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CN100378263C - 用于衬片和衬里的在cd上可伸展的布状非织造物 - Google Patents

用于衬片和衬里的在cd上可伸展的布状非织造物 Download PDF

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CN100378263C
CN100378263C CNB008109419A CN00810941A CN100378263C CN 100378263 C CN100378263 C CN 100378263C CN B008109419 A CNB008109419 A CN B008109419A CN 00810941 A CN00810941 A CN 00810941A CN 100378263 C CN100378263 C CN 100378263C
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nonwoven web
width
machine direction
spunbond
web
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CN1371437A (zh
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S·C·-C·嬴
M·T·莫尔曼
S·E·肖弗
P·W·埃斯蒂
J·S·舒尔茨
D·G·乌伊滕布雷克
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Kimberly Clark Worldwide Inc
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  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
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  • Life Sciences & Earth Sciences (AREA)
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  • General Health & Medical Sciences (AREA)
  • Veterinary Medicine (AREA)
  • Dermatology (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Nonwoven Fabrics (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Laminated Bodies (AREA)
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  • Materials For Medical Uses (AREA)

Abstract

一种制造具有在横截机器方向上的可伸展性的非织造幅面料材料的方法，其中经过使非织造幅面料在横截机器方向(CD)上伸长的机器输送非织造幅面料。然后，使伸长的非织造幅面料收缩，以形成横截机器方向可伸展的非织造幅面料材料。CD可伸展的非织造幅面料材料高度可伸长，并适用于人身护理制品，例如尿布、失禁衣服和女性护理产品。

Description

用于衬片和衬里的在CD上可伸展的布状非织造物
技术领域
本发明涉及弹性化的材料及其制造方法。更具体的是，本发明涉及布状的在横截机器方向可伸展的非织造幅面料，该非织造幅面料包括除了在CD上可伸展外还在全宽上可制造的非织造幅面料，或者包括很容易在CD上可伸展到大大超出其原始制造宽度的减径的非织造幅面料，和制造这种非织造幅面料的方法。本发明还涉及这样的非织造幅面料，即当它与弹性丝或非织造材料例如薄膜、泡沫或熔喷材料连接时，该非织造幅面料构成可伸长的层压制品。这种非织造幅面料和层压制品适合在各种制品中用作衬片、外覆盖物和衬里，所述各种制品包括人身护理制品例如尿布、失禁用衣着，女性护理产品例如卫生垫和卫生巾，和其它类型的制品，例如抹布，包括面罩的衣服、手术服和类似物、薄纱、绷带、敷料和诸如此类。
背景技术
通过非织造物挤制法例如熔喷法和纺粘法形成的非织造幅面料可非常便宜地制造一些产品或产品的部件，这样，该产品可在仅一次或几次使用后即可废弃。这种产品包括尿布、训练裤、失禁用衣着、抹布和女性护理产品。然而，由非弹性聚合物形成的非织造幅面料通常缺乏弹性，因此，限制了这些非织造幅面料材料用于那些弹性是希望的或必要的应用场合，例如一次性尿布、失禁用衣着和卫生垫与卫生巾中。
这方面存在的一些问题是提供可回弹、柔性且摸起来感觉舒服同时没有塑料或橡胶感觉的弹性材料。通过形成一种弹性材料的层压制品可改进弹性材料的美学性能，该层压制品的外面层或表面上具有一种或多种非弹性材料，以提供更佳的触觉和手感。通过将非弹性材料粘合到弹性材料上制成弹性和非弹性材料的复合材料的方式，允许整体复合材料伸长或伸长和恢复。在一种这样的复合材料中，非弹性材料与弹性材料接合，同时，弹性材料处于伸长状态，以便当弹性材料松释时，非弹性材料在它与弹性材料粘合的点之间聚拢。结果，复合弹性材料可伸长到在粘合点之间聚拢的非弹性材料允许弹性材料伸长的程度。这种复合材料由授予Vander Wielen等人的美国专利4720415进行了教导。
目前，在制造用于人身护理制品的一些可伸长的布状材料中，非织造衬片收缩，然后层压，以制造在横截机器方向可伸长的材料。然而，由于非织造幅面料衬片的收缩，使用基础机器的全宽受损，导致以每小时平方码为单位计量的基础机器生产率受损。因此，为了充分发挥基础机器能力，最好能够使用基础机器的整个宽度来处理材料，同时制造横截机器方向可伸长的非织造幅面料和层压制品。
如上所述，在本技术领域中使非织造幅面料材料收缩以赋予可伸展性能是公知的。例如参见授予Morman的美国专利4965122。然而，收缩材料的一个问题是它仅能伸展到几乎其原始制造的宽度。当一种材料在它断裂前仅能收缩这么多时，可能赋予材料的伸长量受限制。
发明内容
因此，本发明的一个目的是提供一种利用基础机器的全部宽度制造横截机器方向可伸长的非织造幅面料材料的方法。
本发明的另一个目的是提供一种在横截机器方向可伸长至大于原始机器宽度的非织造幅面料材料。
本发明的又一个目的是提供一种高度可伸长的非织造幅面料材料。
本发明的这些和其它目的通过制造具有横向可伸展性的非织造幅面料材料的方法来实现，其中将一种非织造幅面料经过用于在横截机器方向上使该非织造幅面料伸长的装置输送。然后伸长的非织造幅面料收缩，形成横截机器方向可伸展的非织造幅面料材料。根据本发明的方法的一个实施例，只要提供超出基础机器的整个机器能力，则非织造幅面料收缩到其原始宽度。根据本发明的方法的另一个实施例，非织造幅面料收缩到小于其原始宽度，导致很高的横向伸长非织造物，这大于仅使原始幅面料收缩。的确，根据本实施例制造的非织造幅面料可伸长到至多约其收缩宽度的七倍。为了锁定收缩宽度，并通过伸展赋予幅面料部分回缩力，可伸长的非织造幅面料材料可被热处理。根据一个实施例，为了形成横向可伸长的层压件，可伸展的非织造幅面料与弹性非织造材料例如薄膜连接。
基于上述目的，本发明提供一种制造热设定收缩的非织造幅面料的方法，该方法包括如下步骤：提供具有一预收缩的原始宽度的非织造幅面料；使所述非织造幅面料在横截机器方向上伸长，直到其具有大于所述原始宽度的至少50％的加宽宽度；使所述非织造幅面料在机器方向上伸长，直到其具有比所述原始宽度至少小50％的收缩宽度；按收缩宽度热处理所述非织造幅面料，以提供热设定收缩的非织造幅面料；以及所述热设定收缩的非织造幅面料可从所述收缩宽度伸长到至少所述加宽宽度。在其它方面，所述热处理步骤包括按收缩宽度将所述非织造幅面料加热到至少65-77℃的温度。使所述非织造幅面料在横截机器方向上伸长，直到其具有大于所述原始宽度的至少100％的加宽宽度。使所述非织造幅面料在机器方向上伸长，直到其具有小于所述原始宽度的至少75％的收缩宽度。所述非织造幅面料包括聚烯烃。所述聚烯烃包括聚乙烯或聚丙烯。所述非织造幅面料可包括纤维性的非织造幅面料、双组分纤维、纺粘幅面料、熔喷幅面料、纺粘-熔喷-纺粘层压件、粘合梳理幅面料、气流交织幅面料以及纺粘-薄膜-纺粘层压件。所述方法的步骤还可包括将热设定收缩的非织造幅面料结合到弹性材料上以形成层压件、在将热设定收缩的非织造幅面料结合到弹性材料上之前使所述弹性材料在机器方向上伸长以及在使所述非织造幅面料伸长之前将所述非织造幅面料结合到弹性材料上以形成层压件。所述弹性材料是从下列组中选出，所述组包括薄膜、泡沫、熔喷材料、纺粘材料、丝和网的排列，以及它们组合。所述弹性材料包括可透气的弹性薄膜。
本发明也提供一种根据上述方法生产的收缩的非织造幅面料。
本发明还提供一种根据上述方法生产的层压件。
本发明另外提供一种包括上述收缩的非织造幅面料制造的制品。
本发明另外还提供一种包括上述层压件制造的制品。
附图说明
从结合附图的下面的详细描述，本发明的这些和其它目的将更容易理解，其中：
图1是表示当非织造幅面料材料经过本发明的伸长和收缩步骤进行处理时，非织造幅面料材料的顶视图。
具体实施方式
定义
如这里所使用，术语“恢复”是指一种伸长的材料在通过施加偏压力使该材料伸长后通过终止偏压力时的立即回缩。例如，如果具有1英寸(2.5cm)松释的无偏压长度的材料通过伸长到1又1/2英寸(3.75cm)的长度从而伸长50％，该材料将伸长50％，并将具有是其松释长度的150％的伸长长度。如果该典型的伸长材料收缩，即在释放偏压力和伸长力后，它恢复到1又1/10英寸(2.75cm)的长度，该材料恢复到其1/2英寸(1.25cm)伸长量的80％。恢复百分比可以表示为[(最大伸长长度-最终样品长度)/(最大伸长长度-原始样品长度)]×100。
如这里所使用的，术语“非织造幅面料”是指具有交织但非以可识别的重复方式的单个纤维或线的结构的幅面料。非织造幅面料在过去通过许多过程例如熔喷过程、纺粘过程、共成形过程和粘合梳理幅面料过程成形。
如这里所使用的，术语“收缩材料”是指通过例如拉拔法或聚拢法收缩到至少一个尺寸的任何材料。
如这里所使用的，术语“可收缩的材料”是指可收缩的任何材料。
如这里所使用的，术语“可伸长的”是指收缩材料和收缩材料的层压制品在其收缩宽度的约100％的范围内在基本上平行于收缩的方向上具有可伸展性。
如这里所使用的，术语“高度可伸长的”或“高度可伸长的材料”是指收缩材料和收缩材料的层压制品在其收缩宽度的约3至约7倍的范围内在基本上平行于收缩方向上具有可伸展性。
如这里所使用的，术语“伸长百分比”是指通过测量伸长尺寸的增加值并将该值除以原始尺寸所确定的比率，即(伸长尺寸的增加/原始尺寸)×100。
如这里所使用的，术语“机器方向”或“MD”是指织物在其制造方向的长度。术语“横截机器方向”或“CD”是指织物在通常垂直于MD的方向上的宽度。
如这里所使用的，术语“纺粘纤维”是指通过将熔融的热塑材料从喷丝头的若干细的通常圆形毛细管挤制成细丝形成的小直径纤维，然后挤制的细丝的直径迅速减少，例如参见授予Appel等人的美国专利4340563，授予Dorschner等人的美国专利3692618，授予Matsuki等人的美国专利3802817，授予Kinney的美国专利3338992和3341394，授予Hartmann的美国专利3502763，和授予Dobo等人的美国专利3542615等。当纺粘纤维沉积在收集面上时，它们通常是不粘的。纺粘纤维通常连续，并具有大于7微米，特别是在约10和30微米之间的平均直径(来自至少10根纤维的一个样品)。纤维还可具有例如在授予Hogle等人的美国专利5277976，授予Hills的美国专利5466410，和授予Largman等人的美国专利5069970和美国专利5057368中的形状，这些专利描述了具有非传统形状的混合物。通过熔融纺丝制造的纺粘纤维的非织造幅面料被称为“纺粘物”。
如这里所使用的，术语“熔喷纤维”是指通过挤压熔融热塑材料经过若干细的通常圆形模具毛细管，以便作为熔融线或细丝进入汇聚的高速的通常热气体(例如空气)流中形成的纤维，该热气体流削弱熔融热塑材料的细丝，从而降低其直径，这可达到微纤维直径。然后，熔喷纤维由高速气体流载运，并沉积在收集面上，以形成随机分散的熔喷纤维的幅面料。这一过程在例如授予Butin等人的美国专利3849241中公开。熔喷纤维可以是连续或不连续的微纤维，其平均直径通常小于10微米。
如这里所使用的，术语“粘合梳理幅面料”是指由送入梳毛单元或梳理单元中的人造短纤维制成的幅面料，该梳毛单元或梳理单元在机器方向上将人造短纤维分离并对齐，以形成通常在机器方向取向的纤维非织造幅面料。这种纤维通常成包购买，它位于在梳理单元之前使纤维分开的松棉机或成纤器内。一旦幅面料形成，接着它通过一种或多种公知的粘合法粘合。
如这里所使用的，“聚合物”通常包括但不限于均聚物、共聚物、例如嵌段共聚物、接枝共聚物、无规共聚物和交替共聚物、三元共聚物等，以及其混合物以及改性物。此外，除非另有特别声明，术语“聚合物”还包括分子的所有可能的几何构形。这些构形包括但不限于全同立构、间规立构和无规对称。
如这里所使用的，“微纤维”是指平均直径不大于约50微米的小直径纤维，例如其平均直径从约0.5微米至约40微米，或更具体的是，微纤维的平均直径从约2微米至约25微米。另一个频繁使用的纤维直径的表述是但尼尔，但尼尔定义为每9000米纤维的克数，并且可用以微米计的纤维直径的平方，乘以以克/立方厘米计的密度，再乘以0.00707来计算。较低的但尼尔表示较细的纤维，较高的但尼尔表示较粗或较重的纤维。例如，给定为15微米的聚丙烯纤维的直径可通过其平方乘以0.89克/立方厘米并乘以0.00707从而转换成但尼尔。这样，15微米聚丙烯纤维具有约1.42但尼尔。在美国之外，测量的单位通常是“特”，“特”定义为克/千米纤维。特可用但尼尔/9来计算。
如这里所使用的，“混合物”是指两种或多种聚合物的混合物，而术语“合成品”是指混合物的一个子分类，其中的成分不可混溶但已经相容。“混溶性”和“不可混溶性”定义为混合物分别具有负值和正值的混合自由能。而且，“相容化”定义为使不可混溶的聚合物的界面性能改性以形成合成品的过程。
如这里所使用的，术语“双组分纤维”是指由单独的挤压机挤制但纺在一起以形成一种纤维的至少两种聚合物形成的纤维。双组分纤维还有时被称为共扼纤维或多组分纤维。聚合物布置在横过双组分纤维的横截面上的基本上恒定布置的不同区域内，并连续地沿双组分纤维的长度延伸。这种双组分纤维的构形可以例如是外鞘/芯构形，其中一种聚合物被另一种聚合物包围，或者可以肩并肩排列、饼排列或“海中岛”排列。双组分纤维在授予Kaneko等人的美国专利5108820，授予Krueger等人的美国专利4795668中，授予Marcher等人的美国专利5540992，和授予Strack等人的美国专利5336552中教导。双组分纤维还在授予Pike等人的美国专利5382400中教导。对于两组分纤维，聚合物可表现为75/25、50/50、25/75或任何其它理想的比率。
如这里所使用的，“热处理“是指对适合用于本发明的方法的材料加热，以提供当该材料收缩从而使其能够恢复到其收缩状态的记忆性的材料。在授予Morman的美国专利4965122中，通常在一般平行于收缩的方向上，通过向材料施加张力，以便使材料收缩、加热该收缩的材料并冷却该收缩的材料，从而制成具有至少约75％伸长能力并且当伸长约75％时恢复至少约50％的可恢复收缩的材料。
“弹性的”或“弹性体的”可互换地用来指在变形后当去掉变形力时通常能够恢复其形状的材料。特别是，如这里所使用的，弹性或弹性体的是指在施加偏压力时允许该材料伸长到比其松释的无偏压长度长至少约25％的伸长后的偏压长度的任何材料的性能，这将导致材料在释放伸长拉长力时恢复到其伸长量的至少约40％。满足一种弹性材料的该定义的假想的一个例子是可拉长到至少约1.25英寸(3.1cm)的1英寸材料样品，在拉长到1.25英寸(3.1cm)并释放时，它将恢复到不超过1.15(2.9cm)英寸的长度。许多弹性材料可伸长大大超过其松释长度的25％，在释放伸长及拉长力后，许多弹性材料将恢复到基本上其原始松释后的长度。后一种材料通常有助于实现本发明的目的。
如在此使用的，“人身护理吸收制品”是指一次性尿布、训练裤、吸收衬裤、成人失禁产品、包括卫生垫和卫生巾在内的女性卫生产品、抹布、薄绢、绷带、敷料和类似物。
根据本发明的方法，通过使非织造幅面料输送经过在横截机器方向使非织造幅面料伸长的装置，，并使得到的在横截机器方向伸长的非织造幅面料收缩，从而形成具有横截机器方向伸展性的非织造幅面料材料，因此来制造具有横截机器方向伸展性的非织造幅面料材料。在横截机器方向的非织造幅面料的伸长可通过本领域中的普通技术人员所公知的任何方式实现，例如拉幅机架设备，但最好通过相互咬合的有槽的辊系统实现，其各种实施例子参见例如授予Müller的美国专利3383449；授予Müller等人的美国专利3849526；授予Schwarz(BLAX过程)的美国专利4116892、4153751、4223059，和4289832；授予Hoge的美国专利4350655；授予Sneed等人的美国专利4517714；和授予Walton等人的美国专利4806300。横截机器方向的伸长量是深度的函数，有槽的辊设定该深度，有槽的辊咬合越深，横截机器方向伸展百分比越大。在有槽的辊内或在横截机器方向取向期间附加热可进一步加强取向并减少对材料的损害。由于不同非织造幅面料材料的横截机器方向的特征是唯一的，辊受到调节，以便不磨损材料。除了在横截机器方向伸长或使非织造幅面料拉长，有槽的辊系统提供使材料软化的益处。
在拉长后，非织造幅面料收缩，以形成横截机器方向可伸展的非织造幅面料材料。收缩可通过本技术领域中的普通技术人员所公知的任何方法实现。根据本发明的一个优选实施例，非织造幅面料的收缩通过在其上施加机器方向的张力实现。为了向可伸展的非织造幅面料材料提供整体性，材料可通过任何适当地粘合过程例如透气粘合或点粘合来粘合。
根据收缩程度，赋予在CD上可伸展的非织造幅面料材料以不同特性。根据本发明的一个优选的实施例，伸长的非织造幅面料回缩到其原始宽度，该原始宽度对应于全机器宽度，然后层压以制造在CD上可伸长的材料。结果，层压制品的衬片材料具有在CD上伸展性，同时还具有机器的全宽的优点。这依次使机器的全部能力发挥效用，从而导致实现成本节约。
根据本发明的另一个实施例，非织造幅面料穿过咬合的有槽的辊系统，其中非织造幅面料在横截机器方向的伸长增加至少约50％。通过施加机器方向张力，在CD上伸长的幅面料收缩或变窄。在该过程中在该点，当非织造幅面料伸长到其加宽的宽度时，该非织造幅面料不具有太多的回缩力。在该收缩的宽度时，幅面料被热处理，以便锁定CD伸展性。以这种方式对幅面料进行热处理可增加回缩力。根据本发明的该方法的该实施例制造的非织造幅面料获得的CD伸展量可以是收缩宽度的约7倍。
特别是，非织造幅面料穿过有槽的辊过程加工，该过程将幅面料从“X”英寸宽向加宽至“Y”英寸宽(见图1)。当“Y”英寸宽的材料离开开槽的轧辊过程时，它立即收缩到约其原始宽度“X”。为了增加回缩力，当幅面料伸长到其扩展的宽度“Y”时，幅面料在其收缩宽度“X”进行热设定。
根据本发明的一个优选实施例，幅面料还被张紧为使材料收缩到宽度“Z”英寸，“Z”英寸小于原始宽度“X”，然后热设定。在横截机器方向对非织造幅面料的伸长，然后使其收缩到小于其原始宽度，这产生了比其本身的收缩更高的很高的CD伸展的非织造物。例如，有槽的辊过程可容易地使有效宽度“X”加倍，而某些幅面料可容易地收缩到其原始宽度的约1/4。有槽的辊和通过热处理进行的高收缩结合产生了可恢复的具有约700％伸长率的幅面料。参见图1，如果非织造幅面料具有10英寸的原始宽度(“X”)，且它在横截机器方向伸长到20英寸的伸长宽度(“Y”)，伸长百分比是100％((Y-X)/X)×100。如果接着拉长的非织造幅面料收缩到其原始宽度的1/2，至5英寸的收缩宽度(“Z”)并热设定，以便保持其收缩宽度，伸长百分比现在是300％((Y-Z)/Z)×100。
根据本发明的一个实施例，CD可伸展非织造幅面料材料粘合到弹性材料上，以制造具有布状感觉和CD伸展性的层压制品。例如在授予Morman的美国专利5226992中教导了一种形成复合弹性收缩粘合材料的方法，其中可收缩材料收缩且然后与弹性片结合。另一方案是，CD可伸展非织造幅面料材料可以以提供具有多方向伸长能力的层压件的方式与弹性片连接。授予Morman的美国专利5116662教导了一种制造能够在至少两个方向上伸长的复合弹性材料，其中收缩材料至少在成非线性构形的三个位置与弹性片连接，因此，收缩幅面料在其中的至少两个位置聚拢。根据本发明的另一个实施例，首先形成层压件，然后经过有槽的辊系统输送。例如，穿过有槽的辊系统输送的具有弹性熔喷部件的不可伸长SMS(纺粘-熔喷-纺粘)层压件产生了一种具有CD伸展/恢复和布状美感的层压件。在该方法中使用的适当的弹性材料和本发明的材料最好选自这样的一组材料中，该组材料包括薄膜、泡沫、纺粘材料、熔喷材料和成排丝和网。适用于本发明的薄膜包括透气薄膜，即薄膜可以是微孔的。这种透气薄膜可以通过开孔或通过使装有填充剂例如CaCO3颗粒的薄膜伸长变薄来制造。
适用于本发明的方法的非织造幅面料材料最好选自一组材料中，该组材料包括纺粘材料、熔喷材料、纺粘-熔喷-纺粘层压件、共成形材料、纺粘-薄膜-纺粘层压件、双组分纺粘材料、双组分熔喷材料、双成分纺粘材料、双成分熔喷材料、粘合梳理幅面料、气流交织及其组合物。
非织造幅面料材料最好由聚合物形成，该聚合物选自一组材料，该组材料包括聚烯烃、聚酰胺、聚酯、聚碳酸酯、聚苯乙烯、热塑弹性体、含氟聚合物、乙烯基聚合物、和其混合物和共聚物。适当的聚烯烃包括，但不局限于，聚乙烯、聚丙烯、聚丁烯和类似材料；适当的聚酰胺包括，但不局限于，尼龙6、尼龙6/6、尼龙10、尼龙12和类似材料；而适当的聚酯包括，但不局限于，聚对苯二甲酸乙二酯、聚对苯二甲酸丁二酯和类似材料。用于本发明的特定的适当聚合物是聚烯烃，这些聚烯烃包括聚乙烯，例如线性低密度聚乙烯、低密度聚乙烯、中密度聚乙烯、高密度聚乙烯和它们的混合物；聚丙烯，聚丁烯及其共聚物，和它们的混合物。另外，形成聚合物的适当纤维可具有混合在其中的热塑弹性体。
试验程序
杯压碎试验(柔性)
可根据“杯压碎”试验测量非织造织物的一致性和可褶皱性。通过测量4.5cm直径的半球状底座所需的最大负载和能量，利用杯压碎试验估计织物，以便在用约6.5cm直径的圆柱围绕杯形织物以保持杯形织物的均匀变形同时，压碎23cm乘以23cm的织物片从而形成约6.5cm直径乘以6.5cm高的倒杯。使用十次读数的平均值。底座和杯子对齐，以避免会影响读数的杯壁和底座之间的接触。在底座以约0.25英寸每秒(380mm每分钟)的速率下降时测量杯压碎负载，并且以克作单位测量。杯压碎能量是压碎一个样本所需的总能量，该总能量是从试验的开始到最大负载点的总能量，即，以克计的负载在一个轴上形成的曲线下的区域，和底座在另一个轴上运动的距离。因此，压碎能量用克-毫米记录。越低的杯压碎值表示越高的可褶皱性和越舒适的层压。测量杯压碎的适当装置是从新泽西州的Pennsauken的Schaevitz公司获得的型号FTD-G-500的测压元件(500克量程)。
张力性能
本程序测量样品的条张力/能量和伸展率。在机器方向(MD)和横截方向(CD)上测量样本。将3英寸×6英寸的样本放置在具有10磅测压元件的Instron张力试验器的气动爪上，将测量长度设定为3英寸和12英寸/分钟的十字头速度。将样本放置在夹具上并且启动设备。用该设备以该十字头速度举起顶夹具直至样品破裂。从仪器读取狭条张力最大负载(磅)，样品裂开前的最大负载，和在破裂时的伸展率(％)(最大应变)。当从零到比例极限计算时，以典型方式计算模数作为张力/应变曲线上最配合的线的斜率。用下述公式计算能量：
E＝R/500×L×S
其中
E＝能量(英寸/磅)
R＝积分仪读数
L＝以磅为单位的满量程负载
S＝十字头速度(英寸/分钟)
这在73+/-2的恒定温度和50+/-2％的相对湿度下进行。
实例
双组分纤维的幅面料包括肩并肩构形的一半聚乙烯和一半聚丙烯，该幅面料加热后，导致较低熔点的聚乙烯变软，因此使纤维能熔化在一起，经BIAX有槽的辊过程产生100％CD可伸展的幅面料。然后，在Sintec张力试验仪中将幅面料伸长，以便将材料收缩成约其原始宽度的1/2。当松释张力时，将材料松释到约其原始宽度。然后除了在收缩条件下使用Revlon1800瓦特吹风机约45秒将材料加热，在用Raytek Raynger型号STAL的红外线枪(可从加利福尼亚州的Santa Cruz的Raytek公司获得)确定时，加热到约150至约170的范围的温度，即除此之外重复试验。当松释张力时，材料没有松释到其原始宽度，而是材料保持大约其收缩宽度。结果，大大增加了材料的回缩特性。
下面的实例显示出经一有槽的辊系统处理非织造材料的效果，并且导致材料在根据本发明的方法“收缩”后横向伸展。
为了模拟“收缩”过程，用双组分聚乙烯/聚丙烯棱镜(根据例如美国专利5382400的方法制造的双组分纤维，在该专利中经相同的挤压机开口挤压两个不同的聚合物)纺粘物准备下面的样本，该纺粘物具有约25克基重，和具有约144克基重的KRATON(得克萨斯州的Houston的Shell化学公司)熔喷(MB)材料，该材料在4663220号美国专利中描述：
1.纺粘对比样
2.纺粘对比样加上KRATON MB
3.有槽的纺粘物加上KRATON MB
4.从6英寸(15cm)收缩到4.25英寸(10.6cm)的有槽的纺粘物加上KRATON MB
5.从6英寸(15cm)收缩到3英寸(7.5cm)的有槽的纺粘物加上KRATON MB
6.从6英寸(15cm)收缩到3英寸(7.5cm)的有槽的纺粘物加上MD伸长的KRATON MB(扩张到4英寸(10cm)的最终层压件宽度)
7.从6英寸(15cm)收缩到3英寸(7.5cm)的纺粘对比样加上KRATON MB
表1在下文比较对比纺粘物和带KRATON熔喷MB的对比纺粘物。数据显示当纺粘物连接到KRATON熔喷物上时，所有被测的张力性能增加了。
  表1：样本1对样本2的横截方向张力性能
  样本  基重(gsm)   最大负载(gm)   最大应变(％)
  1   25   866.2   65
  2   177   1401.5   96.5
表2将对比纺粘物/KRATON MB样本与有槽的纺粘物/KRATON MB相比较。对比纺粘物/KRATON MB样本比有槽的纺粘物/KRATON MB层压件的张力最大负载高。在测量最终CD伸展时，有槽的纺粘物/KRATON MB材料比对比纺粘物/KRATON MB材料具有更高的最大应变百分率。
  表2：样本2对样本3的横截方向张力性能
  样本  基重(gsm)   最大负载(gm)   最大应变(％)
  2  177   1401.5   96.5
  3  165   883.6   174.8
表3给出样本3和4的差异，其中样本4包括有槽的纺粘物，该有槽的纺粘物从6英寸(15cm)收缩到4.25英寸(10.6cm)以便在经过有槽的辊之前与纺粘物的最初基重基本匹配。如可见，最大应变稍有增加。
  表3：样本3对样本4的横截方向张力性能
  样本  基重(gsm)   最大负载(gm)   最大应变(％)
  3  165   883.6   174.8
  4  220   1122.1   189.9
表4在下文中提出有槽的纺粘物/KRATON MB材料和收缩的有槽的纺粘物/KRATON MB材料之间的差异。如所示，最大应变随收缩而增加。
  表4：样本3对样本5的横截方向张力性能
  样本   基重(gsm)   最大负载(gm)   最大应变(％)
  3   165   883.6   174.8
  5   未测量   1300   388.7
表5a和5b比较了样本6和7的材料。表5a显示在横截方向上的特性，而表5b显示在机器方向上的特性。将样本6做成可双轴伸展的。有槽的纺粘物被收缩并且粘接层压到在机器方向上可伸长的KRATON MB材料上。在层压期间纺粘物材料和KRATON MB材料都置于张力下。样本7制成提供横截方向上的伸展性。对比纺粘物材料MD伸长并且获得50％“缩进”。KRATON MB材料被粘接地层压成对比纺粘物。结果显示样本6与样本7相比具有高MD伸展性但稍微低的CD伸展性。
  表5a：样本6对样本7的横截方向张力性能
  样本   基(gsm)   最大负载(gm)   最大应变(％)
  6   118   1460.0   191.2
  7   127   1852.5   263
  表5b：样本6对样本7的机器方向张力性能
  样本   基(gsm)   最大负载(gm)   最大应变(％)
  6   118   2858.5   182.1
  7   127   5098   75.8
*仅重复一次以限制样本尺寸
表6显示有槽的纺粘物/KRATON(3)的比较，从6英寸(15cm)收缩到3英寸(7.5cm)的有槽的纺粘物加KRATON(5)，和从6英寸(15cm)收缩到3英寸(7.5cm)的对比纺粘物加KRATON(7)材料。在所有这三个样本中，收缩的有槽的纺粘物/KRATON MB材料提供最高的最大应变百分比。这表示收缩的有槽的纺粘物加KRATON(5)样本与样本3和7相比更可伸长。
  表6：样本2，样本5和样本7的横截方向张力性能
  样本   基重(gsm)   最大负载(gm)   最大应变(％)
  3   165   883.6   174.8
  5   未测量   1300   388.7
  7   127   1852.5   263
纺粘-熔喷-纺粘(SMS)人工取样经过有槽的辊系统的横截方向的辊。SMS的熔喷层由茂金属弹性聚烯烃(可从Dow化学公司获得的DowENGAGE，30熔融指数，0.5osy)构成。用0.150英寸(0.375cm)接合获得20％CD取向。横截方向(CD)百分比取向是测量的量，通过在材料上放置一个圆，经有槽的辊过程送入材料，并且在其最宽直径处测量最终的圆，从而确定该测量的量。百分比增量是计算值((最终直径-原始直径)/原始直径)×100。将材料经有槽的辊过程送入以便手工取片，这样有最小张力进入有槽从辊，且有槽的辊之间无张力出现。在例如4368565号美国专利中介绍了具有横截方向百分比取向的材料的生产。
表7将对比纺粘-熔喷(弹性)-纺粘(SMS)和有槽的取向的SMS样本进行比较。结果显示有槽的SMS样本具有更低的张力最大负载，和更高的最大应力。
  表7：样本A对样本B的横截方向张力性能
  样本  基重(gsm)   最大负载(gm)   最大应变(％)
  A  97   3868   66.9
  B  80   976.5   118.6
A.SMS@97GSM
B.有槽的SMS@80GSM
伸长-粘合层压(SBL)材料的手工样本经过BLAX CD辊。用2个通道以0.10英寸(0.25cm)接合获得14％最终CD取向。该材料是双轴弹性的。
表8中的数据显示纺粘-熔喷(弹性)-纺粘材料、有槽的纺粘-熔喷(弹性)-纺粘材料、颈缩-粘合-层压(NBL)材料和伸长-粘合-层压(SBL)材料之间的差异。当SMS样本受到有槽的辊伸长时，结果是更柔软的层压，这如杯压碎数据所示。有槽的辊SMS样本与对比SMS样本相比也具有更高的透气性。NBL样本包括纺粘和薄膜，因此它不透气。在与SBL样本的比较中，有槽的SMS样本在松释和CD伸展状态下具有更高的透气性。
 表8：SMS，有槽的SMS的透气性和柔性特性
样本   基重(gsm)   松释状态下的透气性(cfm)   CD伸长下的透气性(cfm)   杯压碎负载(gms)   杯压碎能量(gm/mm)
 SMS   97   274   不能伸长   173   3422
 有槽的SMS   80   446   568   38   459
 NBL   96   0   0   未测   未测
 SBL   133   239   339   未测   未测
在前述说明书中已经描述了与某些优选实施例相关的本发明，并且出于说明的意图提出了许多细节，对本领域的普通技术人员而言显然本发明容许附加一些实施例，并且在不超出本发明的基本原理的前提下，这里描述的某些细节可适当变化。

Claims (25)

1.一种制造热设定收缩的非织造幅面料的方法，该方法包括如下步骤：
提供具有一预收缩的原始宽度的非织造幅面料；
使所述非织造幅面料在横截机器方向上伸长，直到其具有大于所述原始宽度的至少50％的加宽宽度；
使所述非织造幅面料在机器方向上伸长，直到其具有比所述原始宽度至少小50％的收缩宽度；
按收缩宽度热处理所述非织造幅面料，以提供热设定收缩的非织造幅面料；以及
所述热设定收缩的非织造幅面料可从所述收缩宽度伸长到至少所述加宽宽度。
2.根据权利要求1所述的方法，其特征在于，所述热处理步骤包括按收缩宽度将所述非织造幅面料加热到至少65-77℃的温度。
3.根据权利要求1所述的方法，其特征在于，使所述非织造幅面料在横截机器方向上伸长，直到其具有大于所述原始宽度的至少100％的加宽宽度。
4.根据权利要求1所述的方法，其特征在于，使所述非织造幅面料在机器方向上伸长，直到其具有小于所述原始宽度的至少75％的收缩宽度。
5.根据权利要求3所述的方法，其特征在于，使所述非织造幅面料在机器方向上伸长，直到其具有小于所述原始宽度的至少75％的收缩宽度。
6.根据权利要求1所述的方法，其特征在于，所述非织造幅面料包括聚烯烃。
7.根据权利要求6所述的方法，其特征在于，所述聚烯烃包括聚乙烯。
8.根据权利要求6所述的方法，其特征在于，所述聚烯烃包括聚丙烯。
9.根据权利要求1所述的方法，其特征在于，所述非织造幅面料包括纤维性的非织造幅面料。
10.根据权利要求9所述的方法，其特征在于，所述非织造幅面料包括双组分纤维。
11.根据权利要求9所述的方法，其特征在于，所述非织造幅面料包括纺粘幅面料。
12.根据权利要求9所述的方法，其特征在于，所述非织造幅面料包括熔喷幅面料。
13.根据权利要求9所述的方法，其特征在于，所述非织造幅面料包括纺粘-熔喷-纺粘层压件。
14.根据权利要求9所述的方法，其特征在于，所述非织造幅面料包括粘合梳理幅面料。
15.根据权利要求9所述的方法，其特征在于，所述非织造幅面料包括气流交织幅面料。
16.根据权利要求9所述的方法，其特征在于，所述非织造幅面料包括纺粘-薄膜-纺粘层压件。
17.根据权利要求1所述的方法，其特征在于，其步骤还包括将热设定收缩的非织造幅面料结合到弹性材料上以形成层压件。
18.根据权利要求17所述的方法，其特征在于，其步骤还包括在将热设定收缩的非织造幅面料结合到弹性材料上之前使所述弹性材料在机器方向上伸长。
19.根据权利要求1所述的方法，其特征在于，其步骤还包括在使所述非织造幅面料伸长之前将所述非织造幅面料结合到弹性材料上以形成层压件。
20.根据权利要求19所述的方法，其特征在于，所述弹性材料是从下列组中选出，所述组包括薄膜、泡沫、熔喷材料、纺粘材料、丝和网的排列，以及它们组合。
21.根据权利要求19所述的方法，其特征在于，所述弹性材料包括可透气的弹性薄膜。
22.一种根据权利要求1所述的方法生产的收缩的非织造幅面料。
23.一种根据权利要求17所述的方法生产的层压件。
24.一种包括如权利要求22的所述的收缩的非织造幅面料制造的制品。
25.一种包括如权利要求23的所述的层压件制造的制品。
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