Multilayer nonwoven fabric, stretchable multilayer nonwoven fabric, fiber product, absorbent article, and sanitary mask

Patent metadata

Field	Value
Publication number	US-10920349-B2
Application number	US-201615556543-A
Country	US
Kind code	B2
Filing date	Mar 9, 2016
Priority date	Mar 9, 2015
Publication date	Feb 16, 2021
Grant date	Feb 16, 2021

Abstract

A multilayer nonwoven fabric includes: an elastic nonwoven fabric containing a specific low crystalline polypropylene; and a mixed fiber spunbonded nonwoven fabric disposed on at least one surface of the elastic nonwoven fabric, wherein the mixed fiber spunbonded nonwoven fabric contains a long fiber of a thermoplastic elastomer (A) and a long fiber of a thermoplastic elastomer (B) other than the thermoplastic elastomer (A), in a ratio of 10 to 90% by mass:90 to 10% by mass ((A):(B), with the proviso that (A)+(B)=100% by mass).

First claim

The invention claimed is:

1. A multilayer nonwoven fabric, comprising:
an elastic nonwoven fabric containing a long fiber of a first thermoplastic elastomer (A′) and a low crystalline polypropylene satisfying the following (a) to (f); and
two mixed fiber spunbonded nonwoven fabrics,
wherein the multilayer nonwoven fabric has a three-layer structure including the mixed fiber spunbonded nonwoven fabric, the elastic nonwoven fabric and the mixed fiber spunbonded nonwoven fabric, in this order,
wherein each of the mixed fiber spunbonded nonwoven fabrics contains a long fiber of a second thermoplastic elastomer (A) and a long fiber of a thermoplastic resin (B) other than the second thermoplastic elastomer (A) in a ratio of 10 to 90% by mass:90 to 10% by mass ((A):(B), with the proviso that (A)+(B)=100% by mass), and
wherein the thermoplastic resin (B) is an olefinic polymer composition consisting essentially of a propylene polymer and a high-density polyethylene:

(a) [mmmm]=20 to 60 mol %;
(b) [rrrr]/(1−[mmmm])<0.1;
(c) [rmrm]>2.5 mol %;
(d) [mm]×[rr]/[(mr)] 2 <2.0;
(e) weight-average molecular weight (Mw)=10,000 to 200,000; and
(f) molecular weight distribution (Mw/Mn)<4,
wherein:

[mmmm] is a mesopentad fraction;
[rrrr] is a racemic pentad fraction;
[rmrm] is a racemic meso racemic mesopentad fraction; and
[mm], [rr] and [mr] are triad fractions,
wherein the first thermoplastic elastomer (A′) includes a first thermoplastic polyurethane elastomer, and the second thermoplastic elastomer (A) includes a second thermoplastic polyurethane elastomer,
wherein a mixing ratio of the first thermoplastic polyurethane elastomer in the elastic nonwoven fabric is greater than 0% and up to 40% by mass, and is smaller than a mixing ratio of the second thermoplastic polyurethane elastomer in any one of the two mixed fiber spunbonded nonwoven fabrics, and
wherein low temperature heat sealability of the multilayer nonwoven fabric is from 10 N/50 mm to about 18.5 N/50 mm.

2. The multilayer nonwoven fabric according to claim 1 , wherein a maximum point elongation of the long fiber of the thermoplastic resin (B), in a case of being formed into the spunbonded nonwoven fabric, is 50% or more.

3. The multilayer nonwoven fabric according to claim 1 , wherein the first thermoplastic elastomer (A′) is the first thermoplastic polyurethane elastomer, and the second thermoplastic elastomer (A) is the second thermoplastic polyurethane elastomer.

4. The multilayer nonwoven fabric according to claim 1 , wherein:
the first or second thermoplastic polyurethane elastomer has a solidification starting temperature of 65° C. or higher as measured by a differential scanning calorimeter (DSC); and
a number of particles of the first or second thermoplastic polyurethane elastomer insoluble in a dimethylacetamide solvent measured by a particle size distribution measuring apparatus equipped with an aperture of 100 μm based on a pore electrical resistance method, is 3,000,000/g or less.

5. The multilayer nonwoven fabric according to claim 1 , wherein the first or second thermoplastic polyurethane elastomer is a thermoplastic polyurethane elastomer satisfying the following relational expression (I):
a /( a+b )≤0.8  (I)

wherein:
a represents a total amount of fusion heat calculated from an endothermic peak in a range of 90° C. to 140° C., as measured by DSC; and
b represents a total amount of fusion heat calculated from an endothermic peak in a range from higher than 140° C. to 220° C. or lower, as measured by DSC.

6. The multilayer nonwoven fabric according to claim 1 , wherein the thermoplastic resin (B) consists essentially of 99 to 80% by mass of the propylene polymer and 1 to 20% by mass of the high-density polyethylene.

7. A stretchable multilayer nonwoven fabric obtained by drawing the multilayer nonwoven fabric according to claim 1 .

8. A fiber product comprising the multilayer nonwoven fabric according to claim 1 .

9. An absorbent article comprising the multilayer nonwoven fabric according to claim 1 .

10. A sanitary mask comprising the multilayer nonwoven fabric according to claim 1 .

11. A fiber product comprising the stretchable multilayer nonwoven fabric according to claim 6 .

12. An absorbent article comprising the stretchable multilayer nonwoven fabric according to claim 6 .

13. A sanitary mask comprising the stretchable multilayer nonwoven fabric according to claim 6 .

Assignees

• Mitsui Chemicals Inc

Inventors

• Shimada Koichi
• Suzuki Kenichi
• Takaku Shouichi

Classifications

• B32B2571/00

  Protective equipment · CPC title

• B32B2555/02

  Diapers or napkins · CPC title

• B32B2264/0292

  Polyurethane particles · CPC title

• B32B2262/124

  Non-woven fabric · CPC title

• B32B2262/0276

  Polyester fibres · CPC title