CN1161505C - 共聚酯粘合用纤维 - Google Patents

共聚酯粘合用纤维 Download PDF

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CN1161505C
CN1161505C CNB988129671A CN98812967A CN1161505C CN 1161505 C CN1161505 C CN 1161505C CN B988129671 A CNB988129671 A CN B988129671A CN 98812967 A CN98812967 A CN 98812967A CN 1161505 C CN1161505 C CN 1161505C
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copolyesters
binder fibre
dicarboxylic acids
acid
fibre
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L��R���ϰ�
L·R·迪安
W·A·海勒
R·L·麦康尼尔
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Eastman Chemical Co
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Abstract

本发明涉及自共聚酯制造的纤维,尤其是粘合用纤维,以及共聚酯本身。一般说,本发明的共聚酯由下述原料制成:1,3-或1,4-环己烷二甲醇、乙二醇和间苯二甲酸或其酯以及至少一种选自对苯二甲酸、萘二羧酸、1,3-或1,4-环己烷二羧酸的二羧酸或者其酯。这类共聚酯可以制成各种产品,尤其是非织造物粘合用纤维,纺织品和工业纱,以及复合制品。

Description

共聚酯粘合用纤维
优先权资料
本申请要求属于35U.S.C.§119的1998年11月6日提交的临时申请60/064,717的权益,在此引入其全部公开内容供作参考。
发明领域
本发明涉及自共聚酯制造的纤维,尤其是粘合用纤维,以及共聚酯本身。一般说,本发明的共聚酯由下述原料制成:1,3-或1,4-环己烷二甲醇、乙二醇和间苯二甲酸或其酯以及至少一种选自对苯二甲酸、萘二羧酸、1,3-或1,4-环己烷二羧酸的二羧酸或者其酯。这类共聚酯可以制成各种产品,尤其是非织造物粘合用纤维,纺织品和工业纱,以及复合制品。
发明背景
非织造织物广泛应用于各种产品。例如:非织造织物适用于过滤材料、屋面材料、复合材料、衬料、衬里、绝缘材料、医用/外科应用、衬垫、台布和尿布。非常膨松的棉絮非织造织物用于各种产品,包括盖被、长袍和乳罩。通常非织造织物以可以用胶乳粘合剂、粘合用纤维或粉状聚合物粘合的聚酯、丙烯腈系、尼龙、玻璃和纤维素之类的纤维为基础。采用粘合用纤维进行非织造织物的粘合为制造非织造织物提供了一种简便的方法,不需要使用不利于环境的水基粘合剂。采用粘合用纤维粘合的非织造织物在生产方面是经济的,并且提供了制造性能独特或者优良的制品的方法。其它应用有,用于纱线以增加强度或减少起球,用于预浸渍体、预制坯和各种复合结构。
已经发现,某些共聚酯作为粘合用纤维是有效的。例如,过去应用含有1,3-或1,4-环己烷二甲醇的、特性粘度(I.V.)值为约0.6~约0.8的聚对苯二甲酸乙二酯(PET)共聚酯作粘合用纤维粘合聚酯或其它纤维。然而,认为I.V.值较低的共聚酯没有足够的粘合强度。
众所周知,共聚酯能够采用包括聚酯化作用和缩聚作用的方法进行制备。一般说,如在美国专利2,901,466、5,106,944、5,668,243和5,668,243所述,反应物包括二元醇成分和二羧酸成分。一般说,一种二羧酸成分是对苯二甲酸,一种二元醇是乙二醇。这类共聚酯是具有相当的惰性的疏水材料,适用于各种应用,包括模塑制品,如应用于汽车和设备工业的制品,食品盘,纤维、片材、薄膜及诸如瓶子之类的容器。然而,使用乙二醇作为唯一的二醇,则伴随产生诸如变黄和纤维粘合性差等不希望存在的性能。实际上,这类聚合物倾向于成为具有高熔点的不透明结晶聚合物,这使其不适于作粘合用纤维。为了排除对于聚对苯二甲酸乙二酯来说的这些问题,已经采用1,4-环己烷二甲醇或间苯二甲酸制成了聚对苯二甲酸乙二酯共聚酯。
以前采用1,4-环己烷二甲醇制共聚酯的努力主要集中在特性粘度(I.V.)高于0.6的共聚酯方面,其原因在于认为特性粘度低不会具有足够的强度。特别是认为,特性粘度低的共聚酯不能提供足够的粘合强度而形成可接受的市售粘合用纤维。实际上,以前制造的含有1,4-环己烷二甲醇的聚对苯二甲酸乙二酯共聚酯的特性粘度为0.6~0.8,以便制成粘合聚酯或其它纤维的粘合用纤维。然而,这些努力,在提供具有下述性能的共聚酯方面并未完全成功,即,具有所要求的高透明度和色调,或者当在粘合用纤维的形态时在低活化温度下进行粘合的能力。
制造适用作粘合用纤维的共聚酯的其它工作集中在用间苯二甲酸和二乙二醇制的聚对苯二甲酸乙二酯共聚酯。这些工作产生了单组分的和双组分的粘合用纤维,如Unitika公司(日本,大阪)市售的BELLCOMBI、Kanebo公司(日本,大阪)市售的MELTY和Hoech$tCelanese公司市售的CELBOND等。然而,这些产品在诸如透明度、粘合温度、粘合强度以及制造含有间苯二甲酸和1,3-或1,4-环己烷二甲醇的共聚酯在经济上的好处等方面均未得到认可。
本领域需要一类成本上可行的,自1,3-或1,4-环己烷二甲醇、乙二醇、间苯二甲酸和至少一种选自对苯二甲酸、萘二羧酸、1,3-或1,4-环己烷二羧酸的二羧酸或其酯制成的共聚酯。这类共聚酯具有改善的透明度和色泽以及改善了的在低活化温度下的粘合用纤维的粘合强度。
另外,粘合纤维用共聚酯叙述在共同未决美国申请系列号09/143,437,题目“共聚物粘合用纤维”,提交于1998年8月28日,其公开内容在此引入,全部作为参改。在该申请中,共聚酯一般形成自1,4-环己烷二甲醇、乙二醇、以及至少一种选自对苯二甲酸、萘二羧酸、1,4-环己烷二羧酸的二羧酸及其酯。可以加入另外的其它二羧酸,包括间苯二甲酸和1,3-环己烷二羧酸,加入量最高为10mol%;也可以加入另外的其它二醇成分,如1,3-环己烷二甲醇,加入量最高为10mol%。
发明概述
本发明通过提供具有优良色泽、热塑性流动和增加的粘合多功能性的粘合用纤维共聚酯,以及制造这类共聚酯用的催化剂,解决了与以前的粘合用纤维和共聚酯有关的问题。本发明的共聚酯适用于各种应用,例如制造非织造织物用粘合用纤维和纺织物和工业纱。
更具体地说,本发明提供了采用二元醇成分和二元羧酸成分制备的共聚酯。二元醇成分一般包含用量范围为约5~50mol%的1,3-或1,4-环己烷二甲醇和用量范围为约50~约95mol%的乙二醇。二羧酸成分一般包含用量范围为至少10mol%~约50mol%的间苯二甲酸或其酯,和至少约50mol%的选自对苯二甲酸、萘二羧酸、1,3-或1,4-环己烷二羧酸和其混合物的酸或酯的二羧酸成分。本发明所形成的共聚酯具有小于约0.7的特性粘度、优异的热塑流动和粘合能力。实际上,本发明的共聚酯特别适于作粘合用纤维,因为该共聚酯具有较低I.V.,这样能够使非织造织物的粘合用纤维在较低温度下的粘合性能得到改善。如下更详细地叙述本发明。
发明详述
本发明涉及从共聚酯制造的粘合用纤维及共聚酯本身。本发明的共聚酯具有优异的色泽,因为它们是较透明的,呈现正常色调或较以前的共聚酯明亮的外观,可比I.V.较高的共聚酯更易接受染料。实际上,通过使用所制成的I.V.较低的、透明的而不是不透明的共聚酯聚合物,可以容易地加工成具有优良粘合性能的粘合纤维。另外,本发明的I.V.降低了的共聚酯,经较低熔融纺丝温度,即可加工成粘合用纤维。
本发明共聚酯是经二醇成分和二羧酸成分的反应制成的。一般说,二醇成分包括用量范围约5~约50mol%的1,3-或1,4-环己烷二甲醇和用量范围约50~95mol%的乙二醇。二羧酸成分包括用量范围至少10mol%至约50mol%的间苯二甲酸和至少约50mol%的选自对苯二甲酸、萘二羧酸、1,3-或1,4-环己烷二羧酸和其混合物的酸或其酯的二羧酸成分。作为环己烷二羧酸,优选1,4-环己烷二羧酸。本发明的共聚酯的I.V.为约0.4~约0.7。这些特征和其它特征在下文进行较详细讨论。
二醇成分
如上所述,二醇成分一般包含用量为约5~约50mol%的1,3-或1,4-环己烷二甲醇和用量为约50~约95mol%的乙二醇。优选1,3-或1,4-环己烷二甲醇存在量为约5-约35mol%,更优选为约8~约30mol%。1,3-或1,4-环己烷二甲醇可以是顺-、反-异构体,或顺/反异构体混合物,优选1,4-环己烷二甲醇。优选乙二醇存在量为约65~约95mol%,更优选为约70~约92mol%。
除了1,3-或1,4-环己烷二甲醇和乙二醇之外,二醇成分可以包含最高约10mol%普通二醇,包括但不限于,含约3~约12个碳原子的二醇,例如丙二醇、二乙二醇、1,3-丙二醇、1,4-丁二醇、1,5-戊二醇、2,2-二甲基-1,3-丙二醇、1,6-己二醇、2,2,4-三甲基-1,3-丙二醇、2-乙基-2-丁基-1,3-丙二醇、2,2,4,4-四甲基-1,3-环丁二醇、2,4-二甲基-2-乙基己-1,3-二醇、2-乙基-2-异丁基-1,3-丙二醇、1,3-丁二醇、1,8-辛二醇、2,2,4-三甲基-1,6-己二醇、硫联二乙醇(thiodiethanol),和1,2-环己烷二甲醇。
二羧酸成分
二羧酸成分包含用量为至少10mol%至约50mol%的间苯二甲酸或其酯和至少约50mol%选自对苯二甲酸、萘二羧酸、1,3-或1,4-环己烷二羧酸和其混合物的酸或酯的二羧酸成分。应当指出,可以使用任何萘二羧酸异构体或者异构体混合物,优选使用1,4-、1,5-、2,6-和2,7-异构体。另外,1,3-或1,4-环己烷二羧酸部分可以是顺-、反-异构体或顺/反异构体混合物。取决于所用设备,所优选的二羧酸成分包含:或者间苯二甲酸和对苯二甲酸,或者间苯二甲酸和对苯二甲酸二甲酯,或者间苯二甲酸二甲酯和对苯二甲酸二甲酯。
另外的二羧酸成分(除了间苯二甲酸、对苯二甲酸、萘二羧酸和1,3-或1,4-环己烷二羧酸或它们的酯)的加入量可以为最高约10mol%。适宜的其它二羧酸成分含有约4~约40个碳原子,叙述在美国专利5,608,031和5,668,243中,在此引入全部作为参考。优选其它二羧酸成分是芳族二羧酸或其酯,优选其含8~14个碳原子,脂族二羧酸或其酯,优选其含4~12个碳原子,或者脂环族二羧酸或其酯,优选其含8~12个碳原子。
特别优选的,除了使用的间苯二甲酸、对苯二甲酸、萘二羧酸,和1,3-或1,4-环己烷二羧酸之外的另外的二羧酸成分的实例,包括但不限于,磺基间苯二甲酸、1,4-环己烷二乙酸、联苯-4,4’-二羧酸、丁二酸、戊二酸、己二酸、壬二酸、癸二酸、1,12-十二烷二酸、和二聚酸。共聚酯可以自一种或多种上述二羧酸制备。
支化作用剂
少量的一般在约2mol%以下的普通支化作用剂可以与二醇成分和二羧酸成分反应,形成本发明共聚酯。普通支化剂包括多官能的酸、酐、醇及其混合物。适宜的支化作用剂的例子,包括但不限于,1,2,4-苯三酸酐、1,2,4,5-均苯甲酸二酐、甘油、三羟甲基丙烷和季戊甲醇。
制备共聚酯的反应程序
关于制成本发明的共聚酯,二醇成分和二羧酸成分的反应可以采用普通聚酯的聚合条件进行。例如,当借助酯交换反应制备共聚酯时,即从二羧酸成分的酯的形式进行制备时,反应程序可以包含两步。第一步,二醇成分和二羧酸成分,例如间苯二甲酸二甲酯和对苯二甲酸二甲酯,在高温下,一般约180℃~约280℃,在约0.0~约413.4kPa的压力下,进行反应。优选,酯交模反应温度为约190~约240℃,同时优选压力为约103.4~约275.6kPa。此后,反应产物在更高温度和减压下加热形成聚酯,同时脱除二醇,二醇在该条件下易挥发并从反应系统中除去。第二步,即缩聚步骤,在更高的真空下,一般在约240℃~约300℃的温度下,优选在约250℃~约290℃,最优选约270℃~约285℃下,进行,直至获得具有所需聚合度的聚合物,聚合度通过I.V.进行测定。缩聚反应可以在约52.6kPa~约13.2Pa减压下进行。在没有使用适宜催化剂的条件下,上述反应不能以显著速度进行。
为保证二醇成分和二羧酸成分通过酯交换反应历程进行的反应进行到完全,优选使用3mol,更优选约2.3至约2.6mol二醇成分对1mol二羧酸成分的比例关系。然而,应当理解,二醇成分与二羧酸成分的比一般由进行反应的反应器的结构决定。
在通过直接酯化制备聚酯中,即,从二羧酸成分的酸的形式进行制备,共聚酯经间苯二甲酸、和至少一种选自对苯二甲酸、萘二羧酸、和1,3-或1,4-环己烷二羧酸的二羧酸与二醇成分进行反应来制备。反应在约6.89~约1378kPa、优选在689kPa以下的压力下进行,以便生成低分子量、线形或支链的、平均聚合度约1.4~约10的聚酯产物。在直接酯化反应期间所使用的温度一般为约180℃~约280℃,更优选为约220℃~约270℃。然后,可以通过缩聚反应使该低分子量聚合物进行聚合。
为保证二醇成分和二羧酸成分通过直接酯化反应历程进行的反应进行到完全,优选使用约3.0~1.05mols二醇成分对1mol二羧酸成分的比例关系。然而,不用说,二醇成分与二羧酸成分的比由进行反应的反应器的结构决定。
一般说,较低I.V.的共聚酯通过使用,与生成较高I.V.共聚酯的方法相比较,较短的停留时间或缓慢的反应速率来得到。例如,减慢反应速率能够通过降低反应温度、减小催化剂含量,通过增加反应器绝压或者通过这些因素的组合来实现。
本发明的共聚酯的制备方法可以以间歇法、半间歇法或连续法进行。有利地是,该方法按连续法进行操作。实际上,在使用连续法时,能够制成具有优异着色性的共聚酯,因为,如果共聚酯在高温反应器中停留太长的时间,其外观会恶化。
催化剂系统
许多催化剂系统可以用于促进二醇成分和二羧酸成分的反应。典型的催化剂系统总包含催化用物料和催化作用抑制剂。
催化用物料
适用于催化剂系统的催化用物料,包括但不限于,含钛、锰、锌、钴、锑、镓、锂、钙、硅和锗的物料。这类催化剂系统叙述在美国专利3,907,754、3,962,189、4,010,145、4,356,299、5,017,680、5,668,243和5,681,918,在此引入其全部内容作为参考。一般说,本发明催化剂系统包含含有钛、锰和/或锌的物料及其混合物。在改变催化剂系统中各个催化用物料的用量时,希望催化剂系统中催化用物料总量低于约125ppm,优选低于约100ppm和最优选低于约80ppm。关于催化剂系统和以下所述和催化剂抑制剂的“ppm”数指的是涉及的元素的重量,并以最终共聚酯产物的重量为基准计。
当钛催化剂物料以诸如美国专利5,017,680所述的配合物料的形式加入时,钛催化用物料优选以醇盐的形式加入,加入量为约10~约35ppm,更优选约10~约25ppm,最优选约12~约20ppm。实际上,用较低水平的钛催化用物料生成的共聚酯,当保持在熔体状态下时,具有较好的稳定性。适宜的钛的醇盐,包括但不限于,乙酰钛酸三异丙酯、钛酸四异丙酯和钛酸四异丁酯。特别优选的钛催化用物料包括乙酰钛酸三异丙酯、钛酸四异丙酯。钛催化用物料可以在直接酯化或酯交换反应之前或者在缩聚反应之前加入反应过程中。
锰一般以盐的形式加入,例如有机酸盐,加入量为约0~70ppm,优选约20~约70ppm,更优选约30~约70ppm,最优选约40~约70ppm。适宜的锰盐的例子,包括但限于,苯甲酸盐四水合物、氯化锰、氧化锰、醋酸锰、乙酰丙酮锰和琥珀酸锰。在直接酯化或酯交换反应之前将锰加到反应过程中。
除了锰之外,可以把锌加到催化剂系统中,或者用其代替锰催化剂。锌一般以盐的形式加入,加入量为0~100ppm,优选约25~约100ppm和更优选约50~约80ppm。适宜的锌化合物的例子,包括但不限于,醋酸锌、丁二酸锌和锌的醇盐。一般,在酯交换反应之前,将锌加到反应过程中。
如果需要,也可以将钴催化用物料作为催化剂系统的一部分使用。在使用时,钴一般以盐的形式加入,例如有机酸盐。适宜的钴盐的例子,包括但不限于,乙酸钴三水合物、硝酸钴、氯化钴、乙酰丙酮钴、环烷酸钴和水杨酸钴。钴的加入量最高可以为约100ppm,更优选最高约90ppm。如下所述,钴可以起催化用物料和着色剂的作用。作为着色剂,钴一般在直接酯化或酯交换反应之后加到反应过程中。因为钴一般用作着色剂,所以在计算催化用物料总量时,不考虑钴的量。
在某些实施方案中可以使用锑。当使用时,适宜的锑化合物的例子,包括但不限于,无机酸的锑酸酯,氧化锑,锑的醇盐如异丙醇锑,卤化锑如氯化锑、溴化锑和氟化锑,锑酸钠或钾,羧酸锑如乙酸锑和甘醇酸锑,或其混合物。优选锑成分是甘醇酸锑或氧化锑。锑一般在酯交换或直接酯化反应之后加入。当共聚酯用于制造粘合用纤维时,可以将锑从催化剂系统中省略,因为含锑催化剂的存在会引起喷丝板板面聚集沉积物。
钙、镓和硅催化用物料可以在催化剂系统中使用,但较少优选。适宜的钙化合物的例子,包括但不限于,乙酸钙、甘醇酸钙和磷酸钙一水合物。适宜的镓化合物的例子,包括但限于,氯化镓、硝酸镓水合物、氧化镓、乳酸镓和磷化镓。适宜的硅化合物的例子,包括但不限于,乙酸硅和原硅酸四乙酯。锗催化用物料,包括但不限于,氧化物、有机盐及特别是锗的甘醇酸盐。
优选用于使间苯二甲酸二甲酯和对苯二甲酸、萘二羧酸、和1,3-或1,4-环己烷二羧酸的酯与二元醇进行反应的酯交换催化系统包含含有钛、锰和任选钴的物料。在酯交换催化剂系统中,钛的存在量为约10~约35ppm,优选为约10~约25ppm,锰的存在量为约30~约70ppm。另外,在酯催化剂系统的另外的实施方案中,在催化剂系统中的催化用物料的总量小于或等于约125ppm,优选小于约100ppm,更优选小于约80ppm,最优选小于约70ppm。优选的酯催化剂系统一般用与含约40~约90ppm磷的催化作用抑制剂和有效量的着色剂的组合,后者例如约2~约10ppm蓝色和/或红色的取代的取代的蒽醌染料。一般说,优选的酯交换催化系统基本不含锌催化用物料,更优选含5ppm以下锌催化用物料,最优选不含锌催化用物料。另外,当目的应用是粘合用纤维时,所优选的酯催化体剂体系基本不含锑催化用物料,更优选含5ppm以下锑催化用物料,最优选不含锑催化用物料。
催化作用抑制剂
为了稳定催化剂系统的作用和提高锌、锰和钴催化用物料的效率,希望在酯交换或直接酯化反应之后,但在进行缩聚反应的步骤之前,将磷催化作用抑制剂加到反应过程中。一般,以磷酸酯的形式加入磷,例如磷酸或胡机磷酸的酯,其加入量为约40~90ppm,更优选为约60~75ppm。适用于本发明的磷酸酯,包括但不限于,酸式磷酸盐乙酯、酸式磷酸盐二乙酯、磷酸三乙酯、磷酸芳烷酯和磷酸三-2-乙基己酯。一种有效的磷酸盐催化作用抑制剂是杜邦公司市售的MerpolA(商标名)。
着色剂
在制备本发明共聚酯中,可以加入着色剂,往往称作有机调色剂,以便赋予所得共聚酯以正常色调或光泽。当需要着色共聚酯时,颜料或着色剂可在二醇成分和二羧酸成分反应期间包含在反应混合物中,或者可以将它们与预制的共聚酯熔融共混。包含着色剂的优选方法是使用热稳定的、具有反应基团的有机着色化合物,如此着色剂共聚入或并入共聚酯中,以便改善共聚酯的色调。例如,诸如具有反应性羟基和/或羧基基团的染料等着色剂,包括但不限于,蓝色或红色的取代的蒽醌,可以共聚合到聚合物链中。着色剂和染料详述在美国专利4,521,556、4,740,581、4,749,772、4,749,773、4,749,774、4,950,732、5,384,377、5,372,864、5,340,910和5,681,918,在此引入其全部内容作为参考。当用染料作着色剂时,它们可以在酯交换或直接酯化反应之后加到共聚酯反应过程中。另外,当染料或染料混合物作为共聚酯的有机调色着色剂使用时,优选染料总量为10ppm以下。
另外,无机颜料,如二氧化钛和含钴的物料,可以加到反应中。有利的是,当催化剂物料含有钴时,钴也可以起着色剂作用。必须注意控制钴的用量,以避免本发明共聚酯形成不透明和发黑外观。为控制不透明性和发黑的水平,钴的用量最高可达约90ppm。
本发明共聚酯
本发明菜聚酯的特性粘度I.V.为约0.40~0.70。优选本发明共聚酯I.V.为约0.40~0.66,更优选为0.42~约0.65,最优选为约0.45~约0.58。本发明共聚酯I.V.的测定方法包括:采用0.5g聚合物在100ml由60wt%苯酚和40wt%四氯乙烷组成的溶剂中的溶液,在25℃下进行测定。共聚酯I.V.值的基本测定方法陈述在ASTMD-2857-70。所制备的I.V.值较低的共聚酯具有优良的色泽,因为它们比以前的共聚酯更鲜明,并且比I.V.较高的共聚酯更易接收染料。另外,低I.V.共聚酯,与I.V.较高的相似共聚酯相比,更易在较低温度下染色,并能够更容易地进行印染。再者,因为本发明的共聚酯具有低I.V.值,所以共聚酯的生产速度相当快。
从本发明共聚酯制成的纤维,与聚对苯二甲酸乙二酯均聚物相比,在使用相同的含水染色条件时,更易染色,并能染成较深颜色。实际上,当使用相似的染色条件时,将本发明的共聚酯染成较深色泽是可能的。相反,与聚对苯二甲酸乙二酯均聚物的染色相比,对本发明共聚酯来说,能够以较低染色成本得到相同深度的色调。
可以控制1,3-或1,4-环己烷二甲醇、乙二醇、对苯二甲酸和间苯二甲酸的聚合反应,以便制成或者结晶的或者无定形的、玻璃化转变温度相似于或稍低于聚对苯二甲酸乙二酯的聚对苯二甲酸乙二酯共聚酯。二羧酸成分和二醇成分的选择和用量一般情况下总决定所得共聚酯是无定形的或者结晶的。正如本领域已知的那样,一般无定形聚合物具有较高的透明度,且不是象许多结晶聚合物那样是不透明的。所以,在某些用量的1,3-或1,4-环己烷二甲醇和间苯二甲酸可以形成结晶共聚酯的同时,具有优异透明度的无定形聚酯还提供了一些截然不同的优点。
一般说,I.V.较低的共聚酯总有较低的挤出温度。因此,本发明的共聚酯可以有利地在较低温度下熔体纺丝为纤维。例如,I.V.为0.47的本发明间苯二甲酸共聚酯可以在约235℃下进行溶体纺丝,而相似的不含间苯二甲酸的I.V.为0.6~0.7的共聚酯纺丝温度一般需要275~285℃。典型地,本发明的共聚酯熔体纺丝温度低于约265℃,在某些情况下低达约235℃。这些共聚酯能够经约332孔、孔径约0.55mm的喷丝板进行熔体纺丝。一般说,熔体纺丝压力为约6890至13780kPa不等。
一般说,该共聚酯的透明度和色泽(色调)可以采用标准分光色度计进行评价。例如,评价共聚酯的透明度和色泽的适宜分光色度计是HunterLab公司(Reston,Virginia)市售的HunterLabUltraScan。通过使用HunterLab UltraScan分光色度计,可以定量透明度和色泽,即,黄度和/或蓝度。应用HunterLab UltraScan分光色度计评价和定量共聚酯的色泽和透明度叙述在美国专利5,681,918中,在此引入其全部内容作为参考。当使用HunterLabUltraScan时,L★值表示透明度水平,L★值较高代表透明度水平较高。黄度和/或蓝度水平按b★值定量,0.0代表共聚酯中性,而高于0.01的值表示黄度水平,低于0.0的值表示蓝度水平。本发明共聚酯L★值一般为约65以上,而b★值为约-2.5~约+2.5。
从本发明的共聚酯制成的产品
本发明共聚酯可以用于制成工业制品或者用作添加剂,例如用于其它聚合物系统的混配添加剂母料。另外,采用共聚酯可以制成粘合用纤维和其它制品,包括但不限于,含有玻璃、聚酯或其它纤维的汽车和结构预制件,模塑件、片材和挤出薄膜和纤维。本发明共聚酯可以是所制制品的部分或者可以制成整个制品。
常规添加剂可以加到本发明共聚酯中,取决于所要求的共聚酯最终应用。适宜的其聚酯添加剂详述于美国专利5,608,031和5,773,554,在此引入其全部内容作为参考。共聚酯的典型添加剂包括颜料、抗氧剂、稳定剂、阻燃剂、增韧剂、环氧化合物、脱模剂、核化剂、自由基稳定剂、润滑剂和其它加工助剂。
本发明的优选制品是纤维。可以将纤维制成任何本领域已知的要求的长度,一般以长丝或短纤的形式。纤维可以从本发明的共聚酯经任何常规的可利用的手段来制造,包括但不限于熔体纺丝和熔喷。取决于最终应用,可以使用本发明的纤维用共聚酯制成任何所要求的旦数的纤维,包括旦数范围的微旦至约50旦的纤维,优选最高达约20旦,最优选约1.5~约15旦。
共聚酯可以用于制成本领域已知的任何要求结构的粘合用纤维。优选本发明共聚酯是具有纤维状结构的粘合用纤维。粘合用纤维的主要优点在于,含有粘合用纤维的粘合制品,能够通过把热、射频或超声波施加到纤维网或长丝的未粘合的纤维层上来获得。当活化时,共聚酯软化和流动,当冷却时,固体与相邻的纤维粘合。实际上,本发明的共聚酯特别适于用作粘合纤维,因为该共聚酯的I.V.较低,在较低温度下的流动性和软化性能均较好。因此,当使用含有本发明的共聚酯的粘合用纤维时,能够在比非织造织物用的已知的粘合用纤维低的温度下,进行粘合纤维的改善了的粘合。实际上,自本发明的共聚酯制成的粘合用纤维特别适用于粘合聚酯、丙烯腈系、尼龙、玻璃、纤维素纤维、如棉和以浆粕为基础的纤维,以及洗净羊毛。一般说,用本发明共聚酯制成的粘合用纤维的旦数为约1.5~约20。然而,诸如熔喷纤维网或纺粘材料之类的其它纤维形式可以具有微旦细度。
本发明的粘合用纤维可以取单组分或双组分粘合用纤维的形式。异形粘合用纤维可以形成为截面具有分支(leg)的结构,在挤出期间采用粘合物料将其封端。
双组分粘合用纤维可以具有本领域已知的皮芯型、并列型或其它结构。低熔融温度双组分粘合用纤维的制备和粘合方法详述在美国专利3,589,956,在此引入其全部内容作为参考。在本发明的双组分纤维中,本发明共聚酯存在量为双组分纤维的约10~约75wt%。其它组分可以选自范围广泛的其它聚合物材料,包括但不限于,聚酯如聚对苯二甲酸乙二酯或聚对苯二甲酸丁二酯。双组分粘合用纤维可以与其它纤维混纤(blend),或者单独使用,制造非织造织物和具有种种性能的高度膨松的絮棉。一般说,双组分粘合用纤维含有高熔点聚合物,以保证在粘合加工期间的结构完整性,还含有熔点较低的或无定形的聚合物,以粘合非织造织物中的基质。另外,受经济利益的驱使,可以使用廉价得多的芯材料。
本发明的粘合用纤维易与范围广泛的其它纤维混纤,随后受热或经能量活化,以制备具有良好整体性和强度的非织造织物。例如:在混合纤维中的其它纤维能包括,但不限于,聚酯、丙烯腈系、尼龙、玻璃、纤维素(棉、以浆粕为基础的纤维、纤维素酯纤维等)纤维和其它相似的纤维。在非织造物中的掺合也能有助于对其它织物、薄膜和一些金属表面的层合。粘合用纤维在非织造混纺物中的量一般为约5~约30wt%,但是用量也能低达2wt%。在一些情况下织物采用100%粘合纤维制成。
可以用本发明共聚酯制造的其它纤维状结构是通过将本发明约50%以下共聚酯与聚烯烃或官能化聚烯烃熔融共混制成的纤维。在熔融共混时,可以使用适宜的相容剂,以便达到所希望的它们的效果。可以将熔融共混的共聚酯/聚烯烃纺为纤维,形成纤维状结构。该熔融共混使聚烯烃能够以本来的状态进行纺丝,并以单独的随后的操作进行染色,而对于未改性的聚丙烯则会产生不能令人满意的某些情况。
本发明的纤维状结构特别适用于加工成各种用途的种种非织造织物、针织物和簇绒织物,而且特别适于借助于种种手段产生活化来制造绗缝或不绗缝的粘合型非织造纺织品。它们也适于用来制造下述种种产品,包括但不限于,高膨松棉絮、针冲织物、一般非织造织物(flat nonwovens)、流体缠结织物、缝编织物(减少起球)、湿法铺网非织造织物和纸、过滤介质、防护面具、拼块地毯、棉毯、纤维素绝缘体、吸收制品、玻璃纤维复合制品、枕头填料、睡袋填料、衬垫、被褥、盖被、床罩、褥、褥垫、褥罩、家具和汽车装饰、床单、工业和服装用绒头织物、毯、妇女长袍、运动衫、汽车套、中间衬料、外衣、铺地材料、饰面砖、地毯、浴室垫子、鞋袜和手套、条带和模塑制品。
本发明共聚酯的其它适宜应用是作为混配载体材料。例如:本发明的共聚酯可以与包括着色剂的诸添加剂混合,制成共聚酯作载体材料的母料。此等母料可以在以后的工序中与其它聚合物混合,以便提供有关色泽、不透明性阻燃性或其它有益的性能。本发明的共聚酯,与特性粘度相似的聚对苯二甲酸乙二酯相比,能接受较高水平的诸如颜料等添加剂。共聚酯可以通过本领域已知的任何适宜工艺进行共混或混合。
                        实例
实例1含有间苯二甲酸和1,4-环己烷二甲醇的30/70顺/反混合物的低粘度PET共聚酯
含有20mol%间苯二甲酸(IPA)和20mol%1,4-环己烷二甲醇(CHDM)的聚对苯二甲酸乙二酯(PET),以熔融相缩聚,采用含有25ppm Ti、40ppm Mn、55ppm Co和60ppm P的催化剂系统进行制备。所得共聚酯的I.V.为0.55。
该共聚酯粒料在50℃下干燥2hr,然后熔融挤出成为9d/f的复丝,采用的喷丝板有332孔(每孔0.55mm),卷绕速度1000m/m,熔体温度265℃,挤出速度19.4kg/hr。在挤出期间,使用145c.f/min的空气流骤冷长丝。初生丝随后以3∶1拉伸比拉伸,并采用68℃水浴和喷入3.45kPa直接蒸汽的蒸汽箱进行一步拉伸。纤维经填塞箱卷曲,每2.54cm形成7个卷曲,卷曲角为95℃,采用65.5kPa压力不用蒸汽进行夹持定形。所得纤维以松弛状态在60℃下干燥2分钟。所得短纤维为3.2d/f。
上述纤维的初生未拉伸形式也是有效的粘合纤维。例如,4d/f初生粘合纤维特别适用于低收缩率轻量非织造织物。共聚酯粒料在纺丝之前不进行干燥,同样获得有益的结果。
纤维也能自以12mol%IPA和28mol%CHDM或以30mol%IPA和8mol%CHDM制成的PET共聚酯(I.V.分别为0.48,0.06)容易地制备。
实例2非织造纤维网的制备
使实例1 3d/f单组分粘合用纤维与PET短纤维
Figure C9881296700171
混纤,提供含20wt%粘合用纤维的混合纤维。在梳理线形成42.3g/m2完全混合的非织遣纤维网。非织造纤维网中的粘合用纤维经纤维网通过红外炉活化,然后经热压轧(80℃)将纤维粘合成非织造纤维网。获得了良好的机器方向和横向拉伸强度和悬垂性。通过使纤维网自梳理机经150℃空气循环箱停留时间2min,也得到良好粘合。
自本发明组合物的粘合用纤维也可经射频活化。
在粘合用纤维是含15mol%间苯二甲酸和15mol%CHDM的1,4-环己烷二羧酸(PEC)共聚酯,或者是含10mol%问苯二甲酸和25mol%CHDM的萘二羧酸(PEN)共聚酯时,同样获得有益的结果。
实例3皮/芯型双组分纤维
50/50皮/芯型双组分纤维采用聚对苯二甲酸乙二酯均聚物(I.V.0.54)作芯,与实例1相似的聚对苯二甲酸乙二酯共聚酯(I.V.0.47)作皮进行制造。按下述过程制成双组分纤维:在挤出机中熔融结晶的干燥了的PET粒料,并在288℃熔体温度下作为芯喂入。将干燥了的PET共聚酯粒料送到挤出机喂料斗,以喂入皮熔体料流。皮料流在熔体温度250℃下挤出。熔融料流经具有皮/芯孔结构的喷丝板共挤出,其计量速度经调节,以便制出具有50%共聚酯皮/50%PET芯的纤维。所得纤维以牵伸辊牵伸,其辊速设定为制造4d/f纤维的速度。相似的40/60皮/芯双组分纤维也以长丝和短纤维形式制出。对于短纤维来说,还将纤维卷曲,并切断为38mm长度。
当这些双组分粘合用纤维与聚对苯二甲酸乙二酯、玻璃和/或其它基质纤维、织物或薄膜并合成混合时,它们用来制造非织造织物、复合制品和其它成形材料。对于某些非织造结构来说,也能使用100%的这些粘合用纤维。
实例4含有IPA和CHDM的低粘度PET共聚酯
采用实例1所述的催化剂系统,制备含有11mol%IPA和13mol%CHDM的PET共聚酯。该共聚酯I.V.为0.58。采用实例1所述的工艺,对该共聚酯干燥样品进行熔融纺丝,提供粘合用纤维的12d/f初生丝。使其经牵伸、卷曲和切断,得到3.5d/f短纤维。这些粘合用纤维与PET纤维混纤,形成含有15wt%粘合用纤维的混合纤维。该混纺物经红外炉如实例2所述进行粘合。
自本实例共聚酯也能容易地熔融纺丝为长丝纤维,提供6d/f长丝。这些长丝容易地与玻璃纤维缠结或连续混合,粘合用纤维用量为7%,切断成短纤维或粗纱,然后制成复合结构并热活化。

Claims (21)

1.一种粘合用纤维,包含由二醇成分与二羧酸成分的反应产物制成的共聚酯,
其中,二醇成分包含用量为5~50mol%的1,3-或1,4-环己烷二甲醇,和用量为50~95mol%的乙二醇;其中二羧酸成分包含用量为大于10mol%~50mol%的间苯二甲酸或其酯,和至少50mol%的选自对苯二甲酸、萘二羧酸、1,3-或1,4-环己烷二羧酸和其混合物的酸或其酯的第二二羧酸成分,并且其中共聚酯的I.V.为0.4~0.7。
2.权利要求1的粘合用纤维,其中共聚酯的I.V.为0.4~0.66。
3.权利要求1的粘合用纤维,其中共聚酯的I.V.为0.45~0.58。
4.权利要求1的粘合用纤维,其中粘合用纤维可以经加热活化。
5.权利要求1的粘合用纤维,其中粘合用纤维可以经超声波和射频活化。
6.权利要求1的粘合用纤维,其中粘合用纤维的旦数范围为最多20。
7.权利要求1的粘合用纤维,其中粘合用纤维的旦数范围为20~1。
8.权利要求1的粘合用纤维,其中粘合用纤维是单组分粘合用纤维。
9.权利要求1的粘合用纤维,其中粘合用纤维是双组分粘合用纤维。
10.权利要求1的粘合用纤维,其中共聚酯的L★值大于65,b★值范围为-2.5~+2.5。
11.权利要求1的粘合用纤维,其中共聚酯在含有最多35ppm Ti的催化剂系统存在下制成。
12.权利要求11的粘合用纤维,其中共聚酯在含10~35ppm Ti、20~70ppm Mn、0~90ppm Co的催化剂系统存在下和在含40~90ppm的P的催化作用抑制剂存在下制成;上述各ppm以共聚酯重量为基准计。
13.权利要求1的粘合用纤维,其中第二二羧酸成分是对苯二甲酸、萘二羧酸或者1,3-或1,4-环己烷二羧酸的酯或酯的混合物。
14.一种纤维状结构,包括:经聚烯烃或官能化聚烯烃与权利要求1的粘合用纤维熔融共混所制成的纤维。
15.一种由二醇成分与二羧酸成分的反应产物制成的共聚酯,
其中,二醇成分包含用量为5~50mol%的1,3-或1,4-环己烷二甲醇,和用量为50~95mol%的乙二醇;其中二羧酸成分包含用量为大于10mol%~50mol%的间苯二甲酸或其酯,和至少50mol%的选自对苯二甲酸、萘二羧酸、1,3-或1,4-环己烷二羧酸和其混合物的酸或其酯的第二二羧酸成分。
16.权利要求15的共聚酯,其中共聚酯在含最多35ppm Ti的催化剂系统存在下制成。
17.权利要求16的共聚酯,其中共聚酯在含10~35ppm Ti、20~70ppm Mn、0~90ppm Co的催化剂系统存在下和在含40~90ppm的P的催化作用抑制剂存在下制成;上述各ppm以共聚酯重量为基准计。
18.权利要求15的共聚酯,其中共聚酯的L★值大于65,b★值范围为-2.5~+2.5。
19.权利要求15的共聚酯,其中共聚酯与聚烯烃或官能化聚烯烃熔融共混。
20.权利要求15的共聚酯,其中所述共聚酯与具有相同I.V.的聚对苯二甲酸乙二酯聚合物相比,含有含量更高的添加剂。
21.一种从权利要求15的共聚酯制成的纤维,其中该纤维染成比聚对苯二甲酸乙二酯纤维更深的色泽。
CNB988129671A 1997-11-06 1998-11-06 共聚酯粘合用纤维 Expired - Fee Related CN1161505C (zh)

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