CN112585310A - 水分散性复合结构体及其制备方法 - Google Patents

水分散性复合结构体及其制备方法 Download PDF

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CN112585310A
CN112585310A CN201980047019.2A CN201980047019A CN112585310A CN 112585310 A CN112585310 A CN 112585310A CN 201980047019 A CN201980047019 A CN 201980047019A CN 112585310 A CN112585310 A CN 112585310A
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fibers
water
binder
dispersible
fibres
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CN112585310B (zh
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K·金努宁-罗达斯科斯基
M·哈格布鲁姆
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Paptic Oy
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Paptic Oy
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    • D21H27/00Special paper not otherwise provided for, e.g. made by multi-step processes
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    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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Abstract

包含一个或多个层的水分散性复合结构体及其制备方法。所述层的至少一部分由纤维幅材或片材形成,由所述纤维的重量计算,所述纤维幅材或片材含有50至90重量份的木纤维和10至90重量份的一年生或多年生植物纤维和/或10至50重量份的合成短切纤维,以及0.1至20重量%的粘合剂,并且所述粘合剂的至少一部分是水溶性聚合物且另一部分是水分散性粘合剂,并且所述纤维片材或幅材通过湿法成型制备。通过本发明,复合结构体的纤维可以通过在纸和纸板工业中常规使用的设备回收和再循环。

Description

水分散性复合结构体及其制备方法
技术领域
本发明涉及纤维结构体,例如由纤维原料制备的片材-或幅材(web)-形成的层状材料。此类材料可以单独分散在水性介质中,以产生至少一部分可以回收的原料纤维。更具体而言,本发明涉及包含天然来源和合成来源的纤维的结构体,其形成可以分散在水性介质中的复合材料。本发明还涉及制备此类材料的方法及其用途。
背景技术
可分散的非织造织物是本领域已知的。它们用作用于卫生应用的可分散和可冲散的织物。
US 5 346 541教导了水分散性配制物和材料以及影响其水分散性的方法。所述水分散性配制物包含1至90重量%的至少一种水溶性纤维素醚粘合剂。此外,该配制物含有至少约10重量%至约99重量%的长度为大于约300微米至约2毫米或更长的长纤维素纤维。该文献中指出,包含显著量的长纤维素纤维提高了水溶性纤维素醚粘合剂的水分散性。可以包含气体释放剂以增加配制物的水分散性的速率。建议将该材料用于保健和食品工业。
US 3 563 241公开了用于单次使用目的的吸收性类纺织品结构体,该材料表现出强度和耐久性以允许适当使用,但是在使用后仍能够在污水系统中处理。该结构体包含具有可电离基团的水敏性纤维;材料可以选自例如氰乙基纤维素或羟乙基纤维素。
其它可冲散的湿巾在美国专利号5 629 081和EP 1 285 985中有所教导。
US 2014/0318726公开了一种包含浆粕和溶剂纺丝纤维的织物,其可以用于可快速分散的湿巾。溶剂纺丝纤维包括原纤化纤维素,例如Tencel类型的原纤化纤维素。在该专利申请的实施例中,木浆与Tencel短切纤维的共混物用于制备湿法成网织物。将纤维精制,加入1% CMC作为分散助剂,并加入基于表氯醇的湿强树脂以增加湿强度。然后将由此形成的浆料湿法成网(例如在造纸机上)以形成片材。然后,该片材在线或以单独的离线过程形式通过水力缠结过程以形成织物。
所获得的湿巾据说可通过标准厕所系统冲散,并且能够离解(disintegrating)成在处理后生物降解的可分散碎片。
尽管所公开的材料可分散在水中,但它们被设计用作离解和可丢弃的材料(一次性使用材料)。由于这个原因,当与相应的非离解材料相比时,已知的可分散材料在强度和结构完整性方面仍然不足。结果是,它们主要应用于允许已经在废水和污水系统中完全离解的产品中。因此,它们所包含的材料在使用后被浪费,并且不可能再循环。
在本领域中使用水力缠结将损害用于构成材料的回收和再循环的材料再制浆。
需要具有良好机械性质,同时通过纸和纸板工业中采用的常规再循环过程仍能够分散在水相中以产生构成纤维的级分并能够再循环的可分散结构体材料。
发明内容
本发明的目的是提供新的水分散性组合物和结构体,其包含由纤维幅材或片材形成的至少一个层,例如多个叠层。
另一个目的是提供制备此类组合物的方法。
还有第三个目的是提供所述组合物的用途。
本发明基于通过湿法成型制备纤维层的概念,该纤维层含有木纤维、天然和/或合成非木纤维和粘合剂。令人惊讶的是,已经发现,具有机械性质的水分散性片材或幅材可通过提供包含至少50%的木纤维与天然和/或合成纤维的混合物的纤维组合物,并通过使用与湿法成型相容且包含水溶性聚合物和水分散性聚合物的粘合剂将纤维粘合在一起而制备。
本发明的材料可以通过湿法成型由以下步骤制备:
- 将含水纤维淤浆输送到支撑物;
- 通过支撑物排出液体以形成纤维层;以及
- 在纤维层上施加粘合剂以便将纤维至少部分粘合在一起,该粘合剂包含水溶性聚合物的水溶液,并还含有水分散性聚合物。
所述组合物和方法可用于提供非织造产品,例如非织造幅材和非织造片材。
更具体而言,本发明的主要特征在于独立权利要求的特征部分中所述的内容。
本发明获得了相当多的优点。因此,本发明的材料具有良好的机械性质,这使得它们可以用于典型的纸、纸板和非织造应用中。特别地,本发明可用于制备选自幅材和片材的非织造产品。
此外,可以将材料分散在纸或纸板工业中使用的那种类型的常规碎浆机中,以便从水分散性材料中至少分离木纤维。由于材料的结构,木纤维可以至少部分回收,并且如果需要的话,可以再循环用于纤维材料和其它材料。
湿法成型可以在工业上在例如非织造机或造纸机上进行。
不需要机械结合(如水力缠结或射流喷网(spun-lacing))而获得粘合剂结合(adhesive bonding)。
将参考附图更详细地讨论本技术的实施方案。
附图说明
图1是显微照片,其在左手侧显示了参比材料的接受物(accept),并在右手侧显示了这种材料的单纤维;以及
图2是显微照片,其在左手侧显示了根据本技术的材料的接受物,并在右手侧显示了这种材料的单纤维。
具体实施方式
如上所述,本技术提供了水分散性纤维层形式的复合结构体,所述水分散性纤维层含有天然纤维,例如与天然纤维或合成纤维组合的木纤维。
在一个实施方案中,在水分散性复合结构体中,纤维幅材或片材包含主要通过氢键和粘合剂结合保持在一起的纤维网络。
在本发明的上下文中,就所述层包含天然纤维和合成纤维两者而言,层被称为“复合结构体”。
“水分散性”在与本发明的材料结合使用时,是指可以使纤维基体解体,并且构成纤维材料与材料分离并彼此分离。因此,至少一部分,例如至少5重量%、特别是至少10重量%、合适地至少20重量%的木纤维或其它天然纤维可以被回收并任选地再循环。
在一个方面,水分散性涉及材料能够在用于纸、纸板和其它基于纤维的产品的再循环的条件下工业再制浆的性质。例如,低稠度(LC)制浆的常规条件是2至7重量%的稠度和30至60℃的温度。(HC)制浆的常规条件是10至35重量%的稠度和30至60℃的温度。制浆时间取决于工业碎浆机的布置,例如用于碎浆(slushing)的设备和转子的尺寸。通常,进行制浆过程直到从初始材料结构体中释放(deliberated)了适当量的纤维。制浆过程可以包括化学品,如NaOH、H2O2、螯合剂、硅酸钠和表面活性剂。
根据一个实施方案,水分散性复合结构体包含“木纤维”形式的天然纤维。在一个实施方案中,此类木纤维选自漂白和非漂白的、精制和未精制的纤维,特别是未精制的纤维,其选自化学浆纤维、再循环的纤维、机械浆纤维和半机械浆纤维及其组合。
木材可以是桦木(birch)、山毛榉(beech)、山杨(aspen)如欧洲山杨、桤木(alder)、桉木(eucalyptus)、枫木(maple)、金合欢(acacia)、热带混合硬木、松木(pine)如火炬松、冷杉(fir)、铁杉(hemlock)、落叶松(larch)、云杉(spruce)如黑云杉或挪威云杉,或其混合物。
本发明的复合结构体的(一种或多种)第二纤维组分是非木纤维。此类纤维可以是天然纤维,例如一年生植物纤维、或合成纤维或其组合。合成纤维也可以被表征为“人造纤维”,这与在本发明的上下文中被认为是非合成纤维的木纤维和天然非木纤维形成对比。
因此,在一个实施方案中,非木纤维选自由非木材的植物材料(也称为天然非木材(或“非木质”材料))获得的纤维和人造纤维,例如合成纤维,特别是聚合物纤维。
非木纤维可以例如选自下组:
- 一年生或多年生植物纤维,例如大麻、亚麻、洋麻、甘蔗渣、棉、秸秆;
- 热塑性纤维,例如聚交酯(PLA)、乙醇酸聚合物(PGA)、聚羟基链烷酸酯(PHA)、聚烯烃(PO)、聚对苯二甲酸乙二醇酯(PET)、聚酯(PES)、聚乙烯醇(PVA)纤维;
- 包含热塑性聚合物的双组分纤维;
- 矿物纤维、玻璃纤维;
- 再生纤维素纤维,如粘胶纤维、莱赛尔(lyocell)纤维和人造丝纤维;
以及选自上述组中的两个或更多个的纤维的组合。
在一个实施方案中,非木纤维,特别是合成纤维,是“短切”纤维。在本发明的上下文中,“短切纤维”是长度为5至25 mm、特别是6至18 mm的纤维。在一个实施方案中,它们可以具有0.5分特至20分特、特别是1至15分特、例如1.5至10分特的纤度(thickness)。
一年生或多年生植物纤维可以作为短切纤维(如上定义)或作为通过相应植物材料的纤维分离,包括机械纤维分离、半机械纤维分离或化学纤维分离获得的纤维存在。
在一个实施方案中,纤维层由纤维幅材或片材形成,所述纤维幅材或片材含有50至90重量份的木纤维以及0至90重量份、例如10至90重量份的一年生或多年生植物纤维和0至50重量份、例如10至50重量份的合成短切纤维或其组合。天然非木纤维和合成纤维的总量通常为10至50重量份。
在一个实施方案中,纤维层的50至99重量%、特别是60至90重量%的纤维由纤维素纤维或木质纤维素纤维或其混合物构成,并且1至50重量%、特别是10至40重量%的纤维由人造纤维构成。
在一个实施方案中,纤维层的50至99重量%、特别是60至90重量%的纤维由纤维素纤维或木质纤维素纤维或其混合物构成,并且1至50重量%、特别是10至40重量%的纤维由天然非木纤维(例如一年生或多年生植物的纤维),或此类纤维与人造纤维的组合构成。
在一个实施方案中,人造纤维选自再生纤维素纤维、合成纤维、合成热塑性纤维及其混合物。
再生纤维素纤维可以选自粘胶纤维、莱赛尔纤维、人造丝纤维及其混合物。热塑性纤维选自聚烯烃纤维、聚酯纤维和生物聚合物纤维及其混合物。
在一个实施方案中,一年生和其它天然非木(通常为植物)纤维选自谷物作物的秸秆、麦秆、草芦(reed canary grass)、芦苇、亚麻、大麻、洋麻、黄麻、苎麻、种子、剑麻、蕉麻、椰子壳纤维(coir)、竹、甘蔗渣、木棉(cotton kapok)、乳草、菠萝、棉、稻、芦苇、细茎针草(esparto grass)、虉草(Phalaris arundinacea)及其组合。其它非木纤维选自种毛纤维、叶纤维和韧皮纤维。
在一个实施方案中,本发明的复合结构体还包含约0.1至20重量%,基于纤维层的粘合剂干物质和纤维部分干物质计算。
在本发明的上下文中,术语“粘合剂”表示能够将纤维结合在一起以便有助于纤维网络成型的物质。术语“粘合剂”表示单一物质以及物质的混合物。
在一个实施方案中,本发明包括水溶性聚合物和水分散性聚合物的组合。水溶性聚合物通常是亲水性聚合物,而水分散性聚合物通常是疏水性聚合物。
在一个实施方案中,粘合剂选自聚乙烯醇、聚乙酸乙烯酯分散体、乙基乙烯醇分散体、聚氨酯分散体、丙烯酸类胶乳、苯乙烯-丁二烯分散体、基于细碎纤维素的粘合剂、基于纤维素衍生物的粘合剂、生物聚合物如基于淀粉衍生物的生物聚合物、天然树胶胶乳、藻酸盐、瓜尔胶、半纤维素衍生物、壳多糖、壳聚糖、果胶、琼脂、黄原胶、直链淀粉、支链淀粉、交替糖(alternan)、结冷胶、变聚糖(mutan)、葡聚糖、普鲁兰多糖(pullulan)、果聚糖、刺槐豆胶、角叉菜胶、糖原、糖胺聚糖、胞壁质、细菌荚膜多糖等及其组合。
一个实施方案包括使用包含以下的组合的粘合剂:
- 粘合剂的第一部分由水溶性聚合物或此类聚合物的混合物形成;以及
- 粘合剂的第二部分由水分散性聚合物或聚合物混合物形成。
在一个实施方案中,第一部分(由水溶性聚合物或此类聚合物的混合物形成)与第二部分(由水分散性聚合物或聚合物混合物形成)之间的重量比为1:20至20:1、特别是1:10至10:10、例如1.5:10至2:20。
包含水溶性聚合物和水分散性聚合物两者的粘合剂形成用于形成水分散性片材或幅材的纤维层的总粘合剂的至少一部分,优选大部分,特别是75至100重量%,有利地为90至100重量%。
如上所述,水分散性复合结构体包含主要通过氢键和粘合剂结合保持在一起的纤维网络。然而,也可以存在其它组分,所述其它组分改变纤维网络的性质,特别是化学性质或物理性质,或两者。
在一个实施方案中,纤维幅材或片材还含有施胶剂,特别是反应性施胶剂。此类试剂的实例是烷基烯酮二聚体(通常简称为“AKD”)和烯基琥珀酸酐(“ASA”)。
施胶剂可以单独添加。然而,在一个实施方案中,将施胶剂与(一种或多种)粘合剂混合。
施胶剂可以以纤维层干重的0.01至10%、特别是0.1至5%、例如0.15至3%的量添加。
在一个实施方案中,制备含有包含木纤维、短切纤维和粘合剂或粘合剂组合物的层的水分散性复合结构体的方法包括以下步骤:
- 将含水纤维淤浆输送到有孔支撑物,即例如用于湿法成型的常规成型网(wire);以及
- 通过有孔支撑物排出液体以形成纤维层;以及
- 在纤维层上施加粘合剂以便将纤维至少部分粘合在一起。
通常,在本发明的纤维层中,纤维通过氢键和/或粘合剂结合形成纤维网络。
在一个实施方案中,在任选的时间点,使纤维层经受干燥和任选的轧光以形成纤维幅材或片材。
在一个实施方案中,上述方法在造纸机或纸板机上或在湿法成网非织造机上进行。
通常,该过程不包括任何水力缠结步骤。
在一个实施方案中,将粘合剂作为发泡的水性组合物施加在纤维层上。这样的组合物可以包含水溶性聚合物的水溶液,其还含有分散的水分散性聚合物。
在一个实施方案中,进料到成型网或其它有孔支撑物上的纤维淤浆包含人造纤维或天然非木纤维或其组合以及纤维素纤维、木质纤维素纤维或其混合物。含水淤浆的稠度为例如0.01至5重量%、特别是0.1至2重量%。
在一个实施方案中,粘合剂组合物以基于纤维层的粘合剂干物质和纤维部分干物质计算0.1至20重量%、例如0.1至15重量%、特别是1.5至10重量%的粘合剂的量添加。
在一个实施方案中,“在预定阶段”将粘合剂施加在纤维层上。因此,粘合剂可以在纤维层干燥至最终干燥度之前或仅在其后施加到纤维层上。
在一个实施方案中,将粘合剂施加在具有90%至10%的含水量的纤维层上。
在一个实施方案中,将粘合剂施加在具有约85重量%至65重量%的含水量的纤维层上。在另一个实施方案中,将粘合剂施加在具有约2重量%至10重量%的含水量的纤维层上。
在一个实施方案中,在压制纤维层之前将粘合剂施加到纤维层上。优选进行这样的压制以实现除水,并优选在进一步干燥和轧光之前进行这样的压制。
不考虑施加时间,在一个实施方案中,用刮刀、用施加辊将粘合剂施加到通常具有小于约10重量%的含水量的纤维层上。在另一个实施方案中,通过真空增强方法、通过非接触式施加或通过其组合将粘合剂施加到通常具有60重量%或更高的含水量的纤维层上。
将粘合剂施加到纤维层的至少一侧上,优选施加到纤维层的两个相对侧上,或者替代地或另外地,使用抽吸或减压(“真空”)来施加。
如上所述,“粘合剂”可以包括一种或若干种物质。它可以作为水溶液或作为水性分散体或作为其混合物施加。
在一个实施方案中,粘合剂包含干物质含量为1至50重量%、例如1至30重量%、特别是2.5至25重量%的水性组合物,并且该水性组合物含有至少一种水溶性聚合物和至少一种水分散性聚合物。
在一个实施方案中,粘合剂含有重量比为1:20至20:1、特别是1:10至10:10的至少一种水溶性聚合物和至少一种水分散性聚合物。重量比基于聚合物的干重计算。
在上文列举的粘合剂中,特别有利的物类由选自以下的聚合物:聚乙烯醇、聚乙酸乙烯酯分散体、乙基乙烯醇分散体、聚氨酯分散体、丙烯酸类胶乳、苯乙烯-丁二烯分散体、基于细碎纤维素的粘合剂、基于纤维素衍生物的粘合剂、生物聚合物,以及这些的组合和混合物代表。
因此,在一个实施方案中,粘合剂是通过将水溶性聚合物溶解在水中以形成所述聚合物的水溶液,并且随后将水分散性聚合物分散到所述水溶液中而获得的水性组合物。
粘合剂可以例如包含通过以下步骤制备的水性组合物:首先在环境压力下,在10至100℃、特别是15至100℃的温度下,将选自聚乙烯醇和聚乙酸乙烯酯及其组合的至少一种水溶性聚合物溶解在水中,以形成所述聚合物的水溶液,并且随后在环境压力下,在20至100℃的温度下,将选自聚氨酯分散体、丙烯酸类胶乳、苯乙烯-丁二烯分散体、粘合剂的至少一种聚合物分散到所述溶液中。
粘合剂组合物的制备可以在混合器或分散器中通过使水相经受充分混合和任选地经受剪切力来进行。
优选地,粘合剂以稳定分散体的形式提供。
在一个实施方案中,“稳定分散体”是指当在室温下静置24小时的时候,小于20%、特别是小于10%、合适地小于5%的重量的分散固体物质从分散体中沉降出来。
在一个实施方案中,分散体还包含分散剂。这样的试剂可以以分散体的固体物质的至多5重量%、特别是至多2.5重量%的量存在。
在一个实施方案中,通过将可分散在水中的聚合物分散到水溶性聚合物的水溶液中获得的粘合剂组合物随后在施加到纤维层上之前发泡。
根据所用的实际粘合剂,可以加入表面活性剂或发泡剂以实现组合物的发泡。表面活性剂或发泡剂可以以分散体的0.01至15重量%、特别是0.1至10重量%的量添加。然而,在一个实施方案中,在不存在表面活性剂的情况下使水性组合物发泡。
在一个实施方案中,发泡的粘合剂组合物包含40至80体积%、特别是55至75体积%的气体,特别是空气。
本发明的水分散性复合结构体通常包含克重为10至250 g/m2、特别是约20至200g/m2的纤维幅材或片材。这样的纤维幅材或片材优选选自非织造幅材和片材或纸幅材和片材。
根据本技术的材料具有优异的性质。因此,在制备后,纤维片材或幅材表现出良好的机械性质,这部分地通过纤维之间的氢键结合和部分地通过纤维之间的粘合剂结合来实现。不需要水力缠结或射流喷网。
如上所述,本发明类型的组合物优选能够在碎浆机(如在纸和纸板工业中常规使用的碎浆机)中离解。
因此,在一个实施方案中,纤维幅材或片材在碎浆时能够分散在水性介质中。在一个实施方案中,纤维幅材或片材能够在10至75℃的温度和6至8的pH下,通常在1至40重量%、例如2至35重量%的稠度下分散在水性介质(例如水)中。
如下文中讨论的实施例将要显示的那样,由于制浆过程中材料中的粘合剂容易离解,因此纤维将被释放并可以回收和再循环。
以下非限制性实施例说明了本技术的实施方案。
实施例1
在本实施例中,在中试环境中评价了根据本技术的用水溶性聚合物、水分散性聚合物和疏水剂的粘合剂体系结合的纤维基体的消费后模拟的一个实施方案。
对于该测试,在中试湿法成型工艺中制备用粘合剂体系结合的450 kg纤维基体。根据本发明的纤维基体含有以下组分:
纤维组分:
- 漂白的软木松牛皮浆,未精制:纤维基体的60重量%
- 长度为6 mm且纤度为1.7分特的人造纤维:纤维基体的30重量%
粘合剂体系:
- 水分散性聚合物:粘合剂体系的12重量%
- 水溶性:粘合剂体系的4重量%
- 疏水剂:粘合剂体系的1.00重量%
在制备之后,在装配有JP转子和
Figure 49186DEST_PATH_IMAGE001
20mm筛板的OptiSlush Bale碎浆机中将本发明的材料再制浆。再制浆工艺条件如下:
- 稠度:7.45%
- 温度:45℃
- 时间:20分钟
- pH:6.9
- 比能耗:59.4 kWh/吨。
Somerville薄片(TAPPI T 275)的量为35.3%,其与人造纤维和水分散性聚合物的量相当。该试验表明,粘合剂体系溶解在常规的再制浆系统中,并释放了浆粕纤维。此外,浆粕纤维可以在粗筛中与其它组分分离,并再次用于新的消费品(即纸)中。
实施例2
在本实施例中,将具有与实施例1中相同的组分和组分份额的纤维基体的消费后模拟的一个实施方案与从经干燥、未精制的软木浆中离解的纯软木纤维悬浮液进行比较。
根据PTS方法PTS-RH 021/97在由Lorentzen & Wettre制造的British浆粕离解机中将制得的纤维基体和参比的经干燥软木纤维片材离解(40℃,10分钟,3000转)。
使用光学显微镜(Axioplan Carl Zeiss EL-Ensatz)对离解的纤维基体悬浮液和参比软木纤维悬浮液进行研究。显微镜图像显示,未过筛、离解的纤维基体悬浮液(图1)的粘合剂体系已经部分溶解,并且软木浆纤维品质与软木纤维(图2)相同。
参考列表
专利文献
US 5 346 541
US 3 563 241
US 5 629 081
EP 1 285 985
US 2014/0318726。

Claims (41)

1.水分散性复合结构体,其包含纤维层,
其特征在于
- 所述纤维层的至少一部分由纤维幅材或片材形成,所述纤维幅材或片材含有50至90重量%的木纤维、10至50重量%的非木纤维和0.1至20重量%的粘合剂,由所述纤维的重量计算,所述粘合剂的至少一部分是水溶性聚合物,以及
- 所述纤维片材或幅材通过湿法成网成型技术制备。
2.根据权利要求1所述的水分散性复合结构体,其中所述木纤维为漂白或非漂白的、精制或未精制的纤维,其选自化学浆纤维、再循环的纤维、机械浆纤维和半机械浆纤维及其组合。
3.根据权利要求1或2所述的水分散性复合结构体,其中所述非木纤维选自天然非木纤维和人造纤维,特别是聚合物纤维,例如选自下组:
- 一年生或多年生植物纤维,如大麻、亚麻、洋麻、甘蔗渣、棉和秸秆及其组合;
- 热塑性纤维,例如聚交酯(PLA)、乙醇酸聚合物(PGA)、聚羟基链烷酸酯(PHA)、聚烯烃(PO)、聚对苯二甲酸乙二醇酯(PET)、聚酯(PES)、聚乙烯醇(PVA);
- 包含热塑性聚合物的双组分纤维;
- 矿物纤维、玻璃纤维;
- 再生纤维素纤维,如粘胶纤维、莱赛尔纤维、人造丝纤维;以及
- 选自上述组中的两个或更多个的纤维的组合。
4.根据权利要求1至3中任一项所述的水分散性复合结构体,其中所述非木纤维为短切纤维,所述短切纤维特别是具有5至25 mm、特别是6至18 mm的长度,并且优选具有0.5分特至20分特、特别是1至15分特、例如1.5至10分特的纤度。
5.根据前述权利要求中任一项所述的水分散性复合结构体,其中所述粘合剂选自聚乙烯醇、聚乙酸乙烯酯分散体、乙基乙烯醇分散体、聚氨酯分散体、丙烯酸类胶乳、苯乙烯-丁二烯分散体、基于细碎纤维素的粘合剂、基于纤维素衍生物的粘合剂、生物聚合物如基于淀粉衍生物的生物聚合物、天然树胶胶乳、藻酸盐、瓜尔胶、半纤维素衍生物、壳多糖、壳聚糖、果胶、琼脂、黄原胶、直链淀粉、支链淀粉、交替糖、结冷胶、变聚糖、葡聚糖、普鲁兰多糖、果聚糖、刺槐豆胶、角叉菜胶、糖原、糖胺聚糖、胞壁质、细菌荚膜多糖等及其组合。
6.根据前述权利要求中任一项所述的水分散性复合结构体,其中所述粘合剂的第一部分由水溶性聚合物或聚合物混合物形成,并且所述粘合剂的第二部分由水分散性聚合物或聚合物混合物形成。
7.根据前述权利要求中任一项所述的水分散性复合结构体,其中所述纤维幅材或片材包含主要通过氢键或粘合剂结合保持在一起的纤维网络。
8.根据前述权利要求中任一项所述的水分散性复合结构体,其中所述纤维幅材或片材还含有施胶剂,特别是反应性施胶剂,如烷基烯酮二聚体或烯基琥珀酸酐。
9.根据权利要求8所述的水分散性复合结构体,其中所述施胶剂与所述粘合剂混合。
10.根据前述权利要求中任一项所述的水分散性复合结构体,其中所述纤维幅材或片材在碎浆时能够分散在水性介质中。
11.根据前述权利要求中任一项所述的水分散性复合结构体,其中所述纤维幅材或片材能够在10至75℃的温度和6至8的pH下分散在水性介质中。
12.根据前述权利要求中任一项所述的水分散性复合结构体,其包含克重为10至250g/m2、特别是约20至200 g/m2的纤维幅材或片材。
13.根据前述权利要求中任一项所述的水分散性复合结构体,其包含选自非织造幅材和片材的纤维幅材或片材。
14.制备水分散性复合结构体的方法,所述水分散性复合结构体含有包含木纤维、非木纤维和粘合剂的层,所述方法包括以下步骤:
- 将含水纤维淤浆输送到有孔支撑物;
- 通过所述有孔支撑物排出液体以形成纤维层;以及
- 在所述纤维层上施加粘合剂以便至少部分粘合所述纤维,
其特征在于
- 所述粘合剂包含水溶性聚合物的水溶液,其还含有水分散性聚合物。
15.根据权利要求14所述的方法,其中将所述粘合剂作为发泡的水性组合物施加在所述纤维层上,所述发泡的水性组合物包含水溶性聚合物的水溶液,其还含有分散的水分散性聚合物。
16.根据权利要求14或15所述的方法,其中纤维淤浆包含人造纤维和任选的天然非木纤维,以及纤维素纤维、木质纤维素纤维或其混合物,所述含水淤浆的稠度为0.01至6重量%、特别是0.5至3重量%。
17.根据权利要求14至16中任一项所述的方法,其中所述湿法成型在造纸机或纸板机上或在湿法成网非织造机上进行。
18.根据权利要求14至17中任一项所述的方法,其中在将所述纤维层干燥至最终干燥度之前,将所述粘合剂施加在所述纤维层上。
19.根据权利要求14至18中任一项所述的方法,其中将所述粘合剂施加在具有99重量%至10重量%、特别是80重量%至20重量%、例如70重量%至25重量%的含水量的所述纤维层上。
20.根据权利要求14至19中任一项所述的方法,其包括干燥和轧光所述纤维层以形成纤维幅材或片材。
21.根据权利要求14至20中任一项所述的方法,其中用刮刀、用施加辊、通过真空增强方法或通过非接触式施加在所述纤维层的至少一侧上,将所述粘合剂施加到所述纤维层上。
22.根据权利要求14至21中任一项所述的方法,其中所述粘合剂通过将可分散在水中的聚合物分散到水溶性聚合物的水溶液中,并任选使由此获得的组合物发泡而获得。
23.根据权利要求14至22中任一项所述的方法,其中所述粘合剂包含干物质含量为1至50重量%、例如1至30重量%、特别是2.5至25重量%的水性组合物,并且所述水性组合物含有至少一种水溶性聚合物和至少一种水分散性聚合物。
24.根据权利要求14至23中任一项所述的方法,其中所述粘合剂含有基于所述聚合物的干物质计算的重量比为1:20至20:1、特别是1:10至10:10的至少一种水溶性聚合物和至少一种水分散性聚合物。
25.根据权利要求14至24中任一项所述的方法,其中所述粘合剂包含选自以下的聚合物:聚乙烯醇、聚乙酸乙烯酯分散体、乙基乙烯醇分散体、聚氨酯分散体、丙烯酸类胶乳、苯乙烯-丁二烯分散体、基于细碎纤维素的粘合剂、基于纤维素衍生物的粘合剂、生物聚合物、及其组合。
26.根据权利要求14至25中任一项所述的方法,其中所述粘合剂是通过将水溶性聚合物溶解在水中以形成所述聚合物的水溶液,并且随后将水分散性聚合物分散到所述水溶液中而获得的水性组合物。
27.根据权利要求10至26中任一项所述的方法,其中所述粘合剂是水性组合物,所述水性组合物通过在环境压力下,在10至100℃、特别是15至100℃的温度下,将选自聚乙烯醇和聚乙酸乙烯酯及其组合的至少一种水溶性聚合物溶解在水中以形成所述聚合物的水溶液,并且随后在环境压力下,在20至100℃的温度下,将选自聚氨酯分散体、丙烯酸类胶乳、苯乙烯-丁二烯分散体、粘合剂的至少一种聚合物分散到所述溶液中而制备。
28.根据权利要求14至27中任一项所述的方法,其包括提供作为稳定分散体的所述粘合剂。
29.根据权利要求14至28中任一项所述的方法,其包括将施胶剂与所述粘合剂混合,所述施胶剂特别是反应性施胶剂,如烷基烯酮二聚体或烯基琥珀酸酐。
30.根据权利要求14至29中任一项所述的方法,其包括使所述水性组合物发泡,特别是在不存在表面活性剂的情况下。
31.根据权利要求14至30中任一项所述的方法,其中所述纤维层的50至99重量%、特别是60至90重量%的纤维由纤维素纤维或木质纤维素纤维或其混合物构成,并且1至50重量%、特别是10至40重量%的纤维由天然非木纤维或人造纤维或其组合构成。
32.根据权利要求14至31中任一项所述的方法,其中所述木纤维为漂白或非漂白的、精制或未精制的纤维,其选自化学浆纤维、再循环的纤维、机械浆纤维和半机械浆纤维及其组合,特别是所述木纤维选自基本上未精制的纤维素纤维、木质纤维素纤维及其组合。
33.根据权利要求14至32中任一项所述的方法,其中所述人造纤维选自再生纤维素纤维、合成纤维、合成热塑性纤维及其混合物。
34.根据权利要求33所述的方法,其中所述再生纤维素纤维选自粘胶纤维、莱赛尔纤维、人造丝纤维及其混合物。
35.根据权利要求14至34中任一项所述的方法,其中所述天然非木纤维选自一年生或多年生纤维,例如大麻、亚麻、洋麻、甘蔗渣、棉和秸秆及其组合。
36.根据权利要求14至35所述的方法,其中所述热塑性纤维选自聚烯烃纤维、聚酯纤维和生物聚合物纤维及其混合物。
37.根据权利要求14至36中任一项所述的方法,其包括施加基于所述纤维层的干物质计算0.1至20重量%、例如0.5至15重量%、例如1至10重量%的粘合剂。
38.根据权利要求14至37中任一项所述的方法,其包括制备克重为10至250 g/m2、特别是约20至200 g/m2的纤维幅材。
39.根据权利要求14至38中任一项所述的方法,其中所述纤维通过氢键或粘合剂结合形成纤维网络。
40.水分散性复合结构体,其通过根据权利要求14至39中任一项所述的方法获得。
41.根据权利要求14至40中任一项所述的方法用于制备选自非织造幅材、非织造片材或纸幅材或纸片材的非织造产品的用途。
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