JP6784759B2 - 高分子フィルムおよび高分子フィルムの形成方法 - Google Patents
高分子フィルムおよび高分子フィルムの形成方法 Download PDFInfo
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- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/514—Oriented
-
- 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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/54—Yield strength; Tensile strength
-
- 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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/558—Impact strength, toughness
-
- 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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/718—Weight, e.g. weight per square meter
-
- 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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/724—Permeability to gases, adsorption
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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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/724—Permeability to gases, adsorption
- B32B2307/7242—Non-permeable
- B32B2307/7248—Odour barrier
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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
- B32B2555/00—Personal care
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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
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Description
本出願は、本明細書において参照により特に援用されている、2015年11月5日に出願の米国仮特許出願第62/251,415号明細書に基づく米国特許法119条(e)の優先権を主張するものである。
900g/in、780g/in〜900g/in、785g/in〜900g/in、790g/in〜900g/in、795g/in〜900g/inおよび800g/in〜900g/in。
A−C−A
A−A−C−A
A−C−A−A
A−A−C−A−A
A−C−A−A−A
A−C−A−C−A
A−C−A−A−A−A−A
A−A−C−A−A−A−A
A−A−A−C−A−A−A
A−C−A−A−A−C−A
A−C−A−A−C−A−A
A−C−A−C−A−A−A
A−C−A−C−A−C−A
A−C−A−A−A−A−A−A
A−A−C−A−A−A−A−A
A−A−A−C−A−A−A−A
A−C−A−A−A−A−C−A.
A−C−B−C−A
A−C−A−C−B−C−A
A−C−B−C−A−C−A
A−C−A−C−B−C−A−C−A
A−C−B−C−A−C−A−C−A
A−C−B−C−A−B−C−A
A−B−A−A−B−A−A−B−A−A−B−A−A−B−A−A−B−A−A−B−A−A−B−A−A−B−A−A−B−A
第1項:多層フィルムの形成プロセスであって、多層フィルムは少なくとも1層の多孔質化コア層および少なくとも1層の非多孔質化表皮層を含み、プロセスは、
2種以上の押出し可能な材料を押出して溶融ウェブを形成するステップを含む。
第3項:他の項のいずれかまたは項の組み合わせに係るプロセスであって、エアナイフ、エアブランケット、真空チャンバまたはこれらの組み合わせを用いて溶融ウェブをチルロールの表面にキャストして急冷フィルムを形成するステップをさらに含む。
第4項:他の項のいずれかまたは項の組み合わせに係るプロセスであって、急冷フィルムを延伸して多層フィルムを形成するステップをさらに含む。
第5項:他の項のいずれかまたは項の組み合わせに係るプロセスであって、第1のポリオレフィンおよび第2のポリオレフィンは同一もしくは異なるものである。
2種以上の押出し可能な材料を押出して溶融ウェブを形成するステップを含み、少なくとも第1の押出し可能な材料は第1のポリオレフィンおよび無機充填材を含むと共に、少なくとも1層の多孔質化コア層を形成するよう構成されている。
3種以上の押出し可能な材料を押出して溶融ウェブを形成するステップを含み、少なくとも第1の押出し可能な材料は第1のポリオレフィンおよび無機充填材を含むと共に、少なくとも1層の多孔質化コア層を形成するよう構成されている。
例示的なフィルムの製造のために、3台以下の押出し機を備える押出し成形キャストラインを用いた。「A」および「B」押出し機は直径が2.5インチであり、「C」押出し機は直径が1.75インチである。A、BおよびC押出し機からの押出物を多様な構成で積層させることが可能であるCloeren Corporation(Orange,TX)製の多層化フィードブロックに押出し機から供給が行われる。このフィードブロックから、溶融ポリマーが幅約36インチの単層キャストダイ(Cloeren製)に進む。このダイは調節用ギャップを有する。本明細書に記載のサンプルについては、調節用ギャップは10〜40ミルで維持した。溶融ポリマーはチルロール上に落下する。本明細書に記載のサンプルについては、チルロールは、Pamarco(Roselle,NJ)によりパターンP−2739として彫刻されたエンボスパターンFST−250を有していた。エンボスパターンP−2739は、250個の正方形/インチおよび深さ約31ミクロンの正方形のパターン(例えば、線が縦方向に略揃ったもの)である。ロール自体は、18インチの直径を有し、内部水冷式のものである。彫刻ロールのパターンは、真空チャンバにおける急冷に干渉しないよう十分に浅い他のパターンで置き換えられてもよい。クロムメッキロールにサンドブラストプロセスで形成された40Raパターン(40マイクロインチの平均粗度)が代替の1つである。
この実験において、構造CBBBCを有する表皮層付多層バックシートフィルムは、表1に示されている配合物XC3−828−2300.0から調製した。
Claims (51)
- 非通気性の多層フィルムの形成プロセスにおいて、前記非通気性の多層フィルムは少なくとも1層の多孔質化コア層および少なくとも1層の孔を有さない非多孔質化表皮層を含み、前記プロセスは、
2種以上の押出し可能な材料を押出して溶融ウェブを形成するステップであって、前記2種以上の押出し可能な材料の少なくとも1種が第1のポリオレフィンおよび無機充填材を含み、ならびに、前記2種以上の押出し可能な材料の少なくとも他の種が第2のポリオレフィンを含むステップ、
エアナイフ、エアブランケット、真空チャンバまたはこれらの組み合わせを用いて前記溶融ウェブをチルロールの表面にキャストして急冷フィルムを形成するステップ、ならびに
前記急冷フィルムを延伸して前記非通気性の多層フィルムを形成するステップであって、横方向かみ合いギア(CD−IMG)延伸および縦方向(MD)延伸を含み、前記縦方向(MD)延伸が前記横方向かみ合いギア(CD−IMG)延伸の後に行われるステップ、
を含み、
前記第1のポリオレフィンおよび前記第2のポリオレフィンは同一もしくは異なるものであり、
前記非通気性の多層フィルムの形成プロセスが、縦方向かみ合いギア(MD−IMG)延伸を含まないことを特徴とするプロセス。 - 請求項1に記載のプロセスにおいて、前記非通気性の多層フィルムが、第1の非多孔質化表皮層および第2の非多孔質化表皮層を含み、ならびに、前記少なくとも1層の多孔質化コア層が、前記第1の非多孔質化表皮層および前記第2の非多孔質化表皮層の間に配置されることを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、前記第1のポリオレフィンおよび前記第2のポリオレフィンが、ポリエチレン、ポリプロピレン、および、これらの組み合わせからなる群から独立して選択されることを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、前記第1のポリオレフィンがポリプロピレンを含むことを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、前記第2のポリオレフィンがポリプロピレンを含むことを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、前記第1のポリオレフィンおよび前記第2のポリオレフィンの各々がポリプロピレンを含むことを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、前記無機充填材の平均粒径が0.1ミクロン〜15ミクロンであることを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、前記無機充填材が、炭酸ナトリウム、炭酸カルシウム、炭酸マグネシウム、硫酸バリウム、硫酸マグネシウム、硫酸アルミニウム、酸化マグネシウム、酸化カルシウム、アルミナ、雲母、タルク、シリカ、クレイ、ガラス球、二酸化チタン、水酸化アルミニウム、ゼオライト、および、これらの組み合わせからなる群から選択されることを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、前記無機充填材が、アルカリ金属炭酸塩、アルカリ土類金属炭酸塩、アルカリ金属硫酸塩、アルカリ土類金属硫酸塩、または、これらの組み合わせを含むことを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、前記無機充填材が炭酸カルシウムを含むことを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、前記真空チャンバによる負圧下で前記溶融ウェブが前記チルロールの前記表面にキャストされることを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、前記エアナイフにより、正圧下で前記溶融ウェブが前記チルロールの前記表面にキャストされることを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、前記延伸ステップが、さらに、冷延伸を含むことを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、前記非通気性の多層フィルムをアニーリングするステップをさらに含むことを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、前記非通気性の多層フィルムをアニーリングするステップであって、前記アニーリングが摂氏23.9度〜摂氏107.2度の温度で行われるステップをさらに含むことを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、前記少なくとも1層の非多孔質化表皮層の少なくとも一部を不織材料に取り付けるステップをさらに含むことを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、前記非通気性の多層フィルムが、第1の非多孔質化表皮層および第2の非多孔質化表皮層を含み、ならびに、前記プロセスが、前記第1の非多孔質化表皮層または前記第2の非多孔質化表皮層の少なくとも一部を不織材料に取り付けるステップをさらに含むことを特徴とするプロセス。
- 請求項17に記載のプロセスにおいて、前記不織材料および前記不織材料に取り付けられた前記第1の非多孔質化表皮層または前記第2の非多孔質化表皮層の前記少なくとも一部がポリプロピレンを含むことを特徴とするプロセス。
- 多層非通気性フィルムの形成プロセスにおいて、前記多層非通気性フィルムは、孔を有さない第1の非多孔質化表皮層および第2の非多孔質化表皮層、ならびに、前記第1の非多孔質化表皮層および前記第2の非多孔質化表皮層の間に配置された少なくとも1層の多孔質化コア層を含み、
2種以上の押出し可能な材料を押出して溶融ウェブを形成するステップであって、少なくとも第1の押出し可能な材料が第1のポリオレフィンおよび無機充填材を含むと共に、前記少なくとも1層の多孔質化コア層を形成するよう構成され、ならびに、少なくとも第2の押出し可能な材料が第2のポリオレフィンを含むと共に、前記第1の非多孔質化表皮層および前記第2の非多孔質化表皮層の各々を形成するよう構成されているステップ、
エアナイフ、エアブランケット、真空チャンバまたはこれらの組み合わせを用いて前記溶融ウェブをチルロールの表面にキャストして急冷フィルムを形成するステップ、ならびに
前記急冷フィルムを延伸して前記多層非通気性フィルムを形成するステップであって、横方向かみ合いギア(CD−IMG)延伸および縦方向(MD)延伸を含み、前記縦方向(MD)延伸が前記横方向かみ合いギア(CD−IMG)延伸の後に行われるステップ、
を含み、
前記第1のポリオレフィンおよび前記第2のポリオレフィンは同一もしくは異なるものであり、
前記多層非通気性フィルムの形成プロセスが、縦方向かみ合いギア(MD−IMG)延伸を含まないことを特徴とするプロセス。 - 請求項19に記載のプロセスにおいて、前記第1のポリオレフィンおよび前記第2のポリオレフィンが、ポリエチレン、ポリプロピレン、および、これらの組み合わせからなる群から独立して選択されることを特徴とするプロセス。
- 請求項19に記載のプロセスにおいて、前記第1のポリオレフィンがポリプロピレンを含むことを特徴とするプロセス。
- 請求項19に記載のプロセスにおいて、前記第2のポリオレフィンがポリプロピレンを含むことを特徴とするプロセス。
- 請求項19に記載のプロセスにおいて、前記第1のポリオレフィンおよび前記第2のポリオレフィンの各々がポリプロピレンを含むことを特徴とするプロセス。
- 請求項19に記載のプロセスにおいて、前記無機充填材の平均粒径が0.1ミクロン〜15ミクロンであることを特徴とするプロセス。
- 請求項19に記載のプロセスにおいて、前記無機充填材が、炭酸ナトリウム、炭酸カルシウム、炭酸マグネシウム、硫酸バリウム、硫酸マグネシウム、硫酸アルミニウム、酸化マグネシウム、酸化カルシウム、アルミナ、雲母、タルク、シリカ、クレイ、ガラス球、二酸化チタン、水酸化アルミニウム、ゼオライト、および、これらの組み合わせからなる群から選択されることを特徴とするプロセス。
- 請求項19に記載のプロセスにおいて、前記無機充填材が、アルカリ金属炭酸塩、アルカリ土類金属炭酸塩、アルカリ金属硫酸塩、アルカリ土類金属硫酸塩、または、これらの組み合わせを含むことを特徴とするプロセス。
- 請求項19に記載のプロセスにおいて、前記無機充填材が炭酸カルシウムを含むことを特徴とするプロセス。
- 請求項19に記載のプロセスにおいて、前記真空チャンバによる負圧下で前記溶融ウェブが前記チルロールの前記表面にキャストされることを特徴とするプロセス。
- 請求項19に記載のプロセスにおいて、前記エアナイフにより、正圧下で前記溶融ウェブが前記チルロールの前記表面にキャストされることを特徴とするプロセス。
- 請求項19に記載のプロセスにおいて、前記延伸ステップが、さらに、冷延伸を含むことを特徴とするプロセス。
- 請求項19に記載のプロセスにおいて、前記多層非通気性フィルムをアニーリングするステップをさらに含むことを特徴とするプロセス。
- 請求項19に記載のプロセスにおいて、前記多層非通気性フィルムをアニーリングするステップをさらに含み、前記アニーリングするステップが摂氏23.9度〜摂氏107.2度の温度で行われることを特徴とするプロセス。
- 請求項19に記載のプロセスにおいて、前記第1の非多孔質化表皮層または前記第2の非多孔質化表皮層の少なくとも一部を不織材料に取り付けるステップをさらに含むことを特徴とするプロセス。
- 請求項33に記載のプロセスにおいて、前記不織材料および前記不織材料に取り付けた前記第1の非多孔質化表皮層または前記第2の非多孔質化表皮層の前記少なくとも部分がポリプロピレンを含むことを特徴とするプロセス。
- 多層非通気性フィルムを形成するプロセスにおいて、前記多層非通気性フィルムは、第1の非多孔質化表皮層、第2の非多孔質化表皮層、前記第1の非多孔質化表皮層および前記第2の非多孔質化表皮層の間に配置された少なくとも1層の多孔質化コア層、ならびに、前記第1の非多孔質化表皮層および前記第2の非多孔質化表皮層の間に配置された少なくとも1層の極性ポリマー層を含み、
3種以上の押出し可能な材料を押出して溶融ウェブを形成するステップであって、少なくとも第1の押出し可能な材料が第1のポリオレフィンおよび無機充填材を含むと共に、前記少なくとも1層の多孔質化コア層を形成するよう構成され、少なくとも第2の押出し可能な材料が第2のポリオレフィンを含むと共に、前記第1の非多孔質化表皮層および前記第2の非多孔質化表皮層の各々を形成するよう構成されており、ならびに、少なくとも第3の押出し可能な材料が引湿性ポリマーを含むと共に、前記少なくとも1層の極性ポリマー層を形成するよう構成されているステップ、
エアナイフ、エアブランケット、真空チャンバまたはこれらの組み合わせを用いて前記溶融ウェブをチルロールの表面にキャストして急冷フィルムを形成するステップ、および
前記急冷フィルムを延伸して前記多層非通気性フィルムを形成するステップ
を含み、
前記第1のポリオレフィンおよび前記第2のポリオレフィンが同一もしくは異なるものであることを特徴とするプロセス。 - 請求項35に記載のプロセスにおいて、前記引湿性ポリマーが、引湿性エラストマー、ポリエステル、ポリアミド、ポリエーテルエステルコポリマー、ポリエーテルアミドコポリマー、ポリウレタン、ポリウレタンコポリマー、ポリ(エーテルイミド)エステルコポリマー、ポリビニルアルコール、アイオノマー、セルロース、ニトロセルロース、および、これらの組み合わせからなる群から選択されることを特徴とするプロセス。
- 請求項35に記載のプロセスにおいて、前記第3の押出し可能な材料が接着剤をさらに含むことを特徴とするプロセス。
- 請求項37に記載のプロセスにおいて、前記接着剤が、ポリエチレン/アクリレートコポリマー、エチレン/メチルアクリレートコポリマー、酸−変性アクリレート、無水変性アクリレート、エチレン酢酸ビニル、酸/アクリレート−変性エチレン酢酸ビニル、無水変性エチレン酢酸ビニル、または、これらの組み合わせを含むことを特徴とするプロセス。
- 請求項35に記載のプロセスにおいて、前記第1の押出し可能な材料が接着剤をさらに含むことを特徴とするプロセス。
- 請求項35に記載のプロセスにおいて、前記極性ポリマー層が、ナイロン、ポリエステル、エチレンビニルアルコール、または、これらの組み合わせを含むことを特徴とするプロセス。
- 請求項35に記載のプロセスにおいて、前記極性ポリマー層が、ナイロン、ポリエステル、エチレンビニルアルコール、ナイロンのコポリマー、ポリエステルのコポリマー、エチレンビニルアルコールのコポリマー、および、これらの組み合わせからなる群から選択されることを特徴とするプロセス。
- 個人向け衛生製品の製造方法において、
請求項1に記載のプロセスにより調製された少なくとも1層の内側多層フィルム、および
少なくとも1層の外側不織層、を含み、
前記少なくとも1層の非多孔質化表皮層の少なくとも一部が前記外側不織層の少なくとも一部に接着されることを特徴とする個人向け衛生製品の製造方法。 - 請求項42に記載の個人向け衛生製品の製造方法において、前記少なくとも1層の非多孔質化表皮層および前記外側不織層の各々がポリプロピレンを含むことを特徴とする個人向け衛生製品の製造方法。
- 請求項42に記載の個人向け衛生製品の製造方法において、前記少なくとも1層の非多孔質化表皮層の少なくとも一部が、前記少なくとも1層の外側不織層の少なくとも一部に接着剤を用いることなく接着されることを特徴とする個人向け衛生製品の製造方法。
- 請求項42に記載の個人向け衛生製品の製造方法において、前記少なくとも1層の非多孔質化表皮層の少なくとも一部が、前記少なくとも1層の外側不織層の少なくとも一部に超音波圧接により接着されることを特徴とする個人向け衛生製品の製造方法。
- 請求項42に記載の個人向け衛生製品の製造方法において、失禁ブリーフとして構成されることを特徴とする個人向け衛生製品の製造方法。
- 請求項42に記載の個人向け衛生製品の製造方法において、手術着として構成されることを特徴とする個人向け衛生製品の製造方法。
- 請求項42に記載の個人向け衛生製品の製造方法において、婦人用衛生製品として構成されることを特徴とする個人向け衛生製品の製造方法。
- 請求項42に記載の個人向け衛生製品の製造方法において、おむつのバックシートとして構成されることを特徴とする個人向け衛生製品の製造方法。
- 個人向け衛生製品の製造方法において、
請求項19に記載のプロセスにより調製された少なくとも1層の内側多層非通気性フィルム、および
少なくとも1層の外側不織層、を含み、
前記第1の非多孔質化表皮層または前記第2の非多孔質化表皮層の少なくとも一部が前記外側不織層の少なくとも一部に接着されることを特徴とする個人向け衛生製品の製造方法。 - 請求項50に記載の個人向け衛生製品の製造方法において、前記少なくとも1層の内側多層非通気性フィルムが、前記第1の非多孔質化表皮層および前記第2の非多孔質化表皮層の間に配置された少なくとも1層の極性ポリマー層をさらに含むことを特徴とする個人向け衛生製品の製造方法。
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-
2016
- 2016-11-02 EP EP16862828.7A patent/EP3370943A4/en not_active Withdrawn
- 2016-11-02 AU AU2016350820A patent/AU2016350820B2/en not_active Ceased
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- 2016-11-02 JP JP2018522690A patent/JP6784759B2/ja active Active
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- 2016-11-02 PE PE2018000736A patent/PE20181463A1/es unknown
- 2016-11-02 MX MX2018005624A patent/MX2018005624A/es unknown
- 2016-11-02 US US15/341,103 patent/US10717255B2/en active Active
- 2016-11-02 CN CN201680077856.6A patent/CN108778674B/zh active Active
- 2016-11-02 WO PCT/US2016/060006 patent/WO2017079209A1/en active Application Filing
- 2016-11-02 CA CA3004264A patent/CA3004264C/en not_active Expired - Fee Related
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KR20200039818A (ko) | 2020-04-16 |
CA3004264A1 (en) | 2017-05-11 |
BR112018008995A2 (pt) | 2018-10-30 |
CO2018004912A2 (es) | 2018-07-31 |
CN108778674B (zh) | 2022-02-11 |
KR20180083871A (ko) | 2018-07-23 |
EP3370943A4 (en) | 2019-05-01 |
MX2018005624A (es) | 2018-09-05 |
AU2016350820B2 (en) | 2020-06-18 |
EP3370943A1 (en) | 2018-09-12 |
ECSP18042587A (es) | 2018-08-31 |
US20170129228A1 (en) | 2017-05-11 |
PE20181463A1 (es) | 2018-09-13 |
BR112018008995A8 (pt) | 2019-02-26 |
CN108778674A (zh) | 2018-11-09 |
JP2018535852A (ja) | 2018-12-06 |
CA3004264C (en) | 2020-09-22 |
WO2017079209A1 (en) | 2017-05-11 |
AU2016350820A1 (en) | 2018-05-17 |
US10717255B2 (en) | 2020-07-21 |
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