CN103080397A - 加固非织造织物的方法 - Google Patents

加固非织造织物的方法 Download PDF

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CN103080397A
CN103080397A CN2011800439333A CN201180043933A CN103080397A CN 103080397 A CN103080397 A CN 103080397A CN 2011800439333 A CN2011800439333 A CN 2011800439333A CN 201180043933 A CN201180043933 A CN 201180043933A CN 103080397 A CN103080397 A CN 103080397A
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I.贝恩特
W.罗根施泰因
A.陶滕哈恩
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Abstract

本发明涉及通过喷水处理加固非织造织物的方法。本发明方法的特征在于，该非织造织物含有以塌陷的粘胶中空纤维形式的扁平纤维，其宽度B和厚度D的比例B：D≥10：1。

Description

加固非织造织物的方法
本发明涉及通过喷水处理加固非织造织物的方法。
通过喷水法，也被称"水力缠结法"或者"水刺法" 来加固非织造织物是本领域技术人员公知的。
在按照喷水方法制造非织造织物时，通过纤维的编织和涡旋搅动实现呈送的梳理机纤维网的加固。该呈送的纤维通过喷水被包裹，使其运转起来并通过涡旋运动三维相互交织。
一般认为棉花是用于喷水加固特别合适的纤维材料，例如见Alfred Watzl，Fa Fleissner的文章“Aquejet Spunlace Verfahren - Technik für Baumwollfasern”。其中，棉纤维的低湿模量以及纤维不具有圆形光滑的纤维横截面的事实被认为是有利的。
为了达到高的非织造织物强度，高弹性模量（下述：“E模量”）的纤维是合适的。它们基本上是非纤维素纤维。
为了达到足够高的非织造织物强度，在喷水加固过程中需要高压，因此这种方法是耗能的。
本发明的任务在于提供一种喷水加固非织造织物的方法，其可以通过较低的能量消耗而实行。
该任务是通过喷水处理加固非织造织物的方法而实现的，其特征在于，非织造织物含有以塌陷的粘胶中空纤维形式的扁平纤维，其宽度B和厚度D的比例B：D≥10：1。
此外，本发明涉及一种喷水加固的含有以塌陷的粘胶中空纤维形式的扁平纤维的非织造织物，该扁平纤维的宽度B和厚度D的比例B：D≥10：1。
优选的实施方案列举在从属权利要求中。
发明的具体描述
令人惊奇地显示，与不含扁平纤维的相同类型非织造织物的情况相比，在通过喷水要加固的非织造织物中使用塌陷的粘胶中空纤维，可以在相同的能量消耗（也就是使用同样高的处理压力）的喷水加固过程中产生更高的非织造织物强度。同样地，与不含纤维素扁平纤维的非织造织物的情况相比，可以在较低能耗的情况下实现所想要的非织造织物强度。
由此可以节省能量，并因此降低工艺成本。此外，由于较低的压力可以将仪器的损耗保持较低。另外也可以实行更温和的加固，也就是在较低的压力下。举例来说，在混合物含有纤维素的情况下（其中在高压下导致纤维素被洗出）或者在混合物含有敏感性纤维的情况下这是有利的。此外，可以避免或者至少减少使用合成纤维（用于实现特别高的强度）。
在本发明的方法中，非织造织物中含有的扁平纤维的比例B：D优选10：1-30：1，特别优选20：1。
扁平纤维的纤度优选0.9-5 dtex，特别优选1.3-1.9 dtex。
扁平纤维及其制备是已知的。与通常基本上是圆的纤维横截面不同，扁平纤维具有基本上扁平的或者长的横截面。
一方面，纤维素扁平纤维可以通过对含有纤维素或纤维素衍生物的纺丝原液借助隙缝式的纺丝喷丝头进行纺丝来制备。在粘胶纤维情况下，扁平纤维可以替代性地以塌陷的中空纤维形式来制备。其中，在纺丝粘胶中混入气体例如氮气，或发泡剂例如碳酸钠。在通过本身传统的喷丝头进行纤维纺丝时产生中空纤维，但是在选择相应的方法条件时其壁如此的薄，以至于纤维塌陷并随后以扁平纤维的形式存在。
纤维素扁平纤维的制备例如在GB 945 306 A，US 3 156 605 A，US 3 318 990，GB 1 063 217 A中已知。正如上述提及的文献中部分描述的，这些纤维特别推荐用于造纸。
C.R.Woodings, A.J.Bartholomew的文章"The manufacture properties and uses of inflated viscose rayon fibres"; TAPPI 非织造织物研讨会; 1985; 页码 155-165.出自ttp://www.nonwoven.co.uk/publications_cat4.php描述了不同类型的中空纤维及其应用。
WO 2006/134132中描述了在纤维复合材料中使用粘胶扁平纤维，目的是改善纤维复合材料水中的可溶解性。根据WO 2006/134132，使用的扁平纤维优选具有锯齿型（峰尖状的）表面，与塌陷的中空纤维不同，其通过隙缝式喷丝头纺丝来制备。这种扁平纤维的有突起条纹的表面降低了纤维和纤维之间的粘附，并由此降低强度。另一方面，传统扁平纤维中能达到的厚度受喷丝头几何形状的限制。使用开孔为25μm高的喷丝头进行纺丝时，通常产生大约4-6μm的纤维厚度。为了恒定地制备类似在塌陷的中空纤维情况下的大约2-3μm的纤维厚度，喷丝头开孔必须是大约12.5μm高，但这样的喷丝头开孔在喷丝头的制备以及在使用传统的方法生产粘胶纤维中在经济上是不可行的。
与此相比，本发明使用的胶粘扁平纤维是塌陷的中空纤维，如上面提到的，其可以通过在纺丝粘胶中引入气体或者发泡剂（特别是碳酸钠）来制备。该纤维可以完全塌陷或者仍然微微打开。该纤维的吸湿能力应该优选200%或更少（按照DIN 53814测量）。该纤维的纤维横截面应该主要是扁平的和优选不带分支的。
在非织造织物中扁平纤维的比例优选为5%-100%，特别是20%或更多，特别优选50%或更多。因此，该非织造织物可以完全由扁平纤维组成或者也可以含有扁平纤维与其它纤维的混合物。作为混合成分，可以考虑所有适合于喷水加固的纤维素纤维材料和非纤维素纤维材料。本领域的技术人员清楚，在非织造织物中扁平纤维的含量越高，本发明的效果（也就是非织造织物的强度提高以及能源节约）越突出。
本发明也涉及喷水加固的非织造织物，其含有以塌陷的粘胶中空纤维形式的扁平纤维，该扁平纤维的宽度B和厚度D的比例B：D≥10：1。关于扁平纤维以及其在非织造织物中的比例详见从属权利要求和/或上述实施方案。
实施例
用于制造喷水加固的非织造织物，使用下述纤度分别为1.7dtex的纤维：
a）标准粘胶纤维（类型Danufil®）
b）由中空纤维方法制造的粘胶扁平纤维；纤维厚度大约2-3μm；宽：厚的比例=大约20：1
该纤维以梳理机纤维网的形式呈送，并在两道中双面加固。
由各纤维制造具有两种单位面积重量和分别具有两个加固级别（轻度 - 高度加固）的非织造织物。
单位面积重量：50g/m 2 或 80g/m 2
加固级别：（加固压力分别以在两道中所有喷丝头梁（Düsenbalken）的所有压力之和给出）
单位面积重量50g/m 2 - 轻度加固： 65bar
单位面积重量50g/m 2 - 高度加固： 95bar
单位面积重量80g/m 2 - 轻度加固： 95bar
单位面积重量80g/m 2 - 高度加固： 145bar
因此，较高的加固压力分别高出低加固压力大约50%。
检测：
针对所有非织造织物的标准试样5*25cm，确定下列参数：
- 在生产方向上（MD）和与生产方向垂直的方向上（CD）的最大拉力[N/5cm]，分别在湿润和干燥的情况下
- 最大拉力伸长率或者由此推导出的比例MD/CD以及总和MD+CD
其结果总结在下列表格中：
表1a – 由粘胶扁平纤维组成的非织造织物（按照本发明）
Figure 668286DEST_PATH_IMAGE001
表1b – 由粘胶扁平纤维组成的非织造织物（按照本发明）
Figure 585426DEST_PATH_IMAGE002
表2a – 由标准粘胶纤维组成的非织造织物（比较）
表2b – 由标准粘胶纤维组成的非织造织物（比较）
由上面的数据可以得出下面的结论：
伸长率：
在干燥的非织造织物中，与由标准粘胶纤维制造的非织造织物相比，由扁平纤维制造的非织造织物的最大拉力伸长率（在相同的单位面积重量和同样加固的情况下）明显更低。这可能归因于更高比例的纤维和纤维之间的结合。
MD/CD- 比例
与由标准粘胶纤维组成的非织造织物相比，含有扁平纤维的非织造织物在同样的试验设置下展现出基本上更高的MD/CD比例。
基于轻度加固时低的MD/CD比例，MD/CD比例通过在加固过程中纤维的再取向得到提高。在相同的压力下基本上更高的MD/CD比例（由扁平纤维组成的非织造织物相对于由标准粘胶纤维组成的非织造织物）显示出明显更高的扁平纤维柔强度，其使加固过程变得显著更容易。
强度：
表3 – 由粘胶扁平纤维组成的非织造织物（按照本发明）
表4 – 由标准粘胶纤维组成的非织造织物（比较）
Figure 20376DEST_PATH_IMAGE006
为了更简单的研究，在每种情况下使用断裂强度MD+CD的总和来判断强度。
在由扁平纤维组成的本发明的非织造织物中可以发现，通过把加固压力从“低”提高到“高”不能达到更高的强度。也就是说，该非织造织物分别在低的加固级别时明显已经最大程度地被加固。
非织造织物的强度在同样加固的情况下通常与单位面积重量相关联。
在这种情况下，单位面积重量的比例80g/m 2比50g/m 2=1.6。
举例来说，基于单位面积重量为50g/m2的高度加固的非织造织物的强度的测量值大约为72N/5cm，由此对于单位面积重量为80g/m2的同样高度加固的非织造织物，其强度的预期值为72*1.6=115N/5cm，该值很好地与大约为120的实际测量值相符。
也就是说，在所有四组中，非织造织物分别已经最大程度地被加固。
对于由标准粘胶纤维组成的非织造织物，显示出另外的一种情形：
在触觉评价中，低加固级别的两种非织造织物仅仅进行了不充分的加固。
当把加固压力从“低”提高到“高”（分别提高了大约50%）时，在每种情况下可以发现明显增加的非织造织物强度。这里，进一步增加压力明显仍可以进一步加固，也就是说，最大程度的加固需要还要更高的压力。
在50g/m2-非织造织物的较高加固级别中，干燥的非织造织物的强度甚至比由扁平纤维组成的非织造织物的强度高出一些。其原因很可能在于在试验中使用的纤维更高的单纤维强度（标准粘胶纤维：22cN/tex；粘胶扁平纤维：16cN/tex）。但是由此可以推断，这里的非织造织物在很大程度上已经被加固。
因此，按照上面的计算，对于完全加固的单位面积重量为80g/m2的非织造织物，预期强度至少为81.3*1.6=130N/5cm。但是测量值仅仅为大约99N/5cm。因此，80g/m2的非织造织物在使用更高的加固压力时还远远没有完全加固。
在这个加固级别中，非织造织物仅达到其加固潜力的大约75%。
对比例：
80g/m2的非织造织物的实施例明显显示了按照本发明在喷水加固中使用扁平纤维的优点。
由粘胶扁平纤维组成的非织造织物 - 在95bar的加固压力下：
干燥情况下的强度（MD+CD）= 120 N/5cm：
湿润情况下的强度（MD+CD）= 83N/5cm
由标准粘胶纤维组成的非织造织物 - 在145bar的加固压力下：
干燥情况下的强度（MD+CD）= 99N/5cm：
湿润情况下的强度（MD+CD）= 60N/5cm：
与使用标准的粘胶纤维相比，通过在非织造织物中使用粘胶扁平纤维可以在降低50%的压力下达到提高20%的（干燥）或者提高40%的（湿润）强度。

Claims (8)

1. 通过喷水处理加固非织造织物的方法，其特征在于，该非织造织物含有以塌陷的粘胶中空纤维形式的扁平纤维，该扁平纤维的宽度B和厚度D的比例B：D≥10：1。
2. 按照权利要求1的方法，其特征在于，该扁平纤维的比例B：D为10：1-30：1，优选20：1。
3. 按照权利要求1或2的方法，其特征在于，该扁平纤维的纤度为0.9-5 dtex，优选1.3-1.9 dtex。
4. 按照上述权利要求之一的方法，其特征在于，在非织造织物中扁平纤维的比例为5%-100%，优选20%或更多，特别优选50%或更多。
5. 喷水加固的非织造织物，含有以塌陷的粘胶中空纤维形式的扁平纤维，该扁平纤维的宽度B和厚度D的比例B：D≥10：1。
6. 按照权利要求5的非织造织物，其特征在于，该扁平纤维的比例B：D为10：1-30：1，优选20：1。
7. 按照权利要求5或6的非织造织物，其特征在于，该扁平纤维的纤度为0.9-5 dtex，优选1.3-1.9 dtex。
8. 按照权利要求5-7之一的非织造织物，其特征在于，在非织造织物中扁平纤维的比例为5%-100%，优选20%或更多，特别优选50%或更多。
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