CN104470477A - 用于吸收制品的包括吸收芯和/或收集以及分散层的整体吸收结构 - Google Patents
用于吸收制品的包括吸收芯和/或收集以及分散层的整体吸收结构 Download PDFInfo
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- CN104470477A CN104470477A CN201280072375.8A CN201280072375A CN104470477A CN 104470477 A CN104470477 A CN 104470477A CN 201280072375 A CN201280072375 A CN 201280072375A CN 104470477 A CN104470477 A CN 104470477A
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Abstract
本发明涉及一种整体吸收结构及其制造方法,其中所述整体吸收结构包括吸收芯(5)和/或收集(2)和分散(3)层,所述吸收芯(5)和/或收集(2)和分散(3)层包括至少一种无纺纤维基底(23),所述基底(23)具有空隙体积,适用于被高吸水性颗粒渗透,其特征在于,所述高吸水性颗粒沿着所述吸收芯(5)和/或收集(2)以及分散层(3),根据尺寸分布梯度而分散于所述基底(23)内。
Description
技术领域
本申请涉及一种吸收结构,所述吸收结构包括吸收芯和/或收集,以及分散***,所述吸收芯和/或收集以及分散***包括高吸水性颗粒的分散。本发明还涉及包括所述吸收结构的吸收制品,所述吸收制品优选为一次性,例如卫生棉,卫生护垫,婴儿纸尿片,失禁垫,训练裤,汗垫,医用伤口绷带等吸收制品。
背景技术
传统的吸收制品一般通过结合液体可渗透或透过的亲水性或半亲水性的顶层(1),纤维材料,吸收芯(5)和液体可渗透或不透水材料的背层(6)制成。所述顶层(1)和背层(6)指代相对于所述吸收芯(5)的所述层的相对位置。
吸收芯一般由软毛和超强吸收聚合物颗粒(SAP)(21)构成。
多-层吸收制品可包括额外的收集(2)和分散层(3,4),或传统的ADL(19),其具有至少三种功能。顶层为收集层(2),适用于快速获得液体并将该液体传输到位于所述收集层(2)之下的分布层(3,4)处。所述分布层使得液体远离使用者。第三个功能用于防止重新被液体弄湿。
多层ADL在比利时专利BE 1018052中公开,该专利涉及一种改善的多层ADL***,所述ADL***包括3收集(2)和分布层(3,4),改善了液体的分布(图2),收集层(2)一般由粗糙的亲水或疏水纤维构成,所述粗糙的亲水或疏水纤维快速地通过毛细管作用将液体传输到分散层。所述分散层一般包括亲水材料和适用于卫生用品的纤维,所述纤维例如0.7-30dtex、优选为1.5-7dtex的压型或成形多叶型纤维。
SAP颗粒
一般的SAP颗粒(21)由交联的亲水聚合物链构成,所述交联的亲水聚合物链可吸收基于干燥颗粒的重量大约10倍的水。亲水聚合物为天然或合成聚合物或两种的混合物类型。普通的天然聚合物包括纤维素-基聚合物,例如,最终通过额外的亲水功能来改性的纤维素或淀粉,例如:羧化物,膦酸盐或次硫酸盐。合成的亲水聚合物一般为聚醚或聚丙烯酸脂基聚合物。
SAP颗粒(21)可有利地进行涂层或半涂层。额外的涂层可改善SAP颗粒,或提供所述SAP颗粒(21)额外的性质,例如更好的液体吸收能力,颗粒对环境具有更好的粘附力,改善的液体传输能力或更好的机械性能。
吸收芯
吸收芯一般包括SAP颗粒(21)和基底(23),例如纤维,层,软毛或它们的结合的混合物。
当吸收芯是湿的时候,该SAP可吸收大量的液体,然而,湿的SAP颗粒(21)会受到膨胀,因此形成通过邻近的膨胀的SAP颗粒(21)形成凝胶。所述凝胶的形成可阻止液体传输到吸收芯的内部。
结果,凝胶障碍导致了潜在的渗漏和/或可再湿性问题。为了防止凝胶障碍并提高吸收芯的液体吸收能力,各个SAP颗粒(21)应该相互有足够的距离。这一般通过将所述SAP颗粒(21)和纤维素基-软毛混合来获得。
较薄的吸收芯可同样通过减少用在所述吸收芯中组合物的软毛量来获得。
例如,US 5,763,331中公开了一无软毛吸收芯,其包括与支撑层牢固粘附的SAP粒状材料,例如,丙烯酸盐或可生物降解材料。所述支撑层例如为纸,或无纺织布。用于将该超强吸收的粒状物粘附到主支撑层所使用的粘合剂通过喷雾来进行应用。
从US 2003/175418和2002/0090453中可知一种可防止颗粒损失和团聚的方法。
这些专利公开了一种将SAP粉末稳定地粘附到例如:布单,薄膜,泡沫或纤维的基底上的方法,所述SAP粉末经过可固化液态树脂或可固化树脂溶液的处理,
例如:热塑性树脂粉。将SAP粉末用于聚合材料表面,并涂上可固化的液体树脂,随后通过加热固化。所获得的吸收薄膜可减少颗粒团聚和颗粒损失。可替代地,所述SAP粉末可涂有树脂材料并应用于聚合材料表面,并经过固化。以此所获得的吸收薄膜可***布单之间,以形成吸收芯。
WO 03/092757中也公开了一种无软毛吸收芯的方法,所述无软毛吸收芯由SAP颗粒和增塑剂的布单组成。所述增塑剂喷到所述SAP颗粒上,接着通过热压来完成。该增塑剂提高了布单的柔软性和结构整体性,而不会影响所述吸收芯的可再湿性和收集速度。所公开的方法还促进了吸收制品的生产。
从US 4,232,674中还公开了一种液体吸收装置,其中超强吸收聚合物颗粒以预设的方式来放置,例如平行条,使得没有被覆盖的区域用于液体从饱和层到不饱和层区域的毛细管流动。
为了改善吸收制品的液体停留。还需要制备多层吸收芯。例如,US 2003/135178中公开了一种吸收叠层芯,所述叠层芯包括上层和下层,以及内层,其中所述内层之一为中心纤维层,例如包含SAP的纤维丝束。另一个内层选自收集层,分布层,以及可选择地包括SAP额外的纤维层,排汗层,存储层,或它们的结合和分段。
多层吸收芯还可由吸收层或存储层,与传统的ADL(19)结合在单一结构中来获得,以形成吸收芯。单一吸收芯还一般可减少厚度并促进吸收制品的进行。
整体吸收芯的例子如WO 92/11831中所公开的。该专利中的吸收制品包括液体透水顶层,液体非透水背层,以及位于所述顶层和背层之间的多层吸收芯。所述多层吸收芯包括多层吸收体,所述多层吸收体包括收集/分布层和存储层,所述存储层位于每个收集层之下,并包括吸收凝胶材料。利用液体传输包装将所述多-层吸收包裹起来从而得到包裹的多-层吸收体。
WO 91/11163中公开了一种具有ADL的吸收结构,所述吸收结构包括结合工具和优选为卷曲的化学硬化的纤维素纤维,以及液体存储层,所述液体存储层位于每个ADL之下,其包括平均直径为400-700微米的SAP颗粒,以及SAP颗粒的运载工具。
WO 00/41882公开了一种两层吸收的结构,每层包括SAP颗粒,其中的SAP颗粒为不同的浓度,并均匀地处于纤维和粘合剂的矩阵中或位于结构中的离散区域或部分,例如:车道分布。
每层由液体流通的层组成,该两层的不同密度产生了层之间的毛细管压力梯度。
US 2008/312625,US 2008/312632和US 2008/3126621中公开了大致无纤维素的吸收芯,其包括两层吸收层,每层吸收层都具有基底,所述基底包括SAP颗粒和覆盖所述SAP颗粒的热塑性粘合剂。该两层吸收层接合在一起,使得所述两层吸收层的一部分所述热塑性粘合剂相接触。该两层吸收层接合在一起,使得吸收颗粒聚合物材料的各自的形式都相互抵消了。
US 2007/027436中公开了一种薄的,舒适并柔软的吸收制品,该吸收制品包括液体可渗透的顶层,背层,所述背层沿着所述吸收制品周围与所述顶层接合,以及位于所述顶层和所述背层之间的芯,所述芯包括存储层,所述存储层包括超强吸收材料和包括所述超强吸收材料的收集/存储层。
对于所引用的背景技术,需要改进整体吸收结构,提供使用者舒适度,更高的吸收能力,机械稳定性,薄度以及低的可再湿性,而且易于在吸收制品中生产。
发明内容
本发明涉及一种改善的单一吸收结构,所述结构包括吸收芯(5),所述吸收芯具有永久的保持液体能力,以及/或和分散层(16),所述收集(14)和分散层(16)具有暂时保持液体的能力,所述吸收芯(5)和/或收集(14)和分散层(16)包括至少一种无纺材料,例如,纤维基底(23)层,所述纤维基底层具有空的体积,适用于高吸水性颗粒(SAP颗粒)(21)以及粘合剂的渗透,且所述高吸水性颗粒沿着所述吸收芯(5)和/或收集(14)和分散(16)的单一层在深度方向或z-方向上,根据尺寸分布梯度来分散于基底(23)层。图9,10,11,21和23展示了包括基底层(23)中SAP颗粒(21)分布的不同实施例。
在第二方面,本发明涉及一种制造所述吸收芯和/或ADL的方法。
本发明的目的在于在不会影响体液的吸收能力,吸收速度和吸收芯的可再湿润性的情况下,通过减少用于吸收芯所述使用的软毛量来减少所述吸收芯的厚度,该软毛的含量范围一般为40-60wt.%。此外,根据本发明的吸收结构是无软毛的,其中无软毛应该理解成其中的层包括少于4wt.%的软毛,优选地,所述吸收结构一点也不包括任何软毛,且所述软毛指代纤维素软毛。
另一个方面,本发明涉及一种吸收结构,所述吸收结构具有高的体液吸收能力,而不会遇到凝胶障碍的问题。
另一个方面,本发明涉及一种吸收结构,所述吸收结构包括ADL,以形成改善的多层吸收芯,其中的ADL和吸收层为整体的以及集成的。
另一个方面,本发明涉及一种与额外的传统ADL(19)结合的吸收结构或多层吸收结构,所述额外的传统ADL(19)具有或不具有流体保持能力。
本发明的另一个目的在于提供一种结合式的便利,以使用可被直接结合到吸收制品当中的吸收结构
附图说明
图1为一般的吸收制品的截面图,所述吸收制品从上至下包括液体透过的顶层(1),以及液体不可透过的背层(6),收集和分布***(2,3和4),以及吸收芯(5),所述吸收芯(5)一般由软毛和SAP混合组成,通常来说,所述SAP的量的范围是0-60wt.%。
图2为三层传统ADL(19)的截面图,所述三层传统的ADL从上至下包括收集层(2)和两个分布层(3)和(4)。
图3为基底的截面图,所述基底从上至下包括三层的收集(14),再湿层(15)和分布层(16)。
图4为基底的截面图,所述基底包括三层的收集(14),分布层(16)和再湿层(15)。
图5为基底的截面图,所述基底从上至下包括三层的收集(14)和再湿层(15)。
图6为基底的截面图,所述基底从上至下包括三层的收集(14),分布(16)和再湿层(15),其中的第三层为部分疏水的。
图7为基底的截面图,所述基底从上至下包括三层的收集(14),分布层(16)和吸收层(17)。
图8为基底的截面图,所述基底从上至下包括三层的限定空隙体积梯度(18a,18b,18c)的聚酯和聚烯烃的混合物。
图9为基底的截面图,所述基底从上至下包括收集和分散的顶层(19),再湿层,所述再湿层具有更小的空隙体积的空间结构,防止SAP颗粒(21)的损失,以及底层,所述底层具有非常大的空隙体积空间,并包括SAP颗粒(21),以及覆盖层,所述覆盖层涂在所述吸收芯的底部上。
图10为三层基底的截面图,其中的纤维限定了部分填充有SAP颗粒(21)的空隙体积的分布梯度(18a,18b,18c),以及该结构的底部由额外层来覆盖。
图11为完全渗透在基底中的SAP颗粒的截面图,该基底具有空隙体积的分布梯度(18a,18b,18c)。所述芯由顶部和底部(22)的无纺层来覆盖。
图12为部分渗透在基底中SAP颗粒(21)的截面图,所述基底具有空隙体积的分布梯度(18a,18b,18c)。
图13为根据本发明结构制造的方法的简要图。
图14为SAP颗粒(21)的加料***的简要图,展示了沿着无纺基底的y-方向,或横向的SAP颗粒的放置。
图15为在多层吸收芯的制造过程中,SAP颗粒在所述基底上的不连续应用的简要图。所述芯被热熔性粘合剂和芯覆盖层(11)所覆盖,图中还指明了各个芯形成的切割线。
图16为三个所述各个压型的吸收芯的截面图。
图17详细地展示了所提供的辊筒,其用于所述SAP颗粒(21)的粉体分散,以形成压型芯。
图18为沿着x方向或纵向的压型吸收芯的截面图。
图19为在x-y平面上的吸收芯层模式的俯视图。
图20展示了所述SAP颗粒(21)在用于Fibroline方法之前在无纺基底上的放置,以及在用于Fibroline方法之后的,沿着z方向的分散压型。
图21展示了根据本发明的包括分布的有SAP颗粒(21)的ADL,所述ADL位于传统的吸收芯的顶部。
图22展示了根据本发明的涂有覆盖层(22)的吸收结构。
图23展示了根据本发明的位于所述吸收芯的顶部的传统的ADL(19)。
图24为成形吸收制品的俯视图。
图25为经过Fibroline方法分散之后,所述放置于无纺基底上SAP颗粒(21)在x和y方向的形态视图。
图26展示了通过芯包裹材料(25)来将各个芯密封(24)的过程。
具体实施方式
根据本发明,本发明不限于任何形式的体液,包括尿液和血液。
发明人研究了一种无软毛的吸收结构,所述吸收结构包括吸收芯和/或ADL。所述吸收结构包括具有尺寸分布的SAP颗粒(21),以及纤维无纺的亲水或疏水的基底(23),所述SAP颗粒(21)基于它们的尺寸分布而分散在所述纤维基底(23)内。所获得的吸收结构还进一步涂有覆盖层(22),所述覆盖层例如:纺粘,PE膜,PET膜,聚烯烃,多层薄膜,共挤出薄膜,梳理无纺织或任何合适的材料,并通过粘合剂与芯固定。
除了高的体液保持能力,以及吸收制品的薄感,使用本发明的吸收结构还有其它的优点,例如更好的转换,由于SAP颗粒(21)在吸收结构特定部分的分散以及没有软毛所带来的改善的性能和可靠性。使用这种芯和/或ADL更经济,因为不需要额外的方法,例如:锤磨作用来制备软毛,此外,可降低仓库和包装,以及运输的成本。
有利地,根据本发明的所述吸收结构为多层结构,所述多层结构包括顶层,所述顶层可确保液体良好的收集和分布;中间层,所述中间层适于防止液体回到表面,所述中间层为无孔的,其中的无孔由空隙体积值范围在每平方米基底的空隙体积中为约10-600cm3所限定。该吸收结构还包括多孔纤维底层,其中根据本发明的多孔由空隙体积范围在每平方米的基底的空体积为约0.1-20000cm3所限定,并优选为每平方米基底的空体积为约600-6000cm3所限定。所述多孔底层所包括的涂层或非涂层SAP颗粒(21)因此形成了位于所述中间层之下的SAP层。基于所述SAP颗粒(21)的尺寸分布阶梯,包括SAP层的SAP颗粒分散在所述底层内,其中较小SAP颗粒(21)更深地并入所述底层,而较大的颗粒保留在所述底层的外部。使用空隙体积值范围在每平方米基底中的空隙体积为约10-600cm3的合适的无孔芯覆盖层(22)来防止所述SAP颗粒(21)的释放,其中所述芯的覆盖层材料通过粘合剂方式,超声波焊接和/或任何合适的方法来固定在所述吸收结构中。
本发明的吸收结构包括SAP颗粒(21),其中至少90%,优选为95%,或98%的SAP颗粒(21)所具有的颗粒尺寸直径范围约45-850μm,优选为约100-800μm。所述更小的SAP颗粒(21)尺寸可例如:沿着z方向,更深地渗透至所述基底(23)的底部,而较大的SAP颗粒(21)保留在所述基底(23)的外部,或保留在所述基底(23)的表面上,以此基于SAP颗粒(21)的尺寸梯度而形成吸收层。
本发明的吸收结构包括完全结合到所述吸收芯和/或ADL内的SAP颗粒(21)层,可实现比传统的吸收芯更薄的渗透的吸收制品,因为这些传统的芯一般需要软毛吸收分布层或其它纤维素基纤维***,例如,卷曲纤维或标准的ADL***(19)与软毛固定芯结合。
根据本发明的吸收芯具有优越的液体吸收性质和较低的可再湿性。可假设分布在基底(23)的具有尺寸分布梯度的SAP颗粒(21)可在所述SAP颗粒(21)处于膨胀状态时防止凝胶的形成。
高吸水性颗粒
根据本发明,SAP颗粒(21)为未经过涂层,部分或完全经过涂层。
适用于本发明的商业可用的未涂层SAP颗粒(21)为Ecotec EK-X EN 67聚合物等级,一般用在吸收芯中,所述吸收芯包括SAP和软毛,其含量达到80wt.%的SAP装载量,Evonik:Favor SXM 10000。
SAP颗粒(21)可结合到吸收层或ADL或吸收层和ADL两者中。
吸收芯
根据本发明的吸收芯通过利用SAP颗粒(21)来完全渗透无纺基底(23)来获得,因此,可使用额外的传统的ADL(19),如图23所示。
根据本发明的完全被SAP颗粒(21)渗透的基底(23)包括达到1000g/m2的SAP,优选为约300-500g/m2的SAP颗粒(21),这取决于体液保持能力。
为了避免凝胶障碍,膨胀的SAP颗粒(21)必须有足够的距离而足以被渗透,从而使得液体,例如体液,可穿过吸收层。这可通过发明人基于SAP颗粒尺寸梯度来在所述基底(23)中分布SAP颗粒来获得。不受任何理论的限制,相信只有更小的SAP颗粒(21)可沿着z-方向深入地渗透基底(23),而较大的SAP颗粒(21)保留在所述基底(23)的外部上。因为较小的SAP颗粒(21)相互有足够的距离,其确实可防止凝胶障碍问题,而较大的SAP颗粒(21)可逐步地吸收过多的体液。
优选地,本发明的吸收结构可结合传统的ADL(19)。
图23展示了根据本发明的吸收芯,其包括无纺基底(23)以及在所述基底(23)中的SAP颗粒(21)的分散,该分布取决于SAP颗粒(21)的尺寸梯度。所述吸收芯在其顶部进一步地与传统的ADL(19)结合。
图12还展示了根据本发明的吸收制品在吸收液体之后的膨胀状态,该吸收制品使用了3层具有SAP颗粒(21)的ADL结构。
收集,分散,层(ADL)
在第二个实施例中,在包括ADL结构的基底(23)中,基于尺寸分布梯度,分散有特定量和尺寸的SAP颗粒(21),例如,基底(23)部分地被SAP颗粒(21)所渗透,图9和10展示了该第二实施例。
根据本发明,包括足够量的SAP颗粒来吸收液体或体液的ADL可直接用作整体吸收结构(图9和22),所述结构包括ADL部分和吸收部分,所述吸收部分包括分散的SAP颗粒(21)。一般达到1000g/m2,并优选为约300-500g/m2的SAP颗粒(21)足以结合到一个ADL和吸收芯的单元中。
ADL还包括低含量的SAP颗粒(21),所述SAP颗粒(21)用作暂时的存储或量涌层(20)(图21)。一般在0.1-300g/m2并优选在约100-200g/m2的量被认为是低含量的SAP颗粒(21)。在后者的情况下,必须用额外的吸收芯来与所述ADL结合。合适ADL应该吸收水或液体,并缓慢地将其释放到吸收芯。
一般来说,ADL为多-层结构,包括收集层(2)和分散层(3,4)。在一个优选的实施例中,包括SAP颗粒(21)分散的ADL为3层结构,其由一个收集层(2)和2个扩散(3)层构成。
在一个特定的实施例中,根据本发明的三层ADL可包括收集层(14),再湿层(15)和分布层(16),如图3所示。
所述顶层为非常多孔的收集层(14),使得液体可轻易地渗透结构。
中间层为无孔的扩散层,防止液体从回到顶部表面。根据本发明的无孔材料的空隙体积范围由每平方米所述基底(23)的空体积为约10-600cm3所限定。所述扩散层还是非常亲水的,使得液体可在芯上扩散。
所述底层包括压型,或多叶片,纤维来改善在吸收芯上的液体分布。商用的多叶片纤维非限制地为DG 6dn,4T 3dn,三叶形6dn,五叶形6dn,quadfill 7dt,优选地,所述纤维为三叶形6dn或五叶形6dn和其它形状。
在根据本发明的其它实施例中,三层ADL包括收集(14),分布(16)和再湿(15)层,如图4所示。
所述顶层为非常多孔的收集(14)层,以此使得液体可渗透到吸收芯中。
所述中间层为包括压型纤维的分散层,以此改善液体到底层的分布。
所述底层为包括非常精细纤维的无孔层,防止液体回到表面。所述底层非常亲水,使得液体可在芯上扩散。
在根据本发明的另一个实施例中,所述三层ADL包括两层收集(14)层和一个再湿(15)层,如图5所示。
所述顶层为非常多孔的收集层(14),使得液体可渗透到吸收结构中。
所述中间层同样为半多孔的收集层(14),其中根据本发明的所述半多孔由空隙体积在所述每平方米所述基底(23)的空隙体积的约300-500cm3所限定,然而,所述中间层的特点是具有空隙体积分布梯度(18a,18b,18c),以此产生用于传输液体到芯的通道。
所述底层为无孔的,由防止液体回到表面的非常精细的纤维构成。优选地,所述底层为经过轧光的,来甚至降低表面上的空隙体积,防止芯的液体回到表面上,所述底层优选为亲水的,使得液体可在芯上扩散。
在根据本发明的另一个实施例中,所述吸收结构包括三层ADL,还包括收集(14),分布(16)和再湿(15)层,如图6所示。
所述顶层为非常多孔的收集层(14),其适用于使得液体渗透到吸收结构中。
所述中间层适于液体的分布并扩散到底层,并到芯处。
所述底层为无孔层,由精细的亲水和疏水纤维的混合所构成,阻止了液体回到表面上。
在根据本发明的另一个实施例中,所述吸收结构包括三层,收集(14),分布(16)和吸收(17)层,如图7所示。
所述顶层为非常多孔的收集层(14),使得体液可渗透到所述吸收芯中。
所述中间层为分布层(16),包括纤维,以确保可使用分布层(16)的整个表面。
所述底层包括具有粘胶吸收纤维的纤维的混合,来暂时存储在所述底层的液体,以此在液体传输到吸收芯之前可产生缓冲。
在如图8的另一个实施例中,所述三层ADL包括限定所述三层***的聚酯和聚烯烃纤维的混合,其限定了空隙体积梯度(18a,18b,18c)在每平方米所述基底(23)的空隙体积中为3000,1000和300cm3,所述空隙体积梯度(18a,18b,18c)产生了液体通道。这样导致更高的液体吸收速度。
所述使用的纤维提供了较好的弹性和抗压性,产生了尿片的芯和顶部之间的距离,导致干爽的表面。
适用于本发明的ADL为无软毛的,并确保了快速的液体吸收,以及好的再湿性能,从而可防止液体回到表面,并保持顶部表面的干爽。还可确保液体很好地扩散和分布,使得可最大量地使用整个芯。
吸收结构
根据本发明的吸收结构可结合吸收部分和收集(14)和分散(16)部分。在特定的实施例中,如图22所示。所述吸收结构由单一或多层无纺纤维基底(23)构成,该基底例如为:聚酯或聚对苯二甲酸乙二醇酯(PET),聚乙烯(PE),聚丙烯(PP),COPP,PET/PE,PET/PP,PET/COP,PP/PE,PLA,PLA/PP,PVA,粘胶,棉,羊毛,PET/COPET,醋酸酯,PTE,PVC,竹,PBT,PA,亚克力,变性聚丙烯腈,以及/或再生纤维所形成的互穿网络以及SAP颗粒(21),以及来自大约0.1-50g/m2,优选为0.7-25g/m2,更优选为2-7g/m2的粘合剂。优选地,所述吸收结构一点都没有包含软毛。可在吸收层内并入大量的SAP颗粒(21),因为可吸收液体的纤维性质不需要受到SAP颗粒(21)的膨胀而产生的凝胶障碍。在本发明的一个优选的实施例中,所述吸收结构包括:25-300g/m2,但优选为60to 150g/m2的ADL,以及/或基底(23);0.1to 1000g/m2的SAP
颗粒(23),优选的SAP颗粒(21)对于婴儿尿片或成人失禁产品来说为:100-500g/m2,对于女性护理产品来说为10-200g/m2,对于伤口包扎来说为:200-400g/m2。一般来说,所述吸收结构包括10-60g/m2的芯覆盖层(22)。
适合用于制备无纺基底(23)的商用纤维的例子为:Acryl Amicor 3.On;AsotaL10D;Eastlon SN-3450CMP1 4.0dn;Fibervisions ES-C Cure 2.2dt;FibervisionsES-DELTA REPEAT II 5.7dt 40mm;Grisuten 22 3.3dt 60mm;Huvis LMF U16 6dn51mm;Huvis LMF VI 64dn 51mm;Huvis OEPOl N215 2.0dn;Ingeo PLASLN2660E2 6.0dn;Invista 295 6.0dn;Meraklon PP Blend PH/HW 4.4dt;PESGreenfiber 6.7dt;Tesil 84M 6.7dt;Trevira 200 6.0dt;Viscocel 3.3dt 40mm;WellmanH1295 7dt;Wellman T0745 17dt 60mm;Wellman H7112 12dt;Wellman H8015 7dt60mm。
根据本发明的吸收结构具有横向尺寸,所述横向尺寸范围非限制地为0.1-800mm。取决于不同的应用,所述吸收结构一般所具有横向,对于婴儿产品来说为:50-180mm;对于成人失禁产品来说为:30-250mm;对于女性护理产品来说为:30-90mm;对于伤口包扎来说为100×100mm2或200×300mm2。
优选地,所述无纺纤维基底(13)为三层基底(23),包括顶层,所述顶层具有收集(14)和分布(16)功能,用于快速收集液体以及使所述液体在中间层的整个表面具有较好的分布。中间层优选为非常亲水的,使得液体可在整个芯扩散。所述中间层同样为无孔的,以防止液体回到顶部表面,并在使用时,以及在整个吸收制品的使用过程中,可保持所述SAP颗粒(21)在被液体膨胀时候,可处于底层之中。
所述底层为非常多孔的,适于被SAP颗粒(21)所渗透,所述底层用作存储层(20)(图9)。
在另一个实施例中,所述SAP颗粒(21)渗透纤维网络的空隙体积梯度(18a,18b,18c),由于纤维的空隙体积梯度(18a,18b,18c),较小的颗粒可比较大的颗粒具有更深的渗透。所述纤维结构的顶侧基本不含有SAP颗粒(21),并可进一步用作收集(14),分布(16)以及再湿层(15)。
在另一个实施例中,所述SAP颗粒(21)可完全渗透单一层或多层,优选为双层或三层结构中。所述结构的顶部或底部被覆盖层(22)所覆盖,所述覆盖层例如为:纺粘布,无纺布,水刺布或聚丙烯,聚乙烯或PET膜,以防止所述SAP颗粒(21)转移到该吸收的外部。
在一个优选的实施例中,所述多层基底(23)具有多孔的顶层,所述顶层适用于所述SAP颗粒(21)在所述基底(13)中的渗透,而底层,或其中一个中间层,为无孔的,以防止所述SAP颗粒(21)通过转移穿过所述基底(23)而造成损失。优选地,可使用至少一个额外的覆盖层(22)来防止所述SAP颗粒(21)的损失,为了更多的覆盖,可使用额外的两层。
如果使用了两层,粘合所述覆盖层(22)的边缘来密封该结构。如果只使用一个结构覆盖层(22),可折叠所述层来包裹所述结构,并粘合其边缘来密封所述结构(图26)。
制备所述吸收结构的方法
图13展示了一种制备适用于本发明的吸收结构的方法,所述方法包含以下步骤:展开所述纤维基底(7)。通过标准尿片生产线的真空技术,利用粉末分散(8)或转鼓形成来将SAP颗粒覆盖在所述基底(7)上。
利用交变电场来确保所述SAP颗粒(21)的均匀分布,该方法为已知的Fibroline方法(9),如在此参考引入的EP 1 526 214或EP 2 165 015中所述。
所述SAP颗粒随后分散在所述基底(7)中,并通过包埋或纠缠和/或选择性的结合步骤之后来固定在所述纤维基底(7)中,在所述选择性的结合步骤中,其中的SAP颗粒(21)通过加入胶黏剂来与无纺纤维结合。
展开芯覆盖层材料(22)。
在所述芯覆盖层(22)的内表面和/或所述基底表面(7)上应用粘合剂(10)。用所述芯覆盖层材料(22)来覆盖所述基底(7)。
确保通过压力(12)的粘合。
卷起吸收结构(13)。
可选择地,对产品进行轧光,以在纵向方向产生通过结构。
Fibroline方法的合适装置包括2个面对面的电极,所述电极由介质材料保护,并与交变高压发生器(10to 50kV)连接,其中:
SAP颗粒(21)和粘合剂的混合物位于所述两个介质材料之间,并施加强的交变电场。
适用于进行所述吸收结构的方法的装置(13)可在ADL和/或芯生产线或尿片或女性护理产品生产线上使用,或在线下使用。
优选地,经过涂层或没经过涂层的SAP颗粒(21)粘到ADL层的纤维处。结合方法非限制地包括粉末涂层和热粘结,热处理,喷涂,粉末分散,活性胶(活化和固化),或它们的结合。
SAP颗粒(21)的直径范围约45μm-850μπι,优选为约100μm-800μm,并优选地具有平均直径尺寸为约300μm-600μm,因为较小的颗粒可有效地渗透ADL,而较大的尺寸颗粒则保留在扩散层的外侧上,以此形成存储层(20)。
粘合剂
根据本发明的合适的粘胶必须有好的粘附性,必须能渗透液体以让液体到达吸收层,并具有的断裂拉伸度为至少100%,优选为600-1800%,以便当所述SAP颗粒(21)被液体膨胀时可防止凝胶障碍问题。优选的粘胶为水基粘胶以及固体粉末粘胶,其经过雾化来结合所述SAP颗粒(21)。合适的商用粘合剂非限制地包括:Bostik H4245;Bostik H20028;Bostik H4322或Fuller Full-Care 8400A。
制造多层吸收芯和/或ADL的方法
根据本发明的制造吸收结构的方法如图13和26所示,所述吸收结构包括吸收芯和/ADL。
优选地,所述方法可用于生产压型的吸收芯和/或ADL。
展开的基底层(7)必须有足够的宽度来处理几个平行的吸收结构。因此,可以非连续的方式在所述基底(7)的整个宽度或横向或y方向上分散并提供所述SAP颗粒(21),如图14所示。
所述方法包括以下步骤:
展开纤维基底(7)。取决于所述基底(7)的空体积分布,所述基底(7)可在生产过程中保持竖直,以防止SAL颗粒(21)的损失。
在所述基底(7)的横向,或y-方向上通过粉末分散(8)部分地放置一定量的SAP颗粒(21)。
施加交变电场(9),来确保所述SAP颗粒(21)的均匀分布,所述SAP颗粒渗透到所述基底(7)中,并通过包埋,纠缠和/或可选择的结合步骤来固定在所述纤维基底(7)中,在其中的可选择的结合步骤中,所述SAP颗粒(21)通过加入粘胶与无纺纤维结合。
在所述基底(7)的表面和/或覆盖层(22)的芯上施加热熔粘合剂(10)。
卷起(11)所述芯覆盖层材料。
用所述芯覆盖层(22)来覆盖所述基底(7)。其中所述SAP颗粒(21)是存在的,热熔粘合剂将所述覆盖层(22)结合到所述基底(7),结合了总体的的SAP颗粒(21)。当所述基底(7)没有颗粒时,所述粘合剂将所述芯覆盖层(22)材料结合到所述基底层(7)的基本不含SAP颗粒(21)的部分上,以此密封所述吸收芯。这种密封防止了SAP颗粒(21)在进行切割时的掉落,并防止所述SAP颗粒(21)移到一侧。
切割在所述基底(7)基本不含SAP颗粒(21)的层,来获得各个芯,如图15所示。
此外,在Fibroline方法(图20)中,某些迁移会发生在侧部,可在所述吸收结构的整个横向上产生SAP颗粒(21)的分布压型(图16),在所述吸收结构的中心部分形成了更高的SAP颗粒(21)浓度区域,而侧部为较低SAP颗粒(21)浓度区域,以此在吸收结构的中心提供了更高的体液存储能力,防止了渗漏的可能性。
优选地,可沿着所述吸收结构的长度或纵向或x-方向来得到所述SAP颗粒的分布压型。所述分布压型在提供的辊筒中产生压型来完成,该辊筒用于通过粉末分散步骤在所述基底(7)上放置SAP颗粒(21)。图17展示了根据本发明所提供的辊筒,其中所述基底(7)的前部,中部和背部都会接收特定量的SAP颗粒(21)。
通过Fibroline方法,可使不同浓度的部分之间的迁移得到均匀化。
如图18所示,使用所述提供的辊筒,可获得沿着纵向(x-方向)的压型吸收结构,所述结构包括SAP颗粒(21)在尿片的前部和中部的更高含量,在背部则较低含量。
因此获得压型吸收结构可包括具有SAP颗粒(21)的吸收部分,所述SAP颗粒部分地渗透在无纺基底(23),以及被覆盖层(22)所覆盖用作ADL的上部,并通过热熔性粘合剂来固定。因此,压型吸收结构可直接用于吸收制品。
优选地,所述SAP颗粒(21)在无纺基底(23)上的放置具有横向和纵向压型,如图25所示。在通过Fibroline方法进行对SAP颗粒(21)的分散之后,所获得的吸收结构会因为在基底(23)中分散的SAP颗粒(21)的量而具有优化的吸收能力。
在一个优选的实施例中,所述SAP颗粒(21)还可在沿着所述基底(23)的x-方向和/或y-方向的离散区域中分散,每个离散区域相互隔开(图19)。根据Fibroline方法,所得到的吸收芯和/或ADL包括不同的图纹,例如,不含SAP颗粒(21)的带状或通道,以此促进了流体的流动和吸收(图19和20)。
所述吸收结构可简单地用作吸收制品的吸收结构(图26),并可方便地与人体状的吸收制品配用(图24)。
例子
适用于本发明的SAP颗粒(21)为来自Evonik的FAVOR SXM 10000和FAVORSXM 9155。
FAVOR SXM 10000为部分中和的交联聚丙烯酸钠聚合物,其尺寸分布大概如下:
颗粒尺寸(μM) | % |
SAP>850μm | <1% |
600μm<SAP<850μm | 20-45% |
300μm<SAP<600μm | 30-60% |
150μm<SAP<300μm | 5-25% |
45μm<SAP<150μm | <3% |
SAP<45μm | <1% |
FAVOR SXM 9155为交联的聚丙烯酸钠聚合物,其尺寸分布大概为:
颗粒尺寸(μn) | % |
SAP>850μm | <1% |
600μm<SAP<850μm | ~35% |
300μm<SAP<600μm | ~44% |
150μm<SAP<300μm | ~16% |
45μM<SAP<150μm | ~3% |
SAP<45μm | <1% |
Claims (26)
1.一种整体吸收结构,所述整体吸收结构包括吸收芯(5)和/或收集层(2)及分散层(3),所述吸收芯(5)和/或收集层(2)及分散层(3)包括至少一种无纺纤维基底层(23),所述基底层(23)具有适于被高吸水性颗粒渗透的空隙体积,其特征在于,所述高吸水性颗粒根据其沿所述吸收芯(5)和/或收集层(2)及分散层(3)的深度方向或z-方向上的颗粒尺寸分布梯度而分散于所述基底层(23)中。
2.根据权利要求1所述的吸收结构,其特征在于,所述吸收结构不含软毛。
3.根据权利要求1或所述的吸收结构,其特征在于,所述高吸水性颗粒的尺寸分布范围约为45-850μm,优选为约100-800μm。
4.根据前述任一项权利要求所述的吸收结构,其特征在于,所述基底层(23)具有的空隙体积约为基底(23)表面的0.1-20000cm3/m2,优选为所述基底(23)表面的约10-6000cm3/m2。
5.根据前述任一项权利要求所述的吸收结构,其特征在于,所述基底层(23)为多层基底(23)。
6.根据权利要求5所述的吸收结构,其特征在于,所述基底层(23)包括收集层(14)和分散层(16)。
7.根据权利要求6所述的吸收结构,其特征在于,所述基底层(23)为三层,其包括顶部收集层(14)、分散层(16)和中间层,所述中间层具有范围为所述基底(23)的约10-600cm3/m2的空隙体积,还具有底层,所述底层的空隙体积范围为所述基底(23)的约10-600cm3perm2。
8.根据前述任一项权利要求所述的吸收结构,其特征在于,所述无纺纤维选自以下一组:聚酯或聚对苯二甲酸乙酯(PET),聚乙烯(PE),聚丙烯(PP),COPP,PET/PE,PET/PP,PET/COP,PP/PE,PLA,PLA/PP,PVA粘胶,棉,羊毛,PET/COPET,醋酸酯,PTE,PVC,竹,PBT,PA,亚克力,变性聚丙烯腈纤维的再生纤维。
9.根据前述任一项权利要求所述的吸收结构,其特征在于,所述高吸水性颗粒为聚丙烯酸酯聚合物。
10.根据前述任一项权利要求所述的吸收结构,其特征在于,所述高吸水性颗粒根据沿着所述吸收结构的纵向或x-方向上的压型来放置。
11.根据前述任一项权利要求所述的吸收结构,其特征在于,所述高吸水性颗粒根据沿着所述吸收结构的横向或y-方向上的压型来放置。
12.根据前述任一项权利要求所述的吸收结构,其特征在于,所述高吸水性颗粒分散于基底(23)的离散区域,相互间隔,以此促进了沿着所述吸收结构的x-方向和/或y-方向上流体的流动和吸收。
13.一种制造权利要求1所述的吸收结构的方法,其特征在于,所述方法包括以下步骤:
展开纤维基底(7);
用高吸水性颗粒覆盖至少部分的基底(7);
施加交变电场,以确保所述高吸水性颗粒均匀分布;
展开(11)芯覆盖层材料(22);
将粘合剂应用于所述芯覆盖层材料(22)的内表面和/或基底(7)表面;
用所述芯覆盖层材料(22)覆盖所述基底(7);
确保通过压力来粘合。
14.制造多层的如权利要求1所述的吸收结构的方法,其特征在于,所述方法包括以下步骤:
展开纤维基底(7);
用高吸水性颗粒在所述基底(7)的横向上部分覆盖所述基底(7);
施加交变电场,以确保所述高吸水性颗粒均匀分布;
对所述芯覆盖层(22)和/或基底(7)的表面应用热熔性粘合剂;
展开所述芯覆盖层材料(11);
用所述芯覆盖层材料(22)覆盖所述基底(7);
确保通过压力来粘合;
在所述基底(7)中不含高吸水性颗粒的层处进行切割,以获得各个芯。
15.根据权利要求13或14所述的方法,其特征在于,在将高吸水性颗粒覆盖到所述基底(7)表面上的步骤中,使用借助真空技术的粉末分散或转鼓形成术。
16.适用于进行权利要求13或14所述的方法的装置,其特征在于,所述装置可在ADL和/或芯生产线或尿片或女性护理产品的生产线上或线下进行使用。
17.一种包括如权利要求1-12所述的吸收结构的吸收制品。
18.根据权利要求17所述的吸收制品,其特征在于,所述吸收制品包括:
(a)液体可透过的顶层;
(b)液体不可透过的背层;
(c)位于以上(a)和(b)之间的吸收结构。
19.根据权利要求18所述的吸收制品,其特征在于,所述吸收制品包括额外的收集层(2)和分散层(3),所述额外的收集层和分散层位于所述吸收结构的顶部。
20.根据权利要求18所述的吸收制品,其特征在于,所述吸收制品包括额外的吸收芯,所述额外的吸收芯位于所述吸收结构之下。
21.根据权利要求18所述的吸收制品,其特征在于,所述吸收制品包括至少两个如权利要求1所述的吸收结构。
22.根据权利要求17-21所述的吸收制品,其特征在于,所述吸收制品为适应身体形状的。
23.根据权利要求17-22所述的吸收制品,其特征在于,所述吸收制品选自以下组:尿片,轻和/或重的失禁垫,女性护理卫生巾和护垫,或伤口绷带。
24.根据权利要求23所述的尿片或轻和/或重的失禁垫,其特征在于,所述吸收制品包括约0.1-1000g/m2、优选为100-500g/m2的高吸水性颗粒。
25.根据权利要求23所述的女性护理卫生巾或护垫,其特征在于,所述吸收制品包括约0.1-1000g/m2,优选为约10-200g/m2的高吸水性颗粒。
26.根据权利要求23所述的伤口绷带,其特征在于,所述吸收制品包括约0.1-1000g/m2,优选为约100-700g/m2,更优选为200-400g/m2的高吸水性颗粒。
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PH (2) | PH12014502234A1 (zh) |
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