CN101437682A - 弹性叠层以及用于制作弹性叠层的方法 - Google Patents

弹性叠层以及用于制作弹性叠层的方法 Download PDF

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Publication number
CN101437682A
CN101437682A CNA2006800545628A CN200680054562A CN101437682A CN 101437682 A CN101437682 A CN 101437682A CN A2006800545628 A CNA2006800545628 A CN A2006800545628A CN 200680054562 A CN200680054562 A CN 200680054562A CN 101437682 A CN101437682 A CN 101437682A
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Prior art keywords
lamination
elastic
bonded fabric
adhesive
stretching
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CN101437682B (zh
Inventor
M·文纳贝克
J·韦斯特隆德-卡尔松
E·拉克索
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Ai Shui Health And Wellness Jsc
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SCA Hygiene Products AB
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Abstract

本发明涉及一种用于制作可弹性拉伸叠层(19)的方法,所述叠层(19)包括至少三个层(1,6,18),所述方法包括以下步骤:a)制作第一叠层(8),所述第一叠层包括第一非弹性纤维无纺织物(1)和弹性薄膜(6);b)通过沿至少一个方向渐增拉伸来激活所述第一叠层(8),以使所述第一叠层(8)可弹性拉伸;c)沿至少一个方向将所述已激活的第一叠层(8)拉伸10~200%;并且d)将所述已拉伸的第一叠层(8)层叠至第二非弹性无纺织物(18)。还公开了一种根据所述方法制作的可弹性拉伸的叠层。

Description

弹性叠层以及用于制作弹性叠层的方法
技术领域
本发明涉及一种用于制作包括至少三个层的弹性叠层的方法。本发明还涉及一种可弹性拉伸的叠层,所述叠层包括第一非弹性无纺织物、第二非弹性无纺织物以及一个介于所述第一与第二无纺织物之间的弹性穿孔膜。根据本发明的弹性叠层特别适用于一次性的短裤制品,比如短裤尿布、卫生短裤、失禁短裤等等。这种制品包括一个布置在短裤形框架(chassis)中的吸收性单元,并以内衣裤的方式被穿戴。
背景技术
短裤型吸收性制品包括一个短裤形框架结构和一个成一体的吸收芯部件。构造短裤制品的目的在于使它们尽可能接近地类似于普通内衣裤。因而,诸如短裤尿布、卫生短裤和失禁短裤的吸收性制品被设计成舒适和贴身地适合穿戴者。人们期望制品能够在穿戴者的臀部上被提起和脱下,以允许穿戴者或护理者容易地去掉已污染的制品并以一件新的干净制品来替换它。为此,至少在打算覆盖穿戴者臀部的区域中,制品框架通常由可弹性拉伸的材料制成。此外,期望短裤制品吸收性部件周围的框架可使空气和蒸汽透过,即它是可透气的。可透气的制品防止湿气残留在穿戴者皮肤上,并且比非透气性制品穿起来更舒适,且不太热。如果制品柔软、光滑并像纺织品,以致它不会擦伤穿戴者的皮肤,并使其尽可能接近地类似普通内衣裤,则更为有益。
此外,重要的是,吸收性短裤制品能够在穿戴者的臀部上被提起而不破裂。一个常见问题是,穿戴者或护理者在试图良好地握紧以便提起或脱掉短裤时,会由于不小心地使手指划过材料而破坏短裤。
一种先前使用的用于短裤制品的弹性材料是一种叠层,包括一个夹在两层非弹性无纺材料之间的弹性薄膜。为了使叠层可弹性拉伸,将它进行激活处理。一种三层激活叠层被公开于国际专利申请No.WO 03/047488中。该激活叠层是通过渐增地拉伸介于两个非弹性似布层之间的弹性薄膜层来制成的。渐增拉伸是通过使该叠层在互相啮合的齿轮辊之间穿过来实现的。通过渐增拉伸来激活弹性叠层还被公开于美国专利Nos.5,143,679、5,156,793、5,167,897、5,422,172、5,592,690、5,634,216和5,861,074中。该非弹性似布层在激活过程中完全或部分破裂或撕裂,以致激活后叠层的弹性主要由该弹性薄膜层的弹性所支配。在WO 03/047488的三层叠层中,该非弹性层完全破裂,以致激活叠层的弹性基本上与弹性薄膜层的弹性相同。
所公开的叠层具有优良的舒适性,且柔软、透气并有弹性。然而,已知叠层的一个主要缺点是所述激活过程至少部分地损坏和破坏所述似布层,导致形成具有减小的抗拉强度和抗穿刺性的激活叠层。当被用作一次性短裤制品中的框架部件时,在承受穿上或脱下短裤制品所引起的力时,该材料很容易被撕破。所述撕破问题对于女性穿戴者或护理者来说尤其突出,她们往往拥有长的指甲,可能刺入并撕破短裤材料。
因而,存在对于改进的、可弹性拉伸的、类似纺织品的叠层的需求,以便用在一次性的短裤制品中。此外,还存在用于制作这种叠层的方法的需求。
因此,本发明的一个目的是提供一种可弹性拉伸的、类似纺织品的叠层,其具有改进的抗拉强度和抗穿刺性。本发明的另一个目的是提供一种用于制作可弹性拉伸的、类似纺织品的叠层的方法,所述叠层具有改进的抗拉强度和抗穿刺性。
发明内容
本发明提供一种用于制作可弹性拉伸叠层的方法,所述叠层包括至少三个层。根据本发明的方法包括以下步骤:
a)制作第一叠层,所述第一叠层包括第一非弹性纤维无纺织物和一个弹性薄膜;
b)通过渐增拉伸来激活所述第一叠层,以使所述第一叠层可弹性拉伸;
c)沿至少一个方向将所述已激活的第一叠层拉伸10~200%;
d)将所述已拉伸的第一叠层层叠至第二非弹性无纺织物。
所述第一叠层能够以任意合适方式来制成,包括通过胶粘、热粘合以及利用一种弹性膜成形聚合物来对所述第一无纺织物进行挤压涂敷。
所述第一叠层的拉伸量规定为所述叠层沿拉伸方向初始未拉伸尺寸的百分率。举例来说,第一未拉伸长度为1m且被拉伸50%的叠层,将具有1.5m的第二已拉伸长度。
根据本发明的一个优选实施例,所述第一叠层是通过利用弹性塑料薄膜挤压涂敷所述纤维无纺织物来制成的。
所述弹性薄膜优选地被穿孔,以便在制成的叠层中提供透气性。当采用挤压涂敷将所述第一无纺织物粘结到所述弹性薄膜上时,可在所述弹性层处于融化或半融化状态的同时,通过使组合的弹性层和无纺织物越过一个真空层叠鼓来实现所述穿孔步骤。这种工艺公开于美国专利No.5,733,628中,并导致弹性薄膜形成为三维有孔层叠层。
所述激活步骤包括渐增地拉伸所述第一叠层,以使所述非弹性材料破裂或至少部分破裂。可利用加热的或非加热的互相啮合的齿轮辊来实现激活,所述齿轮辊具有沿周向布置的互相啮合的轮齿,从而拉伸所述叠层。所述激活步骤允许所述叠层随后被拉伸而不会受到所述非弹性无纺织物明显地限制。所述非弹性无纺材料破裂的程度决定了所形成叠层的最大可能延伸率。如果所述无纺材料在所述激活过程中完全破裂,则所述叠层将具有与所述弹性薄膜层大致相同的最大延伸率。
在执行第二叠压步骤之前,所述第一叠层沿至少一个方向被拉伸其初始未拉伸尺寸的10~200%。通过选择和控制拉伸量,能够在最终叠层中获得选定的弹性。在与所述第二非弹性无纺织物进行层叠之前,所述第一叠层优选地被拉伸其未拉伸尺寸的35~180%,更优选地被拉伸其未拉伸尺寸的50~150%,且最优选地被拉伸其未拉伸尺寸的70~120%。
所述第二非弹性无纺织物可被胶粘到所述已激活的第一叠层。
可选地,所述第二非弹性无纺织物可被热粘合或超声波粘合到所述已激活的第一叠层。热粘合或超声波粘合可呈现离散粘合的形式,比如点状粘合或线状粘合。与在粘结层之间占据较大比例界面的粘合方式相比,通过选择离散分布的点状粘合方式,能够在形成的叠层中获得更高的灵活性。
叠层中的材料优选地呈现连续织物的形式。所述织物可为相同宽度,以便制成三层的叠层,所述叠层随后可被连续地引入到一次性短裤制品的生产工艺中,并形成制品框架的弹性部分。作为选择,所述叠层可被切割和成形为单独的部件,这些部件用于制作一次性的短裤制品。
作为选择,可能生产一种叠层,其中所述第二非弹性无纺织物具有大于所述第一叠层的宽度。这种三层的叠层适于在生产一次性短裤制品时,被连续地引入到生产工艺中,并可形成制品框架的弹性和非弹性部分。
此外,可将两个或更多连续的第一叠层织物粘结到所述第二非弹性无纺织物。所述不同的双叠层织物可被拉伸至不同的程度,并且/或者可由不同的材料组合制成。
所述第一和第二非弹性纤维无纺织物可包括热塑性纤维。用于纤维无纺织物的合适聚合物的例子有聚乙烯、聚酯、聚丙烯及其它聚烯烃均聚物和共聚物。一种特别适合的无纺织物包括热塑性纤维,为聚丙烯和聚乙烯纤维的混合物。优选的织物具有高含量的热塑性纤维,包含至少50%的热塑性纤维,且优选地包含至少80%的热塑性纤维。所述第二和/或非弹性纤维无纺织物将典型地以连接部和接缝方式结合到一次性短裤制品中。因而,我们高度期望无纺织物可利用热或利用超声焊工艺来焊接。
一种特别用作所述第二非弹性无纺织物的合适类型的无纺织物是一种褶皱(creped)无纺材料。褶皱无纺材料一般具有比非褶皱无纺材料更大的延展性和柔性。通过选择用于所述第二非弹性无纺织物的褶皱无纺材料,能够获得最终的三层的叠层,所述叠层在柔软性和适合性方面具有比非褶皱无纺材料更好的特性。所述褶皱无纺材料使三层的叠层在延伸后更易于收缩,从而与具有非褶皱第二无纺材料层的相应叠层相比,增强了弹性。如果需要的话,所述第一非弹性无纺织物也可为一种褶皱无纺材料。
用于制作根据本发明的三层叠层的弹性薄膜可为任意合适的天然或合成的弹性聚合物。一个已证实能提供良好弹性和透气性的弹性薄膜的例子是一种有孔三层弹性薄膜,其组成为聚乙烯-苯乙烯/乙烯/丁二烯/苯乙烯-聚乙烯(PE-SEBS-PE)。
关于这一点,弹性材料被定义为一种当材料受到本说明书指定弹性试验中的30%延伸率之后,松弛后永久延伸率小于10%的材料。
非弹性材料是指未落入弹性材料定义的材料。相应地,这里使用的非弹性材料是可拉伸或不可拉伸的材料。在可拉伸材料的情况下,在承受根据所述弹性试验所确定的30%延伸率之后,所述材料在拉伸和松弛后具有大于10%的永久延伸率。
本发明还提供一种可弹性拉伸的叠层,包括第一非弹性无纺织物、第二非弹性无纺织物以及介于所述第一与第二无纺织物之间的弹性多孔薄膜。所述第一非弹性无纺织物和所述弹性多孔薄膜形成第一弹性叠层的一部分,通过渐增拉伸和部分撕开所述无纺织物来使所述第一弹性叠层具有弹性。然后所述第一弹性叠层在已拉伸状态下被粘结到所述第二无纺层,从而叠层可被弹性拉伸。
因此,根据本发明的所述三层叠层包括第一弹性双叠层,所述第一弹性双叠层包括无纺织物和弹性多孔薄膜。所述弹性双叠层由纤维材料层和弹性层组成。选择所述纤维层,以使它为叠层提供一种柔软的和似布的感觉和外观。合适材料的例子有熔喷织物和纺粘材料以及褶皱无纺材料,如上所述。这种材料也适用于被附着到所述双叠层的第二无纺织物。然而,可使用任意柔软的、柔韧的且优选可延伸的无纺材料及无纺叠层,比如纺粘-熔喷-纺粘叠层(SMS),可为梳理法和水刺法(spunlaced)材料。
所述第一无纺织物的基重适宜为10~80g/m2,且优选地为13~50g/m2。用于纤维材料的合适聚合物的例子有聚乙烯、聚酯、聚丙烯以及其它聚烯烃均聚物和共聚物。也可使用天然纤维,例如棉花,只要它们提供所需的特性。聚合体的混合物能够有助于使所述无纺层具备较高的柔韧性,通过该柔韧性在最大载荷时赋予无纺材料更高的延伸率。聚乙烯和聚丙烯聚合体的混合物已被证明能够在这方面提供良好的效果。也可使用不同聚合体纤维的混合物。
根据本发明的一个实施例,所述弹性层是一个有孔的弹性薄膜,所述弹性薄膜具有介于10~120g/m2之间的基重,优选地介于15~60g/m2之间。所述薄膜可为任意合适的天然或合成弹性聚合物。用于所述弹性薄膜的有用材料的一些例子有低结晶度聚乙烯、茂金属(metallocene)催化低结晶度聚乙烯、乙烯醋酸乙烯酯共聚物(EVA)、聚氨酯、聚异戊二烯、丁二烯-苯乙烯共聚物、苯乙烯嵌段共聚物,例如苯乙烯/异戊二烯/苯乙烯(SIS)、苯乙烯/丁二烯/苯乙烯(SBS)、或苯乙烯/乙烯-丁二烯/苯乙烯嵌段共聚物。也可使用这些聚合体的混合物以及其它改性弹性或非弹性材料。一个合适的薄膜的例子为一种有孔的三层弹性薄膜,其组成为聚乙烯-苯乙烯/乙烯/丁二烯/苯乙烯-聚乙烯(PE-SEBS-PE)。
所述弹性双叠层例如可根据WO 03/047488或EP 0 715 351中公开的方法通过将所述无纺织物敷设到所述薄膜的一侧来制造和激活。所述无纺织物和所述薄膜可被挤压粘合或可利用粘结剂来粘合。所述双叠层被渐增地拉伸,以便激活所述薄膜层的弹性。渐增拉伸可进行到所述非弹性无纺织物峰值负荷时延伸率以下的一个点,以便在所述无纺织物中保留一些强度。可选地,可进行所述拉伸,以使所述无纺材料被完全撕裂,如WO 03/047488中所公开的那样。
根据本发明,所述已激活的双叠层被进一步层叠到非弹性无纺织物。在所述双叠层沿至少一个方向被拉伸其初始未拉伸尺寸的10~200%时,优选地在被拉伸其未拉伸尺寸的35~180%时,更优选地在被拉伸其未拉伸尺寸的50~150%时,且最优选地在被拉伸其未拉伸尺寸的70~120%时,执行这个第二层叠步骤。
所述第二和/或第一非弹性无纺织物优选地包括高含量的、即至少50%且优选地至少80%的热塑性聚合物纤维,比如聚乙烯、聚丙烯和聚酯。在本发明和一个特别实施例中,所述第二和/或第一非弹性无纺织物包括至少80%的聚丙烯纤维。
所述两步层叠工艺形成一个三层的叠层,所述叠层在敷设所述第一无纺织物的那一面上具有光滑的表面,而在敷设第二无纺织物的相对面上具有一个稍微聚拢、褶皱的表面。当被用作短裤制品中的可拉伸部件时,所述三层叠层可被定位,所述光滑面位于制品的内侧,而所述不规则面朝外。以此方式,接触皮肤的叠层部分将特别柔软、光滑且不会擦伤穿戴者的皮肤。然而,作为选择,可以布置所述叠层,使光滑面位于吸收性制品的外侧。以此方式,获得一种具有光滑面的吸收性制品,所述光滑面与任意穿在吸收性制品之上的衣服相接触。当制品是用于成人的卫生短裤或失禁短裤时,这样的实施方式可能是有利的。叠层的光滑面可阻止衣服与制品的表面摩擦配合,并在覆盖短裤制品的区域中减少短裤和裙子向上缩(ridding-up)和起皱的可能性。此外,光滑的外表面在审美学上是令人愉悦的,并在吸收性制品被穿戴在薄的或紧身衣物之下时将不太显眼。
根据本发明的三层叠层是柔软、有弹性和类似纺织品的,并且与以往已知的叠层相比具有明显更高的抗拉强度和抗穿刺性。因而,当用在短裤制品中时,当在穿戴者的臀部上提起或脱下制品时,所述三层叠层明显减少了无意中破坏短裤的风险。
附图说明
以下将参照附图更详细地描述本发明,其中
图1示出了根据本发明的一个层叠工艺,
图2示出了根据本发明的一个三层的叠层,
图3示出了一个短裤尿布的平面图,其侧面连接部是打开的;且
图4示出了图3中的尿布,其具有封闭的连接部。
具体实施方式
图1示意性地示出了用于制作根据本发明的一个可弹性拉伸三层叠层的方法。第一非弹性无纺织物1从一个储存辊2被供送到介于橡胶辊3与金属辊4之间的第一粘合辊隙。融化的形成弹性薄膜的聚合物6通过模具7被挤到所述辊隙,且所述第一非弹性无纺织物1和所述弹性薄膜形成第一叠层8,所述叠层8在辊子9处离开。随后,通过将所述叠层穿过互相啮合的齿轮辊子10、11以使所述第一叠层8受到渐增拉伸,从而激活所述第一叠层8。存在大量不同的拉伸技术,如EP 0 714 351中所述。依据所述互相啮合的齿轮辊子的设计,可使所述渐增拉伸沿对角线、沿加工方向(MD)或沿横向(CD)拉伸所述叠层。由渐增拉伸引起的所述第一无纺织物的破裂量可通过调节所述齿轮辊子上的齿或相互啮合元件的相互啮合深度来控制。所述渐增拉伸释放或激活所述弹性薄膜的弹性,并允许所述两层的第一叠层8被弹性延伸。
在第二层叠步骤中,所述第一叠层8通过在一对辊子12、13之间穿过而被拉伸,所述辊子12、13以不同的速度被驱动。所述第一叠层8沿至少一个方向被拉伸其初始未拉伸尺寸的10~200%。通过选择和控制拉伸量,能够在最终叠层中获得选定的弹性。在所述第一叠层8与所述第二非弹性无纺织物18进行层叠之前,所述第一叠层8在激活之后优选地被拉伸其未拉伸尺寸的35~180%,更优选地被拉伸其未拉伸尺寸的50~150%,且最优选地被拉伸其未拉伸尺寸的70~120%。所述第一叠层8的拉伸程度在决定最终三层叠层19的弹性方面是一个主要因素。影响最终三层叠层19弹性的其它因素是所述第二非弹性无纺织物18的柔韧性和延展性。所述第一叠层8与所述第二非弹性无纺织物之间的粘结面积也影响着所述三层叠层19的柔韧性和弹性。因此,大的粘结面积将减小最终叠层中的弹性,而离散分布的粘结点将对弹性具有非常小或可忽略的影响。
在拉伸已激活的第一叠层8之后,所述叠层8的薄膜侧14被涂敷或喷涂上粘结剂,并随后与第二非弹性无纺织物18一起穿过两个粘合辊子16、17之间的第二粘合辊隙。所述粘结剂优选地是一种热塑性粘结剂,尽管如果需要的话,也可使用其它类型的粘结剂。
所形成的三层叠层19是弹性可拉伸的,并具有选定的弹性,所述弹性主要取决于所述弹性薄膜的弹性、在渐增拉伸步骤中所述第一无纺织物的撕裂程度、以及在粘结到第二非弹性无纺织物18之前所述第一叠层8的拉伸量。然而,如上所述,所述第二非弹性无纺织物在柔韧性和延展性方面的特性以及在第二层叠步骤中实现的粘结量也影响着最终叠层的弹性。
第一粘合辊隙中的所述金属辊4优选地是一个有孔的吸辊,以致在将薄膜6粘结到所述第一无纺织物1的同时,实现所述挤压弹性薄膜6的三维成形和穿孔。
所述第二层叠步骤可选地可利用热粘合或超声波焊接来实施。
图1是根据本发明的方法的一个高度示意性的图示。然而,所有各个步骤均为众所周知的,并已在现有技术中公开。此外,图1未示出各个织物的宽度。叠层材料可由全部具有相同宽度或CD尺寸的织物制成。可选地,所述第二无纺织物可具有大于所述弹性薄膜6和第一无纺织物1的宽度,并可以在其一个或两个方向上延伸超出所述第一叠层。
图2中所示三层叠层19包括第一双叠层8,所述第一双叠层8由非弹性纤维无纺层1和弹性薄膜组成。所述弹性薄膜被穿孔,且具有大量贯穿其的小孔。所述孔可为三维成形的孔,如WO 03/047488中所公开的那样,或者可为穿过薄膜的简单的两维孔。所述叠层19还包括第二非弹性无纺层18,所述层18通过粘合剂或通过热粘合,比如通过施加热量或施加超声波而被粘结到所述第一叠层8。
所述三层叠层19在第一无纺层1那一侧上具有光滑表面21,且在第二无纺层18那一侧上具有不规则的褶皱的表面22。这是由于所述第二无纺层18已被粘结到第一两层叠层8,而所述两层叠层处于可弹性延伸的状态。所述三层叠层19是柔软、可褶皱(drapable)的,具有预定的、选定的弹性,并且特别适合用在不同类型的一次性短裤制品中。所述非渐增拉伸的第二无纺层为叠层提供了增强,提供了垂直于拉伸方向的更高的抗拉强度,使所述叠层具有抗穿刺性,并使叠层在穿上或脱下短裤制品时能够承受所产生的拉伸力而不破裂或撕破。
此外,通过选择具有热塑性的无纺材料,能够获得一种叠层,所述叠层可容易地通过热焊技术结合到一次性制品中。例如,在一件制品中,其中所述叠层被定位成使第一无纺层1位于制品内侧,如果所述第一无纺层基本上或完全由热塑性纤维,优选地由聚丙烯纤维制成的话,则是有利的。然后,所述第一无纺层可用于形成具有良好抗拉强度的侧面连接部。相反地,如果叠层被定位成使第二无纺层位于短裤制品的内侧,则相应地,选择一种热塑性材料用于第二无纺层是有利的。由于用在侧面连接部中的热粘合通常穿透被焊接的材料,因而只要至少其中一个层主要由热塑性纤维制成,或者两层的组合含有足够的热塑性材料以便实现足够的粘结强度,则叠层相对于第一和第二无纺层的定位对于获得热粘合联结来说通常并不要紧。
图3和图4中所示的短裤尿布300被设计成象普通内衣裤那样包围穿戴者躯干的下部。在图3中,从内侧,即在制品被穿戴时,从朝向穿戴者的那一侧来展示尿布,而在图4中,从外侧或朝向外衣的那一侧,即在制品被穿戴时,从背离穿戴者的那一侧来展示尿布。
所述尿布具有前片301、后片302和裆片303,所述裆片303在所述前、后片301、302之间延伸,并与所述前、后片301、302相比具有相对较窄的宽度。所述前、后片301、302被布置成覆盖穿戴者的臀部,并延伸到穿戴者的腹部和背部,以便围绕穿戴者躯干的下部。
所述尿布还包括一个芯区304,所述芯区304从裆片303延伸到前片301和后片302中。所述前、后片301、302形成框架307的一部分,所述框架307在尿布300朝向外衣的那一侧上延伸,并覆盖和包围所述芯区304。所述框架307包括前片301、后片302、裆片303以及一个固定在所述前、后片上的弹性腰带309。每个所述前、后片分别具有腰边、裆边和一对侧边。
相应地,术语“片”在此用于表示尿布框架的一个功能部分,而术语“区”和“部”用于表示框架中尿布的一个具体特征的位置,或用于描述尿布的一个特定部分相对于使用者身体的预期定位。片可为一个单独的部件或框架的一体部分。区或部可具有一个范围,所述范围完全地或部分地覆盖一个或多个片。
前、后片通过热粘合、超声波焊接、胶条等沿着它们的侧边被相互联结到一起,以形成侧接缝308,如图4中最好地所示。弹性腰带309由前部和后部组成,所述前部和后部分别被固定到前片301和后片302。腰带309的这些部也沿着侧接缝308被相互联结到一起。通过将前、后片301、302和腰带309联结起来,为短裤尿布300提供了腰部开口310和一对腿部开口311。
图3示出了处于平坦状态的尿布,其中在拉伸应力下连接到框架307上的任何弹性部件被拉长至框架307的完全非张紧尺寸。图4示出了当所述侧接缝308已形成,且所述张紧的弹性部件已松弛并将框架材料聚拢到一起以便形成弹性化腿部和腰部开口311、310时,短裤尿布300所呈现的状态。
根据本发明的弹性叠层320可覆盖位于腰带309前、后部之间的整个尿布,包括所述芯区304。然而,优选地,所述短裤尿布300裆片303的相当大部分,即至少50%,且优选地至少75%中不存在所述弹性叠层材料。
因而,裆材料312被布置在所述制品的芯区304中,并与所述弹性前、后片301、302重叠,所述裆材料312优选地是一种非弹性材料,比如一种非弹性无纺材料。所述裆材料312沿着其横向边缘313、314被联结到所述前、后片301、302。在所示实施例中,所述裆材料312以重叠的方式通过裆接缝315被联结到所述前、后片301、302,并形成裆片303。所述联结可通过任意合适的方式,比如通过超声波焊接、粘结或类似方法来实施。在本发明的可选实施例中,一种外部无纺材料可连续地延伸到所述前、后片301、302和裆片303上,从而在片303、301、302之间不需要接缝。
在所示例子中,所述弹性腰带309包括第一层片和第二层片基本上非弹性的无纺材料,所述材料被一个或多个诸如松紧线或松紧带的细长弹性部件316弹性化。所述第一和第二层片材料可由已在其自身上折叠的单层材料形成,或者可为两个单独的材料带。弹性部件16以张紧状态被布置在所述腰带309中,以致当它们被允许松弛时,它们将腰带中的无纺材料收缩和聚拢到一起,如图4中所示。
所述弹性腰带309被固定到所述前、后片301、302,其中弹性部件316处于延伸状态,且前、后片中的材料被夹在腰带中的无纺材料层片之间。可选地,所述弹性腰带可为一个部件,所述部件被预制并被分别联结到所述前、后片301、302的外侧和内侧。位于所述腰带309与所述前、后片301、302之间的腰带连接部317可利用诸如超声波焊接、热焊接、或胶粘以任意合适的方式来制成。另一个可选方案是由一个或多个非弹性无纺层来产生腰带309,这些层也是所述前、后片301、302的一部分,并形成其连续的延伸部分。
弹性部件316还被布置在腿部开口311的边缘,并用于使所述腿部开口弹性化。腿部开口处的弹性部件可为任意类型的常规弹性部件,比如松紧线、松紧带、泡沫条等等。
芯区304的平面范围由一个不透液背层318来限定,所述背层318被布置在吸收芯319与所述框架307之间。所述不透液背层318呈矩形,且所述吸收芯为沙漏形。因而,所述不透液背层318位于所述吸收芯319和吸收芯319之外紧邻的区域之下。所述裆片303中的无纺材料被布置在不透液背层318朝向外衣的一侧。所述芯区304延伸到所述前、后片301、302中,从而这些片中的弹性叠层320与芯区304外部中的不透液背层318重叠,如图3中所示。所述弹性叠层320被布置在不透液背层318朝向外衣的一侧。
如这些图中所示,根据本发明的弹性三层叠层320优选地形成所述短裤尿布300的前、后片301、302。然而,也可仅使各个前、后片301、302的一部分由所述弹性三层叠层320来形成。在这样的实施例中,如图3所示处于平坦状态的所述框架总表面积的至少20%、优选地至少25%,更优选地至少30%,且最优选地至少40%由根据本发明的弹性三层叠层构成。作为一个例子,所述弹性叠层可仅用在前、后片301、302的那些打算覆盖穿戴者臀部的部分中,并从而形成弹性侧片。也可设计一种短裤制品,其中在前、后片301、302中不存在所述芯区304与所述弹性叠层材料之间的任何重叠。
在使用根据本发明的弹性叠层320时,不需要额外的弹性侧片。如果需要的话,特别是在弹性叠层320仅被布置在前片和/或后片301、302的一部分中的情况下,可提供额外的弹性侧片。
试验方法描述
抗拉强度(参照:ASTM D 882)
该方法测量不同弹性材料的抗拉强度和延伸率。一个被良好限定的试件的抗拉强度和延伸率通过拉力试验机来测试。
仪器:拉伸强度试验机(Instron)4301
●连接到计算机上的拉力试验机
●十字头速度:500mm/分钟
●夹持距离:50mm
样品准备:将试样从材料的整个宽度上切割下来。样品的宽度应为25.4mm,且如果可能的话,其长度应至少比夹持距离长50mm。重要的是,样品的边缘应当平滑且无破裂缺口。试样在测试之前在50%RH(相对湿度)±5%RH和23℃±2℃环境中放置4小时。
步骤:根据仪器说明书将拉力试验机校准,并调整到零。安装样品,并保证它不被倾斜或不平稳地固定。通过利用覆盖有纱带或类似材料的夹具来防止材料滑动。启动拉力试验机,并在材料破裂后停机(如果不是自动控制的话)。如果可能的话,忽略由于过早破坏(即样品在夹具中破裂,或者在准备过程中损坏)而产生的测量数据。
通过拉力试验机/计算机示出以下结果:
-  最大力,N/25.4mm
-  最大力时的延伸率,%
-  断裂力,N/25.4mm
-  断裂力时的延伸率,%
-  拐点,N/%
弹性试验
该方法测量弹性材料在重复加载和卸载循环时如何表现。将样品拉伸至一预定的延伸率,并在零与所述预定延伸率之间进行周期运动。所需的加载力和卸载力被记录下来。测量松弛材料永久的、即剩余的延伸率。
使用一台能够进行周期运动并配备有打印机/绘图机或软件显像的拉力试验机,LIoyd LRX。通过将样品切成宽度为25mm,且长度优选地比该拉力试验机中夹具之间距离长20mm来准备样品。
根据仪器说明书来校准拉力试验机。试验(加载和卸载力)所需参数被调整至:
●十字头速度:500mm/分钟
●夹持距离:50mm
●预载力:0.05N
依据记号将样品放置在夹具中,并保证样品居中且垂直地固定在夹具中。启动拉力试验机,在零与预定延伸率之间进行三个循环,该预定延伸率等于最高限定的第一载荷。在最后一个循环之前,样品被松弛1分钟,然后通过拉伸样品,直至检测到0.1N的力,并读取该延伸率,从而测得永久延伸率。
弹性材料被定义为这样一种材料:当材料在上述试验中承受30%的延伸率之后,材料在松弛后应具有小于10%的永久延伸率。30%的延伸率是指比样品初始长度长30%的长度延伸量。
这里使用的非弹性材料是这样一种材料:当所述材料承受根据所述弹性试验所确定的30%延伸率之后,所述材料在拉伸和松弛后具有大于10%的永久延伸率。
抗刺强度
抗刺强度是根据ASTM标号D3763-02来测量的。通过穿刺冲击型试验,该方法可得到载荷-位移数据。可计算出各样品的最大载荷。
实例
对于三个样品,测量了沿加工方向(MD)和沿横向(CD)的抗拉强度。
样品A是一个常规的已被激活的三层叠层,包括基重为36g/m2、内部穿孔的PE-SEBS-PE三层弹性薄膜,以及两个每层基重为22g/m2的PP(聚丙烯)纺粘材料外层。所述叠层通过以下方式来制作:将其中一个纺粘层在胶粘状态下敷设到该薄膜上,而另一纺粘层通过比如压敏热熔性胶粘剂(胶水量3g/m2)胶粘地层叠到该薄膜层上。所述叠层被渐增地拉伸,其中该非弹性纺粘层被拉伸到最大载荷时的延伸率之下的一点,以便在该纺粘层中保持一些强度。
所述叠层中层的基重是激活之后的基重。在激活之前,各层的基重为:内膜层40g/m2,外纺粘层各为25g/m2,胶水层3g/m2
样品B是一个三层叠层,包括一个已首先激活的双叠层,所述双叠层包括基重为22g/m2的纺粘无纺PP层和基重为36g/m2的有孔PE-SEBS-PE三层弹性薄膜,其在拉伸70%的条件下又被层叠到基重为18g/m2的纺粘无纺层(来自Union Industries SpA的S1800PHW)。
样品C是一个三层叠层,包括样品B中的已激活的双叠层,所述双叠层在拉伸70%的条件下又被层叠到基重为20g/m2的纺粘无纺层(来自Freudenberg Fliesstoffe KG的Lutrasil 9520XF)。
样品D是一个三层叠层,包括样品B中的已激活的双叠层,所述双叠层在拉伸25%的条件下又被层叠到基重为20g/m2的褶皱无纺纺粘层(来自First Quality)。所述褶皱无纺层在褶皱时被压缩至50%。
样品E是与样品D相同的三层叠层,但在层叠到褶皱的无纺层的过程中,所述双叠层被拉伸40%。
试验结果示于下面的表1中。
 
样品 抗拉强度MD N/25mm 抗拉强度CD N/25mm 穿刺力N
A 34 9 40
B 42 26 74
C 40 33 80
D 25 38 73
E 22 44 77
表1
由表1中可见,根据本发明的叠层B-E具有比以往技术三层叠层明显更高的MD和CD抗拉强度以及更高的抗穿刺性。

Claims (20)

1、用于制作可弹性拉伸的叠层(19)的方法,所述叠层(19)包括至少三个层(1,6,18),
其特征在于
a)制作第一叠层(8),所述第一叠层包括第一非弹性纤维无纺织物(1)和弹性薄膜(6);
b)通过沿至少一个方向渐增拉伸来激活所述第一叠层(8),以使所述第一叠层(8)可弹性拉伸;
c)沿至少一个方向将所述已激活的第一叠层(8)拉伸10~200%;并且
d)将所述已拉伸的第一叠层(8)层叠至第二非弹性无纺织物(18)。
2、根据权利要求1的方法,其中所述第一叠层(8)是通过利用弹性薄膜(6)挤压涂敷所述第一纤维无纺织物(1)来制成的。
3、根据权利要求1或2的方法,其中所述弹性薄膜(6)被穿孔。
4、根据权利要求1、2或3的方法,其中所述第二非弹性无纺织物被胶粘地粘接到所述已激活的第一叠层(8)。
5、根据权利要求1、2或3的方法,其中所述第二非弹性无纺织物(18)被热粘合或超声波粘合到所述已激活的第一叠层(8)。
6、根据前述权利要求中任意一项的方法,其中所述第一叠层(8)在与所述第二非弹性无纺织物(18)进行层叠之前,被拉伸其未拉伸尺寸的35~180%,更优选地被拉伸其未拉伸尺寸的50~150%,且最优选地被拉伸70~120%。
7、根据前述权利要求中任意一项的方法,其中所述第二非弹性无纺织物(18)具有大于所述第一叠层(8)的宽度。
8、根据前述权利要求中任意一项的方法,其中所述第一和/或第二非弹性纤维无纺织物(1,18)包括热塑性纤维。
9、根据权利要求8的方法,其中所述第一和/或第二非弹性纤维无纺织物包括至少50%的热塑性纤维,且优选地包含至少80%的热塑性纤维。
10、根据前述权利要求中任意一项的方法,其中所述第二非弹性无纺织物是可延伸的。
11、根据权利要求10的方法,其中所述第二非弹性无纺织物是褶皱的无纺材料。
12、一种可弹性拉伸的三层叠层(19),其包括第一非弹性无纺织物(1)、第二非弹性无纺织物(18)以及介于所述第一与第二无纺织物(1,18)之间的弹性薄膜(6),其特征在于所述第一非弹性无纺织物(1)和所述弹性薄膜(6)形成第一弹性叠层(8)的部分,通过渐增拉伸和部分撕裂所述第一无纺织物(1)来使所述第一弹性叠层(8)具有弹性,所述第一弹性叠层(8)在已拉伸状态下被粘结到所述第二非弹性无纺层(18),从而使叠层可弹性拉伸。
13、根据权利要求12的可弹性拉伸的叠层,其中所述弹性薄膜(6)被穿孔。
14、根据权利要求12或13的可弹性拉伸的叠层,其中所述第一无纺织物(1)是熔喷织物或纺粘织物,所述第二无纺织物(18)是熔喷织物或纺粘织物。
15、根据权利要求12、13或14的可弹性拉伸的叠层,其中所述第一无纺织物(1)的基重为10~80g/m2,且优选地为13~50g/m2
16、根据权利要求12-15中任意一项的可弹性拉伸的叠层,其中所述弹性薄膜层具有介于10~120g/m2之间的基重,优选地介于15~60g/m2之间。
17、根据权利要求12-16中任意一项的可弹性拉伸的叠层,其中所述第一和/或第二非弹性无纺织物(1,18)包括热塑性纤维。
18、根据权利要求17的可弹性拉伸的叠层,其中所述第一和/或第二非弹性纤维无纺织物包括至少50%的热塑性纤维,且优选地包括至少80%的热塑性纤维。
19、根据权利要求12-18中任意一项的可弹性拉伸的叠层,其中所述第二非弹性无纺织物是可延伸的。
20、根据权利要求22的可弹性拉伸的叠层,其中所述第二非弹性无纺织物是褶皱的无纺材料。
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CA2649926A1 (en) 2007-11-22
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JP2009536888A (ja) 2009-10-22
EP2024178A4 (en) 2011-08-31
AU2006343662B2 (en) 2011-08-11
JP4975807B2 (ja) 2012-07-11
KR20090018902A (ko) 2009-02-24
US20090208703A1 (en) 2009-08-20
CN101437682B (zh) 2012-08-01
PL2024178T3 (pl) 2013-06-28
TNSN08454A1 (en) 2010-04-14
WO2007133128A1 (en) 2007-11-22
EP2024178A1 (en) 2009-02-18
US8741083B2 (en) 2014-06-03
AU2006343662A1 (en) 2007-11-22
AR060776A1 (es) 2008-07-10
TW200804077A (en) 2008-01-16
CA2649926C (en) 2013-07-23
MY148163A (en) 2013-03-15
EP2024178B1 (en) 2013-01-09
TWI388424B (zh) 2013-03-11
MX2008013624A (es) 2008-10-30
ES2399242T3 (es) 2013-03-26

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