Patent Application
20100191207
The present invention relates to a liquid-pervious nonwoven fabric, particularly to such a nonwoven fabric suitably used as a liquid-pervious topsheet in a liquid-absorbent article such as a disposable diaper or sanitary napkin and to a method for making the same.
Conventionally it has been required for liquid-pervious topsheets used to cover liquid-absorbent cores such as bodily fluid absorbent cores in disposable diapers to spot-absorb bodily fluid without spreading it and to transfer it quickly into the cores. The invention relating to sanitary material having a high water-permeability, for example, disclosed in JP 1998-5275 A has proposed the topsheet of the type described herein. The topsheet disclosed JP 1998-5275 A is obtained by spraying a mixture of polyether compound and polyether modified silicone to modify the topsheet hydrophilic onto a crimped or crimp-free spunbond nonwoven fabric made of polypropylene so that an initial water permeation rate of 0.25 sec or less.
An embodiment of the topsheet disclosed in JP 1998-5275 A is the topsheet formed of a spunbond nonwoven fabric of polypropylene sprayed with an agent modifying the topsheet to be hydrophilic. Most of fibers are placed one upon another between an upper surface and a lower surface of the nonwoven fabric and extend in parallel to these upper and lower surfaces. As a result, discharged bodily fluids can be spot-absorbed so far as discharged bodily fluids is relatively small. However, bodily fluids will horizontally spread and it will become inevitably difficult for the topsheet to spot-absorb bodily fluids when a relatively large amount of bodily fluids is discharged. Furthermore, in the case of such known topsheet, a time necessary for bodily fluids to permeate the topsheet becomes unacceptably long as viscosity of bodily fluids increases.
In view of the problem left unsolved behind by the prior art as has been described above, it is an object of the present invention to provide a nonwoven fabric and a method for making the same improved to solve the problem.
The object set forth above is achieved by a first aspect of the present invention relating to a liquid-pervious nonwoven fabric, on one hand, and by a second aspect of the present invention relating to a method for making the nonwoven fabric, on the other hand.
The first aspect of the invention relates to a liquid-pervious nonwoven fabric having a basis weight in a range of 10 to 200 g/m2, the liquid-pervious nonwoven fabric further having a first direction, a second direction orthogonal to the first direction and a thickness direction in orthogonal relationship one to another, the nonwoven fabric comprising core-sheath type composite fibers of 100 to 30% by weight as composite fibers and thermoplastic synthetic fibers of 0 to 70% by weight as blending fibers for the composite fibers, the core-sheath type composite fibers comprising core and sheath components in concentric relationship with each other wherein a thermoplastic synthetic resin forming the sheath component has a fusion point lower than a fusion point of a thermoplastic synthetic resin forming the core component.
The nonwoven fabric according to the first aspect of the invention further comprising: the composite fiber has a fineness of 1 to 17 dtex and a fiber length of 10 to 150 mm wherein the composite fibers extend in the first direction with curvatures repeated in the thickness direction as viewed in a cut surface of the nonwoven fabric taken in parallel to the first direction and extends in the thickness direction as viewed in a cut surface of the nonwoven fabric taken in parallel to the second direction; the composite fibers intersect themselves and/or with the blending fibers and, at respective points of intersection, the composite fibers are fused together with themselves and/or with the blending fibers as the low fusion point resin is fused; and when the nonwoven fabric is placed in a horizontal plane, some of the composite fibers and the blending fibers intersect, in the cut surface of the nonwoven fabric taken in parallel to the second direction, a vertical line with respect to the horizontal plane at acute angles inclusive of 90° and some of the composite fibers and the blending fibers intersect the vertical line at obtuse angles larger than 90° so that an average fiber angle corresponding to an average value of the acute intersection angles may be 75° or less.
According to one embodiment of the first aspect of the invention, the composite fibers contain among them spirally crimped thermoplastic synthetic fibers at content up to 50% by weight.
According to another embodiment of the first aspect of the invention, at least one of hydrophilic blending natural fibers and hydrophilic blending semi-synthetic fibers are contained in the nonwoven fabric up to 10% by weight with respect to total weight of the nonwoven fabric.
According to still another embodiment of the first aspect of the invention, one of the composite fibers and the blending thermoplastic synthetic fibers have its surface modified to be hydrophilic.
According to further another embodiment of the first aspect of the invention, the nonwoven fabric has upper and lower surfaces opposed to each other in the thickness direction and the upper surface is formed with a plurality of crests extending in parallel to the first direction and a plurality of troughs each extending in the first direction between each pair of adjacent the crests.
According to an alternatively embodiment of the first aspect of the invention, with the lower surface of the nonwoven fabric placed in the horizontal plane, the average fiber angle defined between the vertical line extending through an apex of the crest and the composite fibers and/or the blending fibers are 75° or less.
According to an alternatively another embodiment of the first aspect of the invention, the nonwoven fabric is used as a topsheet in a sanitary napkin.
The second aspect of the invention relates to a method for making a liquid-pervious nonwoven fabric having a basis weight in a range of 10 to 200 g/m2, the liquid-pervious nonwoven fabric further having a mechanical direction and a cross direction in orthogonal relationship to each other and including core-sheath type composite fibers of 100 to 30% by weight as composite fibers, wherein the core-sheath type composite fibers comprising core and sheath components in concentric relationship with each other and a thermoplastic synthetic resin forming the sheath component has a fusion point lower than a fusion point of a thermoplastic synthetic resin forming the core component, the method comprising the steps as follow:
a. forming the core-sheath type composite fibers followed by obtaining a tow from a plurality of the core-sheath type composite fibers and then stretching the tow;
b. mechanically crimping the tow having been stretched in the step (a) so as to repeat curvatures in a longitudinal direction of the tow;
c. subjecting the tow having been crimped in the step (b) to an annealing treatment;
d. cutting the tow having been subjected to the annealing treatment in the step (c) into a length of 10 to 150 mm so as to obtain an assembly of the composite fibers in the form of staples;
e. fibrillating the assembly of the composite fibers through a card to obtain a web comprising the composite fibers and having a desired basis weight;
f. heating the web to fuse the resin of low fusion point and thereby fusing together the composite fibers in the web one at intersection points thereof; and
g. cooling the web after the step (f).
According to one embodiment of the second aspect of the invention, the method further includes a step of arranging a plurality of the cards in the machine direction followed by placing the webs obtained from the respective cards one upon another to form a laminate web so as to be treated as the web in a step subsequent to the step (f).
According to another embodiment of the second aspect of the invention, the method further includes, between the step (e) and the step (f), a step of preheating the web after the composite fibers have been fused together at the intersection points thereof and before the web is conveyed to the step (f).
According to another embodiment of the second aspect of the invention, the step (f) includes a sub-step of compressing the web in the thickness direction using compressed air or mechanical means to increase a density of the web and a sub-step of fusing the composite fibers in the web together at the intersection points of the composite fibers.
According to still another embodiment of the second aspect of the invention, the step of preheating includes a sub-step of emitting a jet of heated and pressurized air from a plurality of individual nozzles arranged in the cross direction to the web being conveyed on support means in the machine direction to form the web with a plurality of crests parallel extending in the machine direction and a plurality of troughs each defined between a pair of the adjacent crests and extending in the machine direction.
According to yet another embodiment of the second aspect of the invention, the step (e) includes a sub-step of adding thermoplastic synthetic fibers having latent crimps as blending fibers to the composite fibers so as to occupy 0 to 50% by weight with respect to total weight of the nonwoven fabric.
According to further another embodiment of the second aspect of the invention, a ratio of thickness T of the nonwoven fabric measured in a region inclusive of an apex of the crest in a cut surface of the nonwoven fabric taken in parallel to the cross direction to a width W of the crest measured at a level corresponding to ½ of the thickness T is in a range of 0.55 to 1.00.
According to an alternatively embodiment of the second aspect of the invention, the step (b) comprises a step of feeding the tow into a box-type crimper so that the composite fibers may be mechanically crimped in zigzags at a rate of 10 to 35 crimps/25 mm.
According to alternatively another embodiment of the second aspect of the invention, the annealing treatment in the step (c) is carried out at a temperature between the fusion temperature of the low fusion point resin forming the sheath component and a temperature 20° C. lower than the fusion temperature.
According to alternatively still another embodiment of the second aspect of the invention, the composite fibers intersect, in the cut surface of the nonwoven fabric taken in parallel to the cross direction, a vertical line with respect to the horizontal plane at acute angles inclusive of 90° and some of the composite fibers and the blending fibers intersect the vertical line at obtuse angles larger than 90° so that an average fiber angle corresponding to an average value of the acute intersection angles may be 75° or less.
According to alternatively yet another embodiment of the second aspect of the invention, the composite fibers and the thermoplastic synthetic fibers used as the blending fibers intersect, in the cut surface of the nonwoven fabric taken in parallel to the cross direction, the vertical line with respect to the horizontal plane at acute angles inclusive of 90° and some of the composite fibers and the blending fibers intersect the vertical line at obtuse angles larger than 90° so that an average fiber angle corresponding to an average value of the acute intersection angles may be 75° or less.
According to alternatively further another embodiment of the second aspect of the invention, the step (e) comprises a sub-step of blending at least one of hydrophilic natural fibers and hydrophilic semi-synthetic fibers in the nonwoven fabric so that a content of the hydrophilic natural fibers or the hydrophilic semi-synthetic fibers may be 0 to 10% by weight with respect to total weight of the nonwoven fabric.
The nonwoven fabric according to the first aspect of this invention primarily comprises the core-sheath type composite fibers and the low fusion point resin forming the sheath component of the composite fibers may be fused together at the intersection points thereof whereby to provide the nonwoven fabric with desired high strength. These composite fibers intersect the vertical line with respect to the horizontal plane on which the nonwoven fabric is placed at an average fiber angles of 75° or less as measured in the cut surface of the nonwoven fabric taken in parallel to the cross direction of the nonwoven fabric. In other words, these composite fibers extend primarily in the thickness direction of the nonwoven fabric and thereby ensure that bodily fluids can be rapidly transferred downward along the composite fibers in the thickness direction. In this way, bodily fluids can spot-permeate the nonwoven fabric.
The method for making the nonwoven fabric according to the second aspect of the invention includes the step of mechanically crimping the tow so that the composite fibers thereby obtained repeat curvatures in the longitudinal direction. Consequentially, the web obtained by carding these composite fibers extends in the machine direction with the repetitive curvatures in the thickness direction of the web. The nonwoven fabric obtained from the web can be improved in its tensile strength by fusing the composite fibers together at the intersection points thereof. So far as the core component is not fused even when the sheath component is fused, there is no possibility that a dimension of the web might be significantly changed in the course of fusing the sheath component and it is assured to obtain the adequately bulky nonwoven fabric from the composite fibers.
Details of a nonwoven fabric and a method for making the same will be more fully understood from the description given hereunder with reference to the accompanying drawings.
The composite fibers 2 have a fineness of 1 to 17 dtex and a fiber length of 10 to 150 mm. The composite fibers 2 comprise a core component and a sheath component wherein the sheath component is made of a thermoplastic synthetic resin selected to have a fusion point lower than a fusion point of a thermoplastic synthetic resin forming the core component so that the composite fibers 2 may be fused together at intersection points of these composite fibers 2 as the thermoplastic synthetic resin form the sheath component is fused. The preferred composite fibers 2 each comprise the core component and the sheath component in a concentric relationship with each other and presents no spiral crimp even when it is heated. It should be understood, however, that the composite fibers each comprising the core component and the sheath component in a slightly eccentric relationship with each other and presenting a negligible latent crimps under heating may be also used as the composite fibers 2 of this invention. Description “the composite fibers presenting a negligible latent crimps” used herein means that, after a web piece of 250×250 mm having a basis weight of 200 g/m2 has been heated at a temperature of 145° C. for 5 min, this web piece exhibits a contraction percentage of 5% or less in the first direction MD. According to the present invention, the composite fibers exhibiting such behavior in the web piece is generically named as the composite fibers each having the core component and the sheath component substantially in the concentric relationship with each other. The term “number of crimps” used herein refers to the value measured using the method specified in Section 8. 12 of JIS (Japanese Industrial Standards) L 1015.
Such nonwoven fabric 1 is suitably useful not only as liquid-pervious sheets in body fluid absorbent articles such as disposable diapers, sanitary napkins, panty liners or tampons or but also as liquid-pervious sheets, for example, body waste disposal sheets for pet animals. The nonwoven fabric 1 is useful as wipes to clean the human body or equipment. It should be noted here that, when the nonwoven fabric 1 is used as the liquid-pervious sheet for the purpose of covering the liquid-absorbent core in the bodily fluid absorbent article, the composite fibers 2 each preferably has a fineness of 2.6 to 4.4 dtex and a fiber length of 38 to 51 mm to achieve a soft touch of the nonwoven fabric 1. Furthermore, for this article, the composite fibers 2 are preferably coated with appropriate surfactant or plasma-treated in order to modify the fiber surface to be hydrophilic. If it is desired to improve a water-absorbing property of the nonwoven fabric 1, hydrophilic natural fibers such as cotton or hydrophilic semi-synthetic fibers such as rayon fiber up to 10% by weight may be added as the blending fibers to the composite fiber 2. While the thermoplastic synthetic resin constituting the core component and the sheath component of the composite fibers 2 may be selected from the group including olefin resins such as polyethylene or polypropylene, polyamide resins such as nylon, polyester resins and polyacrylonitrile resins, it is preferred to use polyethylene as the sheath component to assure that the composite fibers 2 are firmly fused together at the intersection points thereof at a relatively low temperature. For the nonwoven fabric 1 in which the composite fibers 2 are fused together by means of fused polyethylene at the intersection points thereof, it is required that the core component should not be fused even when the sheath component is fused. To meet this requirement, the core component is preferably formed by polypropylene or polyester having a fusion point substantially higher than a fusion point of the sheath component. The thermoplastic synthetic resin used to form the core component and/or the sheath component may contain particles of inorganic substance, for example, titanium oxide as filler. The filler has a particle size preferably in a range of 0.05 to 0.5 μm and such filler makes it possible to regulate respective degrees of glaze and transparency of the composite fiber 2. The nonwoven fabric 1 formed by the composite fibers containing the filler may be advantageously used as liquid-pervious sheets wrapping liquid-absorbent cores to hide any contamination of the core due to bodily fluids.
In a step II, the composite fiber 2a is paralleled to obtain a tow 2b.
In the step III, a tow 2b is heated at a desired temperature and subjected to a primary stretching treatment and a secondary stretching treatment in order to regulate fineness and strength of the composite fibers 2a.
In a step IV, the tow 2b coated with lubricant is fed into a box-type crimper and therein mechanically crimped.
In a step V, the tow 2b is subjected to an annealing treatment. Specifically, the tow 2b is heated in its relaxed condition so that the crimps are fixed and simultaneously the tow 2b is heat-contracted to stabilize a configuration of the tow 2b.
In a step VI, the tow 2b is cut into a desired length and an assembly of the composite fibers 2 in the form of staples.
In a step VII, an assembly of the composite fiber 2 is guided through a card 101 to fibrillate the assembly and thereby to obtain web 102 comprising the composite fibers 2.
In a step VIII, the web 102 is placed on an endless belt 103 serving as a support used to convey the web 102 in the machine direction MD.
In a step IX, the web 102 is exposed to a blast of pressurized air blown downward with a pretreatment chamber 104 to move the composite fibers 2 constituting the web 102 downward in the thickness direction TD of the web 102 to increase a density of the web 102. A temperature of the pressurized air should be limited not to fuse the sheath component. Within the pretreatment chamber 104, the pressurized air is suctioned from below the web 102.
In a step X, the web 102 is exposed within treatment chambers 105, 106, 107 following the pretreatment chamber 104 to a blast of heated air from above to fuse the low fusion point resin forming the sheath component of the composite fiber 2 and the fused resin is utilized to fuse the composite fibers 2 together at the intersection points thereof. Within the respective treatment chambers 105, 106, 107, the heated air is suctioned from below the web 102. While a temperature as well as a flow rate of the heated air within the respective treatment chambers 105, 106, 107 may be selectively adjusted, the temperature of the heated air must be at a fusion temperature of the low fusion point resin or higher.
In a step XI, the web 102 exiting the treatment chamber 107 is cooled to obtain the nonwoven fabric 1 and this nonwoven fabric 1 is reeled.
Referring to
A specific embodiment of the production process of
In the step I, the composite fibers 2a comprising core-sheath type filaments wherein the core component and the sheath component are substantially in concentric relationship with each other are melt spun, using polyester as the high fusion point resin and polyethylene as the low fusion point resin. While the polyethylene may be selected from the group consisting of high density polyethylene, low density polyethylene, straight-chain low density polyethylene and mixture thereof, it is preferred to use high density polyethylene having a density of 0.95 to 0.97 g/cm3 and a melt flow rate specified by JIS K 7210 in a range of 10 to 30 g/10 min.
In the step II, the composite fibers 2a are paralleled to obtain the tow 2b.
In the step III, the tow 2b is stretched by 130 to 400% at a temperature of 70 to 110° C. so that the composite fibers 2a constituting the tow 2b may take the form of filament having a fineness in a range of 1 to 17 dtex, more preferably in a range of 2 to 10 dtex.
In the step IV, the stretched tow 2b is overfed into the box-type crimper and thereby the composite fibers 2a is mechanically crimped so as to repeat curvature in zigzags at a rate of 10 to 35 curvatures/25 mm, more preferably at a rate of 13 to 20 curvatures/25 mm.
In the step V, the crimped tow 2b is annealed by heating the tow 2b at a temperature of 120° C. for 5 to 8 minutes.
In the step VI, the annealed tow 2b is now cut into an absolute size of 10 to 150 mm, more preferably of 25 to 65 mm and thereby to obtain the assembly of the composite fibers 2 in the form of staples.
In the step VII, the assembly of the composite fibers 2 is fibrillated to obtain the web 102. As will be appreciated by those skilled in the art, it is also possible to obtain the web 102 from the composite fibers 2 containing therein the blending fibers 112. As the blending fibers 112, thermoplastic synthetic fibers such as composite fibers or hydrophilic natural fibers such as cotton or hydrophilic semi-synthetic fibers such as rayon, in any case, having a fiber length of 10 to 55 mm and latent crimps may be used. In the nonwoven fabric 1, a content of the blending fibers 112 is preferably 50% or less by weight if the thermoplastic synthetic fibers are used and preferably 10% or less by weight if the natural fiber or the semi-synthetic fibers are used with respect to a total weight of the nonwoven fabric 1. The term “the composite fibers used as the blending fibers 112 and having latent crimps” as used herein refers to the composite fibers reliably expressing the latent crimps under heating in the step X.
In the step IX, the web 102 is exposed to blast of hot air at a temperature limited not to fuse the sheath component of the composite fibers 2, for example, at a temperature in a range of 80 to 125° C., more preferably in a range of 90 to 110° C. at a rate of 1.5 to 3 m/sec if the sheath component is of polyethylene and thereby the composite fibers 2 are moved downward without changing the mechanically crimped state in the thickness direction TD of the web 102.
In the step IX, the sheath components of the composite fibers 2 are fused together at the respective intersection points and thereby interlaced together. For example, if the sheath component is of polyethylene, the web 102 may be exposed to blast of hot air at a temperature of 130 to 150° C. at a rate of 0.5 to 1.5 m/sec. For the web 102 containing therein the composite fibers having latent crimps as the blending fibers 112, such blending fibers 112 are fused with or mechanically interlaced with the composite fiber 2 under blast of hot air and simultaneously spirally crimped. Consequentially, the blending fibers 112 serve not only to restrain undesired movement of the composite fibers 2 but also to prevent orientation of the composite fibers 2 in the machine direction as well as in the cross direction from being changed in the step X.
In this production process, a mechanically crimped tow 2b is annealed under heating at a temperature corresponding to the fusion point of the sheath component constituting the composite fibers 2 or a temperature near to this fusion point. As a result, the crimped state of the composite fibers 2 in the form of staple can be thermally stabilized. In the course of running through the card 101 in the machine direction MD, the composite fibers 2 develops a strong tendency to extend in parallel to the machine direction MD and at the same time develops a strong tendency to repeat zigzag curvatures in the thickness direction TD. In the nonwoven fabric 1 obtained after leaving the step X, the crimps are apt to moderate under the effect of hot blast within the respective treatment chambers 105, 106, 107, but most of the composite fibers can maintain the tendency to extend in the machine direction MD with the repeated curvatures in the thickness direction TD.
With the composite fibers 2 thermally stabilized to be crimped in this manner, the tow 2b behaves to have decreased “deformation residual ratio” representing an elastic recovery. The nonwoven fabric 1 obtained such tow 2b behaves to have a large “specific volume” representing a ratio between volumes of the nonwoven fabric before and after placed under a load. In other words, the nonwoven fabric behaves to maintain a desired bulkiness even after placed under a load. Furthermore, when the nonwoven fabric 1 is placed on a horizontal plane and observed in a cut surface taken in parallel to the cross direction CD, “the fiber angle” defined by an angle at which the vertical line with respect to the horizontal plane intersects the composite fibers 2 have a tendency to narrow. Such tendency suggests the composite fibers 2 behaves to extend vertically as viewed in a cut surface of the nonwoven fabric 1 taken in parallel to the cross direction CD. In addition, when used as the liquid-pervious topsheet in a sanitary napkin, the nonwoven fabric 1 behaves to reduce “liquid permeation rate” for a specified quantity of artificial menstrual blood. Methods for measurement of these “deformation residual ratio”, “specific volume”, “average fiber angle” and “liquid permeation rate” will be described in details with respect to specific embodiments described hereunder.
The production process shown in
The nonwoven fabric 201 shown in
A production process of
The nozzle assemblies 212, 213, 214 may be arranged to be spaced one from another, for example, by an angular distance of 30° C. circumferentially of the suction drum 211 while the individual nozzles 215 in the respective nozzle assemblies 212, 213, 214 are arranged, for example, at a pitch of 5 mm in the cross direction along the air supply piping. The nozzle assemblies 212, 213, 214 are adapted to provide air blast heated at a desired temperature at a desired airflow rate. More specifically, blasts of hot air from the individual nozzles 215 are regulated so that these blasts of hot air themselves or interference among them may not disturb a distribution of the composite fibers 2 in the web 102. Assumed that the web 102 having a basis weight of 35 g/m2 moves past the suction drum 211 having a diameter of 500 mm along a predetermined part of its peripheral surface in 0.5 sec and the individual nozzles 215 in the respective nozzle assemblies 212, 213, 214 are arranged at a pitch of 5 mm in the cross direction CD at a distance of 5 to 8 mm from the peripheral surface of the suction drum 211, the web 102 runs immediately under the individual nozzles 215 preferably after the web 102 has been adjusted under the suction effect to have a thickness of 5 to 8 mm. Preferably, in the course of such processing, the individual nozzles 215 has a diameter in the order of 0.5 to 1.5 mm, the airflow rate from the individual nozzle is 50 to 700 m/sec and a sucking force of the suction drum 211 is 2 to 7 m/sec.
The suction drum 211 in
In the production process of
In the web 102 exposed to the air blast, the composite fibers 2 just underlying the individual nozzles 215 are moved in parallel one to another in the cross direction CD and gathered together between respective pairs of the adjacent individual nozzles 215, 215 to form a crest (not shown) corresponding to the crest 202 as seen in
As will be apparent from
It is possible to increment the temperature of the air blasts blown out from the nozzle assemblies 212, 213, 214 in this order. In this case, the moiety of the composite fibers 2 underlying the individual nozzles 215 may be moved in the cross direction under the effect of the air blasts from the nozzle assemblies 212, 213 located on the side of an entranceway of the web 102 and gathered together between each pair of the individual nozzles 215 adjacent to each other in the cross direction. Temperature and airflow rate of the air blasts from the nozzle assemblies 212, 213 may be regulated so that the web 102 is heated but the sheath component of the composite fibers 2 might not be fused. For the composite fibers 2 each consisting of polyester as the core component and polyethylene as the sheath component, the air blasts may be adjusted to have a temperature in a range of 90 to 200° C. The air blast from the nozzle assembly 214 primarily serves to fuse the sheath components underlying the individual nozzles 215 together and thereby to stabilize a configuration of the web 102. Temperature of the air blasts for this purpose is higher than the temperature of the air blasts from the nozzle assemblies 212, 213 and may be adjusted to a range of 180 to 250° C.
In regard to the nozzle assemblies 212, 213, 214, an alternative embodiment is possible without departing from the scope of the invention. According to this alternative embodiment, the diameter of the individual nozzle 215 in the respective nozzle assemblies may be gradually enlarged in the order of the assemblies 212, 213, 214 and thereby an area of the web 102 exposed to the air blast from the individual nozzle 215 may be gradually enlarged in the cross direction CD. In this way, the width of the trough formed in the web 102 can be gradually enlarged in the cross direction CD in the step of obtaining the nonwoven fabric 201 of
The step of forming the web 102 with the crests and the troughs both extending in the machine direction MD using the nozzle assemblies 212, 213, 214 is applicable also to the case in which the web 102 contains the latently crimped fibers as the blending fibers 112. In the web 102 obtained by blending the composite fibers 2 with the blending fibers 112 in the step VII of
Such problem is avoided, for example, by previously forming the web 102 with the crests and the troughs using the nozzle assemblies 212 and 213 so as to gather the composite fibers 2 together with the composite fibers 112 in the crests, then preheating the web 102 using the nozzle assembly 214 and thereby fusing the fibers in the web 102 together at a slight degree. In such production process, most of the blending fibers 112 are spirally crimped and the apparent dimension of the blending fibers 112 is reduced along the relatively narrow crests of the web 102 under the effect of this preheating. In such production process also, the phenomenon that the composite fibers 2 are pulled by the blending fibers 112 in the various directions of reduction occurring in the apparent dimension of the blending fibers 112. However, this phenomenon occurs not evenly over a large extent of the web 102 but only in the crests. By forming the web 102 with the crests using the latently crimped blending fibers 112 in this manner, the distribution of the composite fibers 2 in the nonwoven fabric 201 obtained from the web 102 can be concentrated in the crests 202. When the latently crimped composite fibers are used as the blending fibers 112, the blending fibers 112 are crimped and thereby dimension-reduced often at a very irregular contraction percentage. However, in the case of the web 102 formed with the crests as the web 102 moves past the molding means 210, most of the blending fibers 112 is concentrated in the crests and therefore a contraction percentage of the blending fibers 112 presents an averaged value. So far as the nonwoven fabric 201 obtained from such web 102 is concerned. The nonwoven fabric 210 should not be remarkably affected by a portion of the blending fibers 112 having a significantly high contraction percentage.
The latently crimped fiber used as the blending fibers 112 may be selected from the group including eccentric core-sheath type composite fibers, eccentric core-sheath type hollow composite fibers and side-by-side type composite fibers wherein the latently crimped composite fibers to be selected has preferably a web contraction percentage (described later in detail) in a range of 10 to 40%. If the web contraction percentage of the latently crimped composite fibers is less than 10%, a contraction percentage of the apparent dimension thereof as the crimps are actualized will be too low to gather the composite fibers 2 together and correspondingly to assist the composite fibers 2 to be interlaced one with another. If the web contraction percentage exceeds 40%, on the contrary, a diameter of each spiral of the latently crimped composite fibers as the crimps are actualized will be often reduced and apt to lay down, in other words, the average fiber angle will be disadvantageously enlarged. In the latently crimped composite fibers suitably useful as the blending composite fibers 112, a volume ratio between the core component and the sheath component is preferably adjusted in a range of 50:50 to 70:30 so that a sufficient volume of the sheath component can be assured to facilitate such latently crimped composite fibers to be fused together with the composite fibers 2. Furthermore, the latently crimped composite fibers preferably has a fiber length in a range of 38 to 64 mm and fineness in a range of 1.5 to 4 dtex to increase the number of points at which the latently crimped composite fiber is fused together with the composite fiber 2.
Referring to
In the crests 202 of the nonwoven fabric 201 obtained in this manner, the composite fibers 2 extend in the thickness direction TD in the same pattern as in the nonwoven fabric 1 of
Furthermore, in the production process of
Referring to
It is also possible to obtain the nonwoven fabric 201 by using the first, second and third cards 301a, 301b, 301c in a manner as follows. The first card 301a supplies the first web 302a comprising the composite fibers each having a relatively short fiber length, for example, in a range of 15 to 44 mm, a small number of mechanical crimps in a range of 10 to 15/25.4 mm and a basis weight of 10 g/m2. The second card 301b supplies the second web 302b comprising the composite fibers having a relative long fiber length, for example, in a range of 44 to 64 mm, a large number of mechanical crimps in a range of 15 to 35/25.4 mm and a basis weight of 10 g/m2. The third card 302c supplies the third web 302c identical to the second web 302b. The laminate web 302d comprising these first, second and third web 302a, 302b, 302c are exposed to the air blasts from the nozzle assemblies 212, 213, 214 and to suction effect by the suction drum 211 while the laminate web 302d is moved on the peripheral surface of the suction drum 211. In the course of such processing, the composite fibers 2 each having a relatively short fiber length and forming the first web 302a has a tendency to extend in the machine direction MD and simultaneously has a remarkable tendency to express the mechanical crimps in zigzags in the plane extending orthogonally to the horizontal endless belt 103. These tendencies are effective to improve a bulk retention ratio and to decrease the average fiber angle θ of the nonwoven fabric 201 so as to improve the liquid-permeation rate. On the other hand, the composite fibers 2 each having a relative long fiber length and forming the third web 302 effectively serves to prevent the composite fibers 2 from fluffing on the surface of the crest, to increase a fiber density on the surface of the crest and to improve appearance of the nonwoven fabric 2.
TABLES 1 and 2 list component fibers and performance evaluation results thereof in various embodiments of the nonwoven fabric obtained by the production process shown in
These are used as the composite fibers 2 in the embodiments of the present invention.
This is latently crimped fiber used as the blending fibers 112 in the embodiments of the present invention.
A length of fiber forced to be linear.
The number of mechanical crimps of fibers included in a tow treated by the box-type crimper after spinning counted in accordance with method prescribed in JIS L 1015 with a pair of fiber-grips spaced from each other by a distance of 25 mm.
5. Heat Treatment after Crimping
A temperature at which the tow is heated in its relaxed state for 7 min for annealing treatment after having been taken out from the crimper.
From web comprising latently crimped fiber and having a basis weight of 200 g/m2, a test sheet of 250×250 mm is prepared. A contraction percentage of this test sheet in the machine direction MD after this test sheet have been heat treated at a temperature of 145° C. for 5 min.
(1) In the step V of
(2) The tow is additionally applied with a load of 75 g and heated at a temperature of 120° C. for 5 min.
(3) After the tow has been cooled to a room temperature, the load of 75 g is removed, then a distance d (mm) between the upper and lower marks is measured and the deformation residual ratio (%) is calculated from a following equation:
(d−100)/100=deformation residual ratio (%)
(1) Approximately 2 mg of composite fibers is sampled from the tow heat treated in the step V.
(2) Based on this sample, DSC (Differential Scanning Calorimeter) is used to measure a fusion heat quantity (J) and thereby to determine a first peak value in the course of a temperature rising process. This first peak value is divided by a weight (g) of the sample to obtain a fusion heat quantity ΔH(J/g) of low fusion point resin constituting the composite fiber, for example, polyethylene.
(3) Measuring instrument and measuring condition:
Measuring instrument: Differential scanning calorimeter DSC-60 of Shimadzu Corporation
Sample container: Model PN/50-020 (container having a capacity of 15 μl) and Model PN/50-021 (crimp cover for the container)
Temperature rising rate: 5° C./min
Range of measured temperature: 50 to 200° C.
Ambient atmosphere for measurement: nitrogen gas
9. Thickness of Web after Passing Through the Card
(1) The web having a basis weight of 30 g/m2 leaving the card of the step VII is cut into 300×300 mm to prepare a sample.
(2) Thickness of the sample is measured under a load of a load of 0.1 g/cm2 and a measured value is recorded as the thickness of the web after it has moved past the card.
(1) Seven (7) samples each prepared by cutting the web having a basis weight of 30 g/m2 leaving the card of the step VII are placed one upon another and a thickness ho of this sample laminate is measured under a load of 0.1 g/cm2.
(2) The sample laminate under the load is treated in a heating furnace at a temperature of 135° C. for 5 min and then a thickness h1 is measured after the sample laminate has been cooled.
(3) The bulk retention ratio is obtained from an equation of h1/h0×100=bulk retention ratio (%)
(1) The nonwoven fabric is cut into 100×100 mm for sample preparation. Ten (10) samples are placed one upon another and a thickness of this sample laminate is measured under a load of 2000 gf. 1/10 of the measured thickness is recorded as the thickness t of the nonwoven fabric.
(2) A basis weight w of the nonwoven fabric is calculated from a weight of the 100×100 mm sample in units of g/m2.
(3) t/w=specific volume (cm3/g) is calculated as the specific volume under a load of 20 gf/cm2.
(1) The topsheet of a commercially available sanitary napkin (SOFY FUWAFUWA SURIMU, 25 cm manufactured by Uni-Charm Corporation) is replaced by a nonwoven fabric according to the embodiments of this invention or according to the comparative embodiments to prepare samples.
(2) An acrylic plate of 40×10 mm formed with a through-hole having a diameter substantially corresponding to a distal diameter of artificial menstrual blood dropping burette is placed upon the sample and a weight is placed on the acrylic plate so that the sample may be applied with a load of 2 gf/cm2.
(3) Primarily, 3 ml of artificial menstrual blood is dropped at a rate of 90 ml/min to the sanitary napkin via the through-hole and left for 1 min permeate the topsheet. The artificial menstrual blood used herein consists of 80 g of glycerin, 8 g of CMC sodium, 10 g of NaCl, 4 g of NaHCO3, 8 g of red pigment No. 102, 2 g of red pigment No. 2 and 2 g of yellow pigment No. 5 mixed together and dissolved in 1000 cc of water.
(4) Secondarily, 4 ma of artificial menstrual blood is dropped.
(5) With respect to each of the primarily dropped artificial menstrual blood and the secondarily dropped artificial menstrual blood, a length of time from a moment at which the artificial menstrual blood begins to be dropped to a moment at which the artificial menstrual blood completely permeates the topsheet into the core is measured. Both the liquid-permeation rates for the primarily and secondarily dropped artificial menstrual blood serve as indices for the high or low liquid-permeation rate of the nonwoven fabric.
(1) The nonwoven fabric used as a sample for measurement is heated at a temperature of 70° C. for 30 min to remove any traces of folding in the course of handling and thereby to flatten the sample.
(2) Standard substitute edge HA-100B for KOKUYO' s cutter knife HA-7NB (Trade Name) is used to cut the sample in the cross direction CD to prepare a cut surface for observation extending in parallel to the cross direction CD and the sample is placed on a horizontal plane.
(3) The cut surface is observed through an electronic microscope (REAL-SURFACE-VIEW microscope VE-7800 manufactured by Keyence Corporation) and a 30 times magnified photograph of the cut surface is taken so as to bring an extent defined between upper and lower surfaces of the sample into view.
(4) At an optional position on the cut surface taken in photo, a vertical line with respect to the horizontal plane is drawn and auxiliary vertical lines are drawn on both sides of the primary vertical line so as to be spaced from this primary vertical line by 100 μm.
(5) Positions at which a single fiber intersects these two auxiliary lines are marked.
(6) The right and left marks are connected by a straight line and intersection angles α and β (See
(7) Such fiber angle is obtained with respect to all the fibers sufficiently focused on the photo of the cut surface to be used as the object to be measured and an arithmetic average value of the measured fiber angles is determined as “average fiber angle θ. These fibers well focused in the photo of the cut surface are referred to, according to the invention, as the fibers appearing in the cut surface.
The nonwoven fabric according to EXAMPLES 1 to 3 listed in TABLES 1 and 2 comprises the composite fibers 2 of 100% by weight. In TABLE 1, the composite fibers 2 are referred to as composite fibers I. Polyester (PET) having a fusion point of 260° C. was used as the core component and high density polyethylene (PE) having a fusion point of 130° C. was used as the sheath component in this composite fiber I. Tow from which the composite fibers I is to be obtained was coated with surfactant of 0.4% by weight as the lubricant treatment in the step IV of
The nonwoven fabric according to EXAMPLES 4-6 comprises the composite fiber 2 of 100% and this composite fiber 2 comprises composite fiber I and composite fibers II mixed together at a weight ratio of 70:30 to 30:70. The composite fibers I each has a fiber length of 38 mm or 51 mm and has previously been, in the form of tow, mechanically crimped at a rate of 15/25 mm. The composite fibers II each has a fiber length of 51 mm and has previously been, in the form of tow, mechanically crimped at a rate of 18/25 mm. Both the composite fibers I and the composite fibers II have previously been subjected to a lubricant treatment. More specifically, the tow was coated with surfactant of 0.4% by weight adapted to modify it to become hydrophilic, then mechanically crimped and heat treated at a temperature of 120° C. for 7 min.
The nonwoven fabric according to EXAMPLE 7 listed in TABLES 1 and 2 was made by using the web comprising the composite fibers I corresponding to the composite fibers 2 used in EXAMPLE 1 and the blending fibers 112 shown in the production process of
The composite fibers I used in EXAMPLE 1 were used as the composite fibers 2 while the latently crimped core-sheath type composite fibers previously coated with surfactant of 0.4% by weight serving to modify the fibers to become hydrophilic and mechanically crimped at a rate of 15/25 mm was used as the blending fiber 112. The composite fibers I and the blending fibers 112 were blended together at a weight ratio of 80:20-50:50. A crimping rate exhibited by the blending fibers 112 as it is heated was evaluated on the basis of a contraction ratio of the web.
The nonwoven fabric having the configuration exemplarily shown in
The nonwoven fabric according to EXAMPLE 12 is similar to the nonwoven fabric according to EXAMPLE 11 except that the first web 301a had a basis weight of 15 g/m2.
The nonwoven fabrics according to COMPARATIVE EXAMPLES 1 and 2 are similar to the nonwoven fabric according to EXAMPLE 1 except the condition under which the tow is heat-treated. Specifically, the mechanically crimped tow was heat-treated at a temperature of 90° C. for 7 min in the case of COMPARATIVE EXAMPLE 1 and at a temperature of 100° C. for 7 min in the case of COMPARATIVE EXAMPLE 2. The remaining conditions for production of the nonwoven fabrics were same as those in EXAMPLE 1.
In COMPARATIVE EXAMPLES 3 and 4, a content of the composite fiber in the nonwoven fabric was 20% by weight or 10% by weight, the average fiber angle θ was 75° or higher, a first liquid-permeation rate was longer than 15 sec and a secondary liquid-permeation rate was longer than 20 sec.
As is suggested by TABLES 1 and 2, a temperature for heat treatment of the tow after it has been mechanically crimped, i.e., a heat treatment temperature after crimping listed in TABLE 1 may be adjusted approximately to a fusion temperature of the low fusion point resin forming the sheath component of the composite fibers, preferably to a range defined between this fusion point and a temperature 20° C. lower than this fusion point to minimize a deformation residual ratio and thereby to maximize an elastic recover of the tow after compression. This was true for the web as well as the nonwoven fabric obtained from such tow and well reflected on a bulk retention ratio of the web and a specific volume of the nonwoven fabric. As will be easily understood from values of the fusion heat quantity ΔH of the tow listed in TABLE 2, increase in the temperature at which the tow is heat-treated resulted in increase of the fusion heat quantity ΔH. The fusion heat quantity ΔH referred to herein should be understood to be the fusion heat quantity ΔH of the low fusion point resin in the composite fiber used in EXAMPLES 1 and 2 as well as in COMPARATIVE EXAMPLES 1 and 2, i.e., the fusion heat quantity ΔH of polyethylene and such increase in the fusion heat quantity ΔH is believed to mean that the low fusion point resin in EXAMPLES has a thermal stability higher than the low fusion point resin in COMPARATIVE EXAMPLES can have and consequentially the tow as well as staple derived therefrom is able to maintain the crimped state even under heating. The nonwoven fabric according to EXAMPLES is also characterized by its average fiber angle θ of 75° or less, which is smaller than the average fiber angle θ of the nonwoven fabric according to COMPARATIVE EXAMPLES. In other words, in the cut surface extending in parallel to the cross direction CD of the nonwoven fabric placed on the horizontal plane, both the composite fibers 2 and the blending fibers 112 tend to extending in the vertical direction rather than tending to extend flatly in the horizontal direction. Such average fiber angle θ is reflected on the liquid-permeation rate of the nonwoven fabric according to EXAMPLES. Specifically, the liquid-permeation rate of the primarily dropped artificial menstrual blood was 15 sec or shorter and the liquid-permeation rate of secondarily dropped artificial menstrual blood was 20 sec or shorter. In the nonwoven fabric according to COMPARATIVE EXAMPLES, the average fiber angle θ exceeded 75° and consequentially the liquid-permeation rate of primarily dropped artificial menstrual blood exceeded 15 sec and the liquid-permeation rate of secondarily dropped artificial menstrual blood exceeds 20 sec. In contrast with the nonwoven fabric according to COMPARATIVE EXAMPLES, the nonwoven fabric according to EXAMPLES can reliably maintain its ability to spot-absorb body fluids repetitively discharged.
According to EXAMPLE 7, the mechanically crimped composite fiber used in COMPARATIVE EXAMPLE 1 may used as the blending fiber 112.
According to EXAMPLES 8-12, the latently crimped composite fiber may be used as the blending fiber 112.
According to EXAMPLES 11 and 12, a plurality of webs obtained from a plurality of cards may be placed one upon another to form the web laminate and the nonwoven fabric according to the invention may be obtained using this web laminate.
Step 1: topsheet of commercially available sanitary napkin (Trade Name: SOFY FUWAPITASURIMU 25 mm manufactured by Uni-Charm Corporation) is replaced by the nonwoven fabric under test to prepare the sanitary napkin to be tested.
Step 2: the sensor is set to 37° C.
Step 3: an acrylic plate having a thickness of 13 mm and formed with a rectangular through-hole of 40×10 mm is placed upon the nonwoven fabric for test in the sanitary napkin.
Step 4: 6 ml of artificial menstrual blood at a temperature of 20° C. is dropped into the through-hole of the acrylic plate.
Step 5: upon disappearance of artificial menstrual blood from the surface of the nonwoven fabric for test, the sensor is pressed against the artificial menstrual blood dropped region to record the temperature changing rate as indicated by the sensor. The sensor is controllably pressed against the nonwoven fabric for test so that a surface pressure of 20 to 30 gf/cm2 may be achieved.
Step 6: the temperature changing rates at 1, 5, 15, 30 and 60 sec after the measurement has been started.
Referring to
The inventors have found that, between a cold sense experienced by the human finger at a moment that the finger comes in contact with the object to be measured by FINGER ROBOT THERMO LAB and a temperature changing rate indicated by the sensor, relationships as follow are established:
No cold sense is experienced at a temperature changing rate of 0 to 0.30° C./sec;
A certain degree of cold sense is experienced at a temperature changing rate of 0.30 to 0.50° C./sec; and
A definite cold sense is experienced at a temperature changing rate of 0.50° C./sec.
This finding suggests that, in the case of the sanitary napkin using the nonwoven fabric according to EXAMPLES, particularly according to EXAMPLES 3, 11 and 12, the temperature changing rate will decrease to 0.30° C. or lower within 30 sec after the measurement has been started. Consequentially, the wearer of such sanitary napkin will experience feeling of incompatibility due to a cold sense merely for a short time. Generally, upon discharge of menstrual blood, the wearer experiences such feeling of incompatibility due to the cold sense and simultaneously immobilizes herself or slows down a movement of her body to minimize leak of menstrual blood and/or contamination of her skin therewith. The sanitary napkin using the nonwoven fabric according to EXAMPLES 3, 11 and 12 not only allows menstrual blood to be rapidly absorbed but also allows any feeling of incompatibility to disappear in a short time. Therefore it is no more necessary for the wearer to immobilize herself or to slow down movement of her body.
A temperature changing rate when the sensor of FINGER ROBOT THERMO LAB is put in contact with artificial menstrual blood at a temperature of 20° C. was 0.80°/sec and a temperature changing rate when the sensor is put in contact with the nonwoven fabric for test before artificial menstrual blood is dropped onto the nonwoven fabric was 0.04° C.
The value of T/W may be measured by executing steps as will be described below in this order.
(1) The nonwoven fabric used as a sample for measurement is heated at a temperature of 70° C. for 30 min to remove any traces of folding in the course of handling and thereby to flatten the sample.
(2) Substitute edge HA-100 for KOKUYO's cutter knife is used to cut the sample in the cross direction CD to prepare a cut surface for observation extending in parallel to the cross direction CD.
(3) With the sample placed on a horizontal plane, the cut surface is observed through digital microscope an VHX-900 manufactured by Keyence Corporation and a macro photograph of the cut surface×25 is taken.
(4) On the macro photograph, a vertical line with respect to a horizontal line defined by the horizontal plate surface so as to extending through the crest's apex of the sample. A distance from the reference line to the apex is measured to obtain a height T of the crest (See
(5) When the vertical line passing the apex is drawn, the crest presenting an average shape is selected for measurement. The crest to be selected for measurement has its apex preferably free from any fibers extraordinarily projecting therefrom.
As will be apparent from
| Number | Date | Country | Kind |
|---|---|---|---|
| 2007-165642 | Jun 2007 | JP | national |
| 2008-025754 | Feb 2008 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2008/054990 | 3/18/2008 | WO | 00 | 12/15/2009 |
