CN1341052A - 弹性层压件的高强度贯通粘合方法 - Google Patents

弹性层压件的高强度贯通粘合方法 Download PDF

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Publication number
CN1341052A
CN1341052A CN00804088A CN00804088A CN1341052A CN 1341052 A CN1341052 A CN 1341052A CN 00804088 A CN00804088 A CN 00804088A CN 00804088 A CN00804088 A CN 00804088A CN 1341052 A CN1341052 A CN 1341052A
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bonding
fabric
bonding agent
layer
elastic
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Granted
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CN00804088A
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CN1107588C (zh
Inventor
鲁塞尔·P·斯塔克齐尼斯基
迪亚娜·M·施特雷洛
詹姆斯·D·卡珀
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Bostik Inc
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Ato Findley Inc
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  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Orthopedics, Nursing, And Contraception (AREA)

Abstract

本发明涉及一种高强度贯通粘合方法。在一优选的实施例中,该结构是一种无纺织物三层结构,该结构具有无纺材料外层(12、18)以及具有多个贯通开口(20)的内部弹性层(16)。在生产过程中,贯通粘合粘接剂(如耐油的聚丁烯基热熔融粘接剂)的液滴被涂布到至少一无纺织物上。然后使内部弹性织物和两个外部无纺织物对准并将它们送进压缩间隙。该压缩间隙将这些织物压在一起,以使两个外部无纺织物通过内部弹性织物中的开口相互紧密接触。在所得到的三层织物中,即使在内部弹性织物和任一外部无纺织物之间的直接粘合失效,内部的弹性织物层也能被机械地固定在所述三层结构中。优选的是,贯通粘合粘接剂的液滴仅被涂布在织物中要求提高强度以确保成品的牢固性和耐久性的区域中,如成品三层件产品的纵向边缘附近。

Description

弹性层压件的高强度贯通粘合方法
本发明所属技术领域
本发明涉及一种用于一次性物品例如尿布等构件中的层压结构。具体地说，本发明涉及一种高强度的贯通粘合(through-bonding)技术，该技术能够提高可伸展层压件的强度和耐久性。
本发明的背景技术
许多在市场上能买得到的一次性物品包括有可透气且可伸展的层压件，例如，用于婴儿的尿布和用于失禁的成人的内衣等吸水物品均采用了可伸展的侧面料。这些一次性物品中的许多(即使不是大多数)都采用了多层无纺材料。其它采用了无纺层压件的产品包括绷带、身体包扎件等。
几种类型的无纺织物在本领域中是公知的。一般来说，无纺织物包含有聚乙烯、聚丙烯、聚对苯二甲酸乙酯、尼龙、或人造丝的纤维，并且以许多方法例如粘接、热粘合、黏结或其它本领域公知的方法被聚集在一起。热粘合的无纺聚丙烯在一次性物品中尤其普遍。热粘合聚丙烯是可透气的且具有柔软的象布料一样的手感，该特点对于这些用途来说尤其适用。
本申请的受让人已经致力于研究各种用在无纺层压结构中的粘接剂，例如参见由Bonnie M.Harris和Moniana Kanderski于1996年4月15日申请的、题目为“基于热熔融粘接剂的耐油聚丁烯基”的美国专利申请No.08/632,117；以及由Mark D.Alper和Diane Strelow于1997年8月19日申请的、题目为“用于一次性柔软物品的酸含量高的热熔融粘接剂”的美国专利申请No.08/914,523，这两篇文献在这里被引用作为参考。如在上面所引用的专利申请中所述，难以找到能够有效地将无纺材料粘合到被要求用于无纺层压件结构中的弹性薄膜或网格布上的粘接剂。某些弹性薄膜或布(例如耐油材料或包括有不相容的操作助剂的材料)完全难以与无纺织物层压在一起。另外，因为在该层压件受到反复伸展的时施加在该粘合件上的机械应力的原因，所以特别难以与弹性薄膜或织物形成有效且长久的粘合。
以下针对弹性薄膜和网格布的说明被加入用来对在用市场上销售的弹性薄膜或织物来生产层压结构时所遇到的一些困难提供更完全的说明。
市场上销售的弹性薄膜和网状织物通常是由A-B-A成块共聚物制成的，例如苯乙烯-丁二烯-苯乙烯共聚物(SBS)、苯乙烯-异戊二烯-苯乙烯共聚物(SIS)、苯乙烯-乙烯/丁烯-苯乙烯以及其它聚烯烃例如但不限于：乙烯醋酸乙烯酯(EVA)和低密度聚乙烯(LDPE)。这些弹性体材料通常包括重量百分比约为20％-30％的弹性块体共聚物，以及重量百分比约为20％-30％的其它聚烯烃或乙烯醋酸乙烯酯。这些薄膜及其特定组成的一个例子可从美国专利No.4,476,180中得到。一旦这些弹性织物被配制并压制而成，该织物可能非常粘。该发粘特性使得在挤压生产线及随后的转换设备中对织物的加工变得困难。为了克服与弹性织物的发粘特性相关的问题，弹性织物的制造商们通常在其组分中加入相对较多数量的防粘剂。例如，具有分子式CH3-R-CO-NH2的脂肪酸酰胺通常被用作防粘剂。其中的字母R通常为具有12-24个原子长度的重复-CH2-单元链。最常用的脂肪酸酰胺为芥酸酰胺。它由HumkoSheffieldChemical公司在市场上以Kemamide E的商标销售。这种特定的防粘剂具有一种碳链，该碳链有22个单元长、分子重量大约为337.6，并且毛细管法熔点大约为82℃。
加入到该弹性薄膜和织物中的防粘剂对于在生产无纺层压件中通常所用的现有技术的热熔融粘接剂来说已经产生出显著的问题。具体地说，人们认为防粘剂在特定的环境情况下变得易流动，或者与用于弹性薄膜或网状织物中的聚合物不相容；这两个因素结合起来导致防粘剂会逐渐沉积在或结合到该薄膜或网状织物的外部表面上。该防粘剂具有蜡的特性，一旦结合到薄膜或网状织物的外部表面上时它们便作为一种润滑剂。对于弹性薄膜和网状织物的生产者来说，这具有两个有价值的好处。第一个好处在于，薄膜或网状织物的外部表面上蜡状层的存在有助于防止相邻的薄膜层在被装成辊形时相互粘结在一起(在本行业中被称作“布层粘连”)。第二个好处在于该蜡状层用作一种润滑剂，从而有利于在该薄膜被开卷以及后面在辊子上方加工时的使用(即在随后的印染加工和/或处理过程中)。
虽然上述的防粘剂有利于甚至能改善在生产中使用这些合成薄膜和网状织物，但是转移到该薄膜或网状织物的外部表面上的防粘剂容易破坏或显著减弱现有技术的粘接剂的粘接力。目前在所销售的产品中的薄膜中存在的防粘剂的重量百分比在大约0.1％到1％的范围内，但是目前在产品中一些薄膜的百分比含量差不多有4.5％。可以在美国专利Nos.4,476,180、4,977,014和4,714,735中找到在薄膜或织物中使用防粘剂的进一步说明，所有这些专利在这里被引用作为参考。
考虑到把热熔融粘接剂涂布到弹性薄膜和织物方面的问题，本行业一直在寻找一种热熔融粘接剂组分，该粘接剂能够有效地把这些弹性薄膜和网状织物粘接到透气材料例如无纺织物上。
发明概述
与现有的试图研制出改善的粘接剂相对照，本发明涉及采用一种用于弹性层压件的高强度贯通粘合方法。在优选的实施例中，该层压结构包括两个无纺材料外层以及层压于这两个无纺材料外层之间的内部弹性层。该内部弹性层优选是一种网状织物，并且根据本发明提供形成贯通的开口，从而第一无纺外层的粘合侧通过这些开口与第二无纺外层的粘合侧粘结在一起。本发明的一个重要方面涉及采用贯通粘合粘接剂，以使第一和第二无纺材料外层通过内层中的至少一些开口直接相互粘合。通过该弹性网状织物中的开口在无纺层之间形成的直接粘合使该弹性网状织物机械地固定在该三层件结构中。在许多应用中，还要求提供用于把外部无纺层直接粘接到所述弹性织物上的粘接剂。但是，主要由通过弹性织物中的开口而在外部无纺层之间出现的直接粘接剂来提高无纺三层件结构的耐久性。
在一些无纺/弹性网状织物三层件或类似结构中，无纺层沿着加工方向是不可伸展的，但是沿着横向方向是可伸展的。该弹性网状织物使得该三层件能够在该三层件伸展时沿着横向方向伸展，并且能够在伸展停止时使该三层件恢复到松弛位置。在外部无纺层直接与弹性网状织物粘接而不是通过该织物中的开口相互粘合的无纺三层件结构中，反复的伸展容易引起分层。这是由在粘接弹性材料过程中的内在问题产生的。即使在有反复伸展的时候，采用根据本发明的贯通粘合方法也能基本上消除了该问题。
本发明并不限于无纺弹性网状织物三层件。例如，该贯通粘合方法除了能提高无纺类型的层压结构的耐久性之外，还能提高采用透气材料类型的层压结构的耐久性。另外，本发明应该不限于三层件(如三层)结构，因为根据本发明该结构还可以包含附加的层。
另一方面，本发明提供一种在层压机上生产透气且可伸展的层压织物的方法，该层压机接收两个透气材料(如无纺的)织物和一个具有多个贯通开口的弹性织物。该方法有利于这些透气层通过弹性织物中的开口贯通粘合。该方法包括将一第一透气材料织物送进层压机。与第一透气材料织物分开，还把一第二透气材料织物送进层压机中。另外，还将具有多个开口的弹性织物送进层压机。上述织物层与设在透气材料层之间的弹性织物层对准。在这些织物层完全对准之前，将贯通粘合粘接剂涂布在至少一个透气材料织物的粘合侧上。该贯通粘合粘接剂优选通过液滴涂布机以液滴进行涂布，但是也可以采用其它公知的方法进行涂布。但是该粘接剂必须在这样的条件(温度、粘度、加工速度、压力等)下进行涂布：该条件足以让贯通粘合粘接剂能够流过弹性层中的开口并且能够在这些织物被对准且随后被压在一起的时候润湿其它透气材料织物的粘合侧。优选的贯通粘合粘接剂是一种耐油的聚丁烯基热熔融粘接剂，但是本发明也可以采用其它类型的贯通粘合粘接剂。在粘接剂已经被涂布且这些织物已经被对准之后，这些织物通过压缩夹缝实现被润湿的第一和第二透气材料织物的粘合侧之间的紧密接触。该压力优选为至少50磅/英寸。优选的是，压缩夹缝由硬质辊(如钢辊)和弹性辊(例如橡胶辊)形成。重要的是，要有足够量的贯通粘合粘接剂，以通过弹性织物中的开口润湿两个透气材料织物的粘合侧，并且还要有足够的压力，以确保被润湿的透气材料织物的粘合侧紧密接触，以利于正确的粘合。然后如本领域所公知的一样，该层压织物可以沿着加工方向被纵向地切开并打上孔，以形成撕开线并且形成多块层压织物。
优选的是，把贯通粘合粘接剂的液滴涂布到其中一个透气材料织物的粘合侧上，但是不直接涂布在第二透气材料织物上。或者，优选把喷涂粘接剂涂布在第二透气材料织物上。此后，弹性织物被对准并且与第二透气材料织物接触并通过喷涂粘接剂与之粘合。之后，优选喷涂上另外的粘接剂。然后所得到的织物(如第二透气材料织物和粘附在其上的弹性织物)与已经被涂布有贯通粘合粘接剂液滴的第一透气材料织物对准。然后这些被对准的织物通过如上所述的压缩间隙。
优选的是，液滴涂布机具有粘接剂集流腔以及多个粘接剂涂布喷嘴，这些喷嘴可以与或不与第一透气材料层的粘合侧接触。为了利于涂布足够量的贯通粘合粘接剂，这些喷嘴可以被布置成一系列倾斜的排。因为需要涂布相当多的贯通粘合粘接剂以牢固地将内部弹性层固定在三层件结构中，所以应该谨慎地选择在生产过程中的贯通粘合粘接剂的涂布量，否则成品会变得太硬。在许多应用中，可以要求只沿着织物的选定部分(如沿着切开的层压织物的纵向边缘)涂布贯通粘合粘接剂，从而使内部弹性织物机械地固定在三层件结构里面而不会产生出太硬的成品。
对于那些本领域普通技术人员来说应该理解的是，该高强度贯通粘合方法改善了采用层压结构的成品的耐久性，而不会显著影响层压机的线速度。重要的是，该贯通粘合方法和粘接剂的化学性质克服了由弹性薄膜或织物上的加工助剂(如防粘剂，油等)在生产层压结构时引起的粘接问题。本发明还能够降低开发新层压件的费用。本发明至少在某些情况中消除了需要找到一种合适的粘接剂以将无纺层直接粘接在内部弹性层上的必要，而这通常在开发普通层压结构过程中是必要的。
通过下面的附图和其说明，本发明的其它特征和优点对于本领域的普通技术人员来说将更加清楚。
附图的简要说明
图1为根据本发明构成的无纺三层结构的透视示意图。
图2为沿着图1的线2-2剖开的根据本发明制成的无纺三层结构的剖视图。
图2a为类似于图2的视图，显示出正被伸展的无纺三层结构。
图3为示意图，显示出应用了根据本发明的高强度贯通粘合方法的层压机。
图4为侧面图，显示出将贯通粘合粘接剂的液滴涂布到第一外无纺织物的粘合侧上的粘接剂液滴涂布机。
图4a为从图4中的直线4A看的该液滴涂布机的喷嘴布置的视图。
图5为示意图，显示出当实施本发明时所采用的优选的粘接剂涂布图案。
附图的详细说明
上述附图显示出实施本发明的最佳模式，但是应该理解的是，本发明的范围不应该只局限于该优选实施例。图1、2和2a显示出一种根据本发明的优选实施例构成的无纺三层结构10。图3至图5涉及构成该无纺三层结构的优选方法。
参照图1，该无纺三层结构10由第一无纺层12(即第一层可透气材料)、内部弹性层16以及第二无纺层18(第二层可透气材料)形成。该弹性层16被层压在第一无纺层12和第二无纺层18之间。该弹性层包括多个贯通的开口20，并且优选为一种可伸展的弹性网状织物。虽然根据本发明可以采用其它尺寸的弹性网状织物，但是优选的弹性织物的厚度为0.025英寸。当要求一种柔软、耐久、透气且有弹性的面料时，该三层结构10能够结合进多种产品。这些产品的示例包括尿布、失禁产品、绷带、身体包扎件等。
在本发明的优选实施例中，无纺层12、18都是热粘合聚丙烯。合适的无纺材料的一个示例的基重为63克/平方米、沿着加工方向的伸展强度为7000克/英寸，且沿着横向方向的伸展强度为425克/英寸。根据本发明还可以采用其它类型的无纺材料。
参照图2和2a，第一外部无纺层12具有一粘合侧14。第二外部无纺层18也具有一粘合侧22。贯通粘合粘接剂24被涂布到该三层结构10上，并且通过该弹性层16中的开口20使第一无纺层12的粘合侧14与第二无纺层18的粘合侧22直接粘合。在实施本发明时没有必要在所有通过内层16的开口20处涂布贯通粘合粘接剂24。优选的是，贯通粘合粘接剂是一种聚丁烯基热熔融粘接剂，其公开在由Bonnie M.Harris合MoninaKanderski于1996年4月15日申请的、题目为“耐油的聚丁烯基热熔融粘接剂”  的美国专利申请No.08/632，117中，该文献在这里被引用作为参考。其它粘接剂也可能适用作为贯通粘合粘接剂。例如，由Wauwatosa，WI的Ato Findley，Inc.生产的并且以H9282F的商标进行销售的粘接剂应该是令人满意的。
虽然没有在图2上示出且对于实施本发明来说不是必要的，但是最好将另一种粘接剂涂布在无纺层12、18之一(或两者)上，以提供与内层16的直接粘接。优选的是，该附加的粘接剂是喷涂的。该优选的喷涂粘接剂是一种弹性的压敏粘接剂，例如由本发明的受让人Wauwatosa，Wisconsin的Ato Findley公司制造的商标名为H2120的粘接剂。
即使在弹性层16和无纺层12、18之一或两者之间的直接粘接都失效的情况，该贯通粘合粘接剂24也能通过内部弹性层16中的开口20使外部无纺层的各个粘合侧14、22固定，这样该弹性层16的条带就被机械固定在该无纺三层结构10中。图2a示意地显示出正在被伸展的无纺三层结构10。如图2a所示，内部弹性层的条带16通常没有直接与外部无纺层12、18中的任何一个粘接。尽管如此，即使在该层压三层结构伸展的时候，该弹性层的条带16也能在周围的粘接剂24的作用下被固定在该结构10中，该粘接剂通过弹性层16中的开口使无纺材料外层粘合。
根据本发明，在外部无纺层12、18之间呈现出的贯通粘合粘接剂24的粘合的平均剥离强度比在弹性层16与任一外部无纺层12、18之间直接形成的粘合的平均强度都高。实际上，由本受让人所做的实验表明，通过开口20在外部无纺层12、18之间产生的粘合的剥离强度可能比在弹性层16和任一无纺层12、18之间直接产生的粘合的剥离强度大两倍以上。
现在将参照图3、4、4a和5对如1、2和2a所示的构成该无纺三层结构10的优选方法进行说明。首先具体参照图3，在一种层压机26中生产该无纺三层件10A，该层压机优选包括在图3中示意性地显示出的部件。在图3中，如在本领域所公知的一样，无纺滚筒式开卷机将第一无纺织物12a送进该层压机。第一无纺织物通过输入辊28并且被输送到贯通粘合粘接剂液滴涂布机30的下方。该贯通粘合粘接剂液滴涂布机30将贯通粘合粘接剂的液滴涂布在第一无纺织物12a上。第二无纺织物18a也被送进该层压机26中。另外，弹性织物16a被送进该层压机26，并且通过辊子32，以使该弹性织物16a与第二无纺织物18a对准。如果不需要任何加工方向的伸展的话，则优选在零张力或接近零张力的情况下将弹性织物16a送到层压机26上，否则成品会被扭曲或变形。在引入弹性织物16a之前，通过喷涂机34在第二无纺织物18a的粘合侧上喷涂普通的粘接剂。在引入弹性织物16a之后，用喷涂机35喷涂上附加的粘接剂。该喷涂粘接剂的一个目的在于将弹性织物16a直接粘接到第二无纺织物18a的粘合侧上，这对于在制造过程中保持弹性织物16a的正确对准来说是重要的。在优选的机器26中，如图5所示，喷涂机34和35以螺旋图案将粘接剂喷涂在无纺织物18a上以及弹性织物16a和无纺织物18a的组合上(由喷涂机34形成排52a并由喷涂机35形成排52b)。每排52a、52b都是由从各自的喷涂机中喷出的螺旋图案交错的排形成的，以确保全部涂覆上喷涂粘接剂。优选地选择喷涂粘接剂，以在无纺织物12a和弹性织物16a之间提供有效的粘合。如结合图1在前面所述的一样，在本发明的优选实施例中，该优选的粘接剂是一种弹性的压敏粘接剂，例如Ato Findley粘接剂H2120，其中内部织物16a是一种弹性织物，并且外部织物18a是一种热粘合的无纺聚丙烯材料。
被对准的第二无纺织物18a和内部弹性织物16a通过对准辊36并且继续向压缩间隙38运动。在压缩间隙38中，第二无纺织物18a和弹性织物16a被压靠在其上被涂布有贯通粘合粘接剂液体的第一无纺织物12a上。被对准的12a、16a和18a以足够的压紧力被压在一起，从而纵使内部弹性织物16a位于它们之间，也能实现第一无纺织物12a的润湿的粘合侧与第二无纺织物18a的粘合侧的紧密接触。已经发现，在压缩间隙38处的压紧力大约为50磅/英寸或更大对于层压结合图1和2所描述的优选的无纺三层结构来说是最佳的。优选的是，该压缩间隙38由硬质圆柱形辊子40(即钢辊)和有弹性的圆柱形辊42(即橡胶辊)形成。该压辊30、42优选被安装到层压机26上的气动控制的固定件上。可以采用一个或多个汽缸来控制压缩间隙38处的压缩量。根据具体的三层结构，位于间隙38处的压辊40、42之间可以具有或不具有固定的最小间隔或间隙。但是选择在间隙38处的压紧力的大小是重要的，从而第一无纺织物12a的粘合侧上的贯通粘合粘接剂能充分地润湿第二无纺织物18a的粘合侧，并且通过内部弹性层16a中的开口20开始它们之间的牢固粘合。然后在压缩间隙38的下游，该层压织物10a就能够通过如在本领域所公知的辊模46被纵向地切片并穿孔。
如上所述的生产工艺能够以相对较高的速度(例如200-300英尺/分钟的加工速度或更高的速度)生产出无纺三层件。在这些速度下，优选借助于一种粘接剂液滴涂布机30涂布贯通粘合粘接剂。参照图4和4a，该液滴涂布机包括大致矩形的粘接剂集流腔48以及多个从该集流腔48向下延伸的喷嘴50。这些喷嘴50以多个倾斜的排的方式布置(参见图4a)。在图4和4a中所示的实施例中，每个倾斜的排有8个喷嘴。其它喷嘴布置可能也是合适的。
根据无纺织物12a和特定贯通粘合粘接剂的特性，当无纺织物12a在加工操作期间通过粘接剂液滴涂布机30时，这些喷嘴50可以与或不与无纺织物12a接触。通过内部弹性织物16a粘合所要求的贯通粘合粘接剂的添加速率直接与弹性织物16a的厚度有关。如果弹性织物16a是一种厚度大约为0.025英寸的弹性织物材料的话，则贯通粘合粘接剂优选的添加速率大约为1.75毫克/英寸/液滴。该贯通粘合粘接剂应该在足以使得该粘接剂能够流动穿过弹性层16a并且能够以层压机正在运行的速度使第二无纺织物18a湿透的情况下被涂布到无纺织物12a上。如上所述，该优选的贯通粘合粘接剂是一种耐油的聚丁烯基热熔融粘接剂，例如在未授权的美国专利申请No.08/632117(现在美国专利No.__)中所披露的，并且由Ato Findley在市场上销售的N9282F。优选的是，当以接触模式涂布时，该特定的粘接剂在320°F的温度下被涂布到第一无纺织物12a上，而在以非接触模式涂布时优选在350-360°F下进行涂布。
在液滴涂布机30和压缩间隙38之间的贯通粘合粘接剂的间隔时间应该足够短，以使贯通粘合粘接剂的液滴不会显著地冷却或固化。该层压机26在液滴涂布机30和压缩间隙38之间的间隔时间大约为1秒或更少的条件下进行有效地工作，但是根据用来生产该无纺三层件的材料，该贯通粘合粘接剂液滴的间隔时间也可以更长。
图5显示出粘接剂在三层织物10a上的分布。被喷涂在第二无纺织物18a以及弹性织物16a和第二无纺织物18a的组合物上的两排喷涂粘接剂在图5中由附图标记52a、52a表示。如图5所示每一排包括40条螺旋线。每条螺旋线的宽度大约为3/4英寸。排52a、52b都是由20条螺旋线交错的排形成。这些交错的排提高了该喷涂粘接剂的完全覆盖率。
贯通粘合粘接剂的液滴50只被涂布在如图5所示的特定的选定区域中。图5显示出织物10a中的切开线54以及织物10a中的穿孔线56。贯通粘合粘接剂的液滴50只被涂布在织物10a中靠近穿孔线56并靠近切开线54的区域中。在本发明优选的实施例中，每组中的液滴相隔大约0.1英寸。如上所述每液滴的涂布速率优选为1.75毫克/英寸(用于液滴的采用Ato Findley粘接剂H9282并且用于螺旋线的采用Ato Findley粘接剂H2120或H9282F)。通过只将液滴50涂布在织物10a上靠近靠近穿孔线56并靠近切开线54的位置处，从而由于液滴50足以保持该层压的结构的缘故，该成品的牢固性得到了改善，但是在每块单独织物(即通过各个切开线54和穿孔线56来限定出每块单独织物)的中间区域中没有液滴，这可防止每块单独的织物变得太硬并且使每块单独织物保持相对的柔软度。
除了没有以液滴(图5中的50)涂布的粘接剂之外，在根据上述方法生产出的无纺三层结构的样品上进行剥离强度实验。该实验结果表明直接在无纺外层12、13之间呈现的贯通粘合的平均剥离强度显著大于在弹性层16和任一外部无纺层12、18之间直接呈现的粘合的平均剥离强度。在MTS张力试验仪上采用标准试验以12英寸/分钟的固定十字头速度对样品进行试验。将这些试验结果与其中用剥离纸来代替该无纺层之一的样品进行比较。必须在没有以液滴涂布的情况下进行试验，否则会破坏该无纺层。以下给出了这些具有剥离纸的样品的各自结果。
                 表1
    样品 平均剥离强度(克/英寸)
    1     119
    2     156
    3     148
    4     147
    5     153
    总平均值     144
在表2中给出了无纺三层样品(没有液滴粘接剂)的结果：
                表2
    样品 平均剥离强度(克/英寸)
    1     1708
    2     1796
    3     1332
    4     1450
    5     1485
    总平均值     1554
从上述剥离强度试验结果可以明显看出，直接在无纺外层12、18之间产生的贯通粘合的平均剥离强度显著大于任何可能在内层16和任一外部无纺层12、18之间直接产生的粘合的平均剥离强度。另外，如根据本发明的优选实施例所要求的液滴粘接剂(图5中的50)的涂布使剥离强度高于表2中所示的结果。因此，对于那些本领域普通技术人员来说，采用根据本发明的高强度贯通粘合方法能够大大提高无纺三层件的牢固性和耐久性是显而易见的。
虽然以上结合实施本发明的优选实施例已经对本发明进行了说明，但是在不脱离本发明的真实范围和精神下可以以变化的形式来实施本发明。例如，操作参数(即粘接剂涂布速率、粘接剂涂布方法、粘接剂涂布温度、加工速度、粘接剂粘度、压紧之前的粘接剂断开时间等)可以根据具体的应用来进行相当大的改变。这些参数应该进行优化，以不仅能保持成品的牢固性而且能在随后的加工、处理和包装过程中保持该层压结构的牢固性。本发明的范围应该按照下面的权利要求来确定。

Claims (31)

1.一种多层层压结构，包括：
第一透气材料层；
第二透气材料层；
具有多个贯通的开口的弹性织物层，该内层被层压在第一透气材料层和第二透气材料层之间，该弹性织物层沿着至少一个尺寸方向是可伸展的；以及
贯通粘合粘接剂，它使第一和第二透气材料层通过内部弹性织物层中的开口相互贯通粘合，其中，直接在这些透气材料层之间产生的贯通粘合的平均剥离强度大于任何可能直接在弹性层和任一透气材料层之间产生的粘合的平均剥离强度，从而弹性织物层借助于直接在透气材料层之间呈现的贯通粘合被固定在该多层层压结构中。
2.如权利要求1所述的多层层压结构，其特征在于，弹性织物层沿着两个尺寸方向是可伸展的。
3.如权利要求1所述的多层层压结构，其特征在于，透气材料层是无纺材料层，这些无纺层材料层沿着加工方向不可伸展并且能够沿着基本上与加工方向垂直的横向方向伸展。
4.如权利要求1所述的多层层压结构，其特征在于，所述贯通粘合粘接剂具有耐弹性织物中的加工助剂的化学性能。
5.如权利要求1所述的多层层压结构，其特征在于，所述贯通粘合粘接剂是一种耐油的聚丁烯基热熔融粘接剂。
6.如权利要求1所述的多层层压结构，其特征在于，直接在外部透气材料层之间产生的贯通粘合的平均剥离强度比任何可能直接在弹性织物层和任一透气层之间产生的粘合的剥离强度大两倍以上。
7.如权利要求1所述的多层层压结构，其特征在于，还包括一种喷涂粘接剂，该粘接剂使至少一个透气层直接与弹性织物层粘合。
8.如权利要求1所述的多层层压结构，其特征在于，透气材料层是三层结构的外层，并且弹性层是该三层织物结构的内层。
9.如权利要求8所述的多层层压结构，其特征在于，外部透气材料层是无纺材料层。
10.一种生产多层层压织物的方法，包括以下步骤：
将一第一透气材料织物送进层压机中；
将一第二透气材料织物送进层压机中；
将一弹性材料织物送进层压机中，该弹性织物具有多个贯通的开口；
使这些织物对准，以使所述弹性织物位于第一透气材料织物的粘合侧和第二透气材料织物的粘合侧之间；
在这些织物完全对准之前，在足以让所述贯通粘合粘接剂能够流动穿过弹性材料织物中的开口并且能够在这些织物被压在一起时润湿第二外部的透气材料织物的粘合侧的条件下，在第一透气材料织物的粘合侧上涂布贯通粘合粘接剂；并且
将这些对准的织物压在一起，以实现第一透气材料织物的被润湿的粘合侧和第二透气材料织物的粘合侧通过弹性材料织物中的开口相互紧密接触。
11.如权利要求10所述的方法，其特征在于，借助于粘接剂液滴涂布机将所述贯通粘合粘接剂涂布到第一透气材料织物的粘合侧上。
12.如权利要求11所述的方法，其特征在于，所述粘接剂液滴涂布机具有多个与第一透气材料织物的所述粘合侧直接接触的液滴涂布喷嘴。
13.如权利要求11所述的方法，其特征在于，所述粘接剂液滴涂布机具有一个或多个不与所述第一透气材料织物的所述粘合侧接触的液滴涂布喷嘴。
14.如权利要求10所述的方法，其特征在于，还包括以下步骤：
采用喷涂粘接剂来直接使弹性材料织物与第二透气材料织物粘合。
15.如权利要求14所述的方法，其特征在于，所述被喷涂的粘接剂被喷射在第二透气材料织物的粘合侧上，随后使该弹性材料织物与第二透气材料织物的粘合侧接合。
16.如权利要求10所述的方法，其特征在于，弹性材料织物沿着至少一个尺寸方向是可伸展的；并且
该弹性织物在接近零张力的条件下被送到层压机。
17.如权利要求10所述的方法，其特征在于：
弹性材料织物沿着两个尺寸方向是可伸展的；
该弹性织物的厚度大约为0.025英寸；并且
贯通粘合粘接剂是通过粘接剂液滴涂布机以大约为1.75毫克/英寸/液滴的速度进行涂布。
18.如权利要求10所述的方法，其特征在于，采用至少为50磅/线性英寸的压紧力将被对准的织物压在一起。
19.如权利要求10所述的方法，其特征在于，利用由硬质辊和弹性辊所形成的压缩间隙将被对准的织物压在一起。
20.如权利要求10所述的方法，其特征在于，所述贯通粘合粘接剂具有耐弹性织物中的加工助剂的化学性能。
21.如权利要求10所述的方法，其特征在于，贯通粘合粘接剂是一种耐油的聚丁烯基热熔融粘接剂。
22.如权利要求10所述的方法，其特征在于，第一和第二透气材料层是无纺材料层。
23.如权利要求10所述的方法，其特征在于，贯通粘合粘接剂由一种粘接剂液滴涂布机来涂布，该涂布机包括多个成排布置的液滴涂布喷嘴，这些排与第一透气材料织物通过所述粘接剂液滴涂布机的方向相对倾斜。
24.如权利要求10所述的方法，其特征在于，贯通粘合粘接剂也被涂布到所述第二透气材料织物的粘合侧上。
25.如权利要求10的方法，其特征在于：
利用由一对压紧辊形成的压缩间隙将所述被对准的织物压在一起；并且
一个或多个汽缸调节由压缩间隙所提供的压缩量。
26.如权利要求10所述的方法，其特征在于，贯通粘合粘接剂的特性使得，在所述贯通粘合粘接剂固化之后，透气材料层之间的贯通粘合的平均剥离强度大于任何可能直接在弹性材料层和任一相应的透气材料织物之间出现的粘合的平均剥离强度。
27.如权利要求10所述的方法，其特征在于，在大约在320°F到360°F的范围内的温度下将所述贯通粘合粘接剂涂布到第一透气材料织物的粘合侧上。
28.如权利要求10所述的方法，其特征在于，所述贯通粘合粘接剂是由一种包括多个粘接剂液滴涂布喷嘴的粘接剂液滴涂布机来涂布的，并且被涂布在第一透气材料的粘合侧上的贯通粘合粘接剂的数量沿着与该织物通过该粘接剂液滴涂布机的方向垂直的方向在该织物上分布是不均匀的。
29.如权利要求28所述的方法，其特征在于，贯通粘合粘接剂的液滴不是沿着第一透气材料织物的粘合侧的选定部分来涂布的。
30.如权利要求10所述的方法，其特征在于，还包括以下步骤：
沿着加工方向将所述层压织物纵向切开以形成多块贯通粘合的三层织物。
31.如权利要求30所述的方法，其特征在于，还包括以下步骤：沿着加工方向对层压织物进行纵向打孔，以在贯通粘合的三层织物中形成一条或多条纵向撕开线。
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