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CN1271309A - 弹性层压物及其制备方法 - Google Patents

弹性层压物及其制备方法 Download PDF

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CN1271309A
CN1271309A CN98809547A CN98809547A CN1271309A CN 1271309 A CN1271309 A CN 1271309A CN 98809547 A CN98809547 A CN 98809547A CN 98809547 A CN98809547 A CN 98809547A CN 1271309 A CN1271309 A CN 1271309A
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carrier layer
laminate structure
strands
softening temperature
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CN1096934C (zh
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D·L·巴罗内
W·R·乌埃利特
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Hui Shi
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Procter and Gamble Co
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Abstract

本发明涉及弹性层压物结构,该结构包含一个整体热粘合在两个织物载体层(37、38)之间的开孔聚合物网(36),以及生产这种层压物的方法。

Description

弹性层压物及其制备方法
                            发明领域
本发明总地涉及弹性层压物领域，更具体地说，涉及从聚合物网以及两层织物层制成的弹性层压物，其中该层压物提供了改进的弹性和舒适性。
                            发明背景
弹性层压物以前已被用于各种制品，包括弹性吸收结构，如汗带、绷带、尿布、失禁装置。目前已有几种生产这些弹性层压物的方法。例如美国专利No.4,606,964(授予Wideman)指出将可收集材料与一拉紧的弹性网的每一侧相连。可收集的材料通过自粘化合物、粘合剂或热结合在预先拉紧的状态下连接弹性网。连接后，当弹性网中的张力松弛时，网发生收缩，从而将可收集材料折叠起来。
美国专利No.4,522,863(授予Keck等人)公开了一种弹性层压物，它包含一个网，该网的一侧连接织物层，另一侧连接一层微纤维。织物层和微纤维层通过粘合剂与网连接，这些层的一部分保持与网不结合，以提供柔软的布一样的手感和外观。
美国专利No.4,977,011(授予Smith)指出了一种弹性层压物，它具有低基重的可透气材料外层、一层弹性中间层，以及将所有层连接在一起的粘合剂层。弹性层可以由置于针眼间的单条弹性线制成以形成多条不交叉弹性线，或可以由呈直角交叉的多条弹性线制成，并与低基本重量的可透气材料粘连起来。
尽管上述弹性层压物适用于其预期的目的，但是仍希望提供一种具有其它优点和特点的改进的弹性层压物。例如，以前描述的结构是在结构上线条从两个不同方向延伸，(或是一种在针脚间单向排列单条线的复杂方法)。然而，在切割所得弹性层压物(如这些层压物)时，线条的切割边缘会伸出结构的切割侧，如果该结构贴身穿戴(例如在绷带、身体护垫、尿布、失禁装置等场合下)，那么线条的切割边缘将引起刺激。另外，如果希望弹性层压物具有大的模量数值(即应力与应变之比)，则通常需要弹性线条具有较大横截面积。然而，此类大的线条在接触身体时会产生粗糙或“竹节(nubby)”的感觉。因此，希望另提供一种弹性层压物，它能提供具有大的横截面积的弹性条，并且穿在身上仍感舒适。本发明提供了一种改进的弹性层压物以及形成该结构的方法，该结构所提供的设计具有上述结构特征和优点。
                            发明概述
本发明涉及一种生产弹性层压物结构的方法，该方法包括下列步骤：
a)提供第一载体层；
b)提供第二载体层；
c)提供一个网，该网置于所述第一和第二载体层之间，具有多股第一线条与多股第二线条交叉，所述第一和第二线条在施加的压力下具有一个软化温度，其中在所述施加的压力下，所述第二线条的所述软化温度大于所述第一线条的所述软化温度；
d)将所述网加热至所述第一线条的所述软化温度且小于所述第二线条的所述软化温度；
e)向所述第一线条施加粘合压力；和
f)使约10％至约100％的所述第一线条与所述第一和第二载体层整体粘合。
本文所用的所有百分数和比值均用重量表示，所用测定均在25℃下进行，除非另有特指。
                            附图简述
尽管本发明是以特定指出的并清楚要求本发明权利的权利要求作为结论，但是相信从结合下列附图的下文描述中可以更好地了解本发明：
图1是网、第一和第二载体层在形成本发明制得的弹性层压物之前的分解图。
图2是根据本发明制得的弹性层压物的部分透视图，其中已除去了一部分第一和第二载体层，以便显示整体粘合的第一线条；
图2A是图2中弹性层压物的整体粘合的第一线条的部分放大透视图；
图3是本发明用于形成图2所示弹性层压物的生产示意图；
图4是本发明用于形成图2所示弹性层压物的平板法示意图。
                            发明详述
现在将详细参照本发明的较佳实施方案，附图中描述了这些实施方案的例子，其中在整个图中，相同的数字代表相同的元件。图1是热粘合的弹性层压物66在其形成前各组成的分解图(弹性层压物66示于图2中)。如图所示，弹性层压物66由一个具有多股第一线条24和多股第二线条26的弹性网36制得，该网置于第一载体层37和第二载体层38之间，并和它们整体热粘合。如图2所示，弹性层压物宜具有至少一个结构方向D，其中结构方向D的至少一部分有弹性。更佳的，弹性层压物66具有这样一个结构方向D，它沿第二线条26的方向和整个长度上有弹性。尽管第一载体层37和第二载体层38最好大致上共同延伸，但是认为它们也可按照需要具有互不相同的形状和大小。还考虑到本发明的弹性层压物结构中可以插入多个弹性网，这些网与一个或多个载体层整体粘合。
本文所用的术语“结构方向”(例如D)是指基本上沿着并且平行于第一载体层37和第二载体层38的平面延伸的方向。弹性层压物66可插入各种制品中(未描述)，其中至少要有一个结构方向，在其长度上有部分或全部弹性。这些制品的例子包括弹性尿布、失禁装置、绷带、身体护垫等。
尽管弹性层压物66最好具有至少一个具有弹性的结构方向D，但是也估计到弹性层压物66可以是没有弹性的，从而不具有弹性的结构方向。或者，弹性层压物66也可具有这样一个结构方向，在该方向上一部分长度是有弹性的，另一部分长度则没有弹性。
本文所用的术语“弹性”指材料的一种性质，当该材料受到张力时，它会在受力方向上拉伸或伸长，而在除去该力后，材料基本上能恢复到其原来未拉伸的尺寸。更具体地说，术语“弹性”是指一种方向上的性质，其中元件或结构在受到大于50％的应变百分数ε％后恢复到其原来长度Lo上下大约10％范围内。本文所用的应变百分数ε％指：
ε％＝[(Lf-Lo)/Lo]×100
其中Lf＝伸长的长度
    Lo＝原来的长度为了保持一致和进行比较，元件或结构的回复率宜在从其伸长长度Lf松弛后30秒测定。如果元件或结构在从50％的应变百分数ε％松弛后在30秒内没有回复到其原来长度Lo上下大约10％的范围内，则认为所有这些元件或结构没有弹性。没有弹性的元件或结构还包括在受到50％的应变百分数ε％时发生破裂和/或永久性/塑性变形的元件或结构。
现在参看图1和图2，弹性网36包括多股第一线条24，这些线条在结节31处以预定角度α与多股第二线条26交叉或交错(有或没有粘合)，从而形成具有多个孔眼33的网状开孔结构。每个孔眼33由至少两条相邻的第一线条(即42和43)以及至少两条相邻的第二线条(即44和45)确定，因此孔眼33的形状基本上为矩形(较佳的是正方形)。也能提供其它孔眼形状，例如平行四边形或圆弧段。这些形状能用来提供非线形的弹性结构方向。较佳的是，第一线条24基本笔直且基本上相互平行，更佳的是，第二线条26也基本笔直并且基本上相互平行。最佳的是，第一线条24与第二线条26在结节31处以大约90°的预定角度α交叉。每个结节31是一个重叠的结节，其中第一线条24和第二线条26宜在交叉点处结合或连接(虽然认为可能不需要连接或结合)，而结节处的线条仍然能单独分辨。然而，相信其它结节构型(如合并的或合并与重叠相组合的构型)也同样是合适的。
尽管较佳的是第一线条24和第二线条26基本笔直、平行并以大约90°的角度α交叉，但应注意，第一线条24和第二线条26也能以其它角度α交叉，第一线条24和/或第二线条26能以圆形、椭圆形或其它相互间呈非线形的图形排列。尽管为了便于生产，打算使第一线条24和第二线条26在插入层压物结构66之前具有基本圆形的横截面形状，但是第一线条24和第二线条26也可以有其它横截面形状，例如椭圆形、正方形、三角形或它们的组合形式。
选择第一线条24的材料，使得第一线条24能在形成层压物结构66之前与第二线条保持相对排列。还希望第一线条24和第二线条26的材料能在施加预定压力或压力与热通量的组合时变形成(或最初形成)预定的形状，这在后文中有更详细的描述。这些经变形的形状(即椭圆形的第二线条、基本扁平的第一线条等)所提供的层压物结构66能舒适地穿在身上而不会引起刺激或其它不舒适。还希望选作第一线条24的材料提供类似粘合剂的性能，以便使变形的第二线条27的一部分外表面49与一部分第一载体层内表面50和第二载体层内表面52连接。
第一线条24的材料还应能和载体层37与38整体粘合，作为形成层压物结构66的一部分。如下文更详细的描述那样，第一线条24能通过施加压力或压力与热通量的组合而与载体层37和38整体粘合。本文所用的术语“整体粘合”及其衍生含义指，整体粘合的线条(即整体粘合的第一线条25)的一部分外表面(即第一线条外表面47)已经渗入载体层37和38并与它们结合。如图2A所示，整体粘合的线条中渗入载体层37和38的线条外表面部分能通过机械方法(即通过包封、合围或吞没)和/或化学方法(即聚合、融合或其它化学反应)与载体层37和38的纤维51结合。关于渗入，整体粘合指一部分线条外表面至少已经渗入层压物结构66中载体层37和38的大约10％(较佳的至少约25％、更佳的至少约50％、还要佳的至少约75％、最佳的约100％)的载体层结构厚度T。另外，由于整体粘合的线条增加了层压物结构66穿在身上的舒适感，因此应有至少约10％、较佳的至少约50％、更佳的至少约90％、最佳的为100％的第一线条24与层压物结构66的载体层37以及38整体粘合。
上述优点可通过选择第一线条材料来实现，该材料在用来形成层压物结构66的加工压力下的软化温度低于第二线条26的软化温度。本文所用的术语“软化温度”是指，材料在施加的压力下开始流动，从而促使材料与一层或多层载体层整体粘合的最低温度。通常是向材料施加热量以达到软化温度。这通常会导致材料的粘度降低，这可能涉及或不不涉及到材料的“融化”，而融化则与融化潜热有关。热塑性材料会表现出因温度增加而粘度降低，从而使得它们在经受施加压力时流动。应理解，随着施加压力的增加，材料的软化温度降低，因此，一个给定的材料能有多个软化温度，因为该温度将随施加的压力而变化。为了便于生产和加工，当通常采用聚合物材料作为线条24和26时，若两种材料经受相同的施加压力(如加工压力)，第一线条24的软化温度宜比第二线条26的软化温度低至少约10℃、更佳的低至少约20℃。本文所用的术语“粘合压力”指，当两股线条在第一线条24的软化温度下但低于第二线条26的软化温度时，使第一线条24与载体层37与38整体粘合、而第二线条26不与载体层37和38整体粘合的压力。除了选择第一和第二线条材料的软化点温度外，第二线条最好由能赋予第二线条26适当弹性的材料制得，这样层压物结构66沿第二线条26结构方向也具有所需的适当弹性。
已经发现，诸如聚烯烃、聚酰胺、聚酯和橡胶(即丁苯橡胶、聚丁二烯橡胶、氯丁橡胶、丁腈橡胶等)之类的聚合物是适用于制成弹性网36的第一和第二线条的材料(但不局限于这些)。具有不同的相对软化温度或弹性的其它材料或化合物(即粘合性第一线条)都可以用来替代，只要替代的材料具有上述优点即可。另外，在包含第一和第二线条的基材中可以加入辅助材料(即，颜料、染料、光亮剂、重质蜡等的混合物)，使其具有所需的视觉、结构或功能上的特征。弹性网36可以用本领域已知的各种方法之一制得。
为了便于生产和减少成本，载体层37和38宜由(但不局限于)无纺织物制得，该无纺织物具有例如从聚乙烯、聚丙烯、聚对苯二甲酸乙二酯、尼龙、粘胶、棉花或羊毛制得的纤维。这些纤维可以通过粘合剂、热结合、针/缩绒、或本领域已知的其它方法结合起来，以形成载体层37和38。尽管载体层37和38宜从无纺织物制得，但是其它织物如机织物和针织物也是合适的。
载体层37和38的软化温度(在所受加工压力下)应高于层压结构66成型时施加在弹性网36上的任何加工温度。另外，当载体层37和38被制成层压物结构66时，它们在沿第二线条26方向上在单位应变εμ至少约为1(即Lf＝2×Lo)时的模量宜小于约100克力/厘米。本文所用的术语“模量”指，施加的应力σ与产生的单位应变εμ之比，其中应力σ和应变εμ是：
σ＝Fa/W
εμ＝(Lf-Lo)/Lo
其中Fa＝施加的力
    W＝受施加力Fa的元件或结构的垂直尺寸(通常是结构宽度)
    Lf＝伸长的长度
    Lo＝原来的长度
例如，20克力垂直施加到宽5厘米的织物时应力σ为4克力/厘米。进而，如果和施加力Fa同一方向上原始长度Lo是4厘米，所得的伸长长度Lf为12厘米，则所得的单位应变εμ为2，模量为2克力/厘米。
据信，当主织物方向(subject fabric direction)与层压物结构66中的弹性第二线条26同向并置，载体层沿主织物方向上模量低于100克力/厘米的话，层压物结构66沿第二线条26方向上的模量在很大程度上是第二线条26的材料性质、尺寸和排列方式的函数。换句话说，载体层37和38的模量将足够地低，使得第二线条26的模量在很大程度上决定着层压物结构66在主方向上的模量。如果希望层压物结构66沿变形的层压物第二线条27方向作为弹性结构方向，那么这种构型是特别有用的。
如果载体层37和38本质上不具备所需的模量，则载体层37和38可以在形成层压物结构66之前或之后经受一个活化过程。例如美国专利No.4,834,741(1989年5月30日授予Sabee，全部纳入本文作参考)中所描述的，载体层37和38经受活化过程(分开进行或作为层压物结构66的一部分进行)将使载体层37和38发生塑性变形，从而提供所需的模量。在一个活化过程(例如Sabee描述的过程)中，使载体层37和38(或插入这些载体层的层压物结构66)在瓦楞辊之间通过，在垂直机器方向上侧向拉伸载体层37和38，以赋予其延伸性。逐渐拉伸载体层37和38，以赋予其在垂直机器方向上的永久性伸长以及织物纤维取向。该方法可在层压物结构66连接之前或之后用来拉伸载体层37和38。这提供了一个较佳的层压物结构，该结构在弹性结构方向上能被最小的力拉伸，因为载体层37和38(以及任何附加层)最初已经被“活化”或在此方向上被分开，从而在主方向上模量较低，使得层压物结构模量取决于层压物第二线条27的模量。
层压物结构66最好这样来形成：并置载体层37和38以及弹性网36，施加预定的压力或预定的压力以及热通量(这取决于载体层37和38以及弹性网36的材料)，从而使第一线条24与载体层37以及38整体粘合。除了使第一线条24与载体层37和38整体粘合外，还希望用上述方法使第一线条24变形，使得整体粘合的第一线条外表面47的形状基本上是扁平的。本文所用的术语“基本扁平的”及其衍生含义指，整体粘合的第一线条25的主要尺寸M的长度(即平行于线条横截面主轴的最大尺寸，如图2所示)至少是次要尺寸N的长度(即平行于线条横截面次轴的最小尺寸，如图2所示)的大约2倍。因此，显然，整体粘合的第一线条25的外表面47可以具有不规则性(即有凸出和凹陷等，如图2A所示)，并且仍在基本上扁平状态。更佳的是，希望整体粘合的第一线条25的一部分外表面47还与载体层内表面50和52基本上共面，这样最小尺寸N大致等于或小于载体层37和38的结构厚度T，并且基本上所有的最小尺寸均在结构厚度T内，如图2所示。还可认为，沿第一线条25长度上，整体粘合的第一线条25的基本扁平和共面形状可以有些变化，并且不脱离这些定义的范围。换句话说，由于加工的差异，部分整体粘合的第一线条25可以是基本扁平的和/或共面，而沿同一线条的其它部分可能并非如此。但这些构型仍在上述的“基本上扁平的”和“共面”的定义范围内。
整体粘合的第一线条25的上述形状对层压物结构66是有利的，裁剪这种层压物结构66(从而使整体粘合的第一线条25外露)并穿在身上后，线条25不会突出而引起刺激或其它不适。因此，至少约25％、较佳的至少约50％、更佳的至少约75％、最佳的约100％的整体粘合的第一线条25基本上是扁平的并且共面。
与层压物结构66中整体粘合的第一线条25的基本扁平的和共面的形状相反，通过施加上述压力和热通量，层压物第二线条27最好只和载体层37和38内表面50和52连接(与整体粘合相反)，如图2所示。然而可以认为，如果需要的话，第二线条26也能和载体层37与38整体粘合。还可以使第一线条24与载体层37以及38整体粘合，从而以第一线条24作为粘合剂，在结节31处，连结第二线条26和载体层内表面50和52。或者，第二线条26可以包括自粘合材料，以帮助一部分第二线条外表面49与载体层内表面50和52的连接。
从图3看出，最好采用这样一种方法来生产层压物结构66，该方法包括一个基本非弹性的第一表面148(即用钢等制成)、一个基本非弹性的第二表面150，以及一个基本为弹性的第三表面152(即由聚硅氧烷或其它能形变的橡胶制成)，这些表面为轧辊表面。第一表面148与第二表面150相邻，它们之间形成了缝隙156，而第二表面150与第三表面152呈表面相互接触，从而形成槽型缝隙(interference nip)。缝隙156的大小宜使得第一线条24和第二线条26容易从中通过。或者，缝隙156的大小可以使第二线条26从中压过时发生变形。
第一载体层37与弹性网36毗邻并置，而弹性网与第二载体层38毗邻并置，这样，当绕第一表面148进料时(如图3所示)，弹性网36被置于第一载体层37和第二载体层38之间。较佳的是，弹性网36的第一线条24与第一载体层37的内表面50毗邻并置，第二线条26与第二载体层38的内表面52毗邻并置。第一载体层37的取向最好毗邻第一表面148。将第一表面148加热至温度T1，该温度与并置的第一载体层37、弹性网36和第二载体层38在第一表面148上的进料速度相结合，将第一线条24的温度升高至或高于它们的软化温度。由于缝隙156处施加的压力Pd较低，因此第一线条24和第二线条26变形很少(如果有的话)。
并置的第一载体层37、弹性网36以及第二载体层38通过缝隙156后，第二载体层38的取向宜毗邻第二表面150并置于第二表面150与弹性网36以及第一载体层37之间。第二表面宜加热至温度T2，该温度和并置的第一载体层37、弹性网36以及第二载体层38在第二表面150上的进料速度相结合，使第二线条26的温度升高至其软化温度。然后，并置的第一载体层37、弹性网36和第二载体层38通过槽型缝隙154，其中第一线条24在辊缝隙154处第二表面150和第三表面152受到粘合压力Pb并整体粘合在第一载体层37和第二载体层38上。由于弹性第三表面152的结构特性，它所提供的粘合压力Pb均匀地施加在第二线条26之间的第一线条24上。更佳的，由第三表面152施加的压力Pb以及来自第二表面150温度为T2的热通量足以使第一线条24变形成为基本扁平的、整体粘合的第一线条25。最佳的是，施加的压力和热通量足以使第一线条24变形成为整体粘合的第一线条25，该线条与第一载体层37的内表面50以及第二载体层38的内表面52基本上共面。
相反，至少约25％(较佳的至少约50％、更佳的至少约75％、最佳的约100％)的第二线条26在缝隙154处被加工成基本椭圆的形状，因为第二表面150将压力Pb全部施加于第二线条26上。希望第二线条27的横截面形状为椭圆形，否则未变形的第二线条26的横截面会在层压物结构66穿在身上时产生一种“竹节”或粗糙的感觉。较佳的，层压物结构层66的辊隙后结构厚度I约为并置的第一载体层37、第一弹性网36以及第二载体层38的辊隙前结构厚度S的大约50％。
可以调节并置的第一载体层37、弹性网36和第二载体层38通过第一、第二和第三表面148、150和152的进料速度，使得第一线条24和第二线条26具有足够的停留时间毗邻加热的第一表面148和第二表面150，从而使这些线条可以如本文所述的那样软化变形。
根据前述方法，已经发现下列组成能形成沿层压物第二线条27的方向具有弹性结构方向的令人满意的层压物结构66：第一载体层37和第二载体层38宜包含从热粘合聚丙烯形成的粗梳无纺织物，它具有32克/m2的基重，单纤维大小约为2.2旦尼尔，厚度在约0.01至0.03厘米之间，在单位应变εμ为1时，模量约为100克力/厘米(例如Fibertech，Landisville，N.J.出售的织物，Phobic Q-1)；弹性网36包含一个网，其中第一线条24由聚乙烯制得，第二线条由苯乙烯或丁二烯嵌段共聚物制得(例如Conwed，Minneapolis，MN生产并以T50018的名称出售的网)。具体地说，将成形前结构厚度S为大约0.09-0.13厘米(较佳的约为0.10-0.12厘米，更佳的约为0.11厘米)的并置的Phobic Q-1织物、T50018网和Phobic Q-1织物，以大约6至14米/分钟(更佳的约7至12米/分钟，最佳的约8至10米/分钟)的速度送到第一表面148上，该表面被加热至大约71℃-141℃(较佳的约为130℃-141℃，更佳的约137℃至139℃)的温度T1。在一个较佳的排列中，缝隙156宜大于或等于0.13厘米。当并置的织物和网通过第二表面150和槽型缝隙154时，第二表面150宜加热至约71℃-141℃(较佳的约130℃-141℃，更佳的约137℃-139℃)内的温度T2。缝隙154处的压力Pb宜为约55至85千克/厘米，更佳的约为70至75千克/厘米。当并置的织物和网从缝隙154出现后，所得热粘合弹性层压物66的厚度I约为0.05至0.09厘米，较佳的约0.06厘米至0.08厘米，更佳的约0.07厘米。
除了用上述方法形成本发明的层压物结构外，这些层压物结构还可用具有第一平板158和第二平板160的方法(如图4所示)来制得。与前述方法相反，第一平板表面最好是基本非弹性的，而第二平板表面151基本上有弹性。第一平板表面149宜加热至温度T1。通过使第一平板表面149向第二平板表面151适当移动，向并置的织物和网施加粘合压力Pf。由于温度T1将第一线条24加热相应粘合压力Pf时的软化温度，因此粘合压力Pf的施加使得第一线条24与第一载体层37以及第二载体层38整体粘合。更佳的是，粘合压力Pf的施加还使第一线条24变形成基本上扁平的形状，并且还与第一载体层37的内表面50以及第二载体层38的内表面52共面。最佳的是，粘合压力Pf的施加还使得第二线条26变形成基本椭圆的形状。
采用上述的Phobic Q-1和T50018网的组合，如果将第一平板158加热至约110℃至约130℃的温度T1，并施加350-700克力/平方厘米的粘合压力Pf约10至20秒，就能获得令人满意的第一线条24与第一载体层37以及第二载体层38整体粘合的层压物结构66。
为使层压结构在沿第二线条27方向上具有弹性结构，必需适当选择第一线条24的线条密度、线条横截面积和/或熔体指数(如果第一线条24由聚合物制成)。第一线条24的线条密度、线条横截面积和/或熔体指数选择不恰当会导致层压物结构中部分整体粘合的第一线条25会在层压物结构66中重叠或合并。整体粘合的第一线条25的这种合并或重叠会导致只有小部分层压物第二线条27在受到拉力时能伸展或延伸，这与没有这种重叠的层压物的情况正好相反，基本上所有第二线条27的伸长分布在整个长度方向上。为了最大程度地减少这种情况，应当选择线条密度、线条横截面积和/或第一线条24的熔体指数，使得整体粘合的第一线条25具有低于约50％的线条覆盖率Sc。本文所用的术语“线条覆盖率”是衡量接触本发明整体粘合的第一线条25的第一载体层内表面50以及第二载体层内表面52的表面积的标准。该线条覆盖率Sc定义为：
Sc＝(E-F)/E×100
其中E＝任何两个毗邻的整体粘合的第一线条25的线条中线间距离，如图2所示
F＝任何两个毗邻的整体粘合的第一线条25的线条边缘间距离，如图2所示
E和F可由本发明层压物结构66的任何横截面上任何毗邻的整体粘合的第一线条25间距测定。
本文所用的术语“线条密度”是指沿主线条横向方向上每厘米的主线条数。例如，第一线条24的线条密度可在第二线条26的预定长度A内测得，如图1所示。同样，第二线条26的线条密度可在第一线条24的预定长度B上测得。本文所用的术语“线条横截面积”是指，用本领域已知的技术测得的任一第一线条24的横截面积。
聚合物的熔体指数表示了聚合物在给定温度或压力时流动的能力。在给定温度下，熔体指数低的聚合物将比熔体指数较高的聚合物更具粘性(因此不容易流动)。因此相信，在施加给定压力和热通量期间，含有熔体指数较高的聚合物的第一线条24比含有熔体指数较低的聚合物、并经受相同压力和热通量的第一线条24更有合并或重叠的趋势。由于这个差别，可以选择形成第一线条24的聚合物具有预定的熔体指数，并再结合线条密度和线条横截面积，使得第一线条24与第一载体层37以及第二载体层38整体粘合的线条覆盖率约为50％。另外，当希望提高第一载体层37和第二载体层38的密度而维持相同的加工条件时，改变聚合物的熔体指数也是特别有用的。在这种情况下，可以改变第一线条24的聚合物，选择较高的熔体指数，使得第一线条24能够在受预定压力和热通量时更容易渗入并粘合载体层37和38。因此，尽管增加了载体层37和38的密度，但是不改变加工条件就能获得相同水平的整体粘合。
根据前述内容，认为第一线条24宜这样排列：使得线条密度为大约2至10股线条/厘米和横截面积约0.0005至0.03平方厘米，更佳的是大约3至6股线条/厘米与大约0.001至0.005平方厘米的横截面积，这样就能避免整体粘合的第一线条25在层压物结构66中发生合并或重叠。已经发现，约2至15的熔体指数(根据ASTMD1238测定)结合上述线条密度和线条横截面积是非常合适的。
对于第二线条26，认为第二线条26的线条密度、线条横截面积以及模量也会影响沿第二线条26方向(即沿图2的方向D)上层压物结构66的弹性性能(即层压物结构66的模量)。例如，随着第二线条26的线条密度和/或线条横截面积的增加，层压物结构66的模量将降低。对于要插入本发明的一次性弹性护背的层压物结构66，希望它在应变εμ为1时模量为约100至250克力/厘米。只要第二线条26的线条密度约为2至5、横截面积约为0.003至0.02平方厘米、且包含苯乙烯丁二烯嵌段共聚物，层压物结构66沿第二线条26方向上就有较佳的模量。层压物结构66的模量可用本领域已知的技术来测定。例如，可以用常规恒速拉伸仪(例如Instron EngineeringCorp.，Canton，MA生产的Instron Model#1122)测定层压物结构66的模量。
层压物结构66还能进行本领域已知的其它各种成形后的加工。例如，根据本文制得的层压物结构可包括与层压物结构连接的附加织物层(即填料层)，以便进一步改进结构的穿着性能和舒适性。附加织物层可以通过粘合剂、热粘合、压粘合、超声粘合、动态力学粘合或本领域已知的其它合适方法固定到层压物上。
在显示和描述了本发明的较佳实例后，本领域技术人员能在不脱离本发明的范围内通过适当变化进一步改进此改进的弹性层压物结构。本文已经描述了许多变化和改动，其它一些对本领域技术人员也将是显而易见的。例如，尽管本发明的弹性层压物结构已经在本发明较佳实例中公开了物理可测定参数的宽范围，但是应当认为，可以改变弹性层压物结构的物理参数，以生产所需的本发明改进的弹性层压物结构的其它较佳例子。另外，很明显的是，第一线条24的排列、性能和组成可以与第二线条26互换，或可以添加附加线条(例如多股第三线条等)以改变或增强本发明制得的弹性层压物结构的性能。因此，本发明的范围应根据下列权利要求来考虑，并应理解成它不局限于说明书和附图显示和描述的具体结构和方法。

Claims (9)

1.一种弹性层压物结构，它由以下步骤制得：
a)提供第一载体层；
b)提供第二载体层；
c)提供一个网，该网置于所述第一和第二载体层之间，并具有与多股第一线条交叉的多股第二线条，所述第一和第二线条在施加的压力下具有一个软化温度，其中在所述施加的压力下，所述第二线条的所述软化温度高于所述第一线条的所述软化温度；
d)将所述网加热至所述第一线条的所述软化温度且低于所述第二线条的所述软化温度；
e)向所述第一线条施加粘合压力；和
f)使10％至100％的所述第一线条与所述第一和第二载体层整体粘合。
2.根据权利要求1所述的弹性层压物结构，其中所述第一载体层与所述网并置，所述网与所述第二载体层并置，其中所述并置的第一载体层、网、以及第二载体层通过一个基本上没有弹性的第一表面，以及基本上没有弹性的第二表面，其中所述表面为轧辊表面。
3.根据权利要求2所述的弹性层压物结构，其中将所述第一和第二表面加热至一温度，该温度足以使所述第一线条的温度升高至所述第一线条的软化温度。
4.根据权利要求3所述的弹性层压物结构，其中所述第一表面的位置与所述第二表面毗邻，它们之间形成一个缝隙，使得所述并置的第一载体层、网以及第二载体层容易通过所述缝隙。
5.根据权利要求4所述的弹性层压物结构，其中所述第二表面的位置与基本上有弹性的第三表面毗邻，它们之间形成一个槽型缝隙，使得10％至100％的所述第一线条在所述并置的第一载体层、网以及第二载体层通过所述缝隙时与所述第一载体层以及第二载体层整体粘合。
6.根据前述任一权利要求所述的弹性层压物结构，其中所述第一线条的外表面渗入所述第一载体层和第二载体层至少10％的结构厚度。
7.根据前述任一权利要求所述的弹性层压物结构，其中在所述施加的压力下，所述第一线条的所述软化温度比所述第二线条的所述软化温度低至少10℃。
8.根据前述任一权利要求所述的弹性层压物结构，其中所述整体粘合的第一线条的至少50％变形成扁平的形状并和所述第一载体层和第二载体层共面。
9.根据前述任一权利要求所述的弹性层压物结构，其中至少25％的所述第二线条变形成基本椭圆的横截面形状。
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CO5060470A1 (es) 2001-07-30
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CA2301291C (en) 2004-12-21
US6090234A (en) 2000-07-18
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EP1005417A1 (en) 2000-06-07
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EP1005417B1 (en) 2003-06-04
DE69815353D1 (de) 2003-07-10
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ES2195362T3 (es) 2003-12-01

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