CN109069311A - 定向拉伸层合体和具有有利于制备定向拉伸层合体的粘结的非织造纤维网材料 - Google Patents

定向拉伸层合体和具有有利于制备定向拉伸层合体的粘结的非织造纤维网材料 Download PDF

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Publication number
CN109069311A
CN109069311A CN201780024120.7A CN201780024120A CN109069311A CN 109069311 A CN109069311 A CN 109069311A CN 201780024120 A CN201780024120 A CN 201780024120A CN 109069311 A CN109069311 A CN 109069311A
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CN
China
Prior art keywords
fiber web
draw direction
stretching
web layer
lamilate
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CN201780024120.7A
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English (en)
Inventor
F.N.德塞
O.E.A.伊塞勒
R.米诺古奇
J.特里吉尔
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Procter and Gamble Ltd
Procter and Gamble Co
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Procter and Gamble Ltd
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Publication date
Application filed by Procter and Gamble Ltd filed Critical Procter and Gamble Ltd
Publication of CN109069311A publication Critical patent/CN109069311A/zh
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Abstract

本发明公开了一种拉伸层合体。该拉伸层合体可包括第一层；第二层；和设置在第一层和第二层之间的一个或多个弹性构件。第一层可包含载有包括多个粘结部的热粘结部图案的非织造纤维网材料，所述粘结部各自具有长度和宽度，对于大多数粘结部，长度垂直于拉伸方向取向并且大于宽度。弹性构件可在沿拉伸方向被预应变时与第一层和第二层接合。当拉伸层合体处于松弛状态时，至少第一层可包括多个收拢部，所述收拢部包括横向于拉伸方向取向的伸长的脊和谷。本发明还公开了一种一次性吸收裤，其具有包括拉伸层合体的弹性化带结构。

Description

定向拉伸层合体和具有有利于制备定向拉伸层合体的粘结的 非织造纤维网材料
背景技术
近年来，许多发达国家的人口已转向中年和老年人口群体。这些人口群体代表了市场对旨在解决与老龄化相关联的问题的产品和服务的需求相对地增加。
一个此类问题是成人尿失禁。尿失禁可由多种健康状况或甚至正常的经历诸如生育导致或加剧。
用于尿失禁患者的一次性吸收裤已市售了多年。这些产品传统上非常类似于一次性婴儿尿布或一次性儿童训练裤，主要差异为尺寸。一种设计类型被称为“有带”或“球囊”型裤，其由环绕穿着者腰部和下体的宽带形成，所述宽带由穿过穿着者的裆区连接前带部分和后带部分的结构桥接。裆部结构包括被设计成在裤被更换之前接收、容纳和保留尿液的吸收结构。带通常由拉伸层合材料形成。
由于它们的设计和制造方法的缘故，产品可在视觉上类似于一次性婴儿尿布或训练裤，而不是普通内衣。由于存在吸收材料，裆部结构可能趋于体积庞大。该结构可具有批量生产的一次性制品比如一次性儿童尿布的外观。带结构(通常由拉伸层合材料形成)也可具有大体积的批量生产的尿布样外观。
这种遗憾的相似之处一直是让使用者感到焦虑和不适的根源。所述大体积可导致外衣贴合不良，或者明显地显露出穿着了吸收内衣。许多使用者可能不乐意使用可能与身体功能的老化和失控相关联的产品。
在这些情况下，对用于成人失禁裤的传统设计和材料的任何改进可提高制造效率，同时提供更类似于普通内衣的外观和感觉，这些均可为其制造商提供竞争优势。
附图说明
图1为球囊裤的一个示例的透视图。
图2为球囊裤的另一示例的透视图。
图3为球囊裤前体结构在接合带的前段和后段之前的示意性平面图。
图4为带的部件的示意性分解透视图。
图5A为粘结部图案的一个示例的平面图。
图5B为粘结部图案的另一个示例的平面图。
图5C为粘结部图案的另一个示例的平面图。
图5D-5I为粘结部图案的附加示例的放大平面图。
图6为图5A所示粘结部图案的一部分的放大视图。
图7为载有粘结部图案的一个示例的拉伸层合体的一部分的平面图，所述层合体被示出处于拉伸状态。
图8为在弹性构件沿拉伸方向弹性收缩之后并且在形成了褶皱或收拢部之后的图7所示拉伸层合体的部分的平面图。
图9为沿图8中的线9-9截取的图8所示拉伸层合体的一部分的横截面。
图10为沿图8中的线10-10截取的图8所示拉伸层合体的一部分的横截面。
具体实施方式
定义
“交叉方向”(CD)-关于非织造纤维网材料的制备、非织造材料本身、其层压体、或制品(其中所述材料为部件)，是指沿材料的方向，其基本上垂直于材料穿过其中制造所述材料和/或制品的生产线而向前行进的方向。
贯穿本说明书，如果当将偏置力施加到材料时，所述材料或复合材料可延伸到其初始松弛长度的至少150％的伸长长度(即，可延伸至少50％)而不产生显著损坏材料或复合材料的破裂或断裂，以及当将力从所述材料或复合材料移除时，所述材料或复合材料恢复此伸长的至少40％，那么所述材料或复合材料被认为是“弹性的”或“弹性体的”。在各种示例中，当将力从可弹性延伸的材料移除时，所述材料或复合材料可恢复其伸长的至少60％或甚至至少80％。
拉伸层合体的“拉伸方向”如如下方向，所述层合体沿所述方向将最容易经历弹性拉伸和收缩。在其中一个或多个弹性构件在处于预应变状态时结合到所述层合体中的拉伸层合体中，拉伸方向为弹性构件所沿着被预应变的方向。拉伸层合体的“横拉伸方向”为垂直于拉伸方向的方向。
“膜”是指由一种或多种聚合物形成的表皮样或隔膜样材料层，其不具有主要由固结的聚合物纤维和/或其它纤维的纤维网状结构组成的形式。
“侧向”-关于裤及其穿着者，是指与穿着者的站立高度大致垂直的方向，或当穿着者站立时的水平方向。
出于本文的目的，粘结部形状的长度(L)和宽度(W)分别为如下矩形的横拉伸方向尺度和拉伸方向(SD)尺度，所述矩形具有最小可能的面积，同时完全外接所述粘结部形状，并且其侧边中的两者平行于拉伸方向SD对齐。
“纵向”-关于裤及其穿着者，是指与穿着者的站立高度大致平行的方向，或当穿着者站立时的竖直方向。“纵向”也是大致平行于从前腰边缘的中点延伸到后腰边缘的中点的线的方向。
“机器方向”(MD)-关于非织造纤维网材料的制备、非织造材料本身、或其层压体，是指沿材料或层压体的方向，其基本上平行于材料或层压体穿过制造所述材料或层压体的生产线向前行进的方向。
关于形成非织造纤维网的纤维，“机器方向偏差”是指大多数纤维(如位于纤维网中且为未拉伸的)具有如下长度，其中机器方向矢量分量大于它们的交叉方向矢量分量。
“非织造物”为所制造的定向取向或随机取向的纤维片材或纤维网，所述纤维首先被成形为絮，然后通过摩擦、内聚力、粘附力或一个或多个粘结部图案和粘结压痕加固并粘结在一起，所述粘结部图案和粘结压痕通过局部压缩和/或施加压力、热、超声或热能、或它们的组合来形成。该术语不包括用纱线或长丝织造、针织或缝编的织物。这些纤维可为天然来源和/或人造来源的，并且可为短纱和/或连续长丝或原位形成的纤维。可商购获得的纤维的直径在小于约0.001mm至大于约0.2mm的范围内，并且它们具有几种不同的形式：短纤维(称作短纱或短切纤维)、连续单纤维(长丝或单丝)、无捻连续长丝束(丝束)和加捻连续长丝束(纱)。非织造织物能够通过许多工艺来形成，包括但不限于本领域已知的熔吹、纺粘法、纺熔法、溶液纺丝、静电纺纱、梳理法、膜原纤化、熔膜原纤化、气流成网法、干法成网、使用短纤维的湿法成网、以及这些工艺的组合。非织造织物的基重通常用克/平方米(gsm)表示。
相对于纤维网的“z方向”表示大致正交于或垂直于由该纤维网沿机器方向维度和交叉方向维度所逼近的平面。
虽然本发明的结构的示例在本文中被描述为用来形成带型或球囊型吸收裤的带，但应当理解，也可使用示例来形成裤、尿布、其它可穿着制品和其它产品的其它部件。
图1和2示出了带型或球囊型吸收裤10的示例。该结构可包括带部分20和中心基础结构30。中央基础结构30可包括一次性尿布和吸收裤中存在的部件的任何组合，所述部件包括但不限于液体不可透过的底片31、液体可透过的顶片(未示出)、吸收芯结构(未示出)、以及弹性化阻隔箍32。中心基础结构的部件和构型的示例和描述可见于美国专利序号13/764,945，其中所述的基础结构包括可包括在中心基础结构30中的部件和特征结构。
在图1所示的示例中，带部分20在下边缘21处终止于不到裤的裆区12处；该构型有时候称为“多片式”构型。在图2所示的示例中，带部分20为外部结构的一部分，该外部结构包括环绕穿着者腰部的带部分20a、上覆中心基础结构至其外部并穿过裆区包裹它的外包裹部分20b；该构型有时候称为“单片式”构型。外包裹部分20b可由非织造纤维网层形成，所述非织造纤维网层也可用作带部分20a的外层。带部分20可具有在接缝24处接合在一起的前部和后部22、23。
图3示意性地示出了在如图1A和1B所示地在接缝24处接合前部和后部22、23之前，作为诸如图2所示裤的前体的结构。中央基础结构30将前部和后部22、23上覆到其内部。
参考图4，带部分20可由非织造纤维网层25、26形成，该非织造纤维网层分别形成带的内层和外层。可用于本发明的合适的非织造纤维网材料也包括但不限于纺粘、纺丝成网、熔喷、纺熔、溶剂纺丝、静电纺纱、梳理成网、膜原纤化、熔膜原纤化、气流法、干法成网、湿铺短纤维、以及部分地或完全地由聚合物纤维形成的其它非织造纤维网材料，如本领域中所公知的。非织造纤维网可主要由聚合物纤维形成。在一些示例中，合适的非织造纤维材料可包括但不限于聚合物材料，诸如聚烯烃、聚酯、聚酰胺、或具体地聚丙烯(PP)、聚乙烯(PE)、聚乳酸(PLA)、聚对苯二甲酸乙二酯(PET)、和/或它们的共混物。在一些示例中，纤维可由PP/PE共混物形成，诸如描述于美国专利5,266,392中，其公开内容以引用方式并入本文。非织造纤维可由作为添加剂或改性剂的组分形成或可包括它们，诸如脂族聚酯、热塑性多糖、或其它生物聚合物。另外的可用非织造材料、纤维组合物、纤维和非织造材料的形成和相关方法描述于以下美国专利中：6,645,569；6,863,933和7,112,621；以及共同未决的美国专利申请序列号10/338,603；10/338,610；和13/005,237，它们的公开内容以引用方式并入本文。
单个纤维可为单组分或多组分。所述多组分纤维可为双组分的，诸如呈芯-皮排列或并列排列。单个组分常常包括聚烯烃诸如聚丙烯或聚乙烯、或它们的共聚物、聚酯、热塑性多糖或其它生物聚合物。
根据一个示例，非织造物可包含在施加和移除外部压力时提供良好恢复的材料。此外，根据一个示例，非织造物可包含不同纤维的共混物，所述纤维选自例如上述类型的聚合物纤维。在一些实施方案中，所述纤维的至少一部分可表现出具有螺旋状形状的螺旋形卷曲。根据一个示例，所述纤维可包括双组分纤维，所述双组分纤维为各自包含不同材料(通常为第一聚合物材料和第二聚合物材料)的单个纤维。据信使用并列型双组分纤维有益于向纤维赋予螺旋形卷曲。
为了增强层压体的柔软感，可通过射流喷射来处理非织造物，该方法也可称为水强化、水刺法或水充。此类非织造物和方法在以下专利中有所描述：例如，美国专利6,632,385和6,803,103、以及美国专利申请公布2006/0057921，它们的公开内容以引用方式并入本文。
可使于本发明的层合体的非织造纤维网的其它示例可为由Avgol Nonwovens LTD(Tel Aviv,Israel)以名称XL-S70-26制备的SMS纤维网(纺粘-熔喷-纺粘纤维网)；由位于Znojmo,Czech Republic的Pegas Nonwovens AS以名称18XX 01 00 01 00(其中XX＝可变基重)制备的SSS(纺粘-纺粘-纺粘)纤维网；由位于Gaziantep，Turkey的Gulsan SentetikDok San VE TIC AS以名称SBXXF0YYY(其中XX＝可变基重，并且YYY＝可变交叉方向宽度)制备的SSS纤维网；由位于Hazelton，Pennsylvania的First Quality Nonwovens Inc.以名称SEH2503XXX(其中XXX＝可变交叉方向宽度)制备的HESB(水强化纺粘)纤维网；和双组分SS纤维网。
可用作部件以形成层25、26中的一者或两者的非织造纤维网可被粘结成粘结部图案。可使松散纤维絮例如纺丝纤维絮穿过一对压延粘结辊之间的辊隙，从而使它们固结并粘结成粘结部图案，从而增加拉伸强度和尺度稳定性，以便将该松散纤维絮转换加工成粘着的且可使用的非织造纤维网材料。粘结可包括热粘结部图案、机械粘结部图案或粘合剂粘结部图案或它们的组合，但在一些情况下热粘结可为优选的。热粘结部可通过向压延辊中的一者或两者或伴随设备供应热能源来形成，该热能源用来加热纤维并且使它们熔融并在介于压延粘结辊之间的辊隙中的粘结突出部下面熔合。辊中的一者或两者可为机加工的、蚀刻的或以其它方式形成的以具有从该辊的圆柱形表面径向向外延伸的成图案的成型粘结突出部。当辊以它们的轴线相平行的方式适宜地保持紧邻时，从它们之间穿过的纤维絮将经受在粘结突出部下面集中于辊隙中的压力，并且穿过辊隙并处在粘结突出部下面的纤维将被变形并至少部分地熔合(通过施加热能)，从而形成粘结部。每个粘结部将具有形状，并且粘结部将具有图案和间距，它们基本上对应于压延粘结辊的粘结突出部的形状、图案和间距。
参考图4，非织造纤维网层25、26可夹置一个或多个弹性构件，诸如多根弹性体材料股线27，诸如弹性纤维(例如，LYCRA HYFIT纤维，其为Invista(Wichita，Kansas)的产品)。非织造纤维网层25、26可由沉积在所述层之间的粘合剂、由热粘结部、由压缩粘结部、或由它们的组合围绕弹性股线27接合在一起。在其它示例中，一个或多个弹性构件可为由弹性体材料形成的条或一段膜。
弹性构件也可由各种其他材料形成，诸如但不限于橡胶、苯乙烯乙基丁烯苯乙烯、苯乙烯乙烯丙烯苯乙烯、苯乙烯乙烯乙烯丙烯苯乙烯、苯乙烯丁二烯苯乙烯、苯乙烯异戊二烯苯乙烯、聚烯烃弹性体、弹性体聚氨酯、以及本领域中已知的其他弹性体材料、以及它们的组合。在一些实施方案中，弹性构件可为带有任何数目的股线(或细丝)的挤出股线弹性部件。弹性股线(如果使用的话)可被选择成具有在50至2000范围内的分特，或该范围内的任何分特值的任何整数值，或由任何这些整数值形成的任何范围。弹性构件可为膜的形式。膜的示例已在现有专利申请中进行了充分描述(参见例如美国专利公布2010/0040826)。膜可以多种树脂组合于若干子层中的至少一层中来形成，后者向膜提供不同有益效果。弹性构件也可呈稀松布、条或弹性体材料带节段的形式，其中它们的较长尺度沿拉伸方向取向。
在带结构的制造期间，所述一个或多个弹性构件诸如弹性股线27可在它们被结合到带结构中时沿长度方向被预应变期望的量。在带随后松弛时，一个或多个弹性构件诸如弹性股线27将朝它们的未应变长度收缩。参考图8-图10，这导致非织造布材料层25、26收拢并形成具有脊28(在图8中被示出为浅色区域)和谷29(在图8中被示出为暗色区域)的褶皱或收拢部，所述脊和谷大致横向于弹性股线27的长度。该应变的方向对应于层合体的拉伸方向。
所述褶皱或收拢部的尺寸和形状将受到影响，并且可受到接合部分图案的设计和/或非织造纤维网层25、26相对于彼此以及相对于弹性股线27之间的粘结的操纵。
在一个示例中，拉伸层合体可结合有作为弹性拉伸机构的弹性股线27。弹性股线27可具有在层合(例如，通过股线涂覆工艺)之前施加于它们的粘合剂，使得当纤维网层25、26被集合在一起以夹置所述股线时，所施加的粘合剂导致所述纤维网层附着在股线周围以形成所述拉伸层合体。施加到弹性股线的粘合剂可为仅有的用来将层合体保持在一起的粘合剂。另选地或此外，粘合剂还可在层合之前沉积在一个或两个层25、26上，并且可按图案沉积。用于向非织造纤维网基底施加图案化粘合剂沉积物以使得能够制造弹性化层合体的方法的示例描述于美国专利8,186,296中。在一个示例中，所选择的粘合剂图案可由对应地设计的辊的设计来实现。旨在施加的粘合剂图案可被设计成影响褶皱或收拢部的尺寸和形状。层25、26可用粘合剂接合和/或在粘合剂沉积物的位置彼此粘结，并且在其它位置处保持彼此不接合或不粘结或分开，使得它们可在制品的穿着期间随着层合体被移动和拉伸而相对于彼此略微移动和移位。
当使用热压延粘结来粘结层25、26中的一者或两者时，接合图案和/或粘结图案可被设计成影响褶皱或收拢部的尺寸和形状。在一些情况下，可能期望将纺丝非织造纤维网用粘结部图案粘结至5％至20％的粘结面积。出于本文所述的目的，可能期望粘结面积为8％至15％。图案化热粘结趋于增强所得粘结的非织造纤维网的机器方向强度和交叉方向强度和尺度稳定性，这在下游的转换操作和加工操作中具有有益效果，并且增加产品(所述纤维网旨在形成其中的部件)的拉伸强度和稳固性。然而，热粘结一般也增大所得粘结的非织造纤维网的硬度。这可不利地影响产品的消费者对产品表面的触觉柔软性的感知。例如，如果所述纤维网用作裤产品的带结构的一层，则赋予所述纤维网的硬度可导致消费者负面地将所述带层感知为具有硬质感或粗糙感。出于该原因，在一些情况下，可能期望将粘结面积限制于小于16％、小于12％、小于10％或甚至小于8％。然而已发现，向旨在用于拉伸层合体的纤维网的粘结部图案赋予如本文所述的某些特征结构可减轻硬化所述纤维网的负面效应，同时除了拉伸强度之外还提供优点。
参考图5A和图6，热粘结图案可包括具有伸长形状的多个单个粘结部40，所述形状具有沿横拉伸方向(垂直于拉伸方向SD)测量的长度尺度L和沿平行于拉伸方向SD的方向测量的宽度尺度W。所述非织造布上的粘结部形状和布置结构将基本上对应于用来产生所述粘结部的压延辊上的粘结突出部(有时候称为“粘结钉”)的径向最向外表面的形状和布置结构。图案可沿两个垂直方向中的一者或两者为规则的或不规则的。单个粘结部的列可按列重复间隔距离CI定位。单个粘结部的行可按行重复间隔距离RI定位。未粘结路径41可存在于粘结部列之间，并且可无限延伸，或者仅不间断地延伸经过多个行。列角α为平行于拉伸方向的线和邻接未粘结路径41(相切于一列粘结部形状中的形状)的线b之间的交点处的角度。每个未粘结路径41具有沿平行于拉伸方向的方向测量的宽度PW。宽度PW为邻接未粘结路径41(分别相切于两个相邻列的粘结部形状中的形状)的两条相应平行线之间的距离，其中不出现任何粘结部的部分。图5A和图6不旨在被视作本文所设想到的合适的粘结图案的限制性示例或排他性示例。附加的、另选的但非限制性示例示出于图5B–5I中。
已发现将硬化的粘结部列取向成使得它们基本上垂直于拉伸方向SD延伸(使得未粘结路径41也基本上垂直于拉伸方向延伸并沿拉伸方向的基本长度延伸)，可在褶皱或收拢部形成于层25和/或层26中时实现有益效果。在被非织造纤维网层25和/或26中的粘结部40所占据的区域中，所述纤维网的组分纤维已被熔融、变形、高度地固结并熔合在一起。因此，在所述粘结部形状内，所述结构相对于周围的未粘结区域来讲被硬化了。硬化区域与周围的未粘结区域相比将趋于对弯曲和挠曲更具抗性。相反，未粘结区域(包括未变形纤维和未粘结纤维)相对于所述粘结部内的硬化区域来讲将趋于更容易弯曲和挠曲。因此，所述纤维网将更容易沿未粘结路径41弯曲和挠曲，同时粘结部40的列将趋于相对地保持对弯曲和挠曲的抗性。这些效应可经由粘结部图案的设计用来有利地影响褶皱或收拢部在拉伸层合体中的形成。
参考图5和图9，粘结部40将趋于导致纤维网层25阻抗粘结区域中的弯曲，使得脊28的峰和基面和谷29更可能沿所述更柔性的未粘结区域诸如未粘结路径41形成。如上所述，在一些情况下，由于感知到的硬度负面效应和感知到的材料柔软性，拉伸层合体的非织造纤维网层的基本粘结(例如，粘结面积大于4％)可为不可取的。然而，当如本文所述地构造粘结部图案时，纤维网的硬化(粘结)区域可通过它们在脊的侧部上的位置有效地被定位成远离使用者的接触范围。脊的峰将由纤维网的未粘结的柔软的纤维区域形成，并且沿z方向突起，从而向拉伸层合体赋予柔软的触感。
粘结部40的形状和尺度可被构造成不仅有益地影响触觉柔软性，而且也有益地影响褶皱或收拢部的形成和尺寸。当前市售的包括作为带拉伸机构的纵向间隔开的弹性股线的带式或球囊式裤趋于具有大体积的臃肿外观，其对于成人产品来讲可能不被视为是可取的。已发现结合粘结的非织造布层25和/或26中的粘结部40的间距和尺度来选择弹性股线的间距可大大减小褶皱或收拢部的尺寸，并且也增强尺寸和形状的规则性和一致性。这帮助向拉伸层合体赋予整洁的小体积布料样外观。
参考图7-图10，直的、平行的且间隔开的弹性股线27可在预应变状态中沿拉伸方向SD结合到拉伸层合体中。参考图8，在完成了拉伸层合体的制造时，并且在完成了弹性股线27朝它们的未应变长度的弹性收缩(如大箭头所示)时，它们将拉伸层25和26并导致它们沿拉伸方向收缩，并且形成具有脊28和谷29的褶皱或收拢部。粘结部形状的尺度和粘结部图案可与弹性股线27的横拉伸间距S协调以便具有各种优点。
单独地或与本文所述的任何其它特征结构组合地，粘结部形状长度L可被选择成不小于行重复间隔RI的33％，更优选地不小于行重复间隔RI的40％、50％、60％，并且甚至更优选地不小于70％。该特征结构有助于有序地且规则地形成带有沿垂直于拉伸方向的方向延伸的峰和谷的收拢部。可能期望粘结部形状长度L不大于行重复间隔RI的90％。这确保了粘结部是离散的(不是无限地长)，并且避免了沿垂直于拉伸方向SD的方向向纤维网赋予太高的硬度。
另选地或与本文所述的任何其它特征结构组合地，粘结部形状宽度W可被选择成为列重复间隔CI的5％至50％，更优选地列重复间隔CI的8％至40％，并且还更优选地10％至30％。该特征结构在如下两者之间实现了平衡：为将阻抗弯曲的粘结部硬化区域提供适当宽度并从而形成脊28的侧部，同时为将弯曲或挠曲的非粘结的非硬化区域留下适当宽度以在纤维网材料中形成收拢部的脊28的峰和基面和谷29。
另选地，或与本文所述的任何其它特征结构组合地，粘结部图案可被布置成使得用于拉伸方向距离(图案在所述距离上重复)上的图案的未粘结路径宽度PW的总和为拉伸方向重复长度的50％至95％，更优选地拉伸方向重复长度的60％至92％，并且还更优选地拉伸方向重复长度的70％至90％。
参考图6和7，与本文所述的任何其它特征结构组合地，粘结部行重复间隔RI可关联于横拉伸弹性股线间距ES，使得RI等于或小于2.0倍，更优选地1.5倍，并且甚至更优选地1.0倍的股线间距ES。如果RI等于或小于1.0×ES，则沿拉伸方向SD延伸的纤维网挠曲线将以与所存在的弹性股线27的数目至少相同的数目和频率存在，从而沿横拉伸方向促进合适的柔韧性。与该特征结构组合地，粘结部长度L可等于或小于2.0倍，更优选地等于或小于1.5倍，并且甚至更优选地等于或小于1.0倍的股线间距ES。
出于减小所形成的褶皱或收拢部的总体尺寸的目的，并且结合本文所述的特征结构的任何组合，可能期望弹性股线27的横拉伸间距ES不大于14mm，更优选地不大于10mm，甚至更优选地不大于7mm，并且还更优选地不大于5mm。(在本文中，相邻弹性股线的横拉伸间距旨在被理解为是指它们的纵向轴线之间的距离，而不是它们的最近外表面之间的距离。)已通过实验确定，以该方式限制弹性股线27的间距具有促进相对小褶皱或收拢部形成的效果，从而促进或增强拉伸层合体中的布料样外观。该效果可通过结合如本文所述的非织造纤维网层25、26中的一者或两者中的粘结部图案的其它特征结构来增强和放大。
与本文所述的其它特征结构中的任一者组合地，列重复间隔CI可关联于横拉伸弹性股线间距ES，使得所述CI不大于1.5ES，更优选地不大于1.3ES，1.0ES，0.9ES，并且甚至更优选地不大于0.8ES。该特征结构使得能够控制所形成的褶皱或收拢部相对于弹性股线27的横拉伸间距的尺寸和规则性/均匀性。例如，如果拉伸层合体具有间隔开ES＝5.0mm的弹性股线，则这是指可能期望粘结部列重复间隔CI为7.5mm或更小，6.5mm或更小，5.0mm或更小，4.5mm或更小，或甚至4.0mm或更小。该尺度连同在拉伸层合体形成期间赋予弹性股线27的预应变程度一起，将进一步影响褶皱或收拢部的拉伸方向尺寸。对于如本文所设想到的拉伸层合体，预期弹性股线中的预应变在50％至200％范围内。(在本文中，预应变百分比的量被表示为如下的计算：将处于预应变状态的股线节段的长度减去处于其松弛状态的相同股线节段的长度(拉伸距离)，然后除以处于其松弛状态的相同股线节段的长度，然后乘以100％。)例如，假定弹性股线中的预应变水平足以导致层合体在松弛至其拉伸方向全拉伸长度的大约二分之一(例如，大约100％的预应变量)时收缩，粘结部列重复间隔CI将促进拉伸层合体在松弛时形成褶皱或收拢部，所述褶皱或收拢部具有为粘结部列重复间隔CI的大约二分之一的峰至峰尺度PP(参见图9)。在该情况下，如果粘结部列重复间隔CI为7.5mm或更小，则可促进规则的均匀褶皱或收拢部的形成，它们具有3.8mm或更小的峰至峰尺度。这是褶皱或收拢部的拉伸方向松弛宽度。已从原型的构造和观察确定，具有此类宽度或更小宽度的均匀且规则的褶皱或收拢部在视觉上显现为相当小的褶皱或收拢部，从而基本上有助于向拉伸层合体赋予布料样外观。
与本文所述的其它特征结构中的任一者组合地，图案中的大多数粘结部40可具有如下形状，其长度对宽度的长宽比等于或大于1.0，更优选地等于或大于1.5，甚至更优选地等于或大于2.0、还更优选地等于或大于2.5、并且最优选地等于或大于3.5。该特征结构将有助于促进规则且均匀的褶皱或收拢部的形成，它们带有沿横拉伸方向取向的脊和谷。
可参考图5I来描述可出于本文的目的而提供某种方式来控制褶皱或收拢部的形成的粘结部图案的另一种特征。粘结部图案将具有沿平行于拉伸方向SD的线SDL测量的拉伸方向重复间隔RDSD。粘结部图案将具有沿垂直于拉伸方向SD的线XL测量的横拉伸方向重复间隔RDX。拉伸方向重复间隔RDSD内所包括的粘结部40可具有例如拉伸方向宽度W1、W2、W3等。横拉伸方向重复间隔RDX内的粘结部40可具有例如横拉伸方向长度L1、L2、L3等。在适用于本文的目的的粘结部图案中：可识别出横拉伸方向线XL，沿所述横拉伸方向线，粘结部长度(L1、L2等)的总和对横拉伸方向重复间隔(RDX)(其包括粘结部长度)的比率大于粘结部宽度(W1、W2等)的总和对拉伸方向重复间隔(RDSD)(其包括粘结部宽度)的比率，对于可被识别的图案，沿任何拉伸方向线(SDL)均是如此。换句话讲，在适用于本文的目的的粘结部图案的一个示例中，可识别出垂直于拉伸方向的线XL，沿所述线，
(L1+L2+等)/RDX>(W1+W2+等)/RDSD，
对于可被识别的沿拉伸方向延伸的任何线SDL均是如此。换句话讲，这是一种如下的粘结部图案，其中相比于被可被识别的任何拉伸方向线交叉的每单位线长度的粘结部宽度的任何总和，横拉伸方向线(粘结部沿所述横拉伸方向线布置)沿纤维网每单位线长度横贯较大的粘结部长度总和。该构型的粘结部的效果为与基本上横拉伸方向列状柔性区域交替的基本上横拉伸方向列状硬化的区域。该构型趋于促进带有改善的均匀性和规则性的褶皱或收拢部的形成，它们带有沿柔性列状区域取向的交替的脊28和谷29、和沿硬化的列状区域的侧部或斜坡，如由图9可理解。假定图5A-5I所示图案的所述各种示例是成比例地从原先准备与本文一起提交的图精确地复制的，可理解每个示例均满足该条件(或将按比例略作调整)，虽然这些仅是非限制性的非排他的示例。
粘结部形状的列可被构造成基本上垂直于拉伸方向SD，例如在图6中，列角α为90度。角度α不是必需精确地为90度，但可优选的是，列角α为70至110度，更优选地80至100度，甚至更优选地85至95度，并且最优选地87至93度。这确保了沿基本上垂直于拉伸方向的方向有序地且规则地形成褶皱或收拢部。
具有未粘结路径41(它们精确地沿粘结的非织造纤维网材料存在)的图案反映了带有粘结突出部的对应的布置结构的压延粘结辊。该布置结构可增大在粘结突出部下面产生增大的或非期望的过度压力的可能性，这可导致非均匀的或有缺陷的粘结部和/或辊和设备的磨损，它们可起因于辊隙中压力的间歇且快速的阶梯式变化，所述变化起因于辊隙中粘结突出部的间歇的缺乏和存在，这种情况可在粘结突出部的横向列与压延粘结辊的圆柱形表面上的不带有突出部的横向未粘结路径交替时发生。
因此，当粘结的非织造纤维网层的机器方向对应于拉伸方向时，可能期望列角α不是精确的90度。另选地或此外，压延粘结辊还可包括间歇地中断未粘结路径41的粘结突出部，从而导致中断粘结部42的横拉伸路径的形成，如图5C所建议。中断粘结部42反映了粘结突出部，它们可被包括以减轻或消除上述介于压延粘结辊之间的辊隙中的压力的快速阶梯式变化。
拉伸层合体的拉伸方向SD可平行于或垂直于非织造纤维网层部件25、26的制造的机器方向。对于由连续地纺成的纤维形成的非织造纤维网，纤维网中的纤维常常具有由将所述纤维纺成并铺设到移动的带上的方式所引起的纵向偏差。由于存在纤维的该纵向偏差，所述非织造纤维网可能被赋予各向异性的拉伸强度特性，例如，机器方向拉伸强度大于交叉方向拉伸强度。然而已确定，当粘结部图案具有上述一个或多个特征结构的组合时，粘结部形状的列基本上垂直于机器方向，粘结部形状的行为偏移或交错的，如图5A所建议(与如图5B所示的情况形成对比)，拉伸强度的所述各向异性可被基本上减小，并且纤维网的尺度稳定性可被基本上改善(具体地但无限制地，不可取的颈缩或颈缩行为可被基本上减小)。如所指出的那样，非织造纤维网的拉伸强度和尺度稳定性对于转换操作和加工操作来讲是非常重要的，并且对于所述非织造纤维网在其中用作部件的产品的结构完整性和稳固性来讲也是如此。因此，可能期望拉伸层合体的拉伸方向基本上平行于(即，基本上相同于)载有如本文所述的粘结部图案的非织造纤维网层的机器方向。
根据以上说明，设想到以下实施例：
1.一种拉伸层合体，其具有拉伸方向和垂直于拉伸方向的横拉伸方向，所述拉伸层合体包括：
第一纤维网层，其包括载有包括多个粘结部的粘结部图案的非织造纤维网材料，所述多个粘结部各自具有长度和宽度，对于大多数粘结部，长度垂直于所述拉伸方向取向并且大于宽度；
第二纤维网层；和
设置在所述第一纤维网层和所述第二纤维网层之间的一个或多个弹性构件，
其中所述第一纤维网层、所述第二纤维网层和所述一个或多个弹性构件共同形成拉伸层合体；
其中所述一个或多个弹性构件已与第一纤维网层和第二纤维网层接合，同时所述一个或多个弹性构件为沿拉伸方向预应变的；并且
其中，当拉伸层合体处于松弛状态时，至少第一纤维网层包括多个收拢部，所述收拢部包括横向于拉伸方向取向的伸长的脊和谷。
2.一种拉伸层合体，其具有拉伸方向和垂直于拉伸方向的横拉伸方向，所述拉伸层合体包括：
第一纤维网层，其包括载有包括多个粘结部的粘结部图案的非织造纤维网材料，所述多个粘结部各自具有长度和宽度，所述长度垂直于拉伸方向取向；
第二纤维网层；和
设置在第一纤维网层和第二纤维网层之间的一个或多个弹性构件，
其中第一纤维网层、第二纤维网层和所述一个或多个弹性构件共同形成拉伸层合体；
其中所述一个或多个弹性构件已与第一纤维网层和第二纤维网层接合，同时所述一个或多个弹性构件为沿拉伸方向预应变的；并且
其中，粘结部图案具有沿平行于拉伸方向的可识别的第一线SDL测量的拉伸方向重复间隔RDSD、沿垂直于拉伸方向的第二线XL测量的横拉伸方向重复间隔RDX，沿第二线XL布置的且在横拉伸方向重复间隔RDX内的粘结部各自具有长度，沿第一线SDL布置的且在拉伸方向重复间隔RDSD内的粘结部各自具有宽度，并且对于任何可识别的第二线SDL，长度总和对横拉伸方向重复间隔RDX的比率大于宽度总和对拉伸方向重复间隔RDSD的比率；并且
其中，当拉伸层合体处于松弛状态时，至少第一纤维网层包括多个收拢部，所述收拢部包括横向于拉伸方向取向的伸长的脊和谷。
3.一种拉伸层合体，其具有拉伸方向和垂直于拉伸方向的横拉伸方向，所述拉伸层合体包括：
第一纤维网层，其包括载有包括多个粘结部的粘结部图案的非织造纤维网材料，所述粘结部各自具有长度和宽度，长度垂直于拉伸方向取向；
第二纤维网层；和
设置在第一纤维网层和第二纤维网层之间的一个或多个弹性构件，
其中第一纤维网层、第二纤维网层和所述一个或多个弹性构件共同形成拉伸层合体；
其中所述一个或多个弹性构件已与第一纤维网层和第二纤维网层接合，同时所述一个或多个弹性构件为沿拉伸方向预应变的；
其中，当拉伸层合体处于松弛状态时，至少第一纤维网层包括多个收拢部，所述收拢部包括横向于拉伸方向取向的伸长的脊和谷；并且
其中粘结部图案中的大多数粘结部具有至少2的长度对宽度的长宽比。
4.实施例1-3中任一者的拉伸层合体，其中所述多个收拢部的每个脊具有峰和两个斜侧，并且脊中的一者或多者的侧面中的一者或两者载有所述多个粘结部中的至少一个粘结部。
5.前述实施例中任一者的拉伸层合体，其中所述一个或多个弹性构件包括设置在第一纤维网层和第二纤维网层之间的多根弹性股线，其中纵向轴线基本上平行于拉伸方向，并且沿横拉伸方向由股线间距ES间隔开。
6.实施例5的拉伸层合体，其中股线间距不大于14mm、更优选地不大于10mm、甚至更优选地不大于7mm、并且还更优选地不大于5mm。
7.实施例5或6的拉伸层合体，其中粘结部的长度不大于股线间距ES。
8.实施例5-7中任一者的拉伸层合体，其中所述多个粘结部中的粘结部被布置成规则间隔的列，列具有列重复间隔CI，并且其中列重复间隔CI不大于1.5ES，更优选地不大于1.3ES、1.0ES、0.9ES，并且甚至更优选地不大于0.8ES。
9.前述实施例中任一者的拉伸层合体，其中所述多个粘结部中的粘结部具有基本上直杆形状。
10.前述实施例中任一者的拉伸层合体，其中非织造纤维网材料具有机器方向和垂直于纵向的交叉方向，并且拉伸方向基本上平行于机器方向。
11.前述实施例中任一者的拉伸层合体，其中非织造纤维网材料具有机器方向，并且包括纺丝纤维。
12.实施例11的拉伸层合体，其中纺丝纤维具有机器方向偏差。
13.实施例12的拉伸层合体，其中机器方向基本上平行于拉伸方向。
14.实施例5-8中任一者的拉伸层合体材料，其中弹性股线在它们结合到拉伸层合体材料中之前已被预应变50％至200％的量。
15.一种一次性吸收裤，其具有围绕腰区的弹性化带，所述带包括前述实施例中任一者的拉伸层合体材料。
***
本文所公开的量纲和值不应理解为严格限于所引用的精确值。相反，除非另外指明，否则每个这样的量纲旨在表示所述值以及围绕该值功能上等同的范围。
除非明确排除或换句话讲有所限制，否则将本文引用的每篇文献，包括任何交叉引用或相关专利或申请，全文均以引用方式并入本文。任何文献的引用不是对其作为与本发明任何公开或本文受权利要求书保护的现有技术的认可，或不是对其自身或与任何其它参考文献或多个参考文献的组合提出、建议或公开了此发明任何方面的认可。此外，当本发明中术语的任何含义或定义与以引用方式并入的文献中相同术语的任何含义或定义矛盾时，应当服从在本发明中赋予该术语的含义或定义。
虽然已举例说明和描述了本发明的具体实施方案，但是对于本领域技术人员来说显而易见的是，在不脱离本发明的实质和范围的情况下可作出多个其它变化和修改。因此，本文旨在于所附权利要求中涵盖属于本发明范围内的所有此类变化和修改。

Claims (15)

1.一种拉伸层合体，所述拉伸层合体具有拉伸方向和垂直于所述拉伸方向的横拉伸方向，所述拉伸层合体包括：
第一纤维网层，所述第一纤维网层包含非织造纤维网材料，所述非织造纤维网材料载有包括多个粘结部的热粘结部图案，所述多个粘结部各自具有长度和宽度，对于所述粘结部中的大多数粘结部，所述长度垂直于所述拉伸方向取向并大于所述宽度；
第二纤维网层；和
一个或多个弹性构件，所述一个或多个弹性构件设置在所述第一纤维网层和所述第二纤维网层之间，
其中所述第一纤维网层、所述第二纤维网层和所述一个或多个弹性构件共同形成所述拉伸层合体；
其中所述一个或多个弹性构件已与所述第一纤维网层和所述第二纤维网层接合，同时所述一个或多个弹性构件沿所述拉伸方向被预应变；
并且
其中，当所述拉伸层合体处于松弛状态时，至少所述第一纤维网层包括多个收拢部，所述多个收拢部包括横向于所述拉伸方向取向的伸长的脊和谷。
2.一种拉伸层合体，所述拉伸层合体具有拉伸方向和垂直于所述拉伸方向的横拉伸方向，所述拉伸层合体包括：
第一纤维网层，所述第一纤维网层包含非织造纤维网材料，所述非织造纤维网材料载有包括多个粘结部的热粘结部图案，所述多个粘结部各自具有长度和宽度，所述长度垂直于所述拉伸方向取向；
第二纤维网层；和
一个或多个弹性构件，所述一个或多个弹性构件设置在所述第一纤维网层和所述第二纤维网层之间，
其中所述第一纤维网层、所述第二纤维网层和所述一个或多个弹性构件共同形成所述拉伸层合体；
其中所述一个或多个弹性构件已与所述第一纤维网层和所述第二纤维网层接合，同时所述一个或多个弹性构件沿所述拉伸方向被预应变；
并且
其中，所述粘结部图案具有沿平行于所述拉伸方向的可识别的第一线SDL测量的拉伸方向重复间隔RDSD、沿垂直于所述拉伸方向的第二线XL测量的横拉伸方向重复间隔RDX，所述粘结部中的沿所述第二线XL布置的且在所述横拉伸方向重复间隔RDX内的各个粘结部具有长度，所述粘结部中的沿所述第一线SDL布置的且在所述拉伸方向重复间隔RDSD内的各个粘结部具有宽度，并且对于任何可识别的第二线SDL，所述长度总和对所述横拉伸方向重复间隔RDX的比率大于所述宽度总和对所述拉伸方向重复间隔RDSD的比率；并且
其中，当所述拉伸层合体处于松弛状态时，至少所述第一纤维网层包括多个收拢部，所述多个收拢部包括横向于所述拉伸方向取向的伸长的脊和谷。
3.一种拉伸层合体，所述拉伸层合体具有拉伸方向和垂直于所述拉伸方向的横拉伸方向，所述拉伸层合体包括：
第一纤维网层，所述第一纤维网层包含非织造纤维网材料，所述非织造纤维网材料载有包括多个粘结部的热粘结部图案，所述多个粘结部各自具有长度和宽度，所述长度垂直于所述拉伸方向取向；
第二纤维网层；和
一个或多个弹性构件，所述一个或多个弹性构件设置在所述第一纤维网层和所述第二纤维网层之间，
其中所述第一纤维网层、所述第二纤维网层和所述一个或多个弹性构件共同形成所述拉伸层合体；
其中所述一个或多个弹性构件已与所述第一纤维网层和所述第二纤维网层接合，同时所述一个或多个弹性构件沿所述拉伸方向被预应变；
其中，当所述拉伸层合体处于松弛状态时，至少所述第一纤维网层包括多个收拢部，所述多个收拢部包括横向于所述拉伸方向取向的伸长的脊和谷；并且
其中，所述粘结部中的处于所述粘结部图案的所述大多数粘结部具有至少为2的长度对宽度的长宽比。
4.根据权利要求1-3中任一项所述的拉伸层合体，其中所述多个收拢部的每个脊具有峰和两个斜侧，并且所述脊中的一者或多者的侧面中的一者或两者载有所述多个粘结部中的至少一个粘结部。
5.根据前述权利要求中任一项所述的拉伸层合体，其中所述一个或多个弹性构件包括设置在所述第一纤维网层和所述第二纤维网层之间的多根弹性股线，其中纵向轴线基本上平行于所述拉伸方向，并且沿所述横拉伸方向由股线间距ES间隔开。
6.根据权利要求5所述的拉伸层合体，其中所述股线间距不大于14mm、更优选地不大于10mm、甚至更优选地不大于7mm、并且还更优选地不大于5mm。
7.根据权利要求5或6中任一项所述的拉伸层合体，其中所述粘结部的长度不大于所述股线间距ES。
8.根据权利要求中5-7任一项所述的拉伸层合体，其中所述多个粘结部中的粘结部被布置成规则间隔的列，所述列具有列重复间隔CI，并且其中所述列重复间隔CI不大于1.5ES，更优选地不大于1.3ES、1.0ES、0.9ES，并且甚至更优选地不大于0.8ES。
9.根据前述权利要求中任一项所述的拉伸层合体，其中所述多个粘结部中的粘结部具有基本上直杆形状。
10.根据前述权利要求中任一项所述的拉伸层合体，其中所述非织造纤维网材料具有机器方向和垂直于所述机器方向的交叉方向，并且所述拉伸方向基本上平行于所述机器方向。
11.根据前述权利要求中任一项所述的拉伸层合体，其中所述非织造纤维网材料具有机器方向并包括纺丝纤维。
12.根据权利要求11所述的拉伸层合体，其中所述纺丝纤维具有机器方向偏差。
13.根据权利要求12所述的拉伸层合体，其中所述机器方向基本上与所述拉伸方向平行。
14.根据权利要求5-8中任一项所述的拉伸层合体材料，其中所述弹性股线在它们结合到所述拉伸层合体材料中之前已被预应变50％至200％的量。
15.一种一次性吸收裤，所述一次性吸收裤具有围绕腰区的弹性化带，所述带包含根据前述权利要求中任一项所述的拉伸层合体材料。
CN201780024120.7A 2016-05-04 2017-05-04 定向拉伸层合体和具有有利于制备定向拉伸层合体的粘结的非织造纤维网材料 Pending CN109069311A (zh)

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