CN1175226A - 薄厚度薄膜和薄膜/无纺织物层压制品 - Google Patents

薄厚度薄膜和薄膜/无纺织物层压制品 Download PDF

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CN1175226A
CN1175226A CN95197584A CN95197584A CN1175226A CN 1175226 A CN1175226 A CN 1175226A CN 95197584 A CN95197584 A CN 95197584A CN 95197584 A CN95197584 A CN 95197584A CN 1175226 A CN1175226 A CN 1175226A
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layer
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CN1092563C (zh
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A·L·麦克科马克
K·G·赫茨勒
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Kimberly Clark Worldwide Inc
Kimberly Clark Corp
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Abstract

一种薄厚度多层薄膜(10),该薄膜可以与其它材料,例如纤维无纺织物层压在一起。所述多层薄膜可以包括一层或多层表层(18,20),这些表层在某种构型中的厚度不超过总厚度的15%,而在另一些构型中可不超过多层薄膜总厚度的10%。这种薄膜和层压制品有着广泛的用途,例如作为个人维护用有吸收性的产品、衣服和与健康护理相关的用品,如外科手术用消毒盖布和手术服,但并不限于此。

Description

薄厚度薄膜和薄膜/无纺织物层压制品
本发明涉及薄厚度的多层薄膜，该薄膜具有极薄的外层。
本发明涉及极薄的多层薄膜以及把它们用于层压制品。这种材料有极其广泛的用途，特别是在限制使用和可弃物品领域。
今天很多产品要求经过高度设计的成份，但同时这些产品要求是受限使用或可弃的物品。受限使用或可弃，意思是产品和/或成份在抛弃之前仅仅使用很少几次或仅仅用一次。这种产品的例子包括，但不限于此，与个人维护和外科手术有关的产品，例如外科用消毒盖布及外科医生服，可弃工作服，例如工作服和实验室服，以及个人维护用的有吸收性的产品，例如尿布，训练服，失禁衣裤，卫生巾，绷带，揩布以及类似物品。所有的这些产品能够且必须使用薄膜和纤维无纺织物作其组成部分。这两种材料经常交互使用，薄膜有很强的阻挡性能，特别是对液体而言，而纤维无纺织物与其它物品相比有较好的触觉感，舒适感及美感。当这些材料用于受限使用或可弃产品中时，对设计性能最好，成本最低的要求很高。为此，经常要求使用薄膜或使用无纺织物来实现所要求的结果，这是因为薄膜和无纺织物的组合件常常很贵。在薄膜领域，曾尝试过生产薄厚度的多层薄膜。例如从授予Vischer的美国专利No.5261899中可知一种具有中间层的三层薄膜，此中间层占三层薄膜总厚度的30～70％。形成多层薄膜的一个优点在于可使薄膜设计成具有特殊的性能，并且通过将薄膜制成多层形式，可以把较昂贵的组份转移到外层上可能是最需要的部位上。
本发明的目的是提供这样一种多层薄膜，它可设计成提供特殊的性能，同时能以很薄的厚度提供这种性能。
由独立权利要求1，3与11所述的多层薄膜，独立权利要求12和16所述的个人贴身用有吸收性的物品，独立权利要求13和15所述的层压制品；独立权利要求18和19所述的外科医生服；独立权利要求20和21所述的外科用盖布，以及独立权利要求22和23的衣服制品，都可以实现上述目的。
从从属权利要求，描述及附图可了解到见本发明的其它优点。特点，有关的各个方面以及细节。这些权利要求应理解为从总体上来界定本发明的第一种非限制性的方法。
本发明的另一个方面是将这种薄厚度薄膜与其它支持层，例如纤维无纺织物层组合起来以增强强度并提供美观特点。
本发明涉及多层薄膜和多层薄膜/无纺织物层压制品。此外，本发明还涉及这种薄膜层压到其它材料，例如纤维无纺织物上。
上述薄膜由普通的薄膜成形技术制成，如铸-吹(cast andblown)复合挤压薄膜成形法。此薄膜与由可挤压热塑性聚合物制成的芯层一起形成，此芯层具有第一外表面和第二外表面。在绝大多数基本结构中，由于混合挤压过程，第一表层同时固定在芯层的第一外表面上以形成多层薄膜。多层薄膜界定了总体厚度，由第一表层界定的第一表层厚度不超过多层薄膜总厚度的10％。这是由于将挤压薄膜牵伸到能使多层薄膜变薄到指定的尺寸范围的程度内。结果是第一表层的厚度不超过2μm。如果多层薄膜有非常薄的性质，就可将多层薄膜与其它材料，例如支持层层压在一起。适当的支持层包括，但不限于，例如其它薄膜，纤维无纺织物，纺织材料或前述材料的交织和组合。在本发明的其它一些实施例中，芯层的第一外表面连接到第一表层，而第二外表面连接到第二表层。在这种情况下，第一表层和第二表层的总厚度不应超过多层薄膜总厚度的15％，而更好是使第一表层厚度或第二表层厚度都不超过此总厚度的7.5％。如有需要，一层或多层中可有其它的添加物，例如粒状填料。更典型的是这种填料主要用在芯层中，例如粒子层的重量至少为这一特定层总重量的60％。
还可能生产出可透气的多层薄膜，这是通过采用允许气体通过这些层扩散的特殊聚合物和/或通过采用粒子填料实现的。一般，为使这种薄膜透气，是在两压辊之间拉伸和/或挤出这种薄膜，以在这批粒子内或其周围产生空隙而允许水蒸汽和其它气体穿过。一般这种可透气的多层薄膜的水蒸汽穿透率至少为每24小时每平方米300克。
这种薄膜和层压制品有广泛的用途，例如但不限于，用于贴身的有吸收性的物品中，这种物品包括尿布，训练服、失禁衣裤、卫生巾、绷带和类似物件。同样，这些薄膜和层压制品也可作为整体或仅仅是作为组成部分用于外科用消毒盖布，和外科医生服及各种衣物中。
结合附图参照下面对本发明的实施例的描述，可以更好地理解本发明，附图中：
图1是根据本发明的多层薄膜的横剖侧视图，薄膜的右侧被分开以简化它的描述；
图2是根据本发明的多层薄膜/无纺织物层压制品的横剖侧视图；
图3是形成本发明的多层薄膜和多层薄膜/无纺织物层压制品的工艺过程的示意性侧视图；
图4是部分切除的示例性贴身用、有吸收性物品(在本例中是一尿布)的顶视平面图，其采用了根据本发明的多层薄膜和多层薄膜/无纺织物层压制品。
本发明涉及多层薄膜，即有两层或三层的薄膜，以及与支持层例如纤维无纺织物层压在一起的薄膜。参见图1，其中示出一种多层薄膜10，但并非按比例示出，出于说明目的，在附图右侧已被分开。多层薄膜10包括由可挤压的热塑性聚合物，例如聚烯烃或聚烯烃混合物制成的芯层12。芯层12有第一外表面14和第二外表面16。此芯层还有一芯层厚度22。与芯层12的第一外表面14相连的是第一表层18，它具有第一表层厚度24。与芯层的第二外表面相连的是一可选择的第二表层20，它具有第二表层厚度26。此外，多层薄膜10有一总厚度28。这种多层薄膜10可由薄膜生产工业中普通技术人员所熟知的各种工艺来生产。两种特别优选的工艺是铸膜复合挤压工艺和吹膜复合挤压工艺。在这类工艺中，两或三层同时形成，并以多层形式从挤压机出来。由于本发明的多层薄膜极薄的特性，已证明此种工艺极可能最为有利，当然，也可以采用各自独立的挤出工艺来形成多层薄膜。有关这两种工艺更详细的信息可参见例如，美国专利4522203、4494629和4734324，它们所公开的内容已全部引用作为参考。
本发明重要的特点是可以采用更普通的芯层12再结合一种很薄并经特殊设计的表层，例如第一表层18或是采用两层或更多层表层与芯层12的一面或两面相连的组合件。由此就可能形成具有多层材料的多层薄膜10。例如具有第一表层18和可选择的第二表层20的芯层12可由任何在多层薄膜结构中能利用的聚合物制成，这种聚合物包括，但不限于，聚烯烃，所述聚烯烃包括均聚物共聚物和混和物。为进一步降低芯层12的成本，在芯层聚合物挤出混合物中可加入一种或更多种填料。既可用有机填料也可用无机填料。对填料应进行选择，以便不会对挤出薄膜造成不利影响，或与其发生化学反应。这些填料能用于减少芯层12的聚合物的数量和/或赋予甚某些特性例如透气性，和/或减轻气味。填料的例子能包括，但不限于碳酸钙(CaCO3)、各种粘土、二氧化硅(SiO2)、氧化铝、硫酸钡、碳酸钠、滑石、硫酸镁、二氧化钛、泡沸石、纤维素型粉末、硅藻土、硫酸镁、碳酸镁、碳酸钡、高岭土、云母、碳、氧化钙、氧化镁、氢氧化铝、纸桨粉末、木材粉末、纤维素衍生物、聚合物颗粒、粘合剂及其衍生物。
使用的填料的数量取决于最终的使用目的，并且可以采用占芯层12总重量的0～80％的添加量。一般填料是粒子形状，通常约略呈球形，平均粒度约0.1～7微米。更进一步讲，如果有足够的填料与多层薄膜10的足够的牵伸相结合，则能在芯层12内的粒子周围产生空隙，从而使芯层可透气。当用超过芯层12重量60％的大量的填料与薄膜拉伸结合时，便可产生透气薄膜。这种可透气薄膜一般具有每24小时每平方米大于300克的水蒸汽穿透率(WVTR)。
表层18和20一般包括可挤压出的热塑性聚合物和/或为多层薄膜10提供特殊性质的添加物。这样，第一表层18和/或第二表层20可以由这样的聚合物制成，它们可赋予下述种种特性，如抗微生物性，水蒸汽穿透性，粘附性和/或防阻塞性。因此表层18和20对一种或多种特殊聚合物的选择取决于所要求的特殊的性质。可采用的聚合物的例子可包括下列物质中的一种或其组合物：均聚物，共聚物，聚烯烃混合物和乙烯-乙酸乙烯酯(EVA)、乙烯-丙烯酸乙酯(EEA)、乙烯丙烯酸、乙烯丙烯酸甲酯(EMA)、乙烯丙烯酸丁酯(EBA)、聚酯(PET)、尼龙(PA)、乙烯乙烯醇(EVOH)、聚苯乙烯(PS)、聚氨酯(PU)和烯属热塑性弹性物，它们都是多级反应产物，其中非晶体乙烯丙烯不规则共聚物则以分子形式分散在主要是半结晶的高聚丙烯单体/低乙烯单体的连续基质内。
常要求把多层薄膜10与一层或多层基质或支持层30层压在一起，如图2所示。芯层可以没有足够的使其结合到支持层30上的粘附性或接附性。第一表层18可由一种或多种具有比芯层12高的粘附性和/或低的粘合点的聚合物构成。
对于本发明的材料所希望达到的结果是，能实现极薄的总的薄膜厚度，更重要的是，使表层仅仅占多层薄膜10总厚度的一小部分。如以下例子所述，设多层薄膜10的总厚度为28，则在两层结构中，第一表层18的第一表层厚度24不应超过总厚度28的10％。在三层薄膜结构中，第一表层18和第二表层20的厚度和不应超过总厚度的15％，且一般情况下，第一表层18不应超过总表层厚度28的7.5％。对第二表层20同样如此。因此芯层至少占总厚度28的85％，而第一表层18和第二表层20一般各不超过总厚度28的7.5％。一般情况下，可能生产总厚度28为30μm或更薄的薄膜，在某些应用中，可使表层不超过2μm。为此，只需先形成多层薄膜10，再使薄膜沿机器方向拉伸或定向，如下面将更详细描述的，使最终的多层薄膜10沿机器方向的强度特性得到改进，所述机器方向即平行于薄膜从薄膜挤出设备出来的方向。
最终的薄膜，如果需要可以与一层或更多层支持层30相层压，如图2所示。如图2所示的支持层30是纤维无纺织物。这种纤维无纺织物的制造对无纺制造领域的普通技术人员而言是熟知的。这种纤维无纺织物可赋予多层薄膜10以其它的特性，如更软，更类似于布的触感。多层薄膜10特别有利于用作液体的阻挡层，如应用于作为贴身用的有吸收性物品的外层，和作为医院外科的阻挡材料以及清理房间等场合，例如外科用消毒盖布，外科医生服和以其形式的服装。支持层30与第一表层18和第二表层20的连接可以通过采用单独的粘合剂，例如热融体的或溶剂基的粘合剂，或通过采用受热粘接辊的加热和/或加压来实现。结果可能要求对第一表层18和第二表层20的一层或两层进行设计，使之具有固有的粘结性能以简化层压过程。
特别合适的支持层是纤维无纺织物。这种织物可由多种工艺制成，如纺粘，熔喷，粘合粗梳织造等制造工艺，但不限于此。喷熔法非织造纤维是按下述方式进行：通过将熔融的热塑性材料挤过多个纤细的，通常为圆形的毛细模具作为熔融纱线或纤维进入一高速热气流中，例如空气，该气流减薄熔融热塑性材料的纤维从而减小其直径。然后，将此喷熔出的纤维由高速热气流携带并置于收集表面上，形成由随机分布的喷熔纤维组成的织物。喷熔法无纺织织造工序是熟知的，且在各种专利和公开文件中描述过，如NRL报告4364，B.A.Wendt，E.L.Boone和C.D.Fluharty的(“Manufacture of super-Fine Organic Fibers”)“超细有机纤维的制造”；NRL报告5265，K.D.Lawtence，R.T.Lukas，J.A.Young的“形成超细热塑性纤维的改进装置”(An Improved DeviceFor the Formation of Super-Fine Thermoplasbic Fibers)；1972年7月11日授予Prentice的美国专利3676242，和1974年11月19日授予Buntin等人的美国专利3849241。上述参考文件的内容已全部引用作为参考。
纺粘纤维是通过将熔融的热塑性材料从喷丝板上多个纤细的一般为圆柱形的毛细管中挤出而形成的，其中挤出纤维的直径通过非喷射或喷射流体牵引或其它已知的纺粘设备迅速变细。在例如授予Appel等人的美国专利No.4340563，授予Matsuki等人的美国专利3802813和授予Dorschner等人的美国专利3692618，授予Kinney的美国专利3338992，3341394，授予Levy的美国专利3276944；授予Peterson的美国专利3502538；授予Hartman的美国专利3502763，授予Dobo等人的美国专利3542615，和授予Harman的加拿大专利803714中都说明了纺粘无纺织物的生产。上述各专利的内容已全部引用于此作为参考。
也可使用多层支持层30，这种材科的例子包括，例如纺粘/喷熔层压制品和纺粘/喷熔/纺粘层压制品，如在授予Brock等人的美国专利4041203中所示的，它们的全部内容已引用于此作为参考。
粘合梳理织物由经常成包购买的短纤维制成。将这种纤维包放在分离纤维的清棉机上。然后使纤维通过精梳或粗梳单元，继续分离并使短纤维沿机器方向排列好，从而形成沿机器方向定向的纤维无纺织物。一旦织物形成，它就通过一种或多种粘合方法粘合起来。一种粘合方法是用粉末粘合剂粘合，其中粉末粘合剂分散贯穿织物，然后用热空气加热织物和粘合剂使其活化。另一种粘合方法是图案粘合法，其中采用轧辊或超声波粘合设备将纤维粘合在一起，如果需要，在织物的定位粘合图案中遍及其整个表面进行粘合。当采用双组分短纤维时，应用通风粘合设备在许多应用场合中特别有利。
形成多层薄膜10的工艺在附图中的图3示出。参照附图，多层薄膜10由复合挤压薄膜设备40，例如上述的铸塑单元或吹塑单元形成。一般，这种设备40包括两个或更多的聚合物挤压机41。多层薄膜10挤入一对有图案的轧辊或冷却辊42，从而将凸凹图案施加到新成形的薄膜10上。这对减少薄膜光洁度，使其有暗淡色调外观很有好处。利用图1所示的三层薄膜结构，一般最初形成的薄膜的总厚度28近似为40μm或更大，第一表层18和第二表层的起始厚度为3μm或更大，这两层的厚度和近似占薄膜总厚度的75％。
薄膜10从复合挤压薄膜设备40出来后，导向薄膜牵伸单元44，例如一沿机器方向的定向器，后者例如可从Marshall and WilliamsCompany of Providence Rhode Island购置到。这一单元44有多个牵引辊46，它们沿机器方向，即薄膜10通过图3所示工艺过程的方向，牵伸并减薄薄膜。离开薄膜牵伸单元44后，薄膜10的总厚度近似为30μm，每层表层的最大厚度不应超过2μm，各表层的厚度和不超过薄膜总厚度的15％，更为理想的是少于总厚度的10％。
如果需要，多层薄膜可以连接到一层或多层支持层30上以形成多层薄膜/无纺织物层压制品32。再次参照图3，采用一种普通的纤维无纺织物形成设备48，例如一对纺粘机器形成支持层30。长的连续纤维50放在成形网52上作为非纺粘织物54，非纺粘织物54送入一对粘合辊56之间以将纤维粘合在一起，并增加最后的织物支持层的抗撕裂强度。将一或两个辊加热到能进行粘合的程度。一般一个辊56上是有图案的，从而能将离散的粘合图案按预定表面区域施加到织物30上。另一个辊通常是光滑的砧辊，如需要此辊上也可以有图案。一旦多层薄膜已经足够薄并已定向，支承层30已经形成，就将两层放在一起，并使用一对层压辊或其它设施58使其层压在一起。如同粘合辊56一样，层压辊58可以被加热。至少一个辊上有图案以在最终的层压制品32上以预定的粘合表面区域产生离散的粘合图案。一般而言，在层压制品32的一侧表面的给定区域内，最大粘合点的表面面积不超过整个表面积的50％。可以利用现有的大量的离散的粘合图案。例如参看授予Brock等人的美国专利4041203，其中的内容已全部引用于此以作参考。层压制品32从层压辊58出来后，可以卷绕到辊60上供进一步处理。或者层压制品32可以继续在机器上作进一步处理或印象。
图3示出的工艺可以用于生产图2所示的三层层压制品32。对上术工艺的唯一的改动是任与另一纤维无纺织物支持层30相对的多层薄膜10的一侧，将第二纤维无纺织物支持层30喂入层压辊58。如图3所示，支持层30是以预制卷62的形式喂入的。或者与另一支持层一样，支持层30直接在机器上形成。在任何情况下，第二支持层30都是喂入层压辊58并与其它支持层30以同样的方式层压到多层薄膜上。
如前所述，多层薄膜10和层压制品32可以用于许多场合，不限于贴身用可吸湿物品，例如尿布，训练服，失禁装置，妇女卫生用品，例如卫生巾。图4是一示例性物品80，此例中为尿布。参照图4，多数这种贴身用有吸湿性的物品80包括一液体可渗透的顶层或内衬82，背层或外覆层84，和一在顶层82和背层84之间的有吸湿性的芯层。物品80，例如尿布还可以包括一些固定装置88，例如粘接固定翼片或机械钩-环型固定件。
多层薄膜10自身或其它形式的如多层薄膜/支持层层压制品32可以用于制成各种物品中的一部分，包括全如上述的顶层82和背层84，当然不限于此。如果薄膜用作顶层或衬里82，最好使其有孔或能以其它方式使液件渗透。当采用多层薄膜/无纺织物层压制品作外覆层84时，最好将无纺织物侧朝向远离使用者的方向。此外，在此实施例中，可以利用层压制品32的无纺织物部分作为钩-环组合物的环部分。
根据本发明的多层薄膜和多层薄膜/支持层层压制品的其它用途包括，外科手术用盖布，外科医生服，揩布，衣物的阻隔材料或物品或工作服和实验室服的一部分。
本发明的性能通过下述的系列实验测定。这些性能包括薄膜厚度，水蒸汽穿透率以及剥离强度。水蒸汽穿透率
试样材料的水蒸汽穿透率(WVTR)根据ASTM标准E96-80进行计算。从试验材料上割下直径为7.62cm(3英寸)的圆形试样。比较材料是一块Hoechst Celanese Corporation of Sommerville NewJersey的CELGARD2500薄膜。CELGARD2500薄膜是一种微孔聚丙烯薄膜。对每种材料准备三块试样。试验盘为Thwing-AlbertInstrument Company of Philadelphia Pennsylvania的60-1 Vapometer盘。将100毫升的水注入每个Vapometer盘中，并将试验材料和比较材料的样品放入每个盘的敞开的顶部。拧紧凸缘以沿每个盘的边缘形成密封，使相关的试验材料或比较材料以6.2厘米直径的圆孔，即面积近似为33.17平方厘米的圆孔暴露于环境大气。这些盘放在温度高于32℃(100°F)的强制通风烘箱中。烘箱的温度恒定，外部空气通过它循环以阻止水蒸汽积聚在其中。合适的烘箱是例如Blue M Electric Companyof Blue Island Illinois的Blue M Power-O-Matic 60烘箱。24小时后。从烘箱内取出盘子再次称重。最初实验的水蒸汽穿透率值按下述公式计算：
实验WVTR＝(24小时的克重损失)×315.5g/m2/24小时
烘箱内的相对湿度没有特定控制。
在预设定的32℃(100°F)以及环境相对湿度的状态下，CELGARD2500比较织物的WVTR为5000克每平方米24小时。因此将这一比较样品用于每次试验中，并对初始实验值用下述公式按设定状况校正：
WVTR＝(实验WVTR/比较WVTR)×(5000g/m2/24小时)
      (g/m2/24小时)。薄膜/薄膜层厚度
总厚度28，第一表层厚度24，芯层厚度22和第二表层厚度26由场发射扫描电子显微法(FESEM)通过截面测定。每一薄膜试样浸入液氮内并与剃刀刃相碰触而切开。刚割开的截面用铜带放在处于竖直位置的样品根部。用日立S-800型场发射型电子显微镜在5和10Kev下观察试样。放大2000倍的扫描电子图片示出每种试样的薄膜结构。为每种多层薄膜准备了试样及相应的图片。由12.7厘米×10.2厘米页片放大到25.4厘米×20.4厘米的图片，并且从这些图片上直接进行了测量。在每一图片上叠置一放大2000倍的15μm标尺。对每一薄膜试样的三幅图片的每一幅上作五次测量，因此对每一厚度都会产生15个数据点或测量结果。对第一表层，第二表层和芯层进行了测量。将对每一层的15个测量值结合起来，平均后产生每一层的以μm表示的厚度值。薄膜的总厚度通过把每一试样的芯层、第一表层和第二表层的厚度平均值加起来获得。每一表层的厚度相对百分比是通过把表层的平均厚度去除试样总厚度，再把结果放大100倍而获得。180°T剥离实验
为检验薄膜层和纤维无纺织物舒适层之间的粘合强度，在各种材料的试样上进行分层或剥离强度检验。切下一块10.2厘米宽15.2厘米长的试样。在试样的薄膜侧放有宽10.2cm长15.2cm的3M2308遮蔽翼片(masking tape)。然后在2.2千克的辊重下滚动试样，令遮蔽翼的面朝上，前后两次。可以用手对试样的一个短端进行剥层以产生若干边缘，这类边缘可放在MTS Systems Corporation of Eden Prairie，MN产的a Sintech/2计算机整体试验系统(Computer Integrated TestingSystem)的夹爪内。夹爪间隙设成100毫米的跨度，并在层压状态下留有足够的材料，从而使夹爪能行进65毫米。样品置于夹爪中，这样在夹爪扩张10毫米以前样品开始剥层。十字头的速度为每分300毫米，并在10毫米的始点和65终点之间记录数据。
记录的数据表明了为将两层分开所需的剥离强度或负荷克数以及具有最大、最小平均值的标准克数指数。
所有例子中的薄膜是三层的薄膜，每例中都有相同的两个外层或表层。所有薄膜都是铸膜，并且在牵伸以前压花以在薄膜上产生无光光洁度。此外，所有的薄膜都与由近似0.22特(2旦尼尔)的纤维制成的每平方米17克的聚丙烯纺粘织物层压。这种纺粘织物预粘合有近似占总粘合面积15％的点状粘合花纹。例1
在例1中，芯层以其总重的百分重量为基数，有65％的ECC EnglishChina SupercoatTM碳酸钙，粒度平均为1μm，有7cm的顶部切口(Topcut)。碳酸钙从ECC International的分部ECCA Calcium Product，Incof Sylacauga，Alabama购得。芯层还包括15％的Exxon ChemicalCompany of Houston Texas产的Exxon9302无规共聚物，聚丙烯(Random Copolymer Polypropylene)，15％的Himot USA ofWilmington Delaware产的Himont KS059 Catalloy聚合物，和5％的Quantum Chemical Corporation of New York，New York产的QuantumNA206低密度聚乙烯。所述Himont Catalloy聚合物是一种烯烃类热塑性弹性体或TPO多级反应产品，其中非晶形乙烯丙烯无规共聚物以分子形式分散在主要是半晶体高聚丙烯单体/低乙烯单体的连续基质中。
在芯层两侧的两个外或表层包括15％的Himont USA产的HimontKS059 Catalloy聚合物，20％的Ampaet 10115防粘剂和65％的Exxonxc-101(28％的EMA共聚物)。Ampacet10115防粘剂包括20％硅藻土，79.75％的Chevron2207EMA和0.25％的硬脂酸铝。Ampacet10115防粘剂可从Ampacet Corporation of Tarrytown，NewYork购得。Chevron2207EMA可从Chevron Chemical Corporation ofSan Ramon California购得，Exxon xc-101可从Ezzon ChemicalCompany of Houston Texas购得。
采用上述类型的铸膜挤压设备可挤出三层薄膜。测得表层的出口熔融温度为196℃，而芯层为223℃。空气间隙(模具和冷轧辊之间的距离)为53厘米，成品薄膜的规格为38微米。薄膜卷到辊上，然后通过Marshall and Williams Company of Providence Rhode Island产的机器方向定向器(MDO)。MDO单元预热至77℃，薄膜在77℃时被牵伸4倍。所谓薄膜被牵伸4倍，意味着例如1米长的薄膜最后被牵伸至4米长。最终测得的薄膜厚度为16.08μm，而基重为每平方米重量为17克(17gsm)。两表层中的每一层近似占薄膜总厚度的2.7％。因此芯层占总厚度的94.6％采用上述的薄膜厚度测量方法，两表层厚度为0.44μm，芯层厚度为15.2μm。
采用一有图案的温度近似为77℃的粘合辊和温度近似为54℃的光滑砧辊，以每米4218千克的夹紧力，每分钟152米的线速度，占薄膜一侧总表面积15％的粘合面积将成品薄膜热层压在上述的纺粘层上。此层压制品以这种形式通过粘合器，即纺粘层与图案辊相邻，而薄膜层与平滑砧辊相邻。最终的层压制品依上述方式测得的水蒸汽穿透率为每平方米每24小时2570克。
层压制品有70厘米的水头(hydrohead)和48克的剥离强度。例2
在例2中，芯层在其总重量中含65％的ECC English ChinaSupercoatTM碳酸钙，15％的Exxon 9302无规共聚物，聚丙烯(RCP)，15％的Himont KS059 Catalloy聚合物，和5％的QuantumNA206低密度聚乙烯(LDPE)。
在芯层两对侧的外层或表层包括15％的Ampacet10115防粘剂(20％的硅藻土，增至24％的共聚物甲基丙烯酸乙酯(EMA))的浓缩物或母料(masterbatch)和85％Himont KS057 Catalloy聚合物。
采用上述类型的铸膜挤压设备将三层薄膜挤出。从挤出器出来的表层的出口熔融温度为188℃并且芯层的出口熔融温度为223℃。空气间隙(模具头和成形轧辊之间的距离)为53厘米，成品薄膜的厚度为35.5μm。薄膜卷在辊上然后送过预热至88℃的MDO单元，薄膜在88℃时被牵伸3倍。最终测得的薄膜厚度为17.28μm，基重为15gsm。两层表层的每一层占薄膜总厚度的2％。因此，芯层占总厚度的96％。利用上述的薄膜厚度测量方法，两表层中每一层有0.33μm的薄膜厚度，和芯层为16.62μm厚。
然后利用有图案的温度为约77℃的粘合辊和温度近似为54℃的平滑砧辊，以4218千克/米的夹紧力，每分钟152米的线速度，占薄膜一侧表面积15％～18％的粘合面积将最终的薄膜热压制到上述的纺粘层上。然后将层压制品以这样一种方式通过粘合器，即纺粘层与图案辊相邻，而薄膜层与砧辊相邻。依上所述方式测得薄膜的水蒸汽穿透率为每平方米每24小时925克，层压制品的水蒸汽穿透率为820克/米2/24小时。层压制品的水头为113厘米而剥离强度为62克。例3
例3中芯层包括占其重量百分比为63％的ECC English ChinaSupercoatTM碳酸钙，19％的Himont KS059 Catalloy聚合物，13％shell chemical Company of Houston Texas产的Shell 6D81聚丙烯，5％的Dow Chemical USA of Midland Michigan的Dow4012低密度聚乙烯(LDPE)。
芯层两对侧的芯层或表层包括30％的Himant KS057 Catalloy聚合物，20％的Techmer S110128E62防粘剂/EVA的浓缩物，或TechmerPM of Rancho Dominguez，California的母料，20％的Exxon760.36EMA和Elf Atochem N.A.of philadelphia Pennsylvania产的30％Lotryl 29MA03酯化的EMA共聚物。
采用铸膜挤压设备挤出三层薄膜，从挤出器出来的表层的出口温度为188℃，芯层的出口温度为209℃。空气间隙(模具头和成形轧辊之间的距离)为66厘米，最终的薄膜厚度为38μm，薄膜绕到辊上，随后送过预热至71℃的MDO单元，薄膜在71℃时被牵伸4倍，随后在近似85℃的温度下退火。
上述薄膜的最终厚度为16.98μm，且基重为17gsm。两表层中的每一层占薄膜总厚度的3.7％。因此芯层占总厚度的92.6％。采用上述的薄膜厚度测量方法，两表层每一层有0.6μm的薄膜厚度，而芯层厚15.77μm。
利用温度近似为110℃的有图案的粘合辊，和温度近似为32°的平滑砧辊，以4570千克/米·2.54cm(英寸)的夹紧力，每分61米的线速度和占薄膜一侧表面积15％～18％的总粘合面积将最终的薄膜热层压在上述的纺粘层之上。此层压制品然后以下述方式通过粘合器，即纺粘层与图案辊相邻，而薄膜层与砧辊相邻。如依上述方式测得薄膜的水蒸汽穿透率(WVTR)为每平方米每24小时1301克，并且最终的层压制品的水蒸汽穿透率为1184g/m2/24Hr。层压制品有110厘米的水头和161克的剥离强度。例4
在例4中，芯层有占其总重量63％的ECC Eglish ChinaSupereoatTM碳酸钙，19％的Himont KS059 Catalloy聚合物，13％的Shell 6D81聚丙烯和5％的Dow 4012LDPE。
芯层两对侧的外层或表层包括35％的Himont KS057 Katalloy聚合物，20％的Techmer S110218E62防粘连剂/EVA浓缩物/母料和45％的Exxon 760.36EMA。
利用铸膜挤压设备将三层薄膜挤出。从挤压机出来的表层的出口温度为187℃，芯层的出口温度为208℃。气隙(模具头和成形辊之间的距离)为66厘米，成品薄膜的厚度为35.5μm。薄膜卷绕到辊上，随后通过预热至71℃的MDO单元，在71℃的温度被牵伸4倍，随后在近似85℃退火。最终测得薄膜厚度为15.96μm，基重为15gsm。两表层中的每一层占薄膜总厚度的3％。因此芯层占总厚度的94％。利用上述的薄膜厚度测量方法，两表层每一层有0.48μm的薄膜厚度，芯层厚度为15.0μm。
利用有图案的温度近似为110％的粘合辊和温度近似为66℃的平滑砧辊，以4570千克/米的夹紧力，每分钟61米的线速度，薄膜一侧占单位面积15％～18％的粘合面积将成品薄膜热层压到上述纺粘层上。层压制品以这样一种方式通过粘合器，即纺粘层与图案相邻辊；而薄膜层与砧辊相邻。最终的层压制品的水蒸汽穿透率为1522g/m2/24小时，水头为89厘米，剥离强度为148克。例5
在例5中，芯层包括占其总重量65％的ECC English ChinaSupercoatTM碳酸钙，15％的Himont KS059 Catalloy聚合物，15％的Exxon9302无规共聚物，聚丙烯(RCP)和5％的Dow 4012 LDPE。
芯层两对侧的外层或表层包括35％的Himont KS057 Catalloy聚合物，20％Techmer S110128E62防粘连剂/EUA浓缩物/母料和45％的Exxon 760.3EMA。
利用铸膜挤压设备将三层薄膜挤出。表层的出口温度为175℃，芯层的出口温度为234℃。空气间隙(模具头和成形轧辊之间的距离)为33厘米，成品薄膜的厚度为35.5μm。薄膜卷到辊上，随后送过预热至77℃的MDO单元，在77℃时牵伸4倍，然后在近似75℃时退火。最终测得薄膜的厚度为16.92μm，基重为15gsm。两表层中的每一层占总厚度的1％。因此芯层占总厚度的98％。利用上述的薄膜厚度测量方法，两表层每一层有1.75μm的薄膜厚度，芯层厚度为16.57μm。
利用有图案的温度近似为75℃的粘合辊和温度近似为51℃的平滑砧辊，以4218千克/m的夹紧力，每分152米的线速度和薄膜一侧占单位面积15％～18％的总粘合面积将成品薄膜热层压在上述纺粘层上。然后将此层压制品以下述方式通过纺粘层，即纺粘层与图案辊相邻，而薄膜层与砧辊相邻。成品层压制品的水蒸汽穿透率为1930g/m2/24小时，水头为66厘米，剥离强度为116克。
如本发明的上述实施例所表明的，能形成厚度很薄(小于30μm)的多层薄膜。此外，这种薄膜能有极薄的表层，这样的表层给出各种各样的功能，例如，薄膜水蒸汽穿透性，液体可渗透性以及粘性。此外这种薄膜还能连接到其它支持层上，例如无纺织物上，以形成层压制品。
虽然已对本发明进行了详细描述，但很明显在不脱离所附权利要求实质和范围的前提下可做出各种改形。

Claims (23)

1.一种多层薄膜，它包括：
由可挤压的热塑性聚合物制成的芯层(12)，所述芯层有第一外表面(14)和第二外表面(16)，
第一表层(18)固定到所述芯层的第一外表面(14)上形成所述多层薄膜(10)，
所述多层薄膜(10)限定一总厚度(28)，所述第一表层(18)限定第一表层厚度(24)，第一表层厚度(24)至少占所述总厚度(28)的10％，上述总厚度不超过30μm。
2.如权利要求1所述的多层薄膜，其中第一表层(18)的第一表层厚度(24)不超过2μm。
3.特别是根据权利要求1或2所述的多层薄膜，它包括：
由可挤压的热塑性聚合物制成的芯层(12)，所述芯层有第一外表面(14)和第二外表面(16)，
第一表层(18)固定在所述芯层的第一外表面(14)上，同时，第二表层(20)，固定在所述芯层的第二外表面(16)上以形成所述多层薄膜(10)，
所述多层薄膜(10)限定一总厚度(28)，所述第一表层(18)限定第一表层厚度(24)，所述第二表层(20)限定第二表层厚度(26)，所述芯层限定一芯层厚度(22)，所述第一表层厚度(24)不超过总厚度(28)的7.5％。所述总厚度不超过30μm。
4.如权利要求3所述的多层薄膜，其中所述第二表层(20)的第二表层厚度(26)不超过总厚度(28)的7.5％。
5.如权利要求3或4所述的多层薄膜，其中所述第一表层(18)的第一表层厚度(26)不超过2μm。
6.如权利要求3至5中之一所述的多层薄膜，其中所述第二表层(20)的第二表层厚度(26)不超过2μm。
7.如权利要求3至6中之一所述的多层薄膜，其中所述第一表层(18)的第一表层厚度(24)和所述第二表层(20)的第二表层厚度(26)的总和不超过所述总厚度(28)的15％。
8.如前述各权利要求中之一所述的多层薄膜，其中所述芯层还包括颗粒状填料，所述的颗粒状填料在芯层(12)内，且按重量计至少占芯层(12)总重量的60％。
9.如前述权利要求之一所述的多层薄膜，其中所述芯层(12)有许多空隙。
10.如前述各权利要求中之一所述的多层薄膜，其中，所述多层薄膜(10)的水蒸汽穿透率至少为每平方米每24小时300克。
11.特别是依据前述权利要求之一所述的多层薄膜，它包括：
由可挤压的热塑性聚合物制成的芯层，所述芯层(12)有第一外表面(14)和第二外表面(16)，
第一表层(18)固定到所述芯层的第一外表面(14)上，同时有第二表层(20)固定到所述芯层的第二外表面(16)上以形成所述的多层薄膜(10)，
所述多层薄膜(10)限定一总厚度(28)，所述第一表层(18)限定一大约为2μm或更薄的第一表层厚度(24)，所述第二表层(20)限定一大约为2μm或更薄的第二表层厚度(26)，所述芯层(12)限定一芯层厚度(22)，所述第一表层厚度(26)不超过总厚度(28)的7.5％，总厚度(28)不超过30μm，所述芯层包括填料，所述芯层(12)内的填料按重量计至少为芯层(12)总重量的60％，其中所述多层薄膜(10)的水蒸汽穿透率至少为每平方米每24小时300克。
12.一种个人维护用的用有吸收性的物品(80)，它包括液体可渗透的顶层(82)和背层(84)，有吸湿性的芯层则置于上述两者之间，所述背层(84)和顶层(82)中至少有一层包括权利要求1至11之一所述的多层薄膜。
13.一种层压制品，它包括：
固定在支持层(30)上的如权利要求1至11之一所述的多层薄膜(10)。
14.如权利要求13所述的层压制品，其中所述支持层(30)是纤维无纺织物。
15.特别是根据权利要求13或14所述的层压制品，它包括权利要求3至11中之一所述的多层薄膜，其中将各支持层固定在第一表层和第二表层上。
16.一种个人维护用有吸收性的物品(80)，它包括液体可渗透的顶层(82)和背层(84)并具有置于这两层之间的有吸收性的芯层(86)，所述背层(84)和顶层(82)中至少有一层包括权利要求13至15之一所述的层压制品。
17.如权利要求12或16所述的个人维护用的有吸收性的物品，其中所述物品是尿布、训练服、卫生巾、失禁装置或绷带。
18.一种外科医生服，其中所述外科医生服的至少一部分包括权利要求1至11之一所述的多层薄膜。
19.一种外科医生服，其中所述外科医生服的至少一部分包括权利要求13至15中所述的层压制品。
20.一种外科用消毒盖布，其中至少所述盖布的一部分包括权利要求1至11之一所述的多层薄膜。
21.一种外科用消毒盖布，其中至少所述盖布的一部分包括权利要求13至15之一所述的层压制品。
22.一种衣物，其中所述衣物的至少一部分包括权利要求1至11之一所述的多层薄膜。
23.一种衣物，其中所述衣物的至少一部分包括权利要求13至15所述的层压制品。
CN95197584A 1994-12-20 1995-12-19 薄厚度薄膜和薄膜/无纺织物层压制品 Expired - Lifetime CN1092563C (zh)

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Cited By (4)

* Cited by examiner, † Cited by third party
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CN106457806A (zh) * 2014-06-12 2017-02-22 陶氏环球技术有限责任公司 多层薄膜及由其制造的制品
CN108214812A (zh) * 2017-12-25 2018-06-29 福建省大投科技有限公司 一种人造纤维纸发泡纸板的生产方法
CN111988987A (zh) * 2018-04-19 2020-11-24 3M创新有限公司 可生物降解的层状复合材料
WO2021104183A1 (zh) * 2019-11-25 2021-06-03 福建恒安集团有限公司 一种一次性裤型卫生用品的制备方法

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FR2728786A1 (fr) 1996-07-05
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GB2296216B (en) 1997-09-17
FR2728786B1 (fr) 2004-09-10
CO4440499A1 (es) 1997-05-07
GB9526112D0 (en) 1996-02-21
CA2208535A1 (en) 1996-06-27
FR2786726B1 (fr) 2003-01-03
RU2147521C1 (ru) 2000-04-20
WO1996019346A3 (en) 1996-10-17
AU4603596A (en) 1996-07-10
TR199501613A2 (tr) 1996-07-21
PL320886A1 (en) 1997-11-10
EG20808A (en) 2000-03-29
EP0799128B1 (en) 2004-03-31
AU698621B2 (en) 1998-11-05
EP0799128A2 (en) 1997-10-08
BR9510475A (pt) 1998-05-26
GB2296216A (en) 1996-06-26
CN1092563C (zh) 2002-10-16
AR000355A1 (es) 1997-06-18
DE69532821D1 (de) 2004-05-06
FR2786726A1 (fr) 2000-06-09
ES2214514T3 (es) 2004-09-16
ZA9510604B (en) 1996-07-03
WO1996019346A2 (en) 1996-06-27
MX9704496A (es) 1997-10-31
US6075179A (en) 2000-06-13

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