CN1839040A - 微孔拉伸变薄的膜/非织造层压材料和有限用途或一次性产品应用 - Google Patents

微孔拉伸变薄的膜/非织造层压材料和有限用途或一次性产品应用 Download PDF

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CN1839040A
CN1839040A CNA2004800239731A CN200480023973A CN1839040A CN 1839040 A CN1839040 A CN 1839040A CN A2004800239731 A CNA2004800239731 A CN A2004800239731A CN 200480023973 A CN200480023973 A CN 200480023973A CN 1839040 A CN1839040 A CN 1839040A
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A·L·麦科尔马克
R·J·帕尔默
C·E·希
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Kimberly Clark Corp
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Abstract

膜和非织造物的透气层压材料具有增加的韧性和经历应变而不分裂的能力，用于作为个人护理产品组件和其它用途。使用载体/调制树脂方法形成膜，其中填充的载体树脂是密度比调制树脂的高至少0.003g/cc的乙烯聚合物或共聚物，所述调制树脂也是乙烯共聚物，但密度小于约0.915g/cc和熔融指数小于约6。可以将树脂相干共混、成形为膜、拉伸和粘合到非织造支撑层。

Description

微孔拉伸变薄的膜/非织造层压材料和 有限用途或一次性产品应用
相关申请
本申请是同一天提交的涉及相关主题的两个申请之一。另一个申请的题目是″微孔透气弹性膜、其制备方法和有限用途或一次性产品应用″，发明人为Ann Louise McCormack和Susan Elaine Shawver(代理案号18842；快递邮件号Ey 008 269 822 US)，该文献在此引入作为参考。
发明领域
本发明涉及拉伸变薄的膜和它们在用于诸如一次性尿布组件应用的膜/非织造层压材料中的用途。
膜/非织造层压材料用于很多种应用，它相当重要地作为个人护理产品如游泳衣和吸收制品如尿布、训练裤、失禁衣服、女性卫生产品、创伤敷料、绷带等的外罩。膜/非织造层压材料也在健康护理领域中与这种产品结合作为外科盖布和睡衣及用于清洁室、健康护理的其它衣服和其它相关用途。特别地在个人护理领域中，重点是开发低成本层压材料，该层压材料具有良好的屏蔽性能，特别是对于液体，以及良好的美学和触觉性能如衣服状手感和触感。为此目的，渐增地更有利地使用更薄的膜。更薄的膜成本更低，并且由于它们降低的规格，通常更软和更安静。更薄的膜也可以作成更透气的用于增加舒适性。
更薄的膜，有时它的基础重量小于30克每平方米(gsm)，也倾向于相当薄弱。这在横向(″CD″或与在制造或加工中膜移动正交的方向)特别如此，因为为了获得这样的低厚度，通常在纵向(″MD″或制造或加工中膜移动的方向)高度拉伸膜。纵向的严格取向倾向于使组成膜的聚合物分子取向。这种取向可极大地增加膜在纵向的强度，但也倾向于降低相同膜在横向的延伸性，这例如对于制衣和使用中的条件是重要的。通过层压支撑层如纤维性非织造网到膜层，可以产生具有附加性能的层压材料。非织造层可向总体复合材料添加增加的强度。此外，它可赋予诸如衣服状触感的性能，该触感在许多应用中，包括个人护理吸收制品中是重要的。令人遗憾地，迄今为止膜/非织造层压材料不总是提供最优的益处，特别是在延伸性领域中。结果，这种层压材料的膜部分倾向于分裂，由此在总体产物中提供小于最优的性能。当膜/非织造层压材料的膜用作屏蔽材料，例如个人护理吸收制品的外罩时特别如此。因此，需要改进的膜/非织造层压材料，特别是在其中膜层已经在单一方向高度取向和膜的总厚度或基础重量极大地降低的情况下。
发明概述
本发明提供方法和透气膜/非织造层压材料及在个人护理产品如一次性尿布中的应用。层压材料的膜组件使用调制/载体浓缩物形成方法，该方法在调制相中使用乙烯共聚物树脂和在载体树脂相中使用乙烯聚合物或共聚物。特别地，调制乙烯共聚物的密度小于约0.915和熔融指数小于约6。载体树脂包括填料并且也使用乙烯聚合物或共聚物树脂，但是是密度比调制树脂大至少约0.003g/cc的树脂。以一定的数量使用调制和载体相，导致膜中的最终填料浓度为约30％-约70％。将为透气性而拉伸膜并层压到非织造如纺粘、纺粘层压材料或梳理网。具体的实施方案包括使用碳酸钙作为填料和使用粘合剂层压步骤。其它包括小于约0.913g/cc或约0.900-约0.912g/cc的具体调制树脂密度范围。非织造物可以是例如纺粘或粘合的梳理网。本发明也涉及其中膜基础重量为约13gsm-约25gsm的实施方案和其中一种或两种乙烯共聚物树脂是线性低密度聚乙烯(LLDPE)的实施方案。本发明也涉及透气性为5000-10,000g/m/24小时或更高的高透气性实施方案。此外，本发明包括制备透气膜/非织造层压材料的方法，该方法包括如下步骤：
a.选择密度小于0.915g/cc和熔融指数小于约6的调制乙烯共聚物树脂；
b.在密度比调制树脂高至少约0.003g/cc的载体乙烯聚合物或共聚物树脂中分散填料；
c.采用一定的数量干共混调制树脂和填充的载体树脂以提供共混物中约30％-70wt％的填料浓度；
d.挤出共混物以形成膜；
e.拉伸膜；和
f.粘合膜到非织造层。
本发明也涉及透气膜/非织造层压材料的应用，包括作为个人护理产品的组件如尿布衬垫。
附图简述
通过参考结合附图的本发明实施方案的如下描述更好地理解本发明，其中：
图1是根据本发明的膜/非织造层压材料的横截面侧视图。
图2是显示为引入本发明的层压材料作为背片的一次性尿布的代表性个人护理制品的顶部俯视图。
图3说明在负荷、伸长率的结果和总能量吸收(TEA)能量之间的关系。
图4是使用本发明制备微孔膜/非织造层压材料的方法的简要说明。
详细描述
本发明希望克服现有技术膜/非织造层压材料的以上问题。该目的由膜/非织造层压材料解决，其中膜组合物提供忍受横向应变的增加能力或延伸性而没有失败。
本发明的进一步优点、特征、方面和细节从权利要求、说明书和附图是显然的。
本发明涉及微孔膜组合物和非织造层压材料，其中在将膜层连接到支撑层如纤维性非织造网之前或之后至少在纵向对其进行取向。
更具体地本发明涉及具有非常低规格或基础重量膜和在层压材料中在应变条件下改进的膜整体性的膜/非织造层压材料。
目前的许多产品特别是在一次性产品如个人护理吸收产品领域，采用膜和纤维性非织造网作为组件。从成本的观点来看，通常需要材料具有尽可能低的规格。对膜这样做的一种方式是拉伸或取向膜，例如在纵向降低膜的基础重量或厚度。在取向膜时，膜通常在纵向(拉伸方向)获得强度，但同时在横向(垂直于拉伸方向的方向)损失强度。结果，通常将支撑层如纤维性非织造网层压到膜层以增加强度以及提供衣服状属性。
膜层、支撑层和层压材料都具有纵向和横向。在层压之前，将膜层在至少纵向取向使得它的基础重量为约30gsm或更小。可以通过比较取向膜的纵向和横向强度确定膜层已经在纵向取向的事实。取向膜在一个方向由下述条拉伸测试测量的强度通过是通常垂直于第一方向的方向中强度的至少约两倍。具有更强强度的方向是拉伸方向，在目前情况下，纵向和具有更弱强度的方向是横向。膜层、纤维性非织造支撑层和层压材料都具有或限定纵向和横向，膜和非织造层的纵向在许多情况下在层压之前在纵向彼此对准。
除非另外指明，对于膜层数值在横向在纵向取向之后，在层压之前或之后测量，膜断裂应变如由1英寸(2.54cm)条拉伸测量和延伸性如由断裂伸长率数值测量。
配制用于制备透气填充膜的膜的两种方法是浓缩物调制方法和完全配混方法。在浓缩物调制方法中，一种树脂用作载体树脂以制备含有碳酸钙或其它填料的浓缩物。载体树脂，典型地为高熔融指数/低粘度树脂用于分散高载荷填料。调制树脂支配膜的拉伸性能，相信是由于与载体树脂分子量相比它的分子量更高。将浓缩物与另一种树脂，典型地为低熔融指数/高粘度树脂调制(结合)，以稀释碳酸钙到所需百分比。采用此方式使用两种不同的树脂提供加工和效率优点，但在希望提供延伸性属性的膜配制中保持所需组分比方面可能出现困难。
本发明涉及用于调制方法的改进膜配制剂，它得到更好的膜性能，包括膜断裂应变(降低的分裂倾向)并涉及这种膜的应用，特别是作为透气层压材料的薄组件。
用于所述和其它应用的一些常规膜典型地要求约550-约800克或更高力每3英寸以在横向延伸膜约25％-约50％。其它常规膜具有更低的延伸性要求，但事实上在所有情况下，希望膜可靠地忍受在使用条件下遇到的力而没有破裂，特别地在如用于诸如尿布背片、训练裤外罩和设计以符合穿用者身体的其它吸收衣服应用的更薄厚度下。通过在延伸下改进膜整体性可以达到更好的性能和效率。
支撑层可以从很多种材料制备，该材料包括各种纤维性非织造网。这种网的例子包括但不限于纺粘非织造网、粘合的梳理网和层压材料如纺粘/熔喷和纺粘/熔喷/纺粘网。对于纺粘/熔喷网通常更希望连接层压材料的熔喷部分到膜层。此外，在某些应用中可能希望对膜/非织造层压材料增加其它层，例如第二非织造或其它支撑层到与其它非织造层的表面相对的膜层表面。在此再次，第二支撑层可能例如作为非织造材料的或层压材料如纺粘/熔喷/纺粘层压材料。
本发明的膜/非织造层压材料具有很多种应用，该应用包括在个人护理吸收制品如尿布、训练裤、失禁衣服、卫生巾、创伤敷料、绷带等中的用途。典型地这种制品具有渗透液体的顶片和背片及位于顶片和背片之间的吸收芯。如果将膜/非织造层压材料的膜层制成渗透液体的，则它可以用作顶片。如果它是基本渗透液体的，它可以用作背片。其它应用包括但不限于使用根据本发明的膜/非织造层压材料作为这种产品的所有或一部分，作为手术盖布和睡衣以及通常的衣服制品。在许多这些应用中可能希望层压材料透气，在该情况下层压材料由Mocon测试过程测定的水蒸汽透过速率应该为至少300克每平方米每24小时。理想地水蒸汽透过速率高得多，例如1000-5000克每平方米每24小时或5000-10,000克每平方米每24小时或甚至更高。
本发明涉及由于它的改进膜配制而具有增加的横向(CD)延伸性和整体性的膜/非织造层压材料。用于本发明的膜已经在至少纵向(MD)取向通常足够的数量以得到基础重量为约30克每平方米(gsm)或更小，合适地约25gsm或更小，和理想地约13gsm-约25gsm的膜。这种取向通常要求将膜拉伸至少两倍于它的初始或未拉伸长度。一旦将膜取向，则使用热量和压力如采用受热的压延机辊或通过超声粘合技术将它层压到纤维性非织造网。或者，可以使用粘合剂将两个层层压在一起。作为进一步的替代选择，对于一些具体的应用，膜可以通过如下方式拉伸：拉伸层压材料而不在层压之前拉伸或除在层压之前拉伸以外拉伸层压材料。
对于设计本发明的膜/非织造层压材料重要的是选择非常低密度、低模量的树脂作为膜配制剂中的调制树脂。更具体地调制树脂是密度小于0.915g/cc，优选小于0.913g/cc和更理想地为0.900-0.912g/cc的LLDPE。树脂的熔融指数也小于6g/10min，理想地小于4g/10min，和更理想地小于2.5g/10min。尽管下限不是关键的，但实际上，调制树脂熔融指数正常地大于约1.5g/10min。膜配制剂也包括包含充分分散的填料如CaCO3的载体树脂，并且可以选自例如密度比调制树脂高至少0.003g/cc，理想地至少0.007g/cc的乙烯聚合物和共聚物。例子包括购自Dow ChemicalCompany的聚乙烯和乙烯共聚物，如Dowlex 2517(25MI，0.917g/cc)；Dow LLDPE DNDA-1082(155MI，0.933g/cc)；Dow LLDPEDNDB-1077(100MI，0.929g/cc)，Dow LLDPE 1081(125MI，0.931g/cc)，和Dow LLDPE DNDA 7147(50MI，0.926g/cc)。在一些情况下，更高密度聚合物可以是有用的，如Dow HDPE DMDA-8980(80MI，0.952g/cc)。不认为密度差异的上限是关键的，但树脂的选择将不正常导致大于约0.060g/cc的差异。对一些应用，希望载体树脂的熔融指数大于约10g/10min，和在其它情况下大于约20g/10min。配制剂由例如如下方式获得：混合填料与载体树脂，形成浓缩物粒料，和然后结合载体树脂粒料，例如通过以选择的数量与调制树脂的粒料干共混而产生所需的最终填料浓度和获得的膜透气性。理想地对于上述范围的透气性，浓缩物填料树脂含有的填料为约65wt％-约85wt％，更理想地约70wt％-约80wt％。根据本发明，采用例如由购自多个供应商例如Davis Standard的常规线性聚乙烯机筒单螺杆混合机提供的有限混合加工载体树脂和调制LLDPE，结果产生的膜包括至少两相，富含填料的载体树脂相和包含较少或不包含填料的调制树脂相。通常选择载体树脂的填料浓度以得到约30％-约70％，通常约40％-约65wt％的最终膜树脂浓度，基于总膜重量。采用常规数量的添加剂可以包括在载体和调制组合物的任一种或两种中用于稳定和或加工目的，如本领域技术人员已知的那样。
迄今为止，由于层压材料的膜部分过早撕裂或破裂，使用MD取向膜的膜/非织造层压材料有时出现故障。本发明考虑每种组分的性能和其它必须的设计参数，该参数包括膜基础重量、膜的MD取向和膜的某些最小应变要求以得到改进的膜/非织造层压材料。
参考图1，根据本发明的膜/非织造层压材料10包括膜层12和支撑层14，它可以从许多除所说明的非织造物以外的材料制备，该材料包括例如膜、粗麻布、织造物和上述的组合。如所示，出于举例说明的目的，层是夸大的且未按比例。在膜层12中是调制树脂相15和载体树脂相13，由于膜12被拉伸或取向，载体树脂相13自身包含由孔19围绕的填料粒子17。从经济、美学性能和强度的观点来看，发现纤维性非织造网特别好地工作。支撑层14的聚合物选择不是关键的，条件是可以达到合适的粘合和强度性能。合适的聚合物包括但不限于聚烯烃和其它热塑性聚合物。合适的纤维性非织造网形成方法包括例如纺粘、熔喷、缠结和梳理方法。
参考图2，该图显示了形式为一次性尿布的个人护理制品200，将它部分断开以展示衬里201、吸收层203和衬垫205，该衬垫205是包括膜组件207和非织造层209的本发明的膜/非织造层压材料。例如，常规的这种制品包括显示为88的封闭机构如粘合带或机械紧固件。如对本领域技术人员显然的那样，依赖于特定的用途和所需的功能属性，对此基础个人护理制品的可能变化是多种多样的。本发明的膜/非织造层压材料也广泛用于这些变化。
尽管如提及的那样，根据本发明使用的非织造物的生产是充分建立的并且不需要对本领域技术人员详细描述，但仍总结几个通用方法。熔喷纤维由如下方式形成：将熔融热塑性材料通过多个细的通常圆模头毛细管作为熔融丝线或长丝挤出进入高速度通常受热的气体流如空气，该气体流使熔融热塑性材料的长丝变细以降低它们的直径。其后，熔喷纤维由高速度通常受热气体流携带并沉积在收集表面上以形成随机分散的熔喷纤维网。熔喷方法是公知的并公开于各种专利和出版物，包括NRL报告4364，″超细有机纤维的制造″，B.A.Wendt，E.L.Boone和D.D.Fluharty；NRL报告5265，″形成超细热塑性纤维的改进设备″，K.D.Lawrence，R.T.Lukas，J.A.Young；美国专利3,676,242，1972年7月11日授权予Prentice；和美国专利3,849,241,1974年11月19日授权予Butin等人。上述参考文献在此全文引入作为参考。
纺粘纤维由如下方式形成：将熔融的热塑性材料作为长丝从喷丝头中的多个细的通常圆形毛细管挤出，挤出长丝的直径快速降低，例如由非引出或引出流体拉动或其它公知纺粘机理。这些长丝通常是连续的和在形成表面如移动线或带上收集为网。由常规方法如在受热条件下通过由印花辊和砧辊形成的辊隙而粘合。纺粘非织造网的生产说明于专利如Appel等人的美国专利4,340,563；Matsuki等人的美国专利3,802,817；Dorschner等人的美国专利3,692,618；Kinney的美国专利3,338,992和3,341,394；Levy的美国专利3,276,944；Peterson的美国专利3,502,538；Hartman的美国专利3,502,763；Dobo等人的美国专利3,542,615；和Harmon的加拿大专利803,714。所有上述参考文献在此全文引入作为参考。
粘合的梳理网也可以使用，并且通常从短纤维制备，该短纤维通常以捆包购买。将捆包放入分离纤维的投梭器。然后，将纤维送过进一步在纵向破裂和排列短纤维的结合或梳理单元，以形成纵向取向的纤维性非织造网。一旦形成网，然后通过几种粘合方法的一种或多种粘合。一种粘合方法是粉末粘合，其中将粉状粘合剂在整个网中分布和然后活化，通常通过采用热空气加热网和粘合剂。另一种粘合方法是图案粘合，其中受热的压延辊或超声粘合设备用于将纤维粘合在一起，通常采用定域的粘合图案通过网并且如需要如此可以将网经过它的整个表面粘合。当使用双组分短纤维时，通空气粘合设备对于许多应用是特别有利的。
从多成分和多组分纤维，例如双组分纤维制备的纤维性非织造网也可用于形成支撑层14。参见例如Strack等人的美国专利5,336,552，它描述了如何制备双组分纺粘非织造网。Strack等人的专利在此全文引入作为参考。
也可以形成用作支撑层14的层压材料如纺粘/熔喷层压材料和纺粘/熔喷/纺粘层压材料，例如在Brock等人的美国专利4,041,203中教导的那样，该文献在此全文引入作为参考。
再次参考图1，包括碳酸钙富集载体相13和调制树脂相15的膜层12可以是单一或单层膜或多层膜，如使用共挤出工艺形成的。在载体相13中的是由孔19围绕的预定数量的碳酸钙粒子17。当形成多层膜时，本发明的膜组合物通常形成至少约75％，理想地至少约90％总膜厚度，并且当形成三个或多个层时，是芯组分。选择另外层的组合物以与本发明组合物的层的性能相容和不实质上改变本发明组合物的层的性能。
膜的形成是膜形成领域技术人员公知的，不需要在此详细讨论。存在许多可按照说明书制造这种膜的供应商。例如，Forte的USP6,114,024详细描述了膜形成和在此全文引入作为参考。
为降低层12的基础重量，典型地到小于30gsm，和提供透气性，必须通过在设备如纵向取向器(MDO)单元中拉伸或取向它使膜变薄，该单元例如从Marshal and Williams Company of Providence，Rhode Island购得。MDO单元具有多个拉伸辊，该拉伸辊在纵向逐渐拉伸膜和使膜变薄，纵向是膜通过设备的运动方向。可以使用其它拉伸机构如相互啮合有槽辊，例如在Sabee的美国专利4,153,664中所述，该文献在此全文引入作为参考。
一旦膜形成并且变薄到其中它的基础重量例如为约13gsm-约25gsm和具有所需透气性，就将它层压到支撑层14。合适的层压方法包括但不限于粘合剂、超声粘合和热机械粘合如通过使用受热的压延辊。这种压延辊通常包括采用印花辊和平滑砧辊的热点粘合，尽管两个辊可以有图案或是平滑的并且可以加热一个、两个辊或一个辊也不加热。在此使用的术语″热点粘合″包括让待粘合的织物或纤维网在受热的压延辊和砧辊之间通过。压延辊尽管不总是但也通常采用一些方式形成图案使得整个织物不经过它的整个表面粘合，并且砧辊通常是平的。结果，由于功能以及美学原因已开发压延辊的各种图案。图案的一个例子具有点并且是具有带有约200粘合点/平方英寸的约30％粘合区域的Hansen Pennings或″H&P″图案，如在Hansen和Pennings的美国专利3,855,046中教导的那样，该文献在此全文引入作为参考。H&P图案具有正方形点或销粘合区域，其中每个销的侧面尺寸为0.038英寸(0.965mm)，销之间的间距为0.070英寸(1.778mm)，和粘合深度为0.023英寸(0.584mm)。获得的图案具有约29.5％的粘合区域。另一种典型的点粘合图案是膨胀的Hansen Pennings或″EHP″粘合图案，它产生具有正方形销的15％粘合区域，该销的侧面尺寸为0.037英寸(0.94mm)，销间距为0.097英寸(2.464mm)和深度为0.039英寸(0.991mm)。记作″714″的另一种典型点粘合图案具有正方形销粘合区域，其中每个销的侧面尺寸为0.023英寸，销之间的间距为0.062英寸(1.575mm)。和粘合深度为0.033英寸(0.838mm)。获得的图案的粘合区域为约15％。另一种通常的图案是C-星图案，它具有约16.9％的粘合区域。C-星图案具有横向的棒或由流星间隔的″灯芯绒″设计。其它通常的图案包括具有约16％粘合区域的重复和轻微偏置金刚石的金刚石图案和看起来如名称建议那样的丝线编织图案，例如类似粘合区域为约15％-约21％和具有约302个粘合点每平方英寸的窗纱图案。典型地，粘合区域百分比在织物层压材料网的约10％到约30％区域变化。如本领域公知的那样，点粘合将层压材料层保持在一起以及通过在每个层中粘合长丝和/或纤维而对每个单独层赋予整体性。除非特定的上下文另外要求，在此使用的术语″粘合″和衍生物包括通过中间层连接。
图4是在膜/非织造层压材料中引入本发明的膜的膜/非织造总体工艺的简要说明。如所示，纺粘非织造物710由如下方式形成：从聚合物料斗714向挤出机712进料和从长丝形成器718形成连续长丝716到网形成器720上，网形成器720可以是例如在支撑辊周围旋转的小孔线或带，可以驱动它们的一个或所有。将获得的网710在由压花辊724和砧辊726形成的压延机辊隙722热点粘合，可以将该辊的一个或两个加热到热粘合温度。在压延机辊隙722之后粘合剂敷料器734采用连续或图案施加粘合剂涂层到纺粘网710。膜728由如下方式形成：从包含如上所述根据本发明共混的载体和调制树脂的聚合物料斗732向挤出机730进料和流延到急冷辊732上。膜728由MDO 731拉伸并且膜和纺粘物在保持在所需粘合剂粘合温度的辊738、740之间的辊隙736结合。然后如需要将层压材料在切开部分741切开并导引到卷绕机746或任选地导引到进一步的加工中。
可用于本发明实践的合适粘合剂的例子包括购自HuntsmanPolymer of Houston，TX的Rextac 2730，2723，以及购自BostikFindley，Inc.of Wauwatosa，WI的粘合剂。在实施方案中，采用粘合剂层压膜和非织造支撑层使得粘合剂的基础重量为约1.0-3.0gsm。使用的粘合剂的类型和基础重量根据最终层压材料中所需的属性确定。在另一个实施方案中，将粘合剂在与非织造物层压之前直接施加到膜层。
由本发明人确定的采用先前膜/非织造层压材料发生的问题是当层压材料拉伸或用作尿布的外罩时，层压材料的膜部分撕裂。结果，研究膜韧性和延伸性性能。根据此研究，确定膜的韧性，特别地在横向可以使用根据本发明的调制树脂和膜配制剂实质增加。此外，为了总体层压材料良好进行，使用下述2.54cm(一英寸)切割条拉伸测试，根据本发明的层压材料能够承受某最小负荷而不出现故障，即至少300克。
考虑到如上情况，制备层压材料，其中膜具有不同水平和类型的调制树脂。获得这些各种膜(纵向取向的)、非织造物和层压材料在TEA和延伸性数据方面的韧性。在其中调制树脂在上述密度和MI范围内的情况下，膜具有改进的韧性和延伸性。在拉伸样品层压材料时视觉观察样品层压材料，观察到膜不过早出现故障。过早表示膜在横向中的应变下撕裂和/或空穴在正常使用条件下可能遇到的条件下形成。
如下测试过程用于帮助分析以下列出的实施例。伸长率和应变的测试过程包括断裂伸长率和峰负荷伸长率以及断裂负荷和峰值负荷。其它测试包括膜厚度或有效规格。对于膜、非织造物和层压材料在横向测量所有的数值。此外，当制备层压材料时，将膜层和非织造层在层压之前对准使得每个层的纵向取向彼此平行。
条拉伸
在％数值下的负荷由如下方式确定：首先在特定的方向(如CD)伸长样品到给定百分比(如所示的70％或100％)的确定伸长率和然后在选择的％数值下测量负荷。
对于在此反映的结果，除非另外说明，确定的伸长率是25％。以下描述测定负荷值的实际测试方法。
使用例如购自使用Instron负荷池的Instron Corporation ofCanton，Mass.或Sintech Corp.of Cary，NC的恒定伸长速率测试设备测试材料。样品尺寸是25.4mm乘152.4mm，夹持在握柄之间，并以508mm/min的恒定速率拉伸直到样品断裂。握柄间隔是51mm。对样品加载使得样品的横向在垂直方向。测试在具有Renew MTS猫鼬箱(控制器)的Sintech Corp.恒定伸长速率测试仪2/S上使用TESTWORKS 4.07b软件进行。(Sintech Corp of Cary，NC)。测试在约73.5°F和50％相对湿度的环境条件下进行。记录以克/力计在25％伸长率下的负荷。图3说明在此测试中获得的典型曲线，其显示在作为伸长率的函数的负荷、断裂负荷和TEA、曲线下的面积之间的关系。此测试在关于ASTM D882-97的材料中适合，该文献在此全文引入作为参考。
WVTR
Mocon测试由INDA(非织造织物工业协会(Association of theNonwoven Fabrics Industry))标准化，编号为IST-70.4-99，题目为″使用防护膜和蒸气压传感器测试水蒸汽通过非织造和塑料膜的透过速率的标准测试方法″，该文献在此引入作为参考。INDA过程提供WVTR的测定，膜对水蒸汽的渗透，和对于均匀材料，水蒸汽渗透率系数。
INDA测试方法是公知的，不在此详细说明。然而，测试过程总结如下。由永久防护膜和待测试的样品材料分隔干燥腔和已知温度和湿度的潮湿腔。防护膜的目的是限定一定的空气间隙和平静或静止空气间隙中的空气同时表征空气间隙。干燥腔，防护膜和潮湿腔组成扩散池，其中密封测试膜。样品夹具已知为由Mocon/ModernControls，Inc.，Minneapolis，明尼苏达制造的Permatran-W型号100K。第一测试由防护膜的WVTR和产生100％相对湿度的蒸发器组合体之间的空气间隙组成。水蒸汽通过空气间隙和防护膜扩散并随后与对水蒸汽浓度成比例的干燥气体流混合。将电信号送到处理用计算机。计算机计算空气间隙和防护膜的透过速率和贮存数值用于进一步的用途。
防护膜和空气间隙的透过速率在计算机中贮存为CaIC。然后在测试池中密封样品材料。再次，水蒸汽通过空气间隙扩散到防护膜和测试材料并随后与扫描测试材料的干燥气体流混合。此信息用于根据如下公式计算水分透过测试材料的透过速率：
TR(-1)(测试材料)＝TR(-1)(测试材料、防护膜、空气间隙)-TR(-1)(防护膜、空气间隙)
WVTR ＝Fρ(sat)(T)RH/(Ap(sat)(T)(1-RH))
其中：
F＝以cc/min.计的水蒸汽流量，
ρ(sat)(T)＝在饱和空气中在温度T下的水密度，
RH＝在池中规定位置的相对湿度，
A＝池的横截面积，和
p(sat)(T)＝在温度T下的水蒸汽的饱和蒸汽压。
熔融指数
熔融指数是树脂流动容易程度的量度，并可以使用ASTM标准D1238，条件190℃/2.16kg(条件E)测定。膜中的两种组分具有不同的熔融指数数值以获得在此所述的改进结果。更具体地，密度广泛地小于0.915g/cc的调制树脂的熔融指数小于6g/10min。通常，具有高熔融指数的聚合物具有低粘度。根据本发明载体和调制树脂的熔融指数和密度参数的组合得到具有降低的由分裂而出现故障的倾向的改进两相膜。
开发一系列实施例以证明和区别本发明的属性。
实施例1
在实施例1中产生膜/非织造层压材料。膜层包含在载体树脂中分散的碳酸钙。使用例如从Omya以名称2SST购得的具有8-10微米顶切和约1％硬脂酸涂料的碳酸钙。碳酸钙(75％)和载体树脂(25％)，Dowlex 2517 LLDPE(熔融指数25和密度0.917)，然后将复合物在单螺杆常规挤出机中与密度为0.902和熔融指数为3.0的AffinityPL-1850 LLDPE调制树脂共混，以提供52wt％的最终碳酸钙浓度。Dowlex和Affinity聚合物购自Dow Chemical U.S.A.ofMidland，Michigan。
在40gsm的未拉伸基础重量下通过流延到设定到80°F的急冷辊上将此配制剂成形为膜。使用纵向取向器(MDO)将膜拉伸3.6倍于它的初始长度到16gsm的拉伸基础重量。在此使用的拉伸膜3.6倍表示例如具有1米初始长度的的膜如果拉伸3.6倍将具有3.6米的最终长度。将膜加热到155°F的温度并以498英尺每分钟的线速度通过MDO运行以拉伸膜。然后将膜在180°F的温度下退火。
纤维性非织造网是使用由ExxonMobil Chemical Company生产的Exxon 3155聚丙烯制备的0.4osy纺粘网。使用的纺粘方法通常如在Haynes等人的美国专利申请公开US 2002-0117770中所述，该文献全文引入作为参考，并使用线编织粘合图案。
使用粘合剂层压采用槽模头涂覆器进行两层的层压。将由Huntsman Polymers Corporation，Odessa，Texas生产的Rextac2730 APAO基粘合剂熔融到350°F的温度并采用1.5gsm的加上水平施加到纺粘片。然后通过在提供足够压力以保持完全接触的低压结合辊隙中以约435fpm的速度走过和采用未受热的辊将纺粘片和膜网组装在一起。获得的层压材料的结合基础重量为31gsm。
通过使用剪切纵切机将层压材料切开到13英寸的宽度。层压材料立即走过s-缠绕以从纵切机和粘合剂层压单元分离拉出物(drawaway)。将层压材料在纵向在s-缠绕和退火单元中的第一辊之间拉伸6％，引起CD宽度降低到9.75英寸，25％颈缩。然后将层压材料在200°F下在两个辊上退火以将材料中的颈缩定形及膜侧接触辊。最后将材料采用最小拉伸携带到卷绕机用于38gsm的最终基础重量。
实施制2
在实施例2中产生另一个膜/非织造层压材料。膜层与用于实施例1的相同，区别在于使用AffinityPF1140 LLDPE(53％)/Dowlex2244 LLDPE(47％)干共混物调制树脂代替AffinityPL-1850。PF1140的密度是0.897和熔融指数是1.6。Dow 2244的密度是0.916和熔融指数是3.3。纤维性非织造网与用于实施例1的相同。
采用与实施例1中相同的方式和相同的条件进行两层的层压。
也采用与实施例1中相同的方式和相同的条件进行层压材料的加工。
实施例3
在实施例3中产生另一个膜/非织造层压材料。膜层与用于实施例1的相同，区别在于使用由Dow Chemical Company生产的Attane4404G LLDPE调制树脂代替Affinity PL-1850。Attane 4404G的密度是0.904和熔融指数是4.0。纤维性非织造网与用于实施例1的相同。
采用与实施例1中相同的方式和相同的条件进行两层的层压。
也采用与实施例1中相同的方式和相同的条件进行层压材料的加工。
对比例1
在对比例中产生膜/非织造层压材料。膜层包含如在实施例1中在载体树脂中分散的碳酸钙。碳酸钙(75％)和载体树脂(25％)，Dow2517 LLDPE，然后将复合物在单螺杆常规挤出机与密度为0.917和熔融指数为2.3的Dowlex 2047 LLDPE调制树脂共混，以提供49wt％的最终碳酸钙浓度。Dowlex聚合物购自Dow Chemical U.S.A.ofMidland，Michigan。
在54.7gsm的未拉伸基础重量下通过流延到设定到90°F的急冷辊上将此配制剂成形为膜。使用纵向取向器(MDO)将膜拉伸3.46倍于它的初始长度到20gsm的拉伸基础重量。将膜加热到190°F的温度并以495英尺每分钟的线速度通过MDO运行以拉伸膜。
对比例2
在对比例中产生膜/非织造层压材料。膜层包含如在实施例1中在载体树脂中分散的碳酸钙。碳酸钙(75％)和载体树脂(25％)，Dow2517 LLDPE，然后将复合物在单螺杆常规挤出机与密度为0.917和熔融指数为2.3的Dowlex 2047 LLDPE调制树脂共混，以提供58wt％的最终碳酸钙浓度。Dowlex聚合物购自Dow Chemical U.S.A.ofMidland，Michigan。
在45gsm的未拉伸基础重量下通过流延到设定到89°F的急冷辊上将此配制剂成形为膜。使用纵向取向器(MDO)将膜拉伸3.45倍于它的初始长度到17.5gsm的拉伸基础重量。将膜加热到190°F的温度并以581英尺每分钟的线速度通过MDO运行以拉伸膜。
对比例3
在该对比例中，评价用于主导尿布产品的典型商业膜。它据信是由Pliant Corporation提供并包含Affinity和Dowlex共混物调制物的微孔碳酸钙填装膜。
测试来自上述实施例和对比例的样品的断裂应变和断裂强度，结果显示于下表1：
表1
实施例 在25％下的负荷 断裂应变％   在峰值下的总吸收能量 In-Lb/Sq.In
  16000* 103 647 2.02
  26000*   112   584   1.76
  36000*   113   624   1.88
  对比例11500*   165   402   1.40
  对比例212000*   109   297   0.74
  对比例36000*   165   361   1.55
*标称MOCON透气性MVTR数值，g/m/24小时
根据本发明获得的在25％伸长数值下的较低负荷表明：当例如尿布被打开和拉伸用于放在穿用者上时容易延伸。较高的断裂应变和TEA数值表示膜/层压材料忍受穿戴中和使用中施加的拉伸力的能力。
在涉及30名婴儿(50％男性，50％女性)给定5个尿布每天共7天时间的研究中，归纳于表2的结果显示采用利用来自实施例1的膜的外罩的尿布在尿泄漏、外罩湿度、BM泄漏和红色标记方面的改进。外罩湿度和％尿泄漏数作为消费者接受性的决定性因素给人特别深刻的印象。
表2
 编码描述   目标#   使用的尿布#   ％尿泄漏   ％外罩湿度  #BM泄漏   ％红色标记
 相似于对比例1和2的热层压材料w/膜   25   768   5.5   9.1  32   15.2
 相似于实施例1的热层压材料w/膜   28   807   2.9   6.7  30   13.9
因此，根据本发明提供了适于许多用途的具有改进应变性能的膜和这种膜的层压材料，所述用途包括个人护理产品如一次性尿布的组件。尽管就具体的实施方案描述了本发明，但它不限于这样的实施方案，并且希望包括如宽泛陈述的所附权利要求的全部范围，包括这些权利要求可以给予其权利的所有同等物。

Claims (20)

1.一种MVTR为至少约300g/m/24小时的透气层压材料，包括粘合到取向膜的非织造支撑层，所述取向膜包括调制树脂相和填充的载体树脂相，其中所述调制树脂包括密度小于约0.915和熔融指数为6或更小的乙烯共聚物，所述填充的载体树脂相包括密度比所述调制树脂大至少约0.003g/cc的不同乙烯聚合物或共聚物。
2.权利要求1的透气层压材料，其中膜调制树脂的密度小于约0.913g/cc，优选为约0.900g/cc-约0.912g/cc。
3.权利要求1或权利要求2的透气层压材料，其中载体树脂乙烯聚合物或共聚物的密度比所述调制树脂的高至少约0.007g/cc。
4.任何前述权利要求的透气层压材料，其中载体树脂乙烯聚合物或共聚物的熔融指数为至少约10g/10min，优选至少约20g/10min。
5.任何前述权利要求的透气层压材料，膜基础重量为约13gsm-约25gsm。
6.任何前述权利要求的透气层压材料，其中膜的碳酸钙填料浓度为约30wt％-约70wt％，基于总膜组合物。
7.任何前述权利要求的透气层压材料，其中两种膜乙烯共聚物选自LLDPE。
8.任何前述权利要求的透气层压材料，其中所述非织造物包括纺粘非织造物。
9.权利要求1-7任意一项的透气层压材料，其中所述非织造物包括粘合的梳理网。
10.任何前述权利要求的透气层压材料，其中所述非织造物包括多于一个层。
11.任何前述权利要求的透气层压材料，其中所述膜包括多于一个层。
12.任何前述权利要求的透气层压材料，其中所述膜在横向的断裂应变大于300％。
13.任何前述权利要求的透气层压材料，MVTR为约5000g/m/24小时-约10,000g/m/24小时。
14.任何前述权利要求的透气层压材料，其中所述膜更高密度乙烯共聚物的密度大于0.915g/cc。
15.任何前述权利要求的透气层压材料，其中所述调制树脂相和所述载体树脂相包括构成总膜厚度至少约90％的层。
16.个人护理产品，包括任何前述权利要求的透气膜层压材料。
17.一次性尿布，包括任何前述权利要求的透气膜层压材料作为衬垫组件。
18.一种形成膜和非织造物的透气层压材料的方法，包括如下步骤：
a.选择密度小于0.915g/cc和熔融指数小于约6的调制乙烯共聚物树脂；
b.在密度比所述调制树脂高至少约0.003g/cc的载体乙烯聚合物或共聚物树脂中分散填料；
c.采用一定的数量干共混所述调制树脂和所述填充的载体树脂以提供共混物中约30wt％-70wt％的填料浓度；
d.挤出所述共混物以形成膜；
e.拉伸所述膜；和
f.粘合所述膜到非织造层。
19.权利要求18的方法，其中拉伸所述膜的步骤在粘合所述膜和非织造层之后进行。
20.权利要求18或权利要求19的方法，其中所述粘合步骤包括粘合剂粘合步骤。
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CN104558792A (zh) * 2013-10-25 2015-04-29 中国石油化工股份有限公司 一种聚乙烯组合物及其制备方法
CN104558792B (zh) * 2013-10-25 2017-06-30 中国石油化工股份有限公司 一种聚乙烯组合物及其制备方法
CN109705437A (zh) * 2014-05-13 2019-05-03 克洛佩塑料产品公司 透气且多微孔的热塑性薄膜
CN111035790A (zh) * 2019-12-17 2020-04-21 湖北君言医疗科技有限公司 一种留置针用透明敷贴及其制备方法

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KR20060134903A (ko) 2006-12-28
AU2004272492A1 (en) 2005-03-24
EP1656253B1 (en) 2007-05-30
JP2007503326A (ja) 2007-02-22
US20050042962A1 (en) 2005-02-24
EP1656253A1 (en) 2006-05-17
AR045228A1 (es) 2005-10-19
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ZA200600764B (en) 2007-06-27
DE602004006760D1 (de) 2007-07-12

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