CN100564641C

CN100564641C - The laminate web of bunch shape

Info

Publication number: CN100564641C
Application number: CNB2003801050347A
Authority: CN
Inventors: J·J·科若; R·H·特纳; J·L·霍耶; S·N·劳埃德; J·L·哈蒙
Original assignee: Procter and Gamble Ltd
Current assignee: Procter and Gamble Ltd
Priority date: 2002-12-20
Filing date: 2003-12-16
Publication date: 2009-12-02
Anticipated expiration: 2023-12-16
Also published as: CN1722999A; ZA200504240B; CN100396271C; CN100579495C; ZA200504231B; CN100384621C; ZA200504229B; CN1720362A; ZA200504264B; CN1722998A; CN100522119C; CN1723120A; CN1728979A

Abstract

A kind of laminate web that comprises first and second precursor web, at least described first precursor web is a non-woven web, described laminate web has first side and second side, first side comprises second precursor web and the tuft that at least one is discrete, and each discrete tufts has the linear orientation that limits longitudinal axis and comprises a plurality of clustered fibers that divide and extend through second precursor web as the integral extensions of first precursor web; Second side comprises described first precursor web.

Description

The laminate web of bunch shape

Technical field

The present invention relates to for example fiber web of film and fibrous woven net and non-woven web.Specifically, the present invention relates to these and handle the laminating webs material that strengthens flexibility or bulk property through mechanical molding.

Background technology

Laminating webs material for example film and fiber web is known in the art.For example, often that non-woven web and thin polymer film is laminated together so that they can be used as material in the disposable products, the egative film of for example disposable absorption diaper.In such laminated material, the non-woven material part can provide flexibility, and film portion can provide the impenetrability of convection cell simultaneously.

In many application, need fiber web lamination material to have fluffy structure and/or flexibility.In addition, need fiber web lamination material to have different textures and flexibility in fibroreticulate both sides.That is to say that fiber web can have veined, coarse relatively surface in a side, and can have soft, smooth relatively surface at opposite side.This can realize by two different fiber web layers are forced together, and for example passes through the method for adhesive or thermal.For example, the non-woven web useful binders of bunch shape adheres on the non-woven web of non-bunch of shape to make the laminate web of the side with two complete different texture and soft feature.

In addition, known two kinds of non-woven materials can being attached in a kind of laminated material so that obtain the beneficial effect of dissimilar material in single laminate web.For example, the known non-woven web that comes production integrated bond and entanglement with the acupuncture non-woven web.This method often is called " acupuncture " for short.For example, authorized the United States Patent (USP) 5 of Guthrie on January 14th, 1992,080,951 disclose a kind of non-woven web of a plurality of layers of formation by the needle-punching method combination, described needle-punching method makes some fibre extend through the thickness of whole fabric and exceeds the surface, thereby stays from the outstanding short segment length's silk of fibroreticulate outer surface.Twine the similar entanglement that realizes two fiber non-woven knitmesh with water continually.Acupuncture is similar to hy-droentanglement, is a kind ofly to be used to make non-woven web, especially to be intended for use the fibroreticulate relatively slow and expensive method of disposable product.

Generally speaking, the present method that is used to be manufactured on the film that has fluffy or bunch shape structure on its at least one face and laminating webs material is relatively costly concerning these fibroreticulate many purposes, or owing to uses adhesive or thermal to make the fiber web of gained too hard.

Therefore, need a kind of low-cost laminate web with terry cloth-like performance.

In addition, also need a kind of laminate web, non-woven material has a bunch shape zone in this laminate web, and film or another kind of nonwoven material layer can preferably engage to keep laminar structure by the method that does not need adhesive or thermal.

In addition, also need a kind of laminate web, in this laminate web, each layer not only is engaged but also runs through each other and become one.

In addition, also need a kind of method that can make laminate web with terry cloth-like performance relatively inexpensively.

In addition, also need a kind of fibroreticulate cost effective method of porous lamination of making the softness of film, textile material and/or non-woven material, high stacking volume.

Summary of the invention

The present invention relates to a kind of laminate web, described laminate web comprises first and second precursor web, at least described first precursor web is a non-woven web, described laminate web has first side and second side, described first side comprises the tuft that described second precursor web and at least one are discrete, each described discrete tufts have the linear orientation that limits longitudinal axis and comprise a plurality of as described first precursor web integral extensions and extend through bunch shape fibrae circulares of described second precursor web; The fiber diameter of described bunch of shape fibrae circulares is less than the fiber diameter of the fiber of described first precursor web; Described second side comprises described first precursor web.

Be preferably described laminate web and comprise a plurality of discrete tufts; Described first precursor web comprises the non-woven web of basic randomly oriented fiber; Described fiber comprises at least a material that is selected from cellulose, polyethylene, polypropylene and the polyester; Described fiber comprises bicomponent fiber; Described fiber comprises non-circular fiber; Described laminate web comprises at least 10 discrete tufts for every square centimeter; The part of each described tuft with the clearance gap area limiting in described tuft inside.

The invention still further relates to a kind of cleaning piece, described cleaning piece comprises above-mentioned laminate web of the present invention.

The invention still further relates to a kind of laminate web, described laminate web comprises first and second precursor web, at least described first precursor web is the non-woven web that comprises fiber, described laminate web has first side, described first side comprises described second precursor web and a plurality of discrete tufts, each described discrete tufts comprises with described first precursor web and is one and the fibrae circulares that stretches out from described first precursor web and is the fiber that one is not stretched out from described first precursor web again with described first precursor web neither that the fiber diameter of described bunch of shape fibrae circulares is less than the fiber diameter of the fiber of described first precursor web.

Be preferably fiber described in the described laminate web and comprise at least a material that is selected from cellulose, polyethylene, polypropylene and the polyester; Described fiber comprises bicomponent fiber; Described fiber comprises non-circular fiber; Described laminate web comprises at least 10 discrete tufts for every square centimeter.

The invention still further relates to disposable absorbent article, described goods have at least one parts that comprise laminate web, described laminate web comprises first and second precursor web, at least described first precursor web is a non-woven web, described laminate web has first side and second side, described first side comprises described second precursor web and at least one discrete tufts, each described discrete tufts has the linear orientation that limits longitudinal axis and comprises a plurality of bunches of shape fibrae circulares, the integral extensions that described bunch of shape fibrae circulares is described first precursor web is divided and is extended through described second precursor web, and the fiber diameter of described bunch of shape fibrae circulares is less than the fiber diameter of the fiber of described first precursor web; Described second side comprises described first precursor web.

Disposable absorbent article of the present invention is selected from sanitary tampons or diaper.Laminate web constitutes the top flat of described disposable absorbent article described in the disposable absorbent article of the present invention; Described laminate web constitutes the core of described disposable absorbent article.

Description of drawings

Fig. 1 is the fibroreticulate perspective view of the present invention.

Fig. 2 is a fibroreticulate guide wire of alternative shape shown in Figure 1.

Fig. 3 is the profile in the 3-3 cross section of Fig. 2.

Fig. 4 is the plane of a fibroreticulate part shown in the 4-4 among Fig. 3.

Fig. 5 is the perspective view that is used to form the fibroreticulate device of the present invention.

Fig. 6 is the cross-sectional view of the part of device shown in Figure 5.

Fig. 7 is the perspective view of a part that is used to form the device of the fibroreticulate embodiment of the present invention.

Fig. 8 is the enlarged perspective that is used to form the part of the fibroreticulate device of the present invention.

Fig. 9 is the guide wire of alternative shape of fibroreticulate another embodiment of the present invention.

The plane that Figure 10 partly excises for sanitary napkin of the present invention.

The perspective view that Figure 11 partly excises for sanitary tampons of the present invention.

Figure 12 to 15 is the fibroreticulate microphoto of the present invention.

The specific embodiment

Fig. 1 represents laminate web 1 of the present invention, is designated hereinafter simply as fiber web 1.Fiber web 1 comprises two-layer at least.Described each layer refers to be generally the precursor web of plane, two dimension at this paper, as first precursor web 20 and second precursor web 21.Any one precursor web all can be film, non-woven material or woven web.Precursor web 20 and 21 (and any accessory fibers net) can engage by adhesive, thermal, combination of ultrasound etc., but does not preferably use adhesive or other adhesive-bonded form to engage.Following disclosed, the composition precursor web of fiber web 1 can engage by the interlocked mechanical engagement that is produced by forming of tuft 6.

Fiber web 1 has first side 3 and second side 5, and term " side " is used in the common usage of the two-dimensional fiber net (as paper and the film that has two sides when being in common flat condition) that is generally the plane.Each

precursor web

20 and 21 has first surface 12 and 13 respectively, and has second surface 14 and 15 (as shown in Figure 3) respectively.Fiber web 1 has as vertical (MD) and horizontal (CD) of web manufacture field known to usually.Although the present invention can implement with thin polymer film and woven fiber web, first precursor web 20 non-woven web that basic randomly oriented fiber constitutes of serving as reasons in preferred embodiments." basic random orienting " is meant the processing conditions owing to described precursor web, and the amount of possible MD (vertically) orientation fibers is higher than the amount of CD (laterally) orientation fibers, and vice versa.For example, spunbond and melt and spray in the processing continuously that a strand fiber is deposited in the support that vertically moves.Although the fiber orientation real " at random " of attempting to allow spunbond or melt-blown nonwoven knitmesh, the percentage of common machine-direction oriented fiber with horizontal compare high slightly.In a preferred embodiment, second precursor web 21 is the non-woven webs that are similar to first precursor web 20, or thin polymer film or apertured polymer film, as polyethylene film.

In one embodiment, first side 3 of fiber web 1 is by the exposed parts of the first surface 13 of second precursor web 21 and at least one but preferred a plurality of discrete tufts 6 is limited, and this discrete tufts is the integral extensions branch of the fiber of nonwoven first precursor web 20.As shown in Figure 3, each tuft 6 all can comprise and a plurality ofly extends through second precursor web 21 and by the outside ring-type of their first surface 13, the fiber 8 of alignment.In another embodiment, each tuft 6 all can comprise a plurality of from first surface 13 outward extending non-looped fibers 18 (as shown in Figure 3).

Term used herein " non-woven web " refers to have interlaced but there is no the fiber web of the individual fibers or the silk thread structure of repeat patterns such in woven or the braided fabric, and described woven or braided fabric does not typically have randomly oriented fiber.Non-woven web or fabric have been formed at several different methods, and for example meltblown, spun-bond process, water twine method, air lay and bonded carded web method, comprise the carded thermal.Quantitatively representing with gram every square metre (gsm) usually of bondedfibre fabric.Laminate web quantitatively be each combined basis weight of forming layer and any other optional feature.Fibre diameter is represented with micron usually; Fiber size can represent that also it is the unit of every fibre length weight with the dawn.What be applicable to laminate web of the present invention quantitatively can be 10gsm to 500gsm, and it depends on the final use of fiber web 1.For example, for being used as towel, first precursor web 20 and second precursor web 21 can be quantitative non-woven webs between 25gsm and 100gsm.For as bath towel, first precursor web 20 and second precursor web 21 all can have between 125gsm and the 250gsm quantitatively.For as mulch film, as corrosion protective lining, laminated material quantitatively between 350gsm and 500gsm or higher may be suitable.

Nonwoven precursor web

20 or 21 composition fiber can be made of polymer, for example polyethylene, polypropylene, polyester and their blend.Described fiber can comprise the blend of cellulose, artificial silk, cotton thread or other natural material or polymer and natural material.Fiber also can comprise superabsorbent material, as any combination of polyacrylate or suitable material.Fiber can be one pack system, bi-component and/or two composition, non-circular (for example, capillary pipe fiber), and the major cross-sectional dimension that can have (for example, the diameter of cylindrical fibre) is 0.1 micron to 500 microns.For example, a kind of fiber of non-woven web that is applicable to comprises nanofiber.Nanofiber is described to average diameter less than 1 micron fiber.Nanofiber can comprise all fibres in the non-woven web or the part fiber in the non-woven web.The composition fiber of nonwoven precursor web also can be the mixture of different fiber types, and these different fiber types are inequality on some features as chemistry (for example PE and PP), component (single-and two-), dawn (little dawn and＞20 dawn), shape (being capillary and circle) etc.The scope of forming fiber can be about 0.1 dawn to about 100 dawn.

" spun-bonded fibre " used herein is meant the fiber of the minor diameter that forms with following method: molten thermoplastic material from a plurality of meticulous of spinning head and be generally circular capillary and be extruded as long filament, is reduced the filament diameter of extruding then fast.When being deposited on the collection surface, spun-bonded fibre is not clamminess usually.Spun-bonded fibre is generally continuous and average diameter that have (from least 10 sample) greater than 7 microns, more particularly, between about 10 microns and 40 microns.

Term used herein " meltblown " is meant the method for following formation fiber: with molten thermoplastic material by a plurality of meticulous and be generally circular punch die capillary and be extruded as fusion silk thread or long filament, convergence high-speed gas (as the air) stream that enters common heating then weakens the long filament of molten thermoplastic, so that its variation in diameter, even may diminish to the microfiber diameter., when meltblown fibers still be clamminess by high velocity air deliver and be deposited on collection surface on, form the fiber web of the meltblown fibers of random thereafter.Meltblown fibers is continuous or discontinuous microfiber, and common average diameter is less than 10 microns.

Term " polymer " used herein " generally include but be not limited to homopolymers, copolymer, for example block, grafting, random and alternate copolymer, terpolymer etc., and their blend and modifier.In addition, unless otherwise specifically limited, term " polymer " " comprise all possible geometrical configuration of described material.Described configuration includes, but not limited to isotaxy, atactic, syndiotaxy and symmetrical at random.

Term used herein " one pack system " fiber is meant the fiber that only uses a kind of polymer to be shaped by one or more extruders.This and do not mean that eliminating is formed by a kind of polymer, wherein add that a small amount of additive is used to dye, the fiber of antistatic property, lubricated, hydrophily etc.These additives for example are used for the titanium dioxide that dyes, exist with the content less than about 5% weight and more typical about 2% weight usually.

Term " bicomponent fibers " used herein " be meant and extrude from extruder separately by at least two kinds of different polymer but be spun the fiber that forms a fiber.Bicomponent fiber is also referred to as conjugate fibre or multicomponent fibre sometimes.Described polymer is arranged in the constant distinct zone of basic fixed position, and these regional cross sections with bicomponent fiber intersect and extend continuously along the length of bicomponent fiber.For example, the configuration of this bicomponent fiber can be that sheath/core pattern is arranged, and wherein a kind of polymer is centered on by another kind of polymer, or parallel type is arranged, the cake formula is arranged or " it is starlike " arranges.

Term used herein " biconstitutent fibre " is meant by same extruder extrudes the fiber that at least two kinds of polymer as blend form.Biconstitutent fibre does not have the various polymers compositionss in the basic fixed position of being arranged on completely different zone constant, that intersect with fiber cross section, and various polymer are not continuous along the whole length of fiber usually, but are generally the shaping fibril of random start and end.Biconstitutent fibre also refers to multicomponent fibre sometimes.

Term used herein " non-circular fiber " is to describe to have the fiber of non-circular cross sections, and comprises " shaped fibers " and " capillary pipe fiber ".Such fiber can be solid or hollow, and they can be trilobal, △ shape, and preferably its outer surface has the fiber of capillary channel.Capillary channel can be various shape of cross sections, as " U-shaped ", " H shape ", " C shape ", " V-arrangement ".A preferred capillary pipe fiber is T-401, called after 4DG fiber, and available from TN, the Fiber InnovationTechnologies of Johnson City.The T-401 fiber is polyethylene terephthalate (a PET polyester).

Term used herein " integral body " " integral extensions " of tuft 6 (as be used for) is meant that the fiber of tuft 6 works the fiber that is derived from first precursor web 20.Therefore, the fibrae circulares 8 of tuft 6 and non-looped fibers 18 can be the plastic deformation of first precursor web 20 and the fiber that stretches out, and therefore become one with first precursor web 20." integral body " used herein is the fiber that is used for being different from the precursor web of introducing or join separation in order to make tuft, for example, and common doing in the conventional carpet manufacturing.

The quantity of tuft 6, spacing and size can change the texture that first side 3 of thinking fiber web 1 provides variation.For example, if tuft 6 has fully close spacing, first side 3 of fiber web 1 can have the sensation of terry cloth-like fabric.Alternatively, tuft 6 can have stronger texture, flexibility, stacking volume, absorbability or visual pattern attraction with a part that causes laminate web as the arranged in patterns of linear or filling shape.For example, when tuft 6 during with straight line or microgroove arranged in patterns, tuft can have the outward appearance of embroidery.Tuft 6 also can be arranged and form specific shape, for example style, letter or logo.For example, these shapes can be used to can have the title or the logo in hotel in the above on the used laminated material of hotel bath towel or bathing gown.Similarly, the size of single tuft 6 also can change as height, length and width.Single tuft can be about 3cm, and can make separately or be dispersed among the tuft of various sizes.

First precursor web 20 can be fibrous woven net or non-woven web, and it fiber that comprises has enough elongation characteristics so that its part forms as the following tuft of describing more comprehensively 6.Tuft is in the Z direction by fiber in the discrete local part of first precursor web 20 and is pushed out outside the plane and forms.Be the displacement owing to fiber outside the release plane, promptly fiber can and be we can say with respect to other fiber movement and be drawn out outside the plane.Yet to most of nonwoven first precursor web 20 more commonly, releasing outside the plane is because the fiber of tuft 6 is formed tuft 6 by part plastic elongation and permanent deformation at least.Therefore, in one embodiment, according to the height of required tuft 6, the composition fiber of nonwoven first precursor web 20 can show that the elongation at break that has is at least about 5%, more preferably at least about 10%, more preferably at least about 25%, more preferably at least about 50%, and more preferably at least about 100%.Elongation at break can be measured by simple tension test, for example adopts the Instron tension tester, and can find in the material data table that these fibers or fibroreticulate supplier provide usually.

Should be understood that suitable nonwoven first precursor web 20 should comprise and can stand enough plastic deformations and tensile elongation or have the ambulant fiber of enough fibers, thereby can form fibrae circulares 8.Yet people recognize that the fiber of the out-of-plane certain percentage of the first surface 12 that is pushed out first precursor web 20 will not form ring, and generation be fracture and form loose end.These fibers are called as " loose " fiber or " loose fiber ends " 18 as shown in Figure 3 at this paper.Loose fiber ends 18 is not necessarily undesirable for the present invention, and in some embodiments, the great majority of tuft 6 or whole fiber can be loose fiber ends 18.Loose fiber ends 18 also can be formed the result of tuft 6 by the non-woven web that short staple fiber is formed or comprised to short staple fiber.In this case, some artificial staple fiber ends may be projected among the tuft 6, and this depends on these situations such as height as the quantity of staple fiber in the fiber web, staple fiber cut length and tuft.In certain embodiments, may in precursor web, use the blend of different length fiber or in different layers, use the blend of different length fiber.Can optionally long fiber and staple fibre be separated like this.Long fiber can mainly form tuft 6, and staple fibre mainly is retained in the fiber web part that does not form tuft 6.The mixture of an exemplary fiber length can comprise the long fiber that is approximately 2 to 8 centimetres and less than the fiber of about 1 centimetre staple fibre.

First precursor web 20 can be fibrous woven net or the non-woven web that comprises elastomer or elastomeric fibre.Elastomer or elastomeric fibre can be stretched its original size at least about 50% and can return to its original size 10% in.If because the mobility of fiber, fiber is by simple substitute in non-woven material, or be stretched above their elastic limit and plastic deformation as fruit fiber, tuft 6 can be formed by elastomer.

Second precursor web 21 in fact can be any web material, unique requirement is that it should have enough integralities so that be formed in the laminated material by method described below, and it should have enough little elongation characteristics with respect to first precursor web 20, so that when standing on the direction of second precursor web 21, to be pushed out out-of-plane fiber strain from first precursor web 20, second precursor web 21 will be broken, for example, because elongation destroys and is torn, the part of the precursor web 20 of winning can be stretched out (that is, so-called " passing ") second precursor web 21 is to form tuft 6 on first side 3 of fiber web 1.In one embodiment, second precursor web 21 is a thin polymer film.Second precursor web 21 also can be woven woven web, non-woven web, thin polymer film, apertured polymer film, paper web (for example, tissue paper), metal forming (for example, aluminium package foil), foam (for example, urethane foam plate) etc.

The typical tuft 6 of the embodiment of fiber web 1 shown in Figure 1 is shown in the further zoomed-in view of Fig. 2.Shown in Fig. 2 or 3, tuft 6 comprises a plurality of fibrae circulares 8, and described fibrae circulares substantial alignment is so that tuft 6 has tangible linear orientation and longitudinal axes L.Tuft 6 also has the axis T that is orthogonal to longitudinal axes L usually in the MD-CD plane.In embodiment as illustrated in fig. 1 and 2, longitudinal axes L is parallel to MD.In one embodiment, all isolated tufts 6 all have parallel longitudinal axes L usually.Tuft 6 number of per unit area fiber web 1, i.e. the area density of tuft 6, can from per unit area for example 1 bunch every square centimeter change to up to every square centimeter 100 bunches.Every square centimeter can have at least 10 or at least 20 tufts 6, and this is decided by final use.Usually, be not required for consistently in the whole area inner area density of fiber web 1, but tuft 6 can only exist at some region memory of fiber web 1, for example has reservation shape, as the zone of linear, bar shaped, band shape, circle etc.

Should be appreciated that by this paper explanation in many embodiments of fiber web 1, the opening 4 of second precursor web 21 will have tangible linear orientation and longitudinal axis, this opening is oriented the longitudinal axes L of the tuft 6 that is parallel to its correspondence.Similarly, opening 4 also will have the axis of pitch that is orthogonal to longitudinal axis in the MD-CD plane usually.

Shown in Fig. 1 to 4, tuft 6 extends through the opening 4 in second precursor web 21.Opening 4 forms through partial fracture second precursor web 21 according to the method that describes in detail below.Breaking to relate to simply splitting of second precursor web 21, makes opening 4 stay the simple two-dimensional hole.Yet for some material such as thin polymer film, part second precursor web 21 can be deflected or release the outer structure that forms the flap shape in plane (that is, the plane of second precursor web 21), and this paper is called fin 7.The shape of fin 7 and structure height depend on the material property of second precursor web 21.Fin 7 can have the ordinary construction of one or more fins, as illustrated in fig. 1 and 2.In other embodiment, fin 7 can have the structure that more resembles the volcano shape, comes out from fin 7 eruptions as tuft 6.

In one embodiment, fin 7 is not significantly contributed the material of tuft 6, and especially the tactile qualities of tuft 6 is not significantly contributed.Therefore, laminate web 1 comprises two-layer at least (that is, precursor web 20 and 21) in one embodiment, but one of them layer (that is the precursor web among Fig. 1 to 4 21) does not produce appreciable impact to the tactile qualities of tuft 6.

In one embodiment, fin 7 can significantly stretch out outside the plane, even we can say the same high with tuft 6 itself.In this embodiment, fin 7 can cause tuft 6 more to be added with elastic force and be not easy more flattening owing to the effect of compression or bending force.Therefore, in one embodiment, laminate web 1 comprises two-layer at least (that is, precursor web 20 and 21), and the two-layer tactile qualities that all influences tuft 6.

Tuft 6 " passes " second precursor web 21 and in some sense by being " locked " in position with being frictionally engaged of opening 4.For example, in certain embodiments, the transverse width of opening 4 (that is, being parallel to the size that its axis of pitch is measured) can be less than the Breadth Maximum of the tooth that forms opening (through method described below).This is illustrated in a certain amount of recovery of opening part and is tending towards constrain tuft 6 and outwards is pulled via opening 4.The friction engagement of tuft and opening 4 provides and need not adhesive or thermal and form have the laminate web structure of permanent tuft a side.

Because one of them layer (for example in certain embodiments, the thin polymer film of relatively low percentage elongation or tissue paper second precursor web 21 among Fig. 1 to 4) be not significantly contribution material (for example in the embodiment shown in Fig. 1 to 4) of tuft 6, the feature that comprises the fiber web 1 of nonwoven first precursor web 20 can be on two sides of fiber web 1 with the main fiber of only being contributed by nonwoven first precursor web 20 of fiber conduct.Therefore, tuft 6 can be spaced apart enough closely so that it effectively covers first side 3 of fiber web 1.In such embodiment, two side surface bodies of fiber web 1 all look like nonwoven, and the difference between two

sides

3 and 5 is the superficial makings difference.Therefore, in one embodiment, this invention can be described as the laminated material of two or more precursor web, and two sides of wherein said laminate web are all covered by the fiber from a precursor web only basically.

Shown in Fig. 1 to 4, characteristics of tuft 6 can be fiber 8 or fiber 18 main directions are alignd.For example, the fiber 8 of ring-type, alignment can be described to have effective vector component or the master vector component that is parallel to the Z-CD plane, and this fibrae circulares 8 has alignment orientation with respect to the axis T basically identical when observing in plan view (as Fig. 4)." ring-type " fiber 8 be meant the fiber 8 and first precursor web 20 be one and beginning and ending in first precursor web 20, but the first surface 13 from second precursor web 21 extends outward on the Z direction.About " alignment " of the fibrae circulares 8 of tuft 6 thus be meant that fibrae circulares 8 is directed usually all, if in plane, observe as Fig. 4, each fibrae circulares 8 has the effective vector component that is parallel to axis T, and preferably has the master vector component that is parallel to axis T.

On the contrary, the non-looped fibers 18 and first precursor web 20 are one, but only start from first precursor web 20 and have on the Z direction first surface 13 outward extending free terminals from second precursor web 21.Loose fiber 18 also can have the alignment orientation of common unanimity, and this alignment orientation is described to have effective vector component or the master vector component that is parallel to the Z-CD plane.

For fibrae circulares 8 and loose fiber 18 for both and since use when making goods be wound on the roller or compression, described alignment is the feature of tuft 6 before distortion after any manufacturing.

As used herein, when in plane as shown in Figure 4, observing, have the effective vector component that is parallel to axis T greater than the fibrae circulares 8 of miter angle orientation to depart from longitudinal axes L.As used herein, when in plane, observing, have the master vector component that is parallel to axis T greater than the fibrae circulares 8 of angular orientations of 60 degree to depart from longitudinal axes L as Fig. 4.In a preferred embodiment, at least 50%, more preferably the fiber 8 of at least 70% and more preferably at least 90% tuft 6 has an effective vector component that is parallel to axis T, and more preferably is parallel to a master vector component of axis T.If desired, the orientation of fiber can use amplifier unit to determine, the microscope of suitable measurement scale for example is housed.Usually, for the nonlinear fiber segment in viewed in plan view, longitudinal axes L and fibrae circulares 8 done all straight line is approximate to can be used to determine that fibrae circulares 8 departs from the angle of longitudinal axes L.For example, as shown in Figure 4, a fiber 8a shows emphatically with heavy line, and the approximate 8b of its straight line shows with dotted line.This fiber becomes the angle (measuring counterclockwise from L) of about 80 degree with longitudinal axis.

The orientation of fibrae circulares 8 is used for ining contrast to the orientation of the fibre composition and first precursor web 20 in the tuft 6, is described as having the alignment of fibers of basic random orienting best for its orientation of non-woven web.In a woven fiber web embodiment, the orientation of fibrae circulares 8 can be same as described above in the tuft 6, but the fiber of first precursor web 20 will have and be used for making the relevant orientation of fibroreticulate concrete weaving techniques (as, cubic weave patterns).

In the embodiment depicted in fig. 1, the longitudinal axes L of tuft 6 is in line along the MD direction usually.Therefore, tuft 6 and longitudinal axes L can be in line along any direction with respect to MD or CD in principle.Therefore, we can say usually that the fiber 8 of ring-type, alignment is orthogonal to longitudinal axes L usually and is in line and makes them have the effective vector component that is parallel to axis T, and more preferably has the master vector component that is parallel to axis T for each tuft 6.

In some embodiments, because the method for optimizing of formation tuft 6 as described below, another characteristics that mainly comprise the tuft 6 of ring-type, aligned fibers 8 are its common open structures, and this structure is characterised in that the clearance gap zone 10 that is limited to tuft 6 inside, shown in Fig. 2 and 3.Interstice coverage 10 can have is shaped as far-end 31 place's broads or bigger at tuft 6, and narrower at base portion 17 places of tuft 6.This shape is opposite with the shape of the tooth of the tuft 6 that is used for being shaped." interstice coverage " is not meant complete zone without any fiber; This term is meant the general description as the common outward appearance of tuft 6.Therefore, may be that a loose fiber 18 or many loose fibers 18 can appear in the interstice coverage 10 in some tufts 6." opening " interstice coverage is meant that two of tuft 6 vertically terminally open wide usually and do not have fiber, makes tuft 6 be formed with the structure in point image " tunnel " at uncompressed state like this, as shown in Figure 3.

In addition, owing to make a method for optimizing of fiber web 1, second side 5 of fiber web 1 shows to have is interrupted 16, the tooth that it is characterized in that being generally linear breach (this breach is limited by the original random fiber of the second surface 14 of the first precursor web 20) equipment that has been formed directionally (promptly, as shown in figs. 1 and 3, usually be orthogonal to " the Z direction " on MD-CD plane) be advanced in the tuft 6, will describe in detail below.The flip-flop of the shown orientation that has of fiber of first precursor web, 20 original random orientings has been determined interruption part 16, and its demonstration has linearity makes it can be described to have the longitudinal axis of the longitudinal axes L that is parallel to tuft 6 usually.Because as the character of many non-woven webs of first precursor web 20, be interrupted part 16 and may do not resemble the tuft 6 clearly visible.For this reason, the interruption part 16 on second side 5 of fiber web 1 do not observe and may detect usually less than, unless scrutiny fiber web 1.Equally, second side 5 of fiber web 1 can have the outward appearance and the sense of touch of non-bunch of shape first precursor web 20.Thereby in certain embodiments, fiber web 1 has the look and feel of the band texture of towel cloth on first side 3, and on second side 5, has smooth, soft relatively the look and feel, these two sides constitute by the fiber from same non-woven web (that is first precursor web 20).In other embodiments, be interrupted part 16 and can be rendered as the hole, and may be the hole of passing fiber web 1 via the end of tunnel-like tufts 6.

From to the narration of the fiber web 1 that comprises nonwoven first precursor web 20 as can be seen, the fiber 8 of tuft 6 or fiber 18 can and extend from the first surface 12 or second surface 14 origins of first precursor web 20.Certainly the fiber 8 or the fiber 18 of tuft 6 also can extend out from the inside 28 of first precursor web 20.As shown in Figure 3, the fiber 8 of tuft 6 or fiber 18 extend owing to (that is, being pushed out in " Z direction " as shown in Figure 3) outside the plane that has been pushed out first precursor web 20 that is generally two dimension.Usually, the fiber 8 of tuft 6 or fiber 18 comprise the fiber that the fiber with first precursor web 20 becomes one and extends from it.

Therefore, be understood that from the above description in one embodiment, fiber web 1 can be described as the laminate web that is formed by the selectivity mechanically deform of at least the first and second precursor web, at least described first precursor web is a non-woven web, described laminate web has first side and second side, described first side comprises second precursor web and a plurality of discrete tufts, and each discrete tufts comprises that a plurality of is the first precursor fiber integral extensions and the clustered fiber that extends through second precursor web; Described second side comprises first precursor web.

Because the plastic deformation and the Poisson's ratio effect of fiber, fiber 8 or 18 elongation may be accompanied by totally reducing of the fiber cross sectional dimension diameter of circular fiber (for example, for).Therefore, the alignment fibrae circulares 8 of tuft 6 fiber diameter that can have is less than the fiber diameter of the fiber of first precursor web 20.It is believed that the flexibility that the minimizing of this fibre diameter helps fiber web 1 first side 3 to aware, depend on the material property of first precursor web 20, this flexibility can compare favourably with cotton towel cloth.Found tuft 6 base portion 17 and not end parts 31 the mid portion fiber cross sectional dimension reduce maximum.It is believed that this is owing to following more detailed disclosed preferable production process causes.In simple terms, as shown in Figure 3, it is believed that tuft 6 base portion 17 and the fiber at end parts 31 places contiguous below the top of the tooth 110 of roller 104 in greater detail, and in process, locked and fix by frictional property.Thereby the mid portion of tuft 6 is more free to stretch, or prolongs, and therefore, can experience reducing of corresponding fiber cross sectional dimension.The fiber of some first precursor web 20 may laterally push the base portion 17 of tuft 6.The base portion 17 of tuft 6 even can be closed (if from the fiber close enough of tuft 6 together to contact) or keep opening.Usually, any opening at base portion 17 places all is narrow.Can help to stablize the tuft 6 and second precursor web 21 in the closure of base portion 17 other fibers of place or constriction or extruding.

With reference to figure 5, show a kind of apparatus and method of making fiber web 1 of the present invention.Device 100 comprises a pair of

intermeshing roller

102 and 104, and each is all around axle A rotation, and axle A is parallel in same plane.Roller 102 comprises a plurality of protruding 106 and corresponding grooves 108, and its whole circumference around roller 102 is intactly extended.Roller 104 is similar to roller 102, but be not the projection that has around the complete extension of whole circumference of roller 102, roller 104 comprises the projection that many rows circumferentially extend, and this projection has been modified into the circumferentially spaced tooth 110 of several rows, and this tooth extends with spaced relationship around at least a portion roller 104.Each toothrow 110 of roller 104 is separated by corresponding grooves 112.On-stream,

roller

102 and 104 intermeshes and makes the projection 106 of roller 102 put in the groove 112 of roller 104, and the tooth 110 of roller 104 puts in the groove 108 of roller 102.This engagement is shown in more detail in the cross-sectional view of the Fig. 6 that discusses

below.Roller

102 and 104 both or one of them can heat by methods known in the art, for example use deep fat to fill roller or electric heating roller.

In Fig. 5, device 100 is shown as the preferred configuration of the fluted roller 102 with knurling rolls (as roller 104) and a non-embossing.Yet it may be preferred using two knurling rolls 104 in certain embodiments, and these two knurling rolls are in that the same respective regions or the different respective regions of roller have identical or different patterns separately.This device can be produced the fiber web that has from the outstanding tuft 6 in two sides of fiber web 1.Device can be designed to have the tooth of directed in opposite directions on same roller.This will be created in the fiber web that tuft 6 is all made in fibroreticulate two sides.

The method of making fiber web 1 of the present invention with the continuation method of commericially feasible is depicted among Fig. 5.Fiber web 1 is made by mechanically deform precursor web (as first and second precursor web 20 and 21), its each be generally plane and two dimension all can being described as by device first being processed shown in Figure 5." plane " and " two dimension " only is meant that fiber web begins processing with the flat condition with respect to finished fiber net 1, and described finished fiber net is because the shaping of tuft 6 has tangible, out-of-plane, Z direction three-dimensional." plane " and " two dimension " do not refer to comprise any special glacing flatness, smoothness or dimension.

Method and apparatus of the present invention is similar to the United States Patent (USP) 5 of called after " Web Materials ExhibitingElastic-Like Behavior " in many aspects, 518,801 described methods, and in patent documentation afterwards, be called as " SELF " fiber web, " SELF " representative " structural elasticity shape film ".Yet, have marked difference between the disclosed apparatus and method in apparatus and method of the present invention and ' 801 patents, thereby difference is obvious in the fiber web of making separately.As described below, the tooth 110 of roller 104 have with forward position and back along relevant concrete how much proterties, its forward position and back make fiber web be out of shape along allowing basic " wearing " the relative excessively precursor web 20,21 of tooth in itself.In a double-layer lamination fiber web 1, described tooth 110 is released fiber and is released outside the plane simultaneously and pass second precursor web 21 that is pierced from first precursor web 20, we can say, promotes fibers 8 by tooth 110 and passes and form tuft 6.Therefore, fiber web 1 of the present invention can have " tunnel-like " tuft 6 of the fiber 8 of the tuft 6 of loose fiber ends 18 and/or ring-type, alignment, the fiber 8 of alignment extends through and away from the surface 13 of first side 3, do not resemble SELF fibroreticulate " tent like " rib linear element, its each all have a continuous related with it continuous side walls, that is, continuous " transitional region ", and it does not have the mutual perforation that one deck wherein passes another layer.

Precursor web

20 and 21 is directly provided or is provided (both is not shown) indirectly by donor rollers by their web manufacture technology separately, and moves to the roller 102 of counter-rotating engagement and 104 roll gap 116 in the vertical.Precursor web preferably remains on enough web tension makes the known method of use fiber web process field enter roll gap 116 with common smooth state.When each

precursor web

20,21 is passed through roll gap 116, simultaneously part first precursor web 20 is released outside the plane of first precursor web 20 with the tooth 110 of the groove 108 intermeshing rollers 104 of roller 102, passed second precursor web 21 then and form tufts 6.In fact, tooth 110 " pushed away first precursor web 20 " or " passing " second precursor web 21.

When the top of tooth 110 pushed through from first and

second precursor web

20,21, the fiber that mainly is oriented to part first precursor web 20 of the CD that intersects with tooth 110 was released outside the plane of first precursor web 20 by tooth 110.Fiber can be pushed out outside the plane owing to the fiber mobility, perhaps they can owing to the z direction be stretched and/or plastic deformation is pushed out outside the plane.Released out-of-plane part first precursor web 20 by tooth 110 and push through second precursor web 21, it is owing to relatively low ductility is broken, thereby causes forming the tuft 6 on first side 3 of fiber web 1.Mainly be orientated and be parallel to longitudinal axes L usually, promptly the fiber of first precursor web 20 on the MD direction of precursor web 20 is only trailed by tooth 110 and keeps the state of their original random orientings substantially as shown in Figure 1.Here it is why in embodiment (this as shown in Fig. 1 to 4) fibrae circulares 8 can show reason with unique fiber alignment, this fibrae circulares 8 accounts for the significant percentage of each tuft 6 fiber, and described tuft 6 has the effective vector component or the master vector component of the axis T that is parallel to tuft 6.

By above-mentioned explanation be to be understood that when fiber web 1 be when preparing with apparatus and method of the present invention,

precursor web

20,21 should have and precursor web is destroyed the relevant differing material properties of (as owing to tensile stress is destroyed) preceding elongation ability.Specifically, nonwoven first precursor web 20 can have than bigger fiber mobility of second precursor web 21 and/or bigger elongation characteristics relative, make its fiber can fully move or stretch to form tuft 6, second precursor web 21 is broken simultaneously, that is, be not stretched to the needed degree of formation tuft.

The fiber of nonwoven precursor web can stretch out outside the plane and plastic-less deformation's degree can be depending on the degree of precursor web inter-fiber.For example, if the fiber of nonwoven precursor web only is that very loosely is entangled to each other, they will be easier slide (promptly moving with respect to adjacent fibre by reptation) between mutually so, and therefore easier stretching out with the formation tuft on the plane outside.On the other hand, the fiber of the nonwoven precursor web of more bonding (for example by a large amount of thermal point bond, water entanglement method etc.) will more may need to stretch out out-of-plane tuft and has plastic deformation greatly.Therefore, in one embodiment, first precursor web 20 can be to have the bonding non-woven web of relatively low fibrous inside, and second precursor web 21 can be to have the non-woven web that relative high inter-fiber connects, make the extended plane of fiber of the precursor web of winning like this, and the fiber of second precursor web 21 can not stretch out the plane.When enough power was applied to first precursor web 21, fiber wherein was tending towards stretching, and the not tensible of fiber of second precursor web and be tending towards breaking.

For given maximum strain (as, the strain that applies by device 100 tooth 110), second precursor web 21 must be under the tensile load that strain produced that applies actual destruction.That is to say, for the tuft of the present invention 6 on first side 3 that will be arranged on fiber web 1, second precursor web 21 must have enough low fiber mobility (if having) and/or relatively low elongation at break makes its part (promptly, at strain regions) under strain, break, thereby produce opening 4, tuft 6 can stretch out from this opening.If second precursor web 21 only produces distortion or stretches in the zone that strain takes place, thereby but in fact do not have to destroy to produce opening 4 therein, tuft 6 possibly can't form so.In one embodiment, the elongation at break of second precursor web 21 is in 1% to 5% scope.Though the elongation at break of actual needs depends on the strain that causes forming fiber web 1, but be to be understood that for most of embodiments second precursor web 21 can show that the fiber web elongation at break that has is 6%, 7%, 8%, 9%, 10% or bigger.Be to be understood that also actual elongation at break can be depending on strain rate, it is the function of linear velocity for device as shown in Figure 5.Being used for fibroreticulate elongation at break of the present invention can measure with methods known in the art, as the standard tension test method of using standard tension test device (as Instron, MTS, those that Thwing-Albert produces) etc.

In addition, for first precursor web 20, second precursor web 21 should have lower fiber mobility (if having) and/or lower elongation at break (promptly, the elongation at break of single fiber, perhaps if film, be the elongation at break of film) make that second precursor web 21 is not the degree of stretching out outside the plane to tuft 6, but in that tension force dies down under the strain that tuft 6 produced by forming, as passing through the tooth 110 of device 100.In one embodiment, if second precursor web, 21 relative first precursor web 20 show to have the feasible words completely of enough low elongation at break, the fin 7 relative tufts 6 of opening 4 only stretch out outside the plane a little.Usually, it is believed that the elongation at break that second precursor web 21 should have is littler by at least 10% than first precursor web 20, preferred little by at least 30%, more preferably little by at least 50%, even more preferably little of 100% than first precursor web 20.Being used for fibroreticulate relative elongation at break values of the present invention can measure with methods known in the art, as the standard tension test method of using standard tension test device (as Instron, MTS, those that Thwing-Albert produces) etc.

In one embodiment, second precursor web 21 can comprise basic all fibers of MD orientation, and as bunch fiber, making does not have the fiber of CD orientation substantially.For the embodiment of such fiber web 1, the fiber of second precursor web 21 can separate at opening 4 places that tuft 6 stretches out easily.Therefore, in this embodiment, the elongation at break that second precursor web 21 needn't have any minimum is not because breaking and rupturing of material is the mode that forms opening 4.

The quantity of tuft 6, spacing and big I by changing tooth 110 quantity, spacing and size and pair roller 104 and/or roller 102 carry out corresponding change in size and change in case of necessity.This change makes it possible to make together with possible variation in the precursor web 20,21 and is used for multi-purpose many different fiber webs 1.For example, by comprise have MD and CD player knit the extending line of plasticity relative high quantitative textiles first precursor web 20 with comprise relative high quantitatively, the fiber web 1 made of second precursor web 21 of low relatively ductile synthetic polymer non-woven material can be made into mulch film firm, porous, as is used for reducing the erosion protection system that ramp way damages and the native country vegetation can be grown at unsettled soil.By first precursor web 20 of the low relatively quantitative non-woven web that comprises the extending spunbond polymer fiber of plasticity with comprise that fiber web 1 that second precursor web 21 of relative low ductile synthetic polymer film is made can be used as the terry cloth-like fabric and is used for partly durable or durable clothing, perhaps be used for the personal-care supplies described in WO 01/76523.As following more fully narration, the fiber web 1 that comprises the combination of non-woven material/film first precursor web/second precursor web also can be used as the parts in the disposable absorbent article.

Fig. 6 represents part nip

roller

102 and 104 and the projection 106 and the cross section of tooth 110.As shown in the figure, tooth 110 has tooth depth TH and (notices that TH also can be applicable to height of projection; Tooth depth and height of projection equate in a preferred embodiment) and the section of being called apart from tooth-space width (or projection-protruding spacing) of P.As shown, depth of engagement E is measuring of

roller

102 and 104 engagements, and measures from top to the top of tooth 110 of projection 106.Depth of engagement E, tooth depth TH and section can change according to the character of

precursor web

20,21 and the desirable characteristics of fiber web 1 if desired apart from P.For example, usually, mesh degree E is big more, and essential percentage elongation that the fiber of first precursor web 20 must have or fiber-fiber mobility is big more.Equally, the required density (tuft 6 on the per unit area fiber web 1) of tuft 6 is big more, and section is apart from should be more little, and the long TL of tooth and tooth pitch TD should be more little, and is as described below.

Fig. 7 represents to have an embodiment of the roller 104 of a plurality of teeth 110, this roller can be used for by quantitatively between about 60gsm and 100gsm, preferably nonwoven first precursor web 20 of about 80gsm and density be about 0.91 to 0.94 and quantitative for the polyolefin film of about 20gsm (as, polyethylene or polypropylene) second precursor web, 21 manufacturing terry cloth-like fiber webs 1.

The zoomed-in view of tooth 110 as shown in Figure 8.In this embodiment of roller 104, tooth 110 has consistent circumferential length size TL, usually from forward position LE to tooth top 111 afterwards be measured as about 1.25mm along TE, and mutual spacing is identical, is about 1.5mm apart from TD.For quantitatively making terry-cloth web 1 at about 60 fiber webs 1 to about 100gsm scope by total, the length T L scope that the tooth 110 of roller 104 can have is from about 0.5mm to about 3mm, and spacing TD is that about 0.5mm is to about 3mm, tooth depth TH scope for about 0.5mm to about 5mm, and section apart from P between about 1mm (0.040 inch) and about 5mm (0.200 inch).Depth of engagement E is that about 0.5mm is to about 5mm (equaling tooth depth TH up to maximum).Certainly, E, P, TH, TD and TL can change tuft 6 numbers with size, spacing and the area density per unit area fiber web 1 that obtains required tuft 6 independently of each other).

As shown in Figure 8, each tooth 110 has top 111, forward position LE and back along TE.Tooth top 111 is elongated and is generally portrait orientation, and is consistent with the longitudinal axes L of tuft 6 and interruption part 16.It is believed that the looped tufts 6 that rises bunch for the fiber web 1 that obtains being described as being terry cloth-like, LE and TE should almost completely be orthogonal to the local periphery surface 120 of roller 104.Best, from the top 111 and the transition of LE or TE should be acute angle, as the right angle, have enough little radius of curvature and make tooth 110 can push through second precursor web 21 in LE and TE place.Be not bound by theory, it is believed that the top transition that has into relative acute angle between the top of tooth 110 and LE and the TE makes that tooth 110 can " neatly ", that is to say, local and clearly penetrate precursor web 20,21, make first side 3 of gained fiber web 1 can be described as " bunch shape " rather than " distortion " like this.When adding man-hour like this, except that the elasticity that precursor web 20 and 21 may have at first, fiber web 1 is not endowed any special elasticity.Penetrating precursor web 21 can cause sub-fraction fiber web 21 to form " paper scrap " or small pieces.

Under the higher line speed conditions, promptly higher relatively fiber web is by the process velocity of

rotation roller

102 and 104 roll gaps, and similar material can make tuft 6 show to have very different structures.Tuft 6 shown in Fig. 9 is similar with the structure of the tuft shown in Fig. 2, is to show to have very different structures, and the structure that looks like typical spunbond non-woven material is under relatively at a high speed, that is, high strain rate is processed down to form tuft 6.The typical case of this structure be tuft 6 near part, i.e. the end portion of base portion 17 and tuft 6, promptly broken fiber between the top 31 and tuft 6 tops look like those of " bunch clump " 19 of fiber.Bunch clump 19 comprises the fibrae circulares 8 of not fracture and is supported by it at the top of tuft 6, and comprises no longer the part broken fiber 11 that becomes one with first precursor web 20.That is to say that bunch clump 19 comprises the original pars fibrosa that becomes one with precursor web 20 but separate from precursor web 20 fully after (as the linear velocity of 30 meters of per minutes in method as described in Figure 5) processing under the sufficiently high linear velocity.

Therefore, be understood that from the above description in one embodiment, fiber web 1 can be described as the laminate web that is formed by the selectivity mechanically deform of at least the first and second precursor web, at least described first precursor web is a non-woven web, described laminate web has first side, this first side comprises described second precursor web and a plurality of discrete tufts, and each discrete tufts comprises and becomes one with first precursor web but stretch out the fiber of first precursor web and be the fiber that one is not stretched out first precursor web again with first precursor web neither.

Although it is believed that observed obvious fiber alignment at not end parts 31 places of tuft 6, as bunch clump 19, mainly be because process velocity, but it is believed that also it also is subjected to the influence of other parameter, and quantitatively and can influence the bonding processing temperature of fiber-fiber as the fiber type of first precursor web 20.Bunch clump of fiber it is believed that the top that appears at the tooth 110 of roller 104 adds relevant tuft 6 parts in man-hour.It is believed that fiber with fiber " locking " in position, thereby restriction elongate fiber and/or fiber move, and believe that these two kinds of mechanism make the formation of tuft 6 become possibility in the friction engagement of tooth tip.Therefore, in case we can say and be locked in the appropriate position, the fiber on adjacent teeth 110 tops just can rupture, and because any entanglement of precursor web and because possible the cold welding of the fiber that pressure and friction cause, broken fiber 11 begins also to remain resident in bunch clump 19 of tuft 6 ends 31.

First precursor web 20 with relative high basis weight has more relatively fiber 11 parts usually in bunch clump 19.On a kind of meaning, only seem to seem in process of production near most of fibre compositions of first precursor web 20 of tooth top portion 110 in the Z direction to be produced bunch clump 19 by the not end parts 31 of simple substitute to tuft 6.First precursor web 20 that comprises relative low elongation fiber or have a fiber of relatively low fiber-fiber mobility (as, relatively limited fiber surface wriggling ability) it seems that the fiber that can cause relatively small amount begins and remains resident in bunch clump 19 at tuft 6 terminal 31 places.Fiber-fiber mobility can fiber-fiber is bonding to be increased by reducing or eliminating.Heat bonding can be eliminated (that is, by there not being bonding avoiding) fully or significantly reduce to increase fiber-fiber mobility in some non-woven web.Similarly, water thorn fiber web can still less tangle to increase fiber-fiber mobility.For any precursor web 20, in first being processed as disclosed herein it being lubricated also to increase fiber-fiber mobility.For example, can before first precursor web 20 enters the roll gap 116 of roller 102 and 104, mineral oil lubricant be used thereon.In addition, plasticizer such as vaseline can be added in some plastic wire such as polyethylene web or polyethylene and the polypropylene fiber net, to strengthen ductility.

The result that bunch clump 19 exists is that fiber web 1 has fluffy and disorderly a little, veined effect on the one side, for example needing can be used for the cleaning piece of more scouring textures.On a kind of meaning, the fiber web that has fur towel shape sense of touch under relative low speed processing conditions when making can have the sensation of grinding relatively when add man-hour under identical but relative higher line velocity conditions.This fluffy and disorderly, veined sense of touch on the fiber web can be used for some purposes, as is used for the hard surface cleaning cleaning piece or the facial cleaning piece of peeling.Therefore, no matter fiber web 1 whether need be softness or textile-like to be applied to the red and swollen part of health together with stickum, as opoultice, or as suitable shape, half durable light grinding agent to be to remove dust and oxide lightly from the metal bending surface, the speed that tuft 6 forms can be regulated the texture that needs to obtain.

Not bound by theory, it is believed that if the fiber of first precursor web has highly crooked shape as crimped fibre, compare with more linear fiber conformation so, gained tuft 6 will have more fibrae circulares 8 and less broken fiber 18.The chance that it is believed that the bridging between two adjacent teeth of this fiber conformation is less, and since they at it more than breakaway poing and be not easy to stretch, the chance that therefore forms complete circulus is bigger.In addition, these curvilinear-shaped fibers also can be made by using eccentric bicomponent fibers or side-by-side bicomponent fibre (as the bicomponent fiber of being made up of polyethylene and nylon).

Found some non-woven web, as comprise the carded web of staple length fiber, when as first precursor web 20, in tuft 6, produce considerably less fibrae circulares 8, make the tuft 6 that in these fiber webs, produces to be described as like this and comprise a plurality of fibers 8 as the described ring-type of above Fig. 1 to 4, alignment.But the carded non-woven web can produce the tuft 6 of the unjustified and/or broken fiber 18 of fiber 8 with a small amount of (if any) ring-type, alignment and a large amount of (if being not entirely).It is believed that the unjustified of fiber in the tuft of being made by carded web 6 is that part is because the character of carded web fibre composition.Staple fiber is not " endless ", but has about 15mm to about 100mm, and more typical about 40mm is to the predetermined length of about 80mm.Therefore, when carded web adds man-hour with the described device of Fig. 5, it is believed that to have very large this possibility: the loose fibres end will be positioned at tuft 6 near, thereby in tuft 6, produce acyclic fiber ends.In addition, staple fiber does not have and for example spun-bonded fibre or the identical elongation characteristics of meltblown fibers usually.Yet even tuft 6 does not have fibrae circulares, fibrous tuft still provides soft beneficial effect, and the fiber web that obtains having the terry cloth-like characteristic.

Therefore, be understood that from the above description in one embodiment, fiber web 1 can be described as the laminate web that is formed by the selectivity mechanically deform of at least the first and second precursor web, at least described first precursor web is a non-woven web, described laminate web has first side, this first side comprises described second precursor web and a plurality of discrete tufts, and described tuft comprises and becomes one with described first area but stretch out a plurality of fibers of described first area.

If utilize weaving first precursor web 20, the structure of tuft 6 can be in close proximity to identical with structure with the tuft 6 shown structures that have that are formed at non-woven web with structure.For example, mainly be orientated horizontal extending warp and/or parallel if first precursor web 20 of weaving has, when adding man-hour with above-mentioned device 100, tooth 110 is tending towards separating vertical line (warp or parallel) and only x wire being released outside the plane.Therefore, the fiber web of being made by weaving first precursor web 20 1 can seem and feel to resemble very much the towel cloth fabric.

In preferred embodiments, first precursor web 20 is a non-woven web, wherein exists minimum fiber-fiber bonding.For example, precursor web can be the non-woven web with pattern of discrete thermal point bonds, and this is generally known in art for nonwoven webs.Yet, need make the minimum number of bounding point usually, and make spacing maximum so that the fiber maximum that moves and misplace when tuft 6 is formed.Usually, utilize and to have big relatively diameter and/or high relatively elongation at break and/or the high relatively ambulant fiber of fiber can produce better and the tuft 6 of clearer shaping.

Although fiber web 1 is disclosed in the two layer web of being made by two precursor web in preferred embodiments, it need not be confined to two-layer.For example, can make three layers or more laminated material, as long as one of precursor web is extending and push through the formation tuft from the opening of another layer by three precursor web.For example, fiber web 1 can comprise the top flat of hygienic articles, inferior top flat and core.Usually, needn't utilize adhesive or other adhesive bonding method to make laminate web 1.

The composition layer of fiber web 1 (as,

precursor web

20 and 21 and any other layer) can rely on " locking " effect of tuft 6 to remain on face-to-face lamination to concern that described tuft 6 stretches out from the opening 4 of second precursor web 21.In certain embodiments, may need to use adhesive or thermal or other adhesive bonding method, this depends on the final use of fiber web 1.For example, the fiber web 1 that comprises the bicomponent fiber non-woven web can carry out the convection current air bonding layer-layer is bonding to obtain bigger peel strength to provide after forming tuft 6.In addition, also may need adhesive is applied at least a portion of one of precursor web.For example, in certain embodiments, the specific region that adhesive, chemical adhesion, resin or powder-stuck between the layer or thermal optionally are applied to precursor web or whole.For example, using under the situation of adhesive, adhesive can be used in a continuous manner, as by the slot type coating, or uses in discontinuous mode, as by spraying, extrude etc.The discontinuous forms such as can be bar, band, droplet of using of adhesive.

Comprise nonwoven first precursor web although fiber web 1 is disclosed as in preferred embodiments, in fact, any precursor web can be non-woven web, thin polymer film, woven web or paper web.Certainly, no matter the fiber web characteristic how, first precursor web must have enough material characters such as ductility with the breaking yield rate so that the tuft that local deformation becomes to disperse.Similarly, second precursor web must have relatively little ductility or breaking yield rate, makes can to break man-hour when it adds with method as disclosed herein.

In multi-layered web 1, each precursor web can have different material characters, thereby the fiber web 1 with beneficial property is provided.For example, comprise the fiber web 1 of two (or a plurality of) precursor web, can have useful fluid treatment character to be used as the top flat on the disposable absorbent article, as following described more comprehensively as first and second precursor web.For example, for the fluid treatment of excellence, first precursor web 20 can be by hydrophilic relatively fibrous.Second precursor web 21 can be thin polymer film such as polyethylene film, and can be hydrophobic or by become hydrophobic.When as the top flat on the disposable absorbent article, this fibroreticulate tuft 6 can form the upper strata, i.e. the body contact layer.The fluid that is deposited on upper strata, the hydrophilic relatively tuft is transferred to the first precursor fiber mesh portions under the second film precursor fiber web layer from hydrophobic relatively film rapidly.The reason that observed rapid liquid shifts is common aligned fibers 8, the 18 formed capillary pipe structures by distortion 6.

Fiber

8,18 forms the capillary of direction alignment between adjacent fiber, and capillarity is strengthened by near the fiber convergence total tuft 6 base portions 17.

It is believed that fluid shifts the further enhancing because fluid can enter fiber web 1 by the space 10 that is surrounded by looped tufts 6 rapidly." side direction enters " ability and/or the capillarity that structure provided of fiber web 1, and/or hydrophilic gradient makes fiber web 1 become the ideal material of the best fluid treatment that is used for disposable absorbent article.Specifically, multi-layered web 1 can provide the improvement flow handling feature aspect even bigger.

Depend on used precursor web 20 and 21 and roller 102 and comprise the dimensional parameters of tooth 110, fiber web 1 of the present invention can show the physical attribute with wide region.Fiber web 1 can show have subjective be felt as soft to coarse texture range, never absorb absorbability, the bulkiness that absorbs very much from low relatively stacking volume to high relatively stacking volume; Tearing strength from low tearing strength to high-tear strength; From the nonelastic extremely ductile elasticity of at least 100% elasticity; From the low relatively paramount chemical-resistant chemical resistance of chemical resistance, this depend on chemically consider be described as the variable parameter, alkali resistance, opacity, wiping properties, water imbibition, oil absorption, poisture-penetrability, thermal insulation, weather fastness, high strength, high tear edge, anti-abrasiveness, Electrostatic Control ability, drapability, dye affinity, security etc. of barrier propterty usually with many other.Usually, according to the elongation characteristics of first precursor web 20, the size of device 100 can change the fiber web 1 that has various tuft 6 sizes to make, and described size comprises height h (as shown in Figure 3), and spacing (area density that comprises tuft 6).In addition, tuft can be easily forms linearity by having tooth 110 shown required patterns on the roller 104, fills the patterns such as selection zone of shape and laminate web.

Fiber web 1 can be used for various purposes, comprises various filters such as air cleaner, bag filter, liquid filter, vacuum filter, drain filter and bacterium protective filter; The sheet such as capacitor barrier paper and the floppy disk packaging material that are used for various electrical equipment; Various industrial sheet such as adhesive tape base cloth, oil absorption material and paper felt; Various wiper blade such as household wipes, maintenance and medical treatment, marking roll cleaning piece, the cleaning piece that is used to clean duplicator, baby wipes and be used for the cleaning piece of optical system; Various medical and health tablets, as in the base cloth of surgery apparel, operation dress, drop cloth, cap, face shield, coverlet, towel, gauze, paste, diaper, the diaper, base cloth, hygenic towelette and the thin paper of diaper cover, sanltary towel cover layer, sanltary towel or diaper acquisition layer (below cover layer), diaper cores, sanitary tampons lining, adhesive plaster; The sheet that clothes are used is as lining cloth, liner, Work Clothes lining and disposable underclothes; Filling, packaging material and the packing of the base cloth of various life material piece such as artificial leather and synthetic leather, desktop, wallpaper, drier, shopping bag, cover encapsulation and pillow cases; Various agricultural, as mulch film and erosion protection system, cooling and sun protection clothes, lining curtain, the sheet that all covers, anti-mating plate, the packaging material of agricultural chemicals, the liner sheet of seeding-growth jar; Various screening glass such as face mask for preventing smoke and dust protection mask, lab-gown and dust protection clothes; The sheet that various civil engineering works are used is as house wrap layer, adrainage material, filter medium, parting material, cover layer, roof, looped pile and ground blanket base cloth, material, sound insulation or vibration-damping sheet and cured sheets within the walls; With sheet in the various automobiles, as except the spacer of alkaline battery, also having rug and Che Nei pad blanket, molding top material, head rest and satinet.Other purposes comprises utilizes the cleaning piece of fiber web 1 as personal cleanliness or health, as is used for baby wipes, face-cloth or cleansing tissue or body towel.

In one embodiment, fiber web 1 or comprise that the compound of fiber web 1 can be used as the ight soil storage unit.Fiber web 1 can be used as time top flat or subgrade when being set at perforate fiber web or film following time, so as to accept and hold defecation after leave the low viscous ight soil of wearer's skin or the body excretions of thickness.The embodiment of the present invention that has big total three-D volumes in the fiber web or between the tuft 6 provides the ability of stronger storage low-viscosity fecal material usually.Use the absorbent article of this ight soil storage unit or subgrade to be described in inter alia the United States Patent (USP) 5,941,864,5,957,906,6,018,093,6,010,491,6,186,992 and 6,414,215.

In one embodiment, fiber web 1 comprises nonwoven first precursor web 20 and second precursor web, described nonwoven first precursor web comprises quantitatively for the spunbond non-woven material of about 80gsm and comprises that average diameter is about 33 microns polyethylene/polypropylene (sheath/core pattern) bicomponent fiber, and described second precursor web comprises the quantitative polyethylene film of 20gsm that is.In this embodiment, fiber web 1 every square centimeter of 24 tufts 6 of having an appointment, tuft 6 has a plurality of ring-types, aligned fibers 8, and wherein the fiber diameter of each is about 18 microns.Such fiber web can benefit the top flat as disposable absorbent article, as following shown in Figure 10.For example, this fiber web 1 is fluid impermeable except in tuft 6 zone, but described tuft 6 zone wicking fluids are from 3 to second sides 5, first side of fiber web 1.

Figure 10 represents the sanitary napkin plane of part excision, and described sanitary napkin is with the parts one of of fiber web 1 of the present invention as it.Usually, sanitary napkin 200 comprise egative film 202, top flat 206 and be arranged on top flat 206 and egative film 202 between absorbent core 204, described sanitary napkin can be engaged near 210 at periphery.Sanitary napkin 1 can have the part of extending laterally, so-called " wing " 208, and it is designed to wrap up the side of sanitary napkin 1 user's interior crotch area.Sanitary napkin (comprising as its top flat towards body surface) is well known in the art, and does not need to describe in detail various replacements and optional design.Except sanitary napkin, fiber web 1 also can be used in diaper or adult incontinence products or other disposable sanitary product.Yet, notice that fiber web 1 can be used as one or more in egative film, core, top flat, inferior top flat or the wing material, or as their parts.Fiber web 1 also can have multilayer, and comprises top flat, inferior top flat, core, egative film or any several target zone.

Fiber web 1 especially can be used as the top flat 206 of sanitary napkin 200.Fiber web 1 especially is of value to the top flat 206 as sanitary napkin because it can be gathered fluid admirably and be dispensed to absorbent core 204, and top flat 206 wetting once more towards body surface when preventing to use admirably.Wetting once more may be due at least two reasons: (1) since the pressure on the sanitary napkin 200 fluid that absorbs is extruded; And/or (2) are collected in the top flat 206 or the humidity on it.In preferred top flat 206, two character, it is maximum that fluid acquisition and fluid keep all reaching, and wetting once more be minimum.In other words, preferred top flat has higher fluid acquisition speed and wetting once more than low degree with demonstration.

Top flat 206 can use polyethylene film second precursor web 21 of nonwoven first precursor web 20 and fluid impermeable to make.Form fibroreticulate quantitatively can be different, yet for the consideration of cost and benefit, between about 20gsm and the 80gsm always quantitatively is that fiber web 1 is needed usually.When being made as film/non-woven laminating material, fiber web 1 is with wetting the combining that prevent once more of the flexibility of fiber tuft and fluid capillarity and fluid impermeable thin polymer film.When using sanitary napkin, top flat 206 conducts that comprise the fiber web 1 with first side 3 are towards bodyside, and transmit as the fluid with following absorbent core second side 5, fluid can be gathered by the tuft on first side 3 of fiber web 16 and pass through second side 5 of second precursor web, 21 wickings to fiber web 1 then, and it is separated and is drawn in the absorbent core 204 then.Because tuft 6 is that disperse and spaced apart, and separated, so can make once more wetting minimum by second precursor web 21 of fluid impermeable.Alternatively, fiber web 1 can use first side 3 as the fluid transmission equipment side, and second side 5 is towards bodyside.This makes interruption part 16 can allow fluid be transferred in the tuft 6 or passes through tuft 6 transmission.

Figure 11 represents the plane of the part excision of catamenial tampons plug 300, and described sanitary tampons is with the parts one of of fiber web 1 of the present invention as it.Usually, sanitary tampons 300 comprises the covering wrappage 304 of absorbent core 302 with the fluid penetrable that covers absorbent core 302 of compression.Cover wrappage 304 and can be extended out an end of absorbent core 302 to form shirt rim part 306.Can provide and remove parts such as cord 308 so that use the back to take out sanitary tampons.Sanitary tampons comprises the covering wrappage that touches the surface as its body, is well known in the art, and does not need to describe in detail various replacements and optional design.Yet, notice that fiber web 1 can be used as to cover wrappage, absorbent core material or remove one or more in the component materials, or as their parts.

Following table 1 is represented the exemplary embodiments of fiber web 1 as described in the present invention, and the size relevant with equipment therefor in their process of preparation 100, and is disclosed as mentioned.The brief description of each listed embodiment is behind table 1.

Figure 12 is the microphoto of sample 1.First precursor web of sample 1 is for quantitatively being the carded PET non-woven web of 145 grams every square metre (gsm), it is that (model is F30A for polyester/copolyester trefoil fiber by 38mm (1.5 inches) staple length, available from FIT (Fiber Innovation Technology) Inc., JohnsonCity, the manual carded of TN..Second precursor web of sample 1 is that thickness is low density polyethylene (LDPE) (LDPE) film of 0.1mm (0.004 inch), and it is by Huntsman Film Products Co., and Carrolton OH makes, called after X420.Sample 1 is produced on device as described above in Figure 5, and linear velocity is 3 meters of about per minutes (10 feet of a per minute).As shown in figure 12, fin 7 almost stretches out second precursor web significantly and (that is, thin layer outside) the plane, and approximately covers half of tuft 6.As above illustrated, this can be desirable when harder, the springy tuft 6 of needs.

Figure 13 is the microphoto of sample 2.First precursor web of sample 2 is quantitatively to be spunbond PE/PP 50/50 core/skin non-woven web of 30gsm, and it is by BBA, and Simpsonville SC makes.Second precursor web of sample 2 is incited somebody to action for passing through The binder removal of 1803 aluminium foil strip falls the aluminium foil that (that is, wiping) obtained, and described aluminium foil strip is available from Avery Dennison, U.S.Specialty Tape Division, PainesvilleOH.Sample 2 is produced on device as described above in Figure 5, linear velocity be 3 meters of about per minutes (10 feet of per minutes) as shown in figure 13, aluminium foil is tending towards splitting, and the plastic deformation of fin 7 is very little.

Figure 14 is the microphoto of sample 3.First precursor web of sample 3 is quantitatively to be spunbond PE/PP 50/50 core/skin non-woven material of 30gsm, and it is by BBA, and Simpsonville SC makes.Second precursor web of sample 3 is brown 100% a callable 301b kraft wrapping, available from any brown paper source, as UlineShipping Supplies, Waukegan, IL.Sample 3 is produced on device as described above in Figure 5, linear velocity be 3 meters of about per minutes (10 feet of per minutes) as shown in figure 14, second precursor web of brown paper can produce the opening 4 and the fin 7 of similar volcano shape opening.

Figure 15 is the microphoto of sample 4, and described sample comprises three precursor web.The first and the 3rd precursor web of sample 4 is quantitatively to be the spunbond polypropylene non-woven material of 13.5gsm, and called after NW30 is available from First Quality Nonwovens, Haxleton, PA.The first and the 3rd precursor web is outer, second precursor web is clipped in the middle, described second precursor web is the loose bonding air lay non-woven web that is formed by the long staple fiber of 44mm (1.75 inches), it comprises polyester fiber and PE/PP 50/50 core/skin non-woven material bicomponent binder fibers, and ratio of fibers is respectively 80/20 by weight.Polyester fiber is that model is 1311 fiber, is 851607 fiber and the PE/PP fiber is a model, and two kinds of fibers are all available from FIT (FiberInnovation Technology) Inc., Johnson City, TN.Sample 4 is produced on device as described above in Figure 5, linear velocity be 30 meters of about per minutes (100 feet of per minutes) as shown in figure 15, in the embodiment of some fiber web 1, may not refer to fin 7, but only near the opening that tuft 6 extends through second precursor web break a little.Can find out that the tuft 6 shown in Figure 15 comprises two kinds of fiber types.The fiber of one of nipped air fibres net and skin all helps the formation of tuft 6 in the centre.

From the description of above fiber web of the present invention 1 and device 100, be appreciated that the structure that can under the situation that does not deviate from protection scope of the present invention, produce many various fiber webs 1, as in additional claims, being subjected to those of claims protection.For example, fiber web 1 can be used distillate medicinal water, medicament, cleaning fluid, antiseptic solution, emulsion, aromatic, surfactant coated or processing.Similarly, device 100 can be configured to only form tuft 6 on the part of fiber web 1, or forms the tuft 6 of different size or area density.

Another advantage of the fibroreticulate method of described production the present invention is that described fiber web can be with other web production equipment online production or with the online production of disposable absorbent article production equipment.In addition, also existing can be in first being processed of the present invention or other solid molding method of using afterwards.For example, fiber web can be processed as described herein, uses the drawing process perforate then, as authorizes described in people's such as Curro the United States Patent (USP) 5,658,639 that.Alternatively, material can be made composite by the whole bag of tricks, as authorizes U.S.'s announcement 2003/028 of people such as Curro, that method described in the 165A1, or as authorize people's such as Weber United States Patent (USP) 5,167, annular roll-in in 897 is processed then as described herein.Therefore the gained fiber web can show the combination beneficial effect with these multiple material modifications.

The relevant portion of all documents of quoting in detailed Description Of The Invention is incorporated herein by reference; It is to its approval as prior art of the present invention that the quoting of any document not can be regarded as.

Although illustrated and described specific embodiments of the present invention, it will be apparent to those skilled in the art that many other variations and modifications may be made in the case of without departing from the spirit and scope of protection of the present invention.Therefore in additional claims, comprise all such changes and modifications in the scope of the invention consciously.

Claims

1. laminate web, described laminate web comprises first and second precursor web, at least described first precursor web is a non-woven web, described laminate web has first side and second side, described first side comprises described second precursor web and the tuft that at least one is discrete, each described discrete tufts has the linear orientation that limits longitudinal axis and comprises and a plurality ofly divide and extend through bunch shape fibrae circulares of described second precursor web as the integral extensions of described first precursor web, and the fiber diameter of described bunch of shape fibrae circulares is less than the fiber diameter of the fiber of described first precursor web; Described second side comprises described first precursor web.

2. laminate web as claimed in claim 1, wherein said laminate web comprises a plurality of discrete tufts.

3. laminate web as claimed in claim 1, wherein said first precursor web comprises the non-woven web of basic randomly oriented fiber.

4. laminate web as claimed in claim 3, wherein said fiber comprise at least a material that is selected from cellulose, polyethylene, polypropylene and the polyester.

5. laminate web as claimed in claim 3, wherein said fiber comprises bicomponent fiber.

6. laminate web as claimed in claim 3, wherein said fiber comprises non-circular fiber.

7. laminate web as claimed in claim 1, wherein said laminate web comprises at least 10 discrete tufts for every square centimeter.

8. laminate web as claimed in claim 1, wherein the part of each described tuft with the clearance gap area limiting in described tuft inside.

9. cleaning piece, described cleaning piece comprises the described laminate web of claim 1.

10. laminate web, described laminate web comprises first and second precursor web, at least described first precursor web is the non-woven web that comprises fiber, described laminate web has first side, described first side comprises described second precursor web and a plurality of discrete tufts, each described discrete tufts comprises with described first precursor web and is one and the fibrae circulares that stretches out from described first precursor web and is the fiber that one is not stretched out from described first precursor web again with described first precursor web neither that the fiber diameter of described bunch of shape fibrae circulares is less than the fiber diameter of the fiber of described first precursor web.

11. laminate web as claimed in claim 10, wherein said fiber comprise at least a material that is selected from cellulose, polyethylene, polypropylene and the polyester.

12. laminate web as claimed in claim 11, wherein said fiber comprises bicomponent fiber.

13. laminate web as claimed in claim 11, wherein said fiber comprises non-circular fiber.

14. laminate web as claimed in claim 10, wherein said laminate web comprises at least 10 discrete tufts for every square centimeter.

15. a cleaning piece, described cleaning piece comprise the described laminate web of claim 10.

16. disposable absorbent article, described goods have at least one parts that comprise laminate web, described laminate web comprises first and second precursor web, at least described first precursor web is a non-woven web, described laminate web has first side and second side, described first side comprises described second precursor web and at least one discrete tufts, each described discrete tufts has the linear orientation that limits longitudinal axis and comprises a plurality of bunches of shape fibrae circulares, the integral extensions that described bunch of shape fibrae circulares is described first precursor web is divided and is extended through described second precursor web, and the fiber diameter of described bunch of shape fibrae circulares is less than the fiber diameter of the fiber of described first precursor web; Described second side comprises described first precursor web.

17. the article of claim 16, wherein said goods are selected from sanitary tampons or diaper.

18. the article of claim 16, wherein said laminate web constitutes the top flat of described disposable absorbent article.

19. the article of claim 16, wherein said laminate web constitutes the core of described disposable absorbent article.