CN1062922C - 新型絮填纤维胎 - Google Patents

新型絮填纤维胎 Download PDF

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CN1062922C
CN1062922C CN94193052A CN94193052A CN1062922C CN 1062922 C CN1062922 C CN 1062922C CN 94193052 A CN94193052 A CN 94193052A CN 94193052 A CN94193052 A CN 94193052A CN 1062922 C CN1062922 C CN 1062922C
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M·S·弗兰科斯基
W·K·郭
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Invista Technologies Sarl
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Abstract

用低dpf(单丝旦数)聚酯纤维和粘合剂纤维制造并以烘箱粘合喷涂了一种软树脂的服装及其他用途改良聚酯絮填胎。这种方法提供的粘合纤维胎特点在于，柔性及垂感、良好隔热性能、漏出或渗出面料量低、提高的耐水洗/干燥或耐干洗度以及增强的结构整体性，从而能不需衍缝成小尺寸格子地自由悬挂。

Description

新型絮填纤维胎
本发明是关于粘合聚酯絮填胎(有时称做纤维胎)及其有关方面的改良，尤其是具有可人外观和维护品质的此种改良纤维胎，同时也关于充入此种改良纤维胎的制品。
在U.S.专利号5，225，242和WO 93/11292(此二文件公开内容收作本文的参考文献)里，我们提供了一种制造粘合纤维胎的方法，包括用约70-约96％(重量)的聚酯絮填纤维同一种粘合剂纤维，较好是双组分粘合剂纤维，含熔点低于该聚酯絮填纤维软化点的粘合剂材料，用量约4-约30％(重量)，均匀混合制成共混物；用所说共混物制成连续纤维胎，所说纤维胎带有一个上表面和一个下表面；把所说纤维胎送过一个以上的喷涂区，借此纤维胎的两面均被喷涂上树脂，总喷涂量约为喷涂后纤维胎(包括树脂)的约10-约30％(重量)，所说树脂的选择标准是，固化后能提供玻璃化温度(Tg)在0℃以下的固化树脂；把喷涂后纤维胎置于烘箱内令树脂固化并令粘合剂材料软化；继而热辊轧加热后纤维胎，以达到胎表面纤维与树脂间的密切接触；最后冷却辊轧后纤维胎；这种热辊轧较好采用轧光机或S形缠绕型的加热辊实现，于是通过象这样一种方法便制成具有改进外观和性能的粘合纤维胎。胎内纤维重量(即聚酯絮填纤维与粘合剂纤维共混物的重量)被称做纤维胎的“基本重量”，也就是喷涂封闭树脂之前的重量。
可是，按照本发明我们却发现，惊奇的是，为赋予充分的封闭不一定非要进行热辊轧，而只要采用低旦絮填纤维(叫法不一，象亚旦或微纤维等等)以帮助胎的至少一面或两面封闭即可。因此，现在提供了一种粘合纤维胎，具有上、下两面，所说纤维胎包括单丝旦数约1以下、含量约75-约96％，而且沿胎内空间被互补的数量为约4-25％的较低熔点粘合剂材料粘结，所说数量是按胎的基本重量计算的，所说胎具有耐洗牢度(WB，按定义)至少是4以及弯曲刚度(B，按定义)约40cN/cm2以下，其中所说胎面中至少一面是用玻璃转变温度(Tg)约0℃以下、数量约为0.02-约0.35盎斯/平方码，较好数量约0.1-约0.25盎斯/平方码(按所说胎的表面积计算)的树脂封闭的，故其中所说表面的封闭性等级(SR，按定义)是至少4。较好所说面的每面都是这样封闭起来。
本文既使用公制单位象分特(dtex)也使用旦，1 dtex等于0.9旦/单丝(dpf)。
这样，本发明能提供一类絮填纤维胎，例如制做高级服装所需，制造过程是首先制备聚酯絮填纤维(混合纤维的75-96％(重量))和一种合适粘合剂纤维(混合纤维的4-25％(重量))的均匀共混物。把这种共混物放在梳理机或锯齿打手上转化成纤维网，然后可以将其层叠或交叉铺网制成纤维胎，在其上(较好也连续地在其下)表面施涂一种合适的胶乳(例如一种丙烯酸均聚物和/或共聚物在水中的胶体分散体，细节详见下文)，例如用喷涂方法。加热喷涂纤维胎，例如传统地采用把胎体送过加热炉，使涂层干燥同时使聚合物组分进一步聚合成高分子量并活化粘合剂纤维。这可以用传统方法完成，例如分3程通过该炉，其中2程是让每个这种涂层施涂上去以后逐次地干燥并部分固化，最后一程是补加其他的成分并保证粘合剂纤维在(可能)的热辊轧制备当中活化，在后一过程中可以让粘合纤维胎绕着或直接通过加热辊(S形缠绕或轧光方法)使固化树脂软化并散开，从而保证其沿纤维胎表面(大表面)层内的纤维之间全面均匀的分布，防止纤维从胎的该表面层漏出，以及，若需要的话，保证胎体有符合要求的厚度，参见U.S.专利号5，225，242的公开。
但是，当絮填纤维单丝旦数为0.2-1旦而且当胎表面施涂的所说树脂的玻璃转变温度(Tg)约为0℃且施涂量介于约0.02盎斯/平方码(0.7g/m2)-0.35盎斯/平方码(12g/m2)时，则进一步的处理，象采用加热辊，对防止纤维泄漏就不需要了，尤其当使用于絮填纤维时。热辊处理可被用来保证纤维胎具有要求的厚度和降低弯曲刚度。
由不同制造厂家供应的能用于本发明的树脂有各种不同的叫法，象称之为“柔软”或“中软”或甚至“极软”，但共同的特点在于其二级玻璃转变温度(Tg)均在0℃以下。它们当用于，例如服装时，赋予纤维胎以柔软和垂感，同时也起着防止纤维从胎体漏出的阻隔层作用。成品纤维胎的基本重量可以在1.5-12盎斯/平方码(50-400g/m2)之间，以及厚度0.07-0.20英寸/盎斯/平方码(0.05-0.15mm/g/m2)。这样，本发明的纤维胎便可以用一种聚酯絮填纤维和粘合剂纤维的共混物制备，然后借助适当柔软型树脂涂层将面层纤维封闭。聚酯絮填纤维可以全部是经上油的，例如本发明所说明的，也可以是上油与未上油纤维的共混物。絮填纤维可以是实心、中空，或者实心与中空纤维的混合物，且不受任何纤维断面型式的限制，即可以是十字形、三叶形、丫形、狗骨形、贝壳椭圆形以及其他非断面形状，自然还有圆形。
絮填纤维的单丝旦数(dpf)介于0.2-10之间，以约1.65的dpf为最有用，且占共混物重量的约70-96％。如同已指出的，亚旦纤维能赋予粘合纤维胎表面层良好封闭性，故用于此表面层常常是较好的。单根纤维均借助传统手段被赋予了卷曲并典型地具有5-15个卷曲/英寸(cpi)，其长度介于3/4-3英寸范围。粘合剂纤维占胎重量的约4-30％且可以是皮/芯(S/C)、并列(S/S)或单组分型的。它们可以由，例如(共)聚酯、聚烯烃、聚烯烃/聚酯、聚酰胺/聚酰胺等等制成。有用种类的粘合剂纤维及其功能模式见诸于，例如&#60非织造布世界&#62，3月/4月，1990，第37页。共混物中合适粘合剂纤维的初始dpf典型地介于2-15范围且以dpf等于4为普遍采用。有用的粘合剂纤维包括披露于上述Scott.Pamm.Frankosky和Marcus的U.S.专利中的纤维，此外还见诸于Haris等人的U.S.专利号4，732，809；Taniguchi等人的U.S.专利号4，789，592；Tomioka等人的U.S.专和号4，500，384；Hirose等人的日本专利公开57-210，015(1982)；以及其他将在本文披露的烘箱温度下起作用的技术上已知纤维。较好粘合剂纤维包括市售“Melty 4080”(UnitiKa公司，日本)和“ES”及“EA”聚烯烃(Chisso公司，日本)。
纤维胎两面的固化树脂涂层可以方便地占成品粘合胎的约10-30％(重量)，对于1.65dpf(1.83 dtex)情况以12-25％为较好，其中较少树脂量往往降低耐洗牢度和封闭性等级，而较多的数量往往增加僵挺性和降低隔热效力。若只在胎的一面如是封闭，则仅需上述数量的一半。当使用低旦纤维(小于约1dpf)时，只需较少树脂涂敷便能达到纤维泄漏控制的目的。而且，表面层内的树脂量不需要根据纤维胎的基本重量来决定，因为如此，对较重的纤维胎，总树脂施用量可以少到3％，既使对上油絮填纤维胎而言亦是。对于完全干(未上油)纤维来说，树脂需要量比使用上油絮填纤维胎时要少。
如上面提到，合适的涂层树脂具有约0℃以下的Tg。有用的树脂由市售丙烯酸及乙烯基胶组合物获得，其中包括，例如Rhoplex E-32(Rohm及Haas公司)、TR-934(Rohm及Haas公司)、X-4280J(Kanebo，日本)，下列的B.F.Goodrich公司生产的Hycar胶乳组合物：26146.26171.26322.26083.26092.2671.26120.2679.26796，下述的National Starch and Chemical公司生产的胶乳产品：NACRYLIC X 4445、NACRYLIC X 788-6007、NACRYLIC X 4483、NACRYLICX 4460、NACRYLIC X 4260、NACRYLIC X 4425、NACRYLIC X 4465、NACRYLIC 4401、NACRYLIC X 78-3990、NACRYLIC X 78-3997、NACRYLIC X 78-3905、NACRYLIC X 4280、NACRYLIC 4441、NACRYLICX 78-6114、X-LINK 2873、X-LINK 2849、X-LINK 78-6119、X-LINK2893、X-LINK 2833、X-LINK 78-6004、X-LINK 2813、RESYN2375、DUR-O-SET E-230、DUR-O-SET E-669，以及其他能固化成Tg值低于约0℃以下的树脂的市售胶乳。某些此类市售树脂及其Tg值列于各种小册子当中，例如由B.F.Goodrich 1989年出版的题为&#60HYCAR丙烯酸胶乳&#62的小册子以及National Starch andChemical公司题为&#60粘合剂.饱和剂.层合剂&#62的小册子。
纤维胎的制备一般从聚酯絮填纤维和粘合剂纤维的传统开松与混纤开始，继而用梳理或刺毛辊处理制成纤维网。可以将此种纤网与来自一系列梳理机或锯齿开松机的其他纤网层叠，也可以将其与其他纤网交叉铺网并结合成未粘合纤维胎。接下去在胎的一面或两面喷涂上胶乳组合物然后喂入烘箱，使树脂固化并使粘合剂纤维粘合。烘箱处理可以在150-190℃之下进行2-5分钟，而且可以按前面提到的让纤维胎按3程通过方便地完成。继而，让粘合纤维胎穿过/绕辊通过(较好至少2个)热辊，其表面温度介于150-250℃范围(可使用2个以上的辊筒)。纤维胎可以按S形包缠辊筒，以提供同辊筒的最大程度接触。辊筒的间隙为2-5mm，具体依要求的成品胎厚度而定。另一种办法，可以让粘合纤维胎通过轧光辊，加热情况如前。在这种处理当中，希望的话，可以只加热一只辊，既使要封闭胎的两面也是，此时，若希望封闭两面的话，可以让粘合纤维胎第二次通过或绕过辊筒使胎的反面加热。与辊的接触时间是3-25秒。这样的热辊处理使树脂软化并散开，保证其沿胎表面层全面而均匀的分布从而防止漏纤维和提供均一的表面、不带结块，故使用时舒适和外观性能好。此种纤维胎的基本重量和厚度范围如前文指出。
本发明纤维胎显示出理想的热阻或隔热水平，通常表示为CLO等级(参见Hwang U.S.专利号4，514，455)。本发明纤维胎希望具有至少约0.36 CLO/盎斯/平方码，且较好为0.48 CLO/盎斯/平方码或以上的CLO值。
应该理解，要选择本文所描述的成分和方法来提供本发明的纤维胎。必须谨慎选择的确能提供这样的纤维胎的组合。例如，必须正确地挑选纤维的油剂和施于该纤维胎的胶乳使之充分粘结，以便成品胎能表现出，例如充足的耐洗涤性。
测试方法
CLO评定按前面提到的Hwang的描述获得。
本发明纤维胎的耐洗涤性(“WD”)按照ASTM D-4770-88方法评评定。实例中，试片的尺寸为24英寸X24英寸。耐洗涤性等级是针对按第8·6·1段所做测量给出的。本发明的纤维网表现出3以上的等级(第8·5段的评级标准)。
纤维漏出或钻出面料的性能按封闭等级(“SR”)度量，测量方法见诸于Levan的U.S.专利号4，869，771(3次洗涤循环以后)，封闭等级(SR)5为优而封闭等级(SR)1为差。本发明纤维胎表现出3以上的封闭等级(SR)(3次洗涤循环以后)。表2中(实例3)，也进一步给出1次洗涤后(1W)和3次洗涤后(3W)的封闭性数值，并与任何洗涤之前的初始数值(NEW)做了比较。
本发明纤维胎的柔软或悬垂性(垂感)是按照德国工业标准53362悬臂法(DIN 53362悬臂法)测定的，该方法测定纤维胎沿机器和垂直于机器方向纤维胎的弯曲刚性(“B”)并且求和；这些合并的结果与悬垂性和柔软性有关。纤维胎试样被裁成25cm长，2.5cm宽，并且沿机器方向(MD)和垂直于机器方向(XD)两方向裁切。对每个测试样品称重并将其重量记录为“W”。然后测定弯曲长度(“LU”)，方法是将试样放在平台上水平滑动直至弯曲试样的前沿达到41度角和30秒为止。继而进行下列计算：
  B=F1(LU÷2)3
其中B=弯曲刚性，单位cN/cm2
  LU=弯曲长度，单位cm。
  F1=9.8(W÷L)
  W=试样重量，克
  L=试样长度，cm。
本发明纤维网表现出80cN/cm2以下的弯曲刚度(“B”是从该纤维胎测得的沿机器(MD)与垂直机器(XD)2方向数据之和)，较低的弯曲刚度是较好的。
本发明在下列实例中获得进一步的说明，除另外指出，全部份数和百分数均指重量，针对“BW”(基本重量)计算的，也就是说仅对聚酯絮填纤维和粘合剂纤维而言(即不算涂在表面以改善封闭性的附加树脂)。
实例
制备并测试了各种纤维胎试样，其结果载于表中。每次的粘合剂纤维均为“Melty 4080”(4dpf)，但使用了不同的絮填纤维。
用一种由37.5％含油剂1.65 dpf(用一种硅润滑剂处理过)、37.5％干1.65 dpf(不合硅润滑剂)和25％粘合剂纤维组成的市售聚酯纤维共混物。将共混物放在类似于U.S.专利号5，225，242的实例1中描述的传统梳理交叉铺网的设备上加工。把获得的胎喂过维持在约165℃的3程烘箱。在胎(除A外)的每一面喷涂上当量数量的软树脂(玻璃转变温度(Tg)等于-10℃)，总树脂施加量如表中所示，计算基准是“BW”，即此阶段胎中纤维基本重量，约4.5盎斯/平方码(150g/m2)。进入第一程之前在胎的一面喷涂树脂，然后在进入第二程之前在另一面上喷涂。重要的是，让整个纤维网在高到足以保证树脂完全固化和粘合剂纤维定形的温度下暴露足够的时间(通常，纤维胎达到165℃之后1分钟已足)。然后，在单独的操作中将纤维胎轧光，其作用是封闭表面和降低膨松度。
从表中的封闭性数值看，在表中条件下即使采用8％树脂(试样B)量，轧光效果也未改善1次洗涤周期后1.65dpf纤维胎的封闭性，而采用15％树脂量时(试样C)，1次洗涤循环后的封闭性改善了，可是3次洗涤循环后的封闭性仍不充足。及至到25％树脂量，还是在此条件下，试样D的表面封闭等级才令人满意(3次洗涤循环后)。
还对此纤维胎测定了纤维泄漏性，即将其套入纱线支数为104X84的织物中，在压力降0.5英寸水柱下以13.2立方英尺/分的弗雷泽透气性等级测定。
试样E和F与试样A和D分别相同，但测试是放在纱线支数为102X84的织物中和采用48弗雷泽等级进行。由于还使用比试样A～D中使用的更富透气的织物测试了0.7dpf纤维胎，故把E和F的结果也包括在该表中以便将试样A～D与G～Q之间的数据联系起来。试样E，不含树脂，新时因织物疏松而未能通过试验，但经3次洗涤循环之后变得足够致密从而改善了其泄漏性能。试验F的封闭值开始为5并提供了满意的封闭等级(即指3次洗涤循环后)。
试样G·H·I和J是用约85磅干聚酯纤维(0.7dpf，0.78dtex，切断长度1.5英寸，12cpi(卷曲数/英寸)，不含任何特别润滑油剂)和15磅粘合剂纤维的共混物制备的。对这些试样进行了树脂喷涂、轧光并如同试样E和F那样做了测试。
试样K和L系由一种约55磅类似的0.7dpf上油纤维(油剂为硅润滑剂)，27磅干(未上油)0.7dpf纤维和18磅粘合剂纤维的共混物制备的。这些试样未经过轧光(如表中用双星标出)，但却给出了良好封闭等级。
试样M·O·P和Q系利用与K和L相同的共混物类似地制备的，但做成了较高的基本重量(见表)而且显示出良好封闭等级，原因在于使用了低dpf纤维，尽管树脂施加量较低(少于10％)和未经过轧光。试样N则经过了轧光(与其他试样不同)。各试样结果间的比较显示，对改善封闭性等级轧光并非是必要的(当使用亚旦纤维再配合软树脂时)。
采用48弗雷泽尔织物透气性测定条件测定了从G到L全部试样的纤维泄漏。
相应地，在此表中，试样G～I和K～Q都是符合本发明的，而其他的则是对比例，有些未喷涂上树脂，有些则只使用了常规旦数絮填纤维，而这后2类洗涤后的封闭性都不足。
表弗雷泽    BW       纤维    树脂               封闭值dpf      ％    *       New   1W   3WA     13.2     4.5     1.65      0     0        5     1    1B     13.2     4.5     1.65      8     0.36     5     1    1C     13.2     4.5     1.65      15    0.67     5     3    1D     13.2     4.5     1.65      25    1.125    5     5    5E     48       4.5     1.65      0     0        1     1    4F     48       4.5     1.65      25    1.125    5     5    5G     48       4.5     0.7       4     0.18     5     5    5H     48       4.5     0.7       2.2   0.10     5     5    5I     48       4.5     0.7       1.6   0.07     5     5    5J     48       4.5     0.7       0     0        4     1    1K**   48       4.5     0.7       10    0.45     5     5    5L**   48       4.5     0.7       5     0.225    5     5    5M**   48       6.1     0.7       6     0.37     5     5    4N     48       5.1     0.7       7     0.36     5     5    5O**   48       8.0     0.7       6     0.48     5     5    5P**   48       8.1     0.7       8     0.65     5     5    5Q**   48       9.3     0.7       5     0.47     5     5    5*标出的是胎上的树脂喷涂总量(两面)，单位盎斯/平方码(每
一面上的量则是各数量的一半)。**表示，烘箱固化之后未进行轧光。

Claims (3)

1.一种带有上、下两面的粘合纤维胎，所说胎包括单丝旦数为约1以下的聚酯絮填纤维，含量约75-约96％，并与含量互补地为约4-25％的低熔点粘合剂材料均匀粘合；所说含量均以纤维胎的基本重量为基准计算，所说胎的耐水洗牢度(WD，按定义)至少是4，弯曲刚性(B，按定义)约在40cN/cm2以下，其中所说面中至少一面用大约0.7g/m2(0.02盎斯/平方码)-约12g/m2(0.35盎斯/平方码)(针对所说胎面而言)，玻璃转变温度(Tg)约0℃或以下的一种树脂封闭，从而所说面的封闭性等级(SR，按定义)是至少4。
2．按照权利要求1的纤维胎，其中树脂用量约为3.4-约8.5g/m2(约0.1-约0.25盎斯/平方码)。
3．按照权利要求1或2的纤维胎，其中所说上、下面中的每一面均由所说数量的所说树脂封闭，并且其封闭性等级至少为4。
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EP0437268A1 (en) * 1990-01-12 1991-07-17 National Starch and Chemical Investment Holding Corporation Method for binding a non-woven fiber-web by using a formaldehyde-free binder composition and products manufactured therewith
WO1993011292A1 (en) * 1991-11-27 1993-06-10 E.I. Du Pont De Nemours And Company New fiberfill battings

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