CN101511579A - 包含有孔弹性膜的非织造复合材料 - Google Patents
包含有孔弹性膜的非织造复合材料 Download PDFInfo
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- CN101511579A CN101511579A CNA2007800321208A CN200780032120A CN101511579A CN 101511579 A CN101511579 A CN 101511579A CN A2007800321208 A CNA2007800321208 A CN A2007800321208A CN 200780032120 A CN200780032120 A CN 200780032120A CN 101511579 A CN101511579 A CN 101511579A
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Abstract
本发明涉及包含有孔弹性膜的非织造复合材料。提供了包含层压至一种或多种非织造网材料的弹性膜的弹性非织造复合材料。该复合材料是通过将所述膜通过辊隙以将膜粘合至非织造网材料而制得的。与粘合形成同时,还在弹性膜上形成了孔。所述孔具有的大小足以提供给所述复合材料理想程度的质地、柔软性、手感和/或审美效果,而对其弹性性能并没有明显的负面影响。在本发明中,孔和粘合形成通过选择性地控制层压工艺的特定参数,例如膜含量、粘合图案、膜拉伸度、粘合条件等而实现。
Description
发明背景
弹性复合材料通常引入产品(例如,尿布、训练裤、服装等)以提高更好地适合主体的轮廓的能力。例如,弹性复合材料可以由弹性膜和一种或多种非织造材料形成弹性材料。当该膜处于拉伸状态下时,可以将非织造网材料结合于弹性膜,这样当它被松开时,非织造网材料会在其被粘合于该膜的位置间打摺(gather)。在粘合点之间打摺的非织造网材料允许弹性膜伸长的程度上,所得的弹性复合材料是可拉伸的。不利地是,弹性膜通常具有不良的手感外观性能,例如触摸感觉类似橡胶或有黏性,使得它们对于穿着者是不舒适的。为改进这些性能,已经尝试对此复合材料打孔。例如,Curro等的US专利6,830,800描述了其中弹性材料结合于两层网之间的方法。该弹性材料在粘合点的重合区域打孔(aperture),使得第一和第二层网通过这些孔而结合。尽管获得了益处,但是,改进的需要依旧存在。
发明概述
根据本发明的一个实施方式,公开了形成非织造复合材料的方法。本方法包括由聚合物组合物制备弹性膜和将该膜和非织造网材料通过由至少一个刻花辊(patterned roll)形成的辊隙。在辊隙处,所述膜和非织造网材料被熔合(melt fuse)并且同时形成带有孔的膜,而并没有充分软化所述非织造网材料的聚合物。所述孔的至少一个具有约200至约5000微米的长度。而且,所述膜在辊隙处是处于在纵向约1.5或更高的拉伸比的拉伸下。
根据本发明的另一个实施方式,公开的非织造复合材料包含与非织造网材料相邻放置并在多个分离的粘合点(discrete bond site)熔合于非织造网材料的弹性膜。所述弹性膜确定了多个孔,所述孔具有分离的粘合点接近地位于周围的周界(perimeter)。这些孔中的至少一个具有约200至约5000微米的长度。
本发明的其它特征和方面在下面更详细地描述。
附图说明
本发明的完整的和授权的内容,包括其最佳方式,针对本领域技术人员,更特别地在说明书的剩余部分阐述,其参考了附图,其中:
图1示意性地说明了根据本发明的一个实施方式用于制备复合材料的方法;
图2说明了根据本发明可以使用的“S-波纹(S-weave)”粘合图案的一个实施方式;
图3说明了根据本发明可以使用的“罗纹(rib-knit)”粘合图案的一个实施方式;
图4说明了根据本发明可以使用的“金属丝波纹(wire-weave)”粘合图案的一个实施方式;
图5是可以用于本发明的一个实施方式的刻槽辊的透视图;和
图6是显示了图5的两个刻槽辊之间的啮合的横截面图;
图7是本发明的非织造复合材料的一个实施方式的横截面图;
图8是可以根据本发明的一个实施方式制备的个人护理产品的透视图;
图9是在实施例1中制备的样品的SEM显微图(5kv,60x),显示了通过罗纹粘合图案的条形成的弹性膜上的孔;
图10是是在实施例1中制备的样品的SEM显微图(5kv,100x),显示了通过罗纹粘合图案的钉(pin)形成的弹性膜上的孔;
图11是在实施例1中制备的样品的SEM显微图(5kv,20x),显示了通过罗纹粘合图案形成的弹性膜中的孔;
图12是在实施例1中制备的样品的SEM显微图(5kv,250x);
图13是在实施例1中制备的样品的SEM显微图(5kv,120x);
图14是在实施例1中制备的样品的SEM显微图(5kv,30x);
图15是在实施例1中制备的样品的SEM显微图(5kv,30x);
图16是在实施例1中制备的样品的SEM显微图(5kv,50x);
图17是在实施例1中制备的样品的SEM显微图(5kv,30x)。
拟重复使用本发明说明书和附图中的标号以代表本发明的相同或相似的特征或元件。
定义
如在本发明所用,术语“非制造网”通常指是夹层的具有单独纤维或纱线结构的网,但并不是以如针织织物的可辨别的方式。合适的非织造织物或网的例子包括,但不限于,熔喷纤网、纺粘纤网、粘合-梳理纤网(bonded carded webs)、气流纤网、共成型纤网(coform web)、水力缠结纤网等。
如在本发明中所用的,术语“熔喷纤网”通常指通过如下方法制备的非织造网,其中:通过将熔融的热塑性材料经许多通常为圆形的细小的模头毛细孔作为熔融纤维挤出进入聚集的高速气(例如空气)流,这使得熔融热塑性材料的纤维变细以降低其直径。其后,通过高速气流运送熔喷纤维并将其放置于收集表面上以形成随机分布熔喷纤维的网。例如,在授予Butin等的美国专利3,849,241中公开了此方法,其为所有目的全文引入本文作为参考。一般来说,熔喷纤维可以是连续的或非连续的微纤维,通常直径小于10微米,并通常当放置于收集表面时是粘性的。
如在本发明中所用的,术语“纺粘纤网”通常指包含小直径的基本上连续纤维的网。所述纤维是通过将熔融的热塑性材料经许多通常为圆形的细小的喷丝板毛细孔挤出而制得的,接着,挤出纤维的直径通过例如导出牵伸(eductive drawing)和/或其它公知的纺粘机构迅速地减小。纺粘纤网的生产在例如Appel等的U.S.专利4,340,563、Dorschner等的3,692,618、Matsuki等的3,802,817、Kinney的3,338,992、Kinnev的3,341,394、Hartman的3,502,763、Levy的3,502,538、Dobo等的3,542,615和Pike等的5,382,400中描述和说明。
如在本发明中所用的,术语“纵向”或“MD”通常指材料的生产方向。术语“横向”或“CD”是指垂直于纵向的方向。
如在本发明中所用的,术语“可伸长的”或“可延伸性”通常指在受力方向拉伸或伸长其松弛长度或宽度的至少约25%,在一些实施方式中约50%,和在一些实施方式中至少约75%的材料。可伸长的材料并不必须具有恢复性能。例如,弹性体的材料是具有恢复性能的可伸长材料。熔喷纤网可以是可伸长的,但不具有恢复性能,并因此是可伸长的非弹性材料。
如在本发明中所用的,术语“弹性体的”或“弹性的”通常指,通过施加拉伸力,材料在至少一个方向上(例如CD方向)被拉伸,并且通过解除拉伸力,其收缩/回复到大约其原始尺寸。例如,拉伸的材料可以具有比其松弛的未拉伸长度至少长约50%的拉伸长度,并且,通过解除该拉伸力,其可以恢复至其拉伸长度的至少50%范围内的长度。假设的例子可以是:材料的(1)英寸样品,其可被拉伸至1.50英寸和,通过解除拉伸力,将恢复至不多于1.25英寸的长度。理想地,材料收缩或回复至少50%,和甚至更理想地,至少该拉伸长度的80%。
如在本发明中所用的,术语“颈缩的”或“颈缩材料”通常指任何材料在至少一个维度(例如,纵向)被拉伸以减少其横向尺寸(例如,横向),使得当去除拉伸力时,材料可以被拉回其初始宽度。颈缩材料通常比非颈缩材料具有更高的每单位面积基重。当颈缩材料被拉回其初始宽度,其应具有与非颈缩材料基本相同的基重。这与膜的取向不同,其中膜被减薄且基重被减少。颈缩方法典型地包括从供应辊上退卷(unwind)材料和使其通过以给定的线速度驱动的制动轧辊组件(brakenip roll assembly)。以高于制动轧辊的线速度运行的提取辊或辊隙,拉伸材料并产生拉伸和颈缩材料所需的拉力。
如在本发明中所用的,术语“热点粘合”通常指例如通过将材料通过刻花辊(例如,砑光辊)和可以是或可以不是有花纹的其它辊(例如,支承辊)之间来进行的方法。通常所述辊中的一个或两个可以加热。
如在本发明中所用的,术语“超声粘合”通常指例如通过将材料通过超声发生器(sonic horn)和刻花辊(例如,支承辊)之间来进行的方法。例如,在Grgach等的U.S.专利3,939,033、Rust Jr.的3,844,869和HNI的4,259,399中描述了通过使用静止的发生器和旋转的花纹支承辊的超声粘合,其为所有目的全文引入本文作为参考。而且,在Neuwirth的U.S.专利5,096,532、Ehlert的5,110,403和Brennecke等的5,817,199中描述了通过使用旋转的发生器与旋转的花纹支承辊的超声粘合,其为所有目的全文引入本文作为参考。当然,在本发明中可以使用任何超声粘合技术。
发明详述
详细参考本发明的各实施方式,下面将描述本发明的一个或多个实施例。通过解释提供每个实施例,其并非对本发明的限制。事实上,在本发明中可以进行各种改进和变化而并不偏离本发明的领域和精神,这对于本领域技术人员是显而易见的。例如,作为一个实施方式的部分说明或描述的特征,可以用于另一个实施方式以产生又一个实施方式。因此,本发明意在包括此改进和变化。
一般来说,本发明涉及包含层压至一种或多种非制造网材料的弹性膜的非织造复合材料。该复合材料通过将所述膜通过辊隙以将所述膜粘合于非织造网材料来制备。在粘合形成的同时,孔也在弹性膜上形成。所述孔具有的大小足以提供给所述复合材料理想程度的质地、柔软性、手感和/或审美效果,而对其弹性性能并没有明显的负面影响。在本发明中,孔和粘合形成通过选择性地控制层压工艺的特定参数,例如膜含量(film content)、粘合图案、膜拉伸度(degree of film tension)、粘合条件等而实现。在此方面,现在本发明各实施方式将更详细地描述。
I.弹性膜
本发明的弹性膜是由一种或多种可熔体加工的,即热塑性的,弹性体聚合物制备的。在本发明中,通常可以使用多种热塑性弹性体聚合物中任一种,例如弹性体聚酯、弹性体聚氨酯、弹性体聚酰胺、弹性体共聚物、弹性体聚烯烃等。在一个具体实施方式中,由于其独特的机械和弹性体性能的组合,使用了弹性体半结晶聚烯烃。即,此半结晶聚烯烃的机械性能允许在热粘合的过程中易于成孔的膜的制备,而还保留其弹性。
半结晶聚烯烃具有或能够显示出基本上规则的结构。例如,半结晶聚烯烃可以在其未变形状态基本上是无定形的,但经拉伸形成结晶畴。该烯烃聚合物的结晶度可以是约3%-约30%,在一些实施方式中,约5%-25%,和在一些实施方式中,约5%-15%。同样,半结晶聚烯烃可以具有约15-约75焦耳每克(“J/g”)、在一些实施方式中约20-约65J/g,和在一些实施方式中约25-约50J/g的熔化潜热(latent heat of fusion)(ΔHf),其是结晶度的另一个指标。所述半结晶聚烯烃还可以具有约10℃-约100℃,在一些实施方式中约20℃-约80℃,在一些实施方式中约30℃-约60℃的维卡软化温度。所述半结晶聚烯烃可以具有约20℃-约120℃,在一些实施方式中约35℃-约90℃,在一些实施方式中约40℃-约80℃的熔化温度。如本领域技术人员公知的,熔化潜热(ΔHf)和熔化温度可以使用示差扫描量热仪(“DSC”)根据ASTM D-3417来确定。维卡软化温度可以根据ASTM D-1525来确定。
示例性的半结晶聚烯烃包括聚乙烯、聚丙烯、其共混物和共聚物。在一个具体实施方式中,所用的聚乙烯是乙烯和α-烯烃,例如C3-C20α-烯烃或C3-C12α-烯烃的共聚物。合适的α-烯烃可以是线性的或支化的(例如,一个或多个C1-C3支链,或芳基)。具体的例子包括1-丁烯;3-甲基-1-丁烯;3,3-二甲基-1-丁烯;1-戊烯;具有一个或多个甲基、乙基或丙基取代基的1-戊烯;具有一个或多个甲基、乙基或丙基取代基的1-己烯;具有一个或多个甲基、乙基或丙基取代基的1-庚烯;具有一个或多个甲基、乙基或丙基取代基的1-辛烯;具有一个或多个甲基、乙基或丙基取代基的1-壬烯;乙基、甲基或二甲基取代的1-癸烯;特别理想的α-烯烃共聚单体是1-丁烯、1-己烯和1-辛烯。此共聚物的乙烯含量可以是约60摩尔%-约99摩尔%,在一些实施方式中约80摩尔%-约98.5摩尔%,和在一些实施方式中,约87摩尔%-约97.5摩尔%。α-烯烃含量可以同样介于约1摩尔%-约40摩尔%,在一些实施方式中约1.5摩尔%-约15摩尔%,和在一些实施方式中,约2.5摩尔%-约13摩尔%。
聚乙烯的密度可以根据所用聚合物的类型变化,但通常介于0.85-0.96克每立方厘米(“g/cm3”)。聚乙烯“塑性体”,例如,可以具有0.85-0.91g/cm3范围内的密度。同样,“线性低密度聚乙烯”(“LLDPE”)可以具有0.91-0.940g/cm3的密度;“低密度聚乙烯”(“LDPE”)可以具有0.910-0.940g/cm3的密度;和“高密度聚乙烯”(“HDPE”)可以具有0.940-0.960g/cm3的密度。密度可以根据ASTM1505测量。
特别的,合适的聚乙烯共聚物是“线性的”或“基本上线性的”那些。术语“基本上线性的”是指,除有助于共聚单体引入的短链支链(branch)外,乙烯聚合物还包含在聚合物骨架(polymer backbone)中的长链支链。“长链支化”是指至少6个碳原子的链长度。每个长链支链可以具有与聚合物骨架相同的共聚单体分布,并可与其所连接的聚合物骨架一样长。优选的基本线性聚合物是以0.01个长链支链每1000个碳-1个长链支链每1000个碳被取代,在一些实施方式中0.05个长链支链每1000个碳-1个长链支链每1000个碳被取代。与术语“基本线性”相反,术语“线性”是指缺少可测量或可证明长链支链的聚合物。即,聚合物是以每1000个碳平均小于0.01个长链支链被取代。
线性乙烯/α-烯烃共聚物的密度是α-烯烃的长度和数量两者的函数。即,α-烯烃的长度越长,α-烯烃存在的量越大,共聚物的密度越低。尽管不是必然需要的,线性聚乙烯“塑性体”是特别理想的,因为α-烯烃短链支化部分的含量使得乙烯共聚物显示出塑性和弹性体的两种特性-即,“塑性体”。因为与α-烯烃共聚单体的聚合降低了结晶度和密度,通常所得塑性体具有的密度低于聚乙烯热塑性共聚物(例如,LLDPE)的密度,但与弹性体的密度接近和/或重叠。例如,乙烯塑性体的密度可以是0.91克每立方厘米(g/cm3)或更低,在一些实施方式中,0.85-0.88g/cm3,和在一些实施方式中,0.85-0.87g/cm3。尽管具有与弹性体接近的密度,塑性体通常显示出更高的结晶度,是相对地非粘性的(non-tacky),和可以制备成非粘黏的和相对自由流动的粒料。
典型地,α-烯烃共聚单体在聚乙烯塑性体中的分布,在形成乙烯共聚物的不同分子量片段之间是无规的和均匀的。在塑性体中共聚单体分布的均匀性可以表示为60或更高的共聚单体分布宽度指数值(comonomer distribution breadth index value),在一些实施方式中为80或更高,和在一些实施方式中为90或更高。另外,聚乙烯塑性体可以通过DSC熔点曲线来表征,其显示出现在50℃-110℃的区域内的单个熔点峰的发生(第二个熔化下降(rundown))。
用于本发明的优选塑性体是ExxonMobil Chemical Company ofHouston,Texas的EXACTTM商品名下的可得的乙烯基共聚物塑性体。其它适合的聚乙烯塑性体是Dow Chemical Company of Midland,Michigan的ENGAGETM和AFFINITYTM商品名下的可得的聚乙烯塑性体。再其它的合适的乙烯聚合物是The Dow Chemical Company的DOWLEXTM(LLDPE)和ATTANETM(ULDPE)商品名下可得的。在Ewen等的U.S.专利4,937,299;Tsutsui等的5,218,071;Lai等的5,272,236;和Lai等的5,278,272中描述了其它合适的乙烯聚合物,其在本发明中为所有目的全文引入作为参考。
当然,本发明绝不限于使用乙烯聚合物。例如,丙烯聚合物还可以适于用作半结晶聚烯烃。合适的塑性体的丙烯聚合物可以包括,例如,丙烯的共聚物或三元聚合物,包括丙烯与α-烯烃(例如,C3-C20)的共聚物,所述α-烯烃例如乙烯、1-丁烯、2-丁烯、各种戊烯异构体、1-己烯、1-辛烯、1-壬烯、1-癸烯、1-十一烯、1-十二烯、4-甲基-1-戊烯、4-甲基-1-己烯、5-甲基-1-己烯、乙烯基环己烯、苯乙烯等。丙烯聚合物的共聚单体含量可以是约35wt%或更少,在一些实施方式中是约1wt%-约20wt%,和在一些实施方式中是约2wt%-约10wt%。优选地,聚丙烯(例如,丙烯/α-烯烃共聚物)的密度可以是0.91克每立方厘米(g/cm3)或更小,在一些实施方式中,是0.85-0.88g/cm3,和在一些实施方式中,是0.85-0.87g/cm3。合适的丙烯聚合物是可在ExxonMobil Chemical Co.of Houston,Texas的VISTAMAXXTM商品名下;Atofina Chemicals of Feluy,Belgium的FINATM(e.g.,8573)商品名下;available from Mitsui PetrochemicalIndustries的TAFMERTM商品名下;和Dow Chemical Co.of Midland,Michigan的VERSIFYTM商品名下可商购的。在Datta等的U.S.专利6,500,563;Yang等的5,539,056;和Resconi等的5,596,052中描述了其它合适的丙烯聚合物的例子,其在本发明中为所有目的全文引入作为参考。
通常可以使用多种已知技术中的任意一种来制备半结晶聚烯烃。例如,可以使用自由基或络合催化剂(例如,齐格-纳塔)制备烯烃聚合物。优选地,烯烃聚合物是由单一活性点催化剂(single-site catalyst)例如金属茂催化剂制备的。此催化剂体系产生了乙烯共聚物,其中共聚单体在分子链中随机分布并且在不同分子量片段中均匀分布。例如,在McAlpin等的U.S.专利5,571,619;Davis等的5,322,728;Obijeski等的5,472,775;Lai等的5,272,236;和Wheat等的6,090,325中描述了金属茂催化的聚烯烃,其在本发明中为所有目的全文引入作为参考。金属茂催化剂的例子包双(正丁基环戊二烯基)二氯化钛、双(正丁基环戊二烯基)二氯化锆、双(环戊二烯基)氯化钪、双(茚基)二氯化锆、双(甲基环戊二烯基)二氯化钛、双(甲基环戊二烯基)二氯化锆、二茂钴、三氯化环戊二烯基钛、二茂铁、二氯化二茂铪、异丙基(环戊二烯基-1-芴基)二氯化锆、二氯化二茂钼、二茂镍、二氯化二茂铌、二茂钌、二氯化二茂钛、氯氢二茂锆(zirconocene chloride hydride)、二氯化二茂锆等。通常,使用金属茂催化剂制备的聚合物具有窄的分子量范围。例如,金属茂催化的聚合物可以具有低于4的多分散系数(Mw/Mn),控制的短链支化分布,和控制的全同立构规整度。
半结晶聚烯烃的熔体流动指数(melt flow index)(MI)通常可以变化,但典型地,在190℃下确定,在约0.1克每10分钟-约100克每10分钟,在一些实施方式中约0.5克每10分钟-约30克每10分钟,和在一些实施方式中约1-约10克每10分钟的范围。熔流指数是,当在190℃下在10分钟内受到5000克的力时,会被压出挤出流变仪(0.0825-英寸直径)小孔的聚合物的重量(克),且可以根据ASTM Test Method D1238-E确定。
当然,其它热塑性聚合物,或者单独地或者与半结晶聚烯烃相结合,还可以用于制备所述弹性膜。例如,可以使用基本上无定形的嵌断共聚物,该嵌段共聚物具有被至少一个饱和共轭二烯聚合物片段分隔的至少两个单链烯基芳烃聚合物(monoalkenyl arene polymer)片段。所述单链烯基芳烃片段可以包括苯乙烯和其类似物和同系物,例如,邻甲基苯乙烯;对甲基苯乙烯;对叔丁基苯乙烯;1,3-二甲基苯乙烯对甲基苯乙烯等,以及其它单链烯基多环芳族化合物,例如乙烯基萘;乙烯基蒽(vinyl anthrycene)等。优选的单链烯基芳烃是苯乙烯和对甲基苯乙烯。所述共轭二烯片段可以包括共轭二烯单体的均聚体、两种或多种共轭二烯的共聚物、和一种或多种所述二烯与另外的单体的共聚物,后者中所述片段主要是共轭二烯单元。优选地,所述共轭二烯包括4-8个碳原子,例如1,3丁二烯(丁二烯);2-甲基-1,3丁二烯;异戊二烯;2,3-二甲基-1,3丁二烯;1,3戊二烯(戊间二烯);1,3己二烯;等。
单链烯基芳烃(例如,聚苯乙烯)片段的量可以变化,但典型地占共聚物的约8wt%-约55wt%,在一些实施方式中约10wt%-约35wt%,和在一些实施方式中约25wt%-约35wt%。合适的嵌段共聚物可以包含具有约5000-约35000的数均分子量的单链烯基芳烃端片段(endblock)和具有约20000-约170000的数均分子量的饱和共轭二烯中间片段(midblock)。所述嵌段聚合物的总数均分子量可以是约30000-约250000。
特别合适的热塑性弹性体共聚物可由Kraton Polymers LLC of Houston,Texas的商品名获得。聚合物包括苯乙烯-二烯嵌段共聚物,例如苯乙烯-丁二烯、苯乙烯-异戊二烯、苯乙烯-丁二烯-苯乙烯、和苯乙烯-异戊二烯-苯乙烯。聚合物还包括通过苯乙烯-二烯嵌段共聚物的选择氢化形成的苯乙烯-烯烃嵌段共聚物。此苯乙烯-烯烃嵌段共聚物的例子包括苯乙烯-(乙烯-丁烯)、苯乙烯-(乙烯-丙烯)、苯乙烯-(乙烯-丁烯)-苯乙烯、苯乙烯-(乙烯-丙烯)-苯乙烯、苯乙烯-(乙烯-丁烯)-苯乙烯-(乙烯-丁烯)、苯乙烯-(乙烯-丙烯)-苯乙烯-(乙烯-丙烯)、和苯乙烯-乙烯-(乙烯-丙烯)-苯乙烯。这些嵌段共聚物可以具有线性的、辐射状的或星形的分子构型。具体的嵌段共聚物包括以G 1652、G1657、G1730、MD6673和MD6973商标销售的那些。在U.S.专利4,663,220,4,323,534,4,834,738,5,093,422和5,304,599中描述了各种合适的苯乙烯(styrenic)嵌段共聚物,其在本发明中为所有目的全文引入作为参考。其它可商购的嵌段共聚物包括可由Kuraray Company,Ltd.of Okayama,Japan的商标名下得到的S-EP-S弹性体共聚物。另外其它合适的共聚物包括可由Dexco Polymers of Houston,Texas的商标名下得到的S-I-S和S-B-S弹性体共聚物。如在Taylor等的U.S.专利5,332,613中讨论的,由A-B-A-B四嵌段共聚物(tetrablock copolymer)也是合适的,其在本发明中为所有目的全文引入作为参考。此四嵌段共聚物的例子是苯乙烯-聚(乙烯-丙烯)-苯乙烯-聚(乙烯-丙烯)("S-EP-S-EP")嵌段共聚物。
在所述膜中所用的弹性体聚合物的量可以变化,但典型地是所述膜的约30wt%或更高,在一些实施方式中约50wt%或更高,和在一些实施方式中是所述膜的约80wt%或更高。例如,在一个实施方式中,半结晶聚烯烃组成所述膜的约70wt%或更高,在一些实施方式中组成所述膜的约80wt%或更高,和在一些实施方式中组成所述膜的约90wt%或更高。在其它实施方式中,可以使用半结晶聚烯烃和弹性体嵌段共聚物的共混物。在此实施方式中,所述嵌段共聚物可以组成所述共混物的约5wt%-约50wt%,在一些实施方式中约10wt%-约40wt%,和在一些实施方式中约15wt%-约35wt%。同样,所述半结晶聚烯烃可以组成所述共混物的约50wt%-约95wt%,在一些实施方式中约60wt%-约90wt%,和在一些实施方式中约65wt%-约85wt%。当然,应该理解,在所述膜中还可以使用其它弹性体和/或非弹性体聚合物。
除聚合物外,本发明的弹性膜还可以包含如本领域已知的其它组分。例如,在一个实施方式中,所述弹性膜包含填料。填料是颗粒或其它形式的材料,其可以添加到膜聚合物挤出共混物中并且不会化学干扰挤出的膜,但是其可以均匀地分布于整个膜中。填料可以服务于各种目的,包括增强膜不透明性和/或透气性(即,气体可渗透的和基本上液体不可渗透的)。例如,填充的膜可以通过拉伸变得可透气,其导致聚合物从填料脱离和产生微孔的通道。在McCormack等的U.S.专利5,997,981;6,015,764;和6,111,163;Morman等的5,932,497;Taylor等的6,461,457中描述了可透气的微孔弹性膜,其在本发明中为所有目的全文引入作为参考。
填料可具有球形的或非球形形状,具有约0.1-7微米范围的平均粒径。合适的填料的例子包括,但不限于,碳酸钙、各种粘土、硅石、氧化铝、碳酸钡、碳酸钠、碳酸镁、滑石、硫酸钡、硫酸镁、硫酸铝、二氧化钛、沸石、纤维素型粉末、高岭土、云母、碳、氧化钙、氧化镁、氢氧化铝、矿浆粉末(pulp powder)、木材粉末、纤维素衍生物、壳多糖、壳多糖衍生物。任选地,合适的涂料,例如硬脂酸,还可以施加于所述填料颗粒。当使用时,填料含量可以改变,例如膜的约25wt%-约75wt%,在一些实施方式中,膜的约30wt%-约70wt%,和在一些实施方式中,膜的约40wt%-约60wt%。
还可以在膜中加入其它添加剂,例如熔体稳定剂(melt stabilizers)、加工稳定剂、热稳定剂、光稳定剂、抗氧化剂、热老化稳定剂、增白剂、抗结块剂、粘合剂、增粘剂、粘度改性剂等。合适的增粘剂树脂的例子可以包括,例如,氢化的烃类树脂。REGALREZTM烃类树脂是是此氢化的烃类树脂的例子,并可得自Eastman Chemical。其它增粘剂可得自ExxonMobil的ESCOREZTM商品名下的产品。还可以使用粘度改性剂,例如聚乙烯蜡(例如Eastman Chemical的EPOLENETM C-10)。亚酸盐稳定剂(例如,得自Ciba Specialty Chemicals of Terrytown,N.Y.的IRGAFOS和得自Dover Chemical Corp.of Dover,Ohio的DOVERPHOS)是熔体稳定剂的例子。此外,位阻胺稳定剂(例如,CibaSpecialty Chemicals的CHIMASSORB)是示例性的热和光稳定剂。而且,通常使用位阻酚作为膜生产中的抗氧化剂。一些合适的位阻酚包括可得自Ciba Specialty Chemicals的在商品名""下的那些,例如 1076,1010或E201。而且,还可以添加粘合剂至所述膜中以促使所述膜至附加材料(例如,非织造网)的粘合。当使用时,这些添加剂(增粘剂、抗氧化剂、稳定剂等)每种可以以所述膜的约0.001wt%-约25wt%的量存在,在一些实施方式中,为膜的约0.005wt%-约20wt%的量,和在一些实施方式中,为膜的约0.01wt%-约15wt%的量。
本发明的弹性膜可以是单层或多层的。多层膜可以通过所述层的共挤出、挤出涂覆、或通过任何常规铺设工艺来制备。此多层膜通常包含至少一个基层和至少一个表面层,但可以包含所需的任意数量的层。例如,所述多层膜可以由基层和一个或多个表面层来制备,其中所述基层由半结晶聚烯烃制备。在此实施方式中,所述表面层可以由任何膜形成聚合物制备。任选地,所述表面层包含更软的、更低熔聚合物或聚合物共混物,其使得所述层更适合作为用于热粘合所述膜至非织造网的热密封粘合层。例如,如上所述,表面层可以由烯烃聚合物或其共混物制得。其它的可以适用于本发明的膜形成聚合物,单独或与其它聚合物相结合,包括乙烯乙酸乙烯酯(ethylene vinyl acetate)、乙烯丙烯酸乙酯、乙烯丙烯酸(ethylene acrylic acid)、乙烯丙烯酸甲酯、乙烯丙烯酸正丁酯、尼龙、乙烯乙烯醇、聚苯乙烯、聚氨酯等。
通常对所述表面层的厚度进行选择,以基本上不致损害所述膜的弹性体性能。在此方面,每个表面层可以分别地包含膜的总厚度的约0.5%-约15%,和在一些实施方式中包含膜的总厚度的约1%-约10%。例如,每个表面层可以具有约0.1-约10微米的厚度,在一些实施方式中,约0.5-约5微米的厚度,和在一些实施方式中,约1-约2.5微米的厚度。同样,所述基层可以具有约1-约40微米的厚度,在一些实施方式中约2-约25微米的厚度,和在一些实施方式中约5-约20微米的厚度。
所得膜的性能可以通常按需要改变。例如,在拉伸前,所述膜典型地具有约100克每平方米或更低的基重,和在一些实施方式中,约50-约75克每平方米的基重。经拉伸,所述膜通常具有约60克每平方米或更少的基重,和在一些实施方式中,约15-约35克每平方米的基重。经拉伸的膜还可以具有约1-约100微米的总厚度,在一些实施方式中,约10-约80微米的总厚度,和在一些实施方式中,约20-约60微米的总厚度。
II.非织造网材料
如以下将详细描述的,用于制备非织造网材料的聚合物通常具有的软化温度高于在粘合期间所给予的温度。如此,所述聚合物在粘合期间并不充分软化至非织造网材料的纤维变成完全可流动的熔体的程度。例如,可使用的聚合物具有约100℃-约300℃的维基软化温度(ASTMD-1525),在一些实施方式中,约120℃-约250℃的维基软化温度,和在一些实施方式中,约130℃-约200℃的维基软化温度。用于制备非织造网材料的示例性的高软化点聚合物可以包括,例如,聚烯烃例如,聚乙烯、聚丙烯、聚丁烯等;聚四氟乙烯;聚酯,例如聚对苯二甲酸乙二酯等;聚乙酸乙烯酯;聚氯乙烯乙酸乙烯酯;聚乙烯醇缩丁醛;丙烯酸树脂,例如聚丙烯酸酯、聚丙烯酸甲酯、聚甲基丙烯酸甲酯等;聚酰胺,例如尼龙;聚氯乙烯;聚偏二氯乙烯;聚苯乙烯;聚乙烯醇;聚氨酯;聚乳酸;其共聚物等。任选地,还可以使用可生物降解聚合物,例如上述的那些。还可以使用合成的或天然的纤维素聚合物,包括但不限于,纤维素酯;纤维素醚;硝酸纤维素;乙酸纤维素;乙酸-丁酸纤维素(cellulosic acetate butyrates);乙基纤维素;再生纤维素,例如粘胶、人造丝等。应注意的是,所述聚合物还可以包含其它添加物,例如加工助剂或处理组合物以赋予纤维所需的性能、剩余量的溶剂、颜料或着色剂等。
单组份和/或多组分纤维可以用于制备非织造网材料。通常单组份纤维是由聚合物或者自单个挤出机挤出的聚合物的共混物制备的。多组分纤维通常是由分别的挤出机挤出的两种或多种聚合物(例如,双组份纤维)制备的。所述聚合物可以安置于穿过纤维的横截面的基本固定定位的不同区域。所述组分可以以任何需要的构型安置,所述构型例如皮芯型、并列型(side-by-side)、饼型、天星状(island-in-the-sea)、三岛型(three island)、牛眼型、或本领域已知的各种其它构型等。在Taniguchi等的U.S.专利4,789,592和Strack等的U.S.专利5,336,552,Kaneko等的5,108,820,Kruege等的4,795,668,Pike等的5,382,400,Strack等的5,336,552和Marmon等的6,200,669中描述了用于制备多组分纤维的各种方法,,其在本发明中为所有目的全文引入作为参考。例如在Hogle等的U.S.专利5,277,976,Hills的5,162,074,Hills的5,466,410,Largman等的5,069,970和Largman等的5,057,368中描述,还可以制备具有各种不规则形状的多组分纤维,其在本发明中为所有目的全文引入作为参考。
尽管可以使用任何组合的聚合物,多组分纤维的聚合物典型地由具有不同玻璃转化温度或熔化温度的热塑性材料制得,其中第一组分(例如,皮)在低于第二组分(例如,芯)的温度熔化。多组分纤维的第一聚合物组分的软化或熔化允许所述多组分纤维形成粘性的骨架结构(skeletalstructure),其经冷却稳定纤维结构。例如,所述多组分纤维可以具有约20%重量-约80%重量的低熔聚合物,和在一些实施方式中,约40%重量-约60%重量的低熔聚合物(low melting polymer)。而且,所述多组分纤维可具有约80%重量-约20%重量的高熔聚合物,和在一些实施方式中,约60%重量-约40%重量的高熔聚合物。已知的皮芯双组分纤维的部分例子可由KoSa Inc.of Charlotte,North Carolina的商品名T-255和T-256产品获得,其两者都使用聚烯烃皮,或T-254,其具有低熔共聚酯皮。再可以使用的其它已知双组分纤维包括可由Chisso Corporation of Moriyama,Japan或Fibervisions LLC of Wilmington,Delaware获得的那些。
可以使用任何所需长度的纤维,例如短纤维、连续纤维等。在一个具体实施方式中,例如,可以使用的短纤维具有约1-约150豪米范围内的纤维长度,在一些实施方式中约5-约5豪厘米范围内的纤维长度,在一些实施方式中约10-约40豪米范围内的纤维长度,和在一些实施方式中约10-约25豪米范围内的纤维长度。尽管并不需要,如本领域公知的,可以使用梳理工艺以形成具有短纤维的纤维层。例如,通过将成包的纤维置于分离纤维的清棉机中,纤维被制成梳理纤维网。接着,纤维被送入通过精梳或粗梳装置,其进一步脱离和在纵向上排列纤维以形成纵向取向的纤维非织造网。然后,可以使用已知技术粘合梳理纤维网以形成粘合的梳理非织造网。
任选地,用于形成非织造复合材料的非织造网材料可具有多层结构。合适的多层材料可包括,例如,防粘/熔喷/防粘(SMS)层压板和防粘/熔喷(SM)层压板。在Brock等的U.S.专利4,041,203;Timmons等的5,213,881;Timmons等的5,464,688;Bornslaeger的4,374,888;Collier等的5,169,706;和Brock的4,766,029中描述了合适的SMS层压板的各种例子,其在本发明中为所有目的全文引入作为参考。此外,可商购的SMS层压板可以由Kimberly-Clark Corporation的商品名和的商品获得。
多层结构的另一个例子是在多个旋转纱架机(spin bank machine)上制备的纺粘纤网,其中旋转纱架在由前面的纺丝纱架铺置(deposit)的纤维层上面铺置纤维。此单独的防粘非织造网还可以被视为多层结构。在此情况下,在非织造网中的各层铺置纤维可以是相同的,或者它们可以在基重上和/或在组成、类型、大小、卷曲度和/或制备的纤维的形状的方面上是不同的。作为另一个例子,单个非织造网可以作为纺粘纤网、梳理纤维网等的两层或多层单独制备层提供,其已经被粘合在一起以制备非织造网。这些单独制备层可以在如上论述的生产方法、基重、组成和纤维上不同。
非织造网材料还可以包含附加的纤维组分,使得它被视为是复合材料。例如,使用本技术领域已知的多种缠结技术(例如,水力、空气、机械等)中的任意一种,非织造网可以与其它纤维组分缠结在一起。在一个实施方式中,非织造网是使用水力缠结(hydraulic entanglement)与纤维素纤维整体缠结的。典型地水力缠结方法利用高压喷射水流缠结纤维以形成高度缠结的紧固的(consolidated)纤维结构,例如非织造网。例如,在Evans的U.S.专利3,494,821和Boulton的4,144,370中公开了短纤维长度和连续纤维的水力缠结非织造网,其在本发明中为所有目的全文引入作为参考。例如,在Everhart的U.S.专利5,284,703和Anderson的6,315,864中公开了连续纤维非织造网和矿浆层的水力缠结复合材料非织造网,其在本发明中为所有目的全文引入作为参考。所述复合材料的纤维组分可以包含任何所需量的所得基材(substrate)。所述纤维组分可以包含大于约50%重量的所述复合材料,和在一些实施方式中包含约60%重量-约90%重量的复合材料。同样,所述非织造网可以包含小于约50%重量的复合材料,和在一些实施方式中,约10%重量-约40%重量的复合材料。
尽管不需要,在层压至本发明的膜之前,所述非织造网材料可以在一个或多个方向颈缩。在Morman的U.S.专利5,336,545、5,226,992、4,981,747和4,965,122以及Morman的U.S.专利申请公开2004/0121687中描述了合适的技术劲缩技术。可选择地,在层压至膜前,所述非织造网可以在至少一个方向保持相对地不能可延伸。在此实施方式中,在层压至所述膜后,任选地,所述非织造网可以在一个或多个方向拉伸。
所述非织造网材料的基重通常可以变化,例如从约5克每平方米("gsm")至120gsm,在一些实施方式中,从约10gsm至约70gsm,和在一些实施方式中,从约15gsm至约35gsm。当是多个非织造网材料时,此材料可具有相同或不同的基重。
III.层压技术
为同时形成孔和所述膜与非织造网材料之间的粘合,在本发明中,层压通常通过刻花粘合技术(patterned bonding technique)(例如,热点粘合、超声粘合等)实现,其中所述材料被提供到通过至少一个刻花辊限定的辊隙。例如,热点粘合典型地利用两个辊之间形成的辊隙,至少其中一个辊是有刻花的。另一反面,超声粘合典型地利用超声发生器和刻花辊之间形成的辊隙。无论选择的技术,刻花辊包含多个突起的粘合部件(bondingelement)以同时将所述膜粘合至非织造网材料并在所述膜上形成孔。所述粘合部分的大小可以特别地制定以促使在所述膜上孔的形成,并提供所述膜和非织造材料之间的粘合。例如,典型地选择粘合部件以具有相当大的长度尺寸。所述粘合部件的长度尺寸可以是约300-约5000微米,在一些实施方式中约500-约4000微米,和在一些实施方式中,约1000-约2000微米。所述粘合部件的宽度大小同样可以介于约20-约500微米,在一些实施方式中约40-约200微米,和在一些实施方式中,约50-约150微米。此外,“部件长宽比”(部件的长度对其宽度的比率)可介于约2-约100,在一些实施方式中,介于约4-约50,和在一些实施方式中,介于约5-约20。
除粘合部件的尺寸,还可以选择地控制总体的粘合图案以获得所需的孔形成。例如,在一个实施方式中,选择粘合图案,其中一个或多个所述粘合部件的纵轴(沿所述部件的中心线的最长尺寸)相对于所述弹性膜的纵向(“MD”)是偏斜的。例如,一个或多个所述粘合部件可以相对于所述膜的纵向取向约30°至约150°,在一些实施方式中,取向约45°至约135°,和在一些实施方式中,取向约60°至约120°。如此,在基本上垂直于所述膜移动方向的方向上,所述粘合部件对于所述膜将占相当大的表面。这增加了施予膜剪切应力的面积且相应地促使孔形成。
通常选择所述粘合组件的花纹以使非织造复合材料具有小于约50%的总粘合面积(如通过常规的光学显微方法确定),和在一些实施方式中,具有小于约30%的总粘合面积。典型地,粘合密度还大于约50针粘合(bond)每平方英寸,和在一些实施方式中,为约75-约500针粘合每平方英寸。一个适用于本发明的粘合图案被认为是“S-波纹”,且在McCormack的U.S.专利5,964,742中描述,其在本发明中为所有目的全文引入作为参考。典型地,S-波纹图案具有约50-约500个粘合部件每平方英寸的粘合部件密度,和在一些实施方式中,约75-约150个粘合部件每平方英寸的粘合部件密度。在图2中显示出合适的“S-波纹”图案的例子,其说明了S-形粘合部件88具有长度尺寸“L”和宽度尺寸“W”。另一个合适的粘合图案被认为是“罗纹”图案并在Levy的U.S.专利5,620,779中描述,其在本发明中为所有目的全文引入作为参考。典型地,罗纹图案具有约150-约400个粘合部件每平方英寸的粘合部件密度,和在一些实施方式中,约200-约300个粘合部件每平方英寸的粘合部件密度。在图3中显示了合适的“罗纹”图案的例子,其说明了粘合部件89和粘合部件91,其是以不同的方向取向的。然而,另一个合适的图案是“金属丝波纹”图案,其具有约200-约500个粘合部件每平方英寸的粘合部件密度,和在一些实施方式中,约250-约350个粘合部件每平方英寸的粘合部件密度。在图4中显示了合适的“金属丝波纹”图案的例子,其说明了粘合部件93和粘合部件95,其是以不同的方向取向的。在Hansen的U.S.专利3,855,046;Havnes的5,962,112;Sayovitz的6,093,665;Edwards的D375.844;Romano的D428.267;和Brown的D390.708中描述了可以用于本发明的其它粘合图案,其在本发明中为所有目的全文引入作为参考。
适合的粘合温度的选择会帮助在邻近粘合部件的区域熔融和/软化所述膜的低软化点弹性体聚合物。然后,在粘合过程中,所述软化的弹性体聚合物例如通过由所述粘合部件施加的压力会流动和变得移位。围绕所述孔的膜的移位部分还能够熔合至所述非织造网材料,由此形成整体的非织造复合材料。而且,由于弹性体聚合物可以物理上包嵌或粘附于所述粘合点的纤维,可以在不需要充分软化用于制备非织造网材料的聚合物的条件下获得充分的粘合形成。因此,在位于直接相邻于(例如,在...之上或在...之下)所述孔的那些区域,非织造网材料基本上保持未粘合至所述膜或其它材料。而且,通常,所述非制造网材料还是无孔的,尽管其在加工过程中当然会逐渐形成一些小的切口或裂缝。
为获得此同时的孔和粘合形成,而并不充分软化所述非织造网材料的聚合物,可以选择性地控制所述粘合温度和压力。例如,可以加热一个或多个辊至约50℃-约160℃的表面温度,在一些实施方式中,至约60℃-约140℃的表面温度,和在一些实施方式中,至约70℃-120℃的表面温度。同样,在热粘合过程中通过辊施加的压力(“辊隙压力”)可以介于约75-约600磅每线性英寸,在一些实施方式中,介于约100-约400磅每线性英寸,和在一些实施方式中,介于约120-约200磅每线性英寸。当然,材料的停留时间可以影响所用的具体粘合参数。
如所指出的,影响同时的孔和粘合形成的另一个因素是在层压过程中的拉伸程度(degree of tension)。例如,膜拉伸的增大典型地与孔大小的增大相关。当然,过高的膜拉伸会不良地影响膜的完整性。因此,在本发明的大部分实施方式中,采用约1.5或更高的拉伸比,在一些实施方式中约2.5-约7.0的拉伸比,和在一些实施方式中约3.0-约5.5的拉伸比,以获得在层压过程中在所述膜上理想的拉伸程度。可以通过将膜的最终长度除以其初始长度来确定拉伸比。所述拉伸比还可以近似地与可以通过将在层压过程中膜的线速度(例如,轧辊的速度)除以所述膜制得的线速度(例如,铸塑辊(casting rolls)或吹塑轧辊(blown nip rolls)的速度)来确定的牵伸比(draw ratio)相同。
所述膜可以通过辊以不同的旋转速度旋转而被“预拉伸”(在层压前),使得片层在纵向被拉伸至所需的拉伸比。此单轴向拉伸的膜还可以在横向上取向以形成“双轴向拉伸的”膜。在“预拉伸”操作的过程中,取向温度曲线一般低于所述膜中的一种或多种聚合物的熔点,但足够高以使组合物能够被牵伸或拉伸。例如,所述膜可以在约15℃-约50℃的温度下被拉伸,在一些实施方式中在约25℃-约40℃的温度被拉伸,和在一些实施方式中在约30℃-约40℃的温度被拉伸。当以上述方式“预拉伸”时,在层压过程中的拉伸程度可以增大、保持、或轻微减小(收缩的)至所需的拉伸度。
通过层压,所述弹性膜被被粘合至所述非织造网材料和打孔。所得孔的大小和/或图案通常对应于所述粘合部件的大小和图案。即,如上所述,所述孔可以具有长度、宽度、长宽比和取向。例如,所述孔的长度大小可以为约200-约5000微米,在一些实施方式中为约350-约4000微米,和在一些实施方式中为约500-约2500微米。同样,所述孔的宽度大小可以介于约20-约500微米,在一些实施方式中介于约40-约200微米,和在一些实施方式中介于约50-约150微米。此外,“长宽比”(孔的长度对其宽度的比率)可以介于约2-约100,在一些实施方式中介于约4-约50,和在一些实施方式中介于约5-约20。类似地,一个或多个所述孔的纵轴(沿孔的中心线的最长尺寸)可以相对于所述弹性膜的纵向偏斜,例如约30°-约150°,在一些实施方式中偏斜约45°-约135°,和在一些实施方式中相对于所述膜的纵向偏斜约60°-约120°。
现在将更详细地描述本发明的各种实施方式。当然,应理解以下提供的说明仅是示例性的,且本发明考虑了其它方法。例如,参照图1,显示了用于由弹性膜和非织造网材料制备复合材料的方法的一个实施方式。如示,所述膜的原材料(例如,弹性体聚合物)可以干混在一起(即,没有溶剂)并加入挤出装置40的料斗(未显示)。可选择地,原材料可以与溶剂共混。在料斗中,所述材料在熔体中分散地混合并使用任何已知技术混炼,例如使用例如Banbury混合机、Farrel连续混合机、单螺杆挤出机、双螺杆挤出机等的间歇和/或连续混炼技术。
可以使用任何已知的技术来由所述混炼的材料制备膜,包括吹塑、注塑、平摸挤出等。在一个具体实施方式中,所述膜可以通过吹塑方法制备,其中使用气体(例如,空气)以通过环形模头使挤出的聚合物共混物的气泡膨胀。然后,压瘪气泡并以平膜形式收集。例如,在Ralev的U.S.专利3,354,506;Schippers的3,650,649;和Schrenk的3,801,429以及McCormac的U.S.专利申请公开2005/0245162和Boggs的2003/0068951中描述了用于制备吹塑膜的方法,其全部在本发明中为所有目的全文引入作为参考。例如,在图1的具体实施方式中,提供混炼的材料(未显示)至挤出装置40和然后吹进辊隙42以制备单层前体弹性膜10。当制备所述前体弹性膜10时,保持辊42在足以固化和冷却它的温度,例如约20℃-60℃。典型地,所得前体弹性膜一般是无孔的,尽管由于加工其当然可以具有小的切口或裂纹。使用初始无孔膜可以提供许多益处,包括在层压过程中调准孔与粘合点所需的对准步骤的避免。
再参考图1,显示了用于制备单轴向拉伸膜的一种方法。在说明的实施方式中,通过使其通过膜取向装置或纵向取向器(“MDO”)44,例如,可由Marshall and Willams,Co.of Providence,Rhode Island商购,膜10被在纵向拉伸和减薄。在说明的实施方式中,MDO具有在纵向上逐步拉伸和减薄膜10的多个拉伸辊46。而在图1中说明了4对辊46,应理解,根据所需的拉伸程度和在各辊之间的拉伸的角度(degree of stretching),辊的数量可以更高或更低。膜10可以以单一或多个不连续的拉伸操作来拉伸。膜10还可以在其它方向拉伸。例如,所述膜可通过链夹(chain clip)在其横向边缘夹持并传送进入伸幅烘箱。在伸幅烘箱中,所述膜可以通过在它们向前进程中分开的(diverged)链夹在横向上被拉伸至所需的拉伸比。
非织造网材料还可以用于层压至弹性膜10。例如,非织造网材料可以容易地从供应辊(supply roll)上退绕。可选择地,如图1所示,非织造网材料30可以在线(jn-line)制备,例如通过纺粘挤出机48。所述挤出机48将纤维50铺置于成型金属丝(forming wire)52上,其是围绕一系列辊循环的连续皮带装置(continuous belt arrangement)的部分。任选地,可以使用真空(未显示)以将纤维保持于成型金属丝52上。纺粘纤维50形成了垫54,其可任选地通过压紧辊56压制。尽管不是必需的,由供应辊62引入的第二种材料30a也可以被层压至弹性膜10。所述第二种材料30a可以是第二种非织造网材料等。
无论如何,利用热粘合技术来将材料层压至弹性膜。例如,在图1中,为层压至弹性膜10,材料30和30a被导入辊58之间确定的辊隙。辊58的一个或两者可包含多个凸起的粘合部件和/或可以加热。通过层压,弹性膜10可以在多个分离的粘合点31(见图7)被粘合至非织造网材料30和30a。即,膜10的弹性体聚合物被软化和/或熔融,使得它们可以物理上包嵌非织造网材料30和30a的纤维。当然,弹性膜10可具有一定的粘性,使得其通过层压还粘附于纤维。如图7所示,粘合点31可以位于接近(邻近或靠近)由相应的孔33限定的周界37的位置,所述孔33是通过膜10的移位形成的。粘合点31的具体位置邻近或靠近孔33可以通过加强围绕孔33的区域提高所得复合材料32的完整性。如上所述,因为热粘合发生在不足以充分软化非织造网材料30和30a的聚合物的温度,它们并未充分地彼此熔合。如此,复合材料32可以更好地保持单个非织造网材料的物理性能(例如,液体可渗透型、柔软性、体积和手感)。
然后所得复合材料32可以被卷绕和贮存在卷绕辊60上。任选地,复合材料32保持在拉伸下,例如通过对辊60使用与一个或多个拉伸辊46的速度相同的线速度。但是,更优选地,在卷绕到卷绕辊60上之间,复合材料32允许轻微地收缩。这可以通过使用更慢的辊60的线速度而实现。因为弹性膜10在层压前被拉伸,它将会向其初始纵向长度收缩并在纵向上变得更短,由此使复合材料起皱或形成褶皱。因此所得弹性复合材料在纵向上变得可伸长至所述网上的褶皱或皱褶可以被拉回变平和允许弹性膜10伸长的程度。
而并未在图1中显示,可以进行本领域已知的各种其它的潜在的加工和/或整理步骤,例如切膜、处理、印刷图案等,而并不偏离本发明的精神和范围。例如,任选地复合材料可以在横向和/或纵向上进行机械拉伸以提高可延伸性。在一个实施方式中,所述复合材料可以行经通过两个或多个在CD和/或MD方向具有槽的辊。在Rhim等的U.S.专利申请公开2004/0110442和Gerndt的2006/0151914中描述了此刻槽的伴辊(satelliteroll)/支承辊装置,其在本发明中为所有目的全文引入作为参考。例如,层压板可以行经通过两个或多个在CD和/或MD方向具有槽的辊。所述刻槽辊可以是由钢铁或其它硬材料(例如硬橡胶)构成的。
图5-6进一步说明了刻槽辊可以不断增量地(incrementally)拉伸复合材料的方式。如示,例如,伴辊182可以啮合支承辊184,其每个包括多个隆脊(ridge)183,该隆脊限定多个在横向上横过所述刻槽辊而定位的槽185。槽185通常垂直于材料的拉伸方向来取向。换而言之,槽185在纵向取向以在横向拉伸所述复合材料。同样,槽185可以在横向取向以在纵向拉伸所述复合材料。伴辊182的隆脊183与支承辊184的槽185相啮合,及伴辊182的槽185与支承辊184的隆脊183相啮合。
所述槽185和隆脊183的尺寸和参数对由辊182和184提供的可伸长性具有显著影响。例如,辊上包括的槽185的数量一般介于约3-15个槽每英寸,在一些实施方式中介于约5-12个槽每英寸,和在一些实施方式中介于约5-10个槽每英寸。所述槽185还可以具有一定的深度“D”,其一般介于约0.25-约1.0厘米,和在一些实施方式中介于约0.4-约0.6厘米。此外,典型地,在所述槽185之间的峰-峰距离“P”介于约0.1-约0.9厘米,和在一些实施方式中介于约0.2-约0.5厘米。而且,在所述槽185和隆脊183之间刻槽辊啮合距离“E”可以达到约0.8厘米,和在一些实施方式中,约0.15-约0.4厘米。无论如何,所述复合材料32(图6)可以在一个或多个方向上以约1.5-约8.0的拉伸比拉伸,在一些实施方式中以至少约2.0-约6.0的拉伸比拉伸,和在一些实施方式中以至少约2.5-约4.5的拉伸比拉伸。任选地,在施加增量拉伸的刚好之前或过程中,可以对所述复合材料施加热以使其松弛少许和易于伸长。可以通过本领域已知的任何合适的方法施加热,例如加热的空气、红外加热器、加热的轧辊、或环绕一个或多个加热辊或蒸汽罐(steam canister)的层压板的部分包覆(partial wrapping)等。还可以将热施加到刻槽辊自身。还应该理解,其它刻槽辊装置是同样适合的,例如正好彼此相邻定位的两个刻槽辊。
除上述刻槽辊外,还可以使用其它技术以在一个或多个方向上机械拉伸所述复合材料。例如,可以将所述复合材料通过拉伸复合材料的伸幅架(tenter frame)。此伸幅架在本领域是公知的,并且在例如Morman的U.S.专利申请公开2004/0121687中描述。所述复合材料还可以是颈缩的。在Morman的U.S.美国专利5,336,545,5,226,992,4,981,747和4,965,122以及Morman的U.S.专利申请公开2004/0121687中描述了合适的技术颈缩技术,其全部在本发明中为所有目的全文引入作为参考。
本发明的非织造复合材料还可以用于广泛的应用中。如上所述,例如,所述在非织造复合材料可以用于吸收制品。通常“吸收制品”是指能够吸收水或其它液体的任何制品。部分吸收制品的例子包括,但不限于,个人护理吸收制品,例如尿布、训练裤、吸收衬裤、失禁制品、女性卫生产品(例如,卫生棉)、游泳衣、婴儿拭布等;医用吸收制品,例如外罩、开口薄膜材料(fenestration materials)、衬垫(underpad)、床垫、绷带、吸收盖布(absorbent drapes)和医用拭布;食品服务抹布;服装制品等。适用于制备此吸收制品的材料和方法是本领域技术人员公知的。吸收制品可以包括基本上液体不可渗透层(例如,外罩层)、液体可渗透层(例如,体侧衬里、浪涌层等)和吸收芯。
在一个具体实施方式中,本发明的非织造复合材料可以用于制备所述吸收制品的液体可渗透层(例如,体侧衬里、浪涌层)。如上所述,所述弹性膜在位于接近所述孔的周界的分离的粘合点被粘合到非织造网材料上。但是,通过选择控制层压工艺的条件,所述非织造网材料基本上在位于邻近所述孔的区域保持未粘合(例如,基本上没有熔合在一起)。例如,当所述弹性膜位于两种非织造网材料之间时,通常所述非织造网材料在那些邻近所述孔的区域并没有形成熔融粘合点。层压工艺的条件还可以允许所述非织造网材料在那些邻近所述弹性膜上的孔的区域一般保持无孔。在非织造网材料上的此通常未粘合和无孔区域的存在,提高了所述复合材料被用作吸收制品中的液体可渗透层的能力。即,因为所述非织造网材料在那些邻近所述膜的孔的区域并未熔合在一起,液体可以更容易地流过非织造网材料和进入孔。同样,在非织造网材料上没有大量开孔,允许其保持其它的理想性能(例如,体积、柔软度、手感等)。
除液体可渗透材料(例如,衬里、浪涌层等),本发明的非织造复合材料可以具有大量其它用途,例如在提供弹性腰带、腿箍带/垫圈(legcuff/gasketing)、可拉伸凸耳(stretchable ear)、侧板(side panel)、外罩或任何需要弹性性能的其它组件。
现在将更详细地描述可以根据本发明制备的吸收制品的各种实施方式。仅为说明目的,在图8中示出作为尿布201的吸收制品。但是,如上所述,本发明可以以其它类型的吸收制品体现,例如,失禁制品、卫生棉、尿裤、女性卫生巾、儿童训练裤等。在说明的实施方式中,尿布201在未紧固的构造(unfastened configuration)中作为具有沙漏形状示出。但是,当然可以使用其它形状,例如,一般地长方形、T形或I形。如示,尿布201包括由各种组件形成的地盘,包括外罩层217、体侧衬里205、吸收芯203和浪涌层207。但是,应理解,在本发明中还可以使用其它层。同样,在本发明的特定实施方式中,还可以除去在图8中的一个或多个层。
通常使用体侧衬里205来帮助使穿着者的皮肤与在吸收芯203中容留的液体分隔开。例如,衬里205显示了面向身体的表面,其典型地是柔性的、柔软感的和对穿着者无刺激的。典型地,衬里205是比吸收芯203较少亲水的,使得其表面保持对穿着者相对干燥。如上所示,衬里205可以是液体可渗透的以允许液体容易地透过其厚度。在Proxmire等的U.S.美国专利5,192,606;Collier,IV等的5,702,377;Stokes等的5,931,823;Paul等的6,060,638;和Varona的6,150,002,以及Jameson的U.S.专利申请公开2004/0102750;Morman等的2005/0054255;和Baldwin等的2005/0059941中描述了包含非织造网的示例性的衬里构造,其全部在本发明中为所有目的全文引入作为参考。在一个具体实施方式中,衬里包括本发明的非织造复合材料。
如在图8中所示,尿布201还可以包括浪涌层207,其帮助减速和扩散会快速引入进吸收芯203的浪涌或喷涌的液体。理想地,在将液体释放进入吸收芯203的贮存或存留部分前,浪涌层207迅速地接受和临时容留所述液体。例如,在说明的实施方式中,在体侧衬里205的面向里的表面216和吸收芯203之间插入浪涌层207。可选择地,浪涌层可以位于体侧衬里205的面向外的表面218上。典型地,浪涌层207由高液体可渗透材料构成。在Ellis等的U.S.专利5,486,166和Ellis等的5,490,846中描述了合适的浪涌层的例子,其在本发明中为所有目的全文引入作为参考。在一个具体实施方式中,浪涌层207包括本发明的非织造复合材料。
典型地,外罩层217由基本上对液体不可渗透的材料制成。例如,外罩层217可以由薄塑料膜或其它挠性的液体不可渗透材料制成。在一个实施方式中,外罩层217由具有约0.01毫米-约0.05毫米的厚度的聚乙烯膜制成。所述膜可以是对液体不可渗透的,但对气体和水蒸气是可渗透的(即,“可透气的”)。这允许蒸汽从吸收芯203逸出,但仍然阻止液体流出物通过外罩层217。如果需要更布样的感觉,外罩层217可以由层压至非织造网的聚烯烃膜制成。例如,可以热层压拉伸-减薄的聚丙烯膜至聚丙烯纤维的纺粘网。
除上述组件外,尿布201还可以包含如本领域已知的各种其它组件。例如,尿布201还可以包含基本上亲水的薄纸包片(tissue wrapsheet)(未示出),其帮助保持吸收芯203的纤维结构的完整性。典型地,所述薄纸包片环绕吸收芯203越过至少两个其主要朝向表面放置,和由吸收纤维素材料组成,例如皱纹衬料(creped wadding)或高湿强度薄纸。所述薄纸薄片可以经构造以提供芯吸层,以有助于快速分布液体于吸收芯203的全部吸收纤维上。在吸收纤维块的一面上的包片材料可以粘合到位于所述纤维块的背面的包片上,以有效地包裹吸收芯203。而且,尿布201还可以包括通气层(未显示),其位于吸收芯203和外罩层217之间。当使用时,通气层可以有助于将外罩层217与吸收芯隔离,由此减少在外罩层217中的潮湿。此通气层的例子可以包括层压至可透气膜的非织造网,例如在Blaney等的U.S.专利6,663,611中描述,其在本发明中为所有目的全文引入作为参考。
在一些实施方式中,尿布还可以包括一对侧板(side panel)(或凸耳(ear))(未显示),其从尿布201的侧边缘延伸进入腰部区域之一。所述侧板可以由选择的尿布组件整体成型。例如,所述侧板可以由外罩层217或所用的材料整体成型以提供顶面(top surface)。在可选择的构型中,所述侧板可以由连接并组装至外罩层217、顶面、外罩层217和顶面之间、或在多种其它构型中的部件提供。任选地,所述侧板可以是经弹性处理的或通过使用本发明的弹性非织造复合材料致使弹性体的。在Roessler的PCT专利申请WO 95/16425;Roessler等的U.S.专利5,399,219;Fries的U.S.专利5,540,796;和Fries的U.S.专利5,595,618中描述了包括经弹性处理的侧板和选择地配置地紧固突出件(fastener tabs)的吸收制品的例子,其每个在本发明中为所有目的全文引入作为参考。
如在图8中代表性说明的,尿布201还可以包括一对护翼(containment flaps)212,其经构造以构造以提供阻障和容纳横向流动的身体流出物。所述护翼212可以沿着相邻于吸收芯203的侧边缘的体侧衬里205的横向相对的侧边缘232设置。护翼212可以沿吸收芯203的整个长度纵向延伸,或可以仅沿着吸收芯203的长度局部延伸。当护翼212在长度上短于吸收芯203时,它们可以选择性地设置在裆部区域210沿着尿布201的侧边缘232的任何位置。在一个实施方式中,护翼212沿着吸收芯203的整个长度延伸以更好地容纳身体流出物。此护翼212通常对于本领域技术人员是公知的。例如,在Enloe的U.S.专利4,704,116中描述了对于护翼212的合适的构架和布置,其在本发明中为所有目的全文引入作为参考。
如在下面解释的,为提供改进的贴合和帮助减少身体流出物的泄漏,可以使用合适的弹性部件对尿布201进行弹性化处理。例如,如在图8中代表性地说明的,尿布201还可以包括腿部弹性构件206,其被构造以可操作地拉伸尿布201的侧边幅(side margin)以提供能够紧贴地与穿着者的腿部周围适配的经弹性化处理的腿部束带(leg band),从而减少泄漏和提供改进的舒适性和外观。还可以使用腰部弹性构件208以对尿布201的端部边幅进行弹性化处理以提供经弹性化处理的腰带。腰部弹性构件208被构造以提供弹回的、与穿着者的腰部周围舒适地紧贴的适配。本发明的弹性非织造复合材料适于用作腿部弹性部件206和腰部弹性部件208。此材料的例子是包含或粘附于外罩层217的层压片,使得能够对其施加弹性收缩力。
尿布201还可以包括一个或多个紧固件230。例如,在图8中说明了在腰部区域的相对侧边缘上的两个弹性紧固件,以产生环绕穿着者的腰部开口和一对腿部开口。通常紧固件230的形状可以变化,但可以包括,例如,一般长方形、正方形、圆形、三角形、椭圆形、线形等。所述紧固件可以包括,例如,钩-和-环材料、纽扣、别针、摁扣、粘合胶带紧固件、粘合剂、织物-和-环紧固件等。在一个具体实施方式中,每个紧固件230包括固定于弹性背衬的内表面的分开件的钩材料。
尿布201的各个区域和/或组件可以使用任何已知的,例如胶粘、超声、热粘合等的连接方式组装在一起。合适的胶粘剂可以包括,例如,热熔粘合剂、压力敏感粘合剂等。当使用时,所述胶粘剂可以作为均匀层、图案层、喷雾的图案、或任何分离的线、涡或点施加。例如,在说明的实施方式中,外罩层217和体侧衬里205是使用胶粘剂彼此装配和装配至吸收芯203的。可选择地,可以使用常规紧固件,例如纽扣、钩和环型紧固件、粘合胶带紧固件等连接至外罩层217的。类似的,其它尿布组件,例如腿部弹性构件206、腰部弹性构件208和紧固件230,还可以使用任何连接方法装配成尿布201。
尽管上面已经描述了各种构造的尿布,应理解,其它尿布和吸收制品构造也应包括在本发明的范围内。此外,本发明绝不限于尿布。事实上,任何可以根据本发明制备的其它吸收制品,包括,但不限于,其它个人护理吸收制品,例如训练裤、吸收衬裤、成人失禁产品、女性卫生产品(例如,卫生棉)、游泳衣、婴儿拭布等;医用吸收制品,例如外罩、开口薄膜材料、衬垫、绷带、吸收盖布和医用拭布;食品服务抹布;服装制品等。在DiPalma等的U.S.专利5,649,916,Kielpikowski的6,110,158,Blanev等的6,663,611中描述了此吸收制品的几个例子,其在本发明中为所有目的全文引入作为参考。在Fell等的U.S.专利申请公开2004/0060112 A1,以及Damico等的U.S.专利4,886,512,Sherrod等的5,558,659,Fell等的6,888,044,和Freiburger等的6,511,465中描述了其它合适的制品,其全部在本发明中为所有目的全文引入作为参考。
参考一下实施例可以更好地理解本发明。
测试方法
周期测试
使用周期测试方法测试材料以确定负载损耗和永久变形率。特别地,利用1-周期测试达到150%确定的伸长。对此测试,样品大小是横向3英寸X纵向6英寸。夹具尺寸是宽3英寸。夹具分隔距离是4英寸。加载样品使得样品的纵向是在垂直方向上。设定约10-15克的预负载。测试以20英寸每分钟的速度将样品拉至100%伸长,然后立即(没有停顿)以20英寸每分钟的速度返回至零。测试数据的结果全部来自第一周期。使用TESTWORKS 4.07b软件(Sintech Corp,of Cary,NC)在Sintech Corp的恒定速率伸长测试器2/S与Renew MTS mongoose box(控制)上进行测试。测试是在周围条件下进行。
空气渗透性
空气渗透性是使用“Frazier渗透性”确定的,其是作为标准立方英尺每分钟的通过材料的空气流测量的,每平方英尺的材料具有通过样品的0.5英寸的水的气压微分(an air pressure differential of 0.5 inches of water)(125Pa)。测试是在周围条件下进行的。
剥离强度:
使用特定的织物宽度、夹钳钳口宽度和恒定的伸长速率得到剥离强度值。此测试使用两个夹钳,每个具有两个钳口,每个钳口具有与样品接触的面,以在同一平面握持材料,通常垂直地分开2英寸以开始。样品大小是宽4英寸(实施例1)或3英寸(实施例1),和具有分层足够的样品长度所需的同样长度。钳口面的尺寸是1英寸高X至少4英寸宽,和恒定伸长速率是300mm/min。样品通过手分层足够的量以允许其被夹持到合适位置,和夹具以特定的伸长速率移开以将层压板撕开。样品试样以两层之间分开180°被撕开,剥离强度作为克为单位的最大负荷的平均值报告。当已经撕开16mm的层压板时,力的测量开始并持续到已经分层总的170mm。系统可以采用MTS SYNERGY 200 Tensile Tester和TESTWORKS4.08B软件,其可购自MTS Systems Corporation of Eden Prairie,Minnesota。结果作为三个试样的平均值报告,并可以使用在横向(CD)和纵向(MD)的样品进行。测试可以在周围条件下进行。
变形:
测试材料以确定伸长或变形。对此测试,样品尺寸是在横向上3英寸和纵向上7英寸。夹具尺寸是3英寸宽,和利用啮合的夹具使得当测试时材料不会滑动。夹具分隔距离是4英寸。装载样品使得样品的纵向是在垂直方向。设定大约10-15克的预负载。该测试拉样品直至产生2000克的拉伸,然后停止测试。测试速度是500毫米每分钟的伸长或变形。当在材料中产生2000克的拉伸时,测试从开始报告以百分率为单位的伸长或变形。测试是使用TESTWORKS 4.07b软件(Sintech Corp,of Cary,NC)在SintechCorp.的恒定速率伸长测试器2/S与Renew MTS mongoose box(控制器)上进行的。测试是在周围条件下进行的。
实施例1
证明了制备弹性非织造复合材料的能力。弹性膜是由93wt%的EXACTTM 5361(ExxonMobil Chemical Co.),5wt%的Dow聚乙烯640I(Dow Chemical Co.),和2wt%的SCC116921颜料(Standridge Color Corp.)制备的。EXACTTM 5361是金属茂催化的聚乙烯塑性体,其具有0.86克每立方厘米的密度、36℃的最高熔化温度、和3.0克每10分钟(190℃,2.16kg)的熔融指数。Dow聚乙烯640I是低密度聚乙烯,其具有0.9215克每立方厘米的密度、111℃的熔点、和2.0克每10分钟(190℃,2.16kg)的熔融指数。SCC1 16921颜料包含约聚丙烯和聚丙烯无规共聚物共混的二氧化钛。
通过称量合适份的每种聚合物的粒料,将它们在一个容器中合并,和通过搅拌将它们混合来混炼聚合物。在混炼后,在压瘪辊隙(collapsing nip)(以38英尺每分钟运转)间吹塑膜样品,使得获得了约375℉的熔化温度。该吹塑膜在两个具有大约14克每平方米基重的聚丙烯纺粘面之间被热粘合。特别地,所述膜和面是在支承辊和刻花辊(罗纹)之间送入的。刻花辊被加热到184℉的辊面温度,支承辊被加热到193℉的辊面温度,和压力是157磅每线性英寸。所述辊以182英尺每分钟的速度运转,使得所述膜在纵向上以4.8的拉伸比(即,其初始长度的4.8倍)被拉伸。一旦制得,复合材料然后被引入啮合的刻槽钢辊的辊隙,例如自图5-6中所示,以在横向上拉伸复合材料。加热刻槽钢辊至125℉的温度。最后,复合材料被传送至卷绕器,其以81英尺每分钟的速度运转以允许复合材料收缩。最终基重是大约105克每平方米。
图9-17显示了所得样品的扫描电子显微图。例如,图9显示了由罗纹图案的条形成的近似长方形孔333a(见,例如图3),而图10显示了由罗纹图案的钉形成了近似圆形的孔333b。所述孔的透视图在图11中示出。孔333还在图14-17中示出。除了说明的孔外,所述显微图还证明了弹性膜熔合至非织造网的纤维。例如,图12-13显示了,在分离的粘合点331熔合至非织造网330的弹性膜310。粘合点331位于接近由孔333限定的周界337的位置。
实施例2
证明了制备弹性非织造复合材料的能力。弹性膜是由71wt%的EXACTTM 5361(ExxonMobil Chemical Co.),25wt%的MD6673(Kraton Polymers,LLC of Houston Texas),和2wt%的SCC116921颜料(Standridge Color Corp.)制备的。 MD6673包含68wt%苯乙烯-乙烯-丁烯-苯乙烯嵌段共聚物(MD6937),20wt%的REGALREZTM 1126(Eastman Chemical)和12wt%的EPOLENETM C-10聚乙烯蜡(Eastman Chemical)。SCC1 16921颜料包含约聚丙烯和聚丙烯无规共聚物共混的二氧化钛。通过称量合适份的每种聚合物的粒料,将它们在一个容器中合并,和通过搅拌将它们混合来混炼聚合物。
在混炼后,聚合物组合物在403℉的熔化温度挤出并铸入到以约45英尺每分钟的速度运转的冷却辊(设定到21℃的温度)上。然后,所述膜在两个具有大约14克每平方米基重的聚丙烯纺粘面之间被热粘合。特别地,所述膜和面是在支承辊和刻花辊(罗纹)之间送入的。刻花辊被加热到230℉的辊面温度,支承辊被加热到242℉的辊面温度,和压力是176磅每线性英寸。所述辊以147英尺每分钟的速度运转,使得所述膜在纵向上以约3.3的拉伸比(即,其初始长度的3.3倍)被拉伸。一旦制得,复合材料然后被引入啮合的刻槽钢辊的辊隙,例如在图5-6中所示,以在横向上拉伸复合材料。加热刻槽钢辊至125℉的温度。最后,复合材料被传送至卷绕器,其以74英尺每分钟的速度运转以允许复合材料收缩。最终基重是大约100克每平方米。
实施例3
证明了制备弹性非织造复合材料的能力。弹性膜是由98wt%的EXACTTM 5361(ExxonMobil Chemical Co.)和2wt%的Dow聚乙烯640I(Dow Chemical Co.)制备的。通过称量合适份的每种聚合物的粒料,将它们在一个容器中合并,和通过搅拌将它们混合来混炼聚合物。在混炼后,在压瘪辊隙(以30英尺每分钟运转)间吹塑膜样品,使得获得了约386℉的熔化温度。该吹塑膜在两个具有大17克每平方米基重的聚丙烯纺粘面之间被热粘合。特别地,所述膜和面是在支承辊和刻花辊(S-波纹)之间送入的。刻花辊被加热到211℉的辊面温度,支承辊被加热到203℉的辊面温度,和压力是117磅每线性英寸。所述辊以110英尺每分钟的速度运转,使得所述膜在纵向上以3.7的拉伸比(即,其初始长度的3.7倍)被拉伸。一旦制得,复合材料被传送至卷绕器,其以70英尺每分钟的速度运转以允许复合材料收缩。最终基重是大约88克每平方米。
实施例4
证明了制备弹性非织造复合材料的能力。弹性膜是由93wt%的V1STAMAXXTM 1100(ExxonMobil Chemical Co.),4wt%的Dow聚乙烯640I(Dow Chemical Co.),和3wt%的SCC116921颜料(Standridge ColorCorp.)制备的。SCC116921颜料包含约聚丙烯和聚丙烯无规共聚物共混的二氧化钛。通过称量合适份的每种聚合物的粒料,将它们在一个容器中合并,和通过搅拌将它们混合来混炼聚合物。在混炼后,在压瘪辊隙(以38英尺每分钟运转)间吹塑膜样品,使得获得了约390℉的熔化温度。该吹塑膜在两个具有大约14克每平方米基重的聚丙烯纺粘面之间被热粘合。特别地,所述膜和面是在支承辊和刻花辊(罗纹)之间送入的。刻花辊被加热到193℉的辊面温度,支承辊被加热到203℉的辊面温度,和压力是117磅每线性英寸。所述辊以210英尺每分钟的速度运转,使得所述膜在纵向上以5.5的拉伸比(即,其初始长度的5.5倍)被拉伸。一旦制得,复合材料然后被引入啮合的刻槽钢辊的辊隙,例如在图5-6中所示,以在横向上拉伸复合材料。加热刻槽钢辊至125℉的温度。最后,该复合材料被传送至卷绕器,其以79英尺每分钟的速度运转以允许复合材料收缩。最终基重是大约98克每平方米。
实施例5
测试了实施例1-4的复合材料的弹性(例如,周期测试)、气体渗透性、剥离强度和变形。结果在下面表1和表2中阐述。
表1:样品的周期测试
表2:样品的孔隙率和机械性能
Ex. | 空气渗透性(ft3/min) | MD剥离强度(gf/英寸) | 在200gf的变形(%) |
1 | 190.0 | 31.8 | 148 |
2 | 181.7 | - | 115 |
3 | 243.3 | - | 56 |
4 | 9.0 | 73.0 | 156 |
如上所示,本发明的复合材料显示出弹性特性,同时还保持了良好的空气流动和机械性能。
关于其特定的实施方式,本发明已经进行了详细描述,然而应该理解,本领域技术人员,通过获得上述理解,可以容易地想象出对这些实施方式的替换、改变和等同。相应地,本发明的范围应作为所附权利要求和其任何等同的范围来评价。
Claims (27)
1.制备非织造复合材料的方法,所述方法包括:
由聚合物组合物制备弹性膜;
将该膜和非织造网材料通过由至少一个刻花辊形成的辊隙;和
在辊隙处,同时地将所述膜熔合至非织造网材料和在所述膜上形成孔,而并没有充分软化所述非织造网材料的聚合物,其中所述孔的至少一个具有约200-约5000微米的长度,而且其中所述膜在辊隙处是处于在纵向上约1.5或更高的拉伸比的拉伸下。
2.权利要求1的方法,其中所述聚合物组合物包含弹性体半结晶聚烯烃、弹性体嵌段共聚物或其组合。
3.权利要求2的方法,其中所述半结晶聚烯烃是乙烯/α-烯烃共聚物、丙烯/α-烯烃共聚物或其组合。
4.权利要求2的方法,其中所述半结晶聚烯烃是单一活性点催化的。
5.前述权利要求中的任意一项的方法,其中所述拉伸比是约2.5-约7.0,和优选是约3.0-约5.5。
6.前述权利要求中的任意一项的方法,其中所述弹性膜是在通过所述辊隙前拉伸的。
7.前述权利要求中的任意一项的方法,其中所述弹性膜还是在横向的拉伸下。
8.前述权利要求中的任意一项的方法,其中所述孔的至少一个具有约350-约4000微米的长度。
9.前述权利要求中的任意一项的方法,其中所述辊是具有突起的粘合部件的刻花的。
10.权利要求9方法,其中所述粘合部件中的至少一个相对于纵向取向约30°-约150°,和优选相对于纵向取向约45°-约135°。
11.前述权利要求中的任意一项的方法,其中所述辊隙是在两个辊之间形成的。
12.权利要求11方法,其中所述辊中的至少一个被加热至约50℃-约160℃的表面温度,和优选约70℃-约120℃的表面温度。
13.权利要求11或12的方法,其中在辊隙处施加约75-约600磅每线性英寸的压力,和优选在辊隙处施加约120-约200磅每线性英寸的压力。
14.前述权利要求中的任意一项的方法,其中所述非织造网材料包含纺粘纤维、熔喷纤维、短纤维或其组合。
15.前述权利要求中的任意一项的方法,其中所述非织造网材料的聚合物是聚烯烃。
16.前述权利要求中的任意一项的方法,其中所述至少一个分离的粘合点是在所述膜和所述非织造网材料之间形成的,其位于接近由至少一个所述孔限定的周界的位置。
17.前述权利要求中的任意一项的方法,其中所述非织造网材料在熔合于所述膜后通常是无孔的。
18.前述权利要求中的任意一项的方法,进一步包括允许所述复合材料在卷绕到辊上之前或期间在纵向上收缩。
19.根据前述权利要求中的任意一项的方法制备的非织造复合材料。
20.权利要求19的非织造复合材料,其中所述弹性膜设置在所述非织造网材料和附加的非织造网材料之间。
21.权利要求19或20的非织造复合材料,其中所述孔的至少一个位于直接相邻于分别的非织造网材料的第一和第二区域,所述第一和第二区域是液体可渗透的。
22.权利要求19-21中的任意一项的非织造复合材料,其中所述复合材料在纵向上是弹性的。
23.吸收制品,包括外罩层、连接至所述外罩层的体侧衬里、和设置于所述外罩层和所述体侧衬里之间的吸收芯,其中所述吸收制品包括权利要求19-22中的任意一项的非织造复合材料。
24.权利要求23的吸收制品,其中所述外罩层、所述衬里和吸收芯形成底盘,至少所述底盘的部分包含非织造复合材料。
25.权利要求24的吸收制品,其中所述体侧衬里包含非织造复合材料。
26.权利要求24的吸收制品,其中所述底盘进一步包含浪涌层,该浪涌层包括非织造复合材料。
27.权利要求23的吸收制品,进一步包含包括非织造复合材料的腰带、腿部束带或其两者。
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Also Published As
Publication number | Publication date |
---|---|
CN101511579B (zh) | 2013-08-14 |
AU2007290942B2 (en) | 2011-09-08 |
KR101386800B1 (ko) | 2014-04-21 |
AR062608A1 (es) | 2008-11-19 |
BRPI0715910A2 (pt) | 2013-03-26 |
US20080132866A1 (en) | 2008-06-05 |
US8361913B2 (en) | 2013-01-29 |
CN103434239B (zh) | 2015-11-18 |
RU2009111401A (ru) | 2010-10-10 |
EP2064052A2 (en) | 2009-06-03 |
US9011625B2 (en) | 2015-04-21 |
WO2008026106A2 (en) | 2008-03-06 |
US20080095978A1 (en) | 2008-04-24 |
MX2009002160A (es) | 2009-03-11 |
BRPI0715910B1 (pt) | 2018-10-09 |
EP2064052B1 (en) | 2011-10-26 |
WO2008026106A3 (en) | 2008-07-03 |
AU2007290942A1 (en) | 2008-03-06 |
CN103434239A (zh) | 2013-12-11 |
KR20090045293A (ko) | 2009-05-07 |
US20130126070A1 (en) | 2013-05-23 |
US7803244B2 (en) | 2010-09-28 |
RU2439223C2 (ru) | 2012-01-10 |
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