阅读说明：本技术 用于吸收装置的活化复合幅材 (Activation composite web for absorption plant ) 是由 A·D·马斯基诺 B·C·卢米斯 T·R·斯科奇多波勒 于 2018-03-12 设计创作，主要内容包括：一种活化复合幅材,包括无纺布层和附接到无纺布层的成形膜层。成形膜层包括具有至少35的目数的多个第一带孔突起,和多个第二带孔突起。每个第二带孔突起的横截面面积均大于每个第一带孔突起的横截面面积。多个第一道痕在第一方向上对准并且具有在基本垂直于第一方向的第二方向上延伸的第一宽度。第一带孔突起位于第一道痕中。多个第二道痕在第一方向上对准并且具有在第二方向上延伸的小于第一宽度的第二宽度。第一道痕和第二道痕在第二方向上彼此交替。第二带孔突起位于第二道痕中。(A kind of activation composite web, including nonwoven layer and the formed film for being attached to nonwoven layer.Formed film includes the multiple first protrusions with holes and multiple second protrusions with holes of the mesh number at least 35.The cross-sectional area of each second protrusion with holes is all larger than the cross-sectional area of each first protrusion with holes.Multiple first of trace are aligned in a first direction and have the first width upwardly extended in the second party basically perpendicular to first direction.First protrusion with holes is located in first of trace.Multiple second traces are aligned in a first direction and have the second width less than the first width extended in a second direction.First of trace and second trace are alternating with each other in a second direction.Second protrusion with holes is located in second trace.)

1. a kind of activation composite web comprising:

Nonwoven layer；

It is attached to the formed film of the nonwoven layer, the formed film includes: multiple first of the mesh number at least 35 Protrusion with holes, the multiple first protrusion with holes have multiple first holes with the first cross-sectional area；With multiple second bands Hole protrusion, the multiple second protrusion with holes have multiple second holes with the second cross-sectional area, each second cross section Area is all larger than each first cross-sectional area；

Multiple first of trace, the multiple first of trace are aligned in a first direction, and are had basically perpendicular to described the The first width that the second party in one direction upwardly extends, first protrusion with holes are located in first of trace；With

Multiple second traces, the multiple second trace are aligned in said first direction, and are had in the second direction The second width less than first width of upper extension, first of trace and the second trace are in this second direction Alternating with each other, second protrusion with holes is located in the second trace.

2. activation composite web according to claim 1, wherein each first hole all has the first long axis and first short Axis, wherein first long axis is substantially aligned in said first direction, and wherein, and it is long that each second hole all has second Axis and the second short axle, wherein second long axis is substantially aligned in this second direction.

3. activation composite web according to claim 1, wherein it is flat that the first top surface of first of trace is located at first In face, and the second top surface of the second trace is located at least one second plane different from first plane.

4. activation composite web according to claim 1, wherein the activation composite web is than its non-woven fabrics and formed film The summation of the original components of layer is light.

5. activation composite web according to claim 4, wherein the activation composite web is than its non-woven fabrics and formed film The summation gently at least 15% of the original components of layer.

6. activation composite web according to claim 1, wherein the formed film is oriented such that the first band Hole protrusion and second protrusion with holes extend far from the nonwoven layer.

7. activation composite web according to claim 1, wherein the nonwoven layer includes with the pattern for pressing molten position Spun-bonded non-woven fabrics material.

8. activation composite web according to claim 7, wherein the nonwoven layer includes being located at described press at molten position Multiple openings.

9. activation composite web according to claim 7, wherein the nonwoven layer includes prolonging far from the formed film The fracture fiber end for the multiple softnesses stretched.

10. activation composite web according to claim 1, wherein the activation composite web is vacuum-formed laminates.

11. activation composite web according to claim 1, wherein the first direction is machine direction.

12. activation composite web according to claim 1, wherein the part of the second trace is not straight.

13. activation composite web according to claim 12, wherein the part of the second trace is waveform.

14. activation composite web according to claim 1, wherein the cross-sectional area of second protrusion with holes is institute State at least the 150% of the cross-sectional area of the first protrusion with holes.

15. activation composite web according to claim 1, wherein it is described activation composite web the moisture-inhibiting time be less than or Equal to about 2.45 seconds.

16. activation composite web according to claim 1, wherein the activation composite web is the top in absorption plant Piece.

17. activation composite web according to claim 1, wherein the activation composite web is obtaining in absorption plant Take distribution layer.

18. a kind of method of manufacture activation composite web comprising:

Formed film is laminated in non-woven fabrics web to form composite web, the formed film includes the mesh at least 35 Several multiple protrusions with holes；

So that the composite web is passed through intermeshing gear to form activation composite web, the intermeshing gear be constructed with It is arranged to form multiple first of trace and multiple second traces in the activation composite web, first of trace is than described Two traces are wide, wherein the first subset of the protrusion with holes is located in first of trace, and the first protrusion with holes has with the Multiple first holes of one cross-sectional area, and the second subset of the protrusion with holes is located in the second trace, the second band Hole protrusion has multiple second holes with the second cross-sectional area, and second cross-sectional area is greater than first cross section Area.

19. according to the method for claim 18, wherein first cross-sectional area before activation and later basic phase Together.

20. according to the method for claim 18, wherein it is long that each hole all has first be substantially aligned in a first direction Axis and the first short axle being substantially aligned in the second direction basically perpendicular to the first direction, and wherein, each second Hole all has the second long axis being substantially aligned in this second direction and is substantially aligned in said first direction and is second short Axis.

21. according to the method for claim 18, wherein the lamination includes that polymer melt curtain is expressed into vacuum forming On cylinder, while the non-woven fabrics web being introduced on laminating roll so that the non-woven fabrics web the vacuum forming cylinder with The polymer melt curtain is contacted at touch points between the laminating roll.

22. according to the method for claim 21, wherein form the institute in the formed film using the vacuum forming cylinder State protrusion with holes.

23. according to the method for claim 22, wherein the vacuum forming cylinder includes the forming screen of pattern with hole Net.

24. according to the method for claim 18, wherein the initial basis weight of the non-woven fabrics web is about 10gsm.

25. according to the method for claim 24, wherein the initial basis weight of the formed film is about 12gsm.

26. according to the method for claim 25, wherein the base weight of the activation composite web is less than about 19gsm.

27. according to the method for claim 18, wherein the base weight of the activation composite web is than the formed film and institute The combination base weight for stating non-woven fabrics web is small by least 15%.

Technical field

The present invention relates to the activation composite web that can be used in absorption plant and the methods for preparing the activation composite web.

Background technique

The absorption that plastics forming film and non-woven fabrics are used as such as feminine hygiene articles, adult incontinence products and baby' diaper fills Top flat in setting.Top flat is the top layer of absorption plant, the skin of the user (wearer) of the top layer contact absorption plant.Nothing Woven fabric material is typically used as the topsheet component of such absorption plant, because of the wearing of top flat and absorption plant at the topsheet component The skin contact of person and it is expected obtain flexibility.Although having been generally acknowledged that high-loft and nonwoven cloth material when using against skin The ratio between overall thickness it is not only soft but also nice and cool, but usually require special processing to realize this characteristic, this may will increase product Cost.

For the top flat made of formed film, it is desired to have soft cloth rather than the visual appearance and softness of rigid plastics film Property.Although the top flat made of plastic foil usually has when being used for absorption plant compared with the top flat made of nonwoven cloth material There is better performance feature, but the visual appearance glossiness with higher of the top flat made of plastic foil, therefore compare nonwoven Cloth top flat has more " plastics appearance ".In addition, compared with nonwoven topsheet, possible wearer feel plastic foil top flat it is more "sticky" or " tacky ".

Be desired to have the lightweight web that can be used for absorption plant, for example, with attribute of performance relevant to formed film and with nothing The top flat of the relevant flexibility attribute of woven fabric material.

Summary of the invention

According to aspects of the present invention, a kind of activation composite web is provided comprising nonwoven layer and be attached to the nothing The formed film of woven fabric layer.Formed film includes: the multiple first protrusions with holes, has at least 35 mesh number and with the first cross Multiple first holes of area of section: and multiple second with multiple second holes with the second cross-sectional area are with holes prominent It rises.Each second cross-sectional area is all larger than each first cross-sectional area.Activating composite web includes multiple first of trace, It is aligned in a first direction, and there is the first width extended in the second direction basically perpendicular to first direction.First band Hole protrusion is located in first of trace.Multiple second traces are aligned in a first direction, and have and extend in a second direction Less than the second width of the first width.First of trace and second trace are alternating with each other in a second direction.Second protrusion position with holes In second trace.

In one embodiment, each first hole all has the first long axis and the first short axle, wherein the first long axis is in first party Alignment upwards, each second hole all has the second long axis and the second short axle, wherein the second long axis is aligned in a second direction.

In one embodiment, the first top surface of first of trace is located in the first plane, the second top surface of second trace In at least one second plane different from the first plane.

In one embodiment, activation composite web is lighter than the summation of the original components of its non-woven fabrics and formed film.One In embodiment, summation gently at least 15% of the activation composite web than the original components of its non-woven fabrics and formed film.

In one embodiment, formed film is oriented so that the first protrusion with holes and the second protrusion with holes far from nonwoven layer Extend.

In one embodiment, formed film is oriented so that the first protrusion with holes and the second protrusion with holes towards nonwoven layer Extend.

In one embodiment, nonwoven layer includes the spun-bonded non-woven fabrics material for melting the pattern at position with pressure.Implement one In example, nonwoven layer includes positioned at the multiple openings pressed at molten position.In one embodiment, nonwoven layer includes far from formed film The fracture fiber end for multiple softnesses that layer extends.

In one embodiment, activation composite web is vacuum-formed laminates.

In one embodiment, first direction is machine direction.

In one embodiment, first direction is transverse direction.

In one embodiment, the part of second trace is not straight.

In one embodiment, the part of second trace is waveform.

In one embodiment, the cross-sectional area of the second protrusion with holes be the first protrusion with holes cross-sectional area at least 150%.

In one embodiment, activation composite web has the moisture-inhibiting time less than or equal to about 2.5 seconds.

In one embodiment, activation composite web is the top flat in absorption plant.

In one embodiment, activation composite web is the acquisition distribution layer in absorption plant.

According to aspects of the present invention, a kind of method of manufacture activation composite web is provided.The described method includes: will forming Film layer is laminated to non-woven fabrics web to form composite web, and the formed film includes the multiple with holes of the mesh number at least 35 Protrusion；Make the composite web by pitch wheel to form activation composite web.Pitch wheel is constructed Be arranged to form multiple first of trace and multiple second traces in composite web.First of trace is wider than second trace.It is with holes First subset of protrusion is located in first of trace, and the first protrusion with holes has multiple first holes with the first cross-sectional area, The second subset of protrusion with holes is located in second trace, and the second protrusion with holes has multiple second with the second cross-sectional area Hole.Second cross-sectional area is greater than the first cross-sectional area.

In one embodiment, before activation and later, the first cross-sectional area is essentially identical.

In one embodiment, each first hole all has the first long axis being substantially aligned in a first direction and is hanging down substantially Directly in the first short axle being substantially aligned in the second direction of first direction, each second hole all has substantially right in a second direction The second quasi- long axis and the second short axle being substantially aligned in a first direction.

In one embodiment, lamination includes that polymer melt curtain is expressed on vacuum forming cylinder, while by nonwoven webs Material introduces on laminating roll, so that non-woven fabrics web contacts polymer melt at the touch points between vacuum forming cylinder and laminating roll Curtain.

In one embodiment, the protrusion with holes in formed film is formed using vacuum forming cylinder.

In one embodiment, vacuum forming cylinder includes the forming sieve of pattern with hole.In one embodiment, Mei Gekong All have ship shape.

In one embodiment, the initial basis weight of non-woven fabrics web is about 10gsm.

In one embodiment, the initial basis weight of formed film is about 12gsm.

In one embodiment, the base weight for activating composite web is less than about 19gsm.

In one embodiment, the base weight for activating composite web is smaller at least than the combination base weight of formed film and non-woven fabrics web 15%.

The method of the operations and functions of these and other aspects of the invention, features and characteristics and associated structural elements with And the economy of combination and the manufacture of component will become more after reference attached drawing considers the following description and the appended claims It is obvious, it is all these to form part of this specification.However, it should be expressly understood that attached drawing is merely for illustrating and describing Purpose and be not intended as the definition of limitation of the present invention.As used in the specification and claims, singular " one (a) ", " one (an) " and " being somebody's turn to do (the) " include plural reference, unless the context clearly indicates otherwise.

Detailed description of the invention

The component of the following drawings is shown the General Principle to emphasize the disclosure and is not drawn necessarily to scale.For one For the sake of causing and being clear, the reference character of specified corresponding component is repeated as needed in all the appended drawings.

Fig. 1 is the schematic diagram of the equipment of the composite web of the lightweight for manufacturing activation of embodiment according to the present invention；

Fig. 2 is the schematic diagram of a part of the equipment shown in FIG. 1 of embodiment according to the present invention；

Fig. 3 is the signal of the cross section of a part of the composite web of the lightweight of the activation of embodiment according to the present invention Figure；

Fig. 4 is the photo of the side of the composite web of the lightweight of the activation of embodiment according to the present invention；

Fig. 5 is one opposite with side shown in Fig. 4 of the composite web of the lightweight of the activation of embodiment according to the present invention The photo of side；

Fig. 6 is the photo of the amplifier section of the side of the composite web of the lightweight of activation shown in fig. 5；

Fig. 7 is the schematic diagram of the side of the composite web of the lightweight of activation shown in fig. 5；

Fig. 8 is the photo of the cross section of the composite web of the lightweight of the activation of Fig. 5；With

Fig. 9 is the photo of the amplifier section of the cross section of the composite web of the lightweight of the activation of Fig. 8.

Specific embodiment

Throughout the specification, term " web " is the material for referring to be wound into a roll.Web can be film web material, nonwoven Cloth web, laminate web, laminate web with holes etc..The face of web refers to one of its two-dimensional surface, rather than its edge.Term " composite web " refers to such web comprising two or more individual webs, the individual web is with face-to-face Relationship be attached to each other.Attachment can pass through the edge of component web, but component web is placed with relation of plane facing with each other, Or attachment can be located at the specific position in component web.

In the present specification, term " film " refers to the melting by being cast or being blow molded extrusion molding for thermoplastic, polymeric materials Sheet material squeeze out then the cooling sheet material to form solid polymer web manufactured web.Film can be monofilm, co-extrusion Membrane, coated film and composite membrane.Coated film is the film for including single layer or co-extruded films, then with the single layer or coextrusion The thin layer coating (for example, Extrusion Coating, coining coating, printing etc.) for the identical or different material that film combines.Composite membrane is to include The film of more than one film, wherein at least two film combine in cohesive process.Cohesive process may include the bonding between film layer Oxidant layer.

Throughout the specification, term " hole membrane ", which indicates wherein to exist from a surface, extends to the multiple of second surface The film in hole.Two-dimentional hole membrane is the film that three-dimensional structure is not present in its mesoporous, then the hole connects the second surface of planar film It is connected to the first surface of film." formed film " is the three-dimensional films with protrusion, and three-dimensional hole membrane is the presence of three-dimensional knot in its mesoporous Structure (for example, the depth in hole is thicker than the thickness of film) or protrusion have the film in the hole passed through.

Term " non-woven fabrics " refers to the web comprising plurality of fibers.Fiber can be bonded to each other or can not combine.Fiber It can be staple fiber or continuous fiber.Fiber may include homogenous material, or may include multiple material, the multiple material It is the combination of different fibers, or the respectively combination of the similar fiber including different materials.As used herein, " non-woven fabrics web " For limiting relatively flat, flexibility and porous and substantitally planar knot including staple fiber or continuous filaments in generic sense Structure.Non-woven fabrics web can be the product of any technique for forming it, such as non-woven fabrics spunbond and melt blown non-woven fabrics web. Non-woven fabrics web may include compound or the combination of web.In one embodiment, non-woven fabrics web is made of polypropylene fibre Spunbonded materials.However, non-woven fabrics web may include can from its produce fiber any polymeric material and/or may include cotton or its His natural fiber.For example, non-woven fabrics web may include polyethylene, polypropylene, elastomer, polyester, artificial silk, cellulose, nylon, The fiber of cotton (or other natural fibers) and the mixture of these fibers.The fiber including different polymer can also be mixed.

As used herein, term " ductility " refer to can be applied in given directions by drawing force in web and The maximum strain amount that will not make fibrous fracture or destroy the combination between fiber (is single with % relative to zero strain state Position).It is extending on any assigned direction to refer to and apply drawing force to web in this direction for non-woven fabrics web When, web is expanded in this direction, and causes to strain in web, and will not make substantially fibrous fracture or destroy fiber it Between combination.

As used herein, term " sieve " refers to three dimensional molded equipment comprising for forming protrusion or hole in film Dent and/or hole and/or protruding portion.In one embodiment, sieve includes the tubular element with width and diameter.It is real in substitution It applies in example, sieve includes the band with width and length.Transverse direction is parallel to the direction of mesh widths.Machine direction is flat Row in sieve direction of rotation direction and perpendicular to transverse direction.

As used herein, term " protrusion " refers to three-dimensional structure comprising the band in the plane of the first surface of film Hole base segments and the sidewall sections substantially upwardly extended in the side of the second surface of film.Each base segments all have sidewall portion Point.Sidewall sections terminate at " end " in the plane of the second surface of film.It the end of protrusion can be with holes or non-porous.Such as Used herein, " protrusion with holes " refers in its protrusion with hole of end in the plane of second surface.The base portion of protrusion Hole in part, also referred to as " main aperture ", can with rule or random pattern in polygon (such as rectangular, hexagon, pentagon), Oval, round, oval or slot shape.In one embodiment, hole can be ship shape, such as in U.S. Patent number 7,198, Described in 836 like that, which is herein incorporated by reference.End outstanding is then known as " secondary aperture " if it is aperture And it can be polygon (such as square, hexagon, pentagon), oval, round, oval, slot or ship shape.

As used herein, statement " absorbent commodity " and " absorption plant " indicates to absorb and receiving body fluids and other bodies are arranged Let out the article of object.More specifically, absorbent commodity/absorption plant include against or close to wearer body place to absorb and Accommodate the clothes for the various excretas being discharged from body.

As used herein, term " activation " or " activation " refer to the point that material is stretched beyond to the change of its physical property Process.In the case where non-woven fabrics web, the abundant activation of web will lead to non-woven fabrics web and have more ductility and/or improve it Tactile properties.It in activation process, exerts a force on material, so as to cause material stretching.Formed film and non-woven fabrics web example It such as can be by mechanical activation.Mechanical activation process includes the stretching for causing web to web applied force using machine or equipment. Method and apparatus for activated material web includes but is not limited to activate web by pitch wheel or plate, is passed through Increment stretches to activate web, activates web by looping mill rolling, passes through stenter frame drawing, angle wheel stretcher or adjustable bow curved roll Activate web, and between the roll gap or roller heap operated with friction speed along machine direction activation web with mechanical stretching portion Part and their combination.

Referring now to Figure 1, Fig. 1 shows the compound width of the lightweight that can be used for manufacturing activation of embodiment according to the present invention The equipment 100 of material.As shown, equipment 100 includes being constructed and arranged to polymer melt curtain (molten polymer web) 104 The extrusion die 102 being expressed on vacuum forming cylinder 106.In one embodiment, molten polymer web 104 may include being selected from The polyolefin in group be made of polyethylene, polypropylene, ethylene ﹣ vinyl acetate and metallocene based polyolefins.Polyethylene can be with Selected from the group being made of ultra-low density polyethylene, linear low density polyethylene and linear density polyethylene.In one embodiment, Molten polymer web 104 may include selected from by polypropylene based elastomer, based elastomers, copolyesters based elastomeric, alkene The elastomer polymer in group that hydrocarbon block copolymer and styrene block copolymer are constituted.

Vacuum forming cylinder 106 includes forming sieve 108 and vacuum tank 110.The feed rolls 112 of non-woven fabrics web 114 are at this The position of sample centers in mandrel, and the position allows for non-woven fabrics web 114 to be supplied to the layer for adjoining vacuum forming cylinder 106 On pressure roller 116.With non-woven fabrics web 114 rotated around laminating roll 116 and enter laminating roll 116 and vacuum forming cylinder 106 it Between roll gap 118 in, non-woven fabrics web 114 contacts polymer melt curtain 104, at the same polymer vacuum forming cylinder 106 at It is still melted at touch points between shape sieve 108 and laminating roll 116.It is desirable that touch points are located at the vacuum of vacuum forming cylinder 106 Right above the leading edge of vacuum seal at slot 110.

The pattern in the hole in forming sieve 108 has determined the pattern of the protrusion in formed film.In one embodiment of the invention In, formed film includes the pattern of the protrusion with holes of the mesh number (i.e. every 57 holes of linear inch) with 57, wherein each with holes The cross section of protrusion is in ship shape (i.e. ship shape unit or " BSC ").Such pattern can be referred to as " 57BSC ".Ship shape unit Type hole is described in more detail in U.S. Patent number 6,989,187, which is incorporated herein by reference.It is many in formed film field Other well known formed film sectional hole patterns be also possible to it is useful, such as with every linear inch such as 100,80,60 or 40 The hexagon of the mesh number in hole, rectangular or round hole.Mesh number is 30 or smaller pattern may lose soft feeling, and may nothing Well in response to activation, this will be described in detail below method.

In one embodiment, formed film has multiple protrusions with holes of at least 35 mesh number.In one embodiment, described Protrusion with holes has at least 40 mesh number.In one embodiment, the protrusion with holes has at least 45 mesh number.In an embodiment In, the protrusion with holes has at least 50 mesh number.In one embodiment, the protrusion with holes has at least 55 mesh number.In In one embodiment, the protrusion with holes has at least 60 mesh number.In one embodiment, the protrusion with holes is at least 65 Mesh number.In one embodiment, the protrusion with holes has at least 70 mesh number.In one embodiment, the protrusion with holes has At least 75 mesh number.In one embodiment, the protrusion with holes has at least 80 mesh number.In one embodiment, described with holes Protrusion has at least 85 mesh number.In one embodiment, the protrusion with holes has at least 90 mesh number.In one embodiment, The protrusion with holes has at least 95 mesh number.

The fiber web material part of non-woven fabrics web 114 is embedded into molten polymer web 104, to form forming Laminate web 120.As protrusion with holes (this is discussed in further detail below) is formed in molten polymer web 104, two A web 104,114 continues on vacuum tank 110.Start air-flow by the hole in forming sieve 108, the air-flow is cooling And solidification of molten polymer web 104, and by becoming solid, polymer web is captured from the embedding of non-woven fabrics web 114 Enter fiber, to non-woven fabrics web 114 be combined on the formed film formed till now, to form vacuum-formed laminate web 120。

Formed film can have the base weight between about 6gsm and about 20gsm.In one embodiment, formed film has about The base weight of 6gsm.In one embodiment, formed film has the base weight of about 7gsm.In one embodiment, formed film has about The base weight of 8gsm.In one embodiment, formed film has the base weight of about 9gsm.In one embodiment, formed film has about The base weight of 10gsm.In one embodiment, formed film has the base weight of about 11gsm.In one embodiment, formed film has The base weight of about 12gsm.In one embodiment, formed film has the base weight of about 13gsm.In one embodiment, formed film has There is the base weight of about 14gsm.In one embodiment, formed film has the base weight of about 15gsm.In one embodiment, formed film Base weight with about 16gsm.In one embodiment, formed film has the base weight of about 17gsm.In one embodiment, formed film Layer has the base weight of about 18gsm.In one embodiment, formed film has the base weight of about 19gsm.In one embodiment, it shapes Film layer has the base weight of about 20gsm.

Non-woven fabrics web can have the base weight between about 8gsm and about 18gsm.In one embodiment, non-woven fabrics web has The base weight of about 8gsm.In one embodiment, non-woven fabrics web has the base weight of about 9gsm.In one embodiment, non-woven fabrics web Base weight with about 10gsm.In one embodiment, non-woven fabrics web has the base weight of about 11gsm.In one embodiment, nonwoven Cloth web has the base weight of about 12gsm.In one embodiment, non-woven fabrics web has the base weight of about 13gsm.In an embodiment In, non-woven fabrics web has the base weight of about 14gsm.In one embodiment, non-woven fabrics web has the base weight of about 15gsm.One In embodiment, non-woven fabrics web has the base weight of about 16gsm.In one embodiment, non-woven fabrics web has the base of about 17gsm Weight.In one embodiment, non-woven fabrics web has the base weight of about 18gsm.

Fig. 1 is returned to, vacuum forming laminate web 120 is pulled down and along machine by stripper roll 122 from vacuum forming cylinder 106 Direction continues on idler roller 124 and is introduced in activation roll gap 126.When the first intermeshing mill pinion 128 and second Mill pinion 130 is intermeshed to form activation roll gap 126 when certain depth of engagement engagement.Lightweight relative to activation it is compound The direction of motion of web 132 can be activated in machine direction (MD) or transverse direction (TD).

Fig. 2 shows intermeshing gear (" the IMG ") rollers 128,130 that can be used for TD activation in device 100 of fig. 1 Embodiment.As shown, roller 128,130 is carried on respective rotatable shaft 228 and 230, the rotation of the rotatable shaft Axis is arranged with parallel relation.Each of roller 128,130 includes multiple axially spaced circumferentially extendings side by side The tooth 232 of equivalent constructions, these teeth can be the form of the thin fin with generally rectangular cross section.

Space between adjacent teeth 232 limits the slot 234 of the equivalent constructions of recessed circumferentially extending.Do not limiting the present invention In the case where, tooth (gear) 232 is referred to herein as " tooth (teech) 232 ".When tooth 232 has generally rectangular cross section, Slot 234 can have generally rectangular cross section.Therefore, each of forming rolls 128,130 includes multiple teeth spaced apart Alternate slot 234 between 232 and each pair of adjacent teeth 232.Tooth 232 and slot 234 need not respective width having the same, it is preferred that The width of geosyncline 234 is greater than the width of tooth 232, to allow to be received in each bar groove by the material between forming rolls 128,130 In 234 and it is partially stretched.Uniquely in response to the stress, this is resulted according to the present invention vacuum forming laminate web 120 Activation lightweight composite web 132.

In MD activation, the forming rolls 128 looked down from the axis of the rotatable shaft 228,230 of forming rolls 128,130, 130 viewgraph of cross-section will show the gear teeth (not shown) for the circumference cut and around forming rolls 128,130, wherein its Long axis is basically parallel to the axis of forming rolls 128,130.In the slot in tooth engagement to adjacent roller 130 on one forming rolls 128, With in order to web 120 provide stretching action.

The depth of engagement of roller tooth, gear or fin 232 determines the elongation journey that vacuum forming laminate web 120 is subjected to Degree.Balance usually is obtained between the depth of engagement of roller tooth 232 and the ingredient of vacuum forming laminate web 120, this is because this A little factors affect many important physical attributes of the composite web 132 of the lightweight of activation.It some influence pitches, tooth depth and nibbles The factor for closing depth includes that the ingredient of composite web 132 of lightweight of activation, required final attribute are (gas permeability, absorbability, strong Degree, cloth sense) and IMG roller 128,130 width and diameter.The final application of the composite web 132 of the lightweight of activation also influences These selections, reason is it is determined that required final attribute.There may be economic and technicals for the width of IMG roller 128,130 Limitation.Particularly, as width increases, the weight of IMG roller 128,130 also increases, the deflection that IMG roller 128,130 is undergone Increase.Flexure not only generates variation during stretching, but also variation is also generated during manufacturing IMG roller 128,130, especially It is the increase with pitch and tooth depth.Those of skill in the art be able to use guidance provided herein change IMG roller 128, 130 parameter is to realize desired stretching.

Back to Fig. 1, vacuum forming laminate web 120 is activated in activation roll gap 126 by IMG roller 128,130, with shape It at the composite web 132 of the lightweight of activation, can be introduced into further downstream procedures, such as needed for addition final products Processing, joint-cutting and be wound into a roll.

Fig. 3 shows the schematic cross-section of a part of the composite web 300 of the lightweight of embodiment according to the present invention. As shown, the composite web 300 of lightweight includes formed film 310 and nonwoven layer 320.Shown in cross section be derived from lightweight The wide road trace part of composite web 300, this is detailed further below.Formed film 310 includes far from nonwoven layer 320 The multiple protrusions 312 with holes extended.In one embodiment, formed film 310 can be oriented such that 312 direction of protrusion with holes Nonwoven layer 320 extends.The orientation of protrusion 312 with holes can leave absorption plant designer's discretion for.Each protrusion with holes 312 is Including hole 314, the hole is surrounded at area (land) 318 at coronal side wall 316, and the area is in adjacent protrusion Extend between 312 hole 314.Area 318 can be plane or slight curving, and the range of the size in area 318 can be with From the measurable distance between hole 314 to distance very sharp and similar to razor of ignoring.

Formed film 310 is attached to nothing at multiple fusion points 330 at the area 318 for being usually located at formed film 310 Woven fabric layer 320, so that composite web 300 is laminated to enough peeling forces, with for can in the stress wherein applied Retaining layer 310,320 is attached during capable of tending to the subsequent conversion method for causing layer to separate and during final use.In the U.S. Vacuum forming laminating method for leading to the fused portion 330, the patent have been described in further detail in the patent No. 6,242,074 It is incorporated herein by reference.

In one embodiment, 300 shape of composite web can be run through before or after activating by any suitable means At other hole.For example, in one embodiment, pin punching unit is such as special in such as U.S. being incorporated herein by reference Benefit number 6, pin punching unit described in 849,319 can be positioned at vacuum cylinder 106 and IMG roller depending on required effect 128, between 130 or after IMG roller 128,130.For example, such additional holes can be less than 35 holes of every linear inch to have Mesh number pattern arrangement.In one embodiment, after film layer is laminated in non-woven fabrics web, pin can be used Punch unit replaces vacuum cylinder 106 and forming sieve 108 to form multiple protrusions with holes 312.

Fig. 4 is that the amplification of the side (i.e. the lateral surface of nonwoven layer 320) backwards to formed film 310 of nonwoven layer 320 is shone Piece 400.As shown in Figures 3 and 4, nonwoven layer 320 includes that multiple fibers 322 and multiple press melt position 324, the multiple to press molten portion Fiber is locally combined together to form the width for nonwoven layer 320 with generally uniform thickness and integrality by position Material.Fiber 322 is made of polymer, can be polyolefin, such as polypropylene.

Press molten position 324 be for spun-bonded non-woven fabrics material it is typical, such as one in the present embodiment.If do not pressed Molten position 324, fiber 322 will separate and away from one another, so that nonwoven layer 320 loses integrality.As needed or According to expectation, press molten position 324 that may or may not be aligned with fused portion 330.It such as can be obviously from embodiment shown in Fig. 3 Out, molten position 324 is pressed not to be aligned with fused portion 330 usually.

U.S. Patent number 5,916,661 (it is incorporated herein by reference) teaches the molten position of pressure, such as Fig. 3 and Fig. 4 institute The pressure shown melts position 324, also makes the fiber in the region being fused together under pressure spot thinning and dies down.It can use pattern The stack of change and smooth anvil roller, which are formed, presses molten position, the patterned stack and smooth anvil roller can be heated and Pressure between adjustable two rollers is to provide required temperature and pressure, to weaken and melt simultaneously at these multiple positions Stablize non-woven fabrics web.It is complete to provide web that this pre-existing pressure that not only can use any spun-bonded non-woven fabrics melts position Property, and more positions can be provided, so that being pressed molten when being activated using a pair of rolls with intermeshing gear The fiber of reduction can be broken to form opening in non-woven fabrics.In this way it is possible to be formed at the molten position of pressure with multiple The non-woven fabrics web of the activation of opening.

Fig. 5 is enlarged photograph 500, and it illustrates the composite webs with several arrow path traces 510 and several wide road traces 520 300 plan view.Wide road trace 520 includes most of lesser protrusions 312 with holes substantially, and arrow path trace 510 includes biggish with holes Protrusion 312.In general, one or two of arrow path trace 510 protrusion 312 with holes is extended.In the embodiment of 57BSC pattern In, wide road trace is usually three, and sometimes four holes 314 are wide.Although the shadow that the most aperture 314 in wide road trace is not activated It rings, but some random holes 314 may become slightly larger.Road trace width and its spacing are mainly by intermeshing gear spacing and gear Width determines.This can change for different meshes to influence not people having a common goal's trace width.

For the embodiment, gear, with 0.105 inches apart, has 0.043 inch of width and 0.260 at center The height of inch.They taper slightly and have flat rectangular end.In this embodiment, formed film before activation Base weight be about 11.7g/m²(gsm).In conjunction with the non-woven fabrics web of 10gsm, formed film 310 and nonwoven layer before activation The summation of 320 original components is about 21.7gsm.But the composite web 132 of the lightweight of activation is lighter and about 17.2gsm. Therefore, summation gently about 20% of the composite web 132 of the lightweight of activation than its original components.In formed film 310 and non-woven fabrics In the applicable basis weight range of layer 320, it is believed that most of activation composite webs are by the summation than its original components gently at least about 15% To no more than about 25%.

Most generally, as the embodiment, arrow path trace 510 is aligned in a machine direction.In random areas, in lightweight Composite web 300 in arrow path trace 510 can along its length for segment have wave.This will not damage its performance, even Aesthetic values can be can increase.Equally, if it is desired, activation method as known in the art can be used to manufacture the compound of lightweight Web 300, wherein arrow path trace 510 is aligned in a lateral direction.

Referring now to Figure 6, showing the bigger enlarged photograph 600 of the composite web 300 of lightweight, focus on from arrow path Several holes 616 of trace 510 and come at the several holes 614 for trace 520 of comforting oneself.

Fig. 7 schematically shows figure more evenly, the graph show in wide road trace 520 hole 614 with narrow The difference between hole 616 in road trace.As shown, an arrow path trace 510 is located between the road Liang Gekuan trace 520.In wide road trace It is the smaller hole 614 with long axis 610 and short axle 620 in 520.In the figure, the long axis 610 of smaller hole 614 is along machine Direction (MD) axis 622 is vertically aligned in a first direction.In arrow path trace 510, it is provided with short axle 650 and long axis 660 expanded hole 616.In the figure, long axis 660 is upper opposite in orientation and horizontal along transverse direction (TD) axis 624 Ground is aligned in a second direction.

As shown in fig. 7, each of wide road trace hole 614 all has long axis 610 and short axle for the 57BSC embodiment 620.Even if replacing BSC pattern using hexagon or circular pattern, when producing formed film or forming film composite, machine Web is downstream drawn by a series of driven vollers and/or driven nip rolls.In order to keep web without wrinkle, it is necessary to slightly increase The speed of each subsequent driven voller system.This referred to as " is pulled ".Machine direction pulling will to be directed in the pattern in hole 314 The imparting of machine direction axis 622 extends to a certain degree and narrows to a certain degree for the imparting of transverse direction axis 624.Therefore, nothing It as a result all will be such wide road trace 520, wherein smaller hole 614 has along machine direction by whether expected BSC pattern is used The short axle 620 of the long axis 610 of axis 622 and in transverse direction axis 624.Smaller hole for the embodiment, in wide road trace 520 614 include long axis 610, are aligned along machine direction, wherein be measured as about 0.0080 inch；Short axle 620, in transverse direction Alignment, wherein be measured as about 0.0045 inch.

Surprisingly, the hole 616 in arrow path trace 510 not only becomes larger, but also many expanded holes 616 have opposite axis Line alignment.For example, in this embodiment, the expanded hole 616 of arrow path trace has opposite axes orientation, and short-and-medium axle 650 is in machine Device is aligned on direction, and long axis 660 is aligned in a lateral direction.(it is in machine for the short axle 650 of the expanded hole 616 of the embodiment Be aligned on direction) size be about 0.0075 inch.The long axis 660 of the expanded hole 616 of the embodiment is (right in a lateral direction It is quasi-) size be about 0.0100 inch.Therefore, activation causes such effect, wherein with the smaller hole 614 in wide road trace 520 It compares, many arrow path trace expanded holes 616 have opposite axis, wherein its long axis 610 is along transverse direction, and its short axle 620 Along machine direction.

The area in hole 314,614,616 be calculated as ellipse area: 1/2 long axis 610,660 multiplied by 1/2 short axle 620, 650 multiplied by 3.14159 (Pi, π).For the smaller hole 614 of the wide road trace of the embodiment of Fig. 5, following equation is obtained: 0.004 × 0.00225 × 3.14159=0.0000283 square inches.For the arrow path trace expanded hole 616 of the embodiment of Fig. 5, obtain Following equation: 0.0050 × 0.00375 × 3.14159=0.0000589 square inches.Therefore, compared with smaller hole 614, expand The expansion factor of macropore 616 is about 200%.For the pattern range useful for the web, activation can substantially at least About 150% expansion factor.

Referring now to Figure 8, showing the enlarged photograph of the cross section of the composite web 132 of the lightweight of activation of the invention 800.Photo 800 shows the single arrow path trace 510 that the road Liang Gekuan trace 520 is separated.Wide road trace 520 is present in the first plane In 810, and arrow path trace 510 is present in the second plane 820 different from the first plane 810.First plane 810 and the second plane The distance between 820 be the engagement depth that changes and will generally depend upon the pitch wheel 228,230 of activation step How degree and the specific pattern and blend polymer of the protrusion in formed film are in response to activating stress.This is also depended on Thickness between the road Hen Yu trace in the entire web with common non-woven fabrics and forming film figure and blend polymer With the slight change of homogenieity.

Another theory advantage of these road traces 510,520 in Different Plane 810,820 can be it and provide additionally cool Refreshing and comfort.For example, in diaper, as infant pee and warm urine accumulate in diaper cores, warm tide can be generated Wet moist steam.If these steam cannot be discharged quickly, diaper may become wet viscous and uncomfortable.In the second plane The path that lateral or longitudinal void space is escaped as moist steam can be provided with arrow path trace 510 in 820.In United States Patent (USP) Shen Please describe the design in publication number 2003/0195487, which is incorporated herein by reference, and provide provided that Void space then improves the data of cooling rate.It is provided therefore it is believed that the composite web 132 of the lightweight of activation of the invention has Some void spaces are to improve the feature of cooling rate.

Referring now to Figure 9, showing the selection area for representing multiple similar areas in highly enlarged photo 900.According to Piece 900 shows region 910, which has soft fracture fiber end 912, and the fracture fiber end of the softness is again It is oriented to nearly vertical.It is well known that thin vertical fiber end in sense of touch field, such as undergone in napping cotton Those of, soft feeling can be generated.U.S. Patent number 7,351,297 (it is incorporated herein by reference) is taught using certain The activation that the intermeshing gear of the depth of engagement carries out is so that some non-woven fabrics fibers are broken, to form generation more high-flexibility Fiber end.In this way, being formed simultaneously with reorientation is nearly vertical soft fracture fiber end Activate non-woven fabrics web.In embodiments described herein, non-woven fabrics is spunbond polypropylene web or " SBPP " and has By gram/m or gsm in terms of average out to 10gsm base weight.

The composite web 132 of the lightweight of above-mentioned activation is not only lighter and softer but also right than such conventional web There is the faster moisture-inhibiting time in synthetic urine solution.Using according to the moisture-inhibiting equipment of 150.5 ﹣ 02 of EDANA ERT (including with electricity The funnel of magnet valve, the ring stand for supporting funnel, moisture-inhibiting plate, substrate and electronic timer with electrode) moisture-inhibiting time test is carried out, The equipment is sold by the Lenzing Technik of Austria with the title of Lister.Synthetic urine solution is a kind of salting liquid, by going 9g/l analysis level sodium chloride solution in ionized water forms and on 23 DEG C (2 DEG C of+/ ﹣) generation 70mN/m (+/ ﹣ 2mN/m) surfaces Tension.

By web sample be cut into about 4 inches × 4 inches and be placed on absorption paper heap it is stacked on.The stacking is placed on Lister Below moisture-inhibiting plate, the aperture of plate is aligned with the outlet of funnel.The sample of 10ml salt water is introduced into Lister plate hole mouth.Go out for the first time When existing salt water, it can contact the electric contact in aperture, this forms the circuit of starting timer.Once salt water break through web sample with It is fully absorbed by the stacking of paper, and has therefore been emptied completely the aperture of plate, circuit just will disconnect, this closes timer.With This mode determines and records " moisture-inhibiting time ".If the moisture-inhibiting time is slower than the function time, urine may be gathered on surface And be displaced sideways, to be leaked out from diaper.

Many combinations of non-woven fabrics and formed film are had existed in absorption plant market.It was found that various uses, such as obtain Take layer and occasionally tergite.But due to their heavinesses, lack flexibility, lack nice and cool property and it is many have it is slower saturating The wet time, therefore they are usually not used as top flat.Preferably the formed film of composite web has mesh number with holes greater than 35 Protrusion, to generate the activation composite web of lightweight and softness.In this embodiment, screen number be 57 mesh, and composite web with 11.7gsm carries out vacuum forming lamination, this is precisely half mil hereinafter, thinking that this is very thin for film.Hole 314,614, 616 is very small, and not necessarily has an impact to the functional moisture-inhibiting time.

When testing the moisture-inhibiting time of the web of non-activated web or activation depth less than about 0.16 inch, they have Average about 2.85 seconds high level.When activation depth is 0.165 to about 0.180 inch, the moisture-inhibiting time is down to 2.27 seconds, fast about 25%.In the range of web of the invention, it is contemplated that their moisture-inhibiting time will be less than or equal to about 2.5 seconds.

Wherein the layer of the web will be found to have high functionality (especially as top flat or as the enhancing below top flat Layer) absorption plant include but is not limited to baby' diaper, adult incontinence devices, the female sanitary towel including labia option, health Sliver, pantiliner, mop, cleaning cloth, absorption pad (such as mattress and overflow prevention pad) etc..Web of the invention is the softness of lightweight With it is flexible and any of these good with should all show on the way.

Embodiment described here represents many feasible embodiments and example, and has no intention to limit the disclosure In any specific embodiment.On the contrary, can be carry out various modifications to these embodiments, and such as the ordinary skill people of this field As member will be understood that, even if not being expressly recited, the various combination of various embodiments described herein is also used as this A part of invention.Any such modification is intended to be included in spirit and scope of the present disclosure, and is wanted by appended right Ask protection.