CN1176672A - 用含有特种共聚物并具有美学上愉快手感的聚合物制成的非织造布 - Google Patents

用含有特种共聚物并具有美学上愉快手感的聚合物制成的非织造布 Download PDF

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CN1176672A
CN1176672A CN96192173A CN96192173A CN1176672A CN 1176672 A CN1176672 A CN 1176672A CN 96192173 A CN96192173 A CN 96192173A CN 96192173 A CN96192173 A CN 96192173A CN 1176672 A CN1176672 A CN 1176672A
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cloth
copolymer
polymer
weight
personal care
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S·E·肖维尔
P·W·艾斯特
L·A·科诺尔
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Kimberly Clark Worldwide Inc
Kimberly Clark Corp
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Abstract

公开一类用所谓“手感改善”聚合物的聚合物制成的纤维及非织造布。该手感改善聚合物是丙烯共聚物,含有乙烯、1－丁烯或1－己烯,或者它是丙烯、乙烯及丁烯的三元共聚物。如果该聚合物是乙烯共聚物,该共聚物可以是无规的或无规并嵌段的,而其乙烯存在的量必须介于共聚物的大于5～7.5%(重量)之间。如果该共聚物包含1－丁烯,它存在的量必须介于共聚物的1～15.4%(重量)。如果该共聚物包含1－己烯,它的存在量必须为共聚物的2～5%(重量)。如果该共聚物是丙烯、乙烯及丁烯的三元共聚物,聚丙烯的存在量为90～98%(重量),乙烯存在的量为1～6%(重量),丁烯的存在量为1～6%(重量)。该纤维可另外含有皮/芯、海岛或并列型等形式的共轭取向的、与该第一聚合物毗邻的第二聚合物。

Description

用含有特种共聚物并具有美学上愉快手感 的聚合物制成的非织造布
发明背景
本发明概括地说涉及可用多种方法纺成纤维并制成非织造布的热塑性聚合物。如此制成的纤维及非织造布可应用于多种多样的个人护理制品之中，例如尿布、训练裤、失禁用品、抹布、妇女卫生制品等。这些非织造布还可应用于医疗用途，例如用作手术罩衣或消毒用包布的组成材料，用作户外用布，例如土工布、设备外罩或篷帐布。
用于上述用途的最常见热塑性塑料是聚烯烃，特别是聚丙烯。其他材料，例如聚酯、聚醚酯、聚酰胺及聚氨酯，也可用于制作非织造布。用于这些用途的非织造布常常是层合物形式的，例如纺粘/熔喷/纺粘(SMS)层合物。而且，这种非织造布可用共轭纤维类纤维制作。
非织造布的强度高是人们最希望的特性之一。纤网强度高，就可以使用较薄的材料层而得到与较厚层相当的强度，从而给包含这种纤网的任何产品的消费者带来成本、体积及重量上的节省。可能同样希望的是，此种纤网，尤其是当作为诸如尿布或妇女卫生制品之类的消费品时，具有令人非常舒适的手感。
本发明的目的是提供一种具有充分的强度，而同时又具有令人非常舒适手感的非织造布或纤网。
发明简述
本发明的目的是借助用一种“手感改善”共聚物制成的纤维及非织造布实现的。这种“手感改善”聚合物是一种含有乙烯、1-丁烯或1-己烯的丙烯共聚物，或者它是一种丙烯、乙烯及1-丁烯的三元共聚物。如果该聚合物是乙烯共聚物，则该共聚物必须是无规的，或无规及嵌段的，且乙烯存在的量必须大于该共聚物的5到7.5％(重量)。如果该共聚物含有1-丁烯，则1-丁烯在共聚物中存在的量必须介于1～15.4％(重量)。如果共聚物含有1-己烯，则1-己烯在共聚物中存在的量必须介于2～5％(重量)。如果该聚合物是丙烯、乙烯和丁烯的三元共聚物，则聚丙烯存在的量介于90～98(重量)，乙烯存在的量介于1～6％(重量)，而丁烯存在的量介于1～6％(重量)。
这种纤维可另外含有按皮芯、海岛或并列等形式共轭取向的、与第一聚合物毗邻的第二聚合物。
定义
这里所用的“非织造布或纤网”一词是指这样一种纤网，它具有由单根纤维或丝互相绞缠而成的，而不是如针织织物中那样以可辨认的方式组成的结构。非织造布或纤网一向可采用多种方法成形，例如熔喷法、纺粘法、熔体喷撒以及粘合梳理纤网法。非织造布的单位重量通常以每平方码材料的盎司数(osy)或每平方米的克数(gsm)来表示，使用的纤维直径通常以微米表示。(注：要从osy换算到gsm，可用33.91乘上以osy表示的数值)。
这里所使用的“微纤维”一词是指平均直径不大于约75微米的细直径纤维，例如其平均直径约为0.5微米～约50微米，或者更具体地说，微纤维的平均直径为约2微米～约40微米。另一个经常使用的纤维直径表示方法是旦。例如，一个按微米给出的聚丙烯纤维直径的数值可以通过将其乘方，然后将结果乘上0.00629，换算为旦数，比如，15微米聚丙烯纤维的旦数为约1.42(152×0.00629＝1.415)。
这里所使用的“纺粘纤维”一词是指这样的小直径纤维，其制取方法是：将熔融热塑性材料从一种纺丝板的通常为圆形的许多细孔中挤出成为一束丝，然后通过诸如以下文献所述的方法使挤出的丝的直径迅速变细：授予Appel等人的美国专利4,340,563及授予Dorschner等人的美国专利3,692,618、授予Matsuki等人的美国专利3,802,817、授予Kinney的美国专利3,338,992及3,341,394、授予Levy的美国专利3,502,763及3,909,009，以及授予Dobo等人的美国专利3,542,615。纺粘纤维通常是连续的，其直径大于7微米，特别是约10微米～30微米。
这里所使用的“熔喷纤维”一词是指这样的纤维，其制取方法是：将熔融热塑性材料从许多细小的、通常为圆形的模板孔中以熔融丝或丝束的形式挤出到会聚的高速气体(例如空气)流中，气流将熔融热塑性材料的丝束拉细，以致可将其直径降低到微纤维直径的水平。此后，该熔喷纤维被高速气流夹带并沉积到收集表面上，形成由无规散落的熔喷纤维组成的纤网。这样一种方法例如公开在美国专利3,849,241中。熔喷纤维属于微纤维，它可以是连续的或不连续的，其直径通常小于10微米。
这里所用的“聚合物”一词一般包括但不限于，均聚物、共聚物，例如嵌段、接枝、无规及交替共聚物、三元共聚物等，及其共混物及改性物。此外，除非另行界定，“聚合物”一词应涵盖该材料全部可能的几何构型。这些构型包括但不限于，等规及无规的对称体。
这里所用的“机器方向”或MD一词是指非织造布的长度方向，即沿着它被生产出来的方向。“垂直(于)机器方向”或CD一词是指非织造布的幅宽方向，即通常垂直于MD的方向。
这里所用的“单组分”纤维一词是指仅用一种聚合物由一台或多台挤出机成形的纤维。该定义不排除由一种为了着色、抗静电特性、润滑、亲水等目的而加入了少量添加剂的聚合物所制成的纤维。这些添加剂，例如为着色的目的加入二氧化钛，一般存在的量少于5％(重量)，更典型地约2％(重量)。
这里所用的“共轭纤维”一词是指用来自分开的挤出机的至少两种聚合物，但共同纺成一种纤维时所制成的纤维。共轭纤维有时也叫做多组分或双组分纤维。这些聚合物沿共轭纤维的横断面排列在基本固定的界限分明的区内，并沿该共轭纤维的长度连续地延伸。此种共轭纤维的配置例如可以是皮/芯排列的，其中一种聚合物被另一种聚合物包围着，或者可以是并排排列的，或是呈“海-岛”式排列的。共轭纤维公开在授予Kaneko等人的美国专利5,108,820、授予Strack等人的美国专利5，336,552以及美国专利5,382,400中。就二组分纤维而言，聚合物存在的比例可为75/25、50/50、25/75，或者任何希望的其他比例。
这里所用的“双成分纤维”一词是指从同一挤出机以共混物形式挤出的至少两种聚合物制成的纤维。其中“共混物”的定义见下文。双成分纤维不具备沿纤维的横断面内排列在相对固定位置的界限分明区内的不同聚合物组分，其不同聚合物通常不是沿纤维的全长连续延伸的，相反，它们通常形成无规地开始和结束的原纤。双成分纤维有时也叫做多成分纤维。这种大体类型的纤维例如见诸于授予Gessner的美国专利5,108,827。共轭纤维和双成分纤维还见诸于教科书聚合物共混物及复合物，John A.Manson及Leslie H.Sperling编，Plenum出版社1976年出版，纽约Plenum出版公司一分支机构，IBSN 0-306-30831-2，273～277页。
这里所用的“共混物”一词是指两种或更多种聚合物的混合物，而“合金”是指共混物的一个子类，其中的成分不相混溶，但具有相容(共存)关系。“混溶性”和“不混溶性”的定义指共混物分别具有负值和正值的混合自由能。进而，“相容化”的定义是改变不混溶的聚合物共混物的界面性质以制成合金的方法。
这里所用的“粘合范围”一词是指将非织造布粘合在一起并做到“成功”的粘合时可采用的热轧辊温度区间。对聚丙烯纺粘法而言，该粘合范围典型地为约270°F～约310°F(132℃～154℃)。低于约270°F，则该聚丙烯表现出未热到足以发生熔融和粘合，而超过约310°F，则聚丙烯将会过度熔融，并可能粘在热轧辊上。聚乙烯的粘合范围就更加窄了。
这里所用的“阻隔布”一词是指一种对液体传输而言相对地不可透过的布料，即一种根据ASTM试验方法22血液透过速率等于或小于1.0的布料。
这里所用的“服装”一词是指任何非医用的可穿戴衣物。这包括工业工作服及连衣裤防护服、内衣裤、裤子、衬衫、夹克、手套、袜子等。
这里所用的“防感染制品”一词是指医用的制品，例如手术罩衣及帘子、面罩、象厨师帽之类的头罩、手术帽子及罩子、脚上穿戴物，例如鞋罩、靴罩及拖鞋，伤口敷裹物、绷带、消毒用包布、抹布、诸如实验室罩衣的服装、连衣裤防护服以及罩衫、围裙及夹克、病床铺盖物、担架及童车铺单等。
这里所用的“个人护理制品”一词是指尿布、训练裤、吸收性内裤、成人失禁用品以及妇女卫生制品。
这里所用的“防护外罩”一词是指用于运输工具，例如汽车、卡车，船、飞机、摩托车、自行车、高尔夫小车等的外罩，经常放在户外的设备外罩，例如用于烧架、庭院及园艺设备(割草机、圆盘犁等)以及草坪家具，直至地板覆盖物、桌布及野餐铺地布、
这里所用的“户外用布”一词是指主要，虽不是唯一户外使用的布料。户外用布包括用于防护外罩的布料、野营/拖车布料、帆布、篷帐布、华盖、帐篷、农用布以及户外服装，例如头罩、工业工作服及连衣裤防护服、裤子、衬衫、夹克、手套、袜子、鞋罩等。
测试方法
杯形压扁：非织造布的柔软性可根据“杯形压扁”试验来衡量。杯形压扁试验评定非织造布刚挺性的方法是，测量一只直径4.5厘米的半球形压脚将一块23厘米见方的非织造布做成的大约直径6.5厘米、高6.5厘米的倒置杯形试样压扁，所需要的峰值载荷，测试过程中该杯形布料被一个直径大约6.5厘米的圆筒包围着，以保持杯形布料的均匀变形。压脚与杯子对中，以免杯壁与压脚之间发生接触而影响峰值载荷。测量峰值载荷时压脚以大约0.25英寸/秒(38厘米/分)的速率下降。杯形压扁值低，表明该层合物柔软。一种适合测量杯形压扁值的装置是FTD-G-500型载荷传感器(量程500克)，制造者：Schaevitz公司，Pennsauken，NJ。杯形压扁值用克数来衡量。
熔体流动速率：熔体流动速率(MFR)是聚合物粘度的度量。MFR采用规定载荷或剪切速率下在测量的一段时间内从已知尺寸的毛细管流出的物质重量来表示，根据例如ASTM试验1238，条件E，该值在230℃下进行测定，以克/10分钟为单位。
Grab拉伸试验：Grab拉伸试验是在单方向应力作用下布料破裂强度及伸长或应变的度量。该试验是本领域已知的方法并符合联邦试验方法标准号191A的方法5100的规定。结果用直至破裂的磅数，及破裂前的伸长百分数来表示。数值较高，表明是一种较结实、可拉长性较大的布料。“载荷”一词是指在拉伸试验中要将试样破裂或破坏所需要的、以重量单位表示的最大载荷或力。“应变”或“总能量”一词是指在载荷-伸长曲线下方的总能量，以重量-长度单位表示。“伸长”一词是指拉伸试验期间试样长度的增加。Grab拉伸强度和Grab伸长的数值是采用规定的布宽度、夹具宽度及恒定伸长速率的情况下获得的，布宽通常为4英寸(102毫米)。该试样比夹具宽，给出的结果代表处于夹持宽度内纤维的有效强度与布料中邻近纤维所贡献的附加强度之和。将试样夹在测力计上，例如一台Instron TM型仪，生产者：Instron公司，2500 Washington St.，Canton，MA 02021，或者一台Thwing-AlbertINTELLECT II型，生产者：Thwing-Albert仪器公司，10960 DuttonRd.，费城，PA19154，该机备有一对3英寸(76毫米)长的彼此平行的夹具。该结果逼真地模拟了实际使用当中布料的应力条件。
发明详述
纺粘非织造布采用本领域已知的并在列举的大量参考文献中描述过的方法生产。扼要地说，纺粘法通常采用一个料斗向加热的挤出机供应聚合物。挤出机将熔融聚合物送至纺丝板，在此随着聚合物通过纺丝板中通常排列成一排或多排的细孔，聚合物就变为纤维状，形成由丝束构成的幕。对丝束通常用低压空气进行骤冷，牵伸，一般靠气力，然后将其沉积在移动的多孔垫、带或“成形金属网”上，成形为非织造布。通常制作的纺粘布，其单位重量约0.1osy～约3.5osy(3gsm～119gsm)。
用纺粘法生产出的纤维，其直径依工艺条件及由该纤维生产出的非织造布的预期最终用途而定，一般在约10～约30微米范围内。例如，提高聚合物分子量或降低加工温度，生产出的纤维直径较粗。骤冷流体温度及气力牵伸压力的变化也会影响到纤维直径。
在成形金属网上成形之后，纺粘布一般要经过某种方式的粘合，以赋予其进一步加工需要的足够整体性。点热轧粘合应用得相当普遍，涉及：让待粘合纤维的非织造布或纤网从加热的轧辊与砧辊之间通过。轧辊通常带有某种花纹，以便非织造布不致沿整个表面都粘合在一起。于是，开发出各种各样的轧辊花纹，既为了功能的目的，也出于美观的考虑。一个例子是如授予Hansen及Pennings的美国专利3,855,046中所公开的Hansen Penning s或H&P花纹，它具有约30％粘合面积以及约100粘合点/平方英寸。这种H&P花纹带有方形凸点粘合区，其中每个凸点的边长为0.038英寸(0.965毫米)，相邻点之间的间距是0.070英寸(1.778毫米)，凸点的粘合深度是0.023英寸(0.584毫米)。产生的花纹粘合面积为约29.5％。另一种典型的粘合花纹是扩展的Hansen及Pennings或“EHP”粘合花纹，它组成15％粘合面积，其中方形凸点边长为0.037英寸(0.94毫米)、凸点间距为0.097英寸(2.464毫米)，深度为0.039英寸(0.991毫米)。另一种定名为“714”的典型粘合花纹具有方形凸点粘合区，其中每个凸点的边长为0.023英寸，点间距为0.062英寸(1.575毫米)，粘合深度为0.033英寸(0.838毫米)。产生的花纹粘合面积为约15％。其他常用的花纹包括由重复然而稍许偏置的菱形组成的菱形花纹以及其外观如同其名字所提示的--像窗纱似的窗纱波纹花型。就典型而言，粘合面积百分率在非织造布层合物纤网面积的约10％～约30％之间变化。正如技术上熟知的，这种点粘合在将各层结合在一起的同时，通过对每一层中的丝或纤维的粘合也赋予每一层以整体性。
用于纺粘法中的聚合物通常的加工熔融温度约350°F～约610°F(175℃～320℃)，其如前面所定义的熔体流动速率介于约10～约150，特别是在约10～50之间。合适聚合物的例子包括如聚丙烯和聚乙烯的聚烯烃、聚酰胺及聚酯。
在实施本发明中也可生产共轭纤维，其中至少一种组分是本发明的手感改善聚合物。共轭纤维常见的排列方式包括皮/芯、“海-岛”或并列的配置。
用于实施本发明的聚合物包括：其中乙烯存在的量是共聚物的大于5～7.5％(重量)的含有乙烯的丙烯共聚物、其中1-丁烯存在的量是共聚物的1～15.4％(重量)的含有1-丁烯的丙烯共聚物、其中1-己烯存在的量是共聚物的2～5％(重量)的含有1-己烯的丙烯共聚物，以及丙烯、乙烯和丁烯的三元共聚物，其中聚丙烯存在的量介于90～98％(重量)，乙烯存在的量介于1～6％(重量)，而丁烯存在的量介于1～6％(重量)。
由本发明的纤维制成的纺粘布可层合到其他材料上以形成有用的多层产品。这种层合物的例子是SMS(纺粘、熔喷、纺粘)或SFS(纺粘、薄膜、纺粘)结构，其中至少一个纺粘层是按照本发明生产的。这种层合布的制法包括：首先在成形金属网上沉积一层纺粘纤维。在该纺粘纤维上面沉积由熔喷纤维或薄膜构成的中间层。最后，在熔喷层上面又沉积另一层纺粘纤维，而这一层通常是预制的。可以有一个以上的中间层。
替代地，所有的层均可单独的生产出来，然后在一个层合步骤中合在一起。用作中间层的非织造熔喷纤维或薄膜可用非弹性体聚合物，例如聚丙烯和聚乙烯制成，或者用热塑性弹性体聚合物制成。
热塑性弹性体聚合物可以是由下列制成的聚合物：苯乙烯嵌段共聚物、聚氨酯、聚酰胺、共聚多酯、乙烯乙酸乙烯酯(EVA)等。一般而言，任何能形成弹性体纤维或薄膜的合适树脂或含有该树脂的共混物均可用于成形该弹性体纤维非织造纤网或弹性体薄膜。
苯乙烯嵌段共聚物包括苯乙烯/丁二烯/苯乙烯(SBS)嵌段共聚物、苯乙烯/异戊二烯/苯乙烯(SIS)嵌段共聚物、苯乙烯/乙烯-丙烯/苯乙烯(SEPS)嵌段共聚物、苯乙烯/乙烯-丁二烯/苯乙烯(SEBS)嵌段共聚物。例如，有用的能形成弹性体纤维的树脂包括通式为A-B-A’或A-B的嵌段共聚物，其中A和A’每一个是含有苯乙烯部分的，例如聚(乙烯基芳烃)的热塑性聚合物链端嵌段，而其中B是诸如共轭二烯或低级烯烃聚合物的弹性体聚合物链中嵌段。A-B-A’型嵌段共聚物可以含有不同或相同A与A’嵌段的热塑性嵌段共聚物。而本发明的嵌段共聚物意在涵盖线型、支链及星形嵌段共聚物。就此而言，星形嵌段共聚物可表示为(A-B)m-X，其中X是多官能原子或分子，且其中每一个(A-B)m-以A作为链端嵌段自X呈放射状伸出。在该星形嵌段共聚物中，X可为有机或无机多官能原子或分子，m是整数，其值与原来存在于X中的官能团数相同、它一般至少是3，常常是4或5，然而并不限于此。所以，在本发明中，“嵌段共聚物”，特别是“A-B-A’”及“A-B”嵌段共聚物一词意在涵盖所有含有这种橡胶嵌段以及上面讨论过的热塑性嵌段的嵌段共聚物，它们可挤出(例如通过熔喷)，且嵌段数目不受限制。
授予Wisneski等人的美国专利4,663,220公开一种纤网，包括含有至少约10％(重量)A-B-A’嵌段共聚物的微纤维，其中“A”和“A’”每一个是含有苯乙烯部分的热塑性链端嵌段，且其中“B”是弹性体聚(乙烯-丁烯)链中嵌段，以及大于0％(重量)～约90％(重量)这样的聚烯烃：当与该A-B-A’嵌段共聚物掺混并受到高温与高压条件的有效组合的作用时适合以与A-B-A’嵌段共聚物的共混形式挤出。Wisneski等人所用的聚烯烃可以是聚乙烯、聚丙烯、聚丁烯、乙烯共聚物、丙烯共聚物、丁烯共聚物及其混合物。此种弹性体共聚物的商品例子例如有：叫做KRATON材料的共聚物，生产者：壳牌化学公司，Houston，Texas。供应的KRATON嵌段共聚物有几种不同的配方，其中有许多种可见诸于美国专利4,663,220，该文收作本文的参考。特别合适的弹性体层可用例如如下的弹性体聚(苯乙烯/乙烯-丁烯/苯乙烯)嵌段共聚物制成，其商品名为KRATONG-1657，由壳牌化学公司生产。
可用来制作弹性体层的其他范例弹性体材料包括：聚氨酯弹性体材料，例如商品名为ESTANE的材料，生产者：B.F.Goodrich公司；聚酰胺弹性体材料，例如商品名为PEBAX的材料，生产者：Rilsan公司；以及聚酯弹性体材料，例如商品名为HYTREL的材料，由杜邦公司生产。
用聚酯弹性体材料制作弹性体非织造布的方法例如公开在授予Morman等人的美国专利4,741,949中，该文收入本文作为参考。此类共聚多酯材料的商品例子例如有商品名为ARNITEL的材料，原生产者：AKZO塑料公司，Arnhem，荷兰，现生产者：DSM公司，Sittard，荷兰，或者商品名为HYTREL的材料，生产者：杜邦公司，Wilmington，Delaware。
弹性体层还可以用乙烯与至少一种乙烯基单体，例如乙酸乙烯酯、不饱和脂族单羧酸及这种脂族单羧酸的酯生成的弹性体共聚物来制作。弹性体共聚物以及用这种弹性体共聚物制取弹性体非织造纤网的方法公开在例如美国专利4,803,117中。
特别有用的弹性体熔喷热塑性纤网由例如公开在授予Boggs的美国专利4,707,398、授予Morman等人的美国专利4,741,949以及授予Wisneski等人的美国专利4,663,220中的材料的纤维构成。另外，弹性体熔喷热塑性聚合物层本身可由较薄的弹性体熔喷热塑性聚合物层构成，这些层是采用本领域技术人员已知的方法一层层地顺序沉积或层合在一起的，例如采用热粘合、超声粘合、水力缠结、针刺粘合及粘合剂粘合。
本发明的非织造布可在层合之前或之后用各种化学品按照已知的技术进行处理，以赋予适合专门用途的性能。这些处理剂包括拒水化学品、柔软剂、阻燃剂、拒油化学品、抗静电剂及其混合物。在非织造布粘合后处理时也可加入颜料，或者替代地，在制取纤维之前加在选定层的聚合物中。
对按照本发明制作的非织造布及层合物进行了强度和手感试验。表中使用的单位，对杯形压扁总能量为克/毫米，对杯形压扁载荷为克，对峰值载荷为磅，对峰值能量为英寸-磅，对破裂伸长为英寸。
表1表示按照授予Appel等人的美国专利4,340,563生产的以及按照本发明，以丙烯与1-丁烯的共聚物为手感改善共聚物所生产的纺粘布的试验结果。在表1中，所有的布样均系按单位重量约0.7osy(24gsm)以0.7克/孔/分钟(ghm)的速率，经过0.6毫米的纺丝孔挤出而生产出来的。聚合物的熔体温度及布的粘合温度载于表1。非织造布是采用带有窗纱波纹花型的点热轧粘合辊粘合的。表1中作为PP对比例给出的聚丙烯不是共聚物，两种情况下均为壳牌化学公司生产的牌号为E5E65的市售聚丙烯聚合物，它在230℃时的熔体流动速率为约38。各试样是根据共聚物中1-丁烯的重量百分率来区分的。1％(重量)1-丁烯共聚物的熔体流动速率依次为约44和52。14％(重量)1-丁烯共聚物的熔体流动速率为约41。12.5％(重量)1-丁烯共聚物的熔体流动速率为约32。15.4％(重量)1-丁烯共聚物的熔体流动速率为约30。这些数据是未经规格化的。
表2表示按照授予Appel等人的美国专利4,340,563生产的以及按照本发明，以丙烯与1-己烯的共聚物为手感改善共聚物所生产的纺粘布的试验结果。在表2中，所有的布样均系按单位重量约0.7osy(24gsm)以0.7克/孔/分钟(ghm)的速率，经过0.6毫米的纺丝孔挤出而生产出来的。聚合物的熔体温度及布的粘合温度载于表2。非织造布是采用带有扩展的Hansen-Pennings花纹的点热轧粘合辊粘合的。表2中作为PP对比例给出的聚丙烯不是共聚物而是壳牌化学公司生产的E5E65。各试样是根据共聚物中1-己烯的重量百分率来区分的。2.5％(重量)1-己烯共聚物的熔体流动速率为约40。5％(重量)1-己烯共聚物的熔体流动速率为约38。
表3表示按照授予Appel等人的美国专利4,340,563生产的以及按照本发明，以乙烯与丙烯的共聚物为手感改善共聚物所生产的纺粘布的试验结果。在表3中，头4个布样代表按单位重量约0.7osy(24gsm)生产的布，而后4个试样代表按单位重量1.0osy(34gsm)生产的布。所有的布样都是以0.7克/孔/分钟(ghm)的速率，经过0.6毫米的纺丝孔挤出而生产出来的。聚合物的熔体温度及布的粘合温度载于表3。非织造布是采用带有窗纱波纹花型的点热轧粘合辊粘合的。表3中作为PP对比例给出的聚丙烯不是共聚物而是壳牌化学公司生产的E5E65，各试样是根据共聚物中乙烯的重量百分率来区分的。3％(重量)乙烯的丙烯共聚物的熔体流动速率为约35。5.5％(重量)乙烯的丙烯共聚物的熔体流动速率为约34，系壳牌化学公司生产的商品名为WRD6-277的市售品。7.5％(重量)乙烯的丙烯共聚物的熔体流动速率为约40。
表4表示按照授予Appel等人的美国专利4,340,563生产的以及按照本发明，以丙烯、乙烯及丁烯的三元共聚物为手感改善共聚物所生产的纺粘布的试验结果。在表4中，所有的布样均系按单位重量约1.0osy(34gsm)以0.7克/孔/分钟(ghm)的速率，经过0.6毫米的纺丝孔挤出而生产出来的。聚合物的熔体温度及布的粘合温度载于表4。非织造布是采用带有扩展的Hansen-Pennings花纹的点热轧粘合辊粘合的。表4中作为PP对比例给出的聚丙烯不是共聚物，而是Exxon化学公司，Baytown，Texas，生产的商品名为ESCORENE3445聚丙烯的市售聚丙烯均聚物。各试样是根据三元共聚物中聚丙烯/乙烯/丁烯依次的重量百分率来区分的。96/2/2三元共聚物的熔体流动速率为约40。94/4/2三元共聚物的熔体流动速率为约37。94/2/4三元共聚物的熔体流动速率为约42。92/4/4三元共聚物的熔体流动速率为约40。
以上各表显示，用本发明的手感改善共聚物制作的纺粘纤网表现出明显优越的杯形压扁数值，说明是一种明显地较为柔软的纤网。事实上，本发明人发现，用本发明纤维制作的非织造布，其杯形压扁能量值比不用合乎本文规定要求的聚合物制作的布低至少25％。这种在杯形压扁数值上改善的取得并未伴随出现反映在峰值载荷、峰值能量以及破裂伸长等试验结果上的非织造布强度的明显恶化。
                 表1丙烯/1-丁烯共聚物(未规格化数据)，％1-丁烯
试样     杯形压扁     峰值载荷     峰值能量     破裂伸长 熔体温度(F) 粘合温度(F)
总能量 载荷     MD     CD     MD     CD   MD   CD
PP对比标准偏差     1371.4     71.6     10.91.6     13.00.6     9.73.6     14.01.6     2.60.4     3.40.3     450     280
1％标准偏差     1294.4110.7     65.45.0     13.01.6     11.21.5     13.13.0     13.43.1     3.30.4     3.20.5     410     276
1％标准偏差     1307.2137.7     65.01.2     12.10.6     10.71.5     13.91.6     10.92.9     3.80.4     3.20.4     410     270
14％标准偏差     822.461.3     41.84.6     12.20.9     8.21.4     14.33.0     8.61.9     3.80.6     3.30.5     410     220
PP对比标准偏差     1462.02225.5     72.67.0     16.30.9     11.41.7     17.02.5     12.24.5     3.30.4     2.60.1     450     286
12.4％标准偏差     881.883.6     47.89.3     11.61.5     9.00.5     13.72.3     12.03.7     4.10.2     3.90.6     415     213
15.4％标准偏差     682.427.4     37.42.3     12.00.9     9.21.3     11.91.5     10.63.2     3.50.2     3.50.3     415     214
             表2丙烯/1-己烯共聚物(未规格化数据)，％C6
试样     杯形压扁     峰值载荷     峰值能量     破裂伸长 熔体温度(F)   粘合温度(F)
总能量 载荷     MD     CD   MD     CD   MD   CD
PP对比标准偏差  1174.6234.1  65.89.0     16.00.8     12.20.9     18.92.8     15.13.1     3.80.3     3.00.5    430     285
 2.5％标准偏差  817.2131.6  45.25.1     16.11.2     11.62.1     18.33.6     13.94.9     3.90.4     3.40.4    430     260
 5％标准偏差  501.052.9  28.83.8     13.00.9     8.50.9     15.01.8     11.03.5     3.90.5     3.60.3    430     240
         表3乙烯丙烯无规共聚物，％乙烯
试样     杯形压扁     峰值载荷     峰值能量     破裂伸长 熔体温度(F) 粘合温度(F)
总能量 载荷     MD     CD     MD     CD     MD     CD
PP对比标准偏差  2095.276.581  105.63.9     16.61.7     11.41.7     14.92.8     9.82.5     2.60.4     3.20.3  430  285
 3％标准偏差  1273.2144.581  59.67.4     14.61.8     11.01.0     10.32.8     9.31.7     3.40.5     2.90.3  430  270
 5.5％标准偏差  623.686.6  34.86.6     12.21.1     6.50.5     10.02.4     7.01.7     3.60.2     3.60.2  430  240
 7.5％标准偏差  310.822.6  16.80.8     8.30.2     5.10.6     7.50.9     7.51.6     4.10.4     4.61.2  430  223
PP对比标准偏差  3785.8531.8  202.417.2     21.42.0     14.32.0     16.93.7     11.33.8     3.00.2     3.00.5  430  285
 3％标准偏差  2462.883.4  113.86.5     19.41.4     12.91.6     14.62.1     13.21.5     3.80.3     4.50.5  430  270
 5.5％标准偏差  1222.472.8  67.06.2     18.51.4     10.41.0     17.23.1     11.24.0     3.70.4     3.90.3  430  240
7.5％标准偏差  664.852.2  36.84.1     12.00.3     7.72.0     11.20.9     9.63.9     4.00.5     3.90.3  430  223
           表4三元共聚物，％C3＝/C2＝/C4＝
试样     杯形压扁     峰值载荷     峰值能量     破裂伸长 熔体温度(F) 粘合温度(F)
  总能量   载荷     MD   CD     MD     CD   MD     CD
PP对比标准偏差   1309.871.7     71.64.9     17.40.5     9.80.8     17.81.5     10.81.5     4.40.3     3.60.2   450   285
96/2/2标准偏差   952.840.9     53.66.1     14.30.6     12.11.0     19.33.0     16.72.4     5.20.5     4.30.5   430   257
94/4/2标准偏差   389.841.4     22.02.2     10.71.3     8.21.1     15.34.6     14.14.0     5.60.4     5.40.5   430   244
PP对比标准偏差   1557.0144.1     84.07.3     18.10.7     13.01.2     19.82.0     16.13.0     4.00.2     4.30.4   450   285
94/2/4标准偏差   801.860.1     43.67.1     14.40.7     11.50.3     21.82.6     19.52.4     5.30.3     5.10.6   430   244
92/4/4标准偏差   284.610.7     16.41.5     8.20.9     6.30.9     15.02.9     10.73.2     5.80.5     5.60.7   430   234

Claims (19)

1.一种含有选自如下的手感改善聚合物的热塑性聚合物纤维：
聚丙烯与乙烯的共聚物，其中所述乙烯的存在量是共聚物的大于5～7.5％(重量)，
聚丙烯与1-丁烯的共聚物，其中所述1-丁烯的存在量是共聚物的1～15.4％(重量)，
聚丙烯与1-己烯的共聚物，其中所述1-己烯存在的量是共聚物的2～5％(重量)，以及
丙烯、乙烯及丁烯的三元共聚物，其中所述聚丙烯存在的量是90～98％(重量)，所述三元共聚物的乙烯存在的量是1～6％(重量)而所述三元共聚物的丁烯存在的量是1～6％(重量)，
其中由所述纤维组成的非织造布的杯形压扁能量值比不用所述手感改善聚合物制成的类似布低至少25％。
2.由权利要求1的纤维构成的非织造布，其中所述布选自纺粘布、熔喷布以及熔体喷撒布。
3.一种非织造层合物，包括：作为第一层的权利要求2的布，其中所述布是纺粘布，以及第二层纺粘聚丙烯纤网。
4.权利要求3的非织造层合物，其中所述非织造纺粘层之间夹有至少一层选自熔喷非织造布及薄膜的中间层材料。
5.权利要求1的纤维，它还包含作为一个单独的相与所述第一聚合物相毗邻的第二聚合物，从而构成一种共轭纤维。
6.权利要求5的纤维，其中所述第一及第二聚合物是按照选自皮/芯、海-岛及并列等共轭取向方式排列的。
7.由权利要求6的纤维构成的非织造布，其单位重量为约0.3～3.5osy。
8.权利要求7的非织造布，它是采用选自纺粘法、熔喷法及熔体喷撒的方法生产的。
9.权利要求8的非织造布，其中所述方法是纺粘法。
10.一种非织造层合物，包括：作为第一层的权利要求9的布，其中所述布是纺粘布，以及第二层纺粘聚丙烯纤网。
11.权利要求10的非织造层合物，其中所述非织造纺粘层之间夹有至少一层选自熔喷非织造布及薄膜的中间层材料。
12.权利要求11的非织造层合物，其中所述中间层材料是熔喷非织造布，它是弹性体并且用选自下列的材料制成：苯乙烯嵌段共聚物、聚烯烃、聚氨酯、聚酯、聚醚酯以及聚酰胺。
13.权利要求11的非织造层合物，其中所述中间层材料是薄膜，它是弹性体并且用选自下列的成膜聚合物制成：苯乙烯嵌段共聚物、聚烯烃、聚氨酯、聚酯、聚醚酯以及聚酰胺。
14.权利要求11的非织造层合物，其中所述各层采用选自热粘合、超声粘合、水力缠结、针刺粘合及粘合剂粘合的方法粘合在一起。
15.权利要求14的层合物，它存在于选自防感染制品、个人护理制品及户外用布等产品之中。
16.权利要求14的层合物，其中所述产品是个人护理制品，而所述个人护理制品是尿布。
17.权利要求14的层合物，其中所述产品是个人护理制品，而所述个人护理制品是妇女卫生制品。
18.权利要求14的层合物，其中所述产品是个人护理制品，而所述个人护理制品是成人失禁用品。
19.权利要求14的层合物，其中所述产品是个人护理制品，而所述个人护理制品是训练裤。
CN96192173A 1995-02-27 1996-02-09 用含有特种共聚物并具有美学上愉快手感的聚合物制成的非织造布 Pending CN1176672A (zh)

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CN109056108A (zh) * 2018-10-19 2018-12-21 如皋福大工程技术研究院有限公司 一种具有防紫外线的纤维
CN112639182A (zh) * 2018-09-21 2021-04-09 北欧化工公司 用于熔纺纤维应用的聚丙烯组合物
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CN106968051A (zh) * 2017-03-06 2017-07-21 东华大学 具有反滤排水功能的丙纶土工布复合排水网的制备方法
CN112639182A (zh) * 2018-09-21 2021-04-09 北欧化工公司 用于熔纺纤维应用的聚丙烯组合物
CN109056108A (zh) * 2018-10-19 2018-12-21 如皋福大工程技术研究院有限公司 一种具有防紫外线的纤维
CN113677840A (zh) * 2019-04-16 2021-11-19 陶氏环球技术有限责任公司 非织造纤网及其制造方法
CN113677840B (zh) * 2019-04-16 2023-09-08 陶氏环球技术有限责任公司 非织造纤网及其制造方法

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WO1996027041A1 (en) 1996-09-06
PL321957A1 (en) 1998-01-05
US5652051A (en) 1997-07-29
KR19980702521A (ko) 1998-07-15
DE69612841T2 (de) 2001-12-13
TW350882B (en) 1999-01-21
CA2210914A1 (en) 1996-09-06
DE69612841D1 (de) 2001-06-21
BR9607279A (pt) 1998-06-23
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