CN101563485A - 电吹制多层片材的方法 - Google Patents

电吹制多层片材的方法 Download PDF

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CN101563485A
CN101563485A CNA2007800467661A CN200780046766A CN101563485A CN 101563485 A CN101563485 A CN 101563485A CN A2007800467661 A CNA2007800467661 A CN A2007800467661A CN 200780046766 A CN200780046766 A CN 200780046766A CN 101563485 A CN101563485 A CN 101563485A
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J·B·霍瓦内克
M·J·老穆尔
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DuPont Safety and Construction Inc
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Abstract

本发明公开了一种电吹制多层片材的方法，所述方法采用多个纺丝箱体来制备不同组成的纤维网，其中所述片材不会粘附到所述成形筛网上，并具有改善的纤维网稳定性。

Description

电吹制多层片材的方法
发明领域
本发明涉及电吹制多层片材的改进。
发明背景
由纤维制成的织物和纤维网可用于多种客户最终应用，例如过滤介质、能量存储器隔膜、防护服等。制备这类纤维网的一种方法是电吹制，其中聚合物溶液在存在静电场的情况下通过喷嘴进行纺丝并且喷吹或推进流体以蒸发溶剂，从而形成收集在筛网上的纤维。通常，并非所有的溶剂都在沉积期间从纤维中移除，从而需要附加的溶剂移除处理。然而，如果在筛网上纤维沉积期间遗留在纤维中的溶剂太多，则纤维网会粘附到筛网上，从而在将纤维网从筛网上移除时会导致纤维网破损。另外，如果在筛网上纤维沉积期间遗留在纤维中的溶剂太少，则纤维网不会表现出足够的有利于表面稳定性以允许对纤维网进行处理的粘着性。
需要的是一种电吹制片材结构的方法，该片材结构可从收集筛网上移除，同时具有便于处理的足够的表面稳定性。
发明概述
本发明涉及电吹制多层片材的方法，该方法包括：在存在推进气体和电场的情况下，通过包括线性排列的纺丝喷嘴的至少两个纺丝箱体对包含溶解在溶剂中的聚合物的导电液体流进行纺丝以形成纤维，并且将该纤维沉积在收集筛网上，其中：(a)第一纺丝箱体提供沉积在收集筛网上的、具有约0至约30重量％溶剂浓度以制备第一纤维网的纤维；并且(b)第二纺丝箱体提供沉积在第一纤维网上的、具有约30至约70重量％溶剂浓度以制备第二纤维网的纤维，其中纤维网之间的溶剂浓度差值为至少约10重量％。
发明详述
本发明涉及由纤维网制成的多层片材的改进，该纤维网采用相应于美国专利申请10/477,882的世界专利公开WO 03/080905中描述的电吹制法制备，该专利全文以引用方式并入本文。
该电吹制法包括：将包含聚合物和溶剂的聚合物溶液流从储罐喂入喷丝头内的一系列纺丝喷嘴，向喷丝头施加高电压并且聚合物溶液从其通过而排出。同时，任选加热的压缩空气由空气喷嘴排出，该空气喷嘴设置在纺丝喷嘴的侧面或周边。通常向下引导空气，以形成吹气流，吹气流包裹住新排出的聚合物溶液并使其向前，并且帮助形成纤维网，纤维网收集于真空室上方的接地多孔收集筛网上。
聚合物溶液可与添加剂混合，添加剂包括与相关聚合物相容的任何树脂、增塑剂、紫外线稳定剂、交联剂、固化剂、反应引发剂等。虽然溶解大多数的聚合物可以不需要任何具体的温度范围，但是可能需要加热以有助于溶解反应。
已经发现，在根据该电吹制法制备纤维网时，如果纤维网在沉积到收集筛网期间包含具有太多溶剂的纤维，则纤维网会粘附到筛网上，从而导致在将纤维网从筛网上移除后损坏纤维网。如果沉积期间纤维网具有约0至约30重量％的溶剂浓度，则该粘附问题就可避免。
还发现，在根据该电吹制法制备纤维网时，如果纤维网在沉积到收集筛网期间包含具有太少溶剂的纤维，则纤维将不具有足以使其互相粘附以形成足够的表面稳定性从而防止处理纤维网时纤维受损的粘着性。如果沉积期间纤维网具有约30至约70重量％的溶剂浓度，则表面稳定性则可改善。
根据本发明的多层片材可通过使低溶剂浓度含量的纤维网与高浓度溶剂含量的纤维网相结合来制备，这种方法不会使纤维网粘附到收集筛网上，同时会形成有利于纤维网处理的足够的表面稳定性。多层片材可通过以下方法制备：通过第一纺丝箱体(其形成沉积在收集筛网上的、具有约0至约30重量％溶剂浓度以制备第一纤维网的纤维)和第二纺丝箱体(其形成沉积在第一纤维网上的、具有约30至约70重量％溶剂浓度以制备第二纤维网的纤维)对聚合物溶液进行纺丝，其中纤维网之间的溶剂浓度差值为至少约10重量％。
制备在沉积期间具有不同溶剂浓度的纤维网的一种方法是：控制从纺丝箱体出来的聚合物溶液的液体流通量。第一纤维网可通过对来自纺丝箱体的纤维进行纺丝来制备，该纺丝箱体具有每喷嘴约0.5至约2.0立方厘米/孔/分钟的液体流通量。第二纤维网可通过对来自纺丝箱体的纤维进行纺丝来制备，该纺丝箱体具有每喷嘴约2.0至约4.0立方厘米/孔/分钟的液体流通量。这两种液体流之间的通量差值为至少约1立方厘米/孔/分钟。
制备在沉积期间具有不同溶剂浓度的纤维网的另一种方法为控制推进气体的温度。第一纤维网可通过对具有第一推进气体的纤维进行纺丝来制备，该第一推进气体具有约50℃至约150℃的温度。第二纤维网可通过对具有第二推进气体的纤维进行纺丝来制备，该第二推进气体具有约25℃至约50℃的温度。所述推进气体之间温度的差值为至少约25℃。
在沉积期间可用来独立地控制从每个纺丝箱体纺成的纤维以获得所需程度的溶剂含量的可供选择的工艺变量包括纺丝仓温度和纺丝模具到收集器或纺丝箱体到收集筛网的距离。
可在该方法中添加附加的纺丝箱体以将附加的纤维网沉积在第一和第二纤维网之间、沉积在在第二纤维网上、或两者的组合。
该方法还包括根据最终用途将已收集的纤维网中的溶剂移除至所需的溶剂含量。
优选的聚合物/溶剂组合为溶解在甲酸中以制备聚酰胺多层片材的聚酰胺。
测试方法
纤维网中的溶剂含量的测量方法如下：首先对制备出的纤维网称重，然后干燥纤维网并对纤维网重新称重，之后用下式进行计算：
Figure A20078004676600061
实施例
在下文中将采用以下实施例对本发明进行更详细的描述。
用于制备本发明的多层片材的纤维网可采用相应于美国专利申请10/477,882的世界专利公开WO 2003/080905中描述的电吹制法来制备，该专利全文以引用方式并入本文。
比较实施例A
由溶解在纯度为99％的甲酸(得自Kemira Oyj，Helsinki，Finland)中的浓度为24重量％的尼龙6，6聚合物
Figure A20078004676600062
FE3218(得自E.I.du Pont de Nemours and Company，Wilmington，Delaware)聚合物溶液来制备纤维网。在室温下，使用温度为约50℃的吹气流并且在纺丝箱体和收集器之间的电势差为50kV的情况下对聚合物溶液进行静电纺丝。纺丝箱体具有约4.0立方厘米/孔/分钟的聚合物溶液通量，由此形成纤维，所述纤维收集在筛网上以形成甲酸含量为约60％的纤维网。纤维网粘附到收集筛网上，从而导致在将其移除时纤维网受损。
比较实施例B
以类似于比较实施例A的方法来制备另一种纤维网，不同的是纺丝箱体具有约1.0立方厘米/孔/分钟的聚合物溶液通量，由此形成纤维，所述纤维收集在筛网上以形成甲酸含量为约25％的纤维网。在移除纤维网时，纤维网不会粘附到收集筛网上。然而，该纤维网的表面稳定性不足以防止处理时纤维网受损。
实施例1
以特定的顺序结合比较实施例A和B来制备根据本发明的多层片材。如在比较实施例B中所述，第一纺丝箱体具有约1.0立方厘米/孔/分钟的聚合物溶液通量，由此形成纤维，所述纤维收集在筛网上以形成甲酸含量为约25％的第一纤维网。如在比较实施例A中所述，第二纺丝箱体具有约4.0立方厘米/孔/分钟的聚合物溶液通量，由此形成纤维，所述纤维收集在第一纤维网的顶部以形成甲酸含量为约60％的第二纤维网。这两种纤维网形成了多层片材。将该片材从筛网上移除，它未粘附到筛网上。此外，第二纤维网的附加粘着性有助于固定片材，同时使其具有良好的表面稳定性以允许对纤维网进行处理。对多层片材进行溶剂反萃取以移除残余的甲酸。

Claims (6)

1.电吹制多层片材的方法，所述方法包括：在存在推进气体和电场的情况下，通过包括线性排列的纺丝喷嘴的至少两个纺丝箱体对包含溶解在溶剂中的聚合物的导电液体流进行纺丝以形成纤维，并将所述纤维沉积在收集筛网上，其中：
(a)第一纺丝箱体提供沉积在所述收集筛网上的、具有约0至约30重量％溶剂浓度以制备第一纤维网的纤维；并且
(b)第二纺丝箱体提供沉积在所述第一纤维网上的、具有约30至约70重量％溶剂浓度以制备第二纤维网的纤维，其中所述纤维网之间的溶剂浓度差值为至少10重量％。
2.权利要求1的方法，所述方法还包括：
(c)一个或多个附加的纺丝箱体，所述一个或多个附加的纺丝箱体提供沉积在所述第一和第二纤维网之间、沉积在在所述第二纤维网上、或两者的组合的纤维，从而构成一个或多个附加的纤维网。
3.权利要求1的方法，所述方法还包括将所述溶剂从所述已收集的纤维上移除。
4.权利要求1的方法，其中所述第一纺丝箱体具有每喷嘴约0.5至约2.0立方厘米/孔/分钟的液体流通量，并且所述第二纺丝箱体具有每喷嘴约2.0至约4.0立方厘米/孔/分钟的液体流通量，其中所述液体流之间的通量差值为至少约1立方厘米/孔/分钟。
5.权利要求1的方法，其中所述第一纺丝箱体具有温度为约50℃至约150℃的第一推进气体，并且所述第二纺丝箱体具有温度为约25℃至约50℃的第二推进气体，其中所述推进气体之间的温度差值为至少约25℃。
6.权利要求1的方法，其中所述聚合物为聚酰胺，并且所述溶剂为甲酸。
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