CN1205025C - 三维高弹性膜/非织造织物复合物 - Google Patents

三维高弹性膜/非织造织物复合物 Download PDF

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CN1205025C
CN1205025C CNB018096603A CN01809660A CN1205025C CN 1205025 C CN1205025 C CN 1205025C CN B018096603 A CNB018096603 A CN B018096603A CN 01809660 A CN01809660 A CN 01809660A CN 1205025 C CN1205025 C CN 1205025C
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woven
fibrage
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film
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CN1429149A (zh
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J·A·米德尔斯沃斯
J·W·克里
S·D·布鲁斯
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Feiteshi Film Products Co ltd
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Abstract

本发明公开了一种三维高弹性膜/非织造织物的复合物(10)，它有不透液体和空气芯层(16)和第一与第二固结层(12、14)。该固结层(12、14)有单向和非单向纤维。该复合物(10)通过在两层固结的非织造织物(12、14)之间叠加不透液体和空气的弹性芯层(16)形成。由于固结非织造织物材料的单向性能，所形成的复合物(10)仅沿横向拉伸。然后，将所述层点粘合或焊接起来。所述层优选这样焊接，将复合物通过超声波角状物与超声波粘合辊之间，该粘合辊具有凸起区，用于产生焊接点。在每个焊接点处形成一层非弹性薄膜。然后，可以预拉伸该焊接的复合物(10)，使膜破裂，由此形成孔，这样使复合物透气。

Description

三维高弹性膜/非织造织物复合物
发明的领域
本发明总的来说涉及膜/非织造织物复合物，更具体地，本发明涉及点粘合的高弹性膜/非织造织物复合物，它通过拉伸复合物使非弹性膜破裂来制成制造后可透气，所述非弹性膜由用来点粘合复合物的焊接点形成于复合物上。
发明的背景
在消费者的一次性用品市场上，有改进尿布制品等的贴合性和舒适性的需求。作为可满足该需求的制品，具有高伸长率、高弹性回复性、透气性和耐撕性的叠层物一直是所寻求的目标。
过去，用来在非织造织物叠层物内达到高拉伸的技术经常损害非织造织物的纤维或其结合，由此降低叠层物的强度，尤其是拉伸强度。另外，现有技术制成的叠层物经常缺乏足够的弹性回复性，不能在所要求的应用中起最佳的作用。
这些叠层物的透气性一般由膜叠层到非织造织物上之前使膜形成孔来产生。膜叠层到非织造织物上通常采用粘合剂来实现。这些粘合剂会堵塞叠层物内的洞或孔，由此会降低所要求的透气性。
透气性也可以通过其他成孔方法使膜形成孔来产生，例如膜叠层到非织造织物上后使膜形成孔。但是，这些成孔方法会在整个叠层物上形成各种薄弱点。所述薄弱点经常变成撕裂的起始点。
在现有技术中，要制成具有所要求性能的叠层物，经常必须经过许多烦琐和昂贵的加工步骤。
因此，就需求开发一种这样的叠层物及其制造方法，该叠层物具有高弹性和高弹性回复性，可用于一次性制品市场。另外，也最好开发一种这样的叠层物及其制造方法，该叠层物没有在现有技术叠层物中形成的撕裂起始点。还需求制造一种这样的叠层物，它在叠层物的预定拉伸伸长时具有较高的抗撕裂性。最后，需要减少制备叠层物所需的步骤的数目，同时又可保持上述性能。
发明的概述
本发明提供一种改进的膜/非织造织物复合物，它仅沿横向拉伸，并具有不透液体和空气的性能。
本发明所提供的一种三维的高弹性膜/非织造织物复合物包含：
一层具有第一面和第二面的不透液体和空气的膜芯层；
通过许多焊接点点粘合到所述芯层的第一面的第一非织造的纤维层；
通过许多焊接点点粘合到所述芯层的第二面的第二非织造的纤维层；
其中所述的焊接点基本无弹性，当所述复合物沿横向拉伸至伸长率为200％或更小时，焊接点破裂形成孔。
本发明一个实施方式中的膜/非织造织物复合物包含两层叠压到芯层上的固结层。所述固结层包含单向和非单向纤维。单向和非单向纤维在复合物上提供可拉伸和不可拉伸的区域。
复合物各层在非连续点处焊接起来。在一个实施方式中，使用超声波角状物焊接复合物。焊接后，复合物上形成下述明显的区域：非焊接区、粘合区和膜区。非焊接区是焊接点周围的复合物区域。形成实际粘合的焊接点是在焊接步骤中被应力和热/熔融能量移位的合并的聚合物团块。膜区域是施加热/熔融能量后保留下来的很薄的不渗透聚合物材料膜。
复合物形成后，复合物的一部分区域具有高弹性。最终的使用者可以拉伸该复合物，撕裂膜区域内的膜，并赋予膜透气性。固结层内纤维的纵向断裂拉伸力与横向断裂拉伸力之比约为1.8∶1。
附图的简要说明
图1是焊接步骤之前本发明的膜/非织造织物复合物的剖面图；
图2是焊接步骤之后图1所示的膜/非织造织物复合物的俯视图；
图3是图1和2所示的复合物经过焊接步骤后沿图2所示的线3-3剖开的剖面图；
图4是图1和3所示的膜/非织造织物复合物经过焊接步骤的视图；
图5是表明固结和非固结的膜/非织造织物复合物的拉伸力与伸长率的关系图；
图6是表明固结和非固结的复合物的拉伸力与产生的洞(孔)的数量的关系图；
发明的详细说明
参照图1，该图显示了三维高弹性膜/非织造织物复合物10，它具有高伸长率和低弹性模量。该复合物10包括第一固结片12、第二固结片14和不渗透膜芯层16。固结片由纺粘纤维18构成(图2)。纺粘纤维18可以是非织造的双组分纤维或共混纤维。如果纺粘纤维18是双组分纤维，那么纤维18的组分优选具有两个明显的熔点。同样，如果片12和14包含共混纤维，那么优选的是共混纤维具有两个明显的熔点。纺粘纤维18的重量优选约为15-30gsm。膜芯层16可以是不同材料，但是所述材料必须不透液体和空气。在一个实施方式中，芯层16可以包含多层膜。也可以使用另一种弹性膜作为芯层16，例如单层弹性体或泡沫材料层，但是这样的膜必须包含不透液体和空气的材料。
在另一个实施方式中，芯层16是高弹性配混料，例如包含至少一种或多种嵌段共聚物的配混料，所述嵌段共聚物带有氢化二烯，类型为A-B-A或A-B-A′。通常，这样的配混料在单独挤出为单层时，拉伸100％以上，表现出较好的弹性回复性或低永久变形。苯乙烯/异戊二烯、丁二烯或乙烯-丁烯/苯乙烯(SIS、SBS或SEBS)嵌段共聚物尤其有用。其他有用的的用作芯层16的弹性组合物可以包括弹性聚氨酯、乙烯共聚物例如乙烯一乙酸乙烯酯、乙烯/丙烯共聚物弹性体或乙烯/丙烯/二烯三元共聚物弹性体。这些聚合物或它们与其他改性的弹性或非弹性材料的共混物也可以用于本发明中。在某些优选的实施方式中，所述弹性材料可以包含高性能弹性材料例如SEBS、SBS、SIS或购自壳化学品公司的KratonTM弹性树脂，它是弹性嵌段共聚物。
为了形成膜/非织造织物复合物10，根据美国专利№ Re35206(Hassenboehler，Jr.等，其内容参考引用于此)的启示，纺粘纤维18的第一和第二片在烘箱内取向或其他加热设备内取向。该加工结果形成第一固结片12和第二固结片14。各根纤维18紧密地装在片12和14上，仅沿横向拉伸(即各向异性纤维)。在固结片12、14之间封入芯层16就形成了弹性膜/非织造织物复合物10(图1)。
使用组合的力和热/熔融能量例如超声波焊接或热接触焊接，在不连续的焊接点20处将所述三层12、14、16组合起来，形成焊接的膜/非织造织物复合物21。(如图2和3所示)。在如图2和3所示的一个优选实施方式中，使用超声波焊接来形成焊接点20，所述焊接点将固结层12、14和不渗透膜芯层16结合起来。所述焊接点20占膜/非织造织物复合物21的总表面积的约2-10％。发现，直径约为0.75mm并沿横向以约3.5mm的中心线-中心线间距而间隔的焊接点20是符合要求的。超声波焊接是形成焊接点20的优选方法。也可以使用其他合适的方法，包括热接触焊接和点焊接，来形成焊接点20。从图3中可很好地看出，施加焊接点20的结果是形成材料的焊接膜22和粘合区24。焊接膜22是很薄的不渗透聚合物膜，它在施加焊接点后保留下来。所述膜22基本无弹性。焊接后，第一和第二固结片12和14和不渗透膜芯层16包含三个区域。非焊接区26是粘合区24周围的复合物21的区域。形成实际粘合的粘合区24包含在施加焊接点步骤中被力和热/熔融能量移位的合并的聚合物团块25。下面更详细地描述了形成膜的方法。
焊接的弹性膜/非织造织物复合物21的透气性由膜22的撕裂产生。膜22在复合物21受拉伸时撕裂。在拉伸期间，膜22由于无弹性会被撕裂。沿横向拉伸约50-200％，就可以使膜/非织造织物复合物21具有透气性。例如，当拉伸50％时，复合物21的2.54厘米(1英寸)样品变成至少长3.81厘米(1.5英寸)。尽管复合物21受到拉伸和膜22撕裂，但是膜/非织造织物复合物21仍可提供足够的抵抗力，尤其对使复合物21伸长约200％以上的力具有抵抗力，以避免膜/非织造织物复合物21的撕裂。膜/非织造织物复合物21可以在使用期间拉伸，例如在消费者或使用者拉伸最终产物时拉伸，或在使用之前在制造地点采用本行业内的已知技术拉伸。这些方法包括使用拉幅机、弓形杆或交指型辊，例如授予Schwarz的美国专利№4368565所述，其内容参考引用于此。
下面参照图4，该图显示出弹性膜/非织造织物复合物10经历了形成焊接点20的焊接工序。焊接点20将固结片12、14点粘合或焊接至不渗透的膜芯层16上，形成焊接的弹性膜/非织造织物复合物卷材21。为了实现超声波焊接，将弹性膜/非织造织物复合物卷材10通过超声波角状物30与超声波粘合辊32之间。超声波粘合辊32具有许多凸起区域34。在超声波焊接期间，最接近超声波粘合辊32的凸起区域34的固结层12、14的物质变成熔融态，并离开超声波角状物30向外流成焊接点20。保留的薄层材料形成膜22，它被合并的团块25包围(图3)。膜22在焊接后保持不渗透液体或空气。膜22的位置对应于粘合辊32的各个凸起区域34，为超声波粘合提供焊接点。凸起区域34不完全穿透膜/非织造织物复合物10，但是用作从超声波角物30发出的能量力的主通道。没有凸起区域34，角状物30提供的穿过弹性膜/非织造织物复合物卷材10的力会是均匀的。结果，凸起区域34就在焊接的膜/非织造织物复合物21上形成图案。
所形成的焊接的膜/非织造织物复合物21在横向上具有高弹性，所述横向是复合物10和所形成的焊接的复合物21在如图4所示的焊接工艺中运行方向的横向。焊接的复合物21在纵向上抗拉伸，所述纵向是复合物10和所形成的焊接的复合物21在焊接工艺中运行方向平行的方向。焊接的膜/非织造复合物21的最终重量约为40～150gsm。
在本发明的焊接工艺之后，拉伸复合物21使膜22破裂，在膜/非织造复合物21中形成孔，并使复合物21回复到其起始长度。
试验
建立了下述试验，来说明所形成的透气性对各种叠层物性能的影响。所述试验有三个步骤：
1.形成叠层物步骤；
2.叠层物激活步骤；
3.叠层物性能的量化步骤。
形成叠层物的步骤包括形成三个叠层物样品：样品A、样品B和样品C。样品A由弹性膜组成，弹性膜由超声波粘合，并在膜的两面上使用Softspan非织造织物。样品B由超声波粘合的弹性膜组成，两面上用两层与样品A相同的Softspan非织造织物覆盖。另外，每层Softspan非织造织物层在结合到膜的每面上之前都以2∶1缩幅比固结。样品C与样品B相同，除了每层Softspan非织造织物层在结合到膜的每面上之前都以3∶1缩幅比固结。
在叠层物激活或形成孔的步骤中，通过将样品拉伸至不同的程度并使它们回复到起始长度，而在样品A、B和C内形成孔。在该试验中，叠层物是用手拉伸的。具体地说，在每个样品上作出2.54厘米(1英寸)的标记，将材料拉伸至预定的伸长。接着，将材料拉伸不同的拉伸量，记录下拉伸至每种拉伸量所需的力。
下表1和图5比较了样品A、B、C在预拉伸至100％后的拉伸性能。数据说明固结的样品B、C比非固结的样品A获得了额外的100％伸长率。固结样品B、C需要较小的力进行拉伸，尤其在拉伸60％后。拉伸非固结样品B、C的拉伸力较高暗示了实际纤维18发生了变形而不是拉伸。所述数据支持了这样的假定，即较大的变形引起固结片的拉伸基质发生不可逆破坏。另外，固结样品B和C与非固结样品A相比，获得较大的伸长率就使样品更容易，即需要更小的力来拉伸复合物。
                                       表1
                       样品
        A       B      C
非织造织物   SoftspanTM   SoftspanTM   SoftspanTM
缩幅比(起始/最终宽度)   1∶1   2∶1   3∶1
速度比(最终/起始)   1.00   1.38   1.75
温度(℃)   室温   127(260F)   127(260F)
宽度(厘米)   89.218(35.125in)   76.518(30.125in)   59.198(22.125in)
单位重量(g/m2)   118.4   133.5   142.1
横向10％(g/cm)   14(35g/in)   12(30g/in)   15(39g/in)
横向25％(g/cm)   309(784g/in)   83(210g/in)   82(209g/in)
横向50％(g/cm)   452(1147g/in)   118(300g/in)   104(264g/in)
横向100％(g/cm)   556(1412g/in)   169(430g/in)   121(308g/in)
横向最终力(g/cm)   902(2290g/in)   908(2306g/in)   981(2491g/in)
横向最终伸长率(％)   277   441   500
在叠层物性能的量化步骤中，材料被预拉伸后，在预定面积上数样品A、B和C上孔的数量。接着，测试样品沿横向的拉伸力，和最终的断裂伸长率。
下面参照图6，该图显示了拉伸力与产生的孔的数量之间的关系。在试验中，拉伸焊接的膜/非织造织物复合物21的样品A、B和C至产生孔，或进行预拉伸。接着，在样品面积上数每个样品A、B和C上的孔，确定膜22(图3)的破裂百分率。另外，测试将膜/非织造织物复合物21沿横向拉伸至100％伸长率时的拉伸力。
参照图6，可以看出，在非固结的膜/非织造织物样品A中，一旦孔达到48％，整个样品A的整体性就开始遭到破坏。另外，即使固结样品B和C拉伸至膜22全部破裂，即产生100％孔，100％时的模量性能也没有损坏或变化。
图6的数据支持了这样的结论，即对于固结的膜/非织造织物复合物(样品B和C)，膜/非织造织物复合物内可以形成很高百分率的孔，而不会损坏纤维18的网状结构或损坏膜/非织造织物复合物的整体性。这对于材料例如样品A损坏之前可能在非固结材料内形成的孔的百分率是很大的改进。此外，固结的膜/非织造织物样品B和C的性能明显比过去已经制出并被拉伸变成可透气的其他叠层物或织物好。
本行业内的普通技术人员会明白，可以根据应用来调节本发明所述的各种参数，包括改变非织造织物层12、14的重量，层12、14的固结比例，和对用作弹性膜/非织造织物复合物卷材的不渗透膜芯层16的选择。
本发明的关键是可透气和可渗透固结膜/非织造织物复合物，它通过在两层固结的非织造织物之间叠压不透液体和空气的弹性层，并形成可渗透空气或液体的薄结构体而形成，所述薄结构体具有明显的弹性和选择出的可透气的区域，而不需采用一种工艺或设备使膜内形成孔。所形成的复合物便于通过拉伸复合物从给定数量的焊接点形成高百分率的孔，而不会损坏该复合物的结构。另外，本发明的方法可以在不使用过多热或熔融能量力的情形下实施，使用过多的热或熔融能量力会损坏压花辊的销钉或凸起区域。此外，由于固结的非织造织物材料的单向性能，所形成的复合物仅沿横向拉伸。
虽然仅描述了本发明的几种实施方式，但是本发明也可以应用到许多其他的应用领域。本行业内的普通技术人员会明白，不脱离本发明的精神和范围，可以对本发明进行各种改变和改进，所附权利要求书覆盖所述所有的改变和改进。所有这样的改进都位于本发明的范围内。

Claims (30)

1.一种三维的高弹性膜/非织造织物复合物，它包含：
一层具有第一面和第二面的不透液体和空气的膜芯层；
通过许多焊接点点粘合到所述芯层的第一面的第一非织造的纤维层；
通过许多焊接点点粘合到所述芯层的第二面的第二非织造的纤维层；
其中所述的焊接点基本无弹性，当所述复合物沿横向拉伸至伸长率为200％或更小时，焊接点破裂形成孔。
2.如权利要求1所述的三维高弹性膜/非织造织物复合物，其特征在于所述的芯层包含选自弹性膜、泡沫材料和多层膜的材料。
3.如权利要求1所述的三维高弹性膜/非织造织物复合物，其特征在于所述的第一非织造的纤维层和第二非织造的纤维层包含双组分纤维，所述双组分纤维具有两个清楚的熔点。
4.如权利要求1所述的三维高弹性膜/非织造织物复合物，其特征在于所述的第一非织造的纤维层和第二非织造的纤维层包含共混纤维，所述共混纤维具有两个清楚的熔点。
5.如权利要求1所述的三维高弹性膜/非织造织物复合物，其特征在于所述的第一非织造的纤维层和第二非织造的纤维层包含单向和非单向纤维；
所述第一非织造的纤维层包含各向异性纤维。
6.如权利要求1所述的三维高弹性膜/非织造织物复合物，其特征在于所述的第一非织造的纤维层和第二非织造的纤维层包含单向和非单向纤维；
所述第二非织造的纤维层包含各向异性纤维。
7.如权利要求1所述的三维高弹性膜/非织造织物复合物，其特征在于所述焊接点占膜/非织造织物复合物总表面积的2-10％。
8.如权利要求1所述的三维高弹性膜/非织造织物复合物，它还包含：
形成在所述焊接点内的膜，当复合物沿横向拉伸至伸长率大于50％时，所述膜破裂，形成孔。
9.如权利要求1所述的三维高弹性膜/非织造织物复合物，其特征在于所述复合物足以耐受590克/厘米以上的力，阻止复合物撕裂。
10.如权利要求1所述的三维高弹性膜/非织造织物复合物，其特征在于所述复合物在拉伸方向上的最终伸长率为400-650％。
11.如权利要求1所述的三维高弹性膜/非织造织物复合物，它还包含可拉伸区和不可拉伸区。
12.如权利要求1所述的三维高弹性膜/非织造织物复合物，其特征在于所述第一非织造的纤维层和第二非织造的纤维层包含单向纤维和非单向纤维；和
所述第一非织造的纤维层的单向和非单向纤维的纵向与横向的断裂拉伸力之比为3∶1--1.8∶1。
13.如权利要求1所述的三维高弹性膜/非织造织物复合物，其特征在于所述第一非织造的纤维层和第二非织造的纤维层包含单向纤维和非单向纤维；和
所述第一非织造的纤维层的单向和非单向纤维的纵向与横向的断裂拉伸力之比为1.8∶1。
14.如权利要求1所述的三维高弹性膜/非织造织物复合物，其特征在于所述第一非织造的纤维层和第二非织造的纤维层包含单向纤维和非单向纤维；和
所述第一非织造的纤维层的单向和非单向纤维的纵向与横向的断裂拉伸力之比为3∶1。
15.如权利要求1所述的三维高弹性膜/非织造织物复合物，其特征在于所述第一非织造的纤维层和第二非织造的纤维层包含单向纤维和非单向纤维；和
所述第一非织造的纤维层的纵向与横向的断裂拉伸力之比为1.8∶1。
16.如权利要求1所述的三维高弹性膜/非织造织物复合物，其特征在于所述第一非织造的纤维层的纵向与横向的断裂拉伸力之比为3∶1。
17.一种三维高弹性膜/非织造织物复合物，它包括：
具有第一面和第二面的不透液体和空气的芯膜层；
由许多焊接点点粘合到所述芯层的第一面上的第一非织造的纤维层，该第一非织造的纤维层有单向和非单向纤维，其中所述第一非织造的纤维层的单向和非单向纤维的纵向与横向的断裂拉伸力之比为3∶1--1.8∶1；
由许多焊接点点粘合到所述芯层的第二面上的第二非织造的纤维层，所述第二非织造的纤维层有单向和非单向纤维；
由将所述第一非织造的纤维层、第二非织造的纤维层和芯层粘合起来的所述焊接点所形成的许多粘合区；
所述粘合区内的无弹性膜，所述膜适合于在复合物拉伸时撕裂，由此形成孔。
18.如权利要求17所述的三维高弹性膜/非织造织物复合物，其特征在于所述单向和非单向纤维的纵向与横向的断裂拉伸力之比为3∶1～1.8∶1，其中所述的第二非织造的纤维层的单向纤维的取向方向与所述第一非织造的纤维层纤维的单向纤维的相同。
19.一种三维高弹性膜/非织造织物复合物的制造方法，它包括下述步骤：
将第一非织造织物片叠压到不透液体和空气的弹性芯膜层的第一面上，
将第二非织造织物片叠压到不透液体和空气的弹性芯层的第二面上，
沿横向拉伸该复合物，在所述复合物内形成孔。
20.如权利要求19所述的方法，它还包括如下步骤：
将所述第一和第二非织造的纤维层点粘合到所述芯膜层上，由所述点粘合步骤形成基本无弹性的膜。
21.如权利要求20所述的方法，其特征在于所述点粘合第一和第二非织造的纤维层的步骤通过超声波焊接实现。
22.如权利要求20所述的方法，其特征在于所述点粘合第一和第二非织造的纤维层的步骤通过力和热能的组合实现。
23.如权利要求20所述的方法，其特征在于所述点粘合第一和第二非织造的纤维层的步骤通过热接触焊接实现。
24.如权利要求19所述的方法，其特征在于所述沿横向拉伸复合物的步骤由该复合物的最终使用者完成。
25.如权利要求19所述的方法，其特征在于所述沿横向拉伸复合物的步骤由拉幅机完成。
26.如权利要求19所述的方法，其特征在于所述沿横向拉伸复合物的步骤由辊上的弓形杆完成。
27.如权利要求19所述的方法，其特征在于所述沿横向拉伸复合物的步骤由交指型辊完成。
28.如权利要求5所述的三维高弹性膜/非织造织物复合物，其特征在于所述第一非织造的纤维层包含双组分纤维，所述双组分纤维具有两个清楚的熔点。
29.如权利要求5所述的三维高弹性膜/非织造织物复合物，其特征在于所述第一非织造的纤维层包含共混纤维，所述共混纤维具有两个清楚的熔点。
30.如权利要求1所述的三维高弹性膜/非织造织物复合物，其特征在于所述复合物横向拉伸至伸长率至少为20％时，焊接点破裂，形成孔。
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