CN1346253A - 用于个人护理用品的吸液/分布材料 - Google Patents

用于个人护理用品的吸液/分布材料 Download PDF

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CN1346253A
CN1346253A CN00805877A CN00805877A CN1346253A CN 1346253 A CN1346253 A CN 1346253A CN 00805877 A CN00805877 A CN 00805877A CN 00805877 A CN00805877 A CN 00805877A CN 1346253 A CN1346253 A CN 1346253A
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M·A·达利
Y·L·哈蒙兹
T·L·马斯
D·M·马特拉
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Kimberly Clark Worldwide Inc
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    • A—HUMAN NECESSITIES
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    • 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
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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
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    • 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
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    • A61F13/53713—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 characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer the layer having a promotional function on liquid propagation in at least one direction the layer having a promotional function on liquid propagation in the vertical direction
    • A—HUMAN NECESSITIES
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    • A61F13/00—Bandages or dressings; Absorbent pads
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    • A—HUMAN NECESSITIES
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    • A61F13/53743—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 characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer characterised by the position of the layer relative to the other layers
    • A61F13/53747—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 characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer characterised by the position of the layer relative to the other layers the layer is facing the topsheet
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    • 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
    • A61F13/537—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 characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer
    • A61F2013/53765—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 characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer characterized by its geometry
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    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322—Composite web or sheet
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
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Abstract

本发明提供用于个人护理用品的吸液/分布层,它是一共开孔分布层和其间的一传递迟缓层。所述共开孔分布层和传递迟缓层可用于存贮液体并以个人护理用品中吸液芯可吸液的速率释放到吸液芯中。其接收不规则和大流量的能力使得本发明的的吸液/分布层特别适合于“喷流”控制。所述分布层优选为气流成网织物,所述传递迟缓层优选为纺粘织物,并且它们使用优选为约2.5针/平方厘米的针密度的共开孔。

Description

用于个人护理用品的吸液/分布材料
本申请书要求1999年4月3日提出的美国临时专利申请60/127682的优先权。
发明领域
本发明涉及可接收和分布液体的个人护理用品如尿布、训练用紧身裤、吸水衬裤、成人失禁用品、绷带和妇女卫生用品的结构物。
发明背景
个人护理用品包括诸如尿布、训练用紧身裤、妇女卫生用品如卫生巾、紧身短衬裤-衬里和棉塞、失禁衣服和装置、绷带等用品。这种物品的最基本设计一般包括身体侧衬里、外罩和置于身体侧衬里和外罩间的吸湿剂芯。
为了减少流体漏出个人护理用品的可能性，用品必须能很快接收和锁住流体。用品必须柔软并且让皮肤感到舒适，即使是吸液后也不会缩紧或粘附在用户上。遗憾的是，尽管先前的产品在不同程度上满足了许多这些要求，但是许多要求则没达到。
现已发现进入妇女卫生用品的连续流量平均为1ml/hr并且不是字面上的连续或恒定，而是速率上可不同并可能在周期内有停顿。“喷流”被定义为突然的大的流动状况并以最高1ml/sec的流速出现。在喷流时，1-5毫升的流体从身体流入到用品上。术语“连续流”是指并非喷流的流动。
连续流和喷流一起构成了动态流(variable flow)。基本上“动态流”是指中间有喷流的连续流。图1说明了单个用品的生命周期中动态流(菱形)和连续流(方形)间的差异，图中y轴为以g/hr为单位的流量，x轴为以小时为单位的时间。
对该问题的对策被称为“动态流控制”并定义为产品生命周期内吸收和包容连续量少的液流(1-2ml/hr)以及多次的喷流或突发的量多的液流(1ml/sec，总体积1-5ml)的能力。
例如许多妇女护理外罩材料具有低的z-向传导性、低的表面能、低的孔隙体积，并且由于其二维结构而在吸附剂芯和用户之间几乎没有提供分离的效果。结果，这些外罩材料导致缓慢和不完全的吸收、高的再湿润和大的表面沾污。此外，常规的吸收或截获层为有利于液体快速吸收的低密度、高孔隙体积结构物，但是因为这些结构物通常具有低的毛细作用，液体不能从外罩材料足够解吸，导致浸润和表面湿润。增强外罩解吸的材料通常是高密度、高毛细作用的材料，但是因为这些材料具有低的孔隙体积和低的z-向渗透性，它们本身阻滞了液体的吸收。
因此仍然需要开发具有快速吸液所需的孔隙体积和足够的外罩解吸(即表面干燥度)所需的高毛细作用并且维持有适当液体分布的毛细结构的吸收/分布材料以满足动态流控制的需要。
因此本发明的一个目标是提供能应付各种流动状况(包括突发的量多的液流或喷流)的这种吸收/分布材料。
本发明简述
本发明的目标通过经开孔或“共-开孔”连接的气流成网织物层和纺粘型非织造织物传递迟缓层获得。用于妇女卫生用品时结果是成倍改善了吸收性能并使覆盖层表面干净和干燥。材料工艺开发了针对获得适合的材料结构和兼顾快速吸收和改善覆盖层解吸、覆盖层沾污和再湿润特性间的性能平衡的各种动态流控制。这些功能性质通过改善材料工艺和产品结构来提供。
附图的简要说明
图1是在单种产品的生命周期动态流(菱形)和连续流(方形)的图，其中y-轴为以g/hr为单位的流量，x-轴为以小时为单位的时间。
图2说明共-开孔材料的三-模态孔结构。
图3、4和5显示小孔的SEM图象。图3显示在复合材料气流成网侧的小孔。图4显示复合材料气流成网侧一小孔的近视图。图5显示复合材料纺粘侧的小孔。
图6比较了开孔气流成网材料与非开孔气流成网材料的孔径分布。
图7说明了一单孔的详细情况和通过材料的流动。
图8显示使用2.06mm直径的针获得的7.4针/cm2的针开孔样式。
图9显示使用相同直径的针获得的2.5针/cm2的针开孔样式。
图10为具有和不具有小孔的气流成网织物的所测容量图，其中Y-轴为容量，X-轴为织物密度(cc/g)。
图11为两种开孔和两种未开孔的气流成网织物的水平吸湿距离(Y-轴)对时间的图。
图12为以g/g为单位的饱和度(Y轴)对以英寸为单位的水平吸湿距离的图。
定义
“一次性”是指用后弃置、不欲洗涤和再使用。
“亲水”接触时被含水液体湿润的纤维或纤维表面。材料的润湿度本身可通过涉及的液体和材料的接触角和表面张力来描述。适合测量具体纤维材料的设备和技术可通过Cahn SFA-222表面力分析仪系统或基本等价的系统来提供。用这种系统测量时，具有90°以下接触角的纤维被认为“可润湿”或亲水，而具有等于或大于90°的接触角的纤维被称为“不可润湿”或疏水。
“层”单独使用时，可具有单件或多件的双重意义。
“液体”是指可流动并具有其倾注或放置的容器的内部形状的非颗粒物质和/或材料。
“液体交换”是指液体可从一层传送到另一层或者可从一层内的一处传送到另一处。
“共轭纤维”是指由独立的挤压机挤出的至少两种聚合物形成但一起纺成一股纤维的纤维。共轭纤维有时称为多组分纤维或双组分纤维。尽管共轭纤维可以是单组分纤维，但是其聚合物通常相互不同。聚合物排布于越过共轭纤维横截面的基本恒定座落的不同区域并沿共轭纤维的长度方向连续延伸。这种共轭纤维的结构可以是例如壳/芯结构，其中一种聚合物由另一种包绕或可以是并排结构、薄饼结构或“海中岛”结构。共轭纤维描述于Kaneko等人的美国专利5108820、Strack等人的美国专利5336552和Pike等人的美国专利5382400。对于双组分纤维来说，聚合物可以75/25、50/50、25/75或其它所需的比率出现。所述纤维也可具有诸如Hogle等人的美国专利5277976和Largman等人的美国专利5069970与5057368中所述的形状，所述专利文献的全文通过引用并入本文，它们描述具有非常规形状的纤维。
“双成分纤维”是指由从相同挤压机以共混物挤出的至少两种聚合物形成的纤维。双成分纤维并不具有越过纤维的横截面的相对恒定座落的不同区域排布的各种聚合物组分并且沿整个纤维的长度方向各种聚合物通常并不是连续的，代之的是通常随机开始和结尾的原纤维或原生原纤。双成分纤维有时也称为多成分纤维。这种常规类型的纤维讨论于例如Gessner的美国专利5108827。双组分和双成分纤维也可参见纽约Plenum出版公司的分支Plenum出版社1976年获得版权并由John A.Manson和Leslie H.Sperling编的教科书Polymer Blends and Composites的273到277页，国际书号为IBSN 0-306-30831-2。
此中所用的术语“纵向”或MD是指织物生产方向织物的长度。术语“横向”或CD是指织物的宽度即通常与MD垂直的方向的长度。
此中所用的术语“纺粘型纤维”是指通过从具有挤出长丝直径的喷丝板的多个细小、通常圆形的毛细管挤出长丝形式的熔融热塑性材料形成，然后快速降低直径的小径纤维，其通过例如Appel等人的美国专利4340563、Dorschner等人的美国专利3692618、Matsuki等人的美国专利3802817、Kinney的美国专利3338992和3341394、Hartman的美国专利3502763和Dobo等人的美国专利3542615所述的方法制备。当沉积到收集表面上时纺粘型纤维通常是不粘的。纺粘型纤维通常是连续的，并且具有7微米以上的平均直径(至少10个样品)，更常的直径是在约10到35微米之间。所述纤维也可具有诸如Hogle等人的美国专利5277976、Hill的美国专利5466410和Largman等人的美国专利5069970与5057368中所述的形状，所述专利文献描述具有非常规形状的纤维。
此中所用的术语“熔喷纤维”是指通过多个细小、通常圆形的模毛细管挤出熔体线或长丝形式的熔融热塑性材料到汇聚高速、通常热的气体(如空气)流而降低熔融热塑性材料长丝的直径(可达到微纤维的直径)形成的纤维。然后，熔喷纤维由高速气流携带并在收集表面沉积形成随机分散的熔喷纤维织物。这种方法公开于例如Butin等人的美国专利3849241。熔喷纤维是连续或非连续的微纤维，平均直径通常小于10微米，沉积于收集表面时通常具有粘性。
此中所用的术语“共成型”是指至少一个熔喷模头布置在一个滑槽附近并通过滑槽其它材料加入到正在形成的织物中的方法。例如当所述纤维可以为扯样长度时，这种其它材料可以是浆粕、超强吸水剂或其它颗粒物、天然聚合物(如嫘萦或棉纤维)和/或合成聚合物(如聚丙烯或聚酯)纤维。共成型方法可参见Lau的常规授权的美国专利4818464和Anderson等人的美国专利4100324。通过共成型方法制备的织物常常称为共成型材料。
“粘合粗梳纱织物”是指由通过送过梳理机的短纤维制备的织物，其断开并将短纤维在纵向对直而形成沿纵向定位的纤维无纺织物。这种织物通过一种或多种已知的粘合方法粘合。
“气流成网”是一种人们熟悉的可形成纤维无纺层的方法。在气流成网法中，常规约3-52毫米长度的小纤维的纤维束被分离并包夹在空气流中，然后通常借助于真空而沉积形成网。然后使用例如热空气或喷洒粘合剂将随机沉积的纤维相互粘合。气流成网工艺的例子可参见美国专利4494278、5527171、3375448和4640810。
无纺织物的粘合可通过众多方法来进行；粉末粘合剂粘合法：将粉末粘合剂分布在整个织物上并通常通过用热空气加热织物和粘合剂活化；花纹粘合法：用加热的轧辊或超声粘合设备以通常为局部粘合的形式将纤维粘合一起，尽管如果需要可将织物整个表面粘合在一起；通空气粘合法，将热度达到足以软化织物的至少一种组分的空气导过织物；化学粘合法：通过例如喷涂将例如胶乳粘合剂沉积在织物上；通过机械方法如针刺和hydroentanglement固定。
此中所用的术语“热点粘合”包括将织物或纤维网通过加热的轧辊和砧辊之间粘合。轧辊通常(尽管非总是)某种程度上具花纹图案，因此织物并非整个表面粘合，砧辊通常是平的辊。结果，为了美观方面的原因，发展出各种用于轧辊的花纹图案。花纹图案的一个例子是具有一些点并且是Hansen Pennings或“H&P”花纹，其具有约30％的粘合区域，每平方英寸具有约200粘合点(诸如Hansen和Pennings的美国专利3855046的所述)。H&P花纹具有方形点或纹钉粘合区域，其中每个纹钉具有0.038英寸(0.965mm)的侧边尺寸(sidedimension)、0.070英寸(1.778mm)英寸的纹钉间的间隔和0.023英寸(0.584mm)粘合深度。得到的花纹图案具有约29.5％的粘合区域。另一种典型的点粘合花纹是扩展的Hansen Pennings或“EHP”粘合花纹，其产生约15％的粘合区域，方形针具有0.037英寸(0.94mm)的侧边尺寸、0.097英寸(2.464mm)的针间隔和0.039英寸(0.991mm)的深度。另一种称为“714”的典型点粘合花纹具有方形针粘合区域，其中每个针具有0.023英寸的侧边尺寸、0.062英寸(1.575mm)的针间间隔和0.033英寸(0.838mm)的粘合深度。得到的花纹具有约15％的粘合区域。还一种常规的花纹是具有约16.9％粘合区域的C-Star花纹。所述C-Star花纹具有被射星间隔的横向条或“条绒”设计。其它常规的花纹包括具有约16％粘合区域并具重复和稍有偏移的菱形的菱形花纹和具有约19％粘合区域的看上去象字面如象纱窗的金属丝织图案。通常粘合区域百分比范围为织物层压织物面积的约10-30％。正如本领域技术人员所熟悉的那样，点粘合维持了层压层的层压并且通过粘合每层内的长丝和/或纤维赋予各层的整体性。
“共开孔”是指开了孔的材料以及开孔的方法，其中两种或多种材料一起开孔。所述开孔从材料的顶部延伸到底部并且基本上相互对直。共开孔可通过缠结、物理粘合或化学粘合将材料暂时或永久地连接一起。优选共开孔在室温而非升高的温度下进行。
“个人护理用品”是指尿布、训练用紧身裤、吸水衬裤、成人失禁用品、泳衣、绷带和其它伤口敷料以及妇女卫生用品。
“妇女卫生用品”是指卫生巾、垫和塞。
“目标区”是指个人护理用品系带者正常排液的区域或位置。测试方法
材料厚度
材料厚度是材料厚程度的度量，其在0.05psi(3.5g/cm2)下用Starret型膨松度测试仪测量，单位为毫米。
密度
材料的密度通过样品的单位面积重量(g/m2)除以0.05psi(3.5g/cm2)下的材料厚度(mm)并将结果乘以0.001(将结果转换成每立方厘米克数(g/cc))来计算。总共取三个样品评价，取其平均值作为密度值。
水平毛细吸水测试步骤：
该试验的目的是测定材料从无尽的贮液容器吸液时其水平吸液能力。
所需设备：水平吸液架、按下面所述制备的月经模拟物、尺、定时器。
步骤：
将材料切割成1”(2.54cm)宽和所需的长度。
用月经模拟物装满水平吸液装置中的贮液容器。
将材料的一端置于模拟物中并将材料的其它部分置于吸液装置上。
打开定时器。
测量规定时间吸液的距离或吸液到规定距离的时间。
月经模拟物的制备：
为了制备流体、血液，在这里通过在3000转/分下离心30分钟分离去纤维蛋白的猪血，但是也可使用有效的其它方法或速度和时间。分离血浆并分开存贮，移除并弃去血沉棕黄层，将包装了的血红细胞也分开存贮。
分离蛋(这里是大鸡蛋)，弃去蛋黄和卵带并保留蛋白。通过在1000微米尼龙筛过滤蛋白约3分钟，将蛋白分离成稠和稀的部分，弃去稀的部分。注意可使用另外的筛目并且只要粘度达到至少所需的水平可使用不同的时间或方法。收集保留在筛上的蛋白的稠部分并吸入到60cc注射器中，软化置于程序控制的注射泵上，通过推挤和重吸内容物五次进行均化。在该实例中，通过约100ml/min的注射泵速率和约0.12英寸的管子内径控制均化的量，均化后，稠蛋白在150sec-1下具有约20厘泊的粘度，然后将其置于离心机中并以约3000rpm旋转约10分钟去除碎屑和空气泡，但也可使用其它去除碎屑和气泡的其它有效方法。
离心后，用注射器将含ovamucin的稠的均化蛋白加入到300ccFenwal转移包(transfer pack)中。然后将60cc猪血浆加入到转移包中。夹(clamp)住转移包，去除所有气泡，并置于常规(或中等)速度混合的Stomacher实验室用混合器中混合约2分钟。然后从混合器移出转移包，加入60cc猪血红细胞，手搓混合物约2分钟或直到内容物显得均匀。最后混合物的血细胞比容显示出约30％(重量)的血红细胞含量，并且对于按照该实施例制备的人工月经而言通常应至少在28-32％(重量)的范围内。蛋白的量为约40％(重量)。
在制备这种人工月经中所用的成分和设备是易于获得的。下面列出了在该实施例中所用的物品，当然也可使用其它适合的等价物来源。
血(猪血)：Cocalico Biologicals，Inc.，449 Stevens Rd.，Reamstown，PA 17567，(717)336-1990。
300ml具联接器Fenwal转移包容器样品4R2014：BaxterHealthcare Corporation，Fenwal Division，Deerfield，IL60015。
55-4143型Harvard Apparatus程控注射泵：Harvard Apparatus，South Natick，MA01760。
BA 7021型Stomacher400实验室用混合器系列号31968：SewardMedical，London，England，UK。
1000微米筛(部件号CMN-1000-B)：Small Parts，Inc.，PO Box 4650，Miami Lakes，FL 33014-0650，1-800-220-4242。
测量血细胞比容的HemataStat-II装置(系列号1194Z03127)：Seperation Technology，Inc.，1096 Raine DriVe，Altamon Springs，FL32714。本发明的详细说明
本发明的是通过开孔连接的气流成网织物层和纺粘型非织造织物传递迟缓层。注意尽管在本发明的实施中优选气流成网和纺粘型织物，但是只要能具有同等的性能也可使用其它织物诸如熔喷法非织造织物、共成型和粘合粗梳纱织物。只要性能相同，也可使用各种泡沫材料。也可使用膜，特别是作为传递迟缓层，并且用于一些下面的实施例中。
所述气流成网分布层可由各种纤维和纤维混合物制成，包括合成纤维、天然纤维如水力缠结浆、机械和化学软化浆、短纤维、纱条、熔喷和纺粘型纤维等。在这种织物中的纤维可由相同或不同直径的纤维制备并可具不同形状诸如五叶形、三叶形、椭圆形、圆形等。上面描述了气流成网法。
纺粘型非织造织物传递迟缓层也可由各种不同形状和尺寸的纤维制备。
为了提供织物机械整体性，在纺粘型非织造层或气流成网层中也可包括粘合剂。粘合剂包括可被热活化的纤维、液体或其它粘合剂。优选的纤维是具有较低熔点的纤维如聚烯烃纤维。低熔点聚合物提供了施加热时在纤维交叠点将纤维粘合一起的能力。此外，具有作为至少一种组分的较低熔点聚合物的纤维如复合纤维和双组分纤维适用于本发明的实践。具有较低熔点聚合物的纤维通常称为“易熔”纤维。所指的“较低熔点聚合物”是具有低于约175℃的玻璃化温度的纤维。示例性粘合剂纤维包括聚烯烃和/或聚酰胺和液体粘合剂的复合纤维。这两种适用的粘合剂是可购自KoAS Inc.的称为T-255和T-256的壳芯复合纤维，但也可使用本领域技术人员熟知并由许多制造商如wilmington，DE的Chisso和Fibervisions LLC制造的许多适用的粘合纤维。
合成纤维包括由聚酰胺、聚酯、嫘萦、聚烯烃、丙烯酸类、超强吸水剂、Lyocel再生纤维素制备的纤维和本领域技术人员熟知的其它适用的合成纤维。合成纤维也包括用于产品降解的kosmotropes。
许多聚烯烃适用于纤维生产，例如聚乙烯象Dow Chemical’sASPUN6811A线性低密度聚乙烯、2553LLDPE和25355和12350高密度聚乙烯是这种适合的聚合物。所述聚乙烯分别具有约26、40、25和12的熔体流动速率。成纤维聚丙烯包括Exxon ChemicalCompany’s EscorenePD3445聚丙烯和Montell Chemical Co的PF-304。许多其它聚烯烃均可从商业渠道获得。
天然纤维包括羊毛、棉花、亚麻、大麻和木浆。浆粕包括标准软木短纤浆如Coosa Mills of Coosa，Alabama的CR-1654、可购自Weyerhaeuser Corporation of Tacoma，WA的高松密度添加剂无甲醛浆粕(HBAFF)，并且是交联的湿模量增高的南方软木浆纤维和化学交联的浆粕纤维如Weyerhaeuser NHB 416。除了赋予纤维增加的干湿硬挺性和弹性外，HBAFF进行了卷曲加捻化学处理。另一种适用的浆粕是Buckeye HP2浆粕，再一种是Intemational Paper Corporation的IPSupersoft。适用的嫘萦纤维有Courtaulds Fibers Incorporated of Axis，Alabama的1.5旦Merge 18453。
气流成网分布层和纺粘型非织造织物传递迟缓层使用机械针穿孔技术共开孔。分布和传递迟缓层的共开孔提供了喷流排液控制的独有特征。产生了具三-模式孔结构的独特的材料，所述孔包括1)以原气流成网结构为特征的气流成网织物体中的孔，2)由开孔方法所用的针限定的大孔隙和3)围绕开孔周边的小界面孔。从复合材料的气流成网织物侧观察，所述开孔一般以锥入圆锥状结构中的开孔结构为特征。由于开孔过程的增密和纤维重新定位，界面孔比周围的孔要小。
在妇女卫生用品中传递迟缓层通过防止气流成网分布层和下面的停留保持层之间紧密接触而提供了两层间的渗透性和润湿性梯度。因为传递迟缓层是不可润湿的并且具有低渗透性，它在连续流动条件下促进了流体在气流成网织物层中的分布。传递迟缓层的润湿性可通过本领域技术人员熟知的改变材料疏水性的局部化学处理来改变。一些适用于改变润湿性的化学品以AHCOVEL、Glucopon、Pluronics、Triton和Masil SF-19的商品名出售。
传递迟缓层也控制Z-方向的液体流动。所述传递层促使液体集聚或保持在气流成网分布层中并然后在出现高压或高饱和水平时让流体转移到蓬松物中。相信在连续流动条件下液体并不优先移动到开孔中。这种受控的传递机制使得蓬松物中延长了受污时间并防止了接受排液的区域超饱和。在喷流条件下，在传递迟缓层中的孔使流体立即通过到下面的蓬松层。另外，传递迟缓层可将指示物混入到产品形式中。
图2说明了共开孔材料的三模式孔结构。在图2中，说明了三种类型的孔。大孔1位于织物的开孔处。较小的孔2位于原气流成网织物4中。另一种类型的孔3可发现于织物开孔处的周围区域，其源于开孔过程的增密和纤维重新定位。
图3、4和5显示了开孔的SEM图象。图3以一英寸(2.54cm)等于1mm的放大率显示了所述复合材料气流成网织物侧上的开孔。图4以一英寸等于200微米的放大率显示了所述复合材料气流成网织物侧上开孔的近视图，图5以一英寸等于2mm的放大率显示了所述复合材料纺粘型织物侧上的开孔。
图6比较了开孔气流成网材料与非开孔的气流成网材料的孔径分布。在图6中，未开孔气流成网材料由大的黑方框表示，开孔的气流成网材料由浅色菱形表示。孔体积(cc/g)为Y-轴，孔半径(微米)为X-轴。该图显示出开孔材料存在孔轻微变小的变动。这是由于在开孔周围材料的轻微密化的结果。由开孔形成的大孔没有显示在图中，因为其尺寸较大。但是，它们确实构成了材料另外的孔隙体积。
图7详细说明了与吸收复合材料的功能相关的单个开孔。在图7中，排液(由箭头指示)排放到覆盖层1。排液流过覆盖层1进入本发明的共开孔层压层，其在开孔3或经气流成网层2本身通过气流成网层2。这种排液也可以沿其长度方向分布到气流成网层2内的其它区域。许多排液最终通过气流成网分布层2和传递迟缓层6进入吸湿剂保持芯4。
共开孔系统的功能可分解成五个：覆盖层解吸、增加表面积、开孔孔隙体积、进入蓬松物和吸湿能力。这些功能益处的每一项将分别在下面讨论。
1、覆盖层解吸
气流成网材料的未开孔区域在接触排液后保持了高度的毛细管作用并且良好地适合于解吸覆盖层。气流成网材料的小孔提供了解吸覆盖物的通常大的孔脱附所需的毛细管作用，依此从用品表面去除了大部分的流体。改善的覆盖层解吸导致低的沾污和覆盖物受污水平。
2、增加的表面积
气流成网材料的开孔区域提供了更大地用于吸收流体的表面积。在遇到喷流的情况下，与开孔接触的流体可通过开孔的壁在x、y和z方向吸收，而非只通过表层在z-方向吸收。所以，通过开孔的壁提供的增大的表面积增强了气流成网分布层的吸液特性。另外，开孔也增加了气流成网分布层的整体渗透性。
3、开孔孔隙体积
由开孔产生的空间和孔隙体积可以让液体在吸收到气流成网材料中前在用品内积聚。在气流成网材料局部饱和而阻止了流体即时吸收时可防止积聚在用品表面并促进吸收。
4、达到保持
在气流成网材料中的开孔提供了流体直接进入到开孔区域保持材料的通道。在喷流条件下，流体直接通过开孔进入保持材料。通过提供在这些条件下即时达到保持的能力，气流成网材料的孔隙体积得以维持，减少了多次排液时的吸液次数。
5、吸湿能力
由于气流成网材料的稳定性和高度的湿完整性，在用品接触排液时孔隙并不会坍塌到大的程度。稳定的孔结构允许进行毛细吸湿而将流体转移出排液区并进入用品的其它区域。气流成网材料的未开孔区域保持了这种功能，毛细吸湿防止了在排液区出现高饱和。毛细吸湿与材料稳定性一起可使接触排液后孔隙体积再生从而达到可接收另一次排液。适合的吸液/分布层水平吸收约1.2-15.25cm的距离的月经。
下面为检查本发明优选形式的实验。评价三种不同单位重量的气流成网织物：100、175和250克/平方米(gsm)。比较三种开孔的气流成网织物样品和一种未开孔对照样品。气流成网织物由Weyerhaeuser NB416浆粕和KoSa T-255粘合纤维制成。纺粘层由Union Carbide Company的E5D47聚丙烯制成。
所述纺粘层是点粘的，并具扩张的Hansen Pennings(EHP)图案花纹。分开制备的气流成网层和纺粘层被置于一起并以所示的针密度开孔。或者，相信气流成网层可直接在纺粘层上制备并然后将两者开孔。
开始使用图8的开孔样式，使用0.081”(2.06mm)直径的针开孔而达到每平方英寸48针的密度(7.4针/平方厘米)。
使用平式系统流体分布试验，测试在浆粕蓬松物吸收芯上的这些材料。关键测量项目包括沾污区大小、饱和曲线平还是斜、流体保持和在气流成网层中转移的量。结果列于表1。
表1：平式系统流体分布试验-共开孔材料基质
开孔*100gsm0.06g/cc，80/20 开孔*175gsm，0.08g/cc，88/12 开孔*250gsm，0.14g/cc，90/10 对照250gsm，0.14g/cc，90/10
污渍大小 12.7cm 10.2cm 10.2cm 15.2cm
饱和曲线 平 平 平 平
保持量 3.5g 3.8g 3.0g 4.5g
转移 2.5g 2.3g 3.0g 1.5g
*上面反映的密度是开孔前密度，开孔材料的密度更高。
该试验显示出与对照相比开孔样品的污渍长度和流体保持均得到了下降，表明对气流成网织物开孔极大地提高了气流成网的密度，因为最初开孔样式(图8)的针密度是如此之高。对于高单位重量、高原始密度样品来说，这是最值得关注的。随着密度增加，孔径和孔隙体积下降。
这种样品试验的结果表明开孔具有影响产品性能的潜力。以16针/平方英寸(2.5针/cm2)的针密度(如图9所示)进行进一步试验从而降低开孔后材料的密度。针直径保持在0.081”。研究的织物密度范围缩窄到175-200gsm，将气流成网织物与纺粘织物传递迟缓层一起开孔以维持分布功能。
表2和3显示了所评价的其它材料基质。除了所指明的膜外，这里的传递迟缓层为纺粘聚丙烯织物。所述纺粘传递迟缓层具有所指明的密度和单位重量。所述纺粘织物并未用表面活性剂处理，从而保持了天然的非润湿性。所述薄膜为1密尔厚聚乙烯膜。
表2：共开孔气流成网材料/传递迟缓层
单位重量 密度 传递迟缓层
175gsm 0.08g/cc 27gsm
175gsm 0.08g/cc 33.9gsm
175gsm 0.10g/cc 27gsm
175gsm 0.10g/cc 33.9gsm
表3：共开孔气流成网材料/传递迟缓层
单位重量 密度 传递迟缓层
175gsm 0.12g/cc 27gsm
175gsm 0.14g/cc 33.9gsm
200gsm 0.12g/cc 27gsm
200gsm 0.12g/cc 33.9gsm
200gsm 0.12g/cc 膜
200gsm 0.14g/cc 27gsm
200gsm 0.14g/cc 33.9gsm
200gsm 1.14g/cc 膜
表2和3所示的材料代表着由于其较低的开孔针密度和较低的单位重量和/或初始密度而相信具有更好的性能特征潜力。测试这些材料的容量、水平吸湿能力、饱和容量、流体分配特征和三向吸收喷流能力。这些参数将分别在下面讨论。
容量
图10显示了测得的具开孔和不具开孔的气流成网织物的容量，其中容量为Y-轴，织物密度(cc/g)为X-轴。在图10中，上端线代表175和200gsm-未开孔的气流成网织物，中线为200gsm共开孔气流成网织物，底线为175gsm共开孔织物。正如所估计的那样，容量随密度增加而降低。对于开孔样品来说，容量也稍有降低。这些数据表明200gsm和0.14g/cc的开孔气流成网织物具有等于未开孔的175gsm、0.14g/cc织物的容量。
水平毛细吸湿-无限储库
进行水平毛细吸湿试验以评价开孔处理对水平吸湿距离的影响。水平吸湿距离很重要，因为它提供了警示产品系带者用品接近容量并需要更换的可见信号。没有适当的吸湿功能，可见信号不会以所需的程度的表现出来。
表2的175gsm低密度气流成网样品的水平毛细吸湿结果表明气流成网材料的开孔降低了毛细吸湿距离。相信开孔过程产生了中断吸湿的液体通道的开孔并围绕每个开孔产生密度梯度。依原始密度不同，开孔的材料比未开孔样品吸湿的距离少17到30mm。原始密度越大的材料，差值越大。这些结果列于图11，其中单位为mm的吸湿距离显示于y-轴，分钟为单位的时间显示于x-轴。在图11中，33.9gsm未开孔织物为最高线，就在其下方的为27gsm未开孔织物的线，接着是27gsm开孔织物和33.9gsm开孔织物的线。
图11也表明了开孔导致的吸湿通道干扰比增加气流成网织物密度对水平吸湿性能具有更大的影响。这表明开孔影响并非是简单的致密化影响。水平吸湿结果表明在开孔样品中存在导致显著破坏吸湿通道的毛细管间断。
为了提高吸湿距离，对更高密度的气流成网织物样品开孔并评价它们的毛细吸湿性能。其结果也表明较高密度的样品也不能象未开孔的对照材料那样远距离吸湿。这进一步表明毛细作用的破坏是开孔处理的结果，也表明毛细吸湿距离不能通过开孔材料的密度来控制。
水平吸湿饱和容量
为了评价水平吸湿测试后得到的饱和水平，将饱和材料分割并称重。然后计算g/g为单位的饱和水平，从而确定开孔处理如何影响材料的总体容量水平(g/g)。注意这些饱和水平是以毛细管吸湿为基础而并非以浸泡和滴注的方法为基础的。
图12显示了表2的175gsm低密度气流成网样品的开孔对饱和水平的影响。结果表明不仅水平吸湿距离因为开孔处理而降低，而且吸湿饱和容量也随之降低。尽管在不同开始密度的样品间没有观察到显著差异，无论起始密度多少，开孔样品均比未开孔样品的饱和要小许多。开孔的影响比起始密度的影响显得更主要。在图12，g/g为单位的饱和度显示于y-轴，英寸为单位的吸湿距离显示于x-轴。最上面的线代表未开孔的0.1g/cc样品，次高的线为0.08g/cc未开孔样品，接着的线为0.08g/cc共开孔样品，最低的线为0.1g/cc共开孔样品。
也评价了开孔对更高密度气流成网材料的毛细吸湿饱和度的影响。同样，开孔样品具有比未开孔对照更低的g/g为单位的饱和度。依此看来共开孔样品的单位重量对水平吸湿距离或饱和水平具有最小的影响。175和200gsm样品性能相仿，只在密度间观察到有轻微不同。0.12和0.14g/cc样品的总吸湿距离相同，但0.12g/cc样品的饱和水平更高，相信是由于0.12g/cc样品具更高的孔隙体积。
因为使用时用品经历各种不同的压力和流动条件，也研究了在所需吸液性下的吸湿力。结果显示材料在其整个长度上均匀饱和，表明在所需吸液性吸湿设定值下吸湿并不由于开孔而降低。相信稳定的气流成网织物结构可允许开孔气流成网织物得到充分利用，即使其并不具有在未开孔气流成网织物中发现的连续毛细管流体通道。
从该试验结果来看，相信良好性能下的针密度应在约10-40针/平方英寸(1.6-6.2针/平方厘米)之间。最佳针密度取决于置有本发明的层压品的实际产品形式。
尽管上面只描述了一些本发明的示例性实施方案，本领域技术人员容易理解在没有实质背离本发明的新思路和优点情况下可对示例性实施方案进行许多修改。因此，所有这种修改均应包括在下面权利要求书限定的本发明的范围内。在权利要求书中，方法和功能权利将覆盖执行所述功能时本文所述的结构，不仅是结构等价物而且还有等价结构体。因此，尽管钉和螺丝可能不是结构等价物，因为钉使用圆柱面固定木部件，而螺丝使用螺旋面，但是在固定木部件上，钉和螺丝可以是等价结构体。
还应指出此中所引用的专利、申请或公开均完整地通过引用并入本文。

Claims (17)

1.一种用于个人护理用品的吸液/分布层，包括共开孔分布层和传递迟缓层。
2.权利要求1的层，其中所述共开孔材料用针以约1.6-6.2针/平方厘米的密度开孔。
3.权利要求2的层，其中所述共开孔材料用针以约2.5针/平方厘米的密度开孔。
4.权利要求1的层，其中所述传递迟缓层为选自无纺织物和膜的材料。
5.权利要求1的层，其中所述分布层水平吸收约1.2-15.25厘米距离的月经。
6.权利要求5的层，其中所述分布层是选自气流成网织物、粘合粗梳纱织物、共成型织物、hydroentangled浆粕织物和熔喷法非织造织物的材料。
7.一种个人护理用品，选自包括权利要求1的层的尿布、训练用紧身裤、吸水衬裤、成人失禁用品和妇女卫生用品。
8.权利要求6的用品，其中所述个人护理用品为妇女卫生用品。
9.权利要求6的用品，其中所述个人护理用品为成人失禁用品。
10.权利要求6的用品，其中所述个人护理用品为尿布。
11.一种用于个人护理用品的吸液/分布层，包括一共开孔分布层和一传递迟缓层，其中所述分布层包括短纤维聚烯烃并且通过气流成网法在所述传递迟缓层上制备，并且其中所述层以约1.6-6.2针/平方厘米的针密度开孔。
12.权利要求10的层，其中所述共开孔材料用针以约2.5针/平方厘米的密度开孔。
13.权利要求10的层，其中所述气流成网层由浆粕和热塑性纤维组成。
14.权利要求10的层，其中所述传递迟缓层包括通过纺粘法制备的聚烯烃纤维。
15.权利要求13的层，其中所述聚烯烃为聚丙烯。
16.权利要求10的层，其中所述传递迟缓层包括聚烯烃膜。
17.权利要求15的层，其中所述聚烯烃为聚乙烯。
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* Cited by examiner, † Cited by third party
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CN107405235A (zh) * 2015-03-30 2017-11-28 金伯利-克拉克环球有限公司 具有三维形状保持结构的吸收制品
CN107405235B (zh) * 2015-03-30 2019-02-01 金伯利-克拉克环球有限公司 具有三维形状保持结构的吸收制品

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EP1171068A1 (en) 2002-01-16
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US6534149B1 (en) 2003-03-18
WO2000059430A1 (en) 2000-10-12
KR20010112390A (ko) 2001-12-20
BR0009425A (pt) 2002-03-26
AU762458B2 (en) 2003-06-26
AU4060100A (en) 2000-10-23

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