Nonwoven fabric laminate, and stretchable nonwoven fabric laminate, textile product, absorbent article and sanitary mask

Abstract

To provide a nonwoven fabric laminate excellent in stretchability and stress retention.SOLUTION: A nonwoven fabric laminate has an elastic nonwoven fabric containing α-olefin copolymer in which ratio between storage elastic modulus E40 at 40°C and storage elastic modulus E23 at 23°C (E40 / E23) is 37% or higher, and a stretchable spun-bonded nonwoven fabric disposed at least on one surface side of the elastic nonwoven fabric.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to nonwoven laminates and to stretchable nonwoven laminates, textiles, absorbent articles and sanitary masks. [Background technology]

[0002] In recent years, nonwoven fabrics have been widely used for various purposes due to their excellent breathability and flexibility. Therefore, nonwoven fabrics are required to have various properties according to the purpose, and there is a demand for improvements in these properties.

[0003] For example, nonwoven fabrics used in sanitary materials such as disposable diapers and sanitary napkins, and as base fabrics for compresses, are required to be water resistant and moisture permeable, and also to have stretchability and bulkiness depending on the location of use.

[0004] As a method for imparting stretchability to a nonwoven fabric, a method using a thermoplastic elastomer as a raw material for a spunbond nonwoven fabric (see, for example, Patent Document 1) and a method using low-crystalline polypropylene (see, for example, Patent Document 2 and Patent Document 3) have been proposed.

[0005] Patent Document 2 and Patent Document 3 propose adding high-crystalline polypropylene or a release agent to low-crystalline polypropylene in order to improve stickiness of spunbonded nonwoven fabrics. Patent Document 4 discloses a laminate of a nonwoven fabric containing low-crystalline polypropylene and a mixed-fiber spunbonded nonwoven fabric of long fibers of a thermoplastic elastomer and long fibers of a thermoplastic resin. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Special Publication No. 7-503502 [Patent Document 2] Japanese Patent Application Laid-Open No. 2009-62667 [Patent Document 3] Japanese Patent Application Laid-Open No. 2009-79341 [Patent Document 4] International Publication No. 2007 / 138733 Summary of the Invention [Problem to be solved by the invention]

[0007] In the methods described in Patent Document 2 or Patent Document 3, when producing a nonwoven fabric, it is necessary to increase the amount of high-crystalline polypropylene or a release agent added to the low-crystalline polypropylene to prevent adhesion to rotating equipment in the equipment and other parts that come into contact with the nonwoven fabric, and as a result, the residual strain of the resulting spunbonded nonwoven fabric tends to be large and the stretchability tends to be poor. In the method described in Patent Document 4, stretchability is maintained by laminating a nonwoven fabric containing low-crystalline polypropylene and a mixed fiber spunbonded nonwoven fabric, but further improvement in stretchability is strongly desired.

[0008] Furthermore, in applications such as disposable diapers, sanitary napkins, and other hygiene materials, and as base fabrics for wet compresses, low elongation stress is required so that they can be worn with little force, and high recovery stress is required so that they do not slip off when worn. In other words, in these applications, a high value for the stretchability property (ratio of recovery stress / elongation stress) is required.

[0009] Furthermore, for applications such as disposable diapers, sanitary napkins, and other sanitary materials, and for the base fabric of compresses, there is a demand for the recovery stress to not decrease in the temperature range from room temperature (23°C) to body temperature (for example, 23°C to 40°C), i.e., for excellent stress maintenance. This means that disposable diapers, sanitary napkins, and other sanitary materials will not slip off even if their temperature rises to body temperature when worn. In view of the above problems, one aspect of the present invention aims to provide a nonwoven fabric laminate that has excellent stretchability and stress retention, as well as a stretchable nonwoven fabric laminate, a textile product, an absorbent article, and a sanitary mask. [Means for solving the problem]

[0010] Specific means for solving the above problems include the following aspects. [1] An elastic nonwoven fabric containing an α-olefin copolymer having a ratio (E40 / E23) of the storage modulus E40 at 40°C to the storage modulus E23 at 23°C of 37% or more; an extensible spunbond nonwoven fabric disposed on at least one side of the elastic nonwoven fabric; A nonwoven fabric laminate having:

[0011] [2] The nonwoven fabric laminate according to [1], wherein the storage modulus E23 at 23°C of the α-olefin copolymer is 30 MPa or less.

[0012] [3] The nonwoven fabric laminate according to [1] or [2], wherein the α-olefin copolymer comprises a copolymer of ethylene and propylene.

[0013] [4] The nonwoven fabric laminate according to any one of [1] to [3], wherein the α-olefin copolymer has a tensile modulus of 30 MPa or less.

[0014] [5] The nonwoven fabric laminate according to any one of [1] to [4], wherein the extensible spunbonded nonwoven fabric is disposed on both sides of the elastic nonwoven fabric.

[0015] [6] The nonwoven fabric laminate according to any one of [1] to [5], wherein the extensible spunbonded nonwoven fabric has a maximum elongation under load of 45% or more in at least one direction.

[0016] [7] The nonwoven fabric laminate according to any one of [1] to [6], wherein the elastic nonwoven fabric is an elastic spunbonded nonwoven fabric.

[0017] [8] The nonwoven fabric laminate according to any one of [1] to [7], wherein the extensible spunbond nonwoven fabric is an extensible spunbond nonwoven fabric made of concentric core-sheath composite fibers, the core of which is a low MFR olefin polymer having an MFR in the range of 1 g / 10 min to 1000 g / 10 min, and the sheath of which is a high MFR olefin polymer having an MFR in the range of 1 g / 10 min to 1000 g / 10 min, and the difference in MFR between the low MFR olefin polymer and the high MFR olefin polymer is 1 g / 10 min or more.

[0018] [9] The nonwoven fabric laminate according to any one of [1] to [8], wherein the extensible spunbonded nonwoven fabric contains an olefin polymer composition comprising 80% by mass to 99% by mass of a crystalline propylene polymer and 1% by mass to 20% by mass of a high-density polyethylene.

[0019]

[10] The nonwoven fabric laminate according to any one of [1] to [9], wherein the basis weight ratio of the elastic nonwoven fabric to the extensible spunbonded nonwoven fabric (elastic nonwoven fabric:extensible spunbonded nonwoven fabric) is in the range of 10:90 to 90:10.

[0020]

[11] A stretchable nonwoven fabric laminate which is a stretched product of the nonwoven fabric laminate according to any one of [1] to

[10] above.

[12] A textile product comprising the nonwoven fabric laminate according to any one of [1] to

[10] above or the stretchable nonwoven fabric laminate according to

[11] above.

[13] An absorbent article comprising the nonwoven fabric laminate according to any one of [1] to

[10] above or the stretchable nonwoven fabric laminate according to

[11] above.

[14] A sanitary mask comprising the nonwoven fabric laminate according to any one of [1] to

[10] above or the stretchable nonwoven fabric laminate according to

[11] above. [Effects of the Invention]

[0021] According to one aspect of the present invention, there are provided a nonwoven fabric laminate having excellent stretch properties and excellent stress retention, as well as a stretchable nonwoven fabric laminate, a textile product, an absorbent article, and a sanitary mask. [Brief explanation of the drawings]

[0022] [Figure 1] FIG. 1 is a schematic diagram of a gear stretching device. DETAILED DESCRIPTION OF THE INVENTION

[0023]

[0023] The following describes embodiments of the present disclosure. These descriptions and examples are intended to illustrate the embodiments and are not intended to limit the scope of the embodiments.

[0024] In the numerical ranges described in stages in this disclosure, the upper or lower limit value described in one numerical range may be replaced with the upper or lower limit value of another numerical range described in stages. Furthermore, in the numerical ranges described in this disclosure, the upper or lower limit value of that numerical range may be replaced with a value shown in the examples.

[0025] In the present disclosure, each component may contain multiple corresponding substances. When referring to the amount of each component in a composition in the present disclosure, if multiple substances corresponding to each component are present in the composition, the total amount of the multiple substances present in the composition is meant unless otherwise specified.

[0026] In this disclosure, the term "process" refers not only to an independent process, but also to a process that cannot be clearly distinguished from other processes, as long as the purpose of that process is achieved. Furthermore, in this disclosure, numerical ranges indicated using "to" indicate ranges that include the numerical values ​​before and after "to" as the minimum and maximum values, respectively. Furthermore, in this disclosure, the content of each component in a composition means the total amount of the multiple substances present in the composition, unless otherwise specified, when multiple substances corresponding to each component are present in the composition.

[0027] -Nonwoven fabric laminate- The nonwoven fabric laminate according to the present disclosure comprises an elastic nonwoven fabric containing an α-olefin copolymer having a ratio (E40 / E23) of the storage modulus E40 at 40° C. to the storage modulus E23 at 23° C. of 37% or more, and an extensible spunbond nonwoven fabric arranged on at least one side of the elastic nonwoven fabric. The nonwoven fabric laminate may also comprise other layers.

[0028] The nonwoven fabric laminate according to the present disclosure contains an α-olefin copolymer as an elastic nonwoven fabric, and therefore is believed to have superior stretchability and stress retention compared to elastic nonwoven fabrics that do not contain an α-olefin copolymer, such as elastic nonwoven fabrics made of polypropylene homopolymer. Furthermore, the α-olefin copolymer has a ratio (E40 / E23) of the storage modulus E40 at 40°C to the storage modulus E23 at 23°C of 37% or more. This means that the elastic nonwoven fabric is less likely to lose its elasticity even in a temperature-varying environment (e.g., 40°C to 23°C). This is thought to result in a nonwoven fabric laminate with excellent stress retention.

[0029] In the nonwoven fabric laminate of the present disclosure, an extensible spunbond nonwoven fabric is disposed on at least one side of an elastic nonwoven fabric. This is thought to facilitate preventing adhesion of the nonwoven fabric laminate to components such as various rotating devices in devices used in embossing processes, etc., and to result in excellent formability and productivity. Furthermore, because the extensible spunbond nonwoven fabric has extensibility, the stretchability due to the excellent elasticity of the elastic nonwoven fabric is easily maintained.

[0030] From the viewpoint of obtaining a nonwoven fabric laminate having excellent stretchability and stress retention, it is preferred that extensible spunbonded nonwoven fabrics be disposed on both sides of an elastic nonwoven fabric.

[0031] The nonwoven fabric laminate of the present disclosure has a basis weight of 360 g / m 2 Preferably, it is 240 g / m or less. 2 More preferably, it is 150 g / m or less. 2 More preferably, it is 120 g / m or less. 2~15g / m 2 It is particularly preferable that the 2 ~20g / m 2 It is even more preferable that the 2 ~25g / m 2 It is highly preferred that:

[0032] The basis weight ratio (composition ratio) of the elastic nonwoven fabric to the extensible spunbond nonwoven fabric may be set appropriately depending on various applications. For example, the basis weight ratio of the elastic nonwoven fabric to the extensible spunbond nonwoven fabric (elastic nonwoven fabric:extensible spunbond) is preferably within the range of 10:90 to 90:10, more preferably within the range of 20:80 to 80:20, and even more preferably within the range of 40:60 to 60:40. When the basis weight ratio of the elastic nonwoven fabric is 10 or more, the decrease in the stretchability of the nonwoven fabric laminate tends to be suppressed. On the other hand, when the basis weight ratio of the elastic nonwoven fabric is 90 or less, the proportion of the fibers constituting the elastic nonwoven fabric that extend beyond the extensible spunbonded nonwoven fabric layer and are exposed to the surface tends to decrease. As a result, a nonwoven fabric laminate with excellent formability and tactile feel can be easily obtained.

[0033] When two or more elastic nonwoven fabrics (or extensible spunbonded nonwoven fabrics) are present, the basis weight of the elastic nonwoven fabrics (or extensible spunbonded nonwoven fabrics) is the sum of two or more.

[0034] Nonwoven fabric laminate weight (g / m 2 ) is a value determined by measurement as follows. The basis weights of the elastic nonwoven fabric and the extensible spunbond nonwoven fabric are determined in the same manner. Six test pieces measuring 200 mm in the machine direction (MD) and 50 mm in the cross direction (CD) are taken from the nonwoven fabric laminate. The pieces are taken from three randomly selected locations in both the MD and CD (six locations in total). Next, the mass (g) of each test piece is measured using a top-pan electronic balance (manufactured by Kensei Kogyo Co., Ltd.), and the arithmetic mean value of the mass of each test piece is calculated. From the calculated arithmetic mean value, the mass of 1 m 2 Convert this into mass (g) per unit, round off to the nearest tenth, and calculate the basis weight [g / m 2 〕

[0035] The nonwoven fabric laminate preferably has a maximum load elongation in at least one direction of 100% or more, more preferably 150% or more, and even more preferably 220% or more.

[0036] The maximum load elongation (%) of the nonwoven fabric laminate is determined by the following measurement. Five test pieces measuring 200 mm in the machine direction (MD) and 50 mm in the cross direction (CD) are taken from the nonwoven fabric laminate. A tensile test is performed on these test pieces using a constant-rate extension tensile tester with a chuck distance of 100 mm and a tensile speed of 100 mm / min. The maximum load [N / 50 mm] applied to the test piece is measured, and the elongation [%] of the test piece at this maximum load is measured. The arithmetic average of the five test pieces is calculated and this is the maximum load elongation.

[0037] [Elastic nonwoven fabric] The elastic nonwoven fabric according to the present disclosure comprises an α-olefin copolymer having a ratio (E40 / E23) of the storage modulus E40 at 40°C to the storage modulus E23 at 23°C of 37% or more.

[0038] The weight of the elastic nonwoven fabric is 120 g / m 2 Preferably, it is 80 g / m or less. 2 More preferably, it is 50 g / m or less. 2 More preferably, it is 40 g / m or less. 2 ~2g / m 2 It is particularly preferable that the 2 ~5g / m 2 It is even more preferable that the 2 ~8g / m 2 It is highly preferred that: The fibers constituting the elastic nonwoven fabric preferably have a fiber diameter of 50 μm or less, more preferably 40 μm or less, and even more preferably 30 μm or less. The fibers constituting the elastic nonwoven fabric may have a fiber diameter of 1.0 μm or more.

[0039] The method for producing the elastic nonwoven fabric is not particularly limited, and various known methods may be applied. For example, the elastic nonwoven fabric may be produced by techniques such as the spunbond method, meltblowing method, flash spinning method, etc. Among the above, the elastic nonwoven fabric is preferably an elastic spunbond nonwoven fabric produced by the spunbond method, from the viewpoint of using long fibers to form the nonwoven fabric.

[0040] (α-olefin copolymer) The elastic nonwoven fabric comprises an α-olefin copolymer. The α-olefin copolymer refers to a copolymer in which two or more copolymerization components having an α-olefin skeleton are copolymerized. Examples of copolymerization components having an α-olefin skeleton include α-olefins such as ethylene, propylene, 1-butene, 1-pentene, 3-methyl-1-butene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, and 1-eicosene. Among the above, the α-olefin copolymer preferably contains an ethylene and propylene copolymer having ethylene (referred to as "C2" in Tables 1 and 2 below) and propylene (referred to as "C3" in Tables 1 and 2 below) as copolymerization components, from the viewpoint of making the nonwoven fabric laminate lower stress and more excellent stretchability.

[0041] In the copolymer of ethylene and propylene, the content of structural units derived from ethylene (hereinafter also simply referred to as "ethylene content") is preferably 1% by mass to 50% by mass, more preferably 5% by mass to 25% by mass, even more preferably 10% by mass to 20% by mass, and particularly preferably 12% by mass to 18% by mass.

[0042] The α-olefin copolymer may be any of an alternating copolymer, a graft copolymer, a block copolymer and a random copolymer.

[0043] The ratio (E40 / E23) of the storage modulus E40 at 40°C to the storage modulus E23 at 23°C of the α-olefin copolymer is 37% or more, from the viewpoint of obtaining a nonwoven fabric laminate with excellent stress retention. The larger the ratio (E40 / E23), the better, and it is more preferably 40% or more, even more preferably 45% or more, and particularly preferably 50% or more. There is no particular upper limit for the ratio (E40 / E23), and it may be 100% or less, 95% or less, or 90% or less.

[0044] An example of a method for adjusting the storage modulus ratio E40 / E23 in an α-olefin copolymer to fall within the above-mentioned specific range is to use a copolymer of ethylene and propylene as the α-olefin copolymer.

[0045] From the viewpoint of providing the nonwoven fabric laminate with superior stretchability, the storage modulus E23 of the α-olefin copolymer at 23°C is preferably 30 MPa or less, more preferably 22 MPa or less, even more preferably 20 MPa or less, and particularly preferably 18 MPa or less. The storage modulus E40 of the α-olefin copolymer at 40°C is preferably 10 MPa or less, and more preferably 9 MPa or less, from the viewpoint of providing a nonwoven fabric laminate with lower stress and better stretchability. The storage modulus E23 of the α-olefin copolymer at 23° C. may be 5 MPa or more, or may be 10 MPa or more. The storage modulus E40 of the α-olefin copolymer at 40° C. may be 3 MPa or more, or may be 5 MPa or more.

[0046] The storage modulus of each α-olefin copolymer is a value measured using the following apparatus and conditions. Temperature: 23℃ or 40℃ Device: RSA-III (manufactured by TI Instruments) Deformation mode: Tensile mode Temperature range: -20℃~120℃ Heating rate: 2°C / min Deformation frequency: 10Hz Initial strain: 0.1% Measurement temperature sensitivity: 0.3℃ Environment: Nitrogen atmosphere

[0047] The density of α-olefin copolymer (ASTM D 1505) is 0.850 g / cm 3 ~0.950g / cm 3 and preferably in the range of 0.855 g / cm 3 ~0.900g / cm 3 More preferably, the range is 0.860 g / cm 3 ~0.895g / cm 3 It is more preferable that the range is . The density of the α-olefin copolymer is a value obtained by measurement according to the density gradient method of JIS K7112 (1999).

[0048] To provide a nonwoven fabric laminate with superior stretchability, the tensile modulus of the α-olefin copolymer is preferably 30 MPa or less, more preferably 20 MPa or less, and even more preferably 15 MPa or less. The upper limit of the tensile modulus of the α-olefin copolymer is not particularly limited, and may be, for example, 5 MPa or more. The tensile modulus is a value obtained by measurement according to a method in accordance with JIS K7161 (2011).

[0049] The molecular weight distribution (Mw / Mn) of the α-olefin copolymer is preferably 1.5 to 5.0, and more preferably 1.5 to 4.5, in that fibers having good spinnability and particularly excellent fiber strength can be obtained.

[0050] The weight average molecular weight (Mw) and number average molecular weight (Mn) of the α-olefin copolymer are values determined by GPC (gel permeation chromatography) and are values measured under the following conditions. The weight average molecular weight (Mw) is the weight average molecular weight in terms of polystyrene, and the molecular weight distribution (Mw / Mn) is a value calculated from the number average molecular weight (Mn) and weight average molecular weight (Mw) measured in the same manner. <GPC measurement conditions> Column: TOSO GMHHR-H(S)HT Detector: RI detector for liquid chromatogram WATERS 150C Solvent: 1,2,4-trichlorobenzene Measurement temperature: 145 °C Flow rate: 1.0 ml / min Sample concentration: 2.2 mg / ml Injection volume: 160 μl Calibration curve: Universal Calibration Analysis program: HT-GPC (Ver.1.0)

[0051] The melt flow rate (MFR) of the α-olefin copolymer is not particularly limited, and for example, it is preferably 1 g / 10 min to 100 g / ten minutes, more preferably 10 g / 10 min to 80 g / 10 min, even more preferably 15 g / 10 min to 70 g / 10 min, and particularly preferably 15 g / 10 min to 50 g / 10 min.

[0052] The melt flow rate of the α-olefin copolymer is measured under the conditions of ASTM D-1238, 230 °C, and a load of 2.16 kg.

[0053] The α-olefin copolymer may be a synthetic product or a commercially available product. [[ID=3,4]]When the α-olefin copolymer is a synthetic product, the α-olefin copolymer can be prepared by polymerizing or copolymerizing a monomer by a conventionally known polymerization method such as a gas phase method, a bulk method, a slurry method, or a solution method in the presence of a conventionally known catalyst such as a Ziegler-Natta catalyst or a metallocene catalyst. Commercially available α-olefin copolymers include, for example, Tafmer (manufactured by Mitsui Chemicals, Inc.) and Vistamaxx series (manufactured by ExxonMobil Chemical Corporation).

[0054] The composition of the α-olefin copolymer can be determined using a conventionally known method (for example, IR analysis, NMR analysis, microanalysis, etc.).

[0055] The proportion of the α-olefin copolymer relative to the total amount of the elastic nonwoven fabric is preferably 90% by mass to 100% by mass, and more preferably 98% by mass to 100% by mass.

[0056] When the α-olefin copolymer contains a copolymer of ethylene and propylene, the proportion of the ethylene and propylene copolymer to the total amount of the elastic nonwoven fabric is preferably 80% by mass to 100% by mass, and more preferably 90% by mass to 100% by mass, from the viewpoint of the stretch properties of the nonwoven fabric laminate.

[0057] When the α-olefin copolymer is a copolymer of ethylene and propylene, the crystallinity of the α-olefin copolymer is preferably 1% to 15%, more preferably 1% to 13%, even more preferably 2% to 10%, and particularly preferably 4% to 10%, from the viewpoint of the stretch properties of the nonwoven fabric laminate.

[0058] The crystallinity of an α-olefin copolymer is calculated from the heat of fusion curve resulting from the melting of the main component in the melting endothermic curve obtained by holding a sample at -100°C for 5 minutes under a nitrogen atmosphere using a differential scanning calorimeter (DSC) and then heating it at 10°C / min. Specifically, using a differential scanning calorimeter (Perkin-Elmer, DSC-7), a 5 mg sample is held at -100°C for 5 minutes under a nitrogen atmosphere and then heated at 10°C / min. The crystallinity can be calculated from the heat of fusion curve resulting from the melting of the main component in the melting endothermic curve obtained by holding a sample at -100°C for 5 minutes under a nitrogen atmosphere using a differential scanning calorimeter (Perkin-Elmer, DSC-7) and then heating it at 10°C / min. Crystallinity = (ΔH / ΔH0)×100(%) In the formula, ΔH is the heat of fusion (J / g) calculated from the heat of fusion curve derived from the melting of the main component of an α-olefin copolymer containing ethylene and propylene, and ΔH0 is the heat of fusion (J / g) of perfect crystals of the main component. In other words, when the main component is ethylene, ΔH0 is 293 J / g, and when the main component is propylene, ΔH0 is 210 J / g.

[0059] When the α-olefin copolymer is a copolymer of ethylene and propylene, the melting point of the α-olefin may be 130°C or lower, 115°C or lower, 100°C or lower, 40°C to 85°C, or 40°C to 60°C.

[0060] The melting point of an α-olefin copolymer is defined as the peak top of the lowest temperature peak observed in the melting endothermic curve obtained by holding a sample at -100°C for 5 minutes under a nitrogen atmosphere and then increasing the temperature at 10°C / min using a differential scanning calorimeter (DSC-7, Perkin-Elmer) after holding a 5 mg sample at -100°C for 5 minutes under a nitrogen atmosphere and then increasing the temperature at 10°C / min.

[0061] [Stretchable spunbond nonwoven fabric] The extensible spunbond nonwoven fabric according to the present disclosure preferably has a maximum load elongation in at least one direction of 45% or more, more preferably 70% or more, even more preferably 100% or more, and particularly preferably 150% or more. The extensible spunbond nonwoven fabric is preferably a nonwoven fabric having almost no elastic recovery. The maximum load elongation [%] of the extensible spunbond nonwoven fabric is determined in the same manner as the maximum load elongation of the nonwoven fabric laminate. The extensible spunbond nonwoven fabric according to the present disclosure may have a maximum load elongation in at least one direction of 600% or less, or may be 500% or less.

[0062] The stretchable spunbond nonwoven fabric has a basis weight of 120 g / m 2Preferably, it is 80 g / m or less. 2 More preferably, it is 50 g / m or less. 2 More preferably, it is 40 g / m or less. 2 ~5g / m 2 It is particularly preferable that the 2 ~5g / m 2 It is even more preferable that the 2 ~8g / m 2 It is highly preferred that:

[0063] The fibers constituting the extensible spunbonded nonwoven fabric preferably have a fiber diameter of 50 μm or less, more preferably 40 μm or less, and even more preferably 30 μm or less. The fibers constituting the extensible spunbonded nonwoven fabric may have a fiber diameter of 1.0 μm or more.

[0064] The extensible spunbonded nonwoven fabric may be any of a concentric sheath-core type composite fiber having a core and a sheath, a sea-island type composite fiber having a sea portion and an island portion, a side-by-side type composite fiber, and a crimped composite fiber. The extensible spunbonded nonwoven fabric is preferably a concentric sheath-core type composite fiber or an island-in-sea type composite fiber.

[0065] The extensible spunbond nonwoven fabric containing the concentric core-sheath composite fibers preferably has a core made of a low MFR olefin polymer having an MFR in the range of 1 g / 10 min to 1000 g / 10 min, and a sheath made of a high MFR olefin polymer having an MFR in the range of 1 g / 10 min to 1000 g / 10 min, and the difference in MFR between the low MFR olefin polymer and the high MFR olefin polymer is preferably 1 g / 10 min or more. The difference in MFR is more preferably 15 g / 10 min or more, even more preferably 30 g / 10 min or more, and particularly preferably 40 g / 10 min or more. The difference in MFR may be 100 g / 10 min or less, or may be 70 g / 10 min or less.

[0066] The extensible spunbond nonwoven fabric containing the islands-in-sea type composite fibers may be islands-in-sea type composite fibers in which the sea portion is made of a propylene-based polymer (preferably a propylene homopolymer) and the island portion is made of an ethylene-based polymer (preferably high-density polyethylene).

[0067] Examples of extensible spunbond nonwoven fabrics include nonwoven fabrics made using one or more of the olefin polymer compositions described below.

[0068] (Olefin polymer composition) The extensible spunbond nonwoven fabric preferably contains an olefin polymer, and is preferably formed from an olefin polymer composition containing an olefin polymer. The olefin polymer may be a polyolefin elastomer.

[0069] The olefin polymer composition may contain, as optional components, various known additives such as antioxidants, heat stabilizers, weather stabilizers, antistatic agents, slip agents, antifogging agents, lubricants, dyes, pigments, natural oils, synthetic oils, waxes, and hydrophilic agents, provided that the object of the present disclosure is not impaired.

[0070] The olefin polymer is preferably a crystalline polymer. Examples of the crystalline component in the crystalline polymer include poly-1-butene and poly-4-methyl-1-pentene. The olefin polymer may be used alone or in combination of two or more.

[0071] Examples of the olefin polymer include homopolymers and copolymers of α-olefins such as ethylene, propylene, 1-butene, 1-hexene, 4-methyl-1-pentene, 1-octene, etc. Examples of the α-olefin copolymer include ethylene polymers and propylene polymers.

[0072] Examples of ethylene polymers include ethylene homopolymers such as high-pressure low-density polyethylene, linear low-density polyethylene (so-called LLDPE), and high-density polyethylene (so-called HDPE), as well as random or block copolymers of ethylene and an α-olefin.

[0073] The density of the ethylene polymer is not particularly limited, but is, for example, 0.94 g / cm 3 ~0.97g / cm 3 and preferably 0.95 g / cm 3 ~0.97g / cm 3 More preferably, it is 0.96 g / cm 3 ~0.97g / cm 3 It is more preferable that:

[0074] The MFR of the ethylene polymer is not particularly limited as long as it has spinnability, but from the viewpoint of exhibiting extensibility, it is preferably 0.1 g / 10 min to 100 g / 10 min, more preferably 0.5 g / 10 min to 50 g / 10 min, and even more preferably 1 g / 10 min to 30 g / 10 min.

[0075] Propylene-based polymers are generally crystalline resins manufactured and sold under the name of polypropylene. Propylene-based polymers are preferably propylene homopolymers or copolymers containing propylene as the main component. Examples of copolymers containing propylene as a main component include copolymers containing an α-olefin having two or more carbon atoms (preferably an α-olefin having 2 to 8 carbon atoms) as a copolymerization component, such as ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, or 4-methyl-1-pentene (however, alkenes having three carbon atoms, i.e., propylene, are excluded). The copolymer containing propylene as a main component may be either a random copolymer, a block copolymer, or the like.

[0076] The melting point (Tm) of the propylene homopolymer is preferably 155°C or higher, and more preferably 157°C to 165°C. The melting point (Tm) of the copolymer containing propylene as the main component is preferably 130°C or higher and lower than 155°C, and more preferably 130°C to 150°C. The MFR of the propylene polymer is not particularly limited as long as it can be melt-spun. The MFR of the propylene polymer is, for example, preferably 1 g / 10 min to 1000 g / 10 min, more preferably 5 g / 10 min to 500 g / 10 min, and even more preferably 10 g / 10 min to 100 g / 10 min.

[0077] The extensible spunbond nonwoven fabric may contain a polymer other than an olefin-based polymer (hereinafter also referred to as "other polymer"), or may not contain any other polymer. Examples of other polymers include thermoplastic elastomers and thermoplastic resins other than olefin-based polymers.

[0078] Specific examples of the thermoplastic elastomer include styrene-based elastomers, polyester-based elastomers, polyamide-based elastomers, thermoplastic polyurethane-based elastomers, vinyl chloride-based elastomers, and fluorine-based elastomers.

[0079] Specific examples of thermoplastic resins other than olefin polymers include polyesters (polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, etc.), polyamides (nylon-6, nylon-66, polymetaxylene adipamide, etc.), polyvinyl chloride, polyimide, ethylene-vinyl acetate copolymer, ethylene-vinyl acetate-vinyl alcohol copolymer, ethylene-(meth)acrylic acid copolymer, ethylene-acrylic acid ester-carbon monoxide copolymer, polyacrylonitrile, polycarbonate, and polystyrene.

[0080] The content of the olefin polymer in the extensible spunbond nonwoven fabric is preferably more than 90% by mass and 100% by mass or less, and more preferably 95% by mass to 100% by mass, of the total of the olefin polymer and other polymers (thermoplastic elastomers and thermoplastic resins other than olefin polymers).

[0081] The stretchable spunbonded nonwoven fabric does not contain any other polymers, or the content of other polymers (thermoplastic resins other than thermoplastic elastomers and olefin-based polymers) in the stretchable spunbonded nonwoven fabric is preferably more than 0% and less than 10% by mass, more preferably more than 0% and 5% by mass or less, of the total of the olefin-based polymers and other polymers.

[0082] When the olefin polymer composition contains a propylene polymer and an ethylene polymer, the content of the propylene polymer is preferably 80% by mass to 99% by mass, more preferably 84% by mass to 96% by mass, based on the total amount of the olefin polymer composition, while the content of the ethylene polymer is preferably 20% by mass to 1% by mass, more preferably 16% by mass to 4% by mass, based on the total amount of the olefin polymer composition (provided that the propylene polymer + the ethylene polymer = 100% by mass).

[0083] (Examples of stretchable spunbond nonwoven fabrics) The extensible spunbonded nonwoven fabric preferably includes an extensible spunbonded nonwoven fabric that satisfies the following requirements (1) to (3).

[0084] (1) Spunbond nonwoven fabrics using core-sheath type composite fibers, parallel type composite fibers (side-by-side type composite fibers), or crimped composite fibers made of two or more olefin-based polymers whose crystallization induction time difference in flow-induced phase separation is 100 seconds or more.

[0085] The two or more kinds of olefin polymers may be, for example, a propylene polymer having a high melting point and a propylene polymer having a low melting point.

[0086] (2) A spunbond nonwoven fabric using islands-in-sea type composite fibers, sheath-core type composite fibers, side-by-side type composite fibers, or crimped composite fibers made of an olefin polymer composition containing a propylene polymer and an ethylene polymer. In particular, the olefin polymer composition is preferably one shown below. (2-1) An olefin polymer composition comprising 80% by mass to 99% by mass of a propylene homopolymer and 20% by mass to 1% by mass of a high-density polyethylene. (2-2) An olefin polymer composition containing a high-melting propylene polymer having the same or different MFR and a melting point in the range of 157°C to 165°C.

[0087] The propylene-based polymer may be, for example, a propylene-based polymer obtained by copolymerizing a propylene homopolymer with a random copolymer of propylene and an α-olefin having a low melting point in the range of 130°C to 150°C.

[0088] (3) A spunbond nonwoven fabric using concentric core-sheath composite fibers, wherein the core is a low MFR propylene polymer having an MFR in the range of 1 g / 10 min to 200 g / 10 min, and the sheath is a high MFR propylene polymer having an MFR in the range of 16 g / 10 min to 215 g / 10 min, and the difference in MFR between the core and sheath is 15 g / 10 min or more.

[0089] Examples of extensible spunbonded nonwoven fabrics that satisfy the requirements (1) to (3) above include the extensible spunbonded nonwoven fabrics (A) and (B) below. (A) A spunbond nonwoven fabric using a concentric core-sheath composite fiber, a side-by-side composite fiber, or a crimped composite fiber, wherein the core is a propylene polymer (preferably a propylene homopolymer) having a low MFR and a high melting point, with an MFR in the range of 10 g / 10 min to 200 g / 10 min and a melting point in the range of 157°C to 165°C, and the sheath is a propylene-α-olefin random copolymer having a high MFR and a low melting point, with an MFR in the range of 10 g / 10 min to 200 g / 10 min and a melting point in the range of 130°C to 150°C, and the difference in MFR between the core and sheath is 1 g / 10 min or more. (B) A spunbond nonwoven fabric comprising concentric core-sheath composite fibers, the core of which is a low MFR propylene polymer (preferably a propylene homopolymer) having an MFR in the range of 1 g / 10 min to 200 g / 10 min, and the sheath of which is a high MFR propylene polymer (preferably a propylene homopolymer) having an MFR in the range of 31 g / 10 min to 230 g / 10 min, and the difference in MFR between the core and sheath is 30 g / 10 min or more. In the above-mentioned (B), the core may be a low MFR propylene polymer having an MFR in the range of 10 g / 10 min to 50 g / 10 min, and the sheath may be a high MFR propylene polymer having an MFR in the range of 50 g / 10 min to 100 g / 10 min. The difference between the MFR of the core and the MFR of the sheath may be 30 g / 10 min to 100 g / 10 min, or 40 g / 10 min to 80 g / 10 min.

[0090] [Other layers] Other layers may be laminated to the nonwoven fabric laminate of the present disclosure depending on various applications. The other layers to be laminated to the nonwoven fabric laminate of the present disclosure are not particularly limited, and various layers may be laminated depending on the application.

[0091] Specific examples of other layers include knitted fabrics, woven fabrics, nonwoven fabrics other than elastic nonwoven fabrics and extensible spunbonded nonwoven fabrics, films, etc. The method for laminating (bonding) other layers to the nonwoven fabric laminate of the present disclosure is not particularly limited, and various methods can be used, such as heat embossing, ultrasonic welding, and other heat fusion methods, needle punching, water jet welding, and other mechanical entanglement methods, methods using adhesives such as hot melt adhesives and urethane adhesives, and extrusion lamination.

[0092] When the nonwoven fabric laminate of the present disclosure contains a nonwoven fabric other than an elastic nonwoven fabric and an extensible spunbond nonwoven fabric, examples of the nonwoven fabric include various known nonwoven fabrics such as spunbond nonwoven fabrics, meltblown nonwoven fabrics, wetlaid nonwoven fabrics, drylaid nonwoven fabrics, drylaid pulp nonwoven fabrics, flash-spun nonwoven fabrics, and spread-fiber nonwoven fabrics. These nonwoven fabrics may be stretchable or non-stretchable nonwoven fabrics. Here, a non-stretchable nonwoven fabric refers to one that does not generate return stress after being stretched in the MD (machine direction, machine direction) or CD (direction perpendicular to the machine direction, cross direction) of the nonwoven fabric.

[0093] When the nonwoven fabric laminate of the present disclosure includes a film, the film is preferably a breathable (moisture-permeable) film in order to maintain the breathability and hydrophilicity characteristic of the nonwoven fabric laminate of the present disclosure. Examples of breathable films include various known breathable films, such as films made of moisture-permeable thermoplastic elastomers such as polyurethane elastomers, polyester elastomers, and polyamide elastomers, and porous films obtained by stretching a film made of a thermoplastic resin containing inorganic or organic fine particles to make it porous. Preferred thermoplastic resins used for porous films include polyolefins such as high-pressure low-density polyethylene, linear low-density polyethylene (LLDPE), high-density polyethylene, polypropylene, polypropylene random copolymers, and combinations thereof. However, if the breathability and hydrophilicity of the nonwoven fabric laminate do not need to be maintained, films of thermoplastic resins such as polyethylene, polypropylene, and combinations thereof may also be used.

[0094] [Method for producing nonwoven fabric laminate] The nonwoven fabric laminate of the present disclosure can be produced by a known method for producing nonwoven fabrics using an elastic nonwoven fabric containing an α-olefin copolymer, an extensible spunbond nonwoven fabric, and additives used as needed.

[0095] As an example of a method for producing a nonwoven fabric laminate, a method using a nonwoven fabric production apparatus equipped with at least two rows of spinning devices will be described below. The following example is an example of a method for producing a nonwoven fabric laminate using an olefin polymer as the extensible spunbond nonwoven fabric and an α-olefin copolymer as the elastic nonwoven fabric. From the viewpoint of manufacturing, the nonwoven fabric laminate of the present disclosure preferably has an extensible spunbond nonwoven fabric disposed on the surface that comes into contact with a rotating device associated with the nonwoven fabric manufacturing apparatus. First, an olefin polymer, if necessary two or more types of olefin polymers, is melted in an extruder, if necessary two or more extruders, provided in the first line of spinning equipment, and introduced into a die equipped with a large number of spinning holes (nozzles), if necessary spinning holes having a core-sheath structure, and discharged. Thereafter, the melt-spun long fibers containing the olefin polymer are introduced into a cooling chamber and cooled with cooling air, and then stretched (pulled) with stretching air, and an extensible spunbond nonwoven fabric is deposited on a moving collecting surface. On the other hand, a resin composition containing the α-olefin copolymer of the present disclosure is melted in an extruder provided in the second row of spinning equipment and introduced into a spinning die having a number of spinning holes (nozzles), and the resin composition is extruded. The melt-spun long fibers containing the resin composition are then introduced into a cooling chamber and cooled with cooling air. Then, the long fibers are stretched (pulled) with stretching air and deposited on an extensible spunbond nonwoven fabric to form an elastic nonwoven fabric. If desired, a third row of spinning equipment may be used to deposit an extensible spunbond nonwoven onto the elastic nonwoven.

[0096] The melting temperature of each polymer in the elastic nonwoven fabric and the extensible spunbonded nonwoven fabric is not particularly limited as long as it is equal to or higher than the softening or melting temperature of each polymer and lower than the thermal decomposition temperature. The die temperature depends on the type of polymer used, but for example, when a copolymer of ethylene and propylene is used as the α-olefin copolymer, the die temperature is preferably 180°C to 240°C, more preferably 190°C to 230°C, and even more preferably 200°C to 225°C.

[0097] The temperature of the cooling air is not particularly limited as long as it is a temperature at which the polymer solidifies, and is preferably 5° C. to 50° C., more preferably 10° C. to 40° C., and even more preferably 15° C. to 30° C. The wind speed of the drawing air is preferably 100 m / min to 10,000 m / min, and more preferably 500 m / min to 10,000 m / min.

[0098] The nonwoven fabric laminate of the present disclosure preferably has a structure in which at least a portion of the elastic nonwoven fabric and at least a portion of the extensible spunbonded nonwoven fabric are heat-fused together. In this case, at least a portion of the elastic nonwoven fabric and at least a portion of the extensible spunbonded nonwoven fabric may be pressed together using nip rolls before being heat-fused together.

[0099] The method of heat fusion is not particularly limited and can be selected from various known methods. For example, pre-bonding methods include a method using ultrasonic waves, a heat embossing process using an embossing roll, and a method using hot air through. Among these, heat embossing is preferred from the viewpoint of efficiently stretching the long fibers during stretching, and the temperature range is preferably 40°C to 115°C.

[0100] When a portion of the laminate is heat-sealed by heat embossing, the embossed area ratio is preferably 5% to 30%, more preferably 5% to 20%. The non-embossed unit area is 0.5 mm 2 It is preferable that it is 4 mm or more. 2 ~40mm 2The non-embossed unit area refers to the maximum area of ​​a rectangle inscribed in the embossment in the smallest unit of non-embossed area surrounded by embossed areas on all four sides. Examples of the shape of the mark include a circle, ellipse, oval, square, diamond, rectangle, square, and continuous shapes based on these shapes.

[0101] <Stretchable nonwoven fabric laminate> The stretchable nonwoven fabric laminate of the present disclosure is a stretchable nonwoven fabric laminate obtained by stretching the nonwoven fabric laminate.

[0102] The stretchable nonwoven fabric laminate of the present disclosure is a stretched nonwoven fabric laminate obtained by stretching the nonwoven fabric laminate. There are no particular limitations on the stretching method, and conventionally known methods can be used. The stretching method may be a partial stretching method or a full stretching method. It may also be a uniaxial stretching method or a biaxial stretching method. An example of a method for stretching in the machine direction (MD) is passing the partially fused mixed fibers through two or more nip rolls. The partially fused nonwoven fabric laminate can be stretched by increasing the rotation speed of the nip rolls in the machine direction. Gear stretching can also be performed using the gear stretching device shown in Figure 1.

[0103] The lower limit of the stretching ratio is preferably 50% or more, more preferably 100% or more, and even more preferably 200% or more, while the upper limit of the stretching ratio is preferably 1000% or less, and more preferably 500% or less.

[0104] In the case of uniaxial stretching, it is preferable that the stretch ratio in either the machine direction (MD) or the direction perpendicular to the machine direction (CD) satisfies the above-mentioned stretch ratio. In the case of biaxial stretching, it is preferable that the stretch ratio in at least one of the machine direction (MD) and the direction perpendicular to the machine direction (CD) satisfies the above-mentioned stretch ratio.

[0105] By performing the stretching process at the above-mentioned stretch ratio, both the (long) fibers forming the elastic nonwoven fabric and the extensible spunbonded nonwoven fabric are stretched. The long fibers forming the extensible spunbonded nonwoven fabric layer are plastically deformed and elongated (i.e., lengthened) according to the above-mentioned stretch ratio. When the stress is released after stretching the nonwoven fabric laminate, the (long) fibers forming the elastic nonwoven fabric elastically recover, while the long fibers forming the extensible spunbonded nonwoven fabric fold without elastic recovery, resulting in a bulky feel in the nonwoven fabric laminate. Furthermore, the long fibers forming the extensible spunbonded nonwoven fabric tend to become thinner. This is thought to improve the flexibility and feel of the nonwoven fabric, as well as provide stretch-resistance.

[0106] <Textile products> The textile product of the present disclosure includes a nonwoven fabric laminate or a stretchable nonwoven fabric laminate of the present disclosure. The textile product is not particularly limited, and examples include absorbent articles such as disposable diapers and sanitary products, hygiene articles such as sanitary masks, medical articles such as bandages, clothing materials, and packaging materials. The textile product of the present disclosure preferably includes a nonwoven fabric laminate or a stretchable nonwoven fabric laminate of the present disclosure as an elastic member. [Example]

[0107] The present invention will be described in more detail below based on examples, but the present invention is not limited to the following examples. The materials, amounts used, ratios, processing procedures, etc. shown in the following examples can be changed as appropriate without departing from the spirit of this disclosure. Unless otherwise specified, "parts" means "parts by mass."

[0108] -Preparing the materials- The following materials were prepared as raw materials for the elastic nonwoven fabric. α-Olefin copolymer 1A (propylene / ethylene copolymer) Manufactured by ExxonMobil, product name "Vistamaxx" TM 6202", MFR (230°C, load 2.16 kg): 20 g / 10 min, ethylene content: 15 mass%, tensile modulus: 9.8 MPa. α-Olefin copolymer 1B (propylene / ethylene copolymer) Manufactured by ExxonMobil, product name "Vistamaxx" TM 7050FL", MFR (230°C, load 2.16 kg): 48 g / 10 min, ethylene content: 13 mass%, tensile modulus: 14.4 MPa.

[0109] Synthesis of α-olefin homopolymer 1C (low crystalline polypropylene) With agitator, internal volume 0.2m 3 A stainless steel reactor was continuously fed with n-heptane at 20 L / h, triisobutylaluminum at 15 mmol / h, and a catalyst component prepared by pre-contacting dimethylanilinium tetrakispentafluorophenylborate, (1,2'-dimethylsilylene)(2,1'-dimethylsilylene)-bis(3-trimethylsilylmethylindenyl)zirconium dichloride, triisobutylaluminum, and propylene at 6 μmol / h per zirconium. Propylene and hydrogen were continuously fed at a polymerization temperature of 70 °C, maintaining a gas-phase hydrogen concentration of 8 mol%, and a total pressure in the reactor of 0.7 MPa·G. SUMILIZER GP (Sumitomo Chemical Co., Ltd.) was added to the resulting polymerization solution to a concentration of 1000 ppm, and the solvent was removed to obtain a propylene polymer. The weight average molecular weight (Mw) of the obtained propylene polymer was 1.2 × 10 4 , Mw / Mn = 2. In addition, [mmmm] was 46 mol%, [rrrr] / (1-[mmmm]) was 0.038, [rmrm] was 2.7 mol%, and [mm] × [rr] / [mr] was 2 The elastic modulus was 1.5 and the tensile modulus was 32.9 MPa. Here, [mmmm] is the mesopentad fraction, [rrrr] is the racemic pentad fraction, [rmrm] is the racemic-mesoracemic-mesopentad fraction, and [mm], [rr], and [mr] are triad fractions. These values ​​can be determined, for example, by the method described in WO 2016 / 143834.

[0110] [Example 1] MFR (measured in accordance with ASTM D1238 at 230°C and 2.16 kg load) 8.5 g / 10 min, density 0.91 g / cm 3 A propylene homopolymer having a melting point of 160°C (hereinafter referred to as "Polymer 2A"; referred to as "PP" in Tables 1 and 2) was melted using a 50 mmφ extruder, and independently, a polymer having an MFR (measured in accordance with ASTM D1238 at a temperature of 230°C and a load of 2.16 kg) of 60 g / 10 min and a density of 0.91 g / cm 3 A propylene homopolymer (hereinafter referred to as "Polymer 2B"; referred to as "PP" in Tables 1 and 2) having a melting point of 160°C was melted using a 75 mmφ extruder, and then conjugate melt spinning was carried out by the spunbonding method using a spunbond nonwoven fabric molding machine (length perpendicular to the machine direction on the collecting surface: 800 mm) equipped with a spinneret (die, number of holes: 2887) capable of molding concentric core-sheath composite fibers in which "Polymer 2A" was the core and "Polymer 2B" was the sheath, under conditions of resin temperature and die temperature of 250°C, cooling air temperature of 20°C, and drawing air speed of 3750 m / min, and an extensible spunbond nonwoven fabric consisting of concentric core-sheath composite fibers with a core-to-sheath mass ratio of 10 / 90 was deposited on the collecting surface as the first layer. Next, the α-olefin copolymer 1A was melted on the deposition surface using a single-screw extruder with a screw diameter of 75 mm, and then melt-spun using a spunbond nonwoven fabric molding machine (length perpendicular to the machine flow direction on the collection surface: 800 mm) with a spinneret (die, number of holes: 808) under conditions of resin temperature and die temperature both 215°C, cooling air temperature 20°C, and drawing air speed 3750 m / min, to deposit an elastic nonwoven fabric (elastic spunbond nonwoven fabric) as the second layer. The spinnability of the α-olefin copolymer 1A in this process was very good. Next, as the third layer, the same core-sheath type composite fibers as in the first layer were deposited in the same manner to form a three-layer deposit. This deposit was then subjected to a heat and pressure treatment with an embossing roll (embossed area ratio 18%, embossing temperature 70°C) to form a three-layer deposit with a total weight of 30.0 g / m. 2 The weight of the first and third layers is 10.0 g / m 2 The second layer, the elastic nonwoven fabric layer, has a basis weight of 10.0 g / m 2A nonwoven fabric laminate was produced (mass fraction of the elastic nonwoven fabric layer relative to the entire body was 33.3%). The nonwoven fabric laminate obtained as described above showed almost no adhesion to the metal roll surface during the embossing process, and had good formability. Furthermore, when the nonwoven fabric laminate was wound into a roll, roll blocking (a phenomenon in which overlapping nonwoven fabrics stick to each other and the roll hardens) did not occur, and the laminate could be easily unwound.

[0111] [Example 2] A nonwoven fabric laminate was obtained in the same manner as in Example 1, except that the raw material for the elastic nonwoven fabric was changed from α-olefin copolymer 1A to α-olefin copolymer 1B.

[0112] [Comparative Example 1] A nonwoven fabric laminate was obtained in the same manner as in Example 1, except that the raw material for the elastic nonwoven fabric was changed from α-olefin copolymer 1A to α-olefin homopolymer 1C.

[0113] [Example 3] The basis weight of the stretchable spunbond nonwoven fabric in the first and third layers and the basis weight of the elastic nonwoven fabric in the second layer are 10.0 g / m 2 to 16.7 g / m 2 A nonwoven fabric laminate was obtained in the same manner as in Example 1, except for the above change.

[0114] [Example 4] The basis weight of the stretchable spunbond nonwoven fabric in the first and third layers is 10.0 g / m 2 to 15.6 g / m 2 The weight of the elastic nonwoven fabric in the second layer was changed to 10.0 g / m 2 to 18.8 g / m 2 A nonwoven fabric laminate was obtained in the same manner as in Example 1, except for the above change.

[0115] [Example 5] The basis weight of the stretchable spunbond nonwoven fabric in the first and third layers and the basis weight of the elastic nonwoven fabric in the second layer are 10.0 g / m 2to 20.0 g / m 2 A nonwoven fabric laminate was obtained in the same manner as in Example 1, except for the above change.

[0116] [Example 6] The basis weight of the stretchable spunbond nonwoven fabric in the first and third layers and the basis weight of the elastic nonwoven fabric in the second layer are 10.0 g / m 2 to 20.0 g / m 2 A nonwoven fabric laminate was obtained in the same manner as in Example 2, except for changing the above.

[0117] Comparative Example 2 The basis weight of the stretchable spunbond nonwoven fabric in the first and third layers and the basis weight of the elastic nonwoven fabric in the second layer are 10.0 g / m 2 to 20.0 g / m 2 A nonwoven fabric laminate was obtained in the same manner as in Comparative Example 1, except for changing the above.

[0118] Comparative Example 3 The weight of the elastic nonwoven fabric in the second layer is 20.0 g / m 2 to 25.0 g / m 2 A nonwoven fabric laminate was obtained in the same manner as in Comparative Example 2, except for changing the above.

[0119] -evaluation- (Spinnability) For each nonwoven fabric, the spinning condition near the nozzle surface of the spunbond nonwoven fabric manufacturing device was visually observed during production, and the number of times that thread breakage occurred per 5 minutes (unit: times / 5 minutes) was counted. If the number of times that thread breakage occurred per 5 minutes, it was evaluated as "A," and if thread breakage occurred but did not result in the production of nonwoven fabric, it was evaluated as "B" (Tables 1 and 2).

[0120] -Evaluation of stretch properties (stress at 50% elongation, stress at 50% recovery)- Five 50 mm (CD) x 200 mm (MD) test specimens were prepared from each nonwoven fabric laminate using a universal tensile tester (Intesco, Model IM-201). Each test specimen was then stretched to 100% using a 50 mm sample width, a 100 mm chuck distance, and a 100 mm / min tensile speed. The specimens were then immediately returned to their original length at the same speed. This procedure was repeated for another cycle. The stress at which the stretch ratio reached 50% during the second stretch cycle was recorded as the stress at 50% elongation, and the stress at which the stretch ratio reached 50% during the second recovery cycle was recorded as the stress at 50% recovery. The value of [stress at 50% recovery / stress at 50% elongation] was then measured as a measure of stretchability, and the arithmetic average of the five test specimens was used to evaluate the stretchability. Note that a larger value of [stress at 50% recovery / stress at 50% elongation] indicates better stretchability (Tables 1 and 2).

[0121] In addition, the storage modulus at each temperature, the storage modulus ratio, the maximum load elongation, and the basis weight of each nonwoven fabric in each example were measured using the above-mentioned measurement methods, and the results are shown in Tables 1 and 2.

[0122] [Table 1]

[0123] [Table 2]

[0124] As shown in Tables 1 and 2, the nonwoven fabric laminates of the Examples were found to be superior in stretchability and stress retention compared to the nonwoven fabric laminates of the Comparative Examples.

[0125] The disclosure of Japanese Patent Application No. 2018-201247, filed on October 25, 2018, is incorporated herein by reference in its entirety. All publications, patent applications, and technical standards mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent application, or technical standard was specifically and individually indicated to be incorporated by reference.

Claims

1. An elastic nonwoven fabric containing an α-olefin copolymer having a ratio (E40 / E23) of the storage modulus E40 at 40°C to the storage modulus E23 at 23°C of 37% or more (however, excluding elastic nonwoven fabrics containing propylene homopolymers); an extensible spunbond nonwoven fabric disposed on at least one side of the elastic nonwoven fabric; A nonwoven fabric laminate having the MFR of the α-olefin copolymer in the elastic nonwoven fabric is 15 g / 10 min to 50 g / 10 min; the α-olefin copolymer is a copolymer of ethylene and propylene, the content of structural units derived from ethylene in the copolymer of ethylene and propylene is 10% by mass to 18% by mass; The nonwoven fabric laminate has a basis weight of 80 g / m ２ ~25g / m ２ and the α-olefin copolymer has a tensile modulus of 5 MPa to 20 MPa; A nonwoven fabric laminate in which a [stress at 50% recovery / stress at 50% elongation] value in a 50 mm (CD) x 200 mm (MD) test piece prepared from the nonwoven fabric laminate is 0.41 to 0.

58.

2. 2. The nonwoven fabric laminate according to claim 1, wherein the storage modulus E23 at 23° C. of the α-olefin copolymer is 30 MPa or less.

3. 3. The nonwoven fabric laminate according to claim 1, wherein the extensible spunbonded nonwoven fabric is disposed on both sides of the elastic nonwoven fabric.

4. 4. The nonwoven fabric laminate according to claim 1, wherein the extensible spunbonded nonwoven fabric has a maximum load elongation of 45% or more in at least one direction.

5. The nonwoven fabric laminate according to any one of claims 1 to 4, wherein the elastic nonwoven fabric is an elastic spunbonded nonwoven fabric.

6. 6. The nonwoven fabric laminate according to claim 1, wherein the extensible spunbonded nonwoven fabric is an extensible spunbonded nonwoven fabric comprising concentric core-sheath composite fibers, the core of which is a low MFR olefin polymer having an MFR in the range of 1 g / 10 min to 1000 g / 10 min, and the sheath of which is a high MFR olefin polymer having an MFR in the range of 1 g / 10 min to 1000 g / 10 min, and the difference in MFR between the low MFR olefin polymer and the high MFR olefin polymer is 1 g / 10 min or more.

7. 7. The nonwoven fabric laminate according to claim 1, wherein the extensible spunbonded nonwoven fabric contains an olefin polymer composition comprising 80% by mass to 99% by mass of a crystalline propylene polymer and 1% by mass to 20% by mass of a high-density polyethylene.

8. The nonwoven fabric laminate according to any one of claims 1 to 7, wherein the basis weight ratio of the elastic nonwoven fabric to the extensible spunbonded nonwoven fabric (elastic nonwoven fabric:extensible spunbonded nonwoven fabric) is in the range of 10:90 to 90:

10.

9. A stretchable nonwoven fabric laminate, which is a stretched product of the nonwoven fabric laminate according to any one of claims 1 to 8.

10. A textile product comprising the nonwoven fabric laminate according to any one of claims 1 to 8 or the stretchable nonwoven fabric laminate according to claim 9.

11. An absorbent article comprising the nonwoven fabric laminate according to any one of claims 1 to 8 or the stretchable nonwoven fabric laminate according to claim 9.

12. A hygienic mask comprising the nonwoven fabric laminate according to any one of claims 1 to 8 or the stretchable nonwoven fabric laminate according to claim 9.

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