CN104837453B - 具有高吸收材料含量的吸收制品 - Google Patents
具有高吸收材料含量的吸收制品 Download PDFInfo
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- CN104837453B CN104837453B CN201380063248.6A CN201380063248A CN104837453B CN 104837453 B CN104837453 B CN 104837453B CN 201380063248 A CN201380063248 A CN 201380063248A CN 104837453 B CN104837453 B CN 104837453B
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- absorbent article
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
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Abstract
本发明公开了一种用于个人卫生的诸如尿布或训练裤的吸收制品(20),该吸收制品具有前边缘(10)和后边缘(12)、沿该制品的纵向延伸的纵向轴线(80),该制品具有长度L和裆点(C),长度L沿纵向轴线从前边缘至后边缘测量,裆点(C)被限定为在与制品的前边缘相距L的五分之二的距离处放置在纵向轴线上的点。该制品包括具有凸起段(34)的一对腿箍(32)和包括至少一个通道(26,26’)的吸收芯(28),该至少一个通道至少部分地沿该制品的纵向(80)取向。该制品具有在裆点水平处在腿箍的近侧边缘之间测量的70mm至200mm的使用前的裆部宽度(Wd)、和至少30mm/kg的“相对裆部宽度减小”(RCWR)。
Description
技术领域
本发明提供了一种用于个人卫生的吸收制品,诸如婴儿尿布、训练裤或成人失禁制品。
背景技术
用于个人卫生的吸收制品诸如用于婴儿的一次性尿布、用于学步儿童的训练裤或成人失禁内衣被设计成吸收和容纳身体流出物,尤其是大量的尿液。这些吸收制品包括提供不同功能的多个层,例如顶片、底片和其间的吸收芯、还有其它层。
吸收芯的功能是为了长时间地吸收并保持流出物例如尿布过夜使用、最小化回渗以保持穿着者干燥并避免弄脏衣服或床单。大部分当前市售的吸收制品包含作为吸收材料的粉碎的木浆与呈颗粒形式的超吸收聚合物(SAP)的共混物,也被称为吸收胶凝材料(AGM),参见例如US5,151,092(Buell)。也已经提出具有基本上由作为吸收材料的SAP组成的芯(所谓的“不含透气毡”的芯)的吸收制品,但与传统的混合芯相比更少见(参见例如WO2008/155699(Hundorf)、WO95/11652(Tanzer)、WO2012/052172(Van Malderen))。
也已经提出包括具有狭缝或沟槽的芯的吸收制品,通常是为了增大芯的流体采集特性。WO95/11652(Tanzer)公开了包括超吸收材料的吸收制品,所述超吸收材料位于具有水敏围堵结构和非水敏围堵结构的离散口袋中。WO2009/047596(Wright)公开了一种具有狭缝吸收芯的吸收制品。
这些吸收制品通常可包括腿箍,所述腿箍改善了对液体和其它身体流出物的围堵。腿箍也可称为腿围、侧翼、阻隔箍、或弹性箍。通常每个腿箍将包括一个或多个弹性绳或元件,所述弹性绳或元件包括在尿布的基础结构中,例如在腿部开口区域中的顶片和底片之间,以在使用尿布时提供有效的密封。这些与吸收制品的基础结构基本上在一个平面的弹性化元件将在本文中称为衬圈箍。腿箍通常也包括凸起的弹性化翼片(在本文中称为阻隔腿箍),它们改善了对腿部-躯干接合区域中的流体的围堵。每个阻隔腿箍通常包括一个或多个弹性绳。US4,808,178和US4,909,803(Aziz)描述了具有此类凸起的弹性化翼片的一次性尿布。US4,695,278(Lawson)和US4,795,454(Dragoo)描述了具有双箍(包括衬圈箍和阻隔腿箍)的一次性尿布。US4,704,116(Enloe)公开了一种包括一对衬圈箍和一对阻隔腿箍的吸收衣服,所述衬圈箍和阻隔腿箍附接到顶片或由顶片形成,并向内与所述弹性化腿部开口隔开,从而限定排泄物密封口袋。
吸收制品一般具有高吸收容量,并且吸收芯能够膨胀至其重量和体积的若干倍。这些增大通常将导致吸收制品在变得液体饱和时在裆区中发生松垂,这可导致阻隔箍部分地失去与穿着者皮肤的接触。这可能导致阻隔箍的功能损失,从而增大渗漏的可能性。
US2007/088308(Ehrnsperger)通过提出阻隔箍条来解决该问题,所述阻隔箍条沿顶片从前腰区纵向地延伸至后腰区并包括前端和后端以及连接前端和后端的近侧边缘和远侧边缘。远侧边缘在箍端部粘结区处附接,所述箍端部粘结区具有外粘结边缘和与外粘结边缘纵向地隔开的内粘结边缘。从内粘结边缘至前腰区和后腰区之一处的侧向延伸侧的纵向距离为前腰区或后腰区的纵向长度的约1/2或更多。
US2004/220541(Suzuki)公开了一种吸收片,所述吸收片在其表面上具有凹形部分和凸形部分,并由于形成了凹-凸结构而自发地表现出三维结构。US2007/244455(Hansson)公开了吸收制品中的吸收芯,其具有至少两个折叠引导件,所述折叠引导件沿在裆区中沿基本上纵向延伸并将吸收芯的裆区的至少一部分分成中心部分和在横向上见到的两个侧向部分。至少两个可拉伸的裆部弹性构件被布置在制品的裆部部分中并附接到吸收芯和/或内覆盖件或外覆盖件。
虽然现有技术已对改善渗漏阻止的问题提供了不同的解决方案,但仍然有益的是开发出新的且改善的解决方案以提供腿箍在高负载下的更好的贴合性。本发明人已发现,可有益地使阻隔腿箍的自由边缘沿循腿部和躯干之间的折叠线。这些折叠线是供阻隔腿箍的凸起边缘沿循的非常好的位置,原因是(a)其为低运动区域、和(b)其处于最靠近身体的区域。这些解剖学上的折叠线不是直的,而是左折叠线和右折叠线之间的距离在前部和后部中比在裆部中大。
本发明人已发现,当如下所详述地减小裆部部分中的阻隔腿箍之间的尿布宽度时,阻隔腿箍的自由边缘在制品被加载时能够更好地沿循弯曲折叠线,这改善渗漏阻止。这是尤其有利的,因为当制品被高度地加载并因此最需要渗漏阻止时,通过这种方式增大了渗漏阻止。本发明人已发现,当吸收芯包含高比例的超吸收聚合物和至少部分地纵向延伸的通道时,该效应尤其明显。
发明内容
本发明提供了一种用于个人卫生的吸收制品,诸如具有前边缘和后边缘的尿布或训练裤。该制品具有沿纵向轴线从其前边缘测量至其后边缘的长度L、和裆点(C),所述裆点被限定为放置成在纵向轴线上与制品的前边缘相距L的五分之二的距离的点。该制品包括:
-液体可透过的顶片;
-液体不可透过的底片;
-一对阻隔腿箍,所述阻隔腿箍在纵向轴线的相对侧上至少部分地在尿布的前边缘和后边缘之间延伸并在裆点的至少纵向位置处存在,每个阻隔腿箍均由直接接合或间接接合到顶片和/或和底片的近侧边缘界定;和自由末端边缘;
-和包括芯包裹物的吸收芯,所述芯包裹物包封吸收材料,其中吸收材料包含按吸收材料的重量计至少80%的超吸收聚合物,其中吸收芯包括至少部分地沿制品纵向取向的至少一个通道。
该制品具有至少30mm/kg的“相对裆部宽度减小”(RCWR),其中RCWR根据下式计算:
其中Wd为裆点处的干裆部宽度并且Ww为湿裆部宽度,并且Mw为制品的湿质量且Md为制品的干质量,所述测量是根据本文所述的RCWR测试所指出的那样进行的。该制品在裆点水平处具有70mm至200mm的干裆部宽度(Wd)(使用前)。
附图说明
图1为呈尿布形式的本发明的实施例的顶视图,其中部分地移除了一些层;
图2为图1的实施例在裆点处的横截面;
图3为在与图2相同的点截取的图1的实施例的横截面,其中尿布已被加载有流体;
图4为具有两个通道的本发明的另选实施例的顶视图;
图5为图4的实施例在裆点处的横截面;
图6为图4的吸收芯的实施例的顶视图,其中部分地移除了一些层;
图7为图6的芯在裆点处的横截面;
图8为图6的实施例的纵向剖视图。
具体实施方式
引言
如本文所用,术语“吸收制品”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一次性装置,诸如婴儿或成人尿布、训练裤等等。通常这些制品包括顶片、底片、吸收芯和任选地采集系统(其可由一个或若干个层构成)和通常的其它部件,其中吸收芯通常放置在底片和采集系统或顶片之间。
本发明的吸收制品将以胶粘尿布的形式在下面说明书和附图中进一步举例说明。然而,除非另有明确地指明,不应认为该说明限制权利要求的范围。除非另外指明,本说明书是指干燥制品,即使用之前的制品,并且在21℃+/-2℃和50+/-20%的相对湿度(RH)下调理至少24小时。
如本文所用,“非织造纤维网”是指由定向或任意取向的纤维通过摩擦和/或结合和/或粘合而粘结成的、或通过湿磨法而毡化成的人造片、纤维网或毛层,不包括纸张和通过织造、编织、簇成、缝编而组合接结纱或长丝的产品,无论是否附加地缝过。这些纤维可具有天然的或人造的来源,并且可为短纤维或连续长丝或为原位形成的纤维。可商购获得的纤维具有介于小于约0.001mm至大于约0.2mm的范围内的直径,并且它们具有若干不同的形式,例如短纤维(已知为化学短纤维或短切纤维)、连续单纤维(长丝或单丝)、无捻连续长丝束(丝束)和加捻连续长丝束(纱线)。非织造纤维网可通过许多方法形成,诸如熔喷法、纺粘法、溶液纺丝、静电纺纱、梳理法和气流成网法。非织造纤维网的基重通常用克/平方米(g/m2或gsm)表示。
如本文所用,术语“接合”或“粘结”或“附接”包括通过将元件直接附连到其它元件而将元件直接固定到另一个元件的构型,以及通过将元件附连到一个或多个中间元件,该中间元件继而附连到另一个元件,从而将元件间接固定到另一个元件的构型。
“包括”和“包含”是开放式术语,每个均指定其后所述例如部件的存在,但不排除本领域已知的或本文所公开的其它特征结构例如元件、步骤或部件的存在。这些基于动词“包括”的术语应当被解读为涵盖较窄的术语“由…组成”,其排除未指定的任何元件、步骤或成分;和“基本上由…组成”,其将元件的范围限制于指定材料或步骤;以及不显著地影响元件执行其功能的方式的那些。下文所述的任何优选的实施例或示例性实施例不限制权利要求的范围,除非具体地指明这样做。词“典型地”、“通常”、“有利地”等也限定元件,其不旨在限制权利要求的范围,除非明确地指明如此进行。
对吸收制品的一般说明
图1-3示出了根据本发明的呈婴儿尿布20形式的示例性吸收制品。图1为处于平展状态的示例性尿布20的平面图,其中部分结构被切除以更清楚地示出尿布20的构造。该尿布20仅出于例证的目的示出,因为本发明可用于制备多种尿布或其它吸收制品。
吸收制品包括液体可透过的顶片24、液体不可透过的底片25、位于顶片24和底片25之间的吸收芯28、以及阻隔腿箍34。吸收制品也可包括采集-分配系统(“ADS”),其在所示的示例中包括将在下文详述的分配层54和采集层52。该制品也可包括弹性化衬圈箍32,所述衬圈箍通常经由顶片和/或底片接合到吸收制品的基础结构,并基本上与尿布的基础结构在一个平面。
附图还示出了典型的胶粘尿布部件诸如包括粘合剂插片42的扣紧系统,所述粘合剂插片朝制品后边缘附接并与制品的前部上的着陆区44协作。所述吸收制品也可包括未示出的其它典型元件,诸如后弹性腰部结构、前弹性腰部结构、一个或多个横向阻隔箍、洗剂应用等。
吸收制品20包括前边缘10、后边缘12、和两个侧边缘。前边缘10为制品的旨在当被穿着时朝向使用者的前部放置的边缘,并且后边缘12为相对的边缘。在胶粘尿布中,如图1示例性所示,尿布的后边缘通常位于尿布的包括扣紧插片42的侧面上,并且前边缘通常位于尿布的包括匹配的着陆区44的侧面上。更一般地,制品前部通常比制品后部具有更大的吸收容量。在将制品平坦放置并如图1所示地俯视时,吸收制品可设想地被纵向轴线80划分,所述纵向轴线从制品的前边缘延伸到后边缘并将制品相对于该轴线划分成两个基本上对称的半部。可沿纵向轴线80从前边缘10到后边缘12来测量制品的长度L。所述制品包括裆点C,其在本文中被定义为在从制品20的前边缘10开始五分之二(2/5)L的距离处设置在纵向轴线上的点。
裆区可被定义为尿布的如下区域,所述区域的纵向中心位于裆点C处,并且朝吸收制品的前部且朝后部沿每个方向延伸L的五分之一(L/5)的距离,共延伸L的2/5的总长度。前区和后区可被定义为分别朝制品的前边缘和后边缘放置的尿布的剩余部分。
顶片24、底片25、吸收芯28和其它制品部件可以多种熟知的构型来组装,具体地通过胶粘或热压花。示例性尿布构型大体描述于US3,860,003、US5,221,274、US5,554,145、US5,569,234、US5,580,411和US6,004,306中。吸收制品优选为薄的。由本文所述的“厚度测试”测量,该制品的裆点C处的厚度可为例如4.0mm至12.0mm,具体地6.0mm至10.0mm。
吸收芯28具有包含至少80重量%的超吸收聚合物的吸收材料和包封吸收材料的芯包裹物。芯包裹物通常可包括用于芯的顶侧面和底侧面的两个基底16和16’。芯还包括至少一个通道,在图1中被示出为四个通道26,26’和27,27’。
现在将更详细地讨论该制品的这些和其它部件。
顶片24
顶片24是吸收制品的直接接触穿着者皮肤一部分。如本领域中所公知的,顶片24可接合到底片25、芯28和/或任何其它层。通常,顶片24和底片25在一些位置直接接合到彼此(例如在制品周边上或靠近制品周边处),并且通过使它们直接接合到制品20的一个或多个其它元件,从而在其它位置间接接合在一起。
顶片24优选地为柔顺的、感觉柔软的,并且不刺激穿着者的皮肤。另外,顶片24的至少一部分为液体可透过的,从而允许液体容易地穿透其厚度。适合的顶片可由许多各种不同的材料制成,诸如多孔泡沫、网状泡沫、开孔塑料膜、或者天然纤维(例如,木纤维或棉纤维)、合成纤维或长丝(例如,聚酯纤维或聚丙稀纤维或PE/PP双组分纤维或它们的混合物)或天然纤维与合成纤维组合的织造或非织造材料。如果顶片24包含纤维,纤维可为纺粘、梳理成网、湿法成网、熔喷、水刺法、或以本领域已知的方式处理的,具体地为纺粘PP非织造织物。包括短纤维长度聚丙烯纤维的纤维网的合适的顶片由International PaperCompany的分部Veratec,Inc.(Walpole,MA)制造,商品名为P-8。
合适的成形膜顶片描述于US3,929,135、US4,324,246、US4,342,314、US4,463,045和US5,006,394中。其它合适的顶片可根据授予Curro等人的US4,609,518和4,629,643制成。此类成形膜可以商品名“DRI-WEAVE”购自Procter&Gamble Company(Cincinnati,Ohio),并以商品名“CLIFF-T”购自总部在Richmond,VA的Tredegar Corporation。
如本领域中所公知的,顶片24的任何部分均可涂覆有洗剂。合适的洗剂的示例包括描述于US5,607,760、US5,609,587、US5,643,588、US5,968,025和US6,716,441中的那些。顶片24也可包含抗菌剂或经抗菌剂处理,一些示例公开于PCT公布WO95/24173中。此外,顶片24、底片25或所述顶片或底片的任何部分可经压花和/或糙面精整以提供更类似于布料的外观。
顶片24可包括一个或多个孔以便于流出物透过,诸如尿液和/或粪便(固体、半固体、或液体)。至少主孔的尺寸对于获得期望的废物包封性能是重要的。如果主孔太小,废物可不穿过孔,这是由于废物源和孔位置未对齐,或者由于粪块具有大于孔的直径。如果孔太大,可能被制品的“回渗”污染的皮肤区域增大。通常,尿布表面处的孔的总面积可具有介于约10cm2和约50cm2之间,具体地介于约15cm2和35cm2之间的面积。开孔顶片的示例公开于转让给BBA NONWOVENS SIMPSONVILLE的US6632504中。WO2011/163582还公开了合适的着色顶片,其具有12至18gsm的基重并包括多个粘结点。粘结点中的每一个具有2mm2至5mm2的表面积,并且所述多个粘结点的累加表面积为所述顶片总表面积的10至25%。
典型的尿布顶片具有约10至约21gsm,具体地约12至约18gsm的基重,但是其它基重是可以的。
底片25
底片25通常是制品20的邻近吸收芯28的面向衣服的表面定位的部分,并且其防止其所吸收和容纳的流出物弄脏制品诸如床单和内衣。底片25通常是对液体(例如,尿液)不可透过的。底片可例如为薄塑料膜或包括薄塑料膜,诸如具有约0.012mm至约0.051mm的厚度的热塑性膜。示例性底片膜包括由总部在Richmond,VA的Tredegar Corporation制造并以商品名CPC2膜出售的那些。其它合适的底片材料可包括允许水蒸汽从尿布20逸出同时还防止流出物通过底片25的透气材料。示例性的透气材料可包括材料诸如织造纤维网、非织造纤维网、复合材料诸如膜包衣的非织造纤维网、微孔膜诸如由Mitsui Toatsu Co.(Japan)以名称ESPOIR NO制造的和由Tredegar Corporation(Richmond,VA)制造并以名称EXAIRE出售的、以及单片膜诸如由Clopay Corporation(Cincinnati,OH)以名称HYTREL共混物P18-3097制造的。一些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专利申请WO 95/16746;授予LaVon等人的US5,938,648,授予Linman等人的US4,681,793,授予Curro的US5,865,823;以及授予Dobrin等人的US5,571,096,授予London Brown的US6,946,585B2中。
可通过本领域已知的任何附接方法将底片25接合到尿布20的顶片24、吸收芯28或任何其它元件。合适的附接装置已在上文针对用于将顶片24接合到制品20的其它元件上的部件进行了说明。例如,附接装置可包括均匀连续的粘合剂层、图案化粘合剂层、或分离的粘合剂线、螺旋线或点的阵列。合适的附接装置包括粘合剂长丝的开放图案网络,如US4,573,986中所公开的。其它合适的附接装置包括若干盘绕成螺旋图案的粘合剂长丝,如美国US3,911,173、US 4,785,996;和US 4,842,666中所示的设备和方法所图示说明的。由H.B.Fuller Company(St.Paul,Minnesota)制造且以HL-1620和HL1358-XZP出售的粘合剂已被发现为令人满意的。另选地,附接方法可包括热粘结、压力粘结、超声粘结、动态机械粘结、或本领域已知的任何其它适合的附接方法或这些附接方法的组合。
吸收芯28
如本文所用,术语“吸收芯”是指该制品的单个部件,其具有最大吸收容量并包含吸收材料和包封该吸收材料的芯包裹物。术语“吸收芯”不包括不是芯包裹物的整体部分或不是放置在芯包裹物内的制品的采集-分配系统或层或任何其它部件。芯可基本上由或由芯包裹物、如下文所限定的吸收材料、和包封在芯包裹物内的胶组成。
本发明的吸收芯28包含吸收材料,所述吸收材料具有包封在芯包裹物内的大量的超吸收聚合物(在本文中缩写为“SAP”)。SAP含量表示包含在芯包裹物中的至少80重量%的吸收材料。出于评估SAP占吸收芯的百分比的目的,芯包裹物不被认为是吸收材料。
所谓“吸收材料”是指具有一些吸收特性或液体保持特性的材料,诸如SAP、纤维素纤维以及合成纤维。通常,用于制备吸收芯的胶不具有吸收特性,因而不被认为是吸收材料。SAP含量可高于80%,例如至少85%,至少90%,至少95%,并且甚至多至并包括芯包裹物内所包含的吸收材料重量的100%。相比于通常包含介于40-60%之间的SAP和高含量纤维素纤维的常规芯,这提供了相对薄的芯。具体地,吸收材料可包含少于10重量%的天然或合成纤维,或少于5重量%或甚至基本上不含天然和/或合成纤维。吸收材料可有利地包含很少或不包含透气毡(纤维素)纤维,具体地吸收芯可包含按所述吸收芯的重量计少于15%、10%、5%的透气毡(纤维素)纤维,或甚至基本上不含纤维素纤维。
图4-5的吸收制品的示例性吸收芯28单独地示出于图6-8中。吸收芯通常包括前边缘280、后边缘282以及接合前边缘280和后边缘282的两个纵向边缘284,286。吸收芯也可包括大致平面的顶部边缘和大致平面的底部边缘。芯的前边缘280为芯的旨在朝吸收制品的前边缘10放置的边缘。如在图1所示的平面视图中从顶部看,所述芯可具有基本上对应于制品80的纵向轴线的纵向轴线80’。通常,相比于朝后边缘,吸收材料将有利地朝前边缘分布更大的量,因为在前部需要更多吸收性。通常,芯的前边缘和后边缘短于芯的纵向边缘。芯包裹物可由两个非织造材料16,16’形成,它们可沿吸收芯的边缘至少部分地密封。芯包裹物可沿其前边缘、后边缘和两个纵向边缘至少部分地密封,使得基本上无吸收材料渗漏出吸收芯包裹物。
本发明的吸收芯还可包括例如粘合剂以帮助将SAP固定在芯包裹物内和/或确保芯包裹物的完整性,尤其是当芯包裹物由两个或更多个基底制成时。芯包裹物通常将比在其内包含吸收材料严格所需的区域延伸至更大的区域。根据WO2010/0051166A1中所述的湿固定作用测试,吸收芯有利地实现不超过约70%、60%、50%、40%、30%、20%、10%的SAP损失。
过去已经提出了包括相对高含量SAP并具有各种芯设计的芯,参见例如US5,599,335(Goldman)、EP1,447,066(Busam)、WO95/11652(Tanzer)、US2008/0312622A1(Hundorf)、WO2012/052172(Van Malderen)。
吸收材料可为存在于芯包裹物内的连续层。在其它实施例中,吸收材料可包含单个口袋或包封在芯包裹物内的吸收材料条。在第一种情况下,吸收材料可例如通过施加单一连续吸收材料层来获得。吸收材料具体地SAP的连续层也可通过组合具有不连续的吸收材料施加图案的两个吸收层而获得,其中所得层在吸收颗粒聚合物材料区域上基本上连续地分布,如例如US2008/0312622A1(Hundorf)所提出。吸收芯28可例如包括第一吸收层和第二吸收层以及纤维热塑性粘合剂材料51,第一吸收层包括第一基底16和第一吸收材料层61(它们可为100%SAP),并且第二吸收层包括第二基底16’和第二吸收材料层62(它们也可为100%SAP),所述纤维热塑性粘合剂材料将每个吸收材料层61,62至少部分地粘结到其相应基底。这示出于图8中,其中第一SAP层和第二SAP层已被施加为横向条或“着陆区域”,它们在被组合之前与其相应基底上所期望的吸收材料沉积区域具有相同的宽度。这些条或着陆区域可由接合区域分开。这些条可有利地包含不同量的吸收材料(SAP)以提供沿芯80’的纵向轴线的分布的基重。第一基底16和第二基底16’可形成芯包裹物。
纤维热塑性粘合剂材料51可在着陆区域中至少部分地接触吸收材料61,62并在接合区域中至少部分地接触基底层。这赋予热塑性粘合剂材料51的纤维层基本上三维的结构,所述三维的结构本身为基本上二维的结构,具有相比于长度方向和宽度方向上的尺寸相对小的厚度。从而,纤维热塑性粘合剂材料可提供腔以覆盖着陆区域中的吸收材料,并从而固定该吸收材料(其可为100%SAP)。
热塑性粘合剂材料51可整体包括单一热塑性聚合物或热塑性聚合物的共混物,当通过ASTM方法D-36-95“环球法”测定时,所述聚合物具有在介于50℃和300℃之间的范围内的软化点,和/或热塑性粘合剂材料可为热熔性粘合剂,其包括与其它热塑性稀释剂诸如增粘树脂、增塑剂和添加剂诸如抗氧化剂相组合的至少一种热塑性聚合物。
热塑性聚合物通常具有超过10,000的分子量(Mw)和通常低于室温的玻璃化转变温度(Tg)或-6℃<Tg<16℃。热熔体中聚合物的典型浓度在约20重量%至约40重量%的范围内。所述热塑性聚合物可以为水不敏感性的。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,且B嵌段为不饱和共轭双烯或(部分)氢化的此类变体。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,它们为利用单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。同样适用的是无定形聚烯烃或无定形聚α-烯烃(APAO),它们为C2至C8α烯烃的均聚物、共聚物或三元共聚物。
增粘树脂可示例性地具有低于5,000的Mw和通常高于室温的Tg,热熔体中树脂的典型浓度在约30至约60%的范围内,并且增塑剂具有通常小于1,000的低Mw和低于室温的Tg,其典型浓度为约0至约15%。
用于纤维层的热塑性粘合剂优选具有弹性体特性,使得由SAP层上的纤维形成的纤维网在SAP溶胀时能够被拉伸。示例性弹性体热熔性粘合剂包括热塑性弹性体诸如乙烯乙酸乙烯酯、聚氨酯、硬组分(一般来讲,结晶的聚烯烃诸如聚丙烯或聚乙烯)和软组分(诸如乙烯-丙烯橡胶)的聚烯烃共混物;共聚酯诸如聚(对苯二甲酸乙二酯-共聚-壬二酸乙二酯);以及热塑性弹性体嵌段共聚物,其具有热塑性端嵌段和橡胶中嵌段,被表示成A-B-A嵌段共聚物:结构上不同的均聚物或共聚物的混合物,例如,聚乙烯或聚苯乙烯与A-B-A嵌段共聚物的混合物;热塑性弹性体与低分子量树脂改性剂的混合物,例如苯乙烯-异戊二烯苯乙烯嵌段共聚物与聚苯乙烯的混合物;以及本文所述的弹性体热熔性压敏粘合剂。这些类型的弹性体热熔性粘合剂详述于在1988年3月15日授予Korpman的美国专利4,731,066中。
热塑性粘合剂材料有利地被施加为纤维。纤维可示例性地具有约1微米至约50微米或约1微米至约35微米的平均厚度和约5mm至约50mm或约5mm至约30mm的平均长度。为了改善热塑性粘合剂材料对基底层或任何其它层尤其是任何其它非织造层的粘附性,此类层可用辅助粘合剂预处理。纤维彼此附着以形成纤维层,其还可描述为网。
在某些实施例中,热塑性粘合剂材料将符合至少一个、或多个、或所有以下参数。示例性热塑性粘合剂材料可具有在20℃下测量的至少30,000Pa且小于300,000Pa,或小于200,000Pa,或介于140,000Pa和200,000Pa之间,或小于100,000Pa的储能模量G'。在另一方面,在35℃下测量的储能模量G'可大于80,000Pa。在另一方面,在60℃下测量的储能模量G'可小于300,000Pa且大于18,000Pa,或大于24,000Pa,或大于30,000Pa,或大于90,000Pa。在另一方面,在90℃下测量的储能模量G'可小于200,000Pa且大于10,000Pa,或大于20,000Pa,或大于30,000Pa。在60℃和90℃下测量的储能模量可为热塑性粘合剂材料在高环境温度下的形式稳定性的量度。如果吸收产品在炎热的气候中使用,则该值是特别重要的,如果60℃和90℃下的储能模量G'不足够高,则在所述气候中,热塑性粘合剂材料将失去其完整性。
可使用流变仪测量G',如WO2010/27719所指出的那样。流变仪能够向粘合剂施加剪切应力,并且测量在恒定温度下所引起的应变(剪切变形)响应。将粘合剂置于用作下固定板的Peltier元件和具有例如10mm半径R的上板之间,所述上板连接到马达的驱动轴上以生成剪切应力。两个板之间的间隙具有例如1500微米的高度H。Peltier元件使得能够控制材料的温度(+0.5℃)。应选择应变速率和频率使得所有测量在线性粘弹性区域进行。
超吸收聚合物(SAP)
如本文所用,“超吸收聚合物”(“SAP”)是指如下吸收材料,它们是交联聚合材料,当使用离心保留容量(CRC)测试(EDANA方法WSP 241.2-05E)测量时,所述聚合材料能够吸收至少10倍于其自身重量的含水的0.9%盐水溶液。所用的SAP具体地可具有大于20g/g,或大于24g/g,或20至50g/g,或20至40g/g,或24至30g/g的CRC值。可用于本发明中的SAP包含多种水不溶性但水可溶胀性的能够吸收大量流体的聚合物。
超吸收聚合物可为颗粒形式,以便在干燥状态下可流动。典型的颗粒吸收性聚合物材料由聚(甲基)丙烯酸聚合物制成。然而,例如还可使用基于淀粉的颗粒吸收性聚合物材料,以及聚丙烯酰胺共聚物、乙烯马来酸酐共聚物、交联羧甲基纤维素、聚乙烯醇共聚物、交联聚环氧乙烷、以及聚丙烯腈的淀粉接枝的共聚物。超吸收聚合物可以为聚丙烯酸酯和聚丙烯酸聚合物,其为内部交联和/或表面交联的。合适的材料在PCT专利申请WO07/047598或例如WO07/046052或例如WO2009/155265和WO2009/155264中有所描述。在一些实施例中,合适的超吸收聚合物颗粒可通过本领域现阶段的制备工艺获得,如更具体地在WO 2006/083584中描述。优选将超吸收聚合物内部交联,即在具有两个或更多个聚合型基团的化合物的存在下进行聚合,所述化合物可自由基共聚到聚合物网络中。可用的交联剂包括例如如EP-A 530 438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-A 547 847、EP-A 559 476、EP-A 632 068、WO 93/21237、WO 03/104299、WO 03/104300、WO 03/104301和DE-A103 31450中所述的二丙烯酸酯和三丙烯酸酯,如DE-A 103 31 456和DE-A 103 55 401中所述的混合丙烯酸酯(其不仅包括丙烯酸酯基团,还包括烯键式不饱和基团),或者如例如DE-A195 43 368、DE-A 196 46 484、WO90/15830和WO 02/32962中所述的交联剂混合物,以及WO2009/155265中所述的交联剂。超吸收聚合物颗粒可为外表面交联的,或:后交联的)。可用的后交联剂包括包含能够与所述聚合物的羧酸根基团形成共价键的两个或更多个基团的化合物。可用的化合物包括例如EP-A 083 022、EP-A543 303和EP-A 937 736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、二或聚缩水甘油基化合物;如DE-C 3314 019中所述的多元醇;如DE-A 40 20 780中所述的环状碳酸酯;如DE-A 198 07 502中所述的2-唑烷酮及其衍生物,诸如N-(2-羟乙基)-2-唑烷酮;如DE-A198 07 992中所述的双和聚-2-唑烷酮;如DE-A 198 54 573中所述的2-氧代四氢-1,3-嗪及其衍生物;如DE-A 198 54 574中所述的N-酰基-2-唑烷酮;如DE-A 102 04 937中所述的环脲;如DE-A 103 34 584中所述的二环酰胺缩醛;如EP1,199,327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。
在一些实施例中,SAP由聚丙烯酸聚合物/聚丙烯酸酯聚合物形成,例如具有60%至90%,或约75%的中和度,具有例如钠抗衡离子。
可用于本发明的SAP可具有很多种形状。术语“颗粒”是指小粒、纤维、薄片、球体、粉末、薄板、以及在超吸收聚合物颗粒领域中技术人员已知的其它形状和形态。在一些实施例中,SAP颗粒可为纤维的形状,即细长的针状超吸收聚合物颗粒。在那些实施例中,超吸收聚合物颗粒纤维具有小于约1mm,通常小于约500μm,并且优选小于250μm下至50μm的小尺度(即纤维的直径)。纤维的长度优选为约3mm至约100mm。纤维也可呈可被织造的长丝的形式。
通常SAP是球状颗粒。与纤维相反,“球状颗粒”具有最长和最短尺寸,其中颗粒的最长和最短颗粒尺寸之比在1-5范围内,其中值1等于完美的球状颗粒,而值5将允许与此类球状颗粒有一些偏差。根据EDANA方法WSP 220.2-05测量,超吸收聚合物颗粒可具有小于850μm,或50至850μm,优选100至710μm,更优选150至650μm的粒度。具有相对低粒度的SAP有助于增加吸收材料的与液体流出物接触的表面积,并因此支持液体流出物的快速吸收。
SAP可具有在45μm至4000μm的范围内的粒度,更具体地具有在45μm至约2000μm,或约100μm至约1000,850或600μm的范围内的粒度分布。颗粒形式的材料的粒度分布可如本领域中已知来测定,例如借助于干筛分析法(EDANA 420.02“粒度分布)。
在本文的一些实施例中,超吸收材料为颗粒的形式,颗粒具有至多2mm,或介于50微米和2mm之间或至1mm,或优选地从100或200或300或400或500μm,或至1000或至800或至700μm的质量中值粒度;所述质量中值粒度可例如通过在例如EP-A-0,691,133中所述的方法来测量。在本发明的一些实施例中,超吸收聚合物材料呈颗粒形式,所述颗粒中至少80重量%为具有介于50μm和1200μm之间的尺寸且具有介于上述任何范围组合之间的质量中值粒度的颗粒。此外,或在本发明的另一个实施例中,所述颗粒为大致上球形的。在本发明的另一个或附加实施例中,超吸收聚合物材料具有相对窄范围的粒度,例如其中大部分(例如至少80%或优选地至少90%或甚至至少95重量%)的颗粒具有50μm和1000μm之间,优选地100μm和800μm之间,并且更优选地200μm和600μm之间的粒度。
合适的SAP可例如由如US4,340,706和US5,849,816所述的反相悬浮聚合反应获得,或者由如美国专利申请2009/0192035、2009/0258994和2010/0068520所述的喷雾或其它气相分散聚合反应获得。在一些实施例中,合适的SAP可通过本领域现阶段的制备工艺获得,如更具体地由WO2006/083584,第12页第23行至第20页第27行中所述。
SAP表面可涂覆有例如阳离子聚合物。优选的阳离子聚合物可包括聚胺或聚亚胺材料。在一些实施例中,SAP可涂覆有脱乙酰壳多糖材料如在US7,537,832B2中公开的那些。在一些其它实施例中,SAP可包含混合床离子交换吸收聚合物,如WO 99/34841和WO 99/34842中所公开的那些。
吸收芯通常将包括仅一种类型的SAP,但不排除可使用SAP的共混物。可使用其“尿液渗透性测量”(UPM)值来量化超吸收聚合物的流体渗透性,所述值在欧洲专利申请EP12174117.7所公开的测试中测量。SAP的UPM可为例如至少10×10-7cm3.sec/g,或至少30×10-7cm3.sec/g,或至少50×10-7cm3.sec/g,或更高,例如至少80或100×10-7cm3.sec/g。流动特性也可通过改变在第二吸收层中使用的SAP量和分布进行调节。
就大多数吸收制品而言,液体排放主要在制品(具体地尿布)的前半部中进行。因此,制品的前半部(如由介于前边缘和在距前边缘或后边缘一半L的距离处设置的横向线90之间的区域限定)可包括芯的大部分吸收容量。因此,至少60%的SAP,或至少65%,70%,75%或80%的SAP可存在于吸收制品的前半部中,剩余的SAP设置在吸收制品的后半部中。
存在于吸收芯中的SAP总量也可根据期望的使用者而变化。用于新生儿的尿布可比婴儿尿布或成人失禁尿布需要较少的SAP。芯中的SAP量可例如占约5至60g,具体地5至50g。SAP的沉积区域8(或者如果存在多个,则“至少一个”)内的平均SAP基重可以为例如至少50、100、200、300、400、500g/m2或更多。由吸收材料沉积区域推导存在于吸收材料沉积区域8中的通道的区域以计算该平均基重。
芯包裹物(16,16’)
芯包裹物可由围绕吸收材料折叠的单一基底制成,或可有利地包括附接到另一个的两个(或更多个)基底。典型的附接件为所谓的C形包裹物和/或夹心包裹物。在C形包裹物中,如图2和7示例性所示,基底中的一个的纵向边缘和/或横向边缘被折叠到另一个基底上以形成翼片。然后这些翼片通常通过胶粘粘结到另一个基底的外表面。
芯包裹物可由适用于接收并包含吸收材料的任何材料形成。可使用用于制备常规芯的典型的基底材料,具体地,纸、薄纸、膜、织造织物或非织造织物、或任何这些材料的层合体。芯包裹物可具体地由非织造纤维网形成,诸如梳理非织造织物、纺粘非织造织物(“S”)或熔喷非织造织物(“M”)、以及这些中任何织物的层合体。例如,熔纺聚丙烯非织造织物是合适的,尤其是具有层压纤维网SMS、或SMMS或SSMMS结构,并具有约5gsm至15gsm基重范围的那些。合适的材料例如公开于US7,744,576、US2011/0268932A1、US2011/0319848A1或US2011/0250413A1中。可使用由合成纤维诸如PE、PET,尤其是PP所提供的非织造材料。
如果芯包裹物包括第一基底16和第二基底16’,则其可由相同类型的材料制成,或可由不同的材料制成,或者一个基底可以与另一个不同的方式进行处理以向其提供不同的特性。因为用于非织造织物制备的聚合物是固有疏水的,如果置于吸收芯的流体接收侧上,它们优选地涂覆有亲水性涂层。有利的是,芯包裹物的顶侧面,即在吸收制品中更靠近穿着者放置的侧面,比芯包裹物的底侧面更具亲水性。一种制备具有耐久亲水性涂层的非织造织物的可能方法是通过将亲水单体和自由基聚合引发剂施加到非织造织物上,并且进行通过紫外光所激发的聚合作用,从而导致单体化学地结合到非织造织物的表面上。一种制备具有耐久亲水性涂层的非织造织物的另选的可能方法是用亲水性纳米颗粒来涂覆非织造织物,例如,如WO 02/064877中所述。
永久性地亲水性非织造织物也可用于一些实施例中。如US7744576(Busam等人)所述,表面张力可用于测量获得的某种亲水性水平的持久性。如US7744576所述,液体透湿可用于测量亲水性水平。当用盐水溶液润湿时,第一和/或第二基底可具体地具有至少55,优选地至少60,还更优选至少65mN/m或更高的表面张力。基底也可具有对液体的第五涌流小于5s的液体透湿时间。这些值可使用US7,744,576B2所述的测试方法:“Determination OfSurface Tension”和“Determination of Strike Through”中分别描述的测试方法来测量。
亲水性和可润湿性通常根据流体例如通过非织造织物的接触角和透湿时间来定义。在由Robert F.Gould编辑的名称为“Contact angle,wettability and adhesion”的美国化学学会出版物(1964版权所有)中对此进行了详细的讨论。可认为水和基底表面之间的接触角较小的基底比另一种基底更具亲水性。
所述基底还可以为透气的。因此可用于本文的膜可包括微孔。基底可具有例如40或50至300或至200m3/(m2×min)的透气率,所述透气率通过EDANA方法140-1-99(125Pa,38.3cm2)测定。芯包裹物的材料可另选地具有较低的透气率,例如为非透气的,以例如有利于对移动表面的处理,包括真空。
芯包裹物可沿吸收芯的所有侧至少部分地密封,使得在执行下述RCWR测试期间基本上无吸收材料渗漏出芯。所谓“基本上无吸收材料”是指小于5%,有利地小于2%,或小于1%或0重量%的吸收材料逸出芯包裹物。具体地,芯包裹物不应当在进行测试期间以加剧的方式破裂开。术语“密封”旨在被广义地理解。密封不需要沿芯包裹物的整个周边是连续的,而是沿其部分或全部可以为不连续的,诸如由在一条线上间隔的一系列密封点形成。通常,密封可由胶粘和/或热粘结形成。
如果芯包裹物由两个基底16,16’形成,则通常可使用四个密封件以将吸收材料60包封在芯包裹物内。例如,第一基底16可置于芯的一个侧面(如图所示的顶侧面)上并围绕芯的纵向边缘延伸以至少部分地包裹芯的相对底侧面。第二基底16’通常存在于第一基底16的包裹的翼片和吸收材料60之间。第一基底16的翼片可胶粘到第二基底16’以提供强效密封。与夹心密封件相比,该所谓的C-包裹物构造可提供有益效果,诸如在润湿加载状态下改善的耐破裂性。然后,芯包裹物的前侧面和后侧面也可例如通过将第一基底和第二基底彼此胶粘来密封,从而在芯的整个周边上提供对吸收材料的完全包封。对于芯的前侧面和后侧面,第一基底和第二基底可在基本上平面方向上延伸并接合在一起,从而对于这些边缘形成所谓的夹心构造。在所谓的夹心构造中,第一基底和第二基底也可在芯的所有侧上向外延伸并沿芯周边的全部或部分平坦密封,通常通过胶粘和/或热/压力粘结来密封。通常第一基底和第二基底均不需要成形,使得它们可被矩形切割以方便制备,但是当然其它形状也是可能的。
芯包裹物也可由单一基底形成,所述基底可将吸收材料包封在包裹物中,并可例如沿芯的前侧面和后侧面以及一个纵向密封来密封。
吸收材料沉积区域8
从吸收芯的顶侧面观察,吸收材料沉积区域8可由如下层的周边限定,所述层由芯包裹物内的吸收材料60形成。吸收材料沉积区域8可采用各种形状,具体地显示所谓的“狗骨”或“沙漏”形状,其表现出沿其宽度朝芯的中部或“裆”区渐缩。这样,吸收材料沉积区域在旨在置于吸收制品的裆区中的芯区域中可具有相对窄的宽度,如图1所示。这可提供例如更好的穿着舒适性。吸收材料沉积区域8可因此在其最窄点处具有小于约100mm、90mm、80mm、70mm、60mm、或甚至小于约50mm的宽度(如在横向上所测量的)。该最窄宽度还可比所述沉积区域在沉积区域8的前区和/或后区中的其最大点处的宽度小例如至少5mm,或至少10mm。吸收材料沉积区域8也可为大致矩形的,例如如图4-6所示,但也可使用其它沉积区域,诸如“T”或“Y”或“沙漏”或“狗骨”形状。
SAP的基重(每单位表面沉积的量)也可沿沉积区域8有变化以产生吸收材料(具体地SAP)在芯的纵向、横向、或这两个方向上的异形分布。从而沿芯的纵向轴线,以及沿横向轴线或平行于这些轴线中的任一个的任何轴线,吸收材料的基重可以变化。相对高基重的区域中的SAP基重可因此比相对低基重区域中的SPA基重高例如至少10%、或20%、或30%、或40%、或50%。具体地,相比于吸收材料沉积区域8的另一个区域,存在于裆点C水平处的吸收材料沉积区域中的SAP每单位表面可具有更多沉积的SAP。
可使用已知的技术来沉积吸收材料,所述技术可允许以相对高的速度相对精确地沉积SAP。具体地,可使用例如US2006/24433(Blessing)、US2008/0312617和US2010/0051166A1(均授予Hundorf等人)所公开的SAP印刷技术。这种技术使用印刷辊以将SAP沉积在基底上,该基底设置在可包括多个交叉条的支撑件的网格上,该多个交叉条基本上彼此平行延伸并彼此间隔以便形成在多个交叉条之间延伸的通道。这种技术允许将SAP高速并精确地沉积在基底上。吸收芯的通道可例如通过如下方法形成:修改网格图案和接收转筒,使得无SAP施加于某些区域中以形成呈通道形式的无吸收材料区域。EP专利申请号11169396.6更详细地公开了该修改。
通道26,26’
吸收材料沉积区域8包括至少一个通道26,所述通道至少部分地沿制品80的纵向取向。在下文中,复数形式的“通道”将用来指“至少一个通道”。通道可具有投射在制品的纵向轴线80上的长度L’,所述长度为制品长度L的至少10%。可以各种方式来形成通道。例如,通道可由吸收材料沉积区域内的可基本上不含吸收材料(具体地SAP)的区形成。此外或另选地,通道也可如下形成:通过吸收材料沉积区域将芯包裹物的顶侧面连续地或不连续地粘结到芯包裹物的底侧面。通道可有利地为连续的,但不排除通道为间歇的。采集-分配系统或顶片与吸收芯层或制品的另一个层之间的任何子层也可包括通道,它们可或可不对应于吸收芯的通道。
通道可具体地至少在与裆点C相同的纵向水平处存在于吸收制品中,如图1关于所述两个纵向延伸的通道26,26’所示。通道也可从裆区延伸或存在于制品的前区和/或后区中。
吸收芯28也可包括多于两个通道,例如至少3个,或至少4个或至少5个或至少6个通道。较短的通道也可存在于例如芯的后区或前区中,如图1中朝向制品的前部的一对通道27,27’所示。通道可包括相对于纵向轴线80对称地布置的一对或多对通道。
当吸收材料沉积区域为矩形时,通道可在吸收芯中尤其有用,因为通道可改善芯的柔韧性至在使用非矩形(成形的)芯时优势较小的程度。当然,通道也可存在于具有成形沉积区域的SAP层中。
通道可基本上纵向延伸,这是指通常每个通道在纵向上比在横向上延伸得更多,并且通常在纵向上是在横向上的至少两倍那么多(如在投射到相应轴线上之后测量的)。在一些实施例中,芯中不存在完全或基本上横向的通道。
通道可为完全纵向取向的并平行于纵向轴线,但也可为弯曲的。具体地,一些或全部通道,具体地存在于裆区中的通道,可朝纵向中心线80为凹形的,如例如图1一对通道26,26’所示。曲率半径通常可至少等于吸收层的平均横向尺寸(并且优选地为该平均横向尺寸的至少1.5或至少2.0倍);并且也可以为直的,但在(例如从5°)至多30°,或例如至多20°,或至多10°的角度下,具有平行于纵向轴线的线。曲率半径对于通道可为恒定的,或可沿其长度变化。这也可包括在其中具有角度的通道,前提条件是在通道两部分之间的所述角度为至少120°,优选地至少150°;并且在任何这些情况下,前提条件是通道的纵向延伸超过横向延伸。通道也可为分支的,例如在裆区中与纵向轴线叠加的中心通道朝制品的后部和/或朝前部分支。
在一些实施例中,不存在与制品或芯的纵向轴线重合的通道。当作为相对于纵向轴线的对称对存在时,通道可在它们的整个纵向尺寸上彼此间隔开。最小间距可为例如至少5mm,或至少10mm,或至少16mm。
此外,为了减小流体渗漏的风险,纵向主通道通常不延伸多至吸收材料沉积区域的任何边缘,并因此完全被涵盖在芯的吸收材料沉积区域内。通常,通道和吸收材料沉积区域的最近边缘之间的最小距离为至少5mm。
通道沿其长度的至少一部分可具有宽度Wc,所述宽度为至少2mm,或至少3mm或至少4mm,至多例如20mm,或16mm或12mm。通道的宽度可在通道的基本上整个长度上为恒定的或可沿其长度变化。当通道由吸收材料沉积区域内的无吸收材料区形成时,通道的宽度被认为是无材料区的宽度,而无关通道内可能存在芯包裹物。如果通道不是由无吸收材料区形成的,例如主要是经由通过吸收材料区粘结芯包裹物形成的,则通道的宽度为该粘结部的宽度。
至少一些或全部通道有利地为持久通道,这意味着它们的完整性在干燥状态和润湿状态下均被至少部分地保持。持久通道可通过提供一个或多个粘合剂材料来获得,例如粘合剂材料纤维层或帮助在通道壁内粘附例如基底与吸收材料的构造胶。持久通道也可具体地通过将芯包裹物的上侧和下侧(例如第一基底16和第二基底16’)通过通道粘结在一起而形成。通常,粘合剂能够用来通过通道粘结芯包裹物的这两个侧面,但有可能经由其它已知的方式诸如压力粘结、超声粘结或热粘结或它们的组合来粘结。可沿通道连续地粘结或间歇地粘结芯包裹物。当吸收制品完全加载有流体时,如下文的“润湿通道完整性测试”所公开,通道可有利地保持或变得至少透过顶片和/或底片可见的。这可通过制备基本上不含SAP的通道来获得,因此它们不溶胀,并且足够大使得它们在润湿时将不闭合。此外,通过通道将芯包裹物粘结到其自身也可为有利的。下述“润湿通道完整性测试”可用来测试通道在润湿饱和后是否是持久且可见的并且至何种程度后是持久且可见的。有利地是,根据本发明的持久通道根据润湿通道完整性测试具有至少20%、或30%、或40%、或50%、或60、或70%、或80%、或90%的完整性百分比。
阻挡腿箍34
吸收制品包括一对阻隔腿箍34。阻隔腿箍可由一片材料,通常为非织造织物形成,其部分地粘结到制品的剩余部分,使得材料(阻挡腿箍)的一部分在制品被拉平时可从由顶片限定的平面局部突起并直立,如例如图1所示。阻挡腿箍可大约在穿着者的躯干和腿部的接合处提供液体和其它身体流出物的改善的围堵。阻挡腿箍在纵向轴线的相对侧上至少部分地在尿布的前边缘和后边缘之间延伸并至少部分地在裆点(C)的水平处存在。阻挡腿箍由接合到制品的剩余部分(通常顶片和/或底片)的近侧边缘64以及自由端边66界定,所述端边旨在接触穿着者皮肤并与穿着者皮肤形成密封。阻挡腿箍在近侧边缘64处通过粘结部65与制品的基础结构接合,所述粘结部可例如由胶粘、熔融粘结或已知粘结方式的组合而制成。近侧边缘64处的粘结部65可以为连续或间歇的。最靠近腿箍的凸起段的粘结部65的一侧界定腿箍的直立段的近侧边缘64。出于RCWR测试的目的(见下文),这些粘结部65的内侧之间的距离限定制品在该水平处的干宽度和湿宽度。
阻隔腿箍可与顶片或底片为一体的,或更典型地可由接合到制品的剩余部分的独立材料形成。通常,阻挡腿箍的材料可延伸通过尿布的整个长度,但朝向制品的前边缘和后边缘“粘性粘结”到顶片,使得在这些段中阻挡腿箍材料与顶片保持齐平。每个阻挡腿箍34可包括靠近该自由端边66的一个、两个或更多个弹性绳35,以提供更好的密封。
除了阻隔腿箍34以外,制品还可包括衬圈箍32,所述衬圈箍接合到吸收制品的基础结构(具体地顶片和/或底片)并相对于阻隔腿箍横向向外放置。衬圈箍可提供围绕穿着者的大腿的更好密封。通常每个衬圈腿箍将包括一个或多个弹性绳或弹性元件,所述弹性绳或弹性元件包括在尿布的基础结构中,例如介于腿部开口区域中的顶片和底片之间。
US3,860,003描述了提供可收缩腿部开口的一次性尿布,所述腿部开口具有侧翼和一个或多个弹性构件以提供弹性化腿箍(衬圈箍)。授予Aziz等人的US4,808,178和US4,909,803描述了具有“直立”弹性侧翼(阻挡腿箍)的一次性尿布,所述侧翼改善腿部区域的围堵。分别授予Lawson和Dragoo的US4,695,278和US4,795,454描述了具有双箍(包括衬圈箍和阻挡腿箍)的一次性尿布。阻挡腿箍和/或衬圈箍中的全部或一部分可用洗剂处理。
采集-分配系统50
本发明的吸收制品可包括采集-分配层或系统50(本文称为“ADS”)。ADS的功能是快速采集流体并以高效方式将其分配到吸收芯中。ADS可包括一个、两个或更多个层,它们可形成一体的层或保持可彼此附接的离散层。在下文的实例中,ADS包括两个层:设置在吸收芯和顶片之间的分配层54和采集层52,但本发明不限于该实例。
通常,ADS将不包括SAP,因为这可减慢对流体的采集和分配。现有技术公开了许多类型的采集-分配系统,参见例如WO2000/59430(Daley)、WO95/10996(Richards)、US5,700,254(McDowall)、WO02/067809(Graef)。ADS可包括(虽然不是必须)两个层:分配层和采集层,现在将更详细地对它们进行举例说明。
分配层54
分配层可例如包含至少50重量%的交联纤维素纤维。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)。该类型的材料已在过去作为采集系统的一部分用于一次性尿布中,例如US 2008/0312622A1(Hundorf)。交联纤维素纤维在产品包装或使用条件下(例如在婴儿重量下)提供较高的弹性和因此较高的第一吸收层抗压缩抗性。这向芯提供较高的空隙体积、渗透性和液体吸收,从而减少渗漏并改善的干燥性。
适用于分配层的示例性化学交联的纤维素纤维在US5,549,791、US5,137,537、WO9534329或US2007/118087中公开。示例性交联剂包括多元羧酸诸如柠檬酸和/或聚丙烯酸诸如丙烯酸和马来酸共聚物。例如,交联纤维素纤维可具有基于纤维素葡糖酐摩尔计介于约0.5摩尔%和约10.0摩尔%之间的C2-C9多元羧酸交联剂,与所述纤维以纤维间酯交联键形式反应。C2-C9多元羧酸交联剂可选自:
-脂族和脂环族C2-C9多元羧酸,其具有至少三个羧基基团/分子;
和
-脂族和脂环族C2-C9多元羧酸,其具有两个羧基基团/分子,并且具有位于羧基基团的一个或两个的α-β的碳-碳双键,其中在所述C2-C9多元羧酸交联剂中的一个羧基基团与第二羧基基团通过两个或三个碳原子分开。纤维可具体地具有基于纤维素葡糖酐摩尔计介于约1.5摩尔%和约6.0摩尔%之间的交联剂,它们与其以纤维间酯交联键形式反应。交联剂可选自柠檬酸、1,2,3,4丁烷四羧酸、和1,2,3丙烷三羧酸,具体地柠檬酸。
聚丙烯酸交联剂也可选自聚丙烯酸均聚物、丙烯酸共聚物、以及它们的混合物。纤维可具有基于干纤维重量计介于1.0重量%和10.0重量%之间,优选地介于3重量%和7重量%之间的这些交联剂,它们与其以纤维间交联键形式反应。交联剂可为聚丙烯酸聚合物,其具有500至40,000,优选地1,000至20,000的分子量。聚合聚丙烯酸交联剂可为丙烯酸和马来酸的共聚物,具体地其中丙烯酸对马来酸的重量比为10:1至1:1,优选地5:1至1.5:1。有效量的柠檬酸可与所述聚合聚丙烯酸交联剂进一步混合。
本发明的包含交联纤维素纤维的分配层可包含其它纤维,但该层可有利地包含按该层的重量计至少50%,或60%,或70%,或80%,或90%或甚至多至100%的交联纤维素纤维(包括交联剂)。此类混合的交联纤维素纤维层的示例可包含约70重量%的化学交联的纤维素纤维、约10重量%的聚酯(PET)纤维和约20重量%的未经处理的纸浆纤维。又如,交联纤维素纤维层可包含约70重量%的化学交联的纤维素纤维、约20重量%的莱赛尔纤维和约10重量%的PET纤维。又如,该层可包含约68重量%的化学交联的纤维素纤维、约16重量%的未处理纸浆纤维和约16重量%的PET纤维。又如,交联纤维素纤维层可包含约90重量%-100重量%的化学交联的纤维素纤维。
分配层54可为具有如按US5,137,537所公开的过程所指出的那样测量的25至60,优选地30至45的保水值的材料。
分配层可通常具有30至400g/m2,具体地100至300g/m2的平均基重。分配层的密度可根椐制品的压缩而有差别,但在0.30psi(2.07kPa)下测量时可介于0.03至0.15g/cm3之间,具体地0.08至0.10g/cm3。
采集层52
ADS可包括采集层52。采集层可设置在分配层54和顶片24之间。采集层52通常可为非织造材料或可包含非织造材料,例如SMS或SMMS材料,其包括纺粘层、熔喷层和另外的纺粘层或梳理成网的化学粘结非织造织物。非织造材料可具体地被胶乳粘结。示例性上部采集层52公开于US7,786,341中。可使用梳理成网的树脂粘结的非织造织物,尤其是在所用的纤维为实心圆形或圆形中空PET短纤维的情况下(6旦尼尔纤维和9旦尼尔纤维的50/50或40/60混合物)。示例性粘结剂为丁二烯/苯乙烯胶乳。非织物具有可在转换加工生产线外制造并以材料卷的形式储存和使用的优点。
另外可用的非织物描述在授予Cramer等人的美国专利6,645,569、授予Cramer等人的美国专利6,863,933、授予Rohrbaugh等人的美国专利7,112,621、和授予Cramer等人的共有专利申请US2003/148684与授予Cramer等人的US2005/008839中。
采集层52可由胶乳粘合剂例如苯乙烯-丁二烯胶乳粘合剂(SB胶乳)来稳定。用于获取此类晶格的方法是已知的,例如来自EP 149 880(Kwok)和US 2003/0105190(Diehl等人)。在某些实施例中,粘结剂可以超过约12%重量%、约14重量%或约16重量%的量存在于采集层52中。SB胶乳可以商品名GENFLOTM3160(OMNOVA Solutions Inc.;Akron,Ohio)购得。
除了上述第一采集层之外,还可使用其它采集层。例如,薄纸层可置于第一采集层和分配层之间。与上述采集层相比,薄纸可具有增强的毛细管分布特性。薄纸和第一采集层可具有相同尺寸或可具有不同尺寸,例如与第一采集层相比,薄纸层还可在吸收制品的后部中延伸。亲水性薄纸的示例为13-15gsm高湿强度,由得自供应商Havix的纤维素纤维制成。
扣紧系统
吸收制品可包括扣紧系统。扣紧系统可用于提供围绕吸收制品的周边的侧向张力,以将吸收制品保持在穿着者上,这对于胶粘尿布而言是典型的。该扣紧系统对于训练裤制品而言不是必需的,因为这些制品的腰区已经被粘结。扣紧系统通常包括扣件,诸如胶带插片、钩-环扣紧部件、联锁扣件诸如插片、&狭槽、扣环、纽扣、按扣和/或雌雄同体扣紧部件,但是任何其他已知的扣紧部件通常也是可接受的。着陆区通常设置在前腰区上以用于扣件被可释放地附接。一些示例性表面扣紧系统公开于授予Buell的US 3,848,594、US4,662,875、US 4,846,815、US4,894,060、US4,946,527、US5,151,092和US 5,221,274中。示例性联锁扣紧系统公开于US6,432,098中。扣紧系统也可提供用于以配置构型保持制品的部件,如授予Robertson等人的美国专利US 4,963,140所公开的。
扣紧系统还可包括主扣紧系统和辅扣紧系统,如US4,699,622中所公开的,以减少重叠部分的位移或改善贴合性,如US5,242,436、US5,499,978、US5,507,736和US5,591,152中所公开的。
前耳片46和后耳片40
吸收制品可包括如本领域所公知的前耳片46和后耳片40。所述耳片可以为基础结构的整体部分,例如以侧片形式由顶片和/或底片形成。另选地,如图1所示,其可以为通过胶粘和/或热压花或压力粘结而附接的独立元件。后耳片40有利地是可拉伸的,以有助于插片42附接在着陆区40上,并将胶粘尿布围绕穿着者腰部保持在适当位置。后耳片40还可以为弹性或可延展的,以通过初始适形地配合吸收制品来为穿着者提供更舒适和适形性贴合,并且当吸收制品负载有流出物时在整个穿着期间维持该贴合性,因为弹性化耳片允许吸收制品的侧边伸展和收缩。
弹性腰部结构
吸收制品还可包括至少一个弹性腰部结构(未示出),其有助于提供改善的贴合性和围堵。弹性腰部结构通常旨在弹性伸展和收缩以动态适合穿着者的腰部。弹性腰部结构优选地从吸收芯28的至少一个腰部边缘至少纵向向外延伸,并通常形成吸收制品的端边的至少一部分。可构造一次性尿布使得具有两个弹性腰部结构,一个定位在前腰区中而一个定位在后腰区中。弹性腰部结构可被构造成许多不同的构型,包括描述于US4,515,595、US4,710,189、US5,151,092和US 5,221,274中的那些。
各层之间的关系
通常相邻层和部件将使用常规的粘结方法诸如通过槽式涂布或喷涂到层的整个或部分表面上的粘合剂涂层,或热粘结、或压力粘结或它们的组合而接合在一起。为清楚和易读起见,图中未示出该粘结(除了腿箍65的凸起元件与顶片24之间的粘结之外),但应当认为存在制品各层之间的粘结,除非具体地排除。粘合剂可通常用于改善不同层之间,例如底片和芯包裹物之间的粘附。所述胶可为本领域已知的任何标准热熔融胶。
如果存在采集层52,则可能有利的是该采集层在纵向尺寸和/或横向尺寸上大于分配层54或至少与分配层54一样大。这样,在制造过程中,分配层52能够在将这些层装配到成品中之前被沉积在采集层54上。这简化了处理,尤其是如果采集层为可从库存材料卷展开的非织造织物时。分配层还可直接沉积在芯包裹物的吸收芯的上侧或制品的其它层上。另外,大于分配层的采集层52还允许将采集层直接胶粘到储存芯(在较大区域处)。这能够赋予制品增加的完整性和更好的液体连通。
吸收芯且具体地其吸收材料沉积区域8可有利地至少与采集-分配系统(ADS)一样大和长,并有利地至少部分地大于和/或长于采集-分配系统。这是由于芯中的吸收材料通常可比ADS更有效地保持流体并在较大区域上提供干燥有益效果。吸收制品可具有矩形SAP层和非矩形(成形的)ADS。吸收制品也可具有矩形(非成形的)ADS和矩形SAP层。
制备制品的方法
本发明的吸收制品可由本领域已知的任何常规方法制成。具体地,所述制品可手工制成或以高速在工业上生产。
实验设置
除非另外指定,本文所示的值根据下文所示的方法测量。除非另外指定,所有测量均是在21±2℃和50±20%RH下进行的。除非另外指明,在进行这些测试之前,应当将所有样本在这些条件下保持至少24小时以达到平衡。除非另外指明,应当对至少4个样本重复进行所有测量,并且指示所获得的平均值。
离心保留容量(CRC)
CRC测量超吸收聚合物颗粒在过量液体中自由溶胀所吸收的液体。CRC根据EDANA方法WSP 241.2-05来测量。
厚度测试
设备:分辨率为0.01mm的Mitutoyo手动测径规--或等同的仪器。
接触脚:直径为17.0mm(±0.2mm)的圆形平脚。可将圆形砝码施加到脚上(例如,具有狭槽的砝码以有利于围绕仪器轴施加)以获得目标重量。选择脚和添加的砝码(包括轴)的总重量以向样品提供2.07kPa(0.30psi)的压力。如果存在向样本推动脚的弹簧,则从该设备上移除所述弹簧,使得实际上该设备施加2.07kPa的压力。
安装测径规,其中接触脚的下表面在水平面中,使得接触角的下表面接触约20×25cm的基板的平坦水平上表面的中心。在接触角搁置在基板上的情况下,标距设置成读数为零。
标尺:以mm为刻度的校准金属标尺。
秒表:精度为1秒
样本制备:
如果吸收制品被提供于包装件中,则从包装件的中心区域取出待测试的样本制品。如果该包装件包含多于4个的制品,则在该测试中不使用该包装件的每个侧面上的最外两个制品。如果该包装件包含多于4个但少于14个制品,则需要多于一个包装件的制品来完成该测试。如果该包装件包含14个或更多的制品,则仅需要一个包装件的制品来进行测试。如果该包装件包含4个或更少的制品,则测量包装件中的所有制品,并且需要多个包装件来进行测量。厚度的读取应当在从包装件中取出制品后24±1小时进行。应当尽可能少地对产品进行物理操纵,并且物理操纵仅限于必要的样本制备。
切除或移除制品的阻止制品在测厚仪脚下被展平的任何弹性部件。这些可包括腿箍或腰带。根据需要,将裤型制品沿侧缝打开或切开。施用足够的张力以展平任何折叠/褶皱。注意不要接触和/或压缩吸收芯和ADS区域。
测量程序:
将制品在台面上展平,使面向衣服侧朝下。在裆点C的水平处,在制品的面向身体的表面上作出侧向线。
抬起测径规的接触脚并将制品放置在基板上,向向衣服的表面侧朝下,使得当被放低时,脚的中心位于裆点C处的标记的测量点上。
将所述脚轻轻下降到制品上并释放(确保在测量开始前校正成“0”)。在释放所述脚10秒之后,读取厚度值并精确到0.01mm。
对于每个测量点重复该程序。如果在测量点处存在折叠,则在最接近该点但不具有任何折叠的区域中进行测量。对于给定的产品,以这种方式测量十个制品,并且计算并记录平均厚度,其中精度为十分之一毫米。
润湿通道完整性测试
这个测试设计用于检查通道在润湿饱和后的完整性。该测试能够直接对吸收制品进行或对单独获取的吸收芯进行。
1.通道的全长(以毫米计)在干燥状态下测量(如果通道不是直的,则测量穿过通道中心的曲线长度)。
2.随后将吸收制品或芯完全浸入大量过量的(例如5升)合成尿液“盐水溶液”中,其浓度为9.00g NaCl/1000mL溶液,所述溶液是通过将适量氯化钠溶解在蒸馏水中而制备的。溶液温度必须为20+/-5℃。
3.在放入所述盐水溶液中1分钟之后,取出吸收制品或芯并抓住一个端部将其保持竖直5秒以进行沥干,随后在水平表面上展平,使旨在面向穿着者的穿着者(顶片)侧朝上。如果吸收制品或芯包括拉伸元件,则将其在X维度和Y维度上拉紧,使得观察不到收缩。将吸收制品或芯的前边缘和后边缘固定到水平表面,使得不能够发生收缩。
4.将吸收制品或芯覆盖上矩形的合适重量的刚性板,其尺寸如下:长度等于吸收制品或芯的全长,并且宽度等于最宽点处的最大吸收结构或芯宽度。
5.将18.0kPa的压力在上文提及的刚性板区域上施加30秒。基于刚性板的覆盖总面积计算压力。通过将附加砝码置于刚性板的几何中心来获得压力,使得刚性板和附加砝码的总重量导致在刚性板总面积上18.0kPa的压力。
6.在30秒后,移除附加的砝码和刚性板。
7.随后立即测量通道的保持完整的部分的总长度(以毫米计;如果通道不是直的,测量穿过通道中心的曲线长度)。如果无通道部分保持完整,则通道不是永久性的。
永久性通道的完整性百分比通过用保持完整的通道部分总长度除以干燥状态下的通道长度、并且随后用商乘以100进行计算。
相对裆部宽度减小(RCWR)测试
原理:该测试测定在根据下文的测试过程施加了盐水溶液之后尿布在裆点水平的宽度减小量。裆点为纵向轴线上的被放置在制品的长度L的五分之二(2/5)距离处的点,如从制品的前边缘测量。
吸收制品的裆点C的水平处的凸起腿箍的直立段34的近侧端部64之间的距离限定制品的裆部宽度。该方法需要单独地测量干裆部宽度Wd(即使用前)和(加载的吸收制品的)湿裆部宽度Ww。
样本制备:测量制品的干重量并记录为Md。将吸收制品放置在足够大的树脂玻璃板上,其中顶片侧朝上。用夹钳将吸收制品的前边缘和后边缘固定在树脂玻璃板上,使得制品平放在所述板上。仅在吸收制品的前区和后区中施加夹钳,并且应当施加足够的张力以整平制品。对于裤型吸收制品,在侧缝处将吸收制品切开。如果所述裤型吸收制品不具有侧缝,则在带处的对应的两个侧部处切割它。对于具有扣紧系统的吸收制品,则打开该制品。将树脂玻璃板连同吸收制品放置在水平位置,其中制品的顶片朝上。
在吸收制品的顶片上标记出纵向轴线,并且测量制品前边缘和后边缘之间的长度L。纵向轴线大致将所述产品沿其长度分成顶片平面内的两个大致对称的部分。也在顶片上标记出裆线。裆线在顶片的平面中垂直于纵向轴线,在吸收制品长度L的2/5处(从吸收制品的前边缘测量)与纵向轴线相交。前部为吸收制品的旨在更靠近穿着者肚脐放置的部分。后部为更靠近臀部的部分。
测量干裆部宽度Wd:
如前文所指出的那样,阻隔腿箍34为箍的能够从由顶片限定的平面凸起的部分。阻隔腿箍34在它们的近侧边缘64处由一个或多个粘结部65粘结到制品的其余部分(通常为顶片)。通过如下方法测定干裆部宽度Wd:利用测径规沿裆线测量从一个阻隔腿箍的最内粘结部65到相对阻隔腿箍的最内粘结部65的距离,如图2-3所示。可将阻隔腿箍轻轻地保持在制品外侧以便测量干宽度和湿宽度,使得测量规能够直接在最靠近纵向轴线的粘结部的一侧被保持。测径规的顶端应当接触裆线和阻隔腿箍的近侧边缘的两个交叉点。测径规的顶端应当接触所述交叉点,但不使所述交叉点发生扭曲。测径规不应当接触吸收制品的其它部分。将干裆部宽度记录为Wd。本发明的制品的干裆部宽度(Wd)在70mm至200mm的范围内。
吸收制品加载:流体加载步骤用来以可再现方式对吸收制品进行加载。将盛有大量过量盐水溶液(0.9%NaCl)的足够大的碗设置在平坦载体上。通过如下方法来加载仍然附接到树脂玻璃板的吸收制品:将其完全浸没到盛有盐水溶液的碗中,其中“顶片”侧朝上进入到碗中,使得液体覆盖整个吸收制品15秒。在整个时段中,盐水溶液需要完全覆盖吸收制品的表面。在所述15秒之后立即从碗中取出树脂玻璃板(具有吸收制品)。通过将树脂玻璃板放置在水平位置(制品朝上)使吸收制品平衡3分钟。
湿测量:在这3分钟之后,测量湿裆部宽度并将其记录为Ww。通过如下方法测量湿裆部宽度:将测径规施加在裆线处并测量阻隔腿箍的两个近侧边缘之间的距离而不褶皱吸收材料,测量方式与测量干宽度Wd的方式相同。然后从树脂玻璃板上取下吸收制品并测量吸收制品的湿重量。将其记录为湿重量Mw。
计算相对裆部宽度减小(RCWR):
根据下式计算RCWR:
实验
根据本发明制备了以下产品:
发明实例1:
制备了具有矩形吸收材料沉积区域和两对通道的尿布,其类似于图1实施例表示的尿布,具有以下规格。一对通道相对较长并主要存在于制品的裆区中,并且另一对通道较小并朝制品的前部放置。通道不含吸收材料,并且芯包裹物的顶侧面和底侧面通过这些通道附接在一起。通道的宽度为均匀地8mm,并且长通道和短通道在制品纵向轴线上的投射长度分别为约170mm和40mm。较长通道为弯曲的并朝制品的纵向中心线成凹形,如图1所示。较长通道之间的最小距离为约16mm。较短通道之间的最小距离为约14mm。较小通道也是略微弯曲的。
吸收芯包括施加于沉淀区域中的总计14.1g的快速吸收SAP,所述沉积区域具有360mm的长度和成形的宽度轮廓,如图1所示。吸收材料沉积区域的宽度在沉积区域的前部和后部为110mm并且在吸收材料沉积区域的裆点处为90mm。SAP被分布成使得SAP的基重在裆区中比在前区中高,并且朝后区更低。SAP在横向方向(“横向”或“CD”)上无异形分布。吸收芯通过如US2010/0051166A1所公开的SAP印刷技术形成,所述技术组合两个非织造基底,所述非织造基底各自支撑SAP层并具有施加于每个SAP层上的微纤维弹性胶,所述微纤维弹性胶将SAP层固定在基底上。这些非织造基底将上基底C形包裹到下基底上而形成芯包裹物。将辅助胶施加于SAP层和它们相应的基底之间,所述辅助胶是用41个1mm宽的狭槽槽式涂布的,沿芯包裹物的整个长度(390mm),狭槽之间的距离为1mm。施加于每个SAP层上的微纤维胶(来自H.B.Fuller)以108mm的宽度和390mm的长度均匀地施加于每个SAP层上,0.211g的微纤维胶用于芯覆盖件(顶部)侧面上,并且0.168g用于除尘层(底部)侧面上。通道通过使用限定通道形状的合适的印刷转筒来形成,关于如何形成通道的另外的信息可见于使用印刷的SAP技术的欧洲专利申请号EP12174117.7。
芯包裹物具有390mm的长度,其中不含吸收材料的两个端片在吸收芯的后部和前部具有15mm的长度。芯的前端密封件和后端密封件被槽式胶粘在一起,胶槽距前端密封件具有30mm的长度并距后端密封件具有20mm的长度。芯包裹物的折叠宽度为120mm。芯包裹物包括两个非织造织物,顶部基底(图1中的16,还称为“芯覆盖件”)为10gsm SMMS非织造织物,其经表面活性剂处理成为亲水性的。下基底(图1中的16’,还称为“除尘层”)为11gsmSMMS非织造织物。芯覆盖件具有390mm的切割长度和165mm的切割宽度。除尘层具有390mm的切割长度和130mm的切割宽度。芯覆盖件围绕除尘层在芯的横向侧上C形包裹,并且除尘层的侧向边缘略微向上形成于芯的吸收材料的边缘上,使得折叠的芯包裹物的总体宽度为约120mm。
芯覆盖件和除尘层通过通道粘结在一起。所述粘结由上文所讨论的辅助微纤维胶形成。所述粘结为强效的。
采集-分配系统由采集层和分配层形成,所述采集层为具有298mm的长度和90mm的宽度的43gsm胶乳粘结的非织造织物,所述分配层为具有248mm的长度和80mm的宽度和207gsm的均匀基重的交联纤维素纤维。使用槽式涂布,采集层胶粘到分配层并且分配层胶粘到非织造芯覆盖件。顶片为15gsm非织造织物,并且底片为16gsm不可透过性的膜。
腿箍为类似于图1-2所示那些的商业腿箍,并且在尿布的每个侧面上包括两个15gsm、478mm长和77mm宽的非织造织物。腿箍钉扎粘结在与前部相距100mm的距离处,并在与自由边缘相距4mm的距离处与尿布边缘的后部相距91mm。非织造织物沿它们的长度熔合粘结到顶片,沿它们的粘结线具有3mm的连续粘结宽度。还沿连续粘结部将1mm宽的胶槽施加在腿箍材料和顶片之间。连续粘结部之间的距离为148mm(该距离对应于Wd)。衬圈箍(箍的不凸起的部分)为弹性化的,在箍的每个侧面上具有三条弹性粘合剂线(参见图中的33),始于与尿布的前边缘相距75mm处,并沿266mm的长度(对于所述两条最外侧线)和301mm的长度(对于最内侧线)延伸。凸起的阻隔腿箍为弹性化的,具有两个弹性部件(参见图中的35),它们各自靠近阻隔腿箍的末端边缘(参见图中的66)。这些弹性部件具有300%的预应变和119.5mm的收缩的切割长度。胶合的弹性长度为298mm。除非另外指明,尿布的所述各种部件均以常规方式装配,通常通过胶粘或熔合粘结装配。
发明实例2:
所制备的用于第二实例的尿布类似于发明实例1的这些。芯包括两对通道,一对在裆部部分中相对较长,而一对朝制品的前部相对较小。通道如在实例1中那样不含材料,并且芯包裹物通过通道附接到其自身。除非另外指明,将相同的材料用于所有发明实例。
与实例1的差别包括SAP分配区域,其为矩形并具有110mm的宽度和360mm的长度。采集层为318mm长和90mm宽。分配层沿纵向异形分布,朝尿布的前区和裆区比在后区中具有较高的基重。分配层的基重为196.5gsm(对于从前部算起的第一247mm)和120gsm(从后41mm算起),具有10mm的过渡长度(对于298mm的总长度和80mm的宽度)。在芯覆盖件侧上不存在辅助胶。用于前部和后部芯包裹物端部密封件的胶的基重为15gsm,而不是用于发明实例1的20gsm。
发明实例3:
该实例是以与实例1相同的方式制备的,差别在于吸收材料(SAP)分配区域为矩形,具有110mm的SAP沉积宽度,并在吸收制品的裆区中仅包括一对不含吸收材料的通道,如图4和5示例性所示。通道相对于纵向轴线80为对称的,在其上具有约227mm的投射长度、约8mm的宽度并且彼此相距20mm的最短距离。与实例的另一个差别是,在SAP层和除尘层上的基底之间不存在辅助胶,并且除尘层为10gsm非织造织物。分配层为298mm长和80mm宽并具有176gsm的均匀基重。如同先前的实例一样,芯覆盖件围绕除尘层C形包裹,并且这两个层通过通道永久性地粘结。
现有产品
还测试了若干个可商购获得的产品,除非另外指明,它们均为尺码4产品
实例4为可在德国商购获得的 Baby-Dry尿布。该产品中的吸收芯是由纤维素绒毛和SAP的混合物制成的。该产品包括类似于本发明实例中所用的双层采集-分配系统。
实例5为可在德国商购获得的 Active Fit尿布。该产品中的吸收芯不包含纤维素绒毛,吸收材料包含基本上SAP。该产品也包括类似于本发明实例中所用的双层采集-分配系统。
实例6为可在瑞典由SCA制造以商品名商购获得的尿布。该尿布包括纤维素绒毛/SAP混合芯,其特征在于芯的裆区中的两个不含材料的通道。
实例7为可在德国在零售商处以商品名Toujours商购获得的尿布。该产品的吸收芯基本上不含纤维素绒毛。不受理论的束缚,据信该产品是根据WO 2012/048879(VanDe Maele)的教导制备的。
实例8为尺码为M的成人失禁裤产品,可在日本从Unicharm公司商购获得。该产品具有不含纤维素的吸收芯,该吸收芯包括由横向延伸的胶粘结部分开的相对大的SAP口袋。不希望受该评估的束缚,该结构似乎类似于Unicharm WO2012/101934A1和WO2012/102034A1所述的结构。
测试结果
对于每种上述产品的五个样本,如上述测试方法所指示地测量了宽度减小和负载以测定产品的RCWR。下文编辑了平均结果:
讨论
不受理论的束缚,据信相对于不具有下述特征结构中的一者或多者的吸收制品,以下特征结构可单独地或以组合方式增大RCWR。除非具体地声明,这些特征结构均不应当被看作是限制权利要求的范围。
1)芯包裹物的顶侧面(其接触吸收材料的上侧)和芯包裹物的底部部分(其接触吸收材料的下侧)可有利地至少部分地通过通道彼此粘结。这些粘结部可为连续的或间歇的,并且可经由胶粘和/或热粘结制成,并且可有利地足够强效以在流体加载时阻抗分层(“持久通道”),如上文所讨论。通过将芯包裹物约束在通道中,这些粘结部增大了芯包裹物的应变,因而能够促进加载时的芯宽度减小。
2)芯包裹物可包括第一层和第二层,这两个层通常由非织造织物制成,其中第一层至少沿芯的纵向边缘围绕第二层形成C形包裹物。第一层可为形成芯包裹物的顶侧面的层,并且第二层可为形成芯包裹物的底侧面的层。通常,这些层为粘结的,例如通过沿第一层的包裹的翼片连同第二层的底侧面胶粘粘结。本发明人相信,C形包裹物,尤其是沿吸收芯的纵向侧的一部分或全部的C形包裹物,能够更好地抑制吸收材料朝制品侧部的膨胀,因此提供吸收材料在竖直方向上的更多膨胀,并增大裆点处的制品宽度的收缩,因为吸收制品的各层收缩以沿循该膨胀。
3)能够将相对非弹性的材料用于芯包裹物,因为这些材料将比相对更具弹性的材料提供更大的约束,并因此将通过减小吸收芯的宽度而沿循吸收材料的竖直(厚度方向)膨胀。
4)相比于包含较高含量的非超吸收吸收材料诸如纤维素绒毛的芯,芯吸收材料中的较高相对量的SAP材料将在加载时提供芯的相对较大的膨胀。在制品的裆区中具有较高基重的SAP也可为有利的。
5)芯能够直接或间接接合到底片以提供制品宽度的较大减小,因为底片将在芯被加载时沿循芯的收缩。
上文所列出的因素被本发明人确认为潜在的特征结构,它们可单独地使用或以组合方式使用以增大吸收制品的RCWR。它们不应当被视为是限制权利要求的范围,除非明确地在权利要求中提到;但可用作对技术人员的指导以设计提供受权利要求书保护的RCWR的吸收制品。裆点处的“相对裆部宽度减小”可有利地在32mm/kg至150mm/kg,具体地35mm/kg至100mm/kg的范围内。
本文所公开的量纲和值不应被理解为严格限于所引用的精确值。相反,除非另外指明,每个这样的量纲旨在表示所述值以及围绕该值功能上等同的范围。例如,所公开的量纲“40mm”旨在表示“约40mm”。
Claims (17)
1.一种用于个人卫生的吸收制品(20),所述吸收制品具有前边缘(10)和后边缘(12)、沿所述制品的纵向延伸的纵向轴线(80),所述制品具有长度L和裆点(C),所述长度L沿所述纵向轴线从所述前边缘至所述后边缘测量,所述裆点(C)被限定为在与所述制品的前边缘相距五分之二L的距离处放置在所述纵向轴线上的点,所述吸收制品包括:
-液体可透过的顶片(24);
-液体不可透过的底片(25);
-一对阻隔腿箍(34),所述一对阻隔腿箍在所述纵向轴线的相对侧上至少部分地在所述吸收制品的前边缘和后边缘之间延伸并在所述裆点(C)的至少纵向位置处存在,每个阻隔腿箍由自由末端边缘(66)和直接或间接接合到所述顶片和/或所述底片的近侧边缘(64)界定;
-吸收芯(28),所述吸收芯位于所述顶片和底片之间并包括包封吸收材料(60)的芯包裹物(16,16'),其中所述吸收材料包含按所述吸收材料的重量计至少80%的超吸收聚合物(“SAP”),其中所述吸收芯包括至少部分地沿所述制品的纵向取向的并且相对于所述纵向轴线对称设置的至少一对通道(26,26'),其中至少一个通道具有投射在所述制品的纵向轴线(80)上的长度,所述长度为所述吸收制品的长度L的至少10%,并且/或者其中所述通道的宽度至少在所述通道的一些部分中为至少2mm,以及其中至少一个通道至少在与裆点C相同的纵向水平处存在于吸收制品中,
其中所述制品具有至少30mm/kg的“相对裆部宽度减小”(RCWR),
其中所述RCWR根据下式计算:
<mrow>
<mi>R</mi>
<mi>C</mi>
<mi>W</mi>
<mi>R</mi>
<mo>=</mo>
<mfrac>
<mrow>
<mi>W</mi>
<mi>d</mi>
<mo>-</mo>
<mi>W</mi>
<mi>w</mi>
</mrow>
<mrow>
<mi>M</mi>
<mi>w</mi>
<mo>-</mo>
<mi>M</mi>
<mi>d</mi>
</mrow>
</mfrac>
</mrow>
其中Wd为所述裆点处的干裆部宽度并且Ww为所述裆点处的湿裆部宽度,并且Mw为所述制品的湿质量并且Md为所述制品的干质量,所述测量是根据本文所述的RCWR测试所指出的那样进行的,并且其中所述制品具有70mm至200mm的干裆部宽度Wd。
2.根据权利要求1所述的吸收制品,其中所述吸收制品为尿布或训练裤。
3.根据权利要求1所述的吸收制品,其中所述RCWR为32mm/kg至150mm/kg。
4.根据权利要求1所述的吸收制品,其中所述RCWR为35mm/kg至100mm/kg。
5.根据权利要求1-4中任一项所述的吸收制品,其中所述芯包裹物包括第一非织造织物(16)和第二非织造织物(16'),并且其中所述第一非织造织物围绕所述第二非织造织物形成C形包裹物。
6.根据权利要求1-4中任一项所述的吸收制品,其中所述吸收制品包括采集-分配系统(50),所述采集-分配系统包括一个或若干个层(52,54)并至少部分地设置在所述吸收芯和所述顶片之间。
7.根据权利要求1-4中任一项所述的吸收制品,其中所述吸收制品包括采集-分配系统(50),所述采集-分配系统包括至少一个层(54),所述至少一个层包含至少50重量%的交联纤维素纤维。
8.根据权利要求1-4中任一项所述的吸收制品,其中所述芯包裹物内的所述吸收材料的周边限定吸收材料沉积区域(8),并且其中所述吸收材料沉积区域为矩形的或被成形为具有在所述裆点处比所述吸收材料沉积区域的最大宽度窄的宽度。
9.根据权利要求1-4中任一项所述的吸收制品,其中所述吸收芯包括第一吸收层和第二吸收层以及纤维热塑性粘合剂材料(51),所述第一吸收层包括第一基底(16)和第一超吸收聚合物层(61),所述第二吸收层包括第二基底(16')和第二超吸收聚合物层(62),所述纤维热塑性粘合剂材料至少部分地将所述超吸收聚合物层粘结到它们相应的基底,所述第一基底和所述第二基底形成所述芯包裹物。
10.根据权利要求1-4中任一项所述的吸收制品,其中所述吸收芯的吸收材料(60)包含按所述吸收材料的总重量计至少90重量%的超吸收聚合物。
11.根据权利要求1-4中任一项所述的吸收制品,其中所述吸收芯的吸收材料(60)包含小于10重量%,或小于5重量%的天然纤维或合成纤维,或不含天然纤维或合成纤维。
12.根据权利要求1-4中任一项所述的吸收制品,其中所述芯包裹物包括顶侧面和底侧面,并且所述顶侧面和所述底侧面通过所述通道的至少一部分彼此粘结。
13.根据权利要求1-4中任一项所述的吸收制品,其中所述SAP的基重在SAP分配区域内沿所述芯的纵向轴线不均匀地分布。
14.根据权利要求13所述的吸收制品,其中所述SAP的基重在所述制品的裆点(C)处比在所述纵向轴线上的另一个点处高至少10%。
15.根据权利要求1-4中任一项所述的吸收制品,其中所述吸收芯包含5g至60g的SAP。
16.根据权利要求1-4中任一项所述的吸收制品,其中所述吸收芯包含10g至50g的SAP。
17.根据权利要求1-4中任一项所述的吸收制品,其中根据本文所述的“厚度测试”在所述裆点处测量的所述制品的厚度为5mm至12mm。
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