CN101965253A - 穿孔带有衬里的穿孔非织造布 - Google Patents

穿孔带有衬里的穿孔非织造布 Download PDF

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Publication number
CN101965253A
CN101965253A CN200980108877XA CN200980108877A CN101965253A CN 101965253 A CN101965253 A CN 101965253A CN 200980108877X A CN200980108877X A CN 200980108877XA CN 200980108877 A CN200980108877 A CN 200980108877A CN 101965253 A CN101965253 A CN 101965253A
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China
Prior art keywords
cloth
perforation
surfactant
weaving
film
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CN200980108877XA
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L·鲁列安埃特
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Tredegar Film Products LLC
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Tredegar Film Products LLC
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Publication of CN101965253A publication Critical patent/CN101965253A/zh
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  • Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Public Health (AREA)
  • Animal Behavior & Ethology (AREA)
  • Veterinary Medicine (AREA)
  • Epidemiology (AREA)
  • Biomedical Technology (AREA)
  • Heart & Thoracic Surgery (AREA)
  • Vascular Medicine (AREA)
  • General Health & Medical Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Forests & Forestry (AREA)
  • Textile Engineering (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Nonwoven Fabrics (AREA)
  • Treatment Of Fiber Materials (AREA)

Abstract

披露了一种穿孔的非织造布，对布上的穿孔用活性材料进行处理，使穿孔的内表面在性质、特征或外观方面不同于布的毗邻穿孔的表面。

Description

穿孔带有衬里的穿孔非织造布
发明背景
本发明涉及穿孔的非织造布，尤其涉及有穿孔而穿孔又衬有活性材料的非织造穿孔布。
非织造布在已有技术中一直有广泛的应用。例如，非织造布在诸如尿裤、妇女卫生用品和成年人失禁用品的一次性使用吸收物品中的应用是已知的。非织造布在诸如限制性使用的童裤或工作服的一次性使用服饰中的应用也是已知的；在医用方面，用作诸如帷帘和吸收垫；在工业用方面，用作诸如房屋外表覆盖物、屋顶衬垫材料和地毯背衬；在人身护理应用方面，用于各种擦洗和涂抹用具；以及许多其它应用。
穿孔的非织造布也是已知的并被发现作为一次性使用吸收物品中的顶层和转移层，以及上述人身护理方面的应用特别实用。穿孔的非织造布的各种制造方法是已知的。其中一种方法是利用一个针辊和配对辊子，针辊的圆周表面上有许多针状突起，配对辊子具有多个适于并布置成当针辊和配对辊子互相啮合时接纳突起的凹陷。随着非织造布通过针辊和配对辊之间形成的轧隙，针在非织造布上穿孔。在这种方法的一个方案中，可将这两个辊子或其中之一加热，并把穿孔过程的速度和辊子的温度调整为使非织造布上形成圆锥形的孔。这种圆锥形孔突出至非织造布的平面以上，形成本技术领域所谓的三维穿孔非织造布。美国公开专利申请第.200300085213号披露了制造这种三维穿孔非织造布的一个示例性过程，其内容以引用方式包含于此。
在某些应用中，可能希望给非织造布施加活性物质，以改变非织造布的被施加了活性物质的那些部位的外观、性质或特性。例如，本技术领域已知给非织造布施加表面活化剂来改变它的相对憎水性。类似地，还已知给非织造布涂抹墨来使非织造布上形成绘画图案，或用其它方法来改变它的外观。在所有这些情况中，都是在非织造布成形之后在一个独立的步骤中给其施加物质，而且，就本发明人所知，施加物质的步骤还总是独立于在非织造布上形成穿孔的任何过程。
发明内容
在一个实施例中，本发明提供包括多个穿孔的非织造布，其中至少一个穿孔的内表面在性质、特征或外观方面不同于布的毗邻该穿孔的表面。
在一个实施例中，本发明提供包括多个穿孔的非织造布，其中至少一个穿孔的内表面比布的毗邻该穿孔的表面更亲水。
在另一个实施例中，本发明提供有第一表面和第二表面的非织造布，这种非织造布包括多个穿孔，这些穿孔起始于该布的第一表面并终止于一个平面，这个平面与非织造布的第一表面和第二表面都间隔开，其中至少一个穿孔的内表面在性质、特征或外观方面不同于该布的毗邻那个穿孔的表面。
在再一个实施例中，本发明提供具有第一表面和第二表面的非织造布，这种布包括多个穿孔，这些穿孔起始于布的第一表面并终止于一个平面，这个平面与布的第一表面和第二表面都间隔开，其中至少一个穿孔的内表面比织布的毗邻那个穿孔的表面更亲水。
在再一个实施例中，本发明提供有第一表面和第二表面的非织造布，这种布包括多个穿孔，这些穿孔起始于布的第一表面并终止于一个平面，这个平面与布的第一表面和第二表面都间隔开，其中至少一个穿孔的内表面在颜色上不同于布的毗邻那个穿孔的表面。
在再一个实施例中，本发明提供由非织造布粘合于第二布构成的层叠制品，这种层叠制品包括多个穿孔，其中至少一个穿孔的内表面在性质、特征或外观方面不同于该布的毗邻该穿孔的表面。在某些实施例中，第二布可以是一种非织造布或一种膜。在某些实施例中，各穿孔可包括圆锥形的穿孔，这些穿孔突出至层叠制品的表面以上，因此，这种层叠制品包括三维的层叠制品。
本发明的这些和其它特点将在配有附图的说明书中和权利要求书中显现出来。
附图说明
图1是一个采用按照本发明生产的非织造布的吸收物品的侧视剖视图；
图2是一个部分剖视侧视图，示出本发明的非织造布的一种穿孔方法；
图3是可用于制备本发明的非织造布的设备的立体图。
详细说明
如本技术领域所知，非织造布是由以随机或非重复图案分布的聚合物纤维构成的纤维布。对大多数非织造布来说，通过诸如纺粘、熔喷、粘梳布工艺、水力缠结等各种工艺中的任何一个或多个工艺，和/或通过在一根纤维接触另一根纤维的点或自身的交点把纤维粘合到一起，使纤维成形为粘合成片的布。用于制造非织造布的纤维可以是本技术领域已知的单组分或双组分纤维，而且可以是连续的纤维或短纤维。
术语“熔喷的纤维”是指通过模具上的许多精细的-通常是圆形的-毛细孔把熔化的热塑性材料挤出成熔化材料线或细丝，让它们进入高速气流(例如空气流)，气流使熔化的热塑性材料细丝变细而减小它们的直径，使其可达到微纤维级的直径而形成的纤维。术语“微纤维”是指平均直径不超过100微米的小直径纤维。然后，熔喷纤维由高速气流带走并沉积在一个收集表面上以形成随机分散的熔喷纤维的布。
术语“纺粘纤维”是指通过把熔化的热塑性材料通过喷丝头上的许多精细的-通常是圆形的-毛细孔挤出成细丝而形成的小直径纤维，其直径等于喷丝头毛细孔的直径，然后通过例如喷射式拉丝或其它众所周知的旋转拔丝粘合机理使纤维直径迅速减小。
术语“普梳纤维”是指非织造布中的那些有某种运动自由度并且相对于其它纤维没有固定位置的纤维。换言之，这类纤维一般不是被压紧在一起或不是被熔合到穿孔不能封闭的程度，而是穿孔可能被某些交叉延伸并部分地阻塞它的纤维束堵住。
相反，术语“压实的”意味着纤维一般是被压紧的、熔合的或粘合的，所以可限制各单根纤维的运动。压实的纤维一般不会伸出来而进入穿孔，并且其密度比疏松的纤维的密度高。
术语“归一的布(unitary web)”是指一种由两层或多层材料的织物，包括非织造布构成的多层布，这些层被充分地粘合起来，诸如通过热粘合，并经处理、加工，或以其它方式利用，而成为单一的布，
术语“层叠的”和“复合的”，在用于描述本发明的布时，是同义词。两者都是指一种包括至少两层布的布结构，两层布以面对面的关系结合而形成一个多层的归一的布(unitary web)。
术语“聚合物”包括均聚物、共聚物，诸如成块共聚物、接枝共聚物、无序共聚物和交替共聚物、三元共聚物等，以及这些共聚物的混合物和改性物。而且，若无特别限定，术语“聚合物”还意味着包括材料的所有可能的几何构造，诸如全同立构的、间同立构的和随机对称性的。
词语“大致”或“基本上”意味着某一给定性质或参数可能相对于规定的数值变化约20％。
在整个说明书中，词语“顶层”和“背层”表示这些材料或这些层相对于起吸收作用的芯部的关系。应能理解，吸收芯与顶层和背层之间可能存在附加层，并且那些附加层和其它材料可能存在于从顶层或背层来看与吸收芯相反的那一侧。
术语“成形的膜”是指一种三维成形的有弹力的膜，在结构上类似于用真空成形过程生产的那种膜，如Thomas的美国专利第4,456,570号和Thompson等人的美国专利第3,929,135号中所述。
术语“活性物质”和“活性材料”可以互换使用，是用于表示那种在被施加于穿孔的衬里时会使布的性质、特性或外观发生变化的物质。按照本发明，活性物质可以是允许其从针上转移到布上的任何适当的形式。下文中将提到液体、半液体(例如浆糊)和固体(例如粉末)的活性物质。仅举一例来说，作为活性物质的表面活性剂将能通过改变相对憎水性而改变穿孔衬里的性质。类似地，涂料或墨将能改变非织造布的外观。可以施加某种上浆剂来改变穿孔衬里的特性，诸如通过改变穿孔的刚性，或通过在穿孔的内表面成形一个膜状的表面，来改变穿孔衬里的特性。也可以用几种活性物质的混合物来造成例如颜色和表面能的变化。
示例实施例
具体实施方式为了读者的方便，本发明将着重于让穿孔的内表面比布的表面更为亲水的实施例，并将其作为一个示例性实施例。但是，对读者和熟悉本技术领域的人来说，很明显，可将表面活性剂之外的液体施加于布来改变穿孔的内表面的性质、特性或外观，使之不同于布的毗邻于穿孔的表面。
在一个实施例中，本文披露的穿孔的布包括一种有许多穿孔的非织造布，其中，那些穿孔中的至少一个的内表面在性质、外观或特性上不同于非织造布的毗邻于那个穿孔的表面。在一个实施例中，至少一个穿孔的内表面比布的表面更亲水。
在一个实施例中，本文披露的穿孔的布包括一种有许多穿孔的非织造布，其中，那些穿孔中的至少一个的内表面在性质、外观或特性上不同于布的毗邻于那个穿孔的表面。在一个实施例中，至少一个穿孔的内表面比布的表面更亲水。这些实施例特别适于用在卫生用品方面，尤其是用作婴儿或成年人尿裤、妇女卫生用品、绷带或其它类似用品的顶层。
用于制造非织造布中的纤维的聚合物，且因此布本身，都是天然地憎水的。对于用作吸收性物品中的诸如顶层和转移层，重要的是，布应有相当好的液体输送和液体管理性能。因此，把表面活性剂掺入布而使其变成亲水的，或至少让它比没有表面活性剂的布更亲水(不那么憎水)，这是本技术领域已知的。可将表面活性剂掺入用于制造纤维的聚合物成分中，或在布成形之后通过处理布把表面活性剂掺入布。通过让布变得更亲水，可使布变成更能吸水，而有利于诸如尿液或月经的液体向这类用品中的吸收芯运动。
为了补偿常规的表面处理容易被蹭掉的情况，常规的表面处理往往大量地施加于聚合物纤维。表面处理物的大量应用导致成本增高。而且，现在已知表面活性剂的这种用量已在某些个体特别是有过敏性皮肤的人身上引起皮炎。一般来看，现在表面活性剂的用量已高达顶层的被处理部分的1重量％，更具体的说，是在顶层的被处理部分的0.3重量％到0.6重量％之间。在过去，一般认为，如果表面活性剂的用量低于这些数值，顶层就达不到足够的吸水性。
尽管希望用作例如顶层的非织造布有亲水性，但是未必希望整个布都变成亲水的。的确，往往有这样的情况，通过在布内建立憎水性梯度来增强流体输送性能。这种梯度产生使流体从一个区域向另一个区域运动的驱动力，诸如从憎水区域向亲水区域，或从亲水区域向更亲水的区域，或从憎水区域向不那么憎水的区域。
还有，在非织造布的表面，特别是各穿孔之间的桥部区域，是亲水的时，各纤维之间的空间容易保持液体。保持在贴近布的表面的任何液体都可能产生使使用者有不舒服的感觉。此外，如果能够把布上只是需要的地方变成更为亲水，那么将能降低使用表面活性剂的费用并可降低某些消费者出现过敏反应的危险。参见例如专利文件U.S.3,730,184、U.S.4,112,153、U.S.4,328,279、U.S.4,585,449、U.S.4,950,264、U.S.4,861,652、U.S.5,562,650、U.S.5,330,456、U.S.5,486,381、U.S.5,057,361、U.S.5,620,788、U.S.5,980,814、U.S.6,599,575、以及WO 2000/066058，它们的发明内容以引用方式包含于此。
热塑性材料，尤其是热塑性纤维，可用各种热塑性聚合物来制造，包括诸如聚乙烯和聚丙烯的聚烯烃、聚酯、共聚酯、多乙酸乙烯酯、聚酰胺、共聚酰胺、聚苯乙烯、聚氨酯和任何诸如氯乙烯/乙酸乙烯等的几个上述物质的共聚物等。适当的热塑性纤维可用单一聚合物制造(单组分纤维)，或可用一种以上聚合物制造(例如双组分纤维)。例如，“双组分纤维”可以指的是这样的热塑性纤维，它包括用一种聚合物制造的芯纤维，而这个芯纤维被包在用不同的聚合物制造的热塑性表层里。构成表层的聚合物往往在不同的、典型地低于构成芯纤维的聚合物的熔化温度的温度下熔化。因此，这类双组分纤维，由于表层聚合物熔化，可进行热粘合，同时又能保持所希望的芯部聚合物的强度特性。
适用的双组分纤维可包括具有以下聚合物组合的表层/芯部纤维：聚乙烯/聚丙烯、聚乙烯乙酸酯/聚丙烯、聚乙烯/聚酯、聚丙烯/聚酯、共聚酯/聚酯、以及类似的组合。双组分纤维可以是同心的或偏心的，这是指表层在双组分纤维的横剖面上的厚度是否是均匀的或不均匀的而言。在以较小的纤维厚度提供较大的压缩强度方面，偏心的双组分纤维是符合需要的。
就热塑性纤维而言，可根据具体的熔点和希望这些纤维具有的其它性质，来改变它们的长度。典型地，这些热塑性纤维的长度是约0.3cm到约7.5cm，优选的是约0.4到约3.0cm。也可通过改变这些热塑性纤维的直径(卡尺)来调整它们包括熔点在内的性质。这些热塑性纤维的直径典型地是用丹尼尔(一根9000米长的纤维的重量的克数)或分特(decitex)(一根10000米长的纤维的重量的克数)来定义。根据结构内的具体安排，适用的热塑性纤维的分特(decitex)可以在远低于1分特(decitex)的诸如0.4分特(decitex)到约20分特(decitex)范围内。
为了使布的结构有一定的强度和完整性，一般是将它们进行粘合。最广泛应用的技术是：a)化学粘合；或b)通过熔化布的一部分进行的热粘合。在后一方法中，纤维可被压缩，而产生许多独特的粘合点，这些粘合点，例如对非织造材料来说，可能覆盖总面积的很大一部分。或者，对于希望有低密度结构的情况特别有用，可以采用“空气-通过”粘合法，其做法是，让加热的空气流过(往往是气流成网)布，使纤维的一些部分例如双组分纤维的表层材料部分地熔化。当非织造布冷却时，部分地熔化的纤维在它们互相接触的地方就粘合起来了。
参照图1，其示出吸收物品10的剖视图。吸收物品10包括顶层12、背层14和定位在顶层12和背层14之间的吸收芯16。对本发明来说，背层14和吸收芯16不是关键性的，它们可以包括本技术领域已知的、适合具体用途和目的的任何已知材料和材料组合。
顶层12包括层叠的穿孔非织造布20，是由上非织造布30粘合于下非织造布42而形成的。在所示的实施例中，多个穿孔32延伸穿过非织造布20。
穿孔32有内表面33，诸如尿液之类的液体可从人体那一侧的表面22透过内表面33进入吸收芯16。按照本发明，穿孔32的内表面33比布20的其它部分更亲水。在一个实施例中，穿孔32的内表面33包括表面活性剂，而布20的其余部分基本上没有表面活性剂。在一个实施例中，非织造布20是憎水的，只有穿孔32的内表面33是亲水的。
穿孔32是大致圆锥形的，有大端开口34和小端开口36。具体地说，大端开口34位于非织造布的将毗邻吸收物品使用者的那个表面，本技术领域一般将这个表面称为面对人体的表面22。穿孔32的小端开口36位于圆锥形穿孔的端部，且与层叠的非织造布20的面对人体的表面22和下侧表面44间隔开。小端开口36和布30的下侧表面44之间的这种间隔关系产生一种本技术领域称为“三维”布的东西。在某些实施例中，靠近大端开口34的纤维基本上是疏松的，而靠近小端开口36的纤维基本上是压实的。
在一个实施例中，非织造布是用热风粘合的、普梳热粘的、纺粘的、或纺粘-熔喷-纺粘的非织造品。在一个实施例中，非织造品是普梳热粘的非织造布。对于卫生用品，普梳热粘的非织造布，诸如以色列的Shalag Shamir公司销售的那些非织造布，是适合使用的。在一个实施例中，纤维是单组分或双组分的。在大多数情况中，非织造品将包括聚烯烃纤维，诸如聚丙烯或聚乙烯。但是，用聚酯以及聚烯烃和聚酯的组合制造的布也是可以的。非织造布的基本重量(即单位面积的重量)不是关键性的，且可根据非织造布的预定用途以及非织造布是否是单层的还是层叠的来确定。对于卫生用品，20-30克每平方米(GSM)的非织造布是符合要求的，更优选的是22-26克每平方米。
图2表示出一种用于成形穿孔32的优选的机构。针辊50和配对辊52互相反转而形成一个轧隙，非织造布20通过这个轧隙馈送。针54从针辊50的表面突出。凹坑56凹入配对辊52。针辊50和配对辊52互相对准成使各针54与各凹坑56互相配对。随着非织造布20通过轧隙，各针54刺穿非织造布而进入对应的各凹坑56。很明显，这就可使非织造布上形成各图中所描绘的三维圆锥形穿孔，或根据轧隙的设定、辊子的速度、温度、以及其它因素，可使布上形成简单的穿孔。
凹坑56可以比针54大并可做成为某种形状的。在一个实施例中，凹坑56的形状被穿孔32部分地复现。在一个实施例中，凹坑56是大致圆锥形的，因此当针54把材料推进凹坑56时，靠近针54的尖头的材料被压缩得比任何其它部位的材料都厉害，而且如果针54是加热的，还经受较多的传热。细的加热的针54和大致圆锥形的凹坑56的这一组合可产生在小端开口36附近的纤维基本上压实，而大端开口34附近的纤维基本上疏松的穿孔32。
在这一用于卫生用品的示例性实施例中，穿孔32的深度可以是在0.5mm到2.0mm之间，这是举例而已，对本发明不是特别重要的，穿孔32的任何适当的尺寸、形状和深度可基于非织造布的预定用途来选择。
在一个实施例中，针辊50和配对辊52是用刚性材料制造的并安装在可调整的底座上，以允许改变两个辊子之间的距离。在一个实施例中，针辊50是用金属材料制造的，针54也是用金属材料制作的。在一个实施例中，针54有尖的端头并且是从其长度大约一半的地方开始到其端头逐渐变尖。在一个实施例中，针54是加热的，这将在下文更详细讨论。针辊50的每平方厘米表面上可以有7、11、18或22个针。针的直径可以是1mm到约4mm，更优选的是1.4mm到约3.1mm。1.4mm、2.5mm或3.1mm的针径是优选的。也可以混合地采用不同尺寸的针。一般地说，对用于卫生用品，在穿孔之后布的开口面积可以是在5％到20％之间。其它应用可能需要比这个范围高或低一些的开口面积。
在另一个实施例中，配对辊52可以用柔软性材料制造。根据配对辊52的柔软性，可以不设置凹坑56，因为针54能够简单地刺进配对辊52的柔软性材料。在再一个实施例中，配对辊52可以由密实插置的刚毛构成，诸如刷子辊。
可因几个理由将针54加热。加热针54的一个理由是为了恰到好处地成形穿孔32，特别是如图所示的三维穿孔。加热的针54还可加热到足以使非织造布30粘合于另一非织造布而形成层叠制品的温度。而且，加热的针54有助于小端开口36附近形成基本上压实的纤维。还可把针54加热到能够为大尺寸的穿孔32提供结构弹性的程度，以便维持顶层12和吸收芯16之间的空的容积(见图1)。
在某些实施例中，以及如图3所示，可能愿意用一系列针环取代针辊50。如果采用针环51，应将其套在实体的辊子53上并固定之，采用针环51的好处是例如能只给非织造布的希望穿孔的地方穿孔，而不是给整个非织造布穿孔。
按照这个示例性实施例，穿孔32中至少一个的内表面33比布的其它部分特别是布的毗邻该穿孔的表面更亲水。在这一示例性实施例中，穿孔32的内表面33包括表面活性剂。通过在成形穿孔的过程中把表面活性剂从针54上转移到非织造布上而把表面活性剂施加于穿孔32的内表面33。
例如，从图2可看到，针54的稍部先伸进活性材料施加区70，然后配合布20或于配对辊52上的凹坑56。在活性材料施加区70，其内装有的活性材料，不管是表面活性剂溶液、油漆涂料、墨汁墨粉，还是其它物质，被施加到针54上。当针54刺穿布20时，活性材料就被从针54转移到正在成形的穿孔的内表面。这样，活性材料就仅被施加于针54所触及的布的那些地方，因而可避免表面活性剂的没必要和不希望的泛用。
可以用任何适当的方法在施加区70中把表面活性剂施加到针54上。例如，施加区70可包括一个喷淋装置，用以把活性材料喷淋到针54上。在其它实施例中，施加区70可包括一个海绵或刷子施加器，让其沾饱活性材料，并通过表面接触转移把活性材料施加给针54。在一个实施例中，施加区70包括一个半刚性的施加器，是用诸如BASF公司生产的
Figure BPA00001221895600101
的微胞聚氨酯制造的。在某些实施例中，可改变施加区70里的活性材料的粘度，其可呈液体、糊浆、胶体、粉末的形式或其它形式。在确定用适当的机构在区域70里的将物质转移给针54时，需要考虑被转移物质的粘度。
一般地说，把施加区70定位成靠近由针辊50(或针环51)和配对辊52之间形成的轧隙，将是有利的，以使活性材料在非织造布穿孔之前的损失为最小。在一个实施例中，如图3所示，施加区70被支承为靠近针环51和配对辊52之间的轧隙。在所示的实施例中，施加区70包括一个由托架73支承的转移施加器72。一个活塞或类似的装置定位成能够迫使施加器72与针54啮合和脱离啮合和/或可以调整施加器72相对于针环51的位置。可以设置一个给施加器72提供补给的料池76。
如上所述，在这一示例性实施例中，表面活性剂是施加于穿孔32的内表面33。在这样一个实施例中，表面活性剂的选择不是特别重要的。可以采用具有增大聚合物纤维的吸湿性的性质的任何剂物。示例性的表面活性剂包括非离子化的表面活性剂和阴离子表面活性剂。除非离子化表面活性剂之外，也可采用阴离子表面活性剂。表面活性剂的例子包括：ICI Americas Inc公司销售的
Figure BPA00001221895600102
76；由Glyco Chemical，Inc公司以
Figure BPA00001221895600103
商标销售的各种表面活性剂；辛基含苯氧基聚乙氧基乙醇(octylphenoxypolyethoxy ethanol)；二辛基钠磺基琥珀酸酯(由Union Carbide公司作为
Figure BPA00001221895600104
GR-SM销售)；用月桂酸反应的脂肪状物质(甘油和/或山梨醇)(由Ciba Chemical公司以
Figure BPA00001221895600105
商标销售)；X-200，这是一种由UnionCarbide公司销售的烷基聚醚硫酸盐的钠盐；由GE Silicones公司销售的Nu-；
Figure BPA00001221895600107
由Henkel Corporation公司制造的
Figure BPA00001221895600108
表面活性剂；以及由Schill & Seilacher公司销售的
Figure BPA00001221895600109
PST。也可采用非常规的表面活性剂，诸如WO2000/066058和U.S.6,599,574中披露的涂料。
本发明的一个优点是可将表面活性剂仅施加于布的穿孔内。顶层和各分布层的常规的表面活性剂处理都是使用足够多的表面活性剂，所以，在烘干之后，表面活性剂占顶层的被处理部分的重量的0.3％到0.5％。一般认为超过这个量级的表面活性剂处理有引起皮炎的潜在危险。甚至这个量级的处理都有可能引起过敏性个体的皮炎。按照本发明制造的非织造布，表面活性剂只存在于穿孔内，所以可使引起皮炎的危险为最小，并可降低制造成本。
其它实施例
在其它的示例性实施例中，适当的活性材料的选择当然应是由要使非织造布的穿孔具有的性质来决定。如果活性物质是液体，被施加给穿孔衬里的液体或其它物质的迁移是可能需要考虑的。具体地说，现在已知，例如低分子量的表面活性剂容易“渗漏”过非织造布的纤维。渗漏的表面活性剂可能进入非织造布的其它区域，诸如穿孔周围的区域，这可能使这些区域有与穿孔衬里相同的性质。这种“渗漏”现象可能与储存条件有关。例如，如果非织造布是以卷状储存(一层挨着一层)和/或储存在高温下，渗漏现象可能更容易产生。
这里描述的各实施例包括一个层叠的非织造顶层。本发明不应被认为是限于这样的实施例。例如，可以用单层非织造布有利地替代上述和各图中描绘的层叠的布。类似地，也可将单层膜材料用作布。此外，也可用包括非织造布和膜的层叠制品替代非织造/非织造层叠制品物。
非织造/膜层叠制品可包括热塑性膜和成形的膜。还有，如果愿意，层叠制品可包括不只两层。此外，布不是一定要有各图所描绘的三维结构。
如果使用层叠的布，可以用任何已知的方法，诸如粘结粘合、超声波粘合、热粘合、等等，把各层布粘合到一起。在一个实施例中，穿孔32里小端开口36附近的基本上压实的纤维可与可用在层叠物里的任何附加布形成粘合点。
本发明的教示可以有相对于示例性实施例的许多可能的变化。例如，可将活性物质施加于穿孔衬里，然后使它硬化而加强穿孔。经加强的布，在吸收物品方面以及在穿孔过程中形成的圆锥形孔的完整性是重要的其它装置中，将非常有用。活性物质可以是洗涤液、霜膏、清洗溶液、防腐溶液、或能沉积在穿孔内并随后可被从表面除去的类似物。这样的布可用在例如擦洗涂抹用具中。在另一个实施例中，活性材料可以是固体的，诸如除臭剂、活性炭、干的墨、以及装有药品或香料的微胶囊。可以制造这样的布，以便在施加压力或在其它具体的条件下除去穿孔内表面的活性材料。可用活性材料的浆液或例如通过给针施加静电荷，把固体的活性材料转移到穿孔的内表面。
在其它设想的实施例中，根据本发明的布可用在让流体(例如液体、气体或粉状固体)穿过穿孔的任何应用中。然后可用能够溶解于流体或能以其它方式对流体起作用的活性物质给穿孔加上衬里。这样的布的适当应用可以是农用化学品(例如覆盖田地的地膜或阻止杂草生长的纤维制品)的输送；卫生用品、食品包装物、医用创伤敷料、水处理设备、消毒袋、医用服饰和帷帘中的杀菌物质的输送；药物的输送；过程流中的化学品(例如催化剂、反应物)以及蓄电池和燃料电池中的固体电解质的输送。

Claims (20)

1.一种具有多个穿孔的非织造布，其特征在于，至少一个穿孔的内表面在性质、特征或外观上不同于所述布的毗邻所述穿孔的表面。
2.如权利要求1所述的布，其特征在于，还包括布，从非织造品和膜选择的至少一个其它布。
3.如权利要求2所述的布，其特征在于，所述膜选自平的膜和三维成形的膜。
4.如权利要求1所述的布，其特征在于，所述各穿孔占所述布的总面积的20-40％。
5.如权利要求1所述的布，其特征在于，所述各穿孔中的至少某些穿孔的所述内表面包括表面活性剂。
6.如权利要求5所述的布，其特征在于，所述表面活性剂选自非离子表面活性剂和阴离子表面活性剂。
7.如权利要求5所述的布，其特征在于，所述表面活性剂包括PST。
8.如权利要求5所述的布，其特征在于，所述穿孔的所述内表面比所述布的毗邻所述穿孔的所述表面更亲水。
9.如权利要求1所述的布，其特征在于，所述布选自热风粘合、普梳热粘的、纺粘的、熔喷的、以及纺粘-熔喷-纺粘的非织造布。
10.一种包括权利要求1所述的布的吸收物品。
11.一种方法，包括：
a)提供一种非织造布；以及
b)给成阵列的针施加表面活性剂；以及
c)使各针穿过所述布以形成穿孔，由此形成具有内表面的多个穿孔，所述内表面在性质、特征或外观方面不同于所述布的毗邻所述穿孔的表面。
12.如权利要求11所述的方法，其特征在于，所述非织造布被粘合于选自非织造品和膜的至少一个其它布以形成层叠布。
13.如权利要求12所述的方法，其特征在于，所述膜是选自平的膜和三维成形的膜。
14.如权利要求11所述的方法，其特征在于，所述布包括三维穿孔的布。
15.如权利要求11所述的方法，其特征在于，所述穿孔占所述布的总面积的20-40％。
16.如权利要求11所述的方法，其特征在于，所述各穿孔中的至少某些穿孔的所述内表面包括表面活性剂，由此所述内表面比所述布的毗邻所述穿孔的所述表面更亲水。
17.如权利要求16所述的方法，其特征在于，所述表面活性剂包括
Figure FPA00001221895500021
PST。
18.如权利要求11所述的方法，其特征在于，所述布选自热风粘合的、普梳热粘的、纺粘的、熔喷的、以及纺粘-熔喷-纺粘的非织造布。
19.如权利要求18所述的方法，其特征在于，所述布包括选自聚乙烯、聚丙烯及其组合的纤维。
20.如权利要求11所述的方法，其特征在于，所述布包括聚乙烯和聚丙烯的双组分纤维。
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US20090233046A1 (en) 2009-09-17
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KR20100122094A (ko) 2010-11-19
CA2716200A1 (en) 2009-09-17
WO2009112956A2 (en) 2009-09-17
BRPI0906151A2 (pt) 2015-06-30

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