CN107496080A - 具有高超吸收材料含量的吸收芯 - Google Patents
具有高超吸收材料含量的吸收芯 Download PDFInfo
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Abstract
本发明公开了一种吸收芯(28)和包括该芯的吸收制品(20)诸如尿布。该吸收芯包括包封吸收材料(60)的芯包裹物(16,16’),其中吸收材料包含按所述吸收材料的重量计至少80%的超吸收聚合物(“SAP”)。该吸收芯具有按如本文所述的“湿厚度和压缩力(WCACF)测试”测量的小于10%的压缩之后的“相对湿厚度增加”(RWCI),并且其中芯包裹物(16,16’)为至少部分地密封的,使得在执行“WCACF测试”期间基本上无吸收材料渗漏出芯包裹物。
Description
本申请是基于申请日为2013年12月10日,优先权日为2012年12月 10日,申请号为201380064546.7(PCT/US2013/074068),发明名称为:“具有高超吸收材料含量的吸收芯”的专利申请的分案申请。
技术领域
本发明涉及用于个人卫生吸收产品的吸收芯,诸如但不限于婴儿尿布、训练裤、女性护垫或成人失禁制品。
背景技术
用于个人卫生的吸收制品诸如婴儿用的一次性尿布、学步儿童用的训练裤或成人失禁内衣被设计成吸收和容纳身体流出物,尤其是大量的尿液。这些吸收制品包括提供不同功能的若干层,例如顶片、底片和其间的吸收芯、还有其它层。
吸收芯的功能是长时间地吸收并保持流出物例如尿布过夜使用、最小化回渗以保持穿着者干燥并避免弄脏衣服或床单。大部分当前市售的吸收制品包含作为吸收材料的粉碎的木浆与呈颗粒形式的超吸收聚合物 (SAP)的共混物,也被称为吸收胶凝材料(AGM),参见例如US 5,151,092(Buell)。也已经提出具有基本上由作为吸收材料的SAP组成的芯(所谓的“不含透气毡”的芯)的吸收制品,但与传统的混合芯相比更少见(参见例如WO2008/155699(Hundorf)、WO95/11652(Tanzer)、 WO2012/052172(Van Malderen))。
也提出过包括具有狭缝或沟槽的吸收芯的吸收制品,所述狭缝或沟槽通常用以增大芯的流体采集特性或充当折叠引导件。WO95/11652 (Tanzer)公开了包括位于离散口袋中的超吸收材料的吸收制品,所述口袋具有水敏围堵结构和非水敏围堵结构。WO2009/047596(Wright)公开了一种具有狭缝吸收芯的吸收制品。
在裆区中为柔性的吸收产品提供如下有益效果:对于穿着者改善的运动自由度,尤其是当使用者的腿部侧向地压缩制品裆区时。然而,本发明人已发现,高度柔性的产品一般来讲在被润湿时可具有较差的回弹力,因此当受到穿着者腿部运动的压缩时趋于失去它们的形状。由于吸收芯变形,产品可能不能够适当地起作用,并且这增大了失效诸如流体渗漏的可能性。本发明人现已发现了一种新的吸收芯结构,其能够提供如下有益效果:当被流体加载时,其具有良好的柔韧性,并兼具良好的回弹力。
发明内容
本发明涉及一种如权利要求所限定的吸收芯和包括该吸收芯的吸收制品。该吸收芯包括包封吸收材料的芯包裹物,其中吸收材料包含按所述吸收材料的重量计至少80%的超吸收聚合物(“SAP”)。该吸收芯包括前边缘、后边缘和两个纵向边缘,并具有在纵向上取向的纵向轴线。吸收材料包括至少一个通道,具体地至少部分地在纵向上取向的至少一对通道。该吸收芯具有按如本文所述的“湿厚度和压缩力(WCACF)测试”测量的小于10.0%的“相对湿厚度增加”(RWCI)值,并且芯包裹物为至少部分地密封的,使得在执行“WCACF测试”期间基本上无吸收材料渗漏出芯包裹物。该吸收芯还可具有按“WCACF测试”测量的低于5.00N,具体地 1.00至3.00N的“湿法压缩力”。
本发明还包括以下内容:
实施方式1.一种适于在吸收制品(20)中使用的吸收芯(28),其中所述吸收芯包括包封吸收材料(60)的芯包裹物(16,16'),其中所述吸收材料包含按所述吸收材料的重量计至少80%的超吸收聚合物 (“SAP”),
所述吸收芯(28)包括前边缘(280)、后边缘(282)和两个纵向边缘(284,286),所述吸收芯(28)具有在纵向上取向的纵向轴线 (80')和沿所述纵向轴线在所述前边缘和后边缘之间测量的长度L,所述长度L为至少320mm,
所述吸收芯包括至少部分地在所述纵向上取向的至少一个通道 (26,26'),
其中所述吸收芯具有压缩之后的小于10.0%的“相对湿厚度增加”(RWCI),所述“相对湿厚度增加”通过本文所述的“湿厚度和压缩力(WCACF)测试”测量,并且
其中所述芯包裹物(16,16')被至少部分地密封,使得在执行所述“WCACF测试”的压缩步骤时基本上无吸收材料渗漏出所述芯包裹物。
实施方式2.根据实施方式1所述的吸收芯,其中所述芯具有通过本文所述的“WCACF测试”测量的小于5.00N,具体地1.00N至3.00N的湿法压缩力(WCF)。
实施方式3.根据前述实施方式中任一项所述的吸收芯,所述吸收芯包括至少一对通道(26,26'),优选地其中所述一对通道中的通道相对于所述芯的纵向轴线(80')对称地设置。
实施方式4.根据前述实施方式中任一项所述的吸收芯,其中至少一个通道具有投射在所述芯的纵向轴线(80')上的长度L',所述长度L'为所述吸收芯的长度L的至少10%。
实施方式5.根据前述实施方式中任一项所述的吸收芯,其中至少一个通道基本上不含吸收材料,并且优选地其中所述通道的宽度(Wc)至少在所述通道的一些部分中为至少2mm,具体地4mm至16mm。
实施方式6.根据前述实施方式中任一项所述的吸收芯,其中所述芯包裹物包括第一非织造织物(16)和第二非织造织物(16'),并且其中所述第一非织造织物围绕所述第二非织造织物形成C形包裹物。
实施方式7.根据前述实施方式中任一项所述的吸收芯,其中所述吸收材料(60)在所述芯包裹物内限定吸收材料沉积区域(8),并且其中所述吸收材料沉积区域(8)为矩形或被成形为具有如下宽度,所述宽度在所述吸收芯的裆区(81)中具有最小值,所述裆区为所述芯的从所述裆点(C)朝所述吸收芯的后边缘和前边缘在两个方向上延伸四分之一L(L/4)的距离的区域,所述裆点为被放置成与所述吸收芯的前边缘(280)相距所述长度L的45%的点。
实施方式8.根据前述实施方式中任一项所述的吸收芯,其中所述吸收芯包括第一吸收层和第二吸收层,所述第一吸收层包括第一基底(16) 和第一超吸收聚合物层(61),所述第二吸收层包括第二基底(16') 和第二超吸收聚合物层(62),并且所述吸收芯还包括位于所述第一吸收层和所述第二吸收层之间的纤维热塑性粘合剂材料(51),具体地其中所述纤维热塑性粘合剂材料(51)至少部分地有助于将每个超吸收聚合物层(61,62)粘结到其相应基底(16,16'),并且其中所述第一基底和所述第二基底形成所述芯包裹物(16,16')。
实施方式9.根据前述实施方式中任一项所述的吸收芯,其中所述吸收材料(60)包含按所述吸收材料的总重量计至少90%的SAP,多至基本上100%的SAP。
实施方式10.根据前述实施方式中任一项所述的吸收芯,其中所述吸收材料(60)包含小于10重量%,或小于5重量%的天然纤维或合成纤维,或基本上不含天然纤维或合成纤维。
实施方式11.根据前述实施方式中任一项所述的吸收芯,其中所述芯包裹物包括顶侧面(288)和底侧面(290),并且其中所述芯包裹物的形成所述顶侧面的部分和所述芯包裹物的形成所述底侧面的部分通过至少一个通道至少部分地彼此粘结。
实施方式12.根据前述实施方式中任一项所述的吸收芯,其中所述SAP 的基重在所述SAP分配区域(8)内沿所述芯的纵向轴线不均匀分布,具体地其中所述SAP的基重在所述芯的裆点(C)处比在所述纵向轴线上的所述吸收材料沉积区域的另一个点处高至少10%。
实施方式13.根据前述实施方式中任一项所述的吸收芯,所述吸收芯包含 5g至60g的SAP,具体地10g至50g。
实施方式14.根据前述实施方式中任一项所述的吸收芯,其中根据本文所述的“芯厚度测试”在所述裆点(C)处测量的所述芯的厚度为 0.25mm至5.0mm,具体地0.5mm至3.0mm。
实施方式15.一种吸收制品(20),诸如尿布、训练裤、女性护垫或成人失禁制品,所述吸收制品包括液体可透过的顶片、液体不可透过的底片以及位于所述顶片和所述底片之间的根据前述实施方式中任一项所述的吸收芯。
附图说明
图1为呈尿布形式的吸收制品的顶视图,其包括根据本发明的示例性吸收芯;
图2为图1的尿布的横截面;
图3为单独获取的图1的尿布的示例性吸收芯的顶视图;
图4为图3的芯的横截面;
图5为图3的芯的纵向剖视图;
图6示出了本发明的另选吸收芯的顶视图。
图7为用来执行下文所详述的“湿厚度和压缩力测试”的设备的示意图。
具体实施方式
引言
如本文所用,术语“吸收制品”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一次性产品,例如婴儿或成人尿布、训练裤等等。通常这些制品包括顶片、底片、吸收芯和任选地采集层和/或分配层和通常的其它部件,其中吸收芯通常放置在底片和采集系统或顶片之间。
如本文所用,术语“吸收芯”是指单个部件,其被放置在或旨在被放置在吸收制品内并包含包封在芯包裹物中的吸收材料。术语“吸收芯”不包括吸收制品的不是芯包裹物的整体部分或不是放置在芯包裹物内的采集层或分配层或任何其它部件。该吸收芯通常为吸收制品的如下部件,所述部件包括全部或至少大部分超吸收颗粒(SAP)并且在吸收制品的所有部件中具有最大吸收容量。
如本文所用,“非织造纤维网”是指由定向或任意取向的纤维通过摩擦和/或结合和/或粘合而粘结成的、或通过湿磨法而毡化成的人造片、纤维网或毛层,不包括纸张和通过织造、编织、簇成、缝编而组合接结纱或长丝的产品,无论是否附加地缝过。这些纤维可具有天然的或人造的来源,并且可为短纤维或连续长丝或为原位形成的纤维。可商购获得的纤维具有介于小于约0.001mm至大于约0.2mm的范围内的直径,并且它们具有几种不同的形式,诸如短纤维(已知为化学短纤维或短切纤维)、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(纱线)。非织造纤维网可通过许多方法形成,诸如熔喷法、纺粘法、溶液纺丝、静电纺纱、粗梳法和气流成网法。非织造纤维网的基重通常用克/平方米(g/m2或gsm)表示。
“包括”及“包含”是开放式术语,每个均指定其后特征例如部件的存在,但不排除本领域已知的或本文所公开的其它特征例如元件、步骤或组分的存在。这些基于动词“包括”的术语应当被解读为涵盖较窄的术语“基本上由……组成”,其排除未提及的显著地影响所述特征执行其功能的任何元件、步骤或成分;和术语“由……组成”,其排除未指定的任何元件、步骤或成分。下述任何优选的或示例性实施例均不限制权利要求的范围,除非具体地指明如此。词语“典型”、“通常”、“有利地”等也限定不旨在限制权利要求的范围的特征,除非具体地指明如此。
除非另外指明,本说明书是指使用之前的(即干燥的且未加载有流体的)并在21℃+/-2℃和50+/-20%的相对湿度(RH)下调理了至少24小时的吸收芯和吸收制品。
对吸收制品20的一般说明
一种能够在其中使用本发明的吸收芯28的示例性吸收制品20为如图1 所示的婴儿胶粘尿布20。图1为处于平展状态的示例性尿布20的顶部平面图,其中部分结构被切除以更清楚地示出尿布20的构造。该尿布20仅出于例证的目的示出,因为本发明可用于制备多种尿布或其它吸收制品。
吸收制品20包括液体可透过的顶片24、液体不可透过的底片25、位于顶片24和底片25之间的吸收芯28。吸收制品也可包括下文将详述的另外的典型部件,诸如采集层52和/或分配层54(统称为采集-分配系统“ADS”,在图2中被标示为50)、和存在于顶片和底片之间的弹性化衬圈箍32以及直立的阻隔腿箍34。图1-2也示出了其它典型的胶粘尿布部件诸如包括扣紧突片42的扣紧系统,所述扣紧突片朝制品的后边缘12附接并朝制品的前边缘与着陆区44协作。吸收制品也可包括其它图中未示出的典型部件,诸如后弹性腰部结构、前弹性腰部结构、一个或多个横向阻隔箍、洗剂应用等。
吸收制品20包括前边缘10、后边缘12、和两个纵向边缘。前边缘10 为制品的旨在当被穿着时朝向使用者的前部放置的边缘,并且后边缘12为相对边缘。当在平展构型中从面向穿着者侧观察制品时,吸收制品可假想地被从制品的前边缘延伸至后边缘的纵向轴线80划分,并将制品划分成相对于该轴线基本上对称的两个半部,如图1示例性所示。如果该制品的一些部分由于弹性化部件而处于张力下,则通常可使用夹钳沿制品周边和/或粘性表面来整平制品,使得顶片和底片可被拉紧以便成为基本上平坦的。吸收制品20也可假想地被横向轴线90划分成长度相等的前区和后区,所述长度是当制品处于这种平坦状态时在纵向轴线上测量的。该制品的横向轴线90垂直于纵向轴线80并被置于制品的二分之一长度处。制品的长度可沿纵向轴线80从前边缘10至后边缘12测量。
顶片24、底片25、吸收芯28和其它制品部件可按多种熟知的构型装配,具体地通过胶粘和/或热压花装配。示例性尿布组件例如一般描述于 US3,860,003、US5,221,274、US5,554,145、US5,569,234、US5,580,411、和 US6,004,306中。吸收制品优选为薄的。该制品可有利地在纵向轴线和横向轴线的交汇处较薄,例如具有1.0mm至8.0mm,具体地1.5mm至6.0mm 的厚度,所述厚度使用下述“吸收制品厚度测试”测量。
现在将更详细地讨论该制品的这些和其它部件。
吸收芯28
本发明的吸收芯包括吸收材料,所述吸收材料具有包封在芯包裹物内的高含量的超吸收聚合物(在本文中缩写为“SAP”)。SAP含量表示包含在芯包裹物中的至少80重量%的吸收材料。出于评估SAP占吸收芯的百分比的目的,芯包裹物不被认为是吸收材料。吸收材料限定吸收材料沉积区域8,如当芯被放置成基本上平坦时所见的那样。如本文所用,术语“吸收芯”不包括顶片、底片和(如果存在)采集-分配系统或层,所述采集-分配系统或层不是吸收芯的整体部分,具体地不是被置于芯包裹物内。芯可基本上由或由芯包裹物、吸收材料和任选地胶组成。术语“吸收芯”和术语“芯”在本文中互换使用。
图1的吸收制品的示例性吸收芯28单独地示出于图3-5中。本发明的吸收芯包括前边缘280、后边缘282以及接合前边缘280和后边缘282的两个纵向边缘284,286。芯的前边缘280为芯的旨在朝吸收制品的前边缘10 放置的边缘。通常,吸收材料将有利地以比朝后边缘更高的含量朝前边缘分布,因为在前部需要更多吸收性。通常,芯的前边缘和后边缘280,282 短于芯的纵向边缘284,286。该吸收芯也可包括顶侧面和底侧面。在成品20中,芯的顶侧面288为旨在朝顶片放置的侧面,并且底侧面290为旨在朝底片放置的侧面。芯的顶侧面288通常比底侧面290更具亲水性。在两个纵向边缘284,286之间测量的裆点处的芯宽度应当足够用于要进行的“WCACF测试”,即应当为至少40mm。裆点处的芯宽度可具体地为 45mm至200mm,或50mm至150mm。
当在平展构型中从顶侧面观察芯时,吸收芯可假想地被从芯的前边缘延伸至后边缘纵向轴线80’划分,并将芯划分成相对于该轴线基本上对称的两个半部,如图3示例性所示。通常,当从顶部观察时,如图1所示,芯的纵向轴线80’和制品(芯旨在被置于其中)的纵向轴线80将是邻接的。芯的横向轴线(在本文中也称为“裆线”)垂直于纵向轴线并经过芯的裆点C。裆点C为被放置成与吸收芯的前边缘相距0.45L的距离的吸收芯的点,L为在纵向轴线80’上从其前边缘至其后边缘测量的芯的长度,如图3 所示。芯的全长L是沿其纵向轴线80’从芯的前边缘280至后边缘282测量的长度,并且也包括芯包裹物的不包封吸收材料的区域,具体地在前端密封件和后端密封件(当存在时)处。芯的长度L为至少320mm,例如320mm至600mm。
裆区81在本文中被限定为芯的从裆线延伸的区域,即在裆点C的水平,在两个方向上朝芯的后边缘和前边缘延伸四分之一L(L/4)的距离,共延伸L/2的总长度。芯的前区82和后区83为沉积区域的分别朝向芯的前边缘和后边缘的剩余区域。
芯包裹物可由两个非织造材料16,16’形成,它们可沿吸收芯的边缘至少部分地密封。芯包裹物可至少部分地沿芯的前边缘、后边缘和两个纵向边缘密封,使得当执行下述WCACF测试的压缩步骤时,基本上无吸收材料渗漏出吸收芯包裹物。如果芯包裹物包括单一基底,不排除芯包裹物可用与芯的边缘相比处在更内侧的密封线来密封,例如如在礼品包裹物中那样。根据WO2010/0051166A1中所述的“湿固定作用测试”,该吸收芯也可有利地实现不超过约70%,60%,50%,40%,30%,20%,10%的SAP 损耗。现在将更详细地描述该吸收芯的另外的方面。
本发明的吸收芯可相对较薄并薄于常规透气毡芯。具体地,根据本文所述的“芯厚度测试”在裆点(C)处测量的芯的厚度(在使用之前)可为 0.25mm至5.0mm,具体地0.5mm至4.0mm。
所谓“吸收材料”,是指具有至少一些吸收性和/或液体保持特性的材料,诸如SAP、纤维素纤维以及一些经亲水性处理的合成纤维。通常,用于制备吸收芯的胶不具有吸收特性,因而不被认为是吸收材料。SAP含量可高于80%,例如至少85%,至少90%,至少95%,并且甚至多至并包括芯包裹物内所包含的吸收材料重量的100%。相比于通常包含介于40-60%之间的SAP和其余的纤维素纤维的常规芯,该高SAP含量可提供相对薄的芯。具体地,本发明的吸收材料可包含小于10重量%,或小于5重量%的天然纤维和/或合成纤维,或甚至基本上不含天然纤维和/或合成纤维。吸收材料可有利地包含很少或不包含透气毡(纤维素)纤维,具体地该吸收芯可包含按该吸收芯的重量计小于15%,10%,或5%的透气毡(纤维素)纤维,或甚至基本上不含纤维素纤维。
本发明的吸收芯还可包含例如粘合剂以帮助将SAP固定在芯包裹物内和/或确保芯包裹物的完整性,尤其是当芯包裹物由两个或更多基底制成时。芯包裹物通常将比用于在其内包含吸收材料严格所需的区域延伸至更大的区域。
过去已经提出了包含相对高含量SAP并具有各种芯设计的芯,参见例如US5,599,335(Goldman)、EP1,447,066(Busam)、WO95/11652 (Tanzer)、US2008/0312622A1(Hundorf)、WO2012/052172(Van Malderen)。在一些实施例中,吸收材料可连续地存在于芯包裹物内。在这种情况下,吸收材料可例如通过施加单一连续吸收材料层来获得。在其它实施例中,吸收材料可包含单个的吸收材料口袋或吸收材料条,所述吸收材料口袋或吸收材料条被包封在芯包裹物内并被接合区域分开。
吸收材料具体地SAP的连续层也可通过组合具有不连续的吸收材料施加图案的两个“半部”吸收层而获得,其中所得层在吸收颗粒聚合物材料区域上基本上连续地分布,如例如US2008/0312622A1(Hundorf)所提出。吸收芯28可例如(如图5所示)包括第一吸收层和第二吸收层以及纤维热塑性粘合剂材料51,第一吸收层包括第一基底16和第一吸收材料层61(其可为100%SAP),并且第二吸收层包括第二基底和第二吸收材料层 (其也可为100%SAP),纤维热塑性粘合剂材料51将每个吸收材料层61, 62至少部分地粘结到其相应基底。第一基底16和第二基底16’形成芯包裹物。第一吸收层和第二吸收层可按沉积图案沉积于它们相应的基底上,所述沉积图案包括具有吸收材料的着陆区域和介于着陆区域之间的不含吸收材料的接合区域。如例如图5所举例说明的着陆区域可为例如横向地取向的并跨越吸收材料沉积区域8的宽度。纤维热塑性粘合剂材料51可至少部分地接触着陆区域中的吸收材料61,62并至少部分地接触接合区域中的基底层。这赋予热塑性粘合剂材料51的纤维层基本上三维的结构,所述结构本身为基本上二维的结构,其中与长度方向和宽度方向上的尺寸相比厚度相对小。从而,纤维热塑性粘合剂材料可提供腔以覆盖着陆区域中的吸收材料,并从而固定该吸收材料(其如已经指出的那样可为100%SAP)。
热塑性粘合剂材料可整体包含单一热塑性聚合物或热塑性聚合物的共混物,当通过ASTM方法D-36-95“环球法”测定时,所述聚合物具有在介于50℃和300℃之间的范围内的软化点,并且/或者热塑性粘合剂材料可为热熔融粘合剂,其包括与其它热塑性稀释剂诸如增粘树脂、增塑剂和添加剂诸如抗氧化剂相组合的至少一种热塑性聚合物。
热塑性聚合物通常具有超过10,000的分子量(Mw)和通常低于室温的玻璃化转变温度(Tg)或-6℃<Tg<16℃。热熔体中聚合物的典型浓度在约20重量%至约40重量%的范围内。该热塑性聚合物可以为水不敏感性的。示例性聚合物为包括A-B-A三嵌段结构、A-B两嵌段结构和(A-B)n 径向嵌段共聚物结构的(苯乙烯)嵌段共聚物,其中A嵌段为通常包含聚苯乙烯的非弹性体聚合物嵌段,且B嵌段为不饱和共轭双烯或(部分)氢化的此类变体。B嵌段通常为异戊二烯、丁二烯、乙烯/丁烯(氢化丁二烯)、乙烯/丙烯(氢化异戊二烯)、以及它们的混合物。可采用的其它合适的热塑性聚合物为茂金属聚烯烃,它们为利用单位点或茂金属催化剂制备的乙烯聚合物。其中,至少一种共聚单体可与乙烯聚合以制备共聚物、三元共聚物或更高级的聚合物。同样适用的是无定形聚烯烃或无定形聚α- 烯烃(APAO),它们为C2至C8α烯烃的均聚物、共聚物或三元共聚物。
增粘树脂可示例性地具有低于5,000的Mw和通常高于室温的Tg,热熔体中树脂的典型浓度在约30至约60%的范围内,并且增塑剂具有通常小于1,000的低Mw和低于室温的Tg,其典型浓度为约0至约15%。
用于纤维层的热塑性粘合剂51优选具有弹性体特性,使得由纤维在 SAP层上形成的纤维网在SAP溶胀时能够被拉伸。示例性弹性体热熔融粘合剂包括热塑性弹性体,诸如乙烯-乙酸乙烯酯、聚氨酯、硬组分(一般为结晶聚烯烃诸如聚丙烯或聚乙烯)和软组分(诸如乙烯-丙烯橡胶)的聚烯烃共混物;共聚酯,诸如聚(对苯二甲酸乙二酯-共壬二酸乙烯酯);和被命名为A-B-A嵌段共聚物的具有热塑性端块和橡胶状中间嵌段的热塑性弹性体嵌段共聚物;结构上不同的均聚物或共聚物的混合物,例如,具有A- B-A嵌段共聚物的聚乙烯或聚苯乙烯的混合物;热塑性弹性体和低分子量树脂调节剂的混合物,例如苯乙烯-异戊二烯-苯乙烯嵌段共聚物与聚苯乙烯的混合物;以及本文所述的弹性体热熔融压敏粘合剂。这些类型的弹性体热熔融粘合剂详述于在1988年3月15日授予Korpman的美国专利 4,731,066中。
热塑性粘合剂材料有利地被施加为纤维。纤维可示例性地具有约1微米至约50微米或约1微米至约35微米的平均厚度和约5mm至约50mm或约5mm至约30mm的平均长度。为了改善热塑性粘合剂材料对基底层或任何其它层尤其是任何其它非织造层的粘附性,此类层可用辅助粘合剂预处理。纤维彼此附着以形成纤维层,其还可描述为网。
在某些实施例中,热塑性粘合剂材料将符合至少一个、或多个、或所有以下参数。一种示例性热塑性粘合剂材料可具有在20℃下测量的至少 30,000Pa且小于300,000Pa,或小于200,000Pa,或介于140,000Pa和 200,000Pa之间,或小于100,000Pa的储能模量G'。在另一方面,在35℃下测量的储能模量G'可大于80,000Pa。在另一方面,在60℃下测量的储能模量G'可小于300,000Pa且大于18,000Pa,或大于24,000Pa,或大于 30,000Pa,或大于90,000Pa。在另一方面,在90℃下测量的储能模量G'可小于200,000Pa且大于10,000Pa,或大于20,000Pa,或大于30,000Pa。在 60℃和90℃下测量的储能模量可为热塑性粘合剂材料在高环境温度下的形式稳定性的量度。如果吸收产品在炎热的气候中使用,则该值是特别重要的,如果60℃和90℃下的储能模量G'不足够高,则在所述气候中,热塑性粘合剂材料将失去其完整性。
G'可使用流变仪,如WO2010/27719所述进行测量。流变仪能够向粘合剂施加剪切应力,并且测量在恒定温度下所引起的应变(剪切变形)响应。将粘合剂置于用作下固定板的珀尔帖元件和具有例如10mm半径R的上板之间,所述上板连接到马达的驱动轴上以生成剪切应力。两个板之间的间隙具有例如1500微米的高度H。珀尔帖元件使得能够控制材料的温度(+0.5℃)。应选择应变速率和频率使得所有测量在线性粘弹性区域进行。
吸收材料沉积区域8
该吸收芯可包括由芯包裹物内的吸收材料60形成的层的周边所限定的吸收材料沉积区域8,如当该吸收芯被展平时从顶部观察的那样,如图3所示。吸收材料60可连续地或不连续地施加于吸收材料沉积区域8中。如果在吸收材料口袋或吸收材料条之间存在不含吸收材料的通道或接合区域,则这些被认为是吸收材料沉积区域8的一部分,例如出于测量吸收材料沉积区域的宽度或长度L的目的。
吸收材料沉积区域8的形状可变化,具体地其可为如图3所示的矩形或被成形为具有所谓的“狗骨”或“沙漏”的形状,其至少在吸收材料沉积区域的裆区81中沿其宽度表现出渐缩,如图6所示。当被成形(非矩形)时,吸收材料沉积区域8可在芯的裆区81中具有相对窄的宽度,因为这可在引入了所述芯的成品中提供例如更好的穿着舒适性。吸收材料沉积区域8可因此在其最窄点处具有小于约100mm,90mm,80mm,70mm, 60mm或甚至小于约50mm的宽度(如在垂直于纵向轴线80’的横向上测量的那样)。该最窄宽度通常可在裆区中,并且还可例如比吸收材料沉积区域8在该吸收芯的前区82和/或后区83中的其最大点处的最大宽度小至少 5mm,或至少10mm,或至少20mm。
吸收材料的基重(每单位表面的沉积量)也可沿吸收材料沉积区域8 变化以产生吸收材料在芯的纵向、横向、或这两个方向上的异形分布。从而沿芯的纵向轴线80’、以及沿横向轴线或平行于这些轴线中任一个的任何轴线,吸收材料的基重可变化。相对高基重区域诸如裆点中的吸收材料的基重可因此比相对低基重区域中的高例如至少10%,或20%,或30%,或 40%,或50%。具体地,相比于沉积区域8的前区82或后区83的任何其它区域,存在于吸收材料沉积区域8中的吸收材料在裆点C的水平处每单位沉积面积可具有更多SAP。SAP的基重可在芯的裆点(C)处比在纵向轴线上的吸收材料沉积区域的另一个点处(具体地在芯的前区或后区中)高至少10%,或20%,或30%,或40%,或50%。
可使用已知的技术来沉积吸收材料60,所述技术可允许以相对高的速度相对精确地沉积SAP。具体地,可使用如例如US2006/24433 (Blessing)、US2008/0312617和US2010/0051166A1(均授予Hundorf等人)所公开的SAP印刷技术。这种技术使用印刷辊以将SAP沉积在基底上,该基底设置在可包括多个交叉条的支撑件网格上,该多个交叉条基本上彼此平行并彼此间隔地延伸以形成在多个交叉条之间延伸的通道。这种技术允许高速并精确地将SAP沉积在基底上。可例如通过如下方法来形成该吸收芯的通道:修改网格图案和接收转筒,使得无SAP被施加在对应于通道的区域中。例如EP专利申请号11169396.6更详细地公开了该修改。
超吸收聚合物(SAP)
如本文所用,“超吸收聚合物”(“SAP”)是指如下吸收材料,所述材料是交联聚合材料,当使用离心保留容量(CRC)测试(EDANA方法 WSP 241.2-05E)来测量时,所述聚合材料能够吸收至少10倍于其自身重量的含水的0.9%盐水溶液。本发明的SAP具体地可具有超过20g/g,或超过24g/g,或20至50g/g,或20至40g/g,或24至30g/g的CRC值。用于本发明中的SAP包含多种水不溶性却水可溶胀的能够吸收大量流体的聚合物。
超吸收聚合物可为颗粒形式,以便在干燥状态下可流动。典型的粒状吸收性聚合物材料由聚(甲基)丙烯酸聚合物制成。然而,例如还可使用基于淀粉颗粒的吸收性聚合物材料,以及聚丙烯酰胺共聚物、乙烯马来酸酐共聚物、交联羧甲基纤维素、聚乙烯醇共聚物、交联聚环氧乙烷、以及聚丙烯腈的淀粉接枝的共聚物。超吸收聚合物可以为聚丙烯酸酯和聚丙烯酸聚合物,其为内部交联和/或表面交联的。合适的材料在PCT专利申请 WO07/047598或例如WO07/046052或例如WO2009/155265和 WO2009/155264中有所描述。在一些实施例中,合适的超吸收聚合物颗粒可通过本领域现阶段的制备工艺获得,如更具体地在WO2006/083584中描述。优选将超吸收聚合物内部交联,即在具有两个或更多个可聚合基团的化合物的存在下进行聚合,所述化合物可自由基共聚到聚合物网络中。可用的交联剂包括例如如EP-A 530 438中所述的乙二醇二甲基丙烯酸酯、二甘醇二丙烯酸酯、甲基丙烯酸烯丙酯、三羟甲基丙烷三丙烯酸酯、三烯丙基胺、四烯丙氧基乙烷,如EP-A 547 847、EP-A 559476、EP-A 632 068、 WO 93/21237、WO 03/104299、WO 03/104300、WO 03/104301和DE-A103 31 450中所述的二丙烯酸酯和三丙烯酸酯,如DE-A 103 31 456和DE- A 103 55 401中所述的混合丙烯酸酯(其不仅包括丙烯酸酯基团,还包括烯键式不饱和基团),或者如例如DE-A 195 43 368、DE-A 196 46 484、WO 90/15830和WO 02/32962中所述的交联剂混合物,以及WO2009/155265中所述的交联剂。超吸收聚合物颗粒可为外部表面交联的(或:后交联的)。可用的后交联剂包括包含能够与所述聚合物的羧酸根基团形成共价键的两个或更多个基团的化合物。可用的化合物包括例如EP-A 083 022、 EP-A 543 303和EP-A 937 736中所述的烷氧基甲硅烷基化合物、聚氮丙啶、聚胺、聚酰氨基胺、二或聚缩水甘油基化合物;如DE-C 33 14 019中所述的多元醇;如DE-A 40 20 780中所述的环状碳酸酯;如DE-A 19807 502中所述的2-唑烷酮及其衍生物,诸如N-(2-羟乙基)-2-唑烷酮;如DE-A 198 07992中所述的双和聚-2-唑烷酮;如DE-A 198 54 573中所述的2-氧代四氢-1,3-嗪及其衍生物;如DE-A 198 54 574中所述的N-酰基-2-唑烷酮;如DE-A 102 04 937中所述的环脲;如DE-A 103 34 584中所述的二环酰胺缩醛;如EP1,199,327中所述的氧杂环丁烷和环脲;以及如 WO03/031482中所述的吗啉-2,3-二酮及其衍生物。
在一些实施例中,SAP由聚丙烯酸聚合物/聚丙烯酸酯聚合物形成,例如具有60%至90%,或约75%的中和程度,具有例如钠抗衡离子。
可用于本发明的SAP可为很多种形状。术语“颗粒”是指小粒、纤维、薄片、球体、粉末、薄板、以及在超吸收聚合物颗粒领域中技术人员已知的其它形状和形态。在一些实施例中,SAP颗粒可为纤维的形状,即细长的针状超吸收聚合物颗粒。在那些实施例中,超吸收聚合物颗粒纤维具有小于约1mm,通常小于约500μm,并且优选小于250μm下至50μm的小尺度(即纤维的直径)。纤维的长度优选为约3mm至约100mm。纤维也可为可被织造的长丝的形式。
通常SAP是球状颗粒。与纤维相反,“球状颗粒”具有最长和最短尺寸,并且颗粒的最长和最短颗粒尺寸之比在1-5范围内,其中值1等于完美的球状颗粒,而值5允许与此类球状颗粒有一些偏差。根据EDANA方法 WSP 220.2-05测量,超吸收聚合物颗粒可具有小于850μm,或50至 850μm,优选100至710μm,更优选150至650μm的粒度。具有相对低粒度的SAP有助于增加吸收材料与液体流出物接触的表面积,并因此支持对液体流出物的快速吸收。
SAP可具有在45μm至4000μm的范围内的粒度,更具体地具有在 45μm至约2000μm,或约100μm至约1000,850或600μm范围内的粒度分布。颗粒形式的材料的粒度分布可如本领域中已知来测定,例如借助于干筛分析法(EDANA 420.02“Particle Size分配)。
在本文的一些实施例中,超吸收材料呈颗粒形式,具有多至2mm,或介于50微米和2mm或至1mm之间,或优选地100或200或300或400或 500μm,或至1000或至800或至700μm的质量中值粒度;所述质量中值粒度可例如通过例如EP-A-0,691,133中所述的方法来测量。在本发明的一些实施例中,超吸收聚合物材料呈颗粒形式,所述颗粒中按重量计至少80%为具有介于50μm和1200μm之间的尺寸且具有介于上述任何范围组合之间的质量中值粒度的颗粒。此外,或在本发明的另一个实施例中,所述颗粒为大致上球形的。在本发明的另一个或附加实施例中,超吸收聚合物材料具有相对窄范围的粒度,例如其中大部分(例如至少80重量%或优选地至少90重量%或甚至至少95重量%)的颗粒具有50μm和1000μm之间,优选地100μm和800μm之间,并且更优选地200μm和600μm之间的粒度。
合适的SAP可例如由如US4,340,706和US5,849,816所述的反相悬浮聚合反应获得,或者由如美国专利申请2009/0192035、2009/0258994和 2010/0068520所述的喷雾或其它气相分散聚合反应获得。在一些实施例中,合适的SAP可通过本领域现阶段的制备工艺获得,如更具体地由WO 2006/083584,第12页第23行至第20页第27行中所述。
SAP表面可涂覆有例如阳离子聚合物。优选的阳离子聚合物可包括聚胺或聚亚胺材料。在一些实施例中,SAP可涂覆有脱乙酰壳多糖材料,诸如US7,537,832中所公开的那些。在一些其它实施例中,SAP可包含混合床离子交换吸收聚合物,如WO 99/34841和WO 99/34842中所公开的那些。
吸收芯通常将包含仅一种类型的SAP,但不排除可使用SAP的共混物。可使用其“尿液渗透性测量”(UPM)值来量化超吸收聚合物的流体渗透性,所述值在欧洲专利申请号EP12174117.7所公开的测试中测量。 SAP的UPM可为例如至少10×10-7cm3.sec/g,或至少30×10-7cm3.sec/g,或至少50×10-7cm3.sec/g,或更高,例如至少80或100×10-7cm3.sec/g。流动特性也可通过改变在第二吸收层中使用的SAP量和分布进行调节。
就大多数吸收制品而言,液体排放主要在制品(具体地尿布)的前半部中进行。该吸收芯可因此被置于吸收制品中,使得吸收制品的前半部包括芯的大部分吸收容量。因此,按重量计至少60%,或65%,或70%,或 75%,或80%的SAP可存在于吸收制品的前半部中,剩余的SAP设置在吸收制品的后半部中。吸收制品的前半部区域可被定义为介于吸收制品的前边缘10和吸收制品的横向轴线90之间的区域。横向轴线90垂直于纵向轴线80并被置于制品长度的二分之一的距离处,所述距离是在制品的纵向轴线上从其前边缘或后边缘测量的。
存在于吸收芯中的SAP总量也可根据期望的使用者而变化。用于新生儿的尿布可比婴儿尿布或成人失禁尿布需要较少的SAP。芯中的SAP量可例如占约5至60g,具体地5至50g。SAP的沉积区域8(或者如果存在多个,则“至少一个”)内的平均SAP基重可以为例如至少50、100、200、 300、400、500g/m2或更多。由吸收材料沉积区域推导存在于吸收材料沉积区域8中的通道区域以计算该平均基重。
芯包裹物(16,16’)
芯包裹物可由围绕吸收材料折叠的单一基底制成,或可有利地包括附接到另一个的两个(或更多个)基底。典型的附接件为所谓的C形包裹物和/或夹心包裹物。在C形包裹物中,如图2和4示例性所示,基底之一的纵向边缘和/或横向边缘被折叠到另一个基底上以形成翼片。然后这些翼片通常通过胶粘粘结到另一个基底的外表面。
芯包裹物可由适用于接收并包含吸收材料的任何材料形成。可使用用于制备常规芯的典型的基底材料,具体地,纸、薄纸、膜、织造织物或非织造织物、或任何这些材料的层合体。芯包裹物可具体地由非织造纤维网形成,诸如梳理非织造织物、纺粘非织造织物(“S”)或熔喷非织造织物 (“M”)、以及这些中任何织物的层合体。例如,熔纺聚丙烯非织造织物是合适的,尤其是具有层压纤维网SMS、或SMMS或SSMMS结构,并具有约5gsm至15gsm基重范围的那些。合适的材料例如公开于 US7,744,576、US2011/0268932A1、US2011/0319848A1或 US2011/0250413A1中。可使用由合成纤维诸如PE、PET,尤其是PP所提供的非织造材料。
如果芯包裹物包括第一基底16和第二基底16’,则其可由相同类型的材料制成,或可由不同的材料制成,或者一个基底可以与另一个不同的方式进行处理以向其提供不同的特性。因为用于非织造织物制备的聚合物是固有疏水的,如果置于吸收芯的流体接收侧上,它们优选地涂覆有亲水性涂层。有利的是,芯包裹物的顶侧面,即在吸收制品中更靠近穿着者放置的侧面,比芯包裹物的底侧面更具亲水性。一种制备具有耐久亲水性涂层的非织造织物的可能方法是,通过将亲水单体和自由基聚合引发剂施涂到非织造织物上,并且进行通过紫外光所激发的聚合作用,从而导致单体化学地结合到非织造织物的表面上。一种制备具有耐久亲水性涂层的非织造织物的另选的可能方法是用亲水性纳米颗粒来涂覆非织造织物,例如,如 WO 02/064877中所述。
永久性地亲水性非织造织物也可用于一些实施例中。如US7744576 (Busam等人)所述,表面张力可用于测量获得的某种亲水性水平的持久性。如US7744576所述,液体透湿可用于测量亲水性水平。当用盐水溶液润湿时,第一和/或第二基底可具体地具有至少55,优选地至少60,还更优选至少65mN/m或更高的表面张力。基底也可具有对液体的第五涌流小于 5s的液体透湿时间。这些值可使用US7,744,576B2:“Determination Of SurfaceTension”和“Determination of Strike Through”分别所述的测试方法来测量。
亲水性和可润湿性通常根据流体例如通过非织造织物的接触角和透湿时间来定义。在由Robert F.Gould编辑的名称为“Contact angle,wettability and dhesion”的美国化学学会出版物(1964版权所有)中对此进行了详细的讨论。可认为水和基底表面之间的接触角较小的基底比另一种基底更具亲水性。
所述基底还可以为透气的。因此可用于本文的膜可包括微孔。基底可具有例如40或50至300或至200m3/(m2×min)的透气率,所述透气率通过EDANA方法140-1-99(125Pa,38.3cm2)测定。芯包裹物的材料可另选具有较低的透气率,例如为非透气的,以例如有利于对移动表面的处理,包括真空。
在本发明中,芯包裹物可至少部分地沿吸收芯的所有侧边密封或以其它方式密封,使得在执行下述“WCACF测试”期间基本上无吸收材料渗漏出芯包裹物。所谓“基本上无吸收材料”,是指小于5%,有利地小于 2%,或小于1%或0重量%的吸收材料逸出芯包裹物。具体地,芯包裹物不应当在进行测试期间以可测量的方式破裂开。
术语“密封”旨在被广义地理解。密封不需要沿芯包裹物的整个周边是连续的,而是沿其部分或全部可以为不连续的,诸如由在一条线上密集间隔的一系列密封点形成。虽然所述密封可位于芯的周边,但不排除密封也可位于芯的其它位置,例如靠近纵向中心线80。通常,密封可由胶粘和/ 或热粘结形成。
如果芯包裹物由两个基底16,16’形成,则芯的每个边缘通常可使用一个密封件将吸收材料60包封在芯包裹物内。这举例说明于图4和5中。例如,如图4所示,第一基底16可放置于芯的一个侧面(如图所示的顶侧面)上并围绕芯的纵向边缘延伸以至少部分地包裹芯的相对(底)侧面。第二基底16’可存在于第一基底16的包裹的翼片和芯的吸收材料60之间。第一基底16的翼片可胶粘到第二基底16’以提供强效密封。与夹心密封件相比,该所谓的C形包裹物构造可提供有益效果,诸如在润湿加载状态下改善的耐破裂性。然后,芯包裹物的前边缘和后边缘也可例如通过将第一基底和第二基底彼此平坦胶粘来密封,从而在芯的整个周边上提供对吸收材料的更完全包封。可有利地至少在芯的纵向边缘上使用C形包裹物,所述纵向边缘长于前边缘和端部边缘。在所谓的夹心构造中,第一基底和第二基底也可在芯的所有边缘上向外延伸并沿芯周边的全部或部分平坦密封,通常通过胶粘和/或热/压力粘结来密封。通常第一基底和第二基底均不需要成形,使得它们可被矩形切割以方便制备,但是当然其它形状也是可能的。
芯包裹物也可由单一基底形成,所述基底可将吸收材料包封在包裹物中,并可例如沿芯的前边缘和后边缘以及一个纵向密封件来密封。
通道26,26’
该吸收芯包括至少部分地在芯的纵向上取向的至少一个通道。在下文中,复数形式的“通道”将用来表示“至少一个通道”。通道可按各种方式来形成。例如,通道可由吸收材料沉积区域内的如下区形成,所述区可基本上不含或完全不含吸收材料,具体地SAP。此外或另选地,通道也可如下形成:通过吸收材料沉积区域将形成芯包裹物的顶侧面的材料连续地或不连续地粘结到形成芯包裹物的底侧面的材料。通道可有利地为连续的,但不排除通道为间歇的。采集-分配系统或顶片和吸收芯或制品的另一个层之间的任何子层也可包括通道,它们可或可不对应于吸收芯的通道。通道可具体地被完全涵盖在吸收材料沉积区域8内。
一个或多个通道可具体地存在于芯的裆区(81)内,具体地至少与裆点C处在相同的纵向水平,如图3由所述两个纵向延伸的通道26,26’所示。一些通道也可从裆区81延伸到芯的后区82和/或前区83中,或可仅仅存在于芯的前区和/或后区中,如图6由较小通道27,27’所示。
吸收芯28也可包括超过两个通道,例如至少3个,或至少4个或至少 5个或至少6个通道。较短通道也可存在于例如芯的后区或前区中,如图6 中朝芯前部的一对通道27,27’所示。通道可包括相对于纵向轴线80’对称地布置的一对或多对通道。
当吸收材料沉积区域为矩形时,通道可尤其用于吸收芯,因为通道可改善芯的柔韧性至在使用非矩形的(成形的)芯时优势较小的程度。当然,通道也可存在于具有成形沉积区域的SAP层中。
通道可基本上纵向延伸,这通常是指每个通道在纵向上比在横向上延伸得更多,并且通常在纵向上延伸为在横向上至少两倍那么多(如在投射到相应轴线上之后所测量的)。通道可具有投射在芯的纵向轴线80’上的长度L’,所述长度为吸收材料沉积区域8的长度L的至少10%。可为有利的是,通道中的至少一些或全部不是在芯中完全或基本上完全横向取向的通道。
通道可为完全纵向取向的并平行于纵向轴线,但也可为弯曲的。具体地,一些或所有通道,具体地存在于裆区中的通道,可朝纵向轴线80’为凹形的,如例如图3和7所述一对通道26,26’所示。曲率半径通常可至少等于吸收材料沉积区域8的平均横向尺寸(且优选地为该平均横向尺寸的至少1.5或至少2.0倍);并且也是直的,但与平行于纵向轴线的线成(例如从5°)多至30°,或例如多至20°,或多至10°的角度。曲率半径对于通道可为恒定的,或可沿其长度变化。这也可包括在其中具有角度的通道,前提条件是通道的两个部分之间的所述角度为至少120°,优选地至少150°;并且在任何这些情况下,前提条件是通道的纵向延伸量超过横向延伸量。通道也可为分支的,例如与裆区中的纵向轴线叠加的中心通道朝制品的后部和/或朝前部分支。
在一些实施例中,不存在与芯的纵向轴线80’重合的通道。当作为相对于纵向轴线的对称对存在时,通道可在它们的整个纵向尺寸上彼此间隔开。最小间距可为例如至少5mm,或至少10mm,或至少16mm。
此外,为了减小流体渗漏的风险,纵向主通道通常不延伸多至吸收材料沉积区域8的任何边缘,并因此完全被涵盖在芯的吸收材料沉积区域内。通常,通道和吸收材料沉积区域的最近边缘之间的最小距离为至少 5mm。
通道沿其长度的至少一部分可具有宽度Wc,所述宽度为至少2mm,或至少3mm或至少4mm,至多例如20mm,或16mm或12mm。通道的宽度可在通道的基本上整个长度上为恒定的或可沿其长度变化。
至少一些或全部通道有利地为持久通道,这意味着它们的完整性在干燥状态和润湿状态下均被至少部分地保持。持久通道可通过提供一个或多个粘合剂材料来获得,例如粘合剂材料纤维层或帮助在通道壁内粘附例如基底与吸收材料的构造胶。持久通道也可具体地通过将芯包裹物的上侧和下侧(例如第一基底16和第二基底16’)通过通道粘结在一起而形成。通常,粘合剂能够用来通过通道粘结芯包裹物的这两个侧面,但有可能经由其它已知的方式诸如压力粘结、超声粘结或热粘结或它们的组合来粘结。可沿通道连续地粘结或间歇地粘结芯包裹物。当吸收制品被流体完全加载时,如下文的“润湿通道完整性测试”所公开,通道可有利地保留或变得至少透过顶片和/或底片为可见的。这可通过制备基本上不含SAP的通道来获得,因此它们不溶胀,并且足够大使得它们在润湿时将不闭合。此外,通过通道将芯包裹物粘结到其自身也可为有利的。下述“润湿通道完整性测试”可用来测试通道在润湿饱和后是否是持久且可见的并且至何种程度后是持久且可见的。有利地,根据本发明的持久通道具有根据下述“湿通道完整性测试”测量的至少20%,或30%,或40%,或50%,或60,或 70%,或80%,或90%的完整性百分比。
顶片24
顶片24是吸收制品的直接接触穿着者皮肤的一部分。如本领域已知的那样,顶片24可接合到底片25、芯28和/或任何其它层(如本文所用,术语“接合”涵盖通过将一个元件直接附连到另一个元件而将该元件直接固定到另一个元件的构型以及通过将一个元件附连到中间构件继而将该中间构件附连到另一个元件而将元件间接固定到另一个元件的构型。通常,顶片24和底片25彼此在一些位置直接接合(例如在制品周边上或靠近制品周边处),并且通过在其它位置使它们直接接合制品20的一个或多个其它元件,从而间接接合在一起。
顶片24优选地为柔顺的、感觉柔软的,并且不刺激穿着者的皮肤。另外,顶片24的至少一部分为液体可透过的,从而允许液体容易地穿透其厚度。合适的顶片可由许多各种不同的材料制成,诸如多孔泡沫、网状泡沫、开孔塑料膜、或者天然纤维(例如,木纤维或棉纤维)、合成纤维或长丝(例如,聚酯纤维或聚丙稀纤维或PE/PP双组分纤维或它们的混合物)或天然纤维与合成纤维组合的织造或非织造材料。如果顶片24包含纤维,纤维可为纺粘、梳理成网、湿法成网、熔喷、水刺法、或以本领域已知的方式经处理的,具体地为纺粘PP非织造织物。包括短纤维长度聚丙烯纤维的纤维网的合适的顶片由International PaperCompany的一个分部 Veratec,Inc.(Walpole,MA)制造,商品名为P-8。
合适的成形膜顶片描述于US3,929,135、US4,324,246、US4,342,314、 US4,463,045和US5,006,394中。其它合适的顶片可根据授予Curro等人的 US4,609,518和4,629,643来制备。此类成形膜以“DRI-WEAVE”购自The Procter&Gamble Company(Cincinnati,Ohio)并以“CLIFF-T”购自总部设在 Richmond,VA的Tredegar Corporation。
如本领域已知的那样,顶片的任何部分均可涂覆有洗剂。合适的洗剂的示例包括描述于US5,607,760、US5,609,587、US5,643,588、US5,968,025 和US6,716,441中的那些。顶片24也可包含抗菌剂或用抗菌剂进行处理,一些示例公开于PCT公布WO95/24173中。另外,顶片、底片或者顶片或底片的任何部分可经压花和/或糙面精整以提供更类似于布料的外观。
顶片24可包括一个或多个孔以便于流出物透过,诸如尿液和/或粪便 (固体、半固体、或液体)。至少主孔的尺寸对于获得期望的废物包封性能是重要的。如果主孔太小,废物可不穿过孔,这是由于废物源和孔的位置未对齐,或者由于粪块具有大于孔的直径。如果孔太大,可能被制品的“回渗”污染的皮肤区域增大。通常,尿布表面处的孔的总面积可具有介于约10cm2和约50cm2之间,具体地介于约15cm2和35cm2之间的面积。开孔顶片的示例公开于转让给BBA NONWOVENS SIMPSONVILLE的 US6632504中。WO2011/163582还公开了合适的着色顶片,其具有12至18gsm的基重并包括多个粘结点。粘结点中的每一个具有2mm2至5mm2的表面积,并且所述多个粘结点的累加表面积为所述顶片总表面积的10至 25%。
典型的尿布顶片具有约10至约28gsm,具体地介于约12至约18gsm 之间的基重,但其它基重也是可能的。
底片25
底片25一般为吸收制品20的在被使用者穿着时形成制品的大部分外表面的部分。底片朝吸收芯的底侧面定位并防止其中所吸收和容纳的流出物脏污制品诸如床单和内衣。底片25通常是对液体(例如,尿液)不可透过的。底片可例如为或包括薄塑料膜诸如具有约0.012mm至约0.051mm厚度的热塑性膜。示例性底片膜包括由总部在Richmond,VA的Tredegar Corporation制造并以商品名CPC2膜出售的那些。其它合适的底片材料可包括允许水蒸汽从尿布20逸出同时还防止流出物通过底片25的透气材料。示例性的透气材料可包括的材料诸如织造纤维网、非织造纤维网、复合材料诸如膜包衣的非织造纤维网、微孔膜如由Mitsui Toatsu Co.(Japan)以名称ESPOIR NO制造的和由Tredegar Corporation(Richmond,VA)制造并以名称EXAIRE出售的、以及单片膜诸如由Clopay Corporation(Cincinnati, OH)以名称HYTREL共混物P18-3097制造的。一些可透气的复合材料更详细地描述于以下专利中:以E.I.DuPont的名义公布于1995年6月22日的 PCT专利申请号WO 95/16746;授予LaVon等人的US5,938,648,授予 Linman等人的US4,681,793、授予Curro的US5,865,823;和授予Dobrin等人的US5,571,096、授予London Brown的US6,946,585B2。
可通过本领域已知的任何附接部件将底片25接合到尿布20的顶片 24、吸收芯28或任何其它元件上。合适的附接部件已在上文针对用于将顶片24接合到制品20的其它元件上的部件进行了说明。例如,附接部件可包括均匀连续的粘合剂层、成图案的粘合剂层、或分离的粘合剂线、螺旋线或点的阵列。合适的附接部件包括粘合剂长丝的开放图案网络,如US4,573,986中所公开的。其它合适的附接部件包括一些盘绕成螺旋图案的粘合剂长丝,如US3,911,173、US 4,785,996;和US 4,842,666中所示出的设备和方法所说明。由H.B.Fuller Company(St.Paul,Minnesota)制造且以 HL-1620和HL1358-XZP出售的粘合剂已被发现为令人满意的。另选地,附接方法可包括热粘结、压力粘结、超声粘结、动态机械粘结、或本领域已知的任何其它合适的附接方法或这些附接方法的组合。
采集-分配系统
本发明的吸收制品可包括采集层52、分配层54、或两者的组合(在本文中均统称为采集-分配系统“ADS”)。ADS的功能通常是快速采集流体并以高效方式将其分配到吸收芯中。ADS可包括一个,两个或更多个层,它们可形成一体的层或保持为可彼此附接的离散层。在以下实例中,ADS 包括两个层:设置在吸收芯和顶片之间的分配层54和采集层52,但本发明不限于该实例。
通常,ADS将不包含SAP,因为这可减慢对流体的采集和分配。现有技术公开了许多类型的采集-分配系统,参见例如WO2000/59430 (Daley)、WO95/10996(Richards)、US5,700,254(McDowall)、 WO02/067809(Graef)。ADS可包括(虽然不是必须如此)两个层:分配层54和采集层52,现在将更详细地举例说明它们。
分配层54
分配层54的功能是将侵害性流体液体铺展到制品内的较大表面上,使得能够更有效地使用芯的吸收容量。通常,分配层由基于合成纤维或纤维素纤维的非织造材料制成并具有较低密度。分配层的密度可根椐制品的压缩而有差别,但在0.30psi(2.07kPa)下测量时通常可在0.03至 0.25g/cm3,具体地0.05至0.15g/cm3范围内。分配层54也可为具有如按US5,137,537所公开的规程所指示地那样测量的25至60,优选地30至45 的保水率值的材料。分配层可通常具有30至400g/m2,具体地100至 300g/m2的平均基重。
分配层可例如包含至少50重量%的交联纤维素纤维。交联的纤维素纤维可为起褶皱的、加捻的、或卷曲的、或它们的组合(包括起褶皱的、加捻的、和卷曲的)。该类型的材料已在过去作为采集系统的一部分用于一次性尿布中,例如US 2008/0312622 A1(Hundorf)。交联纤维素纤维在产品包装或使用条件下(例如在婴儿重量下)提供较高的弹性和因此较高的第一吸收层抗压缩抗性。这向芯提供较高的空隙体积、渗透性和液体吸收,从而减少渗漏并改善的干燥性。
适用于分配层的示例性化学交联的纤维素纤维在US5,549,791、 US5,137,537、WO9534329或US2007/118087中公开。示例性交联剂包括聚羧酸诸如柠檬酸和/或聚丙烯酸诸如丙烯酸和马来酸共聚物。例如,交联纤维素纤维可具有基于纤维素葡糖酐摩尔计约0.5摩尔%至约10.0摩尔%的 C2-C9多元羧酸交联剂,与所述纤维以纤维间酯交联键形式反应。C2-C9 多元羧酸交联剂可选自:
-脂族和脂环族C2-C9多元羧酸,其具有至少三个羧基基团/分子;和
-脂族和脂环族C2-C9多元羧酸,其具有两个羧基基团/分子,并且具有位于羧基基团的一个或两个的α-β的碳-碳双键,其中在所述 C2-C9多元羧酸交联剂中的一个羧基基团与第二羧基基团通过两个或三个碳原子分开。纤维可具体地具有基于纤维素葡糖酐摩尔计约 1.5摩尔%至约6.0摩尔%的交联剂,它们与其以纤维间酯交联键形式反应。交联剂可选自柠檬酸、1,2,3,4丁烷四羧酸、和1,2,3 丙烷三羧酸,具体地柠檬酸。
聚丙烯酸交联剂也可选自聚丙烯酸均聚物、丙烯酸共聚物、以及它们的混合物。纤维可具有基于干纤维重量计1.0重量%至10.0重量%,优选地 3重量%至7重量%的这些交联剂,它们与其以纤维间交联键形式反应。交联剂可为聚丙烯酸聚合物,其具有500至40,000,优选地1,000至20,000 的分子量。聚合聚丙烯酸交联剂可为丙烯酸和马来酸的共聚物,具体地其中丙烯酸对马来酸的重量比为10:1至1:1,优选地5:1至1.5:1。有效量的柠檬酸可与所述聚合聚丙烯酸交联剂进一步混合。
包含交联纤维素纤维的分配层可包含其它纤维,但该层可有利地包含按该层的重量计至少50%,或60%,或70%,或80%,或90%或甚至多至 100%的交联纤维素纤维(包括交联剂)。此类混合的交联纤维素纤维层的示例可包含约70重量%的化学交联的纤维素纤维、约10重量%的聚酯 (PET)纤维、和约20重量%的未经处理的纸浆纤维。又如,交联纤维素纤维层可包含约70重量%的化学交联的纤维素纤维、约20重量%的莱赛尔纤维、和约10重量%的PET纤维。又如,该层可包含约68重量%的化学交联的纤维素纤维、约16重量%的未处理纸浆纤维、和约16重量%的PET纤维。又如,交联纤维素纤维层可包含约90-100重量%的化学交联的纤维素纤维。
采集层52
吸收制品20可包括采集层52,其功能是快速地采集流体使其远离顶片以使为穿着者提供良好的干燥性。采集层52通常被直接置于顶片下方。如果存在,分配层可至少部分地设置在采集层下方。采集层通常可为非织造材料或可包含非织造材料,例如SMS或SMMS材料,其包括纺粘层、熔喷层和另外的纺粘层或梳理成网的化学粘结非织造材料。非织造材料可具体地被胶乳粘结。示例性上部采集层52公开于US7,786,341中。可使用梳理成网的树脂粘结的非织造织物,尤其是在所用的纤维为实心圆形或圆形且中空PET短纤维的情况下(6旦尼尔纤维和9旦尼尔纤维的50/50或 40/60混合物)。示例性粘结剂为丁二烯/苯乙烯胶乳。非织物具有其可在转换加工生产线外部制造并以材料卷的形式储存和使用的优点。
另外可用的非织物描述在授予Cramer等人的美国专利6,645,569、授予Cramer等人的美国专利6,863,933、授予Rohrbaugh等人的美国专利 7,112,621、和授予Cramer等人的共有专利申请US2003/148684与授予 Cramer等人的US2005/008839中。
采集层52可由胶乳粘合剂例如苯乙烯-丁二烯胶乳粘合剂(SB胶乳) 来稳定。用于获取此类晶格的方法是已知的,例如来自EP 149 880 (Kwok)和US 2003/0105190(Diehl等人)。在某些实施例中,粘结剂可以超过约12重量%、约14重量%或约16重量%的量存在于采集层52中。 SB胶乳可按以商品名GENFLOTM3160购得(OMNOVA Solutions Inc.;Akron,Ohio)。
除了上述第一采集层之外,还可使用其它采集层。例如,薄纸层可置于第一采集层和分配层之间。与上述采集层相比,薄纸可具有增强的毛细管分布特性。薄纸和第一采集层可具有相同尺寸或可具有不同尺寸,例如与第一采集层相比,薄纸层还可在吸收制品的后部中延伸。亲水性薄纸的示例为13-15gsm高湿强度,由得自供应商Havix的纤维素纤维制成。
扣紧系统42-44
吸收制品可包括扣紧系统。扣紧系统可用来提供围绕吸收制品的周边的侧向张力,以将吸收制品保持在穿着者身上。该扣紧系统对于训练裤制品而言不是必需的,因为这些制品的腰区已经被粘结。扣紧系统通常包括扣件,诸如胶带突片、钩-环扣紧部件、联锁扣件诸如插片&狭槽、扣环、纽扣、搭锁、和/或雌雄同体扣紧部件,虽然任何其它已知的扣紧部件一般也是可接受的。着陆区通常设置在制品的前腰区上以用于待可释放地附接的扣件。一些示例性表面扣紧系统公开于授予Buell的US 3,848,594、 US4,662,875、US 4,846,815、US4,894,060、US4,946,527、US5,151,092和 US 5,221,274中。示例性联锁扣紧系统公开于US6,432,098中。扣紧系统也可提供用于以配置构型保持制品的部件,如授予Robertson等人的美国专利 US 4,963,140所公开的。
扣紧系统还可包括主扣紧系统和辅扣紧系统,如US4,699,622中所公开的,以减少重叠部分的位移或改善贴合性,如US5,242,436、 US5,499,978、US5,507,736和US5,591,152中所公开的。
前耳片46和后耳片40
吸收制品可包括如本领域所已知的前耳片46和后耳片40。所述耳片可以为基础结构的整体部分,例如以侧片形式由顶片和/或底片形成。另选地,如图1所示,它们可为通过胶粘和/或热压花附接的独立元件。后耳片 40有利地是可拉伸的,以有助于插片42附接在着陆区40上,并将胶粘尿布保持在围绕穿着者腰部的适当位置。后耳片40还可以为弹性或可延展的,以通过初始适形地配合吸收制品为穿着者提供更舒适和适形性贴合,并且当吸收制品加载有流出物时在整个穿着期间维持该贴合性,因为弹性化耳片允许吸收制品的侧边伸展和收缩。
阻隔腿箍34和衬圈箍32
吸收制品诸如尿布或训练裤通常还可包括增大该制品围绕穿着者腿部的贴合性的部件,具体地阻隔腿箍34和衬圈箍32。阻隔腿箍32可由一片材料,通常为非织造织物形成,其部分地粘结到制品的其余部分,并在制品被拉平时可部分地从由顶片限定的平面凸起并因此直立,如例如图1-2所示。阻挡腿箍可在靠近穿着者的躯干和腿部的接合处提供对液体和其它身体流出物的改善的抑制性。阻隔腿箍至少部分地在纵向轴线的相对侧的吸收制品的前边缘和后边缘之间延伸,并且至少存在于裆点(C)的水平处。
阻隔腿箍可由接合到制品的剩余部分(通常顶片和/或底片)的近侧边缘64以及自由的端边66界定,其旨在接触穿着者皮肤并形成密封件。阻隔腿箍34可在近侧边缘64处通过粘结部65与制品的基础结构接合,所述粘结部可例如通过胶粘、熔融粘结或已知粘结方式的组合制成。近侧边缘 64处的粘结部65可以为连续或间歇的。
阻隔腿箍32可与顶片或底片一体(即由它们形成),或更典型地由接合到制品的其余部分的独立材料形成。通常,阻隔腿箍的材料可延伸通过制品的整个长度,但朝向制品的前边缘和后边缘“粘性粘结”到顶片,使得在这些节段中,阻隔腿箍材料保持与顶片齐平。每个阻挡腿箍34可包括靠近该自由端边66的一个、两个或更多个弹性带35,以提供更好的密封。
除了阻隔腿箍34以外,该制品还可包括衬圈箍32,所述衬圈箍形成于与吸收制品的基础结构相同的平面中,具体地可至少部分地被包封在顶片和底片之间,并且可相对于阻隔腿箍横向向外放置。衬圈箍可提供围绕穿着者的大腿的更好密封。通常每个衬圈腿箍将包括一个或多个弹性带或弹性元件,所述弹性带或弹性元件包括在尿布的基础结构中,例如位于腿部开口区域中的顶片和底片之间。
US3,860,003描述了提供可收缩腿部开口的一次性尿布,所述腿部开口具有侧翼和一个或多个弹性构件以提供弹性化腿箍(衬圈箍)。授予Aziz 等人的US4,808,178和US4,909,803描述了具有“直立”弹性侧翼(阻挡腿箍)的一次性尿布,所述侧翼改善腿部区域的抑制性。分别授予Lawson和 Dragoo的US4,695,278和US4,795,454描述了具有双箍(包括衬圈箍和阻挡腿箍)的一次性尿布。阻挡腿箍和/或衬圈箍中的全部或一部分可用洗剂处理。
弹性腰部结构
吸收制品还可包括至少一个弹性腰部结构(未示出),其有助于提供改善的贴合性和抑制性。弹性腰部结构通常旨在弹性伸展和收缩以动态适合穿着者的腰部。弹性腰部结构优选地从吸收芯28的至少一个腰部边缘至少沿纵向向外延伸,并通常形成吸收制品的后侧的至少一部分。可构造一次性尿布使得具有两个弹性腰部结构,一个定位于前腰区内而另一个定位于后腰区内。弹性腰部结构可被构造成许多不同的构型,包括描述于 US4,515,595、US4,710,189、US5,151,092和US 5,221,274中的那些。
各层和各部件之间的关系
通常,相邻层将使用常规的粘结方法诸如经由槽式涂布或喷涂到层的整个或部分表面上的粘合剂涂层,或热粘结、或压力粘结或它们的组合而接合在一起。为清楚和易读起见,图中未示出该粘结(除了腿箍34的凸起元件与顶片24之间的粘结65之外),但应当认为存在制品各层之间的粘结,除非具体地排除。粘合剂可通常用于改善不同层之间,例如底片和芯包裹物之间的粘附。所述胶可为本领域已知的任何标准热熔融胶。
如果存在采集层52,则可能有利的是该采集层在纵向尺寸和/或横向尺寸上大于或至少与分配层54一样大。因此,分配层54可沉积于采集层52 上。这简化了处理,尤其是如果采集层为可从库存材料卷展开的非织造织物时。分配层还可直接沉积在芯包裹物的吸收芯的上侧或制品的其它层上。另外,采集层52大于分配层还允许将采集层直接胶粘到储存芯(在较大区域处)。这可提供增大的制品完整性和更好的液体连通。
该吸收芯且具体地其吸收材料沉积区域8可有利地至少与ADS中的任何层一样大和长,并有利地至少部分地大于和/或长于ADS中的任何层。这是由于芯中的吸收材料通常可比ADS更有效地保持流体并在较大区域上提供干燥有益效果。吸收制品可具有矩形SAP层和非矩形(成形的)ADS。吸收制品也可具有矩形(非成形的)ADS和矩形SAP层。
制备方法
本发明的吸收芯和制品可通过本领域已知的任何常规方法来制备。具体地,所述制品可手工制备或以高速在现代转换加工生产线上工业化生产。
实验设置
除非另外指定,本文所示的值根据下文所示的方法测量。除非另外指定,所有测量均是在21℃±2℃和50%±20%RH下进行的。除非另外指明,在进行这些测试之前,应当将所有样本在这些条件下保持至少24小时以达到平衡。除非另外指明,应当对至少4个样本重复进行所有测量,并且指示所获得的平均值。
离心保留容量(CRC)
CRC测量超吸收聚合物颗粒在过量液体中自由溶胀所吸收的液体。 CRC根据EDANA方法WSP 241.2-05来测量。
干吸收芯厚度测试
该测试可用来以标准化方式测量吸收芯(在使用之前,即无流体加载时)的厚度。
设备:分辨率为0.01mm的Mitutoyo手动测径规--或等同的仪器。
接触脚:直径为17.0mm(±0.2mm)的平坦圆形脚。可将圆形砝码施加到所述脚上(例如,具有狭槽的砝码以有利于围绕仪器轴施加)以获得目标重量。选择脚和添加的砝码(包括轴)的总重量以向样品提供2.07kPa (0.30psi)的压力。
安装测径规,其中接触脚的下表面在水平面中,使得接触角的下表面接触约20×25cm的基板的平坦水平上表面的中心。在接触角搁置在基板上的情况下,标距设置成读数为零。
标尺:以mm为刻度的校准金属标尺。
秒表:精度为1秒
样本制备:如上所述地将芯调理至少24小时。
测量规程:将芯展平,使底侧面(即在成品中旨在朝底片放置的侧面)朝下。小心地在芯的顶侧面上画出测量点(例如裆点C),注意不要压缩芯或使芯变形。
将测径规的接触脚提起并将芯平坦放置在测径规的基板上,使芯的顶侧面朝上,使得当被放低时,所述脚的中心位于所标记的测量点上。
将所述脚轻轻下降到制品上并释放(确保在测量开始前校正成“0”)。在释放所述脚10秒之后,读取厚度值并精确到0.01mm。
对于每个测量点重复该程序。如果在测量点处存在折叠,则测量在最接近该点但不具有任何折叠的区域中进行。对于给定的产品,以这种方式测量十个制品,并且计算并记录平均厚度,其中精度为十分之一毫米。
吸收制品厚度测试
“吸收制品厚度测试”可与“干吸收芯厚度测试”一样执行,差别在于测量的是成品吸收制品的厚度而不是芯的厚度。测量点可为吸收制品的纵向轴线(80)和横向轴线(90)的交点。如果所提供的吸收制品为折叠的和/或处在包装件中,则展开待测量的制品和/或从包装件的中心区域取出待测量的制品。如果该包装包含多于4个的制品,则在该测试中不使用该包装的每个侧面上的最外两个制品。如果该包装包含多于4个但少于14个制品,则需要多于一个包装的制品来完成该测试。如果该包装包含14个或更多的制品,则仅需要一个包装的制品来进行测试。如果该包装包含4个或更少的制品,则测量包装中的所有制品,并且需要多个包装件来进行测量。厚度读数应当在制品从包装件中取出、展开和调理之后24±1小时获取。应当尽可能少地对产品进行物理操纵,并且物理操纵仅限于必要的样本制备。
切除或移除制品的阻止制品在测厚仪脚下被展平的任何弹性部件。这些可包括腿箍或腰带。根据需要,将裤型制品沿侧缝打开或切开。施用足够的张力以展平任何折叠/褶皱。注意不要触碰和/或压缩测量区域。
润湿通道完整性测试
该测试被设计成在润湿饱和之后检查吸收芯中通道的完整性。
1.通道的全长(以毫米计)在干燥状态下测量(如果通道不是直的,则测量穿过通道中心的曲线长度)。
2.然后将吸收芯完全浸入大量过量的(例如5升)合成尿液“盐水溶液”中,其浓度为9.00g NaCl/1000ml溶液,所述溶液是通过将适量氯化钠溶解在蒸馏水中制备的。溶液温度必须为20+/-5℃。
3.在放入所述盐水溶液中1分钟之后,取出芯并抓住一个端部保持竖直5秒以进行沥干,然后在水平表面上展平,使顶侧面(在该制品中旨在面向穿着者的侧面)朝上。如果芯包括拉伸元件,则将其拉紧使得观察不到收缩。芯可由夹钳在其前边缘和后边缘固定到水平表面,使得不能够发生收缩。
4.将吸收芯覆盖上矩形合适重量的刚性板,其尺寸如下:长度等于芯的全长,并且宽度等于最宽点处的最大芯宽度。
5.施加18.0kPa的压力在上文提及的刚性板区域上30秒。基于刚性板的覆盖总面积计算压力。通过将附加砝码置于刚性板的几何中心获得压力,使得刚性板和附加砝码的总重量导致在刚性板总面积上18.0kPa的压力。
6.在30秒后,移除附加的砝码和刚性板。
7.紧接其后,测量保持未受损的通道的部分的累积长度(以毫米计;如果通道不是直的,则测量穿过通道中部的曲线长度)。如果无通道部分保持完整,则通道不是永久性的。
永久性通道的完整性百分比通过用保持完整的通道部分总长度除以干燥状态下的通道长度、并且随后用商乘以100进行计算。
湿厚度和压缩力(WCACF)测试
该测试测量a)饱和的吸收芯在一次侧向压缩之后的厚度增加百分比;和b)将饱和的吸收芯侧向地压缩至40mm的宽度所需的力。“WCACF测试”旨在根据以下指示对吸收芯进行。
1.在芯的顶侧面上标记出该吸收芯上的纵向轴线。当从顶部观察芯时,纵向轴线沿吸收芯的长度大致将芯的顶侧面划分成两个大致对称的部分,如图3示例性所示。芯的顶侧面为旨在朝吸收制品的面向穿着者侧放置的侧面。不确定的是,顶侧面通常比底侧面更具亲水性。如果仍然不能够识别顶侧面,则对相等数目的芯在交替侧面上进行测试并对结果取平均值。可用任何笔来作标记,注意在作标记时不要损坏芯。
2.在该吸收芯的与纵向中心线相同的侧面上标记出裆线。裆线垂直于纵向轴线并与纵向轴线相交于等于45%的吸收芯长度L (0.45L)的距离处。该距离是从吸收芯的前侧测量的(参见图3 的示例性例证)。吸收芯的前侧为芯的旨在朝吸收制品前部放置的一侧。如果芯的预期取向不是已知的,则前边缘位于其中SAP 的量较高的芯的一侧上。如果仍然不能够识别前边缘,则能够以起始于一侧的距离测试样本的二分之一并以起始于另一侧的距离测试另外二分之一,并对结果取平均值。裆线和纵向轴线的交点为裆点C。
3.然后将吸收芯浸没在大量过量的,例如5升浓度为9.00g NaCl/1000ml溶液的合成尿液“盐水溶液”中,所述盐水溶液是通过将适量的氯化钠溶解在蒸馏水中而制备的。容器必须足够大以适应于处于平坦构型的芯。在浸没期间,芯的标记的侧面朝上。
4.在放入所述盐水溶液中1分钟之后,取出吸收芯并抓住前侧保持竖直10秒以进行沥干。
5.通过将其在水平表面上拉平而让吸收芯平衡10分钟,使顶侧面朝下。被置于芯的前侧和后侧上的夹钳可用来保持加载的芯平坦。
6.然后在裆点处测量压缩之前的加载的吸收芯的厚度,并记录为C 初始。出于该目的,使用直径为17.0mm的压脚,并施加2.07kPa (0.30psi)的压力。在树脂玻璃板上展平吸收芯,使标记的侧面朝上,并且轻轻地放低压脚,使得其中心位于裆点C上。在所述脚和芯之间初始地接触之后30±2秒测量并记录厚度C初始,精确至0.1mm。
7.然后将加载的吸收芯(使其顶侧面朝上)固定在刚性塑料圆筒上,如图7示例性所示。圆筒600具有150mm(+-1mm)的直径 d。首先经由先前施加于圆筒上的双面胶带或其它扣紧部件将芯28 的前边缘280的最后20.0mm(+-0.5mm)附接到最靠近操作者的圆筒的外表面,使得吸收芯可牢固地并可释放地附接到圆筒。然后将芯28的后边缘282的最后20.0mm(+-0.5mm)以如下高度附接在圆筒的沿直径相对的外表面处,所述高度足以使裆点C与圆筒600的中心轴线610重合。
8.应当理解,圆筒需要足够地高,使得芯的后边缘可附接到它。
9.然后如下所详述地侧向压缩吸收芯。通过包含一对压缩板630,640 的组件将压缩力施加于吸收芯,所述压缩板模拟在使用期间压缩吸收芯的腿部的部分。每个压缩板均应当具有90mm(+-1mm)× 90mm(+-1mm)的尺寸。这些板可由可被成形为所需的平坦正方形形状的任何合适的材料制成(例如铝、树脂玻璃)。这些板应当被放置成彼此相对地对齐的。压缩板被放置成使得芯的顶侧面上的“裆线”和每个压缩板的几何中心对齐并处在水平面中。
10.以100mm/min的恒定速率朝裆点驱动每个压缩板。(总闭合速度为200mm/min)。这两个压缩板之间的间隙起始时为140.0mm+- 0.5mm,或更大的距离,如果芯的宽度如此要求的话,然后当吸收芯被压缩时收窄至40.0mm+-0.5mm的最终间隙。压缩板可例如使用诸如Zwick Z 1.0之类的设备或类似设备。测试仪器包括用于固定一个压缩板的右夹钳和用于固定另一个压缩板的左夹钳。该设备应当包括具有适当测量范围的测力传感器,例如多至100N并且精度为至少+/-0.01N。
11.一旦吸收芯被压缩至40mm,就保持压缩30秒。在所述30秒结束时在释放压缩之前立即记录所述力,精确至0.01N,并记录为“湿法压缩力”。然后对于每个板,可使压缩板以100mm/min的速度返回到它们的初始位置。
12.其后立即从圆筒600取下吸收芯,注意不要触碰已被压缩的区域。如果在压缩步骤期间有一些吸收材料渗漏出芯包裹物,则收集并称重所渗漏出的吸收材料。
13.再次使用如上文在步骤6中所述的厚度测量规程测量裆点C处的厚度。将该厚度值记录为C最终。
对至少4个芯样本重复进行该规程。然后如下计算吸收芯的“相对湿厚度增加”(RWCI):
相对湿厚度增加(%)=(ΣC最终-ΣC初始)*100/ΣC初始
其中ΣC最终为所测量的所有样本的C最终值的总和,并且ΣC初始为所测量的所有样本的C初始值的总和。根据本发明的芯的“相对湿厚度增加”值小于10.0%,具体地其可在1.0%至9.5%,或2.0%至9.0%,或至2.5%至 8.0%的范围内。
如果一些吸收材料在步骤12处渗漏,则可提取并且也可称重仍然包含在芯中的其余吸收材料。如果渗漏的量表示小于芯的总吸收材料(渗漏的和提取的)的5重量%,则认为在测试期间“基本上无吸收材料”渗漏。有利地,在步骤12期间小于2%,或小于1%或甚至0重量%的吸收材料逸出芯包裹物。具体地,芯包裹物不应当在进行测试期间以可测量的方式破裂开。
实验
制备了根据本发明的以下吸收芯:
发明实例1:
该实例中所测试的吸收芯类似于图3所示的芯。这些芯包含SAP作为吸收材料,无纤维素纤维。芯包裹物包括形成芯的顶侧面和底侧面的两个基底,上基底沿芯的纵向边缘以及芯的平坦附接的前边缘和后边缘形成C 形包裹物。芯在裆区中包括两个不含吸收材料的通道。通道相对于纵向轴线80为对称的,在其上具有约227mm的投射长度、约8mm的宽度并且彼此相距20mm的最短距离。芯包裹物还通过通道附接到其自身。
吸收芯包括施加于沉积区域中的总计14.1g的快速吸收SAP,所述沉积区域具有360mm的长度和110mm的宽度(矩形轮廓)。SAP被分布成使得SAP的基重在裆区中比在前区高,并且朝后区更低。在横向方向 (“横向”或“CD”,除了不含吸收材料的通道之外)不存在异形分布的 SAP。吸收芯通过如US2010/0051166A1所公开的SAP印刷技术形成,所述技术组合两个非织造基底,所述非织造基底各自支撑一个SAP层并具有施加于每个SAP层上的微纤维弹性胶,所述微纤维弹性胶将SAP层固定在基底上。通道通过使用限定通道形状的合适的印刷转筒来形成,关于如何形成通道的另外的信息可见于使用印刷的SAP技术的欧洲专利申请号 EP12174117.7中。
将辅助胶施加于SAP层和上基底16之间,所述辅助胶是用41个1mm 宽的狭槽槽式涂布的,沿芯包裹物的整个长度(390mm),狭槽之间的距离为1mm。分别将0.211g和0.168g的微纤维胶(源自H.B.Fuller)施加于上SAP层和下SAP层,施加区域在每个SAP层上具有110mm的宽度和 390mm的长度。
芯包裹物具有390mm的长度,在吸收芯的后边缘和前边缘具有长度为 15mm的不含吸收材料的两个端片。芯的前端密封件和后端密封件被槽式胶粘在一起,胶槽具有从前端密封件算起的30mm的长度并与后端密封件相距20mm。芯包裹物的折叠宽度为120mm。
上基底16为10gsm经亲水性处理的SMMS非织造织物,并且下基底 16’为10gsmSMMS非织造织物。上基底具有390mm的切割长度和165mm 的切割宽度。下基底具有390mm的切割长度和130mm的切割宽度。上基底围绕下基底在芯的侧向边缘上C形包裹,并且下层的侧向边缘略微向上形成于芯的吸收材料的边缘上,使得折叠的芯包裹物的总体宽度为约120mm。通过在芯的基底之间施加折叠胶将所述C形包裹物制成为持久的,所述折叠胶用2个狭槽以20gsm施加于芯的每个侧面上,所述狭槽具有3mm的狭槽宽度和390mm的长度。
所述两个基底另外还通过通道粘结在一起。所述粘结通过施加压力和辅助性徽纤维胶来形成。所述粘结为强效的。芯包裹物密封件在“WCACF 测试”期间阻抗压缩,因而无吸收材料逸出芯包裹物。
发明实施例2
该实例中所测试的芯具有两对通道和类似于图6所示的成形沉积区域。吸收材料沉积区域的宽度在前区和后区为110mm,并且在吸收材料沉积区域的裆点处为90mm。
长通道和短通道在芯的纵向轴线上的投射长度分别为约170mm和 40mm。较长通道之间的最小距离为约16mm。较短通道之间的最小距离为约14mm。芯包括11.53g的SAP。芯包裹物包括两个非织造织物,顶部基底(16)为10gsm SMMS非织造织物,其经表面活性剂处理成为亲水性的。下基底(16’)为11gsm SMMS非织造织物。将辅助胶施加于下SAP 层和其相应的下基底之间,所述辅助胶是用41个1mm宽的狭槽槽式涂布的,沿芯包裹物的整个长度(390mm),狭槽之间的距离为1mm。施加于每个SAP层上的微纤维胶(源自H.B.Fuller)以108mm的宽度和390mm 的长度均匀地施加于每个SAP层上,0.211g的微纤维胶用于芯覆盖件侧面上,并且0.211g用于除尘层侧面上。其余的芯构造基本上类似于发明实例 1中的芯。
比较例
比较例1基本上类似于发明实例2,差别在于该吸收芯不包括不含材料的通道。
测试结果
根据上述“WCACF测试”测试了每种上述产品的四个样本以测量芯的“相对湿厚度增加”和“湿法压缩力”。下文编排了平均结果:
讨论
不希望受理论的束缚,据信对于缺少下述特征部中的一者或多者的吸收芯,以下特征部可单独地或以组合方式增大相对湿厚度。除非具体地声明,这些特征部均不应当被看作是限制权利要求的范围。
1)包裹物的顶侧面和包裹物的底侧面可有利地通过通道至少部分地彼此粘结。这些粘结部可为连续的或间歇的,并且可经由胶粘和/ 或热粘结制成,并且可有利地足够强效以至少部分地阻抗流体加载时的分层(“持久通道”),如上文所讨论。通过在通道中约束芯包裹物,这些粘结部增大了芯包裹物的应变,因而能够减弱芯加载时的润湿厚度增加。
2)芯包裹物可包括第一基底(16)和第二基底(16’),这两者通常由非织造织物制成,其中第一基底围绕第二基底形成C形包裹物。第一基底可形成芯包裹物的顶侧面,并且第二基底可形成芯包裹物的底侧面的至少一部分。通常,这些基底可沿第一基底的包裹的翼片连同第二基底的底侧面粘结,例如通过胶粘粘结。本发明人相信,C形包裹物,尤其是沿吸收芯的纵向侧面的一部分或全部的C形包裹物,能够更好地抑制吸收材料在压缩时逸出芯。
3)“湿法压缩力”受到吸收材料的量和裆区中芯的沉积区域形状的影响。据信芯的裆区处的较低量的吸收材料和/或较窄的沉积区域 (如在成形区域中那样)能够提供减小的“湿法压缩力”。本发明的吸收芯可示例性地具有通过“WCACF测试”测量的低于 5.00N,具体地小于3.00N,或1.00N至5.00N的“湿法压缩力”。
本文所公开的量纲和值不应被理解为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的范围。例如,所公开的量纲“40mm”旨在表示“约40mm”。
Claims (19)
1.一种适于在吸收制品(20)中使用的吸收芯(28),其中所述吸收芯包括包封吸收材料(60)的芯包裹物(16,16'),
所述吸收芯(28)包括前边缘(280)、后边缘(282)和两个纵向边缘(284,286),所述吸收芯(28)具有在纵向上取向的纵向轴线(80')和沿所述纵向轴线在所述前边缘和后边缘之间测量的长度L,所述长度L为至少320mm,
所述吸收芯包括至少部分地在所述纵向上取向的并且相对于所述吸收芯的纵向轴线(80’)对称设置的至少一对通道(26,26'),
其中至少一个通道具有投射在所述吸收芯的纵向轴线(80')上的长度L',所述长度L'为所述吸收芯的长度L的至少10%,
其中至少一个通道不含吸收材料,并且其中所述通道的宽度(Wc)至少在所述通道的一些部分中为至少2mm,
其中所述芯包裹物包括顶侧面(288)和底侧面(290),并且其中所述芯包裹物的形成所述顶侧面的部分和所述芯包裹物的形成所述底侧面的部分通过至少一个通道至少部分地彼此粘结,
其中所述吸收芯具有压缩之后的小于10.0%的“相对湿厚度增加”(RWCI),所述“相对湿厚度增加”通过本文所述的“湿厚度和压缩力(WCACF)测试”测量,并且
其中所述芯包裹物(16,16')被至少部分地密封,使得在执行所述“WCACF测试”的压缩步骤时基本上无吸收材料渗漏出所述芯包裹物,
其中所述吸收芯具有通过本文所述的“WCACF测试”测量的小于5.00N的湿法压缩力(WCF)。
2.根据权利要求1所述的吸收芯,其中所述吸收材料包含按所述吸收材料的重量计至少80%的超吸收聚合物(“SAP”)。
3.根据权利要求1所述的吸收芯,其中所述吸收芯具有通过本文所述的“WCACF测试”测量的1.00N至3.00N的湿法压缩力(WCF)。
4.根据权利要求1-3中任一项所述的吸收芯,其中至少一个通道不含吸收材料。
5.根据权利要求4所述的吸收芯,其中所述通道的宽度(Wc)至少在所述通道的一些部分中为4mm至16mm。
6.根据权利要求1-3中任一项所述的吸收芯,其中所述芯包裹物包括第一非织造织物(16)和第二非织造织物(16'),并且其中所述第一非织造织物围绕所述第二非织造织物形成C形包裹物。
7.根据权利要求1-3中任一项所述的吸收芯,其中所述吸收材料(60)在所述芯包裹物内限定吸收材料沉积区域(8),并且其中所述吸收材料沉积区域(8)为矩形或被成形为具有如下宽度,所述宽度在所述吸收芯的裆区(81)中具有最小值,所述裆区为所述吸收芯的从裆点(C)朝所述吸收芯的后边缘和前边缘在两个方向上延伸四分之一L(L/4)的距离的区域,所述裆点为被放置成与所述吸收芯的前边缘(280)相距所述长度L的45%的点。
8.根据权利要求1-3中任一项所述的吸收芯,其中所述吸收芯包括第一吸收层和第二吸收层,所述第一吸收层包括第一基底(16)和第一超吸收聚合物层(61),所述第二吸收层包括第二基底(16')和第二超吸收聚合物层(62),并且所述吸收芯还包括位于所述第一吸收层和所述第二吸收层之间的纤维热塑性粘合剂材料(51),并且其中所述第一基底和所述第二基底形成所述芯包裹物(16,16')。
9.根据权利要求8所述的吸收芯,其中所述纤维热塑性粘合剂材料(51)至少部分地有助于将每个超吸收聚合物层(61,62)粘结到其相应基底(16,16')。
10.根据权利要求1-3中任一项所述的吸收芯,其中所述吸收材料(60)包含按所述吸收材料的总重量计至少90%的SAP,多至100%的SAP。
11.根据权利要求1-3中任一项所述的吸收芯,其中所述吸收材料(60)包含小于10重量%,或小于5重量%的天然纤维或合成纤维,或不含天然纤维或合成纤维。
12.根据权利要求1-3中任一项所述的吸收芯,其中所述SAP的基重在SAP分配区域内沿所述吸收芯的纵向轴线不均匀分布。
13.根据权利要求12所述的吸收芯,其中所述SAP的基重在所述吸收芯的裆点(C)处比在所述纵向轴线上的所述吸收材料沉积区域的另一个点处高至少10%,所述裆点为被放置成与所述吸收芯的前边缘(280)相距所述长度L的45%的点。
14.根据权利要求1-3中任一项所述的吸收芯,所述吸收芯包含5g至60g的SAP。
15.根据权利要求1-3中任一项所述的吸收芯,所述吸收芯包含10g至50g的SAP。
16.根据权利要求1-3中任一项所述的吸收芯,其中根据本文所述的“芯厚度测试”在裆点(C)处测量的所述吸收芯的厚度为0.25mm至5.0mm,所述裆点为被放置成与所述吸收芯的前边缘(280)相距所述长度L的45%的点。
17.根据权利要求1-3中任一项所述的吸收芯,其中根据本文所述的“芯厚度测试”在裆点(C)处测量的所述吸收芯的厚度为0.5mm至3.0mm,所述裆点为被放置成与所述吸收芯的前边缘(280)相距所述长度L的45%的点。
18.一种吸收制品(20),所述吸收制品包括液体可透过的顶片、液体不可透过的底片以及位于所述顶片和所述底片之间的根据前述权利要求中任一项所述的吸收芯。
19.根据权利要求18所述的吸收制品,其中所述吸收制品为尿布、训练裤、女性护垫或成人失禁制品。
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DE202013012617U1 (de) | 2017-12-08 |
CA2894669A1 (en) | 2014-06-19 |
GB2522596A (en) | 2015-07-29 |
US20140163502A1 (en) | 2014-06-12 |
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DE202013012616U1 (de) | 2017-12-06 |
CN107496080B (zh) | 2020-12-04 |
MX2015006849A (es) | 2015-09-16 |
DE202013012614U1 (de) | 2017-12-06 |
RU2015120712A (ru) | 2017-01-16 |
CL2015001585A1 (es) | 2015-10-02 |
DE112013005898T5 (de) | 2015-10-22 |
US20190336360A1 (en) | 2019-11-07 |
JP2015536229A (ja) | 2015-12-21 |
CN104837454B (zh) | 2017-12-08 |
JP6129986B2 (ja) | 2017-05-17 |
GB201509856D0 (en) | 2015-07-22 |
BR112015013519A2 (pt) | 2017-07-11 |
RU2630891C2 (ru) | 2017-09-13 |
BR112015013519B1 (pt) | 2021-07-27 |
CA2894669C (en) | 2019-02-26 |
WO2014093311A1 (en) | 2014-06-19 |
CN104837454A (zh) | 2015-08-12 |
US20170281426A1 (en) | 2017-10-05 |
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