Nonwoven fabric and method for producing same

Patent metadata

Field	Value
Publication number	US-12329622-B2
Application number	US-202218278002-A
Country	US
Kind code	B2
Filing date	Mar 1, 2022
Priority date	Mar 23, 2021
Publication date	Jun 17, 2025
Grant date	Jun 17, 2025

Abstract

The present invention addresses the problem of providing a nonwoven fabric that is bulky, has excellent softness, and has high strength. Provided is a nonwoven fabric in which the points at which heat fusible composite fibers intersect with each other are fused by heat. The nonwoven fabric has a high-density-side surface layer where the fiber density is 5 to 20 fibers/mm2. The ratio of the fiber density of the high-density-side surface layer and the fiber density of a low-density-side surface layer of the nonwoven fabric is 1.4 or less. The strength per unit basis weight of the nonwoven fabric is 0.40 N/50 mm or greater.

First claim

What is claimed is:

1. A nonwoven fabric in which points at which heat fusible composite fibers intersect with each other are fused by heat, the nonwoven fabric comprising:
a high-density-side surface layer having a fiber density of 5 to 20 fibers/mm 2 ,
wherein a ratio of the fiber density of the high-density-side surface layer and a fiber density of a low-density-side surface layer of the nonwoven fabric is 1.4 or less, and
a strength per unit basis weight of the nonwoven fabric is 0.40 N/50 mm or greater, wherein a specific volume is 100 cm 3 /g or greater.

2. The nonwoven fabric according to claim 1 , wherein a compression work amount at a maximum compression load of 4 gf/cm 2 is 0.20 gf cm/cm 2 or greater.

3. The nonwoven fabric according to claim 1 , wherein a fineness of the heat fusible composite fiber is 0.8 to 20 dtex.

4. The nonwoven fabric according to claim 1 , wherein a fiber length of the heat fusible composite fiber is 20 to 102 mm.

5. A method for producing a nonwoven fabric, the method comprising:
forming a web containing heat fusible composite fibers; and
fusing points at which the heat fusible composite fibers intersect with each other by heat under no pressure using superheated steam gas,
wherein a blowing pressure of the superheated steam gas is less than 0.1 kPa, and a blowing speed of the superheated steam gas is less than 0.1 m/minute.

6. The method for producing a nonwoven fabric according to claim 5 , wherein the step of forming the web is a carding method or an airlaid method.

7. The method for producing a nonwoven fabric according to claim 5 , further comprising heat-treating after fusing the heat fusible composite fibers by heat.

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

Assignees

• Jnc Corp
• Jnc Fibers Corp

Inventors

• Terada Hirokazu

Classifications

• D10B2509/026

  Absorbent pads; Tampons; Laundry; Towels · CPC title

• D10B2403/022

  Lofty fabric with variably spaced front and back plies, e.g. spacer fabrics · CPC title

• D10B2401/063

  high strength · CPC title

• D10B2401/022

  hydrophylic · CPC title

• D04H1/541 Primary

  Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres · CPC title