CN101374986B - 聚吡啶并唑短纤维的无基质非织造层 - Google Patents

聚吡啶并唑短纤维的无基质非织造层 Download PDF

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CN101374986B
CN101374986B CN2006800463755A CN200680046375A CN101374986B CN 101374986 B CN101374986 B CN 101374986B CN 2006800463755 A CN2006800463755 A CN 2006800463755A CN 200680046375 A CN200680046375 A CN 200680046375A CN 101374986 B CN101374986 B CN 101374986B
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M·J·乔
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    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
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    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
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    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
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Abstract

提供包含聚吡啶并唑短纤维的非织造构造物和织物；所述短纤维的特征在于：平均长丝韧度为至少15克每旦(gpd)；平均长丝模量为至少500gpd；平均长丝密度为至少1.6g/cc；平均长丝长度为30～100mm；并且平均每根长丝的长丝旦数(dpf)为0.1～10；其中所述构造物基本上不含基质。

Description

聚吡啶并唑短纤维的无基质非织造层
相关申请
本申请要求2005年12月8日提交的美国申请号60/748,877的权益，在此将其公开内容收作参考。
发明领域
本发明涉及可用于防弹应用的非织造层。
背景技术
个人身体防弹盔甲，特别是背心、头盔和其它制品一般由用于防止子弹或其它抛射体，以及任何其它有力地作用于盔甲的物体如刀的材料形成。这些制品主要用于武装部队，但也用于警察和民用应用。对于改善处于战斗环境中的战士和警察局所用盔甲系统的穿着性能和总体有效性的要求正日益提高。盔甲系统的总厚度和重量能影响穿着性能，但是降低当前公知系统中的这些参数会损害盔甲的防穿透有效性。
美国专利5,569,528公开了一种具有聚烯烃短纤维的非织造层。该纤维据报道具有40～100mm的长度、至少1.2GPa的拉伸强度和至少40GPa的模量。
PCT专利申请号WO 94/21450公开了一种包含至少两种类型纤维材料的防弹材料。描述了芳族聚酰胺和聚乙烯的共混物。这些材料被共混在一起并加固成为单层非织造复合材料。
PCT专利申请号WO2005/001373教导了一种防弹材料，它具有由防弹非织造纺织材料形成的外层和布置在外层之间的防弹机织纺织材料的内层。
本领域需要继续改进防弹织物和制品的构造。
发明概述
提供包含聚吡啶并唑(polypyridazole)短纤维的非织造构造物(constructions)和织物；所述短纤维的特征在于：平均长丝韧度为至少15克每旦(g/d)；平均长丝模量为至少500gpd；平均长丝密度为至少1.6g/cc；平均长丝长度为30～100mm；并且平均每根长丝的长丝旦数(dpf)为0.1～10；其中所述构造物基本上不含基质。
还提供含有一种或多种此种非织造构造物的防穿透制品和服装，或制造此种构造物和织物的方法。
上面的概述和下面的详述仅是举例和示例性的，不构成对由所附权利要求限定的本发明的限制。
示例性实施方案详述
提供包含聚吡啶并唑短纤维的非织造构造物；所述短纤维的特征在于：平均长丝韧度为至少15克每旦(g/d)；平均长丝模量为至少500gpd；平均长丝密度为至少1.6g/cc；平均长丝长度为30～100mm；并且平均每根长丝的长丝旦数(dpf)为0.1～10；其中所述构造物基本上不含基质。
在某些实施方案中，该构造物是织物或层压材料。
在某些实施方案中，聚吡啶并唑纤维的比浓对数粘度大于20dl/g。在其它方案中，聚吡啶并唑纤维的比浓对数粘度大于25dl/g。在进一步的其它实施方案中，聚吡啶并唑纤维的比浓对数粘度大于28dl/g。一种优选的聚吡啶并唑是聚[2，6-二咪唑并[4，5-b：4，5-e]-亚吡啶基-1，4(2，5-二羟基)亚苯基]。
在某些实施方案中，该构造物还包含数量占全部纤维重量最高15wt％的芳族聚酰胺纤维。一种优选的芳族聚酰胺纤维是聚(对苯二甲酰对苯二胺)短纤维。
还提供的是多层织物，它包含至少一个含有聚吡啶并唑短纤维的层；所述短纤维的特征在于：平均长丝韧度为至少15克每旦(g/d)；平均长丝模量为至少500gpd；平均长丝密度为至少1.6g/cc；平均长丝长度为30～100mm；并且平均每根长丝的长丝旦数(dpf)为0.1～10；其中所述层基本上不含基质。合适的聚吡啶并唑纤维包括这里所描述的那些。
该多层织物还可包含数量占全部纤维重量最高15wt％的芳族聚酰胺纤维。
本发明还涉及包含至少一种这里描述的织物或构造物的防穿透制品和服装。
本发明还涉及一种制备含有聚吡啶并唑短纤维的织物的方法；所述短纤维的特征在于：平均长丝韧度为至少15克每旦(g/d)；平均长丝模量为至少500gpd；平均长丝密度为至少1.6g/cc；平均长丝长度为30～100mm；并且平均每根长丝的长丝旦数(dpf)为0.1～10；其中所述层基本上不含基质；
所述方法包括对聚吡啶并唑短纤维进行针刺加工。
本发明可通过下面作为本公开一部分的示例性和优选的实施方案的详细描述而变得更容易理解。应该理解，权利要求的范围不局限于这里描述的和/或展示的具体装置、方法、条件或参数，且这里所使用的术语仅为举例说明特定实施方案的目的之用，不拟作为对所公开发明的限制。同样，正如在包括所附权利要求的本说明中使用的，单数形式“一个”、“一种”(“a”、“an”以及“the”)包括复数，且当提到特定数值时意在至少包括那个特定数值，除非另行明确指出。当表示出某一数值范围时，另一实施方案包括从这一个特定数值和/或到其它特定数值。类似地，当数值以前置词“约”修饰表示为近似值时，应当理解，该特定数值构成另一种实施方案。所有范围都包括端值并且是可组合的。
有用的纤维包括聚(吡啶并唑)。聚(吡啶并唑)包括聚(吡啶并咪唑)、聚(吡啶并噻唑)、聚(吡啶并噁唑)、聚(吡啶并双咪唑)、聚(吡啶并双噻唑)和聚(吡啶并双噁唑)。
聚(吡啶并双咪唑)是具有高强度刚性棒状聚合物。聚(吡啶并双咪唑)纤维可具有至少20dl/g或至少25dl/g或至少28dl/g的比浓对数粘度。这种纤维包括PIPD纤维(亦称作M5纤维和由聚[2，6-二咪唑并[4，5-b：4，5-e]-亚吡啶基-1，4(2，5-二羟基)亚苯基]制成的纤维)。PIPD纤维基于以下结构：
Figure S2006800463755D00032
聚(吡啶并双咪唑)纤维区别于公知的市售供应PBI纤维或聚(苯并咪唑)纤维之处在于：聚(苯并咪唑)纤维是聚(双苯并咪唑)。聚(双苯并咪唑)纤维不是刚性棒状聚合物，并且当与聚(吡啶并双咪唑)相比时，具有低纤维强度和低拉伸模量。
PIPD纤维据报道具有达到约310Gpa(2100克/分特(g/d))的平均模量和最高约5.8Gpa(39.6g/d)的平均强度的潜力。这些纤维曾由Brew等，Composites Science and Technology 1999，59，1109；Van der Jagt和Beukers，Polymer 1999，40，1035；Sikkema，Polymer 1998，39，5981；Klopand Lammers，Polymer，1998，39，5987；Hageman等，Polymer 1999，40，1313描述。
就本发明的目的而言，术语“纤维”被定义为相对挠性、宏观上均质的物体，具有高的长度与沿垂直于其长度的横截面的宽度之比。纤维横截面可以是任何形状，但典型的是圆形。这里，术语“长丝”或“连续长丝”与术语“纤维”可互换使用。
这里所使用的术语“短纤维”是指被切断成希望长度的纤维或者天然存在或天然具有低的长度与沿垂直于其长度的横截面的宽度之比(当与长丝相比时)的纤维。长度可从约0.1英寸变化到几英尺。在某些实施方案中，长度从0.1英寸到约8英寸。人造短纤维被切断为适合在棉、毛或精纺纱线的纺纱设备上加工的长度。
短纤维可具有(a)基本均匀的长度，(b)可变或随机的长度，或(c)短纤维的亚组具有基本均匀的长度，而另一些亚组中的短纤维则具有不同长度，其中混合在一起的各亚组中的短纤维形成基本均匀的分布。
在某些实施方案中，合适的短纤维具有1～30cm的长度。由短纤维工艺制造的短纤维得到的纤维长度为1～6cm。
短纤维可由任何方法制造。短纤维可由连续纤维的拉断得到变形横截面的短纤维来形成，所述变形的横截面起到卷曲作用。短纤维可采用旋转切断机或铡刀式切断机由连续直纤维经切断而得到直(即不卷曲的)短纤维，或另外由具有沿短纤维长度的锯齿形卷曲的卷曲连续纤维切断，其中卷曲(或重复的弯曲)频率不大于8个卷曲每厘米。
拉断短纤维可通过在拉断操作期间拉断连续长丝的丝束或捆来制造，该操作具有一个或多个相隔规定距离的拉断区，产生随机变化的纤维团，该纤维团具有通过调节拉断区来控制的平均切断长度。
本发明的短纤维可利用本领域熟知的传统长和短纤维环锭纺纱方法转化为纱线。对于短的短纤维，一般采用3/4英寸到2-1/4英寸(即1.9～5.7cm)的棉系统纺纱纤维长度。对于长的短纤维，一般采用最长6-1/2英寸(即16.5cm)的精纺或粗纺系统纺纱纤维长度。然而，这不拟局限于环锭纺纱，因为纱线也可以采用喷气纺纱、自由端纺纱以及许多其它将短纤维转化为可用纱线的纺纱类型。
拉断的短纤维一般具有最长7英寸(即17.8cm)长的长度，并且可采用传统拉断丝束成毛条短纤维方法制成15。最大长度最长约20英寸(即51cm)的短纤维可通过例如描述在PCT专利申请号WO 0077283中的方法完成。纱线是采用利用喷气的长丝缠结将纤维加固成为纺纱而制备的，其韧度介于3～7gpd范围。这些纱线可具有二次捻度，就是说，它们可在形成之后加捻以便赋予纱线更高的韧度，在此种情况中，韧度可达到10～18gpd(即9～17克/分特)范围。拉断的短纤维一般不要求卷曲，因为该方法赋予纤维一定程度的卷曲。
“非织造”织物指的是网状纤维，包括单向(如果被包含在基质树脂中)、毡子、纤维垫等。
本发明将通过下面的实施例加以举例说明，但不拟用它们限制本发明的范围。
对比例1
在对比例1中，多层机织织物由高韧度660分特聚(对苯二甲酰对苯二胺)连续长丝纱制成，该长丝纱具有1.66分特每根长丝的线密度，织物组织在经纬向均为13.4根/厘米，由E.I.DuPont de Nemours andCompany以商品名Kevlar KM2
Figure S2006800463755D00051
销售。用于该机织织物中的660分特芳族聚酰胺纤维的拉伸强度是25克/分特(g/d)，并且纤维密度是1.44g/cm3。尺寸约15英寸×15英寸的21层织物被沿着边缘并以十字线迹缝合在一起，从而形成总面积密度约3.8kg/m2的复合结构。然后该装配体按照MIL-STD-662E试验标准接受17-格令碎片的测试，获得1750ft/s的V50结果。
实施例1
在本发明的实施例1中，由韧度35gpd、模量2000gpd和纤维密度1.65g/cm3的M5连续长丝纱制备M5纤维的毡子。连续长丝纱首先被卷曲，然后被切断为约5cm长的短纤维。该短纤维随后通过各种不同设备和方法，包括业界熟知的针刺，转化为毡子。M5
Figure S2006800463755D00054
毡子的压实层的面积密度是180g/m2。21层尺寸约15英寸×15英寸的本发明M5毡子被沿着边缘并以十字线迹缝合在一起，从而形成总面积密度约3.8kg/m2的复合结构。然后该装配体按照MIL-STD-662E试验标准接受17-格令碎片的测试。V50结果预期好于如对比例1所述按现有技术采用机织织物制成的。
实施例2
在本发明的实施例2中，由韧度35gpd、模量2000gpd和纤维密度1.65g/cm3的M5连续长丝纱制成M5
Figure S2006800463755D00063
纤维的毡子。连续长丝纱首先被卷曲，然后被切断为约5cm长的短纤维。随后该短纤维通过各种不同设备和方法，包括如实施例所述业界熟知的针刺，转化为毡子，不同的是，M5
Figure S2006800463755D00064
毡子压实层的面积密度是420g/m2。9层尺寸约15英寸×15英寸的本发明M5
Figure S2006800463755D00065
毡子被沿着边缘并以十字线迹缝合在一起，从而形成总面积密度约3.8kg/m2的复合结构。随后，该装配体按照MIL-STD-662E试验标准接受17-格令碎片的测试。V50结果预期好于如对比例1所述按现有技术采用机织织物制成的。
实施例3
在本发明的实施例3中，如实施例1所公开的由韧度35gpd、模量2000gpd和纤维密度1.65g/cm3的M5
Figure S2006800463755D00066
连续长丝纱制成M5
Figure S2006800463755D00067
纤维的毡子。短纤维是通过将连续长丝纱拉断成7和11cm的典型长度而制成的。随后，该短纤维通过各种不同设备和方法，包括业界熟知的针刺，转化为毡子。M5
Figure S2006800463755D00068
毡子压实层的面积密度是180g/m2。21层尺寸约15英寸×15英寸的本发明M5
Figure S2006800463755D00069
毡子被沿着边缘并以十字线迹缝合在一起，从而形成总面积密度约3.8kg/m2的复合结构。然后该装配体按照MIL-STD-662E试验标准接受17-格令碎片的测试。V50结果预期好于如对比例1所述按现有技术采用机织织物制成的。
实施例4
在本发明的实施例4中，如实施例1所公开的由韧度35gpd、模量2000gpd和纤维密度1.65g/cm3的M5
Figure S2006800463755D000610
连续长丝纱制成M5
Figure S2006800463755D000611
纤维的毡子。连续长丝首先被卷曲，随后切断为约5cm长的短纤维。随后，该短纤维通过各种不同设备和方法，包括业界熟知的针刺，转化为毡子。M5
Figure S2006800463755D00071
毡子的压实层的面积密度是180g/m2。11层尺寸约15英寸×15英寸的本发明M5
Figure S2006800463755D00072
毡子与10层对比例1制成的机织织物重叠在一起，并进一步沿着边缘并以十字线迹缝合在一起，从而形成总面积密度约3.8kg/m2的复合结构。然后该装配体按照MIL-STD-662E试验标准接受17-格令碎片的测试。V50结果预期好于如对比例1所述按现有技术采用机织织物制成的。
应该理解，为清楚起见，在本文中在分开的实施方案的上下文中描述的某些特征也可以在单一实施方案中组合提供。反过来，为简化起见，在单一实施方案的上下文中描述的各种特征也可以分开或以任意亚组合的形式提供。

Claims (16)

1.一种经针刺的非织造构造物，包含聚吡啶并唑短纤维；所述短纤维的特征在于：平均长丝韧度为至少15克每旦(gpd)；平均长丝模量为至少500gpd；平均长丝密度为至少1.6g/cc；平均长丝长度为30～100mm；并且平均每根长丝的长丝旦数(dpf)为0.1～10；其中所述构造物基本上不含基质，
其中聚吡啶并唑短纤维具有大于25dl/g的比浓对数粘度。
2.权利要求1的构造物，其中聚吡啶并唑短纤维具有大于28dl/g的比浓对数粘度。
3.权利要求1的构造物，其中聚吡啶并唑是聚[2，6-二咪唑并[4，5-b：4，5-e]-亚吡啶基-1，4(2，5-二羟基)亚苯基]。
4.权利要求1的构造物，还包含数量占全部纤维重量最高15wt％的芳族聚酰胺纤维。
5.权利要求4的构造物，其中芳族聚酰胺纤维是聚(对苯二甲酰对苯二胺)短纤维。
6.一种多层织物，它包含至少一个含有聚吡啶并唑短纤维的经针刺的层；所述短纤维的特征在于：平均长丝韧度为至少15克每旦(gpd)；平均长丝模量为至少500gpd；平均长丝密度为至少1.6g/cc；平均长丝长度为30～100mm；并且平均每根长丝的长丝旦数(dpf)为0.1～10；其中所述层基本上不含基质，其中聚吡啶并唑短纤维具有大于25dl/g的比浓对数粘度。
7.权利要求6的织物，其中聚吡啶并唑短纤维具有大于28dl/g的比浓对数粘度。
8.权利要求6的织物，其中聚吡啶并唑是聚[2，6-二咪唑并[4，5-b：4，5-e]-亚吡啶基-1，4(2，5-二羟基)亚苯基]。
9.权利要求6的织物，还包含数量占全部纤维重量最高15wt％的芳族聚酰胺纤维。
10.权利要求9的织物，其中芳族聚酰胺纤维是聚(对苯二甲酰对苯二胺)短纤维。
11.包含至少一种权利要求1的构造物的防穿透制品。
12.包含权利要求6的织物的防穿透制品。
13.包含至少一种权利要求1的构造物的服装。
14.包含权利要求6的织物的服装。
15.一种制备包含聚吡啶并唑短纤维的织物的方法；所述短纤维的特征在于：平均长丝韧度为至少15克每旦(gpd)；平均长丝模量为至少500gpd；平均长丝密度为至少1.6g/cc；平均长丝长度为30～100mm；并且平均每根长丝的长丝旦数(dpf)为0.1～10；其中所述织物基本上不含基质，其中聚吡啶并唑短纤维具有大于25dl/g的比浓对数粘度；
所述方法包括对聚吡啶并唑短纤维实施针刺加工。
16.权利要求15的方法，其中聚吡啶并唑是聚[2，6-二咪唑并[4，5-b：4，5-e]-亚吡啶基-1，4(2，5-二羟基)亚苯基]。
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