CN111663339A - 含纤维的结构、其制造方法及其应用 - Google Patents

含纤维的结构、其制造方法及其应用 Download PDF

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Publication number
CN111663339A
CN111663339A CN201910312973.1A CN201910312973A CN111663339A CN 111663339 A CN111663339 A CN 111663339A CN 201910312973 A CN201910312973 A CN 201910312973A CN 111663339 A CN111663339 A CN 111663339A
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China
Prior art keywords
fiber
elastomer
welded
base material
fibers
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CN201910312973.1A
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English (en)
Inventor
林至逸
冯崇智
杨高隆
朱格甫
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San Fang Chemical Industry Co Ltd
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San Fang Chemical Industry Co Ltd
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Publication of CN111663339A publication Critical patent/CN111663339A/zh
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Abstract

本发明是关于一种含纤维的结构、其制造方法及其应用，其包含至少于一交织处熔接的织布基材，及熔接弹性体层，且该织布基材与该熔接的弹性体的至少一部分彼此熔接。本发明亦提供一种制造上述含纤维的结构的方法及包含上述含纤维的结构的鞋型结构。

Description

含纤维的结构、其制造方法及其应用
技术领域
本发明是关于一种含纤维的结构，具体而言，是关于一种可应用于制鞋的含纤维的结构、其制造方法及其应用。
背景技术
人工皮革在纺织产业中至为重要，人工皮革大量使用于例如家具及制鞋的领域上，特别是鞋面材(Upper leather)。
举例言之，目前鞋面材通常包含内里布及人工皮革或网布当表层，表面再使用热熔胶贴合聚胺酯赋予多彩的表面变化，即可制得成品鞋。但此工艺繁复，而且当表层使用人工皮革时，有良好的防水性，但透气性不佳；当表层使用网布时，有良好的透气性，但无法防水。
为了改善此一繁复的工艺，业界将例如热塑性聚胺酯的热塑性树脂经由熔喷工艺施予鞋楦模具上，可直接制成鞋型套，亦可进一步组装成鞋成品。此熔喷热塑性树脂的工艺具有产速快、无废料产生，及材料和工艺环保等优点。然而另一方面，因此制造方法是使用熔喷方式形成热塑性树脂纤维网，其为堆栈的网状结构，且因热塑性树脂具有弹性，造成物性及尺寸稳定性不佳，如抗张强度低、伸长率高、易产生层间剥离，无法实际直接应用于鞋的制造。
为克服此问题，中国台湾专利公开第200742671号提供一纤维结构制品，其包括基布层以及第一致密层，第一致密层设置于基布层的一侧表面，其中第一致密层是由部分的基布层转变而成的，且第一致密层的平均密度大于基布层的平均密度。基布层与第一致密层的纤维的结构包括核心以及外鞘，其中外鞘包覆核心，且核心与外鞘为不同的材质。此公开案利用由基布层转变的致密层，试图提高人工皮革的结构强度，然而此致密层的设计改良有限，由熔喷或纺黏制得的基布仍为不织布，纤维与纤维间，并没有传统针轧不织布工艺中，使纤维产生纠落以提高强度，而仅为堆叠的纤维网状结构，仍旧无法解决网状非织物的物性、尺寸稳定性不佳的问题。
因此，本领域中亟需开发一新颖的纤维结构，以克服上述人工皮革的物性及尺寸稳定性不佳的缺点。
发明内容
本发明提供一织布基材，通过该织布基材与弹性体的熔接，使纤维结构的物性及尺寸稳定性大幅提升，改善先前技术的缺点，非常适合应用于鞋面材的制造。
本发明提供一种含纤维的结构，其包含：
织布基材，其包含交织的基材纤维，且该基材纤维于至少一交织处熔接；及
熔接弹性体层，其包含熔接的弹性体，且该基材纤维与该熔接的弹性体的至少一部分彼此熔接。
本发明亦提供一种制造根据上述含纤维的结构的方法，其包含：
(a)提供一织布，该织布包含交织的基材纤维；
(b)加热该织布，使该基材纤维于至少一交织处上熔接，形成一织布基材；及
(c)于该织布基材上熔喷弹性体，形成熔接的弹性体，并使该基材纤维与该熔接的弹性体的至少一部分彼此熔接。
本发明再提供一种鞋型结构，其包含上述含纤维的结构。
参看图1及图2，本发明提供一种含纤维的结构1、2，其包含：
织布基材11、21，其包含交织的基材纤维，且该基材纤维于至少一交织处熔接；及
熔接弹性体层12、22，其包含熔接的弹性体，且该基材纤维与该熔接的弹性体的至少一部分彼此熔接。
本文中所使用的“织布基材”一词是指经由纤维交织形成并经熔接的基材，本文中所使用的“交织”或“织”包含但不限于以梭织、针织或编织方式进行纤维间的织造。举例言之，利用纤维形成的经纱与纬纱互相交叉通过方式抱合；利用纤维形成的多根纱线环环相扣，将线圈(Loop)不断套叠而成。较佳地，该交织是为编织，或利用纤维形成的多根纱线环环相扣，将线圈不断套叠。可使用各式织造机器形成织布基材，例如使用袜管织造机、梭织机、圆编机或横式编织机，织造而得的该织布可为片状、卷状或管状。通过织布的提供，根据本发明的含纤维的结构可明显提升物性及尺寸稳定性。
根据本发明交织形成该织布基材的纤维为基材纤维。较佳地，多个基材纤维可聚集形成纱线或长纤维，有利于交织织造。较佳地，该基材纤维由选自以下各物组成的至少一种材料制成：聚酰胺、聚对苯二甲酰对苯二胺、聚烯烃、聚甲基丙烯酸甲酯 (PMMA)、聚对苯二甲酸乙二酯(PET)、聚对苯二甲酸丙二酯(PTT)、聚对苯二甲酸丁二酯(PBT)、聚丙烯腈(PAN)及其混合物。更佳地，该基材纤维的至少一部分是为热塑性弹性体，尤佳地，该基材纤维的至少一部分是为热塑性聚胺酯(thermoplastic polyurethane，TPU)或热塑性聚酯弹性体(thermoplastic polyester elastomer，TPEE) 或热塑性聚烯烃(thermoplasticolefin，TPO)。
根据本发明的基材纤维是于织布基材的至少一交织处上熔接。本文中所使用的“熔接”一词是指加热一聚合物至高于熔点温度，使其软化，并与另已加热至高于熔点温度的另一聚合物融合，并于温度下降至两聚合物的熔点温度下，产生的融合连接。虽不愿为理论所限制，但因织布基材上基材纤维于至少一交织处上熔接，使整体的织布基材的物性及尺寸稳定性大幅提高，例如抗张强度、撕裂强度及剥离强度，且本发明所属领域的一般技术人员可通过控制熔接的强度或密度，而制得物性及尺寸稳定性合宜且仍保有织物柔软韧性及手感的含纤维的结构，可控制的熔接条件包含但不限于熔接方式、温度或时间。较佳地，织布基材上的基材纤维于至少一交织处熔接，且至少一交织处不熔接；或织布基材上的基材纤维于所有交织处皆熔接。
本文中使用的“基材纤维”一词指单丝纤维或复合纤维，较佳是指复合纤维。根据本发明的复合纤维是指使用不同材质的纤维材料复合形成物，依据不同的复合形式，可为蕊鞘复合纤维、并列复合纤维或分割复合纤维。于本发明的一较佳具体实施例中，该基材纤维包含一第一组分及一第二组分，其中该第一组分于该至少一交织处上熔接，该第二组分不熔接，该第一组分较佳是暴露于该基材纤维表面，并为热塑性弹性体，有利于进行熔接，该第二组分则可视物性需要选择适合的材料，以与该第一组分配合提供所需特性的基材纤维。举例言之，该第二组分由选自由以下各材料组合中至少一种材料制成：聚酰胺、聚对苯二甲酰对苯二胺、聚烯烃、聚甲基丙烯酸甲酯 (PMMA)、聚对苯二甲酸乙二酯(PET)、聚对苯二甲酸丙二酯(PTT)、聚对苯二甲酸丁二酯(PBT)、聚丙烯腈(PAN)及其混合物；较佳是为聚对苯二甲酸乙二酯、聚对苯二甲酸丙二酯、聚对苯二甲酸丁二酯或尼龙6。于本发明的具体例中，该第一组分与第二组分的重量比例是自10:90至90:10，较佳为自30:70至70:30。
于本发明的一较佳具体实施例中，该基材纤维另包含一弹性纤维，可便于如下述制造方法的过程中进行包覆模具步骤，亦可使根据本发明的含纤维的结构具有所需的弹性。
根据本发明的熔接弹性体层，其包含熔接的弹性体，且该基材纤维与该熔接的弹性体的至少一部分彼此熔接。根据本发明的该熔接弹性体层的弹性体选自由以下各物组成：聚胺酯、聚酰胺、聚烯烃、聚甲基丙烯酸甲酯(PMMA)、聚对苯二甲酸乙二酯 (PET)、聚对苯二甲酸丙二酯(PTT)、聚对苯二甲酸丁二酯(PBT)、聚丙烯腈(PAN)及其混合物。更佳地，该熔接弹性体层的弹性体为热塑性弹性体，尤佳地，该熔接弹性体层的弹性体为热塑性聚胺酯或热塑性聚酯弹性体或热塑性聚烯烃。该弹性体为彼此熔接形成熔接的弹性体，并与该基材纤维熔接，该熔接的弹性体与基材纤维可于基材纤维已熔接的交织处进一步熔接，亦可于基材纤维的非交织处熔接。
于本发明的一较佳具体实施例中，该基材纤维包含一第一组分及一第二组分，其中该第一组分与该熔接的弹性体的至少一部分彼此熔接，该第二组分不熔接。该第一组分较佳是暴露于该基材纤维表面，并为热塑性弹性体，有利于进行熔接。
于本发明的一较佳具体实施例中，该熔接弹性体层包含一熔接网状层，其包含交叉非交织的网状纤维，且网状纤维于至少一交叉非交织处上熔接，且该基材纤维与该网状纤维的至少一部分彼此熔接。于本实施例中，该弹性体是形成网状纤维，且该网状纤维以非交织而仅交叉方式，熔接提供一网状结构。较佳地，该网状纤维层的网状纤维于至少一交叉非交织处熔接，且至少一交叉非交织处不熔接；或该网状纤维层的网状纤维于所有交叉非交织处皆熔接。另一方面，该弹性体是彼此熔接形成熔接的弹性体，并与该基材纤维熔接，该熔接的弹性体与基材纤维可于熔接的弹性体已熔接的交叉非交织处进一步熔接，亦可于熔接的弹性体的非交叉非交织处熔接。
于本发明的一具体实施例中，该熔接弹性体层的厚度为约0.2mm至约5.0mm间；较佳为约0.3mm至约4.0mm间；更佳为约0.35mm至约3.0mm间。
于本发明的一较佳具体实施例中，该含纤维的结构另包含一黏着剂，其位于该织布基材与该熔接弹性体层间，该黏着剂可辅助该织布基材与该熔接弹性体层间的链接，且不妨碍该基材纤维与该熔接的弹性体的至少一部分彼此熔接。于本发明的一较佳具体实施例中，该黏着剂是为热塑性弹性体，且该黏着剂与该织布基材及熔接弹性体层共同熔接，其具体材料包含但不限于热塑性聚胺酯、热塑性聚酯弹性体或热塑性聚烯烃。
本发明亦提供一种制造根据上述含纤维的结构的方法，其包含：
(a)提供一织布，该织布包含交织的基材纤维；
(b)加热该织布，使该基材纤维于至少一交织处上熔接，形成一织布基材；及
(c)于该织布基材上熔喷弹性体，形成熔接的弹性体，并使该基材纤维与该熔接的弹性体的至少一部分彼此熔接。
根据本发明的方法，其中步骤(a)提供一织布，该提供的方式包含但不限于以梭织、针织或编织方式进行基材纤维间的交织织造。举例言之，利用基材纤维形成的经纱与纬纱互相交叉通过方式抱合；利用基材纤维形成的多根纱线环环相扣，将线圈不断套迭而成。可使用各式织造机器提供织布，例如使用袜管织造机、梭织机、圆编机或横式编织机。
根据本发明的方法，其中步骤(b)包含加热该织布，使该基材纤维于至少一交织处上熔接。于本发明的一具体实施例中，是加热基材纤维的至少一部分至高于熔点温度，使其软化，并与另已加热至高于熔点温度的另一基材纤维部分融合，并于温度下降至交织的基材纤维的熔点温度下，产生的融合连接。本发明所属领域的一般技术人员可通过控制熔接的强度或密度，可控制的熔接条件包含但不限于熔接方式、温度或时间。
于本发明的一较佳具体实施例中，步骤(b)进一步包含提供一内模具，并将该织布包覆该模具，并加热该织布，使该基材纤维于至少一交织处上熔接。由于该基材纤维是于该内模具上熔接，故该织布基材大体上可具有固定且相应该内模具的外型，但仍具有纤维的柔软度。于本发明的一较佳具体实施例中，该内模具为一鞋楦。
根据本发明的方法，其中步骤(c)于该织布基材上熔喷弹性体，形成熔接的弹性体，并使该基材纤维与该熔接的弹性体的至少一部分彼此熔接。根据本发明的熔喷是指将已加热熔融的弹性体利用空气压力喷出，可依所需的厚度、位置调整喷出的量及型态，且弹性体于喷出后冷却，而可形成熔接的弹性体。较佳地，可于熔喷后进一步加热该弹性体，以控制熔接的程度。根据本发明的加热方式包含但不限于热烘或红外线加热。
于本发明方法的一较佳具体实施例中，于步骤(c)前另包含施加一黏着剂于该织布上。该黏着剂的施加方式包含但不限于以熔喷方式施加于织布基材上。
于本发明方法的一较佳具体实施例中，步骤(c)进一步包含提供一外模具，使该外模具包覆该弹性体，并加热该弹性体，形成熔接的弹性体，并使该基材纤维与该熔接的弹性体的至少一部分彼此熔接。较佳地，该外模具与该内模具彼此互为对应，可一起应用而使该含纤维的结构具有所需的外型，且该外模具可进一步使该弹性体进一步熔接，具有更佳的剥离强度、抗张强度及撕裂强度。
较佳地，该方法另包含移除该内模具及/或外模具的步骤。
本发明再提供一种鞋型结构，其包含上述含纤维的结构，例如利用鞋楦作为内模具，以制得此鞋型结构，可一体成型，减少人工缝制各部位的时间及工序，增加生产效率及生产速度，再者，此含纤维的结构可使所制得的鞋具有透气的特性，可增进使用者的足部健康。
根据本发明的含纤维的结构可明显提升物性，如抗张强度、撕裂强度、伸长率及层间剥离强度，另外也有良好的尺寸稳定性，但仍保持相当的柔软度、弹性、手感及韧性，且其材料及制造方法，无需使用溶剂，亦无废料产生，具有环保的功效，再者，通过熔喷的一体成形制造，增加生产效率及生产速度。
附图说明
图1显示根据本发明一具体实施例的含纤维的结构的剖视示意图；及
图2显示根据本发明一具体实施例的含纤维的结构的外观示意图。
符号说明
1 本发明含纤维的结构
2 本发明含纤维的结构
11 织布基材
12 熔接弹性体层
21 织布基材
22 熔接弹性体层
具体实施方式
兹以下列实例予以详细说明本发明，但并不意味着本发明仅局限于此等实例所提供的内容。
实施例一
1.原料：
基材纤维第一组分原料：“Lubrizol，BF-85”热塑性聚胺酯弹性体，萧式硬度shoreA为85A，Tm为125℃。以下以(A)代称。
基材纤维第二组分原料：“新光，C03800”低熔点聚酯，Tm为170℃。以下以(B) 代称。
弹性体：“BASF，A8000”热塑性聚胺酯弹性体，萧式硬度shore A为80A，Tm 为140℃。以下以(C)代称。
2.干燥：
分别将原料(A)、(B)及(C)进行干燥，进而控制各材料的含水率至300ppm以下，干燥温度设定为70℃，时间6小时或以上。
3.押出：
将原料(A)投入一#a押出机，及将原料(B)投入另一#b押出机。
押出机温度设定：
#a押出机，从原料入口到出口，分三段加热区，温度分别设定180℃、210℃、 200℃。
#b押出机，从原料入口到出口，分三段加热区，温度分别设定190℃、230℃、 240℃。
纺丝箱体温度设定：
#a区，设定为220℃。
#b区，设定为235℃。
产量设定：
#a，计量泵(Gear Pump)转速，设定为9.25rpm。
#b，计量泵(Gear Pump)转速，设定为9rpm。
原料一起进入一纺丝组件(Spinneret)，喷出成丝，并经过一冷却风区，将纤维进行冷却，最后经卷绕机，以2400m/min速度进行卷绕后，可制得丹尼数为300den，伸长率为65％，断裂强度为1.6g/den的TPU/CoPET复合长纤。
4.交织织造：
使用单口圆编织造机，将该复合长纤，织造成可套入鞋楦的圆编织布，并套入鞋楦中。
5.熔接塑形：
设定烘箱温度为150℃，将已套上织布的鞋楦放入烘箱中，并加热30分钟后取出。
6.熔喷：
准备一押出机，分四段加热区，温度设定，从入料口到出料口，分别为180℃、 200℃、220℃、225℃，并投入原料(C)，熔喷模头温度为250℃，空气压力为4.5kg/cm2，将原料(C)熔喷到已熔接的织布基材上。
7.成品：
将喷涂0.3mm厚度的熔喷弹性体纤维层于双组分织布基材的半成品，再使用公母模进行热压，热压温度为125℃，压力2kg/cm2，热压时间30sec，即可制得新颖的鞋面结构。
实施例二
1.原料：
基材纤维第一组分原料：“Lubrizol，BF-92”热塑性聚胺酯弹性体，萧式硬度shoreA为92A，Tm为130℃。以下以(A)代称。
基材纤维第二组分原料：“新光，T-2164A”聚酯，Tm为250℃。以下以(B)代称。
弹性体：“BASF，A8230“热塑性聚胺酯弹性体，萧式硬度shore A为82A，Tm 为160℃。以下以(C)代称。
2.干燥：
分别将原料(A)、(B)及(C)进行干燥，进而控制各材料的含水率至300ppm以下，干燥温度设定为70℃，时间6小时或以上。
3.押出：
将原料(A)投入一#a押出机，及将原料(B)投入另一#b押出机。
押出机温度设定：
#a押出机，从原料入口到出口，分三段加热区，温度分别设定180℃、210℃、 200℃。
#b押出机，从原料入口到出口，分三段加热区，温度分别设定230℃、280℃、 285℃。
纺丝箱体温度设定：
#a区，设定为235℃。
#b区，设定为265℃。
产量设定：
#a，计量泵(Gear Pump)转速，设定为10.10rpm。
#b，计量泵(Gear Pump)转速，设定为12rpm。
原料一起进入一纺丝组件(Spinneret)，喷出成丝，并经过一冷却风区，将纤维进行冷却，最后经卷绕机，以2800m/min速度进行卷绕后，可制得丹尼数为150den，伸长率为45％，断裂强度为3.2g/den的TPU/PET复合长纤。
4.交织织造：
使用单口圆编织造机，将该复合长纤，织造成可套入鞋楦的圆编织布，并套入鞋楦中。
5.熔接塑形：
设定烘箱温度为150℃，将已套上织布的鞋楦放入烘箱中，并加热30分钟后取出。
6.熔喷：
准备一押出机，分四段加热区，温度设定，从入料口到出料口，分别为180℃、200℃、220℃、225℃，并投入原料(C)，熔喷模头温度为255℃，空气压力为4.5kg/cm2，将原料(C)熔喷到已熔接的织布基材上。
7.成品：
将喷涂0.3mm厚度的熔喷弹性体纤维层于双组分织布基材的半成品，再使用公母模进行热压，热压温度为130℃，压力2.5kg/cm2，热压时间36sec，即可制得新颖的鞋面结构。
上述实施例仅为说明本发明的原理及其功效，而非限制本发明。本发明所属领域中的一般技术人员对上述实施例所做的修改及变化仍不违背本发明的精神。本发明的保护范围应如权利要求所列。

Claims (10)

1.一种含纤维的结构，其包含：
织布基材，其包含交织的基材纤维，且该基材纤维于至少一交织处熔接；及熔接弹性体层，其包含熔接的弹性体，且该基材纤维与该熔接的弹性体的至少一部分彼此熔接。
2.根据权利要求1所述的结构，其中该基材纤维为一复合纤维，其中该复合纤维是为蕊鞘复合纤维、并列复合纤维或分割复合纤维。
3.根据权利要求1所述的结构，其中该基材纤维包含一第一组分及一第二组分，其中该第一组分于该至少一交织处上熔接，该第二组分不熔接。
4.根据权利要求1所述的结构，其中该基材纤维包含一弹性纤维。
5.根据权利要求1所述的结构，其中该熔接弹性体层包含一熔接网状层，其包含交叉非织的网状纤维，且网状纤维于至少一交叉非织处上熔接，且该基材纤维与该网状纤维的至少一部分彼此熔接。
6.根据权利要求1所述的结构，其中该基材纤维包含一第一组分及一第二组分，其中该第一组分与该熔接的弹性体的至少一部分彼此熔接，该第二组分不熔接。
7.一种制造根据权利要求1至6任何一项所述的结构的方法，其包含：
(a)提供一织布，该织布包含交织的基材纤维；
(b)加热该织布，使该基材纤维于至少一交织处上熔接，形成一织布基材；及
(c)于该织布基材上熔喷弹性体，形成熔接的弹性体，并使该基材纤维与该熔接的弹性体的至少一部分彼此熔接。
8.根据权利要求7所述的方法，其中步骤(b)进一步包含提供一内模具，并将该织布包覆该模具，并加热该织布，使该基材纤维于至少一交织处上熔接。
9.根据权利要求7所述的方法，其中步骤(c)进一步包含提供一外模具，使该外模具包覆该弹性体，并加热该弹性体，形成熔接的弹性体，并使该基材纤维与该熔接的弹性体的至少一部分彼此熔接。
10.一种鞋型结构，其包含权利要求1至6任何一项所述的结构。
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