CN109072513A - 包含熔喷层和纺粘层的无纺层压织物 - Google Patents

包含熔喷层和纺粘层的无纺层压织物 Download PDF

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Publication number
CN109072513A
CN109072513A CN201780029138.6A CN201780029138A CN109072513A CN 109072513 A CN109072513 A CN 109072513A CN 201780029138 A CN201780029138 A CN 201780029138A CN 109072513 A CN109072513 A CN 109072513A
Authority
CN
China
Prior art keywords
nonwoven layers
fabric
spunbond nonwoven
layer
spunbond
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201780029138.6A
Other languages
English (en)
Inventor
M·R·汉森
S·索摩
W·K·华
T·W·维
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Reifenhaeuser GmbH and Co KG Maschinenenfabrik
Fibertex Personal Care AS
Original Assignee
Reifenhaeuser GmbH and Co KG Maschinenenfabrik
Fibertex Personal Care AS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from EP16170156.0A external-priority patent/EP3246443B1/en
Priority claimed from EP16170169.3A external-priority patent/EP3246444B1/en
Application filed by Reifenhaeuser GmbH and Co KG Maschinenenfabrik, Fibertex Personal Care AS filed Critical Reifenhaeuser GmbH and Co KG Maschinenenfabrik
Publication of CN109072513A publication Critical patent/CN109072513A/zh
Pending legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
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    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
    • D04H1/565—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres by melt-blowing

Abstract

本发明涉及无纺层压织物，其包括夹在第一纺粘无纺层和第二纺粘无纺层之间的熔喷无纺层，其中至少一个纺粘无纺层是包含卷曲的多组分纤维或者由卷曲的多组分纤维组成的高蓬松度纺粘无纺层。

Description

包含熔喷层和纺粘层的无纺层压织物
技术领域
本发明涉及一种无纺层压织物，其包含夹在第一纺粘无纺层和第二纺粘无纺层之间的熔喷无纺层。本发明还涉及制造这种织物的方法和这种织物的用途。
背景技术
包含夹在纺粘(S)层之间的熔喷(M)层的无纺织物在本领域中是已知的，并且通常被称为SMS型织物。这些织物经常用于卫生产品，例如婴儿尿布、女性护理护巾和成人失禁产品，其中对诸如尿液、月经等体液的高阻隔性是必要的。在SMS型织物中，S层负责机械性能和表面触感，M层主要负责阻隔性能。
制造纺粘无纺织物时的较新的技术是所谓的高蓬松度技术，其中纺制卷曲的(crimped)纤维并将其放置在移动的带上以获得纺粘无纺织物。由于纤维的卷曲，所得的纺粘织物比由线性纤维制成的常规纺粘织物具有更高的蓬松度。高蓬松度导致高柔软性，高柔软性也是卫生行业所期望的。在US 6,454,989 B1中描述了高蓬松度纺粘织物，其中纤维的卷曲是在使用多组分纤维时实现的，其中两种组分具有不同的熔体流动速率。在EP 2343 406 B1中描述了另一种高蓬松纺粘织物，其中纤维的卷曲是在使用多组分纤维时实现的，其中两种组分具有相似的熔体流动速率和熔点，但重均分子量分布与Z-平均的比例存在一定差异。在EP 1 369 518 B1中描述了又一种高蓬松织物，其中纤维的卷曲是在使用多组分纤维时实现的，其中一种组分是均聚物而另一种组分是共聚物。
发明内容
本发明的目的是提出一种同时具有优异的柔软性和阻隔性的无纺层压织物。
在此背景下，本发明涉及无纺层压织物，其包含夹在第一纺粘无纺层和第二纺粘无纺层之间的熔喷无纺层，其中至少一个纺粘层是包含卷曲的多组分纤维或者由卷曲的多组分纤维组成的高蓬松度纺粘无纺层。
熔喷层构成织物的芯，并且上纺粘层和下纺粘层覆盖芯的两个表面。这种织物通常被称为SMS型织物，并且包括诸如SMS、SMMS、SSMS、SSMMS、SMMMS等等变体。根据本发明，双MM或SS层是使用不同的机器在不同的位置进行熔喷纤维或纺粘纤维的两步沉积而得到的，但仍然分别被理解为熔喷层或纺粘层。在双MM或SS层中两个M或S区域可具有相同或不同的构造、重量和性质。相同的考虑适用于三重MMM或SSS层等。在一个实施方式中，第一纺粘无纺层和第二纺粘无纺层是相同的。
因此，根据本发明，包含卷曲的纤维的纺粘层与夹在纺粘层之间的标准熔喷纤维组合。已经通过实验发现，这种层压材料与没有高蓬松层的标准SMS产品相比在柔软性和阻隔性方面可以具有优异的性能。
在一个实施方式中，两个纺粘层均是包含卷曲的多组分纤维或者由卷曲的多组分纤维组成的高蓬松度纺粘无纺层。
本发明超越了在本身已知的SMS层压材料中本身已知的高蓬松度纺粘织物的简单用途。如从工作实例中明显看出的，已经发现，当高蓬松度纺粘织物用作夹层结构时，熔喷层的液体阻隔效率(以每熔喷基重的液体阻隔性表示)增加。这是令人惊讶的，因为无法预期S层的性质会影响M层的液体阻隔效率。如果有的话，预期可能会出现相反的情况，因为人们可能会认为，与层压在作为基础的更均匀的标准蓬松度S层上相比，当层压在更不均匀的高蓬度S层上时，M层的质量会变得更差。不希望受理论束缚，发明人认为，传统SMS结构中熔喷层的较低阻隔性能可能是由于整个层压材料的柔韧性较差造成的。当非柔韧性或相对非柔韧性的层压材料在液体阻隔测试期间变形时，或者甚至在实践中甚至更显著地，一些微结构可能破裂并且织物可能在断裂点处局部变得更多孔而打开先前不存在的可能的流体路径。由于卷曲的纺粘纤维结构，本发明的层压材料可具有相对较高的整体柔韧性，因此，根据该理论，微结构的破裂将会较少，因此阻隔性能较好。
考虑到，从例如织物的机械性能、熔喷层的高液体阻隔效率的角度来看，低M含量可以是有利的，因此M层在较低基重(g/m2)下保持一定液体阻隔特性的能力是非常有吸引力的。
已经观察到所描述的效果，将在如下文所述的某些优选实施方式中特别强调。
织物的各层之间的接合是通过在制造中经由结构化压延辊的机械接合来实现的。压延辊的表面结构为织物提供特定的接合模式。在所谓的接合区域中，织物被热压缩并且使得纤维牢固地彼此附着。接合区域是离散的，并且可以很好地与织物的其余未接合部分区分开。接合模式由接合区域的形状(如果是离散的，则为每表面面积的接合点的数量)来描述，以及由“接合面积”(即接合区域所占的整个织物表面的分数)来描述。以下实施方式中列出的设定已用于获得本发明的有益效果。
在一个实施方式中，织物的接合面积是10-15％并且优选地是12-14％。
在一个实施方式中，接合区域由离散的且优选为圆形的点构成，其中进一步优选地，点面积是1-5mm2或1.5-3mm2和/或点直径是0.5-1.5mm或0.7-1.0mm。
在一个实施方式中，织物每平方厘米包含20-30个且优选地22-26个点。
这些具有低接合面积的相对开放的(open)接合模式允许柔韧性产品。
如上所述，本发明在保持相同的液体阻隔性能的情况下允许降低熔喷层的(绝对和相对)基重。较低的熔喷层基重是期望的，因为在层压材料的总基重恒定下，在较低的熔喷基重下将获得更好的机械性能。以下实施方式中描述的无纺织物利用了该观察结果。
在一个实施方式中，熔喷层的基重小于4.0g/m2，优选地小于3.0g/m2且更优选地小于2.0g/m2。它可以在0.5g/m2和4.0g/m2之间或者在1.0g/m2和2.0g/m2之间。织物的总基重可以在10g/m2和20g/m2之间，优选地在13g/m2和17g/m2之间。
在一个实施方式中，熔喷层的基重占织物的总基重的5-15％且优选地8-12％。已经发现，熔喷含量低至织物的总基重的恰好10％或大约10％可获得非常好的结果。
在本发明的上下文中进一步观察到，当熔喷层的基重可以变得较小时，给定的机械设定和输出将可以生产较小直径的熔喷纤维。较小的熔喷纤维直径可以对阻隔性能具有额外的有益效果，而不会损害其他织物性能。
在一个实施方式中，熔喷层的熔喷纤维的平均直径低于3.0μm，优选地低于2.0μm，更优选地低于1.7μm。例如，熔喷层的熔喷纤维的平均直径可以在0.8μm和3.0μm之间，优选地在1.0μm和2.0μm之间。线性质量密度可以低于0.5旦尼尔，优选地低于0.3旦尼尔，更优选地低于0.2旦尼尔。
高蓬松度纺粘层的卷曲的纺粘纤维的平均直径和(如果有的话)常规纺粘层的常规纺粘纤维的平均直径可以在15μm和20μm之间。高蓬松度纺粘层的卷曲的纺粘纤维的线性质量密度和(如果有的话)常规纺粘层的常规纺粘纤维的线性质量密度可以是1.4-2.0旦尼尔。
在一个实施方式中，高蓬松度纺粘层的卷曲的纺粘纤维的平均卷曲直径是50-500μm，优选地60-150μm且更优选地80-125μm。
在一个实施方式中，高蓬松度纺粘层的密度是0.02-0.08g/cm3且优选地0.04-0.06g/cm3。
在一个实施方式中，卷曲的纤维是多组分纤维，优选地双组分纤维，并且更优选地并排或偏心的鞘芯型双组分纤维。为了获得卷曲的纺粘纤维，使用所谓的多组分或更具体地双组分技术。在双组分纤维中，在纤维的横截面上有两个不同的区域。这些区域可以并排构造或者以偏心的鞘芯型构造布置。适用于产生卷曲的其他可能的纤维构造包括三叶形、分段的饼状或海中的岛状。所有纤维构造可以是实心的或以空心布置制成。在一个实施方式中，卷曲的纤维是螺旋地卷曲的。
在一个实施方式中，纤维包含聚烯烃或者由聚烯烃组成，优选地包含如下或由如下组成：聚丙烯、聚乙烯或聚丙烯-聚乙烯-共聚物，更优选地聚丙烯。
为了在双组分纺粘纤维中产生卷曲，需要两种具有不同特性的聚合物。特性的差异可以通过例如两种聚合物之间的多分散性(Mw/Mn)差异、两种聚合物的熔点差异、两种聚合物的结晶速率差异、两种聚合物的弹性差异或者两种聚合物的熔体流动速率(MFR)差异来实现。在一个实施方式中，双组分纤维的这两种聚合物的多分散性相差至少1.2因数。
在一个实施方式中，双组分纤维中这两种不同的聚合物的重量比小于90/10，优选地小于80/20，更优选地小于70/30，还更优选地小于60/40至80/20。该比率应理解为当在纤维的代表性长度上进行平均时在横截面上的重量比。对于聚丙烯和聚丙烯-聚乙烯-共聚物的组合，优选的是在90/10和30/70之间的比例，更优选地在70/30和40/60之间的比例。
在一个实施方式中，当具有至少15g/m2的总基重和小于2g/m2的熔喷基重时，织物表现出大于160mm、优选地大于180mm且更优选地大于190mm的静水压头的值(当按照WSP80.6测量时)。
在一个实施方式中，当具有小于2g/m2的熔喷基重时，织物表现出大于100且优选地大于120熔喷效率(其定义为层压材料的总静水压头(mm)除以熔喷基重(g/m2))。
在一个实施方式中，当具有至少15g/m2的总基重且小于2g/m2的熔喷基重时，织物表现出大于15N/50mm且优选地大于17N/50mm的在机器方向上的拉伸强度的值(当根据WSP110,4测量时)。
在一个实施方式中，当具有至少15g/m2的总基重且小于2g/m2的熔喷基重时，织物表现出大于6N/50mm且优选地大于7N/50mm的在横向于机器方向上的拉伸强度的值(当根据WSP 110.4测量时)。
在一个实施方式中，当具有至少15g/m2的总基重且小于2g/m2的熔喷基重时，织物表现出大于90％的在机器方向上的拉伸伸长率的值(当根据WSP 110.4测量时)。
在一个实施方式中，当具有至少15g/m2的总基重且小于2g/m2的熔喷基重时，织物表现出大于120％的在横向于机器方向上的拉伸伸长率的值(当根据WSP 110.4测量时)。
本发明还涉及制造根据本发明的织物的方法，其包括如下步骤：(a)在移动的带上沉积纺粘纤维后，形成第一纺粘无纺层；(b)在第一纺粘无纺层的表面上沉积熔喷纤维后，形成熔喷无纺层；并且(c)在熔喷无纺层的表面上沉积纺粘纤维后，形成第二纺粘无纺层；其中至少一个且优选地两个纺粘无纺层是高蓬松度纺粘无纺层，并且其中至少一部分且优选地所有的沉积在移动的带和/或熔喷层上的纺粘纤维是卷曲的多组分纺粘纤维。
为了纺制高蓬松度纺粘无纺层，优选的是，熔融温度位于250-265℃。每个模孔的熔体产量可以被设定在0.4-0.8g/孔/分钟。淬火空气温度可以被设定在18-22℃。淬火舱压力可以被设定为3500-4000Pa。SAS间隙(即在纤维进入扩散器之前的旋转室下部中的引导板的距离)可以被选择在19-21mm之间。通过这样的设定，结合上文所描述的聚合物，可以获得非常好质量的螺旋地卷曲的纤维，并且可以观察到关于柔软性和阻隔性的突出的效果。
在对卷曲的纺粘纤维淬火和铺设之后，重要的是通过压实辊轻柔地使纤维固结。在本发明的构思内，已经发现有利的是，将压实辊的温度设定在50-90℃之间并将压实辊的线性接触力设定为小于5N/mm。
更进一步地，本发明涉及包含根据本发明的织物的卫生产品。示例性卫生产品包括成人失禁产品、婴儿尿布和卫生巾。卫生产品可进一步包括颗粒状吸收材料。根据本发明的无纺织物可以用作卫生产品的芯覆盖物的一部分并且位于不透水膜附近。合适的颗粒状吸收材料包括超吸收颗粒/聚合物(SAP)。芯材料可包含高含量(例如大于50重量％、60重量％或70重量％)的颗粒状吸收材料或仅由颗粒状吸收材料组成。高含量的颗粒状吸收材料和较低含量的副组分(例如纸浆/纤维素纤维)产生更薄和更舒适的产品，这种产品也可需要更少的货架空间和运输成本。然而，由于颗粒状吸收材料更多地暴露于后片，这可能使消费者察觉到负面感觉。当用作芯覆盖物时，根据本发明的织物的高蓬松度纺粘层可有助于改善触感和感觉。在芯中高浓度的颗粒材料也导致膜后片被颗粒状吸收材料刺穿的风险更大。当被放置在吸收芯和后片膜之间时，本发明的高蓬松度纺粘层可有助于提高抵抗这种穿刺的能力。
在卫生产品中的其它合适应用是使用本发明的产品作为阻隔腿箍(leg cuff)。本发明的材料柔软且柔韧并且还具有高静压头，这种材料非常适合用作在卫生产品例如婴儿尿布或失禁产品中的所谓的阻隔腿箍。
附图说明
将参考下面描述的工作实例和附图来描述本发明的进一步细节和优点。附图示出了：
图1：根据本发明的一个实施方式的用于生产SMS型无纺层压材料的设备的示意图；
图2：包含在这种层压材料的高蓬松度纺粘层中的卷曲的多组分纤维的一部分的示意图；以及
图3：双组分纤维的不同可能构造的示意图。
具体实施方式
图1说明了用于生产本发明的SMS型无纺层压材料的设备。具体地，该机器被构造用于生产SHMMSH型层压材料。它包括作为主要部件的移动带1、用于形成第一高蓬松度纺粘层的第一纺丝机2、用于形成第一熔喷层的第一熔喷机3、用于形成第二熔喷层的第二熔喷机4和用于形成第二高蓬松度纺粘层的第二纺丝机5。对于每个机器来说，纺丝机2和5都被构造以生产双组分纤维，分别由两个聚合物贮存器2a、2b和5a、5b表示。在每个纺丝机2和5的下游分别有预压实辊6和7。在预压实辊6-7和机器2-5的下游，有用于将层压材料的各层牢固地接合在一起的压延辊8。标号9表示两个纺丝机2和5的SAS间隙。
图2是存在于本发明的织物的高蓬松度纺粘层中的卷曲的连续纤维的一部分的示意图。卷曲的纤维部分形成具有一定卷曲半径的圆形，因而限定了一定的卷曲面积。例如，卷曲面积可以是20000-50000μm2，对应于约80-125μm的卷曲半径。
图3示出了双组分纤维的不同的可能构造的示意图。纤维包含第一和第二聚合物组分，第一和第二聚合物组分布置在沿纤维的长度连续延伸的纤维横截面内的不同区域中。在图3a中描绘了并排布置。图3b中描绘了偏心的鞘/芯型布置，其中一个组分完全包围另一个组分但是不对称地位于纤维中，以允许纤维卷曲。纤维也可以是中空的，如图3c和图3d所示，或者可以是多叶形纤维，如图3e所示。
在如图1所示的机器上已经生产了许多SH-M-M-SH层压无纺片材，以证明本发明的层压材料的有益性质。表达式SH表示由螺旋地卷曲的并排双组分纤维组成的高蓬松度纺粘层。所有片材均使用Reicofil纺粘-熔喷机制备。纺粘喷丝头具有每米约5000个孔。熔喷喷丝头是具有每英寸35-42个孔的单排模具(单排技术(Single RowTechnology))。在下面的表1中，给出了不同片材的构造的概述。
表1
实例A-D是对比例。
实例A是基于未卷曲的纤维的常规15g/m2SS无纺物，没有熔喷层。压延设定使得获得18.8％的椭圆形接合。S层各自的基重为7.5g/m2。将MFR为25的PP聚合物Sabic 511A用于S层。
实例B对应于实例A，但具有不同的压延设定，以获得具有13.6％的接合面积和每平方厘米24个点的开放的点接合。每个接合点是圆形的，且直径为0.85mm。
实例C是17g/m2 SHSH纺粘无纺织物物，其基于具有螺旋地卷曲的纤维而没有熔喷层的高蓬松度纺粘层。每个S层的基重为8.5g/m2。SH层的螺旋地卷曲的纤维包含以并排构造且50/50关系的两种不同聚合物。Sabic 511 A用于一侧。另一侧使用MFR也为25的PP/PE无规共聚物Molplen RP248R。接合与实例B中的相同。
实例D是15g/m2 SMMS无纺织物，其基于未卷曲纤维并且具有两个熔喷层，每个为1.0g/m2。每个S层的基重为6.5g/m2。接合再一次如实例B和C中所述。将MFR为800的PP聚合物Borealis HL708FB用于M层。制备M层时的设定如下：模具温度：280℃；空气温度275℃；气流：3200m3/h；模具与纺织带之间的距离：98mm。
实例1-6是本发明的实施例。
实例1是15g/m2 SHMMSH纺粘无纺织物，其基于具有螺旋地卷曲的纤维的高蓬松度纺粘层且在高蓬松度纺粘层之间具有两层熔喷纤维。SH层的螺旋地卷曲的纤维如实例C中所述。将Borealis HL708FB用于M层，如实例D中所述。每个SH层均具有6.6g/m2的基重。每个M层均具有0.9g/m2的基重。当制造M层时设定如实例D中所述。接合如实例B、C和D中所述。
实例2与实例1的不同之处在于SH层和M层的面积重量，其他方面相同。每个SH层的基重为6.7g/m2。每个M层的基重为0.8g/m2。
实例3与实例1和2的不同之处在于SH层和M层的面积重量，其他方面相同。每个SH层的基重为6.8g/m2。每个M层的基重为0.7g/m2。
实例4-6与实例1-3的不同之处在于总基重以及因而各层的基层，其他方面相同。实例4-6中总基重均为17g/m2。在实例4中，每个SH层均具有7.6g/m2的基重，并且每个M层均具有0.9g/m2的基重。在实例5中，每个SH层均具有7.7g/m2的基重，并且每个M层均具有0.8g/m2的基重。在实例6中，每个SH层均具有7.8g/m2的基重，并且每个M层均具有0.7g/m2的基重。
为了确定实例D和实例1-3的每一个中纺粘纤维和熔喷纤维两者的纤维尺寸，已经采用Phenom ProX机器和Fibermetric v2.1评价软件通过扫描电子显微镜(SEM)分析每个实例的样品，对S纤维应用400倍放大率，对M纤维应用3000倍放大率。对于各个纺粘纤维和熔喷纤维，每个实例测量了100个数据点。结果列于下表2中。
表2
参考实例D和实例1-6的所有工艺设定相同。只有熔喷纤维的等级不同。在实例D中，每个M铺层的等级为1g/m2。在实例1-3中，每个M铺层的等级分别为0.9g/m2、0.8g/m2和0.7g/m2。在实例4-6中，每个M铺层的等级再一次分别为0.9g/m2、0.8g/m2和0.7g/m2。
从结果可以看出，在其他参数恒定的情况下，特别是在恒定的气流下，降低熔喷基重的等级将导致更小的纤维直径。等级为1.0g/m2的实例D中的平均直径均为1.71μm，并且在实例1-3的组中分别随着0.9g/m2、0.8g/m2和0.7g/m2的等级降低而略微降低(1.69μm、1.55μm、1.35μm)。
对实例A-D和实例1-6中的每一个，已经进行了不同的物理性质测试。
静水压头性质测试按照WSP80,6进行。在该测试中，安装无纺织物以在测试头贮存器上形成覆盖物。然后使织物以恒定速率经受标准化的水压增加，直到在无纺织物的外表面上出现泄漏。静水压力测试的测试结果是在样品上三个独立区域中首次出现液滴时测量的。所采用的水压(水柱的高度)的增加速率为60±3cm H2O/分钟。所采用的测试头是100cm2测试头。当在试样的表面上出现三处液滴时，读取测试结果。获得的压力(水柱的高度)以毫米报告。
根据WSP 110,4测量在机器方向上的拉伸强度(TSMD)、在机器方向上的拉伸伸长率(TEMD)、在横向于机器方向上的拉伸强度(TSCD)和在横向于机器方向上的拉伸伸长率(TECD)。
根据WSP 120,6测量织物测径器数(caliper)。
结果报告于下表3中。
表3
与实例B-C的仅纺粘的SS无纺织物相比，基于未卷曲的纤维并以18.8％接合面积接合的实例A的传统的仅纺粘的SS无纺织物在TSMD和TSCD方面显示出更高的值。另一方面，实例A的伸长率值低于实例B-C的伸长率值。推测这两个观察结果都归因于较高的接合面积和未卷曲的纤维的组合应用。
实例A的静水压头测得为90.4mm，这是一个相对较低的值。这被认为是由于脆性材料具有很小的柔韧性引起的，这与低伸长率值一致，当然，原因是缺少M层。实例B表现出111mm的较高的静水压头值。据认为，这是因为材料更加柔韧，如也在伸长率值方面所见。实例C显示了117mm的也较高的静水压头值。据认为，这是因为螺旋地卷曲的单根纤维更柔韧，并且这突显了开放的点接合对静水压头的有益效果。
实例D包含熔喷层并且因此具有比其他方面类似的实例B高得多的静水压头值(167mm)。由于用熔喷材料代替一些纺粘材料，拉伸强度和伸长率性质较低。
与实例D相比，所有实例1-3表明显著更高的静水压头值，即使熔喷含量确实更低(并且拉伸强度因此更高)。据认为，与实例D相比时，实例1-3的显著更高的静水压头值的效果可归因于螺旋地卷曲的单根纤维的更高的柔韧性与开放的点接合相结合。当将实例1-3相互比较时，还可以观察到的是，随着熔喷含量的降低，静水压头变得略高。据认为，该效果可归因于：在其他参数恒定下、特别是在恒定气流下，随着熔喷基重等级下降，平均熔喷纤维直径更小，如表2中所示。
对于实例4-6的无纺织物观察到相同的趋势，其具有比实例1-3的无纺织物更高的纺粘基重(并因此含量)，但在其他方面是相同的。
以下表4给出了上述最重要发现的概览，其另外地计算了各个无纺层压材料的“熔喷效率”值，该值为层压材料的静水压头(mm)除以层压材料的总熔喷基重(g/m2)。
表4
从表4中可以看出，根据实例1-6的本发明的织物中熔喷层的熔喷效率值通常且有时显著高于每g/m2 100mm，而在对比实例D中显著低于该值。考虑到，从机械性能、柔软性水平和片材成本的角度来看，低熔喷含量是有利的，因此本发明的片材所表现出的高熔喷效率是非常期望的。
总结各实例的发现，由于外部高蓬松度纺粘层，使用本发明的无纺纤维网具有非常期望的柔软特性。同时，与具有相同或甚至更高熔喷含量的现有技术SMS结构相比，已经发现作为静水压头测量的阻隔性能更高。

Claims (10)

1.一种无纺层压织物，包含夹在第一纺粘无纺层和第二纺粘无纺层之间的熔喷无纺层，
其特征在于，
所述第一纺粘无纺层和第二纺粘无纺层中的至少一个是包含卷曲的多组分纤维或者由卷曲的多组分纤维组成的高蓬松度纺粘无纺层。
2.根据权利要求1所述的织物，其中所述第一纺粘无纺层和第二纺粘无纺层两者是包含卷曲的多组分纤维或者由卷曲的多组分纤维组成的高蓬松度纺粘无纺层。
3.根据前述权利要求中任一项所述的织物，其中所述织物的接合面积是10-15％且优选地是12-14％。
4.根据前述权利要求中任一项所述的织物，其中接合区域是由离散的且优选为圆形的点构成，其中进一步优选地，点面积为1-5mm2或1.5-3mm2和/或点直径为0.5-1.5mm或0.7-1.0mm。
5.根据权利要求4所述的织物，其中所述织物每平方厘米包含20-30个且优选地22-26个点。
6.根据前述权利要求中任一项所述的织物，其中所熔喷层的基重小于4.0g/m2，优选地小于3.0g/m2且更优选地小于2.0g/m2。
7.根据前述权利要求中任一项所述的织物，其中所述熔喷层的基重占所述织物的总基重的5-15％且优选地占所述织物的总基重的8-12％。
8.根据前述权利要求中任一项所述的织物，其中所述熔喷层的熔喷纤维的平均直径低于3.0μm，优选地低于2.0μm且更优选地低于1.7μm。
9.一种制造根据前述权利要求中任一项所述的织物的方法，包括如下步骤：
(a)在移动的带上沉积纺粘纤维后，形成第一纺粘无纺层；
(b)在所述第一纺粘无纺层的表面上沉积熔喷纤维后，形成熔喷无纺层；并且
(c)在所述熔喷无纺层的表面上沉积纺粘纤维后，形成第二纺粘无纺层；
其中至少一个纺粘无纺层且优选地两个纺粘无纺层是高蓬松度纺粘无纺层，并且其中至少一部分且优选地所有的沉积在所述移动的带和/或所述熔喷层上的所述纺粘纤维是卷曲的多组分纺粘纤维。
10.一种卫生产品，包含根据前述权利要求中任一项所述的织物。
CN201780029138.6A 2016-05-18 2017-05-18 包含熔喷层和纺粘层的无纺层压织物 Pending CN109072513A (zh)

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