CN1273285C - 含有双面柔软弹性组件的吸收性制品 - Google Patents

含有双面柔软弹性组件的吸收性制品 Download PDF

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CN1273285C
CN1273285C CNB02823636XA CN02823636A CN1273285C CN 1273285 C CN1273285 C CN 1273285C CN B02823636X A CNB02823636X A CN B02823636XA CN 02823636 A CN02823636 A CN 02823636A CN 1273285 C CN1273285 C CN 1273285C
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elastic
elastic layer
compound
elastic cloth
cloth
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R·O·赫特森
A·J·皮科克
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Feiteshi Film Products Co ltd
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    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent 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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    • B32B5/02Layered 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
    • B32B5/04Layered 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 characterised by a layer being specifically extensible by reason of its structure or arrangement, e.g. by reason of the chemical nature of the fibres or filaments
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered 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
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    • B32B7/022Mechanical properties
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS 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
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    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
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    • A61F13/00Bandages or dressings; Absorbent pads
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    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS 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
    • A61F13/00Bandages or dressings; Absorbent pads
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    • A61F13/51Absorbent 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
    • A61F13/511Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/513Topsheet, i.e. the permeable cover or layer facing the skin characterised by its function or properties, e.g. stretchability, breathability, rewet, visual effect; having areas of different permeability
    • A61F2013/51322Topsheet, i.e. the permeable cover or layer facing the skin characterised by its function or properties, e.g. stretchability, breathability, rewet, visual effect; having areas of different permeability being elastomeric or stretchable
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    • A61F13/00Bandages or dressings; Absorbent pads
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    • A61F13/514Backsheet, i.e. the impermeable cover or layer furthest from the skin
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    • A61F2013/51409Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by the material being a film
    • A61F2013/51429Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by the material being a film being elastomeric or stretchable sheet
    • YGENERAL 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
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    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10Methods of surface bonding and/or assembly therefor
    • Y10T156/1002Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1043Subsequent to assembly
    • YGENERAL 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
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    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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    • Y10T156/10Methods of surface bonding and/or assembly therefor
    • Y10T156/1052Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1056Perforating lamina
    • Y10T156/1057Subsequent to assembly of laminae
    • YGENERAL 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
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    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10Methods of surface bonding and/or assembly therefor
    • Y10T156/1052Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1084Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing of continuous or running length bonded web
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
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Abstract

本发明涉及吸收性制品和非吸收性制品,它们包含至少一种经过改进的双面柔软弹性材料复合物(10)。本发明复合物(10)也可以是透气的。所述复合物通过增量拉伸两个非弹性似布层(12、16)之间的弹性层(14)的层合物而形成。非弹性似布层在拉伸过程中撕裂,使得层合物(10)拉伸后的弹性基本上与膜弹性层(14)的弹性相同。

Description

含有双面柔软弹性组件的吸收性制品
前期相关专利申请
本专利申请要求2001年11月30日提交的美国临时专利申请60/334913“具有双面柔软弹性组件的吸收性制品”的优先权。
发明领域
本发明总体上涉及吸收性制品和非吸收性制品,具体涉及包含要求为柔软的弹性组件的吸收性制品和非吸收性制品。
发明背景
吸收性和非吸收性制品的设计者努力改善材料的触感,增加制品的透气性和改善手感。设计者还希望通过在制品中加入弹性区、弹性薄片或其他弹性组件使制品更加贴身。但是,触感和手感较好的材料一般是非弹性的,而弹性材料通常又触感和手感不佳。因此,提供弹性与提供较好的触感与手感之间存在二分法。
Weber等的美国专利5143679、5156793和5167897,以及Newkirk等的美国专利5,921,973介绍了增量拉伸制品的一部分的方法,所述制品由触感良好的非弹性材料与弹性材料层合物构成,拉伸是为了赋予层合物弹性。更具体地说,这些方法使层合物在相互啮合的齿轮辊之间通过,由此拉伸层合物。拉力撤去后,层合物回缩,使非弹性层抽褶或膨大。所得层合物具有有限弹性。由于非弹性层的纤维保持不断裂,所以弹性层合物只能容易地拉伸到它以前拉伸到的地方。因此,该层合物能强烈抵抗进一步拉伸,因为要继续拉伸层合物,就必须拉伸非弹性层。此外,Weber的层合物应是多孔的或不透气。
另一种层合物的说明见Wu的美国专利5422172、5592690、5634216和5861074。在这些专利中,Wu介绍了一种非常类似于Weber的方法,不同之处在于Wu拉伸的整个层合片。所述片是弹性层挤出层合到非弹性无纺层上形成的层合物。所述层合片用相互啮合的齿轮辊拉伸之后,能弹性拉伸到其原来长度的150%。同Weber的层合物一样,Wu的层合物在拉伸后膨大,表明其中的纤维没有断裂。因此,Wu的层合物只能容易地拉伸到它最初拉伸到的位置(这里是其原来长度的150%),因为拉伸范围受到非弹性无纺层上未断裂纤维的限制。Wu的层合物也不是多孔的。
制品中所用材料除了触感和手感之外,其透气性往往也很重要。如美国专利6255236所述,透气性对侧翼、弹性耳件和其他扣件来说不及在侧嵌片中重要,因为侧嵌片与穿戴者的身体直接贴紧。多孔或者透气弹性膜能让膜透气,同时又能保持良好的贴合性。此外,透气弹性层能让排出的汗蒸发掉,增加吸收性制品内部的空气流通。空气流通性尤其有益,因为它能减少许多穿戴者在使用过程中粘乎乎的感觉。由于弹性得到改善,制品的贴合性增加,因此制品的透气性就越发重要,因为空气无法从制品与穿戴者皮肤之间逃走。而Weber的专利和Wu的专利中所介绍的层合物都不是多孔的。
因此,需要改进弹性复合物,使它不受层的非弹性的限制,同时还具有良好的触感和手感。此外,需要一种弹性复合物,它具有良好的触感和手感以及透气性。
发明概述
本发明涉及双面柔软的弹性复合物。所述复合物包含第一非弹性似布材料,第二非弹性似布材料,位于第一非弹性似布材料与第二似布材料之间的弹性层,所述弹性膜的断裂伸长至少为50%,并且复合物的弹性基本上等于弹性层的弹性。
本发明还涉及含有复合物的吸收性制品,所述复合物包含第一非弹性似布材料,第二非弹性似布材料,位于第一非弹性似布材料与第二非弹性似布材料之间的弹性层,所述弹性层的断裂伸长至少为50%,并且复合物的弹性基本上等于弹性层的弹性。
本发明还涉及含有复合物的非吸收性制品,所述复合物包含第一非弹性似布材料,第二非弹性似布材料,位于第一非弹性似布材料与第二非弹性似布材料之间的弹性层,所述弹性层的断裂伸长至少为50%,并且复合物的弹性基本上等于弹性层的弹性。
本发明还包括制备弹性层合物的方法,所述方法包含:将第一非弹性似布材料粘合到弹性层的第一面,将第二非弹性似布材料粘合到弹性层的第二面,使层合物在啮合齿轮辊之间通过,使第一非弹性似布材料和第二非弹性似布材料均断裂。在一个优选的实施方式中,所述啮合齿轮辊不在加热或冷却的条件下操作,除了层合物在辊之间通过时由层合物提供的加热或冷却之外。
附图简介
通过下面的描述、权利要求书和附图可以更好地理解本发明的上述及其他特点、方面和优点。
图1A和1B是本发明制造的两个示例性多孔双面柔软弹性复合物的截面图;
图2是本发明制造的另一个示例性多孔双面柔软弹性复合物的截面图;
图3A是用来生产本发明双面柔软弹性复合物的示例性生产工艺实意图;图3B是图3a示例性生产工艺中一个局部的另一种形式示意图;
图4是用来生产本发明双面柔软弹性复合物的另一个示例性生产工艺的示意图;
图5是用本发明双面柔软弹性复合物制造的带扣件的示例性制品;
图6是用本发明双面柔软弹性复合物制造的带侧嵌片的示例性制品;
图7是用本发明双面柔软弹性复合物制造的示例性非吸收性制品;
图8是用本发明双面柔软弹性复合物制造的示例性吸收性制品的截面图;
图9是用本发明双面柔软弹性复合物制造的吸收性制品面片视图。
发明优选实施方式详述
定义
这里所用术语“基本上”指给定性质或参数可以在所述数值的基础上变动约20%。
这里所用术语“直接包围最大流体排泄区的面积”表示包围最大流体(例如液体)和/或固体废物排泄区并由该区向各个方向延伸约1英寸后形成的表面积。术语“周围”、“周围面积”或“……周围的面积”表示最大流体排泄区和与它直接包围的区域以外的区域的表面积。
这里所用术语“透气性”指材料对蒸气或液体的透气性。
这里所用术语“超声粘合”指一种进行的过程,例如使织物从超声喇叭(sonic horn)和支承辊之间通过,如Bornslaeger在美国专利4374888或Goodman等在美国专利5591278中所示。在超声粘合方法的一个实例中,要粘合在一起的各层同时送入超声单元的粘合辊隙中。这些单元中有许多在市场上有售。一般,这些单元能产生高频振动能,使热塑性组件在各层的粘合部位熔化,从而将各层粘合在一起。因此,感应能量大小、合并组件通过辊隙的速度、辊隙的距离以及粘合部位的数量决定了各层之间的粘合程度。根据各层之间所需粘合程度和所选材料,可以使用非常高的频率,超过18000cps(周/秒)的频率通常可称为超声。低至5000cps或更低的频率也可获得可接受的产品。
这里所用术语“点粘合”指在许多分散点上粘合一块或多块织物。例如,热点粘合通常涉及使要粘合的一层或多层从加热辊(例如刻花辊)和光滑砑光辊之间通过。刻花辊以特定方式刻花,使整块织物不是在其整个表面上粘合,而砑光辊通常是光滑的。结果,出于功能原因和美学原因,人们为刻花辊研制出许多刻花图案。
这里所用术语“防渗层”指膜、层合物或其他织物,它基本上不透液,且宜耐至少50毫巴(mbar)的水压头(hydrohead)。这里所用水压头指织物的防液体渗透性质的量度。但是应当指出,本发明的防渗织物的水压头可以超过80毫巴、150毫巴或甚至300毫巴。
这里所用术语“透气性”指能透过水蒸气的材料,其水蒸气透过速率(WVTR)宜至少约为300g/m2/d(24h)。织物的WVTR可以反映该织物穿起来是不是舒服。WVTR可根据ASTM E96-00测定。一般,使用可透气防渗层能获得较高的WVTR,本发明的透气层合物的WVTR可超过约800g/m2/d、1500g/m2/d,或甚至超过3000g/m2/d。
这里所用术语“整体透气性”指至少部分因其化学组成而透气的材料。
这里所用术语“可伸长的”指施加位移力后至少可在一个方向上拉长或拉伸的材料。
这里所用术语“弹性”指施加位移力后材料可以拉伸,即可伸长至其放松未位移长度的较佳至少150%的位伸,有位移长度并且撤去拉伸力后,其伸长会回缩至少50%。
这里所用术语“永久变形”指撤去位移力后留下的拉伸量,用原来长度的百分数表示:永久变形(%)=((最终长度-原来长度)×100)/原来长度。
可以假设这样一个例子,有一个材料样品长1.00英寸,可伸长至1.50英寸,释放位移力后,回缩至1.25英寸,因此该样品的“永久变形”为25%。
这里所用术语“无弹性”和“非弹性”指如上定义的“弹性”材料之外的任何材料。
这里所用术语“衣服”指任何类型的可以穿的衣物,其中包括工作服和外套、内衣、裤子、衬衣、夹克、手套、袜子等。
这里所用术语“传染控制产品”指医用物品,其中包括手术服和窗帘,面罩,头套如圆帽、手术帽和头巾,鞋类如鞋套、靴套和拖鞋,伤口敷料,绷带,消毒敷料,擦拭用品,外衣如实验服、外套、围裙和护套,病人被褥,担架和摇篮床单等。
这里所用术语“防护罩”指各种物品的外罩,例如,交通工具如汽车、卡车、船、飞机、摩托车、自行车、高尔夫车等的外罩,经常放在户外的设备的外罩,如烤架、院落和花园用设备(割草机、旋转耕耘机等)及草坪用设备的外罩,以及地板覆盖物、桌布和野餐用布。
这里所用术语“吸收性制品”指吸收并容纳体液和其他体内排出物的制品。更具体地,吸收性制品包括放在穿戴者身体上或在其附近吸收并容纳体内排出的各种排泄物的衣物。非详尽的例子有尿布、训练裤、吸收性内裤、成人失禁产品和妇女卫生产品。
这里所用术语“非吸收性制品”指不是用来吸收液体的制品。非详尽的例子包括衣物、防护罩和感染控制产品。
这里所定义的“拉伸比”或“l/w”是拉伸样品的变形长度与原来长度之比。对于相互啮合的齿轮装置(IMG),它是是齿轮齿中心线之间的距离“w”和齿轮装置相互啮合达到最大深度的情况下层合物在齿轮齿间受到拉伸时所经历的最大长度“1”。等价定义如下:
拉伸比=变形长度/原来长度。
这里所定义的“伸长百分比”是:
伸长百分比=(样品长度增加值×100)/原来长度
或伸长百分比=(拉伸比-1)×100
示例性实施方式详述
首先看图1A,它是用于吸收性或非吸收性制品中的双面柔软弹性复合物10。所述双面柔软弹性复合物10在弹性层14的一面上有第一非弹性材料12,在弹性层14的另一面上有第二非弹性材料16。
在一个示例性实施方式中,弹性层14是共挤出膜,它有一个弹性芯18、位于弹性芯18外表面上的第一表层20和第二表层22。但是,采用其他弹性结构也包括在本发明范围之内。弹性层14的断裂伸长范围可在50%至超过700%之间。
如果希望复合物10透气,则弹性层14可具有穿过弹性芯18和表层20、22的孔24。图1A和1B所示均为含有孔24的示例性复合物10。图2所示为复合物10不含孔的另一个示例性实施方式。弹性层14也可由不透气材料和填料(如碳酸钙、滑石或本领域已知的其他材料)制成,通过使其拉伸在填料颗粒周围产生彼此连通的孔隙,从而使之具有透气性;也可以由整体透气性材料制备,从而使如图2所示无孔实例仍然具有透气性。
弹性层14可由任何合适的弹性材料,如天然或合成聚合物材料制成。合适的聚合物的例子包括低结晶度聚乙烯、茂金属催化的低结晶度聚乙烯、乙烯-醋酸乙烯酯共聚物(EVA)、聚氨酯、聚异戊二烯、丁二烯-苯乙烯共聚物、苯乙烯嵌段共聚物如苯乙烯/异戊二烯/苯乙烯共聚物(SIS)、苯乙烯/丁二烯/苯乙烯(SBS)或苯乙烯/乙烯-丁二烯/苯乙烯(SEBS)嵌段共聚物。这些聚合物的混合物可单独用于本发明或者这些聚合物与其他改性弹性或非弹性材料的混合物也可用于本发明。在某些优选实施方式中,弹性材料可包含高性能弹性材料,如弹性嵌段共聚物。合适的弹性嵌段共聚物的例子有KRATON牌(壳牌石油公司注册的商标)嵌段共聚物。
选用非弹性材料12、16来提供似布感觉,即柔软且/或像丝一样的纤维感觉。但是,非弹性材料12、16本身不必是纤维来提供这种感觉。在一个示例性实施方式中,非弹性材料12、16是梳理或纺粘无纺片。但是,用其他非弹性材料也包括在本发明范围之内,包括(但不限于)熔喷和气流铺置无纺片和织造织物。
非弹性材料可由任何合适的材料制备。非详尽的合适材料的例子有聚酯、聚乙烯、聚丙烯和其他聚烯烃均聚物和共聚物、丙烯酸类聚合物树脂及其多层混合物、人造丝、棉花、纤维素和它们的任何混合物。在一个示例性实施方式中,选择第一非弹性材料12的断裂伸长与第二非弹性材料16的断裂伸长不同,而它们的其他性质可基本上相同。
下面将讨论制备本发明复合物10的示例性方法,见图3。制备复合物10时,将弹性层14从薄膜模头30挤出(单组分弹性层)或共挤出(弹性层14含芯18和表层20、22),进入粘合段32a或32b,在该粘合段中第一非弹性材料12粘合到弹性层14上。第一非弹性材料12可用本领域已知的各种技术粘合到弹性层14上。粘合段32a是真空层压过程,如James Pelkie在美国专利5733628中所描述的真空层压过程,该过程可用来生产三维多孔弹性层14,如图1A所示。根据Pelkie所介绍的方法,熔融或半熔融态弹性层14与第一非弹性材料12一起经过真空层压鼓34,例如真空网。第一非弹性材料12在冲击辊36的作用下与弹性层14的表面接触。真空层压鼓34内的低压将弹性层14的某些部分局部拉入鼓34中。拉入鼓34中的部分使弹性层14具有三维形状(而不是其挤出的基本上呈二维平面的形状),并最终破裂形成孔24(如图1A所示)。弹性层14形成孔之后,在弹性层14冷却时,鼓34的内的低压也使第一非弹性材料12与弹性材料14保持接触,从而使第一非弹性材料12粘合到弹性层14上。在这里不需要粘合剂。使用粘合段32a产生了透气的三维复合物10。
或者,也可使第一非弹性材料12与真空层压鼓34接触,并将熔融或半熔融弹性层14涂敷到与真空层压鼓34相反的非弹性材料12上。在此情况下,弹性层14上没有形成孔,复合物10类似于图2所示。
在另一个粘合阶段32b中,用点粘合系统,如热系统或超声系统、粘合剂或本领域已知其他方法将第一非弹性材料12和弹性材料14粘合在一起。在上述每个系统中,弹性层14在辊38的作用下与第一非弹性材料12接触。辊38可是印花辊和光滑辊(即热粘合)、超声喇叭和支承辊(即超声粘合)或其他类型的辊。使用粘合段32b不一定能形成透气或三维复合物10,因为粘合段32b的粘合过程不涉及使弹性层14打形成或使弹性层14形成三维形状。如果要得到三维弹性层14和/或多孔弹性层14,则必须另外进行成型和/或形成孔过程。例如,弹性层14可机械打孔,如用加热针或非加热针穿刺弹性层(下面将讨论)。
在一个示例性方法中,使第二非弹性层16与粘合弹性层14上粘合了第一非弹性材料12的反面接触。第二非弹性材料16可通过粘合剂、点粘合方法如热粘合或超声粘合、或者本领域已知其他方法粘合到弹性层14上。
见图4,第一非弹性材料12和第二非弹性材料16中的一个或两个可挤出层压到弹性层14上。在挤出层压过程中,弹性层14与第一非弹性材料12和第二非弹性材料16中的一个或两个一起挤出到辊40的辊隙中。由于弹性层14是熔融或半熔融的,它在冷却时与第一非弹性材料12和/和第二非弹性材料16粘合。此外,可急冷一个或两个辊40,以使弹性层14骤冷。如果采用粘合段32b,则挤出层压不会使弹性层14形成孔或三维形状。因此,如果要使弹性层14具有三维形状和/或孔,则必须另外进行成型和/或形成孔过程。图4还示出了用加热或未加热针穿刺复合物10以形成孔的示例性过程。所得复合物10类似于图1B所示。
再来看图3,第一非弹性材料12和第二非弹性材料16粘合到弹性层14上之后,拉伸复合物10,使非弹性材料12、16断裂。图3示出了用加热或未加热啮合齿轮辊(IMG)42拉伸复合物10过程;但拉伸复合物10的其他方法,如纵向取向(MDO)和拉幅也是可接受的。IMG辊42的圆周上有取向齿(未具体示出),这些齿相互啮合,当复合物10通过辊42时,就得到拉伸。复合物10通过IMG辊42的运动方向通常称作纵向。IMG辊42以大致垂直于纵向的方向,也就是横向拉伸复合物10并使第一非弹性材料12和第二非弹性材料16断裂。另一方面,在纵向拉伸复合物10并使非弹性材料12、16断裂也包括在本发明范围之内。此外,可单独拉伸复合物10上的有限部位,形成可弹性回复材料的局部区域。
在第一非弹性材料12的断裂伸长不同于第二非弹性材料16的实施方式中,在复合物10拉伸时,一种非弹性材料比另一种非弹性材料先断裂。由于非弹性材料12、16不是同时断裂的,拉伸复合物10并使非弹性层断裂所需的最大力小于这两个非弹性层在相同伸长下断裂的情况中所需的力。这是所希望的情况,因为许多拉伸装置,例如IMG辊42,不能施加使第一非弹性材料12和第二非弹性材料16同时断裂所需的力。
所得复合物10既柔软又有弹性。由于非弹性材料断裂,复合物10的伸长可以超过增量伸长点,并且不受非弹性材料的拉伸模量的限制。换句话说,层合物的伸长主要取决于弹性层,因此其拉伸基本上超过了啮合齿轮所能达到的拉伸比。
图5所示为在扣件52中含有本发明双面柔软弹性复合物10的示例性制品50。扣件52至少可围绕穿着者的身体来局部固定制品。虽然图中描述的是采用特定结构的扣件52的尿布或成人失禁制品,但在其他吸收性和非吸收性制品中在其他结构的扣件中使用复合物10也包含在本发明范围之内。
图6所示为用本发明双面柔软弹性复合物10作弹性侧嵌片62的另一个示例性织品60。侧嵌片62允许制品弯曲,从而至少局部贴合穿着者的身体。此外,复合物10可通过含有孔24(最佳见图1A和1B)或整体透气性材料而形成透气结构,使气流通过侧嵌片62,从而增加穿着者的舒适性。虽然图中描述的是采用特定结构的侧嵌62的尿布或成人失禁制品,但在其他吸收性和非吸收性制品中在其他结构的侧嵌片中使用复合物10也包含在本发明范围之内。
图7所示为含有双面柔软弹性复合物10的示例性非吸收性制品70,在图中是车辆防护罩。当用于非吸收性制品中时,复合物10可形成透气结构,方法是在结构中含有孔24(最佳见图1A或1B),或使用整体透气材料,或使用非透气材料和填料,并对其进行拉伸以在填料颗粒周围产生相互连通的孔隙。非吸收性制品70可以由复合物10的单层,也可以由复合物10层和其他材料层组成的多层构成。虽然图中所示为防护罩,但在其他非吸收性制品中使用复合物10也包含在本发明范围之内。
图8所示为示例性吸收性制品80的截面图。吸收性制品80至少有一个面向穿着者的面片82、吸收芯84和不面向穿着者的后片86。此结构中也可含有其他层,但为清楚起见,只示出了面片82、吸收芯84和后片86。双面柔软弹性复合物10可以单独,也可以与其他膜一起包含在面片82或后片86中。作为后片86,最好复合物10是多孔的,虽然不是必需的。作为面片82,复合物10应当含有孔24(最佳见图1),以使排泄物通过孔进入吸收芯84。任选地,如图9所示,在面片82中可直接在最大流体排泄区周围省去第一非弹性材料12,以使透过弹性层14的流体最多,同时在其余区域保持非弹性材料12的柔软感觉。
说明性实施例
实施例1是第一层(第一非弹性材料)为15gsm(克/平方米)纺粘无纺材料的复合物,所述材料以FPN-639购于BBA Nonwovens。第二层(弹性层)是68.6μm(2.7mil)厚的共挤出多孔弹性层,它有两个3.8μm(0.15mil)厚的非弹性聚乙烯表层和61.0μm(2.4mil)厚的弹性芯。孔呈正方形阵列排列,在正方形图案中,每线性米787.4个孔(619998.8个孔/平方米,20目,20个孔/线性英寸,400孔每平方英寸),形成了约10%的孔面积。第三层(第二非弹性层)是20gsm梳理无纺片,可以商品名FPN-337D购于BBA Nonwovens。第一和第二层根据Pelkie的专利采用真空层压工艺粘合。然后在粘合剂层压过程中,使用购于国立淀粉公司的Easy Melt 34-563A压敏热熔粘合剂将双层层合物(第一和第二层)粘合到第三层上。使层合物一次性在一对圆周有凹槽的啮合齿轮辊之间通过,以此进行拉伸,在30.5mpm(米/分钟)(100fpm(英尺/分钟))速度下得到4.60拉伸比(360%伸长)。
实施例2由与实施例1一样的材料构成,并用与实施例1一样的方式制备,不同之处在于啮合齿轮辊在15.2mpm(50fpm)的表面速度下操作。
增量拉伸,使第一和第三层纤维断裂,结果出乎意料,两个层合物都能耐受超过700%的伸长,而弹性层不会发生撕裂或其他破坏。
所得层合物的弹性如表1所示。为作参考,用来测量表1-5中数值的测试方法介绍如下。
拉伸性(断裂拉伸强度、断裂伸长和198N/m负载下的伸长)通过用线夹以50.8mm/min(2.00英寸/分钟)的速度拉伸夹持长度为50.8mm(2.00英寸)、宽25.4mm(1.00英寸)样品来测定。
“负载@100%”和“负载@30%Rc2”都横向测定。“负载@30%Rc2”是宽为25.4mm(1.0英寸)、夹持长度为25.4mm(1.0英寸)的样品按照下列顺序拉伸之后所保持的负载。该样品以12.7mm/min(0.50英寸/分钟)的速度拉伸至500%应变,并立即以12.7mm/min(0.50英寸/分钟)的速度放松,使之伸长为0%,并在0%伸长下保持60秒。然后以254mm/min(10.00英寸/分钟)的速度拉伸至200%应变,在200%应变下保持30秒,接着以254mm/min(10.00英寸/分钟)的速度放松,使伸长降低到0%,并保持30秒。此后,以254mm/min(10.00英寸/分钟)的速度将样品拉伸至200%应变,在200%应变下保持30秒,并以254mm/min(10.00英寸/分钟)的速度放松。然后观察到30%应变下的负载。
永久变形如下测定:以254mm/min(10.00英寸/分钟)的速度拉伸宽为25.4mm(1.0英寸)、夹持长度为25.4mm(1.0英寸)的样品,使其伸长为200%,使样品在200%伸长下保持30秒,让样品以254mm/min(10.00英寸/分钟)的速度放松到伸长量为0%,在0%的伸长下保持样品30秒,然后以254mm/min(10.00英寸/分钟)的速度拉伸样品。测定非零负载时的伸长,记录为永久变形度。
                                                         表1
  实施例   1   2
  弹性层厚度(μm)   68.6   68.6
  表面速度(mpm)   30.5   15.2
  TD断裂拉伸强度(N/m)   764   870
  TD断裂伸长(%)   786   778
  TD伸长@193N/m负载(%)   218   213
  负载@100%(N/m)   63.0   71.7
  负载@30%Rc2(N/m)   3.5   5.5
  永久变形(%)   8.7   7.0
实施例3所含材料与实施例1一样,并用与实施例1一样的方法制备,不同之处在于弹性芯厚度从61.0减少到53.3μm(2.4-2.1mil),因而弹性层厚度减少到61.0μm(2.4mil)。
实施例4所含材料与实施例1一样,并用与实施例1一样的方法制备,不同之处在于弹性芯厚度从61.0增加到71.1μm(2.4-2.8mil),因而弹性层厚度增加到78.7μm(3.1mil)。拉伸比为4.28(328%)(实施例1中为4.60(360%)),啮合齿轮辊以15.2mpm(50fpm)的表面速度操作。
增量拉伸,使第一和第三层纤维断裂,结果出乎意料,两个层合物都能耐受超过700%的伸长。
所得层合物的弹性列于表2:
                                                            表2
  实施例   3   4
  弹性层厚度(μm)   61.0   78.7
  表面速度(mpm)   30.5   15.2
  拉伸比   4.60   4.28
  TD断裂拉伸强度(N/m)   803   937
  TD断裂伸长(%)   815   778
  TD伸长@193N/m负载(%)   212   196
  负载@100%(N/m)   64.6   78.3
  负载@30%Rc2(N/m)   4.7   7.5
  永久变形(%)   7.8   5.3
比较例5是第一层、第二层和第三层形成的层合物,其中第一层是20gsm梳理无纺中,以商品名FPN-337D购于BBA Nonwovens;第二层是厚78.7μm(3.1mil)的共挤出多孔弹性层,含有两个厚3.8μm(0.15mil)的非弹性聚乙烯表层和一个厚71.1μm(2.8mil)弹性芯;第三层是20gsm梳理无纺片,以商品名FPN-337D购于BBA Nonwovens。第二层的孔呈正方形排列,每线性米787.4个孔,得到约10%的孔面积。第一和第二层按照Pelkie的专利用真空层压工艺粘合。然后在粘合剂层压过程中,使用购于国立淀粉公司的EasyMelt 34-563A压敏热熔粘合剂将双层层合物(第一和第二层)粘合到第三层上。使层合物一次性在一对圆周有凹槽的啮合齿轮辊之间通过,以此进行拉伸,在15.2mpm(50fpm)速度下得到4.28拉伸比(328%伸长)。实施例4和5之间的差别是比较例5中的两个似布层都是20gsm梳理无纺片,而实施例4中的第一层为15gsm纺粘无纺片。
比较例6所含材料与实施例5一样,并用与实施例5一样的方法制备,不同之处在于用24gsm无纺材料(BBA FPN-333D)作为第一和第三层。
所得层合物的弹性列于表3:
                                                            表3
  实施例   4  比较例5  比较列6
  似布层1   15gsm纺粘  20gsm梳理  24gsm梳理
  似布层2   20gsm梳理  20gsm梳理  24gsm梳理
  TD断裂拉伸强度(N/m)   937  1035  996
  TD断裂伸长(%)   778  797  780
  TD伸长@193N/m负载(%)   196  147  142
  负载@100%(N/m)   78.3  90.9  95.3
  负载@30%Rc2(N/m)   7.5  7.5  7.1
  永久变形(%)   5.3  6.3  6.7
比较例7的制备材料和方法同实施例2,不同之处在于不对其进行拉伸——对该实验样品进行非拉伸测定。数据表明,在所有样品中,此样品所具有的TD断裂伸长最高。这表示在拉伸过程中出现了一定程度的破坏。数据还表明,在193N/m负载下的TD伸长极低。这与未拉伸样品是一致的,也清楚地表明本发明的价值,即形成在不需要大的拉伸力量作用下即可拉伸的高弹性柔软材料。
比较例8类似于实施例2,不同之处在于第二层似布材料是15gsm纺粘无纺片(FPN-639)。此样品得到的拉伸比小于其他样品得到的拉伸比,因为啮合齿轮在啮合深度大于2.67mm(105mil)(相对于3.30mm(130mil))时不会转动。这证实了本发明在使用断裂点基本上不同的似布材料的价值。在此情况下,由于断裂伸长没有本质上的差异,所用设备受力,在某些情况下根本无法工作。如果得不到高拉伸比,则所得复合物将在193N/m负载下表现出低TD伸长。
所得层合物的性质列于表4:
                                                                 表4
  实施例   2   比较例7   比较列8
  似布层1   15gsm梳理   15gsm梳理   15gsm纺粘
  似布层2   20gsm纺粘   20gsm纺粘   15gsm纺粘
  拉伸比   4.60   1.00   3.79
  TD断裂拉伸强度(N/m)   870   913   933
  TD断裂伸长(%)   778   905   774
  TD伸长@193N/m负载(%)   213   28   91
  负载@100%(N/m)   71.7   399.2   253.5
  负载@30%Rc2(N/m)   5.5   0.4   3.1
  永久变形(%)   7.0   18.3   8.0
比较例9是只有膜的样品(即不含非弹性似布层的弹性膜),所用材料与实施例1中的弹性层相同。弹性芯的厚度是53.3μm(2.1mil),表层厚度是3.8μm(0.15mil),总厚度为61.0μm(2.4mil),而实施例1中的总厚度为68.6μm(2.7mil)。比较例9在测试之前不在啮合齿轮辊之间拉伸。比较例9和实施例1的数据列于下表5。从本发明和弹性层厚度差异及加工过程差异容易理解实施例1和比较例9之间的差别。比较例9的拉伸强度和断裂伸长稍微高于实施例1,显示出啮合齿轮辊对实施例1的弹性层的作用。比较例9在193N/m下的TD伸长明显高于实施例1;其差异可归因于无纺材料经啮合齿轮辊拉伸后的剩余强度。比较例9伸长100%下的负载明显高于实施例1,因为其表层没有通过使其在啮合齿轮辊之间通过而得到拉伸。实施例1的负载@30%Rc2稍微高于比较例9,这主要是因为实施例1的弹性层比比较例9厚。
                                                     表5
  实施例   1   比较例9
  弹性层厚度(μm)   68.6   61.0
  TD断裂拉伸强度(N/m)   764   893
  TD断裂伸长(%)   786   897
  TD伸长@193N/m负载(%)   218   452
  负载@100%(N/m)   63.0   94.5
  负载@30%Rc2(N/m)   3.5   2.0
  永久变形(%)   8.7   5.0
虽然结合本发明某些示范性实施方式对本发明进行了相当详细的介绍,但其他实施方式也是可能的。

Claims (34)

1.一种含有复合物的吸收性制品,所述复合物包含:
第一非弹性似布材料;
第二非弹性似布材料;和
位于第一非弹性似布材料与第二非弹性似布材料之间的弹性层,所述弹性层的断裂伸长至少为50%,并且复合物的弹性基本上等于弹性层的弹性,所述复合物已拉伸至使第一和第二非弹性似布材料断裂。
2.权利要求1所述的吸收性制品,其特征在于所述第一非弹性似布材料的断裂伸长基本上不同于所述第二非弹性似布材料的断裂伸长。
3.权利要求1所述的吸收性制品,其特征在于所述复合物可以加入到面片、后片、扣件、腰带、侧嵌片和防漏裤边中的至少一个中。
4.权利要求1所述的吸收性制品,其特征在于所述弹性层是透气的。
5.权利要求1所述的吸收性制品,其特征在于所述弹性层包含整体透气材料。
6.权利要求1所述的吸收性制品,其特征在于所述弹性层包含复合材料,所述复合材料包含不透气材料和填料,该复合材料已拉伸至产生相互连通的孔隙。
7.权利要求1所述的吸收性制品,其特征在于所述弹性层包含多孔三维膜。
8.权利要求1所述的吸收性制品,其特征在于所述弹性层包含多孔二维膜。
9.权利要求1所述的吸收性制品,其特征在于所述非弹性似布材料包含无纺材料。
10.权利要求1所述的吸收性制品,其特征在于所述弹性层包含:
第一非弹性表层;
第二非弹性表层;和
位于第一和第二表层之间的弹性芯。
11.一种包含复合物的非吸收性制品,所述复合物包含:
第一非弹性似布材料;
第二非弹性似布材料;和
位于第一非弹性似布材料与第二非弹性似布材料之间的弹性层,所述弹性层的断裂伸长至少为50%,并且复合物的弹性基本上等于弹性层的弹性,所述复合物已拉伸至使第一和第二非弹性似布材料断裂。
12.权利要求11所述的非吸收性制品,其特征在于所述第一非弹性似布材料的断裂伸长基本上不同于所述第二非弹性似布材料的断裂伸长。
13.权利要求11所述的非吸收性制品,其特征在于所述弹性层是透气的。
14.权利要求11所述的非吸收性制品,其特征在于所述弹性层包含整体透气材料。
15.权利要求11所述的非吸收性制品,其特征在于所述弹性层包含不透气材料和填料,该层已拉伸至产生相互连通的孔隙。
16.权利要求11所述的非吸收性制品,其特征在于所述弹性层包含多孔三维膜。
17.权利要求11所述的非吸收性制品,其特征在于所述弹性层包含多孔二维膜。
18.权利要求11所述的非吸收性制品,其特征在于所述非弹性似布材料包含无纺材料。
19.一种弹性复合物,它包含:
第一非弹性似布材料;
第二非弹性似布材料;和
位于第一非弹性似布材料与第二非弹性似布材料之间的弹性层,所述弹性层的断裂伸长至少为50%,并且复合物的弹性基本上等于弹性层的弹性,所述复合物已拉伸至使第一和第二非弹性似布材料在拉伸作用下断裂。
20.权利要求19所述的复合物,其特征在于所述第一非弹性似布材料的断裂伸长基本上不同于所述第二非弹性似布材料的断裂伸长。
21.权利要求19所述的复合物,其特征在于所述弹性层是透气的。
22.权利要求19所述的复合物,其特征在于所述弹性层包含整体透气材料。
23.权利要求19所述的复合物,其特征在于所述弹性层包含不透气材料和填料,该层拉伸至产生相互连通的孔隙。
24.权利要求19所述的复合物,其特征在于所述弹性层包含多孔三维膜。
25.权利要求19所述的复合物,其特征在于所述弹性层包含多孔二维膜。
26.一种制备弹性层合物的方法,所述方法包含:
将第一非弹性似布材料粘合到弹性层的第一面;
将第二非弹性似布材料粘合到弹性层的第二面;
使层合物在啮合齿轮辊之间通过,使第一非弹性似布材料和第二非弹性似布材料均断裂。
27.权利要求26所述的方法,其特征在于第一非弹性似布材料和第二非弹性似布材料中至少有一个在点粘合系统中粘合到弹性层上。
28.权利要求26所述的方法,其特征在于第一非弹性似布材料和第二非弹性似布材料中至少有一个在挤出层压系统中粘合到弹性层上。
29.权利要求26所述的方法,其特征在于弹性层是三维成型膜,它有一个基本平的面和一个有突起的面;
第一非弹性似布材料和第二非弹性似布材料中至少有一个在真空层压系系统中用粘合剂粘合到三维透气弹性层的平面上。
30.权利要求29所述的方法,其特征在于第一非弹性似布材料和第二非弹性似布材料中至少有一个通过点粘合系统粘合到三维透气弹性层的有突起的面上。
31.权利要求26所述的方法,其特征在于弹性层是三维成型膜,它有一个基本平的面和一个有突起的面;
第一非弹性似布材料和第二非弹性似布材料中至少有一个用粘合剂粘合到三维透气弹性层的有突起的面上。
32.权利要求26所述的方法,其特征在于啮合齿轮辊是加热的。
33.权利要求26所述的方法,其特征在于啮合齿轮辊是冷却的。
34.权利要求26所述的方法,其特征在于啮合齿轮辊不在加热或冷却的条件下操作,除了层合物在辊之间通过时由层合物提供的加热或冷却之外。
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