CN1245119C - 用热收缩材料制造的环搭扣部件 - Google Patents

用热收缩材料制造的环搭扣部件 Download PDF

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CN1245119C
CN1245119C CNB018182801A CN01818280A CN1245119C CN 1245119 C CN1245119 C CN 1245119C CN B018182801 A CNB018182801 A CN B018182801A CN 01818280 A CN01818280 A CN 01818280A CN 1245119 C CN1245119 C CN 1245119C
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T·R·马丁
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Kimberly Clark Worldwide Inc
Kimberly Clark Corp
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Abstract

用纤维状热收缩材料制造的钩环搭扣的环部件。制造此环部件的方法包括加热纤维状可热收缩材料的一面至足够使材料收缩的温度，从而连接这一面上的纤维并同时使反面的纤维打皱形成环。

Description

用热收缩材料制造的环搭扣部件
技术领域
本发明涉及钩环搭扣的环部件，以及制造此环部件的方法。
背景技术
许多搭扣系统，如尿布搭扣系统，将钩和环系统合并以易于扣紧和放松。钩部件典型地包括层压了许多凸起钩的平面塑料片，钩与环部件——第二片平面塑料片上突起的大量环——啮合。各种类型的环部件可以由许多不同方法制造。为了在生产过程中和生产之后稳定环部件，制造环部件的方法典型地需要大量步骤。例如，包括有绉状环材料和机械收缩拉伸材料的方法就需要额外的稳定丝网的处理步骤。此外，有时为了改进环部件的制造工艺，就要舍弃环部件的柔软性。
需要或期望可以高效制造并保持其柔软性的钩环搭扣的环部件。
发明简述
本发明涉及用热收缩材料制造的钩环搭扣的环部件。此环部件是通过在热收缩网的一面加热，使材料收缩而制备的。更明确地说，是加热纤维，拉伸，并在拉伸状态下淬火，使得纤维趋于收缩。收缩使网的第二面打皱形成环。通过将纤维热连接而在热收缩材料的受热面获得附加稳定性。
例如，S编织连接花纹纺丝粘合网可从有足以加热到使材料收缩的热风刀下通过。然后在处理过程中对编织丝控制真空，从而使网在收缩方向运动。所得环部件保持了热收缩网的柔软性并在横向收缩。
了解了前述内容，本发明的特征和优点是提供钩环搭扣的环部件，它可以高效制造并保持原材料的柔软性。本发明的另一个特征和优点是提供制备钩环搭扣环部件的高效方法。
附图简述
图1是相互啮合前，钩部件和环部件的侧视图；
图2是环部件的侧视图；
图3是制备环部件的设备的俯视图；
图4是设备俯视图，包括制备环部件的分区热风刀；和
图5是具有S编织连接花纹的环部件的顶视图。
定义
在专利说明书的上下文中，下面每个术语或短语将包含下面的意义：
“横向”指织物的宽度方向，通常正交于它的生产方向。
“纵向”指织物的长度方向，在它的生产方向上。
“聚合物”包括但不局限于，均聚物、共聚物，例如，嵌段、接枝、无规和交替共聚物、三元共聚物等，以及它们的混合和改性。此外，除非有特别限定，术语“聚合物”应当包括材料所有可能的几何结构。这些结构包括但不局限于，全同立构、间同立构和无规立构对称。
“可释放粘贴”、“可释放啮合”和它们的变换说法指连接的或可连接的两个元件，在缺少施加于其中一个或两个元件的分离力时趋于保持连接，且两元件可以在不造成本质上永久变形或破裂的情况下被分离。所需分离外力典型地超过戴吸收套时遭遇的力。
“可热收缩”指当暴露于某种阈值或热时会收缩，或拉回的材料。
这些术语可在专利说明书的余下部分用附加的语言来定义。
优选实施方案的详述
本发明涉及钩环搭扣的环部件以及制造此环部件的方法。环部件由可热收缩的材料制备。
环部件特别适合用于一次性使用的吸收制品的搭扣系统。合适的制品的例子包括尿布、训练裤、妇女卫生产品、失禁产品、其他个人护理或健康护理套，包括医用套等等。
如图1所示，钩部件20和环部件22可以相互连接在一起形成可释放粘贴或可释放啮合。钩部件20具有许多独立钩24，通常垂直突出于有回弹力的钩衬背材料26。类似的，环部件22具有许多独立环28，通常垂直突出于有回弹力的环衬背材料30。独立钩24和独立环28，当相互接触时便相互啮合，钩24锁入环28中，直至强制分离，将钩24从环28中拉出。
许多不同的钩部件20适合于和本发明的环部件22一起使用。合适的钩部件20的某实例可以是Velcro，美国，曼彻斯特，新罕布什尔州，商业名称HTH-851。其它合适的钩部件20也可以是Velcro，美国。独立钩24典型地具有基本垂直突出于钩衬背材料26的基本部件和延伸自基本部件的自由端，自由端弯曲或成角以便于和环部件22上相应的环28啮合。钩24典型的是与钩衬背材料26一起成型的。
合适的钩部件20通常每平方厘米上有约16～约620个钩，或每平方厘米上有约124～约388个钩，或每平方厘米上有约155～约310个钩，钩24合适地具有约0.00254厘米(cm)～约0.19cm高度，或约0.0381cm～约0.0762cm。钩合适地由热塑性聚合物聚酰胺、聚酯、聚烯烃(例如聚丙烯或聚乙烯)或其他合适的材料模制或挤制而成。同样地，钩衬背材料26可由任何这些或其它合适的材料制成。钩衬背材料26通常厚度在约0.5毫米(mm)～约5mm范围内，合适的范围是约0.8～3mm，每平方米基重约20克～约70克。
本发明的环部件22基本上是单层可热收缩纤维状材料，如图2所示。选择性地，多层可热收缩纤维状材料可用于制备本发明的环部件22。材料纤维在材料的第一面32上形成了环28并热接合在材料第二面34上，从而稳定了纤维并在材料第二面34上产生了相对光滑的表面。第一面32和第二面34间的纤维是连续地，使得单纤维可形成多个环28且每个环28通过材料第二面34上纤维的热接合部件36而相互分开。
环28不一定要是统一的高度，但优选地具有高度范围约0.00254cm～约0.19cm高度，或约0.0381cm～约0.0762cm。环衬背30包括纤维材料的热接合部件36，因此厚度是材料第二面34上的热接合纤维的厚度。因而，环衬背30合适地不厚于0.04cm，更合适地不厚于0.01cm，甚至更合适地不厚于0.0025cm。环衬背30应具有的厚度至少为0.000254cm，合适地至少为0.000381cm。环部件22上环28的密度很大程度上依赖于所用可热收缩纤维状材料的类型，并可在每平方厘米约16～约620个环范围内，或每平方厘米上有约124～约388个环，或每平方厘米上有约155～约310个环。
如所提及的，本发明的环部件22是由可热收缩纤维状材料制造的。此材料合适地是连接梳毛网、纺丝粘合网或熔吹网形式的无纺网。如所提及的，此材料也可以是多层材料，具有例如，至少一层熔吹网和至少一层纺丝粘合网，或其它合适的无纺网的组合。多层材料的多个层合适地是相互热连接的，并且在树脂、旦数、基重或其它材料特性或这些特性的组合方面有所不同。
无纺网或纤网，合适地是聚合物或聚合物的组合，如聚烯烃、聚酯、聚酰胺和弹性热塑性聚合物。合适的聚烯烃的实例包括聚乙烯、聚丙烯、聚丁烯、乙烯共聚物、丙烯共聚物和丁烯共聚物。
用于本发明材料的合适的弹性热塑性聚合物包括由嵌段共聚物制得的聚合物，如聚氨酯、共聚醚酯、聚酰胺聚醚嵌段共聚物、聚酰胺聚酯嵌段共聚物、乙烯乙酸乙烯酯共聚物(EVA)，具有通式A-B-A’或A-B的嵌段共聚物，如共聚(苯乙烯/乙烯-丁烯)、苯乙烯-聚(乙烯-丙烯)-苯乙烯、苯乙烯-聚(乙烯-丁烯)-苯乙烯、聚苯乙烯/聚(乙烯-丁烯)/聚苯乙烯、聚(苯乙烯/乙烯-丁烯/苯乙烯)等等。
合适的弹性共聚物的商业实例有，例如，被称为KRATON材料的那些弹性共聚物，由美国德克萨斯州的Shell化学品公司提供。KRATON嵌段共聚物可有几种不同的配方，其中许多由美国专利4,663,220、4,323,534、4,834,738、5,093,422和5,304,599确认，在此引入作为参考。
其它可以使用的实例性的弹性材料包括聚氨酯弹性材料，如B.F.Goodrich & Co.提供的商标为ESTANE的材料或Morton Thiokol Corp.提供的商标为MORTHANE的材料，聚酯弹性材料如，美国特拉华州的E.I.Dupont De Nemous公司提供的商标为HYTREL的材料，和被称为是ARNITEL的那些材料，先前由荷兰的Akzo Plastics of Arnhem提供而现在由荷兰的DSM of Sittard提供。
环部件22可通过加热可热收缩纤维状材料的第二面34来生产，如图3和图4中的设备38显示的那样。加热可通过使用设备40如热风刀、红外热源或其它合适的方式来实施，如这里所用的，术语“热风刀”指一种装置，压力下的热空气流可以通过它发射和引导。有了这样的设备，也可以控制热空气的合成喷射空气流。传统的热风刀描述于1986年2月4日公开的美国专利4,567,796中，在此引入作为参考。分区热风刀，其中热空气可应用于间隔分离区域，描述于2000年5月23日公开的美国专利6,066,221中，在此引入作为参考。图3中的设备38显示了在可热收缩纤维状材料的整个宽度上方进行的连续加热。图4中的设备38显示了热风刀40在可热收缩纤维状材料的宽度上方的间隔分离区域进行加热，从而得到了环部件22，它具有分布在没有环28的区域之间的环28间隔分离区域。
加热足以引起材料第二面(暴露的)34的收缩并使得材料第二面34上的纤维连接在一起或至少成为热稳定的。更明确地，加热温度在材料熔点的±5℃以内。当使用热风刀40时，材料以线速度约100～3000英尺/分从热风刀40下方通过，更普遍的是约500～2500英尺/分，希望达到约1000～2000英尺/分。通常，从热风刀40出口的风速为约1,000～25,000英尺/分，优选约5,000～20,000英尺/分，更优选8,000～15,000英尺/分。材料在加热状态下拉伸并在拉伸状态下淬火，从而使材料收缩。典型地，当暴露在热风刀的热量下时，材料趋于在横向上收缩。然而，材料可以在任何合适的方向上收缩。在图3和图4中，横向由箭头48显示，纵向由箭头50显示。
收缩量应为起始材料长度/或宽度的约10％～约40％，合适的是起始材料长度/或宽度的约15％～约35％，更合适的是起始材料长度/或宽度的约20％～约30％，当材料收缩时，材料第一面32上的纤维聚集，这样就形成了环28。期望的是，无纺材料具有预存的内纤维连接花纹，如纺丝粘合网中的热连接花纹。连接花纹42的合适实例为S-编织，如图5所示。另一个合适的内纤维连接花纹包括△连接。具有预存的内纤维连接花纹的优点是更好地决定趋于在连接区域之间出现的环28的间隔和尺寸。
如图3和图4所示，当加热材料第二面34时，可以将材料放在有真空器46的成型丝网44上。可控制真空器的，即，加大力度、减小力度或关闭，使得加热的材料在收缩方向运动。成型丝网44可通过在其表面形成凹槽、孔、锯齿等等花纹而变换，以使得加热材料第二面34时，只有与有花纹的成型丝网44接触的材料部分发生热收缩。使用有花纹的成型丝网44得到有花纹的环部件22。
连接花纹，如图5所示的S-编织连接花纹42，可在热连接工艺中应用到材料上。S-编织连接花纹42和其它合适的连接花纹描述于1999年10月12日公开的美国专利5,964,742中，在此引入作为参考。期望的是，纺丝粘合网的约10～25％与S-编织花纹连接。
本发明的环部件22保持了材料第一面32上的原材料的柔软性。环部件22由至少一层材料制造，不经过任何机械拉伸并且除加热外，未使用粘接剂或其它任何类型的连接机构。因此，本发明的方法是制造功能环部件22的高效、高经济的方法。
应该认识到前述实施方案的细节是作为举例说明的目的给出的，并不解释为限定了本发明的范围。尽管上面只详细描述了少数本发明的实用性的实施方案，但本领域技术人员应该易于理解，即对于本实用性实施方案的不从本质上脱离本发明的许多改进是可能的。因此，意味着所有这些改进都包括在本发明范围之内，它们在下面的权利要求中有定义并且所有的改进意义相同。此外，认识到可能认为许多实施方案都不具备某些实施方案所有的优点，尤其是优选实施方案的优点，然而缺少某个特定的优点不应该被理解为此实施方案超出了本发明范围。

Claims (15)

1.一种含有钩部件和环部件的钩环搭扣；
钩部件包括钩衬背和多个突出于钩衬背的钩；
环部件包括第一热收缩材料层，在此材料的第一面上带有多个环纤维，和第二热收缩材料层，在此材料第二面上有多个热稳定纤维，其中第一热收缩材料和第二热收缩材料热连接在一起。
2.权利要求1的钩环搭扣，其中第一热收缩材料和第二热收缩材料含有彼此不同的旦数。
3.权利要求1的钩环搭扣，其中第一热收缩材料和第二热收缩材料含有彼此不同的基重。
4.权利要求1的钩环搭扣，其中第一热收缩材料和第二热收缩材料含有彼此不同的树脂。
5.权利要求1的钩环搭扣，其中第一热收缩材料和第二热收缩材料各含有热收缩无纺网。
6.权利要求5的钩环搭扣，其中第一热收缩材料和第二热收缩材料的热收缩无纺网选自连接梳毛网、纺丝粘合网和熔吹网。
7.权利要求5的钩环搭扣，其中每个热收缩元纺网含有选自聚烯烃、聚酯、聚酰胺和热塑性弹性聚合物的聚合物。
8.权利要求7的钩环搭扣，其中每个热收缩元纺网含有选自聚乙烯、聚丙烯、聚丁烯、乙烯共聚物、丙烯共聚物和丁烯共聚物中的一种或几种的聚烯烃。
9.权利要求5的钩环搭扣，其中该热收缩无纺网中的至少一种具有S-编织连接花纹。
10.权利要求5的钩环搭扣，其中该热收缩无纺网中的至少一种具有10～25％的连接区域。
11.权利要求1的钩环搭扣，其中第一和第二热收缩材料中的至少一种在横向上收缩。
12.含有权利要求1-11任一项的钩环搭扣的吸收制品。
13.权利要求12的吸收制品，其中该制品为尿布、训练裤或失禁产品。
14.权利要求12的吸收制品，其中该制品为妇女卫生产品。
15.含有权利要求1-11任一项的钩环搭扣的医用服装。
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