CN1217646A - 由顶层、底层和含液体转移层的吸水芯组成的吸水件 - Google Patents

由顶层、底层和含液体转移层的吸水芯组成的吸水件 Download PDF

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CN1217646A
CN1217646A CN97194396.6A CN97194396A CN1217646A CN 1217646 A CN1217646 A CN 1217646A CN 97194396 A CN97194396 A CN 97194396A CN 1217646 A CN1217646 A CN 1217646A
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亨利·J·奇米耶卢斯金
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Abstract

在具有顶层(12)和底层(14)间的吸水结构(32)的吸水件(10)中,吸水结构(32)包括一个上层(28)和一个下层(30)和一个细长的吸水芯(40),吸水芯由纤维素纤维和超级吸水性聚合物(SAP)分散颗粒构成,吸水芯细长中心部分(40)有不小于12克/克的压力下吸水率(AUL)。下层(30)具有不大于150/米2的基本重量,和不大于约6克/克的压力下吸水率(AUL),具有极小的吸水率,但能够将从吸水芯(32)渗透到下层(30)的液体转移到吸水芯(32)的下表面。

Description

由顶层、底层和含液体转移层的 吸水芯组成的吸水件
本发明涉及一种吸水件，如一次性的尿布，它包括顶层，底层和吸水芯，吸水芯在靠底层处有一液体转移层，以加强吸水芯的吸水效果。
通常，一个吸水件，如一次性的尿布或成人的失禁衣服，包括一个液体可渗透的顶层，一个液体不可渗透的底层和一个吸水芯，吸水芯一般由粉末的软木纸浆纤维素纤维和超级吸水性的聚合物(SAP)分散的颗粒做成，位于顶层和底层间。为了进行各种液体吸水，液体分布和缓冲功能，已知可以给吸水件另设由纤维素纤维或其他材料形成一层或多层其他层。
因此，人们在顶层和吸水芯上表面间设置由纤维素纤维形成的上层。上层吸收从顶层渗过上层的一些液体。而且，上层将其余的液体，主要通过虹吸作用，传递到吸水芯的上表面。位于顶层和吸水芯间的上层也被称为虹吸层，传递层，或捕获层。
此外，人们也用由纤维素纤维形成的一层或多层，如卫生纸层，包裹这样的吸水件的吸水芯。一般来说，每个包裹层能吸收渗过包裹层的一些液体。
本发明的目的在于改进上述具有可渗透液体的顶层，不可渗透液体的底层和吸水芯的吸水件，强化吸水芯的液体储存效果。
本发明的发明人意识到，如果上述具有可渗透液体顶层，不可渗透液体的底层和吸水芯的吸水件的吸水结构带有一个下层，它仅具有有限的吸收从吸水芯渗透到下层的液体的能力，但具有很强的将从吸水芯渗透到下层的液体转移到吸收芯下表面的能力的话，就会更有效地存储液体，如尿液。
本发明提供的吸水件，包括一个可渗透液体的顶层，不可渗透液体的底层，和一个吸水结构，该吸水结构位于顶层和底层间，包括一个吸水芯。吸水结构还包括一个下层，它具有极小的吸水性，但能将从吸水芯渗透到下层的液体传递到吸水芯的下表面。具体地说，本发明设计的下层其基本重量不大于约150克/米2，在压力下的吸水率(AUL)不大于6克/克。
另外，吸水结构可包括象现有吸水件那样的上层。如果有上层的话，上层具有吸收一些从顶层渗透到上层的液体的能力，并能向吸水芯的上表面传递从顶层渗透到上层的剩余液体。包括或不包括上层，均可应用本发明。
这样，吸水芯具有足够的吸水率，构成本发明的优点。本发明中，吸水芯由纤维素纤维和有超级吸水性的聚合物(SAP)的分散颗粒做成，具有一个细长的中心部分，它在压力下的吸水率不小于12克/克。
在一个优选实施例中，吸水芯有一个前端，一个后端，和两个靠近前端的从细长的中心部突出的耳部。在此优选实施例中，超级吸水性聚合物(SAP)不是集中在上表面上，在每个耳部超级聚合物(SAP)的浓度大约为细长中心部分的一半。
如果下层是由纤维素纤维做成的，下层的基本重量必须适当地选择，以使得下层具有有限的能力吸收从吸水芯渗透到下层的液体，但却具有加强的能力将吸水芯渗透到下层来的液体转移到吸水芯的下表面。
最好，吸水芯的密度较高，为0.12-0.22克/厘米3。最好，当下层由纤维素纤维做成时，其密度较低，约为0.06-0.12克/厘米3。
最好，下层是一层含空气的纸浆层，其基本重量约为105克/米2，或是一个三层折叠的含空气的纸浆层，每层的基本重量约为35克/米2。或者，下层也可以是凸起的或不凸起的，折叠的三层卫生纸，每层的基本重量约为37克/米2。
由本发明设计的另一形式中，上层和下层都是一层卫生纸，该卫生纸的基本重量约为16克/米2。在其他形式中，下层是一个非织造的带，所述带由纤维素，合成聚合物或合成共轭(conjugate)纤维制成，或者是这些纤维的混合物制成，或者是由有开放气孔的合成聚合物泡沫材料制成。
最好，为使吸水芯稳定，下层在加工方向或横向湿状态下的强度不小于0.04千牛/米，并且上层和下层延伸到外面，在一端或两端贴在一起。
下面结合附图对本发明的优选实施例进行说明，以更明了本发明的目的，特征和优点。附图中：
图1是一个一次性尿布的部分透视图，示意出组装状态下本发明的吸水件；
图2是在展平状态下图1所示一次性尿布的部分透视图；
图3是沿图2中3-3线的箭头所示方向的部分剖面图；
图4是现有技术吸水件的相似的部分剖面图。
如图1,2和3所示，一次性尿布10构成本发明的一个优选实施例。根据本发明，尿布10具有强化的储存液体，如尿液，的能力。
一次性尿布10可做成适于婴儿或成人使用的尺寸。如果给成人用，一次性尿布10可以称为失禁服。在此应注意，本发明也可用作伤口包扎，或一次性尿布以外的其他吸水件。
广而言之，一次性尿布10包括一个已知类型的渗透液体的顶层12，一个已知类型的不渗透液体的底层14，和位于顶层12和底层14间的吸水结构16。一次性尿布10具有已知类型的固定带18，已知类型的松紧带20，和其他本发明外的已知特点。顶层12和底层14在尿布10的外边22以已知的方式粘结结合，在内封装吸水结构16。顶层12也可称为面层，可以由纤维素纤维，合成聚合物纤维，或纤维素纤维和合成聚合物纤维的混合物的非织造带制成，并可以开孔。底层14可由合成聚合物膜，如聚乙烯膜制造。顶层和底层的具体结构等不在本发明之内。
除了本文图示和说明的之外，一次性尿布10基本与本文参引的Huffman等的美国专利5,403,301公开的一次性尿布相似。
在优选实施例中，吸水结构16包括一个靠近顶层12的上层28，一个靠近底层14的下层30，和位于上层28和下层30间的吸水芯32。如图3所示，吸水芯32有一个靠近上层18的上表面34，和一个靠近下层30的下表面36。如图2所示，吸水芯32具有一个细长的中心部分40，它有前端42和后端44，接近前端42处有两个耳部46。在另一实施例(未示出)中，省掉了上层28。
上层28具有吸收一些从顶层12渗透到上层28的液体，如尿液的能力，并将从顶层12渗透到上层28的剩余液体转移到吸水芯32的上表面34。最好，上层26是由经过梳理的，或镂空编结(through-air-bonded)的，非纺织的带制造，如由聚酯(聚乙烯对酞酸盐)纤维，聚烯烃或合成共轭纤维或它们的混合物制造，其基本重量约为40克/米2，宽度约为76毫米。
或者，上层28也可是纤维素纤维制的卫生纸，基本重量约为16克/米2，宽度约为90毫米，长度足以盖住吸水芯32全长。在另一实施例中(未示出)，上层是上述的非纺织带，上层28具有的长度足够盖上吸水芯长度的一部分，而不是全部。
吸水芯32用已知方式做成，如通过一个凹模成型工艺(pocket-forming)，由纤维素纤维，如木纸浆，和已知类型的超级吸水性聚合物(SAP)的分散颗粒制造。较好的超级吸水性聚合物(SAP)有HoechstCeleneseIM-4510表面交联超级吸水聚丙烯酸酯，它由弗吉尼亚朴次茅斯的Hoechst-Celenese公司生产。
在优选实施例中，吸水芯32用约10克软木纸浆和约7克超级吸水性聚合物(SAP)制成，使得软木纸浆的表面层在上表面34上的基本重量约为40克/米2，密度约为0.12-0.22克/厘米3。最好密度为约0.17克/厘米3，沿细长中心部分40的基本重量约为800克/米2，并且在细长中心部分40上，在压力下的吸水率(AUL)不小于约12克/克。一般，因为制造中的变化因素，这个吸水芯在压力下的吸水率(AUL)可控制到约为±3克/克的精确度。
在此优选实施例中，吸收芯32做得使超级吸水性聚合物(SAP)基本上在上表面34的表面层上不集中存在，但沿细长中心部分具有足以达到上述压力下的吸水率的超级吸水性聚合物浓度，并在每个耳部46，浓度达到细长中心部分SAP浓度的一半。
根据本发明，下层30具有极小的液体储存能力，但具有将从吸水芯32渗透到下层30的液体，如尿液，转移到吸水芯32的下表面36的能力。具体而言，本发明设计的下层30在压力下的吸水率(AUL)不大于6克/克。一般因为制造过程变化的因素，这个下层在压力下的吸水率(AUL)可控制的准确度约为±1克/克。虽然下层30会显出虹吸作用，但虹吸作用不是必需的。
如果下层30是由纤维素纤维制造的，下层30的密度优选为约0.06-0.12克/厘米3，最好是0.08克/厘米3。与前面讨论的高密度吸水芯32比较，下层30的密度较低。
对于本发明，吸水制品的压力下吸水率(AUL)指的是由吸水制品的几个靶样吸收的合成尿液的量，在试样保持器中的每个靶样浸泡在合成尿液中，这些靶样受到约0.5psi压力(713.2克/米2)，浸泡约10分钟，然后每个靶样和它的试样保持器排水约60秒。
对每个吸水制品用几个靶样，每个靶样是用两英寸直径的压模从这些吸水制品上截取的。对每个吸水制品，这样从吸水制品截取的靶样的压力下的吸水率(AUL)的平均值取作该吸水制品的压力下的吸水率(AUL)。
对于本发明，合成尿液是遵照弗吉亚朴次茅斯的Ricca Chemical Co.提供的Synthetic Urine Concentrate,Catalog No.8362的说明书制备的。重量百分之一的氯化钠水溶液可以代替合成尿液使用。使用几个试样保持器，每个靶样一个，每个试样保持器具有在精确度约为0.03克内的已知重量。使用几个重量，每个靶样一个，每个重量设计为可施加713.3克/米2的压力(±0.03克)。使用精确度为±0.01克的天平。
在这些靶样及它们的保持器浸泡在合成尿液中后，即受到约10分钟浸泡，约0.5psi(713.2克/米2)压力，并然后约排水60秒钟后，对每个靶样，从每个靶样的湿重量中，将该靶样的干重和它的试样保持器的重量减去，就得到靶样压力下的吸水率(AUL)。
本发明设计的一个第一结构的下层是三层折叠的含有空气木纸浆层，每层的基本重量约为35克/米2，每层的密度约0.08克/厘米3，总重量约4克，折叠层的折叠宽度约为90毫米，长度足以盖住吸水芯32的全长，在压力下的吸水率(AUL)约为6克/克。
本发明设计的一个第二结构的下层，是凸起或不凸起的，三层折叠的纤维素纤维制的卫生纸，每层的基本重量约为35克/米2，每层的密度为约0.08克/厘米3，总重量约4克，折叠层的折叠宽度约为90毫米，长度足以盖住吸水芯32的全长，在压力下的吸水率(AUL)约为6克/克。
本发明设计的一个第三结构的下层，是由含空气的纤维素纤维制的一个单层，基本重量约为105克/米2，密度约米0.08克/米3，宽度约为90毫米，全长大于吸水芯32的全长。
用上述的第一、第二和第三结构的任何一种做的下层30，在加工方向或横向宽度中的湿强度不小于约0.04千牛/米。下层的湿强度是由TAPPI Test Method T 494,“Tensile breaking properties of paper andpaperboard(using constant rate of elongation apparatus)”，以及TAPPITest Method T 456,“Wet tensile breaking strength of paper andpaperboard”测量的。
对于下层30，本发明设计的一个第四结构是由纤维素纤维制的一个单层卫生纸，基本重量约为16克/米2，宽度约为90毫米，全长大于吸水芯32的全长。
下层30也可用非织造的纤维素，合成聚合物，或合成共轭纤维，或这些纤维的混合物制成的带，或开放气孔的合成聚合物泡沫材料制成，只要它们在压力下的吸水率不超过约6克/克。
在吸水芯32上放上上层28，但不与吸水芯32粘着。用一种热熔性的粘结剂将下层30粘着到吸水芯32，该粘结剂最好是通过在吸水芯32全长上，由两个螺旋喷嘴施加，在吸水芯32的每厘米长度施加约0.05毫克粘结剂。在吸水芯32的周边48上，最好用在连续作业线中的热熔性粘结剂将上层28与下层30粘结在一起。最好用在连续作业线中施加的热熔性粘结剂将下层30粘结到一次性尿布10的底层14上。
在图3中，虚线D1,D2,D3分别表示由上层28向吸水芯32的上表面34转移的液体，如尿液，浸湿的吸水芯32的区域。如图3中箭头所示，渗透到吸水芯32的任何液体被下层30转移到吸水芯32的下表面36，因此吸水芯重又被下层30输送的液体浸湿。
因为本发明的吸水芯32储存液体，如尿液，的效果加强，因此，吸水芯32全长可以比下层30全长小40％-80％，从而使得吸水芯沿下层30的前部分延伸，并终止在图2虚线所示的底边44a上，却并不显著减小储存尿液的有效能力，这样不仅使得尿布成本，而且使一次性尿布10的体积都相应地减少。
图4中示出现有技术的尿布10’，其中的带撇的数码用于指示，图1,2和3中的不带撇的相似的数码所指的组成部分。一次性尿布10’具有一个相似于顶层12的顶层12’，相似于底层14的底层14’，和一个吸水结构，它包括相似于上层28的上层28’，一个相似于吸水芯32的吸水芯32’，但是吸水芯32’不具有相似于下层30的下层。
在图4中，虚线D4,D5，和D6分别表示由上层28转移到吸水芯32’上表面34’的液体，如尿液，浸湿的吸水芯32’的区域。一次性尿布10’不具有将渗透到吸水芯32’的任何液体转移到吸水芯32’的下表面36’，从而使得吸水芯32’重浸湿的能力。
如果一次性尿布10’的吸水芯32’的下表面36’上带有的下层(未示出)具有比约6克/克明显大的压力下的吸水性(AUL)，与在优选实施例中吸水芯32的下层将吸水芯32的下表面36重新浸湿的效果比较，下层在使得吸水芯32’的下表面36’重新浸湿上就不大有效。
不偏离本发明的范围和精神，对优选实施例可作出种种修改。

Claims (20)

1．一种吸水件，包括一个可渗透液体的顶层，一个不可渗透液体的底层，和一个吸水结构，吸水结构位于顶层和底层间，吸水结构包括一个靠近顶层的上层，靠近底层的下层，和一个在上下层间的吸水芯，吸水芯具有一个前端和一个后端，吸水芯是由纤维素纤维和超级吸水性的聚合物(SAP)的分散颗粒做成，吸水芯的密度约为0.12克-0.22克/厘米3，具有一个在压力下的吸水率(AUL)不小于12克/克的细长的中心部分，吸水芯具有面向顶层的上表面和面向底层的下表面，上层是由聚酯，聚烯烃，纤维素和合成共轭(conjugate)纤维或它们的混合物中选择的纤维制成，具有吸收由顶层渗透到上层的一些液体的能力，并向吸收芯上表面转移从顶层渗透到上层的剩余液体，下层具有将从吸收芯渗透到下层的液体转移到吸收芯下表面的能力，下层在加工方向或横向，具有不小于0.04千牛/米的湿强度，上层和下层延伸在吸收芯外，在吸收芯的前端和后端之一或两端彼此结合，使得吸收芯稳定，下层的基本重量不大于约150克/米2，在压力下的吸水率(AUL)不大于6克/克，下层具有全长，吸收芯沿下层的前部延伸，具有的全长比下层的全长小40-80％，吸收芯起吸水件的主要液体储存层的作用。
2．根据权利要求1所述的吸水件，其特征在于，吸水结构的上下层在吸收芯的前端和后端彼此结合。
3．根据权利要求1所述的吸水件，其特征在于，吸收芯具有一个前端，一个后端，和两个接近前端的从细长中心部分伸出的耳部，超级吸水聚合物〔SAP〕在上表面基本上不集中分布，在每个耳部区域的浓度大约是细长中心部分的浓度的一半。
4．根据权利要求1所述的吸水件，其特征在于，下层是由纤维素纤维制成，密度约为0.06-0.12克/厘米3。
5．根据权利要求4所述的吸水件，其特征在于，吸水结构的下层是一层含空气的纸浆层，具有约105克/米2的基本重量。
6．根据权利要求4所述的吸水件，其特征在于，吸水结构的下层是折叠的三层含空气的纸浆层，每层具有约35克/米2的基本重量。
7．根据权利要求4所述的吸水件，其特征在于，吸水结构的下层是折叠的三层带凸起的卫生纸层，每层具有约37克/米2的基本重量。
8．根据权利要求4所述的吸水件，其特征在于，吸水结构的下层是折叠的多层不带凸起的卫生纸层，每层具有约37克/米2的基本重量。
9．根据权利要求1所述的吸水件，其特征在于，吸水结构的上下层都是卫生纸层，具有约16克/米2的基本重量。
10．根据权利要求1所述的吸水件，其特征在于，吸水结构的下层是纤维素纤维，或合成纤维或合成共轭纤维，或它们的混合物的非织造的带。
11．根据权利要求1所述的吸水件，其特征在于，吸水结构的下层的材料是开口气孔的合成聚合物泡沫材料。
12．一种吸水件，包括一个可渗透液体的顶层，不可渗透液体的底层，和一个吸水结构，吸水结构位于顶层和底层间，吸水结构包括一个靠近顶层的上层，靠近底层的下层，和一个放在上下层间的吸水芯，吸水芯是由纤维素纤维和超级吸水性的聚合物(SAP)的分散颗粒做成，具有一个细长的中心部分，它在压力下的吸水率(AUL)不小于12克/克，吸收芯具有面向顶层的上表面和面向底层的下表面，上层具有吸收由顶层渗透到上层的某些液体的能力，并向吸收芯上表面转移从顶层渗透到上层的剩余液体，下层具有将从吸收芯渗透到下层的液体转移到吸收芯下表面的能力，下层的基本重量不大于约150克/米2，在压力下的吸水率(AUL)不大于6克/克。
13．根据权利要求12所述的吸水件，其特征在于，下层具有全长，吸收芯沿下层的前部延伸，长度比下层的全长小40-80％。
14．根据权利要求12所述的吸水件，其特征在于，下层是由纤维素纤维制成，吸水芯的密度约为0.12-0.22克/厘米3，下层的密度约为0.06-0.12克/厘米3。
15．根据权利要求14所述的吸水件，其特征在于，为了稳定吸水芯，下层在加工方向或横向宽度上，具有不小于0.04千牛/米的湿强度，上层和下层延伸在吸收芯外，在吸收芯的前端和后端之一或两端彼此结合。
16．根据权利要求15所述的吸水件，其特征在于，吸水芯的上层和下层，在吸收芯的前端和后端彼此结合。
17．根据权利要求12所述的吸水件，其特征在于，吸水芯的上下层是卫生纸层，具有约16克/米2的基本重量。
18．一种吸水件，包括一个可渗透液体的顶层，不可渗透液体的底层，和一个吸水结构，吸水结构位于顶层和底层间，吸水结构包括一个靠近底层的下层，和一个在下层上的吸水芯，吸水芯是由纤维素纤维和超级吸水性的聚合物(SAP)的分散颗粒构成，具有一个细长的中心部分，它在压力下的吸水率(AUL)不小于12克/克，吸收芯具有面向顶层的上表面和面向底层的下表面，下层具有将从吸水芯渗透到下层的液体转移到吸收芯下表面的能力，下层的基本重量不大于约150克/米2，在压力下的吸水率(AUL)不大于6克/克。
19．根据权利要求18所述的吸水件，其特征在于，下层具有全长，吸水芯沿下层的前部延伸，具有的全长比下层的全长小40-80％。
20．根据权利要求18所述的吸水件，其特征在于，下层是由纤维素纤维制成，吸水芯的密度约为0.12-0.22克/厘米3，下层的密度约为0.06-0.12克/厘米3。
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