CN101553361B - 具有阻隔性质的弹性复合材料 - Google Patents

具有阻隔性质的弹性复合材料 Download PDF

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Publication number
CN101553361B
CN101553361B CN2007800358700A CN200780035870A CN101553361B CN 101553361 B CN101553361 B CN 101553361B CN 2007800358700 A CN2007800358700 A CN 2007800358700A CN 200780035870 A CN200780035870 A CN 200780035870A CN 101553361 B CN101553361 B CN 101553361B
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Prior art keywords
film
composite
nonwoven web
nursing products
skin nursing
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CN101553361A (zh
Inventor
A·L·麦科尔马克
J·西奎拉
L·E·克克
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Kimberly Clark Worldwide Inc
Kimberly Clark Corp
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Kimberly Clark Worldwide Inc
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    • B32B29/02Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
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    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
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    • B29C66/737General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7377General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
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    • B29C66/739General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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  • Textile Engineering (AREA)
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  • Physics & Mathematics (AREA)
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  • Composite Materials (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

提供了含有层压到一个或更多个非织造材料上的弹性薄膜的弹性复合材料。通过选择性控制该复合材料的成分及其形成方法,本发明人已经发现,该复合材料可以耐受油和其它皮肤护理组合物。更具体地,该弹性薄膜由一种或更多种具有机械性质、弹性和抗油性的独特组合的低密度半结晶丙烯基聚合物形成。通过使用这类弹性体聚合物,不需要抗油粘合剂,所得弹性薄膜也可以热粘到非织造网材料上。此外,可以选择粘合条件以便在该薄膜中不形成孔。由此,所得复合材料不可被油或其它液体(例如溶剂、水、溶液等)透过并因此在使用过程中充当阻隔层。

Description

具有阻隔性质的弹性复合材料
相关申请
本申请要求2006年9月27日提交的美国临时申请No.60/847,560的优先权。
发明背景
弹性复合材料通常并入产品(例如皮肤护理产品、个人护理产品、服装等)中以改进其更好贴合身体轮廓的能力。例如,该弹性复合材料可以由接合到一个或更多个非织造网(nonwoven web)材料上的弹性薄膜形成。在许多情况下,这类弹性复合材料所并入的产品可包括皮肤护理组合物,如油(例如矿物油、矿脂(petrolatum)等)、蜡、乳霜、洗液、凝胶等。该皮肤护理组合物可以直接施加到弹性材料上,或可以最后在使用过程中接触弹性材料。在任一情况下,对于由某些类型的弹性体聚合物制成的弹性材料,皮肤护理组合物可能造成各种问题。苯乙烯-烯烃嵌段共聚物(例如,苯乙烯-乙烯-丁烯-苯乙烯四嵌段共聚物)例如在性质上是亲油的并往往在亲油皮肤护理组合物(例如油)存在下溶胀、软化和甚至溶解。这不仅不利地影响弹性材料的拉伸和回缩性质,其还可能导致该复合材料层离并由此破坏产品完整性。
已经作出各种尝试以克服这些问题。例如,出于各种目的全文经此引用并入本文的授予Taylor等人的美国专利申请公开No.2004/0121692描述了含有在弹性体片的至少一个表面上用油不敏感的粘合剂处理过的弹性体片和至少一个层压到弹性体片的该至少一个表面上的非织造饰面片的弹性复合材料。该油不敏感的粘合剂粘合或增强弹性体片与饰面片之间的粘合,以使所得层压件在暴露在油基产品中时具有极大改进的抗劣化性。但是,尽管作出改进,但油不敏感的粘合剂通常昂贵并可能导致过度复杂的层压法。
因此,需要简单、便宜且仍抗油的弹性复合材料。
发明概述
根据本发明的一个实施方案,公开了一种非织造复合材料,其包含在多个离散粘合点(bond sites)紧邻非织造网材料放置并热熔到该非织造网材料上的弹性薄膜。该弹性薄膜包含密度大约0.88克/立方厘米或更低的半结晶丙烯基聚合物,其中该复合材料基本上为液体不可透的。
根据本发明的另一实施方案,公开了形成非织造复合材料的方法。该方法包括由聚合物组合物形成弹性薄膜,该聚合物组合物包含密度大约0.88克/立方厘米或更低的半结晶丙烯基聚合物。使该薄膜和非织造网材料通过由至少一个压花辊(patterned roll)形成的辊隙(nip)。在该辊隙处,使该薄膜热熔到非织造网材料上,该热熔薄膜通常不含尺寸大约10微米或更大的孔。
下面更详细描述本发明的其它特征和方面。
附图简述
在参照附图的本说明书剩余部分中向本领域普通技术人员更特别阐述本发明的完整和致用(enabling)公开内容,包括其最佳实施方式,在附图中:
图1显示了根据本发明的示例性实施方案的制造弹性复合材料的方法;
图2是根据本发明形成的手套的一个实施方案的透视图。
本说明书和附图中标号的重复使用旨在表示本发明的相同或类似要素或元件。
代表性实施方案详述
定义
本文所用的术语“非织造网”通常是指具有以与针织物不同的方式交织的独立纤维或线结构的纤网。合适的非织造布或网的实例包括但不限于,熔喷网(meltblown web)、纺粘网(spunbond web)、粘合梳理网(bonded carded web)、气流纤网(airlaid web)、共成形纤网(coform web)、水力缠结纤网(hydraulically entangled web)等。
本文所用的术语“熔喷网”通常是指通过下述方法形成的非织造网:在该方法中,将熔融的热塑性材料通过多个细的,通常圆形的模头毛细管以熔融纤维形式挤入会聚的高速气体(例如空气)流,其使熔融热塑性材料的纤维渐细以降低其直径,这可以为微纤维直径。此后,熔喷纤维由该高速气流携带并沉积在收集表面上以形成无规分散的熔喷纤维网。这类方法公开在例如,授予Butin等人的美国专利No.3,849,241中,其出于各种目的全文经此引用并入本文。一般而言,熔喷纤维可以是基本连续或不连续的、直径通常小于10微米并在沉积到收集表面上时通常发粘的微纤维。
本文所用的术语“纺粘网”通常是指含有小直径基本连续纤维的网幅。通过以挤出纤维的直径从喷丝头(spinnerette)的多个细的通常圆形的毛细管中挤出熔融热塑性材料然后例如通过抽引(eductive)牵拉(draw)和/或其它公知的纺粘机制迅速减细来形成纤维。例如在授予Appel等人的美国专利No.4,340,563、授予Dorschner等人的3,692,618、授予Matsuki等人的3,802,817、授予Kinney的3,338,992、授予Kinney的3,341,394、授予Hartman的3,502,763、授予Levy的3,502,538、授予Dobo等人的3,542,615和授予Pike等人的5,382,400中描述和例举了纺粘网的制造,这些专利出于各种目的全文经此引用并入本文。纺粘纤维在沉积到收集表面上时通常不发粘。纺粘纤维可以有时具有小于大约40微米,且通常大约5至大约20微米的直径。
本文所用的术语“加工方向”或“MD”通常是指制造材料的方向。术语“横向”或“CD”是指与加工方向垂直的方向。
本文所用的术语“可伸展”或“可伸展性”通常是指在外加力方向上拉伸或伸长其松弛长度或宽度的至少大约25%,在一些实施方案中至少大约50%且在一些实施方案中至少大约75%的材料。可伸展材料不一定具有回缩性。例如,弹性体材料是具有回缩性的可伸展材料。熔喷网可能是可伸展的,但没有回缩性,因此是可伸展的非弹性材料。
本文所用的术语“变定(set)”是指材料样品在伸长和回缩后,即在该材料在周期测试过程中已拉伸和松弛后保持的伸长。
本文所用的术语“变定百分率(percent set)”是材料在周期测试后从其原始长度拉伸的量的衡量标准(在周期测试后的立刻变形)。变定百分率是一个周期的缩回(retraction)曲线与延长轴(elongation axis)相交之处。测量移除外加应力后的残留应变作为变定百分率。本发明的弹性复合材料在1周期后的变定百分率可以例如为大约18%或更低,在一些实施方案中大约15%或更低,且在一些实施方案中大约13%或更低。
本文所用的术语“弹性体的”和“弹性的”是指在施加拉伸力时在至少一个方向(如CD方向)上可拉伸并在释放拉伸力后收缩(contract)/返回(return)至大致其原始尺寸的材料。例如,拉伸材料可以具有比其松弛的未拉伸长度高至少大约50%,在一些实施方案中至少大约60%,且在一些实施方案中至少大约75%的拉伸长度。同样,拉伸材料在释放拉伸力后回缩至其拉伸长度的至少大约50%,在一些实施方案中至少大约60%,且在一些实施方案中至少大约75%内。假设的实例是1英寸材料样品,其可拉伸至至少1.50英寸并在释放拉伸力后将回缩至不大于1.25英寸长度。
本文所用的术语“颈缩的”和“颈缩材料”通常是指已经在至少一个方向(例如加工方向)上牵拉以降低其横向尺寸(例如横向)以致在移除牵拉力时可以被拉回(pulled back)至其原始宽度的任何材料。该颈缩材料通常具有比未颈缩材料更高的每单位面积基重。当颈缩材料被拉回至其原始宽度时,其应该具有与未颈缩材料大致相同的基重。这不同于其中薄膜变细且基重降低的薄膜取向。颈缩法通常包括从进给辊退卷材料并使其通过以给定线速驱动的制动轧辊组装件(brake nip rollassembly)。以高于制动轧辊(brake nip roll)的线速运行的卷取辊或辊隙牵拉该材料并产生使该材料伸长和颈缩所需的张力。
本文所用的术语“热点粘合”通常是指例如通过使材料在压花辊(例如压延辊)和另一辊(例如砧辊)(其可以是压花或未压花的)之间穿过而进行的方法。这两个辊之一或两者通常被加热。
本文所用的术语“超声粘合”通常是指例如通过使材料在声角(sonic horn)和压花辊(例如砧辊)之间穿过而进行的方法。例如,在授予Grgach等人的美国专利No.3,939,033、授予Rust Jr.的3,844,869和授予Hill的4,259,399(它们出于各种目的全文经此引用并入本文)中描述了使用固定角和旋转压花砧辊的超声粘合。此外,在授予Neuwirth等人的美国专利No.5,096,532、授予Ehlert的5,110,403、和授予Brennecke等人的5,817,199(它们出于各种目的全文经此引用并入本文)中描述了使用旋转角和旋转压花砧辊的超声粘合。当然,在本发明中也可以使用任何其它超声粘合技术。
详述
现在详细提到本发明的各种实施方案,其一个或更多个实例如下所述。各实例作为本发明的解释而非本发明的限制提供。实际上,本领域技术人员显而易见的是,可以在不背离本发明的范围或精神的情况下在本发明中作出各种修改和变动。例如,作为一个实施方案的一部分例举或描述的要素可用在另一实施方案中以产生又一实施方案。因此,本发明旨在覆盖这类修改和变动。
一般而言,本发明涉及含有层压到一个或更多个非织造材料上的弹性薄膜的弹性复合材料。通过选择性控制该复合材料的成分及其形成方法,本发明人已经发现,该复合材料可以耐受油和其它皮肤护理组合物。更具体地,该弹性薄膜由一种或更多种具有机械性质、弹性和抗油性的独特组合的低密度半结晶丙烯基聚合物形成。通过使用这类弹性体聚合物,不需要抗油粘合剂,所得弹性薄膜也可以热粘到非织造网材料上。此外,可以选择粘合条件以便在该薄膜中通常不形成孔。由此,所得复合材料不可被液体(例如油)透过并因此在使用过程中充当阻隔层。现在更详细描述本发明的各种实施方案。
I.弹性薄膜
半结晶丙烯基聚合物具有或能够表现出基本规则结构。例如,半结晶丙烯基聚合物可以在其未形变状态下基本非晶,但在拉伸时形成结晶畴。结晶度可以为大约3%至大约30%,在一些实施方案中大约5%至大约25%,且在一些实施方案中大约5%至大约15%。同样地,该半结晶丙烯基聚合物可以具有大约15至大约75焦耳/克(“J/g”),在一些实施方案中大约20至大约65J/g,且在一些实施方案中25至大约50J/g的熔化潜热(ΔHf),其是结晶度的另一指征。该半结晶丙烯基聚合物还可以具有大约10℃至大约100℃,在一些实施方案中大约20℃至大约80℃,且在一些实施方案中大约30℃至大约60℃的Vicat软化温度。该半结晶丙烯基聚合物可以具有大约20℃至大约120℃,在一些实施方案中大约35℃至大约90℃,且在一些实施方案中大约40℃至大约80℃的熔融温度。熔化潜热(ΔHf)和熔融温度可以使用差示扫描量热法(“DSC”)根据本领域技术人员公知的ASTM D-3417测定。Vicat软化温度可以根据ASTM D-1525测定。
在一个具体实施方案中,该半结晶丙烯基聚合物包括丙烯与α-烯烃,如C2-C20α-烯烃或C2-C12α-烯烃的共聚物。合适的α-烯烃可以是直链或支链的(例如一个或更多个C1-C3烷基支链、或芳基)。具体实例包括乙烯、1-丁烯;3-甲基-1-丁烯;3,3-二甲基-1-丁烯;1-戊烯;含一个或更多个甲基、乙基或丙基取代基的1-戊烯;含一个或更多个甲基、乙基或丙基取代基的1-己烯;含一个或更多个甲基、乙基或丙基取代基的1-庚烯;含一个或更多个甲基、乙基或丙基取代基的1-辛烯;含一个或更多个甲基、乙基或丙基取代基的1-壬基;乙基、甲基或二甲基-取代的1-癸烯;1-十二烯;和苯乙烯。特别需要的α-烯烃共聚单体是乙烯、1-丁烯、1-己烯和1-辛烯。这类共聚物的丙烯含量可以为大约60摩尔%至大约99.5重量%,在一些实施方案中大约80摩尔%至大约99摩尔%,且在一些实施方案中大约85摩尔%至大约98摩尔%。α-烯烃含量也可以为大约0.5摩尔%至大约40摩尔%,在一些实施方案中大约1摩尔%至大约20摩尔%,且在一些实施方案中大约2摩尔%至大约15摩尔%。在构成丙烯共聚物的不同分子量级分之间,α-烯烃共聚单体的分布通常是无规和均匀的。
通常可以使用任何各种已知技术形成半结晶聚烯烃。例如,可以使用自由基或配位催化剂(例如齐格勒-纳塔)形成烯烃聚合物。优选地,烯烃聚合物由单点配位催化剂,如金属茂催化剂形成。这类催化剂体系产生其中共聚单体无规分布在分子链内且均匀分布在不同分子量级分之间的乙烯共聚物。例如,在授予McAlpin等人的美国专利No.5,571,619;授予Davis等人的5,322,728;授予Obijeski等人的5,472,775;授予Lai等人的5,272,236和授予Wheat,等人的6,090,325(它们出于各种目的全文经此引用并入本文)中描述了金属茂催化的聚烯烃。金属茂催化剂的实例包括双(正丁基环戊二烯基)二氯化钛、双(正丁基环戊二烯基)二氯化锆,双(环戊二烯基)氯化钪、双(茚基)二氯化锆、双(甲基环戊二烯基)二氯化钛、双(甲基环戊二烯基)二氯化锆、二茂钴(cobaltocene)、环戊二烯基三氯化钛、二茂铁、二氯化二茂铪(hafnocene)、异丙基(环戊二烯基,-1-芴基)二氯化锆、二氯化二茂钼(molybdocene)、二茂镍、二氯化二茂铌(niobocene)、二茂钌(ruthenocene)、二氯化二茂钛(titanocene)、氢氯二茂锆(zirconocenechloride hydride)、二氯化二茂锆等。使用金属茂催化剂制成的聚合物通常具有窄分子量范围。例如,金属茂催化的聚合物可以具有低于4的多分散数(Mw/Mn)、受控短链分支分布、和受控全同立构规整度。
丙烯/α-烯烃共聚物的密度可以是α-烯烃的长度和量的函数。也就是说,α-烯烃越长且α-烯烃存在量越大,共聚物密度越低。尽管本发明中所用的丙烯基聚合物的密度可变,其通常为大约0.88克/立方厘米(g/cm3)或更低,在一些实施方案中大约0.83至大约0.88克/立方厘米,且在一些实施方案中大约0.85克/立方厘米至大约0.87克/立方厘米。该丙烯基聚合物的熔体流动速率也可以在一定范围内选择以优化所得弹性薄膜的性质。熔体流动速率是在230℃下经受2160克力10分钟内可压过挤出流变孔(0.0825英寸直径)的聚合物重量(以克计)。一般而言,熔体流动速率高到足以改进熔体可加工性,但不会高到不利地干扰薄膜的粘合性质。因此,在本发明的多数实施方案中,该丙烯基聚合物具有大约0.1至大约10克/10分钟,在一些实施方案中大约0.2至大约5克/10分钟,且在一些实施方案中大约0.5至大约4克/10分钟的根据ASTM测试方法D1238-E测得的熔体流动指数。
合适的丙烯聚合物可以以VISTAMAXXTM为名购自ExxonMobilChemical Co.of Houston,Texas;以FINATM(例如8573)为名购自Atofina Chemicals of Feluy,Belgium;以TAFMERTM为名购自MitsuiPetrochemical Industries;和以VERSIFYTM为名购自Dow Chemical Co.of Midland,Michigan。在授予Datta等人的美国专利Nos.7,105,609;授予Datta等人的6,500,563;授予Yang等人的5,539,056;和授予Resconi等人的5,596,052(它们出于各种目的全文经此引用并入本文)中描述了合适的丙烯聚合物的其它实例。
当然,也可以使用其它热塑性聚合物形成弹性薄膜,只要它们不会不利地影响该复合材料的弹性和阻隔性。例如,该弹性薄膜可以含有其它聚烯烃、弹性体聚酯、聚氨酯、聚酰胺、嵌段共聚物等。例如,在本发明的一些实施方案中可以使用聚乙烯。聚乙烯密度可以随所用聚合物的类型而变,但通常为0.85至0.96克/立方厘米(“g/cm3”)。聚乙烯“塑性体(plastomers)”例如可以具有0.85至0.91克/立方厘米的密度。同样地,“线型低密度聚乙烯”(“LLDPE”)可以具有0.91至0.940克/立方厘米的密度;“低密度聚乙烯”(“LDPE”)可以具有0.910至0.940克/立方厘米的密度;且“高密度聚乙烯”(“HDPE”)可以具有0.940至0.960克/立方厘米的密度。
无论所用聚合物如何,半结晶丙烯基聚合物的量通常为薄膜的大约30重量%或更多,在一些实施方案中大约50重量%或更多,且在一些实施方案中大约80重量%或更多。当使用聚合物共混物时,半结晶聚烯烃可以构成共混物的大约50重量%至大约99重量%,在一些实施方案中大约60重量%至大约98重量%,且在一些实施方案中大约65重量%至大约96重量%。当然应该理解的是,在该薄膜中也可以使用其它弹性体和/或非弹性体聚合物。
除聚合物外,本发明的弹性薄膜也可以含有本领域已知的其它添加剂,如熔体稳定剂、加工稳定剂、热稳定剂、光稳定剂、抗氧化剂、热老化稳定剂、增白剂、抗粘连剂、粘合剂、增稠剂、粘度改性剂等。合适的粘度改性剂可以包括,例如聚乙烯蜡(例如来自EastmanChemical的EPOLENETM C-10)。亚磷酸酯(phosphite)稳定剂(例如可获自Ciba Specialty Chemicals of Terrytown,N.Y.的IRGAFOS和可获自Dover Chemical Corp.of Dover,Ohio的DOVERPHOS)是示例性的熔体稳定剂。此外,受阻胺稳定剂(例如可获自Ciba Specialty Chemicals的CHIMASSORB)是示例性的热和光稳定剂。此外,受阻酚通常用作薄膜制造中的抗氧化剂。一些合适的受阻酚包括可以以商品名“Irganox
Figure G2007800358700D00081
”,如Irganox1076、1010或E 201获自Ciba SpecialtyChemicals的那些。此外,粘合剂也可以添加到该薄膜中以促进薄膜与附加材料(例如非织造网)的粘合。在使用时,这类添加剂(例如增稠剂、抗氧化剂、稳定剂等)可以各自以薄膜的大约0.001重量%至大约25重量%,在一些实施方案中大约0.005重量%至大约20重量%,且在一些实施方案中0.01重量%至大约15重量%的量存在。
本发明的弹性薄膜可以是单层或多层的。多层薄膜可以通过层的共挤出、挤出涂布或通过任何传统分层法制备。这类多层薄膜通常含有至少一个基底层(base layer)和至少一个表层(skin layer),但可以含有所需任何层数。例如,多层薄膜可以由基底层和一个或更多个表层形成,其中基底层由本发明的半结晶丙烯基聚合物形成。在这类实施方案中,表层可以由任何成膜聚合物形成。如果需要,该表层可以含有使该层更适合作为将该薄膜热粘到非织造网上的热封粘合层的较软的较低熔点的聚合物或共混聚合物。例如,该表层可以如上所述由烯烃聚合物或其共混物形成。可适合单独或与其它聚合物结合用于本发明的其它成膜聚合物包括乙烯乙酸乙烯酯、乙烯丙烯酸乙酯、乙烯丙烯酸、乙烯丙烯酸甲酯、乙烯丙烯酸正丁酯、尼龙、乙烯乙烯基醇、聚苯乙烯、聚氨酯等。
该表层也可以含有不需要耐受油或其它皮肤护理组合物的弹性体聚合物。在这类实施方案中,基底层可以用抗油的半结晶丙烯基聚合物形成以在即使表层受到不利影响时仍保持该复合材料的完整性。在使用时,表层的弹性体聚合物可以包括任何热塑性弹性体聚合物,例如弹性体聚酯、弹性体聚氨酯、弹性体聚酰胺、弹性体嵌段共聚物、弹性体聚烯烃等。通常选择表层的厚度以基本不会损害薄膜的弹性体性质。为此,各表层可以独立地构成薄膜总厚度的大约0.5%至大约15%,在一些实施方案中构成薄膜总厚度的大约1%至大约10%。例如,各表层可以具有大约0.1至大约10微米,在一些实施方案中大约0.5至大约5微米,且在一些实施方案中大约1至大约2.5微米的厚度。同样地,基底层可以具有大约1至大约40微米,在一些实施方案中大约2至大约25微米,且在一些实施方案中大约5至大约20微米的厚度。
所得薄膜的性质通常可以按需要改变。例如,在任何拉伸之前,该薄膜通常具有大约100克/平米或更低,且在一些实施方案中大约50至大约75克/平米的基重。在拉伸时,该薄膜可以具有大约60克/平米或更低,且在一些实施方案中大约15至大约35克/平米的基重。拉伸薄膜也可以具有大约1至大约100微米,在一些实施方案中大约10至大约80微米,且在一些实施方案中大约20至大约60微米的总厚度。
II.非织造网材料
在本发明中通常使用非织造网材料降低摩擦系数和提高复合材料表面的布类感觉。用于形成非织造网材料的示例性聚合物可以包括,例如聚烯烃,例如聚乙烯、聚丙烯、聚丁烯等;聚四氟乙烯;聚酯,例如,聚对苯二甲酸乙二酯等;聚乙酸乙烯酯;聚氯乙烯乙酸酯;聚乙烯基丁缩醛;丙烯酸树脂,例如,聚丙烯酸酯、聚丙烯酸甲酯、聚甲基丙烯酸甲酯等;聚酰胺,例如,尼龙;聚氯乙烯;聚偏二氯乙烯;聚苯乙烯;聚乙烯基醇;聚氨酯;聚乳酸;它们的共聚物;等等。如果需要,也可以使用可生物降解的聚合物,如上述那些。也可以使用合成或天然纤维素聚合物,包括但不限于,纤维素酯;纤维素醚;硝酸纤维素;乙酸纤维素;乙酸丁酸纤维素;乙基纤维素;再生纤维素,例如粘胶纤维(viscose)、人适丝(rayon)等。应该指出,该聚合物也可以含有其它添加剂,如加工助剂或赋予该纤维所需性质的处理组合物、残留量的溶剂、颜料或着色剂等。
可以使用单组分和/或多组分纤维形成非织造网材料。单组分纤维通常由从单一挤出机中挤出的聚合物或聚合物共混物形成。多组分纤维通常由从分立挤出机中挤出的两种或多种聚合物(例如双组分纤维)形成。这些聚合物可以在纤维整个横截面上排列在位置基本不变的分立区域中。组分可以以任何所需构造排列,例如皮-芯型、并排型、派型(pie)、海岛型、三岛型、牛眼(bull’s eye)型或本领域中已知的各种其它排列。在授予Taniguchi等人的美国专利No.4,789,592和授予Strack等人的美国专利No.5,336,552、授予Kaneko等人的5,108,820、授予Kruege等人的4,795,668、授予Pike等人的5,382,400、授予Strack.等人的5,336,552和授予Marmon等人的6,200,669中描述了形成多组分纤维的各种方法,这些专利出于各种目的全文经此引用并入本文。也可以如授予Hogle等人的美国专利No.5,277,976、授予Hills的5,162,074、授予Hills的5,466,410、授予Larqman等人的5,069,970和授予Largman等人的5,057,368中所述形成具有各种不规则形状的多组分纤维,这些专利出于各种目的全文经此引用并入本文。
尽管可以使用聚合物的任何组合,但多组分纤维的聚合物通常由具有不同玻璃化转变温度或熔融温度的热塑性材料制成,其中第一组分(例如皮)的熔融温度低于第二组分(例如芯)。多组分纤维的第一聚合物组分的软化或熔融使该多组分纤维形成粘性骨架结构,其在冷却后使纤维结构稳定。例如,该多组分纤维可以具有按重量计大约20%至大约80%,且在一些实施方案中大约40%至大约60%的低熔点聚合物。此外,该多组分纤维可以具有按重量计大约80%至大约20%,且在一些实施方案中大约60%至大约40%的高熔点聚合物。已知皮-芯双组分纤维的一些实例可以以T-255和T-256(两者均使用聚烯烃皮)或T-254(其具有低熔体共聚酯皮)为名获自KoSa Inc.of Charlotte,NorthCarolina。可用的另一些已知的双组分纤维包括可获自ChissoCorporation of Moriyama,Japan或Fibervisions LLC of Wilmington,Delaware的那些。
可以使用具有任何所需长度的纤维,如短切纤维、连续纤维等。在一个具体实施方案中,例如,可以使用纤维长度为大约1至大约150毫米,在一些实施方案中大约5至大约50毫米,在一些实施方案中大约10至大约40毫米,且在一些实施方案中大约10至大约25毫米的短切纤维。尽管不要求,但可以使用梳理(carding)技术形成如本领域中公知的含短切纤维的纤维层。例如,可以通过将纤维捆放入分离纤维的拣选机中来将纤维形成梳理网。接着,将纤维送经精梳(combing)或梳理装置,其进一步以加工方向分裂和校直纤维以形成加工方向取向的纤维非织造网。可以随后使用已知技术将梳理网粘合以形成粘合梳理非织造网。
如果需要,用于形成非织造复合材料的非织造网材料可以具有多层结构。合适的多层材料可以包括,例如,纺粘/熔喷/纺粘(SMS)层压材料和纺粘/熔喷(SM)层压材料。在授予Brock等人的美国专利No.4,041,203;授予Timmons等人的5,213,881;授予Timmons等人的5,464,688;授予Bornslaeger的4,374,888;授予Collier等人的5,169,706;和授予Brock等人的4,766,029中描述了合适的SMS层压材料的各种实例,这些专利出于各种目的全文经此引用并入本文。此外,市售SMS层压材料可以以Spunguard和Evolution
Figure G2007800358700D00112
为名获自Kimberly-Clark Corporation。
多层结构的另一实例是在多纺丝纱架(bank)机上制成的纺粘网,其中纺丝纱架将纤维沉积在由前一纺丝纱架沉积的纤维层上。这种独立的纺粘非织造网也可以被视为多层结构。在这种情况下,该非织造网中的各个沉积纤维层可以相同,或它们可以在基重和/或组成、类型、尺寸、卷曲度和/或制成纤维的形状方面不同。作为另一实例,单个非织造网可以作为纺粘网、梳理网等的两个或多个独立制成的层提供,它们已经粘合在一起以形成非织造网。这些独立制成的层可以如上所述在制造方法、基重、组成和纤维方面不同。
非织造网材料也可以含有附加纤维组分以使其被视为复合材料。例如,可以使用本领域中已知的各种缠结技术(例如水力、空气、机械等)将非织造网与另一纤维组分缠结。在一个实施方案中,使用水力缠结法将该非织造网与纤维素纤维缠结成一体。典型的水力缠结法采用高压水射流以使纤维缠结形成高度缠结的固结纤维结构,例如非织造网。在例如授予Evans的美国专利No.3,494,821和授予Boulton的4,144,370(它们出于各种目的全文经此引用并入本文)中公开了水力缠结的具有短纤长度的非织造网和连续纤维。例如在授予Everhart等人的美国专利No.5,284,703和授予Anderson等人的6,315,864(它们出于各种目的全文经此引用并入本文)中公开了连续纤维非织造网和纸浆层的水力缠结复合材料非织造网。该复合材料的纤维组分可以构成(contain)所得基材(substrate)的任何所需量。该纤维组分可以构成该复合材料的多于大约50重量%,且在一些实施方案中构成该复合材料的大约60%至大约90重量%。同样地,该非织造网可以构成该复合材料的少于大约50重量%,且在一些实施方案中构成该复合材料的大约10%至大约40重量%。
尽管不要求,但该非织造网材料可以在层压到本发明的薄膜上之前在一个或多个方向上颈缩。合适的颈缩技术描述在授予Morman的美国专利Nos.5,336,545、5,226,992、4,981,747和4,965,122以及授予Morman等人的美国专利申请公开No.2004/0121687中。或者,该非织造网可以在层压到薄膜上之前在至少一个方向上仍相对不可伸展。在这些实施方案中,该非织造网可以任选在层压到薄膜上之后在一个或多个方向上拉伸。
非织造网材料的基重通常可变,如大约5克/平米(“gsm”)至120gsm,在一些实施方案中大约10gsm至大约70gsm,且在一些实施方案中大约15gsm至大约35gsm。在多个非织造网材料的情况下,这类材料可以具有相同或不同的基重。
III.层压技术
在本发明中通常使用热粘技术将弹性薄膜层压到非织造网材料上。这尤其使对粘合剂的需求最小化,该粘合剂在油存在下变弱或者是抗油但昂贵的。在本发明中可以使用各种热粘技术。热点粘合例如通常使用在两个辊之间形成的辊隙,其中至少一个辊是压花的。另一方面,超声粘合通常使用在声角和压花辊之间形成的辊隙。
无论具体技术如何,热粘通常包括使用含有多个凸起粘合元件(raised bonding elements)的压花辊。通常选择粘合元件(bondingelements)的图案以使该复合材料具有小于大约50%(通过传统光学显微法测得),且在一些实施方案中小于大约30%的总粘合面积。粘合密度也通常大于大约50个粘合(bonds)/平方英寸,且在一些实施方案中大约75至大约500个针粘合(pin bonds)/平方英寸。本发明中所用的一种合适的粘合图案被称作“S-波(S-weave)”图案并描述在授予McCormack等人的美国专利No.5,964,742中,其出于各种目的全文经此引用并入本文。S-波图案通常具有大约50至大约500个粘合元件/平方英寸,且在一些实施方案中大约75至大约150个粘合元件/平方英寸的粘合元件密度。另一合适的粘合图案被称作“罗纹(rib-knits)”图案并描述在授予Levy等人的美国专利No.5,620,779中,其出于各种目的全文经此引用并入本文。罗纹图案通常具有大约150至大约400个粘合元件/平方英寸,且在一些实施方案中大约200至大约300个粘合元件/平方英寸的粘合元件密度。再一合适的图案是“线波(wireweave)”图案,其具有大约200至大约500个粘合元件/平方英寸,且在一些实施方案中大约250至大约350个粘合元件/平方英寸的粘合元件密度。在授予Hansen等人的美国专利No.3,855,046;授予Haynes等人的5,962,112;授予Sayovitz等人的6,093,665;授予Edwards等人的D375,844;授予Romano等人的D428,267;和授予Brown的D390,708(它们出于各种目的全文经此引用并入本文)中描述了本发明中可用的其它粘合图案。
尽管热粘如上所述使粘合剂的使用最小化,通常控制层压条件以抑制弹性薄膜中孔的形成。粘合温度(例如加热辊的温度)例如通常高到足以在粘合元件邻近区域熔融和/或软化薄膜的弹性体聚合物,但不会高到使较大(substantial)部分的弹性薄膜在层压过程中撕裂和形成孔。例如,可以将一个或更多个辊加热至大约40℃至大约120℃,在一些实施方案中大约55℃至大约110℃,且在一些实施方案中大约60℃至大约90℃的表面温度。一经软化,弹性体聚合物随后可以流动和熔合到非织造网材料上,由此形成整体非织造复合材料。辊在热粘过程中施加的压力(“辊隙压力”)可以高到足以熔化聚合物,但不会高到撕裂薄膜。例如,辊隙压力可以为大约5至大约100磅/线性英寸,在一些实施方案中大约10至大约75磅/线性英寸,且在一些实施方案中大约15至大约50磅/线性英寸。当然,该材料的停留时间可能影响所用的特定粘合参数。
尽管不要求,但弹性薄膜和非织造网材料有时在材料热粘之前可以“预粘合”。例如,该材料可以通过在两个辊之间形成的辊隙,这两个辊通常都是未压花的,即平滑的。由此,在热层压之前在材料上施加少量压力以将它们轻微粘合在一起。不希望受制于理论,但本发明人相信,这类轻微粘合的材料与完全未粘合的材料相比较不可能在压花粘合过程中形成孔。例如,辊隙压力可以为大约0.1至大约20磅/线性英寸,在一些实施方案中大约1至大约15磅/线性英寸,且在一些实施方案中大约2至大约10磅/线性英寸。尽管可以选择使弹性体聚合物软化的粘合温度,但通常要求该聚合物主要基于其粘性粘合到非织造网材料上。例如,一个或更多个辊可以具有大约15℃至大约60℃,在一些实施方案中大约20℃至大约50℃,且在一些实施方案中大约25℃至大约40℃的表面温度。
为抑制孔形成而可以控制的另一参数是层压过程中薄膜上的张力度。当薄膜的张力提高至一定程度时,在薄膜经受热和/或压力时更可能在薄膜中形成孔。在避免孔形成的同时,以不同旋转速度旋转的辊仍可拉伸该薄膜,以将该片材在加工方向上拉伸至所需拉伸比。例如,使用大约4.0或更低,在一些实施方案中大约3.5或更低,且在一些实施方案中大约1.0至大约2.5的拉伸比实现层压过程中薄膜中所需的张力度。可以通过将薄膜最终长度除以其原始长度来测定拉伸比。该拉伸比也可以与牵伸比大致相同,牵伸比可以通过将层压过程中的薄膜线速(例如轧辊速度)除以薄膜成型时的线速(例如流延辊或吹塑轧辊的速度)来测定。
薄膜拉伸方式不重要。因此,例如,薄膜可以在层压过程中拉伸至如上所述的一定程度。此外,该薄膜也可以“预拉伸”(在层压之前),如在弹性薄膜的上述预粘合到非织造网材料上的过程中。“预拉伸”操作过程中的取向温度分布通常低于该薄膜中一种或更多种聚合物的熔点,但高到能使该组合物能够被牵伸或拉伸。例如,该薄膜可以在大约10℃至大约50℃,在一些实施方案中大约15℃至大约40℃,且在一些实施方案中大约20℃至大约40℃的温度下拉伸。在“预拉伸”时,层压过程中的拉伸度可以提高、保持或降低(缩回)至所需张力度。
现在更详细描述本发明的各种实施方案。当然,应该理解的是,下面提供的描述仅是示例性的,且本发明设想了其它方法。例如,参照图1,显示了由弹性薄膜和非织造网材料形成复合材料的方法的一个实施方案。如图所示,可以将薄膜原材料(例如弹性体聚合物)干混在一起(即无溶剂)并添加到挤出装置40的料斗(未显示)中。或者,原材料可以与溶剂混合。在料斗中,将这些材料在熔体中分散性混合并使用任何已知技术,如采用例如班伯里密炼机、Farrel连续混合机、单螺杆挤出机、双螺杆挤出机等的分批和/或连续配混技术配混。
可以使用任何已知技术由该配混材料形成薄膜,包括吹塑、流延、平模挤出等。在一个具体实施方案中,可以通过吹塑法形成薄膜,其中使用气体(例如空气)通过环形模头使挤出的共混聚合物气泡膨胀。然后使该气泡坍塌并以平膜形式收集。例如在授予Raley的美国专利No.3,354,506;授予Schippers的3,650,649;授予Schrenk等人的3,801,429、以及授予McCormack等人的美国专利申请公开No.2005/0245162和授予Boggs等人的2003/0068951(所有这些都出于各种目的全文经此引用并入本文)中描述了制造吹塑薄膜的方法。例如,在图1的具体实施方案中,向挤出装置40供应配混材料(未显示),然后吹到轧辊42中以形成单层前体弹性薄膜10。辊42可以保持在足以将前体弹性薄膜10在其形成时固化和骤冷的温度下,如大约20至60℃。通常,所得前体弹性薄膜一般地不带孔,尽管其由于加工而当然具有小切口。
也使用非织造网以层压到弹性薄膜10上。例如,非织造网30可以简单地如图1中所示从供给辊22上退卷。或者,该非织造网可以联机形成,例如通过从一对喷丝头将聚合物长丝分配到传送机组装件上。在图1中,使用一对轧辊56将纤网30压缩形成长丝间粘合。在压实后,将非织造网30导向辊58之间限定的辊隙以层压到弹性薄膜10上。可以采用各种技术将弹性薄膜10粘合到非织造网30上。尽管不一定要求,但也可以将来自供给辊62并经过轧辊56a的第二材料30a层压到弹性薄膜10上。该第二材料30a可以是第二非织造网材料、薄膜等。
再参照图1,将弹性薄膜10和非织造网材料30和30a导向在一组预粘合辊46之间限定的辊隙。这两个辊46都具有平滑表面,其将弹性薄膜10和非织造材料30和30a轻微粘合。在此具体实施方案中,辊46以大于轧辊42的速度运行以使弹性薄膜10也在加工方向上拉伸和变细。尽管图1中显示了两个辊46,但应该理解的是,辊数可以更高或更低,这取决于所需拉伸水平和各辊之间的拉伸程度。薄膜可以在单个或多个分立的拉伸操作中拉伸。或者,弹性薄膜也可以使用如可购自Marshall and Williams,Co.of Providence,Rhode Island的传统薄膜取向装置或加工方向取向器(“MDO”)拉伸。
在任一情况下,使用热粘技术将材料层压到弹性薄膜上。在图1中,例如,将材料30和30a导向在辊58之间限定的辊隙以层压到弹性薄膜10上。两个辊58之一或两者可以含有多个凸起粘合元件和/或可以被加热。优选地,辊58以比辊57慢的速度或至少以由于弹性薄膜10的张紧而能使预粘合的层压材料57a缩回的速度旋转。在层压后,弹性薄膜10在多个离散粘合点(bond sites)热熔到非织造网材料30和30a上。也就是说,薄膜10的弹性体聚合物软化和/或熔融以致它们可以物理固定(entrap)非织造网材料30和30a的纤维。当然,弹性薄膜10可以具有一定粘性以在层压时进一步粘合到纤维上。
然后可以将所得复合材料32卷绕和储存在卷取辊60上。任选地,该复合材料32保持在张力下,例如辊60使用与一个或更多个拉伸辊46的速度相同的线速。但是,更优选地,使复合材料32在卷绕到卷取辊60上之前略微缩回。这可以通过使辊60使用较慢线速来实现。当弹性薄膜10在层压之前张紧时,其朝其原始加工方向长度缩回,并在加工方向上变短,由此在复合材料中皱缩或形成皱裥。所得弹性复合材料因此变得在加工方向上可伸展至可将纤网中的皱裥或皱缩拉平(pulled back out flat)并使弹性薄膜10伸长的程度。
尽管未显示在图1中,但可以在不背离本发明的精神和范围的情况下进行本领域中已知的各种附加的潜在加工和/或精加工步骤,如纵切、处理、印刷图形等。例如,该复合材料可以任选在横向和/或加工方向上机械拉伸以提高可伸展性。在一个实施方案中,可以使该复合材料在CD和/或MD方向中经过具有凹槽的两个或多个辊。这类带槽的卫星(satellite)/砧辊布置描述在授予Rhim等人的美国专利申请公开No.2004/0110442和授予Gerndt等人的2006/0151914中,它们出于各种目的全文经此引用并入本文。例如,可以使该层压材料在CD和/或MD方向中经过具有凹槽的两个或多个辊。该带槽辊可以由钢或其它硬材料(如硬橡胶)构成。如果需要,可以就在施加递增拉伸之前或在此过程中对该复合材料施热以使其略微松弛且易于伸展。可以通过本领域中已知的任何合适的方法施热,如加热的空气、红外加热器、加热轧辊、或层压材料部分缠绕在一个或更多个加热辊或蒸汽罐(steam canisters)周围,等。也可以对带槽辊本身施热。还应该理解的是,其它带槽辊布置同样合适,如彼此紧邻放置的两个带槽辊。
除了带槽辊外,也可以使用其它技术在一个或更多个方向上机械拉伸复合材料。例如,可以使复合材料通过拉伸该复合材料的拉幅机。这类拉幅机是本领域中公知的并例如描述在授予Morman等人的美国专利申请公开No.2004/0121687中。该复合材料也可以颈缩。在授予Morman的美国专利No.5,336,545、5,226,992、4,981,747和4,965,122以及授予Morman等人的美国专利申请公开No.2004/0121687(所有这些都出于各种目的全文经此引用并入本文)中描述了合适的颈缩技术。
由于本发明,可以形成具有各种有益性质的弹性复合材料。如上所述,例如,该弹性薄膜通常抗油(例如矿物油)并因此能够在使用过程中保持良好的拉伸和回缩性质。此外,尽管独立的非织造网材料可能是液体可透的,但该复合材料整体通常被视为液体不可透的。因此,该复合材料可以充当油或其它液体(无论是油基、水基等)的阻隔层并因此使施加到其上的组合物的泄漏最小化。该弹性复合材料的液体不可透性质主要基于弹性薄膜中不含孔。也就是说,该弹性薄膜通常不含尺寸足以使液体流过的孔。例如,该薄膜通常可不含尺寸(最大维度)为大约100微米或更大,在一些实施方案中大约50微米或更大,且在一些实施方案中大约10微米或更大的孔。“液体不可透”材料可以是通过基本根据下述ASTM F 1670-03(只是将合成血换成矿物油)进行的矿物油渗透测试的任何材料。除了其液体不可透性外,本发明的弹性复合材料也是蒸气相对不可透过的。也就是说,该复合材料可以具有大约1立方英尺/分钟或更小,在一些实施方案中大约0.5立方英尺/分钟或更小,且在一些实施方案中0.1立方英尺/分钟或更小的“Frazier渗透率”。在环境条件,在样品两侧0.5英寸水(125Pa)的空气压差下,按每平方英尺材料,每分钟标准立方英尺的跨越材料的空气流量计,测量Frazier渗透率。
由于其机械性质、弹性体性质和阻隔性质的独特组合,本发明的弹性复合材料可用在多种产品中。例如,该弹性复合材料可用于形成皮肤护理产品,其限定了使用者可以将其身体的一部分(例如手指、脚趾、手、脚、手腕、前臂等)插入该产品内部。或者,该产品可以简单放在皮肤上或包裹在皮肤周围。该皮肤护理产品可以将皮肤护理组合物转移到皮肤上和/或阻碍或减少从皮肤中可能迁移出的液体,如水的量以优化水合或保湿。无论如何,该弹性复合材料可以构成整个皮肤护理产品,或仅仅是该产品的一部分。例如,该产品可以包括接合到一个或更多个基材,如织造织物、非织造织物、针织织物、薄膜、泡沫、弹性材料等上的弹性复合材料。如果需要,多个弹性复合材料可以彼此接合并用在本发明中。
可以根据具体皮肤护理产品调节该弹性复合材料的形状和尺寸。例如,该弹性复合材料可以以手套、管材、袖子、连指手套、短袜、圆形、矩形、正方形等形状提供。参照图2,例如,显示了人手形状的手套110的一个实施方案。手套110具有手掌区域110a、多个手指部分110b、和拇指部分110c。在该具体实施方案中,手套110含有分别根据本发明形成的第一和第二弹性复合材料120和122。复合材料120和122在紧邻其周界的位置通过缝合并且然后将手套110翻面以使缝线136位于手套110内部来接合。当然,手套110不需要翻面,且缝线136可以留在手套110外部上。此外,复合材料120和122不需要以产生缝线的方式接合。例如,各基材120和122的边缘可以彼此紧邻放置,并通过超声、热、粘合、内聚(cohesively)、使用胶带、通过将材料熔合在一起(例如使用适当的溶剂)、通过将材料焊接在一起、或通过其它方法接合。手套110可以用在皮肤护理组合物用途中,例如用于润湿和/或水合皮肤。例如,手套110可以预处理或套在用皮肤护理组合物处理过的手上。由于该手套110由本发明的弹性复合材料构成,手套110也将抵抗油基制剂的侵袭并因此保持其弹性。
各种皮肤护理组合物可以与该个人护理产品一起使用。仅作为例子,这类组合物可以包括乳化剂、表面活性剂、肽、粘度改性剂、天然保湿因子、抗微生物活性剂、pH改性剂、酶抑制剂/灭活剂、悬浮剂、颜料、染料、着色剂、缓冲剂、香精、抗菌活性剂、抗真菌活性剂、药物活性剂、成膜剂、除臭剂、遮光剂、收敛剂、溶剂、有机酸、防腐剂、药物、维生素、真芦荟,和类似物。该组合物可以包括特定添加剂,如有助于使干燥皮肤恢复至更正常的水分平衡的润肤剂。润肤剂通过供应融入皮肤的油脂来作用于皮肤,从而使皮肤柔软、修复角质层中的一些裂纹和龟裂,并形成锁住皮肤中的水分的保护膜。合适的润肤剂可以包括蜂蜡、硬脂酸丁酯、神经酰胺(cermides)、棕榈酸鲸蜡酯、羊毛醇(eucerit)、异十六烷、棕榈酸异丙酯、肉豆蔻酸异丙酯、貂油、矿物油、胡桃油、油醇、凡士林或矿脂、硬脂酸甘油酯(glyceralstearate)、鳄梨油、荷荷芭油、羊毛脂(或羊毛蜡)、羊毛脂衍生物,如羊毛脂醇、棕榈酸视黄酯(维生素A衍生物)、鲸蜡硬脂醇(cetearylalcohol)、角鲨烷、角鲨烯、硬脂酸、硬脂醇、十四酸十四酯(myristalmyristate)、某些水凝胶润肤剂、各种脂质、油酸癸酯和蓖麻油。
可适用在该组合物中的其它试剂包括抗氧化剂。抗氧化剂防止或减缓氧化过程,由此保护皮肤以免过早老化。用在本发明中的示例性抗氧化剂包括抗坏血酸酯、维生素C(抗坏血酸)、维生素E(卵磷脂)、α-糖基芸香苷(glycosyl rutin)(AGR,或Alpha Flavon,一种植物源抗氧化剂)、和辅酶Q10(也被称作泛醌)。可以在本发明的实施方案的使用过程中输递到皮肤上的另一些有益剂包括螯合剂,如EDTA;吸收/中和剂,如高岭土、锂蒙脱石、蒙脱石或膨润土;其它维生素和维生素源和衍生物,如泛酰醇、棕榈酸视黄酯、生育酚和乙酸生育酚;和抗刺激剂,如甲壳质和壳聚糖。
本发明可用的组合物中可存在的有益剂的另一些实例包括有助于皮肤保持湿润、改进柔软度或改进质地的皮肤调节剂。皮肤调节剂包括,例如,氨基酸,包括丙氨酸、丝氨酸和甘氨酸;尿囊素、角蛋白和甲基葡萄糖二油酸酯;α-羟酸,包括乳酸和乙醇酸,它们通过从皮肤表面上剥除死皮细胞来发挥作用;润湿剂(增加或锁住干燥皮肤中的水分的试剂),包括紫锥菊(echinacea)(金光菊植物的提取物)、牛油树脂(shea butter)和某些硅酮,包括环甲基硅氧烷(cyclomethicon)、二甲基硅氧烷(dimethicone)和西甲硅油(simethicone)。可适用于本发明的有益的植物制剂、提取物或其它材料的其它实例包括杏仁、甘菊提取物,如红没药醇(被认为缓解皮肤中的刺激、溶胀和发痒)、接骨木花、蜂蜜、红花油和弹性蛋白(红花油和弹性蛋白被认为有助于维持皮肤弹性)。
除了可能在使用者皮肤上具有临床有益作用的上述一种或多种试剂外,该组合物中可以包含其它添加剂。例如,可以包含硅酮聚合物以改进弹性体基材的滑爽特征。可能的硅酮聚合物包括反应性硅酮、非反应性硅酮、或反应性和非反应性硅酮的混合物。合适的硅酮可以包括,例如,氨基硅酮、聚醚改性的氨基硅酮、具有末端羟基的氨基取代硅氧烷、环氧硅酮、季硅酮(quaternary silicones)、二甲基硅氧烷、硅酮聚醚、聚醚环氧硅酮、硅烷醇流体、聚甲硅烷氧基亚油基(linoleyl)吡咯烷酮、磷脂、和可能的硅酮的组合。
该组合物可以以水溶液、分散体或乳状液形式施加到器具上。例如,在一个实施方案中,个人护理组合物可以以微乳状液形式施加到基材表面上。微乳状液是可以以喷雾形式施加的特别细粒的乳状液。微乳状液的粒度通常小于大约1微米,而传统乳状液表现出大于大约50微米的粒度。
除了皮肤护理产品外,本发明的弹性复合材料也可用在其它用途中。例如,该弹性复合材料可用在安全手套、健康护理或紧急取暖(emergency warming)手套或短袜、美容用手套或短袜、怀孕用品、腿部用品、和各种其它健康或卫生相关产品中。该弹性复合材料也可用在能够吸收水或其它流体的吸收制品中。一些吸收制品的实例包括但不限于,个人护理吸收制品,例如尿布、训练尿裤、吸收性衬裤、失禁制品、女性卫生产品(例如卫生巾)、游泳裤、婴儿湿巾等;医疗吸收制品,例如外衣、开窗术材料、衬裤、床垫、绷带、吸收性帷帘(drapes)和医疗抹布(wipes);饮食服务抹布;服装制品;等等。通常,吸收制品包括液体基本不可透层(例如外罩层)、液体可透层(例如体侧内衬、浪涌层等)和吸收芯。在一个具体实施方案中,本发明的弹性复合材料可用于提供弹性腰带、裤边/垫圈(gasketing)、可拉伸耳(stretchable ear)、侧翼等。
参照下列实施例可以更好理解本发明。
测试方法
周期测试
使用周期测试程序测试该材料以测定负载损耗和变定百分率。特别地,采用2周期测试至100%指定伸长。对于该测试,样品尺寸为横向上3英寸×加工方向上6英寸。夹具尺寸为3英寸宽。夹具间隔4英寸。对样品加载以使样品的加工方向为垂直方向。设定大约10至15克的预载荷。该测试将样品以20英寸/分钟的速度拉至100%伸长,并立即(无停顿)以20英寸/分钟的速度恢复至0。测试数据的结果都来自第一和周期。使用TESTWORKS 4.07b软件(Sintech Corp,of Cary,NC)在带有Renew MTS mongoose箱(对照)的Sintech Corp.恒速伸展测试器2/S上进行测试。在环境条件下进行测试。
矿物油渗透测试:
除了使用矿物油代替合成血外,根据出于各种目的全文经此引用并入本文的ASTM F 1670-03测量样品对矿物油的阻隔性质。此测试中所用的矿物油是Penreco
Figure G2007800358700D00211
Peneteck
Figure G2007800358700D00212
轻矿物油,NF,其可获自Penreco of Los Angeles,California。在该测试中,将矿物油倒入室中并使其在环境压力下接触样品5分钟。然后,施加2磅/平方英寸的压差1分钟。压力恢复至环境条件,并使样品与油再保持接触54分钟。仅使用目测测定何时或是否发生渗透。结果被报道为通过(“合格”)或失败。通过渗透测试的样品被视为符合ASTM F 1670-03的标准。
实施例1
论证形成弹性非织造复合材料的能力。弹性薄膜由100重量%VISTAMAXXTM 1100(ExxonMobil Chemical Co.)形成。VISTAMAXXTM1100是密度0.860克/立方厘米且熔体流动速率为3克/10分钟(230℃,2.16千克)的金属茂催化的丙烯-乙烯塑性体。使用“Killion”吹塑薄膜生产线(可获自Davis-Standard of Pawcatuck,Connecticut,3.8厘米直径环形薄膜模头)形成吹塑薄膜。具体而言,将该弹性聚合物加热至大约380°F(193℃)并以30RPMs的速率和3050磅/平方英寸的出口压力挤过环形模头。通过在环境温度下供应空气,将挤出的弹性薄膜组合物吹至大约3.5的吹胀比。然后在压扁辊隙中将薄膜气泡压扁以形成宽度大约9英寸(大约22.9厘米)且基重大约49克/平米的前体薄膜片。
在成型后,将该吹塑薄膜热粘在基重大约14克/平米的两个聚丙烯纺粘饰面之间并用线波图案粘合。纺粘饰面以大约80英尺/分钟(大约24.4米/分钟)的速率从各自的供给辊上退卷并进给到第二辊隙中以在前体薄膜片的各侧面上压上一个非织造网,从而形成轻微粘合的三层层压材料(“预粘”构造)。第二辊隙的辊未加热。此后,放松这些层并在砧辊和压花辊(S-波)之间进给。将压花辊加热至185°F(85℃)的辊表面温度,将砧辊加热至180°F(82.2℃)的辊表面温度,且压力为25磅/线性英寸。辊以50英尺/分钟的速度运行。然后将所得弹性复合材料在松弛状态下以34英尺/分钟卷绕到辊上。最终基重为大约123克/平米。
实施例2
如实施例1中所述形成弹性非织造复合材料,只是砧/压花辊在大约29磅/线性英寸的压力下运行且卷绕器速度为大约37英尺/分钟。
实施例3
如实施例2中所述形成弹性非织造复合材料,只是砧/压花辊在大约38磅/线性英寸的压力下运行。
实施例4
如实施例2中所述形成弹性非织造复合材料,只是砧/压花辊以大约80英尺/分钟的速度运行。
实施例5
如实施例4中所述形成弹性非织造复合材料,只是砧/压花辊在大约25磅/线性英寸的压力下运行。薄膜基重为53克/平米且复合材料基重为117克/平米。
实施例6
如实施例4中所述形成弹性非织造复合材料,只是不使用砧/压花辊。薄膜基重为46克/平米且复合材料基重为108克/平米。
实施例7
如实施例5中所述形成弹性非织造复合材料,只是不使用第二辊。薄膜基重为100克/平米且复合材料基重为172克/平米。
实施例8
如实施例4中所述形成弹性非织造复合材料,只是不使用砧/压花辊。
实施例9
如实施例8中所述形成弹性非织造复合材料,只是聚合物以15RPMs的速率挤过环形模头。
实施例10
论证形成弹性非织造复合材料的能力。弹性薄膜由100重量%KRATONMD6673(Kraton Polymers,LLC of Houston Texas)形成。KRATONMD6673含有68重量%苯乙烯-乙烯-丁烯-苯乙烯嵌段共聚物(KRATON
Figure G2007800358700D00223
MD6673)、20重量%REGALREZTM 1126(EastmanChemical)和12重量%EPOLENETM C-10聚乙烯蜡(EastmanChemical)。使用“Killion”吹塑薄膜生产线(可获自Davis-Standard ofPawcatuck,Connecticut,3.8厘米直径环形薄膜模头)形成吹塑薄膜。具体而言,将该弹性聚合物加热至大约380°F(193℃)并以30RPMs的速率和2250磅/平方英寸的出口压力挤过环形模头。通过在环境温度下供应空气,将挤出的弹性薄膜组合物吹至大约3.5的吹胀比。然后在压扁辊隙中将薄膜气泡压扁以形成宽度大约9英寸(大约22.9厘米)且基重大约75克/平米的前体薄膜片。
在成型后,将该吹塑薄膜热粘在基重大约14克/平米的两个聚丙烯纺粘饰面之间并用线波图案粘合。纺粘饰面以大约80英尺/分钟(大约24.4米/分钟)的速率从各自的供给辊上退卷并进给到第二辊隙中以在前体薄膜片的各侧面上压上一个非织造网,从而形成轻微粘合的三层层压材料(“预粘”构造)。第二辊隙的辊未加热。此后,放松这些层并在砧辊和压花辊(S-波)之间进给。将压花辊加热至185°F(85℃)的辊表面温度,将砧辊加热至180°F(82.2℃)的辊表面温度,且压力为25磅/线性英寸。辊以50英尺/分钟的速度运行。然后将所得弹性复合材料在松弛状态下以34英尺/分钟卷绕到辊上。最终基重为大约169克/平米。
实施例11
如实施例10中所述形成弹性非织造复合材料,只是砧/压花辊在大约38磅/线性英寸下运行且卷绕器速度为大约37英尺/分钟。
实施例12
如实施例11中所述形成弹性非织造复合材料,只是砧/压花辊以大约80英尺/分钟的速度运行。
实施例13
如实施例12中所述形成弹性非织造复合材料,只是砧/压花辊在大约25磅/线性英寸的压力下运行。薄膜基重为74克/平米且复合材料基重为164克/平米。
实施例14
如实施例13中所述形成弹性非织造复合材料,只是不使用砧/压花辊。薄膜基重为78克/平米且复合材料基重为174克/平米。
实施例15
如实施例13中所述形成弹性非织造复合材料,只是不使用第二辊。薄膜基重为119克/平米且复合材料基重为199克/平米。
实施例16
如实施例12中所述形成弹性非织造复合材料,只是不使用第二辊。
实施例17
论证形成弹性非织造复合材料的能力。该弹性薄膜由96重量%VISTAMAXXTM 1100(ExxonMobil Chemical Co.)和4重量%SCC 11692颜料(Standridge Color Corp.)形成。该SCC116921颜料含有与聚丙烯和聚丙烯无规共聚物共混的二氧化钛。该聚合物组合物在435°F的熔体温度下挤出并流延到以大约54英尺/分钟的速度运行的冷却辊(设定至大约80°F的温度)上。薄膜基重为53克/平米。在成型后,将该流延薄膜热粘在基重大约14克/平米的两个聚丙烯纺粘饰面之间并用线波图案粘合。纺粘饰面以大约80英尺/分钟(大约24.4米/分钟)的速率从各自的供给辊上退卷。此后,放松这些层并在砧辊和压花辊(S-波)之间进给。将压花辊加热至260°F的辊表面温度,将砧辊加热至260°F的辊表面温度,且压力为35磅/平方英寸。辊以162英尺/分钟的速度运行。然后将所得弹性复合材料在松弛状态下以34英尺/分钟卷绕到辊上。最终基重为大约139克/平米。
实施例18
以上述方式测试实施例1、5-7、10、13-15和17的复合材料充当油渗透阻隔层的能力。只有样品10和13-15(在弹性薄膜中含有Kraton
Figure G2007800358700D00241
MD6673)没有通过油渗透测试。也测试样品弹性(例如周期测试)。结果列在表1和2中。
表1:第一周期
Figure G2007800358700D00242
表2:第2周期
Figure G2007800358700D00251
如上所述,本发明的组合物表现出弹性特征。
尽管已经参照其具体实施方案详细描述了本发明,但要认识到,本领域技术人员在理解前述内容后可以容易地想到对这些实施方案的更改、变动和对等物。相应地,应该根据所附权利要求及其任何对等物来评估本发明的范围。

Claims (16)

1.一种皮肤护理产品,其限定了构成容纳使用者的手或脚的内部,所述皮肤护理产品包括:
非织造复合材料,其包含在多个离散粘合点紧邻非织造网材料放置并热熔到该非织造网材料上的弹性薄膜,该弹性薄膜包含密度0.88克/立方厘米或更低的半结晶丙烯基聚合物,其中所述丙烯基聚合物为丙烯和α-烯烃的共聚物,其中所述α-烯烃为乙烯、1-丁烯、1-己烯或1-辛烯,并且其中该复合材料基本上为液体不可透的;以及
施加至所述非织造复合材料的皮肤护理组合物,其中所述弹性薄膜耐受所述皮肤护理组合物,
其中所述产品为手套或短袜的形式,其中所述皮肤护理组合物与所述产品一起使用。
2.权利要求1的皮肤护理产品,其中丙烯构成该共聚物的60摩尔%至99.5摩尔%且α-烯烃构成该共聚物的0.5摩尔%至40摩尔%。
3.权利要求1的皮肤护理产品,其中丙烯基聚合物是单点催化的。
4.权利要求1的皮肤护理产品,其中丙烯基聚合物具有0.83至0.88克/立方米的密度。
5.权利要求4的皮肤护理产品,其中丙烯基聚合物具有0.85至0.87克/立方米的密度。
6.权利要求1的皮肤护理产品,其中丙烯基聚合物具有0.1至10克/10分钟的熔体流动速率。
7.权利要求6的皮肤护理产品,其中丙烯基聚合物具有0.5至4克/10分钟的熔体流动速率。
8.权利要求1至7中任一项的皮肤护理产品,其中半结晶丙烯基聚合物构成该薄膜的80重量%或更多。
9.权利要求1至7中任一项的皮肤护理产品,其中非织造网材料含有纺粘纤维、熔喷纤维、短切纤维或其组合。
10.权利要求9的皮肤护理产品,其中该非织造网材料含有聚烯烃。
11.权利要求10的皮肤护理产品,其中聚烯烃是聚丙烯。
12.权利要求1至7中任一项的皮肤护理产品,其中弹性薄膜位于该非织造网材料和另一非织造网材料之间。
13.权利要求1至7中任一项的皮肤护理产品,其中该复合材料在加工方向、横向或两者上是弹性的。
14.权利要求1至7中任一项的皮肤护理产品,其中该非织造网材料在横向上可伸展。
15.权利要求14的皮肤护理产品,其中该非织造材料颈缩。
16.形成前述权利要求任一项的皮肤护理产品的方法,该方法包括:
使该薄膜和非织造网材料通过由至少一个压花辊形成的辊隙;
在该辊隙处,使该薄膜热熔到非织造网材料上,该热熔薄膜通常不含尺寸10微米或更大的孔;和
将所述皮肤护理组合物施加至所述非织造复合材料的表面上。
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