CN102762375B - 挤出涂覆的穿孔非纺织网和制造方法 - Google Patents
挤出涂覆的穿孔非纺织网和制造方法 Download PDFInfo
- Publication number
- CN102762375B CN102762375B CN201080064255.4A CN201080064255A CN102762375B CN 102762375 B CN102762375 B CN 102762375B CN 201080064255 A CN201080064255 A CN 201080064255A CN 102762375 B CN102762375 B CN 102762375B
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- CN
- China
- Prior art keywords
- perforation
- nonwoven web
- coating
- micropunch
- density
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
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Classifications
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
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- Y10T428/24322—Composite web or sheet
- Y10T428/24331—Composite web or sheet including nonapertured component
Landscapes
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Abstract
制造挤出涂覆的穿孔非纺织网的方法。所述方法包括以下步骤:将熔融的聚乙烯涂层挤出到非纺织网上,和通过热和气动压力差对熔融聚乙烯涂层开孔,以在其中产生约35到约120个穿孔/线性英寸的密度的微穿孔。然后通过将所得的经微穿孔的非纺织网供给通过穿孔辊来对其进行热机械穿孔,其中穿孔辊中的至少一个具有凸起的凸起物以产生延伸通过至少聚乙烯涂层的大穿孔。所述大穿孔具有约6到约35个穿孔/线性英寸的密度。所述穿孔的非纺织网作为吸收制品的外衬是有用的。
Description
技术领域
本发明涉及一种挤出涂覆的穿孔非纺织网(nonwovenweb),其具有凸起的带纹理的(textured)多孔涂层,该涂层提供柔软的、可悬垂的(drapale)和非粘性的感受;和制造这样的网的方法。
背景技术
有孔的非纺织网用在各种工业和消费产品部门。例如,有孔的非纺织网用于生产一次性床单(sheet)、一次性服装、过滤面具以及卫生和清洁产品,例如卫生棉、失禁垫和婴儿尿布。
有孔的非纺织物可使用各种技术来制造。一种技术需要:获得热粘或纺粘非纺织物并且使用一组凸起的针对非纺织物进行开孔,如在美国专利4,128,679和4,886,632中所描述的。
打算用作显示出单向的、类似阀的行为的吸收制品外衬(topsheet)的有孔的非纺织物可通过以下产生:将使用传统挤出技术所制备的塑性膜片(例如,传送通过铸塑或吹塑挤出头的LDPE的薄片)进行层压,和使用本领域中已知的固体成型(solidforming)技术(例如,如在美国专利4,780,352中所描述的层压材料的压延穿孔(calenderperforation))而对膜和非纺织物的组合体开孔。通过将形成的膜和非纺织物结合或对齐所产生的层压材料可通过如在美国专利7,204,907中所描述的机械技术进行穿孔。
用于产生有孔的网、特别是基于纤维的有孔的网的另一技术使用热机械接触穿孔例如针穿孔(pinperforation)或与平滑圆筒接触的雕刻圆筒(engravedcylinder),如在美国专利5,814,389、4,128,679和4,886,632中所描述的。用于产生网的又一技术使用真空开孔的层压材料,如在美国专利4,995,930中所描述的。
目前在吸收制品中用作皮肤接触覆盖层例如外衬的开孔的网在它们的如下能力方面是受限的:对于皮肤为皮肤柔软的(skinsoft)、分离的(安静的(quiet))、可塑造的(moldable)和/或为维持干燥的触觉(feeling)和传达干燥的感觉的流体吸收材料的能力。如上所描述的、特别是在美国专利4,995,930中所描述的膜和非纺织物的层压材料使用非纺织纤维作为面对皮肤的材料来提供柔软性的好处。然而,当这样的层压材料是湿的时,该纤维覆盖物保持流体并且膜材料没有能力排去纤维非纺织物基体的流体。由于毗邻的外衬湿气,使用者的身体可能得皮疹。当穿戴者行走时,这样的层压材料也可是有噪音的,因为它缺乏符合身体形状的柔性(flexibility),这归因于它不能够以低基重(如,少于27gsm)制造。另外,因为这样的层压材料要求购买塑性膜并将其与非纺织材料组合,所以其是昂贵的。结果,使用该层压材料制造的层压材料和/或产品可是僵硬、有噪音的和有刮擦的(scratchy)或者提供通常不舒适或潮湿的感觉。
发明内容
本发明涉及制造挤出涂覆的穿孔非纺织网的方法,包括:将具有约7到约17gsm基重的熔融聚乙烯涂层挤出到具有约9到约40gsm基重的非纺织网上,通过热和气动压力差对所述熔融聚乙烯涂层开孔,以在其中产生约35到约120个穿孔/线性英寸(linearinch)的密度的微穿孔(microperforation),从而提供经微穿孔的非纺织网,通过将所述经微穿孔的非纺织网供给通过穿孔辊而对其进行热机械穿孔,所述穿孔辊中的至少一个具有凸起的凸起物以在其中产生延伸通过至少聚乙烯涂层的大穿孔(macroperforation),所述大穿孔具有约6到约35个穿孔/线性英寸的密度。
本发明还涉及通过上述方法制造的挤出涂覆的穿孔非纺织网,和包括由所述穿孔非纺织网制成的外衬(topsheet)的吸收制品。
附图说明
图1显示了将熔融的聚乙烯涂层挤出到非纺织网上同时对所述涂层开孔以在其中产生微穿孔的方法。
图2显示了对使用在图1中显示的方法制造的非纺织网进行热机械穿孔而在其中产生大穿孔的方法。
图3显示了使用在图1和2所示的方法制造的本发明的穿孔非纺织网的顶视图。
图4是图3的穿孔非纺织网的一部分的放大的截面图。
具体实施方式
本发明涉及用作吸收制品的外衬的挤出涂覆的穿孔非纺织网。该产品通过如下制造:首先将聚乙烯涂层挤出和开孔到非纺织网上以在其中形成微穿孔,所述微穿孔具有凸起的小圆锥形的孔的外观,所述孔施加到非纺织网将面对穿戴者的皮肤的一侧。在一个实施方案中,挤出涂层是聚乙烯共混物的层状组合,该聚乙烯共混物包括在非纺织网经历第二热机械穿孔步骤之后帮助保持非纺织网的凸起纹理的惰性填料粒子。在一个实例中,在施加压力差的同时将聚乙烯混合物以低重量水平物理挤出到穿孔鼓(perforateddrum)的表面上,例如在美国专利4,995,930中描述的,以对熔融的聚乙烯涂层穿孔且几乎同时通过接触和真空压力的组合在熔融的聚乙烯有机会冷却之前将多孔纤维状非纺织网粘附到所述熔融的聚乙烯上。然后将所得的经微穿孔的涂覆的非纺织网进行第二开孔步骤,所述第二开孔步骤在其中产生延伸至少通过非纺织网的所述涂层的大穿孔。
图1显示了将熔融的聚乙烯涂层挤出在非纺织网上同时对所述涂层开孔以在其中产生微穿孔的方法。在图1中,将薄的熔融的聚乙烯层2从挤出机模头1供给到圆筒或鼓4的筛状(sievelike)的表面3上。使聚乙烯层经历气动真空(pneumaticvacuum)的真空室5位于圆筒4的内部,在聚乙烯层接触圆筒4的点处。在导向辊6帮助下,将纤维非纺织网7与聚乙烯层同时供给到筛状表面3上。由真空室5所施加的气动真空将聚乙烯层的段(section)吸到筛状表面中的开口中,形成突起物并在这些突起物之内将层进行穿孔。空气被吸过纤维非纺织网7,且将所述网压向聚乙烯层以及同时冷却所述层。导向辊6可帮助该按加压操作,但这对于将聚乙烯层作为涂层粘结到网上而言不是必要的。其它二个真空室8和9位于圆筒4中。真空室8吸取空气以冷却该微穿孔非纺织网10,而真空室9冷却筛状表面3。
在上述方法中,聚乙烯涂层具有约7到约17gsm、典型地约10到约15gsm、例如约14到16gsm的基重。在一个实施方案中,聚乙烯涂层是两层共混物(blend),典型地是A/B层状共混物,其中B层邻接于非纺织物侧,其具有能够帮助层状涂层粘住非纺织物的聚合物组分。A层将具有容易裂开或穿孔的聚合物组分。两层都可通过在美国专利4,995,930中描述的真空方法进行微穿孔,该文献引入本文作为参考。
非纺织网可是任何具有纤维状外观的多孔网。非纺织网可以由各种各样的方法使用粗梳纤维(cardedfiber)制造,所述粗梳纤维是经由称为纺粘或熔喷的方法热粘合的、气流穿透粘合的(airthroughbonded)或者直接挤出的。非纺织网具有约9gsm到约40gsm、典型地约10到约30gsm、例如约10到约16gsm的基重。非纺织纤维主要地是聚乙烯或聚丙烯或者它们的共混物。非纺织物典型地是亲水的,或者它可是层状的气流穿透的非纺织物,其中面向吸收核(absorbentcore)的侧比接触微穿孔涂层的侧更加亲水。在一个实施方案中,非纺织物具有毛细梯度(capillarygradient),使得离吸收核更近的毛细管小于邻近涂层的毛细管。面向所述核的非纺织层可具有对流体更高的亲和力,其可通过使用降低网的接触角的更加耐久的亲水材料或通过使用有毛细槽的纤维来产生。
在一个实施方案中,熔融聚乙烯涂覆的网用压力差来开孔以显示凸起的三维的火山状穿孔(例如在美国专利6,228,462中所描述的,该文献引入本文作为参考),所述穿孔从非纺织物层向外延伸。这些火山状穿孔(例如在图1-4中显示的微穿孔12)产生纤维状表面的感觉。当吸收制品外衬由本文中的穿孔的非纺织网制成时,具有指向所述制品的穿戴者的一侧的这样的开孔锥体以提高舒适感是理想的。微穿孔12具有约35到约120个穿孔/线性英寸、典型地约45到约80个穿孔/线性英寸的密度。锥状孔在图4中看上去有些倒置,其中最大的直径在聚乙烯膜2和非纺织网7之间的界面处。
在一个实施方案中,具有A/B层的薄的熔融聚乙烯层(其中B层主要是聚乙烯和A层含有2%到30重量%的填料粒子)被共挤出在具有支撑筛(supportingscreen)例如在图1中显示的筛状表面的鼓上且在所述聚乙烯层接触亲水性热粘合的非纺织网的支持载体层的同时气动地形成。非纺织网可具有积极的(aggressive)流体输送机构例如异形纤维(shapedfiber)。如上所述,聚乙烯层可包括共挤出层,其中邻近支撑筛的层包括容易裂开的LDPE。
在聚乙烯涂层中的填料粒子可是有机或无机填料粒子,例如在美国专利申请公开2002/0098341Al中描述的,其引入本文作为参考。合适的无机填料包括:碳酸钙、粘土、二氧化硅、氧化铝、硫酸钡、碳酸钠、滑石、硫酸镁、二氧化钛、沸石、硫酸铝、硅藻土、硫酸镁、碳酸镁、碳酸钡、高岭土、云母、碳、氧化钙、氧化镁、氢氧化铝和它们的组合。合适的有机填料包括:由聚苯乙烯、聚酰胺、聚乙烯醇、聚环氧乙烷、聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、聚碳酸酯、聚四氟乙烯和其它合适的聚合物和它们的衍生物制成的粒子。填料粒子的平均直径应该是约0.1-10微米,典型地是约0.5-7.0微米,例如约0.8-2.0微米。
图2显示了将使用图1中所示的方法制造的涂覆的非纺织网热机械穿孔以在其中产生大穿孔的方法。该第二开孔步骤包括:使涂覆的经微穿孔的非纺织网在通过使所述网遭受的凸起的凸起物或针所提供的穿孔力的作用下通过,和施加平衡的热机械接触穿孔压力以在其中产生延伸穿过至少聚乙烯涂层的大穿孔。热机械穿孔步骤可通过将挤出涂覆的网***到一组穿孔辊之间完成,所述穿孔辊在圆筒表面的至少一个上具有凸起的图案纹理,例如雕刻图案(engravingpattern)或单独的针状物,其可通过对与所述雕刻的圆筒的凸起区域接触的所述网的区域施加压力和必要时的热量来将涂层进行穿孔。由雕刻的钢、橡胶或者纸板制成的匹配的反向旋转圆筒可具有匹配所述凸起区域的接收槽(receptacle)。
如图2所示,将微穿孔非纺织网10在压力下供给通过穿孔压辊(calendarroll)16和18,以产生延伸通过至少所述网的聚乙烯涂层2的大穿孔22。大穿孔典型地是椭圆形的形状和典型地延伸通过聚乙烯涂层和非纺织网二者。大穿孔具有约6到约35个穿孔/线性英寸、典型地约8到约25个穿孔/线性英寸的密度。一个压辊,例如辊16,具有凸起的穿孔表面20,并且另一压辊,例如辊18,具有光滑的表面或者具有用于辊16的凸起表面的接收槽。辊18可被加热,典型地到约300°F(约148.9°C),或被冷却;且可在促进孔形成的方向上被辊16驱动或者自驱动。在另一实例中,将非纺织网供给通过经加热的针的压区(nip)和反向转动的刷辊。在这种情况下,所述针对所述网进行穿孔。在穿孔完成之后,非纺织网14可缠绕在辊上并运送给顾客以用在期望的产品应用中。
图3是使用图1和2的方法制成的本发明的穿孔的非纺织网14的穿戴者侧的顶视图,并且显示了在其中的微穿孔12和大穿孔22。如上所述,聚乙烯涂层可具有更合适用于穿孔的侧A以及更适合用于附着到非纺织网的侧B。在一个实施方案中,宏观展开的(expanded)非纺织网具有凸起的漏斗状穿孔,其典型地面向穿戴者的那侧。
在另一个实施方案中,穿孔装置具有凸起的针状物(needle)用于将非纺织网在面对吸收制品的吸收核的下平面(lowerplane)上展开。典型地将穿孔辊装置加热到接近或低于非纺织网的软化点的温度,通常大于70°C但低于200°C,并且由于压力和热的组合而产生穿孔。所获得的网,例如在图3中显示的网14,具有从凸起的微穿孔12和大穿孔22两者吸收流体的能力。大的、深的大穿孔吸收最大量的流体,而微穿孔作为吸收任何剩余的靠近穿戴者皮肤的流体并且防止非纺织网粘于皮肤上的毛细缓冲器(capillarybuffer)。
在一些实施方案中,不同地处理穿孔的非纺织网的各个区域来提供视觉上不同的结构(具有超过一个的微观纹理(microtexture)形状和/或宏观纹理(macrotexture)形状)可是期望的。例如,可***大穿孔图案,或者挤出涂层的筛在其表面上可具有不同的图案。
不同的穿孔针状物或凸起的压花图案可用于各种尺寸或形状的宏观压花(macroscopicembossing)。可全部或部分使用各种大穿孔的和带微观纹理的非纺织物,以为各种类型的吸收制品提供外衬,所述吸收制品包括有和没有吸收部分的成人、儿童或婴儿失禁产品(例如,尿布、内裤等等)、女性卫生产品(例如,月经用品、卫生棉、护垫等),包裹物(wrap)以及无菌的和非无菌绷带。本发明的非纺织网在其它一次性和/或多次使用产品中也是有用的,所述产品包括服装(garment)、服饰(apparel)、内衣、汗衫、胸罩、内裤、童裤、游泳衣、工作服,袜子,头罩(headcovering)和头带、帽子、连指手套和手套衬里、医用服装、床单、医用消毒被单(medicaldrape)、包装材料、防护罩、家用和办公用品和医疗或治疗设备和包裹物。
进一步处理也可是期望的,例如将乳液(lotion)或半固化的纳米纤维施加到宏观上产生的压花区域上。可使用机械活化方法来改变孔的形状以及压花区域和其余的孔之间的距离。
本文中的非纺织网也可以结合有其它组分以形成成品和半成品的层压材料或复合材料,其可通过在本领域中已知的压花、穿孔、缝合(sewing),结合、印花(printing)、裁切、成形、胶合、开槽和/或杀菌方法来进一步处理。
在本发明的一个实例中,将具有约15gsm的基重的熔融的聚乙烯A/B共混物(其中A层包括约88重量%的LDPE,8重量%的碳酸钙和4重量%的LLDPE,且B层包括约88%的LDPE和12%的EVA(乙烯乙烯醇))使用共挤出真空层压生产线(line)挤出到粗梳的、热粘合的聚丙烯非纺织网(具有16gsm的基重,可从ShalagShamirCorporation获得)上,伴随在其表面上具有熔融涂层的所述非纺织网接触可从StorkCorporationNetherland获得的52目形成筛。施加气动压差以迫使聚乙烯涂层压到模具上并在涂层中以约52个微穿孔/线性英寸的密度产生微穿孔。几乎在将聚乙烯涂层穿孔的同时,其被牢固地和连续地附着到非纺织网上,如图1所示。一旦聚乙烯涂层开始结晶,通过将该经微穿孔的涂覆的非纺织网供给通过穿孔辊(例如在图2所显示的,所述辊中的一个具有凸起的椭圆匕首形的针状物)而对其进行第二热机械穿孔步骤。针状物具有8个/线性英寸的密度且是椭圆形的以帮助保持所述网的柔性。由光滑的橡胶制成的反向辊用于确保大穿孔延伸通过乙烯涂层和非纺织网。这样的穿孔单元可从几个供应商获得,包括瑞士巴塞尔的BurckhardtAG。在非纺织网离开针状物穿孔压区之后,将它卷绕在辊上并且之后运送给顾客以用作吸收制品上的外衬。
虽然本发明已对具体实施方案进行了描述,但是各种改变从本公开来看将是明显的而且意图在以下权利要求的范围内。
Claims (20)
1.制造挤出涂覆的穿孔非纺织网的方法,包括:
(a)将具有7到17gsm基重的熔融聚乙烯涂层挤出到具有9到40gsm基重的非纺织网上;
(b)同时通过热和气动压力差对所述熔融聚乙烯涂层开孔,以在其中产生35到120个穿孔/线性英寸的密度的凸起的圆锥形的微穿孔,以提供经微穿孔的非纺织网;和然后
(c)通过将所述经微穿孔的非纺织网供给通过与所述非纺织网接触的穿孔辊而对其进行热机械穿孔,所述的穿孔辊中的至少一个具有凸起的凸起物以在其中产生延伸通过至少聚乙烯涂层的大穿孔,所述大穿孔具有6到35个穿孔/线性英寸的密度,其中所述微穿孔和所述大穿孔能够吸收和输送液体。
2.权利要求1的方法,其中聚乙烯涂层具有10到15gsm的基重。
3.权利要求1的方法,其中聚乙烯涂层包括共挤出的聚合物共混物和无机填料粒子。
4.权利要求1的方法,其中非纺织网包括低密度聚乙烯。
5.权利要求1的方法,其中微穿孔具有45到80个穿孔/线性英寸的密度。
6.权利要求1的方法,其中大穿孔在形状上是椭圆形的并且延伸通过聚乙烯涂层和非纺织网两者。
7.权利要求1的方法,其中大穿孔具有8到25个穿孔/线性英寸的密度。
8.权利要求1的方法,其中非纺织网由至少二层制成并且至少一层包含异形纤维以提供优先的流体输送。
9.权利要求1的方法,其中非纺织网在不同的区域中具有附加的纹理或宏观压花以提升该网的性能或外观。
10.挤出涂覆的穿孔非纺织网,所述非纺织网通过如下制造:
(a)将具有7到17gsm基重的熔融聚乙烯涂层挤出到具有9到40gsm基重的非纺织网上;
(b)同时通过热和气动压力差对所述熔融聚乙烯涂层开孔,以在其中产生35到120个穿孔/线性英寸的密度的微穿孔,以提供经微穿孔的非纺织网;和然后
(c)通过将所述的经微穿孔的非纺织网供给通过穿孔辊而对其进行热机械穿孔,所述穿孔辊中的至少一个具有凸起的凸起物以在其中产生延伸通过至少聚乙烯涂层的大穿孔,所述大穿孔具有6到35个穿孔/线性英寸的密度,其中所述微穿孔和所述大穿孔能够吸收和输送液体。
11.权利要求10的挤出涂覆的穿孔非纺织网,其中聚乙烯涂层具有10到15gsm的基重。
12.权利要求10的挤出涂覆的穿孔非纺织网,其中聚乙烯涂层包括共挤出的聚合物共混物和无机填料粒子。
13.权利要求10的挤出涂覆的穿孔非纺织网,其中微穿孔具有45到80个穿孔/线性英寸的密度。
14.权利要求10的挤出涂覆的穿孔非纺织网,其中大穿孔在形状上是椭圆形的并且延伸通过聚乙烯涂层和非纺织网两者。
15.权利要求10的挤出涂覆的穿孔非纺织网,其中大穿孔具有8到25个穿孔/线性英寸的密度。
16.权利要求15的挤出涂覆的穿孔非纺织网,其中大穿孔在形状上是椭圆形的并且延伸通过聚乙烯涂层和非纺织网两者。
17.权利要求16的挤出涂覆的穿孔非纺织网,其中微穿孔具有45到80个穿孔/线性英寸的密度。
18.权利要求17的挤出涂覆的穿孔非纺织网,其中聚乙烯涂层包括共挤出的聚合物共混物和无机填料粒子。
19.权利要求18的挤出涂覆的、穿孔的非纺织网,其中聚乙烯涂层具有10到15gsm的基重。
20.一种吸收制品,其包括吸收结构,该吸收结构与由权利要求10的穿孔的非纺织网制成的外衬呈液体连通。
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2010
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BR112012014968B1 (pt) | 2019-12-10 |
WO2011075669A3 (en) | 2011-11-03 |
CN102762375A (zh) | 2012-10-31 |
US10821622B2 (en) | 2020-11-03 |
EP2512804B1 (en) | 2015-07-29 |
US9849602B2 (en) | 2017-12-26 |
EP2512804A2 (en) | 2012-10-24 |
US20180104842A1 (en) | 2018-04-19 |
EP2512804A4 (en) | 2014-02-26 |
BR112012014968A2 (pt) | 2016-04-05 |
WO2011075669A2 (en) | 2011-06-23 |
US20110151185A1 (en) | 2011-06-23 |
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