CN1283422A - 弹性伸缩性复合层 - Google Patents

弹性伸缩性复合层 Download PDF

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CN1283422A
CN1283422A CN00124261A CN00124261A CN1283422A CN 1283422 A CN1283422 A CN 1283422A CN 00124261 A CN00124261 A CN 00124261A CN 00124261 A CN00124261 A CN 00124261A CN 1283422 A CN1283422 A CN 1283422A
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小林利夫
丹下悟
八卷孝一
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Unicharm Corp
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Abstract

本发明公开了由弹性层和纤维集合体组成的弹性伸缩性复合层,把具有非弹性伸长特性的纤维集合体2通过间断配置的接合部4接合在弹性层3的至少一个面上形成复合片1。构成纤维集合体2的纤维6在接合部4与4之间是连续的长纤维,并在所述这些接合部4与4之间构成曲线。

Description

弹性伸缩性复合层
本发明涉及弹性伸缩性复合层，具本地说涉及由弹性层和层状纤维集合体组成的弹性伸缩性复合层。
把弹性伸缩性的无纺布接合在由塑性弹性体等组成的弹性伸缩性层上，使该弹性伸缩性层表面的橡胶质与皮肤的触感变成类似布的触感是公知的。例如为了把一次性尿布的不透液体的里层变成弹性伸缩性里层而使用的不透液体的弹性伸缩性层，往往把弹性种缩性无纺布层叠在该层的表面上。
对这样层叠获得的复合层，一般是在弹性伸缩性无纺布中使用纤维长度为50mm左右的短纤维。在这种复合层中，为了防止由于在其伸缩时互相缠绕地形成无纺布的短纤维之间的缠绕顺序解开，而损伤作为无纺布的组织从而也损伤复合层的组织，同时为了不起毛必须使纤维缠绕部位之间互相接近。同时还必须使无纺布与弹性伸缩层的接合部位互相接近。这样形成的互相接近的缠绕部位和接合部位变成了发挥复合层的高弹性伸缩时的障碍。
本发明的任务是尽可能排除防碍弹性伸缩性复合层伸缩性的原因，从而可以发挥该弹性复合层的高伸缩性能。
为了完成上述任务，本发明的前序部分是：在沿互相垂直的两个方向具有伸缩性的弹性层的至少一个面上接合具有沿上述两个方向具有伸长性的片状纤维集合体形成的荦性伸缩性复合层。
在该前序部分的基础上，本发明的特征是：上述纤维集合体是具有非弹性伸长性的集合体，上述弹性层和上述纤维集合体在沿上述两方向间歇地形成的接合部处形成为一体，构成上述纤维体合体的每根纤维是在与上述弹性层形成一体的接合部与接合部之间连续的长纤维，并且在这两个接合部之间构成曲线。在本发明的优选实施方式中有以下各例：
(1)上述各纤维在上述接合部之间不互相熔接和连接。
(2)上述各纤维在上述接合部之间互相分开独立。
(3)上述纤维在上述接合部之间构成环形。
(4)上述纤维是聚丙烯和聚酯中之一的拉伸丝。
(5)上述纤维是直径0．1～50μm的纤维。
(6)上述纤维是连续纤维。
(7)上述纤维集合体的单位面积重量是2～100g／m2。
(8)上述弹性层是由弹性伸缩性薄膜和弹性伸缩性的连续纤维中之一组成。
(9)上述弹性伸缩性薄膜是透湿性的薄膜。
(10)上述弹性伸缩性薄膜是JISZ0208规定的透湿度至少为1000g／m2／24小时，由JISL1092规定的耐水压力至少为1m的薄膜。
(11)上述弹性伸缩性薄膜是硬成分和软成分的嵌段共聚聚酯，上述软成分是由聚酯和聚酯共聚物中之一组成。
(12)上述弹性伸缩性的连续纤维是硬软成分和软成分的嵌段共聚聚酯，上述软成分是由聚酯和聚酯共聚物中之一组成。
(13)上述复合层沿上述两方向至少可弹性伸缩20％。
图1是复合层的斜视图。
图2是表示一个实施方式实例的复合层的立体图。
图3是表示另一个实施方式实例的复合层的立体图。
图4是表示复合层制造工序的一个实例的图。
图5是表示复合层制造工序的另一个实例的图。
下面参照附图详细说明与本发明有关的弹性伸缩性复合层。
在图1中以立体图示出的弹性伸缩性复合层1具有上层2和下层3，上层2和下层3在接合部4熔接成一体。复合层1沿着由互相垂直的双头箭头X-X，Y-Y中的至少箭头Y-Y方向的点划线所示的那样可弹性伸缩。
复合层1的上层2是沿X-X、Y-Y方向中的至少Y-Y方向可非弹性伸长的层。该上层2是在接合部4与4之间连续的热塑性合成树脂的长纤维，最好是热塑性合成树脂的连续纤维6的集合体，纤维之间只在接合部4处互相熔接，在接合部4彼此之间既不熔接也不粘接，而纤维之间互相分离独立。另外，纤维6在接合部4与4之间构成不规则的曲线，并向下层3的上面扩展。在复合层1沿Y-Y方向和／或X-X方向伸长时，构成曲线的纤维6对应该伸长在接合部4与4之间朝向Y-Y方向和／或X-X方向延伸并改变走向，上层2非弹性地伸长。在该连续纤维6上有由作为非弹性合成树脂的聚丙烯或乙烯-丙烯无规共聚物、乙烯-丙烯-丁烯无规共聚物、聚酯、聚乙烯等组成的材料。连续纤维6的直径最好为0．1～50μm。
复合层1的下层3是沿Y-Y方向、最好沿Y-Y方向和X-X方向具有弹性伸缩性的层，可沿Y-Y方向至少伸长200％，最好可至少伸长400％，在伸长100％后可以弹性收缩到原长度的1．3倍以下。在该层上有由包括热塑性弹性体等弹性原材料组成的连续纤维的集合体，通过使这种集合体的连续纤维互相熔接或机械缠绕形成的无纺布，热塑性合成橡胶形成的薄膜等。在薄膜上可以使用透湿性或非透湿性的材料。图中以举例方式示出了这样的层中由连续纤维10组成的无纺布。
下层3的连续纤维和薄膜可以使用硬成分和软成分的嵌段聚酯共聚物。如果是由该聚酯组成的连续纤维，则因为象天然纤维那样地对应应环境条件发挥吸湿性和放湿性，所以由该连续纤维组成的复合层1是最适合用作一次性外衣等的衣料的材料。另外，因为由该聚酯形成的薄膜具有透湿性，所以通过适当调整硬成分和软成分的组合，使其透湿度至少为由JISZ0208规定的1000g／m2／24小时，其耐水压至少为由JISL1092规定的1m，优选的是至少2m，使用这样调整过的薄膜1最适合作一次性尿布或生理用卫生巾等一次性体液处理用品的不透液体的底层材料。复合层1可使用的薄膜的一个例子是东洋纺织株式会社的商品名“ベレプレン P30B”的薄膜。
硬成分是玻璃化转变温度50℃以上的物质，最好是由二羧酸和二醇类制得的聚酯。二羧酸和二醇类中至少一方最好包含芳香族环。在二羧酸的例子中有邻苯二甲酸、对苯二甲酸、间苯二甲酸、2，6-萘二羧酸，2，7-萘二羧酸、1，-5萘二羧酸，二苯基-4，4′-萘二羧基酸，3，3′-二甲基二苯基4，4二羧酸，4，4′二羧酸，4．4′二苯基砜二羧酸，4，4′-二苯氧基乙烷二羧酸等芳香族二羧酸，琥珀酸，草酸、已二酸、癸二酸、十二碳二酸酸等脂肪族系二羧酸；1，4环已烷二羧酸，萘烷-2，6二羧酸等脂环族系二羧酸。
软成分是玻璃化转变温度20℃以下的物质，最好是聚醚、脂肪族聚酯，聚醚与脂肪族聚酯的共聚物。聚醚的例子有聚乙二醇，聚(乙烯／丙烯)嵌段聚二醇、聚1，4-丁二醇、聚1，6-己醇等；脂肪族聚酯的例子有聚已二酸乙二醇酯、聚已二酸丁二醇酯、聚已内脂等。
上层2和下层3除了可以通过在接合部4加热加压形成一体外，还可以用超声波处理形成一体。另外，在通过上层2的连续纤维6与下层3的组织机械缠绕使两者形成一体的情况下，作为用于该缠绕的手段可以采用针刺，高压柱状水流处理等。接合部4的每个面积在0．03～10mm2的范围内，占复合层的面积的比例最好在1-50％的范围内。
当沿着例如Y-Y方向拉该复合层1时，下层3沿Y-Y方向弹性伸长，随着该伸长使上层2的曲线的连续纤维6在改变走向的同时沿Y-Y方向非弹性伸长。在直到纤维6的曲线伸展到极限之前的期间，为拉伸复合层1所需要的力主要为拉伸下层3所需要的力。因为上层2只改变纤维6的走向，所以对拉伸复合层1的力几乎没有影响。当进一步拉伸复合层1时，构成曲线的连续纤维6伸展到极点，在接合部4与4之间变成直线形状。为了拉伸变成这样的复合层1，则需要拉伸下层3的力和拉伸直线形纤维6的力。连续纤维6由于在构成曲线的同时延伸，所以即使下层3沿X-X方向伸长时，也不会防碍该伸长。连续纤维6的曲线最好是在复合层1的表面方向形成环状，通过这样的构成容易获得沿Y-Y方向和X-X方向相同的例如至少20％弹性伸缩的各向同性的复合层1。
图2表示复合层1的另一实施例，它具有与图1同样的图面。在该复合层1中用由热塑性弹性材料组成并具有沿Y-Y方向和X-X方向弹性收缩性的薄膜20作为下层3，上层2和下层3在接合部4熔接。
图3是表示复合层1的另一例的图，它具有与图2同样的图面。在该复合层1中，在由薄膜20组成的下层3的下面预先形成与上层2同样的可弹性或非弹性伸长的第3层300，上层2，下层3与第3层300在接合部4互相熔接成一体。第3层300是由热塑性合成树脂组成的连续纤维310的集合体，纤维310之间最好是只在接合部4互相熔接，而在接合部4之间既不熔接也不粘接，在接合部4与4之间连续纤维310一边构成不规则曲线、最好是在复合层1的表面方向构成的环形一边向下层3的下面扩散。在复合层1伸长时，第3层300与上层2一样非弹性伸长。连续纤维310使用与连续纤维6相同的原材料。
按照本发明也可以从图1的复合层获得与图3相同3层构造的复合层。例如在图1的复合层1的下层3的下面形成与图3相同的第3层300，也可以使该第3层300在接合部4处接合在下层3上。
图4是获得图1所例示的复合层1的制造工序图。在图中环形传送带30从左向右行进。在图的左侧部分，在传送带30的上方设置第一熔喷纤维成形机31，在传送带30的下方设置吸入机构31A，第1成形机31在传送带30的宽度方向有并排的若干个喷嘴，由非收缩性的热塑性合成树脂组成的第1连续纤维35从这些喷咀中喷出，在传送带30的上面边构成不规则的曲线，边堆积形成第1网41。在第1网41上为了不使堆积层叠的第1连续纤维35之间熔接并且即使已熔接也能在后面的工序中容易地分开，而选择第1成形机31的喷射条件和皮带30的运行条件。第1连续纤维35至少具有70％的断裂延伸率。
第1成形机31的右方设置第2熔喷纤维成形机32和吸入机构32A。第2成形机32也具有沿传送带宽度方向并列配置的若干个喷嘴，由可弹性伸缩的热塑性合成树脂组成的第2连续纤维40从这些喷嘴中喷出，在第1网31的上面边构成不规则的曲线边堆积形成第2网42。堆积层叠的第2连续纤维40之间互相熔接，为了形成第2网42沿传送带30的运行方向上、更好是沿该运行方向和与该运行方向相垂直的方向具有可弹性伸缩性能的无纺布，而选择第2成形机32的喷射条件。这个第2连续纤维40的断裂延伸率比第1连续纤维35高。
重叠的第1、2网41、42在上下一对压纹辊34、34之间通过并在作为网41、42行进方向的长度方向和与该长度方向垂直的宽度方向中的至少长度方向上间断地加压加热互相熔接而形成第1复合网43。
第1复合网43通过拉伸用的第1、2、3辊36、37、38。虽然第1、3辊36、38的转动速度相同，但比第2辊37的转动速度慢。设定第1辊36与第2辊37的转动速度差，以使复合网43在10～60℃、更好是在15～40℃的室温附近拉伸到所需的倍率。拉伸后的第1复合网43在第2辊37与第3辊38之间弹性地收缩到原长度并形成第2复合网44。
第1复合网43拉伸时，在用压纹辊34熔接的部位与部位之间第1连续纤维35在其断裂拉伸率以内的范围拉伸。沿其长度方向产生塑性变形，尺寸伸长，直径变细。由第2连续纤维37组成的第2网42在熔接的部位与部位之间在第2连续纤维40的弹性极限内弹性地伸长，最好是在这个拉伸工序中，除了用压纹辊34熔接的部位之外，将在形成第1网41的连续纤维35之间的几乎全部的熔接和机械的缠绕脱开，另外最好还能基本上脱开第1连续纤维35与第2网42的熔接。第1复合网43的优选拉伸率是50～300％。
将第2复合网44卷成卷，然后裁剪成适当的尺寸，使之成为复合层1。第2复合网44中的第1网41和第2网42成为图1中复合层1的上层2和下层3。在第2复合网44中用压纹辊34熔接的部分变成为复合网1的接合部4。
由于第1、2网41、42由连续纤维形成，所以这两个网41、42的接合部4即使远离也能保持两网41、42成一体。另外由于接合部4互相远离，而使对第2复合网44即复合层1的伸缩性的防碍变小。
在把这样获得的第2复合网44即复合层1使用在一次性尿布、一次医疗用外衣等穿用物品上时，即使在第2复合网42中含有橡胶材料，在用第1网41与皮肤接触时，也不会因橡胶材料特有的相对皮肤打滑不良的特性而刺激皮肤。由于第1连续纤维35伸长后直径变细，所以比喷射后状态下的连续纤维35柔软，皮肤触感良好。第2复合网44的第1连续纤维35如果在除压纹加工的接合部4之外，连续纤维35之间不熔接，则在与第2网42也不熔接的相互分离独立的情况下，使笫2复合网44拉伸时的初始力只需用使第2网42拉伸的比较小的力就够了。这样第2复合网44即使由上下层组成，也能成为伸缩容易和柔软的层。如果是图示例的工序，第2复合网44中的第1、2网41、42的各自单位面积重量成各从成形机31、32喷射出时的单位面积重量，另外，因为第1、2网41、42都是连续纤维的集合体，所以由它们获得的第2复合网44一般透气性良好，即使反复伸缩，也不会发生起毛，短纤维不会从该网44上脱落，第二复合网44因为具有弹性而不容易发生断裂和拆痕等。这些性质使复合层1用在医疗用外衣上是最优选的。
可以对获得复合层1的图4的工序进行各种各样的改变，例如可以使第2网42先于第1网41供给传送带30，为了使第1、2网41、42接合，可以采用针刺和高压柱状水流处理等手段代替利用压纹用的辊34的加工。另外，如果在图4的第2成形机32的下游侧设置第3熔喷纤维成形机，用从该成形机喷射出的第3连续纤维在第2网42上形成与第1网41相同的第3网，则也可以制造由第1、2网41、42和第3网细成的三层结构的复合层1。第1网41和第3网在树脂的种类和纤度、色泽等外观上既可以相同也可以不同。
图5是与表示图2的复合层1的制造方法的图4相同的工序图。在该例中，把由热塑性弹性材料组成的并在传送带30的行进方向具有弹性伸缩性的薄膜52作为第2网42从图中的左方供给，在该薄膜52上，供给由第1连续纤维35组成的第1网41。使第1、2网41、42与图2相同地通过压纹辊34、34之间进行间断地熔接形成第1复合网43，在被第1～3辊36、37、38拉伸后通过收缩而形成第2复合网44。这样，在采用薄膜52形态的第2网42上熔接第1网41形成图1中接合部4的第2复合网4上由连续纤维形成与图4的第2复合网44相同的第一网41，这些接合部4的各个面积小到例如0．03～1mm左右，即使使其面积总和减小到第2复合层44的表面积的1～10％左右，在第二复合层44伸缩时第1、2网41、42也不能简单地分开。但是在本发明中，根据需要可以使接合部4的面积在0．03～10mm2的范围内变化，可以使其面积总和在第二复合网44的表面积的1～5％范围内变化。
如果改变图5的工序，使用第3熔喷纤维成形机将第3连续纤维供给上面已供给有第1连续纤维35的薄膜52的下面，则可以获得利用纤维网夹着薄膜52的图3的复合层1。
与本发明有关的弹性收缩性复合层，因为层叠在弹性层的至少一个面上的伸长性纤维集合体是连续纤维组成的，所以即使弹性层与纤维集合体的接合部分之间互相远离，也能将所述弹性层与纤维集合体保持为一体。这样获得的复合层也不会因互相接近形成的接合部位而防碍伸缩性。该复合层由于即具有伸缩性又由于连续纤维的存在而使其触感类似于布，所以适合作一次性尿布、生理用卫生巾、一次外衣等穿着物品的面料。

Claims (14)

1．一种弹性伸缩性复合层，其在互相垂直的两个方向具有伸缩性的弹性层的至少一个面上接合有在上述两方向具有伸长性的片状的纤维集合体，其特征在于：
上述纤维集合体是具有非弹性伸长的集合体，上述弹性层和上述纤维集合体在沿上述两方向间断地形成的接合部处形成为一体，构成上述纤维集合体的各纤维是在与上述弹性层形成一体的接合部与接合部之间连续的长纤维，并且在这两个接合部之间构成曲线。
2．如权利要求1所记载的复合层，其特征在于：上述各纤维在上述接合部之间不互相熔接和粘接。
3．如权利要求1或2所记载的复合层，其特征在于：上述各纤维在上述接合部之间互相分离独立。
4．如权利要求1、2或3所记载的复合层，其特征在于：上述纤维在上述接合部之间构成环形。
5．如权利要求1～4中任一项所记载的复合层，其特征在于：上述纤维是聚丙烯和聚酯中之一的拉伸丝。
6．如权利要求1～5中任一项所记载的复合层，其特征在于：上述纤维是直径0．1～50μm的纤维。
7．如权利要求1～6中任一项所记载的复合层，其特征在于：上述纤维是连续纤维。
8．如权利要求1～7中任一项所记载的复合层，其特征在于：上述纤维集合体的单位面积重量是2～100g／m2。
9．如权利要求1～8中任一项所记载的复合层，其特征在于：上述弹性层是由弹性伸缩性薄膜和弹性伸缩性的连续纤维中之一组成。
10．如权利要求1～9中任一项所记载的复合层，其特征在于：上述弹性伸缩性薄膜是透湿性的薄膜。
11．如权利要求9或10所记载的复合层，其特征在于：上述弹性伸缩性薄膜是由JISZ0208规定的透湿度至少为1000g／m2／24小时，由JISL1092规定的耐水压力至少为1m的薄膜。
12．如权利要求9、10或11所记载的复合层，其特征在于：上述弹性伸缩性薄膜是硬成分和软成分的嵌段共聚聚酯，上述软成分是由聚酯和聚酯的共聚物中之一组成。
13．如权利要求9所记载的复合层，其特征在于：上述弹性伸缩性的连续纤维是硬成分和软成分的嵌段共聚聚酯，上述软成分是由聚酯和聚酯的共聚物中之一细成。
14．如权利要求1～13中任何一项所记载的复合层，其特征在于：上述复合层沿上述两方向至少可弹性伸缩20％。
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CN110191982A (zh) * 2017-01-31 2019-08-30 宝洁公司 成型非织造布
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CN107019594A (zh) * 2016-01-29 2017-08-08 大王制纸株式会社 吸收性物品的伸缩结构及其制造方法
CN107019595A (zh) * 2016-01-29 2017-08-08 大王制纸株式会社 吸收性物品的伸缩结构及其制造方法
CN107019595B (zh) * 2016-01-29 2021-06-29 大王制纸株式会社 吸收性物品的伸缩结构及其制造方法
CN107019594B (zh) * 2016-01-29 2021-07-13 大王制纸株式会社 吸收性物品的伸缩结构及其制造方法
CN110191982A (zh) * 2017-01-31 2019-08-30 宝洁公司 成型非织造布
US11427943B2 (en) 2017-01-31 2022-08-30 The Procter & Gamble Company Shaped nonwoven
US11661689B2 (en) 2017-01-31 2023-05-30 The Procter & Gamble Company Shaped nonwoven
US11666488B2 (en) 2017-01-31 2023-06-06 The Procter & Gamble Company Shaped nonwoven
US11773521B2 (en) 2017-01-31 2023-10-03 The Procter & Gamble Company Shaped nonwoven
US11872112B2 (en) 2017-01-31 2024-01-16 The Procter & Gamble Company Shaped nonwoven
US11987917B2 (en) 2017-01-31 2024-05-21 The Procter & Gamble Company Shaped nonwoven
US11992393B2 (en) 2017-01-31 2024-05-28 The Procter & Gamble Company Shaped nonwoven

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JP3794903B2 (ja) 2006-07-12
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US6730390B1 (en) 2004-05-04
BR0009150A (pt) 2001-11-20
ID26544A (id) 2001-01-18
EP1069223A1 (en) 2001-01-17
CN1221379C (zh) 2005-10-05
CA2313707C (en) 2014-08-12
SG92721A1 (en) 2002-11-19
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MY125135A (en) 2006-07-31
CA2313707A1 (en) 2001-01-12

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