Nonwoven laminates, stretchable nonwoven laminates, textile products, absorbent articles, and masks

Abstract

A nonwoven fabric laminate with excellent stretchability is provided. [Solution] The nonwoven laminate of the present disclosure comprises an elastic nonwoven fabric made of a semicrystalline resin composition and an extensible spunbond nonwoven fabric disposed on at least one main surface of the elastic nonwoven fabric. The semicrystalline resin composition contains an α-olefin copolymer having a melting point of 100°C or less and crystalline polypropylene having a melting point exceeding 100°C. The content of the α-olefin copolymer is 97.0% to 99.9% by mass with respect to the total amount of the semicrystalline resin composition. The content of the crystalline polypropylene is 0.1% to 3.0% by mass with respect to the total amount of the semicrystalline resin composition.

Description

Technical Field

[0001] The present disclosure relates to a nonwoven fabric laminate, a stretchable nonwoven fabric laminate, a fiber product, an absorbent article, and a mask.

Background Art

[0002] In recent years, nonwoven fabrics have been widely used in various applications because of their excellent air permeability and flexibility. Therefore, various characteristics corresponding to their applications are required for nonwoven fabrics, and improvement of those characteristics is demanded. For example, nonwoven fabrics used for sanitary materials (such as disposable diapers, sanitary napkins, and masks, etc.) are required to have stretchability depending on the location where they are used.

[0003] Patent Document 1 discloses a nonwoven fabric laminate. The nonwoven fabric laminate has an elastic nonwoven fabric containing a specific α-olefin copolymer and an extensible spunbond nonwoven fabric disposed on at least one side of the elastic nonwoven fabric. Patent Document 1 does not specifically disclose that the elastic nonwoven fabric contains crystalline polypropylene.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] Particularly in applications such as sanitary materials, it is required that they can be worn with a weak force and do not shift during wearing. Therefore, a nonwoven fabric laminate having more excellent stretch characteristics is required.

[0006] <​​​

[0007] The following embodiments are included as specific means for solving the aforementioned problems. <1> An elastic nonwoven fabric made of a semicrystalline resin composition, The elastic nonwoven fabric comprises an stretchable spunbond nonwoven fabric disposed on at least one main surface of the elastic nonwoven fabric, The aforementioned semicrystalline resin composition α-olefin copolymers with a melting point of 100°C or lower, Crystalline polypropylene with a melting point exceeding 100°C, Includes, The content of the α-olefin copolymer is 97.0% to 99.9% by mass relative to the total amount of the semicrystalline resin composition. A nonwoven laminate in which the content of the crystalline polypropylene is 0.1% to 3.0% by mass relative to the total amount of the semicrystalline resin composition. <2> The content of the crystalline polypropylene is 0.5% by mass or more and less than 1.0% by mass relative to the total amount of the semicrystalline resin composition. <1> The nonwoven laminate described above. <3> The return stress per unit area is 1.60 N / 50 mm / (g / m 2 ) × 100 ~ 3.0 N / 50 mm (g / m 2 ) × 100, the above <1> or <2> The nonwoven laminate described above. <4> The ratio of the α-olefin copolymer (E40 / E23) is 37% or more. The aforementioned ratio (E40 / E23) represents the ratio of the storage modulus E40 at 40°C to the storage modulus E23 at 23°C. <1> ~ <3> A nonwoven fabric laminate as described in any one of the following. <5> The α-olefin copolymer comprises a copolymer of ethylene and propylene. <1> ~ <4> A nonwoven fabric laminate as described in any one of the following. <6> The resin composition constituting the stretchable spunbond nonwoven fabric consists of a propylene homopolymer and the polyolefin (B) having a density of 0.94 g / cm³. 3 ~0.97g / cm 3The above includes polyethylene, <1> ~ <5> A nonwoven fabric laminate as described in any one of the following. <7> The stretchable spunbond nonwoven fabric is arranged on both main surfaces of the elastic nonwoven fabric. <1> ~ <6> A nonwoven fabric laminate as described in any one of the following. <8> The aforementioned, including elastic thread <1> The nonwoven laminate described above. <9> The film layer, <1> The nonwoven laminate described above. <10> The aforementioned <1> ~ <9> A stretchable nonwoven fabric laminate, which is a stretched product of a nonwoven fabric laminate described in any one of the following. <11> The aforementioned <10> Textile products including the stretchable nonwoven laminate described in [reference]. <12> The further includes an engaging means that can be engaged, <11> Textile products as described above. <13> The aforementioned <10> An absorbent article containing the stretchable nonwoven fabric laminate described in [reference]. <14> The aforementioned <10> A mask containing the stretchable nonwoven fabric laminate described in [reference]. [Effects of the Invention]

[0008] According to one embodiment of this disclosure, a nonwoven fabric laminate with excellent stretchability, a stretchable nonwoven fabric laminate, a textile product, an absorbent article, and a mask are provided. [Brief explanation of the drawing]

[0009] [Figure 1] Figure 1 is a schematic diagram of a gear extension device. [Modes for carrying out the invention]

[0010] The embodiments of this disclosure are described below. These descriptions and embodiments are illustrative and do not limit the scope of the embodiments. In numerical ranges described in stages within this disclosure, the upper or lower limit of one numerical range may be replaced by the upper or lower limit of another numerical range described in stages. In numerical ranges described within this disclosure, the upper or lower limit of that range may be replaced by the values ​​shown in the examples. In this disclosure, each component may contain multiple types of the corresponding substance. When referring to the amount of each component in a composition in this disclosure, if there are multiple types of the substance corresponding to each component in the composition, it means the total amount of those multiple types of substances present in the composition unless otherwise specified. In this disclosure, the term "process" includes not only independent processes but also processes that are not clearly distinguishable from other processes, provided that their objective is achieved. In this disclosure, numerical ranges indicated using "~" represent a range that includes the numbers before and after "~" as the minimum and maximum values, respectively. In this disclosure, the content of each component in a composition means the total amount of multiple substances present in the composition if multiple substances corresponding to each component exist in the composition, unless otherwise specified.

[0011] (1) Nonwoven fabric laminate according to the embodiment A nonwoven laminate according to an embodiment of the present disclosure comprises an elastic nonwoven fabric made of a semicrystalline resin composition and an extensible spunbond nonwoven fabric disposed on at least one main surface of the elastic nonwoven fabric. The semicrystalline resin composition contains an α-olefin copolymer having a melting point of 100°C or less (hereinafter also simply referred to as "α-olefin copolymer") and crystalline polypropylene having a melting point exceeding 100°C (hereinafter also simply referred to as "crystalline polypropylene"). The content of the α-olefin copolymer is 97.0% to 99.9% by mass of the total amount of the semicrystalline resin composition. The content of the crystalline polypropylene is 0.1% to 3.0% by mass of the total amount of the semicrystalline resin composition.

[0012] "Semi-crystalline resin composition" refers to a resin composition that has a melting point. "Elastic nonwoven fabric" refers to a nonwoven fabric that has elasticity. "Elastic nonwoven fabric" refers to a nonwoven fabric that, after being stretched and then released from stress, recovers to its original shape due to its elasticity. The fibers contained in the elastic nonwoven fabric in this disclosure consist of a semicrystalline resin composition. The storage modulus E23 of the α-olefin copolymer contained in the semicrystalline resin composition is preferably 25.0 MPa or less. If the storage modulus E23 of the α-olefin copolymer contained in the semicrystalline resin composition exceeds 25.0 MPa, the stretchability of the nonwoven laminate tends to decrease. From the viewpoint of improving the stretchability of the nonwoven laminate, the storage modulus E23 of the α-olefin copolymer contained in the semicrystalline resin composition is preferably 22.0 MPa or less, more preferably 18.0 MPa or less. The method for measuring the storage modulus E23 is the same as in the example. Furthermore, the storage modulus of the polymer used in the nonwoven laminate can affect the stretchability of the nonwoven laminate, regardless of whether the laminate contains a surface layer, a backing layer, or an intermediate layer. "Nonwoven fabric" refers to a planar fiber assembly that has obtained a predetermined level of structural strength by physical and / or chemical methods, excluding weaving, knitting, and papermaking. "Stretchable spunbond nonwoven fabric" refers to a spunbond nonwoven fabric that is stretchable. "Stretchable" means that the spunbond nonwoven fabric has a first property and a second property. The first property is that when an external force is applied to the spunbond nonwoven fabric, the shape of the spunbond nonwoven fabric stretches in one direction. The second property is that even when the external force applied to the spunbond nonwoven fabric is released, the shape of the spunbond nonwoven fabric does not easily return to its original state. Specifically, a stretchable nonwoven fabric has a maximum elongation of 50% or more, preferably 70% or more, more preferably 100% or more, and exhibits almost no elastic recovery. "Spunbond nonwoven fabric" refers to a nonwoven fabric composed of continuous fibers (long fibers) and made by bonding one or more spunlaid webs. "Spunlaid web" refers to a web laminated by spinlay lamination. "Spinlay lamination" refers to a method of creating a web by extruding molten or dissolved polymer from a nozzle and laminating the filaments onto a moving screen. "α-olefin copolymer" refers to a copolymer obtained by copolymerizing two or more components having an α-olefin skeleton, in which crystalline polypropylene has been removed. "Crystalline polypropylene" refers to polypropylene polymers that have a melting point. Polypropylene polymers mainly contain constituent units derived from propylene. "Main component" refers to the component with the highest mass percentage among the components that make up the polymer. Specifically, "crystalline polypropylene" refers to propylene homopolymers (hereinafter also referred to as "h-pp") or copolymers with propylene as the main component (hereinafter also referred to as "propylene copolymers").

[0013] The nonwoven laminate disclosed herein has the above-described structure and therefore exhibits excellent stretchability. This effect is presumed to be due to, but is not limited to, the following reasons. In this disclosure, the crystalline polypropylene content is 0.1% to 3.0% by mass. In other words, the semi-crystalline resin composition contains a small amount of crystalline polypropylene. It is believed that the crystalline polypropylene acts as a nucleating agent, promoting the crystallization of the polymer chains of the α-olefin copolymer. As a result, it is presumed that the stretchability of the elastic nonwoven fabric and the stretchability of the nonwoven laminate are improved.

[0014] Hereinafter, a nonwoven fabric laminate that has not undergone secondary processing (e.g., stretching) will simply be referred to as a "nonwoven fabric laminate," and a nonwoven fabric laminate that has undergone stretching will be referred to as a "stretchable nonwoven fabric laminate."

[0015] Nonwoven laminates are sheet-like materials. The layer configuration of the nonwoven laminate is appropriately selected according to the application of the nonwoven laminate, and may consist of two layers, three layers, or four or more layers. A two-layer configuration consists of an elastic nonwoven fabric and an extendable spunbond nonwoven fabric placed on one main surface of the elastic nonwoven fabric, and from the viewpoint of stretchability, it preferably consists of an elastic spunbond nonwoven fabric and an extendable spunbond nonwoven fabric. A three-layer configuration consists of an elastic nonwoven fabric and an extendable nonwoven fabric placed on both main surfaces of the elastic nonwoven fabric, and preferably consists of an extendable spunbond nonwoven fabric, an elastic spunbond nonwoven fabric, and an extendable spunbond nonwoven fabric. The extendable nonwoven fabric may be directly laminated on the main surface of the elastic nonwoven fabric or indirectly laminated.

[0016] In particular, it is preferable that the stretchable spunbond nonwoven fabric is arranged on both main surfaces of the elastic nonwoven fabric. In other words, it is preferable that the nonwoven laminate comprises an elastic nonwoven fabric and a stretchable spunbond nonwoven fabric arranged on both main surfaces of the elastic nonwoven fabric. Elastic nonwoven fabrics are generally adhesive. By arranging the stretchable spunbond nonwoven fabric on both main surfaces of the elastic nonwoven fabric, the occurrence of blocking is suppressed. "Blocking" refers to the phenomenon in which nonwoven laminates wound on a nonwoven roll stick together, making it impossible to unwind the nonwoven laminate from the nonwoven roll (for example, the occurrence of breakage of the nonwoven laminate). A nonwoven roll comprises a roll and a nonwoven laminate wound on the roll. As a result, the production efficiency of the nonwoven laminate is improved.

[0017] The thickness of the nonwoven laminate is not particularly limited and can be appropriately selected depending on the application. The thickness of the nonwoven laminate may be 0.1 mm to 1.0 mm, 0.15 mm to 0.7 mm, or 0.2 mm to 0.5 mm.

[0018] The basis weight of the nonwoven laminate is not particularly limited and can be appropriately selected depending on the application. From the viewpoint of stretchability, the basis weight of the nonwoven laminate (hereinafter also referred to as "overall basis weight") is preferably 100 g / m². 2 More preferably 80 g / m² 2 More preferably 70 g / m²2 The following applies. In applications that further require better breathability, the total basis weight is particularly preferably 10 g / m 2 ~60 g / m 2 , more preferably 20 g / m 2 ~60 g / m 2 , even more preferably 30 g / m 2 ~60 g / m 2 . In applications where mechanical strength is required, the total basis weight is particularly preferably 40 g / m 2 ~100 g / m 2 , more preferably 60 g / m 2 ~100 g / m 2 . The method for measuring the basis weight of the nonwoven fabric laminate is the same as the method described in the examples.

[0019] The basis weight ratio (i.e., the composition ratio) of the elastic nonwoven fabric to the stretchable spunbond nonwoven fabric is appropriately selected according to the application of the nonwoven fabric laminate. The ratio of the basis weight of the stretchable spunbond nonwoven fabric to the basis weight of the elastic nonwoven fabric (basis weight of stretchable spunbond nonwoven fabric / basis weight of elastic nonwoven fabric) is preferably 10 / 90 to 90 / 10, more preferably 20 / 80 to 80 / 20, even more preferably 30 / 70 to 70 / 30, and most preferably 40 / 60 to 60 / 40 from the perspective of elasticity. From the perspective of return stress among elastic properties, it is even more preferably 30 / 70 to 70 / 30, and most preferably 40 / 60 to 60 / 40.

[0020] The maximum elongation at the maximum point of the nonwoven fabric laminate (nonwoven fabric laminate without stretching treatment) is not particularly limited and is appropriately selected according to the application. The maximum elongation at the maximum point of the nonwoven fabric laminate is preferably 45% or more, more preferably 70% or more, even more preferably 100% or more, and particularly preferably 150% or more from the perspective of proper stretching. The maximum elongation at the maximum point of the nonwoven fabric laminate may be 600% or less, or 500% or less. From the perspective of obtaining return stress and better stretching suitability, it is even more preferable that the maximum elongation at the maximum point exceeds 155% and is 400% or less. "Proper stretching" means suppressing the occurrence of blocking and uniformly stretching the nonwoven fabric laminate, or not causing damage such as local perforation in the nonwoven fabric laminate as a result of the stretching treatment. The method for measuring the maximum elongation at the maximum point of the nonwoven fabric laminate is the same as the method described in the examples.

[0021] The forward stress per basis weight of the nonwoven laminate is not particularly limited and can be appropriately selected depending on the application. Preferably, the forward stress per basis weight of the nonwoven laminate is 5.00 N / 50 mm / (g / m 2 ) × 100 or less, more preferably 4.50 N / 50 mm / (g / m 2 The coefficient of force per unit area is 5.00 N / 50 mm / (g / m²). 2 ) × 100 or less (for example, 30g / m 2 ~60g / m 2 When the forward stress of a nonwoven fabric laminate having a basis weight is preferably 1.60 N / 50 mm to 2.5 N / 50 mm, more preferably 1.90 N / 50 mm to 2.5 N / 50 mm, it becomes easier to spread out when wearing absorbent articles or masks, improving wearability. A forward stress per basis weight of 4.50 N / 50 mm / (g / m 2 If the ratio is 100 or less, the nonwoven fabric laminate becomes a firm nonwoven fabric, improving operability during installation. The method for measuring the forward stress per basis weight of the nonwoven fabric laminate is the same as the method described in the examples.

[0022] The return stress per unit weight of the nonwoven laminate is not particularly limited and is selected appropriately depending on the application. The return stress per unit weight of the nonwoven laminate is 1.60 N / 50 mm / (g / m 2 ) × 100 ~ 3.0 N / 50 mm / (g / m 2 It is preferable that the dimensions are ) × 100. The return stress per basis weight of the nonwoven laminate is more preferably 1.70 N / 50 mm / (g / m 2 The coefficient of measurement is 1.60 N / 50 mm / (g / m²). The return stress per unit area is 1.60 N / 50 mm / (g / m²). 2 ) × 100 or more (for example, 30g / m 2 ~60g / m 2 When the return stress of a nonwoven fabric laminate having a basis weight is preferably 0.67 N / 50 mm to 1.5 N / 50 mm, more preferably 0.90 N / 50 mm to 1.5 N / 50 mm, the fit when the nonwoven fabric laminate is stretched and applied to the skin is particularly superior to conventional materials. 2If the dimensions are ) × 100 or less, it becomes an excellent material for applications requiring moderate tightening. Furthermore, the return stress per unit area is 3.00 N / 50 mm / (g / m 2 If the ratio exceeds 100, it is suitable for applications requiring relatively strong clamping. The method for measuring the return stress per basis weight of the nonwoven laminate is the same as described in the examples.

[0023] (1.1) Elastic nonwoven fabric The nonwoven laminate of this disclosure comprises an elastic nonwoven fabric.

[0024] The types of elastic nonwoven fabrics are not particularly limited and include spunbond nonwoven fabrics, meltblown nonwoven fabrics, flash-spun nonwoven fabrics, and carded staple nonwoven fabrics. Among these, from the viewpoint of using long fibers in the elastic nonwoven fabric, spunbond nonwoven fabrics or meltblown nonwoven fabrics are preferred, and from the viewpoint of spinnability, spunbond nonwoven fabrics are more preferred.

[0025] The basis weight of the elastic nonwoven fabric is preferably 2 g / m². 2 ~120g / m 2 Therefore, from the standpoint of breathability, more preferably 2g / m 2 ~40g / m 2 More preferably 12 g / m 2 ~37g / m 2 Therefore, from the viewpoint of return stress, 12 g / m is particularly preferred. 2 ~32g / m 2 More preferably 16 g / m 2 ~26g / m 2 , more preferably 16 g / m 2 ~20g / m 2 The method for measuring the basis weight of the elastic nonwoven fabric is the same as that described in the examples.

[0026] (1.1.1) Fibers From the viewpoint of achieving the effects of this disclosure, the average fiber diameter of the fibers contained in the elastic nonwoven fabric (hereinafter also referred to as "elastic fibers") is preferably 50 μm or less, more preferably 40 μm or less, even more preferably 30 μm or less, and most preferably 26 μm or less. The average fiber diameter of the elastic fibers is preferably 1 μm or more, more preferably 10 μm or more, even more preferably 20 μm or more, and most preferably 22 μm or more. It is preferable that the fiber diameter of the stretchable nonwoven fabric laminate is within the above range.

[0027] The method for measuring the average fiber diameter of elastic fibers is as follows: Ten 10mm x 10mm test pieces were taken from the elastic nonwoven fabric, and the fiber diameter was read to one decimal place in μm units using a Nikon ECLIPSE E400 microscope at 20x magnification. The diameter was measured at 20 arbitrary points on each test piece, and the average value was used as the average fiber diameter.

[0028] The elastic fiber may consist only of long fibers or may contain short fibers, but it is preferable from the viewpoint of stretchability to consist of long fibers (continuous fibers). The cross-sectional shape of the elastic fiber is not particularly limited and can be circular, elliptical, or irregularly shaped.

[0029] The elastic fiber may be a single-component fiber or a composite fiber. "Single-component fibers" refer to fibers made from one type of thermoplastic resin, or fibers made from components mixed in the same extruder, even if they contain two or more types of thermoplastic resins (generally also called blended fibers). Examples of single-component fibers include fibers made from one type of thermoplastic resin and sea-island type fibers. A "composite fiber" refers to a fiber having two or more components in different regions in its cross-section along the longitudinal direction. Examples of composite fibers include core-sheath type, side-by-side type, and parallel type. A core-sheath type composite fiber only needs to have a core and a sheath, and may be either a concentric core-sheath type or an eccentric core-sheath type. In an eccentric core-sheath type composite fiber, the core may or may not be exposed on the surface.

[0030] (1.1.2) Material The elastic fiber is made of a semi-crystalline resin composition. The semi-crystalline resin composition includes an α-olefin copolymer and crystalline polypropylene, and the polymer may consist of an α-olefin copolymer and crystalline polypropylene.

[0031] The effects of the present invention can be achieved by including an α-olefin copolymer as the main component of the semi-crystalline resin composition, and by including a combination of the α-olefin copolymer and crystalline polypropylene. In this disclosure, the α-olefin copolymer content is 97.0% to 99.9% by mass relative to the total amount of the semicrystalline resin composition. The crystalline polypropylene content is 0.1% to 3.0% by mass relative to the total amount of the semicrystalline resin composition. In other words, the crystalline polypropylene content is very small. It has been found that the nonwoven laminate of this disclosure has superior stretch properties (return stress) compared to cases where the elastic fibers of this disclosure do not contain crystalline polypropylene, and cases where the crystalline polypropylene content exceeds 3.0% by mass. Furthermore, because the nonwoven laminate of this disclosure has the above configuration, the nonwoven laminate also has excellent spinnability.

[0032] (1.1.2.1) Crystalline polypropylene Crystalline polypropylene is a homopolymer of propylene or a copolymer of propylene. Crystalline polypropylene may also be a homopolymer of propylene.

[0033] Examples of propylene copolymers include copolymers in which an α-olefin having 2 or more carbon atoms (preferably an α-olefin having 2 to 8 carbon atoms) is used as the copolymer component (except for alkenes with 3 carbon atoms, i.e., propylene). Examples of α-olefins having 2 or more carbon atoms include ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, and 4-methyl-1-pentene. The propylene copolymer may be a random copolymer or a block copolymer.

[0034] The melting point of crystalline polypropylene is above 100°C. When crystalline polypropylene is a homopolymer of propylene, the melting point of crystalline polypropylene is preferably 155°C or higher, more preferably 157°C to 165°C. When crystalline polypropylene is a propylene copolymer, the melting point of crystalline polypropylene is preferably 130°C or higher and less than 155°C, more preferably 130°C to 150°C.

[0035] The melt flow rate (MFR) of crystalline propylene is not particularly limited as long as it can be melt-spun. The MFR of propylene polymers is 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. The method for measuring the MFR of crystalline propylene is in accordance with ASTM D-1238, and the measurement conditions are 230°C and a load of 2.16 kg.

[0036] The density of crystalline propylene is not particularly limited. Preferably, the density of crystalline propylene is 0.80 g / cm³. 3 ~0.98g / cm 3 , more preferably 0.85 g / cm³ 3 ~0.95g / cm 3 That is the case.

[0037] Crystalline polypropylene may be a commercially available product.

[0038] The crystalline polypropylene content is 0.1% to 3.0% by mass relative to the total amount of the semi-crystalline resin composition, preferably 0.4% to less than 2.0% by mass, more preferably 0.4% to less than 1.2% by mass, and even more preferably 0.5% to less than 1.0% by mass. When the crystalline polypropylene content is 0.5% to less than 1.0% by mass, the return stress per basis weight of the nonwoven laminate becomes higher, resulting in superior fit. Furthermore, even if the crystalline polypropylene content is less than 1.0% by mass, by using an α-olefin copolymer in the semi-crystalline resin composition, the degree of crystallinity of the semi-crystalline resin composition can be made appropriate, the solidification of the crystalline resin composition progresses, and it can be easily spun. In other words, both the stretchability and spinnability of the nonwoven laminate are improved.

[0039] (1.1.2.2) α-olefin copolymer The melting point of the α-olefin copolymer is 100°C or less, preferably 40°C to 85°C, more preferably 40°C to 60°C, and even more preferably 40°C to 50°C. The method for measuring the melting point is the same as that described in the examples.

[0040] Examples of copolymer components having an α-olefin skeleton include α-olefins. Examples of α-olefins include 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. In particular, α-olefin copolymers are preferably ethylene-propylene copolymers, and more preferably ethylene-propylene copolymers, from the viewpoint of making nonwoven laminates lower stress and more elastic. For example, elastomers include propylene-based plastomers (PBP) or elastomers (PBE) (PBP and PBE are collectively called "PBPE") such as "VERSIFY® Elastomer" sold by Dow Chemical Company and "VISTAMAXX® Elastomer" sold by ExxonMobil, and olefin block copolymers such as "INFUSE® Elastomer" commercially available from Dow Chemical Company.

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

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

[0043] The ratio of α-olefin copolymer (E40 / E23) is preferably 37% or higher. This ratio (E40 / E23) represents the ratio of the storage modulus E40 at 40°C to the storage modulus E23 at 23°C. This makes it easier to suppress the decrease in elasticity of the elastic nonwoven fabric under temperature fluctuations (e.g., 40°C to 23°C). Therefore, the nonwoven laminate exhibits excellent stress retention.

[0044] The ratio (E40 / E23) is preferable to be as large as possible, more preferably 40% or more, and even more preferably 45% or more, from the viewpoint of obtaining a nonwoven laminate with excellent stress maintenance. The ratio (E40 / E23) is not particularly limited and may be 100% or less, 80% or less, or 60% or less.

[0045] One example of a method to set the ratio (E40 / E23) within the specified range is to use an α-olefin copolymer as a copolymer of ethylene and propylene.

[0046] The storage modulus E23 of the α-olefin copolymer 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, from the viewpoint of improving the elasticity of the nonwoven laminate. The storage modulus E23 of the α-olefin copolymer is preferably 5 MPa or more, more preferably 10 MPa or more, and even more preferably 15 MPa or more. The storage modulus E40 of the α-olefin copolymer is preferably 10 MPa or less, more preferably 9 MPa or less, from the viewpoint of making the nonwoven laminate lower stress and more elastic. The storage modulus E40 of the specific α-olefin copolymer is preferably 3 MPa or more, more preferably 5 MPa or more, and even more preferably 7 MPa or more.

[0047] The density of the α-olefin copolymer (ASTM D 1505) is preferably 0.850 g / cm³. 3 ~0.950g / cm 3 , more preferably 0.855 g / cm³ 3 ~0.900g / cm 3 More preferably 0.860 g / cm³ 3 ~0.895g / cm 3 That is the case. The density of the α-olefin copolymer was obtained by measuring it according to the density gradient method of JIS K7112 (1999).

[0048] From the perspective of improving the elasticity of the non-woven fabric laminate, 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 tensile modulus of the α-olefin copolymer is not particularly limited and may be 5 MPa or more, or may be 7 MPa or more. The tensile modulus is a value obtained by measuring according to the method specified in JIS K7161 (2011).

[0049] The molecular weight distribution (Mw / Mn) of the α-olefin copolymer is preferably 1.5 to 5.0. In terms of obtaining fibers with good spinnability and particularly excellent fiber strength, Mw / Mn is preferably 1.5 to 4.5. It has been found that single-component fibers exhibit both effects of elasticity and spinnability when the Mw / Mn of the α-olefin copolymer falls within this numerical range. The weight average molecular weight (Mw) and number average molecular weight (Mn) of the α-olefin copolymer are values determined under the following conditions by GPC (gel permeation chromatography). 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)

[0050] The MFR of the α-olefin copolymer is not particularly limited, but is preferably 1 g / 10 min to 100 g / 10 min, 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 35 g / 10 min to 50 g / 10 min. The method for measuring the MFR of the α-olefin copolymer is in accordance with ASTM D-1238, and the measurement conditions are 230°C and a load of 2.16 kg.

[0051] The α-olefin copolymer may be a synthetic product or a commercially available product. When the α-olefin copolymer is a synthetic product, it can be prepared by polymerizing or copolymerizing monomers in the presence of known catalysts (e.g., Ziegler-Natta catalysts and metallocene catalysts) using known polymerization methods (e.g., gas phase, bulk, slurry, and solution methods). Examples of commercially available α-olefin copolymers include Tuffmer® (manufactured by Mitsui Chemicals, Inc.) and the Vistamaxx® series (manufactured by ExxonMobil Chemicals).

[0052] The composition of α-olefin copolymers can be analyzed using conventionally known methods (e.g., IR analysis, NMR analysis, and trace analysis).

[0053] The proportion of α-olefin copolymer to the total amount of elastic nonwoven fabric is preferably 90% to 100% by mass, more preferably 98% to 100% by mass.

[0054] When the α-olefin copolymer contains an ethylene-propylene copolymer, the ratio of the ethylene-propylene copolymer to the total amount of elastic nonwoven fabric is preferably 80% to 100% by mass, more preferably 90% to 100% by mass, from the viewpoint of stretchability in the nonwoven laminate.

[0055] The α-olefin copolymer content is 97.0% to 99.9% by mass relative to the total amount of the semicrystalline resin composition, preferably more than 99.0% by mass and 99.5% by mass or less, and more preferably 99.1% to 99.4% by mass.

[0056] (1.1.2.3) Any component The semi-crystalline resin composition may contain known additives as optional components, to the extent that they do not impair the purpose of this disclosure. Examples of additives include antioxidants, heat stabilizers, weather stabilizers, antistatic agents, slip agents, antifogging agents, lubricants, dyes, pigments, natural oils, synthetic oils, waxes, hydrophilic agents, and water repellents.

[0057] (1.2) Stretchable spunbond nonwoven fabric The nonwoven laminate disclosed herein comprises an stretchable spunbond nonwoven fabric.

[0058] The basis weight of the stretchable spunbond nonwoven fabric is preferably 5 g / m². 2 ~120g / m 2 From the standpoint of breathability, more preferably 8 g / m 2 ~50g / m 2 More preferably 13 g / m² 2 ~35g / m 2 From the viewpoint of elasticity, the basis weight of the stretchable spunbond nonwoven fabric is particularly preferably 13 g / m². 2 ~35g / m 2 More preferably 13 g / m 2 ~24.9g / m 2 , more preferably 16 g / m 2 ~21g / m 2 The method for measuring the basis weight of the stretchable spunbond nonwoven fabric is the same as that described in the examples.

[0059] (1.2.1) Fibers The average fiber diameter of the fibers constituting the stretchable spunbond nonwoven fabric (hereinafter also referred to as "stretchable fibers") is preferably 50 μm or less, more preferably 40 μm or less, and even more preferably 30 μm or less. The average fiber diameter of the stretchable fibers is preferably 1 μm or more, more preferably 10 μm or more, and even more preferably 20 μm or more. The method for measuring the average fiber diameter of the stretchable fibers is the same as the method for measuring the average fiber diameter of the elastic fibers. The fiber diameter of the stretchable fibers in the stretchable nonwoven laminate that has been stretched is preferably within the same range as described above.

[0060] The stretchable fibers may be long fibers. The cross-sectional shape of the stretchable fibers is not particularly limited and includes, for example, circular, elliptical, and irregularly shaped cross-sections.

[0061] The stretchable fiber may be a single-component fiber or a composite fiber. The composite fiber preferably consists of two or more thermoplastic resins. Single-component fibers and composite fibers are defined as described above. The stretchable fibers are preferably of the sea-island type or concentric core-sheath type, and more preferably of the sea-island type. When the stretchable fibers are of the sea-island type, the number of yarn breaks that occur during spinning of the resin composition, which is the raw material for the stretchable spunbond nonwoven fabric, is reduced, resulting in excellent spinnability. As a result, the productivity of the nonwoven laminate is improved. In addition, when the stretchable fibers are of the sea-island type, the stretchability properties (return stress) of the nonwoven laminate tend to be excellent.

[0062] (1.2.2) Resin composition for stretchable spunbond nonwoven fabrics The stretchable fibers consist of a resin composition for stretchable spunbond nonwoven fabrics (hereinafter also referred to as the "stretchable resin composition"). The stretchable resin composition preferably contains an olefin polymer, and may contain only an olefin polymer. The olefin polymer may be a polyolefin homopolymer or a polyolefin elastomer. The olefin polymer may be used alone or in combination of two or more types.

[0063] (1.2.2.1) Olefin-based polymers The olefin polymer preferably contains a crystalline polymer as its main component. Examples of crystalline components in crystalline polymerization include polypropylene, poly-1-butene, and poly-4-methyl-1-pentene. The olefin polymer may be a single type or a combination of two or more types. When the olefin polymer contains a polyolefin elastomer, from the viewpoint of stretchability (return stress), the amount of polyolefin elastomer is preferably less than 15% by mass of the total amount of the olefin polymer.

[0064] Examples of olefin polymers include propylene polymers (A) and polyolefins (B) (excluding propylene polymers (A)) (hereinafter also simply referred to as "polyolefins (B)"). Each of the propylene polymers (A) and polyolefins (B) may be of only one type, or there may be two or more types that differ from each other in terms of melting point, molecular weight, crystal structure, etc.

[0065] (1.2.2.1.1) Propylene-based polymer (A) The propylene polymer (A) contains constituent units derived from propylene. Examples of propylene polymers (A) include propylene homopolymers and propylene copolymers. Examples of propylene copolymers are the same as those exemplified as propylene copolymers included in semicrystalline resin compositions. In particular, the propylene polymer (A) preferably contains a propylene homopolymer as its main component. Examples of propylene homopolymers include those similar to those exemplified as crystalline polypropylene.

[0066] The content of the propylene polymer (A) is preferably 55.0% to 95.0% by mass, more preferably 65.0% to 95.0% by mass, even more preferably 75.0% to 95.0% by mass, and particularly preferably 85.0% to 95.0% by mass, based on the total amount of the stretchable resin composition.

[0067] (1.2.2.1.2) Polyolefin (B) Polyolefin (B) is an α-olefin homopolymer (excluding propylene homopolymer) or an α-olefin copolymer. The α-olefin is an α-olefin having 2 or more carbon atoms (excluding 3 carbon atoms), preferably including a homopolymer of α-olefins having 2 to 8 carbon atoms (excluding 3 carbon atoms), and more preferably a homopolymer of α-olefins having 2 to 8 carbon atoms (excluding 3 carbon atoms). Specific examples of α-olefins include, for example, ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, and 4-methyl-1-pentene. Among these, ethylene is preferred as the α-olefin. Specifically, examples of polyolefin (B) include polyethylene (ethylene homopolymer), 1-butene polymers, and poly-4-methyl-1-pentene. Examples of polyethylene include high-pressure low-density polyethylene, linear low-density polyethylene (LLDPE), and high-density polyethylene (HDPE). Examples of 1-butene polymers include 1-butene homopolymers, 1-butene-ethylene copolymers, and 1-butene-propylene copolymers.

[0068] The density of polyolefin (B) is preferably 0.94 g / cm³ from the viewpoint of improving the maximum point elongation, stretchability, and flexibility of the stretchable spunbond nonwoven fabric. 3 ~0.98g / cm 3 , more preferably 0.94 g / cm³ 3 ~0.97g / cm 3 That is

[0069] The melting point of polyolefin (B) is preferably 120°C or higher, more preferably 130°C or higher, and even more preferably 130°C to 165°C.

[0070] The MFR of polyolefin (B) is not particularly limited as long as it can spin the molten material of the stretchable resin composition, and is preferably 1 g / 10 min to 1000 g / 10 min, more preferably 2 g / 10 min to 500 g / 10 min, and even more preferably 3 g / 10 min to 100 g / 10 min. From the viewpoint of achieving both the maximum point elongation of the nonwoven laminate and the spinnability of the stretchable fibers, it is particularly preferable to have a MFR of 4 g / 10 min to 50 g / 10 min. When polyolefin (B) is polyethylene, the MFR measurement method conforms to ASTM D-1238, and the measurement conditions are 190°C and a load of 2.16 kg.

[0071] The polyolefin (B) content is preferably 1.0% to 10.0% by mass, more preferably 3.0% to 8.0% by mass, and even more preferably 5.0% to 7.0% by mass, based on the total amount of the stretchable resin composition. If the polyolefin (B) content is within the above range, the stretchability of the stretchable spunbond nonwoven fabric will be improved.

[0072] (1.2.2.2) Other fractions The resin composition for stretchable spunbond nonwoven fabrics may contain polymers other than olefin polymers (hereinafter also referred to as "other polymers"), or it may not contain other polymers. Examples of other polymers include thermoplastic elastomers and thermoplastic resins other than olefin polymers.

[0073] Examples of thermoplastic elastomers include styrene-based elastomers, polyester-based elastomers, polyamide-based elastomers, thermoplastic polyurethane-based elastomers, vinyl chloride-based elastomers, and fluorine-based elastomers.

[0074] Examples of thermoplastic resins other than olefin polymers include polyester, polyamide (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. Examples of polyesters include aliphatic polyesters or polyester copolymers. Examples of polyester copolymers include those obtained by polymerizing an aliphatic dicarboxylic acid alone or a mixture of an aliphatic dicarboxylic acid and an aromatic dicarboxylic acid with one or more diols.

[0075] (1.2.2.3) Optional component The stretchable resin composition may contain known additives as optional components, to the extent that they do not impair the purpose of this disclosure. Examples of additives include antioxidants, heat stabilizers, weather stabilizers, antistatic agents, slip agents, antifogging agents, lubricants, dyes, pigments, natural oils, synthetic oils, waxes, hydrophilic agents, and water repellents.

[0076] (1.2.2.4) Preferred composition The nonwoven laminate of the present disclosure preferably satisfies the first condition. "Condition 1" is, The fibers contained in the stretchable spunbond nonwoven fabric consist of a resin composition for stretchable spunbond nonwoven fabrics. The resin composition for the stretchable spunbond nonwoven fabric is A propylene polymer (A) and Polyolefins (B) (excluding propylene-based polymers (A)) and This indicates that it includes. By satisfying the first condition, the nonwoven laminate of this disclosure reduces the number of yarn breaks that occur during the spinning of the resin composition, which is the raw material for the stretchable spunbond nonwoven fabric. As a result, the productivity of the nonwoven laminate is improved.

[0077] The nonwoven laminate of the present disclosure preferably satisfies the second condition. The "second condition" is: The resin composition constituting the stretchable spunbond nonwoven fabric is A propylene polymer (A) and Polyolefins (B) (excluding propylene-based polymers (A)) and Includes, The propylene polymer (A) includes a propylene homopolymer, The aforementioned polyolefin (B) has a density of 0.94 g / cm³. 3 ~0.97g / cm 3 This indicates that it contains polyethylene. By satisfying the second condition, the tensile strength, elongation, and flexibility of the stretchable nonwoven fabric are improved.

[0078] The stretchable resin composition preferably contains a propylene homopolymer and an α-olefin copolymer as a propylene polymer (A), and high-density polyethylene as a polyolefin (B). When a propylene homopolymer, an α-olefin copolymer, and high-density polyethylene are used in the stretchable resin composition, the following is one of the preferred embodiments for their respective content. The propylene homopolymer is preferably 55.0% to 95.0% by mass, more preferably 65.0% to 95.0% by mass, even more preferably 75.0% to 95.0% by mass, and particularly preferably 85.0% to 95.0% by mass, based on the total amount of the stretchable resin composition. The α-olefin copolymer is preferably 6% or more and less than 70% by mass, more preferably 10% to 45% by mass, even more preferably 15% to 45% by mass, and even more preferably 15% to 35% by mass, based on the total amount of the stretchable resin composition. The amount of high-density polyethylene is preferably 1.0% to 10.0% by mass, more preferably 3.0% to 8.0% by mass, and even more preferably 5.0% to 7.0% by mass, based on the total amount of the stretchable resin composition. If the content of propylene homopolymer, α-olefin copolymer, and high-density polyethylene is within the above ranges, the stretchability of the stretchable nonwoven fabric will be improved.

[0079] (1.2.2.4.1) Sea-island type composite fiber When the stretchable fibers include sea-island composite fibers, it is preferable that the sea-island composite fibers have a sea-island structure in which the sea phase is a propylene-based polymer (A) (preferably a propylene homopolymer) and the island phase is a polyolefin (B) (preferably high-density polyethylene). This inhibits the oriented crystallization of the main component, the sea phase, and improves the stretchability of the stretchable spunbond nonwoven fabric. As a result, the stretchability properties (return stress) of the nonwoven laminate are improved.

[0080] (1.2.2.4.2) Concentric core-sheath type composite fiber When the stretchable fiber includes a concentric core-sheath composite fiber, it is preferable that the core portion of the concentric core-sheath composite fiber is made of a low MFR olefin polymer, the sheath portion is made of a high MFR olefin polymer, and the difference in MFR between the low MFR olefin polymer and the high MFR olefin polymer is 1 g / 10 min or more. The MFR of the low MFR olefin polymer is 1 g / 10 min to 1000 g / 10 min. The MFR of the high MFR olefin polymer is 1 g / 10 min to 1000 g / 10 min. The difference in MFR is preferably 15g / 10min or more, more preferably 30g / 10min or more, and particularly preferably 40g / 10min or more. The difference in MFR is preferably 100g / 10min or less, more preferably 70g / 10min or less.

[0081] (1.3) Other layers The nonwoven laminate may or may not include other layers or other components, depending on the application. The other layers are laminated to at least one of the stretchable spunbond nonwovens. For example, other layers may be included between the nonwoven laminates, such as a stretchable spunbond nonwoven / meltblown nonwoven / elastic spunbond nonwoven / stretchable spunbond nonwoven laminate. For example, other components may be added to the nonwoven laminate, such as a crimpable spunbond nonwoven / nonwoven laminate, a nonwoven laminate / polyurethane-based elastic nonwoven, a nonwoven laminate / film, and a nonwoven laminate / elastic material.

[0082] Other layers include nonwoven fabrics other than elastic nonwoven fabrics and stretchable spunbond nonwoven fabrics, knitted fabrics, woven fabrics, and films. The method for further laminating (bonding) other layers to the nonwoven laminate is not particularly limited and includes methods such as thermal embossing, thermal fusion (e.g., ultrasonic fusion), mechanical entanglement (e.g., needle punching, water jetting), adhesives (e.g., hot melt adhesives, urethane adhesives), and extrusion lamination.

[0083] Nonwoven fabrics other than elastic nonwoven fabrics and stretchable spunbond nonwoven fabrics include spunbond nonwoven fabrics, meltblown nonwoven fabrics, wet-laid nonwoven fabrics, dry-laid nonwoven fabrics, dry-laid pulp nonwoven fabrics, flash-spun nonwoven fabrics, carded nonwoven fabrics, and open-fiber nonwoven fabrics. These nonwoven fabrics may be stretchable or non-stretchable nonwoven fabrics. A "non-stretchable nonwoven fabric" refers to a fabric that does not generate return stress after being stretched in the MD (the direction of the nonwoven fabric's flow, longitudinal direction) or CD (the direction perpendicular to the direction of the nonwoven fabric's flow, transverse direction).

[0084] (1.3.1) Film layer The nonwoven laminate of the present disclosure may further include a film layer. If the nonwoven laminate has a film, the film is preferably a breathable (moisture-permeable) film. Examples of breathable films include films made of moisture-permeable thermoplastic elastomers (e.g., polyurethane elastomers, polyester elastomers, polyamide elastomers, etc.) and porous films made by stretching and porous a film made of a thermoplastic resin containing inorganic or organic fine particles. The breathable film may be any known breathable film. Polyolefin is preferred as the thermoplastic resin used for the porous film. Examples of thermoplastic resins used for the porous film include high-pressure low-density polyethylene, linear low-density polyethylene (so-called LLDPE), high-density polyethylene, polypropylene, polypropylene random copolymer, and combinations thereof. Depending on the application, if it is not necessary to maintain the breathability and hydrophilicity of the nonwoven fabric laminate, a film made of thermoplastic resin (e.g., polyethylene, polypropylene, and combinations thereof) may be used. In particular, using a film made of the same type of thermoplastic resin as the nonwoven fabric laminate of this disclosure is preferable from the viewpoint of improving the adhesion of the nonwoven fabric laminate including the film. For applications where further improvement of stretchability is desired, a laminate with an elastomer film layer may also be used.

[0085] (1.3.2) Elastic materials Other components include elastic materials. When the nonwoven laminate comprises two stretchable spunbond nonwoven fabrics, the elastic material may be placed between the two stretchable spunbond nonwoven fabrics, or it may be placed on the outside of the nonwoven laminate. Examples of elastic materials include spandex materials (also called rubber yarn, elastic thread, elastic rubber cord, or elastic strand) or elongated stretchable films. The elastic material may be an elastic material formed by bonding spandex yarn and a stretchable film. The nonwoven laminate of this disclosure may contain elastic thread. Known methods can be used for arranging and joining the elastic material.

[0086] (1.4) Biomass-derived propylene polymers In this disclosure, the thermoplastic resin (e.g., a propylene-based polymer) is preferably a thermoplastic resin containing biomass-derived raw materials. Since biomass-derived raw materials are carbon-neutral materials, they can reduce the environmental impact in the production of spunbond nonwoven fabrics. Monomers used as raw materials for biomass-derived thermoplastic resins can be obtained by cracking biomass naphtha or by synthesis from biomass-derived ethylene. Biomass-derived thermoplastic resins are obtained by polymerizing these biomass-derived monomers using the same methods as those used for conventionally known petroleum-derived thermoplastic resins. A polymer of thermoplastic resin synthesized using bio-derived monomers as raw materials becomes a biomass-derived thermoplastic polymer. The content of the bio-derived thermoplastic polymer in the raw material monomers is greater than 0% by mass relative to the total amount of raw material monomers, and may be 100% by mass or less. "Biomass content" indicates the percentage of carbon derived from biomass and is calculated by measuring radioactive carbon (C14). Atmospheric carbon dioxide contains a certain percentage (approximately 105.5 pMC) of C14. Therefore, it is known that the C14 content in plants that grow by taking in atmospheric carbon dioxide (e.g., corn) is also approximately 105.5 pMC. It is also known that fossil fuels contain almost no C14. Therefore, by measuring the percentage of C14 contained in the total carbon atoms in the polymer, the percentage of biomass-derived carbon in the raw material can be calculated. In this disclosure, one preferred embodiment is a thermoplastic resin that includes a thermoplastic polymer obtained by recycling, a so-called recycled polymer, which is used as a raw material. "Recycled polymers" include polymers obtained by recycling waste polymer products, and can be manufactured, for example, by the method described in DE102019127827(A1). Recycled polymers may contain markers that indicate they were obtained through recycling.

[0087] (2) Laminate of stretchable nonwoven fabric The stretchable nonwoven laminate of this disclosure is a stretched product of the nonwoven laminate of this disclosure. The stretchable nonwoven laminate is stretchable.

[0088] A stretchable nonwoven laminate is obtained by stretching the nonwoven laminate of the present disclosure. The stretching method is not particularly limited, and conventionally known methods can be applied. The stretching method may be a partial stretching method or a whole stretching method. It may be a uniaxial stretching method or a biaxial stretching method. As a method of stretching in the machine flow direction (MD), for example, a method of passing a partially fused mixed fiber through two or more nip rolls is included. In this case, the partially fused nonwoven laminate can be stretched by increasing the rotation speed of the nip rolls in order of the machine flow direction. Gear stretching can also be performed using the gear stretching device shown in Figure 1.

[0089] The stretching ratio is preferably 50% or more, more preferably 100% or more, and even more preferably 200% or more. The stretching ratio is preferably 1000% or less, and more preferably 500% or less.

[0090] In the case of uniaxial stretching, it is preferable that the stretching ratio in the machine's flow direction (MD) or in the direction perpendicular to it (CD) satisfies the above stretching ratio. In the case of biaxial stretching, it is preferable that at least one of the machine's flow direction (MD) and the direction perpendicular to it (CD) satisfies the above stretching ratio.

[0091] As described above, both elastic and tensile fibers are stretched by stretching them at the specified stretching ratio. Tensile fibers undergo plastic deformation and are stretched (i.e., become longer) according to the stretching ratio. After stretching a nonwoven laminate, when the stress is released, the elastic fibers recover their elasticity, while the stretchable fibers fold instead of recovering their elasticity, resulting in a bulky feel in the nonwoven laminate. Furthermore, the stretchable fibers tend to become thinner. Therefore, it is thought that this improves flexibility and tactile feel, while also providing a stretch-retaining function.

[0092] (3) Textile products The textile products of this disclosure include the nonwoven laminates of this disclosure or the stretchable nonwoven laminates of this disclosure. The textile products are not particularly limited and include absorbent articles (e.g., disposable diapers and sanitary products), sanitary articles (e.g., masks), medical articles (e.g., bandages, medical gowns and medical drapes), clothing materials, and packaging materials. The textile products of this disclosure preferably include the stretchable nonwoven laminate as an elastic component. Clothing using the clothing material includes pants, trousers, socks, and shirts.

[0093] The textile products of this disclosure preferably further include engageable means. By applying the engageable means to the outermost surface of the nonwoven laminate or the stretchable nonwoven laminate of this disclosure, a removable stretchable sheet can be formed. Furthermore, the nonwoven laminate or the stretchable nonwoven laminate of this disclosure has excellent fit (rebound stress). Therefore, by stretching the textile product of this disclosure, wrapping it around a person or article, and engaging it with the engageable means, the stretchable textile product can be made to adhere closely to the article or to be lightly compressed. In particular, even when the adherend has an uneven shape, the textile product of this disclosure is excellent in that it can follow the uneven shape. The textile products of this disclosure are useful as bandages, gowns, clothing materials, base materials for adhesive bandages, base materials for ointments, and packaging materials. Bandages can be used to hold gauze applied to wounds, as well as to prevent ointments from peeling off from the applied area, or to prevent ointments from adhering to clothing. Furthermore, when a nonwoven fabric laminate is composed solely of nonwoven fabric, the nonwoven fabric is a breathable material, resulting in superior comfort. The engaging means may be known engaging means provided on the surface that contacts the nonwoven laminate of the present disclosure. Examples of engaging means include hook and loop fasteners with engaging protrusions, mechanical fastening, adhesive tapes with re-peelability and re-adhesion properties, hooks, and clips. The engaging means may be provided for the purpose of preventing slippage by improving surface friction characteristics. Depending on the application, a portion of the nonwoven laminate may be treated to prevent slippage. The engaging means may also be provided on a portion of the surface of the nonwoven laminate for the purpose of temporarily fastening the tip of an adhesive bandage or dressing. As mechanical fastening, crimped nonwoven fabric can be used. Among crimped nonwoven fabrics, crimped nonwoven fabric using propylene-based thermoplastic resin can constitute a nonwoven laminate made only of polyolefin raw materials, and the product of the present disclosure has excellent recyclability and elasticity.

[0094] (4) Absorbent articles The absorbent articles of this disclosure include the nonwoven laminates of this disclosure or the stretchable nonwoven laminates of this disclosure. The absorbent article may further include an absorbent material that absorbs liquids. The stretchable nonwoven laminate of the present disclosure may be positioned in a location that comes into contact with the wearer's skin when the absorbent article is worn.

[0095] (5) Mask The masks of this disclosure include nonwoven fabric laminates or stretchable nonwoven fabric laminates of this disclosure. The mask comprises a covering portion that covers at least a portion of the wearer's face, and ear loops extending from both sides of the covering portion, the ear loops of which may include a nonwoven fabric laminate of the present disclosure or a stretchable nonwoven fabric laminate of the present disclosure.

[0096] (6) Variant The nonwoven laminate relating to the modified form of this disclosure is An elastic nonwoven fabric made of a semicrystalline resin composition, The elastic nonwoven fabric comprises an stretchable spunbond nonwoven fabric disposed on at least one main surface of the elastic nonwoven fabric, The aforementioned semicrystalline resin composition α-olefin copolymers with a melting point of 100°C or lower, Crystalline polypropylene with a melting point exceeding 100°C, Includes, The content of the α-olefin copolymer is 50% to 97% by mass relative to the total amount of the semicrystalline resin composition. The nonwoven laminate is characterized in that the crystalline polypropylene content is 3% to 50% by mass relative to the total amount of the semicrystalline resin composition.

[0097] The modified nonwoven laminate has the above-described structure and therefore exhibits excellent spinnability.

[0098] The modified nonwoven laminate is the same as the nonwoven laminate according to the embodiment of the present disclosure described above, except that the content of the α-olefin copolymer and the content of the crystalline polypropylene are different. Therefore, the description of the modified nonwoven laminate according to the present disclosure can be made by referring to the description of the nonwoven laminate according to the embodiment of the present disclosure described above. [Examples]

[0099] The present disclosure will be described in more detail below based on examples, but the present disclosure is not limited to the following examples. The materials, amounts used, proportions, processing procedures, etc., shown in the following examples can be modified as appropriate without departing from the spirit of the present disclosure. Unless otherwise specified, "parts" means "parts by mass".

[0100] [1]Measurement method The physical properties of nonwoven fabric laminates, etc., were measured using the following method.

[0101] [1.1] Measuring Ten test specimens were taken from the nonwoven fabric laminate, each measuring 300 mm in the flow direction (MD) and 250 mm in the transverse direction (CD). The sampling locations were arbitrarily selected from 10 locations within the nonwoven fabric laminate. Next, the mass (g) of each sampled test specimen was measured using a top-loading electronic balance (manufactured by Kensei Kogyo Co., Ltd.). The average mass of each test specimen was calculated. From the calculated average value, 1 m 2 The value obtained by converting it to mass per unit (g) and rounding it to the first decimal place was defined as the "basis weight of the nonwoven laminate."

[0102] [1.2] Storage modulus E40 and storage modulus E23 The storage moduli E23 and E40 of the "α-olefin copolymer" were measured using the following apparatus and conditions. Temperature: 23℃ or 40℃ Equipment: RSA-III (manufactured by T.I. Instruments Corporation) Transformation mode: Tension mode Temperature range: -20℃ to 120℃ Heating rate: 2°C / min Deformation frequency: 10Hz Initial strain: 0.1% Temperature measurement interval: 0.3℃ Environment: Under a nitrogen atmosphere

[0103] [1.3] Melting point The melting point is defined as the peak top of the lowest temperature peak observed in the endothermic melting curve obtained by holding a sample at -100°C in a nitrogen atmosphere for 5 minutes using a differential scanning calorimeter (DSC), followed by a temperature increase of 10°C / min. Specifically, a differential scanning calorimeter (Perkin-Elmer, DSC-7) was used to hold 5 mg of the sample at -100°C in a nitrogen atmosphere for 5 minutes, followed by a temperature increase of 10°C / min. The temperature of the peak top of the lowest temperature peak observed in the resulting endothermic melting curve was defined as the "melting point."

[0104] [1.4] Maximum point elongation (%) Five test specimens measuring 200 mm (MD) x 50 mm (CD) were taken from the nonwoven fabric laminate. The sampling locations were arbitrarily selected. Next, each of the sampled specimens was subjected to a tensile test using a universal tensile testing machine (Intesco, IM-201 model) under the conditions of 100 mm between the chucks and a tensile speed of 100 mm / min, and the elongation (maximum point elongation [%)) was determined. The average value of the elongation from the above five points was defined as the "maximum point elongation of the nonwoven fabric laminate."

[0105] [1.5] Stress per unit area (N / 50mm / (g / m 2 )×100) and return stress per unit area (N / 50mm / (g / m 2)×100) Five 50mm (CD) x 200mm (MD) test specimens were taken from the nonwoven fabric laminate, and the forward stress at 50% elongation and the return stress at 50% recovery were evaluated using a universal tensile testing machine (Intesco, IM-201). Each taken test specimen was stretched to MD with a tensile ratio of 100% under the conditions of a sample width of 50mm, a chuck distance of 100mm, and a tensile speed of 100mm / min. Then, the stretched test specimen was immediately restored to its original length (100mm) at the same speed (hereinafter also referred to as the "stretch recovery operation"). Subsequently, a second stretch recovery operation was performed. In the second stretch recovery operation, the stress at which the stretch ratio reached 50% during the stretching of the test specimen was divided by the basis weight of the nonwoven laminate (i.e., the total basis weight) and multiplied by 100 was defined as the "forward stress per basis weight." The stress at which the stretch ratio reached 50% during the recovery of the test specimen was divided by the basis weight and multiplied by 100 was defined as the "return stress per basis weight." The stretch ratio is expressed by the following formula (1). The allowable range for the return stress per basis weight is 1.60 N / 50 mm / (g / m 2 ) × 100 or more. Formula (1): Stretch ratio = [(Chuck distance of the specimen after stretching - Chuck distance of the specimen before stretching (100 mm) / Chuck distance of the specimen before stretching (100 mm)] × 100

[0106] [1.6] Evaluation of spinnability The number of yarn breaks that occurred in 30 minutes during the spinning of elastic spunbond nonwoven fabric was measured. The fiber stretching air speed was set in the range of 3922 m / min to 4657 m / min. An acceptable evaluation of spinnability is "A" or "A-" when the stretching air speed is in the range of 4314 m / min to 4412 m / min.

[0107] [1.6.1] Evaluation criteria for spinnability "A": No thread breakage occurred for 30 minutes. "A-": One thread break occurred within a 30-minute period. "B": The thread broke more than twice in a 30-minute period.

[0108] [2] Preparation of materials The following materials were prepared as raw materials for the elastic nonwoven fabric.

[0109] [2.1] Outer layer (stretchable spunbond nonwoven fabric) • "h-pp" (propylene homopolymer, MFR (measured according to ASTM D1238 at 230°C and 2.16 kg load): 60 g / 10 min, density: 0.91 g / cm³) 3 (Melting point: 160℃) • "α-olefin copolymer" (manufactured by ExxonMobil, product name "Vistamaxx") TM 7050FL, Composition: Propylene / ethylene copolymer, MFR (230℃, load 2.16kg): 48g / 10min, Ethylene content: 13% by mass, Tensile modulus: 9.82MPa, Storage modulus E23: 17.4MPa, Storage modulus E40: 8.77MPa, Ratio (E40 / E23): 50.4%, Melting point: 44.4℃) • "HDPE" (High-density polyethylene, MFR (measured according to ASTM D1238, at a temperature of 190°C and a load of 2.16 kg): 5 g / 10 min, Density: 0.95 g / cm³ 3 (Melting point: 134℃)

[0110] [2.2] Intermediate layer (elastic nonwoven fabric) • "h-pp" (propylene homopolymer, MFR (measured according to ASTM D1238 at 230°C and 2.16 kg load): 60 g / 10 min, density: 0.91 g / cm³) 3 (Melting point: 160℃) • "α-olefin copolymer" (manufactured by ExxonMobil, product name "Vistamaxx") TM 7050FL, Composition: Propylene / ethylene copolymer, MFR (230℃, load 2.16kg): 48g / 10min, Ethylene content: 13% by mass, Tensile modulus: 9.82MPa, Storage modulus E23: 17.4MPa, Storage modulus E40: 8.77MPa, Ratio (E40 / E23): 50.4%, Melting point: 44.4℃)

[0111] Only the spunbond nonwoven fabrics constituting the outer layers (first or third layer) of Examples 1 to 6 and Comparative Examples 1 to 3 were obtained in the same manner as described in "[3] Laminated Nonwoven Fabrics" below. The maximum point elongation of the obtained spunbond nonwoven fabrics was 50% or more. In other words, the spunbond nonwoven fabrics constituting the outer layers of Examples 1 to 6 and Comparative Examples 1 to 3 were stretchable spunbond nonwoven fabrics.

[0112] [3] Nonwoven fabric laminate [3.1] Examples and Comparative Examples [3.1.1] Example 1 A mixture of 74 parts by mass of "h-pp", 20 parts by mass of "α-olefin copolymer", and 6 parts by mass of "HDPE" (stretchable resin composition) was melted using a 75 mmφ extruder. Melt spinning was performed using the spunbond method with a spunbond nonwoven fabric molding machine (length perpendicular to the machine's flow direction on the collection surface: 320 mm) having a spinneret with 1093 holes, under the conditions of resin temperature and die temperature both at 220°C, resin discharge rate of 23.0 kg / hour, cooling air temperature of 20°C, and stretching air velocity of 2941 m / min, to deposit a stretchable spunbond nonwoven fabric consisting of sea-island type composite fibers as the first layer on the collection surface. Next, a mixture of 99.9 parts by mass of "α-olefin copolymer" and 0.1 parts by mass of "h-pp" (a semi-crystalline resin composition) was melted on the deposition surface using a single-screw extruder with a screw diameter of 75 mmφ. Then, using a spunbond nonwoven fabric molding machine (length perpendicular to the flow direction of the machine on the collection surface: 320 mm) equipped with a spinning die (1093 holes), the material was melt-spun by the spunbond method under the conditions that the resin temperature and die temperature were both 245°C, the cooling air temperature was 20°C, and the stretching air velocity was 4118 m / min, thereby depositing an elastic nonwoven fabric (elastic spunbond nonwoven fabric) as the second layer. Next, as the third layer, an extendable spunbond nonwoven fabric made of the same sea-island type composite fibers as the first layer was deposited using the same method, resulting in a three-layer deposit. This deposit was subjected to heat and pressure treatment with an embossing roll (embossing area ratio 18%, embossing temperature 60°C) to produce a nonwoven fabric laminate (the elastic nonwoven fabric layer accounted for 42% of the total mass). Table 1 shows the measurement results for the total basis weight, maximum point elongation, forward stress per basis weight, and return stress per basis weight of the nonwoven fabric laminate.

[0113] [3.1.2] Examples 2 to 6 and Comparative Examples 1 to 3 A nonwoven laminate was obtained in the same manner as in Example 1, except that the content of "α-olefin copolymer" and "h-pp" in the intermediate layer were changed to the content shown in Table 1. Table 1 shows the measurement results for the total basis weight, maximum point elongation, forward stress per basis weight, and return stress per basis weight of the nonwoven fabric laminate.

[0114] [Table 1]

[0115] In Table 1, "Stretchable SB" refers to stretchable spunbond nonwoven fabric. "Elastic nonwoven fabric" refers to elastic spunbond nonwoven fabric. "h-PP" refers to a homopolymer of propylene.

[0116] [3.1.3] Results In Comparative Examples 1 to 3, the content of "h-PP" (crystalline polypropylene) was outside the range of 0.1% to 3.0% by mass relative to the total amount of the semicrystalline resin composition. Therefore, the return stress per basis weight for Comparative Examples 1 to 3 was 1.60 N / 50 mm / (g / m 2 It was not more than 100 times the number of ) These results indicate that the nonwoven fabric laminates in Comparative Examples 1 to 3 do not exhibit superior stretchability.

[0117] The nonwoven laminates of Examples 1 to 6 comprise an elastic nonwoven fabric and an extensible spunbond nonwoven fabric disposed on both main surfaces of the elastic nonwoven fabric. The α-olefin copolymer content was 97.0% to 99.9% by mass relative to the total amount of the semicrystalline resin composition. The "h-PP" (crystalline polypropylene) content was 0.1% to 3.0% by mass relative to the total amount of the semicrystalline resin composition. Therefore, the return stress per basis weight of Examples 1 to 6 was 1.60 N / 50 mm / (g / m²). 2 The result was ) × 100 or more. These results show that the nonwoven fabric laminates in Examples 1 to 6 are nonwoven fabric laminates with excellent stretchability.

[0118] [3.2] Reference example [3.2.1] Reference example 3 A mixture of 74 parts by mass of "h-pp", 20 parts by mass of "α-olefin copolymer", and 6 parts by mass of "HDPE" (stretchable resin composition) was melted using a 75 mmφ extruder. Melt spinning was performed using the spunbond method with a spunbond nonwoven fabric molding machine (length perpendicular to the machine's flow direction on the collection surface: 320 mm) having a spinneret with 1093 holes, under the conditions of resin temperature and die temperature both at 220°C, resin discharge rate of 23.0 kg / hour, cooling air temperature of 20°C, and stretching air velocity of 2941 m / min, to deposit a stretchable spunbond nonwoven fabric consisting of sea-island type composite fibers as the first layer on the collection surface. Next, a mixture of 97 parts by mass of "α-olefin copolymer" and 3 parts by mass of "h-pp" (crystalline resin composition) was melted on the deposition surface using a single-screw extruder with a screw diameter of 75 mmφ. Then, using a spunbond nonwoven fabric molding machine (length perpendicular to the flow direction of the machine on the collection surface: 320 mm) equipped with a spinning die (1093 holes), the material was melt-spun by the spunbond method under the conditions that the resin temperature and die temperature were both 245°C, the cooling air temperature was 20°C, and the stretching air velocity was 4118 m / min, thereby depositing an elastic nonwoven fabric (elastic spunbond nonwoven fabric) as the second layer. Next, as the third layer, sea-island type composite fibers similar to those used in the first layer were deposited using the same method, resulting in a three-layer sediment. This deposit was subjected to heat and pressure treatment with an embossing roll (embossing area ratio 18%, embossing temperature 60°C) to produce a nonwoven fabric laminate (the elastic nonwoven fabric layer accounted for 42% of the total mass). Table 2 shows the evaluation results for the total basis weight, maximum point elongation, forward stress, return stress of the nonwoven laminate, and the spinnability of the stretchable spunbond fiber.

[0119] [3.2.2] Reference Examples 1, 2, and 4-9 A nonwoven laminate was obtained in the same manner as in Reference Example 3, except that the content of "α-olefin copolymer" and "h-pp" in the intermediate layer were changed to the content shown in Table 1. Table 2 shows the measurement results for the total basis weight, maximum point elongation, forward stress, and return stress of the nonwoven fabric laminate.

[0120] [Table 2]

[0121] In Table 2, "Stretchable SB" refers to stretchable spunbond nonwoven fabric. "Elastic SB" refers to elastic spunbond nonwoven fabric. "h-PP" refers to a homopolymer of propylene.

[0122] [3.2.3] In Reference Examples 1 and 2, the content of "h-PP" (crystalline polypropylene) was outside the range of 3% to 50% by mass relative to the total amount of the crystalline resin composition. Therefore, in the range of 4314 (m / min) to 4412 (m / min) for the stretching air speed, the spinnability evaluation for Reference Examples 1 and 2 was "B". These results indicate that the nonwoven laminates in Reference Examples 1 and 2 are not nonwoven laminates with excellent spinnability.

[0123] The nonwoven laminates in Reference Examples 3 to 9 comprise an elastic nonwoven fabric and an extensible spunbond nonwoven fabric disposed on both main surfaces of the elastic nonwoven fabric. The α-olefin copolymer content was 50% to 97% by mass relative to the total amount of the crystalline resin composition. The "h-PP" (crystalline polypropylene) content was 3% to 50% by mass relative to the total amount of the crystalline resin composition. Therefore, in the range of stretching air speeds from 4314 (m / min) to 4412 (m / min), the spinnability evaluation of Reference Examples 3 to 9 was "A" or "A-". These results show that the nonwoven laminates in Reference Examples 3 to 9 are nonwoven laminates with excellent spinnability.

Claims

1. An elastic nonwoven fabric made of a semicrystalline resin composition, The elastic nonwoven fabric comprises an stretchable spunbond nonwoven fabric disposed on at least one main surface of the elastic nonwoven fabric, The aforementioned semicrystalline resin composition α-olefin copolymers with a melting point of 100°C or lower, Crystalline polypropylene with a melting point exceeding 100°C, Includes, The content of the α-olefin copolymer is 97.0% by mass to 99.9% by mass relative to the total amount of the semicrystalline resin composition. A nonwoven laminate in which the content of the crystalline polypropylene is 0.1% by mass to 3.0% by mass relative to the total amount of the semicrystalline resin composition.

2. The nonwoven laminate according to claim 1, wherein the content of the crystalline polypropylene is 0.5% by mass or more and less than 1.0% by mass, relative to the total amount of the semicrystalline resin composition.

3. The return stress per unit area is 1.60 N / 50 mm / (g / m). ２ )×100~3.0N / 50mm (g / m ２ The nonwoven fabric laminate according to claim 1, wherein the dimensions are ) × 100.

4. The ratio of the α-olefin copolymer (E40 / E23) is 37% or more. The nonwoven laminate according to claim 1, wherein the ratio (E40 / E23) represents the ratio of the storage modulus E40 at 40°C to the storage modulus E23 at 23°C.

5. The nonwoven laminate according to claim 1, wherein the α-olefin copolymer comprises a copolymer of ethylene and propylene.

6. The resin composition constituting the stretchable spunbond nonwoven fabric is A propylene polymer (A) and Polyolefins (B) (excluding propylene polymers (A)) and Includes, The propylene polymer (A) includes a propylene homopolymer, The polyolefin (B) has a density of 0.94 g / cm³. ３ ~0.97 g / cm³ ３ A nonwoven fabric laminate according to claim 1, comprising polyethylene.

7. The nonwoven laminate according to claim 1, wherein the stretchable spunbond nonwoven fabric is arranged on both main surfaces of the elastic nonwoven fabric.

8. A nonwoven fabric laminate according to claim 1, comprising elastic thread.

9. A nonwoven fabric laminate according to claim 1, comprising a film layer.

10. An expandable nonwoven fabric laminate, which is a stretched product of a nonwoven fabric laminate according to any one of claims 1 to 9.

11. A textile product comprising the stretchable nonwoven fabric laminate described in claim 10.

12. The textile product according to claim 11, further comprising an engaging means that can be further engaged.

13. An absorbent article comprising the stretchable nonwoven fabric laminate described in claim 10.

14. A mask comprising the stretchable nonwoven fabric laminate described in claim 10.

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