CN1360488A - 带有非织造布抑湿剂的吸收制品 - Google Patents

带有非织造布抑湿剂的吸收制品 Download PDF

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CN1360488A
CN1360488A CN00809500A CN00809500A CN1360488A CN 1360488 A CN1360488 A CN 1360488A CN 00809500 A CN00809500 A CN 00809500A CN 00809500 A CN00809500 A CN 00809500A CN 1360488 A CN1360488 A CN 1360488A
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fibre web
long filament
absorbent article
filament fibre
woven long
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CN1131707C (zh
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C·A·布拉尼
A·L·麦科尔马克
S·C·保罗
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Kimberly Clark Worldwide Inc
Kimberly Clark Corp
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    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/514Backsheet, i.e. the impermeable cover or layer furthest from the skin
    • A61F13/51456Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its properties
    • A61F13/51458Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its properties being air-pervious or breathable
    • A61F13/51462Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its properties being air-pervious or breathable being defined by a value or parameter
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F2013/51002Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers with special fibres
    • A61F2013/51009Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers with special fibres characterized by the shape of the fibres
    • A61F2013/51011Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers with special fibres characterized by the shape of the fibres characterized by the count of the fibres, e.g. denier or tex
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/647Including a foamed layer or component
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/674Nonwoven fabric with a preformed polymeric film or sheet
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/674Nonwoven fabric with a preformed polymeric film or sheet
    • Y10T442/678Olefin polymer or copolymer sheet or film [e.g., polypropylene, polyethylene, ethylene-butylene copolymer, etc.]

Abstract

一种吸收制品,包括:透液面层、吸收剂芯层、透气外包覆层和位于吸收剂芯与透气外包覆层之间的内非织造长丝层。外包覆层包括透气薄膜和外非织造长丝层。内非织造长丝层的平均纤维旦数高于外非织造长丝层的平均纤维旦数。内非织造长丝层起到抑湿剂的作用,它通过降低吸收剂芯与外包覆层表面之间的导热性,可减轻或防止外包覆层外表面的湿粘感。

Description

带有非织造布抑湿剂的吸收制品
                       技术领域
本发明涉及一种具有至少一个面层、一个吸收剂芯以及一层透气性外包覆材料的吸收制品。在吸收剂芯与透气性外包覆材料之间布置着具有较高旦数纤维的纤维非织造纤网,从而导致吸收剂芯打湿时透气性外包覆材料外表面的表面湿度的降低,又不显著降低干态时吸收制品外包覆层的透气性。
                     背景技术
吸收制品,例如尿布、儿童训练裤、成人失禁服装、泳装之类,一般都包括至少一个直接接触穿戴者的透液面层、一个吸收剂芯层以及一个基本不透液的外包覆材料。吸收剂芯布置在面层与外包覆材料之间。当吸收制品遇到排液时,液体将透过面层并进入到吸收剂芯中。外包覆层防止吸收剂芯中的液体跑到该服装以外。
许多当今的吸收性服装采用透气性外包覆材料。透气性外包覆材料基本不透液,但允许水蒸汽透过。透气性外包覆材料容许水蒸气从吸收性服装逸出,从而增加该服装的舒适,减少皮疹以及其它当水蒸气窝藏在该服装内部,又经穿戴者身体加热所引起的刺激。许多当今的吸收性服装是高度透气的,旨在达到最大程度的舒适。
透气性吸收制品的一个缺点是该服装外面,即,外包覆材料外表面,常常给人冷、潮、粘的感觉。随着吸收剂芯内液态水的蒸发并透过外包覆材料,与之相联系的蒸发冷却作用导致吸收剂芯和相邻外包覆材料温度下降,从而造成外包覆材料的湿粘感。因此,目前吸收性服装工业需要或希望有这样一种吸收制品,它既具有高透气性,却又能减少或避免因蒸发冷却造成感觉上的潮湿。
                       发明概述
本发明涉及一种具有透气性外包覆材料并且其外包覆材料潮湿感减轻的吸收制品。该吸收制品包括至少一个透液面层、一个透气、基本不透液外包覆材料,以及位于面层与外包覆材料之间的吸收剂芯层。该外包覆材料包括层合在非织造长丝纤网的透气性薄膜,并布置成,以其薄膜朝内(即,朝向吸收剂芯),而非织造纤网朝外。按照本发明,将一层第二非织造长丝纤网铺在吸收剂芯与透气性外包覆材料之间。第二非织造纤网的长丝平均旦数比外包覆材料中的第一非织造纤网的长丝平均旦数高。
具有较高旦数的第二(内)非织造长丝纤网的存在,通过在吸收剂芯与外包覆材料之间提供一个空气隙,降低了第一非织造纤网外露表面的湿度。该空气隙将吸收剂芯与外包覆材料隔开,从而在受到冷却的吸收剂芯与触摸外包覆层的手指之间提供一种热绝缘。外包覆体系的导热率因此而降低,手的热量散失量因而减少。这使得尿布表面摸上去感觉更暖和、更干爽。湿粘和冰冷的感觉减少了,因此增强干爽和织物样感觉。
当旦数等于或大于2时,内层非织造纤网一般就具备足够膨松性以提供足够的热绝缘。当旦数小于2时,外包覆层的非织造纤网将具备极佳的织物样手感。
根据以上情况,本发明的特征和优点是提供一种吸收制品,它具有透气性外包覆体系,该体系的导热率通过在外包覆层与吸收剂芯之间加入一种包含大于2旦的纤维的非织造纤网而有利地降低。
本发明的特征和优点还在于提供一种具有不妨碍透气的抑湿层的透气性吸收制品。
本发明的特征和优点还在于提供一种具有在各种各样条件下摸上去总是暖和、干爽的透气性外包覆材料的吸收制品。
上述以及其它特征和优点,在结合着所附实施例和附图研读了下面有关目前优选实施方案的详述之后将变得更加清楚。给出详述、实施例和附图的目的仅在于说明而不是对本发明范围做出限制,该范围仅由所附权利要求及其等价物规定。
                     附图简述
图1是本发明吸收制品的透视图;
图2是本发明吸收制品,沿着图1中线2-2截取的放大剖面图;以及
图3是该透气性外包覆材料的一种实施方案的放大剖面图。
                         定义
术语“透气性薄膜”、“透气性层合物”或“透气性外包覆材料”是指一种薄膜、层合物或外包覆材料,它具有,用本文所描述的WVTR试验程序测定,至少约300g/m2-24 h的水蒸气透过速率(“WVTR”)。
术语“外包覆体系”是指一个外包覆层合物与一个第二内层、抑湿非织造纤网的组合。
术语“液态水-可透材料”是指一种存在于一个或多个层中的材料,例如薄膜、非织造布,或者开孔泡沫塑料,它是多孔的,并且由于水和其它含水液体能穿过孔流动因而是可透水的。这些薄膜或泡沫塑料中的孔隙,或者非织造纤网中纤维或长丝之间的空隙足够大,而且足够多,以致容许液态水透过材料渗漏或流过。
术语“非织造布或纤网”是指其结构系由单根纤维或丝交叉铺置构成的纤网,但它们不是像针织物中那样按照规则或可辨认方式排列的。非织造布或纤网一向采用多种方法成形,如熔喷法、纺粘法、气流铺网法以及粘合-梳理纤网法。以浆粕或纤维素为基础的纤网也是非织造布。非织造布的基重通常以每平方码材料的盎司数(osy)或每平方米的克数(gsm)表示;有用的纤维直径通常表示为μm数。(注:要从osy数值换算为gsm值,可用33.91乘上osy的数值)。
术语“微纤维”是指平均纤维旦数为约0.005~10,例如,平均纤维旦数为约0.05~6的小直径纤维,或者更具体地,微纤维可具有约1~4的平均纤维旦数。
术语“旦数”被规定为每9000米纤维的克数。对于圆形断面的纤维来说,旦数可根据以微米表示的纤维直径取平方,乘上以g/cc为单位的密度,再乘上0.00707计算出来。旦数越低,表明纤维越细;旦数越高,表明纤维越粗或越重。例如,已知聚丙烯纤维直径为15μm,要换算为旦数,可取平方,该结果乘上0.89g/cc,再乘上0.00707。于是,15μm的聚丙烯纤维的旦数为约1.42(152×0.89×0.00707=1.415)。在美国以外,较常用的度量单位是“特(tex)”,其定义是每千米纤维的克数。特数可按旦数/9来计算。“平均纤维旦数”是每根纤维旦数之和,除以纤维根数。
术语“纺粘纤维”是指一类小直径纤维,其成形方法是通过将熔融热塑性材料从纺丝板的多个纤细,圆形或其它形状的纺丝孔中挤出为丝束,随后,挤出丝束的直径,借助例如以下文献中的方法迅速拉细:授予Appel等人的美国专利4,340,563及授予Dorschner等人的美国专利3,692,618、授予Matsuki等人的美国专利3,802,817、授予Kinney的美国专利3,338,992及3,341,394、授予Hartmann的美国专利3,502,763、授予Petersen的美国专利3,502,538、授予Dobo等人的美国专利3,542,615,在此均全文收作参考。纺粘纤维经骤冷,当沉积到收集表面上时通常是不发粘的。纺粘纤维通常为连续状且平均旦数通常大于约0.3μm,更具体地,介于约0.6~10。
术语“熔喷纤维”是指按如下方法成形的纤维:将熔融热塑性材料从多个纤细,通常为圆形的纺丝孔中以熔融丝束或长丝形式挤出到逐渐汇聚的高速加热气流(例如空气流)中,气流将熔融热塑性材料丝束拉细,直径变小,可能小到微纤维的直径范围。然后,熔融纤维被高速气流夹带着,最后沉积在收集表面上,形成由无规分布的熔喷纤维组成的纤网。此类方法,例如公开在授予Buntin的美国专利3,849,241中。熔喷纤维属于微纤维,可以是连续的或不连续的,通常小于约0.6旦,且当沉积到收集表面上时通常是自粘的。本发明中使用的熔喷纤维优选在长度上为基本连续的。
术语“薄膜”是指采用薄膜挤出法,例如流延薄膜或吹胀薄膜挤出法制成的热塑性薄膜。术语“水-可透多孔薄膜”是指通过冲孔或穿孔而变成多孔的薄膜,也指通过聚合物与填料的混合,再由该混合物成形为薄膜,然后拉伸该薄膜,而变得多孔的薄膜。
术语“聚合物”包括但不限于:均聚物;共聚物,如嵌段、接枝、无规及交替共聚物、三元共聚物等;以及上述的共混物及各种改性形式。而且,除非另行具体限定,术语“聚合物”应涵盖该材料所有可能的分子几何构型。这些构型包括但不限于,全同立构、间同立构及无规立构的对称构型。
术语“浆粕纤维”是指取自天然来源的纤维如,取自木本或非木本植物。木本植物例如包括阔叶和针叶树。非木本植物例如包括棉花、亚麻、西班牙草、马利筋属植物、麦稻秸、黄麻、大麻和甘蔗渣。
术语“超吸收性材料”是指在最有利条件下能够吸收至少约20倍于自身重量,优选至少约30倍于自身重量含0.9wt%氯化钠的水溶液的水可溶胀、不溶于水的有机或无机材料。
术语“个人护理吸收制品”是指包括但不限于尿布、训练裤、泳装、吸收性内裤、婴儿擦拭布、成人失禁用品和妇女卫生用品。
术语“医用吸收产品”包括但不限于吸收性服装、贴身垫、绷带、吸收性被单和医用抹布。
                   优选实施方案详述
参见附图1,本发明吸收性服装2具有裤子样形状,可用作尿布、儿童训练裤、儿童泳装、成人失禁制品等。服装2包括废物容纳段(“大身”)4,它具有前部5和后部7,二者由中(“裆”)部15连接起来,还有2个侧部6和8,每一个的边缘分别连接前部和后部。侧片6包括松紧片18和20,二者彼此沿接缝30互连并分别沿着接缝29和31连接到废物容纳段上。接缝29、30和31每一个沿纵向取向,并从腰围10的上口开始延伸到腿口12。侧片8包括松紧片24和26,彼此沿着接缝33连接,并沿着接缝32和34连接到废物容纳段上。接缝32、33和34每一个沿纵向取向,并从腰围的上口开始延伸到腿口14。
大身4包括许多层(如下所述),例如包括透液面层、吸收剂芯层和背向穿戴者的透气、不透液外包覆层16。下面描述布置在吸收剂芯和外包覆层16之间的内非织造长丝纤网。废物容纳段4还包括位于服装前后的弹性化腰部22。腿口部12和14还包括弹性部分46,后者基本上围绕着由废物容纳段4围成的腿口一周延伸。
图2显示沿着图1,线2-2截取的吸收制品各个层的放大剖面图。看图2,吸收性服装2包括位于中区15的若干层。这些层包括,透液面层21、面层21下面并与之相邻的透液缓冲层13、缓冲层13下面并与之相邻的吸收剂层17、吸收剂层17下面并与之相邻的内非织造长丝纤网50、以及内非织造长丝纤网50下面并与之相邻的透气的、基本不透液外包覆层16。
在图示的实施方案中,面层21和外包覆材料16比缓冲层13、吸收剂芯17和内纤网50宽。面层21基本上包裹着缓冲层13、吸收剂芯17和内非织造长丝纤网50,并在端部区23和25处利用粘合剂、超声波或热粘合技术固定在外包覆材料16上。外包覆材料16在侧端9和11处折叠,以便使它搭接并包裹住面层21的边缘23和25。在搭接部分内,各层可利用热、超声波或粘合剂粘合技术结合在一起。弹性区46可利用粘合剂、超声波或热粘合技术将弹性带19固定到外包覆材料16上和/或其内部。
纵缝29和34可通过传统方法形成,包括但不限于超声焊接、热粘合、粘合剂粘合、缝合等的技术。超声焊接是目前优选的技术。这些各种不同粘合技术均属传统技术,对本发明来说既非关键,也不构成限制。
松紧侧片6和8可由各种各样弹性和可拉伸聚合物制成的传统织造或非织造材料构成。术语“弹性”和“松紧(stretchable)”涵盖任何可拉长,并当松开时趋于返回到其原来形状的材料。合适的聚合物包括但不限于聚苯乙烯、聚异戊二烯和聚丁二烯的嵌段共聚物;乙烯、天然橡胶和氨基甲酸酯的共聚物;以及上述的组合。尤其合适的是苯乙烯-丁二烯嵌段共聚物,由壳牌化学公司以商品名KRATON销售。其它合适的聚合物包括乙烯的共聚物,包括但不限于,乙烯-醋酸乙烯酯、乙烯-丙烯酸甲酯、乙烯-丙烯酸乙酯、乙烯-丙烯酸、可拉伸乙烯-丙烯共聚物,及其组合。合适的还有上述材料的共挤出复合物,以及弹性体短纤维一体化复合物,其中聚丙烯、聚酯、棉花以及其它材料的短纤维被结合成为弹性熔喷纤网。某些弹性体、单部位或金属茂催化的烯烃聚合物和共聚物也适合用于侧片中。松紧侧片优选呈矩形,并优选从腰围10的上口延伸到腿口12和14。侧片也可以是多层的层合物,优选透水蒸气但不透液体。
缓冲层13和体侧衬里21均由高透液材料制成。这些层的功能是将液体从穿戴者转移到吸收剂层17。合适的材料包括多孔机织材料、多孔非织造布材料和穿孔薄膜。例子包括但不限于,任何聚烯烃纤维的柔性多孔片材,例如聚丙烯、聚乙烯或聚酯纤维;纺粘聚丙烯、聚乙烯或聚酯纤维的纤网;人造丝纤维的纤网;合成或天然纤维或其组合的粘合梳理纤网。其中任何一层也可以是穿孔塑性薄膜。服装2的各层的尺寸随着穿戴者的尺寸和形状而有所变化。
吸收剂层17可由木浆短绒或木浆短绒与超吸收性材料的混合物制成,或者由木浆短绒结合经表面活性剂处理的热塑性吸收材料构成。用短绒和超吸收剂进行掺混或层合时可使用热粘合剂,例如Pulpex。层17也可以是熔喷合成纤维絮片、合成或天然纤维或其共混物的粘合梳理纤网、熔喷纤维的复合材料等。合成纤维可以是,但不限于,聚丙烯、聚乙烯、聚酯和这些或其它聚烯烃的共聚物。
术语“超吸收剂”或“超吸收性材料”是指在最有利条件下能够吸收至少约20倍于自身重量,优选至少约30倍于自身重量的含0.9wt%氯化钠的水溶液的水可溶胀、不溶于水的有机或无机材料。超吸收性材料可以是天然、合成和改性的天然聚合物和材料。另外,超吸收性材料可以是无机材料,例如硅胶,或者是有机化合物如交联聚合物。术语“交联”是指任何能够将通常水溶性材料转变为基本不溶于水但能溶胀的手段。此类手段可包括,例如物理缠结、结晶区、共价键、离子配合以及缔合,亲水缔合,例如氢键,以及疏水缔合或范德华力。
合成超吸收性材料聚合物的例子包括聚(丙烯酸)和聚(甲基丙烯酸)的碱金属和铵盐,聚丙烯酰胺、聚乙烯基醚、马来酐与乙烯基醚和α-烯烃的共聚物,聚乙烯基吡咯烷酮、聚乙烯基吗啉(poly(vinylmorpholinone)、聚乙烯醇,及其混合物以及共聚物。另一些超吸收性材料包括天然和改性天然聚合物,例如水解的丙烯腈-接枝淀粉、丙烯酸接枝淀粉、甲基纤维素、聚氨基葡糖、羧甲基纤维素、羟丙基纤维素,以及天然树胶,例如海藻酸盐、黄原胶、刺槐豆胶等。天然与完全或部分合成的超吸收性聚合物的混合物也可用于本发明。其它合适的吸收性胶凝材料公开在,Assarsson等人,美国专利3,901,236,1975-08-26授权。制备合成吸收性胶凝聚合物的方法公开在美国专利4,076,663,1978-02-28授予Masuda等人,以及美国专利4,286,082,1981-08-25授予Tsubakimoto等人。
外包覆材料16可透过水蒸气。一般地,外包覆层16的WVTR,采用下面所描述的试验程序测定,至少为约300g/m2-24h,优选至少约1500g/m2-24h,更优选至少约3000g/m2-24h。图2所示外包覆层16包括2层35和37,彼此通过热或超声粘合,或者粘合剂结合。层35是非织造长丝纤网。层37是透气性薄膜。外包覆层16的布置方式是,非织造纤网35朝外,而透气性薄膜37朝内面向抑湿内非织造纤网50。
非织造长丝纤网35可以是纺粘纤网、熔喷纤网、粘合梳理纤网、气流铺网纤网,或者任何其它不显著吸收含水流体的长丝型非织造纤网。优选的是,非织造纤网35由一种或多种热塑性聚合物制成。合适的聚合物包括但不限于,聚乙烯、聚丙烯、以乙烯为主与C3~C12α-烯烃生成的共聚物(通常称之为线型低密度聚乙烯)、以丙烯为主与乙烯和/或C4~C12α-烯烃生成的共聚物,以及柔性聚烯烃,包括在丙烯主链中既有无规也有全同立构丙烯基团的丙烯系聚合物、聚酰胺以及聚酯。其它合适的聚合物包括但不限于高弹体,例如,聚氨酯、共聚醚酯、聚酰胺-聚醚嵌段共聚物、乙烯-醋酸乙烯酯共聚物、通式为A-B-A’或A-B的嵌段共聚物,例如共聚(苯乙烯/乙烯-丁烯)、苯乙烯-聚(乙烯-丙烯)-苯乙烯、苯乙烯-聚(乙烯-丁烯)-苯乙烯、聚苯乙烯/聚(乙烯-丁烯)/聚苯乙烯、聚(苯乙烯/乙烯-丁烯/苯乙烯)等。金属茂催化聚烯烃也是有用的,包括描述在美国专利5,571,619、5,322,728和5,272,236中的那些,在此将其公开内容收作参考。
采用金属茂催化剂制备的聚合物具有非常窄的分子量范围。多分散性指数(Mw/Mn)低于4,甚至低于2,对于金属茂生产的聚合物都是可能的。这类聚合物还具有,与其它方面均类似的齐格勒-纳塔生产的那类聚合物相比,可控的短链支化分布。还可利用金属茂催化剂体系相当准确地控制聚合物的全同立构规整度。
非织造纤网35优选由聚乙烯、聚丙烯或者半结晶丙烯-乙烯共聚物制成。纤网35采用带图案的热压花辊粘合、超声粘合,粘合剂粘合等的方法层合到透气性薄膜37上。优选的是,粘合区域占到纤网35与薄膜37之间界面的小于约25%,更优选小于约20%,以便使粘合不损害层合物16的透气性。
透气性薄膜37更详细地表示在图3中,这是外包覆层16的放大剖面图。在一种实施方案中,透气性薄膜37包括至少一个微孔层58。微孔层58可利用各种各样已知技术成形。优选的是,层58包括:聚合物基体62,在该基体内部有大量孔隙64,孔外面包围着更薄的微孔膜63,它围成弯弯曲曲的路径;以及在每个孔隙64内,一个或多个填料颗粒66。层58是微孔的和透气的,其中孔隙之间的微孔膜63容许水蒸气靠分子扩散从薄膜层58的第一表面68到达到第二表面70。
聚合物基体62可由任何合适的成膜热塑性聚合物成形。合适的聚合物的例子包括但不限于,上面列举用于非织造纤网35的热塑性聚合物。优选聚烯烃,最优选采用齐格勒-纳塔催化剂或金属茂催化剂制成的线型低密度聚乙烯。
填料颗粒66可包括任何合适的无机或有机填料。填料颗粒66优选很小,为的是获得尽可能大的孔隙的水蒸气透过速率。一般而言,填料颗粒的平均直径为约0.1~7.0μm,优选约0.5~7.0μm,最优选约0.8~2.0μm。合适的填料包括但不限于,碳酸钙、不可溶胀粘土、二氧化硅、氧化铝、硫酸钡、碳酸钠、滑石粉、硫酸镁、二氧化钛、沸石、硫酸铝、硅藻土、硫酸镁、碳酸镁、碳酸钡、高岭土、云母、碳、氧化钙、氧化镁、氢氧化铝和聚合物颗粒。碳酸钙是目前优选的填料。
填料颗粒66可涂以少量(例如最高2wt%)脂肪酸或其它材料以促进它们在聚合物基体中的分散。合适的脂肪酸包括但不限于硬脂酸,或者较高级链脂肪酸如二十二烷酸。填料颗粒66在层52中的含量应占到层58的约30~80wt%,优选约40~70wt%,最优选约50~65wt%。类似地,聚合物基体62应占到层58的约20~70wt%,优选约30~60wt%,更优选约35~50wt%。
聚合物组成、填料含量、填料粒度以及拉伸度是帮助确定微孔薄膜层58的透气性的因素。一般而言,微孔薄膜层58的厚度将小于约50μm,优选小于约30μm,最优选小于约20μm。透气性薄膜37可单轴拉伸到其原长的约1.1~7.0倍,优选到其原长的约1.5~6.0倍,最优选到其原长的约2.5~5.0倍。该薄膜可替代地采用本领域技术人员熟悉的传统技术进行双轴拉伸。
在图3的实施方案中,微孔透气性薄膜层58与一个或两个比较薄的外皮层56和60相邻,形成2或3-层的薄膜37。一个或两个皮层的引入可改善薄膜的加工性,还可赋予该透气性薄膜37以可热合性能。透气性薄膜37可通过各层的流延或吹胀薄膜共挤出、通过挤出涂布,或通过任何传统层合技术来制备。外层56和60中的聚合物,与微孔层58中的聚合物可相同或不同。优选的是,该一个或多个外层中的聚合物的软化点低于微孔层58中的,并对薄膜37的热合性做出贡献。
还有,外层56和60的厚度和组合物应选择为基本上不妨碍水份经透气性薄膜37透过。这样,微孔层58便可能决定整个薄膜的透气性。为达到此目的,皮层56和60各自一般应小于约10μm厚,优选小于约5μm厚,最优选小于约2.5μm厚。优选的皮层聚合物包括乙烯-醋酸乙烯酯、丙烯-醋酸乙烯酯、乙烯-丙烯酸甲酯、其它蒸汽可透聚合物,以及这些聚合物与其它聚烯烃的共混物。
按照本发明,一层抑湿非织造长丝纤网50布置在吸收剂芯17与外包覆层16之间。非织造纤网50的平均纤维旦数高于外包覆层16的非织造纤网35的平均纤维旦数。优选的是,非织造纤网50的平均纤维直径比非织造纤网35的平均纤维旦数至少高出约10%,更优选至少高出约20%。最优选的是,非织造纤网50的平均纤维旦数比非织造纤网35至少高出约30%。
非织造纤网50的平均纤维旦数应至少为2.0,优选2.2-10,更优选2.5-6.0。非织造纤网35的平均纤维旦数应小于2.0,优选0.1~1.8,更优选0.5~1.5。
非织造纤网50可以是纺粘纤网、熔喷纤网、粘合梳理纤网、气流铺网纤网、纤维素纤网或者任何其它微纤维非织造纤网。优选的是,非织造纤网50由热塑性聚合物纤维制成。用于制造该非织造纤网的聚合物包括上面列举用于透气性微孔薄膜37以及非织造纤网35的聚合物。非织造纤网50优选由聚烯烃构成,更优选聚乙烯或聚丙烯均聚物或共聚物。非织造纤网50的基重应介于约0.1~4.0盎司/平方码(osy),优选由约0.3~2.0osy,更优选约0.4~1.0osy。非织造纤网50也可以是由一个以上非织造纤网层组成的层合物。例如,纤网50可以是如同公开在美国专利4,041,203,授予Brock等人那样的纺粘-熔喷-纺粘的构造。倘若非织造纤网50包括一个以上的层,则其基重和平均纤维旦数的计算以结合的各层为基础,给出的数值代表整个纤网50。
优选的是,非织造纤网35和50是疏水的。疏水材料具有较大传递湿蒸汽,而不是吸收或截留它的倾向。相比之下,亲水材料具有较高吸收或截留湿蒸汽的倾向。本文所使用的术语“疏水的”描写一种材料,它具有大于90°的水在空气中的接触角。术语“亲水的”是指一种材料,它具有小于90°的水在空气中的接触角。水在空气中的接触角宜于按照P.K.Chatterjee主编(E1sevier,纽约,1985)的《吸收度》一书给出的方法确定。
在诸如尿布或训练裤之类吸收制品的正常使用期间,外包覆层16的透气性主要受透气性薄膜37,其次受非织造纤网35的影响。倘若抑湿层50用平均旦数低于非织造纤网35的长丝的长丝构成,则层50便开始对外包覆层16的透气性产生抑制。这是因为,纤维旦数较低的纤网往往比纤维旦数较高的纤网更致密。一种抑湿层50,倘若能降低外包覆层的透气性,将是有悖初衷的,因为服装内部的湿度将增加,从而导致皮肤水化的增加和舒适度的降低。
另一方面,若提供一种较高纤维旦数、结构较为稀松的非织造纤网50,则大部分时间外包覆层16的透气性基本不受影响。较高纤维旦数的非织造纤网50还具有较高的膨松度,因此可容纳较大量隔热空气。此种隔热因素可降低外包覆体系(即,外包覆层加上抑湿非织造布层)的导热率,从而消除“湿粘”感。
弹性带19可采取每条腿单一或多根带的形式。有多种多样弹性材料可供使用。例子包括采用下列单体的嵌段或接枝共聚物成形的薄膜或熔喷纤网:丁二烯、异戊二烯、苯乙烯、乙烯-丙烯酸甲酯、乙烯-醋酸乙烯酯、乙烯-丙烯酸乙酯或其共混物。一种优选的弹性体是苯乙烯-乙基丁二烯-苯乙烯嵌段共聚物。可用于制造弹性带19的具体材料是:Kraton G系列,壳牌化学公司出品,例如Kraton G-1650、Kraton G-1652、Kraton GX-1657,以及优选地Kraton G-2740X。还有,也可使用Kraton D系列,以及聚酯弹性体材料、聚氨酯弹性体材料和聚酰胺弹性体材料。弹性体单部位或金属茂催化的烯烃聚合物和共聚物也可使用。还有,弹性带19也可由在未拉伸状态下施加上去的可活化材料制成,然后利用热、光或潮湿或辐射予以活化,造成其收缩和弹性。可活化弹性材料可由3M公司获得。
             水蒸气透过速率(WVTR)的试验程序
下面所描述的程序用于试验透气性薄膜和层合物的水蒸气透过速率(WVTR)。WVTR的测定方法类似于ASTM测试材料的水蒸气传递标准试验方法,代号E-96-80,具体内容如下。就本发明目的而言,从试验材料和对照材料裁下直径3英寸(76mm)圆形试样,对照材料是CELGUARD2500(Hoechst Celanese公司)。CELGUARD2500是0.0025cm厚微孔聚丙烯构成的薄膜。每种材料制备2或3个试样。
测试用杯是铸铝制,带凸缘,2英寸深的,并配备机械密封和氯丁橡胶垫圈。杯子由Thwing-Albert仪器公司(Philadelphia,宾夕法尼亚州)经销,商品名Vapometer杯#681。在每只Vapometer杯中倒入100mL蒸馏水,然后将每一个试验材料及对比材料的试样罩在单个杯的整个顶部敞口上。旋紧螺纹凸缘以在杯边缘的一周形成密封,于是,相关的试验材料或对比材料便在沿着62mm直径的圆形范围上暴露于环境气氛中(开放、暴露面积为约30cm2)。杯子称重后,放在托盘上置于100°F(38℃)强制循环烘箱中。
该烘箱为恒温烘箱,备有外部空气循环通过,以防止水蒸气在内部的积累。合适的强制循环烘箱,例如是Blue M Power-O-Matic 60烘箱,由Blue M电气公司(Blue Island,Illinois)供应。24小时后,从烘箱中取出试样杯并称重。按下式计算初步试验的水蒸气透过速率值:
试验WVTR=[(24小时失重的克数)×7571]/24烘箱内部的相对湿度未着意控制。在规定的一组试验条件,即100°F及环境相对湿度下,预先测得CELGUARD2500的WVTR为5000g/m2/24h。据此,在每一次试验操作中均同时用CELGUARD2500作为对比样进行测试,然后,根据对照样相对于已知WVTR值的变化来校正试验获得的数值。
虽然这里所描述的本发明实施方案目前被认为是优选的,但是在不偏离本发明的精神或范围前提下还可做出各种各样修改和改进方案。本发明范围由所附权利要求指出,所有改变,凡是属于其等价含意和范围之内的,均应被包括在其中。

Claims (32)

1.一种吸收制品,包含:
透液面层;
吸收剂芯层;
疏水内非织造长丝纤网;以及
透气外包覆层,其WVTR至少为约300g/m2-24小时;
该透气外包覆层包括至少一个透气性薄膜和一个具有一定平均纤维旦数的外非织造长丝纤网;
其中内非织造长丝纤网的平均纤维旦数高于外非织造长丝纤网的平均纤维旦数。
2.权利要求1的吸收制品,其中内非织造长丝纤网的平均纤维旦数至少是2.0。
3.权利要求1的吸收制品,其中内非织造长丝纤网的平均纤维旦数为约2.2~10。
4.权利要求1的吸收制品,其中内非织造长丝纤网的平均纤维旦数为约2.5~6.0。
5.权利要求1的吸收制品,其中外非织造长丝纤网的平均纤维旦数小于2.0。
6.权利要求1的吸收制品,其中外非织造长丝纤网的平均纤维旦数为约0.1~1.8。
7.权利要求1的吸收制品,其中外非织造长丝纤网的平均纤维旦数为0.5~1.5。
8.权利要求1的吸收制品,其中内非织造长丝纤网的平均纤维旦数比外非织造长丝纤网的平均纤维旦数高出至少约10%。
9.权利要求1的吸收制品,其中内非织造长丝纤网的平均纤维旦数比外非织造长丝纤网的平均纤维旦数高出至少约20%。
10.权利要求1的吸收制品,其中内非织造长丝纤网的平均纤维旦数比外非织造长丝纤网的平均纤维旦数高出至少约30%。
11.权利要求1的吸收制品,其中透气外包覆层的WVTR至少为约1500g/m2-24小时。
12.权利要求1的吸收制品,其中透气外包覆层的WVTR至少为约3000g/m2-24小时。
13.权利要求1的吸收制品,其中外包覆层布置成使透气性薄膜面朝内非织造长丝纤网。
14.权利要求1的吸收制品,其中内非织造长丝纤网包含的聚合物选自:聚乙烯、聚丙烯、以乙烯为主与C3~C12α-烯烃生成的共聚物(通常称之为线型低密度聚乙烯)、以丙烯为主与乙烯和/或C4~C12α-烯烃生成的共聚物、柔性聚烯烃,包括在丙烯主链中既有无规也有全同立构丙烯基团的丙烯系聚合物、聚酰胺、聚酯以及以上材料的组合。
15.权利要求1的吸收制品,其中内非织造长丝纤网包含的聚合物选自:聚氨酯、共聚醚酯、聚酰胺-聚醚嵌段共聚物、乙烯-醋酸乙烯酯共聚物、通式为A-B-A’或A-B的嵌段共聚物,例如共聚(苯乙烯/乙烯-丁烯)、苯乙烯-聚(乙烯-丙烯)-苯乙烯、苯乙烯-聚(乙烯-丁烯)-苯乙烯、聚苯乙烯/聚(乙烯-丁烯)/聚苯乙烯、聚(苯乙烯/乙烯-丁烯/苯乙烯),以及以上材料的组合。
16.权利要求1的吸收制品,其中内非织造长丝纤网包含聚烯烃。
17.权利要求1的吸收制品,其中内非织造长丝纤网包含金属茂催化的聚烯烃。
18.一种吸收制品,包含:
透液面层;
吸收剂芯层;
具有第一平均纤维旦数的疏水内非织造长丝纤网;以及
透气外包覆层,其WVTR至少为约300g/m2-24小时;
该透气外包覆层包括一层面朝内非织造长丝纤网的透气性薄膜和一层背向内非织造长丝纤网的具有第二平均纤维旦数的外非织造长丝纤网;
其中第一平均纤维旦数比第二平均纤维旦数高出至少约10%。
19.权利要求18的吸收制品,其中内非织造长丝纤网的基重为约0.1~4.0osy。
20.权利要求18的吸收制品,其中内非织造长丝纤网的基重为约0.3~2.0osy。
21.权利要求18的吸收制品,其中内非织造长丝纤网的基重为约0.4~1.0osy。
22.权利要求18的吸收制品,其中内非织造长丝纤网包含纺粘纤网。
23.权利要求18的吸收制品,其中内非织造长丝纤网包含熔喷纤网。
24.权利要求18的吸收制品,其中内非织造长丝纤网包含粘合梳理纤网。
25.权利要求18的吸收制品,其中内非织造长丝纤网包含气流铺网纤网。
26.权利要求18的吸收制品,其中内非织造长丝纤网包含多个非织造布层。
27.一种吸收制品,包含:
透液面层;
吸收剂芯层;
具有第一平均纤维旦数的、基重为约0.1~4.0osy的疏水内非织造长丝纤网;以及
透气外包覆层,包括面朝内非织造长丝纤网的透气性微孔薄膜和背向内非织造长丝纤网的具有第二平均纤维旦数的外非织造长丝纤网;
其中第一平均纤维旦数比第二平均纤维旦数高。
28.权利要求27的吸收制品,它包含尿布。
29.权利要求27的吸收制品,它包含训练裤。
30.权利要求27的吸收制品,它包含成人失禁服装。
31.权利要求27的吸收制品,它包含泳装。
32.权利要求27的吸收制品,它包含医用吸收产品。
CN008095000A 1999-06-25 2000-06-22 带有非织造抑湿层的吸收制品 Expired - Fee Related CN1131707C (zh)

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US6177607B1 (en) 2001-01-23
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KR20020026196A (ko) 2002-04-06
BR0011790B1 (pt) 2009-01-13
JP2003503107A (ja) 2003-01-28
DE60036109T3 (de) 2012-01-26
AU5758700A (en) 2001-01-31
DE60036109T2 (de) 2007-12-13
KR100652851B1 (ko) 2006-12-01
AU768036B2 (en) 2003-11-27
MXPA01012761A (es) 2002-07-30
BR0011790A (pt) 2002-03-12
EP1191913B2 (en) 2011-03-16
DE60036109D1 (de) 2007-10-04
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