Patent Application
20190117469
A first aspect of the present invention is related to elastic material. Furthermore, an additional aspect of the present invention is related to an underpants type sanitary article prepared with an elastic part
An elastic material manufactured by attaching a non-woven cloth to both surfaces of an elastic film while stretching is well known (see international publication 2015/168032 pamphlet). The non-woven fabric is crimped to the elastic film such as by using spot welding.
Patent Document 1: International publication 2015/168032 No. pamphlet
For example, in the case that elastic material with extension processing performed is applied to a sanitary article, breathability and extendibility are important and there was room for improvement from the perspective of balancing these.
An elastic material according to an aspect of the present invention comprises an elastic film, non-woven fabric laminated on both surfaces of the elastic film, and crimped parts where the non-woven fabric and elastic film are crimped and indented, the crimped part is prepared with a plurality of first emboss formed on a first line and a plurality of second emboss formed on a second line beside the first line in a direction diagonally intersecting the MD direction of the elastic film,
wherein the first emboss is a long lengthy shape in a direction orthogonal to the MD direction, the first line and second line are alternately placed,
at least a part of the intervals of adjacent first emboss on the same line are smaller than the intervals of adjacent second emboss on the same line.
The elastic material is extended in the MD direction and partially cleaved ensuring breathability. Cleaving is avoided at crimped parts as cleavage would readily expand in at least the MD direction causing loss of the basic function of elasticity and so must be avoided. Here, a first emboss has a long lengthy shape in the direction orthogonal to the MD direction and furthermore, at least a part of the spacing between adjacent first emboss on the same line is smaller than the spacing between adjacent second emboss on the same line. As a result, cleavage more readily occurs between adjacent first emboss as compared to between adjacent second emboss. In other words, breathability can be ensured using cleavage in the area along a first line while cleavage does not occur readily in areas along a second line so elasticity (with suitable tension and durability) can be ensured in the area between the first line and second line. Furthermore, the first emboss and second emboss that are crimped are harder areas than other parts where if the first emboss and second emboss are, for example, aligned with the MD direction rather than in a direction intersecting the MD direction diagonally, hardness (high tension) will be readily apparent when extended in the MD direction and this can easily lead to low elasticity. On the other hand, if the first emboss and second emboss are, for example, aligned in the CD direction rather than intersecting diagonally, hardness (high tension) when extending in the CD direction will be readily apparent (to soft in MD direction lowering durability) and can easily lead to low elasticity. However, with the elastic material described above, the first line that the first emboss is lined up on and the second line that the second emboss is lined up on both intersect diagonally with the MD direction so elasticity is not easily lost and so are beneficial for providing both breathability and elasticity.
The elastic material according to a first embodiment can have a plurality of first emboss on the same line be arranged at equidistant intervals. With this type of elastic material, cleavage achieving balance between first emboss can easily be formed.
The elastic material according to the first embodiment can have a plurality of first emboss on the same line be arranged at non-equidistant intervals with interval spacing high density areas and interval spacing low density areas being formed. Cleavage is easier to achieve in the high density areas than the low density areas and cleavage in high density areas more readily coalesces and grows and so is beneficial for ensuring breathability.
Furthermore, the space between vertical emboss can bulge dramatically and this bulge can generate resistance to bending in the vertical direction and lead to reduction in softness. However, the elastic material according to this embodiment is prepared with a high density area where the bulging of a high density area is lower than that of a low density area enabling forming an area where the resistance described above is reduced. As a result, this elastic material is beneficial from the perspective of softness in addition to breathability and elasticity.
With the elastic material according to the first embodiment, the high density area can have a plurality of types with differing numbers of first emboss. With this type of elastic material, areas with varying density can be formed simplifying optimization of achieving breathability, elasticity, and softness.
With the elastic material according to the first embodiment, the second emboss can be a long lengthy shape in a direction diagonal to the MD direction. Compared to having the second emboss be a long lengthy shape in the MD direction or a long lengthy shape orthogonal to the MD direction, cleavage between second emboss occurs less readily enabling promoting effective cleavage in the area along the first line along which the first emboss are lined up.
An elastic material according to another aspect of the present invention comprises an elastic film, non-woven fabric laminated on both surfaces of the elastic film, and crimped parts where the non-woven fabric and elastic film are crimped and indented and extension processing performed, the crimped part is prepared with a plurality of first emboss formed on a first line and a plurality of second emboss formed on a second line beside the first line in a direction diagonally intersecting the MD direction of the elastic film, wherein the first emboss is a long lengthy shape in a direction orthogonal to the MD direction, the first line and second line are alternately arranged, at least a part of the intervals of adjacent first emboss on the same line are smaller than the intervals of adjacent second emboss on the same line.
With the elastic material described above, breathability can be ensured using cleavage in the area along a first line while cleavage does not occur readily in areas along a second line so elasticity (with suitable tension and durability) can be ensured in the area between the first line and second line. Furthermore, the first line that the first emboss is lined up on and the second line that the second emboss is lined up on both intersect diagonally with the MD direction so elasticity is not easily lost and so are beneficial for providing both breathability and elasticity.
An elastic material according to another aspect of the present invention comprises an elastic film, non-woven fabric laminated on both surfaces of the elastic film, and crimped parts where the non-woven fabric and elastic film are crimped and indented, the crimped part is prepared with a plurality of first emboss formed on a first line and a plurality of second emboss formed on a second line beside the first line in a direction diagonally intersecting the MD direction of the elastic film, wherein the first emboss is a long lengthy shape in a direction orthogonal to the MD direction, the first line and second line are alternately arranged, at least a part of the intervals of adjacent first emboss on the same line are smaller than the intervals of adjacent second emboss on the same line, and cleavage is formed on the elastic film on at least a part of the space between adjacent first emboss on the same line.
With the elastic material described above, breathability can be ensured using cleavage in the area along a first line while cleavage is difficult to generate in areas long a second line so elasticity (with suitable tension and durability) can be ensured in the area between the first line and second line. Furthermore, the first line that the first emboss is lined up on and the second line that the second emboss is lined up on both intersect diagonally with the MD direction so elasticity is not easily lost and so are beneficial for providing both breathability and elasticity.
The elastic material according to the first embodiment can have a plurality of first emboss on the same line be arranged at non-equidistant intervals with interval spacing high density areas and interval spacing low density areas being formed. Cleavage is easier to achieve in the high density areas than the low density areas and cleavage in high density areas more readily coalesces and grows and so is beneficial for ensuring breathability. Furthermore, this elastic material is prepared with a high interval density area and so is beneficial from the perspective of softness in addition to breathability and elasticity.
With the elastic material according to the first embodiment, the second emboss can be a long lengthy shape in a direction diagonal to the MD direction. Compared to having the second emboss be a long lengthy shape in the MD direction or a long lengthy shape orthogonal to the MD direction, cleavage between second emboss occurs less readily enabling promoting effective cleavage in the area along the first line along which the first emboss are lined up.
Another aspect according to the present invention is an underpants type sanitary article comprising, a main body part with an abdomen part and back part with both parts connected, the main body part being provided with a waist opening part, the main body part being provided with a pair of leg openings, and the main body part being provided with an elastic part at least along the waist opening, wherein the elastic part comprises an elastic film, non-woven fabric laminated on both surfaces of the elastic film, and crimped parts where the non-woven fabric and elastic film are crimped and indented, the crimped part is prepared with a plurality of first emboss formed on a first line and a plurality of second emboss formed on a second line beside the first line in a direction diagonally intersecting the MD direction of the elastic film, and the first emboss is a long lengthy shape in a direction orthogonal to the MD direction, the first line and second line are alternately arranged, at least a part of the intervals of adjacent first emboss on the same line are smaller than the intervals of adjacent second emboss on the same line.
With the elastic material for the sanitary article described above, breathability can be ensured using cleavage in the area along a first line while cleavage does not occur readily in areas along a second line so elasticity (with suitable tension and durability) can be ensured in the area between the first line and second line. Furthermore, the first line that the first emboss is lined up on and the second line that the second emboss is lined up on both intersect diagonally with the MD direction so elasticity is not easily lost and so are beneficial for providing both breathability and elasticity.
The elastic material for the sanitary article according to the first embodiment can have a plurality of first emboss on the same line be arranged at non-equidistant intervals with interval spacing high density areas and interval spacing low density areas being formed. Cleavage is easier to achieve in the high density areas than the low density areas and cleavage in high density areas more readily coalesces and grows and so is beneficial for ensuring breathability. Furthermore, this elastic material for sanitary articles of this embodiment is prepared with a high interval density area and so is beneficial from the perspective of softness in addition to breathability and elasticity.
An aspect of the present invention is beneficial for both breathability and elasticity.
In the terms of this specification the “first line and second line being alternately arranged” is satisfied if at least a second line is arranged between adjacent first lines or a first line is arranged between adjacent second lines. Furthermore, this is not limited to the case where the first line and second line are alternately arranged over the entire area of the full surface of the elastic member but includes an aspect where the edges are excluded and only the center area has the first line and second line arranged alternately. Note, the first line and second line do not respectively need to be straight and parallel and for example, the second line can be wave shaped.
Embodiments of the present invention are described in detail with reference to attached drawings below. Note, the same codes are used for the same or equivalent elements in description of the drawings and duplicate descriptions are omitted.
As shown in
The elastic film 2 passes over a film transport roll 53, is fed along a pattern role 52 and laminated with non-woven fabric 3 here and emboss process is performed forming a prescribed crimp part 4. Here, the pattern role 52 rotates faster than the film transport roll 53 causing the elastic film 2 to be stretched in the MD direction (for example 2 to 5 times). If the elastic film 2 has tensile yield strain (if a skin-core multilayer structure, plastic deformation of the skin) this multiplication factor should be greater than the yield. With the crimp part 4, the non-woven fabric 3 is hollow and crimped to the elastic film 2 and as a result, the elastic film 2 and both sides of non-woven fabric 3 become integrated and form the elastic material 1A.
The crimp part 4 crimps the non-woven fabric 3 and elastic film 2 and is provided with a plurality of hollow embossed parts. The plurality of embossed parts can basically be classified into two types of conditions. Specifically this is a vertical emboss 5 long and lengthy in the CD direction and non-vertical emboss 6 other than the vertical emboss 5. The dimension in the longitudinal direction of the vertical emboss 5 is in the range of 0.1 mm to 10 mm. Furthermore, the vertical emboss 5 is an example of a first emboss and is a long groove shape in the present embodiment. However, it is sufficient for the vertical emboss 5 to be specified as a long and lengthy shape in the CD direction for instance an elliptical shape, rectangular shape, or other shape.
Furthermore, the non-vertical emboss 6 is an example of the second emboss and in the present embodiment is a long grove with a long and lengthy shape in the direction intersecting diagonally with the MD direction. The dimension in the longitudinal direction of the non-vertical emboss 6 is in the range of 0.1 mm to 10 mm. Furthermore, the non-vertical emboss 6 can be an elliptical shape, rectangular shape, or other shape as long as it is not long and lengthy in the MD direction or CD direction.
Non-woven fabric 3 is laminated on both surfaces of the elastic material 1A. When viewing the surface of the non-woven fabric 3, a plurality of vertical emboss 5 are formed in the first line lined up in the direction intersecting diagonally relative to the MD direction and a plurality of first lines are formed on the surface of the non-woven fabric 3 without differentiating front and back. When identifying the first line, for example, one of the vertical emboss 5 are designated as reference. Next, the closest adjacent vertical emboss 5 to the reference vertical emboss 5 is specified and straight lines are suppositioned in the direction these two vertical emboss 5 are lined up with. Note that in the case a plurality of vertical emboss are lined up in a wave shape, the lineup direction is taken to be a straight line that connects between the amplitude (center point) of the wave shapes. Next, if a plurality of other vertical emboss 5 are arranged overlapped on this straight line, the first line is judged to be formed by this plurality of vertical emboss 5 lined up on this straight line.
Furthermore, the plurality of non-vertical emboss 6 form a second line lined up in a direction diagonally intersecting relative to the MD direction. The surface of the non-woven fabric 3 has a plurality of second lines formed and the second lines are respectively formed along the first line. Specifically, if the plurality of non-vertical emboss 6 provided along the first line exist, the second line is made up of these plurality of non-vertical emboss 6.
Here, a “direction intersecting diagonally relative to the MD direction” means not being a direction in the MD direction (Machine Direction) or a direction in the CD direction (Cross Machine Direction) that is orthogonal to the MD direction. Specifically describing this, a direction that diagonally intersects relative to the MD direction is a direction 10 degrees to 80 degrees, preferably 15 degrees to 75 degrees, and more preferably 20 degrees to 60 degrees relative to the MD direction. In further detail, prior to extension processing and under tension (when performing emboss processing using the elastic material manufacturing equipment 50); preferably 10 degrees to 50 degrees relative to the MD direction, prior to extension processing and released from the elastic material manufacturing equipment 50 and loosened; preferably 35 degrees to 75 degrees relative to the MD direction, after extension processing and while under tension (while performing cleavage); preferably 15 degrees to 55 degrees relative to the MD direction, after extension processing and loosening after performing extension processing, preferably 40 degrees to 80 degrees relative to the MD direction.
A plurality of first lines and plurality of second lines are alternately arranged. The being alternately arranged is satisfied if at least a second line is arranged between adjacent first lines or a first line is arranged between adjacent second lines. However, this is not limited to the case that a plurality of first lines and plurality of second lines being alternately arranged over the entire surface of the elastic material 1A but first lines can be lined up on a part or second lines can be lined up on a part.
A plurality of emboss 5 on the same line can be arranged at non-equidistant intervals with interval spacing high density areas Sa and interval spacing low density areas Sb being formed. Specifically, with the present embodiment, three vertical emboss 5 are lined up forming one emboss group G and a plurality of emboss groups G are lined up on the first line. The interval between a plurality of emboss group G (hereafter “low density intervals”) db is larger than the interval between three vertical emboss 5 (hereafter “high density interval”) that form an emboss group G. In other words, areas that are emboss group G are high density areas Sa and areas between emboss group G are low density areas Sb.
On the other hand, the intervals between non-vertical emboss 6 are the same. The intervals for non-vertical emboss 6 are at least larger than the vertical emboss 5 high density interval da. This means that at least a part of the intervals (high density intervals) between vertical emboss 5 lined up on the same line are smaller than the intervals of non-vertical emboss 6.
Note, the intervals for vertical emboss 5 and intervals for non-vertical emboss 6 basically mean the distance in the direction along line one or line two. In other words, when looking at two vertical emboss 5 lined up next to each other along line 1, the closest distance can be taken to be the interval between vertical emboss 5. Furthermore, when looking at two non-vertical emboss 6 lined up next to each other along line 2, the closest distance can be taken to be the interval between non-vertical emboss 6.
When considering the arrangement relationship of the vertical emboss 5 and non-vertical emboss 6, the small interval part (high density part) between vertical emboss 5 adjacent on the same line is smaller than the interval with a non-vertical emboss 6. Specifically, with an arbitrary vertical emboss 5 designated as reference, of two vertical emboss 5 adjacent to the reference vertical emboss 5 (reference emboss), specify the vertical emboss 5 (adjacent emboss) with the smaller interval. Here, the interval between the adjacent emboss and the reference emboss is smaller than the interval of the non-vertical emboss 6 closest to the reference emboss with the reference emboss.
Note, the interval of vertical emboss 5 is the interval between vertical emboss 5 on the same line and means the closest position of the vertical emboss 5 and in the present embodiment is a distance along the first line. The intervals of vertical emboss 5 of the high density areas Sa can be 0.1 mm to 3 mm and preferably are 0.3 mm to 1 mm. The intervals of vertical emboss 5 of the low density areas Sb are larger than the high density areas Sa and can be 0.5 mm to 20 mm and preferably are 0.8 mm to 3 mm. Furthermore, with the present embodiment, each of the high density interval da are uniform and the low density interval db are also uniform but these do not have to strictly be uniform. Furthermore, by there being both high density interval da and low density interval db, overall, the interval of a plurality of vertical emboss 5 are non-uniform.
Furthermore, according to the present embodiment, the elastic material 1A has non-woven fabric 3 laminated on both surfaces and the natural softness of the material is not readily lost due to forming of crimp part 4. This softness can be shown using a Gurley stiffness value and means, for example, the lowness of rigidity when bent in a vertical direction relative to the surface thereof (vertical direction from either MD direction or CD direction). For example, the non-woven fabric 3 bulges between vertical emboss 5 generating a mountain, hill, or fold type bulge. This bulge part generates resistance relative to bending in the vertical direction and in particular if this bulge part is formed over the entire elastic material 1A, it may lead to reducing the level of softness. However, the elastic material 1A according to this embodiment is prepared with an interval spacing high density areas Sa and interval spacing low density areas Sb where the bulging of a high density area Sa is lower than that of a low density area Sb enabling forming an area where the resistance described above is reduced. As a result, this elastic material 1A is better from the perspective of softness. Furthermore, the first line on which a plurality of vertical emboss 5 are lined up on is along a direction diagonally intersecting relative to the MD direction where even if there is a bulge part formed, the bulge part will be formed along a direction intersecting diagonally relative to the MD direction. As a result, this does not readily cause resistance for a position along the MD direction or CD direction and is therefore more beneficial from the perspective of softness in the MD direction and CD direction.
The elastic film 2 is made up of a resin material containing elastomer. The type of elastomer is not in particular restricted and examples are styrene-isoprene-styrene block copolymer (SIS), styrene-butadiene-styrene block copolymer (SBS), styrene-ethylene/butylene-styrene block copolymer (SEBS), polyurethane, ethylene copolymer (for example ethylene vinyl acetate, ethylene propylene copolymer, ethylene propylene diene terpolymer), and propylene oxide (PO). From the perspective of convenience during the manufacturing process, a multilayer structure with a polyolefin or the like skin on at least one surface of an elastomer core is preferable.
Resin material that makes up the elastic film 2 preferably contains components other than those described above. For example this resin material preferably contains a stiffening agent (for example polyvinyl styrene, polystyrene, poly α-methyle styrene, polyester, epoxy resin, polyolefin, coumarone-indene resin), a viscosity reducing agent, plasticizer, tackifier (for example, aliphatic hydrocarbon tackifier, aromatic hydrocarbon tackifier, terpene resin tackifier, hydrogenated terpene resin tackifier), dyes, pigments, antioxident, antistatic agent, adhesive, antiblocking agent, slip agent, maturation stabilizer, light stabilizer, foaming agent, glass bubble, starch, metal salt, and micro fibers and the like.
The non-woven fabric 3 can be widely used as a material machined into fibers where materials can be suitably combined or fiber length or fiber size adjusted to provided a prescribed level of softness. The material of the non-woven fabric 3 is preferably a mixed fiber of, for example, polypropylene fiber, polyester fiber, and polyolefin fiber blended, a concentric composite fiber of a polyethylene terephthalate core material with polyethylene covering the core material. The manufacturing method of the non-woven fabric 3 is preferably, for example, the spun bond method, spun lace method, or thermal bond method.
Next, elastic material 1B according to embodiment 2 will be described with reference to
Temperature conditions when extending the elastic material 1B are not in particularly restricted and can be at room temperature. The extension multiple of the elastic material 1B should be roughly 1.5 to 3 times compared to the elastic material 1A loosened after manufacturing on the elastic material manufacturing equipment 50 (equivalent to 2 to 5 times that of the elastic film 2 prior to manufacturing the elastic material 1A) and can be greater than the extension multiple assumed for practicality.
Performing extension processing on the elastic material 1B according to embodiment 1 causes cleavage 7 to be generated on the elastic film 2 and as a result suitable breathability is ensured. The cleavage 7 is generated outside of the vertical emboss 5 and non-vertical emboss 6. Here, the vertical emboss 5 have a long length shape in the direction orthogonal to the MD direction and the intervals between adjacent vertical emboss 5 on the same line are smaller than the intervals between adjacent non-vertical emboss 6 on the same line. As a result, cleavage more readily occurs between adjacent vertical emboss 5 as compared to between adjacent non-vertical emboss 6.
In other words, with the elastic material 1B according to embodiment 2, cleavage 7 is formed in the elastic film 2 and the cleavage 7 is generated in the area along line 1. In
If extension processing is performed in the MD direction, stress more readily concentrates in the high density areas Sa rather than low density areas Sb and thus cleavage 7 are more likely to be generated in high density areas Sa. Furthermore, the intervals between high density areas Sa in other words between vertical emboss 5 that form an emboss group G are narrow causing aggregation of cleavage 7 that occur separately causing larger cleavage 7 to more readily grow. As a result this can be said to be beneficial for improving breathability.
Next, elastic material 1C according to embodiment 3 will be described with reference to
The elastic material 1C according to embodiment 3 is a non-woven fabric material with non-woven fabric 3 laminated on both sides of an elastic film 2. The elastic material 1C is prepared with crimp parts 4 crimped to the elastic film 2 where the non-woven fabric 3 is hollow and is integrated with the elastic film 2 and non-woven fabric 3 on both surfaces by the crimp part 4.
The crimp part 4 is provided with a plurality of vertical emboss 5 and plurality of non-vertical emboss 6. The plurality of vertical emboss 5 form a first line lined up in a direction diagonally intersecting relative to the MD direction. The surface of the non-woven fabric 3 has a plurality of first lines formed. Furthermore, the plurality of non-vertical emboss 6 form a second line lined up in a direction diagonally intersecting relative to the MD direction. The surface of the non-woven fabric 3 has a plurality of second lines formed and the second lines are respectively formed along the first line. A plurality of first lines and plurality of second lines are alternately arranged. Furthermore, the intervals between adjacent vertical emboss 5 on the same line are smaller than the intervals between adjacent non-vertical emboss 6 on the same line.
The intervals of a plurality of vertical emboss 5 lined up on the same line are the same (equidistant intervals) and the intervals of a plurality of non-vertical emboss 6 lined up on the same line are the same (equidistant intervals). In other words, with the elastic material 1C of the present embodiment, high density areas Sa and low density areas Sb are not formed. Note, judgment of whether or not intervals are equidistant is that there is not variability between the intervals of the plurality of vertical emboss 5 and the intervals of the non-vertical emboss 6 and if there is error of roughly 1 mm between the widest interval and the narrowest interval, they are judged to be equidistant intervals.
Performing of extension processing in the MD direction with regards to the elastic material 1C according to embodiment 3 provides post extension processed elastic material 1C. With the post extension processed elastic material 1C, cleavage 7 is formed in the elastic film 2 and the cleavage 7 is generated in the area along line 1. With the present embodiment, the intervals of the plurality of vertical emboss 5 lined up on the same line are the same so there is no difference in density causing cleavage 7 to occur relatively uniform.
Next, elastic material 1D according to embodiment 4 will be described with reference to
The elastic material 1D according to embodiment 4 is a non-woven fabric material with non-woven fabric 3 laminated on both sides of an elastic film 2. The elastic material 1D is prepared with crimp parts 4 crimped to the elastic film 2 where the non-woven fabric 3 is hollow and is integrated with the elastic film 2 and non-woven fabric 3 on both surfaces by the crimp part 4.
The crimp part 4 is provided with a plurality of vertical emboss 5 and plurality of non-vertical emboss 6. The plurality of vertical emboss 5 form a first line lined up in a direction diagonally intersecting relative to the MD direction. The surface of the non-woven fabric 3 has a plurality of first lines formed. Furthermore, the plurality of non-vertical emboss 6 form a second line lined up in a direction diagonally intersecting relative to the MD direction and the surface of the non-woven fabric 3 has a plurality of second lines formed and the second lines are respectively formed along the first line. A plurality of first lines and plurality of second lines are alternately arranged.
In the case of the elastic material 1D according to embodiment 4, there are two vertical emboss 5 that form the emboss group G and a plurality of emboss group G are lined up on line 1. The intervals between a plurality of emboss group G (low density intervals) are larger than the intervals of the two vertical emboss 5 (high density intervals). Areas that are emboss group G are high density areas Sa and areas between emboss group G are low density areas Sb. Furthermore, the intervals between adjacent vertical emboss 5 on the same line are at least smaller than a part of (dense intervals) the intervals between adjacent non-vertical emboss 6 on the same line.
Performing of extension processing in the MD direction with regards to the elastic material 1D according to embodiment 4 enables forming post extension processed elastic material 1D. With the post extension processed elastic material 1D, cleavage 7 is formed in the elastic film 2 and the cleavage 7 is generated in the area along line 1. Furthermore, the intervals between high density areas Sa in other words between vertical emboss 5 that form an emboss group G are narrow causing aggregation of cleavage 7 that occur separately causing larger cleavage 7 to more readily grow.
Next, elastic material 1E according to embodiment 5 will be described with reference to
The elastic material 1E according to embodiment 5 is a non-woven fabric material with non-woven fabric 3 laminated on both sides of an elastic film 2. The elastic material 1E is prepared with crimp parts 4 crimped to the elastic film 2 where the non-woven fabric 3 is hollow and is integrated with the elastic film 2 and non-woven fabric 3 on both surfaces by the crimp part 4.
The crimp part 4 is provided with a plurality of vertical emboss 5 and plurality of non-vertical emboss 6. The plurality of vertical emboss 5 form a first line lined up in a direction diagonally intersecting relative to the MD direction. The surface of the non-woven fabric 3 has a plurality of first lines formed. Furthermore, the plurality of non-vertical emboss 6 form a second line lined up in a direction diagonally intersecting relative to the MD direction. The surface of the non-woven fabric 3 has a plurality of second lines formed and the second lines are respectively formed along the first line. A plurality of first lines and plurality of second lines are alternately arranged.
The elastic material 1E according to embodiment 5 is a hybrid of embodiment 1 and embodiment 3 where forming two types of emboss group G provides two types of high density areas Sa. Specifically being provided with a first emboss group G made up of three vertical emboss 5 and a second emboss group G being provided with two vertical emboss 5.
The first emboss group G and second emboss group G are arranged alternately on the same line; however, the intervals of the emboss group G are not uniform; there being locations where the interval is wide and locations where the interval is narrow. In other words, with regards to the high density areas Sa of the elastic material 1E, there are a plurality of different types of vertical emboss 5 enabling forming various high density areas Sa.
On the other hand, the intervals between the three vertical emboss 5 that form the first emboss group G and the intervals between the two vertical emboss 5 that form the second emboss group G (high density intervals) are uniform. Areas that are the first emboss group G or second emboss group G are high density areas Sa and areas between emboss group G are low density areas Sb. Furthermore, the intervals between adjacent vertical emboss 5 on the same line are at least smaller than a part of (dense intervals) the intervals between adjacent non-vertical emboss 6 on the same line.
Performing of extension processing in the MD direction with regards to the elastic material 1E according to embodiment 5 enables forming post extension processed elastic material 1E. With the post extension processed elastic material 1E, cleavage 7 is formed in the elastic film 2 and the cleavage 7 is generated in the area along line 1. Furthermore, the intervals between high density areas Sa in other words between vertical emboss 5 that form an emboss group G are narrow causing aggregation of cleavage 7 that occur separately causing larger cleavage 7 to more readily grow.
With the elastic material 1A, 1C to 1E of embodiments 1, 3 to 5 described above being extended in the MD direction enables locational generation of cleavage 7 ensuring breathability as in elastic material 1B according to embodiment 2. Cleaving is avoided at crimped parts as cleavage would readily expand in at least the MD direction causing loss of the basic function of elasticity and so must be avoided. Here, the vertical emboss 5 have a long length shape in the direction orthogonal to the MD direction and the intervals between at least a part of adjacent vertical emboss 5 on the same line are smaller than the intervals between adjacent non-vertical emboss 6 on the same line. As a result, cleavage more readily occurs between adjacent vertical emboss 5 as compared to between adjacent non-vertical emboss 6, elasticity (with suitable tension and durability) can be ensured in areas between the first line and second line. Furthermore, the vertical emboss 5 and non-vertical emboss 6 that are crimped are harder areas than other parts where if the vertical emboss 5 and non-vertical emboss 6 are, for example, aligned with the MD direction rather than in a direction intersecting the MD direction diagonally, hardness (high tension) will be readily apparent when extended in the MD direction and this can easily lead to low elasticity. On the other hand, if the vertical emboss and non-vertical emboss are, for example, aligned in the CD direction rather than intersecting diagonally, hardness (high tension) when extending in the CD direction will be readily apparent (to soft in MD direction lowering durability) and can easily lead to low elasticity. However, with the elastic material 1 to 1E described above, the first line that the vertical emboss 5 is lined up on and the second line that the non-vertical emboss 6 is lined up on both intersect diagonally with the MD direction so elasticity is not easily lost and so are beneficial for providing both breathability and elasticity.
Furthermore, with the elastic material 1C according to embodiment 3, a plurality of vertical emboss 5 are arranged on the same line so with regards to this elastic material 1C, cleavage 7 is readily formed in a balanced manner between the vertical emboss 5.
With the elastic materials 1A, 1B, 1D, 1E of embodiments 1, 2, 4, and 5, a plurality of vertical emboss 5 on the same line are formed at non-equidistant intervals with interval spacing high density areas Sa and interval spacing low density areas Sb being formed. Cleavage 7 is easier to achieve in the high density areas Sa than the low density areas Sb and cleavage 7 in high density areas Sa more readily coalesce and grow and so is beneficial for ensuring breathability. Furthermore, the space between vertical emboss can bulge dramatically and this bulge can generate resistance to bending in the vertical direction and lead to reduction in softness. However, the elastic materials 1A, 1B, 1D, 1E are prepared with an interval spacing high density areas Sa where the bulging of a high density area Sa is lower than that of a low density area Sb enabling forming an area where the resistance described above is reduced. As a result, these elastic materials 1A, 1B, 1D, 1E are beneficial from the perspective of softness in addition to breathability and elasticity.
Furthermore, with the elastic material 1E according to embodiment 5, there are a plurality of types of high density areas Sa with differing number of vertical emboss 5 and with this type of elastic material 1E, various high density areas Sa can be formed simplifying optimization of achieving breathability, elasticity, and softness.
Furthermore, with the elastic material 1A to 1E according to embodiments 1 to 5, the non-vertical emboss 6 can be a long lengthy shape in a direction diagonal to the MD direction. Compared to having the non-vertical emboss 6 be a long lengthy shape in the MD direction or a long lengthy shape orthogonal to the MD direction, with the elastic material 1A to 1E of the embodiments described above, cleavage between non-vertical emboss 6 occurs less readily enabling promoting effective cleavage in the area along the first line along which the vertical emboss 5 are lined up.
Next, sanitary articles that apply the elastic material 1A to 1E according to each of the embodiments described above are described. The sanitary articles can be widely applied to underpants shape and can be applied to disposable diapers used for infants, disposable diapers used for adults, and for sanitary napkins.
In order to improve fit to the body elastic parts 15A, 15B, 15C are arranged and secured in suitable locations. The elastic parts 15A, 15B, 15C are formed by attaching the elastic materials 1A to 1E according to each of the embodiments described above. There are no restrictions in particular regarding attaching of elastic materials 1A to 1E and, for example, adhesive such as hot melt adhesive or sonic bond can be used. Note, in
Note, in the case that the elastic material 1A according to embodiment 1 described above or elastic material 1C, 1D, 1E according to embodiments 3 to 5 are applied as the elastic parts 15A, 15B, 15C described above, extension processing is performed for the elastic parts 15A, 15B, 15C of the sanitary articles 10A, 10B, 10C and can be attached after forming cleavage 7 for breathability with regards to the elastic film 2 of the elastic parts 15A, 15B, 15C or after attaching the elastic material 1A, 1C, 1D, 1E, cleavage can be formed through stretching to the wearer when putting on the sanitary article.
For example, in the case of applying the first emboss or second emboss to the periphery of the waist or buttocks of sanitary articles of a diaper prepared with an elastic part lined up in the MD direction of the first emboss and second emboss, the sanitary article will not widen out (not stretch) when being put on and therefore be more difficult to put on. For example, if the first emboss or second emboss is applied to the periphery of the waist or buttocks of a sanitary article such as a diaper prepared with an elastic part lined up in the CD direction, they are unable to follow the movements of the wearer after the sanitary article is put on causing the sanitary article to stick or gaps between the sanitary article and the body lowering the feeling of fit.
However, with the sanitary articles 10A, 10B, 10C prepared with elastic parts 15A, 15B, 15C, the line 1 that the vertical emboss 5 are lined up on and line 2 that the non-vertical emboss 6 are lined up on both diagonally intersect the MD direction and so are beneficial with regards to elasticity. In other words, sanitary articles 10A, 10B, 10C prepared with elastic parts 15A, 15B, 15C are beneficial from the perspective of both breathability and elasticity. Furthermore, in the case that the elastic material 1A, 1B, 1D, 1E described above are applied as the elastic parts 15A, 15B, 15C, they are beneficial from the perspective of softness in addition to breathability and elasticity.
The present invention is described in further detail below using examples but the present invention is not restricted to these examples. Note, polypropylene spun bond non-woven fabric 15 g/sqm was used for all of the examples. A three layer film that is a 35 g/sqm skin-core-skin was used as the elastic film that is the elastic material raw material and polypropylene was used for each skin and SIS type was used as the core.
The non-woven fabric material according to example-1 is a non-woven fabric material with non-woven fabric laminated on both surfaces of an elastic film and emboss forming performed to form crimped parts. The surface of the non-woven fabric material has a plurality of vertical emboss and plurality of non-vertical emboss formed. The non-woven fabric material according to example-corresponds to the elastic material according to example-1 and to the elastic material according to example-2. In other words, three vertical emboss are lined up in a dense manner forming one emboss group and a plurality of emboss groups are lined up on the first line. The intervals between a plurality of emboss group (low density intervals) are larger than the intervals of the three vertical emboss 5 (high density intervals) that form the emboss group. Areas that are emboss group are high density areas and areas between emboss group are low density areas.
The dimension in the longitudinal direction of the vertical emboss is approximately 1 mm and width is approximately 0.2 mm. The dimension in the longitudinal direction of the non-vertical emboss is approximately 1 mm and width is approximately 0.2 mm. Furthermore, the high density interval of vertical emboss is approximately 0.7 mm and low density interval is approximately 2 mm. Furthermore, the interval of non-vertical emboss lined up on the same line is larger than the high density interval of vertical emboss and is approximately 4 mm. Furthermore, the thickness of the non-woven fabric material according to example-1 is 1 mm.
The non-woven fabric material according to example-2 is the same as the non-woven fabric material according to example-1 except for the shape, size, and placement of the plurality of vertical emboss and plurality of non-vertical emboss. The non-woven fabric material according to example-2 corresponds to the elastic material according to embodiment 3 described above. In other words, the plurality of vertical emboss formed on one line are lined up uniformly.
The dimension in the longitudinal direction of the vertical emboss is approximately 1 mm and width is approximately 0.3 mm. The dimension in the longitudinal direction of the roughly non-vertical emboss is approximately 1 mm and width is approximately 0.3 mm. Furthermore, the interval of the vertical emboss on the same line is approximately 2 mm and the interval of the non-vertical emboss on the same line is larger than the interval of the vertical emboss and is approximately 4 mm. Furthermore, the thickness of the non-woven fabric material according to example-2 is 1.9 mm.
The non-woven fabric material according to example-3 is the same as the non-woven fabric material according to example-1 except for the shape, size, and placement of the plurality of vertical emboss and plurality of non-vertical emboss. The non-woven fabric material according to example-3 corresponds to the elastic material according to embodiment 4 described above. In other words, an emboss group is made up of two vertical emboss.
The dimension in the longitudinal direction of the vertical emboss is approximately 1 mm and width is approximately 0.2 mm. The dimension in the longitudinal direction of the non-vertical emboss is approximately 1 mm and width is approximately 0.2 mm. Furthermore, the high density interval of vertical emboss is approximately 0.9 mm and low density interval is approximately 2.9 mm. Furthermore, the interval of non-vertical emboss lined up on the same line is larger than the high density interval of vertical emboss and is approximately 4 mm. Furthermore, the thickness of the non-woven fabric material according to example-3 is 1 mm.
The non-woven fabric material according to example-4 is the same as the non-woven fabric material according to example-1 except for the shape, size, and placement of the plurality of vertical emboss and plurality of non-vertical emboss. The non-woven fabric material according to example-3 corresponds to the elastic material according to embodiment 5 described above. In other words, being provided with a first emboss group made up of three vertical emboss and a second emboss group being provided with two vertical emboss.
The dimension in the longitudinal direction of the vertical emboss is approximately 1 mm and width is approximately 0.2 mm. The dimension in the longitudinal direction of the non-vertical emboss is approximately 1 mm and width is approximately 0.2 mm.
Furthermore, the high density interval of the vertical emboss is approximately 0.9 mm and of the intervals for emboss groups, the wide interval is approximately 2.9 mm and the narrow interval is approximately 2 mm. Furthermore, the thickness of the non-woven fabric material according to example-4 is 1 mm.
With the example-described above, the direction of the first line and second line intersecting diagonally with regards to the MD direction respectively is as described below. As shown in
The non-woven fabric material according to a comparative example is the same as the non-woven fabric material according to example-1 except for the shape, size, and placement of the plurality of vertical emboss and plurality of non-vertical emboss. With regards to the non-woven fabric material according to the comparative example, the vertical emboss is not in a direction that intersects diagonally with the MD direction but is lined up along the CD direction (see dashed line in
The dimension in the longitudinal direction of the vertical emboss is approximately 1 mm and width is approximately 0.3 mm. The dimension in the longitudinal direction of the non-vertical emboss is approximately 1 mm and width is approximately 0.3 mm. Furthermore, the thickness of the non-woven fabric material according to the comparative example is 2.5 mm.
Next, extension processing tests performed with regards to each of the example and the comparative example described above will be described with reference to
As shown in
Furthermore, as shown in
Furthermore, as shown in
Furthermore, as shown in
Next, breathability tests performed with regards to each of the example-and the comparative example described above will be described. Breathability testing was performed using the air permeability test equipment described below. The results of breathability testing are shown in Table 1.
Gurley densometer manufactured by Toyo Seiki Co., Ltd. (breathability test equipment)
Internal cylinder weight (pressure): 567 g
Air permeability: 300 ml
Transmission surface hole diameter: 28.6 mm (6.45 cm2)
As shown in Table 1, the time required to transmit 300 ml for example-1 is 0.3 seconds. Furthermore, this 0.9 seconds for example-2, 0.4 seconds for example-3, and 0.3 seconds for example-4. On the other hand, this was 1.5 seconds for the comparative example. In other words, each of the examples-were better than the comparative example from the perspective of breathability.
Next, as a result of tension and compression tests performed with respect to each of the examples-and the comparative example described above, the elastic force in the MD direction (MD loading force) will be described with reference to
Next, the results of the stretch test performed in the CD direction with regards to each of the example-and the comparative example described above will be described. This testing used a rectangular sample S respectively for each example-and for the comparative example. The dimension of each sample in the MD direction was 25 mm and the dimension in the CD direction was 25 mm. In this state, the amount of extension for a 1 N load in the CD direction was measured. The measurement results are shown in Table 1.
Next, the results of a Gurley stiffness test performed with regards to each of the examples-and the comparative example described above will be described. Gurley stiffness is specified by JIS L 1913 and measures the stiffness when non-woven fabric material or the like is bent from the surface to a vertical direction (vertical direction from either MD direction or CD direction). A low value indicates softness. Gurley stiffness in the MD direction is the results of applying a force in the vertical direction in a line (bending line) that bends in the MD direction. Gurley stiffness in the CD direction is the results of applying a force in the vertical direction in a line (bending line) that bends in the CD direction. A TAPPI T543 om-11 was used for this test. The results of this testing are shown in Table 1.
The Gurley stiffness value of the comparative example in the MD direction is 4.6 mN/cm and the Gurley stiffness in the CD direction is 1.5 mN/cm. On the other hand, the Gurley stiffness in the MD direction for-example-1, example-3, and example-were relatively lower and that for example-2 at least ensured the same level. Furthermore, with regards to the Gurley stiffness in the CD direction, all of the examples-were lower than that for the comparative example.
Bulges between vertical emboss become a mountain, hill, or fold type bulge. This type of bulge causes resistance regarding bending in the vertical direction and in particular, when this bulge part is formed uniform between the vertical emboss, it can cause reduction in softness. However, the non-woven fabric material according to example 1, example-3, and example-4 is prepared with an interval spacing high density areas and interval spacing low density areas where the bulging of a high density area is lower than that of a low density area enabling forming an area where the resistance described above is reduced. As a result, the non-woven fabric material according to example-1, example-3, example-4 is better from the perspective of softness. Furthermore, while being common with example-2, the first line on which a plurality of vertical emboss are lined up on is along a direction diagonally intersecting relative to the MD direction where even if there is a bulge part formed, the bulge part will be formed along a direction intersecting diagonally relative to the MD direction. As a result, this does not readily cause resistance for a position along the MD direction or CD direction and less likely to generate resistance and better from the perspective of softness in the MD direction and CD direction.
Next, stress characteristic tests performed with regards to each of the example-and the comparative example described above will be described with reference to
As shown in
| Number | Date | Country | Kind |
|---|---|---|---|
| 2016-091516 | Apr 2016 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2017/029900 | 4/27/2017 | WO | 00 |
