CN1135778A - 高强度细纺粘纤维及其织物 - Google Patents

高强度细纺粘纤维及其织物 Download PDF

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CN1135778A
CN1135778A CN94194239A CN94194239A CN1135778A CN 1135778 A CN1135778 A CN 1135778A CN 94194239 A CN94194239 A CN 94194239A CN 94194239 A CN94194239 A CN 94194239A CN 1135778 A CN1135778 A CN 1135778A
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polymer
bondedfibre fabric
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R·M·布顿
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Kimberly Clark Corp
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
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    • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
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    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
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    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2535/00—Medical equipment, e.g. bandage, prostheses or catheter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • Y10T428/2915—Rod, strand, filament or fiber including textile, cloth or fabric
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Abstract

提供一种制备无纺纤维及其织物的工艺，它们具有类似于普通纤维和织物的强度特性，且它们的直径更细。这个目的实现可通过如下工艺：由至少一种熔融温度约410-470°Ｆ(210-243℃)，二甲苯溶解度在3.5-7.0％之间、熔融流动速率约30-45，全同立构规整度至少约94％的聚合物，纺细孔挤出，牵伸聚合物生成1.4或更小旦尼尔的纤维，然后将纤维化聚合物铺放在收集表面而形成分布纤维的网。本发明的无纺织物可用作如下制品，如尿布、成年人失禁制品，妇女卫生制品，绷带，绑带，消毒巾，医用布以及毛巾。

Description

高强度细纺粘纤维及其织物
发明背景
本发明涉及的是一种由热塑性树脂的细纺粘纤维形成的无纺织物或网及其将它们加工成织物的工艺。
多年来热塑性树脂被用来挤出以形成纤维和网。应用于这方面的最常规的热塑性材料是聚烯烃，特别是聚丙烯。由这类纤维制成的最终产品的性能，使每种材料既有优点也有缺点。
无纺织物在很多应用领域是有用的，诸如尿布，妇女卫生制品，失禁制品，毛巾，医用外衣以及很多其它用途。这些应用领域的无纺织物通常是叠层形成的，就象纺粘/熔喷/纺粘(SMS)层状制品。在SMS层状产品中，外层是纺粘聚丙烯，它的存在通常是为了增强，而内层是熔喷聚丙烯，它通常是隔离层。
用来制造无纺织物的纤维的理想特性之一是它们应尽可能的细。在很多注重平滑和均匀的应用埸合，例如，类似尿布的婴幼儿护理制品中，希望较细的纤维。希望采用细纤维还因为它们能在指定量的聚合物时提供较好的表面覆盖并可采用较轻基重的织物。基重是表面覆盖性的测量单位，它是以每平方码(OSY)织物的盎司数来表达的。降低基重将使得由这类织物制成的产品更轻、薄，并且设定相同的消耗时，其费用低于那些用普通纤维制成的产品。
同时合乎要求的较细的纤维，具有的缺点通常是，相对较大直径的纤维而言其强度更低。实际上这就设定了由纤维制成的织物基重的低限，这是因为存在纤维化或织物加工过程的困难，或是因为最终的织物缺乏强度。工业上一直在研究一种既很细又能尽可能保持普通纺粘材料强度的纤维。
本发明的目的在于提供一种纤维，它比那些常规工艺制备的纤维更细，而且具有类似的强度性能。
本发明简要说明
提供一种无纺纤维和织物，其具有类似于普通纤维和织物的强度特性并且具有更细的直径。这个目的可以通过所提供的制备无纺织物的工艺得以实现，所述的工艺包括如下步骤，熔融至少一种聚合物，该聚合物的熔融温度为约430-460°F(220-240℃)，二甲苯溶解度约为4.5-6.5％，熔融流动速率为约35-41，全同立构规整度至少为约94％：通过细孔挤出聚合物，牵伸该聚合物以制备1.4或更小旦尼尔的纤维，然后将纤维化的聚合物沉积在收集表面以形成分布纤维的网。
本发明所述的无纺织物可以被用在如下产品中，如尿布，妇女卫生用品，成年人失禁用品，绷带，绑带，消毒巾，医用布和毛巾(Wipers)。
定义
这里所用的词“无纺织物或网”指的是一种具有独立纤维或线结构的网，它们是层叠的，但不是以规整方式的，如针织和机织工艺。无纺织物或网可由多种方式制造，如熔喷工艺，纺粘工艺以及粘接梳理网工艺。
这里所用的词“熔喷纤维”指的是由下述工艺形成的纤维，即从一组细的，通常是圆形的毛细模板中挤出熔融的热塑性材料，如熔融的线或长丝，使之进入高速气体(如，空气)流中使熔融的热塑性材料的长丝变细以降低它们的直径，它们可以达到微纤的直径。其后，熔喷纤维被高速气流携带着并沉积在收集表面以形成随机分布的熔喷纤维网。这类工艺已被公开，如美国专利3849241，由BuTin申请的。
这里所用的词“纺粘纤维”指的是小直径纤细，它的形成如下所述：将类似于长丝的熔融热塑性材料从一组细孔中挤出，所述细孔通常是圆形毛细管的喷丝板，被挤出的长丝具有的直径然后迅速降低，例如Appel等人申请的美国专利4340563，Dorschner等人申请的美国专利3692618。
这里所用的词“聚合物”通常包括，但不限制于，均聚物，共聚物，诸如嵌段、接枝、无规和交替共聚物、三元共聚物等，以及它们的混合物和改性物。另外，除非特别指出，词“聚合物”还包括所有可能的几何构型的材料。这些构型包括，但不限于，间同立构、全同立构和无规对称。
附图说明
图1是2种聚丙烯的分子量分布图，它们是Shell Chemical公司的5E65和UnipolTM 1208。
图2是UnipolTM 1208聚丙烯的碳13核磁共振图(NMR)，采用三甲基甲硅烷作为载体，在Bruker AC-250核磁共振光谱仪上用已知方式完成的。
详细说明
用于纺粘工艺的聚烯烃的重要性能是那些在现有技术中已知的。熔融流动速率(MFR)、分子量分布(MWD)以及结晶度是部份最重要的性能，并且这些性能的每一个通常是通过测量存在的聚丙烯分子的大小而得。
MFR是用来表征聚合物的粘度的，较高的值表征较低的粘度。MFR指的是在指定的负载或剪切速率下测量时间内从已知尺寸的毛细管中流出的材料重量，在230℃下以克/10分钟测得，例如，按照ASTM试验方法1238，条件E。分子量分布给出了所给试样主要的分子大小的表征。高分子量分子表征的缺乏是存在于试样中很长聚丙烯分子缺乏的表征。
二甲苯溶解度(Xylene Solubles)测定聚合物中低分子量全同立构和中分子量无规立构试样的量。分子量分布的二甲苯溶解部份不结晶而且被认为有助于纤维气动变细工艺中的纤维牵伸处理。
聚合物结晶度的另一种测量法是全同立构的聚合物相对总的聚合物的百分比。这被定义为全同立构整度或全同立构整度指数，并可以通过聚合物核磁共振曲线计算得到。业已发现，用于本发明实施的聚合物必须具有至少约94％的全同立构整度。
可用于本发明实施的一种聚烯烃是新型的聚丙烯，可从Shell化学公司(Houston，Texas)按注册商标UnipolTM购得。图1表明了UnipolTM 1208聚丙烯，它比普通的例如被用于高速纤维工艺的5E65聚丙烯有更宽的分子量分布。聚合物相对于普通聚丙烯还具有更高的二甲苯溶解(XS)度。UnipolTM 1208聚丙烯有着如下的物理特性：熔融流动速率(MFR)约38dg/m，约6％的二甲苯溶解度。
UnipolTM 1208聚丙烯的NMR曲线中无规立构和全同立构的峰的积分区域在图2中已给出，并且显示全同立构部份在21.4ppm是3662而无规部份在20.8ppm处为99。这就得到了约97％的全同立构整度或全同立构整度指数，计算如下：3662/(3662+99)。
制备本发明所述织物的纤维可采用现有技术的纺粘工艺来制备，例如，在Appel等人的U.S 4340563和Dorschner等人的U.S3692618中已有描述，它们作为参考文献并入本文。
纺粘工艺通常采用一个挤出器向喷丝板提供熔融的聚合物，其间聚合物在通过设置在喷丝板上一排或多排细孔时被纤维化，形成长丝帘。长丝通常用低压空气冷却，牵伸(通常靠压缩空气)并沉积在移动的有孔毡、皮带或成形带上形成无纺织物。用于纺粘工艺的聚合物通常有约406-608°F(208-320℃)的加工熔融温度。
由纺粘工艺生产出的纤维的直径通常在约15-50μm之间，取决于加工条件和用这种纤维制备的织物的期望的最终用途。例如，增加聚合物分子量或降低加工温度将导致较大直径的纤维。改变冷却流体温度和气动牵伸压力也将影响纤维的直径。正如前面指出的，较细的纤维通常是更理想的，并且是本发明的目的。
本发明的织物可以以单层形式实施或作为结合本发明织物的多层复合使用，这种复合可采用很多不同的技术来实施，包括(但不限于此)采用粘接、针刺、超声波粘合、热压和任何其它的已知方法。这类多层复合可以是一个实例，其中部份层是纺粘的而部份是熔喷的，诸如纺粘/熔喷/纺粘(SMS)叠层物，如Brock等人的USP4041203以及Collier等人的USP 5169706中公开的。这类叠层物可以通过如下方式制备，顺序地将第一层纺粘织物层铺放在移动的传送带或成型网上，然后是一层熔喷织物层和最后的另一层纺粘织物层，然后用上述一种方法粘合成叠层物。另一种方法是三层织物层可单独制备，在辊简中收拢并在单独的粘合工序中复合。本发明的织物也可以与膜、玻纤、短纤维、纸、以及其它常用的材料叠层。本发明织物的应用领域是成年人失禁用品，妇女卫生用品，绷带，绑带，消毒巾，医用布和毛巾等。毛巾可以是工业用或家庭用，如Countertop或浴室揩布。
过去，不能生产出强度类似于普通直径聚丙烯的细纤维。可以相信，虽然发明人不希望受特定理论的束缚，其理由是在纤维被牵伸时有竟争性反应发生。当聚合物由模板毛细管出来时，可以认为聚合物暴露时由于压力减少而得到膨胀。这种现象被称为模膨胀。聚合物同时被暴露在牵伸力中，可以认为它将引起应力，而应力诱导结晶的发生。在该位置增加牵伸力以降低纤维大小会导致纤维断裂或导致更大纤维，这是因为应力的增加诱导了结晶。可以相信降低聚合物离开模板时的膨胀将降低全部纤维的直径，并且为了降低模膨胀，聚丙烯中很长链分子必须剔除。可以相信，能满足本发明需求的聚合物中很少有很长链分子存在。
下面的实施例和比较例显示了能满足本发明需要和不能满足本发明需要的聚合物制成的纤维特性。
实施例
纤维是在约450-460°F(230-240℃)的温度下用UnipolTM 1208聚丙烯纺制而成。喷丝板孔径是0.6毫米，并且通量是在0.6-0.7克/孔/分钟(ghm)之间。纤维采用气动牵伸，气动牵伸力以逐步方式增加直至发生纤维断裂。其结果列于表1中。
表1实施例      聚合物       微米     断裂负荷    韧度1          1208        16.3     4.5          2.72          1208        14.8     4            2.93          1208        15       4.2          2.94          1208        13.9     3.5          2.95          1208        13.5     4.2          3.7  6          1208        11.3     2.9          3.67          1208        12.6     2.8          2.88          1208        14.9     4.5          3.29          1208        15.4     4.4          2.910          1208        15.5     4.3          2.911          1208        15.7     4.4          2.812          1208        15       4.1          2.913          1208        14.6     3            2.314          1208        14.6     4            3
比较例
采用上述实施例中的方式将Exxon化学公司的3445聚丙烯和Shell化学公司的5E65聚丙烯纺成纤维。Exxon 3445聚丙烯的熔融流动速率为35，二甲苯溶解度为约3.5，全同立构整度为92％，其加工熔融温度约为450-460°F。Shell 5E65聚丙烯的熔融流动速率为约36，二甲苯溶解度为约3.5％，全同立构整度为92％，其加工熔融温度约为450-460°F。其结果列于表2。
表2对比例       聚合物    微米    断裂负荷    韧度1          3445      17.8    4.1         22          3445      16.7    5.7         3.33          5E65      19.1    4.8         2.1
纤维的直径是以微米给出的，它可以借助求方并将结果乘以系数0.00629换算成旦尼尔，因而，15微米相当于约1.42旦尼尔(152X0.00629＝1.415)。断裂负荷以克给出，且通过使用Instron拉伸试验机以单纤维拉伸测得。韧度是用断裂负荷除以旦尼尔数确定的。
其结果令人惊异的显示，由用于本发明的聚合物纺制的纤维能制备出具有类似于普通大直径聚丙烯纤维(断裂负荷优选至少4)物理性能的细纤维。直径几乎低至11微米的纤维采用纺粘工艺被成功地制备，而且它们具有商业上可接受的强度。

Claims (11)

1.制备无纺织物的工艺，包括如下步骤：
熔融至少一种聚合物，所述聚合物具有约430-460°F(220-240℃)的熔融温度，二甲苯溶解度约4.5-6.5％，熔融流动速率约35-41，以及至少约94％的全同立构规整度；
将所述聚合物从细孔中挤出；
牵伸所述聚合物以制备1.4或更小旦尼尔的纤维，以及；
将所述纤维化的聚合物铺放在收集表面上而形成分布纤维的网。
2.权利要求1的方法制备的无纺织物，所述织物以如下制品存在：尿布、成年人失禁制品、妇女卫生用品、绷带、绑带、消毒巾、医用布和毛巾(Wipers)。
3.权利要求1的方法制备的无纺织物，所述方法还包括将一层熔喷材料铺放在所述聚合物之上的工序。
4.权利要求3的方法制备的无纺织物，所述方法还包括将一层纺粘材料铺放在所述熔喷材料之上的工序。
5.权利要求1的方法制备的无纺织物，其中，所述聚合物具有图2的NMR曲线。
6.无纺织物，包括小于1.4旦尼尔的细纤维，这种纤维由熔融温度约430-460°F(220-240℃)，二甲苯溶解度约4.5-6.5％，熔融流动速率约35-41之间以及至少约94％的全同立构规整度的聚合物制成。
7.权利要求6的无纺织物，其制品形式选自尿布、成年人失禁制品、妇女卫生用品、绷带、绑带、消毒巾、医用布和毛巾。
8.权利要求6的无纺织物，其中，所述纤维的断裂负荷至少约4磅。
9.权利要求6的无纺织物，它是由纺粘工艺制成的。
10.权利要求6的无纺织物，其中，所述聚合物具有图2的NMR曲线。
11.权利要求6的无纺织物，它叠合至由如下材料中选出的一种材料上，所述材料包括膜、玻纤、短纤维和纸。
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