CN1982046B - 弹性层压物和其制造方法 - Google Patents

弹性层压物和其制造方法 Download PDF

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CN1982046B
CN1982046B CN2006101630102A CN200610163010A CN1982046B CN 1982046 B CN1982046 B CN 1982046B CN 2006101630102 A CN2006101630102 A CN 2006101630102A CN 200610163010 A CN200610163010 A CN 200610163010A CN 1982046 B CN1982046 B CN 1982046B
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nonwoven layers
elastic
laminate
activation
elastic membrane
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CN1982046A (zh
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杰弗里·艾伦·米德尔斯沃思
布赖恩·L·马特
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Tredegar Film Products LLC
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Abstract

本发明提供形成弹性层压物的方法，其包括：将第一无纺层结合至弹性膜，从而形成层压物；将所述层压物活化，从而形成活化层压物；将固结无纺层结合至活化层压物的弹性膜，从而形成弹性层压物。

Description

弹性层压物和其制造方法
对相关申请的引用
本申请要求2005年11月28日提交的美国临时申请号60/740,036的优先权，其全文此处引入作为参考。
技术领域
本发明通常涉及弹性层压物和其制造方法，更特别地，本发明涉及两侧面均具有无纺表面的透气性弹性层压物。
背景技术
透气性弹性层压物用于制造许多产品，包括例如一次性物品，如尿布、女性卫生用品和绷带。这些应用要求层压物强力、可拉伸和触觉柔软。但是，改进上述特征中的一种往往会导致其他特征受损。因此，之前采用的层压物往往代表了柔软性、弹性和强度之间的折衷。
例如，一种现有技术的层压物包括有孔的弹性层压物，其通过将粗梳的聚丙烯无纺层真空层压至多层共挤出的弹性膜而制得。然后采用啮合齿轮将层压物横向活化。这种构造具有的优点是触觉柔软，但仅限于两层(无纺层和膜层)且缺少高剥离强度。
另一现有技术产品包括有孔的弹性膜，其在横向(CD)被活化并且各侧面被超声结合至固结(consolidated)的无纺层。尽管这种层压物倾向于具有强力，但其具有比期望更粗糙的触觉，为结合各层需要相当的超声能量，并且因其具有三层，其倾向于缺少由仅具有无纺单层的层压物可得到的拉伸水平。
因此对于任一侧面触觉均柔软、且可拉伸和强力的透气性层压物存在需求。本发明即满足了这种需求。
发明内容
本发明涉及弹性层压物，其在两侧面均具有柔软的无纺表面，并且是可拉伸和强力的。具体地，该弹性层压物包括弹性内层和两个无纺外层，其中通过不同方法对各无纺层赋予了可延伸性。也就是说，一个无纺层是被活化的，而另一个无纺层是被固结的。
申请人出乎意料地发现，本发明的层压物具有特别的横向拉伸度，具有令人愉悦的柔软触觉，并且可以完全线速经超声而结合，从而获得特别强的层间结合。尽管不受任何特定理论的束缚，但申请人猜测该高拉伸水平是因采用两种不同技术即活化和固结对两个无纺层进行“增弹化”而得到的。该方法将上述两种技术的强度协同结合，从而使所得层压物具有固结/超声结合无纺层的高抗张强度和强结合特性，以及具有活化无纺层的柔软性和抗撕裂特性。此外，该方法使同一层压物内观测到的一个无纺层限制另一无纺层延伸性的趋势最小化。
因此，本发明的一方面是具有两个无纺外层的弹性层压物，所述两个无纺外层通过采用不同技术而被赋予可延伸性。在优选实施方式中，该弹性层压物包含：(1)具有第一和第二侧面的弹性层；(2)结合至弹性层第一侧面的第一无纺层，所述第一无纺层已经通过活化被赋予可延伸性；和(3)结合至弹性层第二侧面的第二无纺层，所述第二无纺层已经通过热固结被赋予可延伸性。
本发明另一方面是上述层压物的制造方法。在优选实施方式中，该方法包含：(1)将第一无纺层结合至弹性膜从而形成层压物；(2)将层压物活化从而形成活化的层压物；和(3)将固结的无纺层结合至活化层压物的弹性膜，从而形成弹性层压物。
附图说明
图1示出本发明弹性层压物的示意图。
图2示出制造图1的弹性层压物的生产线示意图。
优选实施方式
本发明涉及弹性层压物及其制造方法。参照图1，简单地说，弹性层压物10包括具有第一和第二侧面14、15的弹性层12。优选但非必须地，该弹性层具有孔13或以别的方式改造成具有可透气性。第一侧面14上是结合至弹性膜材料12的活化无纺层16。此处所用术语“活化的”或“活化”是指将包含弹性层和至少一个低弹性层的层压物拉伸至超出低弹性层形变点的延伸极限，从而使弹性层伸长至基本不受低弹性层阻碍的该延伸极限的方法或状态。活化是公知的技术。第二侧面15上是结合至弹性膜12的固结无纺层17。此处所用术语“固结的”或“固结”是指将无纺层的纤维或纤维样要素排列成行(aligned)，从而使无纺层在垂直于排列的方向上伸长的方法或状态。与活化一样，固结是对无纺层赋予延伸性的公知技术。
参照图2，其描述了与优选制造设备有关的制备层压物10的方法100。该方法包含将第一无纺层50结合至弹性膜60从而形成层压物65。该弹性膜任选是可透气的。一旦形成层压物65，即将其活化而形成活化的层压物75。然后将固结的无纺层55结合至活化层压物75的弹性膜50，从而形成弹性层压物95。下文对该弹性层压物95、其应用及其制备方法作详细描述。
重新参照图1，弹性层12对层压物提供了弹性。弹性层包含至少一种弹性材料。合适的弹性材料包括能够成形为薄片材、赋予可透气性且结合至无纺层的任意材料。例如，弹性材料包括天然和/或合成的聚合材料，包含异戊二烯，丁二烯-苯乙烯材料，苯乙烯嵌段共聚物(如苯乙烯/异戊二烯/苯乙烯(SIS)、苯乙烯/丁二烯/苯乙烯(SBS)或苯乙烯/乙烯-丁二烯/苯乙烯(SEBS))，烯烃弹性体，聚醚酯，聚氨酯等。在某些优选实施方式中，弹性材料可包含高性能弹性材料，如KratonPolymers，LLC制造的弹性嵌段共聚物Kraton弹性树脂。
对弹性层12的形式可作改变，例如可包括弹性绳股(strands)、弹性无纺层、弹性膜、弹性粘合剂、弹性粘结聚合料片(web)、弹性棉麻布等。为简易起见，如无另外指出，本文中这些不同的形式统称为“弹性膜”。在某些优选实施方式中采用了单层弹性膜。但应理解本发明并不限于单层膜，在某些应用中可采用具有多层的膜。例如，可有利地使两个表层之间具有弹性芯，从而增强对无纺层的结合或促进可加工性。合适的表层是本领域公知的，包括例如比弹性材料更具弹性或弹性更低的聚乙烯。弹性膜的厚度可根据应用而改变，尽管膜的各单个层通常较薄(例如弹性芯通常但非必须地低于100微米，如使用表层的话，则表层通常低于20微米)。
优选地，弹性膜是可透气的，或以常规方式改造成可透气的。此类方式包括，例如开孔、切缝、或以小粒子浸渍从而在弹性膜拉伸时产生出微孔。
第一无纺层16一旦活化(如下论述)即在弹性层的第一侧面14上提供了柔软和可透气的表面。合适的无纺层能够被活化并且弹性低于弹性层12。合适的无纺层包括采用公知技术制得的散纤维和料片，所述公知技术例如空中压条(air laying)、纺粘、纺花边(spun lace)、粘结熔喷、热粘合、粘结粗梳(bonded carded)。无纺材料可以是均质的，或者含有多种织造材料，所述织造材料包括双组分纤维(如具有一种材料的内芯和第二种材料的外芯)，不同形态、几何形状和表面光洁度的纤维。合适的无纺材料包括，例如纤维状聚烯烃如聚乙烯和聚丙烯，以及天然纤维如棉和纤维素。
如第一无纺层16一样，固结的无纺层17对弹性层12的第二侧面15提供了柔软和可透气的覆层。不同于第一无纺层的是，固结的无纺层通过固结方法而非活化方法赋予了可延伸性。下文对固结方法作详细描述。
层压物10可用于需要柔软、可拉伸、可透气材料的任何应用中，尤其适用于相对低成本的一次性物品。合适的应用包括例如吸收性物品，包括成人、小孩或婴儿尿失禁产品(尿布，包括诸如尿布穗(ears)、头布(tabs)和/或侧幅，贴身内裤等部件)；包括消毒和未消毒的包装材料(例如具有或不具有吸收部分的绷带)，以及其他一次性和/或多用途产品；例如贴近人或动物身体的物品，如(如衣装、服饰，包括内衣、内/外衣裤，如汗衫、乳罩、贴身内裤、短衬裤等，游泳衣、工作服、短袜、头罩和领饰、帽子、连指手套和手套衬里、医用服装等)床单；医用窗帘；包装材料；防护罩；家居材料；办公材料；医用或建筑材料；包装材料；等治疗器具和包装物。
下文参照图2描述层压物的制造方法。图2示出了提供弹性膜60的弹性源20。在该实施方式中，弹性源20包括冲模或吹制模，用于挤出熔融或半熔融的弹性材料，或者将其中一或多层为弹性的多层膜结构共挤出。但应理解任何常规的弹性源均可采用，包括例如成卷的弹性材料。
第一无纺源70提供第一无纺层50。在该实施方式中，第一无纺源70包括成卷的材料，但可使用任何合适的无纺源，包括原位形成材料。
将第一无纺层50与弹性膜60接触并与之结合。在此实施方式中，弹性膜60的熔融或半熔融相促进了与第一无纺层50的结合。也可采用其他常规技术将第一无纺层50全部或部分地结合至弹性层，所述方法例如热针成孔(hot pin aperturing)、胶粘结合、热结合、超声结合以及其组合。
任选地，将弹性膜60改性以赋予其透气性。使弹性膜开孔的一种优选方法如图2所示，其中采用了压差源30。具体地，将第一无纺层50和弹性膜60提供给压差源30，从而使弹性膜60置于压差源30与第一无纺层50之间。压差源30沿层压物的厚度方向产生压差，该压差足够大从而在弹性膜60中引起破裂(即开孔)。这一方法产生出三维孔，这在期望层压物具有可透气性或渗透性的场合是特别优选的。
压差源30是公知的。在优选实施方式中，压差源30包含真空(未示出)和定孔(aperture definition)设备120。在该实施方式中，定孔设备120包含在方形图案中每线性英寸具有20个孔的筛板，此处称为20方板。可采用其他几何结构的筛板，以改变开孔面积、孔径、几何形状、图案和其他属性的量。此外，可采用多于一个的定孔设备，例如一个区域中的设备可提供一种孔图案，而另一区域中的设备可提供另一期望的图案。
在某些实施方式中，期望地可对弹性膜进行改性，以使其在结合至第一无纺层之前可透气。此外，优选地可使用其他公知的开孔技术，例如齿辊(pin roll)、切缝、液喷、或激光，作为压差源的替代或补充，从而对层压物赋予渗透性或透气性。但还应理解，如果弹性膜包含已具有可透气性的弹性绳股或棉麻，则无需对弹性膜进行赋予可透气性的改性。
压力源35对材料提供压力。在优选实施方式中使用压送辊，但也可使用任意的合适源作为压力源。另外，某些实施方式可省去压力源，或者也使用压差源作为压力源。此外，图2所示压力源35位于压差源的上游，但其可位于压差源30的邻近，或位于压差源30的下游。
弹性层一旦结合至第一无纺层，即对第一无纺层进行活化。重新参照图2，层压物65在活化区域40被活化。在优选实施方式中，活化区域40涉及啮合齿轮(“IMG”)活化，但也可采用任何常规活化方法。在图2所示的实施方式中，活化发生在横向(CD)，但所述活化也可发生于任意期望的方向，例如纵向(MD)、对角方向、或者其组合。另外，活化可沿整个层压物而发生，或者仅发生于层压物的预定区域。在其他实施方式中，可对活化程度进行改变，例如可使用轻微活化区域从而对层压物赋予低弹性，而重度活化区域则可用于对层压物赋予高弹性。当然也可将活化的区域置于非活化区域之间，从而对层压物提供具有可延伸性的地带或区域。
重新参照图1，第二无纺源80提供了第二无纺层55。在此实施方式中，第二无纺源80包含成卷的材料，但也可采用任何合适的无纺源，例如原位形成所述材料。
在一个实施方式中，对第二无纺层55在线进行固结。可采用各种技术进行固结，例如热固结、冷拉或其结合。优选采用热固结，其方法公开于例如美国专利号RE35,206中，其全文此处引入作为参考。如图2所示，第二无纺层55穿过施热区域45，在该处对其施加热，并将料片的纤维取向成纵向，从而为横向伸长作好准备。尽管在此实施方式中是在线进行固结，但应理解可提前进行固结，并将固结的无纺源提供给生产线。
将固结的无纺层91通过辊81、82与活化的层压物75接触，并采用公知技术进行结合。优选地，固结的无纺层91和层压物75在超声结合区域85中进行超声结合。已经发现，可按例如70mpm的正常线速度快速进行该结合。
改变材料和方法条件可改变层压物的特性。例如，选择特定的弹性和/或无纺材料，或对这些材料进行选择性加工，可导致期望性能如结合强度、柔软性、弹性、透气性的优化。可用于改变层压物特性的方法变量的例子包括在结合之前对弹性层的相进行变更；对压差源施加的压差进行变更；对压力源赋予的压力进行变更；对无纺层中的开孔进行变更；对在定孔设备中提供的开孔进行变更；对层压物和/或层压物的组分进行各种二次处理(例如等离子体处理)，层压后对层压物的拉伸进行变更，以及其组合。也可以任意合适的方式对层压物进行改性，例如可对层压物进行缝合、结合、印刷、切割、成形、胶粘、刻槽或消毒等。
尽管已参照各种特定实施方式对本发明作了描述，但其各种变更从本申请公开内容中是显见的，并且均处于所附权利要求的范围之内。

Claims (19)

1.一种形成弹性层压物的方法，其包括：
将第一无纺层结合至弹性膜，从而形成层压物；
将所述层压物活化，从而形成活化层压物；和
将固结无纺层结合至所述活化层压物的所述弹性膜，从而形成所述弹性层压物，
其中，所述第一无纺层和所述固结无纺层的弹性低于所述弹性膜的弹性，所述固结无纺层是热固结的。
2.权利要求1的方法，其中所述弹性膜是开孔的。
3.权利要求2的方法，其中所述弹性膜结合至所述第一无纺层，并同时对弹性膜进行开孔。
4.权利要求3的方法，其中对所述第一无纺层和所述弹性膜同时进行开孔。
5.权利要求3的方法，其中采用真空层压从而将所述第一无纺层结合至所述弹性膜，并使所述弹性膜开孔。
6.权利要求2的方法，其中在第一结合步骤之后对弹性膜进行开孔。
7.权利要求2的方法，其中在第一结合步骤之前对弹性膜进行开孔。
8.权利要求1的方法，其中对所述层压物的活化包括横向活化所述层压物。
9.权利要求8的方法，其中采用啮合齿轮活化对所述层压物进行活化。
10.权利要求1的方法，其中所述固结无纺层在所述横向是可延伸的。
11.权利要求1的方法，其中至少一个所述结合步骤包括超声结合。
12.权利要求11的方法，其中所述固结无纺层的所述结合是以超声法进行的。
13.权利要求1的方法，其中所述固结无纺层的所述结合以与所述活化步骤相同的线速度进行。
14.一种弹性层压物，其包括：
具有第一侧面和第二侧面的弹性层；
结合至所述弹性层的所述第一侧面上的第一无纺层，所述第一无纺层已经通过活化被赋予可延伸性；和
结合至所述弹性层的所述第二侧面上的第二无纺层，所述第二无纺层已经通过热固结被赋予可延伸性。
15.权利要求14的弹性层压物，其中所述弹性层是可透气的。
16.权利要求15的弹性层压物，其中所述弹性层是开孔的。
17.权利要求14的弹性层压物，其中所述第一无纺层是粗梳的无纺层。
18.权利要求17的弹性层压物，其中所述第一无纺层是聚丙烯。
19.权利要求14的弹性层压物，其中所述第一无纺层在第一方向可延伸，且所述第二无纺层在所述第一方向可延伸。
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CN1982046A (zh) 2007-06-20
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US7955457B2 (en) 2011-06-07

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