CN100522119C - Tufted fibrous web - Google Patents
Tufted fibrous web Download PDFInfo
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- CN100522119C CN100522119C CNB2003801053773A CN200380105377A CN100522119C CN 100522119 C CN100522119 C CN 100522119C CN B2003801053773 A CNB2003801053773 A CN B2003801053773A CN 200380105377 A CN200380105377 A CN 200380105377A CN 100522119 C CN100522119 C CN 100522119C
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Abstract
Disclosed is a fibrous web comprising a first region and at least one discrete integral second region, the second region having at least one portion being a discontinuity exhibiting a linear orientation and defining a longitudinal axis, and at least another portion being a deformation comprising a plurality of tufted fibers integral with but extending from the first region.
Description
Technical field
The present invention relates to fleece, as textile web and non-woven web.Specifically, the present invention relates to handle with the flexibility with increase and the fleece of stacking volume characteristic with mechanical molding.
Background technology
Fleece is known in the art.For example, textile web such as textile and braided fabric are known as the material of clothes, furniture cover, curtain etc.Equally, non-woven web as the fleece that is formed by polymer fiber, is known as the material that is used for the surface layer on disposable products such as the absorbent article (for example diaper).
In many application, need fleece to have fluffy structure and/or flexibility.For example, known textile fabric as towelling has fluffy structure and flexibility and is commonly used for bath towel, cleaning wiping cloth, bib, clothes and furniture cover fabric.Towelling for example is made on the rapier loom at specially-made loom.Towelling is characterised in that the coil of bunch shape, and the coil number of tuft and density can change.Yet, need relative complex and expensive loom owing to make towelling, so towelling is relatively costly.The expense of towelling makes it be applied in commercial being difficult to carry out for many, especially for the goods of planning limited use, as disposable absorbent article.
Attempted producing adhesive-bonded fabric with appearance of terry cloth.For example, all authorize people's such as Holmes United States Patent (USP) 4,465,726 and United States Patent (USP) 4,379,799 described perforate, rib-loop terry cloth-like adhesive-bonded fabric, it is wrapped on the special forming belt by the fiber fluid and makes.Even can avoid perforate in people's disclosed methods such as Holmes, but for making non-woven web, especially to being intended for use the fleece of disposable product, fluid is wound up as relatively costly method and knows.In addition, the net Wrapping formed by fluid typically is subjected to hydrokinetic effect in the All Ranges of net, make whole net be subjected to the hydrokinetic effect that applies mechanical energy.
Therefore, need to obtain a kind of low-cost fleece with similar towelling character.
In addition, need to obtain a kind of can the manufacturing relatively cheaply have the fibroreticulate method of similar towelling character.
In addition, need to obtain a kind of softness of textile material or non-woven material, method of porous fibre net made cheaply.
Summary of the invention
The invention discloses fleece with first surface and second surface.This fleece comprises first area and a plurality of discrete integral second region, described fleece has the planar vertical and horizontal of the MD-CD of qualification, at least a portion of described second area is for being interrupted, described interruption shows to have linear orientation and limit longitudinal axis in the MD-CD plane, and another part is distortion at least, described distortion comprise many with the first area become one but from the first area extended clustered fiber, described second area is by mechanically deform, in the described distortion with the recessed axis (L) along the longitudinal of described interruption.
Description of drawings
Fig. 1 is the fibroreticulate perspective view of the present invention.
Fig. 2 is a fibroreticulate guide wire of alternative shape shown in Figure 1.
Fig. 3 is the profile of the cross section 3-3 of Fig. 2.
The a part fibroreticulate plane graph of Fig. 4 in Fig. 3, representing with 4-4.
Fig. 5 is the fibroreticulate displaing micro picture of the present invention's part.
Fig. 6 is a part of fibroreticulate displaing micro picture among Fig. 5.
Fig. 7 is the perspective view that is used to form the fibroreticulate device of the present invention.
Fig. 8 is the viewgraph of cross-section of the part of device shown in Figure 7.
Fig. 9 is the perspective view of a part that is used to form the device of the fibroreticulate embodiment of the present invention.
Figure 10 is the enlarged perspective that is used to form the part of fleece device of the present invention.
Figure 11 is the fibroreticulate displaing micro picture of the present invention's part.
Figure 12 is the fibroreticulate displaing micro picture of the present invention's part.
Figure 13 is the fibroreticulate displaing micro picture of the present invention's part.
Figure 14 is the fibroreticulate displaing micro picture of the present invention's part.
Figure 15 is the fibroreticulate displaing micro picture of the present invention's part.
Figure 16 is the fibroreticulate displaing micro picture of the present invention's part.
Figure 17 is the fibroreticulate displaing micro picture of the present invention's part.
Figure 18 is the fibroreticulate sketch map of the present invention's part.
Figure 19 is fibroreticulate another sketch map of the present invention's part.
Figure 20 is fibroreticulate another sketch map of the present invention's part.
Figure 21 is the fibroreticulate displaing micro picture of the present invention's part.
Figure 22 is the enlarged photograph of a fibroreticulate part shown in Figure 180.
Figure 23 is the plane graph of local excision of sanitary towel of the present invention.
Figure 24 is the perspective view of tampon of the present invention local excision.
The specific embodiment
Fig. 1 shows fleece 1 of the present invention.Fleece 1 is formed at usually planar, two-dimentional nonwoven precursor net 20 (following about shown in the manufacture method), this fleece has first surface 12 and second surface 14, and having vertically (MD) and laterally (CD), this point is normally known in art for nonwoven webs.First " side " of first surface 12 corresponding fleeces 1, second " side " of second surface 14 corresponding fleeces 1.Term " side " is the common usage of common two-dimensional mesh (as paper and thin film).Although available textile web is put into practice the present invention, in preferred embodiments, precursor net 20 constitutes for non-woven web and by basic randomly oriented fiber, more properly say, and are random orientings for vertical and horizontal at least.So-called " basic random orienting " is meant because processing conditions, may be vertically than at the fiber alignment that high level is laterally arranged, and vice versa.For example, in spun-bond process and meltblown, strand fiber laydown is on the holder that vertically moves continuously.Although attempt to make the orientation " at random " of spunbond or melt-blown nonwoven knitmesh fiber, usually the fiber alignment of higher percent with laterally opposite vertically on.
Term used herein " non-woven web " is meant to have the fleece that is inserted into intermediary individual fibers or silk thread structure, but does not form as the repeat patterns in textile fabric or the braided fabric (it does not have randomly oriented fiber).Non-woven web or adhesive-bonded fabric are formed by several different methods, and for example meltblown, spun-bond process, water twine method, jet net-spraying method, air lay method and bonded-carded web method.The gram every square metre (gsm) of quantitatively using usually of adhesive-bonded fabric represents that fibre diameter is represented with micron usually.The also available dawn of fiber size is represented.The quantitative scope of precursor net 20 is 10gsm to 500gsm, and this depends on the final use of fleece 1.For example, if as towel, quantitatively between 25gsm and 100gsm, may the suiting of precursor net 20.If as bath towel, quantitatively may suit between 125gsm and the 250gsm.If as floor covering, milch cow carpet for example, quantitatively may suit between 350gsm and the 500gsm.The composition fiber of nonwoven precursor net 20 can be by constituting as polyethylene, polypropylene, polyester and their polymer such as blend.Fiber can comprise the blend of cellulose, artificial silk, cotton or other natural material or polymer and natural material.Fiber also can comprise excellent absorbing material such as any combination of polyacrylate or suitable material.Fiber can be homofil, bi-component and/or biconstitutent fibre, circular fiber, non-circular fiber (for example shaped fibers or capillary pipe fiber), and can have 0.1 micron main cross sectional dimensions (for example diameter of circular fiber) to 500 micrometer ranges.For example, a fibrid that is suitable for non-woven web comprises nanofiber.Nanofiber is described to average diameter less than 1 micron fiber.Nanofiber can comprise all fibres in the non-woven web or a part of fiber in the non-woven web.The composition fiber of precursor net also can be the mixture of different fiber types, and difference is such as features such as chemical property, component, diameter, shapes.
Term used herein " spun-bonded fibre " is meant the small diameter fibers that forms with following method: molten thermoplastic material from a plurality of meticulous of spinning head and be generally circular capillary tube and be extruded as long filament, is reduced the filament diameter of extruding then fast.When being deposited on the collection surface, spun-bonded fibre is not clamminess usually.Spun-bonded fibre is generally successive and average diameter (coming from least 10 samples) greater than 7 microns, more particularly, between about 10 microns and 40 microns.
Term used herein " melts and sprays " method that is meant following formation fiber: with molten thermoplastic material by a plurality of meticulous and be generally circular punch die capillary tube and be extruded as fusion silk thread or long filament, convergence high-speed gas (as the air) stream that enters common heating attenuates the long filament of molten thermoplastic, so that its diameter reduces, it may diminish to the microfibre diameter., when meltblown fibers through be everlasting still be clamminess by high velocity air deliver and deposit to collection surface on, form the net of meltblown fibers random thereafter.Meltblown fibers is a microfibre, and it can be continuous or discontinuous, and common average diameter is less than 10 microns.
Term " polymer " used herein " generally include, but be not limited to homopolymer, copolymer (for example block copolymer, graft copolymer, random copolymer and alternate copolymer, terpolymer etc.), and their blend and modifier.In addition, unless in addition specifically limit term " polymer " " comprise all possible geometrical configuration of described material.These configurations include, but not limited to isotaxy, atactic, syndiotaxy and symmetrical at random.
Term used herein " one pack system " fiber is meant the fiber that only uses a kind of polymer to be formed by one or more extruder.This and do not mean that eliminating has added wherein that a small amount of additive is used to dye, the fiber of a kind of polymer formation of antistatic property, lubricated, hydrophilic etc.These additives for example are used for painted titanium dioxide, with less than about 5% weight, are more typically about the content existence of 2% weight usually.
Term " bicomponent fibers " used herein " be meant and extrude from extruder separately by at least two kinds of different polymer but be spun the fiber that forms a fiber.Bicomponent fibre is also referred to as conjugate fiber or multicomponent fibre sometimes.Polymer is arranged in the zones of different of basic fixed placement along the cross section of bicomponent fibre, and stretches continuously along the length of bicomponent fibre.The configuration of this bicomponent fibre can be arranged (wherein a kind of polymer is centered on by another kind of polymer) for for example sheath/caryogram, perhaps can arrange for parallel type, the cake formula is arranged or arrange " day starlike ", each is arranged in multicomponent fibre (comprising bicomponent fibre) field is known.Bicomponent fibre can be splittable fibers, and this fiber can vertically be split into plurality of fibers before processing or during the processing, and the cross sectional dimensions that every fiber has is less than initial bicomponent fibre.Because having shown, reducing of splittable fibers cross sectional dimensions, splittable fibers can be used to produce more softish non-woven web.Be used for representational splittable fibers of the present invention and comprise T-502 type and T-512 type 16 block polyethylene terephthalate (PET)/62.5 dawn of nylon fiber; With T-522 type 16 block polyethylene terephthalate (PET)/polypropylene splittable fibers, all available from Fiber Innovation Technology, Johnson City, TN.
Term used herein " biconstitutent fibre " is meant by the fiber of extruding from same extruder as at least two kinds of polymer formation of blend.Biconstitutent fibre does not have along the cross section of described fiber and is arranged in multiple polymers component in the zones of different that relative fixed places, and the various polymer of whole length along described fiber are discontinuous usually, but often form the fibril of random start and termination.Biconstitutent fibre is also referred to as multi-constituent fibre sometimes.
The fiber with non-circular cross sections described in term used herein " non-circular fiber ", comprises " shaped fibers " and " capillary pipe fiber ".These fibers can be solid or hollow, and they can be trilobal cross, Δ shape, and be preferably the fiber that has capillary channel at its outer surface.Described capillary channel can have multiple shape of cross section, for example " U-shaped ", " H shape ", " C shape " and " V-arrangement ".A kind of preferred capillary pipe fiber is T-401, is appointed as the 4DG fiber, available from Fiber InnovationTechnologies, and Johnson City, TN.The T-401 fiber is polyethylene terephthalate (a PET polyester).
Term used herein " integral body " (in " integral extensions " used at second area 4) is meant the fiber of second area 4, it originates from the fiber of precursor net 20, therefore, for example be out of shape 6 fibrae circulares 8 and can be the plastic deformation of precursor net 20 and the fiber that stretches out, and therefore become one with the first area 2 of fleece 1." integral body " used herein is different from the fiber that is incorporated into or joins independent precursor net in order to make tuft, and for example this carries out in the carpet manufacturing of routine usually.Can recognize that suitable non-woven web 20 should comprise the fiber that can stand enough plastic deformations and tension force elongation, thereby perhaps can have enough fiber motilities can form fibrae circulares 8.Yet, have recognized that the fiber of the certain percentage that inspires out from first surface 12 planes of precursor net 20 will not form the collar, but will rupture and form loose end.This paper is called as shown in Figure 3 " loose fiber " or " broken fiber " 18 with these fibers.Loose fiber ends 18 also can be the result that non-woven web forms distortion 6, and this non-woven web is formed or comprised the staple fiber of cutting by the staple fiber of cutting.For the purpose of the present invention, loose fiber ends 18 needs not to be worthless, but it is believed that fleece 1 can its fluffy and soft characteristic of easier maintenance when distortion 6 mainly comprises fibrae circulares 8.In a preferred embodiment, the fiber that inspires in the Z direction is at least about 50%, and more preferably at least 70%, most preferably at least 90% is fibrae circulares 8.
To the embodiment of fleece shown in Figure 11, representational distortion 6 is shown in the further zoomed-in view of Fig. 2.As shown in the figure, distortion 6 comprises many fibrae circulares 8, and this fiber aligns substantially and makes distortion 6 have tangible portrait orientation and longitudinal axes L.Distortion 6 also has axis T, and it is orthogonal to longitudinal axes L usually in the MD-CD plane.In embodiment as illustrated in fig. 1 and 2, longitudinal axes L is parallel to vertically (MD).In one embodiment, all isolated distortion 6 have parallel longitudinal axes L usually.The number of the distortion 6 of fleece 1 per unit area promptly is out of shape 6 area density, can change in 6 to every square centimeter scope up to 100 distortion 6 of 1 every square centimeter distortion.Depend on final use, every square centimeter can have at least 10, perhaps at least 20 distortion 6.Usually, needn't be consistent along the whole region area density of fleece 1, can only be in some zone of fleece 1, for example in zone but be out of shape 6 with reservation shape (as microgroove, striped, band shape, circle etc.).
As shown in Figure 2 and be shown more clearly in Fig. 3 and 4, in an embodiment of fleece 1, a feature of the fiber 8 of distortion 6 is fibrae circulares 8 significant orientation alignment.Shown in Fig. 3 and 4, when observing in plane graph (as Fig. 4), fibrae circulares 8 has the alignment with respect to the axis T basically identical.So-called " ring-type " fiber 8 is meant that fiber 8 begins and stops in fleece 1.So-called fibrae circulares 8 " alignment " with respect to distortion 6 is meant that fibrae circulares 8 is orientation usually, make when in plane graph, observing as Fig. 4, each fibrae circulares 8 has an effective vector component that is parallel to axis T, and preferably has a master vector component that is parallel to axis T.When observing in the plane graph as Fig. 4, used herein being oriented in apart from the angle of longitudinal axes L has an effective vector component that is parallel to axis T greater than 45 fibrae circulares 8 of spending.When observing in the plane graph as Fig. 4, used herein being oriented in apart from the angle of longitudinal axes L has a master vector component that is parallel to axis T greater than 60 fibrae circulares 8 of spending.In a preferred embodiment, at least 50%, more preferably at least 70%, more preferably the fiber 8 of at least 90% distortion 6 has an effective vector component that is parallel to axis T, more preferably a master vector component.If desired, can use amplifier unit to determine machine direction, the graduated microscope of suitable measurement for example is installed.Usually, to observed nonlinear fiber block in plane graph, longitudinal axes L and fibrae circulares 8 are all made the approximate angle that can be used to definite fibrae circulares 8 apart from longitudinal axes L of straight line.
The orientation of the fibrae circulares 8 in second area 4 distortion 6 and the fiber composition of first area 2 and directed formation thereof contrast, and for nonwoven precursor net 20, the first area is preferably described owing to have the alignment of fibers of basic random orienting.In the textile web embodiment, the orientation of the fibrae circulares 8 in the distortion 6 can be same as described above, but the fiber of second area 2 will have and the relevant orientation of the unique weaving method that is used for making this net (for example square patterns for knitting).
In the embodiment depicted in fig. 1, the longitudinal axes L of distortion 6 is usually in vertically (MD) alignment.Therefore, distortion 6 and longitudinal axes L can be alignd with respect to vertical (MD) or horizontal (CD) substantially in any direction.Therefore, we can say that usually to each distortion 6, looped, aligned fibers 8 is orthogonal to the longitudinal axes L alignment usually, makes it have an effective vector component that is parallel to axis T, more preferably a master vector component.
Fig. 5 is scanning electron microscope (SEM) picture that is similar to the described fleece 1 of Fig. 1.Fleece 1 among Fig. 5 is the spunbond non-woven web of 70gsm, and it comprises polyethylene/polypropylene (sheath/caryogram) bicomponent fibre.The perspective view of Fig. 5 is the first surface 2 of fleece 1 and the side view of distortion 6 substantially.So-called " side view " is meant what the photo among Fig. 5 normally obtained in the CD direction as Fig. 1 to 4 described in, make vertical (MD) of each distortion 6 and longitudinal axes L in Fig. 5 along for example common horizontal direction orientation.As shown in Figure 5, distortion 6 comprises looped, aligned fibers 8, and this fiber is orthogonal to the longitudinal axes L alignment usually, and has effective vector component that at least one is parallel to axis T.
In some embodiments, because the method for optimizing of formation as described below distortion 6, another feature of distortion 6 is its common hatch frame, and this architectural feature is to be limited to as shown in Figure 3 the clearance gap zone 10 of distortion 6 inside.What void area 10 can have is shaped as at the terminal surface 3 terminal broads or bigger that are out of shape 6, narrower at the pedestal 5 of distortion 6.This shape is opposite with the shape of the tooth that is used to form distortion 6.So-called " void area " also do not mean that and do not contain any fiber fully, and be meant the general description as its common outward appearance.Therefore, may be out of shape in 6 at some, a loose fiber 8 or many loose fibers 8 can be present in the void area 10.So-called " opening " void area is meant that two of distortion 6 are vertically terminal and opens wide usually and fibre-bearing not, makes distortion 6 be formed with the structure (as shown in Figure 3) in point image " tunnel ".For example, Fig. 6 is the close-shot SEM view of a distortion 6 of fleece 1 shown in Figure 5.As shown in the figure, except looped, aligned fibers 8, also has a clearance gap zone 10 that is significantly limited by many looped, aligned fibers 8.Can only see considerably less broken fiber 18.As can be seen, the pedestal 5 of distortion 6 can perhaps can keep opening for (as touching adequate closure together in the fiber that forms distortion 6) of closure.Usually, any opening of pedestal 5 is narrow.
In addition, result as the method for optimizing of making fleece 1, be interruption 16 with second surface 14 bonded second areas 4, the breach that it is characterized in that the common linearity that limited by the original random fibers of second surface 14 has been formed, and direction ground is arranged (is " the Z direction " that expression that the non-woven material field is generally understood is orthogonal to MD-CD planar " outside the plane " direction usually for the tooth of structure, as shown in figs. 1 and 3) inspire enter the distortion 6, hereinafter will describe in detail.The direction that original randomly oriented fiber of precursor net 20 demonstrates sharply changes to define is interrupted 16, thereby its demonstration has the longitudinal axis that rectilinearity can be described to have the longitudinal axes L that is parallel to distortion 6 usually.Because many non-woven webs can be used as the person's character of precursor net 20, being interrupted 16 may be apparent unlike for example being out of shape 6.Just because of this, unless very near-earth check fleece 1, the interruption 16 on fleece 1 second side can may detect out in the cold and usually less than.Therefore in some embodiments, fleece 1 has the look and feel of towelling in first side, have smooth relatively, softish the look and feel in second side.In other embodiments, be interrupted 16 and can look like the hole, and pass the hole of fleece 1 for end by tunnel-shaped ring-type distortion 6.
In addition, as the result of the method for optimizing of making fleece 1, no matter whether second area 4 has looped, aligned fibers 8, each should the zone respectively first and second surfaces 12 of fleece 1 and 14 or near demonstration have tangible rectilinearity.Following more abundant disclosed about manufacture method, can recognize that each second area 4 of precursor net 20 has linear orientation bonded with it owing to the geometry of the tooth 110 of roller 104.Linear orientation is the inevitable outcome of manufacturing fleece 1 method as described herein.A kind of approach of understanding this linear orientation is to consider to be interrupted on the second surface 14 of fleece 1 16 linear orientation.Similarly, remove from fleece 1 at first surface 12 if will be out of shape 6, the linearity that second area 4 will look like on the first surface 12 of fleece 1 is interrupted, and for example seems linear slit or the otch made in the position of precursor net 20 internal strains 6.This linear fibre net is interrupted the corresponding longitudinal axes L in directivity ground.
Can find out that from the description of fleece 1 fibrae circulares 8 of distortion 6 can originate from and stretch out in the first surface 12 or the second surface 14 of fleece 1.Certainly, the fiber 8 of distortion 6 is also extended in the inside 19 of fleece 1.Distortion 6 fiber 8 stretches owing to the common two-dimensional plane from precursor net 20 inspires out (promptly inspiring in as shown in Figure 3 " Z direction ").Usually, the fiber 8 or 18 of second area 4 comprises that fiber with fleece first area 2 becomes one and from the extended fiber of first area fiber.
Therefore, by above description, according to understanding the fleece 1 that fleece 1 in one embodiment can be described to have first surface 12 and second surface 14, described fleece 1 comprises first area 2 and a plurality of discrete integral second region 4, at least a portion of second area 4 for be interrupted 16 (its demonstration has linear orientation and limits longitudinal axes L) and at least another part be distortion 6 (it comprise many become one and from first area extended clustered fiber with first area 2).
Because the plastic deformation of fiber and the influence of Poisson's ratio, fibrae circulares 8 stretch out the common minimizing that can follow fiber cross sectional dimension (as the diameter of circular fiber).Therefore, the fiber diameter of the fiber 8 of distortion 6 is less than the fiber diameter of precursor net 20 fibers and first area 2 fibers.It is believed that the flexibility (this flexibility can compare favourably with cotton towel cloth) that the minimizing of fibre diameter helps fleece 1 to aware, depend on the material character of precursor net 20.Found that fiber cross sectional dimension reduces at most in the middle of pedestal 5 and end portion 3.It is believed that this causes owing to more abundant disclosed manufacture method hereinafter.In brief, it is believed that on the top (hereinafter will describe more fully) of the tooth 110 of the contiguous roller 104 of part fiber of distortion 6 pedestal 5 and end portion 3, thereby and by frictional property fix and can during processing, stablize.So the mid portion of distortion 6 can more freely stretch or prolong, therefore can carry out corresponding fiber cross sectional dimension reduction easilier.
With reference to figure 7, it illustrates the apparatus and method of making fleece 1 of the present invention.Device 100 comprises a pair of intermeshing roller 102 and 104, and each roller is round axle A rotation, and A is parallel in same plane for axle.Roller 102 comprises a plurality of protruding 106 and corresponding grooves 108, and they intactly stretch along the whole circumference of roller 102.Roller 104 is similar to roller 102, but not to have the projection that intactly stretches along whole circumference, roller 104 comprises the projection (they be improved to tooth 110 that many rows along circle spacing open) of many rows along circumferential extension, and this tooth stretches in the spaced around of at least a portion roller 104.The monorow tooth 110 of roller 104 is separated by corresponding grooves 112.In operation, roller 102 and 104 engagements make the projection 106 of roller 102 stretch and enter in the groove 112 of roller 104, and tooth 110 stretching, extensions of roller 104 enter in the groove 108 of roller 102.Engagement is shown in the cross sectional representation of Fig. 8 in more detail, hereinafter can be discussed.Utilize methods known in the art such as deep fat fill roller or electric heating roller can with roller 102 and 104 all or one of heat.
In Fig. 7, device 100 illustrates with preferred structure, and it has a patterned roll (for example roller 104) and a non-rollet roller 102.Yet in certain embodiments, it may be preferred using two patterned roll 104, and these two rollers have identical or different decorative pattern in the identical or different corresponding region of roller separately.This device can be produced the fleece with distortion of all giving prominence to from two sides of fleece 1.
Make the method for fleece 1 of the present invention describes in Fig. 7 with the continuation method of commericially feasible.Can make fleece 1 by mechanically deform precursor net 20, this precursor net can be described to be generally the plane and be two dimension.So-called " planar " and " two dimension " only refers to that this net is flat with respect to finished fiber net 1, and described finished fiber netting gear has the three-dimensional of tangible, out-of-plane, the Z direction of giving owing to the formation of second area 4." planar " and " two dimension " is not meant and means any special plane, smoothness or dimension.
Described method is similar to United States Patent (USP) 5 in many aspects, 518, method described in 801 is called " SELF " fleece, its representative " elastic construction shape thin film " in this patent " Web Materials Exhibiting Elastic-Like Behavior " by name and the patent documentation afterwards.Yet, in apparatus of the present invention and above-mentioned 801 patents, between the disclosed device marked difference is arranged.The fibroreticulate novel feature of these difference explanation the present invention.As described below, the tooth 110 of roller 104 has and forward position and the bonded special geometric form of tailing edge, and it allows basic " passing " precursor net 20 of tooth (as tooth 110), and this is opposite with the embossing fleece in itself.Difference in apparatus of the present invention 100 causes the fleece of fundamental difference.For example, distinguished " tunnel-like " that fleece 1 of the present invention has looped, aligned fibers 8 plays a bunch distortion 6, this is different from prior art SELF fibroreticulate " tent like " rib linear element, and each this element has continuous side walls bonded with it, i.e. continuous " transitional region ".It is believed that fleece 1 of the present invention distinguished " tunnel-like " plays bunch distortion 6 by allowing fluid through being out of shape 6 void area 10 and entering and by fleece 1, helping the good fluid treatment character of fleece 1.
Precursor net 20 or directly provided by web manufacture technology is perhaps provided indirectly by the donor rollers (not shown), and at roller 102 that is longitudinally moving to the counter-rotating engagement and 104 roll gap 116.The precursor net can be the non-woven web that comprises any known fiber type, and fiber type comprises bicomponent fibre, capillary pipe fiber, microfibre or splittable fibers.Precursor net 20 can preheat by methods known in the art (for example by heating on oily warm-up mill).And the precursor net can be the non-woven web of making by known method, and these methods are for example meltblown, spun-bond process and carded method.Along with precursor net 20 by roll gap 116, the tooth 110 of roller 104 enters the groove 108 of roller 102, simultaneously fiber is inspired from the plane of precursor net 20 out-of-plane outside and forms second area 2, this zone comprises distortion 6 and interruption 16.In fact, tooth 110 is " pushing away " or " passing " precursor nets 20.Along with the top of tooth 110 pushed away precursor net 20, mainly be oriented in laterally (CD) and inspired out outside the plane of precursor net 20 by tooth 110 along the part fiber of tooth 110, and in the stretching of Z direction, tractive and/or plastic deformation, the result forms second area 4, and it comprises the fibrae circulares 8 of fleece 1 distortion 6.Mainly at the fiber that generally is parallel to longitudinal axes L (promptly as shown in Figure 1 precursor net 20 vertically) direction orientation by the tooth 110 simple first areas 2 of launching and remaining on fleece 1 substantially.Although as the formation speed of finding common distortion 6 that hereinafter more discusses fully influences fiber alignment, and low at least formation speed can influence, but still can be interpreted as that what fibrae circulares 8 shows to have unique fiber alignment, this fibrae circulares is the fiber with high percentage ratio of the effective vector component that is parallel to distortion 6 axis T or master vector component, as above Fig. 3 and 4 described.Usually, being out of shape 6 some fibre at least is looped, aligned fibers 8, and it can be described to have effective vector component or the master vector component that is parallel to the orthogonal Z direction plane of axis T.
Number, spacing and size that can be by changing tooth 110 and if necessary pair roller 104 and/or roller 102 carry out number, spacing and the size that corresponding change in size changes distortion 6.This change allows manufacturing to be used for multi-purpose many various fleeces 1 with the 20 interior possible variations of precursor net and the variation of linear velocity.For example, can be made into softish porous mulching material, for example be used to reduce the milch cow carpet of cow breast and nipple problem by the high quantitatively fleece 1 of textile fabric manufacturing with the extending silk thread of MD (vertically) and CD (laterally) weaving.The terry cloth-like fabric that can be used as partly durable or durable clothes by the fleece 1 that hangs down quantitative non-woven web manufacturing relatively of extending spunbond polymer fiber.Following more abundant description, fleece 1 also can be used in the disposable absorbent article.
Fig. 8 illustrates the roller 102 and 104 that part meshes with cross section, comprises projection 106 and tooth 110.As shown in the figure, tooth 110 has tooth height TH and (notices that TH also can be applicable to projection 106 height; Tooth height equates with height of projection in preferred embodiments), and the spacing of tooth and tooth (or spacing of projection and the projection) section of being called is apart from P.As shown in the figure, depth of engagement E is measuring of roller 102 and 104 mesh degrees, and is to measure from top to the top of tooth 110 of projection 106.Depth of engagement E, tooth height TH and section can be depending on the character of precursor net 20 and the desirable characteristics of fleece 1 changes as required apart from P.For example, be generally the fibrae circulares that obtains distortion 6, mesh degree E is high more, and necessary fiber motility and/or elongation characteristics that the fiber of precursor net 20 must have are strong more.Also have, as described below, if the density of required second area 4 (second area 4 of per unit area fleece 1) is big more, section is apart from should be more little, and tine length TL and tooth pitch should be more little from TD.
Fig. 9 illustrates an embodiment of roller 104, it has a plurality of teeth 110 that are used for being made by spunbond nonwoven precursor net 20 the terry cloth-like fleece 1 of spunbond non-woven material, this precursor net quantitatively between about 60gsm and 100gsm, be preferably about 70gsm, or 80gsm, or 90gsm.The enlarged drawing of tooth 110 shown in Figure 9 is shown among Figure 10.In this embodiment of roller 104, tooth 110 has the unified about 1.25mm of circumferential length size TL (measuring to tailing edge TE from forward position LE usually in tooth tip 111), and the circumference mutual spacing is identical, and the TD distance is about 1.5mm.In order to make terry cloth-like fleeces 1 by quantitative precursor net 20 in the scope of about 60gsm to 100gsm, the length T L scope that the tooth 110 of roller 104 has is that about 0.5mm is to about 3mm, spacing TD is that about 0.5mm is to about 3mm, tooth height TH scope for about 0.5mm to about 10mm, and section apart from P between about 1mm (0.040 inch) and 2.54mm (0.100 inch).Depth of engagement E can be about 0.5mm to about 5mm (up to maximum near tooth height TH).Certainly, E, P, TH, TD and TL each can change independently of each other to reach the area density (number of the distortion 6 of per unit area fleece 1) of required size, spacing and distortion 6.
As shown in Figure 8, each tooth 110 has top 111, forward position LE and tailing edge TE.Tooth tip 111 for elongated, and the longitudinal axes L of corresponding second area 4 be generally portrait orientation.It is believed that to be bunch shape distortion 6 of the fleece 1 that obtains being described to terry cloth-like, LE and TE should almost be orthogonal to the local periphery surface 120 of roller 104.Equally, the transition of top 111 and LE or TE should be acute angle (for example right angle), makes that to have enough little radius of curvature in use tooth 110 pushed away precursor net 20 at LE and TE place.Be not bound by theory, it is believed that the top transition that has relative acute angle between tooth 110 tops and LE and TE allows tooth 110 " neatly " (promptly partly and significantly) to pass precursor net 20, be " bunch shape " rather than for example " embossing " thereby gained fleece 1 can be described as be in second area 4.When so adding man-hour, except the precursor net 20 initial elasticity that have, fleece 1 is not endowed the elasticity of any uniqueness.
Found that the speed of the formation distortion 6 of linear velocity (being the precursor net 20 processed speed of passing through the roll gap of rotation roller 102 and 104) and gained influences the structure of gained distortion 6.For example, the distortion shown in Fig. 5 and 66 is to form under the relatively low speed of about per minute 3 meters (10 feet of about per minutes).For being used for the commodity production that many consumers use, per minute is considered to relatively slow speed for three meters, but for the spunbond bicomponent fibre that is used in the non-woven web shown in Fig. 5 and 6, this relatively slow speed can obtain very consistent, looped, aligned fibers 8 in distortion 6.
Under higher linear velocity, promptly under the relative higher speed of processing by rotation roller 102 and 104 roll gap, similar material is that tuft shows to have very different structures for distortion 6.For example, Figure 11 and 12 illustrates fleece 1 representational distortion 6, both are made by identical materials with identical processing conditions, and unique difference is the rotary speed of roller 102 and 104, promptly are processed to the linear velocity (unit is length/time) of the precursor net 20 of fleece 1.Be used for the fibroreticulate precursor net 20 of each shown in Figure 11 and 12 and be the non-woven web of 25gsm, it comprises polypropylene and available from BBANonwovens, Simpsonville, and SC, and with trade name Softspan
Sell.The processed roll gap 116 of fleece shown in Figure 11 through roller 102 and 104, depth of engagement E is about 3.4mm (about 0.135 inch), section is about 1.5mm (about 0.060 inch) apart from P, tooth height TH is about 3.7mm (about 0.145 inch), tooth pitch is 1.6mm (about 0.063 inch) from TD, and tine length TL is about 1.25mm (about 0.050 inch).Fleece turns round under the linear velocity of about 15 meters/minute (about 50 feet per minutes).Fleece shown in Figure 12 and fleece shown in Figure 11 are identical, and are processing under the identical condition except linear velocity, and this linear velocity is about 150 meters of per minute (about 500 feet an of per minute).
As finding out by observing Figure 11 and 12, shown in distortion 6 obviously different.Distortion 6 shown in Figure 11 structurally is similar to the distortion shown in Fig. 1 to 6.In other words, its demonstration has the fibrae circulares 8 of basic alignment, has only considerably less broken fiber (fiber 18 as shown in Figure 3).Yet distortion 6 shown in Figure 12 shows to have very different structures, a kind of structure that seems to be typically the spunbond non-woven material that is processed to form distortion 6 under higher relatively speed.This structure is typically the broken fiber between the most approaching part (promptly be out of shape 6 pedestal 5) and the end portion (promptly be out of shape 6 top 3), and looks like " felt " 7 of the top fiber of distortion 6.Felt 7 comprises the fibrae circulares 8 of not fracture and is supported by it at the top of distortion 6 that also comprise part broken fiber 11, this broken fiber no longer becomes one with precursor net 20.That is to say that felt 7 comprises pars fibrosa, this part is original to become one with precursor net 20, but is separating from precursor net 20 fully after processing under the sufficiently high linear velocity in reference to figure 7 and 8 described methods.
Therefore, by above description, according to understanding the fleece 1 that fleece 1 in one embodiment can be described to have first surface 12 and second surface 14, described fleece 1 comprises first area 2 and a plurality of discrete integral second region 4, at least a portion of second area 4 is for being interrupted 16 (its demonstration has linear orientation and limits longitudinal axes L), and at least another part for distortion 6 (distortion 6 comprise become one with first area 2 but from the first area extended fiber and neither with the first area 2 not extended fiber that becomes one also from the first area).
Another of fleece 1 except material the linear velocity and the identical embodiment of processing conditions shown in Figure 13 and 14.To the fleece 1 shown in each Figure 13 and 14, precursor net 20 is the spunbond non-woven web of 60gsm, and it is available from BBA Nonwovens, Simpsonville, and SC, and with trade name Softspan
Sell.Fleece shown in Figure 13 is processed by the roll gap 116 of roller 102 and 104, depth of engagement E is about 3.4mm (about 0.135 inch), section is about 1.5mm (about 0.060 inch) apart from P, tooth height TH is about 3.7mm (about 0.145 inch), tooth pitch is about 1.6mm (about 0.063 inch) from TD, and tine length TL is about 1.25mm (about 0.050 inch).Fleece turns round under the linear velocity of about 15 meters of per minute (about 50 feet of per minute).Fleece shown in Figure 14 and fleece shown in Figure 13 are identical, and are processing under the identical condition except linear velocity, and this linear velocity is about 150 meters of per minute (about 500 feet an of per minute).
1 of fleece shown in Figure 13 is processed under the linear velocity of about 15 meters of per minute (about 50 feet of per minute).As shown in the figure, even under this moderate relatively linear velocity, still can find the felt of some quantity at distortion 6 far-ends.These look like that being out of shape on 6 with the bonded part in tooth 110 tops of roller 104 during manufacture appears in the felt of highdensity pressing conpressed fibers part.Along with linear velocity increases, felt (being felt 7) becomes more and more obvious as shown in figure 14, and Figure 14 is illustrated in and fleece the same terms shown in Figure 13 fleece of processing down, but processing line speed be per minute about 150 meters (about 500 feet of per minute).Distortion shown in Figure 14 6 shows to have more obvious felt 7, and be described to comprise become one with first area 2 but from the first area extended fiber 8 or 18 and neither with the first area 2 not extended fiber 11 (felt 7) that becomes one also from the first area.
It is believed that the observed tangible fiber alignment of end portion (for example felt 7) in distortion 6 mainly causes owing to processing speed, also it is believed that the influence that will be subjected to other factors, as fiber type, precursor net 20 quantitatively and the processing temperature that can influence fiber and inter-fibre-bond degree.For example, being out of shape on 6 with the bonded part in tooth 110 tops of roller 104 during manufacture appears in as above viewed fiber mat.It is believed that in the frictional engagement of tooth tip fiber fiber " is fixed " in position, thereby restriction elongate fiber and/or fiber activity it is believed that it is the formation that these two kinds of mechanism allow distortion 6.Therefore we can say, in case be fixed on the appropriate location, adjacent teeth 110 vertical fibers can rupture, and because possible the cold fusion of the fiber that the entanglement at random of precursor net and pressure and friction cause, and broken fiber 11 beginnings and remaining resident in are out of shape in the felt 7 at 6 far-end 3 places.
The result that felt 7 exists is that fleece 1 has more coarse a little texture sense on the one side, and this fleece for example wherein needing can be used for the cleaning piece of more scouring textures.In some sense, the fleece that has softish terry cloth-like sense of touch when making under the processing conditions in relatively low speed if process, can have the sensation of cheap hotel towel under except all the other identical conditions of relative higher line speed.Fibroreticulate this coarse, veined sense of touch is useful to some application, for example can be used for hard surface cleaning cleaning piece or facial decortication cleaning piece.
Found some fleece, for example comprised that the carded web of staple fiber produces considerably less fibrae circulares 8 in distortion 6, made the distortion 6 that in these fleeces, produces to be described to as above about the described many looped, aligned fibers 8 that comprise of Fig. 1 to 6.Yet shown in scanning electron microscope (SEM) picture of Figure 17, the carded non-woven web can produce the distortion 6 with (if there is) looped, aligned fibers 8 seldom and many (if not all) non-alignment fibers and/or broken fiber 18.The precursor net 20 that is used to make fleece shown in Figure 17 1 is the carded web of 40gsm, and it is as HighElongation Carded
Available from BBA Nonwovens, Simpsonville, SC, and it is processed by the roll gap 116 of roller 102 and 104, depth of engagement E is about 3.4mm (about 0.135 inch), and section is about 1.5mm (about 0.060 inch) apart from P, and tooth height TH is about 3.7mm (about 0.145 inch), tooth pitch is about 1.6mm (about 0.063 inch) from TD, and tine length TL is about 1.25mm (about 0.050 inch).Fleece turns round under the linear velocity of about 15 meters of per minute (about 50 feet of per minute).It is believed that by the non-alignment fiber in the distortion 6 of carded web manufacturing be partly because the person's character of carded web fiber content causes.Staple fiber is not " endless ", is extremely about 400mm of 25mm but have predetermined length, and is more typically about 40mm to about 80mm.Therefore, when with as described in Figure 7 device processing carded web, it is believed that the bigger loose fiber ends that may make will be near distortion 6, thus in distortion 6 generation non-looped fibers end.In addition, for example common staple fiber does not have the elongation characteristics identical with spun-bonded fibre or meltblown fibers.Yet, there is not fibrae circulares even be out of shape 6, the fiber tuft still provides the beneficial effect of flexibility and produces the fleece with terry cloth-like characteristic.
Therefore, by above description, needn't have looped, aligned fibers according to understanding fleece of the present invention, and can be described in one embodiment that (this precursor netting gear has first surface 12 and second surface 14 by precursor net 20, and comprise basic randomly oriented fiber) the fleece 1 that forms of selectivity mechanically deform, described fleece comprises first area (this zone is substantially free of the distortion by selecting mechanically deform to form) and a plurality of discrete integral second region of basic randomly oriented fiber, described second area 4 comprises the 20 isolated distortion 6 of precursor net, at least a portion of each described second area 4 is for being interrupted 16 (its demonstration has linearity and limits longitudinal axes L), and at least another part comprise many become one with described first area but from the first area extended clustered fiber.
If utilize weaving precursor net 20, the formation of second area 4 is in close proximity to and is formed at fleece 1 shown have identical of non-woven web with structure.For example, if weaving precursor net 20 contains warp or parallel (it has enough elongation characteristics and mainly is oriented in laterally), when being added man-hour by aforesaid device 100, tooth 110 is tending towards separating vertical line (warp or parallel) and only inspires out on the x wire plane.Therefore, the look and feel of the fleece of being produced by weaving precursor net 20 1 resembles the towelling fabric very much.
In preferred embodiments, precursor net 20 is a non-woven web, wherein has minimum fiber and interfibrous bonding.For example, the precursor net can be the non-woven web with discrete thermal bonding patterns, and this is generally known in art for nonwoven webs.Yet, need the number and the spacing minimum of bounding point usually, thereby can allow to have the fiber activeness and the dislocation of maximum at second area 4 places of fleece 1.Usually, utilizing to have that big relatively diameter and/or high relatively fracture are stretched out and/or the fiber of high relatively fiber activeness, can cause better and form second area 4 more significantly, is that distortion 6 forms specifically.
Although be disclosed in the single layer fibre net of fleece 1 for being made by monolayer precursor net 20 in the embodiment preferred, this is not necessary.For example, can use lamination or composite precursor net 20 with two or more layers or synusia.Usually, the above description of fleece 1 insists that the looped, aligned fibers 8 that for example is formed at lamination precursor net will be made of two-layer (or all layers) fiber of laminated material.Therefore, in this fiber net structure, it is important that all fibres of all layers has enough diameters, elongation characteristics and fiber activeness, thus unlikely fracture before stretching out and being out of shape.In this mode, can help a bunch shape distortion 6 from the fiber of all layers of laminated material.In multi-layered web, different fibroreticulate fibers can mix in distortion 6 or mix.Described fiber is outstanding to be passed the fiber of adjacent fiber net but combines with it.When processing fiber net under very high speed, this observes through regular meeting.
In multi-layered web 1, each precursor net can have different character.For example, fleece 1 can comprise two (or a plurality of) precursor nets, for example first and second precursor net 20A and the 20B.The first precursor net 20A can form and show the upper strata with high elongation and remarkable elastic recovery, and this layer can make fleece 20A resilience.Resilience helps the base part 5 of lateral compression two fibroreticulate distortion 6 as shown in figure 18.Resilience or lateral compression also help to protect with steady-state deformation 6 in Z direction fiber.The lateral compression that is provided by precursor net 20A also can increase by the stability of the second precursor net 20B.Multi-layered web 1 except material the linear velocity and processing identical embodiment shown in Figure 15 and 16.Multi-layered web 1 shown in Figure 15 and 16 comprises the first precursor net 20A, and it is by BBA, and the spunbond PE/PP sheath that Washougal WA makes/caryogram non-woven web constitutes.The second precursor net 20B constitutes (the common PET Kanematsu LM651 type that PET Wellman 204 types that 50%6dpfCharlotte NC makes and 50% 6dpf Gastonia NC make) by the common PET non-woven web of the carded PET/ of thermal point bond.The second precursor net 20B can bondingly can play bunch it by loose, so the lateral compression of the first precursor net 20A also can increase by the stability of the second precursor net 20B.Two multi-layered webs 1 are all processed under the depth of engagement of about 3.4mm (about 0.135 inch).Multi-layered web 1 shown in Figure 15 is in low speed (3 meters of per minutes) processing down, and multi-layered web 1 shown in Figure 16 is processed under the high speed of 150 meters of per minutes.As can be seen, more severe from the fiber of first and second precursor net 20A in the distortion 6 among Figure 16 (High-speed machining) and 20B than those fiber dopings of (low speed processing) shown in Figure 15.When using multi-layered web 1 as the top flat on the disposable absorbent article, it can be utilized as body contacting layer.
In multi-layered web 1, each precursor net can have different material characters, thereby the fleece 1 with beneficial property can be provided.For example, fleece 1 comprises two (or a plurality of) precursor nets, and for example the first and second precursor net 20A and 20B are used as top flat on the disposable absorbent article because of having useful fluid treatment character, as hereinafter describing more fully.For example, for obtaining first-class fluid treatment, the first precursor net 20A can form upper strata (i.e. body contacting layer when as the top flat on the disposable absorbent article), and is made of hydrophobic relatively fiber.The second precursor net 20B can form lower floor's (promptly being set between top flat and the absorbent cores) when being used for disposable absorbent article, and is made of hydrophilic relatively fiber.The fluid that is deposited on the hydrophobic relatively upper strata is transported to hydrophilic relatively lower floor fast.One of reason that observed rapid fluid is carried is the capillary pipe structure that is formed by the common aligned fibers 8,18 of being out of shape 6. Fiber 8,18 forms the capillary tube of direction alignment between adjacent fiber, and capillarity is by strengthening near the common convergence of the fiber of part 5 near distortion 6.
It is believed that the rapid fluid conveying also can be owing to fluid enter the ability of fleece 1 and further enhancing by being out of shape 6 spaces 10 that produce." side direction enters " ability and/or the capillarity that structure provided of fleece 1, and/or hydrophilic gradient makes fleece 1 become the ideal material of the best fluid treatment that is used for disposable absorbent article.Specifically, multi-layered web 1 can be provided for the bigger improvement of flow handling feature.In another embodiment, the first precursor net 20A can be made of soft relatively fiber (as polyethylene), and the second precursor net 20B can be made of hard relatively fiber (as polyester).In this multi-layered web 1, even after exerting pressure, distortion 6 can keep or recover a certain amount of height h.The beneficial effect of this structure, especially when with aforesaid hydrophilic gradient (making the fiber hydrophobic or hydrophilic) when combining by methods known in the art, be that fleece 1 is applicable to as the top flat in the feminine hygiene article, it can provide first-class fluid acquisition and the good character (being the hypokinesia that fluid returns topsheet surface) that bleeds back.It is believed that the hardness increase that is provided by the hard relatively fiber of the second precursor net 20B can make fibroreticulate incompressible thickness increase, and the soft relatively fiber of the first precursor net 20A can provide flexibility at fleece/skin contact place.This additional thickness can keep the relative soft fluid that also do not contain relatively together with the ability that the end of distortion 6 is provided with part 3, thereby can obtain good, softish, exsiccant (with the drying sensation) top flat, it can be used for feminine hygiene article and baby diaper, adult incontinence product, binder etc.
Figure 18 to 20 illustrates the representational sketch map of distortion 6 possibility structures, and they depend on the material character of precursor net 20A and 20B.Also can obtain unshowned other structure, the only restriction of various structures is the inherent restriction of precursor net materials character.
Therefore, find out that depend on the precursor net 20 (or fleece) of utilization and the dimensional parameters (comprising tooth 110) of roller 102 and 104, fleece 1 of the present invention can show the physical attribute with wide region as above-mentioned.Fleece 1 can show the structural change scope with subjective experience, as from flexibility to coarse variation, absorbability never absorbs very strong absorption, bulkiness is from low relatively bulk to high relatively bulk; Tearing strength from low tearing strength to high tearing strength; Elasticity extends from non-resilient elasticity at least 100%, chemical resistance from low relatively resistance to high resistance, chemicals and many other variable elements that this depends on consideration are described as shielding properties, alkali resistance, opacity, wiping properties, water absorption, oil absorption, seepage of water, heat-insulating property, against weather, high strength, high tear edge, anti-grinding, control electrostatic capacity, drapability, dyestuff affinity, safety etc. usually.Usually, depend on precursor net 20 elongation of fiber characteristics, device 100 size can change with production and has fleece 1 with second area 4 bonded wide size ranges, comprises height h (as shown in figure 22) and spacing (area density that comprises the second area 4 that disperses).
Fleece 1 can be used for multiple use, comprises various filters for example air filter, bag filter, liquid filter, vacuum filter, drain filter and antibacterial air filter; The thin slice such as capacitor release paper and the floppy disk packaging material that are used for multiple electrical equipment; Fabricbase adhesive tape, oil absorption material and tarred brown paper that various industrial thin slices for example are clamminess; Various cleaning piece thin slices for example household wipes, service and medical treatment, print roller cleaning piece, cleaning photocopier cleaning piece and be used for the cleaning piece of optical system; Health and personal cleansing wipe thing be baby wipes, women's cleaning piece, facial cleaning piece or health cleaning piece for example; Various medical treatment and health thin slice for example in operation dress, bed gown, tarpaulin, medicated cap, mask, coverlet, towel, gauze, fabricbase paste, diaper, diaper cores, diaper acquisition layer, the diaper, diaper cover, fabricbase rubber plaster, wet tissue and thin paper; Various cloth sheets are lining cloth, pad, jump liner and disposable underclothes for example; Various life material sheets are cloth based artificial leather and synthetic leather, desktop, wallpaper, shoji-gami (paper that is used for the paper screen), blind window, calendar, wrapping paper, desiccant package, shopping bag, garment bag and pillowcase for example; Various agriculture thin slices for example milch cow carpet, cooling and screening sunlight cloth, lining curtain, the thin slice, brake sack and the anti-blade that are used for covering, insecticide comprehensively packaging material, be used for the lining paper of the jar of seed growth; Various protection thin slices are smoke mask and dust mask, lab-gown and dustproof clothes for example; The various thin slices that are used for civil engineering work are building dampproofing paper, adrainage material, optical filtering media, parting material, covering, roof Material, tuft and carpet backing, pars intramuralis material, sound insulation or vibration-damping sheet and maintenance thin slice for example; And various automotive interior thin slices for example also have car mat and Che Nei pad blanket the isolation thin slice in alkaline battery, cast roof material, the headstock and lining cloth.
Figure 21 is the displaing micro picture of terry cloth-like adhesive-bonded fabric net 1, and this Netcom crosses method of the present invention and makes with the roller shown in Fig. 9 and 10 104, and is used as the parts (as following shown in Figure 23) of disposable absorbent article.The precursor net 20 that is used for fleece shown in Figure 21 1 is spunbond non-woven material, and it has the quantitative of about 80gsm, and comprises the about 33 microns polyethylene/polypropylene of average diameter (sheath/caryogram) bicomponent fibre.Figure 21 fleece 1 every square centimeter have about 24 the distortion 6, and with tangible flap folded to clearly show that a plurality of isolated, ring-type distortion 6 of rising bunch, this distortion has many looped, aligned fibers 8, and the fiber diameter of each this fiber is about 18 microns.
The size that single distortion 6 usefulness show is shown among Figure 22.As shown in figure 10, for the described fleece of Figure 22, the void area 10 of the ring-type distortion 6 that rises bunch typically shape is generally circular or oval, and has the key dimension that is called height h, and this highly is 1mm at least.It has been generally acknowledged that height is not crucial for fibroreticulate operation, but it can change according to the final use of required fleece 1.Height h is that 0.1mm is to about 10mm or more.Be formed at nonwoven precursor net 20 and have height h that the fleece 1 of the look and feel of towelling should have and be about 1mm about 3mm extremely.
The fibroreticulate representative dimensions that following table 1 illustrates representative device and makes thereon.
Table 1: the embodiment of plant bulk parameter and fleece size
| Sample number into spectrum | The precursor net | Section is apart from (P)＜mm〉(inch) | Engagement (E)＜mm〉(inch) | Tooth height (TH)＜mm〉(inch) | Collar height (h) (mm) | The fiber diameter of precursor net (μ m) | The fiber diameter of fibrae circulares (μ m) |
| 1 | The nuclear of the 80gsm/spunbond PE/PP of sheath type | <1.5> (0.060) | <3.4> (0.135) | <3.7> (0.145) | 1.07 | 33 | 18 |
| 2 | The nuclear of the 80gsm/spunbond PE/PP of sheath type | <1.5> (0.060) | <2.2> (0.085) | <3.7> (0.145) | 0.49 | 31 | 23 |
| 3 | The spunbond PE/PP copolymer of 60gsm | <1.5> (0.060) | <3.4> (0.135) | <3.7> (0.145) | 1.10 | 23 | 14 |
| 4 | The spunbond PE/PP copolymer of 60gsm | <1.5> (0.060) | <3.4> (0.135) | <3.7> (0.145) | 1.41 | 28 | 15 |
In the superincumbent table 1, all sample standard deviations are available from BBA Fibrous, non-woven webs, Simpsonville, SC.Sample 1 and 2 is with trade name
Sell.Sample 3 and 4 is with trade name Softspan
Sell.
Figure 23 illustrates the plane graph that catamenial articles (in particular to sanitary towel) part is cut away, and fleece 1 of the present invention is as one of this article component.Usually, sanitary towel 200 comprise egative film 202, top flat 206 and be arranged on top flat 206 and egative film 202 between absorbent cores 204, this absorbent cores can be connected the periphery 210 around.Sanitary towel 200 can have the side extension, so-called " flank " 208, and it is designed to wrap up the side of the short crotch area of sanitary towel's 200 user.The top flat 206 of sanitary towel 200 is included in its fleece 1 that has distortion 6 on the bodyside.Alternatively, can distortion 6 with the side 12 opposite towards bodyside on, and second side 14 be a use fleece 1 under the condition of bodyside.Can make interruption 16 transmit fluids like this and enter distortion 6.Sanitary towel's (comprising as its top flat towards body surface) is well known in the art, needn't describe various alternative and optional designs in detail.Other catamenial articles, for example panty liners, interlabial devices also will have the similar structure with sanitary towel.Notice that fleece 1 can be used as one or more egative films, core material, top flat, inferior top flat or flank material, perhaps can be used as their parts.For example, fleece 1 can have multilamellar and comprise the top flat of health product, inferior top flat, core and/or egative film.
Can utilize fleece 1 as the absorbent cores in the health product.Fleece 1 in the absorbent cores can have high relatively quantitatively also/or constitute by which floor.Specifically, absorbent cores can comprise the fleece with respect to the X-Y plane randomly oriented fiber.This core will comprise first surface and second surface.First surface will comprise a plurality of zone of dispersions that fiber is directed again.Each zone of dispersion has longitudinal axis is limited to the linear orientation in the X-Y plane and comprises plurality of fibers, and described pars fibrosa redirects in the direction that is orthogonal to described X-Y plane substantially.
The complex that also can utilize fleece 1 or comprise fleece 1 is as the feces memory element.When below fleece that fleece 1 is arranged on perforate or the thin film, can utilize its as time top flat or sublevel to accept and to hold low viscous feces or the heavy-gravity body excretions that leaves wearer's skin behind the defecation.The present invention is in fleece or be out of shape the ability that the embodiment that has bigger total three-D volumes between 6 provides stronger storage low viscosity fecal material pass usually.Utilize the absorbent article of this feces memory element or sublevel to be described in inter alia United States Patent (USP) 5,941,864; 5,957,906; 6,018,093; In 6,010,491,6,186,992 and 6,414,215.
Figure 24 illustrates the perspective view that menstruation tampon 300 parts are cut away, and fleece 1 of the present invention is as one of this article component.Usually, tampon 300 comprises the covering wrappage 304 of the fluid penetrable of compressed absorbent core 302 and covering absorbent cores 302.Cover that wrappage 304 is extensible to be surpassed an end of absorbent cores 302 and form shirt rim part 306.Can provide to remove and remove after parts such as cord 308 use with convenient and healthy bolt.Tampon (comprising the covering wrappage that touches the surface as its body) is well known in the art, needn't describe various alternative and optional designs in detail.Yet, notice that fleece 1 can be used as one or more covering wrappages, absorbent core material or removes component materials, perhaps can be used as their parts.
Another advantage of described production web processes of the present invention is that this fleece can be with other web production equipment online production or with the online production of disposable absorbent article production equipment.In addition, also having other solid-state formation method used before or after the inventive method.For example, can process part or all fleece as described herein, use the drawing process perforate then, for example be described in the method in the United States Patent (USP) 5,658,639 of authorizing people such as Curro.Alternatively, can materials processing be become complex, for example be described in the U.S. that authorizes people such as Curro and announce 2003/028 by several different methods, 165A1, perhaps annular rolling is for example authorized people's such as Weber United States Patent (USP) 5,167,897, process as described herein then.Therefore the gained fleece can show the beneficial effect with these multiple material modified combinations.
As what understand, can under the situation that does not deviate from protection scope of the present invention, produce many various fleeces 1, as in additional claims, being subjected to those of claims protection by the top description of fleece of the present invention 1 and device 100.For example, fleece 1 can be used distillate medicinal water, medicament, cleaning fluid, antiseptic solution, emulsion, aromatic, surfactant coated or processing.Similarly, device 100 can be set for only and be out of shape 6, perhaps form the size or the area density of the variation of distortion 6 in the part formation of fleece 1.
The relevant portion of all documents of quoting in detailed Description Of The Invention is incorporated herein by reference; It is to its approval as prior art of the present invention that the quoting of any document not can be regarded as.
Although illustrate and described specific embodiments of the present invention, it will be apparent to those skilled in the art that many other variations and modifications may be made in the case of without departing from the spirit and scope of protection of the present invention.Therefore in additional claims, comprise all such changes and modifications in the scope of the invention consciously.
Claims (27)
1. a fleece (1), described fleece (1) comprises first area (2) and at least one discrete integral second region (4), described fleece has the planar vertical and horizontal of the MD-CD of qualification, at least a portion of described second area (4) is for being interrupted (16), described interruption (16) shows to have linear orientation and limit longitudinal axis (L) in the MD-CD plane, and another part is distortion (6) at least, described distortion (6) comprises that many become one but from described first area (2) extended clustered fiber (8 with described first area (2), 18), described second area is by mechanically deform, in the described distortion with the recessed axis (L) along the longitudinal of described interruption.
2. fleece as claimed in claim 1, wherein said fleece comprises a plurality of discrete integral second region.
3. fleece as claimed in claim 2, wherein said a plurality of discrete integral second region are evenly distributed on the described fleece.
4. fleece as claimed in claim 1, wherein said fleece comprises the non-woven web of basic randomly oriented fiber.
5. fleece as claimed in claim 2, wherein said fiber comprise the material that is selected from cellulose, artificial silk, Cotton Gossypii, polyethylene, polypropylene, polyester and their blend.
6. fleece as claimed in claim 2, wherein said fiber comprises bicomponent fibre.
7. fleece as claimed in claim 2, wherein said fiber comprises non-circular fiber.
8. fleece as claimed in claim 1, wherein said fleece comprises at least 10 discrete integral second region for every square centimeter.
9. fleece as claimed in claim 1, the part of wherein said clustered fiber with the clearance gap area limiting in described second area inside.
10. cleaning piece, described cleaning piece comprises the described fleece of claim 1.
11. one kind softish, tufted fibrous web (1), described fleece (1) comprises the fiber of basic random orienting, described fleece has the planar vertical and horizontal of the MD-CD of qualification, described fleece (1) comprises first area (2) and a plurality of discrete second area (4), at least a portion of each described second area (4) is for being interrupted (16), described interruption (16) shows to have linear orientation and limit longitudinal axis (L) in the MD-CD plane, and another part is distortion (6) at least, wherein said distortion (6) comprises and becoming one with described first area (2) but from described first area (2) extended fiber (8,18) and neither become one also not from the extended fiber in described first area (2) (11) with described first area (2), described second area is by mechanically deform, in the described distortion with the recessed axis (L) along the longitudinal of described interruption.
12. fleece as claimed in claim 11, wherein said fiber comprise the material that is selected from cellulose, artificial silk, Cotton Gossypii, polyethylene, polypropylene, polyester and their blend.
13. fleece as claimed in claim 12, wherein said fiber comprises bicomponent fibre.
14. fleece as claimed in claim 12, wherein said fiber comprises non-circular fiber.
15. fleece as claimed in claim 11, wherein said fleece comprises at least 10 discrete integral second region for every square centimeter.
16. a cleaning piece, described cleaning piece comprise the described fleece of claim 11.
17. disposable absorbent article, described goods have at least one parts, described goods comprise fleece (1), described fleece (1) comprises first area (2) and a plurality of discrete integral second region (4), described fleece has the planar vertical and horizontal of the MD-CD of qualification, at least a portion of described second area (4) is for being interrupted (16), described interruption (16) shows to have linear orientation and limit longitudinal axis (L) in the MD-CD plane, and another part is distortion (6) at least, described distortion (6) comprises that many become one but from described first area (2) extended clustered fiber (8 with described first area (2), 18), described second area is by mechanically deform, in the described distortion with the recessed axis (L) along the longitudinal of described interruption.
18. goods as claimed in claim 17, wherein said goods are selected from catamenial articles, tampon or diaper.
19. goods as claimed in claim 17 comprise that described fleece is as top flat.
20. goods as claimed in claim 17 comprise that described fleece is as absorbent cores.
A 21. multi-layered web (1), described fleece has the planar vertical and horizontal of the MD-CD of qualification, described fleece (1) comprises the upper and lower at least, described multi-layered web also comprises first area (2) and a plurality of discrete integral second region (4), at least a portion of described second area (4) is for being interrupted (16), described interruption (16) shows to have linear orientation and limit longitudinal axis (L) in the MD-CD plane, and another part is distortion (6) at least, described distortion (6) comprises that many become one but from described first area (2) extended clustered fiber (8 with described first area (2), 18), wherein said distortion (6) comprises described upper strata at least, described second area is by mechanically deform, in the described distortion with the recessed axis (L) along the longitudinal of described interruption.
22. fleece as claimed in claim 21, each includes the non-woven web of basic randomly oriented fiber wherein said the upper and lower.
23. fleece as claimed in claim 21, wherein said fiber comprise the material that is selected from cellulose, artificial silk, cotton, polyethylene, polypropylene, polyester and their blend.
24. one kind comprises fibroreticulate absorbent cores, described fleece has the planar vertical and horizontal of the MD-CD of qualification, described fleece comprises the fleece with respect to described MD-CD plane randomly oriented fiber, described absorbent cores comprises first surface and second surface, fiber redirects a plurality of zone of dispersions on described first surface at least, each described zone of dispersion has longitudinal axis (L) is limited to linear orientation in the described MD-CD plane, and comprise plurality of fibers, described fiber has the part that redirects being orthogonal to the planar direction of described MD-CD substantially, described second area is by mechanically deform, in the described distortion with the recessed axis (L) along the longitudinal of described interruption.
25. absorbent cores as claimed in claim 24, wherein said a plurality of zone of dispersions are only on described first surface.
26. absorbent cores as claimed in claim 24, wherein said zone of dispersion comprises the fiber that extends to described second surface from described first surface.
27. absorbent article, described absorbent article comprises top flat, egative film and be arranged on described top flat and described egative film between absorbent cores, described absorbent cores comprises fleece, described fleece has the planar vertical and horizontal of the MD-CD of qualification, described fleece comprises with respect to described MD-CD plane randomly oriented fiber, described absorbent cores comprises first surface and second surface, fiber redirects a plurality of zone of dispersions on described first surface at least, each described zone of dispersion has longitudinal axis (L) is limited to linear orientation in the described MD-CD plane, and comprise plurality of fibers, described fiber has the part that redirects being orthogonal to the planar direction of described MD-CD substantially, described second area is by mechanically deform, in the described distortion with the recessed axis (L) along the longitudinal of described interruption.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US32466102A | 2002-12-20 | 2002-12-20 | |
| US10/324,661 | 2002-12-20 | ||
| US10/435,996 | 2003-05-12 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1722998A CN1722998A (en) | 2006-01-18 |
| CN100522119C true CN100522119C (en) | 2009-08-05 |
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ID=35912801
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNB2003801069663A Expired - Fee Related CN100396271C (en) | 2002-12-20 | 2003-12-16 | Cloth-like personal care articles |
| CNB2003801054827A Expired - Fee Related CN100384621C (en) | 2002-12-20 | 2003-12-16 | Inverse textured web |
| CN200380105487A Expired - Fee Related CN100579495C (en) | 2002-12-20 | 2003-12-16 | Fixable tufted laminate |
| CNB2003801053773A Expired - Fee Related CN100522119C (en) | 2002-12-20 | 2003-12-16 | Tufted fibrous web |
| CNB2003801050347A Expired - Lifetime CN100564641C (en) | 2002-12-20 | 2003-12-16 | The laminate web of bunch shape |
Family Applications Before (3)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNB2003801069663A Expired - Fee Related CN100396271C (en) | 2002-12-20 | 2003-12-16 | Cloth-like personal care articles |
| CNB2003801054827A Expired - Fee Related CN100384621C (en) | 2002-12-20 | 2003-12-16 | Inverse textured web |
| CN200380105487A Expired - Fee Related CN100579495C (en) | 2002-12-20 | 2003-12-16 | Fixable tufted laminate |
Family Applications After (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNB2003801050347A Expired - Lifetime CN100564641C (en) | 2002-12-20 | 2003-12-16 | The laminate web of bunch shape |
Country Status (2)
| Country | Link |
|---|---|
| CN (5) | CN100396271C (en) |
| ZA (4) | ZA200504229B (en) |
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| ES2545877T3 (en) * | 2007-12-07 | 2015-09-16 | The Procter & Gamble Company | Absorbent core |
| US20100310845A1 (en) * | 2009-06-03 | 2010-12-09 | Eric Bryan Bond | Fluid permeable structured fibrous web |
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| US20100312212A1 (en) * | 2009-06-03 | 2010-12-09 | Eric Bryan Bond | Fluid Permeable Structured Fibrous Web |
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| EP2533744A1 (en) * | 2010-02-11 | 2012-12-19 | The Procter & Gamble Company | Absorbent article comprising fluid handling zones |
| US8308702B2 (en) * | 2010-04-21 | 2012-11-13 | Johnson & Johnson Consumer Companies, Inc. | Foaming porous pad for use with a motorized device |
| US20120238982A1 (en) * | 2011-03-15 | 2012-09-20 | Paul Thomas Weisman | Structured Fibrous Web |
| US20150359400A1 (en) * | 2013-02-26 | 2015-12-17 | Toray Industries, Inc. | Nonwoven fabric |
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| RU2694282C2 (en) * | 2014-12-17 | 2019-07-11 | Прималофт, Инк. | Batting from fiber balls and articles containing such batting |
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| WO2018048845A1 (en) * | 2016-09-09 | 2018-03-15 | The Procter & Gamble Company | Three-dimensional apertured substrates |
| US20200000205A1 (en) * | 2017-02-28 | 2020-01-02 | L'oreal | Nonwoven solid material suitable for topical applications |
| CN110832129B (en) * | 2017-08-31 | 2022-03-22 | 花王株式会社 | Non-woven fabric |
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| KR102606001B1 (en) * | 2018-06-29 | 2023-11-23 | 유니챰 가부시키가이샤 | Liquid-permeable sheets for absorbent articles |
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- 2003-12-16 CN CNB2003801050347A patent/CN100564641C/en not_active Expired - Lifetime
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Also Published As
| Publication number | Publication date |
|---|---|
| CN1722999A (en) | 2006-01-18 |
| ZA200504240B (en) | 2006-02-22 |
| CN100396271C (en) | 2008-06-25 |
| CN100579495C (en) | 2010-01-13 |
| ZA200504231B (en) | 2006-02-22 |
| CN100384621C (en) | 2008-04-30 |
| ZA200504229B (en) | 2006-04-26 |
| CN1720362A (en) | 2006-01-11 |
| ZA200504264B (en) | 2006-04-26 |
| CN1722998A (en) | 2006-01-18 |
| CN1723120A (en) | 2006-01-18 |
| CN1728979A (en) | 2006-02-01 |
| CN100564641C (en) | 2009-12-02 |
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