CN104510575B - 用于吸收性物品的有孔外覆层 - Google Patents

用于吸收性物品的有孔外覆层 Download PDF

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Publication number
CN104510575B
CN104510575B CN201410520492.7A CN201410520492A CN104510575B CN 104510575 B CN104510575 B CN 104510575B CN 201410520492 A CN201410520492 A CN 201410520492A CN 104510575 B CN104510575 B CN 104510575B
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China
Prior art keywords
hole
nonwoven
covering layer
outer covering
ventilated membrane
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CN201410520492.7A
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English (en)
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CN104510575A (zh
Inventor
K·金
J·柳
S·朴
J·李
E·黄
S·赵
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Kimberley Clark Global Ltd
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Kimberley Clark Global Ltd
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Abstract

一种用于吸收性物品的外覆层，其包括具有在其中形成的多个孔的非织造部件和接合到有孔的非织造部件的膜。在非织造部件中的孔在膜接合到非织造部件之前通过针刺形成。用于制造外覆层的方法包括将非织造材料纤网输送到针刺站，对非织造材料纤网进行针刺以在其中形成多个孔来限定出有孔的非织造材料纤网，并将有孔的非织造材料纤网接合到膜。

Description

用于吸收性物品的有孔外覆层
技术领域
本发明的领域总体涉及用于吸收性物品的外覆层，更具体涉及包括构造成改善柔软度、增强用户对外覆层的透气性的观感和减小湿度的有孔非织造材料的外覆层。
背景技术
吸收性物品诸如尿布、失禁服、训练裤、卫生巾、卫生护垫等等是本领域众所周知的，这些往往是一次性的物品能够吸收和保持液体和其它身体排泄物。这些吸收性物品通常包括具有不透液塑料膜诸如聚丙烯和/或聚乙烯膜的外覆层，以防止穿用者排泄的液体从物品泄漏。
具有不透液外覆层的一些已知的吸收性物品包括不透水蒸汽以及液体的膜。因为外覆层不透液体和水蒸汽，尤其是在排出身体排泄物之后，穿用者往往会感到吸收性物品热和湿粘。另外，液体和水蒸汽渗透性的缺乏导致刺激穿用者的皮肤。除了引起对皮肤的健康状况的担忧，不透液塑料膜往往使吸收性物品缺乏期望的美感和触觉品质。
用于吸收性物品的其它已知外覆层是“透气的”。这样的外覆层通常为若干不同类型材料的层压材料，其是基本不透液的但“透气的”，这意味着水蒸汽可透过外覆层。在吸收性物品中，透气的外覆层已经日益普遍并且高度商业化。
虽然往往提供皮肤友好型产品，透气不透液的外覆层往往出现外覆层潮湿。也就是说，很多吸收性物品具有这样的外覆层，其在液体由穿用者排出并被物品吸收后，会在外覆层的外表面上出现湿气的感觉。这种令人不快的潮湿感觉通常不是由于液体渗透通过不透液外覆层或物品泄露，而是由于相对于暖热的水蒸汽穿过外覆层、冷却和在外覆层上冷凝造成水蒸汽在外覆层上凝结而导致。
吸收性物品的用户(例如穿用者、看护人员)往往难以轻易确定他们正使用的物品是否具有不透气或透气的外覆层。也就是说，通常不容易将具有透气外覆层的物品与具有不透气外覆层的物品辨别区分开。如上所述，从穿用者的角度来看，与不透气外覆层相比，透气外覆层往往提供使皮肤更健康的产品。
因此，对这样的吸收性物品存在需要，其具有充分的水蒸汽渗透性以仍作为对穿用者的健康且舒适的产品，但防止外覆层产生潮湿或润湿的感觉。另外，还对这样的吸收性物品存在需要，其构造成增强用户对外覆层透气性的观感。还对这样的吸收性物品存在需要，其具有例如柔软的外覆层。
发明内容
在一个方案中，用于吸收性物品的外覆层总体包括具有在其中形成的多个孔的非织造部件，和接合到有孔的非织造部件的膜。在非织造部件中的孔在该膜接合到该非织造部件之前通过针刺形成。
在另一个方案中，用于吸收性物品的外覆层总体包括限定出在其中形成的多个孔的非织造部件和胶粘接合到有孔的非织造部件的膜。非织造部件限定出从所述膜向外延伸出的多个穹顶区域。非织造部件在邻近所述孔的位置胶粘接合到所述膜。
在又一个方案中，制造用于吸收性物品的外覆层的方法总体包括将非织造材料纤网供给到针刺站。非织造材料纤网在针刺站被针刺以在其中形成多个孔来限定出有孔的非织造材料纤网。有孔的非织造材料纤网胶粘接合到膜。
附图说明
图1是根据本发明的一个实施例的呈尿布形式的吸收性物品的俯视图，该尿布以展开平摊状态显示，以示出在尿布穿用时面向穿用者的尿布内表面。
图2示出了处于展开平摊状态的尿布的仰视图，以示出当尿布穿用时背离穿用者的外表面。
图3示出了处于穿用构型的尿布的正视图，其中扣合系统处于未扣合位置。
图4是处于穿用构型的尿布的正视图，其中扣合系统处于扣合位置。
图5是尿布的外覆层的一个合适实施例的端视图；
图6是从图5中取的放大端视图。
图7是尿布的外覆层的另一合适实施例的俯视平面图；
图8是示出制造外覆层的一种合适的方法的示意图。
图9是从包括胶粘层压到膜的SMS非织造材料的SMS层压对照样品截取的截面的照片。
图10是从根据本发明的包括胶粘层压到膜的有孔SMS非织造材料的有孔SMS层压样品截取的截面的照片。
图11是示出设置在SMS层压对照样品的膜上的絮状胶粘剂的照片。
图12是示出设置在有孔SMS层压样品的膜上的絮状胶粘剂的照片。
图13是示出了用于测试与外覆层中的层压非织造材料和膜之间的间隙距离有关的学生T分布置信度极限范围的图表。
图14是示出了用于测试与胶粘剂在膜上的覆盖面积百分比有关的学生T分布置信度极限范围的图表。
具体实施方式
现在参考附图，图1-4示出了本发明的吸收性物品的一个合适的实施例，其呈总体用10标示的尿布的形式。虽然本发明在上下文中针对尿布进行描述，但应当理解本发明适用于其它吸收性物品，例如成人失禁服、儿童训练裤、纸尿短裤、泳裤、女性护理用品(例如卫生巾、卫生护垫)、创伤敷料、绷带、消毒包、手术服、盖布、擦拭巾、防护服等等。
在一个合适的实施例中，尿布10是一次性吸收性物品。在本文中，术语“一次性吸收性物”是指吸收和容纳身体排泄物并要在有限使用期限之后被丢掉的物品。这类物品不打算被清洗或以其它方式恢复以供重复使用。物品可贴靠或接近穿用者的身体放置以吸收和容纳从身体排出的多种排泄物。应当理解，在其它合适的实施例中，尿布10(或广义讲吸收性物品)可重复使用。也就是说，吸收性物品打算使用多次，而不会背离本发明的某些方面。
图1示出了处于展开平摊状态的尿布10，以示出当穿用尿布时面向穿用者的尿布内表面。另一方面，图2显示了处于展开平摊状态的尿布10，以示出了当穿用尿布时背离穿用者的尿布外表面。在图1和图2中，切去了尿布10的一些部分，以显示尿布的内部组成部件。
仍参见图1和2，尿布10具有纵向42和横向33。沿纵向42，尿布10限定出前部14、后部16以及在前部14和后部16之间延伸并连接前部14和后部16的裆部18。尿布10的前部14在使用期间总体位于穿用者的正面；后部16在使用期间通常总体穿用者的背面；裆部18在使用期间总体位于穿用者的两腿之间。
在示出的实施例中，后部16和前部14包括直腰(或端)边缘。在本文中，“直边缘”是指基本没有曲线、弯曲、角、凹口或不规则部分的边缘。然而，应当理解，后和/前腰边缘22可被切制成本领域已知的任何合适的形状(例如弓形)。如图1和图2所见，尿布10具有在后腰边缘和前腰边缘22之间延伸的相对的纵向侧边缘24。在示出的实施例中，所述侧边缘24中的每一个包括在尿布10的穿用期间限定出至少一部分腿部开口的非线性部分。应当理解，所述侧边缘24可具有包括直线的任何合适的形状。
如图1和2所见，尿布10包括体侧内衬30，外覆层32以及定位在体侧内衬和外覆层之间的吸收性结构48。如图1所示，尿布10的体侧内衬30限定出尿布的体侧表面。因此，当穿用者穿戴尿布10时，体侧内衬30用来靠近和直接接触穿用者的身体。因此，体侧内衬30适宜地对穿用者的皮肤来说是顺应的、感觉柔软且无刺激的。在一个合适的实施例中，体侧内衬30构造成将穿用者的身体与保持在吸收性结构48中的液体隔离开。为了给穿用者提供较干燥的表面，体侧内衬30可比吸收性结构48的亲水性小并且具有足够多的孔以容易地透过液体。
用于体侧内衬30的合适材料是本领域众所周知的，包括例如多孔泡沫、网状泡沫、有孔塑料膜、天然纤维(即羊毛或棉纤维)、合成纤维(即聚酯、聚丙烯、聚乙烯等)或者天然和合成纤维的组合。例如，体侧内衬30可包括聚丙烯纤维的熔喷或纺粘纤网或者由天然和/或合成纤维组成的粘合梳理纤网。体侧内衬30可由用表面活性剂处理或以其它方式加工以赋予期望水平的润湿性和渗透性的基本疏水的材料组成。例如，表面活性剂可通过传统手段例如喷射、印刷、刷涂等等以一定的量施加以赋予期望等级的亲水性。在一个合适的实施例中，体侧内衬30可包括经表面活性剂处理的聚丙烯纺粘纤维或聚乙烯/丙烯多组分纺粘纤维构成的纤网，该表面活性剂例如是购自美国康涅狄格州的Union Carbide of Danbury公司、商标名为TRITON X-102的乙基苯基聚乙二醇，或等同物。
在图2中示出的尿布10的外覆层32限定出要靠近穿用者衣物穿用的尿布衣服侧表面。在一个合适的实施例中，外覆层32是包括至少两层的层压材料(例如第一层接合到第二层)。在示出的实施例中并且如图5和6所见，例如，外覆层32包括(例如通过胶粘剂层36)胶粘接合到膜38的纤维性非织造部件34。在一个合适的实施例中，例如，外覆层32可包括使用絮状胶粘剂与拉伸变薄的聚丙烯膜胶粘接合的聚丙烯纺粘织物。
在一个合适的实施例中，膜38是“透气性”材料，其允许水汽离开尿布10并且是不透液的。因此，在一个实施例中，膜38可构造成保持液体，而允许水汽穿过。在一个合适的构造中，膜38可以是多微孔材料，其是“透气性的”以允许水汽离开尿布，而阻止液体排泄物从其中穿过。例如，外覆层32可包括已经涂覆或以其它方式处理以赋予期望等级的不透液性的非织造织物或多微孔聚合物膜。
应当理解膜38的透气性可大幅变化而不会违背本发明的一些方面。在一个合适的实施例中，例如膜38的水蒸汽透过率(WVTR)为约1500克/米2-24小时到约10000克/米2-24小时，这由下面描述的WVTR试验程序确定。在一个尤其合适的实施例中，例如，膜层的透气性为约2,500克/米2-24小时到约7000克/米2-24小时，这由WVTR试验程序确定。在另一个尤其合适的实施例中，例如膜层的透气性为约3500克/米2-24小时到约5000克/米2-24小时，这由WVTR试验程序确定。在一个优选的实施例中，膜38的透气性为约4500克/米2-24小时，这由WVTR试验程序确定。
用于所述膜38的合适的材料包括但不限于聚烯烃膜和任何其它合适的不透液且可透水汽的聚合膜。一种合适的多微孔膜例如是商购自位于日本东京的三井东压化学株式会社的PMP-1膜或商购自美国明尼苏达州的明尼阿波利斯市的3M公司的XKO-8044聚烯烃膜。用作所述膜38的一种合适的不透液膜例如是商购自美国弗吉尼亚州纽波特纽斯市的亨斯迈包装公司的0.2毫米聚乙烯膜。
适用于所述膜38的另一种材料包括聚合物基材组分和填料组分。聚合物基材优选包括聚烯烃、并构成膜层重量的30-90％。膜层还包括填料组分。填料组分可以是有机或无机填料，并构成膜层重量的约10-70％。填料和聚合物基材组分最初熔融共混，并且共混物被挤入前体膜层。前体膜层可作为单层膜被挤出，或者构成多层膜结构中的一层或多层。该膜则优选在低于聚合物组分的熔解温度的升高温度下拉伸。当膜被拉伸时，在填料颗粒的周围形成孔隙以形成多微孔透气膜。
外覆层32的纤维性非织造部件32可包括包含单层非织造或非织造层压材料的任何合适的非织造材料。例如，由单层构成的非织造部件34可以是纺粘纤网。在由非织造层压材料构成的非织造部件34的一个合适的实施例中，非织造部件可含有布置在两纺粘层之间的熔喷层以形成纺粘/熔喷/纺粘(“SMS”)层压材料。当然，非织造层压材料可具有其它构造和具有任何期望数目的熔喷和纺粘层，诸如纺粘/熔喷/熔喷/纺粘层压材料(“SMMS”)，纺粘/熔喷层压材料(“SM”)等。除了纺粘纤网，多种其它非织造纤网也可以用来形成非织造部件34，诸如熔喷纤网、粘合梳理纤网、湿法成形纤网、空气成形纤网、同成形纤网、水力缠结纤网等等。
应当理解，非织造部件34的基重可以是任何合适的基重。在一些合适的实施例中，非织造部件34的基重可以为约8克/平方米(gsm)至约30gsm，并更特别地为约10gsm至约18gsm。例如，用于非织造部件34合适的基重包括12gsm和15gsm。
如图2和图3所示，外覆层的非织造部件34具有多个孔70。在一个合适的实施例中并且如作为俯视图的图2和图3所见，每个所述开孔70大致为圆形并应当理解所述孔可具有任何合适的形状(例如椭圆形、方形和三角形)。在一个合适的实施例，孔70大致为圆形(当从上方或下方看时-在俯视图中)并且直径(即第一宽度118，如图6可见)在约0.5mm至约4mm之间。
如为外覆层32的放大端视图的图6所见，每个所述孔70的截面大致为锥形。因此，孔70具有位于该膜38附近的第一宽度118(或“最小宽度”)和位于该非织造部件34的外侧延伸部分附近的第二宽度120。在示出的实施例中，第一宽度118明显小于第二宽度120。示出的孔70例如具有约1mm的第一宽度(或直径)118和约1.5mm的第二宽度(或直径)120。在示出的实施例中，每个所述孔具有大致相同的尺寸和形状(即当从俯视图看时圆孔具有大约1mm的直径和当从端视图或截面图看时大致为锥形)
应当理解，所述孔70可具有任何合适的尺寸和/形状，而不会背离本申请的某些方面。例如图7示出了当从俯视图看时具有大致椭圆形的孔170的合适的非织造部件134。可以想到在某些合适的实施例中，第二宽度120可由通道的宽度限定。例如，该通道可在两个或更多个孔70之间延伸，并且所述孔可形成在通道的底部。
应当理解，外覆层32的非织造部件34可包括具有不同尺寸和/形状的孔70。例如，尿布10的不同部分可有不同尺寸和/形状的孔70。在一个合适的例子中，尿布10的后部和前部12、14中的孔70可具有的直径比裆部16中的孔大。可以想到，在这样的实施例中，尿布10的裆部16可没有孔70。在另一个合适的例子中，非织造部件34的与吸收性结构48间隔开的多个部分的孔70可具有的直径大于对应于(例如叠合)该吸收性结构48的部分中的孔。应当想到，在这样的实施例中，非织造部件34的叠合于吸收性结构48的部分可没有孔70。
如图2更好地所见，孔70限定出沿尿布的纵向42延伸的多个纵列和沿尿布的横向44延伸的多个横行。在一个合适的实施例中，每个所述孔与相邻的孔大致等距的间隔开。换句话说，每个所述纵列和每个所述横行以大约相同的距离间隔分开。在一个合适的实施例中，每个所述孔与相邻的孔间隔(从一个孔的边缘到相邻孔的最近边缘测得)约0.5mm至约6mm的距离122(图6)。在所示的实施例中，例如在相邻孔70之间的距离122为大约1mm。应当理解，孔70之间的间距可以是任何合适的距离并且在不同孔之间可变化。因此，所述孔70可具有包括随机间距的任意合适的间距。此外，在非织造部件34中的孔70密度可以为9孔/平方厘米左右到36孔/平方厘米左右。在示出的实施例中，例如孔70密度可以为18孔/平方厘米左右。
应当理解，非织造部件34中的孔70可具有任何合适的间距和密度。还应当理解，孔70的间距和/密度在非织造部件34的不同部分中可以变化。因此，非织造部件34的不同部分可比其它部分更多或更少的孔70，而不会背离本发明的某些方面。
如从图5中取得外覆层32的放大端视图的图6所见，非织造部件34大致限定出在所述孔70之间延伸的多个穹顶区域，其在图6中大致呈弓形。如本文描述的，非织造部件34在靠近形成所述孔70的突出部开口端的位置通过胶粘剂36胶粘接合到所述膜38。非织造部件34的远离所述孔的多个部分(例如穹顶区域)由于气隙与所述膜38间隔开，所述气隙由非织造材料纤维在非织造部件中形成孔70时从非织造部件的X-Y平面正交移位而形成。通过成孔工艺如此形成的锥形突起据信有利于形成外覆层32的最终层压材料具有增加的空气调节能力并因此具有使层压材料提供改善的容量以降低通常与个人护理吸收性物品诸如尿布的透气性外覆层复合材料相关的潮湿或湿润的感觉的能力。如图6所示，将非织造部件34的大部分与膜38间隔开还在非织造部件中产生了顶部结构。这种顶部结构增加了非织造部件34的松密度和回弹性，这有助于本文描述的外覆层32的增加的总体舒适性和感觉。因此，具有如本文公开的孔70的非织造部件34与没有孔的相同非织造部件相比具有较高的松密度和弹性。
此外，非织造部件34与所述膜38间隔开的部分阻止使用者感觉到外覆层的湿润或潮湿。如上文提到的，在吸收性物品的使用期间，有时相对暖热的水汽透过外覆层、冷却并凝结在外覆层上且更具体地凝结在膜上。聚集在本文公开的外覆层32的膜38上的任何冷凝物可通过非织造部件34与使用者间隔开。因此，本文公开的外覆层32将不会使用户感觉到潮湿或湿润。应当理解，通过使用具有较大基重的非织造部件也可以获得类似的效果。然而，这样做将明显增加外覆层的成本。
此外，在本发明的一个合适的实施例中，非织造部件34中的孔对用户来说是容易看见的。因此，孔70可为用户提供这样的视觉提示，即尿布10包括透气性的外覆层和更特别地所述膜38是透气性的。
如上面提到的，外覆层32的膜38和非织造部件34可合适地彼此胶粘接合。然而，应当理解，在某些实施例中，非织造部件34和膜38可使用任何合适的接合技术接合在一起。例如，在某些合适的实施例中，非织造部件34可热接合或压力接合到膜38。
在一个合适的实施例中，膜38和非织造部件34具有基本相同的长度和相同的宽度，并且彼此对齐(即膜38和非织造部件34是同延的)。在另一个合适的实施例中，如图1和2所见，膜38的宽度明显小于非织造部件34的宽度。因此，膜38的纵向延伸侧边缘比至少部分由非织造部件34限定的尿布10侧边缘24明显靠内。在示出的实施例中，膜38的宽度大致等于或稍微大于吸收性结构48的宽度。因此，要吸收和保持液体污物的吸收性结构48由膜38充分覆盖。应当理解，膜38可具有任何合适的尺寸和形状，而不会背离本发明的某些方面。
如图5和图6所见，膜38和非织造部件34以面对面的关系接合在一起。可连续或者间歇地以珠滴、喷洒状、平行涡旋或类似方式施加的合适的层压胶粘剂可购自美国威斯康星州沃瓦托萨市的Findley Adhesives公司或者购自位于美国新泽西州的Bridgewater的国民淀粉化学公司。合适的胶粘剂的例子包括弹性胶粘剂(即，能够伸长至少75％而不断裂的材料)，诸如基于水的苯乙烯丁二烯胶、氯丁橡胶、聚氯乙烯、乙烯基共聚物、聚酰胺和乙烯乙烯基三元共聚物。在一个合适的实施例中并如图12所见，胶粘剂36为絮状胶粘剂。合适地，在非织造部件34层压到膜之前，胶粘剂以约0.5gsm到约2gsm的量施加到膜38。在示出的实施例中，例如，大约0.9gsm的胶粘剂施加到膜。应当理解，在其它合适的实施例中，胶粘剂可在层压到膜38之前施加到非织造部件34。还应当理解，可以使用任何合适量的胶粘剂。
在一个合适的实施例中，非织造部件34中的孔70合适地通过针刺工艺形成。针刺工艺是这样的工艺，其中多个针(或销针)被驱入或穿过非织造材料。参见图8，示出了用于制造外覆层32的总体用300标示的设备的一个合适的实施例，合适的非织造材料的入料连续纤网312可通过纤网送入组件例如一个或多个驱动辊314送入砧辊316。在示出的实施例中，砧辊316为真空辊，但可以想到可以使用其它合适的纤网处理装置。砧辊315可内装真空源或以其它方式连接到合适的真空源(例如真空泵、真空腔室等等，未示出)，所述真空源能够通过一个或多个真空孔选择性地施加真空压力(即负压力)，使得提供到真空辊外表面的材料大致被抽吸到外表面和贴靠外表面固定。
图8示出的设备300还包括针辊318(广义地说“针刺站”)，该针辊包括多个针320。在一个合适的实施例中，每个针320大致为锥形。然而，应当理解所述针可具有任何合适的尺寸或形状，而不会背离本发明的某些方面。所述针320构造成当非织造纤网由砧辊316运载经过针辊318时刺入非织造纤网312预定的深度。应当理解，可以使用其它合适的方法(例如空气或水射流)以使非织造纤网312的纤维沿z-方向偏转(离开x和y平面)并在非织造纤网31形成孔，而不会背离本发明的某些方面。
如图8所见，合适膜38材料的连续移动纤网324被输送到砧辊316。在所示实施例中，在抵达砧辊316之前或之时，将合适的胶粘剂例如絮状胶粘剂在胶粘剂站315处施加到纤网324。更尤其是，其上有胶粘剂的膜材料纤网324和非织造纤网312被引导通过由砧辊316和压模件323(或其它合适的装置例如辊)限定的辊隙。应当理解，可以省略压模件323。在这样的一个实施例中，非织造纤网312可粘附到膜材料纤网324，而不使用任何辊隙。可以想到，外覆层32可使用任何合适方法制成，而不背离本发明的某些方面。
再参见图1和图2，体侧内衬30和外覆层32可布置在吸收性结构48的相反两侧。因此，吸收性结构48布置在体侧内衬30和外覆层32之间。在一个合适的实施例中，体侧内衬30和外覆层32可绕吸收性结构48的外周通过本领域已知的任何手段例如胶粘接合、声接合、热接合等等以及它们的组合相互连接。在本文中，术语“连接”及其派生词包含这样的结构，其中一个元件通过将该元件直接附连到另一个元件而直接固定到该另一个元件，以及这样的结构，其中一个元件通过将该元件附连到中间件、而该中间件又附连到另一个元件而间接固定到该另一个元件。
在一个合适的实施例中，体侧内衬30和外覆层32(并更特别是非织造部件34)通常是共同延伸的。也就是说，体侧内衬30和外覆层32具有大致相同的尺寸和形状，并定位成使得体侧内衬的外周与外覆层32的外周大致对齐。在示出的实施例中，体侧内衬30和外覆层32大致成面对面关系并超出膜38的延伸范围接合在一起。然而，应当理解，体侧内衬30和外覆层32可具有任何合适的尺寸和形状，包括其中体侧内衬30的尺寸和形状不同于外覆层32的尺寸和形状的多个实施例。
如上面提到的，吸收性结构48布置在体侧内衬30和外覆层32之间。吸收性结构48是大致顺应的且能够吸收和保持液态身体排泄物。吸收性结构48可包括超吸收性材料、短纤维、粘合纤维等等以及它们的组合，如本领域中已知的。吸收性结构48可具有多种形状和尺寸中的任意一种。例如，复合吸收芯可以是矩形的、I-形的或T形的。吸收性结构48的尺寸和吸收能力应当与目标穿用者的尺寸相适应和与由尿布10的预定用途赋予的流体装载量相适应。
在一个合适的实施例中，尿布10可包括布置在吸收性结构48和体侧内衬30之间的涌流部(未示出)。涌流部用于快速收集和临时保持由穿用者排出的液体并随后将液体释放至吸收性结构48。多种织造和非织造材料可用来构造涌流部。例如，涌流部可以是聚烯烃纤维的纺粘或熔喷纤网层。涌流部还可以是天然和合成纤维的粘合梳理纤网。涌流部可以是基本疏水材料和可选地可用表面活性剂处理或以其它方式赋予期望等级的润湿性和亲水性。
在示出的实施例中，吸收性结构48包括棉纸包裹片90。棉纸包裹片90有助于保持某些吸收性结构诸如气流成网纤维结构的完整性。此外，棉纸包裹片90有助于将液体分布到吸收性结构48上，尤其是当使用具有强芯吸性能的材料诸如吸收性纤维素材料时。常用棉纸包裹片材料的例子包括绉纱纤维填料或高湿强度棉纸。此外，亲水非织造织物也可用作吸收芯包裹片，参见共同转让给Abuto等人的美国专利US5,458,592，该专利的整体内容通过引用结合入本文。
参见图1和图2，尿布10包括一对经弹性处理的、纵向延伸的腿部套箍74。腿部套箍74适合在使用中绕穿用者的腿部适配并用作身体排泄物侧向流动的机械阻隔结构。在一个合适的实施例中，腿部套箍74可通过外覆层32、和/或体侧内衬30的延伸超出吸收性结构48纵向侧边的部分形成。在图1和2示出的另一个合适的实施例中，腿部套箍74可由连接到外覆层32和/或尿布10的其它组成部件的单独的材料(例如腿部弹性绞线)形成。
尿布10还可包括前腰弹性件(未示出)和/或后腰弹性件72。在示出的实施例中，例如，尿布10具有后腰弹性件72，但不具有前腰弹性件。后腰弹性件72布置成拉伸和保持尿布10贴靠穿用者，尤其是贴靠穿用者的腰部。
适用于形成腿部套箍74和/或腰弹性件72的材料是本领域技术人员已知的。这类材料的例子是聚合弹性体材料构成的绞线或带，所述绞线或带在拉伸状态附着到尿布10，或者当尿布打摺时附接到尿布，使得弹性束紧力赋予尿布10。腿部套箍74和/或腰弹性件72可具有提供期望性能的任何构造。腿部套箍74可是大致直线的或可选的曲形的(如图1和图3所示)以更紧密地适配穿用者腿部的轮廓。在本文中，“弹性的”、“弹性体的”以及类似术语是指材料或复合物被伸长了其初始长度的至少约50％并在松弛时恢复其初始长度的至少50％以内的能力。
腿部套箍74和/或腰弹性件72可以本领域技术人员已知的任何方式附接到尿布10。例如，套箍74和/或弹性件72可通过超声接合、热接合、胶粘接合和类似方式，以及它们的组合连接到尿布10。
尿布10还可包括一对防渗漏片(未示出)，其沿尿布10的纵向延伸并适合提供身体排泄物的侧向流动的阻隔结构，如本领域已知的那样。防渗漏片可连接到体侧内衬或尿布的10的其它部件。防渗漏片的合适的结构例如在于1997年2月4日赋予K.Enloe的美国专利US5,599,338中有所描述，该专利的整体内容通过引用结合入本文。
参见图1和图2，尿布的后部14包括总体用110标示的一对后耳部。在一个合适的实施例中，后耳部110可由体侧内衬30、外覆层32或体侧内衬和外覆层两者组合的延伸部形成。在另一个如图1和图2所示的实施例中，后耳部110可作为独立部件形成并附接到体侧内衬30、外覆层32和/或体侧内衬和外覆层两者，如本领域已知的那样。在示出的实施例中，后耳部110附接到体侧内衬30的体侧表面，使得所述后耳部的附接部分当穿用者穿用时位于穿用者的身体和体侧内衬之间。
在一个合适的实施例中，后耳部110中的每一个包括弹性部112，非弹性部114以及安装到非弹性部的扣件116(图1)。后耳部110的弹性部112可由能够执行本文所述的功能的任何类型的弹性体材料形成。在一个合适的实施例中，弹性体材料将能沿至少一个方向(例如在图1看沿尿布10的横向44)伸展并且优选地，所述弹性体材料将能沿两个方向(例如在图1看沿纵向42和横向44)伸展。合适地，当弹性体材料沿单个方向伸展时，弹性体材料的伸展方向将定向成提供弹性力，所述弹性力趋向于朝向彼此拉伸物品的前部和后部，使得物品大致保持在穿用者的腰部周围。
在一个合适的实施例中，形成后耳部110的弹性部112的弹性体材料能够伸长了至少50％，或者伸长了至少约100％，或者伸长了至少约130％。在伸长了其初始长度的50％(如果弹性体材料能够伸长不超过100％)或100％(如果弹性体材料能够伸长超过100％)后，弹性体材料合适地恢复其初始长度的至少约50％，或者恢复其初始长度的至少约80％。弹性体材料可以是固有的弹性体材料，即一种以弹性状态形成的材料，或者通过成型后处理的而造成的弹性体。例如，弹性体材料可以是热或压力激活的。后耳部110的弹性部112可由拉伸粘合层压(SBL)材料、颈缩粘合层压(NBL)材料、弹性膜、弹性泡沫材料或类似材料形成。
参见图1，后耳部110的每个所述非弹性部114附接到弹性部112的相应的一个中，而第一扣件116(例如钩材料)又布置在非弹性部上。如图1和图2所示，后耳部110的非弹性部114部分地在相应的弹性部112横向外部延伸，在穿用构型，每个所述非弹性部114的第一扣件116构造成适于接合布置在尿布10的前部12中的毛圈构件，如下文中更详细地所述。
最好参见图1，示出的非弹性部114中的每一个还包括位于第一扣件116横向外部的捏持区域210，用于相对于尿布10捏持和操纵非弹性部并且更宽泛地捏持和操纵相应的后耳部110。捏持区域210不可附接到尿布10。在这种情况下使用的术语“不可附接的”意指捏持区域210既不是可解除的或者以其它方式可移除地附接到尿布10，也不是所述捏持区域永久附接到尿布。在一个实施例中，捏持区域210从相应的第一扣件116横向向外延伸约1mm的距离，例如约1mm到约10mm的距离，以提供足够的未附接材料以便容易地捏持和拉动非弹性部114。
如图3和图4所示，通过总体用180标示的扣合系统将后部14(更具体地后部110)附接到前部12，尿布10可选择性地移动到扣紧或穿用构型，以限定出尿布的三维穿用构型，其具有腰部开口150和一对腿部开口152。尽管在图3和图4中示出的尿布10示出了后部14(且更具体地后耳部110)在连接到前部12时方便地叠覆该前部12，这是尿布还可构造成使得在连接时前部叠覆该后部。
实验
对四个外覆层样品来测试水蒸汽透过率(WVTR)、非织造材料和膜之间的间隙距离，等效圆直径(ECD)，开口区域百分比、开口区域之间的间距、剥离强度、和胶粘剂分析，如下文所述。所述经测试的四个外覆层样品由两个对照样品和两个根据本发明制成的样品构成。
所述两个对照样品为1)基重为约12gsm、胶粘接合到聚合物膜的纺粘/熔喷/纺粘(“SMS”)纤网；和2)基重为约15gsm、胶粘接合到聚合物膜的纺粘纤网。
根据本发明制成的两个样品为1)基重为约12gsm、胶粘接合到聚合物膜的有孔纺粘/熔喷/纺粘(“SMS”)纤网；2)基重为约15gsm、胶粘接合到聚合物膜的有孔纺粘(“SB”)纤网。
每个样品使用相同的材料和工艺制造，除了根据本发明制造的两个样品在胶粘接合到聚合物膜之前进行针刺。更特别地，用于每个所述样品的膜为购自位于韩国大邱HansChemical株式会社的、WVTR为4000克/m2-24小时的17gsm透气聚乙烯膜。SMS材料为购自位于韩国庆尚北道的TORAYAdvanced Materials Korea公司的12gsm聚丙烯纺粘-熔喷-纺粘材料。SB材料为购自位于韩国大田市的大田工厂的柳韩-金伯利公司的名称为T-Soft的15gsm纺粘材料。有孔SB和SMS样品通过位于韩国京畿道的Korea Vilene公司使用具有18针/cm2的针冲压机成孔以形成具有约1mm直径的孔。
水蒸汽透过率(WVTR)
用于确定本发明的膜或层压材料的WVTR(水蒸汽透过率)值的一种合适的技术是由INDA(非织造布行业协会)，在第1部分方法编号WSP 70.5，水蒸汽透过率Mocon/EDANA中所制定标准的试验程序，上述内容通过引用结合入本文。INDA方法为确定WVTR提供膜的水蒸汽透过性，且针对均质材料提供水蒸汽渗透系数。
INDA测试方法是众所周知的并且将不在本文中详细阐述。然而，测试过程概述如下。干腔室通过永久防护膜和要测试的样品材料与具有已知温度和湿度的湿腔室分隔开。防护膜的用途是限定一定的气隙并平静或静止气隙中的空气，而气隙被表征化。干腔室、防护膜和湿腔室构成扩散单元，其中测试膜密封在该扩散单元中。样品支架称为Permatran-WModel 100K，其由位于美国明尼苏达州的明尼阿波利斯市的Mocon/Modern Controls公司制造。第一测试为获得防护膜的WVTR和产生100％相对湿度的蒸发器组件之间的气隙。水蒸汽扩散通过气隙和防护膜，并随后和与水蒸汽浓度成比例的干燥气流混合。电信号被发送至计算机以进行处理。计算机计算出气隙和防护膜的透过率并储存该值以待进一步的应用。
防护膜和气隙的透过率作为CaIC(计算机辅助标引和分类)存储在计算机中。样品材料则密封在测试单元中。另外，水蒸汽扩散通过气隙到防护膜和测试材料并随后与扫过测试材料的干燥气流混合。再者，所述混合物又传送至蒸汽传感器。计算机随后计算气隙、防护膜和测试材料的组合透过率。该信息则用来根据以下等式计算湿气传输通过测试材料的透过率：
TR-1 测试材料＝TR-1 测试材料，防护膜，气隙-TR-1 防护膜，气隙
计算：
WVTR的计算使用公式：
WVTR＝Fρsat(T)RH/Apsat(T)(1-RH))
其中：
F＝以立方厘米/分钟为单位的水蒸汽流量，
ρsat(T)＝温度T下饱和空气中的水密度，
RH＝测试单元中特定位置处的相对湿度，
A＝测试单元的截面面积，和，
psat＝温度T下水蒸汽的饱和蒸汽压。
表1-WVTR测试结果
WVTR测试
层压材料
平均值 标准偏差
12gsm非有孔SMS 3954 219
12gsm有孔SMS 3552 114
15gsm非有孔SB 3580 59
15gsm有孔SB 3795 304
膜从层压材料移除
平均值 标准偏差
12gsm非有孔SMS 4021 304
12gsm有孔SMS 4024 76
15gsm非有孔SB 3814 188
15gsm有孔SB 3873 229
仅聚合物膜
平均值 标准偏差
“4000WVTR” 3797 173
经测试的四个外覆层样品的WVTR测试数据表明在根据本发明制造的两个样品中的孔不会影响WVTR值。也就是说，两个对照样品的WVTR数据基本近似于根据本发明制造的对应样品。
特别地，对照SMS层压材料样品的WVTR平均值为3954克/m2-24小时，而有孔SMS层压材料样品的WVTR平均值为3552克/m2-24小时。此外，在去除SMS非织造材料和胶粘剂的对照样品中的膜的WVTR平均值为4021克/m2-24小时；而在去除SMS非织造材料和胶粘剂的有孔样品中的膜的WVTR平均值为4024克/m2-24小时。
对照SB层压材料样品的WVTR平均值为3580克/m2-24小时，而有孔SB层压材料样品的WVTR平均值为3795克/m2-24小时。此外，在去除SB非织造材料和胶粘剂的对照样品中的膜的WVTR平均值为3814克/m2-24小时；而在去除SB非织造材料和胶粘剂的有孔样品中的膜的WVTR平均值为3873克/m2-24小时。
对于所有四个样品来说相同的膜的WVTR平均值为3797克/m2-24小时。
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在一个尤其合适的实施例中，本文公开的外覆层32的由WVTR测试法测定的透气性为约1,500克/m2-24小时至约10,000克/m2-24小时。在一个优选的实施例中，外覆层的由WVTR测试法测定的透气性为约2,500克/m2-24小时至约7,000克/m2-24小时。在另一个优选的实施例中，外覆层的由WVTR测试法测定的透气性为约3,500克/m2-24小时至约5,000克/m2-24小时。在一个特别优选的实施例中，外覆层的由WVTR测试法测定的透气性为约4,000克/m2-24小时。
非织造材料和膜之间的间隙距离
在外覆层(OC)样品中的层压非织造材料和膜之间的间隙距离采用本文描述的图像分析测量方法(宽泛地，“间隙距离程序”)测定。图像分析方法采用层之间的间隔或间隙的特定图像分析测量法测定外覆层的两最外层之间的数字距离尺寸值。层间隙方法采用传统的光学图像分析技术实施以检测外最外面的非织造材料层和相邻的膜层部件两者的截面层区域，随后在使用具有低入射角照射的照相机观察时测量这两者之间的平均直线距离值。得到的测量数据用来比较不同类型的外覆层结构的间隙距离特性。
在进行图像分析测量之前，相关样品如此制备，以允许包括所有外覆层部件的代表性截面可视化。外覆层样品件使用剪刀由尿布产品裁切出尺寸为大约1英寸×1英寸的四件。理想地，每件应当从各单独的尿布产品裁切下。所述样品件的截面切割平行于机器方向沿着直边缘(例如直尺)进行，在切割过程中所述直边缘还向下固定代表性的样品件。截面切割使用一种新的、先前从未使用过的单刃碳钢蓝刀片(PAL)在机器方向上沿直边缘并切透外覆层样品件地进行。这类用于截面切割的刀片可以从位于宾夕法尼亚州的Hatfield的Electron Microscopy Sciences公司获得(Cat.#71974)。一种新的先前未使用过的刀片用于每个新截面的切制。切制好的截面随后装配成使用安装在体视显微镜上的视频照相机观察到。将由照相机观察到的装配台自身和样品后的任何背景分别使用非反射性黑胶带和黑色建筑用纸暗化。四个单独的截面分别切制和装配，由此从每个截面测定大约两个层间隙值。外覆层的最内层与样品装配台接触，使得要测量的层间隙背离样品装配台表面。胶粘体例如透明的双面胶带用来将样品件轻柔地附接到装配台。
莱卡微系统公司的M205体显微镜系统用来获取外覆层的截面图像和外覆层的任何层间隙。该系统使用Leica Application Suite软件(版本4.3.0)进行控制。体视显微镜的放大率设置为25.0X。数码照相机为莱卡微系统公司的DFC 450C型号的照相机，其曝光时间设置为80毫秒，伽马值设置成1.0并在单色模式下操作。装配好的截面的照明使用LEDMCI模式进行，其中三个LED(发光二极管)中每个LED中的三个灯中上面两个通电。两个外侧LED单元布置在可能的最外位置。在对样品成像之前，留下阴影的光学器件使用LeicaApplication Suite软件中提供的工具进行校正。空白的、白色的稍微散焦的背景用来形成阴影校正图像。
使切制出截面的样品层曝光的暗化样品装配台放置在体视显微镜的光轴之下。样品装配台定向成使样品截面沿着所生成图像的水平方向延伸，其中相关的最外两层位于水平延伸的截面的底部，如图像中所示。所述截面使用先前描述的LED MCI形式的灯光进行照射。LED灯的照明度使用Leica Application Suite软件进行控制并调节成使图像的灰度直方图大致位于所显示区域的中间，并且不具有任何过曝区域。在焦点被正确地调节成使所述层的截面边缘的清晰度最优化后，获取图像。随后使用对应于每个样品编号的、后面跟着所获取图像的重复数字(即1-8)的唯一图像前缀名保存图像。针对每个样品件的截面获取和保存两幅图像。
用来执行测量的图像分析软件平台为购自在瑞士Heerbrugg设有办事处的莱卡微系统公司QWIN Pro(版本3.5.1)。系统和图像使用从Leica Application Suite体视显微镜系统获得值进行校准。使用微米/像素为单位用于QWIN Pro软件中的校正。
图像分析算法使用定量电视显微镜用户交互程序设计系统(QUIPS)语言来处理图像和执行测量。图像分析算法复制如下：
QUIPS算法使用QWIN Pro软件平台执行。最初提示分析人员输入样品识别信息，该样品识别信息被发送到指定的EXCEL文件，测量数据也随后发送该指定的EXCEL文件。
随后提示分析人员输入在先前描述的图像获取步骤中使用的图像文件前缀名。
算法读入第一图像并且提示分析人员最优化检测阈值，从而检测相关的层。为了有助于这种最优化过程，分析人员可来同时按键盘上的“control”键和“B”键，以打开和关闭叠加的二进制图像来评估调整过的二进制图像与以截面中示出的样品层的边缘界限有多密切吻合。
接下来提示分析人员使用计算机鼠标和二进制编辑模式窗口中的编辑工具来确保相关层被选择横跨整个测量框宽度。初始编辑模式设置成“accept(接受)”，使得分析人员尽可能好地从已经检测到的二进制图像选取非织造和聚合物膜层。当使用鼠标选定时，选定区域在显示屏上以绿色示出。如果较早的检测步骤被很好地最优化，则这是容易且简单的。如果没有这样的话，分析人员需要使用“Draw(绘图)”功能来完成没有完全检测到的层区域。当完成时，覆盖相关层边缘的绿色二进制图像从内部测量框的左边界到右边界是连续的。在这些情况下，存在这样的区域，其中两层聚集在一起形成单层。如果在编辑过程中出现错误，分析人员可通过单击位于二进制编辑窗口的“Undo(还原)”按钮来简单地恢复初始检测的二进制图像，并且再次开始选择过程，直至完成了精确且最优的层选定。
在最优化层检测和选定后，算法则自动执行另外的图像处理步骤和随后的测量。数据被传输到指定的EXCEL电子数据表文件中。在EXCEL文件中，显示样品信息、图像重复数量和间隙距离数据。
然后，再次提示分析人员在另七幅图像上重复检测优化和层选定，直至所有已经分析所有八幅图像并将数据传输到EXCE文件。
QUIPS算法对单个样品提供八个重复层间隙测量值，从而使每个样品产生八个值。最终样品平均离散值通常基于从八个单独的子样品测量值的N＝8分析。不同样品之间的比较使用学生T分布(Student’s T)分析在90％置信水平下进行(图13)。
所述四个样品中的每一个样品的截面通过刀片割口和光学显微术在MD中获得。图9是SMS层压材料对照样品中获取的截面的照片和图10是从有孔SMS层压材料样品中获取的截面的照片。
所有四个截面的分析表明有孔样品比对照样品具有明显大的间隙。更特别地，有孔SMS层压材料的平均间隙为345μm，而对照SMS层压材料的平均间隙为115μm。有孔SB层压材料的平均间隙为259μm，而对照SB层压材料的平均间隙为120μm。
表2-非织造材料和膜之间的间隙距离
样品编号 层间隙(um) 标准偏差
12gsm SMS无孔 115.1 109.7
12gsm SMS有孔 345.0 100.2
15gsm SB无孔 120.2 38.5
15gsmSB有孔 259.1 108.5
进行学生T分布比较(90％置信度)以确定平均值之间的差异是否明显。在图13中给出了结果。如本文所示，置信度极限范围的分开证实相应的平均值在特定基重下彼此不同。
在一个尤其合适的实施例中，本文公开的外覆层32的非织造部件34和膜38之间的间隙使用本文公开的测试程序测定为约200μm至约600μm。在一个优选的实施例中，外覆层32的非织造部件34和膜38之间的间隙为约250μm至约350μm。
胶粘剂分析
对于四个样品中的每一个样品来说，手动将非织造纤网与膜分开。对于每个样品来说，非织造纤网和膜用四氧化锇染色并允许搁置一整晚。用来将非织造纤网接合到膜的胶粘剂变得可见并且明显呈现胶基本粘附到膜。图11示出了设置在从对照SMS层压材料取的膜的絮状胶粘剂的照片。图12是示出了设置在从有孔SMS层压材料取的膜上的絮状胶粘剂的照片。照片中的较暗区域对应于用来将非织造纤网和膜粘合在一起的胶粘剂。较亮的灰色区域对应于布置在膜的相反侧上的胶粘剂(即膜的远离非织造纤网的一侧)。
如预先考虑的，在所有四个样品胶粘剂看起来类似。如下面的表中给出的，覆盖面积百分比在3.7％到4.7％的范围内，并且胶纤维的宽度在53.4μm到59.4μm的范围内。数据看起来与目视观察的结果一致，这表明在用在对照样品和有孔样品中的胶粘剂存在差异的很小。在图14中给出的学生T分布分析适用于覆盖面积百分比。
表3-胶粘剂分析总结
等效圆直径(ECD)，开孔面积百分比和开孔区域之间的间隔
12gsm SMS有孔非织造材料和15gsm SB有孔非织造材料的孔尺寸(等效圆直径(ECD))、覆盖面积百分比(％)和孔间间距使用本文描述的图像分析测量方法测定。图像分析测量方法采用单位图像分析测量值来确定孔特性的尺寸数值。该方法使用传统的光学图像分析技术执行以检测相应的非织造材料中的孔并随后当使用相机利用透射光照明观察时测量平均孔尺寸、覆盖面积％和间隙值。
在执行图像分析测量之前，如此准备每个样品，以允许仅有孔非织造层的代表性区域隔离和可视化。特别地，外覆层样品件是使用剪刀从尿布裁切出尺寸为大约3英寸×3英寸的四片。理想地，每一件应当从各单独的尿布产品裁切。在从产品移除时，非织造有孔层与外覆层的其它层(膜)分开。这通过使用有机溶剂诸如己烷或氯仿，并将胶粘接合层使用镊子轻轻剥离分开来完成。
用于获取有孔非织造层的图像的设备包括莱卡微系统公司的DFC 310照相机(曝光时间28.2微秒，伽马值＝1)，在单色模式下操作；和配备有10mm伸缩管的40-mm El-Nikkor镜头(F-制光圈＝4)。镜头和伸缩管通过标准C-座接头附接到照相机。样品层的透射光照明使用ChromaPro 45(由位于亚利桑那州的滕比的Circle S公司制造)执行。现有的自动样品台(型号H112)用来放置样品并在分析过程中通过经编程的运动扫描。宝丽来MP4照相机架用来将照相机和透镜附接到现有的自动样品台用于成像。ChromaPro 45布置在现有的自动样品台下面。
用来执行测量的图像分析软件平台是购自在瑞士Heerbrugg设有办事处的莱卡微系统公司的QWIN Pro(版本3.5.1)。系统和图像使用具有公制刻度的尺子进行校准。单位微米/像素被用于在QWIN Pro软件中的校准。阴影校正使用通过Chroma Pro 45照明的空白视场执行。
图像分析算法用来处理图像以及使用电视显微镜用户交互程序设计系统(QUIPS)语言来执行。该图像分析算法复制如下：
QUIPS算法使用QWIN Pro软件平台执行。最初提示分析人员输入样品识别信息，该样品识别信息被发送到指定的EXCEL文件，测量数据也随后发送该指定的EXCEL文件。随后提示分析人员输入图像文件前缀名，该图像文件前缀名用来将正被分析的图像储存到计算机硬盘驱动器。
在将样品放置在现有的自动样品台上并确保其摊平而没有明显的折皱，最优化焦点和将白光照明等级设置到约0.95后，算法获取图像。随后提示分析人员将与孔不关联的任何检测区域移除。在二进制编辑模式下使用计算机鼠标，分析人员圈出那些不涉及孔的检测区域。当选定时，被移除区域的颜色从绿色转为金色。为了有助于这种最优化过程，分析人员可同时按下键盘上的“control”键和“B”键，以打开和关闭叠加的二进制图像来评估调整过的二进制图像与在图像中示出的孔的边缘界限有多密切吻合。一旦完成优化，仅所述孔显示有二进制绿色覆盖它们的上面。如果在编辑过程中出现错误，分析人员可通过单击位于二进制编辑窗口的“Undo(还原)”按钮来简单地恢复初始检测的二进制图像，并且再次开始选定过程，直至完成了精确且最优的孔选定。
在检测和选定孔的最优化之后，算法则自动执行测量。数据以直方图格式存储，直至算法已经获取和分析所有图像。
算法随后将样品自动移动到下一视场，并且重复图像获取和处理步骤。在图像分析算法一次运行过程中，针对每个样品总共分析16幅图像。当已经完成获取和分析所有16幅图像时，算法将直方图数据传送到EXCEL电子数据表。
QUIPS算法在EXCEL电子数据表中提供代表单个样品的等效圆直径(ECD)尺寸，覆盖面积％和间隙测量值的三个直方图。每个直方图具有基本统计数据，诸如平均值和标准偏差等等。
如下面在表4中提供的，12gsm有孔SMS的平均ECD为约1mm。15gsm有孔SB的平均ECD为约0.7mm。12gsm有孔SMS和15gsm有孔SB两者的平均间距超过1mm。12gsm有孔SMS的开孔面积百分比为约13％，15gsm有孔SB的开孔面积百分比为约7％。
表4-ECD尺寸，覆盖面积％和间隙测量值总结
在一个尤其合适的实施例中，本文公开的非织造部件34的开孔面积百分比位为约5％至约30％。更合适地，非织造部件34的开孔面积百分比为约8％至约20％，并且，在一个更优选的实施例中，开孔面积百分比为约10％至约18％。如上面描述的，在一个合适的实施例中，孔70大致为圆形并且具有约0.5mm至约4mm的直径(或ERD)。如上面描述的，在一个合适的实施例中，每个所述孔70与相邻孔间隔开约0.5mm至约6mm的距离。
剥离强度
对四个样品中的每一个进行测试以测量非织造纤网和膜层之间的附接强度。每个层压材料的非织造纤网和膜之间的接合效果通过测量将该样品分层所需的力来确定。在本文中，“剥离强度”意指将接合织物以180°角分开超过50.8mm(2英寸)的距离所需的用克力表示的平均值。
每个样品通过将样品裁切成101.6±1.3mm(4±0.05英寸)宽和152.4±1.3mm(6±0.05英寸)长的试样，该试样的长度方向平行于测试和力施加的机器方向。宽度为101.6mm(4英寸)的一连续不透光胶带被施加到每个样品的膜侧。胶带用手确定是平滑的以确保均匀地附接到膜。在测试中使用的不透光胶带以产品编号#2307商购自美国明尼苏达州圣保罗的3M公司。
试样随后通过合适试样机的夹持件夹住，确保试样是直的且不松弛的。更特别的，非织造纤网的自由端被放置在移动的夹持件中和膜的自由端被放置在静止不动的夹持件中。一旦非织造纤网和膜通过相应的夹持件正确地固定，则进行该测试、测试参数在下表5中给出。
表5-测试参数
对照SMS层压材料的平均剥离强度为32.0克-力每英寸(gf/in)，而有孔SMS层压材料的平均剥离强度为28.5gf/in。对照SB层压材料的平均剥离强度为约25.75gf/in，而有孔SB层压材料的平均剥离强度为约26.75gf/in(参见表6)。因此，对非织造纤网开孔看起来不会对剥离强度产生较大的影响。
表6-剥离强度总结
样品 平均载荷(gf/in)
15gsm无孔SB 25.75
15gsm有孔SB 26.75
12gsm无孔SMS 32.0
12gsm有孔SMS 28.5
————————————
在一个尤其合适的实施例中，本文公开的外覆层32的剥离强度，更具体地说是非织造部件34和膜38之间的剥离强度合适地为约本文公开的试验程序测定的约25gf/in至约35gf/in。
川端(Kawabata)热传导系数
适合用于外覆层的多种非织造材料的热传导系数使用川端(Kawabata)评价系统(KES)和特别地KES–Thermolabo的热测试仪对多个样品评估得出。在下表中给出了每个样品的描述。
表7-样品描述
KES的Thermolabo测试仪用来测量材料的热和湿气传输特性。Thermolabo测试仪的关键部件是10cm×10cm和5cm×5cm的两块热板。当不存在对流热损失时，使用5cm×5cm的较小热板来测量材料的热传导系数。当样品夹在维持在35℃的较小热板和维持在20℃的测试表面之间时，测量较小热板的以瓦计的热损失。测量结果用W/m2℃标示。较高的热传导系数值表示较高的热传导性。
干燥非织造材料的热传导系数值使用KES的Thermolabo测试仪测得。非织造材料的传导特性是不同的。如表8所见，五组数据以下列顺序产生：样品2(无孔12gsm SMS)>>样品4(无孔15gsm SB)>>样品1(有孔12gsm SMS)>样品6(中国有孔15gsm SB)>>样品3(Taejeon有孔15gsm SB)>>样品5(有孔15gsm SB)>样品7(有孔13gsm SMS)。清楚地看出趋势是无孔非织造材料比有孔非织造材料具有较高的热传导能力。据信有孔面料中的孔提供良好的热绝缘。
表8-传导系数测试结果
等级 传导系数W/m<sup>2</sup>℃
样品#2 A 158.9
样品#4 B 132.7
样品#1 C 92.9
样品#6 C D 85.5
样品#3 D E 78.2
样品#5 E 73.4
样品#7 E 70.3
不通过相同字母关联的等级是明显不同的。
—————————————
在一个合适的实施例中，本文公开的外覆层32的非织造部件34的传导系数使用本文公开的试验程序确定为约70W/m2℃到约100W/m2℃。在一个优选实施例中，非织造部件34的传导系数使用本文公开的试验程序确定为约80W/m2℃到约90W/m2℃。
川端压缩应变
在表7中列出的非织造材料的压缩应变(EMC)使用KES测得并且结果在表9中列出。如在下面的等式中给出的，压缩比测量在两压力等级，即0.5gf/cm2和50gf/cm2之间的厚度变化百分比。EMC的较高值表示样品具有较高的可压缩性和减震性。
EMC＝(T0-Tm)/T0X100
其中：
T＝试样厚度,cm
T0＝在0.5gf/cm2压力下的试样厚度,cm
Tm＝在50gf/cm2压力下的试样厚度,cm
表9-EMC测试结果
等级 EMC
样品#3 A 78.5
样品#5 A 75.8
样品#1 A 75.4
样品#7 A B 74.6
样品#6 B 69.3
样品#2 C 50.9
样品#4 C 46.7
不通过相同字母关联的等级是明显不同的。
—————————————
在一个合适的实施例中，本文公开的外覆层32的非织造部件34的EMC值使用本文公开的试验程序确定为约60至约90。在一个优选实施例中，非织造部件34的EMC值使用本文公开的试验程序确定为约70至约80。
在介绍本发明的元件或者其优选实施例时，用语“一个”、“该”和“所述”是旨在表示存在一个或多个所述元件。术语“包括”、“包含”和“具有”是旨在表示开放式的，旨在表示可以有除所列元件之外的其它元件。
因为可以在不超出本发明范围的情况下在上述构造中做出各种不同的改变，所以包含在以上说明书中的或如附图所示的所有内容本该被解释为示范性的，而没有限制意味。
本文的描述使用例子来公开本发明，包括最佳模式，并且还能够使任何本领域技术人员实施本发明，包括制造和使用任何装置或系统并执行任何相结合的方法。本发明的专利权范围由权利要求来限定，并且可包括本领域技术人员可以想到的其它例子。如果这些例子并不具有不同于权利要求的文字预先的结构元件，或者它们包括与权利要求的文字语言具有非实质性区别的等同结构元件，则这类其它例子仍在权利要求的范围内。

Claims (17)

1.一种用于吸收性物品的外覆层，该外覆层包括具有在其中形成的多个孔的纤维性非织造部件和接合到有孔的该非织造部件的透气膜，在所述非织造部件中的所述孔在该透气膜被接合到该非织造部件之前通过针刺形成，使得非织造部件在靠近所述孔的位置被接合到所述透气膜上，形成延伸远离所述透气膜的多个穹顶区域，使得在所述非织造部件和所述透气膜之间形成气隙，并且所述孔的截面为锥形，其中所述孔具有位于所述透气膜附近的最小宽度和位于所述非织造部件的外侧延伸部分附近的最大宽度，所述透气膜没有多个孔，所述非织造部件的传导系数在70W/m2℃至100W/m2℃之间，在所述非织造部件和所述透气膜之间的间隙在200μm至400μm之间。
2.如权利要求1所述的外覆层，其中，所述透气膜被胶粘接合到所述有孔的非织造部件。
3.如权利要求1所述的外覆层，其中，所述多个孔中的至少一些孔具有在0.5mm到4.0mm之间的最小宽度。
4.如权利要求3所述的外覆层，其中，所述非织造部件中的所述孔为圆形并且所述最小宽度由圆形孔的直径限定。
5.如权利要求1所述的外覆层，其中，所述多个孔中的每个孔与相邻的孔间隔开在0.5mm至6mm之间的距离。
6.如权利要求1所述的外覆层，其中，所述多个孔限定出9孔/平方厘米至36孔/平方厘米的孔密度。
7.如权利要求6所述的外覆层，其中，所述多个孔限定出18孔/平方厘米的孔密度。
8.一种用于吸收性物品的外覆层，该外覆层包括限定出在其中形成的多个孔的纤维性非织造部件和被胶粘接合到有孔的该非织造部件的透气膜，在所述非织造部件中的所述孔在该透气膜被接合到该非织造部件之前通过针刺形成，该非织造部件限定出延伸远离所述透气膜的多个穹顶区域，使得在所述非织造部件和所述透气膜之间形成气隙，所述非织造部件在靠近所述孔的位置被胶粘接合到所述透气膜，并且所述孔的截面为锥形，其中所述孔具有位于所述透气膜附近的最小宽度和位于所述非织造部件的外侧延伸部分附近的最大宽度，所述非织造部件的传导系数在70W/m2℃至100W/m2℃之间，在所述非织造部件和所述透气膜之间的间隙在200μm至400μm之间，该外覆层具有由水蒸汽透过率(WVTR)测试程序试验程序测定的1500克/m2-24小时至10000克/m2-24小时的透气性。
9.如权利要求8所述的外覆层，其中，该外覆层具有由水蒸汽透过率(WVTR)试验程序测定的3000克/m2-24小时至5000克/m2-24小时的透气性。
10.如权利要求9所述的外覆层，其中，该外覆层具有由水蒸汽透过率(WVTR)试验程序测定的4000克/m2-24小时的透气性。
11.如权利要求8所述的外覆层，其中，所述非织造部件的压缩应变(EMC)值在60至90之间。
12.如权利要求11所述的外覆层，其中，所述非织造部件的压缩应变(EMC)值在70至80之间。
13.如权利要求8所述的外覆层，其中，所述多个孔中的至少一些孔对用户来说是容易看见的。
14.一种制造用于吸收性物品的外覆层的方法，该方法包括：
将非织造材料纤网输送到针刺站；
在该针刺站对该非织造材料纤网进行针刺，以在其中形成多个孔来限定出有孔的非织造材料纤网，所述孔的截面为锥形；
将所述有孔的非织造材料纤网胶粘接合到透气膜，使得非织造材料在靠近所述孔的位置被接合到所述透气膜上，形成延伸远离所述透气膜的多个穹顶区域，使得在所述非织造材料和所述透气膜之间形成气隙，
其中所述孔具有位于所述透气膜附近的最小宽度和位于所述非织造部件的外侧延伸部分附近的最大宽度，所述透气膜没有多个孔，所述非织造部件的传导系数在70W/m2℃至100W/m2℃之间，在所述非织造部件和所述透气膜之间的间隙在200μm至400μm之间。
15.如权利要求14所述的方法，其中，将非织造材料纤网输送到针刺站包括输送连续的非制造材料纤网。
16.如权利要求14所述的方法，其中，将所述有孔的非织造材料纤网胶粘接合到透气膜包括：
将所述透气膜输送到胶粘剂站；
在胶粘剂站将絮状胶粘剂施加到所述透气膜；和
将所述非织造材料纤网和所述透气膜以面对面的关系连接成使得所述絮状胶粘剂将该非织造材料纤网胶粘接合到所述透气膜。
17.如权利要求14所述的方法，其中，对所述非织造材料纤网进行针刺以在其中形成多个孔包括驱动多个锥形针进入该非织造材料纤网。
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