CN113301838B - 包含夹层和聚乙烯的多层基材 - Google Patents
包含夹层和聚乙烯的多层基材 Download PDFInfo
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- CN113301838B CN113301838B CN201980088320.8A CN201980088320A CN113301838B CN 113301838 B CN113301838 B CN 113301838B CN 201980088320 A CN201980088320 A CN 201980088320A CN 113301838 B CN113301838 B CN 113301838B
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- fibers
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Images
Classifications
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Abstract
披露了多层基材,其包括包含合成非织造纤维的顶表面层和底表面层、以及在该顶层与底层之间的熔融热塑性材料层,其中热塑性材料包含聚乙烯或在100°F至350°F的温度范围内具有0.2至0.4的tanδ值。该多层基材可以包含负载到该多层基材上的清洁组合物,其中通过熔融热塑性材料的流体路径允许该清洁组合物从该顶表面层行进到该底表面层。该多层基材可以不含化学粘合剂,其中在该顶表面层与该热塑性层之间的粘合以及在该底表面层与该热塑性层之间的粘合替代地由热塑性材料本身提供,该热塑性材料与该顶表面层和底表面层中的与该热塑性材料在其熔融时接触的纤维组粘结。
Description
相关申请的交叉引用
本申请要求于2019年6月12日提交的美国临时专利申请号62/860,655、2019年4月2日提交的美国临时专利申请号62/828,301和2018年12月21日提交的美国临时专利申请号62/784,274的权益。前述美国临时专利申请中每一个的披露内容通过援引以其全文并入本文。
发明背景
1.发明领域
本发明涉及由多层基材形成的清洁擦巾、更具体地涉及预先润湿的清洁擦巾。
2.相关技术说明
许多清洁擦巾是可获得的,例如像高乐士公司(CLOROX)的消毒擦巾。虽然此类擦巾提供了良好的整体清洁和消毒特征、多功能性、和方便性,但是仍持续需要改进的清洁擦巾,以及它们的制造方法。
简要概述
本发明涉及典型地可以在制造期间预先润湿的擦巾,其中该擦巾包括多层基材,该多层基材包括包含合成非织造材料的顶表面层和底表面层,以及包含聚乙烯的熔融热塑性材料或在100°F至350°F的温度范围内具有从0.2至0.4的tanδ值的另一种材料。该合成非织造材料是纤维非织造物,例如像熔喷的、纺粘的、纺丝成网的(spunlaid)、SMS(纺粘-熔喷-纺粘的)、共成形的、气流成网的(airlaid)、湿法成网的、梳理成网的、热粘的、通气粘结的(through-air bonded)、热成形的、水刺的(spunlace)、水刺缠结的(hydroentangled)、针刺的、化学粘结的,或其组合。形成顶表面层和底表面层的合成非织造材料可以由或基本上由此类合成材料组成(例如,基本上所有纤维都可以是合成的)。在另一个实施例中,可以使用合成纤维和纸浆纤维的共混物。顶表面层和底表面层可以彼此相同。除了这3层之外,还提供了负载到该多层基材上的清洁组合物。因为在“夹层”结构内部的热塑性膜层已经熔解,所以它是多孔的,并且提供了通过熔融热塑性材料层的流体路径,该流体路径允许清洁组合物从顶表面层通过多孔的熔融热塑性材料层的流体路径行进到底表面层。该多层基材可以不含任何化学粘合剂来将多个层保持在一起,或甚至将给定层的纤维保持在一起。在一些实施例中,还用作粘结剂的试剂可以在技术上(例如以相对较少的量)存在于给定层中作为加工助剂,但是此种包含的试剂(像碱性熟化阳离子树脂)的目的可以是赋予给定纤维强度,而不是出于实际上将任一表面层粘合到热塑性材料层的任何目的。替代地,熔融热塑性材料与顶层和底层中的与热塑性材料在其熔融时接触的纤维(例如组粘结,从而将整体结构保持在一起。
另一个实施例涉及一种多层基材,该多层基材包括基本上由合成纤维组成的顶表面层和底表面层、以及在顶合成层与底合成层之间的多孔熔融热塑性膜层,其中该热塑性膜层在100°F至350°F的温度范围内具有0.2至0.4的tanδ值。该热塑性膜层非常薄,例如,厚度小于0.05mm。多层基材还可以包含负载到该多层基材上的清洁组合物,其中通过多孔熔融热塑性膜层的流体路径允许该清洁组合物从顶表面层行进到底表面层。多层基材可以不含化学粘合剂,其中在顶表面层与热塑性层之间的粘合以及底表面层与热塑性层之间的粘合替代地由热塑性膜层本身提供,该热塑性膜层与顶表面层和底表面层中的与热塑性膜层在其熔融时接触的纤维组粘结。
提及的tanδ值被定义为粘性模量除以弹性模量的比值。因此,提供了关于材料的粘性液相刚度或流动特征相对于该材料的固相刚度特征的比值的信息。不同的聚合材料展现出不同的tanδ特征,并且对于给定材料这个比值也随着温度而改变。聚乙烯是在100°F至350°F的温度范围内展现出在0.2至0.4范围内的tanδ值的示例性材料。其他聚合材料(例如聚丙烯)不一定展现出此种特征。申请人已发现,tanδ是给定聚合材料是否将产生熔融热塑性“夹层”的良好指标,该熔融热塑性“夹层”有效地与在热塑性内“夹层”的上方和下方二者的非织造层粘结,同时打开通过热塑性层的流体路径,允许液体(例如清洁组合物)通过该热塑性层在顶层与底层之间流动。
另一个实施例涉及一种制造多层基材的方法,该方法包括:提供顶表面层和底表面层二者,例如各自包括或基本上由各种合适的合成非织造物中的任一种组成;提供热塑性膜材料层(例如初始地不透液体的),该热塑性膜材料层包含聚乙烯和/或在100°F至350°F的温度范围内具有0.2至0.4的tanδ值;以及将该膜材料层加热至该热塑性膜材料软化的温度;打开穿过该膜的孔或者破入该膜中,从而提供通过该热塑性膜层的流体路径,以便负载到顶表面层上的任何液体能够通过流体路径到达底表面层。一旦如此形成,该多层基材可以负载有清洁组合物,例如通过将该清洁组合物施加到一个或多个顶表面层和/或底表面层。由于流体路径,通过热塑性膜层中的流体路径从一个表面层到达另一个表面层的流体连通是可能的。
在此制造期间,压力可以在通过热塑性材料的流体路径形成期间随着施加热进行施加。施加热以及任选地同时施加压力可用于将热塑性材料与顶层和底层中的与该热塑性材料在其软化时接触的纤维组粘结,使得不使用化学粘合剂来将顶层和底层粘合到热塑性材料。在类似的条件下使用不具有所述tanδ特征的热塑性材料的情况下,即使当施加热和压力时,也可能不会实现粘结和/或流动路径打开。
鉴于以下优选实施例的详细说明,本发明的进一步特征和优点将对于本领域普通技术人员变得清楚。
附图说明
为了进一步阐明本发明的以上及其他优点和特征,将通过参照在位于本说明书中的附图中示出的其具体实施例来呈现本发明的更具体的描述。应了解这些附图仅描绘了本发明的典型实施例,并且因此不应视为对本发明范围的限制。将通过使用附图来描述和解释本发明附加的特征和细节。
图1A-1D示出具有各种点图案的示例性多层基材纹理的示意图。
图1E是示出可以形成的4种不同的示例性多层基材纹理的照片,每种都具有不同尺寸的未粘结的凸起纹理特征(即凸起的点)。
图2是示例性多层基材的顶表面的SEM图像,示出两个相邻的未粘结凸起区域,在其间延伸着粘结区域。
图3示出穿过示例性多层基材(如图2的多层基材)的截面视图或边缘视图的SEM图像,示出了顶表面层、底表面层、以及夹在其间的热塑性膜层,其中存在两个粘结区域以及其中热塑性层和一个或多个相邻外表面层相对于彼此未粘结的区域。
图4是示出聚乙烯、聚丙烯、以及包含“双组分”纤维的聚合物即(“双组分(bico)”)聚合物的弹性模量和tanδ值相对于温度的图。
图5A-5B图示各种示例性擦巾包装,其可以用于储存和分配根据本发明形成的擦巾。
图6是示出包封相邻的顶表面层的相邻纤维的夹层的纺粘热塑性纤维的SEM图像。
图7A-7F图示附加的示例性纹理和图案。
优选实施方式的详细说明
I.定义
在详细描述本发明之前,应理解的是本发明不限于具体例示的体系或工艺参数,这些体系或工艺参数当然可以改变。还应当理解的是在此使用的术语仅仅是为了描述本发明的具体实施例的目的,并且不旨在以任何方式限制本发明的范围。
在此引用的所有出版物、专利和专利申请(无论上文或下文)均以其全文通过引用并入本文,其程度如同明确且单独地表明每一个单独的出版物、专利或专利申请通过引用并入。
与“包括(including)”、“含有(containing)”、或“特征在于”同义的术语“包含(comprising)”是包容性的或开放式的并且不排除附加的、未列举的要素或方法步骤。
术语“基本上由……组成”将权利要求的范围限制于指定的材料或步骤“以及不实质地影响所要求保护的发明的一个或多个基础且新颖的特征的那些”。
如本文中使用的术语“由……组成”排除未在所述权利要求中指定的任何元素、步骤、或成分。
必须指出的是,除非上下文另外清楚地指出,如在本说明书以及所附权利要求书中所用的,单数形式“一个/一种(a/an)”以及“该(the)”包括复数指示物。因此,例如,提及“表面活性剂”包括一种、两种或更多种表面活性剂。
除非另有说明,否则本文中使用和描述的所有百分比、比率、份数、和量都按重量计。
本文中陈述的数字、百分比、比率、或其他值可以包括该值,并且还包括约或大约为该陈述值的其他值,如本领域普通技术人员将理解的。因此,本文中所有值都应理解为被术语“约”修饰。因此,此类值包括量或状态,其接近于仍执行希望功能或达到希望结果的该陈述的量或状态。因此,陈述值应该被广泛地解释,足以涵盖至少足够接近该陈述值以执行希望功能或达到希望结果的值,和/或四舍五入为该陈述值的值。陈述值至少包括在典型的制造或其他工艺中预期的变化,并且可以包括在陈述值的10%内、5%内、1%内等的值。
一些范围可以在本文中披露。附加的范围可以定义在本文披露的作为特定参数的示例性值的任何值之间。所有此类范围被设想到并且在本披露内容的范围内。
在本申请中,有效量总体上是在此以下说明中作为成分范围或水平列出的那些量。除非另有说明,否则以百分比(“%”)列出的量是占任何组合物的重量百分比(基于100%活性物)。
如在本文中使用,短语‘无’或类似短语意指组合物或制品包含0%的所陈述组分,即,该组分并非有意添加的。但是,将理解,此类组分可能在其后在某些情形下偶然形成,或者此类组分可能例如作为偶然污染物偶然地存在。
如本文中使用的短语‘基本上无’或类似短语意指组合物或制品优选地包含0%的所陈述组分,但是将理解,非常小的浓度可能存在,例如通过偶然形成、污染、或甚至通过有意添加。此类组分(如果有的话)可以以小于1%、小于0.5%、小于0.25%、小于0.1%、小于0.05%、小于0.01%、小于0.005%、小于0.001%、或小于0.0001%的量存在。在一些实施例中,本文中描述的组合物或制品可以无或基本上无本说明书内未提及的任何特定组分。
如本文中使用的,“随弃式的”以其普通意义使用,意指在有限数量的使用事件,优选小于25次、更优选小于约10次、最优选在单次使用事件之后被处置或废弃的制品。本文中披露的擦巾典型地是随弃式的。
如本文中使用的,术语“基材”旨在包括用于清洁制品或表面的任何材料。清洁基材的实例包括,但不限于擦巾、手套、垫子、或用于手工清洁表面的单一材料片材,或者可以附着于清洁工具(如地板拖把、把手)或手持式清洁工具(如马桶清洁装置)的材料片材。术语“基材”还旨在包括用于个人清洁应用的任何材料。这些基材可以用于硬表面、软表面、和个人护理应用。此类基材可以典型地呈擦巾的形式。
此类基材可以由插入中间的单根纤维的结构典型地以不可辨识的方式形成,与非织造物类似。本发明基材中包括的顶表面层和底表面层或纸浆层可以通过任何合适的方法形成。例如,它们可以被熔喷、纺粘、纺丝成网、SMS(纺粘-熔喷-纺粘)、共成形、梳理成网、热粘、热成形、水刺、水刺缠结、针刺、或化学粘结。形成此种非织造物的各种方法对于本领域技术人员而言将是显而易见的,其中许多方法在美国专利号7,696,109中描述,该美国专利通过援引以其全文并入本文。合成纤维的截面通常可以是圆形的。各种聚合物中的任一种或者各种聚合物的组合可以用于形成合成非织造外层。合适的材料的实例可以包括聚乙烯、聚丙烯、PET、PVC、聚丙烯酸化物、聚乙酸乙烯酯、聚乙烯醇、聚酰胺、聚苯乙烯等。在实施例中,外层可以包含除聚乙烯之外的材料,例如,当夹层可以是聚乙烯时。热塑性夹层还可以以根据任何希望的方法形成的合成非织造物形式提供。热塑性层还可以是例如“流延”膜,而不是由纤维构成。该基材的多层中的任一层的基重可以以克/平方米(gsm)表示。此类基材的基重也时常可以以“磅”(例如是指lbs/3000ft2的片材材料)表示。
因此,术语“擦巾”、“基材”等可以在含义方面重叠,并且虽然为方便起见可以典型地在本文中使用“擦巾”,但是将理解这个术语经常可以是与“基材”可互换的。
如本文中使用的,“擦拭”是指擦巾在与目标表面接触时所经历的任何剪切动作。这包括在手或身体运动,表面上的基材-工具运动,或者基材经由能源(如超声、机械振动、电磁等等)的任何扰动。
定量给送到本文描述的基材上的清洁组合物可以提供卫生处理、消毒、或灭菌、其他清洁、或其他处理。如本文中使用的,术语“卫生处理”应意指将无生命环境中的“目标”污染物减少至根据公共卫生条例被认为安全的水平,或在没有建立公共卫生要求的情况下降低显著数目的“目标”细菌群体。举例而言,在24小时时间段内细菌群体的至少99%降低被认为是“显著的”。当卫生处理或消毒时,更高水平的降低(例如99.9%、99.99%等)是可能的,更快速的处理时间(例如在10分钟内、在5分钟内、在4分钟内、在3分钟内、在2分钟内、或在1分钟内)也是可能的。
如本文中使用的,术语“消毒”应意指消除表面上的除细菌内生孢子之外的许多或所有“目标”病原微生物。
如本文中使用的,术语“灭菌”应意指完全消除或破坏所有形式的“目标”微生物生命,并且其根据可适用的管制法律授权以合法声明为“灭菌剂”或具有灭菌特性或品质。一些实施例可以在指定的时间段(例如10分钟、5分钟、4分钟、3分钟、1分钟、30秒、10秒等)内提供细菌群体的至少2或更大的对数降低(例如3-对数降低或6-对数降低)。2-对数降低相当于99%降低,3-对数降低相当于至少99.9%降低,4-对数降低相当于至少99.99%降低,5-对数降低相当于至少99.999%降低等。目标微生物的实例可以是金黄色葡萄球菌(Staphylococcus aureus)。将理解,微生物功效(microefficacy)还可以实现对抗其他目标微生物,其许多实例对于本领域技术人员而言将是显而易见的。还将理解,本发明清洁组合物不需要包含抗微生物剂,其中卫生处理或消毒不一定是希望的。
如本文中使用的术语“纹理”是指基材的如通过其构成纤维的布置和厚度确定的特征或外观。在至少一些实例中,纹理可以通过使用成像技术和/或卡尺测量在局部和宏观标度上进行量化,如在2018年7月23日提交的申请人的申请序列号16/042,690(案号510.174)中描述的,该申请通过援引以其全文并入本文。作为解释,“图案”典型地是看得见的,其具有可辨别的对比区域。“纹理”典型地是能触知的,并且涉及相对于基材的法平面的变化(即基材中的3维纹理)。对于给定基材,除与其相关联的其他可量化的其他技术特征之外,看得见的图案和能触知的纹理以复杂的方式与使用者的视觉/触觉相互作用而产生给定的美学感知。
除非另有定义,否则在此使用的所有技术与科学术语具有与本发明所属领域普通技术人员通常理解的相同含义。尽管在本发明的实践中可以使用与本文中描述的方法和材料类似或等效的许多方法和材料,但是本文中描述了优选的材料和方法。
II.引言
在一方面,本发明涉及包括至少3层的多层基材,其中擦巾的外部面由合成纤维提供,如熔喷的、纺粘的、纺丝成网的、SMS(纺粘-熔喷-纺粘的)、共成形的、梳理网的、热粘的、热成形的、水刺的、水刺缠结的、针刺的、或化学粘结的纤维。在一些实施例中,外表面层可以被形成为此类纤维组合纸浆(例如植物基结构化的)纤维的共混物。在顶外层与底外层之间提供包含热塑性材料的内“夹层”(例如不同于外层),该夹层将整个多层基材一起粘合成一体,层离风险低,同时提供与手感、刚度、和吸收性(基材负载清洁组合物至希望负载比率的能力)相关的希望特征,同时还提供通过热塑性层的流体路径,通过该流体路径清洁组合物可以从顶表面层迁移至底表面层,反之亦然。因为热塑性层熔融而与相邻外表面层的纤维接触,并且特别考虑到热塑性材料的tanδ特征,熔融软化的热塑性材料封装、包封、包裹、或以其他方式包覆薄纸层的单根邻近纤维,从而在相邻两层之间提供强粘结,使得不易发生层离。外表面层的纤维可以提供不同的特征,使得它们在给定的加工条件下不会与内夹层一样熔融软化。此外,热塑性“奶酪”夹层典型地不穿透外“面包”表面层,使得具有特定tanδ特征的熔融软化的热塑性材料都没有在擦巾的暴露外部面上。这产生如下优点,相比于与较硬的更粗糙的熔融软化纤维接触,可以使用相对较软的纤维进行擦拭和清洁。例如,甚至非常软的纸浆纤维也可以被掺入外表面层中。因此,对于正被处理的表面,该擦巾可以毛糙性较低,从而降低不希望的机械刮擦、磨损、或磨蚀的风险。
此类多层基材可以通过热压压延工艺形成,其中提供了顶合成层和底合成层(例如提供了预成形的这些非织造层),并且还提供了热塑性膜层,该热塑性膜层包含聚乙烯或具有合适的tanδ值的另一种聚合物。许多可商购的多层硬表面清洁基材具有由合成热塑性材料制成的外层,其中纸浆纤维层位于该合成材料层中间,以确保纸浆纤维在清洁过程期间不会因磨损而损失。相比之下,本发明的实施例使任何纸浆纤维“逸出”的风险最小化,是通过确保“奶酪”夹层具有希望的tanδ特征,使得它在制造过程中在加热期间熔解并且形成与相邻外表面层的纤维的强粘结。即使在外表面层包含一些负载的纸浆纤维(例如,作为合成纤维和纸浆纤维的共混物)的情况下,外表面层的纤维也有利地强力地固持到在该基材结构中心处的熔融软化的热塑性“奶酪”内层,而不易磨损。无论外表面层的组成如何,这种配置允许将这3层粘结成一体式单基材结构,而无需任何化学粘合剂。
这些层可以被组装(例如以合成顶层和底层作为“面包”将热塑性膜层(作为“奶酪”)夹在其间),随后将该组件在使热塑性材料熔融软化的温度下加热(以及典型地加压)。有利地,这些条件可以不使顶层和底层熔融软化,其可能使制造复杂化。即便如此,其中不仅仅“奶酪”层发生此种熔融软化的实施例可以是可能的。加热位于合成外层之间的热塑性层打开通过热塑性膜层的孔,例如即使该膜初始地不透液体,同时还使热塑性材料软化,使得其包围或以其他方式包覆顶表面层和底表面层的邻近纤维,有效地在无任何化学粘合剂的情况下将相邻层彼此相连以防止层离或彼此拉开。在发生这种层粘结的同时,关于内热塑性层先前存在的任何不可透过的膜特征被破坏,使得产生通过热塑性层的流体路径,通过该流体路径,施加于顶层或底层的清洁组合物或其他液体可以从一个表面层通过热塑性膜层到达另一个表面层。
一旦已经形成干基材,就可以将希望的清洁组合物负载到该多层基材上。由于流体路径的存在,即使清洁组合物作为液体仅被负载于顶层或底层之一,它也将通过破裂的热塑性膜层流过基材到达另一外层。
III.示例性多层基材
图1A-1D图示了示例性擦巾100a-100d,各自都具有不同施加的表面纹理和粘结图案,但是其中,各自都被配置为多层基材,该多层基材包括夹在顶合成层与底合成层之间的熔融热塑性膜层。虽然示出为具有各种纹理,但是将理解,可以提供许多其他纹理,或者可能根本没有纹理。附加的示例性纹理示于图7A-7F中。图1E示出了4种示例性多层擦巾100a-100d的照片,示出了与图1A-1D中类似的纹理。
图2示出了示例性擦巾的凸起脊102之一的特写视图,示出了凸起的圆形脊102(“点”)如何未粘结到其下布置的热塑性膜层,使得在脊102处实际上存在其间的间隙。围绕凸起脊102的区域104粘结(并且如此标记)到其下布置的下层热塑性膜层。取决于具体施加的纹理化图案,粘结区域104可以是连续的,如所示出的(即存在单个连续的粘结区域,而不是彼此完全分离的多个粘结区域)。换言之,通过“连续”,可以通过仅横越其他粘结区域而无需横越未粘结区域而从粘结区域中的任何其他特定位置到达粘结区域的任何特定位置。粘结区域104因此可以是连续的,尽管它没有覆盖擦巾的整个顶外部面(或底外部面),因为存在着间隔开的未粘结区域102。通过类比以另一种方式陈述,未粘结区域可以配置为粘结区域“海”中的“岛”。将理解,其他配置当然是可能的。
纹理可以是压花纹理,其是在热压延或者将“夹层”结构的3个层层压在一起的其他制造操作期间施加。可替代地,纹理可以在一个或多个合成顶表面层和底表面层的制造期间被引入基材结构中。纹理可以存在于顶层、底层或二者中。
图3是穿过示例性多层基材(如图2的多层基材)的末端或截面的SEM图像,示出夹在顶表面层108a与底表面层108b之间的热塑性膜层106(标记为“Bico”)。在图3中还标记了粘结区域104,以及邻近底层108b的凸起脊“点”的未粘结区域。在这个标记的未粘结区域中,在热塑性层106与底层108b之间存在间隙。虽然在这个区域中底层108b是未粘结的,但是在这一相同区域中,热塑性层106可以(或者可以不)粘结到顶层108a。换言之,未粘结的特征可以适用于热塑性层的一面或两面。
a.顶外表面层和底外表面层
顶表面层和底表面层由包含合成纤维的材料形成。可以使用各种非织造材料中的任一种,其广泛地从各种商业来源可获得。此类层和纤维可以是熔喷的、纺粘的、纺丝成网的、SMS(纺粘-熔喷-纺粘的)、共成形的、梳理成网的、热粘的、热成形的、水刺的、水刺缠结的、针刺的、或化学粘结的。在实施例中,此类表面层还可以在其中掺入一小部分的纸浆纤维(例如,作为随机分布的合成纤维和纸浆纤维的均匀共混物,或者其中纸浆纤维非随机地位于例如外表面或位于内表面)。在任何情况下,在顶外表面层和底外表面层内合成纤维的分数可以是给定层中存在的纤维的按重量计至少50%、至少60%、至少70%、至少80%、至少90%、或至少95%。在实施例中,在给定外表面层中100%的纤维可以是合成纤维。
可形成为纤维并成网为非织造基材层的各种合成材料适合用于设想的多层基材。此类聚合物合成材料的实例包括但不限于聚乙烯、聚丙烯、PET、PVC、聚丙烯酸化物、聚乙酸乙烯酯、聚乙烯醇、聚酰胺、聚苯乙烯等。在实施例中,外表面层可以包含除聚乙烯之外的材料,和/或不具有热塑性内层所具有的tanδ特征的材料,该热塑性内层被配置成熔融软化的,从而将3层粘结在一起。
多层基材的合成非织造顶层和合成非织造底层可以具有不超过50lbs、不超过40lbs、不超过30lbs、或不超过20lbs、至少3lbs、至少5lbs、或至少10lbs,如从7lbs至20lbs、或8lbs至15lbs的基重。此类“lbs”值是指重量/3000ft2,如本领域技术人员将理解的。
用于制造多层基材的顶层和底层的单个层可以通过多种不同的技术中的任一种形成,例如像对本领域技术人员而言将是显而易见的那些技术中的任一种。实例包括但不限于熔喷、纺粘、纺丝成网、SMS(纺粘-熔喷-纺粘)、共成形、气流成网、湿法成网、梳理成网、热粘、通气粘结、热成形、水刺、水刺缠结、针刺、或化学粘结,这些对于本领域技术人员而言将是显而易见的,其中一些技术在美国专利号7,696,109中描述,该美国专利已通过援引并入。
非织造合成层中的任一层可以包括多于一个单层,或者各自都可以包括仅一个单层。在提供多个层的情况下,它们可以通过任何合适的技术(包括在这些层之间使用化学粘合剂)而被粘合在一起,从而具有足够的剥离强度。在顶表面层和底表面层中的每层中仅存在单层的情况下,在该多层基材的任何地方都可以不存在化学粘合剂。在外表面层之一或二者中使用两层的情况下,化学粘合剂可以存在于表面层(即在层之间)中,但是可以不存在于热塑性层与相邻的顶表面层和底表面层之间。
b.热塑性层
本发明多层擦巾包括夹层结构,在其中热塑性层被提供在擦巾的内侧上,夹在顶表面层与底表面层之间。虽然这些表面层也可以是热塑性的,但是这些外层可以包括与热塑性夹层不同的tanδ特征。在不使用化学粘合剂将3个层粘合成层间不易层离的整体单一结构,但是其中热塑性“奶酪”夹层本身用于此目的的情况下,本申请人已发现并非任何热塑性聚合物都将适用于此种目的。例如,在测试各种热塑性聚合物时,本申请人发现各种材料即使经过加热时也不易于粘结到邻近的非织造顶表面层或底表面层,若有任何粘结,也将形成非常弱的粘结。此种弱粘结当然在要用作清洁擦巾的多层基材(其中必须避免层离)中是不可接受的。在本发明中,多层基材具有足够的层间粘合,以至即使当湿润(例如在储存中被允许浸泡数周)或当用于清洁硬表面时它们也不会层离。热塑性内层在其熔融时不仅将多层基材粘结在一起,而且它也可以赋予外层(在这些层可能相对较弱的情况下)附加的强度。出人意料地是,外层的这种粘结发生得如此充分以至例如在多层基材通过典型的擦巾分配孔口拉出时外表面层没有任何显著的撕碎。
例如,本申请人发现,虽然聚丙烯可能看上去像适用于实现被热塑性材料内层分开的非织造表面顶层与非织造表面底层之间的此种粘结的热塑性材料,但是聚丙烯没有提供良好的粘结,而在3个层之间产生弱粘结和层离。本申请人发现,关于给定热塑性材料是否将有效作为内层的关键特征或指标是tanδ值。Tanδ值是可以评价热塑性聚合材料的工程特征,并且给出关于在给定材料中在给定温度下“液体”粘性相特征相对于“固体”弹性相特征占多少主导的信息。对于给定材料在给定温度下,tanδ简单地计算为粘性模量除以弹性模量的比率。
图4绘制了3种测试的热塑性材料-聚乙烯、聚丙烯和包含聚乙烯的双组分材料的tanδ值和弹性模量值二者。例如,测试的双组分材料被认为包含双组分纤维,即纤维芯(即非聚乙烯)以及在该芯上的外部涂层(即聚乙烯)。图4绘制了这3种材料在约100°F至350°F的温度范围内的弹性模量和tanδ值二者。图4示出了聚丙烯的弹性模量(即刚度)如何最高,其次是“bico”,随后是聚乙烯,并且各自的刚度随着温度升高而降低。
聚丙烯的tanδ值非常低,小于0.2,并且在从100°F至超过300°F的温度下保持小于0.15。直至接近350°F,tanδ值才稍微增大,但是仅略微地增大,最高达约0.15的值,并且仍然一定小于0.2。聚乙烯tanδ值相当不同,在100°F的温度下为约0.2,并且在约175°F-190°F下增大至约0.25至0.3。在大约这个温度下达到峰值之后,tanδ值开始下降,在约250°F下降至0.2,并且在约260°F-270°F稍微下降低于0.2(例如约0.18)。“bico”的Tanδ在大部分温度范围下介于聚丙烯与聚乙烯之间,直至约250°F其高于聚乙烯。聚乙烯和“bico”材料(其包含聚乙烯)二者包括沿着100°F至350°F的温度范围的点,其中tanδ为至少0.2(例如大于0.2至0.4,或者大于0.2至0.3)。聚丙烯tanδ在100°F至350°F的这个温度范围内从未达到0.2。因此,在实施例中,选择用于内“夹层”的热塑性材料在100°F至350°F的温度范围内的某温度下具有至少0.2(例如从0.2至0.4,或从0.2至0.3)的tanδ值。在实施例中,选择的热塑性材料可以在特定温度下具有此tanδ值,在该特定温度下(例如150°F、175°F、200°F、225°F、250°F、275°F、300°F、325°F等)或者在100°F至350°F的温度范围内的任何较窄范围下进行热压延步骤。
选择的热塑性材料可以有利地具有小于400°F、小于375°F、小于350°F、小于325°F、小于300°F、至少150°F、至少175°F、至少200°F、或至少225°F的熔融温度。具有相对较低的熔解温度当然减少压延方法中所需的能量需求,但是也可能是重要的,取决于在顶表面层和底表面层中使用什么合成材料,以确保它们不分解、点燃、或熔融。在外表面层中包含任何纸浆纤维含量的情况下,可能重要的是确保温度足够低以至此类纸浆纤维没有点燃或没有因“燃烧”而变脆或褪色(其即使在低于纸着火温度451°F下也可能发生)。因此,可以优选选择较低熔融温度的热塑性材料,只要它们可以提供与合成外顶层和合成外底层的良好粘结。
图5A-5B示出了本发明多层基材如何可以被包装在各种示例性挠曲包装(图5A)、圆筒(图5B)或其他用于储存和分配的容器中的任一种内。擦巾100可以通过孔口(如此类容器典型地提供的)被拉出,而无需担心各种层的撕碎或层离。例如,当将本发明擦巾通过与此类容器相关联的典型分配孔口中的任一种拉出时,外表面层没有显著的撕碎,或者层彼此没有显著的层离。更确切地,每张擦巾都能够通过孔口被反复拉出,且保持完全完整。图6示出纺粘纤维热塑性内层106与邻近外表面层(例如108a)之间的界面的SEM图像,示出了在该界面处外层的纤维如何被熔融软化的热塑性材料包围、包封、或包覆(在热压延工艺期间发生)。非织造外表面层与热塑性内层之间的这种强连接提供强粘结,从而当将擦巾通过典型的擦巾包装孔口时不发生撕碎或层离。这些特征被认为是由于以上结合图4所述的热塑性材料内层的tanδ特征而产生的。
热塑性膜层不需要特别厚。例如,热塑性膜层可以具有0.01mm至0.1mm或者0.01mm至0.05mm的厚度。它在组装成夹层结构之前可以如此薄以至透明或半透明。即便如此,但将显而易见的是,如果希望,则热塑性中间夹层可以更厚。例如,它可以具有根据此种层的结构特征而改变的厚度(例如,它是否沉积为松散纤维(例如松散的bico纤维,或者以其他方式包含具有希望的tanδ特征的材料的松散纤维)、完整膜、纱线(例如松散纱线)、完整非织造层、织造层等)。将显而易见的是,该热塑性中间夹层因此可以具有范围从0.01mm至5mm、从0.01mm至3mm、从0.01mm至2mm、从0.01mm至1mm、从0.01mm至0.5mm等的厚度。
擦巾的强度和/或刚度特征可以至少部分地取决于本发明基材的热塑性中间层的特征。例如,基材作为整体的强度和刚度可以分别随着使用纤维、膜、纱线、非织造结构材料(例如bico非织造物)、或织造结构材料用于中间夹层而逐步地增高。此类材料总体上以弹性增强的顺序列出,其中整体基材的强度和/或刚度随着中间层弹性的增大而增高。当然,中间层的厚度也将影响成品基材的强度和/或刚度。作为进一步解释,在给定厚度下,用于热塑性中间夹层的织造结构可以为基材提供最大的强度和/或刚度,而非织造热塑性中间夹层将典型地提供稍微较低的强度和/或刚度。例如,在将多个纤维进行加捻或以其他方式布置在一起的情况下,假定纱线直径显著地大于构成该纱线的单根纤维的直径,纱线的使用可以提供稍微较低的刚度和强度,并且膜或为了形成热塑性中间夹层而使单根松散的纤维简单沉积到外表面层的任一层上可以提供甚至更低的刚度和/或强度。
将显而易见的是,就热塑性中间夹层的结构而言,许多可能的配置是可能的,并且许多可能的方法可能用于提供简单地置于外层之间的此种热塑性中间夹层(例如,提供预成形的层,例如以膜、非织造物、或织造物的形式),或者通过提供外表面层之一并且然后将单根松散纤维、纱线等沉积到此种外层的内表面上,随后将另一外表面层置于其上,其后接着将该3-层结构加热和/或加压以将这些层彼此粘合并且造成穿过该热塑性中间夹层的裂缝、裂纹等的形成,最终被负载到该基材中的清洁洗液通过这些裂缝、裂纹等可以从一个外表面层通过该热塑性中间夹层到达另一外表面层。例如,可以提供具有任何合适材料(例如PET)的非织造外表面层,其用作载体以将松散纤维(或形成纱线的纤维)铺设到PET外表面层上或其他合适的外表面层上。最终,相反的外表面层(例如另一PET非织造层)可以被置于松散纤维或松散纱线上,并且该3-层结构可以用适当的热和/或压力进行加工以使如本文所述的热塑性中间夹层熔融软化。
在一些实施例中,可能希望的是对基材提供隆起(lofted)结构,从而增大该基材的体积和厚度,其中此类隆起特征可以不以其他方式提供给所有合成层。在合成基材层的情况下,此种隆起可以通过任何合适的技术来提供,通过向其添加隆起材料可以增大该层的体积和厚度,该隆起材料包括间隙、气穴、和/或绒毛状隆起特征。
举例而言,用于增加完全合成基材(例如其中至少3个所述层中的每一层都是合成的)的隆起的一种可能的方法可以是通过将这些层(例如外层)中的一个或多个过度进给到加热和加压该分层基材的辊中。例如,一个或两个外表面层的进给速率可以大于此类辊另一侧上的拾起速率,由此导致过度进给的层的材料随着其进入辊(例如加热夹辊和相对的辊)而聚成一团或产生皱褶,在这些辊处中间层发生熔融软化。这导致包括空气间隙的此种聚成一团的、起褶的、或类似隆起的配置随着中间层熔融软化而被锁入,并且粘结到过度进给的外层(包括此种聚成一团的、起褶的、或以其他方式隆起的配置)。这给予过度进给层隆起配置,其在定量给送之后和使用期间是持久的,更类似于用含有绒毛状隆起纸浆的(非合成)层所提供的。还可以使用(例如特别是在一个或两个外表面层上)提供隆起层的其他技术。例如,销辊可以用于将外表面层的部分从基材平面横向地向外拉,从而产生绒毛状隆起纹理,给予此种层降低的密度以及增大的体积和厚度。鉴于本披露,对于本领域技术人员而言各种其他技术将是显而易见的。
在希望时,基材层或材料中的任一种可以被选择为可生物降解的和/或可堆肥的(例如满足ASTM D6400的标准或其他可适用的标准)。
c.清洁组合物
本领域内已知的许多清洁组合物组分可以合适用于本发明的预先定量给送的擦巾。在实施例中,清洁组合物是水性组合物,包含按重量计至少70%、至少80%、或至少90%的水(例如90%至99%的水)。组合物可以包含按重量计0.05%至5%的季铵化合物和/或按重量计0.1%至5%的二醇醚溶剂。例如,按清洁组合物的重量计,可以包含从0.05%、从0.1%最高达5%、最高达4%、最高达3%、最高达2%、或最高达1%的季铵化合物。例如,按清洁组合物的重量计,可以包含从0.1%、从0.25%最高达5%、最高达4%、最高达3%、最高达2%、或最高达1%的二醇醚溶剂。清洁组合物中经常包含的其他溶剂、表面活性剂、及各种其他辅助剂可以任选地存在。虽然一些实施例可以包含低级醇溶剂(例如C1-C4醇),但此类挥发性溶剂的量可以限于例如按重量计小于10%、小于5%、小于3%、小于2%、或小于1%。在一些实施例中,组合物可以无或者基本上无此种低级醇或者其他高度挥发性溶剂。
季铵化合物具有广谱抗微生物特性。各种不同的季铵化合物可以用于清洁组合物中。季铵化合物的非限制性实例典型地是烷基二甲基苄基铵、烷基二甲基乙基苄基铵、烷基二甲基铵等的卤化物(例如氯化物)。此类季铵化合物的烷基可以典型地范围从C12至C18。季铵化合物更详细地在美国专利号6,825,158中描述,该专利通过援引并入本文,并且将是本领域技术人员熟悉的。
有机酸也可以用来提供抗微生物特性。举例而言,按清洁组合物重量计,可以包含至少0.1%、或至少0.5%、最高达5%、最高达4%、最高达3%、最高达2%、或最高达1%的量的此种有机酸。
清洁组合物可以包含二醇醚溶剂。示例性二醇醚溶剂包括但不限于:乙二醇单丙醚、乙二醇单丁醚、丙二醇正丙醚、丙二醇单丁醚、丙二醇叔丁醚、二乙二醇单乙醚或二乙二醇单丙醚或二乙二醇单丁醚、二聚丙二醇或三聚丙二醇甲醚或乙醚或丙醚或丁醚、二醇醚的乙酸酯和/或丙酸酯。
本领域技术人员将理解,根据需要,各种表面活性剂(例如阴离子的、阳离子的、非离子的、两性离子的、和/或两性的)可以被包含在清洁组合物中。在包含表面活性剂的情况下,按清洁组合物的重量计,可以存在从0.05%、从0.1%最高达10%、最高达5%、最高达4%、最高达3%、最高达2%、或最高达1%的表面活性剂。各种表面活性剂及其他任选的辅助剂在以下中披露:Laughlin和Heuring的美国专利号3,929,678、Murphy的美国专利号4,259,217、Giret等人的美国专利号5,776,872;Furman等人的美国专利号5,883,059;Addison等人的美国专利号5,883,062;Ouzounis等人的美国专利号5,906,973;Llenado的美国专利号4,565,647,以及美国公开号2013/0028990。以上专利和申请各自以其全文通过援引并入本文。
如本文中使用的,术语“液体”和“清洁组合物”包括但不限于溶液、乳液、悬浮液等等。因此,液体可以包含和/或含有以下中的一种或多种:消毒剂;防腐剂;稀释剂;表面活性剂,如非离子的、阴离子的、阳离子的;蜡;抗微生物剂;灭菌剂;杀孢子剂;杀菌剂;杀细菌剂;杀真菌剂;杀病毒剂;杀原虫剂;灭藻剂;抑细菌剂;抑真菌剂;抑病毒剂;消毒杀菌剂;抗生素类;杀虫剂;等等。一些此类组分的实例包括但不限于以下中:美国专利号6,825,158;8,648,027;9,006,165;9,234,165、9,988,594,以及美国公开号2008/003906和2018/0216044,其中每一个都通过援引以其全文并入本文。在一些实施例中,可以以干燥形式提供基材,其中之后可能发生定量给送选择的清洁组合物(例如通过使用者)。
关于预先润湿的基材,选择量的液体可以在制造期间被添加到容器或擦巾中,使得清洁基材含有希望量的液体。基材不一定负载至它们的饱和点,但是典型地以小于完全饱和的某比率负载清洁组合物。例如,许多基材能够保留约8至14倍于其重量的液体。出于各种原因,基材可以以小于饱和的负载比率例如小于6:1、小于5:1、小于4:1,如从1:1至4:1、从2:1至4:1、从2.5:1至3.5:1、从2.5:1至3:1或从2.5:1至3.75:1进行负载。
在基材可以被配置成为全合成的情况下,这可以在化学物质方面提供附加的灵活性,这些化学物质可以被定量给送(例如在制造期间)到此种基材上以供使用,同时最小化或消除在此种组合物的组分与可以包含纸浆、其他天然纤维、或其他天然组分的基材之间可能产生的不希望的不容性的风险。作为非限制性实例,各种漂白剂(例如基于氯的漂白剂以及包含过氧化物的其他漂白剂)可以与此种合成基材一起使用。还可以使用基于酸而实现消毒的组合物。此种酸消毒剂和漂白剂经常是与非合成基材材料不相容的。此种组合物的非限制性实例在以下中披露:Andrews等人的美国专利号5,460,833;Crisanti的美国专利号6,221,823;Rochon等人的美国专利号6,346,279;Wisniewski等人的美国专利号6,551,980;Rees等人的美国专利号6,699,825;Ramirez等人的美国专利号6,803,057;Rees等人的美国专利号6,812,196;Urban的美国专利号6,936,597;Katsigras等人的美国专利号7,008,600;Bains等人的美国专利号7,070,737;Ramirez等人的美国专利号7,354,604;Cusack等人的美国专利号7,598,214;Tamarchio等人的美国专利号7,605,096;Bobbert的美国专利号7,658,953;McCue等人的美国专利号7,696,143;Chopskie等人的美国专利号7,915,207;Gaudrealt的美国专利号8,569,220;Gaudrealt的美国专利号8,575,084;Hazenkamp等人的美国专利号10,064,409;Salminen等人的美国专利号10,076,115;Bobbert的美国公开号2007/0190172;Raso等人的PCT公开号WO 99/18180;Masotti等人的PCT公开号WO 99/53006;Arrigoni等人的PCT公开号WO 2004/067194;Rosiello等人的PCT公开号WO 2004/104147;Convery的PCT公开号WO 2017/174959;以及Nedic等人的欧洲专利局公开EP 2843034。
d.其他特征
擦巾的尺寸和形状可以根据其预期应用和/或最终用途而改变。清洁基材可以具有基本上矩形的形状,具有的尺寸允许其容易接合标准清洁装置或工具例如像拖把头、除尘器头、刷子头、用于擦拭或清洁的手套形工具,等等。在另一个实施例中,可以提供另一种形状,例如圆形、椭圆形等)。
擦巾或其他清洁基材可以用清洁组合物预先润湿的形式提供。湿清洁基材可以随时间推移而保持在可密封的容器中,例如像在具有可连接盖子的桶或盆内、在可密封的塑料小袋或袋、罐、广口瓶等等内。希望地,湿叠放的清洁基材保持在可再密封的容器中。可再密封容器的使用在使用水性挥发性液体组合物时是特别希望的,因为大量的液体可能在使用第一片时蒸发,由此使剩余的片材留下少许液体或无液体。示例性可再密封容器和分配器包括但不限于以下中描述的那些:Doyle等人的美国专利号4,171,047、McFadyen的美国专利号4,353,480、Kaspar等人的美国专利号4,778,048、Jackson等人的美国专利号4,741,944、McBride等人的美国专利号5,595,786;其中前述参考文件中每一个的全部内容通过援引并入本文。
典型地,清洁基材被叠置于容器中并且随后向其添加液体,全部在批量制造期间进行。有利的是,在每片擦巾中心处的热塑性层是不透液体的,以有利于擦巾的负载更容易。如本文中描述的,申请人已发现,如本文中设想的,即使在将3个层层压在一起之前初始提供的热塑性膜是不透液体的,裂缝或其他流体路径在热压延期间在该膜内打开。虽然这可能不一定发生在任何和全部热压延操作中,但是它的确发生在本文中设想的条件下。
在多层基材的制造期间打开的此种裂缝或其他流体路径的存在有利地允许定量给送在基材任一面上的液体清洁组合物通过热塑性膜层迁移通过擦巾到达相反的外部面。这类似地允许定量给送的清洁组合物从一个基材迁移到下一基材,例如其中这些基材是叠放的(例如通过从一个基材芯吸到下一基材)。例如,给定体积或重量的清洁组合物可以简单地被定量给送到容器的底部,以允许其芯吸到一叠擦巾中。在甜甜圈配置的情况下,通过将清洁组合物置于圆柱形容器的底部,每片擦巾的末端实际上在该容器的底部与清洁组合物同时接触,其中它可以被向上芯吸到每片擦巾的高度(和甜甜圈的高度)。这实际上在甜甜圈配置的情况下都可以发生,无论热塑性膜层是否“破裂”从而包括所述流体路径(即它是否保持是不可透过的),因为顶表面层和底表面层二者将同时在容器的底部处与清洁组合物接触。在膜的任何初始不透液体特征通过热压延工艺而“破坏”的情况下,这可以进一步有助于清洁组合物向上芯吸通过每片擦巾的全高度和整个甜甜圈。
无论包装和定量给送工艺如何,一旦被制造和包装,随后基材就可以用于擦拭表面。润湿的清洁基材可以用于处理各种表面。如本文中使用的,“处理”表面广义地使用并且包括但不限于擦拭、抛光、擦洗、清洁、洗涤、消毒、刷洗、冲刷、卫生处理和/或向其施加活性剂。
本发明的擦巾或其他清洁基材可以以试剂盒形式提供,其中多个清洁基材和清洁工具被提供在单个包装中。
除了材料组成和构造(例如,在外部的合成非织造物、仅在内部而不在暴露面上的具有特定tanδ特征的热塑性层、清洁“洗液”的组合物等),擦巾或其他基材尺寸还可以用于控制定量给送并且提供人体工学吸引力。在一个实施例中,基材尺寸为约51/2英寸至约11英寸长度和约51/2英寸至约11英寸宽度以舒适地适合于手。基材可以具有使得长度和宽度相差不超过约2英寸的尺寸。较大的基材可以提供成其可以被使用并然后折叠一次或两次,从而将污垢包含在折起基材的内侧内并且然后擦巾可被再使用。此种较大的基材可以具有从约51/2英寸至约13英寸的长度和从约10英寸至约13英寸的宽度。此种基材可以被折叠一次或两次并且仍然舒适地适合于手。
e.抗微生物功效及其他特征
对示例性多层基材测试了其在模拟清洁期间有效地将抗微生物的季铵化合物递送到表面的能力。举例而言,本发明的多层基材可以负载有清洁组合物,该清洁组合物包含按重量计从0.1%至3%、如0.1%至2%的季铵化合物。在实施例中,擦巾可以释放至少40%、至少50%、至少55%、至少60%、或至少65%的季铵化合物(即,相比于负载前的清洁组合物,挤出物中的季铵化合物)。擦巾可以在给定的时间范围(例如像5分钟、4分钟、3分钟、1分钟、30秒、10秒等)内展现出目标微生物如金黄色葡萄球菌的至少3-log降低。
本发明擦巾相比于可商购的常规擦巾(其不包括与本文所述相同的构造几何结构)可以提供显著更高的季铵化合物释放。这可能是由于若干因素,例如,包含有限的(如果包含的话)化学粘合剂含量,以及存在吸收性穴或间隙,例如像图3中所见,邻近的未粘结区域。此类间隙在热塑性膜层与未粘结的凸起区域102之间提供显著的吸收性区域,其可以用作清洁组合物的储库。此类区域允许显著量的清洁组合物得以储存在基材内以便在挤压、擦拭、或其他压缩(其中组合物中的季铵化合物与可能和外表面层相关联的任何阴离子结合位点之间的接触减少)时被释放。
多层基材中相邻层之间的层压程度和粘结强度典型地取决于与压延操作相关联的温度、加压或接触时间、以及施加的压力。温度可能是决定获得的粘结强度的主要变量,但是压力和时间也可以具有效应,并且也可以影响“压花”到纸浆纤维表面层中的所得纹理,以及所得粘结图案。在提供在两个外部面上的合成非织造外层压花有纹理的情况下,相比于仅两面之一压花有纹理的情况,所得多层基材展现出更具垂感(drapable)且刚度较小的“布般”手感。此外,观察到,在所有其他方面相同的情况下,较重的非织造物(即较大的lb或gsm重量)产生刚度更大的基材。图7A-7F图示可以通过压延辊施加的各种可能的压花图案。将显而易见的是,这些可能性几乎是无限的。
在压延期间施加的温度可以是至少150°F、至少175°F、至少200°F、从200°F至400°F、或从200°F至350°F。施加的压力可以是至少50psi、至少100psi、至少150psi、至少200psi、从100psi至1000psi、或从300psi至600psi。接触时间(在给定压力和/或温度下的时间)可以是至少100ms、至少200ms、从100ms至5s、从200ms至1s、或从200ms至500ms。
此种制造方法可以是令人关注的,例如相比于传统的非织造基材制造,因为其可以不需要对尚未提供在非织造层中的单根纤维的任何加工、用水量、水过滤、干燥步骤、加工期间纤维损失等。此外,本发明压延方法可以允许更高的生产线速度(例如最高达900m/min,典型地从50m/min至600m/min),相比于以显著更低的生产线速度水刺制造常规的共混基材(其不是多层的)。
生产线速度增高导致接触时间减少(所有其他方面都相同)。为了提供希望的良好粘结,更高的生产线速度可以通过增大网表面温度(因此需要较短的接触时间)、增大辊直径(因此增大接触时间)或增大施加的压力(压区压力)来适应。举例而言,对于生产线速度增长每25m/min,温度可以增高约5%(℃)以保持粘结水平)。
关于压花纹理,观察到,“针形”纹理(例如与细点相关联)可以导致在纤维被钩在针上时撕裂顶表面层和底表面层。因此,可以优选通过利用更多“扁条”型接触而非尖“针形”形成的纹理,照此更大的特征不会导致此种撕裂。此外,观察到,当通过压延操作制造此类基材时,热塑性“奶酪”层的宽度应窄于顶表面和底表面“面包”层,以便进一步最小化制造期间的复杂化。从此种加工的多层层压网中,可以将单独尺寸的擦巾切割成希望的尺寸。网的可能不包含热塑性“奶酪”层的边缘可以在此种切割期间被切除(如果希望)。本发明基材还提供通过改变压延期间施加的图案(例如,参见图1E或7A-7F的各种图案)来调节基材刚度的能力,以及通过在基材面中的一面或两面上提供纹理化来调节刚度和拉伸强度特征的能力。
在不背离本发明的精神和范围的情况下,普通技术人员可对本发明做出不同修改以使其适应不同用途和条件。因此,这些改变和修改适当地、合理地并旨在在以下权利要求的等价方案的全部范围内。
Claims (19)
1.一种多层基材,其包括:
(a)顶表面层,所述顶表面层包含合成非织造材料,所述合成非织造材料是以下中的至少一种:熔喷的、纺粘的、纺丝成网的、纺粘-熔喷-纺粘的、共成形的、梳理成网的、热粘的、热成形的、水刺的、水刺缠结的、针刺的、或化学粘结的;
(b)中间层,所述中间层包含热塑性材料,所述热塑性材料包含聚乙烯,或者在100°F至350°F的温度范围内具有0.2至0.4的tanδ值;
(c)底表面层,所述底表面层包含合成非织造材料,所述合成非织造材料是以下中的至少一种:熔喷的、纺粘的、纺丝成网的、纺粘-熔喷-纺粘的、共成形的、梳理成网的、热粘的、热成形的、水刺的、水刺缠结的、针刺的、或化学粘结的;以及
(d)负载到所述多层基材上的清洁组合物;
(e)其中所述多层基材不含任何化学粘合剂,替代地所述热塑性材料当熔融时与所述合成非织造材料中的与所述热塑性材料在其熔融和破裂时直接接触的纤维组粘结,形成流体路径;并且
(f)其中所述热塑性材料初始地是呈不透液体的薄膜形式,其在熔融时变成多孔的,从而提供所述流体路径,通过所述流体路径所述清洁组合物能够从所述顶表面层行进到所述底表面层并且从所述底表面层行进到所述顶表面层。
2.如权利要求1所述的多层基材,其中,所述顶表面层和所述底表面层各自基本上由所述合成非织造材料组成。
3.如权利要求1所述的多层基材,其中,所述顶表面层和所述底表面层的所述合成非织造材料具有与所述热塑性材料的tanδ值不同的tanδ值。
4.如权利要求1所述的多层基材,其中,所述顶表面层和所述底表面层的所述合成非织造材料各自基本上由纸浆纤维和合成非织造纤维的共混物组成。
5.如权利要求1所述的多层基材,其中,所述清洁组合物包含季铵化合物。
6.如权利要求1所述的多层基材,其中,所述清洁组合物包含有机酸。
7.如权利要求1所述的多层基材,其中,所述中间层是具有从0.01mm至0.05mm的厚度的膜。
8.如权利要求1所述的多层基材,其中,所述多层基材包括:
(i)未结合区域,其中所述热塑性材料未结合到所述顶表面层或底表面层的邻近纤维;以及
(ii)结合区域,其中所述热塑性材料结合到所述顶表面层和底表面层二者的邻近纤维。
9.如权利要求8所述的多层基材,其中,所述未结合区域对应于在所述顶表面层或底表面层中压花的凸起的纹理特征。
10.如权利要求9所述的多层基材,其进一步包括与所述未结合区域相关联的间隙,在所述间隙中储存所述清洁组合物。
11.如权利要求1所述的多层基材,其中,所述清洁组合物中包含的季铵化合物的至少50%从所述多层基材释放到正被清洁或以其他方式处理的表面。
12.一种多层基材,其包括:
(a)顶表面层,所述顶表面层基本上由合成非织造纤维组成,所述合成非织造纤维是以下中的至少一种:熔喷的、纺粘的、纺丝成网的、纺粘-熔喷-纺粘的、共成形的、梳理成网的、热粘的、热成形的、水刺的、水刺缠结的、针刺的、或化学粘结的;
(b)热塑性膜层,所述热塑性膜层在100°F至350°F的温度范围内具有从0.2至0.4的tanδ值,所述热塑性膜层具有小于0.05mm的厚度;
(c)底表面层,所述底表面层基本上由合成非织造纤维组成,所述合成非织造纤维是以下中的至少一种:熔喷的、纺粘的、纺丝成网的、纺粘-熔喷-纺粘的、共成形的、梳理成网的、热粘的、热成形的、水刺的、水刺缠结的、针刺的、或化学粘结的;以及
(d)负载到所述多层基材上的清洁组合物;
(e)其中所述多层基材不含任何化学粘合剂,替代地所述热塑性膜层当熔融时与所述顶表面层或底表面层中的与所述热塑性膜层在其熔融时直接接触的纤维组粘结;并且
(f)其中所述热塑性膜层初始地是呈不透液体的薄膜形式,其在熔融时变成多孔的,从而提供流体路径,通过所述流体路径所述清洁组合物能够从所述顶表面层行进到所述底表面层并且从所述底表面层行进到所述顶表面层。
13.如权利要求12所述的多层基材,其中,所述清洁组合物包含季铵化合物。
14.如权利要求12所述的多层基材,其中,所述清洁组合物包含有机酸。
15.如权利要求12所述的多层基材,其中,所述热塑性膜层具有从0.01mm至0.05mm的厚度。
16.如权利要求12所述的多层基材,其中,所述热塑性膜层包含聚乙烯,并且所述顶表面层和底表面层包含PET或PP中的至少一种。
17.如权利要求12所述的多层基材,其中,所述清洁组合物中包含的季铵化合物的至少50%从所述多层基材释放到正被清洁或以其他方式处理的表面。
18.如权利要求12所述的多层基材,其中,所述多层基材包括:
(i)未结合区域,其中所述热塑性膜层未结合到所述顶表面层或底表面层的邻近纤维;以及
(ii)结合区域,其中所述热塑性膜层结合到所述顶表面层和底表面层二者的邻近纤维。
19.如权利要求18所述的多层基材,其中,所述未结合区域对应于在所述顶表面层或底表面层中压花的凸起的纹理特征,所述多层基材进一步包括与所述未结合区域相关联的间隙,在所述间隙中储存所述清洁组合物。
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WO1998055295A1 (en) * | 1997-06-05 | 1998-12-10 | Bba Nonwovens Simpsonville, Inc. | High strength baby wipe composite |
CN101848807A (zh) * | 2007-09-07 | 2010-09-29 | 因维斯塔技术有限公司 | 多层可变拉伸性非织造织物复合材料 |
WO2010028238A1 (en) * | 2008-09-05 | 2010-03-11 | Nutek Disposables, Inc. | Composite wipe |
CN102365167A (zh) * | 2009-04-08 | 2012-02-29 | 宝洁公司 | 非织造纤维网和弹性薄膜的可拉伸层压体 |
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CN113329674A (zh) | 2021-08-31 |
CN113329674B (zh) | 2022-11-11 |
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WO2020131602A1 (en) | 2020-06-25 |
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US11858238B2 (en) | 2024-01-02 |
EP3897332A1 (en) | 2021-10-27 |
CN113301838A (zh) | 2021-08-24 |
US20200198288A1 (en) | 2020-06-25 |
US11273625B2 (en) | 2022-03-15 |
EP3897332A4 (en) | 2022-09-07 |
US20200199824A1 (en) | 2020-06-25 |
MX2021007598A (es) | 2021-10-13 |
CA3124075A1 (en) | 2020-06-25 |
MX2021007597A (es) | 2021-08-05 |
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