CN101432477A - 各向异性的可伸长非织造布 - Google Patents

各向异性的可伸长非织造布 Download PDF

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CN101432477A
CN101432477A CNA2007800149940A CN200780014994A CN101432477A CN 101432477 A CN101432477 A CN 101432477A CN A2007800149940 A CNA2007800149940 A CN A2007800149940A CN 200780014994 A CN200780014994 A CN 200780014994A CN 101432477 A CN101432477 A CN 101432477A
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weaving cloth
extensible nonwovens
machine direction
fiber
fiber web
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CN101432477B (zh
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K·E·马丁
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Invista Technologies SARL Switzerland
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Abstract

本发明涉及一种非织造织物，该织物中的纤维在铺列时使多数纤维具有基本平行于纵向或与纵向的夹角成+/－45°之内的纤维方向。本发明还涉及一种非织造织物粘结纤网，其粘合点沿垂直于纵向的轴分布的图案的距离间隔大于沿平行于纵向的轴分布的粘合点的距离间隔。所制成的非织造布在纵向具有很低的伸长，在横向只需相对小的力即可被拉伸。

Description

各向异性的可伸长非织造布
技术领域
本发明涉及一种非织造织物，该织物中的纤维沿主要为纵向的取向铺列。所得到的非织造布在纵向具有高拉伸强度和非常低的伸长率，而在横向中具有低的拉伸强度和在非常小的力的作用下能够被拉长。该非织造织物的生产方法中，不需要单独的“紧缩(consolidation)”或“颈缩”步骤即可获得所要求的纤维取向性质。
背景技术
弹力非织造布在卫生行业具有快速的增长。所使用的多数产品要么具有纵向伸长能力，例如Kimberly Clark 
Figure A200780014994D00031
和“Flex-All”产品，要么具有横向伸长能力，例如“Golden Phoenix”或“Tredegar”非织造布-弹性薄膜层压产品。然而，真正多方向弹力非织造布能为卫生用相关产品提供宝贵的功能，同时也能开辟在例如服装用弹力非织造布等领域的新用途。
生产商采用在传统纺粘方法中使用弹性热塑性聚合物来生产多方向全弹力纺粘非织造布。不过，这些产品在具有优异弹性的同时也具有热塑性聚合物特有的令人反感的橡胶一样的手感。据悉，通过后续的“颈缩”或“紧缩”步骤来生产纤维主要朝向纵向取向的非织造布，在非织造布初步生产后，其在上述独立步骤中被沿纵向拉伸。
受让给田纳西州大学的部分相关美国专利包括：
US5441550(颁证日：1995-08-15)；
US 5443606(颁证日：1995-08-25)；
US 5486411(颁证日：1996-01-23)；
US再颁号35206(颁证日：1996-04-16；补发专利公开号US5244482的再颁)；
US 5599366(颁证日：1997-02-04)；
US 5730923(颁证日：1998-03-24)；
US 5747394(颁证日：1998-05-05)；
US 6030906(颁证日：2000-02-29).
由现有技术公开内容明确可知，颈缩或紧缩可以生产至少具有所要求的横向伸长性的非织造布。此横向伸长性是由非织造布生产后的第二个步骤获得的。整个生产程序中此步骤的附加费用使得该产品的生产是一个缺少经济可行性的途径。
发明内容
本发明提供了一种不经过紧缩或颈缩步骤而直接生产的具有横向伸长性的非织造布。
由本发明方法所生产的非织造布在纵向和横向具有显著不同的物理性质，其特征在于此非织造布在横向的断裂伸长率至少为约50％。纵向和横向至少在未断裂时的伸长率具有显著不同的物理性质。
本文一个实施方案提供的非织造布在横向具有约100％至约200％的断裂伸长率。
本文一个实施方案提供的非织造布选自纺粘结构、熔喷结构、机梳热粘合结构、水刺结构。
本发明提供一种生产在纵向和横向具有显著不同的物理性质的非织造布的方法，包括：铺列纤网，随后粘结纤维网(纤网)。该方法在纵向中基本上将非织造布的纤维校直并且粘结所得到的纤维网，使所得到的材料具有横向伸长性，且具有横向和纵向的充分一致性以适合后续印染加工(conversion)步骤。
本发明的一个方面是提供一种生产可伸长非织造布的方法，包括步骤：铺列纤维网和通过选择包括少量粘合点的粘结图案来粘合纤维网，此粘合点沿垂直于纵向的轴的分布，其间距大于沿平行于纵向的轴的分布间距，且粘合点由热能提供。
本发明的另一方面是提供一种生产可伸长非织造布的方法，包括步骤：校直机梳的纤维絮片，以使得多数纤维具有基本平行于纵向或者与纵向成+/-45°之内的夹角，以及粘结纤维网。
定义
以下非限制性定义包含弹力非织造布技术术语的词典。这些定义能引导技术人员对本申请中各种术语有一个清晰、扼要的认知。
Figure A200780014994D00041
位于特拉华州Wilmington，19808，Centreville路2801，3LittleFalls中心的英威达公司(Invista)的注册商标，
Figure A200780014994D00042
纤维设计为黏附而不是针织或编织成型，用于尿布和成人失禁产品。“XA”代表“特粘”或“特粘性”。
分特或旦尼尔有关纱线的密度，线密度。分特是指10000米长的纱线的重量克数。旦尼尔是指9000米长的纱线的重量克数。
非织造织物的纵向轴是指与织物通过机器前进方向平行的方向；在此方向上生产织物。
非织造织物的横轴方向是指与织物生产方向垂直的方向。
紧缩非织造布是指用相对小的力即可在横向(也即“颈”向)拉伸(伸长)的非织造布。通常，紧缩非织造布具有低收缩力和在延伸后的高永久应变(变形)。紧缩非织造布由几乎任何“as made”非织造布经过牵伸方法(例如，“the KimberlyClark”技术)或者牵伸加加热(田纳西大学TANDEC)方法制得。紧缩非织造布通常在纵向中具有高模量和高拉伸强度，例如在未断裂的情况下能够伸长200或250％。
可伸长非织造布是指用相对小的力即可在纵向(加工方向)延伸的非织造布。这样的非织造布可以是紧缩非织造布或“AS MADE”的可伸长非织造布。“As-made”可伸长非织造布具有与紧缩非织造布相似的特性，但是一般具有较低的伸长率，且与特殊颈缩或紧缩方法无关。
各向异性非织造布在纵向和横向具有不同性质(例如，伸长性和拉伸强度)的非织造布。各向异性非织造布是“as-made”可伸长非织造布。
GSM“每平方米克数”是用来衡量单位面积内非织造布重量或密度的常用度量。通常，此范围从低端的纺粘和熔喷非织造布10GSM到100-400GSM的针刺非织造布。例如，“尿布面料(cover stock)”非织造布在15至25GSM。
MDXA代表“纵向XA”，是指
Figure A200780014994D00051
弹性纤维(spandex)层压品，非织造布或
Figure A200780014994D00052
薄膜(例如非织造布/
Figure A200780014994D00053
非织造布)。在拉伸下采用热熔粘合剂粘合到非织造布。该层压品在收缩时形成特有的褶皱状。MDXA家族产品的性质根据
Figure A200780014994D00055
间距、分特以及非织造或薄膜的类型而明显不同。
CDXA(也即是CDXA-1)代表“横向XA”，是指
Figure A200780014994D00056
弹性纤维在非织造布各层间的层压品，其中
Figure A200780014994D00057
纤维采用曲折(“之”)形式放置。当胶粘于某处时
Figure A200780014994D00058
即伸长，且在松弛状态下，产品呈现特有的褶皱状。CDXA产品通常为狭窄的带状，在纵向呈坚挺状，但在横向具有弹性(伸长和恢复)。横向弹性组件用于尿布和成人失禁用品，例如腰带，侧嵌料，弹性尿布挂耳以及封闭带。
CDXA-III(所谓的“型号3”及CDXA后继型)，该产品为浸渍有硬链段和软链段聚氨酯树脂的单层弹性非织造布的胶合品。同一聚合物用于生产
Figure A200780014994D00061
弹性纤维长丝。该具有高收缩力浸渍层压品是通过凝结涂敷方法生产的弹性织造布。浸渍层压品特征在于在纵向坚挺而在横向具有弹性。
EDXA“各向XA”，是指非织造布具有多向(横向和纵向)伸长和恢复性。例如采用热塑性弹性聚合物由德国ADC(Advanced Design Concept股份有限公司)制造的纺粘非织造布。
非织造布生产技术：非织造布生产分为三部分：成网，粘合和整理。
成网可分为：以热塑性聚合物切片开始的“纺熔”方法，“闪纺”非织造布是“纺熔”非织造布的一个溶剂纺形式，“机梳或气流铺网”非织造布以短纤维开始，“纺熔”进一步分为“纺粘”非织造布和“熔喷”非织造布。纺粘非织造布中的纤维熔化纺入气流拉伸器，在其中，通过“气流拉细”方法来拉伸纤维以提高纤维强度，然后将纤维铺列于移动带上。在熔喷方法，聚合物熔体被气流挤入高剪切区，气流将纤维撕裂为小段并在熔融状态下将其拉成非常细的纤度。纺粘法是生产广泛应用在卫生工业(例如，尿布)的结实、耐用的非织造织物的最普遍的非织造方法。熔喷织物一般较脆弱，但是具有很细小且同一的孔径，常被用于过滤方面。
纺粘、熔喷以及闪纺非织造布通常采用热粘合程序加固(consolidated)。复合非织造布，例如SMS或SMMS(纺粘-熔喷-纺粘)也越来越常见。在闪纺非织造布中，聚合物(通常为聚乙烯和聚丙烯或其混合物)在压力下由在压力下降时就立即蒸发的低沸点溶剂溶解，并从喷丝板挤出聚合物溶液。最重要的闪纺非织造布是由特拉华州，Wilmington，E.I.DU PONT公司生产的非织造布。
机梳或气流铺网非织造布通常用传统的机梳或气流铺网方法从短纤维开始形成网，其中单纤维通过气流转化成网，机梳和气流铺网非织造布通过热、化学或机械方式粘合。
“粘网”是将非织造布中纤维粘结在一起的方法。通常有三类粘网形式：“热粘合”是将纤维部分熔融在一起，通常采用具有凸起图案的砑光辊在织物特定点(圆点)处将纤网粘合在一起。“化学(或粘合剂)粘合”是采用树脂或粘合剂将纤维粘合在一起。“机械结网”是通过采用大量的钢针反复穿过织物来缠结纤维，也被认作是针刺而获得的。同样，高压水流喷射来而使纤维缠结，通常被称作水刺或水力缠结非织造布。由特拉华州，Wilmington，E.I.DU PONT公司生产的
Figure A200780014994D00063
水刺非织造布是射流喷网法非织造布的一个实例。与其他非织造布相比，射流喷网法非织造布具有更好的三维空间结构和织物特性，也被认为在非织造布领域中具有最高的品质。
“纤网整理”是指整理或处理，通常采用化合物来赋予非织造布一些特性，通常为亲水性。
附图说明
图1A具有多个结合点20的弹力非织造布10的部分示意图。
图1B具有与纵向(MD)夹角在+/-a之内的纤维200的弹力非织造布100的部分示意图。
图2A本发明中一个生产弹力非织造布的生产过程图。
图2B本发明中另一个生产弹力非织造布的生产过程图。
详细说明
根据本发明，采用纺粘、熔喷和二种方法的混合将例如聚丙烯、聚乙烯、聚酯或聚丙烯-聚乙烯共混物等的纺粘或熔喷硬质纤维制成的轻质层包裹主要(primayr)纺粘弹性非织造布(例如基于EXXON 
Figure A200780014994D00071
弹性聚丙烯)来获得手感似织物的全弹性非织造布。在此过程中，硬质纤维层在纺粘弹性体任一侧上的沉积要粘合的足够薄且足够轻的以不妨碍中间弹性层的强度和恢复性。通过将高质量熔纺弹性体作为主要弹性层来增强弹性非织造布。
根据本发明的另一个方面，提供织物纤维主要朝向纵向取向铺列的非织造织物。制成的非织造布在纵向具有高拉伸强度和很低的伸长率，但是在横向却具有较低拉伸强度且能够被相对小的力拉伸。在生产此非织造布的过程中，所要求的纤维取向性质不需要单独的“紧缩”或“颈缩”步骤即可获得。
在横向和纵向具有显著不同的性质的非织造布意味着所制成的非织造布，即下文中的“可伸长性非织造布”，在纵向严格具有高断裂韧度。同时，该可伸长非织造布在施加相对小的力即可在横向伸长，且不断裂。相对小的力是50％伸长下小于1牛顿的施加力。
通常，非织造布的生产需要注意的是无序化纤维铺列方向以生产具有相似物理性质(模量，伸长率和断裂韧度)的片状结构。然而，可伸长非织造布已经显示对生产各种利用横向性非织造片的材料是有用的。
众所周知，可伸长非织造布具有200％的横向伸长，但是却是采用过去的非织造布转化方法制造。与此技术相关的专利公开受让予TANDEC(田纳西大学非织造布研究中心)、Kimberly Clark和BBA。根据美国再颁专利号35206，通常认作“颈缩”或“紧缩”的方法是以伸长非织造布开始，特别是纺粘非织造布和机梳热粘合非织造布，接着将非织造布在纵向牵伸来将非织造布中的纤维基本按纵向校直以产生所需性质。另外，包括杜邦公司、胜宏公司(Sheng Hung)和BBA等多家厂家所生产的射流喷网(水力缠结)非织造布具有与所要求的“可伸长”非织造布相似的性质，但是伸长一般小于100％。本发明中，可伸长非织造布不需要后成型过程而直接由非织造布成型过程生产，由以下的图2A和图2B示意。
对于基于纤维网的非织造布(图1A)，非织造布的可伸长特性通过以下方式来增强：选择具有少量粘合点20(图1A)的粘结图案，和/或其中粘合点排列成使沿垂直于纵向的轴分布的粘合点20间隔更远，例如具有图1A的间距A，而沿平行于纵向的轴分布的粘合点相对紧密间隔，例如具有图1A的间距B，的粘结图案。通常，粘合点间距符合A>B的关系。更特别的是，粘合点距离选择以达到至少A＝1.1(B)，更通常是A>2(B)。对于纺粘非织造布，粘合点图案通过适当地调整在纤维铺列点上的无序气流喷射，以生产与上述机梳热粘合非织造布一样的纤维铺列，并也使用上述粘结图案。
对于基于机梳网的非织造布(图1B)，校直形成非织造布的机梳毛胎，其方式使得纤维方向基本上平行于纵向或与纵向的夹角在+/-a之内，这里a为45°。如此形成的非织造布的粘合性质通过采用已知粘结手段进行的粘结而增强。
测试方法
断裂伸长测试基于ASTM D 5035-90方法。

Claims (6)

1.一种在纵向和横向上具有显著不同的物理性质的可伸长非织造布，其特征在于所述非织造布具有至少大约50％的横向伸长率。
2.如权利要求1所述可伸长非织造布，其具有大约100-大约200％的横向伸长率。
3.如权利要求1所述可伸长非织造布，其选自纺粘、熔喷、机梳热粘合以及射流喷网法结构。
4.一种生产可伸长非织造布的方法，包括步骤：铺列纤维网和通过选择的包含多个粘合点的粘结图案粘结该网，其中沿垂直于纵向的轴分布的粘合点距离间隔大于沿平行于纵向的轴分布的粘合点的距离间隔，且粘合点由热能提供。
5.一种生产可伸长非织造布的方法，包括步骤：校直纤维机梳毛胎使得多数纤维具有基本平行于纵向或处于纵向成+/-45°之内夹角的纤维方向和粘结该纤维网。
6.一种生产可伸长非织造布的方法，包括步骤：使用无序气流喷射铺列纤维网，使得多数纤维具有基本平行于纵向或与纵向的成+/-45°之内夹角的纤维方向和粘结该纤维网。
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CN113179628A (zh) * 2018-11-30 2021-07-27 金伯利-克拉克环球有限公司 三维非织造材料及其制造方法
CN113179628B (zh) * 2018-11-30 2023-02-28 金伯利-克拉克环球有限公司 三维非织造材料及其制造方法
CN115262093A (zh) * 2022-09-25 2022-11-01 苏州多瑈新材料科技有限公司 一种定向弹性非织造材料、制备方法及弹性制品

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US20070254545A1 (en) 2007-11-01
KR101497711B1 (ko) 2015-03-03
EP2010704B1 (en) 2013-12-25
WO2007127442A2 (en) 2007-11-08
CN101432477B (zh) 2013-11-20
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