JP6673846B2 - 有孔フィルム及びその製造方法 - Google Patents
有孔フィルム及びその製造方法 Download PDFInfo
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- JP6673846B2 JP6673846B2 JP2016559543A JP2016559543A JP6673846B2 JP 6673846 B2 JP6673846 B2 JP 6673846B2 JP 2016559543 A JP2016559543 A JP 2016559543A JP 2016559543 A JP2016559543 A JP 2016559543A JP 6673846 B2 JP6673846 B2 JP 6673846B2
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Description
本願は、2014年8月1日に出願された米国特許仮出願第62/032246号、2014年4月3日に出願された同第61/974877号、及び2014年4月3日に出願された同第61/974870号の優先権を主張し、それらの開示は、その全体が参照により、本明細書中に組み込まれる。
本開示によるフィルム400、500の他の実施形態を図6及び図7に示す。図6及び図7に示す実施形態は、第1のセグメント410、510のうちの少なくとも一部が、フィルムの厚さ「z」方向において第4の層426、526、第5の層427、527、及び第6の層428、528をそれぞれ含む層状化された第1のセグメントであるという点で、図5に示す実施形態と同様である。第4の層426、526は、第5の層427、527とフィルムの対向する表面上にある第6の層428、528との間に配置される中間層である。図示する実施形態では、中間の第4の層426、526は、フィルムの表面部分を形成しない。第5の層427、527又は第6の層428、528のうち少なくとも1つは、第1のポリマー組成物を含むが、これらは同じ組成物を有してもよいし、異なる組成物を有してもよい。第5の層427、527のポリマー組成物は、第2の層408、508の第3のポリマー組成物と同じであっても異なってもよく、また第6の層428、528のポリマー組成物は、第3の層409、509の第4のポリマー組成物と同じであっても、異なってもよい。第4の層426、526は、第5の層427、527及び第6の層428、528の両方より厚さが薄い。例えば、第4の層426、526は、第5の層427、527又は第6の層428、428のいずれかの厚さの最高30(いくつかの実施形態では、最高25、20、15、又は10)パーセントの厚さを有する。第4の層426、526はまた、第1の層406、506よりも厚さが薄く、第1の層406、506の厚さの最高30(いくつかの実施形態では、最高25、20、15、又は10)パーセントの厚さを有してもよい。これらの実施形態では、第4の層426、526のポリマー組成物が第1の層406、506の弾性的なポリマー組成物と同一にするのが有用な場合があり、あるいは、高い互換性がある程十分に、弾性的なポリマー組成物と類似していてもよい。これらの実施形態のいずれかでは、第1の層406、506及び第4の層426、526のポリマー組成物は、第1のポリマー組成物、第3のポリマー組成物若しくは第4のポリマー組成物のいずれか1つより、又は第2の層408、508、第3の層409、509、第5の層427、527、及び第6の層428、528のポリマー組成物のいずれかより弾性的であってもよい。
第1の実施形態では、本開示は、フィルムの幅方向に沿って配設された第1のセグメント及び第2のセグメントを備えるフィルムであって、前記第2のセグメントは、前記第1のセグメントより弾性的であり、前記第2のセグメントを延伸するのに必要な力は、前記第1のセグメントを延伸するのに必要な力よりも小さく、前記第1のセグメントの少なくとも一部は、それらの厚さを通した開孔を備え、前記開孔によって占有される前記第1のセグメントの面積の割合は、前記第2のセグメントを通じて延在し得る任意の開孔によって占有される面積の割合より大きい、フィルムを提供する。
前記フィルムの幅方向に配設された第1のセグメント及び第2のセグメントを備えるフィルムであって、前記第2のセグメントは、前記第1のセグメントより弾性的であり、前記第2のセグメントを延伸するのに必要な力が、前記第1のセグメントを延伸するのに必要な力より小さい、フィルムを提供することと、
開孔によって占有された前記第1のセグメントの面積の割合が、前記第2のセグメントを通して延在し得る任意の開孔によって占有された面積の割合より大きいように、前記第1のセグメントの少なくとも一部に開孔を形成することと、を含む、第1〜第20の実施形態のいずれか一つのフィルムの製造方法を提供する。
MVTRを、塩化カルシウムを含有するステンレス鋼チャンバを用いて測定した。フィルムのサンプルは、半径が30mmの開口部を有する容器の上部上方に定置され、ゴムワッシャ及びステンレス鋼ワッシャを受け入れるための柱に糸をかけられた。柱に位置付けられた3つの孔をそれぞれ有するゴムワッシャ及びステンレス鋼ワッシャは、その後、連続的にフィルムの上方に定置され、組立は蝶ナットを用いて締め付けした。露光されたフィルムの面積は、0.002826m2であった。組立品を、温度が20°Cで湿度が50%の部屋に用意し、初期重量(W1)を提供するために秤量した。その後、組立品は、オーブン内に定置され、50°C及び湿度75%で5時間加熱した。組立品は、20°Cで湿度が50%で30分間平衡化され、その後、最終重量(W2)を提供するために秤量された。
MVTR=(W2−W1)g×(24時間)/0.002826m2×5時間
MVTRを張力下で測定したとき、フィルムを約80%の伸びまで延伸し、チャンバの側部にテープで貼り付けながら、上述の方法を繰り返した。
図10A〜図16に概して図示するように、それぞれ3つのキャビティを有する6インチ(150mm)共押出ダイ(ダイ1)を、実施例1〜7及び例示の実施例1について使用した。ダイ1は、表1に示すシムの繰り返しパターンを用いて組み立てられた。シムの表記(例えば、1500、1600、1700、1800、又は1900)は、図10A〜図14Aに示したシムを指す。シムの厚さは、シムの最も狭い寸法を指す。ダイの構造要素は、本開示によるダイのどの部分にシムが寄与するかを記載する。フィルムの構造要素は、本開示によるフィルムの、示されたシムから押し出される部分を指す。2×1600及び4×1500という表記は、2つのシム1600が互いに隣り合って定置されたこと、及び4つのシム1500が互いに隣り合って定置されたことを意味する。表1に示す配列は、6インチ(150mm)の幅を達成するために数回繰り返された。シムの分注開口部は、図15に示すように、0.030インチ(760マイクロメートル)の高さで分注スロットを提供するように、同一線上の配設で位置合わせされた。シム1500は、0.100インチ(2.54mm)のランド高さを有した。シム1900及びシム1800は、0.070(1.78mm)のランド高さを有し、シム1700及びシム1600は、0.080インチ(2.03mm)のランド高さを有した。シム組立体は、位置合わせキーを用いて位置合わせされ、2つの末端ブロックの間に4本の1/2インチ(12.7mm)ボルトを使用して圧縮された。異なるポリマー組成物を、後述するようにフィルム1及びフィルム2に対して使用した。
面積100cm×200cmのフィルム1がレーザ穴加工を受けた。サンプルを、Coherent社(米国カリフォルニア州Santa Clara)からの3ワットUVレーザ「AVIA 355−3000」からの355ナノメートルの波長でのレーザ放射線に露光した。レーザエネルギーは、GSIグループ(米国マサチューセッツ州Billerica)のスキャナModel HPLK 1330によってサンプルにわたって向けられた。サンプルは、スキャナシステムの焦点面にあるスキャナ筐体からおよそ300mmの距離に位置決めした。サンプルの面内で、レーザビームのスポットサイズは、幅がおよそ50マイクロメートルであり、ほぼガウスプロファイルである、と判定した。レーザパターンは、点群アレイ(5mm×5mm)であり、各点が4〜50ミリ秒のドリル持続時間が付与され、典型的な露光は5ミリ秒であった。飛越し速度は、4マイクロ秒のトリガーパルスで6m/sであった。レーザは、パルス当たりおよそ40ミリジュールを付与するように電流の70%で使用した。約5mm離間した約100マイクロメートルの平均直径を有する開孔は、第1のセグメントのみに形成した。
実施例2及び3は、実施例1の方法を用いて、修正して用意され、その修正は、実施例2については、点群アレイ5mm×2.5mmを使用し、実施例3については、点群アレイ5mm×1mmを使用した。実施例2については、約2.5mm離間した約100マイクロメートルの平均直径を有する開孔は、第1のセグメントのみに形成した。実施例3については、約1mm離間した約100マイクロメートルの平均直径を有する開孔は、第1のセグメントのみに形成した。
実施例4は、実施例1の方法を用いて修正して用意され、その修正は、0.8mm×0.8mmの点群アレイを使用し、レーザビームはおよそ10kHzの周波数で1ミリ秒にパルス化し、それによって孔当たり約10パルスを付与した。約0.8mm離間した平均直径が約50マイクロメートルの開孔は、第1のセグメントのみに形成した。
実施例5は、フィルム2をフィルム1の代わりに使用する以外は、実施例4の方法を用いて用意された。
面積100cm×200cmのフィルム1がレーザ穴加工を受けた。サンプルを、Coherent社のCO2レーザ(E−400)からの10.6マイクロメートルの波長でのレーザ放射線に露光した。レーザエネルギーは、Model HPLK 1330スキャナによってサンプルにわたって向けられた。サンプルを、スキャナ筐体からおよそ600mmの距離に位置決めした(これに対して、スキャナシステムの焦点面は、スキャナ筐体からおよそ560mmに位置していた)。サンプルの面内で、レーザビームのスポットサイズは、幅がおよそ220マイクロメートルであり、ほぼガウスプロファイルである、と判定した。レーザをドリルモードに設定して、0.5mm〜15mm離れた点のカラムを設定した。
[項目1]
フィルムの幅方向に沿って配設された第1のセグメント及び第2のセグメントを備えるフィルムであって、前記第2のセグメントは、前記第1のセグメントより弾性的であり、前記第2のセグメントを延伸するのに必要な力は、前記第1のセグメントを延伸するのに必要な力よりも小さく、前記第1のセグメントの少なくとも一部は、それらの厚さを通した開孔を備え、前記開孔によって占有される前記第1のセグメントの面積の割合は、前記第2のセグメントを通じて延在し得る任意の開孔によって占有される面積の割合より大きい、フィルム。
[項目2]
前記第1のセグメント及び前記第2のセグメントは、第1のポリマー組成物及び弾性的なポリマー組成物をそれぞれ含む交互になっているサイドバイサイドのストライプであり、前記弾性的なポリマー組成物は前記第1のポリマー組成物より弾性的である、項目1に記載のフィルム。
[項目3]
前記第1のセグメント又は前記第2のセグメントのうち少なくとも一部は、前記フィルムの厚さ方向において第1の層及び第2の層を含む層状化されたセグメントであり、前記第1の層及び前記第2の層は異なるポリマー組成物を有する、項目1に記載のフィルム。
[項目4]
前記第1のセグメントは第1のポリマー組成物を含み、前記第2のセグメントは、芯及び鞘を備えるストランドであり、前記芯は弾性的な組成物を含み、前記鞘より弾性的であり、前記第1のポリマー組成物より弾性的である、項目1に記載のフィルム。
[項目5]
前記第1のセグメントは、第1のポリマー組成物を含み、前記第2のセグメントは、前記第1のセグメントと連続する前記第1のポリマー組成物のマトリックスに埋め込まれた前記第1のポリマー組成物より弾性的である弾性的なポリマー組成物のストランドを備える、項目1に記載のフィルム。
[項目6]
前記フィルムは、弾性的なポリマー組成物の層と前記第1のポリマー組成物の少なくとも一層とを備える多層積層体であり、前記フィルムは前記第2のセグメントを前記第1のセグメントより弾性的にするように漸増的に延伸されている、項目1に記載のフィルム。
[項目7]
前記第1のセグメントは、紫外線吸収性添加剤、造孔剤、染料、又は顔料のうち少なくとも1つを含む第1のポリマー組成物を含む、項目1に記載のフィルム。
[項目8]
前記第1のセグメントが微細空孔を更に含む、項目1に記載のフィルム。
[項目9]
前記第1のセグメント及び前記第2のセグメントがそれぞれ、長さ、幅、及び高さを有し、前記長さは最長寸法であり、前記厚さは最小寸法であり、前記第1のセグメント及び前記第2のセグメントのそれぞれの幅は、最大5ミリメートルである、項目1に記載のフィルム。
[項目10]
繊維状担体と結合した項目1〜9のいずれか一項に記載のフィルムを含む積層体。
[項目11]
項目1〜9のいずれか一項に記載のフィルムを含む、吸収性物品。
[項目12]
フィルムの幅方向に沿って配設された第1のセグメント及び第2のセグメントを備えるフィルムであって、前記第2のセグメントは、前記第1のセグメントより弾性的であり、前記第2のセグメントを延伸するのに必要な力が、前記第1のセグメントを延伸するのに必要な力より小さい、フィルムを提供することと、
開孔によって占有された前記第1のセグメントの面積の割合が、前記第2のセグメントを通して延在し得る任意の開孔によって占有された面積の割合より大きいように、前記第1のセグメントの少なくとも一部に開孔を形成することと、を含む、項目1〜9のいずれか一項に記載のフィルムの製造方法。
[項目13]
開孔が前記第2のセグメントを通して形成されていない、項目12に記載の方法。
[項目14]
前記フィルムを延伸させて、前記開孔を形成する前に、前記第1のセグメントを塑性変形することを更に含む、項目12に記載の方法。
[項目15]
前記開孔が、レーザ、加熱したニードル、打抜き、又は真空成形を用いて前記第1のセグメントに形成されている、項目12に記載の方法。
Claims (10)
- フィルムの幅方向に沿って配設された第1のセグメント及び第2のセグメントを備えるフィルムであって、前記第2のセグメントは、前記第1のセグメントより弾性的であり、前記第2のセグメントを延伸するのに必要な力は、前記第1のセグメントを延伸するのに必要な力よりも小さく、前記第1のセグメントの少なくとも一部は、それらの厚さを通した開孔を備え、当該開孔という用語は、フィルム内の孔を指し、その少なくとも一部分は、前記フィルムの全厚を通して直線経路を形成し、前記開孔によって占有される前記第1のセグメントの面積の割合は、前記第2のセグメントを通じて延在し得る任意の開孔によって占有される面積の割合より大きい、フィルム。
- 前記第1のセグメント及び前記第2のセグメントは、第1のポリマー組成物及び弾性的なポリマー組成物をそれぞれ含む交互になっているサイドバイサイドのストライプであり、前記弾性的なポリマー組成物は前記第1のポリマー組成物より弾性的である、又は
前記第1のセグメント又は前記第2のセグメントのうち少なくとも一部は、前記フィルムの厚さ方向において第1の層及び第2の層を含む層状化されたセグメントであり、前記第1の層及び前記第2の層は異なるポリマー組成物を有する、又は
前記第1のセグメントは第1のポリマー組成物を含み、前記第2のセグメントは、芯及び鞘を備えるストランドであり、前記芯は弾性的な組成物を含み、前記鞘より弾性的であり、前記第1のポリマー組成物より弾性的である、又は
前記第1のセグメントは、第1のポリマー組成物を含み、前記第2のセグメントは、前記第1のセグメントと連続する前記第1のポリマー組成物のマトリックスに埋め込まれた前記第1のポリマー組成物より弾性的である弾性的なポリマー組成物のストランドを備える、請求項1に記載のフィルム。 - 前記フィルムは、弾性的なポリマー組成物の層と前記第1のポリマー組成物の少なくとも一層とを備える多層積層体であり、前記弾性的なポリマー組成物は、前記第1のポリマー組成物より弾性的であり、前記フィルムは前記第2のセグメントを前記第1のセグメントより弾性的にするように漸増的に延伸されている、請求項1に記載のフィルム。
- 前記第1のセグメントは、紫外線吸収性添加剤、造孔剤、染料、又は顔料のうち少なくとも1つを含む第1のポリマー組成物を含む、請求項1〜3のいずれか一項に記載のフィルム。
- 前記第1のセグメントが微細空孔を更に含む、請求項1〜4のいずれか一項に記載のフィルム。
- 前記第1のセグメント及び前記第2のセグメントがそれぞれ、長さ、幅、及び高さを有し、前記長さは最長寸法であり、前記厚さは最小寸法であり、前記第1のセグメント及び前記第2のセグメントのそれぞれの幅は、最大5ミリメートルである、請求項1〜5のいずれか一項に記載のフィルム。
- 繊維状担体と結合した請求項1〜6のいずれか一項に記載のフィルムを含む積層体。
- 請求項1〜6のいずれか一項に記載のフィルムを含む、吸収性物品。
- フィルムの幅方向に沿って配設された第1のセグメント及び第2のセグメントを備えるフィルムであって、前記第2のセグメントは、前記第1のセグメントより弾性的であり、前記第2のセグメントを延伸するのに必要な力が、前記第1のセグメントを延伸するのに必要な力より小さい、フィルムを提供することと、
開孔によって占有された前記第1のセグメントの面積の割合が、前記第2のセグメントを通して延在し得る任意の開孔によって占有された面積の割合より大きいように、前記第1のセグメントの少なくとも一部に開孔を形成することと、を含む、請求項1〜6のいずれか一項に記載のフィルムの製造方法。 - 前記開孔が、レーザ、加熱したニードル、打抜き、又は真空成形を用いて前記第1のセグメントに形成されている、請求項9に記載の方法。
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JP (3) | JP6673846B2 (ja) |
CN (3) | CN106163790A (ja) |
MX (2) | MX2016012962A (ja) |
WO (3) | WO2015153998A1 (ja) |
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CN106164146B (zh) | 2020-02-18 |
EP3126433A1 (en) | 2017-02-08 |
MX2016012879A (es) | 2016-12-07 |
CN106164146A (zh) | 2016-11-23 |
EP3126139A1 (en) | 2017-02-08 |
JP2017518389A (ja) | 2017-07-06 |
US20170174852A1 (en) | 2017-06-22 |
US20170182695A1 (en) | 2017-06-29 |
CN106163789A (zh) | 2016-11-23 |
JP2017512869A (ja) | 2017-05-25 |
US20170022339A1 (en) | 2017-01-26 |
EP3126434A4 (en) | 2017-11-29 |
CN106163790A (zh) | 2016-11-23 |
JP2017512870A (ja) | 2017-05-25 |
WO2015153979A1 (en) | 2015-10-08 |
EP3126434A1 (en) | 2017-02-08 |
WO2015153998A1 (en) | 2015-10-08 |
MX2016012962A (es) | 2016-12-07 |
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