CN101619521A - 非织造纤维多层织物和用于生产该织物的方法及设备 - Google Patents

非织造纤维多层织物和用于生产该织物的方法及设备 Download PDF

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Publication number
CN101619521A
CN101619521A CN200910149582A CN200910149582A CN101619521A CN 101619521 A CN101619521 A CN 101619521A CN 200910149582 A CN200910149582 A CN 200910149582A CN 200910149582 A CN200910149582 A CN 200910149582A CN 101619521 A CN101619521 A CN 101619521A
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Prior art keywords
tissue layer
roller
fiber web
pair
fabric
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CN200910149582A
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CN101619521B (zh
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延斯·奥勒·布勒克纳·安德森
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Oerlikon Textile GmbH and Co KG
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Oerlikon Textile GmbH and Co KG
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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
    • D04H1/54—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 by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—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 by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
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    • B32B2432/00—Cleaning articles, e.g. mops, wipes

Abstract

非织造纤维多层织物和用于生产该织物的方法及设备，织物包括：由纤维素纤维和合成纤维的混合物组成的第一织物层；由纤维素纤维和超吸收性粉末的混合物组成的第二织物层；仅由纤维素纤维组成的第三织物层。设备包括：环形金属丝筛网；在筛网上形成第一织物层的第一干法成形工段；对第一织物层进行压缩的第一对罗拉；在第一织物层的顶面上形成第二织物层的第二干法成形工段；在罗拉之间对织物层进行压缩以形成粘合的纤维网的第二对罗拉；乳胶施加工段；加热工段；加湿工段；在第三织物层一侧上对纤维网进行压花的第三对罗拉；和冷却工段。能通过简单且功能有效的方法和设备以低成本获得具有优异的强度、吸收性和耐用性的非织造纤维多层织物。

Description

非织造纤维多层织物和用于生产该织物的方法及设备
技术领域
本发明涉及用于生产由织物层组成的非织造纤维多层织物的方法，所述织物层干法成形在可移动的支撑物上。
背景技术
非织造织物广泛应用于许多应用场合，例如卫生巾和擦拭布。
市场要求织物应具有如强度、吸收性和耐用性等品质，并且该织物的价格还应具有竞争力，因为这类织物通常在它们被丢弃之前仅使用了一次或几次。
通过使织物包含不同的纤维和材料来获得非织造纤维多层织物的预期属性。
因此，适合多种应用场合的公知的织物包括：由纤维素纤维和合成纤维的混合物组成的第一织物层、由纤维素纤维和超吸收性粉末的混合物组成的第二织物层，以及仅由纤维素纤维组成的第三织物层。
该公知的织物通常以如下工艺生产：三个织物层被接连地气流成网在环形的金属丝筛网上，其中第一织物层在最上面而第三织物层在最下面。
在该工艺中，在将第二织物层和第一织物层接连地气流成网到第三织物层上之前，在第一对罗拉之间对第三织物层进行压缩。第三织物层在第一对罗拉之间的压缩导致所述织物层的纤维素纤维之间产生氢键。
这些织物层随即在第二对罗拉之间被校准以形成粘合的纤维网，然后该纤维网的底侧通过在80-180℃之间的温度下穿过第三对罗拉而被压花。该罗拉在第一织物层一侧上的温度低于合成纤维的熔点。
随后该纤维网受到进一步的处理，其中可能涉及到加湿、乳胶施加和加热。
对纤维网的加热使得在第一织物层的合成纤维之间形成热粘合，还导致水分蒸发，由此使纤维素纤维之间的氢键断裂。
纤维素纤维之间的氢键通过对纤维网再次进行加湿并然后在第四对罗拉之间校准该纤维网而重建。
然而，一个严重的问题在于：当在第二对罗拉之间进行校准时，第二织物层的超吸收性粉末趋于被挤出纤维网，由此可能污染金属丝，从而使设备无法再正常运行。因此，在该阶段，对纤维网的压缩需要轻微地进行。
由于纤维网仅被轻微压缩，超吸收性粉末将容易在后续的压花加工中被挤出纤维网。那么该超吸收性粉末将粘附到罗拉上并使得不适合使用该压花罗拉来压花，在此之后不再发生纤维网的压花。
对纤维网的压花是在被置于纤维网的底侧上的第三织物层上实施的。该第三织物层的纤维素纤维在此阶段尚未覆盖有例如为乳胶的层。该层仅在工艺的后期阶段才被施加。
缺少覆盖层的后果就是：在压花过程中会产生污染环境的灰尘。
另外的问题在于，该工艺的执行成本高，并且用于执行该工艺的设备复杂且昂贵。
发明内容
根据本发明，通过如下方面克服了前述现有技术中的用于生产非织造纤维多层织物的方法的缺点：
在本发明的第一方面，提供了一种能够通过其廉价地生产出非织造纤维多层织物的方法。
在本发明的第二方面，提供了一种能够通过其生产出牢固的非织造纤维多层织物的方法。
在本发明的第三方面，提供了一种能够通过其生产出具有优异的吸收性能的非织造纤维多层织物的方法。
在本发明的第四方面，提供了一种能够通过其安全而准确地执行对非织造纤维多层织物的压花的方法。
在本发明的第五方面，提供了一种能够通过其生产出无尘的非织造纤维多层织物的方法。
在根据本发明的第六方面，提供了一种便宜的非织造纤维多层织物。
在根据本发明的第七方面，提供了一种便宜的压花非织造纤维多层织物。
在根据本发明的第八方面，提供了一种简单、便宜且功能有效的设备用于生产便宜的压花非织造纤维多层织物。
在根据本发明的第九方面，提供了一种简单、便宜且功能有效的设备用于生产便宜的非织造纤维多层织物，通过该非织造纤维多层织物能够压花出无尘织物。
本发明由此获得的新颖独特的特征在于，用于生产非织造纤维多层织物的方法包括以下步骤：形成第一织物层；在第一对罗拉之间对该第一织物层进行压缩；在该第一织物层的顶面上形成第二织物层；在第二对罗拉之间对所述织物层进行压缩以形成粘合的纤维网；在该纤维网的顶面上施加乳胶层；加热纤维网；加湿纤维网；在第三对罗拉之间对所述纤维网进行压花；和冷却该纤维网。
该方法是节省成本的，因为其工艺包含了比现有技术中的同类方法明显更少的生产步骤。
根据本发明，所述方法能够用于在环形金属丝筛网上形成由两个或更多个织物层组成的非织造纤维多层织物，由此获得有效生产。
在根据本发明的一个有利的实施例中，该非织造纤维多层织物能够形成有：由纤维素纤维和合成纤维的混合物组成的第一织物层、由纤维素纤维和超吸收性粉末的混合物组成的第二织物层，以及仅由纤维素纤维组成的第三织物层。
根据本发明，能够在第一对罗拉之间以高到足以使纤维素纤维之间产生氢键的压力对由纤维素纤维和合成纤维的混合物组成的第一织物层进行压缩。以此方式，第一织物层和制成的非织造纤维多层织物也已经在该阶段被赋予优异的强度。
对第一织物层的相对大的压缩还使该织物层中的合成纤维一起形成压缩结构，从而与那些通常的由现有技术中的方法生产的非织造纤维多层织物的织物层相比，其需要更少量的合成纤维。因此通过根据本发明的方法生产的非织造纤维多层织物变得相对便宜。
根据本发明，能够在第二对罗拉之间通过使用相对轻微的压力来将三个织物层压缩成粘合的纤维网，该相对轻微的压力不会使超吸收性粉末被挤出纤维网并进入金属丝中。由此避免了金属丝网眼被超吸收性粉末填塞，网眼被填塞会致使金属丝不适合用于生产非织造纤维多层织物。
根据本发明，乳胶层在实施压花过程之前被施加在由纤维素纤维组成的第三织物层的顶面上，因而能够在执行压花而不产生对环境有不良影响的灰尘。
由于在压花过程中为防止灰尘的产生仅需要薄的乳胶层，施加在由纤维素纤维组成的第三织物层上的乳胶层具有如下这种厚度，即一部分乳胶能够在加热纤维网之前渗透到第三织物层内。这样，第三织物层能够覆盖有非常薄的乳胶层，从而降低非织造纤维多层织物的成本。根据本发明，位于由纤维素纤维组成的第三织物层的顶面上的乳胶层部分渗透到第三织物层内，从而该第三织物层包括70％和90％之间的纤维素纤维部分以及10％和30％之间的乳胶部分。
在非织造纤维多层织物的由纤维素纤维组成的第三织物层的顶面上施加乳胶层之后，加热该纤维网具有在合成纤维之间形成热粘合的效果。
由于第一织物层的纤维已经紧密地形成压缩结构，在通过第一对罗拉的过程中，在合成纤维之间形成许多接触点，所以即使合成纤维在第一织物层中所占的百分比相对较小，也会大量形成热粘合。
借助于根据本发明的方法，通过向第一织物层的混合物中加入比现有技术中同类方法更少量的合成纤维，能够形成牢固的非织造纤维多层织物。以此方式，有利地获得了又便宜又牢固的织物。
根据本发明，对纤维网的加热可以发生在140℃和200℃之间的温度下。
加热也会导致纤维网中的水分蒸发，由此使纤维素纤维之间的氢键断裂。
根据本发明，纤维素纤维之间的氢键能够通过在加热过程之后对纤维网进行加湿并然后在第三对罗拉之间以80℃和180℃之间的温度对纤维网进行压花而重建。
本发明还涉及一种非织造纤维多层织物，其包括：由纤维素纤维和合成纤维的混合物组成的第一织物层、由纤维素纤维和超吸收性粉末的混合物组成的第二织物层，以及由纤维素纤维组成的第三织物层。
本发明的新颖独特的特征在于，仅使用相对少量的合成纤维来形成织物。
根据本发明，第一织物层中合成纤维的含量可以在5％和30％之间，优选在12％和18％之间，由此获得了便宜的非织造纤维多层织物。
根据本发明，能够通过第三织物层的顶面上的乳胶层来提高非织造纤维多层织物的质量。
根据本发明，所述乳胶层部分渗透到第三织物层内，从而该第三织物层包括70％和90％之间的纤维素纤维部分以及10％和30％之间的乳胶部分。
此外，本发明还涉及一种用于生产非织造纤维多层织物的设备。
本发明的新颖独特的特征在于，该设备包括：至少一个环形金属丝筛网；第一干法成形工段，用于在该环形金属丝筛网上形成第一织物层；第一对罗拉，用于对第一织物层进行压缩；第二干法成形工段，用于在第一织物层的顶面上形成第二织物层；第二对罗拉，用于通过在所述罗拉之间对织物层进行压缩来形成粘合的纤维网；乳胶施加工段，用于给纤维网施加乳胶；加热工段，用于加热纤维网；加湿工段，用于加湿纤维；第三对罗拉，用于在纤维网的第三织物层一侧上对纤维网进行压花；和冷却工段，用于冷却纤维网。
该设备具有简单、便宜且有效的功能结构，其生产工段明显少于现有技术中的同类设备。
附图说明
下面将更详细地说明本发明，其中参考附图描述另外的有利特征和具体实施例，其中：
图1分别示出了根据本发明的非织造纤维多层织物片段的各层的横截面，
图2示出了具有组合的层且处于压花状态下的所述非织造纤维多层织物，
图3示出了从上方观察的所述非织造纤维多层织物，
图4示意性示出了根据本发明的设备的第一实施例，和
图5示意性示出了根据本发明的设备的第二实施例。
具体实施方式
图1-3中所示的非织造纤维多层织物整体上以附图标记1表示。
在此情况下，该织物包括在图1中分别示出的四个层，所述层是第一织物层2、第二织物层3、第三织物层4和乳胶层5。
第一织物层由纤维素纤维6和合成纤维7的混合物组成，第二织物层由纤维素纤维6和超吸收性粉末8的混合物组成，而第三织物层仅由纤维素纤维6组成。
第一织物层中合成纤维的含量在5％和30％之间，优选在12％和18％之间，并且由纤维素纤维组成的第三织物层的顶面上的乳胶层已部分渗透到第三织物层内，从而该第三织物层包括70％和90％之间的纤维素纤维部分以及10％和30％之间的乳胶部分。
然而，在其它实施例中，第一织物层中合成纤维的含量和第三织物层顶面上的乳胶的厚度可以具有与上述不同的值。
在图2中，织物层被组合在一起并且被压缩，所以它们现在形成了粘合的纤维网。
由图2和3中可见，该纤维网的顶面被压花出许多的角锥形压痕9，由此增加了纤维网的表面积，因此还增加了织物的吸收能力。同时赋予该织物表面预期的图案。
然而，在本发明的范围内，该压痕可以具有许多其它行驶，并能够以其它方式形成不同于图2和3中所示的其它预期的图案。
图4示出了用于生产图1-3中所示的非织造纤维多层织物的设备的第一实施例。
该织物在金属丝筛网(未示出)上从右向左传送，该筛网可以分成更多更小的金属丝筛网(未示出)。
非织造纤维多层织物1处于以线10表示的所有生产步骤中。
三个织物层2、3和4在三个连续的工段中彼此叠置地干法成形。干法成形技术本身可以是任何适当的类型，但在本图中为通过第一气流成网站11、第二气流成网站12和第三气流成网站13执行的气流成网技术。
在图中仅示意性示出的气流成网站11、12和13各自包括分别置于金属丝上方的分配箱11’、12’和13’，和分别置于金属丝下方的抽吸箱11”、12”和13”。
在运行过程中，纤维在分配箱与抽吸箱之间的气流中被连续彼此叠置地层层铺置在金属丝上。
可以使用其它类型的干法成网站来代替这种气流成网站，也可以使用其它类型的移动支撑物来代替金属丝筛网。
第一织物层2的纤维素纤维6和合成纤维7通过第一气流成网站11在金属丝上铺置成一层。
随后，当通过优选具有光滑表面的第一对罗拉14时，该层借助于高压力而被紧密压缩。
对第一织物层的重度压缩导致在纤维素纤维之间形成氢键，结果使第一织物层获得相对大的强度。
第一织物层的合成纤维同时一起形成紧密结构，从而仅需要少量的合成纤维就能够有助于该织物层和所制成的织物获得预期的强度。
因此，对第一织物层的重度压缩赋予所制成的织物高强度和低成本。
随后，第二织物层3的纤维素纤维6和超吸收性粉末8通过第二气流成网站12在第一织物层2上铺置成一层，此后，第三织物层的纤维素纤维6通过第三气流成网站13在第二织物层3上铺置成一层。
随即，在第二对罗拉15之间对所述织物层进行压缩以形成粘合的纤维网。所使用的压力是适度的，以避免超吸收性粉末被挤出纤维网并填塞金属丝的网眼，如果那样就无法再以正常方式运行了。
罗拉15的表面优选为光滑的。
乳胶层5在乳胶施加站16中被施加在纤维网的顶面上。例如，该乳胶可以被喷涂在纤维网上。
所施加的乳胶层的厚度是如下的类型，即使一部分乳胶渗透到第三织物层内，该第三织物层也将被薄的乳胶层完全覆盖。该层厚到足以防止在后续的压花过程中产生灰尘。然而，该乳胶层又很薄，所使用的乳胶量少于同类传统设备的用量，由此进一步有助于降低织物的生产成本。
现在，纤维网在加热器17中被加热到140℃-200℃范围内的温度，由此在非织造纤维多层织物的第一织物层的合成纤维之间形成热粘合。
凭借预先通过第一对罗拉14而形成的第一织物层的紧密结构确保在合成纤维之间有许多接触点，并由此在通过加热器17对纤维网进行加热的过程中，在合成纤维之间也形成大量热粘合。
即使仅使用了缩减量的相对昂贵的合成纤维，大量的热粘合赋予第一织物层高的强度并因此也赋予织物高的强度。而且，以此方式，还因此有助于降低织物的生产成本。
在加热器17中将纤维网加热到高达140℃-200℃之间的温度还导致纤维网中的水分蒸发，由此使纤维素纤维之间的氢键断裂。
纤维素纤维之间的断裂的氢键通过加热过程之后在加湿站18中对纤维网进行加湿并然后在第三对罗拉19之间以80℃和180℃之间的温度对该纤维网进行压缩而重建。
对纤维网的加热可以通过例如对该纤维网进行喷雾或汽蒸来进行。
第三对罗拉由带光滑表面的罗拉20和带压花表面的压花罗拉21组成。
压花是在纤维网的仅由纤维素纤维组成的第三织物层一侧上执行的。如之前所提到的，该织物层上的薄乳胶层确保能够在不产生灰尘的情况下下进行压花操作，否则可能会污染环境。
通过第三对罗拉19执行的对纤维网的压缩和压花具有如下风险：超吸收性粉末可能被挤出纤维网并粘附到热的罗拉上，由此可能使得不适合使用压花罗拉21来压花。
然而，纤维网的一侧上的在合成纤维之间具有热粘合的被压缩的第一织物层和纤维网的另一侧上的乳胶层构成了防止超吸收性粉末被挤出纤维网的屏障。
现在，热纤维网在冷却站22中被冷却，此后，所制成的织物1被卷绕在卷筒23上。
图5示出了根据本发明的用于生产如图1-3所示的非织造纤维多层织物的设备的另一实施例。
所述设备的此第二实施例与图4所示的设备的第一实施例相当。因此，相同的部件使用了相同的附图标记。
在该设备的第一实施例中，非织造纤维多层织物的三个织物层2、3和4通过第二对罗拉15进行压缩或压延。所使用的压力是适度的，以防止超吸收性粉末被挤出纤维网并进入到金属丝筛网的网眼中并由此使金属丝不适合使用。因此，在此阶段只允许对织物层进行轻微压缩。
因此，在该设备的第二实施例中，在第二对罗拉15与乳胶施加站16之间插入了第四对罗拉24。
现在，已经借助于由第二对罗拉15施加的适度压力轻微压缩过的纤维网以在此工段中同样也是适度的压力被进一步压缩，以防止超吸收性粉末被挤出纤维网。
然而，对纤维网的最终压缩程度比仅使用一对罗拉时高。
请注意，在本发明的范围内，可以为上述操作提供所述织物的其它预期操作和处理。

Claims (16)

1.一种用于生产由多个织物层组成的非织造纤维多层织物(1)的方法，所述织物层被干法成形在可移动的支撑物上，其特征在于包括以下步骤：
形成第一织物层(2)；
在第一对罗拉(14)之间对所述第一织物层(2)进行压缩；
在所述第一织物层(2)的顶面上形成第二织物层(3)；
在第二对罗拉(15)之间对所述织物层(2，3，4)进行压缩以形成粘合的纤维网(2，3，4)；
在所述纤维网(2，3，4)的顶面上施加乳胶层(5)；
加热所述纤维网(2，3，4)；
加湿所述纤维网(2，3，4)；
在第三对罗拉(19)之间对所述纤维网(2，3，4)进行压花；和
冷却所述纤维网(2，3，4)。
2.如权利要求1所述的方法，其特征在于，在进入所述第二对罗拉(15)之前，在所述第二织物层(3)的顶面上形成第三织物层(4)。
3.如权利要求1或2所述的方法，其特征在于，所述第一织物层(2)由纤维素纤维(6)和合成纤维(7)的混合物形成。
4.如权利要求1、2或3所述的方法，其特征在于，所述第二织物层(3)由纤维素纤维(6)和超吸收性粉末(8)的混合物形成。
5.如权利要求1-4中任一项所述的方法，其特征在于，所述第三织物层(4)由纤维素纤维(6)形成。
6.如权利要求1-5中任一项所述的方法，其特征在于，在所述第一对罗拉(14)之间以高到足以使所述第一织物层(2)的纤维素纤维(6)之间产生氢键的压力对所述第一织物层(2)进行压缩。
7.如权利要求1-6中任一项所述的方法，其特征在于，在所述第二对罗拉(15)之间以未高到使得超吸收性粉末被挤出所述纤维网(2，3)的压力将所述织物层(2，3，4)压缩成粘合的纤维网(2，3，4)。
8.如权利要求1-7中任一项所述的方法，其特征在于，在所述纤维网(2，3，4)的顶面上施加乳胶(5)之后，所述纤维网(2，3，4)被加热到在所述第一织物层(2)的合成纤维(7)之间形成热粘合的温度。
9.如权利要求1-8中任一项所述的方法，其特征在于，当通过所述第三对罗拉(19)时，所述纤维网(2，3，4)的顶面被压花。
10.如权利要求1-9中任一项所述的方法，其特征在于，在压花过程期间，所述纤维网(2，3，4)经受80℃-180℃范围内的温度。
11.如权利要求1-10中任一项所述的方法，其特征在于，当已经通过所述第二对罗拉(15)之后，在第四对罗拉(24)之间对所述纤维网(2，3，4)进行压缩。
12.一种通过根据权利要求1-11中任一项所述的方法生产的非织造纤维多层织物(1)，包括：由纤维素纤维(6)和合成纤维(7)的混合物组成的第一织物层(2)；由纤维素纤维(6)和超吸收性粉末(8)的混合物组成的第二织物层(3)；和由纤维素纤维(6)组成的第三织物层(4)，其特征在于，所述第一织物层(2)中合成纤维(7)的含量在5％至30％之间，优选在12％至18％之间。
13.如权利要求12所述的非织造纤维多层织物(1)，其特征在于，由纤维素纤维(6)组成的所述第三织物层(4)的顶面上的所述乳胶层(5)部分地渗透到所述第三织物层(4)内，从而该第三织物层(4)包括在70％至90％之间的纤维素纤维部分和在10％至30％之间的乳胶部分。
14.一种根据权利要求1-11中任一项所述的方法以及如权利要求12和13所述的非织造纤维多层织物的设备，其特征在于包括：
至少一个环形金属丝筛网；
第一干法成形工段(11)，用于在所述环形金属丝筛网上形成所述第一织物层(2)；
第一对罗拉(14)，用于对所述第一织物层(2)进行压缩；
第二干法成形工段，用于在所述第一织物层(2)的顶面上形成所述第二织物层(3)；
第二对罗拉(15)，用于通过在所述罗拉(15)之间对所述织物层(2，3，4)进行压缩来形成粘合的纤维网(2，3，4)；
乳胶施加工段(16)，用于给所述纤维网(2，3，4)施加乳胶(5)；加热工段(17)，用于加热所述纤维网(2，3，4)；
加湿工段(18)，用于加湿所述纤维网(2，3，4)；
第三对罗拉(19)，用于在具有所述第三织物层(4)的一侧上对所述纤维网(2，3，4)进行压花；和
冷却工段(22)，用于冷却所述纤维网(2，3，4)。
15.如权利要求14所述的设备，其特征在于，包括用于在所述第二对罗拉(15)之后的工段中对所述纤维网(2，3，4)进行压缩的第四对罗拉(24)。
16.如权利要求15所述的设备，其特征在于，所述第一、第二和第四对罗拉(14，15，24)具有光滑的表面，而所述第三对罗拉(19)则具有带光滑表面的罗拉(20)和带压花表面的另一个罗拉(21)。
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CN102883693B (zh) * 2010-01-28 2017-04-26 格拉特费尔特法尔肯哈根股份有限责任公司 柔性的高吸收性材料
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