CN1054805C - 纤维叠层网及其制造方法和设备 - Google Patents

纤维叠层网及其制造方法和设备 Download PDF

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Publication number
CN1054805C
CN1054805C CN93114448A CN93114448A CN1054805C CN 1054805 C CN1054805 C CN 1054805C CN 93114448 A CN93114448 A CN 93114448A CN 93114448 A CN93114448 A CN 93114448A CN 1054805 C CN1054805 C CN 1054805C
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China
Prior art keywords
fibrage
bonding
fiber
fiber material
bond pattern
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Expired - Lifetime
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CN93114448A
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English (en)
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CN1087578A (zh
Inventor
M·I·阿里汗
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Kimberly Clark Worldwide Inc
Kimberly Clark Corp
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Kimberly Clark Worldwide Inc
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
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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
    • A61F13/51—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 outer layers
    • A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
    • 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
    • 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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    • Y10T156/1737—Discontinuous, spaced area, and/or patterned pressing
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/17—Surface bonding means and/or assemblymeans with work feeding or handling means
    • Y10T156/1702—For plural parts or plural areas of single part
    • Y10T156/1712—Indefinite or running length work
    • Y10T156/1741—Progressive continuous bonding press [e.g., roll couples]
    • 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
    • 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
    • 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
    • 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
    • Y10T428/24322—Composite web or sheet
    • Y10T428/24331—Composite web or sheet including nonapertured component

Abstract

本发明涉及的是一种纤维叠层材料，其中包括由一种热塑性材料的多根短纤维或连续纤维丝制成的第一纤维层以及由两种或多种热塑性材料的多根短纤维或连续纤维丝制成的第二纤维层，它们通过彼此分开的粘合花纹被结合在一起，以形成具有改善的液体分散和液体保持特性的纤维叠层材料，当它与人体皮肤相接触时具有更好的舒服感和柔软性。本发明还提供了制造该纤维叠层材料的方法和设备。

Description

纤维叠层网及其制造方法和设备
本发明所涉及的是，适合于制作用来吸收、分散和保持体液用品的纤维网叠层材料，例如用于一次性尿布、卫生巾、失禁病人用的内衣以及类似物。本发明同时还涉及用于制造该材料的方法和设备。更具体地说，本发明所涉及的是一种无纺叠层材料，它具有改善的液体分散和保持性能以及空气流通性能，同时当它与人体皮肤相接触时，能够增加人的舒服感和柔软性。
无纺叠层材料，例如纺粘纤维网和粗梳纤维网，被用来制作一次性吸收用品的面向人体的衬里。所用的典型材料具有疏松和多孔的结构，以便使液体能够很容易地通过该材料，从而使人体的皮肤能够和位于衬里之下的吸收芯层隔离开来。此外，其他的具有厚实和蓬松结构的材料层被置于所述衬里和吸收垫之间，用于减少液体的回流。
Raley的美国专利4,761,322号披露了一种纤维网叠层材料，它将质地柔软的纤维层和相邻的具有更大的结构整体性的纤维层结合在一起，其中质地柔软的纤维层用来作为和人体皮肤相接触的表面，而相邻纤维层可以为叠层材料提供所需的机械强度和整体性。该专利的叠层材料包括第一纤维层，它被粘合在彼此分开的第一粘合花纹上，该花纹的形成方式是诸如让第一纤维层通过被加热的第一花纹滚筒和一个平滑滚筒之间的缝隙而形成；该叠层材料还具有第二纤维层，它被粘合在彼此分开的第二粘合花纹上，该花纹的形成方式是诸如让第一纤维层和第二纤维层通过被加热的第二花纹滚筒和一个平滑滚筒之间的缝隙而形成。上述第二粘合花纹使第一和第二纤维层粘合在一起，而第一粘合花纹则不起这样的作用。
Marsan等人的美国专利43,928,632号披露了一种吸收性用品，它具有一层表面层、一层支持层、一层吸收芯和一层底层。所述表面层由能够渗透液体，非粘合的粗梳的疏水性热塑纤维制成，它通过彼此分开的粘合区域与能够渗透液体的支持层粘合在一起，该支持层由非纺织聚酯或单纤维棉织物制成。
Cumbers的美国专利4,088,726号披露了一种制造非纺织纤维材料的方法，该方法是使由可热粘合的材料制成的非纺织纤维网通过相互配合的压制滚筒之间的缝隙，对其中至少一个滚筒加热，在一个滚筒的表面上具有连续的凸起花纹，另一个滚筒的表面上具有不连续的凸起区，这些凸起区的矩心处在滚筒的缝隙时与最接近的凸起花纹表面的纵向轴线有不同的距离，以便缝隙中彼此相对的粘合区形成不同程度的叠合。
尽管已经有了如上所述的各种非纺织材料，但是人们仍然需要获得更好的非纺织材料，以便在用作一次性吸收用品和人体相接触的衬里层时，能够提供更好的液体吸收和分散性能和空气流通性能，使用品在和人体的皮肤相接触时其表面更加干燥，感觉更为舒服。
本发明所涉及的是一种非纺织叠层材料，其中第一非纺织层由一种热塑性多根短纤维或连续长纤维丝制成，第二非纺织层有两种或多种热塑性短纤维或连续长纤维丝制成，上述两层非纺织层通过彼此分开并具有孔洞的粘合花纹粘合在一起，由此形成的非纺织叠层材料具有改善的液体分散和保持性能，并且在和人体相接触时能够增加舒服感和柔软性。本发明还提供了一种制造该非纺织叠层材料的方法和所用的设备。
通过以下结合附图对本发明的一个实施方案的描述，将对本发明的非纺织叠层材料得到更好的了解。
附图1是本发明的非纺织叠层材料的部分剖视透视图；
附图2是如附图1所示的非纺织叠层材料沿附图1中A-A线的剖视图；
附图3是用于制造本发明的非纺织叠层材料的工艺设备的示意图；
附图3a是用于制造本发明的非纺织叠层材料的热粘合滚筒的透视图；
附图3b和3c是如附图3a所示的热粘合滚筒的外表面的放大视图；
附图4是一种一次性尿布的横截面图，该尿布在其与婴儿身体接触的一侧具有本发明的非纺织叠层材料；
附图5是本发明的非纺织叠层材料有孔洞的部分粘合区的显微照片(放大倍数为13.2，工作距离为12mm，加速电压为5kv)，其中非纺织叠层材料的第一层面向观察者；
附图6是本发明的非纺织叠层材料的有孔洞的部分粘合区的显微照片(放大倍数为28.7，，工作距离为12mm，加速电压为5kv)，其中以非纺织叠层材料的第二层面向观察者；
附图7是一种用于测试本发明的非纺织叠层材料的液体吸收和回流特性的测试仪器的透视图；
附图8是如附图7所示测试仪器的剖视图；
附图9是一种用于测试本发明的非纺织叠层材料的液体回流特性的测试仪器；
附图10是如附图9所示仪器的剖视图。
本发明提供了一种叠层纤维织品或材料，它具有第一纤维层和第二纤维层，前者由一种或多种热塑性材料的多根短纤维或连续纤维丝制成；后者由两种或多种热塑性材料的多根短纤维或连续纤维丝制成。上述第一和第二纤维层可以是非纺织纤维网，通过彼此分开的粘合花纹形成纤维层叠物，形成的方式是诸如让这两层纤维层通过一对被加热的，其外表面上具有凸起粘合花纹的压纹或粘合滚筒之间的缝隙。上述彼此分开的粘合花纹为第一和第二纤维层之间提供了高的结构整体性，但同时也影响第一纤维层表面的柔软质地或所制成的纤维叠层材料的蓬松性。在彼此分开的粘合区域上具有孔洞，以便增强纤维叠层材料的液体分散性和空气流通性。根据本发明所制成的纤维叠层材料具有改善的液体吸收和分散性能以及空气流通性能，因而当与人体皮肤相接触时能够提供更好的表面干燥性和舒服感。本发明的纤维叠层材料还具有蓬松的结构，它能够为使用者提供更好的柔软性和缓冲感觉。本发明的其他优点将通过下面的详细说明和权利要求书进一步体现出来。
在下面的说明中，术语“非纺织网”和“非纺织层”是指一种纤维网或纤维层，其中所述的每根纤维或纤维丝以随机的方式叠合在一起。如本领域里的普通技术人员所知，过去已采用多种不同的工艺方法来制造非纺织纤维网，例如熔喷、纺粘、气流成网、湿法成网、干法成网、干纤维和梳理方法等等。尽管非纺织纤维网适用于本发明，但是本发明并不限于使用非纺织材料，也可以使用其他具有适当纤维结构的材料。
下面将结合在一次性吸收用品中的用途来对本发明的非纺织叠层材料进行说明，但是需要指出的是本发明的用途并不限于这样的一次性吸收用品。在下面的说明中，所谓“一次性吸收用品”，是指用于吸收和保持人体排出的体液的用品，它在使用了一段时间之后被丢掉。这样的用品被置于与使用者皮肤相邻的位置上或者与使用者的皮肤相接触，用于吸收和贮存由人体所排出的各种体液。
参见附图1，该附图显示了本发明的一个实施例的部分剖视透视图。该非纺织叠层材料10包括第一非纺织层12和第二非纺织层22。第一非纺织层12具有上表面14和下表面16，第二非纺织层22具有上表面24和下表面26。在该实施例中，多根热熔粘合带形成了彼此间隔的粘合花纹18，它延伸通过非纺织叠层材料10的厚度，用于在第一非纺织层12和第二非纺织层22之间的交界面20处将两层非纺织层热粘合在一起。第一非纺织层和第二非纺织层的粘合基本上限于粘合区域18，亦即在第一非纺织层和第二非纺织层之间的除粘合区域18之外的区域19上，相应非纺织层的纤维仅仅是在热能量的作用下通过纤维的熔化而轻微地粘合在一起。这样，粘合区域18就被轻微粘合区域19隔离开来。如此实施例1所示，在粘合区域18上形成了孔洞30，以便改善非纺织叠层材料10的液体分布速率和空气流通性能。
尽管在附图所示的实施方案中，所用的纤维材料形成了非纺织层，但本发明的第一纤维层和第二纤维层可以用具有任何适当结构的天然或人造纤维材料制成。一般说来，本发明的第一非纺织层都可以用非连续纤维、连续纤维细丝、或者它们的结合来制造。如本技术领域里的普通技术人员所熟知，本实施方案所用的每一纤维层是采用干纤维工艺来制造的，更具体地说，是采用梳理纤维网技术来制造的。尽管最好是采用梳理纤维网技术来制造本发明所用的纤维层，但是纺粘法、熔喷、气流成网法以及其他本领域里的普通技术人员所熟知的制造非连续纤维和连续纤维细丝的工艺方法也仍然在本发明的适用范围之内。适合于本发明所使用的梳理纤维网可以使纤维处于对齐或不对齐的状态。普通技术人员所熟知的常规梳理机可以用于制造本发明所需的各纤维层。
本发明采用的两层纤维层中最好采用市场上有售的热塑性聚合材料来制造，这样的聚合物包括聚烯烃、聚酰胺、聚酯以及类似物。纤维可以具有任何适合的形状、可以采用空心的或实心的纤维、具有一定形状的纤维、双组分纤维、或者浸渍了高吸收性粉末的纤维。
在附图1所示的实施方案中，非纺织叠层材料10的第一非纺织层12是用热塑性聚丙烯纤维制成的经过粘合和梳理的纤维网，第二非纺织层22是用聚丙烯和聚酯纤维混合制成的基本上非粘合的纤维网或经过梳理的非粘合纤维网。所谓“基本上非粘合”，是指通过已知的粘合工艺将纤维充分地粘合在一起，以便处理成网，但是并未充分粘合到提供具有为最终使用所需的强度和整体性；所谓“非粘合”，是指构成纤维网的纤维没有通过机械热、化学方法使之粘合在一起。
第二纤维层22中不同热塑性纤维的比例可以根据非纺织叠层材料的所需用途确定。例如，第二纤维层22中聚丙烯和聚酯材料的重量比可以在70∶30到25∶75的范围内变化，而本实施例所采用的比例是40∶60。
本发明的一个重要的优点是：某些由于种种原因而在非纺织网中不具有最佳性质的物质可以用在本发明中与一种或多种不同材料制成的纤维网相结合，从而获得更好的特性。例如，由聚丙烯和聚酯纤维制成的非粘合或基本上非粘合的非纺织层对非纺织网的某些用途来说可能是太柔软和易破了，然而采用本发明的技术，用一定比例的聚丙烯和聚酯纤维混合制成的非纺织层可以粘合到一层较为结实的非纺织网上，例如一层粘合的聚丙烯纤维层上，从而提供更为理想的非纺织叠层材料。
根据纤维网的不同的用途，构成本发明的非纺织叠层材料10的纤维层的纤维线径、织物单位重量和密度可以有所不同。例如，在本发明的一种用途中，非纺织叠层材料可以用作一次性吸收用品的面向人体的一层，该用品在衬里和外覆盖层之间具有吸收性芯层。这样的一次性用品例如可以包括尿布、训练裤、卫生巾、供失禁病人使用的内衣以及类似物。对于这样的用途来说，第一纤维层12的聚丙烯纤维的粗细大约为1.0旦尼尔至3.0旦尼尔(即直径为12.5μm至21.6μm)，其卷曲纤维长度为大约1.25英寸至2.5英寸(21.75mm至63.5mm)。不过，为了让使用者更为舒适，上述纤维的粗细最好为大约2.0旦尼尔至2.2旦尼尔(即17.6μm至18.5μm)，其卷曲纤维长度大约为1.5英寸(38.1mm)。(如该领域里的普通技术人员所知，卷曲是纤维类型、直径和密度的函数。)在这样的应用场合，第一纤维层12和人体皮肤相接触，并被用作衬里层，其中所包含的聚丙烯纤维越细，则第一纤维层12的表面质地也就越柔软。第二纤维层22中的聚丙烯纤维可以和第一纤维层12中所采用的聚丙烯纤维相同，但不是必需的。第二纤维层22中的聚酯纤维的粗细大约为3旦尼尔至9旦尼尔(17.5μm至30.4μm)，其卷曲纤维长度大约为1.25至3英寸(31.75mm至76.2mm)，较为适合的聚酯纤维的粗细为6旦尼尔(24.8μm)，卷曲纤维长度为2英寸(50.8mm)。尽管不希望受到任何特定理论的限制，但目前的流行观点认为采用不同类型的纤维能够增强第二纤维层22的液体吸收和分布特性。第一纤维层12中的纤维具有相同的直径，它们趋向于在一个单个的平面上形成具有相似大小的孔洞；而第二纤维层22中的纤维具有不同的直径，它们趋向于在多个平面上形成具有不同大小的孔洞。第二纤维层22中多个平面上的不同大小的孔洞被认为能够增强液体浸入到整个第二纤维层22的性能，并增强第二纤维层22对液体的吸收和分散性能。此外，目前的流行观点还认为，聚酯纤维的弹性有助于改善本发明的非纺织叠层材料对液体的保持特性和空气流通特性。因此，在这样的应用场合，对于通过非纺织叠层材料10流到吸收用品的吸收芯层的液体来说，第二纤维层22能够起到缓冲层或临时储蓄层的作用。
本发明的非纺织叠层材料10的单位重量大约为每平方米25克至78克，其厚度大约为0.03至0.08英寸(0.76mm至2.03mm)，其密度大约为0.020g/cc至0.050g/cc。上述密度是通过如下的公式计算的：
Figure C9311444800131
例如，在上面所述的实施例中，非纺织叠层材料10的单位重量大约为47g/m2至58g/m2，其厚度大约为0.04至0.06英寸(1.02mm至1.52mm)，其密度大约为0.030至0.045g/cc。
非纺织叠层材料10的单位重量是采用一个测量其样品重量的仪器来测量的，每一个被测样品的面积不得小于4平方英寸(2580mm2)。对每一个样品进行切割和平滑，以便消除其折皱，然后用一个其精度为0.01克的分析天平测量其重量。将样品的重量除以样品的面积，便可获得其单位重量。
非纺织叠层材料10的厚度是采用一个对其样品施加0.05psi(35.15kg/m2)的压强的仪器来测量的，每一个样品的面积至少为5×5英寸(127×127mm)。对每一个样品进行切割和平滑，以便消除其折皱，然后将样品放在其直径为3英寸(76.2mm)的胶质玻璃压板下，并尽可能地使样品位于该压板的中心位置，再使该压板降在样品之上。每一个样品的厚度的测量精度应至少为0.001英寸(0.0254mm)。
尽管在其他实施方案中，第一纤维层12在和第二纤维层22相粘合之前的单位重量与第二纤维层相比可以有所不同，在本实施例中，第一纤维层12与第二纤维层相比具有较小的单位重量和较大的密度。第一纤维层的单位重量大约在16g/m2至28g/m2的范围之内，最好在大约18g/m2至22g/m2范围之内；而第二纤维层的单位重量大约在24g/m2至35g/m2的范围之内，最好大约为32g/m2。第一纤维层的密度大约在0.050g/cc至0.065g/cc的范围之内，最好为大约0.055g/cc；第二纤维层的密度大约在0.024g/cc至0.045g/cc的范围之内，最好为大约0.035g/cc。
参见附图2，该附图显示了前面描述的本发明的非纺织叠层材料10的横截面图，它包括第一非纺织层12和第二非纺织层22。多根粘合带形成了彼此分开的粘合花纹18，它在相应纤维层的厚度上延伸，使第一非纺织层10和第二非纺织层22在粘合花纹区域18沿它们的交界面20粘合在一起。现在将对形成彼此分开的粘合花纹18的方式进行说明。
彼此分开的粘合区域18可以通过任何适合的能够将第一非纺织层12和第二非纺织层22在它们的交界面上彼此粘合在一起的方法来形成，其要求是使所形成的非纺织叠层材料10具有液体保持、空气流通和其他所需的特性。热粘合方法，包括采用一对被加热的压纹滚筒，被认为是适合于形成粘合花纹18的方法，下面将对之作详细的说明。
按照本发明，可以通过不同的顺序来粘合相应的纤维层。例如，可以在第一道工序中形成和粘合第一纤维层12，在第二道工序中形成第二纤维层22，然后在进一步的工序中将第二纤维层粘合到第一纤维层上；也可以在第一工序中形成第一纤维层12，在第二工序中形成第二纤维层22，然后在随后的工序中将各纤维层相互粘合在一起，同时将第一纤维层12中的纤维彼此粘合在一起。构成第二纤维层22的热塑性纤维一开始是未粘合或基本上未粘合的，但在形成非纺织叠层材料10时，却形成了一定程度的热粘合，这一点将在下面作进一步的说明。
在本实施例中，第一纤维层12的纤维的粘合程度大于第二纤维层。例如，可以让第一纤维层12通过一对常规结构的粘合滚筒(即一个具有花纹的滚筒和一个平滑滚筒)，使该纤维层中的纤维以热粘合方式粘合在一起，其粘合温度为132℃至149℃，最好为135℃至141℃。采用热粘合滚筒来粘合第一纤维层12的适当温度应随着滚筒的表面转动速度、粘合滚筒的直径、以及所采用的热塑性纤维种类的不同而有所不同。此外，第一纤维层12中的纤维也可以通过其他的已知粘合方法被结合在一起，例如花纹粘合剂粘合方法、缝制方法、或者液体或气体喷射缠绕纤维的方法等等。在本实施例中，第一纤维层12比第二纤维层具有更大的密度。这样，比第二纤维层具有更大的结构整体性和机械强度的第一纤维层就为第二纤维层22提供了一个衬底。
在彼此分开的粘合区域18上，第一纤维层12与第二纤维层22相粘合的程度可以通过改变粘合面积比来加以控制，所述的粘合面积比指的是粘合区域上的粘合剂所占据的纤维层交界面的那一部分表面面积与整个交界面面积之间的比例。如附图1和2所示，在第一纤维层12和第二纤维层22之间的交界面20上具有彼此分开的粘合花纹18，它分布在其表面上，粘合区域18所占据的表面面积与整个交界面20的面积之间的比例即为交界面20的粘合面积比。在本实施例中，非纺织叠层材料10的粘合面积比大约在1％至6％的范围之内，最好为2％至4％。尽管在附图所示的实施例中，粘合花纹呈六边形，本发明可以采用其他适合于本发明的非纺织叠层材料的几何形、非几何形、重复或非重复的粘合花纹。
附图3是用于制造上述本发明的非纺织叠层材料的设备的方框图。如上所述，可以采用常规的梳理机，例如美国专利3,604,062和3,604,475号所述的梳理机，来制造本发明所需的各纤维层。如附图所示，第一梳理机42铺列第一纤维层12到传送带40上，而第二梳理机52铺列第二纤维层22到第一纤维层12上。在这种方式中，当两层纤维层通过成形工序时，第一纤维层12起到了第二纤维层22的衬底的作用。
两层纤维层可以通过一对压制滚筒，它们轻微地对纤维网加压，从而增加纤维网的整体性，以便进行随后的工序。可以让上述两层纤维层中的一层或两层通过一个使纤维网中的纤维定向的设备，从而增强纤维层在机器方向上(MD)和横向方向上(CD)的强度。在本说明书中，机器方向(MD)是指纤维网被铺列的方向(在附图3中是从左到右的方向)，而横向方向(CD)是指和铺列纤维网方向相垂直的方向。本发明所采用的非纺织叠层材料必须具有足够的MD强度，为大约354g/cm至1062g/cm，至少为大约512g/cm，这样，在高速制造诸如尿布的一次性吸收用品的生产过程中，非纺织纤维网才不会破裂。
上述两层非纺织层随后通过两个粘合滚筒60和70，在如附图3所示的实施例中，这两个滚筒均被加热，而且它们的外表面上均具有凸起的粘合花纹。位于下面的滚筒60的表面上具有彼此分开的粘合花纹62，而位于其上的滚筒70的表面上具有凸起的粘合点72。在另一种实施例中，所述粘合滚筒的位置可以颠倒。因此，本发明的一个特征是利用两个外表面上具有不同的凸起粘合花纹的热粘合滚筒，以便形成将非纺织叠层材料的纤维层粘合在一起的彼此分开的粘合花纹。
当两层纤维层12和22通过上述两个被加热的滚筒60和70时，延伸通过每一层非纺织层的大部分厚度的热融化粘合剂形成了离散的致密粘合区域18，使纤维层变得牢固。经过压制的粘合区域18的厚度取决于纤维层12和22的厚度，可以在大约50μm至150μm的范围内选取，在本实施例中大约在70μm至110μm的范围内。非纺织叠层材料10的被压制的粘合区域位于由两个被加热的粘合滚筒60和70表面上的凸起粘合花纹的接触点形成的粘合花纹18内，在粘合花纹之间有被轻微粘合的纤维。
由两个被加热的粘合滚筒60和70表面上的凸起花纹的接触点所形成的粘合区域18上还具有孔洞30，下面将对其作详细的说明。尽管发明人认为孔洞30的大小和形状对于本发明来说并不是决定性的(参见附图5和6)，但采用其平均直径大约为8μm至580μm的孔洞对于本发明的来说是有益的，最好是采用其平均直径大约为29μm至277μm的孔洞。如附图5和6所示，孔洞30在整个非纺织叠层材料10的厚度方向上基本上没有纤维，它们为液体通过非纺织叠层材料10提供了一个直接的通道。因此，孔洞30能够让第一纤维层12所吸收的液体迅速地进入第二纤维层22，并最终进入吸收用品的吸收芯层。经观察发现，液体主要是在与非纺织叠层材料10的接触点处沿着开孔的粘合区域18流走的，它起到了液体通道的作用。孔洞30和纤维层12和22中的纤维所形成的细孔有所不同，因为后者既不够大，同时又是曲折的，因而不能迅速地吸收和分散液体。综上所述，非纺织叠层材料10具有彼此分开的粘合区域18，在其之间具有被轻微粘合的区域19，在所述粘合区域18上具有孔洞30。
两个与粘合滚筒上的凸起花纹的特定结合有关的参数是粘合滚筒的凸起粘合区域的大小以及粘合区域之间的间距。如上所述，这两个参数结合在一起将影响被粘合的非纺织叠层材料10的粘合面积比。很重要的一点是粘合面积比必须足够大，以便使纤维网具有为其用途所需的足够整体性；另一方面，粘合面积比又不能太大，因为太大的粘合面积比通常会降低纤维网的柔软性。在本实施例中，下滚筒60的粘合面积比(即凸起的粘合花纹62的表面积与下滚筒60的总表面积的比值)可以在大约9％至20％的范围之内，最好在大约18％至19.5％的范围之内。上滚筒70的粘合面积比(即凸起花纹72的表面积与上滚筒70的总外表面积的比值)可以在大约10％至30％的范围之内，最好在大约11％至20％的范围之内。如上所述，非纺织叠层材料10的粘合面积比(它是上滚筒70和下滚筒60的粘合面积比的乘积)可以在大约1％至6％的范围之内，最好在大约2％至4％的范围之内。
再一个重要的问题是使两个粘合滚筒的凸起粘合花纹的结合能够在粘合区域内形成最佳数目的孔洞。在附图3a、3b、3c所示的实施例中，下滚筒60的外表面64上的凸起粘合花纹62的宽度可以在大约1.0mm至2.0mm的范围之内，最好为大约1.8mm；凸起粘合花纹62的基部66的宽度可以在大约1.6mm至3.1mm的范围之内，最好为大约2.8mm。本实施例所用的下滚筒60的凸起粘合花纹62的凸起高度大约为1.0mm，所述的凸起高度是指凸起粘合花纹62的外表面64和其基部66之间的距离。下滚筒60的凸起粘合花纹62的单个六边形的重复宽度W在大约16.50mm至17.33mm的范围之内；其重复高度H在大约28mm至30mm的范围之内；其倾斜间距P在大约16.50mm至17.33mm的范围之内，倾斜角度在大约45度至60度的范围之内。
参见附图3a、3b、3c，上滚筒70外表面74上的凸起粘合点72的宽度在大约0.70mm至0.80mm的范围之内，最好为0.75mm。正如在本领域里所常见的那样，凸起粘合点72的基部76的宽度应略微大于粘合点在外表面74处的宽度。上滚筒70的凸起粘合点72的高度大约为0.65mm。在本实施例中，各个凸起粘合点的平均分布密度为33.8点/cm，其重复宽度W′为大约2.4mm至3.0mm，重复高度H′为大约1.72mm，倾斜间距P′为大约1.72mm，倾斜角度为大约30度至45度。尽管在附图所示的实施例中，凸起粘合点72的外表面74具有方形的形状，但是上滚筒70的粘接点72也可以采用其他几何或非几何的形状。
在优化本发明的非纺织叠层材料10的过程中，发明人注意到下面的参数是彼此相关的：
1)粘合滚筒60和70的温度；
2)成形工序的线速度；
3)粘合滚筒之间的缝隙压力；
4)粘合滚筒的直径；
5)纤维层12和22所采用的材料类型。
这就是说，如果改变上述参数中的一个或多个，则其余的参数也将受到影响。例如，增大成形工艺的线速度会减小非纺织叠层材料的纤维层与粘合滚筒相接触的时间，因此就需要提高粘合滚筒的温度，以便使两层纤维层获得所需程度的粘合，从而使两层纤维层获得所需程度的粘合，从而补偿线速度的变化。
如上所述，与两层纤维层的粘合有关的一个重要因素是粘合滚筒60和70所保持的温度。显然，如果该温度低于每一种聚合物的一定温度值，就根本不可能形成任何粘合；而温度过高又会使过多的纤维被熔化。此外，发明人还发现粘合滚筒的温度会影响所形成的非纺织叠层材料的抗拉强度和柔软性。具体地说，在一定的范围之内，较高的温度使所形成的纤维网具有较高的抗拉强度，然而这样的较高温度又会使所形成的纤维网具有较低的柔软性。这一现象可能是由于在这样的温度范围内会导致较高和较低程度的粘合，即较高的温度可能使纤维之间形成更多的更强的粘合，这一点有利于抗拉强度，但不利于柔软性。另外，较高的温度会影响所获产品的蓬松结构，因为热塑性纤维在较高的温度下会出现更多的收缩，从而影响非纺织叠层材料10的柔软性和缓冲感。
发明人进一步注意到滚筒的温度会影响在纤维网的被粘合区域上孔洞的形成。尽管在被粘合区域上形成的孔洞并不是单纯是由热方式来形成的，但热粘合使各纤维层被压缩足够的程度，使纤维层上可以出现孔洞。对此下面将作进一步的说明。
在所示的实施例中，下滚筒60的粘合温度可以在大约127℃至141℃的范围之内选取，最好在大约129℃至135℃的范围之内；而滚筒70的粘合温度可以在大约132℃至160℃的范围之内选取，最好在大约143℃至157℃的范围之内。重要的一点是与第一非纺织层12相接触的粘合滚筒，亦即在本实施例中的下滚筒60，应比与第二非纺织层22相接触的粘合滚筒亦即本实施例中的上滚筒70，具有更低的温度，以便不至于显著地影响第一非纺织层12的柔软性，同时使第二非纺织层22中的热塑性纤维受到足够的加热，以便使之能和第一非纺织层12中的热塑性纤维热熔合在一起。只要保持粘合滚筒60的温度略微低于第一非纺织层12被粘合的温度，而保持如上所述的成形工艺的其他工艺参数恒定，第一非纺织层12的柔软性就不会受到显著的影响。
另一个与两层纤维层的粘合以及在被粘合区域上形成孔洞有关的重要因素是相应的粘合滚筒的旋转线速度。在本实施例中，滚筒的旋转线速度可以在大约20m/min至100m/min或者更大。发明人发现，通过使两个粘合滚筒具有不同的表面旋转速度，能够大大地改善在粘合区域上孔筒的形成。所述表面的旋转速度之间的差值可以在大约4％至20％的范围之内，通常是在大约5％至15％的范围之内。可以选取任何一个粘合滚筒的旋转速度大于另一个滚筒的旋转速度。尽管不希望受到任何特定理论的约束，发明人认为，使滚筒具有不同的速度能够改善孔洞的形成，这是因为在热粘合区域产生的与粘合表面相切的剪切力撕开在粘合滚筒的凸起粘合花纹之间的接触点上的非纺织叠层材料(亦即机械成孔)。
与两层纤维层的粘合有关的再一个重要因素是每一个粘合滚筒的直径。尽管在所示的实施例(以及在后面介绍的实施例)中，每一个滚筒的直径为大约305mm，但也可以采用具有较大或较小直径的滚筒来制造本发明的非纺织叠层材料。此外，两个粘合滚筒的直径也不一定需要相等。
与两层纤维层的粘合以及在粘合区域上形成孔洞有关的再一个重要因素是粘合滚筒之间的缝隙压力。在所示的实施例中，粘合滚筒之间产生大约10kg/1cm至67kg/1cm的缝隙压力。较高的缝隙压力会导致较低的蓬松结构，从而影响非纺织叠层材料10的柔软性。
在所示的实施例中，在采用粘合滚筒60和70使纤维层12和22粘合在一起之后，非纺织叠层材料10被卷在缠绕滚筒78上。此外，使用者可能希望将此设备设计成与最终产品的生产线相连接。缠绕滚筒78上或后继生产线上产生的较大拉力也会成为影响本发明的非纺织叠层材料10的柔软性的一个不利因素。
附图4显示了一种一次性尿布的横截面图，该一次性尿布100具有置于尿布一侧的本发明的非纺织叠层材料80。它与婴儿身体相接触。在所示的实施例中，非纺织叠层材料80形成了面向人体的外层12，它包括一层由聚丙烯纤维制成的粘合梳理纤维网和一层内部的“缓冲”层22，后者如上所述是由聚丙烯和聚酯纤维混合形成的非粘合或基本上非粘合的梳理纤维网。该尿布进一步包括一层能够渗过液体的面向人体的衬里82，它由诸如非纺织纺粘材料或被粘合的梳理织物材料制成；一层吸收芯层84，由诸如亲水性的纤维素木浆和高吸收性颗粒(例如超级吸收材料)混合制成；一层至少包裹一部分吸收芯层84的薄纸层92；以及一层柔软的不能渗过液体的外覆盖层86，它由诸如薄的聚乙烯薄膜制成。术语“超级吸收材料”是指能够吸收或保持至少相当于其自身重量十倍的液体的天然或人造材料。
在所示的实施例中，与衬里82叠合在一起的非纺织叠层材料80基本上具有与吸收芯层84相同的宽度，而衬里82的总面积基本上与外覆盖层86的总面积相等。或者，也可以将非纺织叠层材料80的面积设计得与外覆盖层86基本相等。在另一种结构中，非纺织叠层材料80的宽度小于吸收芯层84的最小宽度。尽管在如附图所示的实施例中，非纺织叠层材料80和外覆盖层具有基本上相同的长度，但在其他最佳结构中，非纺织叠层材料80的长度可以等于或小于外覆盖层86的长度。
如附图4所示，非纺织叠层材料80位于防渗侧翼88之间，该防渗侧翼连接在衬里82的面向人体的表面上。在美国专利4,704,116号中介绍了防渗侧翼的适合结构和安装方式。
在吸收性用品中还可以包括弹性件90，它被置于尿布100的每一纵向边缘附近，用于拉伸并支托住尿布100的横向边缘使其紧贴使用者的腿部。此外，弹性件(图中未示)还可以被置于尿布100的一个或两个端缘处，以便提供一个弹性腰带。
非纺织叠层材料80以适当的方式与面向人体一侧的衬里82或外覆盖层86相连接或相配合。所谓“相配合”包括通过将非纺织叠层材料80的边缘区域或中间区域直接与衬里82相连接，从而将非纺织叠层材料80与衬里82的面向人体的一侧结合在一起；也包括直接将非纺织叠层材料80与衬里82的面向人体的一侧结合在一起；也包括直接将非纺织叠层材料80与外覆盖层86结合在一起，或者先将非纺织叠层材料80与中间件结合在一起，然后再将其与外覆盖层86结合在一起。可以通过连接件(图中未示)，例如粘合剂、声波粘合、热粘合或本领域里的普通技术人员所熟知的其他连接方法，直接将非纺织叠层材料80与面向人体一侧的衬里82或外覆盖层相连接。显然，也可以用这样的连接方式将尿布100的其他部件连接和组装在一起。具有已知结构的固定件(图中未示)也可以被用于图中所示的尿布结构。
尽管附图4显示了尿布100的具有特定形状的构成部件，这些部件可以被组装成为各种已知的尿布形状。需要指出的是：在除了尿布之外的其他一次性吸收用品中，根据它们的具体用途，上述部件中的某一些可以不予采用。
任何面向人体的衬里材料的一个重要特性是其柔软性。为了使婴儿舒服起见，很重要的一点是确保衬里必须既是易弯的，同时也是很柔软的。本发明的非纺织叠层材料80的面向人体的纤维层12具有十分优良的柔软性。
非纺织衬里和非纺织织物的另一个重要特性是其抗拉强度，亦即其抵抗撕裂的能力以及在被撕裂之前的拉伸比，在本发明中，这些特性是采用诸如Instron Model TM1000的测试仪器来测量的。该仪器的一对夹子在非纺织叠层材料样品(其大小大约为25.4×1524mm)的整个宽度上夹住样品，然后以恒定的延伸率朝彼此分开的方向上对该样品进行拉伸。所需的使样品破裂的拉力被纪录为抗拉强度，而在破裂之前样品的长度与原始长度之间的比值即为拉伸比。在进行这些测试时，既可以使夹持的方向为织物的方向，亦即拉力施加在机器方向MD上；也可以夹持的方向为与织物方向相垂直的方向，亦即使拉力施加在横向方向CD上。本发明的非纺织叠层材料具有足够的抗拉强度和拉伸比，这一点将在后面结合几个实例作介绍。
再一个对于诸如一次性尿布之类的吸收性用品的衬里来说特别重要的特性是衬里的可湿性。根据吸收性用品的具体设计，通常希望衬里至少是部分可湿的，其目的是有利于液体通过该衬里进入吸收芯层。此外，更为理想的是在衬里中形成一个可湿性梯度，使液体能够由使用者身上被吸走，从而保持皮肤的卫生，增加舒服感。特别理想的如在本发明中提供一个面向人体的层12，它与最接近吸收材料的“缓冲层”22相比具有较差的可湿性。这样，液体透过它流向吸收芯层比回流到使用者更为容易。
许多适合于制作非纺织纤维网的聚合物都是疏水性的，尤其是聚烯烃纤维，它是完全疏水性的。因此，希望赋于用这些聚合物制造的非纺织纤维网以所需的可湿性和亲水性。如本领域里的普通技术人员所知，诸如聚丙烯纤维之类的疏水性纤维可以通过在其表面上施加可溶于水的表面涂层采增强其可湿性，典型的施加量为大约0.3％至0.6％，用于改善这样的纤维在其最终用途中的液体处理性能。在本实施例中，所采用的聚丙烯纤维可以在形成纤维层12和22之前用可溶于水的表面涂层对其进行处理，使该纤维成为可湿的。
另一个有助于形成所需的可湿性梯度的措施是在制作第二纤维层22的聚丙烯纤维中混合一定量的聚酯纤维。如上所述，通过在制作非纺织层22的聚丙烯和聚酯均匀混合物中采用更粗的、具有更大弹性的聚酯纤维可以使纤维层细孔的大小有所不同，这样就在纤维层12和22之间形成了所需的可湿性梯度。
为了便于更好地理解本发明，下面提供了一些实施例。这些实施例所采用的组份、比例、材料和参数都是实例性的，并非旨在限制本发明的保护范围。
                     实施例
实施例1
第一纤维层是由100％的聚丙烯(PP-196，由Wilmington，DE的Hercules公司生产)在一个如上所述的普通梳理机上进行混合而获得的，其单位重量为大约18g/m2。第二纤维层是由60％的聚酯纤维(SD-10，由南韩的Sam Yang公司生产)和40％和PP-196聚丙烯纤维在一个普通的梳理机上混合而制成的，其单位重量为大约32g/m2。第一纤维层和第二纤维层采用如附图3和3a所示的加热粘合滚筒热粘合在一起，其中与第一纤维层相接触的滚筒的温度为大约133℃，而与第二纤维层相接触的粘合滚筒的温度保持在大约157℃。粘合滚筒的旋转线速度为大约24m/min，粘合滚筒的缝隙压力为大约300pli。由该热粘合工序获得了具有彼此分开的粘合花纹的非纺织叠层材料，在粘合区域上具有孔洞，其粘合面积比大约为2％。
实施例2
第一纤维层是由100％的PP-196聚丙烯在一个如上所述的普通梳理机上进行混合而获得的，其单位重量为大约18g/m2。第二纤维层是由60％的聚酯纤维(PET-295，由南卡罗来纳的州，Greenville的Hoechest Celanese公司生产)和40％的PP-196聚丙烯纤维在一个普通的梳理机上混合而制成的，其单位重量为大约32g/m2。第一纤维层和第二纤维层采用如附图3和3a所示的加热粘合滚筒热粘合在一起，其中与第一纤维层相接触的滚筒的温度为大约133℃，而与第二纤维层相接触的粘合滚筒的温度保持在大约157℃。粘合滚筒的旋转线速度为大约24m/min，粘合滚筒的缝隙压力为大约300pli。由该热粘合工序获得了具有彼此分开的粘合花纹的非纺织叠层材料，在粘合区域上具有孔洞，其粘合面积比大约为2％。
实施例3
第一纤维层由100％的聚丙烯(PT110-20，由德国Neuwied的Lohmann Gmbh & Co KG公司生产)在一个如上所述的普通梳理机上进行混合而获得的，其单位重量为大约20g/m2。第二纤维层是由60％的聚酯纤维(PET-292，由德国法兰克福的Hoechest/AG公司生产)和40％的聚丙烯纤维(PP-71”SOFT-71＂，由丹麦Varde的Danaklon A/S公司生产)在一个普通的梳理机上混合而制成的，其单位重量为大约32g/m2。第一纤维层和第二纤维层采用如附图3和3a所示的加热粘合滚筒热粘合在一起，其中与第一纤维层相接触的滚筒的温度为大约133℃，而与第二纤维层相接触的粘合滚筒的温度保持在大约157℃。粘合滚筒的旋转线速度为大约24m/min，粘合滚筒的缝隙压力为大约300pli。由该热粘合工序获得了具有彼此分开的粘合花纹的非纺织叠层材料，在粘合区域上具有孔洞，其粘合面积比大约为2％。
实施例4
第一纤维层是由100％的PP-71聚丙烯在一个如上所述的普通梳理机上进行混合而获得的，其单位重量为大约22g/m2。第二纤维层是由60％的PET-292聚酯纤维和40％的PP-71聚丙烯纤维在一个普通的梳理机上混合而制成的，其单位重量为大约32g/m2。第一纤维层和第二纤维层采用如附图3和3a所示的加热粘合滚筒热粘合在一起，其中与第一纤维层相接触的滚筒的温度为大约133℃，而与第二纤维层相接触的粘合滚筒的温度保持在大约157℃。粘合滚筒的旋转线速度为大约24m/min，粘合滚筒的缝隙压力为大约300pli。由该热粘合工序获得了具有彼此分开的粘合花纹的非纺织叠层材料，在粘合区域上具有孔洞，其粘合面积比大约为2％。
实施例5
第一纤维层是由100％的聚丙烯(75％的PP-196和25％的PP-190，两者都是由Hercules公司生产的)在一个如上所述的普通梳理机上进行混合而获得的，其单位重量为大约18g/m2。第二纤维层是由60％的PET-292聚酯纤维和40％的PP-71聚丙烯纤维在一个普通的梳理机上混合而制成的，其单位重量为大约32g/m2。第一纤维层和第二纤维层采用如附图3和3a所示的加热粘合滚筒热粘合在一起，其中与第一纤维层相接触的滚筒的温度为大约133℃，而与第二纤维层相接触的粘合滚筒的温度保持在大约157℃。粘合滚筒的旋转线速度为大约24m/min，粘合滚筒的缝隙压力为大约300pli。由该热粘合工序获得了具有彼此分开的粘合花纹的非纺织叠层材料，在粘合区域上具有孔洞，其粘合面积比大约为2％。
实施例6
第一纤维层是由100％的PP-196聚丙烯在一个如上所述的普通梳理机上进行混合而获得的，其单位重量为大约18g/m2。第二纤维层是由60％的PET-295聚酯纤维和40％的PP-196聚丙烯纤维在一个普通的梳理机上混合而制成的，其单位重量为大约32g/m2。第一纤维层和第二纤维层采用如附图3和3a所示的加热粘合滚筒热粘合在一起，其中与第一纤维层相接触的滚筒的温度为大约133℃，而与第二纤维层相接触的粘合滚筒的温度保持在大约157℃。粘合滚筒的旋转线速度为大约24m/min，粘合滚筒的缝隙压力为大约300pli。由该热粘合工序获得了具有彼此分开的粘合花纹的非纺织叠层材料，在粘合区域上具有孔洞，其粘合面积比大约为2％。
在上述实施例中所获得的非纺织叠层材料具有如下面的表1所示的特性：
                      表1实施例   单位重量  厚度   密度    抗拉强度    拉伸比
      (g/m2)  (英寸) (g/cc)   (g/英寸)      MD
                               MD    CD1         49.0     0.046   0.041  1578.0 196.0  33.22    52.0   0.046    0.044   1585.0  198.0    32.03    51.0   0.048    0.042   2672.0  402.0    29.24    56.5   0.051    0.043   1439.0  382.0    26.15    51.2   0.057    0.034   1509.0  228.0    39.66    51.5   0.058    0.035   1610.0  263.0    37.3
如下的测试方法被用来测定本发明的非纺织叠层材料10的特定参数：
液体吸取和回流测试(FIFE)用于测量吸收性/渗透时间、回流量、以及一次性吸收用品所保持的液体量。上述吸收性/渗透时间(单位为秒)采用秒表来测量，并用人眼来确定吸收模拟尿液所需的时间长度。回流测试用于测量吸收性用品在吸收三次体液并施加压力之后，由该吸收性用品的“使用者一侧”所渗出的液体量(其单位为克)。
附图7和8所示的仪器用于进行上述测试。对如附图4所示的尿布样品进行测试，它在附图7中用虚线102来表示，对样品的重量进行测量，其精度为0.1g。在制备样品102时，将其腿部、弹性腰带、弹性防渗侧翼(图中未示)从其根部剪去，以便使样品能够放平。对样品的尺寸、重量、和密度以及吸收性芯层的组份必须加以控制，以便获得有效的测量结果。上述数据是采用305mm×305mm的方形样品所获得的，在实施例4、5、6中，样品具有本发明的非纺织叠层材料10和吸收芯层，该吸收芯层包含大约10克的木桨绒毛和大约12克的超级吸收材料，例如DOW DRYTECH 835或其等价物。
样品102被平整地置于其重量为880g的圆柱筒和平板组件104之下，圆柱筒106的内径为5.1cm，圆柱筒的中心位于指定位置108处。例如，位置108与样品102的边缘之间的距离可以为114.3mm和146.1mm，该位置取决于被测试样品的大小(例如小(s)、中(m)、大(l)、超大(xl)。在样品102的下面具有一个凸起的平台110，其高、长、宽分别为12.7mm、152mm、76.2mm。此外，圆柱筒106由平板104朝下伸出0.8mm的距离(g)。
位于圆柱体106顶部的漏斗112与样品相垂直，并对准样品的指定位置108。一定量的合成尿液(例如对小、中、大、超大型尿布分别为50、80、100ml)被倒入上述漏斗(一种适合的合成尿液是PPGINDUSTRIES公司提供的ITEM NO.K-C 399105)。用秒表来测量液体开始和样品相接触到在样品的表面上不再能够看到液体存在之间的时间间隔。在液体被开始吸收的一分钟之后再加入相同量的第二次液体，到第二次液体被吸收的时间作为第一次液体的吸收时间。
参见附图9和10，在第二次液体被吸收一分钟之后，将样品102放在一个真空仪器114中，上面用吸水纸116和不透水的橡胶层118覆盖起来。施加35000dyne/cm(大约0.50psi)的真空力，使不透水的橡胶层118被吸到吸水纸116和样品102上，施加的时间为两分钟。在取消真空力之后，测量被打湿的吸水纸的重量。吸水纸重量的增加量(单位为克)就代表了回流量。
在样品102上取消真空力的一分钟之后，加入第三次液体并如上面所述那样进行时间测量。液体吸取时间为预先确定量的液体(对于上面所述的测量结果来说为80ml)被样品102吸收所需要的秒数。
在实施例4、5、6中，样品102包含本发明的非纺织叠层材料，测得的液体回流量和液体吸收时间如下表所示：
                   表2
样品    液体吸收时间(秒)         回流量(克)
4             33                    7.1
5             34                    1.9
6             30                    3.2
尽管上述液体吸取和回流测试是针对若干特定的实施例进行的，然而采用本发明的非纺织叠层材料的吸收性用品可以具有大约11秒至38秒的液体吸收时间和大约为1.0克至9.0克的回流量。
本领域里的普通技术人员可以在实际应用中对本发明的非纺织叠层材料10进行改制和调整，以适应不同的使用要求。例如，供失禁病人使用的尿垫和月经垫与婴儿尿布相比有不同的传送速率，体积和时间。而且吸收的液体在其液体粘度、表面张力、温度和其他可能影响在各种实际应用中的非纺织叠层材料10性能的物理特性方面是不同的。因此，本发明是旨在包含各种根据本发明的原理所作的改进和变化，它们都被包括在如下的权利要求书中。

Claims (24)

1.一种纤维叠层材料，它包括：
由一种或多种热塑性聚合材料的多根纤维制成的第一纤维层；
由两种或多种热塑性聚合材料的多根纤维制成的第二纤维层；
所述第一纤维层和第二纤维层通过彼此分开的粘合花纹粘合在一起，该粘合花纹包括很多离散的粘合区域，在这些区域之间有被轻微粘合的纤维；
所述的粘合区域内具有形成的孔洞。
2.如权利要求1所述的纤维叠层材料，其特征是所述的第一和第二纤维层为非纺织纤维网。
3.如权利要求2所述的纤维叠层材料，其特征是第一纤维层和第二纤维层中的至少一层由纺粘纤维网制成。
4.如权利要求2所述的纤维叠层材料，其特征是所述的第一纤维层中的纤维彼此被粘合在一起。
5.如权利要求2所述的纤维叠层材料，其特征是所述的第一纤维层和第二纤维层是通过热粘合方式被粘合在一起的。
6.如权利要求2所述的纤维叠层材料，其特征是被粘合的区域面积为材料表面积的大约1.0％至6.0％。
7.如权利要求2所述的纤维叠层材料，其特征是被粘合的区域面积为材料表面积的大约2.0％至4.0％。
8.如权利要求2所述的纤维叠层材料，其特征是所述的第一纤维层由选自聚烯烃材料组的一种或多种热塑性聚合材料制成；而第二纤维层由选自聚烯烃和聚酯材料组的两种或多种热塑性聚合材料的混合物制成。
9.如权利要求8所述的纤维叠层材料，其特征是所述的第一纤维层由聚丙烯制成，第二纤维层由聚丙烯和聚酯混合制成。
10.如权利要求9所述的纤维叠层材料，其特征是第一纤维层由100％的聚丙烯制成，第二纤维层由大约70％至25％的聚丙烯和30％至75％的聚酯制成。
11.如权利要求9所述的纤维叠层材料，其特征是第一层由100％的聚丙烯制成，第二纤维层由大约40％的聚丙烯和60％的聚酯制成。
12.如权利要求2所述的纤维叠层材料，其特征是第一纤维层在将第一纤维层和第二纤维层粘合在一起之前具有高于第二纤维层的密度。
13.一种吸收用品，包括一层可以渗过液体的面向人体的衬里，一层不可渗过液体的覆盖层，以及位于上述两层之间的吸收性芯层，其特征在于其改进包括邻近所述面向人体的衬里的至少一部分设有一种纤维叠层材料，它包括：
由一种或多种热塑性聚合材料的多根纤维制成的第一纤维层；
由两种或多种热塑性聚合材料的多根纤维制成的第二纤维层；
所述第一纤维层和第二纤维层通过彼此分开的粘合花纹粘合在一起，该粘合花纹包括很多离散的粘合区域，在这些区域之间有被轻微粘合的纤维；
所述的粘合区域内具有形成的孔洞。
14.如权利要求13所述的吸收性用品，其特征在于邻近所述面向人体的衬里的至少一部分设置的纤维叠层材料中，所述的第一和第二纤维层为非纺织纤维网。
15.一种制造纤维叠层材料的方法，包括：
a.制成由一种或多种热塑性聚合材料的多根纤维制成的第一纤维层；
b.制成由两种或多种热塑性聚合材料的多根纤维制成的第二纤维层；
c.将所述第一纤维层和第二纤维层通过彼此分开的粘合花纹粘合在一起，该粘合花纹包括很多离散的粘合区域，在这些区域之间有被轻微粘合的纤维；
d.在所述的粘合区域内形成孔洞。
16.如权利要求15所述的方法，其特征是所述的步骤b包括在制成所述第一纤维层之后将所述第二纤维层置于第一纤维层上。
17.如权利要求15所述的方法，其特征是所述的步骤a包括将第一纤维层中的纤维彼此粘合在一起。
18.如权利要求15所述的方法，其特征是所述的粘合步骤为热粘合。
19.如权利要求15所述的方法，其特征是所述的粘合步骤c包括采用一个在其外表面上具有彼此分开的凸起粘合花纹的第一粘合滚筒和一个在其外表面上具有多个凸起粘合点的第二滚筒进行热粘合。
20.如权利要求15所述的方法，其特征是所述的第一和第二纤维层由非纺织纤维网制成。
21.如权利要求15所述的方法，其特征是所述的第一纤维层和第二纤维层中的至少一层由纺粘纤维网制成。
22.如权利要求15所述的方法，其特征是所述的第一纤维层由选自聚烯烃材料组的一种或多种热塑性聚合材料制成，第二纤维层由选自聚烯烃和聚酯材料组的两种或多种热塑性聚合材料的混合物制成。
23.用于制造纤维叠层材料的设备，包括：
制成第一纤维层的设备，该纤维层由一种或多种热塑性聚合材料的多根纤维制成；
制成第二纤维层的设备，该纤维层由两种或多种热塑性聚合材料的多根纤维制成；
用于通过彼此分开的粘合花纹将所述第一和第二纤维层粘合在一起的粘合设备，该粘合花纹包括很多离散的粘合区域，在这些区域之间有被轻微粘合的纤维；所述的粘合设备包括一个在其外表面上具有彼此分开的凸起粘合花纹的第一粘合滚筒和一个在其外表面上具有多个凸起粘合点的第二滚筒，
用于在所述的粘合区域内形成孔洞的设备，
用于加热所述第一粘合滚筒和第二粘合滚筒中的至少一个的设备；
用于旋转所述第一粘合滚筒的设备；以及
用于旋转所述第二粘合滚筒的设备，
所述第一粘合滚筒以第一旋转速度旋转，第二粘合滚筒以第二旋转速度旋转，所述第一速度比第二速度至少大4％。
24.如权利要求23所述的制造纤维叠层材料的设备，进一步包括第一粘合设备，用于将所述第一纤维层中的纤维彼此粘合在一起。
CN93114448A 1992-11-06 1993-11-05 纤维叠层网及其制造方法和设备 Expired - Lifetime CN1054805C (zh)

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Publication number Priority date Publication date Assignee Title
CN100387212C (zh) * 2003-09-19 2008-05-14 花王株式会社 吸收性物品的表面片和吸收性物品
CN101305085B (zh) * 2005-12-07 2010-09-08 Sca卫生产品股份公司 用于吸收性制品的叠层材料及其制造方法
CN103221195A (zh) * 2010-11-22 2013-07-24 花王株式会社 片材熔接体的制造方法和片材熔接体
CN103221195B (zh) * 2010-11-22 2016-03-23 花王株式会社 片材熔接体的制造方法和片材熔接体

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EP0667814A1 (en) 1995-08-23
EP0596191B1 (en) 2001-09-26
MX9300424A (es) 1994-05-31
KR100255573B1 (ko) 2000-05-01
EP0596191B2 (en) 2008-07-02
CA2088391A1 (en) 1994-05-07
DE69330181D1 (de) 2001-05-31
EP0667814B1 (en) 2001-04-25
US5667619A (en) 1997-09-16
ES2157972T3 (es) 2001-09-01
AU670825B2 (en) 1996-08-01
DE69330814T3 (de) 2009-04-09
DE69330181T2 (de) 2001-08-23
WO1994011186A1 (en) 1994-05-26
KR940011689A (ko) 1994-06-21
JPH071635A (ja) 1995-01-06
CN1087578A (zh) 1994-06-08
CA2148794A1 (en) 1994-05-26
ES2161216T3 (es) 2001-12-01
BR9304478A (pt) 1994-05-17
JPH08504136A (ja) 1996-05-07
US5667625A (en) 1997-09-16
ZA937184B (en) 1994-06-25
UY23667A1 (es) 1994-02-25
DE69330181T3 (de) 2004-11-11
DE69330814D1 (de) 2001-10-31
AU5048893A (en) 1994-05-19
CN1119581A (zh) 1996-04-03
AU5595394A (en) 1994-06-08
EP0667814B2 (en) 2004-07-14
EP0596191A1 (en) 1994-05-11
DE69330814T2 (de) 2002-06-13
MX9306964A (es) 1995-01-31

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