TWI279469B - Elastic nonwoven sheet for medical articles - Google Patents

Abstract

This invention relates to stretchable nonwoven sheets prepared by substantially uniformly impregnating a necked nonwoven substrate or an easily extensible as made nonwoven substrate with an elastomeric polymer by treatment with an elastomeric polymer solution. The nonwoven sheet is useful in the manufacture of diapers and other hygiene articles. The nonwoven sheet is also useful in medical articles and applications.

Description

1279469 IX. INSTRUCTIONS: Cross-Reference to Related Applications This application is a continuation-in-part application of U.S. Application Serial No. 10/413,172, filed on Apr. 14, 2003. TECHNICAL FIELD OF THE INVENTION The present invention relates to stretchable nonwoven sheets suitable for use in the manufacture of medical or personal hygiene articles. More specifically, the stretchable nonwoven fabric sheet is formed by substantially uniformly impregnating a neck-spun nonwoven fabric substrate or a thus-obtained extensible nonwoven fabric substrate with an elastomeric polymer. [Prior Art] Elastomeric nonwoven materials are well known to those skilled in the art. Examples of elastic nonwoven materials include "stretch bonded" and "necked" laminated materials. The stretch bonded laminate is prepared by joining a corrugated layer to an elastic layer while leaving the elastic layer in an extended condition such that the wrinkle layer wrinkles as the layers relax. The neck-bonded laminate is produced by joining a necked inelastic layer to an elastic film on the fiber layer. The elastic layer typically comprises an elastic film or an elastic nonwoven web. These elastic nonwoven laminates require the preparation of at least two separate nonwoven or film layers. U.S. Patent No. 4,366,814 to the name of the entire entire entire entire entire entire entire entire entire entire entire entire entire entire entire entire entire entire entire entire entire entire entire entire The fabric does not fill the elastomer of the holes in the fabric. U.S. Patent No. 5,910,224, the entire disclosure of which is incorporated herein by reference to the entire entire entire entire entire entire entire entire disclosure The shrinkable material is placed in a non-woven mesh sheet. When the neck is stretched, the neckable material is (for example, heated), and the same material is elastic::: under necking conditions to form a bond to the neck.焱佳 elastomer precursors include latex or a sturdy elastomer. The elastomer precursor is applied to the neckable material in an amount of from 2, τ sm to about 50 g/m 2 . The elastic 俨 layer — w body layer is generally permeable to the mesh of about 2 to about 10 fibers, and the degree of penetration of the elastomer precursor is controlled so that the mesh side of the side of the urging layer No osmosis. The resulting stretchable composite thus has a film-like feel on the side comprising the elastomeric layer and retains the inherent soft hand of the neckable material on the opposite side of the elastomeric layer. The publicly-supplied European-speaking body has been described by the above-mentioned owner 1 for the application of the patent, No. 0474942, which describes a kind of elastic saturated non-woven fabric material which has dust shrinkage and recovery in the direction B, and includes a composite material (for example, elastic acrylic (tetra) latex. , a polyurethane mesh saturated with a polyurethane or a nitrile rubber (10) (for example, a non-woven mesh of fibers). Japanese Laid-Open Patent Publication No. 47-24479 relates to a belt for a conveyor and power transmission, which is produced by impregnating a non-woven fabric with rubber or synthetic resin. The industry still needs a system that can be used in a sturdy manner; the female eye 22 κ & Θ k k, elastic sheet material with weak stretch and good retention and both fabrics have a fabric-like feel. SUMMARY OF THE INVENTION The present invention is directed to a method for forming a stretchable nonwoven fabric sheet, the method comprising the steps of: providing a neck having a thickness, first and second outer surfaces, machine direction and transverse direction a nonwoven fabric substrate having an elongation percentage of at least 30% in the transverse direction of 109658.doc, 1279469; substantially uniformly impregnating the neckless nonwoven fabric with a solution comprising an elastomeric polymer dissolved in a solvent Substrate; and removing the solvent from the impregnated nonwoven substrate by wet solidification to substantially uniformly deposit the elastomeric polymer over the thickness of the nonwoven substrate without first or second on the nonwoven substrate A substantially continuous layer of elastomeric polymer is formed on the surface.

The invention further relates to a method for forming a stretchable nonwoven fabric sheet, the method comprising the steps of: providing an extensible nonwoven fabric substrate thus produced having a thickness, first and second outer surfaces, a machine Direction and transverse direction, at least elongation percentage in the transverse direction, a basis weight of about 15 g/m 2 and about (10) g/m 2 , a fracture toughness of more than 500 g/inch; an elastomer of the bar 3 bath in a solvent The polymer solution is substantially uniformly impregnated with the extensible nonwoven fabric substrate thus formed; and the extensible nonwoven substrate transfer agent thus formed by wet solidification is substantially uniform throughout the thickness of the nonwoven substrate The deposition elasticity _ ^: and * forms a continuous elastomeric polymer layer on the first or second outer surface of the nonwoven substrate. Only =: relates to a stretchable nonwoven fabric sheet comprising a non-woven fabric substrate which has been uniformly impregnated along the (four) square (four), the stretchable nonwoven fabric sheet along the neck: :::: The ratio of the stretched non-woven fabric at (10)% stretch: the third force at the periodic force and the elongation at break ^= J09658.doc 1279469 0.3:1 . In addition, Maoyue relates to a stretchable nonwoven fabric sheet comprising the easily stretchable nonwoven fabric substrate 2 thus formed, which has been uniformly impregnated with an elastomeric polymer scallop along the stretchable nonwoven fabric sheet. After the third elongation in the transverse direction to 3〇%, the ratio of the third no-load period force at the 3Q% elongation to the third load period force at the 3〇% elongation is at least ο". Embodiments In the present invention, a -stretchable composite non-woven fabric sheet is provided by using a solvent-impregnated solution of a solvent and an elastomeric polymer to immerse a neck-woven nonwoven fabric substrate or an extensible nonwoven fabric substrate thus produced. The neck-spun nonwoven fabric substrate or the extensible nonwoven fabric substrate thus formed is impregnated under the condition that a non-woven fabric substrate is substantially impregnated: a polymer layer is formed on any surface thereof. After the solvent is removed, a A breathable, impregnated, non-woven fabric sheet having an unloaded periodic force (for good holding power and weak stretching)/, and an unexpected combination of a square fabric-like hand feeling that is relatively negative in the transverse direction and high in periodic force. The cloth of the present invention is generally more conventionally known. Layer Stretch Laminates For ease of example, the panels of the present invention may have a typical scale of from about 0.25 mm to 0.75 mm: and the thickness of the stretch laminate typically exceeds 13 mm. The term "polymer" is used herein. "Generally includes, but is not limited to, homopolymers, mounds such as block copolymers, graft copolymers, random copolymers and alternating, /, ♦), binary copolymers, etc., and blends and modifications thereof. Modifications. Moreover, unless specifically limited, the term "polymer" shall include all possible geometric configurations of the material. Such configurations include, but are not limited to, full gauge, random symmetry. 109658.doc 1279469 The term "polyester," as used herein, is intended to include polymers in which at least 85% of the repeating units are condensation products of a diacid and a dihydric alcohol, the linkages of which are formed by the formation of a unit. Aromatic, aliphatic, saturated and unsaturated diacids and diols. The term "polyester" as used herein also includes copolymers (eg, block copolymers, graft copolymers, random copolymers, and alternating copolymers), Blends and modifications thereof. A common example of a polyester is poly(ethylene terephthalate) (PET), which is a condensation product of ethylene glycol and terephthalic acid.

The term "polyurethane" as used herein is intended to include a block copolymer formed by polycondensation of a difunctional polyfluorene with a diisocyanate and a difunctional chain extender, as will be explained in more detail below. As used herein, the term "polyolefin" is intended to mean any series of substantially saturated open-chain polymeric hydrocarbons consisting solely of carbon and hydrogen. Typical polyolefins include, but are not limited to, polyethylene, polypropylene, polymethylpentene Various compositions of olefins and ethylene, propylene and methyl pentene monomers. The term "polyethylene" as used herein is intended to encompass both ethylene homopolymers and copolymers, wherein at least 85% of the repeating units are ethylene units.浯 "Polypropylene" is intended to encompass both propylene homopolymers and copolymers, wherein at least 85% of the repeating units are propylene units. As used herein, "inhabited elastomeric polymer" means any sheet that is formed into a sheet, fiber or film and applied. - a polymer that is stretchable to a stretched length when biased, at least about 160% of its length that is unbiased with no rain 1 and at least 55 of its elongation when this elongation biasing force is released. The gland is a ^ μ /. Will wait to recover. For example, when a force is extended to a 1.6 cm knife and the force is released, one can be extended to at least 1.6 cm and 1 cm. The sample is restored to a maximum of 1.27. Public 109658.doc 1279469 ί The length of the minute. ▲ in a variety of elastomeric materials that can be stretched to more than 6〇% (eg, 100% or less) of their relaxed length' and a variety of these materials restore the initial relaxation length of the shell when the tensile force is released (10) Within 105% of its initial relaxation length). As used herein, the term "nonwoven fabric" or "nonwoven fabric" refers to the structure of a planar material of an unrecognizable pattern formed by individual fibers, quasi-I or 4-wires, which is the opposite of a knitted or knitted fabric. As used herein, the term "spunbond," refers to a filament formed by the following method: extruding a (four) plastic polymer material from a plurality of fine, generally circular spinneret pores as a filament, The diameter of the wiped filaments is then rapidly reduced by stretching. Other filament cross-sectional shapes such as elliptical, multi-lobed, etc. can also be used. Spunbond filaments are generally continuous and have an average diameter of more than about 100 meters. Spunbonded nonwoven fabrics or webs are formed by placing a spunbond (4) machine on a collecting surface, such as a perforated screen or belt. Spunbond webs are typically bonded by conventional techniques known in the art, such as hot roll opalescence or by passing the web under high pressure through a knuckle, a crucible, a crucible, and a steam chamber. In addition, the web is thermally bonded at a plurality of thermal bonding points at the ends of the spunbond fabric. The term "machine direction" (MD) as used herein refers to the direction in which the nonwoven web is produced. The term "lateral" (XD) refers to the direction generally perpendicular to the machine direction. As used herein, the term "necked" refers to a method that involves applying a force to a nonwoven fabric (eg, parallel to the machine direction of the nonwoven fabric) to cause the nonwoven fabric to elongate in the direction of the applied force and perpendicular to the direction of elongation. The square ^ (for example in the lateral direction) is reduced in width to the desired amount in a controlled manner. In the text 109658.doc ^ 279469 < the direction perpendicular to the direction of elongation is referred to as the "neck direction". The controlled stretching and necking can be carried out at temperatures below or below room temperature. And limited to the increase in the total dimension in the direction of stretching does not exceed the elongation required to tear or break the fabric. The term used herein, neck-spun nonwoven fabric, 'and, neck-spun nonwoven substrate' buckles have been By shrinking in at least one direction by a process such as stretching, crepe, crepe, and smear. A "neckable non-woven fabric" is one in the necking process to

A non-woven fabric of one size shrinkage. The term "neck percentage t," refers to a ratio, which is determined by measuring the difference between the unnecked size and the necking size (measured in the direction of shrinkage) and then dividing the difference by the neck. Shrink the size and will: jin: multiply the ratio by 100. In, the member just, the necking non-woven fabric " can be in the direction of the head + direction - corresponding to (but non-linear relationship) necking hundred > than the amount of extension The necking nonwoven elongation in this paper is measured as the elongation percentage by stretching the _ non-woven fabric to the maximum extent in the _ direction without stretching the individual fibers in the nonwoven fabric, and breaking any interfiber bonding or tearing in the nonwoven fabric. The non-woven fabric. The term "adhesive non-woven fabric thus produced" is not used in any way except for the usual non-woven fabric production process, and the hunting is increased by less than 200 g/inch (g/in). , which is less than 30% (usually: ^〇/^^5 as determined by the method described in the Test Methods section to: 〇% required force) 〇〇/0)#^#^ 〇5〇〇/〇^#^##^_ The sample of the thought can be extended to 15 inches. The easily stretchable nonwoven fabric thus produced has a basis weight of between about 15 and 丨 (,, brother/ten square (g/m) (generally about 109658.doc ^ 1279469 30 to about 80 g/m 2 ). And machine direction fracture dynamics of more than 5 (10) g/inch (as determined by the test method in the test method section >, fracture kinetic analysis). The easily stretchable 彳1f fiber cloth thus produced It may be a spunlace method (also known as spunlace), a meltblown or a thermally bonded non-woven fabric, and it may be prepared by such conventional processes. ^ ~ The term "jet spunlace non-woven fabric" as used herein refers to The high pressure water jet impinges on a web (which may include a pre-formed fabric, a spun-coated web, an air-laid web and a carded web) or a batt formed. The easily stretchable non-woven fabric thus produced comprises the 8075 type Sontar_ (s_ara8 system Μ heart

The registered trademark of Nemours and Company) and the flat spunlace method are not woven (product number 4055-T, manufactured by η g Hung Industrial (Taipei, Taiwan)). The term "flushing and non-woven fabric" used in this article is a slap in the face of a one-person Λ 一 系 系 系 系 系 系 系 系 系 系 系 系 系 精 系 系 系 系 系 系 系 系 系 系 系 系 系 系 系 系 系 系 系 系 系 系 系Non-woven fabric formed in the flow of short fibers. The * temple fibers are deposited on a moving screen or skin W and then consolidated by rolling, laminating, hot air or other heat bonding. The term "thermal bonding does not ^ ^ ^ ^ ^ Λ can be fastened by a fiber mesh or batt, and into a fabric, the mesh ^ ^, and the cushion contains heat sensitive materials (such as the detonator Low melting point binder fiber or monosexual), the melting point of the melting point is lower than that of the mesh fiber. "The animal is with or without pressure. u", 1 force lower yoke heating (for example, by hot air, When the calendering, rolling, infrared heat or its 埶^^^^", and the adhesive 3 process), the heat sensitive material is melted and the fiber web or batt is slid--"bonded to a non-woven fabric. As used herein, the term "nonwoven fabric" is used to buckle a substrate that can be necked without a woven fabric substrate or a stretchable nonwoven fabric made in this manner. The term ''nonwoven fabric'' is used herein. Means a fabric which can be a necked nonwoven fabric or a fabric that is easily stretched. The term "wet coagulation" as used herein describes a process in which a nonwoven substrate that has been impregnated in a solution comprising an elastomeric polymer dissolved in a solvent is contacted with a coagulating liquid, the coagulating liquid to the elastomeric polymer. It is not a solvent but is miscible with the solvent used to form the elastomeric polymer solution. The coagulating liquid can also be selected so that it does not dissolve the nonwoven substrate. The coagulating liquid causes the polymer material to solidify and transfer the solvent to the coagulating liquid. The coagulating liquid is then removed from the non-woven fabric impregnated with the polymer by, for example, air drying or heating. Neckable nonwoven fabrics suitable for use in the present invention include spunbond webs, sheets of adhesive and spunlaced webs. The neckable nonwoven fabric is typically necked in the transverse direction by a method known in the art to achieve a ratio of about 25 〇/〇 to about 5%, to obtain a percentage of elongation in the transverse direction of from about 3% to about 5%. _ shrink non-woven substrate. The neckable nonwoven fabric used in the present invention may be composed of a variety of non-elastomeric polyolefins (e.g., polyethylene, polydiethylene-"Before", polyamide, polyester, polystyrene, and For example, a non-woven fabric, a polypropylene propylene-polyethylene copolymer can be used for the necking of a non-woven fabric. The polypropylene fabric or comb has a fabric of about 10 μm. The initial neckable nonwoven fabric substrate is usually from too much to about 5 grams per square foot. The lower weight can be collapsed. Non-woven fabrics are particularly preferably from square meters to about 3. g/m2": they "have about 10 g / 1 mile. Non-woven substrate pass 109658.doc -13- 1279469 often through wet steam. The nonwoven substrate is necked to provide a necked nonwoven substrate that typically has a basis weight of greater than about 15 grams per square meter. Necked nonwoven fabrics are well known in the art and are typically elongated in the machine direction - The nonwoven fabric can be necked to provide a necked nonwoven fabric that is necked in the transverse direction. An example of a necking process is disclosed in For example, the US Patent 7th State, (1), US 4,965,122, 4th (^1747咕^1;^4,981,747 and 5,114,781) issued to Meitner et al. All are awarded to Morman. A preferred necking process is revealed in the award.

Ha Jr. et al. (Hassenboehler), U.S. Reissue Patent No. 35,2,6. U.S. Patent No. 5,244,482, the disclosure of which is incorporated herein by reference. A non-woven mesh according to the Μ-0* process is also referred to herein as (4) a consolidated mesh. Ί A lower cost system can be used (4) woven and better than other stretchable nonwoven fabrics. Because it has a higher degree of lateral extensibility and requires a lower extension (load) force to extend the non-woven fabric in the transverse direction. Furthermore, the "non-woven fabric is generally not extendable in the machine direction, that is, it is erected in the machine direction - When biasing the force, it has an elongation ratio below about redundancy. The stretching in the substantial direction is discussed below as follows: Highly desirable in use. - In the preferred embodiment, the neck-spun nonwoven substrate is a consolidated web prepared using the method described in Hasse-r. The method comprises passing a bonded thermoplastic nonwoven web having a lower process extensibility through a heated zone (eg, a supply tank to raise the temperature of the web to a web softening temperature of 109658.doc -14 - 1279469) And the temperature between the melting temperature and the degree of progress, while stretching the web in the machine direction, thereby plastically deforming the fibers oriented in the transverse direction and consolidating (necking) the web in the transverse direction. The film is a linear velocity into the heating zone and is / /, taken at a second linear velocity greater than (four) - speed to achieve stretching. The ratio of the speed of the brother to the speed of the brother is (for example) between about u: i Within the scope of the 1st room, the initial bonded non-woven fabric ^, , and the weekly film is a non-elastic neckable non-woven fabric, and it is selected to be at a pressure of more than 2500%/min during the treatment. Rate and higher than the softening point but lower than the melting temperature of the s mesh sheet, the temperature of at least F is less than F. When hot stretching is performed, the T/~ may have a fracture lower than about 4.0:1 and higher than about 1.4:1. Stretch ratio. According to the method of ASTM D 1117-77, an Instron tensile test is used. Machine, the room temperature elongation (strain) of the fracture from the J^ person is between 2% and 40%, for example, between 5% and 20%. The fibers in the mesh can be bonded by inter-fiber fusion, fiber entanglement or thermal bonding (for example, straw bonding by dots). In the case of slaves, the fibers that can be necked and woven have low average fibers. The diameter of the first machine is J飒, and the diameter of the crucible is, for example, less than about 50 micrometers. The spinning is as good as the adhesion in the body, and strong (such as high temperature point bonding) to locally elongate, bend and bend the filament. ^ ... slice slaves without affecting the integrity of the mesh. In the point of bonding dry '4 joints and bonding diagrams, when H (2) is selected, so that the area of the bond points is about 5 and about 25% of the mesh area. Between the _ ^ _. The shape of the bonding point can be a diamond shape or a variety of other shapes known in the art. The hot stretching step allows the fiber rod to be plasticized, the plastic deformation of the door and the consolidation of the mesh, so that the large 2 fibers are usually along Arrangement in the direction of stretching (machine direction). When the web is stretched and heat set relative to the non-woven fabric, it is consolidated in the transverse direction. The elastic non-woven fabric sheet of the present invention is prepared by using a neck-spun nonwoven fabric substrate in the transverse direction of an ancient /, 30% (for example, at least 50%) elongation of 109658.doc 1279469. The non-woven fabric sheet during the consolidation process The percentage of necking is, for example, between about 5% and about 7.5, typically between about 6% and about 7%, which corresponds to between about 100% and 300%, respectively. And the elongation between 15% and 25%. The basic weight of the neckable non-woven fabric can be 3 times or more of the basic weight of the original neckable non-woven fabric. The weight is between about 15 g/m2 and about 1 g/m2, for example between about 2 g/m/

The square meter is between about 1 gram per square meter and is generally between about 25 grams and 7 square meters and about 1 gram per square meter. The basis weight of the necked nonwoven web substrate is selected based on the desired end use. For example, when used as an elastic intermediate lining, the basis weight of the neck-spun nonwoven fabric is generally between about 3 gram per square meter and 70 grams per square meter, and is used for sanitary purposes such as diaper belts. For end use, the basis weight is generally between about 15 g/m2 and (10) g/m2. The basis weight of the neck-spun nonwoven substrate should also be selected to achieve the desired result in the final impregnated nonwoven. Elasticity. Higher basis weight non-woven substrates allow more elastomeric polymer to be immersed in the nonwoven fabric, improving the no-load force of the impregnated nonwoven fabric. f Hassenboehler prefers a lower basis weight in the necking process. Non-woven fabrics preferably produce materials made in accordance with the present invention. Together with an elastomeric water "used and used after being impregnated with it, these factors together provide the stretchable nonwoven fabric with the lower force required to extend the material. (loading force) and the higher retractive force (no-load force) exerted by the material loose material. This feature is preferred for the intended end use of the material. The relationship between the no-load force and the load force and the elasticity Close when not weaving n. For a preferred product of the invention having at least 15% 109658.doc -16·1279469 • > transverse elongation percentage, after the impregnated nonwoven fabric is extended to 140% three times and allowed to relax between extensions, 1〇〇 The ratio of the no-load force at % elongation to the load force at 1 〇 0% elongation is at least 〇3: 丨 and is, for example, higher than 0.45: 1. The elastomeric polymer used in the present invention includes a polyamine group. An acid ester, a stupid ethylene-butadiene block copolymer, and a polyether-ester block copolymer. In a preferred embodiment, the elastomeric polymer is a polyurethane, which is used in the present invention. The elastomeric urethane can be prepared by reacting a polymeric diol with a diisocyanate to form a terminal diol, dissolving the blocked diol (in a suitable solvent), and then allowing the The blocked diol reacts with a difunctional chain extender having an active hydrogen atom. These polyurethanes are referred to as "segmented" because they are derived from diisocyanates and chain extenders. Hard, urethane and urea segments and π soft π segments derived primarily from polymeric diols. Suitable solvents for the preparation of such polymers are guanamine solvents such as dimercaptoacetamide ("DMAc"), dimercaptoamine ("DMF") and N-methyl-pyrrolidine Ketones, but other solvents such as dimethyl sulfoxide and tetradecyl urea can also be used. The polymeric diol used to prepare the elastomeric polyurethane includes polyether diols, polyester diols, polycarbonate diols, and copolymers thereof. Examples of such diols include poly(vinyl ether) glycol, poly(tetramethylene ether) glycol, poly(tetramethylene-co-2-0methyl-4-tetramethylene ether) glycol, Poly(adipic acid ethyl-co-strength butyl S) diol, poly(2,2-dimethyl-i,3-propenyl phthalate) diol, poly(pentane carbonate) -1,5-ester)diol and poly(hexane hexadecane) diol 0, 109658.doc -17- 1279469 Useful diisocyanates include 1-isocyanato groups _4_ [(4-isocyanate) Methyl] stupid, 1-isocyanato-2_[(4-isocyanato-phenyl)methyl]benzene, isophorone diisocyanate, 1,6-ethane diisocyanate and 2,4-toluene diisocyanate. The chain extender can be a diol or a diamine. Useful diols include ethylene glycol, --methylene monool, 1,4-butanediol, and mixtures thereof. A urethane chain extender is used to obtain a polyurethane. Useful diamines include ethylenediamine, H propylene diamine, 2-methyl 1,5-pentanediamine, diaminopentane, hydrazine, 4-cyclohexane _ 1, 1,3-cyclohexane Amines and mixtures thereof. In this case, the resulting product is a polycarbazide urea (a subclass of polycarbazide). When a polyglycol ether and a diamine chain extender are used, the resulting polymer is a polyether urethane urea; when a polyglycol ester is used in combination with a diamine chain extender, a polyesteramine can be produced. Base acid ester urea. A monofunctional amine chain terminator (e.g., diethylamine, butylamine, cyclohexylamine, and the like) may be added to control the polymer molecules. In a preferred embodiment, the elastomeric polymer is a diamine extended polyurethane elastomer. Suitable solvents for the preparation of the elastomeric polymer solution include dimercaptoacetamide, monomethylformamide and N-methyl-pyrrolidone. The viscosity of the elastomeric polymer solution is directly related to the concentration of the polymeric material in the solution and thus the viscosity of the solution can affect the extent to which the polymer penetrates into the neck-woven nonwoven fabric or the easily stretchable nonwoven fabric thus produced and the polymer deposited therein. The amount of both. When the viscosity of the solution is too low, an insufficient amount of elastomer is deposited in the neck-spun nonwoven substrate or the easily stretchable nonwoven fabric substrate thus produced to cause low empty load. When the viscosity of the solution is too high, the penetration of the solution into the nonwoven substrate is reduced, and 109658.doc * 18 - 1279469 results in incomplete or uneven impregnation of the polymer into the nonwoven substrate or formation on the surface of the nonwoven substrate. a layer of polymer. The elastomeric polymer solution to be impregnated into the neck-spun nonwoven substrate or the easily stretchable nonwoven fabric substrate thus produced has, for example, about 1 Torr to 3 Torr, measured at 25 degrees Celsius. The solution viscosity of ("CP") (generally 1 〇, 〇〇〇 to 40,000 PCT). The solution may comprise from about 5% to 20% by weight of the polymer. Or the easily stretchable nonwoven fabric substrate thus produced

It is necessary to absorb the polymer solution and the polymer solution substantially completely and uniformly impregnates the nonwoven substrate. Therefore, the neck-spun nonwoven substrate or the easily stretchable nonwoven substrate thus produced cannot be coated or prevented from being absorbed into the neck-spun nonwoven fabric or the easy-to-weave nonwoven fabric made of & The way to deal with it. The elastomeric polymer solution and/or nonwoven fabric may include a surfactant to promote web impregnation by the polymer solution. Suitable surfactants include nonionic wetting agents such as polymeric surfactants. A small amount of an additive such as a pigment, an antioxidant, an ultraviolet light stabilizer, and a lubricant may be added to the elastomeric polymer solution, with the limitation that the specific additive does not impair the advantages of the present invention. The elastomeric polymer solution may comprise very short fine fibers dispersed therein, such as having a fiber length of less than about ο 10 忖 (2.5 mm) (eg, less than 〇 5 mm) from wood pulp, cotton wadding. The fibrils, and the fibers, are generally small enough to be impregnated with 4 = or natural fibers. penetration. The staple fiber", the non-woven fabric in the heart, the fiber/fiber can be sufficiently immersed in the impregnated nonwoven fabric to 3 to about 12% by weight Μ θ ϋ ϋ & 于 于 于 于 于 于 于Polymer solution, this line 109658.doc -19- 1279469 is calculated as the total weight of the non-woven fabric/elastomer polymer composite. It is generally added to the elastomer polymer solution based on the total weight of the short fibers, elastomer polymer and solvent. a staple fiber between about 10 and about 30% by weight (e.g., between about 1 Torr and about 2 〇 〇/0) by impregnating with an elastomeric polymer solution comprising powdered cellulose. The non-woven fabric of the present invention is prepared from a neck-spun nonwoven fabric or a stretch-formable nonwoven fabric thus produced, which may have a soft hand feeling compared to those of the impregnation solution which does not use short fibers. Suitable for polymerization 10 Examples of the ultrafine fiber particulate material in the solution are powdered cellulose available under the trade name "Arbocel 30" from J. Rettenmaier USA (Sch00lcraft, Michigan). Any solution of the elastomeric polymer can be applied to the neck. Shrink a method of immersing or immersing the neck-spun nonwoven substrate or the easily stretchable nonwoven fabric substrate thus formed on a substrate or a stretch-formable nonwoven fabric substrate thus formed, as long as the fabric is uniformly impregnated and the coating is not concentrated On the surface of the neck-spun nonwoven fabric or one of the surface of the stretchable nonwoven fabric thus formed, or the other surface, it should be noted that the coating method can be used to treat the nonwoven substrate with the elastomer polymer solution. However, the properties of the solution and the non-woven fabric and the coating process conditions are selected such that the polymer/liquid mixture completely wets the nonwoven substrate or completely absorbs or enters the nonwoven substrate so as not to be on any surface of the nonwoven substrate. Forming a polymer layer. In general, the amount of polymer solution applied during coating can be hunted by using a coating tool that is held at a predetermined distance on the neck-spun nonwoven fabric or the stretch-form nonwoven substrate thus produced. To control, the solution can also be mechanically pressed into a nonwoven substrate. Light, plate, doctor blade, knife and the like can be used as a coating tool in the process of the present invention. Spray this solution on 10965 8.doc -20- 1279469 The non-woven substrate is also effective, and the limitation is that the elastomer solution is substantially completely and uniformly impregnated with the non-woven substrate. The spraying force can be adjusted to help obtain good Permeability. Using the technique known in the art as "soaking," a process 2 polymer solution impregnates the nonwoven substrate, and the fiber web/bubble or /X sighs - contains elasticity The excess polymer solution is removed in the tank of the bulk polymer solution by subsequent pressure (e.g., at the clamp). This method is preferred in order to minimize the difference between the two surfaces of the stretchable non-woven fabric sheet.

: The neck-spun nonwoven substrate or the stretch-formable nonwoven substrate thus produced is filled with a liquid-repellent ratio to provide a ratio of the load capacity during the final impregnated nonwoven sheet. The nonwoven substrate is typically impregnated with sufficient polymer to deposit a bomb between about 1 Torr and about 8% by weight. (e.g., an elastomeric mass between about 3 Torr and about 5% by weight) based on the total weight of the elastomeric polymer and the nonwoven substrate. (4) (4) The force and load force (4) are undesirably low, and when the L body is too much, the surface of the I piece is undesirably sticky. The amount of solution can be adjusted in the melted nonwoven fabric or in the easily drawn fabric substrate so as to achieve the desired enthalpy in the impregnated cloth: " For example, $, has been observed to use a lower degree in solution while at the same time obtaining a feel by maintaining a similar elastomer content on the impregnated sheet during the application of the solution by using a wider gap between the members. A product with a better balance with the no-load/load force ratio.

After the aged cloth substrate is impregnated with a solution containing a solvent and an elastomer polymer, the solvent is removed. The cti, Xiao JU, and Qiji were removed by wet reduction followed by removal of the coagulating liquid to remove the solvent. Wet solidification is surprisingly comparable to the thermal drying process in that it provides a product of 109658.doc -21 - 1279469: a hand-feel. Wet coagulation processes are known to those skilled in the art and are commonly used in the production of artificial leather. Since the water is easy to handle and the cost is low: the coagulating liquid is preferred. Other suitable coagulating liquids include carbaryl, ethanol, propanol, acetone or methyl ethyl ketone. A solvent for the elastomeric polymer may be added to the coagulating liquid (for example, dimethylformamide, dimethylacetamide or N-methyl ketone or other additives (such as surfactants)) To change the rate of solidification. In addition, the temperature of the coagulation bath can be controlled to change the rate of solidification. After removal of the solvent, the lower solidification rate gives the impregnated nonwoven a more attractive feel. In the impregnated nonwoven fabric sheet of the present invention, the elastomers are distributed throughout the neck-spun nonwoven fabric substrate or the stretch-formable nonwoven fabric substrate thus formed. In addition, the impregnated non-woven fabric sheet is generally permeable to the soup. The handle of the impregnated nonwoven fabric sheet can be improved by raising or pulling the hair to produce a fiber-softer hand on the surface of the impregnated sheet. The bristles include, and, the sputum passes through a rotating roller 'containing a small metal dot that effectively brushes the fabric to cause the surface to produce fibers. When the pile is raised, the metal brush is replaced with a gray-coated felt covered with sandpaper. In general, both surfaces of the impregnated fabric are napped or woven. For example, t, the fabric can be (4) to the purpose of the sandpaper, the local stretchable impregnated nonwoven fabric generally has a basis weight of about 40 g / square ... spoon 1 GG / square meter. It is particularly suitable for use in diaper belts or sides and other personal hygiene apparel such as underwear. The diapers are assembled in large quantities on the same speed line. The various diaper components in # are usually added in the direction of 109658.doc -22- 1279469 to avoid the special application of the elastomer material which slows down the process. Urine digestion - usually by pulling a component, all of these 16w φ enclosing the phase or more of the diaper is correct for you during the period ... must be accurately placed ^ ^, (cloth, fiber, etc.) along with the diaper When the direction of movement is the same, the card is supplied and the L persons are not transported. In order to add components along the direction of the bridge (for example, stretching in the direction of the gossip, the material itself is in the transverse process. With the addition of the mouth to the diaper production, the belt can be a 7-inch吋 wide and segment, straight injury 6 a 1 Xing Ding long under this arm and glued to diapers or other disposable underwear. Two Si is also preferred to supply the diaper assembly along the machine - The direction is substantially incapable of stretching to facilitate the fact that the stretchable nonwoven fabric sheet is substantially non-stretchable in the machine direction: the center hair is stretchable and has a high recoverable stretch in the transverse direction = making it particularly suitable The stretchable nonwoven fabric sheet of the present invention can also be used as an elastic intermediate lining for repairing various garments (especially jackets and outerwear). The intermediate lining is inserted into the fabric between the outer layer of the garment and the inner layer. Or improving the shape of the garment to maintain, swell, heat retention, harden or bulk. The stretch nonwoven fabric of the present invention is particularly suitable for its low cost and permanent toughness and ability to provide stretching to achieve a comfortable fit size. In an application. Stretchable nonwoven fabric sheets within the scope of the present invention to make them highly suitable for body contours, and which can be used for therapeutic purposes by applying a rebound pressure on an injured or wound area. Therefore, it is within the scope of the present invention. The application can be used for medical supplies and applications. These items and deer use 109658.doc -23- 1279469 k > including (for example) · tape, including adhesive and self-adhesive tape; package, including compression Wraps, bandages; dressings, including surgical and wound dressings; and surgical tendons, including knives that adhere to the skin around the incision. The test method is extended to 30% of the force required to assemble a Merlin data acquisition software. This analysis was performed on the Model 5565 Instr〇n. Both the Merlin system and the instrument hardware were obtained from Instr〇n (Braintree, Massachusetts). The 丨英吋 吋〇·〇5吋吋宽吁 (2 · 54 cm + Λ 0.13 cm) and approximately 8 inches (20.32 cm) of long non-woven fabric samples were clamped in the jaws of the Instron machine, and the sample length was set to 3 inches (7.62 cm). Prepare samples, Make The length direction of the sample is aligned with the transverse direction of the non-woven fabric. The sample is stretched by 30% at a speed of 6 inches/minute (15·24 cm/min). The force at 50% elongation is recorded (in terms of the fracture toughness analysis in grams) Merlin's Data Acquisition Software System Model 5565 Instron _ Implement this analysis. Both Merlin systems and instrument hardware are available from Instr〇n (Braintree, Massachusetts). Will be 1 inch + / _0 05 inches wide (2.54 cm) Samples of +/- 0.13 cm) and approximately 8 inches (2 〇 32 cm) of non-woven fabric were held in the jaws of an Instron machine with a sample length of 3 inches (7.62 cm). Samples were prepared to align the sample length with the lateral direction of the nonwoven. The sample was allowed to elong at a rate of ό 吋 / min (15 · 24 cm / min) until the sample broke into two parts, and the maximum force (in grams) at the breaking point was recorded. Basis Weight '109658.doc -24- 1279469 Carefully loosen a rectangular sample of approximately 1.0 inch of the parent 8.0 inches (2.54 cm / 20.32 cm) of non-woven fabric so that the sample does not contain pleats or wrinkles. Measure both the length and width of the sample (to the nearest millimeter) and weigh the sample (to the nearest tenth of a milligram). The weight is divided by the calculated area and the result is expressed in grams per square meter (accurate to 0.1 gram). Load force and no-load force analysis This analysis was performed on a Model 5565 instr〇n equipped with a Merlin data acquisition software system. Both Merlin systems and instrument hardware are available from instr〇n _ (Braintree, Massachusetts). Hold 1 inch +/- 〇 · 〇 5 inches wide (2.54 cm +/- 〇 · 13 cm) and approximately 8 inches (20.32 cm) long non-woven sheet samples in the jaws of the Instron machine, sample The length is set to 3 inches (7. 62 cm). Prepare the sample 'Align the length direction of the sample with the transverse direction of the non-woven fabric. The sample was stretched by 140% at a speed of 6 inches per minute (15.24 cm/min) and then relaxed to its original length. This operation is repeated twice more, and in the third cycle, when the length of the original sample is elongated, Φ 1 〇 0 ° / ° and U 5 ° / ,, the force exerted by the material on the extension period is recorded (load force) And, likewise, the force (no-load force) exerted by the material on the third relaxation period is also recorded at the same elongation point. The results are expressed in terms of the third cycle load force and the no-load force (expressed in grams) at the appropriate elongation percentage. Percent elongation analysis - 1 pleats or pleats 1 · 〇 吋 (2·54 cm) wide and about 8 inches (2 〇. 32 cm) long non-woven fabric with slack strips at intervals of 40 inches (102 cm) At two points, the pen is marked so that the marks are about the same distance from the ends of the fabric. Then, hold the end of the fabric with the fingers and forefingers of each hand. 109658.docs -25- 1279469 Class = :Ϊ:Extensions but not extended to tear the sample or subject to any addition. As the resistance of the fabric against elongation is significantly increased, it is easy to judge the maximum elongation point. The length between the two points on the back of the bran and by the percentage, wherein the initial length is 10.2 cm: ^ elongation elongation percentage κ silk 彳 by and when ... page shrinkage: denier initial length) / initial length} ; <100% to the party member continuation = when measuring the percentage of elongation, 'cut the fabric sample with the length direction aligned with the horizontal π (short direction). Example 1 %N〇nw〇vens (1) (4)) manufactured by the United Kingdom cut 6 2 cm) 2 5 ' square meters of wettable spunbonded polypropylene non-woven fabric with a 89-minute (four) / minute running milk pro-supply and wear Pass-72 Yangmi (1) Qing rc) under the jet-type box into, = (35 m / min) Yun Hanzhi - + 4 days ^ ^ Yang ruler / knife bell M w - volume _ on. In this system, the central non-woven fabric (76.2 cm) wide non-woven fabric is uniformly and laterally consolidated ("necked) into 10 inches and 4 cm wide. By applying a minimum force, it can be reversed. Extending to its initial 3 〇 (76·2 phantom lateral width. The necked nonwoven fabric has a substantially 机 length and a basic weight of 32·0 g/m2. r long hand and one mil (0.38 mm) scraper and 2% by weight of polyurethane-ureaacetate-f-acetamide (DMAC) solution to apply the necked nonwoven fabric to a surface, the polyamine-based vinegar system is derived from Molecular weight 18 〇〇 poly(四亚尹基趟) diol, !-isocyanato-4_[(4-isocyanatophenyl) fluorene benzene (molar ratio of dicatric acid cyanate to diol) The ear and ear extension ratios are 109658.doc -26- 1279469 t / ethylenediamine and 2-methyl-1,5-pentanediamine) and diethylamine. The following additives can also be used: 0· 5 wt% bis(4-isocyanatocyclohexyl)methane and third-butyl-3-aza-1,5-pentanediol) (Methacrol® 2462Β, Ε.Ι. du Pont de

Polymer of Nemours and Company), 3% by weight of titanium dioxide, 〇6% by weight of polysulfuric acid, 4.4% by weight of 2 4 6-tris(2,6-dimethyl -4-Terti-butyl-3-carbylbenzyl)isocyanurate (Cyanox® 1790, registered trademark of Cytec Industries) and 4 parts by weight. /〇 Mixture of calcium magnesium carbonate and hydromagnesite. (All percentages are based on the weight of the polyamidoacetamide). The polyurethaneurea-DMAC solution sufficiently wets the nonwoven fabric. The coated nonwoven fabric was suspended substantially vertically in the air for about one minute to allow the polymer solution to completely penetrate into the nonwoven fabric, and then immersed in a 70 Torr (21 Torr bath) in which 40% by volume of DMAC was dissolved in water. After 丨 minute, the fabric after the secondary collapse was successively transferred to 3 vol%, 2 vol%, and 丨〇 volume% DMAC/water solution for each minute, and finally immersed in a 丨〇〇% water bath for 2 minutes. The impregnated fabric is dried in air at room temperature. It is known that the π/bei non-woven fabric has the same (dry fabric-like) feel and texture on both surfaces. The photomicrograph of the cross section shows a uniform composite structure of the entire thickness of the material, and there is no continuous polyurethane area on either surface. Then, the non-woven fabric is lightly ground with a 22 mesh sandpaper. Significantly softer sensation and visual observations, this display shows a large number of individual staples from the surface before polishing = a completely smooth surface with raised fibers. Unexpectedly, this treatment was successful A softer feel is obtained 109658.doc -27- 1279469 without significantly impairing the visual aesthetic or elastic properties of the sheet. The resulting impregnated nonwoven sheet has a basis weight of 71.4 g/m 2 , which means that the polyaminocarboxylic acid An elastomeric polymer having an ester urea content of 39.4 grams per square meter or about 55% by weight. The hand elongation of the resulting material in the transverse direction exhibits an elongation between about 160% and 180%. By load and no-load force analysis The following results were obtained: Third load cycle force elongation percentage Load force expressed in grams 50 67.3 100 211.2 135 409.7 Third no-load cycle force elongation percentage In gram of empty load force 50 22.7 100 114.7 135 340.7

Comparing the data in these tables shows that the ratio of the no-load force to the load force at 100% elongation is 0 · 5 4 . Example 2 A 30-foot, 10-inch (25.4 cm) wide roll of 55 g/m2 flat spunlaced nonwoven fabric was used in this example (Product No. 4055-T, by Sheng Hung Industrial Co., Ltd. (116 Hou Kang Street, One of the parts of Shih-Lin District, Taipei, Taiwan, ROC), which operates in a continuous mode. The nonwoven substrate was first impregnated by immersion in a solution of 12.5% solids in D-162 Lycra (R) in dimethylacetamide (DMAC). T-162 Lycra(R) is from INVISTA GmbH (Wilmington, 109658.doc -28-1279469 E=. Fabric speed is 3 ft/min, total fabric length in the bath = 6 sec.) The impregnated fabric passes through - the gap is 〇. The razor reaches the excess of the polymer solution. Then, the resulting impregnated fabric is passed through 4% of the DMAC bath dissolved in water, followed by two Separate (10)% water bath. The speed of the fabric passing through the baths was 3 ft/min. The total fabric length in each bath was ❻. All baths were run at room temperature (about 72 T). A breathable stretch nonwoven fabric having desirable elastic properties and a basis weight of 8 gram per square meter (45% by weight T_i 62 Ly(10)(10). Analysis of the elongation of the obtained elastic nonwoven fabric along the lateral direction shows an elongation between 50% and 60% Rate. The load and no-load force analysis for the third cycle was carried out as described in the Test Methods section (except for the elongation of #品 to a maximum elongation of 50%) and recorded at 2〇%, 3〇% and peach elongation. Load and no-load retraction force. This modified load The no-load force analysis can obtain the following results: The load force expressed in grams for the third load cycle force - 92.6 227.2 _HI40 - 425.9 The third no-load cycle force is expressed in grams - 20.0 __3〇~~~—- _ 75.9 192.0 The data in the table of 乂 乂 "Hai shows 30% elongation and the ratio of space load to load force is 0.33. 109658.doc -29-

Claims (1)

I279469 Patent Application Scope for Use in Medical Applications φ Body Polymers Substantially Uniformly...Main π woven fabrics' including neck-spun nonwoven fabric substrates with elastic stretch-non-woven fabric sheets... J. After the third extension to 14G%, the third load period force of the stretchable, my cloth piece at 100% elongation #徂狎不率: wide load period force and 1^ 2 , (four) 'month force The ratio is at least 0.3:1. The stretchable nonwoven fabric ratio of claim i is at least 0.45:1. With load force I ..., which includes " substrate, can be pulled after two, the stretchable non-woven sheet is at 3. I stretched to 50% force and 30% elongation, the third idle period of the rate 0 0,5, 〇...the ratio of the two load period forces is at least 4. The ratio of the stretchable nonwoven fabric of claim 3 is at least 0.3:1. /, two load and load force 5 · If you can request the project of Hong 3 stretchable non-woven fabric, ... 6 · as requested in item 5 can be stretched non-woven ... face material. A group consisting of the following items: a plastic book selected from the group consisting of a wrap, including a compression wrap; an end band, a singular and self-adhesive tape; a mouth dressing; and a surgical applicator叩, including surgical and wound skins. Further, L is adhered to the periphery of the surgical incision. 7. - Stretchable non-woven fabric of claim 5 - - Stretchable / medical tape of claim 5. A medical package formed by a non-woven fabric. 109658.doc 1279469 h * 9. A bandage formed from the stretchable nonwoven fabric of claim 5. 10. A type of dressing that is formed from the claim 5 and which is formed from a non-woven fabric sheet. 11. A stretchable nonwoven fabric sheet of claim 5 for forming an external use. 109658.doc