CN112689494A - 用作一次性吸收制品组分的多层非织造结构 - Google Patents
用作一次性吸收制品组分的多层非织造结构 Download PDFInfo
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- CN112689494A CN112689494A CN201880095736.8A CN201880095736A CN112689494A CN 112689494 A CN112689494 A CN 112689494A CN 201880095736 A CN201880095736 A CN 201880095736A CN 112689494 A CN112689494 A CN 112689494A
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Abstract
本发明涉及一种可作为一次性吸收制品和服装组分的多层非织造结构,包含超吸水性颗粒从而可以起芯材作用。因此,本发明保证了体液可以从作为收集层的第一层渗透到包含SAP颗粒的第三层,第二非织造层作为常规的分布层,用于减少每个单位表面的流体体积。然而,本发明中的第二层还像单向阀一样,防止或至少强力限制任何流体从第三层转移到第一层。此外,还设计了不含SAP的通道,以改善多层收集‑分布非织造片材的吸入和回渗性能。
Description
技术领域
本发明涉及一种包含超吸收性颗粒的用作一次性吸收制品和服装组成部分的多层非织造结构。本发明还涉及包含所述多层非织造结构的一次性吸收制品或服装,例如卫生巾、内裤衬里、婴儿尿布、成人失禁垫、女性卫生用品、训练裤、汗垫、医用伤口绷带等等。本发明还涉及一种制备所述多层非织造结构的工艺。
背景技术
如图1所示,常规的一次性吸收制品或服装的主要组成部分包括一个液体可以渗透或通过的、优选为亲水的外层11(通常被称为顶片),一层收集-分布层12(通常称为ADL),一个液体不能渗透或通过的外层14(通常称为背片)和一个夹在ADL 12和背片之间的吸收芯13。吸收芯13通常由绒毛构成,所述绒毛通常由像纤维素一样有可膨胀性的纤维制成。为提高绒毛的吸收能力,绒毛内部散布有超吸收性聚合物(SAP)颗粒,即能够大量(优选为其自身重量10至1000倍)吸收水性液体(如尿液、血液或二者共存)的聚合物颗粒。
ADL通常包括一个收集层,收集层用于快速收集流入该层限定区域的液体,并将其转移至至少一个分布层,从而使液体从服装穿着者的身体移除并散布在层内的更大区域中,从而降低了每单位表面的液体流量。
例如在专利BE 1 018 052中公开了一种收集-分布层(ADL)系统。收集层通常由粗纤维组成,这些粗纤维通过毛细作用将液体快速转移到分布层。所述分布层通常包含亲水性材料和适用于卫生制品的纤维。
典型的SAP颗粒由交联的亲水性聚合物链组成。亲水聚合物是天然或合成聚合物或两者的混合物。普通的天然聚合物包括纤维素基聚合物,例如最终被附加的诸如羧酸盐、膦酸盐或亚硫酸盐进行亲水化功能改性的纤维素或淀粉。合成的超吸收性亲水聚合物通常是丙烯酸基聚合物。SAP颗粒可以至少部分地被涂覆。额外的涂层改善或提供了SAP颗粒的其他特性,例如更好的体液吸收和保留能力,颗粒对周围环境的更好附着力或更好的机械性能。
吸收芯通常包括SAP颗粒和基底(例如纤维、绒毛或其任何组合)的混合物。当该吸收芯被体液润湿时,SAP颗粒能够吸收大量液体。但是,湿的SAP颗粒会膨胀,并且由此能够和邻近的膨胀SAP颗粒形成凝胶。所述凝胶的形成通常称为凝胶阻滞作用,可以阻挡液体向吸收芯的内部传输。作为结果,凝胶阻滞可能导致潜在的液体泄漏和/或导致回渗问题。为了防止凝胶阻滞并提高吸收芯的液体吸收能力,单个SAP颗粒与另一个颗粒之间必须距离足够远,即在它们之间留有空隙。这通常是通过将SAP颗粒与纤维素基绒毛混合在一起而得到。
提供更薄的吸收制品的趋势涉及尽可能高效地使用SAP颗粒,且尽可能少用绒毛。具有高SAP-绒毛比例的吸收芯被称为少绒毛或无绒毛芯。
在WO 2013/152809中公开了这种少绒毛/无绒毛的吸收结构的实例,其中吸收芯包括低于4wt%的绒毛。
减少吸收制品中绒毛量的一个缺点是,向制品施加压力时(通常通过身体移动施加),SAP颗粒受到挤压,绒毛的持液量降低,一些液体回流到周围的层中,包括流向身体。因此,水分会以令人不快的回渗作用转移到皮肤上,并可能产生副作用。
因为具有该制品的主要保液功能的吸收芯收集液体的速度不如ADL快,所以对这两个元素的适当组合至关重要。
关于当前已知的一次性吸收制品或服装,在本领域中持续需要改善其持液量且需要在一旦收集液体即对液体进行分布,并减少液体吸入时间和回渗作用。还需要在实现这些目标的同时而无需更昂贵的、化学成分复杂的SAP颗粒,同时保持制品的薄度。还需要提供改进的一次性吸收制品或服装,而不增加其复杂性和制造成本。
发明内容
本发明实现了上述目标和其他优点。
为此,本发明涉及一种用于卫生制品的多层收集-分布片材非织造材料,其包括相互堆叠的至少三层:
- 第一层,用于收集和转移体液至第二层;
- 第二层,用于从第一层接收体液并将体液散布在第二层上,以及
- 第三层包括超吸收性聚合物(SAP)颗粒,用于从第二层接收体液,第二层不可逆地将体液转移至第三层。
因此,本发明中的多层非织造材料起到了芯体的作用。
因此,本发明确保体液可以渗透到用作收集层的第一层,再继续渗透至第三层,第二非织造层用于减少每单位表面的液体量,作为常规的分布层。然而,本发明的第二层还起到单向阀一样的作用,防止或至少强烈地限制了从第三层到第一层的任何液体输送。
在此应理解,在合理使用条件下,不可逆转地,第三层中SAP的液体吸收与第二层的结构相结合防止大多数液体从第三层移回到第二层。根据EDANA WSP 70.3.R3(收集时间-ST)和WSP 80.10(回渗量-WB)测得,回渗量为7g或更小,优选为2g或更小,更优选为1g或更小。
其中,SAP颗粒分散在非织造层材料中,而不是和在吸收芯中那样分散在绒毛中。
为了将体液不可逆地转移至第三层,第二层的空隙体积小于第三层的空隙体积,第三层的纤维为粗纤维(约大于7dtex),而第二层的则更细。
理想情况下,第二层中的空隙体积可以小于SAP颗粒的体积,至少小于SAP颗粒膨胀状态下的体积,以防止SAP颗粒从第三层迁移至第二层。空隙体积的差异,或者说空隙体积梯度,能够产生压力梯度,从而减慢液体从第三层到第二层的回流。
另外,作为收集层,第一层必须迅速吸入体液。这就要求第一层中的空隙体积要足够大,特别是要比第二层中的空隙体积大。
因此,本发明的多层收集-分布片材具有创造性,因为它结合了多种效果来提高ADL层的容量:
- SAP颗粒在第一层和第三层之间形成液体吸入梯度,并通过SAP的布置而避免凝胶阻滞,从而产生了改进的抽吸效应;而且
- 第三层和第二层的空隙体积不同,从而在第三层和第二层之间产生了改进的止回效果。
空隙体积与纤维之间的空间有关,纤维在多个点处缠结在一起,从而形成具有空腔或者说空隙的阵列。非织造材料中的空隙体积是本领域技术人员众所周知的参数,并且对应于材料中所有可用的、未被如纤维和SAP等材料填充的空间。可以通过PMI孔隙度测定法或透气率进行计算和测量。空隙体积通过100Pa–20cm²条件测试透气率进行测量,优选的,空隙体积对应的透气率介于1000 l /m²/s和12000 l /m²/s之间,还优选介于2000 l /m²/s和3000 l /m²/s之间。
结合了SAP颗粒的本发明的多层收集-分布片材能够至少部分地发挥通常在吸收性卫生产品中的吸收芯的功能。作为结果,将这样的ADL/芯材整合进卫生制品中改善了制品的吸收和保持能力,和/或使得应用更薄或无绒毛的吸收芯成为可能。
在后一种情况下,本发明的多层片材既充当收集-分布层又充当吸收层。因此,本发明的多层片材可以直接夹在可渗透顶片和不可渗透背片之间。
在一个特定的实施方式中,SAP颗粒按照一种留有通道的模式分散在第三层中,该通道从第二层延伸穿过第三层,且不含SAP颗粒。通道指该层的任何类型的区域,在其整个厚度上没有SAP。
贯穿第三层的厚度且无SAP颗粒分布的通道能够增加第三层的吸收效率。实际上,通过这些通道,体液能够更快地渗入该层深处,并被更多的SAP颗粒所吸收。这样能够通过增加第三层内的体液路径来提高该层的吸收速度。由于液体甚至可以分布到更深的SAP颗粒上,因此它还具有防止凝胶阻滞的有益效果。
在可以与前述实施方式结合的另一实施方式中,至少一层可以包括连续的空隙空间。连续的空隙空间是指没有非织造材料的空间。这些连续的空隙空间是与非织造层中的纤维之间测得的空隙体积不同的概念,是指非织造层中具有更大尺寸的切口或孔洞。这样的空间可以设置在该层的整个厚度上,如在下面描述的那样切割和重新布置非织造小块时的情况,或者仅设置在该层的部分厚度上,如在对一层或多层进行焊接工艺时的情况。
本发明还涉及一种将SAP颗粒分散至本发明的多层非织造片材第三层内的工艺,包括以下步骤:
- 将SAP颗粒涂覆到第三层表面的至少一部分上,以及
- 将SAP颗粒浸渍入第三层内部。
对于SAP颗粒按照留有通道的模式分散在第三层中,该通道从第二层延伸穿过第三层,且不含SAP颗粒方案的特定实施方式,本发明的工艺可以包括以下步骤中的至少一个:
- 在沉积SAP颗粒之前在第三层的表面上施加掩模;
- 至少对第三层进行焊接;
- 将第三层切成小块,并将这些小块彼此分开粘附到第二层上。
对于至少一层包括连续的空隙空间的特定实施方式,本发明的工艺可以包括以下步骤中的至少一个:
- 将至少一层切割成小块并将这些小块彼此分开,粘附到相邻层上;
- 对至少一层进行焊接。
浸渍指的是使SAP颗粒从表面运动到非织造层内,进入空隙中,从而将颗粒分布在该层的至少一部分厚度内的操作。
焊接是本领域技术人员公知的步骤,指的是在施加热量的过程中将非织造物压在一个离散区域上,以将非织造物不可逆地压紧在该特定区域上的操作。
附图说明
通过以下的实施例描述,参考附图,将能够更好地理解本发明,附图中:
图1是常规的一次性吸收制品或服装的截面设计;
图2是本发明中的多层收集-分布片材的截面设计;
图3示出了体液在图2中的材料片内的流动;
图4示出了包含在卫生吸收制品中的图1和图2中的材料片。
图5是根据本发明的另一种多层收集-分布片材的截面设计图;
图6a、6b和6c是根据本发明的第三层内通道模式的俯视示意图;
图7是本发明中的工艺流程图;
图8示出了本发明中工艺的另一个实施方式;
图9示出了本发明中工艺的另一个实施方式;
图10示出了本发明中工艺的又一个实施方式;
图11示出了本发明中多层收集-分布片状非织造材料的另一种制备方式,图12示出了本发明中多层收集-分布片状非织造材料的又一种制备方式。
具体实施方式
参照图2和3,一种用于卫生制品的多层收集-分布片材20包括相互堆叠的:第一层21、第二层22和包含超吸收性聚合物(SAP)颗粒24的第三层23。
第一层21包括缠结在一起形成空隙27的纤维26,优选粗纤维。
第二层22由细的亲水纤维28制成,其比第一层21的粗纤维更紧密地堆积。细纤维28缠结在一起以形成空隙29。
第三层23包括缠结在一起形成空隙31的粗纤维30,优选相当亲水的粗纤维。一些SAP颗粒24分布在第三层23内的空隙31内。
第一层21和第三层23是多孔层,根据本发明所述的多孔定义为空隙体积在大约300至大约500cm3的空隙体积/m2之间,所述第二层22由非常细的亲水纤维(在0.7至30dtex之间,优选1.5至7dtex)构成,导致产生较小的空隙,从而防止液体流回至表面,也限制了SAP颗粒在其中迁移的可能性。
适用于各层21、22、23的纤维是本领域技术人员众所周知的,并且可以是非织造材料领域中本领域技术人员已知的任何合适的材料或材料混合物。例如,纤维可以是但不限于高分子合成纤维,包括聚对苯二甲酸乙二醇酯(PET)、聚乙烯(PE)、聚丙烯(PP)、乙烯和丙烯共聚物(COP)、PET/PE、PET/PP、PET/COP、PP/PE、PET/COPET、聚丙烯酸(PLA)、PLA/PP、聚乙烯醇、粘胶纤维。
在第一层21中,纤维优选纤度为2至28dtex。
在第二层22中,纤维纤度低于第一层中的纤维,优选纤度包括0至7dtex,以赋予第二层较高的保液和分布能力,从而使下一层的SAP颗粒缓慢吸收液体,以避免任何凝胶阻滞。优选地,第二层中的纤维是本身固有地或通过亲水性涂覆或处理而具有亲水性。
适用于第三层23的纤维具有比第二层更高的纤度,其优选地包括纤度在2至70dtex之间。
如本领域技术人员所知,特定层的空隙体积,如第一层和/或第三层的空隙体积,可以通过热处理来改变。
在实际中,如图3中的箭头所示,诸如尿液或血液之类的体液通过限定区域渗透到第一层21中。第一层21可以迅速地收集液体并将其转移到第二层22。
由于其更小的纤维尺寸,较小的空隙体积和亲水性,体液通过毛细作用在层22的所有方向上渗透并迁移,从而将体液“摊开”在材料片的较大区域上。
然后,体液从第二层22转移到第三层23,在第三层23被SAP颗粒24吸收,从而产生抽吸效应,以保证从第一层21向第三层23的流向。另外,由于第二层22中的空隙29的体积小于第三层23中的空隙31的体积,因此产生了反压,该反压影响了体液渗透到第三层23之后可以返回第二层22的速度,从而给SAP颗粒留出时间以完全吸收液体。即使一些体液回流到第二层22中,第一层21和第二层22之间的亲水性差异也进一步防止体液回流到第一层21中,因此可比作单向阀。
如图4所示,本发明中的多层材料片20能够作为ADL用于诸如尿布、卫生巾或创伤敷料的吸收制品40。可渗透的顶片41被施加到第一层21上,例如为了使制品在其靠近身体侧具有柔软的触感。不可渗透的背片44被施加在相对侧,以确保湿度不会进一步转移。可选地,吸收芯43可被夹在ADL 20和背片44之间。该吸收芯是可选的,并且其形态可以取决于制品的预期用途。例如,吸收芯由内部有SAP颗粒分布的绒毛制成,用于吸收和保留大量流入液体的制品中,例如尿布或叠合纸。例如,对于某些用于应对较少量体液的女性卫生制品而言,绒毛的量可以减少。
在另一种情况下,特别是对于创伤敷料,第三层可以是设计上更靠近身体的层。
至此已经描述了三个层,但是本发明的多层片材可以包括多于三层,例如结合不同非织造材料或纤维的物理性能。
例如,这些额外的层可以表现出递减的空隙体积和/或递增的亲水性,以产生空隙体积和/或亲水性的实际梯度。
类似地,可以添加一个或多个与第二层一侧或另一侧接触的额外的分布层;可以在第二和第三层之间添加一个或多个额外的粗纤维层,其中可能包含分散在其中的SAP颗粒。可以设想,具有不同特性(例如膨胀能力或尺寸)的SAP可以分散在不同的非织造层中。
在某些应用中,制品内不含有吸收芯。内部分散有SAP颗粒的第三层23本身的吸收和保留能力就已足够了。
在这种情况下,略微增加第三层的厚度和/或SAP颗粒载荷以增加其吸收和保液能力可能是值得关注的。
然而,如前所述,增加第三层的厚度和/或SAP颗粒载荷会导致有害的凝胶阻滞效应。
为了防止这种效应,最好在第三非织造层中形成不含SAP颗粒的通道。
参照图5,根据本发明的多层收集-分布片材50包括用于收集和转移体液的第一层51和用于从第一层接收体液并将体液散布在第二层上的第二层52,类似于上述的层21和22。第三层53包括用于从第二层接收体液的超吸收性聚合物(SAP)颗粒54。SAP颗粒54不是均匀地分布在第三层53中,而是按照一定模式分布,在该层的整个厚度上留出一些没有颗粒的区域,从而形成通道55。
如图5的箭头所示,在大部分界面区域上,体液从第二层52转移到第三层53。当渗入到第三层中含有SAP颗粒的区域上时,体液首先被靠近层界面的SAP颗粒吸收。当渗透到第三层53中没有SAP颗粒的区域上时,即进入通道中时,体液能够随着通道渗透到更深的包含SAP的区域中。
这样,不仅靠近第二层52和第三层53界面处的SAP颗粒能够吸收体液,更深处的颗粒也能吸收。如果没有这些通道,体液将会首先抵达靠近界面的SAP颗粒,颗粒继而产生膨胀,之后体液必须在膨胀后的SAP颗粒间找到抵达更深处的吸收性SAP颗粒的路径。
因此通道55可改善该层的吸收潜力以及吸收时间,并能够增加第三层的厚度,同时仍能防止凝胶阻滞效应并且合理利用SAP颗粒。
通道55可以具有任何合适的形状,通常不是圆柱形的。从上方看,通道可以例如具有在层中的整个区域中延伸的条纹状(如图6a所示),或如图6b所示的网格形状,或者如图6c所示的,SAP颗粒54可被分组为岛状。通道和SAP颗粒可以被设置为任何其他合适的形式,只要在第三层53的整个厚度上为体液创建通路即可。
通道和包含SAP颗粒的区域的形状可以取决于在第三层中施加/分散SAP颗粒的工艺过程。
现在我们将描述本发明的多层收集-分布片材的制备工艺。
通常用于制备非织造层的技术适用于本发明的工艺。
如本领域技术人员已知的,本发明的多层片材可以通过例如分别制备三层然后通过焊接或胶合将它们组装在一起而制成。
也可以通过以下方法制得:制备几张梳理纤网,每张纤网包含一种特定类型的纤维或纤维混合物,将纤网相互重叠,然后将纤维粘合在一起,从而在一个粘合步骤中,例如通过热粘合,形成多层非织造物。另一种方法中,部分层可以由粘合在一起的梳理纤网制成非织造布,然后通过焊接或胶合将其组装到另一层上。
在本发明的多层中,挑战是以均匀方式或按照一定模式将SAP颗粒施加进第三层内。
为达到此目的,可以使用通常用于将粉末状材料浸渍入多孔结构(纺织品、非织造物、纸张、泡沫等)中的技术,例如Fibroline技术或经典的湿式浸渍技术,将SAP颗粒浸渍到第三层中。可以将SAP颗粒加入到已经制成的多层片材的第三层上,或加入到单独的非织造层上,然后将其与其他层组装在一起以形成本发明的材料片。然而,由于需要更多的制造步骤,后一种选项效率较低。
参照图7,在步骤A中,将SAP颗粒74施加到对应于本发明的第三层的非织造层73的表面上。在此,由于掩模75的原因,颗粒74按照特定模式施加,躲避了沉积过程的区域对应于预期的通道76。颗粒的沉积可以通过任何合适的途径进行,例如撒粉法。如为了使颗粒均匀分布,不使用掩模。
在步骤B中,通过例如振动和/或电场对覆盖了SAP颗粒74的非织造层73实施浸渍步骤,从而让颗粒向下渗入进层73的整个厚度中。
然后层73可以组装(胶合或焊接)至本发明的多层片材的其他层上。
另一种方法中,如图8,SAP颗粒84被施加到多层片材80的第三层83,该多层片材还包括第一层81和第二层82。根据本发明,第二非织造层82的空隙体积足够小,形成阻碍,防止大部分使用掩模85施加到此处的颗粒84渗入第三层83之外的区域。
上述掩模75或85使得SAP颗粒可选择性地分配或沉积到彼此不相连的离散区域上,从而使得在浸渍时可在含有SAP的区域之间形成不含SAP的通道。其他可以达到类似效果的技术也是适用的。
例如,参考图9,在步骤C中,可以按照一定模式焊接第三层93。焊接涉及对非织造物的离散区域95施压和加热,使得在释放压力后,非织造物在这些区域中保持紧密。这意味着,在区域95中,纤维彼此靠近,纤维连接点的弹性至少部分地丧失,因此减少了非织造物的这些部分中的空隙。没有施加压力或施加适度压力的区域96保持柔软并具有弹性,并且空隙总体上没有改变。可选地,可以采用重新蓬起的步骤,例如加热重新蓬起,以确保非压纹区域96恢复其全部性能。
在步骤D中,SAP颗粒94之后可以施加到层93的整个表面,或者选择性地沉积。
在步骤E中,层93可以例如使用Fibroline技术实施浸渍步骤。压纹部95中的空隙太小而不能容纳SAP颗粒,形成了障碍,颗粒94迁移到非压纹区域96,从而形成了一种SAP颗粒94的分布模式。
可能留在焊接区95表面的SAP颗粒可以通过各种技术移除,比如说吹气清除、吸除或刷除。
如图11,可以通过步骤J中的焊接非织造片材来形成连续的空隙空间115和116,该非织造片材包括其中分散有SAP颗粒的第三层113(这里展示的是按照一定模式分布)和第二层112。对层112和113组装后的层的两个表面进行热压,这使得在两种材料内形成空隙空间115和116,空隙空间在层112和层113的界面位置有压缩后的纤维。
然后,在步骤K中,可以将焊接层112和113组装到第一层111,从而形成非织造片材,该非织造片材包括在第三层中的通道以及在第二和第三层中的连续空隙空间。在图11的特定情况下,在第三层113中,该通道和连续的空隙空间115重叠,但并非一定如此。对于伤口敷料而言,这种构造可能特别值得关注。在这种情况下,第三层可以是更靠近身体的层,即与尿布等其他产品结构相反。
如图12所示,同样的步骤J和K可以应用于其他层。对第一层121和组装于其上的第二层122进行焊接,在两层中分别形成连续空隙空间125和126。然后将第三层123添加至第二层122上方,第三层中的SAP颗粒124按照留有不含SAP颗粒的通道127的模式分布。在这种情况下,连续的空隙空间125和126的位置不与通道127重叠。这种构造可以使进入第一层的部分体液通过连续的空隙空间迅速到达第三层中的SAP颗粒,而一些液体则将通过层121和122以及通道127经过更长的路径到达更深层的SAP颗粒124。这可以应对短时间内大量液体流入该材料。
另一种用于在第三层中产生不含SAP颗粒的通道的技术是将第三层机械切割成小块,并将这些小块互相分散地粘附到第二层上。参考图10,在步骤F中,将适合用作本发明第三层的单独非织造层103切成小块103i。
这些小块可以是任何形状,取决于本发明中ADL的最终用途。例如可以是方形、矩形或条纹形。
在步骤G中,通过本领域技术人员已知的任何合适技术,例如使用胶合或焊接,将小块103i粘附到本发明的第二层102上。对小块103i进行定位以使它们之间留有缝隙。在此也示出了本发明的第一层101。第一非织造层101、第二层102和第三层小块103i代表本发明的多层片材结构。尽管此处的第三层不是连续的非织造层,但是层内的缝隙相对较小。非织造材料占第三层总表面的50%以上,优选占第三层的表面的75%以上,因此落入所要求保护的发明中的“非织造层”说法中。
在步骤H,SAP颗粒104沉积在材料片表面。此处所示的沉积是非选择性的,SAP颗粒在缝隙中和第三层的小块103i上都有沉积。
然而可以预见的是,可以使用掩模将颗粒选择性地沉积到非织造小块103i上。
在步骤I中,使用例如Fibroline技术或任何其他合适的技术将SAP颗粒104浸渍到非织造小块103i中。
分布在小块103i顶部和其间的缝隙中的SAP颗粒104均浸渍到小块103i中,从而在小块103i之间形成不含SAP颗粒的缝隙或通道105。
根据最终用途,可以预见其他几种构造。可以制备以下任意组合:
- SAP在第三层中的连续或离散分布,在后一种情况下形成通道;
- 三层中的任何一层或多层中无连续的空隙空间或连续的多空隙空间;
- 在存在连续的空隙空间和通道的情况下,空隙空间和通道可以对齐或不对齐;
- 连续的空隙空间可以通过焊接或通过机械切割和放置层片小块而获得。
可以例如在第一层的顶部上方或在第三层的下方添加其他层,例如但不限于顶片、吸收芯、增强层或不可渗透片。术语“上”和“下”在此描述相对位置,与任何绝对位置无关。在任何情况下,第二层都与第一层和第三层都直接接触,在它们之间不可插入其他纤维层。
可以对SAP颗粒或非织造片材的任何纤维进行气味控制处理。SAP颗粒可以包括各种类型的SAP颗粒以便组合各种性质。
通常,SAP颗粒的量可以在20gsm至450gsm之间变化,用于女性护理用途时优选为30gsm至80gsm之间,用于婴儿和失禁用途时,优选为200gsm至400gsm之间。•SAP可以是但不限于Ekotec、Sumitomo、BASF、SDP,具体取决于用途。
用于改变空隙体积(例如压纹或重新蓬起)的温度可以在30℃至180℃之间变化,优选在70℃至130℃之间。
下述内容为本发明的多层收集-分布非织造片材的组成和制备的一个实例。
实施例
一种用于卫生用品的150 gsm三层收集-分布片状非织造材料(ADL),采用以下组分制备:
- 相当于25%重量(37.5 gsm)的第一层,由纤度在2dtex至28dtex之间的PET和PET/coPET纤维的混合物组成;
- 相当于25%重量(37.5 gsm)的第二层,由纤度在0dtex至7dtex之间的PET和PET/coPET纤维的混合物组成;
- 相当于50%重量(75 gsm)的第三层,由纤度在 2dtex至28 dtex之间的PET和PET/coPET纤维的混合物组成;
第一层对应于该材料拟用于身体侧的那一侧。
ADL测得的透气率为2500±500 l/m²/s。
按照EDANA WSP 70.3.R3测定,样品的渗透时间(ST)为0.59 s。
按照EDANA WSP 80.10测定,样品的回渗量(WT)为0.09 g。
将SAP颗粒按照400 gsm(克/平方米)的规格施用到第三层的暴露区域上,使用带有扁平电极的Fibroline模块以20m/min的速度进行浸渍。浸渍后,ADL用包芯材料包裹,此处采用9gsm的SMS。
制备两个样品,每个样品的尺寸为40 cm x 10 cm。在第一个样品中,将SAP施加于ADL的整个表面以进行控制。在第二个样品中,由于使用了掩模,因此按照图6a中所示的模式施加SAP,在样品中间形成了一条1 cm的不含SAP的条带。因此,第二个样品的SAP总含量比第一个样品(对照样品)少10%,其面积的10%不含SAP颗粒。
根据基于Hytec测试的内部TWE测试方法对两个样品进行了比较测试。
采用剂量为4 x 70ml的合成尿(0.9%NaCl的盐溶液),两次给样之间的等待时间为5分钟。每次给样的收集时间都用计时器测量。在第四次等待时间之后,通过在样品上放置一些19 cm x 10 cm的回渗纸15秒并测量回渗纸吸收的液体量来测定回渗量。收集和回渗期间的载荷为8kg。
下表1总结了每次给样后的吸入时间和最终的回渗。
表1
由于这些通道的存在,给样后在恒定的剂量下,吸入时间或多或少地保持不变,且尿液保持能力增加,从而证明了ADL中不含SAP的通道带来的改善效果。
Claims (15)
1.用于卫生制品的多层收集-分布非织造片材,至少依次包括三层:
-第一层,用于收集和转移体液至第二层;
-第二层,用于从所述第一层接收体液并将体液散布在第二层上,以及
-第三层,包括超吸收性聚合物(SAP)颗粒的第三层,用于从第二层接收体液,
所述第二层将体液不可逆地输送至所述第三层。
2.如权利要求1所述的片材,其特征在于,所述第二层的空隙体积小于第三层的空隙体积,第三层的纤维为粗纤维,而第二层的则更细。
3.如权利要求1或2中任一项所述的片材,其特征在于,所述第二层中的空隙体积小于SAP颗粒。
4.如权利要求1至3中任一项所述的片材,其特征在于,所述第一层中的空隙体积大于第二层中的空隙体积。
5.如权利要求1至4中任一项所述的片材,其特征在于,所述SAP颗粒按照留有通道的模式分散在所述第三层中,所述通道从第二非织造层延伸穿过第三层,通道不含SAP颗粒。
6.如权利要求1至5中任一项所述的片材,其特征在于,至少一层包括连续的空隙空间。
7.一种一次性吸收制品或服装,包含至少一种如权利要求1至6中任一项所述的多层片材。
8.如权利要求7所述的一次性吸收制品或服装,其是由卫生巾、内裤衬里、婴儿尿布、成人失禁垫、女性卫生用品、训练裤、汗垫、医用伤口绷带组成的组中的一种。
9. 用于制造如权利要求1至6中任一项所述片材的工艺,其包括步骤:通过以下步骤将SAP颗粒分散在所述第三层:
-将SAP颗粒沉积到所述第三层表面的至少一部分上以及
-将所述SAP颗粒浸渍到第三层中。
10.如权利要求9所述的工艺,其特征在于,所述SAP颗粒被沉积到所述第三层的离散区域上。
11.如权利要求10所述的工艺,进一步包括以下步骤:
-在沉积SAP颗粒之前在第三层的表面上施加掩模。
12.如权利要求9或10中任一项所述的工艺,进一步包括以下步骤:
-在沉积SAP颗粒之前,焊接所述第三层的离散区域以形成连续的空隙空间。
13. 如权利要求9或10中任一项所述的工艺,还包括以下步骤:
-将所述第三层切成小块(103i),并且
-将所述小块(103i)粘附到所述第二层上,所述小块彼此隔开缝隙。
14.用于在如权利要求6如权利要求所述片材的至少一层中产生连续的空隙空间的工艺,包括以下步骤:焊接至少一层中的区域。
15.用于在如权利要求6如权利要求所述片材的至少一层中产生连续的空隙空间的工艺,包括以下步骤:
将片材的至少一层切成小块,并且将小块粘附到相邻层。
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