CN101326312B - 可生物降解的多组分纤维 - Google Patents
可生物降解的多组分纤维 Download PDFInfo
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- CN101326312B CN101326312B CN2005800523130A CN200580052313A CN101326312B CN 101326312 B CN101326312 B CN 101326312B CN 2005800523130 A CN2005800523130 A CN 2005800523130A CN 200580052313 A CN200580052313 A CN 200580052313A CN 101326312 B CN101326312 B CN 101326312B
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- aliphatic polyester
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- multicomponent fibre
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Classifications
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- D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
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- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/15203—Properties of the article, e.g. stiffness or absorbency
- A61F13/15252—Properties of the article, e.g. stiffness or absorbency compostable or biodegradable
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- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract
本发明提供了一种含有高熔点脂族聚酯和低熔点脂族聚酯的多组分纤维。该多组分纤维基本上是可生物降解的,而且易于加工成显示出有效纤维机械性能的非织造布结构。
Description
背景技术
可抛型吸收制品一般包含吸收纤维网,例如气流法网或粘合粗梳网。这些网在网形成时常常用粘合用纤维(binder fibers)来稳定。更具体地,粘合用纤维通常是具有显著区别的多组分纤维,即较高熔点和较低熔点组分之间的熔融温度相差至少20℃。因此,在足以熔融较低熔点组分而不会熔融较高熔点组分的温度加热纤维。已经开发了一些可生物降解的粘合用纤维以提高吸收制品的即可抛性(disposability)。很多商业上可获得的生物可降解性聚合物是由脂族聚酯材料形成的。尽管由脂族聚酯制备的纤维是公知的,但在使用中遇到了一些问题。例如,脂族聚酯与聚烯烃聚合物相比结晶速率相对较低,因此常会导致加工性能差。多数脂族聚酯比聚烯烃还具有低得多的熔融温度且在热处理之后难以充分冷却。另外,很多脂族聚酯(例如聚乳酸)在下游热处理加工(例如热粘合和层压)阶段由于聚合物链段的松弛发生严重热收缩。因此,对应这些和其它的问题研发了生物可降解性粘合用纤维。一种所述的粘合用纤维公开在Tsai等人的美国专利6,177,193中。Tsai等人的粘合用纤维由两种组分形成,其中一种是脂族聚酯、多羧酸和润湿剂的共混物。需要多羧酸以降低用于加工的聚合物的粘度,以及在淬火时促进结晶(即成核剂)。但是,这种纤维的一个问题是需要相对复杂且效率低下的生产工艺,另外,该纤维也弱且具有相对低的拉伸强度。
因此,目前需要生物可降解且易于加工成显示出良好机械性能的纤维状结构的纤维。
发明概述
根据本发明的一个实施方案,公开了一种生物可降解性多组分纤维。该纤维包含第一组分,其含有至少一种具有约160℃到约250℃熔点的高熔点脂族聚酯。该纤维还包含第二组分,其含有至少一种低熔点脂族聚酯,低熔点脂族聚酯的熔点比高熔点脂族聚酯的熔点低至少约30℃。在160℃和1000sec-1剪切速率下测定时,低熔点脂族聚酯具有约30,000到约120,000道尔顿的数均分子量和约50到约215帕-秒的表观粘度。本发明人已经发现具有此分子量和粘度的特殊组合的聚合物可以具有提高了的加工性能而不会不利地影响所得纤维的强度和粘合能力。
本发明的其它特征和方面在下文进行更详尽的讨论。
附图简述
本发明对本领域普遍技术人员而言全面且可行的公开内容,包括其最佳方式,在说明书下面的部分参考附图更具体地进行了阐明,附图中:
图1是一个工艺示意图,其可用于本发明中一个实施方案以形成多组分纤维;
图2显示了在实施例3中形成的两个纤维样品的SEM缩微照片(放大40倍),其中图2a显示了13号样品,图2b显示了12号样品;
图3是描绘实施例5中单位重量为25g/m2的点粘合用纤维网的条带拉伸强度相对于粘合温度的图;
图4是实施例5中单位重量为25g/m2的点粘合用纤维网的韧度相对于伸长率%的图;和
图5是可根据本发明的一个实施方案形成的吸收制品的透视图。
本发明说明书和附图中重复使用的附图标记拟表示本发明相同或类似的特征或元件。
典型实施方案详述
现在将详细介绍本发明各种实施方案,其中的一个或多个实施例将在下文阐明。每一个实施例以解释本发明的方式给出,不对本发明进行限定。事实上,对本领域熟练的技术人员来说在本发明的基础上的各种改进和变化都是显而易见的,并不脱离本发明的范围或宗旨。例如,作为一个实施方案的一部分举例说明或描述的特征,可以用在另一个实施方案中产生另外一个实施方案。因此,本发明拟覆盖落在所附权利要求及其等价物范围之内的这种改进和变化。
定义
在本文中,术语“可生物降解的”或“可生物降解的聚合物”通常是指一种材料,其由天然存在的微生物(例如细菌、真菌和藻类);环境的热量;湿气;或其它环境因素的作用而降解。材料的可生物降解性可以用ASTM测试方法5338.92测定。
在本文中,术语“纤维”是指通过使聚合物通过例如模头的成型孔形成的伸长挤出物。除非特别指明,术语“纤维”包括具有一定长度的不连续须条(strand)和连续的材料须条,例如长丝。
在本文中,术语“多组分”是指由至少两种聚合物组分形成的纤维(例如双组分纤维)。
在本文中,术语“非织造网”是指一种纤维网,其具有交织的单纤维或纱线的结构,但不像在针织织物中那样具有可辨识的样式。非织造网包括例如熔喷网、纺粘网、粗梳网(carded webs)、湿法网、气流法网、共成型网(coform webs)、液压缠结网等。
在文中,术语“粘合粗梳网”是指由被输送通过精梳或粗梳装置的短纤维制成的纤维网,所述装置将短纤维分散或打断并且沿机器方向排列形成大致沿机器方向取向的纤维非织造网。这种纤维通常是以大包获得的并放入开棉机/混合器或清棉机中,其在粗梳装置之前将纤维打散。一旦成型,然后就将纤维网按照一种或多种已知的方法进行粘合。
在本文中,术语“气流法网”是指由典型长度介于约3到约19毫米(mm)的纤维束制成的纤维网。纤维被打散,由气源携带,然后沉积在成型表面上,通常要借助于真空源。一旦成型,然后就将纤维网按照一种或多种已知的方法进行粘合。
在本文中,术语“共成型网”通常是指一种复合材料,其包含热塑性纤维和第二非热塑性材料的混合物或稳定化基质。例如,共成型材料可以由一种工艺制得,其中至少一个熔喷模头安装在斜道附近,其它材料在纤维网成网时通过该斜道添加。所述的其它材料可以包括但不限于纤维状有机材料例如木制的或非木制的浆粕如棉、粘胶、再循环纸、浆粕绒毛以及超吸收颗粒,无机和/或有机吸收材料,处理过的聚合物短纤维等等。这种共成型材料的例子公开在Anderson等人的美国专利4,100,324;Everhart等人的美国专利5,284,703;和Georger等人的美国专利5,350,624中,对所有有用的目的在此全文引入这些专利作为参考。
发明详述
本发明涉及一种可生物降解的多组分纤维,其包含由至少一种高熔点脂族聚酯形成的第一组分和由至少一种低熔点脂族聚酯形成的第二组分。所述第一和第二组分可以任何希望的构造排列以形成根据本发明的多组分纤维。所述材料的构造可以是例如皮芯型、并列型、夹心型(pie)、海岛型等等。得到的多组分纤维基本上是生物可降解的,但也易于加工成显示出良好机械性能的纤维状结构。
I.第一组分
如上文所述,多组分纤维的第一组分由一种或多种“高熔点”可生物降解的脂族聚酯形成。典型地,这种聚酯的熔点为约160℃到约250℃,在一些实施方案中为约170℃到约240℃,和在某些实施方案中为约180℃到约220℃。各种“高熔点”脂族聚酯均可用于本发明,例如聚酯酰胺、改性聚对苯二甲酸乙二醇酯、聚乳酸(PLA)、基于聚乳酸的三元共聚物、聚乙醇酸、聚碳酸亚烷基酯(例如聚碳酸乙二醇酯)、聚羟基链烷酸酯(PHA)、聚羟基丁酸酯(PHB)、聚羟基戊酸酯(PHV)和聚羟基丁酸酯-羟基戊酸酯的共聚物(PHBV)。术语“聚乳酸”通常是指乳酸的均聚物,例如聚(L-乳酸)、聚(D-乳酸)、聚(DL-乳酸)、它们的混合物以及含有作为主要组分的乳酸和一小部分可共聚的共聚单体的共聚物,例如3-羟基丁酸酯、己内酯、乙醇酸等等。
任何已知的聚合方法,例如缩聚或开环聚合,均可用于聚合乳酸。例如,在缩聚方法中,L-乳酸、D-乳酸或它们的混合物直接进行脱氢缩聚。在开环聚合方法中,作为乳酸的环状二聚物的丙交酯借助聚合调节剂和催化剂进行聚合。所述丙交酯可以包含L-丙交酯(L-乳酸的二聚物)、D-丙交酯(D-乳酸的二聚物)、DL-丙交酯(L-乳酸和D-乳酸的缩合物),或它们的混合物。如有必要,这些异构体可以混合和聚合以获得具有任何希望组成和结晶度的聚乳酸。也可以使用少量的扩链剂(例如二异氰酸酯化合物、环氧化合物或酸酐)来增加聚乳酸的分子量。一般而言,聚乳酸的重均分子量在约60,000到约1,000,000的范围之内。一种可用于本发明的特别适合的聚乳酸聚合物可从Biomer,Inc.(德国)以商品名BiomerTM L9000商购。其它适合的聚乳酸聚合物可从明尼苏达州明尼阿波利斯的Natureworks,LLC商购。
II.第二组分
第二组分由一种或多种“低熔点”可生物降解的脂族聚酯形成。典型地,这种聚酯具有的熔点为约50℃到约160℃,在一些实施方案中为约100℃到约160℃,和在某些实施方案中为约120℃到约160℃。而且,该熔点还典型地比“高熔点”脂族聚酯的熔点低至少约30℃,在一些实施方案中低至少约40℃,和在某些实施方案中低至少约50℃。“低熔点”脂族聚酯是可用的,因为它们降解速率比“高熔点”脂族聚酯快。另外,它们在触感上一般比大多数“高熔点”脂族聚酯更柔软。低熔点聚酯的玻璃化转变温度(“Tg”)也可以比高熔点聚酯的低以改善聚合物的柔韧性和加工性能。例如,低熔点脂族聚酯可以具有约25℃或更低的Tg,在一些实施方案中为约0℃或更低,在某些实施方案中为约-10℃或更低。所述玻璃化转变温度可以比高熔点聚酯的玻璃化转变温度低至少约5℃,在一些实施方案中低至少约10℃,在某些实施方案中低至少约15℃。
可以具有低熔点和玻璃化转变温度的脂族聚酯的例子包括带有至少5个碳原子重复单元的脂族聚酯(例如,聚羟基戊酸酯、聚羟基丁酸酯-羟基戊酸酯的共聚物和聚己内酯),和基于琥珀酸酯的脂族聚合物(例如聚琥珀酸丁二醇酯、聚琥珀酸己二酸丁二醇酯,和聚琥珀酸乙二醇酯)。更多具体的例子可包括聚草酸乙二醇酯、聚丙二酸乙二醇酯、聚琥珀酸乙二醇酯、聚草酸丙二醇酯、聚丙二酸丙二醇酯、聚琥珀酸丙二醇酯、聚草酸丁二醇酯、聚丙二酸丁二醇酯、聚琥珀酸丁二醇酯,及这些化合物的共混物和共聚物。在这些化合物中,通常优选聚琥珀酸丁二醇酯及其共聚物。
脂族聚酯典型地通过多元醇和脂族二羧酸或其酸酐缩聚合成。所述的多元醇可以是被取代的或未被取代的线性或支链多元醇,其选自含有2到约8个碳原子的多元醇,含有2到8个碳原子的聚亚烷基醚二醇,和含有约4个到约12个碳原子的脂环族二醇。被取代的多元醇典型地含有1个到约4个取代基,其独立地选自卤素、C6-C10的芳基和C1-C4的烷氧基。可以使用的多元醇的例子包括但不限于乙二醇、二甘醇、丙二醇、1,3-丙二醇、2,2-二甲基-1,3-丙二醇、1,3-丁二醇、1,4-丁二醇、1,5-戊二醇、1,6-己二醇、聚乙二醇、二甘醇、2,2,4-三甲基-1,6-己二醇、硫代二乙醇、1,3-环己烷二甲醇、1,4-环己烷二甲醇、2,2,4,4-四甲基-1,3-环丁二醇、三甘醇和四甘醇。优选的多元醇包括1,4-丁二醇、1,3-丙二醇、乙二醇、1,6-己二醇、二甘醇和1,4-环己烷二甲醇。可以使用的有代表性的脂族二羧酸包括被取代或未被取代的、线性或支链的非芳族二羧酸,其选自含有2个到约12个碳原子的脂族二羧酸和含有约5个到约10个碳原子的脂环族二羧酸。所述被取代的非芳族二羧酸典型地含有1个到约4个选自卤素、C6-C10芳基和C1-C4烷氧基的取代基。脂族和脂环族二羧酸的非限制性例子包括丙二酸、丁二酸、戊二酸、己二酸、庚二酸、壬二酸、癸二酸、富马酸、2,2-二甲基戊二酸、辛二酸、1,3-环戊烷二甲酸、1,4-环己烷二甲酸、1,3-环己烷二甲酸、二甘醇酸、衣康酸、马来酸和2,5-降冰片烷二甲酸。聚合反应由催化剂催化,例如基于钛的催化剂(例如四异丙基钛酸酯、四异丙氧基钛、二丁氧基二乙酰乙酸基钛或四丁基钛酸酯)。
如果需要,可使二异氰酸酯扩链剂与脂族聚酯预聚物反应以增加其分子量。有代表性的二异氰酸酯包括甲苯2,4-二异氰酸酯、甲苯2,6-二异氰酸酯、2,4′-二苯基甲烷二异氰酸酯、亚萘基-1,5-二异氰酸酯、苯二亚甲基二异氰酸酯、六亚甲基二异氰酸酯(“HMDI”)、异佛尔酮二异氰酸酯和亚甲基双(2-异氰酸根合环己烷)。三官能异氰酸酯化合物也可以使用,其包括异氰尿酸酯和/或带有不少于三个官能度的二脲,或部分由三-或多异氰酸酯替代二异氰酸酯化合物。优选的二异氰酸酯是六亚甲基二异氰酸酯。基于聚合物的总重量,使用的扩链剂量典型地为约0.3到约3.5wt.%,在一些实施方案中,为约0.5到约2.5wt.%。
脂族聚酯可以是线性聚合物或长链支化聚合物。长链支化聚合物通常使用低分子量的支化剂制备,例如多元醇、多元羧酸、羟基酸等等。可以用作支化剂的有代表性的低分子量多元醇包括甘油、三羟甲基丙烷、三羟甲基乙烷、聚醚三醇、甘油、1,2,4-丁三醇、季戊四醇、1,2,6-己三醇、山梨醇、1,1,4,4-四(羟甲基)环己烷、三(2-羟乙基)异氰脲酸酯和二季戊四醇。可以用作支化剂的有代表性的较高分子量多元醇(分子量为400到3000)包括三元醇,其衍生自具有2到3个碳原子的缩合环氧烷烃,例如带有多元醇引发剂的环氧乙烷和环氧丙烷。可以用作支化剂的典型的多元羧酸包括苯连三酸、偏苯三酸(1,2,4-苯三酸)及其酸酐、均苯三酸(1,3,5-苯三酸)、1,2,4,5-苯四酸及其酸酐、苯四甲酸、二苯甲酮四酸、1,1,2,2-乙烷-四甲酸、1,1,2-乙烷三甲酸、1,3,5-戊烷三甲酸和1,2,3,4-环戊烷四甲酸。可以用作支化剂的有代表性的羟基酸包括苹果酸、柠檬酸、酒石酸、3-羟基戊二酸、粘酸、三羟基戊二酸、4-羧基邻苯二甲酸酐、羟基间苯二甲酸和4-(β-羟乙基)邻苯二甲酸。这些羟基酸含有3个或更多羟基和羧基的组合。特别优选的支化剂包括偏苯三酸、均苯三酸、季戊四醇、三羟甲基丙烷和1,2,4-丁三醇。
聚己内酯聚合物也可以用在本发明中。聚己内酯聚合物一般通过ε-己内酯聚合来制备,其是一个七元环化合物,特征在于其反应性。分裂通常发生在羰基上。较高分子量的聚己内酯可以在宽泛的催化剂影响下制备,催化剂为例如烷基铝,有机金属复合物,如IA、IIA、IIB或IIIA族的烷基金属化合物,格氏试剂,二烷基II族金属化合物,钙或其它金属酰胺或烷基酰胺,碱土hexamoniates、碱的氧化物和乙腈的反应产物,三醇铝(alumihum trialkoxides),碱土铝或硼的氢化物,碱金属或碱土金属的氢化物或单独的碱金属。在聚己内酯的制备中还可以使用引发剂,例如形成终端基团的脂族二醇。可能适于用在本发明中的聚己内酯的例子包括来自Union Carbide Corporation,Somerset,N.J的多种聚己内酯,名称为TONETM聚合物P767E和TONETM聚合物P787的聚己内酯聚合物。
上述低熔点脂族聚酯本质上主要是脂族的,即单体成分主要是脂族的,以优化生物降解性。例如,低熔点脂族聚酯典型地含有至少约50mol.%,在一些实施方案中至少约60mol.%,以及在某些实施方案中,至少约70mol.%的脂族单体。尽管本质上主要是脂族的,但低熔点聚酯还是可以含有少量进一步改善纤维强度和韧度的其它单体成分,例如芳族单体(如对苯二甲酸)。使用时,芳族单体可以组成低熔点脂族聚酯的例如约1mol.%到约50mol.%,在一些实施方案中约10mol.%到约40mol.%,以及在某些实施方案中,约15mol.%到约30mol.%。一个含有芳族对苯二甲酸单体成分(~22mol.%)的脂族聚酯的具体例子可从BASF Corp.以名称EcoflexTM F BX 7011购得。另一个含有芳族对苯二甲酸单体成分(~25mol.%)的脂族聚酯的例子可从IRE Chemicals(南韩)以名称EnpolTM 8060M购得。
无论是怎样特殊的类型,本发明人发现具有热和机械性能的某种组合的“低熔点”脂族聚酯可以为所得多组分纤维提供改进的加工性能和强度。例如,太大分子量的脂族聚酯一般具有严重缠结的聚合物链并因此得到难以加工的热塑性组合物。相反地,太低分子量的脂族聚酯一般不具有足够的缠结,其导致熔融强度相对弱。因此,本发明中采用的“低熔点”脂族聚酯典型地具有介于约30,000到约120,000道尔顿,在一些实施方案中约40,000到约100,000道尔顿,和在某些实施方案中,约45,000到约85,000道尔顿的数均分子量(“Mn”)。同样地,所述“低熔点”脂族聚酯还典型地具有介于约30,000到约240,000道尔顿,在一些实施方案中约50,000到约190,000道尔顿,和在某些实施方案中,约60,000到约105,000道尔顿的重均分子量(“Mw”)。所选聚合物的分子量分布也相对地窄以提高聚合物的加工性并提供更均匀的性能。也就是说,重均分子量与数均分子量的比值(“Mw/Mn”),即“多分散指数”相对较低。例如,多分散指数典型地介于约1.0到约3.0,在一些实施方案中约1.2到约2.0,以及在某些实施方案中,约1.4到约1.8。重均和数均分子量可根据本领域技术人员熟知的方法测定。
为提供改进的加工性,也选择“低熔点”脂族聚酯来获得在一定范围内的表观粘度。更具体而言,具有太高表观粘度的脂族聚酯一般难以加工。另一方面,具有太低表观粘度的脂族聚酯一般会导致压纺纤维缺乏拉伸强度和足够的粘结能力。因此,在多数实施方案中,“低熔点”脂族聚酯具有约50到约215帕秒(Pa·s),在某些实施方案中约75到约200Pa·s,和在某些实施方案中,约80到约150Pa·s的表观粘度,在温度为160℃和剪切速率为1000sec-1时测定。本发明人发现上面提出的分子量和粘度的特定组合会产生具有改进加工性能而不会负面影响所得纤维强度和粘结能力的聚合物。
“低熔点”脂族聚酯的熔体流动指数也可以选定在一定范围以优化所得纤维的性能。熔体流动指数是当在190℃经受2160克力10分钟时,可以强制通过挤出流变仪口(直径0.0825英寸)的聚合物重量(以克计)。一般来说,熔体流动指数应足够高以改善熔融加工性能,但不太高而负面干扰纤维的粘合性能。因此,根据ASTM测试方法D1238-E的测量结果,在本发明多数实施方案中,“低熔点”脂族聚酯具有约5到约200克每10分钟,在一些实施方案中是约15到约160克每10分钟,和在某些实施方案中,约20到约120克每10分钟的熔体流动系数。
脂族聚酯的结晶度也影响所得多组分纤维的性能。也就是说,具有较高熔融程度和结晶焓的聚合物更易于掺合到粘合网产品中。例如,这种聚合物更易于在较高的速度下粘合且还具有较低的收缩率,因而改善纤维网的稳定性、拉伸强度和网的美观性。因此,典型地选择脂族聚酯具有一定的结晶度或大于约25焦耳每克(“J/g”),在一些实施方案中大于约35J/g,和在某些实施方案中,大于约50J/g的熔化潜热(ΔHf)。同样地,还典型地选择脂族聚酯具有大于约35焦耳每克(“J/g”),在一些实施方案中大于约50J/g,和在某些实施方案中,大于约60J/g的结晶潜热(ΔHc)。
在将脂族聚酯聚合物-热加工成纤维时遇到的一个困难是这些聚合物的粘性。机械地或者通过气流拉伸法尝试拉伸纤维时,都经常会导致纤维聚集成固态块。因此,根据本发明,还要选择“低熔点”脂族聚酯具有相对高的结晶温度,从而降低粘性。具体而言,结晶温度可以介于约40℃到约100℃,在一些实施方案中约50℃到约90℃,和在某些实施方案中,约60℃到约80℃。如下文更详尽所述,熔化潜热(ΔHf)、结晶潜热(ΔHc)和结晶温度都可用差示扫描量热法(“DSC”)根据ASTMD-3417测定。
多种“低熔点”脂族聚酯聚合物中的任一种可以具有上文提及的所需热和机械性能。在本发明特定的实施方案中,例如聚琥珀酸丁二醇酯的共聚酯用作多组分纤维的第二种组分。适合的聚琥珀酸丁二醇酯聚合物的一个具体例子可以从IRE Chemicals(南韩)以名称EnpolTMG4500商购。
本发明一个有益的方面是不需常规添加剂就可以提供“低熔点”脂族聚酯上述的热和机械性能。例如,很多常规可生物降解的热塑性组合物在淬火时需要使用成核剂以改进加工工艺和促成结晶。所述成核剂的一个类型是多羧酸,例如琥珀酸、戊二酸、己二酸、庚二酸、辛二酸、壬二酸、癸二酸和这些酸的混合物,如公开在Tsai等人的美国专利6,177,193中。然而,本发明人发现通过精心挑选具有特定热和机械性能的脂族聚酯,这些成核剂不再必要。事实上,本发明人发现使用脂族聚酯作为第二种组分的主要成分可以获得极好的结果。也就是说,脂族聚酯可以构成第二组分的至少约90wt.%,在一些实施方案中至少约92wt.%,和在某些实施方案中,至少约95wt.%。无论如何,应理解成核剂可以用在本发明的一些实施方案中。然而,当使用时,成核剂典型地以少于第二组分的约0.5wt.%,在一些实施方案中少于约0.25wt.%,和在某些实施方案中,少于约0.1wt.%的量存在。
尽管脂族聚酯是第二组分的主要成分,但为了各种不同的目的,第二组分当然也可以使用其它成分。例如,在本发明的一些实施方案中可以使用润湿剂以改善所得纤维的亲水性。适于在本发明中使用的润湿剂一般与脂族聚酯是相容的。适合的润湿剂的例子可以包括表面活性剂,例如480和750乙氧基化醇,或UNICIDTM酰胺乙氧基化物,均可以从俄克拉荷马州塔尔萨的PetroliteCorporation获得。其它适合的润湿剂描述在Tsai等人的美国专利6,177,193中,该专利对于所有相关的目的整体引入作为参考。其它可使用的物质包括但不限于颜料、抗氧化剂、稳定剂、表面活性剂、蜡、流动性促进剂、固体溶剂、增塑剂、散粒剂(particulates)和添加用以提高热塑性组合物的加工性能的其它物质。使用时,通常需要最小化这些附加成分的量以确保最适宜的相容性和成本效率。因此,通常希望的是,这些成分小于第二组分的例如约10wt.%,在一些实施方案中小于约8wt.%,和在某些实施方案中,小于约5wt.%。
III.形成多组分纤维的方法
可以采用各种已知技术的任何一种形成本发明的多组分纤维。典型地,各组分在分开的挤出机中挤出,但它们也可以一起纺丝。例如,参考图1,显示了用于形成根据本发明的多组分纤维的工艺10的一个实施方案。如图所示,布置该实施方案的工艺10以制备双组分纤维,尽管应理解为其它实施方案也在本发明的考虑范畴。工艺10采用一对挤出机12a和12b用于单独挤出第一组分A(即“高熔点”聚合物组分)和第二组分B(即“低熔点”聚合物组分)。组分A和B的相对量一般可根据所需的性能而变化。例如,第一组分A可以构成多组分纤维的约5wt.%到约95wt.%,在一些实施方案中约10wt.%到约90wt.%,和在某些实施方案中,约15wt.%到约85wt.%。同样地,第二组分B可以构成多组分纤维的约5wt.%到约95wt.%,在一些实施方案中约10wt.%到约90wt.%,和在某些实施方案中,约15wt.%到约85wt.%。
将第一组分A从第一加料斗14a中喂入各自的挤出机12a和第二组分B从第二加料斗14b中喂入各自的挤出机12b。组分A和B从挤出机12a和12b中送出经各自的聚合物导管16a和16b进入喷丝板18。用于挤出多组分纤维的喷丝板对本领域技术人员是熟知的。例如,喷丝板18可包括含有纺丝组件的外壳,纺丝组件具有很多个一个堆叠于另一个之上的板并且具有开口图案,开口图案排列形成引导聚合物组分A和B各自通过喷丝板18的流动路径。喷丝板18还具有排列成一排或多排的开口。当从开口挤出聚合物时,开口形成向下的纤维挤出帘。喷丝板18可以排列形成皮/芯型、并列型、夹心型或其它构造。
工艺10还采用了位于喷丝板18延伸方向的纤维帘附近的骤冷鼓风机20。从骤冷空气鼓风机20出来的空气使从喷丝板18延伸出来的纤维骤冷。如图1所示,骤冷空气可以从纤维帘的一侧或者纤维帘的两侧导出。纤维拉伸装置或者吸丝器22位于喷丝板18的下方并接收骤冷后的纤维。用于熔融纺丝聚合物的纤维拉伸装置或者吸丝器在本领域是公知的。用于本发明工艺中的合适的纤维拉伸装置包括美国专利3,802,817和3,423,255中所示类型的线型纤维吸丝器,其在本文中对于所有相关目的整体引入作为参考。纤维拉伸装置22一般包括一个伸长的垂直通道,纤维可以通过其由吸丝空气拉伸,吸丝空气由通道侧面进入并向下流动通过通道。加热器或鼓风机24向纤维拉伸装置22提供吸丝空气。吸丝空气牵拉着纤维和周围的空气通过纤维拉伸装置22。之后,纤维可以卷绕在导丝辊组件42上。作为选择,通过将纤维随机沉积在成形表面(任选地借助于真空器)并随后用任何已知技术粘合所得的纤维网,纤维可以直接形成粘合用纤维网结构。
为开始纤维成形,加料斗14a和14b最初填满各自的组分A和B。熔融组分A和B并由各自的挤出机12a和12b通过聚合物导管16a和16b以及喷丝板18挤出。由于用于本发明的脂族聚酯的表观粘度相对较低,可以采用较低的挤出温度。例如,组分B(“低熔点”聚酯)的挤出机12b可以采用一个或多个区间,其操作温度为约120℃到约200℃,和在一些实施方案中,为约145℃到约195℃。同样地,组分A(“高熔点”聚酯)的挤出机12a可以采用一个或多个区间,其操作温度为约160℃到约250℃,和在一些实施方案中,为约190℃到约225℃。典型的剪切速率介于约100秒-1到约10,000秒-1,在一些实施方案中约500秒-1到约5000秒-1,和在某些实施方案中,约800秒-1到约1200秒-1。
当挤出的纤维在喷丝板18下方延伸时,来自骤冷鼓风机20的空气流至少部分骤冷所述纤维。该工艺在相对短时间内(秒)一般降低挤出聚合物温度至少约100℃。这一般在冷却时降低所需的温度变化到优选低于150℃和,在一些情况下,低于100℃。本发明中使用相对低的挤出温度的能力还允许使用较低的骤冷温度。例如,骤冷鼓风机20可以采用一个或多个区间,其操作温度为约20℃到约100℃,且在某些实施方案中,为约25℃到约60℃。骤冷之后,通过气体流例如空气将纤维牵拉入纤维拉伸装置22的垂直通道,气体流来自加热器或鼓风机24并通过纤维拉伸装置。气体流使得纤维拉伸或抽长,其可增加形成纤维的聚合物的分子取向或结晶度。纤维通过纤维拉伸装置22的出口沉积到导丝辊组件42上。由于本发明纤维的高强度,本发明中可以实现高拉伸倍率(例如导丝辊42的速率除以挤出机12a和12b的熔纺泵速率)。例如,拉伸倍率可以为约200∶1到约6000∶1,在一些实施方案中为约500∶1到约5000∶1,和在某些实施方案中,为约1000∶1到约4000∶1。作为选择,纤维可以直接沉积到网孔表面(未显示)上以直接形成非织造网。
如果需要,收集在导丝辊42上的纤维可以任选地进行另外的在线加工(in line processing)和/或印染加工步骤(未显示),这都将为本领域技术人员所理解。例如,可以通过在低于收集纤维的软化温度下“冷牵伸”到所需直径而形成短纤维,并随后卷曲、变形和/或将纤维切断成所需纤维长度。所需的纤维长度和纤维的旦数可根据所需应用而变化。典型地,纤维成形而具有约3到约80毫米,在一些实施方案中约4到约65毫米,和在某些实施方案中,约5到约50毫米范围之内的平均纤维长度。每根纤维长丝的旦数还可以小于约6,在一些实施方案中小于约3,和在某些实施方案中,为约0.5到约3。另外,所述纤维通常是“微纤维”,即平均直径不大于约100微米,在一些实施方案中为约0.5微米到约50微米,和在某些实施方案中,为约4微米到约40微米的小直径纤维。
用于形成多组分纤维的各种其它方法也可以用于本发明中,如记载在Taniguchi等人的美国专利4,789,592和Strack等人的美国专利5,336,552,Kaneko等人的5,108,820,Kruege等人的4,795,668,Pike等人的5,382,400,Strack等人的5,336,552,和Marmon等人的6,200,669中的,其在本文中对于所有目的整体引入作为参考。还可以形成具有各种不规则形状的多组分纤维,例如记载在Hogle等人的美国专利5,277,976,Hills的5,162,074,Hills的5,466,410,Largman等人的5,069,970,和Largman等人的5,057,368中的,其在本文中对于所有目的整体引入作为参考。
无论是怎样的特殊成形方式,本发明人发现所得的多组分纤维显示出优异的强度特性。一个表明本发明多组分纤维相对强度的参数是“韧度”,它表示纤维的拉伸强度,以每单位线密度上的力来表示。例如,本发明多组分纤维可以具有约0.75到约7.0克力(“gf”)每旦,在一些实施方案中约1.0到约5.0gf每旦,和在某些实施方案中,约1.5到约4.0gf每旦的韧度。此外,本发明的多组分纤维还具有相对高的“峰值拉伸应力”,它表示最大的拉伸应力,以每单位面积上的力来表示。例如,本发明多组分纤维可以具有约100到约600兆帕斯卡(MPa),在一些实施方案中约150到约500MPa,和在某些实施方案中,从约200到约400MPa的峰值拉伸应力。
IV.非织造网
本发明的多组分纤维可用于任何类型的非织造网中,例如熔喷网、纺粘网、粘合粗梳网、湿法网、气流法网、共成型网、液压缠结网等等。在一个实施方案中,例如,通过将纤维包放在分离纤维的清棉机上将纤维形成粗梳网。然后,纤维送入精梳或粗梳装置进一步打散并将纤维排列成机器方向以形成机器方向取向的纤维非织造网。一旦成形,非织造网典型地由一种或多种粘合技术稳定化。例如,可以采用含有一个或多个加热区的空气干燥机加热空气到高于多组分纤维的第二组分(例如皮层)的熔融温度,但要低于第一组分(例如芯层)的熔融温度。该加热的空气通过非织造网,从而熔融第二组分并形成纤维间粘合以热稳定纤维网。当使用聚乳酸和聚琥珀酸丁二醇酯作为聚合物组分时,例如,流过空气粘合机的空气可以具有约100℃到约180℃的温度。在空气粘合机中的停留时间可以是约120秒或更少。然而应理解,空气粘合机的参数取决于诸如使用的聚合物类型和纤维网厚度的因素。
还可以使用超声粘合技术,采用固定的或旋转的导条棒和旋转的形成图案的砧辊。该技术记载在美国专利Grgach等人的3,939,033,RustJr.的3,844,869,Hill的4,259,399,Neuwirth等人的5,096,532,Ehlert的5,110,403,以及Brennecke等人的5,817,199中,在本文中对于所有目的整体引入作为参考。作为选择,非织造网可以热点粘合以提供具有众多细小、离散粘合点的织物。这种工艺通常涉及使纤维网在加热辊之间通过,例如刻花图案辊和第二粘合辊。刻花辊以某种方式形成图案以便纤维网不是在其整个表面都粘合,第二辊可以是光滑的或者是带图案的。对于功能性和/或美观的目的,已经研发了各种各样的刻花辊图案。示例性的粘合图案包括但不限于那些记载在Hansen等人的美国专利3,855,046,Levy等人的美国专利5,620,779,Haynes等人的美国专利5,962,112,Sayovitz等人的美国专利6,093,665,Romano等人的美国工业品设计专利428,267以及Brown的工业品设计专利390,708中的,在本文中对于所有目的整体引入作为参考。例如,非织造网可能粘合而具有小于约30%的总粘合面积和大于约100粘合点每平方英寸的均匀粘合密度,并且优选约2到约30%(由传统光学显微镜方法测定)和约250到约500点粘合每平方英寸的粘合密度。通过用大于约100点粘合每平方英寸的点粘合图案粘合用纤维网可以获得总粘合面积和粘合密度的这种组合,其当与光滑的砧辊全接触时提供小于约30%的总粘合表面积。在一些实施方案中,粘合图案可以具有约250到约350点粘合每平方英寸的点粘合密度和当与光滑砧辊接触时约10%到约25%的总粘合面积。
多组分纤维可以构成非织造网的整个纤维组分或与其它类型的纤维共混。当与其它类型的纤维共混时,通常希望本发明的多组分纤维构成用于非织造网的纤维总量的约0.5wt%到约60wt.%,在一些实施方案中约1wt.%到约40wt.%,和在某些实施方案中,约2wt.%到约20wt.%。
例如,本发明的多组分纤维可以与浆粕纤维,例如纤维平均长度长的浆粕、纤维平均长度短的浆粕或它们的混合物混纺。适合的纤维长度长的软毛浆粕纤维的一个例子包括软木牛皮纸浆粕纤维。软木牛皮纸浆粕纤维源自针叶树并包括浆粕纤维例如但不限于北方、西方和南方的软木类,包括红杉、铅笔柏、铁杉属树木、绿枞、冷杉(true firs)、松树(如南方松树)、云杉(如黑云杉)、它们的组合等等。北方软木牛皮纸浆粕纤维可以用在本发明中。适于用在本发明中的商业上可获得的南方软木牛皮纸浆粕纤维的例子包括那些可从办公地点在华盛顿Federal Way的Weyerhaeuser Company以商品名称“NB-416”获得的产品。用在本发明中的另一种适合的浆粕是漂白的、硫酸盐木浆,主要含有软木纤维,其可从南卡莱罗纳州办公地点在Greenville的BowaterCorp.以商品名称CoosAbsorb S浆粕获得。平均长度短的纤维也可用在本发明中。适合的平均长度短的浆粕纤维的一个例子是硬木牛皮纸浆粕纤维。硬木牛皮纸浆粕纤维源自落叶树并包括浆粕纤维例如但不限于桉树、枫木、桦树、白杨等等。桉树牛皮纸浆粕纤维用于增加柔软性、提高光泽度、增加不透明性和改变片材的孔结构以增加其芯吸能力可能是特别理想的。典型地,浆粕纤维构成非织造网的约30到约95wt.%,在一些实施方案中约40wt.%到约90wt.%,和在某些实施方案中,约50wt.%到约85wt.%。
另外的单组分和/或多组分合成纤维也可以用在非织造网中。一些可用于形成合成纤维的适合聚合物包括但不限于:聚烯烃,例如聚乙烯、聚丙烯、聚丁烯等等;聚四氟乙烯;聚酯,例如聚对苯二甲酸乙二醇酯等等;聚乙酸乙烯酯;聚氯乙烯-乙酸乙烯酯;聚乙烯醇缩丁醛;丙烯酸系树脂,例如聚丙烯酸酯、聚甲基丙烯酸酯、聚甲基丙烯酸甲酯等等;聚酰胺,例如尼龙;聚氯乙烯;聚偏二氯乙烯;聚苯乙烯;聚乙烯醇;聚氨酯;聚乳酸;等等。如果需要,可生物降解的聚合物,如聚(羟基乙酸)(PGA)、聚乳酸(PLA)、聚(β-苹果酸)(PMLA)、聚(ε-己酸内酯)(PCL)、聚(ρ-聚二噁酮)(PDS)和聚(3-羟基丁酸酯)(PHB)。一些已知的合成纤维的例子包括可从北卡来罗纳州夏洛特的KoSa Inc.获得的皮芯型双组分纤维,名称为T-255和T-256,两种都使用聚烯烃皮层,或T-254,它具有低熔点共聚酯皮层。可以使用的其它已知双组分纤维包括那些可从日本Moriyama的Chisso Corporation或从特拉华州成灵顿的Fibervisions LLC获得的产品。合成或天然的纤维素聚合物也可以使用,包括但不限于纤维素酯;纤维素醚;纤维素硝酸酯;纤维素乙酸酯;纤维素乙酸酯丁酸酯;乙基纤维素;再生纤维素,如粘胶、人造丝等等。非木质纤维也可以使用,包括源自大麻、稻草、亚麻、甘蔗渣及其混合物的纤维可以用在本发明中。
此外,超吸收材料也可以包含在非织造网中。超吸收材料是水可膨胀材料,在含有0.9重量%氯化钠的水溶液中能吸收自身重量的至少约20倍,在一些情况下,至少自身重量的约30倍。超吸收材料可以是天然的、合成的和改性的天然聚合物和材料。合成超吸收聚合物的例子包括聚乳酸和聚(甲基丙烯酸)、聚(丙烯酰胺)、聚(乙烯基醚)、马来酐与乙烯基醚和α-烯烃的共聚物、聚(乙烯基吡咯烷酮)、聚(乙烯基吗啉酮)、聚(乙烯醇)及其混合物和共聚物的碱金属和铵的盐。其它超吸收材料包括天然和改性的天然聚合物,如水解的丙烯腈接枝淀粉、丙烯酸接枝淀粉、甲基纤维素、壳聚糖、羧甲基纤维素、羟丙基纤维素,和天然树胶,如海藻酸盐、黄原胶、刺槐豆胶等等。天然的和全部或部分合成超吸收聚合物的混合物在本发明中也可使用。特别适合的超吸收聚合物是HYSORB 8800AD(北卡来罗纳州夏洛特的BASF公司)和FAVOR SXM 9300(可从北卡来罗纳州格林斯博罗的DegussaSuperabsorber获得)。使用时,超吸收材料可构成非织造网的约30wt%到约95wt.%,在一些实施方案中约40wt.%到约90wt.%,和在某些实施方案中,约50wt.%到约85wt.%。
V.吸收制品
如上所述,非织造网可以用在吸收制品中,例如但不限于个人护理吸收制品,如尿布、训练裤、吸收性内裤、失禁制品、女性卫生产品(如卫生巾)、游泳衣、婴儿擦布等等;医用吸收制品,如外衣、开窗术材料(fenestration materials)、衬垫、床垫、绷带、吸收性消毒盖布以及医用擦布;食品服务擦布;衣物制品;等等。适于形成这种吸收制品的材料和工艺是本领域技术人员熟知的。典型地,吸收制品包括基本上液体不可渗透的层(如外覆层),液体可渗透的层(如体侧衬、涌潮层(surge layer)等等)和吸收芯。本发明的非织造网可以用作液体可渗透的层、液体不可渗透的层和/或吸收层的任意一层或多层。
根据本发明可形成的吸收制品的各种实施方案现在将更详尽地阐述。仅用于举例说明的目的,吸收制品以尿布101的形式显示在图5中。然而,如上所注解,本发明可以其它吸收制品类型实施,例如失禁制品、卫生巾、纸尿裤、女性卫生巾、儿童训练裤等等。在图示实施方案中,尿布101显示为在不固定的构造中具有沙漏形状。但是,也可以使用其它形状,如一般的矩形、T形或I形。如图所示,尿布101包括由各种组分形成的底盘102,其包括外覆层117、体侧衬105、吸收芯103和涌潮层107。然而应理解为其它层也可以用在本发明中。同样地,图5中的一层或多层也可以在本发明的某些实施方案中省略。
外覆层117典型地由基本不可渗透液体的材料形成。例如,外覆层117可以由薄的塑料膜或其它柔性不可渗透液体材料形成。在一个实施方案中,外覆层117由聚乙烯膜形成,厚度为约0.01毫米到约0.05毫米。所述膜可以是不可渗透液体的,但可渗透气体和水汽(即是“可呼吸的”)。这使得水汽可从吸收芯103逸出,但仍可阻止液体分泌物穿过所述外覆层117。如果需要更强的衣物感,则可以将聚乙烯膜层压在非织造网上形成所述外覆层117。例如,厚度为约0.015毫米的拉伸变薄聚丙烯膜可以热层压在纺粘聚丙烯纤维网上。如果需要,非织造网可以含有本发明的多组分纤维。
尿布101还包括体侧衬105。体侧衬105通常用以帮助将穿着者的皮肤与吸收芯103中持有的液体隔离。例如,所述衬105提供面体表面,其典型地对穿着者的皮肤是适应的、有柔软感和无刺激性。典型地,所述衬105还比吸收芯103吸水性差,使得其表面对穿着者保持相对干燥。所述衬105可以是液体可渗透的以允许液体易于穿透其厚度。在一个特殊实施方案中,所述衬包括非织造网(如纺粘网、熔喷网或粘合粗梳网),其含有本发明的多组分纤维。含有非织造网的示例性衬结构记载在美国专利5,192,606;5,702,377;5,931,823;6,060,638;和6,150,002以及美国专利申请号2004/0102750,2005/0054255和2005/0059941中,在本文中对于所有目的整体引入作为参考。
如图5所示,尿布101还可包括涌潮层107,其帮助减速并分散可能快速引入吸收芯103的液体涌潮或涌出物。理想地,涌潮层107快速接收并在将液体释放到吸收芯103的存储或保持部分之前暂时留存液体。例如,在图示实施方案中,涌潮层107插入体侧衬105面向内的表面116和吸收芯103之间。作为选择,涌潮层107可以位于体侧衬105面向外的表面118之上。涌潮层107典型地由液体可高度渗透的材料构成。适合的材料包括多孔机织材料、多孔非织造材料和带孔的膜。在一个特殊实施方案中,涌潮层107包括含有本发明多组分纤维的非织造网。适合涌潮层的其它例子记载在Ellis等人的美国专利5,486,166和Ellis等人的5,490,846中,其在本文中对于所有目的整体引入作为参考。
除了上面提及的组件,尿布101还可含有本领域公知的各种其它组件。例如,尿布101还可含有基本亲水的薄纱包覆片(未显示),其帮助保持吸收芯103纤维结构的完整性。薄纱包覆片典型地位于吸收芯103周围在其至少两个主面的表面之上,且由吸收性纤维素材料组成,如绉纱纤维填料或湿强度高的薄纱。薄纱包覆片可以构造以提供芯吸层,其帮助快速将液体分布于吸收芯103的吸收纤维体中。吸收纤维体一侧上的包覆片材料可以粘合到纤维体对侧的包覆片上以有效截留吸收芯103。如果需要,包覆片可以由包括本发明多组分纤维的非织造网形成。
此外,尿布101还可包括透气层(未显示),其位于吸收芯103和外覆层117之间。当使用时,透气层可以帮助将外覆层117与吸收芯103隔离,从而减少外覆层117的湿气。这种透气层的例子可包括层压到可呼吸膜的非织造网,如记载在Blaney等人的美国专利6,663,611中,在本文中对于所有目的整体引入作为参考。这种非织造网可以由包括本发明多组分纤维的非织造纤维网形成。
在一些实施方案中,尿布101还可包括一对耳状物(未显示),其从尿布101的侧边132延伸向腰身区域之一。耳状物可与所选择的尿布组件整体形成。例如,耳状物可与外覆层117整体形成或由用来提供上表面的材料形成。在作为选择的构造中,耳状物可具有与外覆层117、上表面、外覆层117和上表面之间、或各种其它构造连接并组合的元件。
如图5中的典型示例,尿布101还可以包含一对防泄漏护翼112,构造其以提供一个屏障并容纳身体分泌物的侧向流动。防泄漏护翼112可以位于沿着体侧衬105侧边132的侧对面,临近吸收芯103的侧边。防泄漏护翼112可以沿吸收芯103整体长度方向纵向延伸,或者可以沿吸收芯103长度部分延伸。当防泄漏护翼112的长度短于吸收芯103时,其可选择性地位于尿布101侧边132的胯部110的任意位置。在一个实施方案中,防泄漏护翼112沿吸收芯103整体长度方向延伸以更好地留存身体分泌物。这种防泄漏护翼112一般在本领域是公知的。例如,防泄漏护翼112合适的结构和布置记载在Enloe的美国专利4,704,116中,在本文中对于所有目的整体引入作为参考。
尿布101可以包含各种弹性或可拉伸材料,如一对腿部弹性元件106贴在侧边132上以进一步防止身体分泌物的泄漏并支撑吸收芯103。另外,一对腰部弹性元件108可以纵向对着尿布101腰部边缘115粘贴。通常调适腿部弹性元件106和腰部弹性元件108用以紧密贴合使用中的穿着者的腿部和腰部,以保持与穿着者可靠的接触关系并有效减少或消除从尿布101中身体分泌物的泄漏。在本文中,术语“弹性的”和“可拉伸的”包括任何可以拉伸并在松弛时回复原始形状的材料。适于形成这种材料的聚合物包括但不限于聚苯乙烯、聚异戊二烯和聚丁二烯的嵌段共聚物;乙烯、天然橡胶和聚氨酯橡胶的共聚物;等等。特别适合的是苯乙烯-丁二烯的嵌段共聚物,由德克萨斯州休斯顿的KratonPolymers销售,商品名为其它适合的聚合物包括乙烯共聚物,包括但不限于乙烯乙酸乙烯酯、乙烯丙烯酸甲酯、乙烯丙烯酸乙酯、乙烯丙烯酸、可拉伸乙烯-丙烯共聚物,及它们的组合。适合的还有前述的共挤出组合物,和弹性短纤维的整合复合材料,其中聚丙烯、聚酯、棉和其它材料的短纤维整合到弹性熔喷纤维网中。某些弹性体的单部位(single-site)或金属茂-催化的烯烃聚合物和共聚物也适用于所述侧面软垫。
尿布101还可以包括一个或多个固定物130。例如,在图5中腰部区域的对边图示了两个柔性固定物130以产生围绕穿着者的一个腰部开口和一对腿部开口。固定物130的形状一般可以变化,但可以包括例如一般的矩形、正方形、环形、三角形、椭圆形、直线形等等。固定物可以包括例如钩状材料。在一个特殊实施方案中,每一个固定物130包括一片分开的粘贴在柔性衬里内表面的钩状材料。
尿布101的各个区域和/或组件可以使用任何已知连接机构组装在一起,例如粘合剂、超声波、热粘结剂,等等。适合的粘合剂可以包括例如热熔粘合剂、压敏粘合剂等等。使用时,粘合剂可以涂布成均匀的层、带图案的层、喷涂的图案、或任何分开的线、涡旋或点。例如,在图示的实施方案中,外覆层117和体侧衬105彼此组装并用粘合剂与吸收芯103结合。作为选择,吸收芯103可用常规固定物,如按钮、钩和圈型固定物、粘合带固定物等等与外覆层117连接。类似地,其它尿布组件,如腿部弹性元件106、腰部弹性元件108和固定物130,也可以使用任何连接机构组装到尿布101中。
尽管尿布的各种构造已在上文中描述,但应理解其它的尿布和吸收制品构造也包含在本发明范围之内。另外,本发明决不限于尿布。事实上,根据本发明可以形成任何其它的吸收制品,包括但不限于其它的个人护理吸收制品,如训练裤、吸收性内裤、成人失禁产品、女性卫生产品(如卫生巾)、游泳衣、婴儿擦布等等;医用吸收制品,如外衣、开窗术材料、衬垫、绷带、吸收性消毒盖布以及医用擦布;食品服务擦布;衣物制品;等等。这种吸收制品的一些例子公开在DiPalma等人的美国专利5,649,916;Kielpikowski的6,110,158;Blaney等人的6,663,611中,在本文中对于所有目的整体引入作为参考。还有其它适合的制品记载在Fell等人的美国专利申请公开2004/0060112A1中,以及Damico等人的美国专利4,886,512;Sherrod等人的5,558,659;Fell等人的6,888,044;以及Freiburger等人的6,511,465中,所有均在本文中对于所有目的整体引入作为参考。
参考下列实施例可以更好地理解本发明。
测试方法
分子量:
聚合物的分子量分布通过凝胶透过色谱法(“GPC”)测定。最初通过将氯仿中0.5%wt/v的样品聚合物溶液添加到40毫升的玻璃小瓶中制备样品。例如,将0.05±0.0005克聚合物添加到10毫升氯仿中。将制备的样品放到轨道混合器上并摇动过夜。溶解的样品通过0.45微米的PTFE膜过滤并用下面的条件分析:
柱: 41℃时Styragel HR 1、2、3、4和5E(5个串联)
溶剂/洗脱剂: 氯仿,每分钟1.0毫升
HPLC: Waters 600E梯度泵和控制器,Waters717自动取样器
检测器: Waters 2414差示折射仪,灵敏度为30,40℃,比例
因子为20
样品浓度: 0.5%聚合物“原样”
注射体积: 50微升
校准标准: 窄MW的聚苯乙烯,30微升注射体积。
获取数均分子量(MWn)、重均分子量(MWw)和粘均分子量(MWz)的一阶矩(first moment)。
表观粘度:
聚合物样品的流变性能用Rheograph 2003毛细管流变仪测定,使用WinRHEO版本2.31分析软件。设置包括2000巴压力传感器和30/1:0/180圆孔毛细管模头。样品装载在样品添加和用推弹杆填实之间交替进行。每次测试之前有2分钟的熔融时间使得聚合物在测试温度时(一般是160到220℃)完全熔融。毛细管流变仪在七个不同的剪切速率下测定表观粘度(Pa·s):50、100、200、500、1000、2000和5000s-1。所得表观剪切速率相对表观粘度的流变曲线显示在挤出工艺中在所述温度下聚合物如何流动。
熔体流动指数:
熔体流动指数是190℃下经受2160克力10分钟时被强制通过挤出流变仪口(直径0.0825英寸)的聚合物重量(以克计)。熔体流动指数根据ASTM测试方法D1238-E测出。
热性能:(熔点、Tg和结晶度%):
材料的熔融温度、玻璃化转变温度和结晶度用差示扫描量热法(DSC)测定。差示扫描量热计是THERMAL ANALYST 2910差示扫描量热计,其配备有液氮冷却件和THERMAL ANALYST 2200(版本8.10)分析软件程序,都可从特拉华州New Castle的T.A.Instruments Inc.获得。为避免直接处理样品,使用了镊子或其它工具。将样品放在铝盘里并在分析天平上精确到0.01毫克称重。盖子在材料样品上弯曲压在盘上。典型地,直接将树脂粒料放在称量盘里,纤维要切得适于放在称量盘中并盖上盖子。
差示扫描量热计用铟金属标准校准并进行基线校正,如在差示扫描量热计操作手册中所述。将材料样品放入差示扫描量热计的测试箱中测试,并使用空盘作为参考。所有测试均采用每分钟55立方厘米的氮气(工业级)吹扫在测试箱上进行。对于树脂粒料样品,加热和冷却程序是2个循环测试,开始时所述箱平衡到-25℃,接着是第一次加热时段,加热速率为每分钟10℃直至200℃,然后在200℃平衡样品3分钟,接着是第一次冷却时段,冷却速率为每分钟20℃直至-25℃,然后在-25℃平衡样品3分钟,之后是第二次加热时段,加热速率为每分钟10℃直至200℃。对于纤维样品,加热和冷却程序是1个循环测试,开始时所述箱平衡到-25℃,接着是加热时段,加热速率为每分钟20℃直至200℃,然后在200℃平衡样品3分钟,之后是冷却时段,冷却速率为每分钟10℃直至-25℃。所有的测试均采用每分钟55立方厘米的氮气(工业级)吹扫在测试箱上进行。
然后用THERMAL ANALYST 2200分析软件程序评估结果,其识别并量化拐点、吸热峰和放热峰的玻璃化转变温度(Tg)以及在DSC图上所述峰值下的面积。玻璃化转变温度被识别为曲线上斜面发生明显变化的区域,熔融温度采用自动拐点计算来测定。DSC图上峰值下的面积以每克样品的焦耳数(J/g)来测定。例如,树脂或纤维样品的熔融吸热量通过求吸热峰值的积分来确定。面积值是通过将DSC图下的面积(如吸热面积)用计算机软件转换成每千克焦耳数(J/g)来确定的。结晶度%计算如下:
结晶度%=100*(A-B)/C
其中
A是吸热峰面积和(J/g);
B是放热峰面积和(J/g);以及
C是所选定的聚合物的熔融吸热值,其中这种聚合物具有100%的结晶度(J/g)。对于聚乳酸,C是93.7J/g(Cooper-White,J.J.,和Mackay,M.E.,Journal of Polymer Science,Polymer Physics Edition,p.1806,Vol.37,(1999))。从吸热峰下的面积减去在DSC扫描中由于结晶度不足所遇到的任何放热峰下的面积以恰当地表现结晶程度。
拉伸性能:
条带拉伸强度值基本根据ASTM标准D-5034测定。具体地,剪切非织造网样品或提供大小为25毫米(宽)×127毫米(长)的尺寸。采用恒速延伸型拉伸测试仪。拉伸测试系统是MTS SYNERGY 200拉伸测试仪,可从密歇根州Eden Prairie的MTS Systems Corporation获得。拉伸测试仪配备有MTS Corporation的TESTWORKS 4.08B软件支持测试。选择合适的载荷元件使测试值在全刻度载荷的10-90%范围之内。将样品夹持在前后面尺寸为25.4毫米×76毫米的夹钳之间。用橡胶处理夹持面,且夹钳较长的尺寸垂直于拉动的方向。夹持压力由空气作用保持在每平方英寸40磅压力。拉伸测试以每分钟300毫米的速率进行,夹持长度为76毫米且断裂灵敏度为40%。
沿机器方向施加测试载荷测试三个样品且沿横向施加测试载荷测试三个样品。除拉伸强度外,还测量峰值载荷、峰值拉伸(即峰值载荷时的伸长率%)和峰值时的能量。每一个测试样品的峰值条带拉伸载荷取数学平均以测定MD或CD方向的拉伸强度。
纤维韧度:
以不显著拉伸纤维的方式从纤维网上未粘合的部分小心地取出单独的纤维样本。缩短这些纤维样本(例如用剪刀切断)到38毫米的长度,并单独放置在黑色天鹅绒布上。以这种方式收集10到15个纤维样本。然后在基本顺直的条件下将纤维样本安装在一个矩形纸质框架里,该框架外部尺寸为51毫米×51毫米且内部尺寸为25毫米×25毫米。通过小心用胶带将纤维端部固定在框架侧面上使每个纤维样本的末端有效地粘帖在框架上。然后用常规实验室显微镜测量每个纤维样本的外部尺寸、相对较短的尺寸和横向纤维尺寸,显微镜要经过适当校准且设定成放大40倍。将横向纤维尺寸记录为各纤维样本的直径。所述框架以避免过分损坏纤维样本的方式帮助将纤维样品的样本末端安放在恒速延伸型拉伸测试仪的上下夹钳上。
采用恒速延伸型拉伸测试仪和适当的载荷元件进行测试。选择载荷元件(如10N)使测试值在全刻度载荷的10-90%范围之内。拉伸测试仪(即MTS SYNERGY 200)和载荷元件从密歇根州Eden Prairie的MTSSystems Corporation获取。之后将在框架组件内的纤维样本安放在拉伸测试仪的夹钳之间使得纤维末端被拉伸测试仪的夹钳有效地夹持。然后,切除与纤维长度方向平行延伸的纸质框架的侧面或者以别的方式分开使得拉伸测试仪只将测试力施加在纤维上。然后纤维以每分钟12英寸的拉伸率和夹持速率经受拉伸测试。用MTS Corporation的TESTWORKS 4软件程序根据下面的测试设置分析所得数据:
韧度值以每旦的克力值来表示。
实施例1
测试下述脂族聚酯的各种物理性能。
P1:从南韩IRE Chemicals获取的聚琥珀酸丁二醇酯,名称为EnPolTM G4500(级别CE272);
P2:从南韩IRE Chemicals获取的聚琥珀酸丁二醇酯,名称为EnPolTM G4500(级别1DF241);
P3:从南韩IRE Chemicals获取的聚琥珀酸丁二醇酯,名称为EnPolTM G4500(级别2DF242);
P4:从南韩IRE Chemicals获取的聚琥珀酸丁二醇酯,名称为EnPolTM G4560J;
P5:从南韩IRE Chemicals获取的聚琥珀酸丁二醇酯,名称为EnPolTM G4500(级别CE272-高MFI);
P6:从南韩IRE Chemicals获取的聚琥珀酸丁二醇酯,名称为EnPolTM G4500(级别CE272-中等MFI);
P7:从日本Showa获取的聚琥珀酸丁二醇酯,名称为BionolleTM1020;
P8:从日本Showa获取的聚琥珀酸丁二醇酯,名称为BionolleTM1903;
P9:从日本Showa获取的聚琥珀酸丁二醇酯,名称为BionolleTM1003;以及
P10:从德国Biomer Inc.获取的聚乳酸,名称为BiomerTM L9000。
结果列在下面的表1和表2中。
表1:分子量和熔融性能
聚合物 | MWn | MWw | 多分散指数 | 熔体流动指数(190℃,2.16kg) | 熔融温度(℃) | 融化热(J/g) | 结晶温度(℃) | 结晶热(J/g) |
P1 | 78,000 | 126,900 | 1.63 | 47 | 114.95 | 49.45 | 79.08 | 57.86 |
P2 | 59,500 | 99,200 | 1.67 | 150 | 114.94 | 64.26 | 70.86 | 62.38 |
P3 | 72,300 | 122,900 | 1.70 | 41 | 115.03 | 59.69 | 75.13 | 61.26 |
P4 | 77,600 | 142,900 | 1.84 | 25 | 114.40 | - | - | - |
P5 | 49,900 | 92,400 | 1.85 | 127 | 113.21 | 71.48 | 64.90 | 72.34 |
P6 | 61,500 | 105,400 | 1.71 | 56 | 114.06 | 58.54 | 68.02 | 61.25 |
P7 | - | - | - | 28 | 114.28 | 56.88 | 76.36 | 64.13 |
P8 | - | - | - | - | - | - | - | - |
P9 | - | - | - | 4.4 | - | - | - | - |
P10 | 113.5 | 150.7 | 1.33 | 22(210℃)43(230℃) | 169.60 | 3.70 | 71.38 | 33.46 |
表2:流变性能(30/1/180圆孔)
如所示,BionolleTM聚合物(P7-P9)与EnPolTM G4500聚合物(P2-P4)相比相当粘稠。
实施例2
各聚琥珀酸丁二醇酯聚合物在160°F干燥,聚乳酸聚合物在175°F干燥,两者都至少要48小时。目标含湿量是50ppm。然后通过密封加料斗将聚合物喂入挤出机将熔融的聚合物喂入到熔融泵中。挤出机各自是单螺杆型的并且具有五个单独控制的加热区。熔融泵是可靠的置换型泵,其生产量(cc/sec)通过其速度(rpm)来控制。挤出机的生产量通过熔融泵生产量的需求自动控制。将来自泵的熔融聚合物喂入具有16个0.4或0.6毫米尺寸孔的加热纺丝组件中。纺丝组件含有纺丝盘和沟槽盘(32沟槽),沟槽盘保持两种聚合物流分离直至到达纺丝盘。挤出的聚合物是须条的形式,其由通过1.5米长纺丝箱的热或冷空气源进行退火或淬火。纤维须条随后要快速拉伸并收集在导丝辊上。在一定时间之后,停止导丝辊并收集纤维。然后对这些纤维进行分析并与商业上可获得的纤维进行对比。结果列在下表3-7中。
表3:聚合物构造
样品 | 聚合物1 | 聚合物2 | 构造(1/2) |
1 | P6 | P10 | 皮(50%)/芯(50%) |
2 | P5 | P10 | 皮(50%)/芯(50%) |
3 | P5 | - | 单根 |
4 | P1 | - | 单根 |
5 | P1 | EcoPla 6201* | 皮(50%)/芯(50%) |
6 | P6 | EcoPla 6201* | 皮(50%)/芯(50%) |
7 | P1 | - | 单根 |
8 | P1 | P10 | 皮(50%)/芯(50%) |
9 | P6 | - | 单根 |
10 | P1 | EcoPla 6201* | 皮(50%)/芯(50%) |
11 | P2 | P10 | 皮(50%)/芯(50%) |
12 | P3 | P10 | 皮(50%)/芯(50%) |
13 | P2 | P10 | 皮(50%)/芯(50%) |
14 | P3 | P10 | 一侧(50%)-一侧(50%) |
15 | P3 | P10 | 一侧(50%)-一侧(50%) |
16 | P3 | P10 | 一侧(50%)-一侧(50%) |
17 | P2 | - | 单根 |
18 | P2 | P2 | 一侧(50%)-一侧(50%) |
19 | P2 | P2 | 单根 |
20 | P2 | P10 | 一侧(50%)-一侧(50%) |
21 | P10 | - | 单根 |
22 | P9 | - | 单根 |
23 | P7 | - | 单根 |
24 | P7 | P10 | 单根 |
25 | PP3155+ | - | 单根 |
26 | P10 | - | 单根 |
27 | P10 | P3 | 芯(93%)/皮(7%) |
28 | P10 | P3 | 芯(85%)/皮(10%) |
29 | P10 | P3 | 芯(70%)/皮(30%) |
30 | P10 | P2 | 芯(93%)/皮(7%) |
31 | P10 | P2 | 芯(70%)/皮(30%) |
*从Natureworks LLC获得的聚乳酸。
+从Exxon Mobil Chemical Co.获得的全同均聚丙烯。
表5:纤维性能
样品 | 纤维直径(微米) | 峰值拉伸应力(MPa)N=15 | 标准偏差 | 备注 |
1 | 21.9 | 234.0 | 74 | 收集未粘结纤维束 |
2 | 16.3 | 292.0 | 159 | 收集未粘结纤维束 |
3 | 10.1 | 219.8 | 94 | 收集未粘结精细纤维 |
4 | 26.6 | 124.0 | 35 | 纤维断裂>200m/m |
7 | - | - | - | 不粘结,纤维断裂>500m/m |
8 | - | - | - | 加热柱中上方空气改善纺丝 |
9 | - | - | - | 纤维频繁断裂 |
12 | 18.3 | 144.0 | 35 | - |
13 | 16.0 | 167.0 | 49 | - |
14 | 22.3 | 127.0 | 30 | - |
15 | 18.3 | 159.0 | 20 | 800m/min最稳定 |
16 | 16.7 | 204.0 | 31 | - |
17 | 20.3 | 102.3 | 19 | 纤维中一些卷曲和膨化;没有空气运行良好 |
18 | 15.3 | 157.0 | 46 | 许多微卷曲和膨化;没有空气运行良好 |
19 | 15.9 | 148.3 | 21 | 纤维中一些卷曲和膨化;没有空气运行良好 |
20 | - | - | - | 纺丝盘上有螺旋;纤维形成差 |
21 | 11.0 | 283.8 | 38 | 在2000-2400m/min稳定纺丝 |
22 | 28.1 | 257.0 | 89 | 非常粘稠,纤维下落非常慢,泵断开,未粘结纤维 |
23 | 12.0 | 230.0 | 65 | 即使在高冷空气流下纤维也很少粘结 |
24 | 16.9 | 176.0 | 75 | 即使在高冷空气流下纤维也很少粘结 |
25 | 11.7 | 133.0 | 15 | 在纤维级聚丙烯上控制运行 |
26 | 12.9 | 286.4 | 42 | 在纤维级PLA上控制运行 |
27 | 13.4 | 265.0 | 20 | - |
28 | 14.5 | 240.0 | 68 | - |
29 | 18.2 | - | - | - |
30 | 12.9 | 251.0 | 37 | - |
31 | 12.6 | 195.0 | 28 | - |
表6:纤维性能(续)
表7:商用纤维性能
名称 | 厂家 | 类型 | 聚合物 | 纤维尺寸(微米) | 韧度(gf/旦) | 峰值载荷(gf) | %伸长率 | 第一熔化热(J/g) | 熔融温度1(℃) | 第二熔化热(J/g) | 熔融温度2(℃) |
ESC-215A | ESFibervisions | 双组分 | PE/PP | 16.6 | 3.8 | 7.3 | 70.9 | 69.00 | 128.0 | 47.60 | 169.0 |
PL80 | Unitika Ltd. | 双组分 | PLA1/PLA2 | 17.5 | 1.7 | 4.6 | 26.9 | 10.64 | 132.0 | 25.86 | 160.0 |
ESC-806ALAD | ESFibervisions | 双组分 | PE/PP(65/35) | 15.7 | - | - | - | 111.20 | 130.5 | 34.44 | 158.5 |
T-255 | Kosa Inc. | 双组分 | PE/PET | 18.4 | - | - | - | 72.60 | 128.5 | 24.40 | 240.4 |
如上所显示,根据本发明制备的双组分纤维具有与商业上可获得的纤维近似的尺寸、强度和伸长率%。此外,本文中制备的双组分纤维的熔融峰值相差约50℃,而大多数商业上的双组分纤维具有约30-40℃的熔融峰值差异。
实施例3
将实施例2的一些双组分纤维切成6mm的短纤维并气流法制网为未粘结的非织造网的形式。此外,下述的商业上可获得的纤维也形成气流法纤维网以便于对比:(1)T-255:双组分纤维,具有聚乙烯皮层和聚酯芯层,可从北卡来罗纳州夏洛特的KoSa,Inc.获得;(2)ESC-806ALAD:双组分纤维,具有聚乙烯皮层和聚丙烯芯层,可从乔治亚州Athens的ES Fibervision,Inc.获得;和(3)TerramacTM PL80:聚乳酸双组分纤维,可从日本Osaka的Unitika Ltd.获得。一些样品使用双组分纤维与每根长丝1.5旦(dpf)的H215963型纤维的50%/50%共混物,后一种纤维具有6mm短纤维长度(纤维可从阿拉巴马州Axis的Lenzing Fibers Inc.获得),而其它样品采用100%的双组分纤维。气流法纤维网然后在一定时间和温度下通过空气粘合(TAB)以促进粘结。将粘合的纤维网切成1”×5”的条带以进行拉伸测试评估粘结效果。结果列在下面的表8-9中。
如所示,本发明的双组分纤维显示出纤维网拉伸强度、粘合窗口(bonding window)和低粘合温度的良好平衡。例如,该纤维显示出在较低的温度下比商业上气流法成网级粘合剂,如T-255和PLA纤维更好的粘合性能。较低的粘合温度可以得到较低的加热成本、较高的粘合(转换)速度,和较柔软的纤维网。即使在相对低的95℃和115℃,PL80纤维导致不希望的非织造布面积收缩80%或更多。相反,本发明的纤维收缩程度小得多。值得一提的是根据本发明形成的一些纤维具有相对低的拉伸强度。例如,用13号样品纤维(表8)形成的纤维网的SEM显微照片(放大40倍)显示在图2a中。当分析显微照片时发现皮层聚合物起珠,据信这是高表面张力和皮层聚合物熔体粘度低的结果。为提高粘合力,熔融的皮层聚合物理想地流到纤维连接点并形成焊接,如图2b所示(第12号样品(表8))。另外,由于其分子量低13号样品(表8)使用的皮层聚合物显示出轻微的形成粘结纤维的趋势。
实施例4
证明了根据本发明形成双组分纤维网的能力。具体地,将实施例2的一些纤维切断成6毫米短纤维并气流成网为尺寸是12”×4”的未粘结非织造网的形式。商业上的双组分纤维(即Invista的T-255)也要作为对照进行测试。气流纤维网然后在125℃经历通过空气粘合(TAB)30秒。之后测试各项性能,包括预稳定密度和后稳定密度,即通过空气粘合之前和之后的密度。通过将沿贯穿纤维网长度方向四(4)个位置的厚度平均来测定密度。纤维网的预稳定性(在每平方英寸约0.05磅的压力下)介于0.07和0.08克每立方厘米的纤维网密度之间。最终结果列在下面的表10中。
表10:并列型可生物降解的双组分纤维网的性能
如所示,根据本发明形成的并列结构的纤维形成较大的纤维网。例如,实施例12号皮/芯型纤维(~70gsm)的尺寸为18毫米,而并列结构的纤维的尺寸范围为2.7到3.3毫米,因此提供更多空闲的体积。值得指出的是T-255纤维具有一些卷曲,为其提供了提高的预粘结尺寸。
实施例5
实施例2的一些纤维如实施例2所述气流成网,但在一定的压力、温度和时间间隔下,在雕刻压机(carver press)中粘合到“金属丝织物”点粘合图案上。最初将纤维用模头切成6mm的长度并在纤维网成型机中开松。将0.85克开松后的纤维由成型机收集在4”×12”放在金属丝织物粘合图案表面上的条带中。在一定温度下(112℃到158℃)安装一个压机,上部板设置成低于压机温度35℃以最小化纤维网发粘。将条带放在压机上然后以每平方英寸14,000磅压5秒钟。轻轻地从粘合图案表面移除粘合的条带并且切成6个不同的1”×5”条带用于条带拉伸测试。结果显示在表11-13和图3-4中。
如所示,含有100%聚乳酸的纤维得到具有较低强度和伸长率%的纤维网。在较高的粘合温度时,纤维网的拉伸增加,但纤维网变硬。相反地用本发明的纤维制成的纤维网相对结实,具有高伸长率%,且柔软。
虽然本发明已经相对于具体实施方案进行了详细阐述,但应理解,在理解了前述内容时,本领域技术人员可以容易地想到这些实施方案的改进、变化和等效方案。因此,本发明的范围应以所附的权利要求及其任何等价物进行评定。
Claims (33)
1.一种可生物降解的多组分纤维,包含:
第一组分,含有至少一种具有160℃到250℃的熔点的高熔点脂族聚酯;
第二组分,含有至少一种低熔点脂族聚酯,该低熔点脂族聚酯的熔点比所述高熔点脂族聚酯的熔点低至少30℃,其中低熔点脂族聚酯具有30,000到120,000道尔顿的数均分子量以及50到215帕斯卡·秒的表观粘度,在温度为160℃以及剪切速率为1000秒-1时测定,
其特征在于第二组分不含多羧酸成核剂。
2.权利要求1的可生物降解的多组分纤维,其中所述高熔点脂族聚酯具有180℃到220℃的熔点。
3.权利要求1的可生物降解的多组分纤维,其中所述高熔点脂族聚酯是聚乳酸。
4.权利要求1的可生物降解的多组分纤维,其中所述低熔点脂族聚酯具有75到200帕斯卡·秒的表观粘度,在温度为160℃以及剪切速率为1000秒-1时测定。
5.权利要求1的可生物降解的多组分纤维,其中所述低熔点脂族聚酯具有80到150帕斯卡·秒的表观粘度,在温度为160℃以及剪切速率为1000秒-1时测定。
6.权利要求1的可生物降解的多组分纤维,其中所述低熔点脂族聚酯具有比所述高熔点脂族聚酯的熔点低至少40℃的熔点。
7.权利要求1的可生物降解的多组分纤维,其中所述低熔点脂族聚酯具有120℃到160℃的熔点。
8.权利要求1的可生物降解的多组分纤维,其中所述低熔点脂族聚酯具有40,000到100,000道尔顿的数均分子量。
9.权利要求1的可生物降解的多组分纤维,其中所述低熔点脂族聚酯具有1.0到3.0的多分散指数。
10.权利要求1的可生物降解的多组分纤维,其中所述低熔点脂族聚酯具有20到120克每10分钟的熔体流动指数,根据ASTM测试方法D1238-E在190℃2160克力时测定。
11.权利要求1的可生物降解的多组分纤维,其中所述纤维具有每旦0.75到7.0克力的韧度。
12.权利要求1的可生物降解的多组分纤维,其中所述纤维具有150到500兆帕的峰值拉伸应力。
13.权利要求1的可生物降解的多组分纤维,其中所述纤维具有200到400兆帕的峰值拉伸应力。
14.权利要求1的可生物降解的多组分纤维,其中所述低熔点脂族聚酯具有低于50℃的玻璃化转变温度。
15.权利要求1的可生物降解的多组分纤维,其中所述低熔点脂族聚酯具有低于0℃的玻璃化转变温度。
16.权利要求1的可生物降解的多组分纤维,其中所述低熔点脂族聚酯具有低于-10℃的玻璃化转变温度。
17.权利要求1的可生物降解的多组分纤维,其中所述低熔点脂族聚酯含有10mol.%到40mol.%的芳族单体成分。
18.权利要求1的可生物降解的多组分纤维,其中所述低熔点脂族聚酯是聚琥珀酸丁二醇酯。
19.权利要求1的可生物降解的多组分纤维,其中所述纤维是皮/芯结构或并列结构构造。
20.一种制备权利要求1的多组分纤维的方法,该方法包括:
挤出第一种热塑性组合物,所述第一种热塑性组合物包含所述高熔点脂族聚酯;和
挤出第二种热塑性组合物,所述第二种热塑性组合物包含所述低熔点脂族聚酯,其中第二种热塑性组合物在120℃到200℃的温度挤出;和
使挤出的热塑性组合物淬火;并
拉伸挤出并淬火后的热塑性组合物。
21.权利要求20的方法,其中所述第二种热塑性组合物在145℃到195℃的温度挤出。
22.权利要求20的方法,其中所述纤维以200∶1到6000∶1的倍率拉伸。
23.一种包含可生物降解的多组分纤维的非织造网,其中所述多组分纤维包含:
第一组分,包含至少一种具有160℃到250℃的熔点的高熔点脂族聚酯;
第二组分,包含至少一种低熔点脂族聚酯,所述低熔点脂族聚酯的熔点比所述高熔点脂族聚酯的熔点低至少40℃,其中所述低熔点脂族聚酯具有30,000到120,000道尔顿的数均分子量以及50到215帕斯卡·秒的表观粘度,在温度为160℃以及剪切速率为1000秒-1时测定,
其特征在于第二组分不含多羧酸。
24.权利要求23的非织造网,其中所述高熔点脂族聚酯具有180℃到220℃的熔点。
25.权利要求23的非织造网,其中所述高熔点脂族聚酯是聚乳酸。
26.权利要求23的非织造网,其中所述低熔点脂族聚酯具有75到200帕斯卡·秒的表观粘度,在温度为160℃及剪切速率为1000秒-1时测定。
27.权利要求23的非织造网,其中所述低熔点脂族聚酯具有80到150帕斯卡·秒的表观粘度,在温度为160℃及剪切速率为1000秒-1时测定。
28.权利要求23的非织造网,其中所述低熔点脂族聚酯具有120℃到160℃的熔点。
29.权利要求23的非织造网,其中所述低熔点脂族聚酯具有40,000到100,000道尔顿的数均分子量。
30.权利要求23的非织造网,其中所述低熔点脂族聚酯是聚琥珀酸丁二醇酯。
31.权利要求23的非织造网,其中所述纤维具有150到500兆帕的峰值拉伸应力。
32.权利要求23的非织造网,其中所述纤维具有200到400兆帕的峰值拉伸应力。
33.一种吸收制品,包含液体基本不可渗透的层、液体可渗透的层和吸收芯,其中吸收芯、液体可渗透的层或两者都包含权利要求24的非织造网。
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Also Published As
Publication number | Publication date |
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EP1966419A1 (en) | 2008-09-10 |
DE602005023671D1 (de) | 2010-10-28 |
US20080287024A1 (en) | 2008-11-20 |
CN101331257B (zh) | 2012-01-04 |
WO2007070064A9 (en) | 2008-08-28 |
AU2006325484A1 (en) | 2007-06-21 |
KR101254813B1 (ko) | 2013-04-15 |
EP1966423B1 (en) | 2012-01-04 |
US20080227355A1 (en) | 2008-09-18 |
EP1966423A1 (en) | 2008-09-10 |
CN101331257A (zh) | 2008-12-24 |
AU2005339151B2 (en) | 2011-09-08 |
KR20080075931A (ko) | 2008-08-20 |
WO2007070064A1 (en) | 2007-06-21 |
US7972692B2 (en) | 2011-07-05 |
WO2007070075A1 (en) | 2007-06-21 |
AU2006325484B2 (en) | 2012-05-10 |
KR101275404B1 (ko) | 2013-06-14 |
AU2005339151A1 (en) | 2007-06-21 |
US7989062B2 (en) | 2011-08-02 |
EP1966419B1 (en) | 2010-09-15 |
CN101326312A (zh) | 2008-12-17 |
KR20080080687A (ko) | 2008-09-05 |
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