TWM245953U - Breathable cloth-like film/nonwoven laminate - Google Patents

Description

M245953 新型 Description of the new type: [Technical field to which the new type belongs] This creation relates to breathable films and breathable, cloth-like films / non-woven laminates. In particular, this creation is related to breathable Lai / Laiwu Shi, which contains a breathable film that is mechanically aged. This application has a wide range of applications, and can be used in any field that requires strength, comfort, breathability, and liquid impermeability. The two specific implementation areas include personal absorption items and health items (the shots include drapes, robes, and related surgical supplies). Examples of human protection absorbent articles are diapers, sanitary napkins, incontinence clothes, training pants, warp belts, etc. This creative material can also be used to form all or part of clothing items. [Prior art] Many of today's products contain synthetic protective components for personal protection and absorption, one example being a diaper. Today's diapers contain synthetic fiber-to-fabrics that fill the human-side lining material that abuts the skin. The diaper has an -absorbent core material 'which may be made of natural wood pulp fibers, in which synthetic fibers and superabsorbent materials are combined. Diaphragm or outer cover, because of the consideration of price and impermeability, f, f is customarily made of plastic film. 0 Although plastic film can effectively contain sundries and other important things, it is based on the health of the wearer. Viewpoint Plastic film has the disadvantages of poor touch and impermeability, so it tends to cause skin hydration (version η hydration) to make baby silk diapers. The method of weaving is as follows: Replace the ordinary non-porous film with breathable valve as the material of the diaper. There are many ways to make breathable films, and the towels include perforations and the use of fillers. When using a filler, in order to create a small gap between the polymer and the polymer in which the particles are embedded, the film is hung in the shop to be crushed by crushing the filler, or stretched. This distorts the passage of the membrane from one surface to another ', thus providing a channel through which water vapor can pass but still block liquids such as urine and water.

5 C: \ Etmice 2004 \ PK-007-02 \ PK-00 ^ 225 \ PKWl-0225-2.DOC Breathable film is usually made of poly film. The fillers can be made into the shape of the knee l, W, and the wealth; for the age and / or inorganic, but the day w 1 and / can be reduced by the breathable material. Nonetheless, Γ ”qianzhizhe system ^ phase in the table _« tree, there will be a cold disadvantage. Yu Yi, another solution is to use non-woven fabrics as the backing material of diapers. When using fiber non-woven fabrics to make diaper backs , To alleviate the problems of the aforementioned film, but this kind of fiber non-woven fabrics carry rain). Silk, full · tear, "the web is used as a back sheet material. Some fiber non-woven materials can drain water more than other materials, especially when They contain a layer of fine fiber fabric material (such as a material layer). Meltblown fiber raisins are formed by melting the heat-converting material through the fiber's pores through the fiber's pressing pores to form Wei threads or filaments, and then Non-woven fabric formed by thin high-speed airflow. The diameter of the finished non-woven fabric is very small, usually 10 microns or less; it is collected in the form of fibrous debris hairs on the surface, which has a small non-stop pour. Porous structure. For example, Buntin et al., Satoshi 3,849,241. However, even when meltblown layers are used, such fibrous non-woven fabrics cannot always prove that they are all suitable for use as backsheet materials for personal protection products. Fabric Attempts have been made to combine these two materials to make them both longer and shorter. One example of the best properties of combining breathable films and fiber non-wovens is the combination of linear polyolefin films with fillers and polypropylene or polypropylene copolymerization Spunbond fabric. In order for the two materials to cooperate, they must be slightly joined or laminated to each other. There are many ways to join films and non-woven fabrics, including thermal and ultrasonic bonding, gluing, needle punching, sewing. In order to maintain Liquid resistance, acupuncture and sewing are usually less desirable, because the holes produced during these processes are large and cause liquid to leak. Adhesives and glues also block the breathable membrane holes and produce all of them. Stiff layers, which are less popular. Films and fibrous non-woven layers should be more complete. ΓΛ Funirf 2Λ〇4 \ ΡΚ-0Π1 ^) 2 \ ΡΚ4) 01 ^) 22ίι ΡΚ-/) 〇ι, • 02 ^ ΠΠΓ M245953 is general and §, in order to adhere the laminated film and the non-woven fabric well, the entire inner surface of the two materials must be coated with a uniform film-like adhesive layer, or a larger amount is used on the separated area, which is more local. Adhesive. Adhesive When applied evenly, it will often block the pores on the surface of the film, thus making the previous porous film non-porous. This is not what I want. Use a larger amount of adhesive in local areas to reduce the area of the film surface blocked by the adhesive. However, the film / non-woven laminate has the disadvantage of being hardened due to the concentrated application of the adhesive. Therefore, it is more worthwhile to use the thermal laminate technology. The thermal laminate can be completed by heat and pressure using a heated pattern roller and ultrasonic waves. Each of these techniques is well-suited for joining films and nonwovens made of the same polymer. But in some cases, the polymers used to make the film are different from those used to make the nonwoven. This is due to price and physical properties. One example is linear low-density polyethylene film (LLDPE) and polypropylene non-woven fabrics. These polymers cannot be thermally laminated with each other with a bonding force of at least 5 grams and are thermally incompatible. There is also a case where when the two layers of materials are the same and compatible at the same time, a great deal of pressure and heat must be applied to generate the heat build-up, which causes perforations on the film and the build-up is usually too stiff. As a result, there is a need for thermal bonding of such incompatible and compatible materials in order to take advantage of the advantages of such a material and thermal lamination. There is also a demand for its finished products. These needs can be met by this author, which we will explain in detail below. [New content] The shortcomings of other things have been solved by this creation. In this article, breathable films and breathable, cloth-like films / non-woven laminated absorbent books are disclosed, which are formed by thermal bonding of transparent fibers and non-woven fabrics. The aforementioned method of making materials is also disclosed. Ideally, the heat-bonding system is the most desirable lamination method for films and nonwovens. Thermal bonding requires thermally compatible materials. Films and nonwovens are usually made of materials that provide the desirable characteristics of the materials in question but are not easily or completely thermally bonded to each other. In the case of this creation, an adhesive is added to the film, which only has to be

C: \ Eunice 2004 \ ΡΚ-00Ί-02 \ PK-W1-0225 \ PK- < X) 1 ^) 225-2.DOC M245953 The hydrocarbon-containing polymer part of the fiber nonwoven is compatible, while the domain layer Acts as a heat and secretive adhesive during processing. Alternatively, the binder may be incorporated into the fibers of the fibrous non-woven fabric to assist the lamination of the film and the woven fabric. For the integrity of the temples and fibers, the risk of pinhole formation and loss of strength is reduced during lamination. The value of the layer should be less than the melting point of the polymer of the membrane or fiber. Therefore, neither the membrane nor the fiber can reach its county. When it is remanufactured. By using the bonding of point-bonding additives and separation to "local" thermal bonding, we provide an attachment method that minimizes the damage to the porosity of the air-permeable membrane and transfers the entire absorbent article or laminate. In one embodiment of the present invention, the method for producing a breathable film / non-woven laminate is formed by forming a film containing the following absorbent substance: 10 to 68% (based on the total dry weight of the main polyolefin polymer), About 30 to 80% of the filler (particle size between 05 and 5 microns), about 2 to 20% of the binder. The film is then stretched or crushed between rollers to create breathability. The produced film should have a water vapor transmission rate of 100 g / m2 per 24 hours, and then a polyolefin non-woven fabric is thermally laminated on the film to form a laminated or absorbent substance. The laminate should be made larger than 5 grams. Suitable materials for the film layer include, but are not limited to, advantageous linear polyolefin polymers (such as linear low density polyethylene) and fillers (such as calcium carbonate). Suitable materials for fibrous nonwovens include, but are not limited to, polypropylene ' polyolefin blends (polypropylene fibers and linear low-density polyethylene fibers) and composite fibers (wherein the components of flue-cured tobacco form the outer surface of the fibers). Processing first involves the formation of an extruded mixture before the aforementioned polymers, and then extruded the mixture into a film. Once the film is formed, it is stretched at a temperature below the melting point of the film's predominant linear polymer, where the temperature is more desirable than the softening point of the adhesive. By stretching the film, the film is thinned and becomes porous and transparent

〇 \ Eunice 2m \ PK ^ 2 \ PK ^ 225 \ PK ^ 225-2.DOC M245953 gas. The stretched film is based on a water vapor transport rate of at least 100 g / m2 per 24 hours. The film is then adhered to the fibrous polyolefin nonwoven at a temperature below the melting point of the film's dominant linear polymer to form a laminate. In addition, if desired, the film can be compressed after bonding to the non-woven fabric and then cause the entire composite to shrink, creating a corrugated surface and a bulky composite. The formed breathable, fabric-like / non-woven laminated absorbent article has a variety of coatings, not just the outer cover for personal protection of the absorbent article. Such articles typically include a bodyside and outer cover, and an absorbent core material sandwiched therebetween. The material created can be used as an outer cover, in which the fibrous non-woven layer faces the outer surface of the product and the film layer abuts the absorbent core material. Alternatively, the right thermal bonding is thermally incompatible with the polymer that forms part or all of the film that we want, but the bonding can be added to the fibrous non-woven support layer instead of or also Into the film layer. Binders can be added to the fiber-forming polymer mixture, and when the fiber is a single pass fiber, the binder can be added to the entire fiber. In addition to monocomponent fibers, composite fibers can also be used to maintain all or part of the non-woven support layer. Examples of composite fibers include, but are not limited to, sheath / core fibers, side-by-side fibers, and sea-island fibers. In addition, bicomponent fibers can be used to form a fibrous nonwoven support layer. In all configurations of such fibers, a binder should be added to the fiber portion that forms at least a portion of the outer surface of the fiber, so that the adhesive polymer can contact and adhere to the film layer. After the fibrous non-woven support layer is formed, heat, pressure, pressure, and / or ultrasound can be used to adhere heat to the film layer. [Embodiment] The present invention discloses an improved film / non-woven laminate, in which a film composed of an advantageous linear polyolefin polymer, a filler, and a fibrous non-woven adhesive that are thermally bonded to a polyolefin base are used. Due to the incompatibility of the linear low-selectivity polyethylene film and polypropylene-based nonwovens and the melting point of the film and the nonwoven layer, he

C: \ Eumce 2004 \ PK-001 ~ 02 \ PK-001 ^) 225 \ PK-00i-0225-2.DOC M245953 They cannot be thermally bonded. This creation provides-a kind of breathable film, special _ special compound and special processing conditions, which can be combined with the woven __ material silk. The finished laminate provides several considerations, including the soft 'cloth-like feel of the outer surface and the ability to block liquids from passing but still have excellent water vapor permeability. In addition, because of the linear high-density hearing resistance of linear low-density polyethylene, the county Wei, transcribed and has a very low "noise" or "drinking sound." As a result, the laminate of this creation is particularly suitable for use as a backsheet material for personal protection absorbent products (including diapers, sanitary napkins 'training pants' incontinence clothing, end straps, etc.), but it is not meant to be used only for the purposes described herein. The material of this grip can also be used to form all or part of a clothing item. In addition, the materials created can be used to form all or part of medical supplies, such as surgical drapes, gowns, wipes, shoe covers, masks, caps, etc. Therefore, these uses are also considered within the scope of this creation. In another embodiment, a binder may be added to the fibrous nonwoven fabric, particularly to at least a portion of the outer surface of the fibrous nonwoven fabric. As a result, the two layers which are not thermally compatible can be thermally bonded or laminated with another device. Finished laminates are also suitable for the applications described above. Referring to the first figure, the most basic form of this creative absorbent body or laminate (ίο) includes a film layer (12) adhered to each other and a fiber polyolefin non-woven comfort and support layer (14). Although this is the most basic configuration of the creation, additional layers of material can be added to the composite (10) to form a multilayer composite if needed. For example, a second fiber polyolefin non-woven fabric (not shown) may be adhered to the film layer (12) on the side facing the first fiber polyolefin non-woven fabric (14). The film layer (12) contains three basic components. The first is a dominant linear polyolefin polymer (such as a linear low-density polyethylene), the second is a filler, and the third is an adhesive or tackifier. These three ingredients are mixed, and any film that is well-known to those skilled in the art is processed to extrude the film after heating (casting and blowing> other additives or ingredients, if it does not seriously affect the breathability of the film and the film and fiber polymerization Heat of olefin non-woven comfort layer (14)

in C: \ Ewnice 2004 \ ΡΚ-002 * 02 \ PK-001 »0225 \ PK ^ OOl > 0225-2, DOC M245953 Adhesive force can be added to the film. Generally speaking, the film layer contains about 10 to 68% by weight (based on the total dry weight of the film) of the advantageous linear thermoplastic polymer, about 2 to 20% by weight of the binder, and about 30 to 80% by weight of the filler. 6 More specifically In embodiments, it may additionally contain 0 to 68 wt% of other polyolefins (such as polypropylene). When mixed with a suitable amount of binder, linear low density polyethylene has been found to be a fairly good film base. But in general, other advantages of linear paraffin polymers can also be used in this work. As used herein, "linear low density polyethylene" refers to polymers of ethylene and higher alpha olefin comonomers, such as: "Dominant linear" means that the main polymer chain is linear, with approximately less than 5 long-chain branches per 1,000 ethylene units. The long-chain branches contain carbon chains greater than Q2. Non-elastic dominant linear polyolefin polymerization Short-chain branches (cvc) 2) will typically be limited to less than 20 short chains per 1,000 ethylene units due to the presence of comonomers, while elastic polymers are 20 or more. Advantages Linear Polyolefins Examples of polymers include, but are not limited to, linear polyolefins, such as: ethylene, propylene roast, μbutylene, winter methyl_pentene, L-Fife, bucin and higher olefins, and co-pentyl In addition, copolymers of ethylene with other olefins (including pentene, hexene, heptene, octene, nonene, decene, etc.) are also examples of advantageous linear thermoplastic polymers. The main purpose of this creation is to provide A method for thermally bonding a breathable film and a fibrous non-woven fabric, wherein the breathable film is made of a dominant linear polyolefin polymer, and the method does not damage the integrity of the individual layer (especially the film layer). By adding an adhesive In membrane polymers mixed to some extent, At lower temperatures and / or pressures, films and nonwovens are bonded with a lower percentage of total bonding area. In addition, incompatible films and nonwovens (such as LLDPE films and polyfluoride non-fibers) are now effectively laminated. After the layer is produced, it is still soft and there is usually no accidental perforation caused by over-threading, so as to obtain a suitable layer. For compatible LLDPE film and polymer surface, the cake is at the scale of the LLDpE film. The thickness of the wire is 15% of the combined area to heat build up the two layers, and the finished product should be strong enough to require

11 C: \ Eunice2004 \ PK-001-02 \ PK-Wl-0225 \ PK-Wl-0225-2.DOC M245953 Delaminate the layer with a load of at least 5 grams (determined by the stick strength test of the branches below). The above is possible by adding a bonded rhenium membrane polymer mixture. "Adhesive" in this context is an additive that, when added to a mold polymer mixture, allows film-level non-wovens to be at least 5 ° C below the melting point of the linear polymer component, which is the main advantage of film polymer mixture Under-bonding (in this example, the "main" polymer is a linear low density polyethylene). In addition, the adhesive or peel strength of the finished laminate should be less than 5 grams. Binders also refer to tackifying resins, which are discussed in Kieffer et al. USP 4,789,699, which is incorporated herein by reference. The purpose of this adhesive is to allow non-woven fabrics to be bonded at lower temperatures. Examples of adhesives include hydrogenated hydrocarbon resins such as REGALREZ series tackifiers and ARKON series tackifiers. REGALREZ resins are available from Hercules of Dalaware Wilmington. Regalrez tackifying resins are highly stable, light-colored, low molecular weight, non-polar lipids. Grade 3102 is said to have a softening point of 102 R & B ° C, a specific gravity of 1.04 at 21 ° C, a melt viscosity of 100 centipoise at 149 ° C, and a glass transition point (Tg) of 51QC. REGALREZ 1094 is said to have a softening point of 94 ° C, a specific gravity of 0 · 99 at 21 ° C, a melt viscosity of 100 centipoise at 126 ° C, and a glass transition point of 33 ° C. Grade 1126 is said to have a softening point of 126 ° C, a specific gravity of 0/97 at 21 ° C, a melt viscosity of 100 centipoise at 159 ° C, and 65. (: Glass transition point. ARKON series resins are synthetic tackifying resins made of petroleum hydrocarbon resins by Arakawa of Illionis Chicago. For example, the grade P-70 has a softening point of 70 ° C, while the P-100 With a softening point of 100 ° C, P-125 has a softening point of 125 ° C. ZONATEC 501 stone resin is another tackifier, which is an olefinic hydrocarbon with a softening point of 150 ° C. Made by Arizona Chemical. EASTMAN 1023 PL resin is amorphous polypropylene

C: \ Eunice 2004 \ ΡΚ-00Ί-02 \ ΡΚ-ΌΟΊ-Ό225 \ PK-001-0225-2.DOC M245953 ene tackifier 'its softening point is 150-155125 QC' Eastman Chemical available from Longview Other Examples of adhesives generally include, but are not limited to, polyamines, ethylene copolymers (such as ethylene ethylene acetate (EVA), ethylene ethyl acrylate (EEA), ethylene acrylic acid (EAA), ethylene propylene Ethyl Methyl Ester (EMA), Ethylene Acrylic N-Butyl Vinegar (ENBA), Wood Pine Balm and Its Derivatives, Hydrocarbon Resin, Polycarbonate Resin, Random Polyacrylamide and Amorphous Acrylic Copolymer In order to refine materials such as polypropylene baking (Tτρ) and olefin thermoplastic polymers, ERR is mostly polymerized by internal reaction gas in polypropylene or polypropylene / polyethylene mixture, and is mechanically or molecularly dispersed. The aforementioned adhesives or tackifiers are for illustration only and are not meant to limit the scope of this creation. Any adhesive that can be adhered to other films and / or fiber polymers can be lower than the film or fiber mixture. Advantageous linear thermoplastic polymer composition with a melting point of at least 5. <: below, allowing the film layer to be bonded to the non-fibrous layer; and anyone who can generate a bond between the layers that needs a 5 gram load to be able to be unlocked is also considered an adhesive for the sake of this creation Including about 2 to 20% of the total weight of the film. Although weight percentages outside this range can also be used, at higher percentages, the breathability of the film is compromised. For personal hygiene absorbent articles, this is usually I do n’t want it. In addition to the advantageous linear polyolefin polymers and adhesives. The film layer also contains fillers. In this article "fillers," means materials that can be added to the film polymer extrusion mixture 'and The film enumerated by this material does not have any negative chemical interference and can be uniformly dispersed in the film. The filler is generally particulate and usually circular, and its average particle size is about αι to 0.7 microns. As long as it does not affect The film permeability of the finished film and its thermal adhesive ability to newly formed polyolefin non-woven fabrics or co-formers are considered as organic and inorganic fillers. Examples of fillers include carbonic acid, a variety of Clay, silica, aluminum, barium sulfate, sodium carbonate, talc, sodium sulfate, titanium dioxide, zeolite, sulfate 'cellulose powder, diatomaceous earth, magnesium sulfate, magnesium carbonate, barium carbonate, kaolin, mica, carbon , C: V £ U „icc2004VPK ^^ 2VpK ^^ 225VpK ^^ 225_2Dfx: M245953 Oxygen, Magnesium Oxide, Hydroxide, Muli Powder, Wood Powder, Cellulose Derivatives, Chitin and Chitin Derivatives As mentioned previously, the film can be formed by the known " Carbon to be familiar to the former < 1 > to the ratios described above. The predominant linear polyolefin polymers, adhesives, fillers are mixed together, and then the film is heated and extruded. In order to provide uniform air permeability (which can be expressed by the water vapor transport rate of the film), the filler should be evenly dispersed in the polymer mixture, and the face towel should be uniformly dispersed. For the sake of abstraction, if the water vapor transmission rate is at least 100 g / m2 per 24 hours (calculated using the test method described below related to the sample), it is "breathable". In general, once the film is formed, it will have a unit weight of less than York / square, and it will be thinner and thinner, and its unit weight will be less than _% g / m2. Desirably less than about 18 grams / square meter. The film used in the examples below is a blown surface, but other types of films are considered to be in this category as long as the forming count is compatible with the filled film. The scales are usually too thick and produce a "noisy noise" in the lion coffee, and the membrane is not yet sufficiently breathable (as measured by its water vapor transport rate). As a result, the membrane is heated to a temperature below the melting point of the dominant linear thermoplastic polymer 50 ° C, and then stretch at least 2.5 times its original length, thinning the film and causing sluggishness. At the temperature of stretching and lying, a small hybrid provides a soft tilt. The softening point of some adhesives is at New L. Therefore "Heating below the silkening point" refers to the temperature below the thin maximum temperature. An additional feature of thinning is the change in film opacity. The film was more transparent when formed, but became opaque after stretching. In addition, although the film becomes directional during the stretching process, it also becomes softer and lower than the stretching 刖 i ”sound. If all factors are taken into account, and it is desired to discuss at least every% hours G / m2 water vapor delivery rate should be reduced to a unit area weight of less than about 35 g / m2 (just

C: \ Eunice 2004 \ PK-001 ^ 2 \ PK-001-0225 \ PK-001-022S-2.DOC M245953 for personal protection hygiene applications), and more desirable less than about 15 grams / Square meters. The fibrous non-woven comfort layer (14) is made of feminine fiber (such as polypropylene). In the example, the nonwoven is polypropylene spunbond, but other polyolefin fibers may be used. Fiber mixtures can also be used, which include different polyolefin fibers, polyolefins, and non-polyolefin fiber mixtures (such as polyethylene sheath / polypropylene core composite fibers and polyester fibers, and fiber non-woven fabrics can also include natural fibers. Specific The types of fibers include single-component fibers and composite fibers (such as: side-by-side, sheath / core, sea-island composite fibers). The fibers can be straight or curly, hollow or solid. They are usually round or non-circular cross-sections (including limbs) , Limbs, "χ ,, cross-section). Fiber length may be short (such as human short fibers) or long (spunbond and meltblown fibers). The thickness of the fibers depends on the desired properties. Narrow fibers provide softness Non-fabric and thicker fibers will provide greater strength and elasticity. Alternatively, a combination of multiple fiber diameters may be utilized. For personal protection absorbent applications, the fiber diameter is typically about 1 to 5 deniers. As a result of this creation For this reason, "polyolefin-based fibrous nonwoven fabrics, and fibrous polyolefin nonwoven fabrics" refer to fibrous nonwoven fabrics whose polyolefins constitute at least 50% of the fiber surface. Fabric formation processing can be applied to this creation. Examples include (but are not limited to): air-flow and wet-laying, artificial staple fiber carding and bonding, solution spinning, meltblowing and spunbonding. All of the foregoing processes are It is well known to those skilled in the art. Spunbond polypropylene non-woven fabrics are particularly suitable for this creation. Spunbond non-woven fabrics can be manufactured according to the teachings of USP 4,340,563 by Appel, which is incorporated herein by reference. Spunbond The material is formed by extruding a thermoplastic material through a plurality of spinnerets of a spinneret to form filaments, wherein the diameter of the extruded filaments is reduced by, for example, ejection or other spunbond mechanisms familiar to us. A fibrous non-woven comfort layer (14) is formed, which can be pre-bonded to increase strength and integrity. The polypropylene spunbond fabric used in the example has a bonding density of about 100 to 300 bonding points / square inch. Inch bonding pattern (bonding area is about 15%) to pre-bond. If the bonding density is above and below this range, C: \ Eunice 20 ° 4 \ ^^-001 ^ 2 \ ΡΚ · 0〇ιτ〇 225 \ ρΚ ^ 〇1 ^^ M245953 is used, the specific density is It depends on the size of the hybrid point. In order to form the breathability of this creation, the cloth-like film / non-woven composite (10), the film layer (12) and the fiber poly ^ non-woven layer (14) are joined together, and then The second ® decoupling device (16) is used to thermally bond the film before it is incorporated into the composite, which has typically been extruded, stretched and thinned. When it is in the unstretched state, it is fed into the process and re-stretched. And thinning. In addition, the film can be formed or stretched on the line. The fibrous non-woven fabric can also be formed in advance and unwound from the supply roller (22) to enter the bonding processing line. Alternatively, it can also be formed on the line. If the film ( 12) and non-woven fabric (14) feed the adhesive (16) to the person at a speed of _, the composite (10) can be made more bidirectional. Or, it can cause the composite (10) to shrink to produce wrinkles, Thicker, three-dimensional structure. One method of causing shrinkage is to place one or two layers under tension during processing ' such as by continuing and folding by accelerating and / or stopping them-the layers being temporarily stretched and swelled. On the other hand, it is a linear hydrocarbon-collecting molecule with a directional property in the film towel under the contracted state. After applying heat to the film layer (12), it usually causes shrinkage. Therefore, if the compound (10) is wound onto the collection drum (16) at a speed lower than that on the compound binder (16), the film will relax and cause creases. At least two methods can be used to complete the two-layer thermal bonding. The first is a bonding drum that uses heat and pressure, such as heating. Both rollers are available in style, or one or the other. Both of the drums may be heated, or a first heating source may be utilized. If conditions specify 'one of the drums can also be cooled. In any case, the heat should be adjusted to make the adhesive in the film sticky to adhere the two layers, while maintaining a temperature of at least 5 ° C below the melting point of the main linear polyolefin polymer in the film. The term "primary" refers to the dominant linear polyolefin polymer with the highest percentage of total film weight (if there is more than one dominant linear polysmoke polymer in the membrane polymer blend). Bonding style and area can be changed with special end use. Suitable bonding patterns can include point bonding M245953 bonding, continuous lines, decoration », and combinations of the foregoing. The bonding area depends on the desired degree of lamination. For the application of personal protective absorbent articles, adhesion should be sufficient to require at least a 5 gram load to transfer the two layers. The second bonding method is ultrasonic bonding, which is also well known to those skilled in the art. In this method, the anvil roller can also be designed in any of the manners previously described. Once the composite is formed, it can be used in a wide range of applications, not just for personal protective absorbent articles. Such articles typically include a bodyside liner, an absorbent core, a backing layer, or a cover. The material of this creation can be used as a cover ' wherein the fibrous nonwoven layer faces the exterior of the article ' Therefore, the film layer and the body-side lining can be heat-sealed by the adhesive in the same manner as the two-layer composite material of this creation. In the foregoing discussion, an 'adhesive' was added to the film layer (12) to make it compatible with the fibrous nonwoven comfort and support layer (14). However, it is also possible to add a binder to the fibers of the support layer (14). As mentioned above, the fiber-forming layer (14) may be a short artificial staple fiber or a longer and continuous fiber (such as a spunbond and meltblown nonwoven). In all cases, fibers can be made from a single polymer (such as a linear paraffin fiber) or from a multicomponent fiber (such as a composite fiber). In these two types of fibers, the binder must be on the outer surface of the fiber to cause adhesion between the film and the nonwoven layer. In the case of linear fibers (such as polyethylene baking fibers), the binder can be added to the polyethylene premix and extruded into fibers. For composite fibers, a binder must be added to the polymer that will end up on the exposed surface of the fiber. In the case of sheath / core fibers, it should be the Le 'portion, and in the case of side-by-side fibers, binders can be added to either or both of the polymers because they will all expose the fiber's outer surface. Binders usually make up 2 to 20% by weight of the polyolefin polymer to which they are added. (Based on the total polymer mixture weight used to form the fiber portion). Therefore, in a linear polyethylene fiber, the polymer mixture contains about 2 to 20% by weight of a binder and about 80 to 89% by weight of polyethylene (no other additives in the fiber polymer mixture

17 C: \ Eunice 2004 \ ΡΚ-ΟΟΊ-Ό2 \ PK-001-0225 \ PK-Wi-0225-2.DOC). For composite or multicomponent fibers, the percentages will be based on the total weight of the blend of special fibers. In addition, if, for example, the fibers are side-by-side polyethylene / polypropylene fibers, the binder can be added to the two polymer components at the same weight percentage (relative to each individual fiber), that is, for each A bulk fiber polymer content is 2 to 20 wt%. Because it is possible to mix different types and compositions of fibers in the same non-woven fabric, not all of the fibers juxtaposed in the woven fabric must have a binder present on the outer surface, so long as sufficient adhesion can be achieved between the film and the non-woven layer, so that The layers need to be at least 5 grams to separate or deconstruct the layers. This will typically occur if the non-woven layer of fibers is at least 50 wt% bonded in the manner described above. Finally, when selecting the adhesive and the bonding conditions, a bonding agent whose bonding temperature can be lower than the melting point of the polyolefin in the film layer should be selected. To illustrate the thermal adhesion of this creation, several samples were prepared one after the other. There are many samples that are restricted to test the adhesive strength between the double layers based on the film's water vapor transport rate (WVTR). (The test method for calculating the WVRT and adhesive strength of the composite in Example 4 is as follows. Water Vapor Delivery Rate Sample Material Water Vapor Transmission Rate (WVRT) is calculated according to ASTM standard E96-80. A circle with a diameter of 3 mm ✓Sample: A piece of Hoechst Celanese in Sommerville, New Jersey

Corporation's CELGUARD (trade name) 2500 membrane. CELGUARA 2500 membrane is a microporous acrylic film master material prepared from 5 samples. The test discs are volatility meter discs sold by the Thwing-Albert Instument Company, number 6 (M. Each volatility meter disc is filled with brain-raised water and a separate sample of test material. The opening edge Gu. The edge edge disk is tightened tightly to form a seal at the edge of the disk, so that the material to be torn or controlled in the disk is a circular towel with a diameter of M cm and is exposed to the surrounding atmosphere. Put it in the blast oven of Renqing 0F (32〇c) for one hour, until flat

C: \ Eunice 2004 \ PK-001-02 \ ΡΚ-001-0225 \ ΡΚ-00Ί -0225-2.DOC M245953. The oven is a constant temperature oven, from which outside air can be circulated to prevent water vapor from accumulating in the oven. A suitable blast oven is, for example, the Schmid Power-O-Matic 60 oven sold by Blue M Electric Company of Blue Island. When the balance is complete, remove the pan from the oven, weigh it, and immediately place it in the supply bin. After 0.4 hours, the value of the crude test water vapor transmission rate is calculated as described below. Test TVWR = (24-hour weight loss) x 315 · 5 g / m² / 24-hour relative humidity in the oven is not specifically controlled. Under the conditions of 100 ° F (32 ° C) and relative relative fishery, the WVTR of the CELGUar 205 control sample was 5000 g / m2 / 24 hours. It is necessary to test the control sample in each test, and the initial test value is modified to set the conditions using the following formula: WVTR = (test WVTR / control WVTR) X 500 g / m² / 24 small employment (g / m²) Feet / 24 hours). Adhesive strength In order to test the adhesive strength between the film layer and the comfort layer of the fibrous non-woven fabric, delamination or tear strength tests were performed on samples of various materials. A 2x approximately 6-inch sample was cut out; then one of the short ends of the layer was deconvoluted by hand to produce a clamp that can be placed in a Sintech / 2 computer integrated test system made by MTS Systems Corporation. The jaw gap is set to a pitch of 100mm, which is enough to allow the material in the accumulated state to stay in it, so the jaw can move 65mm. As for the sample in the clamp, before the clamp is extended 10 mm, the sample can begin to deconstruct the layer. The crosshead speed was set to 300mm / min, and the data was recorded between the starting point of 10mm and the end point of 65mmmm. The recorded information indicates the tear strength or load (g) required to separate the two layers, and the standard index (g) of the maximum, minimum, and average values. C: \ Euniee 2Ω04 \ ΡΚ-00Ί-η2 \ ΡΚ · ϋ01-0225 \ ΡΚ4) 0Ί-02? ^.? M245953 Example Example 1 Two air-permeable membranes / non-woven laminates were prepared and evaluated to determine the application of the adhesive The effect on water vapor transport rate and the bonding strength of the whole composite. First, three air-permeable membranes with a mixture of multiple polymers were prepared, and then each membrane was bonded to about 2 deniers, 0.5 ounces (17 gsm) of polypropylene spunbond non-woven material, and the non-woven fabric was pre-bonded with a 15% bonding surface. Each film component contains (based on the total weight) 65% by weight of British and Chinese Super Coatings, which has an average micron size of 1 micron and a top cross section of 7 micron. Calcium carbonate was purchased from ECCA Calcium Products of Sylacaga, a division of ECC International. Carbonic acid is mixed with about 15-25wt% linear low-density polyethylene. The polymer is made of Dowlex 2517 linear low-density polyethylene and Dowlex 2532 linear low-density polyethylene at a weight ratio of 1: 4, so the mixture melts. The index is 10 MI (/ 10 points at 194 ° F). Dowlex polymer was purchased from Dow Chemical, U.S.A., Midland. The remaining 10-20% by weight of the composition includes a polymer of KS051P polypropylene base, which was purchased from Himont, U.S.A. of Wilmington, Delaware. KS051P polymer is an olefin-based thermoplastic elastomer or TPO multi-step reactor product, in which the molecules of amorphous ethylene propylene random copolymer are dispersed in a continuous matrix of dominant semi-crystalline high polypropylene monomer / low ethylene monomer. Amorphous components begin to soften around 55 ° C and act as a binder. As shown in Table 1 below, Sample 1 contains 65% calcium carbonate, 10% KSO51P polymer, and 25% linear low density polyethylene. Sample 2 contains 65% calcium carbonate, 15% KS051P polymer, and 20% linear low-density polyethylene. Sample 3 contains 65% carbonic acid, 20% KSO51P polymer, and 15% linear low density polyethylene. All three formulations are blown into a film at 375 ° F (19ΓΟ) with an inflation ratio of about 1.7. The resulting film is a stretch specification of about 1.25 mils (50gsm). Then each film is on a mechanically oriented unit at i40 Stretching at ° F (60 ° C), the stretching rate is 3 times. The finished film can be breathable according to the water vapor transmission rate indicated in Table 1, and its M245953 basis weight is 14gsm. Table 1 Sample calcium carbonate (wt%) LLDPE (wt%) KS051P (wt%) WVTR g / m2 / 24 hr Adhesive strength (g) MDO strength of film processing 1 65 25 10 4530 24 Excellent and good 2 65 20 15 4300 27 Excellent and good 3 65 15 20 3710 26 Excellent

It can be seen from Table 1 that as the adhesive amount increases (in this example, the amorphous ethylene propylene copolymer portion of the olefin KS051P polymer begins to soften at about 55 ° C), the water vapor transmission rate decreases. However, as tackifiers or adhesives were added, the samples on the contrary showed an increase in peel strength and were therefore more resistant to delamination. If an adhesive is added, the ease of film processing and the stretchability of the film in the mechanical direction are observed with the naked eye. Table 1 indicates that the film processability is excellent, regardless of the binder added to the pre-extrusion mixture. Conversely, as the adhesive was increased in the film, an increase in tensile ability was observed. In Sample 1, the ability to stretch the film in the mechanical direction is still good, while Sample 3 is particularly excellent. Each film was laminated with 17 gsm (0.5 ounces) of polypropylene spunbond non-woven fabric at a rate of 100 ft / min (30.5 m / min) and laminated to 20 pieces per square inch (ι · 4ΐkg / cm²), and its bonding pattern is a discontinuous bonding pattern with a bonding area of about 15%. The temperature of the model roller is maintained at 2500F (121 ° C), while the temperature of the smooth anvil roller that is in direct contact with the film is 1600F. From the information in Table 1, it can be proved that the three samples according to this creation all have special characteristics. Excellent water and gas transport rate and excellent bonding strength. The sample requires a load of 24 to 27 grams to pull away the layer with only 15% of the bonded area. In addition, the membrane is non-perforated, which allows the material of this creation to provide barrier properties when used as a personal protective absorbent article.

Ml In this example, the effect of the stretching temperature was evaluated on the film formulation related to sample 1 of the previous example 1. when

21 C: \ Eunice 2004 \ ΡΚ-ΟΟΊ-02 \ ΡΚ-ΟΟΊ-0225 \ ΡΚ-00ί · 0225-2. DOC M245953 KS051P When the amorphous component of the polymer becomes more adhesive-like in nature, its gradually Softening is believed to prevent complete fracture of the polymer mixture at the interface of the calcium carbonate particles and the resin matrix. To determine this point, film samples were stretched 3 times (that is, samples of 1 meter were stretched to 3 meters) at 140 ° F (63 ° C) to 186 ° F (86 ° C). As the stretching temperature increases, the water vapor transport rate decreases, probably because fewer or smaller pores are formed around the carbonic acid dance particles in the film. As shown in Table 2, an increase in the stretching temperature does increase the fluidity of the linear low-density polyethylene molecules, thereby improving the ease of stretching. As the temperature increases from 146 ° F (63 ° C) to 186 ° F (86 ° C), the ease of stretching increases. Between 177 $ (81 ° C) and 186 ° F (86 °), the molecules of the film show extreme orientation, so they show more splitting and easier tearing in the mechanical direction. As a result, the Stretching temperature is selected to maximize the balance of WVTR, processability, and mechanical properties of the film. Stretching can achieve the best when the temperature is lower than the melting point of the film mixture's main advantage, the linear polyolefin polymer, and around the softening point of the adhesive. Tensile and air permeability. Table 2 Tensile temperature ° F / ° C WVTR g / m2 / 24 hr Pull MDO extension 146/63 4300 Fair 157/69 4100 Excellent 167/75 3960 Excellent 177/81 3730 Rip 186 / 86 3515 Cracking more Example 3 In Examples 1 and 2, all samples (based on dry weight) contained 65% calcium carbonate, 15 to 25% linear low density polyethylene, and 10 to 20% olefin KS051P polymer. A propylene-based polymer resin containing an amorphous ethylene propylene random copolymer that can act as a tackifier or adhesive. In Example 3, 65% by weight of carbonic acid and 30% by weight of linear low density polyethylene were mixed. As shown in Table III, add to the basic mixture

r \ F.unicp 20M \ PKJ) 0i-02 \ PK-O0 ^ 225 \ PK ^ 0i-022S-2.D0C M245953 5wt% —A series of known tackifiers and adhesives. Adhesives include Chem 1094 < 3102 and 1126 adhesives and Zonatac 50L and Eastman 1022 muscle adhesives. In addition, Example] The film formulation of Sample 2 was also formed into a film as described in Example 1. Each film was blow-molded to a size of about 15 ㈣ (60 gsm) at a blow-up ratio of 1/7. The film was stretched to 3 times its original length at 1460F (63 < t) in the mechanical direction. The tensile temperature is lower than the melting point of the best-in-class polymer. Then, under the condition of acidic acid, laminated with the polypropylene non-woven fabric described in Example 1, the total bonding area is about 15%. The temperature of the pattern roller is maintained at 250 ° F (121 ° C), and the smooth anvil roller in direct contact with the film is 1600F (71.0, 175F (79C) '185F (85 ° C) and 195 ° F (91 ° C). The film / non-woven laminates at all four bonding temperatures were tested for bonding strength. In addition, the mother and film were tested for water vapor transmission rate, and the ease of film processability was visually observed. The results are shown in Table 3. Table 3 wt% calcium carbonate LLDPE (wt%) (wt%) WVTR g / m2 / 24 hr 160 ° F Adhesive strength (g) 175〇F 185〇F 195〇F Film processing MDO Stretch 65% 20% 4300 41 ♦ Original * Excellent 65% 30% 2300 3 5 6 10 Premium 65% 30% 3840 3 3 7 5 Premium 65% 30% 3198 3 3 5 7 Excellent 65% 30% 2990 4 4 10 9 Special Excellent 65% 30% 4900 8 7 10 7 Excellent Excellent KSO50 15%

Regalrez 1094 5%

Regalrez 3102 5%

Regalrez 1126 5%

Zonatac 501L 5% 1023PL 5% * Cannot be separated (good adhesion) The olefin KSO50 adhesive provides the best two-layer adhesion strength, but keep in mind that it occupies in the film

23 C: \ EMmce 2004 \ PK-001-02 \ PK-001-0225 \ PK-001-0225-2.DOC M245953 15wt%, while other adhesives are 5wt%. Most adhesives appear to increase adhesion as the adhesion temperature increases ', but the highest peak of some adhesives is 185 ° F' and then the adhesive strength begins to decrease at 1950F. All adhesives have good workability between excellent and special, but the _Ks⑽ adhesive lay-up film only stretches in the mechanical direction. All films showed good water vapor transport rates. Example 4 In Example 4, the original wound-like, breathable cloth-like compound with ordinary female polyethene (control group) was used as a diaper cover for clinical research to determine its efficiency of reducing skin hydration. The manufactured diaper includes a material control cover and a film / material layer of sample 1 on side 1. The composite film has a water vapor transport rate of 4300 g / m 2 per 24 hours, and the water vapor transport rate of the composite is 41 g / m 2 per hour. The wvtr of a single-layer L2 mil-thick polyethylene film for controlling a diaper is about 40 to 50 grams per square meter per 24 hours. Each diaper was flushed with 60 ml of synthetic urine and then wrapped around the subject's forearm. At predetermined intervals, the WVTR is measured to determine the degree of skin hydration. Based on the test results, the skin hydration of the user's skin under the diaper using this creative compound is significantly smaller than that of the control group. Therefore, it can be proved that it can be used in the second layer while maintaining breathability and reducing skin hydration. To obtain effective bonding. As can be seen from the foregoing examples, the material of this creation provides a breathable cloth-like film / non-woven composite with excellent adhesion between the layers. The non-woven layer is used to strengthen the breathable film layer, and the non-woven layer helps to overcome the wet and cold nature of the breathable film when the composite acts as a personal protective absorbent article, such as a diaper. In addition, incompatible polymers / layers can be thermally laminated to each other due to the incorporation of a binder into the film and / or fiber polymer mixture. After describing this creation in such detail, it is generally known that many modifications and changes can be made without departing from the spirit of this creation and the scope of subsequent patent applications.

24 C: \ Eunice2004 \ PK-001-02 \ PK-001-O225 \ PK-001 ^ 225-2.DOC Graphic element description 10 composite laminated 12 film layer film layer 14 support layer 16 bonder adhesive 18 take up roll Starting roller M245953 [Schematic description] The first picture is a cross-sectional view of the breathable, cloth-like film / non-woven composite of the creation. The second picture is the processing diagram of the breathable, cloth-like film / non-woven composite created.

25 C: \ Eunice 2004 \ PK-001-02 \ ΡΚ-ΟΟΊ -0225 \ ΡΚ-ΟΟΊ -0225-2. DOC

Claims (1)

M245953 范围 Application scope: 1. A breathable cloth-like film / non-woven laminated absorbent article, wherein the laminated layer comprises: a film 'formed of a mixture containing the following, containing 10 to 68% (based on the dry total of the film Weight basis) Advantages of linear polyolefin polymers, 30 to 80% filler, 2 to 20% binder, the film has a water vapor transmission rate of at least 100 g / m2 per 24 hours, and a fiber property Polyolefin non-woven fabric, which is directly bonded to the film to form a laminate, the laminate having a tear strength of at least 24 grams. 2. The absorbent article according to item 1 of the patent application, wherein the advantageous linear polyolefin polymer is a linear low-density polyethylene. 3. If the absorbent article in item 1 of the patent application scope, the filling material of the towel is carbonic acid. 4. If applying for the absorbent article of the special fiber enveloping item 1, the towel face is a stretched film with a weight per unit area of greater than 0 g / m2 and less than 35 g / m2. 5. The absorptive article according to item 1 of the patent application scope, wherein the film is a stretched film with a weight per unit area of more than 0 grams square meters and less than 18 grams per square meter. 6. For an absorbent article such as a patent application, the fiber-containing hydrocarbon non-woven fabric is a polypropylene non-woven fabric. 7. The absorbent article according to item i of the patent application scope, wherein the fiber polyolefin non-woven fabric comprises composite fibers, and the composite fibers have a polyolefin component. Tong Shen kissed her about the 1st lion sucking object, and the towel was reduced to the side of the fibrous hydrocarbon non-woven fabric with a second fibrous polyolefin non-woven fabric. 9. A kind of breathable cloth-like film / non-woven laminated seam-like articles, among which the personal protection and absorbent articles include: 26 C: ⑽- 纲: ⑽ 卿 ⑽ 面 ㈣㈣ M245953 Integrated side lining and a cover and sandwiched between the two An absorbent core material for the user, the cover includes a film formed by a mixture of the following ingredients, containing 10 to 68% (based on the total dry weight of the film) of the advantageous linear polyolefin polymer, 30 to 80 % Filling material, 2 to 20% adhesive, the film has a water vapor transmission rate of at least 100 g / m 2 per 24 hours, and a fibrous polysmoky non-woven fabric directly bonded to the film to form a laminate, the laminate Has a tear strength of at least 24 grams. 10. A breathable cloth-like film / non-woven laminated absorbent article, wherein the laminated layer comprises: a film formed of a mixture containing the following ingredients (based on the total dry weight of the film) with an advantage of 10 to 68% Linear polyolefin polymer, 30 to 80% filler, 2 to 20% binder, the film has a water vapor transmission rate of at least 100 g / m2 per 24 hours, and a fibrous polysmoky non-woven fabric directly bonded The film is formed into a laminate having a peel strength of at least 24 grams. 11. A breathable cloth-like film / non-woven laminated absorbent article, wherein the laminated layer contains an extruded mixture before formation, and the mixture contains (based on the total dry weight of the film) 10 to 68% of the advantageous linear polyolefin polymer 30 to 80% of filler, 2 to 20% of binder; a film formed from an extruded mixture; the film is stretched at a temperature lower than the refining point of the advantageous linear thermoplastic polymer; and The laminate formed by directly bonding the film to a fibrous polyolefin non-woven is bonded at a temperature lower than the melting point of the dominant linear thermoplastic polymer in the film, and the laminate has a tear strength of at least 24 grams. 12. If the non-woven absorbent article of item η in the scope of patent application, the layer further includes 27 C: \ Eunice 2004 \ ΡΚ-ΌΟΊ-ΟZ \ PK-00J-0225 \ ΡΚ-00Ί-0225-2. DOC M245953 Corrugated surface. For example, the non-woven absorbent article of the patent application No. M11, wherein the stretching of the film is completed when the temperature is the softening point of the adhesive. 14. A breathable cloth-like film / non-woven laminated absorbent article, wherein the laminated layer comprises: forming a film layer, which (based on the total dry weight of the film) of 30 to 70% of the filler and 20 to 70% A polyolefin polymer; stretching the film layer; using the majority of fibers in a fibrous nonwoven fabric containing a polyolefin polymer and an adhesive, directly bonding the fibrous nonwoven fabric to the film layer, the polyolefin polymer and the The adhesive forms at least a portion of the outer surface of the fiber to produce a tear strength of at least 24 grams. 15. A breathable cloth-like film / non-woven laminated absorbent article, wherein the laminated layer comprises: a film layer containing (based on the total dry weight of the film) 30 to 80% of the filler and 20 to 70% of the polymer An olefin polymer; and a fibrous non-woven fabric containing a polyolefin polymer and a binder, and through the majority of the fibers in the fibrous non-woven fabric are directly bonded to the aforementioned film, the polyolefin polymer and the binder form at least A portion of the outer surface of the fiber to produce a tear strength between the film layer and the fibrous nonwoven of at least 24 grams. 28 C: \ Eunice 2004 \ PK-001-02 \ PK-001-022S \ PK-001-0225-2. DOC