CN104271827A - 一种生产水刺交缠无纺材料的方法 - Google Patents

一种生产水刺交缠无纺材料的方法 Download PDF

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CN104271827A
CN104271827A CN201280072920.3A CN201280072920A CN104271827A CN 104271827 A CN104271827 A CN 104271827A CN 201280072920 A CN201280072920 A CN 201280072920A CN 104271827 A CN104271827 A CN 104271827A
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M·斯特兰德奎斯特
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Aishirui Health and Health Co., Ltd.
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Abstract

一种通过水刺交缠包括纺丝成网长丝、天然纤维和合成短纤维的纤维混合物来生产无纺材料的方法，其中，由天然纤维和纤维重量至少为10％的人造短纤维构成的纤维料幅(13)通过斜网成形而被湿法成网，湿法成网纤维料幅在第一水刺交缠站(14)中被水刺交缠，纺丝成网长丝(18)被铺设在所述水刺交缠湿法成网纤维料幅(13)的顶部上以形成组合料幅(19)，所述组合料幅(19)在第二水刺交缠站(24)中被水刺交缠。

Description

一种生产水刺交缠无纺材料的方法
技术领域
本发明涉及一种制造水刺交缠无纺材料的方法，所述无纺材料包括天然纤维、人造短纤维和纺丝成网长丝的混合物。
背景技术
吸收性无纺材料常用于擦拭工业、服务场合、办公室和家庭地点的各种溢出物和泄露物。人们对用于擦拭目的的无纺材料的性能有很多的要求。一个理想的擦拭物需要结实、有吸收性、耐磨损并且掉毛少，更进一步的，还需要柔软和具有纺织品的手感。水刺交缠无纺材料由于其吸收性和类纺织品性能而常常用于擦拭。
水刺交缠或射流喷网是20世纪70年代引进的技术，可参见专利文献CA841938。该方法为：形成被干法成网或者湿法成网的纤维料幅，在此之后，纤维通过高压下非常细小的水射流交缠。几行水射流直接射向由可移动织物支撑的纤维料幅，然后干燥交缠的纤维料幅。在该材料中所使用的纤维可以是合成的或再生的短纤维，如聚酯、聚酰胺、聚丙烯、人造纤维及类似物、浆粕纤维或浆粕纤维和短纤维的混合物。射流喷网材料能够以合理的成本进行高品质的制造，且具有高吸收容量。它们可以用作家庭或工业使用的擦拭材料，用作医疗和卫生用品等用途的一次性材料。
通过文献，例如EP-B-0333211和EP-B-0333228，可以获知的是水刺交缠这样的纤维混合物：在该纤维混合物中，纤维组分之一由熔喷纤维形式的连续长丝构成。基础材料，即受到水刺交缠的纤维材料，或者由至少两层组合预制纤维层构成且其中至少一层由熔喷纤维组成，或者由“同成形材料”构成且其中熔喷纤维和其它纤维的实质上均匀的混合物在成形织物上被气流成网。
通过专利文献EP-A-0 308320已知的是将连续长丝的预粘合料幅和含有浆粕纤维和短纤维的分离的预粘合湿法成网纤维料幅放到一起，并且将单独形成的各纤维料幅水刺交缠到一起成为层压体。在这种材料中，由于纤维在水刺交缠之前已经彼此粘合，仅具有非常有限的移动性，因此不同纤维料幅的纤维不会彼此成为一体。该材料具有明显的两面性。
WO 99/22059公开了一种通过水刺交缠连续长丝、天然纤维和/或合成短纤维的混合物生产无纺材料的方法。天然纤维和/或合成短纤维的纤维料幅被形成泡沫、水刺交缠，并且与连续长丝例如熔喷纤维整合在一起。
WO 2005/042819公开了一种通过以下步骤生产无纺材料的方法：在成形织物上形成连续长丝的料幅，将含有长度为3-7mm的合成短纤维和天然纤维的湿法成网制成的纤维分散液施加在所述连续长丝的顶部上。随后，所述纤维料幅被水刺交缠以形成无纺材料。
在制造高品质无纺材料时，至关重要的是，要在针对连续长丝和湿法成网层二者的整个制造过程中都获取和保持好的纤维构形。它赋予材料良好的视觉效果和材料性能。如EP0972873,EP1929080和EP0411752所披露的，通过斜网成形来湿法成网纤维分散液使用了低粘稠度纤维分散液，从而提供了良好的纤维构形。斜网成形使得处理混合在一起的浆粕纤维和短切纤维二者成为可能。然而，由于流浆箱放置在斜网上，密封件被设置在流浆箱和斜网之间以防止纤维分散液沿错误的方向行进。密封件使得预制料幅(例如未粘合纤维料幅)不可能穿过流浆箱。
此外，由于水分在长丝周围移动，在未粘合长丝料幅顶部上湿法成网纤维分散液将破坏未粘合纤维的形成。如WO 99/22059文献中所披露的纤维分散液的泡沫成形方法可以解决这一问题。然而，泡沫可能会通过使得水刺交缠水的过滤更复杂而在工艺下游产生问题。
发明内容
本发明的目的是提供一种生产水刺交缠无纺材料的在线方法，所述无纺材料包括天然纤维、人造短纤维和纺丝成网长丝的混合物。在整个所述方法中获得并保持良好的纤维成形，从而获得具有良好视觉效果和材料性能的无纺材料。这已通过包括以下步骤的方法来获得：水刺交缠包括纺丝成网长丝、天然纤维和合成短纤维的纤维混合物，通过斜网成形来湿法成网由天然纤维和至少10％纤维重量的人造短纤维的纤维料幅，在第一水刺交缠站中水刺交缠所述湿法成网纤维料幅，在所述水刺交缠湿法成网纤维料幅顶部上铺设纺丝成网长丝以形成一个组合料幅，在第二水刺交缠站中水刺交缠所述组合料幅。
在第二水刺交缠站，从湿法成网纤维料幅侧水刺交缠所述组合料幅。
第一水刺交缠站中使用的流体压力为10-15bar。
第二水刺交缠站中使用的流体压力为70-200bar。
由天然纤维和人造短纤维构成的湿法成网纤维料幅可包含10-40％纤维重量百分比的人造短纤维和60-90％纤维重量百分比的天然纤维。
天然纤维可以是木浆纤维。
人造短纤维可具有为3-25mm的长度。
纺丝成网长丝之间可以无热粘合点。
在将纺丝成网长丝铺设到所述水刺交缠湿法成网纤维料幅顶部上之前，所述水刺交缠湿法成网纤维料幅可以被脱水至30-50％重量百分比的干含量。
定义
纺丝成网长丝
长丝是与其直径相比非常长的纤维，原则上是无限的。它们可以这样制造：将热塑性聚合物融化并通过细小喷嘴挤出，然后将聚合物冷却，优选地，通过在聚合物流处或沿着聚合物流吹送气流实现冷却，然后固化成可以通过牵引、拉伸或卷曲处理的线。用于添加剂功能的化学物质可以加到其表面。长丝也可以通过成丝反应物溶液进入反应介质的化学反应而生成，例如由黄原酸纤维素溶液进入硫酸中纺出粘胶纤维。
通过将融化的热塑性聚合物通过细小喷嘴呈非常细的流挤出来生产纺丝成网长丝。长丝通过空气拉伸以得到合适的直径。纤维直径通常大于10um，常介于10-100um之间。在例如美国专利US4,813,864或US5,545,371中都对纺粘的生产有描述。
具有足够连贯性以用此方式在熔融状态下拉出的任何热塑性聚合物，原则上都可以用来制作纺丝成网长丝。可利用的聚合物的示例有聚烯烃，如聚乙烯和聚丙烯，聚酰胺，聚酯和聚交酯。当然，也可以使用这些聚合物的共聚物，以及具有热塑性的天然聚合物。
天然纤维
可以应用在水刺交缠无纺材料的天然纤维有很多种，尤其是那此具有吸附水分的能力以及具有有助于产生连贯片层的趋势的材料。可以利用的天然纤维主要有纤维素纤维，像种毛纤维，如棉、木棉和马利筋属植物；叶纤维如剑麻、蕉麻、菠萝和新西兰hamp；或韧皮纤维，如亚麻，大麻，黄麻，洋麻，纸浆。木浆纤维尤其适合，软木纤维和硬木纤维都是适合的。可循环纤维也是可以使用的。
对于软木纤维来说，浆粕纤维长度在3mm左右变化，对于硬木纤维来说，在1.2mm左右变化，对于可循环纤维来说，为上述长度的混合，甚至更短。
短纤维
所使用的人造短纤维可以由与针对上述纺丝成网长丝所述的相同的聚合物来制造。其他可用的人造短纤维是那些由可再生纤维素制成的人造短纤维，如粘胶和莱赛尔。短纤维由长丝切成段。它们可用纺丝油剂进行处理并且被卷曲，但这对于优选用来制作本发明所述的材料的工艺类型来说，不是必须的。纤维束的切断通常是为了导致单个切割长度，这由切割轮的刀之间的距离来确定。根据计划用途，使用不同的纤维长度。湿法成网水刺交缠无纺布能使用3-25mm之间的长度。
附图说明
本发明将在下面参考附图所示的实施例进行说明。
图1示意性地示出了根据本发明用于制造水刺交缠无纺材料的方法。
具体实施方式
根据本发明用于制造水刺交缠无纺材料的方法的示例之一如图1所示。天然纤维和人造短纤维的混合物的分散液由流浆箱11湿法成网在成形织物10的倾斜部上，即所谓的斜网成形。斜网成形中所用的纤维分散液的粘稠度相对低。这提供了良好的纤维构形，以及处理混合在一起的浆粕纤维和短切短纤维二者的能力。分散液除水外可含有常规造纸添加剂如湿强剂和/或干强剂、助留剂和分散剂。
如下所述，当空气被抽吸穿过料幅时，斜网成形能够产生相对膨松的料幅，其中相当大数量的纤维沿Z方向定向，这对于随后的水刺交缠以及随后的纺丝成网步骤是有好处的。
通过布置在成形织物10的倾斜部分下面的抽吸箱12，水穿过成形织物10被抽吸，从而包括天然纤维和人造短纤维的湿法成网纤维料幅13形成在成形织物10上。密封件(未示出)布置在流浆箱11和成形织物10之间，以防止纤维沿往回的方向行进。
用于形成第一纤维料幅的天然纤维和人造短纤维的重量百分为，天然纤维为60％-90％，人造短纤维为10％-40％。天然纤维和人造短纤维为上述提到的类型。也可使用长度为3-25mm的短切短纤维。短切短纤维的纤维长度可为3-20mm，优选为3-15mm，更优选为10-15mm。
成形织物10重定向至水平方向，在成形织物10的水平部分上设置有第一水刺交缠站14。湿法成网纤维料幅13在由成形织10支撑的同时，在所述第一水刺交缠站14中被水刺交缠。第一水刺交缠站14包括可横杆，横杆上有一排喷嘴，射流在压力下从所述喷嘴直接对着湿法成网纤维料幅导向，从而提供纤维的交缠。抽吸箱15布置在成形织物10下面以排出水刺交缠用水。
第一水刺交缠站14的喷嘴中所用的交缠压力可以相对低，在10-50bar之间，以提供仅第一纤维料幅13的稍微粘合。湿法成网纤维料幅13的粘合可以仅为足以使料幅13自支撑，例如从而其可以从第一成形织物10转移至第二成形织物16。第一成形织物10应该具有相对高的经纬密度(相对低的开放面积)以便保持湿法成网料幅中的纤维，而第二成形织物具有相对低的经纬密度(相对高的开放面积)，如下文所述。
为了实现自支撑，湿法成网纤维料幅12在MD(机器方向或纵向)上的拉伸强度应该为至少50N/m，但是，优选为不超过100N/m。
优选只有一行喷嘴14应用于第一水刺交缠站。湿法成网纤维料幅12的基重可为10-100g/m2。如果有必要的话，在转移至第二成形织物16后，湿法成网纤维料幅13可以通过抽吸箱17进一步脱水以获得第一纤维料幅的合适干含量。由于在随后的纺丝成网(如下所述)中，空气被抽吸穿过料幅，湿法成网纤维料幅的合适干含量为30-50％重量百分比。
一个或多个纺丝成网站19布置成产生纺丝成网长丝18并将它们铺设在水刺交缠湿法成网纤维料幅13的顶部上。所述纺丝成网长丝18由从喷嘴20挤出的熔融热塑性粒料制成并且直接铺设于第一纤维料幅13上。所述纺丝成网长丝18得以形成料幅。在纺丝成网站中，通过布置在成形织物16下方的抽吸箱21将空气抽吸穿过料幅。为了允许空气抽吸穿过第二成形织物16，第二成形织物需要有相对较低的经纬密度(相对开放的区域)。纺丝成网长丝18可稍微被粘合或者可替换地不粘合，从而使得纺丝成网长丝可以彼此相对自由地移动。因纺丝成网长丝的粘性所致的粘合度由喷嘴20和成形织物16之间的距离控制。如果这个距离相对大，就允许纺丝成网长丝18在落到湿法成网纤维料幅13之前冷却下来，从而使得其粘性大大减小。可选地，长丝的冷却也可以通过其他方式来实现，例如使用多个空气源，在该多个空气源处，在长丝已被抽出或拉伸至优选的程度时用空气来冷却长丝。
由于纺丝成网长丝18铺设在潮湿的湿法成网纤维料幅13的顶部上，长丝将在着陆于潮湿料幅13上时附着和停留，由此保持成形，该成形否则将难以保留在成形线上。为了进一步改善纺丝成网长丝18的成形，它们可以带电荷以彼此排斥或者由两个或更多纺丝成网站19按序铺设。
纺丝成网长丝18落在湿法成网纤维料幅13上的速度比成形织物16的速度要高许多，从而当纺丝成网长丝在湿法成网纤维料幅13顶部上在成形织物上聚集以形成非常随机的前体料幅时，长丝形成不规则环和弯曲。成形的长丝前体料幅的基重可以为10-50g/m2。
附着在由天然纤维和人造短纤维构成的湿法成网纤维料幅13上的连续长丝18的组合料幅22从成形织物16转移至水刺交缠筒23，在该筒处，通过在第二水刺交缠站24中从湿法成网纤维料幅13侧进行水刺交缠，组合料幅22的整合开始。因此，纺丝成网长丝18层面对筒23。在高压下水射流使浆粕纤维和短纤维移动进入长丝层。
在附图所示实施例中，第二水刺交缠站24包括三行水刺交缠喷嘴。可以使用任何合适行数的喷嘴。第二水刺交缠站24的喷嘴中使用的交缠压力比第一水刺交缠站14中的要高，并且优选为70-200bar的范围。水刺交缠水通过筒23排出。在第二水刺交缠站24中获得短纤维、浆粕纤维(或其他天然纤维)和连续长丝的强混合。通过使连续长丝18未粘合即连续长丝18之间没有热粘合点或者仅有轻微粘合，连续长丝可以自己缠绕并交缠以及与短纤维和浆粕纤维交缠，这就使得不同类型的纤维和长丝之间有了很好的整合。
已被水刺交缠的组合料幅22可被转移至另一水刺交缠织物25并且在第三水刺交缠站26中从与第二水刺交缠站24中相同的一侧进行水刺交缠，例如从湿法成网纤维料幅13侧进行水刺交缠。在图1所示的实施例中，第三水刺交缠站26包括三行水刺交缠喷嘴。在第三水刺交缠站26中可以使用任何适当行数的喷嘴。第三水刺交缠站26的喷嘴中使用的交缠压力可以与第二水刺交缠站24中的压力范围相同，即优选为70-200bar的范围。水刺交缠水通过抽吸箱27穿过织物25排出。在第三水刺交缠站26中获得纺丝成网长丝和短纤维、浆粕纤维(或其他天然纤维)的进一步整合，以产生复合水刺交缠料幅28。
但是，第三水刺交缠站26是可选的，因此也可以省略。
具有两行或更多行喷嘴的水刺交缠站中的水射流压力可被适配成具有某种压力分布，其中不同行喷嘴中具有不同压力。
水刺交缠复合料幅28随后被干燥，这可在传统料幅干燥设备中进行，干燥设备优选为用于棉纸干燥的类型，例如空气穿透干燥或者扬克式干燥设备。所述材料在干燥后在转化前通常被缠绕以形成母卷。然后材料通过已知的方式转化成合适的形式和包装。
所述材料的结构可以通过进一步的处理来改变，例如微皱、热压延、压花等工艺。不同添加剂，如湿强剂、粘合剂、乳胶、分离剂等可在干燥前或后进一步加入到料幅中。

Claims (10)

1.一种通过水刺交缠包括纺丝成网长丝、天然纤维和合成短纤维的纤维混合物来生产无纺材料的方法，其特征在于，通过斜网成形来湿法成网第一纤维料幅(13)，该第一纤维料幅由天然纤维和纤维重量至少为10％的人造短纤维构成，在第一水刺交缠站(14)中水刺交缠所述第一纤维料幅，将纺丝成网长丝(18)铺设在所述水刺交缠湿法成网纤维料幅(13)的顶部上以形成组合料幅(19)，在第二水刺交缠站(24)中水刺交缠所述组合料幅(19)。
2.如权利要求1所述的方法，其特征在于，所述组合料幅(19)在第二水刺交缠站(24)中从湿法成网纤维料幅(13)侧被水刺交缠。
3.如权利要求1或2所述的方法，其特征在于，在所述第一水刺交缠站(13)中使用的流体压力为10-50bar。
4.如上述权利要求中任一项所述的方法，其特征在于，在第二水刺交缠站(24)中使用的流体压力为70-200bar。
5.如上述权利要求中任一项所述的方法，其特征在于，由天然纤维和人造短纤维构成的所述湿法成网纤维料幅(13)包含纤维重量10-40％的短纤维和纤维重量60-90％的天然纤维。
6.如上述权利要求中任一项所述的方法，其特征在于，所述天然纤维为木浆纤维。
7.如上述权利要求中任一项所述的方法，其特征在于，所述人造短纤维的长度为3-25mm。
8.如上述权利要求中任一项所述的方法，其特征在于，纺丝成网长丝(18)之间无热粘合点。
9.如上述权利要求中任一项所述的方法，其特征在于，在将纺丝成网长丝(18)铺设在所述水刺交缠湿法成网纤维料幅(13)的顶部上之前，将所述水刺交缠湿法成网纤维料幅(13)脱水至30-50％重量百分比的干含量。
10.一种根据权利要求1-10中任一项所述的方法生产的无纺材料。
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EP2844793A1 (en) 2015-03-11
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