CN103596535A - 用于一次性吸收制品的吸收芯 - Google Patents
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F13/534—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad
- A61F13/535—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad inhomogeneous in the plane of the pad, e.g. core absorbent layers being of different sizes
- A61F13/536—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad inhomogeneous in the plane of the pad, e.g. core absorbent layers being of different sizes having discontinuous areas of compression
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F13/531—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having a homogeneous composition through the thickness of the pad
- A61F13/532—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having a homogeneous composition through the thickness of the pad inhomogeneous in the plane of the pad
- A61F13/533—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having a homogeneous composition through the thickness of the pad inhomogeneous in the plane of the pad having discontinuous areas of compression
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C2270/00—Control; Monitoring or safety arrangements
- F04C2270/04—Force
- F04C2270/041—Controlled or regulated
Abstract
本发明提供了用于一次性吸收制品的吸收芯。所述吸收芯包括至少两个吸收结构，所述吸收结构包括基底层和吸收层，其中一个吸收结构包括通道并且一个不含通道。
Description
技术领域
本发明涉及用于一次性吸收制品如尿布的吸收芯，其向制品提供干燥和润湿状态（即当加载有体液时）下的改善的贴合性以及改善的液体输送。
背景技术
用于接收和保留诸如尿液或粪便的身体排出物的一次性吸收制品在本领域为人们所熟知。这些的例子包括一次性尿布、训练裤和成人失禁制品。通常，一次性尿布包括面向穿着者身体的液体可透过的顶片、面向穿着者衣服的液体不可透过的底片和插在液体可透过的顶片与底片之间的吸收芯。
自从将它们引入市场中之后，一次性尿布的相关舒适度、贴合性和功能性已经得到了持续改善。
一次性吸收制品的重要组件为吸收芯结构。吸收芯结构通常包括吸收聚合物材料，诸如水凝胶形成聚合物材料，也称为吸收胶凝材料AGM、或超吸收性聚合物SAP。该吸收性聚合物材料确保在其使用期间大量的体液例如尿液能够被所述吸收制品吸收并且被锁藏，从而提供低回渗和良好的皮肤干燥性。
传统上，吸收性聚合物材料与纤维素或纤维素纤维一起掺入吸收芯结构中。然而，在过去几年中，已花费了巨大的努力以制造更薄的吸收芯结构，其仍然能够采集和贮存大量排出的体液，尤其是尿液。因此，已经提议从吸收芯结构减少或消除这些纤维素纤维。为维持吸收芯结构的机械稳定性，可加入少量的热塑性粘合剂材料如纤维热塑性粘合剂材料，以稳定吸收性聚合物材料。结果，提供了具有所要求的透过性/孔隙率、减少的凝胶阻塞，并且在使用或传输中形成稳定结构的吸收结构。
然而发现，具有减少的纤维素纤维含量的一些吸收芯结构虽然在不加载有体液时非常薄，但是当部分加载或满载时，尤其是在包含吸收制品的大部分吸收容量的那些区域，诸如尿布的前区和裆区中，可能具有增加的刚度。增加的刚度是不可取的，因为其降低了吸收制品与穿着后穿着者的身体适形的能力。此外，还发现包含高吸收容量的吸收性聚合物颗粒的一些吸收芯结构，在加载有身体流出物时显著地溶胀。因此，在使用期间，吸收制品的体积可显著地增加，尤其是在包括吸收制品的大部分吸收容量的这些区域，诸如尿布的前区和裆区中。此类体积增加可使一次性制品对于穿着者而言不舒适。还发现具有减少的纤维素纤维含量的这些吸收芯结构中的一些可具有负面地影响液体采集速度的减少的空隙体积。
因此，仍然需要吸收制品，其在制品的整个使用期间具有良好的液体处理性能并具有增加的柔韧性，并且其尤其在润湿状态下递送更好的贴合性。
发明内容
本发明涉及用于一次性吸收制品如尿布的吸收芯。所述吸收芯包括至少第一和第二吸收结构，所述第一和第二吸收结构分别包括基底层和包含吸收性聚合物颗粒的吸收层以及任选地由基底层承载的纤维素。每个吸收层具有横向和纵向尺寸，一对在其纵向尺寸上延伸的相对的纵向边缘，一对在其横向尺寸上延伸的相对的横向边缘，以及依次布置在纵向尺寸上的前区、裆区和后区。垂直于吸收层的中心纵向轴线的平面划分两个纵向区。所述第一吸收结构的吸收层包括延伸穿过吸收层厚度的基本上不含所述吸收性聚合物颗粒的两个或更多个通道，然而，所述第二吸收结构不含通道。吸收层的每个纵向部分包括在吸收层的纵向尺寸上延伸的至少一个通道。所述通道具有至少3mm或为所述吸收层横向尺寸的至少4%的宽度，并且至少存在于所述裆区或前区中。所述第一吸收结构的吸收层不含延伸直至所述吸收层的纵向和横向边缘的通道。
本发明还涉及一次性尿布，所述一次性尿布包括如上文和本文的下文所公开的吸收芯。
附图说明
图1是一次性尿布的平面图。
图2是包括不含通道的吸收层的吸收结构的透视图。
图3A是具有两个纵向通道的吸收层的透视图。
图3B是包括具有四个纵向通道的吸收层的吸收层的透视图。
图4A是在裆区中包括两个纵向通道的吸收层的透视图。
图4B是在前区中包括两个纵向通道的吸收层的透视图。
图4C是包括至少存在于裆区中的两个纵向通道和前区中的两个纵向通道的吸收层的透视图。
图4D是包括至少存在于裆区中的两个纵向通道、前区中的两个纵向通道以及后前区中的两个纵向通道的吸收层的透视图。
图5A至5E为通道的示意图。
图6A是包括具有四个纵向通道的吸收层的吸收结构的顶视图。
图6B为图6A的吸收结构的透视图。
图7至9是在横向尺寸上截取的吸收芯的示意性截面图。
图10是用于制备吸收结构的方法的示意图，所述吸收结构包括具有通道的吸收层。
具体实施方式
定义
“吸收制品”是指吸收和容纳身体流出物的装置，并且更具体地，是指紧贴或邻近穿着者的身体放置以吸收和容纳从身体排出的各种流出物的装置。吸收制品可包括尿布、训练裤、成人失禁内衣、妇女卫生产品。
如本文所用，“尿布”是指旨在紧贴穿着者的皮肤放置以吸收和容纳从身体排出的各种流出物的装置。尿布一般由婴儿和失禁人员围绕下体穿着，以便环绕穿着者的腰部和腿部。尿布的例子包括婴儿或成人尿布和类似裤的尿布，例如训练裤。
如本文所用，“训练裤”是指具有腰部开口和腿部开口的一次性衣服，衣服是为婴儿或成人穿着者设计的。通过将穿着者的腿插入腿部开口并将裤提拉到围绕穿着者下体的适当位置中，可将裤穿到穿着者身上的适当位置中。可通过任何合适的技术将裤预成形，包括但不限于使用可重复扣紧的和/或不可重复扣紧的粘结物（例如，接缝、焊接、粘合剂、胶粘剂粘结、扣件等）将所述制品的部分接合在一起。可沿制品圆周的任何位置将裤预成形（例如，侧扣紧的、前腰扣紧的）。
本文使用“一次性的”来描述一般不旨在被洗涤或换句话讲恢复或重新使用的制品（即它们旨在单次使用后被丢弃，并且可被回收再循环、堆肥处理或换句话讲以环境相容的方式处理）。
如本文所用，“吸收芯”是指通常设置在吸收制品的顶片与底片之间的吸收制品的组件。吸收芯包括至少两个吸收结构以及任选地另外的层，例如覆盖层。
如本文所用，“吸收结构”是指可用于吸收和容纳液体如尿液的三维结构。吸收结构为吸收制品的吸收芯的一部分，即为吸收芯的吸收组件，如将在本文中进一步描述。
如本文所用，“吸收性聚合物颗粒”是指基本上水不溶性的聚合物颗粒，其能够吸收如使用离心保留容量测试（Edana441.2-01）测量的至少10倍于其重量的0.9%的去离子水中的盐水溶液。
如本文所用，“非织造材料”是指由定向或任意取向的纤维制造的纤维网，不包括纸材和掺入接结纱或长丝的织造、针织、簇成、缝编、或通过湿磨法毡化的产品，无论是否另外针刺。非织造材料以及用于制备它们的工艺是本领域中已知的。一般来讲，制备非织造材料的工艺包括将纤维成形铺设到表面上，所述工艺可包括旋转铺设、熔吹、粗梳、空气铺设、湿法铺设、共成形、以及它们的组合。所述纤维可为天然的或人造的来源，并且可为人造短纤维或连续长丝或为就地形成的。
如本文所用，术语“基重”是指每单位面积的材料质量，即每单位面积的吸收性聚合物颗粒的质量，例如，克/平方米(gsm)。
在本发明的以下描述中，在使用中在面向穿着者方向上的吸收制品或其元件的表面称为“面向穿着者的表面”。相反，将在使用中面向衣服方向上的表面称为“面向衣服的表面”。因此，吸收制品以及其任何元件例如吸收结构具有面向穿着者的表面和面向衣服的表面。
如本文所用，“热熔融粘合剂”是指符合由Alphonsus V.Pocius在“Adhesion and Adhesives Technology:An Introduction”（Hanser publishersMunich，1997）中给出的描述的粘合剂。本文中，热熔体被定义为由熔体施加的并在固化时获得强度的粘合剂。
除非另有说明，如本文所用，吸收层的纵向尺寸或长度将理解为平均长度。
除非另有说明，如本文所用，吸收层的横向尺寸或宽度将理解为平均宽度。
一次性吸收制品
一次性吸收制品是吸收和容纳身体流出物的装置。其可包括尿布、训练裤、成人失禁内衣、妇女卫生产品。通常，一次性制品包括顶片、底片以及顶片与底片之间的吸收芯。
一次性吸收制品的示例性实施例为一次性尿布，如图1中所示。
一次性尿布1具有纵向尺寸（沿纵向轴线A）以及与其垂直的横向尺寸（沿横向轴线B）。
将尿布的一个端部构造为前腰区2（其为制品的前三分之一，具有制品长度的三分之一）。将相对的端部构造为后腰区3（其为制品的后三分之一，具有制品长度的三分之一）。将尿布的中间部分构造为裆区4（其为制品的中心三分之一）。裆区在前腰区与后腰区之间纵向延伸。裆区为当尿布被穿着时通常定位在穿着者的腿部之间的尿布部分。
所述尿布通常包括顶片5、底片6以及设置在顶片与底片之间的吸收芯7。
顶片可为液体可透过的。所述顶片可为至少部分亲水性的。还可使用所谓的开孔顶片。还可使用具有一个或多个（大）开口的顶片。顶片也可包含护肤组合物，例如洗剂。顶片可完全或部分弹性化或者可缩短以在顶片与吸收芯之间提供空隙空间。包括弹性化的或缩短的顶片的示例性结构更详细地描述于以下专利中：1991年8月6日授予Allen等人的题目为“Disposable Absorbent Article Having Elastically Extensible Topsheet”的美国专利5,037,416；和1993年12月14日授予Freeland等人的题目为“Trisection Topsheets for Disposable Absorbent Articles and DisposableAbsorbent Articles Having Such Trisection Topsheets”的美国专利5,269,775。
底片可为蒸气可透过的但液体不可透过的。底片可用于防止被吸收和容纳在吸收芯中的流体润湿接触吸收制品的材料诸如内裤、裤、睡衣、内衣、以及衬衫或夹克，从而用作对流体传送的屏障。在某些实施例中，底片可为液体（例如，尿液）基本上不可透过的，并且包括非织造物和塑料薄膜的层压体，所述塑料薄膜如具有约0.012mm（0.5密耳）至约0.051mm（2.0密耳）厚度的热塑性膜。合适的底片膜包括由Tredegar Industries Inc.（Terre Haute，Ind.）制造并以商品名X15306、X10962和X10964出售的那些。其它合适的底片材料可包括允许蒸气从尿布逸出，同时仍然防止液体流出物穿过底片的可透气材料。示例性可透气材料可包括诸如织造纤维网、非织造纤维网的材料、诸如膜包衣的非织造纤维网的复合材料、以及诸如由日本的Mitsui Toatsu Co.制造的命名为ESPOIR NO和由EXXONChemical Co.（Bay City，TX）制造的命名为EXXAIRE的微孔膜。包括聚合物共混物的合适透气复合材料以名称HYTREL blend P18-3097购自俄亥俄州Cincinnati的Clopay Corporation。此类可透气复合材料更详细地描述于1995年6月22日以E.I.DuPont的名义公布的PCT申请WO95/16746中。包括非织造纤维网和开孔成形膜的其它可透气底片描述于1996年11月5日授予Dobrin等人的美国专利5,571,096中。
吸收芯7设置在吸收制品的顶片与底片之间。吸收芯包括至少两个吸收结构，所述吸收结构将在本文下文中进一步详细描述。
如本领域所已知，尿布还可包括前腰带和后腰带和/或通常接合到腰带的扣紧系统。优选包括扣紧插片8和着陆区的9扣紧系统，其中扣紧插片附接或接合到尿布的后腰区，并且着陆区为尿布的前腰区的一部分。所述尿布还可具有腿箍10和/或遮挡箍，如弹性化的遮挡箍11。合适的箍描述于例如U.S.3,860,003；U.S4,808,178和4,909；U.S.4,695,278和4,795,454中。
如图1中所示，吸收芯可包括采集系统，所述采集系统包括上部采集层12和下部采集层13以及任选地芯覆盖件14。
组装尿布的方法包括本领域中已知的用于构造和配置一次性吸收制品的常规技术。例如，可通过粘合剂的均匀连续层、粘合剂的图案化层、或粘合剂的一系列单独线、螺纹或圆点，将底片和/或顶片接合到吸收芯或将它们彼此接合。明尼苏达州圣保罗的H.B.Fuller公司制造的名称为HL-1258或H-2031的粘合剂已被发现为令人满意的。尽管顶片、底片和吸收芯可以多种熟知的构型组装，但优选的尿布构型一般描述于以下专利中：1996年9月10日授予Roe等人的名称为“Absorbent Article With MultipleZone Structural Elastic-Like Film Web Extensible Waist Feature”的美国专利5,554,145；1996年10月29日授予Buell等人的题目为“Disposable Pull-OnPant”的美国专利5,569,234；和1999年12月21日授予Robles等人的题目为“Absorbent Article With Multi-Directional Extensible Side Panels”的美国专利6,004,306。
吸收芯
如上文所述，吸收芯包括吸收和容纳液体如尿液的至少两个吸收结构，其中至少一个包括通道并且至少一个不含通道。
如本文所用，“吸收结构”是指包括一个吸收层的三维结构，所述吸收层包含吸收性聚合物颗粒以及任选地由基底层承载的纤维素。
如本文所用，“通道”是指基本上不含吸收性聚合物颗粒的延伸穿过吸收层厚度的吸收层的离散部分，即吸收性聚合物颗粒不有意地存在于吸收结构的此类通道中。然而，应当理解，偶然地，可忽略的少量吸收性聚合物颗粒可存在于通道中，这不影响总体功能性（例如吸收结构的吸收性）。通道还优选不含纤维素。通常，通道拥有两个横向边缘（在最短的尺寸上）和在横向边缘之间运行的两个纵向边缘（在最长的尺寸上）。通道的横向边缘可为直的（即垂直于纵向侧边缘）、成角的或弯曲的。通道具有至少3mm或吸收层平均宽度的至少4%的平均宽度w（通道的平均宽度定义为纵向侧边缘之间的平均距离）。在一些实施例中，纵向通道可具有复杂的形状：通道可不以直的、成角的或弯曲的横向边缘结束，但是可具有在其末端边缘处的一个或多个分支。分支也拥有纵向边缘和一个横向边缘。通道以及它们的分支具有至少3mm的平均宽度w。
吸收结构
吸收结构15为三维结构，所述三维结构包括基底层16和吸收层17，所述吸收层包含吸收性聚合物颗粒50以及任选地由所述基底层16承载的纤维素，并优选地固定在所述基底层上。吸收结构的例子示于图2、3A、6A和6B中。
基底层具有在尿布的纵向尺寸上延伸的纵向尺寸以及在尿布的横向尺寸上延伸的横向尺寸。
吸收层具有在尿布的纵向尺寸上延伸的纵向尺寸M（即，吸收层具有长度M）以及在尿布的横向尺寸上延伸的横向尺寸N（即，吸收层具有宽度N）。吸收层17拥有中心纵向轴线x、垂直于所述中心纵向轴线x的中心横向轴线y、在一次性吸收制品如一次性尿布的纵向尺寸上延伸的一对相对的纵向边缘18以及在一次性吸收制品如一次性尿布的横向尺寸上延伸的一对相对的横向边缘19。吸收层的纵向边缘或横向边缘可相对于中心纵向轴线或中心横向轴线平行（如图2、3A、6A和6B中所示）或它们可符合这些轴的大致方向但是不严格平行，例如它们可为曲线的，以在裆区中提供更窄的横向尺寸（如图3B、4A至4D中所示）。
吸收层17的中心纵向轴线x划分吸收层的两个区域，所述区域在本文中称作纵向区20（垂直于中心纵向轴线的平面将吸收层17分成设置在所述平面任一侧上的两个纵向区20）。
将吸收层的一个端部构造为前区21（其是朝向一次性尿布的前腰区取向的区域），其构成吸收层纵向尺寸M的25%。将相对的末端区域构造为后区22（其是朝向尿布的后腰区取向的区域），其构成吸收层纵向尺寸M的25%。将吸收层的中间部分构造为裆区23，其构成吸收层纵向尺寸M的50%。所述前区、裆区和后区依次布置在吸收层的纵向尺寸上。
吸收结构的基底层可为能够承载吸收性聚合物颗粒的任何材料。通常，其可为纤维网或片材料，诸如泡沫、膜、织造和/或非织造材料。如本文所用，“非织造材料”是指定向或任意取向纤维通过摩擦和/或胶粘和/或粘附结合制造的纤维网，不包括纸材和掺入接结纱或长丝的织造、针织、簇成、缝编、或通过湿磨法毡化的产品，无论是否另外针刺。非织造材料以及用于制备它们的工艺是本领域中已知的。通常，用于制备非织造材料的方法包括两个步骤：将纤维铺设到成形表面上，以及纤维粘结。纤维铺设步骤可包括旋转铺设、熔吹、粗梳、空气铺设、湿法铺设、共成形、以及它们的组合。所述纤维粘结步骤可包括水刺法、冷压延、热压延、通过空气热粘结、化学粘结、针刺法、以及它们的组合。非织造材料可为层压体。层压体可包括一个或多个纺粘层（S）、和/或一个或多个熔喷层（M）、和/或一个或多个粗梳层（C）。合适的层压体包括但不限于SS、SSS、SMS或SMMS。非织造材料可具有约5至100g/m2，或约10至40g/m2、或约10至30g/m2的基重。织造或非织造材料可包括天然纤维或合成纤维或它们的组合。天然纤维的例子可包括纤维质天然纤维，例如来自硬木来源、软木来源、或其它非木植株的纤维。天然纤维可包括纤维素、淀粉、以及它们的组合。合成纤维可为任何材料，例如但不限于选自以下的那些：聚烯烃（聚丙烯和聚丙烯共聚物、聚乙烯和聚乙烯共聚物）、聚酯（例如，聚对苯二甲酸乙二醇酯）、聚醚、聚酰胺、聚酯酰胺、聚乙烯醇、聚羟基链烷酸酯、多糖、以及它们的组合。此外，合成纤维可为单一组分（即构成整个纤维的单一合成材料或混合物）、双组分（即将纤维分成多个区域，所述区域包含两种或更多种不同的合成材料或它们的混合物，并且可包含共挤出的纤维以及芯和鞘纤维）、以及它们的组合。双组分纤维能够用作非织造材料的组分纤维，和/或它们可存在以用作非织造材料中的其它纤维的粘合剂。纤维中的任一种或所有可在制造之前、期间、或之后处理以改变纤维的任何所期望的性能。
基底层16和吸收层17可为共延的，或者基底层16可略微比吸收层17更长或更宽（如图2、3B、6A和6B中所示）。
吸收层17包含吸收性聚合物颗粒50。所述吸收性聚合物颗粒可以单独使用或与其它材料组合使用。在一些实施例中，所述吸收层包含与纤维素组合的吸收性聚合物颗粒。如本文所用，“纤维素”是指纤维形式的粉碎的木浆，通常在本领域中也称为“空气毡”。在一些实施例中，吸收层包含超过70重量%、或超过80重量%、或超过90重量%、或超过95重量%、或甚至100重量%的吸收性聚合物颗粒。在一些实施例中，吸收层包含吸收性聚合物颗粒以及少于5重量%的纤维素，更典型地少于2重量%的纤维素，并且最典型地所述吸收层不含纤维素。与包含纤维素纤维的常规吸收结构相比，所得的吸收结构在干燥状态下具有减小的厚度。减小的厚度有助于改善吸收制品对于穿着者的贴合性和舒适度。
可例如通过热塑性粘合剂材料，将吸收性聚合物颗粒和纤维素（当存在时）固定在基底层上。
通常，适用于吸收层中的吸收性聚合物颗粒可包括从超吸收剂文献已知的任何吸收性聚合物颗粒，例如Modern Superabsorbent PolymerTechnology，F.L.Buchholz，A.T.Graham，Wiley1998中所述。
吸收性聚合物颗粒可为通常得自反相悬浮聚合类型的球形、类似球形或不规则形状的颗粒，诸如维也纳香肠形颗粒、或椭圆形颗粒。还可任选地使颗粒附聚至少至一定程度以形成更大的不规则颗粒。
吸收性聚合物颗粒可选自内部和/或表面交联的聚丙烯酸酯和基于聚丙烯酸酯的材料，例如部分中和的交联聚丙烯酸酯或酸性聚丙烯酸酯。本发明中合适的吸收性聚合物颗粒的例子如在PCT专利申请WO07/047598、WO07/046052、WO2009/155265和WO2009/155264中所述。
优选使吸收性聚合物颗粒内部交联，即在具有两个或更多个可聚合基团的化合物的存在下聚合，所述化合物能够自由基共聚到聚合物网络中。有用的交联剂包括例如如EP-A530438中所述的乙二醇二甲基丙烯酸酯、二甘醇二丙烯酸酯、甲基丙烯酸烯丙酯、三羟甲基丙烷三丙烯酸酯、三烯丙基胺、四烯丙氧基乙烷，如EP-A547847、EP-A559476、EP-A632068、WO93/21237、WO03/104299、WO03/104300、WO03/104301和DE-A10331450中所述的二丙烯酸酯和三丙烯酸酯，如DE-A10331456和DE-A10355401中所述的混合的丙烯酸酯（其不仅包含丙烯酸酯基团，还包含烯键式不饱和基团），或者如例如DE-A19543368、DE-A19646484、WO90/15830和WO02/32962中所述的交联剂混合物，以及WO2009/155265中所述的交联剂。
吸收性聚合物颗粒可为外部交联的（后交联的）。有用的后交联剂包括包含能够与所述聚合物的羧酸酯基团形成共价键的两个或更多个基团的化合物。有用的化合物包括如例如EP-A083022、EP-A543303和EP-A937736中所述的烷氧基甲硅烷基化合物、聚氮丙啶、聚胺、聚酰氨基胺、二缩水甘油基或聚缩水甘油基化合物，如DE-C3314019中所述的多元醇，如DE-A4020780中所述的环状碳酸酯、如DE-A19807502中所述的2-
唑烷酮及其衍生物（如N-(2-羟乙基)-2-
唑烷酮）、如DE-A19807992中所述的双-和聚-2-
唑烷酮、如DE-A19854573中所述的2-氧代四氢-1,3-
嗪及其衍生物、如DE-A19854574中所述的n-酰基-2-
唑烷酮、如DE-A10204937中所述的环脲、如DE-A10334584中所述的二环酰胺缩醛、如EP-A1199327中所述的氧杂环丁烷和环脲、以及如WO03/031482中所述的吗啉-2,3-二酮及其衍生物。
吸收性聚合物颗粒可具有表面改性，例如涂覆或部分涂覆有涂层剂。涂覆的吸收性聚合物颗粒的例子公开于WO2009/155265中。涂层剂可为使得吸收性聚合物颗粒更加亲水性的那些。涂层剂可为聚合物，诸如弹性聚合物或成膜聚合物或弹性成膜聚合物，其在颗粒上形成弹性体（弹性）膜涂层。涂层可为在吸收性聚合物颗粒表面上的均相和/或均匀涂层。涂层剂可以所述表面改性的吸收性聚合物颗粒的0.1重量%至5重量%、或0.2重量%至1重量%的含量施加。
通常，吸收性聚合物颗粒可具有选择的粒度分布。例如，所述吸收性聚合物颗粒可具有在45μm至4000μm、更具体地45μm至约1000μm、或约100μm至约850μm、或约100μm至约600μm范围内的粒度分布。颗粒形式的材料的粒度分布可如本领域中所已知来测定，例如借助干筛分析法（EDANA420.02“Particle Size distribution”）。也可使用如基于光散射和图像分析技术的光学方法。
本文中，将如图2中所示的包括基底层和不含通道的吸收层的吸收结构称为“不含通道的吸收结构”。
本文中，将如图3A、3B、4A至4D、6A和6B中所示的包括基底层、具有通道26的吸收层的吸收结构称为“具有通道的吸收结构”。
吸收芯的吸收结构中的至少一个包括通道26。更具体地，在其中吸收芯包括两个吸收结构的实施例中，它们中的一个包括通道且它们中的一个不含通道。在其中吸收芯包括超过两个吸收结构诸如三个或四个吸收结构的实施例中，另外的吸收结构可包括通道或不含通道。
“具有通道的吸收结构”包括至少两个纵向通道26，所述通道在吸收层的纵向尺寸上延伸穿过吸收层的厚度，并且其分布在吸收层中，使得吸收层的每个纵向部分20包括至少一个通道26。所述通道至少存在于吸收层的裆区和/或前区中。所谓在吸收层的纵向尺寸上延伸，是指通道基本上在纵向尺寸上延伸，即它们在纵向尺寸上比在横向尺寸上延伸更多，例如在纵向尺寸上的延伸多达横向尺寸上的至少两倍。
下文中，适用时，所述说明适用于每个独立获取的通道。例如，所谓“两个纵向通道可延伸覆盖距离L，所述距离为…的至少15%”，是指两个纵向通道中的每一个可延伸覆盖距离L，所述距离为…的至少15%”通道可相同或不同。
在一些实施例中，如图3A和4A中所示，吸收层17可包括至少存在于裆区中的两个纵向通道26。所谓至少存在于裆区中，是指通道可从裆区延伸直至前区和/或后区。两个纵向通道可延伸覆盖距离L，所述距离为吸收层纵向尺寸的至少15%、或至少20%、或至少30%且至多50%、或至多70%、或至多90%（即，它们可延伸覆盖距离L，所述距离为吸收层的长度M的至少15%、或至少20%或至少30%且至多50%、或至多70%或至多90%）。在一些实施例中，如图4A中所示，纵向主通道可仅存在于裆区中。当仅存在于裆区中时，纵向通道可延伸覆盖裆区的整个纵向尺寸，即吸收层纵向尺寸的50%，或者它们可仅在裆区的部分中延伸，即吸收层纵向尺寸的至少15%至40%、或至45%或至小于50%。（即，它们可延伸覆盖距离L，所述距离为吸收层的长度M的至少15%且至多50%）。在一些实施例中，两个纵向通道26可存在于裆区或其部分、以及前区的部分和/或后区的部分中。例如，在一些实施例中，纵向通道可存在于前区和裆区中，即通道延伸穿过裆区（或其部分）以及前区的部分。在这些实施例中，纵向通道可延伸至吸收层纵向尺寸的至多70%，通常吸收层纵向尺寸的15%、或20%、或30%至70%（即，它们可延伸覆盖距离L，所述距离为吸收层的长度M的至多70%）。在一些实施例中，纵向通道可存在于后区和裆区中，即通道延伸穿过裆区（或其部分）以及后区的部分。在这些实施例中，纵向通道可延伸至吸收层纵向尺寸M的至多70%，通常吸收层纵向尺寸的15%、或20%、或30%至70%（即，它们可延伸覆盖距离L，所述距离为吸收层长度M的至多70%）。在一些实施例中，纵向通道可存在于前区、裆区和后区中。在这些实施例中，纵向通道可延伸至吸收层纵向尺寸M的至多90%，通常吸收层纵向尺寸的55%或60%至70%或至80%（即，它们可延伸覆盖距离L，所述距离为吸收层长度M的至多90%）。
两个纵向通道通常在裆区中以距离D隔开，所述距离为所述裆区中吸收层横向尺寸（宽度）的至少5%、或至少10%、或至少20%、或至少25%。发现当在两个纵向通道之间存在此类距离D时，一次性尿布采取改善尿布贴合性的期望的桶形。在一些实施例中，纵向通道可在裆区中以至少10mm、或至少15mm、或至少20mm、或至少30mm的距离隔开。在一些实施例中，在裆区中隔开纵向通道的距离为20至30mm。
在一些实施例中，如例如图4B中所示，纵向通道可仅存在于吸收层的前区中。在这些实施例中，纵向通道可延伸覆盖距离L，所述距离小于吸收层纵向尺寸M的25%，通常吸收层纵向尺寸的15%、或17%、或20%至小于25%。
纵向主通道26不延伸直至吸收层17的横向边缘19，即不从一个横向边缘延伸至另一横向边缘。通常，吸收层包括沿每个横向边缘且与所述边缘直接相邻的不含通道的条，其在吸收层的横向尺寸上从一个纵向边缘延伸至另一纵向边缘（例如图3A中所示）。所述条分别具有宽度F’或G’，所述宽度为吸收层纵向尺寸的至少5%（即，宽度F’或G’为吸收层长度M的至少5%）。换句话讲，通道的边缘与吸收层的横向边缘之间的最小距离F’或G’为吸收层纵向尺寸M的至少5%。在一些实施例中，宽度F’或G’为吸收层纵向尺寸的至少5%至15%，或至10%。
此外，为了降低流体渗漏和溢出的风险，纵向主通道不延伸直至吸收层17的纵向边缘18。通常，吸收层包括沿每个纵向边缘且与所述边缘直接相邻的不含通道的条，其在吸收层的纵向尺寸中从一个横向边缘延伸至另一个横向边缘。所述条分别具有宽度I’或F’，所述宽度为给定区域中的吸收层横向尺寸N的至少5%、或至少10%、或至少12%至25%，（即宽度I’或F’为给定区域中吸收层宽度N的至少5%）。换句话讲，通道的边缘与吸收层的纵向边缘之间的最小距离I’或F’为吸收层横向尺寸的至少5%至25%。例如，裆区中的距离I’或F’可相当于所述裆区中吸收层横向尺寸的至少5%、或至少10%、或至少12%。在一些实施例中，距离I’和/或F’为10mm、或15mm或20mm。
纵向通道26可相对于吸收层的中心纵向轴线x彼此成镜像，即在一个纵向区20中的纵向通道可为吸收层17的另一纵向区中的纵向通道的镜像。
纵向通道可为平行于吸收层的纵向轴线运行的直通道（如示意性地示出于图5A中）。直通道用作吸收结构中的折叠线，其有助于向穿着时的尿布提供期望的桶形。一次性吸收制品如尿布在被穿着时适形于穿着者的紧身衣内部。因此，可获得类似U形，其可使渗漏最小化并增加舒适度。这些通道还改善了吸收结构内的流体输送，因此有助于加快侵害物采集。
作为另外一种选择，纵向通道可为弯曲的，如图5B中所示。弯曲的通道用作吸收结构中的折叠线，其辅助吸收结构跟随吸收制品穿着者的形态，即当尿布被穿着并被穿着者紧身衣压缩时，通道约束产品以采取类似U形。从而，除了允许改善的流体输送之外，通道还提供舒适且优异的贴合性。
纵向通道可为倾斜通道，如图5C中所示，即直通道相对于吸收结构的纵向中心轴线以至多30度、或至多20度、或至多10度的角θ取向。
在一些其它供选择的替代方案中，纵向通道可为成角通道，如图5D中所示。成角通道为由以角度σ彼此连接的两个或更多个部分制成的通道。通常，成角通道由以至少150度、或至少160度、或至少170度的角σ连接的两个部分制成。
在一些实施例中，纵向通道可为所谓的“分支”通道，即通道具有不以直的、成角的或弯曲的横向边缘28而是以分支29结束的至少一个极端。分支29可相对于通道的纵向中心轴线形成至多30度、或至多20度或至多10度的角α。
纵向通道26可具有3mm至15mm、或4mm至14mm或5mm至12mm的平均宽度w（通道的平均宽度为其纵向侧边缘27之间的平均距离）。通道的平均宽度可为吸收层宽度的至少4%，或至少7%且至多15%、或20%或25%。在一些实施例中，纵向通道可具有3mm至18mm、或5mm至15mm或6至10mm的平均宽度w。分支29也具有至少3mm的平均宽度w或为吸收层宽度的至少4%、或至少7%且至多15%、或20%或25%（分支29的纵向边缘27’之间的平均距离）。
吸收层可包括如上所公开的两个或更多个纵向通道。包括超过两个纵向通道的示例性吸收结构如图3B、4C和4D、6A和6B中所示。在一些实施例中，吸收层可包括3、4、5、6、8或甚至10个通道。优选地，吸收层包括平均数的纵向通道，其优选均等分布在吸收层的两个纵向区域中。
在一些实施例中，如图3B、6A和6B中所示，吸收层可包括至少存在于裆区中的四个纵向通道26。如上文关于两个纵向通道所公开，四个纵向通道可独立地至少存在于裆区中。在一些实施例中，另外的纵向通道可存在于后区和/或前区中。在一些实施例中，可能优选的是裆区中通道的最大数目为使得通道的宽度的总和小于裆区中吸收层横向尺寸N的50%的那些。
在一些实施例中，如图4C中所示，吸收层17可包括至少存在于裆区中的两个纵向通道26以及前区中的两个纵向通道26。所谓至少存在于裆区中，是指所述通道可从裆区延伸直至前区和/或后区。至少存在于裆区中的两个纵向通道可延伸覆盖距离L，所述距离为吸收层纵向尺寸M的至少15%、或至少20%或至少30%且吸收层纵向尺寸的至多90%（至少存在于裆区中的两个纵向通道可如上所述）。前区中的两个纵向通道可延伸覆盖吸收层纵向尺寸M的至少15%至20%的距离。裆区中的两个纵向通道可为弯曲通道，然而前区中的两个纵向通道可为倾斜通道。优选地，纵向区域之一中的通道在另一纵向区域中为彼此的镜像。
在一些其它实施例中，如图4D中所示，吸收层17可包括裆区中的两个纵向通道26、前区中的两个纵向通道26、以及后区中的两个纵向通道26。裆区中的两个纵向通道可延伸横跨吸收层纵向尺寸M的至少15%，或至少20%或至少30%。前区和后区中的纵向通道可延伸横跨吸收层纵向尺寸M的至少15%至20%。裆区中的两个纵向通道可为弯曲的通道，然而前区和后区中的纵向通道可为倾斜通道。优选地，在纵向区域之一中的通道在另一纵向区域中为彼此的镜像。
通常，通道分布成使得沿吸收层的每个横向边缘且与所述边缘直接相邻，在吸收层的横向尺寸上从一个纵向边缘延伸至另一纵向边缘、覆盖距离F’或G’的条保持不含通道（如上文关于纵向通道分布所公开）。
通常，通道分布成使得沿每个纵向边缘且与所述边缘直接相邻，在吸收层的纵向尺寸上从一个横向边缘延伸至另一个横向边缘、覆盖距离H’或I’的条保持不含通道（如上文关于纵向通道分布所公开）。
两个或更多个纵向通道可分布在吸收层中，使得沿吸收层的中心纵向轴线（且包括所述轴线）从一个横向边缘延伸至另一个横向边缘，并且具有宽度D’的条保持不含通道，所述宽度为吸收层横向尺寸N的至少5%、或至少10%且至多60%、或至多70%、或至多75%（如图4D中所示）。优选所述吸收性聚合物颗粒连续地存在于所述条中。例如，所述条可具有至少5mm、或至少10mm、或至少15mm或至少20mm且至多70mm或至多40mm的宽度D’。在所述条中不存在通道是有利的，因为其防止尿布在穿着时采取倒V-形构型。倒V-形构型增加了流体渗漏的风险。在一些实施例中，所述条中的吸收性聚合物颗粒的平均基重较高，即至少350gsm且至多1000gsm，或例如450gsm至750gsm。
吸收结构也可包括在吸收层的横向尺寸上延伸的一个或多个通道，条件是吸收层在裆区中不包括任何此类通道。在裆区中在横向尺寸上延伸的通道将传送液体至横向边缘并且将不可取地增加液体渗漏和/或溢出的风险。然而，此类通道可存在于吸收层的前区和/或后区中。在一些实施例中，吸收结构不包括任何此类通道。
如关于纵向通道所公开，横向通道可为平行于吸收结构的横向中心轴线的直通道（如图5A中所示）、弯曲通道（如图5B中所示）、成角通道（如图5D中所示）、倾斜通道（如图5C中所示）或分支通道（如图5E中所示）。横向通道可具有3mm至15mm、或4mm至14mm或5至12mm的平均宽度w。在一些实施例中，横向通道可具有6至10mm的平均宽度。
在本文的一些实施例中，可能优选的是与通道直接相邻（如图4C中所示）并从通道的边缘延伸覆盖至少3mm、或至少5mm、或至少7mm的距离k的吸收层的区域30包含基本上连续存在的吸收性聚合物颗粒。优选地，在这些区域30中，吸收性聚合物颗粒的平均基重较高，即至少350gsm、至少400gsm、或至少500gsm或至少600gsm。
通道优选为永久的。所谓永久的，是指在干燥和润湿两种状态下至少部分地维持通道的完整性，即通道抵抗由尿布穿着者的运动造成的摩擦并抵抗体液如尿液的润湿。永久通道通过将吸收性聚合物颗粒固定在基底层上而获得，如通过将热塑性粘合剂材料施加在吸收层之上。作为另外一种选择，可通过将基底层折叠到通道中或允许基底层进入通道，以便固定吸收性聚合物颗粒而使通道永久，如将在下文进一步详述。作为另外一种选择，可通过允许另外的基底层，如芯覆盖件（当存在时）折叠到通道中，即呈波浪形进入通道中而使通道永久。
可使用下文所述的润湿通道完整性测试以测试通道在润湿饱和后是否是永久的以及到什么程度。
润湿通道完整性测试
设计该测试以检验润湿饱和后通道的完整性。测试可在吸收结构上或在包含吸收结构的吸收芯上直接进行。
1.在干燥状态下测量通道的长度（以毫米为单位）（如果通道不直，则测量穿过通道中间的曲线长度）。
2.然后将吸收结构或芯浸入5升的合成尿液“盐水溶液”中，其中通过将适量的氯化钠溶解在蒸馏水中来制备9.00g NaCl每1000mL溶液的浓度。溶液的温度必须为20+/-5℃。
3.1分钟后，取出盐水溶液中的吸收结构或芯，并通过一端竖直地保持5秒以排水，然后在水平表面上展平，其中如果面向衣服侧可辨别，则该侧向下。如果吸收结构或芯包括拉伸元件，则将吸收结构或芯在X和Y两个尺寸上拉紧，使得没有观察到收缩。将吸收结构或芯的极端/边缘固定到水平表面上，使得收缩不能发生。
4.吸收结构或芯覆盖有合适重量的刚性板，其中尺寸如下：长度等于吸收结构或芯的延伸长度，并且宽度等于横向上的最大吸收结构或芯宽度。
5.在上述刚性板的区域之上施加18.0kPa的压力并持续30秒。压力基于被所述刚性板涵盖的总面积来计算。压力通过在刚性板的几何中心中放置附加的砝码，使得刚性板和附加砝码的组合重量在刚性板的总面积之上产生18.0kPa的压力来实现。
6.30秒后，移除附加的砝码和刚性板。
7.紧接其后，测量保持未受损的通道部分的累计长度（以毫米为单位；如果通道不直，则测量穿过通道中间的曲线长度）。如果没有保持未受损的通道部分，则通道不是永久的。
8.永久通道的完整性百分比通过将保持未受损的通道部分的累计长度除以干燥状态下通道的长度，然后将商乘以100来计算。
有利的是，根据本发明的永久通道在该测试后具有至少20%、或30%、或40%、或50%、或60、或70%、或80%、或90%的完整性百分比。
当吸收结构包含吸收性聚合物颗粒和纤维素时，可能优选的是所述通道也不含此类纤维素。
“不含通道的吸收结构”的吸收层可包含吸收性聚合物颗粒以及任选地分布在基底层上的纤维素，其例如形成为连续层，即吸收性聚合物颗粒和纤维素（当存在时）的不间断层。作为另外一种选择，吸收层可包含吸收性聚合物颗粒以及任选地分布在基底层上的纤维素，其例如形成不连续层。在一些实施例中，吸收层不含纤维素。在这些实施例中，吸收性聚合物颗粒（以及当存在时纤维素）可以颗粒的簇沉积在基底层上，从而形成吸收性聚合物颗粒（以及当存在时纤维素）的不连续层或插入层。吸收性聚合物颗粒（以及当存在时纤维素）的簇可具有多种形状，包括但不限于圆形、椭圆形、正方形、矩形、三角形等。适用于以颗粒的簇沉积颗粒的方法公开于EP1621167A2、EP1913914A2和EP2238953A2中。通常，当将两个此类吸收结构（即其中一个包括通道）组合以形成吸收芯时，将吸收性聚合物颗粒以颗粒的簇沉积在基底层上。将两个吸收结构组合，使得所得的吸收芯包括基本上连续分布在两个基底层之间（除了通道存在处之外）的吸收性聚合物颗粒。如本文所用，“基本上连续分布的”表示第一基底层和第二基底层被大量吸收性聚合物颗粒隔开。已经认识到，在吸收性聚合物材料区域（即，两个基底层之间的区域）内，在第一基底层与第二基底层之间可存在微量的偶然接触区域。第一基底与第二基底之间的偶然的接触区域可为有意的或无意的（例如制造人工痕迹），但不形成几何形状例如枕块、口袋、管、绗缝图案等。
“具有通道的吸收结构”的吸收层可包含吸收性聚合物颗粒以及任选地分布在基底层上的纤维素，其形成为连续层，即吸收性聚合物颗粒以及当存在时纤维素的不间断层，然而其包括基本上不含吸收性聚合物颗粒的区域。这些基本上不含吸收性聚合物颗粒的离散区域相当于吸收结构的通道。作为另外一种选择，“具有通道的吸收层”可包含吸收性聚合物颗粒以及当存在时分布在基底层上的纤维素，其形成为如上所公开的不连续层，然而，所述不连续层包括基本上不含吸收性聚合物颗粒以及当存在时纤维素的簇的离散区域。
可将吸收性聚合物颗粒和任选的纤维素固定在基底层上。固定可通过施加热塑性粘合剂材料来实现，所述热塑性粘合剂材料将吸收性聚合物颗粒保持并固定在基底层上。一些热塑性粘合剂材料还可渗入吸收性聚合物颗粒层以及基底层中以提供进一步的固定和粘附。当存在时，热塑性粘合剂材料不仅有助于将吸收性聚合物颗粒固定在基底层上，而且有助于维持通道的完整性。热塑性粘合剂材料避免了显著量的吸收性聚合物颗粒迁移到通道中。
热塑性粘合剂材料可作为连续层（即均匀地）施加在吸收层之上。在一些实施例中，当吸收性聚合物颗粒（以及当存在时纤维素）以簇沉积时，热塑性粘合剂材料接触吸收性聚合物颗粒（以及当存在时纤维素）以及基底层的部分。
在一些实施例中，热塑性粘合剂材料可作为在吸收层之上形成纤维性网络的纤维层而施加。当吸收性聚合物颗粒（以及当存在时纤维素）以簇沉积时，热塑性粘合剂纤维层可与吸收性聚合物颗粒（以及当存在时纤维素）至少部分地接触并且与吸收结构的基底层部分地接触。从而，热塑性粘合剂材料可提供腔体以覆盖吸收性聚合物颗粒，从而将该材料以及当存在时所述通道固定。
适于固定吸收性聚合物颗粒的热塑性粘合剂材料通常将良好的胶粘性和良好的粘附性性能组合。良好的粘附性促进了热塑性粘合剂材料与吸收性聚合物颗粒以及基底层之间的良好接触。良好的胶粘性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。当吸收结构/芯吸收液体时，吸收性聚合物颗粒溶胀并使热塑性粘合剂材料经受外力。热塑性粘合剂材料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聚合物颗粒的溶胀。
适用于本发明中的热塑性粘合剂材料包括热熔融粘合剂，所述热熔融粘合剂包括至少热塑性聚合物与塑化剂和其它热塑性稀释剂（如增粘树脂）以及添加剂（如抗氧化剂）的组合。示例性的合适热熔融粘合剂材料描述于EP1447067A2中。在一些实施例中，热塑性聚合物具有超过10,000的分子量（Mw）和低于室温的玻璃化转变温度（Tg）或-6℃>Tg<16℃。在某些实施例中，热熔体中的聚合物的浓度在约20重量%至约40重量%的范围内。在某些实施例中，热塑性聚合物可为对水不敏感的。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）氢化的此类型式。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，它们为使用单一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。也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。
热塑性粘合剂材料，通常热熔融粘合剂材料一般以纤维的形式存在，即可将热熔融粘合剂纤维化。在一些实施例中，热塑性粘合剂材料在吸收性聚合物颗粒之上形成纤维性网络。通常，纤维可具有约1μm至约100μm，或约25μm至约75μm的平均厚度，以及约5mm至约50cm的平均长度。具体地，可例如提供热熔融粘合剂材料层以包括类似网的结构。在某些实施例中，热塑性粘合剂材料以0.5至30g/m2，或1至15g/m2，或1至10g/m2或甚至1.5至5g/m2每基底层的量施加。
适用于本发明中的热熔融粘合剂的典型参数可为值低于1或值低于0.5的60℃下的损耗角tanδ。60℃下的损耗角tanδ与高环境温度下的粘合剂的液体特性相关联。tanδ越低，粘合剂表现得越像固体而不是液体，即，其流动或迁移的趋势越低，并且本文所述的粘合剂超结构随时间恶化或甚至崩落的趋势越低。因此，如果吸收制品用于热的气候中，则该值是尤其重要的。
其对于例如加工原因和/或性能原因可能是有益的，所述热塑性粘合剂材料在175℃下具有800与4000mPa·s之间，或1000mPa·s或1200mPa·s或1600mPa·s至3200mPa·s或至3000mPa·s或至2800mPa·s或至2500mPa·s的粘度，如由ASTM D3236-88，使用锭子27，20pmp，在所述温度下预加热20分钟，并且搅拌10分钟可测量。
所述热塑性粘合剂材料可具有60℃与150℃之间，或75℃与135℃之间，或90℃与130℃之间，或100℃与115℃之间的软化点，所述软化点可用ASTM E28-99（Herzog方法；使用甘油）测定。
在本文的一个实施例中，热塑性粘合剂组分可为亲水性的，其具有小于90°、或小于80°或小于75°或小于70°的接触角，如用ASTM D5725-99可测量。
在一些实施例中，吸收结构还可包括在将吸收性聚合物颗粒施加在基底层上之前沉积在基底上的粘合剂材料，本文中称为辅助粘合剂。辅助粘合剂可增强吸收性聚合物颗粒在基底层上的固定。其可为热塑性粘合剂材料，并包含如上文所述的相同热塑性粘合剂材料，或者其为可不同的。可商购获得的粘合剂的例子为H.B.Fuller Co.（St.Paul，MN）产品号HL-1620-B。可通过任何合适的方式将热塑性粘合剂材料施加到基底层。
将具有通道的至少第一吸收结构和不含通道的至少第二吸收结构组合以形成吸收芯。
吸收芯还可包括覆盖层。覆盖层可为单独层或者其可为与基底层一体的。在此类情况下，将承载吸收性聚合物颗粒的基底层折叠以形成包封吸收性聚合物颗粒的顶层和底层。覆盖层可由与基底层相同的材料提供，或者可由不同的材料提供。可例如通过粘合剂粘结和/或热粘结，将所述层在围绕周边处粘结在一起以将吸收性聚合物颗粒包封在其中。在一些实施例中，芯覆盖件可呈波浪形进入通道中。
在一些实施例中，吸收芯可包括采集系统，所述采集系统设置在吸收结构的顶片与面向穿着者侧之间。采集系统可用作液体的临时贮存器，直到吸收结构能够吸收液体为止。采集系统可包括单一层或多个层，诸如面朝穿着者皮肤的上部采集层和面向穿着者衣服的下部采集层。采集系统可与吸收结构直接接触。在这些实施例中，采集系统可填充通道或其部分。在一些实施例中，可将采集系统放置在芯覆盖件（当存在时）的顶部上。在芯覆盖件或基底层折叠进入通道中，即呈波浪形进入通道中的实施例中，采集系统可填充通道或其部分。在一些实施例中，采集系统或其一个层可结合到呈波浪形进入通道中的芯覆盖件或基底层，从而向所述采集系统提供波浪形轮廓。
在某个实施例中，采集系统可包括化学交联的纤维素纤维。此类交联的纤维素纤维可具有所期望的吸收性能。示例性化学交联的纤维素纤维公开于美国专利5,137,537中。在某些实施例中，化学交联的纤维素纤维与基于葡萄糖单元的约0.5摩尔%与约10.0摩尔%之间的C2-C9聚羧酸交联剂或约1.5摩尔%和约6.0摩尔%之间的C2-C9聚羧酸交联剂交联。柠檬酸为一种示例性交联剂。在其它实施例中，可使用聚丙烯酸。此外，根据某些实施例，交联的纤维素纤维具有约25至约60，或约28至约50，或约30至约45的保水值。用于测定保水值的方法公开于美国专利5,137,537中。根据某些实施例，交联的纤维素纤维可为起褶皱的、加捻的、或卷曲的、或它们的组合（包括起褶皱的、加捻的和卷曲的）。
在某个实施例中，上部采集层和下部采集层之一或两者可包括非织造物，所述非织造物可为亲水性的。此外，根据某个实施例，上部采集层和下部采集层之一或两者可包括化学交联的纤维素纤维，所述纤维素纤维可或可不形成非织造材料的一部分。根据一个示例性实施例，上部采集层可包括非织造（无交联的纤维素纤维），并且下部采集层可包括化学交联的纤维素纤维。此外，根据一个实施例，下部采集层可包括与其它纤维诸如天然的或合成的聚合物纤维相混合的化学交联的纤维素纤维。根据示例性实施例，此类其它天然的或合成的聚合物纤维可包括高表面积纤维、热塑性粘合纤维、聚乙烯纤维、聚丙烯纤维、PET纤维、人造丝纤维、lyocell纤维、以及它们的混合物。用于上部和下部采集层的合适的非织造材料包括但不限于SMS材料，包括纺粘层、熔喷层和另外的纺粘层。在某些实施例中，永久亲水性的非织造物（并且具体地为具有耐久亲水性涂层的非织造物）是所期望的。另一个合适的实施例包括SMMS结构。在某些实施例中，非织造材料为多孔的。
图7至9示出实施例，其中具有通道26的第一吸收结构15与不含通道的第二吸收结构15’组合。在图7中所示的实施例中，第一吸收结构15的热塑性粘合剂材料40直接接触第二吸收结构15’的热塑性粘合剂材料40’，然而在图8和9中，第二吸收结构15’不包括任何此类热塑性粘合剂材料40’（然而，其可存在以将吸收层固定在基底层上）。辅助粘合剂60可存在于第一和/或第二吸收结构的基底层上，用于进一步固定吸收性聚合物颗粒50（如图7中所示）。在一些实施例中，第一吸收结构15的基底层16可呈波浪形进入第一吸收结构的通道26中（如图8和9中所示）。吸收芯还可包括如上所公开的采集系统70，所述采集系统穿透并填充通道（然而，在一些实施例中，采集系统不填充通道）。图9示出实施例，其中采集系统70包括第一层12和第二层13，其中所述第二层填充通道。
在一些实施例中，在使用中，具有通道的吸收结构可比不具有通道的一个或多个吸收结构更靠近穿着者。
在一些实施例中，在使用中，具有通道的吸收结构可比不具有通道的一个或多个吸收结构更靠近衣服。
在一些实施例中，吸收性聚合物颗粒以及任选地纤维素可均匀地分布在吸收层的纵向和/或横向尺寸上，而不考虑吸收层是如上所述的吸收性聚合物颗粒以及任选地纤维素的连续层还是不连续层，以提供具有吸收性聚合物颗粒的均匀分布的吸收芯。吸收性聚合物颗粒的平均基重可取决于可在其中掺入吸收性聚合物颗粒的特定尿布。在一些实施例中，吸收芯中的吸收性聚合物颗粒的平均基重可为350gsm至1500gsm。相应区域中的吸收性聚合物颗粒的量通过测定该区域中吸收性聚合物材料的重量并将其除以区域的总表面积来计算（从而获取平均量）。
在一些实施例中，吸收性聚合物颗粒以及任选地纤维素可不均匀地分布在吸收层中的至少一个的纵向和/或横向尺寸上以提供异形吸收芯。例如，与吸收结构/芯的前区和后区相比，吸收结构/芯的裆区可包括更高量的吸收性聚合物颗粒每面积。在一些实施例中，吸收芯的前半部包括大部分的吸收容量，即，其可包含以吸收芯中吸收性聚合物颗粒的总重量计超过约60%的吸收性聚合物颗粒，或超过约65%，或超过70%。
在一些实施例中，吸收芯可通过将如上所述的包括通道的一个或多个吸收结构与不含通道的吸收结构组合或叠加而制成。在一些实施例中，吸收芯可通过将如上所述的包括通道的一个吸收结构与不含通道的一个或多个吸收结构组合或叠加而制成。吸收结构可全部包含少于5重量%的纤维素、或少于2重量%的纤维素、或不含纤维素，或者仅它们中的一些可包含少于5重量%的纤维素、或少于2重量%的纤维素、或不含纤维素。
在一些实施例中，其中吸收芯包括如上所述的包括通道的两个吸收结构与不含通道的吸收结构的组合，可将包括通道的吸收结构组合，使得一个吸收结构的吸收层或当存在时热塑性粘合剂材料直接接触其它吸收结构的吸收层，或当存在时热塑性粘合剂材料。一个吸收结构的通道可基本上与邻近吸收结构的通道叠加。所得的吸收芯为具有通道的吸收结构的层压体，其中通道基本上延伸穿过组合的吸收结构中的两个的厚度（如本文所用，所谓基本上是指在此忽略基底层的厚度）。在一些实施例中，一个吸收结构的通道可不与邻近吸收结构的通道叠加，但是与邻近结构的通道互补。所谓互补，是指吸收结构之一的通道形成其它吸收结构的通道的延伸。可将不含通道的吸收结构与如为更靠近尿布的底片或顶片的吸收结构的所述两个吸收结构组合。
制备吸收芯的方法
本文中不含通道的吸收结构可通过任何方法制备，所述方法包括将吸收性聚合物颗粒以及任选地纤维素以吸收层的形式沉积在基底层上的步骤。
本文具有通道的吸收结构可通过任何方法制成，所述方法包括将吸收性聚合物颗粒以及任选地纤维素沉积在基底层上以形成吸收层的步骤，例如通过首先将所述基底层以所述待产生通道的形状和尺寸放置在凸起部分上，然后将所述吸收性聚合物颗粒和任选地纤维素沉积在其上；从而，吸收性聚合物颗粒以及任选地纤维素不保留在所述凸起部分上，而是仅在基底层的剩余部分上。
在一些实施例中，具有基底层的吸收结构中具有基本上不具有吸收材料的两个或更多个通道，例如可通过包括以下步骤的方法获得：
a)提供喂料机，用于将所述吸收材料（吸收性聚合物颗粒以及任选地纤维素）给料于第一移动连续表面，如料斗；
b)提供转移装置，用于将基底层转移到第二移动连续表面；
c)提供第一移动连续表面，其具有一个或多个吸收层形成贮存器，所述贮存器具有纵向尺寸和平均长度、与其垂直的横向尺寸和平均宽度、以及垂直于它们两者的深度尺寸和平均深度、和用于在其中容纳所述吸收材料的空隙体积，所述一个或多个贮存器包括基本上纵向延伸的一个或多个凸起条，所述凸起条不具有空隙体积，例如各自具有为贮存器的平均宽度的至少4%或至少5%的平均宽度W以及为贮存器的平均纵向尺寸的至少5%且至多30%的平均长度L，所述一个或多个贮存器用于将所述吸收材料转移至与所述第二移动连续表面邻近并接近；
d)提供第二移动表面，其具有外壳，所述外壳具有一个或多个空气可透过或部分空气可透过的容器，所述容器用于在其上或其中容纳所述基底层，具有容纳区域以及一个或多个基本上纵向延伸的配合条，所述配合条可为空气不可透过的并且各自具有例如至少2.5mm的平均宽度W’，优选地0.5×W至1.2×W，例如为约0.8×L至1.2×L的平均长度；
从而将所述空气可透过的外壳连接至一个或多个二次真空系统以有助于将基底层和/或所述吸收材料保持在其上，并且
从而，在会合点中，所述第一移动连续表面和所述外壳在转移所述吸收材料期间至少部分地彼此邻近并彼此接近，并使得每个配合条在转移所述吸收材料期间基本上完全邻近并接近凸起条；
e)在其至少一个或多个所述贮存器中，用所述喂料机将吸收材料给料于所述第一移动连续表面；
f)任选地，移除一个或多个所述凸起条上的任何吸收材料；
g)同时，将所述基底层转移至所述第二移动连续表面，到一个或多个所述容器上或所述容器中；
h)用所述第一移动连续表面选择性地将所述吸收材料转移到会合点中，仅到支撑片材的所述部分，所述支撑片材在所述容器的容纳区域之上或之中。
所述一个或多个贮存器可由多个具有空隙体积的槽和/或腔体形成，用于在其中容纳所述吸收材料。在一些实施例中，（每个）条的平均宽度W优选为至少6mm，或例如至少7mm，和/或为相应贮存器的平均宽度的至少7%，或例如至少10%。
所述槽和/或腔体可在横向上各自例如具有至少3mm的最大尺寸，从而直接相邻的腔体和/或槽在基本上横向尺寸上的最短距离小于5mm。直接邻近凸起条的腔体和/或槽可具有体积，所述体积超过其一个或多个或所有相邻腔体或槽的体积，所述相邻腔体或槽不直接邻近所述条或另一个条（从而进一步从条移除）。
所述第一移动连续表面的贮存器可为至少部分空气可透过的，并且所述第一移动连续表面可具有围绕定子旋转移动的具有所述贮存器的圆柱体表面，其包括真空室；所述第二移动表面的外壳可为围绕定子旋转移动的圆柱体，其包括连接至所述二次真空系统的二次真空室。
然后可将通过所述方法获得的吸收结构与不含通道的吸收结构组合。
所述方法还可包括以下任选步骤：i）将粘合剂材料施加到步骤h的吸收结构；和/或在步骤f之前或与其同时，在任何情况下都在步骤g）之前，将粘合剂材料（即第二粘合剂材料）施加到所述基底层。
步骤i）1）可涉及例如基本上连续地将纤维形式的所述第一粘合剂材料喷涂到所述吸收层或其部分上，因此其还存在于所述通道中。
步骤i）2）可涉及连续地或例如以对应于通道图案的图案槽式涂布或喷涂支撑片材。
本文所公开的尺寸和值不应被理解为严格限于所述精确数值。相反，除非另外指明，每个此类尺寸旨在表示所引用的值以及该值附近的函数等效范围。例如，公开为“40mm”的尺寸旨在表示“约40mm”。
具体实施方式中引用的所有文献的相关部分以引用方式并入本文；任何文献的引用均不可解释为是对其作为本发明的现有技术的认可。当本文献中术语的任何含义或定义与以引用方式并入的文献中相同术语的任何含义或定义冲突时，应当服从在本文献中赋予该术语的含义或定义。
尽管举例说明和描述了本发明的特定实施例，但是对本领域的技术人员显而易见的是，在不脱离本发明的实质和范围的情况下可作出许多其它的改变和变型。因此，所附权利要求书旨在涵盖本发明范围内的所有此类改变和变型。
Claims (15)
1.一种吸收芯（7），包括至少第一和第二吸收结构（15、15’），所述吸收结构分别包括基底层（16、16’）和吸收层（17、17’），所述吸收层包含吸收性聚合物颗粒（50、50’）以及任选地由所述基底层承载的纤维素，所述吸收层中的每一个具有：
i.横向和纵向尺寸（M,N）；
ii.在所述纵向尺寸上延伸的一对相对的纵向边缘（18）；
iii.在所述横向尺寸上延伸的一对相对的横向边缘（19）；
iv.依次布置在所述纵向尺寸上的前区、裆区和后区（21,23,22）；
v.由垂直于所述吸收层的中心纵向轴线的平面划分的两个纵向部分；
其中所述第一吸收结构的吸收层包括两个或更多个通道（26），所述通道具有至少3mm，或为所述吸收层横向尺寸的至少4%的宽度，所述通道基本上不含所述吸收性聚合物颗粒并且其延伸穿过所述吸收层的厚度；并且
其中所述第二吸收结构（15’）的吸收层（17’）不含所述通道，并且
其中所述第一吸收结构的所述吸收层的每个纵向部分包括在吸收层的纵向尺寸上延伸并且至少存在于所述裆区和/或前区中的至少一个纵向通道（26），条件是所述吸收层不含延伸直至所述吸收层的纵向和横向边缘的通道。
2.根据权利要求1所述的吸收芯，其中所述第一和/或第二吸收结构包括吸收层，所述吸收层包含少于5重量%的纤维素。
3.根据权利要求1或2所述的吸收芯，其中所述纵向通道中的每一个延伸横跨所述吸收层纵向尺寸的15%至90%。
4.根据前述权利要求中任一项所述的吸收芯，其中所述第一吸收结构的吸收层包括四个纵向通道，所述通道中的两个在所述吸收层的前区中，并且所述通道中的两个在所述吸收层的裆区中。
5.根据权利要求1、2或3中任一项所述的吸收芯，其中所述第一吸收结构的吸收层包括六个纵向通道，所述通道中的两个在所述吸收层的前区中，所述通道中的两个在所述吸收层的裆区中，并且所述通道中的两个在所述吸收层的后区中。
6.根据前述权利要求中任一项所述的吸收芯，其中所述裆区中的所述纵向通道以所述裆区中吸收层横向尺寸的至少10%的距离隔开。
7.根据前述权利要求中任一项所述的吸收芯，其中所述第一吸收结构的吸收层还包括在所述吸收层的前区或后区中具有至少3mm宽度的横向通道，所述通道基本上不含所述吸收性聚合物颗粒。
8.根据前述权利要求中任一项所述的吸收芯，其中所述通道为直通道、倾斜通道、弯曲通道、成角通道、分支通道、以及它们的组合。
9.根据前述权利要求中任一项所述的吸收芯，其中所述吸收性聚合物颗粒通过热塑性粘合剂材料固定在所述基底层上。
10.根据前述权利要求中任一项所述的吸收芯，其中所述通道具有6至10mm的宽度。
11.根据前述权利要求中任一项所述的吸收芯，其中所述第一吸收结构的基底层呈波浪形进入通道中。
12.根据前述权利要求中任一项所述的吸收芯，其中所述吸收芯还包括采集系统。
13.一种具有横向和纵向尺寸的一次性尿布，包括底片、顶片以及设置在顶片与底片之间的吸收芯，所述吸收芯为根据前述权利要求中任一项所述的。
14.根据权利要求13所述的一次性尿布，其中所述第一吸收结构面朝所述尿布的顶片。
15.根据权利要求13所述的一次性尿布，其中所述第一吸收结构面朝所述尿布的底片。
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| WO1999051178A1 (en) * | 1998-04-03 | 1999-10-14 | Kimberly-Clark Worldwide, Inc. | An absorbent article |
| WO2004084784A1 (en) * | 2003-03-26 | 2004-10-07 | Sca Hygiene Products Ab | Absorbent article comprising an absorbent structure |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106470711A (zh) * | 2014-06-27 | 2017-03-01 | 宝洁公司 | 与第二开孔泡沫相联的开孔泡沫 |
| CN106470711B (zh) * | 2014-06-27 | 2019-10-15 | 宝洁公司 | 与第二开孔泡沫相联的开孔泡沫 |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2012170808A1 (en) | 2012-12-13 |
| SG195105A1 (en) | 2013-12-30 |
| BR112013030599A2 (pt) | 2016-09-27 |
| EP2717822B1 (en) | 2019-06-05 |
| JP5940655B2 (ja) | 2016-06-29 |
| CL2013003520A1 (es) | 2014-07-11 |
| US20120316529A1 (en) | 2012-12-13 |
| JP2014515985A (ja) | 2014-07-07 |
| RU2013156991A (ru) | 2015-07-20 |
| EP2717822A1 (en) | 2014-04-16 |
| MX2013014596A (es) | 2014-01-24 |
| US9974699B2 (en) | 2018-05-22 |
| ZA201400182B (en) | 2016-01-27 |
| CN103596535B (zh) | 2015-11-25 |
| CA2838980A1 (en) | 2012-12-13 |
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