CN115107336A - 一种具有吸水功能的混合无纺布及其制造方法 - Google Patents

一种具有吸水功能的混合无纺布及其制造方法 Download PDF

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CN115107336A
CN115107336A CN202210831847.9A CN202210831847A CN115107336A CN 115107336 A CN115107336 A CN 115107336A CN 202210831847 A CN202210831847 A CN 202210831847A CN 115107336 A CN115107336 A CN 115107336A
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layer
melt
water
fiber
blown
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孙宏宇
宋凯
张凯能
张强
高中心
焦枢栋
任振锋
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Junfu Nonwovens Co ltd
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    • B32B5/02—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 characterised by structural features of a fibrous or filamentary layer
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
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  • Nonwoven Fabrics (AREA)

Abstract

本发明公开了一种具有吸水功能的混合无纺布及其制造方法，包括顶层和底层，所述顶层为纺粘纤维层或熔喷纤维层，所述底层为纺粘纤维层或熔喷纤维层，所述顶层和底层之间设有至少一层由亲水性短纤与熔喷纤维混合而成的吸水混合层，所述顶层、底层和吸水混合层自粘合在一起或通过热轧辊压合在一起，本混合无纺布不需要胶粘合，健康环保不易掉屑，而且制造简单，应用广泛。

Description

一种具有吸水功能的混合无纺布及其制造方法
技术领域
本发明涉及一种卫生用品技术领域，尤其涉及一种具有吸水功能的混合无纺布及其制造方法。
背景技术
现在具有吸水性的混合无纺布的应用非常广泛，很多需要具有吸水性的产品，如干湿巾、医用铺单、纸尿裤芯体、隔尿垫、卫生巾和产褥垫等产品中都会用到具有吸水性的混合无纺布，目前，具有吸水功能的混合无纺布通常是融合了吸水性材料(通常是木浆)和熔喷布两种材料，将吸水性材料制成层状，夹在熔喷层里面，利用吸水性材料的吸水性能实现吸水功能，这种吸水性材料和熔喷布结合的混合无纺布具有以下缺点，吸水性材料和熔喷层的结合通常需要用胶粘合，存在一定的污染，对人的身体健康不利，若不用胶粘合则容易掉屑，掉屑严重就影响产品的使用，产品质量不过关。
发明内容
本发明提供一种健康环保且不容易掉屑的一种具有吸水功能的混合无纺布。
为解决上述技术问题，本发明的技术方案是：一种具有吸水功能的混合无纺布，包括顶层和底层，所述顶层为纺粘纤维层或熔喷纤维层，所述底层为纺粘纤维层或熔喷纤维层，所述顶层和底层之间设有至少一层由亲水性短纤与熔喷纤维混合而成的吸水混合层，所述顶层、底层和吸水混合层自粘合在一起或通过热轧辊压合在一起。
熔喷纤维属于长纤维，制作熔喷纤维时，需要用两侧风进行牵伸和冷却，将亲水性短纤混在两侧风内，使亲水性短纤穿插在熔喷纤维内，即可形成一个整体的吸水混合层，顶层、吸水混合层和底层合在一起，就能制成混合无纺布，本产品不容易掉屑，不需要用胶粘，健康环保，而且制造工艺简单，节省成本，而且使用范围广泛，干湿巾、医用铺单、纸尿裤芯体、隔尿垫、卫生巾和产褥垫等需要吸水性的产品里均可应用。
作为一种优选方案，所述亲水性短纤的长度为1-4mm，所述亲水性短纤为亲水性化纤、木浆、棉纤、麻纤和高分子吸水树脂中的至少一种，所述亲水性化纤包括双组份纤维和卷曲纤维。亲水性短纤可以采用的种类很多，可以单独选用一种，也可以组合使用，根据产品应用范围选择不同的材料，如制造高端一些的产品可以采用木浆，一些低端产品可以采用价格较低的材料，木浆的应用是最常见最普遍的。亲水性化纤的种类也很多，其中双组份纤维和卷曲纤维除亲水性外有一些特别的特性，双组份纤维外层是低熔点材料，芯是高熔点材料，通过热轧，双组份纤维的外层可以熔融粘到其他纤维上，减轻掉屑的发生，卷曲纤维可以起到增加厚度的作用，再制作某些特定需要的混合无纺布时，可以添加双组份纤维或卷曲纤维。
作为一种优选方案，所述顶层、底层和吸水混合层通过点对点热轧辊压合在一起，并在所述顶层和底层上压印上凹进去的轧点，此种结构可以使亲水性短纤与熔喷纤维结合更加紧密，防止掉屑，同时能增加混合无纺布的强力，防止分层，同时轧点可以设计为装饰性图案，使产品作为商品出售时能提升商品的价值。
作为一种优选方案，本混合无纺布的组成成分按质量份数计，包括木浆50-90份，PP熔喷料10-50份，弹性体0-5份，白母粒0-1份。此种材料配比可以用于制造质量较高的干湿巾。
作为进一步优选方案，本混合无纺布包括两层吸水混合层。
作为进一步优选方案，所述顶层的轧点面积占所述顶层总面积的10-25％。
作为一种优选方案，本混合无纺布的克重为20-120gsm。
本发明还涉及一种上述的混合无纺布的制造方法，包括以下步骤：
a)准备制造所述顶层、吸水混合层和底层的原料；顶层和底层的原料相同，为PP纺粘料或PP熔喷料，用以制造纺粘纤维层或熔喷纤维层，吸水混合层的原料包括PP熔喷料、亲水性短纤维以及其他根据需要添加的辅料。
b)采用熔喷法分别制造出形成所述顶层、吸水混合层和底层的长丝纤维，形成所述顶层和底层的长丝纤维通过冷却水冷却，形成所述吸水混合层的长丝纤维通过冷却风冷却，所述冷却风内添加有亲水性短纤维，使所述亲水性短纤维穿插粘连在形成所述吸水混合层的长丝纤维上；熔喷法是目前最常用的制造工艺，具体步骤见实施方式。
c)形成所述顶层、吸水混合层和底层的长丝纤维按照顺序叠置在一起形成纤网，所有的纤网通过自粘合在一起或一对热轧辊压合在一起形成混合无纺布。
通过此工艺可以制造出一种具有吸水功能的混合无纺布，而且此工艺简单，在现有工艺的基础上增加了往冷却风内混入亲水性短纤维的步骤，对现有生产线的改动较小，工艺成本较低。
作为一种优选方案，采用熔喷法制造所述顶层、吸水混合层和底层的长丝纤维时，采用多排喷丝板生成长丝纤维，多排喷丝板的每个出丝口处均设有热风对熔体进行牵伸。多排喷丝板可以产生多排长丝纤维，方便木浆附着在长丝纤维上，可以更好地固定木浆，防止木浆掉落。
作为一种优选方案，原料按质量份数计，包括木浆50-90份，PP熔喷料10-50份，弹性体0-5份，白母粒0-1份。
附图说明
以下附图仅旨在于对本发明做示意性说明和解释，并不限定本发明的范围。其中：
图1是本发明实施例的部分截面的示意图；
图2是本发明实施例的部分布面的俯视图；
图中：1，顶层；2，吸水混合层；3，轧点；4，底层。
具体实施方式
下面结合附图和实施例，进一步阐述本发明。在下面的详细描述中，只通过说明的方式描述了本发明的某些示范性实施例。毋庸置疑，本领域的普通技术人员可以认识到，在不偏离本发明的精神和范围的情况下，可以用各种不同的方式对所描述的实施例进行修正。因此，附图和描述在本质上是说明性的，而不是用于限制权利要求的保护范围。
此外，下面所描述的本发明各个实施方式中所涉及的技术特征只要彼此之间未构成冲突就可以相互组合。
如图1和图2所示，一种具有吸水功能的混合无纺布，包括顶层1和底层4，顶层1为纺粘纤维层或熔喷纤维层，底层4为纺粘纤维层或熔喷纤维层，顶层1和底层4之间设有两层由亲水性短纤与熔喷纤维混合而成的吸水混合层2，顶层1、底层4和吸水混合层2通过一对点对点热轧辊压合在一起，形成的混合无纺布的克重为20-120gsm，吸水混合层2采用的亲水性短纤的长度为1-4mm，亲水性短纤为亲水性化纤、木浆、棉纤、麻纤和高分子吸水树脂中的至少一种，可以是单独一种材料，也可以是上述材料的混合，具体根据制造的产品选择，亲水性化纤有很多种选择，其中双组份纤维和卷曲纤维这两种材料有各自的特点，双组份纤维有防止掉屑的作用，卷曲纤维有增加厚度的作用。
以本混合无纺布用来制造湿巾为例，亲水性短纤选用木浆，产品的原料按质量分数计，木浆50-90份，PP熔喷料10-50份，弹性体0-5份，白母粒0-1份。顶层1、底层4和吸水混合层2通过一对点对点热轧辊压合在一起，并在顶层1和底层4上压印上凹进去的轧点3，顶层1的轧点3面积占顶层1总面积的10-25％，轧点1设计为某种特定图案，增加美观性。
上述实施例中吸水混合层2的层数是两层，吸水混合层2的层数可以根据需要设定，亲水性短纤选用的材料也可以根据产品性质确定。
以下是本产品的制造工艺流程的实施例：
实施例一；
(1)原料的选择与分配；
以质量份数计，准备以下原料：
木浆：68.04份；PP熔喷料：31.38份；白母粒：0.58份；
熔喷模头从最初生产端开始命名为模头A、模头B、模头C、模头D。PP熔喷料加入模头A和模头D，PP熔喷料及白母粒分别加入模头B和模头C进行混合熔融。
(2)熔融挤出及木浆破碎
各个模头的原料通过各自对应的螺杆挤出机混合均匀、熔融、然后通过计量泵定量挤出，模头A、模头B、模头C、模头D挤出量比例为1:10.42:10.42:1；；
各个模头对应的螺杆挤出机的螺杆及连接区温度为186-201℃，模头温度204℃；
成卷的纸浆喂入破碎机进行破碎形成短纤维的木浆，木浆投入风机送入下一工序。
(3)纺丝成网；
模头A、模头B、模头C和模头D的原料经过各自的计量泵送入对应的纺丝组件，原料形成的熔体经由多排喷丝板生成熔喷纤维，每个熔喷纤维的出丝口(也称为喷丝孔)都吹有热风，熔喷纤维靠出丝口周围的热风进行牵伸。模头A和模头D的原料对应的多排喷丝板通常设有两排或四排出丝口，模头B和模头C的原料对应的多排喷丝板通常设有十一排出丝口。模头B、模头C对应的熔喷纤维分别在两侧吹有冷却风，通过冷却风对熔喷纤维进行冷却，冷却风来自于上游带有木浆的风机，冷却风沿着幅宽方向吹，冷却风内携带的木浆穿插到熔喷纤维中，四处冷却风携带的木浆比例为1：1：1：1。模头A和模头D对应的熔喷纤维，靠两侧冷却水喷向熔喷纤维来冷却，冷却水不接触熔喷纤维，靠冷却水蒸发带走熔喷纤维的热量，所有的熔喷纤维按顺序铺设到网带上形成纤网。
(4)热轧；
叠置在一起的所有纤网经过一对点对点热轧辊热压后形成具有一定图案的混合型无纺布，其结构如图1和图2所示，热轧辊在混合型无纺布上压有凹进去的轧点3，模头A的原料最终形成底层4，底层4为熔喷纤维层。模头B和模头C模头的原料及两侧木浆最终形成的是吸水混合层2。模头D的料形成的是顶层1，顶层1为熔喷纤维层。
(5)卷绕；
经过热轧后的形成的混合型无纺布，进行卷绕成卷。
制备的混合型复合无纺布的性能如下：
指标 单位 本产品指标 测试方法
克重均值 gsm 50.96 ASTM D 3776
MD断裂强力 N 13.64 WSP 110.4
CD断裂强力 N 7.21 WSP 110.4
MD断裂强力(湿态) N 13.39 WSP 110.4
CD断裂强力(湿态) N 7 WSP 110.4
厚度 mm 0.88 WSP 120.6
吸液倍率 ％ 12.13 WSP 10.1
透气 L/m<sup>2</sup>/s 672.06 ASTM D737
实施例2：
(1)原料的选择与分配；
以质量份数计，准备以下原料：
木浆：63份；PP熔喷料：33.76份；白母粒：0.54份；弹性体2.7份；
熔喷模头从最初生产端开始命名为模头A、模头B、模头C、模头D。PP熔喷料加入模头A和模头D，PP熔喷料、白母粒及弹性体分别加入模头B和模头C进行混合熔融。
(2)熔融挤出及木浆破碎
各个模头的原料通过各自对应的螺杆挤出机混合均匀、熔融、然后通过计量泵定量挤出，模头A、模头B、模头C、模头D挤出量比例为3:8.1:8.1:3；
各模头对应的螺杆挤出机的螺杆及连接区温度为186-201℃，模头温度204℃；
成卷的纸浆喂入破碎机进行破碎形成短纤维的木浆，木浆投入风机送入下一工序。
(3)纺丝成网；
模头A、模头B、模头C和模头D的原料经过各自的计量泵送入对应的纺丝组件，原料形成的熔体经由多排喷丝板生成熔喷纤维，每个熔喷纤维的出丝口都吹有热风，熔喷纤维靠出丝口周围的热风进行牵伸。模头A和模头D的原料对应的多排喷丝板通常设有两排或四排出丝口，模头B和模头C的原料对应的多排喷丝板通常设有十一排出丝口。模头B、模头C对应的熔喷纤维分别在两侧吹有冷却风，通过冷却风对熔喷纤维进行冷却，冷却风来自于上游带有木浆的风机，冷却风沿着幅宽方向吹，冷却风内携带的木浆穿插到熔喷纤维中，四处冷却风携带的木浆比例为1：1：1：1。模头A和模头D对应的熔喷纤维，靠两侧冷却水喷向熔喷纤维来冷却，冷却水不接触熔喷纤维，靠冷却水蒸发带走熔喷纤维的热量，所有的熔喷纤维按顺序铺设到网带上形成纤网。
(4)热轧；
叠置在一起的所有纤网经过一对点对点热轧辊热压后形成具有一定图案的混合型无纺布，其结构如图1和图2所示，热轧辊在混合型无纺布上压有凹进去的轧点3，模头A的原料最终形成底层4，底层4为熔喷纤维层。模头B和模头C模头的原料及两侧木浆最终形成的是吸水混合层2。模头D的料形成的是顶层1，顶层1为熔喷纤维层。
(5)卷绕；
经过热轧后的形成的混合型无纺布，进行卷绕成卷。
制备的混合型复合无纺布的性能如下：
指标 单位 本产品指标 测试方法
克重均值 gsm 61.84 ASTM D 3776
MD断裂强力 N 16.8 WSP 110.4
CD断裂强力 N 8.85 WSP 110.4
MD断裂强力(湿态) N 15.54 WSP 110.4
CD断裂强力(湿态) N 8.78 WSP 110.4
厚度 mm 1.00 WSP 120.6
吸液倍率 ％ 11.4 WSP 10.1
透气 L/m<sup>2</sup>/s 509.65 ASTM D737
实施例3：
(1)原料的选择与分配；
以质量份数计，准备以下原料：
木浆：83.25份；PP熔喷料：15.64份；白母粒：0.19份；弹性体：0.93份。
熔喷模头从最初生产端开始命名为模头A、模头B、模头C、模头D。PP熔喷料加入模头A和模头D，PP熔喷料、白母粒及弹性体分别加入模头B和模头C进行混合熔融。
(2)熔融挤出及木浆破碎
各个模头的原料通过各自对应的螺杆挤出机混合均匀、熔融、然后通过计量泵定量挤出，模头A、模头B、模头C、模头D挤出量比例为3:3.7:3.7:3；
各模头对应的螺杆挤出机的螺杆及连接区温度为186-201℃，模头温度204℃。
成卷的纸浆喂入破碎机进行破碎形成短纤维的木浆，木浆投入风机送入下一工序。
(3)纺丝成网；
模头A、模头B、模头C和模头D的原料经过各自的计量泵送入对应的纺丝组件，原料形成的熔体经由多排喷丝板生成熔喷纤维，每个熔喷纤维的出丝口都吹有热风，熔喷纤维靠出丝口周围的热风进行牵伸。模头A和模头D的原料对应的多排喷丝板通常设有两排或四排出丝口，模头B和模头C的原料对应的多排喷丝板通常设有十一排出丝口。模头B、模头C对应的熔喷纤维分别在两侧吹有冷却风，通过冷却风对熔喷纤维进行冷却，冷却风来自于上游带有木浆的风机，冷却风沿着幅宽方向吹，冷却风内携带的木浆穿插到熔喷纤维中，四处冷却风携带的木浆比例为1：1：1：1。模头A和模头D对应的熔喷纤维，靠两侧冷却水喷向熔喷纤维来冷却，冷却水不接触熔喷纤维，靠冷却水蒸发带走熔喷纤维的热量，所有的熔喷纤维按顺序铺设到网带上形成纤网。
(4)热轧；
叠置在一起的所有纤网经过一对点对点热轧辊热压后形成具有一定图案的混合型无纺布，其结构如图1和图2所示，热轧辊在混合型无纺布上压有凹进去的轧点3，模头A的原料最终形成底层4，底层4为熔喷纤维层。模头B和模头C模头的原料及两侧木浆最终形成的是吸水混合层2。模头D的料形成的是顶层1，顶层1为熔喷纤维层。
(5)卷绕；
制备的混合型复合无纺布的性能如下：
指标 单位 本产品指标 测试方法
克重均值 gsm 80.49 ASTM D 3776
MD断裂强力 N 11.95 WSP 110.4
CD断裂强力 N 6.14 WSP 110.4
MD断裂强力(湿态) N 10.67 WSP 110.4
CD断裂强力(湿态) N 5.76 WSP 110.4
厚度 mm 1.29 WSP 120.6
吸液倍率 ％ 12.68 WSP 10.1
透气 L/m<sup>2</sup>/s 563.90 ASTM D737
以上显示和描述了本发明的基本原理、主要特征及本发明的优点。本行业的技术人员应该了解，本发明不受上述实施例的限制，上述实施例和说明书中描述的只是说明本发明的原理，在不脱离本发明精神和范围的前提下，本发明还会有各种变化和改进，这些变化和改进都落入要求保护的本发明范围内。本发明要求保护范围由所附的权利要求书及其等效物界定。

Claims (10)

1.一种具有吸水功能的混合无纺布，包括顶层和底层，其特征在于：所述顶层为纺粘纤维层或熔喷纤维层，所述底层为纺粘纤维层或熔喷纤维层，所述顶层和底层之间设有至少一层由亲水性短纤与熔喷纤维混合而成的吸水混合层，所述顶层、底层和吸水混合层自粘合在一起或通过热轧辊压合在一起。
2.如权利要求1所述的一种具有吸水功能的混合无纺布，其特征在于：所述亲水性短纤的长度为1-4mm，所述亲水性短纤为亲水性化纤、木浆、棉纤、麻纤和高分子吸水树脂中的至少一种，所述亲水性化纤包括双组份纤维和卷曲纤维。
3.如权利要求1所述的一种具有吸水功能的混合无纺布，其特征在于：所述顶层、底层和吸水混合层通过点对点热轧辊压合在一起，并在所述顶层和底层上压印上凹进去的轧点。
4.如权利要求3所述的一种具有吸水功能的混合无纺布，其特征在于：组成成分按质量份数计，包括木浆50-90份，PP熔喷料10-50份，弹性体0-5份，白母粒0-1份。
5.如权利要求4所述的一种具有吸水功能的混合无纺布，其特征在于：包括两层吸水混合层。
6.如权利要求5所述的一种具有吸水功能的混合无纺布，其特征在于：所述顶层的轧点面积占所述顶层总面积的10-25％。
7.如权利要求1所述的一种具有吸水功能的混合无纺布，其特征在于：其克重为20-120gsm。
8.如权利要求1所述的一种具有吸水功能的混合无纺布的制造方法，包括以下步骤：
a)准备制造所述顶层、吸水混合层和底层的原料；
b)采用熔喷法分别制造出形成所述顶层、吸水混合层和底层的长丝纤维，形成所述顶层和底层的长丝纤维通过冷却水冷却，形成所述吸水混合层的长丝纤维通过冷却风冷却，所述冷却风内添加有亲水性短纤维，使所述亲水性短纤维穿插粘连在形成所述吸水混合层的长丝纤维上；
c)形成所述顶层、吸水混合层和底层的长丝纤维按照顺序叠置在一起形成纤网，所有的所述纤网通过自粘合在一起或一对热轧辊压合在一起形成混合无纺布。
9.如权利要求8所述的一种具有吸水功能的混合无纺布的制造方法，其特征在于：采用熔喷法制造所述顶层、吸水混合层和底层的长丝纤维时，采用多排喷丝板生成长丝纤维，多排喷丝板的每个出丝口处均设有热风对熔体进行牵伸。
10.如权利要求8所述的一种具有吸水功能的混合无纺布的制造方法，其特征在于：原料按质量份数计，包括木浆50-90份，PP熔喷料10-50份，弹性体0-5份，白母粒0-1份。
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CN102407552A (zh) * 2011-10-21 2012-04-11 成都彩虹环保科技有限公司 多层纤维板成型装置
US20120177888A1 (en) * 2009-07-20 2012-07-12 Ahlstron Corporation High cellulose content, laminiferous nonwoven fabric
CN106661787A (zh) * 2014-06-17 2017-05-10 株式会社可乐丽 吸水性叠层体及其制造方法
CN107217392A (zh) * 2017-07-20 2017-09-29 徐家潼 双组份熔喷设备

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101395315A (zh) * 2006-02-21 2009-03-25 纤维网辛普森维利有限公司 可伸展的吸水性复合材料
US20120177888A1 (en) * 2009-07-20 2012-07-12 Ahlstron Corporation High cellulose content, laminiferous nonwoven fabric
CN102407552A (zh) * 2011-10-21 2012-04-11 成都彩虹环保科技有限公司 多层纤维板成型装置
CN106661787A (zh) * 2014-06-17 2017-05-10 株式会社可乐丽 吸水性叠层体及其制造方法
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