CN116100884A - 弹性非织造片材 - Google Patents

弹性非织造片材 Download PDF

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Publication number
CN116100884A
CN116100884A CN202211309297.0A CN202211309297A CN116100884A CN 116100884 A CN116100884 A CN 116100884A CN 202211309297 A CN202211309297 A CN 202211309297A CN 116100884 A CN116100884 A CN 116100884A
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CN
China
Prior art keywords
sheet
elastic
propylene
fibers
olefin copolymer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN202211309297.0A
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English (en)
Inventor
M·R·汉森
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Fibertex Personal Care AS
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Fibertex Personal Care AS
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Publication date
Application filed by Fibertex Personal Care AS filed Critical Fibertex Personal Care AS
Publication of CN116100884A publication Critical patent/CN116100884A/zh
Pending legal-status Critical Current

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    • A61F13/00—Bandages or dressings; Absorbent pads
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Abstract

本发明涉及弹性可拉伸非织造片材，其包括可拉伸非织造弹性层和可拉伸饰面层；以及涉及用于制造此类片材的在线方法。

Description

弹性非织造片材
技术领域
本发明涉及一种弹性可拉伸非织造片材，包括弹性可拉伸非织造弹性层和可拉伸非织造饰面层，以及涉及用于制造此类片材的在线方法。
背景技术
非织造片材广泛用于卫生行业，作为大规模制造婴儿尿布和成人失禁产品的材料。然而，在许多情况下，例如，在开口尿布中制作后耳或在尿布裤中制作腰带部分，需要弹性可拉伸材料，而标准非织造片材不符合该要求。
解决非织造片材的有限弹性拉伸问题的传统方法包括在非织造材料层之间包括弹性膜。所得层压材料可具有良好的弹性性能，但弹性膜不透气，这可能导致穿戴者不适。另一种方法包括将弹性股(通常称为莱卡股)纳入片材。这种方法的缺点是具有局部弹性力，其也可能导致穿戴者不适，并且在生产过程中该股容易断裂。
此外，弹性膜或股的掺入使片材具有弹性，但仅在与弹性膜或股相关联的非织造材料的最大拉伸范围内。大多数传统的非织造材料的最大断裂伸长率值在机器方向(MD)为约50-80％并且在横跨机器方向(CD)为约70-100％(WSP 110.4)，最通常甚至更小，这意味着它们在被破坏之前只能伸长到非常有限的程度。然而，对于上述规定的应用，需要将片材弹性拉伸其初始尺寸的150％(即达到其初始尺寸的250％)，并且根据具体应用，该要求可适用于横跨机器方向或机器方向拉伸。例如，对于制作传统的开口或胶带式婴儿尿布，典型的生产工艺要求用于后耳的材料在CD中表现出该幅度的弹性拉伸。另一方面，对于制作成人或婴儿尿布裤，典型的生产工艺要求用于其中的弹性应用材料，如皮带，在MD中表现出该幅度的弹性拉伸。
解决非织造材料拉伸受限问题的传统方法是，在将非织造片材层压到弹性膜或股时打褶。这样，非织造材料本身缺乏延伸性，可以通过在每个褶皱中存储额外的材料得到补偿。然而，褶皱的缺点是在生产过程中需要更多的材料和更高的最终产品厚度，这造成隔热性增强和外观更明显，使得消费者产生负面印象。
最近的方法使用固有弹性可拉伸非织造材料。这些片材最终包括一个可拉伸但本身不是很有弹性的非织造饰面层和弹性非织造层。
WO 2020/187540 A1中公开了生产这种弹性可拉伸非织造片材的离线工艺。该方法包括使用由卷曲纤维形成的预制饰面层，并在纺粘过程中在其上沉积弹性纤维以形成纺粘弹性层。然后在一对瓦楞辊中预拉伸片材。所得产品可以CD方向弹性拉伸其初始尺寸的150％或甚至更多，在这个范围满足行业要求，但已证明其MD方向的弹性拉伸更为有限。离线工艺获得更高MD方向拉伸的潜力有限，因为当预制饰面层第二次通过生产线时，已证明它们已失去了相当多的拉伸能力。
EP 3 715 517 A1中公开了生产弹性可拉伸非织造片材的在线工艺。该方法使用多光束纺粘生产线来制造片材，该片材包括由卷曲纤维形成的可拉伸饰面层和在压延粘合和预拉伸材料之前由同一生产线中的弹性纤维形成的弹性层。该工艺生产的产品在CD方向显示出令人满意的拉伸能力，但在MD方向也同样缺乏拉伸能力。
因此，卫生行业仍然需要在机器方向具有较高固有的弹性拉伸能力的非织造片材。
发明内容
在该上下文中，本发明提出了一种弹性可拉伸的非织造片材，包括至少两层非织造材料，其中一层是弹性可拉伸非织造层，该非织造层包括由热塑性弹性体聚合物材料形成的纺粘弹性纤维；另一层是可拉伸饰面层，该饰面层包括纺粘卷曲多组分纤维；其中相邻层通过压花粘合点粘合在一起，并且其中卷曲多组分纤维的至少一种组分是丙烯-α-烯烃共聚物材料。
与EP 3 715 517 A1中公开的非织造片材相比(该片材使用聚丙烯作为饰面层的双组分纤维的两种组分)，在双组分纤维的至少一种组分中使用丙烯-α-烯烃共聚物(co-PP)，这令人惊讶地导致片材的整体弹性显著增加，尤其是在机器方向(MD)上。具体地，当根据WSP 100.4测量时，此类片材MD方向已经实现断裂伸长率的目标值超过150％，优选超过200％。
根据本发明的片材优选地表现出有利的弹性行为，尤其是在机器方向上。
发明详述
在一个实施方案中，在第一次循环后根据ASTM D5459测量的机器方向的永久变形小于15％，优选小于10％，更优选小于5％。
在一个实施方案中，在根据ASTM D5459测试的滞后曲线中，第二个循环的机器方向的上升和下降的应力-应变曲线之间的面积比，以曲线(A)下的面积与初始上升曲线下的总面积(A+B)之比，％[A/(A+B)x100]表示，该百分比为小于40％，优选小于30％。
多组分纤维的两个或多个组分在纤维的横截面上不对称排列。在优选实施方案中，多组分纤维是双组分纤维。标准并且在许多情况下优选是并排双组分纤维，但本发明的概念不限于并排纤维，并且也可以通过其他横截面实现，例如偏心-护套-芯横截面。
所述饰面层和弹性层两者的非织造材料均为纺粘非织造布，且所述非织造布优选全部为纺粘非织布片材。
术语“α-烯烃”具有本领域技术人员所通常理解的含义。α-烯烃优选具有1至5个碳原子，例如可以是乙烯、丙烯或α-丁烯。
与丙烯共同形成共聚物的α-烯烃优选为乙烯。换句话说，共聚物优选为聚(丙烯-乙烯)共聚物。同样优选地，共聚物是无规共聚物。
丙烯-α-烯烃共聚物中的共聚单体含量或聚(丙烯-乙烯)共聚物中的乙烯含量优选≥1wt.-％，更优选≥2wt.-％。作为上限，共聚单体含量可以是≤8wt.-％，优选≤6wt.-％。
卷曲多组分纤维的另一种组分优选为聚丙烯均聚物(PP)。本文中的聚丙烯均聚物被理解为单体纯度大于99.5wt.-％，优选大于99.8wt.-％，更优选大于99.9wt.-％。
实验证明，使用聚丙烯作为一种组分且聚(丙烯-乙烯)共聚物作为另一种组份的双组分纤维导致MD拉伸显著增加。
在另一优选的实施方案中，卷曲多组分纤维的丙烯-α-烯烃共聚物的分子量分布(如通过多分散性(Mw/Mn)表示的)比其他组分，优选用作双组分纤维的另一种组分的聚丙烯均聚物的分子量分布更宽。
就具体数值而言，两种聚合物的Mw/Mn之间的差值优选为≥1，更优选≥2，且最优选≥3。另一方面，两种聚合物的Mw/Mn之间的差值优选≤10，且优选≤8。合适的Mw/Mn的绝对数值可以在例如，聚丙烯为2.5至7.5，且丙烯-α-烯烃共聚物为4至10的范围内。
作为多组分纤维的组分，共聚PP或均聚PP可与其他聚合物或其他添加剂(如滑动助剂、填料材料或色母粒)共混，但二者应占相应混合物重量的大于50％，优选大于75％且更优选大于90％。
在卷曲双组分纤维中，双组分纤维中的共聚PP组分与其他组分、优选均聚PP的重量比优选为20/80至80/20，更优选为30/70至70/30，并且还更优选为40/60至60/40。
用于弹性纤维的热塑性弹性体材料可包含热塑性聚烯烃弹性体(TPE-o)，优选包含丙烯-α-烯烃共聚物的热塑性聚烯烃弹性体。EP 2 342 075 A1中公开了用于本发明上下文中的合适TPE-o材料。备选地或另外地，作为混合物，可以使用其他热塑性弹性体材料，例如尤其是热塑性聚氨酯(TPU)或苯乙烯嵌段共聚物(TPE-s)。在一个实施方案中，热塑性弹性体材料中可包含至多20wt.-％和优选至多10wt.-％的热塑性烯烃(例如均聚聚丙烯)。也可以添加添加剂，诸如过滤剂、滑动助剂或色母粒。在一个实施方案中，双组分弹性纤维可以由两种不同的热塑性弹性体形成，其例如以并排或皮芯结构排列。
片材的弹性层和饰面层可以包括如上定义的弹性纤维或双组分纤维以及其他纤维，但优选由所述定义的弹性或双组分纤维组成。
在一个实施方案中，片材包括弹性层两侧上的至少一个饰面层，因此总体上为至少三层。这种结构有利于覆盖两侧上固有粘性的弹性层。
在各实施方案中，可以如上所述为第一饰面层配置附加饰面层。弹性层的不同侧面上的饰面层可能相同，但也可能不同。例如，其中一个非织造饰面层可以是纺粘非织造层，且另一个非织造材料饰面层可能是不同的纺粘非织造层或熔喷非织造层。
每个饰面层的基础重量可能在5-40g/m2之间，优选在8-30g/m2之间，更优选在10-25g/m2之间，且还更优选在15-20g/m2之间。弹性层的基础重量可在10-140g/m2之间，优选在20-120g/m2之间，且更优选在25-100g/m2之间。
片材通常包括宏观粘合点的图案。在优选的实施方案中，织物表面每cm2的粘合点数量可以低于100，优选低于80，且另一方面优选高于20。在一个实施方案中，局部粘合点占织物表面的总面积小于18％，且优选小于15％，这意味着粘合图案优选为相对开放的。
在一个实施方案中，即使本发明的片材已经具有固有的高的机器方向拉伸能力，也可以通过进行机器方向的预拉伸来进一步激活片材，如下文进一步详细描述的。
本发明还提出了一种根据本发明制造弹性可拉伸非织造片材的方法，包括以下在线步骤：(a1)纺丝卷曲多组分纤维，其中卷曲多成分纤维的至少一种组分是丙烯-α-烯烃共聚物；并将其铺设在移动的纺带上以形成网；(a2)纺丝由热塑性弹性体聚合物材料形成的弹性纤维，并将其铺设在步骤(a1)中形成的网的表面上，以形成另一网；(b)将相邻的网粘合以形成弹性可拉伸纺粘非织造片材。
步骤(a1)和(a2)的纺丝包括在纺粘机中挤出、淬火和拉拔纤维。在步骤(a1)等中形成的纤维网是在粘合步骤(b)后形成的分别用于非织造片材的饰面层和弹性层的非织造材料的未粘合前体。
步骤(b)的粘合最优选为压花。具体地，所述粘合可包括将粘合点压花到片材中，压花通过设置在至少一个压延辊表面上的压花凸起而实现。实施方案包括超声粘合，其中超声振动被引入压花凸起。其他实施方案包括在加热压花凸起处使用热粘合。
在优选的变体中，织物表面每cm2的粘合点数量可能低于100。局部粘合点占织物表面的总面积优选小于18％，且更优选小于15％，这意味着粘合图案是相对开放的。
在一个实施方案中，该方法还包括纺丝附加纤维，优选卷曲多组分纤维的步骤(a3)，其中最优选卷曲多组分纤维的至少一种组分是丙烯-α-烯烃共聚物，并将其铺设在步骤(a2)中形成的网的表面上，以形成另一网。在该方法的变体中，提供了根据本发明的优选实施方案的片材，其具有插入在两个饰面层之间的弹性层的夹层结构。
在一个实施方案中，该方法还包括预压实饰面层的网。优选地，在每个相应步骤即步骤(a1)和，如果适用，步骤(a3)之后有一个预压实步骤。预压实优选包括使网通过两个平的预压实辊。所施加的线性压力优选在3-5N/mm之间。辊温度可为50-110℃，更优选为60-100℃。由于由热塑性弹性体形成的纤维的固有粘性，在步骤(a2)之后不需要预压实或预压实不可行。
在一个实施方案中，该方法还包括机器方向预拉伸片材的步骤(c)。
例如，机器方向预拉伸可能会受到在各组辊以不同速度在机器方向上拉动材料的影响。
实现机器方向预拉伸的另一种选择包括在铣床中机械激活片材，铣床由一对相互作用的辊组成，辊的表面包括联锁环形肋和凹槽(“环轧”)或联锁横向肋和凹槽。
步骤(c)的机器方向预拉伸可以在线进行，备选地可以作为独立过程进行。
在步骤(c)期间，片材的机器方向预拉伸程度可能影响最终片材在机器方向上的弹性拉伸的程度。在一个实施方案中，在步骤(c)期间，片材因此在机器方向上被预拉伸。机器方向预拉伸的程度可以使得，例如，片材被拉伸其初始尺寸的40-160％，优选60-140％，更优选80-120％。
在备选实施方案中，该方法没有机器方向预拉伸。与现有技术的材料相比，由于双组分纤维中聚合物的特殊选择，使得甚至不需要通过机器方向预拉伸获得合适的机器方向拉伸性能。
本发明不限于两层或三层片材。通过具有其他弹性层或其他饰面层或无弹性层，可以存在多于三层。此外，在每层中，可存在两个或更多个相同或相似类型的子层，所述子层由生产过程中的单独纤维铺设阶段形成。
根据本发明的非织造片材特别适合用于制造卫生制品。例如，非织造片材可用于制造尿布裤，所述尿布裤包括作为弹性腰部材料的片材。该行业在该应用中目前采用的典型生产工艺要求材料能够在MD弹性拉伸。
本发明的进一步细节和优点将从以下描述的图和实施例中显而易见。
附图简要说明
图1：根据本发明的弹性可拉伸非织造片材的示意性截面图；
图2：用于进行本发明的方法的示例性机器设置；
图3：通过沿机器方向拉伸来激活片材的装置的示意图；
图4：运行中的图3所述装置的示意图；
图5：根据比较例配置，单独的饰面纺粘层的MD拉伸(应力-应变)曲线；
图6：根据本发明的配置，单独的饰面纺粘层的MD拉伸(应力-应变)曲线；
图7：根据本发明的配置，另一单独的饰面纺粘层的MD拉伸(应力-应变)曲线；
图8：单独的弹性纺粘非织造层的MD拉伸(应力-应变)曲线；
图9：根据本发明的片材、单独的片材饰面层和单独的片材弹性层的叠加MD拉伸(应力-应变)曲线；
图10：拉伸(应力-应变)图和后续应力-应变循环的增减曲线的示意图，代表ASTMD5459的测试；和
图11：实施例5的样品5-1的机器方向拉伸(应力-应变)图，显示该材料的滞后曲线。
图1显示了根据本发明的弹性可拉伸非织造片材100的示意性横截面，其中包括弹性纤维的弹性非织造层130，其夹在第一非织造饰面层110和第二非织造饰面层120之间。
图2显示了根据本发明制造弹性可拉伸非织造片材100的示例性机器设置。
该设置包括传送带10和设置在传送带上的三台纺粘机20、30和40。
在每台纺粘机中，熔融热塑性聚合物被挤出通过模具孔。然后对挤出的纤维股淬火、拉拔/拉伸，以形成无接头纤维，然后将其铺设在传送带10上或铺设在先前沉积在传送带的网上。
第一纺粘机20将卷曲双组分纤维网沉积在传送带10上。两种聚合物进料在第一纺粘机20的顶部用符号代表。中间纺粘机30将由热塑性弹性体形成的纤维网沉积在先前形成的网上。最后一台纺粘机40在弹性纤维网上沉积另一卷曲双组分纤维网。各个纺粘机20和40后面分别有一对预压辊21和41，用于预压实各自的网。
然后在包括一对反向旋转压花辊51、52的压延单元50中压延预压实网以形成非织造片材。压延之后是激活单元60中的激活步骤，该激活单元包括一对反向旋转的激活辊61、62，其表面包含联锁结构元件，如下文更详细描述。在整个在线过程结束时，将产品片材收集在产品辊70上。
图3显示了激活单元60的激活辊61、62的实施方案，其配置用于增加机器方向的弹性。具体地，图3的图片为沿垂直于辊轴的径向平面的放大截面。辊61和62在它们的作用面上包括多个有规律间隔的肋63，在这些肋之间形成凹槽65。肋63沿横跨机器方向定向，并轴向延伸到辊61和62的表面上。肋63的宽度用字母“a”表示，啮合深度用字母“b”标记，且相邻肋之间的距离用字母“c”标记。
图4显示了在运行中的如图3所示的单元。在图4中，从左到右，包括两个饰面层和夹在其之间的弹性层的未激活前体片材进入到激活过程中。当片材进入两个辊61、62的夹缝时，激活过程开始，且片材在啮合肋63之间局部拉伸。在此过程期间，弹性层将因其弹性能力而伸长。参数“a”、“b”和“c”可以根据需要变化，取决于非织造片材上可能施加的和可能需要的伸长率特性。
在实施方案中已证明，即使未经活化，在卷曲双组分纤维中使用分子量分布相对窄的聚丙烯均聚物和分子量分布相对宽的乙烯-丙烯无规共聚物的组合也能实现具有很大程度，如高达300％的拉伸，并且不会在机器方向上发生断裂的片材。这足以满足任何行业标准，并与本发明片材中使用的弹性非织造层的高伸长率特性相匹配，在实施方案中，该弹性非织造层可以弹性拉伸400-500％。
本发明片材的有利性能在以下实施例中展示。
实施例
使用以下规定的材料，制备多个使用并排双组分卷曲纤维的纺粘饰面层。
表1：使用的材料：
Figure BDA0003906637610000091
511A聚合物是Sabic公司的聚丙烯均聚物，该聚合物的分子量分布较窄(Mw/Mn为3.8)，MFR为25g/10min且Tm为161℃。
HP552N聚合物是LyondellBasell公司的聚丙烯均聚物，该聚合物的分子量分布较宽(Mw/Mn为6.8)，MFR为13g/10min且Tm为161℃。
RP248R聚合物是LyondellBasell公司的乙烯-丙烯无规共聚物，MFR为30g/10min，中等分子量分布(Mw/Mn为5.2)且Tm为148℃。它还含有澄清剂和滑动助剂。
QR674K聚合物是Sabic公司的乙烯-丙烯无规共聚物，MFR为40g/10min，分子量分布较宽(Mw/Mn为8.5)且Tm为150℃。它还含有澄清剂和滑动助剂。
本文使用的熔体流动速率(MFR)应理解为已根据ISO 1133测定，条件为230℃和2.16kg。
本文使用的熔化温度(Tm)应理解为已根据ISO 11357-3用DSC测定。
本文使用的分子量平均值(Mw和Mn)和分子量分布的所得值(MWD，Mw/Mn)应理解为已根据ISO 16014-1:2003、ISO 16014-2:2003、ISO16014-4:2003和ASTM D 6474-12使用以下公式通过GPC确定：
Figure BDA0003906637610000101
Figure BDA0003906637610000102
Figure BDA0003906637610000103
对于恒定的洗脱体积间隔ΔVi，其中Ai和Mi分别是色谱峰切片面积和聚烯烃分子量(MW)，与洗脱体积Vi相关，其中N等于从积分极限之间的色谱图中获得的数据点数量。
使用高温GPC仪器，配备PolymerChar(Valencia,Spain)的红外(IR)检测器(IR4或IR5)或Agilent Technologies的差示折射计(RI)，配备3xAgilent-PLgel Olexis和1xAgilent-PLgel Olexis保护柱。使用250mg/L的2,6-二叔丁基-4-甲基苯酚稳定的1,2,4-三氯苯(TCB)作为溶剂和流动相。色谱体系在160℃和1mL/min的恒定流速下运行。每次分析注入200μL的样品溶液。使用Agilent Cirrus软件版本3.3或PolymerChar GPC-IR控制软件进行数据采集。
使用通用校准(根据ISO 16014-2:2003)，使用19种具有窄MWD的聚苯乙烯(PS)标准品，在0.5kg/mol至11500kg/mol范围内，对色谱柱组进行校准。PS标准溶液在室温下溶解数小时。聚苯乙烯峰值分子量到聚烯烃分子量的转换是通过使用Mark Houwink方程和以下Mark Houwink常数实现的：
KPS＝19x10-3mL/g，aPS＝0.655
KPE＝39x10-3mL/g，aPE＝0.725
KPP＝19x10-3mL/g，aPP＝0.725
使用三阶多项式拟合来拟合校准数据。
所有样品均在0.5-1mg/ml浓度范围内制备，并在160℃下溶解2.5小时。
下表2显示了从这些材料中获得的单独的20gsm的纺粘饰面片材的性能。
表2：获得的性能：
Figure BDA0003906637610000111
表2(续)：获得的性能：
Figure BDA0003906637610000112
*根据WSP120.6测定
**根据WSP 100.4测定
值得注意的是，没有使样品在图3至图4所示的铣床中激活，该样品具有12％的粘合面积和24个粘合位点/cm2的开放点状粘合模式。
实施例1是比较例。实施例2-3是本发明的实施例。比较例的样品1-3的MD拉伸(应力-应变)曲线分别显示在图5至7中，其中图5和图6显示了随后平均的多次测量的曲线，且图7仅显示了一条已经平均的曲线。
从表2中的值和图5-7中的曲线可以明显看出，实施例2的饰面层的MD断裂伸长率已经明显高于比较实施例1的饰面层伸长率(断裂伸长率增加了约20％，至188％)。根据实施例3的具体优选配置的饰面层，其中Co-PP的分子量分布比实施例2中更宽，且PP和Co-PP之间的MWD差比实施例2中更大，效果变得非常显著(断裂伸长率从188％又提高了约80％，至270％)。尽管甚至没有进行激活/预拉伸，但与比较实施例(即实施例1)相比，MD断裂伸长率值几乎为200％(实施例2)，更不用说超过250％(实施例3)，这对于其中通常纤维取向主要在机器方向的纺粘材料来说是非常独特的。还值得注意的是，通常饰面层的厚度在某种程度上与卷曲水平相关，但实施例2和3的饰面层尽管具有相同的基础重量，但它们的厚度显著低于比较实施例1的饰面层厚度，表明除了简单的卷曲水平之外，显然还有其他原因影响控制根据本发明配置的纺粘饰面层在机器方向上伸长的能力。
接下来，如实施例4所示，在图2所示的生产线上制造三个根据本发明的片材(样品4-1、4-2和4-3)，该片材包括夹在两个根据本发明的饰面层之间的弹性纺粘层，但是没有用激活材料的铣床进行处理(片材保持未激活状态)。如下文规定制备和配置各层。样品4-1、4-2和4-3的差异仅在于其层的基础重量。
表3：实施例4中使用的材料/结构：
Figure BDA0003906637610000121
样品4-1的片材的两个饰面层对应于实施例3中以单独方式研究的饰面层。粘合模式为如上所述的用于单独的饰面层那样。
弹性层由ExxonMobil的单一市售TPE-o材料VistamaxxTM 7050FL制成，该材料是基于丙烯的热塑性弹性体共聚物，乙烯含量为13wt.-％且熔体流动速率为45g/10min。粘合模式也如上所述。
下表4显示了针对实施例4的三个样品获得的特性。
表4：获得的性能：
Figure BDA0003906637610000131
表4(续)：获得的性能：
Figure BDA0003906637610000132
*根据WSP120.6测定
**根据WSP 100.4测定
作为实施例4的变体，在另一实施例5中，生产了与实施例4相同的材料，不同之处在于它们在如图3和图4所示的激活单元60中被沿机器方向进行预拉伸和激活。具体地，当材料进入激活单元60的辊夹缝时，通过生产线中平移速度的变化，材料被沿机器方向预拉伸100％(至其初始长度的200％)。在激活单元中，啮合深度“b”为2mm(在肋总高度为5mm处)。
下表5显示了针对实施例5的三个样品获得的特性。
表5：获得的性能：
Figure BDA0003906637610000133
Figure BDA0003906637610000141
表5(续)：获得的性能：
Figure BDA0003906637610000142
*根据WSP120.6测定
**根据WSP 100.4测定
除了本发明实施例4和5之外，作为实施例6，还纺丝和研究了单独的实施例4中的样品4-1的弹性层。
图8显示了实施例6的40gsm的单独的弹性纺粘非织造层的MD拉伸(应力-应变)曲线。在断裂前，材料可以在MD显著拉长；具体地，在施加20-25N/50mm的应力时，伸长率超过500％。
图9显示了根据本发明的片材的叠加MD拉伸(应力-应变)曲线，包括实施例4的样品4-1、实施例3的饰面层和实施例6的弹性层。从叠加曲线可以明显看出，在伸长率超过300％之前，饰面层不会限制弹性层的弹性行为。片材具有较高的伸长率和弹性，这意味着一旦放松，它将缩回到其初始状态。
图8和9中所示的曲线，与图7中的曲线一样，是多次测量的平均曲线。
本文的弹性材料的另一个重要参数是根据ASTM D5459测定的永久变形。永久变形是弹性材料在经受ASTM D5459中的测试程序中规定的延伸后未能恢复到初始长度时的长度增加量，表示为初始长度的％。永久变形百分比越低，弹性材料的弹性性能越好。
图10显示了拉伸(应力-应变)图和后续应力-应变循环的增减曲线的示意图，代表ASTM D5459的测试。永久变形值为(AD/AE)x100。
另一个重要参数是在根据ASTM D5459测试的滞后曲线中，第二个循环的机器方向的上升和下降的应力-应变曲线之间的面积比，以曲线(A)下的面积与初始上升曲线下的总面积(A+B)之比，％[A/(A+B)x100]表示。这是为了计算由于内部摩擦而耗散的能量的百分比。当加载和卸载过程中的曲线不一致时，如在现实材料中通常观察到的那样，这意味着会损失一定量的能量。百分比越低，材料的弹性性能越好。
图11显示了根据ASTM D5459测试(第一和第二个循环)获得的实施例5的样品5-1的机器方向的应力-应变曲线。滞后曲线显示了该材料具有机器方向上非常理想的弹性性能。具体地，第一个循环后的永久变形值((AD/AE)x100)仅为1.28％，而第二个循环中上升和下降曲线之间的面积([A/(A+B)])仅为24.8％。

Claims (18)

1.一种弹性可拉伸非织造片材，包括至少两个非织造材料层，
其中一层是可拉伸非织造弹性层，包括由热塑性弹性体聚合物材料形成的纺粘弹性纤维，
其中另一层是可拉伸饰面层，包括纺粘卷曲多组分纤维，
其中相邻层通过压花粘合点粘合在一起，和
其中所述卷曲多组分纤维的至少一种组分是丙烯-α-烯烃共聚物材料。
2.根据权利要求1所述的片材，其中当根据WSP 100.4测量时，所述片材在机器方向上的断裂伸长率大于150％，优选大于200％。
3.根据前述权利要求任一项所述的片材，其中根据ASTM D5459测量，在第一次循环后，所述片材在机器方向上的永久变形小于15％，优选小于10％。
4.根据前述权利要求任一项所述的片材，其中在根据ASTM D5459测试的滞后曲线中，第二个循环的机器方向的上升和下降的应力-应变曲线之间的面积比，以曲线(A)下的面积与初始上升曲线下的总面积(A+B)之比，％[A/(A+B)x100]表示，该百分比为小于40％，优选小于30％。
5.根据前述权利要求任一项所述的片材，其中所述卷曲多组分纤维的一种其他组分为聚丙烯均聚物材料。
6.根据权利要求5所述的片材，其中所述丙烯-α-烯烃共聚物是聚(丙烯-乙烯)无规共聚物。
7.根据权利要求6所述的片材，其中所述丙烯-α-烯烃共聚物的乙烯单体含量为1-8wt％。
8.根据前述权利要求任一项所述的片材，其中所述卷曲多组分纤维的丙烯-α-烯烃共聚物的分子量分布比其其他组分的分子量分布更宽。
9.根据权利要求5所述的片材，其中所述丙烯-α-烯烃共聚物与聚丙烯均聚物的分子量分布Mw/Mn的差值为1至10。
10.根据前述权利要求任一项所述的片材，其中所述卷曲多组分纤维是双组分纤维，优选为并排双组分纤维。
11.根据权利要求5所述的片材，其中所述卷曲多组分纤维是双组分纤维，并且所述丙烯-α-烯烃共聚物与所述聚丙烯均聚物的重量比为20/80至80/20。
12.根据前述权利要求任一项所述的片材，其中形成弹性纤维的所述热塑性弹性体聚合物材料是热塑性聚烯烃弹性体，优选所述热塑性聚烯烃弹性体包含丙烯-α-烯烃共聚物。
13.根据前述权利要求任一项所述的片材，其中所述片材包括位于其每一侧的至少一个饰面层之间的可拉伸非织造弹性层的夹层结构，其中所述片材优选由这些弹性层和饰面层组成。
14.根据前述权利要求任一项所述的片材，其中每个饰面层的基础重量在5-40g/m2之间；和/或弹性层的基础重量在10-140g/m2之间。
15.一种用于制造根据前述权利要求任一项所述的弹性可拉伸非织造片材的方法，所述方法包括以下在线步骤：
(a1)对卷曲多组分纤维进行纺丝，并将其铺设在移动的纺带上以形成网；其中所述卷曲多组分纤维的至少一种组分是丙烯-α-烯烃共聚物；
(a2)对由热塑性弹性体聚合物材料形成的弹性纤维进行纺丝，并将其铺设在步骤(a1)中形成的网的表面上，以形成另一网；
(a3)任选地，对卷曲多组分纤维进行纺丝，并将其铺设在步骤(a2)中形成的网的表面上，以形成另一网；其中所述卷曲多组分纤维的至少一种组分是丙烯-α-烯烃共聚物，
(b)将相邻的网粘合，以形成所述弹性可拉伸纺粘非织造片材。
16.根据权利要求15所述的方法，还包括使所述片材在机器方向上进行预拉伸的在线或离线步骤(c)。
17.根据权利要求16所述的方法，其中，在步骤(c)期间，使所述片材在机器方向上预拉伸其初始尺寸的40-160％，优选60-140％，更优选80-120％。
18.根据权利要求1-17中任一项所述的弹性可拉伸非织造片材在制造卫生制品，优选尿布裤中的用途，所述尿布裤包括所述片材作为弹性腰部材料。
CN202211309297.0A 2021-11-10 2022-10-25 弹性非织造片材 Pending CN116100884A (zh)

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