CN1089576C - 体液吸收制品的覆盖层及其制造方法 - Google Patents

体液吸收制品的覆盖层及其制造方法 Download PDF

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CN1089576C
CN1089576C CN94104838A CN94104838A CN1089576C CN 1089576 C CN1089576 C CN 1089576C CN 94104838 A CN94104838 A CN 94104838A CN 94104838 A CN94104838 A CN 94104838A CN 1089576 C CN1089576 C CN 1089576C
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layer
cover layer
fiber
body fluid
absorption core
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CN1096441A (zh
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高井尚志
城户勉
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Unita Corp
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    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
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Abstract

一种体液吸收制品的覆盖层，它包括由热塑性合成树脂膜制成并具有横贯其中、向下延伸的液体通道的第一层和含70-100%(重量)纤维素纤维并在各液体通道的下部开口周围结合于所述第一层的第二层，它含有仅以机械定型固定在一起的纤维。第二层的密度比在液体吸收芯中所含纤维的密度高。

Description

体液吸收制品的覆盖层及其制造方法
本发明涉及用于体液吸收制品如卫生巾和一次性尿布的覆盖层，也涉及该覆盖层的制造方法。
制备一种用于体液吸收制品的覆盖层，该覆盖层具有大量的液体通道，每一个液体通道均从其上开口穿过覆盖层延伸至其下开口，使上部表面与使用者的皮肤相接触，而液体通道的下开口则与液体吸收芯接触，借助于每个液体通道之毛细管作用将体液引入液体吸收芯中，这是众所周知的事。
例如，日本专利公报No.1982-17081公开了这样一项技术，即由聚乙烯层制成覆盖层，其液体通道为圆锥台形毛细管，使每个液体通道的下端与液体吸收芯紧密接触。
日本专利公报No.1992-58950公开了这样一项技术，即，以熔喷法制成热塑性合纤无纺布，然后加工使其具有液体通道，并在液体通道的下开口周围形成纤维绒毛，从而得到覆盖层。
在上述的两项已有技术中，每个液体通道的下端必需一直与液体吸收芯保持紧密的接触。然而，既薄且又缺乏刚性的覆盖层在体液吸收制品的实际使用中易于起皱，结果，使每个液体通道的下端与液体吸收芯分离，从而妨碍了体液向液体吸收芯的顺利传递。
一般说来，柔软的手感对体液吸收制品来说是必不可少的。例如，如果液体吸收芯是由短绒浆粕制成，其密度便受到了限制，因为短绒浆粕的密度过高会给使用者带来不愉快的硬性手感。然而，短绒浆粕密度过低则会降低体液的扩散效果。结果，体液自液体通道向液体吸收芯的转移速度就不可能快，因为此时体液由通道下部开口的侧向扩散不可能快，从而使体液在覆盖层上停留较长的时间，给使用者带来潮湿的不适感觉。
因此，本发明的主要目的是解决前述技术所存在的问题，解决的途径是，以双层组织构成覆盖层，以第二层固定于第一层液体通道之下部开口周围，并将第二层的密度调整至与液体吸收芯的密度相当。
按照本发明的方法之一，前述目的可以如此达成：它包括一个用于体液吸收制品的覆盖层，该层具有大量液体通道，每一通道自上开口向下延伸至下开口，从所述液体通道的上开口周围连续向外延伸形成皮肤接触区，一个液体不透性的背衬层和一个夹在这两层中间的液体吸收芯；上述的覆盖层包括：由热塑性合成树脂膜制成并具有上述液体通道和皮肤接触区的第一层；位于该第一层之下并在液体通道下开口周围与其相结合的第二层；其中所述的第二层仅由机械定型捻结在一起的纤维制成并具有比所述液体吸收芯更高的密度。
所述覆盖层之第二层的纤维要求沿所述覆盖层的纵向定向排列，该第二层应由70-100％(重量)纤维素纤维和30-0％(重量)热塑性合成纤维的混合物所组成。
按照本发明的另一种方法，前述目的亦可如此达成：该体液吸收制品包括一个具有大量液体通道，每一通道均自上开口向下延伸至下开口，并从所述液体通道上部开口周围连续延展形成皮肤接触区的覆盖层，一个液体不可透过性的背衬层和夹在它们之间的液体吸收芯。所述的方法包括下列步骤：使用熔融体挤出机进行熔喷，将熔喷纤维喷入一个具有大量相同高度突起的成形模中，所述的突起具有平顶，由此而形成一定形状的熔喷无纺织物；将加热元件置于所述的突起平顶上，与所述的熔喷无纺布纤维接触，以形成锯齿状周边的开口，在该熔喷无纺织物上叠加纤维网，它含有仅以机械定型捻结在一起的纤维并具有比在所述液体吸收芯中所含纤维更高的密度，由此将所述纤维网机械地附着在所述开口之齿状周边上，以得到所述的覆盖层。
纤维网中的纤维应该沿所述的覆盖层之纵向取向。该纤维网应由70-100％(重量)纤维素纤维和30-0％(重量)热塑性合成纤维所组成。
在按本发明上述方式所制成的覆盖层中，第二层被结合于第一层各液体通道的下开口周围，并由此与第一层连为一体。因此，覆盖层的刚性就获得有效的加强足以防止覆盖层起皱，且限制了下开口的变形。结果，液体通道便不易堵塞。这样，一方面每个下开口的周边都与密度大于吸收芯的第二层相结在一起，另一方面，该第二层又与液体吸收芯接触，因此，到达各液体通道的下开口的体液不仅能通过第二层顺利地向下转移至液体吸收芯内，而且还能迅速地沿着第二层平面方向扩散，并迁移至液体吸收芯内。
第二层的纤维沿所需方向定向排列，体液便能容易地纤维定向的方向扩散。例如，纤维的排列方向选择与体液吸收制品的纵向相一致，以确保体液能快速地沿液体吸收芯纵向扩散，从而使整个液体吸收芯得到了充分地利用。
按照本发明制造覆盖层的方法，由齿状周边所形成的各开口可通过熔化在熔喷无纺织物上的突起物来形成，纤维网通过机械捻连纤维形成，以使该网的纤维易于解散并易于牢靠地缠结在所述齿状周边上。结果，熔喷无纺织物能容易地与纤维网连为一体。
参考附图本发明的覆盖层及制造方法将得到更详尽地说明，其中：
图1是卫生巾的透视图；
图2是沿图1中的X-X轴所得截面图；以及
图3是制成覆盖层所用生产线的流程图。
                        实施例
参考图1，它显示了使用本发明覆盖层2的卫生巾1，为明白起见，它的一部分已被切除。它包括液体透过性的覆盖层2、液体不透过性的背衬层3和夹在层2、3之间的液体吸收芯4。覆盖层2完全地将液体吸收芯包裹起来，相对的两边在巾1的后部彼此交叠地结合在一起，覆盖层两端的上和下两层各于卫生巾1的两端相互结合在一起。背衬层3被安放在巾1下侧的覆盖层2和液体吸收芯4之间。
图2是沿图1中X-X轴剖切所得的截面图，它示意地表明覆盖层2与液体吸收芯4相接触的状态。覆盖层2包括贴近使用者皮肤的上层5和紧靠液体吸收芯4的下层6。上层5具有上表面7、下表面8、液体通道10(每一个通道均从上表面7延伸至下表面8，高度为h)和从各液体通道10的上开口11周围连续延伸的皮肤接触区13。下层6具有其上表面15、下表面16和在各液体通道10中的暴露区17、和与皮肤接触区13相对的非暴露区18。下表面16至少在暴露区17处为平面，或朝液体吸收芯4方向鼓起，亦即不朝上鼓入液体通道10中，这样下表面16就轻易地与液体吸收芯4紧密接触。在非暴露区18处，下表面16最好也与暴露区17的情况相似。
在上层5中，液体通道10的下开口12具有大量的不规则边缘和绒毛形成的齿状周边12A。另一方面，下层6为由纤维机械定型捻连在一起形成的网，它也与齿状周边粘连并与上层5结合在一起，由此形成覆盖层2。
上层5由疏水性热塑性合成树脂膜或热塑性合成纤维无纺织物制成。合成树脂膜可以是，例如，厚度为0.01-0.10mm的聚乙烯膜，无纺织物层可以是，例如，单重5-100g/m2的熔喷无纺织物。
下层6由纤维网形成，它含有70-100％(重量)纤维素纤维，如浆粕或人造纤维，和30-0％(重量)热塑性合成纤维。下层6比上层5具有更大的亲水性，并且具有比液体吸收芯4更高的密度。如当使用短绒浆粕和高吸水能力的聚合物粉末的混合物制成液体吸收芯4时，下层6的密度应调节至比所述短绒浆粕的密度更高的水平。通常，这样短绒浆粕的密度可在0.02-0.1g/cm3的范围选择。形成下层6的大部分纤维沿卫生巾1的纵向定向，体液在毛细管效应的作用下更易于沿纤维定向的方向扩散。如果需要，可于主要由纤维素组成的下层6中混入30％(重量)或更少些地热塑性合成纤维，以便获得比100％(重量)纤维素纤维网更高的体液扩散性。
上层5的液体通道10可以是朝液体吸收芯4逐渐收细的毛细管或向相反方向逐渐收细的毛细管、或具均匀直径的圆柱形毛细管。液体通道10应具有0.1-7mm的长度。上下部开口11、12可以是圆形、多角形或其它任意适宜的外形，其直径应为0.3-7mm。
参照图3，它示意地说明制成覆盖层2的生产流程。该生产线包括一个用作成形模的可顺时针旋转的辊子51、对着辊子51有一个熔喷挤出机52、一个可调节温度的加热辊子53、纤维网喂入器54和一个卷取装置62。
辊子51的外周表面具有大量的突起58，它们具有基本均一的高度，每个突起均有平顶和在每个突起58周围的凹陷59。整个辊子51的周边具有大量细小透孔(未标出)与辊子51内的抽吸装置41相通。
熔喷的纤维40从熔喷挤出机中被喷出至辊子51的外周边表面上，在抽吸装置41的作用下随着突起58和凹陷59的形态形成熔喷无纺织物40a。
加热辊子53被安置得与突起58的平顶60相接触，使处于加热辊53和平顶60之间的无纺织物40a在各顶60上熔融，以形成开口61。
纤维网喂入器54通过一对导辊55将网42喂子无纺织物40a上，该无纺织物上已被借助抽吸装置41的作用形成了开口61，同时借助于压力辊56的作用使网42被缠结在各开口61周围，与熔喷无纺织物形成一体。以此方式结合为一体的熔喷无纺织物40a和纤维网42被卷取装置62所卷取以得到用作覆盖层2的连续疋卷2A。该连续疋卷2A将被剪裁成尺寸适合于每个卫生巾1与覆盖层2的片材。
按上述方法制得的连续疋卷2A的结构与从其上剪裁下来的单片覆盖层2的结构有关，所以，喷熔无纺织物40a和纤维网42分别形成了上、下层5、6；突起和凹陷的变形部分分别形成了液体通道10和皮肤接触区13；位于各突起顶60上的纤维网部分便形成暴露区17。暴露区17并不朝向覆盖层2中的开口11升起，而是与卫生巾1中的液体吸收芯牢靠地接触，因为顶60是平的。
纤维网是由含有仅以机械地方式相互绕结的纤维网形成的，如无定向纤维网、梳理纤维网、气流成形网或在压喷水器的高压下上述任一纤维网定型得到的无纺织物，其密度应调节到比所用之液体吸收芯4密度高些。纤维网42含有亲水性的纤维素纤维，例如占所使用纤维总重量的70-100％的浆粕或人造丝纤维，并且，如果需要，可将这些亲水性纤维与30-0％(重量)的疏水性热塑性合成纤维混合。这些纤维网或无纺织物中的纤维通常在其制造过程中沿加工进行的方向定向排列，因此纤维网42的喂入和/或剪切时，要使其纤维定向与所制备的卫生巾1的纵向一致。
本发明的覆盖层，是以上层和下层结合在一起，因此能有效地阻止液体通道的变形。
下层的密度调节到高于液体吸收芯密度的水平，结果，当体液到达每个液体通道下端后，不仅立即被通过下层透入液体吸收芯中，而且在下层中以平面方向迅速扩散开来，并随之向下渗透入液体吸收芯。这样，采用应用本发明的覆盖层制成的体液吸收制品，体液在较大区域被吸入液体吸收芯，并且，体液在覆盖层停留的时间也相应地缩短。从而减轻了潮湿的不适感。
下层中的纤维可以按所需的方向进行定向，以加速体液在此方向的扩散，这种扩散可通过于下层中混入热塑性合成纤维而进一步得到加强。
含仅以机械空形粘结纤维的纤维网被用于下层，因而这些纤维可容易地被解散并容易地被固定在每个液体通道下端开口的齿状周边上。这种特征便于使上层和下层结合成一体而形成完整的覆盖层。

Claims (6)

1.一种用于体液吸收制品的覆盖层，该体液吸收制品由该液体透过性覆盖层，一个液体不透性背衬层和夹在该两层中间的液体吸收芯所组成，所述之覆盖层含有大量由上开口向下延伸，横贯其中直至下开口的液体通道和由所述液体通道上开口向周围连续延展而形成的皮肤接触区，所述的覆盖层包括下列部分：
第一层，由热塑性合成树脂膜制成，它具有上述之液体通道和皮肤接触区；和，
第二层，该层处于第一层之下，并于各通道之下开口周边与第一层联结在一起；
其特征在于，该第二层由仅以机械定型手段固定在一起的纤维所组成，其密度高于所述液体吸收芯的密度。
2.如权利要求1所述的覆盖层，其特征在于：所述其中的第二层中的纤维定向排列，其方向与覆盖层的纵向一致。
3.如权利要求1所述的覆盖层，其特征在于：所述的第二层由含有70-100％(重量)纤维素纤维和30-0％(重量)热塑性合成纤维的混合物所构成。
4.一种制造用于体液吸收制品之覆盖层的方法，其中，该体液吸收制品由该液体透过性覆盖层，一个液体不透性背衬层和夹在该两层之间的液体吸收芯所组成，所述的液体适过性覆盖层具有大量的液体通道，每个通道都自其上部开口横贯该层并延伸至其下部开口，从通道上部开口周围向外连续延展而形成的皮肤接触区，该制造方法包括下述步骤：
以熔喷挤出机将熔喷纤维喷向一个具有大量高度基本相等并具有平顶的突起的成形模，以制得形状与成形模构型相一致的熔喷无纺织物；
使加热元件与所述之熔喷无纺织物之突起顶处相接触以便形成开口，该开口的边缘呈锯齿状；以及
将仅由机械定型纤维构成，密度高于液体吸收芯的纤维网喂入并与上述熔喷无纺织物相叠合，并于上述各开口的齿状边缘处借助于机械绕结作用固定在一起，以形成所述的覆盖层。
5.如权利要求4所述的方法，其特征在于：所述纤维网中的纤维以纵向方向取向。
6.如权利要求4所述的方法，其特征在于：所述的纤维网70-100％(重量)纤维素纤维和30-0％(重量)热塑性合成纤维的混合物。
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US5656232A (en) 1997-08-12
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TW271391B (zh) 1996-03-01
JP3058533B2 (ja) 2000-07-04
EP0626159B1 (de) 1999-07-14
KR100272133B1 (ko) 2000-12-01
AU677633B2 (en) 1997-05-01
SG52331A1 (en) 1998-09-28
MY118934A (en) 2005-02-28
ES2136676T3 (es) 1999-12-01
GB2277480B (en) 1997-03-19
JPH06304203A (ja) 1994-11-01
DE59408480D1 (de) 1999-08-19
EP0626159A1 (de) 1994-11-30
KR940023453A (ko) 1994-11-17

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