CN101443502B - Nonwoven fabric - Google Patents

Abstract

The invention claims a non-woven fabric that in a form of non-woven fabric provided with unevenness and openings, is regulated so as to avoid extremely high density at protrudent portion, concave portion, and the like, and a process for manufacturing the non-woven fabric. Against fiber web (100) supported from its bottom face side by given support member (220), a fluid composed mainly of a gas is blown from the upper face side of the fiber web (100) so as to move fibers (101) constituting the fiber web (100), thereby forming a plurality of openings (3). In the non-woven fabric (170), a plurality of openings (3) continuously formed at given intervals along given direction and a plurality of coupling parts (4) formed between openings (3) adjacent to each other in given direction are provided.

Description

non-woven fabric

technical field

This invention relates to nonwoven fabrics.

Background technique

In the past, nonwoven fabrics have been used in a wide range of fields, including hygiene products such as disposable diapers and sanitary napkins, cleaning products such as wipes, and medical products such as masks. In this way, nonwoven fabrics are used in various fields, but actually, when they are used in products in various fields, they must be manufactured with properties and structures suitable for the uses of various products.

The nonwoven fabric is formed, for example, by forming a fiber layer (fibrous web) by a dry method or a wet method, and bonding fibers forming the fiber layer to each other by a chemical bonding method or a thermal bonding method. In the process of bonding the fibers forming the fiber layer, there is also a method of applying physical force to the fiber layer from the outside, including a method of repeatedly piercing the fiber layer with a plurality of needles, or a method of spraying water.

However, these methods merely interweave the fibers, and do not adjust the orientation or arrangement of the fibers in the fiber layer, or the shape of the fiber layer. That is, what is produced by these methods is only a simple sheet-shaped nonwoven fabric.

In addition, a nonwoven fabric provided with openings has also been proposed. Said proposal discloses that in order to form openings on the nonwoven fabric, the nonwoven fabric is sandwiched between a stamper equipped with protrusions such as needles protruding outward and a receiving side support that receives the protrusions, by making the protrusions A method of forming a three-dimensional opening through a nonwoven fabric (for example, refer to JP-A-6-330443).

Contents of the invention

However, in such a nonwoven fabric, concavo-convex or openings are formed by biting the fiber assembly constituting the nonwoven fabric between the protruding portion and the support on the receiving side. Therefore, for example, when the fibers located in the wall portion of the convex portion, the peripheral portion of the opening, etc. are compressed to increase the fiber density, and then heated to form a nonwoven fabric, film formation may occur.

Therefore, for example, when such a nonwoven fabric is used for a top sheet of an absorbent article, etc., it may become difficult for liquid to permeate through a convex portion with a high fiber density or a thinned opening edge. In this way, when a large amount of liquid is attracted by the convex portion or the periphery of the opening, the liquid may remain in the nonwoven fabric, which may stain the wearer's skin or give the wearer an uncomfortable feeling.

An object of the present invention is to provide a nonwoven fabric in which concavities and convexities or openings are formed, and adjustments are made so that liquid can easily permeate through the convex parts or concave parts.

The inventors of the present invention have found that openings or irregularities can be formed by injecting gas from the upper side to the fiber web supported from the lower side by an air-permeable support member having a predetermined air-impermeable part, thereby moving the fibers constituting the fiber web. the invention.

(1) A nonwoven fabric having a first longitudinal direction and a second direction, comprising: a plurality of openings formed along the aforementioned first direction; a plurality of connecting parts , the plurality of connection portions are formed between a predetermined opening portion of the plurality of opening portions and an opening portion adjacent to the predetermined opening portion in the first direction; each of the plurality of connection portions The content of second direction oriented fibers oriented in the second direction is higher than the content of first direction oriented fibers oriented in the first direction.

(2) The nonwoven fabric as described in the aforementioned item (1), with respect to the aforementioned plurality of openings, the fibers on the periphery of each of the plurality of openings run along the length of each of the plurality of openings A perimeter orientation.

(3) The nonwoven fabric as described in the aforementioned item (1) or (2), wherein each of the plurality of openings has a substantially circular or substantially elliptical shape.

(4) In the nonwoven fabric described in any one of the aforementioned items (1) to (3), for each of the aforementioned plurality of openings, the length of the aforementioned plurality of openings in the aforementioned first direction is 0.1 mm to 5mm.

(5) The nonwoven fabric as described in any one of the aforementioned items (1) to (4), wherein the plurality of openings and the plurality of connecting portions are formed on the first surface side of the nonwoven fabric along the thickness. The plurality of recessed grooves further includes a plurality of convex portions protruding in the thickness direction on the first surface side adjacent to each other along a predetermined one of the plurality of grooves.

(6) In the nonwoven fabric as described in item (5), the height in the thickness direction of the nonwoven fabric for each of the plurality of grooves is equal to or greater than the height of each of the plurality of convex portions. Below 90%.

(7) The nonwoven fabric according to item (5) or (6), wherein a predetermined convex portion among the plurality of convex portions is adjacent to a predetermined groove portion sandwiching a predetermined groove portion among the plurality of groove portions. Compared with the convex part, the aforementioned height is different.

(8) The nonwoven fabric as described in any one of items (5) to (7), each of the aforementioned plurality of connection portions, in each of the aforementioned plurality of groove portions, further along the nonwoven fabric The thickness direction of the object is concave.

(9) The nonwoven fabric according to any one of items (5) to (8), wherein the top of each of the plurality of convex portions is substantially flat.

(10) The nonwoven fabric as described in any one of items (5) to (9), on the side opposite to the surface on which the plurality of grooves and the plurality of protrusions are formed in the nonwoven fabric On the second surface of the first surface, a plurality of regions protruding toward the side opposite to the direction in which the convex portion protrudes are formed.

(11) The nonwoven fabric as described in any one of items (5) to (10), which undulates in a wave shape in the aforementioned first direction.

(12) The nonwoven fabric according to any one of items (5) to (9), wherein the second surface side of the nonwoven fabric is substantially flat.

(13) The nonwoven fabric according to any one of items (5) to (12), wherein for each of the plurality of side portions in each of the plurality of convex portions, the aforementioned first direction oriented fibers The content rate of the fiber is higher than the content rate of the aforementioned second direction oriented fibers.

(14) In the nonwoven fabric as described in any one of items (5) to (13), for each of the plurality of convex portions, measured from the first surface side of the predetermined convex portion The space area ratio is larger than the space area ratio measured from the second surface side in the predetermined convex portion.

(15) The nonwoven fabric according to any one of items (5) to (14), wherein each of the plurality of convex portions has a plurality of central For each of the plurality of central portions, the fiber density in each of the plurality of central portions is higher than the fiber density of each of the aforementioned plurality of connection portions, and is higher than the fiber density of each of the aforementioned plurality of side portions low density.

(16) The nonwoven fabric as described in any one of items (5) to (15), wherein the fiber density of each of the plurality of convex portions is 0.20 g/cm ³ or less, and the fiber density of each of the plurality of connecting portions is The fiber density of each is below 0.20 g/cm ³ .

(17) The nonwoven fabric as described in any one of items (5) to (16), wherein each of the aforementioned plurality of connecting parts has a weight per unit area in each of the aforementioned plurality of connecting parts that is larger than the aforementioned Each of the convex portions has a low weight per unit area.

(18) The nonwoven fabric according to any one of items (5) to (17), wherein each of the plurality of convex portions has a weight per unit area of 15 g/m ² to 250 g/m ² ,

Each of the aforementioned plurality of connection parts has a weight per unit area of 5 g/m ² to 200 g/m ² .

(19) The nonwoven fabric as described in any one of items (1) to (18), wherein fibers constituting the nonwoven fabric are mixed with hydrophobic fibers.

The effect of the invention

According to the present invention, it is possible to provide a nonwoven fabric that is adjusted so that liquid can easily permeate through convex parts, concave parts, etc. in a nonwoven fabric formed with irregularities and openings.

Description of drawings

Fig. 1A is a plan view of a nonwoven fabric of a first embodiment.

Fig. 1B is a bottom view of the nonwoven fabric of the first embodiment.

FIG. 2 is an enlarged perspective view of a region Y in FIG. 1 .

3A is a plan view of a support member in which elongated members are arranged side by side on a mesh support member at equal intervals.

Fig. 3B is a perspective view of a support member in which elongated members are arranged side by side on a mesh support member at equal intervals.

4A is a plan view of the mesh support member of FIG. 3 .

4B is a perspective view of the mesh support member of FIG. 3 .

Fig. 5 is a diagram showing a state in which the nonwoven fabric of the first embodiment shown in Fig. 1 is produced by injecting gas toward the upper side with the fiber web being supported on the lower side by the supporting member of Fig. 3 .

Fig. 6 is a side view illustrating the nonwoven fabric manufacturing apparatus of the first embodiment.

Fig. 7 is a plan view illustrating the nonwoven fabric manufacturing apparatus of Fig. 6 .

FIG. 8 is an enlarged perspective view of a region Z in FIG. 6 .

Fig. 9 is a bottom view of the ejection unit in Fig. 8 .

10A is a plan view of a plate-shaped support member formed with a plurality of elliptical openings.

Fig. 10B is a perspective view of a plate-shaped support member formed with a plurality of elliptical openings.

Fig. 11 is an enlarged plan view and an enlarged perspective view of a support member in which wires are helically woven and a plurality of holes are formed in gaps therebetween.

Fig. 12 is an enlarged perspective view of a second embodiment of the nonwoven fabric.

Fig. 13 is an enlarged perspective view of a third embodiment of the nonwoven fabric.

Fig. 14 is a perspective view of a support member in which elongated members are arranged side by side at equal intervals on a net-like support member having wave-like undulations.

Fig. 15 is an enlarged perspective view of a nonwoven fabric of a fourth embodiment.

Fig. 16 is an enlarged perspective view of a nonwoven fabric of a fifth embodiment.

Fig. 17 is an enlarged perspective view of a plate-shaped support member provided with a plurality of elliptical openings.

Fig. 18 is a diagram showing a state in which the nonwoven fabric of the fifth embodiment shown in Fig. 16 is produced by injecting gas toward the upper side with the fiber web supporting the lower side on the plate-shaped supporting member of Fig. 17 .

Fig. 19 is an enlarged perspective view of a nonwoven fabric of a sixth embodiment.

Fig. 20 is a perspective view of a case where the nonwoven fabric according to the present invention is used for a top sheet of a sanitary napkin.

Fig. 21 is a perspective view of a case where the nonwoven fabric according to the present invention is used for a topsheet of a diaper.

Fig. 22 is a perspective view of a case where the nonwoven fabric according to the present invention is used as a middle sheet of an absorbent article.

Fig. 23 is a perspective view of a case where the nonwoven fabric according to the present invention is used as the outermost part of an absorbent article.

Detailed ways

Hereinafter, the best mode for carrying out the present invention will be described with reference to the drawings.

Fig. 1A is a plan view of a nonwoven fabric of a first embodiment. Fig. 1B is a bottom view of the nonwoven fabric of the first embodiment. FIG. 2 is an enlarged perspective view of a region Y in FIG. 1 . 3A is a plan view of a support member in which elongated members are arranged side by side on a mesh support member at equal intervals. Fig. 3B is a perspective view of a support member in which elongated members are arranged side by side on a mesh support member at equal intervals. 4A is a plan view of the mesh support member of FIG. 3 . 4B is a perspective view of the mesh support member of FIG. 3 . Fig. 5 is a view showing a state in which the nonwoven fabric of the first embodiment shown in Fig. 1 is produced by injecting gas toward the upper side while the fiber web is supported on the lower side by the support member shown in Fig. 3 . Fig. 6 is a side view illustrating the nonwoven fabric manufacturing apparatus of the first embodiment. Fig. 7 is a plan view illustrating the nonwoven fabric manufacturing apparatus of Fig. 6 . FIG. 8 is an enlarged perspective view of a region Z in FIG. 6 . Fig. 9 is a bottom view of the ejection unit in Fig. 8 . 10A is a plan view of a plate-shaped support member formed with a plurality of elliptical openings. Fig. 10B is a perspective view of a plate-shaped support member formed with a plurality of elliptical openings. Fig. 11 is an enlarged plan view and an enlarged perspective view of a support member in which wires are helically woven and a plurality of holes are formed in gaps therebetween.

Fig. 12 is an enlarged perspective view of a nonwoven fabric of a second embodiment. Fig. 13 is an enlarged perspective view of a third embodiment of a nonwoven fabric. Fig. 14 is a perspective view of a support member in which elongated members are arranged side by side at equal intervals on a net-like support member having wave-like undulations. Fig. 15 is an enlarged perspective view of a nonwoven fabric of a fourth embodiment. Fig. 16 is an enlarged perspective view of a nonwoven fabric of a fifth embodiment. Fig. 17 is an enlarged perspective view of a plate-shaped support member provided with a plurality of elliptical openings. Fig. 18 is a diagram showing a state in which the nonwoven fabric of the fifth embodiment shown in Fig. 16 is produced by injecting gas on the upper side with the fiber web supporting the lower side on the plate-shaped supporting member of Fig. 17 . Fig. 19 is an enlarged perspective view of a nonwoven fabric of a sixth embodiment.

Fig. 20 is a perspective view of a case where the nonwoven fabric according to the present invention is used for a top sheet of a sanitary napkin. Fig. 21 is a perspective view of a case where the nonwoven fabric according to the present invention is used for a topsheet of a diaper. Fig. 22 is a perspective view of a case where the nonwoven fabric according to the present invention is used as a middle sheet of an absorbent article. Fig. 23 is a perspective view of a case where the nonwoven fabric according to the present invention is used as the outermost part of an absorbent article.

The nonwoven fabric of the present invention is a nonwoven fabric formed with at least predetermined openings.

first form of implementation

Next, a first embodiment of the nonwoven fabric of the present invention will be described with reference to FIGS. 1 to 11 .

[1.1] Shape

As shown in FIG. 1A, FIG. 1B, FIG. 2 or FIG. 5, the nonwoven fabric 120 according to this embodiment is a nonwoven fabric in which a plurality of openings 3 are formed. Specifically, in the nonwoven fabric 120, a plurality of grooves 1 are formed on one side of the nonwoven fabric 120 at approximately equal intervals along the longitudinal direction as the first direction, and at the same time, a plurality of grooves 1 are formed in the grooves 1. A non-woven fabric with 3 openings. Each of the plurality of openings 3 forms a substantially circular or substantially elliptical shape. Here, in the present embodiment, the grooves 1 are formed in parallel at approximately equal intervals, but the present invention is not limited thereto, and may be formed at different intervals, for example, or in such a manner that the intervals between the grooves 1 vary. form.

In addition, a plurality of convex portions 2 are formed between each of the plurality of groove portions 1 . Like the grooves 1 , the convex portions 2 are formed in parallel at substantially equal intervals. In the nonwoven fabric 120 of the present embodiment, the heights (thickness direction) of the convex portions 2 are substantially equal, but it may be formed so that the heights of the convex portions 2 adjacent to each other are different. For example, the height of the protruding portion 2 can be adjusted by adjusting the intervals between discharge ports 913 described later that discharge fluid mainly composed of gas. For example, the height of the convex portion 2 can be reduced by reducing the distance between the discharge ports 913 , and conversely, the height of the convex portion 2 can be increased by increasing the distance between the discharge ports 913 . Furthermore, by forming the intervals of the ejection ports 913 alternately at narrow intervals and at wide intervals, convex portions 2 having different heights can also be alternately formed. In addition, in this way, if the height of the convex portion 2 is partially changed, since the area in contact with the skin is reduced, there is an advantage that the burden on the skin can be reduced.

In addition, in the present embodiment, the height of the convex portion 2 in the nonwoven fabric 120 in the thickness direction of the nonwoven fabric 120 is formed to be higher than that of the groove portion 1 . Specifically, 0.3 to 15 mm, preferably 0.5 to 5 mm can be cited. In addition, the length of the convex portion 2 in the width direction as the lateral direction may be, for example, 0.5 to 30 mm, preferably 1.0 to 10 mm. In addition, the distance between the convex portions 2 adjacent to each other across the groove portion 1 is 0.5 to 30 mm, preferably 3 to 10 mm.

Moreover, the height of the groove part 1 in the thickness direction of the nonwoven fabric 120 is formed so that it may be lower than the convex part 2. As shown in FIG. Specifically, it is 90% or less of the height of the convex portion 2 in the thickness direction, preferably 1 to 50%, more preferably 0 to 20%. Here, the height in the thickness direction being 0% means that this is the opening 3 .

The length in the width direction of the groove portion 1 may be, for example, 0.1 to 30 mm, preferably 0.5 to 10 mm. The distance between the grooves 1 adjacent to each other across the convex portion 2 may be 0.5 to 20 mm, preferably 3 to 10 mm.

By designing in this way, for example, when using the nonwoven fabric 120 as a top sheet of an absorbent article, it is possible to form grooves that are difficult to penetrate widely on the surface even when a large amount of predetermined liquid is discharged. 1. In addition, even if the convex portion 2 collapses when excessive external pressure is applied, it is easy to maintain the space formed by the groove portion 1, and it is difficult to discharge a predetermined liquid even when the external pressure is applied. Penetrates extensively on surfaces. Furthermore, even when the prescribed liquid once absorbed into the absorbent body etc. returns under external pressure, since the surface of the nonwoven fabric 120 has unevenness, the area in contact with the skin is small, so it is difficult to Attach to the skin in large areas again.

Here, the method of measuring the height, pitch, and width of the groove portion 1 or the convex portion 2 is as follows. For example, the nonwoven fabric 120 is placed on a table in an unpressurized state, and the measurement is performed from a cross-sectional photograph or cross-sectional image of the nonwoven fabric 120 using a microscope.

When measuring the height (length in the thickness direction), the height is measured from the lowest position of the nonwoven fabric 120 (that is, the table surface) to the highest positions of the convex portions 2 and grooves 1 facing upward.

In addition, the distance between the center positions of the adjacent convex portions 2 was measured as the pitch of the convex portions 2 . Similarly, the distance between the center positions of adjacent grooves 1 was measured as the pitch of the grooves 1 .

When measuring the width of the convex portion 2, measure the maximum width from the lowest position of the nonwoven fabric 120 (that is, the table surface) to the bottom surface of the convex portion 2 facing upward, and measure the groove portion 1 in the same way. .

Here, there is no particular limitation on the cross-sectional shape of the convex portion 2 . For example, a dome shape, a trapezoid shape, a triangle shape, an omega shape, a square shape, etc. are mentioned. In order to provide a good feeling on the skin, the vicinity of the top surface and the side surfaces of the convex portion 2 are preferably curved surfaces. In addition, in order to maintain the space formed by the groove portion 1 even when the convex portion 2 is crushed by external pressure, it is preferable to narrow the width from the bottom surface to the top surface of the convex portion 2 . The top surface of the convex portion 2 is preferably curved (curved surface) such as a substantially dome shape.

In addition, as shown in FIGS. 1A , 1B and 2 , the nonwoven fabric 120 of this embodiment is a nonwoven fabric in which a plurality of openings 3 are formed in the groove portion 1 . Each of the plurality of openings 3 has a substantially circular or substantially elliptical shape. Furthermore, a connection portion 4 is formed between each of the plurality of openings so that the convex portions 2 adjacent to the groove portion 1 are connected to each other. In other words, the plurality of connection portions 4 formed at predetermined intervals connect the convex portion 2 and the adjacent convex portion 2 .

In this embodiment, the openings 3 are formed at approximately equal intervals, but the present invention is not limited thereto, and may be formed at different intervals.

The length of each opening 3 in the length direction as the first direction and the length in the width direction as the second direction may both be, for example, 0.1 to 5 mm, preferably 0.5 to 4 mm. In addition, the pitch of the opening portions 3 adjacent to each other across the connection portion 4 may be, for example, 0.5 to 30 mm, preferably 1 to 10 mm.

The height of the connecting portion 4 toward the thickness direction of the nonwoven fabric 120 is equal to or less than the height of the convex portion 2 toward the thickness direction of the nonwoven fabric 120, preferably 20% of the height of the convex portion 2 toward the thickness direction of the nonwoven fabric 120. % to 100%, more preferably 40% to 70%.

In addition, the length of each connecting portion 4 in the length direction and the width direction of the nonwoven fabric 120 may be, for example, 0.1 to 5 mm, preferably 0.5 to 4 mm. In addition, the pitch between the vertices of the connection portions 4 adjacent to each other across the opening portion 3 may be, for example, 0.5 to 30 mm, preferably 1 to 10 mm.

Moreover, the cross-sectional shape of the connection part 4 in the longitudinal direction of this nonwoven fabric is substantially square. In addition, the cross-sectional shape of the connecting portion 4 in the longitudinal direction is not limited to a quadrangle, but may also be a dome shape, a trapezoid shape, a triangle shape, an omega shape, etc., and there is no specific limitation. In order to suppress the spread of a predetermined liquid in the groove portion 1, it is preferably substantially square. In addition, the top surface of the connection part 4 is preferably a flat or curved surface in order not to give people a foreign body feeling when the connection part 4 contacts the skin under excessive external pressure.

[1.2] Fiber Orientation

As shown in FIG. 2 , in this nonwoven fabric 120 , regions having different content ratios of longitudinally oriented fibers oriented in the longitudinal direction as the first direction are formed. In other words, regions having different contents of transversely oriented fibers oriented in the width direction as the second direction are formed. The respective different regions include, for example, the groove portion 1 , the side portion 8 of the convex portion 2 , the central portion 9 sandwiched between adjacent side portions 8 , and the like.

Here, so-called fibers 101 are oriented in the first direction (longitudinal direction) means that the fibers 101 are oriented relative to the first direction, here the direction (MD direction) in which the nonwoven fabric or fiber web is sent out via a machine for producing the nonwoven fabric. ) is oriented in the range from -45° to +45°, and fibers oriented in the first direction are called longitudinally oriented fibers. In addition, the orientation of the fibers 101 along the second direction (transverse direction in the nonwoven fabric) refers to the orientation of the fibers 101 with respect to the second direction, here, the direction (CD direction) of the nonwoven fabric that is perpendicular to the MD direction. The predetermined width direction is oriented within a range from -45 degrees to +45 degrees, and fibers oriented in the second direction are called laterally oriented fibers.

The side portion 8 is a region corresponding to both sides of the convex portion 2 , and the fibers 101 in the side portion 8 are formed so that many fibers are oriented along the longitudinal direction of the convex portion 2 . For example, more fibers 101 in the side portion 8 are oriented in the longitudinal direction than in the central portion 9 (region between both sides 8 ) of the convex portion 2 . For example, the content of longitudinally oriented fibers at the side portion 8 is 55% to 100%, more preferably 60% to 100%. When the content of longitudinally oriented fibers is less than 55%, the side portion 8 may be elongated when the nonwoven fabric is pulled by a device during manufacture of the nonwoven fabric. Furthermore, when the side part 8 is elongated, when the nonwoven fabric is pulled by the apparatus, the groove part 1 or the center part 9 mentioned later may also be elongated.

The central portion 9 is a region between the side portions 8 serving as both sides of the convex portion 2 , and is a region in which the content of longitudinally oriented fibers is lower than that of the side portions 8 . In this central portion 9, it is preferable that longitudinally oriented fibers and transversely oriented fibers are moderately mixed.

For example, the content of longitudinally oriented fibers at the central portion 9 is lower than that at the side portion 8 by 10% or more, and is higher than the content of longitudinally oriented fibers at the bottom 11 of the groove portion 1 by 10% or more. . Specifically, the content of longitudinally oriented fibers is preferably in the range of 40% to 80%.

The groove portion 1 is a region where the opening portion 3 and the connection portion 4 are formed while a fluid mainly composed of gas (for example, hot air) is directly sprayed. When the fluid mainly composed of gas is sprayed, the part sprayed by the fluid mainly composed of gas is concave in the thickness direction, and at the same time, at the sprayed part, the fibers 101 (longitudinally oriented fibers) oriented in the length direction are blown. to side 8 side. In addition, the fibers 101 oriented in the width direction are oriented by the injected fluid mainly composed of gas and/or the fluid mainly composed of gas blown to the impermeable portion of the supporting member 220 described later, whose flow direction is changed. (Laterally oriented fibers) are sprayed toward the connecting portion 4 side. In this way, the fibers 101 at the connecting portion 4 of the groove portion 1 are oriented in a direction intersecting the longitudinal direction of the groove portion 1 , specifically, in the width direction as a whole. Thus, the fibers 101 at the periphery of the opening portion 3 are oriented along the shape of the opening.

Therefore, in this nonwoven fabric 120, the content rate of the longitudinally oriented fiber in the connection part 4 of the groove part 1 is the lowest. In other words, the connection portion 4 has the highest content of transversely oriented fibers. Specifically, the content of transversely oriented fibers is 55% to 100%, preferably 60% to 100%. When the content of transversely oriented fibers is less than 55%, it is difficult to increase the strength of the nonwoven fabric in the width direction because the basis weight of the groove portion 1 is low as described later. In this way, for example, when using the nonwoven fabric 120 as a top sheet of an absorbent article, during use of the absorbent article, due to friction with the body, warp and weft slippage may occur in the width direction, or damage may occur. of danger.

The measurement of fiber orientation was carried out using Digital Microscope VHX-100 manufactured by Keyence Co., Ltd., by the method described below. (1) Place the sample on the observation table in such a way that its longitudinal direction is in the correct direction. (2) Remove fibers that appear irregularly near the front, and make the focal point of the lens coincide with the fiber closest to the front of the sample. (3) The imaging depth (depth) is set, and a 3D image of the sample is created on the PC screen. Next, (4) convert the 3D image into a 2D image, and (5) draw a plurality of parallel lines on the screen that properly divide the longitudinal direction into equal parts within the measurement range. (6) In each subdivided unit by drawing parallel lines, observe whether the fiber orientation is in the first direction (longitudinal direction) or the second direction (width direction), and measure the number of fibers oriented in each direction. Then, (7) By calculating the ratio of the number of fibers oriented in the first direction (length direction) to all the fiber slivers within the set range, and the number of fibers oriented in the second direction (width direction) The ratio of the number of oriented fibers is measured and calculated.

[1.3] Density of fibers

As shown in FIG. 2 , the convex portion 2 is adjusted so that the average fiber density is higher than the average fiber density of the groove portion 1 . The fiber density of the convex portion 2 can be arbitrarily adjusted by various conditions such as the amount of fluid (for example, hot air) mainly composed of gas, and tension.

The fiber density at the convex portion 2 may be, for example, 0.005 to 0.20 g/cm ³ , preferably 0.007 to 0.07 g/cm ³ . In the case where the fiber density of the convex portion 2 is lower than 0.005 g/cm ³ , not only the convex portion 2 is easily collapsed due to the own weight of the liquid contained in the convex portion 2 or the external pressure, but also the Fluid that was once absorbed sometimes tends to return under pressure. In addition, when the fiber density of the convex portion 2 is higher than 0.20 g/cm ³ , it is difficult for the liquid brought by the convex portion 2 to move downward, and the liquid stagnates at the convex portion 2, which may cause wear. The user feels wet.

The groove portion 1 is adjusted so that the average fiber density is lower than that of the convex portion 2 . Specifically, the average fiber density of the entire groove portion 1 may be, for example, 0.002 to 0.18 g/cm ³ , preferably 0.005 to 0.05 g/cm ³ . When the overall average fiber density of the groove portion 1 is less than 0.002 g/cm ³ , for example, when the nonwoven fabric 120 is used for an absorbent article or the like, the nonwoven fabric 120 may be easily damaged. In addition, when the average fiber density of the entire groove portion 1 is higher than 0.18 g/cm ³ , the liquid is difficult to move downward, so it stagnates at the bottom of the groove portion 1 and may give the user a wet feeling. In addition, the average fiber density at the bottom of the groove portion 1 can be adjusted arbitrarily under various conditions such as the amount and tension of fluid mainly composed of gas (for example, hot air).

In addition, the fiber density of the connecting portion 4 at the groove portion 1 may be, for example, 0.005 to 0.20 g/cm ³ , preferably 0.007 to 0.10 g/cm ³ . When the fiber density of the connecting portion 4 is less than 0.005 g/cm ³ , when excessive external pressure is applied and the convex portion 2 collapses, the connecting portion 4 may also collapse.

On the other hand, when the fiber density of the connecting portion 4 is higher than 0.20 g/cm ³ , the predetermined liquid falling into the groove portion 1 will stay in the connecting portion 4, and when excessive external pressure is applied to the nonwoven fabric 120 In the case of direct contact with the skin, it will give a moist feeling.

In addition, in this nonwoven fabric 120, the space area ratio measured from the surface side where the groove portion 1 and the convex portion 2 are formed as one surface side in the thickness direction of the nonwoven fabric 120 is higher than that measured from the nonwoven fabric 120. The space area ratio measured on the other side of the surface opposite to the surface on which the groove portion 1 and the convex portion 2 are formed in the thickness direction of the object 120 is low.

In the fiber web 100 conveyed on the support member 220 described later, due to gravity, the fibers 101 move toward the surface side opposite to the surface where the fluid mainly composed of gas is sprayed, and at a position near the surface side of the opposite side. Tendency to narrow the distance between fibers. On the other hand, the distance between the fibers tends to increase toward the side where the fluid mainly composed of gas is jetted.

Furthermore, by spraying a fluid mainly composed of gas, the fibers 101 on the side closer to the support member 220 abut on the support member 220 , facing the plane direction of the support member 220 . Thereby, the distance between fibers becomes narrower further, and it becomes easy for fibers to be densely packed. In this state, the fibers are thermally bonded to each other by heat treatment such as oven treatment, the degree of freedom of the fibers 101 decreases, and the space area ratio between the fibers on the other side of the nonwoven fabric 120 decreases.

On the other hand, as the surface on the side of the support member 220 approaches the side where the fluid mainly composed of gas is sprayed, the fibers will not be excessively crushed. The fluid of gas encounters the support member 220 and is bounced off, with respect to which the fibers 101 become partially oriented perpendicularly. In this state, by thermally bonding the fibers to each other, the space area ratio between the fibers is increased.

Here, the "space area ratio" refers to the ratio of the space area where no fibers exist to the total area. In addition, the measuring method of a space area ratio is as follows.

As a measurement device, Digital Microscope VHX-100 manufactured by Keyence Co., Ltd. was used. First, (1) place the sample on the measurement device so that the direction along the groove portion 1 and the convex portion 2 becomes the longitudinal direction on the observation table, (2) at the apex of the convex portion 2, the The surface on which the shape part 2 protrudes and the surface on the opposite side to the surface on which the convex part 2 protrudes are respectively subjected to the following measurements.

(3) Appropriately set the magnification of the lens of the measurement device and the magnification of the personal computer screen, and focus the lens on the fiber closest to the front side of the sample (removing irregular fibers that appear near the front). Then, (4) appropriately set the imaging depth (depth), and create a 3D image of the sample.

(5) Convert the 3D image into a 2D image, planarize the set volume, and specify the space between fibers within the range. Furthermore, (6) perform binarization (binarization) processing on the 2D image, and make the portion where the fiber exists white and the portion where the fiber does not exist black. Then, (7) the color is reversed, the portion where the fiber does not exist is made white, and the whitened area is measured.

Here, in this document, the magnification ratio is 300 times, and the imaging depth is 220 μm (11 imaging times in total at every 20 μm), n=10 measurements are performed, and the average value is taken.

In addition, the space area ratio is calculated as follows.

Space area ratio (%)=(total space area (mm ² )/area of measurement range (mm ² ))×100

Here, the total space area can be calculated from (total space area at the time of measurement/magnification at the time of measurement), and the area of the measurement range can be calculated from (area of the measurement range at the time of measurement/magnification at the time of measurement).

Since the higher the space area ratio, the larger the distance between the fibers, which corresponds to the thicker the surface of the nonwoven fabric, the fibers move easily and have a high degree of freedom. Furthermore, for the non-woven fabric in which the distance between fibers is partially enlarged by opening treatment, etc., by increasing the space area of each space, the entire surface of the non-woven fabric that is sprayed with a fluid mainly composed of gas can be separated between fibers. The distance between becomes larger. Therefore, for example, when the nonwoven fabric is used in an absorbent article or the like, the resistance when a predetermined liquid such as excrement permeates through the nonwoven fabric 120 can be reduced as a whole, and the liquid can move to the absorbent body or the like more easily.

Here, the spatial area of each space refers to the ratio of the total area of spaces where fibers do not exist to the number of spaces where fibers do not exist within a predetermined range. The space area can be calculated with the following calculation formula.

Space area (mm ² /piece) = (total space area (mm ² )/number of spaces (piece))

The difference between the space area ratio measured from the surface on the protruding side of the convex portion 2 and the space area ratio measured from the surface opposite to the protruding surface of the convex portion 2 may be, for example, 5%. to 100%, preferably 5% to 80%, more preferably 15% to 40%.

In addition, the space area ratio measured from the protruding side surface of the convex portion 2 is 50% to 100%, preferably 50% to 90%, more preferably 50% to 80%.

Furthermore, the space area per space measured from the protruding surface of the convex portion 2 may be, for example, 3000 μm ² or more, preferably 3000 to 30000 μm ² , more preferably 5000 to 20000 μm ² .

[1.4] Weight per unit area

Specifically, the overall average basis weight of the nonwoven fabric 120 may be, for example, 10 to 200 g/m ² , preferably 20 to 100 g/m ² . For example, when the nonwoven fabric 120 is used for a top sheet of an absorbent article, if the average basis weight is less than 10 g/m ² , it may be easily damaged during use. In addition, when the average basis weight of the nonwoven fabric 120 exceeds 200 g/m ² , it may be difficult to smoothly move the brought liquid downward.

The convex portion 2 is adjusted so that the weight per unit area of the fiber 101 is higher than that of the groove portion 1 . Here, the weight per unit area of the central portion 9 of the convex portion 2 may be, for example, 15 to 250 g/m ² , preferably 20 to 120 g/m ² . In the case where the weight per unit area of the central portion 9 is lower than 15 g/m ² , the central portion 9 is not only easily collapsed due to the self-weight of the liquid contained in the central portion 9 or the external pressure, but also sometimes absorbed once. The liquid returns easily under pressure. In addition, when the weight per unit area of the central portion 9 exceeds 250 g/m ² , it is difficult to move the liquid brought by the central portion 9 downward, and the liquid may stagnate in the central portion 9, giving the user a wet feeling.

Furthermore, the basis weight of the side portion 8 of the convex portion 2 can be arbitrarily adjusted by various conditions such as the amount of fluid mainly composed of gas (for example, hot air) or the tension applied to the nonwoven fabric. Specifically, the weight per unit area at the side 8 can be, for example, 20 to 280 g/m ² , preferably 25 to 150 g/m ² . When the weight per unit area of the side portion 8 is less than 20 g/m ² , the side portion 8 may be elongated due to a tensile force in the lateral direction. In addition, when the weight per unit area at the side portion 8 is higher than 280 g/m ² , the liquid brought by the side portion 8 is difficult to move downward and stays in the side portion 8, which may give the wearer a wet feeling. Feel.

The average basis weight of the groove portion 1 can be adjusted so that the average basis weight of the fibers 101 becomes smaller than that of the convex portion 2 . In addition, the average basis weight at the groove portion 1 is adjusted so as to be lower than the average basis weight of the entire nonwoven fabric 120 . For example, the average basis weight at the bottom 11 of the groove portion 1 may be 3 to 150 g/m ² , preferably 5 to 80 g/m ² . When the average basis weight at the bottom 11 of the groove portion 1 is less than 3 g/m ² , it may be easily damaged during use. In addition, when the average basis weight at the bottom 11 of the groove portion 1 is higher than 150 g/m ² , the liquid carried in the groove portion 1 is difficult to move downward (the other side), and the liquid stays in the groove portion. 1, it may give the wearer a wet feeling.

Furthermore, the average basis weight of the entire groove portion 1 is adjusted to be lower than the average basis weight of the entire convex portion 2 . Specifically, the average basis weight of the entire groove portion 1 is 90% or less, preferably 3% to 90%, particularly preferably 3% to 70%, of the average basis weight of the convex portion 2 . When the average weight per unit area of the entire groove portion 1 is higher than 90% of the average weight per unit area of the convex portion 2, when the liquid falling into the groove portion 1 moves to the bottom of the nonwoven fabric 120 (the other side) The resistance increases, and sometimes the liquid will overflow from the groove part 1. In addition, when the basis weight of the bottom of the groove part 1 is less than 3% with respect to the basis weight of the convex part 2, for example, when this nonwoven fabric 120 is used for the top sheet of an absorbent article, During use of the absorbent article, the top sheet may be easily damaged.

In addition, the weight per unit area of the connecting portion 4 may be, for example, 5 to 200 g/m ² , preferably 10 to 100 g/m ² . When the weight per unit area of the connecting portion 4 is less than 5 g/m ² , when excessive external pressure is applied and the convex portion 1 collapses, the connecting portion 4 may also collapse in some cases. . When the weight per unit area of the connecting portion 4 is higher than 200 g/m ² , the predetermined liquid falling into the groove portion 1 may stagnate in the connecting portion 4, and when excessive external pressure is applied to the nonwoven fabric 120, In case of contact with the skin, it will give a moist feeling.

[1.5] Others

For example, in the case where the nonwoven fabric of this embodiment is used for absorbing or permeating a predetermined liquid, in order for the groove portion 1 to allow the liquid to pass through, the convex portion 2 is difficult to 3, except for the liquid. , can also pass through solids.

Since a plurality of openings 3 are formed in the groove portion 1, it is suitable for passing liquid and solid. Furthermore, since the fibers 101 at the bottom of the groove portion 1 are oriented in the width direction, it is possible to prevent the liquid from excessively flowing in the longitudinal direction of the groove portion 1 and becoming wider. Although the basis weight of the groove portion 1 is low, since the fibers 101 are oriented in the width direction of the groove portion 1 (CD orientation), the strength in the width direction of the nonwoven fabric (CD strength) is increased.

Although the weight per unit area of the convex portion 2 is adjusted to be high, since the number of fibers increases, the number of bonded points increases and the porous structure is maintained.

In the convex part 2, the side part 8 which adjusted basis weight and fiber density higher than the central part 9 is formed so that the central part 9 of the convex part 2 may be supported. That is, in the side portion 8, since most of the fibers 101 are oriented in the longitudinal direction, the distance between the fibers is shortened, thereby increasing the fiber density and increasing the rigidity. Therefore, the entire convex portion 2 is held by the side portion 8, and the convex portion 2 can be prevented from collapsing due to external pressure or the like.

In addition, in the groove portion 1 , the content of transversely oriented fibers per unit area is higher than that of the central portion 9 , and in the side portion 8 , the content of longitudinally oriented fibers per unit area is higher than that of the central portion 9 . Furthermore, in the central portion 9 , more fibers 101 oriented in the thickness direction are contained than in the groove portion 1 or the side portion 8 . Therefore, in the central portion 9, for example, even if the thickness of the convex portion 2 decreases due to the application of a load in the thickness direction, when the load is released, the rigidity of the fibers 101 oriented in the thickness direction can easily return to the original state. the height of. That is, it is a nonwoven fabric with high recovery from compression.

[1.6] Manufacturing method

Next, a method for producing the nonwoven fabric 120 of this embodiment will be described with reference to FIGS. 6 to 11 . First, the fiber web 100 is placed on the upper surface side of the supporting member 220 which is an air-permeable supporting member. In other words, the fiber web 100 is supported from the lower side by the support member 220 .

Then, the support member 220 supporting the fiber web 100 is moved in a predetermined direction, and the gas is continuously injected from the upper surface side of the moving fiber web 100 to manufacture the nonwoven fabric 120 of this embodiment.

As shown in Fig. 6 and Fig. 7, the non-woven fabric manufacturing device 90 for manufacturing the non-woven fabric 120 of this embodiment includes: an air-permeable support member 200, which supports the air-permeable support member 200 from the lower side (the other side) as a fiber The fiber web 100 of the aggregate; the ejection part 910 and the air supply part not shown in the figure as the injection mechanism, and the said injection mechanism is from the upper side (one surface side) of the fiber web 100 as the fiber aggregate to the The fiber web 100 as a fiber assembly supported by the support member 200 from the lower side (the other side) sprays a fluid mainly composed of gas; the conveyor 930 as a moving mechanism that makes the fiber web as a fiber assembly 100 moves in a predetermined direction F.

The air-permeable support member 200 is, for example, a support member including: a vent portion capable of sending a fluid mainly composed of gas sprayed from the upper side of the fiber web 100 into the air-permeable support member 200 in which the air-permeable support member 200 is disposed. the lower side of the opposite side of the fiber web 100; The lower side of the air-permeable supporting member 200 is ventilated, and the fibers 101 constituting the fiber web 100 cannot move to the opposite side in the air-permeable supporting member 200 .

As the air-permeable supporting member 200 used in this embodiment, for example, as shown in FIG. , a member in which a plurality of predetermined holes are formed on an air-impermeable plate-shaped member, and the like.

As a member for disposing the air-impermeable parts in a predetermined pattern on the predetermined mesh member, for example, as shown in FIG. The elongated member 225 of the support member 220 ( FIG. 3 ). Here, as another embodiment, a member in which the shape or arrangement of the elongated member 225 as the impermeable portion is appropriately changed may be mentioned. The non-ventilating part, in addition to the situation where the elongated member 225 is arranged on one surface of the mesh support member 210 shown in FIG. Mesh holes are formed.

As a member in which a plurality of predetermined holes are formed in the air-impermeable plate-shaped member, for example, a plate-shaped support member 230 shown in FIG. Here, as another embodiment, a method of appropriately adjusting the shape, size, and arrangement of the hole portion 233 can be mentioned. For example, by appropriately adjusting the shape of the plate portion 235 as the air-impermeable portion, it can be used as another embodiment.

Here, the air permeability in the region serving as the air vent can be, for example, 10000 to 60000 cc/cm ² ·min, preferably 20000 to 50000 cc/cm ² ·min. However, in the air-permeable supporting member, for example, in the case of digging through a metal plate to form a vent portion, since there is no resistance of the fluid mainly composed of gas to the plate portion, there is a problem of reaching the above-mentioned numerical value or more described above. airflow situation.

In the nonwoven fabric manufacturing apparatus 90, the nonwoven fabric 120 is formed while moving the fiber web 100 sequentially from a predetermined direction. This moving mechanism moves the fiber web 100 which is a fiber aggregate in a state supported from one side of the air-permeable supporting member 200 in a predetermined direction. Specifically, the fiber web 100 is moved in a predetermined direction F in a state where a fluid mainly composed of gas is sprayed. As a moving mechanism, for example, the conveyor 930 shown in FIG. 6 can be mentioned. The conveyor 930 includes: an air-permeable air-permeable belt portion 939 formed in a horizontally elongated ring shape on which the air-permeable support member 200 is placed; The inner side of the annular air-permeable belt part 939 is arranged at both ends in the longitudinal direction, and the annular air-permeable belt part 939 is rotated in a predetermined direction.

As described above, the conveyor 930 moves the air-permeable supporting member 200 in the predetermined direction F while supporting the fiber web 100 from the lower surface side. Specifically, as shown in FIG. 6 , the fiber web 100 is moved so as to pass through the lower side of the discharge unit 910 . Furthermore, the fiber web 100 is moved so as to pass through the inside of the heater part 950 that is opened on both sides as a heating mechanism.

As shown in FIG. 8 , the spray mechanism includes an air supply unit and a spray unit 910 not shown in the figure. An air supply unit (not shown) is connected to the discharge unit 910 via an air supply pipe 920 . The air supply pipe 920 is connected to the upper side of the discharge part 910 so that ventilation is possible. As shown in FIG. 9 , a plurality of discharge ports 913 are formed in the discharge unit 910 at predetermined intervals.

The gas fed from a gas supply unit (not shown) to the discharge unit 910 via the gas supply pipe 920 is discharged from a plurality of discharge ports 913 formed in the discharge unit 910 . The gas ejected from the plurality of ejection ports 913 is continuously ejected to the upper surface side of the fiber web 100 supported by the air-permeable supporting member 200 from the lower surface side. Specifically, the gas from the ejection ports 913 is continuously ejected onto the upper surface side of the fiber web 100 in a state of being moved in a predetermined direction F by the conveyer 930 .

The air intake unit 915 arranged below the discharge unit 910 and on the lower side of the air-permeable support member 200 takes in the gas or the like discharged from the discharge unit 910 and passed through the air-permeable support member 200 . Here, the fiber web 100 can be positioned so as to be in close contact with the air-permeable supporting member 200 by the suction of the suction unit 915 . Furthermore, by suction, it can be conveyed in the heater part 950 while maintaining the shape of the groove part (concavity and convexity) formed by the air flow further. In addition, the injected fluid mainly composed of gas is sucked (inhaled) by the suction part 915, so that the fluid mainly composed of gas hitting the air-permeable support member 200 can be prevented from bouncing back excessively, and the shape of the fiber web 100 can be prevented from being disturbed. .

The strength of the suction by the suction unit 915 is such that the fiber 101 in the area where the fluid mainly composed of gas is sprayed is pressed against the air-permeable supporting member 200 .

In addition, by adjusting the air volume, temperature, introduction amount, air permeability of the support member, and the weight per unit area of the fiber web 100 of the injected fluid mainly composed of gas, the convex portion 2, the opening portion 3 and the connecting portion 4, etc. shape changes. For example, when the amount of the fluid mainly composed of gas to be injected is almost equal to the amount of fluid mainly composed of gas to be sucked (inhaled), or the amount of fluid mainly composed of gas to be sucked (inhaled) is large Next, the back side of the convex portion 2 in the nonwoven fabric 120 is formed so as to follow the shape of the air-permeable supporting member 200 . Therefore, when the shape of the air-permeable support member 200 is flat, the back side of the nonwoven fabric 120 becomes substantially flat.

Furthermore, by introducing the fluid mainly composed of gas from the lower side of the air-permeable supporting member 200, the fibers in the area where the fluid mainly composed of gas is sprayed move while being pushed to the side of the air-permeable supporting member 200, so the fibers Concentrate on the support member side. In addition, the injected fluid mainly composed of gas collides with the air-permeable supporting member 200 at the convex portion 2 and bounces back appropriately, so that the fibers are partially oriented in the thickness direction.

Although the temperature of the fluid mainly composed of gas ejected from each ejection port 913 may be normal temperature, for example, in order to improve the formability of grooves (concaves and convexes) and openings, the temperature may be adjusted to the temperature of the constituent fibers. The aggregate is at least above the softening point of the thermoplastic fibers, preferably within a temperature range of +50°C to -50°C of the melting point. When the fiber is softened, since the rebound force of the fiber itself becomes low, it is easy to maintain the shape of the rearranged fiber by air flow, etc. When the temperature is further increased, since the thermal bonding of the fibers begins, it can be more easily Holds the shape of grooves (concavities and convexities), etc. Therefore, it is easy to transport into the heater 950 while maintaining the shape of the groove portion (concave-convex) and the like.

The heater portion 950 as a heating mechanism is opened at both ends in a predetermined direction F. As shown in FIG. Accordingly, the fiber web 100 (nonwoven fabric 120 ) placed on the air-permeable support member 200 moved by the conveyor 930 continuously moves in the heating space formed inside the heater unit 950 for a predetermined residence time. For example, when fibers 101 constituting fiber web 100 (nonwoven fabric 120 ) contain thermoplastic fibers, nonwoven fabric 115 in which fibers 101 are bonded together by heating in heater section 950 can be obtained.

The air-permeable supporting member 200 can be replaced appropriately according to the manufactured nonwoven fabric. For example, when producing the nonwoven fabric 120 of this embodiment, the support member 220 can be used as the air-permeable support member 200 .

When manufacturing the nonwoven fabric 120 of this embodiment, in the case of using the supporting member 220 shown in FIG. Move in roughly orthogonal directions. Thereby, the gas is continuously injected on the upper surface side of the fiber web 100 in a direction approximately perpendicular to the elongated member 225 forming it. That is, the groove portion 1 is formed along a direction substantially perpendicular to the elongated member 225 . Furthermore, an opening 3 described later is formed at a position where the elongated member 225 intersects the groove 1 .

As described above, the elongated member 225 is an air-impermeable member, for example, the gas injected from the upper side cannot be ventilated to the lower side. In other words, the gas injected to the elongated member 225 changes its flow direction.

In addition, the elongated member 225 does not move the fibers 101 in the fiber web 100 to the lower side of the supporting member 220 .

Therefore, the movement of the fibers 101 constituting the fiber web 100 is changed by the elongated member 225 while passing through the fiber web 100 by the gas injected from the upper side of the fiber web 100, and/or as the injected gas passes through the fiber web 100. gas in the direction of flow.

For example, the fiber 101 in the area where the gas is sprayed is moved to an area adjacent to the area. In addition, since the region where the gas is injected moves in a predetermined direction, as a result, it moves in a lateral region among the regions continuous along the predetermined direction of gas injection.

Thus, while the groove portion 1 is being formed, the fibers 101 at the bottom 11 in the groove portion 1 are moved so as to be oriented in the width direction. In addition, the convex portion 2 is formed between the groove portions 1 , the fiber density in the side portion of the convex portion 2 becomes high, and the fibers 101 are oriented along the longitudinal direction.

Furthermore, as the injected gas, the gas whose flow direction is changed by the elongated member 225 while passing through the fiber web 100 moves the fibers 101 constituting the fiber web 100 in a direction different from the above.

Since the mesh support member 210 and the elongated member 225 constituting the support member 220 restrict movement of the fibers 101 to the lower surface side of the support member 220 , the fibers 101 move in a direction along the upper surface of the support member 220 .

In detail, the gas injected onto the elongated member 225 changes flow along the direction of the elongated member 225 . The flowing gas is changed in this way, so that the fibers 101 disposed on the upper surface of the elongated member 225 move from the upper surface of the elongated member 225 to the surrounding area. Thus, the opening 3 of a predetermined shape is formed. In addition, one or more of the orientation, density, or basis weight of the fibers 101 is adjusted.

Moreover, in order to form the nonwoven fabric 120 which has the opening part 3, you may use the support member different from the above-mentioned support member 220. Depending on the supporting member used, the size, arrangement, etc. of the groove portion 1, the convex portion 2, the opening portion 3, and the connection portion 4 can be changed. For example, a support member 270 shown in FIG. 11 may be used.

The supporting member 270 may be, for example, a metal wire 271 of a predetermined thickness arranged approximately in parallel, and a metal wire 272 of another predetermined thickness that are alternately wound in a helical shape so as to bridge the plurality of wires 271. Formed helically woven breathable mesh.

The wire 271 and the wire 27 in the support member 270 form an air-impermeable portion. In addition, the portion surrounded by the wire 271 and the wire 272 in the supporting member 270 becomes a hole portion 273 as a vent portion.

In the case of such a support member, the air permeability can be partially changed by partially changing the weaving method, the thickness of the threads, or the shape of the threads. For example, the support member 270 in which the metal wire 271 is a stainless steel round wire and the metal wire 272 is a stainless flat wire and is spirally braided can be used.

However, in this case, the air permeability of the wire 271 and the wire 272 (particularly at the intersection of the metal wires) that become the non-ventilated portion can be enumerated as relative to the air permeability at the hole portion 273 as the vent portion. Below 90%, preferably 0% to 50%, more preferably 0% to 20%. Here, 0% means that the fluid mainly composed of gas is impermeable.

In the case of using the support member 270, for example, when a fluid mainly composed of gas is sprayed onto the intersection portion of the wire 271 and the wire 272 at the support member 270, the fluid mainly composed of gas is changed by the intersection portion. its flow direction. Accordingly, the fibers 101 supported at the intersection are sprayed forward, rear, left, and right to form the opening 3 .

In addition, in the region supported by the groove portion 1 other than the intersection portion or the region located above the hole portion 273, while the downward movement is restricted, the longitudinally oriented fibers move toward the side portion 8 in the convex portion 2. . Furthermore, the connecting portion 4 is formed by causing the transversely oriented fibers formed by the intersection portion of the supporting member 270 to be moved from the opening portion 3 .

Here, by adjusting the temperature, amount or strength of the fluid mainly composed of gas sprayed to the fiber web 100, and in addition, adjusting the moving speed of the fiber web 100 in the moving mechanism, adjusting the tension, etc., even if the same support member is used, it is also possible to Nonwoven fabrics having different openings 3 , grooves 1 , and protrusions 2 in terms of form, basis weight, and fiber density were produced. In addition, by adjusting the temperature, amount or strength of the fluid mainly composed of gas sprayed onto the fiber web 100, and in addition, adjusting the moving speed of the fiber web 100 in the moving mechanism, adjusting the tension, etc., even if different supporting members are used, A nonwoven fabric having the same form, basis weight, and fiber density of the openings 3, the grooves 1, and the convex portions 2 can be produced.

Other forms of implementation

Next, another embodiment of the nonwoven fabric of the present invention will be described. In addition, in the following embodiments, parts not particularly described are the same as those of the first embodiment, and when the reference numerals in the drawings are also the same as those of the first embodiment, the same reference numerals are assigned.

A second to a sixth embodiment of the nonwoven fabric according to the invention will be described below with reference to FIGS. 12 to 19 . The second embodiment is an embodiment in which the surface on the opposite side to the surface on which the convex portion is formed is different. A third embodiment is an embodiment in which the shape of the nonwoven as a whole is different. A fourth embodiment is a different embodiment of the convexity of the nonwoven. The fifth embodiment is a different embodiment of the groove. The sixth embodiment is an embodiment in which the opening is different.

[2.1] The second implementation form

A second embodiment of the nonwoven according to the invention will be described below using FIG. 12 .

As shown in FIG. 12 , the nonwoven fabric 172 of this embodiment differs from the first embodiment in the form of the surface of the nonwoven fabric 172 opposite to the surface on which the grooves 1 and convex portions 2 are formed. The following description will focus on the differences from the first embodiment.

[2.1.1] Non-woven fabric

In the nonwoven fabric 172 of this embodiment, groove portions 1 and convex portions 2 are alternately formed on one side thereof. In addition, on the other side of the nonwoven fabric 172 , a region located on the bottom surface of the convex portion 2 is formed so as to protrude toward the protruding side of the convex portion 2 . In other words, in the nonwoven fabric 172 , on the other side of the nonwoven fabric 172 , a region on the bottom surface of the convex portion 2 on one side is dented to form a concave portion. In addition, a region on the other side of the bottom surface of the groove portion 1 on one side protrudes in a direction opposite to the convex portion 2 on the one side to form a convex portion.

[2.1.2] Manufacturing method

Except for the above, the method of manufacturing the nonwoven fabric 172 of this embodiment is the same as that described in the above-mentioned first embodiment. In addition, as the supporting member used in the manufacture of the nonwoven fabric 172, the supporting member 220 or the supporting member 270 in the above-mentioned first embodiment can be used.

For this nonwoven fabric 172, in the state where the fiber aggregate is supported from the lower side by the support member 220 or the support member 270, a fluid mainly composed of gas is sprayed, and at the same time, from the below of the support member 220 or the support member 270, A fluid consisting mainly of gas that attracts (suctions) a jet. And, by making the amount of the fluid mainly composed of gas to be sucked (inhaled) smaller than the amount of fluid mainly composed of gas to be injected, the ratio of the injected fluid mainly composed of gas to the suctioned (inhaled) When the amount of the fluid mainly composed of gas is large, by slightly rebounding the injected fluid mainly composed of gas, it is possible to protrude in the same direction as the convex part 2 on the upper surface side of the convex part 2. The lower surface side (bottom surface side) of the convex portion 2 is formed in this manner. Thereby, the area|region located in the other side of the bottom surface of the groove part 1 protrudes relatively, and the convex-shaped part which protrudes from the bottom side is formed.

[2.2] The third implementation form

Next, a third embodiment of the nonwoven fabric of the present invention will be described with reference to Figs. 13 and 14 .

[2.2.1] Non-woven fabric

As shown in FIG. 13, the nonwoven fabric 174 of this embodiment differs from the 1st embodiment in that the whole nonwoven fabric 174 undulates like a wave. The following description will focus on the differences from the first embodiment.

The nonwoven fabric 174 of the present embodiment is formed so that the entire nonwoven fabric 174 has undulations substantially perpendicular to the directions in which the groove portions 1 and the convex portions 2 extend.

[2.2.2] Manufacturing method

The method of manufacturing the nonwoven fabric 174 of this embodiment is the same as that of the first embodiment, but the form of the support member 280 which is an air-permeable support member is different. The support member 280 of this embodiment is a support member in which a plurality of elongated members 285 are arranged approximately in parallel at predetermined intervals on the upper surface of the mesh support member 260 as shown in FIG. 14 .

The supporting member 280 of this embodiment is a supporting member having undulations in a parallel direction in either the long direction or the short direction of the supporting member 280 as shown in FIG. 14 . The mesh support member 260 constituting the support member 280, as described above, forms a plurality of small hole portions 263, and the gas injected from the upper surface side of the fiber web 100 passes downward without being hindered by the mesh support member 260. . The mesh support member 260 does not cause a large change in the flow of the jetted fluid mainly composed of gas, and does not move the fiber web 101 below the mesh support member 260 .

Further, the elongated member 285 disposed on the upper surface of the mesh support member 260 constituting the support member 280 is an air-impermeable portion that does not allow the fluid mainly composed of gas injected from the upper surface to vent downward. In addition, the flow direction of the fluid mainly composed of gas sprayed from above is changed. Thereby, the fluid mainly composed of gas sprayed on the elongated member 285 and/or the fluid mainly composed of gas sprayed on the elongated member 285 and its flow direction is changed moves the fiber 101 to form an opening. Part 3.

Furthermore, since the mesh support member 260 constituting the support member 280 itself has undulations, the fiber web 100 is shaped to have a shape along the support member 280 by means of a fluid mainly composed of gas sprayed from the upper side of the fiber web 100. The undulating shape of the shape.

In this embodiment, the fiber web 100 placed on the upper surface of the support member 280 is sprayed with a fluid mainly composed of gas, and the fiber web 100 is moved in the axis X direction, so that the non-woven fabric of this embodiment can be formed. Textiles 174.

The form of undulations in the support member 280 can be set arbitrarily. For example, the pitch between the tops of the undulations in the axis X direction as shown in FIG. 14 may be 1 to 30 mm, preferably 3 to 10 mm. In addition, the height difference between the top and the bottom of the undulations on the supporting member 280 may be, for example, 0.5 to 20 mm, preferably 3 to 10 mm. Furthermore, the cross-sectional shape in the X direction of the support member 280 is not limited to the wavy shape shown in FIG. A shape such as a shape in which substantially square-shaped concavities and convexities are connected so that each vertex is substantially flat.

The nonwoven fabric 174 of this embodiment can be produced using the nonwoven fabric producing apparatus 90 described above. Regarding the method of manufacturing the nonwoven fabric 174 in the nonwoven fabric manufacturing apparatus 90, the contents described in the description of the method of manufacturing the nonwoven fabric 120 and the nonwoven fabric manufacturing apparatus 90 in the first embodiment can be referred to.

[2.3] The fourth implementation form

A fourth embodiment of the nonwoven according to the invention will be described below using FIG. 15 .

As shown in FIG. 15 , the difference between the nonwoven fabric 176 of this embodiment and the first embodiment is that a second convex portion 22 is formed, and the second convex portion 22 is connected to one side of the nonwoven fabric 176. The formed convex portion 2 has different heights in the thickness direction. The following description will focus on points different from those of the first embodiment.

[2.3.1] Non-woven fabric

This is a nonwoven fabric in which a plurality of grooves 1 are formed side by side on one side of the nonwoven fabric 176 . Furthermore, a plurality of convex portions 2 and a plurality of second convex portions 22 are alternately formed between each of the plurality of groove portions 1 . The convex portion 2 and the second convex portion 22 are formed in parallel in the same manner as the groove portion 1 . In addition, an opening 3 and a connecting portion 4 are formed in the groove portion 1 .

The convex portion 2 and the second convex portion 22 are regions on the fiber web 100 that are not sprayed by the fluid mainly composed of gas, and become relatively protruding regions by forming the groove portion 1 . For example, the second convex portion 22 has a lower height in the thickness direction of the nonwoven fabric 176 and a narrower length in the width direction than the convex portion 2 . However, the second convex portion 22 The density, fiber orientation, and basis weight of the fibers on the surface are the same as those of the convex portion 2.

The convex portion 2 and the second convex portion 22 on the nonwoven fabric 176 form the convex portion 2 or the second convex portion 22 between each of the plurality of groove portions 1 formed in parallel. Furthermore, the convex portion 2 is formed adjacent to the second convex portion 22 with the groove portion 1 interposed therebetween. In addition, the second convex portion 22 is formed adjacent to the convex portion 2 with the groove portion 1 interposed therebetween. That is, the convex portions 2 and the second convex portions 22 are alternately formed with the groove portion 1 therebetween. Specifically, such an arrangement pattern is repeated in the order of the convex portion 2 , the groove portion 1 , the second convex portion 22 , the groove portion 1 , and the convex portion 2 . In addition, the positional relationship between the convex portion 2 and the second convex portion 22 is not limited thereto, and may be formed such that at least a part of the nonwoven fabric 176 sandwiches the groove portion 1 and the plurality of convex portions 2 are adjacent to each other. In addition, the plurality of second convex portions 22 may be formed so as to be adjacent to each other with the groove portion 1 interposed therebetween.

[2.3.2] Manufacturing method

The manufacturing method of the nonwoven fabric 176 of this embodiment differs from the ejection outlet 913 of the first embodiment in the form of the discharge port 913 of the nonwoven fabric manufacturing apparatus 90 used for the manufacture of the nonwoven fabric 176 .

For example, this non-woven fabric 176 can be produced by the non-woven fabric manufacturing apparatus 90 in which the intervals of the discharge ports 913 which discharge the fluid mainly composed of gas are adjusted. For example, by making the distance between the discharge ports 913 narrower than that of the discharge ports 913 in the first embodiment, it is possible to form the second convex portion 22 whose height in the thickness direction is lower than that of the convex portion 2 . In addition, by making the interval between the ejection ports 913 wider than that of the ejection ports 913 in the first embodiment, it is also possible to form a convex portion whose length in the width direction is longer than that of the convex portion 2 . In addition, the narrow intervals and wide intervals are alternately arranged in the intervals where the discharge ports 913 are formed, thereby forming the nonwoven fabric 176 in which the convex portions 2 and the second convex portions 22 are alternately arranged in parallel with the groove portions 1 interposed therebetween.

The nonwoven fabric 176 of the present embodiment, as described above, can be manufactured by the nonwoven fabric manufacturing apparatus 90, but, for other contents in the manufacturing method of the nonwoven fabric 176 in the nonwoven fabric manufacturing apparatus 90, it can be Reference is made to the description of the production method of the nonwoven fabric 120 and the nonwoven fabric production device 90 of the first embodiment.

[2.4] The fifth implementation form

Next, a fifth embodiment of the present invention will be described using FIGS. 16 to 18 . The fifth embodiment of the nonwoven according to the invention differs from the first embodiment in that the connecting portion 4 is recessed in the thickness direction. The following description will focus on the differences from the first embodiment.

[2.4.1] Non-woven fabric

As shown in FIGS. 16 to 18 , the nonwoven fabric 178 of this embodiment has grooves 1 and protrusions 2 formed on one side. In addition, a plurality of openings 3 are formed at predetermined intervals in the groove portion 1 .

Between the opening 3 of the groove portion 1 and the adjacent opening 3 , a plurality of recesses 44 are formed that are recessed in the thickness direction of the nonwoven fabric 178 . The bottom of the concave portion 44 is formed at a position lower than the height in the thickness direction of the groove portion 1 .

In the fiber orientation in the bottom of the concave portion 44, the content of transversely oriented fibers is higher than that of longitudinally oriented fibers. That is, the fibers constituting the bottom of the recessed portion 44 are mainly oriented in a direction (lateral direction) substantially perpendicular to the direction in which the groove portion 1 extends.

The bottom of the recess 44 is recessed in the thickness direction of the nonwoven fabric 178 in the groove 1 , and the protrusion 40 protrudes relatively from the groove 1 other than the recess 44 .

In addition, at the protrusion 40 , the fibers 101 at the periphery of the opening 3 are oriented along the periphery of the opening 3 . In this way, the injected fluid mainly composed of gas and/or the fluid mainly composed of gas injected onto the plate portion 295 of the plate-shaped support member 290 to be described later and the flow direction of the fluid mainly composed of gas changes make the fiber 101 move along the opening 3. edge moves.

The size and the like of the recessed portion 44 and the protruding portion 40 at the groove portion 1 can be set appropriately. For example, the pitch between the protruding portion 40 and the adjacent protruding portion 40 in the length direction may be 1 to 30 mm, preferably 3 to 10 mm. In addition, the height difference between the concave portion 44 and the protruding portion 40 may be, for example, 0.5 to 20 mm, preferably 3 to 10 mm.

In addition, the average weight per unit area of the protruding portion 40 may be, for example, 5 to 200 g/m ² , preferably 10 to 100 g/m ² . In addition, the average fiber density of the protruding portion 40 may be, for example, 0.20 g/cm ³ or less, preferably 0.005 to 0.05 g/cm ³ , more preferably 0.007 to 0.10 g/cm ³ .

When the average weight per unit area of the protruding portion 40 is less than 5 g/m ² , or when the average fiber density is less than 0.005 g/cm ³ , when excessive external pressure is applied, the convex portion 2 collapses , the protruding portion 40 may collapse similarly, and the space formed by the recessed portion 44 may not be maintained in the groove portion 1 .

On the other hand, when the average basis weight of the protruding portion 40 is higher than 200 g/cm ² , or the average fiber density is higher than 0.20 g/cm ² , the predetermined liquid falling into the groove portion 1 may be Residing at the protruding portion 40 gives a moist feeling when excessive external pressure is applied to the non-woven fabric 178 and comes into direct contact with the skin.

In addition, the weight per unit area of the concave portion 44 may be, for example, 0 to 100 g/m ² , preferably 0 to 50 g/m ² . In addition, the fiber density of the concave portion 44 may be, for example, 0.20 g/cm ³ or less, preferably 0.0 to 0.10 g/cm ³

When the weight per unit area of the recessed portion 44 exceeds 100 g/m ² , or when the fiber density exceeds 0.20 g/cm ³ , the predetermined liquid that fell into the groove portion 1 once stays in the recessed portion 44 . Specifically, when the nonwoven fabric 178 is used as a top sheet of an absorbent article, if a change in behavior occurs in a state where a predetermined liquid remains in the recessed portion 44, the predetermined liquid is likely to overflow from the recessed portion 44. If it spreads into the groove portion 1 and further spreads onto the surface of the nonwoven fabric 178, the skin may be stained.

[2.4.2] Manufacturing method and supporting member

The method of manufacturing the nonwoven fabric 178 of this embodiment is the same as that described above, but the air-permeable supporting member is different.

In order to manufacture this nonwoven fabric 178, the fiber web 100 placed on the upper surface of the plate-shaped support member 290 can be jetted from the upper side of the fiber web 100 at a strength higher than that of the first embodiment. Produced by spraying fluid mainly composed of gas with stronger intensity and moving it in the Z direction.

The plate portion 295 prevents the injected fluid mainly composed of gas from moving downward. Then, the flow direction of the fluid mainly composed of gas sprayed onto the fiber web 100 above the plate portion 295 is changed. For example, the groove portion 1 is formed by spraying a fluid mainly composed of gas. At this time, the gas sprayed onto the plate portion 295 of the plate-shaped member 290 cannot flow downward, and its flow direction is changed.

In addition, the sprayed fluid mainly composed of gas and/or the flow direction of the fluid mainly composed of gas which is sprayed onto the plate portion 295 moves the fiber 101 to the surrounding area. In detail, the longitudinally oriented fibers on the groove portion 1 are blown to the convex portion 2 side, and the transversely oriented fibers in the groove portion 1 are blown front and rear in a direction along the longitudinal direction of the groove portion 1 . Thereby, the opening 3 is formed.

In addition, as shown in FIG. 18 , when the fluid mainly composed of gas is sprayed onto the hole 293 of the plate support member 290 , it deforms along the inner surface of the hole 293 to form the recess 44 .

In the concave portion 44 , since the longitudinally oriented fibers in the concave portion 44 are largely blown to the convex portion 2 side, the transversely oriented fibers remain in the concave portion 44 . Accordingly, the concave portion 44 is oriented in a direction substantially perpendicular to the groove portion 1 as a whole.

In addition, on the lower side of the plate-like support member 290, for example, the net-like support member 210 etc. may be provided. By providing the mesh support member 210, the side of the support member facing the recess 44 can be formed substantially flat.

In addition, the nonwoven fabric 120 of the above-mentioned first embodiment can also be formed by changing the thickness of the plate-like support member 290 or the amount or strength of the fluid mainly composed of gas. Furthermore, a non-woven fabric may be formed in which the concave portion 44 protrudes from the hole portion 293 to the lower side of the plate-shaped support member 290 in a protrusion shape (Ω shape). In order to form the nonwoven fabric in which the concave portion 44 protrudes below the plate-shaped supporting member 290, for example, the following cases can be cited: when a fluid mainly composed of gas is strongly sprayed or the injected fluid mainly consists of gas When the amount of fluid to be formed is large, when almost no linear tension is applied to the fiber web 100, or when the fiber web 100 is sprayed with a fluid mainly composed of gas, slightly advanced, and the like. In this case, the fiber 101 easily enters the hole portion 293 .

The plate-shaped support member 290 of this embodiment is a plate-shaped member in which a plurality of hole portions 293 are formed, as shown in FIG. 17 . Specifically, it is formed by a plate portion 295 as an impermeable portion and a hole portion 293 as a vent portion.

When the plate-shaped support member 290 has a predetermined thickness, the fibers 101 in the groove 1 enter the hole 293 to form the recess 44 , and a space can be provided under the protruding portion 40 . Thereby, for example, when a high-viscosity liquid is brought into the nonwoven fabric 178, a predetermined amount of high-viscosity liquid can be accommodated in the space.

The thickness of the plate-shaped support member 290 may be, for example, 0.5 to 20 mm, preferably 1.0 to 5.0 mm when forming the nonwoven fabric 178 of this embodiment. In addition, in the case of forming the nonwoven fabric 120 of the first embodiment, it can be, for example, 0.01 to 20 mm, preferably 0.1 to 5 mm. Furthermore, in order to form the nonwoven fabric in which the recessed part 44 protrudes below the plate-shaped support member 290, it can be 0.5 to 20 mm, for example, Preferably it is 1.0 to 10 mm. In addition, for any kind of plate-shaped support member 290, when the thickness of the plate-shaped support member 290 is more than 20 mm, it is difficult for the fibers entering the plurality of holes 293 of the plate-shaped support member 290 to pass through the holes 293. Disengaged, so, sometimes productivity deteriorates.

[2.5] The sixth implementation form

A sixth embodiment of the nonwoven fabric according to the invention will be described below using FIG. 19 .

As shown in FIG. 19, the nonwoven fabric 160 of this embodiment is a nonwoven fabric in which a plurality of openings 3 are formed. It differs from the first embodiment in that no protrusions and grooves are formed. The following description will focus on points different from those of the first embodiment.

[2.5.1] Non-woven fabric

As shown in FIG. 19 , the nonwoven fabric 160 of this embodiment is a nonwoven fabric in which a plurality of openings 3 are formed.

In the fiber web 100 which is a fiber aggregate, for example, a plurality of openings 3 are formed at substantially equal intervals along the longitudinal direction which is the direction in which a fluid mainly composed of gas is jetted. In addition, a plurality of openings 3 are also formed at approximately equal intervals in the width direction of the fiber web 100 . Here, the intervals at which the openings 3 are formed are not limited thereto, and may be formed at different intervals, for example.

Each of the plurality of openings 3 is formed in a substantially circular or substantially elliptical shape. And, the fiber orientation at each of the plurality of openings 3 is oriented along the periphery of the opening 3 . In other words, the ends in the longitudinal direction of the opening 3 are oriented in a direction intersecting the longitudinal direction, and the sides in the longitudinal direction of the opening 3 are oriented along the longitudinal direction.

In addition, since the fluid mainly composed of gas injected into the fibers 101 around the plurality of openings 3 moves to the surroundings of the openings 3, the fiber density around the openings 3 is adjusted to be high. The fiber density in the area other than the periphery of the opening 3.

And, in the thickness direction of this nonwoven fabric 160, the fiber density on the surface (lower) side placed on the support member 220 (FIG. 3) is formed to be higher than that on the surface (upper) side opposite to the surface on which it is placed. The fiber density is high. This is because the fibers 101 having a degree of freedom on the fiber web 100 are concentrated on the support member 220 side by gravity or a sprayed fluid mainly composed of gas.

[2.5.2] Manufacturing method

The manufacturing method of this embodiment is the same as the manufacturing method of the above-mentioned first embodiment, but it is different in that the non-woven fabric 160 is not formed with grooves and protrusions. Hereinafter, the difference will be mainly explained.

The air-permeable supporting member used to form the nonwoven fabric 160 shown in FIG. 19, for example, can enumerate the supporting member 220 shown in FIG. 3, the plate-shaped supporting member 290 shown in FIG. board etc.

In the case of using the support member 220 or the plate-shaped support member 290, for example, the fiber web 101 is placed on the support member, the support member in the state of supporting the fiber web 100 is moved in a predetermined direction, and the Fluid mainly composed of gas is continuously sprayed to the upper surface side of the fiber web 100 to such an extent that no grooves are formed.

Specifically, using the injected fluid mainly composed of gas, and/or as the injected fluid mainly composed of gas, the fiber web 100 is ventilated while the flow direction is changed by the elongated member 225. Only the opening 3 is formed.

In addition, the amount of the fluid mainly composed of gas sprayed onto the nonwoven fabric 160 is such that the fibers of the fiber web 100 are located in the region of the fluid mainly composed of gas sprayed to such an extent that the groove portion 1 is not formed. 101 is enough to be able to move. In this case, the ejected fluid mainly composed of gas may not be sucked (suctioned) by the suction portion 915 introduced to the lower side of the support member 220 . In order not to disturb the shape of the formed web 100 due to the ejected fluid mainly composed of gas bouncing back to the support member 220 , the fluid may also be sucked (suctioned) from below the support member 220 . When performing suction (suction), the amount of suction (suction) of the fluid mainly composed of gas is preferably such that the fiber web 100 is not pressed (collapsed) on the support member 220 .

In addition, in the case of using a plate-like plate without a vent portion, the fiber web 100 is placed on the board, and the support member in the state of supporting the fiber web 100 is moved in a predetermined direction while The nonwoven fabric 160 can be manufactured by intermittently spraying a fluid mainly composed of gas. Since the entire plate-shaped plate becomes a gas-impermeable portion, the intermittently sprayed fluid mainly composed of gas forms the opening 3 together with the fluid mainly composed of gas whose flow direction changes. In other words, the opening 3 is formed at the portion where the fluid mainly composed of gas is sprayed.

In addition, after spraying a fluid mainly composed of gas to form a nonwoven fabric having irregularities, it may be wound on a roll or the like to crush the formed irregularities. Alternatively, the fiber web 100 may be heated in advance with a heating furnace or the like, and a fluid mainly composed of gas may be sprayed in a state in which the fibers 101 are bonded to a certain extent.

Example

13.1] First embodiment

<fibrous structure>

Fiber A with a core-sheath structure of high-density polyethylene and polyethylene terephthalate, an average fineness of 3.3 dtex, an average fiber length of 51 mm, and a hydrophobic oil agent coated with fiber A Blending of different fiber B in this point. The mixing ratio of fiber A and fiber B is 70:30, and the fiber aggregate whose basis weight is adjusted to 40 g/m ² is used.

<Manufacturing conditions>

A plurality of ejection ports 913 shown in FIG. 9 are formed with a diameter of 1.0 mm and a pitch of 6.0 mm. In addition, the shape of the discharge port 913 is circular, and the cross-sectional shape of the discharge port 913 is cylindrical. The width of the ejection port 913 was 500 mm. Hot air was sprayed under the conditions of a temperature of 105°C and an air volume of 10,001/min.

As the support body, a dug-through stainless steel-based sleeve having a circular shape with corners of 2 mm in length and 70 mm in width formed in the horizontal direction was used. On this sleeve, there is an interval of 3 mm in the MD direction (longitudinal direction: the direction in which the grooves or convex parts extend), and in the CD direction (short direction: the direction in which the grooves or convex parts extend) direction) at an interval of 3 mm, and the above-mentioned digging patterns are arranged in a grid pattern. In addition, the thickness of the sleeve is 0.5mm.

The fibers of the aforementioned fiber structure were opened with a carding machine at a speed of 20 m/min to form a fiber web, and the fiber web was cut with a width of 450 mm. Then, the fiber web was conveyed by a 20-mesh air-permeable net at a speed of 3 m/min. Using the above-mentioned design of the ejection part 910 and the ejection port 913, the air flow was ejected under the conditions of a temperature of 105° C. and an air volume of 1200 l/min. Then, suction (suction) is performed from below the air-permeable net with an absorption amount smaller than the amount of hot air. Thereafter, the fiber web was conveyed for about 30 seconds in a furnace set at a temperature of 125° C. and a hot air volume of 10 Hz while being conveyed by an air-permeable net.

<result>

Convex portion: the weight per unit area is 51g/m ² , the length in the thickness direction is 3.4mm (the thickness of the top is 2.3mm), the fiber density is 0.03g/cm ³ , and the width of each convex portion is 4.6mm, The pitch is 6.7mm.

Grooves: Weight per unit area is 9g/m ² , length in thickness direction is 1.8mm, fiber density is 0.005g/cm ³ , each groove has a width of 2.1mm and a pitch of 6.7mm.

Connecting part: the weight per unit area is 18g/ ^m2 , the length in the thickness direction is 1.8mm, the fiber density is 0.01g/ ^cm3 , the width of each connecting part is 2.1mm, and the length of each protruding part is 1.5mm. mm, the pitch in the MD direction is 5.0mm, and the pitch in the CD direction is 6.7mm.

Openings: the width of each opening is 2.1 mm, the length of each opening is 3.5 mm, the pitch in the MD direction is 5.0 mm, and the pitch in the CD direction is 6.7 mm.

Shape: a convex portion, a groove portion, an opening, and a connection portion are respectively formed, the back of the convex portion rises in the same direction as the convex portion, and the innermost shape of the nonwoven fabric is not formed. In addition, in the groove portion, a plurality of connection portions and opening portions are alternately formed along the direction in which the groove portion extends. The opening has an area of 5.2 mm ² in a vertically long rectangular shape with rounded corners.

[3.2] The second embodiment

<fibrous structure>

The fiber structure is the same as in the first embodiment.

<Manufacturing conditions>

Using the above-mentioned design of the ejection part 910 and the ejection port 913, the air flow was ejected under conditions of a temperature of 105° C. and an air volume of 1000 l/min. Then, the fibrous web of the aforementioned fibrous structure is sucked (suctioned) from below the air-permeable web with an absorption amount almost equal to or slightly greater than that of the sprayed air flow.

<result>

Convex part: the weight per unit area is 49g/ ^m2 , the length in the thickness direction is 3.5mm, the fiber density is 0.02g/ ^cm3 , the width of each protruding part is 4.7mm, and the pitch is 6.5mm.

Grooves: Weight per unit area is 12 g/m ² , length in thickness direction is 1.9 mm, fiber density is 0.006 g/cm ³ , each groove has a width of 1.8 mm and a pitch of 6.5 mm.

Connecting part: the weight per unit area is 23g/ ^m2 , the length in the thickness direction is 1.9mm, the fiber density is 0.01g/ ^cm3 , the width of each connecting part is 1.8mm, and the length of each protruding part is 1.5mm. mm, the pitch in the MD direction is 5.0mm, and the pitch in the CD direction is 6.5mm.

Openings: the width of each opening is 1.8 mm, the length of each opening is 3.2 mm, the pitch in the MD direction is 5.0 mm, and the pitch in the CD direction is 6.5 mm.

Shape: a convex part, a groove part, an opening part and a connection part are respectively formed, and the back surface of the convex part is substantially flat. In addition, in the groove portion, a plurality of connection portions and opening portions are alternately formed along the direction in which the groove portion extends. The opening has a vertically long rectangular shape with an area of 4.2 mm ² , and its corners are rounded.

Application example

Examples of uses of the nonwoven fabric in the present invention include topsheets in absorbent articles such as sanitary napkins, liners, and diapers. In this case, the convex part may be on the skin side or the back side, but by forming the convex part on the skin side, since the area in contact with the skin can be reduced, it is not easy to administer the drug caused by body fluids. caused by dampness. Moreover, it can also be used as an intermediate sheet|seat between the top sheet of an absorbent article, and an absorber. Since the contact area with the surface sheet or the absorber decreases, it may not be easy to return from the absorber. In addition, since the contact area with the skin is reduced or has a cushioning feeling, it can also be used on the side panels of absorbent articles or the outer surface (outermost) of diapers, female fasteners of surface fasteners, etc. used in . In addition, it can also be used in various fields such as wipers for removing dust and dirt adhering to the bed or body, masks, and breast milk pads.

[4.1] Top sheet of absorbent article

As the use of the nonwoven fabric of the present invention, as shown in FIGS. 20 and 21 , for example, non-woven fabrics having irregularities, a plurality of openings 3 are provided in the concave parts, and fiber densities that are relatively low compared with the convex parts 2 can be cited. The case where the nonwoven fabric of the connection part is used as the top sheets 301 and 302 of the absorbent article. In this case, it is preferable to arrange the nonwoven fabric so that the surface on which the convex portion 2 is formed becomes the skin side.

When the nonwoven fabric is used as the top sheets 301 and 302 of the absorbent article, when a predetermined liquid is excreted, the liquid mainly falls into the groove portion. In addition, since the opening 3 is provided, for example, even a viscous liquid containing solid content can easily move to the absorber through the opening 3, and the liquid can be suppressed from spreading widely on the surface.

Moreover, since the fiber density of the connection part 4 is relatively lower than that of the convex part 2, the liquid excreted in the connection part 4 can also move to an absorber rapidly.

Furthermore, since most of the fibers at the connecting portion 4 are oriented in the width direction, the tensile strength in the width direction is high, and it is possible to prevent friction in the width direction during wearing of the absorbent article. The surface sheets 301, 302 are damaged by force.

On the other hand, the side portion 8 of the convex portion 2 has high rigidity because the fibers are densely packed together. Moreover, since the content of longitudinally oriented fibers oriented in the longitudinal direction is high, even if a load is applied to the convex portion 2, it is easy to prevent collapse, for example, even if the convex portion 2 is crushed by a load, the compression recovery property very high.

Thereby, even if the load applied to the top sheets 301, 302 changes due to changes in the posture of the body, the area in contact with the skin can be kept low, so the touch can be maintained, and even if the liquid once absorbed by the absorbent body returns, It is also difficult to attach to the skin in a large area again.

[4.2] Middle sheet of absorbent article

As the use of the nonwoven fabric of the present invention, as shown in FIG. 22 , for example, there are concavities and convexities, a plurality of openings 3 are provided in the concavity, and a connecting portion 4 having a relatively low fiber density compared with the convex portion 2 can be cited. The case where the nonwoven fabric is used as the middle sheet 311 of the absorbent article. In this case, it is preferable to arrange this nonwoven fabric so that the surface on which the convex part 2 is formed becomes the surface sheet 310 side.

By arranging this nonwoven fabric as the intermediate sheet 311 so that the surface on which the convex portion 2 is formed faces the surface sheet 310 side, a plurality of spaces can be provided between the surface sheet 310 and the intermediate sheet 311 . Furthermore, by providing the openings 3 in the intermediate sheet 311, when a large amount of liquid is excreted in a short time, there are few factors that hinder the permeation of the liquid, and the liquid can be quickly moved to the absorbent body. And, the liquid can be prevented from widely spreading on the surface sheet 310 .

Furthermore, even if the liquid absorbed by the absorber once passed through the intermediate sheet 311 returns, since the contact rate between the intermediate sheet 311 and the top sheet 310 is low, it is difficult for the liquid to return to the top sheet 310 and adhere to the skin again in a large area.

In addition, since the central part 9 of the convex part in the intermediate sheet 311 contains more fibers oriented in the thickness direction than the side part 8 and the groove part 1, the apex of the convex part 2 contacts the surface sheet 310, so it is easy to The liquid remaining in the surface sheet 310 is directed to the thickness direction. Therefore, it is difficult for liquid to remain on the top sheet 310 .

In this way, the fixed point and low liquid residue in the top sheet 310 can be obtained, and the liquid can be prevented from adhering to the skin in a wide range and for a long time. Furthermore, since the side portion 8 of the convex portion 2 in the intermediate sheet 311 has a high content of longitudinally oriented fibers oriented in the longitudinal direction, the liquid that moves from the surface sheet 310 to the side portion 8 can be guided in the longitudinal direction. . Thereby, even if the liquid spreads in the width direction, it is possible to prevent the leakage from the absorbent article from being induced, and it is possible to improve the absorption efficiency of the absorbent body.

[4.3] The outermost part of the absorbent article

As the use of the nonwoven fabric of the present invention, as shown in FIG. 23 , for example, there are concavities and convexities, a plurality of openings 3 are provided in the concave parts, and a connection part 4 with a fiber density relatively higher than that of the convex part 2 can be cited. A case where a nonwoven fabric is used as the outermost part 321 of an absorbent article. In this case, it is preferable to arrange the nonwoven fabric so that the surface on which the convex portion 2 is formed becomes the outer side of the absorbent article.

Since it is arranged so that the surface on which the convex portion 2 is formed in the outermost portion 321 becomes the outer side of the absorbent article, when the absorbent article is used, it feels good when mainly touched with hands. In addition, the air permeability is good due to the opening 3 in the groove portion 1 .

Each constituent

Each constituent is described in detail below.

[5.1] Regarding non-woven fabrics

[5.1.1] Fiber assembly

The fiber aggregate is a fiber aggregate formed in a substantially sheet shape, and the fibers constituting the fiber aggregate have degrees of freedom. In other words, it is a fiber aggregate with degrees of freedom between fibers. Here, the degree of freedom between fibers refers to the degree to which a fiber web as a fiber aggregate can move freely by a fluid mainly composed of gas. This fiber aggregate can be formed, for example, by blowing mixed fibers mixed with a plurality of fibers to form a fiber layer of a predetermined thickness. Also, for example, it can be formed by ejecting a plurality of different fibers to form a fiber layer by laminating each of them in multiple times.

As the fiber aggregate of the present invention, for example, a fiber web formed by a carding method, or a fiber web thermally bonded and before the thermal bonding between fibers is cured can be mentioned. In addition, a web formed by an air-laid method, or a fiber web before being thermally bonded and the thermal bonding between fibers is cured can be mentioned. In addition, fiber webs before thermobonding and curing by point bonding embossing can be mentioned. In addition, fiber aggregates before spinning and embossing by the point bonding method, or fiber aggregates before thermal bonding and curing of embossing are mentioned. In addition, a semi-interwoven fiber web formed by a needle punching method can be mentioned. In addition, a semi-entangled fiber web formed by a spunlace method can be mentioned. In addition, a fiber aggregate before spinning by a melt-blowing method and thermal bonding between fibers is solidified is exemplified. In addition, a fiber aggregate before the fibers are solidified with a solvent by a solvent bonding method can be mentioned.

In addition, it is preferable to use air (gas) flow to easily rearrange the fibers using a fiber web formed by a carding method using relatively long fibers. Formed thermally bonded to the previous mesh. In addition, after forming grooves (concave-convex) etc. with a plurality of air (gas) flows, in order to keep the shape unchanged and make it into a non-woven fabric, it is processed by a heating furnace (heat treatment) using a predetermined heating device, etc., so that The through-air method of thermally bonding thermoplastic fibers contained within a fiber assembly is preferred.

[5.1.2] Fiber

As the fibers (for example, the fibers 101 constituting the fiber web 100 shown in FIG. It is composed of thermoplastic resins such as propylene, polyethylene terephthalate, modified polypropylene, modified polyethylene terephthalate, nylon, polyamide, etc., and each resin is used alone or fibers combined with each resin.

Composite shapes include, for example, a core-sheath type in which the melting point of the core component is higher than that of the sheath component, an eccentric core-sheath type, and a side-by-side type in which the melting points of the left and right components are different. In addition, hollow, flat, Y-shaped or C-shaped, three-dimensionally crimped fibers with irregular shapes such as hidden crimps or obvious crimps, split fibers that are divided by physical loads such as water flow, heat, or embossing, etc. may also be used. mix.

In addition, in order to form a three-dimensional crimped shape, predetermined obvious crimped fibers or hidden crimped fibers may be combined. Here, the three-dimensional crimped shape is a spiral shape, a zigzag shape, an Ω shape, etc., and the fiber orientation is mainly oriented in the planar direction, and the fiber orientation is also partially oriented in the thickness direction. Therefore, since the buckling strength of the fiber itself acts in the thickness direction, even if an external pressure is applied, the volume does not easily collapse. Furthermore, among them, if it is a spiral shape, when the external pressure is released, the shape will return to the original shape, so even if the volume is crushed due to excessive external pressure, it is easy to return to the original shape after the external pressure is released. thickness.

Significantly crimped fibers are a general term for pre-crimped fibers that have been given a shape by mechanical crimping, or have an eccentric core-sheath structure, or are arranged side by side. Hidden crimped fiber, by heating, the crimp can be found.

For mechanical crimping, the continuous linear fiber after spinning can be controlled by means of the peripheral speed difference of the line speed, heat, and pressure. The more crimps per unit length, the more the external pressure can be improved. of buckling strength. For example, the number of crimps is in the range of 10 to 35 crimps/inch, more preferably, in the range of 15 to 30 crimps/inch.

The shape imparted by heat shrinkage is a so-called three-dimensionally crimped fiber because it is composed of two or more resins with different melting points, and when heated, the heat shrinkage rate changes due to the difference in melting point. Examples of the resin structure of the fiber cross-section include an eccentric core-sheath structure and a side-by-side type in which the left and right components have different melting points. The thermal shrinkage of such fibers may, for example, be in the range of 5 to 90%, more preferably in the range of 10 to 80%.

The measuring method of thermal shrinkage rate is (1) make the net of 200g/m ² with the measured fiber of 100%, (2) make the sample that cuts into 250 * 250mm size, (3) put this sample at 145 ℃ ( 418.15K) in a heating furnace for 5 minutes, (4) measure the length dimension after shrinkage, (5) calculate the heat shrinkage rate from the length dimension difference before and after heat shrinkage.

In the case where the present nonwoven fabric is used as a top sheet, for example, in consideration of penetration of liquid or feeling on the skin, the fineness is preferably in the range of 1.1 to 8.8 dtex.

When using this nonwoven fabric as a surface sheet, as fibers constituting the fiber assembly, for example, in order to absorb a small amount of menstrual blood or sweat remaining on the skin, pulp, chemical pulp, rayon, acetate, etc. Fiber, natural cotton and other cellulose-based hydrophilic fibers. However, since the cellulose fiber does not easily discharge the once-absorbed liquid, for example, as a preferable form, it can be mixed in the range of 0.1 to 5% by mass relative to the whole.

In the case of using the nonwoven fabric as the surface sheet, for example, in consideration of liquid penetration or rewetting, a hydrophilic agent or a water repellent may be added to the aforementioned hydrophobic synthetic fibers or coated. . In addition, hydrophilicity can also be imparted by corona treatment or plasma treatment. In addition, hydrophobic fibers may also be contained. Here, the so-called water-repellent fibers refer to fibers subjected to a known water-repellent treatment.

Moreover, in order to improve whitening property, for example, inorganic fillers, such as titanium dioxide, barium sulfate, and calcium carbonate, may be contained. In the case of a core-sheath type composite fiber, the above-mentioned inorganic filler may be contained only in the core, or may be contained in the sheath.

In addition, as mentioned above, it is easier to rearrange the fibers by air flow by using relatively long fibers to form a fiber web by carding. To make it into a non-woven fabric is preferably a hot-air method in which thermoplastic fibers are thermally bonded by furnace treatment (heat treatment). Fibers suitable for this method are preferably fibers of a core-sheath structure or a side-by-side structure for thermal bonding at intersection points between fibers, and more preferably fibers of a core-sheath structure in which the sheaths are easily and reliably thermally bonded to each other. In particular, it is preferable to use a core-sheath composite fiber composed of polyethylene terephthalate and polyethylene, or a core-sheath composite structural fiber composed of polypropylene and polyethylene. These fibers can be used alone or in combination of two or more. In addition, the fiber length is 20 to 100 mm, particularly, preferably 35 to 65 mm.

[5.2] About nonwoven fabric manufacturing equipment

[5.2.1] Fluids mainly composed of gases

The fluid mainly composed of gas according to the present invention includes, for example, gas adjusted to a normal temperature or a predetermined temperature, or an aerosol containing solid or liquid fine particles in the gas.

As the gas, for example, air, nitrogen, or the like may be used. In addition, the gas may be a liquid vapor containing water vapor or the like.

The term "aerosol" refers to a substance in which a liquid or a solid is dispersed in a gas, and examples thereof are given below. For example, inks for coloring, softeners such as silicone for improving flexibility, hydrophilic or hydrophobic active agents for preventing static electricity and controlling wettability, and activators for increasing fluid energy can be cited. Inorganic fillers such as titanium dioxide and barium sulfate, powder binders such as polyethylene to improve the retention of concave-convex shape during heat treatment while increasing fluid energy, diphenhydramine hydrochloride and thymol to relieve itching Materials for antihistamines, moisturizers, antiseptics, etc. Here, solid also includes gel-like objects.

The temperature of the fluid mainly composed of gas can be adjusted appropriately. Appropriate adjustment can be made according to the properties of the fibers constituting the fiber aggregate or the shape of the nonwoven fabric to be produced.

Here, for example, in order to properly move the fibers constituting the fiber aggregate, the temperature of the fluid mainly composed of gas is preferably higher to some extent in order to increase the degree of freedom of the fibers constituting the fiber aggregate. In addition, when thermoplastic fibers are included in the fiber assembly, the temperature of the fluid mainly composed of gas can be softened by making the temperature of the fluid mainly composed of gas to soften the temperature of the thermoplastic fibers, so that it can be placed in the area where the fluid mainly composed of gas is sprayed. The thermoplastic fibers are softened or melted and, at the same time, hardened again.

Thereby, for example, by spraying a fluid mainly composed of gas, the shape of the nonwoven fabric is maintained. In addition, for example, when the fiber aggregate is moved by a predetermined moving mechanism, the fiber aggregate (nonwoven fabric) is given such strength that it does not unravel.

The flow rate of the fluid mainly composed of gas can be adjusted appropriately. As a specific example of a fiber aggregate having a degree of freedom between fibers, for example, a sheath made of high-density polyethylene, a core made of polyethylene terephthalate, and a fiber length of 20 to 100 mm, preferably The main body is core-sheath fiber of 35 to 65mm, fineness 1.1 to 8.8dtex, preferably 2.2 to 5.6dtex, if carding method is used to open the fiber, then use fiber length of 20 to 100mm, preferably 35 to 65mm fiber, if using For air-laid fiber opening, use fibers with a fiber length of 1 to 50 mm, preferably 3 to 20 mm, and adjust the fiber web 100 to 10 to 1000 g/m ² , preferably 15 to 100 g/m ² . As the condition of the fluid mainly composed of gas, for example, the discharge part 910 (discharge port 913: diameter of 0.1 to 30 mm, preferably 0.3 to 30 mm) shown in FIG. 8 or FIG. 10mm, pitch 0.5 to 20mm, preferably 3 to 10mm, shape is a perfect circle, ellipse or rectangle), at an air volume of 3 to 50 [L/(min·hole)], preferably 5 to 20 [L/ (min·hole)] to the fiber web 100 under the condition of spraying hot air at a temperature of 15 to 300°C (288.15K to 573.15K), preferably 100 to 200°C (373.15K to 473.15K). For example, when a fluid mainly composed of gas is sprayed under the above conditions, a fiber assembly in which the position or direction of the formed fibers can be changed is suitable among the fiber assemblies in the present invention. By making use of such fibers and production conditions, for example, the nonwoven fabric shown in Figs. 2 and 3 can be formed. The size or basis weight of the groove portion 1 or the convex portion 2 can be obtained within the following ranges. For the groove portion 1, the thickness is in the range of 0.05 to 10 mm, preferably 0.1 to 5 mm, the width is in the range of 0.1 to 30 mm, preferably in the range of 0.5 to 5 mm, and the weight per unit area is in the range of 2 to 900 g/m ² , preferably 10 to 5 mm. 90g/ ^m2 range. For the convex part 2, the thickness is in the range of 0.1 to 15 mm, preferably 0.5 to 10 mm, the width is in the range of 0.5 to 30 mm, preferably in the range of 1.0 to 10 mm, and the weight per unit area is in the range of 5 to 1000 g/m ² , preferably 10 to within the range of 100g/m ² . In addition, openings 3 are formed at predetermined intervals in the groove portion 1 , and connection portions 4 are formed between the openings 3 . The size or basis weight of the opening portion 3 or the connection portion 4 can be obtained within the following ranges. For the connection part 4, the thickness is the same as that of the convex part 2 or smaller than the thickness of the convex part, preferably in the range of 20% to 100%, particularly preferably in the range of 40% to 70%, and the width and length are in the range of 0.1 to 30mm, preferably In the range of 0.5 to 10 mm, the weight per unit area is in the range of 5 to 200 g/m ² , preferably in the range of 10 to 100 g/m ² . The width and length of the opening 3 are in the range of 0.1 to 30 mm, preferably 0.5 to 10 mm, and the weight per unit area is in the range of 0 to 100 g/m ² , preferably 10 to 100 g/m ² . In addition, although the nonwoven fabric can be made into the range of the said numerical value substantially, it is not limited to this range.

[5.2.2] Air-permeable support member

As the air-permeable support member 200 , a support member in which the support fiber web 100 side is substantially planar or substantially curved, and whose surface is substantially flat at the substantially planar or substantially curved position is exemplified. As a substantially planar shape or a substantially curved shape, for example, a plate shape or a cylindrical shape can be mentioned. In addition, the term "substantially flat" means, for example, that the surface itself on which the fiber web 100 is placed on the support member is formed in a concave-convex shape. Specifically, a support member in which the mesh of the mesh-shaped support member 210 is not formed in a concave-convex shape or the like can be used.

As this air-permeable support member, a plate-shaped support member or a cylindrical support member is mentioned, for example. Specifically, the aforementioned mesh support member 210 and support member 220 can be mentioned.

Here, the air-permeable support member 200 may be detachably arranged on the nonwoven fabric manufacturing apparatus 90 . Thereby, the air-permeable supporting member 200 corresponding to a desired nonwoven fabric can be appropriately arranged. In other words, in the nonwoven fabric manufacturing apparatus 90, the air-permeable support member 200 can be replaced with another air-permeable support member selected from a plurality of different air-permeable support members.

Next, the net-like portion of the net-like supporting member 210 shown in FIG. 4 or the supporting member 220 shown in FIG. 13 will be described. Examples of the air-permeable net-like portion include filaments formed of resins such as polyester, polyphenylene polyphenylene sulfide, nylon, and conductive monofilament, or those formed of metals such as stainless steel, copper, and aluminum. Silk, etc., through plain weave, twill weave, satin weave, double-layer weave, spiral weave, etc., into breathable nets, etc.

Here, the air permeability of the air-permeable net can be partially changed by, for example, partially changing the weaving method, the thickness of the threads, or the shape of the threads. Specifically, a spirally woven air-permeable mesh made of polyester, and an air-permeable mesh spirally woven with flat and round wires made of stainless steel are exemplified.

Examples of the plate-shaped supporting member 230 shown in FIG. 10 and the plate-shaped supporting member 17 shown in FIG. 17 include sleeves made of metals such as stainless steel, copper, and aluminum. Examples of the sleeve include sleeves in which the aforementioned metal plate is partially penetrated in a predetermined pattern. The part where the metal is dug through becomes the second ventilating part, and the part where the metal is not dug through becomes the non-ventilating part. In addition, as described above, it is preferable that the surface of the non-ventilated portion be smooth in order to improve the sliding properties of the surface.

As the sleeve, for example, a rectangular shape with a length of 3 mm and a width of 40 mm, each corner is rounded in the lateral direction, and the holes formed by metal digging are separated in the direction of the assembly line (moving direction). Stainless steel sleeves with a thickness of 0.3 mm are arranged in a grid at intervals of 2 mm and at intervals of 3 mm in the width direction.

In addition, arranging the holes in a zigzag shape can be mentioned. For example, a circular metal hole with a diameter of 4 mm is used, and a stainless steel with a thickness of 0.3 mm is arranged in a staggered manner with a pitch of 12 mm in the line direction (moving direction) and a pitch of 6 mm in the width direction. made sleeves. In this way, it is possible to appropriately set the pattern (hole portion to be formed) and arrangement of the excavation.

Furthermore, an air-permeable support member 200 provided with predetermined undulations can be mentioned. For example, an air-permeable supporting member may be mentioned in which portions where the fluid mainly composed of gas is not directly sprayed have undulations (for example, waves) alternately in the line direction (moving direction). By using the air-permeable support member 200 having such a shape, for example, a nonwoven fabric in which undulations (for example, waves) are alternately formed on the air-permeable support member 200 as a whole can be obtained while forming predetermined openings.

[5.2.3] Injection mechanism

In the ejection part 910 , since the direction of the fluid mainly composed of gas can be changed, for example, the interval between the concave parts (groove parts) and the height of the convex parts among the formed irregularities can be adjusted appropriately. Also, for example, by using a structure that automatically changes the direction of the above-mentioned fluid, for example, it is possible to appropriately adjust such that the grooves etc. form a meandering shape (wavy shape, zigzag shape) or other shapes. Also, by adjusting the ejection amount or ejection time of the fluid mainly composed of gas, the shape or pattern of the groove or opening can be appropriately adjusted. The injection angle of the fluid mainly composed of gas to the fiber web 100 may be vertical, and may also be directed at a predetermined angle in the direction of the flow line as the moving direction F in the moving direction F of the fiber web 100, or may be Facing the direction opposite to the direction of the assembly line at a specified angle.

[5.2.4] Heating mechanism

As a method of bonding the fibers 101 of the nonwoven fabric 120 forming predetermined openings, for example, bonding by a needle punching method, a spunlace method, or a solvent bonding method, or bonding by a point bonding method or The thermal bonding by the air spun method is preferably used in order to maintain the shape of the formed predetermined openings. In addition, for example, heat treatment in an air lace method using the heating part 950 is preferable.

[5.2.5] Others

The nonwoven fabric 115 heated by the heating unit 950 is moved by the conveyor 930 and the conveyor 940 continuous in a predetermined direction F to, for example, a step of cutting the nonwoven fabric 115 into a predetermined shape or a winding step. The conveyor 940 may be equipped with the belt part 949, the rotation part 941, etc. similarly to the conveyor 930.

The preferred implementation forms of the present invention are described and illustrated above, but these are only examples of the present invention, and should not be construed as limitations on the present invention, supplements, omissions, replacements or other modifications, and do not depart from the spirit and scope of the present invention. Accordingly, the invention is limited only by the claims and not by the description of the specification above.

Claims (17)

1. bondedfibre fabric, for having the bondedfibre fabric of first direction and second direction, described bondedfibre fabric comprises:

A plurality of slot parts, described a plurality of slot parts are recessed in first lateral thickness direction of described bondedfibre fabric, form by a plurality of peristomes and a plurality of connecting portion,

A plurality of convex shaped parts, described a plurality of convex shaped parts are outstanding in described first lateral thickness direction, with mode adjacency along described a plurality of slot parts,

Described a plurality of peristome forms along aforementioned first direction,

Described a plurality of connecting portion be formed on the regulation in aforementioned a plurality of peristome peristome and and the peristome of this regulation between peristome adjacent on the aforementioned first direction,

In aforementioned a plurality of connecting portion each, in each of aforementioned a plurality of slot parts, further the thickness direction at this bondedfibre fabric is recessed on, and the containing ratio of the second direction orientation fibers that is orientated on aforementioned second direction is than the containing ratio height of the first direction orientation fibers that is orientated on aforementioned first direction.

2. bondedfibre fabric as claimed in claim 1 is characterized in that, the fiber of aforementioned a plurality of peristomes on each periphery of described a plurality of peristomes is along each periphery orientation of described a plurality of peristomes.

3. bondedfibre fabric as claimed in claim 1 or 2 is characterized in that each of aforementioned a plurality of peristomes is circular or substantially elliptical.

4. bondedfibre fabric as claimed in claim 1 or 2 is characterized in that, for aforementioned a plurality of peristomes each, the length of aforementioned a plurality of peristomes on aforementioned first direction is 0.1mm to 5mm.

5. bondedfibre fabric as claimed in claim 1 or 2 is characterized in that, height 90% below of each of aforementioned a plurality of slot parts on each thickness direction at this bondedfibre fabric at aforementioned a plurality of convex shaped parts of the height on the thickness direction of this bondedfibre fabric.

6. bondedfibre fabric as claimed in claim 1 or 2, it is characterized in that, the convex shaped part of the regulation in aforementioned a plurality of convex shaped part, with clip aforementioned a plurality of slot part in regulation slot part and the convex shaped part adjacent with the convex shaped part of aforementioned regulation compared the height difference on the thickness direction of this bondedfibre fabric.

7. bondedfibre fabric as claimed in claim 1 or 2 is characterized in that the top of each of aforementioned a plurality of convex shaped parts is the general flat shape.

8. bondedfibre fabric as claimed in claim 1 or 2, it is characterized in that, as in this bondedfibre fabric and the faces face opposition sides that form aforementioned a plurality of slot parts and aforementioned a plurality of convex shaped parts second, form to aforementioned convex shaped part in the side-prominent a plurality of zones of projected direction opposite.

9. bondedfibre fabric as claimed in claim 1 or 2 is characterized in that, is wavyly to rise and fall on aforementioned first direction.

10. bondedfibre fabric as claimed in claim 8 is characterized in that, aforementioned second side in this bondedfibre fabric is general planar.

11. bondedfibre fabric as claimed in claim 1 or 2 is characterized in that, for a plurality of sidepieces in each of aforementioned a plurality of convex shaped parts each, the containing ratio of aforementioned first direction orientation fibers is than the containing ratio height of aforementioned second direction orientation fibers.

12. bondedfibre fabric as claimed in claim 8, it is characterized in that, for each of aforementioned a plurality of convex shaped parts, the spatial area rate of measuring from aforementioned first side of the convex shaped part of regulation is bigger than the spatial area rate of measuring from aforementioned second side of the convex shaped part of aforementioned regulation

The aforesaid space area occupation ratio calculates as follows:

Spatial area rate (%)=(the space gross area (mm ²)/measurement range area (mm ²)) * 100

Here, the space gross area is calculated by (multiplication factor during the space gross area during mensuration/mensuration), and in addition, the measurement range area is calculated by (multiplication factor during the measurement range area during mensuration/mensuration).

13. bondedfibre fabric as claimed in claim 11 is characterized in that, each of aforementioned a plurality of convex shaped parts has as a plurality of central portions that are clipped in the zone in aforementioned a plurality of sidepiece,

For each of aforementioned a plurality of central portions, in each of described a plurality of central portions fibre density than each fibre density height of aforementioned a plurality of connecting portions, lower than each fibre density of aforementioned a plurality of sidepieces.

14. bondedfibre fabric as claimed in claim 1 or 2 is characterized in that, the fibre density of each of aforementioned a plurality of convex shaped parts is at 0.20g/cm ³Below,

The fibre density of each of aforementioned a plurality of connecting portions is at 0.20g/cm ³Below.

15. bondedfibre fabric as claimed in claim 1 or 2 is characterized in that, each of aforementioned a plurality of connecting portions, and the weight per unit area in each of aforementioned a plurality of connecting portions is lower than each weight per unit area of aforementioned a plurality of convex shaped parts.

16. bondedfibre fabric as claimed in claim 1 or 2 is characterized in that, the weight per unit area of each of aforementioned a plurality of convex shaped parts is 15g/m ²To 250g/m ²,

The weight per unit area of each of aforementioned a plurality of connecting portions is 5g/m ²To 200g/m ²

17. bondedfibre fabric as claimed in claim 1 or 2 is characterized in that, the mixed with fibers that constitutes this bondedfibre fabric has hydrophobic fiber.

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