CN102160832B - 吸收制品的转移层 - Google Patents

吸收制品的转移层 Download PDF

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CN102160832B
CN102160832B CN201110037416.7A CN201110037416A CN102160832B CN 102160832 B CN102160832 B CN 102160832B CN 201110037416 A CN201110037416 A CN 201110037416A CN 102160832 B CN102160832 B CN 102160832B
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thin film
drainage tube
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CN102160832A (zh
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R·J·赛勒
G·M·里克尔
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Feiteshi Film Products Co ltd
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Abstract

一种尤其适合用作吸收制品中的转移层的薄膜，所述薄膜具有多个毛细管和多个引流管，所述毛细管的侧壁从所述薄膜的阴面延伸并终止于所述薄膜阳面的孔；所述引流管的侧壁从所述薄膜的阴面延伸并终止于所述薄膜阳面的孔，其中所述引流管相对于所述薄膜的基面成钝角。

Description

吸收制品的转移层
技术领域
本发明涉及成形薄膜，更具体涉及用作吸收制品转移层的三维成形薄膜。
背景技术
吸收制品是暂时收集和固定体液的一般使用一次或有限次数的制品。这些制品包括尿布、成人失禁产品、妇女卫生产品、绷带和类似的制品。一般，这些制品面层、背衬层和位于面层和背衬层之间的吸收芯，其中，面层紧邻使用者的皮肤设置，背衬层与面层相对并且在使用中紧邻使用者的衣服设置。在大多数情况下，面层可渗透体液，背衬层不可渗透体液，从而保护使用者的衣服免于渗漏。吸收芯被设计成收集和保持体液直到制品取出和替换为新制品。
转移层在本领域中也称为获取分布层或“ADL”，已在吸收制品中使用。过去已发现非织造网和三维成形薄膜可用作转移层。转移层通常位于面层和吸收芯之间，一般改善制品吸收和保留液体的效率。例如，已使用转移层来提供空隙容积，用作暂时储库以收集和保留液体直到液体被芯吸收。此外，已采用转移层来促进液体沿大致平行于转移层的平面方向的测流，从而允许更多的芯用于吸收液体。例如，参见美国专利4,324,247。
仍然需要具有以下功能的转移层，该转移层能够更有效地促进液体在吸收芯中的分布，为使用者提供更好的舒适性，降低面层的表面润湿性，以及防止或降低再润湿。
发明内容
在一个实施方式中，本发明提供了一种用作转移层的成形薄膜，该薄膜具有多个三维毛细管和多个三维引流管，其中所述引流管被设置成相对于薄膜基面成钝角。
在另一个实施方式中，本发明提供了一种用作转移层的成形薄膜，该薄膜具有多个三维毛细管和多个三维引流管，其中所述引流管被设置成相对于薄膜基面成钝角，所述毛细管被设置成大致垂直于薄膜基面的角度。
在另一个实施方式中，本发明提供了一种用作转移层的成形薄膜，该薄膜具有多个三维毛细管和多个三维引流管，其中所述引流管被设置成相对于薄膜基面成钝角，所述引流管和毛细管终止于同一平面。
这些和其它实施方式在参考附图和权利要求进一步阅读说明书后是显而易见的。
附图简要说明
图1是具有根据本发明一种实施方式的具有转移层的吸收制品的截面视图。
图2是液体克数与时间的关系图。
图3是液体克数与时间的关系图。
具体实施方式
吸收制品通常包括面层、吸收芯和背衬层。面层位于吸收制品面向身体侧，通常包括液体可渗透材料，允许潮涌的液体从吸收制品面向身体表面转移至吸收芯。术语“潮涌”一般表示在吸收制品的面层上的液体量或添加液体的行为。产品使用期间以及最终产品测试期间可发生潮涌。结果，当同一吸收制品受到多于一次潮涌时发生“多次潮涌”。面层在使用期间通常紧邻使用者的皮肤或者甚至是直接接触，面层通常由柔软材料构成，例如非织造材料、具孔薄膜、或者制成整体复合材料的这些材料的组合。面层通常被设计成即使在潮涌之后仍然让使用者保持舒适、干燥感觉。
背衬层位于吸收制品面向衣服侧或外侧表面。背衬层可以是液体不可渗透的薄膜，不允许液体从吸收制品内转移至吸收制品的外表面或者转移至使用者的衣服。透气的背衬层不可渗透液体，但允许水气通过吸收制品。这可降低使用者的潮湿感，从而提高使用者的舒适性。
在吸收制品的使用中，吸收芯可吸收潮涌并保留液体。吸收芯应充分吸收潮涌和多次潮涌，基本保留潮涌直到吸收制品被取出并丢弃。吸收芯的储存容量以及潮涌跨吸收芯分布的效率决定了吸收制品能够保留的液体量。吸收芯中的吸收材料可包括任何液体吸收性材料，例如但不限于：纤维素材料，包括纤维、微孔海绵或泡沫材料，超吸收材料，例如超吸收聚合物，水胶体材料，凝胶材料以及这些材料的组合。本发明的范围包括这些吸收材料类型中的一种或多种可用于各种实施方式中。具体说，在某些实施方式中，吸收材料可包括吸收颗粒材料和细碎纤维素纤维的混合物。.
尤其有用的吸收材料是高度吸收性的凝胶类材料，通常能够吸收约10-50倍其自身重量的液体。本领域众所周知，吸收芯的液体吸收速率与吸收芯保留吸收液体的能力成反比。因此，芯中使用的超吸收材料在保留液体方面非常好，而在液体摄取方面较慢。液体摄取的延迟导致制品中更多未被吸收或者游离的液体，因而降低了制品的再润湿性能。因为使用这些材料具有其它优点，例如降低芯的体积，通常这些其它的优点弥补了较慢的摄取。
根据各实施方式，转移层位于面层和吸收芯之间或者位于背衬层和吸收芯之间。更优选地，转移层位于面层和吸收芯之间。
转移层可用于控制再润湿，即制品内未被吸收或者“游离”的液体在制品的使用者接触表面上或表面内存在的现象。再润湿包括表面润湿部分和反向润湿部分。表面润湿表示潮涌之后液体保留在面层表面上或表面孔隙内的。反向润湿表示液体已通过面层但又转移回到面层表面。当制品处于负重或压迫下时反向润湿通常更明显，液体被迫向回通过面层。例如，当婴儿在尿布中排尿后坐下时，可发生压迫。不论通过什么机制，面层表面上或表面内存在的液体让制品的使用者产生令人不快的潮湿感。因此，尽可能减少或消除再润湿对于消费者接收度是重要的。转移层通过对反向润湿提供物理限制而可控制再润湿。具体说，薄膜材料用作物理屏障，因为薄膜本身是液体不可渗透的，通常形成孔以限制液体流动离开吸收芯。然而，非织造转移层提供了暂时储库并在液体到达面层表面之前收集液体。在某些情况下，转移层也可通过促进静止液体的转移来降低面层上的表面润湿性，否则这些液体易保留在面层上。
在标准工业测试中，例如EDANA ERT 151.2-99或EDANA ERT 151.3-02，通过以下方式测定再润湿：使制品经历测定液的潮涌，等待10分钟，然后在面层上应用吸液纸和一定的重量并测量吸液纸获取的液体量。等待10分钟的原因在于，让吸收芯有时间获取液体。然而，实际上制品的使用者并不希望润湿感持续10分钟，因为这是非常令人不快的感觉。因此，从消费者的角度考虑，要求潮涌后几乎瞬时干燥。
潮涌可视作包括动态和静态液体的组合。潮涌时动态液体流动通过面层和转移层，而静态液体可保留在面层和/或转移层的孔隙内。为了去除静态液体，转移层必须能够维持z向芯吸或毛细作用。当转移层是三维成形薄膜时，z向芯吸或毛细作用可通过以下方式实现：提供至少一部分直径足够小的孔以实现毛细现象或毛细作用。
如上所述，已使用薄膜和非织造纤维网作为面层和转移层。非织造网在纤维间具有吸引和保留液体的内部空隙空间。因此，非织造网提供了液体的暂时或“缓冲”储库。当潮涌发生时，液体在非织造网的空隙空间内累积，不论非织造网是用作面层还是用作转移层，直到液体有机会排出和/或被芯吸收。非织造网的缓冲功能在两个方向上均有作用。具体说，当潮涌发生时，非织造网用作缓冲层以保留液体直到它们排出或被芯吸收。一旦液体排出，非织造网可用作缓冲层，在液体到达面层表面之间累积液体。排出的液体量、排出时间以及非织造网的缓冲容量取决于非织造网各纤维间孔隙的尺寸、非织造网的相对亲水性/疏水性、纤维密度以及其它因素。潮涌后，非织造网的空隙容量基本上立即饱和，芯并没有足够的时间来吸收潮涌。因此，非织造网不具有用作液体转移回面层表面的缓冲层的容量。通过非织造网但未吸收的潮涌部分以及暂时保留在非织造网的空隙内的潮涌部分可能导致再润湿。
然而，对于成形薄膜，除了少量液体可能保留在孔间平台区域中，潮涌几乎瞬时通过薄膜并储存在薄膜下面的空隙空间内。如果在此时施加载重，薄膜可用作再润湿的物理屏障，只有找到返回途径的液体才能通过孔而导致再润湿。因为成形薄膜中的孔通常逐渐变细，从而在一侧(即“阳性”侧)具有较窄的开口，而另一侧为相对侧或“阴性”侧，薄膜显示的优先液体流动是朝向吸收芯而在相对方向上实际液体不可渗透。结果，成形薄膜可提供吸收制品接近瞬时干燥而非织造网不能。事实上，测试表明，薄膜在再润湿性能方面优于非织造网，尤其是在潮涌后立即测试时。随着潮涌后时间的流逝，非织造网有机会排出并可重新用作液体从芯区转移至面层表面的缓冲层。因此，随着潮涌后时间的增加，与非织造网相比采用薄膜时再润湿性能的差异显著性降低。
表1报道了采用标准再润湿测试方法获得的液体克数与潮涌后时间的函数关系。
表1
                      时间(潮涌后的分钟数)
样品                  0        2       4       6       8       10
具有非织造转移层的4
号尿布(第一次潮涌)    16.32    0.51    0.50    0.30    0.24    0.32
具有薄膜转移层的4号
尿布(第一次潮涌)      1.37     0.29    0.34    0.32    0.22    0.21
具有非织造转移层的4
号尿布(第三次潮涌)    48.65    32.71   22.31   17.68   20.05   12.97
具有薄膜转移层的4号
尿布(第三次潮涌)      24.59    14.25   9.17    5.43    5.34    4.77
根据表1的数据作图，在图2和3中显示了液体克数与时间的图。更具体说，图2描绘了获取第一次潮涌后测量再润湿时获得的结果。曲线100表示采用薄膜的制品，而曲线200表示采用非织造网的制品。如图2所示，与使用非织造网相比，使用薄膜导致潮涌后即刻的再润湿显著较低。在时间上，薄膜与非织造网的差异可忽略，但薄膜显然提供了更迅速的干燥感。这些数据表明，与采用成形薄膜的相同制品相比，再润湿测试中采用非织造网转移层的婴儿尿布在第一次潮涌后可立即多产生6-16克液体。
参考图3，显示了第三次潮涌后再润湿测试中液体克数与时间的曲线。数据表明，与采用非织造网作为转移层相比(曲线400)，采用成形薄膜作为转移层(曲线300)产生显著较少的表面液体。该差异类似于图2的情况；即采用成形薄膜的制品比采用非织造网的制品少6-26克液体。
根据实施方式的转移层是薄膜。本文中所用，“薄膜”表示薄膜聚合物片层或网。例如，薄膜制备过程包括：采用铸塑或吹制挤出工艺挤出熔融热塑性聚合物，可在辊轴间进一步加工并冷却以形成网。例如，薄膜可以是单层薄膜或共挤出薄膜。
术语“聚合物”包括均聚物，共聚物如例如嵌段共聚物、接枝共聚物、无规共聚物和交替共聚物、三元共聚物等，及其掺混物和修饰物。此外，除非另外进行具体限制，术语“聚合物”包括所述材料所有可能的几何构型，如全同、间同以及无规或随机对称。
在尺寸上，转移层可被描述为具有机器方向、横向和Z向。机器方向定义为膜穿过制造过程的方向。通常，制备的薄膜是长度远大于宽度的长片或网的形式。在这种情况下，机器方向通常是片材的长度(也称为x向)。与机器方向垂直的是片材的横向(也称为y向或宽度)。在z向上测量薄膜厚度(在某些实施方式中，有时也称为薄膜的高(loft)或径向)。
三维成形薄膜包括形成标称薄膜厚度的基面，还包括源自薄膜表面并沿z向向外伸出的结构。这些结构的尺寸提供了z向尺寸大于标称薄膜厚度的薄膜。它们也提供了具有第二平面的薄膜，所述第二表面由表面结构限定并在z方向上与薄膜基面隔开。例如，可以采用压花工艺、液压成形工艺或真空成形工艺产生三维成形薄膜的三维特征。所有这些工艺都是本领域众所周知的。
“多平面薄膜”是具有源自薄膜的基面和第二表面的额外表面结构的三维成形薄膜。例如，具有多平面结构的成形薄膜可包括位于薄膜表面上的多个平台，所述平台限定了基面上方或下方至少一个额外的薄膜平面。在多平面三维成形薄膜的某些实施方式中，任何或所有可得平面上可形成突起。
三维具孔成形薄膜仅仅是在三维结构中具有开口或孔的成形薄膜。具孔三维结构的尺寸、间隔和其它性质依据用于产生该三维具孔成形薄膜的具体设备。例如，在真空成形工艺、液压成形工艺和一些机械工艺中，孔的尺寸、形状和间隔由薄膜经历真空压力、加压水流或机械穿孔设备如销钉时支持薄膜的成形结构决定。例如，参见美国专利4,456,570和美国专利3,929,135。
对于具孔成形薄膜，三维结构的z向尺寸与该三维结构的直径成函数关系，进而与成形结构中孔的直径或穿孔销钉的直径成函数关系。例如，与直径较大的结构相比，直径较小的结构通常具有较小的z向尺寸。其它因素也对三维特征的z向高度产生影响，例如薄膜组成、薄膜基重、穿孔时薄膜的温度以及工艺条件和设备相关因素。
例如，三维成形薄膜可包含至少一种选自以下的聚合物：聚烯烃(例如C2-C10烯烃如聚乙烯、聚丙烯等)；聚酯；塑性体；聚酰胺(例如尼龙)；聚苯乙烯；聚氨酯；乙烯基聚合物；丙烯酸和/或甲基丙烯酸聚合物；弹性体(例如，苯乙烯嵌段共聚物弹性体)；来自天然可再生来源的聚合物；可生物降解的聚合物；以及这些物质的混合物或掺混物。优选地，聚合物是热塑性聚合物。
此外，聚合物中可加入任何种类的添加剂以提供某些所需的特征，包括但不限于糙度、降低抗静电电荷累积、耐磨性、可印刷性、可写性、不透明度、亲水性、疏水性、可加工性、UV稳定性、颜色等。这些添加剂是工业上众所周知的，包括例如碳酸钙(耐磨性)、二氧化钛(颜色和不透明度)和二氧化硅(糙度)、表面活性剂(亲水性/疏水性)、加工助剂(可加工性)等。
参照图1的实施方式，吸收制品10包括面层12、芯14、背衬层16以及位于芯14和面层12之间的转移层15。制品10具有面向身体的表面13，使用中面向身体的表面邻近或者以其它方式邻近使用者的皮肤。制品10也具有与面向身体的表面13相对的面向衣服的表面17。使用中，面向衣服的表面17将靠近使用者的衣服或者环境(如果吸收制品是绷带、伤口辅料、外科手术单等)。
面层12包括液体可渗透材料，允许液体进入吸收制品10。面层12通常是具孔薄膜，例如具孔成形薄膜、非织造网或复合材料。在所示实施方式中，面层12包括非织造网。背衬层16通常是液体不可渗透的以防止液体从吸收制品渗漏。通常使用薄膜、非织造网和复合材料作为背衬层。在所示实施方式中，背衬层16包括液体不可渗透的吹制或铸塑薄膜。吸收芯14位于面层12和背衬层16之间，包括能吸收和保留通过面层的液体直到制品被丢弃的材料。
如图1所示，转移层15包括三维成形薄膜，其具有多个三维毛细管18和多个三维引流管25。毛细管18包括突起，突起包括圆锥形结构，其侧壁20源自薄膜15的阴面21并从薄膜15的阴面21沿z方向(图1中由箭头Z表示)延伸。毛细管18终止于薄膜15阳面23的孔22。
毛细管18的尺寸能够经毛细作用提供液体转运并通过提供持续的z向芯吸作用而促进保留在面层薄膜上和面层孔隙中的静态部分潮涌的去除。z-向芯吸作用通过降低表面润湿分量或反向润湿分量或两者而改善再润湿性能。通过提供直径足够小以实现毛细作用的毛细管18实现z向芯吸作用。
为实现持续的毛细作用，必须提供一些机制以去除毛细管18出口侧(即孔22处)的液体。吸收制品中一种简便的机制是将毛细管的出口侧设置成与吸收芯紧密接触。然而，现有技术的转移层难以实现，尤其是还包括较大直径的突起的那些转移层。具体说，快速获取潮涌动态部分所必需的较大直径的突起在其z向通常具有比较小直径的毛细管更大的尺寸。因此，对于与芯紧密接触的毛细管，较大的突起需要压扁以实现紧密接触。当然这是不恰当的，因为这与较大突起的目的相背。因此，在现有技术的薄膜中，毛细管在空隙(即空白)空间中悬吊在吸收芯上方，因而不能提供可持续的液体去除。
转移层15还包括多个引流管25。引流管25是三维结构，其侧壁26源自薄膜15的阴面21并沿z方向延伸，如图1所示。引流管25终止于薄膜15阳面22的孔27。引流管25的直径比毛细管18大，允许液体从薄膜15的阴面21快速转移至薄膜的阳面23。
如图1所示，引流管25的取向相对于薄膜15的基面28成角度29。角度29相对于基面28大于90度，使得引流管25相对于薄膜15的基面28成钝角。角度29并非至关重要，通常可以相对于基面28成100-175°。具有这种角度突起的薄膜是本领域公知的，例如参见EP 1040801；WO 1997/003818和WO 2000/016726，每份专利申请被纳入本文作为参考。
因为引流管25相对于薄膜15的基面28成钝角，引流管不如当它们正交于基面28取向时那样沿z向延伸。因此，引流管25的角度取向允许毛细管18的孔22保持与芯14紧密接触，在芯吸液体远离面层12中提供了维持持续的毛细作用所需的机制。换言之，如图1所示，引流管25和毛细管18均终止于同一平面30，该平面通常平行于薄膜15的基面28并成一定间隔。
引流管25的角度取向也能够至少部分阻碍通过薄膜15到芯层14的视线。因此，薄膜15也起到至少部分隐藏芯14的掩蔽功能。
引流管25可以是任何所需的尺寸并允许液体快速通过。例如，某些实施方式的引流管25的平均横断面积大于0.2mm2，平均水力直径为0.55mm-1.2mm。相反，在阴面21测量，毛细管18的平均直径为50-400微米。引流管25与毛细管18的水力半径之比通常超过3∶1，在大多数情况下为4或5∶1或更高。10∶1或更高的比例也是常见的。
在图1所示的实施方式中，毛细管18和引流管25大致为圆锥形。然而，应理解这些结构的形状并不特别重要。具体说，毛细管和引流管的形状可以是圆形、卵形、三角形、方形、五角形、六角形或任何其它所需的形状。
转移层在吸收制品中的取向可以是阳面或阴面面向吸收芯。在许多应用中，转移层的阳面面向吸收芯，但在一些应用中可能希望阴面面向吸收芯。
可形成任何设计或图案以产生转移层的实施方式。可使用任何比例的引流管与毛细管尺寸的突起。根据应用，与图1所示的实施方式相比，可能希望更多或更少毛细管尺寸的结构。
应理解，虽然本发明描述了一些实施方式，但本领域技术人员可以进行各种显而易见的改进而不背离本说明书和权利要求书所述的本发明的范围。

Claims (13)

1.一种具有多个毛细管和多个引流管的成形薄膜，所述毛细管的侧壁从所述薄膜的阴面延伸并终止于所述薄膜阳面的孔；所述引流管的侧壁从所述薄膜的阴面延伸并终止于所述薄膜阳面的孔，其中所述引流管相对于所述薄膜的基面成钝角，并且在所述薄膜的阴面测量，所述毛细管的平均直径为50-400微米。
2.如权利要求1所述的薄膜，其特征在于，所述毛细管和所述引流管均终止于同一平面，该平面通常平行于所述薄膜的基面并成一定间隔。
3.如权利要求1所述的薄膜，其特征在于，所述引流管相对于所述薄膜的基面成100-175°的角度取向。
4.如权利要求1所述的薄膜，其特征在于，所述引流管的平均横截面积大于0.2mm2，平均水力直径为0.55mm-1.2mm。
5.如权利要求1所述的薄膜，其特征在于，所述引流管与所述毛细管的水力半径之比大于3:1。
6.一种吸收制品，其包括面层、芯和转移层，其中所述转移层包括具有多个毛细管和多个引流管的成形薄膜，所述毛细管的侧壁从所述薄膜的阴面延伸并终止于所述薄膜阳面的孔；所述引流管的侧壁从所述薄膜的阴面延伸并终止于所述薄膜阳面的孔，其中所述引流管相对于所述薄膜的基面成钝角，并且在所述薄膜的阴面测量，所述毛细管的平均直径为50-400微米。
7.如权利要求6所述的制品，其特征在于，所述毛细管和所述引流管均终止于同一平面，该平面通常平行于所述薄膜的基面并成一定间隔。
8.如权利要求6所述的制品，其特征在于，所述引流管相对于所述薄膜的基面成100-175°的角度取向。
9.如权利要求6所述的制品，其特征在于，所述引流管的平均横截面积大于0.2mm2，平均水力直径为0.55mm-1.2mm。
10.如权利要求6所述的制品，其特征在于，所述引流管与所述毛细管的水力半径之比大于3:1。
11.如权利要求6所述的制品，其特征在于，所述转移层位于所述面层和所述芯之间。
12.如权利要求11所述的制品，其特征在于，所述转移层的阴面比所述阳面更接近所述面层。
13.如权利要求6所述的制品，其特征在于，所述制品还包括背衬层，所述转移层位于所述芯和所述背衬层之间。
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BRPI1100111B8 (pt) 2023-02-14
EP2356961B1 (en) 2013-07-10
BRPI1100111A2 (pt) 2012-03-06
TW201125545A (en) 2011-08-01
TWI589281B (zh) 2017-07-01
US20140057071A1 (en) 2014-02-27
BRPI1100111B1 (pt) 2020-03-31
US9554950B2 (en) 2017-01-31
KR20110088448A (ko) 2011-08-03
US8581020B2 (en) 2013-11-12
KR101829059B1 (ko) 2018-02-13
US20110184370A1 (en) 2011-07-28
JP2011156349A (ja) 2011-08-18
CN102160832A (zh) 2011-08-24
EP2356961A1 (en) 2011-08-17
TWI547271B (zh) 2016-09-01
JP5864092B2 (ja) 2016-02-17

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