CN1123854A - 含有线形低密度聚乙烯粘性纤维的织物结构 - Google Patents

含有线形低密度聚乙烯粘性纤维的织物结构 Download PDF

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Publication number
CN1123854A
CN1123854A CN95116322A CN95116322A CN1123854A CN 1123854 A CN1123854 A CN 1123854A CN 95116322 A CN95116322 A CN 95116322A CN 95116322 A CN95116322 A CN 95116322A CN 1123854 A CN1123854 A CN 1123854A
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China
Prior art keywords
fiber
low density
linear low
density polyethylene
fusing point
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CN95116322A
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English (en)
Inventor
J·D·盖曼
R·K·古塔
R·E·科祖拉
R·J·利加
R·G·麦克莱伦
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Hercules LLC
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Hercules LLC
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Abstract

本发明公开了一种含有至少约80％(重量)熔点小于109℃的线性低密度聚乙烯纤维。也公开了一种热固纤维结构，它含有(1)至少约3％(重量)低熔点纤维，基于该结构的总重量，该低熔点纤维含至少80％(重量)线性低密度聚乙烯，优选熔点小于109℃，和(2)不大于97％(重量)的非熔化纤维或熔点高于线性低密度聚乙烯的纤维，基于该结构的总重量。这些纤维结构的形式可以是多丝纱，机织物或无纺织物、毯或层状材料。

Description

含有线形低密度聚乙烯粘性 纤维的织物结构
本发明涉及一种聚乙烯纤维及含有高熔点纤维和低熔点粘性纤维的织物结构。
织物结构可以由天然的或人工合成的各种材料制成。许多方法可用来制造这些织物结构，例如：纺丝、机织、针织、簇绒、梳理、和针刺。用这些方法制造的结构是尺寸不稳定的。有些技术用来稳定这些结构，如浸胶处理或层压。这些处理中的一部分需要溶剂或化学试剂，这带来所不希望的环境影响。另一种方法是用潜在粘性纤维粘合非粘性纤维以形成纱或其他织物结构，然后活化该潜在粘性纤维以将各种纤维彼此粘合在一起。粘性纤维在稳定无纺材料中的用途公开在美国专利US2,277,049和2,464,301中。用粘性纤维制造的具有熔点110-170℃的加捻纱公开在欧洲专利NO.324,773中。美国专利NO.4,668,552中公开了具有熔点小于149℃的含有共聚酰胺和共聚酯类低熔点粘性包覆线的包覆短纤维纱。美国专利NO.4,634,739中公开了一种粘性纤维，该粘性纤维内熔点约为107℃的支链化低密度聚乙烯和晶形聚丙烯混合而制得。美国专利NOS.5,077,874和5,199,141中公开了在针织、无纺织物中的熔点大于110℃聚乙烯纤维和聚丙烯纤维的应用。由于这两种纤维的熔点差别很小，在无纺结构中这两种纤维的组合体需要精密控制热处理温度，以防止对结构中基本纤维即聚丙烯纤维有任何不利的影响。
因此，希望提供织物结构的基本纤维和粘性纤维之间明显的熔点差别，在生产尺寸稳定织物结构中提供更宽容的热处理方法。通过提供非常低熔点温度的粘性纤维来得到这种明显的差别。但是，在本发明之前，尚没有能生产含线性低密度聚乙烯纤维、熔点小于109℃的粘性纤维。
本发明的目的是提供一种纤维，该纤维含有至少约80％(重量)熔点小于109℃的线性低密度聚乙烯(LLDPE)。这些纤维可用于各种类型的纤维结构，该纤维结构可任意地含有除这些LLDPE纤维之外的纤维。
在一优选实施方案中，LLDPE用于制备尺寸稳定、热固纤维结构，该纤维结构含有(1)至少约3％(重量)(基于该结构的总重量)的低熔点纤维，该低熔点纤维含至少80％(重量)线性低密度聚乙烯，和(2)不大于约97％(重量)(基于该结构的总重量)的非熔化纤维，或者具有熔点高于线性低密度聚乙烯纤维的纤维。
通过加热熔化线性低密度聚乙烯粘性纤维而不熔化高熔点纤维将该纤维结构固化。本发明的纤维结构的形式可以是纱、机织物或无纺布、毯、和其中至少一层含有本发明纤维结构的层状物。
该热固纤维结构具有改善的尺寸稳定性，耐磨性和耐服用性能。该线性低密度聚乙烯粘性纤维可提供柔软的具有优良悬重性的柔性仿衣料的织物。
含有至少约80％(重量)线性低密度聚乙烯的该纤维是乙烯和高至20％(重量)3-12个碳原子的α-烯烃如丙烯、丁烯、辛烯和己烯的共聚物。优选具有4-8个碳原子的α-烯烃。α-烯烃共聚用单体的混合物也可使用，如丁烯/辛烯或己烯/辛烯。优选含至少80％乙烯的共聚物。线性低密度聚乙烯(LLDPE)是“线性”的，但可以有悬挂于聚合物链上的α-烯烃共聚用单体的烷基基团，而不是有悬挂于主聚合物链上的聚合的乙烯短链，也看作是低密度聚乙烯。LLDPE的密度典型地为0.88-0.949/cc，LLDPE的熔点是变化的，这取决于乙烯单体和共聚用单体的比值，以及聚合物的结构。
适宜的线性低密度聚乙烯，例如包括INSITMTM、ENGAGETM、和ASPUN R聚乙烯，它们的熔点约为90-130℃，它们从DowChemical Company(Midland，Michigan，U.S.A)购得。优选熔点小于109℃的纤维。以前一直没有得到由熔点小于109℃的线性低密度聚乙烯纺成的纤维。
该线性低密度聚乙烯纤维可以是卷曲或未卷曲的连续长丝；卷曲或未卷曲切断纤维，即人造纤维，长度为约3-150mm，优选约5-150mm，更优选约25-50mm，或不连续的微细纤维，即熔喷纤维。该线性低密度聚乙烯纤维优选具有约1-30旦，更优选约2-15旦，最优选约2-6旦。在本说明书中，“纤维”的概念意指包括上述所有类型的纤维和长丝。该纤维可以含有高至约20％(重量)的其他材料，例如，稳定剂、颜料、添加剂和除线性低密度聚乙烯外的聚合物(即：聚丙烯、聚苯乙烯、烯烃如丙烯、乙烯和丁烯等的共聚物、聚酯和聚酰胺)。
该纤维可含少量，例如高至约20％(重量)的表面整理剂，它可以是亲水的或疏水的。合适的表面整理剂，例如，是磷酸酯抗静电整理剂、乙氧化脂肪酸酯、和聚二甲基硅氧烷。合适的涂饰剂例如公开在US4,832,932和欧洲专利申请公开EP486158、557024和516412中，这些文献引入本文作为参考。
含有至少约80％(重量)熔点小于109°的线性低密度聚乙烯的线性低密度聚乙烯(LLDPE)纤维可用于多种类型的纤维结构，该纤维结构可任意地含有除该特定线性低密度聚乙烯纤维之外的纤维。
本发明的纤维结构包括纱，例如，连续长丝、短纤维纱、包覆纱或新型纱；机织或针织物；簇绒的纺织品如绒；起圈绒头或割绒毯；无纺布或针刺或流体缠绕无纺布结构；含有几层本发明织物结构的层状物；或含有至少一层本发明织物结构和至少一层其他织物结构的层状物。
在优选实施方案中，LLDPE用在热固纤维结构中，该结构含有(1)约至少3％(重量)(基于该结构的总重量)而其中含至少约80％(重量)线性低密度聚乙烯的低熔点纤维，和(2)不大于约97％(重量)(基于该结构的总重量)的非熔化纤维或熔点高于该线性低密度聚乙烯纤维的纤维。从LLDPE纤维优选的范围是约5-10wt％。
其次，在本发明热固结构中的较高熔点纤维可以是其熔点至少比线性低密度聚乙烯纤维高10℃的任何纤维，优选至少高20℃，更优为至少高30℃。当熔点小于109℃的线性低密度聚乙烯纤维与聚丙烯纤维一起使用时，两种纤维之间的差值为大于50℃。这些纤维可以是卷曲的和未卷曲的连续长丝；卷曲或未卷曲的切断纤维；或者不连续微纤维。这种纤维包括，例如，聚丙烯、聚酰胺、和聚酯纤维。优选聚丙烯纤维。也可使用非熔化纤维，这种纤维例如包括棉、毛、丙烯酸类纤维和人造丝纤维。这些纤维优选的用量为约80％-95％(重量)。
在线性低密度纤维和较高熔点纤维掺合后，通过加热，该粘性纤维熔化并将较高熔点纤维彼此之间粘合。冷却后，聚乙烯固化并将高熔点纤维在其位置处置处固定，制成尺寸稳定结构。
使用ENGAGETM树脂，由The Dow Chemical Company(Midlond，Michigan，U.S.A.(Dow))购得，注册号为58200.03，制备用于下述实施例中的熔点为约107℃的线性低密度聚烯多丝纱和人造纤维。用ASPUNTM树脂，由Dow得到，注册号为6835，制备用于实施例中的熔点为128℃的线性低密度聚乙烯多丝纱和人造纤维。用多孔喷丝头于约200-230℃温度(通常的纺丝在170-250℃进行)熔融挤出这些树脂，被挤出的纤维进行卷装。这些纤维进一步拉伸约2-4倍，以得到最后的每根长丝的旦尼尔。切断纤维进行卷曲并切断。
用于下述实施例中的聚乙烯300旦/52丝连续长丝纱含有小于2％的表面整理剂TRYLUBE7640A，这从Henkel Corporation(Ambler，P.A.U.S.A.)得到。聚乙烯切断纤维含少于2％(重量)的表面整理剂LUROL PP912，从George A.Goulston Co.C Monroe，NC，U.S.A)得到。
在本说明书中，除另有注明外，所有的百分数均为重量百分数。
                实施例I
将聚丙烯(PP)膨体连续多丝纱与线性低密度聚乙烯(LLDPE)连续多丝纱多根并合在一起。制成表I中所示的聚丙烯/聚乙烯复合纱。然后于表I所示温度下对该复合纱热处理5分钟。该表中也示出了热处理的纱的物理性能。得到聚丙烯长丝之间粘合优良的尺寸稳定纱。
                                表1
试样号 聚酯烯纱(PP) 聚乙烯纱(LLDPE) PE/LLDPE比值(％/％) 热处理温度(℃) 热处理的复合纱性能
A 500旦单根纱/144丝熔点：162℃ 500旦单根纱/52丝熔点：107℃ 62/38  120℃ 柔软，纤维间粘合优良
B 500旦股纱/144丝熔点：162℃ 300旦单根纱/52丝熔点：107℃ 77/23  120℃ 柔软，纤维间粘合优良
C 500旦单根纱/144丝熔点：162℃ 300旦单根纱/52丝熔点：128℃ 63/38  135℃ 硬，纤维之间粘合优良
                    实施例2
将聚酯(PET)膨体连续多丝纱与线性低密度聚乙烯(LLDPE)连续多丝纱在一起加捻，以制备表2所示的聚酯/聚乙烯复合纱。将该粗细节纱于表2所示温度处理5分钟。表中还示出了热处理纱的物理性能。得到了聚酯纤维间粘合优良的尺寸加捻稳定的纱。
                                表2
试样号 聚酯纱(PET) 聚乙烯纱(LLDPE) PET/LLDPE比值(％/％) 热处理温度(℃) 热处理的复合纱性能
D 400旦2股纱/94丝熔点：260℃ 300旦单根纱/52丝熔点：128℃ 73/27  135℃ 柔软，纤维间粘合优良
E 400旦4股纱/94丝熔点：260℃ 300旦单根纱/52丝熔点：128℃ 84/16  135℃ 柔软，纤维间粘合优良
F 400旦单股纱/94丝熔点：260℃ 300旦单股纱/52丝熔点：128℃ 57/43  135℃ 硬，纤维间粘合优良
                    实施例3
用表3所示的不同的经纱和纬纱制备机织物。LLDPE是线性低密度聚乙烯。然后在表3所示温度下热处理该机织布5分钟。表中还示出了热处理布的物理性能。得到了优良粘合的尺寸稳定织物。在表中，den＝旦，fil＝丝。
                                表3
试样号 经纱 纬纱 LLDPE的熔点(℃) LLDPE(％) 热处理温度(℃) 热处理织物的性能
G 聚酯，500旦短纤维纺纱熔点：260℃ 300旦交替经纱/52丝LLDPE，400旦/92丝聚酯 128  21  135 柔软，纤维间粘合优良
H 聚酯，500旦短纤维纺纱熔点：260℃ 300旦交替经纱/52丝LLDPE，400旦/92丝聚酯 107  21  120 柔软，纤维间粘合优良
I 聚酯，500旦短纤维纺纱熔点：260℃ 300旦交替经纱/52丝LLDPE，500旦/144丝，聚丙烯，熔点：162℃  107  21  120 柔软，纤维间粘合优良
                      实施例4
用50％/50％(重量)的3旦线性低密度聚乙烯/长丝切断纤维的混纺纱(熔点为约107℃)和2.2旦的聚丙烯/长丝切断纤维(熔点为约162℃)制备无纺织物，该织物单位重量为62克/码2。将该无纺织物针刺到95克/码2熔点为260℃的机织聚酯织物上。将这种织物结构的两个试样的每一个都于118℃加热5分钟，然后在123℃加热5分钟。这种热处理的织物结构具有优良的尺寸稳定性和柔软手感。
                      实施例5
用25％/75％(重量)的3旦的线性低密度聚乙烯/长丝切断纤维(熔点为107℃)的混纺纱和2.2旦聚丙乙烯/长丝切断纤维(熔点为约162℃)制备无纺织物，该织物的单位重量为53克/码2。制备含有二层、四层和六层本发明织物的叠层物，并将每一种均在120℃热处理5分钟。这些热处理的无纺结构具有优良的形稳性和柔软手感。
                      实施例6
用50％/50％(重量)的3旦的线性低密度聚乙烯/长丝切断纤维(熔点为约170℃)的混纺纱和2.2旦的聚丙烯/长丝切断纤维(熔点为约162℃)制备无纺织物，该织物单位重量为62克/码2。将该无纺织物与单位重量为95克/码2的平纹聚酯机织物复合并将这两种结构针刺在一起。将这种复合织物结构于120℃加热5分钟以基本上熔化该线性低密度聚乙烯纤维。所得的织物结构具有优良的形状稳定性和柔手感。
                    实施例7
用熔点为约107℃的5旦的线性低密度聚乙烯/长丝切断纤维制备无纺织物，其单位重量为22克/码2。将该无纺织物与单位重量为95克/码2的平纹聚酯机织物复合，并将这两种结构针刺在一起。然后将这种复合织物结构于120℃加热5分钟以基本上熔化该线性低密度聚乙烯纤维。所得的织物结构具有优良的形状稳性和柔软的手感。
                   实施例8
用5旦的线性低密度聚乙烯/长丝切断纤维(熔点约为107℃)制备无纺织物，该织物平均重量为48克/码2。将该无纺织物与平纹聚酯机织物(具有平均重量为95克/码2)复合，并将这两种结构针刺在一起。然后在120℃将该复合织物结构热处理5分钟，以基本上熔化该线性低密度聚乙烯酯。所得的织物结构具有优良的形状稳性和柔软手感。
使用LLDPE提供了非常适宜制备纤维结构的纤维，特别是与其它聚合物如聚丙烯、聚酰胺或聚酯的高熔点纤维一起，或者与天然纤维一起。含有本发明的熔点小于109℃的LLDPE的纤维提供了比用高熔点LLDPE制得的更柔软的组织。另外，使生产者能在低温制备结构，因而降低了对初级纤维的可能的损害。

Claims (16)

1.一种纤维，该纤维含有约80％(重量)熔点小于109℃的线性低密度聚乙烯。
2.一种含有权利要求1所述纤维的纤维结构。
3.一种纤维结构，该纤维结构含有(1)权利要求所述纤维，和(2)除线性低密度聚乙烯纤维(1)外的纤维。
4.权利要求2或3的结构，其形式是多丝纱、机织物、针织物、簇绒织物、无纺织物、或毯。
5.一种叠层材料，该叠层材料含有至少一层权利要求4的结构，其中该结构是无纺织物。
6.一种热固纤维结构，该结构含有(1)至少约3％(重量)低熔点纤维，基于该结构的总重量，该低熔点纤维含至少约80％(重量)线性低密度聚乙烯，和(2)不大于97％(重量)的非熔化纤维或熔点高于线性低密度聚乙烯纤维的纤维，基于该结构的总重量。
7.权利要求6所述热固性结构，其中的线性低密度聚乙烯的熔点小于109℃。
8.权利要求6或7的结构，其中纤维(1)和纤维(2)之间的熔点差值至少为10℃。
9.权利要求8的结构，其中纤维(1)和纤维(2)之间的熔点差值至少为30℃。
10.权利要求9的结构，其中纤维(1)和纤维(2)之间的熔点差值至少为50℃。
11.前述权利要求的任一个之发明，其中的线性低密度聚乙烯是乙烯和至少一个具有3-12个碳原子的α-烯烃的共聚物，且密度为约0.88-0.94克/立方厘米。
12.权利要求11的发明，其中的α-烯烃选自聚丙烯、丁烯、辛烯、己烯及它们的混合物。
13.权利要求11或12的发明，其中的共聚物含有至少80％乙稀。
14.权利要求6-13的结构，其中的纤维(2)选自丙烯、人造丝、棉、丙烯酸纤维和毛纤维。
15.权利要求6-13的结构，其中的纤维(2)是聚丙烯，聚酯或聚酰胺纤维。
16.前述权利要求的任一个之发明，其中的线性低密度聚乙烯纤维是长度为3-150mm的1-30旦短纤维。
CN95116322A 1994-08-09 1995-08-09 含有线形低密度聚乙烯粘性纤维的织物结构 Pending CN1123854A (zh)

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Date Code Title Description
C06 Publication
PB01 Publication
CI02 Correction of invention patent application

Correction item: Description

Correct: Monroe

False: C Monroe

Page: 5-17

Correction item: Description

Correct: 300 denier single root

False: 500 denier single root

Page: 6A second case

Correction item: Description

Correct: PA, U.S.A

False: P.A.U.S.A.

Page: 5-15

Correction item: Description

Correct: 500 denier 2 strands

False: 500 denier

Page: B first case

Correction item: Description

Correct: (melting point is about 107 degrees Celsius)

False: (melting point is about 170 degrees Celsius)

Page: 10-3 paragraph and 2 lines

Correction item: Description

Correct: 27g /yr2

False: 22g/yd2

Page: 11-5

Correction item: Claims

Correct: (1) claim 1

False: (1) claim

Page: P14

Correction item: Description

Correct: Yue 2%

False: About 20%

Page: P3-22 line

Correction item: Description

Correct: At US4938832

False: At US 4,832,932

Page: 4-1

Correction item: Description

Correct: Fiber. Typical structures contain less than 50% (WT) LLDPE fibers. From LLDPE...... About 5-20wt%.

False: Fiber. From LLDPE...... About 5-10wt%

Page: 4-15 elements

Correction item: Description

Correct: (Midland.

False: (Midlond,

Page: 5-5

COR Change of bibliographic data

Free format text: CORRECT: CLAIM OF RIGHT; FROM: (1) CLAIM OF RIGHT TO: (1) CLAIM OF RIGHT 1

C01 Deemed withdrawal of patent application (patent law 1993)
WD01 Invention patent application deemed withdrawn after publication