CN110612206A - 吸收性层压材料 - Google Patents

吸收性层压材料 Download PDF

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Publication number
CN110612206A
CN110612206A CN201780089996.XA CN201780089996A CN110612206A CN 110612206 A CN110612206 A CN 110612206A CN 201780089996 A CN201780089996 A CN 201780089996A CN 110612206 A CN110612206 A CN 110612206A
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CN
China
Prior art keywords
absorbent laminate
layer
spunbond nonwoven
cellulosic
absorbent
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
CN201780089996.XA
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English (en)
Other versions
CN110612206B (zh
Inventor
M·达维斯
H·维阿兹曼斯基
W·佩里
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Cyrus Absorbent Materials
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Cyrus Absorbent Materials
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Publication of CN110612206A publication Critical patent/CN110612206A/zh
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Active legal-status Critical Current
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Classifications

    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
    • A47L13/00—Implements for cleaning floors, carpets, furniture, walls, or wall coverings
    • A47L13/10—Scrubbing; Scouring; Cleaning; Polishing
    • A47L13/16—Cloths; Pads; Sponges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered 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
    • B32B5/02—Layered 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
    • B32B5/06—Layered 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 characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/083—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
    • B29C65/086—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using a rotary anvil
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7858—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined
    • B29C65/7888—Means for handling of moving sheets or webs
    • B29C65/7894—Means for handling of moving sheets or webs of continuously moving sheets or webs
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    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
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    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
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    • B29C66/45—Joining of substantially the whole surface of the articles
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    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411—Roller, cylinder or drum types
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
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    • B32B27/00—Layered products comprising a layer of synthetic resin
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/02—Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/08—Layered 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 the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
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    • D—TEXTILES; PAPER
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    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
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    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
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Abstract

公开了一种吸收性层压材料，所述吸收性层压材料包括两个纺粘非织造层，其中在所述纺粘非织造层之间设置有纤维素层。吸收性层压材料的不同层通过超声处理粘合，并且可进一步经历压纹步骤。另外，吸收性层压材料可用作一次性擦拭产品，以及用于其他应用。

Description

吸收性层压材料
相关申请的交叉引用
本申请要求于2017年3月27日递交的美国临时申请号62/477,242的优先权，其内容以引用的方式全文并入本文中。
技术领域
本公开涉及吸收性层压材料、所述材料的制造方法以及所述材料的用途。
背景技术
擦拭产品(有时称为“擦拭巾”)可由木材和植物纤维制造，例如，有时用作非织造片材或纸制品，有时用作织物(例如棉布或毛巾)。擦拭巾在工业和家庭环境中用于各种用途。一般来说，纸制品(例如，纸巾)生产成本低，但可能具有有限的物理性质。纺织产品可具有改进的物理性质，但通常比纸制品的制造更昂贵。
发明内容
尽管存在各种擦拭产品，但仍需要具有成本效益且具有增强的物理性质(例如柔软度、吸收性和强度)的擦拭产品。
在一个方面，公开了一种吸收性层压材料，所述吸收性层压材料包括基重为约1克/平方米(gsm)至约30gsm并包含热塑性聚合物的第一纺粘非织造层；基重为约1gsm至约30gsm并包含热塑性聚合物的第二纺粘非织造层；和设置在所述第一和第二纺粘非织造层之间并与它们超声粘合的纤维素层，其中基于所述吸收性层压材料的总重量，所述纤维素层的量为约20重量％至约80重量％。
在另一个方面，公开了一种制造吸收性层压材料的方法，所述方法包括提供基重为约1gsm至约30gsm并包含热塑性聚合物的第一纺粘非织造层、基重为约1gsm至约30gsm并包含热塑性聚合物的第二纺粘非织造层和基重为约10gsm至约100gsm的纤维素层；设置所述纤维素层以使其位于所述第一和第二纺粘非织造层之间；并且对设置的层进行超声处理以提供吸收性层压材料，其中所述纤维素层不含粘合剂且剥离强度大于10克/英寸。
在另一个方面，公开了一种一次性清洁用品，所述一次性清洁用品包括基重为约1gsm至约30gsm并包含热塑性聚合物的第一纺粘非织造层；基重为约1gsm至约30gsm并包含热塑性聚合物的第二纺粘非织造层；和设置在所述第一和第二纺粘非织造层之间并与它们超声粘合的纤维素层，其中基于吸收性层压材料的总重量，所述纤维素层的量为约20重量％至约80重量％。
附图说明
图1是根据一个实施方式的具有两个纺粘层和一个纤维素层的吸收性层压材料的图解。
图2是根据一个实施方式的超声粘合工艺的图解。
图3是显示吸收性层压材料的实施方式的剥离强度(克/英寸)与纸张重量(gsm)的图表。
具体实施方式
本文公开了吸收性层压材料，在一个实施例中其包括两个纺粘非织造层(均为外层)以及设置在两个纺粘非织造层之间的纤维素纸基层(中间层)。在一个实施方式中，三个层通过超声处理粘合。这种分层布置赋予吸收性层压材料以改进的柔软度、吸收性和强度(与诸如非织造擦拭物或织物等材料相比)。另外，相对于现有技术中目前使用的上述纸巾和织物擦拭物，某些公开的吸收性层压材料和提供所述材料的方法可以以较低的成本制造。
1.定义
除非本文另有说明，本文中数值范围的描述仅是为了作为单独指示落在范围内的每个单独值的简写方法，并且每个单独值并入说明书中，如同其在本文中被单独描述一样。例如，如果浓度范围表示为1％至50％，则其意图为本说明书中明确列举了诸如2％至40％、10％至30％或1％至3％等值。这些仅仅是特定目的的实例，并且在本申请中明确地说明了在所列举的最低值和最高值之间并包括最低值和最高值的数值的所有可能组合。
与量相关使用的修饰语“约”包括所述值，并具有上下文指定的含义(例如，它至少包括与特定量的测量相关的误差程度)。修饰语“约”也应该被视作公开了由两个端点的绝对值所定义的范围。例如，表述“约2至约4”也公开了“2至4”的范围。术语“约”可指所示数字的正负10％。例如，“约10％”可表示9％至11％的范围，“约1”可意指0.9至1.1。从上下文可看出“约”的其他含义，例如舍入，因此，例如“约1”也可能意味着0.5至1.4。
如本文所使用的，术语“纺粘非织造物”指的是具有单个纤维或纱线的结构的网，所述纤维或纱线是交织的，但并非是与针织织物一样的可识别方式。特别是，纺粘非织造网可由小直径的基本上连续的纤维形成。纤维可通过以下方式形成：将作为长丝的熔融的热塑性材料(例如，热塑性聚合物)从多个细的、通常为圆形的且具有挤出纤维直径的喷丝头的毛细管挤出，然后通过例如引出拉拔和/或其他公知的纺粘机制迅速变细。
如本文所使用的，术语“基本上不含”指的是包含小于所指示的成分或性质的功能量的材料和/或层，包括0重量％。例如，基本上不含可指包含小于5重量％、小于4重量％、小于3重量％、小于2重量％、小于1重量％、小于0.9重量％、小于0.8重量％、小于0.7重量％、小于0.6重量％、小于0.5重量％、小于0.4重量％、小于0.3重量％、小于0.2重量％、小于0.1重量％或小于0.01重量％的所指示的成分或性质的材料和/或层。
2.吸收性层压材料
图1示出了具有第一纺粘非织造层11、纤维素层12和第二纺粘非织造层13的示例性的吸收性层压材料10。
在示出的实施方式中，设置纤维素层12与纺粘非织造层11和13以使纤维素层12位于第一和第二纺粘非织造层11和13之间(或中间)。纤维素层12是用作吸收性层压材料10的吸收芯的吸收层。例如，在吸收性层压材料10接触一种或多种液体(可能是亲水性或疏水性的，取决于实施方式)时，液体通过纺粘非织造层渗入纤维素层。
在一些实施方式中，吸收性层压材料10基本上由第一纺粘非织造层11、第二纺粘非织造层13和纤维素层12构成。在其他的实施方式中，吸收性层压材料10包括超过三个层。例如，吸收性层压材料10可包括纺粘非织造物、纤维素、纺粘非织造物、纤维素和纺粘非织造物的五层层状结构。这种层的布置可以产生具有整体更高的组合基重的吸收性层压材料，其也具有足够的剥离强度以用作擦拭物材料。如下文将更详细地说明的，纤维素层12是例如在湿法成网工艺中形成的纸层。
吸收性层压材料10可包括等量或不等量的纺粘非织造层。例如，相对于吸收性层压材料的第二纺粘非织造层13的按重量(例如基重)或重量百分比计的量，吸收性层压材料10可包括比率为约1:2至约2:1的第二纺粘非织造层11。在一些实施方式中，吸收性层压材料10包括比率为约1:1的纺粘非织造层(例如，第一纺粘非织造层11以吸收性层压材料10的约30重量％存在，第二纺粘非织造层13以吸收性层压材料10的约30重量％存在)。
吸收性层压材料10可以包括相对彼此的比率不同的纺粘非织造层11和13以及纤维素层12，从而改变吸收性层压材料的所得物理性质。相对于吸收性层压材料10的第一防粘非织造层11和第二防粘非织造层13的按重量或重量百分比计的组合量，吸收性层压材料10可包括比率为约4:1至约1:2的纤维素层12。例如，相对于吸收性层压材料的第一和第二防粘非织造层的按重量或重量百分比计的组合量，吸收性层压材料可包括比率为约4:1、约3.5:1、约3:1、约2.5:1、约2:1、约2:1.25、约2:1.5、约2:1.75、约1:1、约1:1.25、约1:1.5、约1:1.75或约1:2的纤维素层。
在一些实施方式中，吸收性层压材料10经构造以使第一纺粘非织造层11、第二纺粘非织造层13和纤维素层12是离散的层，其基本上没有每层所含纤维的机械缠结例如，由针刺或水力缠结提供的缠结。与其他粘合技术(例如超声粘合)相比，含有水力缠结的层压材料在粘合步骤中使用更多的能量，这可能导致材料更昂贵。在一些实施方式中，吸收性层压材料10基本上没有水力缠结或没有水力缠结。
在一些实施方式中，吸收性层压材料10的层11、12和13具有相同的长度和宽度。
A.纺粘非织造层
纺粘非织造层11和13可以是允许一种或多种液体朝纤维素层12(构造为吸收芯)渗透的多孔层。纺粘非织造层11和13可包括纤维网。在一些实施方式中，纺粘非织造层包括熔喷纤维、梳理纤维或其组合。在一些实施方式中，纺粘非织造层包括通常称为纺粘-熔喷-纺粘(SMS)非织造物的层压复合结构。例如，一个或多个纺粘非织造层可包括两个纺粘非织造层和设置在两个纺粘非织造层之间的熔喷层。在美国专利号4,041,203、美国专利号4,374,888和美国专利号5,169,706中描述了SMS层压物的制造，其全部内容以引用的方式并入。在一些实施方式中，纺粘非织造层11和13具有比纤维素层12更大的平均孔隙率。在一些实施方式中，第一纺粘非织造层11可具有与第二纺粘非织造层13相同的平均孔隙率。
在一些实施方式中，纺粘非织造层11和13包含热塑性聚合物。热塑性聚合物可以作为纤维存在，例如作为纤维网中的纤维。热塑性聚合物可以是聚丙烯、聚乙烯、聚对苯二甲酸乙二醇酯、聚酯、尼龙、聚乳酸、聚乙醇酸或其组合。热塑性聚合物可以是前述聚合物中任一种的均聚物、无规共聚物、嵌段共聚物、交替共聚物、无规三聚物、嵌段三聚物、交替三聚物和其衍生物(例如，其接枝共聚物、酯或醚)等。
在某些实施方式中，热塑性聚合物作为由以上列举的聚合物制造的双组份、三组分或多组分纤维存在。例如，由聚丙烯和聚乙烯制造的双组份纤维。在一些实施方式中，热塑性聚合物作为可以梳理并粘合成非织造布的纤维存在。在一些实施方式中，使用热压纹或通过空气加热来梳理粘合热塑性纤维。
纺粘非织造层可经由双组份或多组分纺丝技术制造。在美国专利号4,340,563和纺织和服装技术管理期刊(Journal of Textile and Apparel Technology Management)，第6卷，第3期，1至13页，2010中描述了纺粘制造，均以引用的方式全文并入本文中。另外，制造纺粘网可包括护套/芯设置，其中聚酯或聚丙烯芯被聚乙烯护套包围。美国专利号7,740,777(以引用的方式全文并入本文中)描述了用于制造这种多组分纺粘非织造纤维的设备和方法。
1.第一纺粘非织造层
基于吸收性层压材料10的总重量，吸收性层压材料10可包括大于10重量％、大于15重量％、大于20重量％、大于25重量％或大于30重量％的量的第一纺粘非织造层11。在一些实施方式中，基于吸收性层压材料10的总重量，吸收性层压材料10可包括小于40重量％、小于35重量％、小于30重量％、小于25重量％或小于20重量％的量的第一纺粘非织造层11。在一些实施方式中，基于吸收性层压材料10的总重量，吸收性层压材料10可包括约10重量％至约35重量％，例如约15重量％至约30重量％或约15重量％至约25重量％的量的第一纺粘非织造层11。在一些实施方式中，基于吸收性层压材料10的总重量，吸收性层压材料10可包括约20重量％至约30重量％的量的第一纺粘非织造层11。
基于第一纺粘非织造层的总重量，第一纺粘非织造层11可包含大于80重量％、大于85重量％、大于90重量％、大于95重量％或大于99重量％的量的热塑性聚合物。在一些实施方式中，基于第一纺粘非织造层的总重量，第一纺粘非织造层11包含约80重量％至约100重量％，例如约90重量％至100重量％、约95重量％至约100重量％或约95重量％至约99重量％的量的热塑性聚合物。
在一些实施方式中，第一纺粘非织造层11基本上由热塑性聚合物构成。
第一纺粘非织造层11的基重可以为约1克/平方米(gsm)以上、约5gsm以上、约10gsm以上、或约15gsm以上。在一些实施方式中，第一纺粘非织造层11的基重可以为约40gsm以下、约35gsm以下、约30gsm以下、约25gsm以下、或约20gsm以下。在一些实施方式中，第一纺粘非织造层11的基重可以为约1gsm至约40gsm，例如约1gsm至约30gsm，或约5gsm至约20gsm。在一些实施方式中，第一纺粘非织造层11的基重为约10gsm至约15gsm。
第一纺粘非织造层11的厚度可以大于0.5毫米、大于1毫米、或大于5毫米。在一些实施方式中，第一纺粘非织造层的厚度可以小于10毫米、小于9毫米、小于8毫米、小于7毫米或小于6毫米。在一些实施方式中，第一纺粘非织造层11的厚度为约0.5毫米至约10毫米，例如约1毫米至约8毫米或约3毫米至约6毫米。
2.第二纺粘非织造层
通常，第二纺粘非织造层13的结构与第一纺粘非织造层11相同或类似。因此，用于描述第一纺粘非织造层1的性质也被描述并适用于第二纺粘非织造层13的许多实施方式。为简便起见，这里不再重复。
B.纤维素层
如上所述，纤维素层12是纸层，并用作吸收性层压材料10的吸收芯。纤维素层12不含通常用于将纤维素层12固定于吸收性层压材料10的其他层(如纺粘非织造层11和13)的粘合剂(如粘附剂)。粘合剂的实例包括但不限于热塑性纤维、聚合物粘合剂如丙烯酸、乙酸乙烯酯、苯乙烯丁二烯和苯乙烯丙烯酸等。因此，纤维素层12不含热塑性纤维。
与包括可能需要外部粘合系统的合成纤维的吸收芯的制备相比，使用纸吸收层更具成本效益。在一些实施方式中，纤维素层12是双重皱(double re-creped,DRC)纸。在一些实施方式中，纤维素层12通过空气成形工艺形成。
基于吸收性层压材料10的总重量，吸收性层压材料10可包括大于30重量％、大于35重量％、大于40重量％、大于45重量％或大于50重量％的量的纤维素层12。在一些实施方式中，基于吸收性层压材料10的总重量，吸收性层压材料10可包括小于80重量％、小于70重量％、小于60重量％、小于55重量％、小于50重量％、小于45重量％或小于40重量％的量的纤维素层12。在其他的实施方式中，基于吸收性层压材料的总重量，吸收性层压材料10可包括约20重量％至约80重量％，例如约25重量％至约75重量％、约40重量％至约60重量％或约35重量％至约55重量％的量的纤维素层12。在一些实施方式中，基于吸收性层压材料的总重量，吸收性层压材料包括约45重量％至约55重量％的量的纤维素层。
纤维素层12可包含漂白木浆、未漂白木浆、再生木浆、非木浆或其组合。在一些实施方式中，纤维素层12包含软木牛皮纸浆、硬木牛皮纸浆、亚硫酸盐纸浆或其组合。在其他的实施方式中，纤维素层12包含人造丝、棉或莱赛尔纤维(lyocell fiber)。另外，纤维素层12包含非木材造纸纤维，例如来自诸如马尼拉麻、黄麻、细茎针草和竹子等来源的制浆材料。如上所述，纤维素层12不包含合成纤维。在一些实施方式中，纤维素层12基本上由纤维素构成。
基于纤维素层12的总重量，纤维素层12可包含大于80重量％、大于85重量％、大于90重量％、大于95重量％或大于99重量％的量的纤维素纤维。在一些实施方式中，基于纤维素层12的总重量，纤维素层12可包含约90重量％至约100重量％，例如约95重量％至约100重量％、约95重量％至约100重量％或约95重量％至约99重量％的量的纤维素纤维。
根据应用，纤维素层12可包含脱粘剂和或湿强度剂。在包含脱粘剂和/或湿强度剂的实施方式中，纤维素层12包含的这些成分小于或等于纤维素层的1重量％，例如小于或等于纤维素层的0.9重量％、小于或等于纤维素层的0.8重量％、小于或等于纤维素层的0.7重量％、小于或等于纤维素层的0.6重量％、小于或等于纤维素层的0.5重量％、或小于或等于纤维素层的0.1重量％。在包含一种或多种湿强度剂(例如，Kymene 920A或GHP12；Solenis,Wilmington,DE)的实施方式中，湿强度剂对吸收性层压材料10的干强度没有贡献。在一些实施方式中，纤维素层12可基本上不含脱粘剂和/或表面活性剂。
纤维素层12可以由典型的造纸工艺制造。例如，纤维素层12可以由木材或其他造纸浆在长网造纸机上制造。在美国专利申请公开号2007/0044891中可以找到造纸工艺的额外实例，以引用的方式将其全文并入本文中。
纤维素层12的基重可以为约10gsm以上、约20gsm以上、约30gsm以上、约40gsm以上、约50gsm以上、约60gsm以上或约70gsm以上。在一些实施方式中，纤维素层的基重可以为约80gsm以下、约70gsm以下、约60gsm以下或约50gsm以下。在一些实施方式中，纤维素层的基重可以为约10gsm至约100gsm、约20gms至约80gsm或约20gsm至约70gsm。在一些实施方式中，纤维素层的基重可以为约20gsm至约50gsm。
纤维素层的厚度可以大于0.5毫米、大于1毫米或大于5毫米。在一些实施方式中，纤维素层的厚度可以小于10毫米、小于9毫米、小于8毫米、小于7毫米或小于6毫米。在一些实施方式中，纤维素层的厚度可以为约0.5毫米至约10毫米，例如约1毫米至约8毫米或约3毫米至约6毫米。
3.吸收性层压材料的制造方法
图2示出了用于形成吸收性层压材料10的示例性超声焊接或粘合台20。将纺粘非织造层11和13以及纤维素层12引入超声变幅杆21和砧座25之间。砧座25可具有粘合图案。纺粘非织造层11和13可以经提供(如上所述按基重计)及设置以使纤维素层12处于纺粘非织造层11和13的中间。
在一些实施方式中，相对于纺粘非织造层11和13的合计重量(例如，基重)，纤维素层12以约4:1至约1:2的比率提供。
超声方法20可以在整理两个纺粘非织造层和纤维素层的单个步骤中执行。在一些实施方式中，层压在多个步骤中进行，第一纺粘非织造层11粘合至纤维素层12，然后层压第二纺粘非织造层13，并通过超声变幅杆21和砧座25进行随后的粘合。
在超声方法20的过程中，经整理的层经受来自超声变幅杆21的超声能量和来自超声变幅杆21和砧座25的组合的外加压力，从而导致纺粘非织造层11和13与纤维素层12之间粘合。粘合可以通过连续粘合或通过使用砧座25来传递图案的图案系统来进行。
超声粘合可通过本领域中已知的机器进行。超声粘合可以以约25m/分钟至约700m/分钟进行，例如以约100m/分钟至约300m/分钟或约50m/分钟至约200m/分钟进行。在一些实施方式中，超声粘合以约200米/分钟进行。
另外，超声粘合可以在约500N至约5000N的压力下进行，例如1000N至约5000N、约1000N至约约3000N、或约2000N至约5000N。在一些实施方式中，超声粘合在约2000N的压力下进行。
在超声处理之后，吸收性层压材料10可经历压纹步骤。压纹步骤可改变吸收性层压材料的体积和/或厚度。压纹步骤可使用图案来完成，这可能导致体积在潮湿和干燥状态下均增大。压纹步骤还可使吸收性层压材料10获得有利性质，例如但不限于增大湿强度。
4.包含吸收性层压材料的物品
所公开的吸收性层压材料10可用于许多应用。吸收性层压材料10可用作清洁用品。例如，作为可用于吸收液体和/或清洁表面的物品。清洁用品可以是一次性的或可重复使用的(例如，在处理前使用2、3、4、5次等)。
另外，吸收性层压材料10可以转换为干燥或预湿润的擦拭巾。擦拭巾的包装是在用于美观目的的擦拭巾厚度和在特定包装中具有所需数量的擦拭巾的需求之间的平衡。可使用溶液(包括但不限于水、酒精、一种或多种清洁溶液或其组合)对吸收性层压材料10进行预润湿。本文中描述的吸收性层压材料10可用于折叠包装或卷装。
吸收性层压材料10也可用作卫生擦拭巾(例如婴儿擦拭巾)。包括吸收性层压材料10的物品可包含添加剂，例如皮肤调节剂、乳化剂、pH调节剂、防腐剂、清洁剂或其组合。另外，卫生擦拭巾既可以吸收一种或多种液体，也可以释放卫生擦拭巾(例如，预润湿的擦拭巾)内存在的液体。
通过参考以下实施例将更好地理解所公开的化合物、组合物、方法和过程，这些实施例旨在说明而非限制本发明的范围。
实施例
实施例1
使用两层12gsm的纺粘聚丙烯非织造物制备具有吸收性层压材料10的结构的三层吸收性产品。这些产品用长网造纸机由漂白的北方软木牛皮纸浆生产的20gsm的纸张进行整理。此三层在试验机上以200米/分钟接受超声能量，压辊上的压力为2000N，设置如超声方法20所示。在超声粘合之后，使用不连续的图案对层压的非织造物样品进行压纹。压纹步骤增加了层压物的干和湿体积。层压物的物理性质见表1，并与商用擦拭巾样品进行了比较。对样品002和003进行压纹。
使用以下技术测量物理性质：
单位面积质量：INDA标准试验：IST 130.1
体积或厚度：INDA标准试验：IST 120.1
条带拉伸：ASTM D5035-95
非织造物吸收：INDA标准试验：IST 10.1
胀破强度：INDA标准试验：IST 30.1
表1：实施例1的吸收性层压材料的性质
实施例2
通过改变纤维素层和纺粘非织造层的量来制备具有吸收性层压材料10的结构的一系列三层吸收性产品。具体而言，纤维素层是约12.2gsm至约64.4gsm的100％北方漂白针叶木硫酸盐的纤维素纸，纺粘非织造层是约10gsm至约12gsm的纺粘聚丙烯。吸收性层压产品经由实施例1中描述的超声处理粘合。
层压产品然后由剥离强度(克/英寸)和吸收率％表征。剥离试验包括在样品的每一侧施加胶带，并测量用于将层剥离开的力。吸收率试验是本领域的标准试验，用于测量被样品吸收的液体(例如，水)的％。
剥离强度数据大体表明，纤维素层越厚，剥离强度越低(见图3)。不希望受限于任何特定理论，据假设，剥离强度结果是由于纤维素被认为不容易通过超声粘合，例如粘合至纺粘热塑性聚合物。尽管如此仍可以看出，即使当纤维素层为约50gsm时，剥离强度对于作为擦拭材料的效用也足够高。此外，当纤维素层高于50gsm但热塑性聚合物与纤维素的比率增大时，仍可获得足够的剥离强度(见表2，总重量为85.9gsm的样品)。另外，吸收率数据表明，对于100％纤维素层的不同基重，吸收率％相对恒定。
表2：实施例2的吸收性层压材料的性质
实施例3
使用两层纺粘聚丙烯非织造物制备具有吸收性层压材料10的结构的三层吸收性产品。这些产品用长网造纸机由漂白的北方软木牛皮纸浆生产的纸张进行整理。此三层在试验机上以200米/分钟接受超声能量，压辊上的压力为2000N，设置如超声方法20所示。纺粘外层包含10或12gsm的经热粘合的纺粘的聚丙烯。未经处理的木浆纸的基重为14.7、20、36.5或48.6gsm。表3显示了用于不同吸收性层压材料的每一层的不同量。超声粘合后，测量样品的物理性质，如下表4展示。
使用以下技术测量物理性质：
单位面积质量：INDA标准试验：IST 130.1
体积或厚度：INDA标准试验：IST 120.1
条带拉伸：ASTM D5035-95
非织造物吸收：INDA标准试验：IST 10.1
内部粘合强度：INDA标准试验：IST 110.3
马丁代尔磨损：INDA标准试验：IST 20.5
表3：实施例3的吸收性层压材料的性质
表4：实施例3的不同吸收性层压材料的比较
表3和4中的数据表明，与对照用50gsm纺粘擦拭巾(点粘合，单层)相比，所公开的吸收性层压材料在轻重量和高拉伸强度之间具有有利的平衡。用于评估材料的耐磨性的马丁内尔分析表明，与对照用50gsm纺粘擦拭巾相比，所公开的吸收性层压材料具有良好的耐磨性。有趣的观察是，与对照用纺粘擦拭巾不同，所公开的吸收性层压材料的湿厚度的增加超过干厚度。
总的来说，表4中描述的性质表明所公开的吸收性层压材料具有足够的强度(在纤维素芯中不使用合成纤维)。这与本领域的预期相反，在本领域中认为，为获得足够的内部粘合强度而在纤维素核心内具有合成纤维是重要的。因此，吸收性层压的材料是高度吸收性的、有效的擦拭物，其总体上降低了生产成本。
从上面可以看出，所公开的吸收层压材料可具有以下有利性能中的一些(在某些情况下是全部)。吸收性层压材料10的横向湿拉伸强度为约500gsm至约1500gsm，例如约550gsm至约1450gsm或约600gsm至约1200gsm。
吸收性层压材料10的吸收率至少取决于层压材料中包含的纤维素层12的量。例如，随着纤维素层12的量增加，吸收率增大。在一些实施方式中，例如通过用液体吸附添加剂来处理，纺粘非织造层11和13增大了吸收性层压材料10的吸收率。
在某些实施方式中，吸收性层压材料10的吸收率相对于吸收性层压材料的干重大于250％、相对于吸收性层压材料的干重大于300％、相对于吸收性层压材料的干重大于350％、相对于吸收性层压材料的干重大于400％、相对于吸收性层压材料的干重大于450％、或相对于吸收性层压材料的干重大于500％。在一些实施方式中，吸收性层压材料的吸收率相对于吸收性层压材料的干重为约200％至约800％，例如，相对于吸收性层压材料的干重为约250％至约700％、相对于吸收性层压材料的干重为约250％至约600％、或相对于吸收性层压材料的干重为约300％至约500％。
吸收性层压材料10的剥离强度至少取决于层压材料中包含的纤维素层12的量，并且也受到纺粘非织造层11和13的总量相对于纤维素层的比率的影响。例如，如上文示出的，随着纤维素层12的量增加，剥离强度降低(当保持纺粘层11和13恒定时)。因此，在吸收性层压材料10的吸收率和剥离强度之间存在平衡。
吸收性层压材料10的剥离强度大于10克/英寸、大于20克/英寸、大于50克/英寸、大于75克/英寸、大于100克/英寸、大于125克/英寸、大于150克/英寸、大于175克/英寸、大于200克/英寸、大于250克/英寸、或大于300克/英寸。在一些实施方式中，吸收性层压材料10的剥离强度为约10克/英寸至约400克/英寸，例如约20克/英寸至约300克/英寸、约100克/英寸至约300克/英寸、或约20克/英寸至约200克/英寸。
对所公开的实施方式的各种变化和修改对于本领域的技术人员都将是显而易见的。可以在不脱离本发明的主旨和范围的情况下进行这种变化和修改，包括但不限于与本发明的化学结构、取代基、衍生物、中间体、合成物、组合物、制剂或使用方法有关的变化和修改。

Claims (20)

1.一种吸收性层压材料，所述吸收性层压材料包括：
第一纺粘非织造层，其基重为约1克/平方米(gsm)至约30gsm，并包含热塑性聚合物；
第二纺粘非织造层，其基重为约1gsm至约30gsm，并包含热塑性聚合物；和
纤维素层，其设置在所述第一和第二纺粘非织造层之间并与它们超声粘合，
其中，基于所述吸收性层压材料的总重量，所述纤维素层的量为约20重量％至约80重量％。
2.如权利要求1所述的吸收性层压材料，其中，相对于所述吸收性层压材料的干重，所述吸收性层压材料的吸收率大于300％。
3.如权利要求1或2所述的吸收性层压材料，其中所述吸收性层压材料的剥离强度大于10克/英寸。
4.如权利要求1至3中任一项所述的吸收性层压材料，其中所述热塑性聚合物选自由聚丙烯、聚乙烯、聚酯、尼龙、聚乳酸及其组合组成的组。
5.如权利要求1至4中任一项所述的吸收性层压材料，其中所述纤维素层包含漂白木浆、未漂白木浆、再生木浆、非木浆或其组合。
6.如权利要求1至5中任一项所述的吸收性层压材料，其中，相对于所述第一和第二纺粘非织造层的合计重量，所述纤维素层以约4:1至约1:2的比率存在。
7.如权利要求1至6中任一项所述的吸收性层压材料，其中，基于所述吸收性层压材料的总重量，所述纤维素层的量为约25重量％至约75重量％。
8.如权利要求1至7中任一项所述的吸收性层压材料，其中所述纤维素层是纸层。
9.如权利要求1至8中任一项所述的吸收性层压材料，其中所述吸收性层压材料基本上没有层间的水力缠结。
10.如权利要求1至9中任一项所述的吸收性层压材料，其中所述纤维素层不含粘合剂。
11.如权利要求1至10中任一项所述的吸收性层压材料，其中所述第一纺粘非织造层包括两个纺粘非织造层和设置在所述两个纺粘非织造层之间的熔喷层。
12.如权利要求1至11中任一项所述的吸收性层压材料，所述吸收性层压材料基本上由所述第一纺粘非织造层、所述第二纺粘非织造层和所述纤维素层构成。
13.一种制造吸收性层压材料的方法，所述方法包括：
-提供基重为约1gsm至约30gsm并包含热塑性聚合物的第一纺粘非织造层、基重为约1gsm至约30gsm并包含热塑性聚合物的第二纺粘非织造层和基重为约10gsm至约100gsm的纤维素层；
-设置所述纤维素层以使其位于所述第一和第二纺粘非织造层之间；并且
-对设置的层进行超声处理以提供吸收性层压材料，
其中所述纤维素层不含粘合剂且剥离强度大于10克/英寸。
14.如权利要求13所述的方法，其中，相对于所述第一和第二纺粘非织造层的合计重量，所述纤维素层以约4:1至约1:2的比率提供。
15.如权利要求13或14所述的方法，其中所述纤维素层由造纸工艺或空气成形工艺形成。
16.如权利要求13至15中任一项所述的方法，其中所述方法包括单次超声处理。
17.如权利要求13至16中任一项所述的方法，其中所述方法还包括对所述吸收性层压材料进行压纹。
18.如权利要求13至17中任一项所述的方法，其中，相对于所述吸收性层压材料的干重，所述吸收性层压材料的吸收率大于300％。
19.如权利要求13至18中任一项所述的方法，其中所述吸收性层压材料包括具有相同长度和宽度的层。
20.一种一次性清洁用品，所述用品包括：
基重为约1gsm至约30gsm并包含热塑性聚合物的第一纺粘非织造层；
基重为约1gsm至约30gsm并包含热塑性聚合物的第二纺粘非织造层；和
设置在所述第一和第二纺粘非织造层之间并与它们超声粘合的纤维素层，
其中，基于吸收性层压材料的总重量，所述纤维素层的量为约20重量％至约80重量％。
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