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CN1612719A - 包括电磁粘合的一次性吸收制品及制造该粘合的方法 - Google Patents

包括电磁粘合的一次性吸收制品及制造该粘合的方法 Download PDF

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Publication number
CN1612719A
CN1612719A CNA028269349A CN02826934A CN1612719A CN 1612719 A CN1612719 A CN 1612719A CN A028269349 A CNA028269349 A CN A028269349A CN 02826934 A CN02826934 A CN 02826934A CN 1612719 A CN1612719 A CN 1612719A
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component
receptor
article
electromagnetic field
mhz
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CNA028269349A
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Inventor
约翰·J·安斯塔特
弗雷德里克·W·吉布森
布拉德利·E·沃尔什
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Procter and Gamble Ltd
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Procter and Gamble Ltd
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Publication of CN1612719A publication Critical patent/CN1612719A/zh
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS 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
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/15577—Apparatus or processes for manufacturing
    • A61F13/15707—Mechanical treatment, e.g. notching, twisting, compressing, shaping
    • A61F13/15739—Sealing, e.g. involving cutting
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS 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
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/15577—Apparatus or processes for manufacturing
    • A61F13/15756—Applying tabs, strips, tapes, loops; Knotting the ends of pads
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明公开了包括应用电磁场获得的至少一个熔合粘合的一次性吸收制品和制造该熔合粘合的方法。该制品包括第一组件、第一组件下面的第二组件和第二组件下面的第三组件。熔合粘合被设置在第三组件的正上方并将第一组件粘合到第二组件。熔合粘合包括易受电磁场影响的受体。制品的第一组件的外表面至少包括一个设置在熔合粘合正上方的受体。受体区域的触觉性能基本等同于围绕受体区域的外表面的触觉性能。

Description

包括电磁粘合的一次性吸收制品及制造该粘合的方法
技术领域
本发明涉及包括应用电磁场获得的熔合粘合的一次性吸收制品和制造该熔合粘合的方法。
背景技术
包括婴儿尿布、婴儿套穿尿布、成人失禁制品和妇女卫生制品的一次性吸收制品是为人熟知的制品，这些制品用于吸收和容纳身体排泄物。典型地，通过连接或粘合制品的组件从而在高速生产线上生产这些制品，所述连接或粘合采用粘合剂或非粘合剂粘合方法，如超声键合、压力粘合或热粘合。
当单一类型的粘合不足以提供所期望的有益效果时，典型地使用上述粘合方法的组合。例如，对于在穿戴一次性吸收制品的过程中，粘合承受长期的且基本上为延伸性的力的区域，典型的粘合剂不能足以在一段时间内维持该粘合，这是因为制造一次性吸收制品过程中所使用的典型的粘合剂会发生蠕变，即失去其固体粘合形状，其连接制品的相邻表面，并在长期的延伸力作用下被拉伸，从而允许被粘合表面从其初始粘合位置处分离。这导致粘合被部分或完全地破坏。为防止这种情况的发生，典型地采用溶融粘合来强化该粘合剂粘合，熔合粘合如超声键合、压力粘合或热粘合通过使接触表面相互熔入来提供接触表面的直接熔合。
但是，由超声键合、压力粘合或热粘合所产生的熔合粘合会影响被粘合组件的外表面。例如，超声键合典型地采用与被粘合材料的外表面直接物理接触的超声振动工具来提供，因此，在这些外表面上留下了工具印痕。这些印痕可具有坚硬粗糙的隆起，其会刺激皮肤。此外，压力粘合使用应用于被粘合材料外表面上的压缩工具来提供在被相互粘合的内表面之间的压力和速度差，因此，这会在外表面上产生坚硬粗糙的隆起。另外，热粘合通常使用插入被粘合材料外表面的热工具来提供足以熔化内表面使其相互粘合的热能。这些热工具也会在被粘合材料外表面上产生坚硬粗糙的隆起。
对于多孔材料的粘合，热粘合可以不采用热插工具，而是利用热空气，例如由EP 0 844 062 A1所公开的，将热空气应用于材料的外表面并透入多孔材料从而加热和熔化材料的内表面使其相互粘合。但是，内表面之间的接触是通过外表面的直接物理接触从外表面压缩材料来完成的。虽然上述热空气方法为被粘合材料的外表面提供了增强的触觉特性，但是压缩工具仍对外表面具有负面影响，因为外表面受到进入被粘合材料的热空气加热，会产生不可取的印痕和硬化区域。
在其它例子中，在已装配选择的层之间或一次性吸收制品提供熔合粘合而不影响制品的其它层是可取的。例如，可取的是在邻近一次性吸收制品的吸收芯的材料层之间提供熔合粘合，而不会将芯材粘合到制品的其它层上，并且对芯材自身没有负面影响。(但应当注意的是，在某些情况下，以某种积极的方式影响芯材来获得芯材或制品的改进性能是可取的。)
熔合粘合的实施例包括将制品的较长的弹性化的侧片(也被称为侧连接件或耳部)粘合到制品的外壳上来获取围绕穿着者躯干固定制品时的更大弹性。通常，侧片在芯材区域的外面进行粘合，邻近制品的纵向边缘，这限制了侧片从制品的纵向边缘横向延伸的长度。结果，侧片被限制的长度通常限制了侧片的弹性程度。但是，更长且更大弹性的侧片将会需要侧片延伸进芯材区域，且需要侧片在芯材的正上方熔合粘合到制品的外壳上。通过使用超声键合、压力粘合或热粘合来提供这些熔合粘合将不仅使芯材粘合到制品的其它材料上，还会由于对芯材内部材料的粘合而影响吸收芯自身。基于几个问题，这是不可取的。对芯材内部材料的粘合会破坏芯材，抑制了芯材在其内部吸收和分散身体渗出物方面的所需性能。对于在制品的吸收芯和和外壳之间的熔合粘合，问题包括被芯材吸收的身体渗出物经由外壳上的孔渗漏，这些孔是在把外壳粘合到芯材的过程中产生的。此外，熔合粘合通常比较柔韧的粘合剂粘合更为刚硬，因此，把吸收芯熔合粘合到外壳上也会使制品的刚性增加，并包括芯材自身的刚性。这会在提供制品围绕穿着者身体的柔韧性和贴合性方面产生问题。
因此，提供具有采用熔合粘合方法被粘合在一起的组件或材料的一次性吸收制品，能够承受长期的延伸力而不发生蠕变，其中这些材料的外表面具有所期望的触觉性能，其最低程度地受到或基本不受被粘合材料内部的熔合粘合的影响将是有益的。此外，提供在一次性吸收制品的相邻组件或材料之间具有熔合粘合的一次性吸收制品，能够承受长期的延伸力而不发生蠕变，并且不会反向影响制品的其它组件或材料，如吸收芯将是有益的。另外，提供具有在制品的相邻组件或材料之间，被设置在制品的吸收芯正上方的熔合粘合的一次性吸收制品，其中吸收芯没有被熔合粘合到其上方的材料上将是有益的。另外，提供用于制造这种一次性吸收制品的粘合方法将是有益的。另外，这种粘合方法适用于多孔和无孔材料的熔合粘合将是有益的。而且，提供可应用于一次性吸收制品的高速生产的粘合方法将是有益的。
发明内容
针对上文所讨论的难点和问题，已发现了新的改进的一次性吸收制品和制造这种制品的方法。
在另一方面，本发明涉及一次性吸收制品，该制品包括第一组件、第一组件下面的第二组件和第二组件下面的第三组件。该制品还包括设置在第三组件正上方并且至少部分地将第一组件粘合到第二组件的至少一个熔合粘合。该熔合粘合包括易受电磁场影响的受体，其中所述受体可以有助于或无助于熔合粘合。
在另一方面，本发明涉及上文所述的一次性吸收制品，其中制品的第一组件具有外表面，该外表面包括设置在熔合粘合正上方的至少一个受体区域。受体区域具有的触觉性能基本等同于围绕受体区域的外表面的触觉性能。
在又一方面，本发明涉及粘合一次性吸收制品组件的方法，该方法包括提供一次性吸收制品的步骤，该制品包括第一组件、第一组件下面的第二组件、第二组件下面的第三组件，和易受电磁场影响的受体；受体被设置在第一组件和第二组件之间，其中第一组件和第二组件通过受体至少部分地接触。该方法还包括将受体暴露于电磁场中一段时间的步骤，该时间内足以加热受体从而至少部分地使第一和第二组件相互熔融和熔合。该方法还包括冷却第一和第二组件，而同时维持第一和第二组件的接触关系的步骤，从而使在第一和第二组件之间的熔合粘合凝固。
附图说明
虽然本说明书通过特别指出并清楚地要求保护主题即本发明的权利要求作出结论，但据信通过下列描述并结合附图可更充分地理解本发明，其中：
图1是可以用本发明的方法制造的本发明的一个一次性吸收制品的平面图；该制品是以平展状态显示的尿布，其中尿布的外面侧朝向观察者；
图2是图1中尿布沿剖切线2-2截取的横截面视图；
图3是在图2所示粘合区域的放大横截面视图；
图4是本发明的方法的一个实施方案的横截面视图，该实施方案用于在本发明的一次性制品中产生熔合粘合。
具体实施方式
本发明涉及具有熔合粘合的一次性吸收制品，其通过使制品受电磁场的作用来连接制品的两个或多个组件或材料。
本文所用术语“吸收制品”是指如婴儿游泳尿布、套穿尿布、训练裤、成人失禁制品、妇女卫生制品及类似制品的装置，其紧贴或邻近穿着者的身体放置，用以吸收和容纳从体内排出的各种渗出物。
本文所用术语“一次性的”用于描述通常不打算洗涤、复原或作为吸收制品再使用的吸收制品(即，它们设计在一次性使用后丢弃，优选将其回收利用、堆肥处理或以其它环境相容的方式进行处理)。
为了便于理解，与一次性吸收制品有关的一些下列描述将根据图1所示尿布10来进行，该尿布处于平展未收缩状态，具有朝向观察者一个外覆盖物或外壳，也如图2中沿图1的线2-2截取的横截面图所示。如图1所示，尿布20优选地包括液体不可透过的外壳12；液体可透过的内壳14；优选位于外壳12的至少一部分和内壳14之间的吸收芯16；腰部组件18；腿箍20；紧固件22和侧片24。图1所示尿布10具有前腰区30、与前腰区30相对的后腰区32和位于前腰区30和后腰区32之间的裆区34。本发明的实施方案也可包括用于接收和容纳废物的袋、为废物提供空间的间隔材料、用于限制制品中废物移动的屏障、接受和容纳沉积于尿布10内的废物的隔室或空隙，及类似物或它们的任意组合。
通常被称为底片的外壳12优选是液体(即，尿液)不能透过的，并且包括一张薄塑料薄膜，如厚度为约0.012mm(0.5mil)至约0.051mm(2.0mils)的热塑性薄膜。适当的外壳薄膜包括由位于Terre Haute，IN的TredegarIndustries Inc.生产并以商品名X15306、X10962和X10964销售的那些薄膜。其它适当的外壳材料可包括透气材料，其允许水汽逸出尿布10而同时防止渗出物透过外壳12。示例性透气材料可包括如下材料，例如：纺织网、无纺织网、例如膜包衣无纺织网的复合材料、例如由Japan的Mitsui Toatsu Co.生产以ESPOIR NO命名和由Bay City，TX的Exxon Chemical Co.生产以EXXAIRE命名的微孔薄膜，和例如由Cincinnati，OH的Clopay Corporation生产，商品名为HYTREL混合物P18-3097的单体薄膜。一些透气复合材料更为详细地描述于如下专利中：申请人为E.I.DuPont的公布于1995年6月22日的PCT申请WO 95/16746、1999年8月17日公布的授予LaVon等人的美国专利5,938,648、1999年2月2日公布的申请人为Curro的美国专利5,865,823、1996年11月5日授予Dobrin等人的美国专利5,571,096。所有这些参考文献都引入本文以供参考。
外壳12或其任意部分可以在一个或多个方向上弹性延展。在一个实施方案中，外壳12可包括结构性类弹性薄膜(“SELF”)纤维网。结构性类弹性薄膜纤维网是一种可延展材料，不使用添加的弹性材料，在材料的伸长方向显示具有类弹性性能，在1996年5月21日授予Chappell等人的名为“WebMaterials Exhibiting Elastic-Like Behavior”的美国专利5,518,801中对其有详细说明。该专利引入本文以供参考。在可供选择的实施方案中，外壳12可包括弹性体薄膜、泡沫、线或它们的组合或其它与无纺材料或合成薄膜相关的适当材料。
参见图1-3，其中图3为图2所示熔合粘合50的放大横截面视图，在本发明的优选实施方案中，外壳12包括两层层压结构，该结构包括薄膜层46和无纺层48。外壳12优选地不易受电磁场影响。本文所用术语“不易受电磁场影响”是指在暴露于电磁场的过程中不会被加热或化学活化的任意材料或物质。下文中对该术语进行了更详细的描述。
通过使用本领域所知的联接方法，外壳12可被连接到内壳14和吸收芯16上。(本文所用术语“连接”包括通过将组件直接附加到其它组件上而将组件直接固定到另一个组件的构型，和通过将组件附加到中间组件，中间组件依次附加到其它组件上而将一个组件间接地固定到另一个组件的构型。)例如，联接方法可包括使用均匀连续的粘合剂层或图案形粘合剂层或一排分离线形、螺旋状或点状粘合剂。一个优选的联接方法包括使用粘合剂长丝的开放式图案网络，如美国专利4,573,986所公开，该专利名称为“Disposable Waste-Containment Garment”，于1986年3月4日授予Minetola等人。其它的适当联接方法包括使用多行扭转成螺旋形图案的粘合剂长丝，如在以下专利中的设备和方法所说明的：1975年10月7日授予Sprague，Jr.的美国专利3,911,173、1978年11月22日授予Ziecker等人的美国专利4,785,996、和1989年6月27日授予Werenicz的美国专利4,842,666。这些专利均被引入本文以供参考。已发现的满意的粘合剂为由位于St.Paul，Minnesota的H.B.Fuller Company制造并以HL-1620和HL-1358-XZP商品名销售的产品。可供选择地，联接方法可包括热粘合、压力粘合、超声键合、动态机械粘合或者本领域所知的任何其它合适的联接方法或这些联接方法的组合。
内壳14，其通常被称为顶片，优选地邻近吸收芯16的身体表面26设置，并可通过本领域所知的任意联接方法被连接到外壳12。上文描述了关于用于将外壳12连接到内壳14和芯材16上的方法的适当联接方法。在本发明的一个优选实施方案中，通过将内壳14和外壳12连接到尿布10的一个或多个其它组件，内壳14和外壳12在一些位置上被相互直接连接，在其它位置上被直接连接到一起。
内壳14优选为柔顺的、感觉柔软的，并且对穿着者的皮肤无刺激。另外，内壳14的至少一部分为液体可透过的，使液体易于穿过其厚度。适合的内壳可由多种材料制成，如多孔泡沫、蜂窝状泡沫、有孔塑料膜、或天然纤维(例如木纤维或棉纤维)、合成纤维(例如，聚酯纤维或聚丙稀纤维)或者天然纤维与合成纤维的组合的纺织材料或无纺材料。
吸收芯16可包括任何吸收材料，该材料通常是可压缩的、适形的，对穿着者的皮肤无刺激，并能吸收和存储液体如尿液和其它的某些身体排泄物。采用与上文所述将外壳12连接到内壳14的粘合剂粘合方法相关的任意适当粘合剂粘合方法，吸收芯16可被优选地连接到外壳12和内壳14。吸收芯16可制成多种多样的尺寸和形状(例如矩形、沙漏形、“T”形、不对称形等)，并可包括各种各样的通常用于一次性尿布和其它吸收制品的液体吸收材料，例如粉碎的木浆，这种木浆一般是指透气毡。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。用作吸收芯16的示例性吸收结构描述于下列专利：名称为“High-Density Absorbent Structures”，1986年9月9日授予Weisman等人的美国专利4,610,678；名称为“Absorbent Articles With Dual-LayeredCores”，1987年6月16日授予Weisman等人的美国专利4,673,402；名称为“High Density Absorbent Members Having Lower Density and Lower BasisWeight Acquisition Zones”，1989年5月30日授予Alemany等人的美国专利4,834,735；名称为“Absorbent Core Having A Dusting Layer”，1989年10月19日授予Angstadt的美国专利4,888,231；名称为“Absorbent StructureContaining Individualized，Polycarboxylic Acid Crosslinked Wood PulpCellulose Fibers”，1992年8月11日授予Herron等人的美国专利5,137,537；名称为“High Efficiency Absorbent Articles For Incontinence Management”，1992年9月15日授予Young等人的美国专利5,147,345；名称为“DisposableAbsorbent Article For Low-Viscosity Fecal Material”，1994年8月30日授予Roe的美国专利5,342,338；名称为“Absorbent Foam Materials For AqueousBody Fluids and Absorbent Articles Containing Such Materials“，1993年11月9日授予DesMarais等人的美国专利5,260,345；名称为”Thin-Until-WetAbsorbent Fosm Materials For Aqueous Body Fluids And Process For MakingSame“，1995年2月7日授予Dyer等人的美国专利5,387,207；和名称为“Absorbent Foam Materials For Aqueous Fluids Made From High Internal PhaseEmulsions Having Very High Water-To-Oil Ratios”，1997年7月22日授予DesMarais等人的美国专利5,625,222。所有这些专利都引入本文以供参考。
弹性腰部组件18有助于改善贴合性和容纳性。可采用本领域所知的任意联接方法将弹性腰部组件18连接到内壳14；适当的联接方法已在上文中与将外壳12连接到内壳14的方法相关的进行了描述。通常，弹性腰部组件18旨在弹性延伸和收缩从而动态地贴合穿着者的腰部。弹性腰部组件18可采用许多不同的构型来构成，构型包括在以下专利中所描述的构型：1985年5月7日授予Kievit等人的美国专利4,515,595；1987年12月1日授予Lash的美国专利4,710,189；1992年9月9日授予Buell的美国专利5,151,092；和1993年6月22日授予Buell的美国专利5,221,274。其它适当的腰部构型可包括腰部遮盖构件，如下列专利所描述的：1991年6月25日授予Robertson的美国专利5,026,364和1989年3月28日授予Foreman的美国专利4,816,025。所有上述提及的参考文献均引入本文以供参考。
腿箍20改善对液体和其它身体排泄物的容纳性。可采用本领域已知的任意联接方法将腿箍20连接到内壳14；适当的联接方法已在上文中与将外壳12连接到内壳14的方法相关的进行了描述。腿箍20也可被指作腿部带、侧翼、阻挡型箍或弹性箍。美国专利3,860,003描述了一次性尿布，所述尿布提供了可收缩的腿部开口，其具有侧翼和一个或多个弹性部件来提供弹性化的腿箍(衬圈箍)。分别在1989年2月28日和1990年3月20日授予Aziz等人的美国专利4,808,178和4,909,803描述了一次性尿布，所述尿布具有“直立”的弹性化的垂片(阻挡腿箍)，这改善了腿部区域的容纳性。在1987年9月22日授予Lawson的美国专利4,695,278和在1989年1月3日授予Dragoo的美国专利4,795,454描述了具有双重箍的一次性尿布，包括衬圈箍和阻挡型箍。
在构型中紧固件22优选地保持前腰区30和后腰区32来提供围绕尿布10周边的侧向张力，从而在穿着者身上固定尿布10。可采用本领域所知的任意联接方法将紧固件22连接到侧连接件24；适当的联接方法已在上文中与将外壳12连接到内壳14的方法相关的进行了描述。紧固件22可包括表面紧固件，如带片式组件、钩环紧固组件和/或雌雄同体紧固组件，当然任意其它已知的紧固部件也是可接受的。在可供选择的实施方案中，制品的相对侧面可被缝合或接合形成短裤。这使制品可用作套穿类尿布、训练短裤及类似品。
侧片24优选地为弹性的，通过最初使尿布10与穿着者贴合一致，并在整个穿用时间里，并且由于侧片24可以延伸和收缩，在尿布10装满渗出物时，很好地维持这种贴合性，侧片24可提供更舒适的轮廓帖合性。尽管本发明的尿布10优选地具在设置在后腰区32的侧片24，但尿布10可具有设置在前腰区30的侧连接件，或具有所述两者。侧片24可采用任何适当的构型来构成。具有弹性化的侧连接件的尿布的实施例公开于以下专利：名称为“Disposable Diaper Having Shirred Ears”，1989年8月15日授予Wood等人的美国专利4,857,067；1983年5月3日授予Sciaraffa等人的美国专利4,381,781；1990年7月3日授予Van Gompel等人的美国专利4,938,753；上文已作参考的1992年9月9日授予Buell的美国专利5,151,092；1993年6月22日授予Buell的美国专利5,221,274；名称为“Absorbent ArticlesProviding Sustained Dynamic Fit”，1997年9月23日授予LaVon等人的美国专利5,669,897；和名称为“Absorbent Article With Multi-Directional ExtensibleSide Panels”，1999年12月21日授予Robles等人的美国专利6,004,306,其中每个均引入本文以供参考。侧片24优选地不易受电磁场的影响。
参见图3，在本发明的优选实施方案中，侧片24包括一个三层层压结构，该结构包括设置在2个无纺层，即外层42和内层44之间的弹性薄膜40。如图3所示，外壳12的无纺层48面向侧片24的内无纺层44。但应当注意的是，无纺层44和48的相互面向，或任意其它面向的组合形式不是必需的，例如，无纺层面向薄膜或薄膜面向薄膜可被包括在本发明的范围之内。
在本发明的一个优选实施方案中，通过熔合粘合50，侧片24优选地在吸收芯16的正上方被连接到外壳12，熔合粘合50优选地没有延伸到侧片24的外表面52，从而外表面52的受体区域53的触觉性能基本等同于围绕受体区域53的外表面52的触觉性能。本文所用术语“受体区域”是指外表面52的设置在熔合粘合50正上方的一部分。本文所用术语“基本等同”是指受体区域53和外表面52上没有能通过手触摸而感觉到的粗糙的、不光滑的、刚硬隆起或裂纹。
外表面52可包括任意适当数量的受体区域53。受体区域53在x-y方向上可具有与熔合粘合50在x-y方向上的形状或构型一致的任意适当的形状或构型。例如，如果熔合粘合50在x-y方向上为圆形点，则受体区域53可以为外表面52上的圆形点；如果熔合粘合在x-y方向上为细长形状，则受体区域在x-y方向上也可以为外表面52上的细长形状。
本文所用术语“熔合粘合”是指将一种材料连接到另一种材料来获得一种材料对另一种材料的熔合。熔合可通过热互作用或化学反应来诱导。对于热互作用，待粘合材料的邻近表面被热熔融并以密切接触的方式固定直到冷却，从而形成粘合。对于化学反应，待粘合材料的邻近表面以密切接触的方式被固定，从而使活性反应组分连接界面并发生反应，形成粘合。
本文所用术语“材料”是指任意底物材料，包括薄膜、无纺材料、泡沫、稀松布、层压材料、浸渍热塑性材料的无纺材料和类似材料，及其任意组合。
图4示意说明本发明的方法58的一个实施方案的横截面图，该实施方案用于在一个或多个侧片24和一次性吸收制品10的外壳12之间制造熔合粘合50，其中熔合粘合50位于吸收芯16的正上方。如图4所示，制品10可受电磁场60的作用，电磁场60可由能产生所需电磁场60的任意适当的场源62来提供。所产生的电磁场60可处于从X射线频率段至射频段(从大于约1014MHz至小于约0.1MHz)内的电磁波频谱的任意频率段内，取决于所需熔合的类型。例如，在电磁波频谱可见频率段之上(即，沿频率增加的方向，单位为MHz，从紫外线频率段到X射线频率段)产生的电磁场60通常能制造化学熔合粘合，例如，电子束能量(X射线能量形式)可被用于促进聚乙烯内的化学反应(例如交联)。在电磁波频谱可见频率段之内和下面(即，沿频率减小的方向，单位为MHz，从可见频率段到射频段)的电磁场60通常能促进热熔合粘合。上述电磁波频谱频率段可由任意适当的商购或特别设计的能量源来提供；能量源不是本发明的一部分。
在本发明的一个实施方案中，电磁场60可通过场源62在电磁波频谱的射频段和微波频率段内产生。在射频段内，场源62可以是例如购自位于New York的Ameritherm Inc.的CODACO Cure-On-Demand粘合剂体系。射频段和微波频率段内的电磁场60的频率可在约1.0MHz至约30,000MHz范围内变化。尤其是，在射频段内的频率可在约1.0MHz至约300MHz的范围内变化；在微波频率段内的频率可在约300MHz至约30,000MHz范围内变化。优选地，基于实用考虑(例如，在特定频率范围内容易获得的能量源的成本、对于特定频率范围所需的电磁屏蔽设备，及类似考虑)，在本发明的一个优选实施方案中，在射频段内，电磁场60可在约1.0MHz至约180MHz范围内变化；在微波频率段内，电磁场60可在约300MHz至约5,000MHz范围内变化，或在约915MHz至约2,450MHz范围内变化。
在粘合用于一次性吸收制品生产的材料时，用于产生粘合用电磁场60的设备功率需求是下列因素的函数：被粘合材料的热物理性能、期望的粘合面积和期望的加工速度或暴露于电磁场的持续时间，以及在接受材料内部产生射频场的效率。
参见图4，熔合粘合50可通过使用易受电磁场60影响的受体54来获得。本文所用术语“易受电磁场影响的受体”是指在暴露于具有能获得充分的热量或化学活性的足够能量的电磁场过程中，被充分加热或化学活化的任意材料或物质。
参见图4，受体54可包括易受电磁波频谱的具体频段影响的各种材料，该具体频段取决于具体的材料性能。本文所用术语“易受电磁场影响”是指在暴露于电磁场的过程中会被影响，从而在材料内部发生热或化学反应的任意材料或物质。对于电磁波频谱的不同频段，确定其磁化率大小的基本材料性能描述于技术文献中，并为本领域的技术人员所知。受体54可以是任意适当的形式，如固体、液体、乳液、分散体、浆液、悬浮液，或它们的任意组合。
例如，在射频段内和在微波频率段内，电磁波频谱的上述频段中的材料磁化率可由基本材料性能来确定，例如具体材料的介质损耗因子(DLF)。介质损耗因子小于约0.05的材料被认为是惰性的或不易受射频段和微波频率段两者内电磁场的影响。介质损耗因子在0.05至0.10范围内变化的材料被认为是弱活性的或稍微受射频段和微波频率段两者内电磁场的影响。介质损耗因子在0.10至0.20范围内变化的材料被认为是活性的，并且对于射频段和微波频率段两者内电磁场有良好的磁化率。介质损耗因子大于0.20的材料被认为是非常活性的或非常易受射频段和微波频率段两者内电磁场的影响。
易受射频段和微波频率段影响的材料可包括例如下列材料：基于氯乙烯、1，1-二氯乙烯、乙烯醇、乙烯基酮、碳酸亚乙烯酯、乙烯基碳酸盐、乙烯基酯、酰胺、酰亚胺、酯、碳酸盐、砜、亚砜、磷酸盐、膦酸酯、聚氨酯、内酯、内酰胺、和苯氧基及其盐的聚合物；包含聚酰胺、聚酰亚胺、聚砜、聚酯、聚碳酸酯的热塑性嵌段共聚物；例如酯、醚、羧化物烷氧化物、和硝酸根及其盐的纤维素和纤维素衍生物；包含聚合物和共聚体的乙烯一氧化碳；丙烯酸盐和酸改性丙烯酸及其盐；包含烯属不饱和羧酸及其酯和其盐的烯烃；热塑性离子淀粉聚合物及其盐；蛋白质、环氧树脂；上文所述聚合物，掺入极性溶剂和增塑剂，例如，但不限于，水、甘油、双甘油、山梨醇、聚甘油以及它们的混合物；上文所述聚合物，掺入有机和无机盐，例如，但不限于，氯化钠、氯化钾、氯化铵、氯化钙、氯化锂、硬脂酸钠、醋酸锂、以及它们的组合和混合物。
在本发明的利用电磁波频谱射频段的一个实施方案中，受体54可以是在变化范围为20℃至大于170℃的温度条件下介质损耗因子大于约0.15的任意材料。在本发明的利用电磁波频谱微波段的另一个实施方案中，受体54可以是在变化范围为20℃至大于170℃的温度条件下介质损耗因子大于约0.10的任意材料。应当指出的是，本发明人选择的上述温度范围，20℃至大于170℃，是基于本发明中与受体54一起使用的优选底物材料的熔融温度；但是，取决于被粘合底物的熔融温度，可以选择任意适当的温度(高于或低于上述温度范围)。
在本发明的一个优选的实施方案中，受体54可以是任意适当的受体。例如，受体54可以是购自位于New York的Ameritherm Inc.的按需固化粘合剂之一。适当地，当受射频段和微波频率段的电磁场的作用时，受体54的活化作用时间小于约1.0秒，或小于约0.3秒，或小于约0.15秒。本文所用“活化作用时间”是指一段时间，在该段时间内，受体54受电磁场的作用。
可采用任意适当的装置将受体54提供给粘合表面，包括任何典型的热熔合粘合剂配送设备、螺旋施用装置、熔喷施用装置、珠状施用装置、和适于与例如UFD施用装置一起使用的各种喷嘴，该UFD施用装置购自位于Tennessee的I.T.W.Dynatec。
熔合粘合50没有延伸到侧片24的外表面52，从而外表面52的受体区域53的触觉性能基本等同于围绕受体区域53的外表面52的触觉性能。为提供熔合粘合50，可通过下列因素的组合来控制熔合粘合50在外壳12和侧片24内的扩展：(a)用于产生所期望频率电磁场60的功率；(b)受体54的质量；和(c)受体54受电磁场60作用的持续时间。可采用本发明的方法提供熔合粘合50，其中受体54受电磁场60作用的时间为小于约1秒，优选地小于约0.5秒，更优选地小于约0.3秒。受作用时间也可以适当地大于约0.1秒。
尽管已用具体实施方案和/或个体特征来说明和描述了本发明，但显而易见的是，本领域的技术人员可在不背离本发明的精神和保护范围的情况下作出许多其它的变化和修改。此外，应当清楚，所述实施方案和特征的所有组合均是可能的，并且可得到本发明的优选实施方案。因此，所附的权利要求书旨在包括属于本发明范围内的所有这些变化和修改。

Claims (27)

1.一次性吸收制品，其包括：
a)第一组件；
b)在所述第一组件下面的第二组件；
c)在所述第二组件下面的第三组件；和
d)设置在所述第一组件和所述第二组件之间的至少一个熔合粘合，
其特征在于
所述熔合粘合设置在所述第三组件的正上方并且至少部分地将所述第一组件粘合到所述第二组件上，所述熔合粘合包括易受电磁场影响的受体。
2.如权利要求1所述的制品，其中所述第一组件包括外表面，所述外表面包括至少一个受体区域，并且其中所述受体区域的触觉性能基本等同于所述外表面的触觉性能。
3.如前述任一项权利要求所述的制品，其中所述受体易受频率为1.0MHz至30,000MHz的所述电磁场的影响。
4.如前述任一项权利要求所述的制品，其中所述受体易受频率为1.0MHz至180MHz的所述电磁场的影响。
5.如前述任一项权利要求所述的制品，其中所述受体易受频率为300MHz至5,000MHz的所述电磁场的影响。
6.如前述任一项权利要求所述的制品，其中所述受体易受频率为915MHz至2,450MHz的所述电磁场的影响。
7.如前述任一项权利要求所述的制品，其中所述受体选自固体、液体、乳液、分散体、浆液、悬浮液以及它们的任意组合。
8.如前述任一项权利要求所述的制品，其中所述受体在20℃至170℃范围的温度条件下的介质损耗因子大于0.10。
9.如前述任一项权利要求所述的制品，其中所述受体在暴露于电磁场时的活化作用时间小于1.0秒。
10.如前述任一项权利要求所述的制品，其中所述受体在暴露于电磁场时的活化作用时间小于0.15秒。
11.如前述任一项权利要求所述的制品，其中所述第一组件是所述一次性吸收制品的侧片、侧连接件或耳部。
12.如前述任一项权利要求所述的制品，其中所述第一组件包括一层或多层选自下列的材料：薄膜、无纺材料、泡沫、稀松布、层压材料、浸渍热塑性材料的无纺材料、弹性材料，以及它们的任意组合。
13.如前述任一项权利要求所述的制品，其中所述第二组件是所述一次性吸收制品的外壳。
14.如前述任一项权利要求所述的制品，其中所述第二组件包括一层或多层选自下列的材料：薄膜、无纺材料、泡沫、稀松布、层压材料、浸渍热塑性材料的无纺材料、弹性材料以及它们的任意组合。
15.如前述任一项权利要求所述的制品，其中所述第三组件是所述一次性吸收制品的吸收芯。
16.粘合一次性吸收制品的组件的方法，所述方法包括以下步骤：
(a)提供一次性吸收制品，所述制品包括：
i.第一组件；
ii.在所述第一组件下面的第二组件；
iii.在所述第二组件下面的第三组件；和
iv.易受电磁场影响并设置在所述第一组件和所述第二组件之间的受体，
其特征在于
所述第一组件和所述第二组件通过所述受体至少部分地接触；
(b)将所述受体暴露于所述电磁场中一段时间，所述时间段应足以加热所述受体从而至少部分地使所述第一和第二组件相互熔融和熔合；和
(c)在维持所述第一和第二组件的接触关系的同时，冷却所述第一和第二组件，使在所述第一和所述第二组件之间的熔合粘合凝固。
17.如权利要求16所述的方法，其中所述受体易受频率为1.0MHz至30,000MHz的所述电磁场的影响。
18.如权利要求16所述的方法，其中所述受体易受频率为1.0MHz至180MHz的所述电磁场的影响。
19.如权利要求16所述的方法，其中所述受体易受频率为300MHz至5,000MHz的所述电磁场的影响。
20.如权利要求16所述的方法，其中所述受体易受频率为915MHz至2,450MHz的所述电磁场的影响。
21.如权利要求16所述的方法，其中所述受体在暴露于电磁场时的活化作用时间小于1.0秒。
22.如权利要求16所述的方法，其中所述受体在暴露于电磁场时的活化作用时间小于0.15秒。
23.如权利要求16所述的方法，其中所述受体选自固体、液体、乳液、分散体、浆液、悬浮液以及它们的任意组合。
24.如权利要求16所述的方法，其中所述受体在20℃至170℃范围的温度条件下的介质损耗因子大于0.10。
25.如权利要求16所述的方法，其中所述制品的第一组件是所述一次性吸收制品的侧片、侧连接件或耳部。
26.如权利要求16所述的方法，其中所述制品的第二组件是所述一次性吸收制品的外壳。
27.如权利要求16所述的方法，其中所述制品的第三组件是所述一次性吸收制品的吸收芯。
CNA028269349A 2001-12-14 2002-12-03 包括电磁粘合的一次性吸收制品及制造该粘合的方法 Pending CN1612719A (zh)

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