CN110520086A - 用于吸收装置的活化复合幅材 - Google Patents

用于吸收装置的活化复合幅材 Download PDF

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Publication number
CN110520086A
CN110520086A CN201880025145.3A CN201880025145A CN110520086A CN 110520086 A CN110520086 A CN 110520086A CN 201880025145 A CN201880025145 A CN 201880025145A CN 110520086 A CN110520086 A CN 110520086A
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China
Prior art keywords
composite web
holes
trace
protrusion
activation
Prior art date
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Granted
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CN201880025145.3A
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English (en)
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CN110520086B (zh
Inventor
A·D·马斯基诺
B·C·卢米斯
T·R·斯科奇多波勒
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Tredegar Film Products LLC
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Tredegar Film Products LLC
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Abstract

一种活化复合幅材，包括无纺布层和附接到无纺布层的成形膜层。成形膜层包括具有至少35的目数的多个第一带孔突起，和多个第二带孔突起。每个第二带孔突起的横截面面积均大于每个第一带孔突起的横截面面积。多个第一道痕在第一方向上对准并且具有在基本垂直于第一方向的第二方向上延伸的第一宽度。第一带孔突起位于第一道痕中。多个第二道痕在第一方向上对准并且具有在第二方向上延伸的小于第一宽度的第二宽度。第一道痕和第二道痕在第二方向上彼此交替。第二带孔突起位于第二道痕中。

Description

用于吸收装置的活化复合幅材
相关申请的交叉引用
本申请要求于2017年3月13日提交的美国临时专利申请序列号62/470,671的优先权的权益，其全部内容通过引用合并于此。
技术领域
本发明涉及可用于吸收装置中的活化复合幅材以及制备该活化复合幅材的方法。
背景技术
塑料成形膜和无纺布用作例如女性卫生用品、成人失禁产品和婴儿尿布的吸收装置中的顶片。顶片是吸收装置的顶层，所述顶层接触吸收装置的使用者(穿戴者)的皮肤。无纺布材料通常用作此类吸收装置的顶片部件，在所述顶片部件处因顶片与吸收装置的穿戴者的皮肤接触而期望获得柔软性。尽管当抵靠皮肤使用时通常认为高蓬松度与无纺布材料的总厚度之比既柔软又凉爽，但是通常需要特殊加工来实现这种特性，这可能会增加产品的成本。
对于由成形膜制成的顶片，期望具有软布而不是硬质塑料膜的视觉外观和柔软性。尽管与由无纺布材料制成的顶片相比，由塑料膜制成的顶片在用于吸收装置时通常具有更好的性能特征，但是由塑料膜制成的顶片的视觉外观具有较高的光泽度，因此比无纺布顶片更具有“塑料外观”。另外，与无纺布顶片相比，可能穿戴者感觉塑料膜顶片更“粘”或“发粘”。
期望具有可用于吸收装置的轻质幅材，例如具有与成形膜相关的性能属性和与无纺布材料相关的柔软性属性的顶片。
发明内容
根据本发明的方面，提供了一种活化复合幅材，其包括无纺布层和附接到所述无纺布层的成形膜层。成形膜层包括：多个第一带孔突起，其具有至少35的目数和带有第一横截面面积的多个第一孔：以及具有带有第二横截面面积的多个第二孔的多个第二带孔突起。每个第二横截面面积均大于每个第一横截面面积。活化复合幅材包括多个第一道痕，其在第一方向上对准，并且具有在基本垂直于第一方向的第二方向延伸的第一宽度。第一带孔突起位于第一道痕中。多个第二道痕在第一方向上对准，并且具有在第二方向上延伸的小于第一宽度的第二宽度。第一道痕和第二道痕在第二方向上彼此交替。第二带孔突起位于第二道痕中。
在一实施例中，每个第一孔均具有第一长轴和第一短轴，其中第一长轴在第一方向上对准，每个第二孔均具有第二长轴和第二短轴，其中第二长轴在第二方向上对准。
在一实施例中，第一道痕的第一顶表面位于第一平面中，第二道痕的第二顶表面位于与第一平面不同的至少一个第二平面中。
在一实施例中，活化复合幅材比其无纺布和成形膜层的原始组分的总和轻。在一实施例中，活化复合幅材比其无纺布和成形膜层的原始组分的总和轻至少15％。
在一实施例中，成形膜层定向成使得第一带孔突起和第二带孔突起远离无纺布层延伸。
在一实施例中，成形膜层定向成使得第一带孔突起和第二带孔突起朝向无纺布层延伸。
在一实施例中，无纺布层包括具有压融部位的图案的纺粘无纺布材料。在一实施例中，无纺布层包括位于压熔部位处的多个开口。在一实施例中，无纺布层包括远离成形膜层延伸的多个柔软的断裂纤维端部。
在一实施例中，活化复合幅材是真空成形层压体。
在一实施例中，第一方向是机器方向。
在一实施例中，第一方向是横向方向。
在一实施例中，第二道痕的部分不是直的。
在一实施例中，第二道痕的部分为波浪形。
在一实施例中，第二带孔突起的横截面面积为第一带孔突起的横截面面积的至少150％。
在一实施例中，活化复合幅材具有小于或等于约2.5秒的透湿时间。
在一实施例中，活化复合幅材是吸收装置中的顶片。
在一实施例中，活化复合幅材是吸收装置中的获取分布层。
根据本发明的方面，提供了一种制造活化复合幅材的方法。所述方法包括：将成形膜层层压至无纺布幅材以形成复合幅材，所述成形膜层包括具有至少35的目数的多个带孔突起；使所述复合幅材通过相互啮合的齿轮以形成活化复合幅材。相互啮合的齿轮被构造和布置成在复合幅材中形成多个第一道痕和多个第二道痕。第一道痕比第二道痕宽。带孔突起的第一子集位于第一道痕中，第一带孔突起具有带有第一横截面面积的多个第一孔，带孔突起的第二子集位于第二道痕中，第二带孔突起具有带有第二横截面面积的多个第二孔。第二横截面面积大于第一横截面面积。
在一实施例中，在活化之前和之后，第一横截面面积基本相同。
在一实施例中，每个第一孔均具有在第一方向上基本对准的第一长轴和在基本垂直于第一方向的第二方向上基本对准的第一短轴，每个第二孔均具有在第二方向上基本对准的第二长轴和在第一方向上基本对准的第二短轴。
在一实施例中，层压包括将聚合物熔体幕挤出到真空成形筒上，同时将无纺布幅材引入层压辊上，使得无纺布幅材在真空成形筒和层压辊之间的触碰点处接触聚合物熔体幕。
在一实施例中，利用真空成形筒形成成形膜层中的带孔突起。
在一实施例中，真空成形筒包括具有孔的图案的成形筛网。在一实施例中，每个孔均具有船形。
在一实施例中，无纺布幅材的初始基重为约10gsm。
在一实施例中，成形膜层的初始基重为约12gsm。
在一实施例中，活化复合幅材的基重小于约19gsm。
在一实施例中，活化复合幅材的基重比成形膜层和无纺布幅材的组合基重小至少15％。
本发明的这些和其他方面、特征和特性以及相关结构元件的操作和功能的方法以及部件的组合和制造的经济性将在参考附图考虑了以下描述和所附权利要求后变得更加显明，所有这些均构成本说明书的一部分。然而，应该明确地理解，附图仅出于说明和描述的目的而不意图作为对本发明的限制的定义。如说明书和权利要求书中所用，单数形式的“一(a)”、“一个(an)”和“该(the)”包括复数对象，除非上下文另外明确指出。
附图说明
以下附图的部件被示出以强调本公开的一般原理并且不一定按比例绘制。为了一致和清楚起见，在所有附图中根据需要重复指定相应部件的参考字符。
图1是根据本发明的实施例的用于制造活化的轻质的复合幅材的设备的示意图；
图2是根据本发明的实施例的图1所示的设备的一部分的示意图；
图3是根据本发明的实施例的活化的轻质的复合幅材的一部分的横截面的示意图；
图4是根据本发明的实施例的活化的轻质的复合幅材的一侧的照片；
图5是根据本发明的实施例的活化的轻质的复合幅材的与图4所示的侧相对的一侧的照片；
图6是图5所示的活化的轻质的复合幅材的侧的放大部分的照片；
图7是图5所示的活化的轻质的复合幅材的侧的示意图；
图8是图5的活化的轻质的复合幅材的横截面的照片；和
图9是图8的活化的轻质的复合幅材的横截面的放大部分的照片。
具体实施方式
在整个说明书中，术语“幅材”是指能够卷绕成卷的材料。幅材可以是膜幅材、无纺布幅材、层压幅材、带孔层压幅材等。幅材的面是指其二维表面之一，而不是其边缘。术语“复合幅材”是指这样的幅材，其包括两个或更多个单独的幅材，所述单独的幅材以面对面的关系彼此附接。附接可以穿过部件幅材的边缘，但是部件幅材以彼此面对面的关系放置，或者附接可以位于部件幅材上的特定位置。
在本说明书中，术语“膜”是指通过流延或吹塑挤出法将热塑性聚合物材料的熔融片材挤出然后冷却所述片材以形成固体聚合物幅材而制成的幅材。膜可以是单层膜、共挤出膜、涂布膜和复合膜。涂布膜是包括单层或共挤出膜的膜，其随后用与所述单层或共挤出膜结合的相同或不同材料的薄层涂覆(例如，挤出涂覆、压印涂覆、印刷等)。复合膜是包括多于一个膜的膜，其中至少两个膜在结合过程中组合。结合过程可以包括膜层之间的粘合剂层。
在整个说明书中，术语“带孔膜”表示其中存在从一个表面延伸到第二表面的多个孔的膜。二维带孔膜是其中孔中不存在三维结构的膜，所述孔然后将平坦膜的第二表面连接到膜的第一表面。“成形膜”是具有突起的三维膜，而三维带孔膜是其中孔中存在三维结构(例如，孔的深度比膜的厚度厚)或突起具有穿过其中的孔的膜。
术语“无纺布”是指包含多根纤维的幅材。纤维可以彼此结合或可以不结合。纤维可以是短纤维或连续纤维。纤维可以包括单一材料，或者可以包括多种材料，所述多种材料是不同纤维的组合，或是各自包括不同材料的相似纤维的组合。如本文所用，“无纺布幅材”在其一般意义上用于限定相对平坦、柔性和多孔并且包括短纤维或连续长丝的大体平面结构。无纺布幅材可以是任何形成其的工艺的产物，例如无纺布纺粘和熔体吹制无纺布幅材。无纺布幅材可包括幅材的复合物或组合。在一实施例中，无纺布幅材是由聚丙烯纤维制成的纺粘材料。然而，无纺布幅材可包括可从其生产纤维的任何聚合材料和/或可包括棉或其他天然纤维。例如，无纺布幅材可包括聚乙烯、聚丙烯、弹性体、聚酯、人造丝、纤维素、尼龙、棉(或其他天然纤维)的纤维以及这些纤维的混合物。也可以混合包括不同聚合物的纤维。
如本文所用，术语“可延展性”是指可通过拉伸力在给定方向上施加到幅材上而又不会使得纤维断裂或破坏纤维之间的结合的最大应变量(相对于零应变状态，以％为单位)。对于无纺布幅材而言，在任何给定方向上可延展是指当在该方向上向幅材施加拉伸力时，幅材在该方向上扩张，并且在幅材中引起应变，而基本不会使得纤维断裂或破坏纤维之间的结合。
如本文所用，术语“筛网”是指三维模制设备，其包括用于在膜中形成突起或孔的凹痕和/或孔和/或突出部。在一实施例中，筛网包括具有宽度和直径的管状构件。在替代实施例中，筛网包括具有宽度和长度的带。横向方向是平行于筛网宽度的方向。机器方向是平行于筛网旋转方向的方向并且垂直于横向方向。
如本文所用，术语“突起”是指三维构件，其包括位于膜的第一表面的平面中的带孔基部部分和大致在膜的第二表面的方向上延伸的侧壁部分。每个基部部分均具有侧壁部分。侧壁部分终止于位于膜的第二表面的平面中的“端部”。突起的端部可以带孔或无孔。如本文所用，“带孔突起”是指在其在第二表面的平面中的端部处具有孔的突起。突起的基部部分中的孔，也称为“主孔”，可以以规则或随机图案呈多边形(例如方形、六边形、五边形)、椭圆形、圆形、卵形或槽的形状。在一实施例中，孔可以是船形，例如在美国专利号7,198,836中所描述那样，该专利以引用方式并入本文。突出的端部如果是开孔的话则称为“次孔”并且可以是多边形(例如正方形、六边形、五边形)、椭圆形、圆形、卵形、槽或船的形状。
如本文所用，表述“吸收性物品”和“吸收装置”表示吸收并容纳体液和其他身体排泄物的物品。更具体地，吸收性物品/吸收装置包括抵靠或紧邻穿戴者的身体放置以吸收和容纳从身体排出的各种排泄物的衣服。
如本文所用，术语“活化的”或“活化”是指将材料拉伸超过其物理性质改变的点的过程。在无纺布幅材的情况下，幅材的充分活化将导致无纺布幅材更具延展性和/或改善其触觉属性。在活化过程中，将力施加到材料上，从而导致材料拉伸。成形膜和无纺布幅材例如可以被机械活化。机械活化过程包括使用机器或设备向幅材施加力以引起幅材的拉伸。用于活化材料幅材的方法和设备包括但不限于通过相互啮合的齿轮或板来活化幅材，通过增量拉伸来活化幅材，通过环轧来活化幅材，通过拉幅机框架拉伸、倾斜轮拉伸器或弓形辊来活化幅材，以及在以不同速度操作的辊隙或辊堆之间沿机器方向活化幅材以机械拉伸部件，及它们的组合。
现在参考图1，图1示出了根据本发明的实施例的可用于制造活化的轻质的复合幅材的设备100。如图所示，设备100包括构造和布置成将聚合物熔体幕(熔融聚合物幅材)104挤出到真空成形筒106上的挤出模头102。在一实施例中，熔融聚合物幅材104可以包括选自由聚乙烯、聚丙烯、乙烯﹣乙酸乙烯酯和茂金属基聚烯烃组成的组中的聚烯烃。聚乙烯可以选自由超低密度聚乙烯、线性低密度聚乙烯和线性中密度聚乙烯构成的组。在一实施例中，熔融聚合物幅材104可以包括选自由聚丙烯基弹性体、乙烯基弹性体、共聚酯基弹性体、烯烃嵌段共聚物和苯乙烯嵌段共聚物构成的组中的弹性体聚合物。
真空成形筒106包括成形筛网108和真空槽110。无纺布幅材114的供应辊112在这样的位置中设置在心轴上，所述位置允许将无纺布幅材114供给到毗邻真空成形筒106的层压辊116上。随着无纺布幅材114围绕层压辊116旋转并进入层压辊116和真空成形筒106之间的辊隙118中，无纺布幅材114接触聚合物熔体幕104，同时聚合物在真空成形筒106的成形筛网108和层压辊116之间的触碰点处仍熔融。理想地，触碰点位于真空成形筒106的真空槽110处的真空密封件的前缘正上方。
成形筛网108中的孔的图案确定了成形膜中的突起的图案。在本发明的一实施例中，成形膜层包括具有57的目数(即每线性英寸57个孔)的带孔突起的图案，其中，每个带孔突起的横截面均呈船形(即船形单元或“BSC”)。这样的图案可以被称为“57BSC”。船形单元型孔在美国专利号6,989,187中有更详细的描述，该专利在此引为参考。在成形膜领域中众所周知的其他成形膜孔图案也可以是有用的，诸如具有每线性英寸例如100、80、60或40个孔的目数的六边形、方形或圆形孔。目数为30或更小的图案可能会失去柔软感，并且可能无法很好地响应于活化，这将在下面进行详细说明。
在一实施例中，成形膜层具有至少35的目数的多个带孔突起。在一实施例中，所述带孔突起具有至少40的目数。在一实施例中，所述带孔突起具有至少45的目数。在一实施例中，所述带孔突起具有至少50的目数。在一实施例中，所述带孔突起具有至少55的目数。在一实施例中，所述带孔突起具有至少60的目数。在一实施例中，所述带孔突起具有至少65的目数。在一实施例中，所述带孔突起具有至少70的目数。在一实施例中，所述带孔突起具有至少75的目数。在一实施例中，所述带孔突起具有至少80的目数。在一实施例中，所述带孔突起具有至少85的目数。在一实施例中，所述带孔突起具有至少90的目数。在一实施例中，所述带孔突起具有至少95的目数。
无纺布幅材114的纤维幅材材料部分嵌入到熔融聚合物幅材104中，以形成成形的层压幅材120。随着带孔突起(这在下面进一步详细描述)形成在熔融聚合物幅材104中，两个幅材104、114在真空槽110上继续行进。通过成形筛网108中的孔启动气流，所述气流冷却并固化熔融聚合物幅材104，并且通过变成固体，聚合物幅材捕获来自无纺布幅材114的嵌入纤维，从而将无纺布幅材114结合到现在形成的成形膜层上，以形成真空成形的层压幅材120。
成形膜层可具有约6gsm和约20gsm之间的基重。在一实施例中，成形膜层具有约6gsm的基重。在一实施例中，成形膜层具有约7gsm的基重。在一实施例中，成形膜层具有约8gsm的基重。在一实施例中，成形膜层具有约9gsm的基重。在一实施例中，成形膜层具有约10gsm的基重。在一实施例中，成形膜层具有约11gsm的基重。在一实施例中，成形膜层具有约12gsm的基重。在一实施例中，成形膜层具有约13gsm的基重。在一实施例中，成形膜层具有约14gsm的基重。在一实施例中，成形膜层具有约15gsm的基重。在一实施例中，成形膜层具有约16gsm的基重。在一实施例中，成形膜层具有约17gsm的基重。在一实施例中，成形膜层具有约18gsm的基重。在一实施例中，成形膜层具有约19gsm的基重。在一实施例中，成形膜层具有约20gsm的基重。
无纺布幅材可具有约8gsm和约18gsm之间的基重。在一实施例中，无纺布幅材具有约8gsm的基重。在一实施例中，无纺布幅材具有约9gsm的基重。在一实施例中，无纺布幅材具有约10gsm的基重。在一实施例中，无纺布幅材具有约11gsm的基重。在一实施例中，无纺布幅材具有约12gsm的基重。在一实施例中，无纺布幅材具有约13gsm的基重。在一实施例中，无纺布幅材具有约14gsm的基重。在一实施例中，无纺布幅材具有约15gsm的基重。在一实施例中，无纺布幅材具有约16gsm的基重。在一实施例中，无纺布幅材具有约17gsm的基重。在一实施例中，无纺布幅材具有约18gsm的基重。
返回图1，真空成形层压幅材120通过剥离辊122从真空成形筒106上拉下并沿机器方向在惰辊124上继续行进且被引入到活化辊隙126中。当第一相互啮合齿轮辊128与第二相互啮合齿轮辊130以一定的啮合深度啮合时形成活化辊隙126。相对于活化的轻质的复合幅材132的运动方向可以在机器方向(MD)或横向方向(TD)上进行活化。
图2示出了可以在图1的设备100中用于TD活化的相互啮合齿轮(“IMG”)辊128、130的实施例。如图所示，辊128、130承载在各自的可旋转轴228和230上，所述可旋转轴的旋转轴线以平行关系设置。辊128、130中的每一个均包括多个轴向间隔开的并排的周向延伸的等同构造的齿232，这些齿可以是具有基本矩形横截面的薄翅片的形式。
相邻齿232之间的空间限定凹进的周向延伸的等同构造的槽234。在不限制本发明的情况下，齿(gear)232在本文中也称为“齿(teech)232”。当齿232具有基本矩形横截面时，槽234可以具有基本矩形横截面。因此，成形辊128、130中的每一个均包括多个间隔开的齿232和每对相邻齿232之间的交替槽234。齿232和槽234不必各自具有相同的宽度，但是优选地槽234的宽度大于齿232的宽度，以允许通过成形辊128、130之间的材料被接收在各条槽234中并被局部拉伸。真空成形层压幅材120独特地响应于该应力，这导致形成根据本发明的活化的轻质的复合幅材132。
在MD活化中，从成形辊128、130的可旋转轴228、230的轴线向下看的成形辊128、130的横截面视图将示出切入并且围绕成形辊128、130的圆周的齿轮齿(未示出)，其中，其长轴基本平行于成形辊128、130的轴线。一个成形辊128上的齿啮合到相邻辊130上的槽中，以为了向幅材120提供拉伸作用。
辊齿、齿轮或翅片232的啮合深度决定了真空成形层压幅材120所经受的伸长程度。通常在辊齿232的啮合深度和真空成形层压幅材120的成分之间取得平衡，这是因为这些因素影响了活化的轻质的复合幅材132的许多重要的物理属性。一些影响节距、齿深和啮合深度的因素包括活化的轻质的复合幅材132的成分、所需的最终属性(透气性、吸收性、强度、布感)以及IMG辊128、130的宽度和直径。活化的轻质的复合幅材132的最终应用也影响这些选择，原因在于它确定了所需的最终属性。IMG辊128、130的宽度可能存在经济和技术限制。特别地，随着宽度增加，IMG辊128、130的重量也增加，IMG辊128、130经历的挠曲量也增加。挠曲不仅在拉伸过程中产生变化，而且在制造IMG辊128、130过程中也产生变化，特别是随着节距和齿深的增加。本领域中的技术人员能够使用本文提供的指导改变IMG辊128、130的参数以实现期望的拉伸。
返回到图1，通过IMG辊128、130在活化辊隙126中活化真空成形层压幅材120，以形成活化的轻质的复合幅材132，可以将其引入进一步的下游步骤中，例如添加最终产品所需的处理、切缝和卷绕成卷等。
图3示出了根据本发明的实施例的轻质的复合幅材300的一部分的示意性横截面。如图所示，轻质的复合幅材300包括成形膜层310和无纺布层320。所示的横截面取自轻质的复合幅材300的宽道痕部分，这在下文进一步详细描述。成形膜层310包括远离无纺布层320延伸的多个带孔突起312。在一实施例中，可以将成形膜层310定向为使得带孔突起312朝向无纺布层320延伸。带孔突起312的取向可以留给吸收装置设计者裁量。每个带孔突起312均包括孔314，所述孔被在地带(land)318处成冠状的侧壁316包围，所述地带在相邻的突起312的孔314之间延伸。地带318可以是平面或略微弯曲的，并且地带318的尺寸的范围可以从孔314之间的可测量距离至非常尖锐且类似于剃刀的忽略不计距离。
成形膜层310在通常位于成形膜层310的地带318处的多个熔合点330处附接到无纺布层320，使得复合幅材300被层压为具有足够的剥离力，以用于在其中所施加的应力可能倾向于引起层分离的随后转换方法期间以及最终使用期间保持层310、320附接。在美国专利号6,242,074中进一步详细描述了用于导致该熔合部330的真空成形层压方法，该专利通过引用被并入本文。
在一实施例中，可以在通过任何合适的方式活化之前或之后贯穿复合幅材300形成另外的孔。例如，在一实施例中，销钉冲孔单元，诸如在通过引用并入本文的例如美国专利号6,849,319中描述的销钉冲孔单元，取决于所需效果可以定位在真空筒106和IMG辊128、130之间或IMG辊128、130之后。例如，这样的附加孔可以以具有小于每线性英寸35个孔的目数的图案布置。在一实施例中，在已经将膜层层压到无纺布幅材上之后，可以使用销钉穿孔单元代替真空筒106和成形筛网108以形成多个带孔突起312。
图4是无纺布层320的背向成形膜层310的侧(即无纺布层320的外侧面)的放大照片400。如图3和4所示，无纺布层320包括多个纤维322和多个压熔部位324，所述多个压熔部位将纤维局部结合在一起以形成对于无纺布层320而言具有大致均匀厚度和完整性的幅材。纤维322由聚合物制成，其可以是聚烯烃，例如聚丙烯。
压熔部位324对于纺粘无纺布材料是典型的，例如本实施例中的一个。如果没有压熔部位324，纤维322将分离并且彼此背离，从而使得无纺布层320失去完整性。根据需要或根据期望，压熔部位324可以或可以不与熔合部330对准。如从图3所示的实施例可以明显看出，压熔部位324通常不与熔合部330对准。
美国专利号5,916,661(其通过引用并入本文)教导了压熔部位，例如图3和图4所示的压熔部位324，也使在压力点下熔融在一起的区域中的纤维变薄并变弱。可以利用图案化的压延辊和光滑的砧辊形成压熔部位，所述图案化的压延辊和光滑的砧辊可被加热并且可调节两个辊之间的压力以提供所需的温度和压力，以在多个这些位置处同时弱化和熔融稳定无纺布幅材。这不仅可以利用任何纺粘无纺布的预先存在的压熔部位来提供幅材完整性，而且可以提供更多的部位，使得当利用带有相互啮合齿轮的一对辊进行活化时，压熔的弱化的纤维会断裂以在无纺布中形成开口。以这种方式，可以形成在压熔部位处具有多个开口的活化的无纺布幅材。
图5是放大照片500，其示出了具有几个窄道痕510和几个宽道痕520的复合幅材300的平面图。宽道痕520基本包括大多数较小的带孔突起312，窄道痕510包括较大的带孔突起312。通常，窄道痕510中的一个或两个带孔突起312被扩大。在57BSC图案的该实施例中，宽道痕通常是三个，有时是四个孔314宽。尽管宽道痕中的大多数孔314不受活化的影响，但一些随机孔314可能会变得稍大。道痕宽度及其间距主要由相互啮合齿轮间距和齿轮宽度确定。这可以针对不同目数变化以影响不同道痕宽度。
对于该实施例，齿轮在中心处以0.105英寸间隔开，具有0.043英寸的宽度和0.260英寸的高度。它们略呈锥形并且具有平坦的方形的末端。在该实施例中，活化之前成形膜层的基重为约11.7g/m2(gsm)。与10gsm的无纺布幅材结合，活化之前成形膜层310和无纺布层320的原始组分的总和为约21.7gsm。但是，活化的轻质的复合幅材132更轻且约为17.2gsm。因此，活化的轻质的复合幅材132比其原始组分的总和轻约20％。在成形膜层310和无纺布层320的适用基重范围内，据信大多数活化复合幅材将比其原始组分的总和轻至少约15％至不大于约25％。
最通常地，与该实施例一样，窄道痕510在机器方向上对准。在随机区域中，在轻质的复合幅材300中窄道痕510可沿其长度就小段而言具有波浪线。这不会损害其性能，甚至可能增加美学价值。同样，如果需要，可以使用本领域中已知的活化方法来制造轻质的复合幅材300，其中窄道痕510在横向方向上对准。
现在参考图6，示出了轻质的复合幅材300的更大放大照片600，其聚焦在来自窄道痕510的几个孔616和来自宽道痕520的几个孔614处。
图7示意性地示出了更均匀的图形，该图形示出了在宽道痕520中的孔614与在窄道痕中的孔616之间的差异。如图所示，一个窄道痕510位于两个宽道痕520之间。在宽道痕520内是具有长轴610和短轴620的较小孔614。在该图形中，较小孔614的长轴610沿着机器方向(MD)轴线622竖向地在第一方向上对准。在窄道痕510内，设置有带有短轴650和长轴660的扩大孔616。在该图形中，长轴660在取向上相反并且沿着横向方向(TD)轴线624水平地在第二方向上对准。
如图7所示，对于该57BSC实施例，宽道痕孔614中的每一个均具有长轴610和短轴620。即使使用六边形或圆形的图案代替BSC图案，当生产成形膜或成形膜复合体时，机器也通过一系列从动辊和/或从动夹辊将幅材向下游拉。为了使幅材保持无皱纹，必须稍微增加每个后续从动辊系统的速度。这称为“拉动”。该机器方向拉动将在孔314的图案中使得针对机器方向轴线622赋予一定程度延伸而针对横向方向轴线624赋予一定程度变窄。因此，无论是否使用预期的BSC图案，结果都将是这样的宽道痕520，其中较小孔614具有沿机器方向轴线622的长轴610和沿横向方向轴线624的短轴620。对于该实施例，宽道痕520中的较小孔614具有：长轴610，其沿机器方向对准，其中，测量为约0.0080英寸；短轴620，其沿横向方向对准，其中，测量为大约0.0045英寸。
令人惊讶地是，窄道痕510中的孔616不仅变大，而且许多扩大孔616具有相反的轴线对准。例如，在该实施例中，窄道痕的扩大孔616具有相反的轴线取向，其中短轴650在机器方向上对准，而长轴660在横向方向上对准。该实施例的扩大孔616的短轴650(其在机器方向上对准)的尺寸约为0.0075英寸。该实施例的扩大孔616的长轴660(在横向方向上对准)的尺寸约为0.0100英寸。因此，活化引起这样的效果，其中，与宽道痕520中的较小孔614相比，许多窄道痕扩大孔616具有相反的轴线，其中，其长轴610沿着横向方向，而其短轴620沿着机器方向。
孔314、614、616的面积被计算为椭圆形的面积：1/2长轴610、660乘以1/2短轴620、650乘以3.14159(Pi，π)。对于图5的该实施例的宽道痕的较小孔614，得出以下等式：0.004×0.00225×3.14159＝0.0000283平方英寸。对于图5的该实施例的窄道痕扩大孔616，得出以下等式：0.0050×0.00375×3.14159＝0.0000589平方英寸。因此，与较小孔614相比，扩大孔616的扩大因数约为200％。对于针对该幅材有用的图案范围而言，活化可以大致至少约150％的扩大因数。
现在参考图8，示出了本发明的活化的轻质的复合幅材132的横截面的放大照片800。照片800示出了将两个宽道痕520分开的单个窄道痕510。宽道痕520存在于第一平面810中，而窄道痕510存在于与第一平面810不同的第二平面820中。第一平面810和第二平面820之间的距离是变化的并且通常将取决于活化步骤的相互啮合的齿轮228、230的啮合深度以及成形膜层中的突起的特定图案和聚合物共混物如何响应于活化应力。这也取决于道痕与道痕之间在具有常见的无纺布和成形膜图案以及聚合物共混物的整个幅材上的厚度和均质性的细微变化。
不同平面810、820中的这些道痕510、520的另一理论优势可以是它提供额外的凉爽和舒适感。例如，在尿布中，随着婴儿小便和温暖的尿液在尿布芯中积累，会产生温暖潮湿的湿蒸汽。如果这些蒸汽不能很快排出，则尿布可能会变得湿粘且不舒服。在第二平面820中具有窄道痕510可以提供侧向或纵向空隙空间作为湿蒸汽逸出的路径。在美国专利申请公开号2003/0195487中描述了该构思，该专利通过引用并入本文，并且提供了如果提供空隙空间则提高冷却速率的数据。因此，据信本发明的活化的轻质的复合幅材132具有提供一些空隙空间以提高冷却速率的特征。
现在参考图9，在高度放大的照片900中示出了代表多个相似区域的选定区域。照片900示出了区域910，该区域具有柔软的断裂纤维端部912，所述柔软的断裂纤维端部重新取向为几乎竖直。在触感领域中众所周知的是细的竖直纤维端部，例如在拉绒棉中所经历的那些，会产生柔软的感觉。美国专利号7,351,297(其通过引用并入本文)教导了利用一定啮合深度的相互啮合齿轮进行的活化使得一些无纺布纤维断裂，从而形成产生更高柔软度的纤维端部。以这种方式，同时形成了具有重新取向为几乎竖直的柔软的断裂纤维端部的活化无纺布幅材。在本文所讨论的实施例中，无纺布是纺粘聚丙烯幅材或“SBPP”并且具有以克/平方米或gsm计的平均为10gsm的基重。
上述活化的轻质的复合幅材132不仅比这种类型的常规幅材更轻且更软，而且对于合成尿液具有更快的透湿时间。使用根据EDANA ERT 150.5﹣02的透湿设备(包括带有电磁阀的漏斗、支撑漏斗的环架，带有电极的透湿板、基板和电子计时器)进行透湿时间测试，该设备由奥地利的Lenzing Technik以Lister的名称出售。合成尿液是一种盐溶液，其由去离子水中的9g/l分析级氯化钠溶液组成并且在23℃(+/﹣2℃)产生70mN/m(+/﹣2mN/m)表面张力。
将幅材样品切割成约4英寸×4英寸并放在吸收纸的堆叠上。该堆叠放置在Lister透湿板下方，板的孔口与漏斗的出口对准。将10ml盐水的样品引入Lister板孔口中。首次出现盐水时，它会接触孔口中的电触点，这形成启动计时器的电路。一旦盐水冲过幅材样品以被纸的堆叠完全吸收，且因此已经完全排空了板的孔口，电路就会断开，这关闭计时器。以这种方式，确定并记录“透湿时间”。如果透湿时间比功能时间慢，则尿液可能会在表面积聚并侧向移动，从而从尿布中漏出。
在吸收装置市场中已经存在无纺布和成形膜的许多组合。发现各种用途，例如获取层和偶尔地背片。但是，由于它们笨重，缺乏柔软性，缺乏凉爽性以及许多具有较慢的透湿时间，因此它们通常未被用作顶片。理想的是复合幅材的成形膜具有目数大于35的带孔突起，以产生轻质且柔软的活化复合幅材。在该实施例中，筛孔数为57目，并且复合幅材以11.7gsm进行真空成形层压，这恰好是半密耳以下，对于膜而言认为这非常薄。孔314、614、616非常小，并且不一定对功能性透湿时间有影响。
当测试未活化的幅材或活化深度小于约0.16英寸的幅材的透湿时间时，它们具有平均约2.85秒的高值。活化深度为0.165到约0.180英寸时，透湿时间降至2.27秒，快了约25％。在本发明的幅材的范围内，预期它们的透湿时间将小于或等于约2.5秒。
其中该幅材的层将被发现具有高功能性(特别是作为顶片或作为顶片下方的增强层)的吸收装置包括但不限于婴儿尿布、成人失禁装置、包括阴唇选项的女性卫生巾、卫生棉条、内裤衬里、拖把、清洁布、吸收垫(例如床垫和防溢垫)等。本发明的幅材是轻质的柔软和柔韧的并且在任何这些用途中都应表现良好。
在此描述的实施例代表了许多可行的实施方式和示例，并且无意于将本公开限制于任何特定的实施例。相反，可以对这些实施例进行各种修改，并且如本领域的普通技术人员将理解的那样，即使没有明确描述，本文中描述的各种实施例的不同组合也可以用作本发明的一部分。任何这样的修改旨在被包括在本公开的精神和范围内，并且由所附权利要求保护。

Claims (27)

1.一种活化复合幅材，其包括：
无纺布层；
附接到所述无纺布层的成形膜层，所述成形膜层包括：具有至少35的目数的多个第一带孔突起，所述多个第一带孔突起具有带有第一横截面面积的多个第一孔；和多个第二带孔突起，所述多个第二带孔突起具有带有第二横截面面积的多个第二孔，每个第二横截面面积均大于每个第一横截面面积；
多个第一道痕，所述多个第一道痕在第一方向上对准，并且具有在基本垂直于所述第一方向的第二方向上延伸的第一宽度，所述第一带孔突起位于所述第一道痕中；和
多个第二道痕，所述多个第二道痕在所述第一方向上对准，并且具有在所述第二方向上延伸的小于所述第一宽度的第二宽度，所述第一道痕和所述第二道痕在所述第二方向上彼此交替，所述第二带孔突起位于所述第二道痕中。
2.根据权利要求1所述的活化复合幅材，其中，每个第一孔均具有第一长轴和第一短轴，其中，所述第一长轴在所述第一方向上基本对准，并且其中，每个第二孔均具有第二长轴和第二短轴，其中，所述第二长轴在所述第二方向上基本对准。
3.根据权利要求1所述的活化复合幅材，其中，所述第一道痕的第一顶表面位于第一平面中，并且所述第二道痕的第二顶表面位于与所述第一平面不同的至少一个第二平面中。
4.根据权利要求1所述的活化复合幅材，其中，所述活化复合幅材比其无纺布和成形膜层的原始组分的总和轻。
5.根据权利要求4所述的活化复合幅材，其中，所述活化复合幅材比其无纺布和成形膜层的原始组分的总和轻至少15％。
6.根据权利要求1所述的活化复合幅材，其中，所述成形膜层被取向为使得所述第一带孔突起和所述第二带孔突起远离所述无纺布层延伸。
7.根据权利要求1所述的活化复合幅材，其中，所述无纺布层包括具有压熔部位的图案的纺粘无纺布材料。
8.根据权利要求7所述的活化复合幅材，其中，所述无纺布层包括位于所述压熔部位处的多个开口。
9.根据权利要求7所述的活化复合幅材，其中，所述无纺布层包括远离所述成形膜层延伸的多个柔软的断裂纤维端部。
10.根据权利要求1所述的活化复合幅材，其中，所述活化复合幅材是真空成形层压体。
11.根据权利要求1所述的活化复合幅材，其中，所述第一方向是机器方向。
12.根据权利要求1所述的活化复合幅材，其中，所述第二道痕的部分不是直的。
13.根据权利要求12所述的活化复合幅材，其中，所述第二道痕的所述部分为波浪形。
14.根据权利要求1所述的活化复合幅材，其中，所述第二带孔突起的横截面面积为所述第一带孔突起的横截面面积的至少150％。
15.根据权利要求1所述的活化复合幅材，其中，所述活化复合幅材的透湿时间小于或等于约2.45秒。
16.根据权利要求1所述的活化复合幅材，其中，所述活化复合幅材是吸收装置中的顶片。
17.根据权利要求1所述的活化复合幅材，其中，所述活化复合幅材是吸收装置中的获取分布层。
18.一种制造活化复合幅材的方法，其包括：
将成形膜层层压到无纺布幅材上以形成复合幅材，所述成形膜层包括具有至少35的目数的多个带孔突起；
使所述复合幅材穿过相互啮合齿轮以形成活化复合幅材，所述相互啮合齿轮被构造和布置成在所述活化复合幅材中形成多个第一道痕和多个第二道痕，所述第一道痕比所述第二道痕宽，其中，所述带孔突起的第一子集位于所述第一道痕中，第一带孔突起具有带有第一横截面面积的多个第一孔，并且所述带孔突起的第二子集位于所述第二道痕中，第二带孔突起具有带有第二横截面面积的多个第二孔，所述第二横截面面积大于所述第一横截面面积。
19.根据权利要求18所述的方法，其中，所述第一横截面面积在活化之前和之后基本相同。
20.根据权利要求18所述的方法，其中，每个孔均具有在第一方向上基本对准的第一长轴和在基本垂直于所述第一方向的第二方向上基本对准的第一短轴，并且其中，每个第二孔均具有在所述第二方向上基本对准的第二长轴和在所述第一方向上基本对准的第二短轴。
21.根据权利要求18所述的方法，其中，所述层压包括将聚合物熔体幕挤出到真空成形筒上，同时将所述无纺布幅材引入到层压辊上，使得所述无纺布幅材在所述真空成形筒与所述层压辊之间的触碰点处接触所述聚合物熔体幕。
22.根据权利要求21所述的方法，其中，利用所述真空成形筒形成所述成形膜层中的所述带孔突起。
23.根据权利要求22所述的方法，其中，所述真空成形筒包括具有孔的图案的成形筛网。
24.根据权利要求18所述的方法，其中，所述无纺布幅材的初始基重为约10gsm。
25.根据权利要求24所述的方法，其中，所述成形膜层的初始基重为约12gsm。
26.根据权利要求25所述的方法，其中，所述活化复合幅材的基重小于约19gsm。
27.根据权利要求18所述的方法，其中，所述活化复合幅材的基重比所述成形膜层和所述无纺布幅材的组合基重小至少15％。
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