JP2023147960A - Non-woven fabric roll and manufacturing method thereof - Google Patents

Abstract

[Problem] The present invention provides a nonwoven fabric roll that has a smooth surface, does not wrinkle even when rolled up over a wide width, and has excellent adhesion properties to a film. SOLUTION: The nonwoven fabric roll of the present invention is a nonwoven fabric roll formed by winding up a long fiber nonwoven fabric made of fibers containing a thermoplastic resin as a main component, and wherein the long fiber nonwoven fabric has an apparent density of 0. The nonwoven fabric roll is 40 g/cm 3 or more and 0.85 g/cm 3 or less, the winding hardness of the nonwoven fabric roll is 23.0 g or more and 50.0 g or less, and satisfies the following formula (1). H<1.97×10-5×((L×W)/S)-5.3...(1) Here, H is the rolling hardness measured at 5 cm intervals in the width direction of the nonwoven fabric roll. The maximum value of the hardness difference between two adjacent measurements (g), S is the average value of the cross-sectional area of both ends in the direction perpendicular to the width of the nonwoven fabric roll (m2), L is the winding length of the nonwoven fabric roll (m), and W is the Fabric weight of long fiber nonwoven fabric (g/m2) [Selection diagram] None

Description

The present invention relates to a nonwoven fabric roll used as a laminated base material for construction materials, etc., and a method for manufacturing the same.

BACKGROUND ART In the construction of houses and the like, a ventilation layer construction method in which a ventilation layer is provided between an exterior wall material and a heat insulating material so that moisture that has entered the wall can be released to the outside through the ventilation layer is popular. This ventilation layer uses housewrap material, which is a moisture-permeable waterproof sheet that is both waterproof to prevent rainwater from entering from outside the building and breathable to allow moisture generated inside the wall to escape to the outside. Housewrap materials mainly require a microporous film made of polyolefin that has moisture-permeable and waterproof functions, but housewrap materials laminated with long-fiber nonwoven fabrics made of polyester are mainly used to ensure durability and strength. It will be done.

In recent years, there has been a demand for high performance and high durability for this house wrap material. Specifically, when constructing house wrap materials, waterproof tape such as butyl tape is used in areas where waterproofness is particularly required. After this waterproof tape is affixed to the building frame, the house wrap is placed over it. Attach the wrap material. Therefore, these housewrap materials are required to have excellent durability even at the adhesive part of the waterproof tape, and to have a smooth surface so as to be adhesive to the waterproof tape.

As such a housewrap material, for example, Patent Document 1 discloses a long-fiber nonwoven fabric made of continuous thermoplastic filaments, in which the degree of fiber orientation of the filaments with respect to the longitudinal direction of the nonwoven fabric is 35 to 70 degrees, On one surface of the nonwoven fabric, the filaments are pressed together, and a number of partial thermocompression bonded parts are formed that are discontinuous in any direction throughout the nonwoven fabric. A nonwoven fabric for house wrap material has been proposed in which at least some of the filaments described above are fused and aggregated with each other.

Japanese Patent Application Publication No. 2014-040677

However, since the nonwoven fabric for housewrap material as disclosed in Patent Document 1 has a partial heat-sealed portion, it does not have sufficient adhesion to the waterproof tape and may peel off from the waterproof tape under its own weight. There are issues such as gender.

Therefore, the present invention was made in view of the above circumstances, and its purpose is to provide a tape with a smooth surface that has excellent adhesion to waterproof tape, and which is easy to roll even when widened for industrial production. It is an object of the present invention to provide a nonwoven fabric roll that is free from wrinkles when rolled up and has excellent lamination properties with films.

The present invention aims to solve the above-mentioned problems, and a nonwoven fabric roll according to an embodiment of the present invention is made by winding a long fiber nonwoven fabric made of fibers mainly composed of a thermoplastic resin into a roll shape. A nonwoven fabric roll, wherein the long fiber nonwoven fabric has an apparent density of 0.40 g/cm ³ or more and 0.85 g/cm ³ or less, and a winding hardness of the nonwoven fabric roll is 23.0 g or more and 50.0 g or less, and This is a nonwoven fabric roll that satisfies the following formula (1).
H < 1.97×10 ^-5 × ((L×W)/S) -5.3 ... (1)
here,
H is the maximum value (g) of the hardness difference between two adjacent measured values when the winding hardness is measured at 5 cm intervals in the width direction of the nonwoven fabric roll,
L is the winding length (m) of the nonwoven fabric roll;
W is the basis weight of the long fiber nonwoven fabric (g/m ² );
S is the average value (m ² ) of the cross-sectional area of both ends in the direction perpendicular to the width of the nonwoven fabric roll.

According to a preferred embodiment of the nonwoven fabric roll of the present invention, the winding length L of the nonwoven fabric roll is 100 m or more and 11,500 m or less, and the difference between the thickness of the long fiber nonwoven fabric in the roll outer layer and the long fiber nonwoven fabric in the roll inner layer is It is a nonwoven fabric roll of 0.100 mm or less.

According to a preferred embodiment of the nonwoven fabric roll of the present invention, the nonwoven fabric roll has a roll width of 0.5 m or more and 3.1 m or less.

According to a preferred embodiment of the nonwoven fabric roll of the present invention, the thermoplastic resin is a polyester resin.

A method for producing a nonwoven fabric roll according to an embodiment of the present invention is a method for producing a nonwoven fabric roll, which is characterized by sequentially performing the following steps (a) to (c).
(a) After obtaining long fibers by spinning a thermoplastic resin from a spinneret having discharge holes, gas is applied through a cooling section in a direction perpendicular to the running direction of the long fibers, and then the long fibers are After applying gas through a gas supply section in a direction perpendicular to the running direction of the fiber, the long fibers are passed through an intake and exhaust section with a length of 1 mm or more and 150 mm or less, which is provided directly below the gas supply section. (b) Collecting the drawn long fibers on a moving net conveyor to form a fibrous web. (c) The fibrous web is After obtaining a nonwoven fabric sheet by thermally bonding with a linear pressure of 100 N/cm or more and 900 N/cm or less using a pair of flat rolls whose roll surface temperature is 30° C. or more and 70° C. or less lower than the melting point of the thermoplastic resin. , the process of winding to obtain a nonwoven fabric roll.

In the method for manufacturing a nonwoven fabric roll according to an embodiment of the present invention, the step (a) is the following (a'), and the melting point of the thermoplastic resin in the step (c) is the melting point of the low melting point polymer. , a method for manufacturing a nonwoven fabric roll.
(a') A high melting point polymer and a low melting point polymer having a melting point lower than the melting point of the high melting point polymer by 10° C. or more and 110° C. or less are spun from a composite spinneret having discharge holes. After obtaining long fibers covered with a low melting point polymer without exposing the coalescence, gas is applied through a cooling section in a direction perpendicular to the running direction of the long fibers, and then the long fibers are heated in the running direction of the long fibers. After applying gas through the gas supply section in a direction perpendicular to the gas supply section, the long fibers are passed through an intake and exhaust section with a length of 1 mm or more and 150 mm or less, which is provided directly below the gas supply section, and the fibers are spun. A step of suction stretching at a speed of 3000 m/min or more and 5500 m/min or less.

In the method for producing a nonwoven fabric roll according to an embodiment of the present invention, the thermoplastic resin in the step (a) is a polyester resin, or the high melting point polymer and/or the low melting point polymer in the step (a') is a polyester resin. This is a method for manufacturing a nonwoven fabric roll using a resin based resin.

According to the present invention, when used as a house wrap material, it has excellent adhesive strength with waterproof tape, and even when it is widened, there is no wrinkle when winding it up, and it also has excellent bonding properties with film. A nonwoven fabric roll can be provided.

A nonwoven fabric roll according to an embodiment of the present invention is a nonwoven fabric roll formed by winding up a long fiber nonwoven fabric made of fibers containing a thermoplastic resin as a main component, and wherein the long fiber nonwoven fabric has an apparent density of 0. The nonwoven fabric roll is 40 g/cm ³ or more and 0.85 g/cm ³ or less, the winding hardness of the nonwoven fabric roll is 23.0 g or more and 50.0 g or less, and satisfies the following formula (1).
H < 1.97×10 ^-5 × ((L×W)/S) -5.3 ... (1)
Here, H is the maximum value (g) of the difference in hardness between two adjacent measured values when the winding hardness is measured at 5 cm intervals in the width direction of the nonwoven fabric roll, and S is the cross section at both ends in the direction perpendicular to the width of the nonwoven fabric roll. The average value of the area (m ² ), L is the winding length (m) of the nonwoven fabric roll, and W is the basis weight (g/m ² ) of the long fiber nonwoven fabric. The components will be explained in detail below, but the present invention is not limited to the scope described below unless it goes beyond the gist of the invention, and various modifications may be made without departing from the gist of the invention. Changes are possible.

(Thermoplastic resin)
The nonwoven fabric roll of one embodiment of the present invention is formed by winding up a long fiber nonwoven fabric made of fibers containing a thermoplastic resin as a main component.

Examples of the above-mentioned thermoplastic resin include polyester, polyamide, polyolefin, and mixtures and copolymers thereof. Among them, polyester is preferable because it has excellent mechanical strength and durability such as heat resistance, water resistance, and chemical resistance.

Polyester consists of an acid component and an alcohol component. As the acid component, aromatic carboxylic acids such as terephthalic acid, isophthalic acid, and phthalic acid, aliphatic dicarboxylic acids such as adipic acid and sebacic acid, and alicyclic dicarboxylic acids such as cyclohexanecarboxylic acid can be used. As the alcohol component, ethylene glycol, diethylene glycol, polyethylene glycol, etc. can be used.

Examples of the polyester include polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, polylactic acid, polybutylene succinate, and copolymers thereof.

(Fiber whose main component is thermoplastic resin)
A crystal nucleating agent, a matting agent, a lubricant, a pigment, an antifungal agent, an antibacterial agent, a flame retardant, a hydrophilic agent, and the like may be added to the fiber containing the thermoplastic resin as a main component. In particular, during thermocompression molding of long fiber nonwoven fabrics, metal oxides such as titanium oxide, which have the effect of improving the adhesion of long fiber nonwoven fabrics by increasing thermal conductivity, and mold releasability between the thermocompression roll and the fiber web are used. It is preferable to add an aliphatic bisamide such as ethylene bisstearamide and/or an alkyl-substituted aliphatic monoamide, which has the effect of improving adhesive stability by increasing the adhesion stability. These various additives may be present in the thermoplastic fiber or on the surface of the thermoplastic fiber.

Further, the cross-sectional shape of the fibers containing thermoplastic resin as a main component includes circular, flat, polygonal, multilobal shapes such as X-shape and Y-shape, and hollow shapes.

It is preferable that the average single fiber diameter of the fibers mainly composed of the thermoplastic resin is 10 μm or more and 24 μm or less. By setting the average single fiber diameter to preferably 10 μm or more, more preferably 12 μm or more, and even more preferably 14 μm or more, a nonwoven fabric with excellent uniformity in area weight and mechanical strength can be obtained.

On the other hand, by setting the average single fiber diameter to preferably 24 μm or less, more preferably 22 μm or less, and even more preferably 20 μm or less, hot water used for lamination with polyethylene porous film when producing housewrap materials can be used. It is possible to suppress excessive penetration of the melt resin into the nonwoven fabric, and the adhesive strength between the film and the nonwoven fabric is also good, making it preferable as a housewrap material. In addition, when a plurality of types of fibers are mixed, it is preferable that the single fiber diameter of each fiber is within the above range.

In addition, in the present invention, the average single fiber diameter (μm) of the fibers whose main component is the thermoplastic resin shall be a value calculated by the following procedure.
(1) Ten small samples (100 mm x 100 mm) are randomly taken from the long fiber nonwoven fabric.
(2) Take a surface photograph with a microscope (for example, "VHX-D500" manufactured by Keyence Corporation) at a magnification of 500 times or more and 3,000 times or less, and measure the diameter of a total of 100 single fibers, 10 from each sample. .
(3) Calculate the average single fiber diameter (μm) by rounding off the arithmetic mean value of the 100 measured values to the first decimal place.

(Long fiber nonwoven fabric)
The apparent density of the long fiber nonwoven fabric in one embodiment of the present invention is 0.40 g/cm ³ or more and 0.85 g/cm ³ or less. By setting the apparent density of the long fiber nonwoven fabric to 0.40 g/cm ³ or more, preferably 0.42 g/cm ³ or more, more preferably 0.45 g/cm ³ or more, it will have a sufficiently dense structure and can be used as a house wrap material. It has excellent durability when used and can further increase mechanical strength. On the other hand, by setting the apparent density of the long-fiber nonwoven fabric to 0.85 g/cm ³ or less, preferably 0.80/cm ³ or less, and more preferably 0.75 g/cm ³ or less, the long-fiber nonwoven fabric is crimped too much. When used as a housewrap material, it can be partially formed into a film and can be used without reducing its moisture permeability and waterproof properties. In addition, it becomes easier to create an anchor effect between the waterproof tape and the nonwoven fabric for construction materials, and the adhesive strength with the waterproof tape is excellent.

Note that the apparent density (g/cm ³ ) of the long fiber nonwoven fabric is calculated by the following procedure.
(1) Use the value calculated by converting the unit weight (g/m ² ) of the long fiber nonwoven fabric from the thickness (mm) of the long fiber nonwoven fabric and rounding the result to the third decimal place. shall be taken as a thing.

Note that the thickness (mm) of the long fiber nonwoven fabric is calculated by the following procedure.
(1) Three pieces of long fiber nonwoven fabric with a width of 10 cm in the longitudinal direction are collected.
(2) Using a pressurizer with a diameter of 10 mm, the thickness is measured at 10 points per 1 m at equal intervals in the width direction of the long fiber nonwoven fabric in units of 0.01 mm under a load of 10 kPa.
(3) Calculate the arithmetic mean value of the measured values obtained above for each of the three long fiber nonwoven fabrics that were collected, and then calculate the arithmetic mean value for the three long fiber nonwoven fabrics to the fourth decimal place. Round off and calculate.

The long fiber nonwoven fabric preferably has a basis weight of 10 g/m ² or more and 90 g/m ² . By setting the basis weight to preferably 15 g/m ² or more, more preferably 20 g/m ² or more, even more preferably 25 g/m ² or more, the material has excellent mechanical strength even when used as a house wrap material. On the other hand, by setting the basis weight to preferably 90 g/m ² or less, more preferably 80 g/m ² or less, and even more preferably 70 g/m ² or less, it is lightweight and easy to construct when used as a house wrap material. Excellent.

Note that the basis weight (g/m ² ) of the long fiber nonwoven fabric is calculated by the following procedure.
(1) Three pieces of long fiber nonwoven fabric of 30 cm x 50 cm are collected.
(2) Measure the mass of each sample, convert the average value of the obtained values into mass per unit area (g/m ² ), and calculate the basis weight by rounding to the first decimal place.

(Nonwoven fabric roll)
The nonwoven fabric roll of one embodiment of the present invention has a winding hardness of 23.0 g or more and 50.0 g or less. By setting the winding hardness of the nonwoven fabric roll to 23.0 g or more, preferably 25.0 g or more, and more preferably 27.0 g or more, it is possible to obtain a nonwoven fabric roll that is free from winding misalignment and wrinkles when loosened. On the other hand, by setting the winding hardness of the nonwoven fabric roll to 50.0 g or less, preferably 48.0 g or less, more preferably 47.0 g or less, excessive winding tension is not applied to the nonwoven fabric roll, and a load is applied to the winding core. Since the long fiber nonwoven fabric is free from wrinkles, it is possible to obtain a nonwoven fabric roll without wrinkles.

Further, it is important that the nonwoven fabric roll of the present invention satisfies the following formula (1).
H < 1.97×10 ^-5 × ((L×W)/S) -5.3 ... (1)
Here, H is the maximum value (g) of the hardness difference between two adjacent measured values when the winding hardness is measured at 5 cm intervals in the width direction of the nonwoven fabric roll, and S is the both ends in the direction perpendicular to the width of the nonwoven fabric roll. The average value of the cross-sectional area (m ² ), L is the winding length (m) of the nonwoven fabric roll, and W is the basis weight (g/m ² ) of the long fiber nonwoven fabric.
By doing so, it is possible to suppress the occurrence of wrinkles in the nonwoven fabric roll when the difference in hardness between adjacent nonwoven fabric rolls becomes too large. Regarding the difference in hardness between adjacent portions, the higher the winding density of the nonwoven fabric roll, the greater the difference in hardness between adjacent portions of the nonwoven fabric, and the relationship is shown by equation (1). The maximum value H of the hardness difference between the two adjacent measured values can be determined by applying gas through the gas supply part to suppress the inflow of outside air, and without shaking the thread, to the intake and exhaust part with a length of 1 mm or more and 150 mm or less. By passing , the maximum value H of the hardness difference between two adjacent measured values can be lowered.

In addition, the winding hardness (g) of the nonwoven fabric roll and the maximum value H (g) of the hardness difference between two adjacent measured values when the winding hardness is measured at 5 cm intervals in the width direction of the nonwoven fabric roll are determined by the following procedure. Calculated by
(1) Using a roll hardness tester (for example, ACA System's "RoQ Rolling Hardness Meter", etc.), when the nonwoven fabric roll is left still and the nonwoven fabric roll is viewed from the cross section, it is 3 o'clock or 9 o'clock. From the width direction end to the other end, the measurement was performed a total of three times in the same direction from the angle of Calculate the winding hardness (g) of the roll.
(2) Obtain the difference between the maximum and minimum values of the hardness data obtained by the above method at 5 cm intervals in the width direction, excluding 5 cm at both ends, round to the second decimal place, and calculate the difference between the two adjacent measured values. The maximum value H (g) of the hardness difference is calculated.

The nonwoven fabric roll according to one embodiment of the present invention preferably has a winding density of 4.0×10 ⁵ g/m ³ or more and 10.0×10 ⁵ g/m ³ or less. The winding density of the nonwoven fabric roll is preferably 4.0×10 ⁵ g/m ³ or more, more preferably 4.5×10 ⁵ g/m ³ or more, and still more preferably 5.0×10 ⁵ g/m ³ or more. By doing so, it is possible to obtain a nonwoven fabric roll that does not wrinkle even when processed as a house wrap material. On the other hand, the winding density of the nonwoven fabric roll is preferably 10.0×10 ⁵ g/m ³ or less, more preferably 9.5×10 ⁵ g/m ³ or less, even more preferably 9.0×10 ⁵ g/m ³ By doing the following, excessive winding tension can be prevented from being applied to the nonwoven fabric roll, and deformation of the winding core can be suppressed.

Note that the winding density (g/m ³ ) of the nonwoven fabric roll is determined by the basis weight of the nonwoven fabric (g/m ² )×roll winding length L (m)/average value S of the cross-sectional area of both ends in the direction perpendicular to the width of the nonwoven fabric roll. (m ² ).

Further, the roll length of the nonwoven fabric can also be measured using a length measuring counter installed in a winding machine when winding up the long fiber nonwoven fabric.

Furthermore, the average value of the cross-sectional area of both ends of a nonwoven fabric in the direction perpendicular to the width of the nonwoven fabric roll is determined by placing the nonwoven fabric roll on the floor, passing the center of the end face of the nonwoven fabric perpendicularly from the floor surface to the top of the nonwoven fabric roll. , measured using a ruler. This was measured on both end faces, then one-third of the roll was rolled and measured in the same manner, and one-third of the roll was further rolled and measured in the same manner. The average value of a total of 6 points measured at 3 points on one end surface and 3 points on the other end surface was taken as the roll diameter of the nonwoven fabric roll. The cross-sectional area was determined from the roll diameter, and the cross-sectional area of the outer diameter of the paper tube used ((outer diameter of the paper tube) ² × π/4) was subtracted from that value.

The nonwoven fabric roll according to one embodiment of the present invention preferably has a winding length L of 100 m or more and 11,500 m or less. By setting the winding length of the nonwoven fabric roll to preferably 100 m or more, more preferably 500 m or more, and still more preferably 1000 m or more, it is possible to obtain a nonwoven fabric roll that has excellent handling properties when processed as a house wrap material. On the other hand, the winding length of the nonwoven fabric roll is preferably 11,500 m or less, more preferably 10,500 m or less, and even more preferably 5,500 m or less, thereby preventing excessive winding tension from being applied to the nonwoven fabric roll and deforming the winding core. It is possible to obtain a nonwoven fabric roll that is able to suppress this and also has excellent handling properties when transporting the nonwoven fabric roll.

In the nonwoven fabric roll of one embodiment of the present invention, it is preferable that the difference in thickness between the roll outer layer nonwoven fabric and the roll inner layer nonwoven fabric is 0.100 mm or less. The difference in thickness between the roll outer layer nonwoven fabric and the roll inner layer nonwoven fabric is preferably 0.100 mm or less, more preferably 0.050 mm or less, and still more preferably 0.030 mm or less, so that the difference in thickness of the roll inner layer nonwoven fabric when the roll length is increased is It is possible to wind the film while suppressing winding misalignment.

The roll inner layer nonwoven fabric and roll outer layer nonwoven fabric described here are the inner layer nonwoven fabric within 10% of the distance on the core side of the nonwoven fabric roll minus the radius of the core, and the outermost 10% of the nonwoven fabric roll is the nonwoven fabric outer layer of the roll. and indicates the thickness of a single sheet of nonwoven fabric located within each of the above ranges.
The thickness (mm) of the long fiber nonwoven fabric is calculated by the following procedure.
(1) The roll inner layer nonwoven fabric and the roll outer layer nonwoven fabric are each sampled from three arbitrary locations.
(2) Using a pressure element with a diameter of 10 mm (for example, "Dial gauge 2109S-10 (gauge element: flat gauge element 101117)" manufactured by Mitutoyo Co., Ltd.) at equal intervals of 10 cm in the width direction of the arbitrarily sampled nonwoven fabric, , the thickness is measured in units of 0.001 mm under a load of 10 kPa. For example, if the width of the nonwoven fabric is 105 cm, measurements are taken at 10 points at equal intervals of 10 cm, excluding 7.5 cm at both ends.
(3) Calculate the average value of the values measured at equal intervals above for three each of the roll inner layer nonwoven fabric and the roll outer layer nonwoven fabric, and then calculate the arithmetic mean value of the three average values each of the roll inner layer nonwoven fabric and the roll outer layer nonwoven fabric with a decimal point. The following numbers are rounded off to the fourth place to determine the thickness of the roll inner layer nonwoven fabric and the roll outer layer nonwoven fabric.
(4) Determine the difference between the thickness of the determined roll inner layer nonwoven fabric and the thickness of the roll outer layer nonwoven fabric.

The core used in the nonwoven fabric roll of the present invention may be made of a general paper tube or a resin such as polyethylene, polypropylene, or ABS, but when winding a long length of 3,000 m or more, the core should be It is preferable to use a winding core made of a metal-reinforced paper tube, fiber-reinforced plastic, or the like. The outer diameter size of the core of the nonwoven fabric roll is not limited, but since folding wrinkles are likely to occur at the beginning of winding, it is preferably 50 mm or more to facilitate winding, and to improve loading efficiency in terms of logistics. From this point of view, the length is preferably 200 mm or less.

The nonwoven fabric roll according to one embodiment of the present invention preferably has a roll width of 0.5 m or more and 3.1 m or less. By setting the roll width of the nonwoven fabric roll to preferably 0.5 m or more, more preferably 0.6 m or more, and even more preferably 0.7 m or more, it is possible to obtain a nonwoven fabric roll that has excellent productivity when processing house wrap materials. . On the other hand, by setting the roll width of the nonwoven fabric roll to 3.1 m or less, more preferably 2.6 m or less, and even more preferably 2.1 m or less, the housewrap material can be used without impairing the effects of widthwise variations in the nonwoven fabric roll. A nonwoven fabric roll with excellent processability during production can be obtained.

Further, in the present invention, it is preferable that the winding deviation of the nonwoven fabric roll is 8 mm or less. The winding misalignment refers to the distance between the end face of the roll and the nonwoven fabric that partially protrudes to the outside. The winding deviation of this nonwoven fabric roll is more preferably 5 mm or less. By doing so, it can be processed without wrinkles due to meandering when bonded to a polyethylene porous film as a housewrap material.

(Method for manufacturing nonwoven fabric roll)
Next, the method for manufacturing a nonwoven fabric roll of the present invention is a method for manufacturing a nonwoven fabric roll, which is characterized by sequentially performing the following steps (a) to (c).
(a) After obtaining long fibers by spinning a thermoplastic resin from a spinneret having discharge holes, gas is applied through a cooling section in a direction perpendicular to the running direction of the long fibers, and then the long fibers are After applying gas through a gas supply section in a direction perpendicular to the running direction of the fiber, the long fibers are passed through an intake and exhaust section with a length of 1 mm or more and 150 mm or less, which is provided directly below the gas supply section. and suction stretching at a spinning speed of 3000 m/min to 5500 m/min,
(b) collecting the drawn long fibers on a moving net conveyor to form a fibrous web;
(c) The fiber web is thermally bonded with a linear pressure of 100 N/cm to 900 N/cm using a pair of flat rolls whose roll surface temperature is 30° C. or more and 70° C. or less lower than the melting point of the thermoplastic resin. The process of obtaining a nonwoven fabric sheet and then winding it up to obtain a nonwoven fabric roll.

Examples of the method for producing the long fiber nonwoven fabric constituting the nonwoven fabric roll of the present invention include a spunbond method, a flash spinning method, a wet method, a card method, and an airlaid method.

Among these, a spunbond nonwoven fabric produced by a spunbond method is an example of a preferred embodiment. Spunbond nonwoven fabric, which is a long fiber nonwoven fabric made of thermoplastic filaments, is preferably used because it has excellent productivity, is low cost, and can provide high mechanical strength.

In the present invention, when a core-sheath type composite fiber is used as the fiber constituting the nonwoven fabric, a common composite method can be adopted for manufacturing the composite fiber.

The composite fiber is preferably a composite fiber in which a low melting point polymer having a melting point lower than the melting point of the high melting point polymer is arranged around a high melting point polymer.

By using such composite fibers, the long fibers are easily fused firmly, and as a result, the fluffing of the surface can be suppressed and a smooth surface can be easily obtained. Furthermore, when used as a housewrap material, for example, in addition to the fact that the fibers are strongly fused to each other, the fusion point of the fibers is lower than that of a mixture of fibers with different melting points. Since the number can be increased, mechanical strength can also be improved.

The main component here refers to a component that accounts for 50% by mass or more of the components of the composite fiber.

The difference in melting point between the above-mentioned high melting point polymer and low melting point polymer is preferably 10°C or more and 110°C or less. By setting the difference in melting point to 10°C or more, more preferably 20°C or more, even more preferably 30°C or more, desired thermal adhesiveness can be obtained. In addition, by setting the temperature to 110°C or lower, more preferably 100°C or lower, and still more preferably 90°C or lower, it is possible to suppress the low melting point polymer component from being fused to the thermocompression roll during thermocompression bonding, thereby reducing productivity. I can do it.

Further, the melting point of the high melting point polymer in the composite fiber is preferably 160°C or more and 320°C or less. When the temperature is 160°C or higher, more preferably 170°C or higher, and even more preferably 180°C or higher, excellent morphological stability and durability can be obtained. In addition, by setting the temperature to 320°C or lower, more preferably 300°C or lower, and even more preferably 280°C or lower, it is possible to suppress the consumption of a large amount of thermal energy for melting during the production of long fiber nonwoven fabric, which reduces productivity. I can do it.

Specific examples of such a combination of a high melting point polymer and a low melting point polymer (high melting point polymer/low melting point polymer) include polyethylene terephthalate/polybutylene terephthalate, polyethylene terephthalate/polytrimethylene terephthalate, polyethylene terephthalate/polylactic acid, Examples include polyethylene terephthalate/copolymerized polyethylene terephthalate. Isophthalic acid and the like are preferred as the copolymerization component of the copolymerized polyethylene terephthalate.

In addition, in the present invention, the melting point of the thermoplastic resin shall be a value measured as follows.
(1) Using a differential scanning calorimeter, perform one measurement under the following conditions. Note that as the differential scanning calorimeter, "Q100" manufactured by TA Instruments, etc. is used.
・Measurement atmosphere: Nitrogen flow (150mL/min)
・Temperature range: 30-350℃
・Heating rate: 20℃/min ・Sample amount: 5mg
(2) Calculate the average value of the endothermic peak apex temperature and use it as the melting point of the measurement target.
However, if there are multiple endothermic peaks in the resin before fiber formation, the peak apex temperature on the highest temperature side is used. Furthermore, when fibers are to be measured, the measurement is performed in the same manner, and the melting point of each component is estimated from a plurality of endothermic peaks. In this case, the endothermic peak due to the composite fiber is the endothermic peak (A) on the highest temperature side, the endothermic peak that appears on the side with a shorter elapsed time (the side where the peak appears earlier), and the endothermic peak that appears next to the endothermic peak on the highest temperature side. It is a peak group showing a high peak (endothermic peak (B)), and the endothermic peak (A) indicates the melting point of the high melting point polymer, whereas the endothermic peak (B) above indicates the melting point of the low melting point polymer. It indicates the melting point.

The proportion of the low melting point polymer in such a composite fiber is preferably 10% by mass or more and 70% by mass or less in the composite fiber. By setting the content to 10% by mass or more, more preferably 15% by mass or more, still more preferably 20% by mass or more, desired thermal adhesiveness can be obtained. In addition, by setting the content to 70% by mass or less, more preferably 60% by mass or less, and still more preferably 50% by mass or less, the low melting point polymer component is fused to the thermocompression roll during thermocompression bonding, thereby reducing productivity. Can be suppressed.

Examples of the composite form of such a composite fiber include a concentric core-sheath type, an eccentric core-sheath type, and an island-in-the-sea type. Among these, a concentric core-sheath type, particularly an embodiment in which a low melting point polymer is used as the sheath component, is preferred in that the fibers can be firmly adhered to each other by thermocompression bonding. When the composite fiber has an irregular cross-sectional shape, it is preferable that the low melting point polymer component exists near the outer periphery of the fiber cross section so that it can contribute to thermocompression bonding.

The long fibers made of the nonwoven fabric roll of the present invention are produced by melting and extruding a thermoplastic resin from a spinneret, applying gas through a cooling section in a direction perpendicular to the running direction of the long fibers, and then After applying gas through the gas supply part in a direction perpendicular to the gas supply part, the long fibers are passed through an intake and exhaust part with a length of 1 mm or more and 150 mm or less, which is provided directly below the gas supply part, and the fibers are sucked. Stretch.

By carrying out the procedure described above, the spun long fibers are cooled, the air flow due to suction stretching is suppressed while the inflow of outside air is suppressed, and the fabric weight distribution in the width direction is not deteriorated due to yarn breakage or yarn shaking. A web can be formed.

The gas supply section is additionally installed at the bottom of the cooling section in order to minimize yarn sway; however, in order to minimize yarn sway, the width of the gas supply section is wider than the width of the cooling section. It is preferable that it is long. Note that the width of the cooling section here refers to the shortest distance among the walls of the passage through which the yarn runs in the cooling section, and the width of the gas supply section refers to the width of the gas supply section. , refers to the shortest distance among the distances between the walls of the passage along which the yarn runs.

In addition, there is no particular specification as long as the gas is applied through the gas supply section in a direction perpendicular to the running direction of the long fibers, but a mesh may be used to rectify the flow within the gas supply section to suppress yarn sway. It is preferable that it is included. The size of this mesh is preferably 20 mesh or more, more preferably 40 mesh or more, and even more preferably 100 mesh or more.

Regarding the suction/exhaust part, in order to take in the inflow of gas necessary for suction, it is preferable to arrange a mesh structure or a plate with regularly arranged holes such as a staggered pattern.

The length of the intake/exhaust part is preferably 1 mm or more and 150 mm or less. If the length of the suction/exhaust part is 1 mm or more, more preferably 5 mm or more, and still more preferably 10 mm or more, the inflow of gas necessary for suction is suppressed from increasing the wind speed at the suction/exhaust part, and long fibers are prevented from breaking. can be reduced. Further, if the length of the intake and exhaust part is 150 mm or less, more preferably 100 mm or less, and even more preferably 75 mm or less, it is possible to suppress the yarn sway of the long fibers due to the inflow of outside air, and the fibers have excellent fabric weight distribution in the width direction. You can get the web.

As for suction stretching, it is common to use high-speed suction gas to stretch the fibers. At this time, the fibers may shrink during temporary adhesion or thermocompression bonding in the subsequent process, causing wrinkles, or the low-melting point polymer component may be removed from the heat roll. It is preferable that the long fibers constituting the obtained fibrous web are oriented and crystallized to a higher degree, and the spinning speed is preferably 3000 m/min or more, so that productivity does not decrease due to fusion of the fibers. The speed is preferably 3,500 m/min or more, and even more preferably 4,000 m/min or more. Furthermore, by suppressing excessive oriented crystallization of fibers, it is possible to obtain thermal adhesion that contributes to improving the mechanical strength of the spunbond nonwoven fabric, so the spinning speed is preferably 5500 m/min or less, and more preferably Preferably it is 5000 m/min or less, more preferably 4500 m/min or less.

The fiber web collected and formed on the net conveyor is not limited in any way as long as it is brought into contact with a pair of flat rolls to suppress fuzzing, but the fiber web is heated to a predetermined temperature and then Heat treatment in contact with the web is preferred, and a flat roll is a roll with no unevenness on its surface.

Furthermore, it is preferable to preheat the fiber web collected on the net conveyor before thermally bonding it, and then continuously perform thermocompression bonding. In this preheating, a method is preferably used in which the collected fiber web is preheated with hot air from above a net conveyor, or a flat roll is installed on the net conveyor, and preheating is performed between the net conveyor and the flat roll.

Preferably, this preheating brings the temperature of the nonwoven web to 100°C or more and 160°C or less. By setting the temperature of this nonwoven web to 100°C or higher, preferably 110°C or higher, and more preferably 120°C or higher, the transportability of the nonwoven web can be improved. On the other hand, by controlling the temperature of the nonwoven web to 160°C or lower, preferably 150°C or lower, and more preferably 140°C or lower, appropriate crystallization of the nonwoven web can be promoted.

Regarding the heat treatment process in thermal bonding, the surface temperature of the flat roll is preferably 30°C or more and 70°C or less lower than the melting point of the polymer with the lowest melting point that constitutes the fibrous web present on the surface of the fibrous web. . That is, when this melting point is (Tm), the surface temperature of the flat roll is preferably (Tm-30)°C or more and (Tm-70)°C or less, and (Tm-35)°C or more (Tm-65). )°C or less is more preferable, and (Tm-40)°C or more and (Tm-60)°C or less is most preferable. If the surface temperature of the flat roll is lower than (Tm-70)°C, the thermocompression bonding of the fiber web will be insufficient, the surface smoothness will be impaired, and when used as a house wrap material, it will not be possible to bond with the waterproof tape. The adhesive strength will be poor. Further, if the surface temperature of the flat roll is higher than (Tm-30)°C, the heat treatment becomes too strong, and excessive fusion can be suppressed.

The linear pressure when thermally bonding the fibrous web with a pair of flat rolls is preferably in the range of 100 N/cm or more and 900 N/cm or less, more preferably in the range of 200 N/cm or more and 800 N/cm or less. When the linear pressure is 100 N/cm or more, a linear pressure sufficient for forming a fibrous web can be obtained. When the linear pressure is 900 N/cm or less, sufficient mechanical strength can be obtained without the adhesion between the fibers becoming too strong.

The nonwoven fabric sheet obtained by thermal bonding is wound up to obtain a nonwoven fabric roll, but if necessary, dividing slits may be formed in the width direction using a winding machine. The winding methods for nonwoven fabric rolls include the center winding method, in which the material web is wound around the surface of the winding roll by rotationally driving the central axis of the core, and the center winding method, in which the material web is wound around the surface of the winding roll by rotating the central axis of the core, and the roll core is placed on one or more support rollers. A surface winding method may be used, in which the material web is wound around the roll core by placing the material web on the roll core and rotating at least one of the support rollers. Further, it is preferable that the holding pressure and the winding tension can be adjusted and winding can be performed more stably.

As for the nonwoven fabric roll bonded by thermocompression, it is preferable to slit both ends when winding it up as a nonwoven fabric roll, since a difference in shrinkage occurs between the sheet ends and the center area. The width of the ear slit is preferably 1 cm or more and 10 cm or less. Preferably, the range is 1 cm or more and 10 cm or less, more preferably 2 cm or more and 9 cm or less, and even more preferably 3 cm or more and 8 cm or less. If the ear slit width is 1 cm or more, it is possible to wind up the film without causing slit defects due to breakage when the ear slit portion meanders. Furthermore, if the length is 10 cm or less, loss of the nonwoven fabric roll can be reduced and productivity is also excellent.

Next, the nonwoven fabric roll of the present invention and its manufacturing method will be specifically described based on Examples. However, the present invention is not limited only to these examples. In the measurement of each physical property, unless otherwise specified, the measurement was performed based on the method described above.

[Measuring method]
(1) Intrinsic viscosity IV:
The intrinsic viscosity IV of the polyethylene terephthalate resin was measured by the following method. 8 g of a sample was dissolved in 100 mL of orthochlorophenol, and the relative viscosity η _r was determined by the following formula using an Ostwald viscometer at a temperature of 25°C.
・η _r =η/η ₀ = (t×d)/(t ₀ ×d ₀ )
(Here, η is the viscosity of the polymer solution, η ₀ is the viscosity of orthochlorophenol, t is the falling time of the solution (seconds), d is the density of the solution (g/cm ³ ), and t ₀ is the viscosity of orthochlorophenol. The falling time (seconds) and _d0 represent the density of orthochlorophenol (g/cm ³ ), respectively.)
Next, the intrinsic viscosity IV was calculated from the above relative viscosity η _r using the following formula.
- Intrinsic viscosity IV=0.0242η _r +0.2634.

(2) Melting point (℃):
The melting point of the thermoplastic resin used was measured using a differential scanning calorimeter (TA Instruments Q100) under the above conditions, and the average value of the endothermic peak apex temperature was calculated and used as the melting point of the measurement target.

(3) Winding hardness (g) of nonwoven fabric roll, maximum value of hardness difference (g) between two adjacent measured values when winding hardness is measured at 5 cm intervals in the width direction of the nonwoven fabric roll:
The hardness difference in the width direction of the winding hardness of a nonwoven fabric roll, the maximum value H (g) of the hardness difference between two adjacent measured values when measuring the winding hardness at 5 cm intervals in the width direction of the nonwoven fabric roll, is the hardness difference in the width direction of the nonwoven fabric roll. The hardness was measured by the method described above using "RoQ Roll Hardness Measuring Instrument" manufactured by ACA System. In addition, the maximum value (g) of the hardness difference between two adjacent measured values when the winding hardness is measured at 5 cm intervals in the width direction of the nonwoven fabric roll is hereinafter abbreviated as the maximum value H of the adjacent hardness difference, including in Table 1. There are things to do.

(4) Adhesive strength between nonwoven fabric and waterproof tape (N/25mm):
JIS Z0237:2022 "Adhesive Tape/Adhesive Sheet Test Methods", "10.3.2 Test Procedures", "a) Procedure for testing adhesive strength to test plate", and "g) Testing in a low temperature environment" 180° peel adhesion to the test plate in a low-temperature environment" under the following conditions. The peel adhesive strength was measured and evaluated using the nonwoven fabric of the outermost layer of the roll. In addition, in Table 1, it was simply written as "adhesive strength with waterproof tape".
・Test temperature: -10℃
・Waterproof tape used: “Zenten (registered trademark) tape No. 692” manufactured by Nitto Denko Corporation
・Testing machine: “AGS-X” manufactured by Shimadzu Corporation was used as the tensile testing machine (testing device A) ・Peeling speed: 30 ± 1 cm/min [Example 1]
A composite fiber consisting of a core component and a sheath component was used as the fiber whose main component is a thermoplastic resin. The thermoplastic resin used is shown below.
Core component: polyethylene terephthalate resin having an intrinsic viscosity IV of 0.65, a melting point of 260°C, and containing 0.3% by mass of titanium oxide, dried to a moisture content of 10 ppm or less.
Sheath component: copolymerized polyethylene terephthalate resin with an intrinsic viscosity IV of 0.66, an isophthalic acid copolymerization rate of 11 mol%, a melting point of 230°C, and a titanium oxide content of 0.2% by mass, and dried to a moisture content of 10 ppm or less. thing.

The above core component was melted at 295°C and the sheath component at 280°C, and the core/sheath composite ratio was 80/20 by mass to form a concentric core-sheath type with a circular cross section. A spun long fiber was obtained.
Gas is applied to the spun long fibers through a cooling section in a direction perpendicular to the running direction, and then gas is applied through a gas supply section with a length of 100 mm in a direction perpendicular to the running direction of the long fibers. I guessed it. Note that the gas supply section was 50 mm larger in width than the cooling section, and had a 100 mesh wire mesh mounted inside. After applying gas to the spun filaments through the gas supply section, the fibers were passed through an intake/exhaust section with a length of 20 mm provided directly below the gas supply section, and were suction-stretched at a spinning speed of 4300 m/min using compressed air. , and collected on a moving net conveyor to obtain a fiber web. After preheating the fibrous web collected as above at 160°C, it was passed between a pair of upper and lower metal flat rolls, and thermocompression bonded at a linear pressure of 700 N/cm at a surface temperature of each flat roll of 185°C. It is a nonwoven fabric roll made by winding up a long fiber nonwoven fabric with an average single fiber diameter of 11.3 μm, a basis weight of 25 g/m ² , and an apparent density of 0.50 g/cm ³ , and the roll width is 2.3 m. A nonwoven fabric roll with a winding length of 11,000 m was obtained.

Then, the 11,000 m roll of nonwoven fabric was wound onto a paper tube with an inner diameter of 7.6 cm and a wall thickness of 6 mm at a sheet winding tension of 120 N/m while slitting 0.1 m at both ends using a twin-axis surface type winder. A nonwoven fabric roll having a roll width of 2.1 m and a winding length of 2500 m was obtained. The rolled nonwoven fabric roll has no wrinkles, winding deviation is 0 mm, winding hardness is 29.2 g, maximum adjacent hardness difference H is 4.6 g, winding diameter is 0.40 m, thickness of roll outer layer nonwoven fabric and roll inner layer nonwoven fabric The thickness of the tape was 0.05 mm and 0.05 mm, respectively, and the adhesive force between the nonwoven fabric and the waterproof tape was 15.1 N/25 mm.

[Example 2]
In Example 1, the winding length of the nonwoven fabric roll was changed from 2500 m to 11000 m in the winding machine, but the same method was used.

The rolled nonwoven fabric roll has no wrinkles, winding deviation is 0 mm, winding hardness is 32.3 g, maximum adjacent hardness difference H is 5.2 g, winding diameter is 0.80 m, thickness of roll outer layer nonwoven fabric and inner layer nonwoven fabric The thickness of the tape was 0.05 mm and 0.05 mm, respectively, and the adhesive force between the nonwoven fabric and the waterproof tape was 15.2 N/25 mm.

[Example 3]
In Example 1, a nonwoven fabric roll having a roll width of 2.3 m was sampled at 3.2 m, and slits were made at both ends of 0.1 m using a winder to obtain a nonwoven fabric roll with a roll width of 3.0 m. The same method was used except for the following.

The rolled nonwoven fabric roll has no wrinkles, winding deviation is 0 mm, winding hardness is 29.3 g, maximum adjacent hardness difference H is 4.8 g, winding diameter is 0.40 m, thickness of roll outer layer nonwoven fabric and inner layer nonwoven fabric The thickness of the tape was 0.05 mm and 0.05 mm, respectively, and the adhesive force between the nonwoven fabric and the waterproof tape was 15.1 N/25 mm.

[Example 4]
Example 1 was carried out in the same manner as in Example 1, except that when obtaining the fibrous web, the length of the gas supply section was changed from 100 mm to 20 mm, and the length of the air intake and exhaust section was changed from 20 mm to 100 mm.

The rolled nonwoven fabric roll has no wrinkles, winding deviation is 0 mm, winding hardness is 29.1 g, maximum adjacent hardness difference H is 4.7 g, winding diameter is 0.40 m, thickness of roll outer layer nonwoven fabric and inner layer nonwoven fabric The thickness of the tape was 0.05 mm and 0.05 mm, respectively, and the adhesive force between the nonwoven fabric and the waterproof tape was 15.3 N/25 mm.

[Example 5]
Example 1 was carried out in the same manner as in Example 1, except that the length of the intake and exhaust part was changed from 20 mm to 5 mm when obtaining the fibrous web.

The rolled nonwoven fabric roll has no wrinkles, winding deviation is 0 mm, winding hardness is 29.2 g, maximum adjacent hardness difference H is 4.6 g, winding diameter is 0.40 m, thickness of roll outer layer nonwoven fabric and inner layer nonwoven fabric The thickness of the tape was 0.05 mm and 0.05 mm, respectively, and the adhesive force between the nonwoven fabric and the waterproof tape was 15.2 N/25 mm.

[Example 6]
Example 1 was carried out in the same manner as in Example 1, except that the speed of the net conveyor was adjusted to obtain a fibrous web with a basis weight of 80 g/m ² , and a nonwoven fabric roll with an apparent density of 0.80 g/cm ³ was obtained.

The rolled nonwoven fabric roll has no wrinkles, winding misalignment is 0 mm, rolling hardness is 41.3 g, maximum adjacent hardness difference H is 8.6 g, winding diameter is 0.54 m, thickness of roll outer layer nonwoven fabric and inner layer nonwoven fabric. The thickness of the tape was 0.10 mm and 0.10 mm, respectively, and the adhesive force between the nonwoven fabric and the waterproof tape was 20.1 N/25 mm.

[Comparative example 1]
In Example 1, when obtaining the fibrous web, the length of the gas supply section was changed from 100 mm to 0 mm (that is, no gas supply section was provided), and the length of the intake and exhaust section was changed from 20 mm to 150 mm. Other than that, the same method was used. When obtaining a fibrous web, it was confirmed that the long fibers swayed significantly at both ends. The obtained nonwoven fabric had a basis weight of 25 g/m ² and an apparent density of 0.50 g/cm ³ .

Although the winding deviation was 0 mm in the nonwoven fabric roll wound by the winder, wrinkles occurred, the winding hardness was 29.2 g, the maximum adjacent hardness difference H was 5.8 g, the winding diameter was 0.40 m, The thickness of the roll outer layer nonwoven fabric and the inner layer nonwoven fabric were 0.05 mm and 0.05 mm, respectively, and the adhesive force between the nonwoven fabric and the waterproof tape was 15.0 N/25 mm.

[Comparative example 2]
Example 1 was carried out in the same manner as in Example 1, except that the length of the suction/exhaust part was changed from 20 mm to 0 mm (that is, no suction/exhaust part was provided) when obtaining the fibrous web. When obtaining a fibrous web, the long fibers swayed across the entire width and frequently broke, and the fibrous web wound around the flat roll during thermal bonding, making it impossible to collect it.

[Comparative example 3]
Comparative Example 1 was carried out in the same manner as in Comparative Example 1, except that the speed of the net conveyor was adjusted to obtain a fibrous web with a basis weight of 80 g/m ² . When obtaining a fibrous web, it was confirmed that the long fibers swayed significantly at both ends, similar to Comparative Example 1. The obtained nonwoven fabric had a basis weight of 80 g/m ² and an apparent density of 0.80 g/cm ³ .

Although the winding deviation was 0 mm in the nonwoven fabric roll wound by the winder, wrinkles occurred, the winding hardness was 41.2 g, the maximum adjacent hardness difference H was 12.8 g, the winding diameter was 0.54 m, The thickness of the roll outer layer nonwoven fabric and the inner layer nonwoven fabric were 0.10 mm and 0.10 mm, respectively, and the adhesive strength between the nonwoven fabric and the waterproof tape was 19.9 N/25 mm.

[Comparative example 4]
In Example 1, the speed of the net conveyor was adjusted to obtain a fiber web with a basis weight of 30 g/ ^m2 , and the collected fiber web was preheated at 140°C, and then an embossed pattern with a compression rate of 16% was formed on the upper side. The process was carried out in the same manner, except that the applied roll was passed between heat embossing rolls consisting of a metal roll with a flat bottom, and the surface temperature of each roll was 190°C, and thermocompression bonding was carried out at a linear pressure of 700 N/cm. A 2.3 m wide 8500 m roll of nonwoven fabric having an average single fiber diameter of 11.3 μm, a basis weight of 30.0 g/m ² , and an apparent density of 0.23 g/cm ³ was obtained.
After that, the 8,500 m roll of nonwoven fabric was wound onto a paper tube with an inner diameter of 7.6 cm and a wall thickness of 6 mm at a sheet winding tension of 120 N/m while slitting 0.1 m at both ends using a twin-axis surface type winder. A roll of nonwoven fabric with a width of 2.1 m was obtained. The rolled nonwoven fabric roll has no wrinkles, winding misalignment is 0 mm, winding hardness is 20.0 g, maximum adjacent hardness difference H is 1.4 g, winding diameter is 1.03 m, thickness of roll outer layer nonwoven fabric and inner layer nonwoven fabric The thickness of the tape was 0.13 mm and 0.13 mm, respectively, and the adhesive force between the nonwoven fabric and the waterproof tape was 7.6 N/25 mm.

<Summary>
In addition, the nonwoven fabric rolls obtained in the above Examples and Comparative Examples were sent out and bonded to a porous polyethylene film with a thickness of 0.028 mm and a basis weight of 28 g/m ² by hot melt, and the bonding workability with the film was confirmed. .

As a result, the nonwoven fabric rolls of Examples 1 to 6 could be processed without any wrinkles and without any particular problem in bonding properties. On the other hand, in Comparative Examples 1 and 3, wrinkles occurred and workability was poor.

Furthermore, in Examples 1 to 6 and Comparative Examples 1 and 3, all nonwoven fabrics had smooth surfaces and excellent adhesion to waterproof tapes of 15 N/25 mm or more. On the other hand, in Comparative Example 4, the nonwoven fabric roll was partially heat-pressed using a roll with an embossed pattern, and the roll had poor smoothness and poor adhesion to the waterproof tape.

From the above results, the nonwoven fabric roll of the present invention was found to have excellent adhesion to waterproof tapes, and even when the roll was made wide, there were no winding wrinkles during winding, and it was also excellent in adhesion to films.

The nonwoven fabric roll of the present invention has a smooth surface, has no wrinkles when rolled up even when rolled up in a wide width, and has excellent lamination properties with films, so it is especially suitable for use as house wrap materials. It can be suitably used in a wide range of fields.

Claims (7)

A nonwoven fabric roll formed by winding up a long fiber nonwoven fabric made of fibers containing a thermoplastic resin as a main component, wherein the apparent density of the long fiber nonwoven fabric is 0.40 g/cm ³ or more and 0.85 g/cm ³ The nonwoven fabric roll is as follows, the winding hardness of the nonwoven fabric roll is 23.0 g to 50.0 g, and satisfies the following formula (1).
H < 1.97×10 ^-5 × ((L×W)/S) -5.3 ... (1)
here,
H is the maximum value (g) of the hardness difference between two adjacent measured values when the winding hardness is measured at 5 cm intervals in the width direction of the nonwoven fabric roll,
L is the winding length (m) of the nonwoven fabric roll;
W is the basis weight of the long fiber nonwoven fabric (g/m ² );
S is the average value (m ² ) of the cross-sectional area of both ends in the direction perpendicular to the width of the nonwoven fabric roll. According to claim 1, the winding length L of the nonwoven fabric roll is 100 m or more and 11,500 m or less, and the difference between the thickness of the long fiber nonwoven fabric in the outer layer of the roll and the thickness of the long fiber nonwoven fabric in the inner layer of the roll is 0.100 mm or less. non-woven roll. The nonwoven fabric roll according to claim 1 or 2, wherein the nonwoven fabric roll has a roll width of 0.5 m or more and 3.1 m or less. The nonwoven fabric roll according to any one of claims 1 to 3, wherein the thermoplastic resin is a polyester resin. The method for manufacturing a nonwoven fabric roll according to any one of claims 1 to 4, wherein the following steps (a) to (c) are sequentially performed.
(a) After obtaining long fibers by spinning a thermoplastic resin from a spinneret having discharge holes, gas is applied through a cooling section in a direction perpendicular to the running direction of the long fibers, and then the long fibers are After applying gas through a gas supply section in a direction perpendicular to the running direction of the fiber, the long fibers are passed through an intake and exhaust section with a length of 1 mm or more and 150 mm or less, which is provided directly below the gas supply section. (b) Collecting the drawn long fibers on a moving net conveyor to form a fibrous web. (c) The fibrous web is After obtaining a nonwoven fabric sheet by thermally bonding with a linear pressure of 100 N/cm or more and 900 N/cm or less using a pair of flat rolls whose roll surface temperature is 30° C. or more and 70° C. or less lower than the melting point of the thermoplastic resin. , winding process to obtain a nonwoven fabric roll The method for manufacturing a nonwoven fabric roll according to claim 5, wherein the step (a) is the following (a'), and the melting point of the thermoplastic resin in the step (c) is the melting point of the low melting point polymer.
(a') A high melting point polymer and a low melting point polymer having a melting point lower than the melting point of the high melting point polymer by 10° C. or more and 110° C. or less are spun from a composite spinneret having discharge holes. After obtaining long fibers covered with a low melting point polymer without exposing the coalescence, gas is applied through a cooling section in a direction perpendicular to the running direction of the long fibers, and then the long fibers are heated in the running direction of the long fibers. After applying gas through the gas supply section in a direction perpendicular to the gas supply section, the long fibers are passed through an intake and exhaust section with a length of 1 mm or more and 150 mm or less, which is provided directly below the gas supply section, and the fibers are spun. Step of suction stretching at a speed of 3000 m/min or more and 5500 m/min or less The nonwoven fabric according to claim 5 or 6, wherein the thermoplastic resin in the step (a) is a polyester resin, or the high melting point polymer and/or low melting point polymer in the step (a') is a polyester resin. How to make rolls.