CN1113995C - 透气弹性薄膜/非织造层合物 - Google Patents

透气弹性薄膜/非织造层合物 Download PDF

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Publication number
CN1113995C
CN1113995C CN98805662A CN98805662A CN1113995C CN 1113995 C CN1113995 C CN 1113995C CN 98805662 A CN98805662 A CN 98805662A CN 98805662 A CN98805662 A CN 98805662A CN 1113995 C CN1113995 C CN 1113995C
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China
Prior art keywords
film
laminated thing
constriction
fibre web
web
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CN98805662A
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CN1258327A (zh
Inventor
M·T·莫尔曼
L·J·莫甘
B·科亨
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Kimberly Clark Worldwide Inc
Kimberly Clark Corp
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Kimberly Clark Worldwide Inc
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Abstract

一种透气弹性层合物，其制造方法包括：将包含弹性、水蒸气可溶聚合物的薄膜粘合到可颈缩非织造纤网上，该粘合是在薄膜松弛时纤网处于颈缩状态下进行的。该透气性层合物沿平行于纤网变窄或颈缩的方向为可拉伸的。该层合物具备优异的水蒸气透过性，然而却能起到阻挡包括氨气在内的引起气味化学品透过的作用。

Description

透气弹性薄膜/非织造层合物
发明领域
本发明涉及由薄膜与非织造纤网组成的透气弹性层合物。该层合物尤其可用作“用即弃”尿布及其他个人护理用即弃制品的外包覆层。该层合物还可用于透气性手术罩衣以及其他透气性用途。
发明背景
各种类型蒸汽可透、液体不可透的聚合物薄膜在本领域中是已知的。制作蒸汽可透聚合物薄膜的一种方法涉及，将基体聚合物与相当数量(例如，10～70wt％)有机或无机颗粒填料，如碳酸钙，进行混合，并由该共混物挤出成形为薄膜。基体聚合物可包括聚烯烃，如聚乙烯或聚丙烯，或者各种烯烃共聚物。薄膜可以是单层薄膜、包含充填层作为主要层以及透气性外表面薄层的多层薄膜或者是具有一个以上充填层的多层薄膜。然后，薄膜经过加热和拉伸，从而在薄膜中形成孔隙。
在当今的许多个人护理吸收制品，例如尿布中，透气性薄膜被用作后片，或者作为后片的成分层合到非织造纤网和/或其他层上。充填并拉伸的聚烯烃薄膜提供优良的水蒸气透过性，使得尿布戴在身上更舒适。结果，由于采用了透气性薄膜和层合物，尿布或其他制品内的相对湿度和温度可得到降低。
多孔的充填聚烯烃薄膜和层合物的一项缺点是，它们不但可透过水蒸气，而且也可透过氨气及其他引起气味的蒸汽。譬如氨气，乃是尿液中引起气味的主要成分。而且，多孔的聚烯烃薄膜及层合物通常弹性不明显。再者，在拉伸前薄膜中任何颗粒附聚物将会导致大孔的形成，从而发生泄漏。能浸润此种薄膜的流体(醇、含表面活性剂的水等)将会透过这些孔。细菌和病毒也能透过这些孔。还有，拉伸期间产生的这些孔还会降低薄膜强度。
发明概述
本发明涉及一种可用作尿布、其他个人护理制品外包覆层及手术罩衣的透气弹性薄膜和层合物，它们对水蒸气的透过(速)率高，对氨气及某些其他引起气味的分子透过率低。该薄膜由可溶解水分子的弹性聚合材料制成。不依靠水蒸气透过薄膜中孔隙的分子扩散，本发明薄膜和层合物乃是依靠水分子在固体聚合物薄膜中的溶解，水分子透过无孔隙聚合物薄膜的扩散，最后水穿过薄膜蒸发到周围空气中。水蒸气分子从一面被吸收到薄膜中，以被吸收的状态穿过薄膜，然后从另一面释放出去。
该弹性薄膜对氨气的吸收则小得不可察觉，它们不是微孔或带孔隙的。因此，氨气对该薄膜的透过程度是微乎其微的，故而氨味跑不出来。
该薄膜可由任何表现出能够吸收和扩散水蒸气的合适成膜弹性聚合物构成。合适的聚合物包括但不限于，硫化硅橡胶、其他硅氧烷聚合物、聚氨酯、聚醚酯及聚醚酰胺。
本发明层合物包括至少1个透气弹性薄膜层及可拉伸非织造纤网，如颈缩的非织造纤网。该非织造纤网优选是纺粘纤网或者包括纺粘纤网的层合物。该薄膜与非织造纤网可粘合在一起，或者采用热粘合、超声粘合或者借助粘合剂，在粘合时纤网处于拉长的“颈缩”状态。未拉伸弹性薄膜与颈缩非织造纤网的粘合所提供的透气性层合物，沿平行于层合前纤网变窄或颈缩方向为可拉伸的，而当拉伸力解除之后它又部分或完全地回复。
综上所述，本发明的特征和优点是提供一种弹性改善的透气性层合物。
本发明的特征和优点还在于提供一种防止氨味透过的透气性层合物。
本发明的特征和优点还在于提供一种改进的透气性层合物，它可广泛地用于尿布外包覆层、其他个人护理制品、手术罩衣以及其他各种各样透气性用途。
本发明的上述以及其他特征及优点在研读了目前优选的实施方案，并参考实施例及附图之后，将会变得更清楚。
附图简述
图1是一种成形复合弹性颈缩-粘合材料的范例方法示意图。
图2是一种范例可颈缩材料在拉伸和颈缩之前的平面视图。
图2A是一种范例颈缩(后)材料的平面视图。
图2B是一种范例复合弹性颈缩-粘合材料当沿横向部分拉伸时的平面视图。
图3是一种采用张紧卷取法成形复合弹性颈缩-粘合材料的范例方法示意图。
图4是一种用于将复合弹性颈缩-粘合材料的各个层结合在一起的范例粘合图案的图示。
图5表示由硫化硅橡胶制成的薄膜的蒸汽透过速率与厚度之间的关系。
图6表示一种三角形点压花/粘合图案。
定义
本文所使用的术语“弹性”是指任何这样的材料，它在受到有偏力(biasing force)作用之后为可伸长，就是说可伸长到其松弛无偏长度的至少约160％的某一拉伸的有偏长度，该长度在拉伸力解除之后将回复其伸长的至少55％。一个假设的例子是，某一可拉伸到至少1.60英寸的1英寸材料样品，在拉长到1.60英寸并松开之后，将回复到不超过1.27英寸的长度。许多弹性材料可拉伸远超过其松弛长度的60％，例如100％或更高，且它们当中有许多在拉伸力解除之后将基本上回复到其原来的松弛长度，例如回复到其原来松弛长度的105％。
本文所使用的术语“(可)透气”是指一种薄膜或层合物，其水蒸气透过速率(MVTR)，采用ASTM E96-80，直立杯法并按下文“试验程序”做了稍许改动测定，至少为约300克/米2-24小时。
本文所使用的术语“非弹性”是指任何不符合以上“弹性”定义的材料。
本文所使用的术语“回复”是指，一种材料在有偏力作用下伸长，并在该有偏力解除之后拉长材料出现的收缩。譬如，如果某一松弛、无偏长度为1英寸的材料被拉长50％，到达1.5英寸的长度，就说该材料伸长了50％(0.5英寸)并具有其松弛长度的150％的拉伸长度。如果该范例的拉伸材料发生了收缩，也就是在有偏、拉伸力解除之后回复到1.1英寸的长度，则该材料便回复了其0.5英寸伸长的80％(0.4英寸)。回复值可表示为[(最大伸长长度-最终样品长度)/(最大伸长长度-最初样品长度)]×100。
本文所使用的术语“非织造纤网”是指一种纤网，其结构是由单根纤维或丝交叉铺置构成的，而不是按照可辨认的重复方式排列的。非织造纤网在过去一直采用各种各样的方法成形，例如采用熔喷法、纺粘法以及粘合梳理纤网法。
本文所使用的术语“微纤维”是指平均直径不超过约100μm的小直径纤维，例如其直径为约0.5μm～约50μm，更具体地说，微纤维的平均直径可在约4μm～约40μm的范围。
本文所使用的术语“熔喷纤维”是指这样成形的纤维：将熔融热塑性材料通过许多细小，通常为圆形的纺丝孔以熔融丝束或长丝形式挤出到高速气流(例如空气流)中，后者将熔融热塑性材料的长丝拉细，以致使其直径减少到微纤维直径的程度。随后，该熔喷纤维被高速气流夹带着，并沉积到收集表面上，结果成形为由无规、散乱分布的熔喷纤维组成的纤网。此种方法例如公开在授予Butin的美国专利3,849,241，在此将其公开内容并入本文作为参考。
本文所使用的术语“纺粘纤网”是指这样制成的小直径纤维：将熔融热塑性材料通过许多细小，通常为圆形的纺丝孔以熔融长丝束形式挤出，随后，挤出的长丝直径借助例如射流拉伸或者其他熟知的纺粘机理迅速减少。纺粘非织造纤网的制备在各种专利中做了说明，例如授予Appel等人的美国专利4.340,563以及授予Dorschner等人的美国专利3,692,618。在此将这2项专利的公开内容并入本文作为参考。
本文所使用的术语“纤维间粘合”是指，不采用热粘合，而是借助单根纤维之间的缠结产生的粘合，结果形成有内聚力的纤网结构。这种纤维缠结作用乃是熔喷法所固有的，但是，也可借助诸如水力缠结或针刺来产生或增强。替代地和/或附加地，可利用粘合剂来增强所要求的粘合，从而维持纤网的结构内聚性。例如，可采用粉末粘合剂和化学溶剂粘合。
本文所使用的术语“片材”是指一种层，它或者是薄膜，或者是非织造纤网。
本文所使用的术语“颈缩(的)材料”是指任何曾通过沿一个方向施加张力使其沿另外至少1个方向的尺寸变窄了的材料。
本文所使用的术语“可颈缩材料”是指任何可发生颈缩的材料。
本文所使用的术语“颈缩百分率”是指，通过测定可颈缩材料的未颈缩尺寸与颈缩(后)尺寸之间的差值，然后用可颈缩材料的未颈缩尺寸除该差值所获得的比值。
本文所使用的术语“复合弹性颈缩-粘合材料”是指包含至少在2处与颈缩材料相连接的弹性片材的材料。该弹性片材可与颈缩材料在断断续续的点相连接，或者可与后者全面粘合。该连接是在弹性片材与颈缩材料处于彼此并置构型时完成的。该复合弹性颈缩-粘合材料沿大致平行于颈缩材料的颈缩方向为弹性的。复合弹性颈缩-粘合材料可包括2个以上的层。例如，弹性片材可具有分别与其2面连接的颈缩材料，从而使形成的3层复合弹性颈缩-粘合材料具有颈缩材料/弹性片材/颈缩材料的结构，而这2片颈缩材料是沿着相同方向拉长的。还可加上另外的弹性片材和/或颈缩材料。还可采用其他的弹性片材与颈缩材料的组合。
本文所使用的术语“回方(Palindromic)层合物”是指基本对称的多层层合物，如复合弹性颈缩-粘合材料。回方层合物的例子具有A/B/A、A/B/B/A、A/A/B/B/A/A之类的结构。非普通层合物的例子具有A/B/C、A/B/C/A、A/C/B/D之类的结构。
本文所使用的术语“聚合物”一般包括但不限于，均聚物，共聚物，如嵌段、接枝、无规及交替共聚物，三元共聚物等，以及它们的共混物及改性物。再有，除非另行具体限定，术语“聚合物”将涵盖材料全部可能的几何构型。这些构型包括但不限于，全同立构、间同立构及无规对称体。
本文所使用的术语“水蒸气可透弹性聚合物”是指一种弹性聚合物，由它制成的薄膜在38℃和100％相对湿度下按ASTM E-96-80反向杯法测定，水蒸汽透过速率至少为约150千克-厘米/(千米)2-天。透过速率的进一步讨论可详见Kirk-Othmer，《化学工艺大全)》，第3版，卷3，John Wiley & Sons，pp.486～496，相关内容并入本文作为参考。
本文所使用的术语“基本由……组成”不排除那些不显著影响给定组合物或制品要求特性的附加材料的存在。此类附加材料的例子包括但不限于，颜料、抗氧剂、稳定剂、表面活性剂、蜡、流动促进剂、溶剂、加入以改善组合物加工性能的颗粒和材料。
测定水蒸气透过速率(MVTR)的试验程序
织物透气性的一种衡量指标是水蒸气透过速率(MVTR)，样品材料的该数值大致按照ASTM标准E96-80来计算，其中在试验程序上做了如下给出的稍许变动。从每种试验材料上切取直径3英寸的圆形样品，与一片CELGARD2500片材(Celanese Separation Products公司，夏洛特，北卡罗来纳)的对比样一起进行试验。CELGARD2500片材是微孔聚丙烯片材。每种材料制备3个样品。测试皿为代号60-1Vapometer盘，由Thwing-Albert仪器公司(费城，宾夕法尼亚)提供。在每个Vapometer盘中倒入100mL水，然后将试验材料和对比材料的单个样品横盖在各个盘的顶部敞口上。旋紧凸缘，以便沿着盘子的边缘形成密封，同时留出6.5cm直径的圆，即让约33.17cm2敞露面积的有关试验材料或对比材料暴露于环境气氛中。让盘子在100°F(32℃)强制循环风烘箱中平衡1h。烘箱为恒温烘箱并备有通过烘箱的外部循环风，以防止水蒸气在内部的积累。合适的强制风烘箱例如是Blue M Power-O-Matic 60烘箱，由Blue M电器公司(Blue Island，伊利诺斯)提供。待达到平衡之后，从烘箱中取出盘子，称重并立即放回烘箱中。24h之后，从烘箱中取出盘子并再次称重。按下式计算初步试验水蒸气透过速率值：
试验MVTR＝(24 h期间失重克数)×315.5克/米2-24小时
烘箱内部相对湿度不特意控制。
在预先规定100°F(32℃)和环境相对湿度的设定条件下，CELGARD2500对比样的MVTR被规定为5000克/米2-24小时。据此，对比样随同每个试验一起进行测试，然后采用下式将初步试验值校正到设定条件：
MVTR＝(试验MVTR/对比MVTR)×(5000克/米2-24小时)
目前优选实施方案详述
参考附图的图1，其中10示意地表示出一种复合弹性颈缩-粘合透气性层合材料的成形过程。可颈缩材料12，随着供给辊14沿相应箭头所指方向旋转从供给辊14上退绕下来，并沿相应箭头所指方向移动。可颈缩材料12从传动辊20及22组成的传动辊筒组18的辊隙16穿过。
可颈缩材料12可由已知的纺粘法成形并直接穿过辊隙16，无需预先贮存在供给辊上。
包含水蒸气可溶聚合物的透气性弹性片材32，随着供给辊34沿相应箭头所指方向旋转从供给辊34上退绕下来，并沿相应箭头所指方向移动。该弹性片材从粘合辊28及30组成的粘合辊组26的辊隙24穿过。该弹性片材32可由诸如薄膜挤出法之类的挤出法成形并直接穿过辊隙24，无需预先贮存在供给辊上。
由水蒸气可透聚合物制成的透气性弹性片材的水蒸气透过速率(MVTR)至少约300克/米2-24小时，优选至少约1200克/米2-24小时，最优选至少约2000克/米2-24小时。MVTR是薄膜厚度与聚合物种类二者的函数。在一系列有用薄膜厚度范围表现出要求的MVTR的优选弹性聚合物包括但不限于，硫化硅橡胶、某些其他硅氧烷聚合物、聚氨酯、聚醚酯及聚醚酰胺。下表1给出了范例弹性聚合物的代表性水蒸气透过速率。
聚合物种类     水蒸汽透过速率，kg-cm/(km)2-d
硫化硅橡胶                                11,900
聚氨酯-Estane58237                       760
聚氨酯-Estane58245                      1,270
聚醚酰胺-PEBAX                            830
聚醚酯-Hytrel或Arnitel                 930
聚酯-聚氨酯共聚物                            160
聚酯-聚氨酯共聚物                            310
倘若弹性聚合物的水蒸气透过速率过低，则薄膜可能不得不做得极端薄，方能达到要求的MVTR最低限度。非常薄的薄膜，制备和使用起来都可能不实际，因为薄膜强度过低和加工困难。因此，弹性聚合物本身应具有足够的水蒸气透过速率，以便允许所使用的薄膜具有实用的厚度。优选的是，弹性聚合物的水蒸气透过速率至少为约150千克-厘米/(千米)2-天，更优选至少约500千克-厘米/(千米)2-天，最优选至少约1000千克-厘米/(千米)2-天。
除了(材料)是水蒸气可透的之外，该透气弹性薄膜还不应过厚，以致大大妨碍其水蒸气透过性。具体薄膜组合物的MVTR，如果薄膜与蒸汽之间不存在分子相互作用的话，将大致与其厚度成反比。对于水蒸气可透薄膜来说，这一关系可能由于水与薄膜之间的亲和性，而有所出入。图5给出对硫化硅橡胶制成的薄膜而言，薄膜厚度(密耳)的对数与水蒸气透过速率MVTR(g/m2-24h)对数之间的关系。MVTR是采用ASTM E96-80，直立杯法测定的，而在下面所描述的试验程序中又做了稍许改动。对所给出的6个数据点进行线性回归发现，MVTR与薄膜厚度可按下式关联：
MVTR(g/m2-24h)＝4700x(厚度，密耳)-1.3
于是，2密耳厚硫化硅橡胶薄膜的MVTR应为约2000克/米2-24小时。一般来说，对任何弹性水蒸气可透聚合物而言，薄膜厚度的选择应满足，使获得的MVTR至少为约300克/米2-24小时，优选至少约1200克/米2-24小时，最优选至少约2000克/米2-24小时，其中所指的薄膜为未拉伸状态的。因此，水蒸气透过速率略小于硫化硅橡胶的弹性聚合物应做得薄一些，以便获得大致相同的蒸汽透过速率。例如，未拉伸弹性蒸汽可透薄膜的厚度可小于约1密耳厚，或者小于约0.5密耳厚，或者小于约0.3密耳厚，具体视薄膜强度及聚合物水蒸气透过速率而定。
弹性水蒸气可透聚合物薄膜可以是交联的，或者是热塑性的，具体视聚合物的情况而定。硫化硅橡胶优选是交联的，以便提供足够的薄膜强度。交联可通过热处理，如将薄膜置于烘箱中处理来达到。聚氨酯可以是热塑性的或者是交联的。聚醚酯及聚醚酰胺一般是热塑性的。
在优选的实施方案中，弹性薄膜可经过压花，以进一步提高其MVTR。任何聚合物，只要能够制成弹性薄膜，经过压花，且压花后能保持至少部分压花图案，都将显示出此种改进。某些聚合物，如硅橡胶，可通过交联来固定压花图案。一种合适的压花图形是图6中所示的“三角形点”图形，它是采用传统的压花技术压印在薄膜上的大量实心菱形或方块组成的图案。带有三角形点压花图形的薄膜在压印的方块所确定的“窗口”部位要比窗口周围的“边框”或未压花区域来得薄。倘若MVTR与厚度成反比，或者符合上面给出的公式，那么，压花将起到，相对于未压花区域，提高压花窗口区MVTR的作用，并从而有效地提高薄膜整体的MVTR。
图5表示一种硫化硅橡胶压花薄膜样品的MVTR，其边框区的厚度为19密耳，而通过三角形点图形压花使窗口区厚度仅有3.2密耳，因此总(平均)厚度为约16密耳。该薄膜在图5中由星号(*)代表。该压花薄膜的MVTR大大高于总厚度相同的平坦硫化硅橡胶薄膜，正如大大高于直线的星号的位置所表明的。
层合物的纺粘纤网成分一般为疏松和多孔的，因此对层合物的透气性没有什么显著影响。换句话说，薄膜的透湿性将决定层合物的透气性。然而，应谨慎选用不显著破坏层合物透气性的技术将薄膜与纤网粘合在一起。如果使用粘合剂，则粘合剂应仅覆盖薄膜总表面积的一部分，而且应涂得尽可能地薄。用于将聚醚酯或聚氨酯薄膜附着到纺粘纤网上去的优选粘合剂是以活性聚氨酯为基础的粘合剂，由Shawmut Mills公司(Bridgewater，马萨诸塞)供应。当使用时，粘合剂的单位施涂量应小于约5.0g/m2(gsm)，优选小于约1.0gsm，最优选小于约0.5gsm。粘合剂应优选地覆盖不超过薄膜面积的约75％，除非粘合剂本身是透湿非常好的。
当采用热粘合时，粘合条件不应使粘合纤网受到不必要的压缩或熔结，且薄膜不应受到任何会显著妨碍透湿的损伤或扭曲。热压粘合是优选的技术，其中所采用的将纤网与薄膜贴合在一起的间隔粘合图案(的实心压痕区)应小于总界面面积的约25％，优选小于总界面面积的约20％，最优选小于总界面面积的约15％。
在图1所示的过程中，可颈缩纺粘纤网12按反S路径穿过S-辊组18的辊隙16，正如对应于叠置辊筒20及22的旋转方向箭头所示。从S-辊组18出来，可颈缩纤网12从粘合辊组26构成的压花辊隙24穿过。由于S-辊组18各辊的圆周线速度控制在小于粘合辊组26各辊圆周线速度的水平，可颈缩纤网12在S-辊组18与粘合辊组26的压花辊隙之间受到张紧(拉伸)。借助辊速差异的调节，可颈缩纤网12受到拉伸以致发生要求程度的颈缩并维持在此种张紧、颈缩的状态；与此同时，在从粘合辊组26穿过期间，透气性弹性片材32与颈缩的纤网12彼此结合，从而形成复合弹性颈缩-粘合层合物40。
也可采用其他张紧可颈缩纤网12的方法，例如，拉幅机或其它横向拉伸装置，这些装置可使颈缩纤网在其它方向，比如横向延伸以便在粘合到透气性弹性片材32上之后，所获得的复合弹性颈缩-粘合层合物40在大致平行于颈缩方向的方向，即沿机器方向，为弹性的。
可颈缩纤网12可以是多孔非织造材料，例如纺粘纤网、熔喷纤网、或粘合梳理纤网。如果可颈缩材料是熔喷纤维构成的纤网，它可包含熔喷微纤维。可颈缩材料12可由成纤聚合物，如聚烯烃制成。范例聚烯烃包括聚丙烯、聚乙烯、乙烯共聚物、丙烯共聚物及丁烯共聚物中的一种或多种。有用的聚丙烯例如包括埃克森化学公司按商品名Exxon 3445供应的聚丙烯，以及由壳牌化学公司按商品名DX5A09供应的聚丙烯。
在一种本发明优选实施方案中，可颈缩纤网12是多层材料，例如具有至少1层纺粘纤网，它粘合在至少1层熔喷纤网、粘合梳理纤网或者其他合适的材料上。例如，可颈缩材料12可以是这样的多层材料，它包括：第一层，由单位重量为约0.2～约8盎司每平方码(osy)的纺粘聚丙烯和1层熔喷聚丙烯，单位重量为约0.2～约4osy组成；第二层，由单位重量为约0.2～约8osy的纺粘聚丙烯组成。替代地，可颈缩纤网12可以是单层材料，例如单位重量为约0.2～约10osy的纺粘纤网或者单位重量为约0.2～约8osy的熔喷纤网。
可颈缩纤网12还可以是复合材料，由2种或更多种不同纤维的混合物或者由纤维与颗粒的混合物构成。此种混合物可这样制成：将纤维和/或颗粒加入到夹带着熔喷纤维的气流中，以便使熔喷纤维与其他材料，如木浆、短纤维以及颗粒，如水凝胶颗粒，通常称之为超吸收剂材料，发生紧密共缠结，随即，熔喷纤维被收集在收集装置上，从而形成由无规散布的熔喷纤维与其他材料构成的内聚性纤网，正如美国专利4,100,324中所公开的，在此将其公开内容并入本文作为参考。
如果可颈缩纤网12是纤维的非织造纤网，该纤维应借助纤维间粘合作用连接成整体，形成足以经受颈缩的内聚性纤网结构。纤维间粘合可通过单根熔喷纤维之间的缠结产生。纤维缠结乃是熔喷方法所固有的，然而也可通过诸如水力缠结或针刺之类的加工产生或增强。替代地和/或附加地，也可使用粘合剂来增强所要求的粘合。
弹性片材32也可以是多层材料，这意思是说，它可包含2个或多个单独的内聚性纤网或薄膜。另外，弹性片材12可以是这样的多层材料，其中1个或多个层包含弹性与非弹性纤维或颗粒的混合物。
粘合辊组26可包括带图案的压花辊筒，例如一个针销压花辊筒与一个光面砧辊的组合。压花辊与光面砧辊之一或二者可备有加热，这2个辊筒之间的压力可通过熟知的方法进行调节，以便提供要求的温度(如有调温的话)及粘合压力，从而将颈缩材料12与弹性片材32结合在一起形成复合透气弹性颈缩-粘合材料40。
颈缩材料与弹性片材可全面粘合在一起，且仍可提供弹性优良的复合弹性颈缩-粘合材料。就是说，复合弹性材料可借助诸如图4中所示的正弦粘合图案之类的粘合表面使颈缩材料与弹性片材连接在一起。这种图案具有每平方英寸约75个针销，每个针销直径约0.059英寸，从而提供约20.5％的粘合表面面积。
颈缩材料可通过适当的手段在至少2处连接到透气性弹性片材32上，这些手段例如是，使至少1种材料的至少1部分软化的热粘合或粘合剂粘合或超声焊接，该至少1种材料一般是弹性片材，因为用以构成弹性片材32的弹性体材料具有比颈缩材料12的成分低的软化点。这种连接(结合)可通过层叠的弹性片材32与颈缩材料12加热和/或加压来产生，即，将这部分(或叠层)加热到软化温度最低的材料的软化温度，从而在弹性片材32的再固化的***部分与颈缩材料12之间产生强度合理的、永久性的粘合。所采用的条件不应起到在薄膜上造成穿孔的作用。
可使用单位重量小于0.5 osy(盎司每平方码)，例如在约0.25～约0.4osy的弹性片材。此种单位重量极低的片材之所以有利，一方面由于透气性较高，另一方面成本低，因此尤其适用于用即弃制品。另外，也可使用较高单位重量的弹性片材，例如约0.5～约10osy。
关于热粘合，本领域技术人员会看出，热粘合期间材料或者至少其粘合部位应加热到的温度，不仅取决于加热辊或其他热源的温度，而且取决于材料在加热表面上的停留时间、材料单位重量以及其比热和热导率。然而，就给定的材料组合而言，同时又考虑到本文所公开的内容，为达到满意粘合要求的加工条件可方便地由本领域技术人员确定。
用以配合图1中设备使用的传统驱动手段及其他传统装置是熟知的，为清楚起见，没有在图1的示意图中表示。
可颈缩材料12的原来尺寸与其张紧后尺寸之间的关系决定复合弹性颈缩-粘合材料大致的拉伸极限。由于可颈缩材料12能够沿着例如纵向或横向的方向拉伸并返回到其颈缩(后)的尺寸，因此复合弹性颈缩-粘合材料也将是沿着与可颈缩材料12大致相同的方向可拉伸的。
例如，参见图2.2A和2B，倘若希望制备一种可拉伸150％伸长的复合弹性颈缩-粘合材料，可将如图2中示意地表示但不一定符合比例的具有宽度为“A”，譬如250cm的可颈缩材料的宽度，通过张紧“颈缩到”约100cm的宽度。图2A所示颈缩后的材料随后与宽度约100cm并至少可拉伸到250cm宽的弹性片材(未表示)连接在一起。所形成的复合弹性颈缩-粘合材料，如图2B示意地表示但不一定符合比例，将具有约100cm宽度并可拉伸到至少为可颈缩材料原来的宽度“A”，即250cm，相当于伸长约150％。正如可从这个例子看出的，弹性片材的弹性极限只需要至少与复合弹性颈缩-粘合材料要求的弹性极限一样大即可。
现在来看附图的图3，其中50表示一种通过张紧卷取法成形复合弹性颈缩-粘合材料的范例方法。第一可颈缩材料52从供给辊54上退绕，第二可颈缩材料82从供给辊84上退绕下来。随着供给辊54及84沿相关箭头方向旋转，可颈缩材料52及82随后沿着相应箭头所示方向前进。可颈缩材料52随后从叠置辊筒60与62构成的S-辊组58的辊隙56穿过。类似地，可颈缩材料82从叠置辊筒90与92构成的S-辊组88的辊隙86穿过。可颈缩材料52及82可通过已知的非织造挤出法，如已知的纺粘法和/或已知的熔喷法，成形并穿过辊隙56和86，无需预先贮存在供给辊上。
随着供给辊74沿相关箭头的方向旋转，弹性片材72从供给辊74上退绕并沿着相应箭头所示方向前进。弹性片材72可采用已知的挤出法，如流延膜或吹塑薄膜挤出法来成形，无需预先贮存在供给辊上。
可颈缩材料52随后沿着与叠置辊筒60和62相关的箭头旋转方向所指示的反“S”缠绕路径，从S-辊组58的辊隙56穿过。类似地，可颈缩材料82沿着与叠置辊筒90及92相关的旋转方向箭头所示按反S形缠绕路径从S-辊组88的辊隙86穿过。由于S-辊组58与88的辊筒圆周线速度控制在低于卷取辊94的辊筒圆周线速度的水平，故可颈缩材料52及82被颈缩和张紧，从而使它们在与弹性片材72一起卷绕到卷取辊94的同时将弹性片材72夹在当中。
上面所描述的张紧卷取粘合法适用于低单位重量弹性体片材。例如，可使用单位重量小于0.5osy(盎司每平方码)，例如约0.25～约0.4osy的弹性片材。此种单位重量极低的片材之所以选用，是出于经济的考虑，特别是用于用即弃制品。另外，单位重量较高的弹性片材，例如约0.5～约10osy的，也可使用。弹性片材也可径直地挤出到颈缩后的非织造纤网上。
关于在粘合采用上述张紧卷取法实施时的粘合压力，粘合压力的规定本身没有考虑诸如弹性片材与颈缩材料之间的粘合相容性和/或各材料的单位重量之类的复杂因素。但是，本领域技术人员在考虑到这些因素后将能够很快恰当地选择和改变有效粘合压力。
可用于配合图3设备使用的传统驱动手段和其他传统装置是熟知的，为清楚起见，在图3的示意图中未标示出来。
在一种实施方案中，透气弹性薄膜32可预先粘合在另一层透气弹性层上，然后再层合到可颈缩纤网12上。例如，透气性薄膜12可以是杜邦公司(Wilmington，特拉华)的商品名Hytrel的聚醚酯薄层。薄膜12可与Kimberly Clark公司采用DSM公司(Evansville，印地安纳)出售的另一种商品名Arnitel聚醚酯制成的熔喷层合并在一起。这种组合可提供优异的水蒸气透过性。该熔喷纤网应具有约10～75gsm，优选约15～50gsm，最优选约20～40gsm的单位重量。优选的是，其中的熔喷长丝直径为约10～30μm。合并起来的薄膜与熔喷纤网随后可层合到颈缩的纺粘纤网上，从而提供一种水蒸气透过性和氨味阻隔性极佳、高水头(high hydrohead)、具有单向弹性以及手感柔软的层合物。
聚醚酯熔喷纤网大大增强了薄膜12的强度，同时不妨碍其透气性。薄膜12可采用传统粘合技术，如本领域技术人员已知的粘合剂印刷粘合法粘合到熔喷纤网上。最终层合物可具有“弹性熔喷纤网/弹性薄膜/颈缩纺粘纤网”的构型，或者具有“弹性薄膜/弹性熔喷纤网/颈缩纺粘纤网”的构型。再有，只要熔喷纤网是多孔的，它不需要包括水蒸气可溶的聚合物，而是可以由任何弹性聚合物制成，例如Kraton牌苯乙烯-丁二烯橡胶。
在本发明的另一种实施方案中，透气弹性薄膜或层合物可沿着除平行于非织造纤网颈缩方向以外的某一方向(例如垂直于颈缩的方向)进行拉伸，并在拉伸状态以及纤网处于颈缩状态下，层合到纤网的多个彼此间隔的部位上。层合后，让弹性薄膜或层合物松弛，从而导致粘合区之间出现皱纹或褶裥。形成的复合层合物为沿至少2个不平行方向可拉伸的。该复合材料沿平行于颈缩方向的拉伸通过纤网的颈缩而变得容易。复合材料沿非平行于(例如垂直于)颈缩的方向的拉伸借助纤网沿该方向的褶裥而变得容易。由弹性薄膜与颈缩非织造纤网制造多方向可拉伸层合物的方法描述于美国专利5,116,662和5,114,781中，这2项专利均授予了Morman，在此将其公开内容并入本文作为参考。
将未颈缩非织造纤网用于上述方法将生产出仅在一个方向，即沿粘合前弹性片材拉伸方向有弹性的层合物。此种方法以及获得的层合物描述在授予Vander Wielen等人的美国专利4,720,415中。
其他的层组合方式也可用于本发明的透气弹性层合物。无论层的构型和数目如何，透气弹性层合物均应包括至少1个透气弹性薄膜和至少1个颈缩非织造布(优选纺粘)层。添加剂，例如气味吸收性化学品(如，吸收氨气的化学品)也可包括在层合物中。此种添加剂可以以颗粒形式在例如采用流延挤出成形弹性薄膜期间加入。添加剂的加入量可最高为薄膜的80wt％，优选约20～60wt％。有用的气味吸收添加剂包括沸石、其他吸收性添加剂及其组合。
实施例1
一片由Dow Corning公司(Midland，密执安)提供的未硫化Silastic硅橡胶片材被压印上大三角形点图案。该三角形点(窗口区)覆盖薄膜总面积的16％，而点与点之间的未压花区(边框)则覆盖薄膜总面积的84％。薄膜在加热烘炉内进行硫化以固定压花图形。该硫化薄膜的厚度，在边框区为19密耳；窗口区，3.2密耳；重量平均值为16.1密耳。
薄膜的MVTR，采用ASTM E96-80(直立杯法)测定，其中按如上所述做了稍许改动，结果发现为249克/米2-24小时.同样厚度(16.1密耳)的平坦薄膜，根据从图5数据归纳出的公式计算，预期其MVTR仅有127克/米2-24小时，该公式如下：
MVTR＝4700 X(厚度，密耳)-1.3
从同一公式可以预测，完全平坦的薄膜将必须只有9.6密耳的厚度，才能达到MVTR等于249克/米2-24小时的水平。因此，借助对薄膜压花，可达到通常厚度薄得多的薄膜才会有的显著高出的MVTR数值。
值得注意的是，压花薄膜的MVTR可采用同一公式预测，即，将压花与未压花区域按照各自在总面积中的比例分别作为单独的区域来处理。
预测的MVTR＝0.84(4700)(19)-1.3+0.16(4700)(3.2)-1.3
          ＝0.84(102)+0.16(1036)
          ＝86+165＝251克/米2-24小时。
该预测的MVTR数值251克/米2-24小时与测定的MVTR数值249克/米2-24小时基本一致。从该公式可以看出，约2/3的蒸汽透过量是经由窗口区穿过的，尽管它们仅占薄膜总面积的16％。
实施例2
未拉伸厚度为1密耳的Hytrel8171(聚醚酯)薄膜借助活性聚氨酯粘合剂层合到Arnitel(聚醚酯)非织造熔喷纤网上。该层合物随后借助3M公司按商品名Super77销售的专利技术喷涂粘合剂粘合到可逆颈缩纺粘聚丙烯材料上。可逆颈缩材料描述在授予Morman的美国专利4,981,747和4,965,122中，在此将其公开内容并入本文作为参考。所使用的纤网具有0.8osy的原始单位重量，经过颈缩从17.75英寸的宽度变为8.5英寸的宽度，接着在颈缩状态下热定形。所获3层的层合物兼备：颈缩纺粘层贡献的外包覆层柔软、聚醚酯薄膜和熔喷层贡献的良好弹性、由聚醚酯薄膜贡献的良好总薄膜阻隔性(由采用AATCC 127-89测定，水头超过120cm所证实)，以及优异的水蒸气透过性(由MVTR等于3200克/米2-24小时所证实)，这是由于纺粘和熔喷结构疏松、构成薄膜的聚醚酯湿汽透过速率高所致。该MVTR是采用ASTM E96-80(直立杯法)并按如上所述做了稍许改动测定的。
实施例3
进行本实例的目的是考察透气弹性聚氨酯薄膜在氨味阻隔能力上与先有技术透气性微孔薄膜的对比。2个测定MVTR使用的典型盘子(杯子)(如上面试验程序中所述)，各自以大约50cc以氨为基础的市售清洁剂部分注满，该清洁剂号称“柠檬保鲜帕森斯氨通用清洁剂”。将1密耳厚以Dow AffinityPL-1845为基础的微孔聚烯烃薄膜样品盖在一个杯子上，然后密封。Dow AffinityPL-1845为基础的是金属茂催化的线型低密度聚乙烯(LLDPE)。该LLDPE按如下程序被转变为微孔的：将树脂与50wt％以上碳酸钙填料混合，2种成分进行熔融掺混，由共混物挤出为薄膜，并将挤出的薄膜单向拉伸。将1密耳厚透气弹性聚氨酯吹塑薄膜样品盖在另一个杯子上，然后密封。以LLDPE为基础的微孔膜的MVTR为约4000克/米2-24小时。弹性体聚氨酯的MVTR为约1800克/米2-24小时。
3个人应邀用鼻子闻每个密封的杯子。这3个人全都能闻到从LLDPE为基础的薄膜覆盖的杯子发出非常强烈的氨气。3个人一致仅闻到从聚氨酯薄膜覆盖的杯子发出微弱的柠檬气味。这一结果表明，聚氨酯允许水蒸气和柠檬气味透过，但不允许氨气透过，从而提供微孔充填LLDPE薄膜所不具备的氨味阻隔能力。
虽然这里所公开的实施方案目前被认为是优选的，但是，在不偏离本发明精神和范围的条件下仍可做出各种修改和改进。本发明的范围由所附权利要求规定，所有属于等价意义和范围的改动均视为涵盖于其中。

Claims (45)

1.一种透气弹性层合物，它包含
透气弹性薄膜；以及
可颈缩非织造纤网，它在非织造纤网处于颈缩且薄膜处于未拉伸状态下被粘合到了薄膜上；
该层合物的MVTR至少为约300克/米2-24小时。
2.权利要求1的层合物，其中薄膜包含硅氧烷聚合物。
3.权利要求2的层合物，其中硅氧烷聚合物包含硫化硅橡胶。
4.权利要求1的层合物，其中薄膜包含聚氨酯。
5.权利要求1的层合物，其中薄膜包含聚醚酯。
6.权利要求1的层合物，其中薄膜包含聚醚酰胺。
7.权利要求1的层合物，其中薄膜包含，在38℃和100％相对湿度时水蒸气透过速率至少为约150千克-厘米/(千米)2-天的聚合物。
8.权利要求1的层合物，其中薄膜包含，在38℃和100％相对湿度时水蒸气透过速率至少为约500千克-厘米/(千米)2-天的聚合物。
9.权利要求1的层合物，其中非织造纤网包含纺粘纤网。
10.权利要求1的层合物，其中薄膜包含，在38℃和100％相对湿度时水蒸气透过速率至少为约1000千克-厘米/(千米)2-天的聚合物。
11.权利要求9的层合物，其中纺粘纤网包含聚丙烯。
12.权利要求1的层合物，它具有至少约1200克/米2-24小时的MVTR。
13.权利要求1的层合物，它具有至少约2000克/米2-24小时的MVTR。
14.权利要求1的层合物，它包含第二非织造纤网。
15.权利要求1的层合物，其中薄膜是压花的。
16.权利要求1的层合物，其中薄膜可基本阻挡氨味的透过。
17.权利要求1的层合物作为尿布外包覆层的用途。
18.权利要求1的层合物作为手术罩衣的用途。
19.一种透气弹性层合物，它包含：
水蒸气可透弹性薄膜，它包含选自硅氧烷聚合物、聚氨酯、聚醚酯、聚醚酰胺及其组合的聚合物；以及
可颈缩纺粘纤网，它粘合在薄膜上使得当薄膜未拉伸时纺粘纤网是颈缩的；
该层合物具有至少约1200克/米2-24小时的MVTR。
20.权利要求19的层合物，其中聚合物包含硫化硅橡胶。
21.权利要求19的层合物，其中薄膜的厚度在未拉伸状态不超过约1.0密耳。
22.权利要求19的层合物，其中薄膜的厚度在未拉伸状态不超过约0.5密耳。
23.权利要求19的层合物，其中薄膜的厚度在未拉伸状态不超过约0.3密耳。
24.权利要求19的层合物，其中薄膜与纤网是热粘合在一起的。
25.权利要求19的层合物，其中薄膜与纤网是借助粘合剂粘合在一起的。
26.权利要求19的层合物，其中当纤网与薄膜粘合在一起时纺粘纤网发生了颈缩且薄膜处于未拉伸状态。
27.权利要求19的层合物，其中薄膜还包含1种或多种气味吸收化学品。
28.权利要求27的层合物，其中1种或多种气味吸收化学品包含氨吸收化学品。
29.权利要求19的层合物，其中薄膜是压花的。
30.权利要求19的层合物，它包含附加的非织造纤网。
31.权利要求19的层合物，其中薄膜可基本阻挡氨味的透过。
32.包含权利要求19的层合物作为尿布外包覆层的用途。
33.包含权利要求19的层合物作为手术罩衣的用途。
34.一种透气弹性层合物，它包含：
透气弹性薄膜，它具有第一和第二面；
熔喷非织造层，它粘合在薄膜的第一面；以及
纺粘非织造层，它粘合在薄膜的第二面，使得当薄膜未拉伸时纺粘纤网是颈缩的。
35.权利要求34的层合物，其中薄膜包含聚醚酯。
36.权利要求34的层合物，其中熔喷非织造层包含聚醚酯。
37.权利要求34的层合物，其中薄膜和熔喷非织造层均包含一种聚醚酯。
38.权利要求34的层合物，其中薄膜与熔喷非织造层包含2种不同的聚醚酯。
39.权利要求34的层合物，其中薄膜是压花的。
40.权利要求1的透气弹性层合物，其中可颈缩非织造纤网包含可颈缩非织造层合物。
41.权利要求40的透气弹性层合物，其中可颈缩非织造层合物包含薄膜和熔喷纤网。
42.权利要求41的透气弹性层合物，其中薄膜包含聚醚酯。
43.权利要求41的透气弹性层合物，其中熔喷纤网包含聚醚酯。
44.一种透气弹性层合物，它包含：
透气弹性薄膜；以及
粘合在薄膜上的可颈缩非织造纤网；
该非织造纤网是在薄膜处于未拉伸状态时沿着第一方向颈缩的；
该薄膜与纤网是在薄膜沿着不平行于第一方向的第二方向拉伸时粘合在一起的。
45.权利要求44的透气弹性层合物，其中第二方向基本上垂直于第一方向。
CN98805662A 1997-05-30 1998-05-26 透气弹性薄膜/非织造层合物 Expired - Lifetime CN1113995C (zh)

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DE69809908D1 (de) 2003-01-16
AU7595398A (en) 1998-12-30
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WO1998054389A1 (en) 1998-12-03
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AU736963B2 (en) 2001-08-09
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AR012882A1 (es) 2000-11-22
ZA984072B (en) 1998-11-24
US5883028A (en) 1999-03-16

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