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WO2019203484A1 - Non-woven fabric of crimped composite fiber and laminate thereof, and article including the laminate - Google Patents

Non-woven fabric of crimped composite fiber and laminate thereof, and article including the laminate Download PDF

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Publication number
WO2019203484A1
WO2019203484A1 PCT/KR2019/004037 KR2019004037W WO2019203484A1 WO 2019203484 A1 WO2019203484 A1 WO 2019203484A1 KR 2019004037 W KR2019004037 W KR 2019004037W WO 2019203484 A1 WO2019203484 A1 WO 2019203484A1
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WO
WIPO (PCT)
Prior art keywords
woven fabric
propylene
composite fiber
based polymer
laminate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/KR2019/004037
Other languages
French (fr)
Inventor
Jin Il Jung
Yeong Seok Seo
Dae Hee Kim
Joong Kwon AHN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toray Advanced Materials Korea Inc
Original Assignee
Toray Advanced Materials Korea Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Toray Advanced Materials Korea Inc filed Critical Toray Advanced Materials Korea Inc
Priority to CN201980026780.8A priority Critical patent/CN112074632A/en
Priority to JP2020558439A priority patent/JP7221987B2/en
Publication of WO2019203484A1 publication Critical patent/WO2019203484A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4391—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres
    • D04H1/43918—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres nonlinear fibres, e.g. crimped or coiled fibres
    • D—TEXTILES; PAPER
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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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    • D04H3/007—Addition polymers
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    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/102—Oxide or hydroxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/104—Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/107—Ceramic
    • B32B2264/108—Carbon, e.g. graphite particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/12—Mixture of at least two particles made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/546—Flexural strength; Flexion stiffness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/728—Hydrophilic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2555/00—Personal care
    • B32B2555/02—Diapers or napkins

Definitions

  • One or more embodiments relate to a non-woven fabric of a crimped composite fiber and a laminate thereof, and an article including the laminate, and more particularly, to a non-woven fabric of a crimped composite fiber, having improved softness and bulkiness, and a laminate thereof, and an article including the laminate.
  • Final physical properties of a non-woven fabric are determined according to a web forming method and a binding method.
  • webs are formed by single spinning or core-in-sheath composite spinning.
  • the webs formed in this way have a simple structure with no crimps, and are bound to each other by a heating calender to form a thin non-woven fabric.
  • the thin non-woven fabric is used as a top sheet and a back sheet during the production of a diaper.
  • this thin non-woven fabric has remarkably low softness as compared with a short-fiber air-through non-woven fabric obtained by forming webs through carding and binding the webs through hot air, and thus the softness of the thin non-woven fabric deteriorates.
  • One or more embodiments provide a non-woven fabric of a crimped composite fiber, having improved softness and bulkiness.
  • One or more embodiments provide a non-woven fabric laminate including two or more non-woven fabrics of a crimped composite fiber.
  • One or more embodiments provide an article including the non-woven fabric laminate.
  • a non-woven fabric of a crimped composite fiber includes: a first propylene-based polymer and a second propylene-based polymer, wherein, in the first propylene-based polymer and the second propylene-based polymer, a melting point of the first propylene-based polymer is higher than a melting point of the second propylene-based polymer by 30 °C or more, the melting points being measured by differential scanning calorimetry (DSC), a ratio (second polymer / first polymer) of melt flow rates (MFR: measurement temperature 230 °C, load 2.16 kg) of the first propylene-based polymer and the second propylene-based polymer is 1.7 or more, the melt flow rates being measured according to ASTM D1238, and a component ratio represented by a weight ratio of the first propylene-based polymer / the second propylene-based polymer is 50/50 to 10/90.
  • DSC differential scanning calorimetry
  • MFR measurement temperature 230 °C, load
  • the first propylene-based polymer and the second propylene-based polymer may each independently include a propylene homopolymer, a propylene-ethylene copolymer, an elastomeric random copolymer in which ethylene is copolymerized with polypropylene, a propylene-ethylene-butylene terpolymer, or a combination thereof.
  • the non-woven fabric may further include a fatty acid amide of 5 to 25 carbon atoms in an amount of about 0.01 wt% to about 3 wt% based on a total weight of the non-woven fabric.
  • the non-woven fabric may include an embossing portion and a non-embossing portion, and the embossing portion may be an open embossing portion and include a plurality of unit embossing pattern portions arranged successively at the same or different intervals.
  • Each of the unit embossing pattern portions has the following form:
  • Each embossing pattern included in each of the unit embossing pattern portions may have an area of about 0.2 mm 2 to about 0.7 mm 2 .
  • the non-woven fabric may have a bonding rate of 13 % or less.
  • the crimped composite fiber may be a mono-type composite fiber, a core-in-sheath-type composite fiber, a side-by-side-type composite fiber, or a sandwich-type composite fiber.
  • the non-woven fabric may be a spunbonded non-woven fabric.
  • a non-woven fabric laminate has at least two layers, wherein at least one layer of the laminate is the non-woven fabric of a crimped composite fiber.
  • the non-woven fabric may be a spunbonded non-woven fabric, and the non-woven fabric laminate may be formed by laminating the four spunbonded non-woven fabrics and have a uniformity (CV) of 3 % or less.
  • CV uniformity
  • the non-woven fabric laminate may have a thickness of 0.02 mm or more, a crimp number of 10 EA/10 mm or more, and a bonding rate of 13 % or less, and may have a machine direction (MD) stiffness of 50 mm or less in a bonding region of each embossing pattern.
  • MD machine direction
  • an article includes the non-woven fabric laminate.
  • the article may be a diaper, an absorbent article, a defecation article, a support layer, or a top sheet.
  • the non-woven fabric laminate may have a hydrophilic agent impregnation amount (OPU) of 0.7 % or less, and thus the article may have a water absorption speed of 3 sec or less when the non-woven fabric laminate is applied to a top sheet layer of the diaper.
  • OPU hydrophilic agent impregnation amount
  • the shape of the crimp is clear and the shape stability of the crimp is good, so that softness and bulkiness can be improved.
  • a diaper including the non-woven fabric of a crimped composite fiber cannot hurt a wearer's skin or cannot cause rash.
  • FIG. 1 is a partial view showing an embossing pattern of a nonwoven fabric of a crimped composite fiber according to an embodiment of the present disclosure
  • FIG. 2 is a cross-sectional view of a crimped composite fiber used in Examples and Comparative Examples.
  • FIG. 3 is a partial view showing an embossing pattern of a nonwoven fabric of a crimped composite fiber, prepared in Example 4.
  • composite fiber The non-woven fabric of a crimped composite fiber (hereinafter, simply referred to as "composite fiber) according to an embodiment includes a first propylene-based polymer and a second propylene-based polymer.
  • a melting point of the first propylene-based polymer is higher than a melting point of the second propylene-based polymer by 30 °C or more, the melting points being measured by differential scanning calorimetry (DSC), (ii) a ratio (second polymer / first polymer) of melt flow rates (MFR: measurement temperature 230 °C, load 2.16 kg) of the first propylene-based polymer and the second propylene-based polymer is 1.7 or more, the melt flow rates being measured according to ASTM D1238, and (iii) a component ratio represented by a weight ratio of the first propylene-based polymer / the second propylene-based polymer is 50/50 to 10/90.
  • the melting point of the first propylene-based polymer may be higher than the melting point of the second propylene-based polymer by about 30 °C to about 60 °C or about 30 °C to about 100 °C.
  • the ratio (second polymer / first polymer) of melt flow rates may be about 1.7 to about 2.0, about 1.7 to about 3.0, or about 1.7 to about 4.0.
  • the composite fiber has crimpability, and thus the non-woven fabric including the composite fiber may have good softness and bulkiness.
  • the first propylene-based polymer and the second propylene-based polymer are arranged to occupy substantially respective regions in the cross-section of the composite fiber, and are successively stretched along a length direction. At least one component of the first propylene-based polymer and the second propylene-based polymer may successively form at least a part of a peripheral surface along the length direction of the composite fiber.
  • the first propylene-based polymer and the second propylene-based polymer may each independently include a propylene homopolymer, a propylene-ethylene random copolymer, an elastomeric random copolymer in which ethylene is copolymerized with polypropylene, a propylene-ethylene-butylene terpolymer, or a combination thereof.
  • the propylene-ethylene random copolymer may have an ethylene unit component content of about 10 mol% to about 30 mol% and a melt flow rate (MFR) of about 10 g/10 min to about 200 g/10 min.
  • MFR melt flow rate
  • the ethylene unit component content is determined by 13 C-NMR spectroscopy.
  • the elastomer random copolymer may be included in the first propylene-based polymer in an amount of about 10 wt% to about 30 wt%.
  • the propylene-ethylene-butylene terpolymer may be included in the first propylene-based polymer in an amount of about 10 wt% to about 30 wt%.
  • the elastomeric random copolymer and the propylene-ethylene-butylene terpolymer may be included in the first propylene-based polymer in an amount of about 10 wt% to about 30 wt%.
  • At least one component of the first propylene-based polymer and the second propylene-based polymer may include a propylene homopolymer; a copolymer in which propylene as a main structural unit component is copolymerized with at least one of ⁇ -olefins of 2 to 20 carbon atoms, for example, 2 to 8 carbon atoms, such as ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, and 4-methyl-1-pentene; or a combination thereof.
  • the first propylene-based polymer may be a mixture of 70 wt% to 90 wt% of a propylene homopolymer and 10 wt% to 30 wt% of an elastomeric random copolymer or a propylene-ethylene-butylene terpolymer
  • the second propylene-based polymer may be a propylene homopolymer
  • the melting point of the first propylene-based polymer may be in a range of about 120 °C to about 175 °C, and the melting point of the second propylene-based polymer may be in a range of about 110 °C to about 155 °C.
  • the difference in melting point between the two polymers, as described above, may be in a range of 30 °C or more, about 30 °C to about 60 °C, or about 30 °C to about 100 °C.
  • the aforementioned propylene-based polymers may be prepared using a high stereoregular polymerization catalyst.
  • the high stereoregular polymerization catalyst may include a diester-based catalyst, a succinate-based catalyst, a metallocene catalyst, or a combination thereof.
  • the non-woven fabric including the composite fiber may be obtained by a general composite melt spinning method without using a special apparatus.
  • the non-woven fabric may be a spunbonded non-woven fabric prepared by a spunbonding method exhibiting high productivity.
  • the first propylene-based polymer forming one region of the composite fiber and the second propylene-based polymer forming the other region of the composite fiber are separately melted by two extruders or the like, and each melt is discharged from a spinneret having a composite spinning nozzle configured to form and discharge a desired fiber structure to discharge a composite long fiber.
  • the discharged long fiber is cooled by cooling air, a tensile force is applied to the cooled long fiber by air for stretching to allow the long fiber to have a predetermined fineness, and the stretched long fiber is directly collected on a collecting belt and deposited to a predetermined thickness.
  • post-processing as entangling processing, is performed by a method using a needle punch, a water jet, an ultrasonic wave or the like; an embossing processing using a heating embossing roll; or a thermal fusion method using hot ventilating air.
  • the non-woven fabric may be formed by thermal fusion using embossing processing.
  • the embossing processing may be performed under conditions of a bonding rate (that is, embossing area ratio) of 13 % or less and a non-embossing unit area of 0.2 mm 2 or more, for example, about 0.2 mm 2 to about 0.7 mm 2 .
  • the non-embossing unit area refers to a maximum area of a rectangle in contact with the inner side of an embossing portion in a smallest unit of non-embossing portion whose all sides are surrounded by the embossing portion.
  • the bonding rate and the non-embossing unit area may be adjusted by changing an embossing pattern.
  • the non-woven fabric may include an embossing portion and a non-embossing portion, and the embossing portion may be an open embossing portion and include a plurality of unit embossing pattern portions arranged successively at the same or different intervals.
  • Each of the unit embossing pattern portions may have a shape below:
  • the fineness and basic weight of the non-woven fabric may be appropriately selected depending on use.
  • the fineness of the non-woven fabric may be about 1.0 denier to about 2.5 deniers, for example, about 0.7 deniers to about 2.0 deniers
  • the basic weight of the non-woven fabric may be about 15 g/m 2 to about 100 g/m 2 , for example, about 7 g/m 2 to about 30 g/m 2 .
  • Each embossing pattern included in each of the unit embossing pattern portions may have an area of about 0.2 mm 2 to about 0.7 mm 2 .
  • the non-woven fabric further includes fatty acid amide of 5 to 25 carbon atoms in an amount of about 0.01 wt% to about 3 wt% based on a total weight of the non-woven fabric.
  • the fatty acid amide may serve as a slip agent.
  • the fatty acid amide may include oleic amide, erucamide, stearic acid amide, or a combination thereof.
  • the composite fiber may include, in addition to the first propylene-based polymer and the second propylene-based polymer, other components as necessary as long as an object of the present disclosure is not impaired.
  • other components may include a heat stabilizer, a weather stabilizer, various stabilizers, an antistatic agent, an anti-blocking agent, an anticlouding agent, a filler, a dye, a pigment, natural oil, synthetic oil, wax, and combinations thereof.
  • the stabilizer may include an anti-aging agent such as 2,6-di-t-butyl-4-methylphenol (BHT); a phenolic antioxidant such as tetrakis [methylene-3- (3,5-di-t-butyl-4-hydroxyphenyl) propionate] methane, b-(3,5-di-t-butyl-4-hydroxyphenyl) propionic acid alkyl ester, or 2,2'-oxamidobis [ethyl-3- (3,5-di-t-butyl-4-hydroxyphenyl) propionate; a fatty acid metal salt such as zinc stearate, calcium stearate, or calcium 1,2-hydroxystearate; a polyhydric alcohol fatty acid ester such as glycerin monostearate, glycerin distearate, pentaerythritol monostearate, pentaerythritol distearate, or pentaerythritol tristearate
  • the filler may include silica, diatomite, alumina, titanium oxide, magnesium oxide, pumice powder, pumice balloon, aluminum hydroxide, magnesium hydroxide, basic magnesium carbonate, dolomite, calcium sulfate, potassium titanate, barium sulfate, calcium sulfite, talc, clay, mica, asbestos, calcium silicate, montmorillonite, bentonite, graphite, aluminum powder, molybdenum sulfide, or a combination thereof.
  • the aforementioned propylene-based polymer and the aforementioned other components to be used as needed may be mixed by a known method.
  • the composite fiber may be a mono-type composite fiber, a core-in-sheath type composite fiber, a side-by-side type composite fiber, or a sandwich type composite fiber.
  • the non-woven fabric laminate according to an embodiment of the present disclosure may be a laminate having at least two layers.
  • at least one layer of the laminate may be the aforementioned non-woven fabric.
  • the non-woven fabric laminate may include a spunbonded non-woven fabric among the aforementioned non-woven fabrics.
  • the non-woven fabric laminate may be formed by laminating the four spunbonded non-woven fabrics.
  • the non-woven fabric laminate may have a uniformity (CV) of 3 % or less.
  • uniformity (CV%) refers to a percentage of a value obtained by dividing a weight deviation of 30 test specimens by an average weight of the 30 test specimens after the non-woven fabric laminate is cut to a size of 1 m 2 to make the 30 test specimens.
  • the non-woven fabric laminate formed by laminating the four spunbonded non-woven fabrics may have a thickness of 0.02 mm or more, a crimp number of 10 EA/10 mm or more, and a bonding rate of 13 % or less, and may have a machine direction (MD) stiffness of 40 mm or less, which indicates softness of the non-woven fabric laminate.
  • MD stiffness refers to flexural deformation of the non-woven fabric laminate in a machine direction (that is, degree of warpage of the non-woven fabric laminate).
  • the article according to an embodiment of the present disclosure includes the aforementioned non-woven fabric laminate.
  • the article may be a diaper, an absorbent article, a defecation article, a support layer, or a top sheet.
  • the non-woven fabric laminate When the article is a diaper, the non-woven fabric laminate has a hydrophilic agent impregnation amount (OPU: Oil Pick-Up) of 0.7 % or less, and thus the article may have a water absorption speed of 3 sec or less when the non-woven fabric laminate is applied to a top sheet layer of the diaper.
  • OPU Oil Pick-Up
  • hydrophilic agent impregnation amount may be calculated according to Equation 1 below.
  • OPU(%) (W1-W0)/W0 X 100
  • W0 is a weight of the non-woven fabric laminate including no hydrophilic agent
  • W1 is a weight of the nonwoven fabric laminate including the hydrophilic agent.
  • the hydrophilic agent is used as a form of a water suspension of polydimethylsiloxane having a concentration of 15 wt%.
  • the weight of hydrophilic agent included in the nonwoven fabric laminate only refers to the weight of the solid component.
  • a first propylene-based polymer (A) in which an erucamide slip agent is contained, and a second propylene-based polymer (B) in which an erucamide slip agent is contained were subjected to composite melt spinning by a spunbonding method to deposit a side-by-side type composite fiber having the structure of FIG. 2 on a collecting surface, and the composite fiber was subjected to embossing processing by the embossing pattern shown in FIG. 1 by using a calender roll whose upper portion was heated to 146 °C and whose lower portion was heated to 144 °C, so as to produce a non-woven fabric including a crimped composite fiber.
  • the types, physical properties and content ratio of the first propylene-based polymer (A) and the second propylene-based polymer (B), the amount of the erucamide slip agent, and the characteristics of the embossing pattern are given in Table 1 below.
  • MFR refers to a melt index measured under the conditions of a temperature of 230 °C and a load of 2.16 kg according to ASTM D1238, and the amount of the slip agent refers to a weight with respect to the total weight of the non-woven fabric.
  • PA1 to PA7 and PB are as follows.
  • PA1 a mixture of 70 wt% of a propylene homopolymer (H7700, manufactured by LG Chem.) and 30 wt% of an elastomeric random copolymer (T-7700, manufactured by LG Chem.) in which ethylene is copolymerized with polypropylene
  • PA2 a mixture of 60 wt% of a propylene homopolymer (H7700, manufactured by LG Chem.) and 40 wt% of an elastomeric random copolymer (VISTAMAXX 7020, manufactured by EXXON) in which ethylene is copolymerized with polypropylene
  • PA3 a mixture of 40 wt% of a propylene homopolymer (H7700, manufactured by LG Chem.) and 60 wt% of an elastomeric random copolymer (VERSIFY 4200, manufactured by DOW) in which ethylene is copolymerized with polypropylene
  • PA4 a mixture of 70 wt% of a propylene homopolymer (H7700, manufactured by LG Chem.) and 30 wt% of an elastomeric random copolymer (T-7700, manufactured by LG Chem.) in which ethylene is copolymerized with polypropylene
  • PA5 a mixture of 70 wt% of a propylene homopolymer (MH7700, manufactured by LG Chem.) and 30 wt% of an elastomeric random copolymer (T-7700, manufactured by LG Chem.) in which ethylene is copolymerized with polypropylene
  • PA6 a mixture of 60 wt% of a propylene homopolymer (MH7700, manufactured by LG Chem.) and 40 wt% of an elastomeric random copolymer (T-7700, manufactured by LG Chem.) in which ethylene is copolymerized with polypropylene
  • PA7 a mixture of 70 wt% of a propylene homopolymer (H7700, manufactured by LG Chem.) and 30 wt% of an elastomeric random copolymer (T-7700, manufactured by LG Chem.) in which ethylene is copolymerized with polypropylene
  • PB a propylene homopolymer (H562T, manufactured by PMC)
  • Weight per unit area was measured according to ASTM D 3776-1985.
  • Tensile strength a maximum tensile load was obtained by performing a tensile test using a tensile strength measuring apparatus (Instron) according to KSK 0520 under the conditions of a test specimen width of 5 cm, an interval between test specimens of 10 cm, and a tensile speed of 500 mm/min.
  • Thickness (mm) was measured according to KSK 0506.
  • Crimp number the number of filament crimps in a range of 10 mm was directly measured using a microscope.
  • each of the non-woven fabrics of a crimped composite fiber prepared in Examples 1 to 6 is thick, has a larger number of crimps, and has good or similar other physical properties such as tensile strength (MD: Machine direction), tensile strength (CD: Cross direction), tensile elongation (MD: Machine direction), tensile elongation (CD: Cross direction), and spinnability, as compared with each of the non-woven fabrics prepared in Comparative Examples 1 to 5.
  • FIG. 3 is a partial view showing an embossing pattern of the nonwoven fabric of a crimped composite fiber, prepared in Example 4.
  • the nonwoven fabric of a crimped composite fiber, prepared in Example 4 has a crimp number of about 20/10mm.
  • Evaluation Example 2 Evaluation of physical properties of non-woven fabric laminate including spunbonded non-woven fabrics
  • the spunbonded nonwoven fabrics prepared in Examples 1 to 6 and Comparative Examples 1 to 5 were laminated by four to produce nonwoven fabric laminates. Then, the physical properties of each of the nonwoven fabric laminates were evaluated by the following method, and the results thereof are given in Table 3 below.
  • Crimp number the number of filament crimps in a range of 10 mm was directly measured using a microscope.
  • Bonding rate (%) refers to a percentage of a portion where heat is transferred to bond the non-woven fabric, as a relief portion of an embossing pattern.
  • MD stiffness a bending distance when a nonwoven fabric laminate sample was brought into contact with an inclined surface was measured by a tester machine having an inclination of 45°. The smaller the MD stiffness, the better the flexibility.
  • OPU Olet Pick Up
  • each of the non-woven fabric laminates produced by laminating the four non-woven fabrics of a crimped composite fiber prepared in Examples 1 to 6 has a good uniformity of 3 % or less, is thick, has a large number of crimps, has a small MD stiffness, has a similar OPU, and has a fast water absorption speed, as compared with each of the non-woven fabric laminates produced by laminating the four non-woven fabrics of a crimped composite fiber prepared in Comparative Examples 1 to 5.
  • the shape of the crimp is clear and the shape stability of the crimp is good, so that softness and bulkiness can be improved.
  • a diaper including the non-woven fabric of a crimped composite fiber cannot hurt a wearer's skin or cannot cause rash.

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Abstract

There is provided a non-woven fabric of a crimped composite fiber including: a first propylene-based polymer and a second propylene-based polymer, wherein, in the first propylene-based polymer and the second propylene-based polymer, a melting point of the first propylene-based polymer is higher than a melting point of the second propylene-based polymer by 30 ℃ or more, a ratio (second polymer / first polymer) of melt flow rates (MFR: measurement temperature 230 ℃, load 2.16 kg) of the first propylene-based polymer and the second propylene-based polymer is 1.7 or more, and a component ratio represented by a weight ratio of the first propylene-based polymer / the second propylene-based polymer is 50/50 to 10/90.

Description

NON-WOVEN FABRIC OF CRIMPED COMPOSITE FIBER AND LAMINATE THEREOF, AND ARTICLE INCLUDING THE LAMINATE
One or more embodiments relate to a non-woven fabric of a crimped composite fiber and a laminate thereof, and an article including the laminate, and more particularly, to a non-woven fabric of a crimped composite fiber, having improved softness and bulkiness, and a laminate thereof, and an article including the laminate.
This application claims the benefit of Korean Patent Application No. 10-2018-0044536, filed on April 17, 2018, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.
Final physical properties of a non-woven fabric are determined according to a web forming method and a binding method.
In the production of a conventional spunbonded non-woven fabric, webs are formed by single spinning or core-in-sheath composite spinning. The webs formed in this way have a simple structure with no crimps, and are bound to each other by a heating calender to form a thin non-woven fabric.
The thin non-woven fabric is used as a top sheet and a back sheet during the production of a diaper. However, this thin non-woven fabric has remarkably low softness as compared with a short-fiber air-through non-woven fabric obtained by forming webs through carding and binding the webs through hot air, and thus the softness of the thin non-woven fabric deteriorates.
Further, since crimps are not formed at the time of forming the webs during the production of a diaper such that bulkiness deteriorates, an area directly contacting the skin of a baby's buttocks is large, and there is no space between acquisition distribution layers (ADL) when non-woven fabrics are laminated, such that, when a baby urinates, urine remains in a part of the top sheet, thereby festering on the baby's buttocks or causing a rash. Further, there is a problem in that urine leaks to the outside of a diaper.
One or more embodiments provide a non-woven fabric of a crimped composite fiber, having improved softness and bulkiness.
One or more embodiments provide a non-woven fabric laminate including two or more non-woven fabrics of a crimped composite fiber.
One or more embodiments provide an article including the non-woven fabric laminate.
Additional aspects will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the presented embodiments.
According to one or more embodiments, a non-woven fabric of a crimped composite fiber includes: a first propylene-based polymer and a second propylene-based polymer, wherein, in the first propylene-based polymer and the second propylene-based polymer, a melting point of the first propylene-based polymer is higher than a melting point of the second propylene-based polymer by 30 ℃ or more, the melting points being measured by differential scanning calorimetry (DSC), a ratio (second polymer / first polymer) of melt flow rates (MFR: measurement temperature 230 ℃, load 2.16 kg) of the first propylene-based polymer and the second propylene-based polymer is 1.7 or more, the melt flow rates being measured according to ASTM D1238, and a component ratio represented by a weight ratio of the first propylene-based polymer / the second propylene-based polymer is 50/50 to 10/90.
The first propylene-based polymer and the second propylene-based polymer may each independently include a propylene homopolymer, a propylene-ethylene copolymer, an elastomeric random copolymer in which ethylene is copolymerized with polypropylene, a propylene-ethylene-butylene terpolymer, or a combination thereof.
The non-woven fabric may further include a fatty acid amide of 5 to 25 carbon atoms in an amount of about 0.01 wt% to about 3 wt% based on a total weight of the non-woven fabric.
The non-woven fabric may include an embossing portion and a non-embossing portion, and the embossing portion may be an open embossing portion and include a plurality of unit embossing pattern portions arranged successively at the same or different intervals.
Each of the unit embossing pattern portions has the following form:
Figure PCTKR2019004037-appb-I000001
.
Each embossing pattern included in each of the unit embossing pattern portions may have an area of about 0.2 mm2 to about 0.7 mm2.
The non-woven fabric may have a bonding rate of 13 % or less.
The crimped composite fiber may be a mono-type composite fiber, a core-in-sheath-type composite fiber, a side-by-side-type composite fiber, or a sandwich-type composite fiber.
The non-woven fabric may be a spunbonded non-woven fabric.
According to one or more embodiments, a non-woven fabric laminate has at least two layers, wherein at least one layer of the laminate is the non-woven fabric of a crimped composite fiber.
The non-woven fabric may be a spunbonded non-woven fabric, and the non-woven fabric laminate may be formed by laminating the four spunbonded non-woven fabrics and have a uniformity (CV) of 3 % or less.
The non-woven fabric laminate may have a thickness of 0.02 mm or more, a crimp number of 10 EA/10 mm or more, and a bonding rate of 13 % or less, and may have a machine direction (MD) stiffness of 50 mm or less in a bonding region of each embossing pattern.
According to one or more embodiments, an article includes the non-woven fabric laminate.
The article may be a diaper, an absorbent article, a defecation article, a support layer, or a top sheet.
When the article is a diaper, the non-woven fabric laminate may have a hydrophilic agent impregnation amount (OPU) of 0.7 % or less, and thus the article may have a water absorption speed of 3 sec or less when the non-woven fabric laminate is applied to a top sheet layer of the diaper.
As described above, in the non-woven fabric of a crimped composite fiber according to an embodiment, the shape of the crimp is clear and the shape stability of the crimp is good, so that softness and bulkiness can be improved.
Therefore, a diaper including the non-woven fabric of a crimped composite fiber cannot hurt a wearer's skin or cannot cause rash.
These and/or other aspects will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings in which:
FIG. 1 is a partial view showing an embossing pattern of a nonwoven fabric of a crimped composite fiber according to an embodiment of the present disclosure;
FIG. 2 is a cross-sectional view of a crimped composite fiber used in Examples and Comparative Examples; and
FIG. 3 is a partial view showing an embossing pattern of a nonwoven fabric of a crimped composite fiber, prepared in Example 4.
Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout. In this regard, the present embodiments may have different forms and should not be construed as being limited to the descriptions set forth herein. Accordingly, the embodiments are merely described below, by referring to the figures, to explain aspects of the present description. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items. Expressions such as "at least one of," when preceding a list of elements, modify the entire list of elements and do not modify the individual elements of the list.
Hereinafter, a non-woven fabric of a crimped composite fiber according to an embodiment will be described in detail.
The non-woven fabric of a crimped composite fiber (hereinafter, simply referred to as "composite fiber) according to an embodiment includes a first propylene-based polymer and a second propylene-based polymer.
In the first propylene-based polymer and the second propylene-based polymer, (i) a melting point of the first propylene-based polymer is higher than a melting point of the second propylene-based polymer by 30 ℃ or more, the melting points being measured by differential scanning calorimetry (DSC), (ii) a ratio (second polymer / first polymer) of melt flow rates (MFR: measurement temperature 230 ℃, load 2.16 kg) of the first propylene-based polymer and the second propylene-based polymer is 1.7 or more, the melt flow rates being measured according to ASTM D1238, and (iii) a component ratio represented by a weight ratio of the first propylene-based polymer / the second propylene-based polymer is 50/50 to 10/90.
For example, the melting point of the first propylene-based polymer may be higher than the melting point of the second propylene-based polymer by about 30 ℃ to about 60 ℃ or about 30 ℃ to about 100 ℃.
For example, the ratio (second polymer / first polymer) of melt flow rates may be about 1.7 to about 2.0, about 1.7 to about 3.0, or about 1.7 to about 4.0.
When the first propylene-based polymer and the second propylene-based polymer satisfy all of the above conditions (i) to (iii), the composite fiber has crimpability, and thus the non-woven fabric including the composite fiber may have good softness and bulkiness.
The first propylene-based polymer and the second propylene-based polymer are arranged to occupy substantially respective regions in the cross-section of the composite fiber, and are successively stretched along a length direction. At least one component of the first propylene-based polymer and the second propylene-based polymer may successively form at least a part of a peripheral surface along the length direction of the composite fiber.
The first propylene-based polymer and the second propylene-based polymer may each independently include a propylene homopolymer, a propylene-ethylene random copolymer, an elastomeric random copolymer in which ethylene is copolymerized with polypropylene, a propylene-ethylene-butylene terpolymer, or a combination thereof.
The propylene-ethylene random copolymer may have an ethylene unit component content of about 10 mol% to about 30 mol% and a melt flow rate (MFR) of about 10 g/10 min to about 200 g/10 min. The ethylene unit component content is determined by 13C-NMR spectroscopy.
For example, the elastomer random copolymer may be included in the first propylene-based polymer in an amount of about 10 wt% to about 30 wt%.
As another example, the propylene-ethylene-butylene terpolymer may be included in the first propylene-based polymer in an amount of about 10 wt% to about 30 wt%.
As another example, the elastomeric random copolymer and the propylene-ethylene-butylene terpolymer may be included in the first propylene-based polymer in an amount of about 10 wt% to about 30 wt%.
In detail, at least one component of the first propylene-based polymer and the second propylene-based polymer may include a propylene homopolymer; a copolymer in which propylene as a main structural unit component is copolymerized with at least one of α-olefins of 2 to 20 carbon atoms, for example, 2 to 8 carbon atoms, such as ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, and 4-methyl-1-pentene; or a combination thereof.
In terms of obtaining a non-woven fabric of a composite fiber having good softness and bulkiness, the first propylene-based polymer may be a mixture of 70 wt% to 90 wt% of a propylene homopolymer and 10 wt% to 30 wt% of an elastomeric random copolymer or a propylene-ethylene-butylene terpolymer, and the second propylene-based polymer may be a propylene homopolymer.
The melting point of the first propylene-based polymer may be in a range of about 120 ℃ to about 175 ℃, and the melting point of the second propylene-based polymer may be in a range of about 110 ℃ to about 155 ℃. The difference in melting point between the two polymers, as described above, may be in a range of 30 ℃ or more, about 30 ℃ to about 60 ℃, or about 30 ℃ to about 100 ℃.
The aforementioned propylene-based polymers may be prepared using a high stereoregular polymerization catalyst.
The high stereoregular polymerization catalyst may include a diester-based catalyst, a succinate-based catalyst, a metallocene catalyst, or a combination thereof.
The non-woven fabric including the composite fiber may be obtained by a general composite melt spinning method without using a special apparatus. For example, the non-woven fabric may be a spunbonded non-woven fabric prepared by a spunbonding method exhibiting high productivity.
Hereinafter, a method of producing a spunbonded non-woven fabric will be described in detail.
First, the first propylene-based polymer forming one region of the composite fiber and the second propylene-based polymer forming the other region of the composite fiber are separately melted by two extruders or the like, and each melt is discharged from a spinneret having a composite spinning nozzle configured to form and discharge a desired fiber structure to discharge a composite long fiber.
Then, the discharged long fiber is cooled by cooling air, a tensile force is applied to the cooled long fiber by air for stretching to allow the long fiber to have a predetermined fineness, and the stretched long fiber is directly collected on a collecting belt and deposited to a predetermined thickness.
Then, post-processing, as entangling processing, is performed by a method using a needle punch, a water jet, an ultrasonic wave or the like; an embossing processing using a heating embossing roll; or a thermal fusion method using hot ventilating air.
In an embodiment of the present disclosure, the non-woven fabric may be formed by thermal fusion using embossing processing.
The embossing processing may be performed under conditions of a bonding rate (that is, embossing area ratio) of 13 % or less and a non-embossing unit area of 0.2 mm2 or more, for example, about 0.2 mm2 to about 0.7 mm2. Here, the non-embossing unit area refers to a maximum area of a rectangle in contact with the inner side of an embossing portion in a smallest unit of non-embossing portion whose all sides are surrounded by the embossing portion. When the embossing processing is performed under the condition of this range, it is possible to obtain a nonwoven fabric having better bulkiness while maintaining necessary strength.
The bonding rate and the non-embossing unit area may be adjusted by changing an embossing pattern.
As the results of the embossing processing, the non-woven fabric may include an embossing portion and a non-embossing portion, and the embossing portion may be an open embossing portion and include a plurality of unit embossing pattern portions arranged successively at the same or different intervals.
Each of the unit embossing pattern portions may have a shape below:
Figure PCTKR2019004037-appb-I000002
.
The fineness and basic weight of the non-woven fabric may be appropriately selected depending on use. Generally, the fineness of the non-woven fabric may be about 1.0 denier to about 2.5 deniers, for example, about 0.7 deniers to about 2.0 deniers, and the basic weight of the non-woven fabric may be about 15 g/m2 to about 100 g/m2, for example, about 7 g/m2 to about 30 g/m2.
Each embossing pattern included in each of the unit embossing pattern portions may have an area of about 0.2 mm2 to about 0.7 mm2.
The non-woven fabric further includes fatty acid amide of 5 to 25 carbon atoms in an amount of about 0.01 wt% to about 3 wt% based on a total weight of the non-woven fabric.
The fatty acid amide may serve as a slip agent.
The fatty acid amide may include oleic amide, erucamide, stearic acid amide, or a combination thereof.
The composite fiber may include, in addition to the first propylene-based polymer and the second propylene-based polymer, other components as necessary as long as an object of the present disclosure is not impaired. Examples of other components may include a heat stabilizer, a weather stabilizer, various stabilizers, an antistatic agent, an anti-blocking agent, an anticlouding agent, a filler, a dye, a pigment, natural oil, synthetic oil, wax, and combinations thereof.
The stabilizer may include an anti-aging agent such as 2,6-di-t-butyl-4-methylphenol (BHT); a phenolic antioxidant such as tetrakis [methylene-3- (3,5-di-t-butyl-4-hydroxyphenyl) propionate] methane, b-(3,5-di-t-butyl-4-hydroxyphenyl) propionic acid alkyl ester, or 2,2'-oxamidobis [ethyl-3- (3,5-di-t-butyl-4-hydroxyphenyl) propionate; a fatty acid metal salt such as zinc stearate, calcium stearate, or calcium 1,2-hydroxystearate; a polyhydric alcohol fatty acid ester such as glycerin monostearate, glycerin distearate, pentaerythritol monostearate, pentaerythritol distearate, or pentaerythritol tristearate; or a combination thereof.
The filler may include silica, diatomite, alumina, titanium oxide, magnesium oxide, pumice powder, pumice balloon, aluminum hydroxide, magnesium hydroxide, basic magnesium carbonate, dolomite, calcium sulfate, potassium titanate, barium sulfate, calcium sulfite, talc, clay, mica, asbestos, calcium silicate, montmorillonite, bentonite, graphite, aluminum powder, molybdenum sulfide, or a combination thereof.
The aforementioned propylene-based polymer and the aforementioned other components to be used as needed may be mixed by a known method.
The composite fiber may be a mono-type composite fiber, a core-in-sheath type composite fiber, a side-by-side type composite fiber, or a sandwich type composite fiber.
Hereinafter, a non-woven fabric laminate according to an embodiment of the present disclosure will be described in detail.
The non-woven fabric laminate according to an embodiment of the present disclosure may be a laminate having at least two layers. Here, at least one layer of the laminate may be the aforementioned non-woven fabric.
The non-woven fabric laminate may include a spunbonded non-woven fabric among the aforementioned non-woven fabrics.
The non-woven fabric laminate may be formed by laminating the four spunbonded non-woven fabrics. In this case, the non-woven fabric laminate may have a uniformity (CV) of 3 % or less. In the present specification, the "uniformity (CV%)" refers to a percentage of a value obtained by dividing a weight deviation of 30 test specimens by an average weight of the 30 test specimens after the non-woven fabric laminate is cut to a size of 1 m2 to make the 30 test specimens.
The non-woven fabric laminate formed by laminating the four spunbonded non-woven fabrics may have a thickness of 0.02 mm or more, a crimp number of 10 EA/10 mm or more, and a bonding rate of 13 % or less, and may have a machine direction (MD) stiffness of 40 mm or less, which indicates softness of the non-woven fabric laminate. In the present specification, the "MD stiffness" refers to flexural deformation of the non-woven fabric laminate in a machine direction (that is, degree of warpage of the non-woven fabric laminate).
Hereinafter, an article according to an embodiment of the present disclosure will be described in detail.
The article according to an embodiment of the present disclosure includes the aforementioned non-woven fabric laminate.
The article may be a diaper, an absorbent article, a defecation article, a support layer, or a top sheet.
When the article is a diaper, the non-woven fabric laminate has a hydrophilic agent impregnation amount (OPU: Oil Pick-Up) of 0.7 % or less, and thus the article may have a water absorption speed of 3 sec or less when the non-woven fabric laminate is applied to a top sheet layer of the diaper.
The hydrophilic agent impregnation amount (OPU) may be calculated according to Equation 1 below.
[Equation 1]
OPU(%) = (W1-W0)/W0 X 100
In Equation 1, W0 is a weight of the non-woven fabric laminate including no hydrophilic agent, and W1 is a weight of the nonwoven fabric laminate including the hydrophilic agent. During the impregnation process, the hydrophilic agent is used as a form of a water suspension of polydimethylsiloxane having a concentration of 15 wt%. However, in Equation 1, the weight of hydrophilic agent included in the nonwoven fabric laminate only refers to the weight of the solid component.
Hereinafter, the present disclosure will be described in more detail through Examples. The following Examples are set forth to describe the present disclosure in more detail, and the scope of the present disclosure is not limited to these Examples.
Examples 1 to 6 and Comparative Examples 1 to 5
A first propylene-based polymer (A) in which an erucamide slip agent is contained, and a second propylene-based polymer (B) in which an erucamide slip agent is contained were subjected to composite melt spinning by a spunbonding method to deposit a side-by-side type composite fiber having the structure of FIG. 2 on a collecting surface, and the composite fiber was subjected to embossing processing by the embossing pattern shown in FIG. 1 by using a calender roll whose upper portion was heated to 146 ℃ and whose lower portion was heated to 144 ℃, so as to produce a non-woven fabric including a crimped composite fiber. The types, physical properties and content ratio of the first propylene-based polymer (A) and the second propylene-based polymer (B), the amount of the erucamide slip agent, and the characteristics of the embossing pattern are given in Table 1 below. In Table, MFR refers to a melt index measured under the conditions of a temperature of 230 ℃ and a load of 2.16 kg according to ASTM D1238, and the amount of the slip agent refers to a weight with respect to the total weight of the non-woven fabric.
Examples Comparative Examples
1 2 3 4 5 6 1 2 3 4 5
Firstpolymer Polymer type PA1 PA2 PA3 PA4 PA5 PA1 PA1 PA6 PA7 PA1 PA1
Melting point(℃) 130 120 100 130 130 130 130 140 130 130 130
MFR(g/10min) 35 35 35 30 20 35 35 35 35 35 35
Amount of slip agent (wt%) 1 1 1 1 1 1 1 1 1 1 1
Second polymer Polymer type PB PB PB PB PB PB PB PB PB PB PB
Melting point(℃) 160 160 160 160 160 160 160 160 160 160 160
MFR(g/10min) 60 60 60 60 60 60 60 60 35 60 60
Amount of slip agent (wt%) 1 1 1 1 1 1 1 1 1 1 1
Difference in melting point between first and second polymers(℃) 30 40 60 30 30 30 30 20 30 30 30
Ratio of MFR of first and second polymers 1.7 1.7 1.7 2.0 3.0 1.7 1.7 1.7 1.0 1.7 1.7
Component ratio(weight ratio) of first and second polymers 50/50 50/50 50/50 50/50 50/50 10/90 90/10 50/50 50/50 5/95 60/40
Embossing pattern Bonding rate (%) 12 12 12 12 12 12 12 12 12 12 12
Non-embossing unit area(mm2) 22.944 22.944 22.944 22.944 22.944 22.944 22.944 22.944 22.944 22.944 22.944
In Table 1, PA1 to PA7 and PB are as follows.
(1) PA1: a mixture of 70 wt% of a propylene homopolymer (H7700, manufactured by LG Chem.) and 30 wt% of an elastomeric random copolymer (T-7700, manufactured by LG Chem.) in which ethylene is copolymerized with polypropylene
(2) PA2: a mixture of 60 wt% of a propylene homopolymer (H7700, manufactured by LG Chem.) and 40 wt% of an elastomeric random copolymer (VISTAMAXX 7020, manufactured by EXXON) in which ethylene is copolymerized with polypropylene
(3) PA3: a mixture of 40 wt% of a propylene homopolymer (H7700, manufactured by LG Chem.) and 60 wt% of an elastomeric random copolymer (VERSIFY 4200, manufactured by DOW) in which ethylene is copolymerized with polypropylene
(4) PA4: a mixture of 70 wt% of a propylene homopolymer (H7700, manufactured by LG Chem.) and 30 wt% of an elastomeric random copolymer (T-7700, manufactured by LG Chem.) in which ethylene is copolymerized with polypropylene
(5) PA5: a mixture of 70 wt% of a propylene homopolymer (MH7700, manufactured by LG Chem.) and 30 wt% of an elastomeric random copolymer (T-7700, manufactured by LG Chem.) in which ethylene is copolymerized with polypropylene
(6) PA6: a mixture of 60 wt% of a propylene homopolymer (MH7700, manufactured by LG Chem.) and 40 wt% of an elastomeric random copolymer (T-7700, manufactured by LG Chem.) in which ethylene is copolymerized with polypropylene
(7) PA7: a mixture of 70 wt% of a propylene homopolymer (H7700, manufactured by LG Chem.) and 30 wt% of an elastomeric random copolymer (T-7700, manufactured by LG Chem.) in which ethylene is copolymerized with polypropylene
(8) PB: a propylene homopolymer (H562T, manufactured by PMC)
Evaluation Example 1: Evaluation of physical properties of spunbonded non-woven fabric
The physical properties of the spunbonded non-woven fabrics prepared in Examples 1 to 6 and Comparative Examples 1 to 5 were evaluated as follows, and the results thereof are given in Table 2 below.
(1) Weight per unit area (weight: g/m2) was measured according to ASTM D 3776-1985.
(2) Tensile strength: a maximum tensile load was obtained by performing a tensile test using a tensile strength measuring apparatus (Instron) according to KSK 0520 under the conditions of a test specimen width of 5 cm, an interval between test specimens of 10 cm, and a tensile speed of 500 mm/min.
(3) Tensile elongation: elongations were measured by the method of the above (2) when the non-woven fabrics were stretched to the maximum.
(4) Thickness (mm) was measured according to KSK 0506.
(5) Crimp number: the number of filament crimps in a range of 10 mm was directly measured using a microscope.
(6) Spinnability: filament shaking was visually observed during melt spinning, and polymer drip was detected by a defect detector.
Examples Comparative Examples
1 2 3 4 5 6 1 2 3 4 5
Tensile strength (MD)(kgf/5cm) 4.71 5.19 4.92 5.54 4.32 5.28 4.56 3.89 3.74 3.56 4.12
Tensile strength (CD)(kgf/5cm) 2.57 2.94 2.78 3.45 2.00 3.15 2.28 1.54 1.45 1.23 1.89
Tensile elongation(MD)(%) 117 118 127 127 131 125 110 118 112 124 110
Tensile elongation (CD)(%) 125 125 133 130 145 132 124 130 124 134 119
Thickness (mm) 0.484 0.494 0.549 0.575 0.621 0.529 0.328 0.457 0.243 0.470 0.287
Crimp number(EA/10mm) 11 12 15 19 24 15 3 6 0 7 9
Spinnability good good good good good good good good good good good
Referring to Table 2, it was found that each of the non-woven fabrics of a crimped composite fiber prepared in Examples 1 to 6 is thick, has a larger number of crimps, and has good or similar other physical properties such as tensile strength (MD: Machine direction), tensile strength (CD: Cross direction), tensile elongation (MD: Machine direction), tensile elongation (CD: Cross direction), and spinnability, as compared with each of the non-woven fabrics prepared in Comparative Examples 1 to 5.
FIG. 3 is a partial view showing an embossing pattern of the nonwoven fabric of a crimped composite fiber, prepared in Example 4.
Referring to FIG. 3, it was found that the nonwoven fabric of a crimped composite fiber, prepared in Example 4, has a crimp number of about 20/10mm.
Evaluation Example 2: Evaluation of physical properties of non-woven fabric laminate including spunbonded non-woven fabrics
The spunbonded nonwoven fabrics prepared in Examples 1 to 6 and Comparative Examples 1 to 5 were laminated by four to produce nonwoven fabric laminates. Then, the physical properties of each of the nonwoven fabric laminates were evaluated by the following method, and the results thereof are given in Table 3 below.
(1) Uniformity (CV%) was evaluated by a percentage of a value obtained by dividing a weight deviation of 30 test specimens by an average weight of the 30 test specimens after the non-woven fabric laminate is cut to a size of 1 m2 to make the 30 test specimens. The smaller the uniformity (CV%) value, the better the uniformity.
(2) Thickness (mm) was measured according to KSK 0506
(3) Crimp number: the number of filament crimps in a range of 10 mm was directly measured using a microscope.
(4) Bonding rate (%) refers to a percentage of a portion where heat is transferred to bond the non-woven fabric, as a relief portion of an embossing pattern.
(5) MD stiffness (mm): a bending distance when a nonwoven fabric laminate sample was brought into contact with an inclined surface was measured by a tester machine having an inclination of 45°. The smaller the MD stiffness, the better the flexibility.
(6) OPU (Oil Pick Up) was obtained by calculating the amount of the hydrophilic agent (i.e., solid content) sprayed on the nonwoven fabric laminate as a percentage of the total weight.
(7) Water absorption speed: when artificial urine was dropped on the nonwoven laminate according to EDANA 150.5 (02), the time that the artificial urine passed through the nonwoven fabric laminate was measured by a sensor.
Examples Comparative Examples
1 2 3 4 5 6 1 2 3 4 5
Uniformity (CV%) 2.72 2.84 2.65 2.74 2.78 2.78 2.45 2.87 2.65 2.34 2.57
Thickness (mm) 0.484 0.494 0.549 0.575 0.621 0.529 0.328 0.457 0.243 0.414 0.287
Crimp number (EA/10mm) 11 9 15 19 24 15 3 6 0 7 2
Bonding rate (%) 12 12 12 12 12 12 12 12 12 12 12
MD stiffness (mm) 49 48 44 45 42 47 51 52 58 50 52
OPU(%) 0.67 0.65 0.68 0.64 0.67 0.68 0.68 0.67 0.66 0.67 0.66
Water absorption speed (sec) 2.9 2.7 2.5 2.2 1.8 2.5 3.0 3.0 3.2 3.1 3.1
Referring to Table 3, it was found that each of the non-woven fabric laminates produced by laminating the four non-woven fabrics of a crimped composite fiber prepared in Examples 1 to 6 has a good uniformity of 3 % or less, is thick, has a large number of crimps, has a small MD stiffness, has a similar OPU, and has a fast water absorption speed, as compared with each of the non-woven fabric laminates produced by laminating the four non-woven fabrics of a crimped composite fiber prepared in Comparative Examples 1 to 5.
As described above, in the non-woven fabric of a crimped composite fiber according to an embodiment, the shape of the crimp is clear and the shape stability of the crimp is good, so that softness and bulkiness can be improved.
Therefore, a diaper including the non-woven fabric of a crimped composite fiber cannot hurt a wearer's skin or cannot cause rash.
It should be understood that embodiments described herein should be considered in a descriptive sense only and not for purposes of limitation. Descriptions of features or aspects within each embodiment should typically be considered as available for other similar features or aspects in other embodiments.
While one or more embodiments have been described with reference to the figures, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the disclosure as defined by the following claims.

Claims (15)

  1. A non-woven fabric of a crimped composite fiber, comprising:
    a first propylene-based polymer and a second propylene-based polymer,
    wherein, in the first propylene-based polymer and the second propylene-based polymer, a melting point of the first propylene-based polymer is higher than a melting point of the second propylene-based polymer by 30 ℃ or more, the melting points being measured by differential scanning calorimetry (DSC), a ratio (second polymer / first polymer) of melt flow rates (MFR: measurement temperature 230 ℃, load 2.16 kg) of the first propylene-based polymer and the second propylene-based polymer is 1.7 or more, the melt flow rates being measured according to ASTM D1238, and a component ratio represented by a weight ratio of the first propylene-based polymer / the second propylene-based polymer is 50/50 to 10/90.
  2. The non-woven fabric of a crimped composite fiber of claim 1,
    wherein the first propylene-based polymer and the second propylene-based polymer each independently include a propylene homopolymer, a propylene-ethylene copolymer, an elastomeric random copolymer in which ethylene is copolymerized with polypropylene, a propylene-ethylene-butylene terpolymer, or a combination thereof.
  3. The non-woven fabric of a crimped composite fiber of claim 1,
    wherein the non-woven fabric further includes a fatty acid amide of 5 to 25 carbon atoms in an amount of about 0.01 wt% to about 3 wt% based on a total weight of the non-woven fabric.
  4. The non-woven fabric of a crimped composite fiber of claim 1,
    wherein the non-woven fabric includes an embossing portion and a non-embossing portion, and
    the embossing portion is an open embossing portion and includes a plurality of unit embossing pattern portions arranged successively at the same or different intervals.
  5. The non-woven fabric of a crimped composite fiber of claim 4,
    wherein each of the unit embossing pattern portions has the following form:
    Figure PCTKR2019004037-appb-I000003
    .
  6. The non-woven fabric of a crimped composite fiber of claim 4,
    wherein each embossing pattern included in the unit embossing pattern portions has an area of about 0.2 mm2 to about 0.7 mm2.
  7. The non-woven fabric of a crimped composite fiber of claim 4,
    wherein the non-woven fabric has a bonding rate of 13 % or less.
  8. The non-woven fabric of a crimped composite fiber of claim 1,
    wherein the crimped composite fiber is a mono-type composite fiber, a core-in-sheath-type composite fiber, a side-by-side-type composite fiber, or a sandwich-type composite fiber.
  9. The non-woven fabric of a crimped composite fiber of claim 1,
    wherein the non-woven fabric is a spunbonded non-woven fabric.
  10. A non-woven fabric laminate having at least two layers,
    wherein at least one layer of the laminate is the non-woven fabric of a crimped composite fiber of any one of clams 1 to 9.
  11. The non-woven fabric laminate of claim 10,
    wherein the non-woven fabric is a spunbonded non-woven fabric, and the non-woven fabric laminate is formed by laminating four spunbonded non-woven fabrics and has a uniformity (CV) of 3 % or less.
  12. The non-woven fabric laminate of claim 11,
    wherein the non-woven fabric laminate has a thickness of 0.02 mm or more, a crimp number of 10 EA/10 mm or more, and a bonding rate of 13 % or less, and has a machine direction (MD) stiffness of 50 mm or less in a bonding region of an embossing pattern.
  13. An article comprising the non-woven fabric laminate of any one of claims 10 to 12.
  14. The article of claim 13,
    wherein the article is a diaper, an absorbent article, a defecation article, a support layer, or a top sheet.
  15. The article of claim 14,
    wherein, when the article is a diaper, the non-woven fabric laminate has a hydrophilic agent impregnation amount (OPU) of 0.7 % or less, and thus the article has a water absorption speed of 3 sec or less when the non-woven fabric laminate is applied to a top sheet layer of the diaper.
PCT/KR2019/004037 2018-04-17 2019-04-05 Non-woven fabric of crimped composite fiber and laminate thereof, and article including the laminate Ceased WO2019203484A1 (en)

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CN201980026780.8A CN112074632A (en) 2018-04-17 2019-04-05 Nonwoven fabric of crimped conjugate fiber, laminate thereof, and article comprising the laminate
JP2020558439A JP7221987B2 (en) 2018-04-17 2019-04-05 Nonwoven fabric of crimped composite fibers, laminates thereof, and articles thereof

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KR1020180044536A KR102036763B1 (en) 2018-04-17 2018-04-17 Non-woven fabric of crimped composite fiber and laminate thereof, and article including the laminate
KR10-2018-0044536 2018-04-17

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JP2021518886A (en) 2021-08-05
TW201945457A (en) 2019-12-01
JP7221987B2 (en) 2023-02-14
CN112074632A (en) 2020-12-11
TWI742363B (en) 2021-10-11

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