Nonwoven fabric laminate, footwear manufacturing sheet using same, footwear component sheet, and footwear

Abstract

Provided is a nonwoven fabric laminate in which a first nonwoven fabric layer, a second nonwoven fabric layer, and a third nonwoven fabric layer are laminated in the stated order, wherein the thickness of the nonwoven fabric laminate is 1-12 mm, the stiffness measured according to JIS P 8125-2000 is 70 gf / cm or greater, and the WC value of the nonwoven fabric laminate measured using a KES compression tester is 0.5-5.0.

Description

Nonwoven fabric laminate, footwear manufacturing sheet using the same, footwear component sheet, and footwear

[0001] The present invention relates to a nonwoven fabric laminate, a sheet for manufacturing footwear, a footwear component sheet, and footwear using the same. This application claims priority to Japanese Patent Application No. 2023-016461, filed on February 6, 2023, the contents of which are incorporated herein by reference.

[0002] Disposable indoor shoes are often used as footwear in hotels and other temporary accommodation facilities. While disposable indoor shoes are hygienic, they are discarded after a short period of use, which poses a problem in that they are costly to dispose of and place a heavy burden on the environment.

[0003] In order to solve environmental problems, there is a demand for disposable footwear made from highly sustainable biomass materials. Patent Document 1 proposes slippers with an insole made of polyester nonwoven fabric with a cotton outer and cotton lining attached to the front and back, and these are integrated by quilting with cotton thread.

[0004] However, the slippers described in Patent Document 1 use a large amount of polyester, and it cannot be said that sufficient consideration has been given to the environmental impact when the slippers are discarded.

[0005] As a result of extensive research into disposable nonwoven fabrics for footwear that have a low environmental impact even when discarded as raw materials for paper packaging materials, the inventors have succeeded in developing a nonwoven fabric laminate having at least three layers whose thickness, stiffness, and WC value satisfy specific ranges, which is suitable for recycling, has excellent processability, and provides excellent comfort when processed into footwear for hotels.

[0006] Registered Utility Model No. 3061071

[0007] An object of the present invention is to provide a nonwoven fabric laminate that has a low environmental impact, is highly suitable for processing into footwear, and provides excellent comfort when processed into footwear.

[0008] The present invention has the following aspects: [1] A nonwoven fabric laminate having a first nonwoven fabric layer, a second nonwoven fabric layer, and a third nonwoven fabric layer laminated in this order, the thickness of the nonwoven fabric laminate being 1 mm or more and 12 mm or less, the stiffness measured in accordance with JIS P8125-2000 being 70 gf / cm or more, and the WC value of the nonwoven fabric laminate being 0.5 gf cm / cm as measured using a KES compression tester. ２ More than 5.0gf・cm / cm ２ [2] The nonwoven fabric laminate according to [1], wherein the second nonwoven fabric layer contains 50% by mass or more of any one type of fiber or two or more types of fibers selected from the group consisting of pulp fibers, cotton fibers, and rayon fibers. [3] The nonwoven fabric laminate according to [1] or [2], wherein the first nonwoven fabric layer is at least one type of nonwoven fabric selected from the group consisting of spunbonded nonwoven fabrics, spunlace nonwoven fabrics, and airlaid nonwoven fabrics containing more than 50% by mass of a thermoplastic resin relative to the airlaid nonwoven fabric, and the third nonwoven fabric layer is at least one type of nonwoven fabric selected from the group consisting of spunbonded nonwoven fabrics, spunlace nonwoven fabrics, and airlaid nonwoven fabrics containing more than 50% by mass of a thermoplastic resin relative to the airlaid nonwoven fabric. [4] The nonwoven fabric laminate according to [1] or [2], wherein the bulk density of the first nonwoven fabric layer is 0.10 g / cm ３ the bulk density of the second nonwoven fabric layer is less than 0.10 g / cm ３ 0.30g / cm or more ３ the bulk density of the third nonwoven fabric layer is 0.10 g / cm or less; ３[5] The nonwoven fabric laminate according to any one of [1] to [3], wherein the sum of the layer thicknesses of the first nonwoven fabric layer and the second nonwoven fabric layer is 0.2% to 45% of the thickness of the nonwoven fabric laminate. [6] A footwear manufacturing sheet comprising the nonwoven fabric laminate according to any one of [1] to [5]. [7] A footwear component sheet obtained by cutting or punching the footwear manufacturing sheet according to [6] into the shape of a footwear sole, wherein the density of the peripheral portion of the component sheet is 1.2 times or more the density of the central portion of the component sheet. [8] A footwear component sheet obtained by cutting or punching the footwear manufacturing sheet according to [6], wherein the component sheet has cut portions in at least one part and insert portions in at least another part, and wherein the insert portions can be inserted into the cut portions to form footwear. [9] Footwear using the nonwoven fabric laminate according to any one of [1] to [5].

[10] Footwear using the footwear component sheet according to [7] or [8].

[11] A method for manufacturing the nonwoven fabric laminate according to any one of [1] to [5].

[12] A method for manufacturing the footwear manufacturing sheet according to [6].

[13] A method for manufacturing the component sheet according to [7] or [8].

[14] A method for manufacturing footwear according to [9] or

[10] .

[15] Use of the nonwoven fabric laminate according to any one of [1] to [5] for manufacturing footwear component sheets.

[16] Use of the nonwoven fabric laminate according to any one of [1] to [5] for manufacturing footwear.

[0009] The nonwoven fabric laminate of the present invention has a low environmental impact, is excellent in suitability for processing into footwear, and provides excellent comfort when processed into footwear.

[0010] 1 is an example of an apparatus for producing the nonwoven fabric laminate of the present invention. 2 is an example of a component sheet constituting the sole of footwear using the nonwoven fabric laminate of the present invention. 3 is an example of a component sheet constituting the sole and belt portion of footwear using the nonwoven fabric laminate of the present invention. 4 is an example of footwear constructed using the component sheet of the present invention.

[0011] The nonwoven fabric laminate of the present invention is a nonwoven fabric comprising at least a first layer, a second layer, and a third layer laminated in this order. It is preferred that the first and third layers are surface layers of the nonwoven fabric, and that both surfaces of the second nonwoven fabric layer are in contact with the first and third layers directly or via an adhesive material. However, additional surface or intermediate layers may be included as long as the effects of the present invention are not impaired.

[0012] The thickness of the nonwoven fabric laminate is 1 mm or more, and preferably 2 mm or more. If the thickness of the nonwoven fabric laminate is 1 mm or more, when the nonwoven fabric laminate is used as a footwear sheet, sufficient strength can be obtained to protect the feet of the footwear user. The thickness of the nonwoven fabric laminate is 12 mm or less, and preferably 10 mm or less. If the thickness of the nonwoven fabric laminate is 12 mm or less, the footwear user can feel a sense of stability. Specifically, the thickness of the nonwoven fabric laminate is preferably 1 mm or more and 12 mm or less, and preferably 2 mm or more and 10 mm or less.

[0013] The bulk density of the entire nonwoven fabric laminate is 0.05 g / cm ３ or more, and 0.07 g / cm ３ It is preferable that the density is 0.09 g / cm or more. ３ It is more preferable that the bulk density of the entire nonwoven fabric laminate is 0.05 g / cm or more. ３ If the bulk density of the nonwoven fabric laminate is 0.5 g / cm or more, when the nonwoven fabric laminate is used as a sheet for footwear, the sheet has appropriate softness and breathability, and is strong enough to protect the feet of the footwear wearer. ３ or less, and 0.4 g / cm ３ It is preferable that the bulk density of the entire nonwoven fabric laminate is 0.5 g / cm or less. ３ If the bulk density of the nonwoven fabric laminate is 0.05 g / cm or less, it is not too hard for footwear and can be subjected to processing such as sewing and folding. ３ 0.5g / cm or more ３ It is preferable that the density is 0.05 g / cm or less. ３ 0.4g / cm or more ３ More preferably, it is 0.09 g / cm or less.３ 0.4g / cm or more ３ In the present invention, the bulk density is obtained by dividing the basis weight of the nonwoven fabric laminate or nonwoven fabric layer by the thickness of the nonwoven fabric laminate or nonwoven fabric layer measured by microscopic observation of the cross section of the nonwoven fabric laminate.

[0014] In the second nonwoven fabric layer, natural fibers preferably account for 50% by mass or more of the entire second nonwoven fabric layer, more preferably 70% by mass or more, and even more preferably 80% by mass or more. There is no particular upper limit to the proportion of natural fibers in the second nonwoven fabric layer, but since a material that bonds the natural fibers together is blended, it is preferably 99% by mass or less. Specific examples of the second nonwoven fabric layer include airlaid nonwoven fabrics and wet-laid nonwoven fabrics. In the second nonwoven fabric layer, natural fibers preferably account for 50% by mass or more and 99% by mass or less of the entire second nonwoven fabric layer, more preferably 70% by mass or more and 99% by mass or less, and even more preferably 80% by mass or more and 99% by mass or less.

[0015] Examples of natural fibers contained in the second nonwoven fabric layer include pulp fibers, rayon, cotton, etc. Among these natural fibers, pulp fibers are preferred because they can easily produce a nonwoven fabric having water absorbency and strength suitable for footwear.

[0016] The second nonwoven fabric layer preferably contains a thermally adhesive resin in an amount of 5% by mass or more relative to the mass of the second nonwoven fabric layer. The thermally adhesive resin may be in any form, such as fibrous or particulate. In addition to commonly known polyethylene fibers, polypropylene fibers, polyester fibers, etc., biodegradable polylactic acid fibers may also be used. In the case of fibers, fibers made of a single resin or fibers made of multiple resins with a core-sheath structure may be used. In the second nonwoven fabric layer, the content of the thermally adhesive resin is preferably 5% by mass or more and 70% by mass or less, more preferably 8% by mass or more and 50% by mass or less, and most preferably 10% by mass or more and 30% by mass or less relative to the mass of the second nonwoven fabric layer.

[0017] The fineness of the fiber made of the heat-fusible resin is preferably 1 dtex to 30 dtex, more preferably 2 dtex to 10 dtex. The fiber length is preferably 1 mm to 15 mm, more preferably 2 mm to 12 mm. The sheath melting point is preferably 80°C to 200°C, more preferably 100°C to 180°C.

[0018] When the second nonwoven fabric layer contains natural fibers and fibers made of a thermally adhesive resin, the mass ratio expressed as (natural fibers) / (fibers made of a thermally adhesive resin) is preferably 3 / 7 or more and 9.5 / 0.5 or less, and more preferably 5 / 5 or more and 9 / 1 or less.

[0019] In the nonwoven fabric laminate, the content of natural fibers is preferably 30% by mass or more and 98% by mass or less, and more preferably 50% by mass or more and 98% by mass or less, based on the mass of the nonwoven fabric laminate.

[0020] The materials constituting the first and third nonwoven fabric layers are preferably nonwoven fabrics formed from at least one type of fiber selected from the group consisting of rayon fibers, cotton fibers, polyethylene fibers, and polyester fibers. Specific examples of the first and third nonwoven fabric layers include spunlace nonwoven fabrics, airlaid nonwoven fabrics, thermally bonded nonwoven fabrics, and meltblown nonwoven fabrics. These nonwoven fabrics may be mesh-like or patterned. Crepe paper, Japanese paper, paperboard, etc. may also be used as needed. Films may also be used to impart functions such as anti-slip and water resistance. While the first nonwoven fabric layer of the nonwoven fabric laminate is intended to be the side that comes into contact with the skin of the footwear wearer, this does not necessarily mean that the first and third nonwoven fabric layers have the same structure. The materials constituting the first and third nonwoven fabric layers may be the same or different.

[0021] The sum of the thicknesses of the first and third nonwoven fabric layers is preferably 0.2% to 40% of the total thickness of the nonwoven fabric sheet, and more preferably 0.3% to 30%. By maintaining the ratio of the sum of the thicknesses of the first and third nonwoven fabric layers to the total thickness of the nonwoven fabric sheet within the above range, when the nonwoven fabric is used as a footwear sheet, it quickly absorbs moisture from the soles of the footwear wearer's feet and provides a comfortable fit. To maintain the sum of the thicknesses of the first and third nonwoven fabric layers within the above range, the thickness of the first carrier sheet constituting the first nonwoven fabric layer is preferably 0.05 to 2.0 mm, and more preferably 0.1 to 1.5 mm. Furthermore, the thickness of the second carrier sheet constituting the third nonwoven fabric layer is preferably 0.05 to 2.0 mm, and more preferably 0.1 to 1.5 mm.

[0022] The nonwoven fabric laminate has a WC value of 0.5 gf cm / cm on the first nonwoven fabric layer side measured by a KES compression tester. ２ More than 5.0gf・cm / cm ２ The WC value is an index representing the amount of compression work. The WC value is a compression energy value, and the larger the WC value, the softer and more easily compressed it is in the thickness direction. The WC value can be obtained by measuring the nonwoven fabric laminate using a KES compression tester, for example, a product named KES-G5 manufactured by Kato Tech Co., Ltd.

[0023] By setting the WC value within the above range, when the nonwoven fabric laminate is used as a sheet for footwear, it is possible to achieve both a good hold and softness in the footwear. ２ More than 4.5gf・cm / cm ２ Preferably, it is 1.0 gf cm / cm or less. ２ More than 3.5gf・cm / cm ２ In order to set the WC value in the above range, the density of the first nonwoven fabric layer and the density of the third nonwoven fabric layer are each independently set to 0.10 g / cm or less. ３ It is preferable that the density is less than 0.08 g / cm ３Specifically, it is more preferable that the density of the first nonwoven fabric layer and the density of the third nonwoven fabric layer are each independently set to 0 g / cm or less. ３ Super 0.10g / cm ３ It is preferable that the density is less than 0 g / cm ３ Super 0.08g / cm ３ It is more preferable that the density of the first nonwoven fabric layer and the density of the third nonwoven fabric layer are the same or different. In order to set the WC value within the above range, the sum of the layer thicknesses of the first nonwoven fabric layer and the second nonwoven fabric layer is preferably 0.2% to 10% of the total thickness of the nonwoven fabric laminate, more preferably 0.3% to 1%. In order to set the sum of the thicknesses of the first nonwoven fabric layer and the second nonwoven fabric layer within the above range, it is preferable that the thickness of the first carrier sheet constituting the first nonwoven fabric layer is 0.5 to 2.0 mm. Furthermore, the basis weight of the web material constituting the second nonwoven fabric layer is 50 to 1000 g / m ２ It is preferable that the density is 100 to 800 g / m ２ More preferably, it is 200 to 700 g / m ２ It is most preferable that the second nonwoven fabric layer is made of a plant-derived material, and it is more preferable that pulp be used as the web material for the second nonwoven fabric layer. When forming the second nonwoven fabric layer, the heating temperature during heat compression is preferably 80°C or higher and 200°C or lower, and more preferably 100°C or higher and 180°C or lower.

[0024] The nonwoven fabric has a stiffness of 70 gf / cm or more as measured by JIS P8125-2000 (Testing method for stiffness of paper and paperboard). By setting the stiffness within the above range, when the nonwoven fabric is used as a footwear sheet, the strength of the footwear is maintained. In particular, it is possible to prevent the sole portion from being too soft and rubbing against the ground when walking. Furthermore, by setting the stiffness within the above range, it is possible to obtain the effect of suppressing wrinkles. The stiffness is preferably 70 gf / cm or more, and more preferably 100 gf / cm or more. In order to adjust the stiffness within the above range, the density of the second nonwoven fabric layer is set to 0.10 g / cm or more. ３ 0.30g / cm or more ３ It is preferable that the density is 0.12 g / cm or less.３ 0.25g / cm or more ３ In order to adjust the density of the second nonwoven fabric layer to the above range, it is more preferable that the basis weight of the web material constituting the second nonwoven fabric layer is 50 to 1000 g / m ２ It is preferable that the density is 100 to 800 g / m ２ It is preferable to use plant-derived fibers, and more preferably wood pulp, as the web material for the second nonwoven fabric layer. When forming the second nonwoven fabric layer, the heating temperature during heat compression is preferably 80°C or higher and 200°C or lower, and more preferably 100°C or higher and 180°C or lower.

[0025] The nonwoven fabric preferably has a water absorption rate of 10 seconds or less as measured according to JIS L1913-2010. The water absorption rate can be adjusted by adjusting the mass ratio of the absorbent material, the mass ratio per unit area of ​​each layer, the density of each layer, and the thickness of each layer. Furthermore, by containing 50% by mass or more of any one or more types of fibers selected from pulp fiber, cotton fiber, and rayon fiber in the second nonwoven fabric layer, the water absorption rate can be easily adjusted to 10 seconds or less. The water absorption rate is preferably 0 seconds or more and 10 seconds or less, and more preferably 0 seconds or more and 5 seconds or less. To adjust the water absorption rate within the above range, the blending amount of absorbent fibers (e.g., plant-derived fibers such as pulp fiber, cotton fiber, and rayon fiber) in the second nonwoven fabric layer is preferably 30% to 95%, and more preferably 50% to 90%.

[0026] When spunbond nonwoven fabric layers are used as the first and third nonwoven fabric layers, the ratio of the sum of the thicknesses of the first and third nonwoven fabric layers is preferably 4% to 10% of the overall thickness of the nonwoven fabric laminate. Here, the thicknesses of the first and third nonwoven fabric layers may be the same or different. To adjust the ratio of the sum of the thicknesses of the first and third nonwoven fabric layers within the above range, the thickness of the first carrier sheet made of spunbond nonwoven fabric constituting the first nonwoven fabric layer is preferably 0.05 to 1.0 mm, more preferably 0.1 to 0.5 mm. Furthermore, the thickness of the second carrier sheet made of spunbond nonwoven fabric constituting the third nonwoven fabric layer is preferably 0.05 to 1.0 mm, more preferably 0.1 to 0.5 mm. Here, the thicknesses of the first and second carrier sheets may be the same or different.

[0027] When spunlace nonwoven fabric layers are used as the first and third nonwoven fabric layers, the ratio of the sum of the thicknesses of the first and third nonwoven fabric layers is preferably 18% to 33% of the overall thickness of the nonwoven fabric laminate. Here, the thicknesses of the first and third nonwoven fabric layers may be the same or different. To adjust the ratio of the sum of the thicknesses of the first and third nonwoven fabric layers within the above range, the thickness of the first carrier sheet made of the spunlace nonwoven fabric constituting the first nonwoven fabric layer is preferably 0.1 to 2.0 mm, more preferably 0.3 to 1.0 mm. Furthermore, the thickness of the second carrier sheet made of the spunlace nonwoven fabric constituting the third nonwoven fabric layer is preferably 0.1 to 2.0 mm, more preferably 0.3 to 1.0 mm. Here, the thicknesses of the first and second carrier sheets may be the same or different.

[0028] When airlaid nonwoven fabric layers are used as the first and third nonwoven fabric layers, the ratio of the total thickness of the first and third nonwoven fabric layers to the total thickness of the nonwoven fabric laminate is preferably 35% to 45%. Furthermore, the thicknesses of the first and third nonwoven fabric layers are preferably 0.1 to 2.0 mm, more preferably 0.3 to 1.0 mm. Here, the thicknesses of the first and second nonwoven fabric layers may be the same or different. To adjust the ratio of the total thickness of the first and third nonwoven fabric layers to the above range, the thickness of the first carrier sheet made of the airlaid nonwoven fabric constituting the first nonwoven fabric layer is preferably 0.4 to 2.0 mm, more preferably 0.5 to 1.0 mm. The thickness of the second carrier sheet made of air-laid nonwoven fabric constituting the third nonwoven fabric layer is preferably 0.4 to 2.0 mm, more preferably 0.5 to 1.0 mm, where the thickness of the first carrier sheet and the thickness of the second carrier sheet may be the same or different.

[0029] Methods for laminating the first, second, and third nonwoven fabric layers include coating or spraying commonly known adhesive or binder components to bond the layers together, spraying adhesive particles or fibers or liquids containing the adhesive components at the interface between the layers, or blending a heat-sealable resin into the layers to be bonded or coating or spraying the layers at the interface, and then laminating the layers and heat-sealing them by blowing hot air or using a heated drum. Among these, a preferred method involves spraying an adhesive component onto a first carrier sheet (the first nonwoven fabric layer) to form a first adhesive layer, placing a web material (the second nonwoven fabric layer) on the first adhesive layer, spraying an adhesive component onto the web material to form a second adhesive layer, and then laminating a second carrier sheet (the third nonwoven fabric layer) on the second adhesive layer, followed by heat-sealing. Thermoplastic resin particles are preferred as the adhesive component, and polyethylene powder and polylactic acid powder are more preferred. The melting point of the thermoplastic resin is preferably 80° C. or higher and 200° C. or lower, and more preferably 100° C. or higher and 180° C. or lower. When the adhesive component is in powder form, the average particle size measured by image analysis using an electron microscope is preferably 10 μm or higher and 5 mm or lower, and more preferably 20 μm or higher and 2 mm or lower. By using the above particle size, it is possible to provide footwear that is comfortable to the touch and is less likely to experience delamination between layers.

[0030] The present invention includes a footwear manufacturing sheet made of the nonwoven fabric laminate. The present invention also relates to a footwear component sheet obtained by cutting or punching the footwear manufacturing sheet into the shape of a footwear sole. For example, as shown in FIG. 2, a component sheet corresponding to the sole of a footwear can be created and combined with other components to assemble footwear. The size of the footwear sole is not particularly limited, but the length is preferably 15 cm to 40 cm, and more preferably 20 cm to 30 cm. The width is preferably 5 cm to 10 cm, and more preferably 7 cm to 9 cm. For children's footwear, the preferred ranges are not limited to the above. The density of the peripheral portion of the component sheet is preferably 1.2 times or more, and more preferably 1.5 times or more, the density of the central portion of the component sheet. Here, the central portion of the component sheet refers to the region 1 mm to 15 mm from the edge of the component sheet. The central portion of the component sheet refers to the region excluding the peripheral portion. Increasing the density of the peripheral portion of the component sheet as described above improves the strength of the peripheral portion, preventing paper dust from falling off or decomposing from the footwear sheet. The density of the peripheral portion of the component sheet is preferably 1.2 to 10 times, and more preferably 1.5 to 8 times, the density of the center portion of the component sheet. By setting the density within the above range, it is possible to achieve both resistance to fraying at the peripheral portion and cushioning properties.

[0031] The density of the peripheral portion of the part sheet can be adjusted, for example, by pressing. For example, the peripheral portion of the cut portion can be compressed with a press before, after, or simultaneously with punching the part sheet into the shape of footwear. Heating can also be performed simultaneously with pressing. While the pressure applied during pressing is not particularly specified, it is preferable to change the pressure appropriately to achieve the desired thickness. When heating, the heating temperature is preferably 100°C or higher and 200°C or lower, and more preferably 130°C or higher and 180°C or lower. Compressing within this temperature range melts the resin contained therein, bonding (welding) the fibers together, thereby making it easier to increase the density of the peripheral portion. A method for increasing the density of the peripheral portion other than pressing can be, for example, by heating only the peripheral portion of the cut portion at the above-mentioned heating temperature and welding it, without compressing the peripheral portion of the cut portion with a press. In addition, during the production of the nonwoven fabric laminate, the web raw material and adhesive component may be deposited more around the cut portion than in the center, and then the nonwoven fabric laminate may be heated and welded at the above-mentioned heating temperature without being crushed with a press. Another effective method for increasing the density of the peripheral portion is to partially perforate the fibers with a needle, needle punch, or sewing machine blade, thereby entangling the fibers. The pressurized peripheral portion of the component sheet is preferably 1 mm to 15 mm from the edge of the component sheet.

[0032] The present invention includes a footwear parts sheet in which the footwear manufacturing sheet is cut or punched to create a footwear parts sheet, a cutout portion formed in one portion of the parts sheet, and an insert portion formed in another portion of the parts sheet for inserting into the cutout portion to construct the footwear. In this aspect, footwear can be constructed by inserting the insert portion into the cutout portion of the parts sheet. For example, as shown in FIG. 3 , a parts sheet can be created in which the sole and belt portion of the footwear, which contact the instep, are laid out on a single plane, and the belt can be formed by inserting the insert portion into the cutout portion, thereby assembling the footwear. The size of the parts sheet is not particularly limited, but the length is preferably 15 cm to 40 cm, and more preferably 20 cm to 30 cm. The width, including the belt portion, is preferably 15 cm to 40 cm, and more preferably 20 cm to 30 cm. The size of the sole of the footwear is not particularly limited, but the length is preferably 15 cm to 40 cm, and more preferably 20 cm to 30 cm. The width is preferably 5 cm to 10 cm, and more preferably 7 cm to 9 cm. The size of the belt portion is not particularly limited, but as shown in Figure 3, the region constituting the belt portion is preferably divided into two, with one having a cut portion and the other having an insertion portion. In the region having the cut portion, the widthwise length is preferably 10 cm to 25 cm, and more preferably 15 cm to 20 cm. The lengthwise length is preferably 5 cm to 10 cm, and more preferably 7 cm to 9 cm. In the region having the insertion portion, the widthwise length is preferably 10 cm to 25 cm, and more preferably 15 cm to 20 cm. The lengthwise length is preferably 5 cm to 10 cm, and more preferably 7 cm to 9 cm. When the footwear is constructed by inserting the insertion portion into the cut portion, the widthwise length of the belt portion is preferably 7 cm to 22 cm, and more preferably 12 cm to 17 cm. In addition to the cutouts and the insertion portions, linear fold guide portions may be provided to guide folds when assembling the footwear.Methods for providing linear fold guides include dashed cuts (perforations), cuts only in the surface layer (half slits), press processing, heat pressing, ultrasonic sealing, and combinations thereof. By providing linear fold guides, the footwear can be shaped to fit the shape of the instep, resulting in comfortable footwear. This embodiment provides a single sheet, allowing for compact storage when not in use, easy assembly, and easy return to the single sheet after use. Assembly can be performed using known techniques, such as double-sided adhesive sheets, buttons, hook-and-loop fasteners, adhesives, sewing, hook shapes, perforations, half-cuts, slits, and inserts, or combinations of these, to join the edges of a single sheet. This also reduces transportation costs and CO2 emissions during delivery and disposal.

[0033] The present invention includes footwear constructed using the nonwoven fabric laminate or the footwear sheet. The footwear sheets can be processed into the desired shape by overlapping their edges and joining them using at least one of sewing, adhesive, and thermal bonding. The footwear may be made by joining multiple footwear sheets together, or by bending a single footwear sheet and joining portions of its edges together.

[0034] The footwear sheet can be processed into the shape of footwear by known methods. For example, it can be punched with a Thomson blade or cut with scissors to form the desired shape. The footwear of the present invention is preferably disposable footwear because it places less burden on the environment when discarded, and is preferably indoor footwear because it has excellent water absorbency.

[0035] The footwear sheet can be perforated with a sewing machine blade, needle, pin, or the like to impart strength. For example, by attaching a sewing machine blade, needle, or pin to a cutting die and perforating the footwear sheet around the cut portion, the fibers are compressed and entangled, improving the strength of the sheet, making it less likely to fray, and imparting rigidity. When the density of the peripheral portion is increased, this has the effect of maintaining that density. It can also impart designability.

[0036] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to the following examples.

[0037] [Example 1] <Production of nonwoven fabric sheet> A web raw material for the second nonwoven fabric layer was obtained by mixing defibrated fluff pulp fibers and defibrated short-cut heat-fusible composite fibers (PP / PE composite core-sheath fibers, fineness 3.3 dtex, fiber length 5 mm, sheath melting point 130°C) in an 80 / 20 ratio.

[0038] Next, an air-laid web-containing sheet was formed from the web raw material using the web forming apparatus 1 shown in FIG.

[0039] Specifically, a first carrier sheet 41 to be the first nonwoven fabric layer was fed by a first carrier sheet supplying means 40 onto a gas-permeable endless belt 20 that was attached to a conveyor 10 and running.

[0040] While the gas-permeable endless belt 20 is being sucked by the suction box 60, polyethylene powder is applied onto the first carrier sheet 41 at a rate of 10 g / m. ２ The web material was then dropped and deposited together with the air flow from the web material supplying means 30. At this time, the basis weight of the web material per air-laid web portion was 500 g / m ２ The web material was supplied so that the polyethylene powder was applied thereon at a rate of 10 g / m ２ After the dispersion was spread so as to form a third nonwoven fabric layer, a second carrier sheet 51 was laminated thereon to obtain an air-laid web-containing sheet. The first and second carrier sheets were made of PET spunbond nonwoven fabric (basis weight 15 g / m ２ ) was used.

[0041] The obtained air-laid web-containing sheet was passed through a box-type dryer with a hot air circulation conveyor oven system, subjected to hot air treatment at 150°C, and heated and compressed to obtain a nonwoven fabric laminate with a thickness of 5 mm.

[0042] [Example 2] The basis weight of the web material is 600 g / m ２An air-laid web-containing sheet obtained in the same manner as in Example 1, except that the web raw material was supplied so as to obtain a sheet having a thickness of 6 mm, was passed through a box-type dryer with a hot air circulation conveyor oven system, subjected to hot air treatment at 150°C, and heated and compressed to obtain a nonwoven fabric laminate with a thickness of 6 mm.

[0043] [Example 3] The basis weight of the web material is 400 g / m ２ An air-laid web-containing sheet obtained in the same manner as in Example 1, except that the web raw material was supplied so as to obtain a sheet having a thickness of 4 mm, was passed through a box-type dryer with a hot air circulation conveyor oven system, subjected to a hot air treatment at 150°C, and then heated and compressed to obtain a nonwoven fabric laminate having a thickness of 4 mm.

[0044] Example 4 A nonwoven fabric laminate was obtained in the same manner as in Example 2, except that the heat compression conditions were adjusted so that the thickness of the nonwoven fabric laminate after compression would be 4 mm.

[0045] [Example 5] Rayon spunlace (28 g / m) was used as the first and second carrier sheets. ２ An air-laid web-containing sheet obtained in the same manner as in Example 1, except that a nonwoven fabric laminate was used, was passed through a box-type dryer with a hot air circulation conveyor oven system, subjected to a hot air treatment at 150°C, and heated and compressed to obtain a nonwoven fabric laminate with a thickness of 5 mm.

[0046] [Example 6] Rayon spunlace (28 g / m) was used as the first and second carrier sheets. ２ An air-laid web-containing sheet obtained in the same manner as in Example 2, except that a nonwoven fabric laminate was used, was passed through a box-type dryer with a hot air circulation conveyor oven system, subjected to hot air treatment at 150°C, and heated and compressed to obtain a nonwoven fabric sheet with a thickness of 6 mm. A nonwoven fabric laminate was obtained.

[0047] [Example 7] Rayon spunlace (28 g / m) was used as the first and second carrier sheets. ２ An air-laid web-containing sheet obtained in the same manner as in Example 3, except that a nonwoven fabric laminate was used, was passed through a box-type dryer with a hot air circulation conveyor oven system, subjected to hot air treatment at 150°C, and heated and compressed to obtain a nonwoven fabric sheet having a thickness of 4 mm. A nonwoven fabric laminate was obtained.

[0048] Example 8 A nonwoven fabric laminate was obtained in the same manner as in Example 6, except that the heat compression conditions were adjusted so that the thickness was 4 mm.

[0049] [Example 9] 20 g / m of polyethylene powder was added to the web material. ２ An air-laid web-containing sheet obtained in the same manner as in Example 3, except that the components were blended so as to obtain a nonwoven fabric laminate having a thickness of 4 mm, was passed through a box-type dryer with a hot air circulation conveyor oven system, subjected to a hot air treatment at 150°C, and then heated and compressed.

[0050] [Example 10] Air-laid nonwoven fabrics (40 g / m) made of pulp and an ethylene-vinyl acetate copolymer resin binder were used as the first and second carrier sheets. ２ An air-laid web-containing sheet obtained in the same manner as in Example 4, except that a nonwoven fabric laminate was used, was passed through a box-type dryer with a hot air circulation conveyor oven system, subjected to a hot air treatment at 150°C, and heated and compressed to obtain a nonwoven fabric laminate with a thickness of 4 mm.

[0051] [Example 11] An air-laid web-containing sheet was obtained in the same manner as in Example 4, except that the web raw material was obtained by mixing defibrated fluff pulp fibers and short-cut heat-fusible composite fibers in a ratio of 70 / 30. The air-laid web-containing sheet was passed through a box-type dryer with a hot air circulation conveyor oven system, subjected to hot air treatment at 150°C, and heated and compressed to obtain a nonwoven fabric laminate with a thickness of 4 mm.

[0052] [Example 12] A nonwoven fabric laminate having a thickness of 4 mm was obtained in the same manner as in Example 4, except that the web raw material was obtained by mixing defibrated fluff pulp fibers and short-cut heat-fusible composite fibers in a ratio of 90 / 10. The obtained air-laid web-containing sheet was passed through a box-type dryer with a hot air circulation conveyor oven system, subjected to hot air treatment at 150°C, and heated and compressed.

[0053] Example 13 An air-laid web-containing sheet was obtained in the same manner as in Example 5, except that polylactic acid fibers (PLA composite core-sheath fibers, fineness 2.2 dtex, fiber length 5 mm, sheath melting point 160°C) were used as the heat-fusible composite fibers and polylactic acid powder was used instead of polyethylene powder. The air-laid web-containing sheet was passed through a box-type dryer with a hot air circulation conveyor oven system, subjected to hot air treatment at 150°C, and heated and compressed to obtain a nonwoven fabric laminate with a thickness of 5 mm.

[0054] [Comparative Example 1] The basis weight of the web material was 600 g / m ２ The web raw material was supplied so that the ratio of defibrated fluff pulp fibers and short-cut heat-fusible composite fibers was mixed at a ratio of 30 / 70, and an air-laid web-containing sheet was obtained in the same manner as in Example 1. The air-laid web-containing sheet was passed through a box-type dryer with a hot air circulation conveyor oven system, subjected to hot air treatment at 150°C, and heated and compressed to obtain a nonwoven fabric laminate with a thickness of 1.5 mm.

[0055] Comparative Example 2 An air-laid web-containing sheet obtained in the same manner as in Example 1, except that a PE film was used as the first carrier sheet and a pulp air-laid nonwoven fabric was used as the third layer, was passed through a box-type dryer with a hot air circulation conveyor oven system, subjected to hot air treatment at 150°C, and heated and compressed to obtain a nonwoven fabric laminate with a thickness of 5 mm.

[0056] [Comparative Example 3] An air-laid web-containing sheet obtained in the same manner as in Example 5, except that the defibrated fluff pulp fibers and the short-cut heat-fusible composite fibers were mixed in a ratio of 95 / 5, was passed through a box-type dryer with a hot air circulation conveyor oven system, subjected to hot air treatment at 150°C, and heated and compressed to obtain a nonwoven fabric laminate with a thickness of 10 mm.

[0057] Tables 1 and 2 show the thickness and density after compression treatment of the nonwoven fabric sheets obtained in Examples 1 to 13 and Comparative Examples 1 to 3, the ratio of (total thickness of the first layer + thickness of the third nonwoven fabric layer) / (thickness of all nonwoven fabric layers), the stiffness of the nonwoven fabric sheets measured in accordance with JIS P8125-2000 (Testing method for stiffness of paper and paperboard), the water absorption rate measured by the method described in JIS L1913-2010, and the WC value of the first nonwoven fabric layer side measured using a KES compression tester.

[0058] [Evaluation Method] The nonwoven fabric laminates obtained in Examples 1 to 13 and Comparative Examples 1 to 3 were die-cut according to slipper patterns to create slipper-forming sheets. The slipper-forming sheets were sewn together to create slippers so that the first nonwoven fabric layer or the first carrier sheet would come into contact with the wearer's skin. Subjects were asked to wear the resulting slippers, and a questionnaire was completed based on the following evaluation criteria. The results are shown in Tables 1 and 2.

[0059] [Evaluation Criteria] (1) Softness ◎: Excellent (very soft and very comfortable). ○: Excellent (soft and very comfortable). △: No problem in practical use. ×: Not suitable for practical use. (2) Comfort (Fit) ◎: Excellent (good fit when walking, easy to walk in). ○: Excellent (fits well when walking). △: No problem in practical use. ×: Not suitable for practical use (sole breaks or comes off when walking). (3) Wrinkles ◎: Excellent (almost no wrinkles). ○: Excellent (hard to wrinkle). △: No problem in appearance (some wrinkles). ×: Problem in appearance (many wrinkles). (4) Moisture absorption ◎: Excellent (no stickiness on the soles of the feet, comfortable). ○: Excellent (little stickiness on the soles, comfortable). △: No problem in practical use. ×: Not suitable for practical use (stickiness on the soles of the feet).

[0060] As shown in Tables 1 and 2, the nonwoven fabric sheets of Examples 1 to 13 were more comfortable to wear and had better moisture absorption properties than the nonwoven fabric sheet of Comparative Example 1, and therefore provided footwear that did not feel sticky even when worn after sweating or after a bath.

[0061]

[0062]

[0063]

[0064]

[0065] The nonwoven fabric laminate of the present invention has a low environmental impact, is highly adaptable to be processed into footwear, and provides excellent comfort when processed into footwear.

Claims

1. A nonwoven fabric laminate for footwear, which comprises a first nonwoven fabric layer, a second nonwoven fabric layer, and a third nonwoven fabric layer laminated in this order, which are cut out or punched into component sheets, and which can be assembled by inserting an insertion portion formed on at least one portion of the component sheet into a cut portion formed on at least another portion of the component sheet, wherein the thickness of the nonwoven fabric laminate for footwear is 1 mm or more and 12 mm or less, the stiffness measured in accordance with JIS P8125-2000 is 70 gf / cm or more, and the WC value of the nonwoven fabric laminate for footwear measured using a KES compression tester is 0.5 gf cm / cm. ２ More than 5.0gf・cm / cm ２ A nonwoven fabric laminate for footwear, which is as follows:

2. A nonwoven fabric laminate for footwear, which is made by laminating a first nonwoven fabric layer, a second nonwoven fabric layer and a third nonwoven fabric layer in that order, cutting or punching them into component sheets, and then overlapping the ends of the component sheets and joining them using at least one method of sewing, gluing and heat fusion to form footwear, wherein the thickness of the nonwoven fabric laminate for footwear is 1 mm or more and 12 mm or less, the stiffness measured in accordance with JIS P8125-2000 is 70 gf / cm or more, and the WC value of the nonwoven fabric laminate for footwear measured using a KES compression testing machine is 0.5 gf・cm / cm2 or more and 5.0 gf・cm / cm2 or less.

3. A nonwoven fabric laminate for footwear as described in claim 1 or 2, which is for slippers.

4. 3. The nonwoven fabric laminate for footwear according to claim 1, wherein the second nonwoven fabric layer contains 50% by mass or more of any one type of fiber or two or more types of fibers selected from the group consisting of pulp fibers, cotton fibers, and rayon fibers.

5. the first nonwoven fabric layer is at least one type of nonwoven fabric selected from the group consisting of a spunbond nonwoven fabric, a spunlace nonwoven fabric, and an airlaid nonwoven fabric containing a thermoplastic resin in an amount of more than 50% by mass relative to the airlaid nonwoven fabric; 3. The nonwoven fabric laminate for footwear according to claim 1 or 2, wherein the third nonwoven fabric layer is at least one type of nonwoven fabric selected from the group consisting of spunbonded nonwoven fabrics, spunlace nonwoven fabrics, and airlaid nonwoven fabrics containing more than 50% by mass of a thermoplastic resin relative to the airlaid nonwoven fabric.

6. The bulk density of the first nonwoven fabric layer is 0.10 g / cm ３ is less than The bulk density of the second nonwoven fabric layer is 0.10 g / cm ３ 0.30g / cm or more ３ is as follows: The bulk density of the third nonwoven fabric layer is 0.10 g / cm ３ The nonwoven fabric laminate for footwear according to claim 1 or 2, wherein the thickness is less than 1 / 2 mm.

7. 3. The nonwoven fabric laminate for footwear according to claim 1, wherein the sum of the thickness of the first nonwoven fabric layer and the thickness of the second nonwoven fabric layer is 0.2% or more and 45% or less of the thickness of the nonwoven fabric laminate for footwear.

8. A sheet for manufacturing footwear, comprising the nonwoven fabric laminate for footwear according to claim 1 or 2.

9. 9. A footwear parts sheet obtained by cutting or punching the footwear manufacturing sheet according to claim 8 into the shape of a footwear sole, wherein the density of the peripheral part of the parts sheet is 1.2 times or more the density of the central part of the parts sheet.

10. 9. A footwear parts sheet obtained by cutting or punching the footwear manufacturing sheet according to claim 8, wherein at least one part of the parts sheet has a cutout portion and at least another part of the parts sheet has an insertion portion, and the insertion portion can be inserted into the cutout portion to form footwear.

11. Footwear using the nonwoven fabric laminate for footwear according to claim 1 or 2.

12. Footwear using the footwear component sheet according to claim 9.

13. A method for producing the nonwoven fabric laminate for footwear according to claim 1 or 2.

14. A method for producing the footwear manufacturing sheet according to claim 8.

15. The method for manufacturing a component sheet according to claim 9 .

16. A method for manufacturing footwear according to claim 10.

17. 3. Use of the nonwoven fabric laminate for footwear according to claim 1 or 2 for producing a component sheet for footwear.

18. 3. Use of the nonwoven fabric laminate for footwear according to claim 1 or 2 for producing footwear.