CN1251516A - 带有改进的吸入和分布的高渗透率的衬里 - Google Patents

带有改进的吸入和分布的高渗透率的衬里 Download PDF

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CN1251516A
CN1251516A CN98803875A CN98803875A CN1251516A CN 1251516 A CN1251516 A CN 1251516A CN 98803875 A CN98803875 A CN 98803875A CN 98803875 A CN98803875 A CN 98803875A CN 1251516 A CN1251516 A CN 1251516A
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fabric
shin
goods
individual
liquid
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CN1135100C (zh
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T·J·斯托克斯
D·F·克拉克
E·G·巴罗纳
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Kimberly Clark Worldwide Inc
Kimberly Clark Corp
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    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • 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
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    • 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
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    • 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
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    • A61F13/51474—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its structure
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    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
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    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
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    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
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    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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    • 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
    • A61F13/15203—Properties of the article, e.g. stiffness or absorbency
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Abstract

一种个人贴身制品用的吸湿材料,它是由直径至多为40微米的可润湿纤维制成织物。而这种织物在其远离穿着者一侧具有点不粘合花纹的受控空隙。这种织物是以小于1.5的超过量/透过量之比接收50ml的液体污物。这样的织物材料可以用于个人贴身制品如尿布、运动短裤、成人失禁衣着、吸湿内裤和妇女卫生制品。特别有关的是裤裆宽度最多为7.6cm的窄裤裆尿布。

Description

带有改进的吸入和分布的高渗透率的衬里
发明领域
本发明涉及吸湿制品，特别是可用于个人贴身产品如一次性尿布、失禁保护件、儿童贴身运动短裤或卫生巾等。更具体地说，本发明涉及这样的吸湿制品，其中的一部分设计成用来快速吸入和分布重复地涌到制品的其余部分上的液体。
发明背景
个人贴身产品属于吸湿制品，这包括尿布、运动短裤、妇女卫生产品如卫生巾、失禁衣着等。这类产品是设计用来吸收和包含人体排出物，且一般是在较短时间通常经若干小时使用后即抛弃的一次性物品，即不是用来经洗涤而再次使用的。这类产品通常贴放于穿着者的身体上或邻近其身体放置，以吸收和盛装人体的种种排出物。所有这类产品一般包括透液的体侧衬里或罩、不透液的外罩或背片以及设置于此体侧衬里和外罩之间的吸湿结构。吸湿结构可以包括直接在体侧衬里之下与其成液体连通接触的液涌层以及吸湿芯，此吸湿芯通常由纤维素短绒毛纤维和紧邻其下并与液涌层成液体连通接触的吸湿胶凝粒的混和或混合物形成。
个人贴身吸湿制品最好具有低的从产品中的泄漏并给穿着者以干燥感。业已发现，尿可以以高达15～20ml/sec的流率和高达280cm/sec的速度发生，结果吸湿制品如尿布就可能会从大腿或前或后腰区泄漏出。吸湿制品不能快速地吸液还会造成在液体为吸湿结构吸收之前，过量地汇集于体侧衬里的面向身体的一面。这种汇集的液体会润湿穿用的皮肤并能从吸湿制品的大腿或腰口漏出，造成不适的、潜在的皮肤健康问题，同时脏污穿着者的外衣或床上用品。
液体的泄漏和汇集可以源于产品设计中或产品中个别材料的种种性能缺陷。这方面问题的原因之一是，用来超吸收和保持体排出物功能的吸湿芯缺乏足够的液体吸入率。于是，一定吸湿制品的特别是吸湿制品中所用的体侧衬里和液涌材料的液体吸入本领必须符合或超过进入吸湿制品内的期望的液体输出率。在第二、三或四次液涌时，吸液率的不充分甚至更有害于产品的性能。此外，当有许多脏物存储于目标位置而造成湿重保持材料结构下沉或垂下时，由于湿润的产品配合不良也会造成泄漏。
已采取过种种方法来减少或消除个人贴身吸湿制品的泄漏。例如已在这类吸湿制品中加入了有形的阻挡件，如弹性的裤口和弹性的保持折片。此外，对液涌通常发生的吸湿结构区域(有时称作目标区)中吸湿材料的数量与构型也进行了改进。
另一些改进吸湿制品的整体吸液本领的方法集中于体侧衬里及其能让液体快速传到吸湿制品的吸湿结构的本领。非织造材料，这包括粘结的粗梳织物和纺粘织物已广泛用作体侧衬里。这类非织造材料一般是用来使其充分开口和/或多孔化，以使液体快速通过同时起到使穿着者的皮肤与衬里下的湿润吸湿件保持分开的作用。改进衬里材料的液体吸入的尝试已包括例如，给衬里材料穿孔，用表面活性剂处理形成衬里材料的纤维，以加强衬里的润湿性并改变这种表面活性剂的耐久性。
还有另一种一般在体侧衬里和吸湿芯之间引入一层或多层材料的方法，以加强吸湿产品的液体吸入性能，并将吸湿性和邻近穿着者皮肤的体侧衬里分开。这样一种增设的层通称作液漏层，它能够由厚的膨松的非织造材料合适地形成。液涌层，特别是高度膨松的高松密度的抗压纤维结构的液涌层，对于尚未吸收到吸湿芯中的液体能提供暂时保持或吸收的功能，这种功能常可减少液体回流或由吸湿芯反湿润衬里。
尽管有了上述改进，仍有需要对吸湿制品中所用的衬里材料的吸液性能再作改进。特别是需要有能快速吸收和分布大部分液体污物的衬里材料。这种改进性的处理对于在目标区采用较少保持存储材料的窄裤裆部吸湿制品的设计是关键性的。
本发明提供改进了在使用吸湿制品时非常需要的液体吸入和分布的高渗透率的衬里。
发明概要
本发明的目的是通过用于个人贴身制品的吸湿非织造材料而实现的，这种非织造材料是由直径不超过40μ的可湿润纤维制成织物且此织物在远离穿着者一侧有受控的空隙制成。这种织物将以小于1.5的超过/透过百分比接收50ml的液体污物。这类织物衬里可以用于个人贴身制品如尿布、运动短裤、吸湿内裤、成人失禁衣着、妇女卫生产品。特别有关的是具有窄裆部的尿布，即裤裆宽度至多为7.6cm的尿布。
附图的简要描述
图1是带花纹未粘合的非织造织物；
图2是图1中所示带花纹未粘合的非织造织物的横剖侧视图；
图3是吸湿试验的示意图；
图4是污物在结构1的聚丙烯纺粘织物上约8秒钟后散布的照片图，此时的污物在织物的表面仍然成珠状；
图5是污物在结构2的TAB织物上约8秒钟后散布的照片图，此时的污物刚被吸收；
图6是污物在结构3的PUB织物上约8秒钟后散布的照片图，此时的污物已被完全被吸收和散布开。
                              定义
“一次性的”包括通常经一次使用后不打算洗涤而再次使用的弃置的产品。
“亲水性的”用来描述在与纤维接触的水性液体湿润的纤维或纤维表面。材料的湿润程度又可以用所涉及的液体和材料的接触角和表面张力来描述。适用于测量具体纤维材料的润湿能力的设备与技术可由Cahn SFA-222表面力分析仪系统或与其实际上等效的系统来提供。当用这种系统测量时，接触角小于90°的纤维称之为“可润湿的”或亲水的，接触角等于或大于90°的纤维称之为“不可润湿的”或疏水的。
“层”当用其单数形式时可有双重意义，指单一部件或许多部件。
“液体”指流动的能取其注入或占据的容器内部形状的非气体和非粒状的物质和/或材料。
“液体连通”是指液体如尿等能从一处行进到另一处。
“纵向”与“横向”具有它们的惯常意义。纵轴线处于平置和完全展开的制品的平面中，一般平行于将穿用此制品的站立的穿着者分成左与右半体的垂直平面。横轴线则处在制品的一般垂直于此纵轴线的平面中。
“颗粒”指例如但不限于球粒、柱形纤维或丝等任何几何形式。
“纺粘纤维”指按下述方法形成的小直径纤维，即通过喷丝板的通常为圆形的多个精细的毛细管将熔融热塑材料挤压成丝，然后使挤压成的丝快速减径，例如下述各美国专利中所述，授予Appel等的No.4340563、授予Dorschnel等的No.3692618、授予Matsuki等的No.3802817、授予Kinney的No.3338992和No.3341394、授予Hartman的No.3502763和授予Dobo等的No.3542615。纺粘纤维在其沉积到凝聚面上时通常是无粘性的。纺粘纤维一般是连续的，具有的平均直径(取自至少10个试样)大于7微米，更具体地说约在10至20微米之间。这种纤维可以具有例如描述于下述美国专利中的形状授予Hogle等的No.5277976、授予Hills的No.5466410以及授予Largman等的No.5069970和No.5057368，这些专利描述了具有非常规形状的纤维。
“熔喷纤维”是指按下述过程形成的纤维，将熔融热塑料挤压通过多个精细的通常为圆形的模具毛细管，成为熔融的纱或丝，进入会聚的高速的常为热的气体(例如空气)流，使此熔融热塑料变细减径成为微纤维直径。然后由高速气流载运这种熔喷纤维沉积到凝聚面上，形成无规分配的熔喷纤维织物。这种工艺例如公开于美国专利3849241中。熔喷纤维为微纤维，可以是连续的或不连续的，平均直径一般小于10微米，在沉积于凝聚面上时一般发粘。
这里用到的词“共成形”是指一种方法，其中至少有一个熔喷模具头是设置在一溜槽附近，在织物形成的同时通过此溜槽添加其他材料。这种其他材料例如可以是浆粕、超吸湿粒料、纤维素纤维或短纤维。共成形方法示明于共同转让的授予Lan的美国专利4818464和授予Anderson等的美国专利4100324。由共成形方法生产出的织物一般称为共成形材料。
“共轭纤维”是指由不同的挤压机挤出的至少两种聚合物源形成的纤维而再纺到一起而成的一根纤维。共轭纤维有时称为多组分或双组份纤维。尽管共轭纤维可以是单组份纤维，但上述聚合物通常是互不相同。这些聚合物在共轭纤维的整个横剖面上基本上是恒定地位于不同的区域，并且是沿共轭纤维的长度连续地延伸。这类共纤维的构型例如可以是皮/芯结构，其中一种聚合物为另一种聚合物围绕，或可以取并列结构、饼式结构或“天星状”结构。共轭纤维已描述于以下各美国专利中，授予Kaneko等的No.5108820、授予Strack等的No.5336552、授予Pike等的No.5382400。对于双组分纤维，两种聚合物的比可以是75/25、50/50、25/75或任何其他所希望的比。这种纤维还可以有例如授予Hogle等的美国专利No.5277976、授予Largman的No.5069970和No.5057368之中所示的形状，这些专利的整体内容已综合于此供参考，其中描述了具有非常规形状的的纤维。用于形成共轭纤维的聚合物包括通常用于纺粘和熔喷工艺中的那些，即包括种种聚烯烃、尼龙、聚酯，等等。
“双组份纤维”指由同一挤压机挤出的至少两种聚合物作为混合物形成的纤维。“混合物”的定义如下。双组分纤维并不具有布置在纤维的整个横剖面上较恒定地位于不同的区域中的各聚合物组份，且各聚合物通常并不沿纤维的全长连续，而是形成开始和终结都是无规的原纤维或原生纤维。双组份纤维有时也称作多组份纤维。这种一般类型的纤维例如已在授予Gessner的美国专利5108827中讨论到。双组份和双成份纤维还在下述教科书中讨论到；《聚合物混和物和混合物》(《Polymer B1ends and Composites》)by John A.Manson andLeslie H.Sperling，为Plenum出版社所有，纽约Plenum出版公司分社，IBSN 0-306-30831-2，PP273-227。
“粘合粗梳织物”是指将短纤维送过一精梳或粗梳单元的织物，使短纤维沿机器方向分开或断开并准直，形成大致沿机器方向取向的纤维质非织造织物。这种纤维通常是成包地购入，它置放于开松机/掺合器或清棉机中，将这种纤维在进到粗梳单元之前予以分离。一旦形成织物后，即由一种或多种已知粘合方法粘合。一种这样的粘合方法是粉末粘合法，其中将粉末状粘合剂分布到整个织物上然后激活，这通常是用热空气加热此织物和粘合剂。另一种适用的粘合方法是花纹粘合，其中用加热的轧光辊或超声粘合设备将纤维粘合到一起，通常成为局部的粘合花纹，当然，如果希望，也可将此织物在其整个表面上进行这种粘合。另一种合适的和周知的粘合方法，特别是在采用双组份短纤维时，是通空气粘合法。
“气流成网”是一种周知的能形成纤维质非织造层的方法。在气流成网方法中，具有典型长度约3～约19mm的小纤维束则被分开并包含在空气源中，然后通常借助真空源而沉积到成形网上。最后例如用热空气或喷涂粘合剂将这些无规沉积的纤维相互粘合。
这里所用的词“压实辊”是指在织物上下的一组用来压实此织物的辊，用作一种处理刚生产出的微纤维织物特别是纺粘织物的方法，使之具有充分的整体性供进一步处理，但不是二次粘合处理如通空气粘合、热粘合和超声粘合的那种较强的粘合处理。压实辊轻度挤压织物以提高织物的自粘合性由此改进其整体性。压实辊能很好地实现这种功能但却具有许多缺点。缺点之一是压实辊的确是把织物压实了，导致织物松密度或蓬松度下降而可能不符合所希望的用途。压实辊第二个也是更严重的缺点是，织物有时会卷绕到一个或两个辊上，造成为清理辊而使织物生产线停工，而停工期间显然它使生产损失。压实辊的第三个缺点是，如果在织物的形成中产生轻微的缺陷，例如在织物中形成了聚合物的料滴，压缩辊就将迫使这种料滴进到在其上形成绝大部分织物的多孔带上，给这种带造成缺陷以至损毁。
这里所用的词“热风刀”或HAK是指将刚生产出的微纤维织物特别是纺粘织物作预粘合或初始粘合的方法，使此织物具有充分的整体性即提高织物的刚性供进一步处理用，但不是指较强的粘合的二次粘合方法如TAB、热粘合和超声粘合。热气刀是一种装置，它把加热的气流聚集成极高的流速，一般约1000～约1000英尺/分钟(fpm)(305～3050米/分钟)，更具体地是约3000～5000英尺/分钟(915～1525米/分钟)，在紧接非织造织物成形后导引到其上。此气温通常是在织物中所用的至少一种聚合物的熔点范围，对于纺粘工艺中通常用的热塑聚合物，一般约200～550°F(93～290℃)。对空气的温度、速度、压力、体积和其他因素进行控制有助于在增强织物的整体性的同时避免使其损伤。HAK聚集的气流是由至少一个宽度约1/8～1英寸(3～25毫米)特别是约3/8英寸(9.4毫米)宽的槽来处理和导引的，此槽用作加热的空气朝向织物的通道，此槽基本上是在织物的整个宽度上沿大致横切机器的方向设置。在其他实施例中，可相互邻接或由小缝隙分开设置的多个槽。上述的至少一个槽虽不是必须但通常是连续的，而且可以包括例如紧密分开的孔。HAK具有强制通风系统，在加热的空气从槽中排出之前用来分配和容纳此热空气。HAK的强制通风压力通常约1.0～12.0英寸水柱(2～22mmHg柱)，而HAK则位于成形网上方约0.25～10英寸而更好是0.75～3.0英寸(19～76mm)。在一特定的实施例中，横向流的HAK强制通风系统的横剖面积(即机器方向的强制通风系统横剖面积)至少2倍于总的槽出口面积。由于在上面形成纺粘聚合物的多孔网一般是以高速运动，此织物的任何特定部分暴露于从热气刀排出的空气之下的时间少于1/10秒，一般约1/100秒，而这同具有远为多的驻留时间的通空气粘合过程截然相反。HAK方法对于许多因素如温度、速度、压力、体积、槽或孔的设置和尺寸以及从HAK强制通风系统到织物的距离具有大范围的可变化性和可控性。这种HAK进一步描述于1994月12月22日提交的和共同转让的属于Amold等的美国专利申请08/362328。
这里所用的词通空气粘合或“TAB”指的是粘合非织造双组份纤维织物的方法，在此方法中，充分加热来熔化制造织物中的纤维的聚合物之一的空气强制通过此织物。空气的速度为100～500英尺/分钟fpm而驻留时间可以长达6秒。聚合物的熔化和再固化提供了这种粘合。通空气粘合具有较窄的变化性，同时由于通空气粘合(TAB)需要熔化至少一种组分来实现粘合，就需将织物限制于两种组份如共轭纤维或那些包括有独立粘合剂的如低熔点纤维或粘合剂添加剂的织物。在通空气装置中，将温度高于一种组份的熔点而低于另一种组份的熔点的空气从环绕的罩中通过织物导入支承此织物的多孔辊。或者，此通空气装置可以是一种扁平的装置，其中使空气垂直地向下导引到织物之上。上述两种构型的操作条件类似，主要的差别是粘合过程中的织物结构。热的空气熔化熔点较低的聚合物成分，而在纤维之间形成粘合后集成织物。
这里所用的词“缝编”是指例如根据授予Strack等的美国专利4891957或授予Carey，Jr的美国专利4631933来缝编材料。
这里所用的词“超声粘合”是指例如授予Bornslaeger的美国专利4374888中所阐明的，使织物通过声响喇叭和砧辊之间的方法。
这里所用的词“热点粘合”涉及到便待粘合的纤维的织物通过加热的轧光辊和砧辊之间。此轧光辊通常，虽不是经常，以某种方式带有花纹，使得织物的这些区域不被粘合，而砧辊通常是平的。于是，出于功能和美观的考虑，已开发了用于轧光辊的种种花纹。花纹的例子之一是有许多个点，即所谓Hansen Pennings或“H&P”花纹，具有约30％粘合面积以及约200粘合点/英寸2，如授予Hansen和Pennings的美国专利3855046所述。这种H&P花纹具有平方状的点或针点粘合区，其中各针点的侧边尺寸为0.038英寸(0.965mm)，两针点之间的间距为0.070英寸(1.778mm)，粘合深度为0.023英寸(0.584mm)。所形成的花纹具有约29.5％的粘合面积。另一种典型的点粘合花纹是展开的Hansen Pennings或“EHP”粘合花纹，它形成15％的粘合面积，而方形针点的侧边尺寸为0.037英寸(0.94mm)、针点间距0.097英寸(2.464mm)，粘合深度0.039英寸(0.991mm)。再一种典型的点粘合花纹称为“714”，具有方形的针点粘合区，各针点的侧边尺寸为0.023英寸，针点间距为0.062英寸(1.575mm)，粘合深度为0.033英寸(0.838mm)。形成的花纹具有约15％的粘合面积。还有另一种普通的花纹是C星形花纹，它具有约16.9％的粘合面积。这种C量形花纹是有为流星所中断的横向杆或“灯芯绒设计”。其他的普通花纹包括钻石花纹，具有重复的和稍稍错开的菱形和约16％的粘合面积以及如此名称所示的经织花纹外观，例如窗纱状、有约19％的粘合面积。通常这种层压件织物的百分粘合面积约10-30％。正如本技术中周知的，点粘合能把叠置的层保持到一起，并能通过各层中的丝和/或纤维的粘合而赋予各层以整体性。
这里所用的词“花纹不粘合”或换言之“点不粘合”或“PUB”是指一种织物花纹具有由连续的粘合区确定出多个离散的不粘合区。在离散不粘合区中的纤维或丝由于有连续的粘合区包围或环绕各不粘合区而在尺寸上稳定，因而不需要支承或背衬的膜层或粘合剂。这种不粘合区经过特别设计，在不粘合区内的纤维或丝之间提供空隙。用来形成本发明的花纹不粘合非织造材料的合适方法包括提供非织造织品或织物、提供相对设置的第一和第二轧光辊并在其间限定出辊隙，使这两辊中至少一个加热并在其最外表面上具有粘合花纹，这种花纹包括岛状区域的连续花纹而确定多个离散的口、孔或洞，并且使非织造织品或织物通过这对辊所形成的辊隙。由连续岛状区在所述辊或辊对中确定出的各个孔在非织造织品或织物的至少一个表面中形成了离散的不粘合区，而此织物中的纤维或丝基本上或完全不粘合。换种方式说，在所述的一个或两个辊中的岛状区的连续花纹形成了粘合区的连续花纹，它们在所述非织造织品或织物的至少一面上确定出多个离散的不粘合区。上述方法的另一些实施例包括在使此非织造织品或织物通过轧光辊所形成的辊隙之前对此非织造织品或织物进行预粘合，或者提供多层非织造织物来形成花纹不粘合层压件。PUB织物会开了共同转让的美国专利申请08/754419中，并示明于图1和2内，其中，连续的粘合区6在非织造织物4中界定出多个离散的尺寸稳定的不粘合区8。
可以采用PUB织物的另一些用途包括在形成PUB织物中需要应用膜料的情形，其中此膜料可以提供挡液层，使其能用作贴身制品的布状外罩。
“受控空隙”是指织物的提供了可让液体通过的通道或槽的区域。例子包括PUB织物的粘合区或其他非织造织物的凹凸区以及类似灯芯绒的带肋花纹织物的谷。
“个人贴身制品”是指尿布、运动短裤、吸湿内裤、成人失禁衣着和妇女卫生制品。
                        试验方法
吸湿试验这项试验是测量材料的液体超透过量和透过量。如图3所示，此项试验采用的机头组件1包括有真空口2用来除去超量的液体，即进到3英寸(76mm)直径的试样3的终端而没有通过终端的液体。真空度设定为大气压力下5英寸水柱(约750mm Hg柱绝对值)。试样3位于模拟“理想吸湿体”的多孔烧结玻璃板4上。此多孔板经校正水平地置于一漏斗上，漏斗通过管道将液体排入一称重盘上的烧杯中，用盐溶液注入此管道与漏斗组件至多孔板上方的一点处，将漏斗相对于称重盘升降，使多孔板的透过率约为5ml/s。透过量和超过量分别由初始值设定为零经30秒试验的称重盘上。
将污物垂直地输向试样3，通过位于试样中心上方50mm的2.5mm直径的圆孔5，流率为5ml/s，液体总量为50ml且一般形成泡或坑6。所用的液体为具有0.9％(重量)氯化钠的盐溶液，通过多孔板4的超过(通过真空口2的)量和透过量按重量测度。
合计为污损总量的超过量和透过量是普遍存在的，每项试验只记录一次。在下述结果中，超过量以克(g)记录。还记录了超过量/透过量的百分比，即超过量除以透过率再乘以100％。
垂直芯吸试验将约2英寸(5cm)×15英寸(38cm)的材料试样带垂直地放置，使得此试样带在试验开始时位于液体贮器的上方，而试样带的底部则正好接触液面。所用的液体为8.5g/l盐溶液。在测定时的相对湿度应保持为约90～98％。只由30分钟后8.5g/l溶液的平衡垂直芯吸高度测量3不含超吸湿剂的材料的毛细张力，以厘米记录。
                        详细说明
在个人贴身制品中，衬里有时称为体侧衬里或顶片且可与液涌材料相邻。在此制品的厚度方向，衬里材料乃是对着穿着者的皮肤的料层，所以此第一层是同来自穿着者的液体或其他排出物接触。此衬里还用来使穿着者的皮肤与吸湿结构中保持的液体脱离开，故应是柔顺的、软感的和无刺激性的。
液涌层最通常的情形是设在个人贴身制品的体侧衬里和另一层如分布层或保持层之间，并与它们形成密切的液体连通接触。此液涌层一般直接在体侧衬里的内(未暴露)表面之下。为了进一步提高液体传输能力，最好是使液涌层的上和/或下表面分别与衬里和分布层连接。可以采用常规的连接技术，这包括但不限于粘合剂结合(采用水基的、溶剂基的和热激活的粘合剂)、热粘合、超声粘合、针刺或针穿孔结构，以及这些结合方法相组合的形式或其他适当的连接方法。例如如果此液涌层是由粘合剂连接于体侧衬里上时，这种粘合剂的添加量就应足以能提供所需程度的结合结果而不会过份限制液体从衬里流入液涌层。
保持材料一般是纤维素材料或超吸湿剂或它们的混合物。这类材料一般设计用来快速地吸液和保持它们而常常不会使液体释出。超吸湿剂可从许多制造厂商购得，包括The Dow Chemical Company ofMidland，MI and Stockhausen GmbH。
个人贴身制品的背片有时称作外罩，是离穿着者最远的层。此外罩通常是由薄的热塑性塑料膜如聚乙烯膜形成，基本上是不透液的。外罩用来防止吸湿结构中所含体排出物润湿或污损穿着者的衣服、床上用品或与尿布接触的其他材料。
衬里的开发曾主要集中于流体透过方面，即相对于流体控制，在多次污损性能方面提供耐用性处理。流体控制需要有高渗透性的衬里、Z方向的纤维取向(促进Z方向的芯吸)以及能在衬里之下分布流体的表面结构，由此来更好地利用吸湿产品。这种结构应形成能改进流体吸收和分布的高渗透率的界面。这里所公开的衬里内设有高渗透率的界面，其能从入口点将流体引开的而将液体分布到此系统的其余部分。据认为，这是由于此衬里结构中设置了受控空隙而使得这些地方的渗透率高于而最好的情形是两倍于相继的层中的。因流体动量产生的液压据信将迫使此流体的显著部分进入上述受控空隙，这种空隙可以是均匀的或是通道式的，将流体按特定方向导向。具有这种受控空隙的织物所具有的毛细张力按照上述垂直芯吸试验应大于0.5cm流体静张力。
本发明人发现，按合适定向设置的一种较简单的结构，能在没有这种定向的类似织物上产生惊奇的改进结果。本发明的织物能以极少的超过量吸入污物并快速地分布这种污物。这种吸湿非织造材料能用作衬里、液涌材料以及其他种种用途如水的过滤。
适用于本发明的一种织物是这样一种非织造织物，它已由针刺处理使纤维取向来改进渗透率，然后进行凹凸处理来提供受控空隙。这种非织造织物可以是粘合的粗梳织物。另一种适用于本发明的织物即是以前定义的点不粘合织物，其中的粘合区用作受控空隙。在任何合适的织物中，上述受控空隙必须在远离穿着者的一侧，以便使污物远离穿着者的皮肤布散开。
试验了三种结构来测定它们的吸湿速度和分布。这三种结构虽然从表面上颇为相似，但会产生不同的结果，使得本发明的结构特别引人入胜。这三种结构是热点粘合的聚丙烯纺粘织物(结构1)、通空气粘合(TAB)共轭纤维织物(结构2)和点不粘合(PUB)共轭纤维织物(结构3)。所有这三种结构都进行过可润湿性处理。有关织物的概要内容和试验的细节如下。
结构1
这种材料是由纺粘法制成的热点粘合聚丙烯非织造织物。涉及的纤维是按约0.9克/孔/分(ghm)的速率用冷风拉制的。在通过微热的压缩辊后，织物转送到两个热钢辊之间的辊隙，一个是光滑的砧辊，而另一个是刻花辊，上面有约合17％粘合面积的EHP粘合花纹。平均纤度约4.9旦尼尔，平均织物基重约19gsm。
结构2
这种结构包括用比例的聚丙烯和线性低密度聚乙烯的通空气粘合的(TAB)并列共轭纤维，每种聚合物加有约2％(重量)的二氧化钛颜料。这里的聚丙烯是EscorenePD 34 45聚丙烯，购自EXXONChemical CO.of Houston，TX：聚乙烯则是购自Dow Chemical CO.ofMidland MI的Aspun6811A。聚合物的通过量为1.2ghm。纤维是根据美国专利5382400由热空气激活潜在的卷曲拉制的，再使这种纤维材料通过热风力(HAK)使其固化用于进一步处理。织物是在约124℃和压力差约100Pa下经通空气粘合形成。纤维的平均纤度约5.2旦尼尔，织物的基重约22.5gsm。
结构3
此结构与结构2基本一致，只是织物不是通空气粘合而是在两个加热钢辊之间粘合。一个钢辊是光滑砧辊，而另一个是刻花辊，带有约30％粘合面积的圆圈形PUB花纹。结构3是用与结构2相同的聚合物，按出料量约1.3ghm，由热空气激活潜存的卷曲拉制成的，并具有约22.5gsm的基重和约2.9旦尼尔的纤度。对这种结构试验了由PUB法生产出的向下的隆起部。图6还示明了这种向下隆起部。
可润湿性处理
以上三种结构都依相同的方式用42g的Ahcovel基N-62表面活化剂进行了处理，这种活化剂是约50％(重量)的山梨糖醇-油酸和约50％(重量)的氢化羟乙基化蓖麻油按ICI Chemicals所供给的100％固体形式、4.6g GlucoponUP-220的由Henkel Chemicals按60％固体形式供给的具有C8-10链的烷基聚糖苷，以及由温水稀释至8升的40g的乙醇的混合物，经彻底搅拌。8英寸(2.4m)长的各织物片料浸渍于这种溶液中，经挤干而剩余约为此织物原始干重60％的总的溶液添加量。然后风干这种织物，在织物上余留下0.3～0.4％(重量)的水溶液的干燥化的残余物。
应知这种可润湿性处理方式将因所选聚合物而异。可以采用内行人士熟知的任何处理方法，从外部或从内部，来生产出亲水性纤维。重要的问题是这种纤维是或变成是亲水的。
根据所述吸湿试验测试了所有这三种结构。对4件各种织物(全宽向)的第一、二和三次污损(向下)的结果给出于下面：
吸湿试验结果
结构1
污损                                    平均
1    3.14    1.5     2.05      2.93     2.41
2    2.86    2.45    1.65      2.89     2.46
3    2.44    1.52    1.58      1.56     1.78
                               平均     2.21
                            标准偏差    0.64
               平均超过量/透过量百分比：4.6
结构2
污损                                  平均
1    1.07    2.06    2.22    1.29     1.66
2    0.41    3.85    1.04    2.21     1.88
3    0.51    1.97    2.63    1.45     1.64
                              平均    1.73
                            标准偏差  0.97
          平均超过量/透过量百分比：   3.6
结构3
污损                                          平均
1         0.51     0.88      0        0.57    0.49
2         0        0.67      0        0.74    0.35
3         0.29     0.21      0.38     0.56    0.36
                                      平均    0.40
                                    标准偏差  0.30
                  平均超过量/透过量百分比：   0.8
如试验结果所示并可从图4、5与6中相当清楚地看到，与几乎一致的TAB织物和聚丙烯纺粘织物相比，由PUB织物取得了惊人的良好结果。这些图表明，在8秒钟后，织物上出现一致的散布结果。PUB织物照片(图6)清楚地表明，与其他的类似织物比较，它能更快和更远地分布污物。
本发明的织物一般具有的超过量对透过量的百分比小于1.5，而更好是小于1。这些织物如前述图中所示，在8秒钟内它们将污物布散得要比没有本发明受控空隙的至少要远1倍。
这里公开的衬里内设有高渗透率的界面，将液体从进入点导引到很远并分布到相应系统的其余部分。据信，这是由于在衬里结构中设置了受控空隙而具有高于接续层的渗透率所致。由流体动量造成的液体压力相信会迫使显著部分的液体进入较高渗透率的空隙。这些受控的空隙可以是均匀的或带通道式的，将液流导引到特定的方向。
尽管上面只详述了本发明的几个有代表性的实施例，但内行的人士在未于本质上背离本发明的新颖思想及其优点的前提下，将能迅速地掌握多种变更形式的。因此，所有这类更好形式都应认为包括在后附权利要求书所规定的本发明的范围之内。在此权利要求中，装置与功能方面的权利要求是用来函盖执行这里所述功能的结构，不仅仅是结构的等效物还包括等效的结果。例如，尽管钉子与螺丝由于钉子利用了柱形表面来把木材部件固定到一起而螺丝则是利用螺旋状表面来如此进行，因而不是结构等效物；但就紧固木材部件的环境来说，钉子与螺丝可以是等效的结构。

Claims (16)

1.一种包括有所含纤维直径最多为40微米的可润湿织物的吸湿性非织造材料，其中所述织物在其远距穿着者的一面具有受控空隙并且是以超过量/透过率小于1.5的百分比接收50ml的液体污物。
2.如包含权利要求1所述材料的个人贴身制品用的衬里。
3.如包含权利要求1所述材料的个人贴身制品用液涌层。
4.如包含权利要求1所述材料的选自尿布、运动短裤、吸湿性内裤、成人失禁衣着和妇女用卫生制品所组成中的个人贴身制品。
5.如包含权利要求4所述的产品，其中，所述个人贴身制品是妇女用卫生产品。
6.如包含权利要求4所述的产品，其中，所述个人贴身制品是成人失禁衣着。
7.如权利要求4所述的产品，其中，所述个人贴身制品是尿布。
8.如权利要求7所述的尿布，此尿布的裤裆宽度至多为7.6cm。
9.如权利要求1所述吸湿材料，它所具有的超过量/透过量百分比小于1。
10.如权利要求1所述吸湿材料，其中，所述污物与在没有所述受控空隙的类似织物中相比在8秒钟内布散得至少要远出1倍。
11.一种个人贴身制品用吸湿性非织造材料，它包括聚丙烯/聚乙烯并列的共轭纤维，热粘合成具有隆起部的点不粘合花纹，在此将衬里设于此个人贴身制品内，使得这种点不粘合织物的隆起部面离穿着者。
12.如包含权利要求1所述材料的选自尿布、运动短裤、吸湿性内裤、成人失禁衣着和妇女用卫生制品所成组中的个人贴身制品。
13.如权利要求12所述的产品，其中，所述个人贴身制品是妇女用卫生制品。
14.如权利要求12所述的产品，其中，所述个人贴身制品是成人失禁衣着。
15.如权利要求12所述制品，其中，所述个人贴身制品是尿布。
16.如权利要求15所述的尿布，此尿布的裤裆宽度至多为7.6cm。
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AR012190A1 (es) 2000-09-27
KR100495590B1 (ko) 2005-06-16
ZA982244B (en) 1998-09-17
DE69810089D1 (de) 2003-01-23
PL335933A1 (en) 2000-05-22
BR9808383A (pt) 2000-05-23
AU6464798A (en) 1998-10-22
RU2201191C2 (ru) 2003-03-27
US5931823A (en) 1999-08-03
EP0971667B1 (en) 2002-12-11
EP0971667A1 (en) 2000-01-19
PL191067B1 (pl) 2006-03-31
CA2281508A1 (en) 1998-10-08
CA2281508C (en) 2007-02-27
ID22479A (id) 1999-10-21
KR20010005808A (ko) 2001-01-15
AU724797B2 (en) 2000-09-28
WO1998043587A1 (en) 1998-10-08
DE69810089T2 (de) 2003-09-25
CN1135100C (zh) 2004-01-21

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