CN1236123C - 带有粘合剂和孔的无纺织物材料 - Google Patents

带有粘合剂和孔的无纺织物材料 Download PDF

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CN1236123C
CN1236123C CNB001217097A CN00121709A CN1236123C CN 1236123 C CN1236123 C CN 1236123C CN B001217097 A CNB001217097 A CN B001217097A CN 00121709 A CN00121709 A CN 00121709A CN 1236123 C CN1236123 C CN 1236123C
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nonwoven fabric
fabric material
adhesive composition
absorbent article
zone
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CN1295146A (zh
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V·P·拉斯科
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Johnson and Johnson Consumer Inc
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McNeil PPC Inc
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/15577—Apparatus or processes for manufacturing
    • A61F13/15707—Mechanical treatment, e.g. notching, twisting, compressing, shaping
    • A61F13/15731—Treating webs, e.g. for giving them a fibrelike appearance, e.g. by embossing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • 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
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/51121—Topsheet, i.e. the permeable cover or layer facing the skin characterised by the material
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/512—Topsheet, i.e. the permeable cover or layer facing the skin characterised by its apertures, e.g. perforations
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/514—Backsheet, i.e. the impermeable cover or layer furthest from the skin
    • A61F13/51456—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its properties
    • A61F13/51458—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its properties being air-pervious or breathable
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    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
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    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B38/04—Punching, slitting or perforating
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B32B7/14—Interconnection of layers using interposed adhesives or interposed materials with bonding properties applied in spaced arrangements, e.g. in stripes
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J7/00—Adhesives in the form of films or foils
    • C09J7/20—Adhesives in the form of films or foils characterised by their carriers
    • C09J7/21—Paper; Textile fabrics
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H11/00—Non-woven pile fabrics
    • 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
    • B32B2555/02—Diapers or napkins
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2203/00—Applications of adhesives in processes or use of adhesives in the form of films or foils
    • C09J2203/302—Applications of adhesives in processes or use of adhesives in the form of films or foils for bundling cables
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2301/00—Additional features of adhesives in the form of films or foils
    • C09J2301/20—Additional features of adhesives in the form of films or foils characterized by the structural features of the adhesive itself
    • C09J2301/204—Additional features of adhesives in the form of films or foils characterized by the structural features of the adhesive itself the adhesive coating being discontinuous
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2400/00—Presence of inorganic and organic materials
    • C09J2400/20—Presence of organic materials
    • C09J2400/26—Presence of textile or fabric
    • C09J2400/263—Presence of textile or fabric in the substrate
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/28—Web or sheet containing structurally defined element or component and having an adhesive outermost layer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2484—Coating or impregnation is water absorbency-increasing or hydrophilicity-increasing or hydrophilicity-imparting

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Abstract

本发明提供一种无纺织物材料，例如无纺织物纤维网或塑料膜，它通过将粘合剂以一定图案施加到其一个面上，然后使无纺织物材料开孔来制得。

Description

带有粘合剂和孔的无纺织物材料
本发明涉及带有孔和以图案排布在其表面上的粘合剂组合物的无纺织物材料及其制造方法，和含有该材料的吸收制品。
有多种无纺织物材料即无纺织物纤维网或塑料膜可应用于吸收制品领域。这些材料可以带孔或不带孔，而且常常用作卫生巾、短内裤衬里、尿布、失禁装置和绷带的表层或背衬。为了提高这些材料的功能和美观性，它们被设计成多种特色。
例如，美国专利No.5,906,786涉及带有纤维凸出部分和纤维背景部分的无纺织物的制造。还可以通过调节凸出和背景部分的单位重量和密度，以获得不同的效果。美国专利No.5,824,352描述了制造带孔塑料膜的设备，这种带孔膜内存在一系列的峰和谷，因此具有类似经编针织物的组织。美国专利No.5,736,219涉及具有改善的吸收性能的无纺织物。该织物具有三种不同的互连纤维列，纤维在织物内形成独特的分布。
本申请人发现可以通过将粘合剂组合物施加到无纺织物材料上并打孔形成含有孔洞和优选的带图案的有膜区域的无纺织物材料。这种无纺织物材料尤其可用作吸收制品的一种组分。通过调整粘合剂组合物的配方和它施加到无纺织物材料上时所采用的图案，可以有利地制成具有多种功能性或美观性的无纺织物材料。
本发明提供了一种制备带有第一表面和与第一表面相对的第二表面的无纺织物材料的方法。它依序包括如下步骤：(a)将粘合剂组合物以一定图案施加到无纺织物材料的第一表面上，(b)对含有粘合剂组合物的无纺织物材料打孔。
本发明还提供这样的无纺织物材料，它含有：(1)第一表面和与第一表面相对的第二表面，(2)以一定图案排布在无纺织物材料第一表面上的粘合剂组合物，和(3)在该无纺织物材料内的许多孔。
本发明也提供包含无纺织物材料和吸收芯的吸收制品，所述无纺织物材料包含：(1)第一表面和与第一表面相对的第二表面，(2)以一定图案排布在无纺织物材料第一表面上的粘合剂组合物，和(3)在该无纺织物材料内的许多孔。
图1是本发明的无纺织物材料的剖面图。
图2是图1中的无纺织物材料的俯视图。
图3是图1中的无纺织物材料的仰视图。
图4示出了包含由本发明无纺织物材料制成的表层的短内裤衬里。
用非机织物的任何类似织物的材料来制造无纺织物材料。由梳理或水刺工艺形成的无纺纤维网是尤其有用的原料。也可以使用例如包含聚乙烯、聚丙烯或玻璃纸的塑料膜。已知有多种用于吸收制品行业的无纺纤维网和塑料膜的例子，可以使用其中任何种类。原料的相同与否对本发明并不关键。
无纺织物材料的制造方式是，首先将粘合剂组合物以一定图案施加到无纺织物材料的一个表面上。粘合剂组合物含有一种粘合剂例如由一种或多种丙烯酸或甲基丙烯酸的酯单体合成的丙烯酸聚合物溶液或乳液，所述单体例如2-乙基己基丙烯酸酯、正丁基丙烯酸酯、异辛基丙烯酸酯、1-癸基丙烯酸酯、丙烯酸、甲基丙烯酸、N-甲基丙烯酰胺、丙烯酸乙酯、丙烯酸甲酯、甲基丙烯酸甲酯、甲基丙烯酸乙酯和甲基丙烯酸丁酯。这种粘合剂也可以包括乙烯基共聚单体例如乙酸乙烯酯、氯乙烯、苯乙烯、马来酸酐和巴豆酸。粘合剂也可以通过含有例如酰胺、羧基、羟基侧基或环氧官能度的乙烯基单体进行交联。
市销的有用的粘合剂例子包括购自Air Products的FLEXBOND 974、977、983和986，购自BF Goodrich的CARBOTAC Adhesives(压敏型粘合剂)和也是BF Goodrich的CARBOBOND Adhesives(非压敏型粘合剂)。优选地，粘合剂选自FLEXBOND 974、977、983和986粘合剂。
为了增强无纺织物材料的功能性(例如吸收性)或达到无纺织物材料的美观效果，粘合剂组合物也优选含有添加物。这种添加物可以以固体或液体形式加入到粘合剂组合物中。添加物优选以固体形式例如纤维或粒子形式加入到粘合剂组合物中。
在本发明的一个特别优选的实施例中，粘合剂组合物含有植绒纤维形式的添加物。使纤维植绒的方法在织物的制造技术中是已知的。见例如美国专利No.2,527,501、2,691,611、3,436,442和3,672,929。在本发明中，植绒的纤维在被施加到无纺织物材料表面之后，再被施加到粘合剂组合物上。含有粘合剂组合物的无纺织物材料通过纤维计量站，计量站中采用例如位于无纺织物材料上方和下方的电极，在无纺织物材料周围维持一个静电场。在静电场存在下，把纤维施加到无纺织物材料上的粘合剂组合物上。当纤维接触粘合剂组合物时，静电场使纤维沿垂直于无纺织物材料取向。随后加热无纺织物材料，使粘合剂聚合并锚固纤维。未粘结上的纤维由真空吸走。
总的来说，任何纤维形式的添加物都可以如上所述植绒到粘合剂组合物上。一般来说，植绒纤维的长度应当低于约1毫米，优选低于约0.8毫米。植绒纤维的旦数范围应当约为1.2-1 5旦，优选约为1.8-6旦。
通常，添加物可以选自亲水性材料，包括可湿润材料和吸收剂、憎水材料如斥水性材料、高吸收聚合物、颜料及其组合物。
可湿润材料的例子包括经表面活性剂处理的双组分纤维、聚丙烯纤维和聚酯纤维。优选的可湿润材料是聚酯纤维，例如用购自ICI Americas Inc的Tween 20表面活性剂处理的DuPont Company的DuPont-Akra Polyester Type11A Bright纤维。
吸收剂既对液体具有亲和力又吸收液体，吸收剂一般也以纤维形式使用，可以为人造丝、丙烯腈、尼龙、聚乙烯醇和天然或再生纤维素。优选的吸收剂类型是人造丝纤维。
憎水材料包括某些聚烯烃和聚酯，优选使用旦数至少为3，更优选至少为6的纤维。优选的憎水纤维是购自DuPont Company的15旦聚酯。在本发明的另一个特别优选的实施例中，粘合剂组合物含有高吸收聚合物，该聚合物可以为纤维或粒子形式。高吸收聚合物优选为纤维形式，更优选为植绒纤维形式。高吸收聚合物是亲水性材料，它可溶胀，并能够吸收多于约5克/克(纤维重量)的1％盐水溶液。高吸收聚合物的例子在本行业内是已知的，包括聚丙烯酸酯、接枝纤维素和马来酸。高吸收聚合物纤维的优选类型包括购自Technical Absorbents Limited的OASIS Type 101，和购自加拿大Alberta的Camelot的CAMELOT。粒子形式的高吸收聚合物的例子包括购自Chemdal Corp.的ASAP2000、ASAP2300和ASAP2100A，购自Sumitomo的Aquakeep J-550和Aquakeep SA60N Type 2，购自Stockhausen的SXM-4750。
用于粘合剂组合物中的颜料包括例如二氧化钛、碳酸钙和其他增白剂。也可以使用其他色的颜料。
粘合剂组合物以一定图案施加到无纺织物材料的一个表面上。可以采用任何图案。一个优选的图案包括将粘合剂组合物沿无纺织物材料表面的周边施加，以形成一种沿无纺织物材料边的屏障。例如，含有与憎水性材料(纤维或粒子形式)混合的粘合剂并沿无纺织物材料表面的周边施加的粘合剂组合物可减少液体流出，由此阻止流体流出无纺织物材料的边缘。
施加粘合剂组合物的另一些图案可以部分或全部是装饰性的，例如单花、星等的图案分散于无纺织物材料的整个或部分表面上。
再将粘合剂组合物固化，一般由加热方式进行。粘合剂组合物固化之后，对无纺织物材料开孔。本发明不受限于任何特定的开孔方法。无纺织物材料的开孔在本行业内是熟知的，根据本发明可以采用任何技术。总的来说，将起始材料(本发明中为含有粘合剂组合物的无纺织物材料)放置于带有许多孔(任选其他的构形特征)的支撑元件表面的上方。然后将高压液体例如水或气流导向无纺织物材料，形成与支撑元件一致的构形。另外，也可以在支撑元件的下方抽真空，也可以使无纺织物材料形成与支撑元件一致的表面。美国专利No.4,342,314、5,366,782、5,916,462和5,824,352更详细地揭示了开孔的方法和多种支撑元件。
也可以在施加有粘合剂组合物的无纺织物材料表面上开孔。另外，也可以在与施加有粘合剂组合物的表面相对的无纺织物材料表面上开孔。优选在与施加有粘合剂组合物的表面相对的无纺织物材料表面上开孔。孔的侧壁从这种表面突出、从相反表面向外伸出。孔就“形成”于材料的平面内。
无纺织物材料的开孔可以按所要求的方式进行，即：可在或不在无纺织物材料施加有粘合剂组合物的区域内开孔。优选地，使孔不形成于施加有粘合剂组合物的无纺织物材料区域内。以这种方式，就可基本保持施加粘合剂组合物的图案。实际上，不在施加有粘合剂组合物的区域内开孔，甚至可以增强粘合剂组合物的图案。根据开孔工序期间无纺织物材料的温度和对无纺织物材料所施加的压力，含有粘合剂组合物的无纺织物材料的区域实际上可以比不含粘合剂组合物的区域高出一些。这就可以有利地获得一个整体上类似压花的效果，而且，采用较简单的技术就可以赋予带孔膜以功能性和/或装饰性图案。
图1示出了本发明无纺织物材料的剖面图，其中不在施加有粘合剂组合物的区域内开孔。图1的无纺织物材料含带有第一表面11和第二表面12的塑料膜10，粘合剂组合物8以一定图案分散于其第一表面11上。粘合剂组合物含带有添加物植绒纤维14的粘合剂，例如高吸收聚合物纤维。塑料膜10也含有许多孔9。孔9形成于塑料膜10的第二表面12上。
图2是图1无纺织物材料的俯视图。塑料膜10的第二表面12含有一系列环绕孔9的小平面区域。另外，在粘合剂组合物施加到第一表面11(未示出)的部位，存在大的平面区域15。
图3示出了图1中的无纺织物材料的仰视图。孔9的侧壁从塑料膜10的第一表面11向外突出。植绒纤维14也从粘合剂组合物和第一表面11向外突出。
无纺织物材料也可以用于吸收制品，例如用作表层或背衬。这种吸收制品可以是卫生巾、短内裤衬里、尿布、失禁垫、阴唇间制品、或用来吸收身体排出物例如月经、尿或粪便的其他类似制品。吸收制品优选是卫生巾或短内裤衬里。这种卫生巾或短内裤衬里可以具有近似矩形、椭圆形、哑铃状或花生形状。根据吸收制品的性质，它的尺寸可以不同。例如卫生巾厚度一般约1.4-5毫米、长度约3-16英寸、宽度约1-5英寸。短内裤衬里的厚度一般约低于0.2英寸、长度约低于8英寸、宽度约低于3英寸。
图4示出了一种其表层是本发明的无纺织物材料的短内裤衬里，它用作下述说明。图4所示的短内裤衬里自其朝向身体的表面1至朝向衣服的表面2，依序含有可渗透液体的表层3、吸收芯4、不可渗透液体的背衬5。吸收制品的表层3由含有粘合剂组合物8和具有许多孔9的塑料膜制成。此时，粘合剂组合物以横条和花的图案分散于表层3朝向吸收芯4的一面上。孔9形成于表层朝向身体的表面1上，并向下突出朝向吸收芯4。
根据所选择的材料，表层3的厚度可以自约0.001英寸变化至0.062英寸。表层可以与吸收芯长度相等，或任选比吸收芯长，目的是形成横向边。这种横向边可以用其他层密封，以完全包封吸收芯。
吸收芯4可以含有松散相连的亲水性吸收材料例如纤维素纤维，包括木浆、再生纤维素纤维或棉纤维，或本行业内通常已知的其他吸收材料，包括丙烯腈纤维、聚乙烯醇纤维、泥炭藓和高吸收聚合物。
吸收制品还包含不可渗透液体的背衬5，其外表形成制品朝向衣服的表面2。背衬可以含有任何薄而柔软的不可渗透体液的材料，例如聚乙烯、聚丙烯或纤维素聚合物膜。另外，背衬也可以是将渗透液体的普通材料处理成不可渗透液体，例如斥液体的浸渍纸、或非机织物材料、或柔软泡沫材料如聚氨酯或交联聚乙烯。当由聚合物膜制成时，背衬的厚度一般约为0.001-0.002英寸。本行业中已知的多种材料都可用作背衬，可以采用其中任何种类。
通常，背衬5是单片材料，其宽度足以形成吸收制品朝向衣服的表面2。背衬可以以C形外形环绕吸收芯的侧边，与邻近其纵向边的背衬部分从制品朝向内衣的表面向制品朝向身体的表面延伸。背衬优选是可透气的，即一种能阻挡液体但允许气体通过的膜。用于该用途的材料包括聚氨酯膜和微孔膜，其中的微孔是通过电离辐射或通过采用水性或非水性溶剂滤出可溶物而形成。具有曲径和/或其表面特性具有抗液体渗透的液体表面的单层或多层可渗透膜、织物及其组合，也可以用来制作可透气背衬。
将吸收制品朝向内衣的表面2紧贴着放置于衬裤分叉处的内表面，就可以将吸收制品施用到衬裤的分叉处。可以将压敏型粘合剂6的条子施用到吸收制品朝向内衣的表面2上，帮助它固定在原地。这里所使用的“压敏型粘合剂”一词，指任何可剥离的粘合剂或可剥离的强韧装置。合适的压敏型粘合剂包括例如水基粘合剂如丙烯酸酯粘合剂。另外，粘合剂可以含有快速定型的热塑性“热熔”橡胶粘合剂或双面粘合带。
使用之前，可以应用一面被涂敷的纸剥离条7来保护粘合剂6的条带。涂布聚硅氧烷会降低剥离条的被涂敷面与粘合剂的粘合性。剥离条可由任何合适的片状材料形成，使用之前，当片状材料被涂敷之后，它可以以足够的强韧性与粘合剂结合，使之保持在原位，但当使用吸收制品时，又可以容易地取出。
吸收制品可以含有其他已知的材料、层和添加物，例如传递层、泡沫层、网状层、气味控制剂、芳香剂、药物、增湿剂等，其中的许多例子在行业中是已知的。
根据本发明，按下法制造无纺织物材料。聚酯织物或聚乙烯膜的样品用作起始材料。将一种含有二氧化钛的粘合剂组合物以与图4所示图案相似的花和横条的图案施加到起始材料的一个表面上。高吸收聚合物和聚酯的植绒纤维计量加到粘合剂组合物上，再通过静电场以垂直状态取向。纤维粘合到施加有粘合剂组合物的部位。然后，材料经过一个烘箱，使粘合剂组合物聚合并锚固植绒纤维。过量的纤维被真空吸走。
然后，采用热空气开孔的方法使材料开孔。孔形成于与一个其上施加有粘合剂组合物的表面相反的材料表面上。调节无纺织物材料的温度和紧贴无纺织物材料表面的热空气压力，使孔不形成于粘合剂组合物的花和横条上。无纺织物材料成品的整体外观和手感相似于孔与压花的平面区域。

Claims (13)

1.制造具有第一表面(11)和与第一表面相反的第二表面(12)的无纺织物材料的方法，它依序包括：(a)将粘合剂组合物(8)以一定图案施加到无纺织物材料的第一表面(11)上，(b)使所述粘合剂组合物(8)固化，和(c)使含有所述粘合剂组合物的无纺织物材料开孔；
其特征在于所述开孔步骤包括形成许多起源于无纺织物材料的第二表面(12)内的孔(9)，所述孔(9)的侧壁的形态是：从第二表面(12)突出，从第一表面向外伸出。
2.如权利要求1所述的方法，其中所述的开孔这样实施：使所述孔(9)形成于无纺织物材料未施加粘合剂组合物(8)的区域内。
3.如权利要求1或2所述的方法，其中所述的开孔这样实施：没有孔、只有压花的平面区域(15)形成于无纺织物材料施加粘合剂组合物的区域内，压花的平面区域相对于未施加粘合剂组合物(8)的区域变成凸出。
4.如权利要求1所述的方法，其特征在于所述无纺织物材料是无纺织物纤维网或塑料膜(10)。
5.如权利要求1所述的方法，其特征在于所述粘合剂组合物(8)包含选自亲水性材料、憎水性材料、高吸收聚合物、颜料及其组合的添加物。
6.无纺织物材料，它包含：(1)第一表面(11)和与第一表面相反的第二表面(12)，(2)以一定图案排布在无纺织物材料第一表面(11)上的粘合剂组合物(8)，和(3)在所述无纺织物材料内的许多孔(9)；
其特征在于所述许多孔(9)起源于无纺织物材料的第二表面(12)，使得所述孔(9)的侧壁从第二表面(12)突出，从第一表面向外伸出。
7.如权利要求6所述的无纺织物材料，其特征在于所述无纺织物材料在未施加粘合剂组合物(8)的区域内包含许多孔(9)。
8.如权利要求6所述的无纺织物材料，它在施加粘合剂组合物(8)的区域内不包含孔、只包含压花的平面区域(15)，压花的平面区域(15)相对于未施加粘合剂组合物(8)的区域是凸出的。
9.如权利要求7或8所述的无纺织物材料，其特征在于所述的无纺织物材料是无纺织物纤维网或塑料膜(10)。
10.如权利要求7或8所述的无纺织物材料，其特征在于所述的粘合剂组合物含有选自亲水性材料、憎水性材料、高吸收聚合物、颜料及其组合的添加物。
11.一种吸收制品，它包含权利要求7-10中任一项所述的无纺织物材料和吸收芯(4)。
12.如权利要求11所述的吸收制品，其特征在于所述无纺织物材料是该吸收制品的表层(3)。
13.如权利要求12所述的吸收制品，其特征在于所述无纺织物材料是该吸收制品的背衬(5)。
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EP1099434A1 (en) 2001-05-16
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JP2001140154A (ja) 2001-05-22
BR0002946A (pt) 2001-08-21
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ZA200003583B (en) 2002-01-17
AU4720800A (en) 2001-07-05
AR025207A1 (es) 2002-11-13
CN1295146A (zh) 2001-05-16
AU779913B2 (en) 2005-02-17
MXPA00006977A (es) 2002-04-24
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CA2313711A1 (en) 2001-05-09

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