CN1705464A - 吸收用品中使用的有孔材料及其制造方法 - Google Patents

吸收用品中使用的有孔材料及其制造方法 Download PDF

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Publication number
CN1705464A
CN1705464A CNA2003801019397A CN200380101939A CN1705464A CN 1705464 A CN1705464 A CN 1705464A CN A2003801019397 A CNA2003801019397 A CN A2003801019397A CN 200380101939 A CN200380101939 A CN 200380101939A CN 1705464 A CN1705464 A CN 1705464A
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China
Prior art keywords
thin film
quality
hole
microcosmic
holes
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CN100381277C (zh
Inventor
占士·W·克里
里诺·成里亚纳蒂
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Tredegar Film Products LLC
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Tredegar Film Products LLC
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    • Y10T156/1007—Running or continuous length work
    • Y10T156/1023—Surface deformation only [e.g., embossing]
    • Y—GENERAL 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1056—Perforating lamina
    • Y—GENERAL 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y—GENERAL 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322—Composite web or sheet
    • Y—GENERAL 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component

Abstract

吸收用品中使用的薄膜(14)首先被形成微观质地(16)，然后被开出宏观孔(18)，同时保持微观质地(16)。微观质地(16)可以通过包括真空成形的若干装置实现，并可包括微孔。宏观质地上的宏观孔(18)可以通过具有隔热装置(22)的包括热机械装置的各种装置实现。当使用加热针(20)时，隔热装置(22)保护微观质地(16)不受热，因此，热不会使微观质地(16)变形。

Description

吸收用品中使用的有孔材料及其制造方法
本申请要求享有2002年12月20日提交的美国临时专利申请60/435,942的优先权。在先申请的公开内容被认为是本申请的公开内容的一部分，并且在先申请在此提出作为参考。
技术领域
本发明涉及三维热塑薄膜的成形，特别是涉及具有微观质地和宏观孔隙的薄膜。
背景技术
现实中一直存在对聚烯烃薄膜内形成布状质地然后变成三维有孔流体传输结构的需求。过去该织构化通过形成若干从薄膜表面伸出的微孔来实现。利用现有技术所述的水成形或真空成形技术可生成脆性微观质地。然而，一旦完成微观织构化，在不破坏微观质地的情况下，很难形成三维(“3D”)漏斗形孔，该孔允许流体经过薄膜进入下面的吸收层。人们试图采取水穿孔或针刺穿孔，然而，用水的方法不能在足够高的温度下产生永久变形和应力强化孔。这样，如果在形成孔时承受应力或压力，用水的方法形成的大3D孔趋于再次变平。利用热的针也不够有效，因为如果针太热，来自热针的热将使周围的非常纤细柔软的微观质地熔化，从而使锥形物产生永久的变形。如果微观质地是微孔，针的热将使微孔的边缘“卷缩起皱”，或由于暴露在热中从而变的很硬。这种边缘变硬使最终产品摸起来粗糙。
这里公开了一种利用热机械穿孔的新颖的方法，它利用匹配的一组针、凹槽和保护面来形成这种产品。而且，本发明教导了如何在一次工序中使产品在微观质地薄膜中具有大的3D流体传输孔，以及流体传输层如何可以接合到流体传输薄片下，以便将流体引导离开微观质地薄膜的3D漏斗。利用该方法制造的最终产品主要打算用作吸收卫生产品或绷带并且与身体接触的织构化成形薄膜顶片。而且，该产品可用作这种吸收制品内的下层，或用作婴儿尿布中的顶层。
发明内容
薄膜首先被微观织构化，然后被宏观织构化，同时保持微观质地。通过包括真空成形的不同装置，可以实现微观织构化，并且可包括微孔。通过不同装置可以实现宏观织构，该不同装置包括具有隔热装置的热机械装置。在使用加热针处，隔热装置保护微观质地不受热，因此，热不会使微观质地变形。
本发明的一个或多个实施例的细节在附图和下面的说明书中提出。结合附图，说明书和权利要求书，本发明的其它特征，目的和优点将更清楚。
附图说明
图1是在薄膜中形成微观质地的方法的示意图；
图2是具有由图1所示的方法形成的微观质地的薄膜的横截面视图；
图3是在薄膜中形成宏观质地的方法的示意图；
图4是具有由图1和图3所示的方法形成的微观质地和宏观质地的薄膜的横截面视图；
图5是在薄膜中形成宏观质地同时使非织造层与薄膜结合的方法的示意图；
图6是靠近非织造层并具有由图1和图5所示的方法形成的微观质地和宏观质地的薄膜的横截面视图；
图7是在薄膜中形成宏观质地的方法的示意图；
图8是具有由图1和图7所示的方法形成的微观质地和宏观质地的薄膜的横截面视图；
图9是在薄膜中形成宏观质地同时使非织造层与薄膜结合的方法的示意图；
图10是靠近非织造层并具有由图1和图9所示的方法形成的微观质地和宏观质地的薄膜的横截面视图。
在不同的附图中相同的参考标号表示相同的元件。
具体实施方式
如这里使用的，“微观”指人眼从约18英寸远看去尽管质地变化总体上可辨别，但个体不可辨别的个体特征，而“宏观”指人眼从约18英寸远看去个体可辨别的特征。例如，具有每线性英寸约30个孔和每线性英寸100个孔之间的网目的微孔将改变薄膜的表面质地，但是，人眼从约18英寸远的距离看去，单个孔个体不可辨别。类似的，人眼从约18英寸远的距离看去，具有每平方厘米约5至约11个孔的间距的宏观孔个体可辨别。
典型的是热塑性塑料的薄膜材料10在成形筛12上挤制。成形筛12包含微观质地。成形筛12可具有多种微观质地图案。因此，薄膜材料10形成微观三维薄膜14。薄膜材料10可开孔作为真空成形的一部分，或者可以保持完整无损。
薄膜材料10可以是由从铸模16或吹制模挤压制成的LDPE和LLDPE的50/50混合物组成的薄膜。当薄膜材料10仍处于半熔融韧性状态时，通过压差装置例如真空装置、吹气装置等向薄膜材料10施加压力，以便薄膜材料10形成筛12。尽管也可以采用其它方法，通常利用图1所示的公知的真空成形技术来施加该压力。筛12向薄膜材料10施加微观质地16。如图2所示，当从筛12上取下时，生成的微观质地薄膜14具有微观质地16，该微观质地16可包括本领域公知的微孔、微脊、微点或其它微观质地。如果微观质地16是微孔，该微孔可具有在每线性英寸30孔到每线性英寸100孔之间的密度，这也被称为约30网目至约100网目，最好在约40网目到约60网目之间。在微观质地16由微孔形成的情况下，它们可以是三维微漏斗形，以增加其触觉响应效果以及流体处理性能。在微观质地16由微孔形成情况下，根据优选的质地或流体处理性能，它们可以是圆形、，细长、八角形、椭圆形、六角形、椭圆体、矩形、方形或任意其它形状或图案。
薄膜材料10可包含树脂中的表面活性剂，或者可将表面活性剂添加到微观质地薄膜14中。表面活性剂增加通常憎水薄膜材料10的亲和力(philicity)，并可能影响下述最终产品的性能。作为替换，也可以不添加表面活性剂而直接得到憎水薄膜材料10。
在一个优选实施例中，接着，微观质地薄膜14以热机械方式开孔，以形成宏观三维孔18。宏观孔18在薄膜上形成宏观质地，因此，在全文中使用术语宏观质地和宏观孔18。热防护层22允许使用热针20，以便给微观质地薄膜14开孔，且不会毁坏微观质地16。没有热防护层22时，热针20可能使薄膜14的材料硬化，因此，微观质地16毁坏，或者热针20可能使上述微观质地16的边缘卷缩。如果微观质地薄膜14被热针20过度加热，微观质地16将回熔成薄膜，这样失掉由筛12形成的质地。如图3，5，7和9所示，热防护层22是具有比薄膜高的熔点的防护材料26，例如非织造聚丙烯，它穿过微观质地薄膜14和承载加热穿孔针22的滚筒24之间的穿孔辊隙30。防护材料26的两个有效的实例是本领域公知的非织造物，如纺粘-熔喷-纺粘19gsm，和热粘合梳理24gsm。选择用作防护材料26的适当非织造材料应基于其熔点比薄膜材料10的熔点高的非织造物。其它热防护层包括不同的其它材料，它们能够在具有冷却周期、冷却滚筒/加热针布置和不同的流体冷却装置的连续环路上分布。
图3所示的热机械穿孔单元采用热针20，热针20匹配进入不热的凹槽辊28内以形成辊隙30。微观质地薄膜14和上述防护材料26进给到辊隙30内，以便热针20形成微观质地薄膜14内的宏观三维孔18。孔的形状由针20和辊28之间的关系确定。优选实施例的宏观孔18具有在每平方厘米约4个孔到每平方厘米约15个孔之间的密度，并最好在每平方厘米约5个孔和每平方厘米约12个孔之间的密度。宏观孔18可以形成锥形，该锥形从薄膜14的上表面延伸到下表面，上表面与下表面之间的间隔大于薄膜14的初始厚度的距离。该锥形的锥度取决于凹槽辊28和加热针20的形状。根据薄膜14、加热针20和凹槽辊28移动的相对速度，宏观孔18可以是圆形或细长形。
凹槽辊28可以受温度控制，以便保持在辊隙30形成的宏观孔18的一致性。根据期望的结果所需，温度控制方式可包括冷却或加热。例如，在一些环境下30摄氏度的操作温度可能需要冷却，而其它环境下需要加热。
优选实施例的薄膜32具有真空成形的微观质地16和热机械成形的宏观质地18，这如图4和8所示。图2的微观质地薄膜14具有约25微米的厚度，而图4和6的薄膜32的厚度约为400微米至约1500微米，最好在约800微米和1300微米之间。该优选实施例的薄膜32具有由微观质地16提供的期望的质地和宏观质地18提供的弹性结构。
如图5和9所示，第二材料34，例如芯吸非织造物可进给到热机械成形装置的辊隙30内，以便同时将第二材料34与薄膜层14粘合，这样形成复合材料36。第二材料34可以定位在薄膜层14和凹槽辊28之间，因此微观质地16仍露出来。加热针20在宏观孔18处刺透第二材料34。以这种方式，复合材料36可成形为具有触感和芯吸材料支持的微孔薄膜的流体处理能力，以及不受第二材料34阻碍的宏观孔18的流体处理能力，这如图6所示。第二材料34在芯吸潮气使之离开薄膜层14方面有效，这样改进了吸湿性能。
如图4和8或图6和10的对比可见，在微观质地16是微孔时，微孔可在与图8和10的宏观孔18相同的方向上延伸，或在与图4和6的宏观孔18相反的方向上延伸。
吸收用品一般具有面向身体顶片、与顶片相对的背片和顶片与背片之间的吸收芯。另外，现代的吸收制品可包含顶片与吸收芯之间的中间层。薄膜32或复合材料36可用作吸收用品内的顶片或中间层。
性能测量
对作为顶片的不同材料与对比的顶片材料进行对比测试。其中一种对比材料是用于Procter & Gamble卫生巾产品“Lines Petalo Blu”和这里优选的“HFF”中的水成形顶片。另一种对比材料是用于SCA卫生巾产品“Nuvenia Libresse”和这里优选的“NW”中使用的非织造憎水顶片。不同的实例中使用的材料如下：
实例1：在亲水薄膜材料10中的60网目微孔的微观质地16，和具有每平方厘米约5.6孔间距的宏观孔18。
实例2：与实例1类似，但具有40网目微孔的微观质地16。
实例3：与实例1类似，但具有憎水薄膜材料10。
实例4：与实例2类似，但具有憎水薄膜材料10。
实例5：与实例1类似，但具有25gsm空气透过粘合非织造物(ATB25TAM)的第二材料34。
实例6：与实例2类似，但具有25gsm空气透过粘合非织造物(ATB25TAM)的第二材料34。
实例7：与实例5类似，但具有每平方厘米约11孔的间隔的宏观孔18。
实例8：与实例6类似，但具有每平方厘米约11孔的间隔的宏观孔18。
穿透率是对穿过顶片进入吸收用品内的吸收率的测量，并在下述最终制品上进行测量。为了测试穿透率，除了在测试初始材料试样时之外，初始的顶片材料从吸收用片上取下，并用待测试的顶片材料取代。然后，吸收用品用10ml试样的月经内部合成溶液(MISS)进行污损试验，穿透时间利用制表设备记录，该制表设备在EDANA推荐测试方法ERT 150.5-02液体穿透时间测试方法中描述。较低的穿透量反映了快速吸收，并在大多数吸收用品中是期望的。
吸湿是对上述穿透率试验中使用的相同试样的测量。在测量穿透率后，试样小心从测试设备取出，并放在平表面上。具有10cm乘10cm表面的4kg重物放在污损区域或试样上达三分钟。三分钟后，重物取出，5页预先称重的吸收纸放在污损区域上，重物置于吸收纸上。两分钟后，重物取出，吸收纸取出再称重。吸收纸获得的重量记录作为吸湿。该方法基于EDANA推荐测试方法ERT 151.3-02吸湿。较低的吸湿量反映污损表面完全的吸收，和较少的泄漏，并在大多数吸收用品中是期望的。
下列数据反映以上述方法测试的“Lines Petalo Blu”吸收用品中实施的试验：
顶片                穿透率(秒)            再湿性(克)
HFF                 49.0                  0.93
实例1               38.7                  0.72
实例2               13.0                  0.36
实例5               54.8                  0.43
实例6               27.8                  0.27
实例7               47.0                  0.42
实例8               32.0                  0.26
下列数据反映以上述方法测试的“Nuvenia吸收用品中实施的试验：
顶片                穿透率(秒)            再湿性(克)
NW                  ＞500                 1.3
实例1               143.6                 1.2
实例2               73.4                  1.2
实例3               325.3                  1.1
实例4               164.0                  1.1
实例7               91.78                  0.465
实例8               61.13                  0.570
由上述结果可见，所有的实例表明吸收用品中使用的初始顶片材料得到改进。
尽管对本发明的特定实施例作了图示和描述，对于本领域的普通技术人员而言，显然在不超出本发明的实质和范围的前提下，本发明可作不同的其它变化和修改。因此，附后的权利要求书希望覆盖落在本发明范围内的所有这些变化和修改。

Claims (39)

1.一种制造成形薄膜的方法，该方法包括：
挤压热塑材料，以形成薄膜；
在挤压后立刻形成微孔质地，同时热塑材料仍处于韧性状态；和
在微观质地形成后，形成三维宏观孔。
2.如权利要求1所述的方法，其特征在于微观质地由压差装置形成。
3.如权利要求1所述的方法，其特征在于利用真空装置在筛上拉伸热塑材料形成微孔质地。
4.如权利要求1所述的方法，其特征在于宏观孔利用热机械成形工艺成形。
5.如权利要求4所述的方法，其特征在于热机械成形工艺包括在薄膜处于热机械装置的辊隙内时，利用隔热材料在薄膜内保持微观质地。
6.如权利要求4所述的方法，其特征在于热机械成形工艺包括利用一层非织造织物，该非织造织物的熔点比用作隔热材料的薄膜的熔点高。
7.如权利要求1所述的方法，其特征在于非织造材料粘合在薄膜上，同时形成宏观质地。
8.一种有孔热塑薄膜，它具有面向身体表面和面向吸收芯表面，该有孔热塑薄膜包括：
微观质地表面，该微观质地表面具有高密度的垂直于表面所在平面延伸的细长微漏斗，以形成突起；和
垂直于所述平面延伸的三维宏观孔，以便在薄膜的面向吸收芯表面上形成突起。
9.如权利要求8所述的薄膜，其特征在于微漏斗形成的突起从与宏观孔形成的突起相同的表面突出。
10.如权利要求8所述的薄膜，其特征在于微漏斗形成的突起与宏观孔形成的突起在相反的方向上。
11.如权利要求8所述的薄膜，其特征在于微漏斗具有每线性英寸约30至约100个微漏斗的网目。
12.如权利要求8所述的薄膜，其特征在于微漏斗具有每线性英寸约40至约60个微漏斗的网目。
13.如权利要求8所述的薄膜，其特征在于宏观孔具有在每平方厘米4个孔到每平方厘米15个孔之间的密度。
14.如权利要求8所述的薄膜，其特征在于宏观孔具有在每平方厘米5个孔到每平方厘米12个孔之间的密度。
15.如权利要求8所述的薄膜，其特征在于还包括与薄膜的面向吸收芯表面粘合的非织造层，其孔与薄膜的面向吸收芯表面上的宏观突起对齐。
16.一种吸收用品，它包括：
顶片；和
吸收芯；
其中，顶片是具有孔的薄膜，该孔在表面上形成岛，该孔是三维的并垂直于该表面延伸，该岛具有微孔，微孔是三维的并垂直于该表面延伸。
17.如权利要求16所述的吸收用品，其特征在于孔和微孔在相反方向延伸。
18.如权利要求16所述的吸收用品，其特征在于孔和微孔在相同方向延伸。
19.如权利要求16所述的吸收用品，其特征在于薄膜粘合在具有与孔对齐的开口的非织造层上。
20.如权利要求16所述的吸收用品，其特征在于微孔具有每线性英寸30至约100个微漏斗网目。
21.如权利要求16所述的吸收用品，其特征在于微孔具有每线性英寸40至约60个微漏斗网目。
22.如权利要求16所述的吸收用品，其特征在于孔具有在每平方厘米4个孔到每平方厘米15个孔之间的密度。
23.如权利要求16所述的吸收用品，其特征在于孔具有在每平方厘米5个孔到每平方厘米12个孔之间的密度。
24.一种吸收用品，它包括：
顶片；和
吸收芯；
其中，顶片是具有孔的薄膜，该孔在表面上形成岛，该孔是三维的并垂直于该表面延伸，该岛具有微观质地，该微观质地是三维的并垂直于该表面延伸。
25.如权利要求24所述的吸收用品，其特征在于微观质地与孔相对延伸。
26.如权利要求24所述的吸收用品，其特征在于微观质地是由微点、微脊、随机形状(random matte)和微孔组成的一组中进行选择。
27.如权利要求24所述的吸收用品，其特征在于薄膜与非织造层粘合，该非织造层具有与孔对齐的开口。
28.如权利要求24所述的吸收用品，其特征在于孔具有在每平方厘米4个孔到每平方厘米15个孔之间的密度。
29.如权利要求24所述的吸收用品，其特征在于孔具有在每平方厘米5个孔到每平方厘米12个孔之间的密度。
30.一种制造成形薄膜的方法，它包括：
-在成形筛上挤压树脂，以在树脂上成形出微观质地，因此，树脂形成筛，并形成具有微观质地的薄膜；
用热针对薄膜开孔，以形成三维宏观孔，在宏观孔之间形成岛；和
在开孔工艺期间，采用保护层对在宏观孔之间的岛进行保护，以防止岛被加热到其中的微观质地失去形状的温度。
31.如权利要求30所述的方法，其特征在于保护层是具有高于树脂的熔点的非织造材料。
32.如权利要求30的方法，其特征在于还包括：
在开孔工艺期间，使非织造层与薄膜粘合，以便热针经过非织造层延伸，以便非织造层不会阻碍流体流经孔。
33.如权利要求32的方法，其特征在于向形成筛施加真空，以形成与薄膜中的微观质地相同的微孔。
34.一种吸收用品，它包括：
顶片；
吸收芯；和
在顶片与吸收芯之间的中间层；
其中，该中间层是具有孔的薄膜，该孔在表面上形成岛，该孔是三维的并垂直于该表面延伸，该岛具有微观质地，该微观质地是三维的并垂直于该表面延伸。
35.如权利要求34所述的吸收用品，其特征在于微观质地相对于孔延伸。
36.如权利要求34所述的吸收用品，其特征在于微观质地是由微点、微脊、随机形状和微孔组成的一组中进行选择。
37.如权利要求34所述的吸收用品，其特征在于薄膜与非织造层粘合，该非织造层具有与孔对齐的开口。
38.如权利要求34所述的薄膜，其特征在于孔具有在每平方厘米4个孔到每平方厘米15个孔之间的密度。
39.如权利要求34所述的薄膜，其特征在于孔具有在每平方厘米5个孔到每平方厘米12个孔之间的密度。
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ES2300662T3 (es) 2008-06-16
CN100381277C (zh) 2008-04-16
JP2006511367A (ja) 2006-04-06
AU2003297447A1 (en) 2004-07-22
EP1572053B1 (en) 2008-03-12
US8182728B2 (en) 2012-05-22
US20070029694A1 (en) 2007-02-08
EP1572053A1 (en) 2005-09-14
JP4440785B2 (ja) 2010-03-24

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