JP5985185B2 - Nonwoven fabric production support and method for producing shaped nonwoven fabric - Google Patents

Description

  The present invention relates to a support for producing a nonwoven fabric and a method for producing a shaped nonwoven fabric.

  As a support for supporting a shaped fiber web used in a conventional method for producing a nonwoven fabric, a support having a large number of projections scattered on a continuous smooth surface and a plurality of small through holes in a plane between the projections. It is disclosed. In the method for producing a nonwoven fabric using this support, a fiber web is placed on the support, and a high-speed water stream is sprayed onto the fiber web to distribute the fibers on the protrusions and simultaneously provide openings. A perforated nonwoven fabric is produced by entanglement of fibers on the smooth surface. (For example, refer to Patent Document 1).

  As another method, there is a method in which a fiber web containing thermoplastic fibers is passed between a pair of breathable conveyors having at least one unevenness, and the fiber web is conveyed between the conveyors. This breathable conveyor with unevenness has a plurality of triangular helical wires, insert another triangular helical wire adjacent between the spirals of the triangular helical wire, and the adjacent triangular helical wires It is a net-like conveyor made by knitting wire rods through straight wire rods, and a triangular spiral wire rod constitutes a convex portion. In this non-woven fabric manufacturing method using a breathable conveyor, air is sprayed onto the surface of the fiber web being conveyed by the breathable conveyor, causing the fiber web to follow the irregularities of the breathable conveyor and imparting irregularities to the fiber web. Shape. Then, the nonwoven fabric which heated the fiber web shape | molded to the unevenness | corrugation, melt | fused thermoplastic fibers, and was fixed to the uneven | corrugated shape is manufactured. (For example, see Patent Document 2.)

Since the manufacturing method of the nonwoven fabric disclosed in Patent Document 1 uses water as the energy for moving and shaping the fibers in the web, the portion corresponding to the protrusion of the support is opened. Although a non-woven fabric can be obtained, too much energy is applied, so that a non-woven fabric having a high fiber density, that is, a thin thickness can be obtained. When air is blown into the fiber web and pushed into the support used in the method described in Patent Document 1, the fibers of the fiber web contact on the back side through the small through holes of the support, and hot air is applied in that state. The fibers are fused and entangled with the small through holes interposed therebetween. For this reason, it becomes difficult to peel off the fiber web from the support, and fluffing or poor appearance can be achieved. Moreover, it is inferior to continuous productivity. Moreover, since each small through-hole is as small as 1.0 mm to 2.0 mm and is scattered in the flat part, air hardly converges on the small through-hole. For this reason, the air blown to the area | region where the hole is not arranged bounces off, the bounced air may disturb the fiber web, and the fiber of the fiber web may blow off in some cases. These are particularly noticeable when the wind speed is relatively high.
Moreover, in the manufacturing method of the nonwoven fabric disclosed in Patent Document 2, when the fiber web is pushed in with air, the mesh portion is knitted, so the mesh joint (intersection portion of the wire rod) is microscopically the intersection portion. Since the structure is gradually narrower toward the center, the fibers are easily caught. Also, during manufacturing, the entire net moves while deforming, that is, the wires move relative to each other, and at that time, the gap between the wires is easy to increase and decrease, and when the gap is large, the fibers are in between. When the gap is small and the gap is small, the fiber is in a frightened state. As a result, the fibers are caught and cannot be pulled out. When hot air is blown in this state, the fibers are fused to the wire. Moreover, when a fiber wraps around a wire and entangles and hot air is blown in that state, the fiber is fused in a state where the fiber is entangled. In either case, since the fiber webs are fused one after another, they may be unsuitable for continuous production due to fuzzing or bad appearance, disturbing the product, and depositing fibers on the net.

JP-A 62-69867 JP-A-2-229255

  Non-woven fabric with excellent formability of fiber webs, without disturbing the fibers of the fiber web and preventing fusing and entanglement of the fibers through the holes arranged in the support in the shaping process to make the fiber web uneven It is providing the manufacturing support body and the manufacturing method of a shaping nonwoven fabric.

  The present invention is surrounded by a plurality of rod-shaped bodies arranged in parallel, a plurality of protrusions disposed between the rod-shaped bodies, and the protrusions adjacent to each other between the adjacent rod-shaped bodies and in the longitudinal direction of the rod-shaped body. The projections and the holes are alternately arranged in a first direction and a second direction orthogonal thereto, and the projections are arranged at a predetermined interval, and the projections are opposed to each other. Provided is a nonwoven fabric support having a first surface and a second surface.

  The present invention conveys a fiber web containing thermoplastic fibers onto a support having a plurality of protrusions and a plurality of holes, and blows hot air, and the fiber web is made uneven along the support along the support. A method of manufacturing a shaped nonwoven fabric that shapes a shape, wherein the support is provided with a plurality of rod-like bodies arranged in parallel, a plurality of protrusions arranged between the rod-like bodies, and the adjacent rod-like bodies. And a hole existing in a region surrounded by the protrusions adjacent to each other in the longitudinal direction of the rod-shaped body, and the protrusions and the holes are alternately arranged in a first direction and a second direction orthogonal thereto. And the said processus | protrusion is arrange | positioned at predetermined intervals, The said processus | protrusion provides the manufacturing method of the shaping nonwoven fabric using what has the 1st surface and 2nd surface which oppose.

  The support for nonwoven fabric production and the method for producing a shaped nonwoven fabric according to the present invention include a method for forming irregularities on a fiber web, and without disturbing the fibers of the fiber web by the blown air and through the holes arranged on the support. There is no fusion or entanglement between the fibers. Therefore, the three-dimensional uneven nonwoven fabric is excellent in the shapeability of the fiber web that can be formed into a shaped nonwoven fabric that is effectively thick with little basis weight (density) (low liquid residue when used in an absorber), Moreover, it enables continuous production.

It is the fragmentary perspective view which showed preferable one Embodiment of the support body for nonwoven fabric manufacture of this invention. It is drawing which showed preferable one Embodiment of the support body for nonwoven fabric manufacture of this invention, (1) is a fragmentary top view, (2) is AA sectional view, (3) is BB sectional drawing. is there. It is the fragmentary perspective view which showed the modification of the support body for nonwoven fabric manufacture of this invention. It is the fragmentary top view which showed another modification of the support body for nonwoven fabric manufacture of this invention. It is the schematic block diagram which showed an example of the manufacturing apparatus of the shaping nonwoven fabric suitable for manufacturing a shaping nonwoven fabric using the support body of this invention, and the expanded sectional view of a support body. It is the schematic block diagram which showed an example of the manufacturing apparatus of another shaping nonwoven fabric suitable for manufacturing a shaped nonwoven fabric using the support body of this invention, and the expanded sectional view of a support body. It is drawing which showed the dimension and arrangement | positioning dimension of a processus | protrusion and a hole, (1) is a fragmentary top view, (2) is an AA sectional view, (3) is a BB sectional drawing.

  A preferred embodiment of a support for impurity production (hereinafter referred to as a support) according to the present invention will be described below with reference to FIGS. 1 and 2.

As shown in FIGS. 1 and 2, the support 10 of the present invention has a plurality of rod-like bodies 11 arranged in parallel.
A plurality of protrusions 12 are arranged between the rod-shaped bodies 11, and lower portions on both sides of the protrusion 12 are connected to the rod-shaped body 11. Further, a rod-like body 11A which is one of the plurality of rod-like bodies 11, another rod-like body 11B adjacent to the rod-like body 11A, a projection 12A connected to the rod-like bodies 11A and 11B, and a rod-like shape adjacent to the projection 12A. A hole 13 exists in a region surrounded by another projection 12B connected to the bodies 11A and 11B. The shape of the hole 13 in plan view may be circular, oval, or polygonal. Preferably, it is circular or oval.
The protrusions 12 and the holes 13 are alternately arranged in a first direction (MD direction) orthogonal to the longitudinal direction of the rod-shaped body 11 and a second direction (CD direction) parallel to the longitudinal direction, and the protrusions 12 are predetermined. They are arranged at regular intervals as intervals. Accordingly, the protrusions 12 are arranged at equal intervals around the hole 13. That is, the hole 13 is disposed at the center position of the four protrusions 12 around the hole 13.

  The MD direction mentioned above is the machine direction and the feeding direction of the fiber web during the production of the nonwoven fabric, and the CD direction mentioned above is a direction orthogonal to the MD direction.

The plurality of protrusions 12 have a first surface 12SA and a second surface 12SB that face each other. The first surface 12SA and the second surface 12SB may be flat surfaces or curved surfaces.
When viewed from above, each of the first surface 12 S A of the respective projections oriented in the same direction, each of the second surface 12SB facing in the same direction in the opposite direction to the first surface 12SA. Further, the projection 12 is long in a plan view, in the first and second surfaces 12SA and 12SB directions, and has a rectangular shape with rounded corners, for example. Thus, the shape of the cross section of the protrusion 12 is preferably a rectangle having rounded corners except for the top. Furthermore, between the 1st surface 12SA and 2nd surface 12SB of the protrusion 12, it has the 3rd surface (side surface) 12SC connected to the periphery of each surface, The outer periphery of the 3rd surface 12SC is the 1st surface. It is preferable that it exists in the inside of a cycloid curve seeing from the normal line direction (MD direction) of 12SA or 2nd surface 12SB.

Furthermore, it is preferable that at least one of the first surface 12SA, the second surface 12SB, and the third surface 12SC of the protrusion 12 is roughened. This surface roughness is appropriately selected depending on the fiber type, fiber diameter, and the like of the fiber web.
Furthermore, the protrusion 12 includes a protrusion row 14 (14A) of the protrusion 12 arranged in the surface direction of the first and second surfaces 12SA and 12SB, that is, the MD direction, and another protrusion adjacent in parallel to the protrusion row 14A. It is preferable to have a distance D between the row 14 (14B). A preferable range of the distance D is that the fiber web 50 is shaped according to the shape of the support 10 and has good peeling properties from the support 10 after shaping, has a fine uneven pattern, and has a beautiful appearance. 0 mm ≦ D ≦ 10 mm, a more preferable range is 1 mm ≦ D ≦ 3 mm, and a most preferable range is 1.5 mm ≦ D ≦ 2.5 mm.

Moreover, it is preferable that the said hole 13 has the center of the hole 13 in the center between the processus | protrusions 12 which adjoin each direction in both MD direction and CD direction. And when the said hole 13 is projected from MD direction, it is preferable to arrange | position so that the projection image of the hole 13 distribute | arranged to MD direction may overlap. That is, when the holes 13 are arranged in a rhombus pattern and the pitch of the holes 13 on the same line in the CD direction is Pcd, [pitch Pcd / 2] <[diameter φ c of the hole 13 (not shown) or CD direction Width Wcd ]. [The diameter φc of the hole 13 (not shown) or the width Wcd in the CD direction] − [pitch Pcd / 2] is preferably as large as possible. However, due to processing restrictions and other dimensions, [pitch Pcd / 2] +0.2 <[diameter φc of hole 13 (not shown) or CD-direction width Wcd ]] is preferably used. The rhombus pattern arrangement means that the shape connecting the centers of the four holes 13 arranged around the projection 12 (four sides) is a rhombus.
In addition, the hole area ratio (area ratio) occupied by the holes 13 is preferably as large as possible so that the gas to be blown out is good, but the hole area ratio is determined in consideration of the strength of the support 10. The open porosity is preferably 50% or less than 10%, more preferably 15% to 40% or less, more preferably 20% or more than 35%, particularly preferably 35% or more 30% or less.

  3 (1) and 3 (2), at least the upper surface 11S of the rod-like body 11 of the support 10 is preferably flat. If the upper surface is flat, Thus, the rod-shaped body 11 may be a round bar, or the rod-shaped body 11 may be a square bar as shown in FIG. Although not shown, it is preferable that the side corners of any of the rod-like bodies 11 are rounded.

  Since the support 10 of the present invention has the substantially solid first surface 12SA and the substantially solid second surface 12SB facing the protrusions 12, the fibers enter the protrusions 12 and become entangled. There is no. Here, the term “substantially solid” as used herein refers to a state in which the fibers do not enter even if the structure is densely packed or there is a void to such an extent that the fibers do not enter. Further, since the protrusions 12 and the holes 13 are alternately arranged at equal intervals in the MD direction and the CD direction perpendicular to the MD direction, the protrusions 12 and the holes 13 are orthogonal to the hole 13 and at four locations around the hole 13. The protrusions 12 are arranged at equal intervals. In other words, the center of the hole 13 is arranged at the center of the projection 12 arranged at the four places. For this reason, since the hole 13 can be present in a sufficient size, the air blown to the support 10 hardly converges on the surface of the support 10 and is converged in the hole 13. Therefore, the fiber web can be efficiently shaped into a concavo-convex shape.

Further, the support body 10 is not configured by knitting a wire, but is an integral structure support body 10 in which protrusions 12 and holes 13 are alternately arranged between rod-like bodies 11, and the protrusions 12 are arranged at intervals. Therefore, the fiber is not caught between a part of the support 10 such as between the protrusions 12.
In particular, as shown in FIG. 4, the connecting portion between the rod-like body 11 on the hole 13 side and the protrusion 12 preferably has a corner. That is, the corners 13 </ b> R of the hole 13 in plan view are rounded so that the fibers are less likely to be pinched.
Further, since the protrusions 12 and the holes 13 are alternately arranged in the MD direction and the CD direction perpendicular to the MD direction, there is a sufficient distance between the adjacent holes 13, so that the fibers may be entangled through the adjacent holes 13. Absent.

Further, since the adjacent protrusion rows 14A and 14B are arranged at a distance D, the fiber web can be easily peeled from the support 10 by setting the protrusion row 14 direction to the MD direction.
Therefore, by using the support 10 of the present invention for the production of a shaped nonwoven fabric, the fiber web after shaping is improved and continuous production becomes possible, so that productivity is improved.

  Moreover, the upper surface 11S of the rod-shaped body 11 between the adjacent protrusions 12, between the adjacent holes 13, and between the protrusions 12 and the holes 13 forms a flat surface. For this reason, when air is blown onto the fiber web when the fiber web is shaped using the support 10, the fiber web is brought into surface contact with the flat surface while being pushed into the holes 13. Non-woven fabric is less likely to fluff.

In addition, when the fiber web is shaped into a concavo-convex shape using the support 10, the protrusion 12 is configured to be long in the direction of the first and second surfaces 12SB and 12SA in plan view. The fibers can be easily selected by orienting the fibers along the first and second surfaces 12SB and 12SA. In addition, there is an advantage that an enormous wind speed is not required at the time of shaping .
In addition , it is advantageous that the width of the protrusion in the CD direction is narrow in that the selection is easy and a huge wind speed is not required at the time of shaping.
Considering this point, the base width Wpc of the projection 12 in the CD direction , which will be described later, is preferably as small as possible . Since the unevenness to be shaped becomes too small, the base width Wpc is preferably 0.5 to 10 mm, more preferably 1 to 5 mm, and still more preferably 1 to 2 mm as a preferable projection size. If the base width of the protrusion 12 in the MD direction is Wpm, Wpm / Wpc is preferably 1.1 to 10, more preferably 2 to 4.

In addition, a cycloid drawn so that the outer peripheral edge of the third surface 12SC viewed from the normal direction ( MD direction) of the first surface 12SA or the second surface 12SB passes through the top portion and a rod-like body at an intermediate point between the top portions. Located inside the curve . In this configuration, in particular, when the support 10 is applied to a drum-shaped shaped nonwoven fabric manufacturing apparatus, the fiber web is smoothly separated from the side surfaces of the protrusions 12, so that the fiber web is easily peeled from the support 10. .

  Further, in the configuration in which at least one of the first surface 12SA, the second surface 12SB, and the third surface 12SC of the protrusion 12 is roughened, the fiber is protruded when the fiber web is shaped by blowing air. It becomes easy to get caught moderately on the roughened surface without sliding down the surface. For this reason, it becomes easy to shape the fiber web into an uneven shape along the surface of the protrusion 12.

Further, in the support 10, the protrusion 12 may have a through hole (not shown) penetrating between the first surface 12 SA and the second surface 12 SB. However, it is necessary to ensure a sufficient distance between the third surface 12SC of the protrusion 12 and the through hole. In other words, a distance that does not allow the fibers of the fiber web to be entangled through the through hole is necessary.
Since it has such a through-hole, the mass of the support body 10 can be lightened. In particular, when the support 10 is made of metal, the effect of reducing the weight is great. As a result, the power for transporting the support can be reduced, and the constituent material of the support 10 can be reduced, thereby achieving energy saving and resource saving.

  Next, with reference to FIG. 5, an example of the manufacturing apparatus of the shaped nonwoven fabric preferably used for the implementation of the manufacturing method of the shaped nonwoven fabric using the support body 10 of this invention is demonstrated.

  As shown in FIG. 5, the shaping nonwoven fabric manufacturing apparatus 101 includes a support 10 that conveys a fiber web 50 containing thermoplastic fibers. The fiber web 50 is supplied to the surface of the support 10, and is shaped and heat-treated by an air-through method while being placed on the surface of the support 10, and is sent out in a predetermined direction.

  The support 10 is composed of a conveyor, and a conveyer belt 110B having air permeability is supported by rotation support rollers 110R (110Ra, 110Rb, 110Rc, 110Rd) disposed at four locations on both upper and lower ends. It is configured to rotate. The rotation support rollers 110R are not limited to four places, and may be arranged so that the conveyor belt 110B rotates smoothly. The support 10 described above is arranged on the surface side of the conveyor belt 110B, and a plurality of protrusions 12 and a plurality of holes 13 are alternately arranged on the surface of the support 10 in the MD direction and the CD direction as described above. And it is arranged at equal intervals.

  The support 10 conveys the fiber web 50 so that the fiber web 50 is hooked by the protrusion 12 on the surface side having the protrusion 12 by the rotation of the conveyor belt 10B supported by the rotation support roller 10R. A first air-through process for injecting high-speed gas (for example, high-speed air) W <b> 1 for shaping is sequentially performed along the supply direction of the fiber web 50 above the protrusion 12 of the support 10. 1 nozzle 111 and the 2nd nozzle 112 which performs the 2nd air through process which injects hot air W2 and performs heat processing are arranged.

  The first nozzle 111 injects the high-speed air W1 to the surface of the support body 10 on which the protrusions 12 are disposed, for example, substantially perpendicularly. It is preferable that the high-speed air W <b> 1 ejected from the first nozzle 111 is uniformly blown in the width direction of the surface of the fiber web 50.

  The second nozzle 112 injects hot air W <b> 2 heated by a second heater (not shown) onto the surface of the support 10 having the protrusions 12, for example, substantially perpendicularly. It is preferable that the hot air W2 sprayed from the second nozzle 112 is blown at a uniform temperature in the width direction of the surface of the fiber web 50. As the hot air W2, air heated by the second heater, nitrogen, or the like can be used. Preferably, air that is inexpensive and highly stable and safe when heated is used.

  In the blowing direction of the first nozzle 111, a suction portion (not shown) is provided for exhausting the high-speed air W1 ejected from the first nozzle 111 and passed through the fiber web 50, the support 10 and the like. An exhaust device (not shown) for discharging the sucked high-speed air W1 may be connected to the suction portion. Furthermore, in the blowing direction of the second nozzle 112, a suction section (not shown) is provided for exhausting the hot air W2 ejected from the second nozzle 112 and passing through the fiber web 50, the support 10 and the like. An exhaust device (not shown) for discharging the sucked hot air W2 may be connected to the suction portion. Further, each exhaust device may be connected to each suction unit as one exhaust device.

Next, a preferred embodiment (first embodiment) of the method for producing a shaped nonwoven fabric according to the present invention will be described below with reference to FIG. 5 described above.
As shown in FIG. 5 described above, the method for manufacturing a shaped nonwoven fabric according to the first embodiment is realized by the aforementioned shaped nonwoven fabric manufacturing apparatus 101.

First, the fiber web 50 is supplied to the upper surface side of the support 10 on which the protrusions 12 are arranged.
The fiber material that can be used for the fibers of the fiber web 50 is not particularly limited. Specific examples include the following fibers. There are fibers made of polyolefin fibers such as polyethylene (PE) fibers and polypropylene (PP) fibers, and thermoplastic resins such as polyethylene terephthalate (PET) and polyamide alone. In addition, there are composite fibers having a structure such as a core-sheath type and a side-by-side type. In the present invention, it is preferable to use a composite fiber. Examples of the composite fiber include a core-sheath fiber having a high melting point component as a core portion and a low melting point component as a sheath portion, and a side-by-side fiber in which a high melting point component and a low melting point component are arranged in parallel. Preferable examples thereof include core-sheath fibers in which the sheath component is polyethylene or low-melting polypropylene. Typical examples of the core-sheath fiber include PET (core), PE (sheath), and PP (core). ) And PE (sheath), PP (core), and low melting point PP (sheath). More specifically, the constituent fibers preferably include polyolefin fibers such as polyethylene fibers and polypropylene fibers, polyethylene composite fibers, and polypropylene composite fibers. Here, the composite composition of the polyethylene composite fiber is polyethylene terephthalate and polyethylene, and the composite composition of the polypropylene composite fiber is preferably polyethylene terephthalate and low-melting polypropylene, and more specifically, PET (core). And PE (sheath), PET (core), and low melting point PP (sheath). These fibers may be used alone to form a nonwoven fabric, but can also be used as a mixed fiber in which two or more kinds are combined.

Then, a first air-through process is performed in which high-speed air W <b> 1 is blown onto the fiber web 50 to follow the breathable support 10. At this time, the high-speed air W1 is blown from the vertical direction on the surface of the support 10 on which the fiber web 50 is placed. With this high-speed air W1, the fiber web 50 is shaped into a concavo-convex shape along the shape of the protrusion 12 of the support 10. At this time, the high-speed air W1 may be a temperature at which the fibers are softened or a temperature at which the fibers of the fiber web 50 are fused to such an extent that the uneven shape can be maintained. At this time, the temperature of the high-speed air W1 varies depending on the type of fiber, the processing speed, the speed of the hot air, etc., but is not uniquely determined. However, the fiber of the fiber web 50 has a core part of polyethylene terephthalate (PET). When the sheath is a composite fiber having a core-sheath structure of polyethylene (PE), the temperature is 80 ° C. or higher and 155 ° C. or lower, preferably 120 ° C. or higher and 135 ° C. or lower.
In addition, when the temperature of the high-speed air W1 is too low, the fiber is returned and the formability is lowered. On the other hand, when the temperature is too high, the fibers are fused at a stretch, and the formability is impaired due to a decrease in the degree of freedom.

  The high-speed air W1 has a wind speed of 20 m / sec or more and 120 m / sec or less, preferably 40 m / sec or more and 80 m / sec or less. If the wind speed of the high-speed air W1 is too slow, sufficient shaping cannot be performed, and shaping may be impaired. On the other hand, if the wind speed is too high, the fibers of the fiber web 50 are sorted by the projections 12 and become too shaped. Therefore, the wind speed of the high-speed air W1 is set to the above range.

Furthermore, the spraying time of the high-speed air W1 is 0.01 seconds or more and 0.5 seconds or less, preferably 0.04 seconds or more and 0.08 seconds or less. If the spraying time is too short, the fibers of the fiber web 50 are not sufficiently fused with each other, and the uneven shape cannot be sufficiently shaped. On the other hand, if the spraying time is too long, the fusion of the fibers of the fiber web 50 proceeds too much, and the formability is impaired due to a decrease in the degree of freedom.
Then, the high-speed air W1 that has passed through the fiber web 50 is discharged from the suction portion to the outside through the hole 13 of the support 10.

Next, the fiber web 50 is conveyed to the blowing position of the hot air W2 of the second nozzle 112 along with the rotation of the conveyor belt 10B of the support 10. A second air through process is performed in which hot air W2 is sprayed from the second nozzle 112 and sprayed onto the fiber web 50 to fix the uneven shape by fusing the fibers together while maintaining the uneven shape of the fiber web 50. At this time, the hot air W <b> 2 is blown from the direction perpendicular to the surface of the fiber web 50. The number of blowouts of the second nozzle 112 is preferably set at a plurality of locations along the feeding direction of the fiber web 50.
The temperature of the hot air W2 varies depending on the type of fiber, the processing speed, the speed of the hot air, etc., but is not uniquely determined. However, the fiber of the fiber web 50 is a composite fiber having a core-sheath structure of PET and PE as described above. In this case, the melting point is not less than the melting point of the low melting point component of the fiber of the fiber web 50 and less than the melting point of the high melting point component of the fiber of the fiber web 50. The temperature is preferably 135 ° C. or higher and 155 ° C. or lower, and more preferably 135 ° C. or higher and 150 ° C. or lower.
In addition, when the temperature of the hot air W2 is lower than the melting point of the low melting point component of the fiber of the fiber web 50, the retainability of the uneven shape is lowered, and when the temperature is higher than the melting point of the high melting point component of the fiber of the fiber web 50, the texture becomes worse. Moreover, it becomes difficult to be bulky.

  The hot air W2 is preferably set slower than the wind speed of the high-speed air W1. Specifically, it is 1 m / sec or more and 10 m / sec or less, and more preferably 2 m / sec or more and 8 m / sec or less. If the wind speed of the hot air W2 is too slow, the hot air W2 does not reach the inside of the fiber web 50 and the fibers are not sufficiently fused together. On the other hand, if the wind speed is too high, the fibers of the fiber web 50 are disturbed, and the shaping shape is disturbed. Therefore, the wind speed of the hot air W2 is set to the above range.

  Further, the blowing time of the hot air W2 is 0.03 seconds or more and 5 seconds or less, preferably 0.1 seconds or more and 1 second or less. If the spraying time is too short, the fibers of the fiber web 50 cannot be sufficiently fused together, and it becomes difficult to fix the uneven shape. On the other hand, if the spraying time is too long, the fibers of the fiber web 50 are excessively fused with each other, making it difficult to obtain liquid permeability.

In the manufacturing method of the shaped nonwoven fabric of the first embodiment described above, in the shaping process for forming irregularities on the fiber web 50, the holes 13 provided on the support 10 are not disturbed by the air blown and the fibers 10 are disturbed. There is no fusing or entanglement between the fibers. Therefore, the shaped nonwoven fabric having three-dimensional irregularities can be formed into a shaped nonwoven fabric having a small weight per unit area (density) and effectively having a small thickness (less liquid residue when used in an absorbent body). Excellent shape and enables continuous production.
By using such a shaped nonwoven fabric for an absorbent article, it is possible to obtain an absorbent article having a good appearance and a good touch.

  Next, another preferred example of another production apparatus used in the method for producing a shaped nonwoven fabric according to the present invention will be described below with reference to FIG.

  As shown in FIG. 6, the shaping nonwoven fabric manufacturing apparatus 201 includes a support 10 that conveys a fiber web 50 containing thermoplastic fibers. The fiber web 50 is supplied to the surface of the support 10 by a feed conveyor (not shown), and the shaped fiber web 50 is fed from the support 10 in a predetermined direction by a guide roller (not shown).

The support 10 has a drum shape, and a plurality of protrusions 12 and a plurality of holes 13 are alternately arranged at equal intervals in the MD direction and the CD direction on the surface thereof, as described above. Since the support 10 has a drum shape, the surface of the support 10 excluding the protrusions 12 and the holes 13 is a cylindrical surface, which is a curved surface having a curvature in the MD direction.
A first nozzle 211 that injects high-speed air W1 and a second nozzle 212 that injects hot air W2 in order along the direction in which the fiber web 50 is supplied are formed on the outside of the support 10 where the protrusions 12 are formed. It is provided.

The first nozzle 211 includes a heater (not shown), and jets high-speed air W1 heated by the heater to the surface of the support 10 on which the protrusions 12 are disposed, for example, substantially perpendicularly at a uniform temperature.
For example, when the fiber of the fiber web 50 is a composite fiber having a low melting point component and a high melting point component having a higher melting point than the low melting point component, the high-speed air W1 is 60 ° C. higher than the melting point of the low melting point component of the fiber web 50. The hot air is controlled to a temperature not lower than the low temperature and not higher than 15 ° C. higher than the melting point of the low melting point component. Preferably, the temperature is controlled to be not less than 50 ° C. lower than the melting point of the low melting point component and not more than 10 ° C. higher than the melting point of the low melting point component. For example, when polyethylene having a melting point of 132 ° C. is used as the low melting point component, a preferable temperature range is from 82 ° C. to 142 ° C., more preferably from 132 ° C. to 142 ° C.
When the temperature of the high-speed air W1 is less than 60 ° C. lower than the melting point of the low melting point component of the fiber of the fiber web 50, the fiber returns and the formability deteriorates. On the other hand, when the temperature exceeds 15 ° C. higher than the melting point of the low melting point component of the fiber of the fiber web 50, the fibers are fused at once, and the formability is inferior due to a decrease in the degree of freedom.

  The wind speed of the high-speed air W1 is adjusted as appropriate, but is preferably controlled to a wind speed of 10 m / sec or more and 120 m / sec or less. If the wind speed of the high-speed air W1 blown from the first nozzle 211 is too slow, the fibers do not sufficiently follow the support 10 and the fibers are weakly fused so that they cannot be shaped, resulting in a bulky uneven shape. On the other hand, if the wind speed is too high, the fibers of the fiber web 50 are selected by the protrusions 12, and the fibers do not have an uneven shape along the shape of the support 10, or become a non-woven fabric with holes. Therefore, the wind speed of the high-speed air W1 is preferably in the above range. More preferably, it is 20 m / sec or more and 80 m / sec or less, and particularly preferably 40 m / sec or more and 60 m / sec or less.

The second nozzle 212 includes a heater (not shown), and injects hot air W2 heated by the heater almost perpendicularly to the surface of the support 10 on which the protrusions 12 are disposed, for example, at a uniform temperature.
It is desirable to use a punching metal that is regularly opened in the width direction and the flow direction as the blowing holes of the second nozzle 212. The open area ratio is preferably 10% or more and 40% or less, and more preferably 20% or more and 30% or less. Thus, since the blowing hole of the second nozzle 212 is formed, the hot air W2 is blown at a uniform wind speed in the width direction of the surface of the fiber web 50. As the hot air W2, air, nitrogen, or water vapor heated by the heater (not shown) can be used. Preferably, air that does not cost is used.

The hot air W2 is controlled to a temperature that fuses the fibers of the fiber web 50 and fixes the uneven shape of the fiber web 50 while holding the uneven shape of the fiber web 50 formed by the high-speed air W1 by a heater (not shown). Has been. For example, when the fiber of the fiber web 50 is a composite fiber having a low melting point component and a high melting point component having a higher melting point than the low melting point component, the hot air W2 is equal to or higher than the melting point of the low melting point component of the fiber of the fiber web 50. It is controlled to be hot air at a temperature lower than the melting point of the high melting point component of 50 fibers, preferably 40 ° C. or higher than the melting point of the low melting point component. More preferably, the melting point of the low melting point component is controlled to a temperature not higher than 20 ° C. below this melting point, and the particularly preferable temperature is controlled to be not lower than the melting point of the low melting point component and not higher than 15 ° C. below this melting point. For example, when polyethylene having a melting point of 132 ° C. is used as the low melting point component, a more preferable temperature range is from 132 ° C. to 152 ° C., particularly preferably from 132 ° C. to 147 ° C.
If the temperature of the hot air W2 is lower than the melting point of the low melting point component of the fiber of the fiber web 50, the uneven shape retainability is insufficient. On the other hand, if the temperature is higher than 180 ° C., the texture becomes worse.

  Also, the wind speed of the hot air W2 blown from the second nozzle 212 is appropriately determined in consideration of the purpose, but is preferably controlled to a wind speed of 1 m / sec or more and 10 m / sec or less. If the wind speed of the hot air W2 blown from the second nozzle 212 is too slow, heat cannot be transferred to the fibers, the fibers are not fused, and the uneven shape is insufficiently fixed. On the other hand, if the wind speed is too high, the fiber will be too hot and the texture will tend to be poor. Therefore, the wind speed of the hot air W2 is preferably in the above range. More preferably, it is 1 m / sec or more and 8 m / sec or less, and particularly preferably 2 m / sec or more and 4 m / sec or less.

  Furthermore, in the blowing direction of the first nozzle 211, a suction unit (not shown) that sucks high-speed air W1 ejected from the first nozzle 211 through the fiber web 50 and the support 10 is disposed. An exhaust device (not shown) that exhausts the sucked high-speed air W1 is connected to the suction portion. Furthermore, in the blowing direction of the second nozzle 212, a suction unit (not shown) that sucks hot air W2 jetted from the second nozzle 212 through the fiber web 50 and the support 10 is disposed. An exhaust device (not shown) that exhausts the sucked hot air W2 is connected to the suction portion. Further, each exhaust device may be connected to each suction unit as one exhaust device.

Next, another preferred embodiment (second embodiment) of the method for producing a shaped nonwoven fabric according to the present invention will be described below with reference to FIG.
As shown in FIG. 6, the method for manufacturing a shaped nonwoven fabric according to the second embodiment is realized by the aforementioned shaped nonwoven fabric manufacturing apparatus 201.

  First, the fiber web 50 is fed to the surface of the support 10 on which the protrusions 12 are formed by a feeding unit (not shown). The fiber material that can be used for the fibers of the fiber web 50 is not particularly limited. Specifically, the fiber etc. which were demonstrated in the above-mentioned 1st Embodiment are mentioned.

Then, high-speed air W <b> 1 is jetted from the first nozzle 211 and sprayed onto the fiber web 50 fed to the surface of the support 10. At this time, the high-speed air W <b> 1 is blown from the direction perpendicular to the surface of the support 10. With this high-speed air W1, the fiber web 50 is shaped into a concavo-convex shape along the shape of the protrusion 12 of the support 10. The temperature of the high-speed air W1 at that time may be a temperature at which the fibers are softened or a temperature at which the fibers of the fiber web 50 can be temporarily fused so that the uneven shape can be maintained. At this time, the temperature of the hot air varies depending on the type of fiber, the processing speed, the wind speed of the hot air, etc., and thus cannot be uniquely determined. Usually, however, the temperature of the high-speed air W1 is the low melting point component of the fiber of the fiber web 50. The temperature is preferably controlled around the melting point, preferably 80 ° C. or higher and 150 ° C. or lower, more preferably 120 ° C. or higher and 140 ° C. or lower.
In addition, when the temperature of the high-speed air W1 is too low, the fibers are returned and the formability is deteriorated. When the temperature is too high, the fibers are fused at a stretch and the formability is impaired due to a decrease in the degree of freedom. It will be.

  The wind speed of the high-speed air W1 is adjusted as appropriate, but is preferably controlled to a wind speed of 10 m / sec or more and 120 m / sec or less. If the wind speed of the high-speed air W1 blown from the first nozzle 211 is too slow, the fibers do not sufficiently follow the support 10 and the fibers are weakly fused so that they cannot be shaped, resulting in a bulky uneven shape. On the other hand, if the wind speed is too high, the fibers of the fiber web 10 are selected by the protrusions 12, and the fibers do not have an uneven shape along the shape of the support 10, or become a perforated nonwoven fabric. Therefore, the wind speed of the high-speed air W1 is preferably in the above range. More preferably, it is 20 m / sec or more and 80 m / sec or less, and particularly preferably 40 m / sec or more and 60 m / sec or less.

  The high-speed air W1 that has passed through the fiber web 50 is exhausted to the outside by the exhaust device from the suction portion through the hole 13 of the support 10.

  Next, the fiber web 50 is conveyed to the injection position of the hot air W2 of the second nozzle 212 as the support 10 rotates. And the hot air W2 is sprayed by the 2nd nozzle 212, the fiber of the fiber web 50 is fuse | melted in the state which hold | maintained the uneven | corrugated shape of the fiber web 50, and an uneven | corrugated shape is fixed. At this time, the hot air W <b> 2 is blown from the direction perpendicular to the surface of the support 10. The number of blowouts of the second nozzle 212 is preferably set at a plurality of locations along the feeding direction of the fiber web 50. At this time, the temperature of the hot air W <b> 2 is controlled to be equal to or higher than the melting point of the low melting point component of the fiber of the fiber web 50 and lower than the melting point of the high melting point component of the fiber of the fiber web 50. Preferably, it is controlled to 135 ° C. or higher and 155 ° C. or lower.

  It is desirable to use a punching metal that is regularly opened in the width direction and the flow direction as the blowing holes of the second nozzle 212. The open area ratio is preferably 10% or more and 40% or less, and more preferably 20% or more and 30% or less. Thus, since the blowing hole of the second nozzle 212 is formed, the hot air W2 is blown at a uniform wind speed in the width direction of the surface of the fiber web 50. As the hot air W2, air, nitrogen, or water vapor heated by the heater (not shown) can be used. Preferably, air that does not cost is used.

The hot air W2 is controlled to a temperature that fuses the fibers of the fiber web 50 and fixes the uneven shape of the fiber web 50 while holding the uneven shape of the fiber web 50 formed by the high-speed air W1 by a heater (not shown). Has been. For example, when the fiber of the fiber web 50 is a composite fiber having a low melting point component and a high melting point component having a higher melting point than the low melting point component, the temperature of the hot air W2 is set to be equal to or higher than the melting point of the low melting point component of the fiber of the fiber web 50, The temperature of the fiber web 50 is controlled to be hot air at a temperature lower than the melting point of the high melting point component of the fiber, preferably 40 ° C. higher than the melting point of the low melting point component. More preferably, the melting point of the low melting point component is controlled to a temperature not higher than 20 ° C. below this melting point, and the particularly preferable temperature is controlled to be not lower than the melting point of the low melting point component and not higher than 15 ° C. below this melting point. For example, when polyethylene having a melting point of 132 ° C. is used as the low melting point component, a more preferable temperature range is controlled to 132 ° C. or more and 152 ° C. or less. Particularly preferably, it is 132 ° C. or higher and 147 ° C. or lower.
If the temperature of the hot air W2 is lower than the melting point of the low melting point component of the fiber of the fiber web 50, the uneven shape retainability is insufficient. On the other hand, if the temperature is higher than 180 ° C., the texture becomes worse. Moreover, it becomes difficult to be bulky.

  Also, the wind speed of the hot air W2 blown from the second nozzle 212 is appropriately determined in consideration of the purpose, but is preferably controlled to a wind speed of 1 m / sec or more and 10 m / sec or less. If the wind speed of the hot air W2 blown from the second nozzle 212 is too slow, heat cannot be transferred to the fibers, the fibers are not fused, and the uneven shape is insufficiently fixed. On the other hand, if the wind speed is too high, the fiber will be too hot and the texture will tend to be poor. Therefore, the wind speed of the hot air W2 is preferably in the above range. More preferably, it is 1 m / sec or more and 8 m / sec or less, and particularly preferably 2 m / sec or more and 4 m / sec or less.

  Thereafter, the shaped fiber web 50 is sent out in a predetermined direction from the support 10 by a guide roller (not shown) as a guide portion.

  In 2nd Embodiment of the manufacturing method of the above-mentioned shaped nonwoven fabric, the effect similar to 1st Embodiment of the manufacturing method of the above-mentioned shaped nonwoven fabric is obtained.

  Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples in which a shaped nonwoven fabric is produced by the method for producing a shaped nonwoven fabric according to the first embodiment. The present invention is not limited to these examples.

First, the dimensions of each part of the support 10 will be described below.
As shown in FIG. 7, the thickness of the rod-like body 11 and T b. For the protrusion 12, the MD direction pitch is Ppm, the CD direction pitch is Ppc, the height of the protrusion 12 is H, the base width of the MD direction protrusion 12 is Wpm, and the base width of the CD direction protrusion 12 is Wpc. . The round radius of the top of the side surface of the projection 12 projected from the CD direction is Rts, and the round radius of the top of the projection 12 projected from the MD direction is Rt. Furthermore, the shape of the side surface of the projection 12 projected from the MD direction is a curve.

For the holes 13, the MD direction pitch is Phm, the CD direction pitch is Phc, the hole 13 MD direction length (or diameter) is φm, and the hole 13 CD direction length (or diameter) is φc. To do.
The overlap length Lm of the projected images of the holes 13 arranged in the MD direction projected from the MD direction is expressed by the following formula: Lm = (hole length φc) − [(hole pitch Phc) / 2] When Lm ≧ 0, it is determined that there is an overlap of the projection image of the hole 13, and when Lm <0, it is determined that there is no overlap of the projection image of the hole 13. In this respect, the value of Lm is preferably as large as possible. However, if the value is too large, the uneven pattern may be extended and the appearance may be impaired. Therefore, Lm is preferably −0.1 or more and 8 or less, More preferably, it is 0 or more and 3 or less, and particularly preferably 0 or more and 1 or less.

  The opening ratio R of the holes 13 was expressed as a percentage (%) obtained by dividing the total area of the holes 13 within a predetermined area in plan view by the predetermined area.

[Example 1-10]
The support body 10 of Example 1 is integrally molded. The thickness of the rod-shaped body 11 is T b = 3 mm. The protrusions 12 and the holes 13 are alternately arranged in the MD direction and the CD direction, the protrusions 12 are arranged at equal intervals, and the holes 13 are arranged at equal intervals.
The pitch of the protrusion 12 in the MD direction is Ppm = 10.0 mm, the pitch in the CD direction is Ppc = 5.0 mm, the height of the protrusion 12 is H = 7.5 mm, and the base width of the protrusion 12 in the MD direction is Wpm = 5. The base width of the protrusion 12 in the CD direction is 0 mm and Wpc = 1.5 mm. Further, the shape of the protrusion 12 viewed from the CD direction is generally triangular (Δ) having roundness (R) at the tip, and the shape of the protrusion 12 viewed from the MD direction is generally rectangular having roundness (R) at the corners. (□) . Further, the radius of roundness at the top of the side surface of the projection 12 projected from the CD direction is Rts = 0.6 mm, and the radius of roundness at the top of the projection 12 projected from the MD direction is Rt = 0.5 mm. Further, the outer shape excluding the top of the projection 12 projected from the CD direction is also a shape having a curvature.
The cross-sectional shape of the rod-shaped body 11 is a circular shape having a diameter of 3 mm. Therefore, the thickness of the rod-shaped body 11 is Tb = 3.0 mm, and the width is Wb = 3.0 mm.
The holes 13 have a pitch in the MD direction of Phm = 10.0 mm, a pitch in the CD direction of Phc = 5.0 mm, a length in the MD direction of φm = 2.0 mm, and a length in the CD direction of φc = 3.5 mm. is there.
The overlapping length of the projected images of the holes 13 arranged in the MD direction projected from the MD direction is Lm = 1 mm, and the projected images of the holes 13 arranged in the MD direction projected from the MD direction are overlapped. Furthermore, the hole area ratio is R = 28%.
The distance between the bases of the protrusions is 1. 4 mm.

Example 2 is the same as Example 1 except that H = 2.0 mm.
Example 3 is Example 1 except that Ppc = 7.5 mm, Phc = 7.5 mm, φc = 6.0 mm, Lm = 2.25 mm, R = 32% , and the distance between the bases of the protrusions is 2.1 mm. It is the same.
In Example 4, Ppc = 7.5 mm, Wpc = 3.0 mm, Phc = 7.5 mm, φc = 4.5 mm, Lm = 0.75 mm, R = 26.7% , and the distance between the bases of the protrusions is 1. The same as Example 1 except for 1 mm .
In Example 5, H = 2.0 mm, Wpm = 3.1 mm, Phm = 20.0 mm, Phc = 10.0 mm, φm = 7.0 mm, φc = 8.5 mm, Lm = 3.5 mm, R = 34 %, Which is the same as that of Example 1 except that Rts = 0.5 mm.

In Example 6, Ppc = 3.0 mm, H = 4.0 mm, Phc = 3.0 mm, φm = 3.5 mm, φc = 1.5 mm, Lm = 0 mm, and the protrusion-to-base distance is 1.5 mm . Other than the above, the second embodiment is the same as the first embodiment.

Example 7 is the same as Example 1 except that Wpc = 3.0 mm, φc = 2.0 mm, Lm = −0.5 mm, R = 28%, and the distance between the bases of the protrusions is 0.1 mm .
Example 8 is different from Example 1 except that Ppc = 10.0 mm, Wpc = 3.0 mm, Phc = 10.0 mm, φc = 7.0 mm, Lm = 2 mm, and the distance between the bases of the protrusions is 2.1 mm. It is the same.
Example 9 is Example 1 except that Ppc = 10.0 mm, Phc = 10.0 mm, φc = 8.5 mm, Lm = 3.5 mm, R = 34% , and the distance between the bases of the protrusions is 3.7 mm. It is the same.

In Example 10, Ppc = 6.5 mm, Wpc = 3.0 mm, Phc = 6.5 mm, Lm = 0.25 mm, R = 21.5% , the distance between the bases of the protrusions is 0.6 mm , and the MD direction The outer shape of the projection 12 projected from is the same as that of Example 1 except that it is a triangle (Δ) having a roundness (R) with a roundness radius Rt = 0.6 mm at the tip.

[Comparative Example 1-2]
Comparative Example 1 is an integrally formed product made of aluminum. The thickness T b of the plate-like body 11 is 1.5 mm. A large number of holes 13 are arranged between the protrusions 12. In other words, the support is disclosed in Patent Document 1.
Each dimension is as follows. Ppm = 3.0 mm, Ppc = 3.0 mm, H = 0.8 mm, Wpm = 2.0 mm, Wpc = 2.0 mm. The gap between the protrusions is 1.0 mm.
The holes 13 have an MD pitch of Phm = 1.2 mm, a CD direction pitch of Phc = 1.2 mm, an MD direction diameter of φm = 0.4 mm, and a CD direction diameter of φc = 0.4 mm.
The arrangement pattern of the holes 13 is a square.
The overlap length of the projected images of the holes 13 arranged in the MD direction projected from the CD direction is Lm = −0. 2 mm, and the projected images of the holes 13 arranged in the MD direction projected from the CD direction do not overlap. Further, the open porosity is R = 9.0%.

  Comparative Example 2 is a support disclosed in Patent Document 2. A steel wire rod with a diameter of about 1.5 mm is provided in a net with a knuckle part (convex part). The height (equivalent to H) from the tip of the convex part to the back side base part of the net is 5.0 mm, The pitch in the MD direction is Ppm = 5.0 mm, the pitch in the CD direction is Ppc = 3.5 mm, the base width of the protrusion 12 in the MD direction is Wpm = 7.0 mm, and the base width of the protrusion 12 in the CD direction is Wpc = 2. 0 mm. Further, the opening is a parallelogram type, and the base of the parallelogram in the CD direction is 1.5 mm, and the height of the parallelogram in the MD direction is 1.5 mm.

Next, the evaluation method will be described. The evaluation was performed by examining the formability of the nonwoven fabric as processability and the performance of the nonwoven fabric as sheet performance. The fibers used were 2.2 dtex PET / PE fibers and those having a fiber length of 51 mm (ES fiber vision, ETC fibers). The nonwoven fabric was evaluated under the condition that the basis weight of the nonwoven fabric was 25 gsm ± 1 gsm.
Workability, "fiber blow on Banai", "fiber entanglement", "formation of the shaped nonwoven fabric", "peeling of shaping a nonwoven fabric from the support", etc. "wind speed required shaping" evaluated.

  In Table 2, “fibers do not blow off” means the degree to which the fibers of the fiber web blow off when air is directly blown onto the fiber web placed on the support 10 to form it. evaluated. ◎ When the fibers of the fiber web are shaped without being blown away at all, ◎, when the fibers of the fiber web are slightly disturbed but shaped without being blown up, ○ Although the fibers of the fiber web are not blown away, it is not broken The case where the fiber was blown off was shown as x.

  “Fiber entanglement” means that the fiber is not entangled with the support 10 and is not fused, and the fibers are not entangled through the holes 13 and are not fused, and the fiber is entangled or fused with the support 10. The case where there is a problem in the continuous production and peeling properties of the nonwoven fabric was indicated as x.

  The “texture of the shaped nonwoven fabric” was determined by the homogeneity when the nonwoven fabric was visually observed. Those that appeared to be uniform with no unevenness and those that appeared to be almost homogeneous were indicated as ◯, those that were uneven but overall looked homogeneous were indicated by Δ, and those that were uneven and looked totally heterogeneous were indicated as ×.

  “Peelability of the shaped nonwoven fabric from the support” means that the fiber is not easily left at the tension corresponding to 10% elongation and no fibers are left on the support 10 without blowing air from the back side. When the shape can be released without breaking the shape of the non-woven fabric, air blowing from the back surface is necessary, but it is easy to form at a tension equal to or less than 10% without leaving any fibers on the support 10. If the shape of the nonwoven fabric can be released without breaking, ○, it is necessary to blow air from the back side, but it does not peel off from the support unless a tension that extends 10% or more is applied, but no fibers remain on the support 10, A case where the shape of the shaped non-woven fabric could be released without breaking, and a case where the shape of the shaped non-woven fabric was broken when the support 10 was entangled with fibers, or when the shape was released were indicated as x.

  “Wind speed required for shaping” records the wind speed when the fiber web reaches the bottom surface of the support under various conditions of temperature 120 ° C. and fiber web transport speed 10 / m. To do. It is preferable that the fiber can be shaped at the lowest possible wind speed in terms of preventing the fibers from being blown off and manufacturing costs. When the wind speed was 40 m / sec or less, ◎, when the wind speed was higher than 40, 60 m / sec, ○, when larger than 60, 80 m / sec, Δ, when larger than 80 m / sec, x. In addition, about the support body with which the blown-off of a fiber was remarkable, the mesh net of 60% of a hole area ratio was mounted on top, and it added and evaluated suitably so that a fiber might not blow off.

  The sheet performance is "pattern (uneven shape pattern) sharpness", "longitudinal streaks", "thickness", "softness", "beauty of appearance", "easy to be crushed when loaded" “Fuzzing” was evaluated.

  The “pattern sharpness” was evaluated based on an average score by visual observation of 10 panelists. Five points are given when the irregular shape of the shaped nonwoven fabric is clearly known, four points when the irregular shape of the shaped nonwoven fabric is known, and three points when the irregular shape of the shaped nonwoven fabric is slightly known or partially blurred. And the case where the uneven shape of the shaped nonwoven fabric was unclear was taken as two points. At this time, the average score is 4.5 or more, ◯, 3.5 or more and less than 4.5, ◯, 2.5 or more and less than 3.5 as Δ, and less than 2.5 as x.

  The “longitudinal streaks” were evaluated based on the average score of 10 panelists. When the shaped non-woven fabric has no vertical stripes (thickness of the shaped non-woven fabric is uniform), 5 points, and when the shaped non-woven fabric has no vertical stripes (thickness of the non-woven fabric is almost uniform), give 4 points. The case where longitudinal stripes are slightly recognized in the nonwoven fabric (there is a region where the film thickness of the nonwoven fabric is thin in the MD direction) is three points, and vertical stripes are recognized in the shaped nonwoven fabric (the region where the thickness of the nonwoven fabric is thin is present in the MD direction). ) The case was 2 points. At this time, the average score is 4.5 or more, ◯, 3.5 or more and less than 4.5, ◯, 2.5 or more and less than 3.5 as Δ, and less than 2.5 as x.

The “thickness” is a non-woven fabric, which is subjected to a compression property evaluation up to 5.0 × 10 ³ Pa in a normal mode using a KES compression tester (KES FB-3 manufactured by Kato Tech Co., Ltd.). The thickness (T) of 0.05 × 10 ³ Pa) was read from the chart. As measurement values, three points were measured and the average value was adopted. As a result of such thickness measurement, ◎ indicates a sufficient thickness (3.5 mm or more), ○ indicates a necessary thickness (3.0 mm or more), Δ indicates a thickness (2.0 mm or more), and thickness. Is shown as x (less than 2.0 mm).

  “Softness” was judged by touch and flexibility. An average score of 10 panelists was evaluated with 5 points for soft touch and 5 points for supple, 3 points for soft touch, 3 points for soft touch, and 1 point for soft touch and lack of suppleness. In this case, the average score was expressed as ◎ when 4 points or more, ◯ when 2 points or more and less than 4 points, and × when less than 2.0.

  “Beauty of appearance” was evaluated by an average score by visual observation of 10 panelists. 5 items with regular irregularities on the shaped non-woven fabric and good appearance, 4 items with regular appearance with irregular shapes regularly arranged on the shaped non-woven fabric 3 points where the irregular shape is partially irregularly arranged on the shaped nonwoven fabric and the appearance is slightly inferior, the irregular shape is partially blurred on the shaped nonwoven fabric, or a disordered arrangement It was expressed as two points that were inferior in appearance. In this case, the average score is 4.5 or more, ◯, less than 4.5, 3.5 or more, ◯, less than 3.5, 2.5 or more, Δ, and less than 2.5, x.

“Easiness of crushing under load” was evaluated by a ratio between the above-mentioned “thickness” and “thickness under load” described later. "Thickness under load" / "Thickness" is 0.5 or more, ◎, 0.4 or more and less than 0.5, ◯, 0.3 or more and less than 0.4, △, less than 0.3 It was set as x when it was.
“Thickness under load” was evaluated using a KES compression tester (KES FB-3 manufactured by Kato Tech Co., Ltd.) in a normal mode up to 5.0 × 10 ³ Pa, and 3.5 × 10 ³ The thickness at Pa pressurization was read from the chart. As measurement values, three points were measured and the average value was adopted.

  “Fuzzing” was evaluated by an average score by visual observation of 10 panelists. The case where there was no fluffing was represented as 5 points, the case where there was almost no fluffing, 4 points, the case where there was partial fluffing, 3 points, and the case where fluffing was on the entire surface was represented as 2 points. At this time, the average score is 4.5 or more, ◯, 3.5 or more and less than 4.5, ◯, 2.5 or more and less than 3.5 as Δ, and less than 2.5 as x.

As is clear from the results shown in Tables 1 and 2, the respective supports 10 of Examples 1 to 6 obtained good results (evaluation of ◎ or ○) in any evaluation item. .
Each of the supports 10 of Examples 1 to 10 was integrally molded, and the thickness of the rod-like body 11 was Tb = 3 mm and the width was Wb = 3.0 mm.
In addition, the pitch in the MD direction of the protrusion 12 is Ppm = 10.0 mm, the pitch in the CD direction is Ppc = 3.0 mm to 10.0 mm, the height of the protrusion 12 is H = 2.0 mm to 7.5 mm, MD direction The base width of the protrusion 12 was Wpm = 3.1 mm to 5.0 mm, and the base width of the protrusion 12 in the CD direction was Wpc = 1.5 mm to 3.0 mm.
The pitch of holes 13 in the MD direction is Phm = 10.0 mm to 20.0 mm, the pitch in the CD direction is Phc = 3.0 mm to 10.0 mm, the diameter in the MD direction is φm = 2.0 mm to 7.0 mm, CD direction The diameter was φc = 1.5 mm to 8.5 mm.
Further, the overlapping length of the projected images of the holes 13 arranged in the MD direction projected from the MD direction is Lm = −0.5 mm to 3.5 mm, and the holes 13 arranged in the MD direction projected from the MD direction. The projected images of were touching or overlapping.
The open area ratio was R = 21.5 % to 34%.
Therefore, the shaping which has the outstanding result (evaluation of (double-circle) or (circle)) in each said evaluation item by shape-treating a fiber web using the support body 10 made in the said range, and manufacturing a shaped nonwoven fabric. A non-woven fabric can be made.

  Each support body 10 of Example 1 to Example 10 can obtain the same effects as those of the above-described embodiment. Moreover, since it is an integrally molded product, there is no gap between the parts, so fibers are sandwiched in the gaps between the parts, and in continuous operation, the support 10 becomes dirty, and the fibers of the shaped nonwoven fabric are pulled out. It will not cause dirt.

On the other hand, as is clear from the results of Comparative Example 1, in the production of the nonwoven fabric using the support disclosed in Patent Document 1, when the fiber web is blown and shaped, the fibers are blown away (evaluation ×). Further, the fibers are entangled with the support (evaluation x), and the formable nonwoven fabric is not peeled off from the support (evaluation x). The formation was poor (evaluation x). Further, the pattern was not clear (evaluation x), vertical stripes (stripes in the MD direction) were generated (evaluation x), and the thickness was insufficient (evaluation x). In addition, since the thickness of the nonwoven fabric was thin, the softness was slightly insufficient (evaluation Δ), but fuzz was also noticeable (evaluation ×). Further, even if the fiber web is held by a net or the like so that the fiber does not move, the air resistance increases due to the small hole through which air escapes, and an enormous wind speed is required for shaping. Moreover, since the overlap length Lm of the projected image of the hole 13 of the support 10 is negative, vertical streaks, which are low density areas, were recognized in the shaped nonwoven fabric (Evaluation ×).
In Comparative Example 2, after forming by blowing air onto the fiber web, the fibers are sandwiched at the intersection of the wire material and the wire material as the support, or the fibers inside the knuckle portion and the fibers outside are mutually connected As a result, the shaped nonwoven fabric peeled off from the support was poor (evaluation x). As a result, the pattern was disordered, the appearance was poor (evaluation x), and fluff was generated (evaluation x). When considering industrial production, continuous production was difficult.

  Accordingly, the fibers 10 of the fiber web 50 are disturbed by performing the process of forming irregularities on the fiber web 50 using the respective support bodies 10 having the dimensions and shapes described in the first to tenth embodiments. Without losing the fiber through the holes 13 provided in the support 10 and preventing the fibers from fusing and entanglement, ensuring a uniform and sufficient thickness, being soft and beautiful, having sufficient strength, It is possible to produce a shaped nonwoven fabric in which the shape convex portions are hardly crushed and have almost no fuzz.

10 support 11 rod member 11S upper surface 12 projection 12SA first surface 12SB second surface 12 S C third surface (side surface)
13 hole 14, 14A, 14B Protrusion line D interval (interval of protrusion line)
Tb Bar-shaped body thickness Wb Bar-shaped body width H Projection height Ppm Projection MD direction pitch Ppc Projection CD direction pitch Phm Hole MD direction pitch Phc Hole CD direction pitch Rts Projection projected from CD direction Round radius at top of side surface Rt Round radius at top of projection projected from MD direction Wpm Base width of projection in MD direction Wpc Base width of projection in CD direction φm Length (or diameter) of hole in MD direction
φc Length of CD hole (or diameter)
Lm Overlapping length of projected images of holes arranged in the MD direction projected from the MD direction R Opening ratio of the hole having a value obtained by dividing the total area of the holes within a predetermined area in plan view by the predetermined area

Claims (6)

A plurality of rods arranged in parallel;
A plurality of protrusions disposed between the rod-shaped bodies;
A hole existing in a region surrounded by the protrusions adjacent to each other between the adjacent rod-shaped bodies and in the longitudinal direction of the rod-shaped bodies;
The protrusions and the holes are alternately arranged in a first direction orthogonal to the longitudinal direction of the rod-shaped body and a second direction parallel to the longitudinal direction of the rod-shaped body, and the protrusions are arranged at a predetermined interval. ,
The said protrusion is a support body for nonwoven fabric manufacture which has the 1st surface and 2nd surface which oppose.   The support for producing a nonwoven fabric according to claim 1, wherein a distance between a projection row of the projections arranged in the direction of the first surface and another projection row adjacent to the projection row in parallel is 1 mm or more and 3 mm or less. .   3. The nonwoven fabric production according to claim 1, wherein an opening ratio occupied by the area of the hole obtained by dividing the total area of the holes within a predetermined area in plan view by the predetermined area is 30% or more and 35% or less. Support.   The support for nonwoven fabric production according to claim 1, 2 or 3, wherein a base width of the protrusion in a direction orthogonal to the direction of the first surface is 1 mm or more and 2 mm or less. The support for nonwoven fabric production according to any one of claims 1 to 4 , wherein at least one surface constituting the protrusion is roughened. A fiber web containing thermoplastic fibers is transported onto a support having a plurality of protrusions and a plurality of holes, and hot air is blown to form a concave-convex shape on the fiber web along the support. A method for producing a shaped nonwoven fabric,
For the support,
In a region surrounded by a plurality of rod-shaped bodies arranged in parallel, a plurality of projections arranged between the rod-shaped bodies, and the projections adjacent between the adjacent rod-shaped bodies and in the longitudinal direction of the rod-shaped body Have existing holes,
The protrusions and the holes are alternately arranged in a first direction orthogonal to the longitudinal direction of the rod-shaped body and in a second direction parallel to the longitudinal direction of the rod-shaped body, and the projections are spaced apart from each other,
The said protrusion is a manufacturing method of the shaping nonwoven fabric using what has the 1st surface and 2nd surface which oppose.

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