embossed by the embossing rollers 202b, and wrinkles may be formed less likely. Therefore, in a case where the composite textile sheet 1 of the present embodiment is used as a fabric for clothing, ironing to remove wrinkles is not necessary. The same effect can be achieved even for cases in which the moisture permeable film is used in place of the second textile sheet 3.
The method for manufacturing the composite textile sheet 1 of the present embodiment is as described above. Next, a method for manufacturing the disposable underpants 10 using the composite textile sheet 1 of the present embodiment is described using
The multi-ply sheet 15 is conveyed to the positive side (right direction) in the X-direction in
The multi-ply sheet 15 that has been subjected to the first folding treatment by the first folding device 217 is conveyed to the positive side (right direction) in the X-direction, and holes are formed by a hole formation device 218 to form the leg parts of the disposable underpants 10. A die cut roller can be used, for example, as the hole formation device 218, but the hole formation device 218 is not limited thereto.
The second folding treatment, to prepare for the bonding treatment of step S7, is implemented to mountain-fold the multi-ply sheet 15 at the center in the sheet width direction along the center dotted line of
As the second folding treatment, in place of mountain-folding the multi-ply sheet 15 at the center dotted line, the front and back sides of the multi-ply sheet 15 may be inverted by an inverting mechanism (not illustrated), and the central portion of the inverted multi-ply sheet 15 may be valley-folded.
The multi-ply sheet 15 that was mountain-folded at the center in the sheet width direction is bonded along the sheet width direction by a bonding device 220 to form the disposable underpants 10. As the bonding device 220, various bonding devices such as an ultrasonic welding device, a heat sealing device, and a hot-melt adhesive application device can be used.
The multi-ply sheet 15 in which the bonded sections 16 have been formed is cut by a cutting device 221 including a cutter to form individual disposable underpants 10. That is, the cutting device 221 cuts the center part of the bonded sections 16 along the width direction of the multi-ply sheet 15. Thus, single disposable underpants 10 like that illustrated in
The disposable underpants 10 that is manufactured as described above includes the exterior sheet 11, and the torso fitting section 12 that fits around the waist of the user. In the exterior sheet 11, the first textile sheet 2, the textile material sheet 4, and the second textile sheet 3 are layered in this order from the side that is in contact with the skin of the user.
The torso fitting section 12 is formed by bending the exterior sheet 11. The composite textile sheet 1 does not include an elastic member (for example, an elastic member such as polyurethane), but an elastic member may be used in the torso fitting section 12. In a case where an elastic member is used in the torso fitting section 12, the disposable underpants 10 does not easily shift downward when worn. Note that the torso fitting section 12 may also be formed without bending the exterior sheet 11.
With the disposable underpants 10 formed in this manner, an absorbent member 14 can be attached as illustrated in
The disposable underpants 10 can withstand washing multiple times, and therefore can be used for a certain period of time as long as the absorbent member 14 (
Next, a composite textile sheet according to a second embodiment of the present invention is described. In the present embodiment, an elastic member 305 is provided between a first textile sheet 302 and a textile material sheet 304, and stretchability is imparted to a multi-ply sheet 315 by the elastic member 305.
The elastic member 305 is linear and cylindrical, or in other words, the cross-sectional shape is circular. The elastic member 305 is formed from, for example, a natural rubber or a synthetic rubber based on urethane, silicone, butadiene, or styrene-butadiene. In addition, the elastic member 305 may be a combination of any of the materials of these synthetic rubbers or natural rubbers, as appropriate. Note that the elastic member 305 is not limited to a cylindrical shape, and may be a triangular prism shape, a quadrangular prism shape, or another polygonal prism or elliptical prism shape. In addition, the elastic member 305 may be one which is obtained by bundling or twisting together a plurality of linear members. In the present embodiment, a linear elastic body 305a having stretchability is used as the elastic member 305, and as this linear elastic body 305a, a natural rubber or synthetic rubber based on urethane and silicone can be used. Note that an elastic member having a lattice-like shape can also be used, and in this case, the above-described numerous shirring portions 306 can be formed with a single lattice-like shape. In addition, a stretchable film may be used in place of the numerous elastic members 305. As the stretchable film, films such as a urethane film, a silicone film, and an elastomer film can be used.
The composite textile sheet 300 is not limited to a composite textile sheet having a three layer structure formed by laminating the first and second textile sheets 302, 303 and the textile material sheet 304, and as illustrated in
Moreover, similar to the composite textile sheet 1 of the first embodiment, a moisture permeable film may be layered to the composite textile sheet 300 at a position directly facing the textile material sheet 304. However, from the viewpoint of ensuring the moisture transpiration property by the composite textile sheet 1, the moisture permeable film is preferably layered to a position that is not directly facing the first textile sheet 302, which is the textile sheet that is slated to be positioned at the skin surface side.
Furthermore, various modifications may be made to the configuration of the composite textile sheet 300, and these may be used in the composite textile sheet 301a and composite textile sheet 301c described below. In the present embodiment, as described below, in cases where the composite textile sheet 300 is applied in the gloves 310, 310a, the raincoat 311, the underpants 10, 312, and sheets (not illustrated), the first textile sheet 302 is at the side that contacts the skin of the user (skin surface side), and the second textile sheet 303 is at the outer side (non-skin surface side).
In both cases where the composite textile sheet 300 of the present embodiment is a two-layer configuration and a three-layer configuration, as illustrated in
In the composite textile sheet 300 configured as described above, the moisture transpiration path is formed through which the space section 309 formed in the non-bonded region 308 in the plane of mutual contact between the first textile sheet 302 and the textile material sheet 3044, the space section 309 formed in the non-bonded region 308 in the plane of mutual contact between the second textile sheet 3033 and the textile material sheet 304, the textile gap of the first textile sheet 302, the textile gap of the second textile sheet 303, and the textile gap of the textile material sheet 304 mutually communicate.
The above-described moisture transpiration path is formed in the composite textile sheet 300 of the present embodiment, and therefore the composite textile sheet 300 can exhibit an excellent moisture transpiration property through the action of these moisture transpiration path. In addition, forming the moisture transpiration path also exhibits improvement in the heat dissipation and moisture permeability of the composite textile sheet 300.
As illustrated in
As illustrated in
As indicated hereinabove, the linear elastic body 305a is provided between the first textile sheet 302 and the textile material sheet 304. Numerous shirring portions 306 are formed in the x-direction of
The multi-ply sheet 315 is long in lengthwise, and therefore the sheet is cut to obtain a predetermined length dimension in the longitudinal direction (x-direction in
Elastic force is imparted to the multi-ply sheet 315 by the elastic member 5 disposed inside the multi-ply sheet 315. Therefore, when the composite textile sheet 300 is stretched in the x-direction of
As specific examples of disposable textile products that are manufactured by appropriately using the composite textile sheet 1 presented in the first embodiment and/or the composite textile sheet 300 presented in the second embodiment as fabric, gloves, a raincoat, underpants, and sheets are described below as third, fourth, fifth, and sixth embodiments respectively. Note that for convenience of description, the same reference signs as those presented in the second embodiment are applied in the third to sixth embodiments to configurations that are the same as those of the second embodiment.
An example of the glove 310 that uses a composite textile sheet as the disposable textile product illustrated in
In the glove 310, the composite textile sheet of the second embodiment is used as the composite textile sheet 301a, and the composite textile sheet 301a is configured by laminating the first textile sheet 302, the elastic member 305, the textile material sheet 304, and the second textile sheet 303 in this order from the side contacting the back of the hand. The composite textile sheet 301a is not limited to this example, and in place of the second textile sheet 303, a film (a moisture permeable film for example) may be used. When the elastic member 305 is provided at the back of the hand side, the glove 310 expands and contracts according to the hand of the wearer, and can fit to the hand of the wearer. Therefore, there is no slack between the glove 310 and the hand, and the glove 310 does not slip and fall off. Note that the elastic member 305 is arranged to transect the palm between the thumb and the little finger (lateral direction in the drawing), but may also be arranged to transect between the wrist and the fingertips (longitudinal direction in the drawing).
The composite textile sheet of the first embodiment is used as composite textile sheet 301b, and the composite textile sheet 301b is configured in the same manner as the composite textile sheet of
With the glove 310, the first textile sheet 302 contacts both the back of the hand and the palm, and therefore the glove 310 provides a soft texture when worn, and excels in air permeability. The textile material sheet 304 is bonded to the first textile sheet 302, and therefore when sweat is present at the back of the hand and the palm, the sweat is adsorbed by the textile material sheet 304. Furthermore, as illustrated in
The gloves 310, 310a can be used in various applications such as for protection against cold, for medical care, for operations (assembly, adjustments, sweeping, cleaning), and for sports. Note that when the gloves 310, 310a are used for medical care, a melt-blown nonwoven fabric that is formed from ultrafine fibers having a fiber diameter in a range from 2 to 20 microns, and that excels in filtering performance is preferably used. In this case, the melt-blown nonwoven fabric layer may be layered to the multi-ply sheet 315, or a melt-blown nonwoven fabric may be used for at least one of the first and second textile sheets 302 and 303. Note that a mitten shape can also be adopted as the shape of the gloves.
The textile material sheet 304 wound on a sheet roll 404a is conveyed in the X-direction, and is embossed by a pair of embossing rollers 410a, or in other words, is subjected to a mechanical softening treatment. A pattern is printed in advance onto the back surface (surface opposite to the second textile sheet 303) of the textile material sheet 304 that is wound onto the sheet roll 404a, and the textile material sheet 304 on which the pattern was printed is embossed.
The textile material sheet 304 that has passed through the embossing rollers 410a is coated with an adhesive 307 by an adhesive application device 411 to be bonded with the first textile sheet 302. In the present embodiment, hot-melt adhesive 307 can be used as the adhesive, but the adhesive is not limited thereto. The adhesive application device 411 has a plurality of nozzles, and sprays the hot-melt adhesive in a spray form. The adhesive 307 is heated to a prescribed temperature (from 60° C. to 150° C. for example) by the adhesive application device 411, and the hot-melt adhesive is applied at an amount from 0.8 g/m2 to 2.0 g/m2.
The first textile sheet 302 wound on a sheet roll 402a is conveyed to the negative side (downward) in the Z-direction by a conveyance roller 412a, and is bonded by pressing rollers 413a with the textile material sheet 304 onto which the adhesive 307 was applied.
The elastic member 305 that is wound onto an elastic roll 405 is coated with the adhesive 307 by the adhesive application device 411. In the present embodiment, a hot-melt adhesive can be used as the adhesive 307 that is coated onto the circumferential surface of the elastic member 305, but the adhesive 307 is not limited thereto. Moreover, the hot-melt adhesive that is used in the present embodiment may be the same in each step, or may be different (for example, adhesives with different viscosities). The adhesive 307 is heated to a prescribed temperature (60° C. to 150° C. for example) by the adhesive application device 411. A plurality of elastic rolls 105 is arranged according to the number of elastic members 5 to be used.
The second textile sheet 303 wound on a sheet roll 403a is conveyed to the positive side (upward) in the Z-direction by a conveyance roller 412b. Meanwhile, the first textile sheet 302 and textile material sheet 304 that were bonded as described above are conveyed to the negative side (downward) in the Z-direction. A pair of pressing rollers 413b presses and bonds the second textile sheet 303 and the bonded body of the first textile sheet 302 and the textile material sheet 304, with the elastic member 305, on which the adhesive 307 was applied, interposed therebetween. Thus, the composite textile sheet 301a is manufactured. The composite textile sheet 301a is formed as a multi-ply sheet that is obtained by laminating the first textile sheet 302, the textile material sheet 304, the elastic member 305, and the second textile sheet 303 in this order from the positive side in the Z-direction.
As described above, the elastic member 305 is disposed inside the composite textile sheet 301a, and thereby imparting an elastic force to the composite textile sheet 301a. The surface area of the composite textile sheet 301a can be increased from around 1.5 times to around 5 times by selecting the elastic force of the elastic member 305. For example, in a case where a dimension of 100 mm in the x-direction of
Therefore, the composite textile sheet 301a is heated by a heating device 414, and the residual strain of the elastic member 305 removed by annealing. Thus, the shrinkage ratio of the elastic member 305 approaches the theoretical value. The heating device 414 is, for example, a non-contact type heating device that supplies air of a temperature from 30° C. to 80° C. In the heating treatment, the composite textile sheet 301a is conveyed in an extended state. Non-contact heating by the heating device 414 is performed as the heating treatment in the present embodiment, but contact heating may also be performed in which a heating roller (not illustrated) is made to contact the composite textile sheet 301a.
Such heating treatment described above may further improve bonding of the first textile sheet 302, the second textile sheet 303, and the textile material sheet 304, and prevent the occurrence of issues such as wrinkles and bonding detachment. This can also be applied to the manufacturing of the composite textile sheet 301b described below.
The textile material sheet 304 wound on a sheet roll 404a is conveyed in the X-direction, and is embossed by a pair of embossing rollers 410a, or in other words, is subjected to a mechanical softening treatment. The textile material sheet 304 wound onto the sheet roll 404b may be printed in advance. The textile material sheet 304 that has passed through the embossing rollers 410b is coated with the adhesive 307 by the adhesive application device 411 to be bonded with the second textile sheet 303.
The second textile sheet 303 wound on a sheet roll 403a is conveyed to the negative side (downward) in the Z-direction by a conveyance roller 412c, and is bonded through pressing rollers 413c with the textile material sheet 304 onto which the hot-melt adhesive was applied. Next, the textile material sheet 304 is coated with the adhesive 307 by the adhesive application device 411 to be bonded with the first textile sheet 302.
The first textile sheet 302 wound on a sheet roll 402b is bonded to the bonded body of the second textile sheet 303 and the textile material sheet 304 using the pair of pressing rollers 413d. Thus, the composite textile sheet 301b is manufactured. In a case where the composite textile sheet 301a and the composite textile sheet 301b are of the same configuration, the part of manufacturing the composite textile sheet 301b may be omitted to simplify the manufacturing process 400.
The composite textile sheet 301a and the composite textile sheet 301b are pressed by a pressing roller 413e, and the composite textile sheet 301b is thereby positioned on the composite textile sheet 301a. In this state, the composite textile sheet 301a and the composite textile sheet 301b are not bonded. A bonding device 415 then bonds the composite textile sheet 301a and the composite textile sheet 301b by a bonding method such as heat sealing or ultrasonic welding. In the present embodiment, bonding that is tailored to the exterior form of the glove 310 (310a) is performed. In bonding by the bonding device 415, a bonding margin is included in light of cutting errors in a cutting step described below. With the bonding device 415, bonding using an adhesive, or bonding through sewing may be performed. Note that in the present embodiment, a case was described in which the composite textile sheet 301a includes the elastic member 305, but including the elastic member 305 is not required. That is, the composite textile sheet 301b may be used in place of the composite textile sheet 301a.
The composite textile sheet 301a and composite textile sheet 301b that have been bonded in a manner tailored to the exterior form of the glove 310 are cut by a cutting device 416 having a cutter, and thereby, the glove 310 is manufactured. In the present embodiment, cutting is performed after the composite textile sheet 301a and the composite textile sheet 301b have been bonded, but this order may be reversed. In addition, heat from heat sealing may be used for cutting when bonding the composite textile sheet 301a and the composite textile sheet 301b through heat sealing. Furthermore, bonding and cutting of the composite textile sheet 301a and the composite textile sheet 301b may be performed using a seal cutter that is a combination of ultrasonic welding and a cutter. In this case, bonding between the composite textile sheet 301a and the composite textile sheet 301b and cutting can be performed simultaneously, and therefore the efficiency of manufacturing the glove 310 can be improved.
Next, a raincoat as a disposable textile product is described. Note that in the present embodiment, the same reference signs are assigned to elements having the same configurations as those of the above-described second and third embodiments, and the descriptions thereof are omitted.
The composite textile sheet of the first embodiment is used as composite textile sheet 301d. As illustrated in
By configuring with this type of arrangement, the moisture permeable film 320 of the composite textile sheet 301c and the moisture permeable film 320 of the composite textile sheet 301d are bonding surfaces in the present embodiment. In the embodiments described above, the first textile sheet 302 of the composite textile sheet 301a, and the first textile sheet 302 of the composite textile sheet 301b are bonding surfaces, but using the moisture permeable films 20 themselves as bonding surfaces results in a stronger bonding strength. Thus, a raincoat 311 with improved durability against wind and rain can be realized. Note that bonding of the moisture permeable films 320 themselves results in stronger bonding than bonding of the textile material sheets 304.
In the present embodiment, an additional step is implemented, in which after the moisture permeable film 320 of the composite textile sheet 301c and the moisture permeable film 320 of the composite textile sheet 301d are bonded to form a bonded body, the bonded body is cut, and the front and back sides of the bonded body are turned inside out using an inverting device (not illustrated). Therefore, the moisture permeable films 320 that are bonded at the inner side in the bonded state configure the outside surface when formed into the raincoat 311. Note that as the inverting device, various methods can be used such as a method that inverts the composite textile sheets 301c, 301d using a mechanical arm.
As described above, the moisture permeable films 320 are bonded at the inner side and then turned inside out in this manner, and the moisture permeable films 320 are at the outside of the raincoat 311 when worn, and the bonding surface is at the inner side. Therefore, the bonding strength of the composite textile sheets 301c, 301d is increased, and a raincoat 311 with a good external appearance can be realized. In the manufacturing of the above-described glove 310 (310a) as well, the moisture permeable film 320 may be used in place of the second textile sheet 303, and an inverting step that uses an inverting device or the like may be added, to provide a glove 310 (310a) having a moisture permeable film at the outer side and the bonding surface at the inner side.
As described above, in the examples of
This type of bonding of the composite textile sheet 301d and the composite textile sheet 301c, and bonding of composite textile sheets 301d themselves and of composite textile sheets 301c themselves can be realized through the bonding device 415 illustrated in
It is important that the raincoat 311 suppress as much as possible the penetration of rain through the bonded sections including the bonded section between the textile sheet 301d and the composite textile sheet 301c, the bonded sections of composite textile sheets 301d themselves, and bonded sections of the composite textile sheets 301c themselves. Regarding this point, the penetration of water through the bonded sections can be effectively suppressed by an ultrasonic welding method that uses an ultrasonic sewing machine. According to the ultrasonic welding method that uses an ultrasonic sewing machine, bonding can be realized with an appropriate pattern such as linear bonding and bonding in intermittent lines. In particular, with a pattern of a plurality (a quantity from 2 to 4 for example) of parallel intermittent lines with intermittent portions that are not parallel, the penetration of water at the bonded sections can be suppressed while allowing the passage of air.
Note that in the present embodiment, a raincoat provided with a front bodice and a back bodice was primarily envisioned and described, but the present invention is not limited thereto. For example, the raincoat may also be a so-called poncho type, and in this case, the raincoat is formed from a single composite textile sheet. As this composite textile sheet, the composite textile sheets 301c, 301d presented in the present embodiment can be used.
Next, underpants as a disposable textile product are described. The embodiment illustrated in
The composite textile sheet 301a uses the composite textile sheet of the second embodiment, and has a multi-layered structure that is formed by laminating the first textile sheet 302, the elastic member 305, the textile material sheet 304, and the second textile sheet 303 in this order from the inner side (skin surface side). The composite textile sheet 301a may use the moisture permeable film 320 in place of the second textile sheet 303, or may be a structure in which the moisture permeable film 320 is layered to the non-skin surface side of the multi-layered structure.
The composite textile sheet 301b uses the composite textile sheet of the first embodiment, and has a multi-layered structure that is formed by laminating the first textile sheet 302, the textile material sheet 304, and the second textile sheet 303 in this order from the inner side (skin surface side). The composite textile sheet 301b may use the moisture permeable film 320 in place of the second textile sheet 303, or may be a structure in which the moisture permeable film 320 is layered to the multi-layered structure. In the present embodiment, the composite textile sheet of the first embodiment is used as the composite textile sheet 301b, but the present invention is not limited thereto, and the composite textile sheet of the second embodiment may also be used. That is, the elastic member 305 may be further provided in the composite textile sheet 301b. A specific example of the position at which the elastic member 305 is provided is between the first textile sheet 302 and the textile material sheet 304. In addition, while not illustrated, the textile material sheet 304 can be printed to thereby improve the design aspect of the disposable underpants 312.
In the sixth embodiment, a sheet as a disposable textile product is described. As a disposable textile product, the sheet uses the composite textile sheet of the first embodiment and/or the composite textile sheet of the second embodiment as fabric, and this fabric can then be cut to an appropriate dimension and used. However, from the perspective of being able to achieve more stable dimensions of the fabric, use of the composite textile sheet of the first embodiment is preferable. From the perspective of being able to form a sheet with thickness and elasticity, use of the composite textile sheet of the second embodiment is preferable.
In this manner, a fabric made from the composite textile sheet of the first embodiment, or a composite textile sheet of the second embodiment is favorably selected in accordance with the required properties of the sheet based on conditions such as the purpose of the sheet. Furthermore, the textile sheets configuring the composite textile sheet and the attributes such as the material of the textile material sheet may be appropriately selected. From the viewpoint that the sheet suitably exhibits absorbency of moisture such as sweat at the surface that is in contact with the skin surface, and suppresses the penetration of water to the surface that is not in contact with the skin surface, in a case where the first textile sheet 2 is used as the surface that is in contact with the skin surface, the composite textile sheets like those illustrated by the examples of
The glove 310, raincoat 311, underpants 312, and sheet described above as disposable textile products are disposable types, but can withstand washing multiple times, and therefore are economical, can contribute to resource savings, and can be configured with consideration of the environment. In addition, the glove 310, raincoat 311, underpants 312, and sheet can be used regardless of age (can be configured for children and for adults), gender (for male use, for female use), or body shape, and can also be adopted for pets or other animals.
The composite textile sheets of each of the above-described embodiments have a basic structure in which a textile sheet (nonwoven fabric) is partially bonded to a textile material sheet (paper material), and excel in moisture transpiration property. From the perspective of having an excellent moisture transpiration property in this manner, the composite textile sheet of each of the embodiments may be considered as a material having the same qualities and same effects as those of a paper material. While paper material lacks softness, however, the composite textile sheet of each of the embodiments exhibit abundant softness, and from that viewpoint, the composite textile sheet can be perceived as being a new paper material that are obtained by adding the property of softness to a paper material. In other words, the composite textile sheet can be referred to as a new type of paper material with improved properties obtained by combining with a textile sheet (nonwoven fabric).
The present invention will be explained hereinbelow in greater detail through the presentation of specific examples of the composite textile sheet according to the embodiments of the present invention.
A composite textile sheet of Example 1 was configured by laminating a first textile sheet, a textile material sheet, a moisture permeable film, and a second textile sheet in that order. In Example 1, a hydrophilic spunbonded nonwoven fabric (basis weight of 15 g/m2) was used as the first textile sheet, and as the textile material sheet, paper of 100% pulp (paper sheet for tissue paper: basis weight of 13 g/m2) was used as is without printing. An opalescent film (basis weight of 18 g/m2) was used as the moisture permeable film, and a water-repellent spunbonded nonwoven fabric (basis weight of 15 g/m2) was used as the second textile sheet. These sheets were adhered using a hot-melt adhesive (total basis weight of the hot-melt adhesive of 1.2 g/m2), and a multi-ply sheet having a total basis weight of 62.2 g/m2 was obtained and used as the composite textile sheet of Example 1.
A composite textile sheet of the same layer configuration as that of Example 1 was used, printing was carried out on the textile material sheet (paper), and the resulting multi-ply sheet was used as the composite textile sheet of Example 2.
The composite textile sheet of Example 3 also had the same layer configuration as that of Example 1. In Example 3, a water-repellent spunbonded nonwoven fabric (basis weight of 15 g/m2) was used as the first textile sheet, and as the textile material sheet, paper of 100% pulp (paper sheet for tissue paper: basis weight of 13 g/m2) was used without printing. An opalescent film (basis weight of 18 g/m2) was used as the moisture permeable film, and a water-repellent spunbonded nonwoven fabric (basis weight of 40 g/m2) was used as the second textile sheet. These sheets were adhered using a hot-melt adhesive (total basis weight of the hot-melt adhesive of 1.2 g/m2), and a multi-ply sheet having a total basis weight of 87.2 g/m2 was obtained and used as Example 3.
A composite textile sheet of Example 4 was configured by laminating a first textile sheet and a textile material sheet. In Example 4, a water-repellent spunbonded nonwoven fabric (basis weight of 15 g/m2) was used as the first textile sheet, and as the textile material sheet, paper of 100% pulp (paper sheet for tissue paper: basis weight of 13 g/m2) was used without printing. These sheets were adhered using a hot-melt adhesive (total basis weight of the hot-melt adhesive of 1.2 g/m2), a multi-ply sheet having a total basis weight of 29.2 g/m2 was obtained and used as the composite textile sheet of Example 4.
A composite textile sheet of Comparative Example 1 was configured by laminating a first textile sheet, a moisture permeable film, a textile material sheet, and a second textile sheet in this order. In Comparative Example 1, a water-repellent spunbonded nonwoven fabric (basis weight of 15 g/m2) was used as the first textile sheet, and an opalescent film (basis weight of 18 g/m2) was used as the moisture permeable film. In addition, as the textile material sheet, paper of 100% pulp (paper sheet for tissue paper: basis weight of 13 g/m2) was used without printing, and a hydrophilic spunbonded nonwoven fabric (basis weight of 15 g/m2) was used as the second textile sheet. These sheets were adhered using a hot-melt adhesive (total basis weight of the hot-melt adhesive of 1.2 g/m2), and a multi-ply sheet having a total basis weight of 62.2 g/m2 was obtained and used as Comparative Example 1.
The moisture absorption property (transpiration ratio) of each of the multi-ply sheets of Examples 1 to 4 and Comparative Example 1 was evaluated. The moisture absorption property (transpiration property) was evaluated through a comprehensive evaluation of both the water absorbency and the quick drying ability by performing a transpiration property (ii) test (Boken standard BQEA028). A test piece with a diameter of approximately 9 cm was fabricated for each of the multi-ply sheets of Examples 1 to 4 and Comparative Example 1, and the mass (W) of each test piece and a petri dish were measured. Next, 0.1 mL of water was dropped onto the petri dish, the test piece was placed thereon, and the mass (W0) was measured. The petri dish with the test piece was left in a standard environment (20° C., humidity of 65% RH), and the mass (Wt) was measured after each predetermined interval of time (5 min, 10 min, and every 10 minutes thereafter until a time of 60 minutes was reached). The transpiration ratio (%) at each predetermined period of time was then calculated from the measured masses W, W0, and Wt using the following Equation (1). The results are shown in Table 1.
Equation 1
Transpiration Ratio (%)={(W0−Wt)/(W0−W)}×100 (1)
As is clear from the transpiration ratio results shown in Table 1 (see the graph of
As a criterion for evaluation with respect to the Boken standard BQEA028, in sports applications, the transpiration ratio 20 minutes after beginning testing is preferably 50% or higher for a textile product and 40% or higher for a knitted product, and in general applications, the transpiration ratio is preferably 40% or higher for a fabric product and 30% or higher for a knitted product. Therefore, because a transpiration ratio of 40% or higher can be obtained with the sheet material of Example 1, it can be said that such material can be comfortably worn both in sports applications and general applications. Thus, it is clear that the composite textile sheets of the present examples made from the multi-ply sheets of Examples 1 to 4 have a very high moisture absorption property (transpiration ratio).
The total basis weight of the multi-ply sheet is set from 50 g/m2 to 100 g/m2 by adjusting the basis weights of the first textile sheet and the second textile sheet, for example, and the high moisture absorption property (transpiration ratio) as described above can be obtained.
Furthermore, the transpiration performance (ii) test (Boken method) for evaluating the moisture absorption property of fabric was applied to ISO17617. When the above-described data of Table 1 was applied to this test method, data as shown in the following Table 2 was obtained.
In Table 2, the unit for the drying rate (increase in transpiration ratio per unit time) is %/minute, and the unit for the drying time (time until the transpiration ratio reaches 100%) is minutes. From Table 2, it is clear that the multi-ply sheets of Examples 1 to 4 have a drying rate of 2.0 or higher and a drying time of 50 minutes or less.
Embodiments of the present invention were presented and described above, but the scope of the present invention is not limited to the descriptions of the embodiments, and various modifications and appropriate combinations can be made. That is, the technical scope of the present invention is not limited to the scope described in the abovementioned embodiments. It would be clear to a person skilled in the art that various modifications and improvements can be added to the abovementioned embodiments. It is also clear from the description of the claims that aspects obtained by adding these types of modifications and improvements can also be included in the technical scope of the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| PCT/JP2016/064247 | May 2016 | JP | national |
| 2016-221066 | Nov 2016 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2017/016110 | 4/21/2017 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62329263 | Apr 2016 | US | |
| 62327372 | Apr 2016 | US |
