CN105411754A - 压花的有纹理的网幅及其制造方法 - Google Patents

压花的有纹理的网幅及其制造方法 Download PDF

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CN105411754A
CN105411754A CN201510617125.3A CN201510617125A CN105411754A CN 105411754 A CN105411754 A CN 105411754A CN 201510617125 A CN201510617125 A CN 201510617125A CN 105411754 A CN105411754 A CN 105411754A
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詹姆士.W.克里
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Abstract

本发明公开了压花的有纹理的网幅及其制造方法。通过如下方法制成的有孔薄膜，所述方法包括：使用固相或熔融相成形技术对具有第一面和第二面的聚合物薄膜网幅进行打孔，以生成延伸离开网幅的第一面的锥形孔眼，由此形成范围为每线性英寸35个孔眼到每线性英寸80个孔眼之间；以及通过将所述薄膜网幅与带有图案的压花辊进行接触朝所述薄膜网幅的所述第一面的至少一部分对所述薄膜网幅进行压花，从而在所述网幅中提供至少1/1000英寸的压印痕迹，延伸离开网幅的所述第二面，并使所述压印痕迹中的锥形孔眼平坦化，而不在其中生成额外的孔。

Description

压花的有纹理的网幅及其制造方法
本申请是申请人为：詹姆士.W.克里，申请日为：2010年3月24日，申请号为：201080022321.1，名称为：压花的有纹理的网幅及其制造方法的发明的分案申请。
技术领域
本发明涉及具有压花图案的有纹理的有孔薄膜及制造这类网幅的方法。
背景技术
有孔薄膜在多种不同工业和消费者产品领域中使用。例如，有孔薄膜用于制造一次性片材、一次性服装以及卫生和清洁用品，例如卫生巾、失禁垫和婴儿尿布。
可使用多种不同的技术来制造有孔薄膜。例如，一种用于形成有孔网幅的技术涉及通过传统的薄膜挤压技术来挤压塑料薄膜片(例如，将LDPE薄片供给通过铸造或吹塑挤压头)，并通过如本领域已知的固相或熔融相成形技术来对薄膜进行打孔(例如，如Bussey等人的美国专利No.3,957,414中所描述的经由真空的热和压力差；如Curro等人的美国专利No.4,609,518中所描述的水打孔技术；如Giacometti的美国专利No.5,814,389、Pohland的美国专利No.4,128,679、VanIten的美国专利No.4,886,632等中所描述的通常与光滑滚筒发生接触的热机械接触打孔(例如，销打孔、雕刻滚筒等))。在一些情况下，可在打孔前经由机械或水压花或如本领域已知的其它方法使薄膜纹理化。
然而，当前的顶片的局限包括提供适宜于皮肤接触的柔软性，同时仍然吸收流体并保持对干燥感的感觉和传送。通常，作为结果，干燥得到保持，但是顶片网幅和/或由网幅制成的产品感觉不到柔软，网幅或产品可能具有僵硬的、刺痛的或相似的、总体不舒服的感觉。相反地，网幅或产品可获得期望的柔软性，但是提供不舒服的湿润感觉。
附图说明
图1示出了一实施例的局部剖视图。
图2示出了辊工位的实施例。
图3是剖切制品实施例。
图4是俯视制品的实施例。
图5是一制品实施例的照片。
图6是一制品实施例的局部俯视图。
具体实施方式
如本文所使用的，术语“机器方向”是指网幅形成的方向，即未切网幅的纵向方向。
如本文所使用的，术语“横向方向”是指横切方向，设置成与机器方向成90°，并且延伸横跨最初形成的前体网幅的宽度。
在多个不同实施例中设置了顶片。如本文所使用的术语“顶片”或在如以下进一步描述的打孔后的“打孔顶片”是指聚合物薄膜网幅，并且优选是热塑性聚烯烃(polyolefenic)高可湿性膜片或利用本领域众所周知传统薄膜挤压技术挤压的网幅。典型的聚烯烃混合物是从例如LDPE、LLDPE、HDPE和茂金属基m-LDPE等树脂得到的，并且混合物还可包括多种其它树脂，例如聚丙烯、乙烯聚丙烯共聚物、乙烯-醋酸乙烯酯、碳酸钙、硫酸钡。
在某些实施例中还可希望使这种薄膜成亲水性的。这可通过在挤压前向树脂中***表面活性剂来进行，也可通过用表面活性剂在挤压后的某一时刻，例如可能在打孔后，喷射网幅。包含所使用的表面活性剂的典型树脂包括具有例如山梨醇酯等酯表面活性剂的脂肪酸或硅化低分子量聚合物。
在挤压顶片后，使用如本领域已知的固相或熔融相成形技术对薄膜打孔，例如，通过热和/或压力差、水打孔(waterperforation)等，这在网幅中提供离开网幅的第一平面向外延伸的锥形孔眼。从图1可看出，孔眼通常呈在顶面具有开口端的圆锥形形状，并在接触时呈现出织物样或布样感觉。网幅上的锥体的密度在每线性英寸35个孔眼与每线性英寸80个孔眼之间变化，这提供织物样表面。还示出了网幅的第二平面。
在吸收制品中使用的实施例可具有使吸收制品的其余部分与皮肤分离的顶片，因为顶片上的锥体朝穿戴者侧倾斜而上或指向穿戴者侧。
如以下进一步描述的，在多个不同实施例中也设置了吸收芯。如本文所使用的，术语吸收芯可包括设计成吸收和存储身体分泌物和其它期望流体的一个或多个层。如本领域已知的，吸收层可由各种纤维或疏松小孔的吸收泡沫材料或纤维吸收剂制成，包括短天然纤维素质纤维层、由PP、PE、PET、醋酸纤维素或这类聚合物的组合等的纤维制成的合成纤维网幅。合成纤维通常是使用本领域已知的多种不同加固技术制成的作为由不止一个层构成的加固的网幅出售的，例如，热粘结气流成网(thermobondingairlaid)、热粘结纺粘(thermobondedspunlaid)、热风粘结气流成网(airthroughbondingairlaid)等。实施例可为吸收层提供对所使用的有孔薄膜的贴附亲合力。
多种不同实施例通常以滚筒形式提供吸收芯。实施例也可使用吸收芯的一部分。因此，例如，一实施例由吸收芯层构成，该吸收芯层由基重在10-60gsm之间的热粘结纤维的粗梳的PP/PE非织物形成。卫生巾和其它实施例可使用更完全或较不完全的吸收芯，该吸收芯通常由上述吸收层和基重在30-200gsm之间的热粘结气流成网芯的组合制成。
实施例中如以下进一步描述的打孔和后续加工在各种类型的生产线上发生。那些类型包括宽网幅叠层生产线、制品生产线，包括加工和吸收制品生产线。因此，例如，实施例可被提供在被改良安装在现有加工线等中的尿布或卫生巾生产线中。
不论实施例是否***制品生产线中，在打孔后，实施例均进行对打孔网幅的压花，如例如图2的实施例中所示那样。图2示出了打孔网幅30，以及作为吸收芯层的第二网幅32。网幅在带图案的压花辊36与光滑的支承辊38之间行进，其中压花发生在打孔网幅30上，朝向有孔眼从其延伸出来的平面，从而在网幅中提供至少1/1000英寸的压印痕迹，其包括从网幅的与网幅32相对的另一平面延伸出的升高区域。在具有支承网幅的实施例中，压印将延伸到支承网幅中。
当压花发生时，网幅30上的下垂离开薄膜网幅的顶平面的孔口或锥体(看不见)的至少一部分遇到从压花辊36向外突出的升高的压花图案(例如40)。该接触致使网幅扩大，那些孔口及其孔口周围的连接区域变平，网幅和吸收芯层变薄，薄膜网幅膨胀，从而在网幅32中形成至少1/1000英寸深的压印痕迹。简要地转到图3，其中示出了在孔眼(见例如40A)和大致在网幅10两者上的压印的效果的剖视图。
图4示出了压花辊的升高雕刻压花图案的突起的压印的俯视图。区域50是压印，同时还示出的有被平坦化的孔眼51、52和53以及这些孔眼之间的连接区域(未标注)。其余还有孔眼55、56和57，它们未被平坦化，因为它们落在压花辊的突起的压印外。
应该注意的是，虽然本文在多个不同实施例中描述了压花辊，但是在多个不同实施例中也可使用本领域已知的其它压花方法，例如超声压花，包括超声(ultrasoundhorn)压花等，并且可设置成放置在制品生产线、加工线、宽幅生产线等中，如本领域已知的。这些和其它实施例能够提供压力以及热量来进行压花。
图5示出了作为俯视图拍摄的一个实施例的照片。压印(见例如65)和孔眼(见例如66)均可见。因为照片的对比度，看不见的是例如图4中的51、52和53等平坦化的孔眼。
带压花的打孔网幅提供一种有纹理的扩大的打孔网幅织物样产品，并围绕压印区域具有较薄的薄膜网幅。因此，提供了视觉上有吸引力的制品。下方的吸收芯是可见的，从而让穿戴者安心。此外，在组合网幅中还提供了柔软性、弹性和延展性。整个制品看起来更软，因为打孔顶片与吸收芯之间的层间贴合只发生在压花部位处，这向穿戴者提供舒适感，并且被保持在压印之间的孔眼提供触觉柔软性，因为它们朝穿戴者的皮肤突出。压花部位处的层间贴合也提供柔性和延展性，因为它们的有限贴合部位为组合网幅提供一定程度的柔性和延展性，这在其他情况下是缺乏的。
压花用于帮助将打孔网幅贴附至吸收芯。孔眼的平坦化提供被平坦化了的锥体。因此，孔眼通过压花得到的平坦化的开放孔为薄膜向芯层提供至少一部分贴合，因为围绕平坦化孔眼的顶孔的区域在向下压力后变得与吸收芯网幅缠结，所述向下压力即是压花辊上的突起所施加的克服突出的孔眼的压力。作为克服平坦支承辊或其它基底测得的压力通常在100-175psi的范围内，然而也可高达400psi。此外，该压力还造成网幅薄膜的至少一部分熔化，包括孔眼和周围的连接区域以及压印下方区域中的吸收芯层的相应区域，以实现贴合。
该实施例以及其它实施例中的辊可受热和/或施热，这将实现进一步熔化并且同样能协助缠结。例如，在一实施例中，压花辊通常被加热至近似于顶片的软化点的温度，其通常大于80摄氏度但小于200摄氏度。因此，相似热机械压力和其它实施例的贴合因压力和热的组合而产生，从而如上所述那样通过熔化和缠结提供贴合，以及提供具有相关联的可见吸引力、性能信号、柔软性、柔性和延展性的压印。
沉积在顶片上的流体将主要通过升高的开设的孔口被吸到吸收芯中。这些也因它们的升高的外观而提供峰和谷，有助于通过捕获流体并使之通向吸收芯而防止流体流走。那些平坦化的孔口，它们受到了压花，也能通过毛细管和其它作用为流体提供一些通道，并且实现紧固至吸收芯，如本文进一步描述的那样。
实施例还包括在一条或多条吸收制品生产线或加工线上压花，包括高速生产线。各辊可按照需要设定在生产线上，并且适当地配置压花辊。请注意，进行压花的实施例可单独提供给顶片，也可提供给由薄膜和由一个或多个层构成的吸收芯所组成的半成品，也可在最终切割前提供给成品。如果顶片本身进行了压花，则薄膜将具有压印区域，当然就没有通过平坦化孔口对下方网幅进行的附随贴合。
在某些优选实施例中可能期望通过压花限定出网幅的各个区域。例如，图案区域或其它区域可通过孔眼和压花间插开，不同的压花滚筒可提供整体或部分不同的尺寸、形状或其它参数。例如，如图6所示的实施例可在吸收垫的中间提供更宏观的压花，通过允许流体在被平坦化的孔口吸收前贮藏在顶片的压花区域中来提供更高的吸收性。边缘，没有压花，但是将通过其升高的孔口提供吸收。
也可通过一些方式随后完成、半完成或处理一些实施例，例如，具有纤维样表面的薄膜，扩大织物样打孔的薄膜等。还可期望进行进一步的处理。例如，可施加洗液，半可固化纳米纤维包括在压花区域中，可使用例如机械激活等加工变更孔口的形状，压花区域与孔口之间的距离再次通过激活或本领域已知的其它方式得到修正，等等。在多个不同实施例中也可使用多种不同后压花处理技术的组合。
实施例也可与一个或多个部件组合来形成层叠或复合材料，成品或半成品等，必要时，其可通过压花、打孔等、缝合、粘结、印刷、切割、成形、胶合、打褶、杀菌等，与本领域已知的其它加工组合或独立于本领域已知的其它加工，得到进一步处理。
在一个实施例中，打孔顶片由XIAMENYANJANINDUSTRYCOLtd.(厦门延江工贸有限公司)提供，这是一个位于中国厦门市的商号为SC100(www.yanjan.com)的有孔薄膜公司。打孔顶片以卷装形式提供。卷装在卫生巾加工线上展开，与热风粗梳吸收性非织物发生接触。该非织物由BicoPP和PE的混合物构成，基重为40gsm，并由日本守山市的ChissoCorporation公司供给。该非织物通常在如本领域已知的名称“采集分布层(AcquisitionDistributionLayer)”或ADL下找到。
顶片和非织物在95摄氏度的温度下通过具有受热的升高的椭圆形突起的辊(由Ungricht-RichtungIndustries公司提供)压花。突起提供在机器方向上，每组凸状物之间的距离不小于2mm。
本实施例同样被图案化，并且卫生巾垫的中心范围内的压花区域为80mm或更小。压花后，为组合网幅进一步提供吸收芯层、以及通过卷边加工贴附的底片，然后切割和完成压花制品。
在多个不同实施例中可期望整体地或部分地使用多种不同的图案，在各种类型的制品中，包括成人、儿童或婴儿失禁用品(例如尿布、内裤等)，女性卫生用品(例如，女性月经用品、卫生巾、护垫等)，包括消毒的和不消毒的包裹物(例如具有或者不具有吸收部分的创可贴)，以及其它一次性和/或多次性用品；例如贴近人或动物身体的制品，例如服装、服饰，包括内衣，内外衣，例如汗衫、胸罩、内裤、短衬裤等，泳衣，连体衣，袜子，头罩和头带，帽子，手套和手套内衬，医疗服装等；床单；手术膜衣；包装材料；保护罩；家庭；办公；医疗或治疗器具和包裹物。
虽然已相对于多个不同的具体实施例描述了本发明，但是多种不同的变型将从本公开变得清楚明了，并旨在处于所附权利要求的范围内。

Claims (10)

1.一种通过如下方法制成的有孔薄膜，所述方法包括：
使用固相或熔融相成形技术对具有第一面和第二面的聚合物薄膜网幅进行打孔，以生成延伸离开网幅的第一面的锥形孔眼，由此形成范围为每线性英寸35个孔眼到每线性英寸80个孔眼之间；以及
通过将所述薄膜网幅与带有图案的压花辊进行接触朝所述薄膜网幅的所述第一面的至少一部分对所述薄膜网幅进行压花，从而在所述网幅中提供至少1/1000英寸的压印痕迹，延伸离开网幅的所述第二面，并使所述压印痕迹中的锥形孔眼平坦化，而不在其中生成额外的孔。
2.如权利要求1所述的薄膜，其中，所述薄膜网幅是热塑性薄膜并且在所述压花过程中，所述薄膜网幅与支承网幅结合。
3.如权利要求1所述的薄膜，其中，
对着吸收芯层进行压花，并且压印痕迹延伸进入所述吸收芯层中。
4.如权利要求3所述的薄膜，其中，所述压花还包括使所述薄膜网幅中的所述锥形孔眼的至少一部分、以及位于所述锥形孔眼之间的连接区域的至少一部分平坦化；使所述吸收芯层和所述薄膜网幅的至少一部分薄型化；以及使所述薄膜网幅的至少一部分扩大。
5.一种包括如权利要求1所述的有孔薄膜和吸收芯的制品。
6.一种包括如权利要求1所述的有孔薄膜和附接至其上的吸收芯的尿布或卫生巾。
7.一种通过如下方法制成的织物样吸收薄膜顶片产品，所述方法包括：
通过热和压力差或使用水打孔对具有第一面和第二面的薄膜网幅进行打孔，以生成具有延伸离开网幅的第一面的锥形孔眼的织物样表面，由此形成范围为每线性英寸35个孔眼到每线性英寸80个孔眼之间；以及
通过将所述薄膜网幅与带有图案的压花辊接触而对所述薄膜网幅的至少一部分进行压花，从而生成升高的区域，
其中所述升高的区域突出离开所述薄膜的所述第二面，并且所述压花使所述升高的区域中的锥形孔眼平坦化，而不在其中生成额外的孔。
8.如权利要求7所述的薄膜顶片产品，其中，所述薄膜网幅是热塑性薄膜并且在所述压花过程中，所述薄膜网幅与支承网幅结合。
9.如权利要求7所述的薄膜顶片产品，其中，对着吸收芯层进行压花，并且压印痕迹延伸进入所述吸收芯层中。
10.如权利要求9所述的薄膜顶片产品，其中，所述压花还包括使所述薄膜网幅中的所述锥形孔眼的至少一部分、以及位于所述锥形孔眼之间的连接区域的至少一部分平坦化；使所述吸收芯层和所述薄膜网幅的至少一部分薄型化；以及使所述薄膜网幅的至少一部分扩大。
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