Nonwoven fabric laminate, stretchable nonwoven fabric laminate, fiber product, absorbent article, mask, and poultice

Abstract

This nonwoven fabric laminate comprises: an elastic nonwoven fabric; and an extensible spun-bonded nonwoven fabric disposed on both surfaces of the elastic nonwoven fabric. A surface coefficient represented by formula (1) is 38 or greater.　(1): Surface coefficient = [(average fiber diameter of fiber included in the elastic nonwoven fabric / average fiber diameter of fiber included in the extensible spun-bonded nonwoven fabric) / texture coefficient] × 104

Description

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

[0001] The present disclosure relates to nonwoven fabric laminates, stretchable nonwoven fabric laminates, textile products, absorbent articles, masks, and patches.

[0002] In recent years, nonwoven fabrics have been widely used in various applications due to their excellent breathability and flexibility. Therefore, nonwoven fabrics are required to have various properties according to their applications, and improvements in these properties are also required. For example, nonwoven fabrics used for sanitary materials such as disposable diapers and sanitary napkins, and for the base fabric of compresses, are required to be water-resistant and have excellent moisture permeability. Depending on the location of use, stretchability and bulkiness are also required.

[0003] Patent Document 1 discloses a nonwoven fabric laminate having excellent stretchability, etc. The nonwoven fabric laminate disclosed in Patent Document 1 comprises one or more meltblown nonwoven fabric layers and mixed fiber spunbonded nonwoven fabric layers laminated on both sides thereof. The mixed fiber spunbonded nonwoven fabric layer contains long fibers of a thermoplastic elastomer (A) and long fibers of a thermoplastic resin (B) other than the thermoplastic elastomer (A).

[0004] Patent Document 1: International Publication No. 2007 / 138733

[0005] However, in the nonwoven fabric laminate of Patent Document 1, there is a risk of blocking occurring when the nonwoven fabric laminate is unwound at high speed (e.g., 200 m / min) from the nonwoven fabric roll on which it is wound. "Blocking" refers to a phenomenon in which the nonwoven fabric laminate cannot be unwound from the nonwoven fabric roll due to adhesion of the nonwoven fabric laminate wound around the nonwoven fabric roll (e.g., breakage of the nonwoven fabric laminate, etc.).

[0006] In view of the above-described problems, one aspect of the present disclosure aims to provide a nonwoven fabric laminate that can suppress the occurrence of blocking even when unwound from a nonwoven fabric roll at high speed, as well as a stretchable nonwoven fabric laminate, a textile product, an absorbent article, a mask, and a plaster.

[0007] Specific means for solving the above problems include the following aspects: <1> A nonwoven fabric laminate comprising an elastic nonwoven fabric and an extensible spunbonded nonwoven fabric disposed on both sides of the elastic nonwoven fabric, the nonwoven fabric laminate having a surface coefficient expressed by the following formula (1) of 38 or more: Formula (1): Surface coefficient = [(average fiber diameter of fibers contained in the elastic nonwoven fabric / average fiber diameter of fibers contained in the extensible spunbonded nonwoven fabric) / formation coefficient] x 10 ４ <2> The nonwoven fabric laminate according to <1>, wherein the fibers contained in the elastic nonwoven fabric are made of a resin composition for elastic nonwoven fabrics, and the resin composition for elastic nonwoven fabrics contains an α-olefin copolymer having a ratio (E40 / E23) of storage modulus E40 at 40° C. to storage modulus E23 at 23° C. of 37% or more. <3> The nonwoven fabric laminate according to <2>, wherein a proportion of the α-olefin copolymer relative to the total amount of the elastic nonwoven fabric is 90% by mass to 100% by mass, and the α-olefin copolymer is a copolymer of ethylene and propylene, and the melting point of the α-olefin copolymer is 130° C. or lower. <4> The nonwoven fabric laminate according to any one of <1> to <3>, wherein the fibers contained in the extensible spunbonded nonwoven fabric are made of a resin composition for extensible spunbonded nonwoven fabrics, and the resin composition for extensible spunbonded nonwoven fabrics comprises a propylene-based polymer (A), and a polymer (B) that is at least one selected from the group consisting of polyolefins (excluding the propylene-based polymer (A)) and polyesters. <5> The propylene-based polymer (A) comprises a propylene homopolymer, and the polymer (B) has a density of 0.94 g / cm ３ ~0.97 g / cm ３<6> The nonwoven fabric laminate according to any one of <1> to <5>, wherein the ratio of the basis weight of the elastic nonwoven fabric to the basis weight of the nonwoven fabric laminate is 15% to 48%. <7> A nonwoven fabric laminate comprising: an elastic nonwoven fabric; and an extensible spunbonded nonwoven fabric arranged on both sides of the elastic nonwoven fabric, wherein fibers contained in the extensible spunbonded nonwoven fabric are islands-in-sea fibers, and the islands-in-sea fibers comprise a resin composition for extensible spunbonded nonwoven fabrics, the resin composition for extensible spunbonded nonwoven fabrics comprises: a propylene polymer (A) containing a propylene homopolymer, and a polymer (B) which is at least one selected from the group consisting of polyolefins (excluding the propylene polymer (A)) and polyesters, and wherein the average fiber diameter a of the fibers contained in the extensible spunbonded nonwoven fabric is smaller than the average fiber diameter b of the fibers contained in the elastic nonwoven fabric. <8> The nonwoven fabric laminate according to <7>, wherein the ratio (b / a) of the average fiber diameter b to the average fiber diameter a is 1.0 or more and 1.35 or less. <9> The nonwoven fabric laminate according to any one of <1> to <8>, further comprising a film layer. <10> An elastic nonwoven fabric laminate, which is a stretched product of the nonwoven fabric laminate according to any one of <1> to <9>. <11> A textile product comprising the nonwoven fabric laminate according to any one of <1> to <9>. <12> The textile product according to <11>, further comprising engageable engaging means. <13> An absorbent article comprising the nonwoven fabric laminate according to any one of <1> to <9>. <14> A mask comprising the nonwoven fabric laminate according to any one of <1> to <9>. <15> A plaster comprising the nonwoven fabric laminate according to any one of <1> to <9>.

[0008] According to one aspect of the present disclosure, there are provided a nonwoven fabric laminate that can suppress the occurrence of blocking even when unwound from a nonwoven fabric roll at high speed, as well as a stretchable nonwoven fabric laminate, a textile product, an absorbent article, a mask, and a plaster.

[0009] FIG. 1 is a schematic diagram of a gear stretching device.

[0010] The following describes embodiments of the present disclosure. These descriptions and examples are intended to illustrate the embodiments and do not limit the scope of the embodiments. In the numerical ranges described in stages in this disclosure, the upper or lower limit of one numerical range may be replaced with the upper or lower limit of another numerical range described in stages. In the numerical ranges described in this disclosure, the upper or lower limit of that numerical range may be replaced with a value shown in the Examples. In this disclosure, each component may contain multiple corresponding substances. When referring to the amount of each component in a composition in this disclosure, if multiple substances corresponding to each component are present in the composition, this refers to the total amount of those multiple substances present in the composition, unless otherwise specified. In this disclosure, the term "process" includes not only independent processes, but also processes that cannot be clearly distinguished from other processes, as long as the purpose of the process is achieved. 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. In the present disclosure, the content of each component in a composition means, when multiple substances corresponding to each component are present in the composition, the total amount of those multiple substances present in the composition, unless otherwise specified.

[0011] (1) Nonwoven Fabric Laminate of First Embodiment The nonwoven fabric laminate of the first embodiment of the present disclosure comprises an elastic nonwoven fabric and an extensible spunbonded nonwoven fabric disposed on both sides of the elastic nonwoven fabric. The surface coefficient, expressed by the following formula (1), is 38 or greater. Formula (1): Surface coefficient = [(average fiber diameter of fibers contained in the elastic nonwoven fabric / average fiber diameter of fibers contained in the extensible spunbonded nonwoven fabric) / formation coefficient] x 10 ４

[0012] "Elastic nonwoven fabric" refers to a nonwoven fabric having elasticity. "Elastic nonwoven fabric" refers to a nonwoven fabric that has the property of recovering its shape before stretching due to its elasticity when stress is released after stretching. The fibers contained in the elastic nonwoven fabric according to the present disclosure are made of a resin composition for elastic nonwoven fabric, and the storage modulus E23 of the resin composition for elastic nonwoven fabric is 25.0 MPa or less. If the storage modulus E23 of the resin composition for elastic nonwoven fabric exceeds 25.0 MPa, the stretch properties of the nonwoven fabric laminate tend to be easily reduced. From the viewpoint of improving the stretch properties of the nonwoven fabric laminate, the storage modulus E23 of the resin composition for elastic nonwoven fabric 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 that described in the Examples. A resin composition for elastic nonwoven fabrics having a storage modulus E23 of 25.0 MPa or less can affect the stretch properties of a nonwoven fabric laminate, regardless of whether it is contained in the surface layer, back layer, or intermediate layer. "Nonwoven fabric" refers to a flat fiber assembly that has a predetermined level of structural strength achieved by physical and / or chemical methods, excluding weaving, knitting, and papermaking. "Extensible spunbond nonwoven fabric" refers to a spunbond nonwoven fabric that has extensibility. "Extensibility" indicates that the spunbond nonwoven fabric has a first property and a second property. "First property" refers to the property that the outer shape of the spunbond nonwoven fabric stretches in one direction when an external force is applied to the spunbond nonwoven fabric. "Second property" refers to the property that the outer shape of the spunbond nonwoven fabric does not easily return to its original shape even when the external force applied to the spunbond nonwoven fabric is released. Specifically, a nonwoven fabric having extensibility has a maximum elongation of 50% or more, preferably 70% or more, and more preferably 100% or more, and exhibits almost no elastic recovery. "Spunbond nonwoven fabric" refers to a nonwoven fabric made by one or more bonding methods to a spunlaid web. "Spunlaid web" refers to a web laminated by spinlaid lamination. "Spinlaid lamination" refers to a method of making a web by extruding molten or dissolved polymer from a nozzle and laminating the filaments on a moving screen. "Formation coefficient" refers to the uniformity of a nonwoven fabric. The method for quantifying formation coefficient is the same as the measurement method described in the Examples.A lower formation coefficient indicates a more uniform nonwoven fabric.

[0013] Because the nonwoven fabric laminate of the first embodiment has the above-described configuration, it can suppress the occurrence of blocking even when unwound from a nonwoven fabric roll at high speed (e.g., 200 m / min). This effect is presumably due to, but not limited to, the following reasons: Elastic nonwoven fabrics generally have adhesive properties. A surface coefficient of 38 or greater indicates that, even when pressure is applied to the nonwoven fabric laminate due to tightening of the nonwoven fabric roll around which the nonwoven fabric laminate is wound, the elastic nonwoven fabric contained in the nonwoven fabric laminate is unlikely to be exposed on the surface of the nonwoven fabric laminate. Therefore, nonwoven fabric laminates in the nonwoven fabric roll are unlikely to adhere to each other. As a result, it is presumed that the nonwoven fabric laminate of the first embodiment can suppress the occurrence of blocking even when unwound from a nonwoven fabric roll at high speed.

[0014] The surface coefficient is 38 or more, and from the viewpoint of further suppressing the occurrence of blocking even when the nonwoven fabric is unwound from a roll at high speed (for example, 200 m / min), it is preferably 38 to 60, more preferably 38 to 50. The method for calculating the surface coefficient is the same as that described in the examples.

[0015] A method for achieving a surface coefficient of 38 or more is preferably to design the fibers contained in the elastic nonwoven fabric so as to have a larger average fiber diameter and the fibers contained in the stretchable nonwoven fabric laminate so as to have a smaller average fiber diameter, thereby lowering the formation coefficient. Specific examples include adjusting the single-hole throughput (g / hole), drawing air speed (m / min), and melt flow rate (MFR) of the resin composition. Adjustments to the single-hole throughput (g / hole) and suction blower air volume are examples of means for designing the formation coefficient.

[0016] The ratio of the basis weight of the elastic nonwoven fabric to the basis weight of the nonwoven fabric laminate (hereinafter also referred to as "total basis weight") (hereinafter also referred to as "basis weight ratio (NW / total)") is not particularly limited, but is preferably 15% to 48%. This allows the elastic properties of the nonwoven fabric laminate to be compatible with blocking resistance during roll production. From the viewpoint of improving yarn breakage, the basis weight ratio (NW / total) is more preferably 20% to 48%, and from the viewpoint of a softer nonwoven fabric, it is even more preferably 20% to 43%, and particularly preferably 25% to 43%.

[0017] The total basis weight is not particularly limited, but is preferably 360 g / m ２ or less, more preferably 240 g / m ２ More preferably 150 g / m or less ２ Particularly preferably 15 g / m or less ２ ~120g / m ２ , more preferably 20 g / m ２ ~80g / m ２ , and even more preferably 25 g / m ２ ~70g / m ２ The method for measuring the total basis weight of the nonwoven fabric laminate was the same as in the examples.

[0018] (1.1) Extensible Spunbond Nonwoven Fabric The nonwoven fabric laminate of the first embodiment includes an extensible spunbond nonwoven fabric.

[0019] The basis weight of the extensible spunbond nonwoven fabric is preferably 5 g / m ２ ~120g / m ２ , more preferably 8 g / m ２ ~50g / m ２ The preferred range varies depending on the application, and in applications where a softer nonwoven fabric is required, the basis weight of the extensible spunbond nonwoven fabric is more preferably 13 g / m ２ ~35g / m ２ , particularly preferably 13 g / m ２ ~24.9g / m ２ , more preferably 16 g / m ２ ~21g / m ２ On the other hand, in applications where relatively high strength is required, the basis weight of the extensible spunbond nonwoven fabric is more preferably 35 g / m ２ Super 50g / m２ The method for measuring the basis weight of the extensible spunbonded nonwoven fabric is the same as that described in the examples.

[0020] (1.1.1) Fibers The average fiber diameter (hereinafter also referred to as "average fiber diameter a") of the fibers (hereinafter also referred to as "extensible fibers") constituting the extensible spunbonded nonwoven fabric is preferably 50 μm or less, more preferably 40 μm or less, even more preferably 30 μm or less, and particularly preferably 25 μm or less. The average fiber diameter a of the extensible fibers is preferably 1 μm or more, more preferably 10 μm or more, and even more preferably 20 μm or more. From the viewpoint of further suppressing blocking, it is preferable that the average fiber diameter a of the extensible fibers be equal to or smaller than the average fiber diameter (hereinafter also referred to as "average fiber diameter b") of the fibers (hereinafter also referred to as "elastic fibers") constituting the elastic nonwoven fabric, and it is more preferable that the average fiber diameter b be smaller than the average fiber diameter a. From the viewpoints of suppressing blocking and reducing the number of yarn breakages, the ratio (b / a) of the average fiber diameter b of the elastic fibers to the average fiber diameter a of the extendable fibers (hereinafter also referred to as the "fiber ratio (b / a)") is more preferably 1.0 or more and 1.35 or less, and more preferably more than 1.0 and 1.35 or less. The method for measuring the average fiber diameter a of the extendable fibers is the same as that described in the Examples.

[0021] The extendable fiber may be a long fiber or a short fiber. The cross-sectional shape of the extendable fiber is not particularly limited, and examples thereof include a circular, elliptical, and irregular cross-section.

[0022] The extensible fiber may be, for example, a sheath-core type, a side-by-side type, an islands-in-sea type, or a side-by-side type. The sheath-core type fiber has only to have a core and a sheath, and may be either a concentric sheath-core type or an eccentric sheath-core type. The eccentric sheath-core type fiber may have the core exposed on the surface, or the core may not be exposed on the surface. The islands-in-sea type fiber has a sea phase and multiple island phases. Of these, the extensible fiber is preferably an islands-in-sea type or a concentric sheath-core type, and more preferably an islands-in-sea type. When the extensible fiber is an islands-in-sea type, the number of thread breakages that occur during spinning of the resin composition that is the raw material for the extensible spunbonded nonwoven fabric is reduced. As a result, the productivity of the nonwoven fabric laminate is improved. Fewer thread breakages can reduce the number of fibers whose fiber ends are exposed on the surface of the nonwoven fabric, and can also improve the feel, such as prickly feeling, on the skin.

[0023] (1.1.2) Resin composition for extensible spunbond nonwoven fabric The extensible fiber is made of a resin composition for extensible spunbond nonwoven fabric (hereinafter also referred to as "resin composition (SB)"). The resin composition (SB) preferably contains an olefin polymer, and may contain only an olefin polymer. The olefin polymer may be a polyolefin elastomer. The olefin polymer may be used alone or in combination of two or more types.

[0024] (1.1.2.1) Olefin-based polymer The olefin-based polymer is preferably a polymer having crystallinity. Examples of crystalline components in the crystalline polymerization include polypropylene, poly-1-butene, and poly-4-methyl-1-pentene. The olefin-based polymer may be a single type or a combination of two or more types.

[0025] Examples of the olefin polymer include a propylene polymer (A) and a polyolefin (excluding the propylene polymer (A)). Each of the propylene polymer (A) and the polyolefin (excluding the propylene polymer (A)) may be of a single type, or may be of two or more types that differ from each other in melting point, molecular weight, crystal structure, etc.

[0026] (1.1.2.1.1) Propylene-Based Polymer (A) The propylene-based polymer (A) contains a structural unit derived from propylene. The propylene-based polymer (A) is a propylene homopolymer or a propylene copolymer. The propylene copolymer is preferably a copolymer of propylene and at least one of ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 4-methyl-1-pentene, etc. Among these, the propylene-based polymer (A) preferably contains a propylene homopolymer, and is more preferably a propylene homopolymer.

[0027] The melting point of the propylene polymer (A) is preferably 140° C. or higher, more preferably 150° C. or higher, even more preferably 155° C. or higher, and particularly preferably 157° C. to 165° C. The melting point of the propylene polymer (A) is measured by the same method as described in the Examples. When two or more propylene polymers (A) are contained, the melting point of the propylene polymer (A) refers to the higher of the two (hereinafter the same applies to two or more components).

[0028] The MFR of the propylene polymer (A) is not particularly limited as long as it enables melt spinning of the resin composition (SB), and is preferably 1 g / 10 min to 1,000 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 MFR of the propylene polymer (A) is measured in accordance with ASTM D-1238 under the measurement conditions of 230°C and a load of 2.16 kg. When two or more types of propylene polymers (A) are contained, the MFR of the propylene polymer (A) refers to the MFR of the resin composition containing two or more types of propylene polymers (A) (hereinafter the same applies to two or more components).

[0029] The content of the propylene polymer (A) relative to the total amount of the resin composition (SB) is preferably 55.0 mass% to 95.0 mass%, more preferably 65.0 mass% to 95.0 mass%, still more preferably 75.0 mass% to 95.0 mass%, and particularly preferably 85.0 mass% to 95.0 mass%.

[0030] The propylene polymer (A) may be a commercially available product.

[0031] (1.1.2.1.2) Biomass-derived propylene polymer The propylene polymer (A) may be a biomass-derived propylene polymer.

[0032] The term "biomass-derived propylene polymer" refers to a propylene polymer (A) produced from raw material monomers containing biomass-derived propylene. Since the biomass-derived propylene polymer is a carbon-neutral material, it can reduce the environmental impact during the production of nonwoven fabric laminates.

[0033] Monomers containing biomass-derived propylene, which are used as raw materials for biomass-derived propylene-based polymers, can be obtained by cracking biomass naphtha or by synthesis from biomass-derived ethylene. Biomass-derived propylene-based polymers can be obtained by polymerizing the biomass-derived propylene-containing monomers synthesized in this manner using the same method as that used in the conventionally known case of using petroleum-derived propylene. A propylene-based polymer synthesized using a bio-derived propylene-containing monomer as a raw material is a biomass-derived propylene-based polymer. The content of the bio-derived propylene-based polymer in the raw material monomers is greater than 0% by mass, and may be 100% by mass or less, relative to the total amount of raw material monomers. The raw material monomers for biomass-derived propylene-based polymers may further contain, in addition to bio-derived propylene, propylene derived from fossil fuels such as petroleum, and / or ethylene and propylene, such as 1-butene and 1-hexene.

[0034] Biomass-derived propylene polymers can also be obtained by polymerizing propylene obtained by synthesis of olefins from methanol (MTO) or propylene from methanol (MTP) using gas generated by pyrolysis of empty fruit bunches (EFB) such as coconut shells. Furthermore, biomass-derived propylene polymers can also be obtained by polymerizing propylene obtained by dehydrating isopropanol produced by fermentation from biomass feedstocks mainly consisting of non-edible plants such as sorghum.

[0035] When the content of radioactive carbon (C14) in the raw material monomer such as propylene is defined as PC14, the content of biomass-derived carbon in the raw material, Pbio (%), can be calculated by the following formula: Formula (2): Pbio (%) = PC14 / 105.5 × 100

[0036] That is, if all the raw materials for a propylene-based polymer are biomass-derived, the content of biomass-derived carbon is theoretically 100%. Therefore, the biomass degree of the biomass-derived propylene-based polymer is 100%. Since fossil fuel-derived raw materials contain almost no C14, the content of biomass-derived carbon in a propylene-based polymer produced only from fossil fuel-derived raw materials is 0%, and the biomass degree of the fossil fuel-derived propylene-based polymer is 0%.

[0037] "Biomass content" indicates the content of carbon derived from biomass and is calculated by measuring radioactive carbon (C14). Carbon dioxide in the atmosphere contains a certain proportion of C14 (approximately 105.5 pMC). Therefore, it is known that the C14 content in plants (e.g., corn) that grow by absorbing carbon dioxide from the atmosphere is also approximately 105.5 pMC. It is also known that fossil fuels contain almost no C14. Therefore, the content of biomass-derived carbon in the raw material can be calculated by measuring the proportion of C14 contained in the total carbon atoms in the propylene-based polymer.

[0038] The biomass content of the propylene-based polymer used as the raw material of the nonwoven fabric laminate of the first embodiment is preferably 5% or more.

[0039] The content of the biomass-derived propylene-based polymer used in the nonwoven fabric laminate of the first embodiment may be 5% by mass to 99% by mass, 10% by mass to 75% by mass, or 20% by mass to 50% by mass, relative to 100% by mass of the total of the fossil fuel-derived polypropylene resin and the biomass-derived polypropylene resin.

[0040] The propylene polymer (A) used as a raw material for the nonwoven fabric laminate of the first embodiment may contain a propylene polymer obtained by recycling, i.e., a so-called recycled polymer. The "recycled polymer" includes a polymer obtained by recycling waste polymer products, and can be produced, for example, by the method described in DE 10 2019 127 827 (A1). The recycled polymer may contain a marker that identifies it as having been obtained by recycling.

[0041] (1.1.2.1.3) Polyolefins (excluding propylene polymer (A)) Polyolefins (excluding propylene polymer (A)) are homopolymers or copolymers of α-olefins. The α-olefins are α-olefins having 2 or more carbon atoms (excluding 3 carbon atoms), and preferably include homopolymers of α-olefins having 2 to 8 carbon atoms (excluding 3 carbon atoms), and more preferably homopolymers of α-olefins having 2 to 8 carbon atoms (excluding 3 carbon atoms). Specific examples of α-olefins include ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, and 4-methyl-1-pentene. Of these, ethylene is preferred as the α-olefin. Specific examples of polyolefins (excluding propylene polymer (A)) include polyethylene (ethylene homopolymer), 1-butene polymer, and poly-4-methyl-1-pentene. Examples of polyethylene include high-pressure low-density polyethylene, linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), etc. Examples of 1-butene polymers include 1-butene homopolymer, 1-butene-ethylene copolymer, 1-butene-propylene copolymer, etc.

[0042] The density of the polyethylene is preferably 0.94 g / cm from the viewpoint of improving the tensile strength of the extensible spunbonded nonwoven fabric and from the viewpoint of the extensibility and flexibility of the extensible spunbonded nonwoven fabric. ３ ~0.98g / cm ３ , more preferably 0.94 g / cm３ ~0.97 g / cm ３ is.

[0043] The melting point of the polyolefin (excluding the propylene polymer (A)) is preferably 150°C or higher, more preferably 155°C or higher, and even more preferably 155°C to 165°C.

[0044] The MFR of the polyolefin (excluding the propylene polymer (A)) is not particularly limited as long as the melt of the resin composition (SB) can be spun, and is preferably 1 g / 10 min to 1,000 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. When the polyolefin (excluding the propylene polymer (A)) is polyethylene, the MFR is measured in accordance with ASTM D-1238 under the measurement conditions of 190°C and a load of 2.16 kg.

[0045] The content of the polyolefin (excluding the propylene polymer (A)) relative to the total amount of the resin composition (SB) 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. When the content of the polyolefin (excluding the propylene polymer (A)) is within the above range, the extensibility of the extensible spunbonded nonwoven fabric is improved.

[0046] (1.1.2.2) Other Polymers The resin composition (SB) may contain a polymer other than an olefin-based polymer (hereinafter also referred to as "other polymers"), or may not contain any other polymers. Examples of other polymers include thermoplastic elastomers and thermoplastic resins other than olefin-based polymers.

[0047] 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.

[0048] Specific examples of thermoplastic resins other than olefin polymers include polyesters, polyamides (such as nylon 6, nylon 66, and polymetaxylene adipamide), polyvinyl chloride, polyimides, ethylene-vinyl acetate copolymers, ethylene-vinyl acetate-vinyl alcohol copolymers, ethylene-(meth)acrylic acid copolymers, ethylene-acrylic acid ester-carbon monoxide copolymers, polyacrylonitrile, polycarbonate, and polystyrene. Examples of polyesters include aliphatic polyesters and 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 at least one diol.

[0049] The content of the polyolefin (excluding the propylene polymer (A)) in the extensible spunbonded nonwoven fabric is preferably more than 90 mass % and 100 mass % or less, more preferably 95 mass % to 100 mass %, based on the total of the polyolefin (excluding the propylene polymer (A)) and other polymers (thermoplastic elastomers and thermoplastic resins other than olefin polymers).

[0050] When the resin composition (SB) contains a propylene polymer (A) and an ethylene polymer, the content of the propylene polymer (A) 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 resin composition (SB). 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 resin composition (SB) (provided that the propylene polymer (A) + the ethylene polymer = 100% by mass).

[0051] (1.1.2.3) Optional Components The resin composition (SB) may contain, as optional components, various known additives such as an antioxidant, a heat stabilizer, a weather stabilizer, an antistatic agent, a slip agent, an antifogging agent, a lubricant, a dye, a pigment, a natural oil, a synthetic oil, a wax, and a hydrophilic agent, as long as the object of the present disclosure is not impaired.

[0052] (1.1.2.4) Preferred Composition The fibers contained in the extensible spunbond nonwoven fabric are made from a resin composition for extensible spunbond nonwoven fabrics, and the resin composition for extensible spunbond nonwoven fabrics preferably contains a propylene-based polymer (A) and a polymer (B) that is at least one selected from the group consisting of polyolefins (excluding the propylene-based polymer (A)) and polyesters. This reduces the number of thread breaks that occur during spinning of the resin composition, which is the raw material for the extensible spunbond nonwoven fabric. As a result, the productivity of nonwoven fabric laminates is improved.

[0053] The propylene polymer (A) contains a propylene homopolymer, and the polymer (B) has a density of 0.94 g / cm3 from the viewpoint of improving the tensile strength of the spunbonded nonwoven fabric and from the viewpoint of the extensibility and flexibility of the spunbonded nonwoven fabric. ３ ~0.97 g / cm ３ It is preferred that the polyethylene contains

[0054] The content of polymer (B) 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 resin composition (SB). When the content of polymer (B) is within the above range, the extensibility of the spunbonded nonwoven fabric is improved.

[0055] (1.1.2.4.1) Island-sea fiber When the extensible fiber contains islands-in-sea fiber, the islands-in-sea fiber preferably has an islands-in-sea structure in which the sea phase is a propylene-based polymer (A) (preferably a propylene homopolymer) and the island phase is a polymer (B) (preferably a high-density polyethylene). This inhibits the oriented crystallization of the sea phase, which is the main component, and improves the extensibility of the extensible spunbonded nonwoven fabric.

[0056] (1.1.2.4.2) Concentric Sheath-Core Fibers When the extendable fiber includes a concentric sheath-core fiber, the concentric sheath-core fiber preferably has a core made of a low MFR olefin polymer and a sheath 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 may be 1 g / 10 min to 1,000 g / 10 min. The MFR of the high MFR olefin polymer may be 1 g / 10 min to 1,000 g / 10 min. The difference in MFR is preferably 15 g / 10 min or more, more preferably 30 g / 10 min or more, and particularly preferably 40 g / 10 min or more. The difference in MFR is preferably 100 g / 10 min or less, more preferably 70 g / 10 min or less.

[0057] (1.1.3) Specific Examples of Extensible Spunbond Nonwoven Fabrics The extensible spunbond nonwoven fabric preferably includes an extensible spunbond nonwoven fabric that satisfies the following requirements (a1) and (a3).

[0058] (1.1.3.1) Requirement (a1) (a1) A spunbond nonwoven fabric using core-sheath fibers, side-by-side fibers or crimped fibers made of two or more olefin polymers having a difference in induction time of crystallization in flow-induced phase separation of 100 seconds or more.

[0059] The two or more kinds of olefin polymers may be, for example, a propylene polymer (A) having a high melting point and a propylene polymer (A) having a low melting point.

[0060] (1.1.3.2) Requirement (a2) (a2) A spunbond nonwoven fabric using islands-in-sea fibers, sheath-core fibers, side-by-side fibers, or crimped fibers, which is made of an olefin polymer composition containing a propylene polymer (A) and an ethylene polymer. In particular, the following are preferred as the olefin polymer composition. (a2-1) 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. (a2-2) An olefin polymer composition containing a propylene polymer (A) having the same or different MFR and a high melting point in the range of 157°C to 165°C.

[0061] The propylene polymer (A) may be, for example, a propylene polymer obtained by copolymerizing a propylene homopolymer with a low-melting-point random copolymer of propylene and an α-olefin having a melting point in the range of 130°C to 150°C.

[0062] (1.1.3.3) Requirement (a3) ​​(a3) ​​A spunbond nonwoven fabric using concentric core-sheath fibers, wherein the core is made of a low MFR propylene polymer (A) having an MFR in the range of 1 g / 10 min to 200 g / 10 min, and the sheath is made of a high MFR propylene polymer (A) 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.

[0063] (1.1.3.4) Preferred Examples Examples of extensible spunbond nonwoven fabrics that satisfy the requirements (a1) to (a3) ​​include the extensible spunbond nonwoven fabrics of the following (X1) and (X2).

[0064] (X1) A spunbond nonwoven fabric using concentric sheath-core fibers, side-by-side fibers, or crimped fibers, wherein the core is a propylene polymer (A) (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.

[0065] (X2) A spunbond nonwoven fabric comprising concentric core-sheath fibers, the core of which is a low MFR propylene polymer (A) (preferably a propylene homopolymer) having an MFR in the range of 1 g / 10 min to 200 g / 10 min, the sheath of which is a high MFR propylene polymer (A) (preferably a propylene homopolymer) having an MFR in the range of 31 g / 10 min to 230 g / 10 min, and the difference between the MFRs of the core and the sheath is 30 g / 10 min or more. In the above-mentioned (a2), the core may be a low MFR propylene polymer (A) having an MFR in the range of 10 g / 10 min to 50 g / 10 min, and the sheath of which is a high MFR propylene polymer (A) 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 shell may be 30 g / 10 min to 100 g / 10 min, or 40 g / 10 min to 80 g / 10 min.

[0066] (1.2) Elastic Nonwoven Fabric The nonwoven fabric laminate of the first embodiment includes an elastic nonwoven fabric.

[0067] The type of elastic nonwoven fabric is not particularly limited, and examples thereof include spunbond nonwoven fabric, meltblown nonwoven fabric, flash-spun nonwoven fabric, staple fiber, etc. Among these, the type of elastic nonwoven fabric is preferably spunbond nonwoven fabric from the viewpoint of using long fibers in the elastic nonwoven fabric.

[0068] The basis weight of the elastic nonwoven fabric is preferably 2 g / m ２ ~120g / m ２ and more preferably 2 g / m ２ ~40g / m ２ More preferably, 12 g / m or less ２ ~37g / m ２ , particularly preferably 12 g / m ２ ~32g / m ２ , more preferably 16 g / m ２ ~26g / m ２ , and even 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.

[0069] (1.2.1) Fibers The average fiber diameter b of the elastic fibers is preferably 50 μm or less, more preferably 40 μm or less, even more preferably 35 μm or less, and particularly preferably 30 μm or less. The average fiber diameter b of the elastic fibers is preferably 1 μm or more, more preferably 10 μm or more, even more preferably 20 μm or more, and particularly preferably 24 μm or more. From the viewpoints of blocking suppression and flexibility, it is preferred that the average fiber diameter b of the elastic fibers is more than 20 μm and less than 35 μm, and that the average fiber diameter a of the extensible fibers is smaller than the average fiber diameter b of the elastic fibers. From the viewpoint of preventing yarn breakage, it is preferred that the average fiber diameter b of the elastic fibers is more than 20 μm and less than 35 μm, and that the fiber system ratio (b / a) is 1.0 or more and 1.35 or less. It is more preferred that the fiber system ratio (b / a) is more than 1.0 and 1.35 or less. The method for measuring the average fiber diameter b of the elastic fibers is the same as that described in the Examples.

[0070] The cross-sectional shape of the elastic fiber is not particularly limited, and may be circular, elliptical, irregular, or the like.

[0071] The elastic fiber may be, for example, a sheath-core type, a side-by-side type, an islands-in-the-sea type, or a side-by-side type. The sheath-core fiber has only to have a core and a sheath, and may be either a concentric sheath-core type or an eccentric sheath-core type. The eccentric sheath-core fiber may have the core exposed on the surface, or the core may not be exposed on the surface.

[0072] (1.2.2) Material The elastic fiber is made of a resin composition for elastic nonwoven fabrics (hereinafter also referred to as "resin composition (NW)"). The resin composition (NW) preferably contains an α-olefin copolymer, but may contain only an α-olefin copolymer. The resin composition (NW) may contain only one type of propylene-based polymer, or two or more types may be used in combination.

[0073] (1.2.2.1) α-olefin copolymer The resin composition (NW) preferably contains an α-olefin copolymer. This allows the nonwoven fabric laminate to have better stretch properties and stress retention than when an elastic nonwoven fabric not containing an α-olefin copolymer (e.g., an elastic nonwoven fabric made of a propylene homopolymer) is used.

[0074] It is more preferable that the resin composition (NW) contains an α-olefin copolymer and does not contain a propylene homopolymer. In other words, the elastic nonwoven fabric is preferably an elastic nonwoven fabric containing an α-olefin copolymer (excluding elastic nonwoven fabrics containing a propylene homopolymer). This results in better stretch properties and stress retention of the nonwoven fabric laminate than when an elastic nonwoven fabric not containing an α-olefin copolymer (for example, an elastic nonwoven fabric made of a propylene homopolymer) is used.

[0075] The term "α-olefin copolymer" refers to a copolymer in which two or more copolymerization components having an α-olefin skeleton are copolymerized.

[0076] Examples of copolymerization 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. Among these, the α-olefin copolymer preferably contains an ethylene-propylene copolymer having ethylene and propylene as copolymerization components, from the viewpoint of providing a nonwoven fabric laminate with lower stress and superior stretchability.

[0077] 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.

[0078] The α-olefin copolymer may be any of an alternating copolymer, a graft copolymer, a block copolymer and a random copolymer.

[0079] The density of the α-olefin copolymer (ASTM D 1505) is preferably 0.850 g / cm ３ ~0.950g / cm ３ , more preferably 0.855 g / cm３ ~0.900g / cm ３ , more preferably 0.860 g / cm ３ ~0.895g / cm ３ The density of the α-olefin copolymer is a value obtained by measurement in accordance with the density gradient method of JIS K7112 (1999).

[0080] From the viewpoint of improving the stretchability of the nonwoven 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. The tensile modulus is a value obtained by measurement using a method in accordance with JIS K7161 (2011).

[0081] 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. The mass average molecular weight (Mw) and number average molecular weight (Mn) of the α-olefin copolymer are values ​​determined by GPC (gel permeation chromatography) under the following conditions. The mass average molecular weight (Mw) is the mass 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 mass average molecular weight (Mw) measured in the same manner. <GPC measurement conditions> Column: TOSO GMHHR-H(S)HT Detector: RI detector for liquid chromatography 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)

[0082] 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 15 g / 10 min to 50 g / 10 min. The MFR of the α-olefin copolymer is measured in accordance with ASTM D-1238 under the measurement conditions of 230°C and a load of 2.16 kg.

[0083] 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 a conventionally known catalyst such as a Ziegler-Natta catalyst or a metallocene catalyst by a conventionally known polymerization method such as a gas phase method, a bulk method, a slurry method, or a solution method. Commercially available α-olefin copolymers include, for example, Tafmer (manufactured by Mitsui Chemicals, Inc.), Vistamaxx series (manufactured by ExxonMobil Chemical Corporation), and Versify.

[0084] The composition of the α-olefin copolymer can be determined by a conventionally known method (for example, IR analysis, NMR analysis, microanalysis, etc.).

[0085] 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, more preferably 98% by mass to 100% by mass.

[0086] When the α-olefin copolymer contains a copolymer of ethylene and propylene, the proportion of the ethylene and propylene copolymer relative to the total amount of the elastic nonwoven fabric is preferably 80% by mass to 100% by mass, more preferably 90% by mass to 100% by mass, from the viewpoint of the stretch properties of the nonwoven fabric laminate.

[0087] When the α-olefin copolymer is a copolymer of ethylene and propylene, the melting point of the α-olefin is preferably 130° C. or lower, more preferably 115° C. or lower, even more preferably 100° C. or lower, particularly preferably 40° C. to 85° C., and even more preferably 40° C. to 60° C. The melting point can be measured by the same method as described in the examples.

[0088] (1.1.2.1) Specific α-olefin copolymer The elastic nonwoven fabric preferably contains an α-olefin copolymer (hereinafter also referred to as "specific α-olefin copolymer") having a ratio (E40 / E23) of the storage modulus at 40°C (E40) to the storage modulus at 23°C (E23) of 37% or more. This makes it easy to suppress the loss of elasticity of the elastic nonwoven fabric in a temperature-changing environment (e.g., 40°C to 23°C). As a result, the nonwoven fabric laminate has excellent stress maintenance.

[0089] 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. The ratio (E40 / E23) is not particularly limited and may be 100% or less, 95% or less, or 90% or less.

[0090] An example of a method for adjusting the ratio (E40 / E23) of the specific 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.

[0091] From the viewpoint of improving the stretchability of the nonwoven fabric laminate, the storage modulus E23 of the specific 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. The storage modulus E23 of the specific α-olefin copolymer is preferably 5 MPa or more, more preferably 10 MPa or more. From the viewpoint of making the nonwoven fabric laminate lower stress and more excellent stretchability, the storage modulus E40 of the specific α-olefin copolymer is preferably 10 MPa or less, more preferably 9 MPa or less. The storage modulus E40 of the specific α-olefin copolymer is preferably 3 MPa or more, more preferably 5 MPa or more.

[0092] It is preferred that the elastic nonwoven fabric contains a specific α-olefin copolymer, the proportion of the specific α-olefin copolymer relative to the total amount of the elastic nonwoven fabric is 90% by mass to 100% by mass, the specific α-olefin copolymer is a copolymer of ethylene and propylene, and the melting point of the specific α-olefin copolymer is 130°C or lower.

[0093] (1.2.2.2) Optional Components The resin composition (NW) 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, within the scope of the present disclosure.

[0094] (1.3) Other Layers The nonwoven fabric laminate of the first embodiment may or may not include other layers depending on the application. The other layers are laminated to at least one of the extensible spunbond nonwoven fabrics.

[0095] Examples of other layers include nonwoven fabrics other than elastic nonwoven fabrics and extensible spunbonded nonwoven fabrics, knitted fabrics, woven fabrics, films, etc. The method for further laminating (bonding) other layers to the nonwoven fabric laminate is not particularly limited, and examples include heat embossing, heat fusion methods (e.g., ultrasonic fusion, etc.), mechanical entanglement methods (e.g., needle punching, water jet, etc.), methods using adhesives (e.g., hot melt adhesives, urethane adhesives, etc.), extrusion lamination, etc.

[0096] The nonwoven fabric laminate of the first embodiment may further include a film layer. The film layer may be an elastic or non-elastic film, and may or may not be breathable or moisture-permeable. The film layer may be disposed on one side of the nonwoven fabric laminate (i.e., the extensible spunbond nonwoven fabric) or on both sides of the nonwoven fabric laminate (i.e., the extensible spunbond nonwoven fabric). Examples of such laminates include stretchable nonwoven fabric / film, stretchable nonwoven fabric / film / stretchable nonwoven fabric, and film / stretchable nonwoven fabric / film. By further including a film layer in the nonwoven fabric laminate of the first embodiment, nonwoven fabric laminates suitable for various applications can be provided depending on the properties of the film. The film layer may be heat-welded to the extensible spunbond nonwoven fabric, or may be bonded to the extensible spunbond nonwoven fabric using an adhesive.

[0097] Nonwoven fabrics other than elastic nonwoven fabrics and extensible spunbond nonwoven fabrics include spunbond nonwoven fabrics, meltblown nonwoven fabrics, wetlaid nonwoven fabrics, drylaid nonwoven fabrics, drylaid pulp nonwoven fabrics, flash-spun nonwoven fabrics, and spread nonwoven fabrics. These nonwoven fabrics may be stretchable or nonstretchable nonwoven fabrics. A "nonstretchable nonwoven fabric" refers to a fabric that does not generate return stress after being stretched in the machine direction (MD) or cross direction (CD).

[0098] The film layer is preferably a breathable (moisture-permeable) film. 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. Depending on the application, if the breathability and hydrophilicity of the nonwoven fabric laminate do not need to be maintained, films made of thermoplastic resins such as 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 the first embodiment is preferred from the viewpoint of increasing the peel strength of the nonwoven fabric laminate containing the film. For example, in an embodiment in which the resin composition for extensible spunbonded nonwoven fabrics contains a propylene polymer (A) and at least one polymer (B) selected from the group consisting of polyolefins (excluding the propylene polymer (A)) and polyesters, when a non-elastic film is used, the thermoplastic resin of the non-elastic film is preferably polypropylene, an α-olefin copolymer (including a propylene random copolymer), or a combination thereof. When an elastic film is used, the thermoplastic resin of the elastic film is preferably an α-olefin copolymer.

[0099] (2) Nonwoven Fabric Laminate of Second Embodiment A nonwoven fabric laminate of a second embodiment of the present disclosure comprises an elastic nonwoven fabric and an extensible spunbonded nonwoven fabric disposed on both sides of the elastic nonwoven fabric. The fibers contained in the extensible spunbonded nonwoven fabric (hereinafter also referred to as "extensible fibers") are islands-in-sea fibers. The islands-in-sea fibers are made of a resin composition for extensible spunbonded nonwoven fabrics. The resin composition for extensible spunbonded nonwoven fabrics contains a propylene-based polymer (A) containing a propylene homopolymer, and a polymer (B) that is at least one selected from the group consisting of polyolefins (excluding the propylene-based polymer (A)) and polyesters. The average fiber diameter a of the fibers contained in the extensible spunbonded nonwoven fabric is smaller than the average fiber diameter b of the fibers contained in the elastic nonwoven fabric (hereinafter also referred to as "elastic fibers").

[0100] The nonwoven fabric laminate of the second embodiment has the above-described configuration, and therefore can suppress the occurrence of blocking even when unwound from a nonwoven fabric roll at high speed (e.g., 200 m / min). This effect is presumably due to, but not limited to, the following reasons. By laminating an extensible spunbond nonwoven fabric and an elastic nonwoven fabric with a specific fiber diameter balance, exposure of the elastic fibers on the surface of the nonwoven fabric laminate can be suppressed, thereby reducing the tackiness of the surface of the nonwoven fabric laminate. Furthermore, a more uniform texture of the extensible spunbond nonwoven fabric can achieve even better effects.

[0101] The nonwoven fabric laminate of the second embodiment has the same configuration as the nonwoven fabric laminate of the first embodiment, except that the surface coefficient represented by the above formula (1) of 38 or more is not an essential feature of the invention, the extensible fibers include specific islands-in-sea fibers, and the average fiber diameter a of the extensible fibers is smaller than the average fiber diameter b of the elastic fibers. The description of the nonwoven fabric laminate of the first embodiment can be used to describe the nonwoven fabric laminate of the second embodiment.

[0102] From the viewpoint of further suppressing blocking, the average fiber diameter a of the extendable fibers is smaller than the average fiber diameter b of the elastic fibers. From the viewpoint of suppressing blocking and reducing the number of yarn breakages, the fiber ratio (b / a) of the average fiber diameter b of the extendable fibers to the average fiber diameter a of the extendable fibers is preferably 1.0 or more and 1.35 or less, and more preferably more than 1.0 and 1.35 or less.

[0103] The surface coefficient of the nonwoven fabric laminate is preferably 38 or more, more preferably 38 to 60, and even more preferably 38 to 50, from the viewpoint of further suppressing the occurrence of blocking even when the nonwoven fabric laminate is unwound from a nonwoven fabric roll at high speed (e.g., 200 m / min).

[0104] The method for making the surface coefficient 38 or more is the same as that exemplified in the first embodiment.

[0105] The basis weight ratio (NW / total) of the nonwoven fabric laminate is not particularly limited, but is preferably 18% to 48%. This allows the nonwoven fabric laminate to achieve both elastic properties and blocking resistance during roll production. The basis weight ratio (NW / total) is more preferably 20% to 48%, even more preferably 20% to 43%, and particularly preferably 25% to 43%.

[0106] The total basis weight of the nonwoven fabric laminate is the same as that exemplified in the first embodiment.

[0107] (2.1) Extensible Spunbond Nonwoven Fabric The nonwoven fabric laminate of the second embodiment includes an extensible spunbond nonwoven fabric.

[0108] The basis weight of the extensible spunbond nonwoven fabric is the same as that exemplified in the first embodiment.

[0109] (2.1.1) Fibers The extensible spunbond nonwoven fabric comprises extensible fibers.

[0110] The average fiber diameter a of the extendable fiber is the same as that exemplified in the first embodiment.

[0111] The cross-sectional shape of the extendable fiber is not particularly limited, and examples thereof include a circular, elliptical, and irregular cross-section.

[0112] The extendable fiber of the second embodiment is an islands-in-sea type fiber. Because the extendable fiber is an islands-in-sea type fiber, the number of thread breakages that occur during spinning of the resin composition that is the raw material for the extendable spunbond nonwoven fabric is reduced. As a result, the productivity of the nonwoven fabric laminate is improved. Fewer thread breakages can reduce the number of fibers whose fiber ends are exposed on the surface of the nonwoven fabric, and can also improve the feel of the fabric, such as a prickly feeling.

[0113] (2.1.2) Resin composition for extensible spunbond nonwoven fabric The islands-in-sea fiber is made of a resin composition for extensible spunbond nonwoven fabric (hereinafter also referred to as "resin composition (SB)"). The resin composition (SB) contains a propylene-based polymer (A) containing a propylene homopolymer (hereinafter also referred to as "specific propylene-based polymer (A)") and a polymer (B).

[0114] (2.1.2.1) Specific propylene polymer (A) The specific propylene polymer (A) contains a propylene homopolymer and may or may not contain a propylene copolymer. The propylene copolymer is the same as that exemplified in the first embodiment. In particular, the specific propylene polymer (A) preferably contains a propylene homopolymer, and is more preferably a propylene homopolymer.

[0115] The melting point of the specific propylene polymer (A) is the same as the melting point of the propylene polymer (A) of the first embodiment exemplified above.

[0116] The MFR of the specific propylene polymer (A) is the same as the MFR of the propylene polymer (A) of the first embodiment exemplified above.

[0117] The content of the propylene homopolymer is preferably 0% by mass to 100% by mass, more preferably 20% by mass to 100% by mass, even more preferably 40% by mass to 100% by mass, particularly preferably 60% by mass to 90% by mass, and most preferably 70% by mass to 90% by mass, based on the total amount of the specific propylene polymer (A).

[0118] The content of the specific propylene polymer (A) is preferably 55.0 mass% to 95.0 mass%, more preferably 65.0 mass% to 95.0 mass%, still more preferably 75.0 mass% to 95.0 mass%, and particularly preferably 85.0 mass% to 95.0 mass%, based on the total amount of the resin composition (SB).

[0119] The specific propylene polymer (A) may be a commercially available product.

[0120] (2.1.2.2) Biomass-derived propylene polymer The specific propylene polymer (A) may be a biomass-derived propylene polymer. Examples of the biomass-derived propylene polymer include those exemplified in the first embodiment.

[0121] (2.1.2.3) Polymer (B) The polymer (B) is at least one selected from the group consisting of polyolefins (excluding the propylene-based polymer (A)) and polyesters.

[0122] The content of the polymer (B) relative to the total amount of the resin composition (SB) is preferably 5.0 mass% to 45.0 mass%, more preferably 5.0 mass% to 35.0 mass%, even more preferably 5.0 mass% to 25.0 mass%, and particularly preferably 5.0 mass% to 15.0 mass%.

[0123] (2.1.2.3.1) Polyolefin (excluding specific propylene polymer (A)) The polyolefin (excluding propylene polymer (A)) and the content of polyolefin (excluding specific propylene polymer (A)) are the same as those exemplified in the first embodiment.

[0124] The content of the polyolefin (excluding the specific propylene polymer (A)) relative to the total amount of the polymer (B) is preferably 90% by mass to 100% by mass, more preferably 95% by mass to 100% by mass, even more preferably 99% by mass to 100% by mass, and particularly preferably 100% by mass.

[0125] (2.1.2.3.2) Polyester The polyester is the same as that exemplified in Embodiment 1. The content of the polyester relative to the total amount of polymer (B) is preferably 0% by mass or more and less than 10% by mass, more preferably 0% by mass to 5% by mass, and even more preferably 0% by mass.

[0126] (2.1.2.4) Optional Components The resin composition (SB) may contain, as optional components, various known additives such as an antioxidant, a heat stabilizer, a weather stabilizer, an antistatic agent, a slip agent, an antifogging agent, a lubricant, a dye, a pigment, a natural oil, a synthetic oil, a wax, and a hydrophilic agent, as long as the object of the present disclosure is not impaired.

[0127] (2.1.2.5) Preferred composition The polymer (B) has a density of 0.94 g / cm3 from the viewpoint of improving the tensile strength of the spunbonded nonwoven fabric and from the viewpoint of the extensibility and flexibility of the spunbonded nonwoven fabric. ３ ~0.97 g / cm ３ It is preferred that the polyethylene contains

[0128] (2.1.2.6) Island-in-sea fiber The islands-in-sea fiber preferably has an islands-in-sea structure in which the sea phase is a specific propylene-based polymer (A) (preferably a propylene homopolymer) and the island phase is a polymer (B) (preferably a high-density polyethylene). This inhibits the orientation and crystallization of the main component sea phase, improving the extensibility of the extensible spunbonded nonwoven fabric.

[0129] (2.2) Elastic Nonwoven Fabric The nonwoven fabric laminate of the second embodiment includes an elastic nonwoven fabric. The elastic nonwoven fabric is the same as that exemplified in the first embodiment.

[0130] The elastic nonwoven fabric preferably contains an α-olefin copolymer (hereinafter also referred to as a "specific α-olefin copolymer") having a ratio (E40 / E23) of the storage modulus at 40°C (E40) to the storage modulus at 23°C (E23) of 37% or more. This makes it easier to prevent the elasticity of the elastic nonwoven fabric from decreasing in a temperature-varying environment (e.g., 40°C to 23°C). As a result, the nonwoven fabric laminate has excellent stress retention.

[0131] It is preferred that the elastic nonwoven fabric contains a specific α-olefin copolymer, the proportion of the specific α-olefin copolymer relative to the total amount of the elastic nonwoven fabric is 90% by mass to 100% by mass, the specific α-olefin copolymer is a copolymer of ethylene and propylene, and the melting point of the specific α-olefin copolymer is 130°C or lower.

[0132] (2.3) Other Layers The nonwoven fabric laminate of the second embodiment may or may not include other layers depending on the intended use. The other layers are laminated to at least one of the extensible spunbond nonwoven fabrics. Examples of the other layers include those similar to those exemplified in the first embodiment.

[0133] The nonwoven fabric laminate of the second embodiment may further include a film layer. The film layer is the same as that exemplified in the first embodiment. The film layer may be disposed on one side of the nonwoven fabric laminate (i.e., the extensible spunbond nonwoven fabric), or may be disposed on both sides of the nonwoven fabric laminate (i.e., the extensible spunbond nonwoven fabric). By further including a film layer in the nonwoven fabric laminate of the second embodiment, it is possible to provide a nonwoven fabric laminate suitable for various applications depending on the properties of the film. The film layer may be heat-welded to the extensible spunbond nonwoven fabric, or may be adhered to the extensible spunbond nonwoven fabric using an adhesive.

[0134] (3) Stretchable Nonwoven Fabric Laminate The stretchable nonwoven fabric laminate of the present disclosure is a stretch-processed product of the nonwoven fabric laminate of the first or second embodiment of the present disclosure. The stretchable nonwoven fabric laminate has stretchability.

[0135] A stretchable nonwoven fabric laminate can be obtained by stretching the nonwoven fabric laminate of the present disclosure. The stretching method is not particularly limited, and conventionally known methods can be used. The stretching method may be a partial stretching method or a full stretching method. It may be a uniaxial stretching method or a biaxial stretching method. An example of a method for stretching in the machine direction (MD) is a method in which partially fused mixed fibers are passed through two or more nip rolls. In this case, 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 a gear stretching device as shown in FIG. 1.

[0136] 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.

[0137] In the case of uniaxial stretching, it is preferable that the stretch ratio in either the machine direction (MD) or the cross direction (CD) satisfies the above-mentioned range. In the case of biaxial stretching, it is preferable that the stretch ratio in at least one of the machine direction (MD) and the cross direction (CD) satisfies the above-mentioned range.

[0138] By performing the drawing process at the draw ratio described above, both the elastic fibers and the extensible fibers are drawn. The extensible fibers undergo plastic deformation and are elongated (i.e., lengthened) according to the draw ratio. After the nonwoven fabric laminate is drawn, when the stress is released, the elastic fibers elastically recover, while the extensible fibers fold without elastic recovery, resulting in a bulky feel in the nonwoven fabric laminate. Furthermore, the extensible fibers tend to become thinner. This is thought to improve flexibility and touch, as well as provide stretch-resistance.

[0139] (4) Textile Products The textile products of the present disclosure include the nonwoven fabric laminate of the first or second embodiment of the present disclosure or the stretchable nonwoven fabric laminate of the present disclosure. The textile products are not particularly limited, and examples include absorbent articles such as disposable diapers and sanitary products, hygiene articles such as masks, medical articles such as bandages, clothing materials, and packaging materials. The textile products of the present disclosure preferably include the nonwoven fabric laminate or stretchable nonwoven fabric laminate of the present disclosure as an elastic member.

[0140] Preferably, the textile product of the present disclosure further includes an engageable engaging means. By applying an engageable engaging means to the outermost surface of the nonwoven fabric laminate, the textile product of the present disclosure functions as a removable stretchable sheet. Additionally, the nonwoven fabric laminate of the present disclosure has excellent fit (rebound stress). Therefore, by stretching the textile product of the present disclosure and wrapping it around the human body or an article and engaging it with the engaging means, the stretchable nonwoven fabric laminate can be tightly attached to the article or the like, or can be loosely pressed against the article. In particular, even if the article to which the textile product of the present disclosure is attached has an uneven shape, the textile product of the present disclosure can conform to the uneven shape of the article. From this perspective, the textile product of the present disclosure is useful as a base material for bandages, gowns, clothing materials, adhesive bandages, and poultices, and as a packaging material. Additionally, when the nonwoven fabric laminate does not include other layers, the nonwoven fabric laminate has excellent breathability, resulting in an excellent wearing comfort for the textile product.

[0141] Examples of the engageable engaging means include hook-and-loop fasteners with engaging protrusions, mechanical fastenings, removable and re-adhesive adhesive tapes, claws, clips, etc. The engaging means may be any known engaging means. The engaging means may be provided for the purpose of preventing slippage by increasing surface friction characteristics, or may be used to provide a non-slip finish on a portion of the nonwoven fabric laminate depending on the application. The engaging means may be provided on a portion of the surface of the nonwoven fabric laminate for the purpose of temporarily fastening the tip of a bandage or dressing. Crimped nonwoven fabrics can be used as mechanical fastenings. Among crimped nonwoven fabrics, crimped nonwoven fabrics using propylene-based thermoplastic resins can be used to construct nonwoven fabric laminates made solely from polyolefin raw materials, providing stretchable textile products with excellent recyclability.

[0142] (5) Absorbent Articles The absorbent article of the present disclosure includes the nonwoven fabric laminate of the present disclosure or the stretchable nonwoven fabric laminate of the present disclosure. The absorbent article may further include an absorbent body that absorbs liquid. The nonwoven fabric laminate of the present disclosure or the stretchable nonwoven fabric laminate of the present disclosure may be positioned so as to come into contact with the wearer's skin when the absorbent article is worn.

[0143] (6) Masks The masks of the present disclosure include the nonwoven fabric laminate or stretchable nonwoven fabric laminate of the present disclosure. The masks include 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, and the ear loops may include the nonwoven fabric laminate or stretchable nonwoven fabric laminate of the present disclosure.

[0144] (7) Adhesive Materials The adhesive materials of the present disclosure include the nonwoven fabric laminate or stretchable nonwoven fabric laminate of the present disclosure. A "adhesive material" typically comprises a sheet (e.g., nonwoven fabric, woven fabric, etc.) with a paste layer formed on one side. The adhesive material may include a covering portion that covers at least a portion of the wearer's body. The base material of the covering portion may comprise the nonwoven fabric laminate of the first or second embodiment of the present disclosure or the stretchable nonwoven fabric laminate of the present disclosure. The paste layer may be any known paste layer. The adhesive materials of the present disclosure are specifically used in dressings (e.g., compresses, etc.), patches, adhesive sheets for application to the skin, medical dressings, sterile sheets, or medical patches. A drug, medicine, therapeutic agent, patch, topical ointment, transdermal drug, transdermal agent, or patch is applied to the surface of each of the medical dressings, sterile sheets, and medical patches.

[0145] 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, ratios, processing procedures, etc. shown in the following examples can be changed as appropriate without departing from the spirit of the present disclosure. Unless otherwise specified, "parts" means "parts by mass."

[0146] [1] Measurement Methods The physical properties of the nonwoven fabric laminate and the like were measured by the following methods.

[0147] [1.1] Basis weight Ten test pieces measuring 300 mm in the machine direction (MD) and 250 mm in the cross direction (CD) were taken from an elastic nonwoven fabric, an extensible spunbond nonwoven fabric, or a nonwoven fabric laminate (hereinafter also referred to as "elastic nonwoven fabric, etc."). The test pieces were taken from 10 arbitrary locations on the elastic nonwoven fabric, etc. Next, the mass (g) of each test piece taken was measured using a top-pan electronic balance (manufactured by Kensei Kogyo Co., Ltd.). The average mass of each test piece was calculated. The average mass was then subtracted by 1 m from the calculated average. ２ The weight per unit area of ​​the elastic nonwoven fabric was calculated by converting the weight per unit area into a mass (g) per unit area and rounding off to the nearest whole number.

[0148] [1.2] Average fiber diameter Ten 10 mm x 10 mm test pieces were taken from the elastic nonwoven fabric or the extensible spunbond nonwoven fabric, and the fiber diameters were measured in μm units to the first decimal place at a magnification of 20 times using a Nikon ECLIPSE E400 microscope. The diameters were measured at 20 random locations for each test piece, and the average value was taken as the average fiber diameter.

[0149] [1.3] Formation Coefficient The formation index of the nonwoven fabric laminate was measured using a Nomura Shoji Co., Ltd. Formation Tester FMT-MIII. The average value of five randomly selected points was calculated and rounded to the nearest tenth. The formation coefficient (V) is expressed as V = 10σ / E. Here, σ is the standard deviation of the nonwoven fabric's unevenness in shading, and E is the value calculated from the nonwoven fabric's light transmittance (T [%]) by E = 2 - log T. When the transmittance is close to 100% (poor formation), E is approximately 0, and V exhibits an infinitely large value. The smaller the formation index, the better the formation.

[0150] [1.4] Surface Coefficient The surface coefficient was calculated by substituting the measured values ​​of the average fiber diameter and the formation coefficient into the above formula (1).

[0151] [1.5] Storage modulus E40 and storage modulus E23 The storage modulus E40 of the "α-olefin copolymer" described below was measured using the following equipment and conditions: Temperature: 23°C or 40°C Equipment: RSA-III (manufactured by TI Instruments) Deformation mode: Tensile mode Temperature range: -20°C to 120°C Heating rate: 2°C / min Deformation frequency: 10 Hz Initial strain: 0.1% Measurement temperature range: 0.3°C Environment: Nitrogen atmosphere

[0152] [1.6] Melting Point The melting point of the "α-olefin copolymer" described below is defined as the peak top of the peak observed at the lowest temperature in a melting endothermic curve obtained using a differential scanning calorimeter (DSC) by holding a sample at -100°C for 5 minutes under a nitrogen atmosphere and then heating at 10°C / min. Specifically, the melting point can be determined as the peak top of the peak observed at the lowest temperature in a melting endothermic curve obtained using a differential scanning calorimeter (Perkin-Elmer, DSC-7) by holding a 5 mg sample at -100°C for 5 minutes under a nitrogen atmosphere and then heating at 10°C / min.

[0153] [1.7] Maximum point elongation (%) Only the spunbonded nonwoven fabric constituting the outer layer (first layer or third layer) of Examples 1 to 8 and Comparative Examples 1 to 4 was obtained in the same manner as in "[3] Nonwoven fabric laminate" below. Five test pieces measuring 200 mm (MD) x 50 mm (CD) and five test pieces measuring 50 mm (MD) x 200 mm (CD) were taken from the spunbonded nonwoven fabric. Five test pieces were taken from any five locations in both MD and CD (10 locations in total). Each test piece was then subjected to a tensile test using a universal tensile testing machine (IM-201, manufactured by Intesco Co., Ltd.) under conditions of a chuck distance of 100 mm and a tensile speed of 100 mm / min, and the elongation (maximum point elongation [%)) was determined. The average value of the elongation at these 10 points (5 points each in MD and CD) was defined as the "maximum elongation of the spunbond nonwoven fabrics constituting Examples 1 to 8 and Comparative Examples 1 to 4." The maximum elongation of the spunbond nonwoven fabrics constituting the outer layers of Examples 1 to 8 and Comparative Examples 1 to 4 was 50% or more. In other words, the spunbond nonwoven fabrics constituting the outer layers of Examples 1 to 8 and Comparative Examples 1 to 4 were extensible spunbond nonwoven fabrics.

[0154] [2] Preparation of Materials The following materials were prepared as raw materials for the elastic nonwoven fabric.

[0155] [2.1] Outer layer (stretchable spunbond nonwoven fabric) [2.1.1] Sea-island fiber raw material "h-pp" (propylene homopolymer, MFR (measured in accordance with ASTM D1238 at a temperature of 230 ° C. and a load of 2.16 kg): 60 g / 10 min, density: 0.91 g / cm ３ , melting point: 160 ° C) "HDPE" (high density polyethylene, MFR (measured in accordance with ASTM D1238 at a temperature of 190 ° C and a load of 2.16 kg): 5 g / 10 min, density: 0.95 g / cm ３ , melting point: 134 ° C.)

[0156] [2.1.2] Core-sheath fiber raw materials "h-pp (MFR60)" propylene homopolymer, MFR (measured in accordance with ASTM D1238 at a temperature of 230 ° C. and a load of 2.16 kg) 60 g / 10 min, density: 0.91 g / cm 3, melting point: 160 ° C. h-pp (MFR 8.5): propylene homopolymer, MFR (measured in accordance with ASTM D1238 at a temperature of 230 ° C. and a load of 2.16 kg): 8.5 g / 10 min, density: 0.91 g / cm 3 , melting point: 160 ° C.

[0157] [2.2] Middle layer (elastic nonwoven fabric) [2.2.1] Fiber raw material "α-olefin copolymer" (manufactured by ExxonMobil, product name "Vistamaxx" ＴＭ 7050FL", composition: propylene / ethylene copolymer, MFR (230°C, load 2.16 kg): 48 g / 10 min, ethylene content: 13 mass%, tensile modulus: 9.82 MPa, storage modulus E23: 17.4 MPa, storage modulus E40: 8.77 MPa, ratio (E40 / E23): 50.4%, melting point: 44.4°C)

[0158] The spunbond nonwoven fabrics constituting the intermediate layer (second layer) in Examples 1 to 8 and Comparative Examples 1 to 4 were made of fibers of a resin composition for elastic nonwoven fabrics having a storage modulus of 22.0 MPa or less, as described in the method of "[3] Nonwoven fabric laminate" below. In other words, the spunbond nonwoven fabrics constituting the intermediate layer in Examples 1 to 8 and Comparative Examples 1 to 4 were elastic nonwoven fabrics.

[0159] [3] Nonwoven fabric laminate [3.1] Example 1 A mixture of 94 parts by mass of "h-pp" and 6 parts by mass of "HDPE" was melted using a 75 mmφ extruder, and melt-spun by the spunbonding method using a spunbond nonwoven fabric molding machine having a spinneret with 1,093 holes (length in the direction perpendicular to the machine direction on the collecting surface: 320 mm) under conditions of resin temperature and die temperature both 205°C, resin output rate of 38.7 kg / hour, cooling air temperature of 20°C, and drawing air velocity of 2,762 m / min, and an extensible spunbond nonwoven fabric composed of islands-in-sea fibers was deposited on the collecting surface as a first layer. Next, on the deposition surface, an "α-olefin copolymer" was melted 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: 320 mm) with a spinneret (die, number of holes: 1093) under conditions of a resin temperature and die temperature of 225°C, a cooling air temperature of 20°C, and a stretching air velocity of 4667 m / min, thereby depositing an elastic nonwoven fabric (elastic spunbond nonwoven fabric) as the second layer. Next, as the third layer, the same islands-in-the-sea 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: 60°C) to produce a nonwoven fabric laminate. The mass fraction of the elastic nonwoven fabric layer relative to the total mass was 33.3%. Table 1 shows the total basis weight, basis weight ratio (middle layer / total) and formation coefficient of the nonwoven fabric laminate, the basis weight and average fiber diameter of the extensible spunbonded nonwoven fabric layers which are the outer layers (i.e., the first and third layers), and the basis weight and average fiber diameter of the elastic nonwoven fabric layer which is the middle layer (i.e., the second layer).

[0160] [3.2] Examples 2 to 7 and Comparative Examples 2 to 4 Nonwoven fabric laminates were obtained in the same manner as in Example 1, except that the total basis weight, basis weight ratio (middle layer / total), and formation coefficient of the nonwoven fabric laminate, the basis weight and average fiber diameter of the extensible spunbond nonwoven fabric layer, the air velocity of the extensible spunbond and elastic nonwoven fabric, and the basis weight and average fiber diameter of the elastic nonwoven fabric layer were changed as shown in Tables 1 and 2.

[0161] [3.3] Example 8 "h-pp (MFR 8.5)" was melted using a 50 mmφ extruder, and separately, "h-pp (MFR 60)" was melted using a 75 mmφ extruder. Then, 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 fibers in which "h-pp (MFR 8.5)" was the core and "h-pp (MFR 60)" was the sheath, conjugate melt spinning was carried out by the spunbonding method under conditions of resin temperature and die temperature both 250°C, cooling air temperature 20°C, and drawing air velocity 3750 m / min, and an extensible spunbond nonwoven fabric consisting of concentric core-sheath fibers with a core / sheath mass ratio of 10 / 90 was deposited on the collecting surface as a first layer. Next, an elastic nonwoven fabric (elastic spunbonded nonwoven fabric) was deposited on the deposition surface as a second layer in the same manner as in Example 1, except that the basis weight and average fiber diameter of the elastic nonwoven fabric layer were changed as shown in Table 2. Next, as a third layer, the same core-sheath fibers as in the first layer were deposited in the same manner to form a three-layer deposit. This deposit was heated and pressurized with an embossing roll (embossed area ratio 18%, embossing temperature 60°C) to produce a nonwoven fabric laminate (mass fraction of the elastic nonwoven fabric layer to the total mass was 33.3%). Table 2 shows the total basis weight, basis weight ratio (middle layer / total), and formation coefficient of the nonwoven fabric laminate, as well as the basis weight and average fiber diameter of the outer layer (i.e., the first and third layers) of the extensible spunbonded nonwoven fabric, and the basis weight and average fiber diameter of the middle layer (i.e., the second layer) of the elastic nonwoven fabric.

[0162] [3.4] Comparative Example 1 A nonwoven fabric laminate was obtained in the same manner as in Example 7, except that the total basis weight, basis weight ratio (middle layer / total), and formation coefficient of the nonwoven fabric laminate, the basis weight and average fiber diameter of the extensible spunbond nonwoven fabric layer, and the basis weight and average fiber diameter of the elastic nonwoven fabric layer were changed as shown in Table 2.

[0163] [3.5] Reference Examples 1 to 3 Nonwoven fabric laminates were obtained in the same manner as in Example 1, except that the total basis weight, basis weight ratio (middle layer / total), and formation coefficient of the nonwoven fabric laminate, the basis weight and average fiber diameter of the extensible spunbond nonwoven fabric layer, and the basis weight and average fiber diameter of the elastic nonwoven fabric layer were each changed as shown in Table 3, and a film layer was further bonded to the outer layer (extensible spunbond nonwoven fabric) as shown in Table 3. The film layer was formed by extrusion laminating a resin having the composition shown in Table 3 to a thickness of 30 μm on the surface of the nonwoven fabric laminate at 290°C to bond the film layer to the extensible spunbond nonwoven fabric. In Reference Example 2, the same nonwoven fabric laminate was used as the sandwich-side substrate, and a resin having the composition shown in Table 3 was extrusion sandwich-laminated between them at 290°C to a thickness of 30 μm to bond extensible spunbond nonwoven fabric layers to both sides of the film layer. Delamination evaluation between the nonwoven fabric laminate and the film layer was performed, and the results are shown in Table 3.

[0164] [4] Evaluation Methods The nonwoven fabric laminates were evaluated for blocking, the number of thread breakages, and delamination as follows. The evaluation results are shown in Tables 1 to 3.

[0165] [4.1] Blocking Evaluation A jumbo roll with a winding length of 4000 m produced by the above-mentioned manufacturing method was unwound from the bottom. The speed was gradually increased to 200 m / min, and then a blocking evaluation was carried out for 5 minutes. If there was no excessive adhesion between the layers of the jumbo roll and no breakage of the nonwoven fabric during the blocking evaluation, the blocking evaluation was rated as "A". On the other hand, if there was excessive adhesion between the layers of the jumbo roll and the nonwoven fabric broke, the blocking evaluation was rated as "B". The evaluation was carried out visually according to the above criteria. An acceptable blocking evaluation was "A".

[0166] [4.2] Evaluation of the Number of Yarn Breakage The number of yarn breakages that occurred in 30 minutes during the spinning of the extensible spunbond nonwoven fabric (hereinafter referred to as "number of yarn breakages") was measured. The acceptable number of yarn breakages was 2 or less per 30 minutes.

[0167] [4.3] Evaluation of Delamination A nonwoven fabric laminate laminated with a film layer is cut into a size of 25 mm wide x 100 mm long to prepare a sample. Cloth adhesive gummed tape cut into a size of 25 mm wide x 150 mm long is attached to both sides of the cut sample, at the center of the sample, with both ends of the tape protruding in the length direction. A manual pressure roller conforming to JIS Z 0237:2009 is rolled back and forth twice on the tape-attached sample to uniformly attach the tape to the sample. Holding the portion of the attached tape that protrudes from the sample, the tapes are slowly peeled apart, and the interlayer separation of the sample is observed. Five samples were prepared, and five tests were performed. Delamination evaluation was performed for the five tests according to the following criteria.

[0168] A: No peeling between the SB layer and the film layer occurred in all five attempts, but peeling occurred between the SB layer and the film layer. B: Peeling occurred between the SB layer and the film layer at least once.

[0169]

[0170]

[0171]

[0172] In Tables 1 to 3, "outer layer (SB)" refers to an extensible spunbond nonwoven fabric. "middle layer (NW)" refers to an elastic nonwoven fabric. "C3 / C2" in the carbon chain column indicates that the α-olefin copolymer is a propylene / ethylene copolymer. "Basis weight ratio (middle layer / total)" refers to the ratio of the basis weight of the elastic nonwoven fabric to the total basis weight of the nonwoven fabric laminate. "h-PP" refers to homopolypropylene obtained by polymerizing propylene alone.

[0173] In Comparative Examples 1 to 4, the surface coefficient of the nonwoven fabric laminate was less than 38. Therefore, the blocking evaluation for Comparative Examples 1 to 4 was "B." This result shows that the nonwoven fabric laminates of Comparative Examples 1 to 4 cannot suppress the occurrence of blocking when unwound from the nonwoven fabric roll at high speed.

[0174] The nonwoven fabric laminates of Examples 1 to 8 each comprised an elastic nonwoven fabric and an extensible spunbond nonwoven fabric disposed on both sides of the elastic nonwoven fabric. The surface coefficient was 38 or greater. Therefore, the blocking evaluation for Examples 1 to 8 was rated "A." These results demonstrate that the nonwoven fabric laminates of Examples 1 to 8 can suppress the occurrence of blocking even when unwound from a nonwoven fabric roll at high speed.

[0175] The nonwoven fabric laminates of Examples 1 to 7 included an elastic nonwoven fabric and extensible spunbonded nonwoven fabrics arranged on both sides of the elastic nonwoven fabric. The extensible fibers were islands-in-the-sea fibers. The islands-in-the-sea fibers were made of a resin composition for extensible spunbonded nonwoven fabrics. The resin composition for extensible spunbonded nonwoven fabrics included a specific propylene-based polymer (A) and a polymer (B) that was a polyolefin (excluding the propylene-based polymer (A)). The average fiber diameter a of the extensible fibers was smaller than the average fiber diameter b of the elastic fibers. Therefore, the blocking evaluation for Examples 1 to 7 was "A." These results demonstrate that the nonwoven fabric laminates of Examples 1 to 7 were able to suppress blocking even when unwound from a nonwoven fabric roll at high speed.

[0176] Among the Examples, Examples 1 to 6 were found to have fewer thread breakages. The first nonwoven fabric laminate includes Examples 1 to 6. The first nonwoven fabric laminate comprises an elastic nonwoven fabric and an extensible spunbond nonwoven fabric arranged on both sides of the elastic nonwoven fabric, and has a surface coefficient represented by the above formula (1) of 38 or more, the fibers contained in the extensible spunbond nonwoven fabric comprise a resin composition for extensible spunbond nonwoven fabrics, and the resin composition for extensible spunbond nonwoven fabrics comprises a propylene-based polymer (A) and a polymer (B) that is at least one selected from the group consisting of polyolefins (excluding the propylene-based polymer (A)) and polyesters.

[0177] Among the Examples, Examples 1 to 4 were found to have even fewer thread breakages. The second nonwoven fabric laminate encompasses Examples 1 to 4 of the Examples. The second nonwoven fabric laminate has the following features in addition to the invention-specifying features of the first nonwoven fabric laminate: "the basis weight of the extensible spunbond nonwoven fabric is 13 g / m2" ２ The invention has the specific item of "up to 24.9 g / m."

[0178] The disclosure of Japanese Patent Application No. 2022-200356, filed on December 15, 2022, is incorporated herein by reference in its entirety. All documents, patent applications, and technical standards described herein are incorporated herein by reference to the same extent as if each individual document, patent application, and technical standard was specifically and individually indicated to be incorporated by reference.

Claims

1. A nonwoven fabric laminate comprising an elastic nonwoven fabric and an extensible spunbonded nonwoven fabric disposed on both sides of the elastic nonwoven fabric, the nonwoven fabric having a surface coefficient of 38 or greater, as expressed by the following formula (1): Surface coefficient = [(average fiber diameter of fibers contained in the elastic nonwoven fabric / average fiber diameter of fibers contained in the extensible spunbonded nonwoven fabric) / formation coefficient] x 10 ４ 2. The nonwoven fabric laminate according to claim 1, wherein the fibers contained in the elastic nonwoven fabric are made from a resin composition for elastic nonwoven fabrics, and the resin composition for elastic nonwoven fabrics contains 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.

3. The nonwoven fabric laminate according to claim 2, wherein the proportion of said α-olefin copolymer relative to the total amount of said elastic nonwoven fabric is 90% to 100% by mass, said α-olefin copolymer is a copolymer of ethylene and propylene, and said α-olefin copolymer has a melting point of 130°C or lower.

4. The nonwoven fabric laminate according to claim 1, wherein the fibers contained in the extensible spunbond nonwoven fabric are made from a resin composition for extensible spunbond nonwoven fabrics, and the resin composition for extensible spunbond nonwoven fabrics comprises a propylene-based polymer (A) and a polymer (B) which is at least one selected from the group consisting of polyolefins (excluding the propylene-based polymer (A)) and polyesters.

5. The propylene polymer (A) contains a propylene homopolymer, and the polymer (B) has a density of 0.94 g / cm ３ ~0.97 g / cm ３ 5. The nonwoven laminate of claim 4, comprising a polyethylene having a formula:

6. The nonwoven fabric laminate according to claim 1, wherein the ratio of the basis weight of the elastic nonwoven fabric to the basis weight of the nonwoven fabric laminate is 15% to 48%.

7. A nonwoven fabric laminate comprising: an elastic nonwoven fabric; and an extensible spunbond nonwoven fabric arranged on both sides of the elastic nonwoven fabric, wherein fibers contained in the extensible spunbond nonwoven fabric are islands-in-the-sea fibers, and the islands-in-the-sea fibers are made from a resin composition for extensible spunbond nonwoven fabrics, and the resin composition for extensible spunbond nonwoven fabrics comprises: a propylene-based polymer (A) including a propylene homopolymer; and a polymer (B) which is at least one selected from the group consisting of polyolefins (excluding the propylene-based polymer (A)) and polyesters, and wherein the average fiber diameter a of the fibers contained in the extensible spunbond nonwoven fabric is smaller than the average fiber diameter b of the fibers contained in the elastic nonwoven fabric.

8. The nonwoven fabric laminate according to claim 7, wherein the ratio (b / a) of the average fiber diameter b to the average fiber diameter a is 1.0 or greater and 1.35 or less.

9. The nonwoven fabric laminate of claim 1 or claim 7, further comprising a film layer.

10. A stretchable nonwoven fabric laminate, which is a stretched product of the nonwoven fabric laminate according to claim 1 or claim 7.

11. A textile product comprising the nonwoven fabric laminate of claim 1 or claim 7.

12. The textile product of claim 11, further comprising engageable engagement means.

13. An absorbent article comprising the nonwoven fabric laminate of claim 1 or claim 7.

14. A mask comprising the nonwoven fabric laminate of claim 1 or claim 7.

15. A patch comprising the nonwoven fabric laminate of claim 1 or claim 7.