CN105636782A - 具有良好的阻隔性能的无膜底片 - Google Patents

具有良好的阻隔性能的无膜底片 Download PDF

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CN105636782A
CN105636782A CN201480056223.8A CN201480056223A CN105636782A CN 105636782 A CN105636782 A CN 105636782A CN 201480056223 A CN201480056223 A CN 201480056223A CN 105636782 A CN105636782 A CN 105636782A
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fiber
spunbond
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fusing point
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CN105636782B (zh
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G·J·克拉森
J·M·马丁
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Dow Global Technologies LLC
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Abstract

描述了一种多层非织造结构，其中所述非织造结构包含至少两个纺粘层和至少一个易熔融层。所述易熔融层位于所述至少两个纺粘层之间。所述易熔融层由熔点比构成所述纺粘层的纤维的表面所包含的聚合物的熔点低至少20℃的聚合物构成，或者由易于吸收某种形式的辐射的聚合物制成。在粘合条件下，可使构成所述易熔融层的纤维熔融以形成膜，从而改善所述非织造结构的阻隔性能。

Description

具有良好的阻隔性能的无膜底片
技术领域
一种多层非织造结构，其包含第一纺粘层、第二纺粘层和位于第一纺粘层与第二纺粘层之间的至少一个易熔融层，例如，其可以是熔喷层、纺粘层或甚至是经梳理的短纤维层。所述易熔融层由最大横截面为5微米或更小的纤维构成，且所述纤维由熔点比构成用于第一纺粘层和第二纺粘层的纤维的外表面的聚合物的熔点低至少20℃的聚合物构成。所述易熔融层能够在粘合过程期间熔融以使得可将其转化为膜状形态。
背景技术
如今在织物和非织造物中可接受的阻隔性能通常通过将可透气或不可透气膜层压到非织造物或织物来达到。寻求的是在保持期望的转运和阻隔性能的同时去除这样的层压过程以便可降低成本同时保持织物手感。
在过去几年中，为了消减生产纺粘非织造物的卫生用品市场中的成本，纺粘技术在机器制造商的推动下取得了很大的发展。由于生产速率的不断提高，目前已经安装了高达6轴的机器，其中7轴机器作为下一代。这些机器通常具有组合的纺粘轴和熔喷轴。
因此，当试图替代用于组合膜与非织造物的层压步骤时，决定利用较新的多轴技术产生结构内联并在SXnMXnS的一个或多个内部层中包括低熔点聚合物，其中n可以为0至3(其中S表示纺粘层，M表示熔喷层并且X可以为纺粘层或熔喷层，并且n可以为0至3)。认为通常在纺粘非织造物工艺的粘合阶段将这样的较低熔点熔喷纤维暴露于压力和温度下，可形成膜状结构，以便可根据应用调整这样的结构的透气性和阻隔性能。
因此，本发明涉及多层非织造结构，其包含至少两个纺粘层和至少一个易熔融层，其中所述易熔融层位于至少两个纺粘层之间，并且其中所述易熔融层由熔点低于构成不想被熔融的熔喷层或纺粘层的纤维的外表面所包含的聚合物之熔点的聚合物构成。
本发明提供了更加织物状的制品，其具有与所生产膜状非织造层压制品相同的容量，但具有更好的触觉、等效的透气性并降低了制造成本。
发明内容
如今在织物和非织造物中可接受的阻隔性能通常通过将可透气或不可透气膜层压到非织造物或织物来达到。寻求的是在保持期望的转运和阻隔性能的同时去除这样的层压过程以便可降低成本同时保持织物手感。
在过去几年中，为了消减生产纺粘非织造物的卫生用品市场中的成本，纺粘技术在机器制造商的推动下取得了很大的发展。由于生产速率的不断提高，目前已经安装了高达6轴的机器，其中7轴机器作为下一代。这些机器通常具有组合的纺粘轴和熔喷轴。
因此，当试图替代用于组合膜与非织造物的层压步骤时，决定利用较新的多轴技术产生结构内联并在SXnMXnS的一个或多个内部层中包括低熔点聚合物，其中n可以为0至3(其中S表示纺粘层，M表示熔喷层并且X可以为纺粘层或熔喷层，并且n可以为0至3)。认为通常在纺粘非织造物工艺的粘合阶段将这样的较低熔点熔喷纤维暴露于压力和温度下，可形成膜状结构，以便可根据应用调整这样的结构的透气性和阻隔性能。
因此，本发明涉及多层非织造结构，其包含至少两个纺粘层和至少一个易熔融层，其中所述易熔融层位于至少两个纺粘层之间，并且其中所述易熔融层由熔点低于构成不想被熔融的熔喷层或纺粘层的纤维的外表面所包含的聚合物之熔点的聚合物构成。
本发明提供了更加织物状的制品，其具有与所生产膜状非织造层压制品相同的容量，但具有更好的触觉、等效的透气性并降低了制造成本。
具体实施方式
如本文所用的，术语“非织造网”或“非织造织物”或“非织造物”，是指具有相互插入(但不以任何规则、重复的方式)的单独化纤维或线的结构的网。非织造网在过去通过多种方法形成，如，例如，气流成网法、熔喷法、纺粘法和梳理法，包括粘合梳理成网法。
如本文所用的，术语“熔喷”是指将熔融热塑性材料作为熔融线或丝经过多个细的、通常是圆形的、模头毛细管挤出进入高速气(例如空气)流中的过程，所述高速气流将熔融热塑性材料的丝拉细以减少其直径，其可以为微纤维直径。其后，熔喷纤维由高速气流携带并且沉积在收集表面上，以形成无规分散的熔喷纤维的网。
如本文所用的，术语“纺粘”是指将熔融热塑性材料作为丝从多个细的、通常是圆形的、喷丝头的毛细管挤出并在基板上收集纤维的过程，其中所挤出的丝的直径接着通过拉伸纤维快速减少。
如本文所用的，术语“微纤维”是指平均直径不大于约100微米的小直径纤维。用于本发明的纤维，并且特别是纺粘纤维和熔喷纤维可以是微纤维。更特别地，纺粘纤维可有利地为平均直径约15微米至30微米并且旦尼尔为约1.5旦尼尔/丝至3.0旦尼尔/丝的纤维，而熔喷纤维可有利地为平均直径小于约15微米或更有利地10微米、8微米或甚至5微米的纤维。
如本文所用的，术语“聚合物”通常包括，但不限于，均聚物、共聚物，如，例如，嵌段共聚物、接枝共聚物、无规共聚物和交替共聚物、三元共聚物等，以及其共混物和改性物。此外，除非另外具体地限制，否则术语“聚合物”应包括材料的所有可能的几何构型。这些构型包括，但不限于，全同立构、间同立构和无规对称。
如本文所用的，术语“基于聚丙烯的塑性体(PBP)或基于聚丙烯的弹性体(PBE)”(这些可统称为“PBPE”)包括熔融热小于约100焦耳/gm并且MWD＜3.5的丙烯的反应器级共聚物。PBP的熔融热通常小于约100焦耳/克，而PBE的熔融热通常小于约40焦耳/克。PBP的重量百分比乙烯通常在约3重量％至约10重量％乙烯的范围，而弹性体PBE的乙烯含量为约10重量％至15重量％乙烯。
本发明的非织造层状结构的基重(重量/单位面积)优选为约10克/平方米(gsm)至约200gsm。基重还可以为约15gsm至约60gsm，并且在一个实施例中，其可以为约20gsm至约35gsm，这特别适于卫生用品应用。对于医疗应用，优选的基重可以为50gsm至100gsm，或者对于工业应用可以为80gsm至5000gsm。
如本文所用的，术语“拉伸强度”描述了当以非织造物的纵向(MD)或横向(CD)拉伸时在拉至断裂时对于给定基重的峰值力。峰值力可对应于或可不对应于在断裂处的力或在断裂处的应变。除非另外指明，否则“伸长率”是指对应于拉伸强度的应变。
“熔点”根据ASTMD3418，“通过差示扫描量热计测试聚合物的转变温度和熔融焓以及结晶的标准方法(StandardTestMethodforTransitionTemperaturesandEnthalpiesofFusionandCrystallizationofPolymersbyDifferentialScanningCalorimetry)”来测定。
“水蒸气透过率”(WVTR)有时称为“湿蒸气透过率”(MVTR)根据Edana测试方法WSP070.6.R3(12)来测定。)
本发明涉及多层非织造结构，其包含至少两个纺粘层和至少一个易熔融层，其中所述易熔融层位于至少两个纺粘层之间。所述易熔融层可以是熔喷层、纺粘层或甚至经梳理的短纤维层。所述易熔融层由熔点低于构成所述纺粘层的纤维的表面所包含的聚合物之熔点的聚合物构成。
用于多层非织造结构中的外层的纺粘层可以是双组分纤维或单组分纤维。如果使用双组分纤维，则优选的是纤维呈皮-芯形式。所述纤维可由任何聚合物制造。优选的单组分纤维包括均聚物聚丙烯(hPP)无规共聚物聚丙烯或聚乙烯(PE)，双组分纤维包括hPP/PE、RCP/PE、聚烯烃弹性体/PE或hPP/hPP、聚对苯二甲酸乙二醇酯(PET)/X或聚酰胺(PA)/X双组分，其中X可以为任何聚烯烃或任何弹性非织造纺粘物或PLA。应选择纤维以确保在纤维表面(例如，在双组分皮-芯纤维的皮)处的聚合物的熔点高于用于膜形成熔喷纤维层的聚合物。优选地，在纺粘纤维的表面处使用的聚合物的熔点比用于易熔融层中的聚合物的熔点高至少20℃、30℃或甚至40℃。优选地，用于在外部纺粘层中使用的纤维表面的聚合物的熔点大于125℃，或大于140度或甚至160℃。
用于多层非织造结构的强制内层的易熔融层可以是熔喷层、纺粘层或经梳理的短纤维，但对于许多应用而言，熔喷层可能是优选的。用于易熔融层的纤维可以是基于hPP、PE、聚烯烃(PO)弹性体、PET、PA或其它极性共聚物如乙烯乙酸乙烯酯(EVA)、乙烯一氧化碳(ECO、乙烯丙烯酸(EAA)、马来酸酐接枝共聚物、乙烯甲基丙烯酸(EMA)(其可以是射频(RF)或微波活性的)。PO弹性体包括基于丙烯的塑性体或弹性体(PBPE)如由陶氏化学公司(theDowChemicalCompany)出售的VERSIFYTM弹性体或由埃克森美孚(ExxonMobil)出售的VISTAMAXXTM弹性体，以及烯烃嵌段共聚物如由陶氏化学公司出售的INFUSETM弹性体。聚乙烯纤维包括线性低密度聚乙烯(LLDPE)、高压低密度聚乙烯(LDPE)、高密度聚乙烯(HDPE)等。优选的聚乙烯纤维包括塑性或弹性LLDPE(即，密度为约0.910g/cm3或更小的LLDPE)。这些材料可单独使用或与两种或更多种这样的组分共混使用。为了易于熔融，所述材料的熔点优选为比用于构成外部纺粘层的纤维表面的聚合物的熔点低至少20℃、30℃或甚至40℃。优选地，用于至少一个易熔融层的聚合物的熔点为100℃或低于90度。或者，如果易熔融层是RF、微波或超声波活性的，而纺粘层不是，则可将放射线、超声波或微波辐射用于熔融内部易熔融层而留下外部纺粘层含纤维。用于本发明的易熔融层中的纤维的尤其优选的材料包括基于丙烯的弹性体。如果使用多于一个熔喷层，则熔喷层在组成上可以是相似的或不同的以使得较低熔点聚合物可以是所述层中的任何一个，这取决于所期望的总体阻隔性、渗透性或强度。
本发明的多层非织造结构包含两个外部纺粘层和至少一个内部易熔融层，但是可含有另外的层。通常，可将多层结构描述为SXnMXnS，其中S是纺粘层，M是熔喷层，X是纺粘层或熔喷层并且n可以为0至3。
通常优选的是，非织造结构具有相对高的劲度/强度以在易熔融层熔融时支撑结构。例如，这可通过使用由较硬材料如hPP制成的另外的层和/或使用通常对于易熔融层而言较硬的聚合物如具有较低乙烯含量(例如5％至7％)的PBPE来进行。
在将所述层带到一起之后，通常使其经历压力和/或较高温度以促进这样的结构的粘合。可选择这些较高的温度和压力以便熔融至少一个内层。一旦移除压力和/或热，则通常将聚合物限制在相邻层之间时，其将固化从而形成膜状结构，这可有助于降低非织造结构的水蒸气透过率。或者，不是依赖于热和/或压力来引起内层熔融，而是如果使用放射线或微波活性材料，则可使非织造结构经历放射线或微波辐射以引起熔融。认为内层可根据熔点和厚度而变化以便可根据应用调整这样的结构的透气性和阻隔性。因此，本发明的非织造结构可用于健康和卫生制品如婴儿尿布底片、成人失禁底片、女性卫生底片、手术衣、医用被单和膏药或绷带。非织造结构还可用于工业应用如屋顶膜、土工膜、房屋包层或装饰。
实例
为了证明本发明，如下所述制备了两个分开系列的非织造结构。第一组试验通过将如下所述的非织造物的不同层组合在一起，然后将所述层粘合在一起以形成层压制品来进行。通过使用两个加热辊来完成，一个是光滑的并且另一个的粘合面积为16％。粘合在70N.mm的压力，设置在145℃下的压延机油粘合温度和25m/min的线速度下进行。
第二组试验通过将如下所述的非织造物的不同层组合在一起，然后将所述层粘合在一起以形成层压制品来进行。对这些结构进行第一次粘合，如第一组试验所做的(即，在145℃的压延机油粘合温度，使用一个光滑的辊和另一个具有16％粘合面积的辊，在70N.mm的压力和25m/min的线速度下)。然后在95℃的温度和30巴bip压力25m/min下使用100％粘合面积辊对这些结构进行第二次粘合。如以下所见，使用100％粘合面积大大地提高了水压头，表明易熔融层在第一组条件下并未完全熔融。
将非织造层与材料组合的第一个试验：
实例1：层A/层C/层G/层G/层C/层A(50FPM)
实例2：层A/层C/层G/层G/层C/层A(34FPM)
实例3：层A/层G/层G/层A(24FPM)
实例4：层A/层C/层B/层C/层A
实例5：层A/层C/层B/层B/层C/层A
实例6：层A/层C/层D/层C/层A
实例7：层A/层C/层E/层C/层A
实例8：层A/层C/层E/层C/层A
将非织造层与材料组合的第二个试验：
实例9(比较)：SMS-层A/层C/层A
实例10：SMS-层A/层B/层A
实例11：SMS-层A/层E/层A
实例12：SMMMS层A/层C/层B/层C/层A
实例13：SMMMS层A/层C/层B/层C/层A
实例14：SMMMS层A/层B/层B/层C/层A
实例15：SMMMS层A/层B/层E/层C/层A
实例16：SMMMS层A/层B/层E/层B/层A
实例17：SMMMS层A/层C/层D/层C/层A
所述层的描述
层A是通过Reicofil纺粘技术生产的20克/平方米(GSM)基重的纺粘非织造物，其由MFR(2.16Kg，230℃)为25g/10min且熔点为167℃的均聚物聚丙烯(hPP)制成。
层B是通过Reicofil熔喷技术生产的25GSM基重的熔喷非织造物，其由基于丙烯的塑性体/弹性体(PBPE)制成，所述基于丙烯的塑性体/弹性体的MFR为25g/10min，乙烯含量为5％且熔点为110℃并且添加2％IrgatecCR76母料。
层C是通过Reicofil熔喷技术生产的25GSM基重的熔喷非织造物，其由MFR为～800g/10min且熔点为167℃的均聚物聚丙烯(hPP)制成。
层D是通过Reicofil熔喷技术生产的25GSM基重的熔喷非织造物，其由MI(2.16Kg，190℃)为155g/10min且密度为0.933g/cm3并且熔点为120℃的气相反应器产生的线性低密度聚乙烯(LLDPE)制成。
层E是通过Reicofil熔喷技术生产的25GSM熔喷非织造物，其由基于丙烯的塑性体/弹性体(PBPE)制成，所述基于丙烯的塑性体/弹性体的MFR为25g/10min，乙烯含量为9％且熔点为85℃并且添加2％IrgatecCR76母料。
层G是10GSM(50英尺/分钟)或15GSM(34英尺/分钟)或20GSM(24英尺/分钟)(如上所述)熔喷非织造物，其由基于丙烯的塑性体/弹性体(PBE1)在BIAX膜上生产，所述基于丙烯的塑性体/弹性体的MFR为25g/10min，乙烯含量为5％且熔点为110℃并且添加2％IrgatecCR76母料。
纺粘样品通过Reicofil3单轴技术生产，所述技术具有1.2米宽纺粘试验性生产线，每米具有5000个孔，并且其中孔直径为0.6mm且L/D比为4。所述生产线的通过量恒定在0.6ghm下，其中线速度为150m/min。
熔喷样品层G在具有带128个孔的15cm(6in)宽模头的BiaxFiberfilm线上生产。使用热空气将纤维变细并以不同速度收集于纤维卷筒上从而改变基重并且使其直接沉积在非织造层上。
熔喷样品B、C、D和E在Reicofil/Hills技术熔喷线上生产，其宽度为1.2米宽并且为50孔/英寸。孔直径为0.25mm。熔喷非织造物在20米/分钟线速度下生产，以集中生产25GSM非织造物。
完成了以下分析：
水压头(通过ISO以cm为单位测量)
WVTR(使用ISO在38℃和90％相对湿度下以g/m2/天为单位测量)
基重，以克/平方米为单位测量
将非织造层与材料组合的第一个试验：
样品 WVTR(g/m2/天) 水压头(毫巴)
实例1 5550 25
实例2 5017 20
实例3 5022 17
实例4 4909 11
实例5 4880 11
实例6 5242 12
实例7 5293 15
实例8 5483 13
将非织造层与材料组合的第二个试验：
样品 水压头(毫巴)
实例9(比较) 97
实例10 269
实例11 16
实例12 110
实例13 309
实例14 305
实例15 101
实例16 121
实例17 135

Claims (11)

1.一种多层非织造结构，其包含至少两个纺粘层和至少一个易熔融层，其中所述易熔融层位于所述至少两个纺粘层之间，并且其中所述易熔融层由包含聚合物的纤维构成，所述聚合物的熔点比构成所述纺粘层的纤维的表面所包含的聚合物的熔点低至少20℃。
2.一种多层非织造结构，其包含：
a.第一纺粘外层，其包含单组分或双组分纤维，其中所述纤维具有由具有给定熔点的聚烯烃聚合物构成的表面；
b.易熔融层，其中所述易熔融层由最大横截面为5微米或更小的纤维构成，且所述纤维由熔点比构成用于所述第一纺粘外层和第二纺粘外层的所述纤维的所述表面的所述聚合物的熔点低至少20℃的聚合物构成；
c.第二纺粘外层，其包含单组分或双组分纤维，其中所述纤维具有由具有给定熔点的聚烯烃聚合物构成的表面；
其中所述易熔融层位于所述第一纺粘层与所述第二纺粘层之间；并且
其中所述易熔融层能够在粘合过程期间熔融以使得其可转化为膜状形态。
3.根据权利要求1所述的多层非织造物，其中将热和压力施加到所述多层非织造结构以引起所述易熔融层中的所述纤维至少部分地熔融从而提高所述易熔融层的阻隔性能。
4.根据权利要求2所述的多层非织造结构，其中构成所述易熔融层的所述纤维的所述聚合物的熔点低于125℃。
5.根据权利要求2所述的多层非织造结构，其中构成所述纺粘外层的所述纤维的所述聚合物的熔点高于125℃。
6.根据权利要求2所述的多层非织造结构，其中所述易熔融层由熔点比构成用于所述第一纺粘外层和所述第二纺粘外层的所述纤维的所述表面的所述聚合物的熔点低至少40℃的聚合物构成。
7.一种通过使用内联粘合步骤以在纺粘非织造物之间形成阻隔膜状结构来改善多层膜的阻隔性能的方法，其包含以下步骤：
a.选择多层非织造结构，其包含：
i.第一纺粘外层，其包含单组分或双组分纤维，其中所述纤维具有由具有给定熔点的聚烯烃聚合物构成的表面；
ii.易熔融层，其中所述易熔融层由最大横截面为5微米或更小的纤维构成，且所述纤维由熔点比构成用于所述第一纺粘外层和第二纺粘外层的所述纤维的所述表面的所述聚合物的熔点低至少20℃的聚合物构成；
iii.第二纺粘外层，其包含单组分或双组分纤维，其中所述纤维具有由具有给定熔点的聚烯烃聚合物构成的表面；
其中所述易熔融层位于所述第一纺粘层与所述第二纺粘层之间；并且
b.使所述多层结构经受足以引起所述易熔融层中的所述纤维至少部分熔融从而提高所述易熔融层的所述阻隔性能的条件。
8.根据权利要求6所述的方法，其中使所述多层结构经受增加的热和/或压力从而使所述易熔融层中的所述纤维至少部分地熔融。
9.根据权利要求6所述的方法，其中使所述多层结构经受超声波振动从而使所述易熔融层中的所述纤维至少部分地熔融。
10.根据权利要求6所述的方法，其中使所述多层结构经受RF辐射从而使所述易熔融层中的所述纤维至少部分地熔融。
11.一种多层非织造结构，其包含：
a.第一纺粘外层，其包含单组分或双组分纤维，其中所述纤维具有由具有给定熔点的聚烯烃聚合物构成的表面；
b.易熔融层，其中所述易熔融层由最大横截面为5微米或更小的纤维构成，且所述纤维由比用于所述外层中的所述聚合物更大程度地吸收RF辐射或超声波辐射的聚合物构成；
c.第二纺粘外层，其包含单组分或双组分纤维，其中所述纤维具有由具有给定熔点的聚烯烃聚合物构成的表面；
其中所述易熔融层位于所述第一纺粘层与所述第二纺粘层之间；并且
其中所述易熔融层能够在粘合过程期间熔融以使得其可转化为膜状形态。
CN201480056223.8A 2013-10-25 2014-10-22 具有良好的阻隔性能的无膜底片 Active CN105636782B (zh)

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CN114728511A (zh) * 2019-11-18 2022-07-08 贝里国际公司 具有高的耐热性和屏障特性的非织造织物

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BR112016008314A2 (zh) 2017-08-01
WO2015061417A3 (en) 2016-03-10
EP3060711A2 (en) 2016-08-31
MX2016004688A (es) 2016-07-26
KR20160075557A (ko) 2016-06-29
MX366102B (es) 2019-06-27
US20150114546A1 (en) 2015-04-30
BR112016008314B1 (pt) 2022-03-03
TW201538335A (zh) 2015-10-16
WO2015061417A2 (en) 2015-04-30
AR098190A1 (es) 2016-05-18
TWI652176B (zh) 2019-03-01
CN105636782B (zh) 2018-05-11

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