CN104470478B - 用于吸收制品的包括吸收芯和/收集和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/收集和分散层的整体吸收结构 Download PDFInfo
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- CN104470478B CN104470478B CN201380019858.6A CN201380019858A CN104470478B CN 104470478 B CN104470478 B CN 104470478B CN 201380019858 A CN201380019858 A CN 201380019858A CN 104470478 B CN104470478 B CN 104470478B
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Abstract
本发明涉及一种整体吸收结构,及其制造方法,所述整体吸收结构包括吸收芯(5)和/或收集(2)和分散(3)层,所述吸收结构包括至少一个无纺纤维基底(23)层,所述无纺纤维基底(23)层具有可被高吸水性颗粒穿透的空隙体积,所述高吸水性颗粒根据通过真空(8')和振动,沿着所述吸收芯(5)和/或收集(2)和分散(3)层的深度方向或z‑方向的粒径分布梯度而分散于所述基底层(23)中,其中,较小的颗粒位于吸收制品的身体侧,而较大的颗粒位于该吸收制品的相对侧。
Description
技术领域
本本申请涉及一种吸收结构,所述吸收结构包括在吸收芯和/或收集和分散***内的分散的高吸水性颗粒层。
本发明还涉及一种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的吸收制品,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 1 018 052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纤维,适用于范围在0.7-30dtex,并优选为1.5-7dtex的压型或成形多叶片纤维的卫生用品,其中1dtex代表每10000米当中有1克的纤维。
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 2009/0087636中可得知一种吸收结构,所述吸收结构包括纤维基底和SAP颗粒的分散,然而SAP颗粒仅仅位于所述基底结构内,而且颗粒的分布不一致,特别对于较小的颗粒,它们会从它们的位置移走。US 5,294,478中公开了一种吸收结构,所述吸收结构包括纤维基底和SAP分散的梯度,然而,较大的颗粒置于主身体侧而较小的颗粒位于相对侧。这些文件都没有公开一种较小颗粒位于主身体侧而较大颗粒位于相对侧的梯度。
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)结合在整体结构中来获得,以形成吸收芯。整体吸收芯还一般可减少厚度并促进吸收制品的进行。
整体的吸收芯的例子如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,需要改进整体的吸收结构,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
本申请涉及一种改进的吸收结构,所述吸收结构包括至少一种无纺材料,例如纤维基底(23),所述纤维基底具有适用于被高吸水性颗粒(SAP颗粒)所渗透的空隙体积,以及粘合剂,且所述高吸水性颗粒根据沿着所述吸收芯(5)和/或收集(14)和分散(16)整体层的深度方向或z-方向上的尺寸分布梯度分散于所述基底层(23)内。例如较小的颗粒位于所述吸收制品的主身体侧,而较大的颗粒位于所述吸收制品的相对侧。所述包括SAP颗粒的分散的基底层用于具有永久液体保持能力的吸收芯(5)内,和/或具有暂时保持液体能力的收集和分散层(14,16)内。图9,10,11,21,22和23展示了包括基底(23)中SAP颗粒(21)分布的不同实施例。
在第二个方面,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和13bis为根据本发明的制造结构的方法。
图14为SAP颗粒(21)的加料***的简要图,展示了所述SAP颗粒(21)沿着无纺基底的y-方向,或横向上的放置。
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颗粒在分散步骤之前在无纺基底上的放置。
图21展示了根据本发明的包括分散的SAP颗粒(21)的ADL,所述ADL位于传统吸收芯的顶部。
图22展示了根据本发明的涂有覆盖层(22)的吸收结构。
图24为身体形状吸收制品的俯视图。
图26展示了利用芯包裹材料(25)来密封各个芯的方法。
具体实施方式
根据本发明的液体非限制地包括任何体液,例如:尿液和血液。
本发明研究了一种无软毛的吸收结构,所述吸收结构包括整体吸收结构,该整体吸收结构包括:吸收芯(5)和/或收集和分散层(2,3),包括至少一个无纺纤维基底(23),所述无妨纤维基底(23)具有的空隙体积适于被所述高吸水性颗粒所渗透,所述无纺纤维基底可为亲水或输水,且所述高吸水性颗粒(21)具有尺寸分布,并根据沿着深度方向或z-方向上的尺寸分布梯度而分散于所述基底层(23)内。较小的颗粒位于身体侧而较大的颗粒位于吸收制品的相对侧。所述包括SAP颗粒的纤维基底可合并到吸收芯和/或ADL结构中。
所获得的吸收结构还可通过覆盖层(22)来涂层,所述覆盖层(22)例如为:纺粘,PE膜,PET膜,聚烯烃,多层薄膜,共挤出薄膜,梳理无纺布。
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,所述顶层确保良好的液体吸收和分布;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,例如较小的SAP颗粒位于所述吸收制品的身体侧,而较大颗粒位于所述吸收制品的相对侧。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%,或更优选为98%的SAP颗粒(21)所具有的粒径直径范围约45-850μm,优选为约100-800μm,更优选为约200-500μm。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)的内部,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。所述基底可翻转使得较小的尺寸位于所述吸收制品的身体侧,而较大的颗粒位于所述吸收制品的相对侧。
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SAP颗粒(21)通过尺寸分布梯度而分散在基底(23)上,其中较小的颗粒位于所述吸收制品的身体侧,而较大的颗粒位于所述吸收制品的相对侧,这种吸收制品可在所述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,Favor9155。
有利地,所述SAP颗粒提供了球形,如来自Arkema的Aquakeep SA55SX或SumitomoSA60F。
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粒径梯度来在所述基底(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。翻转该结构,较小的颗粒位于所述吸收制品的身体侧,而较大的颗粒位于所述吸收制品的相对侧。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,基底的使用使得较小的颗粒位于所述吸收制品的身体侧,而较大的颗粒位于所述吸收制品的相对侧。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。所述吸收结构由整体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;Fibervisions ES-DELTA REPEAT II 5.7dt 40mm;Grisuten 22 3.3dt 60mm;Huvis LMF U16 6dn 51mm;Huvis LMF VI 6 4dn 51mm;Huvis OEPOl N215 2.0dn;Ingeo PLA SLN2660E2 6.0dn;Invista 295 6.0dn;Meraklon PP Blend PH/HW 4.4dt;PES Greenfiber 6.7dt;Tesil84M 6.7dt;Trevira 200 6.0dt;Viscocel 3.3dt 40mm;Wellman H1295 7dt;WellmanT0745 17dt 60mm;Wellman H7112 12dt;Wellman H8015 7dt 60mm。
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,SAP颗粒(21)渗透所述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),更小的颗粒将比更大的颗粒渗透得更深。在翻转所述结构后,所述纤维结构的顶侧基本不含有SAP颗粒,并还可用作收集(14),分布(16)和再湿层(15)。
在另一个实施例中,所述SAP颗粒可完全渗透单一层或多层,优选为两层或三层结构。所述结构的顶部和底部被覆盖层(22)所覆盖,所述覆盖层例如为:纺粘,无纺布,水刺或聚丙烯薄膜,聚乙烯或PET,以防止所述SAP颗粒(21)转移到所述吸收的外部。
在一个优选的实施例中,所述多层基底(23)具有多孔的顶层,其允许SAP颗粒在所述基底(23)中的渗透,而底层,或其中一个中间层,为无孔的,其防止了所述SAP颗粒通过转移穿过基底(23)而流失。有利地,使用至少一个额外的覆盖层(22),来防止SAP颗粒(21)的任何流失。为了具有更多的覆盖,
可使用额外的两层。
如果使用了两层,粘合所述覆盖层(22)的边缘来密封所述结构。如果使用了一个结构覆盖层(22),可折叠所述层来包括该结构,并粘合其边缘来密封所述结构。最理想的方式是按照C形状(C-包裹)来包裹所述结构,但这不是必要的(图26)。
制备吸收结构的方法
一种制备本发明的吸收结构的方法包括以下步骤:
展(11)开纤维基底(7),并最终机械打开所述基底,所述基底可在放置SAP颗粒之前或之后使用。
利用标准尿片生产线的真空技术(8'),重力自流;高压喷枪(气压炮),通过粉末分散(8),转鼓形成来将所述SAP颗粒(21)覆盖到基底(7)上。
所述SAP颗粒(21)通过振动和/或真空台(8')的使用随后分散到基底(7)内。从0bar(巴)到150bars;
优选为低于10bars。所述SAP颗粒(21)通过包埋或纠缠和/或可选择的结合步骤之后来固定在所述纤维结构(7)中,在所述的可选择的结合步骤中,所述SAP颗粒(21)通过加入粘合剂与无纺纤维结合,其可在SAP放置之前或之后进行。优选地,所述粘合通过喷枪来应用。
卷起所述吸收结构(13)。
可选择地,对产品进行轧光来在纵向方向产生通道结构。
优选地,经过涂层或未经过涂层的SAP颗粒(21)粘合到ADL层的纤维处。这种粘合方式非限制性地包括粉末涂层,热处理,喷雾涂层,粉末分散,(和固化)或它们的任何结合。
该SAP分散优选地通过喷枪或真空台的结合来完成。
在将SAP颗粒分散并覆盖到基底的步骤之后,所述基底优选地通过以下步骤被额外的覆盖层所覆盖:
展开(11)芯覆盖层材料(22)。
将粘合剂(10)用于芯覆盖层(22)的内表面和/或基底表面(7)上。
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)来粘合。
合适的装置(见图13和13bis)
适于制备本发明的吸收结构的所述装置(见图13和13bis)可在ADL和/或芯生产线或尿片或女性护理生产线的线上或线下使用。
图13和13bis还展示了可选择的所述基底的预切步骤(26),该切割可在加入SAP颗粒之后进行。
SAP颗粒
SAP颗粒的直径范围在约45μm-850μm,优选为在约100μm-800μm之间,更优选为在200μm-500μm,并优选地具有平均粒径为300-600μm,因为较小的颗粒有效地渗透ADL,而较大的颗粒则保留在扩散层的外侧,以此形成了存储层(20)。优选地,所述不同尺寸的SAP颗粒(21)可成功地分散到基底内。较小尺寸的SAP颗粒(21)可在第一步骤中分散,而在第二步骤中,较大尺寸的SAP颗粒(21)可分散在所述基底中。
粘合剂
根据本发明的合适的粘合剂必须具有好的粘合性,可渗透到液体从而使得液体到达吸收层,并具有的断裂拉伸度至少为100%,优选为600-1800%,以便在SAP颗粒(21)被体液所膨胀时能防止凝胶障碍问题。优选的粘合剂为水基粘合剂和固体粉末粘合剂,其经过雾化来与所述SAP颗粒(21)结合。合适的商用粘合剂非限制地包括:Bostik H4245;BostikH20028;Bostik H4322或Fuller Full-Care 8400A。
制备根据本发明的包括吸收芯和/或ADL的方法,如图13和26所示。
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)必须具有足够的宽度,以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。
该方法包括以下步骤:
展开所述纤维基底(7)。根据所述基底(7)的空隙体积分布,所述基底(7)可在生产过程中保持竖直,以防止SAP颗粒(21)的流失。
在所述基底(7)的横向,或y-方向上通过粉末分散(8),真空转鼓(8'),重力自流(8),或高压***,例如喷枪或气压炮(图13bis)来部分地放置一定量的SAP颗粒(21)。粘合剂可在SAP放置步骤之前或之后加入到基底中。优选地,所述粘合剂通过喷枪应用在基底上。
将振动和真空用于基底,以确保所述SAP颗粒(21)在所述基底(7)中的分布,所述SAP颗粒通过包埋或纠缠和/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。
将热熔粘合剂(10)用于基底(7)的表面和/或芯覆盖层(22)。
展开芯覆盖层材料。
用所述芯覆盖层(22)来覆盖所述基底(7)。在所述SAP颗粒(21)存在之处,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,为了防止SAP颗粒的旁路迁移。可通过加热,加压或超声来加入挤压障碍。
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)。
在分散步骤中,使用振动和真空(8')来使得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具有更高含量,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),以及用作ADL的上部,所述上部被覆盖层(22)所覆盖,所述覆盖层(22)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。通过对基底使用真空(8')和/或振动来对SAP颗粒(21)进行分散之后,所获得的吸收结构会因为SAP颗粒(21)在基底(23)根据x,y和z-方向的梯度分散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)。根据分散步骤,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)的例子为来自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是交联聚丙烯酸钠聚合物,其尺寸分布大慨如下
颗粒尺寸(μm) | % |
SAP>850μm | <1% |
600μm<SAP<850μm | ~35% |
300μm<SAP<600μm | ~44% |
150μm<SAP<300μm | ~16% |
45μn<SAP<150μm | ~3% |
SAP<45μm | <1% |
适用于本发明的SAP颗粒的其它例子是BASF E2535-12
颗粒尺寸(μm) | % |
SAP>560μm | ~8% |
400μm<SAP<560μm | ~51% |
300μm<SAP<400μm | ~23.5% |
220μm<SAP<300μm | ~9% |
SAP<220μm | <8.5% |
ARKEMA AQUAKEEP SA55SX
颗粒尺寸(μm) | % |
SAP>560μm | ~30% |
400μm<SAP<560μm | ~41% |
300μn<SAP<400μm | ~24% |
200μm<SAP<300μm | ~4% |
100μm<SAP<200μm | ~0.5% |
SAP<100μm | <0.5% |
ARKFMA SUMITOHO SA60F
颗粒尺寸(μm) | % |
SAP>560μm | ~12% |
400μm<SAP<560μm | ~30% |
SAP<400μm | ~58% |
SA55SX比SA60F要粗糙,SA55SX:30%>560μm对比于>SA60F:12%>560μm。
支持注入的最合适的粒径为低于500μm。基于此,Aquakeep SA60F和BASF最适合注入。然而,Evonik类可具有相同的分布,当在高斯分布曲线,我们还可以注入其它类型的SAP。
ADL***或替换
对比商用的吸收制品与用本发明的ADL替换的相同产品。***新的ADL进行如下操作:
切开尿片的顶片,如果有ADL的话,沿着ADL小心地打开。为了防止对吸收芯的任何损害,尿片的前部必须保持完整,以便不会影响渗漏。
小心地拆掉ADL,用针表明其在顶片的位置;
要测试的新的ADL随后置于该尿片中;
随后密封,如果需要话的还要粘合该尿片:
扩散和吸收能力测试;
扩散代表吸收装置在长度上的液体分布;
吸收能力代表在渗漏发生前被吸收装置所保持的液体。
尿片
在测量之前,将尿片从它们的包装处拆出大概1小时来完全松软该尿片。
尿片的厚度在0.5kPa的负载下,在三个位置,前部,中心和后部区域来测量。
在渗漏测试前的吸收(ABL)
收集能力和扩散测量的方法是基于Courtray所研究的方法,在每组测试中,对4个样品进行测量。
尿片的扩散值根据液体分散的总长度来测量,而吸收能力利用自动进料***的在人体模型中进行测量,其中的自动进料***确定了剂量和次数。
当渗漏发生时,通过控制***来检测该渗漏,且记录该吸收装置的吸收能力的信号发送到监控***,所记录的吸收能力随后与最初尿片的吸收能力进行比较。
在进行任何测试之前,或在每三次系列测试之后,对***进行校正。
使用盐水溶液作为测试流体。所使用的测试流体的量取决于人体模型的尺寸和尿片的类型。
该尿片进行称重,并在3个不同区域测量厚度。
如果必要的话,按照前述来替换该ADL。
所述尿片在人体模型上进行放置和调节。
所述人体模型根据要进行的测量在其背部或其腹部放置,
至少连续三次剂量将所述测试流体用于尿片。每次剂量的测试流体的流量为200ml/min(+/-5ml/min),且每次剂量相隔5min的间隔。第一剂量用于腹部,第二剂量用于背部,而第三和其它剂量用于腹部。
所述方法还可适用于模仿男孩或女孩。
吸收能力的计算通过湿的尿片的重量减去干的尿片的重量。
扩散通过液体的分散的总长度来测量。
吸收装置的收集时间和再湿性测量。
收集时间是测试液体渗透测试样品的时间。
再湿性是在一定的负载量下被尿片表面过滤纸吸收的液体的量。
设备包括具有管的测试板并称重为2x 4.00kg,使用垫作为支撑,140x 190mm的过滤版来自S&S的604类型号;测试液体来自Kanga的LMT-003型号。
测试在在商用的尿片或特定的样品中进行。
卫生尿片
方法
测试基于Hy-Tec方法。
五个样品同时进行。尿片经过称重并在0.5kPa的负载下,在3个不同的地方,尿片的前部,中部和背部进行厚度测量。
如果需要的话,尿片中原来得到ADL可如上所说地替换成本发明的新的ADL。
标记出尿片的中心点,并以相对于中心点向前2.5cm处来确定尿-点。
尿片用重物和板来进行平躺。测试板与尿片平行并对齐,确保管的中心是尿-点。裤边从片下拉起,使其靠着板,并可吸收任何的少量渗漏。称重在板上的管的两侧进行。
测试液体的量通过自动分配器来测量,并通过称重板内的管来加入,以此模仿尿-点。液体的量取决于尿片的类型和尺寸(见下表)
将样品与原来的没有操作并保持完整的尿片作对比,并与拆掉了ADL并如上述重新***的尿片型号对比。液体在5分钟的等待时间内完全吸收到第三块尿片中。
进行收集时间的测量
5分钟之后,加入芯的剂量,并记录收集时间。
这个步骤重复两次,总共加入了4份剂量,以致获得4个收集时间。
所称重的过滤纸大约为20-30g。在最后一份剂量之后的5分钟,过滤纸置于第一尿片上。该过滤纸的中心必须与尿片的中心对其,而纸位于裤边之下。将重物加到板上15秒钟(例如,吸收时间)。
在这15秒的时间内,将第二过滤纸置于第2尿片上。在等待第二尿片的15秒内,移开第一尿片的过滤纸并进行称重。
对第三个尿片重复再湿,等。这样可成对地测量尿片。
再湿性(R)为测量后的过滤纸的重量(NW)减去滤纸最初的重量(VW),R=NW–VW
设备
产品的重量测量为+/-0.1g,且过滤纸(再湿性)的测量重量为+/-0.01g。
结果
吸收结构包括整体吸收芯,所述整体吸收芯由于无纺布层和达到400g/m2的SAP颗粒组成
吸收结构包括ADL和吸收,所述吸收由无纺布层和达到400g/m2的颗粒组成。
尿片的收集和扩散方法
Claims (17)
1.一种吸收制品,其包括至少一个整体吸收结构,所述整体吸收结构包括吸收芯(5)和收集层及分散层(14,16),所述吸收芯(5)具有永久的液体保持能力,所述收集层及分散层(14,16)具有暂时的液体保持能力,所述吸收结构包括至少一个无纺纤维基底层(23),所述无纺纤维基底层(23)适于被高吸水性颗粒(21)部分穿透,所述高吸水性颗粒(21)的粒径分布范围为45-850μm并且根据其沿所述吸收芯(5)和/或所述收集层及分散层(14,16)的z-方向的粒径分布梯度而分散于所述基底层(23)中,其特征在于,所述吸收结构包括少于4wt.%的软毛,并且较小的高吸水性颗粒位于吸收制品的身体侧,而较大的高吸水性颗粒位于该吸收制品的相对侧。
2.根据权利要求1所述的吸收制品,其特征在于,所述被高吸水性颗粒(21)部分渗透的无纺纤维基底层(23)包括在所述整体吸收结构的吸收芯(5)内。
3.根据权利要求1所述的吸收制品,其特征在于,所述吸收结构没有软毛。
4.根据权利要求2所述的吸收制品,其特征在于,所述吸收结构没有软毛。
5.根据权利要求1所述的吸收制品,其特征在于,被所述高吸水性颗粒(21)部分穿透的所述无纺纤维基底层(23)包括在所述整体吸收结构的收集层及分散层(14,16)内。
6.根据前述任一项权利要求所述的吸收制品,其特征在于,所述无纺纤维基底层(23)所具有的空隙体积范围为所述无纺纤维基底层(23)表面的0.1-20000cm3/m2。
7.根据权利要求1或2所述的吸收制品,其特征在于,所述无纺纤维基底层(23)为多层无纺纤维基底层(23)。
8.根据权利要求7所述的吸收制品,其特征在于,所述无纺纤维基底层(23)为三层,其包括顶部收集层及分散层和中间层,所述中间层具有范围为所述无纺纤维基底层(23)的10-600cm3/m2的空隙体积,还具有底层,该底层所具有的空隙体积范围为所述无纺纤维基底层的10-600cm3/m2。
9.根据权利要求1或2所述的吸收制品,其特征在于,
(i)所述高吸水性颗粒(21)根据所述吸收结构的x-方向的压型来分布;或
(ii)所述高吸水性颗粒(21)根据所述吸收结构的y-方向的压型来分布。
10.根据权利要求1或2所述的吸收制品,其特征在于,所述高吸水性颗粒(21)相互间隔地分散于所述无纺纤维基底层(23)上的离散区域中,以此促进了流体沿着所述吸收结构的x-方向和/或y-方向的流动和吸收。
11.根据权利要求1所述的吸收制品,其特征在于,所述吸收制品包括:
(a)液体渗透顶层;
(b)液体不可渗透背层;以及
(c)位于上述(a)和(b)之间的如权利要求1所述的吸收结构。
12.根据权利要求11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(2)和分散层(3)位于所述吸收结构的顶部;或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。
13.根据权利要求1或11所述的吸收制品,其特征在于,所述制品选自以下组:尿片,轻或重的失禁垫,女性护理卫生巾、汗垫,和伤口绷带。
14.根据权利要求13所述的吸收制品,其特征在于,
(i)所述吸收制品为尿片,或者轻或重的失禁垫,其包括0.1-1000g/m2的高吸水性颗粒;或
(ii)所述吸收制品为女性护理卫生巾或护垫,其包括0.1-1000g/m2的高吸水性颗粒;或
(iii)所述吸收制品为伤口绷带,其包括0.1-1000g/m2的高吸水性颗粒。
15.一种制备如权利要求1-10中任一项所述的吸收制品的方法,其特征在于,所述方法包括以下步骤:
展开无纺纤维基底(23);
用高吸水性颗粒(21)至少部分地覆盖所述无纺纤维基底(23);
通过真空台所施加的振动和真空(8'),在所述无纺纤维基底(23)中分散该高吸水性颗粒(21);展开芯覆盖层材料(22),
对芯覆盖层材料(22)的内表面和/或无纺纤维基底(23)表面施加粘合剂;
用所述芯覆盖层材料(22)覆盖所述无纺纤维基底(23);以及
确保通过压力进行粘合。
16.根据权利要求15所述的方法,其特征在于,所述方法还包括步骤:
切割所述无纺纤维基底(23)中基本不含高吸水性颗粒(21)的层,来获得各个芯。
17.根据权利要求15或16所述的方法,其特征在于,所述用高吸水性颗粒(21)覆盖无纺纤维基底(23)表面的步骤通过粉末分散法、利用真空技术(8')进行的转鼓形成法、重力进料(8)法或高压喷枪(8)法来进行。
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