CN103347689B - 茶包以及双组分和单组分聚乳酸和共聚乳酸纤维的组分 - Google Patents

茶包以及双组分和单组分聚乳酸和共聚乳酸纤维的组分 Download PDF

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CN103347689B
CN103347689B CN201180040569.5A CN201180040569A CN103347689B CN 103347689 B CN103347689 B CN 103347689B CN 201180040569 A CN201180040569 A CN 201180040569A CN 103347689 B CN103347689 B CN 103347689B
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CN103347689A (zh
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斯蒂芬·W·福斯
让-玛丽·图拉
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Abstract

本发明涉及一种用于茶包等的生产的网材料、以及包或袋、线和由此组装的包/袋，其中所述茶包等由PLA纤维的非织造网状物制成，所述PLA纤维呈单组分和/或双组分形式。

Description

茶包以及双组分和单组分聚乳酸和共聚乳酸纤维的组分
技术领域
本发明涉及可热封的液体浸泡(infusion)网状材料以及由这种网制造的成品，如茶包或茶袋、咖啡包或咖啡袋、草药香囊、微粒液体清洗剂(含有或不含粘合剂)的包。本发明提供了用于这些应用的非织造网，其含有100％或者近100％的聚乳酸(PLA)纤维，设计为基本100％可生物降解、基本100％可回收、并在热的液体中加热的时候保持最小的孔径变化。
背景技术
需要一种浸泡基材，特别是用于茶和咖啡，所述基材使热水能够快速浸入茶或咖啡颗粒中，同时足够牢固以将颗粒保持在包、或袋、或漏斗(funnel)、或其它过滤罩之内，所述包或袋或漏斗或其它过滤罩绝大部分或完全由该基材制成。还需要用于烟草和烟草制品(即鼻烟和嚼烟)的可热封的袋。
此外，非常期望所述基材介质是100％可生物降解的且不含有任意惰性或不可生物降解组分。还非常期望所述介质(包括所有的生产废料)可以回收为自身。
CargillInc.对聚乳酸(PLA)纤维进行了重要开发以从天然原料制造纤维，所得的工艺和产品描述于美国专利6,506,873中。KimberlyClark在其专利#7,700,500“生物可降解聚合物基材的持久性亲水处理(Durablehydrophilictreatmentforbiodegradablepolymersubstrate)”中述及PLA。Grauer等的美国专利6,510,949教导可将亲水性物质浸入滤纸中以改善其水润湿能力和吸水性。茶包和咖啡袋传统上由纸制成，且茶包浸泡时间慢并倾向于漂浮在液体表面。已经尝试了由PLA生产纺丝熔体非织造物，但是其密封性和在自动包装机械上的性能较差。
已经使用尼龙编织网制造了日本的新型茶包织物，该织物提供快速的浸泡，但是当制成包、袋或漏斗或其它过滤罩时需要非传统的密封方法，该织物昂贵且不可生物降解。
本发明的一个目的在于提供一种用于茶包等的新基材，所述基材满足上述对于生物可降解性、可再循环和可热封的需求中的一种或多种或全部，并且可以在传统设备上运行。
本发明的又一个目的在于提供给该基材和所得的茶包更高的透明度，以看到所含茶叶或其它内容物的颜色和形状，并提供强度以承受内容物(例如茶叶、研磨咖啡)锋利边缘的切割或穿刺。
又一个目的在于通过提供对于袋/包系统可密封的(例如通过热封、超声波焊接或其它方法，所述方法基本或完全不添加中间粘合剂组分，此外是可降解的，且优选可回收的)线，强化整体的袋/包系统。线对于标签的密封性也是材料所需要的。整个袋/包组合件应是上述改进的组合，但还允许不可生物降解但在包和线材料的回收中分离的纸制部分、线或标签。然而，那些部分也可制成可生物降解的形式。
发明内容
本发明提供一种高度多孔的介质，其为网状、可分割且可成形为成品部件(例如，包、袋、漏斗或其它过滤罩)或者其部分，其单独地由PLA、或由PLA和共聚PLA(共聚乳酸，Co-PLA)纤维采用热粘合非织造制造方法生产。介质对于热水浸入咖啡或茶(或者如上面所更广泛地指出的其它液体、或其它袋/包内容物)中表现出高效率。通过在初始的网生产和/或后续的步骤中网的加热和/或施加压力，纤维在许多交叉点自粘结。
本发明的基材网状材料是在连续的工艺中生产，所述连续的工艺提供可控的机器加工方向和机器横向的性质，并且提高介质的性能。通过控制PLA和共聚PLA纤维的初始共混物中较低熔点的共聚PLA的百分率(％)，可在网的制造过程中通过纤维的取向、温度的设定和暴露于加热的时间控制热粘合强度。在包或袋的制造过程中，密封粘合的强度可通过温度、停留时间和刀压控制。在其中一个卡板(card)上，无规发生器辊(randomizerroll)的添加增加了网的机器横向的强度并改善了网的均匀性。
PLA和共聚PLA的比重为1.25，即大于水，其致使包或袋下沉和浸入并完全没入热水中。此外，PLA是天然亲水的，无需特殊处理，其允许水快速流入茶或咖啡中。
可通过改变聚合物中异构体含量而选择熔点125℃至160℃的共聚PLA。因而，可以满足各种自动包装机的密封要求。
不仅是由可再生原料制成的介质，而且废料纤维、非织造的修剪废料和制做包的废料也可被再熔融、挤出成丸粒，并共混入挤出操作中以制成更多的纤维。它来自100％可再生来源且是100％可回收的。在纤维制造的工艺中，任何“废弃物”纤维可以被重新挤出成丸粒并放回到纤维工艺中。在非织造网的生产工艺中，任意启动或修剪“废弃物”可以被重新挤出成颗粒并放回到纤维工艺中。在浸泡包装制造工艺中，任意修剪、启动或其它网的“废弃物”可被重新挤出并放回到纤维制造工艺中。
与含有胶乳和合成填料的PET、尼龙和多数纸不同，本发明的介质是100％可堆肥的(compostable)。在98％湿度和60℃以上的条件下水解后，PLA易被微生物消耗，且其组成的原子被转化，以可能再用于生长更多玉米、甜菜、水稻等，以进一步转化成PLA或其它用途。
本发明以五种重量生产：16、18、20、25和30gsm(克每平方米)，但可以以更轻或更重的重量生产。
附图的简要说明
图1是40x放大倍率下的显微相片(1)，其示出了18gsm的具有30％(重量)共聚PLA/70％PLA的网，其表现出优异的强度和极好的密封特性。在12gsm至20gsm的较轻的重量下它应表现得同样出色；
图2是示出具有10％共聚PLA/90％PLA共混物的16gsm网的显微相片(2)，其表现出足够的强度但不具有足够低熔点的纤维以有效地密封；
图3是具有高熔点芯(PLA175℃M)和低熔点鞘(共聚PLA135℃)的双组分纤维的图。
图4是18gsm的85/15％共混物的显微相片-40倍放大倍率。
图5是18gsm的80/20％共混物的显微相片-40倍放大倍率。
图6是18gsm的80/20％共混物的显微相片-100倍放大倍率；
图7是标准纸的显微相片；以及
图8是日本制造的尼龙织物的显微相片。
优选实施方式的详细描述
进行本发明优选的实施方案并对其解释如下，其包括的所有或大部分纤维为双组分形式，并且其通过将由FiberInnovationTechnologies制造的单组分PLA纤维(T811型)与芯/鞘双组分(BiCo)纤维共混而生产，所述双组分纤维的PLA在芯中且共聚PLA在鞘中。芯/鞘区(area)比为50/50％。以80/20％至20/80％的PLA/共聚PLA比率生产纤维。其它的纤维生产商如PalmettoSynthetics和FossManufacturingCompany可以制造这些纤维。PLA纤维通常使用乳酸作为聚合物制造的起始原料而制成。乳酸来自各种来源的天然糖类的发酵。这些糖类可以来自每年可再生的农作物如玉米或甜菜。这些聚合物在挤出前必须完全干燥以避免水解。PLA是脂肪族的聚酯，并且PLA分子螺旋状的性质使它比PET更容易结晶。PLA可以使用标准的PET纤维装置挤出成为纤维。
在用单组分PLA纤维制造基材的情况下，熔融温度为175℃的高温变体(variant)被挤出成为纤维。然后，初始纤维被拉伸至其长度的3.5倍以得到所需的1.5旦尼尔。然后它被卷曲并热定形至140℃以改善结晶度并稳定卷曲。然后它被被切成1.5”(38mm)。在用Bi-Co纤维制造基材的情况下，使用熔融纺丝生产线(meltspinningline)，所述熔融纺丝生产线使用MelbourneFL的HillsInc制造的共挤出喷丝头(spinerette)。生产线的喷丝头生产类似图3的纤维。较高熔点(175℃)的PLA在芯中，而较低熔点的共聚PLA(135℃)在鞘中。通常，低熔点共聚PLA是完全无定形的，使得其更容易熔融并围绕结晶的单组分PLA纤维流动。为了其强度，芯的PLA纤维保留并在网中的许多交叉点处与单PLA纤维结合(粘合)。
共混百分比从90％PLA/10％BiCo至60％PLA/40％BiCo变化。70/30％的混合百分比产生强度和可密封性最好的纤维。还可能制造结晶的PLA(175℃熔点)和由100％的共聚PLA制成的单组分纤维(熔点在135℃和165℃之间)的共混物。共混是通过手动或由自动重量计量进料器称出需要百分比的PLA和BiCo纤维来进行。两种纤维在彼此之上成层并送入具有进料辊的开启部(opener)，将纤维送入带齿的筒内，将团块拉伸成单独的纤维。然后将纤维吹入共混斗(blendingbin)，以通过首先在斗内均匀成层纤维然后用带尖的挡板交叉切割所述层而生成均匀的混合物，所述带尖的挡板将纤维供至梳理系统。
梳理系统由两个进料料斗组成。第一箱作为储备保持斗，以保证连续的供应。第二进料料斗有具有负载传感器的连续刻度，为梳理机提供设定重量的进料。所述梳理机是一系列覆盖有齿形线的相互作用的筒，其将纤维撕扯并梳理成平行的网。
织物的重量为12gsm至20gsm，选择18gsm进行试验。据认为，16gsm(未进行)会提供最佳的特性。
生产线是Asselin-Thibeau线，其具有3个梳理机器，每个2.3米宽。所述网以直线方式供送并供入压延机中，所述压延机具有直径460mm的辊，所述辊用热油加热，加热温度为130℃至152℃。生产线速度为每秒40米，最终宽度2.0米。
如果期望平行的网，则用另两个梳理机将从梳理系统直接出来的纤维结合并热粘合。这通常导致机器方向(MD)/机器横向(CMD)强度比为4∶1。如果期望更平衡的强度比，那么可以将“无规发生器”辊系统添加至一个或更多个梳理机。结果可以是MD/CMD强度比最高至1.5∶1。
通过控制梳理系统和纤维取向，纤维可以用某种方式排列以控制网中孔隙或开口以提高热水的浸泡速度。
网卷被切成156mm(6.14”)宽，以用于茶包机器。
茶包机器是MiflexMasz制造的ASK020型。在机器上放置两个网卷，并放在模中心。放置正确量的茶，然后顶部和底部的片在135℃的温度下自动密封，停留时间为0.5秒至0.8秒。
本发明的基材网可在标准茶/咖啡包装机上用简单的刀具装置容易地切割，并产生最小量的绒毛或松散的纤维。
因为所述纤维不溶胀，所以所述网在用热的液体浸泡期间维持其孔径。这增强了水流动进入茶或咖啡中，降低了泡制时间。
由于网纤维不溶胀，所以使气压积聚的风险最小化，从而消除了包破损和颗粒泄露的风险
使用沸水，浸泡时间被降至一(1)秒。
当加压时，浸泡的液体完全离开容器(包或袋)，留下丝般的半透明的表面。
PLA的回收非常容易，并依赖于在工艺中的位置。在纤维制造过程中，可以通过使用“Erema”或“MechanicModerne”回收线(许多其它的也可起作用)使纤维废料致密化来将所有来自纺丝和拉伸二者的纤维重新挤出成丸粒。所述装置将使纤维致密化并部分熔融至预干燥以去除任何水分。致密的颗粒被强迫进入挤出口以去除所有的水分。然后PLA被完全熔融和挤出并过滤以形成纯无定形丸粒。然后，可以将所述丸粒与原始的丸粒共混以制造新的纤维。在热粘合工艺过程中，可以将废料纤维、切边和有缺陷的织物打包并运回上述的回收系统。在茶包制作工艺过程中，可以将修剪废料和“骨架”废料(特别是来自制作圆形袋的)打包并如上文所述重新加工。最后，茶包可以在使用之后堆肥，PLA将转变回糖类，该糖类可用于制造更多的PLA。
本发明还可用作袋，用于：柠檬水、草药香囊、肥皂粉、用于游泳池和温泉的化学品和氯、洗涤液、液体着色、除湿化学品、用于加热或冷却的相变材料的载体、烟草袋和所有可被放置在热或超声活化的密封容器中的材料。
再一个优选的实施方案包括全部或部分由单组分纤维制成的茶包材料和成品，所述单组分纤维具有与相似纤维或其它纤维的自粘合性能，以生产有效的网材料和有效的成品。
优选的单组分是熔融温度为135℃的共聚PLA。该纤维被制成1.3旦尼尔x38mm的纤维。这产生了100％粘合剂的纤维，而不是通常由50/50PLA/共聚PLA组成的双组分纤维。单组分纤维与标准PLA纤维以85％PLA/15％共聚PLA的比率共混。共混物以18gsm和20gsm的重量在梳理网线上加工。结果是比由双组分纤维生产的网显著更结实的网。所述网比具有Bi-Co纤维的网更清晰和更少不透明。这点是非常理想的属性。
在第二个试验中，单组分的共聚PLA纤维与811型PLA纤维以80/20％(PLA/共聚PLA)的比率共混。所述网以18gsm和20gsm的重量生产。强度提高，且织物更少不透明或更透明。然后，两种类型的网卷被切割至合适的宽度并在茶包机器上加工。进一步的优势在于PLA/共聚PLA共混物比标准纸吸收更少的水。当PLA和标准纸干重为18gsm时，PLA在水分完全饱和时重90gsm，而标准纸达到200gsm。
第一个试验是在Fuso机器上代替昂贵的尼龙织物。茶包形成良好，且接缝比由尼龙织物制成的那些更结实。80/20共混物的18gsm提供最佳结果。
为改善强度、均匀性和纤维分布，通过将无规化单元置于盖板(doffer)或牵引辊上而对其中一个梳理机(5个中的)进行改进。在标准梳理机上，纤维的取向通常为机器方向：机器横向为5∶1，并且可以被优化至3.5∶1。使用无规化辊，具有无规发生器的梳理机的取向为约1.5∶1。所得复合网的取向在2∶1和3∶1之间。这是一个显著的改进。在潮湿的条件下，所得网表现出强度不劣化，而标准的茶包纸表现出强度的劣化。
通过改变PLA纤维的选择而进行进一步改进。首先，将上述生产系统应用于特定的PLA树脂#6060D，所述PLA树脂具有这些特性：
其满足本发明的目的。第二，通过替换为PLA树脂#7032发现进一步的修改，所述PLA树脂#7032通常不用于纤维，而是被制造用于吹塑，如瓶子。该树脂具有这些特征：
由于较低的二聚物含量和黄色指数，该树脂比606D更透明，而且其增加的相对粘度使得在纤维生产过程中增加拉伸比成为可能，导致增加的韧度，所述韧度为4.7-5.0克/旦尼尔，与此相对6060D和其它标准PLA纤维的韧度为3.5-4.0克/旦尼尔。这产生更结实的茶包基材织物。在织物制造过程中，PLA/共聚PLA纤维的共混比变成70/30％(PLA-共聚PLA)。结果当在135℃加热过程中，共聚PLA变透明。随着PLA纤维韧度的增加，织物更强韧但更不透明。
生产如下织物重量：
a.18gsm(克每平方米)
b.21gsm
c.25gsm
d.28gsm
纤维制造的拉伸比降低，并且由于纤维更加无定形/较少结晶态，较透明的纤维减少。结果是对内容物(如茶叶)具有较好可见度的更透明的织物。生产了如下的重量：
a.18gsm
b.21gsm
c.25gsm
d.30gsm
选择PLA6400D型来制造用于附在茶包上的线的连续丝纱。所述纱的每根丝为3旦尼尔并有50根丝。其被喷气交缠(airentangle)并结构化以制造PLA茶包线。采用在150℃加热或超声焊接法将PLA线焊接至茶包织物。在线的制造过程中，在拉伸或牵拉过程中进行调整以降低线的强度。发现如果线的强度太高，可能在茶包生产过程中引起安全问题。线必须具有足够的强度以用于茶包，但必须能够徒手断开。
现在，对于本领域的技术人员，符合上述公开的文字和精神以及在本专利的范围内其它实施方案、改进、细节和用途将是显而易见的，根据专利法包括等同原则解释，所述本专利的范围仅由所附的权利要求限定。

Claims (21)

1.一种用于生产饮料浸泡包和袋的非织造网，其中该网由单组份聚乳酸(PLA)纤维和单组份共聚PLA纤维的共混物组成，所述共混物通过热粘合形成所述网，其中所述网具有在使用后的可生物降解性和在所述网的制造方法的每个步骤中废弃材料的可回收性；
所述单组分聚乳酸(PLA)纤维具有结晶部分，所述单组份共聚PLA纤维具有无定形部分；所述纤维通过网加热和加压中的至少一种来自粘合；
其中所述单组份聚乳酸(PLA)纤维形成所述网在用热的液体浸泡期间维持的孔径，以增强流动。
2.如权利要求1所述的网，其中所述网纤维的纤维长度为2mm至90mm。
3.如权利要求1所述的网，其中所述网纤维的长度为38mm。
4.如权利要求1所述的网，其中所述网纤维为0.6旦尼尔至6.0旦尼尔。
5.如权利要求1所述的网，其中所述网纤维为3.0旦尼尔。
6.如权利要求1所述的网，其中所述网纤维为1.5旦尼尔。
7.如权利要求1所述的网，其中所述网纤维为1.2旦尼尔。
8.如权利要求1所述的网，其基重为8至50克每平方米。
9.如权利要求1所述的网，其中所述PLA单组份纤维和所述共聚PLA单组份纤维的结晶部分和无定形部分具有两个不同熔点，所述熔点分别为175℃和135-165℃。
10.如权利要求1所述的网，其中所述纤维是在135℃至175℃的温度下熔融的100％的PLA纤维。
11.如权利要求1所述的网，其中一部分纤维是所述单组份PLA纤维，其为4.7克/旦尼尔至5.0克/旦尼尔。
12.如权利要求11所述的网，其中所述网纤维由具有两个不同熔点的单组份纤维组成，其中所述PLA纤维的熔点为145-175℃，所述共聚PLA纤维的熔点为105-165℃。
13.如权利要求1所述的网，其可用作包或袋的材料，所述包或袋用于：柠檬水、草药香囊、咖啡、荼、肥皂粉、用于游泳池和温泉的化学品和氯、洗涤液、液体着色、除湿化学品、用于加热或冷却的相变材料的载体、烟草袋和所有可被放置在至少一种热和超声活化的可密封容器中的材料。
14.一种基本完全由权利要求1所述的网形成的包或袋。
15.一种包或袋，其使用如权利要求1所述的网，但是在梳理过程中使用无规化辊制造。
16.如权利要求1所述的网，其中所述共聚PLA单组份纤维和所述PLA单组份纤维具有不同的熔点以形成所述网。
17.如权利要求1所述的网，其中所述网是具有在使用后的可生物降解性和在由聚合物到最终网的制造方法的每个步骤中废弃材料的可回收性的饮料浸泡包装。
18.如权利要求17所述的网，其可在用于选自以下的材料的包或袋中使用：柠檬水、草药香囊、咖啡、茶、肥皂粉、用于游泳池和温泉的化学品和氯、洗涤液、液体着色、除湿化学品、用于加热或冷却的相变材料的载体、烟草袋，其中所述包或袋通过热或超声可密封。
19.如权利要求18所述的网，其中附在每个所述包上的线是由单组份聚乳酸(PLA)纤维制成的。
20.如权利要求17所述的网，其中所述单组份聚乳酸(PLA)纤维的结晶度通过拉伸然后卷曲和热定型来控制。
21.如权利要求17所述的网，还包括基重为8至50克每平方米。
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