JP4927184B2 - 使い捨て吸収物品の構成部材として使用するための繊維質不織ウェブの改良方法 - Google Patents
使い捨て吸収物品の構成部材として使用するための繊維質不織ウェブの改良方法 Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
- B29C55/10—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial
- B29C55/12—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial
- B29C55/14—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial successively
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
- B29C55/18—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets by squeezing between surfaces, e.g. rollers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/04—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a layer being specifically extensible by reason of its structure or arrangement, e.g. by reason of the chemical nature of the fibres or filaments
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H13/00—Other non-woven fabrics
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0854—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns in the form of a non-woven mat
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Textile Engineering (AREA)
- Nonwoven Fabrics (AREA)
- Absorbent Articles And Supports Therefor (AREA)
- Treatment Of Fiber Materials (AREA)
- Laminated Bodies (AREA)
- Orthopedics, Nursing, And Contraception (AREA)
Description
次に、添付図面のうち特に図1を参照すると、この図には、供給ロール4上に支持されており且つこのロールから引き出される予備成形された不織ウェブ5の物理的性質及び特性、及び所望であれば大きさを変化させるための装置及び方法が参照番号3で示してある。本装置及び方法は、物理的性質が改善されており且つ寸法が変更された物理的に改良された不織ウェブを提供する。このような改善は、このような改善不織材料を組み込んだ使い捨て物品の性能及び装着性の両方を改善する。更に、開示の装置で改良した後、及び以下に説明する物理的性質を獲得した後、このような不織ウェブは、所望であれば、単独で又は他の材料と一緒に、及び改良不織ウェブに崩壊、破れ、又は一体性の欠如を被らせることなく、次のプロセスを行うことができる。
以下の表1の例番号1乃至7は、特定の構造及び大きさの歯を持つ相互係合したフォーミングロール間にウェブを通すことによって三つの異なる不織ウェブ材料を改良した結果得られた物理的性質の変化である。例1及び例2についての材料は、ノースカロライナ州シンプソンビルのファイバウェブノースアメリカ社から得られる第16006942号によって示されるカーデッド不織体である。例3及び例4についての材料は、バージニア州ウェインズボロのポリボンド社から得られる第81350号スタイルと表示される、不織材料の複合3層ウェブである。ここでは、含まれる複合材料は、溶融吹き出し不織体でできた内層及びこの内層の各綿と重なったスパンボンデッド不織体でできた外層である。例5、例6、及び例7についての材料は、ファイバウェブノースアメリカ社から得られる第13561A号によって示されるスパンボンデッド不織材料である。
上文中に説明した種類の改良不織ウェブを使用できる使い捨て吸収物品の構造構成部材の一例はバックシートである。この構成部材は、一般的には、物品の最外構成部材であり、物品の内部吸収性構成部材に吸収されて保持される体液又は滲出物の物品の通過に対して不透過性を提供する。本発明に従って改良した不織体は、中実で液体不透過性のポリマーフィルムの一方の表面に接合して軟質の布様外面をバックシート及び物品に与えることができる。バックシートの別の実施形態は、流体の通過に対して所望の不透過性を提供すると同時に、水蒸気を通過させることができ、更に好ましくは空気を通過させることができる。これらの性質を持つバックシートは、好ましくは、可撓性であり且つ柔軟であり、所望の軟質の布様外面を有し、液体に対して実質的に不透過性であるが水蒸気及び更に好ましくは空気に対して透過性である通気性のあるポリマーフィルムを含む。
フィルムに微孔を形成することによって、液体に対するポリマーフィルムの不透過性を維持しつつ、通気性をポリマーフィルムに与えることができる。所望の微孔の面積は、液体が通過しないようにするのに十分小さいが、これらの微孔は、空気及び水蒸気を通すことができる。微孔は、これらの微孔が設けられていない場合には中実のフィルムに、様々な方法で直接形成できる。これらの方法には、1975年5月6日にエドワード・ウォレンス・ハートレルに付与された「吸収装置用液体不透過性バックシート」という標題の米国特許第3,881,489号に開示されているようにフィルムに孔を設ける方法が含まれる。小孔は、フィルムを機械的に穿孔することによって設けることができるが、この技術は、装置の穿孔エレメントを厳密な許容差で制御することを必要とする。装置の穿孔エレメントは、穿孔エレメントの機械的摩耗により、形成する孔の大きさが経時的に徐々に大きくなる。微孔が大きくなると、望ましからぬことに、液体がこのようなフィルムを通過する。
先駆材料は、接合ステーション13で、熱積層化、接着剤積層化、押出しによる直接積層化、及び真空積層化を含む多くの方法で不織材料に接合できる。これらの方法の各々は当業者に既知である。先駆材料は、予備成形フィルムであるのがよく、不織材料に接合される前の時点で上文中に説明したように活性化させることによって通気性を与えることができる。しかしながら、好ましくは、先駆フィルム11及び改良不織ウェブ9aは、先駆フィルムを通気性にする前に接合され、この接合後、結果的に得られた複合ウェブ12を活性化ステーション16の適当なフォーミングロール間に通して先駆フィルムを局部的に延伸させることによって、複合ウェブのフィルム構成部材に通気性を提供することができる。これにより、不織ウェブの性質を所望の通りに改良でき、この改良と同時にフィルム及び/又は複合材料の望ましからぬ構造的一体化が起こることはない。
フィルム又は複合材料の通気性の一つの計測方法は、水蒸気の通過に対するフィルム又は複合材料の浸透性である。これは、フィルムの水蒸気透過速度(MVTR)によって反映される。使い捨ておむつの場合には、本明細書中上文中に説明したプロセスによって、又は本明細書中上文中に説明した品質を既に備えている複合材料でフィルムを使用することによって、例えば複合バックシートに通気性を与えることができる。これに関し、バックシート等の複合材料のMVTRは、好ましくは、約500g/m2 /24時間乃至約5000g/m2 /24時間であり、更に好ましくは約1000g/m2 /24時間乃至約4000g/m2 /24時間であり、最も好ましくは約2000g/m2 /24時間乃至約3000g/m2 /24時間である。
MVTR=(最終重量(g)−初期重量(g))×24.0
試料面積(m2 )×5時間
通気性フィルム又は複合材料の別の好ましい属性は、空気の通過に対する透過性である。これは、材料の酸素透過速度(OPR)を計測する試験によって評価できる。使い捨ておむつのバックシート等の構成部材の部分として使用される場合、使い捨て複合材料は、周囲空気がバックシートを通っておむつ内に入ることができるように、好ましくは、約2m3 O2 /m2 /24時間乃至約20m3 O2 /m2 /24時間の酸素透過速度を備えていなければならない。これは、おむつ内の雰囲気と周囲大気との間で実質的に熱的に均衡させるためである。その結果、着用時におむつ内部で過剰の熱が発生することがなく、着用者の快適性が向上する。
OPR=(容積(ml))×(8.63×10 -1 )
平均時間(秒)
ここで、
(8.63×10-1)は、酸素移行速度の傾き(時間を分で表した、酸素レベルの%変化(0.5%))を組み込んだ定数である。酸素レベルが1%である場合には、分を日に変換し、フィルム試料の坪量積は5.0×10-4m2 である。
平均時間は、酸素濃度の0.5%上昇と関連した時間間隔の平均値である。
バックシート等の構成部材に水蒸気及び更に好ましくは空気に対する或る程度の浸透性を加えた場合、液体に対する構成部材の不浸透性が大幅に低下することがないということが重要である。バックシートの構成部材に荷重が加わっていない場合、液体に対する不浸透性、及び水蒸気及び好ましくは空気に対する浸透性といった所望の属性に加え、吸収物品に衝撃荷重が加わった場合でも、構成部材の液体に対する大きな不浸透性が維持されるのが望ましい。このような荷重は、例えば、おむつを着用している乳児が立った状態から座った状態にいきなり移行した場合におむつのバックシートに加わる。これに関し、衝撃が加わった状態での液体に対する浸透性が約10g/m2 よりも小さく、更に好ましくは約5g/m2 よりも小さく、最も好ましくは約2.5g/m2 よりも小さいことが好ましい。
DIV=濾紙の質量変化(g)
衝撃面積(m2 )
通気性バックシートとして通気性吸収物品に組み込むことができる通気性の布様複合シートを、図18にブロックダイヤグラムの形態で示す方法工程に従って形成する。初期不織ウェブはスパンボンデッドポリプロピレン繊維のウェブであり、ファイバウェブノースアメリカ社から得られ、指定型式が13561A.20.0であり、先駆フィルムはオハイオ州シンシナチのクロペープラスチックス社から得られるポリエチレン材料であり、指定型式がP18−3931であり、改良後にこれらの材料を接合するのに使用される接着剤は、ウィスコンシン州ワウワトサのアト−フィンドレー社から得られるH−2031型であり、材料間に3.1g/m2 で均等に塗布される。
MVTR 2900g/m2 /24時間
水分衝撃 2.04g/m2
酸素透過 11.1m3 O2 /m2 /24時間
成長 フォーミング−拡張工程316の後、20%
本明細書中上文中に説明した改良不織ウェブ及びポリマーフィルムの組み合わせに加え、改良不織ウェブを或る程度の弾性を持つ材料でできた可撓性ウェブに接合することによっても複合ウェブを提供できる。改良不織ウェブが延長可能であり、エラストマー製ウェブが弾性であるため、このような構成部材の両方を含む複合ウェブ構造は、弾性であり且つ使い捨て吸収物品の延長可能な構成部材として使用できる別の材料を提供する。
本明細書中上文中に説明したように、改良不織体を含む本発明に従って製造された複合構造は、有利には、使い捨ておむつの構成部材として使用される。以下の議論は、このような物品の構造に関する追加の情報を提供する。これに関し、及び使い捨て吸収物品について、「吸収物品」という用語は、全体として、身体の滲出物を吸収して収容するための装置に関する。更に詳細には、身体から排出された様々な滲出物を吸収して収容するために着用者の身体に当てて又は身体の近くに配置される装置に関する。
Claims (4)
- 予備形成したウェブを改良するための方法であって、
a.初期幅、初期厚さ、初期坪量、ウェブに対して横方向で10%伸長するための初期荷重、ウェブに対して横方向で30%伸長するための初期荷重、ウェブに対して横方向の初期強度、及びウェブに対して横方向の初期伸長性を持つ、実質的に張力が加わっていない、予備形成したウェブを、向き合った第1の一対の相互係合したフォーミングロールにウェブ移動方向で供給する工程、
b.第1の一対の相互係合したフォーミングロールの間でこれらのフォーミングロールによって画成されたニップのところでウェブをグリップする工程であって、各フォーミングロールは、軸線方向に間隔が隔てられた周方向に延びる複数の交互の半径方向歯及び介在溝を含み、一方のロールの歯は向き合ったロールの溝と向き合っており且つこれらの溝内に延びる、工程、
c.第1の一対の相互係合したフォーミングロール間をウェブが通過するとき及びロールが反対方向に回転して前記ウェブをウェブ移動方向に対して実質的に垂直なウェブに対して横方向で増加延伸するとき、ウェブに横方向増加延伸を加えることによってウェブを改良し、ウェブに引張引き出し力をウェブ移動方向で加えることによってウェブを第1の一対の相互係合したフォーミングロール間から引き出す工程、及び
d.向き合った第2の一対の相互係合したフォーミングロールにウェブ移動方向でウェブを供給する工程、
を備えた方法において、ウェブは繊維質不織ウェブであり、前記方法は、さらに、
e.工程fを行う前に、改良した不織ウェブをポリマーフィルムに面と面とを向き合わせた関係で接合して複合材料を形成する工程、
f.第2の一対の相互係合したフォーミングロール間でこれらのフォーミングロールによって画成されたニップのところで複合積層体をグリップする工程であって、各フォーミングロールは、軸線方向に間隔が隔てられた周方向に延びる複数の交互の半径方向歯及び介在溝を含み、一方のロールの歯は向き合ったロールの溝と向き合っており且つこれらの溝内に延びる、工程、及び
g.第2の一対の相互係合したフォーミングロール間を積層体が通過し、ロールが反対方向に回転するときに積層体に横方向増加延伸を加え、積層体を積層体移動方向に対して実質的に垂直なウェブに対して横方向で増加延伸させることによって積層体を更に改良し、積層体に引張引き出し力をウェブ移動方向で加えることによって積層体を相互係合した第2の一対のフォーミングロール間から引き出す工程であって、結果的に得られた改良ウェブを10%伸長するための改良された荷重は、10%伸長するための初期荷重の5%乃至100%であり、30%伸長するための改良された荷重は、30%伸長するための初期荷重の5%乃至100%であり、ウェブに対して横方向の改良された強度は、ウェブに対して横方向の初期強度の10%乃至70%であり、ウェブに対して横方向の改良された伸長性は、ウェブに対して横方向の初期伸長性の105%乃至200%である、工程を含む方法。 - 請求項1に記載の方法において、二対のフォーミングロールの一方の対を構成するフォーミングロールは、周方向で連続した歯及び溝を各々有し、二対のフォーミングロールの他方の対を構成するフォーミングロールの少なくとも一方の歯は、間隔が隔てられた複数の周方向凹所を含む、方法。
- 請求項1又は2に記載の方法において、ポリマーフィルムは、このフィルムに亘って実質的に均等に分散された不相容性無機材料を含み、この無機材料は、炭酸カルシウム、粘土、二酸化チタン、及びこれらの混合物からなる群から選択され、接合された改良不織ウェブ及びポリマーフィルムを第2の一対の相互係合したフォーミングロール間に通し、フィルムに引張力を加えてポリマー母材を延伸し、熱可塑性ポリマーを不相容性材料から局部的に分離し、フィルムに微孔を形成する、方法。
- 請求項1乃至3のいずれか一項に記載の方法において、ポリマーフィルムは通気性のモノリシックフィルムである、方法。
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US09/274,946 US6383431B1 (en) | 1997-04-04 | 1999-03-23 | Method of modifying a nonwoven fibrous web for use as component of a disposable absorbent article |
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JP2010011190A Expired - Fee Related JP4927184B2 (ja) | 1999-03-23 | 2010-01-21 | 使い捨て吸収物品の構成部材として使用するための繊維質不織ウェブの改良方法 |
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-
1999
- 1999-03-23 US US09/274,946 patent/US6383431B1/en not_active Expired - Lifetime
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2000
- 2000-03-22 WO PCT/US2000/007583 patent/WO2000056522A1/en active IP Right Grant
- 2000-03-22 EP EP00918243A patent/EP1163102B1/en not_active Expired - Lifetime
- 2000-03-22 CA CA002362678A patent/CA2362678A1/en not_active Abandoned
- 2000-03-22 AT AT00918243T patent/ATE294695T1/de not_active IP Right Cessation
- 2000-03-22 AU AU39089/00A patent/AU3908900A/en not_active Abandoned
- 2000-03-22 JP JP2000606405A patent/JP4898003B2/ja not_active Expired - Fee Related
- 2000-03-22 DE DE60019909T patent/DE60019909T2/de not_active Expired - Lifetime
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- 2000-03-23 PE PE2000000250A patent/PE20001346A1/es not_active Application Discontinuation
- 2000-04-11 TW TW089105333A patent/TW464604B/zh active
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2002
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2010
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US20020105110A1 (en) | 2002-08-08 |
WO2000056522A1 (en) | 2000-09-28 |
TW464604B (en) | 2001-11-21 |
DE60019909D1 (de) | 2005-06-09 |
CA2362678A1 (en) | 2000-09-28 |
DE60019909T2 (de) | 2006-02-16 |
ATE294695T1 (de) | 2005-05-15 |
AU3908900A (en) | 2000-10-09 |
JP2002540299A (ja) | 2002-11-26 |
AR018703A1 (es) | 2001-11-28 |
PE20001346A1 (es) | 2001-02-03 |
EP1163102A1 (en) | 2001-12-19 |
JP4898003B2 (ja) | 2012-03-14 |
US6383431B1 (en) | 2002-05-07 |
JP2010119861A (ja) | 2010-06-03 |
EP1163102B1 (en) | 2005-05-04 |
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