CN102575393A - 多孔支承制品及其制备方法 - Google Patents
多孔支承制品及其制备方法 Download PDFInfo
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- CN102575393A CN102575393A CN2010800451754A CN201080045175A CN102575393A CN 102575393 A CN102575393 A CN 102575393A CN 2010800451754 A CN2010800451754 A CN 2010800451754A CN 201080045175 A CN201080045175 A CN 201080045175A CN 102575393 A CN102575393 A CN 102575393A
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Classifications
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Abstract
本发明公开了多孔支承制品及其制备方法。将多组分聚合物纤维进料到形成腔室内并将其至少填入支承网的内部空隙空间内。所述被填入的至少一些多组分纤维自粘合至彼此以形成嵌入所述支承网内的多孔网。所述嵌入的多孔网可以包含粘合至所述网的所述多组分纤维的颗粒。所述嵌入的多孔网中的任选颗粒可为如研磨剂、吸收剂等。
Description
背景技术
本发明涉及多孔制品及其制备方法。此类制品通常用于刷洗表面,例如地板、工作台面、鞋底等等。通常,此类多孔制品由非织造网构成。此类非织造网的结构和特性可变化,如从致密到开放、从坚硬到柔软、从刚性到柔性等等。
发明内容
本发明公开了多孔支承制品及其制备方法。将多组分聚合物纤维进料到形成腔室内并将其至少填入支承网的内部空隙空间内。被填入的至少一些多组分纤维自粘合至彼此以形成嵌入支承网内的多孔网。嵌入的多孔网可以包含粘合至网的多组分纤维的颗粒。嵌入的多孔网中的任选颗粒可为(例如)研磨剂、吸收剂等。
因此,在一个方面,本文所公开的为一种制备多孔支承网的方法,包括:将不连续的多组分聚合物纤维进料到形成腔室内;在形成腔室内混合多组分纤维;将多组分纤维填入细丝状支承网的至少一些内部空隙空间内,以在支承网的至少一些内部空隙空间内形成被填入的纤维垫;以及使多组分纤维暴露于高温,以使至少一些多组分纤维熔融粘合至彼此,从而使得纤维垫自粘合为嵌入支承网内部的至少一些空隙空间内的多孔网。
在另一方面,本文公开了多孔支承制品,包括:细丝状支承网,其中包含内部空隙空间;位于细丝状支承网内部至少一些空隙空间内的嵌入多孔网,网的纤维基本上由不连续的多组分聚合物纤维组成,该纤维的至少一些至少在纤维接触的某些点熔融粘合至彼此从而构成自粘合网。
本发明的这些方面以及其他方面在下面的具体实施方式中将显而易见。然而,在任何情况下都不应将上述发明内容理解为是对受权利要求书保护的主题的限制,该主题仅受所附权利要求书的限定,并且在审查期间可以进行修改。
附图说明
图1为如本文所公开的示例性多孔支承制品的透视图。
图2为如本文所公开的示例性支承网的剖视图。
图3为如本文所公开的另一个示例性支承网的剖视图。
图4为如本文所公开的示例性多孔支承制品的剖视图。
图5为如本文所公开的示例性嵌入网的一部分的分解剖视图。
图6为如本文所公开的示出用于制备多孔支承制品的示例性方法的部分剖面图中的侧视图。
图7为如本文所公开的另一个示例性多孔支承制品的剖视图。
图8为如本文所公开的另一个示例性多孔支承制品的剖视图。
图9为如本文所公开的另一个示例性多孔支承制品的剖视图。
虽然以上说明的附图和图片示出了本发明的一些实施例,但正如讨论过程中所指出的那样,还可以想到其他的实施例。在任何情况下,本公开都示例性而非限制性地提供本发明。应当理解,本领域的技术人员可以设计出许多其他的修改形式和实施例,这些修改形式和实施例也在本发明的精神和范围之内。
在上述多张图中,相同的参考标号表示相同的元件。某些元件可能以相同或等同形式的倍数存在;在此类情况下,可能仅仅一个或多个代表性元件通过参考标号表明,但应当理解,此类参考标号适用于所有此类相同元件。除非另外指明,否则本文中的所有附图均未按比例绘制,并且选择这些附图是为了示出本发明的不同实施例。具体地讲,除非另外指明,否则各种组件的尺寸仅用于示例性目的,并且不应根据图式推断介于各种组件的尺寸之间的关系。尽管在本公开中可能使用了例如“顶部”、“底部”、“上面”、“下面”、“下方”、“上方”、“前部”、“背部”、“向外”、“向内”、“向上”、“向下”、“第一”和“第二”等术语,但应当理解,除非另外指明,否则这些术语仅在其相对含义下使用。
具体实施方式
图1中示出了示例性多孔支承制品500。制品500至少由细丝状支承网300以及嵌入支承网300内部至少一些空隙空间内的多孔网100构成。参照图2,支承网300可包括含有内部空隙空间350的任何高度开放的细丝状网,在所述空隙空间350的至少一些内可嵌入多孔网100,如本文后面所述。所谓细丝状是指支承网300由聚合物细丝310构成,该细丝的直径可为至少约100微米,其在不同细丝接触的点处或在单根细丝自接触的点处粘合(如,熔融粘合),从而构成粘附网(即,具有足够的机械完整性以在本文所述的方法中进行操纵的网)。
支承网300包括位于支承网300的第一主侧面330上的第一主表面335。本领域的普通技术人员将会认识到,由于支承网300具有高度开放的结构,所以第一主表面335可能不包括真实的表面(如,连续的或甚至部分连续的表面),而是可表示为通过从支承网300的第一主侧面330上向外伸出最远距离的细丝310的那些部分而限定的假想平面(如图2所示)。相似地,支承网300的第二主表面325可能不包括真实的表面,而是可表示为通过从支承网300的第二主侧面320上向外伸出最远距离的细丝310的那些部分而限定的假想平面(再次如图2所示)。支承网300的厚度因此可表示为支承网300的第一主表面335和第二主表面325之间的距离。因此,本文所提到的支承网300的内部是指位于支承网300的第一主表面335和第二主表面325向内(如,介于两者之间)的支承网300的部分。在上下文中,内部空隙空间350各自包括位于至少部分地由细丝310限定的支承网300内部的开放空间(如,真空或者填充有空气、水或一些其他流体的空间)。一般来讲,支承网300的长度和宽度可分别显著大于(如,为其至少三倍或四倍)支承网300的厚度。
在一些实施例中,细丝310可包括细丝的随机不规则取向的环、卷曲以及通常为非线性(超过大于如10mm的距离)的部分等等,它们共同限定支承网300的厚度、第一主侧面330和第一主表面335,以及第二主侧面320和第二主表面325。本领域的技术人员通常将这种一般类型的网称为卷绕网。在特定实施例中,支承网300可包括重叠的不规则环绕并相互缠结的细丝列,其形成高度开放的三维片状结构,如在(例如)美国专利4,212,692、4,252,590和6,272,707中进一步详细描述,这些专利出于此目的以引用的方式并入本文。这种类型的网可以商品名ENKAMAT得自Colbond Geosynthetics公司(St.Denis la Plaine,France)。可能也适用的其他网包括:可以商品名ENKADRAIN得自Colbond的那些网,可以商品名FORTRAC得自Huesker Synthetic GmbH(Gescher,Germany)的那些网;以及可以商品名TENSAR MAT得自Tensar International SARL(Mérignac,France)的那些网。在一些实施例中,支承网300可包括粘附的粘合纤维非织造网,该网由有回弹力的热塑性聚合物的互相啮合连续卷绕或三维波形细丝制成。至少一些细丝在互相接触的点自发地粘合在一起或可拆卸地焊接在一起以形成可操纵的一体化结构。网可任选地包含分散在整个网上并通过粘结剂粘合至细丝的研磨剂微粒。这种类型的网的实例在美国专利3,837,988和4,227,350中有所公开,这些专利以引用的方式并入本文。这种类型的网可以商品名NOMAD得自3M公司(St.Paul,MN)。
不论如何制备并且不论具有何种特定结构,支承网300均包含能够接纳多组分纤维110的内部空隙空间350,从而形成嵌入网100,如本文后面详细描述。内部空隙空间350因此应当具有足够的空间以容纳纤维110,并且应当至少部分地连接(如,采用大体上视线的方式流畅地连接)至支承网300的主表面325或主表面335(如,同时在内部空隙空间350和主表面325或335之间存在足够小和/或宽间距或间隔数量的细丝310),使得纤维110可令人满意地沉积在其中。单独的内部空隙空间350可以连接或可以不连接(如,视线流畅地连接)至彼此。不同空隙空间350之间的界限可能不会总是易于分辨。
为了提高在支承网300的内部空隙空间350内填入多组分纤维110的能力,在多种实施例中,单个空隙空间350的平均尺寸可为至少约3mm、至少约6mm或至少约9mm。在上下文中,尺寸是指在遇到一根或多根细丝之前可横向穿越给定空隙空间的距离,所述一根或多根细丝的设置和/或取向方式可避免多组分纤维110从中通过(如本文所述)。在另外的实施例中,空隙空间350的平均尺寸可为至多约20mm、至多约15mm或至多约12mm。可存在广泛变化或分布的空隙尺寸。在一些实施例中,空隙空间350可在支承网300的整个厚度、宽度和长度内大体上各向同性地分布。此类各向同性的支承网在图2中以示例性方式描绘。
在可供选择的实施例中,空隙空间350可非对称地分布在支承网300内。在另外的实施例中,空隙空间350可包括相对于支承网300厚度的可分辨取向,其中至少一些单独的内部空隙空间350可各自包括位于支承网300的第一主表面335处的大体开放端,以及位于支承网300的第二主表面325处的大体封闭端。所谓大体开放,是指在空隙空间350的这一末端(如,位于支承网300的第一主表面335处)存在足够少的细丝310,以至于可从支承网300的第一主侧面330将纤维填入空隙空间350内。所谓大体封闭,是指在空隙空间350的这一末端(如,位于支承网300的第二主表面325处)存在足够数量的细丝310,以至于无法从支承网300的第二主侧面320填入纤维。图3中示出了这种类型的示例性布置方式。在这种一般类型的结构中,单独的内部空隙空间350可采取阱的形式,所述阱可从位于支承网300第一主表面335处的开放端延伸至位于支承网300第二主表面325处或其附近的封闭端。这种类型的具体实施例为具有以下特性的实施例:其中支承网300的第一主表面335通过大体开放的结构来表征,并且其中网300的第二主表面325通过大体封闭的结构来表征,其中网300的主表面325上的细丝310采取环、涡状形等一般形式,所述环、涡状形等结构平整且共面从而限定主表面325的平面。此类构型在图3中以示例性方式示出,其可例如通过以下过程而实现:在平坦和/或受热表面(如,金属筒或金属带)上收集细丝310(在形成支承网300的过程中),使得接触平坦表面和/或受热表面的仍处于熔化或至少部分软化状态的细丝310可趋于平整并且聚集为大体上共面的构型。
支承网300可具有任何合适厚度、基重等等。在多种实施例中,支承网300的厚度为至少约7mm、至少约10mm或至少约12mm。在另外的实施例中,支承网300的厚度为至多40mm、至多约35mm或至多约30mm。在多种实施例中,支承网300可具有至少50gsm(克/平方米)、至少100gsm或至少200gsm的基重。在另外的实施例中,支承网300可具有至多2000gsm、1000gsm或600gsm的基重。在多种实施例中,支承网300的细丝310可具有至少200微米、至少400微米或至少600微米的平均直径。
支承网300可根据需要包含颗粒,如研磨剂颗粒,包括本文所公开的研磨剂颗粒中的任何一者。如本领域中众所周知的那样,此类研磨剂颗粒可例如通过粘结剂附接到网300的细丝310上。
图1、图4以及图5的分解剖视图中所示出的是嵌入网100。嵌入网100可通过以下过程形成:通过本文所述的方法,将多组分纤维110填入支承网300的内部空隙空间350内,随后使纤维110的至少一些自粘合至彼此。嵌入网100至少包括多组分纤维110,并包括第一主表面135和第二主表面125(两者均由纤维构成并且本身可具有多孔性和/或不连续性)。多组分纤维110限定为至少具有包含第一熔点的第一主聚合物部分(组分)112和熔点要高于组分112熔点的第二主聚合物部分(组分)114的纤维。此类多组分纤维可为双组分纤维,或也可具有额外的组分。当暴露于适当的高温时,第一部分112可以至少部分地熔融,而具有更高熔点的第二部分114可保持大体上完整无缺。在熔融期间,第一部分112可能往往会在纤维彼此接触的接合点处聚集,如图5所示。随后,在冷却时,第一部分112的材料可重新固化并在这样做时使纤维110的至少一些粘合至彼此(此类方法通常被认为是熔融粘合)。该过程在本文中被定义为自粘合。本领域的技术人员将会认识到通过纤维主聚合物组分的此类自粘合而形成的自粘合网与通过以下过程所形成的网之间的差异,所述过程通过使用所施加的不属于纤维主聚合物组分的粘结剂或粘合剂而使纤维粘合在一起,或者通过使用机械加工步骤(例如车针加固缝纫、水缠绕等等)将收集的纤维转化为网等。
因此,使用多组分纤维110是使纤维110的至少一些自粘合至彼此从而使得网100包括嵌入网的基础。术语“嵌入网”是指网100的足够数量的多组分纤维110自粘合至彼此以形成粘附的三维网,并且网100的足够数量的多组分纤维110缠结有、缠绕有和/或熔融粘合至支承网300的细丝310的至少一些,以至于无法在不对网100或网300造成损坏的情况下从支承网300的内部空间350中移除网100。(此类损坏可涉及如纤维110和/或细丝310的破损、纤维110之间自粘合的破裂、网100和/或网300的永久性变形等)。可这样提供嵌入网100:不需要嵌入网100中存在额外的树脂涂层、粘结剂或粘合剂,并且不使用机械加工步骤(如,例如车针加固缝纫、水缠绕等)将形成纤维110转化为嵌入网100。
多组分纤维110可为不连续的(为了本公开的目的被限定为表明长度小于30mm)。在一些实施例中,不连续的纤维110可为切断纤维(如从较长和/或连续纤维短切而得)。在一些实施例中,多组分纤维110可包含较长纤维和较短纤维的混合物。在多种实施例中,纤维110的纤度可为至少1旦尼尔、至少2旦尼尔或至少3旦尼尔。在另外的实施例中,纤维110的纤度可为小于约20旦尼尔、小于约10旦尼尔或小于约5旦尼尔。在一些实施例中,多组分纤维110可包含较高纤度(较大直径)纤维和较低纤度(较小直径)纤维的混合物。
多组分纤维110可为合成聚合物纤维,例如双组分纤维,其至少包含具有第一熔点的第一主聚合物部分和具有高于(如,高20、40或60度或更高)第一熔点的第二熔点的第二主聚合物部分。通常,聚烯烃(如,聚乙烯或其共聚物)可用于第一较低熔点组分,聚酯(如,聚对苯二甲酸乙二醇酯等)可用于第二较高熔点组分。或者,某些聚烯烃(如,聚乙烯)可用于第一组分,其他较高熔点聚烯烃(如,聚丙烯)可用于第二组分。或者,某些聚酯(如,聚丁二酸丁二醇酯)可用于第一组分,其他聚酯(如,聚对苯二甲酸丁二酸乙二醇酯(polyethylene terephthalate succinate))可用于第二组分。如果需要,组分中的一者或两者可具有可生物降解的特性。
可使用多组分纤维,如双组分纤维,其具有如共延的并列构型、共延的同心皮芯型构型(例如,如图5的示例性实施例中的那样)或共延的椭圆皮芯型构型。其他布置方式(如层状结构、叶状结构、分段结构、海岛型结构、基质-原纤型等等)也是可能的。
除了第一主聚合物部分112和第二主聚合物部分114之外,多组分纤维110还可包括本领域的技术人员所知的添加剂中的任何一者。此类添加剂可包括增塑剂、加工助剂、颜料、抗氧化剂、稳定剂、相容性试剂、抗冲击改性剂、颜料、矿物填料、染料、表面活性剂、润滑剂等等。
可用作多组分纤维110的示例性材料可包括可以商品名BicomponentFibers得自Minifibers,Inc.(Johnson City,TN)的材料、可以商品名CELBOND 254得自KoSa Co.(Wichita,Kansas)的材料、可以商品名Bicomponent Fibres得自Trevira GMBH(Bobingen,Germany)的材料、可以商品名MELTY得自Unitika Co.(Osaka,Japan)的材料、可以商品名LMF得自Huvis Corporation(Seoul,Korea)的材料、可以商品名T 254和T 256得自Invista Corp(Wichita,KS)的材料、可以商品名Chisso ES、ESC、EAC、EKC、EPC和ETC得自Chisso Inc.(Osaka,Japan)的材料,以及可以商品名Type LMF得自Nan Ya Plastics Corporation(Taipei,Taiwan)的材料。
在一些实施例中,嵌入网100的纤维总含量全部均由多组分纤维110提供。在可供选择的实施例中,任选填充纤维145与多组分纤维110共混。填充纤维145为除多组分纤维之外的任何种类的纤维。填充纤维145的例子包括单一组分合成纤维、半合成纤维、金属纤维、天然纤维、矿物纤维等等。在多种实施例中,填充纤维145可占嵌入网100的高达约30重量%、高达约20重量%或高达约10重量%。
嵌入网100可具有任何合适厚度、基重等等。在多种实施例中,嵌入网100的厚度为至少约2mm、至少约5mm或至少约10mm。在另外的实施例中,嵌入网100的厚度为至多40mm、至多约30mm或至多约20mm。嵌入网100的厚度可相对于支承网300的厚度进行选择或控制,如本文稍后的详细讨论。在多种实施例中,嵌入网100可具有至少约50gsm(克/平方米)、至少约100gsm或至少约200gsm的基重。在另外的实施例中,嵌入网100可具有至多约2000gsm、至多约1000gsm或至多约500gsm的基重。
如果需要,嵌入网100可包含任选粘结剂。此类粘结剂可存在于如嵌入网100的主表面上和/或该网的整个厚度内。粘结剂可为树脂(如酚醛树脂、聚氨酯树脂、聚脲、苯乙烯一丁二烯橡胶、丁腈橡胶、环氧树脂、丙烯酸类树脂以及聚异戊二烯)。如本领域中众所周知的那样,粘结剂可具有水溶性。
嵌入网100可任选地包含颗粒,同时支承网300也可任选地包含颗粒。虽然在本文中此类颗粒主要在嵌入网100的颗粒140的背景下进行讨论,但应当理解,本文所述颗粒中的任何一者均可存在于支承网300中。此类颗粒可为任何离散颗粒,该颗粒在室温下为固体,添加它是为了(例如)提供清洁、擦洗、抛光、擦拭、吸收、吸附或感观有益效果。在多种实施例中,此类颗粒可具有小于约1cm、小于约5mm、小于约2mm或小于约1mm的平均直径。在另外的实施例中,此类颗粒可具有至少约50微米、至少约100微米或至少约250微米的平均直径。
在一些实施例中,颗粒140为研磨剂颗粒。研磨剂颗粒可用于产生可擦洗和研磨难以移除材料的研磨剂嵌入的多孔网100。研磨剂颗粒可为矿物颗粒、合成颗粒、天然研磨颗粒或它们的组合。矿物颗粒的例子包括氧化铝,例如陶瓷的氧化铝、热处理过的氧化铝和白色熔融氧化铝;以及碳化硅、氧化铝-氧化锆、金刚石、二氧化铈、立方氮化硼、石榴石、打火石、硅石、浮石和碳酸钙。合成颗粒包括聚合物材料,例如聚酯、聚氯乙烯、甲基丙烯酸酯、甲基丙烯酸甲酯、聚碳酸酯、三聚氰胺和聚苯乙烯。天然研磨颗粒包括坚果壳(例如核桃壳)或果仁(例如杏仁、桃仁和鳄梨仁)。可使用多种粒度、硬度和数量的研磨剂颗粒来形成在从非常强效研磨到非常轻度研磨范围内变化的研磨剂多孔层。在一些实施例中,颗粒140为金属,并且例如可以用于形成抛光层。
在一些实施例中,颗粒140为通常存在于洗涤剂组合物中的固体材料,例如表面活性剂和漂白剂。固体表面活性剂的例子包括月桂基硫酸钠和十二烷基苯磺酸盐。固体表面活性剂的其他例子可见于由McCuthcheon′sDivision出版的“2008 McCutcheon′s Volume I:Emulsifiers and Detergents(North American Edition)”(McCutcheon 2008年第1卷:乳化剂和洗涤剂(北美版))。固体漂白剂的例子包括无机过氧化氢合物盐(例如过硼酸钠一水合物/四水合物和过碳酸钠)、有机过氧酸衍生物以及次氯酸钙。
在一些实施例中,颗粒140为固体杀生物剂或抗微生物剂。固体杀生物剂和抗微生物剂的例子包括含卤素化合物,例如二氯异氰脲酸钠二水合物、氯化苯甲烷铵、卤化二烷基乙内酰脲和三氯生。
在一些实施例中,颗粒140为微胶囊,如美国专利No.3,516,941中所述。微胶囊可填充有固体或液体芳香剂、香料、油、表面活性剂、洗涤剂、杀生物剂或抗微生物剂,并且可通过机械应力打碎以便释放其中容纳的材料。
在一些实施例中,颗粒140为吸附剂或吸收剂颗粒。例如,吸附剂颗粒可包括活性炭、木炭、碳酸氢钠等等。在某些实施例中,颗粒140为吸收剂(即,能够吸收大量的液态水和/或水性组合物、溶液和混合物)。例如,吸收剂颗粒可包括多孔材料、天然或合成泡沫,例如三聚氰胺、橡胶、聚氨基甲酸酯、聚酯、聚乙烯、硅树脂和纤维素。吸收剂颗粒也可包括超级吸收剂颗粒,例如聚丙烯酸钠、羧甲基纤维素或颗粒状的聚乙烯醇。
在特定实施例中,颗粒140可包括短切纤维质海绵颗粒或短切氨基甲酸酯海绵颗粒或它们的混合物。此类颗粒可有利地通过例如短切从常规一体化纤维质海绵或氨基甲酸酯海绵的制备中剩下的海绵废料而得到。其中粘合有例如纤维质海绵颗粒140的嵌入网100可具有高度亲水性或水吸收性。
本领域的普通技术人员将认识到,上述颗粒140中的一者或多者的任何组合均可用于嵌入网100内和/或支承网300内。根据嵌入网100的所需属性,可采用相对于多组分纤维110(以及填充纤维145,如果包括的话)的颗粒140的多种填塞度。在多种实施例中,颗粒140可占嵌入网100总重量的小于约90、小于约80或小于约70重量%。在另外的实施例中,颗粒140占嵌入网100总重量的至少10、至少20或至少30重量%。
图6为示出制备多孔支承制品500的示例性方法的侧视图(其中腔室220以剖面图的形式示出)。纤维输入流210将纤维(即,包括多组分纤维110)进料到形成腔室220内,纤维在腔室内混合、共混并最终填入支承网300内。所谓填入是指在重力和施加的至少局部真空的作用下将混合纤维110(与填充纤维145和/或颗粒140一起,如果存在)沉积到支承网300内部空隙空间350的至少一些内,从而形成至少部分地填充支承网300内部空隙空间350的至少一些的纤维垫230。在进入形成腔室220之前,可包括开棉机(未示出)来开启、梳理和/或共混输入纤维,特别是在包括多组分纤维110和填充纤维145的共混物的情况下。如果需要,也可例如经由颗粒输入流212将颗粒140进料到形成腔室220内。虽然纤维输入流210和/或颗粒输入流212可有利地设置成大体上朝向形成腔室220的上部,但应当理解的是,这些中的一者或两者可设置在形成腔室220的其他部分。
形成腔室220的类型为干铺纤维加工设备,例如在标题为“Fiberdistribution device for dry forming a fibrous product and method”(用于干法成型纤维产品的纤维分布装置以及方法)的美国专利申请公布2005/0098910中示出和描述,该公布的公开内容以引用的方式并入本文。形成腔室220不使用强效空气流混合并相互接合纤维而形成垫(例如通过“RandoWebber”网形成机,得自Rando Machine Corporation(Macedon,NY)),而是具有销钉辊222以机械地共混和混合纤维,同时通过重力使得纤维下落穿过移动的环形带筛网224并且使纤维最终填入支承网300内以形成由例如未粘合纤维构成的纤维垫230。在该设计中,混合的纤维(和颗粒140,如果存在)朝向形成腔室220的底部下落(即,在重力作用下下落),以填入支承网300内从而形成纤维垫230。通常,在温度显著低于(如,至少低30℃)多组分纤维110任何部分(如,第一部分112)的熔融温度的腔室220内对多组分纤维110进行加工。
如果需要,可采用这样的方式添加多种纤维和任选颗粒,如本文所说明并在提交于2008年10月14日的名称为“Nonwoven Material ContainingBenefiting Particles and Method of Making”(包含有益颗粒的非织造材料及其制备方法)的美国专利申请No.12/251048中进一步讨论;该专利申请以引用的方式并入本文。
支承网300可进入并穿过形成腔室220的下部,或可在形成腔室220底部的开口下面通过,以使得混合纤维110可填入其中。支承网300可作为自立式自承层以这种方式通过;或它可驻留在通常用于气流成网设备中的那一类环形纤维收集带的一部分上或由其承载。可将至少局部真空施加于支承网300的底部表面(如,主表面335),通过该方式可穿过支承网300的厚度施加压力差以帮助纤维110填入支承网300内。如果使用支承带或筛网(如,位于支承网300下面并且至少部分地从下面对其进行支承),则此类支承带或筛网可为多孔的,以使得可穿过其施加真空。
在其中具有填入纤维垫230的支承网300随后行进至加热单元240,例如烘箱,在其中进行高温暴露。该高温起到第一目的的作用,即将纤维垫230暴露于某温度,在该温度下纤维垫230的多组分纤维110的第一部分112可至少部分地熔融,以将纤维110的至少一些粘合至彼此从而使纤维垫230转化为本文所述的嵌入网100(可能只有在高温暴露之后对材料进行冷却使得纤维110的第一部分112自然重新固化,这些熔融粘合过程才会完全完成)。高温暴露也可起到将颗粒140(如果存在)的至少一些熔融粘合至纤维110的作用。高温暴露也可起到将纤维110的至少一些熔融粘合至支承网300的细丝310的至少一些的作用。如果需要,在一些实施例中,至少一些细丝310的至少一部分可由与多组分纤维110的第一部分112相似或相同的材料构成,以促进这种粘合。然而,可能不必如此就能形成令人满意的嵌入网100。
该过程的结果是制得了多孔支承网,所述多孔支承网包括其中具有嵌入网100的支承网300。随后可将该网通过其整个厚度分隔(如,切断),以形成多孔支承制品500,如图6所示。将多组分纤维110填入支承网300的内部空隙空间350从而在其中形成嵌入网的此类结构的形成过程,将会与常规的暂时将纤维垫沉积到环形纤维收集带上以及随后从环形带移除由此形成的网形成对照。
在一些实施例中,可对本文所述的过程进行操作,使得任选颗粒140在纤维垫230的整个厚度(如,在垫230的整个厚度内大体均匀)内掺入到垫230中(并最终驻留在由其形成的嵌入网100内)。在一些情况下,可通过可任选地将液体溶液214(例如水溶液)进料到腔室220内而对此过程进行增强。液体溶液214可以润湿纤维的至少一些,使得颗粒140依附在纤维的表面上,这样可增强颗粒140总体上在垫230的整个厚度中的分散。(当垫230行进到加热单元240时,液体溶液214可能会蒸发并且在加工过程中不再起进一步作用)。在其他实施例中,颗粒140可例如优先地驻留在网100的主表面135上或其附近。在例如当垫230为具有小型开口的相对致密网,使得颗粒140优先地保留在垫230的最上表面上或其附近时可能会出现这种情况。
高温暴露可例如通过使用任何合适的加热单元240(如一个或多个烘箱)而实现。在特定实施例中,加热单元240可包括所谓的通风粘合器,其中会强制在正压力下加热的空气通过纤维垫230和由其形成的嵌入网100的厚度,从而提高温度暴露的均匀度并促进均匀粘合。在其他实施例中,或者取代此类烘箱暴露和/或通风粘合,或者除此类烘箱暴露和/或通风粘合之外,可例如通过使包含纤维垫230/嵌入网100的支承网300经过包括加热压延辊、压延带组等的一个或多个加热单元240,而在施加压力的同时进行高温暴露。在此类情况下,支承网300和/或纤维垫230/嵌入网100可至少轻微地压缩,例如使得制品500的最终厚度可一定程度地小于支承网300的初始厚度。
在一些实施例中,可以使用大体上各向同性的支承网300(如,为由图2的示例性网所表示的那一类型),使得多组分纤维110大体上均匀地填入支承网300内(例如,如图4的示例性设计那样)。在其他实施例中,支承网300的至少一些内部空间350可以在支承网300内各向异性地分布和/或取向(例如,如图3的示例性设计所示)。在此类情况下,嵌入网100可在支承网300的全部内部空间350内各向异性地分布(例如,如图7的示例性设计所示)。例如,嵌入网100可存在于阱内,所述阱分布在支承网300的整个长度和宽度内并且延伸穿过支承网300厚度的一部分或几乎穿过其厚度的全部(如,从支承网300的一个主表面附近到支承网300的另一个主表面附近)。在特定实施例中,其中各向异性的支承网300包括(如上所述)大体封闭表面和大体开放表面,可能有利的是从承载大体开放的第一主表面335的支承网300的第一主侧面330进行纤维110的沉积,使得纤维110能够最容易地渗透到空隙空间350内。
可结合空隙空间350的尺寸来选择多组分纤维110的长度,以增加纤维填入。在多种实施例中,多组分纤维110可具有小于约15mm、小于约10mm或小于约8mm的平均长度(如,纤维制造商列出的标称长度)。通常,多组分纤维110可足够长,使得可由其形成令人满意的粘附网结构。在多种实施例中,多组分纤维110可具有至少1mm、至少2mm或至少3mm的平均长度。在一些实施例中,可选择多组分纤维110的平均长度,使其小于空隙空间350的上述平均尺寸。
可根据需要改变本文所公开的工艺、设计和材料,以制备具有不同构型、特性和功能的多孔支承制品500。因此在一些实施例中,可将多组分纤维110填入支承网300内,使得嵌入网100具有基本上类似于支承网300的厚度;例如,以使得嵌入网100的主表面125设置为与支承网300的主表面325大致齐平(如,差距在约1-2mm的范围内),并使得嵌入网100的主表面135设置为与支承网300的主表面335大致齐平(如图4中那样)。在其他实施例中,可以沉积多组分纤维110,使得嵌入网100向外延伸到支承网300的主表面之外。例如,在图8的示例性设计中,嵌入网100的主表面135位于支承网300的主表面335向外的位置。
在一些实施例中,也可能有用的是在支承网300的主表面顶上至少沉积第二层多组分纤维,以便至少由所述纤维形成第二张网,作为对嵌入网100的补充。可在支承网300的任何合适主表面顶上(如,在大体封闭表面(如果存在)的顶上)形成此类第二张网。可用于在未必采用多组分纤维大量和/或基本填充多孔基底内部从而形成嵌入其中的网的情况下,在多孔表面的主表面顶上沉积多组分纤维层的方法和设备,在共同待审并共同转让的美国专利申请No.__________中有详细地公开,该专利申请的名称为“Porous Supported Articles and Methods of Making”(多孔支承制品及其制备方法),3M代理人案卷号为65831US002,其随同本文在同一日期提交并且以引用的方式并入本文。
在另外其他实施例中,可以沉积多组分纤维110,使得嵌入网100仅部分填充支承网300的厚度。例如,在图9的示例性设计中,嵌入网100的主表面135位于支承网300的主表面335向内的位置。本领域的技术人员将会认识到,嵌入网100的一个或两个主表面125和/或135可能会有起伏(与例如大体上平坦相反)。
可以执行多个步骤,如后加工步骤,例如由图6的后加工单元250所执行的那样,以便(例如)增加成品500的强度、纹理和/或具体特性或能力。例如,可在嵌入网100的主表面135处设置部分或完全致密的表层160(如图8的示例性设计所示)。这可例如通过以下操作实现:使嵌入网100的表面135暴露于局部热源,使得该区域中的纤维更有力地熔融和/或粘合在一起。可将额外的涂层(如粘结剂涂层)施加于如嵌入网100的主表面135。此类粘结剂涂层可用于例如在嵌入网100的表面135上或其附近提供颗粒(如,本文所提到的研磨剂颗粒140中的任何一者)。
本领域的技术人员将会知道,可由上述支承网300和嵌入网100制成多种制品,涉及组分及其所列特性的任何合适组合。许多此类产品在例如刷洗应用场合(如,用于表面刷洗)可能有用,不管此类刷洗是通过手动还是通过机械(如,地板刷洗器等等)操作执行。此类产品在例如瓷砖地面、瓷砖工作台面等不均匀表面的刷洗中可能特别有用。具体地讲,本文所公开的至少一些实施例的优势在于:支承网300的细丝310可以在嵌入网100内充当内部弹簧,从而得到具有局部回弹性的嵌入网100,以便能够调整以适应不均匀表面。
对于某些刷洗应用(如,地板刷洗),可能期望的是研磨剂颗粒140可沉积到嵌入网100的主表面135上,和/或沉积到嵌入网100的至少一些内部空间内,如本文所提到的那样。为提高制品500用于此类目的的使用性能,而可将制品500设置成为的构型在例如美国专利4,893,439、6,234,886和美国专利申请公开2007/0298697中有更详细的讨论,上述专利全部以引用的方式并入本文。
在另外其他刷洗应用场合,可能有利的是使用图9所示的构型类型,其中支承网300的细丝310的至少一些部分313向外伸出到嵌入网100的主表面之外。在此类设计中,伸出的细丝部分313可起到将碎屑从狭窄间隙或裂缝中逐出的作用,而支承网300可起到接纳此类被逐出的碎屑、吸收液体等的作用。此类方法在如表面(例如鞋底的底部)的刷洗中可能特别有用,并且在已公布的国际专利申请WO2008/051819中有更详细的描述,所述专利申请出于该目的以引用的方式并入本文。
本领域的技术人员将会认识到,如本文所述的制品500可用于其中使制品500相对于要刷洗的表面移动的场合(如,作为地板刷洗垫、表面修整垫、擦洗垫,例如用于与旋转清洁机配合使用或通过手动操作),以及其中使制品500保持静止并且相对于制品500移动要刷洗的表面的刷洗应用场合(如,作为地板垫等等)。也可以想到除刷洗之外的用途。
因此对于本领域的技术人员将显而易见的是,本文所公开的具体示例性结构、特征、细节、构型等可在许多实施例中进行修改和/或组合。本发明人所构思的所有此类变型和组合均在所构思的发明的范围内。因此,本发明的范围不应受本文所述的具体示例性结构限制,而是受权利要求书的文字所描述的结构或这些结构的等同形式限制。如果在本说明书与以引用方式并入本文的任何文献的公开内容之间存在冲突或差异,则以本说明书为准。
实例
通过使用大体上与图6中所示类似的设备和方法制备多孔支承制品。以商品名255从Trevira GMBH(Bobingen,Germany)获得多组分纤维。所述纤维是平均长度为大约6mm的2.2分特皮芯型双组分纤维(外皮由共聚乙烯构成,芯由聚酯(聚对苯二甲酸乙二醇酯)构成)。
以商品名ENKAMAT 7225从Colbond Geosynthetics公司(St.Denis laPlaine,France)获得支承网。所述网包括不规则环状和相互缠结的细丝,其形成高度开放的三维薄板结构。网的一侧包括大体封闭表面,其中细丝为平整、共面的环和涡状形形式。网的另一侧包括大体开放表面,使得许多内部空隙空间朝网的这一侧开放。网因此为图3所表示的一般类型。
使图6所示类型的形成腔室进入适当的稳态运行状态,其中多组分纤维通过销钉辊和环形带筛网进行加工并随后在重力作用下朝向形成腔室的底部下落到环形纤维收集带(多孔目筛网)上,所述环形纤维收集带在形成腔室的底部下面水平运行。将上述支承网的一段设置到环形纤维收集带上,并使支承网的大体开放表面朝上。使支承网以每分钟大约1米的速度从形成腔室下面通过。该速度是结合多组分纤维进料到形成腔室内以制备总基重为大约330gsm(测得的该总基重远大于支承网的重量)的沉积(填入)纤维垫的速率计算得到的。将(局部)真空施加于多孔环形带的下侧以帮助沉积。
将纤维填入支承网的内部空隙空间,其中纤维的至少一些基本上贯穿了支承网的内部空间,从而驻留在支承网大体封闭表面的内侧附近或倚靠在该内侧上(其中这些被填入纤维与支承网的外部分隔开的距离至少为支承网大体封闭表面的环状或涡状形纤维的纤维厚度)。纤维填入支承网的可触及内部空隙空间内,从而得到填有多组分纤维的阱,所述阱(沿着支承网的长度和宽度)散置在未填有多组分纤维的空间(如支承网的这样的空隙空间,其中支承网的细丝在很大程度上抑制多组分纤维刺入这些空间内)之中。进行沉积,使得多组分纤维的纤维垫的上表面略微高于(如,高大约1mm或更小)支承网的顶部(大体开放)表面。
随后使其中具有纤维垫的支承网连续地穿过两个加热单元(使用两个单元是因为可用单元的尺寸和加热容量较小)。第一加热单元为包含大约160℃温度的流动空气的烘箱。叠堆在第一加热单元中的停留时间为大约5分钟。第二加热单元为包含大约160℃温度的流动空气的烘箱。第二烘箱还包括环形带(由结网构成),其中具有纤维垫的支承网连续地两次穿过该环形带。将环形带之间的间隙设置为足够大,使得环形带不对支承网以及其中的纤维垫施加压力。叠堆在每次穿过第二加热单元期间的停留时间为大约1至2分钟。
采用高温暴露来将含颗粒纤维垫自粘合为嵌入支承网内的粘附多孔网,要移除该所述粘附多孔网会很困难,并且会造成嵌入网的损坏和撕裂。
这样制备的是厚度为大约20mm的多孔支承制品,所述制品包括厚度为大约20mm的支承网,并且在其中具有嵌入网的阱(如,外观与图7的示例性设计类似)。嵌入网的顶部表面略高于(如,高大约0.1至0.5mm)支承网的顶部表面(使得支承网任何细丝的任何部分均不会伸出嵌入网的顶部表面),同时嵌入网材料的连续层从而遍布于多孔支承制品的顶部表面。嵌入网的顶部表面缓缓起伏,并显示为包括略为致密的表面层。
进行许多这种类型的实验。一些实验按照与上述类似的方式进行,但其中多组分纤维沉积为大约165gsm的基重。
Claims (22)
1.一种制备多孔支承网的方法,包括:
将不连续的多组分聚合物纤维进料到形成腔室内;
在所述形成腔室内混合所述多组分纤维;
将所述多组分纤维填入细丝状支承网的至少一些内部空隙空间内,以在所述支承网的所述至少一些内部空隙空间内形成填入纤维垫;以及
将所述多组分纤维暴露于高温,以使至少一些所述多组分纤维熔融粘合至彼此,使得所述纤维垫自粘合为嵌入在所述支承网的所述至少一些内部空隙空间内的多孔网。
2.根据权利要求1所述的方法,其中将所述多组分纤维填入所述支承网的所述至少一些内部空隙空间内通过以下过程执行:使所述支承网穿过所述形成腔室或在所述形成腔室下面通过,然后使所述多组分纤维在重力作用下下落至所述支承网内,并且其中所述将所述多组分纤维暴露于高温通过使其中具有所述填入纤维垫的所述支承网穿过与所述形成腔室分开的加热单元而实现。
3.根据权利要求2所述的方法,还包括:向所述支承网的主表面施加至少局部真空,使得穿过所述支承网存在压力差,以帮助将所述多组分纤维填入所述支承网的所述至少一些内部空隙空间内。
4.根据权利要求1所述的方法,其中所述嵌入的多孔网包括第一主表面和第二主表面,并且其中所述嵌入的多孔网的所述第一主表面和所述第二主表面均位于所述支承网的内部。
5.根据权利要求4所述的方法,其中所述支承网的至少一些细丝从所述嵌入的多孔网向外延伸至所述嵌入的多孔网的所述第一主表面和所述第二主表面之外。
6.根据权利要求1所述的方法,其中所述嵌入的多孔网包括第一主表面和第二主表面,并且所述支承网包括第一主表面和第二主表面,并且其中所述嵌入的多孔网的所述第一主表面和所述第二主表面中的至少一者从所述支承网向外延伸至所述支承网的所述第一主表面和所述第二主表面之外。
7.根据权利要求1所述的方法,其中所述嵌入的多孔网包括第一主表面和第二主表面,并且其中所述嵌入的多孔网的所述第一主表面和所述第二主表面中的至少一者包括致密表面层。
8.根据权利要求1所述的方法,其中所述支承网具有大体封闭的第一主表面和大体开放的第二主表面,所述大体封闭的第一主表面包括多个平整、共面的细丝环,所述大体开放的第二主表面由远离所述支承网的所述第一主表面的细丝部分限定,并且其中所述将所述多组分纤维填入细丝状支承网的至少一些内部空隙空间内通过将所述多组分纤维填入所述支承网的所述大体开放的第二主表面内而进行。
9.根据权利要求1所述的方法,其中所述支承网的细丝的平均直径为至少约200微米。
10.根据权利要求1所述的方法,其中所述多组分纤维的纤度介于约1旦尼尔和约5旦尼尔之间。
11.根据权利要求1所述的方法,还包括:将颗粒进料到所述形成腔室内;将所述颗粒与所述多组分纤维混合;将所述颗粒和所述多组分纤维填入所述支承网内;以及将所述多组分纤维和所述颗粒暴露于高温,以使至少一些所述多组分纤维熔融粘合至彼此并使至少一些所述颗粒熔融粘合至至少一些所述多组分纤维以形成多孔含颗粒网,所述多孔含颗粒网嵌入在所述支承网的所述至少一些内部空隙空间内。
12.根据权利要求11所述的方法,其中所述颗粒选自研磨剂颗粒、金属颗粒、洗涤剂颗粒、表面活性剂颗粒、杀生物剂颗粒、吸附剂颗粒、吸收剂颗粒、微胶囊以及它们的组合。
13.根据权利要求12所述的方法,其中所述颗粒为选自短切纤维质海绵颗粒和短切聚氨酯海绵颗粒以及它们的混合物的吸收剂颗粒。
14.根据权利要求1所述的方法,其中至少一些所述多组分纤维熔融粘合至所述支承网的至少一些细丝上。
15.根据权利要求1所述的方法,还包括:提供施加于所述嵌入的多孔网的主表面或其内部的粘结剂涂层。
16.根据权利要求15所述的方法,其中所述粘结剂涂层包含研磨剂颗粒。
17.根据权利要求1所述的方法,还包括:将填充纤维进料到所述形成腔室内并使其与所述多组分纤维混合,并将所述填充纤维和所述多组分纤维填入所述支承网的所述至少一些内部空隙空间内。
18.根据权利要求1所述的方法,还包括:穿过所述支承网以及其中的所述嵌入的多孔网的厚度进行切割,从而把所述多孔支承网分成多个多孔支承制品。
19.根据权利要求1所述的方法,其中所述将所述多组分纤维暴露于高温包括将所述支承网和其中的所述嵌入的多孔网穿过通风粘合器。
20.根据权利要求1所述的方法,其中所述多组分纤维通过多个旋转销钉辊在所述形成腔室内进行混合。
21.一种多孔支承制品,包括:
其中包含内部空隙空间的细丝状支承网;
位于所述细丝状支承网的至少一些所述内部空隙空间内的嵌入多孔网,所述嵌入多孔网的纤维基本上由不连续的多组分聚合物纤维组成,至少一些所述多组分聚合物纤维至少在所述多组分聚合物纤维接触的某些点熔融粘合至彼此从而构成自粘合网。
22.根据权利要求21所述的多孔支承制品,其中所述嵌入多孔网还包含熔融粘合至至少一些所述多组分聚合物纤维的颗粒。
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EP (1) | EP2491174B1 (zh) |
JP (1) | JP5883391B2 (zh) |
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CN (1) | CN102575393B (zh) |
AU (1) | AU2010308287B2 (zh) |
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CA (1) | CA2777244C (zh) |
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Also Published As
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CN102575393B (zh) | 2015-01-21 |
WO2011049927A3 (en) | 2011-08-18 |
EP2491174A4 (en) | 2014-01-08 |
US20120231692A1 (en) | 2012-09-13 |
AU2010308287A1 (en) | 2012-05-03 |
US8828162B2 (en) | 2014-09-09 |
KR20120071404A (ko) | 2012-07-02 |
EP2491174A2 (en) | 2012-08-29 |
MX2012004390A (es) | 2012-05-23 |
EP2491174B1 (en) | 2016-09-21 |
KR101782659B1 (ko) | 2017-09-27 |
WO2011049927A2 (en) | 2011-04-28 |
CA2777244C (en) | 2018-01-09 |
BR112012009561A2 (pt) | 2016-05-17 |
AU2010308287B2 (en) | 2013-09-19 |
CA2777244A1 (en) | 2011-04-28 |
JP5883391B2 (ja) | 2016-03-15 |
JP2013508570A (ja) | 2013-03-07 |
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