CN1181969C - 复合片及其制造方法 - Google Patents

复合片及其制造方法 Download PDF

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CN1181969C
CN1181969C CNB011173556A CN01117355A CN1181969C CN 1181969 C CN1181969 C CN 1181969C CN B011173556 A CNB011173556 A CN B011173556A CN 01117355 A CN01117355 A CN 01117355A CN 1181969 C CN1181969 C CN 1181969C
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continuous fibers
composite sheet
stretch fabric
tensile strength
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CN1322623A (zh
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丹下悟
֮
大幡裕之
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Unicharm Corp
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    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Diaphragms For Electromechanical Transducers (AREA)
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Abstract

本发明提供了能够形成由直径差别小的拉伸性连续纤维构成的层的复合片。在弹性伸缩层3的至少单面上在一方向上间断地接合由有拉伸性的连续纤维6构成的拉伸层2，从而形成复合片10。连续纤维6大致在该方向上定向，该方向和与此方向垂直的方向上的拉伸强度比S1/S2是3.0以上。

Description

复合片及其制造方法
本发明涉及通过由伸缩性织物和拉伸性连续纤维构成的拉伸性织物形成的复合片及其制造方法。
特开平6-184897号公报中公开的复合伸缩性材料是通过拉伸，在保持拉伸带头的材料的状态下，在相对于被拉伸的伸缩性片呈非直线状排列的至少3个点上接合，之后，通过使伸缩性片松弛制造的。根据该制造方法，带头材料如果是由纤维构成的，伴随着伸缩性片的松弛，形成许多折痕，没有损坏伸缩性片的伸缩性，可以将该片的象橡胶似的表面改变为布样肌肤触感好的表面。
根据上述公知的技术，带头的材料的一个例子是在一个方向拉伸热塑性合成纤维相互熔敷形成的纺粘型无纺布得到的带头的材料。由于无规则分布，形成该无纺布的纤维通过在一个方向上被拉，有的朝着那个方向一边塑性变形一边伸长，有的只改变其方向朝那个方向延伸。结果，拉伸的纤维变细，另一方面，只改变了方向的纤维没有改变粗细，因此得到的复合伸缩性纤维的纤维直径差别大，触及肌肤时的感觉不一样，或者外观不一样。
本发明的课题是，提供如上述公知技术所说的由伸缩层和由拉伸性纤维构成的拉伸层形成的、但在拉伸层中的纤维直径差别小的复合片及其制造方法。
为了解决上述课题，本发明提出了新型的复合片及其制造方法。
关于上述复合片，本发明的对象是，在具有上下面的弹性伸缩层的至少单面上在相互垂直的第1方向和第2方向中的至少上述第1方向上间断地结合由拉伸性的连续纤维构成的拉伸层而形成的复合片。
对于该复合片，本发明的特征在于，上述连续纤维大致在上述第1方向定向，上述复合片的第1方向上的拉伸强度S1和上述第2方向上的拉伸强度S2的比S1/S2是3.0以上。
另外，关于上述制造方法，本发明的对象是在具有上下面的弹性伸缩性织物的至少单面上，在相互垂直的第1方向和第2方向中的至少上述第1方向上间断地接合由拉伸性的连续纤维构成的拉伸性织物，以制造复合片。
对于该制造方法，本发明的特征在于，上述连续纤维通过实质上以非结合状态重合而形成上述拉伸性织物，上述连续纤维大致在上述一方向上定向后，在上述伸缩性织物上接合上述拉伸性织物。
在该制造方法的优选的实施方式中，从熔融挤压机挤出上述连续纤维，并收集在向一方向移动的传送带上，形成上述拉伸性织物后，进行处理，使上述连续纤维大致在上述方向上定向，并和上述伸缩性织物重合，之后，在上述一方向上间断地接合这两个织物，得到上述复合片。
再有，在另一个优选的实施方式中，在上述一方向上使上述连续纤维定向的工艺包括以速度V1移动的上述传送带和接续上述传送带并以速度V2移动的第2传送带，这2个传送带的移动速度比V2/V1是1.05-10。
图1是复合片的立体图。
图2是负荷/伸长率曲线。
图3是复合片的制造工艺图。
以下，参照附图详细说明本发明的复合片及其制造方法。
在由苯乙烯类弹性体的连续纤维40构成的弹性伸缩层3的上面上通过在接合部4A处熔敷由拉伸性的聚丙烯连续纤维6构成的拉伸层2，形成图1中以立体图表示的复合片10。复合片10具有X方向和与此垂直的Y方向，伸缩层3在X，Y方向中的至少Y方向上弹性地伸缩。将拉伸层2的连续纤维6定向，使得其大致在Y方向上延伸。伸缩层3的拉伸强度在X方向和Y方向上没有差别的情况下，连续纤维6的定向程度可以用Y方向上的拉伸强度S1和X方向的拉伸强度S2的比S1/S2表示，在本发明优选的复合片10中，将连续纤维6定向，以使S1/S2至少达到3.0。另外，除了接合部4A以外，连续纤维6就不因熔敷或粘附而相互接合，而仅仅是重合着，或者说是如果复合片10稍微在Y方向上拉伸就会相互分离那样的极弱地接合着，实质上只等同于重合的状态。
如果在两层2，3的断裂伸长率以下而且在伸缩层3的弹性极限内在Y方向上拉伸该复合层10，则一方面弹性地拉伸伸缩层3，另一方面非弹性地拉伸拉伸层2，使连续纤维6变细变长进行塑性变形。如果取消拉伸的力，通过伸缩层3的收缩力，复合片10收缩到接近原来的尺寸，此时，在拉长的连续纤维6上形成很多的折痕，拉伸层2的体积比拉伸前的状态大，肌肤的触感变得柔软。
图2是再次拉伸最初拉伸到150％的复合片10时的负荷/伸长率曲线，复合片10的构成如下。再有，定义最初拉伸复合片10时的比例为初始伸长率EI。
拉伸层 拉伸性连续纤维：聚丙烯/丙烯、乙烯、丁烯的三元共聚物＝60/40(重量比)
       纤维直径：           15.2μm
       单位面积重量：       15g/m2
伸缩层 伸缩性连续纤维：苯乙烯系弹性体
       纤维直径：           16.4μm
       重量：               60g/m2
复合片 强度比(S1/S2)：4.9
在图2中，曲线缓慢上升后，以大约相同的负荷直至达到延伸率100％的拐点P，从此之后，急剧上升。复合片10中，首先拉伸拉伸层2的连续纤维6的折痕，与此同时，弹性拉伸伸缩层3直至拐点P。在拐点P以后，连续纤维6塑性变形，拉伸得变细、变长，伸缩层3继续弹性拉伸。这样的复合片10如果最初拉伸至150％，在第2次拉伸中，在延伸率直至100％的范围内，显现出以低应力伸缩的伸缩层3的特性，拉伸层2几乎不对其特性产生影响。第2次拉伸复合片10时，将表示直至观察到的拐点P的低负荷的延伸率定义为第2次延伸率Es。第2次延伸率Es和初始延伸率EI的比Es/EI是拉伸应变效率SE，图2条件下的拉伸应变效率SE是100(％)/150(％)×100＝67(％)。本发明的复合片10中，连续纤维6大致在Y方向上定向，因此在Y方向上拉伸复合片10时，由于在Y方向上许多连续纤维6被拉伸变长，拉伸应变效率SE达到大约60-90％的高值。与该复合片相比，连续纤维6不规则分布情况下的复合片中，拉伸应变效率SE为60％以下。
图3是制造复合片10时的工艺图。在图的左方，标有排出连续纤维6的第1挤出机31、第1传送带32和空吸箱33。通过由第1挤出机的喷嘴的侧面喷出的热风(未示出)或抽吸的作用，在第1传送带32上收集排出的连续纤维6，形成拉伸性织物52。选择第1挤出机31的排出条件、热风或抽吸的作用条件、连续纤维6的冷却条件以及传送带32的速度V1，以使连续纤维6不相互熔敷，还有，即使熔敷，也能够极其容易分离。
向第2传送带36推进拉伸性织物52。第2传送带36以速度V2移动，挤压拉伸性织物52的辊37、38以线速度V2回转。速度V2和V1的比V2/V1是1.05-10，拉伸性织物52在从第1传送带32向第2传送带36移动的的过程中在行进方向上被拉伸，进行定向，以使连续纤维6在行进方向延伸。在连续纤维6相互弱熔敷时，会在第2传送带36上变得零乱。
拉伸性织物52从第2传送带36向第3传送带41前进。从第2挤出机42排出弹性体连续纤维40，受空吸箱43的抽吸作用，在拉伸性织物52上堆积，形成伸缩性织物53。两个织物52、53通过上下一对的热轧花辊44，44时，形成接合部4A而一体化，成为复合片10。
该复合片10的制造工艺中，如果取第1传送带32的速度V1和第2传送带36的速度V2的关系为V2/V1＝1.05-10，使连续纤维6被定向，则该定向对于在复合片10上达到60-90％高的拉伸应变效率SE是足够的程度。该定向充分时的复合片10在机械方向和与此垂直的方向的拉伸强度S1和S2的比S1/S2是3.0以上。
本发明的复合片10，可以用在伸缩层3的上下面上具拉伸层2的复合片代替图示的复合片。再有，与此同时，图3的工艺中，可以追加第3挤出机和多个传送带。
本发明的复合片由于拉伸性的连续纤维大致在一方向上定向，所以如果在该方向上被拉伸，则由于多数连续纤维都一样延伸，伸长后的纤维直径没有差别，接触肌肤时的感觉舒适且外观均匀。
本发明的制造方法由于包括在大致一个方向上使拉伸性织物的连续纤维定向的工序，因此可以容易地制造上述复合片。

Claims (6)

1.一种复合片，在具有上下面的弹性伸缩层的上面或下面上，在相互垂直的第1方向和第2方向中的上述第1方向上间断地结合由拉伸性的连续纤维构成的拉伸层而形成，其特征在于，上述连续纤维在所述的第1方向上定向，上述复合片的上述第1方向上的拉伸强度S1和上述第2方向上的拉伸强度S2的比S1/S2是3.0以上。
2.如权利要求1所述的复合片，其特征在于，在上述第1方向上的拉伸效率是60-90％。
3.一种复合片的制造方法，在具有上下面的弹性伸缩性织物的上面或下面上，在相互垂直的第1方向和第2方向中的上述第1方向上间断地接合由拉伸性的连续纤维构成的拉伸性织物，其特征在于，通过使上述连续纤维以非结合的状态重合，形成上述拉伸性织物，上述连续纤维在所述的第1方向上被定向后，在上述伸缩性织物上接合上述拉伸性织物。
4.如权利要求3所述的方法，其特征在于，从熔融挤出机挤出上述连续纤维，并收集在朝一方向移动的传送带上，形成上述拉伸性织物后，进行处理使上述连续纤维在上述一方向上定向，和上述伸缩性织物重合，之后，通过在上述一方向上间断地接合这两个织物，得到上述复合片。
5.如权利要求3或4所述的方法，在上述一方向上使上述连续纤维定向的工序包括以速度V1移动的上述传送机和接续上述传送机并以速度V2移动的第2传送机，这两个传送机的移动速度比V2/V1是1.05-10。
6.如权利要求3-5中任一权利要求所述的方法，其特征在于，在上述一方向上使上述连续纤维定向，使上述复合片的上述一方向上的拉伸强度S1和与上述一方向垂直的方向上的拉伸强度S2的比S1/S2为3.0以上。
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