CN105229212A - 具有增强的滑移柔软性和良好强度属性的非织造纤维网材料及制造方法 - Google Patents
具有增强的滑移柔软性和良好强度属性的非织造纤维网材料及制造方法 Download PDFInfo
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- CN105229212A CN105229212A CN201480029373.XA CN201480029373A CN105229212A CN 105229212 A CN105229212 A CN 105229212A CN 201480029373 A CN201480029373 A CN 201480029373A CN 105229212 A CN105229212 A CN 105229212A
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Abstract
本发明公开了由第一外纤维积累物、第二外纤维积累物和内纤维积累物形成的非织造纤维网材料。这些外纤维积累物可形成相应的第一宏观外纤维网表面和第二宏观外纤维网表面。这些纤维网可载有压印在第一宏观表面和第二宏观表面中任一者或两者上的热粘结图案，在所述热粘结图案处，第一积累物的纤维热粘结到第二积累物的纤维。内积累物的纤维可交织在第一积累物和/或第二积累物的纤维中并呈现于第一宏观外纤维网表面和/或第二宏观外纤维网表面处。本发明也公开了用于制造非织造纤维网材料的相关方法。
Description
背景技术
制造和营销用于个人护理或卫生的一次性吸收制品(诸如一次性尿布、训练裤、成人失禁内衣、女性卫生制品、胸垫、护理垫、围兜、伤口敷料制品等)的行业资本相对密集且竞争极为激烈。为了保持或提升他们的市场份额并从而保持成功的商业运作，此类制品的制造商们必须以某些方式不断地努力提高他们的产品，所述方式用于将他们的产品与其竞争者的产品区分开来，同时控制成本，以便能够进行竞争性定价并且向市场提供有吸引力的价值-价格主张。
一些制造商可能寻求加强这样的产品的一种方式是通过增强柔软性。父母们和护理者们自然会争取尽他们所能为其婴儿提供尽可能多的舒适性，并且利用被他们视为相对柔软的产品诸如一次性尿布而使他们确信他们正在尽力提供这方面的舒适性。相对于其他类型的被设计成贴近皮肤穿用和/或穿着的一次性吸收制品，柔软性外观能够使穿着者或护理者确信该制品将具有舒适性。
因此，制造商们可致力于增强用来制备此类制品的各种部件诸如各种纤维网材料的柔软性，所述纤维网材料包括由形成这些制品的聚合物纤维和它们的层合体形成的非织造网材料。此类层合体可包括例如形成这些制品的底片部件的聚合物膜和非织造纤维网材料的层合体。
据信人类对非织造纤维网材料柔软性的感知可受到触觉信号、听觉信号和视觉信号的影响。
触觉柔软性信号可受到多种材料的特征和性质的影响，所述特征和性质对其触感具有影响，包括但不限于蓬松度、纤维形状、厚度和密度、基重、单根纤维的微观柔顺性和柔韧性、由所述纤维形成的非织造纤维网的宏观柔顺性和柔韧性、表面摩擦特性、松散纤维或游离纤维端部的数目、以及其他特征。
在通常用于制造旨在用作吸收制品部件的非织造纤维网材料的材料中，聚丙烯和聚乙烯树脂占主要地位，原因是成本较低、可用性好、并且易于加工，即易于进行纤维纺丝。在由这两种类型的聚合物形成的相等尺寸的纤维之间，聚丙烯纤维趋于具有相对较大的机械强度和刚度，并趋于表现出相对较高的与皮肤的摩擦系数(即，趋于具有较小的滑移感)。相比之下，聚乙烯纤维趋于具有相对较小的机械强度和刚度(即，更具柔顺性)，并趋于表现出相对较低的与皮肤的摩擦系数(即，具有较大的滑移感)。另外，由于相对较低的纤维和粘结强度，由聚乙烯形成的纤维还趋于赋予非织造纤维网相对较大程度的可见且可触觉感知的“绒毛”。
当这些纤维用来以形成非织造纤维网时，它们将赋予所述纤维网这些属性。因此，在形成非织造纤维网材料的过程中，已作出过各种尝试来赋予聚丙烯组分和聚乙烯组分的所期望的特性，同时补偿各自的缺点。一般来讲，所述非织造纤维网材料的机械强度是所期望的，以用于在制品的制造中保持加工时的尺寸稳定性，并向所述纤维网材料在其中作为部件的制品赋予结构强度。柔顺性和较低摩擦系数可为所期望的，以用于产生柔顺和丝绸般感觉、以及良好的悬垂性，从而有助于感知触觉柔软性。
另一个影响可使用的每种聚合物类型的相对比例的因素是成本。据信，从历史上看，与由聚丙烯树脂的制成的纤维相比，包含聚乙烯树脂的纤维的制备费用趋于更昂贵。
虽然迄今为止以各种构型制造非织造纤维网材料以从这些材料和其它材料找到所期望的属性的平衡的尝试已取得了一些成功，但总是存在改进的空间。
附图说明
图1为非织造纤维网材料的一部分的示意性剖视图；
图2a为示意性侧正视图，示出了用于制造非织造纤维网的工艺中的设备和部件。
图2b为示意性侧正视图，示出了用于对非织造纤维网进行水射流加工的工艺中的设备和部件。
图3为一次性尿布的透视图，所述尿布被示出为水平展开的，处于松弛状态，面向穿着者的表面向上；
图4为一次性尿布的平面图，所述尿布被示出为水平展开的，处于拉伸的平坦状态(抵抗由所存在的弹性构件引起的弹性收缩而被拉伸)，面向穿着者的表面面对观察者；
图5为图3和4所示尿布的横截面，是沿那些图中的线2-2截取的；并且
图6为沿粘结压痕路径截取的聚合物膜和非织造纤维网的层合体的一部分的示意性横截面。
具体实施方式
定义
“吸收制品”是指吸收和容纳身体流出物的装置，并且更具体地是指紧贴或邻近穿着者的身体放置以吸收和容纳从身体排出的各种流出物的装置。吸收制品可包括尿布、训练裤、成人失禁内衣和衬垫、妇女卫生产品、胸垫、护理垫、围兜、伤口敷料产品等。如本文所用，术语“流出物”包括但不限于尿液、血液、阴道分泌物、乳汁、汗液和粪便。
“吸收芯”是指如下结构体：该结构体通常设置在吸收制品的顶片和底片之间，以用于吸收和容纳由吸收制品接收的液体。吸收芯也可包括覆盖层或包层。覆盖件层或包层可包括非织造物。在一些示例中，吸收芯可包括一个或多个基底、吸收性聚合物材料、和将吸收性聚合物材料粘附和固定到基底的热塑性粘合剂材料/组合物、以及任选地覆盖件层或包层。
“双组分”是指具有横截面的纤维，所述横截面包含两种离散的聚合物组分、两种离散的聚合物组分的共混物、或一种离散的聚合物组分和一种离散的聚合物组分的共混物。“双组分纤维”涵盖在术语“多组分纤维”中。双组分纤维可具有总体横截面，所述总体横截面被分成具有所述不同组分的任何形状或排列的两个或更多个子截面，包括例如同轴子截面、芯-皮型子截面、并列型子截面、径向子截面等。
“膜”–是指由一种或多种聚合物形成的表皮样或隔膜样材料层，其不具有主要由固结的聚合物纤维和/或其它纤维的网状结构组成的形式。
关于由聚合物材料形成的两种结构的“类似的化学性质”，是指所述两种结构的相应的聚合物材料能够在300℃或更低的温度下混合在一起，从而形成作为单一热力学相起作用的混合物。
“单组分”是指由单一聚合物组分或聚合物组分的单一共混物形成的纤维，如与双组分或多组分纤维相区别。
“多组分”是指具有横截面的纤维，所述横截面包括多于一种的离散的聚合物组分、多于一种的聚合物组分的离散的共混物、或至少一种离散的聚合物组分和至少一种聚合物组分的离散的共混物。“多组分纤维”包括但不限于“双组分纤维”。多组分纤维可具有总体横截面，所述总体横截面被分成具有所述不同组分的任何形状或排列的子截面，包括例如同轴子截面、芯-皮型子截面、并列型子截面、径向子截面等。
“非织造物”或“非织造纤维网”为一种制造的定向或无规取向纤维的片或网，所述纤维通过摩擦、内聚、粘附或一个或多个粘结图案和粘结压痕固结和粘结在一起，所述粘结图案和粘结压痕通过局部压缩和/或施加热或热能或它们的组合来产生。该术语不包括用纱线或长丝机织、针织或缝编的织物。这些纤维可具有天然来源或人造来源，并且可为短纤维或连续长丝或原位形成的纤维。可商购获得的纤维的直径范围为小于约0.001mm至大于约0.2mm，并且它们具有几种不同的形式：短纤维(称作短纱或短切纤维)、连续单纤维(长丝或单丝)、无捻连续长丝束(丝束)和加捻连续长丝束(纱)。所述纤维在横截面(其可为基本上圆形或非圆形的)中的尺寸也可用旦尼尔来表示，并且其范围为0.001旦尼尔至400旦尼尔，或更典型地0.001旦尼尔至10旦尼尔。非织造织物能够通过许多工艺形成，诸如熔喷、纺粘、溶剂纺丝、静电纺丝、和梳理、以及使用热方法、化学方法和机械方法进行的粘结(例如，压延、水刺、和通风粘结)。非织造织物的基重通常用克/平方米(gsm)表示。
具体实施方式
如背景技术中所述，一般来讲，聚乙烯纤维趋于比聚丙烯纤维具有更滑溜的触感。它们也趋于更为柔顺，并具有较小的机械(拉伸)强度。因此，可能期望形成具有如下表面层的纤维网，所述表面层由聚乙烯纤维形成以赋予所述纤维网滑溜的丝绸般感觉。然而，这种层可能在摩擦穿着的情况下更易于磨损和起球(形成小的编结的纤维球或纤维卷)，所述摩擦穿着诸如在穿着期间可被例如一次性尿布的外覆盖件遇到。磨损和起球可能不可取地导致消费者感知到较差的品质、和所述材料的结构弱化。
参见图1，一种替代形式是以如下方式形成非织造纤维网，所述方式以使具有聚乙烯组分的纤维暴露于所述纤维网的表面处的接触部的方式使具有聚乙烯组分的纤维交织在其它组分中，而同时将它们包含/约束在所述纤维网内。因此，例如，非织造纤维网材料105可被成形为能够具有第一纤维110的第一外积累物。第一纤维110可由经选择以赋予所述纤维网所期望的属性诸如机械强度的一种或多种聚合物诸如聚丙烯形成。
所述纤维网也可具有第二纤维120的第二外积累物。第二纤维120也可由经选择以赋予所述纤维网所期望的属性诸如机械强度的一种或多种聚合物诸如聚丙烯形成。
相应的第一纤维和第二纤维110，120的第一积累物和第二外积累物可按这种方式设置而形成相应的第一和第二相对面向的宏观纤维网外表面112，122。
第三纤维130的内积累物可被包括，并在某种程度上可大致设置在第一积累物和第二外积累物之间。通过适当的加工诸如下述加工，出自内纤维积累物130的第三纤维可进一步交织在第一纤维和第二纤维中，并可从宏观纤维网表面112，122向外伸出。
第三纤维130可完全由聚乙烯形成，或者可包括聚乙烯组分，使得它们包括带有所期望的滑移感的聚乙烯表面。在一个示例中，第三纤维130可包括具有聚乙烯组分的双组分纤维。所述双组分纤维可具有任何合适的构型，聚乙烯组分通过所述构型呈现于所述纤维的外表面处或者形成所述外表面。例如，双组分纤维可具有并列型排列，其中聚乙烯形成所述纤维的外表面的一个纵向侧和纵向部分。在另一个示例中，双组分纤维可具有皮-芯型排列，其中聚乙烯围绕由第二组分形成的芯形成外皮。所述双组分纤维的第二组分可为聚丙烯，但也可为另一种聚合物或适当选择的聚合物的共混物。
非织造纤维网材料105可载有压印的热粘结图案140。所述粘结可通过使纤维毛絮穿过一对压延/粘结辊之间的辊隙来形成。所述辊至少之一可已在其圆柱形轧制表面上形成了粘结突出部和凹陷区域的图案，其中所述粘结突出部被成型并布置成能够在所述非织造纤维网材料中压印出带有所期望形状的所期望的热粘结图案。所述辊至少之一可被供应有热能，使得热将从所述辊传输至所述纤维，并且在所述毛絮穿过辊隙时致使它们熔融并至少部分地在所述粘结突出部下面熔合。
因此，在图1所示的示例中，相应的第一纤维110和第二纤维120可在粘结部位142处粘结/熔合在一起。如下情况可增强该效应：第一纤维110和第二纤维120具有类似的化学性质，使得它们趋于在熔融时熔合。因此，例如，如果第一纤维110和第二纤维120分别为相同或适宜地类似的聚丙烯配方，则可容易地实现此类热粘结。第三纤维130可由如下聚合物形成，所述聚合物所具有的熔点低于第一纤维和/或第二纤维的熔点，使得形成第三纤维的材料将在由粘结辊上的粘结突出部所施加的压力下容易地熔融并流到旁边，从而允许第一纤维和第二纤维在所选择的粘结温度和/或供应给粘结辊的热能程度下在粘结部位处接触并熔合。
可选择其它聚合物来实现类似的效应。第一纤维和第二纤维的主要聚合物组分可选自一般类别的聚丙烯，尤其是具有典型的纤维级熔流速率诸如范围为例如10至50g/10minMFR的全同立构聚丙烯。它们可为用Ziegler-Natta型催化剂产生的或由茂金属催化剂产生的全同立构PP，通常缩写为zn型或m型i-PP。第三纤维可包含具有与第一纤维或第二纤维相比相对较低软化点或熔点的聚合物组分，并且可选自聚乙烯、乙烯-丙烯共聚物，或者选自带有较低全同立构性的聚丙烯，诸如间同立构或有规立构程度较小的聚丙烯；它们均实现较低的软化点和熔点，同时在所述纤维表面上提供更滑溜的触觉特性。
这些组合物也可包括其它添加剂，比如抗氧化剂包、颜料和染料等。
适当地构造的热粘结图案140可用来使第一纤维110和第二纤维120形成粘结的纤维的外部网络，所述外部网络趋于包含并约束第三纤维130。同时，如下文所详述，可使第三纤维130交织在第一纤维110和第二纤维120中，并穿过由此形成的外宏观表面而伸出，从而被暴露出来以便赋予所述非织造纤维网材料滑溜的丝绸般触感。
图1也分别在由第一纤维110和第二纤维120形成的侧面上示出了纤维网的宏观第一表面和第二表面112和122的一个示例。所述纤维网和热粘结部位142存在如下侧面，所述侧面在一个侧面上为第一纤维110的一定程度地成层的积累物，并且在另一个侧面上为第二纤维120的一定程度地成层的积累物。粘结140可压印到第一宏观表面和第二宏观表面中任一者或两者中，在所述粘结处第一纤维热粘结到第二纤维。
第一纤维110和第二纤维120的成层积累物没有必要在以下方面为类似的或相同的：蓬松度或厚度、基重、纤维尺寸、纤维横截面形状、纤维纵向形状，纤维偏向或取向、或纤维材料成分。例如，相比于第一纤维110的积累物，第二纤维120的积累物可具有较大的密度或每单位面积或单位体积的纤维数目、不同尺寸的纤维、不同形状的纤维、不同成分的纤维等。然而，优选的是，第一纤维110和第二纤维120或至少它们的组分具有类似的化学性质，使得纤维110，120或它们的部分将容易地在粘结部位142处熔合并形成牢固的粘结。
图2a示意性地示出了设备构型和工艺的一个示例，通过所述设备构型和工艺可制备图1所示意性地示出的非织造纤维网材料。第一纤维110可例如以纺粘工艺在第一喷丝头箱体200处纺丝出来。在纺丝之后，可将第一纤维110朝移动带206引导并积累在其上，从而形成第一毛絮114。相似地，第三纤维130可在第三喷丝头箱体202处被纺丝出来，并可朝移动带引导，使得它们积累在第一毛絮之上以形成第一组合毛絮124。如上文所反映出的那样，第三纤维130可由如下材料形成，所述材料不同于为了不同的属性而选择的用来形成第一纤维110的材料。还如所述的那样，第三纤维130可为双组分或多组分纤维。接着，第二纤维120可在第二喷丝头箱体204处被纺丝出来，并可朝移动带引导，使得它们积累在第一组合毛絮124之上以形成第二组合毛絮134。期望第二纤维120或它们的积累物在一些方面不同于第一纤维110或它们的积累物，第二喷丝头箱体204可因此以不同方式构造、可使用附加喷丝头箱体等。还如上文所反映出的那样，第一纤维110和第二纤维120可由具有类似化学性质例如类似配方的聚丙烯的聚合物材料形成。可使用多个箱体200或202或204以分别形成多个成层纤维积累物110或120或130。在一个带有4纺丝出粘结箱体构型的示例中，第一组合毛絮可包括2个纤维层130和一个纤维层110。另选地，可使用2个箱体204以使第二纤维120的积累物产生与第一纤维110的积累物相比不同的基重、蓬松度和/或密度。
在纺丝之后，第二组合毛絮134可被传送到一对压延/粘结辊208，210之间的辊隙中。辊208，210中的一者或两者可被供应有热能，以便被传输至辊隙中的纤维。辊208，210中的一者或两者可已在其圆柱形轧制表面上形成了成型的粘结突出部和凹陷区域的图案，使得具有类似形状的类似的粘结图案被压印在第二组合毛絮134上(当其穿过辊隙时)。可在足以使第一纤维和第二纤维110，120熔融和熔合的程度上供应热能。因此，承载有粘结140的固结且粘结的纤维网150退出辊隙。
接着，粘结的纤维网150可被传送经过一个或多个射流排214，它们将水射流216对准所述纤维网。(该工艺的变体被称为例如“水射流处理”、“水针刺”、“水强化”、“水刺”和“水充”。示例描述于美国专利6,632,385；6,803,103；7,858,544；和RE40,362，以及美国专利申请公布2012/0179126中。)随着所述纤维网被传送经过射流，其可由合适的带212承载并支撑，所述带由可透过的网片形成。当水射流216冲击粘结的纤维网150的纤维时，它们能够移位并挑开所述纤维，从而使第三纤维130交织在第一纤维110和第二纤维120中。利用射流214的合适的构型和水压，第三纤维130可被推压在第一纤维110和/或第二纤维120之间和/或它们中，并向外推压至它们呈现于由第一纤维110和第二纤维120形成的宏观纤维网表面112，122处的程度。在图2a所提出的构型中，第三纤维130将在所述纤维网内被射流214移位以便交织在第一纤维110的积累物的纤维之间和它们中，并相对于所述图呈现于所述纤维网的下侧上的宏观表面处，从而提供面对带212的感觉柔软的侧面。在一个优选的示例中，载有粘结部位142和未粘结区域之间的所述更明显的深度对比的所述纤维网150的宏观表面(例如，在图1中，宏观表面112)将为背向所述水射流的表面，使得所述水射流朝具有更明显的表面特征的表面移位内部感觉更柔软的纤维，从而在一个侧面上引起更具视觉冲击力且感觉柔软的表面，并且在另一侧面上引起相对光滑平坦和/或较少特征化的表面，更适用于粘附到另一种纤维网材料以形成纤维网层合体。为了实现该效应，在图2a所示的示例性构型中，辊210可为载有所述粘结图案的特征结构的刻花的/机加工的辊，而辊208可为表面光滑的(砧)辊。
然而，在另一个替代形式中，纤维网150可暴露于对这两个侧面进行的水射流加工，从而朝这两个宏观表面移位第三纤维130中的一些。如图2b中所提出的那样，射流214、可透过的网片带和/或可透过的表面转筒300等的构型可被布置成使得所述粘结的纤维网受到出自这两个侧面的射流的冲击，从而朝所述纤维网的这两个宏观外表面推挤第三纤维130。
这种水射流加工步骤可用来移位所述纤维网内的第三纤维130，使得它们有利地交织在第一纤维110和/或第二纤维120之间和/或它们中，延伸穿过它们的层，并且呈现于且暴露于第一宏观表面和/或第二宏观表面112，122处的接触部，成为如图1所提出的粘结的且水射流加工的非织造纤维网材料。
在另一种替代形式中，非水的流体射流可指向纤维网150以移位其内的纤维并驱动所述纤维基体内的纤维到达其它纤维中和它们之间，从而使它们与所述其它纤维交织并呈现于宏观表面处。可采用气体诸如但不限于空气的射流。
在另一种替代形式中，可采用针刺工艺来移位所述纤维网结构内的纤维。针刺法涉及将具有向前取向的倒刺结构的成排的针沿横躺于或正交于所述纤维网的宏观表面的方向推过所述纤维网。随着所述针推进穿过所述纤维网，倒刺结构捕获所述纤维网内的各个纤维中的一些并随着针的推进一道运载它们，从而驱动所捕获的纤维向前到达所述纤维网中的其它纤维之间和它们中，并朝背向针的远端的宏观表面移动。针刺工艺描述于例如美国专利申请公布2013/0067706中。
在另一种替代形式中，可采用如例如美国专利7,553,532所述的簇绒工艺来朝外宏观表面移位内层中的纤维或者将所述纤维移位至所述外宏观表面。
可能要注意的是，热粘结和所得粘结具有将纤维部分地锁定在所述纤维网内的适当位置的效应，从而使得更难以通过上述水射流加工或其它纤维移位技术来移位所述粘结的纤维网内的纤维，而不使所述粘结断裂因而损失粘结有益效果中的一些和/或所述纤维网的所期望的机械强度。换句话讲，在一些情况下，足以将纤维从内层移位至宏观表面的能量也可足以基本上改变所述纤维网的粘结结构，并劣化其机械性能(例如，拉伸强度)。
然而，如果第三纤维130是由与第一纤维110和/或第二纤维120相比具有较大延展性的材料形成的，则当被水射流加工机构或其它移位机构冲击和推挤时，在不是大得将基本上劣化所述纤维网结构的能量的作用下，它们能够在所述纤维网结构内塑性地变形(延长)以向外延伸至宏观表面。由于基于聚乙烯的树脂一般比基于聚丙烯的树脂更具延展性，因此据信形成聚丙烯的纤维110，120的第一和第二(例如，外)层和聚乙烯的纤维130的第三层是有利的，并从而适用于本文的目的。然而，设想到具有合适的特性和特性关系的树脂的其它组合，其中纤维毛絮的外层具有第一延展性，并且纤维毛絮的一个或多个内层具有第二且较高的延展性。纤维的位移和重新取向(在厚度方向上)以及所述纤维或第三纤维的部分的持久拉伸变形是导致具有呈现于宏观表面处的感觉更柔软的纤维的所期望效应的可能的机制，同时仍然包含和约束它们以使它们不易于发生不可取的起毛和/或起球。
如本文所述的且如本文所述地形成的增强的非织造纤维网可用来形成吸收制品诸如尿布的部件。例如，所述非织造纤维网可用来形成顶片、腿箍和/或底片。所述非织造纤维网可用作底片的外层/面向外的层，其中所述底片由具有包括不可透过液体的膜的层和所述非织造纤维网的层合体形成。
根据应用和所期望的功能，本文所述的增强的非织造纤维网可为疏水性的或亲水性的。当聚烯烃为用来形成相应纤维的材料时，不需要进一步的表面处理以使其适用于其中期望疏水性的应用，例如，疏水性底片材料、或疏水性箍材料。然而，当期望亲水性时，例如，当所述纤维网旨在用作用于尿布或女性卫生护垫的顶片材料时，可用亲水性局部施用来处理所述纤维网。另选地，可将亲水性熔融添加剂添加到所述聚合物树脂中，形成所述纤维网的纤维从所述聚合物树脂纺丝而成。
图3为尿布10的透视图，所述尿布处在松弛的展开位置，如其在被打开并位于水平表面上时所可能显现的那样。图4为被示出处于平展未收缩状态(即，无弹性诱导收缩)的尿布10的平面图，其示出了尿布10的一些部分被切除以示出底层结构。尿布10在图4中被示出带有其纵向轴线36和其侧向轴线38。尿布10的接触穿着者的部分在图3中被示出为向上取向的，并且在图4中被示出为面对观察者。图5为沿图4中的线2-2截取的尿布的横截面。
尿布10一般可包括基础结构12和设置在基础结构中的吸收芯14。基础结构12可包括尿布10的主体。
基础结构12可包括顶片18(其可为可透过液体的)和底片20(其可为不可透过液体的)。吸收芯14可封装在顶片18和底片20之间。基础结构12也可包括侧片22、弹性化腿箍24、和弹性腰部结构26。基础结构12也可包括紧固系统，所述紧固系统可包括至少一个紧固构件46和至少一个着陆区48。
腿箍24和弹性腰部结构26通常可各自包括弹性构件28。尿布10的一个末端部分可被构造为尿布10的第一腰区30。尿布10的相对的末端部分可被构造为尿布10的第二腰区32。尿布10的中间部分可被构造为裆区34，所述裆区在第一腰区和第二腰区30和32之间纵向延伸。裆区34可包括尿布10的总体长度的33.3％至50％，并且每个腰区30，32可相应地包括尿布10的总体长度的25％至33.3％。
腰区30和32可包括弹性元件，使得它们围绕穿着者的膝部聚拢以提供改善的贴合性和约束性(弹性腰部结构26)。裆区34为当尿布10被穿着时一般位于穿着者两腿之间的尿布10的那部分。
尿布10也可包括此类其它结构，包括前耳片和后耳片、腰帽结构、弹性部件等，从而提供更好的贴合性、约束性和美观特性。此类附加结构描述于例如美国专利3,860,003和5,151,092中。
为了施用尿布10并将其围绕穿着者保持在适当位置，第二腰区32可通过紧固构件46附接到第一腰区30以形成腿部开口和制品腰部。当紧固时，紧固系统承受制品腰部周围的拉伸载荷。
根据一些示例，尿布10可设置有可重复闭合的紧固系统，或者可另选地以裤型尿布的形式提供。当所述吸收制品为尿布时，其可包括接合到基础结构的用于将尿布固定到穿着者身上的可重复闭合的紧固系统。当所述吸收制品为裤型尿布时，所述制品可包括至少两个接合到基础结构并彼此接合的侧片以形成裤。紧固系统及其任何部件可包括适用于这种用途的任何材料，包括但不限于塑料、膜、泡沫、非织造材料、织造材料、纸材、层合体、拉伸层合体、活化的拉伸层合体、纤维增强的塑料等、或它们的组合。在一些示例中，构成紧固装置的材料可为柔性的。在一些示例中，紧固装置可包括用于附加柔软性或消费者柔软感的棉料或棉状材料。该柔韧性可允许紧固系统适形于身体的形状，并因此减小紧固系统将刺激或伤害穿着者皮肤的可能性。
对于一体的吸收制品，基础结构12和吸收芯14可形成在添加其它结构后形成复合尿布结构的尿布10的主结构。虽然顶片18、底片20和吸收芯14可按多种熟知的构型装配，但优选的尿布构型一般描述于以下专利中：1996年9月10日授予Roe等人的名称为“AbsorbentArticleWithMultipleZoneStructuralElastic-LikeFilmWebExtensibleWaistFeature”的美国专利5,554,145；1996年10月29日授予Buell等人的名称为“DisposablePuIl-OnPant”的美国专利5,569,234；和1999年12月21日授予Robles等人的名称为“AbsorbentArticleWithMulti-DirectionalExtensibleSidePanels”的美国专利6,004,306。
顶片18可被完全或部分地弹性化和/或可被缩短以在顶片18和吸收芯14之间产生空隙空间。包括弹性化顶片或缩短顶片的示例性结构更详细地描述于以下专利中：1991年8月6日授予Allen等人的名称为“DisposableAbsorbentArticleHavingElasticallyExtensibleTopsheet”的美国专利5,037,416；和1993年12月14授予Freeland等人的名称为“TrisectionTopsheetsforDisposableAbsorbentArticlesandDisposableAbsorbentArticlesHavingSuchTrisectionTopsheets”的美国专利5,269,775。在一些示例中，顶片18可由如上所述的增强的非织造纤维网105形成。
底片20可与顶片18接合。底片20可用于防止被吸收芯14吸收并容纳在尿布10内的流出物脏污可能接触尿布10的其他外部制品，诸如床单和衣服。参见图6，底片20可为基本上不可透过液体(例如，尿液)的，并包括底片非织造物21和薄聚合物膜23的层合体，所述薄聚合物膜为诸如具有约0.012mm(0.5mil)至约0.051mm(2.0mils)厚度的热塑性膜。在一些示例中，底片非织造物21可由如上所述的增强的非织造纤维网105形成。在粘结部位和未粘结区域之间具有较小深度变化的宏观表面(例如，在图1中，表面122)处，粘结部位142可实用于经由粘合剂粘附到所述膜，因为每个部位均能够形成由所述部位限定的相对平坦、均匀且致密的表面区域，粘合剂能够更容易且更均匀地粘附到所述表面区域。
合适的底片膜包括由TredegarIndustriesInc.(TerreHaute，Ind.)制造并以商品名X15306、X10962和X10964出售的那些。其它合适的底片材料可包括允许蒸气从尿布10逸出同时仍然防止液体流出物透过底片20的可透气材料。示例性可透气材料可包括诸如织造纤维网、非织造纤维网之类的材料、诸如膜包衣的非织造纤维网之类的复合材料、以及诸如由MitsuiToatsuCo.(Japan)制造的命名为ESPOIR和由EXXONChemicalCo.(BayCity，Texas)制造的命名为EXXAIRE的微孔膜。包括聚合物共混物的合适的可透气复合材料以名称HYTREL共混物Pl8-3097购自ClopayCorporation(Cincinnati，Ohio)。此类可透气复合材料的其它示例更详细地描述于1995年6月22日以E.I.DuPont的名义公布的PCT专利申请WO95/16746中。包括非织造纤维网和开孔成型膜的其它可透气底片描述于1996年11月5日授予Dobrin等人的美国专利5,571,096中。
在一些示例中，本发明的底片可具有根据WSP70.5(08)在37.80C和60％的相对湿度下测量的大于约2,000g/24h/m2，大于约3,000g/24h/m2，大于约5,000g/24h/m2，大于约6,000g/24h/m2，大于约7,000g/24h/m2，大于约8,000g/24h/m2，大于约9,000g/24h/m2，大于约10,000g/24h/m2，大于约11,000g/24h/m2，大于约12,000g/24h/m2，大于约15,000g/24h/m2的水蒸气传输速率(WVTR)。
应当了解，本文所公开的量纲和值不旨在严格限于所引用的精确值。相反，除非另外指明，每个这样的量纲旨在表示所述值以及围绕该值功能上等同范围。例如，公开为“40mm”的量纲旨在表示“约40mm”。
除非明确排除或限制，将本文引用的每篇文献，包括任何交叉引用或相关专利或专利申请，全文以引用方式并入本文。任何文献的引用不是对其作为本文所公开的或受权利要求书保护的任何发明的现有技术，或其单独地或与任何其它参考文献的任何组合，或者参考、提出、建议或公开任何此类发明的认可。此外，当本发明中术语的任何含义或定义与以引用方式并入的文件中相同术语的任何含义或定义矛盾时，应当服从在本发明中赋予该术语的含义或定义。
虽然已经举例说明和描述了本发明的特定实施例，但是对于本领域的技术人员来说显而易见的是，在不背离本发明的实质和范围的情况下可做出多个其它改变和变型。因此，本文旨在在所附权利要求中涵盖属于本发明范围内的所有这些改变和变型。
Claims (15)
1.一种非织造纤维网材料，所述非织造纤维网材料包含：
由第一纤维形成的第一外纤维积累物(110)，所述第一纤维基本上由聚丙烯组成，所述第一外纤维积累物形成第一宏观外纤维网表面；
由第二纤维形成的第二外纤维积累物(120)，所述第二纤维基本上由聚丙烯组成，所述第二外纤维积累物形成第二宏观外纤维网表面；
由第三纤维形成的内纤维积累物(130)，所述第三纤维包含聚乙烯，所述第三纤维交织在所述第一纤维和/或所述第二纤维中并呈现于所述第一宏观纤维网表面和/或所述第二宏观纤维网表面处；和
压印在所述第一宏观表面和所述第二宏观表面中任一者或两者上的热粘结图案(140)，在所述热粘结图案处，所述第一纤维热粘结到所述第二纤维。
2.根据权利要求1所述的非织造纤维网材料，其中所述第三纤维为包含聚乙烯组分的多组分纤维。
3.根据权利要求2所述的非织造纤维网材料，其中所述多组分纤维为包含聚乙烯组分和聚丙烯组分的双组分纤维。
4.根据权利要求3所述的非织造纤维网材料，其中将所述双组分纤维的聚丙烯组分至少部分地热粘结到所述第一纤维和所述第二纤维。
5.根据前述权利要求中任一项所述的非织造纤维网材料，所述非织造纤维网材料还包含由第四纤维形成的第二内纤维积累物。
6.根据权利要求5所述的非织造纤维网材料，其中所述第四纤维包含聚乙烯。
7.根据权利要求6所述的非织造纤维网材料，其中所述第四纤维为包含聚乙烯组分的多组分纤维。
8.一种非织造纤维网材料，所述非织造纤维网材料包含：
由第一纤维形成的第一外纤维积累物(110)，所述第一纤维基本上由聚丙烯组成，所述第一外纤维积累物形成第一宏观外纤维网表面；
由第二纤维形成的第二外纤维积累物(130)，所述第二纤维包含聚乙烯，所述第二纤维交织在所述第一纤维中并从所述第一宏观外纤维网表面伸出；和
压印在所述第一宏观表面上的热粘结图案(140)，在所述热粘结图案处，所述第一纤维热粘结到所述第二纤维。
9.根据权利要求8所述的非织造纤维网材料，其中所述第二纤维为包含聚乙烯组分的多组分纤维。
10.根据权利要求9所述的非织造纤维网材料，其中所述多组分纤维为包含聚乙烯组分和聚丙烯组分的双组分纤维。
11.根据权利要求10所述的非织造纤维网材料，其中将所述双组分纤维的聚丙烯组分至少部分地热粘结到所述第一纤维。
12.一种用于制造非织造纤维网材料的方法，所述方法包括以下步骤：
在第一喷丝头箱体处由第一聚合物树脂纺丝出第一纤维(110)；
将所述第一纤维引导到移动带(206)上并将它们积累在其上以形成第一毛絮(114)；
在第二喷丝头箱体处由不同于所述第一聚合物树脂的第二聚合物树脂纺丝出第二纤维(130)；
将所述第二纤维朝所述移动带引导并将它们积累在所述第一毛絮上以形成铺设在所述第一毛絮上的第二毛絮，并且从而形成包含所述第一毛絮和所述第二毛絮的组合毛絮(124)；
使所述组合毛絮传送穿过一对粘结辊(208，209)之间的辊隙，所述辊至少之一被供应有热能，并且从而将热粘结图案(140)压印在所述组合毛絮上，其中将所述组合毛絮的纤维热粘结在一起，并且从而形成粘结的纤维网(150)；以及
使所述粘结的纤维网传送经过纤维移位设备(214)，其中所述粘结的纤维网内的纤维相对于所述粘结的纤维网内的其它纤维被移位。
13.根据权利要求12所述的方法，其中所述纤维移位设备包括多个水射流(214)，其中所述射流冲击所述粘结的纤维网并迫使所述第二纤维穿过所述第一纤维之间的空间和/或穿过所述第一纤维中相应纤维之间的空间。
14.根据权利要求12所述的方法，所述方法还包括以下步骤：
在使所述组合毛絮传送穿过所述辊隙之前：
在第三喷丝头箱体处由第三聚合物树脂纺丝出第三纤维(120)；以及
将所述第三纤维朝所述移动带引导并将它们积累在所述第二毛絮上以形成铺设在所述第二毛絮上的第三毛絮，使得所述组合毛絮包含所述第一毛絮、所述第二毛絮和所述第三毛絮。
15.一种吸收制品，所述吸收制品包含可透过液体的顶片、基本上不可透过液体的底片以及设置在所述顶片和所述底片之间的吸收芯，其中所述顶片或所述底片包含权利要求1-11中任一项所述的非织造纤维网。
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| PCT/US2014/038173 WO2014193660A1 (en) | 2013-05-30 | 2014-05-15 | Nonwoven web material having enhanced glide softness and good strength attributes, and method for manufacturing |
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| CN106637676A (zh) * | 2016-11-01 | 2017-05-10 | 杭州萧山凤凰纺织有限公司 | 一种超柔软水刺非织造布的制备方法 |
| CN114525623A (zh) * | 2020-10-30 | 2022-05-24 | 耐克创新有限合伙公司 | 通过使用热粘合提高抗起球性的复合非织造织物 |
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| EP4082500A1 (en) | 2015-07-31 | 2022-11-02 | The Procter & Gamble Company | Package of absorbent articles utilizing a shaped nonwoven |
| BR112018002061B1 (pt) * | 2015-07-31 | 2023-03-21 | The Procter & Gamble Company | Substrato não-tecido de filamentos contínuos termossoldados |
| RU2673772C1 (ru) | 2015-07-31 | 2018-11-29 | Дзе Проктер Энд Гэмбл Компани | Формирующий ленточный конвейер для формованного нетканого материала |
| JP6158992B2 (ja) * | 2015-08-17 | 2017-07-05 | 大王製紙株式会社 | 吸収性物品 |
| EP3216434A1 (en) * | 2016-03-08 | 2017-09-13 | The Procter and Gamble Company | Absorbent article comprising a topsheet/acquisition web laminate |
| PL3239378T3 (pl) | 2016-04-29 | 2019-07-31 | Reifenhäuser GmbH & Co. KG Maschinenfabrik | Urządzenie i sposób do wytwarzania włóknin z włókien ciągłych |
| DE102018123768B3 (de) | 2018-09-26 | 2019-10-24 | Sandler Ag | Mehrschichtiges Abdeckvlies für eine Fahrzeug-Innenverkleidung, Innenverkleidung mit einem derartigen Abdeckvlies sowie Verfahren zur Herstellung eines derartigen Abdeckvlieses |
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Also Published As
| Publication number | Publication date |
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| EP3004444A1 (en) | 2016-04-13 |
| JP2016524659A (ja) | 2016-08-18 |
| WO2014193660A1 (en) | 2014-12-04 |
| CN105229212B (zh) | 2018-02-06 |
| US20140358101A1 (en) | 2014-12-04 |
| JP6185155B2 (ja) | 2017-08-23 |
| EP3004444B1 (en) | 2017-12-20 |
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