CN1433291A - 防漏间断超声粘合 - Google Patents

防漏间断超声粘合 Download PDF

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CN1433291A
CN1433291A CN01810404A CN01810404A CN1433291A CN 1433291 A CN1433291 A CN 1433291A CN 01810404 A CN01810404 A CN 01810404A CN 01810404 A CN01810404 A CN 01810404A CN 1433291 A CN1433291 A CN 1433291A
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bounding point
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impenetrable liquid
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CN1222407C (zh
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D·J·索伦森
R·L·波普
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Kimberly Clark Worldwide Inc
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Abstract

坚固的防漏密封，包括许多靠近在一起的间断超声粘合。至少两层材料，如叠置在不透液体膜上的无纺网，可通过这些粘合点固定在一起。粘合点可布置成花纹组织，使得在粘合过程中移位的材料阻塞粘合点之间的任何液体通路。

Description

防漏间断超声粘合
发明领域
本发明涉及产生防漏密封的间断超声粘合。
发明背景
吸水服装，包括一次性尿布和运动短裤，和其它个人护理制品在其组件中需要防漏密封以适当容纳例如身体排泄的废物。这种防漏密封通常通过连续的，或实体的粘合花纹组织实现的。这种连续花纹组织通常通过热熔胶、热粘合或超声粘合形成。
超声粘合花纹组织可以是施加在花纹组织中的间断点，它们在两个或多个材料层之间产生热粘合。当使用单个点花纹组织而不是连续的，或者实体的粘合时，粘合通常更坚固。但是，由于间断粘合点彼此之间有间隔，液体可在粘合点之间通过，从而间断粘合通常不是防漏的，或防潮的。
需要或希望有可用在吸水服装和其它个人护理制品组件中的坚固的防漏密封。
发明综述
本发明涉及产生坚固的防漏密封的间断超声粘合。粘合特别适用于吸水服装和个人护理制品的组件中，包括一次性尿布，运动短裤，妇女卫生制品，成人失禁制品，和医用服装。坚固的防漏密封特别适用于将封盖(containment flaps)附着在服装上，以及联接复合结构。
防漏或防潮密封是这样形成的，即用多个点粘合将至少两层材料超声粘合，点粘合的距离足够接近以在粘合之间形成密封。当使用超声粘合形成粘合时，被粘合的一部分基底材料移位到实际粘合点的外部。在本发明中，移位的材料或者相互接触，从而阻塞粘合点之间的任何液体通道，或者足够接近以形成足够弯曲的通路以阻塞粘合点之间的任何液体通路。而且，相对实心粘合，通过使用点粘合使粘合的强度最佳。
如上所述，本发明的一个特征和优点是提供坚固的防漏密封。
本发明的另一个特征和优点是提供将至少两层材料粘合在一起形成坚固防漏密封的粘合过程。
从下面参考附图对优选实施例的详细描述中可以更明显地看出这些和其它特征。
附图简要说明
图1示出了根据本发明将两层材料粘合在一起的一种点粘合花纹组织的放大局部平面图；
图2示出了沿图1中线2-2的将两层材料粘合在一起的间断超声粘合点的放大剖面图。
定义
在该说明书的上下文中，下面的每个术语或短语包含下面的一个或多个含义。
“粘合点”指发生超声粘合处的离散点。
“粘合的”指两个元件的结合，粘接，连接，附着或类似操作。当两个元件直接或间接地粘合在一起时，例如分别直接粘合在中间元件上，就认为它们是粘合在一起的。
“透气的”描述通常阻止粒状物质，水和其它液体通过，但允许水蒸气和空气穿过的材料。
“一次性的”指设计为使用有限次后丢弃而不是进行清洗或用其它方法恢复再用的物品。
“弹性的”，“经过弹性处理的”，“弹性”指材料或复合材料的性质，通过这种性质在去掉产生变形的力后材料趋向于恢复其原始尺寸和形状。
“膜”指利用膜挤压和/或发泡过程，如铸膜或吹膜挤压过程，制造的热塑膜。该术语包括有孔膜，薄膜狭条，和其它组成液体输送膜的多孔膜以及不输送液体的膜。
“层”以单数使用时可具有单个元件或多个元件双重含义。
“不透液体的”当用于描述一层或多层层叠制品时，指在正常使用条件下，液体，如尿液，在液体接触点在基本垂直于层或层叠制品平面的方向上不能完全穿过层或层叠制品。液体，或尿液，只要不穿过层或层叠制品，就可以平行于不透液体层或层叠制品平面地散开或输送。
“可透液体材料”或“液体水可透材料”指在一层或多层中存在的材料，如膜，无纺纤维，或开孔泡沫，它们是多孔的，并且由于水和其它含水液体流过这些孔，它们也是可透水的。膜或泡沫中的孔，或无纺网中的纤维或纤丝之间的空间足够大并且足够密以允许液态水穿过材料泄漏或流动。
“医用服装”指医用(即保护的和/或治疗用的)长外衣，帽子，手套，被单，面罩及类似物。
“纺粘布”指这样形成的纤维，即挤压熔化的热塑材料，使其穿过铸模的小直径管作为熔化的线或细丝进入会聚的高速加热气(例如空气)流，气流使熔化热塑材料细丝变细以使其直径减小，直径可减小到微纤维直径。然后，熔吹的纤维通过高速气流输送并沉积到收集表面上以形成随机分散的熔吹纤维网。例如在授权给Butin等人的美国专利3,849,241中公开了一种这样的过程。熔吹纤维可以是连续的或不连续的，通常小于约0.6旦尼尔，当沉积在收集表面上时通常是自粘结的。本发明中使用的纺粘布在长度上最好是连续的。
“无纺”和“无纺网”指具有单个纤维或细丝结构的材料或材料网，其中纤维或细丝是交叉的，但不是象在针织物中那样可识别的。这里使用的术语“纤维”和“细丝”是可互换的。无纺纤维或网可通过许多过程形成，如例如熔吹过程，纺粘过程，气流成网过程，和粘合梳理网过程。该术语还包括穿孔或用其它方式处理以允许空气穿过的膜。
“偏置”指从一条线上的点到不在该线上的点测量的角度。
“点粘合”指与连续或实心粘合相对的非连续粘合方式。
“聚合物”包括，但不局限于，均聚物，共聚物，例如，嵌段共聚物，接枝共聚物，无规共聚物和交替共聚物，三元共聚物等以及它们的混合物和变型。而且，除另外特别限定以外，术语“聚合物”应该包括材料的所有可能的几何构造。这些构造包括，但不局限于，全同立构的，间同立构的和不规则对称。
“纺粘纤维”指这样形成的小直径纤维，即从具有圆形或其它构造的多个纺丝头细小直径管挤压熔化热塑材料作为细丝，然后通过例如在授权Appel等人的美国专利4,340,563，授权Dorschner等人的美国专利3,692,618，授权Matsuki等人的美国专利3,802,817，授权Kinney的美国专利3,338,992和3,341,394，授权Hartmann的美国专利3,502,763，授权Petersen的美国专利3,502,538，授权Dobo等人的美国专利3,542,615中所述方法快速减小细丝的直径，上述每个专利整体在这里作为参考。当纺粘纤维沉积到收集表面上时，它们被骤冷并且通常不是发粘的。纺粘纤维通常是连续的并常常具有大于约0.3的旦尼尔，更具体地，在约0.6和10之间。
“可拉伸的”指的是在不断裂的情况下，材料在至少一个方向上可被拉伸到至少其原始(未拉伸)长度的150％，适当的是拉伸到其原始长度的200％，可取的是拉伸到其原始长度的250％。
“热塑的”描述的这样材料，即受热变软并在冷却到室温时基本返回到未变软状态。
在说明书的余下部分中这些术语可用另外的语言限定。
优选实施例详细描述
本发明的原理可应用于各种服装和个人护理制品，包括这样的一次性服装，该服装具有至少两层粘合在一起的材料12，14，在日常使用中最终的接缝暴露在潮湿中。实例包括尿布，运动短裤，某些妇女卫生制品，成人失禁制品，其它个人护理或医用服装，以及类似物。更具体地，本发明可应用于将封盖附着在这种服装上或用于粘合复合结构。
参考图1，所示间断超声粘合点10的花纹组织应用到两层材料12，14，其中第一层12位于第二层14之上，并且第二层14延伸超过第一层12。第一层12和第二层14必须至少部分重叠。粘合点10将两个层12，14粘合在一起，产生坚固的防漏密封16。由于有许多粘合点10，所以密封16坚固，而且粘合点10之间的小距离防止潮湿穿过密封16。如图1中所示，本发明的一个实施例包括许多排18平行的粘合点10，其中相邻排18中的粘合点10彼此偏置，在任何地方从约0°到约89°，作为另外一种选择，从约15 °到约75°，作为另外一种选择，从约30°到约60°。本发明要求至少一排18粘合点10，或者至少两排18粘合点10，作为另外一种选择，至少三排18或作为另外一种选择至少四排18。
每个粘合点10例如可取的是圆形，可以是任何其它适当的形状如椭圆形，8字形或矩形。每个粘合适当地在约0.005英寸(0.013厘米)和约0.25英寸(0.64厘米)之间的直径，作为另外一种选择，在约0.010英寸(0.025厘米)和约0.175英寸(0.44厘米)之间，或者作为另外一种选择，在约0.015英寸(0.038厘米)和约0.15英寸(0.38厘米)之间。
类似地，每个粘合点10与至少另一个粘合点10在或者纵向或者横向，或者它们之间的任何方向上的距离在约0.001英寸(0.0025厘米)和约0.20英寸(0.51厘米)之间。作为另外一种选择，每个粘合点10与至少另一个粘合点10之间的距离在约0.0025英寸(0.0064厘米)到约0.175英寸(0.44厘米)以内。作为另外一种选择，每个粘合点10与至少另一个粘合点10之间的距离在约0.005英寸(0.013厘米)到约0.15英寸(0.38厘米)以内。
在图1中示出了粘合点10之间可测距离的各种实例。更具体地，距离W是一排18中的相邻粘合点10之间的直线距离，距离X是彼此对角的两个粘合点10之间的直线距离，距离Y是垂直偏置的两个对角粘合点10之间的水平距离，距离Z是两个水平偏置的两个粘合点10之间的垂直距离。花纹组织宽度是粘合点10的顶排18和底排18之间的总垂直距离。
当向基底12施加超声粘合点10时，一部分被粘合的基底材料移位到实际粘合点10以外，如图2中所示。在本发明中，每层12，14的移位材料20或者彼此接触，或者足够近地靠在一起以产生足够弯曲的通路以阻塞在粘合点10之间任何液体通道。由于超声粘合过程在点粘合10产生的热，在发生移位时，点粘合10之间的移位的材料20处于熔化状态。由于在超声粘合过程中产生的热和施加的压力，熔化的移位的材料20在相互接触时就粘合在一起，从而在相邻层12，14的移位的材料20之间形成精细的粘合。并阻塞粘合点10和层12，14之间移位的材料之间的任何液体通道。而且，相对实心粘合来说，使用点粘合使密封16的强度最佳。
超声粘合过程可通过各种方法进行(未示出)，包括利用超声固定导条角或超声旋转导条角或不同频率导条角。在固定方法中，固定砧位于超声导条角或导波器下方。材料12，14联接在导条角或导波器上使得材料12，14位于导条角和砧之间。导条角以规定速度振动，例如20,000循环/秒，幅值为0.0005英寸(0.0013厘米)到约0.0035英寸(0.0089厘米)，通过摩擦发射超声能并从而将材料12，14粘合在一起。
在旋转方法中，材料放置在旋转盘和旋转砧之间，旋转砧最好是在与材料12，14的接触面上具有花纹组织的圆形砧。旋转盘振动，围绕其圆周以最大约为0.0035英寸(0.0089厘米)膨胀和收缩。与在固定方法中一样，摩擦造成发射超声能，从而将材料12，14粘合在一起。而且，砧上的花纹组织形成传送到材料12，14上的粘合花纹组织。
在本发明中，对于至少两层材料12，14来说，合适的基底材料包括不透液体材料，包括用各种可选材料制造的无纺网层叠制品。各种无纺纤维可叠置在用作基底的膜或其它不透液体层上。例如，基底可由叠置在不透液体层上的熔吹或纺粘聚烯烃纤维网组成。基底也可以是叠置在不透液体层上的由天然和/或合成纤维组成的粘合梳理的网。尽管层12，14优选是不透液体的，但层12，14也可以是透气的。
基底最好是不透液体的材料或叠置在不透液体的材料上。合适的不透液体的材料的一个实例是薄塑料膜，但也可以使用其它柔性不透液体的材料。用作基底的一种合适的不透液体膜是聚烯烃膜，例如，在商业上可从美国，弗吉尼亚州，Packaging of Newport News获得的0.2毫米聚乙烯膜。
基底还可包括弹性材料，例如，在1990年7月10日授权给Gompel等人的美国专利No.4,940,464中所述的一种吸水服装的侧壁。而且，弹性材料可用作几乎吸水服装或个人护理制品的任何部分，并可包括拉伸-热层叠材料(STL)，颈线-粘合(neck-bonded)的层叠材料(NBL)，双面颈缩(reversibly necked)层叠材料，或拉伸-粘合层叠(SBL)材料。制造这种材料的方法对于该技术领域的普通技术人员是公知的，并描述在1987年5月5日授权Wisneski等人的美国专利4,663,220；1993年7月13日授权Morman的美国专利5,226,992；1987年以Taylor等人名字公开的欧洲专利申请No.EP 0217 032中，所有这些专利在这里作为参考。作为另外一种选择，这些弹性材料可包括其它纺织的或无纺材料，或可拉伸但非弹性材料。
如上所述，本发明可应用于尿布，运动短裤，某些妇女卫生制品，成人失禁制品，其它个人护理或医用服装，及类似物。
举例
制造了九种不同粘合花纹组织并评价它们产生不透潮湿密封的能力。对于每个试样，利用20赫兹超声旋转导条角沿层的周边边缘，与边缘距离约为0.1英寸将两个6英寸正方形材料层粘合在一起。材料是粘合层叠在0.6密尔聚丙烯膜上的一薄层纺粘0.6osy聚丙烯，两层中的每一个的膜侧面彼此相对。每一个粘合点都是圆形的，都具有0.045英寸(0.11厘米)的直径。沿每个6英寸边的粘合花纹组织截面布置为四排粘合点。一排中相邻粘合点之间的直线距离，即纵向间隔，范围为从0.05英寸(0.13厘米)到0.11英寸(0.28厘米)，实际的值列在表1中。水平偏置粘合点之间的垂直距离，即横向间隔，范围为从0.10英寸(0.25厘米)到0.30英寸(0.76厘米)，实际的值列在表1中。粘合点截面的花纹组织宽度，即第一排粘合点和第四排粘合点之间的距离，范围为从0.210英寸到0.270英寸，实际的值列在表1中。相邻排中粘合点彼此偏置约35到58度，实际的值列在表1中。
在密封两层的全部周边之前，最终的容器充满250毫升染成蓝色的盐溶液。然后将粘合好的容器在水平表面上放置14天并观察泄漏情况。如表1中所示，在检测的粘合花纹组织截面中唯一泄漏的是纵向间隔为0.11英寸，横向间隔为0.010英寸，花纹组织宽度为0.210英寸的截面。表1检测泄漏情况的粘合点截面
  试样   粘合点间纵向间隔(英寸) 粘合点间横向间隔(英寸)   花纹组织宽度(英寸)  粘合角度(°)   不透潮湿
    1     0.05     0.010     0.210     35     是
    2     0.05     0.020     0.240     40     是
    3     0.05     0.030     0.270     44     是
    4     0.08     0.010     0.210     41     是
    5     0.08     0.020     0.240     46     是
    6     0.08     0.030     0.270     50     是
    7     0.11     0.010     0.210     49     否
    8     0.11     0.020     0.240     54     是
    9     0.11     0.030     0.270     58     是
具有最长的纵向间隔(0.011英寸)和最短的横向间隔(0.010英寸)的试样是唯一泄漏的试样。短横向间隔导致小的花纹组织宽度。小的花纹组织宽度转化成短的通路，液体必须通过该通路才能穿过点粘合截面。我们认为与具有较短纵向间隔和/或较大花纹组织宽度的点粘合截面相比，同时具有较长纵向间隔和较小花纹组织宽度的粘合点截面更容易泄漏。
尽管这里所述的本发明实施例中优选的，但在不偏离本发明精神和范围的情况下可进行各种变型和改进。本发明的范围在附属权利要求中指出，属于等同物意义和范围的所有改变都包括在内。

Claims (33)

1.防漏密封，包括：
至少两层至少部分重叠的不透液体材料；
将至少两层不透液体材料粘合在一起的多个超声粘合点；
其特征在于，粘合点排列在至少两个平行的排内，并且相邻排中的粘合点彼此偏置。
2.根据权利要求1中所述的防漏密封，其特征在于，相邻粘合点彼此距离在约0.001英寸和约0.20英寸之间。
3.根据权利要求1中所述的防漏密封，其特征在于，相邻粘合点彼此距离在约0.0025英寸和约0.175英寸之间。
4.根据权利要求1中所述的防漏密封，其特征在于，相邻粘合点彼此距离在约0.005英寸和约0.15英寸之间。
5.根据权利要求1中所述的防漏密封，其特征在于，每个粘合点的直径在约0.005英寸和0.25英寸之间。
6.根据权利要求1中所述的防漏密封，其特征在于，每个粘合点的直径在约0.010英寸和0.175英寸之间。
7.根据权利要求1中所述的防漏密封，其特征在于，每个粘合点的直径在约0.015英寸和0.15英寸之间。
8.根据权利要求1中所述的防漏密封，其特征在于，相邻排中粘合点彼此偏置约0°到89°。
9.根据权利要求1中所述的防漏密封，其特征在于，相邻排中粘合点彼此偏置约15°到75°。
10.根据权利要求1中所述的防漏密封，其特征在于，相邻排中粘合点彼此偏置约30°到60°。
11.根据权利要求1中所述的防漏密封，还包括至少平行的三排粘合点。
12.根据权利要求1中所述的防漏密封，还包括至少平行的四排粘合点。
13.根据权利要求1中所述的防漏密封，其特征在于，至少不透液体材料层之一是透气的。
14.粘合在第二不透液体材料上的第一不透液体无纺层叠制品的组合，包括：
将第一不透液体无纺层叠制品连接在第二不透液体材料上的多个超声粘合点；
其特征在于，粘合点排列在花纹组织中，每个粘合点与至少另一个粘合点的距离在约0.001英寸到约0.20英寸以内。
15.根据权利要求14中所述的组合，其特征在于，每个粘合点与至少另一个粘合点的距离在约0.0025英寸到约0.175英寸以内。
16.根据权利要求14中所述的组合，其特征在于，每个粘合点与至少另一个粘合点的距离在约0.005英寸到约0.15英寸以内。
17.根据权利要求14中所述的组合，其特征在于，粘合点排列在至少两个平行的排内，并且相邻排中的粘合点彼此偏置。
18.根据权利要求14中所述的组合，其特征在于，第一不透液体无纺层叠制品包括不透液体膜。
19.根据权利要求14中所述的组合，其特征在于，第一不透液体无纺层叠制品是透气的。
20.根据权利要求14中所述的组合，其特征在于，第二不透液体材料包括叠置在不透液体膜上的无纺材料。
21.根据权利要求14中所述的组合，其特征在于，第二不透液体材料是透气的。
22.包括根据权利要求14中所述组合的吸水服装。
23.包括根据权利要求14中所述组合的尿布。
24.包括根据权利要求14中所述组合的运动短裤。
25.包括根据权利要求14中所述组合的妇女卫生品。
26.包括根据权利要求14中所述组合的吸水内衣裤。
27.将两层不透液体材料粘合在一起的粘合过程，包括如下步骤：
用分立的粘合点将两层超声粘合在一起；
偏置每层材料的一部分，其特征在于，偏置部分中的每一个都与至少另一个偏置的部分接触。
28.根据权利要求27中所述的粘合过程，其特征在于，至少不透液体材料层之一包含无纺网。
29.根据权利要求27中所述的粘合过程，其特征在于，至少不透液体材料层之一是透气的。
30.根据权利要求27中所述的粘合过程，其特征在于，粘合点排列在花纹组织中，每个粘合点与至少另一个粘合点的距离在约0.001英寸到约0.20英寸以内。
31.根据权利要求27中所述的粘合过程，其特征在于，粘合点排列在花纹组织中，每个粘合点与至少另一个粘合点的距离在约0.0025英寸到约0.175英寸以内。
32.根据权利要求27中所述的粘合过程，其特征在于，粘合点排列在花纹组织中，每个粘合点与至少另一个粘合点的距离在约0.005英寸到约0.15英寸以内。
33.根据权利要求27中所述的粘合过程，其特征在于，粘合点排列在至少两个平行的排内，并且相邻排中的粘合点彼此偏置。
CNB018104045A 2000-06-01 2001-05-31 超声点粘合的防漏密封和其结合及粘合过程 Expired - Fee Related CN1222407C (zh)

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