CN101395315B - 可伸展的吸水性复合材料 - Google Patents

可伸展的吸水性复合材料 Download PDF

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CN101395315B
CN101395315B CN2007800073087A CN200780007308A CN101395315B CN 101395315 B CN101395315 B CN 101395315B CN 2007800073087 A CN2007800073087 A CN 2007800073087A CN 200780007308 A CN200780007308 A CN 200780007308A CN 101395315 B CN101395315 B CN 101395315B
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extensile
layer
coforming
composite sheet
fibre
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CN101395315A (zh
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塞缪尔·C·巴尔
珈雷德·A·奥斯汀
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Fitesa Simpsonville Inc
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Abstract

本发明涉及一种吸水性片材，所述吸水性片材由吸水性纤维和可伸展的熔喷聚合物纤维的共成型混合物制备。这些可伸展的共成型体的层压体以可伸展的聚合物纤维或长丝的层制备。增量拉伸所述吸水性片材，以改善柔软性和悬垂性。

Description

可伸展的吸水性复合材料
背景技术
纤维非织造材料和纤维非织造复合材料广泛用于一次性擦拭物中。已有数种方法用于制备这些纤维非织造材料。在一种称之为空气沉降(airlaid)的方法中，用粘合剂乳液将木纤维粘合在一起形成网幅。必须将该网幅干燥以除去水分并固化粘合剂。由于粘合所有纤维的粘合剂的存在，所得的网幅往往较硬。 
称之为水刺法(spunlacing)的另一种方法采用高速水流喷射以在机械作用下使纤维联锁成网。该方法通常使用短纤维和木纤维作为网幅组分。在水刺法中也可将通过纺粘法制备的连续长丝与木纤维结合。由于水刺法中不常使用粘合剂，因此纤维具有实质的自由性，可弯曲和扭曲，并且所得的网幅柔软、可悬垂。然而，合成纤维比木纤维贵很多，并且水刺法的基本投资和操作成本较高。 
用于制备吸水性非织造物的第三种方法是形成吸水性纤维和通过熔喷法制备的合成纤维的混合物。这种被称之为共成型材料(coform)的纸浆-聚合物联合型复合材料由空气成型基体组成，所述基体包含平均直径小于10微米的熔喷微纤维和在聚合物微纤维的基体中到处分布并且啮合至少部分微纤维以使所述微纤维彼此隔开的多种个性化吸水性纤维(例如木浆纤维)。通过微纤维与吸水性纤维的机械缠结、微纤维和单独形成粘在一起的联合型纤维结构的吸水性纤维的机械缠结和相互连接，吸水性纤维被微纤维基体相互连接并保持在微纤维基体中。根据Anderson等的美国专利第4,100,324号中的描述制备这些材料。描述共成型非织造材料和混有共成型层的复合织物的用途的专利包括美国专利第4,663,220号、第4,784,892号、第4,906,513号、第5,952,251号、第6，028,018号、第6,946,413号和美国专利申请US2005/0266760A1。共成型非织造物具有良好的吸水性，并已成功用于吸水性擦拭物的制备中。
共成型同时具有原料成本较低和加工的基本投资较低的优势。由于熔喷纤维是热塑性的，所以可通过热粘合将它们用于加强空气成型基体。通常采用热压纹共成型网幅。 
共成型的缺点是复合材料往往较硬，并且热压纹可加剧该硬度。例如，如美国专利第6,946,413号所述，解决该缺点的一种在先方法要求制备混有与一层或多层共成型层粘合的经拉伸的弹性组分的复合物。粘合完成后，释放弹性组分上的张力，产生柔软蓬松的拉伸-粘合层压织物。拉伸-粘合层压的缺点包括加工的基本投资较高，弹性组分的成本较高。 
发明内容
本发明的复合片材适合用在需要吸水性的应用中。最简单形式的复合片材包含吸水性纤维和能被拉伸应力永久性拉长(伸展)的熔喷纤维的共成型混合物。熔喷纤维的拉长使复合物变软，并使其更加悬垂。熔喷纤维的拉长通过使复合片材经过增量拉伸步骤而得以实现。 
在一些实施方式中，复合片材包含可伸展热塑性纤维的附加(第二)层。该附加层可以是，例如层压在可伸展的共成型层的一个表面上的可伸展纤维或长丝的非织造网幅形式。可伸展的共成型层中的熔喷纤维和附加层中的可伸展纤维或长丝可以通过拉伸应力永久性拉长，以提供柔软、悬垂的层压体。附加层中的纤维或长丝为复合片材提供了额外的强度。在另一个实施方式中，可伸展的纤维或长丝的非织造层界定复合片材的反面外表面。在另一个实施方式中，复合片材包含存在于所述复合片材的反面外表面上并与可伸展纤维或长丝的层粘合的含有吸水性纤维的附加共成型层。 
永久性增量拉长非织造网幅中的纤维的方法是众所周知的。US4,153,664中描述了起模网幅(pattern drawing web)法。US4,116,892中描述了拉伸热塑性网幅的增量部分的方法。US5,167,897中将增量拉伸法扩展至非织造层压体。将增量拉伸法进一步改进为通过永久性拉长网幅的选择部分而在非弹性网幅中产生类似于弹性的性能。在EP0991803中描述了拉长网幅的选择部分的方法。
专利技术中已描述了弹性体共成型体的实例。US4,663,220描述了采用来自ABA嵌段共聚物弹性体的熔喷纤维制得的共成型复合物。US4,803,117描述了利用来自乙烯-乙烯基共聚物弹性体的熔喷纤维制得的共成型复合物。 
在本发明的许多有利的实施方式中，可伸展纤维的网幅包含随意排列的热塑性聚合物长丝的纺粘网幅。所述纺粘网幅可包括多个将纺粘网幅的长丝彼此粘合并且还用来将复合片材的各层粘合在一起的离散的热点连接部位。 
在一些实施方式中，将复合片材增量拉伸，以永久性拉长共成型层中的可伸展熔喷纤维和非织造网幅层的可伸展纤维。增量拉伸可产生沿着一个方向伸展的离散的隔开的增量拉伸区，其中可伸展纤维已永久性变形和拉长，其中，通过介入纵向伸展的长丝基本没有变形的非拉伸区将这些增量拉伸区隔开。 
在一个特别的实施方式中，本发明的复合片材包含含有吸水性木浆纤维和可伸展的热塑性熔喷纤维的混合物的第一共成型层。该第一共成型层具有内表面和形成复合片材的吸水性第一外表面的外表面。将连续长丝的可伸展纺粘非织造网幅粘合在第一共成型层的内表面上。连续长丝包含彼此不相混溶的至少两种聚合物的混合物和与所述不相混溶的聚合物混溶或部分混溶的至少一种另外的聚合物。包含吸水性木浆纤维和可伸展的热塑性熔喷纤维的混合物的第二共成型层设有粘合在连续的可伸展长丝层上的内表面和形成复合片材的吸水性第二外表面的外表面。 
在另一个实施方式中，本发明的复合片材包含木浆纤维和可伸展的热塑性熔喷纤维的共成型体。可伸展的熔喷纤维包含聚丙烯均聚物和聚丙烯共聚物的混合物。在另一个实施方式中，复合片材包含含有木浆纤维和可伸展的热塑性熔喷纤维的混合物的第一共成型层，所述第一共成型层具有内表面和形成复合片材的吸水性第一外表面的外表面。将连续长丝的可伸展纺粘非织造网幅粘合在第一共成型层的内表面上。纺粘网幅的长丝包括鞘-芯双组分长丝，所述鞘-芯双组分长丝包含聚乙烯外鞘组分和聚丙烯芯材组分。提供了含有木浆纤维和可伸展的熔喷纤维的混合 物的第二共成型层，所述第二共成型具有粘合在连续的可伸展长丝的层上的内表面和形成复合片材的吸水性第二外表面的外表面。 
本发明还提供制备可伸展复合片材的多种方法。该可伸展复合材料非常适合用作吸水性擦拭物。在一个实施方式中，所述方法包括下述步骤：形成包含吸水性纤维和可伸展的熔喷纤维的共成型层；将可伸展的热塑性纤维的层贴附至所述共成型层的一个表面上；并以面对面紧密接触的方式将所述共成型层与所述可伸展的热塑性纤维的层粘合，以使所述共成型层界定复合片材的吸水性外表面。所述方法可包括进一步的步骤：形成包含吸水性纤维的附加共成型层，以面对面紧密接触并粘合的方式使附加共成型层与所述连续的可伸展长丝层的反面粘合，以使所述附加共成型层界定复合片材的反面外表面。这种方法可包括进一步的步骤：增量拉伸所述复合片材以拉长纤维。所述拉伸可包括通过环轧进行增量拉伸。 
在另一个方面，另一种方法包括下述步骤：通过将纤维化浆引入离开熔喷模具的新挤出的聚合热塑性纤维的通道内而在移动的收集面上形成第一共成型层；引导其上具有第一共成型层的移动的收集面通过纺粘处，并将新挤出的连续的可伸展长丝层沉积在所述共成型层上；从纺粘处引导具有第一共成型层和连续长丝层的移动的收集面通过共成型处，并通过将纤维化浆引入离开熔喷模具的新挤出的聚合热塑性纤维的通道内而在连续长丝层上形成第二共成型层；并将第一共成型层、第二共成型层和连续长丝层粘合到一起以形成复合片材。所述方法还包括增量拉伸所述复合片材以拉长连续长丝和熔喷纤维。 
在一些实施方式中，通过深压纹来增量拉伸复合片材以永久性拉长压纹区内的可伸展的熔喷纤维和可伸展纤维网幅。 
本发明提供适合用在吸水性用途中的复合片材的另一种方法。所述方法包括下述步骤：形成含木浆纤维的共成型层，然后将连续的可伸展长丝层贴附至所述共成型层的两个表面上，并以面对面紧密接触的方式将连续的可伸展长丝与共成型层粘合，以使所述共成型层界定复合片材的内表面。
在另一个方面，所述方法包括下述步骤：在移动的收集面上形成纺粘连续热塑性长丝的第一层；引导其上具有第一连续长丝层的移动的收集面通过共成型处，并在所述连续长丝层上沉积共成型层；引导具有第一连续长丝网幅和共成型层的移动的收集面通过第二纺粘处；将连续热塑性长丝的第二层沉积在共成型层和第一热塑性长丝层上；然后将这三层粘合在一起以形成复合片材。所述方法还可包括增量拉伸复合片材以拉长连续长丝和熔喷纤维。 
附图说明
已经在总体层面上对本发明进行了如此描述，现在将参考无需按比例绘制的下述附图，其中： 
图1是本发明的复合片材的透视图，其中连续的可伸展长丝层粘合在共成型层上； 
图2是本发明的复合片材的透视图，其中连续的可伸展长丝层夹在两个共成型层之间； 
图3是制备图2的复合片材的装置的示意图； 
图4表示根据本发明的一个方面的增量拉伸系统； 
图5表示根据本发明的另一个方面的增量拉伸系统； 
图6表示根据本发明的另一个方面的增量拉伸系统； 
图7是图6的辊对(roll pair)的局部剖面图； 
图8表示根据本发明的再一个方面的增量拉伸系统； 
图9是图8的辊对的局部剖面图； 
图10是显示如何用环轧测量材料的伸长百分比的示意图； 
图11是本发明的复合片材的透视图，其中外部的连续可伸展长丝的纺粘非织造层位于内部的共成型层的相反两侧。 
具体实施方式
下文中将参考附图更充分地描述本发明，其中列出了本发明的部分而非全部实施方式。实际上，可以以许多不同的方式实施这些发明，不 应理解为本发明局限于此处所列举的实施方式；更确切地说，提供这些实施方式是为了使本公开文本满足适用的法律要求。全文中同样的数字表示同样的要素。 
在本申请中，下述术语具有如下含义： 
术语“纤维”可以指有限长度的纤维或无限长度的长丝。 
术语“短纤维”是指有限长度的纤维。 
此处所用的术语“非织造网幅”指这样的材料的结构或网幅：不使用织造法或针织法而形成，以产生互相交错的独特的纤维或线结构，而不是可以确认的、重复形式的纤维或线结构。过去，已通过诸如熔喷法，纺粘法和短纤维梳理法等各种常规方法形成非织造网幅。 
此处所用的术语“熔喷”是指这样的方法：通过将熔融的热塑性材料经由多个细小的、通常为圆形的模具毛细管(die capillary)挤入能使熔融的热塑性材料变细并形成纤维的高速气体(例如，空气)流中而形成纤维，该纤维的直径可以达到微纤维直径的水平。然后，采用气流运送所述熔喷纤维，并将所述熔喷纤维沉积在收集面上以形成随机的熔喷纤维的网幅。例如，在Buntin等的美国专利第3,849,241号中公开了这样的方法。 
此处所用的术语“纺粘”是指这样的方法：将熔融的热塑性材料从多个细小的、通常为圆形的喷丝头毛细管中挤成长丝，然后机械地或气动地使所述长丝变细并进行拉拔。将所述长丝沉积在收集面上以形成随机排列的基本连续的长丝的网幅，然后可将所述网幅粘合在一起以形成粘着的非织造织物。纺粘非织造网幅的制备在例如美国专利第3,338,992号；美国专利第3,692,613号；美国专利第3,802,817号；美国专利第4,405,297号和美国专利第5,665,300号中有所说明。一般说来，这些纺粘方法包括将长丝从喷丝头中挤出，采用空气流使长丝骤冷以促进熔融长丝的固化，通过在空气流中气动地夹带长丝或者通过将长丝缠绕在机械拉伸辊上机械地来施加拉拔张力而使长丝变细，将经拉拔的长丝沉积在有小孔的收集面上以形成网幅，并将松散的长丝的网幅粘合成非织造织物。所述粘合可以是任何热粘合处理或者化学粘合处理，代表性的粘合是热点粘合。
此处所用的术语“微纤维”指平均直径不大于约100微米的小直径纤维，例如平均直径为约0.5微米～约50微米的纤维，或者更具体而言，微纤维的平均直径可以为约4微米～约40微米。 
此处所述的术语“热点粘合”包括使诸如待粘合的两个以上的纤维网幅等材料穿过加热过的砑光机辊和砧辊之间。砑光机辊通常有一定的图案以使织物在离散的点粘合处粘合，而不是在织物的整个表面粘合。 
此处所用的术语“聚合物”通常包括但不局限于均聚物、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)和三元共聚物等，以及它们的混合物和改性物。此外，除非另有特别限定，术语“聚合物”应当包括材料的所有可能的几何构型，包括全同立构、间规立构和无规对称。 
此处所用的术语“可伸展”指材料在施加拉伸张力时被永久性拉长。可以采用图10所描述的增量拉伸装置进行伸展性的实际测试。如果在该装置中，织物在它的原始长度之外能被拉长150％而不断裂，则它是可伸展的。从增量拉伸装置中取出后，织物应当显示至少15％的基重减少。 
此处所用的术语“恢复”和“恢复性”是指释放拉伸张力后经拉伸的材料的收缩。适合用于本发明的可伸展材料在诸如Instron等标准的实验室拉力试验机中被拉长到伸展度为150％以上时具有小于50％的恢复性。 
此处所用的术语“增量拉伸”是指这样的方法：将网幅支撑在被密集地间隔开的部位，然后拉伸这些密集间隔部位之间所述网幅的非支撑部分。这可以通过使网幅穿过一对啮合的瓦楞辊之间形成的辊隙而实现，这一对啮合的瓦楞辊的旋转轴垂直于网幅行进的方向。在美国专利第4,223,059号中描述了被设计成纵向拉伸和横向拉伸的增量拉伸辊，在此通过引证将其引入本文。美国专利第6,344,102中描述了另一种增量拉伸装置，其中这些辊中的一个辊包括多个凸出物，另一个辊包括容纳于凸出物之间的叶片(blade)，从而通过深压纹来增量拉伸所述网幅。 
在一个实施方式中，本发明提供具有附着在热塑性聚合物的可伸展纤维的一个或多个层上的一个或多个的可伸展共成型层(优选为非织造网幅形式)的复合片材。所述一个或多个共成型层提供吸水层。可伸展 纤维的所述一个或多个层使所述一个或多个共成型层具有额外的强度。在一个特别有利的实施方式中，可将复合片材增量拉伸以使片材在保持期望水平的强度和抗撕裂性的同时具有改善的悬垂性和衣料般的质感。 
参考图1对附图标记10所代表的复合片材进行说明。复合片材10包含附着在可伸展热塑性纤维网幅形式的层14上的至少一层共成型层12。在所示的实施方式中，热塑性纤维的层14由基本上连续的长丝的非织造网幅组成。然而，在另一个实施方式中，层14可包含短纤维网幅或熔喷纤维网幅。外面的共成型层12提供复合片材的外表面16。 
图2表示本发明的另一个实施方式，其中附图标记10’指定的复合片材包含布置在两层共成型层12之间的基本连续的可伸展长丝的层14。然而，在另一个实施方式中，层14可包含短纤维网幅或熔喷纤维网幅。在图2所示的实施方式中，两层共成型层12附着在可伸展长丝层14的两个相反表面上并界定复合片材的外表面16。共成型层12提供复合片材的外表面16，所述复合片材是吸水性的并且能够保持期望体积的流体。 
一层或多层共成型层12为复合片材提供外部吸水性表面。在一个实施方式中，一层以上的共成型层包含热塑性可伸展熔喷微纤维的气体成型基体和吸水性纤维素纤维，例如，木浆纤维。如前所述，通过最初形成含合成纤维或聚合物纤维的至少一种主气流并使所述主气流与至少一种天然纤维或纤维素纤维的副气流合并而形成共成型层。所述主气流和副气流在湍流条件下合并以形成包含完全均匀地分布的不同纤维的联合气流。将联合的空气流引导至形成面上以通过空气成型法形成材料层。然后可陆续形成多层的这些共成型层以提供多重共成型层的网幅。 
在一个实施方式中，共成型层12可具有20重量％～50重量％的聚合物纤维和80重量％～50重量％的纸浆纤维。聚合物纤维与纸浆纤维的优选比例可以是25重量％～40重量％的聚合物纤维和75重量％～60重量％的纸浆纤维。聚合物纤维与纸浆纤维的更优选的比例可以是30重量％～40重量％的聚合物纤维和70重量％～60重量％的纸浆纤维。聚合物纤维与纸浆纤维的最优选的比例可以是约35重量％的聚合物纤维和65重量％的纸浆纤维。
共成型层12的熔喷聚合物纤维可以从具有良好的伸长能力的多种聚合物组合物制备，从而在经受增量拉伸应力时，所述聚合物组合物制成的熔喷纤维容易伸长。合适的聚合物组合物的实例包括聚乙烯、诸如聚丙烯、聚乙烯等烯烃的混合物，或者它们与诸如弹性体聚烯烃或苯乙烯弹性体等弹性体聚合物的共聚物。 
多种吸水性纤维可用于制备共成型层12。例如，可以使用来自软木(得自于针叶树)、硬木(得自于落叶树)或棉绒的消化性纤维素纤维。也可以使用来自芦苇草、甘蔗渣、死毛(kemp)、亚麻和其他木质(lignaceous)纤维源和纤维素纤维源的纤维。其他吸水性纤维包括吸水性天然纤维或吸水性合成纤维，例如丙烯酸纤维或由再生纤维素、聚乙烯醇、多糖或其他吸水性纤维形成用组合物制得的纤维。考虑到成本、制备的容易性和可处置性，优选的纤维是从木浆中得到的那些纤维(例如，纤维素纤维)。 
也可以将具有独特功能的微粒混入共成型层12中。可混入高吸水性聚合物的微粒以增加吸水性。可混入活性碳微粒以便于去除污染物。也可以混入离子交换树脂颗粒。 
根据本发明的一个实施方式，层14是随意排列的基本连续的长丝的热点粘合的纺粘非织造网幅。例如，可通过常规的纺粘法制备所述纺粘非织造网幅，其中将熔融的聚合物挤压成连续长丝，随后进行骤冷，通过牵引辊机械性地使长丝变细，或者通过高速流体气动地使长丝变细，并以随意排列的方式收集在收集面上。长丝收集后，可以用任何热粘合处理、化学粘合处理或机械粘合处理来形成粘合网幅，从而得到粘着的网幅结构。优选的是，纺粘网幅是可伸展的并且基本无弹性。所述网幅可拉伸，但长丝被永久性拉长并且不具有恢复到它们拉伸前的尺寸的明显的恢复性。因而，所述网幅具有很小的收缩力(弹性恢复性)，因此是无弹性的。 
可伸展的纺粘网幅由任何一种大量可得的配制成能提供可高度伸展的长丝的热塑性聚合物组合物形成，其中所述长丝在拉伸力作用下会被拉长和拉伸，并永久性伸长，即，所述长丝是非弹性的。例如，如同在共同持有的美国专利5,593,768(在此通过参考将其引入本文)中所更充 分描述的，可由多组分纤维形成具有可伸展的非弹性长丝的纺粘非织造网幅，所述多组分纤维由作为主连续相的彼此不相混溶的至少两种不同的热塑性聚合物的高度分散的混合物和分散在其中的至少一种非连续相形成。所述长丝可另外包含与所述不相混溶的聚合物混溶或部分混溶的至少一种另外的聚合物。在一个具体实施方式中，不相混溶的聚合物的混合物包含丙烯聚合物和聚乙烯。 
也可由多组分长丝制备可伸展的纺粘网幅，在所述多组分长丝中，两种以上的聚合物组分横跨长丝的横截面被分离在截然不同的区域中。具有聚乙烯外鞘和聚丙烯芯材的鞘-芯双组分长丝是这样的长丝的一个实例。 
可以以多种方式将一层或多层共成型层12与连续的可伸展长丝的层14粘合在一起以形成坚固、粘着的复合片材。例如，可采用热粘合、机械粘合、粘合剂粘合和它们的组合将所述层粘合在一起。热粘合法包括热压延、带压延、烘箱粘合、超声波粘合、辐射热粘合、热风粘合(through-air bonding)等。区域粘合和点粘合是可用来粘合复合片材的热粘合的两个实例。 
在图1所示的实施方式中，通过附图标记20所表示的多个断续的粘合点来粘合复合片材。在这点上，热点粘合是最优选的。已知有各种热点粘合技术，最优选的是采用具有点粘合图案的压延辊。可以使用本领域已知的任何图案，代表性实施方式采用连续图案或非连续图案。优选的是，粘接点20覆盖网幅10的面积的4％～30％，更优选为被覆盖层的4％～20％，最优选为被覆盖层的4％～15％。通过依照这些百分比范围粘合网幅，在保持织物的强度和完整性的同时长丝能够在完全程度的拉伸下都被拉长。 
参考图3对制备三层复合片材(例如，图2中所表示的复合片材)的方法和装置进行说明，并将其广泛地指定为附图标记100。所述装置包括第一共成型体形成处110，从所述第一共成型体形成处110将共成型网幅112沉积在收集面114上，例如有孔(foraminous)环形移动带。接下来，在纺粘处120将连续的可伸展长丝的层122沉积在共成型网幅112上。在第二共成型体形成处130将第二共成型层沉积在可伸展的连续长丝层 上。在第二共成型层已沉积后，可将所述层粘合在一起以形成复合片材。 
各共成型体形成处110、130包括被配置以提供熔喷微纤维流142的熔喷模具140和被配置以提供被引入到熔喷微纤维流中的吸水性纸浆纤维流146的疏散辊(picker roll)144。在一个实施方式中，疏散辊144可具有常规的布置，其中多个齿状突出148适合于将吸水性材料垫或吸水性材料毡150分离成单独的吸水性纤维146。供应给疏散辊144的吸水性纤维垫或吸水性材料毡150可以是纸浆纤维片。 
可通过托辊排列152将吸水性材料片或吸水性材料垫150供应给疏散辊144。在疏散辊144的齿状突出148已经将吸水性材料垫150分离成分开的吸水性纤维146之后，将单独的吸水性纤维通过喷嘴154朝着熔喷微纤维流142传送。供应充足量的气体以用作通过喷嘴154传送吸水性纤维146的介质。所述气体可以通过任何常规的装置提供，例如鼓风机(图中未示出)。据设想，可将添加剂和/或其他材料添加到或被夹带到气流中以处理吸水性纤维146，或者在所得网幅中提供所需性质。 
当熔融聚合物流从熔喷模具140中排出时，一股或多股细化气体流带走熔融的聚合物并使其细化成细纤维。将聚合物纤维和纸浆纤维的混合物沉积在收集面114上以形成第一共成型层。在选择性实施方式中，可将先前形成的共成型层与先前形成的由连续长丝构成的纺粘非织造网幅结合，并采用热粘合、机械粘合、粘合剂粘合或这些粘合方式的组合将它们粘合在一起以形成双层复合片材。 
在另一个选择性实施方式中，可经由其上第二共成型层沉积在连续的可伸展长丝层上的辊来提供包含共成型层和连续的可伸展长丝层的预成型的双层复合片材。 
可通过在一个或多个方向上对复合片材机械地施加拉伸力，从而增量拉伸复合片材。所述拉伸改善了复合片材的整体悬垂性和触感。在一个实施方式中，可通过使复合片材穿过一个以上的增量拉伸辊而拉伸复合片材。这种活化过程通常将复合片材增量拉伸约1.1倍～10.0倍。在有利的实施方式中，将复合片材拉伸或拉拔到它的原始长度的约2.5倍。本发明的增量拉伸可通过本领域中已知的任何手段来实现。
可采用许多不同的拉伸器和技术来拉伸复合片材。可以采用，例如斜向啮合拉伸器、横向(“CD”)啮合拉伸设备、纵向(“MD”)啮合拉伸设备来实现增量拉伸。 
一种合适的增量拉伸系统的示例性构造示于图4。增量拉伸系统200通常包括第一拉伸辊202(例如，顶部拉伸辊)和第二拉伸辊204(例如，底部拉伸辊)这一对被布置而形成辊隙的辊。第一增量拉伸辊202通常包含多个突出体206(例如凸起的环)和相应的沟槽208，两者都在第一增量拉伸辊202的几乎全部圆周延伸。第二增量拉伸辊204也同样包含多个突出体206(例如凸起的环)和相应的沟槽208，两者也都在第二增量拉伸辊204的几乎全部圆周延伸。第一增量拉伸辊202上的突出体206与第二增量拉伸辊204上的沟槽208啮合或咬合，同时第二增量拉伸辊204上的突出体与第一增量拉伸辊202上的沟槽啮合或咬合。当复合片材10穿过增量拉伸体系200时，在横向上(“CD”)上增量拉拔或拉伸该复合片材10。在有利的实施方式中，所述突出体由环形成，该增量拉伸体系被称为“环轧”。 
作为可选方案或者另外的方案，可采用一种或多种增量拉伸系统(例如，图5中所提供的增量拉伸系统)纵向(“MD”)增量拉拔或拉伸复合片材。如图5所示，MD增量拉伸系统220同样包括一对具有啮合的突出体226和沟槽228的增量拉伸辊222和224。然而，MD增量拉伸系统内的突出体和沟槽通常平行于辊轴沿着辊的宽度延伸，而不是沿着辊的圆周延伸。当复合片材10穿过增量拉伸体系220时，纵向(“MD”)增量拉拔或拉伸所述复合片材10。增量拉伸片材的方法在美国专利第6,994,763中进行了更详细的讨论。 
另一种可用于本发明的拉伸装置在共同持有的美国专利第6,344,102号中有所描述。如图6所示，该装置包括含有一对协同运转的圆柱形辊的辊组件。第一辊301包含多个从所述辊的表面沿径向向外延伸的凸出物311。另一个辊302包含从所述辊的表面沿径向向外延伸并且平行于辊的转动轴沿着辊的宽度纵向延伸的叶片313。如图7所示，叶片313与第一辊上的凸出物311啮合。当复合片材穿过辊301和302之间时，通过 叶片将材料驱动到第一辊301上的凸出物周围的凹槽中。当在凸出物周围形成深压纹时，通过深压纹增量拉伸复合片材中的可伸展的聚合物纤维，从而软化片材并使片材蓬松。 
另一种可用于本发明的拉伸装置在共同持有的美国申请60/763,543中有所描述，并示于图8中，所述装置包括含一对圆柱形辊401和402的辊组件。第一辊401包含多个从所述辊的表面沿径向向外延伸的凸出物411，并且通常可以是圆柱状或截头圆锥状。另一个辊402包含径向取向的凹槽413，该凹槽的位置与凸出物411相对应，凹槽的形状能在两个辊以相反的方向旋转时相应地容纳凸出物。当复合片材穿过辊401和402时，所述材料被凸出物411驱动入凹槽中。如图9所示，凸出物各自包含用于与片材的离散部分接触并进入对应辊上的相应凹槽的最外表面部分。结果，当凸出物和片材进入相应的凹槽中时，通过深压纹在围绕与凸出物接触的点的离散区或离散带将所述片材增量拉伸。 
如上所述，复合片材的拉伸使所述片状物的多个部分在一个或多个方向上经受拉伸应力。在缺乏可伸展的纤维或长丝时，应力的施加会导致复合物破裂或撕裂。结果，复合片材可能无法用于它的预期用途。连续的可伸展长丝层和可伸展共成型层使得复合片材能够耐受在拉伸过程中可能遭遇的应力。在本发明的优选实施方式中，可将复合片材拉伸至少150％而不使共成型层破裂。测试是否能将样品拉伸到这种程度的合适的方法包括采用具有沿圆周方向延伸的环的辊通过环轧将样品横向增量拉伸。通过调整所述环的咬合深度，可控制伸长百分比。如图10所示，给出相邻环之间的间隔2A和环B的咬合深度，最好通过下述公式大致计算材料的伸长百分比： 
Figure DEST_PATH_G2007800073087D00131
可通过以表面活性剂处理表面层来增加复合片材的吸水性和吸水率。来自陶氏化学公司的Triton X-102、来自Schill & Seilacher AG的 Silastol PST和来自通用电气的Nuwet237是合适的表面活性剂的实例。 
图11说明了本发明的另一个实施方式，其中附图标记10”所指明的复合片材包含置于内部的共成型层12的正反两面上的基本连续的可伸展 长丝的纺粘非织造网幅形式的外层14。然而，在另一个实施方式中，层14可包含短纤维网幅或熔喷纤维网幅。在图11所示的实施方式中，将两层纺粘非织造层14附着在可伸展共成型层12的正反两面，并界定复合片材的外表面16。内部的共成型层12提供能保持所需体积的流体的复合片材的吸水芯。 
图11中的三层复合片材10”可通过与图3中的装置相似的装置来制备，不同之处在于该装置包括与位于第一共成型处110上游的附图标记120所表示的纺粘处基本相同的另一个纺粘处，从而首先将纺粘层沉积在收集面114上，共成型处110会因此将共成型层直接沉积在这样形成的纺粘层上。然后通过纺粘处120沉积第二纺粘层。为了制备三层层压体，图3中所示的第二共成型处130将不工作。如果想得到在一个外表面上具有共成型层的四层复合片材，则可使第二共成型处130工作。 
本发明的复合片材可用于各种用途，包括个人卫生产品、湿巾和干巾、尿布或失禁服装。所述复合片材特别适合用作吸水性擦拭物，例如湿巾。在本发明的上下文中，术语“湿巾”是指一种纤维片状物，所述纤维片状物中具有施加给它的液体从而能将所述液体保持在纤维片状物上或保持在纤维片状物内，直到消费者使用它为止。所述液体可以是能被吸收到湿巾复合弹性材料中的任何溶液，可包括提供所需的擦拭性质的任何合适的组分。例如，如本领域技术人员所熟知的，所述组分可包括水、润肤剂、表面活性剂、芳香剂、防腐剂、螯合剂、pH缓冲剂或它们的组合。所述液体也可以包含洗剂和/或药剂。包含在各湿巾中的液体量可随用来提供湿巾的材料类型、所用的液体类型、用来保存湿巾的包装物类型和湿巾的预期最终用途而不同。通常而言，为了获得改善的擦拭性，基于湿巾的干重，各湿巾可包含约150重量％～约600重量％的液体，优选为约250重量％～约450重量％。在更优选的方面，基于湿巾的干重，包含在湿巾中的液体量为约300重量％～约400重量％，优选为约330重量％。如果液体量小于上述范围，则湿巾可能太干，不能充分进行擦拭。如果液体量大于上述范围，则湿巾可能过饱和和过度湿润，液体可能汇集在包装物底部。
实施例 
用具有各种混和比例的聚丙烯均聚物(Basell Metocene X-11291491)和弹性聚丙烯共聚物(ExxonMobil Vistamaxx2320)的熔喷纤维制备不同伸展性的共成型织物。在直径为5cm的单螺杆挤出机中加工混合物，并将所述混合物加入到能制备25cm宽的网幅的熔喷模具中。模具温度为270℃，牵引空气的温度为215℃。采用与美国专利第3,793,678号中所描述的成纤器具有相同设计的纸浆成纤器使Weyerhaeuser NF405纸浆纤维化，并在熔喷模头下将其推进成约8cm的熔喷网幅。用由聚乙烯(DowDNDA-1082)制得的熔喷纤维制备一种共成型织物样品。所有织物的基重均为65gsm(克每平方米)，熔喷物含量为40％。用粘合面积(bond area)为4％的轧辊以10m/分钟的速度热点粘合这些共成型网幅。含PP(聚丙烯均聚物)熔喷物的织物在128℃的温度粘合。含PE(聚乙烯)熔喷物的织物在115℃的温度粘合。 
通过下述步骤评价这些织物的伸展性，所得结果总结在表I中：使粘合网幅穿过被设置为多种咬合深度的一组环形辊。沿横向和纵向增量拉伸所述织物。环之间的间距为1.6mm。咬合深度为0mm～3.4mm。在逐渐增加的穿透深度下测试所述织物，直到所述织物破碎为止。通过三角学确定增量拉伸器中所述织物的伸长率。用织物破碎前所达到的最高咬合深度确定织物的伸长率。伸长率为150％以上的共成型网幅对本发明特别有利。 
表I 
经CD增量拉伸的共成型体的伸长率 
  
熔喷组合物 伸长率％
100％PP 33
20％ePP，80％PP 67
40％ePP，60％PP 83
60％ePP，40％PP 150
80％ePP，20％PP 180
100％PE 150
PP＝聚丙烯均聚物(Basell Metocene X-11291491) 
ePP＝弹性聚丙烯共聚物(Vistamaxx2320) 
PE＝聚乙烯(Dow DNDA-1082)
悬垂性 
评价了五种共成型样品的悬垂性。所有的样品都在TMI制备的FRL悬臂梁弯曲测试仪中进行测试(参照：ASTM D1388-96)。将2.5cm宽20cm长的样品(长度方向是纵向)放置在金属重物下的平面上。所述重物带着织物在机械驱动下越过所述平面的顶部。重物和重物下的织物越过所述平面的边缘伸展。所述织物样品慢慢弯曲，记录弯曲45°时所述重物越过所述平面边缘的伸展度。较硬的织物在弯曲45°前需要所述重物行进更长的距离。每个样品的重物行进距离列于表V。增量拉伸在改善悬垂性方面的优势非常明显。 
表II 
共成型样品的悬垂性 
  
样品 熔喷组合物 基重(gsm) 悬垂长度(cm)
A 20/80PP/Vistamaxx2320 65 6.4
B 增量拉伸的20/80PP/Vistamaxx2320 66 4.1
C PE 67 4.1
D 增量拉伸的PE 70 2.2
E PP 65 8.9
表III 
共成型样品的描述 
  
样品 组合物
A 65gsm共成型体，40％20/80PP/Vistamaxx2320混合物的熔喷纤维。以4％的图案进行热点粘合
B 130gsm共成型体，40％20/80PP/Vistamaxx2320混合物的熔喷纤维。以4％的图案进行热点粘合。在MD和CD方向上均增量拉伸至180％的伸长率。增量拉伸后的基重为66gsm。
C 67gsm共成型网幅，40％PE熔喷物。以4％的图案进行热点粘合
D 112gsm共成型网幅，40％PE熔喷物。以4％的图案进行热点粘合。在MD和CD方向上均增量拉伸至150％的伸长率。增量拉伸后的基重为70gsm。
E 65gsm共成型体，40％PP熔喷纤维。以4％的图案进行热点粘合
表IV 
共成型样品的拉伸特性 
  
样品 MD拉伸N/5cm CD拉伸N/5cm
A 4.5 3.5
B 3.2 3.2
C 3.8 2.2
D 3.3 2.6
E 14.2 9.5
[0094] 共成型/纺粘层压体 
表IV表明悬垂性最好的共成型织物具有相对较低的拉伸强度。由于这些织物含有热塑性纤维，所以为了增加它们的强度，可能将其热层压成其他非织造品。如果这些非织造品可伸展，则可将所得的层压体机械拉伸以增加它们的柔软性。这种可能性通过表V中所列的一组实施例得以证实。对于样品F～L，用粘合面积为4％的辊以10m/分钟的速度将共成型网幅热点粘合到纺粘网幅上。这些样品中所用的
Figure DEST_PATH_G2007800073087D00171
纺粘织物是根据US5,593,768制备的。在128℃的温度粘合含PP熔喷物的织物。在115℃的温度粘合含PE熔喷物的织物。 
通过增量拉伸技术评价这些层压体的伸展性。用100％PP熔喷物制成的层压体没有伸展到150％，因此没有达到本发明的标准。 
表V 
共成型/纺粘复合物的伸展性 
Figure DEST_PATH_G2007800073087D00172
如表VI所示，层压体的强度使得它们更适合用于重视耐久性的用途中。如表VII所示，拉伸层压体改善了它们的柔软性和悬垂性。 
表VI 
增量拉伸前的共成型/纺粘复合物的特性 
  
样品 基重(gsm) MD拉伸(N/5cm) CD拉伸(N/5cm) 悬垂性(cm)
F 75 30 17 12
G 75 20 14 7
H 75 21 11 6
I 80 36 22 7.5
J 80 31 18 7.5
K 80 26 15 6.25
L 60 14 7.5 3.25
表VII 
增量拉伸至伸长率大于150％后的共成型/纺粘复合物的特性 
  
样品 基重(gsm) MD拉伸(N/5cm) CD拉伸(N/5cm) 悬垂性(cm)
F 破碎      
G 48 13 11 4
H 53 16 8.5 3.25
I 破碎      
J 56 21 8 2
K 51 19 7 2.75
L 26 4 3.5 1.5
共成型物与纺粘织物的三层层压体 
共成型物与纺粘网幅的三层层压体具有性能优势，特别是在耐久性方面。制备了表VIII中所描述的共成型网幅。将样品P和Q作为非层压共成型织物来评价。以较低的基重制备样品R、S和T，并将其设计成混入到具有可伸展的纺粘织物的层压体中。 
表VIII 
共成型网幅 
  
样品# PP重(gsm) Vistamaxx重(gsm) 纸浆重(gsm) 总基重(gsm)
P 26   39 65
Q 10 16 39 65
R 8 10 27 45
S 3.5 5 14 22.5
T 8.5   14 22.5
[0112] 在加热砑光机中用平滑辊和粘合面积为4％的点压纹辊在128℃的温度以10米/分钟的速度热点粘合网幅样品P和Q。 
共成型层压体的制备 
采用共成型网幅样品R、S和T，在点粘合砑光机中在127℃的温度以10米/分钟的速度制备下述三层层压体。用由PP均聚物或US5,593,768中所描述的高伸长率纺粘织物
Figure DEST_PATH_G2007800073087D00191
制得的纺粘织物来制备表IX中所述的层压体。 
表IX 
共成型/纺粘层压体 
Figure DEST_PATH_G2007800073087D00192
共成型体和共成型层压体的增量拉伸 
表I和表II中所述的粘合样品纵向穿过增量拉伸装置以使伸长率为150％。该操作的结果是横向拉伸所述织物。然后将样品旋转90°，并穿过增量拉伸装置。该操作的结果是纵向拉伸所述织物。在增量拉伸过程中，由PP均聚物制得的样品的纺粘组分和熔喷组分都破碎，因此无法达到本发明的标准。 
表X 
经增量拉伸的样品的基重 
  
样品 拉伸前的基重(gsm) MD拉伸和CD拉伸后的基 重(gsm)
P 65 破碎
Q 65 52
层压体1 75 61
层压体2 70 58
层压体3 60 破碎
层压体4 52.5 破碎
悬垂性
在TMI制备的FRL悬臂梁弯曲测试仪中测试所有热点粘合样品和增量拉伸样品(参照：ASTMD1388-96)。将2.5cm宽20cm长的样品(长度方向为纵向)放置在金属重物下的平面上。所述重物带着织物在机械驱动下越过所述平面的顶部。重物和重物下的织物越过所述平面的边缘伸展。所述织物样品慢慢弯曲，记录弯曲45°时所述重物越过所述平面边缘的伸展度。较硬的织物在弯曲45°前需要所述重物行进更长的距离。每个样品的重物行进距离列于表V。样品Q的悬垂性优于用PP均聚物制备的样品P，因此采用可伸展组分的优势非常明显。同样，由可伸展组分制备的层压体1和2的悬垂性优于用不可伸展的共成型组分制备的层压体3和4。在由可伸展组分制备的所有样品中，增量拉伸步骤进一步改善了悬垂性。 
表XI 
织物样品的悬垂性 
  
样品 悬垂长度
P 8.25
Q 6.5
层压体1 5.75
层压体2 5.0
层压体3 8.25
层压体4 7.5
Q* 4.5
层压体1* 4.0
层压体2* 4.0
*经MD和CD增量拉伸 
耐久性 
在安装有CS-10橡胶磨轮的Taber磨耗试验机(Taber abrasion tester)中测试样品的磨耗耐久性。使直径为12cm的样品旋转并使两个磨轮在其表面上旋转。记录样品中有洞产生时的转数。结果列于表XII中。在复合物中混入纺粘长丝的优势很明显。然而，增量拉伸复合材料略微降低了耐磨性。
                            表XII 
        粘合的共成型网幅和共成型/纺粘层压体的物性 
  样品   MD拉伸   (N/5m)   CD拉伸   (N/5m)   厚度(mm)   Taber磨耗循环
  P   14   9.5   0.78   ＜10
  Q   10   6   0.75   ＜10
  层压体1   29   16   0.95   ＞200
  层压体2   36   16   0.70   ＞200
  层压体3   15   9   0.72   ＞200
  层压体4   24   13   0.69   ＞200
  Q*   5.5   3.5   0.62   ＜10
  层压体1*   15   9   0.75   125
  层压体2*   19   9   0.61   85

Claims (35)

1.一种可伸展的复合片材(10，10’，10”)，所述复合片材包含由吸水性纤维和可伸展的熔喷纤维的共成型混合物形成的第一层(12)和可伸展的热塑性纤维的第二层(14)，其中已通过施加拉伸应力将所述第一层的可伸展熔喷纤维和所述第二层的可伸展热塑性纤维永久性拉长。
2.如权利要求1所述的可伸展的复合片材，其中所述可伸展的热塑性纤维的第二层(14)包含非织造网幅。
3.如权利要求2所述的可伸展的复合片材，其中所述非织造网幅是由连续长丝构成的纺粘网幅。
4.如权利要求2所述的可伸展的复合片材，其中所述非织造网幅是短纤维梳理网幅。
5.如权利要求2所述的可伸展的复合片材，其中所述非织造网幅是熔喷纤维的熔喷网幅。
6.如权利要求1所述的复合片材，其中所述第一层的熔喷纤维由聚乙烯组成。
7.如权利要求1所述的复合片材，其中所述第一层的熔喷纤维由聚丙烯均聚物和聚丙烯共聚物的混合物组成。
8.如权利要求1～7任一项所述的可伸展的复合片材，其中所述第二层(14)的可伸展的热塑性纤维由丙烯聚合物或丙烯共聚物制备。
9.如权利要求1～7任一项所述的可伸展的复合片材，其中所述第二层(14)的可伸展的热塑性纤维包含聚乙烯连续长丝。
10.如权利要求1～7任一项所述的可伸展的复合片材，其中所述第二层(14)的可伸展的热塑性纤维包含彼此不相混溶的至少两种聚合物的混合物和与所述不相混溶的聚合物混溶或部分混溶的至少一种另外的聚合物。
11.如权利要求10所述的可伸展的复合片材，其中所述不相混溶的聚合物的混合物包含丙烯聚合物和聚乙烯。
12.如权利要求1～7任一项所述的可伸展的复合片材，其中所述第二层(14)的可伸展的热塑性纤维包含多组分长丝。
13.如权利要求1～7任一项所述的可伸展的复合片材，其中所述第二层(14)的可伸展的热塑性纤维包含鞘-芯双组分长丝，所述鞘-芯双组分长丝具有聚乙烯外鞘组分和聚丙烯芯材组分。
14.如权利要求1～7任一项所述的可伸展的复合片材，其中功能性微粒已混入所述吸水性纤维和熔喷纤维的混和物中。
15.如权利要求1～7任一项所述的可伸展的复合片材(10”)，其中所述第二层(14)与所述第一层(12)的反面面对面地紧密接触并粘合在所述第一层(12)上，以使所述第二层(14)界定所述复合片材(10”)的反面外表面。
16.如权利要求1～7任一项所述的可伸展的复合片材(10’)，其中由吸水性纤维和可伸展的熔喷纤维的共成型混合物形成的第一层(12)与所述可伸展的热塑性纤维的第二层(14)的反面面对面地紧密接触，以使所述第一层(12)界定所述复合片材(10’)的反面外表面。
17.如权利要求1～7任一项所述的可伸展的复合片材，所述复合片材已经通过环轧进行拉伸，以永久性地拉长所述可伸展的纤维。
18.如权利要求1～7任一项所述的可伸展的复合片材，所述复合片材已经通过深压纹进行拉伸，以永久性地拉长所述可伸展的纤维。
19.一种可伸展的复合片材(10，10’，10”)的制备方法，所述方法包括形成包含吸水性纤维和可伸展的熔喷纤维的可伸展的共成型层(12)；将可伸展的热塑性纤维的层(14)贴附在所述共成型层(12)的一个表面上；并以面对面紧密接触的方式将所述共成型层(12)与所述可伸展的热塑性纤维的层(14)粘合，以使所述共成型层界定所述复合片材(10，10’，10”)的吸水性外表面(16)，并拉伸所述复合片材以使所述纤维变形和永久性拉长。
20.如权利要求19所述的方法，所述方法进一步包括以下步骤：形成包含吸水性纤维和可伸展的熔喷纤维的附加的可伸展的共成型层，并以与所述可伸展的热塑性纤维的层的反面面对面紧密接触的方式将所述附加的可伸展的共成型层粘合，以使所述附加的可伸展的共成型层界定所述复合片材(10’)的反面外表面。
21.如权利要求19所述的方法，所述方法进一步包括以下步骤：形成可伸展的热塑性纤维的附加层，并以与所述共成型层(12)的反面面对面紧密接触的方式将所述附加层粘合，以使所述附加层界定所述复合片材(10”)的反面外表面。
22.如权利要求19～21任一项所述的方法，其中所述将可伸展的热塑性纤维的层(14)贴附在所述共成型层(12)的一个表面上的步骤包括形成所述可伸展的热塑性纤维的非织造网幅，并将所述非织造网幅贴附在所述共成型层(12)的所述一个表面上。
23.如权利要求19～21任一项所述的方法，其中所述拉伸步骤包括增量拉伸所述复合片材。
24.如权利要求23所述的方法，其中所述增量拉伸包括环轧。
25.如权利要求23所述的方法，其中所述增量拉伸包括深压纹。
26.如权利要求19～21任一项所述的方法，其中所述形成可伸展的共成型层(12)的步骤包括：移动收集面(114)使之经过第一共成型处(110)；将纤维化的吸水性纤维引入离开熔喷模具的新挤出的可伸展聚合热塑性纤维的通道内；并将所述吸水性纤维和可伸展的热塑性纤维沉积在所述移动的收集面(114)上，以形成所述共成型层；其中所述将可伸展的热塑性纤维的层(14)贴附在所述共成型层(12)的一个表面上的步骤包括引导这样形成的所述共成型层经过纺粘处(120)，并将新挤出的连续的可伸展长丝的层沉积在所述共成型层上。
27.如权利要求26所述的方法，所述方法进一步包括以下步骤：从所述纺粘处(120)引导具有第一共成型层和所述连续的可伸展长丝的层的所述移动的收集面(114)经过第二共成型处(130)，并通过将纤维化的吸水性纤维引入离开熔喷模具的新挤出的可伸展聚合热塑性纤维的通道内而在所述连续的可伸展长丝的层上形成第二共成型层；其中所述粘合步骤包括将所述第一共成型层和所述第二共成型层和所述连续的可伸展长丝的层粘合到一起以形成复合片材。
28.如权利要求19～21任一项所述的方法，所述方法包括移动收集面(114)使之经过第一纺粘处并将新挤出的连续的可伸展长丝的网幅沉积在所述收集面上的步骤，其中所述将可伸展的热塑性纤维的层(14)贴附在所述共成型层(12)的一个表面上的步骤包括将其上具有所述连续的可伸展长丝网幅的所述移动的收集面引导至共成型处下方，将纤维化的吸水性纤维导入离开熔喷模具的新挤出的可伸展的聚合热塑性纤维的通道中，并将所述吸水性纤维和可伸展的热塑性纤维沉积到在所述收集面上移动的所述连续的可伸展长丝的网幅上，从而形成所述共成型层。
29.如权利要求28所述的方法，所述方法进一步包括以下步骤：将上面具有所述连续的可伸展长丝的网幅和由此形成的所述共成型层的所述移动的收集面引导至第二纺粘处下，并将连续的可伸展长丝的第二网幅沉积在所述共成型层上。
30.一种可伸展的复合片材(10，10’，10”)，所述复合片材包含由吸水性纤维和可伸展的熔喷纤维的共成型混合物形成的第一层(12)和含有连续长丝的可伸展纺粘非织造网幅的第二层(14)，所述连续长丝包含彼此不相混溶的至少两种聚合物的混合物和与所述不相混溶的聚合物混溶或部分混溶的至少一种另外的聚合物，其中，可伸展是指材料在经施加拉伸张力时被永久性拉长。
31.如权利要求30所述的可伸展的复合片材，其中所述不相混溶的聚合物的混合物包括丙烯聚合物和聚乙烯。
32.一种可伸展的复合片材(10，10’，10”)，所述复合片材包括由吸水性纤维和可伸展的熔喷纤维的共成型混合物形成的第一层(12)和含有连续长丝的可伸展纺粘非织造网幅的第二层(14)，所述连续长丝包含鞘-芯双组分长丝，所述鞘-芯双组分长丝具有聚乙烯外鞘组分和聚丙烯芯材组分，其中，可伸展是指材料在经施加拉伸张力时被永久性拉长。
33.如权利要求30～32任一项所述的可伸展的复合片材，其中所述片材在它的原始长度之外能够被拉长150％而不断裂。
34.如权利要求30～32任一项所述的可伸展的复合片材(10”)，其中所述第二层(14)与所述第一层(12)的反面面对面地紧密接触，并粘合在所述第一层(12)上，以使所述第二层(14)界定所述复合片材(10”)的反面外表面。
35.如权利要求30～32任一项所述的可伸展的复合片材(10’)，其中由吸水性纤维和可伸展的熔喷纤维的共成型混合物形成的第一层(12)与所述含有连续长丝的可伸展纺粘非织造网幅的第二层(14)的反面面对面地紧密接触，以使所述第一层(12)界定所述复合片材(10’)的反面外表面。
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KR20080090570A (ko) 2008-10-08
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KR101222098B1 (ko) 2013-01-16
CN101395315A (zh) 2009-03-25
US8685870B2 (en) 2014-04-01
CA2640722A1 (en) 2007-08-30
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US20070197117A1 (en) 2007-08-23
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