CN101811383B - 具有渐缩点粘结的弹性膜层叠物 - Google Patents

具有渐缩点粘结的弹性膜层叠物 Download PDF

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Publication number
CN101811383B
CN101811383B CN201010003571.2A CN201010003571A CN101811383B CN 101811383 B CN101811383 B CN 101811383B CN 201010003571 A CN201010003571 A CN 201010003571A CN 101811383 B CN101811383 B CN 101811383B
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CN
China
Prior art keywords
sandwich
film
bonding
elastic membrane
adhesive
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Expired - Fee Related
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CN201010003571.2A
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English (en)
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CN101811383A (zh
Inventor
E·弗罗斯特
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Tredegar Film Products LLC
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Tredegar Film Products LLC
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Publication of CN101811383A publication Critical patent/CN101811383A/zh
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    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/083—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
    • B29C65/086—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using a rotary anvil
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    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
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    • B29C66/81433—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined being toothed, i.e. comprising several teeth or pins, or being patterned
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    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411—Roller, cylinder or drum types
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Abstract

本发明涉及具有渐缩点粘结的弹性膜层叠物，具体是揭示具有改进的蓬松、改进的软度和手感并提供较大卷筒容量的弹性层叠物，该层叠物包括弹性膜和超声波粘结在该膜的任一面上的无纺网状片，其中粘结点具有平面粘合区域，该区域占所述粘结点的总粘合区域的不大于约30％。

Description

具有渐缩点粘结的弹性膜层叠物
技术领域
本揭示内容涉及弹性膜层叠物，这种层叠物的制造方法以及结合有该层叠物的制品。
背景技术
弹性膜层叠物可用于制造各种货品。具体地，弹性膜层叠物可用于制造吸收制品，例如，尿布，训练短裤，成人失禁制品和类似的制品。弹性膜层叠物可用作例如，腰带，脚铐，侧贴片，侧贴条，侧贴板或者作为制品的外壳。弹性膜层叠物还可以用于其他制品，例如外套，帽子，连裤的工作服等，通常用于为制品提供所需的适配特性。
将薄膜或层叠物制成卷形时，该材料沿称作纵向(“MD”)的路径的始点(在该点形成该材料或松解)行进至将制成的网状片卷在一辊上的点。纵向通常相应于该网状片的最长维度。横向(“CD”)是一般垂直于纵向的方向，通常对应于网状片的宽度。已经提出许多弹性膜和层叠物，但是大多数的这类薄膜和层叠物都设计和构造成在横向(“CD”)提供拉伸。
因此仍需要具有改进的软度和硬度而又没有牺牲强度或粘合质量的层叠物。
发明内容
本发明提供一种层叠物，其包含弹性膜和至少一种超声波粘结在所述弹性膜的每一面的无纺织物，所述层叠物具有多个粘结点，每个粘结点具有平面粘合区域和总粘合区域，所述平面粘合区域不大于总的点粘合面积的30%，所述层叠物的粘结点使用具有圆化尖端的支承辊形成，所述圆化尖端具有平面区域，所述层叠物具有约7.0-7.3%的总粘合区域。
参考附图，通过阅读发明内容部分和所附权利要求书将明白所揭示内容的这些和其他方面。
附图简要描述
图1是现有技术层叠物的截面图，具体图示说明超声波粘结点。
图2是现有技术层叠物的平面图，具体图示说明超声波粘结点。
图3是根据本文揭示内容的弹性层叠物的截面图，具体图示说明超声波粘结点。
图4是比较新颖层叠物和现有技术层叠物在纵向拉伸时峰值张力的图。
图5与图4类似，是比较新颖层叠物和现有技术层叠物在横向拉伸时峰值张力的图。
图6是对在揭示内容的实施例部分所述的新颖层叠物和现有技术层叠物在横向100％伸长条件下的一系列应力-应变曲线。
具体实施方式
常规层叠物可以采用各种不同的层叠方法制备，包括：热层压，粘合剂层压，真空层压，挤出涂覆，超声波粘结，它们的组合，以及本领域已知的其他方法。超声波粘结称作“点粘合方法”，其中，将层叠物的各层在离散的、空间隔开的位置或者“点”附连在一起。
超声波粘结是一种非接触粘结方法，该方法中，将未粘合的层叠物各层从超声波喇叭和图案化砧座之间通过。该砧座可以是平坦的板形部件或者是圆柱形辊，在砧座上有一系列的图案化的突起元件。所述突起的横截面形状可以是平坦或是圆化的。超声波喇叭在高频下振动，产生声波。当未粘合的各网状片在该喇叭下通过时，声波产生热能和压力，将这些网状片熔合在一起。因此在该喇叭和支承辊突起部分之间形成的间隙中形成粘结点。
首先参见图1，图1图示说明现有技术的超声波粘结的弹性层叠物的截面。该层叠物10具有第一无纺网状片12，第二无纺网状片14以及夹在第一无纺网状片12和第二无纺网状片14之间的弹性膜16。该层叠物的各层通过多个超声波粘结点18粘合在一起。
现有技术的层叠物的粘结点18是采用具有多个尖端20的支承辊形成，如图1中所示所述尖端具有基本平坦的顶部22。如图2所示，从层叠物上面(或下面)观察时粘结点18的形状一般为圆形。如图1所示，在支承辊(未示出)上的平顶尖端20产生有相对较大平面区域24的粘结点18，该区域基本上占据独立粘结点18的全部粘合区域25。更具体地，现有技术层叠物的累积粘合面积为层叠物总面积的约7.0-7.3%，大于90%的粘合面积是平面面积。换言之，总粘合面积的约6.3-6.6%为平面区域。
使用平顶尖端20还导致迫使熔融聚合物材料从薄膜16和/或无纺层12、14到达粘合区域边缘。当聚合物材料冷却时，在粘结点中形成突起。在大多数情况中，突起为在粘结点周围的圆周隆起或凸缘26的形式。但是，应理解，在将聚合物推向粘合区外边缘时所述突起可以采取任何形状。一般而言，突起是厚度大于薄膜标称厚度的任何瑕疵。
平顶尖端20还在无纺层12、14与粘结点18之间产生相对尖锐的转换28。该转换28在无纺网状片12、14的表面与粘结点18之间产生陡峭的侧面部分。这三种属性，即大的平面区域24、圆周隆起26和尖锐转换区28一起协同产生层叠物，消费者或用户敲击该层叠物时该层叠物具有显著的硬挺性或粗糙度。具体地，敲击该层叠物后的触感是消费者注意到的一种在划过粘结点时独特的碰撞感，被消费者认作为粗糙或刚性。因为该层叠物经常用于接触皮肤的应用例如套穿类型的尿布的侧片，粗糙度或刚性或硬挺性的感觉是不利的。
申请人已经发现，通过降低粘结点中的平面区域，与具有较高的平面粘合区域的层叠物相比，产生的层叠物具有显著改进的软度和良好触觉。
具体参见图3，新颖的层叠物110包含弹性膜116，该弹性膜具有无纺层112、114，所示无纺层通过多个超声波粘结点118粘合在薄膜116的任一侧面。层叠物110的粘结点118是使用具有多个圆化尖端120的支承辊(未示出)形成。圆化尖端120具有平面区域122，与采用截头圆锥形尖端20制造的现有层叠物相比，该区域占总粘合区域125的百分比要小得多。更具体地，虽然图3的层叠物的总粘合面积也约为7.0-7.3%，但是与现有技术的6.3-6.5％相比，平面区域仅占总粘合面积的约1.9-2.2%。
如图3所示，除了较低的平面粘合区域外，新颖层叠物中在粘结点124与无纺层112、114之间的转换区128是更为平缓渐进的。此外，粘结点124没有现有技术层叠物中可见的隆起或圆周凸缘26。因此，新颖层叠物与图1和2的现有技术层叠物相比，极大改进了软度和触感。
在该新颖层叠物中使用的弹性膜116可以是单层膜或多层膜。使用术语“弹性的”来暗示一种可以在至少一个方向拉伸至其初始尺寸的约150％的材料，当释放张力时，该材料回复的尺寸不大于其初始尺寸的125％。例如，1英寸长的弹性材料如果拉伸至长度为1.5英寸，则当释放张力时回复的长度不大于1.25英寸，并能够使该材料松弛。
如果使用多层膜，该弹性膜116优选采用共挤出方法制备，该方法中，将弹性芯和一个或多个外层从一个模头同时挤出。或者，可以采用如挤出涂覆的方法制备多层弹性膜12。较好地，该薄膜116包含共挤出的多层膜，该多层膜包含弹性芯层和在该芯层的任一面上的至少一个外层。应理解，还预期在弹性芯层的每一面都具有一个以上外层的实施方式，采用这种实施方式是有利的。
弹性芯包含天然橡胶或合成橡胶，例如，异戊二烯、丁二烯-苯乙烯材料、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(SEBS)嵌段共聚物)、烯烃弹性体、聚醚酯、聚氨酯以及它们的混合物。如果使用外层，所述外层可以包含弹性小于弹性芯的任何合适的材料。优选的材料是聚烯烃聚合物，具体是聚乙烯聚合物和共聚物，包括茂金属催化的聚乙烯以及聚乙烯聚合物或共聚物的掺混物。如果需要时，也可以有利地使用其他材料，例如乙酸乙烯酯共聚物。
术语“聚合物”包括均聚物、共聚物，例如嵌段、接枝、无规和交替型共聚物、三元共聚物等，以及掺混物和其改进形式。此外，除非另外特别指出，否则术语“聚合物”意味着包括材料所有可能的立体化学构型，例如全同构型、间同构型和无规构型。
多层弹性膜中外层相对于芯层的厚度可以依据具体应用和要求的性质变化。优选的多层弹性膜的实施方式为：外层/芯层/外层的重量比为5/90/5至15/70/15。弹性膜116可以使用本领域已知的有表面纹理的辊进行压花，或者使用例如真空箱制成具有光滑表面的弹性膜。真空箱在制造过程中向弹性膜116施加部分真空，将该膜拉向压在铸型胶辊上，因此与不使用真空箱产生的膜相比，产生的膜更光滑，一般也更薄。
如本领域已知的，无纺网状片是由聚合物纤维以无规或非重复图案方式排列构成的纤维网状片。对大多数无纺网状片，通过例如以下的任何一种或多种方法将纤维形成粘结网状片：纺粘、熔喷、粘结梳理网方法(bonded carded webprocess)、水力缠结(hydroentangling)等，和/或通过在一个纤维与另一个纤维的接触点或在其本身穿过的点上将纤维粘合在一起的方式形成粘结网状片。用于制备所述网状片的纤维可以是本领域已知的单组分或者双组分纤维，并且可以是连续纤维或短纤维。还可以使用不同纤维的混合物用于纤维状的无纺织物网状片。
无纺织物可以由任何形成纤维的热塑性聚合物制备，包括：聚烯烃、聚酰胺、聚酯、聚氯乙烯、聚乙酸乙烯酯，和它们的共聚物与掺混物，以及热塑性弹性体。在以上结合适用于膜层的聚合物说明了聚烯烃、聚酰胺、聚酯、聚氯乙烯，和它们的共聚物与掺混物的具体例子。适合用于纤维层的热塑性弹性体包括三嵌段和四嵌段苯乙烯类嵌段共聚物、基于聚酰胺和聚酯的弹性体等。
热塑性纤维可以由各种热塑性聚合物形成，包括聚烯烃，例如聚乙烯和聚丙烯，聚酯、共聚酯、聚乙酸乙烯酯、聚酰胺、共聚酰胺、聚苯乙烯、聚氨酯和前述的任何的共聚物，例如氯乙烯/乙酸乙烯酯等。合适的热塑性纤维可以由单一聚合物形成(单组分纤维)，或者由一种以上的聚合物形成(如，双组分纤维)。例如，“双组分纤维”表示包含由一种聚合物构成的芯纤维、该芯纤维被不同的聚合物构成的热塑性外壳包封的热塑性纤维。构成外壳的聚合物经常在不同于构成芯的聚合物的温度，通常是低于构成芯的聚合物的温度下熔融。因此，这些双组分纤维因为外壳聚合物熔化而提供热粘合，同时保持芯聚合物的所需强度特性。
双组分纤维可包括具有以下聚合物组合的壳/芯纤维：聚乙烯/聚丙烯,聚乙酸乙基乙烯酯(polyethylvinyl acetate)/聚丙烯、聚乙烯/聚酯、聚丙烯/聚酯、共聚酯/聚酯等。在在双组分纤维的横截面上，双组分纤维可以是同心的或者是偏心的，表示外壳的厚度是均匀或不均匀的。偏心的双组分纤维是优选的，可在较小纤维厚度提供更高的压缩强度。
在用于梳理的无纺织物的热塑性纤维的情况，热塑性纤维的长度可以依据具体的熔点和这些纤维所需的其他性质变化。通常，这些热塑性纤维的长度约为0.3-7.5cm，优选约0.4-3.0cm。还可以通过改变纤维的直径(卡尺)来调节这些热塑性纤维的性质包括熔点。这些热塑性纤维的直径通常或按照旦尼尔(克数/9000米)或者分特(克数/10,000米)定义。根据结构内的具体排列，合适的热塑性纤维的分特在小于1分特例如0.4分特至最大约20分特范围。
术语“熔喷纤维”表示采用以下方式形成的纤维：将熔融的热塑性材料挤出通过许多细小，通常为圆形的模头毛细孔，使熔融细丝进入高速气流(如空气流)，所述气流使熔融热塑性材料的细丝变细，减小其直径，成为微纤维直径。术语“微纤维”表示小直径纤维，其平均直径不大于约100微米。然后，熔喷的纤维被高速气流带出，沉积在收集表面上，形成无规分布的熔喷纤维的网状片。
术语“纺粘纤维”表示采用以下方式形成的小直径纤维：将熔融热塑性材料以细丝形式从喷丝头的多个细小通常为圆形的毛细管挤出，毛细管具有挤出的细丝的直径，然后例如通过喷丝拉制或者其他众所周知的纺粘机理快速减小。
特别优选的无纺网状片是按照US RE35,206中所述的方法制备的热固结的网状片，该文献内容通过参考结合于本文。在该方法中，对无纺网状片施加热和张力以在拉伸方向重新排列和取向网状片的纤维。
需要时，可以通过本领域已知的任何方法使该新颖层叠物为透气性的。提供透气性的方法包括穿孔，裂缝和其他技术，例如热针穿孔、模切、刻划、剪切、真空打孔、或者通过利用高压水射流。
也可以采用这些方法的组合。因为无纺网状片通常是可透气的，因此要求在层叠之前对膜简单穿孔。穿孔膜为本领域已知，并可以采用机械穿孔或真空打孔或者其他用于制备透气性或可渗透膜的其他已知方法制备。
在一些实施方式中，所述膜含有分散在聚合物基质中的微粒填料。形成膜后，拉伸膜时会将聚合物基质拉离所述微粒，在膜中产生微空隙，通过保持该膜的不透液性，这些微空隙允许水蒸汽透过。通过这种方法制备的微孔透气膜为本领域众所周知。
可以将弹性膜116，无纺网状片112、114，或制成的层叠物拉伸或活化，以改进层叠物的弹性性质。例如，虽然膜和/或无纺织物可以由弹性体树脂构成，但是膜的外层(如果存在)和/或附连于该膜的无纺网状片往往是抗拉伸的。因此，除非进行活化，否则对特定应用，可以认为拉伸该层叠物所需的力太大。因此，如本领域的惯例，可能希望在将这些网状片超声波粘结在一起形成层叠物110之前拉伸或活化膜116或无纺织物112、114，或者两者。任选或附加要求在将网状片超声波粘结在一起之后拉伸或活化该层叠物。
拉伸或活化可以采用本领域已知的任何方法完成，例如但不限于：(1)通过使用两对隔开的辊对在纵向拉制网状片，其中，下游辊对的旋转速度大于上游辊对；(2)通过使用拉幅机在横向拉制该网状片；(3)或交叉齿轮(intermeshinggear)(“IMG”)活化。还可以采用这些方法的组合。
IMG方法中，网状片从辊的辊隙间通过，所述辊具有许多在辊的圆周取向的齿。当这些辊在一起时所述齿交叉。网状片被紧握在齿上，使得在一对相邻齿之间的区域中拉伸。所述齿可以沿纵向、横向、或者它们之间的任意角度取向，取决于拉伸后要求伸长的方向。IMG活化是弹性体层叠物领域众所周知的方法。
可以对用于制造新颖层叠物的任何网状片(如本文所用，包括膜层)进行加工、处理、精整，或者如本领域的惯例使得包含添加剂。例如，所述网状片可包含着色剂、表面活性剂、增滑剂、抗静电剂，或者按照需要的其他处理添加剂。
可制备层叠物110产生所谓的细颈粘合的层叠物、拉伸粘合的层叠物、细颈-拉伸粘合的层叠物、或零应变拉伸的层叠物。细颈粘合的层叠物可以通过在无纺层的一层或两层上都施加张力，并在该无纺层处于颈缩条件时将该无纺层和膜粘合在一起的方式制备。拉伸的粘合层叠物可通过在膜上施加张力并在膜处于张力下时使一层或多层无纺层与膜粘合的方式制备。细颈-拉伸的粘合层叠物可通过在膜和无纺层都保持在张力条件下将它们粘合在一起的方式制备。零应变拉伸的层叠物可通过在网状片都处于不施加任何明显张力的条件下将它们粘合在一起的方式制备。如本领域已知的，除了零应变拉伸的层叠物以外，一般都不需要活化，但是也可以不予考虑都进行活化。
实施例
实施例1包括使用共挤出的弹性膜制备的层叠物，该弹性膜具有苯乙烯类嵌段共聚物的芯和聚乙烯外层，基重为54克/米2。该膜结构包括9/82/9重量比的外层/芯/外层。所述膜超声波粘结到两个双组分纺粘无纺织物(Dayuan NDYTB-BM020)，在膜的任一面上有一个所述无纺织物。每一无纺织物的基重为20克/米2。使用施坦德公司(Standex Corporation)的“双点”雕刻钢制支承辊完成该超声波粘结。层叠物的总粘合区域约为7%，平面粘合区域约为2%。
实施例2包括使用共挤出的弹性膜制备的层叠物，该弹性膜具有苯乙烯类嵌段共聚物的芯和聚乙烯外层，基重为40克/米2。该膜结构包括9/82/9重量比的外层/芯/外层。所述膜超声波粘结到两个纺粘无纺织物(Fiberweb Sofspan120NFPN732D)，在膜的任一面上有一个所述无纺织物。每一无纺织物的基重为20克/米2。使用施坦德公司(Standex Corporation)的“双点”雕刻钢制支承辊完成该超声波粘结。层叠物的总粘合区域约为7%，平面粘合区域约为2%。
将这些层叠物与两个商业可获得的层叠物FabriFlexTM309和FabriFlexTM35102(Tredegar Film Products Corporation,Richmond,VA)比较。各比较层叠物的总粘合区域约为7%，平面粘合区域约为7%。
参见图4和图5，由这些数据可以知道，该新颖层叠物在拉伸强度和弹性性质(即拉伸和回复)方面与现有技术层叠物相比更有益。图4和图5的数据是层叠物进行ASTM882中所列的测试方法获得的。
通过使用恒定张力将层叠物卷在制成的卷材上比较层叠物的卷筒可压缩性。还采用与ASTM D6571类似的方法评价层叠物的蓬松(loft)。在该蓬松评价中，在低负荷下用手拉伸层叠物至约80%伸长率。最后，采用公知的测试方法比较各层叠物的剪切强度。
表1列出所述测试方法的结果。由表1可知，新颖层叠物与现有技术层叠物相比，显示改进了卷筒可压缩性和提高了软度。具体而言，该新颖层叠物显示提高可压缩性，使得可以在不增加制成的卷材直径并且没有对层叠物性质或性能产生不利影响的条件下，使卷成卷材的材料的平方米数增加。这是有益的，因为这在使用层叠物制造成品中产生的变化较小，并能降低货运成本和产生更少的废物。此外，新颖层叠物显示在拉伸后增加了蓬松。蓬松和软度之间的相互关系(如由与触感相反的可压缩感所感知的)在现有技术中已经有大量报道(参见，例如，US4,725,473；US5,470,640和US5,288,348)。因此消费者从层叠物的软度改进感知到蓬松增加。最后，表1显示在没有牺牲粘合强度的条件下，在卷筒可压缩性和软度/蓬松方面获得这些改进。
表1

Claims (7)

1.一种层叠物，其包含弹性膜和至少一种超声波粘结在所述弹性膜的每一面的无纺织物，所述层叠物具有多个粘结点，每个粘结点具有平面粘合区域和总粘合区域，所述平面粘合区域不大于总的点粘合面积的30%，所述层叠物的粘结点使用具有圆化尖端的支承辊形成，所述圆化尖端具有平面区域，所述层叠物具有约7.0-7.3%的总粘合区域。
2.如权利要求1所述的层叠物，其特征在于，每一无纺织物独立地选自纺粘、梳理和射流喷网法的无纺网状片。
3.如权利要求1所述的层叠物，其特征在于，至少一种无纺织物是双组分无纺织物。
4.如权利要求1所述的层叠物，其特征在于，所述弹性膜是共挤出的多层膜。
5.如权利要求4所述的层叠物，其特征在于，所述弹性膜包括烯烃类嵌段共聚物。
6.如权利要求1所述的层叠物，其特征在于，所述弹性膜被活化。
7.如权利要求1所述的层叠物，其特征在于，所述层叠物是透气性的。
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