CN113430716A - 一种结构弹性的非织造复合材料及其制备方法 - Google Patents
一种结构弹性的非织造复合材料及其制备方法 Download PDFInfo
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- CN113430716A CN113430716A CN202110347144.4A CN202110347144A CN113430716A CN 113430716 A CN113430716 A CN 113430716A CN 202110347144 A CN202110347144 A CN 202110347144A CN 113430716 A CN113430716 A CN 113430716A
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- D10B2509/026—Absorbent pads; Tampons; Laundry; Towels
Abstract
本发明公开了一种结构弹性非织造复合材料及其制备方法，涉及非织造复合材料领域，该非织造复合材料是由超细弹性纤维和主体纤维共混组成，具有一体结构、比表面积大、结构蓬松、弹性伸长率高和拉伸恢复性强的特点，可以在医疗防护、个人护理和防撞包装等多个领域应用；同时，该非织造复合材料的制备方法为：(1)超细弹性纤维层的准备；(2)主体纤维层的准备；(3)一体化结构的复合成型；(4)收缩‑弹性整理；本非织造复合材料在生产过程中没有使用有毒化学试剂，具有绿色环保，对人体无害的特点，具有大规模化生产和应用的优势。
Description
技术领域
本发明涉及非织造复合材料领域，具体涉及一种具有结构弹性的非织造复合材料及其制备方法。
背景技术
近几年来，非织造材料在原材料和加工工艺选择上不断创新，产品性能不断提高，功能日益多元化，应用领域不断拓大。其中，弹性非织造材料作为一种非织造材料功能化、技术化和复合化的产物，因其优异的回弹性能，广泛应用在医疗卫生和服装领域，如婴儿尿布、卫生巾、医用绷带、运动服、内衣等。具有超弹性功能的非织造材料得到了国内外诸多专家学者的青睐，成为非织造材料行业的研究热点。
目前，弹性非织造布的生产方式主要有三大类：(1)使用弹性聚合物原料通过熔喷法或纺粘法成网制得弹性非织造材料。如专利CN201810205125.6中将聚烯烃弹性共聚物、超高分子量聚乙烯和改性后的热塑性聚合物共混纺丝得到一种聚丙烯基长丝弹性超柔非织造材料；(2)将非织造布与弹性膜或弹性网复合在一起，从而获得具有一定弹性的非织造布。如专利CN202010838954.5中将无纺布基层、胶粘层和弹性层从上到下复合在一起形成具有弹性的非织造材料；(3)弹性纤维和非弹性纤维混合，经非织造加工方法(针刺、水刺、热黏合等)使非织造材料获得弹性。尽管这些方法实现了非织造布的弹性，但是上述的弹性非织造材料技术存在下述这样的难点：(1)使用弹性聚合物原料成本相对较高，同时其结构稳定性不足；(2)非织造布与弹性膜或弹性网复合大量使用乳胶，环保性不足的同时还往往导致制得的非织造布透气性差、轻柔性不够等。
因此如何制造出一种弹性好、强力高、柔软性佳、低成本和绿色环保的非织造材料满足人们对于医疗卫生领域非织造材料的要求是行业内的共性问题。
发明内容
为解决上述问题，本发明提出一种结构弹性的非织造复合材料及其制备方法，所获得的结构弹性非织造布不但弹性好，同时有优越的蓬松、透气性、柔软性，具有皮肤追随性,兼具较高的力学性能，而且具有操作方便，纤维直径小、比表面积大、结构蓬松、孔隙率大、孔径小、工艺先进、流程短、成本低等优势。
本发明采取的技术方案之一是：一种结构弹性的非织造复合材料的制备方法，其包括如下步骤：
(1)超细弹性纤维层的准备：以热塑性非结晶聚合物和热塑性弹性聚合物为原料，采用熔喷成型技术获得一种纤维直径为0.1-10μm、弹性回复率100％～300％、孔隙率为85-95％的超细弹性纤维层；
(2)主体纤维层的准备：直径为30-200μm的纤维组成的孔隙率为90-99％、厚度为0.5-1.0mm、纵向取向角度小于30°的纤维占比大于45％纤维网为主体纤维层；
(3)一体化结构的复合成型：将步骤(1)的超细弹性纤维层和步骤(2)的主体纤维层按照一定的顺序上下叠层组合成复合纤维网，然后利用水射流或者金属刺针对其进行反复穿刺形成具有一体化结构的复合纤维网；
(4)收缩-弹性整理：将步骤(3)的复合纤维网送入到一定温度环境下进行热处理，使得超细弹性纤维收缩而形成一种弹性非织造复合材料。
进一步的，所述步骤(1)中热塑性非结晶聚合物采用聚对苯二甲酸乙二醇-1，4-环己烷二甲醇酯、交联聚乙烯、交联聚氯乙烯和丙烯腈-丁二烯-苯乙烯中的任一种；热塑性弹性聚合物采用乙烯—辛烯共聚物、热塑性聚氨酯和聚酰胺热塑弹性体中的任一种；所述热塑性非结晶聚合物和热塑性弹性聚合物的质量比为3:7～7:3。
进一步的，所述步骤(1)中热塑性非结晶聚合物和热塑性弹性聚合物在加工温度下二者的粘度比接近1。
进一步的，所述步骤(2)中主体层纤维层选择高蓬松度的纤维网，以便于超细弹性纤维层分配到主体纤维层使两层之间纤维互相穿插。
进一步的，所述步骤(2)中主体层纤维层采用纤维素纤维、涤纶、丙纶、腈纶中的一种或几种组合，并且其形态为纺粘长丝纤维形态或者干法梳理纤维形态。
进一步的，所述步骤(3)中的超细弹性纤维层和主体纤维层的叠层组合采用在线复合或者离线复合。
进一步的，所述步骤(3)中的超细弹性纤维层和主体纤维层的叠层组合方式包括：主体纤维层-超细弹性纤维层-主体纤维层和主体纤维层-超细弹性纤维层-主体纤维层-超细弹性纤维层-主体纤维层。
进一步的，所述步骤(4)中热收缩整理的烘干温度高于热塑性非结晶聚合物的玻璃化转变温度5～30°，热收缩整理张力小于5N。
本发明采取的技术方案之二是：一种结构弹性的非织造复合材料，所述非织造复合材料由技术方案一中所述的方法制备而成。其中，制得的非织造复合材料的面密度为90～150g/m2，纵向拉伸强力90～160N，纵向伸长率100～190％，横向拉伸强力40～110N，横向伸长率120～190％，空气透气性650～810cfm，柔软度2.1～2.7g，孔隙率为80～90％，厚度1.0～1.7mm，熔喷层纤维直径0.1-10μm，弹性回复率100～150％。
本发明的有益效果如下：
(1)本发明以热塑性非结晶聚合物和热塑性弹性聚合物为原料，采用熔喷工艺获得超细弹性纤维层并和主体纤维层复合通过机械加固而成，生产工艺简单，操作方便，不使用化学试剂绿色环保且此弹性的原料使用的少，成本低。
(2)超细弹性纤维层和主体纤维层在加固过程中均匀相互穿插到不同纤维网层中，使复合纤网在收缩-弹性整理后弹性更强。且超细弹性纤维层和主体纤维层的高蓬松结构可以是使复合材料具有优异的柔软度和透气性。
(3)本发明的一种结构弹性的非织造复合材料具有熔喷非织造材料较大的比表面积，孔隙小而空隙率大，结构蓬松，具有较好的各向同性同时具有机械加固非织造材料强度高、绿色环保等的特点。本发明的所制备的产品的最终面密度为90～150g/m2(GB/T24218.1—2009)，纵向拉伸强力90～160N/，纵向伸长率100～190％，横向拉伸强力40～110N，横向伸长率120～190％(GB/T 24218.3-2010)，空气透气性650～810cfm(GB/T5453—1997)，柔软度2.1～2.7g(GB/T 18318.1-2009)，孔隙率为80～90％，厚度1.0～1.7mm(GB/T24218.2-2009)，熔喷层纤维直径0.1-10μm，弹性回复率100～150％，(FZ/T 01034—2008)。可以很好用于医疗卫生领域，尤其适用于医用绷带、纸尿裤、卫生巾等需要弹性性能卫生产品。
(4)本发明的一种结构弹性的非织造复合材料具的制备方法是复合技术，且不同组合方式可以获得不同性能弹性非织造复合材料。可以根据产品的性能要求，随机调整热收缩弹性层、主体层的面密度和厚度以及组合方式，不仅可以弹性强、强度高、柔软性好的产品，还具有很好的工艺灵活性。
附图说明
图1为本发明的熔喷制备工艺示意图；
其中标记为：1-料斗；2-螺杆挤压机；3-计量泵；4-熔喷模头；5-热风风源；6-真空抽吸箱；7-输网帘；8-熔喷非织造布。
图2为超细弹性纤维层和主体纤维层其中随意两种组合方式图，(a)表示组合：主体纤维层-超细弹性纤维层-主体纤维层，(b)表示组合：主体纤维层-超细弹性纤维层-主体纤维层-超细弹性纤维层-主体纤维层；
其中标记为：9-主体纤维层；10-超细弹性纤维层。
图3为超细弹性纤维截面图。
图4为复合材料SEM图。
图5为复合材料截面示意图；
其中标记为：9-主体纤维层；10-超细弹性纤维层。
图6成型方法流程图；
其中标记为：11-超细弹性纤维层成型；12-主体纤维层成型；13-一体化结构的复合成型；14-收缩-弹性整理；15-收卷。
图7实施1例弹性回复曲线。
图8实施2例弹性回复曲线。
图9实施3例弹性回复曲线。
图10不同温度超细纤维层热收缩效果图，底布均为未发生收缩的材料:15.5cm×15.5cm；(a)为60℃热处理效果图，(b)为70℃热处理效果图，(c)为80℃热处理效果图。
具体实施方式
下面结合附图和具体实施例对本发明进行详细说明。
实施例一
本实施例提供一种结构弹性的非织造复合材料的制备方法，其制备步骤如下：
(1)超细弹性纤维层的准备：制备工艺流程如图1所示，将聚对苯二甲酸乙二醇-1,4-环己烷二甲醇酯(k2012，SK综合化学株式会社)和聚烯烃类弹性体(7050FL，埃克森美孚化工)按照质量比5：5的比例进行物理共混放入熔喷试验机中，设定具体熔喷工艺参数为：计量泵温度260℃、熔喷模头温度290℃、螺杆挤出机温度(一区-四区)：260℃、270℃、280℃、290℃；计量泵转速7r/min、风机转速45r/min、卷绕速度1.7r/min、接受距离20cm。所得共混纤维直径平均为0.8um，克重为40g/m2。
(2)主体纤维层准备；将涤纶纤维，纤维直径为38um，纤维长度为50mm，利用干法梳理成网(具体流程参照《非织造学》第三章，梳理网克重为60g/m2。
(3)一体化结构的复合成型；将步骤(1)得到的熔喷非织造材料和步骤(2)得到的干法梳理的纤维网通过干法梳理网-超细弹性纤维层-干法梳理网排列方式组合在一起，如图2(a)所示。将复合后的纤维网在高压水刺(水刺头压力设定为40bar、80bar，主水刺机3个水刺头压力设定为110bar、160bar和60bar)进行加固。
(4)收缩-弹性整理：经水刺加固的复合纤维网轧出多余水分后经三道烘箱进行烘干在去除水分的同时使热收缩弹性层纤维热收缩使复合材料获得弹性。三道烘干温度为：第一道烘箱温度60℃，第二道烘箱温度70℃，第三道烘箱温度80℃)。
关于所得的弹性的非织造复合材料，测定面密度、力学性能、空气透气性、柔软度、孔隙率为、厚度、纤维直径、弹性回复率进行测试，测试结果见表1中，产品形态如图4所示，截面如图3所示。
实施例二
本实施例提供的一种结构弹性的非织造复合材料的制备方法，其制备方法与实施例一的制备方法相同，区别在于：热收缩弹性层的接收距离的工艺参数设定为25cm。
实施例三
本实施例提供的一种结构弹性的非织造复合材料的制备方法，其制备方法与实施例一的制备方法相同，区别在于：热收缩弹性层的接收距离的工艺参数设定为30cm。
实施例四
本实施例提供的一种结构弹性的非织造复合材料的制备方法，其制备方法与实施例一的制备方法相同，区别在于：热收缩弹性层的接收距离的工艺参数设定为25cm，将梳理纤网纤维改为粘胶纤维直径为40um，纤维长度为45mm。
实施例五
本实施例提供的一种结构弹性的非织造复合材料的制备方法，其制备方法与实施例一的制备方法相同，区别在于：热收缩弹性层的接收距离的工艺参数设定为25cm，将梳理纤网纤维改为腈纶纤维直径为45um，纤维长度为55mm，
实施例六
本实施例提供的一种结构弹性的非织造复合材料的制备方法，其制备方法与实施例一的制备方法相同，一体化复合的组合为：干法梳理网-超细弹性纤维层-干法梳理网-超细弹性纤维层-干法梳理网，如图2(b)所示。
上述实施例一至六中的特征指标等通过以下方法来测定。
(1)厚度测试
参考GB/T 24218.2—2009《纺织品非织造布试验方法第2部分:厚度的测定》，使用YG141D型织物厚度仪(温州市大荣纺织仪器有限公司)对样品厚度进行测试，测试受压面积为500mm2。
(2)强力测试
根据国标GB/T 24218.3-2010《纺织品非织造布试验方法第3部分:断裂强力和断裂伸长率的测定(条样法)》，每组样品分别沿横向和纵向各取5块尺寸为250mm×50mm的条形试样，取样时应距离布边至少100mm，调湿、测试并记录断裂强力及断裂伸长率，做出应力-应变曲线。
(3)纤维直径的测定
利用扫描电子显微镜(EVO18，ZEISS，德国)观察样品表面形态，并拍照获得扫描电镜图，此后从扫描电镜图中随机选取50根纤维，并利用软件imageJ并测定其纤维直径，获得其算术平均值来表征其纤维直径。
(4)柔软性的测定
采用抗弯长度来表征样品柔软性。依据GB/T 18318.1-2009，将样品裁剪成25cm×2.5cm的条形形态；此后用一根底面粘有橡胶层的滑尺压在试样上，尺端与样品端平齐。然后以一定的速度缓缓将滑尺向斜面方向推出，试样在滑尺的带动下同步向斜面滑出，由于自重的作用试样下垂，当头端刚刚触及斜面时，从标尺读出试样的弯曲长度。
(5)面密度：参照GB/T 24218.1-2009《纺织品非织造布试验方法第1部分：单位面积质量的测定》测定样品的面密度。采用圆刀取样器裁剪面积为100cm2的试样，通过电子天平测试得到其面密度。单组样品裁取5个试样，取其平均值。
(6)孔隙率的计算
计算公式
η＝(1-G/(ρf×T))×100％ (1)
ρf＝ρ1*wi+ρ2*w2+......ρn*wn (2)
式中G为面密度，T为材料厚度，ρf为纤维密度，ρ1、ρ2和ρn为组份的密度，w1、w2和wn为组份的密度分数；
(7)透气性测试
根据GB/T 5453-1997《纺织品织物透气性的测定》，用单位时间内流过试样单位面积的空气体积表征。在各试样的10个不同位置处随机检测，结果取平均值并记录。
(8)弹性回复率
参考FZ/T 01034-2008《纺织品机织物拉伸弹性试验方法》，使用YG065H型电子织物强力机(莱州电子仪器有限公司)通过定长法测试样品的弹性回复率。持距为80mm，宽度为20mm，拉伸速度为100mm/min，拉伸距离为80mm，拉伸停滞时间为60s，松弛停滞时间为180s，拉伸2次。
本发明所制备的产品的最终面密度为90～150g/m2(GB/T 24218.1-2009)，纵向拉伸强力90～160N/，纵向伸长率100～190％，横向拉伸强力40～110N，横向伸长率120～190％(GB/T 24218.3-2010)，空气透气性650～810cfm(GB/T 5453-1997)，柔软度2.1～2.7g(GB/T 18318.1-2009)，孔隙率为80～90％，厚度1.0～1.7mm(GB/T 24218.2-2009)，熔喷层纤维直径0.1-10μm，弹性回复率100～150％，(FZ/T 01034-2008)。
测试结果如表1：
以上显示和描述了本发明的基本原理、主要特征和优点。本领域的普通技术人员应该了解，上述实施例不以任何形式限制本发明的保护范围，凡采用等同替换等方式所获得的技术方案，均落于本发明的保护范围内。
本发明未涉及部分均与现有技术相同或可采用现有技术加以实现。
Claims (10)
1.一种结构弹性的非织造复合材料的制备方法，其特征在于包括如下步骤：
(1)超细弹性纤维层的准备：以热塑性非结晶聚合物和热塑性弹性聚合物为原料，采用熔喷成型技术获得一种纤维直径为0.1-10μm、弹性回复率100％～300％、孔隙率为85-95％的超细弹性纤维层；
(2)主体纤维层的准备：直径为30-200μm的纤维组成的孔隙率为90-99％、厚度为0.5-1.0mm、纵向取向角度小于30°的纤维占比大于45％纤维网为主体纤维层；
(3)一体化结构的复合成型：将步骤(1)的超细弹性纤维层和步骤(2)的主体纤维层按照一定的顺序上下叠层组合成复合纤维网，然后利用水射流或者金属刺针对其进行反复穿刺形成具有一体化结构的复合纤维网；
(4)收缩-弹性整理：将步骤(3)的复合纤维网送入到一定温度环境下进行热处理，使得超细弹性纤维收缩而形成一种弹性非织造复合材料。
2.根据权利要求1所述的一种结构弹性的非织造复合材料的制备方法，其特征在于，所述步骤(1)中热塑性非结晶聚合物采用聚对苯二甲酸乙二醇-1，4-环己烷二甲醇酯、交联聚乙烯、交联聚氯乙烯和丙烯腈-丁二烯-苯乙烯中的任一种；热塑性弹性聚合物采用乙烯—辛烯共聚物、热塑性聚氨酯和聚酰胺热塑弹性体中的任一种；所述热塑性非结晶聚合物和热塑性弹性聚合物的质量比为3:7～7:3。
3.根据权利要求1所述的一种结构弹性的非织造复合材料的制备方法，其特征在于，所述步骤(1)中热塑性非结晶聚合物和热塑性弹性聚合物在加工温度下二者的粘度比接近1。
4.根据权利要求1所述的一种结构弹性的非织造复合材料的制备方法，其特征在于，所述步骤(2)中主体层纤维层选择高蓬松度的纤维网，以便于超细弹性纤维层分配到主体纤维层使两层之间纤维互相穿插。
5.根据权利要求1所述的一种结构弹性的非织造复合材料的制备方法，其特征在于，所述步骤(2)中主体层纤维层采用纤维素纤维、涤纶、丙纶、腈纶中的一种或几种组合，并且其形态为纺粘长丝纤维形态或者干法梳理纤维形态。
6.根据权利要求1所述的一种结构弹性的非织造复合材料的制备方法，其特征在于，所述步骤(3)中的超细弹性纤维层和主体纤维层的叠层组合采用在线复合或者离线复合。
7.根据权利要求1所述的一种结构弹性的非织造复合材料的制备方法，其特征在于，所述步骤(3)中的超细弹性纤维层和主体纤维层的叠层组合方式包括：主体纤维层-超细弹性纤维层-主体纤维层和主体纤维层-超细弹性纤维层-主体纤维层-超细弹性纤维层-主体纤维层。
8.根据权利要求1所述的一种结构弹性的非织造复合材料的制备方法，其特征在于，所述步骤(4)中热收缩整理的烘干温度高于热塑性非结晶聚合物的玻璃化转变温度5～30°，热收缩整理张力小于5N。
9.一种结构弹性的非织造复合材料，其特征在于，所述非织造复合材料由上述权利要求1至7中任意一项所述的方法制备而成。
10.根据权利要求9所述的一种结构弹性的非织造复合材料，其特征在于：所述非织造复合材料的面密度为90～150g/m2，纵向拉伸强力90～160N，纵向伸长率100～190％，横向拉伸强力40～110N，横向伸长率120～190％，空气透气性650～810cfm，柔软度2.1～2.7g，孔隙率为80～90％，厚度1.0～1.7mm，熔喷层纤维直径0.1-10μm，弹性回复率100～150％。
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| CN114232218A (zh) * | 2021-12-27 | 2022-03-25 | 江西省安秀实业发展有限公司 | 一种包络型弹力无纺布及其制备装置和制备方法 |
| CN115262093A (zh) * | 2022-09-25 | 2022-11-01 | 苏州多瑈新材料科技有限公司 | 一种定向弹性非织造材料、制备方法及弹性制品 |
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| CN114232218A (zh) * | 2021-12-27 | 2022-03-25 | 江西省安秀实业发展有限公司 | 一种包络型弹力无纺布及其制备装置和制备方法 |
| CN115262093A (zh) * | 2022-09-25 | 2022-11-01 | 苏州多瑈新材料科技有限公司 | 一种定向弹性非织造材料、制备方法及弹性制品 |
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