CN1824867A - Non-weaving fabric and producing method - Google Patents
Non-weaving fabric and producing method Download PDFInfo
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- CN1824867A CN1824867A CNA2006100095350A CN200610009535A CN1824867A CN 1824867 A CN1824867 A CN 1824867A CN A2006100095350 A CNA2006100095350 A CN A2006100095350A CN 200610009535 A CN200610009535 A CN 200610009535A CN 1824867 A CN1824867 A CN 1824867A
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Abstract
The invention relates to a non-woven cloth made from hot air method, wherein said cloth comprises the first and second layers; the first layer has one surface; the second layer has another surface of said non-woven cloth; the density of second layer is lower than the first layer; at least the fiber section of first layer is flat, whose long axle is along the non-woven cloth; the average bias SMD of surface roughness at one side of first layer is not higher than 2.5 mum; the average bias MMS of friction factor is lower than 0.008; the linearity LC of compress character of non-woven cloth is not higher than 0.3, while the bend rigidity B is not higher than 0.03cN*cm<SUP>2</SUP>/cm; and the inventive non-woven cloth is best made by rolling the non-woven cloth obtained by hot air cloth in several steps; any rolling process is in room temperature, to be rolled at 20-200N/cm, with metallic rolling roller and the resin whose D rigidity (JIS 6253) is 40-100degrees.
Description
Technical field
The present invention relates to nonwoven fabric and manufacture method thereof
Background technology
When judging the feel of nonwoven fabric,, investigate the relation between being out of shape such as the elongation of itself and nonwoven fabric, wrinkling, bending by apply various power to nonwoven fabric normally with pinching, gently drag, touch or method such as bending.The feel of nonwoven fabric is judged from above-mentioned diversified angle comprehensively.
The surface smoothing of one of key element of relevant judgement nonwoven fabric feel, to improve this characteristic is purpose, proposed a kind ofly have up and down double-layer structure, and the fiber that the upper strata comprised has used the nonwoven fabric (with reference to the clear 55-158367 communique of Japanese Patent Application Laid-Open) of the thinner fiber of the fiber that comprises than lower floor.This nonwoven fabric is a kind of chemical bond (chemical bonded) nonwoven fabric, and having with the hydrophobic fibre is the upper and lower that main material constitutes, and upper surface smoothly and by the fiber number fiber thinner than lower floor constitutes to high-density.In nonwoven fabric, the combination of the crosspoint between the fiber by adhesive.This nonwoven fabric of result lacks flexibility or the drapability (drape) that cloth had.In addition, this nonwoven fabric has the peculiar sense of being clamminess of adhesive.Therefore, the comprehensive feel of this nonwoven fabric does not claim well.
In addition, be purpose to improve surface smoothing, the fluffing that has also proposed a kind of surface has obtained the surficial sheets (with reference to Japanese Patent Application Laid-Open 2003-235896 communique and Te Kai 2003-265528 communique) of the absorbent commodity of inhibition.Open in the 2003-235896 communique the spy, by containing superficial layer and carrying out the stacked surficial sheets that obtains with 2 layers of above-mentioned superficial layer stacked the 2nd layer or more multi-layered layer, wherein said superficial layer is to depress by the top of this staple fibre that will form web of staple fibers (web) with the hot-rolling that is heated to 120～130 ℃ and give prominence to from its surface to obtain, and described the 2nd layer is to be obtained by the fiber web that is mixed with natural fabric.On the other hand, open in the 2003-265528 communique the spy, by nonwoven fabric is clipped between two rollers or roller is rolled across on nonwoven surface and with the fluffing fiber overwhelm in nonwoven surface.The fluffing that suppresses nonwoven surface is important factor for improving feel.But, only having suppressed fluffing, comprehensive feel does not also claim well, at other essential factor that the raising of feel is produced considerable influence, i.e. flexibility and loftiness aspect and insufficient.
Summary of the invention
The invention provides a kind of nonwoven fabric of making by hot blast method (through-air), it contains layers 1 and 2, the 1st a layer of surface that has this nonwoven fabric, the 2nd layer of another surface that has this nonwoven fabric, the density of the 2nd layer density than the 1st layer is low, wherein, the cross section of the fiber that comprises at least the 1 layer is flat pattern, the long axis direction in the cross section of this fiber roughly is orientated on the in-plane of above-mentioned nonwoven fabric, the average deviation SMD of the surface roughness on the surface of the 1st a layer of side is 2.5 μ m or following, and the average deviation MMD of coefficient of friction is lower than 0.008, the linear property LC of the compression property of above-mentioned nonwoven fabric be 0.3 or below, and flexural rigidity B is 0.03cNcm
2/ cm or following.
In addition, the invention provides a kind of absorbent commodity, it has above-mentioned nonwoven fabric, and disposes according to the surface of the 1st a layer of side in this nonwoven fabric and user's the contacted mode of skin, and wherein, the 1st layer mass area ratio is 5～15g/m
2, the 2nd layer mass area ratio is 5～45g/m
2, the mass area ratio of nonwoven fabric integral body is 10～50g/m
2
In addition, the invention provides a kind of manufacture method of nonwoven fabric, it comprises: the nonwoven fabric grey cloth that is obtained by the hot blast method is implemented calendering (calender) processing, wherein, above-mentioned calendering adds the work point multistage and carries out, and the calendering in any one stage processing all is at ambient temperature, and with the line pressure of 20～200N/cm, using metal calender and D hardness (JIS K6253) is that 40～100 resin roll of spending are carried out.
And then the present invention also provides a kind of processing method of nonwoven fabric, it comprises: at ambient temperature, line pressure with 20～200N/cm, using metal calender and D hardness (JIS K6253) is the nonwoven fabric grey cloth enforcement calendering processing of resin roll to being obtained by the hot blast method of 40～100 degree, when making the fibre deformation that comprises in this nonwoven fabric grey cloth become flat pattern, the long axis direction in the cross section of the fiber that is deformed into flat pattern roughly is orientated on the in-plane of this nonwoven fabric grey cloth.
Description of drawings
Fig. 1 is the schematic diagram that is used to make the preferred embodiment of nonwoven fabric of the present invention.
Fig. 2 is the surface electronic microphotograph of the 1st a layer of side of the nonwoven fabric that obtains among the embodiment 1.
Fig. 3 is the electron micrograph of the vertical section of the nonwoven fabric that obtains among the embodiment 1.
Fig. 4 is the surface electronic microphotograph of the 1st a layer of side of the nonwoven fabric that obtains in the comparative example 1.
The specific embodiment
Below describe with regard to the preferred embodiments of the invention.Nonwoven fabric of the present invention is to adopt the hot blast manufactured.So-called hot blast method is that carding fiber net fiber webs such as (carded web) is placed on the WEB and cylinder of gas permeability, makes the bonding method of carrying out nonwoven fabricization of crosspoint heat fusing that constitutes fiber by blowing hot blast.By adopting the hot blast method, thus with the manufacture method that adopts other, the situation of manufacturing nonwoven fabric such as the chemical bond method of for example introducing in the background technology is compared, and can productivity ratio obtain the good nonwoven fabric of feel well.Nonwoven fabric of the present invention is the nonwoven fabric that has the 1st layer of comprising one surface and comprise the 2nd layer the sandwich construction on another surface.This sandwich construction is not limited only to 2 layers, also can be 3 layers or the more multi-layered structure that disposes other layer of 1 layer or multilayer between layers 1 and 2.
The feature of nonwoven fabric of the present invention is: have both staple (1) flatness, (2) flexibility, (3) loftiness of judging feel.The nonwoven fabric of the present invention that has both this three specific character has very good hand feeling.
At first the flatness with regard to nonwoven fabric describes.Flatness mainly is by the 1st layer of characteristic that shows in the nonwoven fabric of the present invention.The cross section of the nonwoven fabric that comprises in the 1st layer is flat pattern.This flat pattern is a reason of giving the nonwoven fabric flatness.From this viewpoint, the flat ratio value (long axis length/minor axis length) in preferred its cross section of the fiber that comprises in the 1st layer be 1.2 or above, be preferably 1.3 or the fiber of above flat pattern especially.The fiber that comprises in the 1st layer preferably on its total length the cross section be flat pattern, but be not limited to this, so long as 70% in the total length or above, particularly 80% or the cross section of above part be flat pattern, then can give desired flatness.The cross section of part is flat pattern between the binding site between the special optimum fiber.In the present invention, preferably make fibre deformation become flat pattern by under given conditions the nonwoven fabric grey cloth being implemented calendering processing like that as described later.
The fiber that comprises in the 1st layer is flat fiber all preferably, but is not limited thereto.When the 1st layer vertical section is amplified the transverse shape of observing fiber with electron microscope, be benchmark with the radical, if 70% or above fiber be flat shape, then can obtain desired flatness.
As the cross section is the fiber of flat pattern, can use the cross section that utilizes the special-shaped nozzle spinning fiber as flat pattern; And the cross section during spinning is not flat, but is processed to the fiber of flat pattern through the back processing after the nonwoven fabric manufacturing.From reason described later as can be known, the preferred in the present invention a kind of fiber in back that uses.
In order to give the nonwoven fabric flatness, the above-mentioned cross section that comprises in the 1st layer is the fiber of flat pattern, and another main points are that the long axis direction in its cross section roughly is orientated on the in-plane of nonwoven fabric.Become too big as the long axis direction in the cross section of fruit fiber and the in-plane angulation of nonwoven fabric, then be difficult to give level and smooth sense of touch.From this viewpoint, especially the 1st layer the surface and near fiber, preferably the long axis direction in its cross section is orientated on the in-plane of nonwoven fabric.What is called roughly is orientated, be meant when the 1st layer vertical section amplified the long axis direction of observing flat fiber with electron microscope, be benchmark with the radical, then 70% or the long axis direction of above fiber become with the in-plane of nonwoven fabric ± 30 degree or with interior angle.
For the long axis direction in the cross section that makes the fiber that comprises in the 1st layer is orientated on the in-plane of nonwoven fabric, such as described later, in the calendering processing of the back operation after making as nonwoven fabric, when fiber process is become flat pattern, the method that the long axis direction in its cross section is orientated on the in-plane of nonwoven fabric is easy, thereby is preferred.
From giving the viewpoint of the better flatness of nonwoven fabric, the fiber that comprises in the 1st layer is preferably fine-titred fiber.This is because adopt fine-titred fiber then can become fine and close in the 1st layer surface.From this viewpoint, the fiber number of the fiber that comprises in the 1st layer is preferably 0.05～2.0dtex, is preferably 0.05～1.5dtex especially.Fiber number is measured according to following method.The vertical section of nonwoven fabric is amplified with electron microscope, observe the cross section of fiber.The area of section of the fiber of the standard thickness of 10 positions of mensuration.Calculate fiber number from the density of this value and resin, with its mean value as fiber number.
For the surface that makes nonwoven fabric becomes level and smooth surface, few this point of the fibre pick on surface is also very important.For the fluffing that makes fiber tails off, importantly make strong bonded between the fiber, do not make the free terminal of fiber be present in the surface of fiber.As mentioned above, because nonwoven fabric of the present invention is to adopt the hot blast manufactured, therefore in order to make strong bonded between the fiber, using easily, melt bonded fiber is favourable.From this viewpoint, it is the hot-melt-bondable fiber of raw material that the fiber that comprises in the 1st layer is preferably with the thermoplastic resin, is preferably the hot-melt-bondable fiber that is made of composite fibres such as core sheath (core-sheath) type or (side-by-side) types arranged side by side especially.In addition as described later, in the operation that adopts hot blast manufactured nonwoven fabric grey cloth, by making the 1st a layer of side, and send hot blast, can further reduce the fibre pick on the surface of the 1st a layer of side from the 2nd layer of one side-blown to poromeric material.
Because the 1st layer have above-mentioned formation, the average deviation (hereinafter referred to as SMD) of the surface roughness of the 1st a layer of side surface in the nonwoven fabric reach 2.5 μ m or following, be preferably 2.3 μ m or following extremely low value like this.The lower limit of SMD is not particularly limited, and is preferred near 0 more, if lower limit is low to moderate 1.0 μ m, particularly about 0.5 μ m, then can give nonwoven fabric sufficient flatness.
In addition, the average deviation (hereinafter referred to as MMD) of the coefficient of friction of the 1st a layer of side surface in the nonwoven fabric reaches and is lower than 0.008, is preferably 0.006 or following so extremely low value.The lower limit of MMD does not have particular restriction, and is preferred near 0 more, if lower limit is low to moderate 0.004, particularly about 0.003, then can give nonwoven fabric sufficient flatness.
SMD and MMD are according to the method for putting down in writing in the following book, and the KESFB4-AUTO-A (trade name) that uses KATO TECH Corporation to make measures.Method below concrete the employing is measured.
River end Ji Xiongzhu, " standardization of hand valuation and parsing ", the 2nd edition, the feel metering of civic organization Japan fibre machinery association (The Textile Machinery Society of Japan) and normalization research committee, clear and distribution on 55 years (1980) July 10.
The assay method of the average deviation SMD of surface roughness
Prepare the test film of 20cm * 20cm, be installed on the testing stand of level and smooth metal flat.Power with 9.8cN (in error ± 0.49) overlays contact on test film.Constant speed with 0.1cm/sec makes test film move horizontally 2cm.Test film is applied the single-axle tension of 19.6cN/cm.Contact constitutes the U word shape that the piano wire of 0.5mm diameter bends to wide 5mm, and is attached on the test film with defeating of 9.8cN.Contact is by the spring roof pressure.Spring constant is set at 24.5cN/mm (in error ± 0.98cN/mm), resonant frequency break away from be set under the surperficial state of contact 30Hz or more than.The measured value of the average deviation of surface roughness is represented with SMD.MD and SD also carry out this mensuration simultaneously, calculate mean value by following formula (1), with its average deviation SMD as surface roughness.
Average deviation SMD={ (the SMD of surface roughness
MD 2+ SMD
CD 2)/2}
1/2(1)
The assay method of the average deviation MMD of coefficient of friction
Prepare the test film of 20cm * 20cm, be installed on the testing stand of level and smooth metal flat.Overlay on test film with the power of 49cN contact-making surface, and make test film move horizontally 2cm with the constant speed of 0.1cm/sec with contact.Test film is applied the single-axle tension of 19.6cN/cm.The contact that uses in the mensuration of contact and surface roughness overlays on test film contact-making surface by weight with the power of 49cN equally with the piano wire of 20 0.5mm diameters side by side and bend to the U word shape of wide 10mm and obtain.The measured value of the average deviation of coefficient of friction MMD value representation.MD and SD also carry out this mensuration simultaneously, calculate mean value by following formula (2), with its average deviation MMD as coefficient of friction.
Average deviation MMD={ (the MMD of coefficient of friction
MD 2+ MMD
CD 2)/2}
1/2(2)
Flexibility with regard to nonwoven fabric describes below.Even the surface of nonwoven fabric is very level and smooth, if but drapability difference and when not soft also can present as the very hard sense of touch of paper, feel can not got well.As the yardstick of degree of the flexibility of expression nonwoven fabric, be flexural rigidity (hereinafter referred to as B) what use in the art.The flexural rigidity of nonwoven fabric of the present invention is low to moderate 0.03cNcm
2/ cm or following is preferably 0.025cNcm
2/ cm or following.If flexural rigidity B surpasses 0.03cNcm
2/ cm then can not give nonwoven fabric sufficient flexibility, can't make comprehensive feel become good.The lower limit of flexural rigidity B is not particularly limited, and is preferred near 0 more, if lower limit is low to moderate 0.015, particularly about 0.01, then can give nonwoven fabric sufficient flexibility.
For to make flexural rigidity B be above-mentioned value or be lower than above-mentioned value, for example nonwoven fabric such as is crumpled at operation, the overall structure of nonwoven fabric is deformed, and (for example make the binding site part distortion between the fiber or it is destroyed) is favourable.Specifically, be that the overall structure of nonwoven fabric is deformed is favourable in calendering processing like that as described later by the back operation after the nonwoven fabric manufacturing.So-called flexural rigidity B among the present invention is meant the value of using pure bending testing machine (KESFB2-AUTO-A that KATO TECH Corporation makes) to measure.Flexural rigidity B measures according to the method for record in above-mentioned " standardization of hand valuation and parsing ".The following method of concrete employing is measured.
The assay method of flexural rigidity B
Prepare the test film of 20cm * 20cm, be installed on the testing stand.Test film is fixed on the chuck of interval 1cm.Curvature K=-2.5～+ 2.5cm
-1Scope in, test film is carried out the pure bending of uniform velocity curvature.Deformation velocity is 0.50cm
-1/ sec carries out 1 cycle (cycle) distortion.Bending rigid value B is according to the record of above-mentioned " standardization of hand valuation and parsing ", according to curvature is the inclination calculating of the moment of flexure theory between 0.5～1.5 and-0.5～-1.5, but in the mensuration of nonwoven fabric, between this curvature, might bend, be difficult to obtain correct test number.Therefore, the flexural rigidity B among the present invention is calculated by the inclination of 0～maximum deflection square (moment) value and 0～minimum bend square value.MD and SD also carry out this mensuration simultaneously, calculate mean value by following formula (3), with it as flexural rigidity B.
Flexural rigidity B={ (B
MD 2+ B
CD 2)/2}
1/2(3)
Loftiness with regard to nonwoven fabric describes below.So-called loftiness, thickness will be returned to this sensation of what degree when referring to nonwoven fabric to be compressed which type of degree on its thickness direction and loosening compression.Yet the flatness such as the front of relevant nonwoven fabric are said, are preferably the 1st layer and contain the thinner fiber of fiber number thick and fast.It is higher promptly to be preferably density.Consequently, iff having only the 1st layer, then nonwoven fabric is very difficult to compression on thickness direction, even and unclamp compression, thickness also is difficult to reply.Therefore in nonwoven fabric of the present invention, use density than the 1st layer low the 2nd layer, and give the nonwoven fabric loftiness by the 2nd layer.Particularly, as described later, in calendering processing, make the 2nd aspect to the resin roll that constitutes and be difficult for applying clamping force by soft material.In this case, if the density of the 2nd layer density than the 1st layer is little by 10～80%, particularly little 20～60% o'clock, then loftiness to give effect obvious.As for the density of each layer, consider that from the viewpoint of giving the nonwoven fabric flatness the 1st layer density is preferably 0.01～0.1g/cm
3, be preferably 0.02～0.05g/cm especially
3On the other hand, consider that from the viewpoint of giving the nonwoven fabric loftiness the 2nd layer density is preferably 0.005～0.04g/cm
3, be preferably 0.01～0.03g/cm especially
3
In order to give nonwoven fabric with loftiness by the 2nd layer, flat few fiber that the collapses when fiber that comprises in the 2nd layer is preferably compression.In order to make it flatly collapse for a short time in when compression, it is favourable using the fiber of heavy denier.From this viewpoint, the fiber number of the fiber that comprises in the 2nd layer is preferably 1.5～5.0dtex, is preferably 1.7～3.0dtex especially.If fiber number is in this scope, then the thickness of the 2nd layer fiber is not easy to have influence on the 1st a layer of side, and the average deviation SMD of the surface roughness of the 1st a layer of side surface and the average deviation MMD of coefficient of friction diminish, and it is good that the flatness of nonwoven fabric becomes.In addition, the fiber number of the fiber that comprises in preferred the 2nd layer is bigger than the fiber number of the fiber that comprises in the 1st layer.At this moment, if the fiber number of the fiber that comprises in the 2nd layer is bigger by 20～200% than the fiber number of the fiber that comprises in the 1st layer, big by 40～150% o'clock particularly, then loftiness to give effect obvious.
The 2nd layer except preferred low-density, consider that from improving the loftiness aspect thickness greatly also is favourable.From this viewpoint, the 2nd layer thickness is preferably 0.3～1.2mm, is preferably 0.4～0.8mm especially.On the other hand, from improving the viewpoint of flatness, the thickness of preferred the 1st layer thickness than the 2nd layer is little, particularly, is preferably 0.05～0.5mm, is preferably 0.1～0.3mm especially.The thickness of nonwoven fabric integral body is preferably 0.5～1.5mm, is preferably 0.5～1.0mm especially.
Because the 2nd layer have above formation, the linear property of the compression property of nonwoven fabric (below be also referred to as LC) reach 0.3 or following, be preferably 0.25 or following extremely low value like this.If LC surpasses 0.3, then can not give nonwoven fabric with sufficient loftiness, can not make comprehensive feel become good.The lower limit of LC is not particularly limited, and is preferred near 0 more, if lower limit is low to moderate 0.2, particularly about 0.15, then can give nonwoven fabric sufficient loftiness.So-called LC among the present invention is meant the value that the KESFB3-AUTO-A that uses KATO-TECH Co., Ltd. to make measures.Method according to record in above-mentioned " standardization of hand valuation and parsing " is measured LC.The following method of concrete employing is measured.
The determination method of the linear property LC of compression property
Prepare the test film of 20cm * 20cm, be installed on the testing stand.Is 2cm with this test film having area
2The steel plate of circular flat between compress.Compression speed is 20 μ m/sec, and compressing maximum loading is 4.9kPa.Recovery Process is also measured with same speed.The linear property LC value representation of compression property.The LC value is defined by following formula (4).
LC＝WC/WOC (4)
In the formula,
WOC＝Pm(T0-Tm)/2
In addition, the thickness of the sample when T0 represents that pressure is 40Pa, the thickness of the sample when Tm is illustrated in maximum pressure Pm (4.9kPa).
The mass area ratio of layers 1 and 2 does not have critical value from the viewpoint that improves feel, can determine aptly according to the concrete purposes of nonwoven fabric.Mass area ratio as for nonwoven fabric also is same.When with nonwoven fabric of the present invention during as the constituent material of absorbent commodity such as disposable diaper and sanitary napkin for example, the 1st layer mass area ratio is preferably 5～15g/m
2, be preferably 7～12g/m especially
2The 2nd layer mass area ratio is preferably 5～45g/m
2, be preferably 7～25g/m especially
2The mass area ratio of nonwoven fabric integral body is preferably 10～60g/m
2, be preferably 15～40g/m especially
2At this moment, the TENSILE STRENGTH of nonwoven fabric is preferably 10～100N/50mm on flow direction (MD), be preferably 20～70N/50mm especially, is preferably 4～15N/50mm on width (CD), is preferably 5～12N/50mm especially.It is that 150mm, draw speed are to measure under the condition of 300mm/min in the chuck spacing that TENSILE STRENGTH is to use extensiometer.
Particularly when nonwoven fabric of the present invention was used as the outmost constituent material of absorbent commodity, the 1st layer mass area ratio was preferably 5～15g/m
2, be preferably 7～12g/m especially
2The 2nd layer mass area ratio is preferably 5～25g/m
2, be preferably 7～20g/m especially
2The mass area ratio of nonwoven fabric integral body is preferably 10～40g/m
2, be preferably 15～30g/m especially
2
Formation fiber for layers 1 and 2 is not particularly limited, and can use the fiber of suitable material according to the concrete purposes of nonwoven fabric.In view of nonwoven fabric of the present invention is to adopt the hot blast manufactured, so preferably the fiber that comprises in each layer is the hot-melt-bondable fiber.In addition, be purpose to give the nonwoven fabric desired function, except the hot-melt-bondable fiber, also can in the 1st layer and/or the 2nd layer, mix a spot of non-melt bonded property fiber, for example artificial silk and cotton, paper pulp etc.In addition, also can in the 1st layer and/or the 2nd layer, mix and have hot-melt-bondable originally, but do not show the fiber of hot-melt-bondable under the melt bonded treatment temperature in the manufacture process of nonwoven fabric of the present invention, for example polyester fiber and polyamide-based fiber etc.The fiber of fiber is long also to be not particularly limited, but from the viewpoint of the formation of the raw fiber net of hot blast method, is preferably the staple fibre about 38～60mm.
Describe with regard to the preferable production process of nonwoven fabric of the present invention below with reference to Fig. 1.Fig. 1 is the schematic diagram that is used to make the preferred embodiment of nonwoven fabric of the present invention.Device 10 shown in Figure 1 has fiber web formation portion 20, heat fusing bonding part 30 and calendering portion 40.
Be provided with the 1st and the 2nd carding machine 21,22 in fiber web formation portion 20.The 1st carding machine 21 is used to make the 1st fiber web of the 1st layer of formation.The 2nd carding machine 22 is used to make the 2nd fiber web of the 2nd layer of formation.Raw fiber is supplied to each carding machine 21,22 from the supply unit (not having diagram) of raw fiber, and its fiber obtains combing.The 1st fiber web 11 and the 2nd fiber web 12 have been formed thus.The 2nd fiber web 12 overlaps on the 1st fiber web.Formed the overlapping fiber web 13 of two layer web thus.
Fiber web 13 is imported heat fusing bonding part 30 by endless belt conveyer (endless belt) 31 conveyances that constitute such as steel wire reticular pattern poromeric materials such as (wire mesh).In heat fusing bonding part 30, the position relative with the fiber web 31 of conveyance on the endless belt conveyer 31 is provided with the air blast 32 that blows hot blast.Be provided with suction box (suction box) 33 across endless belt conveyer 31 and air blast 32 relative positions.When fiber web 13 passes through the below of air blast 32, be heated to the hot blast perforating fiber net 13 of set point of temperature, the hot-melt-bondable fiber that comprise in the fiber web this moment softens or fusion because of hot blast, and combination is carried out in the crosspoint between the fiber.Obtained hot blast method nonwoven fabric 14 thus.The hot blast of perforating fiber net 13 is attracted case 33 and reclaims.
The temperature that blows of hot blast is determined aptly according to the conveyance speed of the fusing point of the formation resin of the hot-melt-bondable fiber that comprises in the fiber web 13, fiber web 13 and mass area ratio etc.When the resin of the bonding composition of heat fusing is polyethylene, consider on the one hand in conjunction with this securely that from making the crosspoint between the fiber preferred hot blast temperature is 120～150 ℃, is preferably 130～145 ℃ especially.According to same reason, the time that blows of hot blast is preferably 5～30 seconds, is preferably 5～20 seconds especially.
When fiber web 13 blowed hot blast, the 1st fiber web 11 1 sides in the fiber web 13 were sent hot blast to conveyer belt 31 from 12 1 side-blowns of the 2nd fiber web.Consequently, the 1st fiber web 11 1 sides are pressed against on the conveyer belt 31, and fluffing is inhibited and forms smooth surface.This from can so that to nonwoven fabric to become level and smooth viewpoint be favourable the surface of the 1st a layer of side.
The nonwoven fabric 14 that obtains by said method is imported into the calendering portion 40 of operation afterwards.In calendering portion 40, nonwoven fabric 14 is endowed multistage calendering processing.Calendering portion 40 has metal calender 41 and the 1st and the 2nd resin roll 42,43.Each resin roll 42,43 relatively disposes according to the mode that contacts with pressure roller 41.Each roller 41,42,43 are configured to vertical-type.The 1st resin roll 42 is configured in the upstream side of the conveyance direction of nonwoven fabric 14, and the 2nd resin roll 43 is configured in the downstream of the conveyance direction of nonwoven fabric 14.
Nonwoven fabric 14 at first is imported between the 1st resin roll 42 and calender 41 that is configured in upstream side, carries out the calendering processing in the 1st stage.At this moment, import nonwoven fabric 14 according to the 1st a layer of side to the mode of calender.By calendering processing, towards the 1st a layer of side of calender 41 by cramping, thereby the fibre deformation that comprises in the 1st layer becomes flat pattern.The 1st layer by cramping and by densification in addition.And then, nonwoven fabric 14 has been applied the effect of " rubbing " by cramping, the part distortion of the binding site between the fiber or destroyed, it is soft that nonwoven fabric 14 becomes.The fiber that comprises in the 2nd layer of the 1st resin roll 42 so be not easy to be subjected to clamping force, therefore is not easy distortion because resin roll 42 is made of soft material.Nor densification easily.The long axis direction that is deformed into the cross section of the fiber that comprises in the 1st layer of flat pattern is orientated on the in-plane of nonwoven fabric 14.
Thereby keep high production rate and make the fibre deformation that comprises the 1st layer become the viewpoint of flat pattern easily from the speed that can keep production line, the line pressure in the calendering processing in the 1st stage is preferably 50～700N/cm, is preferably 100～300N/cm especially.Calender 41 and/or resin roll are used after can being heated to set point of temperature, also can use under non-heated condition.In preferred calender 41 and the resin roll 42,43 any used under non-heated condition, and calendering processing is carried out at ambient temperature.Calender 41 can be a flat roll of having implemented mirror finish, also can be to have applied trickle concavo-convex concavo-convex rollers such as pears surface.As resin roll 42, can use the roller that for example constitutes by resins such as vulcanie, silicon rubber, polyurethane rubber, NBR, EPDM.The D hardness of these resins (JIS K6253) is preferably 40～100 degree, is preferably 70～95 degree especially.By using 40 degree or above resin roll, then the flat ratio in the cross section of the 1st a layer of side fiber increases, and can give sufficient flatness.In addition, the overall structure of the nonwoven fabric easy deformation that becomes can be given sufficient flexibility.By using 100 degree or following resin roll (comprising metallic roll etc.), then the density of fiber can not become too high, can give sufficient loftiness.Therefore, be not easy to occur paper very hard sense of touch like that, the bad inappropriate like this situation of feel therefore can not occur.
Then, nonwoven fabric is imported between the 2nd resin roll 43 and calender 41 that is configured in the downstream, is endowed the calendering processing of second stage.Also be to import nonwoven fabric 14 according to the 1st a layer of side to the mode of calender 41 this moment.Calendering processing by second stage, towards the 1st a layer of side of calender 41 further by cramping, thereby the fiber that comprises in the 1st layer further is out of shape, it is big that the degree of flat pattern becomes.In addition, the 1st layer by cramping by further densification.And then the long axis direction orientation in cross section that is deformed into the fiber that comprises in the 1st layer of flat pattern is further near the in-plane of nonwoven fabric 14.And, nonwoven fabric 14 is applied the effect of " rubbing ", further improved flexibility.
Line pressure in the calendering processing of second stage is preferably selected in the above-mentioned scope of the line pressure from the calendering processing of phase I.From the 2nd a layer of side be not easy because of cramping by densification, can make the LC step-down thus, can give the viewpoint of sufficient loftiness and set out, especially preferably in above-mentioned scope, the line pressure in the calendering processing of second stage is set at the line pressure of the calendering processing that is lower than the phase I.Particularly, the line pressure in the calendering of the second stage processing is preferably 20～200N/cm, is preferably 20～150N/cm especially.As the 2nd resin roll 43, preferably use the roller of D hardness in the above-mentioned D hardness range of the 1st resin roll 42 of material.
As mentioned above, one of feature of having of this manufacture method is that the branch multistage carries out calendering processing.Result according to inventor's research carries out calendering with a stage and adds man-hour, even set the calendering processing conditions very harsh, can not make fibre deformation become flat pattern fully.And promptly allow to it and be deformed into flat pattern, the long axis direction of flat fiber is orientated on the in-plane of nonwoven fabric reliably.
After the calendering process finishing, can also implement the processing of various backs to nonwoven fabric 14 as required.For example when as described later nonwoven fabric 14 being used as the surfacing of absorbent commodity, can use various hydrophilic agents to implement hydrophilicity-imparting treatment.
Obtained the purpose nonwoven fabric as mentioned above.The nonwoven fabric that obtains be suitable for the constituent material of absorbent commodity such as disposable diaper and sanitary napkin for example, laminar split-tear formula cosmetic, cleaned slice with base material, dipping thin slice with base material etc.Therefore nonwoven fabric particularly of the present invention is because the 1st a layer of side is smooth and level and smooth, when this nonwoven fabric is used as the constituent material of absorbent commodity, preferably disposes according to the 1st layer of side of this nonwoven fabric and user's the contacted mode of skin.As according to disposing the concrete operational version of nonwoven fabric with the contacted mode of user's skin, can list with nonwoven fabric as the scheme of the surfacing of liquid permeability, with nonwoven fabric as the scheme of the outmost constituent material of absorbent commodity etc., but be not limited to these schemes.When nonwoven fabric is used as the outmost constituent material of absorbent commodity, mostly at the end edge portion of absorbent commodity and/or side edge part this nonwoven fabric being gone back to surfacing one side uses, therefore the outside that absorbent commodity by the 1st a layer of side direction that makes nonwoven fabric disposes this nonwoven fabric, and then the 1st a layer of side in the fold back portion contacts with user's skin.
As above detailed description, nonwoven surface roughness of the present invention is low and level and smooth, has drapability and softness, and the compression and back renaturation on the thickness direction is high and have a loftiness.Therefore, the comprehensive feel of nonwoven fabric of the present invention is very good.
More than, the preferred embodiment of nonwoven fabric of the present invention is illustrated, but the present invention is not limited to above-mentioned embodiment.For example the fiber that comprises in the 1st layer, the cross section of the fiber that comprises in the 2nd layer also can be flat pattern.
In addition in the manufacture method of above-mentioned embodiment, calendering adds two stages of work point to be carried out, but can divide three phases or more the multistage carries out.In addition, preferred whole calendering is processed at ambient temperature, and with the line pressure of 20～700N/cm, using metal calender and D hardness (JISK6253) is that 40～100 resin roll of spending are carried out.
In addition, in the manufacture method of above-mentioned embodiment, the calendering processing of second stage at ambient temperature, with the line pressure in the scope of 20～200N/cm, using metal calender and D hardness is that 40～100 resin roll of spending are carried out, but be not limited to the calendering processing of second stage, the calendering processing in any one stage all can be carried out under this condition.
Embodiment
Illustrate in greater detail the present invention by the following examples.But scope of the present invention is not subjected to the restriction of this embodiment.
Embodiment 1～6
Use device shown in Figure 1 to make nonwoven fabric.Carry out combing and make it have the mass area ratio shown in the table 1 having shown in the table 1 staple fibre of forming, thereby form the 1st and the 2nd fiber web.Overlapping the 2nd fiber web on the 1st fiber web carries out hot blast processing under the conditions shown in Table 1, obtains nonwoven fabric.At this moment, make the 1st fiber net surface, send hot blast from one side-blown of the 2nd fiber web to conveyer belt.At room temperature the nonwoven fabric that obtains is carried out the calendering processing in two stages.Processing conditions is as shown in table 1.Calender is that to have particulate face decorative pattern be the metallic roll of No. 350 pattern.The the 1st and the 2nd resin roll is that D hardness is the vulcanie roller of 90 degree.
Comparative example 1
Obtain nonwoven fabric under the conditions shown in Table 1.In this comparative example, do not implement calendering processing.
Comparative example 2
Except replacing hot blast to process with hot-rolling processing making nonwoven fabric, adopt and embodiment 1 same method obtains nonwoven fabric.The heating-up temperature of roller is 135 ℃.
Comparative example 3
To the nonwoven fabric that obtains by spun-bond process, under the condition identical, implement calendering and add with embodiment 1.
Comparative example 4
Obtain nonwoven fabric under the conditions shown in Table 1.Do not implement calendering processing in this comparative example.
Comparative example 5
Except a stage was processed in calendering, employing and embodiment 1 same method obtained nonwoven fabric.
Comparative example 6
Except the line pressure during calendering is processed is set the line pressure shown in the table 1 for, and the resin roll use D hardness of the calendering of second stage processing is that employing and embodiment 1 same method obtain nonwoven fabric beyond the silica gel roller of 27 degree (A hardness is 75 degree).
Estimate
The mass area ratio and the density of the mass area ratio of the nonwoven fabric that obtains in embodiment and the comparative example and thickness and layers 1 and 2 are as shown in table 2.In addition, the vertical section of nonwoven fabric amplifies with electron microscope, observes the transverse shape of the fiber that comprises in the 1st layer and obtains flatness.Its result is as shown in table 2.And then the SMD of the 1st a layer of side of nonwoven fabric and compression stiffness LC, flexural rigidity B and the TENSILE STRENGTH of MMD and nonwoven fabric have been measured.Its result is as shown in table 2.Moreover the electron micrograph of the surface of the 1st a layer of side of the nonwoven fabric that obtains among the embodiment 1 and the vertical section of nonwoven fabric respectively as shown in Figures 2 and 3.In addition, the electron micrograph on the surface of the 1st of the nonwoven fabric that obtains in the comparative example 1 a layer of side as shown in Figure 4.
Have again, the feel of nonwoven fabric has been carried out functional evaluation from the viewpoint of flexibility and flatness.Being represented as object with 10 estimates according to following 5 ranks.The result is illustrated in the table 3 with 10 people's average.
About flexibility
" softness and feel are good "
5: meet
4: roughly meet
3: being unable to say for certain meets or does not meet
2: not too meet
1: do not meet
About flatness
" level and smooth and feel good "
5: meet
4: roughly meet
3: being unable to say for certain meets or does not meet
2: not too meet
1: do not meet
Table 1
| Fibrous | Nonwoven fabric processing | Calendering processing | ||||||||||
| The 1st layer | The 2nd layer | Method for making | Hot blast is handled | Line pressure | ||||||||
| Core/sheath is formed | Fiber number * length (dtex * mm) | Quality (the g/m of unit are 2) | Core/sheath is formed | Fiber number * length (dtex * mm) | Quality (the g/m of unit are 2) | Temperature (℃) | Time (sec) | (N/cm) | ||||
| The 1st stage | The 2nd stage | |||||||||||
| Embodiment | 1 | PET/PE | 1.2×44 | 10 | PET/PE | 2.0×44 | 10 | The hot blast method | 140 | 8 | 255 | 115 |
| 2 | PET/PE | 1.2×44 | 8 | PET/PE | 2.0×44 | 12 | The hot blast method | 140 | 8 | 255 | 115 | |
| 3 | PET/PE | 1.2×44 | 10 | PET/PE | 1.7×44 | 10 | The hot blast method | 140 | 8 | 255 | 115 | |
| 4 | PET/PE | 1.2×44 | 8 | PET/PE | 1.7×44 | 12 | The hot blast method | 140 | 8 | 255 | 115 | |
| 5 | PET/PE | 2.0×44 | 8 | PET/PE | 1.7×44 | 12 | The hot blast method | 140 | 8 | 255 | 115 | |
| 6 | PP/PE | 1.1×38 | 10 | PET/PE | 1.7×44 | 10 | The hot blast method | 140 | 8 | 255 | 115 | |
| Comparative example | 1 | PET/PE | 2.0×44 | 10 | PET/PE | 1.7×44 | 10 | The hot blast method | 140 | 8 | - | - |
| 2 | PP | 2.0×44 | 22 | - | - | - | The hot-rolling method | 255 | 115 | |||
| 3 | PET/PE | 2.0×- | 16 | - | - | - | Spun-bond process | 255 | 115 | |||
| 4 | PET/PE | 2.0×44 | 10 | PET/PE | 1.7×44 | 10 | The hot blast method | 140 | 8 | - | - | |
| 5 | PET/PE | 1.2×44 | 8 | PET/PE | 2.0×44 | 12 | The hot blast method | 140 | 8 | 255 | - | |
| 6 | PET/PE | 1.2×44 | 10 | PET/PE | 1.7×44 | 10 | The hot blast method | 140 | 8 | 255 | 392 | |
PET/PE ... core is that polyethylene terephthalate, sheath are poly core-sheath-type composite fibres
PP/PE ... core is that polypropylene, sheath are poly core-sheath-type composite fibres
Table 2
| Quality (the g/m of unit are 2) | Thickness mm | Density (g/cm 3) | The fiber flatness | SMD μm | MMD | LC | B cN·cm 2/cm | TENSILE STRENGTH N/50mm | ||||||
| Whole | The 1st layer | The 2nd layer | The 1st layer | The 2nd layer | MD | CD | ||||||||
| Embodiment | 1 | 20.1 | 9.5 | 10.6 | 0.74 | 0.032 | 0.028 | 1.54 | 2.1 | 0.0051 | 0.27 | 0.021 | 32.6 | 6.4 |
| 2 | 21.8 | 8.0 | 13.8 | 0.83 | 0.032 | 0.023 | 1.53 | 2.2 | 0.0049 | 0.27 | 0.024 | 35.8 | 7.0 | |
| 3 | 20.2 | 9.5 | 10.7 | 0.74 | 0.038 | 0.021 | 1.54 | 2.0 | 0.0049 | 0.25 | 0.023 | 39.1 | 6.0 | |
| 4 | 20.2 | 8.4 | 11.8 | 0.70 | 0.038 | 0.030 | 1.45 | 2.1 | 0.0050 | 0.23 | 0.021 | 40.3 | 5.7 | |
| 5 | 19.3 | 8.8 | 10.5 | 0.58 | 0.031 | 0.013 | 1.59 | 1.9 | 0.0053 | 0.23 | 0.018 | 39.6 | 6.7 | |
| 6 | 20.5 | 10.0 | 10.5 | 0.76 | 0.037 | 0.025 | 1.44 | 2.4 | 0.0062 | 0.27 | 0.023 | 44.1 | 7.0 | |
| Comparative example | 1 | 19.2 | 9.5 | 9.7 | 0.83 | 0.043 | 0.026 | 1.08 | 2.9 | 0.0068 | 0.25 | 0.021 | 33.4 | 7.7 |
| 2 | 23.1 | 23.1 | - | 0.37 | 0.062 | - | 1.36 | 2.8 | 0.0064 | 0.42 | 0.013 | 39.8 | 8.4 | |
| 3 | 18.9 | 18.9 | - | 0.22 | 0.086 | - | 1.04 | 1.7 | 0.0099 | 0.30 | 0.020 | 48.0 | 35.8 | |
| 4 | 19.2 | 9.5 | 9.7 | 0.83 | 0.043 | 0.026 | 1.08 | 2.9 | 0.0068 | 0.25 | 0.021 | 33.4 | 7.7 | |
| 5 | 20.2 | 8.3 | 11.9 | 1.23 | 0.026 | 0.018 | 1.10 | 2.3 | 0.0051 | 0.36 | 0.063 | 31.5 | 6.6 | |
| 6 | 21.2 | 10.5 | 10.7 | 0.75 | 0.055 | 0.020 | 1.25 | 2.2 | 0.0058 | 0.35 | 0.027 | 41.3 | 8.6 | |
Table 3
| Functional evaluation | |||
| Flexibility | Flatness | ||
| Embodiment | 1 | 4.3 | 4.5 |
| 2 | 4.1 | 4.5 | |
| 3 | 4.3 | 4.6 | |
| 4 | 4.4 | 4.5 | |
| 5 | 4.5 | 4.7 | |
| 6 | 4.1 | 4.2 | |
| Comparative example | 1 | 4 | 3.4 |
| 2 | 3.2 | 3.5 | |
| 3 | 3.7 | 3.1 | |
| 4 | 4 | 3.4 | |
| 5 | 3.2 | 4.4 | |
| 6 | 3.4 | 4.3 | |
Clear as can be known from the result shown in table 1 and the table 2, the resulting nonwoven fabric of each embodiment, the SMD and the MMD value on the surface of its 1st layer of side are low, can judge it is level and smooth.And bending rigid value is low, can judge it is soft.Moreover compression rigidity is low, can judge the loftiness height.And then can judge to have full intensity.In addition, know as can be known that from the result shown in the table 3 the resulting nonwoven fabric of each embodiment is compared with the nonwoven fabric of comparative example, soft and level and smooth.
In addition, clear as can be known from Fig. 2 and Fig. 3, embodiment 1 resulting nonwoven fabric, the fiber that comprises in its 1st layer is flat pattern, and on the cross section of this fiber, long axis direction roughly is orientated on the in-plane of nonwoven fabric.Relative with it, the fiber that comprises in the 1st layer of the nonwoven fabric of comparative example 1 is circular.Also have, the resulting nonwoven fabric of embodiment beyond the embodiment 1 although do not show among the figure, can confirm that the fiber that comprises in the 1st layer also is flat pattern, and on the cross section of this fiber, long axis direction roughly is orientated on the in-plane of nonwoven fabric.
Claims (14)
1, a kind of nonwoven fabric by the hot blast manufactured, it contains layers 1 and 2, the 1st a layer of surface that has this nonwoven fabric, the 2nd layer of another surface that has this nonwoven fabric, the density of the 2nd layer density than the 1st layer is low, wherein, the cross section of the fiber that comprises at least the 1 layer is flat pattern, the long axis direction in the cross section of this fiber roughly is orientated on the in-plane of described nonwoven fabric, the average deviation SMD of the surface roughness of the 1st a layer of side surface is 2.5 μ m or following, and the average deviation MMD of coefficient of friction is lower than 0.008, the linear property LC of the compression property of described nonwoven fabric be 0.3 or below, and flexural rigidity B is 0.03cNcm
2/ cm or following.
2, nonwoven fabric as claimed in claim 1, wherein, the fiber number of the fiber that comprises in the 2nd layer is bigger than the fiber number of the fiber that comprises in the 1st layer.
3, nonwoven fabric as claimed in claim 1, wherein, the fiber number of the fiber that comprises in the 1st layer is 0.05～2.0dtex, the fiber number of the fiber that comprises in the 2nd layer is 1.5～5.0dtex.
4, nonwoven fabric as claimed in claim 1, wherein, the fiber that comprises in the 1st layer is the hot-melt-bondable fiber of core-sheath-type.
5, a kind of absorbent commodity, it has the described nonwoven fabric of claim 1, and disposes according to the surface of the 1st a layer of side in this nonwoven fabric and user's the contacted mode of skin, and wherein, the 1st layer mass area ratio is 5～15g/m
2, the 2nd layer mass area ratio is 5～45g/m
2, the mass area ratio of nonwoven fabric integral body is 10～50g/m
2
6, absorbent commodity as claimed in claim 5, wherein, described nonwoven fabric uses as the surfacing of liquid permeability.
7, absorbent commodity as claimed in claim 5, wherein, described nonwoven fabric uses as the outmost constituent material of absorbent commodity.
8, a kind of manufacture method of nonwoven fabric, it comprises: the nonwoven fabric grey cloth that is obtained by the hot blast method is implemented calendering processing, wherein, described calendering adds the work point multistage and carries out, and the calendering in any one stage processing all is at ambient temperature, with the line pressure of 20～200N/cm, using metal calender and D hardness (JIS K6253) is that 40～100 resin roll of spending are carried out.
9, manufacture method as claimed in claim 8, wherein, described calendering adds two stages of work point to be carried out, and the calendering processing of second stage at ambient temperature, with the line pressure of 20～200N/cm, using metal calender and D hardness (JIS K6253) is that 40～100 resin roll of spending are carried out.
10, manufacture method as claimed in claim 8, wherein, the nonwoven fabric grey cloth is the 2nd layer the sandwich construction that has the 1st layer of comprising a surface and comprise another surface, the fiber number of the fiber that comprises in the 2nd layer is bigger than the fiber number of the fiber that comprises in the 1st layer, and implements calendering processing according to the 1st a layer of side to the mode of calender.
11, manufacture method as claimed in claim 10 wherein, in the operation with hot blast manufactured nonwoven fabric grey cloth, makes the 1st a layer of side to poromeric material, send hot blast from the 2nd layer of one side-blown.
12, manufacture method as claimed in claim 8, wherein, implement calendering processing in the following way: making the average deviation SMD of the surface roughness of the 1st a layer of side after calendering is processed is 2.5 μ m or following, and the average deviation MMD of coefficient of friction is lower than 0.008.
13, manufacture method as claimed in claim 8, wherein, implement calendering processing in the following way: when making fibre deformation after the calendering processing become flat pattern, the long axis direction in the cross section of the fiber that is deformed into flat pattern roughly is orientated on the in-plane of this nonwoven fabric grey cloth.
14, a kind of processing method of nonwoven fabric, it comprises: at ambient temperature, line pressure with 20～200N/cm, using metal calender and D hardness (JIS K6253) is the nonwoven fabric grey cloth enforcement calendering processing of resin roll to being obtained by the hot blast method of 40～100 degree, when making the fibre deformation that comprises in this nonwoven fabric grey cloth become flat pattern, the long axis direction in the cross section of the fiber that is deformed into flat pattern roughly is orientated on the in-plane of this nonwoven fabric grey cloth.
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| Application Number | Priority Date | Filing Date | Title |
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| JP2005050007A JP4683957B2 (en) | 2005-02-25 | 2005-02-25 | Non-woven |
| JP2005050033A JP4683959B2 (en) | 2005-02-25 | 2005-02-25 | Nonwoven manufacturing method |
| JP050033/2005 | 2005-02-25 | ||
| JP050007/2005 | 2005-02-25 |
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| CN1824867A true CN1824867A (en) | 2006-08-30 |
| CN1824867B CN1824867B (en) | 2012-01-04 |
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| CN 200610009535 Expired - Fee Related CN1824867B (en) | 2005-02-25 | 2006-02-24 | Non-weaving fabric and producing method |
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Also Published As
| Publication number | Publication date |
|---|---|
| JP4683957B2 (en) | 2011-05-18 |
| JP2006233364A (en) | 2006-09-07 |
| CN1824867B (en) | 2012-01-04 |
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