JP6352351B2 - 吸収性物品のための積層体の製造方法 - Google Patents
吸収性物品のための積層体の製造方法 Download PDFInfo
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- JP6352351B2 JP6352351B2 JP2016159969A JP2016159969A JP6352351B2 JP 6352351 B2 JP6352351 B2 JP 6352351B2 JP 2016159969 A JP2016159969 A JP 2016159969A JP 2016159969 A JP2016159969 A JP 2016159969A JP 6352351 B2 JP6352351 B2 JP 6352351B2
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Description
「吸収性物品(1つ以上)」は、本明細書では、その主な機能が汚れ及び排泄物を吸収し保持することである、消費者製品を指すのに使用される。吸収性物品は、パンツ型及び/又はテープ式おむつを指してもよい。用語「おむつ」及び「パンツ」は、本明細書では、一般に、乳児、小児、及び失禁症状のある人によって下部胴体の周りに着用される吸収性物品を指すのに使用される。用語「使い捨て」は、本明細書では、洗濯又は別の方法で吸収性物品として復元若しくは再使用することを一般に意図しない吸収性物品を説明するのに使用される(例えば、それらの物品は、1回の使用後に廃棄することが意図され、またリサイクルするか、堆肥化するか、又は別の方法として環境に適応した形で処分するように構成されても良い)。
パンツは、吸収性物品が着用者に適用される前は、連続した又は閉じた腰部開口部と、少なくとも1つの連続した閉じた脚部開口部とを有して構成されてもよい。パンツは、任意の再締結可能及び/又は恒久的なクロージャ部材(例えば、シーム、熱接着、圧力溶接、接着剤、粘着結合、機械的締結具など)を使用して、物品の一部を共に接合することが挙げられるが、それに限定されない、様々な技術によって予備成形されてもよい。パンツは、腰部領域における物品の周辺に沿った任意の場所で予備成形されてもよい(例えば、側部が締結されるか又は継ぎ合わされるか、前側腰部が締結されるか又は継ぎ合わされるか、後側腰部が締結されるか又は継ぎ合わされる)。パンツは、側部シームの一方又は両方の辺りで開かれ、次に再締結されてもよい。様々な構成のおむつパンツの例が、米国特許第5,246,433号、同第5,569,234号、同第6,120,487号、同第6,120,489号、同第4,940,464号、同第5,092,861号、同第5,897,545号、同第5,957,908号、及び米国特許公開第2003/0233082号に開示されている。
図1は、衣類に面する表面が見る者の方に向いている、テープ式おむつ100Tの平面図の一例を示す。図1Aは、着用者に面する表面が見る者の方に向いている、テープ式おむつ100Tの平面図を示す。図1及び1Aに示されるテープ式おむつ100Tは、シャーシ102と、第1の後側耳部104及び第2の後側耳部106を備えるベルト部分103と、第1の前側耳部108及び第2の前側耳部110とを備えてもよい。第1の後側耳部104及び第2の後側耳部106は、ベルト部分103と一体的に形成されてもよい。ベルト部分103は、1つ以上の弾性要素又は弾性スタンド105を中に備えてもよい。図示されていないが、前側耳部108及び110は、弾性要素又はストランドを備える第2のベルト部分から形成されてもよい。図2は、衣類に面する表面が見る者の方に向いている、平らに広げられた状態のおむつパンツ100Pの平面図を示す。図2に示されるパンツ型おむつ100Pもまた、シャーシ102と、第1のベルト耳部112及び第2のベルト耳部114を備えるか又は形成する、ベルト部分111とを備える。ベルト部分111もまた、中に位置付けられた弾性要素又は弾性ストランド105を備えてもよい。図3は、衣類に面する表面が見る者の方に向いている、平らに広げられた状態のおむつパンツ100P及びシャーシ102を示す。しかしながら、図3のおむつパンツ100Pは、第2のベルト部分111bに形成された第1の後側ベルト耳部112b及び第2の後側ベルト耳部114bと、第1のベルト部分111aに形成された第1の前側ベルト耳部112a及び第2の前側ベルト耳部114bとを備える。様々な実施形態では、ベルト部分111b及び111aは、シャーシ102から横方向及び長手方向の両方で延在してもよく、着用者に面する表面又は衣類に面する表面のどちらかでシャーシ102に接合されてもよく、或いは、シャーシ102の一部分を形成するのに使用される材料の1つ以上と一体的に形成されてもよい。
締結システム及び/又は締結構成要素162、164のいくつかの例が、米国特許第3,848,594号、同第4,662,875号、同第4,846,815号、同第4,894,060号、同第4,946,527号、同第5,151,092号、同第5,221,274号、同第6,251,097号、同第6,669,618号、同第6,432,098号、及び同第7,799,006号、並びに米国特許公開第2007/0078427号において考察されている。
接続区域168は、テープ式おむつ100Tのシャーシ102又はベルト部分と接続された、別個の基材から構築されてもよいことを理解されたい。いくつかの実施形態では、米国特許第5,735,840号及び同第5,928,212号などに記載されているように、接続区域168は、おむつ100Tのバックシート136又はベルト部分の一部として一体的に形成されてもよく、或いは腰部領域の一方若しくは両方の第1及び第2の耳部の一部として形成されてもよい。
例えば、第1のベルト耳部112及び第2のベルト耳部114の近位端領域174はベルト部分111と共に形成され、第1のベルト耳部112及び第2のベルト耳部114の遠位端領域176は、シャーシ102の前側腰部領域116と接続されて、パンツ型おむつ100Pが形成される。
吸収性物品200は、前側又は第1のベルト部分202と、後側又は第2のベルト部分204とを備えてもよい。第1のベルト部分202は第1の腰部領域116に位置付けられてもよく、第2のベルト部分204は第2の腰部領域118に位置付けられてもよい。第1のベルト部分202及び第2のベルト部分204は共に、第1のベルト部分202の一部が第2のベルト部分204の一部と接合されるか、又は取外し可能に接合されると、着用者の腰部の少なくとも一部分を取り囲むことが意図される。第1のベルト部分202及び第2のベルト部分204は、シャーシ206によって互いに接続されてもよい。シャーシ206は、吸収性物品200の股部領域120を形成してもよい。シャーシ206はまた、第1の腰部領域116及び第2の腰部領域118の一部を形成してもよい。様々な実施形態では、第1のベルト部分202及び第2のベルト部分204は、シャーシ206の第1及び第2の終端部と重なり合ってもよい。この重なりは、シャーシ206の着用者に面する表面で、又は衣類に面する表面で生じてもよい。図7の実例では、シャーシ206の着用者に面する表面が見る者の方に向いている。他の実施形態では、第1のベルト部分202及び第2のベルト部分204とシャーシ206とが全く重なり合わないか、又は重なりが非常に限定されていてもよい。かかる実施形態では、第1のベルト部分202及び第2のベルト部分204は、シャーシ206の第1及び第2の終端部とベルト部分202及び204との間の交点又はその付近で終端部に接合されてもよい。図8a〜8gは、様々な実施形態における、図7の線8−8で取った構造的断面のいくつかの例である。また、断面における弾性要素の数は非限定的であり、より多数又はより少数の弾性要素が使用されてもよい。例示を明瞭にするため、図8a〜8gでは、吸収性物品の様々な特徴が除外されている。
第1基材210及び第2基材212は、同じ、若しくは実質的に同じ材料で形成されてもよく、又は異なる材料を含んでもよい。第1基材210及び第2基材212は、不織布、フィルム、発泡体、弾性素材、不織布、又はそれらの組み合わせから形成されてもよい。
第1のベルト部分202及び第2のベルト部分204はまた、第1基材210と第2基材212との間に少なくとも部分的に配設された弾性要素214を備えてもよい。任意の好適な数の弾性要素214が各ベルト部分に設けられてもよい。弾性要素214は、1つ以上の弾性ストランド、エラストマーフィルム、エラストマーリボン、エラストマー不織布、エラストマーフィラメント、エラストマー接着剤、エラストマー発泡体、スクリム、又はそれらの組み合わせを含んでもよい。弾性要素214の一部分は、外側の衣類に面する表面又は層134と直接組み合わされてもよい。シャーシ206は、外側の衣類に面する表面134の少なくとも一部分と、バックシート136と、内側の着用者に面する表面132の少なくとも一部分と、トップシート138と、トップシート138とバックシート136との間に配設された吸収性コア142とを備えてもよい。バックシート136は、不織布材料、織布材料、及び/又はこれらの材料の1つ以上の組み合わせを含むフィルム若しくは積層体で形成されてもよい。一実施形態では、バックシート136はフィルムと不織布の積層体であってもよく、積層体の不織布は、吸収性物品200の外側カバー基材242であってもよい。それに加えて、シャーシ206は、シャーシ206の側縁部152及び154(例えば、図3を参照)に、又はそれらに隣接して配設された、弾性のあるバリア脚部カフ156(例えば、図3を参照)を備えてもよい。第1基材210及び第2基材212は、シャーシ206の少なくとも一部分と重なり合ってもよく、ベルト部分202及び204の一方若しくは両方は、シャーシ206の外側の衣類に面する表面134に、又はシャーシ206の内側の着用者に面する表面132に配設されてもよい。第1基材210及び第2基材212の一部分は、外側カバー基材242に直接取り付けられてもよい。別の方法としては、第1基材210及び第2基材212は、ベルト部分202及び204の1つ以上の第1の表面を形成する、長手方向で離間配置された材料ウェブを含んでもよく、ウェブは、ベルト部分202及び204のうち1つ以上の腰部開口縁部121若しくは122又は脚部開口縁部127に沿って折り畳まれて、弾性要素214を包むと共に、ベルト部分202及び204のうち1つ以上の第2の表面の少なくとも一部分を形成する。言い換えれば、ベルト部分202及び204の各々の、内側の着用者に面する表面132の少なくとも一部分及び外側の衣類に面する表面134の少なくとも一部分は、単一の材料ウェブから形成されてもよい。
弾性要素306は、第1基材302の一部分及び/又は第2基材304の一部分に、間欠的若しくは連続的に接着接合されるか、又は別の方法で接合されてもよい。図9及び11では、第1基材302が見る者の方に向いている。第1基材302及び第2基材304は、不織布材料又は上述したような他の好適な材料で構成されてもよい。長手方向軸線301及び横方向軸線303は、シャーシ310を通って画成されてもよい。
一実施形態では、弾性要素306は、例えば、弾性フィルム材料のストリップを含んでもよい。いくつかの実施形態では、弾性要素は、基材に取り付けられたとき、異なる予歪みレベルを有してもよい。
第2の倍率は第1の倍率よりも大きい。図20B及び20Cはテクスチャー区域のしわを示す。図20D及び20Eは、線MDで取った図20Aのテクスチャー区域の一部分の斜視図である。図20Fは、第3の倍率を使用した、図20Aの線MDで取った断面図である。図20D〜20Fでは、高密度化領域はDRとして示される。図20A〜20Fでは、弾性要素Eはそれらの弛緩した状態にある。
一実施形態では、この非活性化区域は、例えば、吸収性コア350の面積のある範囲又は部分にわたって生じてもよい。
別の実施形態では、1つのみの接着剤要素パターンが基材302及び304の一方若しくは両方に適用されてもよく、弾性要素306は、テクスチャー区域の各々で異なるように弾性要素306に取り付けられてもよい。様々な実施形態では、後述するように、第1基材302及び第2基材304が異なる一次繊維結合パターン又は高密度化領域を有する場合、1つの接着剤要素パターンが基材302及び304の一方若しくは両方に適用される一方で、依然として2つ以上のテクスチャー区域がベルト部分に作成されてもよい。異なる接着剤要素パターンはまた、2つ以上のテクスチャー区域をベルト部分に作成するため、異なる若しくは同じ一次繊維結合パターン又は高密度化領域を有する第1基材302及び/又は第2基材304に適用されてもよい。
一次繊維結合パターン338A及び338Bの例がそれぞれ、図23A及び23Bで第1基材302及び第2基材304上において示されている。パターンは、結合の形状、結合のサイズ、及び/又は結合間の間隔を含む。当業者であれば、不織布材料上で利用可能又は作成可能な複数の一次繊維結合パターンがあり、本開示は、例示される一次繊維結合パターンに限定されないことを認識するであろう。一次繊維結合パターンを形成する一次繊維結合は、不織布材料などの材料の繊維を共に保持し、基材に対して強度及び構造を提供する結合である。一次繊維結合パターンを形成する一次繊維結合は、例えば、熱接着、機械的結合、及び/又は高密度化領域であってもよい。弾性要素306(1つのみが図23A及び23Bの各々に示されている)又はその一部は、一次繊維結合部位のいくつかにおいて、或いは一次繊維結合部位を有さない第1基材302及び第2基材304の範囲において、第1基材302及び/又は第2基材304に貼着されてもよい。一実施形態では、弾性要素306のいくつかは第1基材302に貼着されてもよく、弾性要素306の他のものは第2基材304に貼着されてもよい。弾性要素306のいくつか、又はそれらの一部は、第1基材302及び第2基材304の両方に貼着されてもよい。
弾性要素が第1及び/又は第2基材に貼着された後、弾性要素は弛緩又は収縮することが可能になり、それによって、第1及び/又は第2基材にテクスチャー区域(背景パターンとマクロパターンを形成する)が作成される。第1及び/又は第2基材において、第1の要素パターンは背景パターンを形成する第1のテクスチャー区域と関連付けられてもよく、第2の要素パターンはマクロパターンを形成する第2のテクスチャー区域と関連付けられてもよい。第1のテクスチャー区域は、第1の出現率及び/又は振幅範囲を有するしわを有してもよく、第2のテクスチャー区域は、第2の異なる出現率及び/又は振幅範囲を有するしわを有してもよい。追加の異なるテクスチャー区域が望ましい場合、2つを超える接着剤要素パターンが弾性要素に、又は第1若しくは第2基材に適用されてもよい。
ベルト部分は各々、約5〜約20若しくは約5〜約25の範囲のテクスチャー比(又は本明細書で指定する他のテクスチャー比)を有する、弾性のある部分を備えてもよい。弾性のある部分は単一の均一なテクスチャーを形成してもよい。吸収性物品は長手方向軸線を備える。単一の均一なテクスチャーは、長手方向軸線に平行な方向で、線形又は非線形であってもよい。弾性のある部分は、接着剤又は別の方法で互いに接合された、2つ以上の基材又は2つ以上の不織布基材を備えてもよい。ベルト部分の合計坪量は、後述する坪量方法にしたがって測定して、20gsm〜100gsm、25gsm〜90gsm、35gsm〜70gsm、又は40gsm〜60gsmの範囲であってもよく、具体的には、指定範囲内及びその中で又はそれによって形成される全ての範囲内の、0.5gsmの増分が全て列挙される。
寸法測定は、反射モードにおいて少なくとも2400dpiの解像度でスキャン可能なフラットベッドスキャナーを使用して生成された画像上で実施する(好適なスキャナーは、米国のエプソン(Epson, USA)製のEpson Perfection V750 Proである)。解析は、ImageJソフトウェア(アメリカ国立衛生研究所(National Institutes of Health, USA))、又は等価の画像解析ソフトウェアを使用して実施し、認証済みのNISTルーラーに対して較正する。サンプルは、試験前に、約23℃±2℃及び相対湿度約50%±2%で2時間にわたって事前に調湿する。
ベルト部分の基材の損傷を回避するため、凍結スプレー又は好適な方法を使用して、ベルト部分を吸収性物品から除去する。吸収性物品がパンツである場合、シーム範囲の長手方向軸線に沿ってベルトを切断して、ベルトを前側及び後側ベルト部分に分離し、各ベルト部分を水平ベンチ上に平らに置く。各ベルト部分に対して、次のステップを実行する:
切断したベルト部分を、切断したベルト部分の1つの縁部に沿ってテープでベンチに固定する。選択された縁部は、しわの最長寸法に対して直交又は横断する方向で延在していなければならない。
しわ長さ(mm)及びしわ振幅の測定値を、画像解析を含む光学顕微鏡検査によって得る。好適な計器は、OL−35アダプタ及びMXG 10−Cレンズを取り付けたHIROXマイクロスコープ(モデルKH7700)、又は等価物である。外部白色光源を使用する。画像は、HIROXソフトウェア(バージョン2.10C)又は等価の3D画像解析ソフトウェアを用いて獲得し解析する。サンプルは、試験前に、23℃±2℃及び相対湿度50%±2%で2時間にわたって事前に調湿する。
クレオラ(Creora)の商品名で韓国のヒョースン(Hyosung, Korea)によって供給される、約680デシテックスの線密度を有する弾性ストランドは、米国ウィスコンシン州のボスティック(Bostik, Wisconsin, USA)製のH2401接着剤を使用して第1基材に貼着される。背景パターンを形成する第1のテクスチャー区域は、弾性ストランドを約7mmの間隔で離間配置することによって、また、第1及び第2基材を組み合わせる前に、ノードソン・ユニバーサル(Nordson Universal)接着剤塗布装置及びノードソン・シュアラップ・グルー・ノズル(Nordson sure-wrap glue nozzles)を使用することによって、吸収性物品のベルト部分に作成される。マクロパターンを形成する第2のテクスチャー区域は、第1及び第2基材を組み合わせる前に、図22Eに示されるような直径約5mmの接着剤のドットを使用して、H2401接着剤を第2基材に塗布することによって、吸収性物品のベルト部分に作成される。これらの背景パターン(334)及びマクロパターン(336)により、図17に示されるテクスチャー及び図18の白い部分のテクスチャーが得られる。
しわ長さ、しわ出現率、しわ振幅、弾性要素間隔、及びテクスチャー比の方法を使用して、以下の表1に示されるように、比較用の吸収性物品及び本開示の吸収性物品の様々なテクスチャー区域について試験した。広くは、比較用の吸収性物品は、前側及び後側に均一なテクスチャーを有していた。いくつかの比較用の吸収性物品では、前側を使用し、他の比較用の吸収性物品では、後側を使用した。前側/後側を使用した場合、その特定の比較用の吸収性物品の試験全体に対して使用した。
図33及び34は、試験した比較用の吸収性物品のテクスチャー区域のテクスチャー比を、本開示の吸収性物品のテクスチャー区域のテクスチャー比と比較したグラフを示す。図33は、x軸に沿った平均しわ長さ(cm)を、y軸に沿った平均弾性間隔(cm)と比較したグラフである。図34は、試験した比較用の吸収性物品のテクスチャー区域のテクスチャー比を、本開示の吸収性物品のテクスチャー区域のテクスチャー比と比較した別のグラフを示す。図から分かるように、本開示の吸収性物品におけるベルト部分のテクスチャー区域のテクスチャー比は、試験した比較用の吸収性物品よりも高く、それにより、本開示の吸収性物品は、吸収性物品の製造に対してコストを、又は著しいコストを追加することなく、適合性が改善され、快適な感触、美観的に心地よい外観を備え、衣服又は下着により一層類似した製品を提供する。約6.0のテクスチャー比を有するテクスチャー区域の一例は、例えば、図20Aに示される。
Claims (11)
- 吸収性物品のための積層体の製造方法であって、前記積層体は、第1及び第2の不織布基材の中間に少なくとも部分的に配設された複数の弾性要素を有し、前記第1及び第2の不織布基材は、各々、中に形成された、複数の一次繊維結合パターンを有し、各一次繊維結合パターンは、複数の一次繊維結合を含み、
前記複数の一次繊維結合パターンを形成した後、第1の高密度化領域のパターンを前記第1基材内に形成する工程と、
前記複数の一次繊維結合パターンを形成した後、第2の高密度化領域のパターンを前記第2基材内に形成する工程と、
前記第1及び第2の高密度化領域のパターンを形成した後、パターン状の接着剤を前記基材の1つに塗布する工程と、
前記パターン状の接着剤を使用して、前記弾性要素を予め歪みを付与した状態で前記基材の1つに取り付ける工程と、
前記第2基材を前記第1基材または前記弾性要素のいくつかに接合する工程と、
前記弾性要素が少なくとも部分的に収縮できるようにすることによって、複数のしわを前記積層体に形成する工程と、
を備え、
前記第1の高密度化領域の各々の外周は、前記第1基材における前記一次繊維結合の各々の外周よりも大きく、
前記第2の高密度化領域の各々の外周は、前記第2基材における前記一次繊維結合の各々の外周よりも大きく、
前記しわの構造は、前記第1の高密度化領域の前記パターン及び前記第2の高密度化領域の前記パターンの結果であり、
前記一次繊維結合パターンは、カレンダー加工によって形成される
ことを特徴とする方法。 - 前記第1の高密度化領域の前記パターンは、前記第2の高密度化領域の前記パターンと同じである
ことを特徴とする請求項1に記載の方法。 - 前記一次繊維結合パターンは、前記第1及び第2の基材において同じである
ことを特徴とする請求項1または2に記載の方法。 - カレンダー加工、エンボス加工、熱接着、機械的結合のいずれかによって前記第1及び第2の高密度化領域を形成する工程を備えた
ことを特徴とする請求項1に記載の方法。 - 前記高密度化領域の少なくとも1つは、連続的である
ことを特徴とする請求項1に記載の方法。 - 前記高密度化領域の少なくとも1つは、非線形である
ことを特徴とする請求項1に記載の方法。 - 前記高密度化領域の少なくとも1つは、線形である
ことを特徴とする請求項1に記載の方法。 - 前記積層体は、吸収性物品のシャーシと接合されるように構成され、
前記第1の高密度化領域の各々は、その最も狭い寸法では少なくとも0.5mmであり、その最長寸法では少なくとも1mmであり、
前記しわの振幅及び出現率の範囲は、前記第1の高密度化領域のパターンから得られる
ことを特徴とする請求項1〜7のいずれか一項に記載の方法。 - 前記第1の高密度化領域の各々の外周が3mm超である
ことを特徴とする請求項8に記載の方法。 - 前記第1の高密度化領域の各々のアスペクト比が3超である
ことを特徴とする請求項8または9に記載の方法。 - 前記第1の高密度化領域の各々は、その最長寸法が少なくとも3mmである
ことを特徴とする請求項8に記載の方法。
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JP2015512736A Expired - Fee Related JP5992608B2 (ja) | 2012-05-15 | 2013-05-14 | 背景パターン及びマクロパターンを形成するテクスチャー区域を有する吸収性物品 |
JP2016155884A Expired - Fee Related JP6334619B2 (ja) | 2012-05-15 | 2016-08-08 | 背景パターン及びマクロパターンを形成するテクスチャー区域を有する吸収性物品 |
JP2016159969A Expired - Fee Related JP6352351B2 (ja) | 2012-05-15 | 2016-08-17 | 吸収性物品のための積層体の製造方法 |
JP2016205513A Expired - Fee Related JP6469625B2 (ja) | 2012-05-15 | 2016-10-19 | テクスチャー化区域を有する吸収性物品 |
JP2018056443A Withdrawn JP2018134435A (ja) | 2012-05-15 | 2018-03-23 | テクスチャ比を有するテクスチャゾーンを備えたベルト部分を有する吸収性物品 |
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JP2015512748A Pending JP2015516274A (ja) | 2012-05-15 | 2013-05-14 | テクスチャ比を有するテクスチャゾーンを備えたベルト部分を有する吸収性物品 |
JP2015512739A Pending JP2015516270A (ja) | 2012-05-15 | 2013-05-14 | テクスチャー化区域を有する吸収性物品 |
JP2015512736A Expired - Fee Related JP5992608B2 (ja) | 2012-05-15 | 2013-05-14 | 背景パターン及びマクロパターンを形成するテクスチャー区域を有する吸収性物品 |
JP2016155884A Expired - Fee Related JP6334619B2 (ja) | 2012-05-15 | 2016-08-08 | 背景パターン及びマクロパターンを形成するテクスチャー区域を有する吸収性物品 |
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