JP2017517423A - 多層フィルム及び該多層フィルムから作製される物品 - Google Patents
多層フィルム及び該多層フィルムから作製される物品 Download PDFInfo
- Publication number
- JP2017517423A JP2017517423A JP2017517217A JP2017517217A JP2017517423A JP 2017517423 A JP2017517423 A JP 2017517423A JP 2017517217 A JP2017517217 A JP 2017517217A JP 2017517217 A JP2017517217 A JP 2017517217A JP 2017517423 A JP2017517423 A JP 2017517423A
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- JP
- Japan
- Prior art keywords
- film
- polymer blend
- polyethylene
- density
- propylene
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
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- 239000012792 core layer Substances 0.000 claims abstract description 47
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 claims abstract description 47
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- 239000004707 linear low-density polyethylene Substances 0.000 description 9
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- CRSBERNSMYQZNG-UHFFFAOYSA-N 1 -dodecene Natural products CCCCCCCCCCC=C CRSBERNSMYQZNG-UHFFFAOYSA-N 0.000 description 3
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- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 3
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- 229910000019 calcium carbonate Inorganic materials 0.000 description 2
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- SHFGJEQAOUMGJM-UHFFFAOYSA-N dialuminum dipotassium disodium dioxosilane iron(3+) oxocalcium oxomagnesium oxygen(2-) Chemical compound [O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[Na+].[Na+].[Al+3].[Al+3].[K+].[K+].[Fe+3].[Fe+3].O=[Mg].O=[Ca].O=[Si]=O SHFGJEQAOUMGJM-UHFFFAOYSA-N 0.000 description 2
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Classifications
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
- A61F13/514—Backsheet, i.e. the impermeable cover or layer furthest from the skin
- A61F13/51456—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its properties
- A61F13/51458—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its properties being air-pervious or breathable
- A61F13/51462—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its properties being air-pervious or breathable being defined by a value or parameter
-
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- Y10T442/678—Olefin polymer or copolymer sheet or film [e.g., polypropylene, polyethylene, ethylene-butylene copolymer, etc.]
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Abstract
Description
コア層は、ポリエチレンポリマーブレンドを含む。本明細書で使用するときに、「ポリエチレンポリマーブレンド」は、2つ以上のポリエチレンポリマーの混合物を指す。ポリエチレンポリマーブレンドは、不混和性、混和性、または相溶性とすることができる。2つ以上のポリエチレンポリマーの各々は、エチレンモノマーに由来するその構成単位の重量で50%を超えて構成する。これは、ポリエチレンホモポリマーまたはコポリマーを含むことができる(2つ以上のコモノマーに由来する構成単位を意味する)。本明細書の実施形態において、ポリエチレンポリマーブレンドは、コア層の少なくとも70重量%を含む。いくつかの実施形態において、ポリエチレンポリマーブレンドは、コア層の少なくとも75重量%、コア層の少なくとも85重量%、コア層の少なくとも95重量%、コア層の少なくとも99重量%、またはコア層の100重量%を含むことができる。
スキン層は、不織布材料を含有しない。各スキン層は独立して、プロピレン系ポリマーを含む。プロピレン系ポリマーは、プロピレンホモポリマー、ポリプロピレンポリマーブレンド、またはプロピレンコポリマーとすることができる。プロピレン系ポリマーは、(重合性モノマーの総量に基づいて)過半重量パーセントの重合させたプロピレンモノマー、及び随意に1つ以上のコモノマーを含む。
本明細書で説明される多層フィルムは、同時押し出しフィルムとすることができる。いくつかの実施形態において、多層フィルムは、同時押し出しフィルムであり、それによって、スキン層の少なくとも1つがコア層に同時押し出される。他の実施形態において、多層フィルムは、同時押し出しフィルムであり、それによって、スキン層の1つ(すなわち、第1のスキン層)がコア層に同時に押し出され、他のスキン層(すなわち、第2のスキン層)がコア層に同時に押し出され、そして、コア層が2つのスキン層の間に位置付けられるように、2つの同時押し出しフィルムがともに積層される。更なる実施形態において、多層フィルムは、同時押し出しフィルムであり、それによって、スキン層がコア層に同時押し出しされる。
また、超音波接合した積層体も、本明細書で説明される。超音波接合した積層体は、本明細書において上で説明されるような多層フィルム、及び多層フィルムに少なくとも部分的に超音波接合される不織布基材を備える。本明細書で使用するときに、「不織布基材」は、不織布ウェブ、不織布、及び個々の繊維またはスレッドが間に挿入されているが規則的または繰り返し様式ではない任意の不織布構造を含む。本明細書で説明される不織布基材は、例えば、エアレイング過程、メルトブロウイング過程、スパンボンディング過程、及びボンデッドカーデッドウェブ過程を含むカーディング過程などの、様々な過程によって形成することができる。本明細書で使用するときに、「超音波接合」は、超音波溶接を含む。
本明細書で説明されるフィルムまたは超音波接合した積層体は、様々な応用例で使用することができる。いくつかの実施形態において、フィルムまたは積層体は、おむつ、トレーニングパンツ、及び成人用失禁用衛生物品などの衛生応用例において、または他の類似する吸収性衣類の応用例において使用することができる。他の実施形態において、フィルムまたは積層体は、医療用ドレープ、ガウン、及び外科用スーツなどの医療用応用例において、または他の類似する布地(織布または不織布)の応用例において使用することができる。
別途指示がない限り、以下の試験方法が使用される。全ての試験方法は、この開示の出願日現在のものである。
エチレン系及びプロピレン系ポリマーに関して本明細書で開示される密度は、ASTM D−792に従って決定される。
エチレン系ポリマーのメルトインデックスまたはI2は、190℃、2.16kgで、ASTM D1238に従って決定される。
プロピレン系ポリマーのメルトフローレートまたはMFRは、230℃、2.16kgで、ASTM D1238に従って測定される。
溶融強度の測定は、Gottfert Rheotester 2000キャピラリーレオメーターに取り付けたGottfert Rheotens 71.97(Goettfert Inc.、Rock Hill、SC)上で行う。ポリマーメルト(約20〜30グラム、ペレット)を、キャピラリー直径が2.0mmであり、アスペクト比(キャピラリー長さ/キャピラリー直径)が15である平坦な入口角度(180度)を有するキャピラリーダイを通して押し出し加工する。試料を190℃で10分間平衡させた後に、0.265mm/秒の一定のピストン速度でピストンを動作させる。標準試験温度は、190℃である。試料は、2.4mm/s2の加速度で、ダイの100mm下側に位置する1組の加速ニップに一軸的に引き出す。張力を、ニップロールの巻き取り速度の関数として記録する。溶融強度を、ストランドが破損する前のプラトー力(cN)として報告する。溶融強度の測定では、以下の条件を使用する。プランジャ速度=0.265mm/秒、ホイール加速度=2.4mm/s2、キャピラリー直径=2.0mm、キャピラリー長=30mm、及びバレル直径=12mm。
2%歪み時のセカント係数及び破断応力を含む引張特性は、ASTM D882に従って、長さ方向及び幅方向において決定される。
スペンサーダーツ試験は、ASTM D3420、手順Bに従って決定される。
積層体を形成するために、フィルムを不織布に超音波接合する。試験体サイズは、127mm×25.4mmである。積層体1つあたり5つの試験体を測定する。不織布基材からフィルムを分離することによって剥離力を決定し、剥離力は、単位面積事毎の、層を分離するために必要なエネルギーの測度である。試験体の第1の端部で、1インチのフィルムを不織布基材から手動で分離し、開始空隙を形成する。フィルムをCRE引張試験機(Instron)の可動グリップに配置し、一方で、不織布基材を静止した180°平面に配置する。フィルムは、約304.8のmm/分の速度で不織布基材から剥がす。
穿刺は、ASTM D5748に従って引張試験機上で測定するが、正方形の試験体をシートから6インチ×6インチのサイズに切断すること、試験体を、直径4インチの円形試験体ホルダーに挟持し、挟持したフィルムの中央に穿刺プローブを10インチ/分のクロスヘッド速度で押し付けること、プローブが0.25インチの支持ロッド上の直径0.5インチの研磨した鋼球であること、試験治具への損傷を防止するために7.7インチの最大移動長があること、ゲージ長がないこと、すなわち、試験の前にプローブができる限り近くにあるが試験体には接触していないこと、を除く。試験体の中央において1回の厚さ測定を行う。平均穿刺値を決定するために、合計で5つの試験体を試験する。
雑音試験機装置は、音を取り込むために使用するマイクロホンMK 221及びNeutrix Cortex InstrumentsによるNC 10 Audio Acoustic Analyzerを含む、音響隔離ボックスを含む。マイクロホンは、20Hz〜20,000Hzの周波数(Hz)を有する信号を感知する。マイクロホンは、音響ボックスの中央において、フィルム表面の10cm水平方向に合わせられ、ボックス上部の25cm垂直方向に合わせられる。音響隔離ボックスは、鉛で作製され、53cm×53cm×53cmの寸法を有する。フィルムは、10cm×10cmの試験体サイズに切断する。試験体は、2つのホルダーに固定し、第1のホルダーを静止させ、第2のホルダーをフィルムの撓曲運動を提供するように移動させる。各試験体によって生成される雑音示度から減算する暗騒音示度を得るために、装置を真空中で動作させる。1/3オクターブでデータを収集する。フィルム1つあたり4つの異なる試験体を測定する。
「柔軟度」または「ハンド」の品質は、繊維原料の表面摩擦、可撓性、及び圧縮性による抵抗の組み合わせであるとみなされる。Handle−O−Meter試験機(Thwing−Albert Instrument Co.(West Berlin,N.J.)によって製造される)は、材料の試験体を平行な縁部のスロットに押し込むときにブレードが受ける抵抗を検出するために、線形可変差動変圧器(LVDT)を使用して上記の因子を測定する。試料は、8インチ×8インチの正方形の試験体に切断する。Handle−O−Meterのスロット幅は、20mmに設定する。計器の製造業者の試験マニュアルの必要に応じて、試験体1つあたり4つの位置の各々で測定を行い、4つの測定値を合計して、単一の試験体の合計ハンドをグラム−力で求める。次いで、平均したハンドを試験体の重量及び体積に正規化する。より低い抵抗値を有する試料は、より良好な柔軟度を有すると考えられる。
静水圧力を、ISO 1420に従って測定する。使用された装置は、静水頭試験機(FX 3000,TexTest AG,Switzerland)である。試験体は15cm×15cmの正方形であり、試験面積は100cm2であり、蒸留水の温度を20+/−2℃に設定した。結果をmbar/分で表す。
本発明の実施例は、以下の樹脂、すなわち、オートクレーブ反応器内で作製した、0.918g/ccの密度及び8.0g/10分のメルトインデックスを有する高圧低密度ポリエチレンである、低密度ポリエチレン(LDPE)(The Dow Chemical Company,USAからのLDPE 722)、0.900g/ccの密度及び22g/10分のメルトフローレートを有するアイソタクチックポリプロピレンホモポリマー(LyondellBasell Industries,USAから入手できるポリプロピレン6231)、0.916g/ccの密度及び4.0g/10分のメルトインデックスを有するエチレン−オクテンコポリマーである、エチレン系ポリマー(The Dow Chemical Company,USAからのELITE(商標)5230G)、及び0.947g/ccの密度及び6.0g/10分のメルトインデックスを有するエチレン−オクテンコポリマーである、中密度または高密度ポリエチレン(MDPEまたはHDPE)(The Dow Chemical Company,USAからのAGILITY(商標)6047G)を使用した。多層フィルムを、VE 20 MICROBOND CSI超音波デバイスを使用して、超音波接合した。
比較実施例1は、0.900g/ccの密度及び22g/10分のメルトフローレートを有するアイソタクチックポリプロピレンホモポリマー(LyondellBasell Industries,USAから入手できる、ポリプロピレン6231)である。
本発明及び比較フィルムを、14gsmの坪量を有するスパンボンドポリプロピレン不織布のために超音波接合を使用して点接合する。面積の約9%を接合する。ライン速度は200m/分であり、加圧力は700〜1150Nであり、周波数は90%であった。
2%セカント係数(psi)を、本発明の実施例及び比較実施例フィルムに関して、長さ方向(MD)及び幅方向(CD)において測定した。結果を表1に示す。図1を参照して、本発明の実施例の2%セカント係数は、より多い量のポリプロピレンを含む比較実施例1及び2の2%セカント係数よりも低い。比較実施例3及び4と比較して、本発明の実施例の2%セカント係数は、本発明の実施例における2%セカント係数に対する著しい有害作用が存在しないことを示す類似する値を有する。更に、本発明の実施例の2%セカント係数は、16,000psiの所望のレベルを超える値を有する好適なレベルを達成した。
応力または破断荷重(psi)は、本発明の実施例及び比較実施例フィルムに関して、長さ方向(MD)及び幅方向(CD)において測定される。結果を表1に示す。図2を参照して、本発明の実施例は、比較実施例と比較して増大したフィルム強度を示すことができる、より高い破断応力を有する。
スペンサーダーツ衝撃強度(g)を、本発明の実施例及び比較実施例フィルムに関して測定した。結果を表1に示す。図3を参照して、本発明の実施例は、比較実施例と比較して増大した2軸フィルム強度を示すことができる、より高いダーツ衝撃強度を有する。
耐穿刺性(ft・lbf/in3)を、本発明の実施例及び比較実施例フィルムに関して測定した。結果を表1に示す。図3をなお参照して、本発明の実施例は、比較実施例と比較して増大した2軸フィルム強度を示すこともできる、より高い耐穿刺性を有する。
雑音(dB)を、本発明の実施例及び比較実施例フィルムに関して、20Hz〜20,000Hzの周波数帯域間で測定した。20Hz〜20,000Hzの全周波数帯域に渡る結果を、表1に示す。図4を参照して、人間の耳が雑音に対して最も敏感になる周波数帯域に対応する、1,000〜5,000Hzの周波数帯域間の雑音が、本発明の実施例及び比較実施例に関して示される。描写されるように、本発明の実施例は、比較フィルムよりも大幅に低い雑音値を有する。
柔軟度(g)を、本発明の実施例及び比較実施例フィルムに関して測定した。結果を表1に示す。図5を参照して、本発明の実施例は、ポリプロピレンを使用する比較実施例1及び2よりも良好な柔軟度結果を示すことができる、より低い柔軟度値を有する。また、本発明の実施例は、比較フィルム3及び4と比較して示されるように、柔軟度の好適なレベルを達成する。本発明の実施例における柔軟度への著しい有害作用は存在しない。
本発明の実施例及び比較実施例4のフィルムを超音波接合し、ポリプロピレン不織布が積層体を形成した。積層体内に存在する静水圧力及びフィルムと不織布との間の剥離力を、本発明の実施例及び比較実施例4の両方に関して測定した。下の表は、本発明の実施例が、比較実施例4(100%ポリエチレンフィルム)と比較して、同等で好適なレベルの接着を示し、本発明の実施例が、比較実施例4を超える向上した静水圧力能力を示すことを示す。本発明の実施例のより高い静水圧力は、積層体内に存在するピンホールの減少を示すことができるが、比較実施例のより低い静水圧力は、積層体内に存在するピンホールの増加を示すことができる。
Claims (15)
- 多層フィルムであって、
コア層と、
2つのスキン層と、を備え、
前記コア層が、前記2つのスキン層の間に位置付けられ、
前記コア層が、ポリエチレンポリマーブレンドを含み、前記ポリエチレンポリマーブレンドが、0.900〜0.935g/ccの密度及び0.7〜6g/10分のメルトインデックスを有する、前記ポリエチレンポリマーブレンドの重量で少なくとも40%のエチレン系ポリマーを含み、前記ポリエチレンポリマーブレンドが、約0.910〜0.945g/ccの総合密度及び約0.7〜6g/10分のメルトインデックスを有し、
各スキン層が独立して、プロピレン系ポリマーを含み、前記スキン層が不織布材料ではない、多層フィルム。 - 前記プロピレン系ポリマーが、プロピレンホモポリマー、ポリプロピレンポリマーブレンドの重量で少なくとも約60%の前記プロピレン系ポリマーを含むポリプロピレンポリマーブレンド、またはポリプロピレンコポリマーを含む、請求項1に記載のフィルム。
- 前記プロピレンホモポリマーが、アイソタクチック、アタクチック、またはシンジオタクチックである、請求項2に記載のフィルム。
- 前記ポリプロピレンコポリマーが、ランダム若しくはブロックプロピレン/オレフィンコポリマー、またはプロピレンインパクトコポリマーである、請求項2に記載のフィルム。
- 前記ポリエチレンポリマーブレンドが、約0.915〜0.930g/ccの密度及び約0.2〜15g/10分のメルトインデックスを有する低密度ポリエチレンを更に含む、請求項1に記載のフィルム。
- 前記ポリエチレンポリマーブレンドが、前記ポリエチレンポリマーブレンドの重量で30%未満の前記低密度ポリエチレンを含む、請求項1に記載のフィルム。
- 前記ポリエチレンポリマーブレンドが、約0.930〜0.965g/ccの密度及び約0.7〜10g/10分のメルトインデックスを有する、中密度または高密度ポリエチレンを更に含む、請求項1に記載のフィルム。
- 前記ポリエチレンポリマーブレンドが、前記ポリエチレンポリマーブレンドの重量で15%〜30%の前記中密度または高密度ポリエチレンを含む、請求項4に記載のフィルム。
- 前記コア層が、全フィルム厚さの約50%〜約80%を構成する、請求項1に記載のフィルム。
- 前記2つのスキン層が、等しい厚さを有する、請求項1に記載のフィルム。
- 前記フィルムが、以下の特性、
140gを超えるスペンサーダーツ衝撃強度、
長さ方向において約16,000psiを超え、幅方向において16,000psiを超える2%セカント係数、
幅方向において約1,700psiを超え、長さ方向において約2,000psiを超える破断応力、または
約15ft・lbf/in3を超える耐穿刺性、のうちの少なくとも1つを呈する、請求項1に記載のフィルム。 - 前記フィルムが、以下の特性、
長さ方向において約16,000psiを超える2%セカント係数を有する100%のポリエチレンフィルムと比較したときの5%未満の柔軟度値差分、または、
1,000Hz〜5,000Hzの周波数帯域で0.5dB未満の雑音値、のうちの少なくとも1つを呈する、請求項1に記載のフィルム。 - 前記フィルムが、約10〜20gsmの坪量を有する、請求項1に記載のフィルム。
- 超音波接合した積層体であって、
請求項1に記載の多層フィルムと、
前記多層フィルムに少なくとも部分的に超音波接合される不織布基材と、を含み、前記積層体が、以下の特性、
約1.2Nを超える剥離力値、または
70mbarを超える静水圧力、のうちの少なくとも1つを呈する、超音波接合した積層体。 - 多層フィルムであって、
コア層であって、前記コア層が、ポリエチレンポリマーブレンドを含み、前記ポリエチレンポリマーブレンドが、0.900〜0.935g/ccの密度及び0.7〜6g/10分のメルトインデックスを有する、前記ポリエチレンポリマーブレンドの重量で少なくとも40%のエチレン系ポリマーを含み、前記ポリエチレンポリマーブレンドが、約0.910〜0.945g/ccの総合密度及び約0.7〜6g/10分のメルトインデックスを有する、コア層と、
前記コア層に接触する第1の層であって、前記第1の層が、プロピレン系ポリマーを含み、前記第1の層が不織布材料ではない、第1の層と、
前記コア層に接触する表面に対向する表面で前記第1の層に少なくとも部分的に超音波接合される、不織布基材と、を備える、多層フィルム。
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WO2015191942A1 (en) | 2015-12-17 |
EP3154776B1 (en) | 2022-01-19 |
KR102309063B1 (ko) | 2021-10-08 |
CN106457806A8 (zh) | 2017-07-04 |
CN106457806B (zh) | 2020-07-10 |
US20160000615A1 (en) | 2016-01-07 |
AR100830A1 (es) | 2016-11-02 |
CN106457807A (zh) | 2017-02-22 |
EP3154777A1 (en) | 2017-04-19 |
JP2020147043A (ja) | 2020-09-17 |
EP3154776A1 (en) | 2017-04-19 |
TW201609412A (zh) | 2016-03-16 |
CN106457807B (zh) | 2021-02-05 |
KR20170044614A (ko) | 2017-04-25 |
BR112016029015B1 (pt) | 2021-07-27 |
JP6963498B2 (ja) | 2021-11-10 |
JP2017517424A (ja) | 2017-06-29 |
BR112016028848B1 (pt) | 2022-01-04 |
TWI674971B (zh) | 2019-10-21 |
TWI737580B (zh) | 2021-09-01 |
KR102309064B1 (ko) | 2021-10-08 |
WO2015191944A1 (en) | 2015-12-17 |
TW201601920A (zh) | 2016-01-16 |
JP6993462B2 (ja) | 2022-01-13 |
BR112016028848A2 (pt) | 2017-08-22 |
CN106457806A (zh) | 2017-02-22 |
BR112016029015A2 (pt) | 2017-08-22 |
KR20170044636A (ko) | 2017-04-25 |
AR100866A1 (es) | 2016-11-09 |
JP6807836B2 (ja) | 2021-01-06 |
US20150360449A1 (en) | 2015-12-17 |
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