CN101155563A - 具有波状起伏的吸收芯结构 - Google Patents

具有波状起伏的吸收芯结构 Download PDF

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Publication number
CN101155563A
CN101155563A CNA2006800078601A CN200680007860A CN101155563A CN 101155563 A CN101155563 A CN 101155563A CN A2006800078601 A CNA2006800078601 A CN A2006800078601A CN 200680007860 A CN200680007860 A CN 200680007860A CN 101155563 A CN101155563 A CN 101155563A
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CN
China
Prior art keywords
crest
trough
fibrous material
absorbent core
sap
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CNA2006800078601A
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English (en)
Inventor
史蒂芬·丹尼尔·贝尔纳尔
拉凯利·林恩·本特利
帕特里克·劳伦斯·克拉内
詹姆斯·哈罗德·戴维斯
内扎姆·马拉科蒂
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Nordson Corp
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Nordson Corp
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Publication of CN101155563A publication Critical patent/CN101155563A/zh
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Abstract

一种吸收芯结构,具有至少一个采集区、至少一个分散区和至少一个存储区。所述采集区由纤维材料构成。采集区具有从大约0.018g/cc至大约0.20g/cc的相对低的密度。分散区由所述纤维材料构成。分散区被压实以具有从大约0.024g/cc至大约0.45g/cc的相对适中的密度。分散区与所述采集区流体连通。存储区由所述纤维材料构成。存储区被压实以具有从大约0.030g/cc至大约0.50g/cc的相对高的密度。存储区与所述分散区流体连通。纤维材料的一部分形成为至少一个波峰和至少一个波谷,然后接着被折叠以便形成所述吸收芯结构。

Description

具有波状起伏的吸收芯结构
技术领域
本发明涉及用于一次性吸收产品的吸收芯结构。更具体地,本发明涉及由纤维材料构成的吸收芯结构。
背景技术
具有吸收芯结构的一次性吸收产品在本领域中是熟知的。此外,熟知的是,这种吸收芯结构具有至少三个功能区,即,采集区、分散区和存储区。虽然已知这种区,但具有所述区的吸收芯结构的设计被当前的制造方法和当前的材料选择所限制。
这种传统的吸收芯结构的一种包括纤维素材料的使用。虽然纤维素材料的使用提供了满意的吸收和分散,但纤维素芯结构通常具有很差的湿完整性(即,在湿时候具有很差的结构完整性)。为了提高这种纤维素芯结构的湿完整性,经常结合使用昂贵的粘合剂。当使用纤维素材料时,另一个公知的问题是存在结和细毛时,这些结和细毛是不满意地形成的会对芯的性能(如功效、成本)产生负面影响的纤维。
这种传统的吸收芯结构的另一种包括合成熔喷纤维的使用。虽然合成熔喷纤维的使用提供满意的湿完整性,但由此所得到的芯结构时常在设计中受到限制。例如,合成熔喷纤维通常直径较小(如2-9微米);因此由此得到的芯结构将通常具有很差的采集性能。另外,这些较小的纤维往往是不耐用的,因此不允许产生吸水后的空隙区域。此外,合成熔喷芯结构通常需要使用昂贵的粘结剂。
还已知用于一次性吸收产品的传统吸收芯结构可以由离散的多层材料制成。另外,已知所述的层可以由不同类型的材料组成。例如,一种传统的吸收产品可由以下各物组成:(a)顶层,作为采集区,用于快速吸收穿用者的分泌物,(b)中间层,作为分散区,用于在吸收芯结构内传输分泌物(例如,纵向或横向移动分泌物以更好地利用尿布),和(c)底层,作为存储区,用于长时间存储分泌物。
需要的是一种由纤维材料制成的吸收芯结构,在该吸收芯结构中,采集区、分散区和存储区的性能能够在竖直和/或水平方向被容易地改变。
发明内容
一种吸收芯结构,具有至少一个采集区、至少一个分散区和至少一个存储区。采集区由纤维材料构成。采集区具有从大约0.018g/cc至大约0.20g/cc的相对低的密度。分散区由所述纤维材料构成。分散区被压实以具有从大约0.024g/cc至大约0.45g/cc的相对适中的密度。分散区与所述采集区流体连通。存储区由所述纤维材料构成。存储区被压实以具有从大约0.030g/cc至大约0.50g/cc的相对高的密度。存储区与所述分散区流体连通。纤维材料的一部分形成为至少一个波峰和至少一个波谷,然后折叠以便形成所述的吸收芯结构。所述纤维材料可以选自由以下各材料组成的群组:聚丙烯、聚乙烯、聚酯、聚乙烯醇、聚醋酸乙烯酯、淀粉、醋酸纤维素、聚丁烯、人造纤维、聚氨酯、KratonTM(科腾)、聚乳酸、棉、LyocellTM(莱赛尔)、生物可降解聚合物、适合形成纤维的任何其它材料、以及它们的组合。吸收芯结构也可以包括超吸收材料,如超吸收聚合物(SAP)和/或具有超吸收性能的其它材料。所述SAP可以沉积在所述波谷的至少一个波谷上。所述SAP可以沉积在所述波峰的至少一个波峰上。所述SAP可以沉积在所述波谷的至少一个波谷和所述波峰的至少一个波峰上。所述SAP可以沉积在交替的波谷上。所述SAP可以沉积在交替的波峰上。所述波峰的第一排与第二排可以基本竖直对齐。所述波峰的第一排与所述波谷的第一排可以基本竖直对齐。纤维材料可以包括大体上没有波峰和波谷的线性部分。线性部分可以折叠并位于至少两层波峰和波谷之间。SAP可以沉积在该线性部分上。
一种吸收芯结构,具有至少一个采集区、至少一个分散区和至少一个存储区。所述采集区由第一纤维材料构成。采集区具有从大约0.018g/cc至大约0.20g/cc的较低的密度。所述分散区由第二纤维材料构成。分散区被压实以具有从大约0.024g/cc至大约0.45g/cc的相对适中的密度。分散区与采集区流体连通。分散区具有至少一个波峰和至少一个波谷。所述存储区由第三纤维材料构成。存储区被压实以具有从大约0.030g/cc至大约0.50g/cc的较高的密度。存储区与所述分散区流体连通。存储区具有至少一个波峰和至少一个波谷。第一纤维材料、第二纤维材料和第三纤维材料相互叠置以便形成所述吸收芯结构。纤维材料可以选自由以下各材料组成的群组:聚丙烯、聚乙烯、聚酯、聚乙烯醇、聚醋酸乙烯酯、淀粉、醋酸纤维素、聚丁烯、人造纤维、聚氨酯、KratonTM(科腾)、聚乳酸、棉、LyocellTM(莱赛尔)、生物可降解聚合物、适合形成纤维的任何其它材料、以及它们的组合。吸收芯结构也可以包括超吸收材料,如超吸收聚合物(SAP)和/或具有超吸收性能的其它材料。所述SAP可以沉积在所述波谷的至少一个上。所述SAP可以沉积在所述波峰的至少一个上。所述SAP可以沉积在所述波谷的至少一个和所述波峰的至少一个上。所述SAP可以沉积在交替的波谷上。所述SAP可以沉积在交替的波峰上。所述分散区内的一排所述波峰可以与所述存储区内的一排所述波峰基本竖直对齐。所述分散区内的一排所述波峰可以与所述存储区内的一排所述波谷基本竖直对齐。
本发明进一步设想制造例如用于一次性卫生产品中的吸收芯结构的各种方法。通常,所述方法可以涉及熔纺至少一层纤维材料,在纤维材料的层中形成至少两个波峰和至少一个波谷,并压实该层的至少一部分。在各种实施例中,可以利用超吸收材料来存储液体。超吸收材料可以由聚合物和/或其他材料形成。熔纺工艺可以例如涉及熔喷和/或纺粘工艺,该熔喷和/或纺粘工艺将纤维沉积在例如丝线形成的传送元件的移动的收集器上。
在一个特别的说明性实施例中,第一层纤维材料形成有至少两个波峰和至少一个隔开该波峰的波谷。第一层纤维材料的第一部分被折叠在第一层纤维材料的第二部分上,并且第一层纤维材料的至少一部分被压实。当从纤维材料的层的相对表面测量时,每个波峰处的层的高度可以是每个波谷处的高度的几倍。例如,9∶1的比例可用于某些应用。然而,高一些或低一些的比例也可以是需要的。当前,本发明优选的是大约2∶1的最小比例。波峰和波谷的宽度以及形状也可根据需要而不同。
结合上述实施例或本发明的其他实施例,也可以可任选地使用各种另外的特征。例如,形成第一层纤维材料可以根据需要涉及沿第一层纤维材料的第一表面形成多个交替的波峰和波谷。压实第一层的至少一部分可以进一步涉及压实多个波峰的至少一部分。将第一层纤维材料的第一部分折叠在第一层纤维材料的第二部分上可以进一步包括对齐相对关系的各对波峰,或对齐具有相对波谷的波峰,或反过来,或这两种选择的组合,这都取决于希望的密度性质。取决于这种压缩给予或促使的希望的液体采集、分散和/或存储性质,第一层纤维材料的所述波峰和/或其他区域可以被压缩,或以其它方式均匀压实整个层,或压实选定的一部分或一些部分。
另一方面,纤维材料的第三部分可以折叠在第一和第二部分之间。在具有相互邻近的多层或多层部分的这些实施例的任一个中,取决于要生产的特定产品的需要,超吸收材料可均匀地或在间隔开的位置处沉积在一个或多个层或层部分上。超吸收材料也可以或交替地分散在组成一个或多个纤维层或层部分的纤维内。
在使用第一和第二离散层的、有或没有折叠一层或两层的实施例中,构成第一和第二层的纤维可以由相同的材料或不同特性的材料形成。
涉及使用纤维材料的离散层来形成吸收芯结构,该吸收芯结构形成有第一纤维材料的第一层的一个说明性实施例包括形成具有分离至少两个波峰的至少一个波谷的第一纤维材料的第一层。第二纤维材料的第二层靠着波峰和波谷放置。所述方法进一步包括压实形成第一层的波峰和靠着该波峰放置的第二层的区域的纤维材料。第二层可以大致上平坦,或可以包括一个或多个波峰和波谷。该实施例和本发明的其他实施例一样,取决于应用的需要也可以具有另外的层,并且可包括单独使用或以任何需要的组合使用的上述其他特征。
本领域技术人员在仔细阅读下列结合附图的优选实施例的详细描述后,将可以更容易地了解本发明的各种另外特点、优点和目的。
附图说明
图1a示出具有波峰和波谷的纤维材料的示例性部分;
图1b示出图1a中的纤维材料,其中示出先前的波峰已经基本被压扁成为更短更密的区域;
图2a示出被折叠的示例性纤维材料;
图2b示出图2a的吸收芯结构被压实使得所得到的厚度减小且密度增加;
图2c是图2b中被圆圈包围的区域的特写视图,由此可进一步理解密度变化的区域;
图3a示出被折叠的示例性纤维材料;
图3b示出图3a的吸收芯结构被压实使得所得到的厚度减小且密度增加。
图3c是图3b中被圆圈包围的区域的特写视图,由此可进一步理解密度变化的区域。
图4a示出被折叠的示例性纤维材料;
图4b示出图4a的吸收芯结构被压实使得所得到的厚度减小且密度增加;
图4c是图4b中被圆圈包围的区域的特写视图,由此可进一步理解密度变化的区域;
图5a示出被折叠的示例性纤维材料;
图5b示出图5a的吸收芯结构被压实使得所得到的厚度减小且密度增加;
图5c是图5b中被圆圈包围的区域的特写视图,由此可进一步理解密度变化的区域;
图6a示出被折叠的示例性纤维材料;
图6b示出图6a的吸收芯结构被压实使得所得到的厚度减小且密度增加;
图6c是图6b中被圆圈包围的区域的特写视图,由此可进一步理解密度变化的区域;
图7a示出被折叠的示例性纤维材料;
图7b示出图7a的吸收芯结构被压实使得所得到的厚度减小且密度增加;
图7c是图7b中被圆圈包围的区域的特写视图,由此可进一步理解密度变化的区域;
图8a示出被折叠的示例性纤维材料;
图8b示出图8a的吸收芯结构被压实使得所得到的厚度减小且密度增加;
图8c是图8b中被圆圈包围的区域的特写视图;
图9a示出被折叠的示例性纤维材料;
图9b示出图9a的吸收芯结构被压实使得所得到的厚度减小且密度增加;
图9c是图9b中被圆圈包围的区域的特写视图,由此可进一步理解密度变化的区域;
图10a示出被折叠的示例性纤维材料;
图10b示出图10a的吸收芯结构被压实使得所得到的厚度减小且密度增加;
图10c是图10b中被圆圈包围的区域的特写视图,由此可进一步理解密度变化的区域;
图11a示出具有波峰和波谷的纤维材料的第一离散中层和具有第一起伏区和第二起伏区的纤维材料的第二离散层,第一起伏区和第二起伏区各具有波峰和波谷;
图11b示出所述第二起伏区被压实在第一离散中层上面,使得它们的对齐的波峰被进一步压实,而它们的对齐的波谷仍然提供空隙空间;
图11c是图11b中被圆圈包围的区域的特写视图,由此可进一步理解密度变化的区域;
图12a示出示例性的平放方法,其包括具有波峰和波谷的第一层纤维材料;具有波峰和波谷的第二层纤维材料;和大体上平坦的第三层纤维材料;
图12b示出所述第三层被压实在所述第二层上面使得所述第三层大体上填充波谷;
图12c是图12b中被圆圈包围的区域的特写视图,由此可进一步理解密度变化的区域;
图13a示出一吸收芯的二维示意图,该吸收芯具有在整个芯设计中被选择性地放置的采集区、分散区和存储区;
图13b示出图13a的三维示意图,具有在其内部流动的流体;
图13c示出图13b的三维示意图具有在其内部进一步流动的流体;和
图14示出另一吸收芯的三维示意图,该吸收芯具有在三维布局中变化的采集区、分散区和存储区。
具体实施方式
在此使用的各种术语的定义如下:
术语“吸收产品”在此指吸收和容纳身体分泌物的物品,更具体地,指紧靠或邻近穿用者的身体放置以吸收和容纳身体排泄的各种分泌物的物品,如:失禁贴身短内裤、失禁贴身内衣、吸收衬垫、尿布垫圈或衬垫、女性卫生服装以及类似物。吸收产品可具有吸收芯、上层片和底层片,其中吸收芯具有服装表面和身体表面;上层片靠近吸收芯的身体表面且液体能够渗透;底层片靠近吸收芯的服装表面且液体不能渗透。
术语“一次性”在此是指通常不再清洗或以其它方式存储或再次用作吸收产品的吸收产品(即,它们在使用一次后被丢弃掉,优选地被回收、形成堆肥或以环境兼容的其它方式丢弃)。
术语“尿布”在此是指通常由婴儿或失禁者下身穿着的吸收产品。
术语“裤子”在此是指为婴儿或成人穿用者设计的、具有腰部开口和腿部开口的一次性服装。所述裤子可通过将穿用者的腿插入腿部开口并将裤子滑动至穿用者的下身来放置在穿用者身上的适当位置。所述裤子可以通过任何合适的技术进行预成形,这些技术包括但不限于使用可再次固定和/或不可再次固定的结合(如,缝合、焊接、粘合剂、内聚粘结、紧固件等等)将产品的各部分连接在一起。裤子可以沿产品周围在任意地方预成形(如侧边紧固或前腰部紧固)。虽然在此使用术语“裤子”,但裤子也通常称作“密封式的尿布”、“预固定的尿布”、“穿戴的尿布”、“训练裤”和“尿布裤”。下列文献中公开了合适的裤子:1993年9月21日授予Hasse等人的美国专利No.5246433;1996年10月29日授予Buell等人的美国专利No.5569234;2000年9月19日授予Ashton的美国专利No.6120487;2000年9月19日授予Johnson等人的美国专利No.6120489;1990年7月10日授予Van Gompel等人的美国专利No.4940464;1992年3月3日授予Nomura等人的美国专利No.5092861;2002年6月13日提交的名为“Highly Flexible And Low Deformation Fastening Device”的美国专利申请No.10/171249;1999年4月27日授予Kline等人的美国专利No.5897545;1999年9月28日授予Kline等人的美国专利No.5957908。
术语“机器方向(MD)”或“纵向”在此是指平行于产品和/或紧固材料的最大线性尺寸的方向,并包括纵向±45°范围内的方向。
术语“横向(CD)”、“侧向”或“横穿”在此是指垂直于纵向方向的方向。
术语“连接”包括通过将一个元件直接固定到另一个元件上而将该元件直接紧固到另一个元件的结构,以及通过将一个元件固定到与另一个元件相固定的中间元件上而将该元件间接紧固到另一元件的结构。
在此使用的术语“纺粘纤维”是指大体上分子取向的聚合材料的小直径纤维。纺粘纤维通常是从多根纤细的、通常具有挤压长丝直径的喷丝头的圆形毛细管挤压熔化的热塑性材料作为长丝形成,然后由拉细工艺快速减小其直径。纺粘纤维在它们沉积到收集表面时通常没有粘性而且通常是连续的。
在此使用的术语“纺粘材料”是指由纺粘纤维制成的材料。
在此使用的术语“熔喷纤维”是指聚合材料的纤维,该纤维通常通过以下方法形成:将熔化的热塑性材料挤压过多根纤细的、通常是圆形的模具毛细管作为熔化的线或长丝进入会聚的高速、通常是热的气(如空气)流中,该气流拉细熔化的热塑性材料的长丝来减小它们的直径。然后,熔喷纤维由高密度气流携带并沉积在收集表面以形成随意分散的熔喷纤维的纤网。熔喷纤维可以是连续的或不连续的,通常平均直径小于10微米,并且当沉积在收集表面上时通常是有些粘的。
在此使用的术语“聚合物”通常包括但不限于均聚物、共聚物,例如,嵌段、移植、随机和交替共聚物、三元共聚物等等,及其混合和变体。此外,除非有其他特别的限制,术语“聚合物”包括分子的所有可能的立体构型。这些构型包括但不局限于全同立构、间同立构和随意对称。
如在此使用的,“超声波焊接”是指例如通过将织物穿过声波喇叭和支承辊之间实现的一种工艺。
如在此使用的,术语“采集层”或“采集区”是指一种纤维材料,具有从0.018g/cc左右至0.20g/cc左右的相对低的密度,并且具有从0.41mm左右至5.23mm左右的相对高的厚度。
如在此使用的,术语“分散层”或“分散区”是指一种纤维材料,该纤维材料具有从0.024g/cc左右至0.45g/cc左右的相对适中的密度,并且具有从0.39mm左右到4.54mm左右的相对适中的厚度。
如在此使用的,术语“存储层”或“存储区”是指含有SAP的任何区域。此外,该术语是指一种纤维材料,其具有从0.030g/cc左右至0.50g/cc左右的较高的密度,并且具有0.15mm至3.96mm左右的较低的厚度。
如在此使用的,术语“小直径”描述直径小于或等于10微米的任何纤维。
如在此使用的,术语“大直径”描述直径大于10微米的任何纤维。
如在此使用的,术语“超吸收”是指可以至少吸收其大约10倍重量的液体的材料。
图1a示出纤维材料10的一个示例性部分,该纤维材料具有波峰40和波谷42。波峰40的大致高度为大约9mm至大约35mm(如Hp所示,优选地大约27mm)且大致宽度为大约2.5mm至大约25mm(如Wp所示,优选地大约12mm)。波谷42的大致高度为大约1mm至大约17.4mm(如Hv所示,优选地大约3mm)并且大致宽度为大约2.5mm至大约25mm(如Wv所示,优选地大约12mm)。波峰的大致基本重量为大约99%至大约51%,而波谷的基本重量为大约1%至大约49%。例如,假设平均基本重量为100gsm,则波峰的基本重量可为大约90%(或与高度约为9mm相对应的约180gsm),并且波谷的基本重量可为大约10%(或与大约1mm的高度相对应的约20gsm)。纤维材料10的纤维可以由各种合适的材料构成,这些材料包括但不局限于聚丙烯、聚乙烯、聚酯、聚乙烯醇、聚醋酸乙烯酯、淀粉、醋酸纤维素、聚丁烯、人造纤维、聚氨酯、KratonTM(科腾)、聚乳酸、棉、LyocellTM(莱赛尔)、生物可降解聚合物(biogradeable polymers)、适合形成纤维的任何其它材料、以及它们的组合。本发明的纤维材料的直径可从10微米左右至600微米左右,不同于直径通常为从约2至约9微米的传统熔喷纤维。具有这样较大的直径允许生成低密度的纤维材料,该低密度的纤维材料为采集层提供必要的空隙空间。能够改变密度也是必要的,以便提供分散区和存储区。这种改变技术包括但不局限于:压实(如,在生产卷轴上拉细纤维时的压送辊、真空)、压延(如热压送辊)、超声波和通过空气焊接(如美国专利No.4011124中示例的那样)。
图1b示出图1a的纤维材料10,其中先前的波峰示出为已经基本被压扁成为更短更密的区域30。波峰被压扁成更短更密的区域的基本想法将在下列实施例中进行进一步说明。
图2a示出正在被折叠的示例性纤维材料10。该特别的示例性实施例示出为三层折叠。纤维材料10可由具有波峰40和波谷42的区域组成。纤维材料10也可包含没有波峰40和波谷42的区域。例如,起伏区域10a和10b可具有波峰40和波谷42,而平坦区域10c没有波峰和波谷。平坦区域10c可以位于起伏区域10a和10b之间以生成多层吸收芯结构。平坦区域10c可以有助于俘获SAP,并且也有助于通过将SAP保持在适当位置上来维持整个结构的完整性,以致不会在整个芯结构内产生剪切线。在该特别示例性实施例中,起伏区域10a和10b的波峰40a和40b分别基本上竖直对齐,如线200所示。在折叠纤维材料10之前,超吸收聚合物80(此后称为SAP)可沉积在波谷42内并部分沉积在起伏区域10b的波峰上。例如,假定吸收芯结构内8.4克的沉积量具有100mm×350mm的尺寸,则相应的表观堆积密度可等于大约0.67g/cc,高度约为0.362mm。图2b表示图2a中的被压实使得所得到的厚度减小且密度增加的吸收芯结构。例如,波峰40竖直对齐的区域现在具有相对较高的密度30a、30b和30c,因为与波谷42中的较少量的材料相比,波峰具有更多的材料。还可以看出,波谷42的空隙区间现在基本被填满,使得SAP80上面的区域具有较小的密度。该示例性实施例与先前技术相比的特别的优点在于采集区和分散区并排在一起。当采集区的空隙被填满时,这允许分泌物沿纵向分散。图2c示出图2b中被圆圈包围的区域的特写视图,由此可以进一步理解密度变化的区域。
图3a表示被折叠的示例性纤维材料10。该特别的示例性实施例示出为三层折叠。纤维材料10也可包含具有波峰40和波谷42的区域。纤维材料10也可包含没有波峰40和波谷42的区域。例如,起伏区域10a和10b可具有波峰40和波谷42,而平坦区域10c没有波峰和波谷。平坦区域10c可以位于起伏区10a和10b之间以生成多层吸收芯结构。平坦区域10c可以有助于俘获SAP,并且也有助于通过将SAP保持在适当位置上来维持整个结构的完整性,以致不会在整个芯结构内产生剪切线。在该特别的示例性实施例中,起伏区域10a和10b的波峰40a和40b分别不基本竖直对齐,如线300所示。在折叠纤维材料10之前,SAP80可沉积在波谷42内并部分沉积在起伏区域10b的波峰上。图3b表示图3a中的被压实使得所得到的厚度减小且密度增加的吸收芯结构。例如,波峰和波谷对齐的区域现在在一端上具有相对较高的密度30a、30b,而在另一端上具有相对适中的密度20a、20b。还可以看出,波谷42的空隙区间现在基本被填满使得SAP80上面的区域具有相对适中的密度20c。图3c示出图3b中被圆圈包围的区域的特写视图,由此可以进一步理解密度变化的区域。
图4a表示被折叠的示例性纤维材料10。该特别的示例性实施例示出为三层折叠。纤维材料10可由具有波峰40和波谷42的区域组成。纤维材料10也可包含没有波峰40和波谷42的区域。例如,起伏区域10a和10b可具有波峰40和波谷42,而平坦区域10c没有波峰和波谷。平坦区域10c可以位于起伏区10a和10b之间以生成多层吸收芯结构。平坦区域10c可以有助于俘获SAP,并且也有助于通过将SAP保持在适当位置上来维持整个结构的完整性以致不会在整个芯结构内产生剪切线。在该特别的示例性实施例中,起伏区域10a和10b的波峰40a和40b分别基本竖直对齐,如线400所示。在初始折叠之前,SAP80可沉积在波谷内并部分沉积在波峰上。此外,在最后折叠之前,SAP80可沉积在平坦区域10c的顶侧上。图4b表示图4a中的吸收芯结构被压实使得所得到的厚度减小且密度增加。例如,波峰竖直对齐的区域现在具有相对较高的密度30a、30b。还可以看出,波谷42的空隙区间现在基本被填满,使得SAP80上面的区域具有相对较小的密度10c。还可以理解,该示例性实施例提供两个SAP80区域:一个连续的SAP层,其位于平坦区域10c上方;和由平坦区域10c下方的波谷和波峰上分散沉积的SAP组成的另一区域。图4c示出图4b中被圆圈包围区域的特写视图,由此可以进一步理解密度变化的区域。
图5a表示被折叠的示例性纤维材料10。该特别的示例性实施例示出为三层折叠。纤维材料10可由具有波峰40和波谷42的区域组成。纤维材料10也可包含没有波峰40和波谷42的区域。例如,起伏区域10a和10b可具有波峰40和波谷42,而平坦区域10c没有波峰和波谷。平坦区域10c可以位于起伏区10a和10b之间以生成多层吸收芯结构。平坦区域10c可以有助于俘获SAP,并且也有助于通过将SAP保持在适当位置上来维持整个结构的完整性以致不会在整个芯结构内产生剪切线。在该特别的示例性实施例中,起伏区域10a和10b的波峰40a和40b分别不基本竖直对齐,如线500所示。在开始折叠之前,SAP80沉积在波谷内并部分沉积在波峰上。此外,在最后折叠之前,SAP80沉积在平坦区域10c的顶侧上。图5b示出图5a中的吸收芯结构被压实使得所得到的厚度减小且密度增加。例如,波峰和波谷对齐的区域现在在一端具有相对较高的密度30a、30b,而在另一端具有相对适中的密度20a、20b。还可以理解,该示例性实施例提供两个SAP80区域:一个连续的SAP层,其位于平坦区域10c上面;和由平坦区域10c下面的波谷和波峰的分散沉积的SAP组成的另一个区域。图5c示出图5b中被圆圈包围区域的特写视图,由此可以进一步理解密度变化的区域。
图6a表示被折叠的示例性纤维材料10。该特别的示例性实施例示出为三层折叠。纤维材料10可由具有波峰40和波谷42的区域组成。纤维材料10也可包含没有波峰40和波谷42的区域。例如,起伏区域10a和10b可具有波峰40和波谷42,而平坦区域10c没有波峰和波谷。平坦区域10c可以位于起伏区10a和10b之间以生成多层吸收芯结构。平坦区域10c可以有助于俘获SAP,并且也有助于通过将SAP保持在适当位置上来维持整个结构的完整性,以致不会在整个芯结构内产生剪切线。在该特别的示例性实施例中,起伏区域10a和10b的波峰40a和40b分别基本竖直对齐,如线600所示。在开始折叠之前,SAP80沉积在波谷内而不沉积在波峰上。为了实现这种SAP沉积,可特别注意保证波峰的沉积很少,或结合另外的工艺(如往波峰上部吹气)来除去任何最初沉积的SAP。图6b表示图6a中的吸收芯结构被压实使得所得到的厚度减小且密度增加。例如,波峰竖直对齐的区域现在具有相对较高的密度30a、30b。还可以看出,波谷42的空隙区间现在基本被填满,使得SAP80上面的区域具有较小的密度10c。图6c示出图6b中被圆圈包围的区域的特写视图,由此可以进一步理解密度变化的区域。
图7a表示被折叠的示例性纤维材料10。该特别的示例性实施例示出为三层折叠。纤维材料10可由具有波峰40和波谷42的区域组成。纤维材料10也可包含没有波峰40和波谷42的区域。例如,起伏区域10a和10b可具有波峰40和波谷42,而平坦区域10c没有波峰和波谷。平坦区域10c可以位于起伏区10a和10b之间以生成多层吸收芯结构。平坦区域10c可以有助于俘获SAP,并且也有助于通过将SAP保持在适当位置上来维持整个结构的完整性,以致不会在整个芯结构内产生剪切线。在该特别的示例性实施例中,起伏区域10a和10b的波峰40a和40b分别基本竖直对齐,如线700所示。在开始折叠之前,SAP80沉积在波峰上而不沉积在波谷内。为了实现这种SAP沉积,可特别注意保证波峰的沉积很少和/或可结合另外的工艺(如往波谷内吹气)来除去任何最初沉积的SAP。图7b表示图7a中的吸收芯结构被压实使得所得到的厚度减小且密度增加。例如,波峰竖直对齐的区域现在具有较高的密度30a、30b。还可以看出,波谷42的空隙区间现在基本被填满,使得对应区域现在具有较小的密度10c。还可以理解到,SAP80的沉积在竖直方向上由较高密度30a、30b包围,并在水平方向上由较低密度10c包围。图7c示出图7b中被圆圈包围的区域的特写视图,由此可以进一步理解密度变化的区域。
图8a表示被折叠的示例性纤维材料10。该特别的示例性实施例示出为三层折叠。纤维材料10可由具有波峰40和波谷42的区域组成。纤维材料10也可包含没有波峰40和波谷42的区域。例如,起伏区域10a和10b可具有波峰40和波谷42,而平坦区域10c没有波峰和波谷。平坦区域10c可以位于起伏区10a和10b之间以生成多层吸收芯结构。平坦区域10c可以有助于俘获SAP,并且也有助于通过将SAP保持在适当位置上来维持整个结构的完整性,以致不会在整个芯结构内产生剪切线。在该特别的示例性实施例中,起伏区域10a和10b的波峰40a和40b分别基本竖直对齐,如线800所示。在开始折叠之前,SAP80可以沉积在交替的波谷内并部分沉积在波峰上。因为SAP倾向于在存在流体时会显著膨胀,提供没有SAP的交替的波谷为随后的尿液进入提供了后面可利用的采集区。为了达到这种SAP沉积,可特别注意保证这种沉积和/或可结合另外的工艺(如往交替波谷内吹气)来除去任何最初沉积的SAP。图8b表示图8a中的吸收芯结构被压实使得所得到的厚度减小且密度增加。例如,波峰竖直对齐的区域现在具有较高的密度30a、30b。还可以看出,波谷42的空隙区间现在基本被填满,使得波谷内的区域具有较小的密度10c。图8c示出图8b中被圆圈包围的区域的特写视图,由此可以进一步理解密度变化的区域。
图9a表示被折叠的示例性纤维材料10。该特别的示例性实施例示出为三层折叠。纤维材料10可由具有波峰40和波谷42的区域组成。纤维材料10也可包含没有波峰40和波谷42的区域。例如,起伏区域10a和10b可具有波峰40和波谷42,而平坦区域10c没有波峰和波谷。平坦区域10c可以位于起伏区10a和10b之间以生成多层吸收芯结构。平坦区域10c可以有助于俘获SAP,并且也有助于通过将SAP保持在适当位置上来维持整个结构的完整性,以致不会在整个芯结构内产生剪切线。在该特别的示例性实施例中,起伏区域10a和10b的波峰40a和40b分别基本竖直对齐,如线900所示。在开始折叠之前,SAP80可以沉积在交替的波谷内并部分沉积在波峰上。因为SAP倾向于在存在流体时会显著膨胀,提供没有SAP的交替的波谷为随后的尿液进入提供了后面可利用的采集区。为了达到这种SAP沉积,可特别注意保证这种沉积和/或可结合另外的工艺(如往交替波谷内吹气)来除去任何最初沉积的SAP。此外,在最后折叠之前,SAP80可以以不连续的方式沉积在平坦区域10c的顶侧上。SAP的这个第二沉积层可以与第一沉积层基本相似也可以不基本相似。例如,SAP的上层可以较慢地起作用,以便允许第一次进入的尿液由下层存储,并且然后允许上层SAP可用于随后进入的尿液。此外,SAP的上层SAP可以比下层便宜,因此节省成本且不会降低功效。图9b表示图9a中的吸收芯结构被压实使得所得到的厚度减小且密度增加。例如,波峰竖直对齐的区域现在具有较高的密度30a、30b。还可以看出,波谷42的空隙区间现在基本被填满,使得SAP80上面的区域具有较小的密度10c。还可以理解到,该示例性实施例提供两个SAP80区域:一个非连续的SAP层,其位于平坦区域10c上面;和由平坦区域10c下面的波谷和波峰内的离散沉积的SAP组成的另一个区域。图9c示出图9b中被圆圈包围的区域的特写视图,由此可以进一步理解密度变化的区域。
图10a表示被折叠的示例性纤维材料10。该特别的示例性实施例示出为三层折叠。纤维材料10可由具有波峰40和波谷42的区域组成。纤维材料10也可包含没有波峰40和波谷42的区域。例如,起伏区域10a和10b可具有波峰40和波谷42,而平坦区域10c没有波峰和波谷。平坦区域10c可以位于起伏区10a和10b之间以生成多层吸收芯结构。平坦区域10c可以有助于俘获SAP,并且也有助于通过将SAP保持在适当位置上来维持整个结构的完整性,以致不会在整个芯结构内产生剪切线。在该特别的示例性实施例中,起伏区域10a和10b的波峰40a和40b分别基本竖直对齐,如线1000所示。在开始折叠之前,SAP80可沉积在交替的波谷内而不沉积在波峰上。因为SAP倾向于在存在流体时会显著膨胀,提供没有SAP的交替的波谷为随后的尿液进入提供了后面可利用的采集区。为了达到这种SAP沉积,可以特别注意保证这种沉积和/或可以结合另外的工艺(如往交替波谷内以及沿着波峰吹气)来除去任何最初沉积的SAP。此外,在最后折叠之前,SAP80可以以不连续的方式沉积在平坦区域10c的顶侧上,使得SAP基本位于波谷42内。SAP的这个第二沉积层可以与第一沉积层基本相似也可以不基本相似。例如,SAP的上层可以较慢地起作用,以便允许第一次来袭的尿液由下层存储,并且然后允许上层可用于随后的尿液进入。此外,SAP的上层可以比下层便宜,因此节省成本且不会降低功效。图10b表示图10a中的吸收芯结构被压实使得所得到的厚度减小且密度增加。例如,波峰竖直对齐的区域现在具有较高的密度30a、30b。还可以看出,波谷42的空隙区间现在基本被填满,使得波谷内区域具有较小的密度10c。还可以理解到,该示例性实施例提供两个SAP80区域:一个不连续的SAP层,其位于平坦区域10c上面;和由平坦区域10c下面的交替的波谷内的离散沉积的SAP组成的另一个区域。图10c示出图10b中被圆圈包围的区域的特写视图,由此可以进一步理解密度可变的区域。
在提供大体平坦的折叠的中间部分的可选方法中,图11a示出纤维材料的第一离散中层10m和纤维材料的第二离散层,第一离散中层10m具有波峰40m和波谷42m,第二离散层具有第一起伏区10a和第二起伏区10b,这两个起伏区分别具有波峰40a、40b和波谷42a、42b。第二层被围绕第一层折叠。第二层可以有助于俘获SAP,并且也有助于通过将SAP保持在适当位置上来维持整个结构的完整性,以致不会在整个芯结构内产生剪切线。在该特别实施例中,第二起伏区10b和第一离散中层10m可以设置成使得一层的波谷与另一层的波峰竖直对齐,如线1100所示。可选择地,本领域技术人员将理解到每层的波峰都可以竖直对齐。相似设置的可能性存在于第一起伏区10a和第一离散中层10m之间。在折叠之前,SAP80可以沉积在某些或全部波谷42b内以及某些或全部波峰40b上。虽然没有示出,SAP80可以沉积在某些或全部波谷42m内以及某些或全部波峰40m上。图11b表示第二起伏区10b被压实在第一离散中层10m上使得它们的对齐的波峰被进一步压实,而它们的对齐的波谷仍然提供空隙空间。此外,第二起伏区10b的波峰40b可以对上述对齐的波峰提供不对齐的结构支撑,因此提供空隙空间的第二区域。图11c示出图11b中被圆圈包围的区域的特写视图,由此可以进一步理解密度变化的区域。
在一个可选择的折叠方法中,图12a示出示例性的平放方法,其包括具有波峰40x和波谷42x的第一层纤维材料10x;具有波峰40y和波谷42y的第二层纤维材料10y;和大体上平坦的第三层纤维材料10z。第二和第三层可以有助于俘获SAP,并且也有助于通过将SAP保持在适当位置上来维持整个结构的完整性,以致不会在整个芯结构内产生剪切线。在该特别实施例中,第一层纤维材料10x和第二层纤维材料10y可以设置成使得一层的波谷与另一层的波峰竖直对齐,如线1200所示。可选择地,本领域技术人员将理解到每层的波峰都可以竖直对齐。此外,在该特别的实施例中,SAP80x可以沉积在某些或全部波谷42x内,且SAP80y可以沉积在某些或全部波谷42y内。另外,第三层纤维材料10z可位于第一和第二层之间或上面。SAP的上沉积层可以和下沉积层大体上相似,也可以不大体上相似。例如,SAP的上层可以较慢的起作用,以便允许第一次来袭的尿液由下层存储,并且然后允许上层可用于随后来袭的尿液。此外,SAP的上层可以比下层便宜,因此节省成本且不会降低功效。图12b表示第三层10z被压实在第二层10y上,使得第三层10z大体上充满波谷42y。在该特别的实施例中,第一层10x的波谷40x保持大体上完好,而波峰40x现在具有相对适中的密度。图12c示出图12b中被圆圈包围的区域的特写视图,由此可以进一步理解密度变化的区域。
现在参见图13a,示出二维示意图以描述本发明的一个有益方面。更具体地,本发明的创新方面在于提供创新的芯结构设计。例如,图13a表示吸收芯3000的二维示意图,该吸收芯具有在整个芯设计中被选择性的设置的采集区3010、分散区3020和存储区3030。这种设计提供了全新的流体管理。
众所周知,用于一次性吸收产品的传统吸收芯结构可由多层材料制成。此外,公知的是,这些层可由不同类型的材料组成。例如,传统的吸收产品可由以下各物制成:(a)顶层,作为采集区,用于快速吸收穿用者的分泌物,(b)中间层,作为存储区,用于长时间存储分泌物,和(c)底层,作为分散区,用于在吸收芯结构内传输分泌物(如,纵向或横向移动分泌物以更好地利用尿布)。然而,这种传统的芯通常不允许层间流体连通。本发明不仅提供层间流体连通,还提供如图13a-13c描述的三维流体管理,其中流体3003根据此处公开的芯设计原理被移动。最后,芯结构被设计成其区域(即采集区4010、分散区4020和存储区4030)在三维布局中变化,如图14中的吸收芯4000所示。
在本发明的具体实施方式中引用的所有文献在相关部分以参考的方式在此结合;任何文献的引用都不解释为承认其相对于本发明是现有技术。
可以使用各种方法和设备在纤维材料10的一层或多层中形成波峰40和波谷42以实施本发明。这些可包括和并入熔纺工艺的技术,或所述层成形后实施的技术,或这些工艺的组合。形成波峰40和波谷42的优选方式是与熔纺工艺成一体的方式。在这一方面,例如,其公开内容在此以参考的方式并入这里的2003年11月17日提交的美国专利申请No.10/714778(714778申请)公开的方法和设备可用来实现纤维熔喷材料的层中的条形效果。该条形效果产生由波谷形式的成排的低密度材料分隔开的波峰形式的成排的高密度材料。为了达到这一点,拉细机或纺粘装置的牵伸喷射出口的距离比正常情况下离纤维收集器更近。例如,如果所述距离,即714778申请中所称的“ACD”,是大约10英寸以生产均匀密度的纤维材料层,则大约5英寸的ACD可生产用于本发明的目的的希望的纤维材料层10中的条形或波峰40和波谷42。将理解到,也可以使用其他方法,这些方法包括但不局限于涉及在生产出层之后用成形元件接触纤维材料的层的那些方法。每排波峰40和波谷42可以交替地连续的或不连续,这决定于应用的需要。
虽然已经示出并描述了本发明的几个特别的实施例,但是对本领域技术人员而言显然的是,在不背离本发明的精神和范围的情况下可以作出各种其它改变和修改。因此所附的权利要求意图涵盖本发明的范围内的所有这种改变和修改。
例如,本领域技术人员能够理解可以改变加固度。
例如,本领域技术人员将认识到可以使用各种合适的技术完成SAP的沉积,这些技术包括但不局限于,在形成波峰和波谷后进行寄存沉积,或在形成波峰/波谷期间沉积SAP(如,将SAP添加到生产卷轴拉细机的顶部,其中SAP应跟随扩散部件周围的纤维)。

Claims (10)

1.一种吸收芯结构,其特征在于:
至少一个采集区(10),所述采集区(10)由纤维材料构成,所述采集区(10)具有从大约0.018g/cc至大约0.20g/cc的相对低的密度;
至少一个分散区(20),所述分散区(20)由所述纤维材料构成,所述分散区(20)被压实以具有从大约0.024g/cc至大约0.45g/cc的相对适中的密度,所述分散区(20)与所述采集区(10)流体连通;和
至少一个存储区(30),所述存储区(30)由所述纤维材料构成,所述存储区(30)被压实以具有从大约0.030g/cc至大约0.50g/cc的相对高的密度,所述存储区(30)与所述分散区(20)流体连通;
所述纤维材料的一部分形成为至少一个波峰(40)和至少一个波谷(42),然后接着被折叠以便形成所述吸收芯结构。
2.如权利要求1所述的吸收芯结构,其中,所述纤维材料可以选自由以下各材料组成的群组:聚丙烯、聚乙烯、聚酯、聚乙烯醇、聚醋酸乙烯酯、淀粉、醋酸纤维素、聚丁烯、人造纤维、聚氨酯、KratonTM、聚乳酸、棉、LyocellTM、生物可降解聚合物、适合于形成纤维的任何其它材料、以及它们的组合。
3.如权利要求1所述的吸收芯结构,其进一步的特征是SAP(80),所述SAP(80)沉积到所述波谷(42)的至少一个波谷上。
4.如权利要求1所述的吸收芯结构,其进一步的特征是SAP(80),所述SAP(80)沉积到所述波峰(40)的至少一个波峰上。
5.如权利要求1所述的吸收芯结构,其进一步的特征是SAP(80),所述SAP(80)沉积到所述波谷(42)的至少一个波谷上和所述波峰(40)的至少一个波峰上。
6.如权利要求3所述的吸收芯结构,其中,所述SAP(80)沉积到交替的波谷(42)上。
7.如权利要求4所述的吸收芯结构,其中,所述SAP(80)沉积到交替的波峰(40)上。
8.如权利要求1所述的吸收芯结构,其中,所述波峰(40)的第一排与所述波峰(40)的第二排基本竖直对齐。
9.如权利要求1所述的吸收芯结构,其中,所述波峰(40)的第一排与所述波谷(42)的第一排基本竖直对齐。
10.如权利要求1所述的吸收芯结构,其中,所述纤维材料包括基本上没有波峰(40)和波谷(42)的线性部分,所述线性部分被折叠并位于至少两层波峰(40)和波谷(42)之间。
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CN105451701B (zh) * 2013-03-15 2020-03-03 瑞德科技控股有限公司 具有弹性芯部的吸收物件

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