CN101068968A - 制造长丝层压制品的方法及其产品 - Google Patents

制造长丝层压制品的方法及其产品 Download PDF

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CN101068968A
CN101068968A CNA2005800411154A CN200580041115A CN101068968A CN 101068968 A CN101068968 A CN 101068968A CN A2005800411154 A CNA2005800411154 A CN A2005800411154A CN 200580041115 A CN200580041115 A CN 200580041115A CN 101068968 A CN101068968 A CN 101068968A
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mentioned
web
net
nonwoven fabric
juxtaposed
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N·M·卡特
S·D·德莱昂
R·A·穆迪三世
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PGI Polymer Inc
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PGI Polymer Inc
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Abstract

本发明针对制造层压非织造织物的方法，所述层压非织造织物需要使连续的长丝纤维网与纤维素纤维材料通常是木浆粕的纤维网形成形体。为了减少在水刺成网形成整体期间纤维素纤维材料的损失，本发明设想首先使连续的长丝纤维网经受水刺成网，此后通过水刺成网与纤维素纤维材料形成整体到部分缠结的连续的长丝纤维网中。

Description

制造长丝层压制品的方法及其产品
技术领域
本发明一般涉及水刺成网式(射流喷网式)非织造织物，更具体地说，涉及由连续的长丝纤维网和纤维素纤维网形成的水刺成网式层压非织造织物，上述纤维网如此形成整体，以使纤维素纤维变成与连续的长丝结构形成整体。最终的织物显示极好的强度和吸收能力，且特别适合于在卫生、医药、和工业应用中使用。
发明背景
非织造织物由于通用性而找到广泛应用，上述通用性受可以选择性地设计这些织物的物理特性的方式影响。通过水刺成网法(射流喷网法)形成非织造织物特别有利，因为织物由其形成的纤维或长丝可以有效地按照特殊应用所希望的要求形成整体和定向。不同类型纤维的混和物可以很容易通过水刺成网法组合，因此可以制造显示选定的物理性能的最终织物。
在此之前，已知由合成纤维和纤维素纤维的混和物所形成的非织造织物，同时这些织物理想的是显示构成的合成纤维和纤维素纤维所特有的物理性质。通常，合成纤维可以如此形成织物，以便在最终织物中可以提供一些特点如良好的耐磨性和抗拉强度。利用纤维素纤维提供具有所希望的吸收能力和柔软度的这些织物。
由Oathout申请的美国专利No.5459912包括在本文中作为参考文献，该专利公开了由合成纤维和木浆粕所形成的构成图案的射流喷网式织物，所述织物据说显示良好的吸收能力和低的颗粒数。因此，织物适合于在希望有这些特点的地方使用，如适合用作清扫房间的揩布，用于食品科学的揩布，及类似应用。然而，该专利设想在干的状态下使木浆粕纤维和合成纤维形成整体，同时通过只在一侧上(成孔之前)处理进行随后的水刺成网。可以认为，这造成木浆粕纤维状材料穿过松散粘合的合成纤维相当大的损失，同时有损于制造过程的效率。
此外，由于连续的长丝纤维网内的高度多孔性，所以连续的长丝纤维网和浆粕纤维的并置，在随后的水刺成网处理时显露了木浆粕纤维状材料穿过长丝的相当大的损失。一种可能的解决方案是利用很细纤度的长丝，以便防止木浆粕纤维的损失。对制造连续的长丝和纤维素纤维网层压制品的方法，要求保持不需要细纤度的长丝。
由于用连续的长丝和纤维素纤维所成的层压非织造织物材料可以提供所希望的物理性质的组合，所以本发明针对制造这种层压非织造织物的方法，所述方法通过在水刺成网组合期间减少纤维素纤维损失到滤水中来促进有效的织物形成。
发明概述
本发明针对制造层压非织造织物的方法，所述方法要求连续的长丝纤维网与纤维素纤维材料，通常是木浆粕纤维网形成整体。为了在通过水刺成网形成整体期间减少纤维素纤维材料的损失，本发明设想首先使连续的长丝纤维网经受水刺成网，此后用纤维素纤维状材料通过水刺成网整合到部分缠结的连续的长丝纤维网中。现已发现，这种形成技术理想的是在水刺成网过程期间减少了纤维素纤维损失到供水刺成网用的滤水中。最终的织物显示出用连续的长丝和纤维素纤维一起所达到的所希望的特点的混合，同时本发明的制造技术理想的是促进本发明的织物的有效而低成本的形成。
按照本发明，制造层压非织造织物的方法包括提供连续的长丝纤维网的步骤，并且还包括水刺成网连续的长丝纤维网，以便形成部分缠结的纤维网。这种部分水刺成网理想的是起作用以便在加入相关的纤维素纤维状材料之前，使长丝形成整体并改善纤维网均匀度。
本发明织物的纤维素纤维状材料通过将纤维素纤维网与部分缠结的连续的长丝纤维网并置加入。然后将并置的纤维网进行水刺成网，随后干燥以形成本发明的层压非织造织物。特别是，现已发现，在加入纤维素纤维状材料之前，连续的长丝纤维网的预缠结理想情况是随着连续的长丝和纤维素纤维网通过水刺成网形成整体，使纤维素材料的损失减至最少。可以认为，预缠结的连续的长丝纤维网理想情况是可以起作用，以便改善长丝纤维网的均匀度，及“过滤”纤维素纤维状材料，以使它损失到滤水中减至最少。此外，连续的长丝纤维网的预缠结理想情况是能利用减少的能量输入来缠结长丝和纤维素纤维网，上述情况也可认为是有助于减少纤维素纤维的损失。还可以认为，应用减少的能量输入来缠结组成部分纤维网的能力可用来保持固有的大部分层压非织造织物，并因此可供在增加高压水刺成网的非织造织物上隙间体积情况下改善吸收能力。
本发明的其它特点和优点从下面的详细说明、附图、和所附权利要求书将变得很容易显而易见。
附图简介
图1是应用本发明的原理制造层压非织造织物的装置的示意图。
详细说明
尽管本发明可以有不同形式的实施例，但在附图中示出了并在后面进行说明的是目前优选的实施例，同时应该理解，现有公开内容可认为是本发明的举例说明，并且不打算把本发明限于所说明的特定实施例。
参见图1，其中用简图示出应用本发明的原理实施制造层压非织造织物的方法所用的装置。本发明的层压织物优选的是由并置的连续长丝纤维网和纤维素纤维网形成，上述连续长丝纤维网和纤维素纤维网通过用高压液体流对准它们经受水刺成网，优选的是首先对准并置的纤维网其中一个膨胀的表面，然后对准纤维网反面的膨胀的表面，在本发明的范围内，连续的长丝纤维网和纤维素纤维网各都可以取一个以上纤维网的形式提供，因而能使不同类型的长丝和/或不同类型的纤维素纤维形成整体。另外在本发明的范围内，长丝纤维网和纤维素纤维网各都可以在纤维网内包括同质的组成成分，或者在可供选择的方案中，包括不同的组成成分的混和物。此外，本发明的层压制品可以包括一个或多个不连续的长丝层或薄膜层，其中可以应用透气薄膜，多孔薄膜，成像薄膜，或者它们的组合。
在本发明目前优选的实际操作中，连续长丝以自粘合纺粘纤维网的形式提供，而纤维素纤维以木浆粕纤维的形式提供，所述木浆粕纤维以湿法成网纤维网的形式加入，湿法成网纤维网通常称之为“组织(tissue)”，随后通过与纺粘纤维网一起水刺成网(可供选择地在这点处可以加入气流铺置浆粕)形成整体。特别是，本发明设想使纺粘纤维网经受水刺成网，以便在纤维素纤维与纺粘纤维网水刺成网之前形成部分缠结的纤维网。现已发现，用这种方法形成理想情况是在与纺粘纤维网水刺成网期间减少了纤维素纤维的损失。此外，现已发现，纺粘纤维网的预缠结理想情况是增加了纤维网的均匀度，及在纤维素纤维网与纺粘纤维网形成整体期间能使用较低的缠结压力，这也可认为减少了纤维素纤维在水刺成网期间到所应用的滤水中的损失。
如图1所示，本发明设想利用纺粘纤维网6来制造本发明的层压织物。纺粘过程包括供应熔融的聚合物，然后将所述熔融的聚合物在压力下挤塑穿过通称为纺丝板或模具的板中的大量孔。将所得到的连续长丝急冷，并通过许多方法中的任何方法如狭缝拉伸系统、拉细喷射器(attenuator gun)、或导丝辊进行拉伸。把连续的长丝作为松散的纤维网收集在移动的多孔表面如金属丝网运输皮带上。当把一个以上的导丝板成一行使用以形成多层织物时，将随后的纤维网收集在前面形成的纤维网的最上面表面上。另外，添加连续的长丝织物可以包括由具有纳米纤度的长丝所形成的那些织物，如在美国专利No.5679379和No.6114017中所述，上述两个美国专利都包括在本文中作为参考文献。另外，连续的长丝织物可以由普通长丝和纳米纤度的长丝混合形成。
连续的长丝纤维网的热塑性聚合物可以从包括聚烯烃类、聚酰胺类、及聚酯类的这组聚合物中选定，其中聚烯烃类是从包括聚丙烯、聚乙烯、及其组合的这组中选定。在本发明的范围内，一个或多个连续的长丝纤维网可以包括相同或不同的热塑性聚合物。另外，连续的长丝可以包括均匀的双组分或多组分外形，及改性添加剂，和它们的混和物。
在制造连续的长丝纤维网之后，通过歧管14中的液流16在15处的液压能的冲击使纤维网进一步形成整体，以便在放入一层浆粕8之前，使纤维网部分地缠结。连续的长丝纤维网6可以直接前进到缠结皮带12上，其中过程是成行完成，或者可供选择地，连续的长丝可以卷绕、转移到退绕站4，并退绕到分开的缠结装置上。
在过程的这个阶段，将纤维素纤维网8与部分缠结的连续的长丝纤维网并置，以便形成本发明的层压非织造织物。纤维素纤维网8优选的是取湿法成网的纤维网形式提供，但在本发明的范围内，是以其它形式提供纤维素纤维状材料。并置的连续的长丝纤维网和纤维素纤维网在由合适歧管所产生的减压液流的影响下经受水刺成网，上述歧管设置在缠结皮带的上方。
按照本发明的优选实际操作，将从歧管22出来的减压液体流对准并置的纤维网的第一膨胀表面，所述第一膨胀表面可以是包括如图所示纤维网8的表面。缠结可以在三维图像转移装置18上或其它合适的多孔缠结装置上实施。此后，使纤维网朝向另一个缠结滚筒(未示出)的周围，同时使减压的液体流对准纤维网反面的膨胀的表面。现在可以将形成整体的纤维网转移到在24处的脱水缝隙上，然后烘干和卷绕用于储存和装运。
若纺粘层在加入浆粕层之前进行水刺成网，则由于在水刺成网过程中减少了待穿过纺粘层洗去的纤维素纤维的量，所以使产品内纤维素纤维的数量最佳。结果，揩布产品当在干的状态下利用时显示改善的吸收能力，而当在湿的状态下利用时更好的保持水溶性添加剂。
在本发明的范围内，将层压非织造织物用一种或多种机械或化学后处理进行处理。例如，可以将最后的织物用机械方法压实和/或在织物内加入添加剂以便达到特定的性能。这类添加剂可以包括颜料、热致变色剂、香料、软化剂、天然药草和药材、UV(紫外线)化学药品、抗微生物剂、和它们的组合，及各种其它性能或美学上改性的添加剂。本发明的层压制品适用于各种不同的卫生、医学、和工业终端使用，其中包括但不限于揩布(wipe)、帘布、保护盖。
任选地，经过缠结的非织造层压制品可以具有三维图像。缠结装置还可以包括成像多孔表面，如三维成像滚筒，所述三元成像滚筒包括一用于实施已经缠结的层压制品成像的三维图像转移装置，这类三维图像转移装置已在美国专利No.5098764中公开，该专利包括在本文中作为参考文献。图像转移装置包括可移动的成像表面，所述成像表面相对于多个缠结歧管移动，这些缠结歧管与由图像转移装置的成像表面限定的三维元件协同起作用，以便影响外加的成像，并形成织物的图案。
如上所述，按照本发明所述形成的织物不需要在织物形成时通过使液压水射向织物的两个膨胀的表面经受水刺成网处理。此外，应该认识到，可以利用图示的压缩辊来改善织物密度，并可以减少织物在干燥之前的含水量。
从上述情况可知，在不脱离本发明的新思想的精神和范围的情况下，可以进行许多修改和改变。应该理解，未打算或指出对本文所公开的实施例的限制。本发明打算通过所附权利要求书包括所有属于权利要求书范围内的这些修改。

Claims (10)

1.一种制造层压非织造织物的方法，包括以下步骤：
提供连续的长丝纤维网；
水刺成网上述长丝纤维网，以便形成部分缠结的纤维网；
将一纤维素纤维网与上述部分缠结的纤维网并置；
水刺成网上述并置的部分缠结的纤维网和纤维素纤维网；和
干燥上述水刺成网的纤维网，以便形成上述非织造织物。
2.按照权利要求1所述制造层压非织造织物的方法，其中上述连续的长丝纤维网可以从包括聚烯烃类、聚酰胺类、聚酯类、及它们混和物的一组聚合物中选定。
3.按照权利要求2所述制造层压非织造织物的方法，其中上述聚烯烃类可以从包括聚乙烯、聚丙烯、及其组合的这组聚合物中选定。
4.按照权利要求1所述制造层压非织造织物的方法，其中上述水刺成网上述并置的纤维网的步骤包括首先将高压液体流对准上述并置的纤维网的第一膨胀的表面，和此后将高压液体流对准上述并置的纤维网的反面膨胀的表面。
5.按照权利要求1所述制造层压非织造织物的方法，其中上述层压制品包括外加的木浆粕层、连续或不连续的长丝层、薄膜层、或它们的组合。
6.制造层压非织造织物的方法，包括以下步骤：
提供连续的长丝纤维网；
提供多孔的表面；
水刺成网上述连续的长丝纤维网，以便形成部分缠结的纤维网；
将一纤维素纤维网与上述部分缠结的纤维网并置；
令上述并置的部分缠结的纤维网和纤维素纤维网前进到上述多孔表面上，并在所述多孔表面上水刺成网上述纤维网，以便将至少一个三维图像加到上述层压制品中；和
干燥上述水刺成网纤维网以便形成上述非织造织物。
7.按照权利要求6所述制造层压非织造织物的方法，其中上述多孔表面是三维图像转移装置。
8.按照权利要求6所述制造层压非织造织物的方法，其中：
上述水刺成网上述并置的部分缠结的纤维网和纸纤维网的步骤包括首先将高压液体流对准并置的纤维网的第一膨胀的表面，和此后将高压液体流对准上述并置的纤维网的反面膨胀的表面。
9.如权利要求1所述制造层压非织造织物的方法，其中上述层压制品是揩布。
10.如权利要求6所述制造层压非织造织物的方法，其中上述层压制品是揩布。
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CN101787625B (zh) * 2010-01-30 2012-04-25 杭州诺邦无纺股份有限公司 福耐克无纺布成型装置、成型方法及无纺布
CN114836904A (zh) * 2022-04-26 2022-08-02 大连华阳新材料科技股份有限公司 自动调整成网两边均匀性系统及其调整方法
CN114836904B (zh) * 2022-04-26 2023-11-03 大连华阳新材料科技股份有限公司 自动调整成网两边均匀性系统及其调整方法

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WO2006060403A2 (en) 2006-06-08
EP1836338A4 (en) 2009-01-28
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