JP5475012B2 - 吸収性物品のための押出接着された積層体 - Google Patents
吸収性物品のための押出接着された積層体 Download PDFInfo
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- JP5475012B2 JP5475012B2 JP2011547915A JP2011547915A JP5475012B2 JP 5475012 B2 JP5475012 B2 JP 5475012B2 JP 2011547915 A JP2011547915 A JP 2011547915A JP 2011547915 A JP2011547915 A JP 2011547915A JP 5475012 B2 JP5475012 B2 JP 5475012B2
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- Prior art keywords
- film
- layer
- laminate
- nonwoven
- polymer
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Description
本明細書で使用する場合、以下の用語は下記で指定される意味を有する。
図1を参照すると、本発明のEBLは、エラストマーフィルム(多数の(例えば、A1、B、及びA2)を含んでもよい)フィルム層に接合される(例えば、SMS、SSmmS等の多層を含んでもよい)少なくとも1つの不織布(NW1)を含んでもよい。本発明のエラストマーフィルムが、少なくとも1つの結合層(A1)及び少なくとも1つのコア層(B)を含んでもよい。ある実施形態において、本発明の吸収性物品に有用な積層体が、表面薄層(A2)を含んでもよく、これは、組成的に結合層に全く同じであってもよい。本発明の更なる実施形態は、((1)第1の不織布(NW1)が、第1の結合層(A1)を介してEBLに接合され、かつ第2の不織布(NW2)が、第2の結合層(A2)を介してEBLに接合される、又は(2)第1の不織布(NW1)が、第1の結合層(A1)を介してEBLに接合され、かつ第2の不織布(NW2)が、接着剤を介してBLに接合されるような)2つの不織布を含んでもよい。なお更に、図6A、6B、及び6Cに示されるように、本発明の実施形態は、1つ以上の接着剤(「接着補助剤(adhesive assist)」として称される場合がある)と組み合わせて結合層を介してフィルムに接合される不織布を含んでもよい。接着剤1及び2は、組成的に同質であっても、又は異なってもよい。更に、接着剤1及び2を、同一又は異なる手段(例えば、接着剤2を噴霧しながら、接着剤1を、スロットコーティングしてもよい)によって塗布してもよい。図7及び8は、上記のように、本発明の吸収性物品に有用なEBLの追加の実施形態を例証する。
エラストマーフィルムの1つ以上の層(図1の層A1、B、及びA2として例示される)は、積層体の使用中、所望の量の伸張及び回復力を提供してもよい。上述のように、エラストマーフィルムが、1つ以上のフィルム層を含んでもよい。エラストマーフィルムの1つ以上の層に使用されてもよい多くの好適な弾力性のある材料は、合成又は天然ゴム(例えば、架橋ポリイソプレン、ポリブタジエン及びそれらの飽和変形物(水素添加後)、及びポリイソブチレン)、ポリスチレンブロック(例えば、スチレン−イソプレン−スチレン、スチレン−ブタジエン−スチレン、スチレン−エチレン/ブチレン−スチレン、スチレン−エチレン/プロピレン−スチレン、並びにスチレン−ブタジエン/イソプレン−スチレン(それらの水素添加及び非水素添加形態のものを含む))と共重合されたゴムエラストマーブロックを含むもののような多元ブロックコポリマーに基づく熱塑性エラストマー、ポリウレタン、ポリエステル、ポリエーテルアミド、エラストマーポリオレフィン(ポリエチレン及びポリプロピレンを含む)、エラストマーポリポリオレフィンブレンド、並びにこれらの組み合わせが挙げられる。
本発明のエラストマーフィルムが、不織布と混合されてもよい。(図1のNW1及びNW2に例示されるように)不織布が、布地等のシート状の材料に活性化可能であってもよい。本発明の不織布が、メルトブロー、エアレイイング、コフォーム、及びカーディング等の工程を用いながら、不規則な方法で挿入される繊維から一般的に形成される。いくつかの実施形態において、不織布が、単層(S)又は多層(SSS)において、スパンボンド繊維を含んでもよい。他の実施形態において、異なる直径又は組成物の繊維が、単層において共にブレンドされてもよい、又は異なる直径又は組成物の繊維が、スパンボンド−メルトブローン−スパンボンド(SMS)構造及びスパンボンド−スパンボンド−メルトブローン−メルトブローン−スパンボンド(SSMMS)構造等の場合、多層において存在してもよい。不織布材料の繊維が、従来技術、例えば、熱点接着、超音波点接着、接着剤パターン接着、及び接着剤スプレー接着を用いて互いに接合されてもよい。本発明に有用な活性化可能な不織布の例としては、米国特許第6,417,121号に記載されるものが挙げられる。
本発明のエラストマー積層体のエラストマーフィルムと不織布との間の接着強度の制御は、本発明の重要な態様である。接着強度が、試験方法の下で記載されるように、モードII剥離を用いて測定されてもよい。層間の改善された接着強度が、多くの方法によって達成され得、これは、積層方法に依存する。層が、接着方法によって、積層される場合、接着剤の選択、接着剤の量、及び層を接着するために適用される接着剤のパターンを調整して、所望の接着強度を達成することができる。更に、本発明のEBLに関しては、フィルムと不織布との間の接着強度が、フィルムと不織布との間の化学親和力を最適化する(接着強度を増加又は低下させることを含む)ために選択されてもよく、(図1のA1及びA2として例示される)結合層の使用によって制御されてもよい。特に、エチレンとプロピレンのコポリマー、又はエチレン系及びプロピレン系ポリマーのブレンドを含有する結合層を、「調整(tuned)」して、コポリマーのエチレン含有物の適切な選択によって、最適化学親和力を不織布に提供することができる。例えば、ポリエチレンシースを備える2成分不織布を含む積層体において、PEホモポリマーを含有する結合層は、不織布を有する化学親和力が高すぎる場合がある一方、PPホモポリマーを含有する結合層は、一般的に化学親和力が低すぎる。中間体のエチレン含有物(10〜97重量%)を備えるエチレン−プロピレンコポリマーを含む結合層は、活性化プロセス中、層間剥離を回避するには十分な接着であるが、フィルムにおいて望ましくないピンホールを生じるには十分でない、フィルムと不織布との間に最適接着を必要とする化学親和力を提供する。
エラストマーフィルムを使用する課題は、フィルムを作製するために使用したポリマーが、本質的にべたっとする又はべとつくことである。エラストマーフィルムが、押出しされ、ロールに巻き付けられる際、フィルムが、それ自体に貼り付ける又は「ブロッキング(block)」する傾向にあり、これによって、解巻が困難である、又は不可能になる。フィルムが古くなる、又は保管倉庫内等の温暖な環境で保存される場合、ブロッキングは、更に明白になる。同様の問題は、フィルムの粘着性表面が、巻きつける際、二重積層体の対向する表面の実質的な部分と密接に接触するため、エラストマーフィルムが不織布に押出しされ、二重積層体を作製し、ロールに巻きつけられる場合、存在する。これは、吸収性物品を作製する工程における商業的速度でのロールの解巻を防ぎ得、フィルム、不織布、又は双方への損傷をもたらす場合がある。
EBLの層の一層又は混合は、ドローダウンポリマーの一層又は混合を含み得る。ドローダウンポリマーの一層又は混合が、2つ以上の層に存在する実施形態において、それぞれの層のドローダウンポリマーの量(重量%)は、同等であってもよく、又は異なってもよい。更に、第1の層に存在するドローダウンポリマー又はドローダウンポリマーのブレンドの組成物は、組成的に、第2の層に存在するドローダウンポリマー又はドローダウンポリマーのブレンドと同質であってもよく、又は異なってもよい。ドローダウンポリマーは、フィルム調製中、加工性に役立つもののような1つ以上のフィルム特性又は加工特性を添加する又は強化するポリマーである。例えば、ドローダウンポリマーは、低ゲージ(すなわち、薄)フィルムの製造に役立ち得る。いくつかの実施形態において、ドローダウンポリマーは、増加させたライン速度又は低下させたドローレゾナンスを提供するのを補助することによって、フィルム押出に役立てることができる。追加のドローダウンポリマーからの他の可能な加工性効果には、メルトカーテンの安定性を改善する、平滑フィルム表面を提供する、より低粘度のポリマー溶解を提供する、加熱へのより良好な耐性を提供する(例えば、フィルムの熱容量又は熱安定性を増加させる)、引き裂きへの耐性を提供する、ピンホール形成への耐性を提供する、制御された均一の厚さを提供する、又は均質組成物を提供することが挙げられる。ドローダウンポリマーは、(例えば、エラストマーポリマーの)粘着及び溶解エラストマー樹脂の流動抵抗を軽減するためにダイを潤滑する加工助剤としての役割を果たすことができる。当然のことながら、ドローダウンポリマーの添加により、フィルム押出し又は加工性へのこれらの助剤の1つ又は混合を提供することができる。
図1を参照すると、接着剤は、NW1とA1との間及び/又はA2とNW2との間に使用されてもよい。接着剤は、例えば、スロット塗布機及び/又は噴霧器を介して適用されるホットメルト接着剤であってもよい。一実施例によると、接着剤は、H2031、H2401、又はH2861であってもよく、これらは、Bostik Inc.(Wauwatosa,Wisconsin)より入手可能である。接着助剤を用いて、接着剤は、フィルム押出品を接合する直前に、不織布の表面(例えば、NW1)に、それを適用することによって、EBLの製作中、特に、結合層(例えば、A1)に適用されてもよい。更に、本発明によると、第2の不織布(例えば、NW2)は、EBLの外層(例えば、A2)とともに接着積層されてもよい。なお更に、(第1及び第2の不織布(例えば、それぞれ、NW1及びNW2)を含んでもよい)本発明のEBLは、吸収性コア、ウエストバンド、カフ、トップシート等を含む、吸収性物品の1つ以上の構成要素に接着接合されてもよい。
本発明の押出接着された積層体のいくつかの物理的特性は、吸収性物品の作製及び保存に影響を及ぼす、並びに、積層体が、吸収性物品の一部として、いかに機能するかについて示すものである。例えば、表面薄層(A2)の粘着度は、保存後、積層体を解巻する能力に作用する。活性化プロセスから生じるエラストマー層のピンホールは、積層体に水を透過させ得、積層体の引き裂きを生じる場合がある。層の接着強度が強すぎる場合、積層体の活性化は、損なわれないで、層の接着強度が弱すぎる場合、積層体の層は、剥離される場合がある。更に、積層体の引張強度及びヒステリシスは、吸収性物品の一体性及び咬合に影響を及ぼし得る。表5〜8は、実施例1〜26(実施例5、6、12、13、19、21は、比較である)のいくつかのパラメーターを例示する。本発明の吸収性物品に有用な積層体が、表5〜8に例示されるパラメーターを超えるような、以下の項に開示されるようにパラメーターを有し得る。
本発明の積層体は、バックシート、外側カバー、サイドパネル、ウエストバンド、前若しくは後耳、及びこれらの組み合わせを含む、吸収性物品の1つ以上の構成要素の少なくとも一部を構成してもよい。例えば、本発明の積層体は、米国公開特許第2005/0171499号、同第2008/0208155号、同第2007/0167929号、及び同第2008−0045917号に開示される、パンツ又はおむつの外側カバーの一部を構成してもよい。積層体は、吸収性物品への組み込みの前後の追加のプロセス工程に従ってもよい。例えば、EBLを含む吸収性物品の1つ以上の構成要素は、不織布層、結合層、及び/又は表面薄層を増分的に延伸、変形させる又は分解するために、噛み合いのホイール(リングロール(ring rolling))からそれを通過させることによって、活性化されてもよい。更に、EBLを含む吸収性物品の1つ以上の構成要素は、着用した際、材料を通して空気流を改善し、吸収性物品の快適さを改善するために、開口してもよい。EBLは、印刷、エンボス加工、非平滑化、又は同様に修正し、吸収性物品の審美性を改善してもよく、又は更に着用者に対してある機能若しくはフィードバックを与え得る。
押出接着された積層体の実施例は、表1、2、3及び9(1つの不織布を有する二重積層体)並びに表4及び表10(2つの不織布を有する三重積層体)に記載され、それぞれの実施例のフィルム構造(単層又は多層)、フィルム構成要素、フィルム坪量及び不織布の詳細を提供する。表4及び表10の例は、図1と関連して読むことができ、第1の不織布(NW1)、結合層(A1)、コア層(B)、及び表面薄層若しくは第2の結合層(A2)を含むフィルム、並びに第2の不織布(NW2)を例示する。全ての例(実施例5及び12を除く)のフィルムコアの組成物は、92% VISTAMAXX 6102(ExxonMobil(Houston Texas)より入手可能)、1% Ampacet 10562(加工助剤)及び7% Ampacet 110361(70% TiO2を有する白色マスターバッチ)の重量%ブレンドである。Ampacet材料は、Ampacet Corporation(Cincinnati,Ohio)より入手可能である。実施例5及び12のフィルムコアの組成物は、92% Infuse 9107(The Dow Chemical Company(Midland,Michigan)より入手可能)、1% Ampacet 10562及び7% Ampacet 110361の重量%ブレンドである。実施例5、12、6、13、19及び21は、結合層(A1)及び表面薄層(A2)のない単層フィルムを備える押出接着された積層体である。実施例7及び14は、コアフィルム及び表面薄層(BA2)を備え、結合層(A1なし)を有さない押出接着された積層体であり、表面薄層(A2)は、82% Elite 5800(ドローダウンポリマー)(The Dow Chemical Company(Midland,Michigan)より入手可能)、9% Fina 3868(Total Petrochemicals(Houston,Texas)より入手可能)、1% Luvofilm 9679(Lehmann & Voss & Company(Hamburg,Germany)より入手可能)及び8% PE 20 S(Polytechs SAS(Cany Barville,France)より入手可能な粘着防止剤)の重量%ブレンドである。実施例25及び26は、コアフィルム及び表面薄層(BA2)を備え、結合層(A1なし)を有さない押出接着された積層体であり、表面薄層(A2)は、50% Elite 5800(ドローダウンポリマー)、32% Equistar M6060(Equistar Chemicals,LP(Cincinnati,Ohio)、LyondellBasell Industriesの子会社より入手可能)9% Fina 3868、1% Luvofilm 9679及び8% Polytech PE 20 Sの重量%ブレンドである。
融合指数
融合指数は、ASTM D3418−08「Standard Test Method for Transition Temperatures and Enthalpies of Fusion and Crystallization of Polymers by Differential Scanning Calorimetry」によって規定される測定によって決定される。材料の融解エンタルピー、すなわち、ASTM D3418に従って測定した際に、ジュール/グラムにおいて表される材料の融合指数を決定するために、208J/gで割られるものとする。例えば、実験的に決定された100J/gの融合エンタルピーを有するポリプロピレンの融合指数は、((100/208)*100%)=48.1%として算出される。別の例として、実験的に決定された30J/gの融合エンタルピーを持つPEの融合指数は、((30/208)*100%)=14.4%として算出される。
ASTM D 3418に従って示差走査熱量計(DSC)測定を実行し、DSCサンプルは、ポリマー組成物をテフロンシートの間で、約140℃でおよそ0.0076cm(0.003インチ)の薄フィルムに圧縮成形することによって調製する。フィルムは、真空を引いた真空炉中で、約65℃の温度で一晩焼きなまされた。サンプルは、6ミリメートル直径の皮膚生検パンチを使用して、生じたフィルムから打ち出された。サンプルは、約5〜10ミリグラムを一塊にし、蓋付きの小さなアルミニウムの鍋(Perkin Elmer #0219−0041)に充填し、Perkin Elmer Standard Sample Pan Crimper Press(#0219−0048)を使用してしわ形成する。加熱試験及びその後の分析は、Perkin Elmer Thermal Analyses Softwareのバージョン4.00を備えるPerkin Elmer DSC 7を使用して実行する。
本測定の全工程は、23℃±2℃の温度、及び50%±5%の相対湿度に維持した部屋で行われる。
材料及び装置(以下は全て同じ部屋に設置されなければならない)
欠陥、切り込み、刻み目等のない縁部を有する標本の調製用:
・鋭い#11のXactoナイフブレード又は類似物を備えるナイフ
・ナイフのガイドとしてスチール直定規を使用する
・切り取る間に材料を挟持する業務用印刷/コピー用紙
サンプルの条件付け用
・埃、エアゾール等の汚染物質を含まないようにサンプルを適度に保つことを可能にする、好適なトレイ又は棚
加圧用
・バッフルを開けた、46℃に設定した実験用オーブン(Despach LAC又は等価物)。
・サンプルに0.686MPaの圧縮圧力を適用するための、好適な重量で、平坦な剛性のプレート。
・単一の狭帯域に沿ってはっきりと画定された接触領域を提供するグリップであって、応力を試験する方向に垂直な軸線に沿ってサンプルを保持し、ASTM D882に提供される説明に一致する、グリップを供える、MTS Alliance RT/1又は類似の機能の機械。
2.各サンプルの身体に面する不織布側が上を向くように端部を揃えて、5つのサンプルを互いの上に直接積み重ねる。スタック内の各サンプルは、全て一貫してMD又はCDに揃えられるべきである。
3.5つのストリップの1つ以上のスタックを、46℃±2℃の温度で100時間±1時間、実験用オーブン内で0.686MPaの圧縮負荷に供する。引張試験機のグリップへのその後の装着を容易にするために、ストリップの端の数ミリメートルを圧縮せずに残す。
4.標本から圧力を除去する。
5.オーブンから標本を取り出し、45分±15分間、23℃±2℃の温度及び50%±5%の相対湿度で平衡化させる。
6.一度に1つの境界面を試験し、スタックをT剥離構成の引張試験機のグリップに装着し、100mmの距離、あるいは150mmより短い標本の場合は、それぞれの小片が完全に分離するまで、クロスヘッドを2.12mm/秒(毎分5インチの速度)で走らせる。剥離試験の間に遭遇した最大力の信頼できる指標を提供する、データ収集技術を使用すること。
押出接着された積層体の力対工学的歪曲線を決定するために、本方法を使用する。材料の引張特性を、以下に記載の仕様のASTM方法D882−02に従って測定した。測定は、23℃±2℃の温度で、50.8cm/分の一定のクロスヘッド速度で行う。伸張長さと工学的引張の工学的歪γ引張との関係は、以下の等式によって与えられる。
モードI T−剥離引張試験方法は、室温(23℃±2℃)にて実施される。試験される材料は、実質的に直線形状に切り取られる。サンプル寸法は、計器に適切な力によって、必要な歪が得られるように選択されるべきである。好適なサンプル寸法は、幅約25.4mmで、長さ約100mmである。しかしながら、長さ100mmの標本の材料の入手が困難な場合、より短い標本を使用してもよい。サンプルの長さは、延伸の軸に垂直方向である。好適な計器、グリップ、グリップ面、データ収集のためのソフトウェア、演算、報告書、及び歪率の定義を、上の引張試験(モードII)方法の項に記載する。
この方法は、消費者が押出接着された積層体を含有する製品の適用中に受ける力と相関し得る特性を決定し、また、適用されると製品がどのように適するかを決定するのに使用される。
(2)254mm/分の一定のクロスヘッド速度にて、指定された工学的歪率(すなわち、工学的歪=130%)を達成するまでクロスヘッドを移動する。例えば、セグメント1から調節された標点距離は、26.00mmであり、サンプルは、59.80mmまで延伸され、%工学的歪=((59.80/26.00)−1)*100=130%である。
(3)指定された工学的歪率(すなわち、工学的歪=130%)にて、30秒間サンプルを保持する。
(4)254mm/分の一定のクロスヘッド速度にて、工学的歪を0%工学的歪まで低下させる(すなわち、調節されたゲージ長までグリップを戻す)。
(5)0%工学的歪で、60秒間、サンプルを保持する(セグメント1〜5の完全サイクル1)。
(6)2サイクルヒステリシス試験の第2のサイクルが完了するまで、セグメント2〜5を繰り返す。
直上の2サイクルヒステリシス試験を参照のこと。
Claims (10)
- トップシートと、
外側カバーと、
前記トップシートと外側カバーとの間に配置される吸収性コアと、
を含む、吸収性物品であって、
前記外側カバーが、押出接着された積層体を含み、前記押出接着された積層体が、
コア層、第1の外層、及び第2の外層を含む、多層の共押出しされたエラストマーフィルムであって、前記コア層が、前記第1の外層と第2の外層との間にある、多層の共押出しされたエラストマーフィルムと、
繊維及び/又は長繊維からなる不織布と、を含み、
前記第1の外層が、押出被覆によって前記不織布に非接着接合され、
前記外側カバーが、少なくとも50%の工学的歪に対して弾力性があり、
前記不織布が、前記第1の外層に対して、0〜1.49MPa^0.5の溶解度パラメーターの差異を有し、
前記第1の外層が、前記コア層に対して、2.5MPa^0.5以上の溶解度パラメーターの差異を有し、
前記第1の外層が、45重量%を超える量のドローダウンポリマーを含む、吸収性物品。 - 前記押出接着された積層体は、弾性延伸性が付与されている、請求項1に記載の吸収性物品。
- 前記第1及び第2の外層が、10%〜40%の融合指数を有する、請求項1又は2に記載の吸収性物品。
- 前記不織布が、2成分繊維を含み、前記繊維が、コア及びシースを含む、請求項1〜3のいずれか一項に記載の吸収性物品。
- 前記シースが、ポリエチレンを含み、前記コアが、ポリプロピレンを含む、請求項4に記載の吸収性物品。
- 前記エラストマーフィルムの前記コア層が、5%〜20%の融合指数を有するエチレンコポリマー、5%〜20%の融合指数を有するプロピレンコポリマー、及びこれらの組み合わせからなる群から選択される、請求項1〜5のいずれか一項に記載の吸収性物品。
- 前記第1の外層が、10重量%を超えるエチレンを含む少なくとも45%のポリマーを含む、請求項1〜6のいずれか一項に記載の吸収性物品。
- 前記第2の外層に接合された第2の不織布を更に含む、請求項1〜7のいずれか一項に記載の吸収性物品。
- 引張試験(モードII)によって測定した際に、前記積層体の接着強度が、2.2〜3.5N/cmである、請求項1〜8のいずれか一項に記載の吸収性物品。
- 前記エラストマーフィルムが、
少なくとも1つのオレフィン系エラストマーポリマーと、
少なくとも1つのドローダウンポリマーと、を含み、
前記エラストマーフィルムが、100%の最大工学的歪を用いて、2サイクルヒステリシス試験法によって測定した際に、15%以下の永久歪を有する、請求項1〜9のいずれか一項に記載の吸収性物品。
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- 2009-07-22 RU RU2011123105/12A patent/RU2492840C2/ru not_active IP Right Cessation
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- 2009-07-22 SG SG2011052727A patent/SG173084A1/en unknown
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- 2009-07-22 JP JP2011547915A patent/JP5475012B2/ja not_active Expired - Fee Related
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US8168853B2 (en) | 2012-05-01 |
CA2750360A1 (en) | 2010-07-29 |
MX2011007575A (es) | 2011-09-28 |
AU2009338132A1 (en) | 2011-08-04 |
JP2012515610A (ja) | 2012-07-12 |
US20160015576A1 (en) | 2016-01-21 |
ZA201104427B (en) | 2014-11-26 |
EP2381908A1 (en) | 2011-11-02 |
US9169384B2 (en) | 2015-10-27 |
SG173084A1 (en) | 2011-08-29 |
RU2011123105A (ru) | 2012-12-20 |
US10500107B2 (en) | 2019-12-10 |
CN102292056A (zh) | 2011-12-21 |
RU2492840C2 (ru) | 2013-09-20 |
CN102292056B (zh) | 2014-04-16 |
US20120184169A1 (en) | 2012-07-19 |
US20090264844A1 (en) | 2009-10-22 |
WO2010085280A1 (en) | 2010-07-29 |
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