CN103635167A - 弹性层合件的形成方法 - Google Patents

弹性层合件的形成方法 Download PDF

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Publication number
CN103635167A
CN103635167A CN201180072013.4A CN201180072013A CN103635167A CN 103635167 A CN103635167 A CN 103635167A CN 201180072013 A CN201180072013 A CN 201180072013A CN 103635167 A CN103635167 A CN 103635167A
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China
Prior art keywords
elastica
stretched
film
elastic
combining station
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CN201180072013.4A
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CN103635167B (zh
Inventor
P·傅劳柏格
M·金德多尔
I·加布里埃利
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Ihiti health and health care company
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SCA Hygiene Products AB
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    • B29C55/02Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
    • B29C55/04Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique
    • B29C55/06Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique parallel with the direction of feed
    • B29C55/065Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique parallel with the direction of feed in several stretching steps
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Abstract

一种形成弹性层合件(10)的方法,所述弹性层合件包括至少一个弹性膜(11)和至少两个无纺料幅(12、13),所述无纺料幅被层合至弹性膜(11)的每一侧上,其中弹性膜(11)沿着纵向被朝向结合站(14)进给;沿着纵向以从1.5至8倍于弹性膜初始长度的拉伸比拉伸所述弹性膜(11),藉此形成被拉伸的膜;并且在所述结合站(14)中层合所述被拉伸的膜和所述至少两个无纺料幅(12、13)。在将弹性膜与所述至少两个无纺料幅(12、13)层合之前,所述弹性膜(11)在至少两个拉伸步骤中被拉伸,其中总拉伸量的5%至25%发生在结合站(14)中层合之前的最后拉伸步骤中。

Description

弹性层合件的形成方法
技术领域
本发明涉及一种弹性层合件的形成方法,所述弹性层合件包括至少一个弹性膜和至少两个无纺料幅。当弹性膜保持在被拉伸的状态时弹性膜和无纺料幅被层合。
背景技术
弹性层合材料通常被并入吸收性物品、特别是诸如尿裤、卫生裤、失禁裤等裤状吸收性物品中。这些物品包括设置在裤形基体中的吸收单元并且以内裤方式穿戴。弹性层合材料可作为前体和/或后体裁片的一部分和/或作为弹性侧裁片并入裤状吸收性物品中。
如果弹性膜在结合至至少一个无纺层期间沿纵向(MD)处于拉伸的状态,那么无纺层在松弛的状态下可在结合部位之间积聚并且因而使得层合材料沿所述纵向可弹性地拉伸。这种通过熔化熔接、例如由热结合或超声焊接实现的结合可导致在结合部位或者其附近在膜中形成孔。这将使得弹性膜和层合件可透气,这是一个优点并且在吸收性物品中为穿戴者增加了舒适性。
WO2008/026106公开了一种适合于并入吸收性物品中的可透气弹性层合件。所述层合件包括弹性膜和无纺料幅,通过当所述膜处于拉伸状态时在多个结合部位的熔化熔接将弹性膜和无纺料幅结合在一起。熔化熔接的同时在不实质软化无纺料幅的聚合物材料的情况下在结合部位在膜中形成孔。
WO2009/138887公开了由被层合至无纺面料的多层弹性膜形成潜弹性复合物的方法。多层弹性膜沿纵向以从1.5至7.0的拉伸比拉伸,藉此形成被拉伸的弹性膜。被拉伸的弹性膜允许松弛以实现至少10%的松弛百分比并且然后在松弛的状态下层合至无纺料幅面料。
US2010/0139846公开了一种用于结合弹性的高蓬松度衬底的方法,其中弹性的高蓬松度衬底在拉伸的状态下被引入到结合站内。
国际申请PCT/SE2010/050986公开了一种弹性层合件,其包括至少一个弹性膜层和至少一个无纺层。弹性膜层和无纺层通过如下结合图样结合在一起,所述结合图样包括多个结合元件,膜和无纺物在所述多个结合元件中熔接在一起。在结合期间弹性膜保持在被拉伸的状态。通过由于拉伸而引起的膜的破裂,在紧挨结合元件处在弹性膜中形成孔。这些孔使得膜可透气。
仍需求一种弹性层合件的制造方法,在所述方法中用于在结合至无纺料幅之前拉伸弹性膜的过程是受控的以使得结合将以受控的方式发生。当被拉伸的弹性膜通过熔化熔接以结合图样结合至无纺料幅时这是特别重要的,其中在结合元件中或者在紧挨结合元件处在膜中形成孔。
发明内容
根据本发明,提供了一种弹性层合件的形成方法,所述弹性层合件包括至少一个弹性膜和至少一个无纺料幅,所述方法包括:
提供弹性膜并将其沿着纵向朝向层合站进给;
沿着纵向以从1.5至8倍于其初始长度的拉伸比拉伸所述弹性膜,藉此形成被拉伸的膜;
层合所述被拉伸的膜和至少两个无纺料幅,其中
在将弹性膜与所述至少两个无纺料幅层合之前,所述弹性膜在至少两个拉伸步骤中被拉伸,并且其中总拉伸量的5%至25%发生在层合前最后的拉伸步骤中。
弹性膜和至少两个无纺料幅可通过热结合或超声焊接以包括多个结合元件的结合图样被层合。
在弹性膜中、在至少一些结合元件处或紧挨至少一些结合元件处可形成孔,所述孔通过弹性膜由于拉伸引起的断裂而产生。
弹性膜在进入结合站之前可经过至少两个拉伸辊,其中最后的拉伸步骤在最后的拉伸辊与结合站之间进行。
弹性膜在进入结合站之前可经过至少三个拉伸辊。
弹性膜在进入结合站之前可在至少三个步骤中被拉伸。
相邻的拉伸辊之间的自由长度可以在10mm与150mm之间。
层合件的基重可以在40与100g/m2之间并且弹性膜的基重可以在20与60g/m2之间。
定义
术语“纵向”或“MD”指的是在其中制造材料(当前情况下是指弹性层合件)的方向。术语“横向”或“CD”指的是与纵向垂直的方向。
术语“弹性的”或“弹性体的”指的是如下材料,所述材料在施加拉伸力时能够沿至少一个方向(例如沿MD方向)拉伸,并且在释放拉伸力时收缩、即返回至其初始尺寸。弹性材料被定义为如下材料,所述材料在承受30%的伸长之后具有小于10%的松弛后永久伸长。伸长30%意指伸长至比样品的初始长度长30%的长度。如以下在“弹性测试”中描述的,材料在拉伸测试仪Lloyd LRX中测试。
术语“拉伸比”被定义为被拉伸膜的长度除以其拉伸之前的长度。
附图说明
以下将结合示出了一些实施例的附图描述本发明。
图1示意性地图示了根据本发明的一个实施例的用于形成弹性层合件的方法。
图2示意性地示出了用于结合弹性层合件的结合图样的示例。
图3示出了具有弹性体裁片的裤类吸收性物品的示例。
图4示出了具有弹性侧裁片的裤类吸收性物品的另一示例。
具体实施方式
根据本发明的弹性层合材料10包括至少一个弹性膜11和至少两个纤维无纺层12、13,弹性膜层位于所述纤维无纺层之间。根据弹性层合件打算的用途选择合适的无纺材料和弹性膜。在吸收性物品中使用的合适材料在下文给出。
在图1图示的方法中,层11、12和13在结合站14中通过包括多个结合元件的结合图样结合在一起,在所述多个结合元件中弹性膜11和无纺料幅12和13熔接在一起。结合技术可为热点结合、超声结合等。热点结合采用在两个辊之间形成的辊隙(nip),至少一个辊被图样化。一个或两个辊被加热。超声结合采用形成于超声变幅杆15与带图案的辊16之间的结合辊隙。在本质上在本领域众所周知的两种技术中,带图案的辊16包括多个凸起的结合元件以将膜通过由凸起的结合元件形成的结合图样结合至无纺层。
弹性膜11在结合期间处于被拉伸的状态,所述拉伸沿着层合件的纵向(MD)。拉伸的程度应至少为其初始长度的1.5倍,优选在3至8倍于其初始长度的范围。所述拉伸在将如下文更详细描述的至少两个拉伸步骤中进行。
在膜11的松弛之后,无纺层12、13可在结合部位之间积聚并且因而使得层合材料10沿所述纵向可弹性地拉伸。
在弹性膜11在由超声变幅杆15和带图案的辊16形成的结合站14中被层合至无纺层12和13之前,该弹性膜经过多个拉伸辊17、18、19和20。在图1所示的实施例中拉伸辊的数量是四个。拉伸辊的数量应为两个或更多,且可以是三个、四个、五个、六个或更多。拉伸辊具有光滑的高摩擦表面,例如聚合物涂层。合适的高摩擦聚合物涂层的示例是PlasmaCoat 30301/4001F-12。
通过以比辊17更高的圆周速度运行辊18,弹性膜11在两个或更多拉伸辊之间(例如在辊17和18之间)拉伸。根据本发明,弹性膜11在至少两个拉伸步骤中被拉伸。最后的拉伸步骤发生在最后的拉伸辊20与结合站14之间。弹性膜总拉伸量的5%到25%发生在该最后的拉伸步骤中。因此弹性膜总拉伸量的75%到95%在拉伸辊17-20之间以一个或多个步骤发生。
引导辊21设置在最后的拉伸辊20与结合站14之间以便调节弹性膜11相对于带图案的辊15的缠绕角度。在结合站14之前为无纺层12和13还提供有引导辊22和23。
期望的是弹性膜11所谓的“缩颈”被最小化,其中“缩颈”指的是膜在拉伸期间沿宽度方向(CD)的收缩。通过将拉伸辊17-20之间的距离最小化以防止或减少缩颈。相邻的拉伸辊之间的距离可测量为所述辊之间的自由长度a,即膜离开一个辊处的点和膜与下一个辊接触处之间的距离。该自由长度a可以在10mm与150mm之间以便最小化膜的缩颈。
取决于结合图样中将无纺料幅12、13与弹性膜11结合到一起的结合元件24的选择,孔25可在弹性膜中在紧挨至少一些结合元件24处形成。这在图2中示出。这些孔25通过弹性膜由拉伸而导致的破裂所形成。这些孔25可位于各个结合元件24区域的外部并且由在紧挨结合元件的区域中的膜中的张力形成。“紧挨”意指所述孔从各个结合元件的周界延伸。孔大体上沿MD方向延伸并且可位于各个结合元件24的前面和/或后面。孔使得弹性层合件10能透气。
这在国际申请PCT/SE2010/050986中更详尽地描述,其中给出了结合图样的示例,其将提供在膜中形成孔。
上述将弹性膜在两个或更多步骤中拉伸的方法(其中最后的拉伸步骤发生在最后的拉伸辊与结合站之间)使得弹性膜在结合之前立即张开,导致对所生产的弹性层合件的结合以及特性的改善了的控制。膜在拉伸期间更敏感,这使得其在结合期间“张开”。当在结合期间孔在膜中形成时这是尤其重要的,并且多步骤的拉伸将改善对孔形成的控制以及因而改善层合件的透气性。
弹性层合件可在吸收性物品中使用。术语“吸收性物品”指代抵靠穿戴者皮肤放置以便吸收和容纳人体分泌物(例如尿液、粪便以及月经流体)的产品。这样的吸收性物品通常是一次性的,其意指所述物品并非是打算洗涤的或以其他方式复原或是在使用后再次作为吸收性物品使用。包括弹性层合件的吸收性物品优选为诸如尿裤、卫生裤或失禁裤的裤类吸收性物品。
图3示出了用于婴儿或失禁的成人的裤类吸收性物品26或卫生裤的实施例。所述裤物品大体上包括基体27,所述基体包括前裁片28、后裁片29、裆部部分30以及弹性腰带31。包括吸收芯33的芯部区域32至少位于物品的裆部部分30中并且延伸进前裁片28和后裁片29一定距离。在此裆部部分30限定为物品的意图穿戴在穿戴者***胯部上的狭窄部分。在另一实施例(未示出)中,前裁片和后裁片彼此分开并且包括吸收芯的芯部区域桥接前裁片与后裁片之间的间隙。
芯部区域32还包括位于吸收芯33下面的不透液底片34和在吸收芯的面向穿戴者侧上的透液顶片(未示出)。吸收芯、底片和顶片可以由通常在吸收性物品中使用的材料制成。
所述物品具有纵向方向y和横向方向x。
根据本发明的一个实施例,在物品平坦状态下被测量时,吸收芯30的表面积合计不超过物品总表面积的30%,优选不超过20%。术语“平坦状态”这里意指打开的不受张力的状态,其中侧接缝打开并且任何受张力的弹性件已被去激活。
弹性层合件10可覆盖整个物品,包括芯部区域32和整个基体区域27。然而根据优选实施例,物品的裆部部分30的大部分没有弹性料幅材料10。这里所使用的“大部分”指至少50%,优选至少75%。基体区域的腰部区域也可没有弹性层合件10并且可包括单独的弹性腰带31。弹性腰带31包括通过诸如弹性线的弹性件35赋予弹性的无纺材料,所述弹性件能收缩地贴附在诸如无纺材料的材料层之间。这样的弹性件35也可围绕物品的腿部开口设置。超声焊接37、胶线等将弹性层合件10接合至弹性腰带31。
无纺材料可在物品裆部部分中设置在不透液底片34的朝向衣物侧上。无纺材料借助于超声焊接37、胶线等接合至弹性层合件10。
弹性层合件10优选地设置为基体27的除腰部区域以外的至少大部分前部区域28(其在使用期间意欲抵着穿戴者的胃部施加)之上的外侧盖片材料以及内侧盖片材料。这里使用的“大部分”意指基体前部区域表面积的至少50%,优选至少75%。进一步优选的是,弹性层合件10设置为基体27的前部区域28和后部区域29两者之上的外侧盖片材料以及内侧盖片材料。因而不需要额外的底片或顶片材料,并且弹性料幅材料构成了基体27的这些部分中的单独部件。如在上述的平坦状态中所示,在物品的总表面积的至少20%、优选至少25%、更优选至少30%且最优选至少40%中,弹性层合件10构成了基体的单独部件。
覆盖了基体27的前裁片28和后裁片29的外盖片包括弹性层合材料10,所述弹性层合材料至少沿物品的横向方向x是弹性的。在通过以下具体说明的弹性测试测量时,沿x方向的弹性率应为至少30%、优选至少50%、更优选至少70%。这里物品的横向方向x与上述弹性层合件的MD方向一致。
对于被用作裤类吸收性物品中前裁片28和/或后裁片29的弹性层合件而言,所述层合件包括至少三层,即第一和第二外无纺层12、13,所述外无纺层选择成使得它们连同内弹性膜层11为弹性层合件10赋予了高耐穿刺性,以便防止被例如指甲穿透。它们还为层合件提供了柔软和类似布料的感觉。合适材料的示例为经梳理的料幅以及纺粘材料。纤维材料层的基重应当在10g/m2与35g/m2之间,优选在12g/m2与30g/m2之间,更优选在13g/m2与25g/m2之间。在纤维材料中使用的合适的聚合物的示例为聚乙烯、聚酯、聚丙烯以及其他聚烯烃均聚物和共聚物。也可使用天然纤维(例如棉花),只要它们提供所需的特性。聚合物的混合物能对无纺层更高的柔性有帮助,并且通过于此,赋予无纺材料在最大负载下更高的伸长量。聚乙烯和聚丙烯聚合物的混合物已被证实在这方面能提供良好的效果。不同聚合物纤维的混合物也是可以的。无纺层12、13应被选择为使得层合件的抗拉强度足以适于预期的目的。
优选地,弹性膜11的基重在20g/m2与80g/m2之间,优选在20g/m2与60g/m2之间。弹性膜11可由任何合适的弹性聚合物(天然的或人工合成的)制成。用于弹性膜的合适材料的一些示例为低结晶度聚乙烯、茂金属催化的低结晶度聚乙烯、乙烯乙酸乙酯共聚物(EVA)、聚氨酯、聚异戊二烯、丁二烯-苯乙烯共聚物、苯乙烯嵌段共聚物,例如苯乙烯/异戊二烯/苯乙烯(SIS)、苯乙烯/丁二烯/苯乙烯(SBS)、或苯乙烯/乙烯-丁二烯/苯乙烯嵌段共聚物。也可使用这些聚合物的混合物、还有其他更改的弹性体或非弹性体材料。合适的弹性膜的一个示例是PE-SEBS-PE的三层弹性体膜。
弹性层合件10的总基重优选在40g/m2与100g/m2之间,更优选地不超过90g/m2
尽管根据本发明的弹性层合件10主要意在用于裤类吸收性物品中,其中弹性层合件在前裁片和后裁片的至少一个中一路在物品的侧接缝之间延伸,然而弹性层合件也可用于例如形成吸收性物品中的弹性侧裁片。图4示出了包括弹性侧裁片38的裤类吸收性物品。所述物品进一步包括前体裁片39和后体裁片40以及裆部部分41。前体和后体裁片还有裆部部分大体上包括不透液底片、透液顶片以及位于所述底片与顶片之间的吸收芯42。吸收芯、底片和顶片可由通常在吸收性物品中使用的材料制成。底片可进一步包括被层合至膜层的无纺材料层,与通常仅通过膜底片获得的感觉相比,在这种情况下提供了更加类似于布料和类似于衣物的感觉。
设置能弹性地伸长的侧裁片38以确保更加舒适的随形配合。弹性侧裁片38或者至少其部分可包括根据本发明的弹性层合件10。也可设置腿部弹性区域和腰部弹性区域以分别增强腿部和腰部周围的配合。
测试方法
弹性测试
该方法测量了弹性材料在重复的加载和卸载循环下如何表现。样品被拉伸至预定的伸长量并且实施在0与所述预定伸长量之间的循环运动。记录期望的加载力和卸载力。松弛材料的永久(即剩余)伸长量被测量。
使用能够实施循环运动并且装配有打印机/绘图机或软件演示的拉伸测试仪Lloyd LRX。通过将样品裁切至25.4mm的宽度以及优选比拉伸测试仪中夹具之间距离长50mm的长度而准备好样品。
根据设备说明书将拉伸测试仪校准。用于测试(加载力和卸载力)所需的参数被调节成:
·十字头速度:500mm/分
·夹具距离:50mm
·预加载荷:0.05N
样品在50%±5%的相对湿度(RH)以及23℃±1℃的环境下至少4小时并且根据标记放置在夹具中,并且确保样品在夹具中对中且被垂直地紧固。拉伸测试仪启动并且实施在0与预定伸长量(等于最高定义的第一负载)之间的三次循环。在最后一次循环之前,使样品松弛1分钟,然后通过拉伸样品直至检测到0.1N的力为止而测量永久伸长量并且所述伸长量被读取。
弹性材料定义为如下材料,所述材料在承受30%的伸长之后具有小于10%的松弛后永久伸长。30%的伸长意指伸长至比样品的初始长度长30%的长度。因此具有至少30%弹性率的材料被定义为该材料在上述拉伸测试仪中被施加至30%的伸长之后应当具有小于10%的松弛后永久伸长。具有至少50%弹性率的材料被定义为该材料在上述拉伸测试仪中被施加至50%的伸长之后应当具有小于10%的松弛后永久伸长,等等。
非弹性材料在已承受30%的伸长之后具有超过10%的松弛后永久伸长。
示例
生产了一种弹性层合件,其包括弹性膜以及两个被层合至弹性膜每一侧的无纺层。弹性膜为来自Berry Plastics的30gsm的多层膜,其具有基于苯乙烯的芯部层以及聚烯烃表皮层。一个无纺层是来自Freudenberg的具有编码LS4516(白色)、克数16gsm、纤度1.6-1.8dtex的聚丙烯纺粘无纺层,并且另一无纺层是来自Freudenberg的具有编号Lutrasil 0519XF、克数19gsm、纤度1.6-1.8dtex的聚丙烯纺粘无纺层。
通过超声焊接将弹性膜和无纺层以结合图样层合,所述结合图样包括多个结合元件,在所述结合元件中弹性膜和无纺料幅熔接在一起。结合图样如PCT/SE2010/050986中所限定的。弹性膜以两个拉伸步骤以4.5倍其初始长度的拉伸比沿纵向被拉伸,其中12%的拉伸发生在紧挨如上所述的层合之前的最后的拉伸步骤中。被拉伸的膜和无纺料幅在膜受拉伸的状况下被层合。通过由于上述拉伸而引起的弹性膜的破裂,在紧挨结合元件处在弹性膜中形成孔。生产的弹性层合件是能透气的,在200Pa下其具有高过12[m3/m2·min]的平均的透气性。

Claims (8)

1.一种形成弹性层合件(10)的方法,所述弹性层合件包括至少一个弹性膜(11)和至少两个无纺料幅(12、13),所述无纺料幅被层合至弹性膜(11)的每一侧上,所述方法包括:
提供弹性膜(11)并沿着纵向将其朝向结合站(14)进给;
沿着纵向以从1.5至8倍于弹性膜初始长度的拉伸比拉伸所述弹性膜(11),藉此形成被拉伸的膜;
在所述结合站(14)中层合所述被拉伸的膜和所述至少两个无纺料幅(12、13),
其特征在于:
在将弹性膜与所述至少两个无纺料幅(12、13)层合之前,所述弹性膜(11)在至少两个拉伸步骤中被拉伸,其中总拉伸量的5%至25%发生在结合站(14)中层合之前的最后拉伸步骤中。
2.根据权利要求1所述的方法,其特征在于:所述弹性膜(11)和至少两个无纺料幅(12、13)通过热结合或超声焊接以包括多个结合元件(24)的结合图样被层合。
3.根据权利要求2所述的方法,其特征在于:在所述弹性膜(11)中、在至少一些结合元件(24)处或紧挨至少一些结合元件处形成孔(25),所述孔通过弹性膜由于拉伸引起的断裂而产生。
4.根据前述权利要求中任一项所述的方法,其特征在于:所述弹性膜(11)在进入结合站(14)之前经过至少两个拉伸辊(17-20),其中最后的拉伸步骤发生在最后的拉伸辊(20)与结合站(14)之间。
5.根据权利要求4所述的方法,其特征在于:所述弹性膜(11)在进入结合站(14)之前经过至少三个拉伸辊(17-20)。
6.根据权利要求5所述的方法,其特征在于:所述弹性膜(11)在进入结合站(14)之前在至少三个步骤中被拉伸。
7.根据权利要求4至6中任一项所述的方法,其特征在于:相邻的拉伸辊(17-20)之间的自由长度(a)在10mm与150mm之间。
8.根据前述权利要求中任一项所述的方法,其特征在于:所述层合件(10)的基重在40g/m2与100g/m2之间并且所述弹性膜(11)的基重在20g/m2与60g/m2之间。
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CN111513926B (zh) * 2015-01-30 2021-10-26 大王制纸株式会社 吸收性物品及其制造方法
CN107205859B (zh) * 2015-01-30 2021-07-20 大王制纸株式会社 吸收性物品及其制造方法
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