CN103596533B - 具有降低的吸收芯与底片胶粘的一次性尿布 - Google Patents

具有降低的吸收芯与底片胶粘的一次性尿布 Download PDF

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Publication number
CN103596533B
CN103596533B CN201280028258.1A CN201280028258A CN103596533B CN 103596533 B CN103596533 B CN 103596533B CN 201280028258 A CN201280028258 A CN 201280028258A CN 103596533 B CN103596533 B CN 103596533B
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Prior art keywords
absorbent cores
absorbent
egative film
super
disposable diaper
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CN201280028258.1A
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CN103596533A (zh
Inventor
M·K·希皮
B·埃恩施佩格
E·莱夫勒
E·G·比安基
C·H·克罗伊泽
B·阿里兹蒂
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Procter and Gamble Ltd
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Procter and Gamble Ltd
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Application filed by Procter and Gamble Ltd filed Critical Procter and Gamble Ltd
Priority to CN201610459499.1A priority Critical patent/CN106038075B/zh
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Abstract

本发明涉及具有包括由粘合剂固定的超吸收聚合物颗粒的吸收芯的一次性尿布。所述吸收芯仅在某些附接区中附接到所述一次性尿布的底片以减少透视和所述底片上的张力线形成。

Description

具有降低的吸收芯与底片胶粘的一次性尿布
技术领域
本发明涉及具有包括由粘合剂固定的超吸收聚合物颗粒的吸收芯的一次性尿布。所述吸收芯仅在某些附接区中附接到所述一次性尿布的底片以减少透视和所述底片上的张力线形成。
背景技术
超吸收聚合物材料在一次性尿布中的用途是熟知的。与使用吸收材料如绒毛浆相比,使用超吸收聚合物材料有利于具有较薄吸收芯的一次性尿布,尤其是当一次性尿布为干燥状态下更是如此。
如今,大多数可商购获得的一次性尿布仍具有包含所谓的透气毡(纤维素纤维)和超吸收聚合物颗粒的混合物的吸收芯。吸收芯包括的纤维素纤维一般将超吸收聚合物颗粒保持在原位,因为纤维素纤维卷入颗粒,使得颗粒被捕集在纤维素纤维之间。这一般来讲不导致超吸收聚合物颗粒的完全固定,因为颗粒仍可能具有某些程度的自由度,在纤维素纤维之间的空隙内移动。然而,将超吸收聚合物颗粒保持在期望位置至足够令人满意的程度。
期望使用较大量的超吸收聚合物颗粒,因为它能使吸收芯变薄。然而,在具有大量超吸收聚合物颗粒和少量或没有透气毡的吸收芯中,超吸收聚合物颗粒可不再被原位保持在纤维素纤维之间的空隙,因为超吸收聚合物颗粒对纤维素纤维的比率过高。因此,在具有非常大量超吸收聚合物颗粒(诸如>80%)的吸收芯中,必须将颗粒通过一些其它装置进行固定。一种促进固定作用的方法是使用粘合剂如热熔性粘合剂。热熔性粘合剂可在吸收芯内以细小的纤维性网络形式施用。此外,在具有高百分比超吸收聚合物材料及少量或无透气毡的吸收芯中,超吸收聚合物材料常夹在载体基底之间。载体基底通常是非织造纤维网。
具有相对大量由热熔性粘合剂固定的超吸收聚合物颗粒并具有少量或不具有透气毡的吸收芯具有很少的空隙甚至没有空隙(例如在纤维素纤维中提供的那些)。因此,在其中超吸收聚合物颗粒能够在吸收液体时膨胀的吸收芯内无可利用的“自由空间”。在这些吸收芯中,超吸收聚合物颗粒在溶胀时将施加某些力到非织造纤维网上,其通常包裹并含有超吸收聚合物颗粒。因此,非织造纤维网也将伸长以提供在吸收芯内溶胀超吸收聚合物颗粒所需的附加空间。
已发现,伸长并且有点绷紧的吸收芯当结合到已经附接到穿着者身上的一次性尿布中时,可能引起底片绷紧的外观,导致例如张力线或褶皱的形成。此类绷紧的外观可能引起穿着者的担心,或(如果穿着者是婴儿或幼儿)看护人担心总体质量,尤其是一次性尿布的容量。绷紧的外观可能被认为是一次性尿布已经达到其最大负荷并需要更换的指示,即使事实上仍有相当数量的吸收容量可供利用依然如此。看护人或穿着者可能因此试图更换尿布,即使吸收芯可仍具有吸收更多尿液的容量依然如此。
因此需要具有大量超吸收聚合物颗粒和少量至没有透气毡的吸收芯的一次性尿布,其中当仅部分载入液体时,底片不具有绷紧的外观,尤其是当附接到穿着者身上时更是如此。
发明内容
本发明涉及包括底片、顶片和位于底片与顶片之间的吸收芯的一次性尿布。吸收芯具有纵向和与其垂直的侧向,所述纵向具有纵向轴线,并且所述侧向具有横向轴线,并且吸收芯还具有前区、后区和位于前区与后区之间的裆区,以及前侧向边缘、相对的后侧向边缘和纵向延伸的侧边缘。
吸收芯包括超吸收聚合物颗粒,其被第一芯粘合剂固定。根据以下选项之一将吸收芯附接到底片:
吸收芯在邻近吸收芯的前侧向边缘和后侧向边缘的附接区中附接到一次性尿布的底片,并且吸收芯不在任何其它区域中附接到底片;或
吸收芯在吸收芯的裆区,在吸收芯的纵向轴线上或邻近其的一个或多个附接区中附接到一次性尿布的底片,其中一个或多个附接区覆盖0.2%至3%的吸收芯总表面区域,并且吸收芯不在任何其它区域中附接到底片;或
吸收芯在吸收芯的裆区,在邻近吸收芯的纵向侧边缘的附接区中附接到一次性尿布的底片,并且吸收芯不在任何其它区域中附接到底片;或
吸收芯在a)至c)的任何附接区的组合中附接到一次性尿布的底片,并且吸收芯不在任何其它区域中附接到底片。
附图说明
图1是根据本发明实施例的一次性尿布的平面示意图。
图2是沿图1的截线2-2截取的图1所示一次性尿布的截面图。
图3是根据本发明实施例的吸收芯层的局部剖面示意图。
图4为根据本发明实施例的吸收芯的局部剖面示意图。
图5是根据本发明实施例的吸收芯的局部截面示意图。
图6是用于执行测试方法以可视化底片透视的适用系统的示意性剖视图。
图7是用于执行测试方法以可视化底片透视的设备成像系统图形的示意图。
图8是在测试方法中用于可视化底片透视(前视图)的砝码的示意图。
图9是在测试方法中用于可视化底片透视(侧视图)的砝码的示意图。
具体实施方式
定义
“吸收芯”是指设置在一次性尿布的顶片与底片之间以用于吸收和容纳由一次性尿布所接收的液体的结构。
本文所用“透气毡”是指粉碎的木浆,其为纤维素纤维(吸收纤维)的形式。
“尿布”是指一般被婴儿和失禁患者围绕下体穿着以便环绕穿着者的腰部和腿部并且特别适于接收和容纳尿液和粪便的吸收制品。对于本发明,认为术语“尿布”涵盖“尿布裤”。
本文所用术语“尿布裤”是指为婴儿或成人穿着者设计的具有腰部开口和腿部开口的一次性衣服。通过将穿着者的腿伸入腿部开口并将裤拉到围绕穿着者下体的适当位置可将尿布裤穿到使用者身上。尿布裤可使用任何合适的方法来预成形,所述方法包括但不限于利用可重复扣紧的和/或不可重复扣紧的粘结(例如,缝合、焊接、粘合剂、内聚粘合、扣件等)将制品的各部分粘接在一起。尿布裤可沿制品圆周的任何地方预成形(例如,侧扣紧、前腰区扣紧)。术语“尿布裤”也常称为“预扣紧的尿布、”“套穿尿布、”“训练裤、”和“裤”。
“一次性的”以其普通的意义使用,是指在不同时长内的有限数目的使用事件(例如小于10次事件,小于5次事件,或小于2次事件)之后被处理或丢弃的制品。一次性吸收制品最经常在单次使用后被处理。
如本文所用,“热熔性粘合剂”是指与在Alphonsus V.Pocius(Hanserpublishers Munich,1997)的“Adhesion and Adhesives Technology:AnIntroduction”中给定描述一致的粘合剂。本文中,热熔体被定义为由熔体施用的并在固化时获得强度的粘合剂。
如本文所用,“非弹性的”是指如果经受以下测试的话,回复不超过20%的底片:
将具有2.54cm宽度和25.4cm长度的底片材料矩形片(例如膜或非织造材料或(如果底片包括膜和非织造纤维网)两种材料在其中它们用作底片材料的构型中合在一起)沿着其上部2.54cm宽边缘的整个宽度保持在竖直位置。在25℃下将10N的力沿材料的全宽度施加到相对的下边缘上,持续1分钟。
紧接着这一分钟之后,在仍然施加力的情况下测量矩形件的长度,而伸长度通过从一分钟之后测量的长度中减去初始长度(10英寸)来计算。
紧接着在已经测量矩形件的长度之后,将该力移除并且将该件在台面上展平5分钟(在25℃下)以使其能够恢复。在5分钟之后,立即再次测量该件的长度,而伸长度通过从该5分钟之后的长度中减去初始长度(25.4cm)来计算。
比较施加该力一分钟之后的伸长和该件在台面上展平5分钟之后的伸长。如果伸长不能恢复超过20%,则认为该材料或元件为“非弹性的”。
本文所用“高度非弹性的”是指如下的材料或元件:如果经受上文对于“非弹性的”所作的测试,则其或为“不可延展的”或不能恢复超过10%。
“非织造纤维网”为定向或任意取向的纤维通过摩擦和/或内聚力和/或粘附力而粘结,或通过湿磨法而毡化的制造的片或纤维网,不包括纸材和通过织造、编织、簇成、缝编而合并束缚的纱或长丝产品,不考虑是否另外缝过。这些纤维可具有天然的或人造的来源,并且可为短纤维或连续长丝或为就地形成的纤维。可商购获得的纤维具有的直径范围为小于约0.001mm至大于约0.2mm,并且它们具有几种不同的形式,例如短纤维(已知为化学短纤维或短切纤维)、连续单纤维(长丝或单丝)、无捻连续长丝和加捻连续长丝(纱线)。非织造纤维网可通过许多方法形成,如熔喷法、纺粘法、溶液纺丝、静电纺纱、粗梳法和气流成网法。非织造纤维网可加热和/或加压粘结或可通过粘合剂粘结。粘结可限于非织造纤维网的某些区域(点粘结)。非织造纤维网也可是水刺的或针刺的。非织造纤维网的基重通常用克/平方米(gsm)表示。
如本文所用,“超吸收聚合物颗粒”是指基本上不溶于水的聚合物颗粒,按照离心保留容量测试(Edana441.2-01)方法的测量,该颗粒能够吸收自身重量至少5倍的水中的0.9%盐水溶液。“超吸收聚合物颗粒”是指呈颗粒形式以致在干燥状态下可流动的吸收性聚合物材料。
一次性尿布
图1为如本发明的某个实施例所述的一次性尿布10的平面图。一次性尿布10被示出处于其平展未收缩状态(即无弹性诱导收缩),并且一次性尿布10的一些部分被切除以更清楚地示出一次性尿布10的底层结构。在图1中,一次性尿布10的接触穿着者的部分面对观察者。一次性尿布10一般可包括基础结构12和设置在基础结构12中的吸收芯14。
图1中的一次性尿布10的基础结构12包括一次性尿布10的主体。基础结构12可包括外覆盖件16,所述外覆盖件包括可为液体可透过的顶片18和/或可为液体不可透过的底片20。吸收芯14可包封在顶片18和底片20之间。基础结构12也可包括侧片22、弹性化腿箍24、和弹性腰部结构26。
腿箍24和弹性腰部结构26通常可每个均包括弹性构件28如弹性股线。一次性尿布10的一个端部被构造为一次性尿布10的前腰区30。一次性尿布10的相对的端部被构造为一次性尿布10的后腰区32。一次性尿布10的中间部分被构型为裆区34,裆区在第一腰区30和第二腰区32之间纵向延伸。腰区30和32可包括弹性元件,使得它们围绕穿着者的腰部聚拢以提供改善的贴合性和密封性(弹性腰部结构26)。裆区34为当一次性尿布10被穿着时一般定位在穿着者两腿之间的一次性尿布10的那部分。
一次性尿布10在图1中被描绘成具有其纵向轴线36和其横向轴线38。一次性尿布10的周边40由一次性尿布10的外边缘限定,其中纵向边缘42大致平行于一次性尿布10的纵向轴线36延伸,并且端边44在大致平行于一次性尿布10的横向轴线38的纵向边缘42之间延伸。一次性尿布20还可包括此类本领域已知的其它结构,包括前耳片和后耳片、腰帽结构、弹性部件等以提供更好的贴合性、密封性和美观特性。
为了将一次性尿布10围绕穿着者保持固定,第一腰区30的至少一部分可由扣紧构件46附接到第二腰区32的至少一部分以形成腿部开口和制品腰部。为此,根据某些实施例,一次性尿布10可具有可重新闭合的扣紧系统,或可作为另外一种选择以一次性尿布裤的形式被提供。当吸收制品为一次性尿布时,其可包括接合到基础结构的可重新闭合的扣紧系统以用于将一次性尿布固定到穿着者身上。扣紧系统可包括至少一个扣紧构件46和至少一个着陆区48。当吸收制品为一次性尿布裤时,制品在每个腰区30、32上可包括两个侧片,其沿着面向纵向轴线36的侧片的纵向边缘接合到基础结构。前腰区30的侧片还沿着其远离纵向轴线36的纵向边缘接合到后腰区32的相应侧片以形成裤。
图2显示沿图1的截线2-2截取的图1的横截面:从面向穿着者侧开始,一次性尿布10可包括顶片18、吸收芯14的组件和底片20。一次性尿布10也可包括采集系统50,所述采集系统设置在液体可透过的顶片18和吸收芯14的面向穿着者侧之间。采集系统50可直接接触吸收芯。
采集系统50可包括单一层或多个层(未示出),例如面朝穿着者的上部采集层和面向穿着者衣服的下部采集层。根据某个实施例,采集系统50可用来接收液体涌流,诸如尿液涌流。换句话讲,采集系统50可用作液体的暂时贮存器,直到吸收芯14吸收液体为止。
在某个实施例中,采集系统50可包含化学交联的纤维素纤维和/或非织造纤维网。
吸收芯
本发明的吸收芯具有纵向和与其垂直的侧向,所述纵向具有纵向轴线,并且所述侧向具有横向轴线。纵向轴线基本上平行于一次性尿布的纵向轴线,并且侧向基本上平行于一次性尿布的横向轴线。吸收芯还具有前区、后区和位于前区与后区之间的裆区,以及前侧向边缘、相对的后侧向边缘和纵向延伸的侧边缘。吸收芯可包括第一下部和第二上部载体基底、以及置于第一载体基底上或置于第一和第二载体基底之间的超吸收聚合物颗粒。超吸收聚合物颗粒通过第一芯粘合剂固定。
吸收芯的前区占从吸收芯的前边缘沿着纵向轴线朝裆区延伸的吸收芯的三分之一。前区朝向一次性尿布的前腰边缘放置。后区占从后边缘沿着纵向轴线朝裆区延伸的吸收芯的三分之一。后区朝向一次性尿布的后腰边缘放置。裆区占吸收芯剩余的三分之一,并且在前区和后区之间延伸。将吸收芯的全长定义为吸收芯沿着或平行于吸收芯的纵向轴线的最长延伸。本发明的吸收芯可为矩形。
在一个实施例中,层压吸收芯的裆区具有比吸收芯前区和后区更窄的宽度,而吸收芯的前边缘和后边缘仍形成直线。
在一个实施例中,将超吸收聚合物颗粒66设置在第一载体基底64上,并且将第一芯粘合剂94设置在超吸收聚合物颗粒66上。通常第一芯粘合剂94是热熔性粘合剂。在一个实施例中,第一芯粘合剂94形成纤维层,其至少部分接触超吸收聚合物颗粒66并且部分接触第一和第二载体基底64。可在施用超吸收聚合物颗粒66之前将第二芯粘合剂(未示出)沉积在第一载体基底64上以增强超吸收聚合物颗粒66和/或第一芯粘合剂94与第一载体基底64的粘附性。
可设定第一载体基底64的尺寸,使得在已经施用超吸收聚合物颗粒66和第一94后,第一载体基底64自身折叠,超吸收聚合物颗粒66和第一芯粘合剂94面朝内,并且第一载体基底64围绕超吸收聚合物颗粒66和第一芯粘合剂94。折叠的第一载体基底64区域在折叠前可不含超吸收聚合物颗粒66和第一芯粘合剂94。作为另外一种选择,折叠的第一载体基底64区域也可包括超吸收聚合物颗粒66和第一芯粘合剂,使得在折叠时两层超吸收聚合物颗粒66彼此重叠,并且第一芯粘合剂被夹在这两层超吸收聚合物颗粒之间。超吸收聚合物颗粒66可成簇使用以形成下文详述的着陆区域92和接合区域96。也可仅将第一芯粘合剂94施用于那些区域,其中第一载体基底64是折叠的。在折叠时,第一芯粘合剂94也将接触该未折叠区域的超吸收聚合物颗粒66,从而固定这个区域的超吸收聚合物颗粒66。
作为折叠第一载体基底64的另外一种选择,吸收芯14也可包括第二载体基底72。在另一个实施例中,吸收芯不包括第二载体基底。在这个实施例中,置于吸收芯14顶部的一次性尿布10的组件直接接触超吸收聚合物颗粒66和第一芯粘合剂94。
第一载体基底64在一次性尿布10的使用中面朝穿着者的衣服,并且任选的第二载体基底72在一次性尿布的使用中面朝穿着者。任选的第二载体基底72可为非织造纤维网,或可为薄纸。第一载体基底64可为非织造纤维网,或可为薄纸或膜。第一和第二载体基底64、72可由相同的材料制成,或它们可由不同的材料制成。在其中第一和第二载体基底64、72均为非织造纤维网的实施例中,这些非织造纤维网可为相同的非织造纤维网或它们可彼此不同,例如参照它们的基重、亲水性、透气率或非织造纤维网包括的层数和/或类型。层类型可为纺粘层或熔喷层。非织造纤维网也可为由短纤维制成的梳理纤维网,并且梳理纤维网可包括或可不包括粘合剂材料。非织造纤维网也可是水刺的或针刺的。
吸收芯14可基本上不含透气毡。吸收芯14通常包括按重量计少于5%的透气毡,更典型地按重量计少于2%的透气毡,并且最典型地不含透气毡。吸收芯不包括一次性尿布10的采集系统50、顶片18、或底片20。在一个实施例中,吸收芯14将基本上由第一和任选的第二载体基底64、72、超吸收聚合物颗粒66、第一芯粘合剂94、以及任选地第二芯粘合剂组成。在这个方面“基本上由…组成”是指这些组件构成按重量计至少98%的吸收芯,优选地按重量计至少99%的吸收芯。
超吸收聚合物颗粒66可基本上连续分布在吸收芯14的超吸收聚合物颗粒区域内。如本文所用,“超吸收聚合物颗粒区域”是指包括超吸收聚合物颗粒的吸收芯区域(在面向穿着者的表面上)。邻近吸收芯的纵向侧边缘的区域和邻近吸收芯的前侧向边缘与后侧向边缘的区域可不含超吸收聚合物颗粒以使第一载体基底64的边缘附接到任选的第二载体基底72的边缘上(或在不含第二载体基底64非情况下,第一载体基底的边缘可附接到吸收芯14之上的层上,例如采集系统50的层)。吸收芯14也可包括通道,即,基本上包含超吸收聚合物颗粒66的区域,并且其不邻近吸收芯14的边缘,而是位于一些其它位置。如本文所用,“基本上不含超吸收聚合物颗粒”是指例如由于方法相关的原因,少量的、可忽略不计量的超吸收聚合物颗粒可存在于间隙中,然而其不影响总体功能。术语“基本上不含超吸收聚合物颗粒”涵盖“不含超吸收聚合物颗粒”。然而对于本发明,“超吸收聚合物颗粒区域”包括至少80%的吸收芯表面区域,优选地至少85%或至少90%的吸收芯表面区域。
如本文所用,“基本上连续分布”是指在超吸收聚合物颗粒区域内,第一载体基底64和任选的第二载体基底72(或第一基底和在面朝穿着者的吸收芯14顶部提供的层,例如采集系统50的层)通过多个超吸收聚合物颗粒66分开。已经认识到在超吸收聚合物颗粒区域内的第一载体基底64和第二载体基底72(或第一载体基底64和在面朝穿着者的吸收芯14顶部提供的组件,例如采集系统50)之间可有微量附带的接触。此类附带的接触区域是无意中产生的人工制造痕迹。
本发明的吸收芯可包括两层(或可由两层)组成。第一吸收芯层60在图3中示出。图4示出吸收芯的实施例,其中第一和第二吸收芯层60、62已经组合在一起以形成吸收芯14。图5示出仅由一层组成的吸收芯的实施例。
在具有第一和第二吸收芯层的实施例中,第一吸收芯层60可包括第一载体基底64和第一层超吸收聚合物颗粒66,其中超吸收聚合物颗粒66由第一芯粘合剂94固定。任选地,第一吸收芯层60可包括第二芯粘合剂(未示出)。可在施用超吸收聚合物颗粒66之前将第二芯粘合剂沉积在第一载体基底64上以增强超吸收聚合物颗粒66和/或第一芯粘合剂94与第一载体基底64的粘附性。第一芯粘合剂94可施用于超吸收聚合物颗粒层上成为纤维层,优选地使得纤维性网络形成。
此类实施例的第二吸收芯层62包括第二载体基底72和第二层超吸收聚合物颗粒66,其中超吸收聚合物颗粒66可由第一芯粘合剂94固定。任选地,第二吸收芯层62可包括第二芯粘合剂(未示出)。可在施用超吸收聚合物颗粒66之前将第二芯粘合剂沉积在第二载体基底72上以增强超吸收聚合物颗粒66和/或第一芯粘合剂94与第二载体基底72的粘附性。第一芯粘合剂94可施用于超吸收聚合物颗粒层上成为纤维层,优选地使得纤维性网络形成。
一旦形成第一和第二吸收芯层60、62,两个吸收芯层与它们面朝外的相应载体基底64、72组合并将超吸收聚合物颗粒66夹在它们之间以形成吸收芯14。
在一个实施例中,将另外的基底(未示出)如薄纸或非织造纤维网定位在第一和第二吸收芯层之间。然而,优选地不将此类基底定位在第一和第二吸收芯层之间,并且第一层超吸收聚合物颗粒与第二层超吸收聚合物颗粒分开,仅有第一芯粘合剂的纤维层。
图3示出单个吸收芯层。超吸收聚合物颗粒66沉积在颗粒簇90中的第一载体基底64上,包括着陆区域92和在着陆区域94之间的接合区域96。在着陆区域94中,第一芯粘合剂94不直接接触第一载体基底64或任选的第二芯粘合剂;接合区域96是其中第一芯粘合剂94直接接触第一载体基底64或任选的第二芯粘合剂的区域。接合区域96含有少量或不含超吸收聚合物材料66。着陆区域94和接合区域96可具有多种形状,所述形状包括但不限于圆形、椭圆形、正方形、矩形、三角形等等。
通过施用第一芯粘合剂94成纤维层,第一芯粘合剂94并入超吸收聚合物颗粒66,从而固定该颗粒。在另一方面,第一芯粘合剂94粘结到载体基底64并从而将超吸收聚合物颗粒66附连到载体基底64。在另一个实施例中,第一芯粘合剂68也可在某种程度上渗入载体基底64中,从而提供进一步的固定和附连。
如上文所述,第一和第二载体基底64和72可彼此用粘合剂沿周边附连以形成围绕超吸收聚合物颗粒66的包封,用于将超吸收聚合物颗粒66保持在吸收芯14内。
如图4最佳所示,第一和第二吸收芯层60和62组合形成吸收芯14。
第一和第二吸收芯层60和62可组合在一起以形成吸收芯14,其吸收芯层偏置,使得在第一载体基底64上的超吸收聚合物颗粒66和在第二载体基底72上的超吸收聚合物颗粒66的组合基本上连续地分布在整个超吸收聚合物颗粒区域中。在某个实施例中,超吸收聚合物颗粒66基本上连续地分布在整个超吸收聚合物颗粒区域中,而相应的单独第一和第二吸收芯层的超吸收聚合物颗粒66非连续地分布在簇90内的整个第一和第二载体基底64和72中。在某个实施例中,这些吸收芯层可为偏移的而使得第一吸收芯层60的着陆区域92面对第二吸收芯层62的接合区域96,并且第二吸收芯层62的着陆区域92面对第一吸收芯层60的接合区域96。当适当地将着陆区域92和接合区域96设定尺寸并布置时,所得超吸收聚合物颗粒66的组合是遍及吸收芯14的超吸收聚合物颗粒区域的基本上连续的超吸收聚合物颗粒层。
根据本发明,超吸收聚合物颗粒通常存在的量为按吸收芯重量计大于约85%,或按吸收芯重量计大于约90%,或按吸收芯重量计大于约95%。超吸收聚合物颗粒存在的量也可大于95%的吸收芯所包括的吸收材料。吸收芯可包括少于5%的透气毡(即,纤维素纤维)。典型的吸收材料是超吸收聚合物颗粒、透气毡(即,纤维素纤维)和(较少用到的)吸收泡沫。通常吸收芯包括50g/m2至2200g/m2的超吸收聚合物颗粒,100g/m2至1500g/m2或甚至200g/m2至1200g/m2的超吸收聚合物颗粒。
根据本发明,超吸收聚合物颗粒的量可沿着吸收芯的长度变化或不变,通常吸收芯在其纵向上异形。已发现,对于一次性尿布,液体排泄主要发生在一次性尿布的前半部中。因此吸收芯14的前半部应包括吸收芯的大部分吸收容量。因此,吸收芯14的前半部可包括按重量计大于约60%的吸收芯包括的超吸收聚合物颗粒总量,或按重量计大于约65%,按重量计70%,按重量计75%,按重量计80%,按重量计85%,或按重量计90%的超吸收聚合物颗粒。
通常第一芯粘合剂可用于至少部分地固定干燥和润湿状态下的超吸收聚合物颗粒。第一芯粘合剂可基本上均匀设置在超吸收聚合物颗粒之间的吸收粒状聚合物颗粒内。然而,通常第一芯粘合剂94可以纤维层形式提供,其至少部分地接触超吸收聚合物颗粒66并且部分地接触第一载体基底64以及(如果存在的话)任选的第二载体基底72。第一芯粘合剂94通常在每个吸收芯层的超吸收聚合物颗粒66上形成纤维性网络。如图4所示,超吸收聚合物颗粒66可以不连续层形式提供,并且一层第一芯粘合剂94铺在超吸收聚合物颗粒66和74的层上,使得第一芯粘合剂94在其中载体基底64、72不被超吸收聚合物颗粒66覆盖的位置内直接接触超吸收聚合物颗粒66,但是也直接接触面朝吸收芯14的超吸收聚合物颗粒66的载体基底64和72的表面80和84。这赋予第一芯粘合剂94的纤维层基本三维的结构,所述结构本身与长度方向和宽度方向上的尺度相比为具有相对小厚度的基本二维的结构。换句话讲,第一芯粘合剂94在超吸收聚合物颗粒66和面朝吸收芯14的超吸收聚合物颗粒的载体基底64和72的表面80、84之间起伏。
第一芯粘合剂94可提供用于覆盖超吸收聚合物颗粒的洞,从而固定这种材料。在另一方面,第一芯粘合剂粘结到载体基底并从而将超吸收聚合物颗粒附连到载体基底。当然,虽然本文所公开的第一芯粘合剂提供改善的湿固定作用(即,当一次性尿布和吸收芯至少部分润湿时固定超吸收聚合物颗粒),但这些第一芯粘合剂当吸收芯干燥时也可提供对超吸收聚合物颗粒的良好固定。
超吸收聚合物颗粒
超吸收聚合物颗粒可为多种形状。术语“颗粒”是指颗粒、纤维、薄片、球体、粉末、薄板、以及在超吸收聚合物颗粒领域中技术人员已知的其它形状和形态。例如,颗粒可为颗粒或小珠形式,具有约10μm至约1000μm,优选约100μm至约1000μm,甚至更优选约150μm至约850μm,并且最优选约150μm至约500μm的粒度。在另一个实施例中,超吸收聚合物颗粒可为纤维形状,即,细长的针状超吸收聚合物颗粒。在那些实施例中,超吸收聚合物纤维具有小于约1mm,通常小于约500μm,并且优选小于250μm至至少50μm的小尺度(即纤维的直径)。纤维的长度优选地为约3mm至约100mm。纤维也可是被织造的长丝的形式。
本发明优选的超吸收聚合物颗粒是球形颗粒。根据本发明,并且与纤维相反,“球状颗粒”具有最长和最小尺寸,并且颗粒的最长和最短颗粒尺寸之比在1-5的范围内,其中值1等于完美的球状颗粒,而值5将使得与此类球状颗粒有一些偏差。
可用于本发明中的超吸收聚合物颗粒材料包括多种水不溶性却水可溶胀的能够吸收大量流体的聚合物。这些聚合物材料通常已为本领域所知并且包括在一次性吸收制品技术领域内已使用或认为有用的所有那些熟知的聚合物。
用于制作超吸收聚合物颗粒的优选聚合物材料为部分中和的聚丙烯酸及其淀粉衍生物的微弱网状交联聚合物。本发明也涵盖淀粉基超吸收聚合物颗粒。优选地,超吸收聚合物颗粒包含按重量计25%至95%,更优选按重量计50%至80%的中和的、微弱网状交联的聚丙烯酸。网状交联致使聚合物基本上为水不溶性的,并且部分地确定超吸收聚合物颗粒的吸收能力和可萃取的聚合物含量的特性。
虽然超吸收聚合物颗粒优选为一种类型(即均匀的),但是在本发明中也可使用聚合物的混合物。超吸收聚合物颗粒也可包括低含量的一种或多种添加剂的混合物,例如粉末二氧化硅、表面活性剂、粘合剂、基料等。此外,超吸收聚合物颗粒还可具有粒度梯度,或可具有一定范围的粒度。
多种以前已知的超吸收聚合物颗粒表现出凝胶阻塞。当由超吸收聚合物材料制成的颗粒被润湿时出现“凝胶阻塞”,并且颗粒膨胀以至于抑制流体传输到吸收结构的其它区域。因此,吸收芯这些其它区域的润湿借助于一个非常慢的扩散过程发生。实际上,这种用吸收结构采集流体的方法要比流体排出的速率慢得多,尤其是在涌出的情况下。在吸收芯中的超吸收聚合物颗粒接近于完全浸透之前很久或在流体扩散或芯吸通过“结块”颗粒进入吸收芯的其它部位之前一次性尿布就会发生渗漏。
减小凝胶阻塞的一种常用方法是将颗粒制得更硬,这使超吸收聚合物颗粒能够保持它们的原样,从而在颗粒之间产生或保持空隙空间。用于提高刚度的熟知方法是共价和/或离子交联暴露在超吸收聚合物颗粒表面上的羧基。这种方法通常被称为表面交联。
第一和第二芯粘合剂
吸收芯包括的第一和任选的第二芯粘合剂优选地是热熔性粘合剂。在某些不优选的实施例中,第一芯粘合剂是热熔性粘合剂,而第二芯粘合剂可为另一种类型的粘合剂。吸收芯的第一芯粘合剂加上任选的第二芯粘合剂的平均基重可为0.5g/m2至30g/m2,1g/m2至15g/m2,1g/m2至10g/m2或甚至1.5g/m2至5g/m2
第一芯粘合剂用于至少部分地固定吸收芯的干燥和润湿状态下的超吸收聚合物颗粒。
不受理论的约束,已发现那些热熔性粘合剂最适用于固定超吸收聚合物颗粒,它们兼有良好的内聚性能和良好的粘附性能。良好的粘附性可促进热熔性粘合剂和超吸收聚合物颗粒以及载体基底之间的良好接触。良好的内聚力可减小粘合剂中断的可能性,尤其是响应于外力,即响应于应变而中断的可能性。当吸收芯吸收液体时,超吸收聚合物颗粒溶胀并使热熔性粘合剂经受外力。热熔性粘合剂可允许此类溶胀,而不会中断且不会赋予过多的压缩力,所述压缩力将抑制吸收性粒状聚合物颗粒的溶胀。
根据本发明,热熔性粘合剂可包括(在其整体中)单一热塑性聚合物或热塑性聚合物的共混物,当通过ASTM方法D-36-95“Ring and Ball”测定时,所述聚合物具有在介于50℃和300℃之间的范围内的软化点,或作为另外一种选择,热熔性粘合剂可包括至少一种与其它热塑性稀释剂诸如增粘树脂、增塑剂和添加剂诸如抗氧化剂组合的热塑性聚合物。
在某些实施例中,热塑性聚合物一般具有超过10,000的重均分子量(Mw)和通常在室温(25℃)之下,或不到22℃,或不到18℃,或不到15℃的玻璃化转变温度(Tg)。在某些实施例中,Tg可高于0℃>Tg。在热塑性聚合物具有一个以上的Tg的实施例中,所给出的值是指最低的玻璃化转变温度。热塑性聚合物也可具有软化点,如通过ASTM方法D-36-95“Ring and Ball”所确定的那样,其处在介于50℃和300℃之间的范围内。在一些实施例中,热塑性聚合物的Mw小于10000000。
在某些实施例中,热熔性粘合剂中热塑性聚合物的典型浓度按热熔性粘合剂重量计处在约20%至约40%的范围内。
示例性聚合物为包括A-B-A三嵌段结构、A-B两嵌段结构和(A-B)n径向嵌段共聚物结构的(苯乙烯)嵌段共聚物,其中A嵌段为通常包含聚苯乙烯的非弹性体聚合物嵌段,并且B嵌段为不饱和共轭双烯或(部分)氢化的此类变体。B嵌段通常为异戊二烯、丁二烯、乙烯/丁烯(氢化丁二烯)、乙烯/丙烯(氢化异戊二烯)、以及它们的混合物。
可采用的其它合适的热塑性聚合物为茂金属聚烯烃,它们为利用单位点或茂金属催化剂制备的乙烯聚合物。其中,至少一种共聚单体可与乙烯聚合以制备共聚物、三元共聚物或更高级的聚合物。同样适用的是无定形聚烯烃或无定形聚α-烯烃(APAO),它们为C2-C8α烯烃的均聚物、共聚物或三元共聚物。
在示例性的实施例中,增粘树脂通常具有在5,000以下的Mw和通常在室温(25℃)以上的Tg,增粘树脂在热熔体中的典型浓度处在按热熔性粘合剂重量计约30%至约60%范围内。在某些实施例中,增粘树脂具有超过1,000的Mw。
增塑剂具有通常小于1,000的低Mw和在室温以下的Tg,其中典型浓度为按热熔性粘合剂重量计约0%至约15%。在某些实施例中,增塑剂具有超过100的Mw。
在某些实施例中,第一和/或第二芯粘合剂是以纤维形式存在的热熔性粘合剂。在一些实施例中,这些纤维将具有约1微米至约50微米或约1微米至约35微米的平均厚度和约5mm至约50mm或约5mm至约30mm的平均长度。
吸收芯也可包括未在图中示出的第二芯粘合剂。可在施用超吸收聚合物颗粒之前将第二芯粘合剂沉积在载体基底上以增强超吸收聚合物颗粒和第一芯粘合剂与相应载体基底的粘附性。第二芯粘合剂也可有助于固定超吸收聚合物颗粒并且可为与第一芯粘合剂相同或不同的粘合剂。第二芯粘合剂优选地也为热熔性粘合剂。可商购获得的第二芯粘合剂的一个例子是H.B.Fuller Co.(St.Paul,MN)的产品号HL-1620-B。第二芯粘合剂可通过任何合适的方法施加到载体基底,但根据某些实施例,其可按间隔开约0.5至约2mm的约0.5至约1mm宽的狭槽来施加。
吸收芯与底片的附接
如果穿着者使用一次性尿布,一次性尿布将采用弯曲的形状以适形于穿着者(即,尿布将不是展平的,而是弯曲的,尿布的前腰区和后腰区紧贴穿着者的腰放置,并且尿布的裆区紧贴穿着者的裆区放置)。此外,尿布沿着在穿着者腿部之间基本上平行于尿布纵向轴线的线并朝向前腰区发生某种程度的弯曲。此类弯曲导致尿布扣紧,即,尿布在裆区以及至少部分前腰区向外膨胀。
在弯曲施加一次性尿布于穿着者身上时,一次性尿布的表面区域与展平的尿布相比发生如下改变:当面向穿着者的上表面(即,顶片)被拉动并顶张时,面向衣服的下表面(即,底片)伸长。相同的动作施加于一次性尿布内的吸收芯:当面向穿着者的上表面(诸如第二上部载体基底)被拉动并顶张时,面向衣服的下表面(诸如第一下部载体基底)伸长。
在当今市场上的大多数一次性尿布中,吸收芯包括相当大量的纤维素纤维(透气毡)。在这些吸收芯中包括的超吸收聚合物颗粒与纤维素纤维混合,并且从而将颗粒原位保持在纤维素纤维之间的空隙中。一般来讲,不使用粘合剂来固定超吸收聚合物颗粒。总体来说,这些吸收芯具有相当的塑性特性。如果此种尿布发生上述弯曲,当一次性尿布施加于穿着者时,吸收芯内的材料通过在芯内移动纤维素纤维和超吸收聚合物颗粒,能够抵消至少一些上表面的顶张和下表面的伸长。
当一次性尿布变湿并且超吸收聚合物颗粒溶胀并膨胀时,超吸收聚合物颗粒也能够在纤维素纤维的空隙内发生某种程度的溶胀。因此吸收芯作为一个整体的体积增加小于超吸收聚合物颗粒的体积增加,因为干燥吸收芯提供一些自由空间,颗粒能够在其中膨胀。
在包括少量或不包括透气毡并且其中通过粘合剂固定超吸收聚合物颗粒的本发明吸收芯中,吸收芯与上述常规吸收芯相比具有大得多的弹性特性。因为超吸收聚合物颗粒的固定比在纤维素纤维基底内简单混合的超吸收聚合物颗粒的固定强得多,当将一次性尿布施加于穿着者时,超吸收聚合物颗粒不能在吸收芯内移动。因此,面向穿着者的上表面的扣紧以及面向衣服的下表面的伸长比常规的包含透气毡的一次性尿布要明显得多。
因为一次性尿布是润湿的,超吸收聚合物颗粒也溶胀并膨胀。与常规的包含透气毡的吸收芯相反,具有少量透气毡或不含透气毡的吸收芯不在纤维素纤维之间的空隙中提供超吸收聚合物颗粒能够在其中膨胀的任何“自由空间”。因此,吸收芯作为一个整体将比常规吸收芯膨胀并溶胀地早得多(即,在达到吸收芯吸收容量限之前的时间要长得多),并且膨胀程度也大得多。此种膨胀提高了施加于吸收芯的面向衣服的下表面(例如下部载体基底)的应变,并且继而提高了施加于底片的应变。因此,吸收芯的面向衣服的下表面以及底片将在润湿尿布时进一步伸长。
作为面向穿着者的表面伸长的结果,吸收芯被牢固地压在一次性尿布的底片上。在吸收尿液和稀便时,吸收芯发生应变,并且由于在吸收芯与底片之间的紧密接触,污渍可能透过底片可见,尤其是假如底片材料的基重较低和/或假如底片具有很少的或无印刷的话更是如此。这种污渍透视对一次性尿布的消费者接受度具有负面影响,因为它被认为是低质量。此外,常将透视理解为指示湿透,即,认为吸收芯被液体浸透,标志着吸收芯已经达到其最大容量-即使事实上尿布远未达到其最大容量时依然如此。在目测一次性尿布时,也可能发现底片是润湿的。
此外,在底片伸长并应变时,底片趋于弯曲并形成褶皱和张力线。消费者将这些张力线和褶皱理解为一次性尿布达到吸收容量和需要更换尿布的信号。这种效应可能在达到尿布实际容量限之前很早就发生。
发明人已经发现如果改变吸收芯与底片的附接,可减少上文所述的缺点:在常规的包含透气毡的一次性尿布中,以及在可商购获得的具有少量透气毡或不含透气毡的一次性尿布中(例如2011年5月Germany售卖的Pampers“Active Fit”),吸收芯在吸收芯的整个面向衣服的表面上粘附至底片(因此例如吸收芯的第一载体基底)。这不一定是指100%的载体基底表面区域覆盖有粘合剂,但是它可为将粘合剂如热熔性粘合剂以小螺旋形式施用,并且这些螺旋施用于整个载体基底。
如果将吸收芯在基本上整个吸收芯区域之上粘附至底片,吸收芯不能独立于底片而移动并膨胀。因此,因为吸收芯在超吸收聚合物颗粒溶胀时膨胀,底片也必然将膨胀。
已发现,如果不在整个吸收芯表面上将吸收芯附接到底片,可减少这一缺点。如果仅在某些限定区域将吸收芯附接到底片,并且如果仔细地并有目的地选择这些区域,可减少底片中弯曲和褶皱的形成。也可减少来自吸收芯的尿液污渍透过底片的透视。
根据本发明,在任何以下位置将吸收芯附接到底片:
a)吸收芯在邻近吸收芯的前侧向边缘和后侧向边缘的附接区中附接到一次性尿布的底片,并且吸收芯不在任何其它区域中附接到底片;或
b)吸收芯在吸收芯的裆区,在吸收芯纵向轴线上或邻近其的一个或多个附接区中附接到一次性尿布的底片,其中一个或多个附接区覆盖0.2%至3%的吸收芯总表面区域,并且吸收芯不在任何其它区域中附接到底片;或
c)吸收芯在吸收芯的裆区,在邻近吸收芯的纵向侧边缘的附接区中附接到一次性尿布的底片,并且吸收芯不在任何其它区域中附接到底片;或
d)吸收芯在a)至c)中限定的任何附接区的组合中附接到一次性尿布的底片,并且吸收芯不在任何其它区域中附接到底片。
如果根据选项a)将吸收芯附接到底片,邻近吸收芯的前侧向边缘和后侧向边缘的附接区可仅在吸收芯的角处提供,留下邻近吸收芯的前侧向边缘和后侧向边缘的剩余区域不附接到底片。“剩余区域”是指在邻近前侧向边缘和后侧向边缘的区域中70%,或80%的吸收芯宽度。选项a)或d)的一个或多个附接区可覆盖0.2%至3%,优选地0.5%至2%,或0.5%至1.5%,或0.2%至1.5%或0.2%至1%的吸收芯总表面区域。这些百分比是指合在一起的全部附接区。
在根据选项a)的多个实施例中,可在邻近吸收芯的前侧向边缘的一个附接区中和在邻近吸收芯的后侧向边缘的一个附接区中将吸收芯附接到底片,并且可在任何其它区域中不附接到底片。作为另外一种选择,可在邻近吸收芯的前侧向边缘的两个、三个或更多个附接区中和在邻近吸收芯的后侧向边缘的两个、三个或更多个附接区中将吸收芯附接到底片,并且可在任何其它区域中不附接到底片。作为另外一种选择,可在邻近吸收芯的前侧向边缘的一个附接区中和在邻近吸收芯的后侧向边缘的一个附接区中将吸收芯附接到底片,并且在任何其它区域中不附接到底片;或可在邻近吸收芯的前侧向边缘的一个附接区中和在邻近吸收芯的后侧向边缘的一个附接区中将吸收芯附接到底片,并且在任何其它区域中不附接到底片。
在根据选项c)的多个实施例中,可在邻近一个纵向侧边缘的一个附接区中和在邻近相应的其它纵向侧边缘的一个附接区中将吸收芯附接到底片,并且可在任何其它区域中不附接到底片。作为另外一种选择,可在邻近吸收芯的一个纵向侧边缘的两个、三个或更多个附接区中和在邻近吸收芯的相应其它纵向侧边缘的两个、三个或更多个附接区中将吸收芯附接到底片,并且可在任何其它区域中不附接到底片。作为另外一种选择,可在邻近吸收芯的一个纵向侧边缘的一个附接区中和在邻近吸收芯的相应其它纵向侧边缘的两个、三个或更多个附接区中将吸收芯附接到底片,并且在任何其它区域中不附接到底片。
如果根据选项b)将吸收芯附接到底片,在裆区的一个或多个附接区中可具有基本上平行于吸收芯纵向的纵向,并且可具有基本上平行于吸收芯侧向的侧向。在一个或多个附接区的纵向和侧向之间的比率可为0.5至2.0,或2.0至0.5,或0.5至1.0,或1.0至0.5。选项b)的一个或多个附接区覆盖0.2%至3%,优选地0.5%至2%,或0.5%至1.5%,或0.2%至1.5%或0.2%至1%的吸收芯总表面区域。这些百分比是指合在一起的全部附接区。同样地,如果根据选项b)将吸收芯附接到底片,一次性尿布还可包括润湿指示标记,并且润湿指示标记被置于吸收芯裆区的一个或多个附接区中的至少一个内的吸收芯与底片之间,在吸收芯的纵向轴线上或邻近该轴线。
如本文所用,术语“邻近吸收芯的前侧向边缘和后侧向边缘”是指分别起始于前侧向边缘(对于邻近前侧向边缘的附接区)和后侧向边缘(对于邻近后侧向边缘的附接区),并且沿着或平行于吸收芯的纵向轴线朝裆区延伸的小于15%,或小于10%,或小于5%(按吸收芯总长度计)的向内距离。
如本文所用,术语“邻近吸收芯的纵向轴线”是指附接区或在纵向轴线上,或朝着左或右纵向侧边缘远离纵向轴线小于15%,或小于10%,或小于5%(按吸收芯总宽度计)的距离。对于具有多于一个邻近吸收芯纵向轴线的附接区的实施例,附接区可朝着左和右纵向侧边缘远离纵向轴线小于15%,或小于10%,或小于5%(按吸收芯总宽度计)的距离。
如本文所用,术语“邻近吸收芯的纵向侧边缘”是指分别起始于左和右纵向边缘,并且沿着或平行于吸收芯的横向轴线朝裆区延伸的小于15%,或小于10%,或小于5%(按吸收芯总宽度计)的向内距离。
吸收芯的总表面区域由吸收芯的x-和y-方向限定。不考虑任何潜在的表面不平和厚度不规则(即,在z-方向上)。当将吸收芯平放在台上,不施加应力或应变时(这也应用于潜在可延展的吸收芯),确定吸收芯的x-、y-方向。如果需要的话,可在将吸收芯平放在台上之前仔细移除否则将施加应变于吸收芯的弹性收缩元件。
根据以上选项a)至d)中的任何一个将吸收芯附接到底片,吸收芯当吸收液体膨胀时可相对于底片滑动,从而吸收芯可很大程度上独立于底片膨胀,并且不迫使底片连同吸收芯一起膨胀。从而可减少底片中褶皱和张力线的形成。也可减少尿液污渍透过底片的透视(因为吸收芯与底片的距离不与在其中吸收芯在整个吸收芯区域上附接到底片的实施例中保持得一样紧密)。这据信是由于在吸收芯与底片之间形成小的气垫,其不能在其中吸收芯紧密附接(例如通过粘合剂)到底片的区域中形成。为了减少透视,据信非常小的气垫是足够的。为了可视化透视的减少,可使用下文提出的测试方法。这种测试方法允许用肉眼(即,不需要显微镜等)来定性的可视化。
在本发明的一次性尿布中,顶片可沿着顶片和底片的周边(即,其中将吸收芯包封在顶片与底片之间的区域之外)来密封底片。为了使吸收芯在顶片与底片之间膨胀,顶片可在远离吸收芯周边的一定距离上,尤其是在横向上(即,沿着吸收芯的纵向侧边缘)密封底片。在顶片与底片之间,沿着吸收芯纵向侧边缘的密封可使得吸收芯的宽度小于90%,优选地小于85%的在顶片与底片之间的纵向侧边缘密封之间的宽度。如果吸收芯的宽度和/或在顶片与底片之间的纵向侧边缘密封之间的宽度沿着一次性尿布的长度变化,吸收芯的宽度在沿着一次性尿布长度的每个位置上可为小于90%,优选地小于85%的在顶片与底片之间的纵向侧边缘密封之间的宽度。
在邻近吸收芯的前侧向边缘和后侧向边缘的附接区中或在邻近吸收芯的纵向侧边缘的附接区中的吸收芯与底片的附接具有以下有益效果:吸收芯不能在一次性尿布中加捻或甚至滚动,因为它在多个位置上被固定在原位。这对于某些制造方法来说是尤其有利的,其中各个吸收芯被置于底片材料的连续纤维网(仅在制造方法的后期将其切成单个底片)中。仅在已经将吸收芯置于连续底片材料上方后将顶片置于吸收芯顶部上,顶片通常为顶片材料的连续纤维网形式,在后期将其连同底片一起切成单个顶片。从而在某个阶段将吸收芯平放在底片顶部,并且无上覆组件。吸收芯除了在附接区中被附接到底片材料的连续纤维网之外,还通常通过在底片下施加真空被保持在底片上。然而,在这个阶段,存在吸收芯从底片上提起的风险,尤其是在高速制造方法中更是如此。因此,在多个附接区中将吸收芯附接到底片是上文提出的选项a)、c)和d)的做法,它们减少了选项b)中提起吸收芯的风险,其中吸收芯仅在一个位置附接到底片。
然而,如果制造方法进行相应的调整(即,较高的真空度、较慢的生产线速度、或同时将吸收芯和顶片接合到底片上。)仅在一个位置将吸收芯附接到底片仍然是可能的。根据选项b),即,仅在一个附接区中将吸收芯附接到底片具有以下优点:润湿吸收芯的膨胀不受平行于吸收芯纵向轴线和平行于吸收芯横向轴线的阻碍。
一旦已经将顶片置于吸收芯顶部上,该顶片可围绕顶片和底片的周边密封底片,这可在将连续顶片和底片材料切成单个顶片和底片之前或之后完成。一旦已经将顶片置于吸收芯上,顶片也可附接到吸收芯。
因为减少了透视,本发明允许使用低基重的底片材料。本发明一次性尿布的底片可由膜和任选地一个或多个非织造纤维网组成。包括膜和任选的非织造纤维网的底片的基重可为小于70g/m2,或可为25g/m2至70g/m2,或25g/m2至60g/m2或25g/m2至50g/m2。膜(无非织造纤维网)的基重可为小于25g/m2,或10g/m2至25g/m2,或10g/m2至20g/m2。任选的非织造纤维网的基重可为小于40g/m2,或10g/m2至30g/m2,或10g/m2至25g/m2(在具有多于一个非织造纤维网的实施例中,这些值代表所有非织造纤维网合在一起的总数)。
根据本发明,底片也可为白色,并且可具有区域小于50%,或小于30%的印刷区(具有非白色的颜色),其与吸收芯的前区和裆区一致。
本发明一次性尿布的底片不具有弹性。非弹性材料一般比弹性材料便宜,并且假定吸收芯能够在某种程度上独立于底片而膨胀,底片不必是弹性的。因此,本发明的底片可为非弹性的或高度非弹性的。
可将吸收芯附接到一次性尿布的顶片。因为顶片通常仅在顶片和底片的周边附接到底片,此类与顶片的附接将不对本发明的优点(即,减少透视并减少底片中的褶皱和张力线的形成)产生不利影响。可至少在吸收芯的前区和裆区将吸收芯附接到顶片上。吸收芯可直接附接到顶片。作为另外一种选择,在顶片和吸收芯之间具有采集系统的一次性尿布中,吸收芯可附接到采集系统,其继而附接到顶片。吸收芯与顶片或采集系统的附接可被粘结性地完成,例如使用热熔性粘合剂完成。
根据本发明,吸收芯与底片的附接可使用粘合剂,优选地热熔性粘合剂来完成。附接直接在吸收芯与底片之间。如果吸收芯具有第一载体基底,附接在下部载体基底的面向衣服的表面和底片的面向穿着者的表面之间。
本发明的吸收芯可包括一个或多个通道,即,基本上包含超吸收聚合物颗粒的区域,并且其不邻近吸收芯的边缘,而是位于一些其它位置。如本文所用,“基本上不含超吸收聚合物颗粒”是指例如由于方法相关的原因,少量的、可忽略不计量的超吸收聚合物颗粒可存在于间隙中,然而其不影响总体功能。术语“基本上不含超吸收聚合物颗粒”涵盖“不含超吸收聚合物颗粒”。通道可在吸收芯的裆区和/或前区中提供。通道是细长的,并且可具有1至20,或1至15,或1至10,或1至5,或1至3的宽度对长度比率。通道可为直的或可为弯曲的。此类通道还可有助于改善一次性尿布的适形,即,尿布更好地适形于穿着者。这还可帮助减少上文所述底片的张力线和褶皱。如果吸收芯包括一个或多个通道,其中吸收芯附接到底片的附接区优选地在设有一个或多个通道的区域之外。通道可不在吸收芯的前和后侧向边缘以及纵向边缘上延伸。
本发明的吸收芯还可具有第一载体基底,其为直接平放在底片顶部的吸收芯基底。如果吸收芯包括一个或多个通道,第一载体基底可为水可渗透的(在25℃和50%RH条件下)(诸如薄页纸幅或水可渗透的非织造纤维网)。在此类实施例中,一定量的液体(尿液)可透过吸收芯的整个厚度并且可分布在吸收芯与底片之间的空间中。因此,可改善液体分布,因为液体可在吸收芯与底片之间扩散至其它较远的区域,其中它可被吸收芯吸收。与其中将吸收芯附接到底片并且在任何其它区域保持不与底片附接的本发明附接区组合,在吸收芯与底片之间的液体能够相对无阻碍地扩散。然而,在这些吸收芯中,必须仔细选择一个或多个通道的尺寸以确保在吸收芯与底片之间的空间中通过吸收芯厚度的液体量不变得太多。
可视化底片透视的测试方法
这一方法可视化透过一次性尿布底片的污渍的透视。该测试可用具有不同吸收芯与底片附接方案和程度的一次性尿布进行以定性地可视化差异。使用的负荷方案用于通常指定用于重量范围在8至13kg±20%的穿着者的一次性尿布(诸如尺码4的Pampers“Active Fit”、或尺码4的其它Pampers婴儿尿布、尺码4的Huggies婴儿尿布和尺码4的大多数其它商品名的婴儿尿布)。
设备负荷方案
测试设备如图6所示,并且包括槽111,它由聚碳酸酯(例如)制成,标称厚度为12.5mm(0.5英寸)。槽111包括直线水平基座112,其具有508mm(20.0英寸)的长度和152mm(6.0英寸)的宽度。两个直线垂直侧面113高64mm(2.5英寸)×长508mm(20英寸),它们被附连到基座112的长边缘上以形成U形槽111,其具有508mm(20.0英寸)的长度、152mm(6.0英寸)的内部宽度、和51mm(2.0英寸)的内部深度。不包封槽111的前端和后端。
将一块具有尺寸508×152×25mm的开孔聚氨酯泡沫114包裹在聚乙烯膜内并置于槽111底部,放置方式使得泡沫114和槽111的边缘对齐,并且聚乙烯膜的上表面是平滑的并且无接缝、褶皱或瑕疵。聚氨酯泡沫114具有0.48psi的压缩模量。使用耐久性记号笔从平行于横向中心线的一端(前边缘)横跨聚乙烯盖上表面152mm(6.0英寸)画一条基准线。
直线聚碳酸酯顶板115具有12.5mm(0.5英寸)的标称厚度、508mm(20.0英寸)的长度、和146mm(5.75英寸)的宽度。在顶板115的中心(即,孔中心位于顶板115上表面的纵向和横向轴线的交点)镗出51mm(2.0英寸)直径的孔。将具有51mm(2.0英寸)外径、37.5mm(1.5英寸)内径和102mm(4.0英寸)高度的聚碳酸酯滚筒116胶粘到顶板115中的孔内,使得滚筒116的底部边缘与顶板115的下表面齐平,并且滚筒116竖直突出于顶板115上表面上方89mm(3.5英寸),并且在滚筒116和顶板115之间的接缝是不透水的。环形凹槽117具有2mm的高度和44.5mm(1.75英寸)的直径,将其机加工到滚筒116的底部内部边缘中。与顶板115的上表面成45°角度钻两个1mm直径的孔,使得所述孔紧靠着凹槽117上方并且在滚筒116的相对侧(即,180°分离)相交于滚筒116的内表面。将具有1mm直径的两条不锈钢线118以不透水的方式胶粘到孔中,使得每条线的一端与滚筒内壁齐平并且另一端突出于顶板115的上表面。这些线下文称为电极。画出基准线,其从平行于横向中心线的前边缘横跨顶板115的宽度152mm(6.0英寸)。顶板1415/滚筒116组件具有大约1180克的重量。
两个钢砝码每个重0.9Kg,并且还需要127mm(5英寸)的测量宽度、50mm(1,97英寸)的深度、以及大约16mm(0,63英寸)的高度。
步骤
所有测试均在23±2℃和35±15%的相对湿度条件下进行。
将包含包裹泡沫块114的聚碳酸酯槽111置于合适的平坦水平表面上。一次性吸收产品脱包装,并且以合适的间隔切开箍弹性部件以使产品平铺。产品在合适的顶部加载天平上称重,精确至±0.1克,随后将其置于采集设备中的包裹泡沫块114上,并且产品的前腰边缘与聚乙烯盖的基准标记对齐。产品沿着设备的纵向中心线居中,并且产品的顶片(身体侧)面朝上,后腰边缘面朝泡沫块114的后端。将顶板115置于产品顶部上,并且突起的滚筒面朝上。画出的基准线与产品的前腰边缘对齐,并且顶板115的后端与泡沫块114的后边缘对齐。随后将两个0.9Kg的砝码轻柔置于顶板115上,使得每个砝码的宽度平行于顶板的横向中心线,并且每个砝码距离顶板115的前或后边缘83mm(3.25英寸)。
将合适的电路连接至两个电极以检测它们之间是否存在导电流体。
合适的泵;例如由Cole Parmer Instruments,Chicago,USA提供的Model7520-00,或等同产品;设定为通过软塑料管至多排放0.9质量%的氯化钠水溶液,该软塑料管具有4.8mm(3/16英寸)的内径,例如R-3603或等同产品。0.9%的氯化钠溶液用靛蓝(Indigo)胭脂红(C16H8N2Na2O8S2),Merck(104724Indigocarmin C.I.73015)染色,使用40mg/升的0.9%氯化钠溶液。管端部被竖直夹住,使得它在附接到顶板115的滚筒116中居中,并且管的排放端面朝下并位于滚筒116的上边缘下方50mm(2英寸)处。泵经由定时器运行并进行预先校准以排放90.0ml0.9%盐水溶液的涌流,排放速率为15ml/秒。
启动泵并且在启动泵后立即开始计时。泵以15ml/秒的速率递送90ml的0.9%氯化钠溶液至滚筒116,随后停止。当将测试流体引入滚筒116时,它通常在吸收结构的顶部积聚至某种程度。这种流体在滚筒中的两个电极之间形成电路。在已经递送涌流后,随着流体被吸收到结构中,溶液的弯月面下降。当电路由于在滚筒中的电极之间缺少自由流体而被中断时,记录时间。
特定涌流的采集时间是在启动泵以开始涌流和电路中断的时间点之间的时间间隔。
以这种方式将四个涌流递送到产品中;每个涌流为90ml,并且以15ml/秒的速率递送。在开始每个涌流之间的时间间隔为300秒。
设备成像系统(任选的在样本制备及设置步骤10中使用)
图像采集硬件
图像采集硬件由计算机和照明装置213组成,所述照明装置包含数字照相机211如Fuji HC2500(211)或Sony DFW-X700(211)。颜色校正表是标准8.5"×11"Gretag-Macbeth着色表,以及两个灯212。
周边连接
Fuji HC2500照相机有一个PCI界面卡,它安装在计算机的PCI狭槽2中。Sony DFW-X700插入计算机的任何Firewire(IEEE-1348)端口内。
照明装置
照明装置213如图7所示。灯212应满足D65如OSRAMOSDULUXL36W12或等同装置(CC温度/Kelvin5400K;日光颜色;CRI90CRI)的要求。在基座214和照明装置213之间的角度α是70°。应调节在照明装置213和灯212之间的角度β以达到基座214的均匀照明。
样本制备及设置
1.在尿布吸收所有液体后,必须直接从测试设备中移出尿布。
2.立即打开产品,顶片面朝上。
3.展开尿布并沿着连续粘结处从尿布中除去弹性部件。
4.在台面上铺开尿布,使其平铺并呈矩形,顶片面朝下,无任何折叠。
5.使用一只手使尿布的前腰边缘向下保持在台面上以避免任何移动。
6.紧靠着你的手,将砝码312(9Kg重,并且测量宽度148mm(5.83英寸),深度38mm(1.5英寸),并且高度大约101mm(3.98英寸高))轻柔置于尿布的前腰边缘上,与婴儿尿布前腰边缘成45°或更小的角度。砝码312的侧面应平行于尿布的横向轴线。这时候通过柄部311抓持砝码,使砝码朝着尿布的后腰边缘滑动,保持45°或更小的角度,使得砝码仅用它的其中一个边缘313在尿布上滑动。对于具有400mm至500mm纵向延伸的尿布,这应耗费大约1至2秒。
7.抓住尿布的前边缘和腰部边缘,提起它们并折叠尿布,使之形成一个圆。在该过程中,尿布的裆区应仍旧接触台面。
8.放开尿布端部并在台面上铺开尿布,使其平铺并呈矩形,顶片面朝下,无任何折叠。
9.用你平展的手轻轻接触底片表面,并且轻柔地在横向(即,平行于尿布横向轴线的方向)上来回移动你的手三次。
10.用肉眼目测尿布:其中底片紧密粘着到吸收芯上的区域可被认为是较暗的区域,其中染污的吸收芯在某种程度上透过底片显现。其中底片已经与吸收芯分离的区域可通过较浅的颜色来识别。在具有粘附至芯的较大区域的底片与具有粘附至芯的较小区域的底片之间的差异通常易于识别。
为了把结果归档,可使用“设备成像系统”部分描述的设备给尿布拍照。
本文所公开的量纲和值不应当被理解为严格限于所引用的精确值。相反,除非另外指明,每个这样的量纲均旨在既表示所引用的值,也表示围绕此值功能上等同的范围。例如,公开为“40mm”的量纲旨在表示“约40mm”。

Claims (11)

1.包括底片(20)、顶片(18)和位于底片与顶片之间的吸收芯(14)的一次性尿布(10),所述吸收芯(14)具有纵向和与其垂直的侧向,所述纵向具有纵向轴线,并且所述侧向具有横向轴线,所述吸收芯还具有前区、后区和位于前区与后区之间的裆区,以及前侧向边缘、相对的后侧向边缘和纵向延伸的侧边缘,
其中所述吸收芯包括超吸收聚合物颗粒(66,74),所述超吸收聚合物颗粒通过第一芯粘合剂(94)进行固定,并且其中所述吸收芯包括一个或多个通道,所述通道不含超吸收聚合物颗粒,并且所述吸收芯(14)包括少于5%的透气毡,其中
a)所述吸收芯(14)在邻近所述吸收芯的前侧向边缘和后侧向边缘的附接区中附接到所述一次性尿布(10)的底片(20);并且
b)所述吸收芯(14)在所述吸收芯的裆区,在邻近所述吸收芯的纵向延伸的侧边缘的附接区中附接到所述一次性尿布(10)的底片(20),
并且其中不在任何其它区域将吸收芯附接到底片;
其中所述底片(20)是非弹性的。
2.根据权利要求1所述的一次性尿布(10),其中邻近所述吸收芯(14)的前侧向边缘和后侧向边缘的附接区在所述吸收芯的角中提供,留下邻近所述吸收芯的前侧向边缘和后侧向边缘的剩余区域不附接到所述底片(20)。
3.根据权利要求1或2所述的一次性尿布(10),其中所述底片(20)由膜和一个或多个非织造纤维网组成,并且其中包括膜和非织造纤维网的底片的基重小于70g/m2,并且其中所述膜具有小于25g/m2的基重。
4.根据权利要求1所述的一次性尿布(10),其中所述底片(20)是高度非弹性的。
5.根据权利要求1所述的一次性尿布(10),其中所述吸收芯(14)至少在所述吸收芯的前区和裆区中附接到所述顶片(18)。
6.根据权利要求1所述的一次性尿布(10),其中所述吸收芯(14)的吸收材料包括超过95%的超吸收聚合物颗粒(66,74)。
7.根据权利要求1所述的一次性尿布(10),其中所述吸收芯(14)包括第一和第二载体基底(64,72),并且其中所述超吸收聚合物颗粒(66,74)在所述第一和第二载体基底(64,72)之间提供。
8.根据权利要求1所述的一次性尿布(10),其中所述第一芯粘合剂(94)是热熔性粘合剂。
9.根据权利要求1所述的一次性尿布(10),其中所述一个或多个通道在除所述附接区之外的区域中提供。
10.根据权利要求1所述的一次性尿布(10),其中所述吸收芯(14)通过粘合剂附接到所述底片(20)。
11.根据权利要求10所述的一次性尿布(10),其中所述粘合剂是热熔性粘合剂。
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CN101677889A (zh) * 2007-06-18 2010-03-24 宝洁公司 具有大体上连续地分配的吸收性颗粒状聚合物材料的一次性吸收制品及方法

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