TW200806477A - Elastic film laminates prepared by multiple stretching steps - Google Patents

Elastic film laminates prepared by multiple stretching steps Download PDF

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Publication number
TW200806477A
TW200806477A TW96112364A TW96112364A TW200806477A TW 200806477 A TW200806477 A TW 200806477A TW 96112364 A TW96112364 A TW 96112364A TW 96112364 A TW96112364 A TW 96112364A TW 200806477 A TW200806477 A TW 200806477A
Authority
TW
Taiwan
Prior art keywords
film
laminate
stretching
elastic
fabric
Prior art date
Application number
TW96112364A
Other languages
English (en)
Inventor
Stephen D Bruce
Jeffrey A Middlesworth
Original Assignee
Tredegar Film Prod Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tredegar Film Prod Corp filed Critical Tredegar Film Prod Corp
Publication of TW200806477A publication Critical patent/TW200806477A/zh

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Classifications

    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/144—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/14—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side
    • B32B3/16—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side secured to a flexible backing
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/45—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the shape
    • A61F13/49—Absorbent articles specially adapted to be worn around the waist, e.g. diapers
    • A61F13/49007—Form-fitting, self-adjusting disposable diapers
    • A61F13/49009—Form-fitting, self-adjusting disposable diapers with elastic means
    • A61F13/4902—Form-fitting, self-adjusting disposable diapers with elastic means characterised by the elastic material
    • 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
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/04—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B25/08—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • 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
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/10—Layered products comprising a layer of natural or synthetic rubber next to a fibrous or filamentary layer
    • 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
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/14—Layered products comprising a layer of natural or synthetic rubber comprising synthetic rubber copolymers
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • 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
    • B32B5/022—Non-woven fabric
    • 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
    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • 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
    • B32B2307/51—Elastic
    • 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
    • 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
    • B32B2307/726—Permeability to liquids, absorption
    • 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
    • B32B2555/02—Diapers or napkins
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322—Composite web or sheet
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/601—Nonwoven fabric has an elastic quality
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/674—Nonwoven fabric with a preformed polymeric film or sheet

Landscapes

  • Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Heart & Thoracic Surgery (AREA)
  • Mechanical Engineering (AREA)
  • Epidemiology (AREA)
  • Biomedical Technology (AREA)
  • Textile Engineering (AREA)
  • Vascular Medicine (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • General Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Veterinary Medicine (AREA)
  • Laminated Bodies (AREA)
  • Absorbent Articles And Supports Therefor (AREA)

Description

200806477 九、發明說明： 相關申請案的前後參照 本申請案主張2006年4月10日所申請的名稱為「彈性薄 膜層合物、物件及其製造方法（Elastic Film Uminata
Amcles and Methods of Manufacturing Same)」的美國臨時 申請案No· 60/790,663的優先權。 【發明所屬之技術領域】
本發明關於彈性薄膜層合物及製造此類層合物的方法和 併有此類層合物的物件。 【先前技術】 彈性薄膜層合物用來製造多種物品。彈性薄膜層人物尤 其用以製造吸收性物件’例如，尿布、訓練褲、成：失禁 物件以及類似的物件。該彈性薄膜層合物可用作，例如， 腰帶，褲腳口、側[侧耳、側條或作為物件的外殼。彈 性薄膜層合物還可用於別的物件，例如外衣、帽子、長 袍、連褲的工作服等等，並且通常還絲對物件提供八^ ::同形式製造薄膜或層合物時，原料從原料成形或伸 直方開始’沿著被稱作是機器方向（”_，，）的路線行進 =元4_捲繞於”上為止。該機器方 對 於織物的最長的尺寸。橫 吊于尤 向，並通常對應於織物的寬:已^ 勺見度。已經&出了今客 膜和層合物，但大多H ^ +夕種蜂性薄 α 一 數沒樣的薄膜和層合物都設計且#；^ 成在橫向("CD”)提供拉伸。 郡-4且建構 H9918.doc 200806477 迄令，在機器方向具有拉伸 ^ ^ r m ^ 、弹^層5物的最普通形式 尚未使用薄膜，而是僅用 ^ ^ 吏用的弹性紗的層合物 LYCRA®品牌的彈料紗。赞 灼如， 於張力下並膠黏層合於至少 f、截維置 維織物。已知非織造織物為…？為兩片)非紡織之纖 飞物為層合物提供消費者所直缸 似布的質地。然後，鬆開 、。子之類 ^ ^ " 結果非紡織的纖维桃1 聚集並Μ縮，導致轉料形 ^哉物 褲和成人失禁物件，膨鬆的外形曰^二中’例如訓練 所得到的層合物更光滑和_ 疋7 則快的。為了使 〇 “和孝父不膨鬆，所使用的彈性吵數θ 需要增加約二倍。捭Λη r k 斤丨王數$ -° 弹性紗的數量增加了層合物沾4、 本’還導致了争if M B σ物的成 h 雜較不穩固的製造過程。數量拇力的 、夕'線變得難以控制，而且 3 製造過程相當長一段時門古， 線斷衣，都需要停止 a1直到紗線重新穿引到機器中。 :需要一種具有改良之特性且能以穩固過程心而 較光滑、較不賴之彈性相。 而 【發明内容】 在具肢貫施態樣中，本發明接徂了一猫剎* 層合物的方法m勺社 ⑻了-種製這彈性薄膜 二 去包括在將薄膜層壓成至少一基材之 則，要用多重步驟拉伸薄膜。 在另一具體實施態樣中， 合物，i包衽“了一種彈性薄膜層 基材之彈性薄膜，其中該薄膜 基材接合之前已經以多重步驟拉伸。 复=-具體實施態樣中，本發明提供了一種服裝物件， 括一彈性薄膜層合物，其中薄膜層合物包括接合於至 H99l8.doc 200806477 二已二生溥膜’其中在該薄膜與基材接合之前，薄 膝已經以多重步驟拉伸。 在麥考圖式和所附申請專利範圍而進 後，本發明的此等及其他層面將更明顯。 …曰 % 【實施方式】 •百先麥考圖1’其中顯示了本發明彈性薄膜層合物的一 •"岭’其包括接合於至少-基材之彈性薄膜。圖/ Z不的^㈣膜層合物1G包括具有彈性核心的彈性薄膜 =較佳地，薄膜12還包括至少一表層16，該表層16設置 在彈性核心14的至少—Mi μ ^ , 扪主 > 側上。更佳地，如圖！所示，在核 心14的每一側上都有至少一表層“。應當理解，在核心 的每-側上都具有超過一表層的具體實施態樣已經完成並 且可因使用而獲得好處。該彈性薄膜12附著有至少一基 材，例如非織造織物18。在一較佳具體實施態樣中，層合 _ ⑱包括附著在彈性薄膜12之每—侧的非織造織物1 8。 如前文所述，彈性薄膜12包括一彈性核心14及視情況使 用之一個或多個表層16。彈性核心14包括例如天然的或合 • 成的橡膠，例如，異戊二烯、丁二烯-苯乙烯材料、苯乙 . 烯嵌段共聚物（例如，苯乙烯/異戊二烯/笨乙烯（SIS)、苯 乙烯/ 丁二烯/苯乙烯（SBS)、或苯乙烯/乙烯/ 丁二烯/苯乙烯 (SEBS)嵌段共聚物）、烯烴彈料、聚醚酯、聚胺基曱酸酯 及其混合物。 如果個或多個表層16與彈性核心14 一起使用，則彈性 1199ia.doc 200806477 薄膜12較佳是用共擠壓方法製造，其中彈性核心“和一個 或多個表層同時從一沖模中擠遷出來。或者，可使用諸 如擠屢塗覆的方法製造多層薄膜12。如果使用表層心宜 可包括任何彈性低於彈性核心14的合.適材料。較佳的材料 是聚烤烴聚合物，詳言之是聚乙烯聚合物和共聚物，包括 . $金屬-催化聚乙烯和聚乙烯聚合物或共聚物的混合。若 需要，也可使用如醋酸乙烯酯共聚物的其他材料。 • 在彈性薄膜12中，表> 1 6 g • . . , ffl , 表層1 6相對於核心層14的數量可根據 2= 特性而改變。—多層彈性薄❹的較佳 觸至如:技:二:咖 理Mm 的，薄膜12可用紋 =同：以…或製造為帶有光滑平面。例如，可有效 :用-真空箱來製造帶有光滑平面的薄 中，真空箱將部分直* “過私 造㈣，產生較未使 •更薄的規格的薄膜。產生的薄膜更光滑並通常有 非織造織物18可用任 例如，經由构人_ 式接合到彈性薄膜12， 】、’ 工由黏合劑接合、超聲波接合、熱 - 或其他合適的方法。 2接δ， 使用接合方法的組合。 •辭果非織造織物」意謂著 任何規則或重複圖樣之纖維織物。非^==亚沒有 是習知的且报容易得到。這樣的織二=在f技術界 的、紡黏的或粗梳織物 β 彳如、、方絲黏合 的雙組份纖維。非η、“ 疋早絲纖維或具有芯鞘結構 以是可伸展、不可伸展、 119918.doc 200806477 彈性或無彈性。辭彙. 至少-個方向上“料’該材料可在 白上拉伸至約其原始尺寸的150。/ „ 力釋除後，材料可回復到不大於 。，並且當張 寸。例如，—英^… 原始尺寸的125%的尺 央寸長的材料若能拉伸至1·5 备釋除張力且鬆開材料 、、又，而 該材料係為彈性。 ·25央寸，則 現在參照圖2’其描述了 方法的示意圖。彈性〜” 月層。物的例示 _。在第-或初❹^ 後’進行第—拉伸步驟 ,,, 一。拉伸步驟100中，彈性薄膜12被拉+或 =伸至足夠量以使得能減少薄膜的回復力、 構、薄膜的單位；= 吏：的彈料的類型、薄膜的特殊結 實施態樣中，薄膜里在私類似的考慮而改變。在較佳具體 多。儘管除了在: 伸步驟1〇°拉伸至4°°%或更 力_/、 方向拉伸外，薄膜亦可替代性地或附 加性地在橫向拉伸 ^ 機械方向拉伸。 特“體實施態樣中’薄膜係於 置=中的拉伸可用任何已知和合適的拉伸方法和裝 的> I列如’缚膜可穿過兩套隔開的滚筒，下游滾筒 度要高於上游滾筒的運行速度，從而能在助上 、11或者’如果需要的話，薄膜可以使用拉幅機在 向疋向或者薄膜可進行咬合齒輪（IM⑺拉伸操作， :、中薄膜被迫通過兩相互配合的有齒滾筒形成的夾。當薄 。匕由相互齒合的齒或滾筒形成的夾時，薄膜被拉長和 拉伸。IMG拉伸可以在_也可以在CD完成，如果需要的 H99l8.doc -10- 200806477 話。亦可有利地採用技術界已知的其他拉伸操作或拉伸方 法的組合。如果彈，㈣膜12上存有表層16，如㈣界所羽 知，拉伸步驟刚足以使表層變形，因而能允許彈性核: 伸長和收縮。 % 薄膜12在初始拉伸步驟_中拉伸後，可以在鬆他牛驟 細中放鬆。此時，除了在下—個拉伸操作之前可能二生 的任何處理過程中在MD帶動薄膜及支撐薄膜所需，薄膜 一般不受任何可察覺的張力。例如，t薄膜在這個步驟中 放鬆的時候，若需要，名讳^主 在視丨月况使用之穿孔步驟300時處 理薄膜以給予薄膜透氣性是有利的。 給予透氣性的方法包括穿孔、縱切和其他的技術，例如 熱針穿孔n刻痕、剪切或通過使用高壓水柱。之些 方法的結合也是可以使用的。申請人發現，與在初始拉； 步驟100之丽打孔相比’如果穿孔加在初始拉伸步驟100之 後，薄膜12就不致撕開或斷裂。如果使用穿孔或狹缝，則 可選擇性地引進’也就是說’只在薄膜12的敎的區域引 進。牙孔的數置、大小和形狀由所完成層合物的特定所需 特1·生决&如下將要詳細描述的，也可用「切和放」 ("c—ce”)裝置穿孔來更好的處理薄膜。 儘管並非特佳，在製造彈㈣膜12時，可❹真空形成 方法來給予透氣性。此i雜垂 員〃體貝知恶樣不是較佳的原因是 因為如果在第一拉伸步驟1〇〇之前打?匕，薄膜在拉伸的過 程中撕破、撕裂或斷裂的可能性較大。相似地，若需要， 可在第二拉伸步驟4〇〇之後給予薄膜。透氣性。 1199l^cj〇c 200806477 鬆弛步驟200和任何視情況使用之薄膜穿孔之後，薄膜 12又一次在拉伸步驟4〇〇中拉伸。與第一拉伸步驟1〇〇」 樣’用於拉伸薄膜12的方法和裝置對本發明並不重要。步 騄00的拉伸私度等於或小於第一拉伸步驟1 〇〇給予的拉伸 E。在較佳具體實施態樣中，第二拉伸步驟4〇〇的拉伸程 • I小於第-拉伸步驟1。〇給予的拉伸程度。例如，如心 膜12在第一拉伸步驟100拉伸了 300%(相當於4:1的拉伸 • 比），那麼薄膜12在第二拉伸步驟彻可拉伸2應（3.1:1的 申）相似地，如果薄膜12在第一拉伸步驟1〇〇拉伸 4〇〇%(相當於5:1的拉伸比），那麼薄膜12在第二拉伸 400可拉伸不超過35〇%(4 5:1的拉伸比卜 因為薄膜已於步驟100中預拉伸，故第二次拉伸 力將減少，並且可能降低多達8〇%。另外，第一拉伸： ⑽導致薄膜的回復力減少，回復力也就是薄膜在試圖 復到其原始尺寸時所產生的力。因此，在第二拉伸步驟 春 4GG期間，使薄膜保持張力下所需之力較少。 需要注意的是，圖2所描述的方法只顯示了兩個拉㈣ 驟，依據本發明這是拉伸步驟的最小數量。秋而，〜乂 可以使用多於兩個的拉伸步驟。 右*要 在第二(或之後的)拉伸步驟彻期間，雖 :拉伸狀態’但在層合步請期間，若需要，將薄膜： 者在非織造織物18上是有利的。在薄膜處於拉 、 將非織造織物與薄膜接合，當薄膜上的張力‘= 形成聚集在一起的非織造織物。接著，層合物能夠至= 119918.doc -12- 200806477 伸到其與非織造織物接合時的拉伸狀態，而不破壞或 斷接合或不使非織造織物中的纖維變形。 申請人發現本發明的方法改進了薄膜與頓造織物 的接合強度。雖然不欲受限於任何特殊理論，"人計 彈性薄膜的低⑽力減少了 _試隨離非織造織物而^ 生的力，結果產生較強的接合。
在層合步驟500期間，薄膜12被層合於-個或多個非織 造織物18。層合可通過任何合適的技術實現，例如，黏： 層合、熱接合、超聲波接合、M力黏結或動力機械接合。 也可有效利用這幾種技術的組合。 在層合步驟500之後，所得層合物10在鬆弛步驟_中放 鬆。出人意料之外地，經由多個拉伸過程形成的層合物且 有較只用-次拉伸過程形成的層合物為大的伸長度。/、 鬆弛步驟200之後的低回復力（此亦可視為是保持薄膜處 於拉伸狀態所需的力）在薄膜用於切_和·放型裝置的時候也 是有利的。切和·放型I置用於很多尿布製造過程和其他 工業生產過程中。將原料切成所需的尺寸或形狀時，此等 裝置通常用真空壓力將原料維持在定位，接著此等裝置將 切片放置或移動到生產過程之另一位置。 本發明内文中’在尿布的製造操作中，可使用切-和-放 裝置來形成，例如尿布.的側耳（side ear)或側條（side panel)。詳言之’彈性薄膜12可在製造位置進行第一拉伸 操们00、鬆弛步驟200和才見情況使用之穿孔步驟·。接 著’將原料捲繞於滾筒並送到尿布製造器，在尿布製造器 119918.doc 200806477 處展開4膜並進行第二拉伸操作4〇〇。於拉伸步驟400期 間，使薄膜在處於張力下時接觸真空裝置，並將薄膜切成 所欲的尺寸和形狀。裁切原料之後，保持原料處於張力下 之唯-力係真空麼力。這時候，薄膜切片 織物，並且在層合步驟5。〇,薄膜切片從真空釋放 此時，彈性薄膜仍藉由非織造織物保持處於張力下，若欲 :止非、哉、織物，則保持處於張力下直到附著第二個 非織造織物，之後，可於步驟600放鬆。 從此描述得知，顯然彈性薄膜的回復力需 裝置的能力相匹配以保持 ^ 外，其他的因素也是需要考/^下^^ 而，含餅女纟 考慮的，例如，摩擦係數。然 ，备斤有條件都相同的愔 …、 伸在沒有減少薄膜單位重量，在^明彈性薄膜的預拉 種= )或絲其他措施的情況下、提供了 種方便’節省成本的解決方法。 徒供了一 “所时淪的具體實施態樣涉及將 或多個非織造織物，但應當理解 到—個 他基材。其他合適基 ^要亦可使用其 聚乙婦、聚丙稀、乙烯醋：^ 料；纖維材料(包括纖濰_、心？、它該等聚合物材 聚醋、聚歸煙、丙稀酸樹脂、、人非纺織材料，包括 素材料’熱塑性彈料和彼等的混：室、准、棉花或其他纖維 詳細描述的具體實施態樣預二;膜:二 度或兩個方向相對均勻拉、石者它的長度、寬 H9918.doc 二''而’應當理解，某些具體 -24- 200806477 n广‘對薄膜提供了間歇拉伸或只在某個區域拉伸，從 而提供期望的層合物特性。例如，jmg拉伸就是一種間歇 拉伸形式，因為薄膜接觸滾筒齒的點充當央持點。薄膜在 乂、不拉伸’而疋在緊鄰失持點的位置拉伸。隨著Μ。 啟動的深度增加，拉伸的區域也增加，直到整個位於會間 的薄膜區域被拉伸為止。 圖3顯示了間歇拉仰的另-個例子，其包括使用了兩個 夹’第—個夾30由光滑輥31和肋形輕32組成，第二個夹4〇 由兩個光㈣41、42形成。肋形輥具有蔓延整_長度 (即’如圖3所示的，紙平而夕咖 内和、、、氏平面之外）的平行凸起 部分或肋33y遺著輥旋轉，薄膜12交替地被凸起的⑽夾 持和釋放。第二個夾40的輥41、42比第一個夾的輕的旋轉 速度快。在圖3所示具體實施態樣中，如箭頭5〇所示，薄 顏從夾3〇朝向夾4〇的方向移動。結果，當薄膜12交替地 由第一個夾所夾持和釋放的時候’薄膜被間歇地拉伸及不 拉伸。薄膜的拉伸出現在第一個夾3〇和第二個夹之間 的區域。肋形輥32的旋轉速度、肋33的數量、肋μ的尺寸 和形狀以及肋形輥32的相鄰肋33之間的間距決定了拉伸和 不拉伸區域的相對尺寸。第二個夾4〇的輕ΟΙ的相對 度決定了給予薄膜12的拉伸角度。 、 亦參考圖3,基材18在第二個夾㈣處弓丨進並由此被層 合到薄膜12。如圖3所示的，所得到層合物將包括盘不可 拉伸區46分離的可拉伸區域45 ’可拉伸區域係對應：薄膜 12在受張力下被連接到基材18的位置，不可拉伸區^係對 11991S.doc 200806477 應於基材18在未受張力下被層合到薄膜12的位置 由使用旋轉凸輪或其他致動裝置， 與薄膜112嚙合或脫離。 預期肋33可對應於薄膜12的寬度或可比薄膜以更寬或更 窄。如果肋33比薄膜12的寬度窄，那麼薄膜將只在一部分 被夹持’這-部分沿著薄膜寬度方向並對應於助33的位 置。這樣的具體實施態樣可為層合物的特性提供更大的變 化。另夕卜，預期也可使用間歇失持和釋放的可替換方法來 代替肋形#昆32。例如，爽3〇的兩個輕可皆為光滑，並且藉
將一個這樣的輥移動以 實施例 表!顯示兩片除了單位重量差異外完全相同之薄膜，在 第：和第二拉伸步驟之間拉長薄膜所需之力的減少。因為 在第-拉伸步驟之後’拉長薄膜所需要的力較少，保持薄 膜處於張力下所需之力亦較少(即，亦具有較低回復力）。 ㈣施例中’製備兩片薄膜，—片具有3〇克/公尺 的早位重# ’另―片具有4()綱的單位重量。薄膜首先拉 ㈣4嶋伸長度（表艸記錄為「預拉伸」）並放鬆。接 著’在第—拉伸步驟中，薄膜拉伸到3〇〇%伸長度（表1中記 錄為第一循環」）。表〗記錄拉伸薄膜所需的力。
圖4至圖8描緣力相對於伸長度百分比的數據。詳言之， 圖4顯不將30 §咖和4〇以扣的薄膜初始拉伸（”預拉伸"）到 II9918.doc -16- 200806477 400%所需的力。曲線318-1對應於40 gsm薄膜，曲線318-2 對應於3 0 gsm薄膜。圖中還分別顯示了回復力曲線且枳示 為3 18-1R和318_2R。圖5顯示薄膜第二拉伸步驟第一循 環的相似曲線圖。用相同的數字來確定樣本。 圖6是一類似圖表，顯示薄膜在第三拉伸步驟中拉長至 300%所需的力。最佳可由圖7和圖8看出（其分別是仞ρ
㈣gsm薄膜的圖4至圖6的合成圖），與第二次拉伸薄膜 初次拉伸薄膜所需的力有顯著差異，_，之後的 第三次拉伸薄膜所需的力就只有很小差異了。 f管已經參照各種料的具財施態樣描述了本發明， 但攸本發明的揭示内容可明 請專利範圍的範圍内。 種七改係涵盘於隨後的申 【圖式簡單說明】 圖1為本發明彈性薄膜層合物的示意圖。 圖2為描述本發明製造彈性薄膜 的示意圖。 σ物的例示製程之步 圖3為可用於本發明的間歇拉伸製程的-立 圖4為描繪一具體實施態樣之第一 、^圖。 分比相對於力之圖。 伸週期的伸長度百 圖5為描繪一具體實施態樣之 分比相對於力之圖。 —拉伸週期的伸長度百 圖6為描繪一具體實施態樣之第二 分比相對於力之圖。 〜拉伸週期的伸長度百 圖7為繪製具有4〇 gsm單位 重量的具 體實施態樣之三個 119918.doc •17- 200806477 拉伸週期的伸長度百分比相對於力之合成圖。 圖8為繪製具有30 gsm單位重量的具體實施態樣之三個 拉伸週期的伸長度百分比相對於力的合成圖。 【主要元件符號說明】 10 彈性薄膜層合物 Λ 12 彈性薄膜 14 彈性核心 H 16 表層 18 非織造織物
119918.doc -18-

Claims (1)

  1. 200806477 十、申請專利範圍： 1· 一種層合物，其包括層合於 王夕 暴材織物之彈袖碡 膜，其中該彈性薄膜為厗 4 一、— M在層合至該至少一基材織物之前已 經進行至少兩次拉伸步驟。 2 ·如睛求項1之層合物，苴中兮η 和至少一表層。…、中料性薄膜包括-彈性核心 3·二請求項1之層合物’其中該至少-基材織物係包括一 非織造織物。 括 4。如請求項1之層合物，苴中兮^ α — 具中5亥弹性薄膜係多孔性的。 5· 一種製造層合物的方法，兮古、土 兩"亥方法包括以下步驟： (a) 提供一彈性薄膜； (b) 在至少一方向拉伸該薄膜； (c) 鬆弛該薄膜； (d) 在至少該_ ^ ， 方向上至少再一次拉伸該薄膜； (e) 在拉伸該薄膜時將 、 才竹β溥膜層合於至少一基材織物， 以形成一層合物；以及 (f) 鬆弛該層合物。 6 · 如請求項5 $古、、土 蓉 、 ，，，、中該薄膜在步驟（d)中的拉伸程度 或小於其在步驟（b)中的拉伸程度。 7 ·如請求；；jp 5 古、土 ^ , ,丨、^ 、方法，其中步驟（e)包括將該薄膜層合於至 ^ 一非織造織物。 8 ·如请求項$ 、一、 '，/、中該彈性薄膜包括一彈性核心和 芏/ 一表層。 9. 如請求項〇 ^ > 、 去，其中該步驟（a)包括共擠1 一具有彈 119918.doc 200806477 性核心和至少兩表層的彈性薄膜。 10. ::求項5之方法，其中步驟⑷至步驟⑷係由一薄腺 I °°執仃，且其中步驟（d)至步驟（e)係由一物件製造器執 行。 、 11. 如請求項1 0之方法，盆由 <万居其中该步驟（d)至步驟（0的至少一 分包括使用切-和-放裝置。 12_如請求項5之方法，其進-步包括以下步驟： (g) 捲繞該薄膜；以及 (h) 展開該薄膜； 其中步驟⑻和步驟㈨在步驟⑷和步驟⑷之間造/ 13. 如請求項5之方法，1 j進仃。 • ^ 八進步包括以下步驟： (i) 對該薄膜穿孔； 其中該步驟⑴係於步驟⑷和步驟（d)之間進行 14. 一種由請求項13之方法製造的層合物。 。 15. —種由請求項5之方法製造的層合物。 16. 一種包括層合物之物件，該層合物包括層合 材織物之彈性薄膜，其中該彈性薄膜在層合於）少〜 基材織物之前已經進行至少兩次拉伸步驟。”至少 .如請求項16之物件’其中該層合物係由 方法製借： Λ下步 製 部 基 方法製備： (a) 提供一彈性薄膜； (b) 至少在一方向拉伸該薄膜； (c) 鬆弛該薄膜；⑷在至少該—方向上至少再—次拉伸該薄m ; 之 119918.doc 200806477 (e) 在拉伸該薄膜時將該薄膜層合於至少一基材織.物， 以形成層合物；及 (f) 鬆弛該層合物。 18.如請求項16之物件，其中該彈性薄膜係多孔性的。
    119918.doc
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ATE528132T1 (de) 2011-10-15
US11958279B2 (en) 2024-04-16
DE07105467T1 (de) 2008-02-21
EP1844928B1 (en) 2011-10-12
JP2007276483A (ja) 2007-10-25
KR101325798B1 (ko) 2013-11-05
US20180099495A1 (en) 2018-04-12
EP1844928A1 (en) 2007-10-17
KR20070101136A (ko) 2007-10-16
US20120018083A1 (en) 2012-01-26
US9821542B2 (en) 2017-11-21
ES2291152T3 (es) 2012-02-20
ES2291152T1 (es) 2008-03-01
JP4668944B2 (ja) 2011-04-13
US20070237924A1 (en) 2007-10-11

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