CN1146681C - Process for making laminate of unaged film and unaged nonwoven web and products produced therefrom - Google Patents
Process for making laminate of unaged film and unaged nonwoven web and products produced therefrom Download PDFInfo
- Publication number
- CN1146681C CN1146681C CNB998112100A CN99811210A CN1146681C CN 1146681 C CN1146681 C CN 1146681C CN B998112100 A CNB998112100 A CN B998112100A CN 99811210 A CN99811210 A CN 99811210A CN 1146681 C CN1146681 C CN 1146681C
- Authority
- CN
- China
- Prior art keywords
- film
- aged
- nonwoven web
- laminate
- drawn
- 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.)
- Expired - Fee Related
Links
Images
Classifications
-
- 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
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
-
- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
-
- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
-
- 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
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
- B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state
-
- 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
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/0012—Mechanical treatment, e.g. roughening, deforming, stretching
- B32B2038/0028—Stretching, elongating
-
- 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
- B32B41/00—Arrangements for controlling or monitoring lamination processes; Safety arrangements
- B32B2041/06—Starting the lamination machine or method
-
- 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
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0253—Polyolefin fibres
-
- 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
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/10—Fibres of continuous length
- B32B2305/20—Fibres of continuous length in the form of a non-woven mat
-
- 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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/724—Permeability to gases, adsorption
-
- 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
- B32B2555/00—Personal care
Abstract
The present invention is directed to an in-line, continuous process for making a laminate of film and nonwoven web wherein the film and nonwoven web are made simultaneously, and are therefore nascent or unaged when directly formed into a laminate. In the process of the present invention, the film is formed in-line while the nonwoven web is formed, the newly formed film and nonwoven web being immediately laminated upon forming. Hence, the laminate is formed from 'unaged' film and 'unaged' nonwoven web. As used herein, the term 'unaged', which is synonymous with 'green', means that the film and nonwoven web are immediately laminated upon forming, for example, neither the film nor the nonwoven web is pre-wound into a roll prior to forming into a laminate.
Description
Invention field
The present invention relates to be used to make the method for laminate of unaged film and unaged nonwoven web and the product of making thus.Specifically be, the present invention relates to be used to make the on-line continuous method of laminate, wherein film and nonwoven web are made simultaneously, directly form laminate then.
Background of invention
Have recognized that the benefit that the cloth shape characteristic of the block of film in various medical science, person nursing and commercial application the and supatex fabric combines and brings industrial morning.Utilize aging film and aging nonwoven web to make laminate traditionally, also by aging film of utilization and unaged nonwoven web, or opposite, utilize unaged film and aging nonwoven web to make laminate.As an example, a kind of typical prior art method must at first be wound up into performed thin film on the roller, when making nonwoven, makes film roll up unwinding on one side then, Yi Bian with film laminating to nonwoven web, form laminate thus.There are many technology barriers in manufacturing film or nonwoven web on continuous foundation.And, the control that the success or not of the complicated approach combination of thin film fabrication and nonwoven web manufacturing will be solved by the technical problem of two systems fully simultaneously.Pointed as reliability theory, every kind of intrinsic difficulty of method in fact will cause a those of ordinary skill of this area to be difficult to successfully realize this combination, thereby not have the specific products attribute advantage of expectation, and this will discuss below more fully.
In addition, make the existing method of pre-formed film or nonwoven web unwinding have technical problem to be solved.The problem that previously used unwinding program exists relates at the aging film of a volume and using up and required interpolation step during the aging film of the volume that must more renew.Need splicing so that the end of first volume film is connected with second top of rolling up film.Therefore, in continuation method, be necessary to splice simultaneously and do not stop machine, because roller is usually with rotation at a high speed, splicing is difficult.There are at least two kinds of known methods that splice.In one approach, utilize hanging stick to come tensioning to allow lax in the film of zero velocity splicing.Diaphragm is reeled around the bar strip of hanging stick, for example expands with vertical mode.When the splicing beginning, hanging stick reduces, and this allows roller speed near zero.This method makes splicing easily, because eliminated moving of aging film volume.The shortcoming of this method is necessary purchase, the additional expensive device (for example hanging stick) of maintenance and operation.
The another kind of method of splicing is known as " splicing in-flight " usually, and this need splice when roller rotates.This method is to implement like this, promptly by the rotating speed of first roller that slows down when quickening second roller, so that the surface speed matched of two rollers is spliced." flight splicing " method is the more economical method of cost because do not need to buy, the hanging stick equipment of maintenance and operation costliness.But, can be appreciated that as a those of ordinary skill of this area " splicing " in-flight is more difficult, particularly using long roller and speed all the more so when 400 and 1500 feet per minute clocks (fpm) (perhaps 122 to 457 meters/minute (m/min)).
Can finish splicing by many methods that those of ordinary skill in the art is known.A kind of method is that two diaphragms are connected with belt.The shortcoming that belt connects is that the position of band coupling part must be monitored, and removes subsequently, because belt influences for example gas permeability of film characteristics.
Another shortcoming that makes prefabricated or aging film unwinding is that the adjacent coiling of film is tending towards bonding mutually (being called the film caking again), and this causes tearing during unwinding from roller at volume.In fact, each thin layer has the affinity with the thin layer that is adjacent to, and each layer preferably sticks together and not unwinding.Being used for the pressure that the character of film forming material and winding film produce to the roller is tending towards making each layer to stick together, and film tore when this caused unwinding.This tearing causes losing the product uniformity, therefore reduced block.In addition, film may be torn fully, and this sampling technology must stop, and this need splice film once more.
And, use 120 inches (3.05m) film volume wide and 3000lbs (1360kg) that weighs very common.A those of ordinary skill as this area can be appreciated that difficulty and trouble are enclosed in the processing of this volume at least.
By the online manufacturing of unaged nonwoven web and unaged film, the present invention can avoid these and other difficulty.Except overcoming above-mentioned difficulties, it is favourable utilizing on-line continuous method of the present invention.Advantage is that unaged film before film laminating is to the nonwoven is not had the chance of complete crystallization.When film has been wound up on the roller and has allowed aging depositing at least 48 hours 2-3 weeks at the most, film temperature turns cold and film can crystallization.Unaged film of the present invention will more keep noncrystalline, this means that it will more softly be orientated with being easy to.In addition, this noncrystalline feature can cause using the laminate of hanging down the final formation of basis weight films and/or low basic weight in any prestretched film.Like this, kept the block and the gas permeability of film, even might make it to improve, simultaneously the relevant totle drilling cost of laminate that reduces and make film and finally form.
Method of the present invention has been eliminated all these shortcomings that existing known method has, and in the on-line continuous method of the present invention, unaged film and unaged nonwoven are made simultaneously, and form laminate immediately.This laminate presents the unexpected improvement of peel strength and hydraulic head, and this is particularly useful in the application of laminate being changed system into absorbent article.Restructuring process typically has fully many problems relevant with layering.These problems improve when the laminate of using by method manufacturing of the present invention.
The idea of utilizing the on-line continuous method to make laminate proposes as a kind of possibility is former.Referring to, for example, the PCT open file WO 96/19346 of commonly-assigned us.But,, passed through the long-term and unremitting effort of high level talent from existing way in fact true to nature to the idea that creates on-line continuous method of the present invention and just be achieved as the drafting of model aircraft successful flight early than White brother.And the laminate of being made by method of the present invention presents the performance that does not reckon with, this will discuss in more detail below.
Summary of the invention
The present invention relates to prepare the on-line continuous method of the laminate of film and nonwoven web, wherein this method comprises the steps: to form unaged film, form unaged nonwoven web simultaneously, and with the unaged film and the described unaged nonwoven web lamination of described orientation, so that form laminate in second at the unaged film that forms described orientation and the 1-60 of described unaged nonwoven web.
The invention provides a kind of on-line continuous method that is used for the prepared layer casting die, this laminate comprises the film and a nonwoven web of a drawn, and the step of this method comprises: a) form a not aged nonwoven web by extrude long filament on a collection surface; While b) by extruding a film and making this film bear the film that multiple machine direction stretching forms a not aged drawn, so that a not aged film to be provided, the last ratio of elongation of this film arrives in about 4.08 the scope about 1, and the thickness after its stretching reaches about 12.7 microns; And c) subsequently by calendering immediately will this not aged drawn film and not aged nonwoven web combination, form laminate with 1-30 in second in the shaping of the shaping of the film of not aged drawn and not aged nonwoven web.
The present invention also provides a kind of on-line continuous method that is used for the prepared layer casting die, this laminate comprises the film of a drawn between one first and one second nonwoven web, and the step of this method comprises: a) form one first not aged nonwoven web by extrude long filament on a collection surface; While b) by extruding a film and making film bear the film that multiple machine direction stretching forms a not aged drawn, so that a not aged film to be provided, the last ratio of elongation of this film arrives in about 4.08 the scope about 1, and the thickness after its stretching reaches about 12.7 microns; Wherein, this not aged film has first side and second side; C) utilize step a)
Online formation one second not aged nonwoven web; D) form a laminate, wherein, this first not aged nonwoven web is adjacent to first side of this not aged film, and this second not aged nonwoven web is adjacent to second side of this not aged film; And e) by calendering immediately will this not aged drawn film and this first and second not aged nonwoven web combination, form laminate with 1-30 in second in the shaping of the shaping of the film of not aged drawn and the first and second not aged nonwoven webs.
In one aspect of the invention, the shaping of film comprises that casting film is extruded or blown film is extruded.The shaping of not aged nonwoven web comprises one or more fibers that formation is selected from comprise a group of spunbond and meltblown fibers.The shaping of first and second nonwoven webs comprises one or more fibers that formation is selected from comprise a group of spunbond and meltblown fibers.The combination of not aged film and not aged nonwoven web comprises heat bonding.Not aged film and not aged nonwoven web are with greater than about 152.4 meters/minute and be less than or equal to about 621.8 meters/minute speed combination.The not aged film and the first and second not aged nonwoven webs are with greater than about 152.4 meters/minute and be less than or equal to about 621.8 meters/minute speed combination.Not aged film and not aged nonwoven web are with greater than about 304.8 meters/minute and be less than or equal to about 621.8 meters/minute speed combination.The not aged film and the first and second not aged nonwoven webs are with greater than about 304.8 meters/minute and be less than or equal to about 621.8 meters/minute speed combination.
The present invention also provides a kind of laminate that comprises the film and a nonwoven web of a drawn, this laminate is by the preparation of on-line continuous method, and the step of this method comprises: a) form a not aged nonwoven web by extrude long filament on a collection surface; While b) by extruding a film and making film bear the film that multiple machine direction stretching forms a not aged drawn, so that a not aged film to be provided, the last ratio of elongation of this film arrives in about 4.08 the scope about 1, and the thickness after its stretching reaches about 12.7 microns; Subsequently; Immediately with the film and the not aged nonwoven web combination of not aged drawn, form laminate in second by calendering with 1-30 in the shaping of the shaping of the film of not aged drawn and not aged nonwoven web.And also a kind of laminate that comprises the film of a drawn between one first and one second nonwoven web of the present invention, this laminate is by the preparation of on-line continuous method, and the step of this method comprises: a) form one first not aged nonwoven web by extrude long filament on a collection surface; While b) by extruding a film and making film bear the film that multiple machine direction stretching forms a not aged drawn, so that a not aged film to be provided, the last ratio of elongation of this film arrives in about 4.08 the scope about 1, and the thickness after its stretching reaches about 12.7 microns; Wherein, not aged film has first side and second side; C) utilize the online formation one second not aged nonwoven web of step a); D) form a laminate, wherein, the first not aged nonwoven web is adjacent to first side of not aged film, and the second not aged nonwoven web is adjacent to second side of not aged film; And e) by calendering immediately with the film and the first and second not aged nonwoven web combinations of not aged drawn, form laminate with 1-30 in second in the shaping of the shaping of the film of not aged drawn and the first and second not aged nonwoven webs.
Description of drawings
Fig. 1 is the perspective view that is formed the method for laminate of the present invention by unaged film and unaged nonwoven web on-line continuous;
Fig. 2 a, b and c represent to be formed by aging film and aging nonwoven web the diagrammatic side view of three-step approach of the prior art of laminate;
Fig. 3 is the diagrammatic side view of two step method that is formed the prior art of laminate by aging film and unaged nonwoven web;
Fig. 4 is typical personal care absorbent articles, is diaper under present case, the top plan view that cuts of part, this absorbent article adopts film/nonwoven laminate of the present invention;
Fig. 5 is the perspective view of threader of the present invention;
Fig. 6 a is the diagrammatic side view of prior art machine direction orientation device;
Fig. 6 b is the diagrammatic side view of machine direction orientation device of the present invention.
The specific embodiment
The present invention relates to make the on-line continuous method of the laminate of film and nonwoven web, wherein film and nonwoven web are made simultaneously, therefore direct formation laminate when nascent or unaged.So far it is also not known to form this laminate by the on-line continuous method.In the method for the invention, online formation film when forming nonwoven web, new film that forms and nonwoven web be laminating molding at once.Therefore, laminate is formed by " unaged " film and " unaged " nonwoven web.As used herein, term " unaged " with " prematurity " synonym, refers to film and nonwoven web laminating molding immediately, and for example, film or nonwoven web were not rolled into volume in advance before forming laminate.
Here employed term " supatex fabric or paper web " refers to place the individual fibers of middle and non-and knit goods equivalent way or the paper web of line structure.For example meltblown and spun-bond process form by many methods for supatex fabric or paper web.Basis weight of nonwoven fabrics is usually with every square yard of material ounce number (osy) or every square of Mick number (gsm) expression, and useful fibre diameter is represented with micron usually.(note, convert gsm to by osy and must multiply by 33.91) with osy.
With reference to figure 1, unaged film 10 of the present invention can be by the polymer manufacturing, and this polymer can form film, and adheres to subsequently on the unaged nonwoven web 30.As used herein, term " polymer " " generally include but be not limited to homopolymers, copolymer, for example block copolymer, graft copolymer, random copolymer and alternate copolymer, terpolymer etc. and their mixture and modifier.And unless limited especially, term " copolymer " should comprise all possible molecular geometry configuration.These molecular geometry configurations include, but are not limited to isotactic, syndyotactic and atactic symmetries.These polymer include, but are not limited to squeezable thermoplastic polymer for example polyolefin or polyolefin blend.More particularly, useful polyolefin comprises polypropylene and polyethylene.Other useful polymer is included in those polymer of describing in No. 4777073 United States Patent (USP)s authorizing Sheth that transfer Exxon chemical patent company, for example copolymer of polypropylene and low density polyethylene (LDPE) or linear low density polyethylene.Other useful among the present invention polymer comprises flexible polyolefin.Here employed " flexible polyolefin " refers to comprise the polyolefine material of the propenyl polymer of the controlled area that has the atactic polypropylene unit, to obtain required degree of crystallinity, for example transferring jointly described in No. 5910136 United States Patent (USP)s of Hetzler and Jacobs; The full content of this patent is hereby expressly incorporated by reference.This flexible polyolefinic further describing can be found authorizing Sustic and transfer in No. 5723546 United States Patent (USP)s of Rexene company.
The useful polymer of other of unaged film of the present invention comprises the elasticity thermoplastic polymer.This polymer comprises by the block copolymer polymer made of polyurethane, copolyether ester, polyamide, polyether block copolymer, ethylene-vinyl acetate (EVA), the block copolymer with general formula A-B-A ' or A-B class copolymerization (styrene/ethylene-butylene), styrene-poly-(ethylene-propylene)-styrene, styrene-poly-(ethene-butylene)-styrene, polystyrene-poly (ethene-butylene)-polystyrene, poly-(styrene/ethylene-butylene/styrene) and similar material for example.Particularly, elasticity thermoplastic polymer comprises the polyester elastomeric material, is for example buied with trade mark HYTREL by E.I.du Pontde Nemours and Company; Polyester block amide copolymer for example, divides various grades to buy from the ELF Atochem Inc. of New Jersey Glen Rock with trade mark PEBAX ; And polyurethane elastomeric materials, for example, from B.F.Goodrich﹠amp; Co. with trade mark ESTANE and those materials of buying with trade mark MORTHANE from Morton Thiokol Corporation.
There have been many purposes in the past in elastomeric polymer, but is subjected to the restriction of their proper property to a certain extent.These materials have added the polymer with good barrier, gas permeability and flexible new kind recently.The polymer of this new kind refers to the polymer of single-point catalysis, for example " metallocene " polymer of producing according to the metallocene method.
This metallocene polymers can be buied with trade mark EXACT with trade mark EXXPOL with for the polyvinyl polymer for polypropylene base polymer from the Exxon chemical company of Texas Baytown.The Dow chemical company of state of Michigan Midland has on the market polymer of can trade mark ENGAGE buying.Metallocene polymers is preferably selected from the copolymer of copolymer, ethene and the 1-octene of copolymer, ethene and the 1-hexene of ethene and 1-butylene and compound thereof.Be the method for this useful among more detailed description metallocene copolymer and manufacturing the present invention material, referring to No. 98/29246 PCT application of WO that transfers people such as Gwaltney jointly, this application provides as a reference at this.
The top layer typically comprises squeezable thermoplastic polymer and/or the additive of property is provided for film 10.Like this, the top layer can be by the polymer manufacturing, and these polymer can provide some performances, for example antimicrobial acivity, permeate water steam, bonding and/or agglomeration preventing performance.Be required particular characteristic selective polymer like this.The example that can use or be used in combination possible polymer separately comprises polyolefin and ethylene vinyl acetate (EVA), ethylene ethyl acrylate (EEA), ethylene acrylic (EAA), ethylene methyl acrylate (EMA), ethylene butyl acrylate (EBA), polyester (PET), nylon (PA), ethylene-vinyl alcohol (EVOH), polystyrene (PS), the homopolymers of the olefinic thermoplastic elastomer of polyurethane (PU) and multistage reactor product, copolymer and mixture, amorphous state ethylene, propylene random copolymer molecule is dispersed in the continuous parent of the high polypropylene monomer of dominant merocrystalline/low vinyl monomer in this olefinic thermoplastic elastomer.
Commercial can the buying with trade mark " Catalloy " of suitable polymer that is used for " A " layer from the Himont chemical company of Delaware State Wilmington.Concrete commercial embodiments is Catalloy, KS 357P, KS-084P and KS-057P.Other suitable polymers comprises in nature the polymer for merocrystalline/amorphous or out-phase.This polymer is on EP0444671 A3 european patent application (on application number 91103014.6 bases), EP0472946 A2 european patent application (on application number 91112955.9 bases), EP0400333 A2 european patent application (on application number 90108051.5 bases), open in U.S. Patent number 5302454 and the U.S. Patent number 5368927.
In order to describe film in more detail, provide PCT as a reference WO96/19346 for people such as McCormack at this referring to the invention people who transfers commonly-assigned us with sandwich layer and top layer.
Film can be by ventilative or gas impermeable material manufacturing.In addition, can punch on the film.When forming film, can co-extrusion film, produce to increase bonding and to reduce die lip.Film can be filled filler, manifests filler as micropore, for example calcium carbonate; Opacifier, for example titanium dioxide; With agglomeration resistance additive, for example diatomaceous earth.
During causing the film orientation of ventilative film in order to manifest micropore, can be in conjunction with filler.By in film formation process, adding filler particles, can make some films ventilative to film.In case formed the film that is filled with particle, then or stretch or crumple, to form path through film.Usually, " ventilative property " of the present invention for realizing, finally forming laminate should have at least about 250/g/m
2/ 24 hours steam permeating rate (WVTR), this is by the test method measuring that describes below.
As used herein, " micropore manifests filler " refers to comprise the material of particulate and other form, and these materials can add in the polymer, and can chemical interference or adverse influence extrusion film, but can be evenly distributed in the whole film.Usually, micropore manifests filler will be particulate form, and normally have about 0.5 the summary microspheroidal of average particle size to about 8 micrometer ranges.As used herein, " micron " refers to micron.The micropore at least about 30% that film comprises the gross weight that accounts for thin layer usually manifests filler.Distinct advantages of the present invention is that required micropore manifests filler and lacks than previously used.If organic and inorganic micropore manifest filler not the gas permeability of interference thin film forming process, final film or its be adhered to for example ability on the fiber polyolefin nonwoven web of other layer, organic and inorganic micropore manifests filler to be planned in the scope of the present invention that is provided.
The example that micropore manifests filler comprises calcium carbonate (CaCO
3), various types of clay, tripoli (SiO
2), aluminium oxide, barium sulfate, sodium carbonate, talcum, magnesium sulfate, titanium dioxide, zeolite, aluminum sulfate, cellulose family powder, diatomaceous earth, magnesium sulfate, magnesium carbonate, brium carbonate, kaolin, mica, carbon, calcium oxide, magnesia, aluminium hydroxide, starch, wood powder, cellulose derivative, polymer beads, chitin and chitin derivative.Micropore manifests filler particles and selectively scribbles aliphatic acid, stearic acid for example, perhaps than the starch aliphatic acid of the bigger chain of 22 carbon alkanoic acid for example, this can be convenient to (in a large number) particle flow freely and be easy to spread in the polymer matrix.Contain silica filler and also can measure now by significant figure, so that anti-caking performance to be provided.
In addition, by film being conveyed through film stretching unit 20 as shown in Figure 1, film 10 can be stretched or be directed.Stretching reduces to 0.5 Mill (12.7micron) or littler effective ultimate criterion size with film standard size or thickness from the initial specification of 1.5-2.0 Mill, and usually, this stretching can take place on cross machine direction or machine direction.As used herein, term " machine direction " or MD refer to the fabric length direction of manufacturing.Term " cross machine direction " or CD refer to width of fabric,, are transverse to the direction of MD usually that is.
In the laminate 32 that contains unaged film 10 of the present invention, unaged nonwoven web 30 as shown in Figure 1 can be by including but not limited to that spunbond and many methods meltblown form.This nonwoven web can be constriction polypropylene spun-bonded, play the pleat spunbond or meltblown fabric of elasticity polypropylene spun-bonded, that make by elastomer resin.As used herein, term " constriction " refers to passing through for example pull method or the contraction on a yardstick at least of gathering method.
The suitable fibers that forms unaged nonwoven web 30 comprises natural and artificial fibre, also comprises bi-component and multicomponent/polymer fiber.Also can use the some nonwoven web layers in the laminate 32 according to the present invention.The example of this material can the comprise for example spunbond/compound that melts and sprays and the compound of spunbond/meltblown/spunbonded for example instructed in 4, No. 041203 United States Patent (USP)s of people such as Brock, and this patent provides as a reference at this.
As used herein, term " spun-bonded fibre " refers to small diameter fibers, this small diameter fibers forms by one or more extruder extruding, extruder is connected with the one or more creels that are made of transfer tube and spinning plate at least, so that the thermoplastic material that will melt is made by some thin, the filament that comes out of circular, capillary usually in the spinning head, the filament diameter of extruding then reduces fast, this for example referring to, authorize people's such as Appel No. 4340563 United States Patent (USP)s; Authorize people's such as Matsuki No. 3802817 United States Patent (USP)s; Authorize people's such as Dorschner No. 3692618 United States Patent (USP)s; Authorize 3338992 and No. 3341394 United States Patent (USP)s of Kinney; Authorize No. 3502763 United States Patent (USP)s of Hartman; With No. 3542615 United States Patent (USP)s authorizing people such as Dobo.Spun-bonded fibre is sticking usually on being deposited on collection surface the time.Spun-bonded fibre is continuous usually, and has than 7 microns big average diameters, and is more frequent, between about 10 and 20 microns.
As used herein, term " meltblown fibers " refers to the fiber of formation like this, promptly extrude through some thin, circular, cold mould capillaries usually by the thermoplastic material that will melt, thereby form fine rule or the filament melted, (for example enter the high speed that converges, common hot gas, air) stream, this air-flow attenuate to reduce their diameter the filament of the thermoplastic material that has melted, and it can become the microfiber diameter.After this, meltblown fibers is carried by high velocity air, and is deposited on the collection surface, with the paper web of the meltblown fibers that forms random scatter.In No. 3849241 United States Patent (USP)s authorizing people such as Butin this method is disclosed for example.Meltblown fibers is continuously or the microfiber that is interrupted, and average diameter is less than 10 microns usually, and does not glue, and can not need the adhesion step of separating when being deposited on collection surface on the time usually.
Term as used herein " microfiber " refers to small diameter fibers, and the average diameter of this fiber is not more than about 75 microns, for example have from about 0.5 micron to about 50 microns, or more particularly, microfiber have usually about 2 microns to about 40 microns average diameter.The expression of the another kind of fibre diameter that often uses is a DENIER, and DENIER is defined as the gram number of per 9000 meters fibers, and the gram/cc number that square multiply by density of the micron number of usable fibers diameter multiply by 0.00707 again and calculates.Lower DENIER refers to thinner fiber, and higher DENIER refers to thicker or heavier fiber.For example, be given as the diameter of 15 microns polypropylene fibre, by with its square, the result multiply by 0.89g/cc and multiply by 0.00707, is convertible into DENIER.Like this, 15 microns polypropylene fibres just have about 1.42 DENIER (15
2* 0.89 * 0.00707=1.415).Beyond the U.S., measurement unit uses " spy " usually, and it is defined as gram/kilometer fiber.Calculate special available DENIER/9.
Many polyolefin can be used for fiber product of the present invention, and for example, the fibre forming polypropylene comprises the Escorene PD3445 polypropylene of Exxon chemical company and the PF304 of Himont chemical company.Polyethylene is the ASPUN 6811A linear low density polyethylene of Dow chemical company for example, and 2553LLDPE and 25355 and 12350 high density polyethylene (HDPE)s also are suitable polymers.Polyethylene has about melt flow rate (MFR) of 26,40,25 and 12 respectively.Many other polyolefin are commercially available.
The method of film forming method and formation fiber non-woven paper web all is known usually.Equally, the laminate with two steps and three-step approach formation film/nonwoven paper web also is known.As shown in Figure 2, the prior art method of three-step approach generally includes the aging film 10 ' of continuous formation, and this step comprises final winding film to roller 14.Then, film 10 ' is put in the holder, and common 2 days to 1 week.Form aging nonwoven web 30 ' in another step, in the same coiling 16 of this paper web.Then, each roller 14 and 16 unwindings of aging film 10 ' and aging nonwoven web 30 ', film 10 ' can stretch in film stretching unit 44 or be directed, and lamination forms laminate 32 ' in third step.
The method that has earlier of two steps generally includes the film or the nonwoven web of preprocessing coiling, and unwinding forms material in advance in method is online then, and this step forms respective material simultaneously.For example, as shown in Figure 3, pre-form aging film 10 ' and be wound up on the roller 14.Form unaged nonwoven web 30 in the film 10 ' that spool in advance in unwinding, aging, thereby form laminate 32 ".
Forming film/nonwoven paper web laminate with online, continuation method in practice is unknown before this.As mentioned above, reliability theory points out to estimate that the output of method of the present invention is very low, and this will cause those of ordinary skill in the art not carry out the present invention easily.In fact, the group method efficient of typical film-forming method is about 74% (90% raw material output and 82% machinery utilization rate) usually, and common about 89% (97% raw material output and the 92% machinery utilization rate) of the group method efficient of typically spunbond (nonwoven web) method.By these two methods are combined into on-line continuous method of the present invention, people can expect about 66% group method efficient, and do not have the specialities advantage of expectation.In fact, have found that except the performance improvement that product presented constructed in accordance, method efficient of the present invention is at least about 70%, even at least 75%.For high production rate, the increase of this efficient is very meaningful, and is the function of process condition and parameter described here.
In the method for the invention, when forming unaged nonwoven web 30, the unaged film 10 of online formation, their laminations immediately when being shaped.Therefore, form laminate 32 by " unaged " film and " unaged " nonwoven web." immediately " being meant that unaged film 10 and unaged nonwoven web 30 link together becomes a laminate 32, and arbitrary layer of need not at first reeling.Best, each layer from moment of making each layer in 1 to 60 second, be more preferably in 1 to 30 second, be preferably in lamination in 1 to 10 second scope.By lamination immediately, cause finding the unexpected and wonderful improvement of peel strength and hydraulic head by the ability of processing unaged film 10 and unaged nonwoven web 30 simultaneously, this will emphasize below in more detail.
More particularly, Fig. 1 illustrated form and directed unaged film 10 for example according to the common approach of unaged film of the present invention.With reference to figure 1, unaged film 10 is formed by for example above-mentioned cast of co-extrusion film equipment 40 or blowing unit.Typically, equipment 40 comprises one or more polymer extrusion for example core film extruder 47 and top layer film extruder 45.Unaged film 10 is extruded on the cold die cast roller 49.
The machine direction of prior art stretches and represents with mark 44 in Fig. 6 a usually, and it generally includes uses 6 draw rolls 46 ', and this draw roll 46 ' uses 3-4 the thermal treatment zone and one or more cooling zones usually.In other words, some draw rolls are used for heating, and some are used for cooling off.The prior art method also comprises roll 21, and this roll 21 is arranged to make film and draw roll 46 to keep in touch, and stretches under the condition by roller conduction heating simultaneously.Believe that the roller heating and the stretching that face toward prior art cause inhomogeneous heating, excessive constriction and very poor CD performance profile.On the other hand, Fig. 6 b represents the coiling of film through according to an aspect of the present invention MDO20.The amount and the type that stretch become with the location that roll 21 heads on draw roll 46, and this draw roll 46 can be a chrome-plated roller.Roll 21 is cambered rolls, and it provides the even pinching effect to draw roll 46.Roll 21 of the present invention is positioned to make unaged film 10 at utmost around the draw roll 46 that reclines, and for example holds 270 ° of the diameters of roller.According to one embodiment of present invention, MDO20 this means in the space between the roller to stretch leaving roll 21 after-drawing films, therefore avoids the problem of prior art.MDO is made of at least seven draw rolls.Each draw roll can be heated to 250 °F (121 ℃) from environment temperature, perhaps is cooled to 55 °F (13 ℃) from environment temperature, and drives respectively.The speed of each draw roll is in the scope of 380-1550fpm (116-473m/min).Therefore, last ratio of elongation can be in 1.00 to 4.08 scopes.Described this MDO is designed so that maximum flexibility, and more general than the film stretching apparatus of prior art, because it allows dissimilar films in office why not with processing under the process operation condition and stretching.Have found that in unaged film of the present invention, membrane stress diminishes under low draw ratio, this means does not need so big stretching.This phenomenon has some advantages.The lower stretching that advantage is a film means that film will can not be forced into the so high draw ratio in the prior art, and this finally causes film fracture still less and reduces film defects.Net effect also makes technical process turn round under higher rate except producing high yield.Another advantage is mentioned indirectly as the front, is to manifest filler by micropore still less, this means to use more polymer in combination.This combination will cause more firm film together, this means in last laminate and resultant articles and can use thinner film.
When unaged film during a bit being shaped of machine, nonwoven web forms simultaneously.Refer again to Fig. 1, traditional nonwoven web forming device 48, for example spunbond machine is used for forming unaged nonwoven web 30.Long continuous substantially fiber 50 is deposited on becomes the paper web 54 that does not adhere on the shaping silk ribbon 52, then, the paper web 54 that does not adhere to transmits through a pair of bond roll 56, so that fiber is sticked together.Often one of them or whole two bond rolls of heating are bonding to help.The temperature of bond roll 56 heating is in 250-350 (121-177 ℃) scope.Typically, one of them in the roller 56 also has pattern, so that make unaged nonwoven web 30 form the regulation adhesive surface zone of discrete bond pattern.This thermal point bond is known, will describe in more detail it below.Other rollers are usually smooth anvil rollers, but this anvil roller also can form pattern when needed.In case unaged film 10 enough stretches, and unaged nonwoven web 30 formed, two just combinations as mentioned above immediately of layers, and in this continuation method, install 58 with they mutual laminations with a pair of laminating roll or other.
In preference pattern, smooth anvil roller is positioned at this side that is connected with unaged film 10 of unaged nonwoven web 30.In other words, the smooth side of unaged nonwoven web 30 is connected with unaged film 10, and this causes two-layerly sticking together better.
With heat and/or pressure unaged film 10 and unaged nonwoven web 30 when bonding, can used for example laminating roll of laminater 58.As sticking pressure roller 56, laminating roll 58 can heat and can use thermal point bond.The temperature of laminating roll heating is in 200-275 (93-135 ℃) scope.At least one roller can form pattern, so that be formed for finally forming the discrete bond pattern in the regulation adhesive surface zone of laminate 32.Usually, the maximum bounding point surface area of the given surf zone on the side of laminate 32 is no more than about 50% of whole surface area.Many spendable discrete bond patterns are arranged.Referring to, people's such as Brock No. 4041203 United States Patent (USP)s for example.
It is bonding that " thermal point bond " comprises that the nonwoven web with fabric or fiber is sent between the calender roll of heating and the anvil roller.Calender roll is with forming pattern someway, and whole like this nonwoven web is not bonding on its whole surface.Be function and purpose attractive in appearance, developed many patterns of calender roll.Understand as those skilled in the art, bond area percentage is, inevitably, describes in approximation relation or scope, because bonding pin came to a point gradually along with past of time usually and wore and tore.Recognize also that as those skilled in the art benchmark " pin/square inch " and " bounding point/square inch " are interchangeable to a certain extent, because the bounding point that the anvil pin forms has identical size and surface relationships with pin on the anvil roller in substrate.An example of pattern has a little, and is the Hansen Pennings or the " H﹠amp of about 200 bounding point/square inches; P " pattern, this instructs as No. 3855046 United States Patent (USP)s authorizing Hansen and Pennings.H﹠amp; The P pattern has square dot or pin bonding zone, and wherein each pin can have the lateral dimension of 0.038 inch (0.965mm), for example, causes having the pattern of about 30% bonding zone.Another kind of typical some bonding patterns is Hansen and Pennings or " EHP " bonding patterns of expansion, about 15% to 18% the bonding zone of this pattern generating, this bonding zone has the square pin of 0.037 inch (0.94mm) lateral dimension, for example, the pin density that has about 100 pin/square inches.The another kind of typical some bonding patterns of " 714 " indication has the square pin bonding zone, and wherein each pin has 0.023 inch lateral dimension and for example 15% to 20% bonding zone and about 270 pin/square inches.Other pattern commonly used comprises " Ramisch " argyle design with repetition rhombus, this pattern has 8% to 14% bonding zone and 52 pin/square inches, the HHD pattern, this pattern comprises that the point of about 460 pin/square inches is bonding, bonding zone with about 15% to about 23% also comprises the line Weaving pattern, and this pattern is as suggested in the name, for example, resemble a pane and have 15% to 20% bonding zone and 302 pin/square inches.The another kind of bonding patterns of spunbond facing paper web is the serpentine Weaving pattern, this pattern on September 15th, 1997 with McCormack, the name application of Fuqua and Smith, title is " fabric with the non-woven bonding patterns generation that improves intensity and ABRASION RESISTANCE ", application number is to describe in the United States Patent (USP) that allows of 929808 corotation, and its full content provides as a reference at this.Typically, bond area percentage changes to about 30% wide region in about 10% of nonwoven web zone.
In case laminate 32 is left laminating roll 58, it can coiling 60 so that with post processing.Alternatively, laminate 32 can online continuously further processing or conversion.
As what be explained in more detail below, wondrous and beat all improvement of the present invention is the increase of its peel strength and hydraulic head, and this causes in the advantage that laminate is converted in goods such as the personal care absorbent articles.A major defect of present known laminate be have the conversion before or during laminate be tending towards layering.This layering causes the commercial variety of issue of making and increasing waste product.Recognize that as those of ordinary skill in the art the increase of peel strength or hydraulic head causes the reduction of other performances usually.An advantage of the present invention is that peel strength and hydraulic head increase simultaneously.
In addition, method shown in Figure 1 can be used to form the laminate more than two-layer.Can revise previously described method, so as with the feed 16 of the second aging nonwoven web 30 ' deliver to film 10 facing in the laminating roll 58 on the side of another unaged nonwoven web 30.And the intent of the present invention is that direct-on-line forms the second unaged nonwoven web by the used continuation method of unaged nonwoven web as mentioned above 30.This three layers laminate is particularly useful in the application of medical science and the anti-expansion of industry clothes.Equally, can wear out or unaged thin layer in conjunction with other.
As previously proposed, laminate 32 can be used for extensively different application, comprises personal care absorbent articles incessantly, for example diaper, training underpants, incontinence device and the feminine hygiene products parts of sanitary napkin for example.Typical products and its 80 is a diaper under situation of the present invention, as shown in Figure 4.With reference to figure 4, most of this personal care absorbent articles 80 comprise the top flat of liquid or 82, one egative films of liner or an outer covering layer 84 and between top flat 82 and egative film 84 and bag absorbent core 86 within it thoroughly.Goods 80, diaper for example also can comprise the fastener 88 of some types, for example bonding restraint zone or mechanical hook and ring-like securing member are so that be held in place at clothes on one's body the wearer.
Other purposes of the laminate of membrane according to the invention/nonwoven web comprises, but is not limited to, surgical drage and surgical gown, handkerchief, impervious material and comprise Work Clothes for example and test is outer in being enclosed within clothes product or its part.
By following example, advantage of the present invention and other characteristics will be described better.
Example
Preparation as described below sample of the present invention.Carry out following test with sample then:
Disbonded test: peel off or layering test in, the laminate test determination is pulled away from the required amount of tension of nonwoven web layer with thin layer.Use approximate 4 inches (CD) * 6 inch (MD) (width of 102 * 152mm) fabric samples, this specimen holder is held in 1 * 4 inch, and ((300 ± 10mm/min.) constant percentage elongation stretches, and can obtain the value of peel strength like this between the parallel clamp (pawl) of 25 * 102mm) length and with 12 ± 0.4in./min..Cover up the film side that adhesive tape or some other suitable materials are applied to sample, in case the duration of test film is torn.Cover up on the side that adhesive tape only is bonded at laminate, be unfavorable for the peel strength of sample like this.With the enough amounts of handgrip sample layering so that sample is clamped to usually the position near 2 inches (51mm).This sample clamping is in Instron Model TM for example, it is from Canton, the Instron company that No. 2500, the Washington street of MA02021 buys, or in the Sintech tension test instrument, it can be from North Carolina 27709-4226, research triangle park, the Sintech company of P.O. Box 14226 buys.Sample is pulled away from the distance of 2 inches (51mm) then under 180 ° of separation, average peel strength is in gram.
Tension test:Breaking strength and elongation or strain when tension test measurement fabric is subjected to pure stress.The result represents with gram and the elongation before fracture fracture.Stronger, the more stretchable fabric of bigger digitized representation.Term " peak load " refers to sample burst or rupture required maximum load or power in the tension test, is unit representation with weight.Term " energy " refers to the gross energy of peak load and the ratio that prolongs curve, represents with weight-long measure.Term " strain " or " elongation " refer to that the length of sample during the tension test increases, and represents with percentage.The value that obtains peak load, energy and strain is to utilize the fabric sample of 3 * 6 inches (76 * 152 millimeters), the clamp width of 3 inches (76 millimeters), the clamping length of 3 inches (76 millimeters), with the extension speed of constant 12 inch per minute clocks (300 mm/min), wherein all the sample width are clipped in the clamp.This specimen holder is in 1130 Instron for example, 1130Instron buys from Instron company, perhaps Thwing-Albert Model INTELLECTII, it can be from Dutton road, Philadelphia, 19154 Pennsyivania No. 10960 Thwing-Albert instrument company buy.
Ball burst testing:The resistanee to rupture of this experimental measurement fabric, this fabric present the ultimate elongation of height, and test according to ASTM D 3787-89.Thereby resistanee to rupture is defined as under given conditions by utilizing the vertical power that applies with the plane of fabric to make the fabric expansion make required power or the pressure of textiles fracture.Use the Instron tension test instrument of revising as ball burst testing, head on sample by the steel ball that forces polishing and produce pressure up to sample burst.Write down pressure then in the resistanee to rupture of lbf (N).For specified standard free air test textiles in ASTM Practice D 1776, regulate sample and make it the humidity equilibrium.
Permeability test:The measurement of fabric breathability is steam permeating rate (WVTR), according to the WVTR of ASTM Standard E96-80 calculation sample material.Downcut the circular sample of diameter 3 inches (7.6 centimetres) from each test material.From Charlotte, 2500 of the CELGARD of the Celanese Separation Products of NC are used as contrast material.2500 of CELGARD are the capillary polypropylene sheets.Every kind of material is prepared three samples.Test board is the Vapometer dish of the numbering 60-1 that sells of the Thwing-Albert instrument company by philadelphia, pa.100 ml waters inject each Vapometer dish, and each sample of test material and contrast material is all across the uncovered top placement of dish separately.The tight flange of twisting, to form the sealing along plate edge, on the circle of 6.5 cm diameters with the exposed area that is similar to 33.17 square centimeters, correlation test material or contrast material are exposed in the atmosphere.Dish is transferred in the forced air draft oven 1 hour so that balanced at 100 °F (32 ℃).Stove is a constant temperature oven, and extraneous air accumulates in inside through its circulation with water vapor simultaneously.Suitable forced air draft oven is, Blue M Power-O-Matic 60 stoves for example, and this stove is sold by the Blue M electronics corporation of Illinois Orchid Island.After finishing equilibrium, will coil from stove and take out, weigh and put back in the stove immediately.After 24 hours, will coil from stove and take out, and weigh once more.The preliminary following calculating of test steam permeating rate value:
Test WVTR=(the weight in grams number of loss in 24 hours) * 315.5g/m
2/ 24 hours
Relative humidity in the stove is not controlled especially.
Under the prerequisite of 100 (32 ℃) and relative humidity of atomsphere, the WVTR of CELGARD 2500 contrast materials be defined as 5000 the gram/square metre/24 hours.Therefore, comparative sample is accepted each test, and uses following formula that preliminary test value is calibrated to the condition of setting:
WVTR=(test WVTR/ contrast WVTR) * (5000 grams/square metre/24 hours)
Hydraulic head:The measurement of the liquid impervious of fabric is the hydraulic head test.The height (in centimetre) of the supportable water of fabric before predetermined amount of liquid is passed is determined in hydraulic head test.Fabric with higher hydraulic head reading has higher anti-liquid penetrability than the fabric with low hydraulic head.Use Textest FX-3000 static pressure hydraulic head test instrument according to federal test standard 191A, method 5514 is carried out the hydraulic head test, and this test instrument can be from North Carolina state Concord, and the Mario industrial group of P.O. Box 1071 buys.
Standard deviation:The standard deviation that uses in these examples is represented dispersion measure, and the average distance between tolerance single observation value and its mean value.How this can change very favourable to understanding one group of data.For example, standard deviation can be used to allow people to predict miss ratio and/or decision can receive much variabilities in last product.Example as described below, each performance will be tested 44 specimen materials.When the laminate sheet leaves production line, take off 22 samples, and take off 22 samples from the center of laminate at its edge.The quantity of sample is represented the effective sample size on the statistics.
The used formula of standard deviation is:
In formula, " n " is observation quantity.Use n-1 to replace more natural n to be in the denominator because if use n (replacing n-1), what will cause standard deviation in population misvalues meter partially.Use n-1 that this deviation of small sample size is done correction.From each observation (x
1) provide the basis of measuring variability to the distance of calculating mean value (x-bar).These observations are near more from mean value, and standard deviation is more little.If all observations are identical, standard deviation is zero so.Owing on average be " fulcrum " (than mean value big and than the equilibrium point between those little observations of mean value) of data, to deviation square.If not to deviation square, sum is zero.Get the square root of sum then, so that value is got back to the unit of original date.
Here utilize statistics, so that following example is compared.Be the explanation of these examples being carried out statistical analysis below.A formal method of being carried out statistical inference by sample and parent is through hypothesis testing.The statistics sampling distribution provides a kind of method that proves or refute about the cell mean hypothesis.T test is the method for the inequality between the most general two standard profile groups of assessment.There are two kinds of t tests.The standard t test of independent sample is with such basis that is assumed to be, and this hypothesis is a variance identical (same) in two groups, uses combined standard deviation.If two groups variance is very different, use the t test of the variance estimation that separates so.The identity property hypothesis of available F evidence variance.F test is used for coming by the observation sample variance rate variance of two normal populations of comparison.Null hypothesis is the variance 1=variance 2 (perhaps variance 1/ variance 2=1) of test.
In two basic sampling tests, statistical hypothesis is that two mean values are to be equal to (Var1=Var2).The hypothesis that substitutes is to have difference (Var1-Var2＜＞0).If the alpha degree (0.05) that degree of probability is selected less than you, you negate the null hypothesis of same average value, are different and draw mean value.P-level representative with the t-test report comprises the probability about the mistake in the Research Hypothesis that there are differences of accepting us.
Example 1
Utilize unaged film and unaged nonwoven web prepared layer casting die according to the present invention.Unaged film coextrusion forms three-decker, promptly known A/B/A film.
" B " layer or sandwich layer are made of following ingredients, and promptly percentage by weight is 44.5% linear low density polyethylene (LLDPE), and it can be 3310 to buy with trade mark from Dow chemical company of manufacturer (" Dow "); Percentage by weight is 5.3% low density polyethylene (LDPE) (LDPE), and it can be 4012 to buy with trade mark from the Dow of manufacturer; Percentage by weight is 50% the calcium carbonate that scribbles 22 carbon alkanoic acid, and it can be that FilmLink 2029 buys from the ECC international corporation of manufacturer of Alabama State Sylacauga with the trade mark; With the antioxidant of 2000ppm, it can be buied with trade mark B900 from the Ciba Specialties company of manufacturer of New York Tarrytown.
" A " layer is that known top layer or outer opposite side at sandwich layer are made of following ingredients, and promptly percentage by weight is 50.4% ethylene vinyl acetate, and it can be 768.36 to buy with trade mark from the Exxon chemical company of manufacturer of Houston, Texas; 49.1% Catalloy, it is buied for KS 357P with the trade mark by the manufacturer Montell U.S. limited company of Delaware State Wilmington; With the antioxidant of 5000ppm, it is buied with trade mark B900 from the Ciba Specialties company of manufacturer of New York Tarrytown.
As mentioned above and cold under the following conditions die cast extrude three-layer thin-film.The end fusion temperature of measuring the top layer is approximate 365 °F (185 ℃), and the end fusion temperature of sandwich layer is approximate 420 °F (215 ℃).Included top layer accounts for 2.5% percentage by weight of whole film synthetic.
The thin-film technique operating condition
| Output | Sandwich layer | The top layer | BW before stretching |
| Lb/hr | rpm | ?rpm | ?0sy |
| 3800 | 31.9 | ?30.3 | ?1.76 |
BW refers to basic weight
Film is through having the machine direction guider (MDO) of 7 rollers under condition shown in the following table.Last film stretching is defined as the velocity ratio of last roller to first roller.Film is to have stretched 3.5 times, and the film after final the stretching has the 0.54osy basic weight after elongation.Here the film that said stretching is 3 times is meant that for example 1 meter long film stretching arrives final 3 meters long.
The MDO process condition
| Speed | Stretch | Draw ratio | Temperature | |
| ?Fpm(M/min) | ％ | ?°F(℃) | ||
| Roller #1 | ?410(125) | 98.0％ | 1.02 | ?200(93.3) |
| Roller #2 | ?419(128) | 76.0％ | 1.32 | ?200(93.3) |
| Roller #3 | ?551(168) | 98.0％ | 1.02 | ?195(90.6) |
| Roller #4 | ?562(1?71.3) | 38.0％ | 2.63 | ?190(87.8) |
| Roller #5 | ?1479(450.8) | 101.0％ | 0.99 | ?70(21.1) |
| Roller #6 | ?1464(446.2) | 102.0％ | 0.98 | ?70(21.1) |
| Roller #7 | ?1436(437.7) | 103.0％ | 0.97 | ?210(99) |
Two nonwoven web formers with as shown in Figure 1 prepare unaged nonwoven web by aforesaid spunbond method.Nonwoven web is that 38 polypropylene and percentage by weight are that 2% titanium dioxide concentrate forms by having melt flow rate (MFR), this polypropylene can be buied with trade mark E5d47 from the Union Carbide Corporation of manufacturer of Connecticut State Danbury, and this titanium dioxide concentrate can be buied from the Standridge Color Corporation of Georgia Social Circle.Fiber is stretched to the average diameter of 15-20 micron then, and deposits on the form metal silk ribbon through two extruders and two creel extruding.Regulate the speed of shaping wire belt, so that make nonwoven web have 0.5oz/sqyd (osy) (17g/m
2) basic weight, be heated to 315 °F (157 ℃) through the bond roll of metal silk weaving pattern then and come thermal point bond.
Under heating and pressurized conditions, laminating roll with anvil roller and C-star chart case is sent to unaged nonwoven web under the MDO, so that it is laminated into the unaged film of stretching, lamination is 353PLI (61800N/M) simultaneously, top layer presses anvil roller under 220 (104.4 ℃) temperature, and base pressure flower laminating roll is under 280 (137.8 ℃) temperature.
The unaged film that stretches is laminated into not aged nonwoven web immediately in less than 5 seconds.Laminate is passed through laminating roll by this way, and this mode is the close knurling rolls of spunbond layer, and thin layer is near smooth anvil roller.Test adding up effective sample sets, its characteristic shown in table 1a and 1b, unless indicate, below basic weight in the table of label represent the basic weight of laminate.
Example 2
Under following different process condition, by the unaged film and the unaged nonwoven web prepared layer casting die of above-mentioned example 1.
The MDO process condition
| Speed | Stretch | Draw ratio | Temperature | |
| ?Fpm(M/min) | ％ | ?°F(℃) | ||
| Roller #1 | ?444(135) | 98.0％ | 1.02 | ?210(99) |
| Roller #2 | ?453(138) | 56.0％ | 1.32 | ?200(93.3) |
| Roller #3 | ?809(247) | 65.0％ | 1.02 | ?200(93.3) |
| Roller #4 | ?1245(379) | 85.0％ | 2.63 | ?200(93.3) |
| Roller #5 | ?1464(446) | 101.0％ | 0.99 | ?70(21.1) |
| Roller #6 | ?1450(442) | 101.0％ | 0.98 | ?70(21.1) |
| Roller #7 | ?1435(438) | 102.0％ | 0.97 | ?220(104.4) |
Last film stretching ratio is 3.23
Lamination
| Laminating roll | Pressure | Temperature |
| PLI(N/m2) | °F(℃) | |
| Top (anvil roller) | 353(61800) | 214(101.1) |
| The end (embossing) | 353(61800) | 269(131.7) |
Statistical effective sample sets is tested, and characteristic is shown in table 2a and 2b.
Comparative example
By unaged film and unaged nonwoven web prepared layer casting die.Aging film is coextruded into A/B/A film as described below, and is made by the Huntsman packaging company of salt lake city, the Utah State.
" B " layer is made of the synthetic identical with example 1.Except operating weight percentage is that 4% Superfloss diatomaceous earth and percentage by weight are that " A " layer is configured to example 1 basic identical 45.1% the Catalloy, it is buied by the Celite company of California Lompoc.The top layer accounts for 3.3% percentage by weight of whole film synthetics.
Aging film allows to store aging 4 days.
Aging then film utilization is directed under the following conditions by traditional machine direction finder that Marshall and Williams company make:
The MDO process condition
| Speed | Stretch | Draw ratio | Temperature | |
| Fpm(M/min) | ％ | ?°F(℃) | ||
| Do not reel | 375(114) | 99.21％ | 1 | |
| Preheat roll 1 | 378(115) | 76.99％ | 1.3 | ?225(107.2) |
| Preheat roll 2 | 491(150) | 98.00％ | 1.02 | ?200(93.3) |
| Slow draw roll | 501(153) | 28.98％ | 3.45 | ?200(93.3) |
| Fast draw roll | 1729(527) | 102.01％ | 0.98 | ?77(25) |
| Lehr rollers 1 | 1695(517) | 101.92％ | 0.98 | ?77(25) |
| Lehr rollers 2 | 1663(507) | 107.64％ | 0.93 | ?210(99) |
Last film stretching ratio is 4.44 times
Spunbond unaged nonwoven web is made of the synthetic identical with example 1, is laminated into aging film then under the following conditions:
Lamination
| Laminating roll | Pressure | Temperature |
| PLI(N/m2) | °F(℃) | |
| Top (supporting) | 360(63000) | 216(102.2) |
| The end (embossing) | 360(63000) | 236(113.3) |
Statistical effective sample sets is tested, and characteristic is shown in table 3a and 3b,
Conclusion
These tables have been set up the tabulate statistics analysis of above-mentioned these performance tables, and this can see from following table 4a and 4b.
Data show to be compared with two-step method (comparative example), in these two examples of the present invention hydraulic head and peel strength is had beat all improved impervious characteristic and lamination strength.Opposite with prevailing view, this viewpoint is thought increases so usually one of them meeting variation of these performances (hydraulic head and peel strength) to some extent if find other performances, and method of the present invention is made two kinds of performances improved materials simultaneously.In the goods of being made by product of the present invention, this very needs.
In addition, method of the present invention is also made intensity is enough to be used in describing material in the product here, and it is by tensile strength and steel-ball type bursting performance confirm fully.Although detailed description the present invention, obviously, under the condition of essence that does not deviate from following claim and scope, can carry out various modifications to the present invention.
Claims (14)
1. on-line continuous method that is used for the prepared layer casting die, this laminate comprises the film and a nonwoven web of a drawn, the step of this method comprises:
A) form a not aged nonwoven web by on a collection surface, extruding long filament; Simultaneously
B) by extruding a film and making described film bear the film that multiple machine direction stretching forms a not aged drawn, so that a not aged film to be provided, the last ratio of elongation of this film is in 1 to 4.08 scope, and the thickness after its stretching reaches 12.7 microns; Subsequently;
C) by calendering immediately with the film and the not aged nonwoven web combination of described not aged drawn, form laminate with 1-30 in second in the described shaping of the described shaping of the film of described not aged drawn and described not aged nonwoven web.
2. the method for claim 1 is characterized in that, the described shaping of described film comprises that casting film is extruded or blown film is extruded.
3. the method for claim 1 is characterized in that, the described shaping of described not aged nonwoven web comprises one or more fibers that formation is selected from comprise a group of spunbond and meltblown fibers.
4. the method for claim 1 is characterized in that, the described combination of described not aged film and described not aged nonwoven web comprises heat bonding.
5. the method for claim 1 is characterized in that, described not aged film and described not aged nonwoven web are with greater than 152.4 meters/minute and the speed combination that is less than or equal to 621.8 meters/minute.
6. method as claimed in claim 5 is characterized in that, described not aged film and described not aged nonwoven web are with greater than 304.8 meters/minute and the speed combination that is less than or equal to 621.8 meters/minute.
7. on-line continuous method that is used for the prepared layer casting die, this laminate comprises the film of a drawn between one first and one second nonwoven web, the step of this method comprises:
A) form one first not aged nonwoven web by on a collection surface, extruding long filament; Simultaneously
B) by extruding a film and making described film bear the film that multiple machine direction stretching forms a not aged drawn, so that a not aged film to be provided, the last ratio of elongation of this film is in 1 to 4.08 scope, and the thickness after its stretching reaches 12.7 microns; Wherein, described not aged film has first side and second side;
C) utilize the online formation one second not aged nonwoven web of step a);
D) form a laminate, wherein, the described first not aged nonwoven web is adjacent to described first side of described not aged film, and the described second not aged nonwoven web is adjacent to described second side of described not aged film; And
E) by calendering immediately with the film and the described first and second not aged nonwoven web combinations of described not aged drawn, form laminate with 1-30 in second in the described shaping of the described shaping of the film of described not aged drawn and the described first and second not aged nonwoven webs.
8. method as claimed in claim 7 is characterized in that, the described shaping of described film comprises that casting film is extruded or blown film is extruded.
9. method as claimed in claim 7 is characterized in that, the described shaping of described first and second nonwoven webs comprises one or more fibers that formation is selected from comprise a group of spunbond and meltblown fibers.
10. method as claimed in claim 7 is characterized in that, the described combination of described not aged film and described not aged nonwoven web comprises heat bonding.
11. method as claimed in claim 7 is characterized in that, the described not aged film and the described first and second not aged nonwoven webs are with greater than 152.4 meters/minute and the speed combination that is less than or equal to 621.8 meters/minute.
12. method as claimed in claim 11 is characterized in that, the described not aged film and the described first and second not aged nonwoven webs are with greater than 304.8 meters/minute and the speed combination that is less than or equal to 621.8 meters/minute.
13. a laminate that comprises the film and a nonwoven web of a drawn is characterized in that, described laminate is by the preparation of on-line continuous method, and the step of this method comprises:
A) form a not aged nonwoven web by on a collection surface, extruding long filament; Simultaneously
B) by extruding a film and making described film bear the film that multiple machine direction stretching forms a not aged drawn, so that a not aged film to be provided, the last ratio of elongation of this film is in 1 to 4.08 scope, and the thickness after its stretching reaches 12.7 microns; Subsequently;
C) by calendering immediately with the film and the not aged nonwoven web combination of described not aged drawn, form laminate with 1-30 in second in the described shaping of the described shaping of the film of described not aged drawn and described not aged nonwoven web.
14. a laminate that comprises the film of a drawn between one first and one second nonwoven web, described laminate is by the preparation of on-line continuous method, and the step of this method comprises:
A) form one first not aged nonwoven web by on a collection surface, extruding long filament; Simultaneously
B) by extruding a film and making described film bear the film that multiple machine direction stretching forms a not aged drawn, so that a not aged film to be provided, the last ratio of elongation of this film is in 1 to 4.08 scope, and the thickness after its stretching reaches 12.7 microns; Wherein, described not aged film has first side and second side;
C) utilize the online formation one second not aged nonwoven web of step a);
D) form a laminate, wherein, the described first not aged nonwoven web is adjacent to described first side of described not aged film, and the described second not aged nonwoven web is adjacent to described second side of described not aged film; And
E) by calendering immediately with the film and the described first and second not aged nonwoven web combinations of described not aged drawn, form laminate with 1-30 in second in the described shaping of the described shaping of the film of described not aged drawn and the described first and second not aged nonwoven webs.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US10130698P | 1998-09-22 | 1998-09-22 | |
| US60/101,306 | 1998-09-22 | ||
| US37123499A | 1999-08-10 | 1999-08-10 | |
| US09/371,234 | 1999-08-10 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1334887A CN1334887A (en) | 2002-02-06 |
| CN1146681C true CN1146681C (en) | 2004-04-21 |
Family
ID=26798115
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNB998112100A Expired - Fee Related CN1146681C (en) | 1998-09-22 | 1999-09-17 | Process for making laminate of unaged film and unaged nonwoven web and products produced therefrom |
Country Status (11)
| Country | Link |
|---|---|
| EP (1) | EP1115932A2 (en) |
| JP (1) | JP2002526297A (en) |
| KR (1) | KR20010075218A (en) |
| CN (1) | CN1146681C (en) |
| AU (1) | AU751175B2 (en) |
| BR (1) | BR9913896A (en) |
| ID (1) | ID29844A (en) |
| PL (1) | PL347063A1 (en) |
| RU (1) | RU2243301C2 (en) |
| TR (1) | TR200100838T2 (en) |
| WO (1) | WO2000016974A2 (en) |
Families Citing this family (18)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6638636B2 (en) | 2001-08-28 | 2003-10-28 | Kimberly-Clark Worldwide, Inc. | Breathable multilayer films with breakable skin layers |
| US6803009B2 (en) | 2001-11-28 | 2004-10-12 | Kimberly-Clark Worldwide, Inc. | Process for making necked nonwoven webs and laminates having cross-directional uniformity |
| US6900147B2 (en) | 2001-11-28 | 2005-05-31 | Kimberly-Clark Worldwide, Inc. | Nonwoven webs having improved necking uniformity |
| US6740200B2 (en) | 2001-12-19 | 2004-05-25 | Kimberly-Clark Worldwide, Inc. | Methods and system for manufacturing and finishing web products at high speed without reeling and unwinding |
| US6785937B2 (en) | 2002-04-24 | 2004-09-07 | Kimberly-Clark Worldwide, Inc. | Slit neck spunbond process and material |
| US7008496B2 (en) | 2002-12-16 | 2006-03-07 | Kimberly-Clark Worldwide, Inc. | One-step necked-bonded laminate process and apparatus |
| JPWO2004078213A1 (en) * | 2003-03-06 | 2006-06-08 | 千佳子 錦織 | Target substance introduction composition and target substance introduction method |
| US7033453B2 (en) | 2003-11-21 | 2006-04-25 | Kimberly-Clark Worldwide, Inc. | Method for changing the orientation of the plies within a multi-ply product |
| US7740786B2 (en) | 2005-12-15 | 2010-06-22 | Kimberly-Clark Worldwide, Inc. | Process for making necked nonwoven webs having improved cross-directional uniformity |
| JP4905932B2 (en) * | 2006-07-05 | 2012-03-28 | 花王株式会社 | Elastic sheet transport method |
| CN101181832B (en) * | 2006-11-13 | 2013-07-17 | 厦门延江工贸有限公司 | Fibre synthetic plastic film and production method thereof |
| EP2078769A1 (en) * | 2008-01-11 | 2009-07-15 | Portico Ldt. | A forming head for dry forming a fibrous web |
| CN102458338B (en) * | 2009-06-26 | 2014-04-09 | Sca卫生用品公司 | Method for manufacturing pants-type diaper |
| CN103572504A (en) * | 2012-07-24 | 2014-02-12 | 南京航空航天大学 | Online mandatory layering device of centrifugal glass cotton |
| CN206510545U (en) * | 2015-09-23 | 2017-09-22 | 因特瓦产品有限责任公司 | Panel including decoration panel, console, door and the vehicle of panel and the system for forming panel |
| US10377068B2 (en) * | 2016-09-23 | 2019-08-13 | Inteva Products, Llc | Method and apparatus for non-woven trim panels |
| CN107858760B (en) * | 2017-12-25 | 2023-08-08 | 青岛祥润信息技术有限公司 | Production method and production equipment of functional fiber for clothing |
| CN113550070B (en) * | 2021-07-27 | 2023-07-04 | 杭州凯源过滤器材有限公司 | Melt-blown cloth forming device |
Family Cites Families (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS6359531A (en) * | 1986-08-29 | 1988-03-15 | 花王株式会社 | Manufacture of polyurethane laminate |
| JP2748541B2 (en) * | 1989-04-28 | 1998-05-06 | 東ソー株式会社 | Method for producing air-permeable composite sheet |
| EP0395381A3 (en) * | 1989-04-28 | 1992-04-29 | Tosoh Corporation | Production of breathing composite |
| DE4311867C2 (en) * | 1993-04-10 | 1996-10-31 | Corovin Gmbh | Multi-layer fabric and method for producing a multi-layer fabric |
| CA2148392A1 (en) * | 1994-06-06 | 1995-12-07 | Ann Louise Mccormack | Stretch-thinned film and nonwoven laminate |
| US6309736B1 (en) * | 1994-12-20 | 2001-10-30 | Kimberly-Clark Worldwide, Inc. | Low gauge films and film/nonwoven laminates |
| ZA9510604B (en) * | 1994-12-20 | 1996-07-03 | Kimberly Clark Co | Low gauge films and film/nonwoven laminates |
-
1999
- 1999-09-17 WO PCT/US1999/021500 patent/WO2000016974A2/en not_active Application Discontinuation
- 1999-09-17 KR KR1020017003545A patent/KR20010075218A/en not_active Application Discontinuation
- 1999-09-17 JP JP2000573910A patent/JP2002526297A/en active Pending
- 1999-09-17 RU RU2001111008/12A patent/RU2243301C2/en not_active IP Right Cessation
- 1999-09-17 BR BR9913896-4A patent/BR9913896A/en not_active IP Right Cessation
- 1999-09-17 AU AU63918/99A patent/AU751175B2/en not_active Ceased
- 1999-09-17 CN CNB998112100A patent/CN1146681C/en not_active Expired - Fee Related
- 1999-09-17 EP EP99951486A patent/EP1115932A2/en not_active Withdrawn
- 1999-09-17 TR TR2001/00838T patent/TR200100838T2/en unknown
- 1999-09-17 ID IDW20010644A patent/ID29844A/en unknown
- 1999-09-17 PL PL99347063A patent/PL347063A1/en not_active Application Discontinuation
Also Published As
| Publication number | Publication date |
|---|---|
| RU2243301C2 (en) | 2004-12-27 |
| EP1115932A2 (en) | 2001-07-18 |
| CN1334887A (en) | 2002-02-06 |
| PL347063A1 (en) | 2002-03-11 |
| KR20010075218A (en) | 2001-08-09 |
| ID29844A (en) | 2001-10-18 |
| AU751175B2 (en) | 2002-08-08 |
| JP2002526297A (en) | 2002-08-20 |
| BR9913896A (en) | 2001-07-03 |
| WO2000016974A2 (en) | 2000-03-30 |
| AU6391899A (en) | 2000-04-10 |
| TR200100838T2 (en) | 2001-08-21 |
| WO2000016974A3 (en) | 2000-08-24 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN1146681C (en) | Process for making laminate of unaged film and unaged nonwoven web and products produced therefrom | |
| CN1144671C (en) | Nonwoven web and film laminate with improved tear strength and method of making the same | |
| CN1082887C (en) | Laminated fabric having cross-directional elasticity | |
| CN1125851C (en) | Stretched-thinned film comprising low crystallinity polymers and laminates thereof | |
| US5498463A (en) | Polyethylene meltblown fabric with barrier properties | |
| US5964742A (en) | Nonwoven bonding patterns producing fabrics with improved strength and abrasion resistance | |
| US6179939B1 (en) | Methods of making stretched filled microporous films | |
| JP2002521241A (en) | Laminated products with barrier properties | |
| CN1212032A (en) | Fine fiber barrier fabric with improved drape and strength and method for making same | |
| CN1434767A (en) | Breathable laminate permanently conformable to the contours of a wearer | |
| JPH0320507B2 (en) | ||
| HU225724B1 (en) | High speed method of making plastic film and nonwoven laminates | |
| EP0955158B1 (en) | Laminate material, a process for manufacturing the same and use of the laminate | |
| MXPA01003011A (en) | Process for making a laminate of unaged film and an unaged nonwoven web and products produced therefrom | |
| ZA200101407B (en) | Process for making a laminate of unaged film and an unaged nonwoven web and products produced therefrom. | |
| MXPA01003274A (en) | Nonwoven web and film laminate with improved tear strength and method of making the same | |
| MXPA99006195A (en) | Stretched-thinned films comprising low crystallinity polymers and laminates thereof | |
| MXPA99005816A (en) | Lamination of breathable film using a rubber-covered anvil roll | |
| MXPA00002626A (en) | Nonwoven bonding patterns producing fabrics with improved strength and abrasion resistance |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| C06 | Publication | ||
| C10 | Entry into substantive examination | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| C14 | Grant of patent or utility model | ||
| GR01 | Patent grant | ||
| C19 | Lapse of patent right due to non-payment of the annual fee | ||
| CF01 | Termination of patent right due to non-payment of annual fee |