CN1119581A - 纤维叠层网状产品及其制造方法和设备以及由该网状产品制成的吸收性制品 - Google Patents

纤维叠层网状产品及其制造方法和设备以及由该网状产品制成的吸收性制品 Download PDF

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Publication number
CN1119581A
CN1119581A CN94108791A CN94108791A CN1119581A CN 1119581 A CN1119581 A CN 1119581A CN 94108791 A CN94108791 A CN 94108791A CN 94108791 A CN94108791 A CN 94108791A CN 1119581 A CN1119581 A CN 1119581A
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CN
China
Prior art keywords
top layer
fiber
layer
land
roller
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN94108791A
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English (en)
Inventor
M·I·阿力克汗
D·L·普罗斯迈尔
E·B·黎克特
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kimberly Clark Corp
Original Assignee
Kimberly Clark Corp
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Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=25520557&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=CN1119581(A) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Kimberly Clark Corp filed Critical Kimberly Clark Corp
Publication of CN1119581A publication Critical patent/CN1119581A/zh
Pending legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • 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
    • 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
    • A61F13/51—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
    • 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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/23—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations
    • B29C66/234—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations said joint lines being in the form of tessellations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/433—Casing-in, i.e. enclosing an element between two sheets by an outlined seam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/729—Textile or other fibrous material made from plastics
    • B29C66/7294—Non woven mats, e.g. felt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81433—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined being toothed, i.e. comprising several teeth or pins, or being patterned
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411—Roller, cylinder or drum types
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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

本发明涉及一种纤维叠层材料，其特征在于，一个有多元性人造丝纤维或连续的热塑材料长丝组成的纤维顶层，一个由多元性人造丝纤维或二种或多种热塑或其他材料长丝组成的纤维底层，以一种能形成小孔的隔开结合图案把两层纤维层结合在一起，以形成一个当它置于与人身皮肤接触时，能改善对液体的扩散和易处理特性并且能提高舒适性和柔软性的纤维叠层材料。本发明还包括制造这种纤维叠层物的方法和设备，以及用这种纤维叠层构成的吸收性的制品。

Description

纤维叠层网状产品及其制造方法和设 备以及由该网状产品制成的吸收性制品
本发明一般涉及一种适用于在有吸收扩散和保持身体排液性能的制品中的纤维网状叠层产品，例如，一次性尿衬布，卫生餐巾，失禁衣和类似产品，以及制造这种产品的方法和装置。更准确地说，此发明涉及的无纺叠层材料能改善液体的扩散，易处理和空气循环特性并且将其与人体皮肤相接触能改善舒适性和柔软性，当把这种无纺叠层材料放置在吸收性制品的内部结构时，它能改善液体的穿透性和易处理性。
比如象纺粘(spunbonded)网状物和梳理网状物这样的无纺材料可被用在一次性吸收制品中的身体侧材料。典型地，已使用非常疏松的、多孔的衬料结构可使液体迅速地通过，因此能保持穿着者的皮肤与在衬料下的吸湿的吸收核心层分隔开。同样，在衬料和吸收衬垫之间已设置象那些具有厚的、高的纤维结构的材料的其他层状材料，用于减少液体的回流。
Raley申请的美国专利第4761322号公开了一种有柔软结构纤维层的纤维网状叠层产品，这种产品由一个有较强结构完整性的相邻层叠压而成，这各柔软组织结构层呆以用于与皮肤相接触的表面而且相邻层能给整个叠层物提供强度和完整性。此专利中的叠层产品包括一个第一纤维层和第二纤维层，第一纤维层是以第一种间隔开的结合图案形成的，比如是将第一纤维层通过由有第一种图案的加热辊和一个光辊形成的辊隙成形的。而第二纤维层是以第二种间隔开的结合图案形成的，例如，将第一和第二纤维层通过由第二图案加热辊和光辊形成的辊隙而成形的。而形成第二结合图案时还在第一和第二纤维层之间形成结合，而在第一结合图案中没有此种情况。
Marsan等人申请的美国专利第4,392,862号公开了一种由一个表面部分、一个支持部分，一个有吸水性的核心部分和一个底层组成的吸收性结构。表面部分是一种由疏水性、热塑性纤维组成的可渗液体、非粘接梳理网状物。这种表面部分以间隔的结合区粘结于由无纺聚酯或单丝平纺棉织物组成的能渗透液体的支持部分。
Cumbers申请的美国专利等4,088,726号公开了一种制造无纺纤维的方法。一种可热结合的无纺网状物，通过由两个协同运转的压结辊的所形成辊隙而形成这种无纺纤维。至少其中之一是加热辊，一个压结辊有连续的表面，另一个辊子的表面是由一些相隔开的凸起的表面所成。在辊隙上同时出现的那些凸起物的面的矩心在最接近的连续表面上的纵向位置是不同的，使在辊隙里相对的纹形表面形成不同程度重叠。
虽然研制了以上描述的几种形式的无纺材料，但为使穿着者的皮肤感到更好的表面干燥性和舒适性，仍需要一种用于制造一次性吸收性制品的与体侧接触的无纺材料，使其具有更好的液体吸收性，扩散性和空气流通性。同时这种材料与穿着者的皮肤相接触时应具有更好的柔软性和舒适性。另外，当用于吸性制品的内部结构时，无纺材料也应能改善对液体的渗透性和易处理性。
本发明涉及一种无纺叠层材料，其中的顶层无纺层由多无性的人造短纤维或热塑材料制成的连续细丝组成，底层无纺层由多无性的人造短纤维或以能形成小孔的以间隔结合图案粘接在一起的二种更多种热塑材料细丝组成。因此能形成一种能改善液体的扩散性和易处理性并且当与人皮肤相接触时具有良好的舒适性和柔软性。同时本发明也说明了制造这种无纺叠层产品的方法和设备，以及由这种无纺叠层材料制成的吸收性制品。
参考后面的附图，和对本发明的实施例的说明可以很好的理解本发明的无纺叠层材料。
图1表示的是根据本发明的一种无纺叠层材料的部分断面透视图。
图2表示的是图1中的无纺叠层材料从A-A线剖开的横向剖面图；
图3表示的是根据本发明的用于生产无纺叠层材料的生产设备示意图；
图3a表示的是根据本发明用于形成无纺叠层材料的热结合辊的透视图；
图3b和3c，表示的是图3中热结合辊的外表面一部分的放大视图；
图4表示的是采用本发明无纺叠层材料的一次性尿衬布的横断面视图，无纺叠层材料位于靠近婴儿身体的尿衬布一侧；
图5表示的是一张本发明的无纺叠层材料的部分成孔结合区的显微照片(放大倍数13.2，12mm，工作距离，5KV的加速电压)，图中表示的是面向观者的无纺叠层材料的顶层；
图6表示的是一张本发明的无纺叠层材料的部分成孔结合区的显微照片(放大倍数28.7，工作距离12mm，加速电压，5KV)，图中表示的是面向观者的无纺叠层材料的底层；
图7表示的是一种用于评价在此描述的无纺叠材料的液体吸收性和回流性的测试装置的透视图。
图8是图7的横向剖视图；
图9表示的是用于评价在此描述的无纺叠层材料对液体回流性能的测试装置的透视图；
图10是图9的横向剖视图；
图11a表示的是一种利用本发明的无纺叠层材料的一次性尿布的部分剖视和俯视图，这种材料设置在一对保护挡带的连接边之间，靠近体侧的衬料的内表面。
图11b表示的是图11a中的一次性尿布的横向剖视图，其中在保护挡带末端的弹性材料能促使挡带部分经常保持向上的位置并使之与体侧衬料相隔开；
图11c表示的是图11a的一次性尿布的透视图，其中边部的弹性材料和挡带弹性材料能起到使尿布的边缘收缩和挡污带的末端部收拢的作用。
本发明说明了一种分别有顶层纤维层和底层纤维层的叠层纤维织物或材料，其中的顶层纤维是由一种多元性合成短纤维或一种或一种以上热塑性连续细丝组成的。而底层纤维是由一种多元性合成纤维或二种或二种以上热塑性连续细丝组成的。可能是无纺网状物的顶层和底层，能用一种隔开的结合图案形成一种纤维叠层，例如可以用一对热压纹辊或一对在其外表面有凸起的结合图案的压结辊之间进行热结合制成。在不影响顶层表面质地的韧性和柔软性或整个叠层的高度的情况下，这种隔开的结合图案就能在顶层和底层之间提供良好的结构完整性。在隔开结合的区域中形成的小孔能提高纤维叠层中每各层的液体扩散性和空气流通性。根据本发明成型的纤维叠层能改善对液体的吸收性、扩散性以及对空气的流通性的特性，因此，当用与人体皮肤相接触时能产生更大的干燥表面和更好的舒适性。本发明的纤维叠层还具有高的垫状结构，还能让使用者感到更好的柔软性和类似垫子似的感觉。当所说的叠层材料放在吸收性制品的内部结构时，本发明的纤维叠层也能提供更好的液体渗透性和易处理性。从后面的说明和附属权利要求书中将会了解到本发明的其他特征和优点。
在这里所用的象无纺网状物或无纺层这样的术语指的是一种有以随机形式混杂的单个纤维或长丝形成的结构构成的纤维网或层状物。在现有技术中，通过各种方法已能形成无纺网状物，比如用熔化吹制法，纺粘法，气流成网法，湿法成网法，干法成网法，干人造纤维和梳理网状物法。虽然无纺网状材料可用于本发明，但不认为本发明只局限于使用无纺材料，而合适的其他纤维结构也可使用。
对本发明的纤维叠层材料的说明，在本文中是与它在一次性吸收性制品的使用一起介绍的，但是，应该理解成本发明还有一些潜在的应用而不局限于这种一次性吸收性制品上。这里所用的象＂一次性吸收性的制品＂这样的术语指的是，一种能吸收并且容纳身体的排泄物，而且一段使用时间之后可丢弃的物品。这种物品能放在与使用者的身体紧靠或距离很近的地方，并能吸收和容纳体内排出的各种排泄物。
参见图1它表示的是本发明的一个实施例的有局部断面的透视图。无纺材料10包括顶层无纺层12和底层无纺层22。顶层12有一个上表面14和一个下表面16，底层22有一个上表面14和一个下表面16，底层22有一个上表面24和下表面26。图中所示的实施例，在隔开的结合图案18的多个热熔化结合区，穿过无纺材料10的厚度使顶层12的纤维和底层22的纤维在介面20上相互熔合成结合。顶层和底层的结合基本上局限于在结合区18。这就是说，在结合区18之外的顶层和底层的区域19上，通过熔合纤维的方法，各层纤维只是少量的相互结合在一起。因此，通过轻度结合区19将结合区18分隔开的。在如图所示的具体实例中，在结合区18上形成的小孔30能改善这种无纺材料10的液体扩散性和空气流通性。
虽然在图中所示实施例中，这些纤维形成无纺层，但本发明的顶层和底层也可以由任何合适的天然或人造纤维以任何合适的结构形成。总之，本发明中的每一个无纺层可以是不连续的纤维，连续的长丝或它的结合。在所示实施例中的每层的生产方法用的是干纤维生产过程，或更特别的是梳理网状物技术，正如本技术领域的熟练技术人员所公知的。如果梳理技术能很好地用于形成本发明中各层的话，那么其它生产不连续纤维或不连续长丝的本技术领域熟练技术人员所公知的现有技术如纺粘工艺，熔喷工艺，气流成网工艺，在本发明的范围内也可以考虑使用。实际用在本发明的梳网技术能使纤维成为直线排列或非直经排列的图形。象本技术领域的熟练技术人员所公知的，传统的梳理机可用于生产本发明中的各个纤维层。
本发明中的两层，可以很好地使用能大指供应的塑性聚合材料。仅举例来说，这些聚合物包括聚烯烃类，聚酰胺类，聚酯类和类似的。这种纤维可有任何合适的结构，可以包括中空纤维或芯纤维，成形的纤维，双组分纤维或高吸收粒子浸渍的纤维。
如图1中的实施例所示，由无纺纤维10组成的顶层无纺层12是一种由热塑性聚丙烯纤维组成的结合梳理网状物。无纺纤维组成的底层无纺层22是一种由聚丙烯的聚酯纤维混合组成的实质上非结合或非结合的梳现网状物。在这里用的＂实质上非结合＂这一术语指的是用已知的结合方法，产生一种其纤维是充分地结合在一起的网状物，以便于处理，但结合的程度又不是为最终的用途提供所需的强度和完整性。在这里提到的＂非结合性＂指的是网状物的纤维是不以机械、热成形或化学成形结合在一起的。
在底层22中的不同种类热塑纤维的比率可以改变以适合无纺材料的最终用途。例如，在底层22中的聚丙烯与聚酯按底层总量比可以从大约70∶30变化到大约25∶75，在图中实施例表示的材料中两者的比率大约是40∶60。
本发明的一个显著的优点是，在本发明中的无纺网状物中可使用不是最佳特性的特定材料。所以，由一种或多种不同的材料制成的本发明网状物能产生一系列好的特性。例如，一种由聚丙烯和聚酯纤维组成的非结合或基本上非结合无纺层，对于某种无纺网状物的应用产生太柔软和太薄弱的效果。但是，在本发明的下述技术中，由聚丙烯和聚酯纤维合适的混合制成的无纺层，能够结合形成象由聚丙烯纤维组成的结合层那样有更好强度的无纺网状物，因此能制成更理想的无纺叠层物。
在本发明中使用的无纺织物10中的纤维尺寸，基本重量和纤维层的密度能根据网状物使用的用途容易地改变。例如，在本发明的一个应用例子里，一种在衬料和表面层之间具有一个吸收性核心层的一次性吸收性的制品中，这种无纺材料可用于与身体表面相接触的表层。仅作为说明如下，这种一次性制品包括，尿布，训练用紧身短衬裤，卫生餐巾，失禁衣和相似产品。对于这种应用，顶层12的聚丙烯纤维可以细到大约1.0登尼尔(直径12.5m)，粗到大约3.0登尼尔(21.6m)，然而聚丙烯纤维的粗细在2登尼尔(17.6m)到大约2.2登尼尔(18.5m)。并且卷曲纤维的长度大约1.5英寸(38.1mm)时能让使用者产生舒适感，但本发明中的顶层12的聚丙烯纤维可以细到大约1.0登尼尔(直径12.5m)粗到大约3.0登尼尔(21.6m)和卷曲纤维的长度从大约1.25英寸(31.75mm)到大约2.5英寸(63.5mm)。(从现有技术中可以知道，卷曲度是纤维的形式，直径和密度的函数)。用于与人体皮肤相接触并且起内衬层的作用，在顶层12中的聚丙烯纤维的较细的纤维尺寸能使顶层12产生一个更柔软的表层质地。在底层22的聚丙烯纤维不需要与顶层12的聚丙烯纤维相同。在底层的聚酯纤维粗细可以从大约3登尼尔(17.5m)到大约9登尼尔(30.4m)并且卷曲长度从大约1.25英寸(31.75mm)至3英寸(76.2mm)，而合适的聚酯纤维的粗细为大约6登尼尔(24.8m卷曲长度为大约英寸(50.8mm)。虽然没有任何特别的理论规定，但普通认为不同的纤维能提高底层22对液体的吸收性和扩散性。在顶层12上的有相同直径的纤维，在同一下面上能形成相似尺寸的细孔，在底层22上的不同直径的纤维能在多层的平面上形成各种尺寸的细孔。可以相信，在底层22的多层平面上的不同尺寸的细孔能提高吸收贯穿底层22的液体和对吸入的液体进入和扩散到整个底层22。普遍认为聚酯纤维的回弹性是改善本发明中的无纺叠层的液体的易处理性和空气流通性的一个有益的因素。因此，应用中，底层22的功能是作为以便一各缓冲层或临时储藏器。以便液体流过无纺材料10而进入吸收性制品的吸收性核心层。
本发明的无纺材料10的基本重量是从大约25g/m2(0.7oz/yd2)到大约78g/m2(2.3oz/yd2)，厚度从大约0.03in.(0.76mm)到大约0.08in.(2.03mm)和密度从大约0.020g/cc到大约0.050g/cc。密度是由以下公式决定的：
Figure A9410879100161
例如，在本实施例中，无纺网状物的基本重量的范围是从大约14.7g/m2(1.4oz/yd2)到大约58g/m2(1.7oz/yd2)，厚度的范围是从大约0.04in.(1.02mm)到大约0.06in.(1.52mm)，而密度的范围为大约0.030g/cc到大约0.045g/cc。
无纺材料10的基本重量可用仪器测量无纺材料样品的重量。每种被测量的样品应不少于4in2(2580mm2)。每种样品应进行切断和平整以减少打团和褶皱，分析天平的称重精度应能精确到0.01g。然后，通过样品重量除以样品面积可算得基本重量。
无纺材料10的厚度可用仪器对无纺材料样品施加一个恒定的0.25psi(35.15kg/m2)的载荷压力而测得。每种被测量的样品的面积至少为5×5in.(127×127mm)。每种样品应进行切断和平整以减少打团和褶皱，然后放置在直径大约3in.(76.2mm)的园形有机玻璃板(压块)下，尽可能对中，然后将压块降低到样品上。对每种样品的厚度所计录的精度应达到0.001in.(0.0254mm)。
虽然在其它的实施例中，在与底层22结合之前，顶层12的基本重量和密度可根据底层22的参数而改变，但是实施例表示的顶层12比底层22有较低的基本重量和较高的密度。顶层的基本重量的变化范围可在大约0.4oz/yd2(16g/m2)到大约0.8oz/yd2(28g/m2)，理想值是大约0.5oz/yd2(18g/m2)到大约0.6oz/yd2(22g/m2)，底层的基本重量的变化范围是从大约0.7oz/yd2(24g/m2)到大约1.02OZ/yd2(35g/m2)，理想值是大约0.goz/yd2(32g/m2)。顶层的密度的变化范围是从大约0.050g/cc到大约0.065g/cc，理想值为大约0.055g/cc，底层的密度的变化范围是从大约0.024g/cc到大约0.045g/cc，理想值大约为0.035g/cc。
参见图2，表示的是所述本发明的无纺材料10断面图，它包括一个顶层12和底层22。形成隔开结合图案18的一系列结合区穿过各层厚度，在结合区18和介面20处把顶层12和底层22结合在一起。下面将描述形成隔开结合图案18的方式。
可以用任何合适的方式在介面20中间把顶层和底层结合起来以形成隔开的结合区18。即形成无纺材料10，它具有以上描述的对液体的易处理性、空气流通性和其它特性。通过用一对热的压纹辊的热结合方法是一种形成结合区18的有效方法，下同将详细介绍。
在本发明中设想了各层的结合可以有不同的工序。例如，在第一个工序中成形和结合顶层12，在第二工序中形成底层22，而在进一步的工序中再与顶层12结合在一起。作为另一种选择，在第一工序中形成顶层12，在第二工序中底层22被成形，在另一个工序中各层被结合在一起，同时顶层12的纤维也被相互结合起来。开始是非结合的或基本上非结合的底层22的热塑纤维，在形成无纺叠层材料10时会有一定程度的热结合，下面将会仔细描述的。
在图示的实施例中，顶层12的纤维相对于底层22的纤维具有较大程度的结合。例如，顶层12由于它在一对有普通结构的结合辊(例如一个有雕纹的辊和一个平滑辊，之间通过而形成热结合，辊的温度在270°F(132℃)与300°F(149℃)之间，其理想值是275°F(135℃)到285°F(141℃)。用热结合辊方法结合层12的合适温度将依赖于辊子表面的运动速度，压接辊的直径和所用的热塑纤维。顶层12也可用其它公知的结合方法结合成形，例如用图案粘接，针缝，喷液或喷气缠绕纤维的方法。在本实施例中，顶层12比底层22有更高的密度。这样，比底层22有更好的结构完整性和机械强度的顶层12能给底层22起到基本衬底的作用。
通过改变结合区的百分比可以在隔开的结合区18控制顶层12与底层22的结合程度，这个百分比指的是在各层之间的介面上，即在结合区内结合点所占有的表面积。因此，如图1和图2所示，顶层12和底层22之间的介面20有一个隔开的结合图案18在这个面上，被结合区18占有的表面积对整个介面20的表面积之间的比率就是介面20的结合区百分比。如实施例所示，无纺叠层的结合区百分比的范围可从大约1％到大约6％，理想值为大约2％到4％。尽管本发明表示了一种六角形(蜂窝状)结合区图案，但本发明也包括能适合于结合成本发明的无纺材料的其它几何、非几何、重复的和不重复的结合图案。
图3表示的是用于制造本发明所述的无纺叠层材料实施例的设备示意图。如上所述，能用象在美国专利第3,604,062和第3,604,475中所述的常规的梳理机生产本发明中的各层产品。如图所示，从第一台梳理机42加工出的顶层12由传输带4Q运走，同时第二台梳理52制出底层22放在首层12的上部。在这种方式中，当两层完成成型过程时，顶层12就作为底层22的基本衬底。
可选择地使两层纤维通过一对有轻微压紧纤维网状物作用的压结辊，这样能增加网状物的完整性并有助于后面的工序。纤维层中的一层或二层也可以通过一种能使网状物上的纤维的放置有方向性的设备，以便在机器方向(MD)和横向(CD)上获得最佳的材料的强度。这里所用的机器方向(MD)指的是生产出网状物的方向(图3中的从左到右)，而横向(CD)指的是垂直于生产网状物方向的方向。本发明的无纺叠层的MD强度必须足够高(至少在大约900g/in.(354g/cm)至2700g/in.(1062g/cm)之间，其理想值至少为1300g/in.(512g/cm))，以致在生产象尿衬布这样的一次性吸收性制品的高速生产过程中，无纺网状物不会破裂。
两层无纺层在下一个过程中通过两个压结辊60和70。在图3和图3a的实施例中，两个压结辊都要被加热并且在外表面上有凸起的(阳)压结图案。下辊60的表面图案是一种隔开的压结图案62，同时，在上辊70的表面上有一种凸起的压结图案。在其他的实施例中，压结辊的位置可以是相反的。因此，本发明有这样一个特点，使用这些热的压结辊的外表面上有不同的阳的或凸起的压结图案，以产生一被隔开的压结图，案使无纺材料的每一层结合起来。
当两个无纺层12和22通过两个热的辊60和70之后，由于形成具有能扩展到各个无纺层主要部分的热产生的纤维结合点的独立压实结合区18，所以各层都成为固定了。可依据各层12和22的厚度而变化的压实或结合区18的厚度，能在大约50m到大约150m之间改变，本实施例所用的参数是大约70m到大约110m。分布在无纺材料10的压实结合区18是由二个表面有凸起图案的热压制辊60和70之间的压实点形成的，在它们之间它区域19纤维是轻微地结合在一起。
在结合区18上形成的小孔30是由表面有凸起图案的热压制辊60和70之间的压实点形成的，下面会做更详细的描述。由于本发明者不严格要求孔30的精确的尺寸和形状(见图5和图6)，所以平均直径在大约8m到大约580m或更大的小孔都可有效地用于本发明，理想的值是平均直径是从大约29m到大约277m。如图5和图6所示，小孔30贯穿无纺叠层材料10，在其上基本上没有纤维，并且能提供一个直接的通道使液体通过无纺材料10。因此，小孔30能让液体迅速被吸入顶层12并进入底层22而最终进入吸收性制品的吸收核心层中。据观察，液体主要是沿着有孔的结合区18从无纺材料10的结合点流过的，结合区18起到了液体流通通道的作用。应把小孔30与在层12和纤维层22之间形成的孔区别开，这些孔不很吕而且是弯曲的，不能对液体迅速的吸收和扩散。因此，所示无纺材料10有隔开的结合区18并且小孔30在结合区18上形成，在它们之间有轻微结合区19。
对于所用压结辊上凸起图案的特殊结合的二个参数是，结合辊上凸起区的尺寸和距离，即隔开的结合区的距离。如上所述，两个参数共同影响无纺材料10上结合点的百分率。足够的结合区的百分比对于保证网状物为满足使用而要求的完整性是重要的。另一方面，保持结合区百分比不太大也是重要的，因为，较大的结合区百分比常使网状物的柔软性降低。本实施例中下辊60的结合区百分比(凸起结合图形62的表面积对下辊60的全部表面积的比率)的范围是从大约9％到20％，理想值是大约18％到大约19.5％。上辊70的结合区百分比(凸起点72的表面积对上辊70的全部表面积的比率)在本实施例中的范围是从大约10％到大约30％，理想值为大约11％到20％。如上所述，作为上辊70和下辊60结合区百分比的计算结果的无纺叠层10的结合区百分比能在从大约1％到大约6％的范围，其理想值是大约2％到大约4％。
更重要的是，由于两个压制辊上的凸起图形的共同作用可使在结合区内的小孔数量达到最佳。在图3a，3b和3c所示的实施例中，在下辊60的外表面64上的凸起结合区图案62的宽度可以从大约0.04in.(1.0mm)到大约0.08in.(2.0mm)，宽度的理想值是大约0.07in.(1.8mm)，并且在凸起结合区图案62上的根部66的宽度可在从大约0.06in.(1.6mm)到大约0.12in.(3.1mm)范围，其理想值大约为0.11in.(2.8mm)。在此实例中，下辊60的凸起结合图案62有一个大约0.04in.(1.0mm)的刻模深度，即从凸起结合图案62上根部66到外表部64之间的距离。下辊60的凸起结合图案62中的单个六角形68的边重复宽度W，尺寸在大约0.65in.(16，50mm)到大约0.68in.(17.33mm)，重复高度H，尺寸从大约1.10in.(28mm)到大约1.18in.(30mm)，和一个间距P，尺寸在大约0.65in.(16.50mm)到大约0.68in(17.33mm)之间，并且其间距角，范围在大约45°到大约60°之间。
仍参见图3a，3b和3c，上辊70的外表面74上的凸起结合区72的宽度为从大约0.028in.(0.70mm)到大约0.031in.(0.80mm)，其理想值为大约0.030in.(0.75mm)。象传统的技术一样，凸起结合点72的根部76的宽度只比其外表面74上的宽度稍大。上辊70的凸起结合点72有一个大约0.026in.(0.65mm)的刻模深度。在此实施例中，各个凸起结合点72的布置是以大约218.0结合点/in2(33.8个结合点/cm2)，并有一个从大约0.094in(2.4mm)到大约0.118in(3.0mm)的重复的宽度W′和一个大约0.068in(1.72mm)的重复的高度H′，以及一个大约0.068in(1.72mm)的间距P′，其间距角为从大约30°到大约45°。虽然如实施例所示，凸起结合点的外表面74是正方形的，但其它几何或非几几何形状都可以作为上辊70上的凸起结合点72的形状。
发明者已经观察到要优化本发明的无纺材料10，下面的几个因素是相互联系的：
1)，压结辊60和70的温度。
2)，成形工序的线速度；
3)，在压结辊之间缝隙压力；
4)，压制辊的直径；
5)，用于制作纤维层12和22的材料类型。
就是说，调整一个或多个以上因素会影响其他的因素。例如，增加成形过程的线速度会导致无纺叠层在压结辊中接触的时间缩短。因此，需要增加压结辊的温度以保证所需的两层结合的程度，以补偿线速度的改变。
如上所述，与两层压结有重要关系的是压制辊60和70的温度。理所当然地，对于每种聚合物温度低于一定温度时不会影响任何压结过程，但温度若高于某值将会熔化太多的网状物。同时，也已看到，压结辊的温度也能影响所生产的无纺叠层物的拉伸强度和柔软性。特别是，在一定范围内，较高温将能产生一种有较高拉伸强度的网状物。但是，同样的较高温度也使网状物的柔软性下降。由于这个温度范围能引起压结程度的较高和较低不同，所以以上的情况是可能的。那就是说，较高的温度有可能导致更多和更坚固的内部纤维的结合，这种结合对提高拉伸强度是有利的但对柔软性会有点损害。另外，当热塑纤维有更大的收缩时，较高的温度会导致一个高度较低的垫块结构，反而影响无纺材料10的柔软性和垫子似的感觉。
已进一步的观察到，压结辊的温度也能影响网状物上压结区里的小孔的形成。虽然在压结区里的小孔并不只是由热形成的，但热的压结使受到足够程度压力的各层产生小孔，在下面将更详细的介绍。
在图示实施例中，下辊60的压结温度范围在大约260°F(127℃)到大约285°F(140℃)，其理想值是大约265°F(129℃)到大约275°F(135℃)，上辊70的压结温度范围在大约270°F(132℃)到大约320°F(160℃)，其理想值是大约290°F(143℃)到大约315°F(157℃)。这是重要的，就是与顶层12相接触的压结辊的温度要低于与底层22相接触的压制辊的温度，在本实施例中这二个辊分别是下辊60和上辊70，以致顶层12的柔软性不会明显地降低，同时在底层22中的热塑纤维被加热到足够温度而与顶层12的热塑纤维熔合在一起。只在能使压结辊60的温度保持在稍低于顶层12的压结温度，并设想在以上描述的成形过程中其它所有操作参数的稳定，即纤维层12的柔软性就不会有显著的改变。
有关于在压制区里小孔的形成和二层压结的另一个重要因素是，每一个压制辊的线速度。在实例中，辊的线速度的范围是从大约65feet/min，(20m/min)到大约328feet/min(100m/min)或更大。已进一步的观察到，在压结区内小孔的形成情况可能通过使用二辊的不同的表面速度而得到显著的改善。旋转表面速度的差值能是不同的，可在大约4％到大约20％，常用的差值是大约5％到大约15％。可以使用二个中任一个压结辊比另一个压结辊有更高的转速。虽然不受任一个特定的理论限制，但据信，用不同的压结辊的转速可以改善小孔的成形，这时因为，热压结合区的压结辊表面的切向剪切力在压制辊的凸起图形之间的结合点上撕开无纺材料以形成小孔。
另一个对二层的结合起重要作用的因素是每个压结辊的直径。虽然在所示实施例中(和以后的实施例)每个压结辊的直径大约是12英寸(305mm)，但是直径较大或较小的压结辊都适于本发明的无纺叠层的生产。此外各辊子的直径不需要是一致的。
另一个对两层的结合和在结合区内小孔的形成起重要作用的因素是，在压结辊之间的辊隙压力。在图示实施例中，压结辊产生的辊隙压力从大约60Pli(10kg/1cm)到大约400Pli(67kg/1cm。较高的辊隙压力将会导致形成产生一个薄的垫块式的结构，反而影响无纺材料10的柔软特性。
在图示实施例中，在无纺叠层材料10的纤维层12和22被压制辊60和70压结以后，无纺材料10被卷在一个卷绕辊78上。另外，最好设计这种装置与制造最终产品的生产线联起来。在卷绕辊78或生产线的较高的拉紧力是另一因素，即可能对本发明的无纺材料10的高度起反作用。
图4表示的是使用本发明的无纺材料80的一次性尿布100的剖面图，无纺材料位于能与婴儿身体相紧挨的尿布的一侧。在所示实施例中，无纺材料80形成面向人体的外层12，外层12包括一个由聚丙烯纤维形成的结合梳理网状物和一个内＂吸收＂层22，层22包括由上述的聚丙烯和聚酯纤维混合物制成的基本上非结合或非结合的梳理网状物。尿布还包括一个能渗透液体的身体侧衬料82和一个吸收核心层84，例如是象由亲水性木纤维木浆制成的绒毛和高吸收性凝胶颗粒(例如高吸收性物质)混合而成。一个至少环绕着一部分吸收性核心层84的织物层92，和一个例如是聚乙烯薄片的柔软的不渗液体的外层86。这里所用的＂超吸收性＂指的是不论天然或人造材料能吸收或胶化至少是它自身重量10倍的液体。
在所示实施例中，在衬料82的总面积基本上是与外层86的总面积一样大的同时，覆盖有衬料82的无纺材料80基本上是与吸收性核心层84的宽度一样宽。作为另一种选择，无纺材料80可以做得与外层86一样大。在其它的结构中，无纺材料80的宽度可以小于吸收性核心层84的最小宽度。在各种可选择的结构中，虽然中实施例中无纺材料80和外层86的长度是基本上相等的，但是无纺材料80的长度可以等于或小于外层86的长度。
正如在图4中更进一步表示的。无纺材料80设置在与衬料82的体侧表面相连接的二条任选的保护挡带88之间。已经有对保护挡带的合适结构和布置的描述，例如，K.Enloe在1987年11月3日被准的美国专利第4,704,116号上就有记载。它的内容在这里引作参考。
在吸收性制品中可选择使用的弹性元件90位于尿布100的每一个相邻的长边上弹性元件90的作用是对着穿戴者的双腿收紧和保持住尿布100的侧边缘。另外，弹性元件(未示出)也放在靠近尿布100的两端或一端，起一个弹性腰带的作用。
无纺材料80可以与体侧衬料82或外层86以一各实用的方式联结或结合。在这里所用的＂结合＂这一名词包括这样的结构，在其中，通过固定无纺材料80与衬料82相对的边缘和中部区使无纺材料80与身体侧衬料82直接地连接起来了。和另一种结构，在其中无纺材料80或直接与外层86固定在一起或通过将无纺材料80固定于中间元件，然后中间元件再固定于外层86。无纺材料80可以通过连接的方法(未示出)，例如粘接，声波粘结，热连接或其它本技术领域熟练技术人员公知的连接方法，与体侧衬料82或外层86直接固定起来。把这种连接方法用于尿布100的各部分的内部连接和装配是很显然的。公知的紧固方式(图中未表示)也可在所示的尿布的结构中选择使用。
图11b表示的是一次性尿布120的断面图，尿布中使用包括本发明的无纺材料128，位于尿布侧面的身体侧吸收层衬料146的上面。在此实施例中，无纺材料128包括一个加强层147和一个缓冲层149，加强层147包括一个由聚丙烯纤维形成的结合梳理网状物，缓冲层149包括一个由聚丙烯纤维和聚酯纤维混合制成的基本上非结合或非结合梳理网状物。在此实施例中，应妥善放置无纺材料128使缓冲层149与体侧衬料146的内表面(尿布侧)相邻，并使加强层147面向一次性尿布的内部吸收结构132，在下面会更进一步的描述。把缓冲层149放在邻近体侧衬料146的内表面以便改善用于液体的渗透性和易处理性有关的内部纤维孔尺寸的分布和排列。
更仔细地考虑一次性尿布120，参见图11a和11c，尿布120包括一个液体不可透过的背层或外表层130，它确定了一个前腰带区123，一个后腰带区125和一个与前后腰带区相连的中部岔口区131。比如象吸收核心层132一样的吸收性部件设置在外层130的上方，使得吸收性核心层132夹在无纺材料128和外层130之间。
在图示的实施例中，无纺材料128的缓冲层149的基本重量是大约34g/m2，并且是由40％ 3.0登尼尔的聚丙烯纤维和60％ 6.0登尼尔的聚酯纤维组成的。加强层147的基本重量是大约16.0g/m2，是由100％，3.0登尼尔的聚丙烯纤维组成的。应该认识到，被放在象尿布120这样的吸收性制品中的无纺材料128，基各个层的基本重量和密度的改变应主要基于能使使用性能得到改善，而较少的受到美观和比如柔软性这样的使使用者产生舒适感觉的特点的制约。在所示实施例中，因为无纺材料128是用于内部而不直接与使用者的身体相接触，所以，能用基本重量较低的材料并且缓冲层149不用做得很柔软。
图11a是展开的、非收缩状态(也就是除去了所有的弹性收缩元件)的尿布120的平面示意图。其与使用者相接触侧面向观看者。在所示的该实施例中，尿衬布120有一个宽度尺寸198，一个长度尺寸199，一个前腰带区123，一个后腰带区125和一个岔口131。腰带区包括尿衬布120的上部，当穿着时，此部分全部或部分地覆盖或围着穿着者的腰部或躯干的中下部。中部岔口区131位于腰带区123和125之间，并与二者相连，当穿着时，它包括的尿布120的那部分位于穿着者的双腿之间的部分。因此，岔口区是一个在尿布120或其它一次性吸收制品上经常发生循环液体波动的部件。
所示实施例中，尿布120有二个基本上是一样大的体侧衬料146和外层130，并且它们的长度和宽度都要比吸收性核心层132大。体侧衬料146在外层130上面并与之相连，因此确定了尿衬布120的边缘133。外部纵向延伸边137和横向延伸边缘122限定了尿布的边缘133。如图11b所示，侧边137可以是曲线的并且其轮廓与尿布上腿的开口相符。所示的底边122是直线的，但也可选择曲线。虽然在该实施例中所示的，由体侧衬料146和外表层130形成的边缘是基本对称的，但也可以使用合适的非对称形状。尿布120还具有横向中心线124和纵向中心线126。
体侧衬料146可以有不同形状。例如，体侧衬料146可以有一个与外表层130共同铺开并至少覆盖外表层中部一部分的宽度。另一种选择是，体侧衬料的宽度可以至少与岔口区的吸收核心层132的宽度一样。
体侧衬料146提供了一个面向身体的表面，即有顺从性的，柔软的，并且不刺激于穿着者的皮肤的表面。通常体侧衬料146用于把穿着者的皮肤与在吸收核心层中的液体隔开。体侧衬料146包括一种材料，即能渗透液体的多孔材料并且允许液体迅速地透过它的厚度。一个适用的体侧衬料146应是由宽范围的网状物材料制成，例如，多孔的或网状的泡沫，有孔的塑料薄片，人造纤维(例如，聚酯或聚丙烯纤维)，天然纤维(例如，木质或棉纤维)，或天然和人造纤维的混合物。
各种纺织或无纺纤维都可用于体侧衬料146。例如，体侧衬料可包括由聚烯烃纤维制的熔喷或纺粘网状物。身体侧衬料还可是一种天然和/或人造纤维的粘接梳理网状物。
体侧衬料146基本上可以由疏水性材料组成这种材料可选择性地用表面活化剂或其它方法处理，以得到一个理想的吸湿性和亲水性的性能。例如，体侧衬料146可包括由一个由聚丙烯制成的无纺纺粘网状物。这个网状物可以由2～5登尼尔的纤维组成，基本重量为大约17～51g/m2，密度为大约0.032～0.43g/cc。体侧衬料146也可以包括大约0.11～0.43重量百分比的合适的表面活化剂，例如用Rohm&HaQs，公司的Triton X-102表面活化剂，该公司在宾西法尼亚州的费城市有办事机构。
在所示实施例中，尿布120包括一个基本上与外表层130的总面积一样大的身体侧衬料146，它是由一个无纺，可吸湿的聚丙烯纺粘网状物组成的。这个网状物的基本重量大约为0.7oz/yd2(大约24g/m2)。在此实施例中，至少在网状物的岔口区内，体侧衬料还包括多个小孔，它延伸通过整个衬料材料的厚度。
在该实施例中，沿着挡带的固定边164，保护挡带162连接于体侧衬料146的体侧表面。(见美国专利第4706116说明了合适的结构和布置)。每个保护挡带162上的可动边166包括一带弹性件168，它包括一条或多条专用的弹性塑料材料的绳。例如，弹性绳可以是分开的，一般是平行的排列。弹性元件192以一种弹性收缩的形式与保护挡带162的可动边166相连接，这种收缩造成保护挡带的边收集和缩短，使每个保护挡带的可动边达到它自己的位置，这是一个挡带从身体侧衬料146上离开并保持向上的位置。制造保护挡带的材料可以与身体侧衬料146的相同，也可以不同，对液体可以是渗透性的，也可以是非渗透性的。例如，在所示实例的尿布120中，保护挡带162可以由对液体渗透或非渗透的纺粘－熔喷－纺粘纤维无纺叠层材料制成，这种材料在BrocR等人，申请的美国专利第4041203号中描述，在这里引作参考。
外表层130由基本上不渗水材料组成的，并且典型的是由一个塑料薄片或其它不渗透液体的软材料制成的。在这里所用的术语＂柔软的＂指的是具有柔顺性，能容易的与使用者的身体和轮廓相符合的材料。外表层130能使在吸收核心层132中的排泄物与和尿衬布120相接触的象床单和罩布这样的吸湿物隔离开。例如，外表层130可以是厚度在大约0.012mm(0.5mil)与0.051mm(2.0mils)之间的聚乙烯薄片。由于成本的限制和强度的需要，典型的聚乙烯薄片的厚度在大约1.0mil至大约1.25mils之间。外表层的另一种结构可以一种纺织或无纺纤维网状物，这种网状被制成或处理成能具有理想的对液体不可渗透性。
一种外表层30的合适的材料包括一种聚合物薄片，这种材料可以用位于New Jersey的South Plainfield的Edison塑料公司的聚乙烯薄片。聚合物外表层也可以进行压花和/或打毛处理以得到一个更美的外观
外表层130也可选择能透过蒸气或气体的、＂可吸入的＂材料组成，这种材料应允许来自吸收生核心层132的蒸汽和气体通过并防止液体渗过外表层130。例如，外表层130可包括具有微孔的聚合物薄片或一个经过涂层或其它处理的无纺纤维。这可得到一个理想的对液体的不渗透性和对蒸汽或气体的可渗透性的相结合的效果。
外表层130的形状和尺寸由吸收性核心层132的尺寸和轮廓以及所选择的具有吸收性制品的特殊设计形式决定。例如，外表层130可以是普通的T型，I型或改进的水漏型，并且可以以一个选定的距离伸出在吸收性核心层132的底边外面，这个距离可以是1.3cm到2.5cm(0.5到1.0英寸)。
这里所描述的，体侧衬料146与外表层130是以一种实用的方式连结或其它的结合方式连在一起。用连接的方法(图中未表示)，体侧衬料146与外表层130可在尿布边缘133处被相互直接固定，所说的连接方式例如是粘接，超声波粘接，热结合或其它本技术领域公知的连接方法。例如，一个均匀连续的粘接层，一个有图案的粘接层，或一列分开的线和盘绕式点状的粘接结构都可用于把体侧衬料146固定于外表层130。另外，上述的连接方法可用于尿衬布的其他部件的相互连接和装配。
比如象胶带接头紧固件136这样紧固方法，用在尿布120的后腰带区125给使用者提供一个固定尿布的装置。图中所示的是向内折叠收紧位置的带接头紧固件136，可以从那些任何公知技术的中得到，并且象在图11a和11c那样安置在尿布的角上。紧固带装置的结构应能重复收紧，并且可包括一个或多个辅助的接缝区搭板(图中设有表示)。象聚丙烯薄片这样的带接缝区材料应有一个压纹表面，而且既能与外表层的内表面也能与其外表面相连接。例如，可以参见Pazdernik申请的美国专利4753649和Woon等人申请的美国专利4296750号。另外，除粘接和其它方法外，象用带子，钩环紧固件，伞形和环紧固件，按扣，插头，或卡子等机械紧固件也可以使用，这些紧固件也可以与粘结和其它方法结合在一起使用。在一个吸收性制品中不使用紧固装置也是可能的。
如果在一个特定的制品中有弹性元件134和135的话，它们可以位于邻近尿布120的边缘133上。沿着纵向侧边137，放置的弹性元件196可向使用者的腿部收拉尿衬布120的侧边。另外，也可以将弹性元件135放置在尿布120的一个或二个底边122上，能起到一个对腰部收紧作用。在常用的尿布中典型地使用弹性线制成的腿部和腰部收拢结构，以减少由于普通吸收性结构和材料的不合适而造成的漏出。相应地，本发明的吸收性制品能被方便地成形以减少对为保持液体为目的设计的弹性线收拢结构的依赖。
弹性元件134和135是以一种弹性收缩的形式固定在尿布120中的，这样，如图11c所示，在正常的情况下，处于拉紧状态，弹性元件会有效地反方向收缩并使尿布120的一部分收拢起来。在弹性收缩的情况下，至少有二种方法可以固定弹性元件；例如，当尿布120是在不收缩的条件下，弹性元件可以拉伸并固定。另一个方法是，尿布120可以收缩例如，通过打褶把弹性元件固定并与尿布120相连接，同时弹性元件在不放松或不拉伸的状况下。还有其他可用于尿布收拢的方法，例如，热收缩弹性材料或拉伸结合的无纺纤维叠层材料，如在美国专利第4720415号描述的。上述的专利引用结合于本发明中。
在该实施例所示，弹性元件134的延伸长度可以与尿布120的岔口区131的长度基本相同。另外，弹性元件134可伸展到尿布120的整个长度。或延伸到适合于弹性收缩线排列的其它长度，以满足特定尿衬布或其他吸水性制品的设计要求。
弹性元件134可以是多种形状中的任一种。例如，各个弹性元件的宽度可以0.25mm(0.01inch)到25mm(1.0inch)或更大。弹性元件134可包括单条弹性材料或包括几条平行或不平行的弹性材料。所用的弹性元件134可以以直线或曲线的。弹性元件134可用公知技术中的任一种方法固定在尿布上。例如，可用超声波粘合、加热封接和压力封接，可使用各种结合图案压接或粘接等方法把弹性材料134与尿衬布120结合起来。
在该实施例中，腿弹性元件134有一个载有一组有多个单体分开的弹性带的载体层。例如，载体层可包括一条0.75mi厚的聚丙烯薄片，并且弹性条可包括例如是DuPont公司出口的LYCra的弹性纤维，该公司在Wilmington，DE有办事机构。在该实施例中，虽然较大或较小厚度的弹性带也可以使用，但每个弹性带厚为大约940decitex。每个弹性条应隔开大约2～4mm并且能用任何公知方法例如，盘绕型式的热熔化粘接与载体层相连。
为形成各种想得到的尿衬布120造形，吸收核心层132一般被放置在与外表层130相邻处。吸收核心层一般是可压缩的，相吻合的，无刺激于穿着者的皮肤，而且能吸收和保持由身体排泄液体。为实现本发明的目的，吸收性核心层可包括一块单层完整的材料，也可以包括多个分开的材料层。
吸收性核心层132可以被制成各种尺寸和形状(例如，长方形，梯形，T形，I形，水漏形等)并且可使用各种材料制造。吸收核心层132的尺寸和吸收能力应与预定使用者的大小和准备用的吸性制品吸收的液体量相适应。此外，吸收性核心层132的尺寸和吸收能力可根据使用者是从婴儿到成人的不同而改变。另外，从本发明可以了解到，吸收性核心层132的密度和/或基本重量以及它们的相对比率都可以改变。
各种形式的吸湿性系水性纤维材料都可用在吸收性核心层132的组成部分中。合适的纤维的例子包括有固有吸湿性材料的天然存在的有机纤维，例如纤维质纤维，由纤维素或纤维素派生物组成的人合成纤维，例如人造丝纤维；有固有湿性材料的无机纤维，例如玻璃纤维由有固有吸湿热塑材料制成的合成纤维，例如特定的聚酯或聚酰胺纤维；由有非吸湿性热塑聚合物制成的合成纤维，例如聚丙烯纤维；通过合适的方法已变成亲水性的。非吸湿性纤维可以变为亲水性的，举例来说，可用硅进行处理的方法，可用具有半亲水性并且不易从纤维中除去的材料的处理方法，或在形成纤维的过程中或之后，在非吸湿性疏水性纤维上涂上亲水性聚合物的处理方法。为了本发明的目的，也可以考虑使用上面提到的各种纤维的混合物。
这里所用的＂亲水性＂这一术语指的是纤维或纤维的表面可被与纤维相接触的含水液体沾湿。材料的润湿程度可依次用接触角、液体的表面张力和所用材料等术语描述。适于测量特定纤维或纤维混合物的润湿度的设备和技术可由Cahn SFA－222表面张力分析系统提供。当用此系统并根据下面详细描述的过程测量时，具有接触角小于90°的纤维可称为＂可吸湿的＂，而具有接触角大于90°的纤维可称为＂非吸湿的＂。
普遍认为是有＂超吸收性＂的合适的吸收性胶凝化材料可以是象硅胶这样的无机材料或象交胶的聚合物这样的有机组合物。交联可通过共价、离子，范德瓦耳斯或氢键结合方法得到。吸收性凝胶聚合物材料的例子可包括聚丙烯酰胺、聚乙烯醇、乙烯顺丁烯二酐共聚物、聚乙烯酯、羟丙基纤维素，羧甲基纤维素，聚乙烯吗啉酮，乙烯磺酸的聚合物和共聚物，聚丙烯酸酯，聚丙烯酰胺，聚乙烯吡咯烷酮和类似的。其它的适合于用在吸收核心层的聚合物包括水解的丙烯腈接枝淀粉，丙烯酸接枝淀粉聚丙烯酸酯和异异丁烯马来酐共聚物或它们的混合物。其它适用的水凝胶构成的聚合物，在由阿萨森等人申请的美国专利第3902236号中描述。制备水凝胶构成的聚合物的方法在Masyda等人申请的美国专利第4076663号和Tsubakimoto等人申请的美国专利第4286082号中描述。
吸收性凝化材料一般是离散的颗粒形式的。这种颗粒可具有任何想要的形状。平均尺寸在大约20μm到大约1mm的颗粒都可有利地使用。在这里使用的＂颗粒尺寸＂指的是单个颗粒的最小尺寸的加权平均值。
能大批供应的适用的超吸收凝胶化材料的实例包括由DOW化学公司销售的DOW535；Hoechst Celanese公司销售的SANWET IM5000P；和Stockhausen销售的FAVOR SAB835,836或870。
吸收性信心层132包括一个至少能部分包住核心层的包裹层。包裹层可包括例如，亲水性高湿强度的包层网状物，例如包裹层可耐湿高强度织物或合成纤维，并且能有助于减少从吸收性核心层132来的吸收性凝胶化材料的移动。这种包裹网状物也能增加吸收性核心层的使用完整性。这种网状物能粘结于吸收性制品的吸收性核心层和其它部件。
无纺材料128能具有任何的要求的形状，它符合于保持液体和吸收性核心层132的吸收的需要。例如，适用的形状包括园形，长方形，三角形，梯形，长椭园形，狗骨形(dog-boned)，水漏形或椭园形。无纺材料128应优先设计成能使在无纺材料与吸收性核心层之间接触的液体通过表面积达到最大。例如，在所示实施例的尿布120中，无纺材料128是长方形的具有顶部表面积从大约240到56.0in2(大约154.8到361.2cm2)。
无纺材料128应有一个实用的密度和基本重量值，使之能迅速地收集和临时地抑制液体波动，并且能把液体从初始进入点迅速地传送到尿衬布120的吸收性核心层。这种结构能有助于防止液体在体侧衬料146上形成水塘和集结，因此能减少使用者的潮湿感。
无纺材料128可沿吸收性核心层132和尿衬布120的全长设置。除此之外，无纺材料128可有利地沿尿布长度的一部分或沿吸收性核心层132的一部分长度上延伸。同样地，无纺材料128可沿尿衬布的一部分宽度上或吸收性核心层的一部分宽度上延伸。例如，无纺材料128可比吸收性核心层132短至大约4.0英寸，并且横向对中在尿布的前面部分，但要向尿衬布的前腰部偏移，偏移的位置是使无纺材料128的前边比吸收性核心层132的前边向尿衬布的横向中心线靠近大约0.5英寸到大约1.5英寸。
考虑到是一次性吸收性制品，不笨重或低成本是重要的，可有利地使用不覆盖吸收性制品的整个形状的无纺材料128。倒不如说，无纺材料可被切开，并仅放在使用者的外阴部。
无纺材料128的缓冲层149被放在液体通过接触的体侧衬料146内。无纺材料可通过已知的连接方法与体侧衬料146连结或结合，例如，可应用沿着体侧衬料146的内(尿衬布)侧的全长和/或衬对体侧守料146的缓冲层149的表面，使用粘接盘绕线的连接方法。用于无纺材料128和体侧衬料146的结合方法应考虑到能保持无纺材料128的大小，高度或垫块状特性。例如，有大约在0.5到0.75 inch总宽的粘接盘绕线仅应用在沿无纺材料128的长度延伸的缓冲层149的侧边上，不能沿着缓冲层149的末端或中心部位不粘接上，以保持无纺材料128所需要的厚度，以达到要完成的功能。
应该考虑到，根据本发明制成的无纺材料128，在实际应用时裁剪和调整以提供所要求的各种性能。例如，适度的小便失禁和月经与婴儿的排尿有不同的排出速率、体积和时间。此外，在波动状态的液体可根据液体的粘度、表面张力、温度和其它物理特性而改变，所说的波动能影响各种现行的产品使用中的纤维的性能。
尿布120中的无纺材料128含有弹性纤维结构。无纺材料在载荷下应处于足够的松疏状态以在材料中保持空隙，在吸湿的情况下抗塌陷，以更好地排出液体和更好地允许材料解吸，并在浸湿后可重新使用以保持对其后的吸收作用的空隙体积容量。无纺材料128的耐压缩特性能实现对多种污物疏体的储存。无纺材料128的绗缝结构，在使用时还能使空气流通。
虽然在图4和11a～c中表示了尿布100和120组成部分的特定结构，但这些部分也可装配成各种公知的尿布结构。可以更进一步地看到，除尿布外一次性吸收性制品根据它们的最终用途，可以选择各个部件。
任何体侧衬料一个重要的特性是它的柔软性。特别地，对于衬料来说，考虑到对婴儿的舒适性，衬料具有在接触上感到非常柔顺和柔软是重要的。本发明已观察到，由本发明的无纺材料80制成的面向身体层12具有优异的柔软特性。
一般无纺衬料和无纺纤维的另一个重要特性是拉伸强度，即，耐撕裂和撕裂之前的。这些特性已由本发明人在一种比如是Instron Model TM 1000(Instron公司在迈阿密州的Canton有办事机构)的装置上测量过，过程是，用一对夹子在整个宽度上夹住一条无纺纤维样品(大约1×6in.(25.4×1524mm))，然后，以一个恒定的延伸长率拉开夹子。拉断纤维所需的力被记录为拉伸强度，并且断裂前纤维长度与长的比值为延伸率。完成这样的试验，或者夹子的纤维取向以使所用的力是机器方向(MD)的，或者用纤维取向以使所用的力在横向上(CD)。可以看到，在下面几个讨论的例子中，本发明的无纺材料表现出了足够的拉伸强度和延伸率特性。
对于象一次性尿布这样的吸收性制品的衬料，还有另一个特别重要的特性是衬料的可湿润性。根据吸收性制品的设计，为使液体方便地通过布到达吸收性核心层，通常希望使衬料保持部分地可湿润性。另外，更希望在衬料中有一个可湿润能力梯度，这样能使液体从穿着者一侧吸走以达到增加舒适性和保护皮肤健康的目的。特别是，象在本发明中一样，希望能有一个比缓冲层22不易湿的面向体侧层12，即，这个缓冲层是与吸收性材料靠得最近的层。在这种情况下，液体流到吸收性核心层材料上比它流回到穿着者的皮肤上更容易。
许多适合于制作无纺网状物的聚合物是疏水性的。特别是，聚烯烃纤维是完全疏水性的。结果，这是理想的，用这些聚合物制作无纺网状物提供一个合适的吸湿性和亲水性程度。从现有技术中了解到，象聚丙烯这样的疏水性纤维的吸湿性，能应用水溶性表面涂层而得到提高，典型地从大约0.3％到大约0.6％涂于这种疏水性纤维表面，以使在最终应用时改善这种纤维对液体的易处理特性。在这里描述的实施例中，在形成无纺层12和22之前，通过用水溶性表面涂层处理纤维，可使使用的聚丙烯纤维变成可吸湿性的。
另一个对形成所述的吸湿梯度的影响因素是，在形成底层无纺层22时，使聚丙烯纤维和合适数量的聚酯纤维混合。如上所述，在无纺层22中，用在聚丙烯和聚酯纤维的均匀混合物中的较粗糙和更具弹性的聚酯纤维可导致不同尺寸的孔，在顶层12和底层22之间形成所需的吸湿梯度。
下面提供的实施例可以对本发明有更详细的理解。其特定的组成，比例，材料和参数都是一种举例，并不对本发明的范围作特别的限制。
                      实施例1
通过在如上所述的普通梳理机上混合，可形成由100％聚丙烯(由Hercules制造的PP－196，该公司在Wilmington，DE有办不机构)组成的顶层。顶层的基本重量为大约18g/m2(0.5Oz/yd2)。通过在一台普通的梳理机上混合，可形成由60％聚酯(由Sam yang制造的SD－10，在南朝鲜的汉城有办事机构)和40％PP－196聚丙烯形成底层。底层的基本重量大约为32g/m2(0.9Oz/yd2)。通过如图3和3a所示的热压接辊，顶层和底层被热压接在一起，与顶层接触的压接辊的温度保持在大约272°F(133℃)，与底层接触的压接辊的温度保持在大约315°F(157℃)。压接辊的线速度大约在80f/min(24m/min)，在压接辊之间的辊隙压力大约为300Pli。这种热结合过程形成了无纺叠层材料，在结合区内它具有带孔的间隔的结合图形，并且结合区百分比大约为2％。
                       实施例2
通过在如上所述的普通梳理机混合，可形成一个由100％PP－196聚丙烯的顶层。顶层的基本重量大约为18g/m2(0.5oz/yd2)。通过在普通梳现机上混合，可形成由60％聚酯(PET－295，由Hoechst Celanese制造，在Greenville，SC有办事机构)和40％PP196聚丙烯组成的底层。底层的基本重量大约为32g/m2(0.9oz/yd2)。通过如图3和3a的热压接辊，可把顶层和底层热压接在一起，与顶层相接触的压接辊温度保持在大约272°F(133℃)，与底层相接触的压接辊温度保持在大约315° F(157℃)。压接辊的线速度大约为80ft/min(24m/min)，压接辊间辊隙压力大约为300Pli。这种热结合过程形成无纺叠层材料，在结合区内它具有带孔的间隔结合图形，并且结合区百分比大约为2％。
                   实施例3
顶层是由100％聚丙烯纤维(由Lohmann.GmbH&CO.KG供应的PT110－20，在Neuwide，Germany有办事机构)组成。顶层的基本重量为大约20g/m2(0.5oz/yd2)。通过在如上所述的普通梳理上混合，可形成由60％聚酯(由在Frankfurt，Germany有办事机构的Hoechst/AG制造的PET－292)和40％聚丙烯(由在Varde，Denmark有办事机构的Danaklon A/S制造的PP－71＂SOFT－71＂)组成的底层。底层的基本重量为32g/m2(0.9oz/yd2)。通过如图3和3a所示的压接辊可把顶层和底层热压接在一起，与顶层相接触的压接辊的温度保持在大约272°F(133℃)，与底层相接触的压接辊的温度保持在大约315°F(157℃)。压接辊的线速度大约为80ft/min(24m/nin)，压接辊之间的辊隙压力大约为300Pli。这种热结合过程形成无纺叠层材料，在结合区内具有带小孔的间隔结合图形，并且结合区百分比大约为2％。
                  实施例4
用普通的纺粘成形法，可形成由100％PP－71聚丙烯纤维组成的顶层。顶层的基本重量大约为22g/m2(0.6oz/yd2)。通过在台普通的梳理机上混合，可形成由60％聚酯PET－292和40％PP－71聚丙烯组成的底层。底层的基本重量为大约32g/m2(0.9oz/yd2)。通过如在图3和3a所示的热压辊，可使顶层与底层被热压接在一起与顶层相接触的压接辊的温度保持在大约272°F(133℃)，与底层相接触的压接辊的温度保持在大约315°F(157℃)。压接辊的线速度大约为80ft/min(24m/min)，压接辊之间的辊隙压力大约为300Pli。这种热结合过程形成无纺叠层材料，在结合区内具有带小孔的间隔结合图形，并且结合区百分比大约为2％。
                   实施例5
通过一台如上所述的普通梳理机上混合，可形成由100％聚丙烯(75％PP－196和25％PP－190，由在Wilmington，DE有办事机构的Hercules，Inc制造)组成的顶层。顶层的基本重量大约为18g/m2(0.5oz/yd2)。用一台普通梳理机上混合可形成由60％PET－292聚酯和40％PP－71聚丙烯组成的底层。底层的基本重量大约为32g/m2(0.9oz/yd2)。用如图3和3a所示的热压接辊，可使顶层和底层热压结合在一起，与顶层相接触的热压接辊的温度保持在大约272°F(133℃)，与底层相接触的热压接辊的温度保持在大约315°F(157℃)。压接辊的线速度大允为80ft/min(24m/min)，在压接辊之间的辊隙压力大约为300Pli。这种热压接过程可产生无纺叠层材料，在结合区内具有带小孔的间隙结合图形，并且结合区百分比大约为2％。
                 实施例6
通过在一台如上所述的普通梳理机上混合，可制成由100％PP－196聚丙烯组成的顶层。顶层的基本重量大约为18g/m2(0.5oz/yd2)。通过在一台普通梳理机上混合，可制成由60％PET－295聚酯和40％PP－196聚丙烯组成的底层。底层的基本重量大约为32g/m2(0.9oz/yd2)。用如图3和3a的热压接辊可把顶层和底层热压结合在一起，与顶层相接触的热压接辊的温度保持在大约272°F(133℃)，与底层相接触的压接辊的温度保持在大约315°F(157℃)。压接辊的线速度大约为80ft/min(24m/min)，压接辊间的辊隙压力大约为300Pli。这种热压接过程能形成无纺叠材料，在结合区内具有带小孔的间隔结合图形，并且结合区百分比大约为2％。
上面的合成的无纺叠层材料的例子具有在下面表格表明的特性：                     表I
    基本重量实施例    (g/m2)   厚度(in.)    密度(g/cc)    张力(g/in1)   延伸率(％)Example    Basis     Thick-                    Tensile           ％
       Weight    ness        Density       (g/in.)     Elongation
       (g/m2)   (in.)       (g/cc)          MD        CD      MD1        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
为得到此表内的结果，可用以下的试验过程确定本发明的无纺材料10的特定参数。所设计的液体吸收和回流评价(FIFE)试验可测量在一次性吸收性制品中衬料的吸收/透过时间，回流数量和液体滞留数量。可用一个秒表测量吸收/透过时间(以秒计算)，并且目测决定吸收模拟的尿排泄物所用的时间。在吸收性制品吸收了有压力的三种液体污物中的每一种之后，回流试验可测量从制品的面向＂使用者侧＂渗出的液体数量(以克计算)。
如图7和8所示的装置可用于此试验。如图4和图7中虚线部分102所示的一个用于试验的尿衬布样品，其重量精确为0.1g。样品102要做如下准备，沿着它们的长度，剪裁腿部和腰位的弹性元件和保护挡带(图中没有表示)以使样品能放平。样品102的尺寸，重量和密度分布和吸收性核心层的组成都应被适当的控制以得到有效的结果。这里获得的报告的数据是，从含有无纺材料10的12in×12in(305mm，×305mm)方形样品中得到的，所述的无纺材料在上述实施例4，5和6中描述。并且吸收性核心层包含有大约10克木浆绒毛和大约12克象D0W DRYTECH 835或相类似物这样的超吸收性材料。
样品102被放平并在一个880g力下压平。圆柱平板组件104能使有5.1cm内径的圆筒形体106对准预定的位置108。例如，由被测吸收性制品的尺寸[即小(s)，中(m)，大(1)或超大(xl)]，预定位置108到样品102边缘的范围在从大约4 1/2inehes(114.3mm)到大约5 3/4(nches(146.1mm)。在样品102下面是一个隆起的平台110，其尺寸为1/2inch(12.7mm)高(d)×6inches(152.4mm)长(e)×3inches(76.2mm)宽(f)。在圆柱平板组件104下，圆筒形106也伸出大约1/32inch(0.8mm)的距离(g)。
在园柱106顶部的漏斗112是垂直于样品102，并且与预定位置108对中。可从漏斗112中倒入特定数量的人造尿液(例如，分别对应于小，中，大或超大尿衬布的50ml，80ml或100m1)。(例如，可以在Appleton，WI有办事机构的PPG工业公司得到适用的人造尿液，产品为K－C399105)。可用秒表测量在液体开始与样品102接触时和在样品102表面不再看到液体之间的所经过时间。在吸入首次液体污物1分钟之后，第二次同样量的污物也被倒入。象对第一次污物那样也要测量吸入第二次污物的时间。
参见图9和10，在吸入第二次污物1分钟之后，样品102被放置在一个真空设备114内，并被盖上一张有不可渗透液体的乳胶层118的吸湿纸116。然后用35000dyne/cm2(大约0.5psi)的真空压力吸住在吸湿纸116上的不可渗乳胶层118和样品102，时间为二分钟。在压力解除以后，对湿的吸湿纸116进行称重。吸湿纸116增加的重量(以克计算)代表了回流量。
在从样品102上解除压力一分钟内，加入第三次液体污物象上述那样计时。为描述进入样品102的液体数量(这里所描述的是80ml的试验结果)吸入液体的时间是以多少秒来记录的。
下列表中表明了在上面实施例4，5和6中的无纺叠层材料的回流值和吸收液体时间。
                    表II实施例    FIFE液体吸收时间(秒)    FIFE回流量(克)Example    FIFE Liquid              FIFE
       Intake Time            FlowbacK
        (seconds)              (grams)4           33                    7.15           34                    1.96           30                    3.2
虽然在上面表示了对几个特定实例进行液体吸收和回流评价测试的结果，但是，由在这里所述的无纺材料10组成的吸收性制品的液体吸收时间可从大约11秒变化到大约38，秒并且回流值可从大约1.0克变化到大约9.0克。
可以认为，根据本发明制成的无纺材料10本领域普通技术人员很容易进行裁剪和调整以适应实际使用中的各种性能需要。例如，适度的小便失禁和月经与婴儿的排尿有着不同的排放速率、体积和次数。另外，在缓冲层上的液体会根据液体的粘度、表面张力、温度和其它物理特性而改变，这些特性会影响在各种应用产品中的无纺材料10的性能。因此，虽然本发明是参照上面所述的各种实施例和具体情况进行描述的，但可以理解本发明可以作进一步的改进。因此，根据本发明的总的原则，其应用应包括任何对本发明的变形用途或修改，而且包括那些偏离本说明书的，本技术领域的公知和常规的技术，上述这些均附属于本发明，并落入后面所附权利要求书所限定的范围内。

Claims (31)

1.一种叠层纤维材料包括：
一个由有一种或多种热塑聚合材料的多元性纤维组成的顶层纤维层；
一个由有二种或多种热塑聚合材料的多元性纤维组成的底层维维层；
所述顶层和底层以一种隔开的结合图案结合在一起，所说的图案包括许多单个的压实结合区，在它们之间具有在轻微结合的纤维间隔着；
所述结合区中形成有小孔。
2.如权利要求1中所述的叠层纤维材料，其特征在于：所述顶层和底两层都包括有无纺网状物。
3.如权利要求2中所述的叠层纤维材料，其特征在于：顶和底两层中至少有一层包括一种纺粘网状物。
4.如权利要求2中所述的叠层纤维材料，其特征在于，所述顶层纤维层的纤维是互相连接在一起的。
5.如权利要求2中所述的叠层纤维材料，其特征在于：顶、底两纤维层是被热结合在一起的。
6.如权利要求2所述的叠层纤维材料，其特征在于：结合区占这种材料表面积的大约1.0％到大约6.0％。
7.如权利要求2所述的叠层纤维材料，其特征在于：结合区占这种材料表面积的大约2.0％到大约4.0％。
8.如权利要求2所述的叠层纤维材料，其特征在于：所述顶层包括选自一组含有聚烯烃的一种或多种热塑聚合物材料组成，底层包括选自一组含有聚烯烃和聚酯的两种或多种热塑聚合物材料的混合物。
9.如权利要求8所述的叠层纤维材料，其特征在于：所述顶层包括聚丙烯和所述底层包括一种聚丙烯种聚酯的混合物。
10.如权利要求9所述的叠层纤维材料，其特征在于：所述顶层包括大约100％的聚丙烯和所述底层包括变化范围在从大约70％的聚丙烯和30％的聚酯到大约25％聚丙烯和大约75％的聚酯。
11.如权利要求9所述的叠层纤维材料，其特征在于：所述顶层包括大约100％的聚丙烯和所述底层包括大约40％聚丙烯和大约60％的聚酯。
12.如权利要求2所述的叠层纤维物，其特征在于：所述顶层纤维的密度比底层纤维大，这要在上述的顶底两层连接之前确定。
13.一种吸收性制品包括：
一透液性体侧衬料；
一不透液性外表面；
一在所述体侧衬料和所述外表面之间设置吸收性核心层；
一被靠近地置于至少一部分体侧衬料的叠层纤维材料；
所述叠层纤维材料包括一纤维顶层，它由一种或多种热塑聚合材料的多元性纤维组成；
纤维底层包括二种或多种热塑聚合物材料组成的多元性纤维；
所述的顶层和底层以一种隔开结合图案结合在一起的，所说的图案包括许多单个的压实结合区，在它们之间具有轻微结合的纤维间隔着；
在所述结合区中有小孔形成。
14.一种吸收性制品包括：
一透液性体侧衬料；
一不透水性外表面层；
一靠近地置于至少一部分体侧衬料的叠层纤维材料；
所述叠层材料包括纤维顶层，它由一种或多种热塑聚合物材料的多元性纤维组成；
一底层纤维层包括两种或多种热塑聚合物的多元性纤维；
所述的顶层和底层以一种隔开结合图案结合在一起的，所说的图案包括许多单个的压实结合区，在它们之间具有轻微结合的纤维间隔着；
在所述结合区中有小孔形成；并且一个吸收性核心层位于所叠层纤维材料和外表层之间。
15.如权利要求13或14所述的吸收性制品，其特征在于；所述纤维顶层包括大约100％的聚丙烯和所述纤维底层包括变化范围从大约70％的聚丙烯和大约30％的聚酯至大约25％的聚丙烯和大约75％的聚酯。
16.如权利要求13或14所述的吸收性制品，其特征在于：所述顶层包括一个基基本重量在大约16～28g/m2变化的结合的梳理网状物，并且是由变化范围在1.0～3.0登尼尔的聚丙烯纤维组成，所述底层包括一个其基本重量在大约24～35g/m2变化的结合的梳理网状物，并且是由变化范围在1.0～3.0登尼尔的聚丙烯纤维和变化范围在3.0～9.0登尼尔的聚酯纤维混合的组成。
17.如权利要求14所述的吸收性制品，其特征在于：所述无纺叠层材料的长度小于所述外表层的长度，其宽度小于所述外表层的宽度。
18.如权利要求14所述的吸收性制品，其特征在于：所述无纺叠层材料的长度小于所述吸收性核心层的长度。
19.一种制造叠层纤维材料的方法，包括下列步骤：
a，制成一个具有由一种或多种热塑聚合物材料组成的多元性纤维的纤维顶层；
b，制成一个具有由二种或多种热塑聚合物材料组成的多元性纤维的纤维底层；
c，顶层和底层以一种隔开的结合图案结合在一起，所说的图案包括许多单个的压实结合区，在它们之间具有轻微结合的纤维间隔着；
d，在连接区中形成小孔。
20.如权利要求15所述的制造方法，其特征在于：在顶层成形之后，所述成形步骤b包括一个把所述底层纤维放置在所述顶层之上的步骤。
21.如权利要求15所述的制造方法，其特征在于：所述成形步骤a包括所述顶层的所述纤维的相互结合。
22.如权利要求15所述的制造方法，其特征在于：所述结合步骤c包括热压接。
23.如权利要求18所述的制造方法，其特征在于：所述结合步骤c包括一个在其外表面上具有间隔的凸起结合图案的顶层压接辊和一个在其外表面有多个凸起的结合点的底层压接辊。
24.如权利要求15所述的制造方法，其特征在于：所述的顶层和底层都包括有无纺网状物。
25.如权利要求15所述的制造方法，其特征在于：在所述的顶层和底层之中，至少其中一层包括纺粘网状物。
26.如权利要求15所述的制造方法，其特征在于：一个由选自一组聚烯烃的一种或多种热塑聚合物材料组成的所述顶层和一个由选自一组聚烯烃和聚酯的两种或多种热塑聚合物材料组成的所述底层。
27.一种用于制作叠层纤维材料的设备包括：
用于形成顶层纤维层的装置，所说的顶层纤维层包括一种或多种热塑聚合物材料组成的多元性纤维；
用于形成底层纤维层的装置，所说的底层纤维层包括二种或多种热塑聚合物材料组成的多元性纤维；
用于把顶层和底层以一种隔开的结合图案结合一起的结合装置，所说的图案包括许多单个的压实结合区，在它们之间具有轻微结合的纤维间隔着；
用于在结合区内形成小孔的装置。
28.一种用于制作按权利要求23所述方法形成的叠层纤维材料的设备，其特征在于：所述的结合装置包括一个在其外表面有隔开的凸起结合图案的顶层压接辊和一个在其外表面有多个凸起压接点的底层压接辊。
29.一种用于制作作按权利要求23所述的方法形成的叠层纤维材料的设备，其特征在于：还包括一种用于把所述顶层纤维层的纤维相互结合在一起的顶层结合装置。
30.一种用于制作按权利要求24所述的方法形成的制造叠层纤维材料的设备，其特征在于；它还包括：
用于加热所述的顶层和底层压接辊的其中至少一个辊的装置；
用于使所述底层压结辊旋转的装置。
31.一种用于制作按权利要求26所述方法形成的叠层纤维材料的设备，其特征在于，所述的顶层压结辊有一个顶层辊转速和所述的底层压结辊有一个底层辊转速，所述的顶层辊转速至少要比底层辊转速大4％。
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CN106273943A (zh) * 2015-06-29 2017-01-04 波音公司 复合夹层板和相关制造方法
US10543666B2 (en) 2015-06-29 2020-01-28 The Boeing Company Composite sandwich panel and associated methods of manufacture
CN106273943B (zh) * 2015-06-29 2020-10-13 波音公司 复合夹层板和相关制造方法
US11383503B2 (en) 2015-06-29 2022-07-12 The Boeing Company Composite sandwich panel and associated methods of manufacture
CN105434115A (zh) * 2015-12-30 2016-03-30 泉州市汉威机械制造有限公司 一种立体压点式吸收体
US11891737B2 (en) 2017-04-26 2024-02-06 Fitesa (China) Airlaid Company Limited Airlaid composite sheet material and method

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AU670825B2 (en) 1996-08-01
JPH08504136A (ja) 1996-05-07
DE69330814T2 (de) 2002-06-13
DE69330814T3 (de) 2009-04-09
DE69330181T2 (de) 2001-08-23
US5667625A (en) 1997-09-16
MX9306964A (es) 1995-01-31
KR940011689A (ko) 1994-06-21
ES2161216T3 (es) 2001-12-01
CA2148794A1 (en) 1994-05-26
AU5048893A (en) 1994-05-19
JPH071635A (ja) 1995-01-06
EP0667814B1 (en) 2001-04-25
EP0596191B2 (en) 2008-07-02
US5667619A (en) 1997-09-16
DE69330181T3 (de) 2004-11-11
DE69330181D1 (de) 2001-05-31
UY23667A1 (es) 1994-02-25
DE69330814D1 (de) 2001-10-31
EP0596191A1 (en) 1994-05-11
ZA937184B (en) 1994-06-25
BR9304478A (pt) 1994-05-17
MX9300424A (es) 1994-05-31
WO1994011186A1 (en) 1994-05-26
EP0667814A1 (en) 1995-08-23
EP0667814B2 (en) 2004-07-14
CA2088391A1 (en) 1994-05-07
CN1087578A (zh) 1994-06-08
AU5595394A (en) 1994-06-08
EP0596191B1 (en) 2001-09-26
CN1054805C (zh) 2000-07-26
KR100255573B1 (ko) 2000-05-01
ES2157972T3 (es) 2001-09-01

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