CN107854224B - 一种导流非织造复合材料及其制备方法 - Google Patents

一种导流非织造复合材料及其制备方法 Download PDF

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CN107854224B
CN107854224B CN201711048418.XA CN201711048418A CN107854224B CN 107854224 B CN107854224 B CN 107854224B CN 201711048418 A CN201711048418 A CN 201711048418A CN 107854224 B CN107854224 B CN 107854224B
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张恒
甄琪
宋卫民
张一风
廖喜林
章伟
刘让同
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Zhongyuan University of Technology
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Abstract

本发明涉及一种导流用非织造复合材料及其制备方法。本申请的导流用非织造复合材料,包括依序层叠复合固结的热风无纺布层、阻尼层和防护层;所述的制备方法中将阻尼层喷射在防护层上,此后将蓬松热风无纺布层铺放在阻尼层之上,经过超声波复合作用固结在一起,形成本申请的吸收芯体用导流非织造复合材料。导流用非织造复合材料的制备方法中,在通过在蓬松的热风非织造布层和防护层之间添加纤维表面带有沟槽结构的聚丙烯熔喷非织造布层,不仅具有快速下渗速度,还具有良好的纵向扩散效果,同时兼有柔软特性,可用于纸尿裤、卫生巾等一次性吸收制品。

Description

一种导流非织造复合材料及其制备方法
技术领域
本发明涉及一次性卫生用品领域,特别是指一种导流非织造复合材料及其制备方法。
背景技术
在纸尿裤、卫生巾等一次性卫生用品中,吸收芯体是其关键部件,主要作用是利用内部的超吸水树脂和绒毛浆吸收并存储液体,而超吸水树脂吸收液体后膨胀变大,进而彼此相连阻塞液体扩散通道,进而影响吸水芯体的再次吸水速度和能力,还会造成超吸水树脂的利用率较低。
目前人们大多采用热风非织造布作为导流层来解决这一问题;早期用于导流层的热风非织造布多为单层纤维网,后来出现了由粗旦纤维网和细旦纤维网组成的双层热风非织造布作为导流层;虽然纯热风非织造布作为导流层可以提高超吸水树脂的利用率,但是其克重较大为30-60g/m2,这不仅增大了吸收性卫生用品的成本,还使得制备的产品整体结构过厚、不够柔薄,所制备的纸尿裤、卫生巾往往很厚,会给使用者带来不便,并影响穿着舒适性。
发明内容
本发明提出一种导流非织造复合材料及其制备方法,所述导流非织造复合材料包括依序层叠复合固结的蓬松热风无纺布层、超细纤维阻尼层和聚丙烯纺粘防护层,所述超细纤维阻尼层为聚丙烯熔喷非织造布层,所述聚丙烯纺粘非织造布层和聚丙烯熔喷非织造布层中添加有亲水剂,所述聚丙烯熔喷非织造布层的纤维表面具有不规则的异形沟槽结构,解决了消费者对不同吸收性卫生产品的厚薄和液体吸收速率的需求的问题。
本发明的技术方案是这样实现的:
一种导流非织造复合材料,包括热风无纺布层、阻尼层和防护层;阻尼层为聚丙烯熔喷非织造布,防护层为聚丙烯纺粘非织造布,聚丙烯熔喷非织造布的纤维表面设有不规则的沟槽结构。
所述热风无纺布克重为13-16g/m2,聚丙烯熔喷非织造布的克重为2-6g/m2,聚丙烯纺粘非织造布6-12g/m2
一种导流非织造复合材料的制备方法,步骤为:以ES纤维为原料采用热风非织造技术制备具有蓬松结构的热风无纺布层,以聚丙烯为原料采用纺粘法制备聚丙烯纺粘非织造布,以聚丙烯和水溶性聚酯为原料采用喷熔法制备聚丙烯熔喷非织造布,然后按照顺序铺网后复合固结,经水浸渍后形成导流非织造复合材料,经一定温度的水浸渍处理一定时间后在聚丙烯熔喷非织造布表面形成不规则的沟槽。
所述按照顺序铺网指:从上到下依次为热风无纺布层、聚丙烯熔喷非织造布和聚丙烯纺粘非织造布的顺序进行铺放。
所述热风无纺布层、聚丙烯纺粘非织造布和聚丙烯熔喷非织造布的原料中含有亲水剂。
一种导流非织造复合材料的制备方法,具体步骤如下:
(1)将聚丙烯切片和亲水母粒混合后,参照聚丙烯纺粘法工艺生产防护层;
(2)将热风无纺布层铺放在熔喷装置下面,然后把水溶性聚酯切片、亲水母粒和聚丙烯切片按比例混合后,采用熔喷法制备阻尼层,使阻尼层直接喷射在热风无纺布层上;
(3)将防护层铺设于阻尼层之上,然后经超声波复合固结在一起,形成热风无纺布层+阻尼层+防护层的三层结构的复合材料;
(4)将复合材料送入70-90℃的水中浸渍10-20min,完成非织造复合材料的制备。
所述步骤(1)中聚丙烯切片:亲水母粒的质量比为(16-20):1。
所述步骤(2)中水溶性聚酯切片:亲水母粒:聚丙烯切片的质量比为(1.5-3):1:(16-20)。
本技术方案能产生的有益效果:
1、本申请综合非织造材料的使用特点,创造性的提出将阻尼层夹设于蓬松热风无纺布层和防护层之间,从而制备出适用于吸收性卫生用品的导流非织造复合材料;本申请的导流用非织造复合材料利用蓬松热风无纺布层具有的高孔隙率特性,短暂的储存液体;利用具有致密孔隙结构的聚丙烯熔喷非织造布形成的阻尼层来引导液体在纵向方向上扩散;同时防护层的长丝纤维的强力保护超细纤维阻尼层。
2、本申请进一步的对非织造复合材料的制备方法进行了研究,在本申请的制备方法中,特别是采用聚丙烯熔喷非织造布作为阻尼层的时候,由于聚丙烯熔喷非织造布天然的拒水特性和抗拉伸强力小,加工或者使用过程中容易被破坏,因此,本申请创造性的对聚丙烯熔喷非织造布加工时添加亲水性功能,并在超细纤维表面形成不规则的异形沟槽以提升超细纤维阻尼层对也液体的纵向扩散能力。
3、本申请创造性的将聚丙烯切片和水溶性聚酯切片共混后制备超细纤维熔喷非织造布,利用70-90℃的水清洗超细纤维表面的水溶性聚酯成分,进而在聚丙烯熔喷非织造布纤维表面形成不规则的沟槽。
4、本申请的复合材料包括依序层叠复合固结的蓬松热风无纺布层、超细纤维阻尼层和聚丙烯纺粘防护层,克重范围在21-34g/m2,对比常规导流层,具有克重小、厚度薄、柔、软的特点、可以用来制备薄型的纸尿裤、卫生巾。
5、本发明所涉及到的复合材料自上而下由短暂储存液体的蓬松热风无纺布层、引导液体纵向扩散的超细纤维阻尼层和聚丙烯纺粘防护层组成,因此具有分流和快速传输液体的效果,可以提高吸收芯体内部超吸水树脂的利用率。
6、本发明所述的复合材料可以调整纤维规格和纤维层的结构来满足不同吸收性卫生产品对厚薄和液体吸收速率的需求。
附图说明
图1为本发明的非织造复合材料的结构示意图;其中A-蓬松非织造层;B-超细纤维阻尼层;C-防护层。
图2为纤维表面带有沟槽的聚丙烯熔喷非织造布的电镜图。
具体实施方式
本申请的制备方法中纺粘法、熔喷法、复合固结为常规的技术手段。在本申请的一种实现方式中,热风无纺布层、熔喷阻尼层和纺粘防护层的复合固结,是在超声波复合作用下完成的,即首先将熔喷阻尼层喷射在热风无纺布层上,此后将纺粘防护层铺放在阻尼层之上,经过超声波复合作用固结在一起,经水浸渍后形成导流非织造复合材料,经水浸渍后在聚丙烯熔喷非织造布表面形成不规则的沟槽。
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有付出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例1
本例的吸收芯体用导流非织造复合材料如图1所示,由上至下依次为层叠复合固结的热风无纺布、聚丙烯熔喷非织造布和聚丙烯纺粘非织造布。其制备方法如下:
(1)先按照聚丙烯纺粘法工艺生产克重为8g/m2的聚丙烯纺粘非织造布,在聚丙烯纺粘过程中,将聚丙烯切片和亲水母粒按照19:1的质量比添加;
(2)采用熔喷法制备聚丙烯熔喷非织造布,在熔喷非织造布纺丝时,将水溶性聚酯切片、亲水母粒、聚丙烯切片按照2:1:17的质量比添加,然后按照熔喷法非织造布的工艺进行生产加工;在制备过程中将13g/m2的热风无纺布铺放在熔喷装置下面,使得聚丙烯熔喷超细纤维直接喷射在热风无纺布上形成克重2g/m2聚丙烯熔喷非织造布;
(3)将8g/m2的聚丙烯纺粘非织造布铺于聚丙烯熔喷非织造布上,然后,进行超声波复合作用固结在一起,即形成三层结构的非织造复合材料,其结构为热风无纺布+聚丙烯熔喷非织造布+聚丙烯纺粘非织造布的三层结构;
(4)将三层结构的复合材料送入到温度80℃的水中浸渍10min,使得水溶性聚酯聚合物溶于水中,因此在纤维表面形成各种不规则的沟槽。
结果如图1、图2所示,采用液态水分管理测试仪进行测试,液体在复合材料表层纵向扩散速度为3.3mm/s,液体在复合材料底层纵向扩散速度为3.0mm/s,最大润湿半径为30mm。
实施例2
本实施例的吸收芯体用导流非织造复合材料,由依序层叠复合固结的热风无纺布、聚丙烯熔喷非织造布和聚丙烯纺粘非织造布组成。其制备方法如下:
(1)先按照聚丙烯纺粘法工艺生产克重为12g/m2的聚丙烯纺粘非织造布,在聚丙烯纺粘法过程中,将聚丙烯切片和亲水母粒按照18:1的质量比添加;
(2)采用熔喷法制备聚丙烯熔喷非织造布,在熔喷非织造布纺丝时,将水溶性聚酯切片、亲水母粒、聚丙烯切片按照3:1:16的质量比添加,然后按照熔喷法非织造布的工艺进行生产加工;在制备过程中将聚丙烯纺粘法非织造布铺放在熔喷装置下面,使得聚丙烯熔喷超细纤维直接喷射在13g/m2的热风无纺布上形成克重4g/m2聚丙烯熔喷非织造布;
(3)将12g/m2的聚丙烯纺粘非织造布铺于聚丙烯熔喷非织造布上,然后,进行超声波复合作用固结在一起,即形成三层结构的非织造复合材料,其结构为热风无纺布+聚丙烯熔喷非织造布+聚丙烯纺粘非织造布的三层结构;
(4)将三层结构的复合材料送入到温度90℃的水中浸渍10min,使得水溶性聚酯聚合物溶于水中,因此在纤维表面形成各种不规则的沟槽。
采用液态水分管理测试仪进行测试,液体在复合材料表层纵向扩散速度为3.4mm/s,液体在复合材料底层纵向扩散速度为3.2mm/s,最大润湿半径为34mm。
实施例3
本实施例的吸收芯体用导流非织造复合材料,由依序层叠复合固结的热风无纺布、聚丙烯熔喷非织造布和聚丙烯纺粘非织造布组成。其制备方法如下:
(1)先按照聚丙烯纺粘法工艺生产克重为9g/m2的聚丙烯纺粘非织造布,在聚丙烯纺粘法过程中,将聚丙烯切片和亲水母粒按照20:1的质量比添加;
(2)采用熔喷法制备聚丙烯熔喷非织造布,在熔喷非织造布纺丝时,将水溶性聚酯切片、亲水母粒、聚丙烯切片按照2:1:18的质量比添加,然后按照熔喷法非织造布的工艺进行生产加工;在制备过程中将15g/m2的热风无纺布铺放在熔喷装置下面,使得聚丙烯熔喷超细纤维直接喷射在13g/m2的热风无纺布上形成克重4g/m2聚丙烯熔喷非织造布;
(3)将9g/m2的聚丙烯纺粘非织造布铺于聚丙烯熔喷非织造布上,然后,进行超声波复合作用固结在一起,即形成三层结构的非织造复合材料,其结构为热风无纺布+聚丙烯熔喷非织造布+聚丙烯纺粘非织造布的三层结构;
(4)将三层结构的复合材料送入到温度90℃的水中浸渍10min,使得水溶性聚酯聚合物溶于水中,因此在纤维表面形成各种不规则的沟槽。
采用液态水分管理测试仪进行测试,液体在复合材料表层纵向扩散速度为3.2mm/s,液体在复合材料底层纵向扩散速度为3.3mm/s,最大润湿半径为31mm。
以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。

Claims (2)

1.一种导流非织造复合材料的制备方法,其特征在于,具体步骤如下:
(1)将聚丙烯切片和亲水母粒混合后,参照聚丙烯纺粘法工艺生产防护层;
(2)将热风无纺布层铺放在熔喷装置下面,然后把水溶性聚酯切片、亲水母粒和聚丙烯切片按比例混合后,采用熔喷法制备阻尼层,使阻尼层直接喷射在热风无纺布层上;
(3)将防护层铺设于阻尼层之上,然后进行超声波复合固结在一起,形成热风无纺布层+阻尼层+防护层的三层结构的复合材料;
(4)将复合材料送入70-90℃的水中浸渍10-20min,完成非织造复合材料的制备;
步骤为:以ES纤维为原料采用热风非织造技术制备具有蓬松结构的热风无纺布层,以聚丙烯为原料采用纺粘法制备聚丙烯纺粘非织造布,以聚丙烯和水溶性聚酯为原料采用喷熔法制备聚丙烯熔喷非织造布,然后按照顺序铺网后复合固结,经水浸渍后形成导流非织造复合材料;
所述导流非织造复合材料,包括热风无纺布层、阻尼层和防护层;所述的阻尼层为聚丙烯熔喷非织造布,防护层为聚丙烯纺粘非织造布;所述聚丙烯熔喷非织造布的特征为纤维表面有不规则的沟槽结构;
所述热风无纺布克重为13-16g/m2,聚丙烯熔喷非织造布的克重为2-6g/m2,聚丙烯纺粘非织造布6-12g/m2
所述聚丙烯纺粘非织造布和聚丙烯熔喷非织造布的原料中含有亲水剂;
所述步骤(1)中聚丙烯切片:亲水母粒的质量比为(16-20):1;
所述步骤(2)中水溶性聚酯切片:亲水母粒:聚丙烯切片的质量比为(1.5-3):1:(16-20)。
2.如权利要求1所述的一种导流非织造复合材料的制备方法,其特征在于:所述按照顺序铺网指:从上到下依次为热风无纺布层、聚丙烯熔喷非织造布和聚丙烯纺粘非织造布热风无纺布层的顺序进行铺放。
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