CN102673034A - 弹性复合材料 - Google Patents

弹性复合材料 Download PDF

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Publication number
CN102673034A
CN102673034A CN2012101289908A CN201210128990A CN102673034A CN 102673034 A CN102673034 A CN 102673034A CN 2012101289908 A CN2012101289908 A CN 2012101289908A CN 201210128990 A CN201210128990 A CN 201210128990A CN 102673034 A CN102673034 A CN 102673034A
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CN
China
Prior art keywords
supatex fabric
elastic
elastic composite
elastic membrane
composite according
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CN2012101289908A
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English (en)
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CN102673034B (zh
Inventor
凯文·P·布莱克
迪克依·J·布鲁尔
唐纳德·H·小莱斯特
蒂埃里·马克
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Aplix SA
Aplix Inc
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Aplix SA
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Publication date
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Priority claimed from CNA2007800309210A external-priority patent/CN101505700A/zh
Publication of CN102673034A publication Critical patent/CN102673034A/zh
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/144—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
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    • A61F13/00—Bandages or dressings; Absorbent pads
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Abstract

弹性复合材料包括第一非织造织物、第二非织造织物、和夹在该第一和第二非织造织物之间的两个弹性膜。弹性复合材料还包括其中第一非织造织物与第二非织造织物粘结的侧边部分、在弹性膜之间的没有弹性膜的区带、以及连接第一非织造织物与弹性膜的第一粘结剂和连接第二非织造织物与弹性膜的第二粘结剂。该弹性复合材料可用作一次性衣物的部件。

Description

弹性复合材料
本申请是PCT/US2007/076366进入中国国家阶段后的分案申请，母案的中国国家申请号是200780030921.0，母案进入中国国家阶段的日期是2009年2月19日，母案的发明名称是《弹性复合材料》。
相关申请
本申请要求享有早期提交的待批美国临时申请的优先权，它们是于2006年8月24日提交的No.60/839,998和于2007年2月12日提交的No.60/889,311。
技术领域
本发明涉及用于一次性衣物的弹性复合材料，特别是一次性尿裤的侧片(或襟翼)或搭片。
背景技术
一次性衣物是已知的，例如尿裤或训练裤。这种衣物可以具有侧片(或襟翼)和/或搭片。侧片和/或搭片可以由弹性复合材料制成。弹性复合材料通常包括非织造织物和弹性材料的各种组合，每种组合的设计旨在获得具体问题的特定解决方案。通常来说，这些弹性复合材料需要某种类型的机械功来活化复合材料。
弹性复合材料(也称为弹性层压材料)的例子可见于美国专利No.6,255,236和No.6,726,983。美国专利No.6,255,236披露了一种弹性层压材料，其中两个非织造织物夹着弹性织物，该层压材料具有至少一个弹性区带和至少一个增强区带。美国专利No.6,726,983披露了一种弹性层压材料，其中两个非织造织物夹着弹性膜，弹性膜被挤出涂布到一个非织造织物上并热粘结到另一非织造织物上。
在一次性衣物行业中正在进行着提供新弹性复合材料的努力，其中能在物理及感官性能和成本之间取得平衡。因此，对于新的弹性复合材料存在着需求。
发明内容
弹性复合材料包括第一非织造织物、第二非织造织物、和夹在该第一和第二非织造织物之间的两个弹性膜。弹性复合材料还包括其中第一非织造织物与第二非织造织物粘结的侧边部分、在弹性膜之间的没有弹性膜的区带、以及连接第一非织造织物与弹性膜的第一粘结剂和连接第二非织造织物与弹性膜的第二粘结剂。该弹性复合材料可用作一次性衣物的部件。
附图说明
为了对本发明进行说明的目的，在附图中显示了目前优选的形式；然而，应该理解的是，本发明并不局限于所示的精确结构和方式。
图1是例如为尿裤的典型一次性衣物的示意图。
图2是例如为尿裤的另一典型一次性衣物的示意图。
图3是本发明实施方案的俯视图，为清楚起见，部分被分解。
图4是本发明第一实施方案沿图3的剖切线A-A的分解剖视图。
图5是本发明第二实施方案沿图3的剖切线A-A的分解剖视图。
图6是本发明第三实施方案沿图3的剖切线A-A的分解剖视图。
图7是本发明第四实施方案沿图3的剖切线A-A的分解剖视图。
图8是本发明第五实施方案沿图3的剖切线A-A的分解剖视图。
图9是本发明制备过程的示意图。
具体实施方式
参考附图，其中类似的元件具有类似的附图标记，图1和图2中所示为典型的一次性衣物，尿裤10和30。
在图1中，尿裤10通常包括后腰部分12、前腰部分14、和互连部分16。在后腰部分12的侧边固定有侧片(或襟翼)18。在侧片18的远端可以固定有搭片20。在搭片20的远端可以固定有扣接装置22。在前腰部分14的外表面上可以设置配合扣接装置24(显示为两个元件，但可以是一个连续的元件)。扣接装置22和配合扣接装置24协同起来，以可解开的方式将尿裤10固着到穿着者身上，这是众所周知的。扣接装置22和配合扣接装置24可以为任何已知的扣接装置。这种已知的扣接装置包括，但不限于，钩扣和环扣以及粘性扣件。在尿裤10中，侧片18可以是弹性的(例如，在远离后腰部分12的方向上是可伸缩的)，从而使得可以牢靠地将尿裤配合到穿着者身上，而搭片20可以是非弹性的。
在图2中，尿裤30通常包括后腰部分32、前腰部分34、和互连部分36。在后腰部分32的侧边固定有侧片(或襟翼)38。在侧片38的远端可以固定有搭片40。在搭片40的远端可以固定有扣接装置42。在前腰部分34的外表面上可以设置配合扣接装置44(显示为两个元件，但可以是一个连续的元件)。扣接装置42和配合扣接装置44协同起来，以可解开的方式将尿裤30固着到穿着者身上，这是众所周知的。扣接装置42和配合扣接装置44可以为任何已知的扣接装置。这种已知的扣接装置包括，但不限于，钩扣和环扣以及粘性扣件。在尿裤30中，侧片38可以是非弹性的，而搭片40可以是弹性的(例如，在远离后腰部分32的方向上是可伸缩的)，从而使得可以牢靠地将尿裤配合到穿着者身上。
参考图3，所示为本发明的弹性复合材料50。弹性复合材料50通常包括第一(或下部)非织造织物54、第二(或上部)非织造织物56、以及夹在该第一非织造织物54与第二非织造织物56之间的第一(或左)弹性膜58和第二(或右)弹性膜60。弹性复合材料50通常包括两个侧边部分62、两个伸缩区64、和区带66(区带66由供参考所示的中央线52划分开)。在侧边部分62中，可以将第一非织造织物54和第二非织造织物56粘结在一起(下文更详细讨论)。在伸缩区64中，可以将第一和第二非织造织物54、56粘结到弹性膜58、60的上和下表面上(下文更详细讨论)。
第一和第二非织造织物54、56可以是相同的材料。这些非织造织物可以为任何非织造织物。在一个实施方案中，非织造织物的基重为10-40g/m2，在另一实施方案中，基重为22-30g/m2。非织造织物在一个实施方案中是无弹性的，并且在横向加工方向(CD)上是可高度伸长的。在一个实施方案中，非织造织物具有至少200％的峰值负荷CD伸长率。在另一实施方案中，这些非织造织物进一步的特征可在于其CD/MD(CD-横向加工或横的方向；MD-加工方向)伸长比，该伸长比可以为至少1∶1或至少3∶1，或者为3-6∶1或4-5∶1。在一个实施方案中，非织造织物为由短纤维生产的点粘结梳理非织造织物或水刺非织造织物。该短纤维可以是任何材料的，例如聚酯(如PET)、聚烯烃(如PP)、或两者的共混物。非织造织物可以具有孔。点粘结梳理非织造织物的一个例子为可得自南卡罗莱纳州辛普森维尔(Simpsonville，SC)的Fiberweb公司的FPN 571D或可得自德国施瓦岑巴赫(Schwarzenbach，Germany)的Sandler AG公司的SAWABOND 4132(22g/m2)。水刺非织造织物的一个例子为可得自德国施瓦岑巴赫的Sandler AG公司的
Figure BSA00000709006200031
弹性膜58、60在一个实施方案中是彼此相同的。弹性膜可以由任何弹性体聚合物制成。在一个实施方案中，弹性体聚合物可以为苯乙烯嵌段共聚物。苯乙烯嵌段共聚物包括，但不限于，SIS(苯乙烯-异戊二烯-苯乙烯)嵌段共聚物、SBS(苯乙烯-丁烯-苯乙烯)嵌段共聚物、以及它们的组合。在一个实施方案中的弹性膜的基重可以为40-100g/m2，在另一实施方案中为50-70g/m2。弹性膜进一步的特征可在于其至少200％的CD伸长率。
上文讨论的粘结中使用的粘合剂可以为任意粘合剂。在一个实施方案中，粘合剂为热熔非弹性粘合剂。或者，可以用粘结替代粘合剂(例如，在非织造织物中的热、超声、和/或红外粘结，存在或不存在粘结剂纤维)。
以下将结合图4-8中所示的实施方案进一步详细地讨论本发明的弹性复合材料50。
图4中所示为弹性复合材料50′。在侧边部分62中，第一非织造织物54和第二非织造织物56经侧边粘结剂68粘结在一起。侧边粘结剂68由上文讨论的粘合剂形成。虽然在每个侧边部分62中显示了两个粘合剂层(形成粘结剂68)，但本发明并不受限于此，例如，可以使用单层粘合剂(施加到任一非织造织物上)。在一个实施方案中，侧边粘结剂68可以是连续的粘合剂层(即，粘合剂覆盖了侧边部分的长度和宽度)，由此无弹性但可伸长的非织造织物通常是固定的(即，伸长受阻或基本上受阻)。在另一实施方案中，侧边粘结剂68的形式可以为粘合剂的网格或交叉影线，或者为通常旨在将非织造织物固定在侧边部分62中的任何其它的模式。在弹性复合材料的宽度为170mm的一个实施方案中，侧边粘结剂68的粘合剂重量为8-9g/m2。
同样，在区带66中，第一非织造织物54和第二非织造织物56经区带粘结剂72粘结在一起。区带粘结剂72由上文讨论到的粘合剂形成。虽然在区带66中显示了两个粘合剂层(形成粘结剂72)，但本发明并不受限于此，例如，可以使用单层粘合剂(施加到任一非织造织物上)。在一个实施方案中，区带粘结剂72可以是连续的粘合剂层(即，粘合剂覆盖了区带的长度和宽度)，由此无弹性但可伸长的非织造织物通常是固定的(即，伸长受阻或基本上受阻)。在另一实施方案中，区带粘结剂72的形式可以为粘合剂的网格或交叉影线，或者为通常旨在将非织造织物固定在区带66中的任何其它的模式。在弹性复合材料的宽度为170mm的一个实施方案中，区带粘结剂72的粘合剂重量为2-3.2g/m2。
在伸缩区64中，第一非织造织物54和第二非织造织物56经伸缩区粘结剂70粘结至弹性膜58、60。如所示的那样，伸缩区粘结剂70位于第一非织造织物54与弹性膜58、60之间和第二非织造织物56与弹性膜58、60之间。伸缩区粘结剂70由上文讨论的粘合剂形成。伸缩区粘结剂70由许多粘合粘结剂组成，由此当弹性复合材料在CD方向拉伸时，非织造织物可以随弹性膜伸展，而当弹性复合材料松弛时，非织造织物可以变大。在一个实施方案中，伸缩区粘结剂70可以为在MD方向上延伸的多条粘合剂的连续线(在附图中以点的水平线表示)。在另一实施方案中，伸缩区粘结剂70可以为在MD方向上延伸的多条粘合剂的不连续(例如，点)线(在附图中以点的水平线表示)。弹性膜58、60可以延伸到伸缩区64的侧边，或者可以延伸到略微越过伸缩区64的侧边。作为粘合剂线的替代，可以使用各种粘合剂重量/体积/密度的粘合剂连续膜(例如，一种高密度粘合剂线、且在高密度粘合剂线之间粘合剂密度较低的模式)。在一个实施方案中，粘合剂线可以具有0.5-1.0mm或0.5-0.55mm的宽度。在一个实施方案中，粘合剂的中央线至中央线的间距可以为2.0-2.5mm。
在图5中所示为弹性复合材料50″。除以下所述外，弹性复合材料50″与(图4的)弹性复合材料50′是相同的。在区带66中的第一非织造织物54与第二非织造织物56之间增加增强材料74。增加增强材料74是为了对区带66提供附加的机械强度。区带66可以是弹性复合材料被固定到一次性衣物上的那部分，或者可以将扣件固定于此，因此可能需要附加的机械强度，从而便于在衣物的拼装和/或衣物的使用中与衣物的连接。如上文所讨论的那样，增强材料74经区带粘结剂72粘结至第一非织造织物54和第二非织造织物56。增强材料74是非可伸长的材料(对于弹性膜58、60而言是非可伸长的)。增强材料74可以是膜或非织造织物。在弹性复合材料50″中，增强材料74延伸到略微越过区带66的侧边，并且与弹性膜58、60交搭(但可以不粘结于此)。
在图6中所示为弹性复合材料50′″。除以下所述外，弹性复合材料50′″与(图5的)弹性复合材料50″是相同的。增强材料74不与弹性膜58、60交搭，并且当拼装弹性复合材料50′″时，增强材料74的侧边邻近或邻接其各自的弹性膜之侧边。
在图7中所示为弹性复合材料50″″。除以下所述外，弹性复合材料50″″与(图4的)弹性复合材料50′是相同的。在弹性复合材料50″″中，用膜76替换弹性膜58、60。膜76具有三个区，两个侧伸缩部分78(对应于伸缩区64)和其间的中央部分80(对应于区带66)。侧伸缩部分78是弹性的，而中央部分80是无弹性的。膜76是单一材质的，可以通过共挤出制备。
在图8中所示为弹性复合材料50A。除以下所述外，弹性复合材料50A与前述的弹性复合材料是相同的。弹性复合材料50A没有区带66。代之而来的是，弹性复合材料50A包括弹性膜82(与之前的弹性膜为相同的构造材料)，如所示的那样，弹性膜82可经伸缩区粘结剂70粘附于第一非织造织物54和第二非织造织物56。弹性复合材料50A由两个侧边部分62和中间伸缩区64组成。
参考图9，所示为制备弹性复合材料50的过程100。在挤出步骤102中，弹性膜58、60或膜76是由聚合物树脂制备挤出材料制成的。在冷却步骤104中，挤出的材料冷却并固化。在层压步骤106中，将弹性膜58、60或膜76(和/或根据需要的增强材料74)层压到非织造织物54、56之间(非织造织物54、56由供给108提供)。通常情况下，在层压机中没有张力(除了移动膜和非织造织物通过所需的微小张力外)。然而，任选的是，在层压至膜之前可以增加张力(在MD方向)以使非织造织物“颈缩”。在增强步骤110中，可以使区带66(和/或侧边部分62)经受压延(加热或非加热的辊)，用以确保其中的牢固粘结。最后，在收取步骤112中，可以对弹性复合材料50进行检查、修边、卷绕、和/或包装。
当用于一次性衣物时，可以沿中央线52切开弹性复合材料；这样使其中一部分可用于衣物的右侧，另一部分可用于衣物的左侧。当弹性复合材料50用作侧片(或襟翼)时，弹性复合材料应该具有至少140％的伸长率。当弹性复合材料50用作搭片时，弹性复合材料应该具有至少35％的伸长率(为了获得这一伸长率，对于伸缩区粘结剂70可能需要使用连续的粘合剂层)。弹性复合材料的区带部分用于将弹性复合材料扣合到衣物上。
在不偏离本发明的实质和基本属性的情况下，可以按其它的形式具体实施本发明，因此，应当视所附的权利要求书而非前述的说明书为本发明的范围。

Claims (23)

1.一种弹性复合材料，其包括：
由三个横向部分构成的结构，所述各结构分别是侧边部分、伸缩区、和区带，伸缩区介于侧边部分和区带之间，侧边部分和区带与伸缩区相比沿CD方向基本上不可伸长，伸缩区与侧边部分和区带相比沿CD方向可伸长；所述弹性复合材料进一步包括：
第一非织造织物和第二非织造织物，其间夹设具有侧边的弹性膜，所述第一非织造织物和所述第二非织造织物延伸超过所述弹性膜的侧边，
在侧边部分，所述第一非织造织物与所述第二非织造织物粘结在一起，这样，侧边部分沿CD方向基本上不可伸长，
在伸缩区，所述第一非织造织物以数个横向间隔的、可沿MD方向延伸的伸缩区粘结剂粘结至所述弹性膜，所述第二非织造织物以数个横向间隔的、可沿MD方向延伸的伸缩区粘结剂粘结至所述弹性膜，
在区带，所述第一非织造织物与所述第二非织造织物粘结在一起，这样，区带沿CD方向基本上不可伸长，
这样，当所述弹性复合材料沿CD方向被拉伸时，粘结至所述弹性膜的所述非织造织物与所述弹性膜一起伸长，而当所述弹性复合材料被释放时，粘结至所述弹性膜的所述非织造织物堆积起来。
2.根据权利要求1所述的弹性复合材料，其中，第一非织造织物和弹性膜之间或第二非织造织物和弹性膜之间的伸缩区粘结剂包括多条粘合剂线。
3.根据权利要求2所述的弹性复合材料，其中，多条粘合剂线可以为连续线或不连续线。
4.根据权利要求2所述的弹性复合材料，其中，粘合剂为热熔粘合剂。
5.根据权利要求1所述的弹性复合材料，其中，粘合剂为非弹性的。
6.根据权利要求2所述的弹性复合材料，其中，每条伸缩区粘结剂为具有0.5-1.0mm的宽度。
7.根据权利要求6所述的弹性复合材料，其中，每条伸缩区粘结剂为具有0.5-0.55mm的宽度。
8.根据权利要求1所述的弹性复合材料，其中，粘合剂的中央线至中央线的间距为2.0-2.5mm。
9.根据权利要求1所述的弹性复合材料，其中，所述第一非织造织物、所述第二非织造织物、或两者选自：点粘接梳理非织造织物或水刺非织造织物。
10.根据权利要求9所述的弹性复合材料，其中，所述第一非织造织物、所述第二非织造织物、或两者的CD/MD伸长率比为至少3∶1。
11.根据权利要求1所述的弹性复合材料，其中，所述弹性膜包括苯乙烯嵌段共聚物。
12.根据权利要求1所述的弹性复合材料，其中，在所述区带，所述第一非织造织物粘结至所述第二非织造织物。
13.根据权利要求1所述的弹性复合材料，其中，在所述区带，在所述第一非织造织物和所述第二非织造织物之间粘结有增强部。
14.一种弹性复合材料，其包括：
第一非织造织物，所述第一非织造织物可伸长但没有弹性，所述第一非织造织物的进一步的特征在于CD/MD伸长率比为至少3∶1，所述第一非织造织物为由短纤维生产的点粘结梳理非织造织物或水刺非织造织物，
第二非织造织物，所述第二非织造织物可伸长但没有弹性，所述第二非织造织物的进一步的特征在于CD/MD伸长率比为至少3∶1，所述第二非织造织物为由短纤维生产的点粘结梳理非织造织物或水刺非织造织物，
第一弹性膜和第二弹性膜，所述第一弹性膜和所述第二弹性膜沿横向相互间隔，并且夹设在所述第一非织造织物与所述第二非织造织物之间，所述第一弹性膜和所述第二弹性膜在所述第一弹性膜和所述第二弹性膜没有张力时通过沿MD方向延伸的多条热熔粘合剂线的连续线分别粘结至所述第一非织造织物与所述第二非织造织物，
第一弹性膜和第二弹性膜之间的不可伸长的材料，其夹设在所述第一非织造织物与所述第二非织造织物之间，并且粘结至所述第一非织造织物与所述第二非织造织物，
这样，当所述弹性复合材料沿CD方向被拉伸时，所述非织造织物随弹性膜伸展，而当所述弹性复合材料被松弛时，所述非织造织物变大。
15.根据权利要求14所述的弹性复合材料，其中，所述CD/MD伸长率比为4-5∶1。
16.根据权利要求14所述的弹性复合材料，其中，所述第一非织造织物或所述第二非织造织物为水刺非织造织物。
17.根据权利要求14所述的弹性复合材料，其中，所述第一弹性膜、或第二弹性膜、或两者包括苯乙烯嵌段共聚物。
18.根据权利要求14所述的弹性复合材料，其中，所述第一弹性膜、或第二弹性膜、或两者具有50-70g/m2范围的基重。
19.根据权利要求14所述的弹性复合材料，其中，所述热熔粘合剂为非弹性的粘合剂。
20.根据权利要求14所述的弹性复合材料，其中，所述多条连续线中的线具有0.5-1.0mm的宽度。
21.根据权利要求14所述的弹性复合材料，其中，所述多条连续线中的线具有0.5-0.55mm的宽度。
22.根据权利要求14所述的弹性复合材料，其中，所述多条连续线中的中央线至中央线的间距为2.0-2.5mm。
23.根据权利要求14所述的弹性复合材料，其中，第一弹性膜和第二弹性膜之间的所述不可伸长的材料夹设在所述第一非织造织物与所述第二非织造织物之间，并且通过热熔粘合剂粘结至所述第一非织造织物与所述第二非织造织物。
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