JP7245650B2 - 微孔質通気性フィルムおよび微孔質通気性フィルムの形成方法 - Google Patents
微孔質通気性フィルムおよび微孔質通気性フィルムの形成方法 Download PDFInfo
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- A61F13/513—Topsheet, i.e. the permeable cover or layer facing the skin characterised by its function or properties, e.g. stretchability, breathability, rewet, visual effect; having areas of different permeability
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- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
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- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
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- B29C71/00—After-treatment of articles without altering their shape; Apparatus therefor
- B29C71/02—Thermal after-treatment
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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- A61F13/51121—Topsheet, i.e. the permeable cover or layer facing the skin characterised by the material
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- 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
- A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
- A61F13/5116—Topsheet, i.e. the permeable cover or layer facing the skin being formed of multiple layers
- A61F2013/51178—Topsheet, i.e. the permeable cover or layer facing the skin being formed of multiple layers with the combination of nonwoven webs
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C71/00—After-treatment of articles without altering their shape; Apparatus therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/911—Cooling
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- B29C48/915—Cooling of flat articles, e.g. using specially adapted supporting means with means for improving the adhesion to the supporting means
- B29C48/917—Cooling of flat articles, e.g. using specially adapted supporting means with means for improving the adhesion to the supporting means by applying pressurised gas to the surface of the flat article
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
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- B—PERFORMING OPERATIONS; TRANSPORTING
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Description
A-B-A-A-B-A-A-B-A-A-B-A-A-B-A-A-B-A-A-B-A-A-B-A-A-B-A-A-B-A
第1項:ポリオレフィンおよび無機充填材を含む組成物を押出して溶融ウェブを形成するステップ、
エアナイフ、エアブランケット、真空チャンバ、または、これらの組み合わせを用いて溶融ウェブをチルロールの表面にキャストして急冷フィルムを形成するステップ、および
急冷フィルムを延伸して微孔質通気性フィルムを形成するステップ
を含む微孔質通気性フィルムの形成プロセス。
真空チャンバにより、負圧下で、チルロールの表面に溶融ウェブをキャストして急冷フィルムを形成するステップ、
急冷フィルムを横方向かみ合いギア(CD IMG)延伸により延伸して微孔質通気性フィルムを形成するステップ、ならびに
微孔質通気性フィルムを華氏約75~約225度の温度でアニーリングするステップ
を含む微孔質通気性フィルムの形成プロセス。
微孔質通気性フィルムは約14gsm未満の坪量、および、約50グラムを超えるダート衝撃強度を有する。
アルカリ土類金属は微孔質通気性フィルムの約50%~約75重量%を構成し、
微孔質通気性フィルムは、約13gsm未満の坪量、および、少なくとも約90グラムのダート衝撃強度を有し、ならびに
微孔質通気性フィルムは少なくとも約90%の最大時の縦方向でのひずみを有する。
引湿性ポリマーを含む少なくとも1層の透湿性バリア層
を含む多層通気性バリアフィルム。
引湿性ポリマーを含む少なくとも1層の透湿性バリア層と、
他の項のいずれかまたは項の組み合わせに係るプロセスにより調製された少なくとも1層の追加の微孔質通気性フィルムとを含み、
少なくとも1層の微孔質通気性フィルム層および少なくとも1層の追加の微孔質通気性フィルム層は同一であるかまたは異なり、ならびに
少なくとも1層の透湿性バリア層は、少なくとも1層の微孔質通気性フィルム層と少なくとも1層の追加の微孔質通気性フィルムとの間に配置される多層通気性バリアフィルム。
少なくとも1層の外側不織層とを含む個人向け衛生製品。
例示的なフィルムの製造のために、3台以下の押出し機を備える押出し成形キャストラインを用いた。「A」および「B」押出し機は直径が2.5インチであり、「C」押出し機は直径が1.75インチである。A、BおよびC押出し機からの押出物を多様な構成で積層させることが可能であるCloeren Corporation(Orange,TX)製の多層化フィードブロックに押出し機から供給が行われる。このフィードブロックから、溶融ポリマーが幅約36インチの単層キャストダイ(Cloeren製)に進む。このダイは調節用ギャップを有する。本明細書に記載のサンプルについては、調節用ギャップは10~40ミルで維持した。溶融ポリマーはチルロール上に落下する。本明細書に記載のサンプルについては、チルロールは、Pamarco(Roselle,NJ)によりパターンP-2739として彫刻されたエンボスパターンFST-250を有していた。エンボスパターンP-2739は、250個の正方形/インチおよび深さ約31ミクロンの正方形のパターン(例えば、線が縦方向に略揃ったもの)である。ロール自体は、18インチの直径を有し、内部水冷式のものである。彫刻ロールのパターンは、真空チャンバにおける急冷に干渉しないよう十分に浅い他のパターンで置き換えられてもよい。クロムメッキロールにサンドブラストプロセスで形成された40Raパターン(40マイクロインチの平均粗度)が代替の1つである。
この実験において、微孔質通気性フィルムは、表1に示されている配合物XC3-121-2205.0から形成した。
CaCO3含有化合物(CF7414またはT998K5)を含有する7種の配合物を用いて、本開示に係る微孔質通気性フィルムを調製した。これらの7種の配合物の各々において、CaCO3含有化合物(CF7414またはT998K5)は、70重量%で存在し、および、PPAは2%で存在する。配合物の残りはポリマーまたはポリマーブレンドである。残量を構成するポリマー/ポリマーブレンドの組成を含む7種の配合物の組成は、以下の表3に示されているとおりである。
従来の方法(例えば、Windmoeller & HoelscherブローMDOフィルム、キャストMDOフィルムおよびキャストIMGフィルム)によって調製された一連の微孔質通気性フィルムのデータが以下の表8に示されている。本教示に係る真空チャンバプロセスによって調製された一連の微孔質通気性フィルムのデータが以下の表9に示されている。
構造BBBBBを有する一連の16種の表皮層無し微孔質通気性フィルムを、表10に示されている配合物XC1-2-2269.0から調製した。化合物CF7414の組成が上記の表4に記載されている。
構造CBBBCを有する一連の16種の表皮層付微孔質通気性フィルムを、表13に示されている配合物XC1-22-2270.0から調製した。化合物CF7414の組成が上記の表4に記載されている。
構造CBBBCを有する2種の微孔質通気性フィルムA3およびB3を、表13に示されている配合物XC3-22-2270.0から調製した。得られるフィルムの物理特性が表16に示されている。
構造A/B/A(20/60/20積層)を有するポリプロピレン微孔質通気性フィルムA4~D4、および、構造A/B/A(10/80/10積層)を有するポリプロピレン微孔質通気性フィルムE4~H4は、表17に示されている配合物XC3-828-2287から調製した。表17に示されている化合物T1000J2およびCF7414*の組成が以下の表18に特定されている。
構造A/B/A(20/60/20積層)を有するポリプロピレン微孔質通気性フィルムI4~L4を、表20に示されている配合物XC3-222-2286から調製した。表20に示されている化合物CF7414*の組成が上記の表18に特定されている。
「加圧布透過(PPT)」テストを用いて、疑似血液の加圧下での透過をテストした。PPTテストを用いて、特定の時間に加圧下で、疑似血液が布またはフィルムを透過するか否か、また、その程度を判定する。
ポリエチレン含有微孔質通気性表皮、熱可塑性コポリエステルエラストマーコアおよびA/B/C/B/A構造を有する4種のハイブリッド微孔質-モノリシック多層通気性バリアフィルムA7~D7を、以下の表27に示されている配合物XC5-22922-2301.0から調製した。
ポリプロピレン微孔質通気性表皮、熱可塑性コポリエステルエラストマーコアおよびA/B/C/B/A構造を有する結合樹脂含有多層通気性バリアフィルムA8を、以下の表33に示されている配合物XC5-82328-2351.6Aから調製した。結合樹脂(BYNEL 22E757)は変性エチレンアクリレートである。
Claims (14)
- 微孔質通気性フィルムの形成プロセスであって、
ポリオレフィンおよび無機充填材を含む組成物を押出して溶融ウェブを形成するステップ、
エアナイフ、エアブランケット、真空チャンバ、または、これらの組み合わせを用いて、ニップを用いずに、前記溶融ウェブをチルロールの表面にキャストして急冷フィルムを形成するステップ、ならびに
前記急冷フィルムを延伸して前記微孔質通気性フィルムを形成するステップ
を含み、
前記延伸は、横方向かみ合いギア(CD-IMG)延伸、および、縦方向(MD)延伸を含み、縦方向かみ合いギア(MD-IMG)延伸を含まず、
前記微孔質通気性フィルムは12gsm未満の坪量および少なくとも125%の最大時の縦方向でのひずみを有する、プロセス。 - 前記ポリオレフィンが、ポリエチレン、ポリプロピレン、または、これらの組み合わせを含む、請求項1に記載のプロセス。
- 前記ポリオレフィンが、低密度ポリエチレン、高密度ポリエチレン、直鎖低密度ポリエチレン、超低密度ポリエチレン、または、これらの組み合わせを含む、請求項1に記載のプロセス。
- 前記ポリオレフィンが直鎖低密度ポリエチレンを含み、前記直鎖低密度ポリエチレンがメタロセンポリエチレンを含む、請求項1に記載のプロセス。
- 前記ポリオレフィンがポリプロピレンを含む、請求項1に記載のプロセス。
- 前記無機充填材が、前記微孔質通気性フィルムの30%~75重量%を構成する、請求項1に記載のプロセス。
- 前記無機充填材の平均粒径が0.1ミクロン~15ミクロンである、請求項1に記載のプロセス。
- 前記無機充填材が、炭酸ナトリウム、炭酸カルシウム、炭酸マグネシウム、硫酸バリウム、硫酸マグネシウム、硫酸アルミニウム、酸化マグネシウム、酸化カルシウム、アルミナ、雲母、タルク、シリカ、クレイ、ガラス球、二酸化チタン、水酸化アルミニウム、ゼオライトおよびこれらの組み合わせからなる群から選択される、請求項1に記載のプロセス。
- 前記無機充填材が、アルカリ金属炭酸塩、アルカリ土類金属炭酸塩、アルカリ金属硫酸塩、アルカリ土類金属硫酸塩、または、これらの組み合わせを含む、請求項1に記載のプロセス。
- 前記チルロールを通過する冷却液の出口温度が華氏50度~華氏130度である、請求項1に記載のプロセス。
- 前記延伸の少なくとも一部が、華氏60度~華氏200度の温度で行われる、請求項1に記載のプロセス。
- 前記微孔質通気性フィルムをアニーリングするステップをさらに含む、請求項1に記載のプロセス。
- 前記微孔質通気性フィルムをアニーリングするステップをさらに含み、ここで、前記アニーリングが華氏75度~華氏225度の温度で行われる、請求項1に記載のプロセス。
- 多層通気性バリアフィルムの製造方法であって、
多層通気性バリアフィルムは、
少なくとも1層の微孔質通気性フィルム層と、
引湿性ポリマーを含む少なくとも1層の透湿性バリア層と、
少なくとも1層の追加の微孔質通気性フィルムとを含み、
前記少なくとも1層の微孔質通気性フィルム層および前記少なくとも1層の追加の微孔質通気性フィルム層が同一であるかまたは異なり、ならびに
前記少なくとも1層の透湿性バリア層が、前記少なくとも1層の微孔質通気性フィルム層と前記少なくとも1層の追加の微孔質通気性フィルムとの間に配置され、
多層通気性バリアフィルムの製造方法は、
前記少なくとも1層の微孔質通気性フィルム層を、請求項1に記載のプロセスで製造するステップと、
前記少なくとも1層の追加の微孔質通気性フィルム層を、請求項1に記載のプロセスで製造するステップと、
を含む、多層通気性バリアフィルムの製造方法。
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- 2016-07-08 KR KR1020227046334A patent/KR20230017318A/ko not_active Application Discontinuation
- 2016-07-08 EP EP16824959.7A patent/EP3319571A4/en active Pending
- 2016-07-08 JP JP2018521194A patent/JP7245650B2/ja active Active
- 2016-07-08 CA CA3189969A patent/CA3189969A1/en active Pending
- 2016-07-08 CA CA2992140A patent/CA2992140A1/en active Pending
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Patent Citations (4)
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JP2003526710A (ja) | 2000-01-10 | 2003-09-09 | クロペイ プラスチック プロダクツ カンパニー,インコーポレイテッド | 抗菌性微小孔質フィルム及びその製法 |
JP2002146070A (ja) | 2000-08-29 | 2002-05-22 | Tokuyama Corp | ポリプロピレン系多孔質フィルム及びその製造方法 |
JP2007536110A (ja) | 2004-05-04 | 2007-12-13 | クロペイ プラスチック プロダクツ カンパニー、インコーポレイテッド | 熱可塑性フィルムの均一延伸方法及び装置とそれにより製造される製品 |
JP2006199786A (ja) | 2005-01-19 | 2006-08-03 | Tokuyama Corp | ポリエチレン系多孔質フィルムの製造方法 |
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CO2018000374A2 (es) | 2018-04-10 |
JP2021100814A (ja) | 2021-07-08 |
IL256811A (en) | 2018-03-29 |
AU2016293826B2 (en) | 2020-10-29 |
JP7053913B2 (ja) | 2022-04-12 |
KR20180030628A (ko) | 2018-03-23 |
JP2018528108A (ja) | 2018-09-27 |
CA2992140A1 (en) | 2017-01-19 |
KR20230017318A (ko) | 2023-02-03 |
EP3319571A4 (en) | 2019-03-20 |
IL256811B (en) | 2022-06-01 |
US20240100756A1 (en) | 2024-03-28 |
MX2018000414A (es) | 2018-11-09 |
CN107920926A (zh) | 2018-04-17 |
AU2016293826A1 (en) | 2018-02-01 |
BR112018000507B1 (pt) | 2023-01-24 |
US11872740B2 (en) | 2024-01-16 |
CA3189969A1 (en) | 2017-01-19 |
JP2022177105A (ja) | 2022-11-30 |
PE20180807A1 (es) | 2018-05-09 |
EP3319571A1 (en) | 2018-05-16 |
WO2017011341A1 (en) | 2017-01-19 |
BR112018000507A2 (pt) | 2018-09-11 |
US20170008211A1 (en) | 2017-01-12 |
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