CN1044015C - 耐磨纤维无纺织复合结构物及其制造方法和用途 - Google Patents

耐磨纤维无纺织复合结构物及其制造方法和用途 Download PDF

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CN1044015C
CN1044015C CN93118457A CN93118457A CN1044015C CN 1044015 C CN1044015 C CN 1044015C CN 93118457 A CN93118457 A CN 93118457A CN 93118457 A CN93118457 A CN 93118457A CN 1044015 C CN1044015 C CN 1044015C
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W·A·乔杰
T·J·科帕茨
M·F·琼斯
G·A·策拉佐斯基
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Abstract

公开了一种耐磨纤维无纺织复合结构物,它由下列两组分组成:(1)具有第一外表面、第二外表面和里部的熔喷纤维基体;和(2)至少一种结合进熔喷纤维基体中使熔喷纤维在无纺织结构的每个外表面附近的浓度至少为约60%(重量),且熔喷纤维在里部的浓度小于约40%(重量)的其它纤维材料。这种纤维无纺织结构物提供了有用的强度和低掉绒特性以及比相同组份的均匀混合物耐磨性大至少约25%的耐磨性。本发明的纤维无纺织结构物可作湿擦片使用。

Description

耐磨纤维无纺织复合结构物及其制造方法和用途
本发明是关于由至少两种不同组份组成的纤维无纺织结构物及制造纤维无纺织结构物的方法。
纤维无纺织材料和纤维无纺织复合材料由于它们生产成本低并具有一些特殊性质而被广泛用作产品或产品组成部分。制造纤维无纺织复合材料的一种方法是将不同类型的无纺织材料结合成一层合物。例如,美国专利号3,676,242(发明者Prentice,1972年7月11日公布)描述了一种层合结构物,它是将无纺织的纤维垫粘合到塑料膜上而制成的。美国专利3,837,995(发明者Floden,1974年9月24日公布)透露了一种多层纤维无纺织材料,它含有自粘到一层或多层大直径天然纤维上的一层或多层热塑性聚合物纤维。
另一种制备方法是将热塑性聚合物纤维与一种或多种其它类型的纤维材料和/或颗粒混合。该混合物集合成纤维无纺织复合网的形式,也可以粘合或处理成粘结的无纺织复合材料以至少利用其每个组分的一些性质。例如,美国专利4,100,324(发明者An derson等,1978年7月11日公布)透露了一种无纺织物,它是木桨和熔喷热塑性聚合物纤维的总体均匀混合物。美国专利3,971,373(发明者Braun,1976年7月27日公布)透露了一种含有熔喷热塑性聚合物纤维和离散的固体颗粒的无纺织材料。根据这个专利,在无纺织材料中,颗粒是与熔喷纤维均匀地分散和掺合的。美国专利4,429,001(发明者Kolpin等,1984年1月31日公布)透露了一种有吸收力的片材,它是熔喷热塑性聚合物纤维和高吸收性固体颗粒的组合。据透露这种高吸收性颗粒是均匀分散和物理地固定在熔喷热塑性聚合物纤维网的内部。
上述层合材料的整体性部分靠把层合材料各层间粘结的技术。一个缺点是一些有效的粘合技术增加了层合材料的成本及制造工艺的复杂性。
含有总体均匀分布的组份材料的无纺织纤维复合物可有一些与组分排布有关的缺点。特别是均匀分布的某些纤维和颗粒可导致掉绒和/或颗粒脱落。另一个缺点是,所述复合含有高比例的均匀分布的颗粒或短小纤维(例如,浆粕),因为由热塑性聚合物纤维组份提供的强度较低其整体性通常较差。这个现象也见之于含有高比例浆粕和/或颗粒的总体均匀复合物,其耐磨性和拉伸强度均差。当这种无纺织复合物用来抹拭液体或用作湿擦片时这个问题就特别明显。但是,因为浆粕和某些颗粒比较便宜,又能提供有用的性质,所以常常是极希望在纤维无纺织复合结构中高比例地掺入这些材料。
因之,对于纤维无纺织复合结构一个要求是,既要便宜,但又要有好的耐磨性,整体性和湿强度。对纤维无纺织复合结构也有一个要求是,既要有高浆粕含量并且便宜,但又要有好的耐磨性,整体性和湿强度。
本发明的目的在于提供一种耐磨的纤维无纺织复合结构物。
本发明的另一目的在于提供一种耐磨纤维无纺织复合结构物的方法。
本发明的再一个目的在于提供耐磨的纤维无纺织复合结构物的用途。
这里所用的术语“纤维无纺织结构”是指各个纤维或长丝交叉铺放,但不是以相同的重复方式交叉铺放的结构。无纺织结构,例如无纺织纤维网,过去可用本领域普通技术人员已知的各种方法制造,例如熔喷和熔纺法,纺粘法和粘梳纤维网法等。
这里所用的术语“耐磨纤维无纺织复合结构”是指熔喷热塑性聚合物纤维与至少一种其它组份(例如,纤维和/或颗粒)以纤维无纺织结构形式相结合,这种纤维无纺织结构的耐磨性比相同组份的均匀混合物的耐磨性至少要大约25%。例如,其耐磨性比相同组份的均匀混合物的耐磨性至少要大30%左右。一般地说,要做到这一点可使熔喷热塑性聚合物纤维在纤维无纺织结构物邻近外表面处的浓度大于在其内部的浓度。
这里所用的术语“熔喷纤维”是指这样形成的纤维:将熔融的热塑性材料通过许多细的,通常是园形的模板孔挤出形成熔融的丝束或长丝进入一高速的气(例如空气)流中,高速气流将熔融热塑性材料的长丝拉细以减少其直径(要以减至微纤直径)。然后该熔喷纤维被高速气流带走并沉积于一收集面上形成无规分布的熔喷纤维网。熔喷法是众所周知的,在各种专利和出版物中都有描述,例如NRL报告4364中V.A.Wendt,E.L.Boone和C.D.Fluharty撰写的“超细有机纤维的制造”;NRL报告5265中K.D.Lawrence,R.T.Lukas和J.A.Young撰写的“一种改进的超细热塑性纤维成形设备”;美国专利3849241(发明者Buntin等,1974年11月19日公布)。
这里所用的术语“微纤”是指平均直径不大于约100微米的细直径纤维,例如直径从约0.5微米至约50微米的纤维,更具体地说,微纤平均直径也可从约4微米至40微米。
这里所用的术语“可弃物”不只限于那些一次性或有限次性使用物品,而且也指那些对消费者来说很便宜的物品,当它们变脏或仅用一次或几次后就不能用就可以丢弃的物品。
这里所用的术语“浆粕”是指含有天然来源,如木质和非木质植物之纤维的浆粕。木质植物包括,例如落叶树和针叶树;非木质植物包括,例如:棉、亚麻、茅草、马利筋属植物、稻草、黄麻、和甘蔗渣。
这里所用的术语“透气性”是指一种流体,例如,一种气体通过材料的能力。透气性以每单位时间每单位面积通过流体的体积单位来表示,例如单平方英尺材料每分钟的立分英尺数((立方英尺/分钟/平方英尺)或(cfm/平方英尺))。透气性可以利用Frazier空气透过性试验仪(Frazier精密仪器公司产品)确定,测试方法按照联邦试验方法5450,标准号191A规定进行,但试样大小为8″×8″而不是7″×7″。
这里所用的术语“平均流动孔径”是指用Coulter孔度计和Coulter POROFILTM试验液(购自Coulter电子有限公司,英国Luton)通过液体置换技术测量确定的平均孔径。平均流动孔径是通过用表面张力非常低的液体(即Coulter POROFILTM)湿润试样来测定。在试样的一侧施加空气压力。最终,当空气压力增加时,在最大的一些孔中流体的毛细管吸引力被克服,迫使液体流出而使空气通过试样。随着空气压力进一步增加,越来越小的孔洞也将逐渐畅通。这样就可确定湿试样的流量对压力的关系,并和干试样测定的结果进行比较。平均流动孔径是在50%干试样的流量对压力曲线与湿试样的流量对压力曲线的相交点上测定的,在该特定压力下开通的孔的直径(即平均流动孔径)可以通过下式确定:
孔径(μm)=(40τ)/压力其中τ=以单位mN/M表示的流体的表面张力;压力为以毫巴(mbar)表示的所施压力;由于用来湿润试样的液体表面张力非常低,因此可以假定该液体在试样上的接触角约为零。
这里所用的术语“超吸收剂”是指在吸收剂浸入液体中4小时后在至多约1.5磅/平方英寸(psi)压力下所有被吸液仍基本保持的条件下,每克吸收剂能够吸收至少10克水液(例如蒸馏水)的吸收材料。
这里所用的术语“主要包括”不排除那些对给定的复合物或产物所要求的性质无重大影响的添加物的存在。这类材料的例子包括(不限于此)颜料、抗氧剂、稳定剂、表面活性剂、蜡、流动促进剂及能提高复合物加工性的添加剂的颗粒或材料。
本发明提供一种耐磨的纤维无纺织结构物以响应上述的需要,它是由(1)具有第一外表面,第二外表面和一个里部的熔喷纤维基体;和(2)至少一种结合进熔喷纤维基体的其它材料所组成,使得熔喷纤维在无纺织结构物的每个外表面附近的浓度至少约为60%(重量),熔喷纤维在里部的浓度约低于40%(重量)。较好是,熔喷纤维在每个外表面附近的浓度为约70%至约90%(重量),熔喷纤维在里部的浓度可以低于约35%(重量)。
根据本发明,无纺织结构物的耐磨性要比相同组份的均匀混合物的耐磨性至少大约25%左右。较好是,本发明的纤维无纺织结构物的耐磨性要比相同组份的均匀混合物的耐磨性至少大30%左右。例如,本发明的纤维无纺织结构物的耐磨性比相同组份的均匀混合物的耐磨性大约50%至约150%。
熔喷纤维基体通常是熔喷聚烯烃纤维基体,但其它类型的聚合物也可使用。例如,熔喷纤维基体可以是聚酰胺、聚酯、聚氨酯、聚乙烯醇、聚己内酯等熔喷纤维基体。当熔喷纤维是聚烯烃纤维时,它们可以是聚乙烯、聚丙烯、聚丁烯、乙烯共聚物、丙烯共聚物、丁烯共聚物或同样物质的混合物。
结合进熔喷纤维基体的其它材料的选择可根据耐磨纤维无纺织结构物所要求的功能而定。例如,其它的材料可以是聚酯纤维、聚酰胺纤维、聚烯烃纤维、纤维素衍生物纤维(例如浆粕)、多组分纤维、天然纤维、吸收性纤维、或两种或多种这类纤维的共混物。可选择地和/或附加地,也可用颗粒性材料如木炭、粘土、淀粉、超吸收剂等。
在本发明的一方面中,纤维无纺织结构物是适合用作含约100%至约700%干重液体的湿擦片。较好是,湿擦片含有约200%至约450%干重的液体。
根据本发明,纤维无纺织结构物具有湿强度好的特性,这使得它特别适合作用湿擦片。较好是,纤维无纺织结构物至少在两个方向上具有至少约0.15磅的湿剥离强度及至少约0.30磅的湿梯形撕破强度。更好是,纤维无纺织结构物在至少两个方向上具有范围从约0.15磅至约0.20磅的湿剥离强度及具有范围从约0.3磅至约0.90磅的湿梯形撕破强度。一般地说,强度特性将随纤维无纺织结构物的单位重量而变。
根据本发明,纤维无纺织结构物的单位重量范围从每平方米约20克至500克。较好是纤维无纺织结构物单位重量范围从每平方米约35克至约150克。更好是,纤维无纺织结构物的单位重量范围从每平方米约40克至约90克。两层或多层无纺织纤维结构物可结合起来提供具有所需要的单位重量和/或功能特性的多层材料。
本发明的另一方面,是提供了一种耐磨的,低掉绒,高浆粕含量的纤维无纺织结构物,它是由(1)小于约35%总重量的并具有第一外表面、第二外表面和里部的熔喷纤维形成的基体;和(2)大于约65%总重量的结合到熔喷纤维基体中的浆粕纤维所组成,使得熔喷纤维在纤维无纺织结构物的每个外表面附近的浓度至少约为60%(重量),熔喷纤维在里部的浓度约低于40%(重量)。较好是,无纺织纤维结构物含有约65%至95%(基于结构物总重量)的浆粕纤维和约5%至约35%(基于结构物总重量)的熔喷纤维。同样好是,熔喷纤维在纤维无纺织结构物的每个外表面附近的浓度为约70%至约90%(重量),熔喷纤维在里部的浓度约低于35%(重量)。
这种高浆粕含量的纤维无纺织结构物的耐磨性比相同组份的均匀混合物的耐磨性至少要大约25%。更好是,本发明的纤维无纺织结构物的耐磨性比相同组份的均匀混合物的耐磨性至少要大约30%。例如,本发明的纤维无纺织结构物的耐磨性比相同组份的均匀混合物的耐磨性大约50%至150%。高浆粕含量的纤维无纺织结构物当按照干Climet起绒试验测定掉绒率时,每0.01立方英尺空气中10微米大小的颗粒数约少于50,0.5微米大小的颗粒数约少于200。例如,掉绒率可为每0.01立方英尺空气中10微米大小的颗粒数少于约40,0.5微米大小的颗粒数少于约175。
耐磨的高浆粕含量的纤维无纺织结构物可有较宽范围的单位重量。例如,其单位重量范围可从约40至500克/m2。两层或多层高浆粕含量的纤维无纺织结构物可以结合起来以提供具有所需单位重量的和/或功能特性的多层材料。
本发明这种耐磨的高浆粕含量的纤维无纺织结构物特别适合用作湿擦片。这种湿擦片生产成本很低,价格便宜,在一次或有限次使用后即可丢弃。用作湿擦片的耐磨的高浆粕含量的纤维无纺织结构物可含干重的约100%至700%的液体。较好是,这种湿擦片含有于重的约200%至450%的液体。
图1是可用于制备耐磨的纤维无纺织复合结构物的设备说明图。
图2是图1所示的设备的某些装置说明图。
图3是耐磨的纤维无纺织复合结构物横截面上典型的熔喷纤维浓度梯度的分布图。
图4是一个典型的高耐磨纤维无纺织复合结构物的显微相片。
图5是图4所示的典型的无纺织复合结构物的放大显微相片。
图6是一个典型的均匀纤维无纺织复合结构物的显微相片。
图7是图6所示的典型的均匀无纺织复合结构物的放大显微相片。
图8是一个典型的多层纤维无纺织复合结构物的显微相片。
图9是图8所示的典型的多层纤维无纺织复合结构物的放大显微相片。
首先看一下附图,各图中相同的参考号代表着同样的或等价的结构。现在具体看一下图1,通过参考号10概括地表示了一个制备耐磨纤维无纺织复合结构物的典型装置。在制备本发明的耐磨纤维无纺织复合结构物时,热塑性聚合物的粒料或切片等(图中未画出)加到挤出机14的粒料料斗12中。
挤出机14有一个用常规驱动马达(未画出)驱动的挤出螺杆(未画出)。聚合物在向前移动通过挤出机14时,由于被驱动马达带动的挤出螺杆的旋转而被逐渐加热到熔融态。将热塑性聚合物加热到熔融态是在许多分立的阶段中完成的,当它通过挤出机14的各个加热区分别朝着两个熔喷模板16和18移动时,其温度逐渐地升高。熔喷模板16和18可以是另外一个加热区,在那里,热塑性树脂保持着较高的温度以利挤出。
每个熔喷模板设计成的形状可使每模板两股拉细气流汇聚成一股气流,当熔融的丝束20从熔喷模板的小孔或喷丝孔24出来时,将其带走并拉细。熔隔丝束20被拉伸成通常比喷丝孔24的直径还要小的细直径纤维或微纤(这取决于拉伸程度)。所以,每个熔喷模板16和18都有一个相应的合带走并拉细了的聚合物纤维的单股气流26和28。含聚合物纤维的气流26和28在冲击区30合并成一束。
一种或多种辅助纤维32(和/或颗粒)在冲击区30处加到热塑性聚合物纤维或微纤24的两股气流26和28中。辅助纤维32导入热塑性聚合物纤维24的两股气流26和28要设计成使辅助的纤维32在合并的热塑性聚合物纤维流26和28中产生一个梯度的分布。要完成这一点,可让含辅助纤维32的辅助气流34在热塑性聚合物纤维24的两股气流26和28之间合并,致使所有三种气流以可控的方式汇合。
进行这种合并的设备包括一个常用的开松辊36装置,它有着许多齿38,可以把辅助纤维的片或条40打成单个的辅助纤维32。送入开松辊36的辅助纤维的片或条40可以是浆粕纤维片(如果想得到的是热塑性聚合物纤维和辅助的浆粕纤维的两组份混合物)、短纤维絮垫(如果想得到的是热塑性聚合物纤维和辅助的短纤维的两组份混合物)或浆粕纤维片和短纤维絮垫两者兼有(如果想得到的是热塑性聚合物纤维、辅助的短纤维和辅助的浆粕纤维三组份混合物)。在具体的实例中,例如需要一种吸收性材料,那么辅助纤维32就是吸收性纤维。辅助纤维32通常可以从下列一组纤维中选取一种或几种:聚酯纤维、聚酰胺纤维、纤维素衍生物纤维,例如,粘胶纤维、木浆纤维、多组分纤维例如皮芯型多组分纤维,天然纤维如丝纤维、羊毛纤维或棉纤维或导电纤维,或两种或多种这些辅助纤维的混合物。其它类型的辅助纤维32,例如聚乙烯纤维和聚丙烯纤维,以及两种或多种其它类型辅助纤维32的混合物也可应用。辅助纤维32可以是微纤,或辅助纤维32可以是平均直径从约300微米至约1000微米的长纤维。
辅助纤维32的片或条40通过辊装置42送入开松辊36。当开松辊36的齿38将辅助纤维片40打松成分离的辅助纤维32后,分离的辅助纤维32通过喷管44,朝热塑性聚合物纤维或微纤24的气流输送。机壳46包住开松辊筒36并且在机壳46和开松辊36的齿38的表面之间提供了一个通道或间隙48。一种气体,例如空气,通过气导管50进入开松辊36的表面和机壳46之间的通道或间隙48。气导管50通常在喷管44和间隙48的连结点52处进入通道或间隙48。足量的供气可以作为通过喷管44输送辅助纤维32的介质。从气导管50供给的气体也可用来帮助将辅助纤维32从开松辊36的齿38上脱除。任何常用的装置,例如鼓风机(未画出)都可用作供气设备。可以设想,添加物和或其它材料也可加到或进入气流中以处理辅助纤维。
一般说来,单独的辅助纤维32以其离开开松辊36的齿38的速率通过喷管44。换句话说,辅助纤维32在离开开松辊36的齿38进入喷管44时,一般保持着其离开开松辊36的齿38那一点的速度的大小和方向。这种安排(在Anderson等人的美国专利4,100,324中有着更详细的讨论,这里引作参考)基本上有助于减少纤维的起絮。
在某一方向上对喷管44的宽度进行调整使之与熔喷模板16和18的宽度大致匹配。较好是,喷管44的宽度与熔喷模板16和18大致相同。通常,喷管44的宽度不应超过送入开松辊36的片、条40的宽度。一般说来,喷管44的长度较好是在设备设计所允许的范围内尽可能短。
开松辊36也可用通常的颗粒输入系统代替以制备含有各种辅助颗粒的无纺织复合结构物54。如果在图1所示的系统中增加一个通常的颗粒输入系统,那么就可以在形成无纺织复合结构物54之前将辅助颗粒和辅助纤维两者合并起来加到热塑性聚合物纤维中。这种颗粒可以是例如木炭、粘土、淀粉、和/或通常称之为超吸收剂的水解胶体(水凝胶)颗粒。
图1进一步表示出,带有辅助纤维32的辅助气流34指向热塑性聚合物纤维流26和28之间,以使这些气流在冲击区30相接触。当这些气流在冲击区接触时,辅助气流34的速度通常调节得比每个热塑性聚合物纤维24的气流26和28的速度要大。这个特点与许多常用的制备复合材料的方法不同。这些常用的方法依赖的是吸气效应,即低速的辅助材料流被吸入高速的热塑性聚合物纤维流以增加湍动混合,这样得到的是一个均匀的复合材料。
和均匀复合材料不同,本发明的目标是一个其组份呈梯度分布的无纺织结构物。虽然发明者不应该固守一个特别的生产原理,但是可以相信,当气流在冲击区30相交时,将辅助气流34的速度调节得比每个热塑性聚合物纤维24的气流26和28的速度大可以得到的结果是,当它们在冲击区30和集束表面之间合并成一体时,纤维组分的梯度分布就能形成。
气体流之间的速度差使得辅助纤维32以某种方式结合进热塑性聚合物纤维流26和28中,以使辅助纤维32变成逐渐地和仅局部地在热塑性聚合物纤维中分布。通常,为增加生产速度,进入并拉细热塑性聚合物纤维24的气流应该有较高的初始速度,例如从每秒约200英尺至1000英尺以上。但是,这些气流膨胀并从熔喷模板脱离后它们的速度就迅速降低。因此这此气流在冲击区的速度就可通过调节熔喷模板和冲击区间的距离来控制。带有辅助纤维32的气流34与带有熔喷纤维的气流26和28相比其起始速度比较低。但是,通过调节从喷管44至冲击区30间的距离(以及熔喷纤维气流26和28必需通过的距离),气流34的速度可控制得比熔喷纤维气流26和28的速度大。
由于辅助纤维32进入热塑性聚合物纤维流26和28中时,热塑性聚合物纤维24常常仍然半熔融的和发粘的,所以辅助纤维32通常不仅与热塑性聚合物纤维24形成的基体机械地缠结,而且也被热粘合到热塑性聚合物纤维24上。
为了把热塑性聚合物纤维24和辅助纤维32的复合流56转变为由热塑性聚合物纤维24的粘合基体及其中分布着的辅助纤维32所组成的复合无纺织结构物,在复合流56的途径上设有一个收集装置。收集装置可以是个环形传动带58,通常由按图1中箭头62所示方向旋转的辊筒60所驱动。其它的收集装置对本领域技术人员是众所周知的,也要用来代替环形传动带58。例如,可用有孔的转鼓装置。并合的热塑性聚合物纤维和辅助纤维流以粘合纤网状收集在环形传动带58的表面形成无纺织复合纤维网54。真空箱64有助于把纤网结构保持在传动带58的表面上。真空可以置于大约1至4英寸水柱。
复合结构物54是粘结的,可以作为自承重的无纺织材料从传动带58上取出。一般说来,具有适当的强度和整体性的复合结构物可以直接使用而不需要任何后处理如花纹粘合等。如果需要,可以用一对轧辊或花纹粘合辊粘合部分材料。虽然这种处理可以改进无纺织复合结构物54的整体性,但也往往会将结构物压实。
现在参看一下图2,它是图1所示的典型工艺过程的简图。图2看重突出的是一些将影响制得的纤维无纺织复合结构类型的工艺参数,同时也显示了影响纤维无纺织复合结构物类型的各种成形距离。
熔喷模板装置16和18被安装成各自成一个角度。该角度是自与两模板呈切线的平面(平面A)测量的。一般说来,平面A与成形表面(即环形传动带58)平行。通常,两模各自成一个角度(θ)安装,以使由两个模中形成的纤维和微纤的气载流26和28在平面A下面的地方(即冲击区30)相交。较好是θ角的范围从约30°至约75°。更好是,θ角的范围从约35°至约60°。甚至更好的是,θ角的范围从约45°至约55°。
熔喷模装置16和18之间相隔距离为α。一般说来,距离α最大不超过约16英寸。距离α也可设定甚至比16英寸还大以得到一种膨松、丰满的材料,它比在较短矩离得到的材料强力略低且粘合性差。较好是,α的范围从约5英寸至约10英寸。更好的是,α的范围从约6.5英寸至约9英寸。重要的是,熔喷模之间的距离α和每个熔喷模的角度θ决定着冲击区30的位置。
从冲击区30到每个熔喷模口的距离(即距离X)应该调整成能将每个纤维和微纤流26和28的离散减少到最低的程度。例如,这个距离的范围可从0至约16英寸。较好是,这个距离大于2.5英寸。例如,从约2.5英寸至约6英寸。每个熔喷模口装置至冲击区的距离X可从模口间的距离α和模角θ通过下式算出:
X=α/(2COSθ)
一般来说,复合流56在它与成形表面58接触以前,通过选择适当的垂直成形距离(即距离β)可以将其离散减少到最低程度。3是熔喷模口70和72至成形表面58之间的距离。为了减少离散,通常是希望垂直成形距离短一些。但这必须权衡考虑到挤出纤维在接触成形表面58之前从它们的粘稠的半熔融态固化的需要。例如,从熔喷模口起的垂直成形距离β的范围可从约3英寸至约15英寸。垂直成形距离β也可以设定甚至大于15英寸,这里得到的是一种膨松、丰满的材料,它比在较短距离得到的材料强力略低且粘结性差。较好是,这个从模口起的垂直距离3为约7英寸至约11英寸。
垂直成形距离β中一个重要的部分是冲击区30和成形表面58之间的距离(即距离Y)。冲击区30的位置应使合并的气流到达成形表面的距离(Y)最短,以使被输送的纤维和微纤的离散减少到最低程度。例如,从冲击区至成形表面的距离Y范围可从约0至约12英寸。较好是,从冲击点至成形表面的距离Y的范围从约3至约7英寸。从冲击区30至成形表面58的距离可由垂直成形距离β,两模口间的距离α和模角θ通过下式算出:
Y=β-((α/2)*COSθ)
气体带出的辅助纤维是借助于从喷管44射出的气流34到达冲击区。一般来说,喷管44的定位是使其垂直轴基本垂直于平面A(即与熔喷模16和18相切的平面)。
在某些情况,可能希望冷却辅助气流34。冷却辅助气流可以加速熔融的或粘性的熔喷纤维的骤冷,并且缩短熔喷模口和成形表面间的距离,这又能用于减低纤维的离散和提高复合结构物的梯度分布。例如,辅助气流34的温度可冷却到约15°F至约85°F。
通过熔喷纤维流26和28与辅助纤维气流34之间的平衡,所要求的熔喷模的模角θ,垂直成形距离3,熔喷模口间的距离α,冲击区和熔喷模口间的距离X和冲击区和成形表面间的距离Y之间的平衡,有可能提供一个辅助纤维在熔喷纤维流内部的可控结合以生产纤维无纺织复合结构物,熔喷纤维在该纤维无纺织复合结构物的外表面附近浓度较高,而在其里部浓度较低(也即辅助纤维和/或颗粒的浓度较高)。
这种纤维无纺织复合结构物横截面上典型的熔喷纤维浓度梯度分布概图如图3所示。曲线E代表熔喷聚合物纤维浓度,曲线F代表浆粕浓度。
参看图4-9,这些图是含有约40%(重量)的熔喷聚丙烯纤维和约60%(重量)的木浆的纤维无纺织复合结构物的扫描电镜相片。更具体地说,图4是典型高耐磨的纤维无纺织复合结构物20.7×(线性放大倍数)的显微相片。图5是图4所示的典型无纺织复合结构物的67.3×(线性放大倍数)的显微相片。由图4和5可见,在结构物的上表面和下表面(即外表面)附近,熔喷纤维的浓度较大。熔喷纤维也分布在整个结构物的内部,但是浓度较低。由此可见,图4和5的结构物可以认为是一个熔喷纤维的基体,辅助纤维以可控的方式结合在其中,使得熔喷纤维在结构物外表面附近浓度较高,而在结构物里部的浓度较低。
虽然发明者不应固守一个特别的生产原理,但是可以相信,图4和5的结构物表明了辅助纤维在如上所述的熔喷纤维基体中的可控的或非均匀的分布。尽管辅助纤维在熔喷纤维基体内的分布似乎并不遵循精确的梯度模式,但结构物横截面上的确存在熔喷纤维的浓度在接近其外表面时增加而接近其内部时减少的情况。这种分布相信是特别有益的,因为虽然熔喷纤维在结构物内部的浓度是减少了,但仍存在着足够量的熔喷纤维,所以这种无纺织结构物有着一般均匀结构物所理想的强度和整体性,又由于熔喷纤维在结构物的外表面附近的浓度高,故提供理想的耐磨性。
图6是一个典型的均匀纤维无纺织复合结构物的20.7×(线性放大倍数)的显微相片。图7是图6所示的典型的均匀纤维无纺织复合结构物的67.3×(线性放大倍数)的显微相片。图6和7中所示的复合结构物基本上是熔喷聚丙烯纤维和木浆的均匀混合物。这种均匀混合物是用常规生产纤维无纺织复合网技术制备的一类典型材料的实例。由图6和7明显可见,熔喷纤维和木浆在复合结构物的整个截面上是均匀分布的,熔喷纤维在结构物的外表面附近及在其内部的分布也基本相同。
图8是一个典型的多层纤维无纺织复合结构物的20.7×(线性放大倍数)显微相片。图9是图8所示的典型多层纤维无纺织复合结构物的67.3×(线性放大倍数)显微相片。图8和9所示的复合结构物含有分立的熔喷聚丙烯纤维层,中间夹以分立的木浆层。这些显微相片显示,多层复合结构物的里部基本上没有熔喷纤维。
实施例
试样拉伸强度和伸长的测量是用Instron 1122型万能试验机按照联邦测试法标准191A的方法5100进行的。拉伸强度是指试样拉伸断裂时的最大负荷或力(即峰负荷)。湿试样峰负荷的测量分机器方向和横机器方向两种。测量结果以力的单位(磅力)表示,被测样尺寸是1英寸宽,6英寸长。
样品梯形撕破强度的测量按ASTM试验标准D1117-14的规定进行,但是撕破负荷是按起始负荷和最高负荷的平均值而不是按最低负荷和最高负荷的平均值计算。
颗粒和纤维从织物试样上脱落的测量是用Climet起绒试验机按INDA试验标准160.0-83规定的方法进行,但是试样的大小是6×6英寸而不是7×8英寸。
样品吸水能力的测量是按照关于工业用和机关用的擦手纸和擦拭纸的联邦规程UU-T-595C的规定进行。吸收能力是指在一定的时间内材料吸收液体的能力,它和材料在其饱和吸收点所保持的液体总量有关。吸收能力是由测量试样由于吸收液体造成的重量增加来确定。吸收能力是以被吸收液体的重量除以试样重量的百分数表示,计算式如下:
Figure C9311845700211
“吸水速率或“吸收速率”是指一滴水被一平面的平整的材料试样吸收的速率。吸水速率是按照TAPPI标准方法T432-SU-72的规定测定,但有如下的变动:1)每个试样上先后滴三个分开的水滴;2)每次测5个而不是10个样。
试样的水芯吸速率是按照TAPPI方法UM451的规定测量。芯吸速率是指水被一条吸水材料在垂直方向上吸出的速率。
试样的静态和动态摩擦系数(C.O.F.)按照ASTM 1894的规定测量。
试样的剥离强度或Z向整体性的测量是用符合ASTM试验标准D27 24.13以及联邦试验方法标准191A的方法5951规定的剥离强度试验法进行,但有下列例外:1)材料的剥离强度以所有被测试样平均峰负荷计算;2)试样尺寸是2英寸×6英寸;3)计量长度为1英寸。
测量试样的杯压试验性能。杯压试验可以评估织物的刚性,它是测量用一直径4.5cm的半球形座将一片7.5英寸×7.5英寸的织物压挤成一直径大约为6.5cm,高6.5cm的倒置杯形织物所需要的峰负荷,杯形织物外面围以直径大约为6.5cm的园筒以保持杯形织物的均匀变形。座和杯要对好以避免杯壁与座相接触,否则会影响峰负荷的测定。当座以约每秒0.25英寸(每分钟15英寸)的速度下降时,用FTD-G-500型负荷测定器(量程500克,新泽西州Tennsauken的Schaevitz公司制造)测量峰负荷。
试样的单位重量基本上按照ASTM D-3776-9的规定测定,但有如下的变动:1)试样的大小为4英寸×4英寸见方;2)总共称重9个试样。
液体迁移速率由液体在一叠湿擦片内的分布情况确定。液体的迁移测定是用一叠80个机制或手制的湿擦片,每个被测擦片约7.5英寸×7.5英寸,呈Z形折叠形状。将擦片浸入一个含约97%(重量)水;约1%(重量)丙二醇;和约0.6%(重量)PEG-75羊毛脂的溶液中。PEG-75羊毛脂是购自俄亥俄州辛辛那提的Henkel公司。一旦这些擦片的液体增重达到稳定(约为每个擦片干重的330%),即放入一擦片桶内贮放。在间隔约30天后取出这擦片,将整叠称重。每个擦片分开称重后回放到原来叠中的位置上,将整叠擦片放入烘箱中干燥。在擦片干燥后,将整叠和单个的擦片称重得到了干重。每个擦片的增湿率按下式计算:
增湿率=(湿重-干重)/干重×100
以码放位置(1-80)作X轴,增湿率(以百分数表示)作Y轴,将增湿率数据作图。顶部(1-5)和底部(76-80)的5个擦片的数据由于在烘箱中过干燥而弃之。增湿率和码放位置之间的关系假定为线性的,将数据点线性回归就产生一条直线,该直线的斜率即定义为液体的迁移率。为使液体在一叠擦片中保持相对均匀的分布,较低的液体迁移率(即低的斜率)比高液体迁移率(即高的斜率)更为理想。
耐磨试验是在CS-22C SC1型Stoll Quartermaster万能耐磨测试仪(新泽西州Cedar Knoll的Custom科学仪器公司出品)上进行。试样在约0.5磅的头重下进行磨耗循环。磨耗头装有一片1/8英寸厚的高密度弹性橡胶(购自伊利诺州Elmhurst的McMaster Carr公司,产品目录号8630 K74)。新的磨耗头以两个试样运转1000次循环为限。试验要进行到试样上首次出现完全松散的纤维“球粒”为止。也即是说,直到出现用一个挑针就能容易地从试验面上除去的纤维“球粒”为止。试验时大约每30次循环后就要停下来检查是否有纤维“球粒”。耐磨性是以形成完全松散的纤维“球粒”所需的循环次数表示,取15个试样的平均值。
实施例1
含有纤维化木浆和熔喷聚丙烯纤维的纤维无纺织复合结构物按上述和图1,2所示的通用过程生产。纤维化木浆是约80%(重量)漂白软木牛皮纸浆和约20%(重量)漂白硬木牛皮纸浆(Weyerhaeuser公司产品,牌号Weyerhaeuser NF-405)的混合物。聚丙烯是来自Himont化学公司,牌号Himont PF-015。熔喷纤维的成形是在500°F挤出温度下,以每模每小时90磅的速率将聚丙烯挤出成熔融丝束,熔融熔丝束在530°F温度下,在流速为约600-650标准立方英尺/分(scfm)的气流中被拉细。
卷装木浆(roll pulp)用通常的开松机纤维化。单独的浆粕纤维悬浮在压力约为2.6磅/平方英寸的气流中。夹带有熔喷纤维的两股气流在特定的条件下与含浆粕纤维的气流相撞造成各种不同一体化程度的气流。并合的气流射向一成形金属丝网,在网下真空系统的帮助下收集集合的纤维成为复合的材料。复合材料在加热加压的花纹粘合辊和光滑的砧辊上进行粘合。花纹粘合辊在每线性英寸约49磅的压力下操作,能赋于表面积约8.5%的粘合花纹。在粘合辊的温度为约190℃和砧辊的温度为170℃下进行了粘合操作。
复合材料的一些特定的性质和结构随工艺参数的改变而不同。本实例中为制备不同的材料而改变的工艺参数为(1)两模口间的距离(即距离α)和(2)模口角(即模角θ)。
要制备的材料是以约65%(浆粕/聚合物比)(重量)的浆粕和约35%(重量)的聚合物为目标。浆粕/聚合物比利用物料衡算法确定。物料衡算是以进入工艺过程中的浆粕量和聚合物量为基准。假定所有进入工艺过程中的浆粕和聚合物都转化为复合材料,复合物的浆粕/聚合物比就能算出。例如,上述的工艺包括有两个熔喷模。每个模以约90磅/小时稳定速率(总的聚合物速率约180磅/小时)将聚合物加工成熔喷物。因为复合物的浆粕/聚合物比定为65/35(即约65%(重量)的浆粕和约35%(重量)的聚合物),所以加入工艺过程中的浆粕可算出为约180×(65/35)。因此,加入工艺过程的浆粕应定在约334磅/时。
为了核实设定的工艺配比,可将复合材料的各组份分别成形然后称重。在这种情况下,希望得的是浆粕/聚合物比为65/35及单位重量为72克/平方米的复合材料。首先是在纤维化器中不加浆粕的情况下进行工艺操作,所以在特定的聚合物输入量下形成了熔喷纤维网。熔喷纤维网的单位重量约为39克/平方米。按计算的物料量将浆粕加入工艺过程中,得到了熔喷纤维和浆粕的复合物,该复合物的总单位重量约72克/平方米与约65/35的浆粕/聚合物比相符。在正常的工艺操作时,浆粕/聚合物比可略微偏离目标值,但一般应在目标值的约5~10%的范围之内。这点可从表1中所列的浆粕/聚合物比的数据中看到,该数据是用解析图象分析法确定的。
本实例工艺条件的描述及所制备的各种材料均列于表1和2中。表1工艺条件
    浆粕/聚合物  模口距离(α)  模口角θ  单位重量试样        比          (英寸)       (度)     (g/m2)均匀的     58/42          6.5         50        72梯度的     60/40          6.5         55        72多层的     60/40         16.5         75        72
    模口至成形    模口至冲击   冲击区至成试样    网距离(β)    区距离(X)    形面距离(Y)
      (英寸)        (英寸)       (英寸)均匀的      11            2.5          7.1梯度的      11            2.8          6.4多层的      11           13.8            0表2物理性能
  剥离强度  剥离强度  梯形撕破  梯形撕破  样条拉伸  样条拉伸试样  MD-湿样   CD-湿样     强度      强度      强度      强度
    (磅)      (磅)    MD-湿样   CD-湿样   MD-湿样   CD-温样
                        (磅)      (磅)      (磅)      (磅)均匀的 0.15      0.18       0.40      0.15      1.98      0.47梯度的 0.16      0.15       0.80      0.31      2.21      0.48多层的 0.02      0.02       0.57      0.18      0.74      0.37
湿样杯压  静态摩擦  动态摩擦  Climet   Frazier试样  性能      系数      系数    起绒试验 透气性
 (g/mm)     (g)       (g)  10μ/0.5μ(立方英尺/分钟
                                      /平方英尺)均匀的 2008    0.29    0.23    55/230    71.56梯度的 1849    0.28    0.22    36/157    68.84多层的 1784    0.25    0.20    103/894  181.52
    剥离强度    梯形撕破    耐磨性试样      (MD)      强度(MD)    X     δ
      (磅)        (磅)均匀的    0.15        0.40     161    84梯度的    0.16        0.80     328   173多层的    0.02        0.57     144    39
   吸收能力    吸收速率    芯吸性能试样    (g/m2)      (秒)       CD/MD*
                           (cm/60秒)均匀的   668         0.73       3.5/4.4梯度的   687         0.74       3.7/4.2多层的   691         0.61       3.4/3.0CD-机器横方向,MD-机器方向由表1表2可见,纤维无纺织复合结构物及其相关的物理性能可以通过改变模角和熔喷纤维模口间的距离来调整。当熔喷模口间的距离为6.5英寸时,55°的模角可制成“梯度”材料。也即是制得的材料中,它的外表面附近富集聚合物纤维而里部则富集浆粕。图4和5的显微相片所示的就是这种梯度材料。由图可见,没有明显分界的被完全由熔喷纤维组成的层隔断的浆粕层存在。相反,各组份的混合是逐渐变化的,它也可看作是纤维的浓度从富集浆粕的里部到富集聚合物纤维的外部呈现一种有规律的逐步的过渡。如前所述,可以相信这种逐渐变化的组份混合为结构物提供了期望的整体性和强度。例如,梯度材料的梯形撕破强度和剥离强度达到了所期望的与均匀结构物相当的水平。虽然每种试样在成形后都进行了粘合,但是梯度材料由于结构物的强度和整体性好可不需要进行粘合或其它后处理而直接使用。
梯度结构物成功地加入了高含量的短小辅助纤维(例如浆粕)和/或颗粒,同时比均匀结构物和多层结构物具有更高的耐磨性。梯度结构物也提供了理想的颗粒/纤维间相互抓握或固持的水平。这一点通过比较Climet起绒试验的结果就很清楚。虽然发明者不应固守特定的生产原理,但是可以相信梯度材料的这些突出的结果可归因于:(1)粘稠的、部分熔融熔喷纤维与辅助材料的充分混合,缠结和某种程度的点粘合,和(2)邻近结构物外表面上高浓度的熔喷纤维所提供的包封效应。重要的是,当邻近外表面的高浓度熔喷纤维减少纤维/颗粒的损失时,它并不明显地影响材料对液体的固持能力,这可由吸收能力,吸收速率和芯吸速率的测定结果得到证实。
当模角改变到约50°时,得到的是均匀的材料,也即是得到熔喷纤维和浆粕在整个纤维无纺织结构物中基本上是均匀分布的材料。图6和7的显微相片所示的就是这种均匀材料。
当模角改变到约75°时,得到的是多层的纤维无纺织结构物。这种材料有着熔喷纤维的顶层和底层中间夹以一层基本上无熔喷纤维的浆粕。这种多层的纤维无纺织结构如图8和9的显微相片所示。
虽然这种多层的纤维无纺织复合结构物中实际上所有的聚合物纤维都在其外表面上,并且实际上所有的浆粕都在其里部,尽管将结构物花纹粘合,但这种多层结构的强度特性,耐磨性和浆粕抓握性仍很差。可以相信,多层结构物中存在的明显的浓度分区不能提供达梯度结构物所达到的组份之间整体化的水平。
分析图象解析
熔喷聚合物纤维和浆粕纤维在试样外表面附近和里部的浓度通过分析图象解析法确定。在这个解析技术中,将三个1/2英寸见方,试样的每一边摄成100×(线性)放大倍数的扫描电镜相片。扫描电镜相片的景深约为150μm。每个显微相片有着约为1000μm×700μm视场,并且有一5×5的栅格覆盖,将每个显微相片分成25个分部。每幅视场相隔1000μm。用肉眼观察纪录显微相片每幅视场中浆粕纤维的数量和长度。
浆粕纤维的密度假定为约1.2g/cm3。聚丙烯的密度假定为约0.91g/cm3。面积计算时假定浆粕纤维的平均直径为约50μm。计算体积和质量时假定每个浆粕纤维的横截面约10μm×70μm。
每个试样的厚度通过用入射光观察刀片割出的横截面边缘测定。用酸将试样中的纤维素(例如木浆)提取出来。整个试样的浆粕/聚合物比(即总体浆粕/聚合物比)可通过比较起始试样重(含有浆粕和聚合物)与酸处理后的试样的干重(除去浆粕)来确定。
试样表面浆粕比例的确定是基于面积百分数和体积百分数的空间等效性。这个假定使得有可能用面积和密度数据算出试样表面的质量比。试样内部(非表面层)的浆粕/聚合物比可用下式计算:
Rc=(Ho*Ro-(Hs*(Rs1=Rs2))/HC
其中:
Rc=试样内部(非表面层或中心)的浆粕/聚合物比
Hc=试样里层(非表面层或中心)的高度
Ro=整个试样的浆粕/聚合物比(由酸提取法确定)
Ho=整个试样的高度
Rs1=第一表面层的浆粕/聚合物比(由分析图象解析法确定)
Rs2=第二表面层的浆粕/聚合物比(由分析图象解析法确定)。
Hs=联合表面层的高度(联合的扫描电镜相片的景深)。
在表1和2中所述的试样按上述的方法分析。各种试样的浆粕/聚合物比列于表3中。表3浆粕/聚合物比试样     总体    表面A    表面B    里层均匀的   58/42   54/46    56/45    59/41梯度的   60/40   24/76    30/70    64/36多层的   60/40   10/90    10/90    64/36
作为本发明实例之一的梯度结构物其总的(总体)浆粕/聚合物比为60/40,聚合物纤维在其外表面区(即在扫描电镜相片的可见区域内)的平均浓度约为73%。通过计算,梯度结构物里层聚合物纤维的浓度约为35%。
实施例2
含有纤维化术浆和熔喷聚丙烯纤维的纤维无纺织复合结构物按照实施例1所述的和图1和2所示的通用过程生产。纤维化木浆是约80%(重量)漂白软木牛皮纸浆和约20%(重量)漂白硬木牛皮纸浆(Weyerhaeuser公司产品,牌号Weyerhaeuser NF-405)的混合物。聚丙烯来自Himont化学公司,牌号Himont PF-015。熔喷纤维的成形是在520°F挤出温度下以每个模每小时90磅的速率将聚丙烯挤出成熔融丝束。熔融丝束在530°F温度下,在流速约为800 scfm的主气流中被拉细。
卷装木浆用通常的开松机纤维化。单个的浆粕纤维悬浮在压力约为40英寸水柱的辅助气流中。两个夹带有熔喷纤维的主气流在特定的条件下与辅助气流相撞造成各种一体化程度不同的气流。并合的气流连续射向一成形金属丝网,纤维被收集成复合材料,它的表面附近熔喷纤维的浓度较高而里部熔喷纤维的浓度较低(即浆粕较多)。复合材料的一些特定性质和结构随工艺参数和材料参数的改变而不同。本实施例中为制备不同的材料而改变的工艺参数为(1)两模口间的距离(即距离α)和(2)模口角(即模角θ)。被改变的材料参数是浆粕/聚合物比。浆粕/聚合物比按实施例1所述那样测定和验证。
表4列出了所制备的各种不同的纤维无纺织复合结构物。这些结构物被用来试验确定工艺改变如何影响无纺织复合物的平均流动孔径,这些结构物也被用来试验确定它们保持液体在由单片复合结构物组成垂直叠中均匀分布能力的大小。这种情况在纤维无纺织复合结构物被包装起来用作湿擦片时是很普通的。这种包装也许被几乎是无限期存放,必须使水份在贮叠中有着基本均匀的分布。也即是,叠顶部不应该干透而叠底部不应该积液。这种试验结果是以液体迁移速率表示并列于表4中。No. 浆粕/    模口距    模口角 小于35μ    液体迁移
聚合物   离(α)     (θ)  孔径的%      速率1   55/45      5″       35°       57         2.082   55/45      5″       55°       65         1.903   65/35      5″       35°       61         1.414   65/35      9″       55°       67         1.245   55/45      9″       55°       69         1.186   65/35      9″       55°       68         1.497   65/35      5″       35°       63         1.888   55/45      9″       35°       80         1.049   60/40      7″       45°       72         1.48
如上所述,纤维无纺织复合结构物及其相关连的性质能被改变以满足对产品属性的要求。在一叠湿擦片中,重要的是水份在整个一叠中的均匀分布。没有水份均匀分布则叠顶部将是干的而堆底部将是水饱和的。
已经发现,当结构物的外表面附近含有的聚合物微纤百分数高时可以改进一叠擦片中的水份分布状况,此时增加了极微孔(平均孔径小于35μm的孔)的相对数量。一般来说,在上述的工艺中要完成这一点只要让模口间的距离(即距离α)大于9英寸。模口间的距离越大相应着携带有被拉细熔喷纤维的气流的速度下降越大。这就降低了在冲击区发生在浆粕和熔喷纤维间的混合数量。此外,比较大的熔喷模口间的距离降低了冲击区(气流的汇合处)的位置,使其更接近成形金属丝网。这个变短了的距离限制了用于纤维混合的时间。这两个工艺改变造成了浆粕与熔喷纤维基体的渐变分布。结构物邻近表面部分聚合物微纤的百分含量更高,这也增加了小孔的相对数量。
当本发明与某些优选的实施例相联系时,应该理解,本发明所包含的内容并不限于这些特殊的实例。相反,本发明的内容包括所有隶属于以下权利要求的精神和范围的取舍、改进和等价物。

Claims (18)

1.一种耐磨的纤维无纺织复合结构物,它包括具有第一外表面、第二外表面和里部的熔喷纤维基体,其特征是含有至少另一种结合进熔喷纤维基体中致使熔喷纤维在无纺织结构物每个外表面附近的浓度至少约60%(重量)且熔喷纤维在里部的浓度小于约40%(重量)的材料,且该材料组分是呈梯度分布的。
2.根据权利要求1的纤维无纺织复合结构物,其特征是熔喷纤维基体是选自下列一组聚合物纤维的熔喷纤维基体:聚烯烃纤维、聚酰胺纤维、聚酯纤维、聚氨酯纤维、聚乙烯醇纤维、聚己内酯纤维和其混合物。
3.根据权利要求2的纤维无纺织复合结构物,其特征是聚烯烃纤维由选自以下一组的聚烯烃制成;聚乙烯、聚丙烯、聚丁烯、乙烯共聚物、丙烯共聚物、丁烯共聚物和其混合物。
4.根据权利要求1的纤维无纺织复合结构物,其特征是另一种材料是选自由聚酯纤维、聚酰胺纤维、聚烯烃纤维、纤维素衍生物纤维、多组分纤维、天然纤维、吸收剂纤维、或两种或多种所述纤维的共混物构成的组。
5.根据权利要求1的纤维无纺织复合结构物,其特征是熔喷纤维在每个外表面附近的浓度为约70-90%(重量),熔喷纤维在里部的浓度低于约35%(重量)。
6.根据权利要求1的纤维无纺织复合结构物,其特征是它是由至少两层这种纤维无纺织复合结构物构成的。
7.根据权利要求1的纤维无纺织复合结构物在制造一种含有的液体为干重的约100-700%的湿擦片中的应用。
8.根据一种耐磨的高浆粕含量的纤维无纺织复合结构物,它包括:少于总重量的约35%的熔喷纤维,该熔喷纤维形成具有第一外表面,第二外表面和里部的基体,其特征是含有大于总重量的约65%结合进熔喷纤维基体以使得熔喷纤维在无纺织结构每个外表面附近的浓度为至少约60%(重量),而熔喷纤维在里部的浓度低于约40%(重量)的浆粕纤维,且该浆粕纤维是呈梯度分布的。
9.根据权利要求8的纤维无纺织复合结构物,其特征是复合物当用于Climet起绒试验法测定时,掉绒在0.01立方英尺空气中10微米直径颗粒少于约50个,0.5微米直径颗粒少于约200个。
10.根据权利要求8的纤维无纺织复合结构物,其特征是复合物的耐磨性至少比相同缓份的均匀混合物的耐磨性大约30%。
11.根据权利要求10的纤维无纺织复合结构物,其特征是复合物的耐磨性比相同组份的均匀混合物的耐磨性大约50-150%。
12.根据权利要求8的纤维无纺织复合结构物,其特征是熔喷纤维基体是选自由聚烯烃纤维、聚酰胺纤维、聚酯纤维、聚氨酯纤维、聚乙烯醇纤维、聚己内酯纤维和其混合物构成组的熔喷纤维基体。
13.根据权利要求12的纤维无纺织复合结构物,其特征是聚烯烃是选自由聚乙烯、聚丙烯、聚丁烯、乙烯共聚物、丙烯共聚物、丁烯共聚物和其混合物构成的组。
14.根据权利要求8的纤维无纺织复合结构物,其特征是结构的总浆粕含量范围从约65-95%(以结构物总重量为基)。
15.根据权利要求8的纤维无纺织复合结构物,其特征是熔喷纤维在每个外表面附近的浓度是约70-90%(重量),且熔喷纤维在里部的浓度小于约20%(重量)。
16.根据权利要求8的耐磨的高浆粕含量的纤维无纺织复合结构物,其特征是它是由至少两层这种纤维无纺织复合结构物构成的。
17.根据权利要求8的纤维无纺织复合结构在制造含有液体为干重的约100-700%的湿擦片中的应用。
18.一种制造耐磨纤维无纺织复合结构物的方法,它包括:
将熔喷热塑性聚合物纤维的第一流和第二流呈相交状而形成一个冲击区,
在熔喷热塑性聚合物纤维第一和第二流之间导入可使熔喷纤维在纤维无纺织结构的每个外表面附近的浓度至少约60%(重量)且熔喷纤维在里部的浓度小于约40%(重量)的辅助材料流,并引向冲击区合并成一复合流;和
在一成形面上将收集结合有辅助纤维的熔喷纤维基体的复合流。
CN93118457A 1992-10-05 1993-10-04 耐磨纤维无纺织复合结构物及其制造方法和用途 Expired - Lifetime CN1044015C (zh)

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MX9306128A (es) 1994-04-29
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AU4877593A (en) 1994-04-21
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US5350624A (en) 1994-09-27
US5508102A (en) 1996-04-16
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