Patent Application
20170356126
The present invention relates to a liquid film cleavage agent, a nonwoven fabric containing the liquid film cleavage agent, an absorbent article containing a nonwoven fabric containing the liquid film cleavage agent, and a method of producing a nonwoven fabric containing the liquid film cleavage agent.
Proposals have been recently made on improving liquid-permeation function or liquid-absorption function of a nonwoven fabric.
For example, Patent Literature 1 describes a nonwoven fabric in which absorption time of water drops dropped from a predetermined height is adjusted to be in a predetermined range for the purpose of reducing liquid backflow in an absorbent article, in which a hydrophilic treatment agent such as polyoxyalkylene group-modified polysiloxane is used in order to achieve this absorption time.
Patent Literature 2 describes an art in which a polyoxypropylene glycol-based compound serving as a blood modifier is incorporated into a topsheet for the purpose of reducing residual liquid in an absorbent article, in which the blood modifier used is a moderate material whose affinity with menstrual blood is suppressed in comparison with a surfactant.
Moreover, Patent Literature 3 similarly describes as a topsheet a material formed of two layers having convex portions on a skin contact surface side, in which the convex portions are coated with a blood lubricant that has lower affinity with menstrual blood than a surfactant.
Patent Literature 1: JP-A-2004-256935 (“JP-A” means unexamined published Japanese patent application)
The present invention provides a liquid film cleavage agent having a spreading coefficient of 15 mN/m or more to a liquid having surface tension of 50 mN/m, and a water solubility of 0 g or more and 0.025 g or less; and a nonwoven fabric containing the liquid film cleavage agent.
The present invention also provides a liquid film cleavage agent having a spreading coefficient of more than 0 mN/m to a liquid having surface tension of 50 mN/m, a water solubility of 0 g or more and 0.025 g or less, and an interfacial tension of 20 mN/m or less to the liquid having surface tension of 50 mN/m; and a nonwoven fabric containing the liquid film cleavage agent.
Other and further objects, features and advantages of the invention will appear more fully from the following description, appropriately referring to the accompanying drawings.
The present invention relates to a liquid film cleavage agent with which liquid films formed between fibers of a nonwoven fabric or the like are reduced to realize a dry feeling at a higher level. Moreover, the present invention relates to a nonwoven fabric containing the liquid film cleavage agent preferable for an absorbent article which is excellent in dry feeling and also reduces concern about leakage, an absorbent article employing the nonwoven fabric, and a method for producing the nonwoven fabric containing the liquid film cleavage agent.
The nonwoven fabric according to the present invention contains a liquid film cleavage agent. “Liquid film cleavage agent” in the present invention means an agent which inhibits formation of liquid film by cleaving liquid film formed between fibers or on a surface of the fibers of the nonwoven fabric when a liquid, for example, an excreted liquid such as a high viscosity liquid including menstrual blood or urine comes into contact with the nonwoven fabric. Liquid film cleavage is achieved by effect of the liquid film cleavage agent which thrusts away part of a layer of the liquid film to destabilize the part. It is facilitated by this effect of the liquid film cleavage agent that liquid passes through the nonwoven fabric without retaining in a narrow interfiber region of the nonwoven fabric. That is, a nonwoven fabric excellent in liquid permeability is formed. Thus, even if the fibers which constitute the nonwoven fabric are narrowed to reduce the interfiber distance, both softness of texture and suppression of residual liquid are achieved. Such a nonwoven fabric can be used, for example, in the form of a topsheet of an absorbent article such as a sanitary napkin, a baby diaper or an adult diaper.
Improvement in dry feeling has been indicated so far by nonwoven fabrics that use the treatment agent disclosed in Patent Literature 1, the blood modifier disclosed in Patent Literature 2 or the blood lubricant disclosed in Patent Literature 3. In particular, the blood modifier or the blood lubricant contributes to blood viscosity or lubricity, thereby reduces amount of liquid remaining in the topsheet formed of the nonwoven fabric. However, narrow interfiber regions exist in all nonwoven fabrics, and high interfiber meniscus force, high surface activity by plasma protein or high surface viscosity of the blood causes formation of a stable liquid film between the fibers resulting retention of the liquid in the region. Therefore, wetting is sensed on touch, and dry feeling has not been achievable even in a nonwoven fabric in which the conventional blood modifier or the blood lubricant has so far been applied. Further, in addition to the dry feeling, consumers have also recently shown a desire for good texture, which requires use of fine fibers. However, if fine fibers are used, the interfiber distance is further narrowed. Thus, because interfibre liquid film is even more easily formed and harder to cleave, liquid retention tends to increase.
Moreover, such a phenomenon is not limited to blood as the liquid targeted for absorption, and phospholipid also exhibits surface activity in urine by which liquid film is formed in a manner similar to that described above, so that dry feeling has not yet been satisfiede.
Thus, an art for eliminating liquid film formed in a narrow interfiber part in a nonwoven fabric has been sought, but elimination has been difficult owing to the high stability of liquid film. Moreover, it is also conceivable to eliminate liquid film by applying a water-soluble surfactant to reduce liquid surface tension. However, if an attempt is made to enable removal of liquid film by using such a surfactant in the absorbent article, the liquid is liable to permeate through a liquid leak-proof backsheet.
To solve the above-described problem, formation of liquid film between the fibers of nonwoven fabric or the like is reduced by incorporating the liquid film cleavage agent according to the present invention into the nonwoven fabric or the like to realize a higher level of dry feeling. Moreover, the nonwoven fabric containing the liquid film cleavage agent according to the present invention is excellent in dry feeling, and if this nonwoven fabric is used, an absorbent article that relieves concern about leakage can be provided.
The liquid film cleavage agent is applied on constituent fibers in at least some regions of the nonwoven fabric, and contained. At least some regions on which the agent is coated are preferably regions where a particularly large amount of liquid is received. For example, when the nonwoven fabric according to the present invention is processed into the topsheet of an absorbent article such as a sanitary napkin, the coated region is one corresponding to a wearer's excretion region where an excreted liquid such as menstrual blood is received.
Moreover, with regard to thickness direction of the nonwoven fabric according to the present invention, the cleavage agent is preferably contained at least into a surface on a liquid receiving side. In the topsheet of the above-described example, the liquid film cleavage agent is contained at least into a place on the skin-contact surface side in contact with the wearer's skin.
As termed with respect to the present invention, the expression “the nonwoven fabric contains or has the liquid film cleavage agent” means that the liquid film cleavage agent is mainly attached to the surface of the fibers. However, insofar as the liquid film cleavage agent remains present on the surface of the fibers, it is also acceptable for the liquid film cleavage agent to be present inside the fibers, or to be present inside the fibers by internally incorporating. As a method of attaching the liquid film cleavage agent to the surface of the fibers, any of various commonly utilized methods can be adopted without particular restriction. Specific examples thereof include coating by a sprayer, coating by a slot coater, coating by roll transfer, and immersion. Such treatment may be applied to the fibers before being formed into a web, or may be applied after the fibers are formed into a web by any of various methods. The fibers on the surface to which the liquid film cleavage agent is attached are dried, for example, by a dryer of a hot air blowing type at a temperature sufficiently lower than melting point of a fiber resin (for example, 120° C. or lower). Moreover, when the liquid film cleavage agent is attached to the fibers using the above-described attaching method, the attachment is performed by using a solution containing the liquid film cleavage agent prepared by dissolving the liquid film cleavage agent into a solvent when necessary, or an emulsified liquid or a dispersion liquid of the liquid film cleavage agent.
In order for the liquid film cleavage agent according to the present invention to exhibit the liquid film cleavage effect explained later in the nonwoven fabric, the liquid film cleavage agent is required to be present in a fluid state when the liquid film cleavage agent touches a bodily fluid. Owing to this, melting point of the liquid film cleavage agent according to the present invention is preferably 40° C. or lower, and further preferably 35° C. or lower. Further, the melting point of the liquid film cleavage agent according to the present invention is preferably −220° C. or higher, and further preferably −180° C. or higher.
Hereinafter, preferable embodiments of the liquid film cleavage agent and the nonwoven fabric containing the liquid film cleavage agent according to the present invention will be described.
In a liquid film cleavage agent in a first embodiment, a spreading coefficient thereof to a liquid having surface tension of 50 mN/m is 15 mN/m or more and a water solubility thereof is 0 g or more and 0.025 g or less. A nonwoven fabric in the first embodiment contains the liquid film cleavage agent.
The term “spreading coefficient to a liquid having surface tension of 50 mN/m” of the liquid film cleavage agent means the spreading coefficient in the case where the excreted liquid such as the menstrual blood and urine as described above is assumed. The “spreading coefficient” means a value to be determined, based on Expression (1) and from a measured value obtained by the measuring method mentioned later in an environmental region of a temperature of 25° C. and a relative humidity (RH) of 65%. Further, the liquid film in Expression (1) means a liquid phase of the “liquid having surface tension of 50 mN/m,” including both of the liquid in a state in which the film is formed between the fibers or on the surface of the fibers, and the liquid in a state before the film is formed, which is also referred to only as the liquid. Moreover, the surface tension in Expression (1) means interfacial tension on an interface of the liquid film and the liquid film cleavage agent respectively to a gas phase, and is differentiated from interfacial tension of the liquid film cleavage agent to the liquid film between liquid phases. The same rule of this differentiation also applies to other descriptions herein.
S=γ
w−γo−γwo (1)
γw: surface tension of a liquid film (liquid).
γo: surface tension of a liquid film cleavage agent.
γwo: interfacial tension of a liquid film cleavage agent to a liquid film.
As is known from Expression (1), the spreading coefficient (S) of the liquid film cleavage agent is increased as the surface tension (γo) of the liquid film cleavage agent is reduced, and as the interfacial tension (γwo) of the liquid film cleavage agent to the liquid film is reduced. When the spreading coefficient is 15 mN/m or more, the liquid film cleavage agent has high mobility, namely, high diffusivity, on the surface of the liquid film formed in a narrow interfiber region. From this viewpoint, the spreading coefficient of the liquid film cleavage agent is preferably 20 mN/m or more, more preferably 25 mN/m or more, and further preferably 30 mN/m or more. On the other hand, an upper limit thereof is not particularly limited, but from Expression (1), the surface tension of the liquid which forms the liquid film serves as the upper limit of the spreading coefficient of the liquid film cleavage agent, in such a manner that a value of the upper limit is 50 mN/m when a liquid having surface tension of 50 mN/m is used, a value of the upper limit is 60 mN/m when a liquid having surface tension of 60 mN/m is used, and a value of the upper limit is 70 mN/m when a liquid having surface tension of 70 mN/m is used. Therefore, from a viewpoint of using the liquid having surface tension of 50 mN/m in the present invention, the upper limit is 50 mN/m or less.
The term “water solubility” of the liquid film cleavage agent means mass of the liquid film cleavage agent which is dissolvable in 100 g of deionized water, and is a value to be measured in an environmental range of a temperature of 25° C. and a relative humidity (RH) of 65% based on the measuring method described later. When this water solubility is 0 g or more and 0.025 g or less, the liquid film cleavage agent is hard to dissolve and forms the interface with the liquid film to make the above-described diffusivity more effective. From a similar viewpoint, the water solubility of the liquid film cleavage agent is preferably 0.0025 g or less, more preferably 0.0017 g or less, and further preferably less than 0.0001 g. Moreover, the water solubility is preferably smaller, and is 0 g or more, and from a viewpoint of the diffusivity on the liquid film, the water solubility is practically adjusted to 1.0×10−9 g or more. Further, the water solubility is considered to be applied also to menstrual blood, urine or the like which contains water as a main component.
The surface tension (γw) of the liquid film (a liquid having surface tension of 50 mN/m), the surface tension (γo) of the liquid film cleavage agent, the interfacial tension (γwo) of the liquid film cleavage agent to the liquid film, and the water solubility of the liquid film cleavage agent are measured by the following methods.
In addition, when a measurement object nonwoven fabric is a member (for example, the topsheet) assembled in the absorbent article such as a sanitary napkin and a disposable diaper, the nonwoven fabric is taken as described below and measured. That is, an adhesive or the like used for bonding between a measurement object member and other members in the absorbent article is weakened by a cooling means such as a cold spray, and then the measurement object member is carefully peeled off and obtained. This removal method is applied in measurement related to the nonwoven fabric according to the present invention, such as the measurement of an interfiber distance and fineness to be mentioned later.
Moreover, when the liquid film cleavage agent attached to the fibers is measured, the fibers to which the liquid film cleavage agent is attached are first washed with a washing liquid such as hexane, methanol and ethanol, then a solvent (washing solvent containing the liquid film cleavage agent) used for the washing is dried to isolate the liquid film cleavage agent. Mass of the isolated substance at this time is applied upon calculating a content proportion (OPU) of the liquid film cleavage agent to fiber mass. When an amount of the isolated substance is not enough for the measurement of the surface tension or the interfacial tension, a suitable column and a suitable solvent are selected according to components of the isolated substance, and then each component is fractionated by high performance liquid chromatography, and MS measurement, NMR spectroscopy, elementary analysis or the like is further performed each fraction to identify a structure of each fraction. Moreover, when the liquid film cleavage agent contains a polymer compound, a technique such as gel permeation chromatography (GPC) is simultaneously used to further facilitate to perform identification of a constituent. Then, a sufficient amount is obtained by procurement if the substance is a commercial item or by synthesis if the substance is not the commercial item, to measure surface tension or the interfacial tension. In particular, with regard to the measurement of the surface tension and the interfacial tension, when the liquid film cleavage agent obtained as described above is solid, the liquid film cleavage agent is heated to a temperature of a melting point of the liquid film cleavage agent plus 5° C. to induce phase transition into liquid, and the measurement is performed with keeping the temperature conditions.
In an environmental range of a temperature of 25° C. and a relative humidity (RH) of 65%, measurement can be performed using a platinum plate by a plate method (Wilhelmy method). As a measuring apparatus on the above occasion, an automatic surface tensiometer “CBVP-Z” (trade name, manufactured by Kyowa Interface Science Co., Ltd.) can be used. As the platinum plate, a plate having purity of 99.9%, and a size of 25 mm width and 10 mm length is used.
Further, the above-mentioned “liquid having surface tension of 50 mN/m” is a solution adjusted to be 50±1 mN/m by adding a surfactant to deionized water by applying the above-described measuring method.
Measurement can be performed using the same apparatus by the plate method in the same manner with the measurement of the surface tension (γw) of the liquid film in the environmental range of the temperature of 25° C. and the relative humidity (RH) of 65%. Upon this measurement, as mentioned above, when the obtained liquid film cleavage agent is solid, the liquid film cleavage agent is heated to the level of the melting point of the liquid film cleavage agent plus 5° C. to induce phase transition into liquid, and the measurement is performed with keeping the temperature conditions.
In an environmental range of a temperature of 25° C. and a relative humidity (RH) of 65%, measurement can be performed by a pendant drop method. As a measuring apparatus on the above occasion, Automatic Interface Viscoelasticity Measurement Apparatus (trade name “THE TRACKER,” manufactured by TECLIS-IT CONCEPT) can be used. In the pendant drop method, adsorption of the surfactant contained in the liquid having surface tension of 50 mN/m starts simultaneously when a drop is formed, interfacial tension decreases with elapse of time. Therefore, the interfacial tension when the drop is formed (at 0 seconds) is read. Moreover, upon this measurement, as mentioned above, when the obtained liquid film cleavage agent is solid, the liquid film cleavage agent is heated to a temperature of a melting point of the liquid film cleavage agent plus 5° C. to induce phase transition into liquid, and the measurement is performed with keeping the temperature conditions.
Moreover, upon measurement of the interfacial tension, when a density difference between the liquid film cleavage agent and the liquid having surface tension of 50 mN/m is significantly small, when viscosity is markedly high, or when an interfacial tension value is equal to or less than a measuring limit of the pendant drop, the measurement of the interfacial tension by the pendant drop method becomes difficult in several cases. On the above case, the measurement can be performed by a spinning drop method in the environmental range of the temperature of 25° C. and the relative humidity (RH) of 65%. As a measuring apparatus on the above occasion, a spinning drop interfacial tensiometer (trade name “SITE100,” manufactured by KURUSS) can be used. Moreover, also with regard to the measurement, the interfacial tension when a shape of a drop is stabilized is read, and when the obtained liquid film cleavage agent is solid, the liquid film cleavage agent is heated to a temperature of a melting point of the liquid film cleavage agent plus 5° C. to induce phase transition into liquid, and the measurement is performed with keeping the temperature conditions.
In addition, when the interfacial tension can be measured by both measuring apparatuses, a smaller interfacial tension value is adopted as measurement results.
In an environmental range of a temperature of 25° C. and relative humidity (RH) of 65%, the obtained liquid film cleavage agent is gradually dissolved therein while 100 g of deionized water is stirred by a stirrer, and a dissolved amount at a time point of resulting in no dissolution (when suspension, precipitation, deposition or cloudiness is observed) is taken as the water solubility. Specifically, the agent is added for every 0.0001 g, and the measurement is performed. As a result, a sample in which the agent in an amount as small as 0.0001 g is observed to be not dissolved therein, the water solubility is taken as “less than 0.0001 g,” and a sample in which the agent in an amount of 0.0001 g is observed to be dissolved therein, and the agent in an amount of 0.0002 g is observed to be not dissolved therein, the water solubility is taken as “0.0001 g.” Further, when the liquid film cleavage agent is a surfactant, the term “dissolution” means both monodisperse dissolution and micellar dispersion dissolution, and a dissolved amount at a time point of observation of suspension, precipitation, deposition or cloudiness is taken as the water solubility.
As the liquid film cleavage agent in the embodiment has the spreading coefficient and the water solubility as set out above, it can spread without being dissolved on the surface of the liquid film and can thrust away a layer of the liquid film nearly from the vicinity of a center of the liquid film. Thus, the liquid film is destabilized and cleaved.
The above-described effect of the liquid film cleavage agent in the nonwoven fabric in the embodiment herein is specifically described referring to
As shown in
Thus, the liquid film cleavage agent according to the present invention induces drainage of the liquid from the inside of the nonwoven fabric, not by modifying a property of the liquid such as by reducing its surface tension, but by cleaving the liquid film per se formed between the fibers or on the surface of the fibers, while thrusting away and inhibiting formation of the liquid film. Thus, residual liquid in the nonwoven fabric can be reduced. Moreover, if such a nonwoven fabric is assembled into an absorbent article such as a topsheet, retention of the liquid between the fibers is suppressed, and a liquid permeation route to an absorbent body is ensured. Thus, the liquid permeability is improved, liquid flow on a surface of the sheet is suppressed, and absorption rate of the liquid is improved. In particular, the absorption rate of a liquid which easily retaines between the fibers, such as high viscosity menstrual blood, can be improved. As a result, a comfortable absorbent article of high reliability can be formed in which staining such as redness in the topsheet is inconspicuous and whose absorptive force is perceivable.
Further, in the embodiment, the interfacial tension of the liquid film cleavage agent to the liquid having surface tension of 50 mN/m is preferably 20 mN/m or less, which means that “interfacial tension (γwo) of the liquid film cleavage agent to the liquid film” being one variable for determining the value of the spreading coefficient (S) in Expression (1) mentioned above is 20 mN/m or less. The spreading coefficient of the liquid film cleavage agent is improved by suppressing “interfacial tension (γwo) of the liquid film cleavage agent to the liquid film,” and the liquid film cleavage agent easily moves from the surface of the fibers to the vicinity of the center of the liquid film, and the above-mentioned effect becomes clearer. From this viewpoint, “the interfacial tension to the liquid having surface tension of 50 mN/m” of the liquid film cleavage agent is more preferably 17 mN/m or less, further preferably 13 mN/m or less, still further preferably 10 mN/m or less, particularly preferably 9 mN/m or less, and especially preferably 1 mN/m or less. On the other hand, a lower limit thereof is not particularly limited, and only needs to be larger than 0 mN/m from a viewpoint of insolubility into the liquid film. Further, if the interfacial tension is 0 mN/m, that is, if the liquid film cleavage agent is soluble, the interface between the liquid film and the liquid film cleavage agent cannot be formed, and therefore Expression (1) does not hold, and spreading of the agent does not occur.
As is known from the expression, a numerical value of the spreading coefficient changes depending on the surface tension of a target liquid. For example, when the surface tension of the target liquid is 72 mN/m, the surface tension of the liquid film cleavage agent is 21 mN/m, and the interfacial tension thereof is 0.2 mN/m, the spreading coefficient becomes 50.8 mN/m.
Moreover, when the surface tension of the target liquid is 30 mN/m, the surface tension of the liquid film cleavage agent is 21 mN/m, and the interfacial tension thereof is 0.2 mN/m, the spreading coefficient becomes 8.8 mN/m.
In any cases, in an agent in which the spreading coefficient is larger, a liquid film cleavage effect becomes larger.
In this description, the numerical value in the surface tension of 50 mN/m is defined. However, even if the surface tension is different, there exists no change in a magnitude relationship of the numerical value of the spreading coefficient between substances. Therefore, even if the surface tension of the bodily fluid should be changed depending on a daily physical condition or the like, the agent in which the spreading coefficient is larger shows a superb liquid film cleavage effect.
Moreover, in the embodiment, the surface tension of the liquid film cleavage agent is preferably 32 mN/m or less, more preferably 30 mN/m or less, further preferably 25 mN/m or less, and particularly preferably 22 mN/m or less. Moreover, the surface tension is preferably smaller, and a lower limit thereof is not particularly limited. From a viewpoint of durability of the liquid film cleavage agent, the surface tension is practically 1 mN/m or more.
Next, a liquid film cleavage agent and a nonwoven fabric containing the liquid film cleavage agent in a second embodiment will be described.
In the liquid film cleavage agent in the second embodiment, a spreading coefficient thereof to a liquid having surface tension of 50 mN/m is larger than 0 mN/m, namely, a positive value, a water solubility thereof is 0 g or more and 0.025 g or less, and an interfacial tension thereof to the liquid having surface tension of 50 mN/m is 20 mN/m or less. The nonwoven fabric in the second embodiment contains the liquid film cleavage agent. To have the “interfacial tension thereof to the liquid having surface tension of 50 mN/m” of 20 mN/m or less, as mentioned above, means that the diffusivity of the liquid film cleavage agent on the liquid film is improved as mentioned above. Thus, even when the spreading coefficient is comparatively small as in the case where “spreading coefficient to the liquid having surface tension of 50 mN/m” is less than 15 mN/m, the diffusivity is high, and therefore a large amount of the liquid film cleavage agent is dispersed to the liquid film from the surface of the fibers, and the effect similar to the effect in the case of the first embodiment can be produced by thrusting away the liquid film in many positions.
Further, the “spreading coefficient to the liquid having surface tension of 50 mN/m,” the “water solubility” and the “interfacial tension to the liquid having surface tension of 50 mN/m” with regard to the liquid film cleavage agent are defined in a manner same as definitions in the first embodiment, and the measuring methods thereof are the same.
In the embodiment, from a viewpoint of further effectively exhibiting the effect of the liquid film cleavage agent, the above-described “interfacial tension to the liquid having surface tension of 50 mN/m” is preferably 17 mN/m or less, more preferably 13 mN/m or less, further preferably 10 mN/m or less, still further preferably 9 mN/m or less, and particularly preferably 1 mN/m or less. A lower limit is not particular limited in a manner similar to the first embodiment, and from a viewpoint of insolubility in the liquid film (the liquid having surface tension of 50 mN/m), the interfacial tension is practically adjusted to be larger than 0 mN/m.
Moreover, from a viewpoint of further effectively exhibiting the effect of the liquid film cleavage agent, the “spreading coefficient to the liquid having surface tension of 50 mN/m” is preferably 9 mN/m or more, more preferably 10 mN/m or more, and further preferably 15 mN/m or more. An upper limit thereof is not particularly limited, but from a viewpoint in which the surface tension of the liquid which forms the liquid film serves as the upper limit from Expression (1), the spreading coefficient is substantially 50 mN/m or less.
Moreover, further preferable ranges of the surface tension and the water solubility of the liquid film cleavage agent are the same with the ranges in the first embodiment.
The nonwoven fabric in the first embodiment and the nonwoven fabric in the second embodiment each preferably further contain, in addition to the above-described respective liquid film cleavage agents, a phosphoric acid ester type anionic surfactant. Thus, hydrophilicity on the surface of the fibers is improved and wettability is improved to increase a contact area in which the liquid film and the liquid film cleavage agent are brought into contact. In addition, because blood and urine contain a surface active substance having a phosphoric acid group which originates in a living body, when the surfactant having the phosphoric acid group is used together with the liquid film cleavage agent, the surfactant shows a compatibility and a fine affinity for phospholipid contained in blood and urine. Thereby, the liquid film cleavage agent easily moves onto the liquid film, and cleavage of the liquid film is further induced. A content ratio of the liquid film cleavage agent to the phosphoric acid ester type anionic surfactant is preferably (1:1) to (19:1), more preferably (2:1) to (15:1), and further preferably (3:1) to (10:1) in terms of a mass ratio. In particular, the content ratio is preferably (5:1) to (19:1), further preferably (8:1) to (16:1), and still further preferably (11:1) to (13:1) in terms of a mass ratio.
The phosphoric acid ester type anionic surfactant can be used without particular restriction. Specific examples thereof include alkyl ether phosphoric acid ester, dialkyl phosphoric acid ester and alkyl phosphoric acid ester. Above all, alkyl phosphoric acid ester is preferable from a viewpoint of a function of improving affinity for the liquid film and providing processability of the nonwoven fabric.
As alkyl ether phosphoric acid ester, various kinds thereof can be used without particular restriction. Specific examples include alkyl ether phosphoric acid ester having a saturated carbon chain such as polyoxyalkylene stearyl ether phosphoric acid ester, polyoxyalkylene myristyl ether phosphoric acid ester, polyoxyalkylene lauryl ether phosphoric acid ester and polyoxyalkylene palmityl ether phosphoric acid ester; alkyl ether phosphoric acid ester having an unsaturated carbon chain such as polyoxyalkylene oleyl ether phosphoric acid ester and polyoxyalkylene palmitoleyl ether phosphoric acid ester; and alkyl ether phosphoric acid ester having a side chain in each carbon chain thereof. The alkyl ether phosphoric acid ester is further preferably a completely or partially neutralized salt of mono- or di-polyoxyalkylene alkyl ether phosphoric acid ester having a carbon chain of 16 to 18. Moreover, specific examples of polyoxyalkylene include polyoxyethylene, polyoxypropylene, polyoxybutylene and a material in which constituent monomers thereof are copolymerized. In addition, specific examples of a salt of alkyl ether phosphoric acid ester include a salt with alkali metal such as sodium and potassium, ammonia and various amines. As alkyl ether phosphoric acid ester, one kind can be used alone, or two or more kinds can be mixed and used.
Specific examples of alkyl phosphoric acid ester include alkyl phosphoric acid ester having a saturated carbon chain such as stearyl phosphoric acid ester, myristyl phosphoric acid ester, lauryl phosphoric acid ester and palmityl phosphoric acid ester; alkyl phosphoric acid ester having an unsaturated carbon chain such as oleyl phosphoric acid ester and palmitoleyl phosphoric acid ester; and alkyl phosphoric acid ester having a side chain in each carbon chain thereof. Further preferably, the alkyl phosphoric acid ester is a completely or partially neutralized salt of monoalkyl phosphoric acid ester or dialkyl phosphoric acid ester having a carbon chain of 16 to 18. In addition, specific examples of a salt of alkyl phosphoric acid ester include a salt with alkali metal such as sodium and potassium, ammonia and various amines. As alkyl phosphoric acid ester, one kind can be used alone, or two or more kinds can be mixed and used.
In the first embodiment and the second embodiment, a contact angle of constituent fibers of the nonwoven fabric containing the liquid film cleavage agent, or the liquid film cleavage agent and the phosphoric acid ester type anionic surfactant as described above is preferably 90 degrees or less, more preferably 80 degrees or less, and further preferably 70 degrees or less. Thus, the surface of the fibers becomes hydrophilic, a wettable area is increased, and the liquid film cleavage agent easily moves onto the liquid film.
Measurement of the above-described contact angle can be performed by the following method.
That is, fibers are taken from a predetermined site of a nonwoven fabric, and a contact angle of water to the fibers is measured. As a measuring apparatus, Automatic Contact Angle Meter MCA-J manufactured by Kyowa Interface Science Co., Ltd. is used. Deionized water is used for measurement of the contact angle. Measurement is performed under measurement conditions of a temperature of 25° C. and relative humidity (RH) of 65%. A liquid amount to be dropped from an inkjet system water droplet jet unit (Pulse Injector CTC-25 having a jet unit bore of 25 μm, manufactured by Cluster Technology Co., Ltd.) is set to 20 picoliters, and a water drop is dropped just above the fibers. An aspect of dropping is recorded on a high-speed recording device connected to a horizontally installed camera. From a viewpoint of performing image analysis later, a personal computer in which a high-speed capture device is assembled is preferable as a recording device. In the measurement, an image is recorded for every 17 msec. In the recorded video, a first image in which the water drop is dropped on the fibers taken from the nonwoven fabric is subjected to image analysis by using attached software FAMAS (a software version: 2.6.2, an analysis technique: liquid drop method, an analysis method: θ/2 method, an image processing algorithm: non-reflection, an image processing image mode: frame, a threshold level: 200, and no curvature correction), an angle between a surface of waterdrop in contact with air, and the fibers is calculated, and the calculated angle is taken as the contact angle. The fibers taken from the nonwoven fabric are cut to a fiber length of 1 mm, and the fibers are placed on a sample stage of the contact angle meter, and horizontally maintained. Contact angles in different two places are measured for one piece of the fibers. The contact angles in case of N=5 pieces are measured to one decimal point, and a value obtained by averaging measurement values of ten places in total (rounded to one decimal place) is defined as the contact angle.
Next, specific examples of the liquid film cleavage agents in the first embodiment and the second embodiment will be described. These agents are in the above-mentioned specific numerical value range to have properties of being insoluble in water or hardly soluble in water, and exhibit the above-described liquid film cleavage effect. In contrast, the surfactant or the like to be used as the conventional fiber treating agent is basically a water-soluble agent which is practically dissolved in water and used, and is not the liquid film cleavage agent according to the present invention.
As the liquid film cleavage agent in the first embodiment and the second embodiment, a compound having a mass average molecular weight of 500 or more is preferable. The mass average molecular weight greatly influences viscosity of the liquid film cleavage agent. If the viscosity is excessively low, move of the liquid film cleavage agent from the fibers to the liquid film is enhanced to cause running down of the liquid film cleavage agent when the liquid passes through the nonwoven fabric, so that sustainability of the liquid film cleavage effect is reduced. From a viewpoint of adjusting the viscosity to a level at which the liquid film cleavage effect is sufficiently sustained, the mass average molecular weight of the liquid film cleavage agent is more preferably 1000 or more, further preferably 1,500 or more, and particularly preferably 2,000 or more. On the other hand, if the viscosity is excessively high, diffusivity is reduced in several cases, and from a viewpoint of adjusting the viscosity to a level at which this diffusivity is held, the mass average molecular weight is preferably 50,000 or less, more preferably 20,000 or less, and further preferably 10,000 or less. Measurement of the average molecular weight is performed by using gel permeation chromatograph (GPC) “CCPD” (trade name, manufactured by TOSOH CORPORATION). Measurement conditions are as described below. Moreover, calculation of equivalent molecular weight is performed by using polystyrene.
Separation column: GMHHR-H+GMHHR-H (cation)
Solvent flow rate: 1.0 ml/min
Separation column temperature: 40° C.
Moreover, as the liquid film cleavage agent in the first embodiment, as mentioned below, a compound having at least one kind structure selected from the group consisting of the following structures X, X—Y and Y—X—Y is preferable.
The structure X designates a siloxane chain having a structure in which any of basic structures of >C(A)- (C designates a carbon atom, moreover, <, > and — each designate a bonding hand, hereinafter, the same applies.), —C(A)2-, —C(A)(B)—, >C(A)-C(R1)<, >C(R1)—, —C(R1)(R2)—, —C(R1)2—, >C<, —Si(R1)2O— and —Si(R1)(R2)O is repeated, or two or more kinds thereof are combined; or a mixed chain thereof. The structure X has, in an end of the structure X, a hydrogen atom or at least one kind of group selected from the group consisting of —C(A)3, —C(A)2B, —C(A)(B)2, —C(A)2-C(R1)3, —C(R1)2A, —C(R1)3, —OSi(R1)3, —OSi(R1)2(R2), —Si(R1)3 and —Si(R1)2(R2).
The above-described R1 and R2 each independently designate various substituents such as a hydrogen atom, an alkyl group (the number of carbon atoms is preferably 1 to 20, for example, a methyl group, an ethyl group or a propyl group is preferable.), an alkoxy group (the number of carbon atoms is preferably 1 to 20, for example, a methoxy group or an ethoxy group is preferable.), an aryl group (the number of carbon atoms is preferably 6 to 20, for example, a phenyl group is preferable.) and a halogen atom (for example, a fluorine atom is preferable.). A and B each independently designate a substituent including an oxygen atom or a nitrogen atom, such as a hydroxyl group, a carboxylic acid group, an amino group, an amide group, an imino group and a phenol group. When a plurality of R1, R2, A and B exist for each in the structure X, these may be identical to or different from each other. Moreover, a continuous inter-C(carbon atoms) or inter-Si bonding is ordinarily a single bond, but may include a double bond or a triple bond, and the inter-C or inter-Si bonding may include a linking group such as an ether group (—O—), an amide group (—CONRA—: RA is a hydrogen atom or a monovalent group), an ester group (—COO—), a carbonyl group (—CO—) or a carbonate group (—OCOO—). The number of bonding of one C and one Si with any other C or Si is 1 to 4, and a long-chain silicone chain (siloxane chain) or a mixed chain may be branched or may have a radial structure.
Y designates a hydrophilic group having hydrophilicity, the group containing an atom selected from a hydrogen atom, a carbon atom, an oxygen atom, a nitrogen atom, a phosphorus atom or a sulfur atom. Specific examples include a hydrophilic group alone, such as a hydroxyl group, a carboxylic acid group, an amino group, an amide group, an imino group, a phenol group, a polyoxyalkylene group (the number of carbon atoms of an oxyalkylene group is preferably 1 to 4, for example, a polyoxyethylene (POE) group and a polyoxypropylene (POP) group are preferable.), a sulfonic acid group, a sulfate group, a phosphoric acid group, a sulfobetaine group, a carbobetaine group, a phosphobetaine group (the betaine group means a betaine residual group formed by removing one hydrogen atom from each betaine compound.) and a quaternary ammonium group; or a hydrophilic group formed from a combination thereof. In addition thereto, specific examples also include a group and a functional group listed in M1 as mentioned below. In addition, when a plurality of Y exists, these groups may be identical to or different from each other.
In the structures X—Y and Y—X—Y, Y is bonded with X or a group at an end of X. When Y is bonded with the group at the end of X, for example, the group at the end X is bonded with Y after hydrogen atoms and the like in the number identical with the number of bonding with Y are eliminated.
In this structure, the above-mentioned spreading coefficient, water solubility and interfacial tension can be satisfied by selecting the hydrophilic groups Y, A and B from the groups specifically described. Thus, an objective liquid film cleavage effect is developed.
In the above-described liquid film cleavage agent, a compound in which the structure X has a siloxane structure is preferable. Further, as specific examples of the above-described structures X, X—Y, Y—X—Y in the liquid film cleavage agent, a compound comprising a siloxane chain in which structures represented by any one of the following formulas (1) to (11) are arbitrarily combined is preferable. Further, from a viewpoint of the liquid film cleavage effect, it is preferable that the compound has a mass average molecular weight in the range mentioned above.
In Formulas (1) to (11), M1, L1, R21 and R22 designate the following monovalent or polyvalent (divalent or more valent) group. R23 and R24 designate the following monovalent or polyvalent (divalent or more valent) group or a single bond.
M1 designates a polyoxyethylene group, a polyoxypropylene group, a polyoxybutylene group, a group having a polyoxyalkylene group in combination therewith, an erythritol group, a xylitol group, a sorbitol group, a hydrophilic group having a plurality of hydroxyl groups such as a glycerol group or an ethylene glycol group (a hydrophilic group formed by removing one hydrogen atom from the above-described compound having a plurality of hydroxyl groups such as erythritol), a hydroxyl group, a carboxylic acid group, a mercapto group, an alkoxy group (the number of carbon atoms is preferably 1 to 20, for example, a methoxy group is preferable.), an amino group, an amide group, an imino group, a phenol group, a sulfonic acid group, a quaternary ammonium group, a sulfobetaine group, a hydroxysulfobetaine group, a phosphobetaine group, an imidazolium betaine group, a carbobetaine group, an epoxy group, a carbinol group, a (meth)acrylic group or a functional group in combination therewith. In addition, when M1 is a polyvalent group, M1 designates a group formed by further removing one or more hydrogen atoms from each of the groups or the functional group as mentioned above.
L1 designates a linking group of an ether group, an amino group (the amino group adoptable as L1 is represented by >NRC (RC is a hydrogen atom or a monovalent group).), an amide group, an ester group, a carbonyl group or a carbonate group.
R21, R22, R23 and R24 each independently designate an alkyl group (the number of carbon atoms is preferably 1 to 20, for example, a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, a pentyl group, a hexyl group, a heptyl group, 2-ethylhexyl group, a nonyl group or a decyl group is preferable.), an alkoxy group (the number of carbon atoms is preferably 1 to 20, for example, a methoxy group or an ethoxy group is preferable.), an aryl group (the number of carbon atoms is preferably 6 to 20, for example, a phenyl group is preferable.), a fluoroalkyl group, an aralkyl group, a hydrocarbon group in combination therewith, or a halogen atom (for example, a fluorine atom is preferable.). In addition, when R22 and R23 are a polyvalent group, a polyvalent hydrocarbon group formed by further removing one or more hydrogen atoms or fluorine atoms from the above-described hydrocarbon group is represented.
Moreover, when R22 or R23 is bonded with M1, specific examples of a group adoptable as R22 or R23 include, in addition to each of the groups, the hydrocarbon group or the halogen atom described above, an imino group adoptable as R32.
Above all, the liquid film cleavage agent is preferably a compound having the structure represented by any of Formulas (1), (2), (5) and (10) as X, and having the structure represented by any of the above-described formulas other than these formulas as a group formed of an end of X or formed of the end of X and Y. Further, the liquid film cleavage agent is preferably a compound comprising a siloxane chain having at least one structure represented by any of the above-described formulas (2) (4), (5), (6), (8) and (9) as a group formed of X or formed of the end of X and Y.
Specific examples of the above-described compound include organic-modified silicone (polysiloxane) of a silicone-based surfactant. Specific examples of organic-modified silicone being modified with a reactive organic group include amino-modified silicone, epoxy-modified silicone, carboxy-modified silicone, diol-modified silicone, carbinol-modified silicone, (meth) acrylic-modified silicone, mercapto-modified silicone and phenol-modified silicone. Moreover, specific examples of organic-modified silicone being modified with a nonreactive organic group include polyether-modified silicone (including polyoxyalkylene-modified silicone), methylstyryl-modified silicone, long-chain alkyl-modified silicone, higher fatty acid ester-modified silicone, higher alkoxy-modified silicone, higher fatty acid-modified silicone and fluorine-modified silicone. The spreading coefficient at which the above-described liquid film cleavage effect is produced can be obtained by appropriately changing a molecular weight of a silicone chain, a modification ratio, the addition number of moles of a modifying group, or the like in corresponding to kinds of the organic-modified silicone, for example. The term “long chain” herein means a material in which the number of carbon atoms is 12 or more, and preferably 12 to 20. Moreover, the term “higher” means a material in which the number of carbon atoms is 6 or more, and preferably 6 to 20.
Above all, modified silicone having a structure in which the liquid film cleavage agent being the modified silicone has at least one oxygen atom in a modifying group, such as polyoxyalkylene-modified silicone, epoxy-modified silicone, carbinol-modified silicone and diol-modified silicone, is preferable, and polyoxyalkylene modified-silicone is particularly preferable. Polyoxyalkylene-modified silicone is hard to be permeated into the fibers, and easy to remain on the surface thereof because polyoxyalkylene-modified silicone has a polysiloxane chain. Moreover, with the respect to polyoxyalkylene-modified silicone, the affinity with water is improved, and the interfacial tension is small by comprising a hydrophilic polyoxyalkylene chain, and therefore move onto a surface of the liquid film as mentioned above is easily induced, and such a case is preferable. Moreover, even if thermal fusion processing such as embossing is applied, polyoxyalkylene-modified silicone easily remains on the surface of the fibers in the part, and the liquid film cleavage effect is hardly reduced. The liquid film cleavage effect is sufficiently developed particularly in an embossed part in which the liquid is easy to accumulate, and therefore such a case is preferable.
Specific examples of the polyoxyalkylene-modified silicone include compounds represented by the following formulas [I] to [IV]. Further, the polyoxyalkylene-modified silicone preferably has the mass average molecular weight in the above-mentioned range from a viewpoint of the liquid film cleavage effect.
In the formulas, R31 designates an alkyl group (the number of carbon atoms is preferably 1 to 20, for example, a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, a pentyl group, a hexyl group, a heptyl group, a 2-ethyl-hexyl group, a nonyl group or a decyl group is preferable.). R32 designates a single bond or an alkylene group (the number of carbon atoms is preferably 1 to 20, for example, a methylene group, an ethylene group, a propylene group or a butylene group is preferable.), and preferably designates the alkylene group. A plurality of R31 and a plurality of R32 may be each identical to or different from each other. M11 designates a group having a polyoxyalkylene group, and the polyoxyalkylene group is preferable. Specific examples of the above-described polyoxyalkylene group include a polyoxyethylene group, a polyoxypropylene group, a polyoxybutylene group or a material in which constituent monomers thereof are copolymerized. Then, m and n are each independently an integer of 1 or more. In addition, signs of these repeating units are separately determined in each of Formulas (I) to (IV), and do not always represent an identical integer, and may be different from each other.
Moreover, polyoxyalkylene-modified silicone may have either or both of modifying groups of polyoxyethylene modification and polyoxypropylene modification. Moreover, the modified silicone preferably has a methyl group in R31 as an alkyl group of a silicone chain in order to have insolubility in water and low interfacial tension. A material having this modifying group or the silicone chain is not particularly limited, but materials described in the paragraphs {0006} and {0012} in JP-A-2002-161474 are exemplified. Further specific examples include polyoxyethylene (POE) polyoxypropylene (POP)-modified silicone, polyoxyethylene (POE)-modified silicone and polyoxypropylene (POP)-modified silicone. Specific examples of POE-modified silicone include POE (3)-modified dimethyl silicone to which 3 moles of POE are added. Specific examples of POP-modified silicone include POP (10)-modified dimethyl silicone, POP (12)-modified dimethyl silicone and POP (24)-modified dimethyl silicone, to which 10 moles of POP, 12 moles of POP and 24 moles of POP are added, respectively.
The spreading coefficient and the water solubility in the above-mentioned first embodiment can be adjusted in predetermined ranges, for example, in the polyoxyalkylene-modified silicone, by the addition number of moles of polyoxyalkylene groups (the number of bonding oxyalkylene groups which form a polyoxyalkylene group based on 1 mole of polyoxyalkylene modified silicone), the following modification ratio or the like. In this liquid film cleavage agent, the surface tension and the interfacial tension can be adjusted to predetermined ranges in a similar manner, respectively.
From the above-described viewpoint, the addition number of moles of the polyoxyalkylene groups is preferably 1 or more. At the number less than 1, the interfacial tension is increased for the above-described liquid film cleavage effect to cause reduction of the spreading coefficient, and therefore the liquid film cleavage effect is weakened. From this viewpoint, the addition number of moles is more preferably 3 or more, and further preferably 5 or more. On the other hand, if the addition number of moles is excessively large, the liquid film cleavage agent becomes hydrophilic, and the water solubility is increased. From this viewpoint, the addition number of moles is preferably 30 or less, more preferably 20 or less, and further preferably 10 or less.
If the modification ratio of modified silicone is excessively small, the hydrophilicity is impaired, and therefore the modification ratio is preferably 5% or more, more preferably 10% or more, and further preferably 20% or more. Moreover, if the modification ratio is excessively large, the liquid film cleavage agent is dissolved in water, and therefore the modification ratio is preferably 95% or less, more preferably 70% or less, and further preferably 40% or less. In addition, the modification ratio of the modified silicone means a proportion of the number of repeating units of a modified siloxane bonding portion based on the total number of repeating units of a siloxane bonding portion in one molecule of the modified silicone. For example, the modification ratio is expressed by the expression: (n/m+n)×100% in Formulas [I] and [IV], the expression: (2/m)×100% in Formula [II], and the expression: (1/m)×100% in Formula [III].
Moreover, the spreading coefficient and the water solubility mentioned above each can be set in a predetermined range, in addition to the material described above, for example, in polyoxyalkylene-modified silicone, by simultaneously using a water-soluble polyoxyethylene group, and a water-insoluble polyoxypropylene group and a water-insoluble polyoxybutylene group as a modifying group, by changing a molecular weight of a water-insoluble silicone chain, or introducing an amino group, an epoxy group, a carboxy group, a hydroxyl group, a carbinol group thereinto in addition to polyoxyalkylene modification as the modifying group, or the like.
Polyalkylene modified silicone used as the liquid film cleavage agent is preferably contained in 0.02 mass % or more and 5.0 mass % or less in terms of a content proportion (Oil Per Unit) to fiber mass. If the content proportion of the polyalkylene modified silicone is excessively large, a surface material becomes sticky, and therefore such a case is not preferable. From this viewpoint, the content proportion (OPU) is more preferably 1.0 mass % or less, and further preferably 0.40 mass % or less. Moreover, if the content proportion of the polyalkylene modified silicone is excessively small, the liquid film cleavage effect becomes insufficient. From this viewpoint, the content proportion (OPU) is more preferably 0.04 mass % or more, and further preferably 0.10 mass % or more.
As the liquid film cleavage agent in the second embodiment, as mentioned later, a compound having at least one kind structure selected from the group consisting of the following structures Z, Z—Y and Y—Z—Y is preferable.
The structure Z designates a hydrocarbon chain having a structure in which any of basic structures of >C(A)- (C: carbon atom), —C(A)2-, —C(A)(B)—, >C(A)-C(R3)<, >C(R3)—, —C(R3)(R4)—, —C(R3)2— and >C< is repeated, or two or more kinds thereof are combined. The structure Z has, at an end thereof, a hydrogen atom or at least one kind of group selected from the group consisting of —C(A)3, —C(A)2B, —C(A)(B)2, —C(A)2-C(R3)3, —C(R3)2A and —C(R3)3.
The above-described R3 and R4 each independently designate various kinds of substituents such as a hydrogen atom, an alkyl group (the number of carbon atoms is preferably 1 to 20, for example, a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, a pentyl group, a hexyl group, a heptyl group, a 2-ethyl-hexyl group, a nonyl group or a decyl group is preferable.), an alkoxy group (the number of carbon atoms is preferably 1 to 20, for example, a methoxy group or an ethoxy group is preferable.), an aryl group (the number of carbon atoms is preferably 6 to 20, for example, a phenyl group is preferable.), a fluoroalkyl group, or an aralkyl group, or a hydrocarbon group in combination therewith, or a fluorine atom. A and B each independently designates a substituent containing an oxygen atom or a nitrogen atom, such as a hydroxyl group, a carboxylic acid group, an amino group, an amide group, an imino group or a phenol group. When a plurality of R3, R4, A or B are each included in the structure X, these may be identical to or different from each other. Moreover, a continuous inter-C(carbon atoms) bonding is ordinarily a single bond, but may include a double bond or a triple bond, and the inter-C bonding may include a linking group such as an ether group, an amide group, an ester group, a carbonyl group or a carbonate group. The number of bonding of one C with any other C is 1 to 4, and a long-chain hydrocarbon chain may have a branched structure or may have a radial structure.
Y designates a hydrophilic group having hydrophilicity, the hydrophilic group containing an atom selected from a hydrogen atom, a carbon atom, an oxygen atom, a nitrogen atom, a phosphorus atom and a sulfur atom. Specific examples include: a hydroxyl group, a carboxylic acid group, an amino group, an amide group, an imino group and a phenol group; or a polyoxyalkylene group (the number of carbon atoms of an oxyalkylene group is preferably 1 to 4, for example, a polyoxyethylene group, a polyoxypropylene group, a polyoxybutylene group, or a polyoxyalkylene group in combination therewith is preferable.); or a hydrophilic group having a plurality of hydroxyl groups, such as an erythritol group, a xylitol group, a sorbitol group, a glycerol group and an ethylene glycol group; or a hydrophilic group alone, such as a sulfonic acid group, a sulfate group, a phosphoric acid group, a sulfobetaine group, a carbobetaine group, a phosphobetaine group, a quaternary ammonium group, an imidazolium betaine group, an epoxy group, a carbinol group and a methacrylic group; or a hydrophilic group formed of a combination thereof. In addition, when Y is plural, the plurality may be identical to or different from each other.
In the structures Z—Y and Y—Z—Y, Y is bonded with Z or a group at an end of Z. When Y is bonded with the group at the end of Z, the group at the end of Z is bonded with Y, for example, after hydrogen atoms and the like in the number identical with the number of bonding with Y are eliminated.
In this structure, the spreading coefficient, the water solubility and the interfacial tension mentioned above can be satisfied by selecting the hydrophilic groups Y, A and B from the groups specifically described. Thus, an objective liquid film cleavage effect is developed.
The liquid film cleavage agent is preferably a compound obtained by arbitrarily combining structures represented by the following formulas (12) to (25) as specific examples of the structures Z, Z—Y and Y—Z—Y. Further, from a viewpoint of the liquid film cleavage effect, it is preferable that this compound has a mass average molecular weight in the above-mentioned range.
In Formulas (12) to (25), M2, L2, R41, R42 and R43 designate the following monovalent or polyvalent (divalent or more valent) group.
M2 designates a polyoxyethylene group, a polyoxypropylene group, a polyoxybutylene group, a group having a polyoxyalkylene group in combination therewith, an erythritol group, a xylitol group, a sorbitol group, a hydrophilic group having a plurality of hydroxyl groups such as a glycerol group or an ethylene glycol group, a hydroxyl group, a carboxylic acid group, a mercapto group, an alkoxy group (the number of carbon atoms is preferably 1 to 20, for example, a methoxy group is preferable.), an amino group, an amide group, an imino group, a phenol group, a sulfonic acid group, a quaternary ammonium group, a sulfobetaine group, a hydroxysulfobetaine group, a phosphobetaine group, an imidazolium betaine group, a carbobetaine group, an epoxy group, a carbinol group, a (meth)acrylic group or a functional group in combination therewith.
L2 designates a linking group such as an ether group, an amino group, an amide group, an ester group, a carbonyl group, a carbonate group, a polyoxyethylene group, a polyoxypropylene group, or a polyoxybutylene group, or a polyoxyalkylene group in combination therewith.
R41, R42 and R43 each independently designate various substituents such as a hydrogen atom, an alkyl group (the number of carbon atoms is preferably 1 to 20, for example, a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, a pentyl group, a hexyl group, a heptyl group, 2-ethylhexyl group, a nonyl group or a decyl group is preferable.), an alkoxy group (the number of carbon atoms is preferably 1 to 20, for example, a methoxy group or an ethoxy group is preferable.), an aryl group (the number of carbon atoms is preferably 6 to 20, for example, a phenyl group is preferable.), a fluoroalkyl group, an aralkyl group, a hydrocarbon group in combination therewith, or a halogen atom (for example, a fluorine atom is preferable.).
When R42 is a polyvalent group, R42 designates a group formed by further removing one or more hydrogen atoms from the above-described each substituent.
In addition, at an end of the bonding hand described in each structure, any other structure may be arbitrarily linked, or a hydrogen atom may be introduced.
Further, specific examples of the above-described compounds include the following compounds, but are not limited thereto.
First, examples thereof include a polyether compound and a nonionic surfactant. Specific examples thereof include polyoxyalkylene alkyl (POA) ether represented by any of formulas in Formula [V]; and polyoxyalkylene glycol which is represented by any of formulas in Formula [VI] and has a mass average molecular weight of 1000 or more, Steareth, Beheneth, PPG myristyl ether, PPG stearyl ether and PPG behenyl ether. As polyoxyalkylene alkyl ether, lauryl ether to which POP is added in 3 moles or more and 24 moles or less, and preferably in 5 moles, or the like is preferable. As a polyether compound, polypropylene glycol having a mass average molecular weight of 1000 to 10000 and preferably 3000 to which polypropylene glycol is added in 17 moles or more and 180 moles or less, and preferably in about 50 moles or the like is preferable. In addition, the measurement of the mass average molecular weight can be performed by the above-mentioned measuring method.
The polyether compound or nonionic surfactant is preferably contained in 0.10 mass % or more and 5.0 mass % or less in terms of a content proportion (Oil Per Unit) to fiber mass. If the content proportion of the polyether compound or the nonionic surfactant is excessively large, a surface material becomes sticky, and therefore such a case is not preferable. From this viewpoint, the content proportion (OPU) is more preferably 1.0 mass % or less, and further preferably 0.40 mass % or less. Moreover, if the content proportion of the polyether compound or the nonionic surfactant is excessively small, the liquid film cleavage effect becomes insufficient. From this viewpoint, the content proportion (OPU) is 20 more preferably 0.15 mass % or more, and further preferably 0.20 mass % or more.
In the Formulas, L21 designates a linking group such as an ether group, an amino group, an amide group, an ester group, a carbonyl group, a carbonate group, a polyoxyethylene group, a polyoxypropylene group, or a polyoxybutylene group, or a polyoxyalkylene group in combination therewith. R51 designate various substituents such as a hydrogen atom, a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, a pentyl group, a hexyl group, a heptyl group, 2-ethylhexyl group, a nonyl group, a decyl group, a methoxy group, an ethoxy group, a phenyl group, a fluoroalkyl group, an aralkyl group, a hydrocarbon group in combination therewith, or a fluorine atom. a, b, m and n each are independently an integer of 1 or more. CmHn herein designates an alkyl group (n=2m+1), and CaHb designates an alkylene group (a=2b). In addition, the number of carbon atoms and the number of hydrogen atoms are each independently determined in each of Formulas (V) and (VI), and do not always represent an identical integer, and may be different from each other. Hereinafter, a same rule applies also to m, m′, m″, n, n′ and n″ in formulas (VII) to (XV). In addition, “m” in —(CaHbO)m— is an integer of 1 or more. Values of the repeating units are each independently determined in each of Formulas (V) and (VI), and do not always represent an identical integer, and may be different from each other.
The spreading coefficient, the surface tension and the water solubility described above in the second embodiment each can be set in a predetermined range, in the polyether compound or the nonionic surfactant, for example, by the number of moles of a polyoxyalkylene group, or the like. From this viewpoint, the number of mole of the polyoxyalkylene group is preferably 1 or more and 70 or less. At the number less than 1, the interfacial tension is high, and the above-described liquid film cleavage effect is weakened. From this viewpoint, the number of moles is more preferably 5 or more, and further preferably 7 or more. On the other hand, if the number of moles is excessively large, entanglement of molecular chains is strong, and therefore diffusivity in the liquid film is deteriorated, and such a case is not preferable. From this viewpoint, the addition number of moles is preferably 70 or less, more preferably 60 or less, and further preferably 50 or less.
Moreover, the spreading coefficient, the surface tension, interface tension and the water solubility described above each can be set in a predetermined range, in the polyether compound or the nonionic surfactant, for example, by simultaneously using a water-soluble polyoxyethylene group and a water-insoluble polyoxypropylene group and a water-insoluble polyoxybutylene group, by changing a chain length of a hydrocarbon chain, by using a material having a branched chain in a hydrocarbon chain, by using a material having a double bond in a hydrocarbon chain, by using a material having a benzene ring or a naphthalene ring in a hydrocarbon chain, or by appropriately combining the above.
Second, examples include a hydrocarbon compound having 5 or more carbon atoms. From a viewpoint in which spreading on the surface of the liquid film is further enhanced in a state of fluid, the number of carbon atoms is preferably 100 or less, and more preferably 50 or less. The hydrocarbon compound, excluding polyorganosiloxane, is not limited to a straight chain, and may have a branched chain, in which the chain is not particularly limited to a saturated chain or an unsaturated chain. Moreover, the hydrocarbon compound may have a substituent such as ester and ether in an intermediate and an end thereof. Above all, the hydrocarbon compound in fluid at ordinary temperature is preferable and used alone. The hydrocarbon compound is preferably contained in 0.10 mass % or more and 5.0 mass % or less in terms of a content proportion (Oil Per Unit) to fiber mass. If the content proportion of the hydrocarbon compound is excessively large, the nonwoven fabric becomes sticky, and therefore the above-mentioned liquid film cleavage effect becomes hard to exhibit, and therefore such a case is not preferable. From this viewpoint, the content proportion (OPU) is preferably 1.0 mass % or less, more preferably 0.99 mass % or less, and further preferably 0.40 mass % or less. Moreover, if the content proportion of the hydrocarbon compound is excessively small, the liquid film cleavage effect becomes insufficient. From this viewpoint, the content proportion (OPU) is more preferably 0.15 mass % or more, and further preferably 0.20 mass % or more.
Examples of the hydrocarbon compound include oil or fat, such as natural oil or natural fat. Specific examples include palm oil, camellia oil, castor oil, coconut oil, corn oil, olive oil, sunflower oil, tall oil, and a mixture thereof.
Moreover, specific examples include fatty acid as represented by Formula (VII), such as caprylic acid, capric acid, oleic acid, lauric acid, palmitic acid, stearic acid, myristic acid, behenic acid, and a mixture thereof.
CmHn—COOH [VII]
In Formula [VII], m and n each independently are an integer of 1 or more. CmHn herein designates a hydrocarbon group of the above-described fatty acid.
Examples of straight-chain or branched-chain, saturated or unsaturated, or substituted or unsubstituted polyhydric alcohol fatty acid ester or a mixture of polyhydric alcohol fatty acid ester include glycerol fatty acid ester or pentaerythritol fatty acid ester as represented by Formula (VIII-I) or (VIII-II), and specific examples include glyceryl tricaprylate, glyceryl tripalmitate and a mixture thereof. In addition, a certain amount of monoester, diester and trimester is typically included in the mixture of glycerol fatty acid ester or pentaerythritol fatty acid ester. Specific preferable examples of the glycerol fatty acid ester include a mixture of glyceryl tricaprylate and glyceryl tricapryate. Moreover, from a viewpoint of reducing the interfacial tension to obtain a higher spreading coefficient, polyhydric alcohol fatty acid ester into which a polyoxyalkylene group is introduced in a degree at which water insolubility can be maintained may be used.
In Formulas [VIII-I] and [VIII-II], m, m′, m″, n, n′ and n″ each are independently an integer of 1 or more. A plurality of m or a plurality of n each may be identical to or different from each other. CmHn, Cm′Hn′ and Cm″Hn″ each herein designate a hydrocarbon group of the above-described fatty acid.
Examples of fatty acid or a fatty acid mixture in which straight-chain or branched-chain, saturated or unsaturated fatty acid forms polyol and ester with polyol having a large number of hydroxyl groups, and part of hydroxyl groups remain without being esterified, include a partially esterified product of glycerol fatty acid ester, sorbitan fatty acid ester or pentaerythritol fatty acid ester as represented by any of formulas in Formula (IX), any of formulas in Formula (X) or any of formulas in Formula (XI). Specific examples thereof include ethylene glycol monomyristate, ethylene glycol dimyristate, ethylene glycol palmitate, ethylene glycol dipalmitate, glyceryl dimyristate, glyceryl dipalmitate, glyceryl monooleate, sorbitan monooleate, sorbitan monostearate, sorbitan dioleate, sorbitan tristearyl, pentaerythritol monostearate, pentaerythritol dilaurate, pentaerythritol tristearate, and a mixture thereof. In addition, a certain quantity of a completely esterified compound is typically included in the mixture formed of the partially esterified product of glycerol fatty acid ester, sorbitan fatty acid ester, pentaerythritol fatty acid ester or the like.
In Formula [IX], m and n each are independently an integer of 1 or more. A plurality of m or a plurality of n each may be identical to or different from each other. CmHn herein designates a hydrocarbon group of the above-described fatty acid.
In the formula [X], R52 designates a straight-chain or branched-chain, or saturated or unsaturated hydrocarbon group (alkyl group, alkenyl group, alkynyl group or the like) having 2 or more and 22 or less carbon atoms. Specific examples include a 2-ethylhexyl group, a lauryl group, a myristyl group, a palmityl group, a stearyl group, a behenyl group, an oleyl group and a linoleic group.
In Formula [XI], m and n each are independently an integer of 1 or more. A plurality of m or a plurality of n each may be identical to or different from each other. CmHn herein designates a hydrocarbon group of the above-described fatty acid.
Moreover, examples include sterol, phytosterol and a sterol derivative. Specific examples include cholesterol, sitosterol, stigmasterol and ergosterol, and a mixture thereof, each having a sterol structure of Formula (XII).
Specific examples of alcohol include lauryl alcohol, myristyl alcohol, cetyl alcohol, stearyl alcohol, cetostearyl alcohol, behenyl alcohol and a mixture thereof, as represented by Formula (XIII).
CmHn—OH [XI]
In Formula [XIII], m and n each are independently an integer of 1 or more. CmHn herein designates a hydrocarbon group of the above-described alcohol.
Specific examples of fatty acid ester include isopropyl myristate, isopropyl palmitate, cetyl ethylhexanoate, triethylhexanoin, octyldodecyl myristate, ethylhexyl palmitate, ethylhexyl stearate, butyl stearate, myristyl myristate, stearyl stearate, cholesteryl isostearate and a mixture thereof, as represented by Formula (XIV).
CmHn—COO—CmHn [XIV]
In Formula [XIV], m and n each are independently an integer of 1 or more. Two pieces of CmHn herein may be identical to or different from each other. CmHn in CmHn—COO— designates a hydrocarbon group of each fatty acid described above. CmHn in —COOCmHn designates a hydrocarbon group derived from alcohol which forms ester.
Moreover, specific examples of wax include ceresin, paraffin, vaseline, mineral oil and liquid isoparaffin, as represented by Formula (XV).
CmHn [XV]
In Formula [XV], m and n each are independently an integer of 1 or more.
The spreading coefficient, the surface tension, the water solubility and the interfacial tension each mentioned above in the second embodiment can be set in a predetermined range, in the above-described hydrocarbon compound having the number of carbon atoms of 5 or more, for example, by introducing a small amount of hydrophilicity polyoxyethylene group thereinto at a degree at which water insolubility can be maintained, by introducing a polyoxypropylene group or polyoxybutylene group which is hydrophobic but can reduce the interfacial tension, by changing a chain length of a hydrocarbon chain, by using a material having a branched chain in a hydrocarbon chain, by using a material having a double bond in a hydrocarbon chain, by using a material having a benzene ring or a naphthalene ring in a hydrocarbon chain, or the like.
In the nonwoven fabric according to the present invention, in addition to the above-mentioned liquid film cleavage agent, other components may be contained thereinto, when necessary. Moreover, the liquid film cleavage agent in the first embodiment and the liquid film cleavage agent in the second embodiment may be used in combination in addition to an aspect of separate using. In this regard, the same rule applies also to the first compound and the second compound in the liquid film cleavage agent in the second embodiment.
Further, in the nonwoven fabric according to the present invention, when the liquid film cleavage agent or the phosphoric acid ester type anionic surfactant being contained thereinto is identified, the identifying method described in the above-described measuring method for the surface tension (γw) of the liquid film (the liquid having surface tension of 50 mN/m) or the like can be applied.
Moreover, when a component of the liquid film cleavage agent is a compound in which a main chain has a siloxane chain, or a hydrocarbon compound in which the number of carbon atoms is 1 or more and 20 or less, a content proportion thereof (OPU) to fiber mass can be determined by dividing the content proportion of the liquid film cleavage agent by the fiber mass based on mass of a substance obtained by the above-mentioned analytical method.
The nonwoven fabric according to the present invention is formed into a product having high liquid permeability, irrespective of a thickness of the fibers or the interfiber distance. However, the nonwoven fabric according to the present invention is particularly effective when fine fibers are used. If the fine fibers are used in order to form the nonwoven fabric having softer texture than usual, the interfiber distance is reduced, and a narrow interfiber region is increased. For example, ordinarily, in the case of the nonwoven fabric (fineness: 2.4 dtex) generally used, the interfiber distance is 120 μm, and a liquid film area proportion to be formed becomes about 2.6%. However, if the fineness is reduced to 1.2 dtex, the interfiber distance is 85 μm, and the liquid film area proportion is increased to about 7.8% at a degree as high as about 3 times the proportion in an ordinary nonwoven fabric. To the contrary, the liquid film cleavage agent according to the present invention positively cleaves frequently formed liquid films to reduce liquid remains. As mentioned later, the liquid film area proportion is expressed in terms of a liquid film area proportion to be calculated by image analysis from the surface of the nonwoven fabric, and has a strong correlation with a state of the liquid remains on an outermost surface of a surface material. Therefore, if the liquid film area proportion is reduced, the liquid in the vicinity of skin is eliminated, a comfort level after excretion is improved and thus into the absorbent article which is comfortable to wear even after excretion is obtained. On the other hand, an amount of the liquid remains mentioned later means an amount of the liquid retained in the nonwoven fabric as a whole. If the liquid film area proportion is minimized, the liquid remains are reduced, although the reduction is not unconditionally proportional. Moreover, whiteness of the surface is expressed in terms of an L value mentioned later. With regard to the L value, a numerical value tends to increase by reduction of the liquid remains as induced by cleaving of the liquid film on the surface, in which the whiteness easily becomes visually conspicuous. In the nonwoven fabric containing the liquid film cleavage agent according to the present invention, even if the fibers are thinned, the liquid film area proportion and the amount of the liquid remains are reduced, and the L value can be increased, and therefore both a dry feeling and soft texture given by thinning the fibers can be satisfied at a high level. Moreover, the nonwoven fabric according to the present invention is used as the constituent member such as the surface material of the absorbent article to achieve a high dry feeling in the part in contact with skin, and inconspicuousness of dirt with the bodily liquid by visual whiteness, and therefore the absorbent article can be provided in which a worry about leakage can also be suppressed and the significant comfort to wear is realized.
In the nonwoven fabric containing such the liquid film cleavage agent, from a viewpoint of improving softness of texture, the interfiber distance in the nonwoven fabric is preferably 150 μm or less, and more preferably 90 μm or less. Moreover, from a viewpoint of suppressing liquid permeability from being adversely affected as caused by an excessively narrowed interfiber distance, a lower limit thereof is preferably 50 μm or more, and more preferably 70 μm or more. Specifically, the interfiber distance is preferably 50 μm or more and 150 μm or less, and more preferably 70 μm or more and 90 μm or less.
The fineness of the fibers in this case is preferably 3.3 dtex or less, and more preferably 2.4 dtex or less. Moreover, a lower limit thereof is preferably 0.5 dtex or more, and more preferably 1.0 dtex or more. Specifically, the fineness is preferably 0.5 dtex or more and 3.3 dtex or less, and more preferably 1.0 dtex or more and 2.4 dtex or less.
An interfiber distance is determined by measuring a thickness of a measuring object nonwoven fabric and then applying a measured value to Expression (2).
First, a nonwoven fabric as a measuring object is cut to a piece of 50 mm in a longitudinal direction x 50 mm in a crosswise direction to prepare a cut piece of the nonwoven fabric.
A thickness of the cut piece is measured under 49 Pa pressure. A measurement environment is a temperature of 20±2° C. and a relative humidity of 65±5%, and a microscope (VHX-1000, manufactured by KEYENCE Corporation) is used as a measuring instrument. First, an enlarged photograph of the cross section of the above-described nonwoven fabric is obtained. In the enlarged photograph, a piece having a known dimension is simultaneously photographed. A scale is aligned on the enlarged photograph of the cross section of the above-mentioned nonwoven fabric to measure the thickness of the nonwoven fabric. The operation described above is performed 3 times, and a mean value of 3 times measurement is taken as the thickness (mm) of the nonwoven fabric in a dry state. Further, in the case of a laminated product, a boundary is distinguished from a fiber diameter to calculate the thickness.
Next, the interfiber distance in the fibers which constitute the measuring object nonwoven fabric is determined by the formula based on assumption by Wrotnowski shown below. The formula based on the assumption by Wrotnowski is generally used upon determining the interfiber distance in the fibers which constitute the nonwoven fabric. According to the formula based on the presumption by Wrotnowski, an interfiber distance A (μm) is determined by the following Expression (2) by using a thickness h (mm) of a nonwoven fabric, a basis weight e (g/m2) thereof, a fiber diameter d (μm) of fibers which constitute the nonwoven fabric and a fiber density ρ (g/cm3) thereof. Further, when the nonwoven fabric has concavity and convexity, the interfiber distance is calculated by using a nonwoven fabric thickness h (mm) in a convex portion as a representative value.
With regard to the fiber diameter d (μm), 10 pieces of fiber cross sections of cut fibers are measured by using a scanning electron microscope (DSC6200, manufactured by Seiko Instruments Inc.), and a mean value thereof is taken as the fiber diameter.
The fiber density ρ (g/cm3) is measured by using a density gradient tube in accordance with the measuring method of the density gradient tube method described in JIS L1015 Test methods for chemical staple fibers.
With regard to the basis weight e (g/m2), the measuring object nonwoven fabric is cut into a piece having a predetermined size (0.12 m×0.06 m, or the like), and after mass measurement, the basis weight is determined by calculation in accordance with a Expression “mass/area determined from the predetermined size=basis weight (g/m2).”
Fineness is calculated by measuring a cross-sectional shape of a fiber by an electron microscope or the like to measure a cross-sectional area of the fiber (the cross-sectional area of each resin component in case of a fiber formed of a plurality of resins), and simultaneously specifying a kind of the resin (also an approximate component ratio in the case of a plurality of resins) by DSC (differential scanning calorimeter) to identify specific gravity. For example, if a staple constituted of only PET is used, a cross section is first observed to calculate a cross-sectional area. Then, the fiber is measured by DSC to identify that the fiber is constituted of a single component from a melting point or peak shape, and the component is a PET core. Then, the fineness is calculated by calculating the mass of the fiber by using the density of the PET resin and the cross-sectional area.
As the fibers which constitute the nonwoven fabric according to the present invention, the fibers ordinarily used in this kind of article can be adopted without particular restriction. Specific examples include various fibers such as thermally fusible sheath-core type composite fibers, thermally extensible fibers, thermally non-extensible fibers, thermally shrinkable fibers, thermally non-shrinkable fibers, three-dimensionally crimped fibers, potentially crimpable fibers and hollow fibers. In particular, the fibers preferably have a thermoplastic resin. Moreover, the thermally non-extensible fibers and the thermally non-shrinkable fibers are preferably thermally fusible. The sheath-core type composite fibers may be of a concentric sheath-core type, an eccentric sheath-core type, a side-by-side type or a deformed type, and are preferably of a concentric sheath-core type. In production of the fibers and the nonwoven fabric, the liquid film cleavage agent, or the liquid film cleavage agent and the phosphoric acid ester type anionic surfactant may be incorporated in the fibers in any step. For example, the liquid film cleavage agent, or a mixture of the liquid film cleavage agent and the phosphoric acid ester type anionic surfactant may be blended in a spinning oil for the fibers to be ordinarily used during spinning of the fibers, and the resultant mixture may be applied onto the fibers, or the liquid film cleavage agent, or the mixture of the liquid film cleavage agent and the phosphoric acid ester type anionic surfactant may be blended in a finishing oil for the fibers before or after stretching the fibers, and the resultant mixture may be applied onto the fibers. Moreover, the liquid film cleavage agent or the phosphoric acid ester type anionic surfactant may be blended in a fiber treating agent to be ordinarily used for production of the nonwoven fabric, and the resultant mixture may be coated on the fibers, or the fibers after forming the nonwoven fabric.
The nonwoven fabric according to the present invention contains the liquid film cleavage agent, or the phosphoric acid ester type anionic surfactant further therewith, and therefore is excellent in suppressing the liquid remains in corresponding to various fiber structures. Therefore, even if a large amount of liquid is poured on the nonwoven fabric, a permeation passage of the liquid between the fibers is ensured at all times, and the nonwoven fabric is excellent in the liquid permeability. Thus, various functions can be provided for the nonwoven fabric without being restricted by problems of the interfiber distance and liquid film formation. For example, the nonwoven fabric may be formed of one layer or a plurality of layers of two or more layers. Moreover, the nonwoven fabric may have a flat shape, a concavo-convex shape on one side or both sides, or a shape having a variety with the respect to the fiber basis weight or the fiber density. Further, a width of options is extended also with regard to a combination with an absorbent body. Moreover, when the nonwoven fabric is formed of the plurality of layers, the liquid film cleavage agent may be contained in all the layers, or in part of the layers. The liquid film cleavage agent is preferably contained at least in the layer on a side in which the liquid is directly received. For example, when the nonwoven fabric according to the present invention is incorporated as the topsheet in the absorbent article, the liquid film cleavage agent is preferably contained at least in a layer on a skin-contact surface side.
In the nonwoven fabric according to the present invention, the liquid film cleavage agent is preferably localized at least around part of the points that fibers are entangled to each other or the points that fibers are fusion bonded to each other. The term “localization” of the liquid film cleavage agent herein mean a state in which the liquid film cleavage agent is not evenly attached to the whole surface of the fibers which constitute the nonwoven fabric, but the liquid film cleavage agent is locally attached thereto in the vicinity of the points that fibers are entangled to each other or the points that fibers are fusion bonded to each other rather than each surface of the fibers. Specifically, the term can be defined in which a concentration of the liquid film cleavage agent in the vicinity of the points that fibers are entangled to each other or the points that fibers are fusion bonded to each other is higher in comparison with the surface of the fibers (surface of the fibers between the entangled points or between fusion bonded points). On the occasion, the liquid film cleavage agent existing in the vicinity of the points that fibers are entangled to each other or the points that fibers are fusion bonded to each other may be attached thereto so as to partially cover an interfiber space centering on the fiber entangled points or the fiber fusion bonded points. As the concentration of the liquid film cleavage agent in the vicinity of the points that fibers are entangled to each other or the points that fibers are fusion bonded to each other is preferably as higher as possible. The concentration is changed depending on a kind of the liquid film cleavage agent to be used, a kind of the fibers to be used, or an effective component proportion when the agent is mixed with other agents, or the like, and therefore cannot be unambiguously defined, but from a viewpoint of exhibiting the above-mentioned liquid film cleavage effect, the concentration can be appropriately determined.
Localization of the liquid film cleavage agent facilitates to further develop the liquid film cleavage effect. That is, the area in the vicinity of the points that fibers are entangled to each other or the points that fibers are fusion bonded to each other is a place in which the liquid film is particularly easily formed, and therefore a larger amount of the liquid film cleavage agent exists in the place to easily directly interact with the liquid film.
Such localization of the liquid film cleavage agent exists preferably in 30% or more, more preferably in 40% or more, and further preferably in 50% or more of the places in the vicinity of the points that fibers are entangled to each other or the points that fibers are fusion bonded to each other of the whole nonwoven fabric. In the nonwoven fabric, in a place in which a distance between the fiber entangled points or a distance between fiber fusion bonded points is comparatively short, the interfiber space is small, and the liquid film is particularly easily formed therein. Therefore, if the liquid film cleavage agent is selectively localized in the vicinity of the points that fibers are entangled to each other or the points that fibers are fusion bonded to each other in a place in which the interfiber space is small, the liquid film cleavage effect is particularly effectively developed, and such a case is preferable. Moreover, in the case of the selective localization as described above, it is preferable to adjust a covering ratio of the liquid film cleavage agent, in such a manner that the covering ratio of the liquid film cleavage agent to a comparatively small interfiber space is increased, and the covering ratio of the liquid film cleavage agent to a comparatively large interfiber space is reduced. Thus, while the liquid permeability is retained in the nonwoven fabric, the cleavage effect can be effectively developed in a part in which capillary force is high and the liquid film is easily formed, and an effect on reducing the residual liquid in the whole nonwoven fabric is improved. The term “comparatively small interfiber space” herein means an interfiber space having the interfiber distance of ½ or less relative to the interfiber distance determined in (Measuring method for interfiber distance) mentioned above.
The above-described localized state of the liquid film cleavage agent can be confirmed by the following method.
First, a nonwoven fabric is cut into a piece of 5 mm×5 mm, and the piece is attached on a sample stage by using a carbon tape. The sample stage is placed in a scanning electron microscope (S4300SE/N, manufactured by Hitachi, Ltd.) in a state of no vapor deposition and is made into a low vacuum state or a vacuum state. Localization is detected by using an annular reflection electron detector (attachment). As the atomic number is larger, a reflection electron is further easily emitted. Thus, a part coated with the liquid film cleavage agent containing a large number of oxygen atoms or silicon atoms appears white, in which the oxygen atoms or the silicon atoms each have the larger atomic number in comparison with carbon atoms or hydrogen atoms which mainly constitute polyethylene (PE), polypropylene (PP) or polyester (PET). Therefore, the localized state can be confirmed by whiteness. Further, the whiteness is increased as the atomic number is larger or an attached amount is larger.
Moreover, upon producing the nonwoven fabric according to the present invention, a method ordinarily applied to this kind of article can be adopted. For example, as a method of forming a fiber web, a carding method, an air-laid method, a spunbond method or the like can be applied. As a method of processing the fiber web into the nonwoven fabric, various methods of forming the nonwoven fabrics to be ordinarily applied can be adopted, such as spunlacing, needle punching, chemical bonding and embossing in a dot form. Above all, from a viewpoint of texture, the nonwoven fabric is preferably an air-through nonwoven fabric or a spunbond nonwoven fabric. “Air-through nonwoven fabric” herein means a nonwoven fabric which is produced through a step of blowing a fluid at 50° C. or higher, for example, a gas and a water vapor onto the web or the nonwoven fabric (air-through processing step). Moreover, “spunbond nonwoven fabric” means a laminated nonwoven fabric which is produced by the spunbond method. The nonwoven fabric includes not only one which is produced only in the above step, but also one which is produced by adding the above step to a nonwoven fabric which is produced by any other method, or one which is produced by performing a step of some kind after the above step. Moreover, the nonwoven fabric according to the present invention is not limited to one formed of the air-through nonwoven fabric solely or the spunbond nonwoven fabric solely, but also includes one formed as a composite of the air-through nonwoven fabric or the spunbond nonwoven fabric with a fiber sheet or a film material such as other nonwoven fabrics.
In the method for producing the nonwoven fabric according to the present invention, when the liquid film cleavage agent is applied thereon after the nonwoven fabric is formed as mentioned above, specific examples include a method in which a raw material nonwoven fabric is immersed into a solution containing a liquid film cleavage agent. Specific examples of the solution include a solution in which a liquid film cleavage agent is diluted with a solvent (hereinafter, this solution is also referred to as a liquid film cleavage agent solution.). Moreover, specific examples of another method include a method in which a liquid film cleavage agent alone or a solution containing the liquid film cleavage agent is coated onto a raw material nonwoven fabric. Further, a phosphoric acid ester type anionic surfactant may be mixed with the solution containing the liquid film cleavage agent. In this case, a content proportion of the liquid film cleavage agent to the phosphoric acid ester type anionic surfactant is preferably as mentioned above. As the solvent, a solvent in which the liquid film cleavage agent having a significantly small water solubility can be moderately dissolved, or dispersed and emulsified so as to easily coat the agent onto the nonwoven fabric can be used without particular restriction. Specific examples of the solvent which dissolves the agent include an organic solvent such as ethanol, methanol, acetone and hexane, or when the agent is converted into an emulsified liquid, water can also be obviously used as the solvent or a dispersion medium, and specific examples of an emulsifying agent used upon emulsifying the agent include various surfactants including alkyl phosphoric acid ester, fatty acid amide, alkyl betaine and alkyl sodium sulfosuccinate. Further, the raw material nonwoven fabric means a nonwoven fabric before the liquid film cleavage agent is applied thereon, and as a production method thereof, the production method to be ordinarily applied as mentioned above can be applied without particular restriction.
As the method of coating the agent to the raw material nonwoven fabric, the method applied in this production method for the nonwoven fabric can be adopted without particular restriction. Specific examples include coating by a spray, coating by a slot coater, coating by roll transfer such as a gravure system, a flexographic system and a gate roll system, and coating by a dipping system.
From a viewpoint of the above-mentioned localization of the liquid film cleavage agent in the vicinity of the points that fibers are entangled to each other or the points that fibers are fusion bonded to each other, the liquid film cleavage agent is preferably applied on the raw material nonwoven fabric after the nonwoven fabric is formed, and a method of coating the liquid film cleavage agent to the raw material nonwoven fabric, and not by immersion, is further preferable. Among the coating methods, a coating method by the flexographic system is particularly preferable from a viewpoint of further clearly achieving localization of the liquid film cleavage agent.
Moreover, as the raw material nonwoven fabric, various nonwoven fabrics can be used without particular restriction. In particular, from a viewpoint of keeping localization of the liquid film cleavage agent, a nonwoven fabric in which the fiber entangled points are thermally fusion bonded or thermally compressed is preferable, and use of the nonwoven fabric prepared by thermally bonding the fibers with each other by the above-mentioned air-through processing or thermal embossing is further preferable.
The liquid film cleavage agent, upon attaching the liquid film cleavage agent to the raw material nonwoven fabric or the fibers, is preferably used in the form of the solution in which the liquid film cleavage agent is diluted with the solvent as mentioned above. The solution containing the liquid film cleavage agent can also be prepared separately as a single solution as a fiber treating agent. “Fiber treating agent” described herein means an agent in which an oily liquid film cleavage agent having a significantly small water solubility is formed into a state in which applying processing is facilitated on the raw material nonwoven fabric or the fibers. In the fiber treating agent for applying the liquid film cleavage agent thereon, a content proportion of the liquid film cleavage agent is preferably 50 mass % or less based on mass of the fiber treating agent. Thus, the fiber treating agent can be formed into a state in which the liquid film cleavage agent as an oily component is stably emulsified in the solvent. From a viewpoint of stable emulsification, a content proportion of the liquid film cleavage agent is more preferably 40 mass % or less, and further preferably 30 mass % or less, based on mass of the fiber treating agent. Moreover, from a viewpoint of realizing the above-mentioned localization of the liquid film cleavage agent in the nonwoven fabric by locomotion of the liquid film cleavage agent on the fibers at moderate viscosity after applying, the proportion is preferably adjusted to the above-described content proportion. From a viewpoint of developing a sufficient liquid film cleavage effect, a content proportion of the liquid film cleavage agent is preferably 5 mass % or more, more preferably 15 mass % or more, and further preferably 25 mass % or more, based on mass of the fiber treating agent. In addition, the fiber treating agent containing the liquid film cleavage agent may also contain other agents within the range in which effect of the liquid film cleavage agent is not adversely affected. For example, the fiber treating agent may contain the above-mentioned phosphoric acid ester type anionic surfactant. A content proportion of the liquid film cleavage agent to the phosphoric acid ester type anionic surfactant in this case is preferably as mentioned above. In addition thereto, the fiber treating agent may contain an antistatic agent or an antifriction agent used upon processing the fibers, a hydrophilizing agent for providing the nonwoven fabric with moderate hydrophilicity, an emulsifying agent for emulsification stability, or the like.
Specific examples of the nonwoven fabric according to the present invention include a concavo-convex nonwoven fabric which is constituted with including thermoplastic fibers and has a first surface and a second surface positioned on a side opposite thereto, and, at least on the first surface, has the concavo-convex shape having a plurality of convex portions projecting on a side of the first surface, and concave portions positioned between the convex portions.
In the following, a specific example of the nonwoven fabric having a concavo-convex shape will be described.
Specific examples include a nonwoven fabric shown in
For example, the nonwoven fabric 10 can be produced by the raw material and the production method described in the paragraphs {0032} to {0048} of JP-A-2002-187228. For example, in this production, embossing or the like is applied to a laminate between the upper layer 11 and the lower layer 12 from a side of the upper layer 11, and then the thermally shrinkable fibers are thermally shrunk by heat treatment. At this time, adjacent embossed parts are pulled to each other by shrinking of the fibers, and an interval with each other is shortened. Owing to this deformation, the fibers in the upper layer 11 rise on a side of the top surface 1A with the embossed concave portion 13 as a base point to form a convex portion 14. Alternatively, the upper layer is laminated on the lower layer 12 in a state of extending the lower layer 12 in which thermal shrinkage is developed, and the above-described embossing is applied thereto. Then, when an extended state of the lower layer 12 is released, the side of the upper layer 11 rises on the side of the top surface 1A to form the convex portion 14. The embossing can be performed by a method to be ordinarily applied, such as heat embossing and ultrasonic embossing. Moreover, with regard to bonding of both layers, a bonding method using an adhesive may be applied.
In the thus produced nonwoven fabric 10, the upper layer 11 is compressed and bonded to a place on the side of the lower layer 12 in the embossed concave portion (concave bonding portion) 13. The embossed concave portion 13 is formed on the nonwoven fabric 10 in a plane direction in a scattered dot manner, and a part surrounded by the embossed concave portion 13 is the above-mentioned convex portion 14 formed by rising of the upper layer 11. The convex portion 14 has a three-dimensional solid shape, and forms a dome shape, for example. The convex portion 14 formed by the production method as described above is in a state in which the fiber density is lower than the fiber density in the lower layer 12. An inside of the convex portion 14 may be filled with the fibers as shown in
The nonwoven fabric 10 has a concavo-convex surface having the convex portion 14 and the embossed concave portion 13 on the side of the top surface 1A, and therefore is excellent in shape recoverability when the nonwoven fabric 10 is extended in the plane direction, and compressive deformability when the nonwoven fabric 10 is compressed in the thickness direction. Moreover, the nonwoven fabric 10 is formed into a comparatively bulky nonwoven fabric by rising of the fibers in the upper layer 11 as described above. Thus, a user in touching the nonwoven fabric 10 can feel soft and gentle texture. Moreover, in an absorbent article comprising the nonwoven fabric 10 as a topsheet in which a top surface 10A is applied as the skin-contact surface and the bottom surface 1B is applied as the skin non-contact surface, the skin-contact surface side becomes excellent in air-permeability by the concavo-convex shape having the convex portions 14 and the embossed concave portions 13.
Moreover, liquid remains are reduced in the nonwoven fabric 10 by the effect of the liquid film cleavage agent, or cooperative effect of the liquid film cleavage agent and the phosphoric acid ester type anionic surfactant as mentioned above. Thus, the liquid permeability produced by utilizing the concavo-convex surface and a dense embossed part can be further improved.
In addition, the nonwoven fabric 10 may have further other layers without limiting to the double-layered structure of the upper layer 11 and the lower layer 12. For example, a monolayer or a plurality of layers may be arranged between the upper layer 11 and the lower layer 12, or the monolayer or the plurality of layers may be arranged on the side of the top surface 10A or the side of the bottom surface 10B in the nonwoven fabric 10. The monolayer or the plurality of layers may be a layer having the thermally shrinkable fibers, or a layer having the thermally non-shrinkable fibers.
As other specific examples of the nonwoven fabric according to the present invention having the concavo-convex shape, nonwoven fabrics 20, 30, 40, 50, 60 and 70 (second to seventh aspects) are shown below.
First, as shown in
For example, when the nonwoven fabric 20 is laminated on an absorbent body as a topsheet in which the first surface 1A is directed toward a skin-contact surface side, and used, the nonwoven fabric 20 is excellent in liquid permeability from a side of the first surface 1A to a side of the second surface 2B. Specifically, liquid permeation through the hollow portion 21 is excellent. Moreover, a wearer's body pressure is applied to the convex portions 23, and the liquid in the convex portion 23 directly migrates to a second nonwoven fabric 3. Thus, liquid remains on the side of the first surface 1A are small. Such effect may be sustainably exhibited at a higher level by the effect of the liquid film cleavage agent, or cooperative effect of the liquid film cleavage agent and the phosphoric acid ester type anionic surfactant as mentioned above. That is, even if long-time use or a large amount of excretion is experienced, a permeation passage of the liquid is ensured by liquid film cleaving, and therefore the liquid permeability as described above can be sufficiently exhibited.
Next, as shown in
In the nonwoven fabric 30A (first fiber layer 301) shown in
In the nonwoven fabric 30B shown in
In addition thereto, in the nonwoven fabric 30B, shaping of a fiber web, formation of the nonwoven fabric, and bonding of both layers are performed by hot-air processing in an air-through step, and therefore the nonwoven fabric 30B is formed to be bulky and low in a basis weight as a whole. In particular, bonding of both the fiber layers 301 and 302 is performed by thermal fusion of the fibers with each other by hot air, and therefore a gap is formed between the fibers in the bonded part between the fiber layers, and a liquid passing rate is high even in the concave portion 32 serving as a bonding portion. Moreover, the nonwoven fabric 30B has, on the side of the second surface 1B in a top portion of the first projecting portion 31 in the first fiber layer 301, a part 36 in which a fiber density in the second fiber layer 302 is lower than a fiber density in the first fiber layer 301 and in other parts of the second fiber layer 302. The existence of the part 36 having a lower fiber density facilitate denting of the first projecting portion 31 in the first fiber layer 301 even at a low load, and therefore the cushioning properties of the nonwoven fabric 30B is improved. When the nonwoven fabric 30B is adopted as the topsheet of the absorbent article, the side of the first surface 1A (namely, the side of the first fiber layer 301) is preferably applied as the skin-contact surface side.
Also in the nonwoven fabric 30 (30A and 30B), a permeation passage of the liquid is ensured at all times by the effect of the liquid film cleavage agent, or cooperative effect of the liquid film cleavage agent and the phosphoric acid ester type anionic surfactant as mentioned above. Thus, a width of design with regard to the fiber diameter and the fiber density is extended.
In production of the nonwoven fabric 30 (30A and 30B), for example, air-through processing can be adopted in which multi-stage hot-air processing is applied to the fiber web while a hot-air temperature and an air speed are controlled. For example, in the nonwoven fabric 30A (first fiber layer 301), the production method described in the paragraphs {0031} and {0032} of JP-A-2012-136790 can be applied. Moreover, as a support on which the web is imparted to a concavo-convex shape, the support preferably has a solid projecting portion and an opening portion. For example, the supports shown in FIGS. 1 and 2 of JP-A-2012-149370 or the supports shown in FIGS. 1 and 2 of JP-A-2012-149371 can be used. Moreover, the nonwoven fabric 30B (laminated nonwoven fabric of the first fiber layer 301 and the second fiber layer 302) can be produced by laminating the fiber web serving as the second fiber layer 302 in the air-through step of the first fiber layer 301. For example, the production method described in the paragraphs {0042} to {0064} of JP-A-2013-124428 can be applied. From a viewpoint of shaping the nonwoven fabrics 30A and 30B by air-through processing, both of the first fiber layer 301 and the second fiber layer 302 are preferably thermally non-extensible and thermally non-shrinkable and thermally fusible fibers.
Next, as shown in
Also in the nonwoven fabric 40, a permeation passage of the liquid is ensured at all times by the above-mentioned effect of the liquid film cleavage agent, or the liquid film cleavage agent and the phosphoric acid ester type anionic surfactant. Thus, a width of design with regard to a fiber diameter and the fiber density is extended.
Such a nonwoven fabric 40 can be formed by moving fibers by spraying a fluid such as hot air to a part to be formed into the concave portion 42 relative to a fiber web. Thus, the fiber density in the concave bottom portion 43 can be reduced in comparison with a periphery thereof.
Next, as shown in
The nonwoven fabric 50 has a plurality of thermally fusion bonded portions 55 in intersections among constituent fibers 54. As shown in
Further, from a viewpoint of liquid permeability, the nonwoven fabric 50 is preferably formed in such a manner that a hydrophilic degree of the small diameter portion is smaller than a hydrophilic degree of the large diameter portion. This difference with the respect to the hydrophilic degree can be formed by incorporating a stretchable component (hydrophobic component) into the fiber treating agent which is attached to the fibers. In particular, the stretchable component and a hydrophilic component are preferably contained therein. Specifically, when the fibers are stretched by the above-described gullet stretching processing, the stretchable component is spread in the small diameter portion 35 being formed by stretching to generate a difference in the hydrophilic degree between the small diameter portion and the large diameter portion. In the large diameter portion, the hydrophilic component which is hard to spread stays therein, in which the hydrophilic degree becomes higher in comparison with the small diameter portion. Specific examples of the stretchable component include a silicone resin having a low glass transition point and flexibility in molecular chains, and as the silicone resin, polyorganosiloxane having a Si—O—Si chain as a main chain is preferably used.
In addition thereto, from a viewpoint of the above-described liquid permeability, in the nonwoven fabric 50, a fiber density in a side wall region 30C is preferably lower than a fiber density in a top region 30A and a bottom portion region 30B.
Also in the nonwoven fabric 50, a permeation passage of the liquid is ensured at all times by the above-mentioned effect of the liquid film cleavage agent, or the liquid film cleavage agent and the phosphoric acid ester type anionic surfactant. Thus, a width of design with regard to the fiber diameter and the fiber density is extended.
The nonwoven fabric 50 may be used alone, may be bonded with a flat fiber layer into a laminated nonwoven fabric, or may be laminated on a fiber layer having a concavo-convex shape into a laminated nonwoven fabric unified along the concavo-convex shape. For example, the nonwoven fabric 50 may be laminated on the second nonwoven fabric in the nonwoven fabric 20 in the second aspect (
Next, a nonwoven fabric 60 in the sixth aspect has a concavo-convex shape with thermally extensible fibers. As shown in
Also in the nonwoven fabric 60, a permeation passage of the liquid is ensured at all times by the above-mentioned effect of the liquid film cleavage agent, or the liquid film cleavage agent and the phosphoric acid ester type anionic surfactant. Thus, a width of design with regard to the fiber diameter and the fiber density is extended.
Such a nonwoven fabric 60 can be produced by the following method. First, the linear concave portion 62 is formed by heat embossing to a fiber web. At this time, in the concave portion 62, the thermally extensible fibers are subjected to compression bonding or fusion without being thermally extended, and fixed. Next, the thermally extensible fibers existing in parts other than the concave portion 61 are extended by air-through processing, and the convex portion 61 is formed into the nonwoven fabric 60. Moreover, the constituent fibers of the nonwoven fabric 60 may be mixed fibers of the above-described thermally extensible fibers and thermally non-extensible and thermally fusible fibers. As these constituent fibers, for example, the fibers described in the paragraphs {0013}, and {0037} to {0040} of JP-A-2005-350836, the fibers described in the paragraphs {0012}, and {0024} to {0046} of JP-A-2011-1277258, and so forth can be used.
Next, as shown in
Also in the nonwoven fabric 70, a permeation passage of the liquid is ensured at all times by the above-mentioned effect of the liquid film cleavage agent, or the liquid film cleavage agent and the phosphoric acid ester type anionic surfactant. Thus, a width of design with regard to the fiber diameter and the fiber density is extended.
Such a nonwoven fabric 70 can be produced by the method described in, for example, the line 12 in the left lower column on page 6 to the line 19 in the right upper column on page 8 in JP-A-H4-24263.
The liquid film cleavage agent and the nonwoven fabric containing the liquid film cleavage agent according to the present invention can be applied in various fields by taking advantage of the soft texture and reduction of the liquid remains. For example, such a material is preferably used as a topsheet, a second sheet (a sheet arranged between the topsheet and an absorbent body), the absorbent body, a covering sheet for wrapping the absorbent body, or a leakage preventive sheet in an absorbent article used for absorption of a fluid excreted from a body, such as a sanitary napkin, a panty liner, a disposable diaper, an incontinence pad; a wiping sheet for a person; a sheet for skin care; further, a wiper for an object, or the like. When the nonwoven fabric according to the present invention is employed as the topsheet or the second sheet of the absorbent article, the side of the first layer of the nonwoven fabric is preferably used as a side of skin-facing surface. Further, the liquid film cleavage agent according to the present invention can be applied to various fiber materials such as a woven fabric without limiting to the nonwoven fabric, as long as the liquid film cleavage agent has effect of cleaving the liquid film.
With regard to the basis weight of the web used for production of the nonwoven fabric according to the present invention, a suitable range is selected in corresponding to a specific application of an objective nonwoven fabric. The basis weight of the nonwoven fabric to be finally obtained is preferably 10 g/m2 or more and 100 g/m2 or less, and particularly preferably 15 g/m2 or more and 80 g/m2 or less.
The absorbent article used for absorption of the fluid excreted from the body is typically provided with the topsheet, the backsheet, and a liquid-retainable absorbent body interposed between both sheets. As the absorbent body and the backsheet when the nonwoven fabric according to the present invention is used as the topsheet, a material to be ordinarily used in the technical field can be used without particular restriction. For example, as the absorbent body, such a material can be used as prepared by covering, with a covering sheet such as tissue paper and the nonwoven fabric, a fiber aggregate formed of a fiber material such as pulp fibers, or the fiber aggregate with a superabsorbent polymer therein. As the backsheet, a film of a thermoplastic resin, or a liquid-impermeable or water-repellent sheet such as a laminate between the film and the nonwoven fabric can be used. The backsheet may have water-vapor permeability. The absorbent article may be further provided with various members in corresponding to the specific application of the absorbent article. Such a member is known to those skilled in the art. For example, when the absorbent article is applied to the disposable diaper or the sanitary napkin, one pair or two or more pairs three-dimensional guards can be arranged in both right-left side portions on the topsheet.
With regard to the above-mentioned embodiments, the present invention further discloses the liquid film cleavage agent, the fiber treating agent, the nonwoven fabric, the topsheet, the absorbent article, the method for producing the nonwoven fabric, and use of the compound as the liquid film cleavage agent as described below.
<1>
A liquid film cleavage agent having a spreading coefficient of 15 mN/m or more to a liquid having surface tension of 50 mN/m, and a water solubility of 0 g or more and 0.025 g or less.
<2>
The liquid film cleavage agent according to the above item <1>, wherein the spreading coefficient is more preferably 20 mN/m or more, further preferably 25 mN/m or more, and particularly preferably 30 mN/m or more.
<3>
The liquid film cleavage agent according to the above item <1> or <2>, wherein an interfacial tension to the liquid having surface tension of 50 mN/m is preferably 20 mN/m or less, more preferably 17 mN/m or less, further preferably 13 mN/m or less, more further preferably 10 mN/m or less, particularly preferably 9 mN/m or less, and especially preferably 1 mN/m or less; and more than 0 mN/m.
<4>
The liquid film cleavage agent according to any one of the above items <1> to <3>, comprising a compound having at least one kind structure selected from the group consisting of the following structures X, X—Y and Y—X—Y:
wherein the structure X designates a siloxane chain having a structure in which any of basic structures of >C(A)- (C designates a carbon atom, moreover, <, > and — each designates a bonding hand, hereinafter, the same applies.), —C(A)2-, —C(A)(B)—, >C(A)-C(R1)<, >C(R1)—, —C(R1)(R2)—, —C(R1)2—, >C<, —Si(R1)2O— and —Si(R1)(R2)O is repeated, or two or more kinds thereof are combined; or a mixed chain thereof; the structure X has, in an end of the structure X, a hydrogen atom or at least one kind of group selected from the group consisting of —C(A)3, —C(A)2B, —C(A)(B)2, —C(A)2-C(R1)3, —C(R1)2A, —C(R1)3, —OSi(R1)3, —OSi(R1)2(R2), —Si(R1)3 and —Si(R1)2(R2);
wherein R1 and R2 each independently designate a hydrogen atom, an alkyl group, an alkoxy group, an aryl group, or a halogen atom; A and B each independently designate a substituent having an oxygen atom or a nitrogen atom; when a plurality of R1, R2, A and B exist for each in the structure X, these may be identical to or different from each other; and
wherein Y designates a hydrophilic group having hydrophilicity, the group containing an atom selected from a hydrogen atom, a carbon atom, an oxygen atom, a nitrogen atom, a phosphorus atom or a sulfur atom; and when a plurality of Y exist, these groups may be identical to or different from each other.
<5>
The liquid film cleavage agent according to the above item <4>, wherein A and B each independently designate a hydroxyl group, a carboxylic acid group, an amino group, an amido group, an imino group, or a phenol group.
<6>
The liquid film cleavage agent according to any one of the above items <1> to <5>, comprising a compound composed of a siloxane chain in which structures represented by any one of the following formulas (1) to (11) are arbitrarily combined:
wherein, in Formulas (1) to (11), M1, L1, R21 and R22 designate the following monovalent or polyvalent (divalent or more valent) group; R23 and R24 designate the following monovalent or polyvalent (divalent or more valent) group or a single bond;
M1 designates a polyoxyethylene group, a polyoxypropylene group, a polyoxybutylene group, a group having a polyoxyalkylene group in combination therewith, an erythritol group, a xylitol group, a sorbitol group, a glycerol group or an ethylene glycol group, a hydroxyl group, a carboxylic acid group, a mercapto group, an alkoxy group, an amino group, an amide group, an imino group, a phenol group, a sulfonic acid group, a quaternary ammonium group, a sulfobetaine group, a hydroxysulfobetaine group, a phosphobetaine group, an imidazolium betaine group, a carbobetaine group, an epoxy group, a carbinol group, a (meth)acrylic group or a functional group in combination therewith; when M1 is a polyvalent group, M1 designates a group formed by further removing one or more hydrogen atoms from each of the groups or the functional group;
L1 designates a linking group of an ether group, an amino group (the amino group adoptable as L1 is represented by >NRC (RC is a hydrogen atom or a monovalent group).), an amide group, an ester group, a carbonyl group or a carbonate group; and
R21, R22, R23 and R24 each independently designate an alkyl group, an alkoxy group, an aryl group, a fluoroalkyl group, an aralkyl group, a hydrocarbon group in combination therewith, or a halogen atom.
<7>
The liquid film cleavage agent according to any one of the above items <4> to <6>, preferably comprising a modified silicone having a structure having at least one oxygen atom in a modifying group, more preferably a polyoxyalkylene modified-silicone.
<8>
The liquid film cleavage agent according to the above item <7>, wherein the polyoxyalkylene modified-silicone is represented by any one of Formulas [I] to [IV]:
wherein R31 designates an alkyl group; R32 designates a single bond or an alkylene group; a plurality of R31 and a plurality of R32 may be each identical to or different from each other; M11 designates a group having a polyoxyalkylene group; as the polyoxyalkylene group, a polyoxyethylene group, a polyoxypropylene group, a polyoxybutylene group and a material in which constituent monomers thereof are copolymerized or the like are taken; and m and n each are independently an integer of 1 or more.
<9>
A liquid film cleavage agent having a structure represented by any one of Formulas [I] to [IV], and a water solubility of 0 g or more and 0.025 g or less:
wherein R31 designates an alkyl group; R32 designates a single bond or an alkylene group; a plurality of R31 and a plurality of R32 may be each identical to or different from each other; M11 designates a group having a polyoxyalkylene group; as the polyoxyalkylene group, a polyoxyethylene group, a polyoxypropylene group, a polyoxybutylene group and a material in which constituent monomers thereof are copolymerized or the like are taken; and m and n each are independently an integer of 1 or more.
<10>
The liquid film cleavage agent according to any one of the above items <7> to <9>, wherein the polyoxyalkylene-modified silicone is any of polyoxyethylene (POE) polyoxypropylene (POP)-modified silicone, polyoxyethylene (POE)-modified silicone and polyoxypropylene (POP)-modified silicone.
<11>
The liquid film cleavage agent according to any one of the above items <7> to <10>, wherein the addition number of moles of the polyoxyalkylene groups of the polyoxyalkylene-modified silicone is preferably 1 or more, more preferably 3 or more, and further preferably 5 or more; and preferably 30 or less, more preferably 20 or less, and further preferably 10 or less.
<12>
A liquid film cleavage agent having a spreading coefficient of more than 0 mN/m to a liquid having surface tension of 50 mN/m, a water solubility of 0 g or more and 0.025 g or less, and an interfacial tension of 20 mN/m or less to the liquid having surface tension of 50 mN/m.
<13>
The liquid film cleavage agent according to the above item <12>, wherein the interfacial tension to the liquid having surface tension of 50 mN/m is preferably 17 mN/m or less, more preferably 13 mN/m or less, further preferably 10 mN/m or less, particularly preferably 9 mN/m or less, and especially preferably 1 mN/m or less; and more than 0 mN/m.
<14>
The liquid film cleavage agent according to the above item <12> or <13>, wherein the spreading coefficient to the liquid having surface tension of 50 mN/m is preferably 9 mN/m or more, more preferably 10 mN/m or more, and further preferably 15 mN/m or more; and 50 mN/m or less.
<15>
The liquid film cleavage agent according to any one of the above items <12> to <14>, comprising a compound having at least one kind structure selected from the group consisting of the following structures Z, Z—Y and Y—Z—Y:
wherein the structure Z designates a hydrocarbon chain having a structure in which any of basic structures of >C(A)- (C: carbon atom), —C(A)2-, —C(A)(B)—, >C(A)-C(R3)<, >C(R3)—, —C(R3)(R4)—, —C(R3)2— and >C< is repeated, or two or more kinds thereof are combined; the structure Z has, at an end thereof, a hydrogen atom or at least one kind of group selected from the group consisting of —C(A)3, —C(A)2B, —C(A)(B)2, —C(A)2-C(R3)3, —C(R3)2A and —C(R3)3;
the R3 and R4 each independently designate a hydrogen atom, an alkyl group, an alkoxy group, an aryl group, a fluoroalkyl group, or an aralkyl group, or a hydrocarbon group in combination therewith, or a fluorine atom; A and B each independently designates a substituent containing an oxygen atom or a nitrogen atom;
Y designates a hydrophilic group having hydrophilicity, the hydrophilic group containing an atom selected from a hydrogen atom, a carbon atom, an oxygen atom, a nitrogen atom, a phosphorus atom and a sulfur atom; and when Y is plural, the plurality may be identical to or different from each other.
<16>
The liquid film cleavage agent according to the above item <15>, wherein Y is any of a hydroxyl group, a carboxylic acid group, an amino group, an amide group, an imino group and a phenol group; or a polyoxyalkylene group; or any of an erythritol group, a xylitol group, a sorbitol group, a glycerol group and an ethylene glycol group; or any of a sulfonic acid group, a sulfate group, a phosphoric acid group, a sulfobetaine group, a carbobetaine group, a phosphobetaine group, a quaternary ammonium group, an imidazolium betaine group, an epoxy group, a carbinol group and a methacrylic group; or a hydrophilic group formed of a combination thereof.
<17>
The liquid film cleavage agent according to the above item <15> or <16>, comprising polyoxyalkylene alkyl ether, or a hydrocarbon compound having 5 or more carbon atoms.
<18>
The liquid film cleavage agent according to any one of the above items <15> to <17>, comprising polyoxyalkylene alkyl (POA) ether represented by any of formulas in Formula [V]; or any of polyoxyalkylene glycol, Steareth, Beheneth, PPG myristyl ether, PPG stearyl ether and PPG behenyl ether, which are represented by any of formulas in Formula [VI] and have a mass average molecular weight of 1000 or more:
wherein L21 designates an ether group, an amino group, an amide group, an ester group, a carbonyl group, a carbonate group, a polyoxyethylene group, a polyoxypropylene group, a polyoxybutylene group, or a polyoxyalkylene group in combination therewith; R51 designate a substitute of a hydrogen atom, a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, a pentyl group, a hexyl group, a heptyl group, 2-ethylhexyl group, a nonyl group, a decyl group, a methoxy group, an ethoxy group, a phenyl group, a fluoroalkyl group, an aralkyl group, a hydrocarbon group in combination therewith, or a fluorine atom; a, b, m and n each independently are an integer of 1 or more; CmHn herein designates an alkyl group (n=2m+1), and CmHb designates an alkylene group (a=2b); the number of carbon atoms and the number of hydrogen atoms are each independently determined in each of Formulas (V) and (VI), and do not always represent an identical integer, and may be different from each other; “m” in —(CaHbO)m— is an integer of 1 or more; and values of the repeating units are each independently determined in each of Formulas (V) and (VI), and do not always represent an identical integer, and may be different from each other.
<19>
The liquid film cleavage agent according to any one of the above items <15> to <18>, comprising a compound having a polyoxyalkylene group,
wherein the number of mole of the polyoxyalkylene group is 1 or more and 70 or less, more preferably 5 or more, further preferably 7 or more, and preferably 70 or less, more preferably 60 or less, and further preferably 50 or less.
<20>
The liquid film cleavage agent according to the above item <15> or <16>, comprising a hydrocarbon compound having 5 or more and preferably 100 or less, more preferably 50 or less carbon atoms.
<21>
The liquid film cleavage agent according to the above item <20>, wherein the hydrocarbon compound excludes polyorganosiloxane.
<22>
The liquid film cleavage agent according to the above item <20> or <21>, wherein the hydrocarbon compound is represented by any one of Formulas [VII] to [XV]:
wherein, in Formulas [VII] to [XV], m, m′, m″, n, n′ and n″ each independently are an integer of 1 or more; a plurality of m or a plurality of n each may be identical to or different from each other; and in Formula [X], R52 designates a straight-chain or branched-chain, or saturated or unsaturated hydrocarbon group having 2 or more and 22 or less carbon atoms.
<23>
The liquid film cleavage agent according to any one of the above items <12> to <22>,
wherein the spreading coefficient to the liquid having surface tension of 50 mN/m is 9 mN/m or more, the water solubility is 0 g or more and 0.025 g or less, the interfacial tension to the liquid having surface tension of 50 mN/m is 9 mN/m or less, and the surface tension is 32 mN/m or less.
<24>
The liquid film cleavage agent according to any one of the above items <1> to <23>, wherein the water solubility is preferably 0.0025 g or less, more preferably 0.0017 g or less, further preferably less than 0.0001 g, and 1.0×10−9 g or more.
<25>
The liquid film cleavage agent according to any one of the above items <1> to <24>, wherein a surface tension of the liquid film cleavage agent is preferably 32 mN/m or less, more preferably 30 mN/m or less, further preferably 25 mN/m or less, and particularly preferably 22 mN/m or less; and preferably 1 mN/m or more.
<26>
The liquid film cleavage agent according to any one of the above items <1> to <25>, which has a mass average molecular of 500 or more, more preferably 1,000 or more, further preferably 1,500 or more, and particularly preferably 2,000 or more; and preferably 50,000 or less, more preferably 20,000 or less, and further preferably 10,000 or less.
<27>
The liquid film cleavage agent according to any one of the above items <1> to <26>, which has a melting point of preferably 40° C. or less, and more preferably 35° C. or less; and −220° C. or more, and more preferably −180° C. or more.
<28>
A fiber treating agent containing the liquid film cleavage agent according to any one of the above items <1> to <27> in an amount of 5 mass % or more and 50 mass % or less.
<29>
The fiber treating agent according to the above item <28>, further containing a phosphoric acid ester type anionic surfactant.
<30>
The fiber treating agent according to the above item <29>, wherein a content ratio of the liquid film cleavage agent to the phosphoric acid ester type anionic surfactant is preferably (1:1) to (19:1), more preferably (2:1) to (15:1), and further preferably (3:1) to (10:1) in terms of a mass ratio.
<31>
The fiber treating agent according to the above item <29> or <30>, wherein the phosphoric acid ester type anionic surfactant is any one of alkyl ether phosphoric acid ester, dialkyl phosphoric acid ester and alkyl phosphoric acid ester.
<32>
The fiber treating agent according to the above item <31>, wherein the alkyl phosphoric acid ester is any one of: alkyl phosphoric acid ester having a saturated carbon chain, such as stearyl phosphoric acid ester, myristyl phosphoric acid ester, lauryl phosphoric acid ester and palmityl phosphoric acid ester; alkyl phosphoric acid ester having an unsaturated carbon chain such as oleyl phosphoric acid ester and palmitoleyl phosphoric acid ester; and alkyl phosphoric acid ester having a side chain in each carbon chain thereof.
<33>
A nonwoven fabric containing the liquid film cleavage agent according to any one of the above items <1> to <27>.
<34>
The nonwoven fabric according to the above item <33>, wherein the liquid film cleavage agent is localized at least around part of the points that fibers are entangled to each other or the points that fibers are fusion bonded to each other.
<35>
The nonwoven fabric according to the above item <33> or <34>, further containing a phosphoric acid ester type anionic surfactant.
<36>
The nonwoven fabric according to the above item <35>, wherein a content ratio of the liquid film cleavage agent to the phosphoric acid ester type anionic surfactant is preferably (1:1) to (19:1), more preferably (2:1) to (15:1), and further preferably (3:1) to (10:1) in terms of a mass ratio.
<37>
The nonwoven fabric according to the above item <35> or <36>, wherein the phosphoric acid ester type anionic surfactant is any one of alkyl ether phosphoric acid ester, dialkyl phosphoric acid ester and alkyl phosphoric acid ester.
<38>
The nonwoven fabric according to the above item <37>, wherein the alkyl phosphoric acid ester is any one of: alkyl phosphoric acid ester having a saturated carbon chain, such as stearyl phosphoric acid ester, myristyl phosphoric acid ester, lauryl phosphoric acid ester and palmityl phosphoric acid ester; alkyl phosphoric acid ester having an unsaturated carbon chain such as oleyl phosphoric acid ester and palmitoleyl phosphoric acid ester; and alkyl phosphoric acid ester having a side chain in each carbon chain thereof.
<39>
The nonwoven fabric according to any one of the above items <33> to <38>, wherein the contact angle of constituent fibers of the nonwoven fabric is preferably 90 degrees or less, more preferably 80 degrees or less, and further preferably 70 degrees or less.
<40>
The nonwoven fabric according to any one of the above items <33> to <39>, wherein the interfiber distance in the nonwoven fabric is preferably 150 μm or less, and more preferably 90 μm or less; and preferably 50 μm or more, and more preferably 70 μm or more.
<41>
The nonwoven fabric according to any one of the above items <33> to <40>, wherein the fineness of the fibers in the nonwoven fabric is preferably 3.3 dtex or less, and more preferably 2.4 dtex or less; and preferably 0.5 dtex or more, and more preferably 1.0 dtex or more.
<42>
The nonwoven fabric according to any one of the above items <33> to <41>, comprising thermoplastic fibers, wherein the nonwoven fabric has a first surface and a second surface positioned on the side opposite thereto, and at least in the first surface, has a concavo-convex shape having a plurality of convex portions projecting on a side of the first surface and concave portions positioned among the convex portions to be a concavo-convex nonwoven fabric.
<43>
A topsheet for an absorbent article in which the nonwoven fabric according to any one of the above items <33> to <41> is used,
wherein the topsheet has at least two layers;
the topsheet has a plurality of concave bonding portions in which the layers are bonded to each other with the compression from a skin-contact surface side in a thickness direction;
a layer on a skin non-contact surface side of the topsheet is a layer formed in which thermally shrinkable fibers are being thermally shrunk; and
a layer on the skin-contact surface side of the topsheet has thermally non-shrinkable fibers partially bonded at the bonding portion, and has convex portions projecting on the skin-contact surface side in a region among the concave bonding portions to form a concavo-convex surface of the nonwoven fabric.
<44>
A topsheet for an absorbent article in which the nonwoven fabric according to any one of the above items <33> to <41> is used,
wherein the topsheet has a double-layered structure having a hollow portion and formed of a first nonwoven fabric on a skin-contact surface side and a second nonwoven fabric on a skin non-contact surface side, and both layers contain thermoplastic fibers; and
the topsheet has a bonding portion in which the first nonwoven fabric and the second nonwoven fabric are partially thermally fusion bonded, and in a non-bonding portion surrounded by the bonding portions, the first nonwoven fabric has a large number of convex portions projecting in a direction away from the second nonwoven fabric with the hollow portions inside thereof, and the bonding portion is a concave portion positioned between the adjacent convex portions and constitutes a concavo-convex shape on the skin-contact surface side in cooperation with the convex portions.
<45>
A topsheet for an absorbent article in which the nonwoven fabric according to any one of the above items <33> to <41> is used,
wherein the topsheet comprises one layer containing thermoplastic fibers and has a concavo-convex shape for both sides;
a first projecting portion projecting on a side of a first surface and a second projecting portion projecting on a side of a second surface are alternately continuously arranged in different intersecting directions in a planar view of the nonwoven fabric; and
the first projecting portion and the second projecting portion each have an internal space opened on a side of each opposite surface, which forms concave portions on the each surface.
<46>
A topsheet for an absorbent article in which the nonwoven fabric according to any one of the above items <33> to <41> is used,
wherein the topsheet comprises two layers containing thermoplastic fibers;
a first projecting portion projecting on a side of a first surface and a second projecting portion projecting on side of a second surface are alternately continuously arranged in different intersecting directions in a planar view of the nonwoven fabric, and the first projecting portion and the second projecting portion each have an internal space opened on a side of each opposite surface; and
a first fiber layer has a concave portion formed in the internal space on the each surface, and a second fiber layer is arranged along a concavo-convex shape on the side of the second surface of the first fiber layer and bonded with the first fiber layer, and a side of the first fiber layer is applied as a skin-contact surface side.
<47>
A topsheet for an absorbent article in which the nonwoven fabric according to any one of the above items <33> to <41> is used,
wherein the topsheet comprises one layer containing thermoplastic fibers, and has a shape in which a plurality of hemicylindrical convex portions and a plurality of concave portions arranged along side edges of the convex portions are alternately arranged on a skin-contact surface side; and
concave bottom portions comprising fibers of the nonwoven fabric are arranged on a lower side of the concave portions, and a fiber density of the concave bottom portions are smaller than a fiber density of the convex portions.
<48>
An absorbent article, employing the nonwoven fabric according to any one of the above items <33> to <42>.
<49>
An absorbent article, employing the nonwoven fabric according to any one of the above items <33> to <42> as a topsheet, or containing the topsheet according to any one of the above items <43> to <47>.
<50>
The absorbent article according to the above item <48> or <49>, wherein the absorbent article is a sanitary napkin.
<51>
A method for producing the nonwoven fabric according to any one of the above items <33> to <42>, comprising a step of immersing, into a solution containing a liquid film cleavage agent, a raw material nonwoven fabric prepared by thermally fusing fibers to each other by air-through processing or heat embossing.
<52>
A method for producing the nonwoven fabric according to any one of the above items <33> to <42>, comprising a step of coating a liquid film cleavage agent alone or a solution containing the liquid film cleavage agent to a raw material nonwoven fabric prepared by thermally fusing fibers to each other by air-through processing or heat embossing.
<53>
The method for producing the nonwoven fabric according to the above item <52>, wherein the coating method employs a flexographic system.
<54>
Use of a compound having a spreading coefficient of 15 mN/m or more to a liquid having surface tension of 50 mN/m, and a water solubility of 0 g or more and 0.025 g or less, as a liquid film cleavage agent.
<55>
Use of a compound having a spreading coefficient of more than 0 mN/m to a liquid having surface tension of 50 mN/m, a water solubility of 0 g or more and 0.025 g or less, and an interfacial tension of 20 mN/m or less to the liquid having surface tension of 50 mN/m, as a liquid film cleavage agent.
Hereinafter, the present invention will be described more in detail with reference to Examples, but the present invention is not limited thereto. Further, both terms “part” and “%” in the Example are based on mass unless otherwise noted. Moreover, as mentioned above, a spreading coefficient, interfacial tension, a surface tension and a water solubility were measured in an environmental range of a temperature of 25° C. and a relative humidity (RH) of 65%. A surface tension, a water solubility and an interfacial tension of a liquid film cleavage agent in the Examples described below were measured by the above-mentioned measuring method.
A concavo-convex shaped raw material nonwoven fabric shown in
Before the above-described preparation, a diluted solution having 0.06 mass % of effective component of a liquid film cleavage agent was prepared by dissolving, into ethanol, the liquid film cleavage agent being polyoxyethylene (POE)-modified dimethyl silicone (KF-6015, manufactured by Shin-Etsu Chemical Co., Ltd.), in which X in a structure X—Y was formed of a dimethyl silicone chain composed of —Si(CH3)2O—, Y was formed of a POE chain composed of —(C2H4O)—, an end group of the POE chain was a methyl group (CH3), a modification ratio was 20%, the addition number of moles of polyoxyethylene was 3, and a mass average molecular weight was 4000. A nonwoven fabric sample in Example 1 was prepared by immersing the above-described raw material nonwoven fabric into the diluted solution and drying the resultant material. A content proportion (OPU) of the polyoxyethylene (POE)-modified dimethyl silicone as the liquid film cleavage agent to fiber mass was 0.1 mass %.
With regard to the polyoxyethylene (POE) modified dimethyl silicone, a surface tension was 21.0 mN/m, and a water solubility was less than 0.0001 g. Moreover, a spreading coefficient of the polyoxyethylene (POE)-modified dimethyl silicone to the liquid having surface tension of 50 mN/m was 28.8 mN/m, and an interfacial tension thereof to the liquid having surface tension of 50 mN/m was 0.2 mN/m. These numerical values were measured by the above-mentioned measuring method. On the occasion, as a “liquid having surface tension of 50 mN/m,” a solution was used, in which the solution was prepared by adding, to 100 g of deionized water, 3.75 μL of polyoxyethylene sorbitan monolaurate (trade name “Leodol Super TW-L120,” manufactured by Kao Corporation) being a nonionic surface active substance by using a micropipette (ACURA 825, manufactured by Socorex Isba SA), and adjusting surface tension to 50±1 mN/m. Moreover, the water solubility was measured by adding the agent for every 0.0001 g. As a result, a sample which was observed to be not dissolved even in 0.0001 g was taken as “less than 0.0001 g,” and a sample which was observed to be dissolved in 0.0001 g but not dissolved in 0.0002 g was taken as “0.0001 g.” The numerical values other than the above were measured by the same methods.
A nonwoven fabric sample in Example 2 was prepared in the same manner with Example 1 except that the material described below is used as the liquid film cleavage agent.
Polyoxypropylene (POP)-modified dimethyl silicone (obtained by performing a hydrosilylation reaction between silicone oil and a hydrocarbon compound), in which X in a structure X—Y is formed of a dimethyl silicone chain composed of —Si(CH3)2O—, Y is formed of a POP chain composed of —(C3H6O)—, an end group of the POP chain is a methyl group (CH3), a modification ratio is 20%, the addition number of moles of polyoxypropylene is 3, and a mass average molecular weight is 4150.
A surface tension: 21.0 mN/m
A water solubility: less than 0.0001 g (<0.0001 g)
A spreading coefficient to the liquid having surface tension of 50 mN/m:25.4 mN/m
An interfacial tension to the liquid having surface tension of 50 mN/m:3.6 mN/m
(The four numerical values were measured by the method same as in Example 1.)
A nonwoven fabric was prepared in the same manner with Example 1 except for using, as a liquid film cleavage agent, polyoxypropylene (POP)-modified dimethyl silicone (obtained by performing a hydrosilylation reaction between silicone oil and a hydrocarbon compound), in which X in a structure X—Y was formed of a dimethyl silicone chain composed of —Si(CH3)2O—, Y was formed of a POP chain composed of —(C3H6O)—, an end group of the POP chain was a methyl group (CH3), a modification ratio was 20%, the addition number of moles of polyoxypropylene was 10, and a mass average molecular weight was 7000; and adjusting a content proportion (OPU) of the liquid film cleavage agent to fiber mass to 0.1 mass %. The obtained nonwoven fabric was taken as a sample of Example 3.
With regard to the polyoxypropylene (POP)-modified dimethyl silicone, a surface tension was 21.5 mN/m, and a water solubility was less than 0.0001 g. Moreover, a spreading coefficient of the polyoxypropylene (POP)-modified dimethyl silicone to the liquid having surface tension of 50 mN/m was 28.0 mN/m, and an interfacial tension thereof to the liquid having surface tension of 50 mN/m was 0.5 mN/m. The numerical values were measured by the method same as in Example 1.
A nonwoven fabric sample in Example 4 was prepared in the same manner with Example 1 except that the material described below is used as the liquid film cleavage agent.
Polyoxypropylene (POP)-modified dimethyl silicone (obtained by performing a hydrosilylation reaction between silicone oil and a hydrocarbon compound), in which X in a structure X—Y is formed of a dimethyl silicone chain composed of —Si(CH3)2O—, Y is formed of a POP chain composed of —(C3H6O)—, an end group of the POP chain is a methyl group (CH3), a modification ratio is 15%, the addition number of moles of polyoxypropylene is 10, and a mass average molecular weight is 5160.
A surface tension: 21.5 mN/m
A water solubility: 0.0001 g
A spreading coefficient to the liquid having surface tension of 50 mN/m:27.5 mN/m
An interfacial tension to the liquid having surface tension of 50 mN/m:1.0 mN/m
(The four numerical values were measured by the method same as in Example 1.)
A nonwoven fabric sample in Example 5 was prepared in the same manner with Example 1 except that the material described below is used as the liquid film cleavage agent.
Polyoxypropylene (POP)-modified dimethyl silicone (obtained by performing a hydrosilylation reaction between silicone oil and a hydrocarbon compound), in which X in a structure X—Y is formed of a dimethyl silicone chain composed of —Si(CH3)2O—, Y is formed of a POP chain composed of —(C3H6O)—, an end group of the POP chain is a methyl group (CH3), a modification ratio is 10%, the addition number of moles of polyoxypropylene is 10, and a mass average molecular weight is 4340.
A surface tension: 21.5 mN/m
A water solubility: 0.0002 g
A spreading coefficient to the liquid having surface tension of 50 mN/m:26.9 mN/m
An interfacial tension to the liquid having surface tension of 50 mN/m:1.6 mN/m
(The four numerical values were measured by the method same as in Example 1.)
A nonwoven fabric was prepared in the same manner with Example 1 except for using, as a liquid film cleavage agent, polyoxypropylene (POP)-modified dimethyl silicone (obtained by performing a hydrosilylation reaction between silicone oil and a hydrocarbon compound), in which X in a structure X—Y was formed of a dimethyl silicone chain composed of —Si(CH3)2O—, Y was formed of a POP chain composed of —(C3H6O)—, an end group of the POP chain was a methyl group (CH3), a modification ratio was 20%, the addition number of moles of polyoxypropylene was 24, and a mass average molecular weight was 12500; and adjusting a content proportion (OPU) of the liquid film cleavage agent to fiber mass to 0.1 mass %. The obtained nonwoven fabric was taken as a sample of Example 6.
With regard to the polyoxypropylene (POP)-modified dimethyl silicone, a surface tension was 20.8 mN/m, and a water solubility was 0.0001 g. Moreover, a spreading coefficient of the polyoxypropylene (POP)-modified dimethyl silicone to the liquid having surface tension of 50 mN/m was 28.9 mN/m, and interfacial tension thereof to the liquid having surface tension of 50 mN/m was 0.3 mN/m. The numerical values were measured by the method same as in Example 1.
A nonwoven fabric was prepared in the same manner with Example 1 except for: adjusting an effective component of a liquid film cleavage agent to 3.0 mass % by dissolving, into ethanol, polypropylene glycol (DEFOAMER No. 1, manufactured by Kao Corporation) as the film cleavage agent, in which X in a structure X was formed of a POP chain, the mole number of a polyoxypropylene group was 52, and a mass average molecular weight was 3000; and adjusting a content proportion (OPU) of the liquid film cleavage agent to fiber mass to 5.0 mass %. The obtained nonwoven fabric was taken as a sample in Example 7.
With regard to the polypropylene glycol, a surface tension was 32.7 mN/m, and a water solubility was less than 0.0001 g. Moreover, a spreading coefficient of the polypropylene glycol to the liquid having surface tension of 50 mN/m was 16.3 mN/m, and an interfacial tension thereof to the liquid having surface tension of 50 mN/m was 1.0 mN/m. The numerical values were measured by the method same as in Example 1.
A nonwoven fabric was prepared in the same manner with Example 1 except for using, as a liquid film cleavage agent, epoxy-modified dimethyl silicone (manufactured by Shin-Etsu Chemical Co., Ltd., KF-101), in which X in a structure X—Y was formed of a dimethyl silicone chain composed of —Si(CH3)2O—, Y was formed of an epoxy group composed of —(RC2H3O)—, a modification ratio was 32%, and a mass average molecular weight was 35800; and adjusting a content proportion (OPU) of the liquid film cleavage agent to fiber mass to 0.1 mass %. The obtained nonwoven fabric was taken as a sample of Example 8.
With regard to the epoxy-modified dimethyl silicone, a surface tension was 21.0 mN/m, and a water solubility was less than 0.0001 g. Moreover, a spreading coefficient of the epoxy-modified dimethyl silicone to the liquid having surface tension of 50 mN/m was 26.0 mN/m, and an interfacial tension thereof to the liquid having surface tension of 50 mN/m was 3.0 mN/m. The numerical values were measured by the method same as in Example 1.
A nonwoven fabric was prepared in the same manner with Example 1 except for: using, as a liquid film cleavage agent, carbinol-modified dimethyl silicone (manufactured by Shin-Etsu Chemical Co., Ltd., X-22-4015), in which X in a structure X—Y was formed of a dimethyl silicone chain composed of —Si(CH3)2O—, Y was formed of a carbinol group composed of —(ROH)—, a modification ratio was 4%, and a mass average molecular weight was 9630; and adjusting a content proportion (OPU) of the liquid film cleavage agent to fiber mass to 0.1 mass %. The obtained nonwoven fabric was taken as a sample of Example 9.
With regard to the carbinol-modified dimethyl silicone, a surface tension was 21.0 mN/m, and a water solubility was less than 0.0001 g. Moreover, a spreading coefficient of the carbinol-modified dimethyl silicone to the liquid having surface tension of 50 mN/m was 27.3 mN/m, and an interfacial tension thereof to the liquid having surface tension of 50 mN/m was 1.7 mN/m. The numerical values were measured by the method same as in Example 1.
A nonwoven fabric was prepared in the same manner with Example 1 except for: using, as the liquid film cleavage agent, diol-modified dimethyl silicone at one terminal (X-22-176DX, manufactured by Shin-Etsu Chemical Co., Ltd.), in which X in a structure X—Y was a dimethyl silicone chain composed of —Si(CH3)2O—, and Y was diol having a plurality of hydroxyl groups composed of —(OH)—, a modification ratio was 1.2%, and a mass average molecular weight was 6190; and adjusting a content proportion (OPU) of the liquid film cleavage agent to fiber mass to 0.1 mass %. The obtained nonwoven fabric was taken as a sample of Example 10.
With regard to the diol-modified dimethyl silicone, a surface tension was 21.0 mN/m, and a water solubility was less than 0.0001 g. Moreover, a spreading coefficient of the diol-modified dimethyl silicone to the liquid having surface tension of 50 mN/m was 27.1 mN/m, and an interfacial tension thereof to the liquid having surface tension of 50 mN/m was 1.9 mN/m. The numerical values were measured by the method same as in Example 1.
A diluted solution to be applied to a nonwoven fabric was prepared in a manner similar to Example 1 with mixing polyoxyethylene (POE)-modified silicone used in Example 1 and stearyl (C18) phosphoric acid ester potassium salt (neutralized product with potassium hydroxide, GRIPPER 4131, manufactured by Kao Corporation). A content proportion of polyoxyethylene (POE)-modified silicone to stearyl (C18) phosphoric acid ester potassium salt in the diluted solution was adjusted to 1.67:1.
A nonwoven fabric sample in Example 11 was prepared in the same manner with Example 1 except for: using a raw material nonwoven fabric formed of an upper layer in which an interfiber distance was adjusted to 85 μm by using thermally non-shrinkable and thermally fusible fibers having fineness of 1.2 dtex, and a lower layer in which an interfiber distance was adjusted to 60 μm by using thermally shrinkable fibers having fineness of 2.3 dtex; and using the above-described diluted solution. A basis weight of the nonwoven fabric was adjusted to 74 g/m2.
In the nonwoven fabric sample, a content proportion (OPU) of polyoxyethylene (POE)-modified silicone as the liquid film cleavage agent to fiber mass was adjusted to 0.1 mass %, and a content proportion (OPU) of stearyl phosphoric acid ester potassium salt to fiber mass was adjusted to 0.06 mass %.
A diluted solution to be applied to a nonwoven fabric was prepared in a manner similar to Example 1 with mixing polyoxypropylene (POP)-modified silicone used in Example 3 and stearyl (C18) phosphoric acid ester potassium salt (neutralized product with potassium hydroxide, GRIPPER 4131, manufactured by Kao Corporation). A content proportion of polyoxypropylene (POP)-modified silicone to stearyl (C18) phosphoric acid ester potassium salt in the diluted solution was adjusted to 1.67:1. A spreading coefficient, a water solubility and an interfacial tension of the polyoxypropylene (POP)-modified silicone as the liquid film cleavage agent were measured in the same manner with Example 3.
A nonwoven fabric sample in Example 12 was prepared in the same manner with Example 1 except for: using a raw material nonwoven fabric formed of an upper layer in which an interfiber distance was adjusted to 85 μm by using thermally non-shrinkable and thermally fusible fibers having fineness of 1.2 dtex, and a lower layer in which an interfiber distance was adjusted to 60 μm by using thermally shrinkable fibers having fineness of 2.3 dtex; and using the above-described diluted solution. A basis weight of the nonwoven fabric was adjusted to 74 g/m2.
In the nonwoven fabric sample, a content proportion (OPU) of polyoxypropylene (POP)-modified silicone as the liquid film cleavage agent to fiber mass was adjusted to 0.1 mass %, and a content proportion (OPU) of alkly phosphoric acid ester potassium salt to fiber mass was adjusted to 0.06 mass %.
A nonwoven fabric was prepared in the same manner with Example 1 except for adjusting an effective component of a liquid film cleavage agent to 3.0 mass % by dissolving, into ethanol, polyoxypropylene (POP) alkyl ether (DEFOAMER No. 8, manufactured by Kao Corporation) as the liquid film cleavage agent which was contained in fibers, in which Z in a structure Z—Y was formed of a hydrocarbon chain composed of —CH2—, Y was formed of a POP chain composed of —(C3H6O)—, the addition number of moles of polyoxypropylene was 5, and a mass average molecular weight was 500; and adjusting a content proportion (OPU) of the liquid film cleavage agent to fiber mass was adjusted to 5.0 mass %. The obtained nonwoven fabric was taken as a sample of Example 13.
With regard to the polyoxypropylene (POP) alkyl ether, a surface tension was 30.4 mN/m, and a water solubility was less than 0.0001 g. Moreover, a spreading coefficient of the polyoxypropylene (POP) alkyl ether to the liquid having surface tension of 50 mN/m was 13.7 mN/m, and an interfacial tension thereof to the liquid having surface tension of 50 mN/m was 5.9 mN/m. The numerical values were measured by the method same as in Example 1.
A nonwoven fabric was prepared in the same manner with Example 1 except for: adjusting an effective component of a liquid film cleavage agent to 3.0 mass % by dissolving, into ethanol, caprylic/capric triglyceride (COCONARD MT, manufactured by Kao Corporation) as the liquid film cleavage agent, in which Z in a structure Z—Y was *—O—CH(CH2O—*)2 (* represents a bonding portion.), Y was formed of a hydrocarbon chain of C8H15O— or C10H19O—, a fatty acid composition was composed of 82% of caprylic acid and 18% of capric acid, and a mass average molecular weight was 550; and adjusting a content proportion (OPU) of the liquid film cleavage agent to fiber mass to 5.0 mass %. The obtained nonwoven fabric was taken as a sample of Example 14.
With regard to the caprylic/capric triglyceride, a surface tension was 28.9 mN/m, and a water solubility was less than 0.0001 g. Moreover, a spreading coefficient of the caprylic/capric triglyceride to the liquid having surface tension of 50 mN/m was 8.8 mN/m, and an interfacial tension thereof to the liquid having surface tension of 50 mN/m was 12.3 mN/m. The numerical values were measured by the method same as in Example 1.
A nonwoven fabric sample in Example 15 was prepared in the same manner with Example 1 except for: adjusting an effective component of a liquid film cleavage agent to 3.0 mass % by using, as the liquid film cleavage agent, the material described below, and dissolving the material into diethyl ether; and adjusting a content proportion (OPU) of the liquid film cleavage agent to fiber mass to 5.0 mass %.
Liquid paraffin (manufactured by KISHIDA CHEMICAL Co., Ltd.), having a mass average molecular weight of 300
A surface tension: 30.6 mN/m
A water solubility: less than 0.0001 g
A spreading coefficient to the liquid having surface tension of 50 mN/m:9.9 mN/m
An interfacial tension to the liquid having surface tension of 50 mN/m:9.5 mN/m
(The four numerical values were measured by the method same as in Example 1.)
A nonwoven fabric sample in Example 16 was prepared in the same manner with Example 1 except for: adjusting an effective component of a liquid film cleavage agent to 3.0 mass % by using, as the liquid film cleavage agent, the material described below, and dissolving the material into ethanol; and adjusting a content proportion (OPU) of the liquid film cleavage agent to fiber mass was adjusted to 5.0 mass %.
Polyoxypropylene (POP) alkyl ether (UNILUBE MS-70K, manufactured by NOF CORPORATION), in which a structure Z is formed of a hydrocarbon chain composed of —CH2—, Y is formed of a POP chain composed of —(C3H6O)—, the mole number of a polyoxypropylene group is 15, and a mass average molecular weight is 1140.
A surface tension: 31.8 mN/m
A water solubility: less than 0.0001 g
A spreading coefficient to the liquid having surface tension of 50 mN/m:5.4 mN/m
An interfacial tension to the liquid having surface tension of 50 mN/m:12.8 mN/m
(The above-described four numerical values were measured by the method same as in Example 1.)
A nonwoven fabric sample in Example 17 was prepared in the same manner with Example 1 except for: adjusting an effective component of a liquid film cleavage agent to 3.0 mass % by using, as the liquid film cleavage agent, the material described below, and dissolving the material into ethanol; and adjusting a content proportion (OPU) of the liquid film cleavage agent to fiber mass to 5.0 mass %.
Polypropylene glycol (manufactured by SIGMA-ALDRICH), in which a structure Z is formed of a POP chain, the mole number of a polyoxypropylene group is 17, and a mass average molecular weight is 1000.
A surface tension: 32.4 mN/m
A water solubility: 0.0017 g
A spreading coefficient to the liquid having surface tension of 50 mN/m:14.0 mN/m
An interfacial tension to the liquid having surface tension of 50 mN/m:3.6 mN/m
(The four numerical values were measured by the method same as in Example 1.)
A nonwoven fabric sample in Example 18 was prepared in the same manner with Example 1 except for: adjusting an effective component of a liquid film cleavage agent to 3.0 mass % by using, as the liquid film cleavage agent, the material described below, and dissolving the material into hexane; and adjusting a content proportion (OPU) of the liquid film cleavage agent to fiber mass was adjusted to 5.0 mass %.
Liquid isoparaffin (Luvitol Lite, manufactured by BASF Japan), having a mass average molecular of 450
A surface tension: 27.0 mN/m
A water solubility: less than 0.0001 g
A spreading coefficient to the liquid having surface tension of 50 mN/m:14.5 mN/m
An interfacial tension to the liquid having surface tension of 50 mN/m:8.5 mN/m
(The four numerical values were measured by the method same as in Example 1.)
A diluted solution to be applied to a nonwoven fabric was prepared in a manner similar to Example 1 with mixing polyoxypropylene (POP) alkyl ether used in Example 13 and stearyl (C18) phosphoric acid ester potassium salt (neutralized product with potassium hydroxide, GRIPPER 4131, manufactured by Kao Corporation). A content proportion of polyoxypropylene (POP) alkyl ether to stearyl (C18) phosphoric acid ester potassium salt in the diluted solution was adjusted to 3.58:1. A nonwoven fabric was prepared in the same manner with Example 13 except for: adjusting a content proportion (OPU) of polyoxypropylene (POP) alkyl ether as the liquid film cleavage agent to fiber mass to 5.0 mass %; and adjusting a content proportion (OPU) of stearyl phosphoric acid ester potassium salt to fiber mass to 1.4 mass %. The obtained nonwoven fabric was taken as a sample in Example 19. Further, as an applying method for the above-described agent, the same method as in Example 11 was adopted.
A diluted solution to be applied to a nonwoven fabric was prepared in a manner similar to Example 1 with mixing caprylic/capric triglyceride used in Example 14 and stearyl (C18) phosphoric acid ester potassium salt (neutralized product with potassium hydroxide, GRIPPER 4131, manufactured by Kao Corporation). A content proportion of caprylic/capric triglyceride to stearyl (C18) phosphoric acid ester potassium salt in the diluted solution was adjusted to 3.58:1. A nonwoven fabric was prepared in the same manner with Example 14 except for adjusting a content proportion (OPU) of caprylic/capric triglyceride as the liquid film cleavage agent to fiber mass to 5.0 mass %; and adjusting a content proportion (OPU) of stearyl phosphoric acid ester potassium salt to fiber mass to 1.4 mass %. The obtained nonwoven fabric was taken as a sample in Example 20. Further, as an applying method for the above-described agent, the same method as in Example 11 was adopted.
A diluted solution to be applied to a nonwoven fabric was prepared in a manner similar to Example 1 with mixing liquid paraffin used in Example 15 and stearyl (C18) phosphoric acid ester potassium salt (neutralized product with potassium hydroxide, GRIPPER 4131, manufactured by Kao Corporation). A content proportion of liquid paraffin to stearyl (C18) phosphoric acid ester potassium salt in the diluted solution was adjusted to 3.58:1. A nonwoven fabric was prepared in the same manner with Example 15 except for: adjusting a content proportion (OPU) of liquid paraffin as the liquid film cleavage agent to fiber mass to 5.0 mass %; and adjusting a content proportion (OPU) of stearyl phosphoric acid ester potassium salt to fiber mass to 1.4 mass %. The obtained nonwoven fabric was taken as a sample in Example 21. Further, as an applying method for the above-described agent, the same method as in Example 11 was adopted.
A diluted solution to be applied to a nonwoven fabric was prepared in a manner similar to Example 1 with mixing polyoxypropylene (POP) alkyl ether used in Example 16 and stearyl (C18) phosphoric acid ester potassium salt (neutralized product with potassium hydroxide, GRIPPER 4131, manufactured by Kao Corporation). A content proportion of polyoxypropylene (POP) alkyl ether to stearyl (C18) phosphoric acid ester potassium salt in the diluted solution was adjusted to 3.58:1. A nonwoven fabric was prepared in the same manner with Example 16 except for: adjusting a content proportion (OPU) of polyoxypropylene (POP) alkyl ether as the liquid film cleavage agent to fiber mass to 5.0 mass %, and a content proportion (OPU) of stearyl phosphoric acid ester potassium salt to fiber mass to 1.4 mass %. The obtained nonwoven fabric was taken as a sample in Example 22. Further, as an applying method for the above-described agent, the same method as in Example 11 was adopted.
A diluted solution to be applied to a nonwoven fabric was prepared in a manner similar to Example 1 with mixing polypropylene glycol used in Example 17 and stearyl (C18) phosphoric acid ester potassium salt (neutralized product with potassium hydroxide, GRIPPER 4131, manufactured by Kao Corporation). A content proportion of polypropylene glycol to stearyl (C18) phosphoric acid ester potassium salt in the diluted solution was adjusted to 3.58:1. A nonwoven fabric was prepared in the same manner with Example 17 except for: adjusting a content proportion (OPU) of polypropylene glycol as the liquid film cleavage agent to fiber mass to 5.0 mass %; and adjusting a content proportion (OPU) of stearyl phosphoric acid ester potassium salt to fiber mass to 1.4 mass %. The obtained nonwoven fabric was taken as a sample in Example 23. Further, as an applying method for the above-described agent, the same method as in Example 11 was adopted.
A diluted solution to be applied to a nonwoven fabric was prepared in a manner similar to Example 1 with mixing liquid isoparaffin used in Example 18 and stearyl (C18) phosphoric acid ester potassium salt (neutralized product with potassium hydroxide, GRIPPER 4131, manufactured by Kao Corporation). A content proportion of liquid isoparaffin to stearyl (C18) phosphoric acid ester potassium salt in the diluted solution was adjusted to 3.58:1. A nonwoven fabric was prepared in the same manner with Example 18 except for: adjusting a content proportion (OPU) of liquid isoparaffin as the liquid film cleavage agent to fiber mass to 5.0 mass %; and adjusting a content proportion (OPU) of stearyl phosphoric acid ester potassium salt to fiber mass to 1.4 mass %. The obtained nonwoven fabric was taken as a sample in Example 24. Further, as an applying method for the above-described agent, the same method as in Example 11 was adopted.
A nonwoven fabric sample in Example 25 was prepared in the same manner with Example 11 except for preparing a raw material nonwoven fabric having a concavo-convex shape shown in
A nonwoven fabric sample in Example 26 was prepared in the same manner with Example 11 except for preparing a raw material nonwoven fabric having the same concavo-convex shape as in Example 5 and being formed of first fibers of thermally non-extensible and thermally fusible fibers having fineness of 1.2 dtex and second fibers of thermally extensible fibers having fineness of 4.4 dtex. Further, in the raw material nonwoven fabric, the first fibers and the second fibers were mixed at a mass ratio of 1:1. An interfiber distance at this time was adjusted to 109 μm, and a basis weight of the nonwoven fabric was adjusted to 25 g/m2.
A nonwoven fabric sample in Example 27 was prepared in the same manner with Example 11 except for preparing a raw material nonwoven fabric having a concavo-convex shape shown in
A nonwoven fabric sample in Example 28 was prepared in the same manner with Example 11 except for preparing a raw material nonwoven fabric having a concavo-convex shape shown in
A raw material nonwoven fabric in the same aspect as in Example 1 was prepared. Further, an interfiber distance in an upper layer at this time was adjusted to 86 μm, and an interfiber distance in a lower layer was adjusted to 119 μm. Moreover, a liquid film cleavage agent solution (diluted solution) in which an effective component of a liquid film cleavage agent was adjusted to 2.75 mass % was prepared by diluting, with ethanol, POE3-modified silicone (polyoxyethylene (POE)-modified dimethyl silicone) which was the same as in Example 1. Next, a sample in Example 29 was prepare by applying the liquid film cleavage agent solution (diluted solution) wholly on a surface of the raw material nonwoven fabric by using Anilox rolls of 140 LPI (18 cc) in a flexographic press (Flexiproof 100, manufactured by RK Print Coat Instruments Ltd.) to be 0.4 mass % in a content proportion (OPU) to fiber mass, and then naturally drying the resultant material.
A liquid film cleavage agent was attached to fibers by immersing the fibers used in Example 1 into the diluted solution used in Example 1 before the fibers were processed into a nonwoven fabric. At this time, a content proportion (OPU) of the liquid film cleavage agent to fiber mass was adjusted to 0.2 mass %. Next, in the same manner with Example 1, a concavo-convex-shaped nonwoven fabric shown in
A concavo-convex shaped raw material nonwoven fabric having openings as shown in
A nonwoven fabric was prepared in the same manner with Example 1 except that no liquid surface cleavage agent was incorporated to fibers. The obtained nonwoven fabric was taken as a sample in Comparative Example 1.
A nonwoven fabric was prepared in the same manner with Example 1 except for: using, as an applying agent to a raw material nonwoven fabric, dimethyl silicone oil (manufactured by Shin-Etsu Chemical Co., Ltd., KF-96A-100cs); and adjusting a content proportion (OPU) to fiber mass to 0.1 mass %. The obtained nonwoven fabric was taken as a sample in Comparative Example 2.
With regard to the dimethyl silicone oil, a surface tension was 21.0 mN/m, and a water solubility was 0.0001 g. Moreover, a spreading coefficient of the dimethyl silicone oil to the liquid having surface tension of 50 mN/m was 2.4 mN/m, and an interfacial tension thereof to the liquid having surface tension of 50 mN/m was 26.6 mN/m. The numerical values were measured by the method same as in Example 1.
A nonwoven fabric was prepared in the same manner with Example 1 except for using, as an applying agent to a raw material nonwoven fabric, water-soluble polyoxyethylene/polypropylene glycol butyl ether-modified silicone (KF6012, manufactured by Shin-Etsu Chemical Co., Ltd.) in which the addition number of moles of polyoxyethylene was 82, and a mass average molecular weight was 14400; and adjusting a content proportion (OPU) to fiber mass to 0.1 mass %. The obtained nonwoven fabric was taken as a sample in Comparative Example 3.
With regard to the water-soluble polyoxyethylene/polypropylene glycol butyl ether-modified silicone, a surface tension was 21 mN/m, and a water solubility was more than 0.025 g (>0.025 g). However, a spreading coefficient and an interfacial tension to the liquid having surface tension of 50 mN/m were unable to be measured because the material was water-soluble, and had no extendibility. The numerical values were measured by the method same as in Example 1. Further, HLB of the water-soluble polyoxyethylene/polypropylene glycol butyl ether-modified silicone was 7.0. The HLB was at a substantially same level as “HLB of 6.4 of polyoxyethylene (POE)-modified silicone” described in Patent Literature 1.
A nonwoven fabric similar to a raw material nonwoven fabric containing no liquid surface cleavage agent, which was prepared in Example 26, was taken as a nonwoven fabric sample in Comparative Example 4.
A nonwoven fabric similar to a raw material nonwoven fabric containing no liquid surface cleavage agent, which was prepared in Example 27, was taken as a nonwoven fabric sample in Comparative Example 5.
A nonwoven fabric similar to a raw material nonwoven fabric containing no liquid surface cleavage agent, which was prepared in Example 28, was taken as a nonwoven fabric sample in Comparative Example 6.
A nonwoven fabric similar to a raw material nonwoven fabric containing no liquid surface cleavage agent, which was prepared in Example 31, was taken as a nonwoven fabric sample in Comparative Example 7.
The evaluation described below was performed by using a sanitary napkin for evaluation, which was prepared by removing a topsheet from a sanitary napkin (LAURIER F Shiawase Suhada, 30 cm, manufactured by Kao Corporation in 2014) as one example of an absorbent article, and laminating, in place thereof, a sample of a nonwoven fabric (hereinafter, referred to as a nonwoven fabric sample), and fixing a periphery thereof.
The evaluation described below was performed by using a sanitary napkin for evaluation, which was prepared by removing a topsheet from a sanitary napkin (Hada-Kirei Guard, 20.5 cm, manufactured by Kao Corporation in 2014 Autumn) as one example of an absorbent article, and laminating, in place thereof, a nonwoven fabric sample, and fixing a periphery thereof.
The evaluation described below was performed by using a diaper for babies for evaluation, which was prepared by removing a topsheet from a diaper for babies (Merries Shun So Toki M size, tape type, manufactured by Kao Corporation in 2014) as one example of an absorbent article, and laminating, in place thereof, a nonwoven fabric sample, and fixing a periphery thereof.
The evaluation described below was performed by using a diaper for babies for evaluation, which was prepared by removing a topsheet from a diaper for babies (Merries Sarasara Air Through S size, tape type, manufactured by Kao Corporation in 2014) as one example of an absorbent article, and laminating, in place thereof, a nonwoven fabric sample, and fixing a periphery thereof.
The evaluation described below was performed by using a sanitary napkin for evaluation, which was prepared by removing a topsheet from a sanitary napkin (LAURIER Active Day Double Comfort, 22 cm, no wings, manufactured by Kao Corporation in 2014) as one example of an absorbent article, laminating, in place thereof, a nonwoven fabric sample, and fixing a periphery thereof.
On a surface of each sanitary napkin for evaluation, an acrylic plate having a permeation hole with an inner diameter of 1 cm was stacked, and a predetermined load of 100 Pa was applied to the napkin. Under such a load, 6 g of defibrinated equine blood (prepared by adjusting defibrinated equine blood manufactured by NIPPON BIO-TEST LABORATORIES INC. to 8.0 cP) corresponding to menstrual blood was poured thereinto from the permeation hole of the acrylic plate. Further, the used equine blood was adjusted by TVB-10 Viscometer manufactured by Toki Sangyo Co., Ltd. under conditions of 30 rpm in advance. If the equine blood was allowed to stand, a part with high viscosity (red blood cells or the like) precipitates, and a part with low viscosity (plasma) remains as a supernatant. A mixing ratio in the parts was adjusted to be 8.0 cP. After 60 seconds from pouring 6.0 g of defibrinated equine blood in total thereinto, the acrylic plate was removed therefrom. Next, a weight (W2) of a nonwoven fabric sample was measured, a difference (W2−W1) from a weight (W1) of the nonwoven fabric sample, a weight of which was measured in advance, before pouring the equine blood thereinto, was calculated. The operation described above was performed 3 times, and a mean value in 3 times operation was taken as an amount of residual liquid (mg). The amount of residual liquid serves as an indication as to what degree wearer's skin is wetted, and as the amount of liquid remains is lower, better results are obtained.
An amount of residual liquid was tested in the same manner with the cases in <Examples 1 to 26 and 29 to 31, Comparative Examples 1 to 4 and 7> except for using, in place of the defibrinated equine blood, artificial urine (blended in a proportion of 1.94 mass % of urea, 0.795 mass % of sodium chloride, 0.11 mass % of magnesium sulfate, 0.062 mass % of calcium chloride, 0.197 mass % of potassium sulfate, 0.010 mass % of red No. 2, 96.88 mass % of water and about 0.07 mass % of POE lauryl ether, in which surface tension was adjusted to 53±1 mN/m (25° C.)).
A surface of a nonwoven fabric after 30 seconds from injection of the above-mentioned defibrinated equine blood thereinto was photographed by a microscope “VHX-1000” (trade name, manufactured by KEYENCE Corporation). The surface was analyzed from a photographed image by using image analysis software “NewQube” (trade name, manufactured by Nexus Co., Ltd.). In the analysis, first, an RGB color image was converted into an image of monochrome 256 tones. Then, an area of a liquid film part was calculated by performing binarization processing to the image and extracting only a black part representing the liquid film. A value expressed in terms of a percentage of the calculated area to an area of the image was taken as a liquid film area proportion. As the liquid film area proportion is smaller, an interfiber liquid film cleavage effect is demonstrated to be larger.
An liquid film area proportion was tested in the same manner with the cases in <Examples 1 to 26 and 29 to 31, Comparative Examples 1 to 4 and 7> except for using, in place of the defibrinated equine blood, artificial urine (blended in a proportion of 1.94 mass % of urea, 0.795 mass % of sodium chloride, 0.11 mass % of magnesium sulfate, 0.062 mass % of calcium chloride, 0.197 mass % of potassium sulfate, 0.010 mass % of red No. 2, 96.88 mass % of water and about 0.07 mass % of POE lauryl ether, in which surface tension was adjusted to 53±1 mN/m (25° C.)).
With regard to each nonwoven fabric sample in which the amount of residual liquid were evaluated by using the above-mentioned defibrinated equine blood, an L value in a position to which the defibrinated equine blood was charged was measured by a handy type spectrophotometer NF333 manufactured by Nippon Denshoku Industries Co., Ltd.
The L value (lightness) shows that, as the value is larger, the color is closer to white, and redness is hard to be seen in a topsheet (nonwoven fabric sample). That is, a larger L value shows that the residual liquid between the fibers is smaller.
Further, no defibrinated equine blood was used in Examples 25 to 26 and Comparative Examples 5 to 6, and therefore the L value was not measured.
Compositions in the Examples and the Comparative Examples, and the results in each evaluation with regard to the Examples and the Comparative Examples are shown in the following Tables 1 to 6.
As shown in Tables 1 to 3 and Table 6, in Examples 1 to 24 and 29 to 31 in which the tests were conducted by using the defibrinated equine blood, an interfiber liquid film cleaved by the above-mentioned effect by the liquid film cleavage agent, and the liquid film area proportion significantly reduced in comparison with Comparative Examples 1 to 3 and 7. Further, in Examples 1 to 24 and 29 to 31, the cleavage of the interfiber liquid film results in absorbing the liquid in the absorbent body without delay, and in the nonwoven fabric in which the effect was large, the amount of residual liquid was reduced to about one third of the amount in Comparative Example, and simultaneously whiteness on the surface was significantly improved. In particular, in Example 29, the liquid film area proportion and the amount of residual liquid were the lowest, and the nonwoven fabric was excellent in a dry feeling.
In Examples 25 and 26 each shown in Table 4, the liquid film area proportion was suppressed at a level as significantly low as about 15% or about 18% of the proportion in Comparative Examples 4, and the amount of residual liquid was suppressed at a level as significantly low as about 15% or about 20% of amount in Comparative Examples 4, in which a liquid film cleavage effect was large.
As shown in Table 5, in Example 27 in which the test was conducted by using urine having smaller viscosity than the viscosity of menstrual blood, the liquid film area proportion was suppressed at a level as low as about 6% of the proportion in Comparative Examples 5, and the amount of residual liquid was suppressed at a level as low as about 35% of the amount in Comparative Examples 5. Similarly, as shown in Table 5, also in Example 28 in which the test was conducted by using urine, the liquid film area proportion was suppressed at a level as low as about 9% of the proportion in Comparative Examples 5, and the amount of residual liquid was suppressed at a level as low as about 28% of the amount in Comparative Examples 5. That is, the effect of the liquid film cleavage agent also on urine was found to be high.
Moreover, with regard to each nonwoven fabric sample, a state of attachment of the liquid film cleavage agent to the fibers was confirmed along “Confirmation method for localized state of liquid film cleavage agent” mentioned above. A photograph substituted for drawing in
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As described above, it was found that the dry feeling of the nonwoven fabric at a high level was able to be realized by containing the liquid film cleavage agent in each Example in the nonwoven fabric. Moreover, the absorbent article which is excellent in the dry feeling, is able to suppress a worry about leakage, and is conformable to wear can be provided by using the nonwoven fabric containing the liquid film cleavage agent as the topsheet or the like.
Having described our invention as related to this embodiments, it is our intention that the invention not be limited by any of the details of the description, unless otherwise specified, but rather be construed broadly within its spirit and scope as set out in the accompanying claims.
This application claims priority on Patent Application No. 2014-255639 filed in Japan on Dec. 17, 2014, which is entirely herein incorporated by reference.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2014-255639 | Dec 2014 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2015/085156 | 12/16/2015 | WO | 00 |
