CN109153220A - 包括天然纤维网层的无纺复合物及其形成方法 - Google Patents

包括天然纤维网层的无纺复合物及其形成方法 Download PDF

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CN109153220A
CN109153220A CN201680065530.1A CN201680065530A CN109153220A CN 109153220 A CN109153220 A CN 109153220A CN 201680065530 A CN201680065530 A CN 201680065530A CN 109153220 A CN109153220 A CN 109153220A
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gauze
wipe product
layer
nonwoven web
hydroentangled
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彼得·扎亚茨科夫西
约翰·C·帕森斯
卡尔蒂克·拉马拉特南
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Nutek Disposal Co Ltd
Nutek Disposables Inc
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Nutek Disposal Co Ltd
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Abstract

一种包括通过水刺缠结工艺将至少一个纸网层粘合至至少一个无纺网层的复合结构。纸网层由根据复合结构的所需的光滑度和亲水性而被加工成具有特定的卡伯值的天然纤维制成。在示例性实施方式中，纸网层由结构化纸网制成，并且纸网的结构通过水刺缠结工艺赋予无纺网层。在示例性实施方式中，复合结构是由具有至少一个天然纤维层的两层或三层结构组成的擦拭产品。在水刺缠结工艺期间使用保护层实现了用以生产由一个天然纤维网组成的双层复合网的较高的机器速度。

Description

包括天然纤维网层的无纺复合物及其形成方法
相关申请
本申请要求于2015年11月12日提交的美国临时专利申请No.62/254,528、标题为“NONWOVEN COMPOSITE INCLUDING NATURAL FIBER WEB LAYER AND METHOD OF FORMINGTHE SAME(包括天然纤维网层的无纺复合物及其形成方法)”的优先权，其全部内容通过引用并入本文。
技术领域
本发明通常涉及复合结构，并且特别地涉及意在用于擦拭产品的无纺复合结构。
背景技术
世界各地对一次性擦拭产品诸如卫生擦拭物和面部擦拭物等的需求很大。在北美市场，对以合理的价格点提供的较高质量的产品的需求日益增加。对于这样的擦拭物的消费者来说最重要的质量属性是柔软性、吸收性和强度。
常规擦拭物由无纺材料制成，以赋予擦拭物特定的强度特性。然而，无纺材料可能太粗或可能不能为最终擦拭产品提供所需的吸收性。因此，还已知的是将纸浆纤维引入无纺织物中以增加整体的柔软性和/或吸收性。将纸浆添加到无纺材料的常规方法包括将纸浆纤维在小于150mpm的速度下直接湿法成网或气流成网到纺粘材料上。提高机器速度的尝试导致复合网完整性降低、废水流中纤维(纸浆)损失过多和/或复合材料不均匀。
发明内容
本发明的一个目的是提供一种由天然纤维和无纺材料的组合制成的复合产品，其中该产品与常规产品相比具有改进的结构完整性和松密度性质(bulk property)。
本发明的另一个目的是提供一种制造由天然纤维和无纺材料的组合制成的复合产品的工艺，其中该工艺涉及使用大于150mpm的平均线速度。在本发明的示例性实施方式中使用的天然纤维网优选地具有非常高的湿强度，这使得网在展开和水刺缠结工艺期间能够承受高的机器速度。
本发明的另一目的是在水刺缠结工艺期间在纸网上使用保护层来生产由一个纸层和一个无纺网层组成的双层复合网。与常规工艺相比，保护层有助于在明显大于150mpm的较高的机器速度下用较少的喷射器(例如，在水刺缠结工艺期间4至6个喷射器)生产双层纸-无纺结构。相比之下，用于制造双层纸无纺结构的常规方法涉及在接近150mpm的低速下使用8至10个喷射器。
本发明的另一目的是提供一种由天然纤维网和纺粘/熔纺网的组合制成的擦拭产品。
根据本发明的示例性实施方式的复合结构包括至少一个纸网层和至少一个无纺网层。
在至少一种实施方式中，复合结构包括两个无纺网层，并且纸网层设置在两个无纺网层之间。
在至少一种实施方式中，至少一个无纺网层为粗疏网(carded web)。
在至少一种实施方式中，至少一个无纺网层为熔纺网。
在至少一种实施方式中，至少一个无纺网层为熔纺网、熔喷网或其组合。
在至少一种实施方式中，复合结构通过水刺缠结工艺粘合。
在至少一种实施方式中，纸网层由大麻纤维制成。
在至少一种实施方式中，纸网层为由软木和硬木浆纤维两者组成的多层网，更优选为两层或多于两层的网。
在至少一种实施方式中，纸网层包括永久湿强度添加剂。
在至少一种实施方式中，纸网层包括临时湿强度添加剂。
在至少一种实施方式中，用于形成纸网层的纤维被加工成卡伯值(Kappa number)小于100。
在至少一种实施方式中，至少一个无纺网层为熔纺无纺网层。
在至少一种实施方式中，纸网层由结构化纸网制成。
在至少一种实施方式中，复合结构为擦拭产品。
根据本发明的示例性实施方式，一种用于制造复合结构的方法包括：提供至少一个纸网层和至少一个无纺网层；以及将至少一个纸网层与至少一个无纺网层水刺缠结。
在至少一种实施方式中，纸网层由结构化纸网制成，并且水刺缠结步骤将结构化纸网的结构赋予至少一个无纺网层。
在至少一种实施方式中，结构化纸网层具有微观结构并且水刺缠结步骤将宏观结构赋予复合材料。
在至少一种实施方式中，结构化纸网层具有微观结构和宏观结构两者，然后在水刺缠结步骤期间将其完整地保存并保持在复合材料中。
附图说明
图1是根据本发明的示例性实施方式的无纺复合网的截面视图；
图2是示出根据本发明的示例性实施方式的将纺粘无纺网和纸网进行水刺缠结工艺的框图(block diagram)；
图3是示出根据本发明的示例性实施方式的将熔纺无纺网和粗疏大麻网进行水刺缠结工艺的框图；
图4是示出根据本发明的示例性实施方式的水刺缠结工艺的框图；
图5A是示出根据本发明的示例性实施方式的双滚筒水刺缠结配置的框图；
图5B是示出根据本发明的示例性实施方式的三滚筒水刺缠结配置的框图；
图5C是示出多喷射器带的水刺缠结配置的框图；以及
图5D是示出根据本发明的示例性实施方式的使用保护层的双滚筒水刺缠结配置的框图。
具体实施方式
本发明涉及使用天然纤维诸如大麻和/或木纤维，结合熔纺无纺物以产生具有天然抗微生物性质的熔纺复合材料，具有作为典型的熔喷和/或吸收性擦拭物的替代物的特定应用。天然纤维(特别是大麻纤维)的纤维加工在生产均匀的粗疏网并因此生产均匀的复合织物方面是关键因素。该纤维加工是依据卡伯值来测量，卡伯值与根据T236TAPPI标准测量的纤维脱木素程度有关。改变卡伯值导致复合网的疏水性和亲水性增加或降低。例如，具有50卡伯值的加工的大麻纤维与具有100卡伯值的未加工的大麻纤维相比将是亲水性的、精细且光滑的，具有100卡伯值的未加工的大麻纤维将会是不那么亲水、将会是粗糙的和磨蚀的。
根据本发明制造的擦拭物在没有任何明显添加杀生剂(biocide)的情况下表现出天然的抗微生物性质。此外，微调卡伯值能够使一系列的产品从高吸收性到较少吸收性和/或一系列的产品从软到磨蚀。
图1是根据本发明的示例性实施方式的通常由附图标记10表示的复合网的截面视图。网10包括夹在两个外层14和16之间的内层12。内层12是由天然纤维，优选为大麻或木纤维制成的纸网材料。两个外层14、16由无纺网材料制成。使用水刺缠结、水刺嵌入(hydro-engorging)、热轧法、粘合剂粘合或层压技术将两层或多于两层的复合网10粘合在一起。
内层12可以是结构化或非结构化的天然纤维网。天然纤维网可以使用粗疏、气流成网和或湿法成网技术制造，并具有10gsm至500gsm的基重。所使用的天然纤维包括任何植物纤维、动物纤维和/或木纤维，并且具体实例包括蕉麻、椰壳纤维、棉花、亚麻、大麻、黄麻、苎麻、剑麻、羊驼毛、安哥拉羊毛、骆驼毛、羊绒、马海毛、丝、羊毛、硬木、软木、象草纤维等。天然纤维网被化学或酶促加工成目标卡伯值小于100。具有较低卡伯值的加工的天然纤维主要用于吸收性产品，诸如ADL's、擦拭物等，而具有高卡伯值的加工的天然纤维主要用于尿布底片、尿布套、医疗市场等。
用于形成复合结构的纸网可以是单层或多层结构。纸网优选地具有高的临时和/或永久的湿强度以在随后的水刺缠结工艺期间维持结构完整性。粘结剂溶液可以在水刺缠结工艺之前喷涂到纸网上以进一步保护基片结构。通过使用结构化织物或在HE脱水带上可以在单独的预缠结工艺期间将结构赋予纸网。纸网的结构可以根据在造纸工艺期间使用的热风干燥(TAD)织物而变化。通过使用结构化织物，然后将纸网与纺粘/熔纺网结合，也可以在湿法成网工艺中将结构赋予纸浆/纸网。
无纺网材料层14、16可以由纺粘/熔纺/纺络法织物制成。所使用的无纺基底材料可以用任何可获得的热塑性聚合物纺粘、熔喷及其组合，热塑性聚合物更具体地为聚乙烯、聚丙烯、聚对苯二甲酸乙二醇酯(PET)和/或尼龙。无纺基底材料可以是粗疏和/或纺络材料，包括任何通常可获得的热塑性短纤维。
无纺复合织物具有区别于结构化天然纤维网、水刺缠结工艺中使用的图案化筛网、E-辊设计或任何其他合适的图案化技术的图案。所生产的无纺复合织物由于使用结构化的天然纤维网而具有高大/庞大的外观，并且由于与连续的合成纤维截然相反的天然纤维的离散纤维长度而具有符合额外设计的能力。在示例性实施方式中，由于纺粘和天然纤维在两侧优先存在，所以无纺复合织物具有双面性。无纺复合织物由于某些天然纤维的微观结构而可以具有抗微生物性质。
在至少一种实施方式中，无纺复合织物具有约2.0至3.0的MD/CD拉伸比范围。无纺复合织物还具有在400％至1000％范围内的增加的吸收能力。
可以使用熔纺和高湿强度纸基片的组合来生产稳定且坚固的复合网。纸网的湿强度的量是决定纺粘复合网的完整性和图案从纸基片到复合无纺材料上的转移性的关键因素之一。换句话说，湿强度的量决定了复合材料的整体强度以及其保留来自原始纸网的TAD结构/图案的能力。
用于制造复合网的水刺缠结(HE)能量的量是保留从纸网转移到整个复合网的图案的另一关键因素。较高的HE能量破坏了图案，并且复合网是光滑且平坦，而较低的HE能量产生图案化且庞大的复合材料。
可以还通过在HE工艺期间使用结构化纸(微观)和/或2或3维外壳(宏观)将微观和/或宏观尺度图案并入复合网中，以将纺粘/熔纺网与纸网结合。通过使用低强度HE能量，天然纤维网的图案被保存并被赋予至复合网。
复合网的结构可以在造纸工艺期间预先形成或者使用结构化织物/传送带网在线形成。
在示例性实施方式中，使用吻辊应用将附加处理施加至无纺复合织物。例如，软化剂用于进一步软化复合材料，并且某些水基软化化学品的摄入量由于亲水天然纤维的存在而明显较高。
以下实施例本发明的各种特征和优点的说明：
实施例1：通过在低能量下水刺缠结纸和纺粘网来生产图案化复合网的方法
使用TAD造纸机制造图案化/结构化纸网。纸网具有可购自HerculesIncorporated，Wilmington，Delaware，USA的永久湿强度的KymeneTM 821(PAE树脂)，添加量为至少6kg/ton。通过在水刺缠结工艺期间使用低的HE能量强度将纸网的图案化结构保存在复合无纺织物中。来自滚筒1的三个喷射歧管的HE能量条件为20、40、40bar，和来自滚筒2的两个喷射歧管的HE能量条件为40、40bar，如图2所示。
实施例2：通过在高HE能量下水刺缠结纸和纺粘网来生产平坦复合网的方法
将基重各为12gsm的两个相同纺粘聚丙烯网和用于制造卷纸的20gsm纸网水刺缠绕在一起以制造复合无纺织物。图1示出了纸网夹在两个纺粘网之间的网布置。
使用TAD造纸机制造图案化/结构化纸网。纸网具有永久湿强度的Kymene 821(PAE树脂)，添加量为至少6kg/ton。使用高HE能量水平在来自滚筒1的三个喷射歧管的20、100，100bar下和来自滚筒2的两个喷射歧管的150、150bar下将两个SB和纸网进行缠结，如图2所示。由于使用高HE能量水平，图案化的纸网结构在该工艺中被破坏并损失，从而形成平坦但坚固的复合无纺材料。
实施例3：生产SB-大麻-SB复合网的方法
使用纤维长度在30至60mm范围内且团块(herd)含量少于5％的未加工大麻纤维生产25gsm的大麻粗疏网。然后，将大麻网与基重各为12gsm的两个相同的纺粘网水刺缠结，如图3所示。用于缠结两个SB和大麻网的HE能量水平为针对滚筒1的三个喷射歧管20、80，80bar和来自滚筒2的3个喷射歧管100、100bar，如图3所示。
实施例4：使用纺粘机制造3层图案化复合网的方法。
在具有附加的水刺缠结单元和用于展开纸卷的展开单元的纺粘/SMS机器(可从德国Reicofil of Troisdorf购得)上制造三层复合网。使用TAD造纸机生产的40gsm的三层纸网在两个纺粘束(spunbond beam)之间展开并随后被水刺缠结以制造复合产品。使用TAD造纸机生产的三层纸网是图案化/结构化的网。纸网具有永久湿强度的KymeneTM 821(PAE树脂)，添加量为至少6kg/ton。使用Exxon 3155聚丙烯树脂制造每个纺粘层，并且每个层的基重为12.5gsm。如图4所示，网在被馈入HE单元之前，使用热轧单元定位粘合。顶部和底部轧辊温度均为129℃，并且压区压强(nip pressure)处于25dN/cm。图4中所示出的HE单元被用于将3层网水刺缠结在一起。来自滚筒1的喷射歧管中的一个和滚筒2的两个喷射歧管的HE能量条件为180、240和240bar，靶向1Kwh/kg的HE能量通量。在滚筒1上使用标准MPC-100外壳，并且在滚筒2上使用910p外壳以使复合网图案化。两个外壳均由法国的Andritz of Montbonnot供应。平均纺带(spinbelt)速度为167mpm，并且干燥器温度为130℃。使用该实施例生产的产品具有清晰的三维结构，其具有明显的点(910p外壳图案)和～400％的吸水能力。
实施例5
利用夹在两个无纺网之间的35gsm的纸网制成三层复合网。无纺网中的一个由多层、连续长丝、聚丙烯无纺物制成，重量为10gsm，并与涂有表面活性剂以赋予亲水性的传统18％接触面积(land area)的椭圆形粘合图案热粘合。另一无纺网由多层、连续长丝、聚丙烯无纺物制成，重量为15gsm，并与包含软添加剂聚丙烯树脂制剂的传统18％接触面积的枕形粘合图案轻微热粘合。使用TAD造纸机制造纸网。纸网由3层构成。至流浆箱的每层的流量约占总片材(total sheet)的33％。成品纸网的三层从上至下被标记为空气、核心和干燥。空气层是放置在TAD织物上的外层，干燥层是最靠近扬克式(Yankee)干燥器表面的外层，并且核心是纸巾的中心部分。在所有层中用100％软木纤维制造纸巾。在风机泵送所有样品之前，通过在厚坯(stock)中加入腐蚀剂将流浆箱pH控制到7.0。通过加入添加量为至少6kg/ton的永久湿强度的Kymene 821(Solenis供应的PAE树脂)来生产纸网。同样在1kg/ton的添加率下将干强度添加剂Redibond 2038(Corn Products，10Finderne Avenue，Bridgewater，New Jersey 08807)添加至核心层。图5B中所示的HE单元用于水刺缠结三个层(两个无纺网和一个纸网)以形成复合结构。来自滚筒1的喷射歧管中的两个的HE能量条件为120和160bar；来自滚筒2的喷射歧管中的两个的HE能量条件为180和210bar；以及来自滚筒3的喷射歧管中的两个的HE能量条件为190和200bar。在所有三个滚筒1、2和3上使用标准MPC-100外壳(由法国Andritz of Montbonnot供应)以使复合网图案化。生产复合结构期间的平均线速度为200mpm。
实施例6
使用实施例5中描述的相同工艺形成复合网，除了平均线速度为250mpm并且HE能量条件被改变以使来自滚筒3的喷射歧管中的两个的压力为200和230。
实施例7
使用实施例5中描述的相同方法形成复合网，除了两个无纺网均由多层、连续长丝、聚丙烯无纺物制成，重量为15gsm，并且与含有软添加剂聚丙烯树脂制剂的传统18％接触面积的枕形粘合图案轻微热粘合，平均线速度为150mpm，HE能量条件被改变，使得来自滚筒3的两个喷射歧管的压力为200和200，以及在滚筒3上使用标准9010P外壳(由法国的Andritz of Montbonnot供应)。
实施例8
使用实施例7中描述的相同方法形成复合网，除了平均线速度为200mpm并且在滚筒3上使用100MPC外壳。
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在所有实施例5-9中，所生产的复合网都表现出优异的层压和结构完整性。复合网的其它材料性质在表1中提供，并使用以下测试方法获得：
拉伸测试方法：WSP 110.4(05)B，握持距离为100mm
柔软度测试(Handle-O-Meter)：INDA IST 90.3-95，样品尺寸为4”x 4”
吸收能力：测试程序如下：
a.用10cm×10cm的模切机切割样品
b.对样品称重并记录初始重量
c.将样品浸泡在含有150+mL水的250mL烧杯中；使用玻璃搅拌棒完全浸没样品
d.启动计时器–使样品浸没1分钟
e.1分钟后用镊子移出样品
f.垂直悬挂样品以干燥1分钟。(在仍悬挂以除去任何积聚的流体的同时在样本的底部边缘移动手指)。
g.1分钟后对样品称重并记录最终重量
h.计算：
i.容量，以流体克数/材料克数计
ii.最终重量-(减)初始重量÷(除以)初始重量x 100
表1
根据本发明的另一示例性实施方式，在水刺缠结工艺期间利用充当保护层的牺牲层或保护筛网形成双层复合网。例如，如图5D所示，在水刺缠结期间，在水射流和复合结构之间传送保护筛网100，以保护复合结构。保护筛网100可以是例如合成聚合物筛网。可替代地，如果使用牺牲层，则除去在水刺缠结工艺之后残留的牺牲层部分以生产双层复合网。在优选实施方式中，如果使用三滚筒水刺缠结工艺，则牺牲层仅在三个滚筒的一个处直接暴露于射流以避免过度缠结。
根据本发明的另一示例性实施方式，通过将纸网和熔纺网同时展开到水刺缠结单元中来生产双层复合网，如图5D所示。可替代地，也可以将纸网直接展开到在熔纺机上在线生产的熔纺网层上，然后被馈入水刺缠结单元中，如图5D所示。在这两种情况下，纸网位于熔纺层的上部，并夹在保护筛网和熔纺网层之间。
以下实施例涉及根据本发明示例性实施方式的牺牲层的使用：
实施例10
使用实施例6中描述的相同工艺来形成复合网，除了在水刺缠结工艺中将无纺层中的一个用作牺牲层。最终的复合网产品(在250mpm的线速度下生产)具有48.7gsm的基重、0.49mm的厚度、492％的吸收能力、945g/cm的MD拉伸强度、376g/cm的CD拉伸强度以及25.7g的CD柔软度测试(CD Handle-O-Meter)。
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尽管在前面的说明书中阐述了本发明的具体实施方式的详细描述，但应该理解在不背离本发明的精神和范围的情况下，本领域技术人员可以显著改变本文给出的许多细节。

Claims (25)

1.一种擦拭产品，包括：
复合结构，所述复合结构包括至少一个纸网层和至少一个无纺网层。
2.根据权利要求1所述的擦拭产品，其中，所述复合结构包括两个无纺网层，并且所述纸网层设置在所述两个无纺网层之间。
3.根据权利要求1所述的擦拭产品，其中，所述至少一个无纺网层为粗疏网。
4.根据权利要求1所述的擦拭产品，其中，所述至少一个无纺网层为熔纺网。
5.根据权利要求1所述的擦拭产品，其中，所述至少一个无纺网层为熔纺网、熔喷网或其组合。
6.根据权利要求1所述的擦拭产品，其中，所述复合结构通过水刺缠结工艺结合。
7.根据权利要求1所述的擦拭产品，其中，所述至少一个纸网层由大麻纤维制成。
8.根据权利要求1所述的擦拭产品，其中，所述至少一个纸网层为由软木和硬木浆纤维两者组成的多层网。
9.根据权利要求1所述的擦拭产品，其中，所述至少一个纸网层包括永久湿强度添加剂。
10.根据权利要求1所述的擦拭产品，其中，所述至少一个纸网层包括临时湿强度添加剂。
11.根据权利要求1所述的擦拭产品，其中，用于形成所述至少一个纸网层的纤维被加工成卡伯值小于100。
12.根据权利要求1所述的擦拭产品，其中，所述至少一个纸网层由结构化纸网制成。
13.根据权利要求1所述的擦拭产品，其中，所述复合结构具有2.0至3.0的MD/CD拉伸比范围。
14.根据权利要求1所述的擦拭产品，其中，所述复合结构具有在400％至1000％的范围内的吸收能力。
15.一种形成擦拭产品的方法，包括：
提供至少一个纸网层和至少一个无纺网层；以及
将所述至少一个纸网层与所述至少一个无纺网层水刺缠结以形成复合结构。
16.根据权利要求15所述的方法，其中，所述至少一个纸网层由结构化纸网制成，并且所述水刺缠结步骤将所述结构化纸网的结构赋予所述至少一个无纺网层。
17.根据权利要求15所述的方法，其中，所述擦拭产品使用大于150mpm的平均线速度形成。
18.根据权利要求15所述的方法，其中，所述擦拭产品使用150mpm至250mpm的平均线速度形成。
19.根据权利要求15所述的方法，其中，所述水刺缠结步骤包括将所述至少一个纸网层和所述至少一个无纺网层传送到两个或多于两个水刺缠结滚筒上。
20.根据权利要求15所述的方法，其中，所述复合结构为包括纸网层和无纺网层的双层结构。
21.根据权利要求20所述的方法，其中，所述水刺缠结步骤包括：
为所述纸网层和所述无纺网层提供保护层。
22.根据权利要求21所述的方法，其中，所述保护层为牺牲层。
23.根据权利要求21所述的方法，其中，所述保护层为保护筛网。
24.根据权利要求21所述的方法，其中，所述方法在150mpm至500mpm的机器速度下进行。
25.根据权利要求21所述的方法，其中，所述方法在250mpm至300mpm的机器速度下进行。
CN201680065530.1A 2015-11-12 2016-11-14 包括天然纤维网层的无纺复合物及其形成方法 Pending CN109153220A (zh)

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