JP6876728B2 - ハイドロフォーム膨張スパンボンド不織布ウェブ及びハイドロフォームコンポジット材料並びにそれらの製造方法 - Google Patents
ハイドロフォーム膨張スパンボンド不織布ウェブ及びハイドロフォームコンポジット材料並びにそれらの製造方法 Download PDFInfo
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- JP6876728B2 JP6876728B2 JP2018564761A JP2018564761A JP6876728B2 JP 6876728 B2 JP6876728 B2 JP 6876728B2 JP 2018564761 A JP2018564761 A JP 2018564761A JP 2018564761 A JP2018564761 A JP 2018564761A JP 6876728 B2 JP6876728 B2 JP 6876728B2
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- Prior art keywords
- hydrofoam
- spunbonded non
- expanded
- web
- woven
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Landscapes
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- Nonwoven Fabrics (AREA)
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- Treatment Of Fiber Materials (AREA)
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- Shaping Of Tube Ends By Bending Or Straightening (AREA)
Description
本出願は、その全内容が参照により本明細書に組み込まれる、2016年6月10日に提出された米国仮特許出願第62/348,343号からの優先権の利益を主張する。
10.25gsmの目付け(公称10gsm)を有するスパンボンド不織布ウェブを、本発明の実施形態による方法を用いて、リニアインチ当たり40個の開口部より大きいメッシュ数、並びにリニアインチ当たり40個未満の開口部のメッシュ数を有する、様々な成形スクリーンの上で加工した。Image−Pro Plus(登録商標)画像分析ソフトウェアを備えたNavitarビデオイメージングマイクロスコープを含む拡大光学デバイスによって断面を測定した場合、スパンボンド不織布の最初のロフトは、上面から底面まで平均約0.012cmであった。一実施形態では、拡大光学デバイスは、走査型電子顕微鏡(「SEM」)を含んでもよい。試料をそれぞれ約1.0インチ(2.54cm)幅の細長い切れ端に切断し、次いで断面に対する圧縮損傷を最小にするよう慎重にその幅に亘って剪断切断した。次に、試料を、その端部が顕微鏡のレンズに対向するように上向きに取り付けた。画像に焦点を合わせ、ソフトウェアによって提供されたライン測定で測定した。試料の端部全体にわたって5つの地点を測定し、試料の平均ロフトを決定した。同一のウェブから複数の試料を試験した。本発明の実施形態による方法を用いてスパンボンド不織布ウェブを加工した後、ウェブは0.0267cm、標準偏差0.0053cmの平均ロフトまで膨張し、これは最初のスパンボンド不織布ウェブのロフトの少なくとも約1.7倍であった。
スパンボンド不織布ウェブはまた、上記のような成形スクリーンの配列の上で本発明の実施形態による積層体(コンポジット材料)の一部として上記のような成形スクリーンの配列の上でハイドロフォーム加工された。このようなハイドロフォームコンポジット材料は、ハイドロフォームコンポジット材料が吸収性デバイスに組み立てられる際に変換の問題を生じ得るため、層が剥離して分離しないような十分な一体性を有すべきである。非常にわずかな剥離力、すなわち2つの層の剥離に抵抗する力でさえ、ほとんどの変換加工のためには十分であるはずである。本発明の実施形態によるハイドロフォームコンポジット材料は、任意のブランドの2インチ幅のマスキングテープの片を8〜10インチの長さコンポジット材料の不織布側に適用し、フィルム側からテープを手で約2〜3インチの距離引っ張り、フィルムとテープとをフィルム産業において一般的な引張り試験装置のあごに配置することを含む、剥離力試験法(Peel Force Test法)によって試験した場合、少なくとも約3.0グラムの層間剥離力を示した。次いで、5インチ/分の顎剥離速度が起動され、引張り試験装置は、2つの層が剥離されたときに力計が経験する平均の力を計算する。本発明のいくつかの実施形態では、剥離力は、ほぼ約20グラムと測定された。
約133ミクロン(0.0052インチ)の平均厚さ及び約311m3/m2/分の平均空気透過性を有する公称10gsmのスパンボンド不織布ウェブを、43.5メッシュ(リニアインチ当たり43.5個の開口部)のスクリーンと60メッシュ(リニアインチ当たり60個の開口部)のスクリーンを用いて、種々の水圧でハイドロフォーム加工した。表1は、400psi〜550psiの水圧で43.5メッシュのスクリーンを用いたハイドロフォーム不織布ウェブの、得られた厚さ及び空気透過性を示し、表2は、315psi〜500psiの水圧で60メッシュのスクリーンを用いたハイドロフォーム不織布ウェブの、得られた厚さ及び空気透過率を示す。
Claims (14)
- 一方の側に実質的に平坦な第1表面及び反対側に第2表面を有し、前記第2表面は、パターン状の複数の突起を含む、ハイドロフォーム膨張スパンボンド不織布ウェブの製造方法であって、
最初の平均ロフトと最初の空気透過性とを有する最初の未膨張スパンボンド不織布ウェブからハイドロフォーム加工により膨張させてハイドロフォーム膨張スパンボンド不織布ウェブを形成し、
前記ハイドロフォーム膨張スパンボンド不織布ウェブの平均ロフトを、前記最初の未膨張スパンボンド不織布ウェブの前記最初の平均ロフトよりも少なくとも約1.3倍に膨張させることと、
前記ハイドロフォーム膨張スパンボンド不織布ウェブの空気透過性を、前記最初の未膨張スパンボンド不織布ウェブの前記最初の空気透過性よりも少なくとも約1.2倍に増加することと、を含み、
拡大光学デバイスによって断面を測定した場合、前記最初の未膨張スパンボンド不織布ウェブの前記平均ロフトが約0.0127cm(0.005インチ)〜約0.0635cm(0.025インチ)であり、
前記最初の未膨張スパンボンド不織布ウェブは、複数の結合点によって固定される絡み合った繊維のマットを含み、
前記ハイドロフォーム膨張スパンボンド不織布ウェブは、パターン状の開口部を含む成形構造と、前記成形構造の下方に位置する真空スロット領域との上を通過する間に、前記絡み合った繊維を、密集した実質的に水平の配向から、前記繊維間により大きな垂直間隔を有するより緩やかに充填された配向へと押し広げて再配向させるために、複数の重なり合った加圧液体ジェットを前記最初の未膨張スパンボンド不織布ウェブの実質的に平坦な前記第1表面に適用して形成される、
ハイドロフォーム膨張スパンボンド不織布ウェブの製造方法。 - 前記ハイドロフォーム膨張スパンボンド不織布ウェブの目付けは、前記最初の未膨張スパンボンド不織布ウェブの最初の目付けと実質的に等しい、請求項1に記載のハイドロフォーム膨張スパンボンド不織布ウェブの製造方法。
- 前記目付けは、少なくとも約8グラム/平方メートル(gsm)である、請求項2に記載のハイドロフォーム膨張スパンボンド不織布ウェブの製造方法。
- 空気透過率測定装置で測定した場合、前記最初の未膨張スパンボンド不織布ウェブの平均空気透過性が約3542m 3 /m 2 /分(1080ft3/ft2/分)であり、そして前記膨張スパンボンド不織布ウェブの平均空気透過性が、約5117m 3 /m 2 /分(1560ft3/ft2/分)である、
請求項1に記載のハイドロフォーム膨張スパンボンド不織布ウェブの製造方法。 - 前記ハイドロフォーム膨張スパンボンド不織布ウェブの複数の実質的に水平な繊維が、前記最初の未膨張スパンボンド不織布の対応する複数の実質的に水平な繊維よりも大きな垂直間隔を有する、
請求項1に記載の製造方法により得られたハイドロフォーム膨張スパンボンド不織布ウェブ。 - 前記ハイドロフォーム膨張スパンボンド不織布ウェブの複数の繊維が、実質的に水平な平面から離れる方向に湾曲している、
請求項5に記載のハイドロフォーム膨張スパンボンド不織布ウェブ。 - 前記ハイドロフォーム膨張スパンボンド不織布ウェブは、複数の実質的に水平な連続繊維及び複数の小繊維を含み、前記各小繊維は前記各連続繊維よりも短い、
請求項5に記載のハイドロフォーム膨張スパンボンド不織布ウェブ。 - 前記複数の小繊維の少なくともいくつかは、前記複数の実質的に水平な連続繊維と比較してより垂直な方向に配向されている、請求項6に記載のハイドロフォーム膨張スパンボンド不織布ウェブ。
- 前記ハイドロフォーム膨張スパンボンド不織布ウェブは界面活性剤を含む、請求項6に記載のハイドロフォーム膨張スパンボンド不織布ウェブ。
- 請求項1から4のいずれか一項に記載の製造方法によって得られたハイドロフォーム膨張スパンボンド不織布ウェブ又は請求項5から9のいずれか一項に記載のハイドロフォーム膨張スパンボンド不織布ウェブと、
前記膨張スパンボンド不織布層の連続繊維及び/又は小繊維を含む複数の拡張セルを含む成形フィルム層と、
を有するハイドロフォームコンポジット材料。 - 前記複数の拡張セルは、開口部が形成されている、請求項10に記載のハイドロフォームコンポジット材料。
- 前記複数の小繊維は、前記成形フィルム層の前記拡張セルの頂点を含む平面を超えて、前記成形フィルム層から外側に向けて延在する、請求項11に記載のハイドロフォームコンポジット材料。
- 前記複数の拡張セルは、2.54cm(リニアインチ)当たり約3個のセルから2.54cm(リニアインチ)当たり約120個のセルまでのメッシュ数を有する、請求項10に記載のハイドロフォームコンポジット材料。
- 前記ハイドロフォームコンポジット材料は、少なくとも約3.0グラムの層間剥離力を有する、請求項10に記載のハイドロフォームコンポジット材料。
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