CN1071386C - 具有宽粘合范围的热塑性聚合物纤维和其用途以及赋予非织造布以宽粘合范围的方法 - Google Patents

具有宽粘合范围的热塑性聚合物纤维和其用途以及赋予非织造布以宽粘合范围的方法 Download PDF

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CN1071386C
CN1071386C CN96191594A CN96191594A CN1071386C CN 1071386 C CN1071386 C CN 1071386C CN 96191594 A CN96191594 A CN 96191594A CN 96191594 A CN96191594 A CN 96191594A CN 1071386 C CN1071386 C CN 1071386C
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bonding
weight
cloth
web
syndiotactic polypropylene
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CN1169168A (zh
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M·L·德路思尔
R·L·胡森
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Kimberly Clark Worldwide Inc
Kimberly Clark Corp
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Abstract

提供一种生产具有宽粘合范围的非织造布的方法，包括将含有约0.5(重量)～约25%(重量)间规聚丙烯的热塑性聚合物共混物成形为非织造纤网，然后借助例如点热轧粘合、穿透空气粘合及超声粘合的方法对所述非织造纤网进行热粘合。所述纤网的粘合范围比不含所述间规聚丙烯的类似纤网至少宽10°F。理想的是，该粘合范围向不含间规聚丙烯的类似纤网的粘合范围下方延伸至少10°F。

Description

具有宽粘合范围的热塑性聚合物纤维和其 用途以及赋予非织造布以宽粘合范围的方法
发明背景
非织造纤网的应用正日益广泛，这是由于通过采用不同的聚合物、厚度、粘合工艺以及其制造者可采用的其他数不清的可变参数，可以获得许多不同的性能以满足用户的特殊需要的缘故。粗略地说，这些五花八门的用途包括：过滤、例如汽车车厢空气过滤器；个人护理制品，例如抹布、尿布、妇女卫生用品、训续裤、失禁用品等；医用，例如伤口敷裹物、手术罩衣、绷带及手术帘子；防护外罩，例如设备(如汽车)外罩、服装、户外用布及土工布等。
用于生产非织造纤网的聚合物一般为热塑性聚合物，例如聚烯烃、聚酰胺、聚酯等。热塑性弹性体也使用，其中包括聚醚酯和聚氨酯。
上述用途的具体的非织造材料包括，具有各种不同程度的阻隔性、柔软及透气性的熔喷及纺粘布。
熔喷纤维在生成时通常是发粘的，因此自燃地粘合在一起，故一般无需再进行粘合，虽然也可以再进行粘合。与此不同，纺粘纤维在接触到其他纤维之前一般已经充分地冷却了，故这种纤维不会自然粘合，因此需要进一步粘合。
各种粘合的方法在技术上是已知的，例如包括点热轧粘合、超声粘合、水力缠结以及穿透空气粘合。
点热轧粘合十粉普遍，它包括将待粘合的纤维的非织造布或纤网送过一个加热的热轧辊与一个砧辊之间。热轧辊通常带有一定的花纹，使得该布不致于全部表面整个地粘在一起。于是，例开发出各式各样的热轧辊花纹，既出于功能的目的，也出于美观的考虑。一个例子是如授予Hansen及Pennings的美国专利3,855,046中所公开的扩展的Hansen Pennings花纹，它具有约15％粘合面积以及约100粘合点/平方英寸。另一种常用的花纹是由重复然而稍许偏置的菱形组成的菱形花纹。
大多数类型的粘合都是能量相对密集的操作，需要对工艺条件实施相当精确的控制，以便维持目标温度。之所以需要此精确的温度控制的原因在于大多数聚合物的“粘合范围”，即聚合物发生有效粘合的温度区间都相当窄。某些情况下，该粘合范围仅为数度宽。例如，聚乙烯的粘合范围约为3℃。这样狭窄的粘合范围使得这种材料的工业生产成为一项十分困难的任务。较宽的粘合范围则将使得工艺控制变得比较容易，而如果粘合能在较低的温度下进行，则将带来可观的能量节约。
据此，本发明的目的是提供一种具有宽粘合范围的热塑性聚合物纤维或其中的至少一种是含有这种热塑性聚合物纤维的双纤维以拓宽用于生产粘合非织造纤网的聚合物的粘合范围。本发明的第二个目的是降低非织造纤维网的粘合温度。本发明还提供了包含具有宽粘合范围的热塑性聚合物纤维的热塑性纤维纤网和含有所述纤维纤网的层合物，以及将这种纤维纤网用于制造日用、医用、护理用和户外用的织物制品。
发明简述
本发明的目的是通过提供一种具有宽粘合范围的热塑性聚合物纤维或其中的至少一种是含有这种热塑性聚合物纤维的双纤维，以赋予非织造布以宽粘合范围的方法达到的，包括采用由含有某种热塑性聚合物与约0.5％(重量)～约25％(重量)间规聚丙烯(sPP)形成的共混物制成非织造纤网，其中所述纤维可以在比不含所述间规聚丙烯的类似纤维低至少10°F的粘合范围进行粘合，然后将该纤网进行热粘合。该热粘合可按例如点热轧粘合、穿透空气粘合及超声粘合等方法之一进行。这样一种纤网的粘合范围比不含间规聚丙烯的类似纤网的宽至少10°F。理想的是，其粘合范围向不含间规聚丙烯的类似纤网范围的下方延伸至少10°F。可应用这样一种纤维纤网与选自纺粘布、熔体喷撒布、熔喷布、短纤维纤网及薄膜中的至少一种作为附加层，粘合成一种层合物，还可将这种纤维纤网用于制造包括服装、防感染制品(如手术罩衣)、个人护理用品(如尿布和成人失禁用用品)、和户外用的布料等产品。
附图简述
图1是一幅曲线图，其纵轴为以磅为单位的和开直于机器方向的峰值载荷，而横轴为以华氏度为单位的粘合温度。这些数据载于表1。
图2是一幅曲线图，其纵轴为以磅为单位的垂直于机器方向的梯形试样撕破强度，而横轴为以华氏度为单位的粘合温度。这些数据载于表2。
图3是一幅曲线图，其纵轴为以磅为单位的机器方向的峰值载荷，而横轴为以华氏度为单位的粘合温度。这些数据载于表1。
图4是一幅曲线图，其纵轴为以磅为单位的机器方向的梯形试样撕破强度，而横轴为以华氏度为单位的粘合温度。这些数据载于表2。
在所有这些图中，x符号代表sPP的重量百分数为0时的数据(对比例1的数据)；+号代表sPP的重量百分数为2(％)时的数据(实例1的数据)；小方块代表sPP的重量百分数为5(％)时的数据(实例2的数据)；而小菱形代表sPP的重量百分数为10(％)时的数据(实例3的数据)。
定义
这里所用的“非织造布或纤网”一词是指这样一种纤网，它具有由单根纤维或丝互相绞缠而成的，而不是如针织织物中那样以可辨认的方式组成的结构。非织造布或纤网一向可采用多种方法成形，例如熔喷法、纺粘法以及粘合梳理纤网法。非织造布的单位重量通常以每平方码材料的盎司数(osy)或每平方米的克数(gsm)来表示，使用的纤维直径通常以微米表示。(注：要从osy换算到gsm，可用33.91乘上以osy表示的数值)。
这里所使用的“微纤维”一词是指平均直径不大于约75微米的细直径纤维，例如其平均直径约为0.5微米～约50微米，或者特别是，微纤维的平均直径为约2微米～约40微米。另一个经常使用的纤维直径表示方法是旦，其定义是：每9000米长纤维的克数。例如，一个按微米给出的聚丙烯纤维直径的数值可以通过将其乘方，然后将结果乘上0.00629，换算为旦数，比如，15微米聚丙烯纤维的旦数为约1.42(152×0.00629=1.415)。
这里所使用的“纺粘纤维”一词是指这样的小直径纤维，其制取方法是：将熔融热塑性材料从一种纺丝板的通常为圆形的许多细孔中挤出成为一束丝，然后通过诸如以下文献所述的方法使挤出的丝的直径迅速变细：授予Appel等人的美国专利4,340,563及授予Dorschner等人的美国专利3,692,618、授予Matsuki等人的美国专利3,802,817、授予Kinney的美国专利3,338,992及3,341,394、授予Hartman的美国专利3,502,763、授予Levy的美国专利3,502,538,以及授予Dobo等人的美国专利3,542,615。纺粘纤维在沉积到收集表面上时通常是不发粘的。纺粘纤维通常是连续的，其直径大于7微米，特别是介于约10微米～20微米之间。
这里所使用的“熔喷纤维”一词是指这样的纤维，其制取方法是：将熔融热塑性材料从许多细小的、通常为圆形的模板孔中以熔融丝或丝束的形式挤出到会聚的高速气体(例如空气)流中，气流将熔融热塑性材料的丝束拉细，以致可将其直径降低到微纤维直径的水平。此后，该熔喷纤维被高速气流夹带并沉积到收集表面上，形成由无规散落的熔喷纤维组成的纤网。这样一种方法例如公开在授予Butin的美国专利3,849,241中。熔喷纤维属于微纤维，它可以是连续的或不连续的，其直径通常小于10微米，并且当沉积到收集表面上时通常是发粘并能自行粘合的。
这里所用的“聚合物”一词一般包括但不限于，均聚物、共聚物，例如嵌段、接枝、无规及交替共聚物、三元共聚物等，及其共混物及改性物。
这里所用的“机器方向”或MD一词是指非织造布的长度方向，即沿着它被生产出来的方向。“垂直(于)机器方向”或CD一词是指非织造布的幅宽方向，即通常垂直于MD的方向。
这里所用的“均聚物”一词是指仅用一种聚合物由一台挤出机成形的纤维或纤维的一部分。该定义不排除由一种为了颜色、抗静电特性、润滑、亲水等目的而加入了少量添加剂的聚合物所制成的纤维。这些添加剂，例如为颜色的目的加入二氧化钛，一般存在的量少于5％(重量)，更典型地约2％(重量)。“均聚物”一词的定义也不排除从两台或更多台挤出机挤出，但其中两台装有相同的聚合物时所制成的纤维。
这里所用的“双组分纤维”一词是指用来自分开的挤出机的至少两种聚合物，但共同纺成一种纤维时所制成的纤维。双组分纤维有时也叫做多组分纤维。双组分纤维的聚合物通常彼此不相同，尽管双组分纤维可以是均聚物纤维。这些聚合物沿双组分纤维的横断面排列在基本固定的界限分明的区内，并沿该双组分纤维的长度连续地延伸。此种双组分纤维的配置例如可以是皮/芯排列的，其中一种聚合物被另一种聚合物包围着，或者可以是并排排列的，或是呈“海-岛”式排列的。双组分纤维公开在授予Kaneko等人的美国专利5,108,820、授予Strack等人的美国专利5,336,552以及欧洲专利0586924中。就双组分纤维而言，聚合物存在的比例可为75/25、50/50、25/75，或者任何希望的其他比例。
这里所用的“双成分复合纤维”一词是指从同一挤出机以共混物形式挤出的至少两种聚合物制成的纤维。其中“共混物”的定义见下文。双成分复合纤维不具备沿纤维的横断面内排列在相对固定位置的界限分明区内的不同聚合物组分，其不同聚合物通常不是沿纤维的全长连续延伸的，相反，它们通常形成无规地开始和结束的细纤或原纤。双成分复合纤维有时也叫做多成分复合纤维。这种大体类型的纤维例如见诸于授予Gessner的美国专利5,108,827。双组分纤维和双成分复合纤维还见诸于教科书聚合物共混物及复合物，John A.Manson及Leslie H.Sperling编，Plenum出版社1976年出版，纽约Plenum出版公司一分支机构，IBSN 0-306-30831-2,273～277页。
这里所用的“共混物”一词是指两种或更多种聚合物的混合物，而“合金”是指共混物的一个子类，其中的成分不相混溶，但具有相容(共存)关系。“混溶性”和“不混溶性”的定义指共混物分别具有负值和正值的混合自由能。进而，“相容化”的定义是对不混溶的聚合物共混物进行改性以制成合金的方法。
这里所用的穿透空气粘合或“TAB”是指这样的非织造双组分纤维网的粘合方法：将纤网至少部分地绕到被封闭在热风柜或烘箱内的多孔滚筒上。热度足以使构成纤网纤维的聚合物之一发生熔融的空气被强制从罩子一侧穿过纤网层并进入到多孔滚筒中。该空气的速度介于100～500英尺/分，其停留时间可长达6秒钟。聚合物的熔融及再凝固就造成了粘合。穿透空气粘合在可变性方面受到一定限制，因此通常被视为一种第二步骤的粘合方法。鉴于TAB要求至少一种组分发生熔融以实现粘合，它局限于用在非均聚物的双组分纤网生产上。
这里所用的“粘合范围”一词是指将非织造布粘合在一起并做到“成功”的粘合时可采用的温度区间。“成功”粘合是指这样的粘合，其中非织造纤网符合就特定希望或用途而言的拉伸及撕破强度要求。对纺粘的等规聚丙烯而言，该粘合范围典型地为约275°F～约310°F(135℃～154℃)。低于275°F，则该聚丙烯典型地表现出未热到足以发生熔融和粘合，而超过约310°F，则聚丙烯将会过度熔融，并可能粘在热轧辊上。聚乙烯的粘合范围就更加窄了。
这里所用的“阻隔布”是指一种对液体传输而言相对地不可透过的布料，即一种根据ASTM试验方法22血液透过速率等于或小于1.0的布料。
这里所用的“服装”一词是指任何非医用的可穿戴衣物。这包括工业工作服及连衣裤防护服、内衣裤、裤子、衬衫、夹克、手套、袜子等。
这里所用的“防感染制品”一词是指医用的制品，例如手术罩衣及帘子、面罩、诸如厨师帽之类的头罩、手术帽子及罩子、脚上穿戴物，例如鞋罩、靴罩及拖鞋，伤口敷裹物、绷带、消毒用包布、抹布、诸如实验室罩衣的服装、连衣裤防护服以及罩衫、围裙及夹克、病床铺盖物、担架及童车铺单等。
这里所用的“个人护理制品”一词是指尿布、训练裤、吸收性内裤、成人失禁用品以及妇女卫生制品。
这里所用的“防护外罩”是指用于车辆，例如汽车、卡车、船、飞机、摩托车、自行车、高尔夫小车等的外罩，经常放在户外的设备外罩，例如用于烧架、庭院及园艺设备(割草机、圆盘犁等)以及草坪家具，直至地板覆盖物、桌布及野餐铺地布。
这里所用的“户外布料”一词是指主要，虽不是唯一户外使用的布料。户外布料包括用于防护外罩的布料、野营/拖车布料、帆布、帐篷布、华盖、帐篷、农用布以及户外服装，例如头罩、工业工作服及连衣裤防护服、裤子、衬衫、夹克、手套、袜子、鞋罩等。
测试方法
熔体流动速率：熔体流动速率(MFR)是聚合物粘度的度量。MFR采用规定载荷或剪切速率下在测量的一段时间内从已知尺寸的毛细管流出的物质重量来表示，根据例如ASTM试验1238，条件E，该值在230℃下进行测定，以克/10分钟为单位。
水头：布料的液体阻隔性能的度量之一是水头试验。水头试验测定在规定量的液体透过之前布料能支撑的水柱高度(厘米)。一种水头读数较高的布料表明其抗液体渗透阻隔能力比水头较低的布高。水头试验根据联邦试验标准号191A，方法5514进行。
拉伸性能：布的拉伸强度可根据ASTM试验D-1682-64测定。该试验测出以磅为单位的强度，以布样原长百分数为单位的伸长。
Grab拉伸试验：Grab拉伸试验是在单方向应力作用下布料破裂强度及伸长或应变的度量。该试验在技术上是已知的并符合联邦试验方法标准号191A的方法5100的规定。结果用直至破裂的磅数，及破裂前的伸长百分数来表示。数值较高，表明是一种较结实、可拉长性较大的布料。“载荷”一词是指在拉伸试验中要将试样破坏所需要的、以重量单位表示的最大载荷或力。“应变”或“总能量”一词是指在载荷-伸长曲线下方的总能量，以重量-长度单位表示。“伸长”一词是指拉伸试验期间试样长度的增加。Grab拉伸强度和Grab伸长的数值是采用规定的布宽度、夹具宽度及恒定伸长速率的情况下获得的。该试样比夹具宽，给出的结果代表处于夹持宽度内纤维的有效强度与布料中邻近纤维所贡献的附加强度之和。该结果逼真地模拟了实际使用当中布料的应力条件。
梯形试样撕破强度试验：梯形试样撕破强度试验是一项既适用于织造布也适用于非织造布的张力试验。试样的整个宽度均夹紧在夹具之间，因此该试验基本上测量在张力载荷直接作用下单根纤维的粘合或互锁力及强度，而不是作为一个整体的布料复合结构的强度。该项测试程序对评估布料撕破的相对容易程度是有用的。它对于确定布料在机器与垂直机器方向之间是否存在显著强度差异尤其有用。
在进行梯形试样撕破强度试验时，切取一块梯形试样，3×6英寸(75×150毫米)，沿着其中较长尺寸的方向进行试验。该梯形试样有一个6英寸的边、一个3英寸的边，二者互相平行并彼此相距3英寸。在二平行边中较短边的中点做出一个5/8英寸(15毫米)的小预切口。将试样夹在测力计上，例如一台Instron TM型仪，生产者：Instron公司，2500 Washington St.,Canton,MA 02021，或者一台Thwing-AlbertINTELLECTⅡ型，生产者：Thwing-Albert仪器公司，10960 Dutton Rd..费城，PA19154，或者一台采用Testworks软件的Sintech2/S，生产者：Sintech公司，MTS系统公司的一个分部，1001 Sheldon Dr.,Cary,NC27513。二夹具平行且相距1英寸(25毫米)，3英寸长、1英寸高。试样是沿着梯形的非平行边夹持的，以便使长边处的布料松，短边处的布料紧，同时切口位于二夹具的中间。夹具盖住布料的1×3英寸的面积，在二夹具之间留下具有一条1英寸边和与之平行的4英寸(100毫米)一边的梯形布料。切口深入布料的尖端必须位于二夹具之间。在试样上施加连续载荷，令撕裂沿试样的幅宽传播。应当注意，较长的方向是被测试方向，尽管撕口垂直于试样的长度。把试样彻底撕破所需要的力以磅为单位记录下来，数值较高者表明抗撕裂能力较高。所使用的方法符合ASTM标准试验D1117-14，只不过撕破载荷按记录到的第一与最高峰值的平均值，而不是按最低与最高峰值的平均值计算。每种样品应测定5个试样。
发明详述
非织造布可采用许多技术上已知的方法生产，包括熔喷、纺粘及熔体喷撒。由于本发明涉及非织造纤网的粘合，故大部分重点放在纺粘纤网上。然而下面的描述和方法仍然适用于任何非织造布的粘合。
纺粘非织造布可用技术上已知并在上面列举的大量参考文献中描述过的方法生产。扼要地说，纺粘法通常采用一个料斗向加热的挤出机供应聚合物。挤出机将熔融聚合物送至纺丝板，在此随着聚合物通过纺丝板中通常排列成一排或多排的细孔，聚合物就变为纤维状，形成由丝束构成的幕。对丝束通常用低压空气进行骤冷，牵伸，一般靠气力，然后将其沉积在运动的多孔垫、带或“成形金属网”上，成形为非织造布。
用纺粘法生产出的纤维，其直径依工艺条件及由该纤维生产出的布料的预期最终用途而定，一般在约10～约20微米范围内。例如，提高聚合物分子量或降低加工温度，生产出的纤维直径较粗。骤冷流体温度及气力牵伸压力的变化也会影响到纤维直径。
适用于纺粘法的聚合物，其加工熔体温度通常介于约350°F～约610°F(175℃～320℃)，如上面定义的熔体流动速率介于约10～约150，特别是在约10～50之间。合适聚合物的例子包括聚丙烯、聚乙烯及聚酰胺。
间规聚丙烯(sPP)可按授予Elder等人并转让给Fina Petroleum公司的美国专利5,225,500所建议的方法来生产，该文收入本文作为参考。采用一种对间规聚丙烯选择性很高的新型催化剂体系来择优生产以间规构型为主的聚丙烯。这种催化剂被称之为金属茂催化剂。
授予Peacock并转让给Exxon化学专利公司的美国专利5,272,003，该文同时也收入本文作为参考，公开用规整的间规聚丙烯生产非织造布，而前者从一种旨在排除等规聚丙烯的溶液中获得。
作为本发明目的的拓宽粘合范围是通过选用这样的非织造纤网进行热粘合达到的：其中的纤维由一种包括约0.5％(重量)～约25％(重量)间规聚丙烯的热塑性聚合物的共混物构成，获得双成分复合纤维。该间规聚丙烯可与共混物的其他成分掺混成粒状、片状等干混合物、成为熔融液态混合物或者采用任何其他技术上已知的有效方法进行混合。
采用本发明的方法还可以生产其他类型的双成分复合纤维。丙烯与丁烯或其他烯烃混合物的共聚物与间规聚丙烯的共混物也会是有效的。等规聚丙烯与间规聚丙烯的共混物是优选的。
采用本发明方法也可以生产双组分纤维，其中至少一种组分由包含间规聚丙烯的双成分共混物组成。双组分纤维通常是聚丙烯和聚乙烯，按皮/芯、“海/岛”或并列的构型排列。合适的市售材料包括牌号为PP-3445的聚丙烯，生产者：Exxon化学公司，Baytown,Texas；ASPUN6811A，其中可加入间规聚丙烯，以及2553线型低密度聚乙烯，生产者：道化学公司，Midland,Michigan；25355及12350高密度聚乙烯，生产者：道化学公司；DURAFLEXDP8510聚丁烯，生产者：壳牌化学公司，Houston,Texas；以及ENATHENE720-009乙烯正丁基丙烯酸酯，生产者：Quantum化学公司，Cincinnati,Ohio。
本发明的布料可用于单层的实施方案中，或者作为多层层合物的一个成分，这种层合物可采用许多不同的层合技术制成，其中包括但不限于，采用粘合剂、针刺、热轧以及任何技术上已知的其他方法。该多层层合物可以是这样一种实施方案，其中某些层是纺粘的，某些层是熔喷的，从而形成一种纺粘/熔喷/纺粘(SMS)层合物，正如授予Brock等人的美国专利4,041,203以及授予Collier等人的美国专利5,169,706所公开的，或者形成一种SFS(纺粘、薄膜、纺粘)构造。SMS层合物的制造方法可包括：顺序地向运动着的成形带表面首先沉积一纺粘纤网层，随后沉积一熔喷布层，最后是另一纺粘层，然后用上面所描述的一种方式将该层合物粘合。替代地，可单独制作这3个布层，将之收集成卷，然后在单独进行的粘合步骤中将它们结合在一起。此种SMS或SFS层中的某些层可使用本发明的布制成。本发明的布还可以同玻璃纤维、短纤维、纸以及其他片状材料层合在一起。
应用在中向层里的非织造熔喷纤维或薄膜可由非弹性体聚合物制成，例如聚丙烯及聚乙烯，或者由热塑性弹性体聚合物制成。
热塑性弹性体聚合物可以是那些由苯乙烯嵌段共聚物、聚氨酯、聚酰胺、共聚酯、乙烯乙酸乙烯酯(EVA)等制成的聚合物。一般而言，任何能形成合适弹性体纤维或薄膜的树脂或者含有该树脂的共混物均可用来制成弹性体纤维或弹性体薄膜的非织造纤网。
例如，此类弹性体共聚物的商品例子有：那些叫做KRATON材料的共聚物，生产者：壳牌化学公司，Houston,Texas。供应的KRATON嵌段共聚物有几种不同的配方，其中有许多种可见诸于美国专利4,663,220，该文收入本文作为参考。
可用来制作弹性体层的其他范例弹性体材料包括：聚氨酯弹性体材料，例如那些商品名为ESTANE的材料，生产者：B.F.Goodrich公司；聚酰胺弹性体材料，例如那些商品名为PEBAX的，生产者：Rilsan公司；以及聚酯弹性体材料，例如那些商品名为HYTREL的，由杜邦公司生产。
为了测定制成纤网的粘合范围，制作了间规聚丙烯与等规聚丙烯的各种不同的混合物。还制作了不含间规聚合物的对比非织造布。进行了两组试验，生产出含有稳定剂和颜料的布及含有稳定剂但不含颜料的布，以确定粘合范围的改变是否由间规聚丙烯所致，抑或由其他机制使然。试验结果载于下面的各表中。
对比例1
按照授予Appel等人的美国专利4,340,563的方法制作了含有稳定剂及颜料的纺粘聚丙烯纤维。
该纺粘纤维的聚合物系Exxon PD-3445聚丙烯，在410°F(210℃)的温度下以0.7克/孔/分钟(ghm)的速率通过0.6毫米的孔挤出，生产出单位重量1osy(34gsm)的纤网。该聚合物还含有1.25％(重量)Chimasorb944紫外稳定剂，由Ciba-Geigy公司供应，以及1.0％(重量)SCC-5367颜料包，供应者：Standridge Color Corporation of Social Circle,GA。
生产出3种纤网试样并利用带有扩展的Hansen Penning花纹的点热轧粘合在260、275及290°F(127、135及143℃)温度下进行了粘合。
实例1
制作了含有稳定剂及颜料的纺粘聚丙烯纤维并按照与对比例1相同的条件进行了粘合。
该纺粘纤维的聚合物为2％(重量)间规聚丙烯，生产者：Fina Oiland Chemical公司，Dallas,TX，与Exxon PD-3445聚丙烯的混合物。该聚合物还含有Chimasorb944紫外稳定剂及颜料，数量同对比例1。
实例2
制作了含有稳定剂及颜料的纺粘聚丙烯纤维并按照与对比例1相同的条件进行了粘合。
该纺粘纤维的聚合物为5％(重量)间规聚丙烯，生产者：Fina Oiland Chemical公司，Dallas,TX，与Exxon PD-3445聚丙烯的混合物。该聚合物还含有Chimasorb944紫外稳定剂及颜料，数量同对比例1。
实例3
制作了含有稳定剂及颜料的纺粘聚丙烯纤维并按照与对比例1相同的条件进行了粘合。
该纺粘纤维的聚合物为10％(重量)间规聚丙烯，生产者：Fina Oiland Chemical公司，Dallas,TX，与Exxon PD-3445聚丙烯的混合物。该聚合物还含有Chimasorb944紫外稳定剂及颜料，数量同对比例1。
对比例2
制作了含有稳定剂但不含颜料的纺粘聚丙烯纤维并按照与对比例1相同的条件进行了粘合。
该纺粘纤维的聚合物为Exxon PD-3445聚丙烯。该聚合物还含有1.25％(重量)Chimasorb944紫外稳定剂但不含颜料。
实例4
制作了含有稳定剂但不含颜料的纺粘聚丙烯纤维并按照与对比例1相同的条件进行了粘合。
该纺粘纤维的聚合物为5％(重量)间规聚丙烯，生产者：Fina Oiland Chemical公司，Dallas,TX，与Exxon PD-3445聚丙烯的混合物。该聚合物还含有1.25％(重量)Chimasorb944紫外稳定剂但不含颜料。
表1试样       CD峰值载荷    MD峰值载荷    CD峰值能量    MD峰值能量对比例1260°F     7             13            11            16275°F     12            23            12            20290°F     15            27            18            25实例1,2wt％sPP260°F     7             14            11            12275°F     10            21            17            19290°F     13            25            17            23实例2,5wt％sPP260°F     8             19            14            17275°F     12            26            20            28290°F     12            23            16            20实例3,10wt％sPP260°F     11            21            23            21275°F     15            28            27            36290°F     14            24            20            24
表2试样       CD峰值应变    MD峰值应变    CD梯形撕破    MD梯形撕破对比例1260°F     78            52            4             7275°F     82            49            5             11290°F     72            51            4             9实例1,2wt％sPP260°F     78            37            4             8275°F     87            48            5             11290°F     78            48            5             12实例2,5wt％sPP260°F     88            42            4             11275°F     97            57            6             14290°F     79            45            4             13实例3,10wt％sPP260°F     113           50            5             11275°F     104           67            7             13290°F     84            50            6             13
表3试样               峰值载荷           梯形撕破对比例2260°F              12                   7275°F              20                   10290°F              25                   10实例4,5wt％sPP260°F              16                   9275°F              25                   12290°F              26                   13
如同从上表看到的，间规聚丙烯成功地拓宽可发生粘合的温度范围，使可接受粘合温度降低了约15°F(8℃)。例如，以实例3在260°F的情况做比较表明，其纤网性能与对比例1在高得多的290°F(粘合)时的性能大致相同。当共混物中含有10％或甚至5％(重量)时，便可在比不含sPP的类似纤网低得多的温度下实现成功的粘合。在粘合方面的这项改进使得工艺控制更加容易、废物料产生及能量花费减少，生产出消费者较能承受的产品。

Claims (15)

1．一种具有宽粘合范围的热塑性聚合物纤维，该聚合物纤维包括：
含有约0.5％(重量)～约25％(重量)间规聚丙烯的一种热塑性聚合物共混物；
其中所述纤维可以在比不含所述间规聚丙烯的一种类似的纤维的粘合范围低至少10°F的粘合范围内进行粘合。
2．权利要求1的热塑性纤维，其中所述共混物基本上由约0.5～约25％(重量)间规聚丙烯及约99.5～约75％(重量)等规聚丙烯组成。
3．一种由至少两种从各自的挤出机挤出的聚合物所构成的双组分纤维，其中至少一种所述聚合物是权利要求1所述的包含了0.5％至25％(重量)的间规聚丙烯的热塑性聚合物共混物。
4．一种包含了具有宽粘合范围的热塑性聚合物纤维的热塑性纤维纤网，其中所述的热塑性聚合物纤维包括：
含有权利要求1所述的约0.5％(重量)～约25％(重量)间规聚丙烯的一种热塑性聚合物共混物；
其中所述纤维可以在比不含所述间规聚丙烯的一种类似的纤维的粘合范围低至少10°F的粘合范围内进行粘合。
5．一种层合物，该层合物包含权利要求4的热塑性纤维纤网和至少一个附加层，该附加层选自纺粘布、熔体喷撒布、熔喷布、短纤维纤网以及薄膜，该附加层与所述纤网粘合以形成一种层合物。
6．权利要求5的层合物，其中所述至少一个附加层是由热塑性弹性体聚合物制成的熔喷布。
7．权利要求5的层合物，其中所述至少一个附加层是由热塑性弹性体聚合物制成的薄膜。
8．一种赋予非织造布以宽粘合范围的方法，该方法包括以下步骤：
将含有约0.5(重量)～约25％(重量)间规聚丙烯的热塑性聚合物共混物形成一种非织造纤网；
借助选自点热轧粘合、穿透空气粘合及超声粘合的方法对所述非织造纤网进行热粘合；
其中所述纤网具有的粘合范围比不含所述间规聚丙烯的一种类似的纤网的粘合范围至少宽10°F。
9．权利要求8的方法，其中所述粘合范围向不含所述间规聚丙烯的一种类似的纤网的粘合范围下方延伸至少10°F。
10．权利要求8的方法，其中所述共混物包含约2～约15％(重量)间规聚丙烯和约85～约98％(重量)等规聚丙烯。
11．一种赋予非织造布以宽粘合范围的方法，该方法包括下列步骤：
形成一种双组分纤维的非织造纤网，其中至少一种组分是热塑性聚合物共混物，它包括约5％(重量)～约15％(重量)间规聚丙烯以及约85％(重量)～约95％(重量)等规聚丙烯，以及
采用其温度为不含所述间规聚丙烯的一种类似的纤网的粘合范围以下至少10°F的热轧辊按点热轧粘合方式对所述非织造纤网进行热粘合。
12．权利要求1至4的任一项权利要求的纤维或纤维纤网的用途，其中所述的用途包括应用该纤维或纤维纤网来制造选自服装、防感染制品、个人护理用品和户外用的布料的产品。
13．权利要求12的用途，其中所述产品是个人护理用品，而所述个人护理用品是用尿布。
14．权利要求12的用途，其中所述产品是个人护理用品，而所述个人护理用品是成人失禁用品。
15．权利要求12的用途，其中所述产品是防感染制品，而所述防感染制品是手术罩衣。
CN96191594A 1995-01-27 1996-01-19 具有宽粘合范围的热塑性聚合物纤维和其用途以及赋予非织造布以宽粘合范围的方法 Expired - Fee Related CN1071386C (zh)

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