CN1160187C - 弹性伸缩性叠层片及其制造方法 - Google Patents

弹性伸缩性叠层片及其制造方法 Download PDF

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CN1160187C
CN1160187C CNB001373358A CN00137335A CN1160187C CN 1160187 C CN1160187 C CN 1160187C CN B001373358 A CNB001373358 A CN B001373358A CN 00137335 A CN00137335 A CN 00137335A CN 1160187 C CN1160187 C CN 1160187C
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小林利夫
丹下悟
井上惠美子
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Abstract

本发明提供一种具有即使伸长高度也不变的褶的弹性伸缩性叠层片。弹性伸缩性叠层片1是在弹性伸缩性第一纤维层2上接合有高克重区12和低克重区13的第二纤维层3。第二纤维层3的高克重区12比低克重区13厚，第一纤维层2与高克重区12接合的部位处具有较低的弹性伸缩性，在与低克重区13接合的部位处具有较高的弹性伸缩性。

Description

弹性伸缩性叠层片及其制造方法
本发明涉及一种有褶的弹性伸缩性的叠层片。
特开平公报6-86712号披露了有褶的复合弹性材料的制造方法。该方法是将拉伸的弹性料片和可形成褶的料片间歇地接合后，解除弹性料片的拉伸而收缩后形成复合弹性材料。对于该复合弹性材料，因弹性料片的收缩，在可形成褶的料片上生成大量的褶。
上述公知技术的复合弹性材料若在最初拉伸弹性料片时再朝同方向拉伸，则对应于其伸长量，褶高度降低。然而，根据该种复合弹性材料的用途，有时褶高度降低现象是所不期望的。
因此，本发明目的是对于要形成褶的弹性伸缩性料片，即使使料片伸长，也使褶高度几乎不变。
为了解决上述问题，本发明由涉及到物的第一发明和涉及到该物制造的第二发明构成。
上述第一发明所指的对象是弹性伸缩性叠层片，该叠层片由第一纤维层和第二纤维层构成，其中的第一纤维层由热塑性合成橡胶构成的弹性伸缩性纤维形成，第二纤维层由位于上述第一纤维层的至少单侧面上的非伸缩性热塑性合成纤维形成。
对于所述的叠层，本发明的特征在于如下。即，上述第一纤维层厚度基本一样，在相互正交的第一方向和第二方向中的至少向第一方向具有弹性伸缩性。上述第二纤维屋具有在上述表面上朝着上述第二方向相互平行地延伸的高克重区域和位于相邻的上述高克重区域彼此间的、沿上述第二方向延伸的低克重区域。上述高克重区域的厚度比上述低克重区域厚，而且为了使上述高克重区域的正下方的上述第一纤维层的上述弹性伸缩性比上述低克重区域正下方的上述第一纤维层的上述弹性伸缩性低，而在上述第一方向上间歇地接合于上述第一纤维层。
上述第一发明具有如下的优选实施形式。
(1)上述第一、第二纤维层通过熔合或接合的任何一种方式接起来，上述第一纤维层和上述高克重区域的每单位面积的接合面积比例比上述第一纤维层和上述低克重区域的比例大。
(2)上述第二纤维层在上述第一方向上，反复形成上述高克重区域呈山状，上述低克重区域呈谷状的起伏状。
(3)上述第一纤维层的克重(日本织物的单位面积重量，4.356g/m2，简称克重)是10-200g/m2，上述第二纤维层的高克重区域的克重是10-100g/m2，上述低克重区域的克重是1-10g/m2，处于上述高克重区域的克重的1-30％范围内。
(4)上述第一、第二纤维各自由连续纤维形成。
上述第二发明所指的对象是弹性伸缩性叠层片的连续制造方法，该叠层片的制造方法是将由热塑性合成橡胶构成的弹性伸缩性纤维形成的第一纤维层和位于上述第一纤维层的至少单侧面上的、由非伸缩性的热塑性合成纤维形成第二纤维层相互接合完成。
对于所述制造方法，第二发明的特征如下。上述第一纤维层和第2纤维层分别由第一纺丝机和第2纺丝机形成。上述第一纺丝机具有多个第一喷嘴，上述第一喷嘴在沿上述叠层片的宽度方向延伸的第一方向上横向排列且基本等间隔配置，从上述第一喷嘴向沿与上述第一方向正交的第二方向行走的皮带上喷丝，形成第一连续纤维，由第一连续纤维连续地形成厚度基本一样的上述第一纤维层。第二纺丝机具有沿上述第一方向地横向配置的多个第二喷嘴，上述第二喷嘴至少由2组以上喷嘴组构成，每组至少为3个基本等间隔排成一排，上述组和组之间的间距大于上述间隔。从上述第二喷嘴向上述第一纤维层的表面上喷丝，形成第二连续纤维，由第二连续纤维连续地形成上述第二纤维层，第二纤维层的位于上述喷嘴组正下方的部分较厚，具有高克重，上述第二喷嘴组之间的部分相对较薄，且具有低克重。上述第一纤维层和第二纤维层在上述第一、第二方向中的至少第一方向上间歇地接合，且上述两层的相对于单位面积的接合面积比例在上述高克重部分大，而在上述低克重部分较小地接合。
对于上述第二发明的优选实施例中，构成上述喷嘴组的上述第二喷嘴以0.8～3.5mm间隔配置，相邻的上述组和组的间距为10～50mm。
图1是叠层片的透视图。
图2是裤叉型尿布的透视图。
图3是图2的III-III线断面图。
图4是叠屋片的制造过程图。
图5是从下向上看挤出机时的喷嘴的配置状态图。
下面参照附图，详细地说明本发明涉及的弹性伸缩性叠层片及其制造方法，描述如下。
图1以透视图示出的叠层片1具有基层2和形成在基层2上表面2A上的表面层3。基层2是通过由热塑性合成橡胶构成的弹性伸缩性纤维4相互交织形成的弹性伸缩性层，合成橡胶可使用如苯乙烯类的。对于纤维4而言，较好的是使用连续纤维，更好的是纤维直径为0.5～50μm的连续纤维，较好的是纤维的克重在10～200g/m2，最好是10～100g/m2的范围。纤维4通过机械织合或熔合或粘接等方式交织。所述基层2在相互正交的X方向和Y方向中的X方向上或者在X方向和Y方向上至少具有300％的破断伸度，另外，至少向X方向拉长50-100％时，能够基本上弹性恢复到原来的尺寸。
表层3是通过由热塑性合成树脂构成的非伸缩性的纤维6相互交织而形成的层，可使用合成树脂中的聚乙烯，聚丙烯，聚酯，尼尤等。纤维6优选连续纤维举例来说，可使用纤维直径0.5～50μm的连续纤维的聚丙烯的连续纤维。表层3具有下表面10和上表面11，下表面10是与基层2的上表面2A接触的基本平坦的面，上表面11具有沿Y方向延伸的多峰部12和位于峰部12彼此间的谷部13沿X方向交替排列而形成的起伏。峰部12是具有10～100g/m2克重，和50-100mm的沿X方向延伸的宽度的部位，谷部13是具有峰部克重的1-30％，且克重比10g/m2小，沿X方向的宽度为5-40mm的部位，峰部12比谷部13厚，克重从峰部12向谷部13慢慢减少。表层3下表面10通过粘接或熔接或纤维彼此间的织合的任何一种方式接合基层2的表面2A。其接合的方式在使叠层片1朝X方向拉紧(引张)时，为了峰部12和位于正下方的基层2伸长量相对较小，而谷部13和位于其正下方的基层2的伸长量相对较大，更好地是为了使峰部12和位于其正下方的基层2的伸长量为谷部13和位于其正下方的基层2的伸长量的三分之一以下，对基层2和峰部12及基层2和谷部13的接合面积的比例进行调整。例如，在基层2和表层3于被施加了热轨纹整理的部位17处接合时，为了确保峰部12正下方的接合面积比例比谷部13正下方的接合面积比例大，在峰部12上形成多个接合部位17。结果是在峰部12上，接合部位17彼此接近，在谷部13上接合部位17彼此离得较远。对接合部位17的形状不作特别限制，但为了能够使叠层沿X方向伸缩，在X/Y方向中的至少X方向上以间歇地形成。
对于这样得到的叠层片1，朝X方向拉伸时，表层3主要在谷部13处纤维6沿其拉伸方向再配列，而在相互分离的接合部位17和17之间伸长，基层2的谷部13的正下方部分弹性伸长。表层3的峰部12和峰部12正下方位置的基层2因相互接近的接合部位17，纤维4和6的动作被限制，几乎不能伸长。所以，即使叠层片1沿X方向伸长，峰部12的距谷部13的高度也不变。在沿Y方向拉伸叠片1时，因峰部12的非伸缩性，叠层片1不能伸长。
图2、3分别是把带叠层片1作为身体周围弹性部件使用的一次性裤叉型尿布21的透视图和该图中III-III线断面图。叠层片1是以其表层3与尿布21的穿着者的肌皮接触地与尿布21的前后身体周围区域的布片22的内表面接合。叠层片1的峰部12和谷部13沿尿布21的上下方向延伸，穿着尿布21时，谷部13起到了与尿布21的内外导通的通气槽的作用。所述的尿布21即使沿身体周围方向伸长，通气槽不会受到破坏，槽的深度几乎不会变化。所以，该尿布21与穿着者身体腰围尺寸大小无关，可保持一定的通气性。
图4是示出制造叠层片1的过程的一例的图面。该过程中，从图的左侧向右按顺序布置了第一纺丝机41，第二纺丝机42，轧花辊43，卷取装置44，环形带46在第一、第二纺丝机41、42的下方按顺时钟方向移动。第一、第二真空抽气装置47、48设置在第一、第二纺丝机41、42的正下方，装置47、48夹着带46。
第一纺丝机41在沿皮带46的宽度方向上具有间隔一定的多个喷嘴51，从这些喷嘴51向皮带46上喷出热塑性合成橡胶的连续纤维52。在喷嘴51的两侧上有热风出口53，连续纤维52因从此处向下方吹出的热风的作用而延伸，被吹向皮带46上并堆积在其上，形成叠层1的基层2。
第二纺丝机42由挤出机42A和吸盘42B构成，挤出机42A具有沿皮带46的宽度方向排列的多个喷嘴54。从喷嘴54喷出由热塑性合成树脂构成的非伸缩性的连续纤维57。喷嘴54的两侧上有热风吹出口58，借助于从该口吹出的热风保温的连续纤维57进入吸盘42B内。在吸盘42B内，常温压缩空气从空气吹出喷嘴59向下喷吹，连续纤维57受到该常温空气的急冷，并被吹向位于皮带46上的基层2上，形成叠层片1的表层3。所述的连续纤维57在挤出机42A和吸盘42B之间延伸。
图5示出从图下方向上看挤出机42A时挤出机42A处的多个喷嘴54的配列状态示意图。第二纺丝机42的挤出机42A在皮带的宽度方向上排列着至少2组以上的喷嘴61，每组喷嘴61至少有3个喷嘴54，各喷嘴54间隔一定保持在0.8-3.5mm的范围内。一组喷嘴61的在皮带46宽度方向上的尺寸是5-200mm的范围内，相邻喷嘴组61和61相距2-50mm。从喷嘴54按如此方式配置的第二纺丝机42喷出的连续纤维57堆积在基层2上的量在喷嘴61的正下方较多，而在喷嘴组61和61之间较少，沿皮带46的宽度方向来看，在喷嘴组61的正下方形成图1的峰部12，在喷嘴组61和61之间形成谷部13。
再来看图4，轧花加工装置43由表面上带多个轧花用突起45的第一辊43A，表面光滑的第二辊43B构成，被加热到所需温度的第一辊43A的突起44压在表层3的上表面上，形成图1所示的接合部位17。突起44沿皮带46的宽度方向间歇地配设。在叠层片1上，接合部位17在每单位面积上存在的个数，换言之，接合部件17所占的面积应按如下方式形成，即在表层3上的峰部12处的个数比谷部13处的个数多，最好峰部12处的个数至少是谷部13处的个数的1.3倍。对于叠层片1，也可以这样来形成部位17以代替接合部位17的个数，即在峰部12上的部位17的面积之和是谷部13上的部位17面积之和的至少1.3倍。
对于本发明，基层2和表层3除了轧花加工外，能够通过钟刺法或高压水的喷射等手段接合两层2/3。图例示出只在基层2的上表面2A上形成的表层3也可以只形成在基层2的下表面2B(参照图1)上或形成在上表面2A和下表面2B上。在基层2的上下表面2A/2B上形成表层3的情况，经基层2峰部12、谷部13彼此背靠背放置。
本发明的叠层片是将非伸缩性纤维构成的表层接合在由弹性伸缩性纤维构成的基层的上下表面的任一面上。在表层上相互平行沿一个方向延伸的峰部和谷部交替布置，因峰部和基层接合的面积的比例比谷部和基层接合的面积比例大，所以向垂直于上述方向的方向拉伸叠层片时，峰部限制了基层的伸长，而峰部本身其高度不变。

Claims (7)

1.一种弹性伸缩性叠层片，该叠层片由第一纤维层和第二纤维层构成，其中的第一纤维层由热塑性合成橡胶构成的弹性伸缩性纤维形成，第二纤维层由位于上述第一纤维层的单侧面、或第一纤维层的两侧面上的非伸缩性热塑性合成纤维形成，其特征在于：
上述第一纤维层厚度基本一样，在相互正交的第一方向和第二方向中的第一方向和第二方向的双方、或仅在第一方向上具有弹性伸缩性，
上述第二纤维层具有在上述表面上朝着上述第二方向相互平行地延伸的高克重区域和位于相邻的上述高克重区域彼此间的、沿上述第二方向延伸的低克重区域；上述高克重区域的厚度比上述低克重区域厚，而且为了使上述高克重区域的正下方的上述第一纤维层的上述弹性伸缩性比上述低克重区域正下方的上述第一纤维层的上述弹性伸缩性低，在上述第一方向上间歇地接合上述第一纤维层。
2.根据权利要求1所述的叠层片，其特征在于上述第一、第二纤维层通过熔合或接合的任何一种方式接合起来，上述第一纤维层和上述高克重区域的每单位面积的接合面积比例比上述第一纤维层和上述低克重区域的比例大。
3.根据权利要求1或2所述的叠层片，其特征在于上述第二纤维层在上述第一方向上，反复形成上述高克重区域呈山状，上述低克重区域呈谷状的起伏状。
4.根据权利要求1至3中任何一个权利要求所述的叠层片，其特征在于上述第一纤维层的克重是10-200g/m2，上述第二纤维层的高克重区域的克重是10-100g/m2，上述低克重区域的克重是1-10g/m2，处于上述高克重区域的克重的1-30％范围内。
5.根据权利要求1至4中任何一个权利要求所述的叠层片，其特征在于上述第一、第二纤维分别由连续纤维形成。
6.一种弹性伸缩性叠层片的连续制造方法，该方法是将由热塑性合成橡胶构成的弹性伸缩性纤维形成的第一纤维层和位于上述第一纤维层的单侧面或第一纤维层的两侧面上的、由非伸缩性的热塑性合成纤维形成第二纤维层相互接合完成，其特征在于：
上述第一纤维层和第二纤维层分别由第一纺丝机和第二纺丝机形成，
上述第一纺丝机具有多个第一喷嘴，上述第一喷嘴沿上述叠层片的宽度方向延伸的第一方向横向设置且基本等间隔配置，从上述第一喷嘴向沿与上述第一方向正交的第二方向行走的皮带上喷丝，形成上述第一连续纤维，由第一连续纤维连续地形成厚度基本一样的上述第一纤维层，
第二纺丝机具有沿上述第一方向横向配置的多个第二喷嘴，上述第二喷嘴由2组以上喷嘴组构成，每组至少为3个基本等间隔排成一排，上述组和组之间的间距大于上述间隔、从上述第二喷嘴向上述第一纤维层的表面上喷丝，形成第二连续纤维，由第二连续纤维连续地形成上述第二纤维层，第二纤维层的位于上述第二喷嘴组正下方的部分较厚、具有较高克重而位于上述组间的部分则相对较薄，且具有低克重，
上述第一纤维层和第二纤维层在上述第一、第二方向中的第一方向和第二方向的双方、或仅在第一方向上间歇地接合，且上述两层的相对于单位面积的接合面积比例在上述高克重部分大，而在上述低克重部分较小地接合。
7.根据权利要求6所述的方法，其特征在于构成上述喷嘴组的上述第二喷嘴以0.8～3.5mm间隔配置，相邻的上述组和组的间距为10～50mm。
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