CN108049023B - 凹凸型无纺布及其在纸尿裤上的应用和纸尿裤 - Google Patents

凹凸型无纺布及其在纸尿裤上的应用和纸尿裤 Download PDF

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CN108049023B
CN108049023B CN201711315776.2A CN201711315776A CN108049023B CN 108049023 B CN108049023 B CN 108049023B CN 201711315776 A CN201711315776 A CN 201711315776A CN 108049023 B CN108049023 B CN 108049023B
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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。凹凸型无纺布，经过脱脂处理后的棉纤维为原料，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，凸点呈拒水性，内凹面呈亲水性。本专利的凹凸型无纺布具有柔软、洁白、干爽、吸收和下渗速度快、使用天然原棉纤维的优点。

Description

凹凸型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凹凸型无纺布。
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。
目前市场上的纸尿裤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，经过脱脂加工处理的纯棉即脱脂棉是对原棉进行脱脂和脱蜡得到的吸水能力好、柔软的棉纤维，原棉经过脱脂处理后，除了脱掉采摘棉花时携带纤维面层的脂和蜡外，纤维面层的黑点和杂质也被一起洗脱掉，因而脱脂棉是一种非常清洁而干净的纤维，采用脱脂棉制成的纯棉无纺布洁白而柔软。经过脱脂加工处理的纯棉无纺布亲水性非常好，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。
发明内容
针对上述现有经过脱脂加工处理的纯棉无纺布作为纸尿裤面层存在的不足，本发明的一个目的公开一种使用舒适且吸水性好的凹凸型无纺布；本发明的另一个目的是公开一种使用该凹凸型无纺布的纸尿裤。
为了实现上述目的，本发明采用下述的技术方案：凹凸型无纺布，经过脱脂处理后的棉纤维为原料，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，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26～29mm，直径为1.3～1.6D，制成的面层使用效果好。
作为优选，一种凹凸型无纺布，依次采用下述步骤制作：
(1)经过脱脂处理后的棉纤维为原料；
(2)将柔软润滑液水溶液喷洒在脱脂棉纤维上，闷脱脂棉纤维进行上油处理，使脱脂棉纤维含油率达到1～3％；
(3)采用水刺法加工脱脂棉纤维，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120～140％；
(5)将刻有凹槽的印花辊筒浸渍拒水剂溶液，通过浸渍拒水剂溶液的印花辊筒对水刺无纺布进行印拒水剂处理，拒水剂溶液施加在凸起的凸点上；然后进行烘干处理；
(6)将烘干后的脱脂棉水刺无纺布送入浸轧水槽中，水槽中加入NaOH溶液，经过浸碱和轧碱后烘干；
(7)烘干后进行水洗，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；
(8)烘干后得到凹凸型无纺布。通过对脱脂棉纤维进行上油处理，控制凹凸型无纺布含油率在一定范围；其次通过在脱脂棉纤维水刺无纺布印拒水剂的方式，使脱脂棉纤维水刺无纺布部分区域呈拒水性，然后再进行浸轧碱液，由于采用碱液浓度较高，有拒水剂的棉纤维受到保护，而没有印拒水剂区域的脱脂棉纤维产生剧烈收缩，使得印拒水剂的纤维强迫受到拉伸，进而在无纺布上形成凸点，没有凸点的位置即内凹面呈亲水性，有凸点的位置因为有拒水剂存在而呈拒水性，由于呈拒水性的凸点要高于亲水性的即内凹面1～3mm左右，因此与皮肤直接接触的部位是拒水性的凸点，拒水性的凸点保持干爽即增加了面层的干爽性，而亲水性的内凹面脱脂棉纤维增加了尿裤的吸收性，此外这些凹点也起到了吸收稀便的作用。另外，脱脂棉纤维水刺无纺布带通孔，增加了尿液的下渗速度。
进一步的，棉纤维长度为26～29mm，直径为1.3～1.6D；水槽中NaOH浓度为18～22％，拒水剂溶液浓度为15～25％，保证了有拒水剂的棉纤维受到保护，而没有印拒水剂区域的脱脂棉纤维产生剧烈收缩。进一步的，步骤(3)梳理机金属针布的齿密度为490齿/英寸2，同时选用大隔距，低速开松和梳理以及中低水压的工艺方式，其中控制给棉罗拉速度为0.45～0.6米/分，锡林速度为720～850米/分，盖板速度为155～170毫米/分，刺辊速度为650～700米/分，道夫速度为16.8～21.5米/分，采用五道水刺加工，其中前四道水刺为转鼓水刺加固，第五道水刺为平网水刺加固，第五道采用平网水刺进行提花加工，预湿水压为2～5bar，第二道至第五道主水刺压力分别为，15～30bar，50～55bar，65～70bar，72～85bar，生产线速度为25～40米/分，经过第五道水刺提花加固后，形成带孔的水刺无纺布，孔径为15～30目。通过盖板式梳理机的选用，降低开松梳理速度，通过中低压水刺加工获得具有良好使用强度的脱脂棉水刺无纺布。
进一步的，步骤(4)中采用双辊压机和网带下真空抽吸相结合的方式对脱脂棉水刺无纺布进行轧压和真空抽吸吸水；步骤(5)中温度控制在120～140℃。步骤(6)中，采用双层热风烘箱烘干，在烘箱中热风从上到下穿透浸碱后的脱脂棉水刺无纺布，热风温度为40～50℃，脱脂棉水刺无纺布在烘箱中运行时间为40～50s；步骤(7)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，最后四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(8)中将水洗后的水刺无纺布送入烘箱进行烘干，烘干温度为120～140℃，然后分切并卷绕。
进一步的，步骤(3)中梳理加工时车间温度控制在23±2℃，湿度为70±5％，脱脂棉是对原棉纤维经过脱脂和脱除棉蜡后所获得，纤维本身吸湿能力可以达到自身重量的25倍，因此在梳理加工时控制车间的温湿度环境非常重要。
凹凸型无纺布在纸尿裤上的应用，凹凸型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，外罩包括面层和底层，面层是上述的凹凸型无纺布。
采用了上述技术方案的凹凸型无纺布，原料采用经过脱脂处理后的棉纤维，采用脱脂棉制成的纯棉无纺布洁白而柔软。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，使凹凸型无纺布保持干爽，亲水性的内凹面增强了吸水性和下渗速度。综上所述，本专利的凹凸型无纺布具有柔软、洁白、干爽、吸收和下渗速度快、使用天然原棉纤维的优点。本专利纸尿裤的优点是使用舒适且可以预防产生红臀的情况。
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所示的凹凸型无纺布，经过脱脂处理后的棉纤维为原料，棉纤维长度为26～29mm，直径为1.3～1.6D。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。
凹凸型无纺布，依次采用下述步骤制作：
(1)预先经过脱脂处理后的棉纤维，棉纤维长度为26～29mm，直径为1.3～1.6D；
(2)由于脱脂棉纤维的棉脂和棉蜡已经脱除掉，纤维发涩，纤维之间摩擦力大，直接进行梳理对纤维损伤较大，需要进行上油处理。首先配置柔软润滑液，柔软润滑液例如杭州一诺化工有限公司生产的棉用柔软整理剂YN803，使柔软润滑剂与水的比例为5～10:90～95％，然后用配好的柔软润滑剂溶液喷洒上述脱脂棉纤维，然后蒙上塑料布闷24小时进行上油处理，使脱脂棉纤维面层含油率达到1～3％；
(3)采用水刺方法加工经过上油处理后的脱脂棉纤维，由于棉纤维预先经过脱脂处理，纤维容易脆断，开松梳理过程中易出现缠皮辊、绕罗拉的现象，因此采用盖板式梳理机，梳理机金属针布的齿密度为490齿/英寸2，同时选用大隔距，低速开松和梳理以及中低水压的工艺方式，其中控制给棉罗拉速度为0.45～0.6米/分，锡林速度为720～850米/分，盖板速度为155～170毫米/分，刺辊速度为650～700米/分，道夫速度为16.8～21.5米/分，采用五道水刺加工，其中前四道水刺为转鼓水刺加固，第五道水刺为平网水刺加固，第五道采用平网水刺进行提花加工，预湿水压为2～5bar，第二道至第五道主水刺压力分别为，15～30bar，50～55bar，65～70bar，72～85bar，生产线速度为25～40米/分，经过第五道水刺提花加固后，在水刺无纺布上形成15～30目的通孔；由于脱脂棉是对原棉纤维经过脱脂和脱除棉蜡后所获得，纤维本身吸湿能力可以达到自身重量的25倍，因此在梳理加工时控制车间的温湿度环境非常重要，车间温度控制在23±2℃，湿度为70±5％；
(4)经过第五道水刺提花加固后，采用双辊压机和网带下真空抽吸相结合的方式对脱脂棉水刺无纺布进行轧压和抽吸吸水，使布面含水率控制在120～140％，含水率是针对脱脂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15～25％的拒水剂溶液，例如常州帝日纺织科技有限公司的TG～581，将刻有圆形凹槽的印花辊筒浸渍拒水剂溶液，印花辊筒平方英吋上的孔眼是24个，凹槽深度为2～4mm，然后对经过脱脂棉纤维水刺无纺布进行印拒水剂加工，再送入烘箱中进行烘干，烘箱长度为20米，烘干时烘干温度控制在120～140℃，使脱脂棉纤维水刺无纺布面层均布含拒水剂的印花圆点；
(6)将烘干后的脱脂棉水刺无纺布送入浸轧水槽中，水槽中NaOH浓度为18～22％，经过一浸碱和一轧碱后，送入双层热风烘箱中，在烘箱中热风从上到下穿透浸碱后的脱脂棉水刺无纺布，热风温度为40～50℃，烘箱长度为20米，脱脂棉水刺无纺布在烘箱中运行时间为40～50s；
(7)烘箱后，将脱脂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，最后四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；
(8)将冲洗后的脱脂棉纤维水刺无纺布送入烘箱进行烘干，烘干温度为120～140℃，然后分切成宽度为160mm的宽度，再经过卷绕成为布卷，所制备的脱脂棉纤维水刺无纺布克重为30～38g/m2。
实施例2
凹凸型无纺布在纸尿裤上的应用，凹凸型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，外罩包括底层和实施例1所述的凹凸型无纺布。

Claims (8)

1.凹凸型无纺布，经过脱脂处理后的棉纤维为原料，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；所述内凹面上设置通孔，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；
所述的凹凸型无纺布，依次采用下述步骤制作：
(1)经过脱脂处理后的棉纤维为原料；
(2)将柔软润滑溶液喷洒在脱脂棉纤维上，闷置脱脂棉纤维进行上油处理，使脱脂棉纤维含油率达到1～3％；
(3)采用水刺法加工脱脂棉纤维，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抽吸吸水处理，使布面含水率控制在120～140％；
(5)将刻有凹槽的印花辊筒浸渍拒水剂溶液，通过浸渍拒水剂溶液的印花辊筒对水刺无纺布进行印拒水剂处理，拒水剂溶液施加在凸起的凸点上；然后进行烘干处理；
(6)将烘干后的脱脂棉水刺无纺布送入浸轧水槽中，水槽中加入NaOH溶液，经过浸碱和轧碱后烘干；
(7)烘干后进行水洗，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；
(8)烘干后得到凹凸型无纺布。
2.根据权利要求1所述的凹凸型无纺布，其特征在于棉纤维长度为26～29mm，直径为1.3～1.6D。
3.根据权利要求1所述的凹凸型无纺布，其特征在于棉纤维长度为26～29mm，直径为1.3～1.6D；拒水剂溶液浓度为15～25％；水槽中NaOH浓度为18～22％。
4.根据权利要求1所述的凹凸型无纺布，其特征在于步骤(3)水刺法是采用盖板式梳理机梳理脱脂棉纤维以大隔距，低速开松和梳理，中低水压的工艺方式；梳理机金属针布的齿密度为490齿/英寸2，其中控制给棉罗拉速度为0.45～0.6米/分，锡林速度为720～850米/分，盖板速度为155～170毫米/分，刺辊速度为650～700米/分，道夫速度为16.8～21.5米/分，采用五道水刺加工，其中前四道水刺为转鼓水刺加固，第五道水刺为平网水刺加固，第五道采用平网水刺进行提花加工，预湿水压为2～5bar，第二道至第五道主水刺压力分别为，15～30bar，50～55bar，65～70bar，72～85bar，生产线速度为25～40米/分，经过第五道水刺提花加固后，形成带通孔的水刺无纺布，通孔孔径为15～30目。
5.根据权利要求1所述的凹凸型无纺布，其特征在于步骤(4)中采用双辊压机和网带下真空抽吸相结合的方式对脱脂棉水刺无纺布进行轧压和抽吸吸水；步骤(5)中温度控制在120～140℃；步骤(6)中，采用双层热风烘箱烘干，在烘箱中热风从上到下穿透浸碱后的脱脂棉水刺无纺布，热风温度为40～50℃，脱脂棉水刺无纺布在烘箱中运行时间为40～50s；步骤(7)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，最后四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(8)中将水洗后的水刺无纺布送入烘箱进行烘干，烘干温度为120～140℃，然后分切并卷绕。
6.根据权利要求1所述的凹凸型无纺布，其特征在于步骤(3)中梳理加工时车间温度控制在23±2℃，湿度为70±5％。
7.根据权利要求1～6任意一项所述的凹凸型无纺布在纸尿裤上的应用，其特征在于凹凸型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任意一项所述的凹凸型无纺布。
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