CN1268882A - 具有耐磨熔喷层的个人护理用品 - Google Patents

具有耐磨熔喷层的个人护理用品 Download PDF

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CN1268882A
CN1268882A CN98808644A CN98808644A CN1268882A CN 1268882 A CN1268882 A CN 1268882A CN 98808644 A CN98808644 A CN 98808644A CN 98808644 A CN98808644 A CN 98808644A CN 1268882 A CN1268882 A CN 1268882A
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layer
outer covering
covering layer
meltblown fibers
woven material
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M·T·莫尔曼
T·W·奥多辛斯基
W·W·杰克逊
G·T·苏杜斯
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Kimberly Clark Worldwide Inc
Kimberly Clark Corp
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Kimberly Clark Worldwide Inc
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Abstract

一种由成层非织造材料制成的尿布外覆层,该外覆层具有设置在非织造材料内层上的由熔喷材料构成的熔喷纤维外层,其基重为约1g/m2至约7g/m2,该非织造材料内层优选为纺粘纤维网。

Description

具有耐磨熔喷层的个人护理用品
发明领域
本发明涉及一种成层的非织造材料，它包括一个耐磨熔喷材料层和一个例如纺粘材料的非织造材料层，其中非织造材料层的耐磨性一般比熔喷材料层更高。更具体而言，本发明涉及有限次使用或一次性的物品，例如采用这种材料的一次性尿布和其它的一次性个人护理用品。另外，本发明涉及一种制造这种材料的方法。
发明背景
本发明涉及成层的非织造材料，它包括一个耐磨熔喷层，该材料适于用作例如一次性尿布的个人护理用品和其它一次性个人护理用品以及例如外科手术衣、医用被单等医用服装的外覆层。
成层的非织造材料广泛用于各种应用中，例如用于一次性尿布、成人失禁服装和卫生巾等吸收制品的各个部分，以及例如外科手术衣、外科手术被单、无菌包裹布和外科手术面罩等医用服装。
成层的非织造材料可以通过将不同形式的两种或多种非织造纤维网相结合来获得以实现各个特定的最终用途。因此，已研究开发了成层的非织造材料，使之针对例如微生物等污染物的渗透提供一个阻挡体。这种类型的非织造材料阻挡体一般包括一个或多个例如熔喷纤维网的微纤维聚合物层，该层与一层或多层例如纺粘连续长丝织物或短纤维织物等的另一种类型的非织造纤维网相结合。在诸如此类的已知的成层材料中，在使用过程中其外层用作强度加强层，以便保护较弱的熔喷纤维物免受过度应力作用且防止其遭受损坏。事实上，为了保护熔喷纤维网免受磨损，在纺粘/熔喷/纺粘叠层中，通常将其设置在由另一种材料(例如纺粘材料，它具有较高的耐磨性)所制成的两层之间。因此，这种成层的材料具有耐用的纺粘外层和多孔的熔喷阻挡内层，但是该熔喷阻挡内层与纺粘层相结合来阻止液体透过或防止细菌从成层材料的外侧渗透到内侧。
在需要阻挡性能的应用中采用微纤维网在现有技术中是已知的。微纤维是其每长丝旦尼尔数为不足0.006至约0.664的纤维。微纤维网常常是指通常利用熔喷方法制成的熔喷纤维网。总体认识到，采用直径比较小的纤维能够提供高的排斥性或过滤性能而不会过度影响透气性。到目前为止所制造的拟用作个人护理用品和医用服装中的阻挡层的微纤维网织物是层压的或以其它方式粘合到纺粘热塑性纤维网、或薄膜、或其它提供所需强度的加强纤维网上的微纤维网组合体。非织造材料以及个人护理用品和医用服装的一个重要要求是耐磨性。在一次性尿布中，当幼儿在室外玩耍而没有衣物覆盖着该尿布时，表面的耐磨性是特别重要的。因此，纺粘纤维网、薄膜或其它加强纤维网的外层通常用在熔喷纤维制品中以提供表面耐磨性。
例如一次性尿布、训练用裤、失禁用衣物以及妇女卫生用品的个人护理用品采用非织造材料用于多种用途，例如用作衬层、传递层、吸收介质、背衬层等。在多个这种应用中，非织造材料的阻挡性能起到重要的作用。用于吸收和容纳尿液或其它体内渗出物的一次性服装通常包括一个可透过液体的体侧衬层和一个不可透过流体的背衬层，以及位于其间的吸收材料。
我们已经发现，其上喷射有一薄层熔喷纤维的纺粘材料具有与纺粘材料本身大体相同的耐磨性。由于已知熔喷材料的耐磨性总体较低，事实上这是出乎意外的和令人惊奇的发现。与采用一薄层涂料来保护一个表面类似，与耐磨的非常厚的涂料层相比，薄的熔喷层用作一个保护性涂层，它由其所涂敷的位于下面的非织造纤维网材料所支承。基于这一发现，具有良好阻挡性能的熔喷织物特别适用于例如尿布的个人护理用品中，目前该熔喷织物被用作这些个人护理用品中的外层，例如用作尿布的外覆层，而在此前由于其强度和耐磨性较差，所以需要将该熔喷织物层压在具有包括耐磨性等所需强度的各非织造纤维网层之间。现在，由于不再需要附加的非织造外层来保护熔喷层，所以这又降低了这些制品的制造成本。
通过采用微纤维网使其耐磨性提高的非织造织物在美国专利4774125中有所描述，该专利公开了一个粘合到一个熔喷纱芯纤维网上的耐磨材料表面，其具有的熔喷纤维表面层具有大于8微米的平均纤维直径(对于聚丙烯每长丝0.42旦尼尔)，其中75％的纤维具有至少7微米的纤维直径(对于聚丙烯每长丝0.33旦尼尔)。这种材料适用于医用织物，但由于不具有吸收层，该材料不适用于个人护理吸收制品。
因此，本发明的一个目的是提供一种用于例如尿布等个人护理用品的外覆层，该外覆层具有耐磨的熔喷外层，从而能够使得这些用品无需例如衣物等附加层来覆盖该用品以防损坏即可实现耐磨损。
发明概述
本发明的这个和其它目的通过用于例如尿布等个人护理用品的外覆层来实现，它包括一个设置在一非织造材料内层上的由熔喷材料制成的熔喷纤维外层或薄层，该熔喷材料的平均基重为约1g/m2至约7g/m2。特别适用于本发明的非织造材料内层通常比单个熔喷层的耐磨性更高。按照本发明的特定优选实施方案，非织造材料内层是一个纺粘层。为了进一步提供液体的不可透过性，一个不可透过液体的薄膜层可以沿背离着所述熔喷纤维层的方向层压在非织造材料内层的表面上。
在本发明一个实施方案中纺粘/熔喷成层材料的外表面的耐磨性与仅具有纺粘材料时的耐磨性相对应。也就是说，熔喷材料外层所具有的耐磨性与仅具有纺粘材料层时的耐磨性相对应。这是特别出乎意外的，因为已知其本身所构成的熔喷纤维网的耐磨性要低于例如纺粘等其它非织造纤维网。另外，成层的非织造材料在例如尿布中用作衣服类外覆层的外层时，显著改进了个人护理用品的性能，其中熔喷材料是尿布外覆层的外层，与仅具有纺粘材料相比具有更好的不透明性。由于采用衣服类外覆层，消费者指出这种外覆层在接触到食品、饮料和/或液体时会被沾污。此外，已指出，当幼儿在室外玩耍而没有衣物包覆在尿布上时，该外覆层容易被弄脏且易钩在细树枝上。本发明的尿布外覆层其外表面是一个熔喷材料层，该尿布外覆层除了具有耐磨性之外，还不易被沾污并且不易被条状材料、钩状材料等钩住。本发明外覆层的另一个优点在于其外表面、也就是熔喷层比其它的非织造材料更加易于印刷。
尽管本发明将参照个人护理用品和特别是尿布进行描述，但可以理解，本发明的成层的非织造材料适用于例如外科手术衣和被单、汽车外套、无菌包裹布等各种制品中。
附图简述
从结合附图的下列详细描述中将更清楚地理解本发明，其中：
图1是用于制造非织造成层材料的一个成形机的示意图，该非织造成层材料包括本发明的熔喷阻挡层；以及
图2是按照本发明一个实施方案的成层的非织造材料的剖面图。
定义
在此所用的术语“非织造纤维网”意指一种其结构为具有多个单独纤维或纱线的纤维网，该纤维或纱线是交叉铺置的，但并不是以一种易识别的重复方式进行铺置的。过去，非织造纤维网由各种工艺，例如熔喷工艺、纺粘工艺以及粘合梳理的纤维网工艺来形成。
在此所用的术语“纺粘纤维”指的是小直径的纤维，它通过将熔融的热塑性材料从喷丝板的多个精细(通常为圆形的)毛细管挤压成长丝而制成，然后通过例如引出牵拉机或周知的纺粘机构使得被挤压长丝的直径快速减小。
在此所用的术语“聚合物”通常包括但不限于均聚物，例如嵌段、接枝、无规以及交替共聚物、三元共聚物等，以及其掺合物和变体。而且，除非在其它情况下具体限定的，术语“聚合物”包括该材料的所有可能的几何构型。这些构型包括但不限于等规构型、间规构型和无规对称构型。
在此所用的术语“熔喷纤维”意指通过将熔融热塑性材料通过多个精细(通常为圆形)的模口毛细管挤压成进入高速气体中的熔融纱线或长丝，该高速气体例如为使熔融热塑性材料的长丝变细以便减小其直径的空气、蒸汽。此后，利用高速蒸汽来载带熔喷纤维并将其沉积在一个凝聚面上，以便形成一个由随机分散的熔喷纤维所构成的纤维网。
优选实施方案描述
本发明总体涉及一种用于例如一次性尿布、训练用裤、失禁服装和妇女卫生用品等个人护理吸收制品以及工业用服装、医用服装、医用被单等的外覆层。本发明的外覆层包括一个成层的非织造材料，该非织造材料包括一个设置在非织造材料内层上的由熔喷材料制成的熔喷纤维外层，该熔喷材料的平均基重为约1g/m2至约7g/m2。按照一个优选实施方案，熔喷材料的基重为约3g/m2至约7g/m2，最优选地约为5g/m2。
非织造材料的内层优选是由纺粘纤维形成的纺粘纤维网。因为纺粘纤维网不具有阻挡性能，优选地是尿布外覆层的外层至少具有某些所需的阻挡性能。本发明的成层的非织造材料包括一个设置在纺粘层上的熔喷层，该非织造材料阻止液体渗透的能力要强于仅具有纺粘层时的情况。然而，为了确保防止液体渗透，本发明一个实施方案的尿布外覆层还包括一个层压在纺粘层的内表面上的薄膜层，该纺粘层的内表面即为纺粘层的与熔喷层背离的那个表面。
尿布的外覆层还应该具有相当大的耐磨性和防钩丝性，以便能够承受穿着尿布的幼儿在玩耍时的苛刻环境条件。因此，除了具有约1g/m2至约7g/m2的平均基重之外，我们已发现熔喷材料的微纤维尺寸也是一个需要考虑的问题。按照本发明的一个实施方案，本发明尿布外覆层的熔喷外层是由每长丝旦尼尔数为约0.01至约0.67的微纤维构成的。按照本发明一个特别优选的实施方案，熔喷外层的微纤维具有的每长丝旦尼尔数小于约0.06。具有较小旦尼尔数的微纤维是优选的，因为它们能提供更为均匀的层。例如，对于基重为约3.0g/m2的熔喷纤维层来说，0.035旦尼尔的纤维其每单位面积的纤维长度约为0.42旦尼尔纤维的12倍。因此，每单位面积的纤维越长，所得到的材料层就越均匀。因此，本发明材料的熔喷纤维外层所具有的均匀度使得在熔喷纤维层中没有一个英寸直径圈具有小于约1g/m2和大于约7g/m2的基重。
通常本发明材料的耐磨性是按照ASTM标准D-1175“纺织品的耐磨性”(Abrasion Resistance of Textile Fabrics)的方法来确定的。这些方法采用摇摆缸和均匀的磨损工序来确定纺织品的耐磨性。采用这些方法以可控制方式用机器来确定特定纺织品的耐磨性，即：使试样在已知的压力、拉伸和磨损动作的条件下受到单向的摩擦动作，或者使试样在其表面所在平面内的所有方向上受到均匀的摩擦。本发明材料的试验是借助一个具有旋转平台的双头耐磨实验仪通过采用Taber方法来实现的。在表1中示出了在本发明的材料上所进行的磨损试验的结果。
          表1
    Anvil圈数     Face圈数
    7.000     6.000
    5.000     5.000
    5.000     6.000
    6.000     4.000
    7.000     6.000
    4.000     5.000
    7.000     4.000
    6.000     6.000
    7.000     4.000
    6.000     6.000
  平均6.000     5.200
标准编差1.054     0.919
表1中的数据是在下述这种材料上采集到的，该材料包括一个基重为约17g/m2的纺粘长丝层和一个形成在其上的基重约为4g/m2的熔喷纤维层。如表1中所示，被标识为“FACE”的纺粘面的Taber磨蚀指数为5.2±0.9圈，而被标识为“ANVIL”的熔喷面的Taber磨蚀指数为6.0±1.0。也就是说，熔喷面的耐磨性大于纺粘面的耐磨性，纺粘的耐磨性通常高于熔喷，因此通常用于保护熔喷纤维免受磨损。
本发明成层非织造材料的应用中所考虑的另一个问题是材料的总重量。即：希望使材料尽可能地轻。因此，本发明的成层非织造材料包括一个纺粘层和一个熔喷层，其平均基重优选小于约23g/m2。根据一个特别优选的实施方案，纺粘层的平均基重约为17.3g/m2，而熔喷层的平均基重约为4.0g/m2。
图1是根据本发明用于制造成层纺粘材料的成形机的示意图，该成层纺粘材料包括熔喷阻挡外层。成形机10用于制造成层的非织造材料12，该非织造材料根据本发明具有精细纤维的熔喷阻挡外层32以及纺粘内层28。具体而言，成形机10由卷绕在辊子16和18上的环形小孔成形皮带14构成，该皮带沿箭头所示方向被驱动。成形机10具有两个工位，即纺粘工位20和熔喷工位22。
纺粘工位20是传统的带有喷丝板的挤压机，该喷丝板形成温度约为440°F的聚合物连续长丝26，并且将这些长丝以随机交叉编织的方式沉积在成形皮带14上。纺粘工位20可以根据该工艺的速度和所适用的特定聚合物包括一个或多个喷丝板。对于本领域的普通技术人员而言，本领域中常用的成形纺粘材料和这种纺粘成形工位的设计是周知的。
熔喷工位22由一个用于形成微纤维30的模口31构成。当热塑性聚合物以约510°F的温度从模口31中排出时，高压流体(通常是空气)以约540°F的温度将聚合物流变细并散射以形成微纤维30。微纤维30随机地沉积在纺粘层28的顶部上并形成熔喷层32。用于形成微纤维30和熔喷层32的熔喷工位的构造和操作通常是按常规情况下考虑的，并且其设计和操作均在本领域技术人员的能力范围内。然后，将所得到的非织造材料层喂送通过轧光辊38和40。对于粘合工艺而言，关键的是需要使光滑的轧光辊或砧辊(在图1中，这是轧光辊38)位于非织造材料的与熔喷层相同的一侧，这是因为熔喷层将经常粘附在轧光辊装置中的提花辊(在图1中，这是轧光辊40)上，而粘附到光滑砧辊上的可能性小得多。为了进一步降低粘附的可能性并且仍保持良好的粘合，光滑砧辊38的温度被降至约240°F，而提花辊40的温度被保持在约285°F。在图1所示的工艺图中，砧辊38位于非织造材料的顶侧，以便与已沉积在纺粘层上的熔喷层接触。本领域的技术人员显而易见，可以首先在皮带14上形成熔喷层，然后再施加纺粘层。在这种情况下，砧辊将位于非织造材料的顶侧，以便与在此构型中位于成层非织造材料下侧的熔喷层相接触。
图2是根据本发明一个实施方案的成层非织造材料50的剖视图，它包括设置在非织造材料内层56上的熔喷纤维外层55，并且具有一个薄膜层57，该薄膜层57沿着与熔喷纤维外侧55背离的方向被层压在非织造材料内层56的表面上。
医学专业中采用医用服装和被单的使用者已经指出，当将医用仪器放置在由其外层为纺粘层的传统成层非织造材料制造的这种制品上时，该仪器可能发生滑动。我们已经发现，本发明的具有熔喷外层的材料是耐磨的，但它的静摩擦系数和动摩擦系数要高于纺粘材料。事实上，按照塑料薄膜的静摩擦系数和动摩擦系数的标准试验方法(Standard Test Method forStatic and Kinetic Coefficient of Friction of Plastic Film andSheeting)-ASTM标号D-1894实施的试验表明，本发明成层非织造材料的熔喷外层的静摩擦系数为约0.39至0.45，而其动摩擦系数为约0.29至0.31，相比之下，纺粘材料的静摩擦系数为约0.29至0.31，而其动摩擦系数为约0.20至0.21。
尽管在前面的说明书中已经参照本发明某些优选的实施方案描述了本发明，并且为了示出而描述了许多细节，对于本领域的技术人员而言，其它实施方案是显而易见的，并且在此描述的某些细节可以在不脱离本发明基本原理的条件下进行显著的变化。

Claims (33)

1.一种尿布外覆层，包括：
一个成层的非织造材料，它包括一个设置在一非织造材料内层上的由熔喷材料构成的熔喷纤维外层，该熔喷纤维外层所具有的平均基重为约1g/m2至约7g/m2。
2.权利要求1的尿布外覆层，其特征在于，所述熔喷纤维层的所述基重为约3g/m2至约7g/m2。
3.权利要求1的尿布外覆层，其特征在于，所述熔喷纤维层的所述基重为约5g/m2。
4.权利要求1的尿布外覆层，其特征在于，所述成层非织造材料的平均成层非织造材料基重小于约23g/m2。
5.权利要求1的尿布外覆层，其特征在于，所述非织造材料内层是纺粘的。
6.权利要求5的尿布外覆层，其特征在于，所述纺粘层的平均纺粘基重约为17g/m2，所述熔喷纤维外层的所述平均基重约为4g/m2。
7.权利要求1的尿布外覆层，还包括一个设置在所述非织造材料层的内表面上的薄膜层。
8.权利要求7的尿布外覆层，其特征在于，所述薄膜层是可透气的薄膜层。
9.权利要求1的尿布外覆层，其特征在于，所述熔喷层是由每长丝微纤维旦尼尔数小于约0.67的微纤维构成的。
10.权利要求9的尿布外覆层，其特征在于，所述每长丝微纤维旦尼尔数小于约0.06。
11.权利要求1的尿布外覆层，其特征在于，所述每长丝微纤维旦尼尔数为约0.01至约0.67。
12.权利要求1的尿布外覆层，其特征在于，所述熔喷纤维外层所具有的均匀度使得在熔喷纤维层中没有一个英寸直径圈具有小于约1g/m2和大于约7g/m2的基重。
13.一种制造尿布外覆层的方法，包括以下步骤：
形成一个具有尿布内表面和一个尿布外表面的非织造材料层；以及
将熔喷材料施加在所述非织造材料层的所述尿布外表面上，形成一个致密度为约1g/m2至约7g/m2的熔喷材料外层。
14.权利要求13的方法，其特征在于，通过将所述非织造材料层和所述熔喷材料外层输送通过一个轧光装置来将其二者粘合在一起，该轧光装置包括至少一个光滑的砧辊，使得所述熔喷材料外层面朝着所述至少一个光滑的砧辊。
15.权利要求13的方法，其特征在于，所述非织造材料层是纺粘的。
16.权利要求13的方法，其特征在于，所述熔喷材料包括微纤维，基本上所有的微纤维具有小于约0.67的每长丝微纤维旦尼尔数。
17.权利要求16的方法，其特征在于，每长丝的微纤维旦尼尔数为约0.01至约0.67。
18.一种用于个人护理用品的外覆层，包括：
一个成层的非织造材料，它包括一个设置在非织造材料内层上的由熔喷材料制成的熔喷纤维外层，该熔喷纤维外层的平均基重为约1g/m2至约7g/m2。
19.权利要求18的用于个人护理用品的外覆层，其特征在于，所述熔喷纤维层的所述基重为约3g/m2至约7g/m2。
20.权利要求18的用于个人护理用品的外覆层，其特征在于，所述熔喷纤维层的所述基重为约5g/m2。
21.权利要求18的用于个人护理用品的外覆层，其特征在于，所述非织造材料内层是纺粘的。
22.权利要求18的用于个人护理用品的外覆层，其特征在于，所述熔喷纤维层是由每长丝微纤维旦尼尔数小于约0.67的微纤维构成的。
23.权利要求22的用于个人护理用品的外覆层，其特征在于，每长丝的微纤维旦尼尔数为约0.01至约0.67。
24.权利要求18的用于个人护理用品的外覆层，其特征在于，所述个人护理用品是训练用裤。
25.权利要求18的用于个人护理用品的外覆层，其特征在于，所述个人护理用品是成人失禁服装。
26.一种医用服装的外覆层，包括：
一个成层的非织造材料，它包括一个设置在一非织造材料内层上的由熔喷材料制成的熔喷纤维外层，该熔喷纤维外层的平均基重为约1g/m2至约7g/m2。
27.权利要求26的医用服装的外覆层，其特征在于，所述熔喷纤维层的所述基重为约3g/m2至约7g/m2。
28.权利要求26的医用服装的外覆层，其特征在于，所述熔喷纤维层的所述基重为约5g/m2。
29.权利要求26的医用服装的外覆层，其特征在于，所述非织造材料内层是纺粘的。
30.权利要求26的医用服装的外覆层，其特征在于，所述熔喷纤维层是由其每长丝微纤维旦尼尔数小于约0.67的微纤维构成的。
31.权利要求30的医用服装的外覆层，其特征在于，每长丝微纤维旦尼尔数为约0.01至约0.67。
32.权利要求26的医用服装的外覆层，其特征在于，所述熔喷纤维外层的静摩擦系数为约0.39至约0.45。
33.权利要求26的医用服装的外覆层，其特征在于，所述熔喷纤维外层的动摩擦系数为约0.29至约0.33。
CN98808644A 1997-08-29 1998-08-06 具有耐磨熔喷层的个人护理用品 Pending CN1268882A (zh)

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