CN1182822C - 具备超吸收性粒子与密实区的吸收性物件 - Google Patents
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Abstract
本发明关于一种新颖的吸收性物件,特别是女用卫生物件,所述吸收性物件具有乳化聚合超吸收性粒子及至少一高度密实区。
Description
技术领域
本发明关于一种新颖的吸收性制品,特别是女用卫生制品,其具有乳化聚合超级吸收性粒子及至少一高度密实区。该制品包含一吸收性部件,该吸收性部件包含纤维素纤维与具备大致圆边表面的超吸收性聚合物粒子的组合以及一连续薄膜阻挡层。该制品更具有至少一密实区,该密实区的密度至少为每立方公分0.5克(0.5g/cc),以在该制品使用时作为稳定该部件之用。
背景技术
吸收性制品如卫生棉或女用卫生制品通常具有一吸收性部件,该吸收性部件具有一面体(面向身体的第二)表面及一不透液体的面衣(面向衣物的第一)表面。该面体表面适于将体液接收入该吸收性部件内,而该面衣表面对体液而言为一屏障,以防液体沾染使用者衣物。此等吸收性部件传统地系以容易取得且较便宜的纤维素吸收性材料,如棉纤维、短纤木浆、纤维素组织或填絮、或其他吸收性纤维制成。此等材料在吸收率和整体吸收能力方面提供令人满意的液体吸收能力。不幸的是,由此等纤维素吸收性材料制成的吸收性部件在沾湿时可能会萎陷,从而丧失其部分空隙容积。此外,此种一般称为湿陷(wetcollapse)的情形经常会导致吸收性部件隆起、皱缩、及裂开等,更会降低吸收能力及使用者使用时的舒适感。此等结构亦可能让被吸收的液体又被挤出该结构外,回到该吸收性制品使用者的皮肤或衣物上。此种挤出现象亦对使用者皮肤造成潮湿的不适感。
过去已利用多种方式协助减轻因纤维素吸收性结构湿陷所造成的问题。此等方法中包括如美国第4,654,040号专利所述将该制品预先造型为更接近使用者会阴区轮廓的形状的方法;如美国第3,060,936号专利所述添加弹性材料的方法以及如美国第4,217,901号专利所述形成一密实层的方法。
近来已利用超吸收性聚合物粒子与多数传统吸收性材料组合,以提供具备增强吸收能力及留置能力的吸收性结构。所述方法可协助解决挤出及潮湿表面触感不佳的问题。但,超吸收性聚合物粒子有一缺点是其价格较多数传统吸收性材料昂贵。此外,由于超吸收性聚合物粒子在吸收液体时会膨胀,因此其在吸收性结构内的位置必须考虑到此膨胀效果,以尽可能利用其吸收能力。
虽然对纤维素吸收性结构添加超吸收性聚合物粒子可增强该结构的吸收能力,但仅添加超吸收性添加物对该纤维素结构的稳定性而言,并不比无超吸收性聚合体粒子的纤维素结构好。因此,含有具有高吸收性粒子的纤维素吸收性结构的吸收性产品必须经过处理或作其他处置,以协助减轻纤维素纤维潮湿所造成的问题。一种适于协助避免潮湿的方法为在该吸收性结构内形成密实的稳定区域。不幸的是,在由含有超吸收性粒子的吸收性部件制成的制品内形成密实稳定区可能损及该制品的不透液体的面衣表面。因为压实作业倾向于将该等超吸收性粒子压抵该不透液体的薄膜阻挡层,从而在该薄膜表面内形成小孔或小洞,此等孔一般称为针孔(pinhole)。出现小孔并非理想,因为其会让液体通过并损害到该制品面衣表面的不透液体的本质。
上述在不透液体的表面内因超吸收性粒子而形成针孔问题的解决方式之一为,在该含超吸收性粒子的吸收性部件压实之后方才加上该不透液体的表面作为独立层(separale layer)。不幸的是,在压实之后对吸收性部件添加不透液体的层,使该不透液体的层与该吸收性部件间的配合度非常差。此等不良配合度可能危及压实作业所要克服的稳定度问题。
对针孔问题之另一种解决方式涉及使用已添加如甘油或少量的水的增塑剂的超吸收性粒子,添加增塑剂或水之目的为使粒子略为软化并让粒子更为柔软而不降低其吸收能力。粒子软化便利压实作业能在不透水性阻挡层就定位的情况下进行,而不在该阻挡层上产生针孔。软化粒子在压实压力下能够适应变形,因此不会如干粒子般挤穿不透水性阻挡层。但,软化粒子可能使搬运或加工处理产生困难,因为其可能不会如较干粉末般流动。
因此,在此需要一种吸收性制品,其具备一连续的不透液体的层及一含超吸收性聚合体粒子的吸收性部件,且所述制品具有密实稳定区。
发明内容
本发明目的之一为提出一种吸收性制品及其制造方法,其具备一含超吸收性粒子的吸收性部件且具有密实稳定区,且其具备一连续、完整的不透液体的层,该层没有破洞或仅有极少破洞。此目的因该吸收性部件内具备大致圆边表面的如乳化聚合超吸收性聚合体粒子的超吸收性聚合体粒子,以及随后对该吸收性部件的某些区域作压实以形成密实稳定区而达成。该等密实稳定区必须压实至该制品受使用或变湿时并不丧失其稳定性的程度。该等压实稳定区的期望密度为至少每立方公分0.5克。该等超吸收性聚合体粒子的湿度低于15%重量百分比。所述超吸收性聚合物粒子包含乳化聚合超吸收性聚合物粒子。
附图说明
图1为一本发明吸收性制品的较佳实施例的平面图,该吸收性制品为女用卫生制品。
图2为沿图1中线II-II取得的部面图。
图3a至3e为典型圆粒子及团聚形态的实例。
图4a至4e为典型锯齿状粒子形态的实例。
图1显示依据本发明、女性卫生用的吸收性制品。制品1由一大致矩形吸收性结构2叠加于一连续薄膜阻挡层4上构成。该制品具有密实稳定区,该等区域为沿着该制品侧边及末端的密实沟槽5、6、7和8。如图2所示,吸收性结构2包含纤维素纤维12与大致圆边表面的超吸收性聚合体粒子14的组合。
具体实施方式
在使用时抵住使用者身体的该制品表面可由一层可透体液的材料构成,该层一般称为覆盖层或表层。该覆盖层可由对皮肤产生舒适触感且许可流体穿透至下层吸收性结构的任意一种可透液材料构成,其中该下层吸收性结构吸收并留置该流体。通常,该覆盖层在其结构内仅能留住少量或根本无法保持住该流体,以提供与皮肤邻接的较干爽表面。该可透液的覆盖层可为由如聚乙烯、聚丙烯、聚酯等的聚合物或者纤维素的纤维或长丝制成的纤维非织物(不织布)。或者,该覆盖层可由一穿孔的聚合物膜制成。该覆盖层的厚度可为0.0254~1.5748mm(0.001至0.062英寸),视所选用材料而定。
该制品在使用时背依使用者而贴靠住使用者内衣的表面包含一层不透体液的材料,该层一般称为阻挡层。此不透液阻挡层包含任意薄的挠曲性的不透体液材料,如聚合物膜(例如聚乙烯、聚丙烯、聚酯、聚胺酯,或赛璐玢)。此等聚合物膜阻挡层的厚度通常仅为约0.0254-0.0508mm(0.001至0.002英寸)。
该制品的吸收性结构包含超吸收性聚合体粒子与纤维素纤维的组合。此等纤维素纤维举例来说可为木浆、再生纤维素纤维、人造纤维、泥煤苔绒纤维(peat mossfigers,泥炭纤维之一种)、或是棉纤维该等纤维素纤维最好是随意且松散地结合(例如空气沉降式结构),或者可结合在一起成方向性结构(例如粗梳织物)。另一种选择,该等纤维素纤维可经湿置形成较低密度结构,该结构的一部份能够压实至至少每立方公分0.5克密度。此外,其他吸收性或非吸收性材料可添加至该吸收性结构内。此等其他材料举例来说包括合成弹性纤维、粘合用纤维、气味控制纤维或粒子、香水、合成粘合剂如乙烯醛酸乙烯酯和聚乙烯醇等。
该等纤维素纤维与超吸收性聚合体粒子组合以形成该制品的吸收性结构,该等超吸收性聚合体粒子包含小圆粒或微小边粒子的团聚物。在任一情况中,该等超吸收性粒子的表面均大致为圆边。文中所用“大致圆边(substaintiallyrounded)”一辞意指粒子的表面整体上没有尖突(锯齿)状、锐角状或尖头边缘。图3a至3e显示典型圆粒子及团聚形态的实例。较理想的是,具备大致圆边表面的粒子为乳化聚合超吸收性聚合体粒子。在任一情况中,本发明所用超吸收性聚合体粒子具有整体上为圆边的断面形状及表面。基本上没有锐角状、锯齿状或尖头边缘。适用的乳化聚合超吸收性聚合体粒子为日本大阪住友Seiks化学制品公司所生产的Sumitomo SA60NTM和Sumitomo J550TM。相反地,溶液聚合超吸收性粒子一般在其表面上会具有尖突(锯齿)状、起伏状或尖锐边缘。典型锯齿状粒子形态的实例会于图4a至4e中。关于乳化聚合作用法及溶液聚合作用法的更详细说明参见Brandt等人所有的美国Re.32,649号专利,该专利在此参照引用。
上述纤维和粒子可用数种方式中的任一种组合。这些粒子可在该吸收性结构内与所述纤维大致均匀混合。或者,该等粒子可出现在该吸收性制品内之一不同区域内。
在某些情况中,可能希望将该等超吸收性粒子定位在该吸收性结构内之一指定的不同区域内。该等区域的边界可位于该结构的x-y平面内或z方向。举例来说,该等超吸收性粒子可如图2所示集中在该结构厚度的上部。依此方式将超吸收性粒子集中在结构厚度上部的内能更有助于避免形成针孔。另一种方式,该等超吸收性粒子可遍及该结构的厚度,但聚集在流体将进入的结构的中央部分内,留下结构末端大致没有超吸收性粒子。此外,该等超吸收性粒子也可同时集中在结构厚度之上部以及仅在结构中央部分之内,留下结构末端大致没有超吸收性粒子。形成此等超吸收性粒子区域性分布的方法提示于美国第5,004,579号专利、5,213,817号、5,350,817号及5,614,147号专利,以上专利在此参照引用。
如图所示,吸收性结构2系包容在该制品的表层或覆盖层10与阻挡层4之间。覆盖层10和阻挡层4最好伸出该吸收性结构边缘16之外,以形成覆盖层周缘延伸部18及阻挡层延伸部20。覆盖层周缘延伸部18及阻挡层延伸部20相互接合,以围绕该制品的外侧边缘形成一凸缘密封22。该凸缘密封可由任意已知密封方式构成,举例来说包括热密封、超声波熔接、粘接密封、或是机械式密封。虽然本发明的较佳制品具备一凸缘密封,但密封该制品的边缘的方法并非本发明所重。该制品的边缘亦可藉由下述方式密封:包覆所述覆盖层或屏障层之边缘,或包覆该二层的边缘。
本发明制品之一重要特征为具有至少一密实区,该密实区的密度至少为每立方公分0.5克。如图所示,该至少一密实区最好是采取沟槽5、6、7和8中的至少一种形式,该沟槽系由滚花模压或压入该制品内,使自沟槽最密实部分的底部24测量所得的密度至少约为每立方公分0.5克。较佳地,该密度为约每立方公分0.5克至约每立方公分1.3克。密度小于每立方公分0.5克的密实区在使用时不能维持必要稳定性,因为在该制品一般使用状态下受到汗水及人体排放体液所产生的湿气时,在该沟槽密实部分内的材料可能“弹回”或“复原”。然而,当密实区系作成密度至少每立方公分0.5克时,其在使用时纤维其密度,大幅提高该制品使用时的稳定性,且在该制品变湿且受到一般使用的压力时有助于避免扭绞和隆起。
上述密实区为在至少该阻挡层贴住一吸收结构表面时压入或滚花压入该制品内。在压实作业中让该阻挡层抵住该吸收结构有数项好处。在压实作业中存在着该阻挡层有助于在压实过程中维持该吸收性结构的整体性;能够形成均匀密实区;且提高该吸收性制品的整体稳定度。较佳地,在产生至少一密实区时该覆盖层亦抵住该吸收性结构的面体表面;但这并不是必须的。
上述压实作业基本上将该吸收性结构的区域由未压缩密度的每立方公分0.1至0.5克压缩至少每立方公分0.5克;且最好压缩至至少每立方公分0.9克。所述密实区可采用任意图案。在图1所示的本发明较佳实施例中,密实区呈现两纵向弧线5和6及横向弧线7和8。纵向弧线5和6大体上沿该制品的纵向侧边26延伸,且方向为大体上向内互朝对方弯曲。横向弧线7和8大体上横跨该制品的末端28并延伸,且其方向为大体上向外相互背离弯曲。每一弧形密实区通常在其底部最密实部分的宽度为约小于6.35mm(0.25英寸)。该等纵向延伸弧线的长度大体上为约25毫米至约100毫米,且该等横向延伸弧线的长度大体上为约25毫米至约75毫米。
上述密实区可藉由任意已知压实方式如滚花压制或辊压法形成。在升高的温度下进行压实作业有助于形成密实区。形成本发明密实区之一较佳方法包括:使该吸收性制品自一加热滚花压辊及一支承辊间通过。该压花辊子具有与该等密实区期望图案相处的凸起部分。该支承辊子具有一平滑表面。此二辊间设以一预定间隔,藉以在该压花辊子凸起部分与该支承辊子间产生一间隙。该间隙大小视未压实吸收性制品的厚度而定,且经设定为能使一吸收性制品自此二辊子间通过后会产生密度至少为每立方公分0.5克的密实区。
依据本发明之一个重要方面,具大致边表面的超吸收性粒子系用在吸收性结构内,以使在密实区下方的薄膜层内形成的针孔减至最少。分别以实验测试具备乳化聚合超吸收性粒子、具备溶液聚合超吸收性粒子、及不具备超吸收性粒子(对照组)的吸收性结构试样以判定在薄膜阻挡层内到底形成多少针孔。每一试样系由0.5克超吸收性粒子和5.5克木浆料混合制成的大致矩形吸收性结构且包容在0.0254mm(1密尔,mil)厚聚乙烯和一包含聚内丙烯短纤维的非织造覆盖层间。该薄膜为维吉尼亚州Newport News的Edison Plastics Company所贩售的XP1123。该非织造覆盖层为俄亥俄州辛辛那提市Stearns所购售的T1046。每一类型有五十个试样通过一支承辊和一压花辊之间以形成与图1所示图案相关的密实区。支承辊与压花辊上凸起部分间之间隙设定为0.2286/0.3556mm(9/14密尔)。每一类型的五十个试样上的总针孔色斑数量依据下文所述的针孔色斑测试(PinholeStain Tcst)判定。
该针孔色斑测试的进行方式为将一吸收性制品的定位剂加诸于一层洗过的Alpha Mills白棉布上,该白棉布的大小足以完全覆盖密实区及定位粘结剂。然后经由每一制品的面体表面或覆盖表面对每一密实区施加2.5立方公分的红色塑料溶液。该红色颜料溶液以8.58升(5.0加仑)的水与亚利桑那州Tempe市Pylam公司生产的Calico Scarlet 2 RB红色粉末50克混合而成。一压辊装置由两加重辊子安装在一轴上组成,其总重量为4.53Kg(10磅)重,以该压辊装置在制品上滚过一次,使一辊子覆盖每一纵向密实区。然后以该装置再滚过制品一次,使一辊子覆盖每一横向密实区。然后查看该白棉布是否有因该红色颜料溶液透过该阻挡层而产生的任何色斑。该布料内的色斑即代表有针孔。
表一列出实验结果。
表 1
超吸收性粒子 | 粒子大小 | 聚合方法 | 粒子表面 | 针孔色斑数 |
Chemdal L2100a | 0.25mm | 溶液 | 锯齿状 | 48 |
Sumitomo SA60N | 0.26mm | 乳化 | 圆边 | 10 |
J550 | 0.15mm | 乳化 | 圆边 | 0 |
无超吸收性粒子 | ---- | ---- | ---- | 0 |
如表一所示,以给定大小且具备大致圆边表面的超吸收性粒子作成的制品所呈现针孔数比以同大小的溶液聚合超吸收性粒子制成的制品少。此外,以具备大致圆边表面、且粒子较小的超吸收性粒子制成的制品没有针孔色斑,其针孔色斑与无超吸收性粒子的制品相当。
以上说明及实施例系用以协助对本发明有完整且广泛的了解。由于本发明能够不脱离其精神及范围作出许多改变及实施例,因此本发明存在于后附的权利要求书范围中。
Claims (8)
1.一种女性卫生用吸收性制品,该制品包括:纤维素纤维和具备大致圆边表面的超吸收性聚合物粒子,及一连续薄膜阻挡层;该制品更包括至少一密实区,该密实区的密度至少为每立方公分0.5克,其特征在于,
所述超吸收性聚合物粒子包含乳化聚合超吸收性聚合物粒子。
2.如权利要求1所述的吸收性制品,其特征在于,所述至少一密实区的密度至少为每立方公分0.9克。
3.如权利要求1所述的吸收性制品,其特征在于,所述至少一密实区包含具大致圆边表面的超吸收性聚合物粒子。
4.如权利要求1所述的吸收性制品,其特征在于,所述至少一密实区包含两压缩侧边沟槽。
5.如权利要求1所述的吸收性制品,其特征在于,所述制品包含其面向衣物侧的第一表面和面向人体侧的第二表面,此二表面以一厚度隔开,其中该具备大致圆边表面的超吸收性聚合物粒子位于该厚度以内较接近该第一表面的部分内。
6.一种制造吸收性制品的方法,该吸收性制品用以放置在人类会阴区内用以吸收体液,所述方法包含:
提供一吸收性结构,该吸收性结构包含纤维素纤维与具备大致圆边表面的超吸收性聚合物粒子的组合,该结构具有面向衣物侧的第一表面,面向人体侧的第二表面,且其密度小于每立方公分0.5克;
提供一阻挡层,该阻挡层包含一层不透液体的薄膜;
将该阻挡层贴靠在该吸收性结构第二表面放置;及
压实该吸收性结构第一表面的一部分以形成密度至少约为每立方公分0.5克之一密实区,所述超吸收性聚合物粒子包含乳化聚合超吸收性聚合物粒子。
7.如权利要求6所述的方法,其特征在于,第一表面经压实,以形成密度至少约为每立方公分0.9克之一密实区。
8.如权利要求6所述的方法,其特征在于,所述纤维素纤维与超吸收性聚合物粒子的组合为纤维素纤维与超吸收性聚合的均匀混合物。
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- 1999-12-20 AU AU65342/99A patent/AU771295B2/en not_active Ceased
- 1999-12-21 CA CA002292802A patent/CA2292802C/en not_active Expired - Lifetime
- 1999-12-22 RU RU99127339/15A patent/RU2236259C2/ru not_active IP Right Cessation
- 1999-12-22 AR ARP990106691A patent/AR025147A1/es active IP Right Grant
- 1999-12-22 ZA ZA9907830A patent/ZA997830B/xx unknown
- 1999-12-22 BR BR9907507-5A patent/BR9907507A/pt not_active IP Right Cessation
- 1999-12-23 EP EP99125809A patent/EP1013252B1/en not_active Revoked
- 1999-12-23 CN CNB991245881A patent/CN1182822C/zh not_active Expired - Fee Related
- 1999-12-23 DE DE69934959T patent/DE69934959T2/de not_active Expired - Lifetime
-
2000
- 2000-01-21 TW TW88122693A patent/TW572751B/zh not_active IP Right Cessation
Also Published As
Publication number | Publication date |
---|---|
HUP9904656A3 (en) | 2000-09-28 |
DE69934959D1 (de) | 2007-03-15 |
AU6534299A (en) | 2000-06-29 |
EP1013252A1 (en) | 2000-06-28 |
CN1257697A (zh) | 2000-06-28 |
EP1013252B1 (en) | 2007-01-24 |
HU9904656D0 (en) | 2000-03-28 |
DE69934959T2 (de) | 2007-11-29 |
TW572751B (en) | 2004-01-21 |
HU221691B1 (hu) | 2002-12-28 |
AU771295B2 (en) | 2004-03-18 |
CA2292802C (en) | 2008-10-07 |
RU2236259C2 (ru) | 2004-09-20 |
CA2292802A1 (en) | 2000-06-23 |
HUP9904656A2 (hu) | 2000-08-28 |
AR025147A1 (es) | 2002-11-13 |
BR9907507A (pt) | 2001-08-21 |
ZA997830B (en) | 2001-06-22 |
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