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CN1155470C - 可弹性伸缩的复合薄片的制造方法 - Google Patents

可弹性伸缩的复合薄片的制造方法 Download PDF

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CN1155470C
CN1155470C CNB001240609A CN00124060A CN1155470C CN 1155470 C CN1155470 C CN 1155470C CN B001240609 A CNB001240609 A CN B001240609A CN 00124060 A CN00124060 A CN 00124060A CN 1155470 C CN1155470 C CN 1155470C
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小林利夫
石川秀行
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Unicharm Corp
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Abstract

一种坪量比较小的可弹性伸缩的复合薄片的制造方法，使可弹性收缩的第2网层叠在由可伸长的第1连续纤维(35)组成的第1网(41)上，使第1、2网(41、42)间断地接合后得到的使第1复合网(43)延伸，以便第1连续纤维(35)边塑性变形边拉伸，然后使该网(43)弹性收缩，获得第2复合网(44)。

Description

可弹性伸缩的复合薄片的制造方法
技术领域
本发明涉及可弹性伸缩的复合薄片，更详细地说涉及在一次性尿布、生理用卫生巾，一次性医疗用外衣等中使用的与皮肤接触令人感到舒适的复合薄片的制造方法。
背景技术
在日本专利特公平7-37703公报中公开的无纺弹性薄片的制造方法中，使连续供给的弹性网沿供给方向伸长，在其表面上放置纤维网，通过使利用加热和超声波把两个网结合后的纤维网收缩，使纤维网形成褶裥。所获得的无纺弹性薄片因弹性网的存在而具有伸缩性，因纤维网的存在而具有柔软感，可以作为一次性尿布、生理用卫生巾的顶片材料使用。
在上述公知的方法中，把纤维网供给伸长状态的弹性网，在两网结合后使弹性网收缩，所以使获得的复合薄片中的纤维网的坪量也比供给该网时的坪量大。这样，在上述公知的方法存在不能使复合网中的纤维网的坪量与纤维供给时的坪量相同的困难。
发明内容
本发明的任务是要克服上述公知方法的困难，即提供一种能使可弹性伸缩的复合薄片中的纤维网的坪量与供给时的坪量几乎相同的可弹性收缩的复合薄片的制造方法。
为了解决上述课题，本发明的前提是一种制造复合薄片的方法，该方法使由热塑性合成纤维组成并在一个方向能非弹性伸长的第1网与由热塑性合成树脂组成并至少在上述一个方向可弹性伸缩的第2网的至少一个面接合，从而制造成复合薄片，使其沿上述一个方向具有弹性伸缩性。
在这个前提的基础上，作为本发明的特征在于，使用至少具有70％的断裂延伸率的可延伸的连续纤维作为上述第1网的合成纤维；使用其断裂延伸率比第1网的断裂延伸率高的可延伸的连续纤维作为上述第2网；
用包含下述的工序接合所述第1、2网制成上述可弹性伸缩的复合薄片，这些工序包括：
a.沿上述一个方向连续供给上述第1网的工序；
b.沿上述一个方向连续供给上述第2网，并使其与上述第1网叠合的工序；
c.使叠合一起的上述第1、2网在上述一个方向和对于该方向垂直方向中的至少一个上述方向间断配置的接合工序；
d.使接合后的上述第1、2网沿上述一个方向与垂直方向中的至少一个上述方向延伸的工序，而延伸要在上述第2网的弹性极限内和上述第1网的断裂延伸率范围内进行。
e.使延伸后的上述第1、2网弹性收缩后，获得上述复合薄片的工序。
本发明有几个优选的方式。
(1)上述第2网是可弹性伸缩的无纺布、纺织布、伸缩性薄膜中的任何之一。
(2)所述第2网是由可弹性伸缩的纱组成。
(3)所述第2网是由熔喷纤维组成。
(4)所述第1网是由熔喷纤维组成。
(5)在上述工序d中，在使上述第2网弹性延伸的同时，使上述第1网的合成纤维伸长并使其在它的长度方向塑性变形。
(6)在上述工序d中，在除上述工序c中的与第2网接合的部位之外，使上述第2网的合成纤维相互间的熔接分离。
(7)通过热熔接、超声波熔接、针刺、高压水柱处理中的任何一种使第1、2网接合。
(8)使上述第1网接合在上述第2网的两面上。
(9)接合在上述第2网两面上的上述第1网各自的坪量、使用纤维和外观中的任何一个都互相不同。
附图说明
图1是可弹性伸缩的复合薄片的斜视图。
图2是复合薄片的制造工序图。
图3是与图2不同方式的复合薄片的制造工序图。
具体实施方式
下面，结合附图详细说明本发明可弹性伸缩的复合薄片制造方法。
在图1中，以斜视图表示的可弹性伸缩的复合薄片1具有上层2和下层3，这两个层2、3在接合部4熔接形成一体。复合薄片1沿互相垂直的双头箭头X-X，Y-Y中的至少Y-Y方向如假想线所示的那样可弹性地伸缩。
复合薄片1的上层2是沿X-X，Y-Y中的至少Y-Y方向可非弹性伸长的层。该上层2是热塑性合成树脂的连续纤维6的集合体，优选的是，只在接合部4使纤维之间互相熔接，而在接合部4之间使纤维互相不接合。在接合部4以外的部分，连续纤维6边描绘不规则的曲线边在下层3的上面扩展。在复合薄片1沿Y-Y方向和/或X-X方向伸长时改变方向，以使对应该伸长而画曲线的连续纤维6在接合部4与4之间沿Y-Y方向延伸，上层2非弹性地伸长。在这个连续纤维6上具有由聚丙烯、聚酯和聚乙烯等合成树脂组成的材料。
复合薄片1的下层3是沿Y-Y方向最好是在沿Y-Y方向和X-X方向具有弹性收缩性的薄片，沿Y-Y方向至少可伸长200％，最好可伸长400％，在伸长100％后可弹性收缩到原长度的1.3倍以内。在该薄片上有由弹性纱组成的棉网(カ—ドウエブ)，由弹性纱组成的热结合无纺布和粘胶纤维无纺布(スパンレ—ス不织物)等无纺布、由弹性纱组成的纺织布，由热塑性弹性材料组成的薄膜等。
除了通过在接合部4上加热加压使这两个上层2和下层3成一体之外，还可以用超声波处理成一体。而在使上层2的连续纤维6与下层3的组织机械地缠绕而使两者成一体的情况下，可以采用针刺、高压柱状水流处理作为用于缠绕的手段。优选的是，接合部位4的各个面积在0.03～10mm2的范围内，占复合薄片1的面积的比率在1～50％的范围内。
当该复合薄片1沿例如Y-Y方向延伸时，下层3朝向Y-Y方向弹性地延伸，随着该伸长而描绘曲线的上层2的连续纤维6边改变走向边向Y-Y方向非弹性伸长。延伸复合薄片1所需要的力是主要用于延伸下层3的力，因为上层2只改变连续纤维的走向，所以对复合薄片1的拉伸力几乎不产生影响。在使下层3弹性变形的同时延伸复合薄片1时，描绘曲线的连续纤维6在与下层3成一体的接合部分4与4之间成直线形成延伸。为了延伸变成这种状态的复合薄片1，延伸下层3的力和延伸直线状的连续纤维6的力是必要的。
图2是表示复合薄片1的制造工序的示例图。在图中环状传送带30从左向右移动。在图的左部分，在传送带30的上方设置第1熔喷纤维成形机31，在传送带30的下方设置吸入机构31A，第1成形机31有多个在传送带30的横方向排列的喷嘴，使由非伸缩性的热塑性合成树脂组成的第1熔喷连续纤维35基本上以不延伸的状态从这些喷嘴喷出，在传送带30的上面边描绘不规则的曲线边堆积，边形成第1网41。选择第1成形机31的喷射条件和皮带30的移动条件，以使在第1网41上堆积层叠的第1连续纤维35相互之间不熔接并且即使已熔接在后面的工序中也能容易分开。这个未伸长的第1连续纤维35至少具有70％的断裂延伸率。
第1成形机31的右方设置第2熔喷纤维成形机32和吸入机构32A。第2成形机32也具有多个在沿传送带纵向排列的喷嘴，由可弹性伸缩的热塑性合成树脂组成的第2熔喷连续纤维40从这些喷嘴中喷出，在第1网31的上面边描绘不规则的曲线，边堆积从而形成第2网42。堆积层叠的第2连续纤维40之间互相熔接，为了使第2网42沿传送带30的运行方向，优选的是为了沿该运行方向与该运行方向相垂直的方向具有可弹性伸缩性能，而选择第2成形机的喷射条件。这个第2连续纤维40的断裂延伸率比第1连续纤维35高。
重叠的第1、2网41、42通过上下一对的压纹辊34、34之间，并在这些网41、42的行进方向即纵向和与该纵向垂直的横向中的至少纵向被间断地加压加热，互相熔接，形成第1复合网43。
第1复合网43通过延伸用的第1、2、3辊36、37、38。虽然第1、3辊36、38的转动速度相同，但比第2辊37的转动速度慢。设定第1辊36与第2辊37的转动速度差，以使第1复合网43在10～60℃，更优选的是在15～40℃的室温附近延伸到所需的倍率。延伸后的第1复合网43在第2辊37与第3辊38之间弹性地收缩到原来的长度后形成第2复合网44。
第1复合网43延伸时，在用压纹辊34熔接的部位与部位之间，第1连续纤维35在其断裂延伸率以内的范围延伸。沿其长度方向塑性变形，尺寸伸长，直径变细。由第2连续纤维40组成的第2复合网42在熔接的部位与部位之间，在第2连续纤维40的弹性极限内弹性地伸长。在这个延伸过程中，除了用压纹辊34熔接的部位外，在形成第1网41的第1连续纤维35相互之间的熔接和机械的缠绕基本上消除，另外最好还能基本上消除第1连续纤维35与第2网42的熔接。第1复合网43的优选延伸率是50～300％。
将第2复合网44卷成卷，然后裁剪成适当的尺寸成为复合薄片1。第2复合网44中的第1网41和第2网42成为图1的复合薄片1的上层2和下层3。在第2复合网44用压纹辊34熔接的部分变成为复合薄片1的接合部4。
在该工序中，所谓第1连续纤维35以基本上未伸长状态喷射是意味着：因该第1连续纤维35在几乎或完全没有伸长的状态下喷射在传送带30上，然后在后面的工序中处在10～60℃，更优选的是在15～40℃的室温附近边塑性变形边伸长而得到的状态。第1连续纤维35若是未延伸纱，则在室温附近也能容易地延伸。但如果用延伸的纱代替未延伸的纱，则使用至少具有70％断裂拉伸率延伸纱，才能实施本发明。
在把这样获得的第2复合网44即复合薄片1使用在一次性穿用物品上时，即使在第2网42中含有橡胶性质材料，如果使用时因第1网41与皮肤接触，则也不会因橡胶性质材料特有的对皮肤打滑的不良特性而刺激皮肤。由于第1连续纤维35伸长后直径变细，所以比喷射后的连续纤维35柔软，皮肤触感良好。第2复合网44的第1连续纤维35如在除压纹加工的接合部分4之外的连续纤维35相互之间也不熔接，在与第2网42也没有熔接的情况下，使第2复合网44延伸时的初始力是只使第2网42延伸的比较小的力就够了。这样，第2复合网44即使由上下2层组成，但也成为伸缩容易的柔软层。如果是图示例的工序，则第2复合网44中的第1、2网41、42的各自的坪量变成从各成形机31、32喷射出时的原来的坪量，另外，因为第1、2网41、42可以是纤维材料集合体，所以由它们获得的第2复合网44具有良好的透气性能。
在实施本发明时，可以对图2的工序进行各种各样的改变。例如可以使第2网42先于第1网41供给传送带30，为了使第1、2网41、42接合，可以采用针刺和高压柱状水流处理等手段代替压纹辊34。另外，也可以在第2成形机32的下游侧设置第3成形机，用从该成形机喷射出的非伸缩性的第3熔喷的连续纤维在第2网42上形成与第1网41相同的第3网，也能制造由第1、2网41、42和第3网组成的三层结构的复合薄片1。第1网41和第3网即使相同也可以，树脂的种类和纤度、色泽等外观也可以不同。
图3是与表示本发明的实施方式例的图2相同的工序图。在这例中，把由热塑性弹性材料组成的并在传送带的行进方向具有弹性伸缩的薄膜52作为第2网42从图中的左方供给，在该薄膜52上，供给由第1连续纤维35组成的第1网41。在第1、2网41、42与图2相同通过压纹辊34、34之间，间断地熔接后形成第1复合网43，进而被第1～3辊36、37、38延伸后收缩，形成第2复合网44。这样，在采用薄膜52状态的第2网42上使第1网41熔接形成图1的接合部4时，因为第1网41由连续纤维35形成，该接合部4的各个面积即使小到例如0.03～1mm2左右，即使各个面积的总和小到变成第2复合网44的表面积的1～10％左右，第1、2网41、42也不能简单地分开。但是在本发明中，根据需要可以使接合部4的面积在0.03～10mm2的范围内变化，其面积总和在第2复合网44的表面积的1～50％范围内变化。
用本发明的方法获得的复合薄片1，由于伸缩容易纤维密度均匀、与皮肤接触感良好，所以适合作为一次性尿布、生理用卫生巾、一次性短内裤、一次性医疗用外衣等使用的布质和弹性材料。
按照本发明的弹性伸缩性复合薄片的制造方法，因为对弹性伸缩性网，该网处在非伸长状态时，叠合伸长性的纤维，所以与现有技术相比，可以使复合薄片中的纤维网的坪量减少。
复合薄片通过在制造过程中一次延伸，除使构成纤维网的纤维塑性变形，使直径变细并伸长之外，还可以消除纤维网的纤维相互之间的熔接和缠绕、纤维网与可弹性伸缩性网的熔接，因此使该复合薄片延伸的所需要的初始力是仅使弹性伸缩性网延伸的比较小的力就足以，使复合薄片成为容易伸缩并与皮肤接触良好的网。

Claims (10)

1.一种制造复合薄片的方法，该方法使由热塑性合成纤维组成并在一个方向非弹性伸长的第1网与由热塑性合成树脂组成并至少在上述一个方向可弹性伸缩的第2网的至少一个面接合从而制造复合薄片，使其沿上述一方向具有弹性伸缩性，其特征在于：
使用至少具有70％的断裂延伸率的可延伸的连续纤维作为上述第1网的合成纤维；
使用断裂延伸率比第1网的断裂延伸率高的网作为上述第2网；
包含下述的工序接合所述第1、2网得到上述弹性伸缩性的复合薄片，这些工序是：
a.沿上述一个方向连续供给上述第1网的工序；
b.沿上述一个方向连续供给上述第2网并使其与上述第1网叠合的工序；
c.使叠合了的上述第1、2网在上述一方向和与对于该方向的垂直方向中的至少一个上述方向间断地接合的工序；
d.使接合后的上述第1、2网，在上述第2网的弹性极限内和上述第1网的断裂延伸率以下范围，沿上述方向和垂直方向中的至少一个上述方向延伸的工序；
e.使延伸后的上述第1、2网弹性收缩后，获得上述复合薄片的工序。
2.如权利要求1所述的方法，其特征在于：上述第2网是可弹性伸缩的无纺布、纺织布、薄膜中的任何之一。
3.如权利要求1所述的方法，其特征在于：所述第2网是由可弹性伸缩的纱组成。
4.如权利要求1～3中任一项所述的方法，其特征在于：所述第2网是由熔喷纤维组成。
5.如权利要求1～3中任一项所述的方法，其特征在于：所述第1网是由熔喷纤维组成。
6.如权利要求1～3中任一项所述的方法，其特征在于：在上述工序d中，在使上述第2网弹性延伸的同时，使上述第1网的合成纤维伸长并使其在它的长度方向塑性变形。
7.如权利要求1～3中任一项所述的方法，其特征在于：在上述工序d中，在除上述工序c中的与第2网接合的部位之外，使上述第1网的合成纤维相互间的熔接分离。
8.如权利要求1～3中任一项所述的方法，其特征在于：通过热熔接、超声波熔接、针刺、高压水柱处理中的任何一种使上述第1、2网接合。
9.如权利要求1～3中任一项所述的方法，其特征在于：使上述第1网接合在上述第2网的两面上。
10.如权利要求9所述的方法，其特征在于：接合在上述第2网两面上的上述第1网的各自坪量、使用纤维和外观中的任何一个都互相不同。
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