CN101036613B - 舒适型尿布 - Google Patents
舒适型尿布 Download PDFInfo
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- CN101036613B CN101036613B CN2007100889307A CN200710088930A CN101036613B CN 101036613 B CN101036613 B CN 101036613B CN 2007100889307 A CN2007100889307 A CN 2007100889307A CN 200710088930 A CN200710088930 A CN 200710088930A CN 101036613 B CN101036613 B CN 101036613B
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- absorbent
- thermoplastic
- diaper
- polymeric material
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Abstract
本发明涉及一种吸收制品(20),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(28)。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。该吸收芯适于提供具有增强的穿着舒适性的吸收制品。具体公开的是一种适用于由基底层和吸收材料构成的吸收制品的吸收芯,吸收材料包括吸收性聚合物材料,所述吸收材料可任选地包括吸收性纤维材料。所述吸收性纤维材料的含量不超过吸收性聚合物材料重量的20%,其中当处于润湿状态时吸收材料被固定,使得吸收芯获得依据本文所述的湿固定作用试验超过50%,优选超过60%、70%、80%或90%的湿固定作用。
Description
本申请是申请人为:宝洁公司,申请日为:2004年2月12日,申请号为:200480002691.3,名称为:舒适型尿布的发明的分案申请。
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。这种吸收芯适用于提供具有增强的穿着舒适性的吸收制品。
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。为使它们具有总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,而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,将尿布或其它吸收制品的吸收材料保持在它们的预期位置非常重要。
美国专利4,381,783(Elias)公开一种具有由多个吸收性水胶体材料小袋构成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,而且典型地由纤维素材料提供。因此,要获得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的更多吸收区域,例如水胶体材料区域。
WO 95/17868(Palumbo)公开了一种包括两个纤维层和一个中间层的吸收结构。该中间层包含含量超过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大量液体的制品时,湿固定作用不可能完全令人满意。
EP 724418(Tanzer)公开了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。该制品包含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,这种吸收结构以选择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,而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,据信这种吸收制品对处于载满或部分载有尿液状态的吸收材料没有提供非常满意的固定作用。
发明内容
本发明提供了一种适用于吸收制品的吸收芯,所述吸收制品包括基底层和吸收材料,所述吸收材料包括吸收性聚合物材料,所述吸收材料可任选地包括吸收性纤维材料,所述吸收性纤维材料的含量不超过吸收性聚合物材料重量的20%,当处于润湿状态时所述吸收材料被固定,使得所述吸收芯获得依据本文所述的湿固定作用试验超过50%、优选超过60%、70%、80%或90%的湿固定作用。
所述吸收芯还包括热塑性材料,优选地为热熔融粘合剂,所述热塑性材料与所述吸收性聚合物材料相接触。
所述热塑性材料被纤维化。
所述热塑性材料基本上固定所述吸收性聚合物。
吸收芯具有吸收性聚合物材料的分布,其中所述吸收性聚合物材料的分布呈曲线形。
所述吸收性聚合物材料在所述吸收芯的整个区域内以至少100g/m2、优选至少300g/m2的平均定量存在。
所述吸收芯包括至少两个基底层。
所述吸收芯包括至少一个基底层和至少一个覆盖层。
至少一个所述基底层或至少一个所述覆盖层包括永久亲水性无纺材料。
吸收芯具有小于80mm的裆部宽度。
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,这种制品对吸收性聚合物材料提供改进的固定作用。该吸收芯适用于提供具有增强的穿着舒适性的吸收制品。具体公开的是一种适用于吸收制品的吸收芯,所述吸收制品包括:无纺材料制成的基底层;热熔融粘合剂形式的热塑性材料的层,该热熔融粘合剂粘合到基底层上以在二者之间限定空腔;以及容纳在空腔中的吸收材料,其中所述吸收材料包括吸收性聚合物材料,以及基于吸收性聚合物材料的重量、从0到40重量百分比的吸收性纤维材料,当处于润湿状态时所述吸收材料被固定,使得所述吸收芯获得依据本文所述的湿固定作用试验超过50%的湿固定作用。
附图说明
图1是作为本发明吸收制品的一个优选实施方案的尿布20的平面图。
图2表示图1沿横向轴线110截取的横截面。
图3表示本发明的优选结构中热塑性材料部分与吸收性聚合物材料接触,而部分与基底层接触。
图4表示本发明一个可供选择的优选实施方案,其中吸收芯包括覆盖层。
图5表示沿直线设置的接合区域。
图6表示包括两个基底层的吸收芯材料。
图7表示尿布摇动器。
图8表示流变仪测量。
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,且优选地用可重复利用、可堆肥加工或以与环境相容的方式进行加工)。
“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的一个优选实施方案的尿布20的平面图。尿布以其平展未收缩状态(即,无弹性引起的紧缩)显示。该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中的尿布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的外部边缘所限定,其中纵向边缘44通常平行于尿布20的纵向轴线100延伸,而端边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紧构件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28一般设置在顶片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;超吸收性聚合物;吸收胶凝材料;或任何其它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、并以商品名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。包含共混聚合物的合适的透气复合材料以商品名HYTREL共混物P18-3097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也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在穿着者上的位置,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,扣紧系统承受围绕制品腰部的拉伸载荷。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可装设一个可重新闭合的扣紧系统,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的部件以及底片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。在一个优选的实施方案中,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。采集层优选地为与存储层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,而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以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被围绕存储层60包裹,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EP-A-1403419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,而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层状粘土矿(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WO2004/0158212,其发明者(在美国是申请者)是Ekaterina AnatolyevnaPonomarenko和Mattias NMN Schmidt。
另外的适用无纺材料描述于WO2002/0192366,WO2002/0150678,EP-A-1356152,EP-A-1470281和EP-A-1470282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浸透。
需要说明的是,永久亲水性无纺材料也适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。
表面张力是某种永久亲水性水平所达到的程度的一种度量。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度量。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以及粘合剂纤维层120。基底层100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。至少基底层100的第一表面的一些部分直接与吸收性聚合物材料层110接触。这层吸收性聚合物材料110优选为不连续的层,而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小于10mm,优选为小于5mm、3mm、2mm,而且大于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部分与至少基底层材料100的第一表面的一些部分接触。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材料层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。
在本发明的一个优选实施方案中,热塑性组分120可基本均匀地设置在吸收性聚合物材料110之内。
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,它部分与吸收性聚合物材料110接触,而部分与基底层100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。热塑性材料120粘合到基底100上,从而将吸收性聚合物材料110固定到基底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,即当制品处于润湿状态时或至少部分载有液体时对吸收材料的固定作用,但是当制品处于干燥状态时,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吸收性纤维材料混合,这类吸收性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%。优选采用基本没有透气毡的芯。本文所用术语“吸收性纤维材料”并不意味指任何热塑性材料120,即使这样的热塑性材料是纤维化的或部分吸收性的。
本发明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和基底材料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的纵向边缘直线的设置在纵向形成一些槽,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。在一个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,据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,以及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,而且不互相面对。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是粘性的热塑性组分,也称为热熔融粘合剂。
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,例如经过热、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塑性层120与吸收性聚合物材料110以及特别是与基底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,特别是在响应内力时,即在响应应变时。当吸收制品采集有液体时,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,而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共混物,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,热塑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)典型地大于10,000,而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)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。
其它可采用的适合的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。非晶形的聚烯烃或非晶形的聚α烯烃(APAO)也可采用,聚α烯烃(APAO)是C2至C8α烯烃的均聚物、共聚物和三元共聚物。
树脂的典型Mw小于5,000,而Tg通常高于室温,在热熔体中树脂的典型浓度在30%至60%范围内。增塑剂的分子量小,典型地小于1,000,而Tg低于室温,典型浓度为0%至15%。
优选地,粘合剂以遍及吸收芯的纤维的形式存在,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,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,而且小于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”或永久附着力的量度。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,优选地大于24,000Pa,最优选地大于30,000Pa。在60℃测量的存储模量G’是热塑性材料在升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,在这些地方热塑性材料会失去其完整性。
G’典型地用流变仪测量,如图8的示意图所示,该图仅用于一般示例说明的目的。流变仪400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元件和半径为R(例如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为H,例如1500微米。Peltier元件能控制材料的温度(±0.5℃)。
在另一方面,粘合剂在60℃的损耗角正切tan Delta应小于1,优选小于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℃,优选地小于22℃,更优选地小于18C,最优选地小于15℃。低的玻璃化转变温度Tg有利于良好的附着力。另一方面,低的玻璃化转变温度Tg保证粘合剂热塑性材料不变脆。
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,特别是良好的湿固定作用。因此,Tx优选应高于80℃,更优选高于85℃,最优选高于90℃。
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。
生产本发明所述优选的吸收芯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,使得基底层材料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。优选地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放到具有不平整表面的转筒上,而基底层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上将包括对一体的材料薄片的折叠。
因此,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,而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受真空部件影响。
优选地,吸收性聚合物材料的分布是曲线形的,而且最优选地在纵向呈曲线形分布。因此,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至少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高10%,或20%,或30%,40%或50%。优选地,如果第一和第二正方形以纵向轴线为中心,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。该纤维材料可与吸收性聚合物材料预混,而且在一个工序中放入,或者可供选择地,可在不同的工序中放入。
据发现,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1SFC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 752 892B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的平均定量存在。
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小于100mm、90mm、80mm、70mm、60mm或甚至小于50mm。因此,优选地本发明的吸收芯的裆部宽度小于100mm、90mm、80mm、70mm、60mm或甚至小于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。据发现,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%,更优选大于65%、70%、75%、80%、85%或90%的吸收容量。
湿固定作用试验
设备:
·试验溶液:在37℃下0.90%盐水溶液。
·天平
·尿布摇动器
·在35℃至37℃下保持试验溶液的浴池
·有刻度的流体烧杯,至少是2ml的刻度
·秒表
·温度计
·尺寸为约10x120x220mm的托盘300
尿布摇动器
用于进行湿固定作用试验的试验装置可包括本文所述以及如图7所示的所谓尿布摇动器。该摇动器包括应足够重以得到稳定摇动状态的底板210。两根立柱220a和220b安装到底板上,它们的高度可调节以对不同长度的吸收芯或吸收用品进行试验。立柱220支撑板230。夹具安装台250由橡胶支座240安装到该支撑板上。在夹具安装台250和板230之间的摇动运动由马达产生,优选地为电机260。夹具安装台250刚性地连接到尺寸根据待评估的吸收芯或吸收用品选择的夹具270上。
底板210也可用作托盘300的支持物,在试验操作前,吸收芯或吸收用品如下文描述那样在托盘300中进行预湿。
样品制备:
·提供10件吸收制品或吸收芯样品。从吸收制品样品上取下不直接包裹吸收性聚合物材料的所有层(例如,顶片、底片和不包括吸收性聚合物材料的采集层)。用两条平行的横向切开线切一条200mm长的吸收芯样品。如果吸收芯长度超过200mm,那么可选择任何两条如上定义的平行切开线。
·称量层压材料的干重。
·将层压材料放入托盘中。
·将试验溶液泼洒到吸收芯样品的中心。试验溶液的量应为层压材料设计容量的50%。在本文中,将设计容量与待试验吸收芯的总可用容量之比理解为如下定义的所切出吸收芯样品条的层压材料CRC能力。
·在5分钟膨胀时间后进行下述试验。
试验的进行:
·在摇动试验前称量层压材料的湿重m1。
·用夹具固定层压材料使得不少于180mm的层压材料伸于夹具下方,因而在摇动过程中其自由运动不受限制。夹具需要盖住整个AGM宽度。
·自由运动的层压材料下端至AGM收集托盘的距离应为4cm。
·摇动频率:16.8Hz。
·垂直方向幅值:4mm,水平方向幅值1mm。
·摇动时间2x80秒。
·摇动后,将先前的自由运动端固定到夹具上。
·如果自由运动端被夹具的压力密封住,那么将其打开。
·用相同的设置再进行摇动。
·摇动后称量剩余层压材料的重量m2。
报告结果:
·记录层压材料的干重,精确到十分之一克(例如,10.0g)。
·记录摇动前后的重量m1和m2,二者都精确到十分之一克(例如,m1=130.4g,m2=100.4g)。
·记录平均重量损失,精确到十分之一克(例如,30.0g)。
·计算平均重量损失的百分比,
精确到一个单位(例如,23%)。
·报告单次试验的湿固定作用值,它是与100%之差,例如77%的湿固定作用。
·湿固定作用值,本文也称为湿固定作用,是基于10个单次试验湿固定作用值的平均值。湿固定作用值高代表湿固定作用好,以及颗粒损失少。
层压材料CRC能力
层压材料CRC能力(CLAM)由下式计算:
CLAM=mAGM·CRCAGM
mAGM表示层压材料中AGM的质量。CRCAGM表示层压材料中AGM的CRC能力。
层压材料内AGM的质量(mAGM)可用本领域技术人员所知的任何适合方法测量,例如可用滴定的方法。
AGM CRC(CRCAGM)如下测量:从层压材料中去除一些AGM,然后进行下面的离心保持能力(CRC)试验。
离心保持能力(CRC)
对于大多数水凝胶形成的吸收性聚合物而言,作为吸收能力量度标准的凝胶体积用1988年4月19日重新公开的美国再公开专利32,649(Brandt等人)中所述的方法进行确定,但是用0.9%盐水溶液代替合成尿液。凝胶体积以及CRC能力在干重基础上进行计算。这种方法将用于所有水凝胶形成的不吸收Blue Dextran的吸收性聚合物。
用于将Blue Dextran(参见Re 32,649中的凝胶体积方法)吸收到形成的水凝胶(例如,从阳离子单体制备的聚合物)表面的SAP的凝胶体积测量方法如下:对于这些水凝胶形成的聚合物,进行所述吸收能力试验,但在计算中用水凝胶形成的聚合物干重代替原来的重量。例如,参见1992年6月23日公布的美国专利5,124,188(Roe等人),第27-28栏,对于吸收能力试验的说明。
对于离心保持能力的评价而言,已经发现所谓的茶袋评估法或量度法(在下文中为CRC量度法)最适于反映在SAP材料的吸收能力接近饱和的情况下毛细管压力的保持状况。该试验采用标准实验室条件(21℃-23℃,50%相对湿度)。将样本SAP材料在密闭的烧瓶或其它容器中保持干燥,烧瓶或容器仅在开始评估时打开。用于评估的其它材料(织物、器材等)在测量前在上述实验室条件下存放24小时。
对于CRC测量,将0.2+/-0.0050g SAP颗粒放入茶袋中(袋子需为液体可自由透过的并且必须留存住颗粒,即茶袋孔必需不大于最小的颗粒)。茶袋的大小应为60mmx85mm并在装满后通过焊接进行密封。然后将茶袋浸入0.9%盐水溶液中30分钟,使每克SAP具有至少0.83L的溶液;优选地,基本上超过这个比率。在浸泡30分钟后,将茶袋以250g进行3分钟的离心处理,以去除多余的盐水溶液。称量袋子,精确到0.01g,并计算出所吸收的液体。通过采用放入茶袋中的干SAP的量,将结果以每克SAP颗粒所吸收的克数进行报告。
Claims (19)
1.一种一次性吸收尿布,包括:
底座,该底座包括液体不可透过的底片和液体可透过的顶片;
连接到所述底座上的可重新闭合的扣紧系统,用于将所述尿布紧固到穿着者上;和
位于所述底片和所述顶片之间的吸收芯,该吸收芯包括第一和第二基底层,每个基底层上沉积有吸收性颗粒聚合物材料并用热塑性材料包封;所述第一和第二基底层结合在一起,使得所述第一和第二基底层中的每个层的所述热塑性材料相互接触;
其中所述热塑性材料具有在50℃到300℃范围内的软化点,小于25℃的玻璃化转变温度,以及在60℃时测量的小于300,000Pa而大于18,000Pa的存储模量G’;
其中与所述吸收性颗粒聚合物材料的重量相比,所述吸收芯具有小于10%的纤维素纤维材料。
2.如权利要求1的尿布,其中所述热塑性材料具有大于10,000的分子量。
3.如权利要求1的尿布,其中所述热塑性材料是纤维的形式,纤维的平均粗细为1微米至50微米,平均长度为5mm至50cm。
4.如权利要求1的尿布,其中所述热塑性材料是对水不敏感的。
5.如权利要求1的尿布,其中所述热塑性材料包括单种热塑性聚合物或者热塑性聚合物的共混物。
6.如权利要求5的尿布,其中所述热塑性聚合物包括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。
7.如权利要求6的尿布,其中嵌段A是聚苯乙烯,嵌段B从由异戊二烯、丁二烯、乙烯/丁烯、乙烯/丙烯以及它们的混合物构成的组选择。
8.如权利要求1的尿布,其中当处于润湿状态时所述吸收性颗粒聚合物材料被固定,使得所述吸收芯获得根据湿固定作用试验超过50%的湿固定作用。
9.如权利要求5的尿布,其中所述热塑性材料是茂金属聚烯烃、非晶形的聚烯烃或非晶形的聚α烯烃。
10.如权利要求1的尿布,其中所述热塑性材料为热熔融粘合剂。
11.如权利要求1的尿布,其中所述热塑性材料包括:
按重量计算在30%至60%的聚合物树脂,具有小于5,000的分子量和至少23℃的玻璃化转变温度Tg;
达到15%的增塑剂,具有小于1,000的分子量和小于23℃的玻璃化转变温度Tg。
12.如权利要求1的尿布,其中所述吸收性颗粒聚合物材料沉积在所述第一和第二基底层上的由接合区域分隔的分散的岛屿区域中;其中所述第一和第二基底层互相面对,使得其中一层上的吸收性颗粒聚合物材料面对另一层的接合区域。
13.如权利要求1的尿布,其中热塑性材料具有至少80℃的交叉温度Tx。
14.如权利要求1的尿布,其中所述热塑性材料在60℃测量的存储模量G’小于300,000Pa而大于30,000Pa。
15.如权利要求1的尿布,其中所述热塑性材料在20℃测量的存储模量G’至少为30,000Pa而小于300,000Pa。
16.一种一次性吸收短裤型尿布,包括:
底座,该底座包括液体不可透过的底片和液体可透过的顶片;
至少两个连接到所述底座并相互连接以形成短裤的侧片;
位于所述底片和所述顶片之间的吸收芯,该吸收芯包括第一和第二基底层,每个基底层上沉积有吸收性颗粒聚合物材料并用热塑性材料包封;所述第一和第二基底层结合在一起,使得所述第一和第二基底层中的每个层的所述热塑性材料相互接触;
其中所述热塑性材料具有在50℃到300℃范围内的软化点,小于25℃的玻璃化转变温度,以及在60℃时测量的小于300,000Pa而大于18,000Pa的存储模量G’;
其中与所述吸收性颗粒聚合物材料的重量相比,所述吸收芯具有小于10%的纤维素纤维材料。
17.如权利要求16的短裤型尿布,其中当处于润湿状态时所述吸收性颗粒聚合物材料被固定,使得所述吸收芯获得根据湿固定作用试验超过50%的湿固定作用。
18.如权利要求16的短裤型尿布,其中所述吸收性颗粒聚合物材料沉积在所述第一和第二基底层上的由接合区域分隔的分散的岛屿区域中;其中所述第一和第二基底层互相面对,使得其中一层上的吸收性颗粒聚合物材料面对另一层的接合区域。
19.一种吸收芯,包括:
第一和第二基底层,每个基底层在所述第一和第二基底层上的由接合区域分隔的分散的岛屿区域中具有用热塑性材料包封的吸收性颗粒聚合物材料,其中所述第一和第二基底层互相面对,使得其中一层上的吸收性颗粒聚合物材料面对另一层的接合区域;所述热塑性材料具有内聚力和附着性能,使得所述第一和第二基底层与所述热塑性材料结合在一起;
其中所述热塑性材料具有在50℃到300℃范围内的软化点,小于25℃的玻璃化转变温度,以及在60℃时测量的小于300,000Pa而大于18,000Pa的存储模量G’;
其中与所述吸收性颗粒聚合物材料的重量相比,所述吸收芯具有小于10%的纤维素纤维材料。
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