CN103015044A - 用于制备纤维吸收材料的方法 - Google Patents

用于制备纤维吸收材料的方法 Download PDF

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CN103015044A
CN103015044A CN2012103535447A CN201210353544A CN103015044A CN 103015044 A CN103015044 A CN 103015044A CN 2012103535447 A CN2012103535447 A CN 2012103535447A CN 201210353544 A CN201210353544 A CN 201210353544A CN 103015044 A CN103015044 A CN 103015044A
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CN103015044B (zh
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P·Y·冯
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Johnson and Johnson Consumer Inc
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麦克内尔-Ppc股份有限公司
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Abstract

本发明涉及一种吸收材料，所述吸收材料包含具有多根形成纤维基质的单个纤维的纤维材料、多根吸收纤维，其中所述多根吸收纤维通过针刺法而被插嵌到纤维基质内。

Description

用于制备纤维吸收材料的方法
技术领域
本发明整体涉及一种吸收材料及一种用于制备该吸收材料的方法。更具体地讲，本发明涉及一种用于一次性卫生吸收用品(例如卫生巾、短裤护垫、棉塞、尿布、成人失禁产品等)的吸收材料。
背景技术
蓬松、有回弹力的非织造网，即具有高蓬松度以及保持这种的蓬松度的趋势的非织造网，是人们熟知的。此外，还熟知这类蓬松、有回弹力的非织造网可用于一次性卫生用品(例如卫生巾、短裤护垫、棉塞、尿布、成人失禁产品等)。这类蓬松、有回弹力的非织造网的一个为人们所认识到的好处在于，这类材料可为这类一次性卫生用品的使用者提供更大的舒适度，这是因为在使用过程中，蓬松、有回弹力的非织造网可趋于适形于使用者的身体，并与使用者的身体一起移动。
伴随蓬松、有回弹力的非织造网的一个问题在于，由于这类材料的蓬松度(即它们的低密度)，这类网的收性不是特别好。此外，这类材料可显示出较差的回渗性。也就是说，当受到外部压力时，这类材料可释放或“回湿(wet back)”流体。
鉴于上述问题，需要还提供优异的流体处理特性的蓬松、有回弹力的非织造网。
发明内容
鉴于前述问题，本发明提供一种用于制备吸收材料的方法，所述方法包括以下步骤：提供包含形成纤维基质的多根单个纤维的纤维材料，将多根吸收纤维沉积于所述纤维材料的顶部表面上，并通过针刺法将所述多根吸收纤维插嵌到所述纤维基质中。
附图说明
现在将参照附图描述本发明实施例的实例，附图中：
图1为根据本发明的第一实施例的吸收材料的截面示意图；
图2为用于制备图1所示吸收材料的装置的示意图；
图3为图2所示装置的圈出部分的示意图，其示出了所述装置中所采用的针、基底的顶部表面和设置于基底的顶部表面上的吸收纤维；
图3a为图3所示针的圈出部分的详细视图；
图3b-3e示出了针将吸收纤维插嵌到基底内的方式；
图4为根据本发明的第二实施例的吸收材料的截面示意图；
图5为根据本发明的第三实施例的吸收材料的截面示意图；以及
图6为用于制备图5所示吸收材料的装置的示意图。
具体实施方式
在本说明书通篇中，使用了相同或相似的标号来表示本文所述的本发明各个实施例的相同或相似的元件。
参照图1，其示出了根据本发明的第一实施例的吸收材料10的截面示意图。如图1所示，吸收材料10由纤维材料12形成，纤维材料12包含形成纤维基质16的多根单个纤维14。吸收材料10还包含多根吸收纤维18。如图所示，吸收纤维18插嵌在纤维基质16内。
纤维材料12优选地是通过已知的非织造制造技术(例如气流成网法、梳理-粘结法或树脂-粘合剂粘结法)制成的纤维非织造材料。优选地，所述非织造材料为“高蓬松度”非织造物。具体地讲，在吸收纤维18插嵌到所述非织造物中之前，所述非织造物的密度优选低于0.05g/cc，且优选介于约0.01g/cc与0.03g/cc之间。形成所述纤维非织造材料的单个纤维14可选选自包括可润湿或不可润湿的合成非吸收纤维的纤维，例如，亲水的纤维、疏水的纤维以及它们的组合。具体的纤维类型包括但不限于聚酯、尼龙、共聚酯、聚乙烯、聚丙烯和聚乳酸。当然，所述纤维非织造材料可由如上所列的单个非吸收纤维类型形成，或者可由如上所列的纤维类型的混合物形成。可通过用合适的表面处理(例如表面活性剂等)处理形成纤维材料12的非吸收纤维14而使这类纤维的表面可润湿。
形成所述纤维非织造材料的每根纤维14的纤维直径优选地在11μm至100μm的范围内。纤维材料12优选地还包含粘结剂材料，例如胶乳粘结剂。粘结剂材料优选地以约30重量％至约50重量％的量存在于纤维材料12中。
吸收纤维18优选地选自纤维素纤维类型，例如但不限于硬木浆、软木浆、人造丝和棉。吸收材料10可包含如上所列类型中的单个吸收纤维类型，或作为另一选择，吸收材料10可包含如上所列类型中的多个纤维类型(即吸收纤维的混合物)。每根吸收纤维18的纤维直径优选地在10μm至40μm的范围内。
形成纤维材料12的单个纤维14和吸收纤维18选择为使得每根单个纤维14的纤维直径比每根吸收纤维18的纤维直径大至少1μm。
通过根据本发明的针刺法将吸收纤维18插嵌到纤维基质16内，这将在下面更详细地讨论。下面详细描述的根据本发明的针刺法使吸收纤维18能够插嵌到纤维基质16内，而不损失纤维材料12的高蓬松性。具体地讲，在被插嵌吸收纤维18之前，纤维材料12的密度优选在0.01g/cc至0.03g/cc范围内。
在吸收纤维18插嵌到纤维材料12中之前，纤维材料12的厚度优选在约1.5mm至约5mm范围内。在吸收纤维18插嵌到纤维材料12中之后，吸收材料10基本上保持与原始纤维材料相同的厚度。具体地讲，在所述多根吸收纤维18被插嵌到纤维材料12中之前纤维材料12的厚度与在所述吸收纤维18被插嵌到纤维材料12中之后吸收材料10的厚度之间的变化百分数优选地低于50％，更优选地低于30％，最优选地低于15％。此相对较小的厚度变化反映出吸收材料10保持了纤维材料12的高蓬松性而同时提供优异的流体处理能力。厚度变化百分数如下计算：
％ΔT＝(Ti-Tf)/Ti；其中
Ti＝纤维材料12的初始厚度
Tf＝吸收材料10的最终厚度
现在将结合图2来描述制备吸收材料10的方法，图2示出了用于制备吸收材料10的装置19的示意图。如图2所示，纤维材料12的网自供给辊20进给并由多个辊22、24和26沿纵向传送。利用重力进给料斗28等向纤维材料12的顶部表面30上施加选定量的吸收纤维18。其后，纤维材料12沿纵向被进一步传送并经过本领域技术人员已知的类型的传统针刺装置32。在根据本发明的方法中，针刺装置32用于通过多根针34将吸收纤维18插嵌到纤维材料12中。
如本领域技术人员已知，传统针刺装置包括多根针，所述多根针通常适于将纺粘或梳理网的纤维进行机械取向和互锁。在根据本发明的方法中，使用针刺装置32的针34将吸收纤维18插嵌到纤维材料12中。图3和图3a示出了适用于根据本发明的方法的针34。如图3a所示，针34通常包括刀片36、倒钩38和喉部40。倒钩38的总倒钩深度在图3a中由字母“d”表示。
为实现本发明的目的，关键是将倒钩深度“d”选择为使得每根吸收纤维18的半径均小于倒钩深度“d”。每根吸收纤维18的半径比倒钩深度小至少0.5μm，例如小1μm。此外，倒钩深度“d”应选择为使得纤维材料12的每根单个纤维14的半径均大于倒钩深度“d”。纤维材料12的每根单个纤维14的半径比倒钩深度大至少0.5μm，例如大1μm。如果为多个旦尼尔的纤维材料12，则最小直径的纤维14的直径必须大于每根吸收纤维18的直径。
通过如上所述选择倒钩深度“d”，针刺装置中的多根针34会有效地抓握吸收纤维18并因而可将这类吸收纤维18插嵌至纤维材料12中，如图3b-3e所示。另一方面，所述多根针34将不会抓握纤维材料12的单个纤维14并因而不会破坏纤维材料12的“高蓬松”性。这样，最终的吸收材料10具有优异的流体处理性质，同时仍保持纤维材料12的高蓬松性。尤其适用于本方法的针可从位于威斯康星州马尼托沃克的福斯特针公司(FosterNeedle Co.，Inc.(Manatowoc，Wisconsin))以产品名“福斯特成型倒钩(TheFoster Formed Barb)”商购获得。
再次参照图2，在纤维材料12已被插嵌了吸收纤维18之后，所产生的吸收材料10由辊28和30沿纵向进一步传送。在过程中的此点处，吸收材料10可被设置为卷的形式以便储存或者可被进一步传送以结合到一次性卫生吸收用品(例如卫生巾、短裤护垫、棉塞、尿布、成人失禁产品等)中。
作为另一选择，如图2所示，纤维材料12可被进一步传送至超吸收剂施加工位42。超吸收剂施加工位42包括重力进给料斗44，所述重力进给料斗44被构造和设置为向纤维材料12的顶部表面30上施加选定量的超吸收聚合物材料46。当然，可以使用本领域技术人员已知的任何合适的装置(例如压力进给喷嘴等)来向纤维材料12的顶部表面30上施加超吸收聚合物材料46。在向纤维材料12的顶部表面30上施加超吸收聚合物材料46之后，纤维材料12被传送过真空50上方，真空50用于将超吸收聚合物材料46拉进纤维材料12的纤维基质16中。图4示出了所产生的吸收材料10a，此为根据本发明的第二实施例的吸收材料。如图所示，超吸收聚合物46已被拉进纤维材料12的纤维基质16中并用于进一步增强吸收材料10a的流体处理能力。
就本发明的目的而言，术语“超吸收聚合物”(或“SAP”)是指在0.5psi的压力下能够吸收和保持至少约10倍于其重量的体液的材料。本发明的超吸收聚合物颗粒可为无机或有机交连亲水性聚合物，例如聚乙烯醇、聚环氧乙烷、交连淀粉、瓜耳胶、黄原胶等。所述颗粒可为粉末、细粒、颗粒或纤维形式。用于本发明的优选超吸收聚合物颗粒为交连的聚丙烯酸酯，例如由位于日本大阪的住友精化公司(Sumitomo Seika ChemicalsCo.，Ltd.(Osaka，Japan))以名称SA70提供的产品。
再次参照图2，在吸收材料10a被传送过真空50之后，吸收材料10a可由辊51沿纵向进一步传送并设置为卷的形式以便储存或者可被进一步传送以结合到一次性卫生吸收用品(例如卫生巾、短裤护垫、棉塞、尿布、成人失禁产品等)中。
参照图5，其示出了根据本发明的第三实施例的吸收材料10b的截面示意图。如图所示，吸收材料10b由纤维材料12形成，纤维材料12包含形成纤维基质16的多根单个纤维14。吸收材料10b还包含设置在第一层52中的第一多根吸收纤维18a和设置在第二层54中的第二多根吸收纤维18b。吸收纤维18a和18b可包括与上面关于本发明的第一实施例所述的那些吸收纤维18相同的纤维。吸收纤维18a和18b可以是相同的纤维类型或者可以是不同的纤维类型(即纤维的混合物)。此外，第一多根纤维18a中可采用第一吸收纤维混合物(或单个纤维)，而第二多根纤维18b中可采用不同的吸收纤维混合物(或单个纤维)。
所述单个纤维14可与上面关于第一实施例所述的纤维14相同。此外，单个纤维14可以是相同的纤维类型(即单一纤维类型)或不同的纤维类型(即纤维的混合物)。
在图5所示的本发明的特定实施例中，第一层52与第二层54以隔开的关系设置。吸收材料10b还可任选地包含超吸收聚合物材料46，所述超吸收聚合物材料46分散在纤维材料12的纤维基质16中。在图5所示的本发明的特定实施例中，超吸收剂46设置在吸收纤维18a和18b的第一层52和第二层54之间的层56中。当然，如果需要，超吸收聚合物材料46可从吸收材料10b中省去。
现在将结合图6来描述用于制备吸收材料10b的方法，图6示出了用于制备吸收材料10b的装置19a的示意图。如图6所示，纤维材料12的网自供给辊20进给并由多个辊22、24和26沿纵向传送。利用重力进给料斗28等向纤维材料12的顶部表面30上施加选定量的吸收纤维18a。其后，纤维材料12沿纵向进一步传送并经过针刺装置32以将吸收纤维18a插嵌到纤维材料12中。
之后，纤维材料12被进一步传送至超吸收剂施加工位42。超吸收剂施加工位42包含重力进给料斗44，重力进给料斗44被构造和设置成向纤维材料12的顶部表面30上施加选定量的超吸收聚合物材料46。当然，可使用本领域技术人员已知的任何合适的装置(例如压力进给喷嘴等)来向纤维材料12的顶部表面30上施加超吸收聚合物材料46。在向纤维材料12的顶部表面30上施加超吸收聚合物材料46之后，纤维材料12被传送过真空50上方，真空50用于将超吸收聚合物材料46拉进纤维材料12的纤维基质16中。当然，如果不需要在吸收材料10b中包含超吸收聚合物材料46，则所述超吸收剂施加和真空步骤可从所述方法省去。
在纤维材料12被传送过真空50之后，纤维材料12由辊51和53传送至第二重力进给料斗28a或类似物，以向纤维材料12的顶部表面30施加选定量的吸收纤维18b。其后，纤维材料12由辊55和57沿纵向进一步传送并经过第二针刺装置32a以将吸收纤维18b插嵌到纤维材料12中。
再次参照图6，在吸收材料10b被传送过针刺装置32a之后，吸收材料10b由辊59沿纵向进一步传送并然后可设置为卷的形式以便储存或者可被进一步传送以结合到一次性卫生吸收用品(例如卫生巾、短裤护垫、棉塞、尿布、成人失禁用品等)中。
实例
以下描述本发明的具体实例。
发明实例#1-以如下方式制备如上参照图1和图2所述的吸收材料。纤维材料为通过梳理-粘结法制得的纤维非织造物，基重为68gsm，由100％聚酯纤维(6旦尼尔)形成，厚度为3mm。假设聚酯的密度为1.38g/cc，则6旦尼尔纤维的标称直径为25μm(旦尼尔＝密度*0.0283r2)。该纤维材料包含胶乳粘结剂，胶乳粘结剂以40重量％的量存在。这种类型的纤维非织造材料可从位于北卡罗来纳州夏洛特的凯姆-纺织公司(Kem-Wove，Inc.(Charlotte，NC))以产品代码SCN09-038商购获得。吸收纤维包含旦尼尔为4的100％粘胶纤维人造丝。人造丝的密度为1.5g/cc，因而，该吸收纤维的纤维直径为19μm。向纤维非织造材料的顶部表面施加150gsm(g/m2)的人造丝纤维并通过上面参照图2所述的针刺法将所述人造丝纤维插嵌到材料内2.5mm的深度。针刺过程中所使用的针的倒钩深度“d”为12μm。最终吸收材料的厚度为2.7mm。
发明实例#2-以如下方式制备如上参照图5和图6所述的吸收材料。纤维材料为纤维梳理-粘结非织造材料，基重为68gsm，由100％聚酯纤维(6旦尼尔)形成，厚度为3mm。假设聚酯的密度为1.38g/cc，则6旦尼尔纤维的标称直径为25μm(旦尼尔＝密度*0.0283r2)。该纤维材料包含胶乳粘结剂，该胶乳粘结剂以40重量％的量存在。这种类型的纤维非织造材料可从位于北卡罗来纳州夏洛特的Kem-Wove公司(Kem-Wove，Inc.(Charlotte，NC))以产品代码SCN09-038商购获得。第一多根吸收纤维包含旦尼尔为4的100％粘胶纤维人造丝。人造丝的密度为1.5g/cc，因而，该吸收纤维的纤维直径为19μm。向纤维非织造材料的顶部表面施加75gsm的人造丝纤维并通过第一针刺装置将所述人造丝纤维插嵌到材料内4.0mm至5.0mm的深度。针刺过程中使用的针的倒钩深度“d”为12μm。之后，纤维材料被传送至超吸收剂施加工位。经由重力进给料斗向该纤维材料的顶部表面施加40gsm的超吸收剂(SA70，可自位于日本大阪的住友精化公司(SumitomoSeika Chemicals Co.，Ltd.(Osaka，Japan))商购获得)。借助真空将超吸收剂拉进纤维材料中3.0mm至4.0mm的深度处。之后，纤维材料12被传送至第二重力进给料斗以向该纤维材料的顶部表面施加选定量的第二多根吸收纤维。第二多根吸收纤维包含旦尼尔为4的100％粘胶纤维人造丝。人造丝的密度为1.5g/cc，因此，该吸收纤维的纤维直径为19μm。向纤维非织造材料的顶部表面施加75gsm的人造丝纤维并通过第二针刺装置将所述人造丝纤维插嵌到材料内1.0mm至和3.0mm的深度。该第二针刺过程中所使用的针的倒钩深度“d”为12μm。最终吸收材料的厚度为2.5mm。
虽然已经图示和描述了本发明的具体实施例，但是对于本领域的技术人员显而易见的是，可以在不脱离本发明的精神和范围的条件下，做出各种其他改变和修改。因此在所附权利要求中，旨在涵盖落在本发明范围内的所有此类改变和修改。

Claims (14)

1.一种用于制备吸收材料的方法，包括以下步骤：
提供纤维材料，所述纤维材料包含形成纤维基质的多根单个纤维；
在所述纤维材料的顶部表面上沉积多根吸收纤维；以及
通过针刺法将所述多根吸收纤维插嵌到所述纤维基质中。
2.根据权利要求1所述的方法，其中所述多根单个纤维中的每一根的纤维直径在约11μm至100μm之间的范围内。
3.根据权利要求2所述的方法，其中所述多根吸收纤维中的每一根的纤维直径在约10μm至40μm之间的范围内。
4.根据权利要求3所述的方法，其中所述多根单个纤维中的每一根的纤维直径比所述吸收纤维中的每一根的纤维直径大至少1μm。
5.根据权利要求1所述的方法，其中在所述多根吸收纤维被插嵌到所述纤维材料内之前所述纤维材料具有一厚度，且其中在所述吸收纤维被插嵌到所述纤维材料内之后所述吸收材料具有一厚度。
6.根据权利要求5所述的方法，其中在所述多根吸收纤维被插嵌到所述纤维材料中之前所述纤维材料的厚度与在所述吸收纤维被插嵌到所述纤维材料内之后所述吸收材料的厚度之间的变化百分数小于50％。
7.根据权利要求6所述的方法，其中所述变化百分数小于30％。
8.根据权利要求7所述的方法，其中所述变化百分数小于15％。
9.根据权利要求1所述的方法，其中所述纤维材料为纤维非织造材料。
10.根据权利要求9所述的方法，其中所述纤维非织造材料由多种纤维形成，所述多种纤维选自聚酯、尼龙、共聚酯、聚乙烯、聚丙烯、聚乳酸以及它们的组合。
11.根据权利要求10所述的方法，其中所述纤维非织造物是通过气流成网法、梳理-粘结法或树脂-粘合剂粘结法中的一种制得。
12.根据权利要求11所述的方法，其中所述多根吸收纤维选自硬木浆、软木浆、人造丝、棉以及它们的组合。
13.根据权利要求4所述的方法，其中所述针刺法是借助多个适于将所述吸收纤维插嵌到所述纤维基质内的单个销进行。
14.根据权利要求13所述的方法，其中所述多个销中的每一个包括具有倒钩深度的倒钩，其中所述倒钩深度选择为使得所述吸收纤维中的每一根的纤维半径比所述倒钩深度小至少0.5μm且形成纤维基质的所述单个纤维中的每一根的纤维半径比所述倒钩深度大至少0.5μm。
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CN103015044B (zh) 2016-08-31
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US8695185B2 (en) 2014-04-15
AU2012216711B2 (en) 2015-10-22
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US9150988B2 (en) 2015-10-06
RU2628989C2 (ru) 2017-08-23

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