CN102016150A - 无纺材料 - Google Patents

无纺材料 Download PDF

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Publication number
CN102016150A
CN102016150A CN2009801160950A CN200980116095A CN102016150A CN 102016150 A CN102016150 A CN 102016150A CN 2009801160950 A CN2009801160950 A CN 2009801160950A CN 200980116095 A CN200980116095 A CN 200980116095A CN 102016150 A CN102016150 A CN 102016150A
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China
Prior art keywords
layer
woven material
meltblown
pore size
fiber
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艾查伊·邦内
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Avgol Industries 1953 Ltd
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Avgol Industries 1953 Ltd
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Publication of CN102016150A publication Critical patent/CN102016150A/zh
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    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/0007—Electro-spinning
    • D01D5/0061—Electro-spinning characterised by the electro-spinning apparatus
    • D01D5/0076—Electro-spinning characterised by the electro-spinning apparatus characterised by the collecting device, e.g. drum, wheel, endless belt, plate or grid
    • D01D5/0084—Coating by electro-spinning, i.e. the electro-spun fibres are not removed from the collecting device but remain integral with it, e.g. coating of prostheses
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
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    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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Abstract

提供一种无纺材料，其包括：纺粘层，该纺粘层包括平均直径在12至25微米之间的纤维；熔喷层，该熔喷层与所述纺粘层相邻并包括平均直径在2至5微米之间的纤维；以及电纺层，该电纺层与所述熔喷层相邻并包括平均直径在100至400纳米之间的纳米纤维。所述电纺层的基重为至少0.2g/m2，所述熔喷层的总基重为所述电纺层的总基重的至少两倍，并且所述材料中的所有熔喷层的总基重构成该材料的基重的至少3％。此外，所述纺粘层的平均孔径可在70至120微米之间，所述熔喷层的平均孔径可在15至25微米之间，并且所述电纺层的平均孔径可在500纳米至2微米之间。

Description

无纺材料
技术领域
本发明涉及一种无纺材料。
背景技术
无纺材料或织物是一种纤维状材料，通常由天然纤维或人造材料通过将纤维机械粘合或热粘合而制成。
无纺材料的一个实施例是包括若干层的多层材料，每一层均可利用纺粘或熔喷过程制成。在纺粘过程中，将原材料挤压成细纤维(大约几微米)，并将挤压后的纤维无序地布置在输送带上。在熔喷过程中，挤压纤维，然后将其喷到另一层上或直接喷到输送带上。然后将这些层机械粘合或热粘合，即通过热粘合或水刺。此外，可向材料本身或者以局部处理形式提供添加剂，例如表面活性剂、抗静电剂、浸渗剂、氟碳化合物、防燃剂等。已公知在各制造步骤中所用的参数影响最终材料的性质。
此外，公知由电纺(静电纺纱)制成的纳米纤维形成无纺材料。例如，US 2006/0290031公开了这样一种方法，即：在由带电电极和反电极之间的电势差产生的电场中利用静电纺纱从聚合物溶液制造纳米纤维。利用旋转的带电电极的表面将用于纺纱的聚合物溶液供应到电场中，同时在带电电极的周面的靠近反电极的一部分上形成纺纱表面，借此实现高纺纱性能。此外，该发明涉及一种用于实施该方法的装置，其中带电电极枢转，并通过其周面的一部分(底部)浸没在聚合物溶液中，同时使反电极对着带电电极的外周的自由部分定位。
WO 2008/011840公开了一种用于通过聚合物溶液的静电纺纱制造纳米纤维的装置的集电极，该集电极包含导电的薄壁电极主体，在该电极主体中形成至少一个开口，在该开口的周面上布置边界，在电极主体的内部空间中安装有至少一个电极保持件，该电极保持件与紧固在纺纱腔中的至少一个支架连接，而电极保持件布置在开口边界的后方。
WO 2008/028428公开了一种在用于通过聚合物溶液的静电纺纱制造纳米纤维的装置中的、细长形状的旋转式纺纱电极，该纺纱电极包括一对端面，在这对端面之间定位有由线形成的纺纱部件，这些纺纱部件沿旋转式纺纱电极的周面与该旋转式纺纱电极的旋转轴线平行地等距分布，所述端面由非导电材料制成，并且所有纺纱部件均以导电方式互连。
WO 2007/137530公开了一种用于通过聚合物溶液的静电纺纱制造纳米纤维的装置，该装置包括纺纱腔，聚合物溶液的容器位于该纺纱腔内，细长形状的旋转式纺纱电极的周面的一部分伸到所述容器中，该旋转式纺纱电极与直流高压电源的一个电极相连，与纺纱电极相对布置在纺纱腔内的集电极与该直流高压电源的反电极连接，同时纺纱电极的周面的一部分伸到容器内的聚合物溶液内，聚合物溶液的容器被分成入口部和设有出口的出口部，至少一个入口通向该入口部，并且纺纱电极的周面的一部分伸到该入口部中。
WO 2006/108364公开了这样一种织物，其包含至少一层直径为600纳米的聚合纳米纤维，该聚合纳米纤维通过聚合物溶液的静电纺纱而制成。聚合纳米纤维包含溶解或分散在进行静电纺纱的聚合物溶液中的低分子物质颗粒，可以是通过溶解或分散在进行静电纺纱的溶液中的原始低分子物质的后继化学反应产生的低分子物质颗粒。本发明还涉及纳米纤维层的制造方法，该方法通过在由带电电极和反电极之间的电势差产生的电场中进行静电纺纱而由聚合物溶液制造纳米纤维层，其中通过旋转的带电电极的表面使聚合物溶液进入电场中进行纺纱，同时在该电场中形成的纳米纤维被带至反电极，并沉积在其专用表面上。纺纱用的聚合物溶液包含低分子物质颗粒，这些低分子物质颗粒在纺纱时与聚合物一起被捕获到产生的纳米纤维中。
发明内容
根据本发明的一个方面，提供一种无纺材料，该无纺材料包括：
·纺粘层，该纺粘层包括平均直径在12至25微米之间的纤维；
·熔喷层，该熔喷层与所述纺粘层相邻并包括平均直径在2至5微米之间的纤维；以及
·电纺层，该电纺层与所述熔喷层相邻并包括平均直径在100至400纳米之间的纳米纤维；
其中，所述电纺层的基重为至少0.2g/m2，所述熔喷层的总基重为所述电纺层的总基重的至少两倍，并且所述材料中的所有熔喷层的总基重构成该材料的基重的至少3％。这些特征尤其提供一种具有必要操作参数的材料，这些参数例如与过滤性、透气性、基重等相关。
所述纺粘层可包括平均直径在12至20微米之间的纤维。
此外，所述无纺材料可设置成：
·所述纺粘层的平均孔径在70至120微米之间；
·所述熔喷层的平均孔径在15至25微米之间；并且
·所述电纺层的平均孔径在500纳米至2微米之间
所述纺粘层的平均孔径可为相邻的所述熔喷层的平均孔径的2.8至8倍。
所述熔喷层的平均孔径可为相邻的所述电纺层的平均孔径的7.5至50倍。
所述纺粘层的纤维的平均直径可为所述熔喷层的纤维的平均直径的2.4至10倍。
所述熔喷层的纤维的平均直径可为所述电纺层的纤维的平均直径的5至50倍。
所述层可以以间断方式相互粘合。
所述纺粘层可以由从以下材料构成的组中选出的材料制成，这些材料即：聚酯、PLA、聚烯烃、聚丙烯和聚乙烯。
所述熔喷层可以由从以下材料构成的组中选出的材料制成，这些材料即：聚酯、聚烯烃、聚丙烯、聚氨酯、乳胶、弹性粘合剂、弹性体聚乙烯和弹性体聚丙烯。
所述电纺层可以由从以下材料构成的组中选出的材料制成，这些材料即：PVA、PVA C、PA 6、PA 6/12、PA 12、PAA、PAN、PEOX、PESO、PS、PUR、PVP、PVP、聚烯烃、聚丙烯和聚乙烯。
根据本发明的另一方面，提供一种无纺材料，该无纺材料包括：
·平均孔径在70至120微米之间的纺粘层；
·与所述纺粘层相邻并且平均孔径在15至25微米之间的熔喷层；以及
·与所述熔喷层相邻并且平均孔径在500纳米至2微米之间的电纺层
其中，所述电纺层的基重为至少0.2g/m2，所述熔喷层的总基重为所述电纺层的总基重的至少两倍，并且所述材料中的所有熔喷层的总基重构成该材料的基重的至少3％。
此外，所述无纺材料可设置成：
·所述纺粘层包括平均直径在12至25微米之间的纤维；
·所述熔喷层包括平均直径在2至5微米之间的纤维；并且
·所述电纺层包括平均直径在100至400纳米之间的纳米纤维。
所述纺粘层可包括平均直径在12至20微米之间的纤维。
所述纺粘层的平均孔径可为相邻的所述熔喷层的平均孔径的2.8至8倍。
所述熔喷层的平均孔径可为相邻的所述电纺层的平均孔径的7.5至50倍。
所述纺粘层的纤维的平均直径可为所述熔喷层的纤维的平均直径的2.4至10倍。
所述熔喷层的纤维的平均直径可为所述电纺层的纤维的平均直径的5至50倍。
所述层可以以间断方式相互粘合。
所述纺粘层可由从以下材料构成的组中选出的材料制成，这些材料即：聚酯、PLA、聚烯烃、聚丙烯和聚乙烯。
所述熔喷层可由从以下材料构成的组中选出的材料制成，这些材料即：聚酯、聚烯烃、聚丙烯、聚氨酯、乳胶、弹性粘合剂、弹性体聚乙烯和弹性体聚丙烯。
所述电纺层可由从以下材料构成的组中选出的材料制成，这些材料即：PVA、PVA C、PA 6、PA 6/12、PA 12、PAA、PAN、PEOX、PESO、PS、PUR、PVP、PVP、聚烯烃、聚丙烯和聚乙烯。
附图说明
为理解本发明并清楚本发明在实践中如何实施，现在参照附图仅以非限制性实施例方式描述实施方式，在附图中：
图1A至图1C是无纺材料的示意性剖视图。
具体实施方式
如图1A至图1C所示，提供整体以附图标记10表示的无纺材料。材料10包括至少三个层：纺粘层(S)12、熔喷层(M)14以及纳米纤维的溶剂基或水基电纺或熔融电纺层(E)(以下统称为电纺层)16。
应当理解，用在这里时术语“层”既指不同的层，即由单个层形成的层，也指一个叠一个形成或布置的多个相似的层，例如一个叠一个形成的相同类型(即，纺粘、熔喷或电纺)的多个层可视为是该种类型的单个层。
参照图1A，示出了材料10，其包括纺粘层12、熔喷层14以及电纺层16。这样的材料通常表示为SME。
图1B示出了材料10的另一实施例，其包括第一纺粘层12、熔喷层14、电纺层16以及第二纺粘层12。这样的材料通常表示为SMES。
图1C示出了材料10的又一实施例，其是对称的并包括第一纺粘层12、第一熔喷层14、电纺层16、第二熔喷层14以及第二纺粘层12。这样的材料通常表示为SMEMS。
应当理解，图1A至图1C所示的实施例并非限制，并且材料可包含任何层组合而不背离本发明的精神和范围，只要材料包含至少三个层，依次为一个S、一个M和一个E即可。
根据上述任一实施例，这些层可以以间断方式相互粘合，例如在材料10的表面上形成图案。
纺粘层12可包括平均直径在12至25微米范围内，或者更具体地说在12至20微米范围内的纤维。纺粘层12的平均纤维直径可以是熔喷层14的平均纤维直径的2.4至10倍。纺粘层12的平均孔径可在70至120微米之间。纺粘层12的平均孔径可以是熔喷层14的平均孔径的2.8至8倍。
熔喷层14可包括平均直径在2至5微米范围内的纤维。熔喷层14的平均纤维直径可以是电纺层16的平均纤维直径的5至50倍。熔喷层14的平均孔径可以在15至25微米之间。熔喷层14的平均孔径可以是电纺层16的平均孔径的7.5至50倍。
电纺层16可包括平均直径在100至400纳米(0.1至0.4微米)范围内的纳米纤维。电纺层16的平均孔径可以在15至25微米之间。电纺层16的平均孔径可以在500至2000纳米(0.5至2微米)之间。
电纺层16的基重为至少0.2g/m2(gsm)。熔喷层14的基重为电纺层16的基重的至少两倍。此外，熔喷层14的重量为整个材料的重量的至少3％。
纺粘层12可以以任何已知的方式例如由连续纤维形成，迫使连续纤维通过具有毛细管直径在约0.35至0.8mm的范围内、孔密度在约2000至8000孔/米范围内的喷丝头的挤压机。连续纤维可由任何合适材料制成，包括但不限于包括PLA、聚烯烃、聚丙烯或聚乙烯在内的聚酯级材料。
熔喷层14可以以任何已知的方式例如由挤压通过毛细管直径在约0.2至0.5mm的范围内、孔密度在约15至50孔/英寸范围内的喷丝头的纤维形成。可利用热气流将挤压后的聚合物拉拔成细纤维，从而形成熔喷层。熔喷层14可由任何合适材料制成，包括但不限于聚酯、聚烯烃、聚丙烯、聚氨酯、乳胶、弹性粘合剂、弹性体聚乙烯或者弹性体聚丙烯。
电纺(E)层可以以任何已知的方式制成，并可由PVA、PVA C、PA6、PA 6/12、PA 12、PAA、PAN、PEOX、PESO、PS、PUR、PVP、PVP、聚烯烃、聚丙烯或聚乙烯制成。
层12、14、16中的任何一个或多个层可制成为以上所列的两种或更多种材料或任何其他合适材料形成的双组分纤维。
这些层可直接形成在相邻层上(例如，在参照图1A示出并描述的实施例中，熔喷层14可直接形成在其相邻的纺粘层12上，电纺层16可直接形成在熔喷层上)，之后使这些层相互粘合。另选的是，可独立形成各层，然后以合适的顺序解绕(例如，在参照图1A示出并描述的实施例中，将这些层布置成使得熔喷层14位于纺粘层12和电纺层16之间)，之后使这些层相互粘合。
横过材料10的孔径梯度允许以相邻层之间的减小压降进行高程度过滤。应理解，当纺粘层面向待过滤介质时(例如，在用于期望功能是在空气到达使用者之前对其进行过滤的空气过滤器时，纺粘层12通常会背向使用者)，这样的布置会在不放弃由电纺层16所提供的高水平过滤的情况下提高材料的透气性。
根据以上给出的任意实施例以及根据本发明范围内的任何实施例的材料相对于不具有电纺层的类似形成的材料具有若干优点。例如，其在“防水性(hydro-head)”测试(旨在测量耐水性的测试)中获得高分，呈现较低孔径和较窄孔隙分布、并且对穿过其厚度的气体来说呈现横过材料的较低压降。
这样的材料尤其在以下应用中会是有用的：
·例如由于其低重量、高重量、高透气性、阻流性以及容纳细固体颗粒的性能，该材料可用于尿布内衬或其他尿布构件；
·例如由于其低孔径(使其成为细菌屏障)、低重量、透气性以及其阻流性，该材料可用于医疗服装和面罩；并且
·该材料对于制造高效/低压降过滤介质是有用的。小孔径以及横过其表面经历的低压降使其适用于制造HEPA过滤器(高效微粒空气过滤器)以及/或者ULPA过滤器(超高效微粒空气过滤器)。
应清楚，在不背离本发明的精神和范围的情况下，材料10还可用于除上述以外的应用。
本领域技术人员容易理解，在不背离本发明范围的情况下经过必要修改，可做出多种改变、变型和改进。

Claims (22)

1.一种无纺材料，该无纺材料包括：
·纺粘层，该纺粘层包括平均直径在12至25微米之间的纤维；
·熔喷层，该熔喷层与所述纺粘层相邻，并包括平均直径在2至5微米之间的纤维；以及
·电纺层，该电纺层与所述熔喷层相邻，并包括平均直径在100至400纳米之间的纳米纤维；
其中，所述电纺层的基重为至少0.2g/m2，所述熔喷层的总基重为所述电纺层的总基重的至少两倍，并且所述材料中的所有熔喷层的总基重构成该材料的基重的至少3％。
2.根据权利要求1所述的无纺材料，其中所述纺粘层包括平均直径在12至20微米之间的纤维。
3.根据权利要求1或2所述的无纺材料，其中
·所述纺粘层的平均孔径在70至120微米之间；
·所述熔喷层的平均孔径在15至25微米之间；并且
·所述电纺层的平均孔径在500纳米至2微米之间。
4.根据上述任一权利要求所述的无纺材料，其中所述纺粘层的平均孔径为相邻的所述熔喷层的平均孔径的2.8至8倍。
5.根据上述任一权利要求所述的无纺材料，其中所述熔喷层的平均孔径为相邻的所述电纺层的平均孔径的7.5至50倍。
6.根据上述任一权利要求所述的无纺材料，其中所述纺粘层的纤维的平均直径为所述熔喷层的纤维的平均直径的2.4至10倍。
7.根据上述任一权利要求所述的无纺材料，其中所述熔喷层的纤维的平均直径为所述电纺层的纤维的平均直径的5至50倍。
8.根据上述任一权利要求所述的无纺材料，其中所述层以间断方式相互粘合。
9.根据上述任一权利要求所述的无纺材料，其中所述纺粘层由从以下材料构成的组中选出的材料制成，这些材料即：聚酯、PLA、聚烯烃、聚丙烯和聚乙烯。
10.根据上述任一权利要求所述的无纺材料，其中所述熔喷层由从以下材料构成的组中选出的材料制成，这些材料即：聚酯、聚烯烃、聚丙烯、聚氨酯、乳胶、弹性粘合剂、弹性体聚乙烯和弹性体聚丙烯。
11.根据上述任一权利要求所述的无纺材料，其中所述电纺层由从以下材料构成的组中选出的材料制成，这些材料即：PVA、PVA C、PA 6、PA 6/12、PA 12、PAA、PAN、PEOX、PESO、PS、PUR、PVP、PVP、聚烯烃、聚丙烯和聚乙烯。
12.一种无纺材料，该无纺材料包括：
·平均孔径在70至120微米之间的纺粘层；
·与所述纺粘层相邻并且平均孔径在15至25微米之间的熔喷层；以及
·与所述熔喷层相邻并且平均孔径在500纳米至2微米之间的电纺层；
其中，所述电纺层的基重为至少0.2g/m2，所述熔喷层的总基重为所述电纺层的总基重的至少两倍，并且所述材料中的所有熔喷层的总基重构成该材料的基重的至少3％。
13.根据权利要求12所述的无纺材料，其中：
·所述纺粘层包括平均直径在12至25微米之间的纤维；
·所述熔喷层包括平均直径在2至5微米之间的纤维；并且
·所述电纺层包括平均直径在100至400纳米之间的纳米纤维。
14.根据权利要求13所述的无纺材料，其中所述纺粘层包括平均直径在12至20微米之间的纤维。
15.根据权利要求12至14中任一项所述的无纺材料，其中所述纺粘层的平均孔径为相邻的所述熔喷层的平均孔径的2.8至8倍。
16.根据权利要求12至15中任一项所述的无纺材料，其中所述熔喷层的平均孔径为相邻的所述电纺层的平均孔径的7.5至50倍。
17.根据权利要求12至16中任一项所述的无纺材料，其中所述纺粘层的纤维的平均直径为所述熔喷层的纤维的平均直径的2.4至10倍。
18.根据权利要求12至17中任一项所述的无纺材料，其中所述熔喷层的纤维的平均直径为所述电纺层的纤维的平均直径的5至50倍。
19.根据权利要求12至18中任一项所述的无纺材料，其中所述层以间断方式相互粘合。
20.根据权利要求12至19中任一项所述的无纺材料，其中所述纺粘层由从以下材料构成的组中选出的材料制成，这些材料即：聚酯、PLA、聚烯烃、聚丙烯和聚乙烯。
21.根据权利要求12至20中任一项所述的无纺材料，其中所述熔喷层由从以下材料构成的组中选出的材料制成，这些材料即：聚酯、聚烯烃、聚丙烯、聚氨酯、乳胶、弹性粘合剂、弹性体聚乙烯和弹性体聚丙烯。
22.根据权利要求12至21中任一项所述的无纺材料，其中所述电纺层由从以下材料构成的组中选出的材料制成，这些材料即：PVA、PVAC、PA 6、PA 6/12、PA 12、PAA、PAN、PEOX、PESO、PS、PUR、PVP、PVP、聚烯烃、聚丙烯和聚乙烯。
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