CN100434588C - 垫罩及其制备方法,以及垫子 - Google Patents
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Abstract
本发明涉及由非织造材料和纺织层组成的复合材料制成的垫罩,其中非织造材料包括单一的非织造层,并且其中所述非织造层和所述纺织层被永久性粘合在一起,同时保持纺织层的柔性特征。
Description
本发明涉及一种垫罩、制备该垫罩的方法、该垫罩的应用,并且特别涉及具有该垫罩的垫子。
美国专利号5,187,005涉及所谓的织物复合材料,包括一层纤维状的非织造纤维网和一层纺织热塑性纱线。该纺织热塑性纱线层的形式是纺织织物,如软箱包织物、墙壁覆盖织物或纱罗织物。非织造层和纺织层可以通过热熔体形式的聚合物样材料、挤出涂覆合成物或基于水的粘合剂粘合在一起。所述各层也可以被直接粘合在一起,即不用聚合物样材料而用热粘合法粘合,例如通过压光法。提到聚丙烯、聚酯、聚酰胺以及类似物可以作为非织造层的热塑性树脂。纺织层只包含合成材料。从所述文献中不能得知该复合材料作为垫罩的具体应用,更不用说实施这种应用的具体要求。
美国专利号5,192,601涉及一种由第一层纺织层和非织造的第二层组成的复合材料,其中对第一层纺织层中的一些热塑性纤维进行机械处理,以如下方式进行所谓的针刺法:这些纤维延伸到并穿过非织造的第二层。当该复合材料被加热至超过热塑性纤维的增塑温度时,两个独立层之间将紧密接触,其中纺织层优选由聚丙烯纤维和聚酯纤维形成,非织造层由聚丙烯纤维形成。这种热处理的一个缺点是纱线会收缩变硬,而这是不好的。此外,所述针刺法构成了一个不希望有的额外机械步骤,因此增加了成本并可能导致生产过程的扰动。
从美国专利号5,311,624,已知一种包括一个防水层的双层层压结构构成的垫罩,所述防水层层压或以其他方式粘合在底层上。防水层由乙烯树脂制成,并且所述层还含有抗菌剂。底层是非织造的聚丙烯织物。在层压过程中,由具有纹理的非织造纤维网构成的底层在压力下通过粘合剂和热辊被粘合到乙烯树脂层上。该双层结构的一个缺点是乙烯树脂层的应用将彻底改变垫罩的特性,特别是手感和握持方面的特性。另一个缺点是乙烯树脂层对湿气的通透不足,使得它只能在特定情况下被用作垫罩。
从国际申请WO99/56588,已知一种用于床或枕垫的覆盖材料,其包括与其中所装的内容物或垫子直接接触的多层非织造织物,该织物还进一步被整体附着于多层非织造织物的外部织物所包裹。该多层非织造织物是三层织物,即纺粘(spunbonded)-熔喷(melt-blown)-纺粘(spunbonded)层压制品。没有涉及将单层非织造层和纺织层组合起来,更不用说这些层被永久性粘合在一起而不影响纺织层柔性特征。
此外,已知在纺织材料背面施加涂层的方法,该方法使用丙烯酸树脂等,将它们用刮浆板装置以泡沫的形式施加到纺织材料上。泡沫中的气泡使垫罩能够“呼吸”。这种织物整理法要求很高的设备投资,此外还由于排出泡沫溶液中的溶剂而加重环境的负担。另外,由于泡沫穿透防止结构,会造成一定程度上的纺织材料光滑特性的丧失,而这在实践中被认为是不好的。除此之外,由于存在发泡材料,使该方法所生产垫罩的柔性特征受到轻度损害。
本发明的一个目的是提供一种复合材料,特别是垫罩,其中保留或改善了纺织载体层的有利特性,特别是防经纬滑动特性、线缝强力和其手感或握持特性。
本发明的另一个目的是提供一种制造复合材料特别是垫罩的方法,该方法使设备和/或加重环境负担的溶剂的使用最少。
本发明的另一个目的是提供由便宜材料组成的复合材料,该复合材料特别可用作垫罩,对于该应用必须满足制造垫罩的要求,特别是在防经纬滑动、线缝强力和柔性方面。
本发明的另一个目的是提供一种垫子,该垫子具有非常精制、高线缝强力和良好光泽的垫罩。
本发明的另一个目的是提供一种复合材料,该材料在使用时基本不磨损,并不存在任何“发粘”问题(即轻度粘性的织物,触摸起来呈塑料样)。
本发明的另一个方面涉及提供由稳定织物形成的垫罩,该稳定织物不易磨损并且能够使大规模生产更快、更有效。
本发明的另一方面涉及提供符合缝线强力、防经纬滑动和稳定性等方面具体要求的垫罩,已知的使用刮浆板装置的涂覆系统不能满足这些要求,特别是纬纱/cm的数量要求。
根据本发明,垫罩的特征在于非织造材料包括单一非织造层,其中所述非织造层和所述纺织层被持久地或者永久性粘合在一起,同时保持纺织层的柔性特点。
特别优选通过散布涂覆法、热熔法或在两层之间施加粘合剂的方式进行所述永久性粘合,特别优选使用散布涂覆法。
应用散布涂覆法不排放对环境有害的溶剂以及对环境有害的气体。此外,相对便宜的非织造材料制成的垫罩多少保留了纺织材料的固有光泽,增强了纺织材料的强度,并提供了握持或手感特性。此外,在废水控制、噪音水平和能源消耗方面获得了有利的结果。由于使用了散布涂覆法,粘合剂将不会渗透到纱线或到织物的前面。此外,在本发明垫罩的各层结构中不会有少量纬纱或经纱的磨损。此外,由于没有丙烯酸酯的存在,不会发生气体褪色。另外,散布涂覆法的应用使得可以用简单的方法改变或改性垫罩的特性,例如通过在散布涂覆材料中加入特定的添加剂如抗尘螨剂、阻燃剂、抗真菌剂、抗菌剂、防蚊剂、防过敏剂、防水剂和/或防油剂、抗静电剂、保健制剂、磁粉、温度调节剂、形状记忆制剂、自净剂、蜜胺分解剂等。除了这些,还可以加入被认为具有保健效果的特定的岩石类型,以及真芦荟和吸收或释放气味的物质。应当理解这些添加剂可以通过额外的粉末或液体掺入,也可以通过特定的额外加工步骤掺入,例如喷淋步骤、电晕处理、等离子处理或湿处理。另外,这些改性添加剂也可以已经被加入各层中,特别是通过非织造层加入。
非织造材料,也称纤维网,选自聚丙烯、聚酯、聚酰胺、醋酯纤维和粘胶纤维,或者其中的一种或多种的混合物,特别使用聚丙烯。
在具体的实施方案中,本发明使用的单一非织造层可以由两个单独的非织造材料亚层组成,其中各亚层可以彼此不同,例如是如前所述的“干法成网”、“湿法成网”和“挤压成网”类型。这种组合非常利于改变复合材料以及本发明垫罩的特定性质,例如透气性。
如通常所知,纤维网材料被分成三类,即“湿法成网”、“干法成网”和“挤压成网”,后一组又可以进一步被再分为机械疏理和精梳,以及空气穿透。为了获得要求的拉伸强力和形稳性,对通过空气穿透所获得的纤维网必须进行一种或多种额外的处理。特别优选热粘合处理,其中纤维被粘合在一起,通过热赋予纤维网所需的特性。另一个优选处理是挤压处理或纺粘处理,其中从喷嘴喷淋出纤维的长丝特别是聚丙烯,固化和/或压光后形成纤维网,其中所述压光特别起到将纤维进一步固定在特定位置上的作用。特别优选使用聚丙烯,因为其比重较小,这样同样重量每单位面积的体积就可以较大,这对于本发明复合材料的具体应用特别重要。另外,聚丙烯可以大量和低成本地获得。
非织造材料的优选重量是最多50g/m2,特别是20g/m2,特别是在12-20g/m2的范围内。如果使用上述范围之外的重量,所得垫罩的握持感就会太硬。另外,由于其价格,这种垫罩将失去吸引力。通过选择特定的非织造材料,可以改变最终复合材料的特性如透光度和每单位面积的重量。
在本发明垫罩中,纺织材料选自由聚丙烯、聚乙烯、polyacryl、氯纤维、芳香族聚酰胺、凯夫拉、聚氨酯弹性纤维、Lyocell(商标)、Tencel(商标)、黄麻、大麻、苎麻、西沙尔麻、蚕丝、碳纤维、玻璃纤维、芭蕉属类纤维、竹子、粘胶、聚酯、聚酰胺、醋酯纤维、棉、亚麻、玉米和羊毛、或者其中的两种或两种以上的混合物制成的纱线,例如聚酯/棉纱线、棉/亚麻纱线、聚酰胺/聚氨酯弹性纤维纱线、棉/粘胶/聚酯纱线、聚酰胺/羊毛纱线,这些列举不应被解释为限制性的,而只是说明性的。这些纱线可以被用作纬纱和/或经纱。
特别优选使用聚丙烯和聚酯的组合作为纺织材料。这种组合(其中聚丙烯优选作为纬纱使用,聚酯作为经纱使用)使垫罩的手感柔韧、丰满,还保持光泽。
本发明垫罩织物特别优选使用10-90纱/cm的经纱密度。除此之外,本发明垫罩织物优选使用4-50纬纱/cm的纬纱密度。这使织物的重量为40-1000g/m2。
在一个具体实施方案中,本发明垫罩是合乎提花机原理的纺织品,但在特定的实施方案中优选使用平纹组织、斜纹组织、缎纹组织或它们的组合。虽然在本发明中一直使用术语“纺织“,但应该理解在特定的实施方案中优选针织该织物,其中可根据所用的区(每英寸中针的数目),获得落入上述范围的针织物。
本发明进一步涉及制造由非织造材料和纺织材料组成的垫罩的方法,该方法的特征在于包括以下步骤:
a)提供一种非织造材料,
b)提供一种纺织材料,
c)在步骤b)的纺织材料或步骤a)的非织造材料上施加粘合剂,
d)将步骤a)的非织造材料和步骤b)的纺织材料以如下方式组合:在步骤c)中施加的粘合剂位于两种材料之间,和
e)对所得组合进行处理,获得垫罩,其中步骤a)的非织造层与步骤b)的纺织层被永久性粘合在一起,同时保持了纺织层的柔性特点。
这种方法在非织造层和纺织层之间提供了永久性粘合,其中保留了或改善了纺织层的固有优点,特别是光泽、柔性和手感,正常使用和洗涤后这些特性也被保留。
步骤e)中使用的适宜处理包括:压光、高频加热、超声处理、通过紫外线辐射进行粘合和热粘合,例如通过暴露于红外光下,可以使用施压的力,为了方便、可重复、准确和速度,优选使用压光。压光处理,特别是当使用固定压光机时,提供了更蓬松、更好的织物。
一方面为了获得非织造层和纺织层之间持久的粘合,另一方面为了保持纺织层的柔性特点,特别是在本发明中作为垫罩使用时,优选应用散布涂覆材料作为步骤c)中使用的粘合剂,优选8-20g/m2的量,特别优选5-20g/m2。散布涂覆材料的量少于上述下限则不能提供足够的粘合力,而超过上述的上高限则使最终产品过于昂贵并且太硬。但是,在特定实施方案中,通过步骤c)施加糊状或点状的粘合剂、粘合剂薄片(即薄膜、纤维网或网状物)是有利的。适宜的粘合剂包括:紫外线固化树脂、光敏树脂和压敏粘合剂,可以与红外线或紫外线辐射联合使用。例如,如果本发明复合材料透射紫外线并且使用了紫外线固化树脂作为粘合剂,则通过紫外线辐射可以获得纺织层和非织造层之间的持久粘合。
本发明的另一个实施方案涉及包括纺织层和整理层的特定复合材料,其中整理层是通过散布涂覆法施加的。适宜的整理层包括,例如EVA(乙烯基乙酸乙酯)、聚乙烯、特别是LDPE(低密度聚乙烯)、HDPE(高密度聚乙烯)、聚酯、聚酰胺和聚氨酯粉末,或者它们中的两种或多种的组合。应注意在本说明书中整理层与纺织层粘合使得整理层在正常使用中脱落的风险被减至最小。优选从聚丙烯、聚乙烯、polyacryl、氯纤维、芳香族聚酰胺、凯夫拉、聚氨酯弹性纤维、Lyocell(商标)、Tencel(商标)、黄麻、大麻、苎麻、西沙尔麻、蚕丝、碳纤维、玻璃纤维、芭蕉属类纤维、粘胶、聚酯、聚酰胺、醋酯纤维、棉、亚麻和羊毛、或者其中的两种或两种以上的混合物制成的纱线中选择纺织材料,其中特别使用棉和聚酯的组合作为纺织材料,当用聚酯作为经纱使用棉作为纬纱使用时,该纺织材料在纱线之间具有良好的抗经纬滑动性。
垫罩中非织造材料和纺织材料组合,这些材料被永久性粘合在一起,同时保持纺织层的柔性特征,使用非织造材料和用于将纺织层和非织造层粘合在一起的材料,以及所用的加工条件,在纺织材料的纱线之间提供了增强的线缝强力和增加的抗经纬滑动性,因此纺织材料中的纱线相对彼此固定。此外,由于使用了非织造材料,除了最终垫罩的手感柔韧、柔软和蓬松,纺织材料的固有光泽也被多少保留。此外,使用特定的非织造层使最终复合材料的透光度和重量发生实践中消费者欣赏的改变。
本发明进一步涉及具有垫罩(即上述垫罩或用如上所述的本发明复合材料制成的垫罩)的垫子。
本发明的核心是形成一种复合材料,该复合材料特别适合作为垫罩使用。非织造材料和纺织材料的特定组合形成手感些许蓬松的垫罩,该效果是通过粘合在纺织材料上的非织造材料而赋予的,其中纺织材料的固有光泽被多少保留,与根据上述现有技术由经过丙烯酸酯或聚氨酯整理处理的纺织材料、用刮浆板技术织造的低纬纱密度(例如10纬纱/cm)聚酯-聚丙烯织物所制的垫罩相比不那么透光。除此之外,包括纺织层和整理层(通过散布涂覆法施加整理层)的本发明复合材料特别适于作为垫罩使用。
实施例1-3和比较实施例1-3
由聚酯经纱和棉纬纱制成的纺织材料通过散布涂覆法被永久性粘合于非织造材料特别是聚丙烯上,从而获得本发明的垫罩。此外,依照所谓的湿法制造垫罩,其中通过刮浆板系统施加泡沫状丙烯酸酯涂层。对这样获得的材料进行BS3320(英国标准3320)检测,其中样品被对折,用预定数目的针迹/cm缝合接缝。随后,在两端施力,测量为了获得特定的接缝开口所需的力。下表中的数值代表了获得特定接缝开口所需的力。
从以上测量数据可以看出,对于本发明垫罩,获得特定接缝开口所需的力远高于现有技术垫罩(即使用湿法获得的垫罩)所需的力。因此很明显,本发明方法与现有技术的方法相比获得了显著的进步。
Claims (13)
1.由非织造材料和纺织层组成的复合材料制成的垫罩,其特征在于非织造材料包括单一纺粘非织造层,其中所述非织造层和所述纺织层通过以散布涂覆法施加的粘合剂永久性粘合在一起,同时保持纺织层的柔性特点,其中使用聚丙烯和聚酯的组合作为纺织材料。
2.根据权利要求1的垫罩,其特征在于该单一非织造层的材料选自聚丙烯、聚酯、聚酰胺、醋酯纤维和粘胶,或者其中两种或两种以上的混合物。
3.根据权利要求1的垫罩,其特征在于非织造材料的重量为最多50g/m2。
4.根据权利要求3的垫罩,其特征在于非织造材料的重量为最多20g/m2。
5.根据权利要求4的垫罩,其特征在于非织造材料的重量在12-20g/m2之间。
6.根据权利要求1的垫罩,其特征在于用聚丙烯作为非织造材料。
7.根据权利要求6的垫罩,其特征在于使用纺粘型聚丙烯作为非织造材料。
8.根据权利要求1的垫罩,其特征在于粘合剂的量是8-20g/m2。
9.根据权利要求1的垫罩,其特征在于纺织材料的经纱密度是10-90纱/cm。
10.根据权利要求1的垫罩,其特征在于纺织材料的纬纱密度是4-50纬纱/cm。
11.一种制造权利要求1-10任一项所限定的垫罩的方法,其特征在于该方法包括以下步骤:
a)提供一种包括单一纺粘非织造层的非织造材料,
b)提供聚丙烯和聚酯的组合作为一种纺织材料,
c)在步骤b)的纺织材料或步骤a)的非织造材料上通过散布涂覆法施加粉状粘合剂,
d)将步骤a)的非织造材料和步骤b)的纺织材料以如下方式组合:在步骤c)中施加的粘合剂位于两种材料之间,和
e)对所得组合进行处理,获得垫罩,其中步骤a)的非织造层与步骤b)的纺织层被永久性粘合在一起,同时保持了纺织层的柔性特点。
12.根据权利要求11的方法,其特征在于步骤e)中的处理包括压光处理。
13.具有权利要求1-10任一项所限定的垫罩的垫子。
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DE19636722C2 (de) * | 1996-09-10 | 1999-07-08 | Kufner Textilwerke Gmbh | Vliesverbund für Bekleidung, Verfahren zu dessen Herstellung und dessen Verwendung |
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-
2002
- 2002-03-19 NL NL1020206A patent/NL1020206C2/nl not_active IP Right Cessation
-
2003
- 2003-03-18 AU AU2003209581A patent/AU2003209581A1/en not_active Abandoned
- 2003-03-18 US US10/474,729 patent/US20040176008A1/en not_active Abandoned
- 2003-03-18 CA CA 2444919 patent/CA2444919A1/en not_active Abandoned
- 2003-03-18 PT PT03744474T patent/PT1485529E/pt unknown
- 2003-03-18 CN CNB03808614XA patent/CN100434588C/zh not_active Expired - Fee Related
- 2003-03-18 AT AT03744474T patent/ATE364101T1/de not_active IP Right Cessation
- 2003-03-18 ES ES03744474T patent/ES2287501T3/es not_active Expired - Lifetime
- 2003-03-18 DE DE2003614234 patent/DE60314234T2/de not_active Expired - Fee Related
- 2003-03-18 EP EP03744474A patent/EP1485529B1/en not_active Expired - Lifetime
- 2003-03-18 WO PCT/IB2003/000978 patent/WO2003078720A2/en active IP Right Grant
- 2003-03-19 BE BE2003/0173A patent/BE1014514A4/nl not_active IP Right Cessation
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US4159360A (en) * | 1976-10-15 | 1979-06-26 | Hercules Incorporated | Stabilized fabrics |
US5192601A (en) * | 1991-03-25 | 1993-03-09 | Dicey Fabrics, Incorporated | Dimensionally stabilized, fusibly bonded multilayered fabric and process for producing same |
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Also Published As
Publication number | Publication date |
---|---|
EP1485529B1 (en) | 2007-06-06 |
CN1646755A (zh) | 2005-07-27 |
PT1485529E (pt) | 2007-08-31 |
WO2003078720A3 (en) | 2004-07-22 |
ATE364101T1 (de) | 2007-06-15 |
NL1020206C2 (nl) | 2003-09-23 |
ES2287501T3 (es) | 2007-12-16 |
AU2003209581A1 (en) | 2003-09-29 |
BE1014514A4 (nl) | 2003-11-04 |
CA2444919A1 (en) | 2003-09-25 |
US20040176008A1 (en) | 2004-09-09 |
DE60314234T2 (de) | 2008-01-31 |
WO2003078720A2 (en) | 2003-09-25 |
EP1485529A2 (en) | 2004-12-15 |
DE60314234D1 (de) | 2007-07-19 |
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