CN1741780B - 存储层、包含其的吸收芯以及上述存储层和吸收芯的提供方法 - Google Patents

存储层、包含其的吸收芯以及上述存储层和吸收芯的提供方法 Download PDF

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CN1741780B
CN1741780B CN2004800026881A CN200480002688A CN1741780B CN 1741780 B CN1741780 B CN 1741780B CN 2004800026881 A CN2004800026881 A CN 2004800026881A CN 200480002688 A CN200480002688 A CN 200480002688A CN 1741780 B CN1741780 B CN 1741780B
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absorbent
layer
absorbent cores
thermoplastic
absorbing material
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路德维格·巴萨姆
尤维·J·贝克尔
迈克尔·迪沃
布鲁诺·J·厄恩斯珀格
罗兰·英戈尔
托斯滕·林德纳
西格弗里德·林克
沃尔克·梅尔
桑诺尔·西迪昆
加布里埃尔·斯蒂埃尔
托马斯·汤布尔特-迈耶
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Abstract

本发明涉及一种吸收制品，所述吸收制品优选为一次性吸收制品，例如尿布。公开了一种适用于吸收制品的吸收芯，该吸收芯赋予制品增强的穿着舒适性，并且使制品薄且干爽。进一步公开了获得这样一种吸收芯的方法。具体公开的是一种适于包括基底层的吸收制品的吸收芯，基底层由第一表面和第二表面构成，该吸收芯还包括吸收材料的不连续层，吸收材料包括吸收性聚合物材料，吸收材料可任选地包括吸收性纤维材料，而吸收性纤维材料的含量不超过吸收性聚合物材料总重的20％，吸收材料的不连续层包括第一表面和第二表面，该吸收芯进一步包括热塑性材料层。热塑性材料层包括第一表面和第二表面，并且其中吸收材料的不连续层的第二表面至少部分与基底层的第一表面接触，并且其中所述热塑性材料层第二表面的一些部分与基底层的第一表面直接接触，而所述热塑性材料层第二表面的一些部分与吸收材料的不连续层的第一表面直接接触。进一步公开了一种提供适用于吸收制品的吸收芯的存储层的方法，该方法包括以下步骤：提供包括第一表面和第二表面的基底材料将吸收材料按一种图案放置到基底材料的第一表面上，该图案包括至少一个基本没有吸收材料的区域，并且该图案包括至少一个包含吸收材料的区域。将热塑性材料放置到基底材料和吸收材料的第一表面上，使得热塑性材料的一些部分与基底的第一表面直接接触，并且热塑性材料的一些部分与吸收材料直接接触。

Description

存储层、包含其的吸收芯以及上述存储层和吸收芯的提供方法
技术领域
本发明涉及一种吸收制品，所述吸收制品优选为一次性吸收制品，例如尿布。具体地讲，本发明涉及这样一种吸收制品的吸收芯。当载满或部分载有尿液时，所述吸收芯对吸收性聚合物材料提供改进的固定作用。这种吸收芯适于提供具有增强的穿着舒适性的薄且干爽的吸收制品。
背景技术
诸如尿布和成人失禁用品之类的吸收制品是纤维制造领域所熟知的制品。为使它们具有整体的良好贴合性以及高的吸收容量，人们已进行了多种尝试。现代尿布采用吸收性聚合物材料或所谓的超吸收性材料，这些材料在典型的婴儿尿布中可以存储多达300ml的液体。
虽然这样的尿布通常是一次性用品，但是在一些情况下，它被穿用很多小时，并且既在干燥状态下穿用，也在载有尿液的状态下穿用。
因此，要想在制品处于干燥状态和当制品载满或部分载有尿液(或其它体液)时提供良好的穿着舒适性，将包含在尿布或其它吸收制品中的吸收材料保持在它们的预期位置非常重要。
US 4,381,783(Elias)公开了一种具有包含多个吸收性水胶体材料小袋的吸收芯的吸收制品。提供这些小袋是为了限制水胶体材料的运动，特别是当制品载满或部分载有尿液时。这些小袋形成吸收层的一部分，并且典型地由纤维素材料提供。因此，要达到本发明提出的对水胶体材料的良好固定作用，需要的纤维素材料相对较多。此外，提供这样的小袋可以阻止液体自由地分配到吸收芯上更多的吸收区域，例如水胶体材料区域。
WO 95/17868(Palumbo)公开了一种由两个纤维层和一个中间层构成的吸收结构。该中间层包括含量超过120g/m2的吸收性水凝胶材料和热塑性材料颗粒。虽然这种结构确信对处于干燥状态的吸收性水凝胶颗粒提供良好的固定作用，但是在载有尿液的状态下似乎只能得到较小的固定作用。所公开的热塑性材料出现的膨胀与公开的水凝胶材料相比要小得多。因此，特别是当吸收结构要用于如尿布这样吸收多量液体的用品时，湿固定作用不可能完全令人满意。
EP 724418(Tanzer)公开一种包括位于分散小袋中的超吸收性材料的吸收制品。该吸收制品包括第一和第二载体层以及水敏连接部件，所述水敏连接部件用于将载体层固定在一起并提供多个小袋区域。该制品包括位于所述小袋区域内的高吸收性材料。水敏连接部件提供的湿强度小于由高吸收性材料被暴露于含水液体中时膨胀而施加的分离力。该吸收制品据说提供一种吸收结构，当制品处于干燥状态时，这种吸收结构以选定的小袋方式更可靠地定位和容纳高吸收性材料。然而，由于小袋的结构，并且特别是由于水敏连接部件的选择，当制品载满或部分载有液体时，这些小袋不能维持。因此，据信这种吸收制品没有对处于载满或部分载有尿液状态的吸收材料提供非常满意的固定作用。
发明内容
本发明涉及一种吸收制品，所述吸收制品优选为一次性吸收制品，例如尿布。公开了一种适用于吸收制品的吸收芯，该吸收芯赋予制品增加的穿着舒适性，并且使制品薄且干爽。进一步公开了获得这样一种吸收芯的方法。具体公开的是一种适于包括基底层的吸收制品的吸收芯，基底层由第一表面和第二表面构成，该吸收芯还包括吸收材料的不连续层，吸收材料包括吸收性聚合物材料，吸收材料可任选地包括吸收性纤维材料，而吸收性纤维材料的含量占吸收性聚合物材料总重的0-40％重量，吸收材料的不连续层包括第一表面和第二表面，该吸收芯进一步包括热塑性材料层，热塑性材料层包括第一表面和第二表面，并且其中吸收材料的不连续层的第二表面至少部分与所属层的第一表面接触，并且其中热塑性材料层第二表面的一些部分与基底层的第一表面直接接触，而热塑性材料层第二表面的一些部分与吸收材料的不连续层的第一表面直接接触，吸收材料的不连续层中具有开口并且不连续层设置在彼此连通的区域。
还公开了一种提供适用于吸收制品的吸收芯的存储层的方法，该方法包括以下步骤：
-提供包括第一表面和第二表面的基底材料，
-将吸收材料按一种图案放置到基底材料的第一表面上，该图案包括至少一个基本没有吸收材料的区域，并且该图案包括至少一个包含吸收材料的区域，
-将热塑性材料放置到基底材料和吸收材料的第一表面上，使得热塑性材料的一些部分与基底的第一表面直接接触，以及热塑性材料的一些部分与吸收材料直接接触，
其中，包含吸收材料的区域是连通的。
具体实施方式
本发明涉及一种吸收制品，优选地为一次性吸收制品，例如尿布。
本文使用的下列术语具有下列含义：
“吸收制品”是指吸收和容纳液体的装置，更具体地讲，是指与穿着者的身体紧贴或邻近放置用于吸收和容纳由身体排放的多种渗出物的装置。吸收制品包括但不限于尿布、成人失禁紧身裤、训练裤、尿布固定器、衬垫、卫生巾等等。
本文所用术语“一次性的”用来描述一般不打算被洗涤、恢复或重新使用的制品(即物品在使用一次后即丢弃，且优选地用可回收利用、可堆肥处理或以与环境相容的方式进行处理)。
“尿布”是指通常由婴儿和失禁者绕下部躯干穿着的吸收用品。
“包括”(其动名词形式和动词单数形式)是一个无限制的术语，其指定其后所述例如一个组分的存在，但不排除本领域已知的或本文公开的其它特征、元件、步骤或组分的存在。
图1是作为本发明吸收制品一个优选实施方案的尿布20的平面视图。尿布以其平展未收缩状态(即，无弹性引起的紧缩)示出。结构的一些部分被剖开以更清楚地显示尿布20的底层结构。尿布20接触穿着者的部分面向观察者。图1中尿布20的底座22包括尿布20的主体。底座22包括一个外覆盖件，其包括一个液体可透过的顶片24和/或一个液体不可透过的底片26。底座可包括包封在顶片24和底片26之间的吸收芯28的一部分。底座也可包括包封在顶片24和底片26之间的吸收芯28的大部分或全部。底座优选还包括侧片30、弹性腿箍32和弹性腰部组件34，腿箍32和弹性腰部组件每个都典型地包括弹性构件33。尿布20的一个端部被构型为尿布20的第一腰区36。相对的端部被构型为尿布20的第二腰区38。尿布20的中间部分被构型为裆区37，其在第一和第二腰区36和38之间纵向延伸。腰区36和38可包括弹性构件，使得它们在穿着者的腰部聚拢以提供改进的贴合和容纳效果(弹性腰部组件34)。裆区37是当尿布20被穿用时，尿布20通常位于穿着者大腿之间的部分。图示的尿布20具有纵向轴线10和横向轴线12。尿布20的周边由尿布20的外部边缘确定，其中纵向边缘44通常平行于尿布20的纵向轴线100延伸，并且端边46通常平行于尿布20的横向轴线110在纵向边缘44之间延伸。底座也包括扣紧系统，它可包括至少一个扣系构件42和至少一个存储着陆区45。
对于一体的吸收制品，底座22包括添加了其它部件形成复合尿布结构的尿布的主要结构。虽然顶片24、底片26和吸收芯28可以多种熟知的构型组装，优选的尿布构型通常描述于1996年9月10日授予Roe等人的名称为“Absorbent Article With Multiple Zone Structural Elastic-Like FilmWeb Extensible Waist Feature”的美国专利5,554,145；1996年10月29日授予Buell等人的名称为“Disposable Pull-On Pant”的美国专利5,569,234；以及1999年12月21日授予Robles等人的名称为“Absorbent Article WithMulti-Directional Extensible Side Panels”的美国专利6,004,306中。
图1中的顶片24可以是全部或部分弹性化的，或者可以缩短以在顶片24和吸收芯28之间提供空隙空间。包括弹性化的或缩短的顶片的示例性结构在下列文献中更详细地描述：1991年8月6日授予Allen等人的名称为“Disposable Absorbent Article Having Elastically Extensible Topsheet”的美国专利5,037,416；和1993年12月14日授予Freeland等人的名称为“Trisection Topsheets for Disposable Absorbent Articles and DisposableAbsorbent Articles Having Such Trisection Topsheets”的美国专利5,269,775。
图1中的吸收芯28通常设置在顶片24和底片26之间。吸收芯28可包括通常可压缩的、舒适的、对穿着者的皮肤无刺激性的、以及能够吸收和容纳诸如尿液和其它某些身体排泄物之类液体的任何吸收材料。吸收芯28可包括多种液体吸收材料，这些材料通常用于一次性尿布和其它吸收制品，例如一般称为透气毡的粉碎木浆。其它适用的吸收材料实施例包括绉纱纤维素填料；熔喷聚合物，包括共成型；化学硬化、改性或交联的纤维素纤维；薄纸，包括薄纸包装材料和薄纸层压材料；吸收泡沫；吸收海绵；超吸收聚合物；吸收胶凝材料；或其它任何已知的吸收材料或材料的组合。吸收芯28还可包括少量(典型地少于10％)的非液体吸收材料，例如粘合剂、蜡、油等等。
用作吸收组件的示例性吸收结构在如下专利中描述：美国专利4,610,678(Weisman等人)；美国专利4,834,735(Alemany等人)；美国专利4,888,231(Angstadt等人)；美国专利5,260,345(DesMarais等人)；美国专利5,387,207(Dyer等人)；美国专利5,397,316(LaVon等人)；以及美国专利5,625,222(DesMarais等人)。
底片26可与顶片24相连接。底片26防止被吸收芯28吸收并容纳在制品20内的渗出物弄脏可能接触尿布20的其它外部用品，例如床单和内衣。在优选的实施方案中，底片26基本不能透过液体(例如尿液)并且包括一张无纺层压材料和一张薄塑料薄膜，例如厚度为约0.012mm(0.5mil)至约0.051mm(2.0mils)的热塑性薄膜。合适的底片薄膜包括由位于Terre Haute，IN的Tredegar Industries Inc.制造的、以商品名X15306、X10962和X10964销售的那些产品。其它合适的底片材料可包括使蒸汽能够从尿布20逸出、同时还可防止渗出物透过底片26的透气材料。示例性透气材料可包括诸如织网、无纺织网之类的材料、诸如膜包衣的无纺织网之类的复合材料以及诸如由日本的Mitsui Toatsu Co.制造的命名为ESPOIR NO和由德克萨斯州Bay City的EXXON Chemical Co.制造的命名为EXXAIRE之类的微孔薄膜。包含聚合物共混物的合适的透气复合材料以商品名HYTREL混合物P 18-3097购自Clopay Corporation，Cincinnati，OH。此类透气复合材料更详细地描述于1995年6月22日以E.I.DuPont的名义公布的PCT专利申请WO 95/16746中。包括无纺织网和有孔成形薄膜在内的其它透气底片描述于1996年11月5日授予Dobrin等人的美国专利5,571,096中。
尿布20还可包括这些本领域已知的其它特征，包括前耳片和后耳片、腰部覆盖片、松紧带等，以提供较好的贴合性、容纳性和美观特性。这样的附加特征是本领域所熟知的，并描述于如美国专利3,860,003以及美国专利5,151,092中。
为了保持尿布20处在环绕穿着者的位置，优选地至少第一腰区36的一部分由扣紧构件42连接到第二腰区38的至少一部分上，优选形成腿部开口和制品腰部。当扣紧时，扣紧系统承受制品腰部周围的拉伸载荷。扣紧系统设计允许制品使用者把持扣紧系统的一个构件，例如扣紧构件42，并且至少在两个位置将第一腰区36连接到第二腰区38上。这通过控制扣紧装置元件之间的联结强度来实现。
本发明的尿布20可装设一个可重复闭合的扣紧系统，或者可供选择地以紧身短裤类型的尿布提供。
扣紧系统及其任何部件可包括适于此类用途的任何材料，包括但不限于塑料、薄膜、泡沫、无纺织网、织网、纸张、层压材料、纤维增强塑料等或它们的组合。构成扣紧装置的材料可优选为柔韧材料。柔韧性用来使扣紧系统能够适形于身体形状并因此降低扣紧系统刺激或损伤穿着者皮肤的可能性。
图2表示图1沿横向轴线110截取的横截面。从面向穿着者一侧起，尿布包括顶片24、吸收芯28的部件和底片26。吸收芯优选包括由面向穿着者皮肤的上采集层52和面向穿着者衣服的下采集层54构成的采集系统50。在一个优选实施方案中，上采集层52包括无纺材料，而下采集层优选地包括化学硬化、扭曲和卷曲纤维，高表面积纤维和热塑性粘合纤维的混合物。在另一个优选的实施方案中，两个采集层都由优选地为亲水的无纺材料提供。采集层优选地与存储层60直接接触。
存储层60可由芯包裹材料包裹。在一个优选的实施方案中，芯包裹材料包括顶层56和底层58。芯包裹材料、顶层56或底层58可由无纺材料提供。一种优选的材料是由纺粘层、熔喷层和另一纺粘层构成的所谓SMS材料。高度优选的是永久性亲水无纺材料，并且特别是具有耐用亲水涂层的无纺材料。可供选择的优选材料包括SMMS结构。
顶层56和底层58可由两个或多个分开的材料片来提供或者它们可供选择地由一体的材料片来提供。这样一种一体的材料片可围绕着存储层60进行缠绕，例如，以C折叠形式。
优选的无纺材料由合成纤维提供，例如PE、PET，而最优选为PP。因为用于无纺制品的聚合物本身是疏水的，它们优选涂有亲水涂层。
制造具有耐用亲水涂层的无纺材料的一种优选方法是：通过将亲水单体和自由基聚合引发剂施加到无纺材料上，然后通过紫外光激发而进行聚合反应，导致单体以化学方式接合到无纺材料的表面，如在共同未决的欧洲专利申请EP 02021943.2(代理人档案号为CM2701FQ)中描述的那样。
可供选择的制造具有耐用亲水涂层的无纺材料的优选方法是：如在共同未决的申请WO 02/064877中描述的那样，用亲水纳米颗粒涂敷无纺材料。
典型地，纳米颗粒的最大尺寸小于750nm。尺寸为2nm至750nm的纳米颗粒可经济地进行生产。纳米颗粒的优点在于：它们很多都能容易地扩散在水溶液中，使涂层施加到无纺材料上；它们典型地形成透明涂层，并且从水溶液中施加的涂层典型地足以耐用于暴露在水中的场合。
纳米颗粒可为有机的或无机的，合成的或天然的。无机纳米颗粒通常以氧化物、硅酸盐、碳酸盐存在。适合的纳米颗粒的典型实施例是分层粘土矿(例如，Southern Clay Products，Inc.(美国)的LAPONITETM)，以及水软铝石矾土(例如，North American Sasol.Inc.的Disperal P2TM)
高度优选的纳米颗粒涂敷的无纺材料公开于名称为“Disposableabsorbent article comprising a durable hydrophilic core wrap”的共同未决的专利申请，其发明者(在美国是申请者)是Ekaterina Anatolyevna Ponomarenko和Mattias NMN Schmidt。
另外的适用无纺材料描述于代理人档案号为8837、8838、8408MX、8857和8858的共同未决的专利申请中。
在一些情况下，在涂敷纳米颗粒涂层之前，无纺材料表面可用高能处理方法(电晕、等离子)进行预处理。高能预处理典型地暂时增加低表面能量表面(例如PP)的表面能量，从而使得无纺材料能够被扩散在水中的纳米颗粒更好地润湿。
需要说明的是，永久亲水性无纺材料也适用于吸收制品的其它部分。例如，已发现由上述永久亲水性无纺材料构成的顶片和采集层使用效果良好。
总之，在本发明的一个方面，吸收制品优选为包含无纺织物的制品，无纺织物包含许多纤维，当用盐水溶液润湿后具有至少55，优选至少60，最优选至少65mN/m或更高的表面张力，并且对第五次液体涌出的液体透湿时间小于5秒。
表面张力是某种永久亲水性水平所达到的程度的一种量度。其数值用本文下述试验方法进行测量。
液体透湿时间是某种亲水性水平的一种量度。其数值用本文下述试验方法进行测量。
在本发明的一个优选实施方案中，吸收芯28包括基底层100、吸收性聚合物材料110和粘合剂纤维层120。基底层100优选由无纺材料提供，优选的无纺材料是上面列举用于顶层56或底层58的那些材料。
基底层100包括第一表面和第二表面。基底层100的第一表面中至少有一些部分直接与吸收性聚合物材料层110接触。该层吸收性聚合物材料110优选为不连续的层，并且包括第一表面和第二表面。本文所述的不连续层是指包括开口的层。典型地，这些开口的直径或最大跨度为小于10mm，优选为小于5mm、3mm、2mm，并且大于0.5mm、1mm或1.5mm。吸收性聚合物材料层110的第二表面的至少一些部分与基底层100的第一表面的至少一些部分接触。吸收性聚合物材料的第一表面112定义了吸收性聚合物层高于基底层100的第一表面的某一高度。当吸收性聚合物材料层110作为不连续层提供时，基底层100第一表面的一些部分没有被吸收性聚合物材料110覆盖。吸收芯28还包括热塑性组分120。该热塑性组分120用于至少部分地固定吸收性聚合物材料110。
然而，在本发明的一个甚至更优选的实施方案中，热塑性材料120作为纤维层提供，它与吸收性聚合物材料110部分接触，且与基底层100部分接触。图3表示这样的优选结构。在该优选结构中，吸收性聚合物材料层110作为不连续层提供，一层热塑性纤维材料120往下放置到吸收性聚合物材料层110上，使得热塑性层120直接与吸收性聚合物材料层110的第一表面接触，但也与基底层100第一表面直接接触，这里基底层不被吸收性聚合物材料110覆盖。这使热塑性材料纤维层120基本成为一个三维结构，热塑性材料纤维层120本身与在x和y方向的伸展相比基本上是一个厚度(在z方向)相对小的二维结构。换句话讲，热塑性材料纤维层120在吸收性聚合物材料110的第一表面和基底层100的第一表面之间呈波浪形起伏。
因此，热塑性材料120提供了容纳吸收性聚合物材料110的空腔，从而固定该材料。在另一方面，热塑性材料120粘合到基底层100上，从而将吸收性聚合物材料110固定到基底层100上。高度优选的热塑性材料也会既渗入吸收性聚合物材料110中，又渗入基底层100中，因此提供了进一步的固定和粘附作用。
当然，虽然本文公开的热塑性材料提供了非常良好的湿固定作用(即当制品是湿的或至少部分载有液体时对吸收材料的固定作用)，但是当制品是干的时，这些热塑性材料也给吸收材料提供非常良好的固定作用。
根据本发明，吸收性聚合物材料110也可与如透气毡材料之类的纤维材料混合，这类纤维材料能提供进一步固定超吸收性聚合物材料的基质。然而，优选采用纤维素含量相对低的材料，与吸收性聚合物材料110的重量相比，纤维素纤维材料的重量优选为小于40％、20％或10％。
本发明的一个可供选择的优选实施方案如图4所示。图4所示的吸收芯还包括覆盖层130。这种覆盖层可由与基底层100相同的材料提供，或者可由不同的材料提供。覆盖层的优选材料为无纺材料，典型地为上述适用于顶层56和底层58的材料。在该实施方案中，覆盖层130的一些部分通过热塑性材料120粘合到基底层100的一些部分。因此，基底层100与覆盖层130一起提供固定吸收性聚合物材料110的空腔。
参见图3和4，热塑性材料120和基底层100之间的直接接触区域被称为接合区域140。接合区域140的形状、数量和分布将影响吸收性聚合物材料110的固定作用。接合区域可为正方形、矩形或圆形。优选的接合区域是圆形。优选地，这些圆形的直径为大于0.5mm、1mm或1.5mm，而小于10mm、或5mm、或3mm、或2mm。如果接合区域140不是圆形，那么它们优选地为能放入任何上述优选直径的圆内的尺寸。
接合区域140可设置成规则或不规则的图案。例如，接合区域140可沿图5所示的直线设置。这些直线可与吸收芯的纵向轴线对齐，或者可供选择地，它们可与吸收芯的纵向边缘成某一角度。已发现，沿平行于吸收芯28的纵向边缘的直线的一种安排在纵向形成一些槽，这些槽导致湿固定作用减弱。因此，接合区域140优选地沿与吸收芯28的纵向边缘成20度、30度、40度、45度的角度的直线排列。接合区域140的另一个优选图案是由多边形构成的图案，例如五边形和六边形，或者五边形和六边形的组合。接合区域140的不规则图案也是优选的，也已发现这样的不规则图案具有良好的湿固定作用。
根据本发明，接合区域140可选择两种根本不同的图案。在一个实施方案中，接合区域是分散的。它们象海洋中的岛屿一样位于吸收材料的区域内。于是吸收材料区域被称为连通区域。在可供选择的实施方案中，接合区域可为连通的。于是，吸收材料可以分散的图案存放，或者换句话讲，吸收材料代表在热塑性材料(120)的海洋中的岛屿。因此，吸收性聚合物材料110的不连续层可包括吸收性聚合物材料110的连通区域，或者可包括吸收性聚合物材料110的分散区域。
在本发明的另一方面，已发现提供良好湿固定作用的吸收芯可由如图3所示并在相应上下文中说明的两层组合而成。这样的实施方案如图6所示。如图6所示的吸收芯材料包括两个基底层100、两个吸收性聚合物材料层110和两个热塑性纤维材料层120。当采用两个不连续的吸收性聚合物材料层110时，它们被典型地布置成使得其中一层的吸收性聚合物材料面向另一层的接合区域140。然而，在一个可供选择的优选实施方案中，接合区域(140)是偏移的，并且不互相面对。因此优选地，当两个存储层相连接时，要使得第一存储层(60)的基底层(100)的第一表面面向第二存储层(60)的基底层(100)的第一表面。
本发明，具体地讲是参照图3、4和6描述的优选实施方案，可用于提供吸收芯的存储层60。然而，它们也可用于提供整个吸收芯28。在那种情况下，没有另外的材料包裹吸收芯，就如顶层56和底层58的使用那样。参照图3的实施方案，基底层100可提供底层58的作用，而热塑性纤维材料层120可提供顶层56的作用。参照图4，覆盖层130可提供顶层56的作用，而基底层100可提供底层58的作用。参照图6，所用的两个基底层100可分别提供顶层56和底层58的作用。
根据本发明，热塑性层120可包括任何热塑性组分，优选为粘性的热塑性组分，也称为热熔融粘合剂。多种热塑性组分都适于固定吸收材料。
一些初始时具有热塑性的材料，后来由于固化步骤可失去其热塑性，例如通过热、紫外辐射、电子束照射、或者潮湿激发的固化方法或其它固化方法的固化步骤，导致不可逆地形成共价键交联网。那些已失去其初始热塑性行为的材料本文中也认为是热塑性材料120。
不受理论的约束，已发现那些热塑性组分同时兼有良好的内聚力和良好的附着性能，对固定吸收性聚合物材料110非常有用。良好的附着力对保证热望性层120与吸收性聚合物材料110以及特别是与基底层(100)保持良好的接触是关键的。即当采用无纺基底时，良好的附着力是一个难题。良好的内聚力保证粘合剂不破裂，特别是在响应外力时，即在响应应变时。当吸收制品收集有液体时，这些液体存储在吸收性聚合物材料110中，吸收性聚合物110因而膨胀，使粘合剂承受外力作用。优选的粘合剂将允许这样的膨胀而不破裂，并且不引起过多的会限制吸收性聚合物材料110膨胀的收缩力。根据本发明，重要的是粘合剂不应破裂，粘合剂破裂会恶化湿固定作用。满足这些要求的优选热塑性组分具有下列特点：
热塑性组分整体上可包括单种热塑性聚合物或者热塑性聚合物的混合物，它们具有由ASTM Method D-36-95“Ring and Ball”确定的在50℃和300℃之间的软化点，或者可供选择地，热塑性组分可为由至少一种热塑性聚合物与其它热塑性稀释剂组合而构成的热熔融粘合剂，热望性稀释剂如粘性树脂、增塑剂以及如抗氧化剂之类的添加剂。
热塑性聚合物的分子量(Mw)典型地为大于10,000，并且其玻璃化转变温度(Tg)通常低于室温。在热熔体中聚合物的典型浓度按重量计在20％至40％范围内。很多种热塑性聚合物适用于本发明。这样的热塑性聚合物优选为对水不敏感的。示例性的聚合物是(聚苯乙烯纤维)包括A-B-A三嵌段结构、A-B两嵌段结构、以及(A-B)n径向嵌段共聚物结构的嵌段共聚物，其中嵌段A是非弹性体的聚合物嵌段，典型地由聚苯乙烯构成，而嵌段B是不饱和的共轭双烯或(部分地为)这类物质的氢化形式。嵌段B典型地为异戊二烯、丁二烯、乙烯/丁烯(氢化丁二烯)、乙烯/丙烯(氢化异戊二烯)以及它们的混合物。
其它可采用的适合热塑性聚合物是茂金属聚烯烃，它们是用单一活性点或茂金属催化剂制备的乙烯聚合物。其中，至少一种共聚单体可与乙烯聚合而形成共聚物、三元共聚物、或高阶聚合物。非晶态的聚烯烃或非晶态的聚α烯烃(APAO)也可采用，聚α烯烃(APAO)是C2至C8α烯烃的均聚物、共聚物或三元共聚物。
树脂的典型分子量小于5,000，而Tg通常高于室温，在热熔体中树脂的典型浓度为在30％至60％范围内。增塑剂的分子量小，典型地为小于1,000，而Tg低于室温，典型浓度是0％至15％。
优选地，粘合剂在整个吸收芯中以纤维的形式存在，即粘合剂是纤维化的。优选地，纤维的平均粗细为1微米至50微米，而平均长度为5mm至50cm。
为了提高热塑性材料120附着到基底层100或任何其它层，特别是任何其它无纺层上的附着力，可用辅助粘合剂对这些层进行预处理。
优选地，粘合剂将满足下列至少一个参数，而更优选地将满足几个或全部参数：
优选的粘合剂在20℃时测量的存储模量G’为至少30,000Pa，并且小于300,000Pa，优选小于200,000Pa，更优选小于100,000Pa。在20℃时的存储模量G’是所用热塑性材料永久“粘著性”或永久附着力的度量。良好的附着力将保证热塑性材料和例如基底层100之间良好和永久的接触。另一方面，在60℃测量的存储模量G’应小于300,000Pa而大于18,000Pa，优选大于24,000Pa，最优选大于30,000Pa。在60℃测量的存储模量G’是热塑性材料在提高的环境温度下的形式稳定性的量度。如果吸收制品用于炎热的气候，该值是特别重要的，如果在60℃的存储模量G’不是足够高，在这些地方热塑性组分会失去其完整性。
在另一方面，粘合剂在60℃的损耗角正切tan Delta应小于1，优选为小于0.5。在60℃的损耗角正切tan Delta与粘合剂在提高的环境温度下的液体特性相关。tan Delta越低，粘合剂越表现得象固体而不是液体，即其流动或移动的趋势越小，以及本文所述粘合剂超结构随时间恶化或甚至崩溃的趋势越小。因此，如果吸收制品用于炎热的气候，该值是特别重要的。
在另一方面，优选粘合剂的玻璃化转变温度Tg应小于25℃，优选地为小于22℃，更优选地为小于18℃，以及最优选地为小于15℃。低的玻璃化转变温度Tg对良好的附着力有利。另一方面，低的玻璃化转变温度Tg保证粘性热塑性材料不变脆。
再一方面，优选的粘合剂将具有足够高的交叉温度Tx。据发现足够高的交叉温度Tx有利于热塑性层的高温稳定性，因而保证吸收制品甚至在炎热气候和高温条件下的良好性能，以及特别是良好的湿固定作用。因此，Tx优选应高于80℃，更优选地为高于85℃，而最优选地为高于90C。
还有一个重要的方面，根据本发明优选的粘合剂将具有足够的内聚强度参数γ。该内聚强度参数γ用本文后面所述的流变学蠕变试验进行测量。足够低的内聚强度参数γ是例如能够伸展而不被撕破的弹性粘合剂的典型特征。如果施加的应力τ＝1000Pa，那么内聚强度参数γ优选为小于100％，更优选为小于90％，而最优选为小于75％。对于应力τ＝125,000Pa，内聚强度参数γ优选为小于1200％，更优选为小于1000％，而最优选为小于800％。
适用于本文所述热塑性材料(120)的高度优选的粘合剂将满足以上多数或全部参数。特别注意，应保证粘合剂同时提供良好的内聚力和良好的附着力。
生产本发明优选的吸收芯28的方法包括以下步骤：
将吸收芯28往下放到表面不平整的沉积转筒上。在第一工序中，将基底层100放到所述不平整的表面上。由于重力，或者优选地通过使用真空部件，基底层材料将随着不平整表面的轮廓在那里呈现山和谷一样的形状。通过本领域所知的方法将吸收性聚合物材料放置到该基底层(100)上。吸收性聚合物材料将积累在基底层100所呈的谷中。在进一步的工序中，将热熔融粘合剂放到吸收性聚合物材料上。
虽然可用本领域所知的任何粘合剂涂敷方法将热熔融粘合剂放置到吸收性聚合物材料上，但是热熔融粘合剂优选地由喷嘴系统涂敷。优选采用能提供相对薄而宽的粘合剂帘的喷嘴系统。然后将该粘合剂帘放置到基底层100和吸收性聚合物材料上。由于基底层100的山顶较少被吸收性聚合物材料覆盖，粘合剂将与基底层的这些区域接触。
在一个可供选择的进一步工序中，将覆盖层130放置在基底层100、吸收性聚合物材料以及热熔融粘合剂层上。覆盖层130将在接合区域140与基底层100粘性接触。在这些接合区域140，粘合剂与基底层100直接接触。在基底层100的山谷被填有吸收性聚合物材料之处，覆盖层130将典型地不与基底层100粘性接触。
可供选择地，可将覆盖层130放置到具有不平整表面的转筒上，且基底层100可在后续工序中加入。图4所示的实施方案可用这样的方法生产。
在一个可供选择的实施方案中，覆盖层130和基底层100由一体的材料薄片提供。于是，将覆盖层130放到基底层100上将涉及对一体的材料薄片的折叠。
所以，优选为沉积转筒的沉积系统的不平整表面典型地决定了吸收性聚合物材料在整个存储层60上的分布，并且同样决定了接合区域140的图案。可供选择地，吸收性聚合物材料的分布可由真空部件影响。
优选地，吸收性聚合物材料的分布是曲线形的，并且最优选地在纵向呈曲线形分布。所以，沿通常与如尿布这样吸收制品的纵向轴线重合的吸收芯的纵向轴线，吸收性聚合物材料的定量将是变化的。优选地，在至少一个自由选择的尺寸为1cmx1cm的第一正方形内的吸收性聚合物材料的定量比在至少一个自由选择的尺寸为1cmx1cm的第二正方形内的吸收性聚合物材料的定量至少高10％，或20％，或30％，40％或50％。优选地，如果第一和第二正方形的中心位于纵向轴线附近，那么该标准得到满足。
任选地，吸收芯也可包括吸收性纤维材料，例如纤维素纤维。该纤维材料可为与吸收性聚合物材料的预混物，并且在一个工序中放入，或者可供选择地，可在分开的工序中放入。
已发现，用颗粒吸收性聚合物材料作为本发明制作的吸收芯是有益的。不受理论的约束，据信即使在膨胀状态，即当吸收有液体时，这样的材料也基本不阻碍液体流过材料，特别是当由吸收性聚合物材料的盐流传导性表示的渗透性大于10、20、30或40SFC单位时，其中1个SFC单位是1x10-7(cm3xs)/g。盐流传导性是本领域熟识的参数，它根据在EP 752892B中公开的试验进行测量。
为了充分达到本发明的优选吸收制品中的吸收能力，特别是如果吸收制品是尿布或成人失禁用品时，超吸收性聚合物材料将以大于50、100、200、300、400、500、600、700、800或900g/m2的定量存在。
本发明的优选制品可获得相对狭窄的裆部宽度，增加了穿着舒适性。本发明的优选制品可获得的裆部宽度为小于100mm、90mm、80mm、70mm、60mm或甚至为小于50mm。所以，优选地本发明的吸收芯的裆部宽度为小于100mm、90mm、80mm、70mm、60mm或甚至为小于50mm，该裆部宽度是沿吸收芯上位于到前边缘和后边缘距离相等的位置上的横向直线测量的。已发现，对大多数吸收制品，液体排放主要发生在前半部分。因此吸收芯的前半部分应包括吸收芯的大部分吸收能力。优选地，所述吸收芯的前半部分包括大于60％的吸收能力，更优选地为大于65％、70％、75％、80％、85％或90％。
本文所引用的所有转让给Procter&Gamble Company的专利和专利申请(包括在其上公布的任何专利)均引入本文，以供在与其一致的范围内参考。
流变学蠕变试验
设备：
·TAInstruments公司的AR 2000型流变仪，说明见下文
·天平
流变仪：
进行蠕变试验的试验装置采用TA Instruments公司的AR 2000型流变仪。其它流变仪可从市场上购买，它们给出基本相同的试验结果。图8为流变仪(400)的示意图。流变仪能给粘合剂施加剪切应力并测量在恒定温度下所引起的应变(剪切变形)响应。粘合剂放在用作下固定板(410)的Peltier元件和半径R为10mm的上板(420)之间，上板连接到电机驱动轴以产生剪切应力。两板之间的间隔高度H为1500微米。Peltier元件能控制材料的温度(±0.5℃)。
样品制备：
·在试验烤箱中在150℃至175℃的温度(决定于粘合剂的类型)下，使粘合剂进行均匀化，时间为1小时
·偶尔进行搅拌以确保包裹物与粘合剂的适当混合，但防止形成气泡
·在烤箱中进行均匀化之后，将样品倾倒在硅氧烷纸上冷却
·在材料冷却至室温后，称约0.6g粘合剂进行蠕变试验，并将材料放到Peltier板上
试验实施：
·在Peltier板上将粘合剂在120℃(或更高，如果需要)下融化
·当粘合剂完全融化时，立即降低上板至间隔为1500微米，使其与融化的粘合剂适当接触
·去除多余的材料
·将温度设置到35℃的测量温度
·将适应时间设置为20分钟，以确保Peltier元件、粘合剂以及上板之间的热平衡
·设置在延迟步骤开始时立即施加到粘合剂上的恒定测量应力τ(例如10,000Pa响应125,000Pa)
·设置延迟时间至5分钟
·将应力设置为零，以在回复步骤开始时立即消除应力
·设置回复时间为5分钟
·试验完成后，将粘合剂融化，将上板升高并从Peltier元件和上板上去除粘合剂。
·将温度设置回测量温度或待机温度(室温)
报告结果：
·报告施加应力5分钟后(在延迟步骤结束)以百分比表示的应变(γ值，在本文中指内聚强度参数)与温度和应力的函数关系，例如在本文所述35℃和10,000Pa resp.35℃和125,000PA。
动态机械分析(DMA)-温度扫描
设备：
·TA Instruments公司的AR 2000型流变仪，说明见下文
·天平
流变仪：
进行温度扫描的试验装置包括本文所述TA Instruments公司的AR2000型流变仪。其它流变仪可从市场上购买，它们给出基本相同的试验结果。图8为流变仪(400)的示意图。流变仪能给粘合剂施加剪切应力并测量在恒定温度下所引起的应变(剪切变形)响应。
流变仪能施加小的摆动应力，以在粘合剂的线性粘弹性范围内获得恒定的摆动应变(例如，0.05％)。该仪器使所得存储模量、损失模量以及应力和与应变之间的相移(损失因素)的测量依赖于温度。摆动频率为1Hz。粘合剂放在用作下固定板(410)的Peltier元件和半径R为10mm的上板(420)之间，上板连接到电机驱动轴以产生剪切应力。两板之间的间隔高度H为1500微米。Peltier元件能控制材料的温度(±0.5℃)。
样品制备：
·在试验烤箱中在150℃至175℃的温度(决定于粘合剂的类型)下，使粘合剂进行均匀化，时间为1小时。
·偶尔进行搅拌以确保包裹物与粘合剂的适当混合，但防止形成气泡。
·在烤箱中进行均匀化之后，将样品倒到硅氧烷纸上冷却。
·在材料冷却至室温后，称约0.6g粘合剂进行温度扫描，并将材料放到Peltier板上。
试验实施：
·在Peltier-板上将粘合剂在120℃(或更高，如果需要)下融化
·当粘合剂完全融化时，立即降低上板至间隔为1500微米，使其与融化的粘合剂适当接触
·去除多余的材料，并将温度设置到测量开始温度(例如150℃，由所关心的温度范围决定，见下文
·将温度设置到由需要确定的粘合剂的流变学特性所处的温度范围决定的开始温度(例如150℃，在任何情况下都从最高温度开始)
·将适应时间设置为20分钟，以确保Peltier元件、粘合剂以及上板之间的热平衡
·设置开始温度(见上文)
·设置恒定测量应变(例如0.05％)
·设置恒定频率(例如1Hz)
·设置冷却速度(例如2℃/min)
·设置由需要确定的粘合剂的流变学特性所处的温度范围以及Peltier元件的冷却能力所决定的结束温度(例如-5℃)
·将温度设置至室温
·试验完成后，将粘合剂融化，将上板升高并从Peltier元件和上板上去除粘合剂。
·将温度设置回到室温
报告结果
·报告在20℃和60℃时的存储模量G’(单位为Pa)和损失因素tanDelta(无量纲)
·报告玻璃化转变温度Tg，单位为℃(G’的拐点)
·报告交叉温度Tx，单位为℃，在该温度下在橡胶平台向更高温度(末端区域的开始)的一端G’等于G”
表面张力的确定
表面张力(单位：mN/m)根据下列试验进行确定。
装置：
设备：德国Krüss GmbH或同类公司所提供的K10张力计。容器升高速度应为4mm/min。当使用板或环时，应自动地感测液面高度。设备必须能够将样本位置自动地调节到正确的高度。试验的精度应为+/-0.1mN/m。
步骤：
1.在干净的烧杯中倒入40ml盐水(在去离子水中NaCl的重量为0.9％)。
2.用铂环或铂板测试表面张力。在20℃下，表面张力应为71mN/m至72mN/m。
3.用去离子水和异丙醇清洗烧杯并用煤气灶灼烧几秒。等待直到达到与室温平衡。
4.将10片60mmx60mm的无纺材料试样放入清洗过的烧杯中。无纺材料应具有至少10gsm的定量。
5.加入40ml盐水(在去离子水中NaCl的重量为0.9％)。
6.用干净的无表面活性剂的塑料棒搅拌10秒钟。
7.让具有无纺材料的溶液保持5分钟。
8.再搅拌10秒钟。
9.用干净的无表面活性剂的塑料棒从溶剂中取出无纺材料。
10.让溶液保持10分钟。
11.用铂板或铂环测试表面张力。
透湿性的确定
本试验基于Edana Method 150.3-96(1996年2月)液体透湿时间进行。与Edana Method相比，其主要修改为：下面描述的试验不仅测量第一次涌出并且也测量随后的涌出。
装置：
Lister透湿设备：
-装有电磁阀的漏斗：排放速度为在3，5(±0.25)秒内排放25ml。
-透湿板：制作25mm厚的丙烯酸玻璃。板的总重必须为500g。电极应为抗蚀材料。将电极嵌入在板的底部切削出的截面为(4.0mmx7.0mm)的凹槽中并用快干环氧树脂固定。
-基板：约125mmx125mm见方的丙烯酸玻璃。
Figure G2004800026881D00191
支撑漏斗的环架
量测到0.01秒的电子定时器
容量为50ml的滴定管
Grade 989或相当的芯滤纸(平均透湿时间1.7s+-0.3s，尺寸：10x10cm)
步骤：
1.仔细切取所需数量的12.5cmx12.5cm的样本，仅在样本的边缘接触样本。
2.取10片芯滤纸。
3.将一个样本放在基板上的10层滤纸组上。样本应该以用来朝向使用者皮肤的无纺材料侧(当用于吸收制品中时)在最上面这样一种方式被放置在滤纸上。
4.将透湿板放在顶部，使板中心在试样中心的上方。
5.在板上方对正滴定管和漏斗的中心。
6.确保电极被连接到定时器上。接通定时器并将时钟置为零。
7.用盐水溶液(在去离子水中NaCl的重量为0.9％)填充滴定管。
8.保持漏斗的排出阀关闭，并从滴定管滴5.0ml的液体(＝一次涌出)到漏斗中。
9.打开漏斗的电磁阀排出5.0ml的液体。初始液体流将接通电路并起动定时器。它将在液体已经渗入垫料并降到透湿板上的电极水平之下时停止。
10.记录电子定时器上所显示的时间。
11.等待60s并延续重复第6步进行第二次、第三次涌出和任何随后的涌出，其中每次涌出包括5ml的液体。
12.报告：第一、第二和任何随后涌出的时间，单位为秒。

Claims (19)

1.一种适用于吸收制品(20)的吸收芯(28)，所述吸收芯(28)包括基底层(100)，
所述基底层(100)包括第一表面和第二表面，
所述吸收芯还包括吸收材料的不连续层，
所述吸收材料包括吸收性聚合物材料(110)和吸收性纤维材料，所述吸收性纤维材料的含量占所述吸收性聚合物材料(110)总重的0-40％，
所述吸收材料的不连续层包括第一表面和第二表面，
所述吸收芯(28)还包括热塑性材料层(120)，
所述热塑性材料层(120)包括第一表面和第二表面，
其中，所述吸收材料的不连续层的所述第二表面与所述基底层(100)的所述第一表面至少部分接触，并且
所述热塑性材料层(120)的所述第二表面的一些部分与所述基底层(100)的所述第一表面直接接触，并且所述热塑性材料层(120)的所述第二表面的一些部分与所述吸收材料的不连续层的所述第一表面直接接触，
其特征在于，所述吸收材料的不连续层中具有开口，并且不连续层所设置的区域彼此连通。
2.如权利要求1所述的吸收芯(28)，其中所述热塑性材料(120)是热熔融粘合剂。
3.如权利要求2所述的吸收芯(28)，其中所述热塑性材料(120)被纤维化。
4.如权利要求1、2或3所述的吸收芯(28)，其中所述热塑性材料层(120)包括网状结构。
5.如权利要求1、2或3所述的吸收芯(28)，其中所述吸收性聚合物材料(110)包括吸收性聚合物颗粒。
6.如权利要求1、2或3所述的吸收芯(28)，其中所述吸收性聚合物材料(110)在所述吸收芯(28)的整个区域内以至少100g/m2的定量存在。
7.如权利要求6所述的吸收芯(28)，其中所述定量为至少300g/m2。
8.如权利要求1、2或3所述的吸收芯(28)，所述吸收芯包括至少两个基底层(100)。
9.如权利要求1、2或3所述的吸收芯，所述吸收芯包括至少一个基底层(100)和至少一个覆盖层(130)。
10.如权利要求9所述的吸收芯(28)，其中至少一个所述基底层(100)或至少一个所述覆盖层(130)包含永久亲水性无纺材料。
11.如权利要求10所述的吸收芯(28)，其中永久亲水性无纺材料当用盐水溶液润湿后具有至少55mN/m的表面张力并且对第五次液体涌出的液体透湿时间小于5秒。
12.如权利要求1、2或3所述的吸收芯(28)，其中所述吸收材料包括的吸收性纤维材料的含量占所述吸收性聚合物材料(110)总重的高达20％。
13.如权利要求1、2或3所述的吸收芯(28)，其中所述吸收材料包括100％重量的吸收性聚合物材料。
14.一种提供适用于吸收制品(20)的吸收芯(28)的存储层(60)的方法，所述方法包括以下步骤：
-提供包括第一表面和第二表面的基底层(100)；
-将吸收材料按一种图案放置到所述基底层(100)的第一表面上，所述图案包括至少一个没有吸收材料的区域，并且所述图案包括至少一个包含吸收材料的区域；
-将热塑性材料(120)放置到所述基底层(100)和所述吸收材料的所述第一表面上，使得所述热塑性材料(120)的一些部分与所述基底层的所述第一表面直接接触，并且所述热塑性材料(120)的一些部分与所述吸收材料直接接触，
其特征在于，所述包含吸收材料的区域是连通的。
15.如权利要求14所述的方法，其中所述吸收材料包括80％重量的吸收性聚合物材料。
16.如权利要求14所述的方法，其中所述吸收材料包括90％重量的吸收性聚合物材料。
17.如权利要求14所述的方法，其中所述吸收材料包括100％重量的吸收性聚合物材料。
18.一种提供吸收芯的方法，所述方法包括连接一个或多个依据权利要求14-17中任一项所述的方法制作的存储层(60)以提供包括多个存储层的吸收芯(28)的步骤。
19.如权利要求18所述的方法，其中第一和第二存储层通过叠置相连接，使得所述第一存储层(60)的基底层(100)的第一表面面向所述第二存储层(60)的基底层(100)的第一表面。
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US5425725A (en) * 1993-10-29 1995-06-20 Kimberly-Clark Corporation Absorbent article which includes superabsorbent material and hydrophilic fibers located in discrete pockets
CN1380825A (zh) * 2000-05-23 2002-11-20 东洋卫材股份有限公司 超薄型吸收片体,具有超薄型吸收片体的一次性吸收性物品和超薄型吸收片体的制造装置

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