CN108349222A - 非织造材料及具有非织造材料的吸收制品 - Google Patents

非织造材料及具有非织造材料的吸收制品 Download PDF

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Publication number
CN108349222A
CN108349222A CN201580084560.2A CN201580084560A CN108349222A CN 108349222 A CN108349222 A CN 108349222A CN 201580084560 A CN201580084560 A CN 201580084560A CN 108349222 A CN108349222 A CN 108349222A
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CN
China
Prior art keywords
fibre
core
composite fibre
woven material
fiber
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
CN201580084560.2A
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English (en)
Other versions
CN108349222B (zh
Inventor
刘晓新
宋利民
O·E·A·伊泽勒
王凡成
唐莉
蔡吉祥
G·厄登
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Procter and Gamble Ltd
Procter and Gamble Co
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Procter and Gamble Ltd
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Publication date
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Publication of CN108349222A publication Critical patent/CN108349222A/zh
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Active legal-status Critical Current
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Classifications

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    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022Non-woven fabric
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    • A61F13/15203Properties of the article, e.g. stiffness or absorbency
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Abstract

本发明公开了一种非织造材料,其包括第一纤维网层和第二纤维网层,所述第一纤维网层包括具有不大于约2.5旦尼尔的纤维细度的芯/皮型第一复合纤维,并且所述第二纤维网层包括具有不大于约2.5旦尼尔的纤维细度的芯/皮型第二复合纤维和具有大于约3旦尼尔的纤维细度的均聚物纤维,其中按第二纤维网层的重量计,第一纤维网层中的纤维的平均旦尼尔不大于约2.5,并且均聚物纤维小于约30%。本发明还公开了用于制造非织造材料的方法和包括所述非织造材料的吸收制品。

Description

非织造材料及具有非织造材料的吸收制品
技术领域
本发明涉及非织造材料、用于制造所述非织造材料的方法、和包括所述非织造材料的吸收制品。
背景技术
包括由热塑性树脂形成的合成纤维的非织造材料被广泛用作构成吸收制品诸如卫生巾、婴儿一次性尿布、个人护理一次性尿布等的片材。
从皮肤感觉、干燥感、舒适度、吸收排出的体液、和防止流体回流的观点出发,各种非织造材料已被建议用作用于吸收制品的部件诸如顶片。显然,高性价比的非织造材料在保持有利的物理特性诸如厚度、光滑度、缓冲作用和可取的膨松度的同时,还将满足非织造材料纺织品领域中的纵向进料的需要。
非织造材料的厚度或蓬松度通常取决于基重。增大基重将由于使用了更多原材料而增加成本。希望在一些其中使用非织造材料的应用中具有增大的厚度,而不增大基重。非织造材料的期望的膨松度通常也取决于基重。在一些应用中,希望具有带有增大的期望的膨松度的织物,而不增大基重。
同时,当非织造材料用作吸收制品的部件诸如顶片时,顶片和穿着者的皮肤之间的摩擦在顶片表面上产生绒毛,所述绒毛常常导致皮肤发生皮疹或导致不适感。较高的绒毛含量导致更大的皮肤刺激以及皮肤的更强的瘙痒感。因此,在使用期间减小绒毛的生成是有利的。
美国专利4,883,707公开了一种高蓬松非织造织物复合材料,其由包括具有3或更小的平均旦尼尔的热塑性树脂纤维的柔软的梳理纤维网层和包括具有3或更大的平均旦尼尔的热塑性树脂纤维的蓬松的梳理纤维网层构成。日本未经审查的专利公布2006-233364描述一种具有光滑度和柔软舒适感的非织造材料,其包括第一纤维网层和第二纤维网层,其中至少被包括在第一纤维网层中的纤维具有平坦的横截面,并且所述横截面的长轴在基本上平行于非织造材料表面的方向上取向。US 2015/173975A公开了一种具有改善的表面光滑度和触感的非织造材料,其具有包括第一偏心芯/皮型复合纤维的第一纤维层和包括第二偏心芯/皮型复合纤维的第二纤维层,所述第一偏心芯/皮型复合纤维由包含线性低密度聚乙烯的皮组分构成,并且所述第二偏心芯/皮型复合纤维由包含高密度聚乙烯的皮组分构成。
仍然需要一种高性价比的非织造材料,其带有改善的表面光滑度、适量的缓冲作用和期望的膨松度和/或在使用期间减少的绒毛生成。还需要一种吸收制品,其提供改善的触感、干燥感和舒适度和/或有限的绒毛生成。
发明内容
本发明提供了一种非织造材料,其包括第一纤维网层和第二纤维网层,所述第一纤维网层包括具有不大于约2.5旦尼尔的纤维细度的芯/皮型第一复合纤维,并且所述第二纤维网层包括具有不大于约2.5旦尼尔的纤维细度的芯/皮型第二复合纤维和具有大于约3旦尼尔的纤维细度的均聚物纤维,其中第一纤维网层中的纤维的平均旦尼尔不大于约2.5,并且按第二纤维网层的重量计,均聚物纤维小于约30%。
本发明还提供了一种用于制造非织造材料的方法,所述方法包括以下步骤:形成第一纤维网,所述第一纤维网包括具有不大于约2.5旦尼尔的纤维细度的第一芯/皮型复合纤维;形成第二纤维网,所述第二纤维网包括具有尔不大于约2.5的平均旦尼尔的第二芯/皮型复合纤维和具有大于约3的平均旦尼尔的均聚物纤维,其中按第二纤维网的重量计,均聚物纤维小于30%;通过将第一纤维网覆盖在第二纤维网上来形成复合纤维网;以及使复合纤维网经受热处理,以便经由第一芯/皮型复合纤维和第二芯/皮型复合纤维的皮部分来热粘结所述纤维的至少一部分。
本发明还提供了一种吸收制品,其包括顶片;和接合到顶片的底片,其中顶片包括根据本发明的非织造材料。
对于本领域的技术人员来说,通过阅读本说发明的公开内容,本发明的这些和其它特征、方面和优点将变得显而易见。
附图说明
图1为用于绒毛测量的装置的平面图。
图2为用于在绒毛测量中进行绒毛评估的等级标度。
具体实施方式
所有范围都是包括端值在内的且可组合的。有效位数的数字既不限制所指示的量也不限制测量的精度。所有数值应理解为被词“约”修饰,除非另外特别指明。
如本文所用,术语“吸收制品”包括一次性尿布、卫生巾、卫生护垫、失禁衬垫、阴唇间衬垫、母乳衬垫、汗垫、动物用排泄物处理制品、动物用尿布等。
如本文所用,术语“接合”是指如下状况:其中第一构件直接或间接地附接或连接到第二构件。在第一构件附接或连接到中间构件,所述中间构件继而附接或连接到第二构件的情况下,第一构件和第二构件为间接接合的。
本发明的非织造材料具有至少两个层,它们包括第一纤维网层和第二纤维网层,其中第一纤维网层包括具有不大于2.5旦尼尔的纤维细度的第一芯/皮型复合纤维,并且第二纤维网层包括具有不大于2.5的纤维细度的第一芯/皮型复合纤维和具有大于3的纤维细度的均聚物。有利地,本发明的非织造材料具有增大的初始厚度和压缩厚度,同时保持表面光滑度。所述非织造材料在与皮肤摩擦的情况下具有有限的绒毛生成。不受理论的束缚,本发明的非织造材料的有利特性可通过如下方式来实现:采用至少两个非织造材料层,并且在选定的纤维细度范围内利用芯/皮型复合纤维,并且在第二层中采用不同纤维细度的芯/皮型复合纤维和均聚物。
不受理论的束缚,包含线性低密度聚乙烯的芯/皮型复合纤维的皮组分可赋予奢华的触感,诸如表面柔软性和光滑度。第二层中的均聚物可主要向非织造材料赋予高膨松度和缓冲作用。第二层中的选定范围内的均聚物可有助于进一步减少非织造材料的绒毛含量。
在下文中,描述了构成本发明的非织造材料的纤维、第一纤维网层和第二纤维网层的构型、和用于制造非织造材料的方法、和具有所述片材的吸收制品。
第一芯/皮型复合纤维
本发明中的第一芯/皮型复合纤维包括包含树脂的芯组分和包含以下热塑性树脂的皮组分,所述热塑性树脂具有比芯组分的树脂的熔点低至少约20℃的熔点。第一芯/皮型复合纤维具有不大于约2.5旦尼尔,或不大于约2.0旦尼尔的纤维细度。不受理论的束缚,当纤维细度大于2.5旦尼尔时,根据本发明的非织造材料可能不具有令人满意的非织造材料表面光滑度。第一芯/皮型复合纤维优选地具有小于约100mm的纤维长度。
在第一芯/皮型复合纤维中,复合比率,即芯组分/皮组分的体积比率优选地为约80/20至约30/70,更优选地约70/30至约35/65,并且更优选地约60/40至约40/60。不受理论的束缚,在第一芯/皮型复合纤维中,芯组分可主要有助于膨松度(初始厚度)和膨松度恢复(可压缩厚度)特征,诸如非织造材料的缓冲垫似的感觉,并且皮组分可主要有助于非织造材料的强度和柔软性。当复合比率为约80/20至约30/70,优选地约70/30至约35/65,并且更优选地约60/40至约40/60时,可同时实现优异的非织造材料强度和柔软性和膨松度恢复特征。如果皮组分体积被增大,则所得非织造材料的强度可增大,但非织造材料可能硬化,并且膨松度恢复特征可能受到损害。另一方面,如果芯组分过多,则可存在不足的粘结点,非织造材料的强度可能降低,并且因此膨松度恢复特征可能受到负面影响。
第一芯/皮型复合纤维可具有二维褶皱和/或三维褶皱。在本文中,术语“二维褶皱”可被理解为机械褶皱,其中褶皱的纤维的峰成尖锐角度。三维褶皱可指其中所述峰为弯曲的(波纹形褶皱)或螺旋的(螺旋形褶皱)的褶皱、其中同时存在波纹形褶皱和螺旋形褶皱的褶皱、或其中同时存在机械褶皱以及波纹形褶皱和螺旋形褶皱中的至少一者的褶皱。在一个实施方案中,第一芯/皮型复合纤维具有二维褶皱,其相比于具有三维褶皱的复合纤维来讲性价比较高。
第一芯/皮型复合纤维可为同心或偏心的。在一个实施方案中,第一芯/皮型复合纤维为同心纤维。
芯组分
芯组分包含至少一种树脂,优选地热塑性树脂。用于芯组分的树脂优选地包括聚烯烃基树脂,诸如聚丙烯、聚甲基戊烯等;聚酯树脂,诸如聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、聚对苯二甲酸丙二醇酯、聚萘二甲酸乙二醇酯、聚乳酸、以及它们的共聚物;聚酰胺基树脂,诸如尼龙66、尼龙12、尼龙6等;丙烯酸类树脂;工程塑料,诸如聚碳酸酯、聚缩醛、聚苯乙烯、环状聚烯烃等;它们的混合物。从非织造材料的均匀性和非织造材料生产能力的角度来看,聚烯烃树脂、聚酯和聚酰胺基树脂为更优选的。聚酯的示例包括聚合物和共聚物,诸如聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、聚对苯二甲酸丙二醇酯、聚萘二甲酸乙二醇酯、聚乳酸。芯组分可选自由以下项组成的组:聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、聚丙烯、尼龙、聚酰胺、以及它们的组合。聚对苯二甲酸乙二醇酯和聚对苯二甲酸丁二醇酯为优选的,并且聚对苯二甲酸乙二醇酯为更优选的。另选地,芯组分可仅包含聚酯作为聚合物组分。
芯组分可包含除树脂之外的添加剂,诸如抗静电剂、颜料、消光剂、热稳定剂、光稳定剂、阻燃剂、抗微生物剂、润滑剂、增塑剂、软化剂、抗氧化剂、紫外线吸收剂、晶体成核剂等。这些添加剂可按不超过芯组分的约10质量%的量被包含在芯组分中。
皮组分
第一芯/皮型复合纤维的皮组分包含热塑性树脂,所述热塑性树脂具有比第一芯/皮型复合纤维的芯组分中的树脂的熔点低至少约20℃的熔点。
适用于皮组分的热塑性树脂可包括关于以上芯组分所述的树脂。
皮组分可包含除树脂之外的添加剂,诸如抗静电剂、颜料、消光剂、热稳定剂、光稳定剂、阻燃剂、抗微生物剂、润滑剂、增塑剂、软化剂、抗氧化剂、紫外线吸收剂、晶体成核剂等。这些添加剂优选地按不超过整个皮组分的约10质量%的量被包含在皮组分中。
第二芯/皮型复合纤维
本发明中的第二芯/皮型复合纤维包括包含树脂的芯组分和包含以下热塑性树脂的皮组分,所述热塑性树脂具有比芯组分的树脂的熔点低至少约20℃的熔点。第二芯/皮型复合纤维具有下述不大于约2.5旦尼尔的纤维细度。当纤维细度大于2.5旦尼尔时,由第二芯/皮型复合纤维制成的非织造纤维网表面的光滑度可下降。
以上“第一芯/皮型复合纤维”中关于第一芯/皮型复合纤维的描述也适用于第二芯/皮型复合纤维。
均聚物纤维
本发明中的均聚物包含至少一种树脂,其在非织造材料的制造过程中不在热处理时熔融或变形。
用于均聚物纤维的热塑性树脂优选地包括聚烯烃基树脂,诸如聚丙烯、聚甲基戊烯等;聚酯树脂,诸如聚对苯二甲酸乙二醇酯(“PET”),聚对苯二甲酸丁二醇酯、聚对苯二甲酸丙二醇酯、聚萘二甲酸乙二醇酯、聚乳酸、以及它们的共聚物;聚酰胺基树脂,诸如尼龙66、尼龙12、尼龙6等;丙烯酸类树脂;工程塑料,诸如聚碳酸酯、聚缩醛、聚苯乙烯、环状聚烯烃等;它们的混合物。从非织造材料的均匀性和非织造材料生产能力的角度来看,聚烯烃树脂、聚酯和聚酰胺基树脂为更优选的。聚酯的示例包括聚合物和共聚物,诸如聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、聚对苯二甲酸丙二醇酯、聚萘二甲酸乙二醇酯、聚乳酸。均聚物可包含至少一种选自由以下项组成的组的热塑性树脂:聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、聚丙烯、尼龙、聚酰胺、以及它们的组合。聚对苯二甲酸乙二醇酯和聚对苯二甲酸丁二醇酯为优选的,并且聚对苯二甲酸乙二醇酯为更优选的。另选地,均聚物可仅包含聚酯作为聚合物组分。在一个实施方案中,均聚物为PET。
均聚物纤维可包括成型均聚物纤维。不受理论的束缚,成型纤维可优于圆形纤维以提供改善的缓冲垫似的特征和压缩阻抗,因为成型纤维在相同的纤维旦尼尔下具有较高的回弹性,这是由于其相比于圆形纤维具有较高的有效半径。成型纤维也可引入较高的比表面积,其增大包含成型纤维的第二纤维网层的毛细管压力,这可导致第一纤维网层被包括成型纤维的第二纤维网层更好地排水。在一个实施方案中,成型均聚物可选自由以下项组成的组:双叶形纤维、三叶形纤维、四叶形纤维、Δ形纤维、凹Δ形纤维、新月形纤维、卵圆形纤维、星形纤维、正方形纤维、U形纤维、H形纤维、C形纤维、V形纤维、菱形纤维以及它们的任何组合。
均聚物可包含上文关于芯/皮型复合纤维所示的除树脂之外的添加剂。
不受理论的束缚,大于约3旦尼尔,优选地大于约5旦尼尔的均聚物纤维可有助于膨松度特征。
均聚物纤维优选地为亲水性的。
第一纤维网层
根据本发明的非织造材料中的第一纤维网层包括具有不大于约2.5旦尼尔的纤维细度的第一芯/皮型复合纤维。第一纤维网层中的纤维的平均纤维细度优选地不大于约2.5旦尼尔。在一个实施方案中,第一纤维网层仅包含第一芯/皮型复合纤维。
除了第一芯/皮型复合纤维之外,第一纤维网层还可包括其它纤维。所述其它纤维的示例包括天然纤维,诸如棉、丝、羊毛、大麻、木浆等;再生纤维,诸如人造丝、铜氨纤维等;以及合成纤维,诸如丙烯酸基纤维、聚酯基纤维、聚酰胺基纤维、聚烯烃基纤维、和聚氨酯基纤维。可基于非织造材料的应用从这些纤维中选择一种类型或多种类型。
第二纤维网层
根据本发明的非织造材料中的第二纤维网层包括在上文的“第二芯/皮型复合纤维”和“均聚物”下所述的第二芯/皮型复合纤维和均聚物。
第二纤维网层可包括第二芯/皮型复合纤维,所述第二芯/皮型复合纤维具有不大于第一纤维网层中的第一复合纤维的纤维细度的纤维细度。其可在非织造材料中引入毛细管瀑布,因而更有效地将流体从第一纤维网层传输至第二纤维网层,这在非织造材料用作吸收制品的部件时可改善吸收制品的干燥度和清洁度。
在一个实施方案中,第二芯/皮型复合纤维和均聚物纤维具有不小于约1旦尼尔的纤维细度差值。
按第二纤维网层的重量计,第二纤维网层包括小于约30%,或小于约25%的均聚物纤维。按第二层的重量计,第二纤维网层包括按重量计可大于10%,或大于15%的均聚物纤维。不受理论的束缚,当均聚物多于30%时,所得非织造材料的绒毛生成可受到关注,并且当均聚物低于10%时,所得非织造材料的初始厚度和/或回弹性可受到关注。
除了第二芯/皮型复合纤维和均聚物之外,第二纤维网层还可包括其它纤维。所述其它纤维的示例包括天然纤维,诸如棉、丝、羊毛、大麻、木浆等;再生纤维,诸如人造丝、铜氨纤维等;以及合成纤维,诸如丙烯酸基纤维、聚酯基纤维、聚酰胺基纤维、聚烯烃基纤维、和聚氨酯基纤维。可基于非织造材料的应用从这些纤维中选择一种类型或多种类型。
非织造材料的构型
本发明的非织造材料包括第一纤维网层和第二纤维网层,所述第一纤维网层包括第一芯/皮型复合纤维,并且所述第二纤维网层包括第二芯/皮型复合纤维和均聚物。所述纤维的至少一部分经由芯/皮型复合纤维的皮组分被热粘结。
可根据非织造材料的应用适当地选择非织造材料的基重。对于作为吸收制品的顶片的本发明的非织造材料,非织造材料的第一纤维网层和第二纤维网层的整体基重优选地为约25g/m2至约70g/m2,更优选地约35g/m2至约65g/m2。当非织造材料用作吸收制品的顶片时,在一个实施方案中,非织造材料的整体基重在约30g/m2至约70g/m2,并且优选地约35g/m2至约55g/m2范围内。
第一纤维网层和第二纤维网层的基重分别为优选地约5g/m2至约50g/m2,更优选地约10g/m2至约40g/m2,并且甚至更优选地约14g/m2至约35g/m2。第一纤维网层的基重/第二纤维网层的基重的比率为优选地约80/20至约20/80,并且更优选地约60/40至约50/50。如果第一纤维网层的基重太小并且/或者第一纤维网层的基重对第二纤维网层的基重的比率太小,则第一纤维网层的表面中的柔软性和光滑度可下降。如果第一纤维网层的基重太大并且/或者第一纤维网层的基重对第二纤维网层的基重的比率太大,则非织造材料的膨松度和缓冲作用可下降。
在一个实施方案中,非织造材料可仅由第一纤维网层和第二纤维网层构成。在另一个实施方案中,非织造材料包括三个层,其中第一纤维网层分层在第二纤维网层的双面上。在另一个实施方案中,除了第一纤维网层和第二纤维网层之外,非织造材料还可包括至少一个附加纤维层。用于所述附加纤维网层的纤维可选自天然纤维,诸如棉、丝、羊毛、大麻、木浆等;再生纤维,诸如人造丝、铜氨纤维等;以及合成纤维,诸如丙烯酸基纤维、聚酯基纤维、聚酰胺基纤维、聚烯烃基纤维、和聚氨酯基纤维。这种附加纤维层可包括选自这些纤维的一种或多种类型的纤维。
第一纤维网层和第二纤维网层可包括相同的芯/皮型复合纤维。在一个实施方案中,第一纤维网层包括第一芯/皮型复合纤维,所述第一芯/皮型复合纤维具有的纤维细度相同于或低于第二纤维网层中的第二芯/皮型复合纤维的纤维细度。在另一个实施方案中,第一纤维网层包括第一芯/皮型复合纤维,所述第一芯/皮型复合纤维具有的纤维细度高于第二纤维网层中的第二芯/皮型复合纤维的纤维细度。
在一个实施方案中,第一纤维网层的亲水性弱于本发明的非织造片材中的第二层。在另一个实施方案中,第一纤维网层的亲水性强于本发明的非织造片材中的第二层。
在一些实施方案中,当根据在“测试方法”下所述的“绒毛含量测量”来测量时,非织造材料可具有不大于3,或不大于2.5,或不大于2的绒毛等级。
本发明的非织造材料可包含按非织造材料的干重计约0.1至约6%的不透明剂。适用的不透明剂包括二氧化钛、粘土、碳酸钙、氧化锌和硅藻土。
非织造材料的制造方法
所述非织造材料可经由如下方法来制造,所述方法包括以下步骤:形成第一纤维网,所述第一纤维网包括具有不大于约2.5的纤维细度的第一芯/皮型复合纤维;形成第二纤维网,所述第二纤维网包括具有不大于约2.5的纤维细度的第二芯/皮型复合纤维和具有大于约3的纤维细度的均聚物纤维,其中按第二纤维网的重量计,均聚物纤维小于约30%;通过将第一纤维网覆盖在第二纤维网上来形成复合纤维网;以及使复合纤维网经受热处理,以便经由第一芯/皮型复合纤维和第二芯/皮型复合纤维的皮部分来热粘结第一芯/皮型复合纤维和第二芯/皮型复合纤维的至少一部分。
第一纤维网和第二纤维网可为梳理纤维网,诸如平行纤维网、半无规纤维网、无规纤维网、交叉纤维网、十字交叉纤维网等、气流成网纤维网、湿法成网纤维网、和纺粘纤维网等。第一纤维网和第二纤维网可为相同或不同的。
对复合纤维网的热处理可使用任何常规已知的热处理方法来进行。优选的处理方法的示例包括热处理设备,诸如热透气型热处理设备、热空气吹送热处理设备、红外线热处理设备等。这些热处理设备通常设有用于支撑和传送纤维网的传送载体。热处理可在一定条件下进行,使得第一芯/皮型复合纤维和第二芯/皮型复合纤维的皮组分充分熔融和/或软化并且在所述纤维的接触点或交点处粘结,并且使得第一芯/皮型复合纤维和第二芯/皮型复合纤维的褶皱不塌缩。例如,热处理温度可为约120℃至约150℃,并且优选地约128℃至约145℃。
非织造材料的应用
本发明的非织造材料向皮肤递送柔软且光滑的感觉,当非织造材料的表面被抵压时具有膨松且类似羽毛的触感,并且具有适量的缓冲作用和膨松度恢复特征。
因此,本发明的非织造材料可优选地用于其中非织造材料与皮肤接触的应用,具体地其中第一纤维网层为与皮肤接触的表面的应用。例如,本发明的非织造材料可用于如下应用,诸如接触人类皮肤或非人类动物皮肤的产品,诸如婴儿用一次性尿布、成人用一次性尿布、卫生巾、卫生护垫、失禁衬垫、阴唇间衬垫、母乳衬垫、吸汗片材、动物用排泄物处理制品、动物用尿布、以及类似的各种吸收制品;面罩、冷却/加热垫和类似的化妆用/医用补片的基础织物,伤口表面保护片材、非织造绷带、痔疮垫、直接接触皮肤的加温装置(例如一次性暖手器)、各种动物用补片的基础织物,以及类似的皮肤覆盖片材;化妆移除片材、止汗片材、人用底部擦拭物和类似的擦拭物,动物用各种擦拭片材等。本发明的非织造材料优选地用作用于吸收制品的顶片,其中第一纤维网层的表面与皮肤接触。
吸收制品
根据本发明的吸收制品包括顶片和接合到顶片的底片,其中顶片包括根据本发明的非织造材料。其还可包括设置在顶片和底片之间的吸收芯。
本发明的吸收制品可通过任何合适的方法来工业化生产。因此,所述不同的层可使用标准方法诸如压花、热粘结、胶粘或它们的任意组合来装配。
顶片
顶片可捕集体液和/或允许所述流体渗透到吸收制品内。对于根据本发明的非织造材料,第一纤维网层优选地被设置在与皮肤接触的一侧上。
底片
通常用于吸收制品的任何常规液体不可渗透的底片材料均可用作底片。在一些实施方案中,由所吸收的身体排泄物发出的恶臭气不能透过底片,使得恶臭不逸出。底片可为或可不为可透气的。
吸收芯
可能期望吸收制品还包括设置在顶片和底片之间的吸收芯。如本文所用,术语“吸收芯”是指适于吸收、分配和储存流体诸如尿液、血液、经液和其它身体流出物的材料或材料的组合。用于适用于吸收制品的吸收芯的任何常规材料可用作吸收芯。
测试方法
非织造材料厚度测量
非织造材料的初始厚度使用张力检验器(Synergize 200,MTS SystemCorporation,USA)来测量,其带有用以压缩所述材料的柱塞和用以承载非织造材料的塔板。
1)在进行测量之前,根据制造商的说明归零所述检验器。
2)使用直尺测量样本的大致厚度。
3)设定张力检验器:夹头速度:0.02cm/sec。预负荷=2g。
4)手动下移柱塞,直到其靠近但不接触塔板,从而留出足够的空间以将样本放置在柱塞和塔板之间。
5)根据制造商的说明设定用于张力检验器的程序以自动地执行以下步骤(a)–(d),并且起动张力检验器以收集数据。在步骤(c)和(d)之间,将样本(样本尺寸为8cm×8cm)放置在塔板上以确保柱塞位置与样本的中心对齐。
(a)下移柱塞,直到其接触到塔板。
(b)上移柱塞至台板分离位置。
(c)等待,直到样本被设定在柱塞下方。
(d)下移柱塞,直到负荷超过35gf,然后使其返回到台板分离位置。在张力检验器执行步骤(a)-(d)之前,将台板分离位置值输入到所述程序中。
6)数据分析
在2.0gf负荷下的厚度限定T0(mm),其指示样本的初始厚度。在最大压力下的厚度限定Tm(mm),其指示在限定的最大负荷下塔板和柱塞之间的距离。T0和Tm之间的差值T0-Tm限定可压缩厚度(Tc)。
表面光滑度测量
表面光滑度通过摩擦系数(“COF”)来表征,所述摩擦系数根据制造商的说明用织物接触检验器(M293,SDL Atlas)测量。
绒毛含量测量(也参见图1和2)
具有第一侧面和第二侧面的非织造材料的绒毛如下所述地使用马丁代尔磨蚀机(YG(B)401G,Wenzhou DaRong)来测量。
1)切出直径为140mm的样本(“大样本”)并且将其放置在带有标准毛毡的第一样本夹持器(10)上,使得大样本的第二侧面面对标准毛毡的表面。
2)切出直径为38mm的相同样本(“小样本”)并且将其放置在带有聚氨酯泡沫的第二样本夹持器(20)上,使得小样本的第一侧面面对标准毛毡(10)上的大样本的第一侧面。
3)操作马丁代尔磨蚀机(1),使得第二样本夹持器(20)上的小样本的第一侧面在下述条件下摩擦第一样本夹持器(10)上的大样本的第一侧面。
压力:第一样本夹持器(10)上的样本上的1.3Psi
速度:50次循环/分钟;并且
循环数:30次循环
在摩擦停止之后,根据图2中的等级,通过从与水平线成45度的视角观察大样本,用绒毛的密度和高度以6个含量标度来评估大样本的第一表面的绒毛含量。具有比等级4更严重的绒毛含量的样本被确定为等级5。较高的数值指示较多的绒毛。
实施例
实施例1-5
如表1所示,使用平行梳理机由各种芯/皮型复合纤维制造了各种第一纤维网层。如表1所示,使用平行梳理机由各种芯/皮型复合纤维和均聚物制造了各种第二纤维网层。如表1所示,将第一纤维网覆盖在第二纤维网上,并且使每个覆盖的纤维网在130-140℃的温度下经受热处理。热处理使用带有可透气的传送带的热透气型热处理设备来进行。在热处理中,所述复合纤维网各自被放置在热处理设备的可透气的传送带上,使得第一纤维网层的表面与可透气的传送带接触。经由热处理获得了热粘结的非织造材料。
所获得的非织造材料的评估如下所述。
根据在上文的“测试方法”下所述的“非织造材料厚度测量”测量了非织造材料的初始厚度和可压缩厚度,并且示出于表1中。根据上文的“测试方法”下的“表面光滑度测量”和“绒毛含量测量”测量了表面光滑度和绒毛含量,并且示出于表1中。
表1
*1:PET/PE:ETC214,JNC corporation,Japan
*2:PET/PE:TA21,Jiangnan Fiber,China
*3:PET:W40,Huvis,Korea
比较例1-8
如表2所示,使用平行梳理机由各种芯/皮型复合纤维制造了各种第一纤维网。如表2所示,使用平行梳理机由各种芯/皮型复合纤维和均聚物制造了各种第二纤维网。复合纤维网的制备和热处理是根据在上文的“实施例1-5”下所述的方法进行的。根据在上文的“实施例1-5”下所述的方法评估了所得非织造材料,并且示出于表2中。
表2
*1:PET/PE:ETC214,JNC corporation,Japan
*2:PET/PE:TA21,Jiangnan Fiber,China
*3:PET:W40,Huvis,Korea
*4:PET/PE:ETC244,Indorama,Thailand
*5:PET/PE:ETC244,Indorama,Thailand
*6:PET:HC_7D_64MM_AC,Toray
*7:PET/PE:ETC214,JNC corporation
本文所公开的量纲和值不应理解为严格限于所引用的精确数值。相反,除非另外指明,否则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,公开为“40mm”的量纲旨在表示“约40mm”。
除非明确排除或换句话讲有所限制,否则将本文引用的每篇文献,包括任何交叉引用或相关专利或申请,全文均以引用方式并入本文。任何文献的引用不是对其作为与本发明任何公开或本文受权利要求书保护的现有技术的认可,或不是对其自身或与任何其它参考文献或多个参考文献的组合提出、建议或公开了此发明任何方面的认可。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。
虽然已举例说明和描述了本发明的具体实施方案,但是对于本领域技术人员来说显而易见的是,在不脱离本发明实质和范围的情况下可作出多个其它变化和修改。因此,本文旨在于所附权利要求中涵盖属于本发明范围内的所有这些变化和修改。

Claims (20)

1.一种非织造片材,包括:
第一层,所述第一层包括具有不大于约2.5旦尼尔的纤维细度的芯/皮型第一复合纤维,其中所述第一复合纤维包括芯组分和皮组分,所述芯组分包含至少一种选自由以下项组成的组的热塑性树脂:聚对苯二甲酸乙二醇酯、聚丙烯、尼龙、聚酰胺、以及它们的组合;并且所述皮组分包含热塑性树脂,所述热塑性树脂具有比所述芯组分的熔点低至少20℃的熔点;
第二层,所述第二层包括具有不大于约2.5旦尼尔的纤维细度的芯/皮型第二复合纤维和具有大于约3旦尼尔的纤维细度的均聚物纤维,其中所述第二复合纤维包括芯组分和皮组分,所述芯组分包含至少一种选自由以下项组成的组的热塑性树脂:聚对苯二甲酸乙二醇酯(PET)、聚丙烯(PP)、尼龙、聚酰胺、以及它们的组合;并且所述皮组分包含热塑性树脂,所述热塑性树脂具有比所述芯组分的熔点低至少20℃的熔点,
其中所述第一层中的纤维的平均旦尼尔不大于约2.5,
其中按所述第二层的重量计,所述均聚物纤维小于约30%。
2.根据权利要求1所述的非织造片材,其中所述第二复合纤维和所述均聚物纤维具有不小于约3旦尼尔的纤维细度差值。
3.根据权利要求1或2所述的非织造片材,其中所述第一复合纤维和所述第二复合纤维具有小于约100mm的纤维长度。
4.根据前述权利要求中任一项所述的非织造片材,其中按所述第二层的重量计,所述第二层中的所述均聚物纤维大于10%。
5.根据前述权利要求中任一项所述的非织造片材,其中按所述第二层的重量计,所述第二层中的所述均聚物纤维不大于约25%。
6.根据前述权利要求中任一项所述的非织造片材,其中所述第一复合纤维和所述第二复合纤维中的至少一者具有2维褶皱。
7.根据前述权利要求中任一项所述的非织造片材,其中所述第一复合纤维和所述第二复合纤维具有不大于约1旦尼尔的纤维细度差值。
8.根据前述权利要求中任一项所述的非织造片材,其中所述第一复合纤维具有的纤维细度不大于所述第二复合纤维的纤维细度。
9.根据前述权利要求中任一项所述的非织造片材,其中所述均聚物纤维为亲水性纤维。
10.根据前述权利要求中任一项所述的非织造片材,其中所述均聚物纤维包括成型均聚物。
11.根据前述权利要求中任一项所述的非织造片材,其中所述第一层的亲水性小于所述第二层。
12.根据前述权利要求中任一项所述的非织造片材,其中所述第一纤维层对所述第二层的比率在约80/20至约20/80的范围内。
13.根据前述权利要求中任一项所述的非织造片材,其中所述第一芯/皮型复合纤维和所述第二芯/皮型复合纤维的至少一部分经由所述第一芯/皮型复合纤维和所述第二芯/皮型复合纤维的皮组分被热粘结。
14.根据前述权利要求中任一项所述的非织造片材,其中当根据在测试方法下所述的绒毛含量测量来测量时,所述非织造材料具有不大于3的绒毛等级。
15.一种用于制造非织造材料的方法,所述方法包括以下步骤:
形成第一纤维网,所述第一纤维网包括具有不大于约2.5旦尼尔的纤维细度的第一芯/皮型复合纤维,其中所述第一芯/皮型复合纤维包括芯组分和皮组分,所述芯组分包含至少一种选自由以下项组成的组的热塑性树脂:聚对苯二甲酸乙二醇酯(PET)、聚丙烯(PP)、尼龙、聚酰胺、以及它们的组合;并且所述皮组分包含热塑性树脂,所述热塑性树脂具有比所述芯组分的熔点低至少20℃的熔点,并且所述第一纤维网中的纤维的平均旦尼尔不大于约2.5;
形成第二纤维网,所述第二纤维网包括具有不大于约2.5的纤维细度的第二芯/皮型复合纤维和具有大于约3的纤维细度的均聚物纤维,其中所述第二芯/皮型复合纤维包括芯组分和皮组分,所述芯组分包含至少一种选自由以下项组成的组的热塑性树脂:聚对苯二甲酸乙二醇酯、聚丙烯、尼龙、聚酰胺、以及它们的组合;并且所述皮组分包含热塑性树脂,所述热塑性树脂具有比所述芯组分的熔点高至少20℃的熔点,并且其中按所述第二纤维网的重量计,所述均聚物纤维小于约30%;
通过将所述第一纤维网覆盖在所述第二纤维网上来形成复合纤维网;以及
使所述复合纤维网经受热处理,以便经由所述第一芯/皮型复合纤维和所述第二芯/皮型复合纤维的皮部分来热粘结所述第一芯/皮型复合纤维和所述第二芯/皮型复合纤维的至少一部分。
16.根据权利要求15所述的用于制造非织造材料的方法,其中所述热处理使用包括传送载体的热透气型热处理设备来进行。
17.根据权利要求16所述的用于制造非织造材料的方法,其中将所述第一纤维网放置在所述传送载体上,使得所述第一纤维层在所述热处理期间接触所述传送载体。
18.根据权利要求15至17中的一项所述的用于制造非织造材料的方法,其中当根据在测试方法下所述的绒毛含量测量来测量时,所述非织造材料具有不大于3的绒毛等级。
19.一种吸收制品,包括:
顶片;和
底片,所述底片接合到所述顶片,
其中所述顶片包括根据权利要求1所述的非织造材料。
20.根据权利要求19所述的吸收制品,其中所述第一纤维层被定位在与穿着者的皮肤接触的一侧上。
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