CN1511018A - 混合有合成纤维的吸湿材料和用于制造该材料的方法 - Google Patents
混合有合成纤维的吸湿材料和用于制造该材料的方法 Download PDFInfo
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Abstract
提供一种具有改进特性的柔软的、高密度的吸湿材料(20)。提供一种用于制造该吸湿材料的方法。纤维网是由这样的材料形成的,其包括纤维素纤维(32)和合成聚合物纤维(42)的混合物。然后纤维网最好是致密的并且在提高的温度下被压花使得进一步增加纤维网的密度,以及最好是在纤维网的间隔开的区域中在合成聚合物纤维(42)与纤维素纤维(32)之间产生液体稳定粘合。
Description
技术领域
本发明涉及用作一次性尿布、妇女卫生巾产品与失禁装置之类制品中的吸湿芯的吸湿材料和用于制造该吸湿材料的方法。更具体地说,本发明涉及高密度、强力、柔软且具有优越吸湿性,尤其流体收集能力的改进性吸湿材料。
背景技术
一次性吸湿制品如尿布、妇女卫生巾产品、成年人失禁装置等已获取广泛的认可。为了使他们更有效地起作用,这类吸湿制品必须快速地吸收体液,使这些体液分布到整个吸湿制品内,并能够以足够的能量保持这种体液,在置于载荷下时使体表面干燥。此外,吸湿制品需要有充分的软性和韧性,以舒适地依随人体表面,并能为防止下部泄漏提供紧密的配合。
虽然各种吸湿制品的设计因用途而异,但有些元件或部件对所有这类制品是共同的。吸湿制品包括透液的顶片或面层,其面层是设计成与身体表面相接触。此面层是由考虑到不阻碍体液从身体转移到吸湿制品的芯料的材料制成。这种面层本身不应吸收体液,因而应保持干燥。这种制品还包括设于制品的外表面上的不透液背片或背层,该层设计用来防止体液泄漏到制品之外。
设于面层与背层之间的是本技术领域中称作吸湿芯或嵌料的吸湿件。吸湿芯的作用是吸收和保持通过面层进入吸湿制品的体液。由于体液的源常常是局部的,就必须提供将体液分布到吸湿芯的整个尺寸范围内的装置,以便竭尽可能地利用全部吸湿材料。为此,通常是在面层和吸湿芯之间设置分布件和/或改变吸收芯本身的组成。
通过设于面层与吸湿芯之间任选的过渡层、转移层或获取层可将体液分配到吸湿芯的不同部分上。获取层的目的是便于体液的横向渗开,并且进一步快速把体液转移和分配到吸湿芯中。尽管一种独立获取层基本上能够令人满意的起到上述所执行作用功能,但在吸湿材料产品中独立获取层的加入会使结构复杂并且要求增加制造步骤。其还必需增加吸湿材料制品的成本。另外,在一些应用领域将希望提供一种不使用这种独立获取层的吸湿材料产品,但该产品具有改进的获取能力。此外,这就希望提供一种具有增加获取能力的改进的吸湿材料产品,而没有明显增加产品的硬度。还希望提供一种具有导致形成有柔软和柔顺产品结构的改进的吸湿材料产品。
传统的吸湿芯一般是由纤维素木浆纤维基质形成,其能够吸收大量的流体。吸湿芯能够用不同的方式设计成能提高体液吸湿和保持性质。举例来说,通过在木浆的纤维中增设超吸湿材料就可显著提高吸湿芯的体液保持特性。超吸湿材料是本技术领域中周知的,其具有基本不溶于水的吸湿聚合物组分,相当于其重量而言能吸收大量的体液并在吸湿后形成水凝胶。包含有木浆和超吸湿材料的掺合物或混合物的吸湿制品在本技术领域中是周知的。
超吸湿材料在吸湿芯内的分布可以是均匀的或者是不均匀的。举例来说,邻近背层(远离穿用者)的部分吸湿芯可以形成比邻近面层或获取层的部分吸湿芯含有较多量的超吸湿芯材料。另一实例是,可将吸湿芯最靠近体液进入处(例如获取区)的部分形成能够把体液输送(抽吸)到其芯料的周围部分(例如存储区)。
除了使木浆混合超吸湿材料以外,还描述过其他各种用来改进木浆特性的措施。例如可以用化学去粘剂使浆粕板较容易地被脱纤维化(例如,见US3,930,933)。此外,木浆的纤维素纤维在加入复合纤维网吸湿材料之前可以经过急骤干燥(例如,见1994年6月1日公开的英国专利申请GB2272916A)。此外。木浆的单个化的纤维素纤维能够被交联(例如,见US4,822,453;4,888,093;5,190,563;和5,252,275)。所有这些方法都存在着要求木浆制造商在木浆制备工序中进行费时费钱的步骤的缺点。因此,应用这类工序将显著增加木浆的成本。
尽管所有上述处理步骤都已报道能改进用于吸湿芯的浆粕的吸湿特性,但存在着与这类处理相联系的各种缺点。例如,最终用途的吸湿制品(例如妇女卫生巾产品或尿布)的制造商一般是从木浆制造商中获取片材形式的木浆。最终用途制品的制造商则必须使浆粕片材中的纤维散开,以便分离此浆粕片材中的各纤维束。通常,木浆只具有低的水分,这使得各纤维较脆,导致抖松操作中因纤维断裂而形成微尘。如果浆粕制造商在发货给吸湿制品制造者之前进行这种抖松处理,这种浆粕的运输费用就会增加。至少有过一家浆粕生产商试图通过在窄范围的浆粕密度和基重条件下不使用化学粘合剂生产急骤干燥的浆粕来解决上述问题(参看US5,262,005)。但是,即使采用这种方法,吸湿制品的制造商也仍需在购入这种浆粕后对其进行处理。
吸湿材料的制造商曾作过众多的尝试来生产高吸湿的强力软性芯材。US4,610,678公开了一种含亲水纤维和超吸湿材料的气流成网材料,其中这种材料是在干燥状态下气流成网而且不使用任何添加的粘合剂加以致密化。但是,这种材料的整体性差,易影响到将超吸湿材料抖落掉或显著量的损失。US5,516,569公开了在气流成网过程中,通过给吸湿材料增加显著量的水可以减少从气流成网吸湿材料中抖落掉超吸湿材料。但这种最终形成的材料较僵硬,具有低的密度和高的水份(约大于15%(重量))。US5,547,541公开了可以制成含亲水纤维和超吸湿材料的高密度的气流成网材料,在此材料中加入了增密剂。但应用这种增密剂会增加材料的生产成本。
US 5,562,645公开了低密度(密度小于(0.25g/cm3)的吸湿材料。应用这种低密度的膨松材料会增加运输和处理成本。US5,635,239公开一种吸湿材料中含有两种络合物成形剂,它们当湿润时起反应形成络合物。这类络合物成形剂是聚合烯烃。EP0763364A2公开的超吸湿材料中含有阴离子和阳离子型粘合剂,它们用来将超吸湿材料保持在材料中。应用这种成形剂和粘合剂都会增加吸湿材料的制造成本并且可能有害于环境。
US2,955,641和US5,693,162公开了(1)将蒸气应用于吸湿材料中,以增加吸湿材料的湿量,和(2)压缩吸湿材料。US5,692,162还公开了使用热砑辊(可以轧花)来形成致密结构,并使用适合热粘合的热塑和热固树脂。
US5,919,178公开了一种制造吸湿结构的方法,该吸湿结构具有夹在两个吸湿层之间的包含超吸湿材料的一个中间层,其中底层可以是薄的织物。该专利公开了当薄层织物用作上层或下层时,薄织物的湿量应为20%-70%(例如在线压力为100-200kg/cm、温度为120℃-250℃时,刚好在砑光从而将覆面料压缩成0.1g/cm3的密度,以生产1mm-4mm厚的浆毡之前,用湿气喷在薄织物上)。
一些吸湿结构已研制出包括有由一种或多种热塑性聚合物形成的纤维。已公布的国际申请PCT/US99/29468,公开号WO00/34567,其公开了应用一种双组分合成热塑性纤维,其包括有作为芯的第一聚合物组分和围在其外部作为外皮的第二聚合物组分。通常,热塑性纤维部分被熔融,以形成一种粘骨架结构。在传统的产品中,使用一种具有围绕芯的外皮的双组分纤维,聚合物材料所包括的外皮熔融温度低于芯的熔融温度。外皮的熔融部分然后能够随着冷却与其它热塑性纤维形成热粘合。根据WO00/34567,粘合还可以形成在塑料与浆粕纤维之间。
现有技术的使用热粘合热塑性纤维网的吸湿材料产品通常不是非常柔软,因为现有技术的热粘合方法会把一定程度增加的刚性赋给结构。一些研究者已报道能够观察到没有熔融热塑性纤维加湿或粘合到纤维素纤维表面上(K.Kohlhammer,Dr.Klaus.“气流成网的非织造织物中自交叉可链接的粉末树脂”
非织造织物世界,2000年6-7月,MTS出版,Kalamazoo,Michigan,U.S.A)。此外,传统的热粘合网会有灰尘问题和纤维屑问题。
在这种现有技术中,使用热塑性纤维的结构可提供一种增加粘合的吸湿芯,或增加粘合到吸湿芯上的获取层,其将希望提供一种具有改进吸湿特性的吸湿材料,例如改进体液获取特性,而同时提供一种仍保持相对软和柔顺并且其不会具有刚性显著增加的材料。
一些现有技术的具有低密度和厚的吸湿材料结构具有相对好的吸收体液的功能,但这种现有技术结构的低密度和厚度具有明显的缺点。因此希望提供一种改进的吸湿芯材料,其具有较高的密度和相对的薄,而同时保持柔软和顺从性并提供良好的吸湿特性。
这样一种改进的吸湿材料结构也将较好的适应制造并且随后进行减少断裂或瓦解的趋势的处理。这样一种改进结构将具有足够抗张强度并且在干燥和湿的两种条件下功能上的完整性。其还有一些优点是提供这样一种具有整体性结构的改进的吸湿材料以促进和提高体液获取物进入到结构中。
本领域不断需要一种制造吸湿材料的改进方法,其吸湿材料具有良好的体液获取能力并且其满足需用于一次性吸湿制品中的吸湿芯的吸湿性、强度和柔软性要求,并且还为浆粕制造商和吸湿制品制造商两方面带来时间和成本的节省。
希望提供一种用于有效制造这种减少成本的改进吸湿材料的改进方法,并且对一贯生产具有吸湿、强度和柔软性的预定特性的材料提供改进。
发明概述
本发明提供一种吸湿材料,其可具有相对高的密度特性,以至于由该材料制作的吸湿芯是相对薄的。这种材料表现出良好的吸湿特性,包括良好的体液获取特性。此外,本发明的吸湿材料尽管具有相对高的密度,但其较软和柔顺。另外,本发明的吸湿材料具有相对高的强度和良好的完整性和抗张强度,以致于其能经受住制造和随后的处理以及使用。
本发明的材料具有优良的吸收特性。吸湿材料能够用于制造吸湿制品,例如尿布、妇女卫生巾产品,或失禁装置。该吸湿材料包括纤维素纤维和合成聚合物纤维的致密纤维网,并且纤维网具有小于约1500毫克的格利式织物硬度(Gurley Stiffness),优选小于1200毫克。在一个优选的形式中,纤维网包括超吸湿材料,但纤维网基本没有添加化学粘合剂。
在本发明的一个优选的形式中,至少一些合成聚合物纤维和纤维素纤维是通过液态稳定粘合而连接在一起的。
在本发明的一个优选的形式中,形成在合成聚合物纤维外表面上的总表面区域的至少大部分不被熔融和再固化。
在本发明的一个优选的形式中,纤维网具有的密度是在约0.25g/cm3与约0.5g/cm3之间,并且纤维网具有的基重是在约100g/m2和650g/m2之间。
用于制造本发明吸湿材料的方法包括首先形成纤维素纤维和合成聚合物纤维的纤维网。
纤维网是在一对加热辊之间移动,以压实纤维网,而这时要保持各辊在一定温度下以形成液态稳定粘合,其粘合(1)至少是位于纤维素纤维和合成聚合物纤维之间,和(2)不足以产生大于约1500毫克的纤维网硬度。
在本发明第一个优选的形式中,纤维网无需使用加热烘箱而被生产,并且还包括超吸湿材料,但基本没有添加化学粘合剂。
在本发明的一个优选的形式中,纤维网是以一选择的速度在一对加热辊之间移动,其加热辊被压纹或具有一表面图案并且他们在一选择的压紧负载下把纤维网密度压实到约0.25g/cm3与约0.50g/cm3之间,而这时保持各辊在一定的温度下,其温度不足以在所选择的纤维网移动的速度和选择的压紧负载下使由合成聚合物纤维的外表面所限定的总表面区域的大部分被熔融,由此被压实的纤维网的纤维网硬度小于约1500毫克,最好是小于约1200毫克。
通过下列本发明的详细描述,权利要求书和附图使本发明的许多其它优点和特征将会变得更加清楚明了。
附图说明
在附图中,其形成说明书的一部分,其中:
图1是本发明吸湿材料的第一实施例的纤维网或片材的放大的、局部横截面视图,并且在图1中为便于举例说明,所说明的结构部分的高度或厚度已被夸大,并且应该理解,图1不必相对于各部分的厚度按比例被画出;
图2是本发明吸湿材料的第二实施例的纤维网或片材的放大的、局部横截面视图,并且在图2中为便于举例说明,所说明的结构部分的高度或厚度已被夸大,并且应该理解,图2不必相对于各部分的厚度按比例被画出;
图3是举例说明用于制造本发明改进材料的优选方法的装置的简化示意图;
图4是用于测量吸湿材料芯吸特性装置的简化示意说明图;
图5是在45°芯吸试验中求得液体吸收性相对于距离的关系的代表性曲线图,该试验能够在示于图4的装置上完成;
图6是举例说明装置简化示意图,其是用于制造本发明吸湿材料的不完整的形式或第一阶段形式的装置;
图7是图6中装置的示意图,其表示了吸湿材料制造中的第二阶段;
图8是用于吸湿材料完整制造的装置的简化示意图,其第一和第二阶段制造被示于图6和7中;
图9是用于实现本发明吸湿材料第一阶段制造的另一种装置的简化示意图;
图10是用于在示于已完成图9所示第一阶段之后的材料最后阶段制造的装置的简化示意图;
图11表示的是本发明吸湿材料的表面的第一压花花纹;
图12表示的是本发明吸湿材料的表面的第二压花花纹;
图13表示的是本发明吸湿材料的表面的第三压花花纹;
图14是根据本发明通过使用示于图12中的压花花纹2的方法制成的一部分吸湿材料的放大示意图,并且示于图14的部分材料相应于所示的相对于压花花纹的材料部分的特定区域,该压花花纹是位于图12中总体由参考标记300表示的圆形内;
图15是根据本发明吸湿材料一部分的扫描电子显微镜的显微照片;
图16是类似于图15的一个图,但图16表示了材料的不同部分;
图17是在传统产品中使用的吸湿材料的扫描电子显微镜的显微照片。
实施例详细说明
本发明提供一种改进的吸湿材料,该材料特别适用于作如尿布、妇女卫生巾产品、失禁装置等吸湿制品中的芯料。吸湿材料也可用作任何用来吸收人体排除物(例如尿、***的***、血、月经液)的装置中的吸湿芯。因此,这样的吸湿材料可以并入哺乳母亲的胸罩中或是用作手术单(例如毛巾)或绷带。
本发明的吸湿材料的优选形式包括纤维素纤维、合成聚合物纤维和超吸湿效率的混合物。优选的是,这些材料被气流成网到一支撑层(例如,薄纤维网)上。本发明的吸湿材料具有独特地综合了柔软性、强度和吸湿特性,而使其特别适用于吸湿制品中。本发明的吸湿材料可以为吸湿制品制造商直接使用而不需要制造商除将其按照吸湿制品所需要的尺寸和形状裁剪或折叠外的任何其他加工。
本发明的另外一方面是提供一种能够用于制造吸湿材料的改进方法,其吸湿材料是柔软的,薄的,并且具有相对高的密度。本发明的方法的优选形式是十分有效的,而无需使用昂贵的加热烘箱和不要求使用化学粘合剂,胶粘剂等。这种吸湿材料具有在通常的一次性产品制造设备上进一步处理的足够整体性(强度)而不会使纤维断裂。
关于含有附加物质的目前材料的成分,这里所用的术语“重量百分数”表示附加物质的重量除以附加物质和原始材料总综合重量(如在环境状态下测定)并乘100。例如,含有10重量%的附加的超吸湿材料的吸湿材料产品是指在含有初始吸湿材料和附加超吸湿材料两材料的100g样本中有10g超吸湿材料。
能够用于本发明方法中的纤维素纤维在本技术领域中是众所周知的,包括木浆、棉,亚麻和泥炭苔绒。木浆是较理想的。浆粕可以由机械或化学机械方法从亚硫酸盐、牛皮纸浆、打浆的下脚料、有机溶剂浆粕等中获取。软木浆和硬木浆都可采用。软木浆较为理想。在用于本发明吸湿材料中时,无需用化学去粘剂、交联剂等来处理纤维素纤维。
如上所述,用于本吸湿材料中较理想的纤维素纤维是木浆。能用减少木料中的木质素含量的方法来制备木浆较为理想。优选的是,木浆中木质素的含量应少于约16%。更好的是,木质素含量少于约10%。尤为更好的是木质素少于约5%,最好的是木质素少于约1%。正如本技术领域中周知的,木质素含量是根据浆粕的Kappa值计算出的。此Kappa值是用标准的周知试验方法(TAPPI Test 265-cm85)测定的。已测量了各种浆粕Kappa值,并用TAPPI Test 265-cm85计算木质素含量。
为用于本发明的方法中,纤维素纤维最好是从Kappa值小于约100的木浆中制取。更好的是,Kappa值应小于约75,50,25或10。最好的是,Kappa值小于约2.5。
木浆的一些其他特性使其特别适用于本发明的吸湿材料。绝大多数木浆中的纤维素具有很高的相对结晶度(大于约65%)。在本发明的材料的较理想的形式中,所用木浆的相对结晶度小于约65%是较好的。更好的是相对结晶度小于约50%,而最好的是相对结晶度小于约40%。类似地最好使浆粕具有增大的纤维卷曲值。
处理浆粕使上述特性最佳化的方式是本技术领域中所周知的。例如,用液氨来处理木浆已知能减少相对结晶度,增大纤维的卷曲值。急骤干燥已知能加大纤维的卷曲值和减少结晶度。浆粕的冷碱处理也增大了纤维的卷曲并减小了相对结晶度。化学交联已知可减少相对结晶度。对于本发明的材料的一种形式,由本发明的方法制造吸湿材料的纤维素纤维最好是至少部分地用冷碱处理或急骤干燥制得的。
有关冷碱提取方法的描述见于共同所有的美国专利申请系列号No.08/370,571,1995年1月18日提交,该申请是1994年1月21日提交的美国专利申请系列号No.08/184,377的部分连续申请。这两份美国专利申请中所公开的内容可在此结合供参考。
简单地说,进行碱处理一般是在温度小于约60℃时来完成的,但较好的是在小于50℃,更好的是在约10℃至40℃之间。较理想的碱金属盐溶液是新配制的氢氧化钠溶液,或是浆粕或是造纸过程的溶液副产物,例如半苛性的白液、氧化的白液等。其他的碱金属如氢氧化胺和氢氧化钾等也是可以采用的。但从成本考虑,较理想的盐是氢氧化钠。这种碱金属盐的浓度通常是该溶液的约2至25重量百分数,较好是约6至18的重量百分数。用于高比例快速吸湿应用的浆粕最好以浓度约10-18%(重量)的碱金属盐的溶液处理。
正如本技术领域中周知的,在用来使浆粕干燥的急骤干燥方法中,浆粕被部分脱水、纤维化和送到可使浆粕中所含水份闪蒸掉的热气流中。简单地说,这种初始稠度为30-50%(含水份50-70%)的浆粕直接送入一抖松机(例如,一种盘式提纯机)中,在此,借助机械作用纤维化(破碎和分离),然后使纤维分散用于急骤干燥***。此纤维化的浆粕一旦从抖松机中排出后即送入急骤干燥***。此干燥***本身是由两段组成,每一段包括两个干燥塔。纤维由高速的热空气送过干燥塔。第一段的入口空气温度约为240-260℃,而第二段的入口空气温度约为100-120℃。在各干燥段后,浆粕和热空气便送入旋风分离器,而带有从浆粕中蒸发出的水份的热空气便在此沿垂直方向排出。
在一般小规模***中,这种干燥***的第一段的排气温度约为100-120℃,而第二段的排气温度约为90-100℃。与此同时,材料输送风扇通过旋风锥体抽出浆粕纤维并送到此***的下一个部分。最后,经过第二段旋风分离器,被干燥的浆粕通过包括输送环境空气的冷风扇的冷却段,然后通过最后的冷却用旋风分离器。包括两个干燥段、旋风分离和冷却在内的整个***的停留时间,在所用的供料速率(1.5kg干料/分,其是一般小规模机器的供料速率)下约30-60秒。大规模的,传统的急骤干燥***一般具有较高的供料速率。
在采用上述这种***生产急骤干燥纤维的下侧是生产最终产品中的定位纤维束。纤维束是在浆粕的纤维化过程中通过抖松机的机械作用形成的。此***采用的是盘式提纯机,其包括两个设定间隙宽度在本例中为4mm的带槽圆盘。一个盘处于固定位置,而另一个盘以高速转动。浆粕送入两个盘之间的间隙中,盘的转动导致纤维沿着槽分离。不幸的是,随着浆粕的纤维化,个别的一些纤维会相互缠结,形成若干单个纤维组成的小纤维束。当这些缠结的纤维急骤干燥而除去水份时,这种缠结物紧固并增硬,在整个急骤干燥的浆粕内形成小的定位的纤维束。在用急骤干燥浆粕生产出的最终气流成网产品内会出现大量的这种定位纤维束,就会降低产品的物理特性和性能。通过使用冷碱提取浆粕就能显著地减少这种定位纤维束的量。
根据本发明的方法的一个方面(如下所述),本发明的吸湿材料被制造成含有一种超吸湿材料。这种超吸湿材料是本技术领域中周知的。在此使用的术语“超吸湿材料”是指实质上不水溶的聚合物材料,其能吸收相对其重量而言大量的流体。超吸湿材料可以取粒状物质、絮片、纤维等形状。有代表性的粒状形式包括细粒、粉粒、球粒、块粒和团粒。典型和较理想的超吸湿材料包括交联聚丙烯酸盐如钠的聚丙烯盐,超吸湿材料可从市场买到(如Stockhausen GmbH,Krefeld,德国)。本发明的吸湿材料的优选的形式是含有约0-60%(重量)的超吸湿材料,更好的是约20-60%(重量)的超吸湿材料。
吸湿材抖的优选形式
图1举例说明了本发明的吸湿材料的一种形式。吸湿材料在图中由参考数字20表示。材料20通常由本发明的方法制造成一个相对宽的片材,该片材可呈片的形式或大卷的形式提供给吸湿制品制造商。
材料的一般较理想的厚度在0.5-2.5mm之间。图1中表示的材料20的不同厚度区域不一定按比例表示,在一些情况下,它可以放大以便清楚和方便图示。
图1中所示的吸湿材料20包括一主要的吸湿部分或芯36和一个可选的承载层22。承载层22可以例如是由天然或合成纤维构成的纺粘、熔喷非织造物。
另外,用于承载层22的材料较理想的是薄织物。对于本领域的技术人员来说,用作承载层的适当的薄织物材料是众所周知的。最好这种薄织物由漂白的木浆制成,并且具有约273-300CFM(立方英尺/分)的透气性。薄织物的抗张强度使得其在吸湿材料的成形和其它处理期间保持整体性。以牛顿/米表示的适当的MD(加工方向)和CD(横向方向)的抗张强度分别约为100-130和40-60。薄织物是每英寸具有充分量的绉纱的绉纱织物,以允许加工方向的伸长率在20-35%之间(这由SCAN P44:81试验方法确定)。用于气流成网吸湿材料的薄织物可从市场上买到(例如,源自Cellu Tissue公司,2Forbes Street,East Hartford,CT 06108,美国,和由Duni AB,瑞典)。
表示在图1中的吸湿材料结构20的一种改进结构被示于图2中,在此改进结构一般由参考数字20′表示。图2中表示的材料20′的不同厚度区域不一定按比例表示,在一些情况下,它可以放大以便清楚和方便图示。
表示在图2中的材料20′包括一主要吸湿部分36和一承载层22,他们与上述图1的第一实施例的材料20中的主要吸湿部分36和承载层22是一样的。图2中的吸湿材料20′的改进实施例进一步包括顶部承载层或覆盖层38。覆盖层38可以是薄织物或可以是其他类型的材料,其包括,但不限于,天然或合成纤维所构成的粘附熔喷非织造物。
优选的是,当承载层例如薄织物层22被使用时,薄织物层22少量的埋设在主要吸湿部分36的底层内,在加工期间,通过下面将详细描述的一个或一些砑光辊而实现。
材料20和20′(图1和2)的各实施例的主要吸湿部分36包括浆粕纤维32,在一较理想的形式中,其纤维一般具有约2.40mm的平均长度。在浆粕纤维32的一优选形式中,至少部分浆粕纤维32是由上述冷碱提取法生产的。这包括在从约15℃-60℃的温度下,用水成的碱金属盐水溶液处理包含纤维素纤维的浆粕的液体悬浮达约5-60分钟的一段时间,该水成的碱金属盐水溶液具有所述溶液的约2%-25%(重量)的碱金属盐浓度。然后处理过的浆粕纤维素纤维或者经急骤干燥或者穿过锤式粉碎机处理。
主要吸湿部分36(图1和2)优选的是包括上述的超吸湿材料,并且最好设置成超吸湿颗粒或微粒40的形式。如果需要的话,浆粕和超吸湿材料能够向下铺设成到同质混合物或非均质混合物,其中超吸湿材料含量从近处到底部(即底部承载层22)是变化的。
典型的,吸湿制品制造商对着吸湿材料20或20′的一侧上添加面层(即,顶层或覆盖材料(未图示)),这种面层与穿着制品的人的皮肤接触。邻接于面层的材料20或20′的上部能够容纳在***的第一时刻穿过面层的液体(例如月经或尿)。材料20的上部迅速采集来自吸湿制品面层的液体,并将该液体分布到整个的吸湿部分36。尤其希望在液体第二和随后排放到吸湿制品内期间提供一种便于液体横向散布的装置。
本发明的一个方面是提供一种在主要吸湿部分或芯36中具有改进获取液体和横向分布液体能力的吸湿材料。为此,主要吸湿部分或芯36包括合成聚合物纤维42(图1和2)。这种合成聚合物纤维优选的是长于浆粕纤维32。优选的是,合成聚合物纤维是长于浆粕纤维32的约2-4倍。在此浆粕纤维长约为2mm,而合成聚合物纤维长度约为4-6mm,尽管一些合成纤维可以较短些,一些纤维可以较长些。
与具有稍微成矩形横截面的浆粕纤维3 2相比,合成聚合物纤维42一般具有一圆形横截面。可以确信本发明较为理想的是至少在一些应用中,合成聚合物为42不要太长(不要长于4-6mm),以便比较于使用较长的纤维确保主要吸湿部分的空隙和蓬松特性以及芯吸能力。比较于更倾向平行于主要吸湿部分的长度和宽度平面的较长的合成纤维,约6mm或更短长度的合成聚合物纤维更有可能具有与由主要吸湿部分的长度和宽度所限定的一般平面成斜角延伸的纤维长度取向。
在本发明材料呈现的优选的形式中,吸湿芯部分中的合成聚合物纤维最好是由聚丙烯或聚对苯二甲酸乙二醇制成。合成聚合物纤维可都由单一的合成聚合物制成,例如聚丙烯或聚对苯二甲酸乙二醇。例如聚丙烯纤维可在高卷曲条件下形成为6.7dtex,标准长度6mm(6.7dtex(分特)数字表示纤维10,000米的重量克数)。根据本发明所制造的吸湿材料的数据还包括有在高卷曲条件下具有标准长度6.35mm和6dtex的聚对苯二甲酸乙二醇纤维,和在高卷曲条件下具有标准长度12.7mm和17dtex的聚对苯二甲酸乙二醇纤维。
本发明还设想在吸湿芯部分中使用双组分合成聚合物纤维。适合用于本发明的双组分纤维的一个实例包括一聚丙烯芯和聚乙烯外皮并且具有标准的长度6mm和1.7dtex。
较好的是,主要吸湿部分36(图1和2)的基重是在约100至650g/m2。承载层22的基重一般是在约15至20g/m2之间,但也可多些或少些。覆盖层32(图2)的基重一般是在约10和约50g/m2之间,但也可多些或少些。
吸湿材料20或20的较好的平均密度在约0.25至约0.50g/m3的范围内。在与环境大气平衡之后,吸湿材料20和20的湿量优选小于约10%(占总材料重量的重量百分比),更好的是小于约8%,最好位于约1%与8%之间。
优选的生产方法
上述吸湿材料可由本发明的方法制造。本发明方法的第一优选实施例由图3示意性表示。图示的方法采用了环状丝,筛网或带60,吸湿材料成分沉积于其上。
该方法允许底部承载层可任选地应用于吸湿材料中(例如,分别描述在上述图1和2的吸湿材料20和20中的薄织物层22)。为此,如图3所示,薄织物网62从薄织物网辊64上退绕,并且被引导在环状筛网60上。在成形头工位65上一系列成形头设置在环状筛网60上。工位65包括第一成形头71和第二成形头72。也可提供或多或少量的成形头。
纤维素纤维,其可包括0%-100%上述的冷碱提取的浆粕纤维,是利用传统的锤式粉碎机(未表示)处理以便对纤维分别处理,被分别处理的浆粕纤维能够在提供于各成形头的混合***中与合成聚合物纤维和超吸湿材料(例如,颗粒,微粒等)混合。成形头71与混合***81连接,并且成形头72与混合***82连接。浆粕纤维,合成聚合物纤维,和超吸湿颗粒或微粒在混合***中被混合并且由空气作用传送至一个或多个成形头。在其他方式中,浆粕纤维,合成纤维,和超吸湿颗粒或微粒可单独传送至一个或多个成形头,然后在成形头内混合在一起。一个或多个成形头可仅进行排出浆粕操作,而不排出合成聚合物纤维或超吸湿材料。在纤维处理或纤维素,浆粕纤维与合成聚合物纤维和/或超吸湿材料混合期间不加入化学粘合剂。
材料的混合和分配可针对每个成形头单独控制。例如,在一些***中,在每个混合***中受控制的空气循环和带翼搅拌器产生(混合***81和82的浆粕和超吸湿颗粒和/或合成聚合物纤维的)基本上均匀的混合和分配。
超吸湿颗粒和合成聚合物纤维可以或者在要制造的结构的吸湿芯部分的各处完全和同质地混合,或者通过将超吸湿颗粒和/或合成聚合物纤维分配到所选择的成形头而仅包含一个特定厚度的区域。
如果需要,超吸湿颗粒和合成聚合物纤维可分别地从单独的成形头91和92(图3)中单独排出。在这种可选择的构造中,超吸湿颗粒成形头91和合成聚合物纤维成形头92能够位于如所示的成形头71和72的下游或能够位于其上游,或在其他成形头(未图示)之间。另外,形成头91和92上下游次序会与示于图3的次序相反。如果单独的成形头91和92用于超吸湿材料和合成聚合物纤维,则附加的超吸湿颗粒和/或合成聚合物纤维还可在混合***81和82中混合。作为替换,只有浆粕纤维可专门被分别输送并经过混合***81和82以及成形头71和72,此时超吸湿材料和合成聚合物纤维分别从成形头91和92中排出。
来自每个成形头的材料优选借助真空沉积作为松散的不压实的第一层直接落在薄织物网和承载层62(或直接沉积在环状筛网60上)的材料层。
吸湿材料可包括一个上承载层或覆盖层,如上述图2的实例20中的覆盖层38。如果将要生产这样一种被覆盖的吸湿材料,则覆盖层片或网96从成形头的下游的覆盖层网辊98上退绕并且引导在如图3所示的早先沉积的材料上。
吸湿材料优选借助一个传统的真空传送装置100从环状筛网60输送到一个包括有上辊121和下辊122的压花工位上,其压紧或压实材料以形成一种增加密度的网。
在优选的实施例中,上辊121一般是钢辊,而下辊122一般是具有约85SHD硬度的弯曲辊。在优选的方法中,上辊121具有滚花的表面,而下辊122具有光滑的表面。在一些应用中可希望颠倒经过辊间的网的取向以至于滚花辊接触网的承载层62。在其他应用中,也希望提供上辊121和下辊122两个都具有滚花表面。
上辊121的重量承载在网上。作用在辊121轴上的传统的液压驱动器(未表示)可施加附加力。在本发明的一种形式中,网在约28和400牛顿/毫米横向网宽度(160-2284磅力/英寸横向网宽度)之间的载荷作用下在辊121和122之间被压实。
加工线最好是以约30米/秒至300米/秒的线速度运行。在优选的实施例中,每个辊121和122被加热到至少约120℃。辊121和122的温度足以有助于浆粕纤维相互的氢键结合的形成,以及薄织物层(如果有)与浆粕纤维之间的结合,以便增加完成的吸湿材料的强度和整体性。这就提供了一种具有异常强度的完工产品而阻止超吸湿材料被去掉。
每个辊的温度取决于线速度和所采用的合成聚合物纤维的类型。已发现可应用本发明的方法提供这样一种吸湿材料,其通过合成纤维被赋予有改进的液体获取特性而仍具有较低的格利式织物硬度(Gurley Stiffness),并且因此柔软和柔顺。为此,根据本发明的一种优选形式,其方法要保持辊121和122的温度足以在合成聚合物与纤维素纤维之间形成液体稳定粘合。术语“液体稳定粘合”表示当将被定为使用的吸湿材料经受典型流体(例如,人体流体)时,该粘合随着时间的过去而没有显著的退化。
根据本发明的一个优选的形式,在使用的特殊的线速度和压实载荷下,辊121和122的温度不足以产生结合在网中的合成聚合物纤维的太大表面区域的熔融。优选的是,不多于合成聚合物纤维的外表的表面区域的一半被熔融。更好的是,明显较少的表面区域是被熔融的。由于避免了合成聚合物纤维表面的明显的熔融,本发明的方法使会增加网的刚性和硬度的再固化热熔粘合的形成最小化。
根据本发明的优选形式的一个方面,辊121和122提供有压花花纹,其实例将在下面详细描述。这样的压花花纹提供有较大压实的有限面积和较少压实的相邻面积。被辊的压花花纹的凸起部分更加压实的网的面积经受较大的热传送并由辊加压,并且其能够形成合成聚合物纤维的表面部分的熔融,随后形成再固化,使相邻的纤维素纤维以及相邻的合成聚合物纤维产生热粘合。然而,在位于压花花纹的凸起部分之间的网的区域中,会在合成聚合物纤维与相邻的纤维素纤维之间产生较少或没有热粘合。由于在整个的网上提供了这种未粘合或最小的粘合区域的相对大比例,使所形成的网的硬度能够被控制,以至于其保持了相对的软和柔顺。另一方面,由于凸起部分的压花花纹,在其附近,明显热粘合产生在合成聚合物纤维与纤维素纤维之间,因此足够的刚度连同足够的流体吸收能力一起赋予给网,以至于提供的网仍具有良好的流体获取和吸收性能以及良好的强度和整体性。
当离开辊121和122时,网含有非常少的水分(例如,以网的总重量为基准,有1%-8%的水分)。被压实和致密的网采用传统的卷绕装置被卷绕到辊130上。随着网与环境大气达到平衡,网的水分含量通常将增加,但理想的是其水分含量不要太高,最好的是在网的总重量的约1%-约8%之间。
通过本发明的方法制造包含超吸湿材料和具有良好流体获取和吸收能力的合成聚合物纤维的高密度吸湿材料是有令人惊奇和意想不到的软和柔顺,并且在湿和干的两种情况下仍有相对良好整体性的强度。吸湿材料可通过本发明的方法制备成具有各种范围的基重,且不会反过来影响其柔软性或强度。
通过本发明的方法制造的吸湿材料的强度、吸湿能力和柔顺性的独特的结合对于吸湿制品的制造商来说具有显著的优点。通常,这种制造商购买浆粕,然后在制造最终制品(例如尿布、卫生巾)时,必须在其制造车间在线加工这种浆粕。这种处理步骤可包括使浆粕的纤维分离、添加超吸湿材料,等等。在在线***中,会由于各个步骤中的最慢的步骤而限制了可进行这样一些步骤的快速性。要求这样一些处理步骤(例如纤维分离)的浆粕的实例公开在US5,262,005中。
制造商需要在线地对现有的材料进行纤维分离或其他的处理就意味着整个生产过程实质上使更为复杂。此外,制造商还必须购买、保养和操作为实施这种处理步骤所需的设备。这样就加大了整体的生产成本。
本发明的吸湿材料可直接并入所需的吸湿制品中,而不需要这种处理步骤。吸湿制品的制造商除了将本发明的吸湿材料成形为所需形状外,不需要有对其进行纤维分离或其他方式的处理。这样,制造商就可加速组装过程和显著地节省费用和时间。
根据本发明方法的各种形式可制造出本发明吸湿材料的一些不同的形式。吸湿材料的各种形式的样品被测试以评估各种特性或性能。样品的特性或性能还与所选择的可买到的产品的特性进行比较。测试结果被列在表I,II,III,和IV中并且在下面详细公开了各种测试过程和随之列出的测量结果。
测量和测试过程
基重的确定
吸湿材料的基重是通过从材料的一个试样中对试样首次称重而确定的。测量试样的长度和宽度。长度和宽度相乘以计算面积。然后重量除以面积,其商是基重。
密度的确定
吸湿材料的密度是通过从材料的一个试样中对试样首次称重而确定的。测量试样的长度、宽度和厚度,并使其相乘以计算体积。然后试样重量除以体积,以计算密度。
Gurley硬度的确定
吸湿材料的Gurley硬度是根据用于非织造吸湿纤维领域中的传统的Gurley硬度试验对材料的试样进行试验而确定的。利用美国纽约Troy的Gurley Precision Instruments制造的Gurley硬度试验机(4171E型号)来测量吸湿材料的Gurley的硬度值。该仪器测量所需的外部施加弯矩,以产生试验试样条的特定尺寸的给定弯曲,该试验试样条在一端固定,并在另一端具有施加的集中载荷,结果得到以毫克为单位的“Gurley硬度”值。材料的Gurley硬度值越高,材料的弹性越低,由此柔软度也低。
Gurley硬度的倒数除以1000,并以倒数克(g-1)为单位,用“柔顺度”表示,并且其为表示吸湿材料的柔软、韧性、可弯曲性的量度。
芯吸能量和标准
芯吸能量的确定
芯吸是吸湿材料引导流体离开流体进入点并将流体分配到整个材料的能力。
吸湿材料的芯吸能力可以更好地通过在测试样品的整个长度上示明芯吸性能来表征。通过计算测试样品所吸收和芯吸的总的液体量(计算被吸收的液体对距离的曲线下面积),便可计算出芯吸能量(吸湿材料能进行吸湿工作的能力)。
由于吸收量是超吸湿材料含量的部分函数,这种能量可以相对于超吸湿材料含量标准化。所得的值在此称作为“标准化芯吸能量”,单位为尔格/克(ergs/g)。
图4表示了芯吸试样设备。在吸湿测量装置上接附一个45°芯吸试验槽。此试验槽基本上包括吸湿样品用的圆形的流体供应单元和45°斜坡装置。此流体供应单元有一矩形槽,液面由此测量单元保持成恒定高度。制备的试样样品的尺寸为1英寸×12英寸。样品沿其长度每一英寸作一标记。然后将样品放到试验槽的斜坡装置上,保证样品的其中一个边缘浸渍到槽内。试验进行了30分钟。经过此确定时间后移出样品,沿着有标志的距离处加以切断。切下的部分置于预先称重的铝称皿中。将包含有湿样品的每个称皿再次称重,然后由烘箱干燥至恒重。对数据进行适当的质量平衡,按每一英寸测定样品的吸湿率。对于每一样品,将每克样品吸收的流体量相对于至原点(流体源)的距离标绘出。代表性的曲线表示在图5中。曲线下的面积用下列公式计算:
[(y1)(x2-x1)+0.5(y2-y1)(x2-x1)+(y2)(x3-x2)+0.5(y3-y2)(x3-x2)+…+(yn)(xn-xn--1)+0.5(yn-yn-1)(xn-xn-1)]
其中Xi是在第i英寸处的距离,而Yi是在第i英寸处的吸湿率。
然后将上述面积乘以重力常数(981cm/s2)和45°正弦值,求得功值或以尔格/克(ergs/g)为单位表示的芯吸能量值。对超吸湿材料将推导出的能量值通过除以百分数超吸湿材料(%SAP)含量而标准化。
流体获取性和再湿润性的确定
用本技术领域中周知的标准方法对一些样品测试(1)液体的获取性,和(2)再湿润性。这些试验测量了或吸湿产品吸湿材料对多种液体污染的吸收率,以及在0.5psi载荷下再湿润的液体量。这种方法则适用于所有类型的吸湿材料,特别是用于吸收尿液方面。
流体获取性和再湿润性试验开始记录一种吸湿产品或材料的试验样品40cm×12cm(或其他要求尺寸)的干燥重量。然后在0.1psi的载荷下把80毫升的固定容积量的盐水溶液通过一流体输送圆柱施加到试验样品上。对于被吸收的全部8 0毫升溶液的时间(以秒计)记录为“获取时间”,并且然后试验样品不受干扰等待30分钟后离开。一个预先称重的滤纸(例如,Whatman#4(70mm))放置在溶液冲击区域上,然后0.5psi载荷施加在试验样品上的滤纸上2分钟。移开湿润的滤纸,记录湿重。开始干燥的滤纸重量与最终湿润的滤纸的重量的差被记录为试验样品的“再湿润值”。其全部试验在同样的湿润的样品上重复2次。各次获取时间和再湿润值连同平均数值和标准偏差一起被记录。使用液体的80毫升容积除以预先记录的获取时间来确定“获取率”。对于具有一压花侧的任何样品,其压花侧是最初经受试验流体的侧。
试验样品生产方法和实例
实例1
在实例1中,示于图1的本发明的形式是通过示于图6-8的方法和列于表I中的各种不同的合成聚合物纤维组分而制造的。
吸湿材料的各种样品辊是由示于图6中的装置上第一阶段中的最开始部分所形成的材料网制造的,然后把部分已完成的网再在如图7所示的装置上的处理的第二阶段上运行。随后,第二阶段的网在如图8所示的加工线上的第三阶段被压花。示于图6和7中的加工线一般类似示于上述图3中选用的加工线。示于图6和7中的加工线包括承载网辊64,在环行筛网60上的承载网62从其辊上拉出位于一系列成形头65之下,包括第一成形头71和第二成形头72,他们分别与混合***81和82连接。
在环行筛网60的端部是一传统的真空传输装置100,并且真空传输装置100的下游是一压实工位,其包括上辊141和下辊142。这些传统的光滑表面的压实辊被加热到约60℃。在压实辊141和142的下游,部分地已完成的第一阶段的网卷绕到第一中间辊146上。
在图6所示的加工的第一阶段,第一成形头71把浆粕纤维和超吸湿颗粒沉积在承载层62上,而第二成形头72仅沉积浆粕纤维。
根据该方法制造的所有样品列在表I中,同样的材料用于承载层62。它是一种薄织物,该薄织物由Cellu Tissue Corporation,2Forbes Street,East Hartford,Connecticut 06108,U.S.A销售,指定等级3008。其是由100%南方软木制造,并且具有基重10-11磅/3000平方英尺。其在加工方向的干抗张强度250-275克/英寸,和横向方向的干抗张强度50-60克/英寸。加工方向上断裂点的伸长率是22-28%。透气率是每平方英尺每分钟285立方英尺。光泽度反射能力是在457mm处为78。
在示于图6的实例1成形方法的第一阶段中,从第一成形头71中所沉积的浆粕纤维(连同超吸湿颗粒)和从第二成形头72所沉积的浆粕纤维是未处理的浆粕纤维,其标记为Rayfloc-J-LD纤维,是由Rayonier,Inc.其一个办事处在4474 Savannah Highway,Jesup,Georgia 31545,U.S.A制造。在第一阶段由图6所示的方法生产的底部网材料具有基重500克/平方米和含有55%的超吸湿颗粒的重量。
用于该方法的第一阶段的超吸湿材料连同浆粕纤维是由第一成形头71被沉积的,超吸湿颗粒是以SXM7440表示,由Stockhausen GmbH,Germany,其一个办事处在2401 Doyle street,Greensboro,NorthCarolina 27406,U.S.A销售。
第一阶段底部网为了确立最少量的处理整体性的目的通过压实辊141和142稍微松散地被压实,在此之后该网被卷绕到导辊146上。
在实例1的第二阶段,如图7所示,网146(由图6所示处理过程的第一阶段制造)被安置在加工线的开始处并且运行通过该加工线,此时附加材料由成形头72被沉积在其上。在处理过程的第二阶段,成形头72沉积一种浆粕纤维和合成聚合物纤维的混合物或掺合物。成形头71不操作。在图7所示的处理过程的第二阶段中由成形头72所沉积合的成聚合物纤维和浆粕纤维的混合物是50%浆粕纤维和50%合成聚合物纤维的等重量混合物。沉积在第二阶段的浆粕纤维与使用于图6所示的加工的第一阶段和上述的浆粕纤维是相同类型的。3种不同类型的合成聚合物纤维分别用于制造各种样品,如列于表I中。
所有类型的合成聚合物纤维是在传统的高卷曲(“HC”)条件下提供的,其中纤维被加捻和卷曲。在表I中,第一栏表示2种聚合物纤维:“PP”,其表示为聚丙烯,和“PET”,其表示为聚对苯二甲酸乙二醇。列在表I的左手端第一栏的各合成纤维样品包括“dtex”数,其表示这种纤维的10,000米的以克数计的重量。在表I的左手端栏中还列出了各合成聚合物纤维类型的纤维标准长度,以毫米计(mm)。
在示于图7的处理过程的第二阶段,含有合成聚合物纤维的进一步完成的网运行在一对辊151和52之间,此时压实辊141和142(图6所示,但图7省去)从加工线上脱离。砑光辊151和152是保持温度140℃的光滑表面辊。被砑光的网然后卷绕地导辊148上。
按照图7所示的第二阶段制造的实例1的网具有总基重550克/平方米,其具有约50%(重量)的超吸湿聚合物含量和约50%(重量)的总纤维含量(浆粕纤维和合成聚合物纤维)。纤维混合物中浆粕纤维量约91%(重量),纤维混合物中合成聚合物纤维约9%(重量)。
如图8所示,在用于制造列在表I中的实例1中的样品的处理过程的第三阶段中,来自第二阶段的已砑光的辊148运行通过包括有上压花辊121和下辊122的压花工位,相对于图3所示的方法的优选实施例,其是上述的类型。尤其是,下辊122是光滑表面辊,而上辊121在其表面包括有压花花纹。
各辊121和122被保持在151℃的提高温度。辊121和122对网保持提供加压载荷,其约为240磅/线性英寸横向网宽度。被压花的网卷绕到辊130上(图8)。
3种不同的压花辊121分别用于不同样品试验上以便在各种样品上提供不同的压花花纹。压花辊121具有一些表面凹痕使得产生凹下和凸起(相对于凹下)区域的花纹。3种花纹的每一种的基本复制单元分别表示在图11,12和13中。在表I的第二栏中,3种压花花纹的每一种用独特的标识数字分别地表示:1(图11),2(图12),或3(图13)。花纹复制单元尺寸表示在图中,单位为英寸。压花辊表面下凹深度对于花纹1为0.03英寸,对于花纹2为0.03英寸,对于花纹3为0.03英寸。凸起区域表面对于花纹1是总辊花纹区域的15%,对于花纹2是总辊花纹区域的25%,对于花纹3是总辊花纹区域的10.8%。对于花纹3,凸起表面区域每平方英寸的量是142。
在表I中,样品是用3种不同类型的合成聚合物纤维中的一种制成的:(1)PP-6.7dtex,6.0mm;(2)PET-6denier(旦尼尔),6.35mm,HC;和(3)PET-17denier,12.7mm,HC。聚丙烯(“PP”)纤维和聚酯(“PET”)纤维是由Mini Fiber,Inc.,2923 Boones Creek Road,Johnson City,Tennessee 37615 U.S.A提供。一种控制样品被制成,而不需添加任何合成聚合物纤维,并且其列在表I中的第一行,如“控制样品”。各3种类型合成聚合物纤维样品的各3种标识样品用3种类型的压花花纹中不同的一种进行压花,如表示在表I中的第二栏。各3种类型的合成聚合物纤维样品的第四样品是一种未压花的网制成的(即,样品是在第二阶段(图7)的端部的辊148制成)。控制样品也是由第二阶段(图7)的端部处的一个样品制成的,以便控制样品不被压花。
在表I中,对于密度,硬度,流体获取性,和再湿润性的数值是以6个单个试验样品的测量或试验的平均值所列出的。
在表I中,栏中“Acq1”,“Acq2”和“Acq3”表示流体获取率,其是由上述的流体获取试验方法确定的。
在表I中,栏中所表示的“Rwet1”,“Rwet2”,“Rwet3”表示的再湿润值,其是由上述再湿润试验所确定的。
表I还列出了3种不同的市场上买到的产品的密度,硬度和柔顺性数值,所述产品具有一基重,该基重通常可比较于本发明被试验的材料的基重,其结果列在表I中。然而,3种市场上买到的产品实质上具有比本发明材料低的密度。
表示为“Concert 500.348”的市场上买到的产品是一种热粘合的,气流成网的吸湿芯,其是由Concert Fabrication Ltée,其一办事处在Thurso,Quebec,Canada销售,并且具有总的基重500克/平方米,并且是按下述组成:短纤浆240克/平方米,粘合纤维35克/平方米,超吸湿材料225克/平方米。厚度是4.20毫米,密度是0.12克/立方厘米,干燥抗张强度是在加工方向是1100克/50毫米,吸湿能力是2分钟32克/克水,和2分钟18克/克盐水。亮度是86%,并且再湿润性是在5毫升的第三次浸湿(insult)之后1.4克/浸湿,在5毫升的第四次浸湿之后1.8克/浸湿,在5毫升的第五次浸湿之后0.5克/浸湿。盐水散布/芯吸率是50毫升直径/5毫升/2分钟。
表示在表I中的“Concert 500.382”的市场上买到的产品也是一种热粘合的,气流成网的吸湿芯,其是由Concert Fabrication Ltée销售。标识“Concert 500.382”的市场上买到的产品具有总的基重500克/平方米,并且是按下述组成:短纤浆215克/平方米,粘合纤维35克/平方米,超吸湿材料250克/平方米。厚度是4.20毫米,密度是0.12克/立方厘米,干燥抗张强度是在加工方向是1100克/50毫米,吸湿能力是2分钟32克/克水,和2分钟18克/克盐水。亮度是85%,并且再湿润性是在5毫升的第二次浸湿之后0.8克/浸湿,在5毫升的第三次浸湿之后1.2克/浸湿。盐水散布/芯吸率是50毫升直径/5毫升/2分钟。
表I中标识为“Merfin 44500T40”的市场上买到的产品是由Merfin International,Inc.其一办事处在7979 Vantage Way,Della,British Colombia,Canada V4G186提供的。Merfin产品是一种热粘合的,气流成网的吸湿芯,其具有总的基重450克/平方米,超吸湿材料含量为183克/平方米,厚度2.95毫米/每层,密度是0.156克/立方厘米,干燥抗张强度是在加工方向是1100克/25.4毫米,干燥抗张强度在横向方向是850克/25.4毫米。产品具有的吸收性是对于0.9%的盐溶液为15.7克/克,和84.6%的保持性。对于0.9%盐溶液50毫升浸湿,0.9%盐溶液的再湿润性是第一次浸湿后0.1克,第二次浸湿之后5.7克,第三次浸湿之后14.3克。
根据列在表I中数值的情况,由结合附图6-8所述的三阶段处理过程所制造的本发明的吸湿材料可以看到,当与具有相应基重的市场上买到的气流成网产品比较时,即使这种产品具有比本发明的材料有低的密度,但本发明吸湿材料具有明显较低的硬度(和由此较高的柔顺性)。
表I
合成聚合物纤维类型样品试验标识 | 压花花纹 | 密度(g/cc) | 硬度(mg) | 柔顺性(l/g) | Acq1(ml/s) | Acq2(ml/s) | Acq3(ml/s) | Rwet1(g) | Rwet1(g) | Rwet1(g) |
控制样品-没有使用合成纤维 | 无 | 0.35 | 1212 | 0.83 | 1.43 | 1.52 | 1.29 | .05 | .05 | 8.40 |
pp-6.7 dtex.6.0mm.HC | 无 | 0.30 | 648 | 1.54 | 1.35 | 2.47 | 1.92 | 0.05 | 2.19 | 9.87 |
pp-6.7 dtex.6.0mm.HC | 3 | 0.34 | 750 | 1.33 | 1.35 | 2.14 | 1.73 | 0.06 | 0.10 | 22.91 |
pp-6.7 dtex.6.0mm.HC | 2 | 0.32 | 855 | 1.17 | 1.19 | 1.83 | 1.66 | 0.07 | 0.20 | 1 0.54 |
pp-6.7 dtex.6.0mm.HC | 1 | 0.30 | 983 | 1.02 | 3.35 | 3.60 | 2.98 | 0.05 | 0.58 | 21.48 |
PET-6 denier.6.35mm.HC | 无 | 0.32 | 736 | 1.36 | 1.36 | 2.27 | 1.79 | 0.03 | 1.9 | 11.37 |
PET-6 denier.6.35mm.HC | 3 | 0.32 | 728 | 1.37 | 1.34 | 1.89 | 1.47 | 0.07 | 0.88 | 21.06 |
PET-6 denier.6.35mm.HC | 2 | 0.34 | 770 | 1.30 | 1.21 | 2.01 | 1.72 | 0.06 | 1.48 | 21.54 |
PET-6 denier. 6.35mm.HC | 1 | 0.32 | 876 | 1.14 | 1.43 | 2.26 | 1.83 | 0.36 | 1.98 | 22.17 |
PET-6 denier.12.7mm.HC | 无 | 0.33 | 760 | 1.32 | 1.4 | 2.17 | 1.82 | 0.10 | 0.40 | 17.18 |
PET-6 denier.12.7mm.HC | 3 | 0.32 | 675 | 1.48 | 1.59 | 2.31 | 2.09 | 0.17 | 0.21 | 16.57 |
PET-6 denier.12.7mm.HC | 2 | 0.35 | 803 | 1.25 | 1.46 | 2.32 | 2.03 | 0.05 | 0.13 | 21.51 |
PET-6 denier.12.7mm.HC | 1 | 0.31 | 750 | 1.33 | 2.08 | 2.89 | 2.49 | 0.07 | 0.26 | 21.95 |
Concert 500.384{45%SAP) | 0.12 | 1640 | 0.61 | |||||||
Concert 500.384(50%SAP) | 0.12 | 1535 | 0.65 | |||||||
Merfin 44500T40(40%SAP) | 0.17 | 2702 | 0.37 |
实例2
在实例2中,制造和评估了具有示于图2的构型的本发明样品。图2中的结构包括除了承载层22外的一个覆盖层38,其附在主要吸湿部分或芯36上。样品是根据示于图9和10中的两阶段处理过程而制造的。由示于图9的加工的第一阶段所形成的材料被卷绕在辊148上并且被用作示于图10中加工的第二阶段的开始辊。
示于图9加工的第一阶段在许多方面类似于上述相对于图3的优选加工。尤其是,在示于图9的加工的第一阶段,承载网62从辊64上退绕并且引导到环状筛网65处,在其之上有成形工位65,该工位具有第一成形头71和第二成形头72,他们分别与混合***81和82连接。覆盖层38最开始是以从辊98退绕的覆盖层网96的形式提供的,
纤维素纤维或浆粕纤维连同超吸湿颗粒由第一成形头71排出到承载层62上。浆粕纤维与合成聚合物纤维一起由第二成形头72排出。
用于两个成形头71和72中的浆粕纤维是一种这样的混合物:(1)参看上述实例1的Rayfloc-J-LD浆粕,和(2)上述1995年1月18日申请的申请号为08/370571的美国专利申请所定义的冷碱处理的纤维。在表II中,在左手端的第二栏(命名“吸湿芯纤维混合物”)中,Rayfloc-J-LD浆粕用大写字母“A”表示,而冷碱处理的纤维用大定字母“B”表示。各类型浆粕的百分比列在表II中,其基重是相对于吸湿芯部分的总重量,但不包括承载层和覆盖层(图9中的承载层62或图2中的层22,和图9中的覆盖层96或图2中的覆盖层38)。
在表II中,左手端的第二栏(命名“吸湿芯纤维混合物”)列出了在标识“Bico”下的合成聚合物纤维,其表示双组分纤维,这些纤维是由FiberVisions Company,其一办事处在Engdraget 22,DK-6800Varde,Denmark提供的。这种特别的双组分纤维是在标识“ALAdhesin”下销售的并且一种1.7dtex纤维,该纤维具有标准长度6毫米,50%(重量)的聚乙烯外皮围绕50%(重量)的聚丙烯的中芯。
在表II中,一种控制试验(Control Run)样品列在最后一行,并且是由示于图9和10的方法制成的,除了对于Control Run,在或是成形头71或是成形头72中没有合成聚合物纤维与浆粕纤维混合。
在成形头71中,浆粕纤维与用于实例1相同类型的,通常为Stockhausen产品,由SXM4750标示的超吸湿颗粒相混合。对于各样品试验,在承载层网62与覆盖层网96之间的吸湿芯部分具有基重400克/平方米,并且超吸湿制品40是40%的芯部分基重。基重的剩余60%是由常规的浆粕纤维“A”,冷碱处理的浆粕纤维“B”,和双组分合成聚合物纤维(“Bico”)构成的,其百分比列在表II中左手端第二栏(命为的“吸湿芯纤维混合物”)。
承载层62表示在表II中左手端第三栏(命名为“Carrier Layer”)如标识为“Tissue”或“Pantex”。Tissue(薄织物)是与上述实例1中所用的薄织物类型相同。术语“Pantex”表示一种通过空气的粘合承载层或片62,其标号为AB/S22,由Pantex sr1,其一办事处在Via Terracini,snc,Loc.Spedalion Asnelli I-51331Agliana(PT)-Italy销售。Pantex承载片材具有基重22克/平方米,厚度430毫米(+或-15%),抗张强度/European Disposables AndNonwovens Association(“EDANA”)标准20.2-89,在加工方向至少5N/50mm,在横向方向至少1N/50mm,延伸率/EDANA在加工方向不大于35%,在横向方向不大于55%,瞬间通过时间/EDANA标准150.2-93不多于2秒。
覆盖层网96表示在表II中左手端第四栏(命名为“顶(覆盖)层”)。样品试验C和控制试验样品没有覆盖层。样品试验B和样品试验A包括一种覆盖层网96,其是由Fibervisions Company(上述已表示)提供,标识为FiberVisionsTMES-C。该产品具有基重40克/平方米并且是包括3.3dtex双组分合成聚合物纤维,其具有标准纤维长度40毫米,50%(重量)的聚乙烯外皮围绕50%(重量)的聚丙烯的中芯。
继续参看图9,吸湿芯部分是沿着承载层网62与覆盖层网96之间借助一种传统的真空输送装置100由环状筛网60传送到一个包括有上辊151和下辊152的砑光工位上。砑光辊151和152各为有光滑表面,每一辊均保持在140℃的温度。
示于图9的实例2的第一阶段端部处的网被卷绕到一个中间辊148上。随后,网辊148被输送到示于图10的第二加工工位上,在此其退绕并在一个包括有上辊121和下辊122的压花工位处压花。上辊121具有一个上述相应花纹2的表面压花花纹并且被示于图12中。下辊122具有一个光滑表面。有花纹的上辊121和有光滑表面的下辊122对于各种样品试验被保持在表示于表II的一定的温度下。在压花工位的辊121和122的网保持提供表II中命名为“压力”的栏中的压力或辊载荷。在该栏中,“psi”表示磅/平方英寸,而“PLI”表示磅/线性英寸横向网宽度。被压花的网卷绕在辊130上(图10)。
对于样品试验A,下承载层或Pantex侧被压花,但在其他3个样品试验(样品试验B、样品试验C和控制试验)中,压花是施加到顶部或覆盖层上。因此,对于样品试验A网,比较于控制试验和其他样品试验的网辊148的取向,网辊148必需在压花工位(图10)处翻转过来。
表II
样品试验标识 | 吸湿芯纤维混合物 | 承载层 | 顶(覆盖)层 | 压花工位辊温度℃ | 压力(psi/PLI) | 评论 |
压花辊 光滑辊(顶) (底) | ||||||
样品试验C | 40%A,50%B,10%Bico | Tissue | 无 | 142 123 | 25/150 | 没有顶层;压花花纹在顶侧 |
样品试验B | 38%A,47%B,15%Bico | Pantex | FiberVisions | 148 123 | 23/138 | 没有顶层;压花花纹在顶侧 |
样品试验A | 38%A47%B15%Bico | Pantex | FiberVisions | 124 125 | 23/138 | 没有顶层;压花花纹在顶侧 |
样品试验 | 45%A,55%B, | Tissue | 无 | 110 110 | 12/75 | 控制样品—没有合成纤维 |
表III列出了在各样品试验的6样品上进行的6次测量或试验的平均值,并且这些测量和试验与上述实例1相同。表III还列出了对于市场上可买到的两种产品的密度,硬度和柔顺度数值,并且这种市场上可买到的两种产品与上述实例1的产品相同。
可以看出,比较于具有较低密度的市场上可买到的产品,本发明的表III的样品试验A,B,和C具有低的Gurley硬度(较好或较高的柔顺性)。
表III
样品试验标识 | 压花花纹 | 密度(g/cc) | 硬度(mg) | 柔顺性(l/g) | Acq1(ml/s) | Acq2(ml/g) | Acq3(mg/s) | Rwet1g | Rwet2g | Rwet3g |
控制 | 012 | 0.37 | 991 | 1.10 | 0.64 | 0.70 | 0.55 | 0.08 | 0.13 | 13.20 |
样品试验A | 012 | 0.27 | 1130 | 0.88 | 1.09 | 1.44 | 1.25 | 0.06 | 10.55 | 21.47 |
样品试验A | 012 | 0.28 | 1183 | 0.85 | 1.11 | 1.25 | 1.07 | 0.07 | 11.57 | 19.16 |
样品试验A | 012 | 0.27 | 571 | 1.75 | 1.15 | 1.27 | 1.07 | 0.09 | 8.85 | 18.40 |
Concert500.382 | 0.12 | 1640 | 0.61 | |||||||
Merfin44500T40 | 0.17 | 2702 | 0.37 |
表IV列出了各种样品的密度和超吸湿材料百分比,并且还列出了芯吸能力和上面详细描述的芯吸能力试验所确定的芯吸能力的数值。对于2种市场上可买到的产品的芯吸能力试验结果也列在表IV中,其市场上可买到的产品与实例1中所述的市场上可买到的产品相同。从表IV可以看出,样品试验A,样品试验B,和样品试验C中的高密度,柔软性和本发明的吸湿材料与市场上可买到的,低密度,气流成网的吸湿产品比较所展现出的芯吸能力。
表IV
样品试验标识 | 密度(g/cc) | SAP% | 芯吸能量(Ergs/g) | 标准芯吸能量(Ergs/g) |
控制试验 | 0.37 | 40 | 148679 | 3717 |
样品试验A | 0.27 | 40 | 73296 | 1832 |
样品试验B | 0.28 | 40 | 73296 | 832 |
样品试验C | 0.27 | 40 | 78820 | 1971 |
Concert500.382 | 0.12 | 45 | 93,016 | 2067 |
Merfin | 0.17 | 40 | 62094 | 1552 |
另外的发明方面
图14示意表示了本发明的网的一个放大部分。该网是根据使用实例2的方法利用一般示于图12的菱形压花花纹No.2而生产的。相对于上压花辊121(图8)的菱形压花花纹,示于图14的网区域已位于示于图12中圆形标识300中。如上所述,图12的压花花纹具有深度0.03英寸。即,形成菱形花纹的窄的凸起部分在凹内部之上高0.03英寸。凸起部分的表面区域仅约为总辊花纹区域的25%。当组成网的纤维素纤维和合成聚合物纤维在压花辊121下移动,网的一部分与压花花纹的凸起部分接触,并且网的相邻部分被容纳在花纹的凹进部分内。与花纹凸起部分接触或重合的网的部分比网的相邻部分有较大的力压紧或压实。图14示出了完成的网中的区域,其中花纹的压花凸起部分中的一部分位置位于由两个间隔开的平行虚线所限定的区域内,如由参考数字302示意表示。在图14中,纤维素浆粕纤维是由参考数字32表示,而合成聚合物纤维是由参考数字42表示。在网的区域中,其是与压花花纹凸起部分302相重合,这里在纤维素纤维32与合成聚合物纤维42之间以液体稳定粘合的形式有令人满意的粘合。在本发明的优选的形式中,这种粘合是由合成聚合物纤维的部分熔融热粘合和随后的固化而形成的,该合成聚合物纤维与纤维素纤维相接触。这种粘合是在较大的压实区域上实现的,其压实区域是与压花花纹凸起部分302相重合。这些热粘合由区域36示意表示。合成聚合物纤维32在与压花花纹凸起部分302相重合的区域中也相互粘合。
在压花花纹凸起部分302任一侧上的横向的网的面积中合成聚合物纤维与纤维素纤维或合成聚合物纤维相互之间有较少或是没有热粘合。
由于花纹No.2(图12)凸起部分302仅含有压花辊的总花纹区域的约25%,所有合成聚合物纤维的总表面区域的大部分不会熔融和再固化以形成热粘合。
应理解到,在网与压花花纹凸起部分302相重合地压实的区域中,这可以有一些合成聚合物纤维,其附近是纤维素纤维或其他合成纤维,但此处没有被粘合。类似地,在由压花花纹凸起部分302横向移开的网的一些区域,此处在合成聚合物纤维与纤维素纤维之间以及在合成聚合物纤维与其他合成聚合物纤维之间可有一些粘合。然而,大多数粘合是产生在与压花花纹凸起部分302相重合的相对限定的区域中。
随着网在压花工位处被压实,横过网的压花花纹凸起部分302的菱形排列在贯穿网的有限面积上导致基本粘合的形成。有限粘合面积的花纹给网材提供强度和整体性,而没有产生不希望有的僵硬结构。实际上,吸湿材料网材相对地软和柔顺。在本发明的优选形式中,至少形成在合成聚合物纤维外部上的总表面区域的大部分没有被熔融和再固化,并且所获取的网材具有小于约1500mg的Gurley硬度,优选小于约1200mg。
图15是本发明材料的一样品的扫描电子显微镜的显微照片,其表示了网材的区域,其未与压花花纹凸起部分重合,因此其比与压花花纹凸起部分相重合的区域经受的压力要小。图15表示了纤维素纤维32a和32b和合成聚合物纤维42接近于非常少的粘合或没有粘合。纤维素纤维32a是冷碱处理的纤维,而纤维素纤维32b未被冷碱处理。
反之,图16表示了相同材料的一个区域,其是对着压花花纹凸起部分或与压花花纹凸起部分重合而形成的(例如,示于表示在图14的压花花纹的面积302)。可从图16看到,合成聚合物纤维42的部分与纤维素纤维32a与32b并且与其之间以及与其他合成聚合物纤维42形成有热粘合。
图17是上述示于表I如“Concert”500.382中市场可买到的产品的一部分的扫描电子显微镜的显微照片。在图17中,合成聚合物纤维是由数字242表示,而纤维素纤维是由数字232表示。在图17中可以看到,两个合成聚合物纤维242相互以“X”交叉并且被热粘合。然而,一些纤维素纤维232相邻并且部分地缠绕在合成聚合物纤维242上,但在纤维素纤维232与合成聚合物纤维242之间没有热粘合。
由于在所述产品中在纤维素纤维与合成聚合物纤维之间有少量或者没有粘合。这就表现出所希望的特性和能力,其是在这样的产品中如果根本上仅存在较少区域的粘合而形成的。然而,由于合成聚合物纤维在贯穿材料的一些位置处被基本上粘合在一起,和由于其没有未粘合区花纹,本发明的发明人建立的理论(不会受到任何理论约束)是其有助于使产品较硬和不那么柔软。
此外,从图17清楚地知道,尤其是各合成聚合物纤维的全部长度具有熔融和再固化以至于其沿着其长度显著增加各处产生热粘合的能力,此处可与其他合成聚合物纤维接触。然而,虽然有这种广泛的熔融,但在合成聚合物纤维与相邻的纤维素纤维之间的显著性粘合的产生是最小的或基本不存在的。不会受到任何特殊理论约束,本发明的发明人的理论是在合成聚合物纤维与纤维素纤维之间没有显著粘合的材料将更倾向于表现出较低完整性和具有更多浆粕灰尘。
相反,不使用化学粘合剂,本发明的材料具有良好的结构整体性和最小的灰尘释放,而此时仍保持相对的软和柔顺,并且通过本发明的材料表现出这些所希望的特性。
由以上本发明详细描述和其举例说明,可清楚地知道,在不超出本发明的新颖的概念或原理的真实精神和范围的前提下,可对其进行各种变化和修改。
Claims (20)
1.一种吸湿材料,其包括纤维素纤维和合成聚合物纤维的压实纤维网,其中;
形成在合成聚合物纤维外表面上的总表面区域的至少大部分不被熔融和再固化;和
所述的纤维网具有小于约1500毫克的格利式织物硬度。
2.根据权利要求1所述的吸湿材料,其中
所述的纤维网基本没有添加化学粘合剂;
所述的纤维网具有的密度是在约0.25g/cm3与约0.5g/cm3之间;和
所述的纤维网具有的基重是在约100g/m2和650g/m2之间。
3.根据权利要求1所述的吸湿材料,其中所述的纤维网具有
(A)第一,第二和第三流体获取率分别是至少1毫升/秒,至少1.25毫升/秒,和至少1.07毫升/秒;
(B)第一,第二和第三再湿润性分别是小于0.03克,小于0.1克,和小于9克;和
(C)至少1,800ergs/g的标准芯吸能量。
4.根据权利要求1所述的吸湿材料,其中所述的纤维网
(A)包括暴露在所述纤维网一侧上的承载层;
(B)包括与所述承载层相对的、在纤维网侧上的暴露的覆盖层;和
(C)具有已被压花的花纹表面凹痕,其是在一对辊之间的至少一侧上形成的,每一辊具有至少120℃的温度。
5.根据权利要求1所述的吸湿材料,其中所述的合成聚合物纤维包括聚丙烯纤维、聚对苯二甲酸乙二醇纤维、和双组分纤维中的至少一种。
6.根据权利要求1所述的吸湿材料,其中所述的纤维网包括
(A)超吸湿材料的量是所述纤维网重量的约10%至60%;和
(B)所述的合成聚合物纤维的量至少是所述纤维网的重量的约5%。
7.根据权利要求1所述的吸湿材料,其中液体稳定粘合是形成在所述的纤维素纤维与所述的合成聚合物纤维之间。
8.一种吸湿材料,其包括纤维素纤维和合成聚合物纤维的致密纤维网,其中;
至少一些所述的合成聚合物纤维和纤维素纤维是通过液体稳定粘合而连接的;和
所述的纤维网具有小于约1500毫克的格利式织物硬度。
9.根据权利要求8所述的吸湿材料,其中
所述的纤维网基本没有添加化学粘合剂;
所述的纤维网具有的密度是在约0.25g/cm3与约0.5g/cm3之间;和
所述的纤维网具有的基重是在约100g/m2和650g/m2之间。
10.根据权利要求8所述的吸湿材料,其中所述的纤维网具有:
(A)第一,第二和第三流体获取率分别是至少1毫升/秒,至少1.25毫升/秒,和至少1.07毫升/秒;
(B)第一,第二和第三再湿润性分别是小于0.03克,小于0.1克,和小于9克;和
(C)至少1,800ergs/g的标准芯吸能量。
11.根据权利要求8所述的吸湿材料,其中所述的纤维网:
(A)包括暴露在所述纤维网一侧上的承载层;
(B)包括与所述承载层相对的、在纤维网侧上的暴露的覆盖层;和
(C)具有已被压花的花纹表面凹痕,其是在一对辊之间的至少一侧上形成的,每一辊具有至少120℃的温度。
12.根据权利要求8所述的吸湿材料,其中
所述合成聚合物纤维包括聚丙烯纤维、聚对苯二甲酸乙二醇纤维、和双组分纤维中的至少一种;和
所述的液体稳定粘合是形成在与所述的纤维素纤维接触的合成聚合物纤维的熔融和再固化的部分处。
13.根据权利要求8所述的吸湿材料,其中所述的纤维网包括:
(A)超吸湿材料的量是所述纤维网重量的约10%至60%;和
(B)所述的合成聚合物纤维的量至少是所述纤维网的重量的约5%。
14.根据权利要求8所述的吸湿材料,其中形成在所述合成聚合物纤维外部上的表面区域的至少大部分不被熔融和再固化。
15.用于制造吸湿材料的方法,其包括的步骤是:
(A)由纤维素纤维和合成聚合物纤维形成一种纤维网;和
(B)所述的纤维网在一对加热辊之间移动,以压实所述的纤维网,此时保持每一辊的温度以形成液体稳定粘合,(1)该粘合是至少位于所述纤维素纤维与所述的合成聚合物纤维之间,和(2)不足以使纤维网产生大于约1500毫克的格利式织物硬度。
16.根据权利要求15所述的方法,其中步骤(B)包括(1)以选择的速度移动所述的纤维网,(2)在选择的压实载荷下压实所述的纤维网,使密度在约0.25g/cm3与约0.50g/cm3之间;和(3)保持各所述辊的温度,其温度不足以使纤维网以所选择的纤维网移动速度和所选择的压实载荷下来熔融由所述的合成聚合物纤维外部所限定的总表面区域的大部分。
17.根据权利要求15所述的方法,其中步骤(B)包括保持所述各辊的温度,以便仅是由所述的合成聚合物纤维的外表面所限定的总表面区域的最小部分被熔融。
18.根据权利要求15所述的方法,其中步骤(A)包括
提供超吸湿材料作为部分的所述纤维网,其量是纤维网重量的约10%至60%;
提供所述合成聚合物纤维,其量至少是所述纤维网重量的5%;和
基本上不添加化学粘合剂地形成所述纤维网。
19.根据权利要求15所述的方法,其中步骤(B)包括
采用所述的一个辊把表面凹痕的花纹压花到所述纤维网的一侧,此时所述的每一辊保持至少120℃的温度;
保持所选择的纤维网移动速度在约30米/分钟至300米/分钟之间;和
保持所选择的压实载荷在28至400牛顿/毫米横向网宽度之间。
20.根据权利要求15所述的方法,其中步骤(A)包括形成所述纤维网,其具有的基重约在100克/平方米至650克/平方米之间。
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MXPA03005534A (es) | 2003-10-24 |
US20020133131A1 (en) | 2002-09-19 |
KR20030093195A (ko) | 2003-12-06 |
US20030084983A1 (en) | 2003-05-08 |
TR200301035T2 (tr) | 2004-12-21 |
CA2432436A1 (en) | 2002-07-18 |
BR0116667A (pt) | 2004-09-28 |
EP1349523A2 (en) | 2003-10-08 |
WO2002054977A3 (en) | 2003-01-16 |
WO2002054977A2 (en) | 2002-07-18 |
IL156285A0 (en) | 2004-01-04 |
JP2004535842A (ja) | 2004-12-02 |
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