CN1762691A - 具有透气性的多层层合物及其制造方法 - Google Patents

具有透气性的多层层合物及其制造方法 Download PDF

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CN1762691A
CN1762691A CNA2005100983719A CN200510098371A CN1762691A CN 1762691 A CN1762691 A CN 1762691A CN A2005100983719 A CNA2005100983719 A CN A2005100983719A CN 200510098371 A CN200510098371 A CN 200510098371A CN 1762691 A CN1762691 A CN 1762691A
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layer
cloth
elastic
elastomeric nonwoven
multilayer
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郑元隆
许锡华
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KYO SHAK-UKA
KYO SHAK UKA
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KYO SHAK-UKA
KYO SHAK UKA
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Abstract

本发明涉及一种独特的防液体渗透的弹性层合物。该弹性层合物由弹性薄膜及弹性无纺布粘合而成，在粘合制造过程中，在围绕着用以结合成该弹性层合物的融合点的周围可形成环形小孔，通过该小孔而使该弹性层合物具有透气性。

Description

具有透气性的多层层合物及其制造方法
技术领域
本发明涉及一种由弹性薄膜和弹性无纺布粘合而成的弹性层合物，特别的是，本发明涉及一种点状贴合的弹性无纺布/弹性薄膜/弹性无纺布的层合物，其在粘合制造过程中在接合该弹性层合物的融合点(weld points)处外围形成一定程度的小孔，从而使该弹性层合物具有透气性。
背景技术
在抛弃型消费品市场上，例如：抛弃型尿布、婴儿学习裤及其它抛弃型卫生用品等，一直有要求增加合身及舒适度的需求。具有高度弹性、高度弹性回复率及透气性的层合物能满足此项需求。一般还期待弹性层合物仅可朝双方向伸展。抛弃型个人护理用品及健康护理用品通常具有透气性、液体防渗性及足够的强度去应付一般正常的使用。透气性系指可透过气体或水气，液体防渗性系指液体无法渗透过，而强度与抗拉性有关。虽然可分别增进各聚合物膜的上述任一性质，但难以在维持液体高防渗性及薄膜强度的同时，又增进聚合物膜的透气性。举例而言，当某一聚合物较其它聚合物更具有透气性时，此聚合物的防渗性及抗拉性却不佳。相反，当其它聚合物具有较优异的防渗性或抗拉性，透气性却不够。因此，一直有同时具有良好透气性及良好防渗性及强度的聚合物薄膜来制造个人护理用品、健康护理用品等的需求。
过去，用以使无纺布层合物具有高度伸展性的技术，常会导致层合物组织成分受到损坏，因而降低层合物的强度，特别是抗拉强度。此外，利用已知技术所制造的层合物时，常缺乏足够的弹性回复率而无法有效地使用在所希望的应用上。
在将该薄膜层粘合至无纺布之前，先对该薄膜进行穿孔，这是提供这些层合物透气性的一种简单方法。遗憾地，这些穿孔常使液体易于渗透而无法令人满意。
透气性的产生也能利用熟悉此技术者所知的其它穿孔步骤对该薄膜进行穿孔而得，其它穿孔程序例如在将该薄膜层粘合至无纺布之后，再对该层合物进行穿孔。但这些穿孔步骤会导致整个层合物上出现多个薄弱点。这些薄弱点常会变为撕裂起点而导致液体的通过。
先前有许多已知技术必须经过许多困难及昂贵的步骤，才能制造出具有所希望性质的层合物。例如Middleworth等人的美国专利6,537,930及其相关分案的Cree等人的美国专利6,720,279，皆有伸展性及透气性的本质上问题。这是由于融合点实质上并不具有弹性，但必须被裂开才能形成孔洞。当使用者将层合物在横向方向(cross-machine direction)拉伸约200％时才能形成这样的孔洞。因为在产品使用上通常无法达到所需的大量伸展(200％)，会给终端产品的消费者带来困难。当在制造实质上无弹性的融合点的过程中，要将产品预先伸展(200％)，在许多情形下，形成的孔洞可能会造成对该层合物所结合的抛弃型吸收性产品而言的渗漏点。
因此，目前需要发展一种具有高度弹性的层合物以及制造此高度弹性层合物兼具有高度弹性回复率的方法，以供应抛弃型产品的市场需求。除此之外，更需要发展新型层合物及其制造方法，此层合物必须能大量降低过去存在于旧式层合物上的撕裂起点。最后，还需要在维持上述所希望的效能(透气、防渗、高强度)的同时，减少制造此种层合物所需的复杂步骤数及困难度。
发明内容
为满足上述需求，本发明提供一种透气性的、由弹性聚合物薄膜与无纺布粘合而成的层合物，当其在粘合制造时，同时赋予本产品实质上并且符合商品化标准的足够的水气透过率或透气性。本发明所使用的薄膜具有透气性，但其强度及液体防渗性足以用于例如抛弃型吸收性个人护理及健康护理产品、衣服及其它被覆材料。薄膜的透气性程度以薄膜的水气透过率来说明。本发明的聚合物薄膜的水气透过率较适合在约300至1500克/平方米/24小时以上的范围内。
本发明提供一种独特的多层层合物，该多层层合物由独特的弹性无纺布、弹性薄膜及独特的弹性无纺布粘合而成。于2004年6月8日发行的GregoryF.Ward的美国专利6,746,978中揭示此种独特的弹性无纺布，在此并入本文作为参考。此独特的层合物因层合物中的弹性无纺布组分的性质，仅限于横向方向具有弹性，并且该层合物具有液体防渗性。但是，由于此层合物的独特制造条件，在粘合步骤中，在弹性薄膜的融合点的周围产生空气及水气可透过性的功能。
在粘合步骤中，在分散的点状融合处将层合物的各层接合在一起。在一实施例中，超音波接合工具头(ultrasonic horn)及图案化的旋转铁砧(anvil)被用于接合此层合物。在融合之后，在层合物上形成下列不同的区域：非融合区域、融合区域及过渡区域。非融合的过渡区域是围绕着融合点周围的区域。这些融合点实际上是弹性无纺布与弹性薄膜的融合处。在融合步骤期间产生的非融合的过渡区域是围绕着融合点的周围区域，主体为非定型的聚合物薄膜及无纺布纤维。
出乎意料的发现这些非融合的过渡区域能让水气以可商品化标准300至1500克/平方米/24小时的速率透过。
本文中所述的“双成分或多成分纤维”，是指至少两种以上的聚合物由不同的纺嘴喷出但彼此织在一起而形成的纤维。多成分纤维有时还包括复合纤维(conjugate)或双成分纤维。多成分纤维的各聚合物配置在横越该纤维横截面的、实质上不变的定位的不同区域，且沿着纤维长度方向不间断地延伸。该纤维的组态可为例如鞘状物/核心(sheath/core)排列，其中一聚合物由另一聚合物所包围；或可为并行(side-by-side)排列、饼型(pie)排列或海岛型(islands-in-the-sea)排列。多成分纤维在Kaneko等人的美国专利5,108,820、Krueger等人的美国专利4,795,668及Strack等人的美国专利5,336,552中公开。对双成分纤维而言，这些聚合物可以以75/25、50/50、25/75或任何其它所希望的比率存在。
本文所述的“接合窗口”是指形成机构(例如一对用于将无纺布纤维结合在一起的加热接合辊子)的温度范围，在此温度范围下可完成该融合步骤。本文所述的“透气性”是指材质可透过水气，并且具有至少约300克/平方米/24小时的水气透过率(WVTR)。材料的水气透过率是布料穿著时的舒适度的指针。水气透过率由下文所示方法测得，结果以克/平方米/24小时为单位来记录。通常，当使用透气性防渗材质时，一般会要求较高的水气透过率，而本发明的透气性层合物能具有超过约800克/平方米/24小时、1500克/平方米/24小时、或甚至超过3000克/平方米/24小时的水气透过率。测定水气透过率的标准测试法为ASTM E96-80。
本文所述“弹性”是指施加拉力时，可拉长的材料可伸长至至少150％的松弛未伸展的长度，并在放松拉力时，缩回至少50％的拉长长度。在一假设的例子中，1英寸的材料样品可拉长到至少1.5英寸而在放松拉力时，将缩回到不超过1.25英寸的长度。
本文所述“流体”可为液体或气体。
本文所述“gsm”一词是指每平方米的克数，即层合物的面积重的测量。
本文所述“纵向方向(machine direction)”是指织布在其生产中的长度方向。“横向方向(cross machine direction)”是指织布的宽度方向，即通常垂直于织布的长度的方向。
本文所述“无纺布”是指具有个别纤维或线的结构的织布，这些纤维或线插入其间，而不是以如网状织布或编织织布一样的可辨认方式配置。无纺布可以由许多方法，例如熔喷法(meltblowing)、纺粘法(spunbonding)、水针法(hydroentangling)、气纺法(air-laid)及粘合梳理纤网法(bonded cardedweb)而制得。
本文所述“点融合”是指利用多个分离的融合点将一片或多片织布及薄膜融合在一起。例如，加热的点接合通常包含将欲结合的一层或多层，通过加热的辊子之间，该辊子例如为雕刻图案辊子或平滑压光辊子。雕刻辊子为图案化的，而铁砧辊子通常是平坦的。结果，为了功能及审美原因，已经发展了多种点融合图案。融合面积可为总面积的10％以下至50％以上。点融合亦可利用超音波融合装置来完成。
本文所述“聚合物”通常包含但不限于，单聚合物(homopolymers)、共聚物(例如嵌段、接枝、无规则及交替共聚物、三元共聚物等)、混合物及其修饰物。此外，除非另有其它特别限制，“聚合物”一词包含所有可能的分子空间组态。这些组态包含但不限于，同排、对排及无规则对称。
本文所述“纺粘纤维(Spunbond Fibers)”是指实质上分子定位的聚合物材料的小直径纤维。纺粘纤维可以由挤出熔融热塑材料而形成，如由纺嘴的多个细微且通常为圆形的毛细管挤出来的纺丝，挤出的纺丝的直径随后被迅速缩短。例如，Appel等人的美国专利4,340,563、Dorschner等人的美国专利3,692,618、Pike等人的美国专利5,382,400。纺粘纤维的直径通常约为10微米或10微米以上。
本文所述“超音波接合(Ultrasonic Bonding)”是指将织布中的聚合材料的层合物，通过特定的音波接合工具头(sonic horn)及铁砧辊子之间而产生图案化的融合点(weld)。这些系统的实例公示于Branson公司的应用技术组的技术文献Product Data Sheet PW-48径向超音波促动器及其它文献，皆将并入本文作为参考。
附图说明
图1是本发明在贴合及结合步骤之前由独特的弹性无纺布、弹性薄膜及独特的弹性无纺布所组成的三层层合物的截面图；
图2是三层层合物中的单一融合点的截面图；
图3是在复合材料已进行贴合步骤之后显示出融合点及其周围的非定型区域的复合材料的截面图。
图中
1、5弹性无纺布/弹性薄膜/弹性无纺布的层合物
2、4弹性无纺布层
3核心层(弹性薄膜)
6融合点
8过渡区域(透气性环形小孔)
具体实施方式
图1显示高度弹性无纺布/弹性薄膜/弹性无纺布的层合物1，该层合物1在横向方向具有高度的延伸性。该层合物1包含第一或顶层弹性无纺布层2、不渗透薄膜核心层3以及第二或底层弹性无纺布层4。
弹性无纺布层2、4由纺粘纤维所组成，且弹性无纺布层2、4本质上具有透气性。这些纺粘纤维可为单聚合物、双组分或混合纤维(blended fibers)。此两层弹性无纺布的面积重较佳，约为15至50gsm。薄膜核心层3可以由多种弹性聚合物制得，但材料最初必须对流体以及空气皆不渗透。在目前的实施例中，使用0.02至0.03mm厚度的弹性聚氨基甲酸酯(polyurethane)薄膜。于另一实施例中，核心层3可由多层薄膜组成。其它弹性薄膜亦可用作为核心层3，例如单层弹性体或发泡塑料层，但这些薄膜必须由对液体及空气皆不渗透的材料组成。
核心层3也可由其它高弹性化合物的薄膜所组成，这些高弹性化合物例如为嵌段共聚物，其由相同单体单元(A)的长段(嵌段)与不同型单元(B)的长段共价键结所形成。嵌段之间可以是多种方式连接，即AB嵌段及ABA嵌段构造架构。通常该化合物展现相当优良的弹性回复力，或当以单一层单独挤出时，伸展超过100％但仍不易失去弹性。在一特定实施例中，弹性材料可包括高效能弹性材料，例如苯乙烯/异戊二烯/苯乙烯、苯乙烯/异戊二烯/丁二烯或苯乙烯/乙烯-丁烯/苯乙烯(SIS、SBS或SEBS)或Shell化学公司出产的KratonTM弹性树脂，其皆为弹性嵌段共聚物。嵌段共聚物的特殊形态对主体的功能性及渗透性皆有显著的效果。
其它作为核心层3的有用弹性组合物可包含乙烯共聚物，例如乙烯醋酸乙酯、乙烯/丙烯共聚物弹性体或乙烯/丙烯/二烯三元共聚物弹性体。本发明亦可使用单独这些聚合物的混合物或这些聚合物与其它修饰的弹性或非弹性材料的混合物。
制作形成弹性无纺布/弹性薄膜/弹性无纺布的层合物1，第一层及第二层的纺粘无纺布根据Ward的美国专利6,746,978的说明来处理，此说明将并入本文作为参考。由此制作过程可获得第一及第二弹性无纺布层2、4。弹性薄膜/无纺布的层合物(图1所示)由将核心层3粘合在弹性无纺布2、4之间而制得。
力与热/融合能的结合，例如超音波融合法、加热点贴合法或加热接触融合法，是用于在分散的接合点6处，将三层2、3、4结合一起而形成点融合的弹性无纺布/弹性薄膜/弹性无纺布的层合物5，如图2及图3所示。在图2及图3所示的较佳实施例中，是用超音波融合法以形成将弹性无纺布层2、4及不渗透的薄膜核心层3予以结合的融合点6。这些融合点6理想地占图2所示的层合物的总表面积的约3％至约40％。融合点6的直径应约为0.4mm至1.5mm。理想地，这些融合点在横向方向从中心线至中心线的距离应约为2.5mm至10mm。较佳的融合点的形成是利用熟悉此技艺者所知的超音波融合法。也可使用其它适宜的方法，包含加热接触融合法，和将欲接合的一层或多层，通过图案化的加热辊子之间以制得相对应于加热辊子的图案的融合点6。在此实施例中，三层材质层是由将此三层材质层通过音波接合工具头及铁砧之间而结合。此项结合为一整体图案接合。
在融合之后，在层合物上形成下列不同的区域：非融合区域、贴合区域或融合点以及过渡区域8。非融合的过渡区域8是围绕着融合点周围的层合物的区域。这些融合点实际上是弹性无纺布与弹性薄膜的接合处。在接合步骤期间产生的非融合的过渡区域围绕着融合点的周围区域，含有主体为非定型的聚合物薄膜及无纺布纤维。
值得注意的是，利用点贴合的条件在围绕着融合点周围的区域产生令人惊讶的独特形态，该区域呈现明显程度的透气性。透气性因弹性薄膜及弹性无纺布的单位面积重以及压力、温度及薄膜中的聚合物及无纺布的融合能力而定，可以测量水气透过率(WVTR)方式来观察广泛变化的透气度。这些水气透过率约为300克/平方米/24小时至2500克/平方米/24小时。水气输送程度根据多样的材料特性及制作过程的条件而定。这包含薄膜聚合物型、薄膜厚度、接合能输入位准、融合点大小及融合点密度、无纺布材料差异、基准重量以及纤维直径。目前无公式性的理论可以衍生出制作过程的条件。结果，水气输送程度由各组的条件及材料而定。很清楚地发现，在接合窗口条件下，并不损及液体的非渗透性(impermeability)。据认为所用的独特弹性无纺布的结构在层合物的透气性方面起了相当大的作用。
结果，能形成弹性薄膜/弹性无纺布层合物，当以水气透过率测量时，该层合物具有符合商业价值上可接受的透气性。熟悉此技术者可了解，本发明的各参数可依应用而予以调整，包含改变弹性无纺布层的重量、用作为弹性薄膜/弹性无纺布的层合物的不渗透核心薄膜层的聚合物的选择、弹性薄膜的厚度、以及融合点的大小与数目。
参照图3，弹性无纺布/弹性薄膜/弹性无纺布的层合物1的截面图显示于进行融合步骤之后形成融合点6，这些融合点包含明显不同的区段8。这些融合点6实际上是弹性无纺布与弹性薄膜的接合处。融合点6的中心部分为圆形且相当明显的薄膜区段，其包含融合步骤中嵌入的纤维。围绕着融合点的相当清楚的区段为狭窄的周边区域8，含有融合步骤中产生的非定型主体的聚合物薄膜及无纺布纤维。由于融合点越多或更简洁的说，非定型过渡区域的面积越大则输送水气的速率就越快，因此这些部分接合的非定型过渡区域8是明显地输送水气的区域。
图1及图2中的所获得融合的弹性无纺布/弹性薄膜/弹性无纺布的层合物1在横向方向具有高度弹性，该横向方向是横向于接合步骤中层合物与接合的层合物移动方向的方向。图2中的接合的层合物会抗拒纵向方向(in themachine direction)的伸展，该纵向方向平行于层合物1制造及接合步骤中所获得接合的层合物1移动的纵向方向。此接合的弹性无纺布/弹性薄膜/弹性无纺布的层合物1的最终重量约为15至200gsm。
对所有熟习此技艺者而言，本发明明显地可以作出多种配置、修改及变化而不脱离本发明的实质和范围。因此，本发明包括这些配置、修改及变化，且其皆被包括在权利要求范围及其均等者中。

Claims (19)

1.一种具有弹性及透气性的多层层合物，其由独特的弹性无纺布、弹性薄膜及独特的弹性无纺布所组成，其特征在于：该多层层合物包括：
不渗透流体和空气的核心弹性薄膜层，其具有第一侧面及第二侧面；
第一弹性无纺布层，其由复数个融合点通过点贴合至所述核心弹性薄膜的所述第一侧面；以及
第二弹性无纺布层，其由复数个融合点通过点贴合至所述核心弹性薄膜的所述第二侧面，
其中，所述融合点包括围绕着所述融合点为核心的周围非定型的过渡区域，且所述非定型的过渡区域提供所述多层层合物透气性。
2.根据权利要求1所述的多层层合物，其特征在于：所述弹性薄膜是选自弹性薄膜、发泡塑料及多层薄膜中的任何材料。
3.根据权利要求1所述的多层层合物，其特征在于：所述第一弹性无纺布层和所述第二弹性无纺布层由单一或双成分纤维组成。
4.根据权利要求1所述的多层层合物，其特征在于：所述第一弹性无纺布层和所述第二弹性无纺布层由混合纤维组成。
5.根据权利要求1所述的多层层合物，其特征在于：所述弹性薄膜选自由弹性嵌段共聚物和弹性共聚物所组成的弹性薄膜族群的材料。
6.根据权利要求1所述的多层层合物，其特征在于：所述融合点占所述多层层合物的总表面积的5％至35％。
7.根据权利要求1所述的多层层合物，其特征在于：所述融合点的直径为0.4mm至1.5mm。
8.根据权利要求1所述的多层层合物，其特征在于：所述融合点的中心线的距离为2.5mm至10mm。
9.根据权利要求1所述的多层层合物，其特征在于：相邻融合点的中心形成一菱形图案。
10.根据权利要求1所述的多层层合物，其特征在于：利用ASTM测试法E96-80以水气透过率测得的透气性至少为300克/平方米/24小时。
11.根据权利要求1所述的多层层合物，其特征在于：所述第一弹性无纺布层和所述第二弹性无纺布层是由以40公分/公分/分钟以下的应变率进行加热伸展所制得的弹性织布所组成。
12.根据权利要求1所述的多层层合物，其特征在于：所述第一弹性无纺布层和所述第二弹性无纺布层是由双组分纤维所组成。
13.根据权利要求1所述的多层层合物，其特征在于：所述弹性薄膜层由单层、两层或多层的弹性薄膜的层合物所组成。
14.一种弹性多层层合物的形成方法，其特征在于：该多层层合物由独特的弹性无纺布、弹性薄膜及独特的弹性无纺布所组成，该形成方法包括下列步骤：
将第一弹性无纺布层点接合至不渗透空气和流体的弹性核心薄膜层的第一侧面，同时将第二弹性无纺布层点接合至该不渗透空气和流体的弹性核心薄膜层的第二侧面；以及
该接合产生复数个融合点，其中，所述融合点包括围绕着所述融合点为核心的周围非定型区域，而所述非定型区域提供所述多层层合物透气性。
15.根据权利要求14所述的弹性多层层合物的形成方法，其特征在于：将所述第一弹性无纺布层和所述第二弹性无纺布层点接合至所述弹性核心薄膜层的步骤是由超音波融合条件来达成。
16.根据权利要求14所述的弹性多层层合物的形成方法，其特征在于：将所述第一弹性无纺布层和所述第二弹性无纺布层点接合至所述不渗透空气和流体的弹性核心薄膜层的步骤是由力与热能的结合来达成。
17.根据权利要求14所述的弹性多层层合物的形成方法，其特征在于：所述第一弹性无纺布层和所述第二弹性无纺布层的点接合步骤是由在复数个菱形图案化的加热辊子之间进行加热点接触接合来达成，其中所述融合点占所述加热辊子的总表面积的5％至35％。
18.根据权利要求14所述的弹性多层层合物的形成方法，其特征在于：所述融合点的直径至少为0.4mm至1.5mm。
19.根据权利要求14所述的弹性多层层合物的形成方法，其特征在于：所述融合点的中心线的距离为2.5mm至10mm。
CNA2005100983719A 2004-09-10 2005-09-08 具有透气性的多层层合物及其制造方法 Pending CN1762691A (zh)

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