CN1237926A - 幅片的热接合 - Google Patents

幅片的热接合 Download PDF

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CN1237926A
CN1237926A CN97199933A CN97199933A CN1237926A CN 1237926 A CN1237926 A CN 1237926A CN 97199933 A CN97199933 A CN 97199933A CN 97199933 A CN97199933 A CN 97199933A CN 1237926 A CN1237926 A CN 1237926A
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width
cloth
cloth sheet
absorbent article
diaper
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克里斯托弗·J·施米茨
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Procter and Gamble Co
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Procter and Gamble Co
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    • 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
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • 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
    • A61F13/53—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 absorbing medium
    • A61F13/539—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 absorbing medium characterised by the connection of the absorbent layers with each other or with the outer layers
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/10—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
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    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
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    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
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    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8351—Jaws mounted on rollers, cylinders, drums, bands, belts or chains; Flying jaws
    • B29C66/83511—Jaws mounted on rollers, cylinders, drums, bands, belts or chains; Flying jaws jaws mounted on rollers, cylinders or drums
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06H—MARKING, INSPECTING, SEAMING OR SEVERING TEXTILE MATERIALS
    • D06H5/00—Seaming textile materials
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    • B29C65/10—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
    • B29C65/103—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined direct heating both surfaces to be joined
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    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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Abstract

一种接合至少两片幅片(11，12)的方法，所述幅片(11，12)是多孔的且包括可熔成分，所述幅片(11，12)被设置成相邻状态以形成幅片结构(10)，所述幅片结构(10)包括外表面(13，14)和位于所述幅片(11，12)之间的重叠区域(15)，所述方法包括下列步骤：1)充分加热流体以使所述可熔成分至少部分熔化；2)将所述加热流体的高速射流向着所述外表面(13，14)中的至少一个导出；3)使所述流体在分离的位置上穿透所述幅片(11，12)；和4)使所述流体在所述幅片(11，12)中循环，以至少部分熔化所述可熔成分。本发明的另一方面是一种根据上文所述的方法制造的一次性吸湿用品。

Description

幅片的热接合
本发明涉及一种用于幅片的热接合方法。该方法可使用于一次性吸湿用品中。
一次性吸湿用品，特别是一次性尿布，是公知的设计用来由婴儿或失禁患者穿用的商品。这种尿布被穿戴在穿用者的下躯干部位，用于吸收和容纳尿液或其他身体排出物，由此防止弄脏，弄湿或脏污在使用时与该尿布接触的物品(如衣物，床单，其他人等等)。近年来，一次性套穿式尿布形式的一次性尿布在市场中出现，特别是那些具有固定侧边的一次性套穿式尿布十分流行。这种一次性套穿式尿布的固定侧边通过将前部的侧片接合到后部的侧片而生产出。为达到接合目的，侧片的接触表面需要被至少部分熔化。但是，比较理想的是应避免与要接合区对应的侧片外表面被熔化。通常需要有一种能接合几层较厚材料且并不导致在外表面上形成坚硬的锉状突起。根据有关文献，现有技术更适合薄层材料的接合。因此，接合较厚材料的问题在本领域中是公知的，但据申请人所知，迄今为止提出的唯一解决方案是下文所描述的。
典型的现有技术处理是传统的热接合处理，其使用钢，铝，铜或其他具有高导热系数的材料所制成的热销将熔化所需的能量传递到要接合的幅片中。对于薄膜状的较薄材料，热销接触并熔化幅片结构的外表面。而对于较厚材料，则热销最好能穿透整个幅片结构。热销的向上向下动作不但会造成具有熔化壁的孔的产生，而且会使一些熔化的材料转移并运到幅片结构的表面，从而在冷却后形成坚硬的锉状突起。为保证发生有效的接合，会随之进行对幅片结构的挤压。尽管如此，在挤压工具移动到位之前，热销必须移开，这造成操作复杂。而且仅在融熔材料冷却后，挤压工具才从幅片结构移开。
在美国专利US4667552中公开了一种对薄膜材料的穿孔操作，该材料通常为热塑材料，但并不仅限于热塑材料。加热穿孔销支承在转动滚筒上，而薄膜则由如可变形辊子的加压装置强制压在销上。该热销从塑料薄膜的顶部穿入，而热销对薄膜完成穿孔后在热销熔化周围的薄膜时，薄膜熔化成未“凝固”结构。在穿孔后，该薄膜具有一个光滑表面，和一个因凸起增生而形成凸凹的一个相对的表面。该技术并不适于较厚材料的接合。
美国专利US4,519,798提出了一种为接合目的采用热能以软化两层或多层热塑材料的处理。该专利公开了一种一次性尿布结构，其中吸湿芯被囊包在多个片层之间。每个片层是由一种如聚乙烯等的材料构成的，这些材料可以热封而不必粘接。尿布是通过在吸湿芯的外侧边界将聚乙烯片的重叠边缘彼此直接加热并封闭而形成的。
在美国专利US4,919,738中描述了多层自粘合叠层或片材料叠层。具体说，该专利公开了一种将多叠层动力粘接在一起的方法，而所述多叠层中至少有一个叠层包括热塑材料。叠层是通过使用压力偏压的叠层辊子获得的，所述叠层辊子之间以预定的表面速度差操作运转。实际上，在一些叠层上，粘接的位置会突起造成坚硬的锉状的突起而不是下凹。
在美国专利US3,733,238中公开了用超声波振动设备的方法将热塑材料层粘接在一起的方法。多个彼此间隔开的，具有与片状元件的一侧直接接触的工作表面的超声波振动传导元件被装配在位于片状元件的相对侧的相对的间隔的支承件表面上，生产热塑叠层材料的全宽度幅片。显然，该技术要求热塑材料层总与机械能量转换工具保持直接物理接触，这会导致幅片的污染，机械磨损以及由此产生的机构效率低下。
在美国专利US4,610,681中公开了一种六层结构的接缝，其包括了覆盖片的外织物层，内不透水层，和形成了衣物衬里的透水层。为了形成小的，没有突出的接合，超声波封接形成了多条线，而这些线则形成了加压区和升高线区。如上所述，该技术实际上是机械的，会造成幅片的污染，机械的磨损和机构效率低。
在美国专利US4,909,804公开了一种接合较厚材料层的方法，其中公开了一种一次性训练裤的接缝，该接缝是通过缝合而接合在一起的。
WO96/19313中公开了一种用于在形成吸湿用品的一部分的幅片上加工孔或狭槽形式的穿透开口的方法，如对吸湿用品的顶片开孔以获得液体可透过性。根据该发明，幅片由至少一个来自放射源的聚焦的电磁束或颗粒束照射其至少一个表面以及需要加工开口的那些幅片区域。在照射过程中，幅片可以与另外一个包括与第一幅片相类似的材料的幅片相接触，并且电磁束和颗粒束的特性以及照射经历时间可以进行选择，从而第一幅片和/或另外的幅片中的材料将被供给足够的能量，从而在紧挨开孔的附近区域使幅片接合。一种流体可被导入到幅片上聚焦点的附近，以从幅片上加工出的孔中移走熔化的/燃烧的/汽化的材料。尽管不存在与要接合的幅片的接触，该技术的目的在于开孔，结果造成熔化材料被移动并传送到顶片的表面。
冲压是用于接合幅片材料的机械粘接技术。在美国专利US5,397,632中，一种用于改进的自动深度空气过滤器中的无纺幅片在不连续的位置上被机械固定。在冲压操作过程中，具有纤维促进结构的多个冲针穿过所有幅片。由此，各个幅片通过纤维和长丝的缠绕而彼此机械地连接和互锁。在该冲针的插入和收回过程中，来自上侧幅片的纤维和中间幅片的相对运动纤维被向前驱动进入下侧幅片。而最终产品的表面摸起来并不光滑。
根据上述先有技术产生的结果，本领域技术人员可以认识到需要提供一种接合特别用在一次性吸湿用品中的厚幅片的方法，可以消除由于熔化的幅片材料的固化而引起的在外表面上形成坚硬锉状突起。该方法不采用与要结合的幅片发生物理接触的热传导工具；该方法至少部分的融化幅片结构中可熔成分，以产生足够的用于接合的粘性；并且该方法可以制造具有优异触觉特性和伴生强度的，具有抗磨损及可透气特性的产品。这是通过下述方法解决的：即将加热流体的高速射流在分离的位置上导入至少两个较厚的多孔的幅片的外表面，并且其中的可熔成分在幅片结构的重叠区中至少部分熔化。
现已发现，本发明的优点在于能够提供一种以非常有效的方式接合较厚多孔幅片的方法；在于提供一种消除在先有技术中常会出现的刺激性的坚硬的锉状突起的方法；在于提供一种不依赖于在先有接合处理技术中通常采用的与幅片结构发生直接接触并会污染幅片结构的加热工具的方法；在于提供一种减少处理时间的方法；在于提供一种由于减少了磨擦和磨损从而导致机械效率提高的方法；在于提供一种具有提高的触觉特性和优异的抗磨损特性且能赢得客户的满意和信任的产品。
本发明描述了一种接合至少两片幅片的方法。所述幅片是多孔的且包括可熔成分，所述幅片被设置成相邻状态以形成幅片结构。所述幅片结构包括外表面和接合幅片的重叠区。该方法的特征在于包括下列步骤：
1)充分加热流体以使所述可熔成分至少部分熔化；
2)将所述加热流体的高速射流向着所述外表面中的至少一个导出；
3)使所述流体在分离的位置上穿透所述幅片；和
4)使所述流体在所述幅片中循环，以至少部分熔化所述可熔成分。
本方法还包括在所述可熔成分至少被部分熔化的同时挤压和冷却所述幅片结构的步骤。
特别是本方法适用于制造一次性吸湿用品。在本发明的一个优选实施例中，该方法用于制作套穿式尿布的侧接缝。
在本发明的另一方面，根据上述所述的方法制造出一种一次性吸湿用品。在根据本发明该另一方面的一个优选实施例中，描述了一种套穿式尿布，其具有包括前部的侧片和后部的侧片的幅片，这些幅片相接合形成重叠的侧接缝，即幅片结构。
通过下述结合附图的描述，本发明将得到更好的理解，其中：
图1是示意性示出的幅片的局部侧视图；
图2是用于接合幅片的装置的简化示意图；
图3是具有典型凸起的滚筒的简化局部剖视图。
在此处，“接合”包括通过将一个元件直接附着在另外一个元件上而使元件固定在另外一个元件上的构型。而“幅片”一词则指材料片。“片”一词并非仅限于单一材料层。这里所用的“一次性”一词用来描述那些不打算洗涤或再次作为吸湿用品保存或使用的吸湿性用品(即在一次使用后就扔掉，并且最好以与环境相容的方式再回收，合成或进行其它处理)。“套穿式尿布”一词是指通常由婴儿和失禁者穿戴的衣物，该衣物可类似内裤地套穿，并且在一次使用后就被扔掉。但是，应该理解，本发明还可以用于其它套穿的尿布，如训练裤，失禁用短裤，妇女卫生衣物或衬裤等等。
图1示意性示出了被接合幅片的局部侧视图。具体说，图1示出至少两个设置成相邻状态以形成幅片结构10的多孔幅片11,12。
根据本发明的教导，幅片中至少有一个包括足够可溶材料，易于被热接合到另外的幅片上，由此则幅片的接合成为可能。本发明适于多孔的(可透气，可透水，或蒸汽可透过的)，包括可溶成分的幅片。该幅片可以是纺织的或无纺的，而且可溶成分可包括纤维或聚合粘结剂，例如，包括如纤维素-木浆，棉花，黄麻，麻等的天然纤维，如玻璃纤维，人造丝，聚酯，聚烯烃，丙烯酸纤维，聚酰胺，芳酰胺(aramid)，聚四氟乙烯金属，聚酰亚胺等的合成纤维；还可包括粘合剂，例如双成分高熔/低熔聚合物，共聚聚酯，聚氯乙烯，共聚聚乙酸/氯乙烯酯，共聚酰胺。幅片还额外包括多种材料的混合物，混合物中构成材料的一部分是不可熔的。
图2示出根据本发明的方法用于接合幅片11,12以形成幅片结构10的装置的简化示意图。装置20包括：具有凸起22的滚筒21；支承滚筒23；转动滚筒21,23的机构24,25；辊子26至33，联合在一起用于引导并促进幅片11,12从能量传递发生的位置经过并离开。应注意到不需加热滚筒21和支承滚筒23。装置20还包括框架(未示出)；通向凸起22的流体喷射口(未示出)；用于加热流体的温度控制装置；用于调整流体压力的压力装置(未示出)；用于驱动26至33的辊子以可控制地向前进给幅片11,12经过能量传递发生的位置并将生成的幅片结构10向前送到下游装置的装置，下游装置如将尿布的固定侧边卷起的单个垫处理装置。
为了突出本发明，幅片11,12来源上游端和幅片结构10的下游终点和采用幅片结构10的商品都未示出。尽管如此，已经公知可用辊子方式提供幅片；并设置有上游展开和拼接机构以向前输送连续长度的幅片经过制作幅片结构的接合机构和/或转换机构。为了简化本发明，这里所描述的装置20包括滚筒21和支承滚筒23。但这决不意味着将本发明仅限制在包括滚筒的装置上。
图3示出了具有典型凸起22的滚筒21的简化局部剖视图。滚筒21包括圆锥形或圆柱形区域34，通过这些区域34导出要求其能至少部分熔化幅片11的可溶成分的流体。在图2中，为了简化，画出了圆柱形区域34。流体喷射口(未示出)与圆锥形或圆柱形区域34的顶表面35联通。流体最好为空气，但也可以采用其它气体。另外，也可以采用能量场(energetic fields)获得相同的部分熔化效果。在本发明中，流体被加热到从材料熔点减去30摄氏度的温度到材料熔点加上100摄氏度的温度范围内。压力为从0.1E5至10E5N/m2。圆锥形或圆柱形区域34的顶表面35的直径在1毫米至8毫米之间，锥形或圆柱形区域34的孔36的直径在0.1毫米到6毫米之间。圆锥形或圆柱形区域34最好与幅片11,12的重叠区15以相同的速度或几乎相同的速度运动，延续的时间间隔为10至1000毫秒。这样可根据需要使加热的流体向至少一个外表面13,14导出，以得到在强度和柔软性方面质量最佳的接缝。在滚筒21上的凸起22可以设置预定图案(pattern)：对每个凸起进行设计和定位以促使被接合幅片11,12中的重叠区域15凝结以在幅片结构10的重叠区域15内实现预定的图案。滚筒21可具有锯齿形图案的凸起22，其环绕滚筒21的每个端部周向延伸。
支承滚筒23最好是光滑的，经过表面处理的钢质正圆柱体，该滚筒23可以通过可控速度直流电机独立地驱动。在另外的构型中，滚筒23最好与幅片11,12在重叠区域15上以相同的速度运动，时间延续段为从20到1000毫秒。在该时间间隔内，重叠区域15发生变形和粘接，随后是冷却。也可以有多个支承件和以大小在0.5倍至1.5倍产品节距(product pitch)之间的节距安装在承载件上的流体喷射口。
装置24,25用来驱动滚筒21和支承滚筒23。因此，它们具有动力转动滚筒21和支承滚筒23的驱动机构，从而在其表面速度之间有预定的可调的关系。这些关系包括：同步的，非同步的，表面速度相等的，或者其间有预定表面速度差以使对滚筒21或者支承滚筒23的驱动比另外一个更快。辊子26至33整体上以可保持预定程度的张紧或拉伸的表面速度驱动，从而不管是松懈的幅片条件还是过紧/过拉伸的幅片都不会造成不理想的有害的结果。
根据本发明的创造性方法，如图1所示，相邻布置以形成幅片结构10的至少两个幅片11,12的接合包括下列步骤：对流体进行足够的加热以使可熔成分至少部分熔化；将加热流体的高速射流导向至少一个外表面13,14；使流体从不连续的位置透过幅片11,12；使流体在幅片中循环以至少部分熔化可熔成分。处于优选温度和压力下的加热流体从流体喷射口进入凸起22的圆锥形或圆柱形区域34，并从孔36流出，结果形成加热流体的受控的集中的射流形成。该射流被导向要接合的幅片11,12的外表面13,14。流体还可通过脉动施加装置传送到外表面13,14上。加热流体的射流冲击是可以调节的，从而使射流本身引入的能量加上如加热支承(如果是这种情况的话)，喷射口表面，幅片11,12的变形和幅片11,12的内部摩擦等的其他方式引入的能量足以至少部分地熔化幅片11,12中的可熔成分以产生一定的粘性，而该粘性将在重叠区域15上受挤压时形成牢固的接合。在整个幅片11,12中可熔成分的熔化是以非均匀进行的。特别是，可熔成分的外部表面开始熔化，而可熔成分的内部表面则仍留在固体状态。可熔成分外部表面的熔化的结果是产生了一定的粘着性。
该方法还包括下述步骤：在可熔成分处于部分熔化时即处于粘着状态，用挤压工具挤压幅片结构10。这是通过用挤压工具对幅片结构的加压来完成的。挤压工具的温度至少低于幅片结构10的熔点。可熔成分的粘着性使幅片11,12结合，并且由此避免了熔化的幅片材料的积聚。而这种熔化的材料在固化时通常在许多幅片的外表面上形成坚硬的、锉状的突起。挤压工具可以根据美学标准设计。
该方法在30至500克/平方米单位重量的、包括纤维范围在低于一个但尼尔的微纤维到1至7但尼尔的普通纤维的无纺幅片上可以获得很好的效果。无纺幅片可包括股线直径大于1毫米的洋纱材料。鉴于幅片的厚度，处理幅片11、12所要求的时间间隔在该技术中为100至1000毫秒。在特别的使用中，加热需要100至150毫秒，而挤压/冷却则需要150至250毫秒。
在本发明的另外一个方面，上述方法可用于一次性吸湿用品的制造中。特别是本发明适合为一次性吸湿用品制作侧接缝，其中一次性吸湿用品为一次性套穿式尿布。根据本发明方法制作的一次性套穿式尿布具有外表面、内表面、前部、后部、裆部，各所述前部和各所述后部包括具有侧边和重叠侧接缝的侧片，所述重叠侧接缝将前部和后部的侧片接合在一起以形成腿部开口和腰部区。由此，套穿式尿布最好包括：主体层；位于前部各侧片中的可弹性延伸拉伸叠层，及前拉伸叠层；位于后部各侧片中的可弹性延伸拉伸叠层，及后拉伸叠层；和各位于前部和后部的至少一个弹性腰带。套穿式尿布包括腿部开口，该腿部开口额外具有弹性腿部件以提高在裆部与腿的适配性。
套穿式尿布具有包括主片和一对腿翼片的裆部。吸湿芯通常位于裆部的主片中，这是由于身体排出物通常在该区域排出。腿翼片从主片的各侧边开始并沿着侧边横向向外延伸。各腿翼片大致形成弹性腿部件的至少一部分。套穿式尿布的外表面包括在使用时远离穿用者身体的那部分。尿布的内表面与外表面相反，并包括在使用时靠近穿用者身体的那部分。
可弹性伸展的拉伸叠层(前拉伸叠层和后拉伸叠层)在前部和后部的各侧片形成。各拉伸叠层受到机械的拉伸或牵引而使拉伸叠层可以在至少横向方向上弹性伸展。横向方向(x方向或宽度方向)定义为平行于套穿式尿布的横向中心线的方向。侧片最好为主体层和其它如顶片等部件，或这些部件的任何组合的延伸部分。在重叠侧接缝内，拉伸叠层最好通过机械拉伸而激活以在该区域提供附加的延伸性。重叠侧接缝也可以不通过机械拉伸激活。
为了提供容纳身体排出物所必需的吸湿性，套穿式尿布包括可透液体的顶片和位于顶片和主体层之间的吸湿芯。顶片靠近吸湿芯的朝向身体表面，并最好通过本领域公知的附着装置接合在吸湿芯和主体层上。在一优选实施例中，顶片和主体层通过将它们直接地接合在套穿式尿布的吸湿芯或弹性片件或其它部件上而间接地接合在一起。顶片最好包括被接合在一起的三个不同的层。可透液体的主要层(primary layer)位于吸湿芯上，用于快速地将液体吸收到用品中。阻挡层与主要层接合，并最好是可拉伸的，更优选的是疏水的，而使侧片可以被机械拉伸而不裂开或撕开，同时沿套穿式尿布的侧面提供挡箍。弹性腿部件最好包括衬箍和挡箍。衬箍最好由与主体层、阻挡层或两者都有效接合的一个或多个弹性腿部件形成，最好位于裆部的腿部翼片中的主体层和阻挡层的护翼部之间。挡箍最好由护翼(阻挡层的直立部分)，将直立部分的纵向端部紧固到主要层上的闭合机构，有效接合到直立部分的弹性间隔件形成。
主要层最好是柔顺的，感觉柔软的，并且对穿用者的皮肤没有刺激。主要层是可透液体的，可使液体(如尿液)透过其厚度。合适的主要层可以由多种材料制成，如多孔泡沫、网状泡沫、多孔塑料薄膜或三维扩展成形薄膜；或天然纤维、合成纤维、或天然与合成纤维组合的纺织或无纺网面。主要层最好是不与主体层在末端连接的，从而使液体不会沿着主要层并透过主要层渗透到套穿式尿布的边缘，因此液体不会流到直立部分之下并越过由阻挡层形成的挡箍的直立部分，并且较多的可拉伸材料可位于侧片内以产生更结实的拉伸叠层。主要层最好覆盖吸湿芯的朝向身体表面的主要部分，最好在至少裆部覆盖吸湿芯的所有朝向身体表面区域，从而使排放到套穿式尿布上的排出物穿透主要层，在那里排出物由吸湿芯吸收。主要层向着吸湿芯的侧边横向向外延伸，最好至少在裆部超过吸湿芯的侧边。主要层在裆部的腿部边缘向内终止。在最优选的构型中，主要层靠近阻挡层的近边终止(即主要层的终止边靠近近边)或终止边离开近边并位于近边的内侧。“靠近”在本文中用于表示主要层在近边终止，在制造过程中由于机器的公差或由于制造主要层使其面积变化会加上或减去在近边的内部或超过近边延伸的主要层材料的一小部分。在顶片的优选实施例中，阻挡层形成弹性腿部件(最好是衬箍和/或挡箍)，并且最好是拉伸叠层的一部分。
主体层最好包括形成前部、后部和裆部的连续的片或网面。因此，主体层为套穿式尿布的主要层或层面。(这里所用的“层”一词并不将该部件限于单一的材料层面，层实际上包括必需材料的叠层、或薄片或网面的组合。)主体层具有内表面和外表面，主体层的内表面和外表面在方向上对应套穿式尿布的内表面和外表面。
主体层大致确定套穿式尿布的整体形状。主体层起到套穿式尿布的主要结构层的作用，可以在上面添加或接合其它的部件。主体层位于套穿式尿布的所有或大部分表面区域上，在某些实施例中，主体层的某些部分是开孔的、切去的或去除的(“开窗的”)以提高套穿式尿布的拉伸性和/或透气性或套穿式尿布在那个区域弹性。主体层可以包括没有“接点”或接缝的连续的薄片或网面，而使力透过整个层分配传递或者主体层可以包括与弹性腿箍有“接点”的连续薄片或网面。如上所述，连续薄片或网面可以包括材料的单个网面或不同材料的数个连续网面或层面的叠层。主体层可以形成外表面、内表面、外表面和内表面或两者之一的一部分，或者可以整个地位于套穿式尿布的内部。主体层最好在裆部形成套穿式尿布的外表面。
由于至少主体层的一部分受到机械拉伸，以便在侧片提供拉伸叠层，主体层优选是可拉长的，最好是可拉伸的(但不必是弹性的)，于是，一旦受到机械拉伸，主体层至少具有一定程度的永久伸长，使其无法完全回复到初始的未变形状态。主体层可以具有任何一种在吸湿用品中公知使用的材料；如纺织或无纺网面；如聚乙烯、聚丙烯或其混合物的热塑薄膜的聚合薄膜；上述材料的叠层；或复合材料。在优选实施例中，主体层受到很小的或非断裂或撕裂的机械拉伸。因此，主体层最好是聚合薄膜。
由于主体层最好为聚合薄膜，其通常是不透液体(尿液)的，从而使主体层还起到防止吸湿芯中吸收和容纳的身体排出物弄湿与套穿式尿布10接触的衣物，如床单或内衣(即起到传统的尿布底片的作用)。如果主体层不是不透液体的，在吸湿芯下面通常还需要诸如传统底片的附加层。如果需要的话，主体层为可透气的(允许空气和水蒸气透过)。或者，主体层可以包括微孔的通常为低强度和伸长的可透气材料。这种薄膜的实例为由ExxonChemical Company生产的商品名为EXXAIRE的产品。具有较好的拉伸性但不透气的用作本发明的主体层的示例性薄膜包括由Clopay Corporation ofCincinnati,Ohio生产的代号为Clopay1401的聚合薄膜或可从Tredegar ofTerre Haute,Indiana购得的代号为X-8323或X-9954的薄膜。
套穿式尿布包括带具有改善对液体和其他身体排出物的容纳性能的弹性腿箍的腿部区。弹性腿部件在裆部和绕腿部开口改善对液体和其他身体排出物的容纳性能。各弹性腿部件还包括各种减少身体排出物在腿部护翼片泄漏的不同实施例(弹性腿部件可以是并有时指的是腿带、侧护翼、挡箍或弹性箍)。US3,860,003描述了一种一次性尿布，其提供可收缩的腿部开口16，具有侧护翼和一个或多个弹性片件，以提供弹性腿箍(衬箍)。US4,909,803描述了具有直立弹性护翼(挡箍)的一次性尿布，以改善腿部区域的容纳性能。US4,695,278公开了一种具有包括衬箍和挡箍的双重箍的一次性尿布。US4,795,454公开了一种具有防漏双重箍的一次性尿布，其中顶片弥补了尿布侧边的不足而防止渗漏到衣物的侧面。当各弹性腿部件的构型与所述的腿带、侧护翼、挡箍或弹性箍中的任一类似时，优选的是，各弹性腿部件包括衬箍和挡箍的组合。衬箍和挡箍最好如US4,795,454中所示的形成。
吸湿芯最好靠近主体层的内表面，并最好通过本领域公知的附着手段接合在那里。例如，主体层可以通过均匀连续的粘结剂层、粘结剂的加花层或单独的粘结剂线、粘结剂螺旋线或点的阵列而紧固在吸湿芯上。或者，附着手段可以包括本领域公知的热接合、压力接合、超声波接合、动力机械接合或其它合适的附着手段或这些附着手段的组合。另外也可以用本发明的方法将主体层接合到吸湿芯上。
吸湿芯可以为任何一种吸湿结构，通常是可压缩的、妥贴的、对穿用者的皮肤无刺激并且能够吸收和保持诸如尿液和其它特定身体排出物。吸湿芯可以制成各种形状和尺寸(如长方形、沙漏形、T形、不对称形等)，并由一次性尿布和其它吸湿用品中通常采用的多种液体吸湿材料制成，例如通常称为“空气毡”的粉碎木浆。其它合适的吸湿材料包括起皱的纤维素填料，包括共成的熔喷聚合物，交联纤维素纤维，包括幅片卷(tissue wraps)的幅片，吸湿泡沫，吸湿海绵，超吸湿聚合物，吸湿凝胶材料，或任意等同材料，或这些材料的组合。吸湿芯的构型和结构会是各种各样的(如吸湿芯可以具有不同的厚度区，不同亲水梯度，不同的超吸湿梯度，或较低的平均密度和较低的单位重量接收区；或包括一个或多个层面或结构)。吸湿芯的总吸湿能力应与设计承载能力和套穿式尿布的设计用途匹配。此外，吸湿芯的尺寸和吸湿能力各不相同而适应从婴儿到成人的不同穿用者。
通常，吸湿芯具有非对称的，修正的沙漏形并具有朝向穿用者身体的表面(内表面)和与朝向身体表面相对的衣物表面。在US5,360,420中公开了一种获得了广泛的认可和商业成功的用作本发明吸湿芯的示例性吸湿结构。优选的是，吸湿芯包括化学强化的纤维素纤维的接收/分配层和包括木浆纤维和超吸湿材料混合物的位于接收/分配层之下的存储层，正如US4,610,478中所公开的吸湿芯。
套穿式尿布最好还设有通气口或孔，以使空气和水蒸气能进入或从套穿式尿布排出。在优选实施例中，孔位于侧片中。在这种构型中，可以防止身体排出物从靠近吸湿芯的区域渗漏出来，但允许空气和水蒸气在该产品中交换而不会使该产品由于身体的分泌而过分地润湿，并且不会使穿用者不舒服。在套穿式尿布的其它侧片上或套穿式尿布的某些部件如腰带上还带有通气口。也可以通过在本领域公知的多孔材料中选择套穿式尿布的材料而提供透气性。例如，主体层可以包括可透气(可透水蒸气)但不透液体的塑料薄膜。弹性片件可以为开孔式材料，诸如泡沫、洋纱、无纺物，或透气弹性薄膜，以进一步增加套穿式尿布的透气性。如果根据本发明的方法加工重叠侧接缝，则其可以保持优良的可透气性。腰带还可以为可透气的以使水蒸气从套穿式尿布的前部和后部中逸出。通过对于腰带的结构选择相对可透气的材料和/或通过在此处讨论的相对于侧片中的拉伸叠层的腰带上开孔或通气口而为腰带提供透气性。在另一实施例中，腰带可以是疏水的、亲水的或疏水/亲水件的组合物。亲水腰带用于将水分拉出穿用者的皮肤以保持皮肤不沾水。或者，疏水腰带用于防止尿布吸收的液体通过腰部开口渗漏。疏水/亲水腰带的组合用于防止尿布吸收的液体通过腰部开口渗漏，同时将水分拉出穿用者的皮肤以保持皮肤不沾水。
通常，一次性套穿式尿布可以通过将前部的侧片接合到后部的侧片上而形成。根据本发明的优选实施例，一次性套穿式尿布包括前部侧片和后部侧片。侧片接合形成重叠的侧边，即根据此处所述方法的幅片结构10。

Claims (10)

1．一种接合至少两片幅片(11,12)的方法，所述幅片(11,12)是多孔的且包括可熔成分，所述幅片(11,12)被设置成相邻状态以形成幅片结构(10)，所述幅片结构(10)包括外表面(13,14)和位于所述幅片(11,12)之间的重叠区域(15)，其特征在于，包括下列步骤：
1)充分加热流体以使所述可熔成分至少部分熔化；
2)将所述加热流体的高速射流向着所述外表面(13,14)中的至少一个导出；
3)使所述流体在分离的位置上穿透所述幅片(11,12)；和
4)使所述流体在所述幅片(11,12)中循环，以至少部分熔化所述可熔成分。
2．根据权利要求1所述的方法，其特征在于，还包括在所述可熔成分至少被部分熔化的同时，用挤压工具挤压所述幅片结构(10)的步骤。
3．根据权利要求2所述的方法，其特征在于，所述挤压工具温度至少低于所述幅片结构(10)的熔点。
4．根据前述任一项权利要求所述的方法，其特征在于，所述可熔成分的所述至少部分熔化主要发生在所述重叠区域(15)中。
5．根据前述任一项权利要求所述的方法，其特征在于，所述可熔成分的所述至少部分熔化在所述幅片(11,12)中以非均匀状态发生。
6．根据前述任一项权利要求所述的方法，其特征在于，所述流体是空气。
7．根据前述任一项权利要求所述的方法，其特征在于，此方法可在一次性吸湿用品的制造过程中使用。
8．根据权利要求7所述的方法，其特征在于，所述方法用于制作侧接缝，其中所述一次性吸湿用品为一次性套穿式尿布。
9．一种根据前述任一项权利要求所述的方法制作的一次性吸湿用品。
10．根据权利要求9所述的一次性吸湿用品，其特征在于，所述一次性吸湿用品是一次性套穿式尿布，并且所述幅片结构包括接合形成重叠侧接缝的前部的侧片和后部的侧片。
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