CN107815786B - 纯棉无纺布及其在纸尿裤上的应用和纸尿裤 - Google Patents

纯棉无纺布及其在纸尿裤上的应用和纸尿裤 Download PDF

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CN107815786B
CN107815786B CN201711316938.4A CN201711316938A CN107815786B CN 107815786 B CN107815786 B CN 107815786B CN 201711316938 A CN201711316938 A CN 201711316938A CN 107815786 B CN107815786 B CN 107815786B
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钱程
张春娥
武晓莺
吴云杰
王营杰
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Hangzhou Coco Healthcare Products Co Ltd
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Abstract

本发明涉及无纺布材料领域。纯棉无纺布，未经处理的原棉纤维为原料，面层上设有多个向上凸起的凸点，相邻凸点之间是内凹面，凸点呈拒水性，内凹面呈亲水性。本专利的纯棉无纺布具有干爽、吸收和下渗速度快、使用天然原棉纤维的优点。

Description

纯棉无纺布及其在纸尿裤上的应用和纸尿裤
技术领域
本发明涉及无纺布材料领域，尤其是一种作为纸尿裤面层的纯棉无纺布。
背景技术
纸尿裤的面层很多是采用3D压花结构，如公开号为CN203677388U的中国专利，名称是一种3D立体压纹面层的纸尿裤，面层上分布有多个3D立体压纹。因增加了3D立体压纹，使纸尿裤表层更加美观并减少宝宝屁股与纸尿裤的接触面积，从而增强透气性能，使宝宝在使用纸尿裤过程中更加健康舒适。
目前市场上使用的面层主要有两种材料，一种是合成纤维，例如热熔粘合无纺布和纺粘无纺布，另一种是纯棉无纺布。现有的纸尿裤面层所用的纯棉无纺布，均为经过脱脂加工处理的纯棉无纺布，所得到脱脂棉亲水性非常好，其吸水倍率可达到自身重量的20倍以上，采用这种纯棉无纺布为面层的纸尿裤虽然吸收速度快，保水锁水性好，但存在潮感大的问题，婴儿使用后特别容易产生红臀。如果不对原棉纤维进行脱脂处理，则棉纤维本身属于非亲水态，采用没有进行脱脂加工的原棉纤维无纺布做尿裤面层时，由于原棉纤维不亲水，导致了面层无纺布为拒水型，只能通过面层开孔的形式，吸收尿液效率低，容易导致侧漏的产生。
发明内容
针对现有纯棉无纺布作为纸尿裤的面层存在的不足，本发明的一个目的公开一种使用舒适且吸水性好的纯棉无纺布；本发明的另一个目的是公开一种使用纯棉无纺布作为面层的纸尿裤。
为了实现上述目的，本发明采用下述的技术方案：纯棉无纺布，未经处理的原棉纤维为原料，面层上设有多个向上凸起的凸点，相邻凸点之间是内凹面，凸点呈拒水性，内凹面呈亲水性。
作为优选，内凹面上设置通孔，凸点边缘至内凹面边缘之间的连接面由上至下拒水性逐渐降低，即保证了使用的舒适性，又提高了下渗的速度。
作为优选，棉纤维长度为20～24mm，细度为1.8～2.2D，能够有效利用低品质原棉纤维制作高档产品，且制成的面层使用效果好。
作为优选，纯棉无纺布依次采用下述步骤制作：
(1)未经处理的原棉纤维为原料；
(2)将柔软亲水剂水溶液喷洒在原棉纤维上，闷原棉纤维进行柔软亲水处理，使原棉纤维回潮率达到8～15％；
(3)采用水刺法加工原棉纤维，水刺加工采用多道，形成带孔的水刺无纺布；
(4)对水刺无纺布进行轧压和真空抽吸吸水处理，使布面含水率控制在100～110％；
(5)通过浸渍NaOH溶液的印花辊筒对水刺无纺布进行印碱处理，然后进行烘干处理；
(6)将烘干后的水刺无纺布进行水洗处理，水洗过程中加入稀盐酸，水洗后的水刺无纺布的pH值为7～8；
(7)烘干后得到纯棉无纺布。通过对不亲水的原棉纤维进行柔软亲水处理，使其暂时获得亲水性，并能顺利通过开松梳理和水刺加工；其次通过在原棉纤维水刺无纺布面层印碱液的方式，使原棉纤维水刺无纺布获得部分脱脂的效果，由于采用碱液浓度较高，印有碱液的原棉纤维产生剧烈收缩，而没有印碱液的原棉纤维强迫受到拉伸，进而在布面上形成凸点，有凸点的位置呈拒水性，没有凸点的位置即内凹面呈亲水性，拒水的凸点要高于亲水的内凹面1～3mm左右，因此与皮肤直接接触的部位是拒水的凸点，凸点保持干爽，即增加了面层的干爽性，而亲水的内凹面棉纤维增加了尿裤的吸收性，此外水刺无纺布带孔，增加了尿液的下渗速度。
进一步的，棉纤维长度为20～24mm，细度为1.8～2.2D；印花辊筒以孔为中心进行印碱处理，即孔处于内凹面的中心，吸收效率最佳；NaOH溶液的浓度为32～36％，该NaOH溶液保证了印有碱液的原棉纤维产生剧烈收缩，而没有印碱液的原棉纤维强迫受到拉伸。原棉纤维是五级原棉纤维，通过上述工艺可以将用品级不好的五级原棉纤维做为纸尿裤的面层使用。
进一步的，水刺法是以大隔距，低速开松和梳理，中低水压的工艺。
进一步的，步骤(3)采用罗拉式梳理机梳理原棉纤维，控制锡林速度为920～1050米/分，工作辊速度为65.5～78米/分，剥取辊速度为165～179米/分，杂乱辊速度为1090～1290米/分，道夫速度为29.8～36.9米/分；采用六道水刺加工，其中前五道水刺为转鼓水刺加固，第六道水刺为平网水刺加固，第六道采用平网水刺进行提花加工，预湿水压为5～10bar，第二道至第五道主水刺压力分别为，18～40bar，50～65bar，70～80bar，85～105bar，70～80bar，生产线速度为30～45米/分，经过第六道水刺提花加固后，形成带孔的水刺无纺布，孔径为15～30目；步骤(5)烘干处理是分段烘干，第一段烘干时烘干温度控制在80～100℃之间，第二段烘干时烘干温度控制在60～80℃。
进一步的，步骤(6)中，将烘干后带碱的棉纤维水刺无纺布送入水洗槽中，水洗槽共分成十个槽，前五个水槽的温度为室温，水洗方式为浸渍轧压方式，在第六个水槽中加入稀盐酸，控制水槽中水的pH值为4～5，通过浸渍和轧压方式进一步中和布面上的碱液，最后4个水槽采用喷淋式水洗，喷淋水温为40～50℃，直至布面的pH值为7～8；步骤(7)中，将水洗后的水刺无纺布送入烘箱进行烘干，烘干温度为110～130℃，然后分切并卷绕。
纯棉无纺布在纸尿裤上的应用，纯棉无纺布作为纸尿裤的面层使用。
纸尿裤，包括外罩及其内的芯体，外罩包括底层和面层，面层是上述的纯棉无纺布。
采用了上述技术方案的纯棉无纺布，采用未经处理的原棉纤维为原料，凸点呈拒水性，内凹面呈亲水性，与皮肤直接接触的部位是拒水性的凸点，使纯棉无纺布保持干爽，亲水性的内凹面增强了吸水性和下渗速度。综上所述，本专利的纯棉无纺布具有干爽、吸收和下渗速度快、使用天然原棉纤维的优点。
附图说明
图1：本实用实施例的结构示意图。
具体实施方式
下面结合图1对本专利做进一步的解释。
实施例1
如图1所示的纯棉无纺布，未经处理的五级原棉纤维为原料，棉纤维长度为20～24mm，细度为1.8～2.2D。纯棉无纺布上设有多个向上凸起的凸点1，凸点1呈拒水性，相邻凸点1之间是内凹面2，内凹面2呈亲水性，内凹面2中心处设置通孔3，凸点边缘至内凹面边缘之间的连接面4由上至下拒水性逐渐降低，即保证了使用的舒适性，又提高了下渗的速度，制成的面层使用效果好。
纯棉无纺布，依次采用下述步骤制作：
(1)采用未经任何处理的五级原棉纤维，棉纤维长度为20～24mm，细度为1.8～2.2D；
(2)首先配置柔软亲水水溶液，柔软亲水剂与水的比例为10～15:85～90％，亲水剂是嘉善纺织材料有限公司的JF1601；然后用配好的柔软亲水剂水溶液喷洒上述未经任何处理的原棉纤维，然后蒙上塑料布闷置24小时进行柔软亲水处理，使原棉纤维回潮率达到8～15％；
(3)采用水刺方法加工经过柔软亲水处理后的原棉纤维，由于原棉纤维没有预先经过脱脂处理，亲水性不好，在前述柔软亲水剂处理后有一定的亲水性，但仍需要良好控制开松和梳理工艺参数，避免原棉纤维缠皮辊、绕罗拉的现象产生，因此采用罗拉式梳理机，以大隔距，低速开松和梳理，中低水压的工艺方式，其中控制锡林速度为920～1050米/分，工作辊速度为65.5～78米/分，剥取辊速度为165～179米/分，杂乱辊速度为1090～1290米/分，道夫速度为29.8～36.9米/分，采用6道水刺加工，其中前五道水刺为转鼓水刺加固，第六道水刺为平网水刺加固，第六道采用平网水刺进行提花加工，预湿水压为5～10bar，第二道至第五道主水刺压力分别为，18～40bar，50～65bar，70～80bar，85～105bar，70～80bar，生产线速度为30～45米/分，经过第六道水刺提花加固后，在水刺无纺布上形成15～30目的通孔；
(4)经过第六道水刺提花加固后，采用双辊压机和网带下真空抽吸相结合的方式对带原棉水刺无纺布进行轧压和抽吸吸水，使布面含水率控制在100～110％，含水率是针对原棉纤维的特性特别选定的，其目的是便于后续的凸点形成。
(5)预先配置浓度为32～36％的NaOH溶液，将刻有圆形凹槽的印花辊筒浸渍NaOH溶液，平方英吋上的孔眼是24个，凹槽深度为2～4mm，然后对经过水刺加固的原棉纤维水刺无纺布进行印碱加工，印花辊筒以孔为中心进行印碱处理；再送入烘箱中进行分段烘干，烘箱分为两个区域，长度为30米，预烘第一段烘干时烘干温度控制在80～100℃之间，第一段烘干时烘干温度控制在60～80℃。
(6)将烘干后的带碱原棉纤维水刺无纺布送入水洗槽中，水洗槽共分成十个小槽，前五个水槽的温度为室温，水洗方式为浸渍轧压方式，在第六个水槽中加入稀盐酸，控制水槽中水的pH值为4～5，通过浸渍和轧压方式进一步中和布面上的碱液，最后4个水槽采用喷淋式水洗，喷淋水温为40～50℃，直至布面的pH值为7～8；
(7)将冲洗后的上述原棉纤维水刺无纺布送入烘箱进行烘干，烘干温度为110～130℃，然后分切成宽度为160mm的宽度，再经过卷绕成为布卷；所制备的原棉纤维水刺无纺布克重为30～38g/m2。
实施例2
纯棉无纺布在纸尿裤上的应用，实施例1所述的纯棉无纺布作为纸尿裤的面层使用。纸尿裤，包括外罩及其内的芯体，外罩包括底层和面层，面层是实施例1所述的纯棉无纺布。本专利的纸尿裤的优点是使用舒适且可以预防产生红臀的情况。

Claims (8)

1.纯棉无纺布，未经处理的原棉纤维为原料，无纺布上设有多个向上凸起的凸点，相邻凸点之间是内凹面，其特征在于凸点呈拒水性，内凹面呈亲水性；内凹面上设置通孔，凸点边缘至内凹面边缘之间的连接面由上至下拒水性逐渐降低；
所述的纯棉无纺布，依次采用下述步骤制作：(1)未经处理的原棉纤维为原料；(2)将柔软亲水剂水溶液喷洒在原棉纤维上，闷置原棉纤维进行柔软亲水处理，使原棉纤维回潮率达到8～15％；(3)采用水刺法加工原棉纤维，水刺加工采用多道，形成带通孔的水刺无纺布；(4)对水刺无纺布进行轧压和真空抽吸吸水处理，使布面含水率控制在100～110％；(5)通过浸渍NaOH溶液的印花辊筒对水刺无纺布进行印碱处理，然后进行烘干处理；(6)将烘干后的水刺无纺布进行水洗处理，水洗过程中加入稀盐酸，水洗后的水刺无纺布的pH值为7～8；(7)烘干后得到纯棉无纺布。
2.根据权利要求1所述的纯棉无纺布，其特征在于棉纤维长度为20～24mm，细度为1.8～2.2D。
3.根据权利要求1所述的纯棉无纺布，其特征在于印花辊筒以孔为中心进行印碱处理；NaOH溶液的浓度为32～36％；棉纤维长度为20～24mm，细度为1.8～2.2D；原棉纤维是五级原棉纤维。
4.根据权利要求1所述的纯棉无纺布，其特征在于水刺法是以大隔距，低速开松和梳理，中低水压的工艺。
5.根据权利要求1所述的纯棉无纺布，其特征在于步骤(3)采用罗拉式梳理机梳理原棉纤维，控制锡林速度为920～1050米/分，工作辊速度为65.5～78米/分，剥取辊速度为165～179米/分，杂乱辊速度为1090～1290米/分，道夫速度为29.8～36.9米/分；采用六道水刺加工，其中前五道水刺为转鼓水刺加固，第六道水刺为平网水刺加固，第六道采用平网水刺进行提花加工，预湿水压为5～10bar，第二道至第五道主水刺压力分别为，18～40bar，50～65bar，70～80bar，85～105bar，70～80bar，生产线速度为30～45米/分，经过第六道水刺提花加固后，形成带孔的水刺无纺布，通孔孔径为15～30目；步骤(5)烘干处理是分段烘干，第一段烘干时烘干温度控制在80～100℃之间，第二段烘干时烘干温度控制在60～80℃。
6.根据权利要求1所述的纯棉无纺布，其特征在于步骤(6)中，将烘干后的水刺无纺布送入水洗槽中，水洗槽共分成十个槽，前五个水槽的温度为室温，水洗方式为浸渍轧压方式，在第六个水槽中加入稀盐酸，控制水槽中水的pH值为4～5，通过浸渍和轧压方式进一步中和布面上的碱液，最后4个水槽采用喷淋式水洗，喷淋水温为40～50℃，直至布面的pH值为7～8；步骤(7)中，将水洗后的水刺无纺布送入烘箱进行烘干，烘干温度为110～130℃，然后分切并卷绕。
7.根据权利要求1～6任意一项所述的纯棉无纺布在纸尿裤上的应用，其特征在于纯棉无纺布作为纸尿裤的面层使用。
8.纸尿裤，包括外罩及其内的芯体，外罩包括底层和面层，其特征在于面层是权利要求1～6任意一项所述的纯棉无纺布。
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