专利摘要:
method of forming an elastic laminate the present invention relates to a method of forming an elastic laminate (10) comprising at least one elastic film (11) and at least two non-woven bands (12, 13) laminated on each side the elastic film (11), wherein the elastic film (11) is fed in a machine direction to a connecting station (14); the elastic film (11) is stretched in the machine direction at a stretch ratio of 1.5 to 8 times its original length, thus forming a stretched film; and the stretched film and said two or more non-woven bands (12, 13) are laminated at the binding station (14). the elastic film (11) is stretched in at least two stretching steps before being laminated with two or more non-woven bands (12, 13), where between 5 to 25% of the total stretching occurs during the last stretching step before lamination at the connecting station (14).
公开号:BR112013033633B1
申请号:R112013033633-1
申请日:2011-06-30
公开日:2020-09-29
发明作者:Floberg Per;Kinderdal Mats;Gabrielii Inge
申请人:Essity Hygiene And Health Aktiebolag;
IPC主号:
专利说明:

TECHNICAL FIELD
[001] The present invention relates to a method of forming an elastic laminate comprising at least one elastic film and at least two non-woven bands. The elastic film and the non-woven bands are laminated while the elastic film is kept in a stretched condition. BACKGROUND OF THE INVENTION
[002] Elastic laminated materials are usually incorporated in absorbent articles, especially pants-type absorbent articles, such as diaper-pants, incontinent pants, sanitary pants, and the like. Such articles comprise an absorbent unit arranged in a pants-shaped chassis and are used in the form of a pair of pants. Elastic laminated materials can be incorporated as parts of front panels and / or rear panels and / or as elastic side panels in an absorbent article like pants.
[003] If the elastic film is in a stretched condition in a machine direction (MD) during bonding to at least one layer of nonwoven, the layer of nonwoven may crinkle between the bonding sites in a non-contracted state and thus, making the laminated material elastically extensible in said machine direction. Such melt-melt bonding, for example, carried out by thermal bonding or ultrasonic welding, may result in openings being formed in the film at or adjacent to bonding sites. This will make the elastic film and laminate breathable, which is an advantage and increases user comfort in an absorbent article.
[004] WO 2008/026106 discloses a breathable elastic laminate suitable for incorporation into an absorbent article. The laminate comprises an elastic film and a nonwoven band bonded by melt melt bonding at a plurality of bonding sites, while the film is in a stretched condition. The openings are formed in the film at the connection sites simultaneously with the melt melt without substantially softening the polymer material of the nonwoven web.
[005] WO 2009/138887 describes a method for forming a latent elastic composite from a laminated multilayer elastic film to a non-woven coating. The multilayer elastic film is stretched in the machine direction at a stretch ratio of 1.5 to 1.0, thus forming a stretched elastic film. The stretched elastic film is allowed to relax until it reaches a relaxation percentage of at least 10% and is then laminated to the nonwoven coating band in the relaxed condition.
[006] US 2010/0139846 discloses a method for bonding high loft elastomeric substrates where the high loft elastomeric substrates are introduced into the bonding station in a stretched state.
[007] International application PCT / SE2010 / 050986 describes an elastic laminate comprising at least one layer of elastic film and at least one layer of nonwoven. The elastic film and the nonwoven layer are bonded together in a bonding pattern that comprises a plurality of bonding elements in which the film and nonwoven are fused together. The elastic film is kept in a stretch state during bonding. The openings are formed in the elastic film in close proximity to the connecting elements caused by the rupture of the film as a result of stretching. These openings make the film breathable.
[008] There is still a need for a method of manufacturing an elastic laminate in which the process of stretching the elastic film before bonding to the nonwoven web is controlled so that the bonding occurs in a controlled manner. This is especially important when the stretched elastic film is bonded to the non-woven web (s) by melting by melting in a bonding pattern, where openings in the film are formed in the connecting elements or in close proximity to these. DESCRIPTION OF THE INVENTION
[009] According to the present invention there is provided a method of forming an elastic laminate, said elastic laminate comprising at least one elastic film and at least one non-woven band, the method comprising: providing an elastic film and feeding it in a machine direction to a rolling station; stretching said elastic film in the machine direction at a stretch ratio between 1.5 to 8 times of its original length, thus forming a stretched film; laminating the stretched film and at least two non-woven strips, wherein said elastic film is stretched in at least two stretching steps prior to lamination with said at least two non-woven strips, and where between 5 and 25% of the total stretching takes place in the last stretching step before lamination.
[0010] The elastic film and at least the two non-woven bands can be laminated by a thermal bond or ultrasonic weld in a bond pattern that comprises a plurality of bonding elements.
[0011] The openings may be formed in the elastic film at or in the vicinity of at least some of the connecting elements, said openings being caused by the rupture of the elastic film as a result of stretching.
[0012] The elastic film can pass through at least two drawing rolls before entering the binding station, where the last drawing step takes place between the last drawing roller and the binding station.
[0013] The elastic film can pass through at least three stretching rollers before entering the connection station.
[0014] The elastic film can be stretched in at least three steps before entering the binding station.
[0015] The free length between adjacent drawing rollers can be between 10 and 150 mm.
[0016] The basic weight of the laminate can be between 40 and 100g / m2 and the base weight of the elastic film can be between 20 and 60 g / m2 DEFINITIONS
[0017] The term "machine direction" or "DM" refers to the direction in which the material, in this case, the elastic laminate is produced. The term "direction perpendicular to the machine" or "CD" refers to the direction perpendicular to the machine direction.
[0018] The term "elastic" or "elastomeric" refers to a material that after application of a stretching force and extending in at least one direction, for example, in DM, retracts after the release of the stretching force , that is, it returns to its original dimension. An elastic material is defined as a material that has a permanent stretch after less than 10% relaxation after the material has undergone a 30% stretch. A stretch of 30% means a stretch to a length that is 30% longer than the initial sample length. The material is tested on a tensile tester, Lloyd LRX, as described in the "tensile test" below.
[0019] The term "stretch ratio" is defined as the length of the stretched film divided by its length before stretching. BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The invention will be described below with reference to the accompanying drawings, which show some embodiments.
[0021] Figure 1 schematically illustrates a method for forming an elastic laminate according to an embodiment of the present invention.
[0022] Figure 2 shows schematically an example of a bonding pattern for bonding the elastic laminate.
[0023] Figure 3 shows an example of an absorbent article like pants, having elastic body panels.
[0024] Figure 4 shows another example of an absorbent article like pants, which has elastic side panels. DESCRIPTION OF ACCOMPLISHMENTS OF THE INVENTION
[0025] An elastic laminated material (10) according to the invention comprises at least one elastic film (11) and at least two fibrous non-woven layers (12), (13) comprising the layer of elastic film with each other. Suitable non-woven materials and elastic films are selected depending on the intended use of the elastic laminate. For use on an absorbent article, suitable materials are given below.
[0026] In the method illustrated in Figure 1 the layers (11), (12) and (13) are connected together in a connection station (14), with a connection pattern comprising a plurality of connection elements in which the elastic film (11) and the nonwoven bands (12) and (13) are fused together. The bonding technique can be point thermal bonding, ultrasonic bonding or the like. Punctual thermal bonding uses a narrowing formed between two rollers, at least one of which has a pattern. One or both rolls are heated. Ultrasonic connection employs a narrowing of connection formed between an ultrasonic horn (15) and a standard roller (16). In both techniques, which are well known in the art, the pattern roll (16) comprises a plurality of protruding connecting elements for connecting the film to the non-woven layer (s) in a pattern of connection formed by the highlighted connecting elements.
[0027] The elastic film (11) is in a stretched condition, during the connection, said stretch is in the machine direction (MD) of the laminate. The degree of stretching should be at least 1.5 times its original length, preferably in the range of 3 to 8 times its original length. The stretching takes place in at least two stages of stretching, as will be described in more detail below.
[0028] After relaxation of the film (11) the non-woven layers (12), (13) can crinkle between the connection sites and, thus, make the laminated material (10) elastically extensible in said machine direction.
[0029] The elastic film (11) passes over a series of stretch rollers (17), (18), (19) and (20) before being laminated with the nonwoven layers (12) and (13) at the station connection (14) formed by the ultrasonic horn (15) and the pattern roll (16). The number of drawing rollers and four in the embodiment shown in Figure 1. The number of drawing rollers must be two or more, and can be three, four, five, six or more. The drawing rollers have a smooth, high friction surface, for example, a polymer coating. An example of a suitable high friction polymer coating is PlasmaCoat 30301/4001 F-12.
[0030] The elastic film (11) is stretched between two or more of the stretching rollers, for example, between the rollers (17) and (18), rotating the roll (18) at a peripheral speed greater than the roll ( 17). According to the invention, the elastic film (11) is stretched in at least two stretching steps. The last drawing step occurs between the last drawing roll (20) and the connecting station (14). Between 5 and 25% of the total stretch of the elastic film occurs in this last stretch. Thus, between 75 and 95% of the total stretch of the elastic film takes place in one or more steps between the drawing rollers (17) and (20).
[0031] A guide roll (21) is arranged between the last drawing roll (20) and the connecting station (14), in order to adjust the winding angle of the elastic film (11) in relation to the pattern roll (16). Guide rollers (22) and (23) are also provided for the nonwoven webs (12) and (13) before the binding station (14).
[0032] It is desirable that the so-called "thinning" of the elastic film (11) is minimized, in which the "thinning" refers to the constriction of the film in the width direction (CD) during stretching. Thinning is prevented or reduced, minimizing the distance between the drawing rolls 17 to 20. The distance between the adjacent drawing rolls can be measured as the free length, (a), between the rolls, that is, the distance between the point where the film leaves a roll and the point at which the film comes into contact with the next roll. This free length, (a), can be between 10 and 150 mm in order to minimize the thinning of the film.
[0033] Depending on the choice of connection elements (24) in the connection pattern that joins the non-woven bands (12), (13) and the elastic film (11), openings (25) can be formed in the elastic film in narrow proximity to at least some of the connecting elements (24). This is illustrated in Figure 2. These openings (25) are formed by the rupture of the elastic film as a result of stretching. These openings (25) can be located outside the area of the respective connecting element (24) and are formed due to stresses in the film in the area in close proximity to the connecting elements. In the "close neighborhood" it means that the openings extend from the perimeter of the respective connecting element. The openings extend substantially in the DM and can be located in front of and / or behind the respective connecting element (24). The openings make the elastic laminate (10) breathable.
[0034] This is described in more detail in the international application PCT / SE2010 / 050986 in which examples of connection patterns are given that will provide the formation of openings in the film.
[0035] The method described above of stretching the elastic film in two or more stages, in which the last stretching stage takes place between the stretching roller and the last bonding station, causes the elastic film to open immediately before gluing. , which results in better control of the bond and the characteristics of the elastic laminate produced. The film is more sensitive during stretching, which makes it "open" during bonding. This is especially important when openings are formed in the film during bonding and the multi-step stretching will improve the control of the formation of openings and, therefore, the breathability of the laminate.
[0036] The elastic laminate can be used on an absorbent article. The term "absorbent article" refers to products that are placed against the user's skin to absorb and contain body exudates, such as urine, feces and menstrual fluid. Such absorbent articles are often disposable, which means that the articles are not intended to be washed or otherwise recovered or reused as an absorbent article after use. The absorbent article comprising the elastic laminate is preferably an absorbent type pants, such as a diaper type pants, sanitary pants or incontinence pants.
[0037] Figure 3 shows an embodiment of an absorbent article like pants (26), for a child or an incontinent adult or sanitary pants. Said pants-like article normally comprises a chassis (27), including a front panel (28), a rear panel (29), a hook portion (30) and an elastic waist band (31). The central region (32) comprises an absorbent core (33) and is located at least in the crotch portion (30) of the article and extends a certain distance to the front (28) and rear (29) panels. The hook portion (30) is thus defined as the narrowest part of the article intended for use in the user's groin region between the legs. In another embodiment (not shown), the front and rear panels are separated from each other and the core region, comprising the absorbent core, interconnects the front and rear panels.
[0038] The central region (32) further comprises a liquid impermeable back sheet (34) underlying the absorbent core (33) and a liquid permeable top sheet (not shown) on the side of the absorbent core facing the user. The absorbent core, the backsheet and the topsheet can be of materials commonly used in absorbent articles.
[0039] The article has a longitudinal (y) and a transverse (x) direction.
[0040] According to an embodiment of the invention, the surface area of the absorbent core (30) reaches no more than 30% of the total surface area of the article, preferably not more than 20%, as a measure in a flat state of the article. The term "flat state" here means in a state of rest, open in which the side seams are opened and in which all tensioned elastic elements have been deactivated.
[0041] The elastic laminate (10) can cover the entire article, including the core region (32) and the entire chassis region (27). However, according to a preferred embodiment, a substantial part of the hook portion (30) of the article is free of the elastic material band (10). A "substantial part" as used herein refers to at least 50%, preferably at least 75A. Also the waist region of the chassis region can be free of elastic laminate (10) and can comprise a separate elastic cos (31). The elastic waistband (31) comprises a non-woven material that is elasticized by elastic elements (35), such as elastic threads, contractually affixed between the layers of material, such as non-woven materials. Such elastic elements (35) can also be arranged around the leg openings of the article. Ultrasonic welding (37), glue cord or similar join the elastic laminate (10) to the elastic band (31).
[0042] A non-woven material can be arranged on the garment-facing side of the liquid impermeable back sheet (34) in the crotch portion of the article. The non-woven material is joined to the elastic laminate (10), by means of ultrasonic welding (37), beads of glue or the like.
[0043] The elastic laminate (10) is preferably disposed as an outer covering sheet material, as well as inner covering sheet material over at least a substantial part of the front region (28) of the chassis (27), which during the use is intended to be applied against the user's stomach, except in the waist region. A "substantial part" used here means at least 50% of the surface area, preferably at least 75%, of the surface area of the front region of the chassis. It is further preferred that the elastic laminate (10) is arranged as an outer cover sheet material, as well as inner cover sheet material over the front (28) and rear (29) regions of the chassis (27). Thus, there is no need for any additional back or top sheet materials and the elastic band material is the only component in these parts of the chassis (27). At least 20%, preferably at least 25%, more preferably at least 30% and most preferably at least 40% of the total surface area of the article, as seen in a flat state, as mentioned above, the elastic laminate (10) constitutes the only component of the chassis.
[0044] The outer cover sheet covering the panels (28) and (29) of the chassis (27) comprises an elastic laminated material (10), which is elastic, at least in the transverse direction (x) of the article. The elasticity in the (x) direction should be at least 30%, preferably at least 50%, more preferably at least 70%, as measured by the elasticity test specified below. The transverse direction described here corresponds to the MD of the elastic laminate described above.
[0045] For an elastic laminate used as a front panel (28) and / or a rear panel (25) in an absorbent type of pants, the laminate comprises at least three layers, namely: first and second non-woven outer layers (12), (13), which are chosen so that, in combination with the internal elastic film layer (11), they provide the elastic laminate (10) with high puncture resistance, in order to prevent nail penetration, for example. They also offer a soft, cloth-like feel to the laminate. Examples of suitable materials are carded bands and continuous spinning materials. The base weight of the layers of fibrous material should be between 10 and 35 g / m ", preferably between 2 and 30 g / m2, more preferably between 13 and 25 g / m". Examples of suitable polymers used in fiber materials are polyethylene, polyester, polypropylene and other polyolefin homopolymers and copolymers. Natural fibers, for example cotton, can also be used, as long as they provide the required properties. A mixture of polymers can contribute to greater flexibility of the nonwoven layer, and therefore give the nonwoven material a greater stretch at maximum load. A mixture of polyethylene and polypropylene polymers has been shown to provide good results in this regard. A mixture of fibers of different polymers is also possible. The non-woven layers (12), (13) must be chosen so that the tensile strength of the laminate is sufficient for its intended purpose.
[0046] The elastic film (11) preferably has a base weight between 20 and 80 g / m2, preferably between 20 and 60 g / m2. The elastic film (11) can be of any suitable elastic polymer, natural or synthetic. Some examples of suitable materials for the elastic film are low-crystalline polyethylene, metallocene-catalyzed low-polyethylene, ethylene vinyl acetate (EVA) copolymers, polyurethane, polyisoprene, butadiene-styrene copolymers, styrene block copolymers , such as styrene / isoprene / styrene (SIS), styrene / butadiene / styrene (SBS), or styrene / ethylene-butadiene / styrene. Mixtures of these polymers can also be used, as well as other modified elastomeric or non-elastomeric materials. An example of a suitable elastic film is a three-layer elastomeric film of PE-SEBS-PE.
[0047] The total base weight of the elastic laminate (10) is preferably between 40 and 100 g / m2, more preferably not more than 90 g / m2
[0048] Although the elastic laminate according to the invention is mainly intended to be used in absorbent articles like pants, in which the elastic laminate extends all the way between the side seams of the article, in at least one of the front panels and rear, it can also be used to form, for example, elastic side panels in an absorbent article. Figure 4 illustrates an absorbent shoe type comprising elastic side panels (38). The article further comprises a front body panel (39) and a rear body panel (40) and a crotch portion (41). The front and rear body panels, as well as the crotch portion, are generally composed of a liquid impermeable back sheet, a liquid permeable top sheet and an absorbent core (42) located between the back sheet and the top sheet. The absorbent core, the backsheet and the topsheet can be of materials commonly used in absorbent articles. The backsheet may further comprise a layer of non-woven material laminated to a layer of film, in which case a more cloth-like feel is provided than would normally be achieved with just a backsheet of film.
[0049] Elastic extensible side panels (38) are provided to ensure the most comfortable and contour fit. The elastic side panels (38), or at least parts of them, may comprise the elastic laminate (10) according to the invention. Elastics for the legs and elastic waist region can also be provided to improve the fit around the legs and waist, respectively. TEST METHODS Elasticity Test
[0050] The test measures how an elastic material behaves under repeated loading and unloading cycles. The sample is drawn to a predetermined stretch and a cyclic movement between 0 and said predetermined and performed stretch. The desired loading and unloading forces are recorded. The permanent, ie remaining, stretch of the relaxed material is measured.
[0051] A traction tester, Lloyd LRX, covers to perform cyclic movements and equipped with a printer / plotter or presentation software is used. The sample is prepared by cutting a width of 25.4 mm and a length that is preferably 20 mm longer than the distance between the clamps on the tensile tester.
[0052] The tensile tester is calibrated according to the instructions of the instrument. The parameters required for the test (loading and unloading forces) are set at: - Head speed: 500 mm / min - Clamp distance: 50 mm - Preload: 0.0 5 N
[0053] The sample is conditioned for at least 4 hours at 50% RH ± 5% relative humidity and 23 ° C ± 1 ° C and is placed on the clamps according to the marks and makes sure that the sample is centered and attached perpendicularly to the clamps. The tensile tester is started and three cycles between 0 and the predetermined elongation are performed, equal to the first highest defined load. Before the last cycle, the sample is relaxed for 1 minute, then the permanent elongation is measured by stretching the sample until a 0.1 N force is detected and the elongation is read.
[0054] An elastic material is defined as a material that has a permanent stretch after less than 10% relaxation after the material has been subjected to a 30% stretch. A stretch of 30% means a stretch to a length that is 30% longer than the initial sample length. Thus, a material that has an elasticity of at least 30% is defined as the material that must have permanent relaxation after stretching less than 10% after being subjected to a 30% stretch in the above tensile tester. A material that has an elasticity of at least 50% is defined as the material that should have a permanent relaxation after stretching less than 10% after being subjected to a 50% stretch in the above tensile tester, etc.
[0055] A non-elastic material has a permanent stretch after relaxation of more than 10% after being subjected to a stretch of 30%. EXAMPLE
[0056] An elastic laminate was produced comprising an elastic film and two laminated non-woven layers on each side of the elastic film. The elastic film was a 30 g / m2 multilayer film of Berry Plastics having a styrene-based core layer and layers of polyolefin skin. One non-woven layer was a non-woven material of continuous spinning polypropylene by Freudenberg, code LS 4516 (white), weight 16 g / m2, titre 1.6-1 0.8 dtex, and the other non-woven layer was a non-woven material of continuous spinning polypropylene by Freudenberg, with the code Lutrasil 0519 XF, weight 19 g / m2, titre 1.6-1.8 dtex.
[0057] The elastic film and the non-woven layers were laminated by means of ultrasonic welding in a connection pattern that comprises a plurality of connection elements in which the elastic film and the non-woven bands were fused together. The connection standard was defined as in PCT / SE2010 / 050986. The elastic film was stretched in the machine direction at a stretch ratio of 4.5 times its original length, in two stretching stages, in which 12% of the stretching occurred in the last stretching stage, just before rolling, as described above. The stretched film and the non-woven bands were laminated in the condition that the film was stretched. Openings were formed in the film in close proximity to the connecting elements, caused by the rupture of the elastic film as a result of stretching, as described above. The elastic laminate that was produced is breathable and has an average breathability greater than 12 (m3 / m2 - min) at 200 Pa.
权利要求:
Claims (5)
[0001]
1. METHOD OF FORMING AN ELASTIC LAMINATE (10) comprising at least one elastic film (11) and at least two non-woven bands (12, 13) laminated on each side of the elastic film (1), the method comprising steps of: providing an elastic film (11) and feeding it in the machine direction to a connection station (14); stretching the elastic film (11) in the machine direction at a stretch ratio between 1.5 and 8 times its original length, thus forming a stretched film; where the elastic film (11) is stretched in at least two stretching steps before laminating with at least two non-woven bands (12, 13), and where the elastic film (11) passes over at least three rolls of stretching (17 to 20) before entering a connecting station (14); laminate the drawn film and at least two non-woven bands (12, 13) at the binding station (14), characterized in that between 5 and 25% of the total stretching occurs in the last stretching step before lamination at the binding station (14 ) in which the elastic film (11) passes over at least two stretching rollers (17 to 20) before entering the connecting station (14), where the last stretching step takes place between the last stretching roll (20 ) and the connecting station (14); and wherein the elastic film (11) and the at least two non-woven bands (12, 13) are laminated by thermal bonding or ultrasonic welding in a bonding pattern comprising a plurality of bonding elements (24); and wherein openings (25) are formed in the elastic film (11) in or in close proximity to at least some of the connecting elements (24), the openings being caused by the rupture of the elastic film as a result of stretching.
[0002]
METHOD according to claim 1, characterized in that the elastic film (11) passes through at least three adjacent drawing rollers (17 to 20) before entering the connecting station (14).
[0003]
METHOD according to claim 2, characterized in that the elastic film (11) is stretched in at least three steps before entering the connecting station (14).
[0004]
METHOD according to any one of claims 2 to 3, characterized in that the free length (a) between the adjacent drawing rollers (17 to 20) is between 10 and 150 mm.
[0005]
METHOD according to any of claims 1 to 4, characterized in that the base weight of the laminate (10) is between 40 and 100 g / m2 and the base weight of the elastic film (11) is between 20 and 60 g / m2.
类似技术:
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同族专利:
公开号 | 公开日
EP2726037A4|2014-12-24|
CN103635167B|2018-06-05|
AU2011372077B2|2016-05-12|
US20140130956A1|2014-05-15|
US9199410B2|2015-12-01|
EP2726037A1|2014-05-07|
PL2726037T3|2019-03-29|
BR112013033633B8|2020-10-20|
JP6392118B2|2018-09-19|
BR112013033633A2|2017-01-24|
RU2014103033A|2015-08-10|
EP2726037B1|2018-11-21|
AU2011372077A1|2013-12-19|
JP2014520589A|2014-08-25|
WO2013002691A1|2013-01-03|
RU2566929C2|2015-10-27|
CN103635167A|2014-03-12|
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法律状态:
2018-12-26| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
2019-01-02| B25D| Requested change of name of applicant approved|Owner name: ESSITY HYGIENE AND HEALTH AKTIEBOLAG (SE) |
2019-09-03| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|
2020-06-02| B09A| Decision: intention to grant|
2020-09-29| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 30/06/2011, OBSERVADAS AS CONDICOES LEGAIS. |
2020-10-20| B16C| Correction of notification of the grant|Free format text: REF. RPI 2595 DE 29/09/2020 QUANTO AO ENDERECO. |
优先权:
申请号 | 申请日 | 专利标题
PCT/SE2011/050878|WO2013002691A1|2011-06-30|2011-06-30|Method of forming an elastic laminate|
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