CN1014331B - 高柔软性聚烯烃纺粘型非织造织物 - Google Patents

高柔软性聚烯烃纺粘型非织造织物

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CN1014331B
CN1014331B CN87106614A CN87106614A CN1014331B CN 1014331 B CN1014331 B CN 1014331B CN 87106614 A CN87106614 A CN 87106614A CN 87106614 A CN87106614 A CN 87106614A CN 1014331 B CN1014331 B CN 1014331B
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supatex fabric
machine direction
fabric
directional
polyolefin
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CN87106614A (zh
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小林是则
田村尚之
境孝信
吉田好典
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Mitsui Chemical Industry Co Ltd
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Mitsui Petrochemical Industries Ltd
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Abstract

本发明为高柔软性聚烯烃纺粘型非织造织物，本发明聚烯烃纺粘型非织造织物定义为(A)由细度为0.5-3旦的连续聚烯烃纤维制成，(B)其基本重量为18.5-35.0g/m2，和(c)＝1.4-2.5g，其中SMD和STD分别为手感测定器在机器和横截方向上测得的柔软度。

Description

本发明涉及由聚烯烃制成的高柔软性纺粘型非织造织物。
纺粘型非织造织物已作成各成日用品或作为工业原料而得到广泛应用，因为与其它干法或湿法粘合的非织造织物比起来，其机械性能如抗拉强度等比较好，这又是由于这些织物是用连续纤维制成的。
在市售的各种纺粘型非织造织物中，以聚酰胺如尼龙或聚酯如对苯二酸一乙二醇缩聚物等的柔软度相当高。因此，近来人们已试图将其用作与人体直接接触的材料如尿布的用可弃层或表层。
然而，以聚烯烃制成的纺粘型非织造织物，尽管具有优异的防水和防化学侵蚀并且价廉等优点，但并不象以其它材料制成的类似织物那么软，因此其应用仅限于某些特殊领域，例如土木工程中用作排水材料，农田中用作覆盖材料以及用在其它特定领域如用作地毯基层。当然，聚烯烃纺粘型非织造织物材料在上述领域如作为用可弃尿布表层的应用在不断增长，因为除柔软度而外的其它性能均优于其它纺粘型非织造织物。若能提高其柔软度再加上许多其它优良性能，那么其应用范围可望在将来进一步扩大。
因此，本发明目的是提供高柔软性聚烯烃纺粘型非织造织物，其柔软度高，机械强度好，而且，其手感好，但强度高。
当用非织造织物作纸尿布的表层时，要求具有优良的机械强度如具有 优良的耐磨性。但对柔软性高耐磨性好的非织造织物来说，这是很难达到的。换句话说，如生产过程中进行轧花处理以使其具有耐磨性，则根据其轧花程度而使其变得耐磨，但同时也使其柔软性相应降低。
为使非织造织物柔软，将其进行起绉工艺处理。
当非织造织物由滚筒等向前导送过程中由压载体从上往下压时，非织造织物表层向前导送的速度大于其深层部分向前导送的速度快，这是由织物与压载体接触时产生的摩擦阻力造成的。进行起绉工艺的原理就是借助这种速度上的差异而使非织造织物产生绉纹。
但是，如起绉工艺中压载体向非织造织物施加过大的压力或非织造织物向前导送的速度太快，则纤维可能因工艺中产生的摩擦热而熔化或产生裂缝或与产生飞花时形成的外来物质掺混或产生静电或产生飞花，从而使起绉操作难于加快速度。
因此，本发明一方面提供高柔软性聚烯烃纺粘型非织造织物，其特征是，该织物定义为（A）由细度为0.5～3旦的连续聚烯烃纤维制成，（B）其基本重量为30～15g/m2，和（C）其
Figure 87106614_IMG3
＝2.5g或更低，其中SMD和STD分别为手感测定器在机器和横截方向上测得的柔软度，其最后的基本重量为30g/m2或更低，此基本重量是在机器方向上让纤维网形成波纹状绉纹而提供给非织造织物的，纤维网是在机器方向上将细度为0.5-3旦的聚烯烃连续纤维的轴取向形成的，该纤维网的径向取向因子（机器方向上可加的最大抗拉载荷/横截方向上可加的最大抗拉载荷）为3.0或更高且其基本重量为29g/m2或更低。
图1为本发明纺粘型非织造织物生产设备一实施例的投影图;
图2为生产本发明纺粘型非织造织物所用起绉机的截面图;
图3表明本发明所用起绉机的另一实施例，和
图4为经向取向因子和横截向柔软度的关系图。
本发明聚烯烃纺粘型非织造织物由聚烯烃连续纤维制成，该纤维细度为0.5～3旦更优选为1～2.5旦。如纤维细度低于此范围，则所得非织造织物的强度不够高，而高于此范围的纤维细度又不可能保证所得织物具有足够的柔软度。
制成连续纤维的聚烯烃包括：乙烯，丙烯，1-丁烯，3-甲基-1-丁烯，3-甲基-1-戊烯，4-甲基-1-戊烯，1-庚烯，1-己烯，1-辛烯或1-癸烯等α-烯烃的聚合物或共聚物;上述任何α-烯烃和不饱和羧酸如马来酸或Nadic酸，任何不饱和羧酸酯或不饱和羧酸基团如酐的共聚物;以及上述物质的混合物;主要由上述任何物质构成并混入少量其它聚合物的聚烯烃也可用作本发明的聚烯烃。
本发明非织造织物的基本重量为30g/m2或更低更优选为26g/m2或更低，而为了保证足够的强度和不透明度，将下限定为15g/m2。将由上述细度范围的纤维制成的非织造织物的基本重量定为30～15g/m2的任何值均可生产出柔软度高机械强度好的非织造织物。
本发明非织造织物机器方向上可经受高达4kg/5cm宽度或更高优选是高达5kg/5cm宽度或更高的抗拉强度，而横截方向上可经受高达0.5kg/5cm宽度或更高优选是高达0.8kg/5cm宽度的抗拉强度。抗拉强度定在此范围的非织造织物可同时达到足够的柔软度和抗拉强度。
这里所用“机器方向”和“横截方向”分别表示生产过程中非织造织物的导送方向和此非织造织物导送方向的垂直方向。
SMD（g）和STD（g）分别表示由手感测定器在机器和横截方向上测得的非织造织物柔软度，优选的是分别为4.5或更低和2.5或更低，其中
Figure 87106614_IMG4
则为2.5g或更低，这证明本发明非织造织物是高柔软性的。
以上定义的本发明高柔软性非织造织物的生产方法如下：有目的地在机器方向上将长丝取向以制成粗坯非织造织物，然后将此粗坯非织造织物起绉而使其在机器方向上形成皱纹状绉纹。
在机器方向上将长丝取向可生产出横截方向上柔软性高的非织造织物，但这样得到的非织造织物在机器方向上的柔软性却不够高，因此需进行起绉工艺处理而使其在机器方向上形成皱纹状绉纹以提高该方向上的柔软性。
在机器方向上将长丝取向而使其在横截方向上变软的非织造织物可用已知技术制得。
更具体地说，已知在机器方向上将长丝强制取向以改善该方向上撕裂敏感性的技术，其中如图1所示将熔化聚合物用喷嘴1挤出而抽成长丝。然后用从吸气管3中吸入的空气流将长丝集束到传送表面4上。当长丝落到传送表面4上时，这些长丝于其导送方向上取向以制成符合本发明要求的粗坯非织造织物。本发明可用的此粗坯织物也可由日本特许公告24991/1972所述方法制得，其中要适当调整长丝的移送速度和凝集面移动的速度。日本特许公开112273/1979和70060/1986也提出了在机器方向上将长丝取向而生产纺粘型非织造织物的技术。
这里所用的“在其导送方向将长丝取向”意为让长丝的轴指向其导送方向，其中除了让长丝的轴排列到平行于其导送方向的方向上而外，还包括使长丝相互绞结到一定程度并相对倾斜于其导送方向但整个仍指向其导送方向。
如果按照任何已知技术将长丝的轴在其导送方向上进行取向，则所得 非织造织物在横截方向上的柔软度高但机器方向上的柔软度低。这种使非织造织物在机器方向上的柔软度变低的倾向随长丝取向程度的提高而增大。还有，随着取向程度的提高，在机器和横截方向上可加给非织造织物而又不使其断裂的抗拉载荷就变得不平衡。具体说来，在机器方向上可加的抗拉载荷增大而在横截方向上可加的抗拉载荷减小。因此，若以织物成型和耐用的水准以及所用生产设备能力的观点来平衡非织造织物的强度，那么提高横截方向上柔软度的能力就会受到限制。一般来说，可加给非织造织物的柔软度最低下限为STD≥1.0g。这时，机器方向上的柔软度SMD自然就是4.5或更高而且基本上是5g或更高。机器方向上可加的抗拉载荷高达4kg/5cm宽度或更高而且基本上高达6kg/5cm宽度或更高，而横截方向上可加的抗拉载荷高达0.5kg/5cm宽度或更高而且基本上高达1kg/5cm宽度或更高。
如果长丝在机器方向上的取向程度用经向取向因子（如机器方向为长丝导送方向的话，其定义为“在机器方向上可加给长丝而又不使其断裂的最大抗拉强度/在横截方向上可加给长丝的最大抗拉强度）来表示，则本发明制成纤维网的经向取向因子为3.0或更高，因为长丝在机器方向上取向制成的纤维网在横截方向上的柔软度高，这种符合要求的柔软度是将经向取向因子定为3.0或更高来加以保证的（见图4）。
为了使粗坯非织造织物在机器方向上变得柔软，需将其进行起绉工艺处理以使其在机器方向上形成波纹状绉纹。这里所用的“在机器方向上形成波纹状绉纹”意指在上述定义的机器方向上（长丝导送方向上）生成绉纹波而取代该方向的垂直方向上的绉纹波。将粗坯非织造织物起绉是按已知技术进行的，例如将由滚筒6传送的粗坯非织造织物5的上表面压在具有粗砂低状表面并构成压载体8的压板7上，致使非织造织物在其导送方向即机器方向上因受压产生摩擦力而形成波纹状绉纹。
可将润滑剂涂于与压载体8接触的接触部位上游的一部分非织造织物 上。
涂了润滑剂之后可降低摩擦阻力并因此而限制了摩擦生热。
非织造织物表面不会因该织物的起绉工艺而损坏。起绉工艺还使该非织造织物的导送速度增大，从而提高了生产率。
施涂润滑剂可用喷涂方法进行，其中如图2所示用喷枪9喷涂润滑剂;用浸涂方法进行，其中如图3所示将非织造织物5导入贮槽10以将其浸入其中的润滑剂中或用凹版涂层法进行（未示出），其中用蚀刻辊将贮槽中的润滑剂涂在非织造织物上。
所用润滑剂可减小非织造织物的摩擦阻力而又不会影响其性能，可采用水，表面活性剂水溶液或防水剂水溶液等以及涂层后可减小非织造织物的摩擦阻力并提高其性能的润滑剂。
若采用非织造织物改性剂如表面活性剂作润滑剂，则可将其均匀地涂于压载体所覆盖的整个非织造织物表面以使其得到均匀改性。
润滑剂必须以适当的用量涂于非织造织物上，因为过量涂层会使非织造织物滑动并阻止其起绉。一般来说，涂层量为0.1～1g/cm2，当然所用润滑剂的准确用量还要随纤维的类型，非织造织物的基本重量或其导送速度而变化。
起绉工艺给非织造织物横截方向带来的柔软程度要随所进行的起绉程度而变化。但是，从所用设备的生产率和生产能力观点来看还需对起绉程度加以限制。若需使最后的柔软度值达到SMD≤4.5g且
Figure 87106614_IMG5
≤2.5g，则起绉优选采用4.5＜SMD≤7g且2.5＜
Figure 87106614_IMG6
≤3.5g的粗坯非织造织物。
起绉工艺可使粗坯非织造织物在横截方向以及机器方向上均变得稍为柔软。若横截方向上的目的柔软度要达到2.5g或更低，则可采用STD为2.8g的非织造织物，这可使所得非织造织物的最后柔软度达到2.5g。
起绉工艺会影响可加给非织造织物而又不使其断裂的最大抗拉强度，即起绉趋于减小该强度。因此，若最后的目的最大抗拉强度要在机器方向 上达到4kg/5cm宽度或更高并在横截方向上达到0.5kg/5cm宽度或更高，则安全的作法是将粗坯非织造织物的最大抗拉强度在机器方向上定为5kg/5cm宽度或更高优选为5.5kg/5cm或更高并在横截方向上定为0.6kg/5cm宽度或更高优选为0.8kg/5cm宽度或更高。
起绉工艺还会影响基本重量，因此安全的作法是采用其基本重量比最终产品的基本重量低1g/m2或更低优选是低2g/m2或更低的粗坯非织造织物。
这样制得的高柔软性非织造织物可再进行已知的加工处理如进行轧花或针刺工艺处理或将其涂上亲水试剂或疏水试剂。
若用本发明非织造织物进行轧花处理，则在起绉之前用凹凸轧花机对纤维网进行轧花工艺处理。若纤维网进行了上述工艺处理，那么即使进行轧花工艺处理也不会降低其柔软度。
以下说明本发明试验例。
试验例1～16
使聚丙烯长丝任意指向并以纺粘法制成非织造织物（对比例1），且在其导送方向上（机器方向上）将聚丙烯长丝取向并采用纺粘法制成非织造织物（实施例2～16）。对每一例的各种性能进行测定。机器和横截方向上织物的柔软度用手感测定器测得。
表1表明了测定结果，从中可看出，若纤维的轴在机器方向取向，则所得非织造织物在横截方向上要比使长丝任意指向制成的非织造织物柔软。但是，这种非织造织物在机器方向上基本上没有柔软性。
然后，将非织造织物进行起绉工艺处理以使其在机器方向上绉成波纹状并测定这样得到的非织造织物的各种性能。
表1表明了测定结果。
试验例7～16表明符合本发明要求的非织造织物。
此外，图4作为经向取向因子和起绉非织造织物的横截方向柔软度的 关系图也证明试验例7～16取得了好结果。
然后，向用纺粘法制成的聚丙烯非织造织物（基本重量为25g/cm）上喷水之后用起绉机起绉。这时，改变喷水量和非织造织物导送速度等因素，这样就可对起绉前后每一非织造织物的表面状况，产生飞花状况以及柔软度从感官上进行评价。表2表明了试验结果。
表中将产生飞花水平分为5级，分别是1（非常多），2（多），3（一些），4（少许）和5（非常少）。柔软度分为4级，分别是1（纤维基本上熔化并成为脆性片状材料），2（纤维部分熔化，某些部位出现孔并使纤维变脆），3（有一些纤维部分熔化并变得稍为粗糙）和4（纤维非常软）。
从表中可看出，若在非织造织物起绉时已向该织物喷洒过水，则加快此非织造织物的导送速度也不会在所得的非织造织物的表面上引起异常现象。但若不喷洒水并加速导送非织造织物，则会使所得的非织造织物的表面熔化或产生大量飞花。而喷洒过量的水又会在起绉机内引起非织造织物滑动，致使非织造织物起绉困难并因而难于使非织造织物变得更柔软。
Figure 87106614_IMG7

Claims (3)

1、高柔软性聚烯烃纺粘型非织造织物，其特征是，该织物定义为(A)由细度为0.5-3旦的连续聚烯烃纤维制成，(B)其基本重量为18.5-35.0g/m2，和(c) =1.4-2.5g，其中SMD和STD分别为手感测定器在机器和横截方向上测得的柔软度，并且在机器方向上让纤维网形成波纹状绉纹，纤维网是在机器方向上将细度为0.5-3旦的聚烯烃连续纤维的轴取向形成的，该纤维网的径向取向因子(机器方向上可加的最大抗拉载荷/横截方向上可加的最大抗拉载荷)为3.0-7.5。
2、按权利要求1的高柔软性聚烯烃纺粘型非织造织物，其特征是所说织物在机器方向上的最大抗拉强度为5.0-13.3kg/5cm宽度，而横截方向上的最大抗拉强度为0.9-4.6kg/5cm宽度。
3、按权利要求1的高柔软性聚烯烃纺粘型非织造织物，其特征是所说聚烯烃为：乙烯、丙烯、1-丁烯、3-甲基-1-丁烯，3-甲基-1-戊烯、4-甲基-1-戊烯，1-庚烯，1-己烯，1-辛烯或1-癸烯等α-烯烃的聚合物或共聚物;上述任何α-烯烃和不饱和羧酸如马来酸或Nadic酸，任何不饱和羧酸酯或不饱和羧酸基团如酐的共聚物;以及上述物质的混合物;任何这样制得并混有少量其它聚合物的聚烯烃。
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