CN1253601A - 具有增强延展性的稳定网面及其制造方法 - Google Patents

具有增强延展性的稳定网面及其制造方法 Download PDF

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Publication number
CN1253601A
CN1253601A CN98804610A CN98804610A CN1253601A CN 1253601 A CN1253601 A CN 1253601A CN 98804610 A CN98804610 A CN 98804610A CN 98804610 A CN98804610 A CN 98804610A CN 1253601 A CN1253601 A CN 1253601A
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CN
China
Prior art keywords
nonwoven web
neckable
roller
wire side
face
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Pending
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CN98804610A
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English (en)
Inventor
道格拉斯·H·本森
约翰·J·柯罗
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Procter and Gamble Co
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Procter and Gamble Co
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Application filed by Procter and Gamble Co filed Critical Procter and Gamble Co
Publication of CN1253601A publication Critical patent/CN1253601A/zh
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Abstract

本发明提供了一种稳定的无纺网面及其制造方法,该无纺网面具有增强的延展性。可收缩无纺网面沿第一方向送进。可收缩无纺网面承受与第一方向相垂直方向上的增量展张。拉伸力施加于可收缩无纺网面以收缩无纺网面。然后,收缩无纺网面承受机械稳定化作用,制成稳定的可延展收缩无纺网面。稳定的可延展收缩无纺网面可以很容易地沿着与收缩方向相平行的方向延展。

Description

具有增强延展性的稳定 网面及其制造方法
                    发明的技术领域
本发明涉及一种具有增强延展性的稳定材料以及制造该材料的机械后加工方法。高延展性材料，例如无纺网面和薄膜网面，尤其适合用于诸如尿布、失禁短裤、训练裤、女性卫生衣物之类的一次性吸湿用品，原因在于该材料能够用于用品上需要高延展性来辅助适配身体的部位。
                    发明的背景技术
无纺网面可以低成本地制成用品及用品上的部件，在一次或几次使用后即可丢弃。典型产品包括尿布、训练裤、抹布、衣物、失禁短裤、女性卫生衣物等类似用品。
还可对无纺网面进行处理使其具有某些特性。例如，1993年9月14日授予Hassenboehler，Jr.等人的美国专利No.5,244,482揭示了一种处理无纺网面的方法。该方法中将无纺网面在一增高的温度下加热并单向拉伸以便固化和稳定无纺网面。这种无纺网面在加工后的特征呈现为增强的弹性。这种弹性增加被视为由于加热无纺网面而注入的新“记忆”所形成的。对于希望增强延展性而非弹性的用品则不需要类似的加热。另外，这种单向拉伸以及在增高温度下加热制成的无纺网面常常造成纤维脆化并且无纺网面显示更强的光泽。对于许多与皮肤接触的用品，例如尿布护层，上述特性就与人们所期望的柔软、无塑感(低光泽)等类似于布的特征相反。最后，为使无纺网面固化和稳定的加热过程增加了处理的复杂性和成本。
1991年1月1日授予Morman的美国专利No.4,981,747揭示了一种“可逆的”收缩材料。不稳定的收缩材料必须在高拉伸度的状态下缠绕在重卷辊上，直到执行加热处理步骤使材料稳定为止。这种材料将出现上述针对优选皮肤接触性用品列出的种种缺陷，而且增强的是材料的弹性而非延展性。
1993年6月13日授予Morman的美国专利No.5,226,992揭示了一种生产复合弹性收缩粘结材料的方法。拉伸力作用于至少一种可收缩材料。例如可收缩无纺网面，使材料收缩或固化。代之以加热已固化的无纺网面，该专利公布的方法是，当拉伸的固化无纺网面处于拉伸状态时，将拉伸的固化无纺网面叠加在弹性材料上并将其与弹性材料结合在一起。通过当拉伸的固化无纺网面处于拉伸状态时将其与弹性材料结合，无纺网面限制为其收缩的尺寸。对于生产稳定的可延展网面，且不将无纺网面附着于附加弹性层，该专利并未提供方法。
本发明的目的是提供一种稳定的可延展收缩无纺网面。它能够缠绕成辊轴状或结织(festooned)的形式，便于后序转换或组合应用。
本发明另一个目的是提供一种能够通过机械拉伸方式快速延展的稳定的可延展收缩无纺网面。
本发明再一个目的是为生产稳定的可延展收缩无纺网面提供一种后加工方法。
本发明又一个目的是为生产生产稳定的可延展收缩无纺网面提供一种后加工方法，该方法不要求加热可收缩材料到某一增高温度，提高可收缩无纺网面延展性而非弹性并基本保持其原始特性。
在此使用的术语“弹性”指的是任何在张力作用下可拉伸(即拉长)至少60％(即加以拉伸力的长度至少是其放松后未加力长度的1.6倍)，并且在释放拉伸力后拉伸量至少恢复55％的材料。
在此使用的术语“延展性”指的是任何在张力作用下至少可拉伸60％而不至严重失效(即拉伸后长度至少是其放松后未加力长度的1.6倍)，但在释放拉伸力后拉伸量恢复不到55％的材料。
在此使用的术语“高度延展性”指的是任何在张力作用下至少可拉伸100％而不至严重失效(即拉伸后长度至少是其放松后未加力长度的2倍)，但在释放拉伸力后拉伸量恢复不到55％的材料。
在此使用的术语“稳定”指的是能够以任意常规或惯用网面储放方式存放而不需要加热或附加结合物来使材料稳定的本发明中的材料。这类存放方式包括诸如低拉伸卷轴或结织于盒中的材料。
在此使用的术语“无纺网面”指的是具有以不规则方式交织的单独纤维或丝线结构的网面。过去，可以通过多种工艺可以制成无纺网面。例如熔喷工艺、纺粘工艺和粘结粗梳工艺。
在此使用的术语“收缩材料”指的是通过施加与希望收缩方向垂直的拉伸力使其在至少一个方向收缩的任何材料。
在此使用的术语“可收缩材料”指的是任何可被收缩的材料。
在此使用的术语“收缩百分比”指的是可收缩材料未收缩尺寸与稳定的收缩尺寸在收缩方向的差值除以未收缩尺寸并乘以100后所得的比率。
在此使用的术语“复合弹性材料”指的是包含了结合到稳定的可延展收缩材料中的弹性件的材料。弹性件既可以间断点的方式又可以连续粘结的方式结合到稳定可延展收缩材料中。结合是在弹性件与稳定的可延展收缩材料处于并置结构时完成的。复合弹性材料的弹性方向通常与稳定的可延展收缩材料的收缩方向平行，并可沿此方向拉伸到稳定的可延展收缩材料的断裂点。复合弹性材料可以包含多于两层的材料。
在此使用的术语“聚合物”通常包含但不限于诸如嵌段聚合物、接枝聚合物、不规则聚合物、交替共聚物、三元共聚物等的均聚物、共聚物。及其混合物和改性物质。而且，除非特别限定外，术语“聚合物”包括材料的所有可能的分子几何结构。这些结构包括均衡对称、间同对称以及不规则对称，但也不限于此。
在此使用的术语“表面路径长度”指的是沿该材料指定方向的外型表面测出的长度。
                        发明概述
本发明提供了一种制造稳定的可延展收缩无纺网面的方法，包括下列步骤：
提供可收缩无纺网面；
沿第一方向送进可收缩无纺网面；
使可收缩无纺网面在与第一方向垂直的方向上承受增量展张；
沿与第一方向平行的方向对可收缩无纺网面施加拉伸力，使其在与第一方向垂直的方向上收缩；
使收缩的无纺网面承受机械稳定化作用，以便获得稳定的可延展收缩无纺网面。
稳定的可延展收缩无纺网面在与第一方向相垂直的方向或与收缩方向平行的方向是能轻易伸展的。机械稳定化收缩无纺网面的优选方法包括使收缩无纺网面在与第一方向平行的方向上承受增长的拉伸。
本方法还可包括将稳定的可延展收缩无纺网面缠绕在收料辊上或者结织于盒中这一附加步骤。
本方法还可包括将稳定的可延展收缩无纺网面结合到弹性材料中以形成复合弹性材料这一附加步骤。
如果材料为可拉伸材料，则可通过沿与期望收缩方向垂直的方向拉伸使之收缩。可收缩材料可以是在室温下能有效收缩的任何材料。这类可收缩材料包括针织和松散纺成的织物、粘结粗梳无纺网面，纺粘无纺网面或熔喷无纺网面。可收缩材料可以有多层，例如多纺粘层以及/或者多熔喷层，或者薄膜层。可收缩材料可以由聚合物制成，例如聚烯烃类。典型的聚烯烃类物质包括聚丙烯、聚乙烯、乙烯共聚物、丙烯共聚物及其混合物。可收缩无纺网面可以是非弹性无纺网面，例如非弹性无纺材料。
                    附图简要说明
尽管本发明包括了用于具体指出并明确表是要求保护的发明的权利要求书，可以相信，通过以下结合附图所进行的本发明优选实施例的说明可以对本发明有更好的理解，其中，同样的标号用来不是基本相同的部分，其中：
图1是制成本发明的收缩无纺网面示例性工艺过程的示意图；
图2是横向网面增强装置的放大透视图；
图3是稳定辊筒装置的放大透视图；
图4是示例性可收缩无纺网面在拉伸及收缩之前的平面图；
图5是示例性收缩无纺网面的平面图；
图6是示例性复合弹性材料在部分展张状态下的平面图；
图7是制成本发明的收缩无纺网面另一示例性工艺过程的示意图；
图8是不适于成形收缩无纺网面的带间距凸纹样式的平面图；
图9是适于成形收缩无纺网面的本发明凸纹样式的平面图；
图10是适于成形收缩无纺网面的本发明中另一凸纹样式的平面图。
                    发明详细说明
参照图1，示出了制成本发明中的稳定的可延展收缩网面的工艺10。
根据本发明，当供料辊13绕辊旁箭头所示方向旋转时，可收缩无纺网面从供料辊13展开并沿网面上方箭头所示方向，也即机器方向、MD方向或第一方向送进。从供料辊13送出的可收缩无纺网面穿过压区14，压区是由横间网面增强装置17的两个增量展张辊筒15和16构成的。
可收缩无纺网面12可以通过已知的无纺挤压工艺制成，例如熔喷工艺或纺粘工艺。然后直接穿过压区14，不必首先存放在供料辊上。
图2是横向网面增强装置17之优选实施例的放大透视图。该装置是由具有三维表面并至少在一定程度上相互啮合的两个相对方向的施力器构成。图2中所示的横向网面增强装置17由增量展张辊筒15和16组成。可收缩无纺网面12穿过增量展张辊筒15和16绕箭头所示方向旋转时构成的压区14。上增量展张辊筒15沿整个辊筒圆周表面布满了大量的齿18及相应的凹槽19。下增量展张辊筒16沿整个辊筒圆周表面布满了大量的齿20及相应的凹槽21。辊筒15上的齿18与辊筒16上的凹槽21相啮合，同时辊筒16上的齿20与辊筒15上的凹槽19相啮合。
辊筒15和16上的齿18和20沿着与可收缩无纺网面12送进方向平行的方向，即与可收缩无纺网面12宽度方向垂直的方向延伸。亦即齿18和20沿平行于机器方向、MD方向或第一方向延伸。增量展张辊筒15和16沿着与第一方向或机器方向相垂直的方向渐增地展张无纺网面，使得无纺网面的纤维至少在一定程度上沿横向、CD方向或与第一方向相垂直方向定位。除了沿CD方向定位无纺网面的各条纤维外，沿CD方向或与第一方向相垂直方向所测的无纺网面表面路径长度也将增大。当无纺网面12退出横向网面增强装置17后，无纺网面12上就产生许多折皱22。与进入横向网面增强装置17之前基本平展的无纺网面12相比，折皱22使得无纺网面的表面路径长度增加。
从图2中可以看出，在进入横向网面增强装置17构成的压区14之前，无纺网面在CD方向的表面路径长度为Z。在承受了增量展张辊筒15和16的作用后无纺网面产生许多折皱22，使得无纺网面12具有了较先前的CD向表面路径长度Z更长的新的CD向表面路径长度Z′。CD向表面路径长度Z′优选至少比Z长10％，更为优选的是长至少20％，能长至少30％就最为优选了。无纺网面在未出现严重失效的情况下CD向表面路径长度Z′可以达到尺寸Z的200％，甚至更多。例如，无纺网面12的CD向表面路径长度Z为10英寸，展张50％后的CD向表面路径长度Z′为15英寸。
测量无纺网面表面路径长度的方法可在本详细说明之后部分的测试方法一节找到。
增量展张辊筒15和16可根据需要包含任意数量的齿和凹槽。另外，齿和凹槽还可以是非线性的，例如曲线、正弦、锯齿形等。增量展张辊筒15和16上齿和凹槽啮合的尺寸和数量可以视情况而定。
从横向网面增强装置17出来后的可收缩无纺网面12穿过S型辊筒装置26的压区25，该压区由叠式辊筒28和30构成。可收缩无纺网面12沿叠式辊筒28和30上转动方向箭头所示的反S路径穿过S型辊装置26的压区25。穿出S型辊装置26后，可收缩无纺网面12进入机械稳定装置38的增量展张辊筒34和36构成的压区32。由于S型辊装置26的辊筒圆周线速度控制为低于机械稳定装置38的辊筒圆周线速度，可收缩无纺网面12就在S型辊装置26与机械稳定装置38的增量展张辊筒34和36所形成的压区32之间受到拉伸。通过调整辊筒间的速度差，可收缩无纺网面受到拉伸并收缩所期望的比例，同时保持这种拉伸后收缩的状态。机械稳定装置38提供了可与其他材料结合的稳定的收缩无纺网面。
当无纺网面12在S型辊装置26和增量展张辊筒34与36形成的压区32之间受到拉伸时，拉伸力就沿平行于第一方向、机器方向或MD方向施加给可收缩无纺网面。沿与第一方向相平行方向拉伸无纺网面12，使其在垂直于第一方向的方向上或平行于CD向横向的方向上收缩。
进入S型辊装置26时，无纺网面12具有CD向表面路径长度Z′。当在S型辊装置26和机械稳定装置38的增量展张辊筒34和36的压区26之间受到拉伸时，无纺网面12收缩而具有比CD向表面路径长度Z′小的CD表面路径长度Z″，最好是比CD向表面路径长度Z还要小。CD向表面路径长度Z″优选小于尺寸Z的75％，更优选小于尺寸Z的50％。最优选的是尺寸Z″小于尺寸Z的30％。例如，无纺网面12的CD向表面路径长度Z为10英寸，经展张后扩展为长度15英寸的CD表面路径长度Z′，然后又收缩为CD表面路径长度Z″5英寸，这时Z″就是原CD表面路径长度Z的50％。
还可以使用其他方法拉伸可收缩无纺网面12，例如采用拉幅机装置。
可收缩无纺网面12可以是可延展的、有弹性的或无弹性的无纺材料。可收缩无纺网面12可以是纺粘网面、熔喷网面或者粘结粗梳网面。如果可收缩无纺网面是熔喷纤维制成的网面。则它可以包含熔喷微纤维。可收缩无纺网面可以由形成聚合物的纤维制成，例如聚烯烃类物质。典型的聚烯烃类物质包括聚丙烯、聚乙烯、乙烯共聚物、丙烯共聚物和丁烯共聚物中的一种或多种。
在本发明的一个实施例中，可收缩无纺网面12可以是多层材料。例如，将至少一层纺粘网面与至少一层熔喷网面、粘结粗梳网面或其它合适的材料结合。或者，可收缩无纺网面12还可以是单层材料。例如纺粘网面、熔喷网面或粘结粗梳网面。
可收缩无纺网面12也可是由两种或多种不同纤维混合或者纤维和颗粒混合制成的复合材料。将纤维和/或颗粒添加到传送熔喷纤维的气流中即可形成这样的混合物，在熔喷纤维被收集到收粒设备之前即产生熔喷纤维和其它材料紧密缠结的混合物，这就形成了熔喷纤维和其他材料随意散布的粘着网面。与熔喷纤维混合的其他材料如木桨、人造纤维以及颗粒等，颗粒如通常被称为高吸湿材料的水解胶体(水凝胶)颗粒。
纤维的无纺网面应该是通过粘结而形成的能够耐收缩的粘着网面结构。适合的粘结技术包括化学粘结、热粘结，例如点砑光、水缠结和针织技术等，当然也不限于此。
图3是机械稳定装置38之优选实施例的放大透视图。该机械稳定装置包含两个相向的施力器。施力器具有三维表面并且至少在一定程度上是相互配合的。图3中所示的机械稳定装置38由增量展张辊筒34和36组成。当增量展张辊筒绕箭头方向旋转时，可收缩无纺网面12穿过由增量展张辊筒34和36所形成的压区32。上增量展张辊筒34包含许多齿40和相应的凹槽41，这些齿和槽绕辊筒34的整个圆周表面延伸。下增量展张辊筒36也包含许多绕辊筒圆周表面延伸的齿42和相应凹槽43。辊筒34上的齿40与辊筒36上的凹槽43相啮合或配合，而辊筒36上的齿42又与辊筒34上的凹槽41相啮合或配合。
辊筒34上的齿40和辊筒36上的齿42各自沿着与可收缩无纺网面12第一方向相垂直的方向或者沿着与无纺网面12宽度方向相平行的方向延伸。亦即齿40和42在与横向或CD方向相平行的方向上延伸。增量展张辊筒34和36沿着与收缩方向垂直的方向即平行于第一方向的方向渐增地展张收缩网面，从而使收缩无纺网面12稳定化。这样，在收缩无纺网面穿过增量展张辊筒34和36，施于其上的拉伸力释放，无纺网面仍旧保持收缩状态。通过将收缩无纺网面稳定化。收缩无纺网面将基本保持其收缩后的尺寸，不会回复其先前尺寸。
收缩无纺网面12穿过增量展张辊筒34和36经历稳定化处理后，稳定的收缩无纺网面12将出现大量的稳定化凸纹44。稳定化凸纹44贯穿稳定的收缩无纺网面12的整个宽度沿相互平行的线性方向延伸。稳定化凸纹44显示为在与CD向或横向相平行的方向上延伸。如图3所示，每条稳定化凸纹都是从稳定的收缩无纺网面的一端边缘延伸至另一端边缘。这是非常重要的，因为这使得纤维贯穿网面整个宽度方向定形，从而稳定网面。如果稳定化凸纹44并未贯穿整个可收缩无纺网面12延伸，则未压出凸纹的部分可收缩网面将回复其先前宽度。例如，图8所示的间隔凸纹图案是不能有效地稳定化无纺网面的。各个凸纹之间的无纺网面部分得不到定形而回复其先前尺寸。
增量展张辊筒34和36可以包含任意数量的齿和凹槽。以便使无纺网面达到所希望的稳定程度。另外，齿和凹槽可以是非线性的，例如曲线、正弦、锯齿形等。增量展张辊筒34和36上齿和凹槽啮合的尺寸和数量也可以视情况而定。另外，齿和槽的分布方向也不一定沿着与无纺网面送进方向相垂直的方向。例如，齿和凹槽可以沿着与CD向成一定角度的方向延伸。但最好不要平行于MD向或机器方向，因为这类增量展张扩展的是网面的宽度，是与网面收缩的目的相抵触的。
现在参看图1，可收缩无纺网面12穿过机械稳定装置38之后，卷绕在收料辊50上。将可收缩无纺网面稳定在其收缩状态后即可使其以收缩状态卷绕在收料辊上，便于下一步的使用。一旦可收缩无纺网面被机械稳定或定形后，它就适合在高速常规尿布加工设备上加工了，不需要其它特殊加工设备。另外，还可使用常规结织设备将可收缩无纺网面12结织在盒中存放。
稳定的收缩无纺网面可以很容易地沿平行于收缩方向的方向延伸。即稳定的收缩无纺网面可以很容易地沿横向延伸或伸长。稳定的可延展收缩无纺网面在张力作用下至少可伸张60％，并且不会发生严重失效(即展张后的长度至少是放松状态下未施加张力时长度的160％)。优选的是，稳定的可延展收缩无纺网面在张力作用下至少可伸张100％而不发生严重失效(即展张后的长度至少是放松状态下未施加张力时长度的200％)。由于稳定的可延展收缩无纺网面是可延展而非有弹性的，稳定的可延展收缩无纺网面在展张力释放后不会恢复其伸张量的55％。优选的是释放展张力后不会恢复伸张量的25％。
在施以较低张力的情况下，稳定的可延展收缩无纺网面优选地可伸张至少60％，更优选的情况是伸张100％甚至更多而不发生严重失效。由于在较低张力作用下即可产生至少60％，更优选的100％甚至更多的伸张量。这就使得稳定的可延展收缩无纺网面特别适于制成一次性吸湿用品。例如，尿布、失禁短裤、训练裤、女性卫生衣物等类似用品。原因在于它们能够用于用品上需要高延展性而辅助适配身体的部位。
稳定的可延展收缩无纺网面在小于300克的张力作用下，优选伸张量至少为60％，更优选的情况下可以达到100％且不发生严重失效。张力小于200克就更为优选，张力小于100克就最优选。
由于可以与图1所示装置一起使用的常规驱动装置和其它常规设备为人们所熟知，为清晰起见，就未在图1的示意图中画出。
除了增量展张之外，还有其他方法适于机械地稳定收缩无纺网面。这些方法包括使用肋纹滚压机和/或起皱辊。另一种适合的方法包括使收缩无纺网面穿过一对表面光滑辊筒形成的压区。设定这类稳定化辊筒形成的辊筒啮合挟紧力即可使收缩网面达到所期望的稳定化程度。
图9是另一种适于稳定可收缩无纺网面的凸纹样式的平面图。该样式包括大量沿着与横向平行的方向贯穿网面205整个宽度的线性凸纹210。该样式还包括许多沿着与横向呈一定角度并与凸纹210呈一定角度连续延伸贯穿网面205的整个宽度的线性凸纹212。网面205还包括多个沿与横向成一定角度并且也与凸纹210和212成一定夹角的方向连续延伸的贯穿网面205的整个宽度的线性凸纹214。凸纹212与214之间的夹角可以任意并且二者与凸纹210间的夹角也可以任意。
图10是另一种适于稳定可收缩无纺网面的凸纹样式的平面图。该样式包含许多贯穿网面220的整个网面宽度并与横向呈一定角度连续延伸的凸纹222。网面220还包含许多沿着与横向成一定角度并与凸纹222成一定夹角的方向连续延伸贯穿整个网面220宽度的凸纹224。凸纹222和224最好是相互垂直的。不过，线性凸纹222和224之间也可采用其它夹角。
通过将收缩无纺网面送进由一对压纹辊筒形成的压区即可压出图9和图10中所示的凸纹样式。每个辊筒上包含一些凸起表面，分别类似于辊筒34和36上的齿40及齿42。每个辊筒上的凸起表面是互补的，可以彼此啮合并对收缩无纺网面施压，使之产生图9和10所示的凸纹样式。压纹辊筒提供的压力使各条纤维定形，从而使整个网面稳定在其收缩状态。
另一种方案是，压纹辊筒装置还可以由一个具有一定样式凸起表面的纹路辊筒和一个表面平滑的基面辊筒组成。纹路辊筒上的凸起表面靠在基面辊筒上压收缩无纺网面即可生成图9和10所示的凸纹样式。
稳定的可延展收缩无纺网面可在日后的处理中与弹性件结合。形成复合弹性材料。优选的情况是，当弹性材料处于未拉伸状态时稳定的可延展收缩材料与其结合在一起。无论弹性件处于拉伸状态或未拉伸状态。稳定的可延展收缩无纺网面与弹性件都可沿着其部分共同延展表面以间断或连续的方式相互结合。稳定的可延展收缩无纺网面可以从诸如收料辊50之类的辊筒上展开后与弹性件结合，也可以在实施了机械稳定后直接与弹性件结合。
弹性件可以由任何合适的弹性材料制成。通常，任何高弹性纤维成形树脂或含有上述树脂的混合物都可利用来制成弹性纤维的无纺网面。任何高弹性薄膜成形树脂或含有上述树脂的混合物都可利用来制成本发明的高弹性薄膜。例如，弹性材料可以是由通用化学式为A-B-A′的嵌段共聚物制成的弹性膜，其中A和A′都是热塑性聚合物嵌段端部，包含苯乙烯部分，例如聚(乙烯基芳烃)。其中B是弹性聚合物中段，例如共轭二烯或者低烯烃聚合物。其他可用于制成弹性薄膜的典型弹性薄膜包括聚氨基甲酸(乙)酯弹性材料，例如B.F.Goodrich & Company公司的ESTANE品牌的产品；聚酰胺弹性材料，例如Rilsan公司PEBAX品牌的产品；聚酯弹性材料，例如E.I.DuPont DeNemours公司的Hytrel品牌的产品。
聚烯烃还可以与弹性聚合物混合以提高混合物的可加工性。当聚烯烃与弹性聚合物混合并受到升高压力和温度条件的适当组合时，聚烯烃必须是一种与弹性聚合物在混合状态下可挤压的聚烯烃。适用的混合聚烯烃材料包括聚乙烯、聚丙烯和聚丁烯、乙烯共聚物、丙烯共聚物和丁烯共聚物也包括在内。
弹性件还可以是一种压敏弹性粘结剂片材。例如，弹性材料本身是发粘的，或者将可混增粘树脂添加到上述可挤压弹性复合材料中形成可用作压敏粘结剂的弹性片材，比如将弹性片材与已拉伸收缩的无弹性网面相粘结。弹性片材还可以是多层材料构成的，它可包括两层或更多的单独的粘着网面或薄膜。另外，弹性片材还可以是多层材料，其中一层或多层包含着弹性纤维或颗粒与非弹性纤维或颗粒形成的混合物。
其它适合用作弹性件的弹性物质包括“活性(live)”合成橡胶或天然橡胶，包括热收缩弹性膜，成形的弹性稀洋纱，弹性泡沫胶等类似物质。在特定的优选实施例中，弹性件包含Conwed Plastics公司的弹性稀洋纱。
可收缩无纺网面12的原始尺寸与其经拉伸或收缩后的尺寸之间的关系就决定了复合弹性材料的近似展张极限。由于可收缩无纺网面是可展张并在一定方向上回复到收缩的尺寸，收缩方向可以是机器方向也可以是横向，复合弹性件在与可收缩无纺网面12同样的方向上也是可展张的。
例如，参看图4、5、6，假设希望制备一种可展张伸展量达150％的复合弹性材料，轮廓如图4所示但比例又不一定与图4相同的可收缩材料宽度X为250cm，经过拉伸后收缩为宽度100cm，标号为Y。如图4所示的收缩无纺网面经机械稳定化作用后被制成稳定的可延展收缩无纺网面。然后将稳定的可延展收缩无纺网面与宽度约为100cm并至少可展张为宽度250cm的弹性件结合在一起。生成的与图6轮廓相似但比例不一定相同的复合弹性材料具有宽度Y为100cm，并且其至少可展张到250cm，即伸长量为可收缩材料的原始宽度的150％。从示例中可见，弹性件的弹性极限只需要与复合弹性材料的最小期望弹性极限一样大即可。
现在参看图7，该图示意性说明了本发明提及的制成收缩无纺网面的另一工艺过程100。
当供料辊103绕着辊旁所示箭头方向旋转时，可收缩无纺网面102从供料辊103上展开，并沿着网面上方箭头所示方向，即机器方向或第一方向送进。从供料辊103上展开的可收缩无纺网面102经过横向网面增强装置107的两个增量展张辊筒105和106所形成的压区104。网面增强装置107采用两个相向的施力器，施力器具有三维表面并且至少在一定程度上是相互配合的。横向网面增强装置107包含增量展张辊筒105和106。包含两个增量展张辊筒的横向网面增强装置的详细说明参看图2。
可收缩的无纺网面102可以通过公知的无纺挤压成型工艺制成。例如，人们熟知的熔喷工艺或纺粘工艺。然后，使可收缩的无纺网面直接经过压区104，不必事先将其存放在供料辊上。
从横向网面增强装置107送出的可收缩无纺网面102将穿过由叠式辊筒128和130所形成的S型辊装置126的压区125。可收缩无纺网面102沿着叠式辊筒128和130上旋转方向箭头所示的反S型路径穿过S型辊装置126的压区125。从S型辊装置126穿出后，可收缩无纺网面102穿过压力辊筒装置140所形成的压力压区145，装置140包含两个施压辊筒142和144。由于将S型辊装置126的圆周线速度控制为小于压力辊筒装置140的圆周线速度，可收缩无纺网面102在S型辊装置126和压力辊装置140的压力压区之间受到拉伸。通过调整两组辊装置速度之间的差值，可收缩无纺网面受到拉伸，并收缩所期望的尺寸而且维持这种受拉伸后收缩的状态。从压力辊装置140穿出后，收缩无纺网面102穿过机械稳定装置152所形成的压区，装置152包含增量展张辊筒153和154。由于压力辊装置140的辊筒圆周线速度控制为小于或等于机械稳定装置152的辊筒圆周线速度，无纺网面在压力辊装置140和机械稳定装置152之间维持其受拉伸和/或者收缩状态。经过机械稳定装置152之后，稳定的收缩无纺网面102缠绕在收料辊160上。另外，还可使用常规设备将稳定的收缩无纺网面102结织于收料盒中。
可以与图7中的装置一起使用的常规驱动装置和其他常规设备已为人们所熟知，为清晰起见，未在图7的示意图中示出。
测量方法
利用显微图像分析方法分析无纺网面即可判定无纺网面的表面路径长度。
从无纺网面上切割并分离出用于测量的样本。附着到网面上后，在垂直于“测量边”的方向“计量标定”出半英寸长的未变形样本长度，然后进行精确地切割，并从网面上分离下来。
然后将测量样本固定到显微镜载玻片的长边缘上。将“测量边”向外稍微拉出载玻片边缘一点儿(大约1mm)。在朝向载玻片的边缘处涂上薄薄一层压敏粘合剂，这样可使样本更好地固定。对于具有较深折皱的样本。需要轻轻地展开样本(不要施加太大的力)，以使样本更易于与载玻片边缘接触和附着。这样就改进了图像分析时边缘的识辨性，避免了出现需附加解释分析“折皱”边缘部分的可能性。
采用具有足够高质量和放大倍数的适当的显微测量方法，从载玻片“边缘”以“测量边”视图采集每个样本的图像。利用下列设备来采集数据：Keyence VH-6100(20倍镜片)视频装置，用Sony Video打印机Mavigraph装置制作的视频图像打印件。用HP ScanJet IIP扫描仪进行视频打印件图像扫描。使用NIH MAC Image 1.45版软件在MacIntosh IICi计算机上进行图像分析。
使用此设备时，首先要用具有长度0.500″、增量标记为0.005″的网格作为标定图像来对计算机图像分析程序进行标定设置。然后对所有要被测量的样本进行视频成像和视频图像打印。下一步，将所有视频打印件以100dpi(256级灰度)图像扫描为适当的Mac图像文件格式。最后，使用Mac Image1.45计算机程序分析每个图像文件(包括标定文件)。所有样本将采用选定的徒手直线测量工具进行测量。在样本的两面边缘进行测量并将长度记录下来。薄的样本只需测量一面边缘。厚的样本需要测量双面边缘。沿着切割样本的整个计量长度进行长度测量。在某些情况下，要覆盖整个切割样本可能需要多个(部分重叠)图像。在这些情况下，选择相互重叠图像共同的特征并用作“标记”，使得读取图像长度时是毗邻读取而非重叠读取。
将每段网面的5个单独0.5”计量样本的长度求平均值即可获得表面路径长度的最后确定值。每个计量样本“表面路径长度”是双面边缘表面路径长度的平均值。
尽管上述测量方法对本发明的许多网面都适用，但为适应一些网面可能需要进行修改。
尽管本发明的特定实施例已被图示说明和描述，但那些不偏离发明实质和范围的多种其他变化和改动对于本领域的普通技术人员而言应该是显而易见的。因此试图将所有这些本发明范围内的变化和改动覆盖在所附权利要求书中。

Claims (10)

1.一种制造稳定的可延展无纺网面的方法，所述方法的特征在于下列步骤：
a)提供可收缩无纺网面，优选是由纤维和一种或多种其它吸湿材料相混合的复合材料；
b)将可收缩无纺网面沿第一方向送进；
c)使可收缩无纺网面沿着与所述第一方向相垂直的方向承受增量展张，优选将无纺网面送入由一对增量展张辊筒构成的压区，所述辊筒优选具有多个齿和多个凹槽；
d)对可收缩无纺网面施加拉伸力使无纺网面收缩；
e)使收缩无纺网面承受机械稳定化作用，制成稳定的可延展收缩无纺网面，优选将收缩无纺网面送入由一对压纹辊筒构成的压区，其中所述压纹辊筒优选提供贯穿整个无纺网面宽度的连续加压稳定化凸纹。
2.如权利要求1所述的方法，其特征在于，在步骤e)中使收缩无纺网面沿着与所述第一方向平行的方向承受增量展张。
3.如权利要求1所述的方法，其特征在于，所述可收缩无纺网面是从下列物质组中选出的一种网面：粘结粗梳纤维网面、纺粘纤维网面、熔喷纤维网面，以及包括至少一种所述网面的多层材料。
4.如权利要求3所述的方法，其特征在于，所述纤维包括由下列物质组中选出的一种聚合物：聚烯烃类、聚酯类和聚酰胺类。
5.如权利要求4所述方法，其特征在于，所述聚烯烃是从下列物质组中选出的：聚乙烯、聚丙烯、聚丁烯、乙烯共聚物、丙烯共聚物和丁烯共聚物中的一种或多种。
6.如权利要求1所述方法，其特征在于，所述可收缩无纺网面是包含了纤维与一种或多种其他材料混合物的复合材料，这一种或多种其他材料是从下列物质组中选取的：木桨、人造纤维、颗粒和超吸湿材料。
7.如权利要求1所述方法，其特征在于，包括下列附加步骤：
f)将稳定的可延展收缩无纺网面与弹性件结合，所述弹性件优选是一种从下列物质组中选出的弹性聚合物，弹性聚烯烃类、弹性聚氨基甲酸乙酯类、弹性聚酰胺类和弹性A-B-A′嵌段共聚物类，其中A和A′是相同或相异的热塑性聚合物，B是弹性聚合物段。
8.如权利要求7所述的方法，其特征在于，所述的弹性件包括弹性膜。
9.如权利要求7所述的方法，其特征在于，所述的弹性件包括弹性稀洋纱。
10.一种制造稳定的可延展无纺网面的方法，所述方法的特征在于下列步骤：
a)提供可收缩无纺网面，优选是纤维和一种或多种其它吸湿材料相混合形成的复合材料；
b)将可收缩无纺网面沿第一方向送进；
c)使可收缩无纺网面承受与所述第一方向相垂直方向的增量展张，优选将无纺网面送入由一对增量展张辊筒构成的压区，所述辊筒优选具有多个齿和多个凹槽；
d)沿着与所述第一方向平行的方向对可收缩无纺网面施加拉伸力，使无纺网面沿着与所述第一方向相垂直的方向收缩；
e)使收缩无纺网面承受与所述第一方向相平行方向的增量展张作用。
CN98804610A 1997-04-04 1998-04-02 具有增强延展性的稳定网面及其制造方法 Pending CN1253601A (zh)

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