CN101389286A - 非织造医用织物 - Google Patents

非织造医用织物 Download PDF

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Publication number
CN101389286A
CN101389286A CNA2007800062788A CN200780006278A CN101389286A CN 101389286 A CN101389286 A CN 101389286A CN A2007800062788 A CNA2007800062788 A CN A2007800062788A CN 200780006278 A CN200780006278 A CN 200780006278A CN 101389286 A CN101389286 A CN 101389286A
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nonwoven
medical fabric
web
fabric
materials
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R·达马德希卡里
赵荣国
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ASTROHM Co
Ahlstrom Corp
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ASTROHM Co
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Abstract

本发明一般性涉及有利地用于医用长袍、医用被单和具有开口的医用被单的新型及改进的非织造医用织物。本发明的非织造医用织物包含具有压花图案的亲水处理的挤出网材料。

Description

非织造医用织物
技术领域
简要地，本发明一般性涉及有利地用于医用长袍、医用被单和具有开口的医用被单的新型及改进的非织造医用织物。
背景技术
医用被单可以限定可以通过其进行外科手术的开口或窗口。此种薄膜可以包括围绕部分或全部开口的开口材料。所述开口材料提供了用于在手术部位释放的流体的吸收性储层。
传统上，包含纤维素短纤维的非织造网材料已经用作开口材料。所述包含纤维素纤维的非织造物具有优异的吸收性能。但是，包含纤维素纤维的非织造物显示出例如掉毛和高可燃性的不理想的性能。
亲水处理的纺粘非织造材料也已用于医用被单。但是，亲水处理的纺粘非织造材料未经压花，并通常提供有限的吸收性和感知性。
定义
双组分纤维或长丝—通过从分别的挤出机挤出聚合物源并在一起纺丝以形成单根纤维或长丝而形成的共轭纤维或长丝。典型地，挤出两种单独的聚合物，尽管双组分纤维或长丝可以包括从分别的挤出机中挤出的相同的聚合物材料。所述挤出的聚合物被设置于穿过双组分纤维或长丝的横截面的基本上固定定位的不同区域，并且基本上沿着双组分纤维或长丝的长度连续地伸长。双组分纤维或长丝的构型可以是对称的(例如皮芯型或并列型)或者它们可以是非对称的(例如皮内偏心型；在具有大体上圆形的纤维内的新月构型)。所述两种聚合物源可以以例如(但不排他地)75/25、50/50或25/75的比例存在。
共轭纤维或长丝—通过从分别的挤出机挤出聚合物源并在一起纺丝以形成单根纤维或长丝而形成的纤维或长丝。共轭纤维包括使用两种或多种单独的聚合物，各自由分别的挤出机提供。所述挤出的聚合物被设置于穿过共轭纤维或长丝的横截面的基本上固定定位的不同区域，并且基本上沿着共轭纤维或长丝的长度连续地伸长。所述共轭纤维或长丝的形状可以是方便于制造商拟用于最终用途的任何形状，例如圆形、三叶形、三角形、狗骨形、扁平或中空形。
横向(CD)—垂直于纵向的方向。
旦尼尔—用于指示长丝的细度的单位，其由9000米长的长丝的以克为单位的重量所给出。1旦尼尔的长丝对于9000米的长度具有1克的质量。
挤出网材料—通过纺粘或熔喷法形成的非织造片材材料。如本文所用，挤出网材料排除了使用湿法成网法、气流成网法或梳理法由短纤维制得的非织造网材料。所述挤出网材料可以包括一个或多个层并可以包括后成形处理。
纤维—由极高的长径比表征的材料形式。如本文所用，除非另外特别指出，术语纤维和长丝可互换地使用。
长丝—基本上连续的纤维。如本文所用，除非另外特别指出，术语纤维和长丝可互换地使用。
纵向(MD)—在形成非织造网材料的过程中，纤维或长丝被放置于其上的成形表面的行进方向。
熔喷纤维—通过将熔融的热塑性材料作为长丝从许多通常为圆形的细小的模头毛细孔挤出进入高速气(例如空气)流(使得熔融热塑性材料的长丝变细以减小其直径)而形成的纤维。其后，通过高速气流运送熔喷纤维并将其放置于收集表面上以形成随机分布的熔喷纤维的网。熔喷纤维通常是连续的。所述熔喷工序包括熔融喷射工序。
非热塑性聚合物—任何没有落在热塑性聚合物定义内的聚合物材料。
非织造织物、片材或网—具有互相交叉但不是以如机织或针织织物的可辨认方式的单纤维结构的材料。非织造材料由许多方法制备，例如熔喷法、纺粘法、梳理和湿法成网法。非织造织物的单位重量通常以克每平方米(gsm)表示并且纤维细度以旦尼尔测量。
感知性—样品的主观三维效果或三维外观。
聚合物—具有重复有机结构单元的长链。通常包括例如均聚物；共聚物，例如嵌段共聚物、接枝共聚物、无规共聚物和交替共聚物；三元共聚物等及其共混物和变体。另外，除非另外特别地限定，术语“聚合物”包括所用可能的几何构型。这些构型包括例如等规立构、间规立构和无规立构对称体。
纺粘长丝—通过将熔融的热塑性材料从许多通常为圆形的细小的喷丝板毛细孔挤出而形成的长丝。接着，挤出长丝的直径通过例如抽出牵伸和/或其它公知的纺粘机构迅速地减小。纺粘纤维通常是连续的，具有约0.1至5或更高范围的旦尼尔。
纺粘非织造网—(通常)以单独的方法通过将至少一种熔融的热塑性材料作为长丝从许多通常为圆形的细小的喷丝板毛细孔挤出而形成的网。所述长丝部分地骤冷，然后拉出以减小纤维的旦尼尔并增大在纤维内的分子取向。通常，当被放置到收集表面上作为纤维絮时，所述长丝是连续的且是非粘性的。然后，通过例如热粘合、化学粘合剂、机械针刺、水力缠结或其组合粘合纤维絮以制备非织造织物。
短纤维—以通常1/4至8英寸(0.6至20cm)短纤维长度形成或切割为该长度的纤维。本发明不包括短纤维和短纤维的用途。
基本上连续的—关于非织造网的聚合物长丝，是指通过经小孔挤出而形成的大多数长丝或纤维当被拉伸并随后在收集装置上被冲击时，保持作为连续不断的长丝。在变细或拉伸过程中部分长丝可能断裂，但绝大多数长丝保持连续。
特(tex)—用于指示纤维细度的单位，由1000米的长丝以克为单位的重量给出。1特的长丝对于1000米的长度具有1克的质量。
热塑性聚合物—当暴露于热时是可熔的、软化的和当冷却至室温时通常恢复其未软化状态的聚合物。热塑性材料包括例如聚氯乙烯、部分聚酯、聚酰胺、多氟烃、聚烯烃、部分聚氨酯、聚苯乙烯、聚乙烯醇、乙烯和至少一种乙烯基单体的共聚物(例如聚(乙烯丙烯酸乙烯酯))及丙烯酸系树脂。
发明概述
本发明的主要目的在于提供非织造医用织物，该织物能够避免部分或全部现有技术医用织物的缺点。
本发明的另一目的在于将压花处理应用于亲水处理的纺粘非织造材料以提高其吸收性和感知性。
上述本发明目的通过权利要求1的特征部分的技术特征实现。
本发明的其它技术特征在所附权利要求中更详细地讨论。
附图简述
现参考附图，其中在以下几个图中，相同元件给予相同标号：
图1是包含纺粘长丝的非织造材料的放大图。椭圆形区域是在压延工序中形成的椭圆形点粘合区域。图1的非织造材料是没有压花的。
图2是图1的点粘合的非织造材料在压花后的图。压花工序形成两个交叉的压花区，其是较大的中空钻石图案的部分。
图3a是图1的材料在不同的放大倍数的图。椭圆形区域是在压延工序中形成的椭圆形点粘合区域。非织造材料未经压花。
图3b是图3a的非织造材料在压花中空钻石图案后的图。直线是压花区域。压花线之间的非织造材料是膨胀的。
图4是图3b的非织造材料在不同的放大倍数的图。非织造材料包含纺粘长丝。椭圆形区域是在压延工序中形成的椭圆形点粘合区域。直线是压花区域。压花线之间的非织造材料是膨胀的。
图5是压花的挤出网材料的一个实施方案的横截面示意图。
图6是包含覆盖在第二挤出网材料上的第一挤出网材料的压花复合材料的一个实施方案的横截面示意图。
优选实施方案描述
本发明的优选实施方案包括经压花的具有局部多孔和亲水结构的非织造网。所述非织造材料可以是挤出的网材料。与传统纺粘非织造材料相比，所述压花的网材料可以有利地提供一种或多种理想地提高的性能，包括外观、吸收能力、吸收速率、感知性(三维外观)和柔软性。所述网材料可以有利地用作医用被单中的开口材料或用作医用被单。
本发明的另一优选实施方案包括挤出网材料，该挤出网材料包含经压花的亲水处理的基本上连续的热塑性长丝的非织造网。压花工序提供给挤出网材料局部多孔和亲水结构及理想地提高的三维效果(感知性)。所述压花工序还提供给挤出网材料装饰性的粘合图案和提高的柔软性。
本发明的第三优选实施方案包括复合材料，该复合材料通过使用压花工序将第一亲水处理的挤出网材料接合到第二网材料而制得。所述第二网材料可以是亲水处理的挤出网材料。压花将所述第一和第二网材料局部地接合在一起。所述第一和第二网材料在压花区域之外并未接合。有利地，至少一种挤出网材料包含双组分长丝，所述双组分长丝在长丝表面包含低熔点聚合物。压花工序提供给所述复合材料局部多孔和亲水的结构。
本发明的第四优选实施方案包括压花非织造网或层压至膜的压花非织造复合材料。
本发明的第五优选实施方案包括非织造网材料，所述非织造网材料包含经压花的热塑性短纤维。可以通过例如湿法成网法或气流成网法制备所述非织造网。所述压花工序提供给非织造网材料局部多孔的和亲水的结构及三维效果。所述压花工序还提供给非织造网材料装饰性的粘合图案、优异的感知性和提高的柔软性。
用于压花吸收制品工序的起始网材料包含离散的纤维例如短纤维和/或基本上连续的长丝。所述网材料的纤维和/或长丝由热塑性聚合物组成。所述纤维和/或长丝可以有利地具有约0.5-约2.0的旦尼尔，并且可以有利地具有约1的旦尼尔。所述起始网材料可以具有约15克每平方米(gsm)-约300gsm的克重。所述起始网材料有利地是包含通过纺粘工序形成的基本上连续的长丝的挤出网材料。
在另一个实施方案中，在压花吸收制品工序中，还可以使用接合至包含纤维素材料的层的包含纺粘挤出网材料的复合材料。在压花吸收制品工序中，还可以使用由纤维素材料和/或非纤维素短纤维或连续纤维制造的并通过湿法成网法、气流成网法或梳理法形成的此种非织造网。
典型地，粘合起始网材料以提供组成纤维或长丝足够的粘结性，以便可以在后续工序中累积和处理所述起始网材料而基本上不会丧失其片材形式。可以使用任何已知方法粘合所述起始网。例如，可以通过在转动加热辊间进行压延或通过在烘箱中空气粘合来粘合挤出网材料。所述辊中的一个可以是带图案的，例如具有彼此间隔的椭圆形突起。如图1所示，置于椭圆形图案和光滑辊之间的纤维或长丝被压缩并熔合或点粘合。在点粘合区域，所述纤维或长丝被局部地接合，而在点粘合区域外的纤维或长丝基本上未被粘合。也可以通过例如化学粘合或水力缠结进行粘合。粘合起始网材料以提供“更坚硬的”材料对于在压花工序中的使用是有利的。
典型地，由热塑性聚合物制成的非织造材料是疏水性的并且缺少对于开口产品有利的吸收性能。任选地，可以用表面活性剂或其它被加工以赋予所需程度的润湿性和亲水性的方式处理所述非织造材料。例如，可以用约0.10重量％-约0.50重量％，更理想地约0.20重量％-约0.40重量％的可商购表面活性剂对所述材料进行表面处理。可以通过任何常规方法涂覆所述表面活性剂，例如喷雾、印刷、刷涂等。如果表面活性剂是以水溶液涂覆，则可以通过例如施加热量于所述材料以去除水载体。可以涂覆所述表面活性剂于整个非织造材料或可以选择地涂覆至所述非织造材料的特殊部分。任选地，通过在热塑性长丝形成过程中使用熔体添加剂，所述热塑性非织造材料可以被制成为可润湿的和亲水性的。
存在许多其它已知的可以用以提供理想性能的工序中和工序后非织造网处理。例如，可以在成形后对非制造物涂覆抗静电材料。另外地，或可选择地，只要所得材料具有可在压花吸收制品工序中使用的合适的性能，可以设计非织造材料以包含任何工序、组分、材料、成分、辅助剂或物质。
压花粘合起始网材料。图3a示出了挤出网，即纺粘基材，而图3b示出了已进一步压花的点粘合挤出网材料。如极好地在图4中所示，所述点粘合区域在压花区域和非压花区域可以保持可见。
在图5中示出的优选压花工序包括使起始网材料10通过转动的花纹钢辊12和反向转动的弹性辊(未显示)之间。典型地，将钢辊12加热到室温以上而弹性辊并不加热。所述花纹钢辊12具有限定辊直径的辊表面。所述辊表面的部分14被刻花以提供低于直径的被压下的表面的区域。例如，钢辊12可以限定包含有角度交叉线的表面。在有角度交叉线之间的所述辊表面的部分14被压下低于所述表面。此实施例提供了当施用于片层材料时的间隔的中空钻石图案，如图4所示。压花工序施加热及压力到靠近花纹辊表面的起始网材料10的局部区域。
具有初始厚度Ts的起始网材料10被喂入反向转动的花纹钢辊12和弹性辊之间。如极好地在图5中所示，靠近花纹辊表面16的起始网材料10中的纤维或长丝被压缩并部分熔合以形成具有压缩厚度Tc的压花部分18，所述Tc小于Ts。典型地，压花部分18的热塑性长丝部分地熔合并可以显示出在长丝形态中的变化例如压平和/或热塑性长丝材料的流动。压缩可以将靠近弹性辊(在图5中未显示)的网材料的部分20移动到所述网材料的表面以下。调整弹性辊硬度、辊间间隔、辊隙压力、钢辊温度和线速度以使靠近辊刻花或压下区域14的热塑性长丝被分开并升高于起始网材料10的表面之上以形成具有膨胀厚度Te的膨胀部分，所述Te大于Ts。在所述膨胀区域可以存在热塑性长丝的部分熔合，但是通常没有显著的长丝形态的变化或热塑性聚合物长丝的流动。
所述压花网材料限定了横截面“峰谷”结构。压花网材料中的纤维或长丝限定了在网材料的外表面之间的三维结构。与未压花网材料相比，在膨胀的或峰区域中的纤维或长丝限定了具有相比提高了的空隙容积(void volume)的结构。
压花工序与压延工序是不可互换的。典型地，压延工序使用第一加热平滑钢辊和第二加热刻花钢辊以施加热和压力于非织造网材料的局部粘合区域。在这些局部区域中的热塑性长丝被压缩至低于所述网材料的表面，并且在施加的热和压力下会熔融和流动。当网材料超过辊时，熔融的热塑性长丝固化，在这些局部区域接合被压缩的长丝。压缩的网材料的厚度(Tc)小于起始网材料的初始厚度(Ts)。熔融的热塑性纤维是坚硬的，并且网材料在局部区域中的长丝之间具有极小的容积。在未压缩区域中网材料保持其初始厚度(Ts)。在未压缩区域中空隙容积没有提高。
在一些实施方案中，例如图6中所示意性地显示的，接合两种或多种网材料30和32以提供压花的复合非织造材料。在此实施方案中，在压花前，通过例如点粘合来粘合每种网材料。在压花部分34中的纤维或长丝或其部分在每层内至少部分地熔融并且还与其它层30和32的纤维和长丝熔合。所述熔融的纤维或长丝作为层30和32间的离散粘合区域36。在膨胀部分的纤维或长丝是未粘合的区域38，并且基本上未与在该层或任何其它层的纤维或长丝熔合。在此实施方案中，对于网材料层中的至少一层，包含具有低于所述网材料层所用的其它热塑性组分的熔点的热塑性组分的长丝是有利的。在一些变化方案中，一种网材料层可以包含双组分长丝，该双组分长丝具有较高熔点的聚对苯二甲酸乙二酯芯和较低熔点的聚乙烯外皮。
与非压花复合非织造网材料或压缩部分相比，复合非织造材料的压花区域的膨胀或峰部分限定了在每层内具有相比提高了的空隙容积的结构。此外，存在在每层的相邻的内表面之间限定的空隙容积。这些表面内空隙容积被认为与层间空隙容积是流体连通的。
在本发明的又一实施方案中，可以层压压花材料至非纤维膜以形成复合非织造/膜层压材料。可以使用任何已知的层压方法进行膜到压花材料的层压。例如，可以在压花材料上挤出熔融膜或者可以粘附地将膜粘合到压花非织造物上。
已一般性描述了本发明，为举例说明的目的包括下面的实施例以使本发明可以更易理解，并且除非另外特别地指出不拟限制本发明的范围。
起始网材料是具有约50gsm克重的纺粘非织造物。该起始网材料由约1.6旦尼尔的聚丙烯长丝制得。以约350英尺每分钟(1.5m/s)的线速度和约550磅每线性英寸(0.96kN/cm)的辊隙压力在第一转动加热平滑钢辊和第二转动加热刻花辊间压延铺置好的长丝。所述压花辊具有一系列有间隔的椭圆形设计的重复图案。该椭圆形图案提供超过约20％的起始网材料面积的粘合。图1和图3a显示了点粘合的起始网材料。
实施例1
在针对每个样品不同的条件下，使用具有钻石图案的上部加热金属压花辊对起始网材料样品进行压花。压花辊直径为约15英寸(38cm)。所述压花辊具有一系列钻石形重复图案，提供超过约20％的网材料面积的压花。反向弹性辊是具有45肖氏D硬度的橡胶组合物。在表1中所示的条件下对挤出网材料压花。
Figure A200780006278D00121
测试实施例1的起始网材料和压花非织造材料样品。“压花”结果是样品1-6的结果的平均值。测试结果总结于表2。
Figure A200780006278D00122
在本申请中使用以下测试方法，并且在此引入每一方法作为参考。用于测量“吸收率”的测试方法是Ahlstrom TM 107 Rev.0。用于测量H2O滴的测试方法是TAPPI T-432 OM-94。
实施例2
使用与实施例1相同的装置对部分起始网材料进行压花以提供样品7。测试起始网材料和压花非织造材料(样品7)。测试结果总结于表3。
Figure A200780006278D00131
使用手感测试仪测量起始网材料和压花非织造材料的弯曲刚度。手感测试仪测量将织物推进测量间隙(5mm，10mm或20mm)的狭缝开口所需要的力。使用10mm的间隙。通过将手感测试仪的狭缝在横向(CD)定向测量纵向(MD)(层压网的纵向)上的弯曲刚度，并通过将手感测试仪的狭缝在纵向定向测量横向(CD)上的弯曲刚度。
与未压花的起始网材料相比，压花后样品7具有理想改进的感知性(三维外观)。在样品以转动形式保持后，保持了理想的改进感知性。
实施例3
实施例3的压花材料是包含局部接合于包含纺粘聚丙烯长丝的第二25gsm挤出网材料的由纺粘聚丙烯长丝制备的第一25gsm挤出网材料的复合非织造材料。通过压花工序接合所述复合材料。使用与实施例1相同的装置压花该复合非织造材料以提供样品8。测试复合压花非织造材料(样品8)。样品8的测试结果总结于表4。
Figure A200780006278D00132
实施例4
实施例4的压花材料(样品9)是包含局部接合于包含具有聚乙烯皮和PET芯的纺粘双组分长丝的第二25gsm挤出网材料的包含纺粘聚丙烯长丝的第一25gsm挤出网材料的复合非织造材料。通过在与实施例1相似的条件下压花来接合第一和第二挤出网材料。样品9的测试结果示于表5。
Figure A200780006278D00141
与单层的50gsm压花SB材料相比，样品9显示出在吸收能力上的显著改进。视觉评价显示出对实施例4的材料进行压花提供了有利的三维效果(感知性)。甚至在延长压缩的条件下，例如以转动形式储存非织造材料，保持了三维效果和其它改进的性能。
总之，本发明的组合物可以可选择地配制以包含本文所公开的任何合适的组分，或者由或主要由本文所公开的任何合适的组分组成。另外地，或可选择地，本发明的组合物可以被配制以不含、或基本上不含现有技术组合物所用的任何组分、材料、成分、辅助剂或物质或者对实现本发明的功能和/或目的并不必需的其它物质。
当本文使用词“约”时，是指只要实现本发明的有益效果，其所修饰的量或条件可以超出一定限度而变化。实际上，极少有适用的时间或资源以非常精确地确定一个发明的所有参数的限值，因为这样做所需的努力远远大于开发本发明以实现商业应用所需的合理的努力。本领域技术人员应对此理解并可预见所公开的本发明的结果可以延伸，至少略微地，超出所公开的一个或多个限值。然后，拥有发明人公开内容的受益并理解发明构思和公开的实施方案包括发明人已知的最佳方式，发明人或其他人可以，不经发明的努力，研究超出所公开的限值以确定是否本发明超出那些限值可以实现，并且当上述实施方案被发现不具备不可预见的特性时，那些实施方案落在本文所用术语“约”的含义之内。对于技术人员或其他人，不难确定是否此实施方案或者是可预见的，或由于结果的连续性中断或一个或多个特征显著优于本发明人所报告的而是令人惊讶的，并因此非显而易见的教导带来现有技术的进一步进步。
当为说明目的已经阐述了前述发明的优选实施方案时，前述说明不应被视为对本发明的限制。因此，在不偏离本发明的精神和范围的情况下，本领域技术人员可以做出各种改变、调整和替换。

Claims (19)

1.非织造医用织物，其特征在于该织物包含具有具有局部多孔和亲水结构的压花图案的热塑性聚合物材料的非织造网。
2.权利要求1的非织造医用织物，其特征在于所述非织造网是具有压花图案的亲水处理的挤出网材料。
3.权利要求1或2的非织造医用织物，其特征在于所述非织造网材料限定了起始厚度Ts，所述非织造网材料具有限定小于Ts的压缩厚度Tc的压花部分和限定大于或等于Ts的厚度Te的膨胀部分。
4.权利要求3的非织造医用织物，其特征在于第二压花部分与所述压花部分间隔开，其中所述膨胀部分在所述压花部分之间。
5.权利要求1、2、3或4的非织造医用织物，其特征在于第二热塑性聚合物材料的非织造网具有具有局部多孔和亲水结构的压花图案，并且在许多空间上隔开的区域被局部地接合到所述非织造网材料上。
6.权利要求5的非织造医用织物，其特征在于所述第二非织造网是亲水处理的挤出网。
7.权利要求5或6的非织造医用织物作为靠近在医用被单中限定的开口的开口材料的用途。
8.权利要求5-7中任意一项的非织造医用织物，其特征在于至少第一和第二非织造网材料中之一包含双组分长丝。
9.权利要求8的非织造医用织物，其特征在于所述双组分长丝是聚乙烯/聚对苯二甲酸乙二酯长丝。
10.权利要求1、2、3或4的非织造医用织物，其特征在于非织造材料网或层在许多空间上隔开的区域被局部地接合到所述具有具有局部多孔和亲水结构的压花图案的热塑性聚合物材料的非织造网上。
11.权利要求10的非织造医用织物，其特征在于所述非织造材料网或层是通过湿法成网法、气流成网法和梳理法中的一种形成的。
12.权利要求10或11的非织造医用织物，其特征在于所述非织造材料网或层包含纤维素材料。
13.权利要求10或11的非织造医用织物，其特征在于所述非织造材料网或层包含热塑性短纤维或连续纤维或长丝。
14.权利要求1-13中的任意一项的非织造医用织物，其特征在于具有15gsm-300gsm范围的单位重量。
15.权利要求1-14中的任意一项的非织造医用织物，其特征在于所述非织造网材料的纤维和/或长丝具有0.5-2.0，有利地1.0的旦尼尔。
16.权利要求1-15中的任意一项的非织造医用织物，其特征在于包含纺粘聚丙烯长丝。
17.权利要求1-16中的任意一项的非织造医用织物，其特征在于包含双组分长丝。
18.权利要求1-17中的任意一项的非织造医用织物，其特征在于具有表面和层压到所述表面的膜。
19.权利要求10-11中的任意一项的非织造医用织物，其特征在于所述非织造材料网或层是压花的。
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