CN111247280A - 具有改善的性能的纤维片材 - Google Patents
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Abstract
一种用于生产泡沫形成的多层基材的方法,包括:生产包含至少3重量%的非直合成粘结纤维的水基泡沫,其中所述非直合成粘结纤维具有大于2mm的平均长度;由所述水基泡沫和纤维素纤维层一起形成湿片材层,其中所述纤维素纤维层包含至少60重量%的纤维素纤维;以及干燥合并的层以获得所述泡沫形成的多层基材。多层基材包括第一层,所述第一层包含平均长度大于2mm的至少60重量%的非直合成粘结纤维;以及第二层,所述第二层包含至少60重量%的纤维素纤维,其中所述第一层与所述第二层成面对关系,并且其中所述多层基材具有至少60%的湿/干拉伸比。
Description
背景技术
许多薄纸产品如面巾纸、卫生纸、纸巾、工业擦拭物等是根据湿法成网工艺生产的。湿法成网幅材是通过将纸浆纤维的水性悬浮液沉积到成形织物上,然后去除新形成的幅材中的水而制成的。通常通过将水机械地压出幅材而将水从幅材中去除,这被称为“湿压”。尽管湿压是一种有效的脱水过程,但在该过程中,薄纸幅材被压缩,导致幅材的厚度和幅材的松厚度明显减小。
然而,对于大多数应用,期望在不损害其他产品属性的情况下为最终产品提供尽可能高的强度。因此,本领域的技术人员设计了各种方法和技术以增加湿法成网幅材的强度。使用的一种过程被称为匆促转移。在匆促转移过程中,幅材从第一移动织物转移到第二移动织物,其中第二织物以比第一织物慢的速度移动。匆促转移过程增加了薄纸幅材的松厚度、厚度和柔软性。
作为湿压方法的替代方案,已经开发了穿透干燥方法,其中尽可能地避免幅材压缩,以保持和增强幅材。这些方法提供了对粗网眼织物上的幅材的支撑,同时使加热的空气通过幅材以去除水分并干燥幅材。
然而,仍然需要本领域的其他改进。具体地讲,目前需要一种改进的方法,该方法包括在薄纸幅材中包含独特的纤维以增加幅材的松厚度、柔软性、强度和吸收性,而不必使幅材经受匆促转移过程或起绉过程。
发明内容
一般来讲,本公开涉及薄纸和造纸领域的进一步改进。通过本公开的工艺和方法,可以改善薄纸幅材的特性,例如松厚度、强度、拉伸率、厚度和/或吸收性。具体地讲,本公开涉及用于在泡沫形成过程中形成非织造幅材,特别是含有纸浆纤维的薄纸幅材的方法。例如,可以形成纤维的泡沫悬浮液并将其铺展在移动的多孔传送机上以制备初期幅材。
在一个方面,例如,本公开涉及在第一特定方面,一种用于生产泡沫形成的多层基材的方法包括:生产包含至少3重量%的非直合成粘结纤维的水基泡沫,其中该非直合成粘结纤维具有大于2mm的平均长度;由水基泡沫和纤维素纤维层一起形成湿片材层,其中纤维素纤维层包含至少60重量%的纤维素纤维;以及干燥合并的层以获得所述泡沫形成的多层基材。
在另一方面,多层基材包括第一层,该第一层包含平均长度大于2mm的至少60重量%的非直合成粘结纤维;以及第二层,该第二层包含至少60重量%的纤维素纤维,其中第一层与第二层成面对关系,并且其中多层基材具有至少60%的湿/干拉伸比。
在又一方面,多层基材包括第一层,该第一层包含平均长度大于2mm的至少60重量%的非直合成粘结纤维,其中该非直合成粘结纤维具有三维卷状或卷曲结构,并且是皮-芯双组分纤维;以及第二层,该第二层包含至少60重量%的纤维素纤维,其中第一层与第二层成面对关系,其中多层基材具有至少60%的湿/干拉伸比,并且其中多层基材比具有相同纤维组成的均匀纤维基材表现出更高的柔软性和吸收性。
本公开的其他特征和方面在下文更详细地讨论。
附图说明
通过参考以下说明、所附权利要求书和附图,本公开的前述及其他特征和方面以及实现它们的方式将变得更显而易见,并且本公开本身将得到更好的理解,其中:
图1是在简化的薄纸生产线上将泡沫形成的湿片材从成形线材转移到干燥线材上的示意图;并且
图2是比较分层式与非分层式基材对湿/干几何平均拉伸(GMT)比的影响的图形说明。
在本说明书和附图中反复使用参考字符旨在表示本公开相同或类似的特征或元件。附图是表示性的,并且未必按比例绘制。图中的某些比例可能被放大了,而其他部分则可能被最大程度缩小了。
具体实施方式
本领域的普通技术人员应当理解,本讨论仅是对本公开的示例性方面的描述,并且不旨在限制本公开的更广泛的方面。
通常,本公开涉及具有良好松厚度、强度、吸收性和柔软性特性的薄纸或纸幅的形成。通过本公开的方法,可以形成薄纸幅材,例如具有更好的拉伸特性、改进的吸收性能、增加的厚度和/或增加的柔软性的薄纸幅材。在一个方面,还可以形成图案化幅材。在另一方面,例如,根据本公开制造薄纸幅材,包括使用纤维的发泡悬浮液。
高湿强度对于毛巾产品来说很重要,要使其具有足够的强度以在手干燥或擦去水分时保持在一起。标准毛巾片材力求具有约40%的湿/干拉伸力,以具有足够的湿强度以成功地工作。为了达到毛巾的该湿强度水平,使用了精制且湿强度和干强度的化学物质。泡沫形成过程为能够将非传统纤维添加到薄纸制造过程中提供了机会。通常在常规的湿法成网工艺中会保持成束的纤维,诸如较长长度的合成纤维,现在可以通过泡沫气泡进行悬浮和分离,从而使泡沫形成过程不仅能够用非标准湿法成网纤维制造新型材料,还能提供性能增强的基片。此外,泡沫形成允许使用非直合成粘结纤维。
如本文所用“非直”合成粘结纤维包括弯曲的、正弦的、波状的、短波的、U形的、V形的合成粘结纤维(如下所述),其中角度大于15°但小于180°,弯曲的、折叠的、卷曲的、褶皱的、扭曲的、起皱的、有标记的、双标记的、任意标记的、限定标记的、未限定标记的、分裂的、双分裂的、多叉尖的、双多叉尖的、钩状的、互锁的、锥形的、对称的、不对称的、指状的、有纹理的、螺旋形的、环状的、叶状的、花瓣状的或刺状的。长的非直纤维具有本文所述的优点,但是在通常仅使用纤维长度小于5mm且通常小于3mm的木浆纤维素纤维的典型湿法成网工艺中可能难以使用。合适的非直合成粘结纤维的一个实例是可从Trevira获得的T-255合成粘结纤维。T-255合成粘结纤维是具有聚对苯二甲酸乙二醇酯(PET)芯和聚乙烯(PE)皮的非直且卷曲的双组分纤维。
如上所述的泡沫形成过程具有许多优点和益处。在泡沫形成过程中,用泡沫(即,气泡)代替水作为形成幅材的纤维的载体。代表大量空气的泡沫与造纸纤维共混。由于形成幅材所使用的水较少,因此干燥幅材所需的能量也较少。例如,相对于传统的湿压过程,在泡沫形成过程中干燥幅材可以使能量需求减少大于约10%,或例如大于约20%。
泡沫形成技术已经证明其能够为产品带来许多益处,包括改善纤维均匀性、减少工艺中的水量、由于减少水量和表面张力而减少干燥能量、改进能够将长短纤维和/或粘结纤维以及非常短的细纤维引入常规湿法成网工艺的处理极长或极短纤维的能力,以及增强扩大一种工艺以能够生产从高密度到非常低密度的多种材料以覆盖多种产品应用的堆积/降低的密度。
使用高速混合器和表面活性剂进行的台架实验产生非常低密度(0.008至0.02g/cc之间)的泡沫形成的纤维材料。基于这些结果,可以使用低成本但高速的湿法成网工艺来生产空气形成的、3D结构的非织造类纤维材料。先前使用典型的泡沫形成生产线来生产这种低密度纤维材料的尝试没有产生令人满意的结果。两种方法均具有设备限制,阻止了生产低密度或高松厚度的泡沫形成纤维材料。一种方法缺乏干燥能力,因此必须使用高压压力机尽可能多地从形成的湿片材上除去水以获得湿片材完整性,使得可片材可以被卷到辊上。另外,另一种方法没有压力辊,但是具有连续的干燥通道。尽管后一种方法似乎具有生产低密度纤维材料的潜力,但在将泡沫形成的湿片材在干燥通道内干燥之前,必须将其从成形织物转移到干燥的金属丝上。同样,为了获得足够的湿片材完整性以进行该转移,必须在该转移之前通过真空将泡沫形成的片材尽可能多地脱水。因此,湿片材内部的大部分残留气泡也被真空除去,得到最终的干燥片材,其密度与通过正常湿法成网工艺生产的片材的密度相似。
进一步的实验结果发现,添加非直合成粘结纤维降低了最终的纤维片材密度。
不受限于理论,认为分层式结构的非直合成粘结纤维有助于实现高湿/干拉伸比。卷曲的(非粘结)纤维的现有技术用途的目的是实现高松厚度。本公开的非直合成粘结纤维不能很好地实现高松厚度。虽然现有技术需要具有至少4分特纤维直径的卷曲的(非粘结)纤维,但是本公开的非直合成粘结纤维不具有这种要求。例如,下述实施例中使用的一种非直合成粘结纤维具有2.2分特的纤维直径。
根据本公开,泡沫形成过程与独特的纤维添加相结合,以制备具有所需特性平衡的幅材。
在一个方面,在形成根据本公开的薄纸或纸幅时,首先通过将水与发泡剂组合来形成泡沫。发泡剂例如可以包括任何合适的表面活性剂。在一个方面,例如,发泡剂可包括阴离子表面活性剂,诸如月桂基硫酸钠,其也称为月桂基聚氧乙烯醚硫酸钠和月桂基醚硫酸钠。其他阴离子发泡剂包括十二烷基硫酸钠或月桂基硫酸铵。在其他方面,发泡剂可以包括任何合适的阳离子、非离子和/或两性表面活性剂。例如,其他发泡剂包括脂肪酸胺、酰胺、氧化胺、脂肪酸季化合物、聚乙烯醇、聚乙二醇烷基醚、聚氧乙烯山梨糖醇酐烷基酯、葡糖苷烷基醚、椰油酰胺丙基羟基磺基甜菜碱、椰油酰胺丙基甜菜碱、磷脂酰乙醇胺等。
发泡剂通常以大于约0.001重量%的量、例如大于约0.005重量%的量、例如大于约0.01重量%的量、或例如大于约0.05重量%的量与水组合。发泡剂还可以通常以小于约0.2重量%的量、例如小于约0.5重量%的量、例如小于约1.0重量%的量、或例如小于约5重量%的量与水组合。一种或多种发泡剂通常以小于约5重量%的量、例如小于约2重量%的量、例如小于约1重量%的量、或例如小于约0.5重量%的量存在。
一旦将发泡剂和水混合,就将混合物与非直合成粘合剂纤维混合。通常,可以使用能够制备根据本公开的薄纸或纸幅或其他相似类型的非织造织物的任何非直合成粘结纤维。
粘结纤维可以用于本公开的泡沫形成的纤维结构中。粘结纤维可以是热塑性双组分纤维,诸如PE/PET芯/皮纤维,或者是水敏聚合物纤维,诸如聚乙烯醇纤维。商用粘结纤维通常是具有两种不同熔融聚合物的双组分热塑性纤维。该双组分纤维中使用的两种聚合物通常具有完全不同的熔点。例如,在PE/PET双组分纤维中,PE具有120℃的熔点,PET具有260℃的熔点。当将该双组分纤维用作粘结纤维时,包括PE/PET纤维的泡沫形成纤维结构可通过在略高于120℃的温度下进行热处理而稳定,使得PE纤维部分将熔融并与其他纤维形成纤维间粘结,同时PET纤维部分提供其机械强度以保持纤维网络完整。双组分纤维的两种聚合物组分可以具有不同的形状,诸如,面-面、芯-皮、偏心芯-皮、海中岛状等。芯-皮结构是商用粘结纤维应用中最常用的。商用粘结纤维包括购自Trevira或WL的具有6或12mm纤维长度和2.2分特纤维直径的T-255粘结纤维、购自FiberVisions的具有4mm纤维长度和1.7分特纤维直径的Adhesion C粘结纤维。待添加的粘结纤维的阈值量通常取决于渗滤理论预计将提供纤维网络的最小值。例如,对于6mm、2.2分特的T-255纤维,渗滤阈值为约3%(按质量计)。
一旦发泡剂、水和纤维组合,就将混合物共混或以其他方式经受能够形成泡沫的力。泡沫通常是指多孔基质,其是可以相互连接以形成通道或毛细管的中空单元或气泡的聚集体。
泡沫密度可根据具体应用和各种因素而变化,包括所用的纤维配料。在一个方面,例如,泡沫的泡沫密度可以大于约200g/L,例如大于约250g/L,或例如大于约300g/L。泡沫密度通常小于约600g/L,例如小于约500g/L,例如小于约400g/L,或例如小于约350g/L。在一个方面,例如,使用泡沫密度通常小于约350g/L、例如小于约340g/L、或例如小于约330g/L的较低密度泡沫。泡沫的空气含量通常将大于约40%,例如大于约50%,或例如大于约60%。空气含量通常小于约80体积%,例如小于约75体积%,或例如小于约70体积%。
为了形成幅材,将泡沫与选定的纤维配料和任何辅助剂组合。泡沫可以通过任何合适的方法形成,包括在共同待决的美国临时专利申请序列号62/437974中描述的方法。
通常,任何能够形成纸幅的方法也可用于本公开中。例如,本公开的造纸工艺可利用起绉、双起绉、压花、空气加压、起绉通风干燥、不起绉通风干燥、适形、水力缠结以及本领域已知的其他步骤。
标准工艺包括一条泡沫形成生产线,该泡沫形成生产线设计用于处理长短纤维,并能够与其他组分实现非常均匀的纤维混合。然而,由于如上所述的设备限制,其不被设计用于生产高松厚度纤维材料。图1示出了简化的薄纸生产线,并证明了使用该工艺来生产合成纤维材料的困难,其中片材在两条生产线之间转移。在该生产线中,通过流浆箱35在成形线材30上形成泡沫状的纤维材料或湿片材20,其中当湿片材20刚被放置在成形线材30上时,其具有三层不同组成的纤维材料。然后,使湿片材20经受真空以去除尽可能多的水,使得当湿片材20行进到第一成形线材30的末端时,其获得足够的完整性或强度以允许湿片材20被转移到干燥线材40。
在成形线材30与干燥线材40之间存在接触点50,在该接触点处,湿片材20从成形线材30被转移到干燥线材40。在湿片材20被转移到干燥线材40之后,湿片材20保持与干燥线材40接触,但是如果湿片材20不具有足够的粘附力来克服重力,则会从该干燥线材上掉落。在转移之后,湿片材20被定位在干燥线材40的下方。在湿片材20到达空气穿透干燥(TAD)干燥器或其他合适的干燥器(未示出)之前,需要将其粘附到干燥线材40上。当湿片材20包含大部分纤维素纤维时,湿片材20具有保持足够的水分的吸水能力,使得湿片材20粘附到干燥线材40上而不会由于重力而从干燥线材40上掉落。当湿片材20包含太多的合成纤维,例如大于30%时,湿片材20由于重力而开始从干燥线材40上掉落或分离。在该方法中,当包含超过30%的合成纤维时,湿片材20不具有足够的粘附力以保持片材粘附在图1所示的干燥线材40上。
因此,当前的工艺阻止了具有超过30%的合成纤维的任何泡沫状材料的生产。因此,需要一种改进的方法或一种新的纤维组合物来生产具有高湿/干拉伸比的泡沫形成的片材。本公开通过形成具有两个外层和一个中心层的分层式湿片材20来解决这种不足,所述两个外层包含大部分纤维素纤维,所述中心层包含大部分合成粘结纤维。这种改进的方法克服了弱的线材粘附问题,同时实现了许多益处。首先,粘结纤维可以在中心层中浓缩到几乎100%,以形成完全粘结的纤维网络,从而获得高强度,同时保持总合成纤维部分低于50%,或甚至低于30%,使得最终薄纸保持以纤维素纤维为基础。非分层式结构无法实现这一点。其次,分层式结构产生不均匀的粘结点分布。大多数粘结是在粘结纤维本身之间的中心层内形成的,而位于两个外层中的纤维素纤维之间仅有轻微的粘结。这种布置使薄纸表现出高强度、高湿/干拉伸比、高松厚度、高吸收性和显著增强的整体柔软性。
本文所述的所有薄纸片材均以不起绉空气穿透干燥(UCTAD)模式制造。UCTAD工艺使用真空将湿片材从一种织物转移到另一种织物,如图1所示。从先前的泡沫形成试验得知,在均匀片材中添加超过约30%的合成纤维会影响片材的转移能力。这是由于在片材中没有足够的水用于真空以起作用。在本公开中,通过使用常规湿法成网工艺参数(使用标准的泵和设置从成浆池流出的纸浆)制造具有用于一个或多个外层的纤维素纤维的多层基材来解决该缺点,其中泡沫形成了中心层(从卸料池流出,其中通过添加表面活性剂并混合产生非直合成粘结纤维的泡沫浆料)。由于细小纤维保持更多的水,因此细小纤维素外层保持足够的水以允许片材转移。对于本公开,泡沫形成具有多至80%的非直合成粘结纤维的层用于中心层。
在本公开的多个方面,多层基材可包括一个纤维素纤维外层(通过湿法成网或其他工艺)和一个泡沫形成的合成粘结纤维中间层,或两个纤维素纤维外层(通过湿法成网或其他工艺)和一个泡沫形成的合成粘结纤维中间层。如果可以获得额外的益处,则一个或两个外层也可以是泡沫形成的并且还包含低百分比的合成纤维。优选的方面包括至少一个泡沫形成的层,并且包括高百分比的合成粘结纤维,以使多层基材具有高湿/干拉伸比。优选的方面还包括至少一个外层,该外层在片材转移之后保持与干燥线材40直接接触,其中至少一个外层包含高百分比的纤维素纤维,以在处理过程中具有足够的片材-线材粘附力。添加到多层基材中的其他层可以具有泡沫形成层和湿法成网层的任何组合,并且可以包括任何量的纤维素和/或合成纤维。
多层基材的一个或多个层可以包含纤维素纤维,包括在标准薄纸制造中使用的那些。适用于制造薄纸幅材的纤维包括任何天然和/或合成的纤维素纤维。天然纤维可包括但不限于非木质纤维,诸如棉、马尼拉麻、洋麻、印度草、亚麻、茅草、秸秆、黄麻、甘蔗渣、马利筋绒纤维、竹纤维和菠萝叶纤维;以及木质或纸浆纤维,诸如从阔叶树和针叶树获得的那些,包括软木纤维,诸如北方和南方软木牛皮纸纤维;以及硬木纤维,诸如桉树、枫树、桦树和山杨。纸浆纤维可以高收率或低收率形式制备,并且可以任何已知方法(包括牛皮纸、亚硫酸盐、高收率制浆方法)和其他已知制浆方法进行制浆。也可以使用由有机溶剂制浆方法制备的纤维。
纤维的一部分,例如按干重计至多50%或更少,或按干重计约5%至约30%,可以是合成纤维。再生或改性纤维素纤维类型包括所有品种的人造丝和其他来源于粘胶或化学改性纤维素的纤维。可以使用经化学处理的天然纤维素纤维,诸如丝光纸浆、化学硬化或交联的纤维、或磺化纤维。为了在使用造纸纤维时实现良好的机械特性,可能期望纤维相对不受破坏并且大部分未精制或仅轻微精制。虽然可以使用再生纤维,但原生纤维通常因其机械特性和不含污染物而可用。可以使用丝光纤维、再生纤维素纤维、由微生物产生的纤维素、人造丝以及其他纤维素材料或纤维素衍生物。合适的造纸纤维还可包括再生纤维、原生纤维或它们的混合物。在能够实现高松厚度和良好的压缩特性的某方面,纤维可具有至少200、更具体地讲至少300、更具体地讲至少400并且最具体地讲至少500的加拿大标准游离度。
可用于本公开的其他造纸纤维包括次等纸张或再生纤维以及高收率纤维。高收率纸浆纤维是通过制浆工艺制造的那些造纸纤维,这些制浆工艺提供约65%或以上、更具体地讲约75%或以上、还更具体地讲约75%至约95%的收率。收率是以初始木材质量的百分比表示的所得加工纤维的量。这样的制浆工艺包括漂白化学热磨机械浆(BCTMP)、化学热磨机械浆(CTMP)、压力/压力热磨机械浆(PTMP)、热磨机械浆(TMP)、热磨机械化学浆(TMCP)、高收率亚硝酸盐纸浆以及高收率牛皮纸浆,所有这些纸浆使所得纤维具有高水平的木质素。高收率纤维因其在干燥和湿润两个状态下相对于典型的化学制浆纤维的刚度而为人们熟知。
其他任选的化学添加剂也可以加入到含水造纸配料或所形成的初期幅材中以赋予产品和工艺额外的益处。包括以下材料作为可施加到幅材上的其他化学品的实例。这些化学品作为实例,并非意在限制本公开的范围。此类化学品可以在造纸工艺中的任何时间添加。
可以添加到纸幅中的其他化学品类型包括但不限于通常呈阳离子、阴离子或非离子表面活性剂、湿润剂和增塑剂形式的吸收性助剂诸如低分子量聚乙二醇和多羟基化合物诸如甘油和丙二醇。提供皮肤健康益处的材料诸如矿物油、芦荟提取物、维生素E、有机硅、一般乳液等也可以掺入成品中。
通常,本公开的产品可以与任何已知的材料和化学品结合使用,所述材料和化学品不与其预期用途对立。此类材料的实例包括但不限于气味控制剂,诸如气味吸收剂、活性炭纤维和颗粒、婴儿用爽身粉、小苏打、螯合剂、沸石、香料或其他气味掩盖剂、环糊精化合物、氧化剂等。也可以使用超吸收颗粒。附加选项包括阳离子染料、荧光增白剂、湿润剂、润肤剂等。
根据本公开制备的薄纸幅材的基重可根据最终产品而变化。例如,该方法可用于生产卫生纸、面巾纸、纸巾、工业擦拭物等。通常,薄纸产品的基重可以在约6gsm至约120gsm、或例如约10gsm至约90gsm之间变化。例如,对于卫生纸和面巾纸,基重可在约10gsm至约40gsm的范围内。另一方面,对于纸巾,基重可在约25gsm至约80gsm的范围内。
薄纸幅材的松厚度也可以在约3cc/g至约30cc/g、或例如约5cc/g至15cc/g之间变化。片材“松厚度”计算为以微米表示的干燥薄纸片材的厚度除以以克每平方米表示的干燥基重的商。所得片材松厚度以立方厘米每克表示。更具体地讲,厚度被测量为十个代表性片材的叠堆的总厚度并将叠堆的总厚度除以十,其中叠堆内的每个片材被放置为相同侧朝上。根据TAPPI测试方法T411 om-89“Thickness(caliper)of Paper,Paperboard,andCombined Board”中针对叠堆片材的说明3,测量厚度。用于实施T411 om-89的测微计为可得自Emveco,Inc.,Newberg,Oregon的Emveco 200-A薄纸厚度测试仪。该测微计的负荷为2.00千帕斯卡(132克每平方英寸),压脚面积为2500平方毫米,压脚直径为56.42毫米,停留时间为3秒,并且下降速率为0.8毫米每秒。
在多层产品中,产品中存在的每个薄纸幅材的基重也可以变化。通常,多层产品的总基重通常与上述相同,例如约15gsm至约120gsm。因此,每层的基重可为约10gsm至约60gsm,或例如约20gsm至约40gsm。
实施例
对于本公开,使用标准的三层流浆箱制备基片。这种流浆箱结构允许生产分层和均匀(所有纤维类型在整个片材中混合在一起)结构。两种片材结构均被制成以支持本公开。
本公开的实施例包括使用常规湿法成网工艺参数(使用标准的泵和设置从成浆池流出的纸浆)的具有100%纤维素作为外层的分层式片材。中心层是泡沫形成的,从卸料池流出,在该卸料池处通过添加表面活性剂并混合而产生100%T-255合成粘结纤维的泡沫浆料。泡沫形成多至40%的合成纤维层用于中心层。
在表1中描述了针对本公开生成的不同薄纸编码,以及每个薄纸编码展示的性质。
表1.薄纸组成和性质
编码1的基重为40.5gsm,编码2的基重为42gsm,编码3-5的基重为40gsm。Euc是桉树。编码2和5示出了使用相同的总纤维量在分层基材与混合基材之间的直接比较。
GMT是考虑了纵向(MD)拉伸强度和横向(CD)拉伸强度的几何平均拉伸强度。处于本文的目的,拉伸强度可以使用SINTECH拉伸测试仪测量,在测试前将样品保持在TAPPI条件下4小时之后,使用3英寸钳口宽度(样品宽度)、2英寸钳口跨度(标距长度)和25.4厘米每分钟的十字头速度。“MD拉伸强度”是当样品在纵向上被牵拉至破裂时每3英寸样品宽度的峰值负荷。类似地,“CD拉伸强度”表示当样品在横向上被牵拉至破裂时每3英寸样品宽度的峰值负荷。GMT是幅材的MD拉伸强度和CD拉伸强度乘积的平方根。“CD拉伸”和“MD拉伸”是在断裂点处分别在横向和纵向上的样品伸长量,表示为初始样品长度的百分比。
更具体地,通过使用JDC精确样品切割器(Thwing-Albert Instrument Company,Philadelphia,Pa.,型号JDC 3-10,序列号37333)沿着纵向(MD)或横向(CD)取向切割3英寸(76.2mm)宽乘至少4英寸(101.6mm)长的条带,而制备用于张力强度测试。用于测量张力强度的仪器是MTS Systems SINTECH,序列号为1G/071896/116。数据采集软件是MTSTestWorks.RTM.for Windows Ver.4.0(MTS Systems Corp.,Eden Prairie,Minn.)。测力传感器是MTS 25牛顿最大值测力传感器。夹具之间的标距为2±0.04英寸(76.2±1mm)。夹具使用气动式动作来操作并且涂布有橡胶。最小夹面宽度为3英寸(76.2mm),并且钳口的大致高度为0.5英寸(12.7mm)。断裂灵敏度设置为40%。将样品置于仪器的夹具中,在垂直和水平方向上均居中。为了调整初始松弛度,对于每次测试运行均以0.1英寸/分钟的速率施加1克(力)的预负载。然后开始测试,并在力下降了峰值的40%时结束。根据受测试的样品,峰值负荷被记录为样本的“MD张力强度”或“CD张力强度”。对“按原样”获取的每个产品测试至少3个代表性样本,所有各个样本测试的算术平均值是产品的MD或CD张力强度。
除了表1所示的显著增强的干/湿拉伸比,数据还表明,表1所列的分层式UCTAD薄纸表现出改善的柔软性和吸收性,如表2所示。
表2中描述的两个对照编码由包含100%纤维素纸浆纤维的均匀混合纤维片材组成(2015年1月-2016年9月,UCTAD Bath CHF对照)。PBS代表优质浴得分(Premium BathScore),并且来源于由在薄纸基片上进行的几种感官小组测试组成的以下制剂。
PBS=5*(平均起毛度+体积–刚度–平均粗度)+25
PBS值越高,可感觉到薄纸越软。表2表明,与均匀结构相比,在相同强度下的分层式结构表现出改善的柔软性。
表2.感觉的薄纸柔软性
编码 | 基重(gsm) | GMT(gf) | PBS |
1* | 40.5 | 1272 | 64 |
2* | 42 | 1054 | 64 |
对照编码A | 40 | 1100 | 46 |
对照编码B | 40 | 1300 | 41 |
注:*编码1和2与表1中的编码1和2是相同的材料,但表2中的编码1和2已被压延。GMT是几何平均拉伸强度,在上文有更详细的描述。
编码1和2被制造为卫生纸。如表3所示,具有分层式结构的编码1和2的卫生纸表现出与当前商用毛巾产品相比相同或稍好的吸收性。毛巾产品通常比卫生纸具有更高的吸收性。使用最初称重的4英寸乘4英寸的样品确定吸收能力。然后将称重的样品浸入测试流体(例如石蜡油或水)的盘中三分钟。盘中的测试流体应至少2英寸(5.08cm)深。从测试流体中移出样品,并允许在悬挂处于“菱形”形状的位置(即,在最低点有一个角)时排出。允许样品排水三分钟,排油五分钟。在指定的排出时间后,将样品放入称重盘中并称重。根据用于测试对水的吸收能力的程序来测试粘度与水更相似的酸或碱的吸收能力。吸收能力(g)=湿重(g)-干重(g);比吸收能力(g/g)=吸收容量(g)/干重(g)。
表3.吸收能力数据,以g/g计的比吸收能力
注:*编码1和2与表1中的编码1和2是相同的材料,但表2中的编码1和2已被压延。
应当注意,虽然本公开中的实施例是使用泡沫形成过程来制造的,但是本公开不应当限于这种过程。由于其处理长纤维(例如6mm或12mm粘结纤维)的能力,因此采用泡沫形成过程。相反,如果使用短粘结纤维(例如2mm或更短),则可以使用标准的水形成过程来生产相同的分层式结构。
结果
如表1至表3所示,当与具有相同纤维组成但均匀混合的基材(即,非分层式结构)相比时,具有两个富含纤维素纤维的外层和一个富含非直合成粘结纤维的中间层的分层式结构在湿/干拉伸比方面表现出显著的增强。通过比较表1中的编码2和5,可以最好地看出这一点。图2提供了另外的数据,证明了具有相同纤维组成的分层式和非分层式基材的湿/干拉伸比得到了改善。
在第一特定方面,一种用于生产泡沫形成的多层基材的方法包括:生产包含至少3重量%的非直合成粘结纤维的水基泡沫,其中该非直合成粘结纤维具有大于2mm的平均长度;由水基泡沫和纤维素纤维层一起形成湿片材层,其中纤维素纤维层包含至少60重量%的纤维素纤维;以及干燥合并的层以获得所述泡沫形成的多层基材。
第二特定方面包括第一特定方面,其中泡沫形成层具有0.008g/cc至0.1g/cc之间的干密度。
第三特定方面包括第一方面和/或第二方面,其中非直合成粘结纤维具有4mm至60mm的平均长度。
第四特定方面包括方面1-3中的一个或多个,其中非直合成粘结纤维具有6mm至30mm的平均长度。
第五特定方面包括方面1-4中的一个或多个,其中非直合成粘结纤维具有至少1.5分特的直径。
第六特定方面包括方面1-5中的一个或多个,其中非直合成粘结纤维具有三维卷状结构。
第七特定方面包括方面1-6中的一个或多个,其中非直合成粘结纤维具有三维卷曲结构。
第八特定方面包括方面1-7中的一个或多个,其中非直合成粘结纤维是双组分纤维。
第九特定方面包括方面1-8中的一个或多个,其中双组分纤维是皮-芯双组分纤维。
第十特定方面包括方面1-9中的一个或多个,其中皮是聚乙烯,芯是聚酯。
第十一特定方面包括方面1-10中的一个或多个,其中生产包括至少10重量%的非直合成粘结纤维。
第十二特定方面包括方面1-11中的一个或多个,其中多层基材具有60%或更高的湿/干拉伸比。
第十三特定方面包括方面1-12中的一个或多个,其中纤维素纤维是桉树纤维。
在第十四特定方面,多层基材包括第一层,该第一层包含平均长度大于2mm的至少60重量%的非直合成粘结纤维;以及第二层,该第二层包含至少60重量%的纤维素纤维,其中第一层与第二层成面对关系,并且其中多层基材具有至少60%的湿/干拉伸比。
第十五特定方面包括第十四特定方面,其中多层基材比具有相同纤维组成的均匀纤维基材表现出更高的柔软性和吸收性。
第十六特定方面包括第十四方面和/或第十五方面,其中非直合成粘结纤维具有6mm至30mm的平均长度和至少1.5分特的平均直径。
第十七特定方面包括方面14-16中的一个或多个,其中非直合成粘结纤维具有三维卷状或卷曲结构。
第十八特定方面包括方面14-17中的一个或多个,其中非直合成粘结纤维是皮-芯双组分纤维。
第十九特定方面包括方面14-18中的一个或多个,其中皮是聚乙烯,芯是聚酯。
在第二十特定方面,多层基材包括第一层,该第一层包含平均长度大于2mm的至少60重量%的非直合成粘结纤维,其中该非直合成粘结纤维具有三维卷状或卷曲结构,并且是皮-芯双组分纤维;以及第二层,该第二层包含至少60重量%的纤维素纤维,其中第一层与第二层成面对关系,其中多层基材具有至少60%的湿/干拉伸比,并且其中多层基材比具有相同纤维组成的均匀纤维基材表现出更高的柔软性和吸收性。
在不脱离本公开的精神和范围的情况下,本公开的这些和其他修改和变型可由本领域的普通技术人员实践,在所附权利要求中对此更具体地描述。此外,应当理解,本公开的各个方面中的方面可以整体或部分地互换。此外,本领域的普通技术人员将会知道,上述描述仅仅是举例,并非意图限制此类所附权利要求书中进一步描述的本公开。
Claims (20)
1.一种用于生产泡沫形成的多层基材的方法,所述方法包括:
生产包含至少3重量%的非直合成粘结纤维的水基泡沫,其中所述非直合成粘结纤维具有大于2mm的平均长度;
由所述水基泡沫和纤维素纤维层一起形成湿片材层,其中所述纤维素纤维层包含至少60重量%的纤维素纤维;以及
干燥合并的层以获得所述泡沫形成的多层基材。
2.如权利要求1所述的方法,其中所述泡沫形成层具有0.008g/cc至0.1g/cc之间的干密度。
3.如权利要求1所述的方法,其中所述非直合成粘结纤维具有4mm至60mm的平均长度。
4.如权利要求1所述的方法,其中所述
非直合成粘结纤维具有6mm至30mm的平均长度。
5.如权利要求1所述的方法,其中所述非直合成粘结纤维具有至少1.5分特的直径。
6.如权利要求1所述的方法,其中所述非直合成粘结纤维具有三维卷状结构。
7.如权利要求1所述的方法,其中所述非直合成粘结纤维具有三维卷曲结构。
8.如权利要求1所述的方法,其中所述非直合成粘结纤维是双组分纤维。
9.如权利要求8所述的方法,其中所述双组分纤维是皮-芯双组分纤维。
10.如权利要求9所述的方法,其中所述皮是聚乙烯,所述芯是聚酯。
11.如权利要求1所述的方法,其中生产包括至少10重量%的非直合成粘结纤维。
12.如权利要求1所述的方法,其中所述多层基材具有60%或更高的湿/干拉伸比。
13.如权利要求1所述的方法,其中所述纤维素纤维是桉树纤维。
14.一种多层基材,包括:
第一层,所述第一层包含平均长度大于2mm的至少60重量%的非直合成粘结纤维;以及
第二层,所述第二层包含至少60重量%的纤维素纤维,其中所述第一层与所述第二层成面对关系,并且其中所述多层基材具有至少60%的湿/干拉伸比。
15.如权利要求14所述的多层基材,其中所述多层基材比具有相同纤维组成的均匀纤维基材表现出更高的柔软性和吸收性。
16.如权利要求14所述的多层基材,其中所述非直合成粘结纤维具有6mm至30mm的平均长度和至少1.5分特的平均直径。
17.如权利要求14所述的多层基材,其中所述非直合成粘结纤维具有三维卷状或卷曲结构。
18.如权利要求14所述的多层基材,其中所述非直合成粘结纤维是皮-芯双组分纤维。
19.如权利要求18所述的多层基材,其中所述皮是聚乙烯,所述芯是聚酯。
20.一种多层基材,包括:
第一层,所述第一层包含平均长度大于2mm的至少60重量%的非直合成粘结纤维,其中所述非直合成粘结纤维具有三维卷状或卷曲结构并且是皮-芯双组分纤维;以及
第二层,所述第二层包含至少60重量%的纤维素纤维,其中所述第一层与所述第二层成面对关系,其中所述多层基材具有至少60%的湿/干拉伸比,并且其中所述多层基材比具有相同纤维组成的均匀纤维基材表现出更高的柔软性和吸收性。
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GB2582508B (en) | 2022-02-16 |
GB2582508A (en) | 2020-09-23 |
BR112020007694B1 (pt) | 2022-12-13 |
BR112020007694A2 (pt) | 2020-10-13 |
US20200370246A1 (en) | 2020-11-26 |
AU2017441040A1 (en) | 2020-06-11 |
US11255051B2 (en) | 2022-02-22 |
MX2020004101A (es) | 2020-07-24 |
RU2733957C1 (ru) | 2020-10-08 |
GB202008746D0 (en) | 2020-07-22 |
US20220127792A1 (en) | 2022-04-28 |
CN111247280B (zh) | 2021-08-17 |
KR20200066741A (ko) | 2020-06-10 |
KR102165232B1 (ko) | 2020-10-13 |
WO2019108172A1 (en) | 2019-06-06 |
AU2017441040B2 (en) | 2023-12-21 |
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