CN1221698C - 用于制造适于制作净化间防护服的无纺布的方法 - Google Patents

用于制造适于制作净化间防护服的无纺布的方法 Download PDF

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CN1221698C
CN1221698C CNB008108331A CN00810833A CN1221698C CN 1221698 C CN1221698 C CN 1221698C CN B008108331 A CNB008108331 A CN B008108331A CN 00810833 A CN00810833 A CN 00810833A CN 1221698 C CN1221698 C CN 1221698C
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nonwoven fabric
primary filaments
water spray
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water
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罗伯特·格罗腾
霍尔格·希林
阿诺尔德·布雷曼
哈特维希·冯德米伦
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Carl Freudenberg KG
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    • 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
    • D04H3/016—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the fineness
    • 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
    • D04H3/018—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the shape
    • 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
    • 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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    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
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    • Y10T442/614—Strand or fiber material specified as having microdimensions [i.e., microfiber]
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    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/689—Hydroentangled nonwoven fabric
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    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
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Abstract

用于制造适于制作多次重复使用的净化间防护服的无纺布的方法，其中，通过熔融纺丝法形成纤度小于2分特的可分裂的多成分长丝作为初级长丝，把该初级长丝气动伸展、直接放置成一纤维网，其特征在于：上述放置的纤维网首先经受水喷预固化，这时上述初级长丝被机械地相互缠结；随后，通过高压水喷分裂方式，把初级长丝分裂成纤度小于0.2分特的超微长丝。

Description

用于制造适于制作净化间防护服的无纺布的方法
技术领域
本发明涉及一种用于制造适于制作多次重复使用的净化间防护服的无纺布的方法。
背景技术
净化间防护服的作用是用来保护那些在这些净化间中所制造或处理的制品(如微电子部件、药品、光导纤维等)免受人这一作为干扰性微粒(如灰尘微粒或皮肤微粒、细菌等)发射“源”的影响。
因此对一种用于制造这种防护服的材料的最重要的要求便是要具有屏障作用。防护服材料必须既挡住由人体不断释放出来的微粒(皮屑、断发、细菌等)，也挡住由一纺织品下身服装所掉出来的纤维碎屑，从而来防止对净化间空气以及制品的污染，当然材料本身也不应该发射任何纤维物品或其它成分到净化间空气中去。
除了所要求的屏障作用之外，防护服材料还应具有高的机械承载能力、尤其是高的抗撕裂性和抗磨损性，以减小因外部作用或普通的穿着应力而形成裂口或孔的危险性。还为了使防护服能多次重复使用，所用的材料应该尽量无损坏地经受住行业上常采用的水洗或清洗过程(目前为放在高压釜中进行消毒)，亦即能抗湿法机械式磨损和起毛工艺过程，并且具有足够的尺寸不变性。
除了屏障作用和(湿法)机械抵抗能力外，防护服材料尤其在被用于微电子工业的净化间中时还必须具有一种抗静电作用，亦即该材料在穿着时由于不可避免的摩擦作用不被过分地带上静电或者差不多能快速地将这些静电耗散和导出。这一点十分必要，这样一方面不会因点放电而损坏灵敏的微电子零件，另一方面也不会从周围空气中吸收灰尘微粒，这些灰尘微粒否则会积聚到材料表面上且可能的话还会在以后重新被发射出来。
此外，防护服材料还应具有好的穿着舒适性，亦即具有一种最大可能的纺织物特性或挺括程度、手感和外观以及透气性好且可能的话还要是绝热的，以便能使穿着者不过分地出汗或受冻。
已知有采用超细纤度合成纤维或合成长丝来制造净化间防护服材料的。“超细纤度”在这里意指具有小于1分特的纤度的纤维，亦称“微纤维”。对具有小于0.3分特纤度的纤维习惯上也称“超微纤维”。
以微纤维或微长丝织物或织品为基的普通防护服材料是采用多道加工步骤来制造的。先要从聚合物原材料来喷丝出微纤维或微长丝。微纤维或微长丝然后被处理为线，这些线在某些情况下还要经过一道后续的织物组织工序。从该(被形成纹理的)微纤维线或微长丝线最终织成最后的防护服材料。在织布工序中另外使传导性好的线被织成一种规则图案的形式，比如织成条纹或菱形的形式，以能得到所要求的抗静电效应。使传导性好的线具有比如带含炭黑或石墨芯或套的芯/套式长丝或者具有比如金属纤维或金属化的长丝。所要求的屏障功能以及高(湿)机械承载性则通过对微纤维线的一种极致密和规则的编织来达到。这种高编织密度和主要平行于表面的长丝走向对于材料的透气性来说却是不利的。它们仅具有很少的微孔或微通道能让水蒸汽通过它们被传送通过织物。
这种由防护服材料的屏障作用和透气性两者相结合所产生的问题是通过采用颗粒致密的、但却是透水汽的膜来解决的。这些“微孔”层可通过胶合或直接挤压来形成到普通密度的纺织材料上，以得到一种具有纺织物特性的材料。
从透气性好的屏障膜和纺织物来制造高密度的微长丝织物和复合材料的加工过程是多步骤的且因此较费时间。作为较简单的加工替代方案可采用微纤维无纺布。
平面轧光的聚乙烯基微长丝纺丝无纺布可满足屏障方面的要求且制造成本很低。这种材料实际上却是不透气或不透水蒸汽的且具有一种箔式特性，亦即其穿着舒适性较低。此外，它仅仅是不充分地能经受水洗或清洗，因此它仅局限于用于一次性的或用后即弃的防护服。
微纤维无纺布由多段或多股人造纤维制成，它们在被用溶剂或水喷进行敷纤和最终的预固化之后被分裂成单根的微纤维，因而在具有好的屏障功能下较之上述的高轧光微长丝纺丝无纺布能提供好得多的穿着舒适性。
在欧洲专利说明书EP 0 624 676中便比如描述了一种方法，介绍了如何通过水喷分裂法来制造微纤维无纺布，这种无纺布具有特别大的填充密度且因此也具有很好的屏障作用。然而这种无纺布却缺乏柔软性和绝热性。因此对这种水喷固化的无纺布在(防护)服装领域的应用便受到限制。因此在上述专利说明书中提出了另一种方法，其中不再应用水喷技术。
在PCT申请WO 98/23804中，与前述专利说明书不同地建议将无纺布在水喷分裂之前先逐点热焊。这样可防止无纺布在水喷分裂时与水喷设备的筛带挂住且然后在被掀起时受损或完全毁坏。另一方面，这样做能得到一个较高的纤维分开度，由此则能得到改善的屏障性和手感度。
在欧洲专利说明书EP 97 108 364中力图对无纺布的应用范围加以扩展。其中描述了用很细的长丝来制造一种无纺布，该无纺布具有可与纺织或编织的纺织品相比的性质。这种具有0.005至2分特纤度的很细的长丝是用水喷分裂法从具有0.3～10分特纤度的液态喷丝制成的、起皱或不起皱的多成分—多扇形长丝制成的。对这样制成的无纺布还要以不同的方式进行后续处理(例如用热固定、点轧光等)，以取得专门的使用性质。以这种方法制造的喷丝无纺布则应特别适宜于用来制造服装以及其它的纺织制品。
发明内容
在以下试验中可以惊奇地看到：根据上述专利说明书EP 97108 364所制成的无纺布当它们由小于0.2分特的超微长丝组成且被作轧光处理后特别适宜于制造净化间防护服。这种超微长丝本身则通过水喷分裂工艺由小于2分特纤度的多成分长丝组成，该长丝采用液态喷丝法形成、采用水动法进行拉伸并经水喷作预结合。
本发明成功地描述一种新型的无纺布材料及其制造方法步骤。该无纺布满足对一种多次重复使用的净化间防护服材料的一切要求。其特征在于它具有好的屏障作用、高的机械承载性和尺寸稳定性、有效的抗静电作用以及好的穿着舒适性(透气性和纺织物特性)。这些有利的性质即使在经过多次、行业上常规的水洗和清洗工艺(直至30次循环)仍能大部分被保持。所有这些性质倘若用一种具有分裂制成的最细长丝的无纺布是不能达到的。
无纺布由小于0.5分特纤度的超微长纤组成，这些长丝则从未皱的1.5～2分特纤度的初级长丝制成。作为初级长丝则优选地使用由两种不兼容聚合物、尤其是由聚酯和聚酰胺组成的双成分多扇形长丝。这种组合方式是已有的，这一点尤其可参见EP 97108 364。聚酯成分选择得比聚酰胺的高，优选地在60～70％重量比之间。为取得所要求的抗静电作用，上两种聚合物之一或两者被提供有相应的永久性的、亦即不能被洗掉的添加剂。抗静电效应可比如通过混入炭黑或石墨或者通过将聚合物添加有强亲水性特性或添加有(半)导电性特性并在加有调合剂的条件下取得。初级双成分长丝具有一种桔子式多扇形结构(馅饼结构)的截面。这些扇形交互地各具有那些不兼容的、被添加聚合物中的一种。这种已知的长丝截面已经证明对下文所述的超微长丝的产生是有利的。为得到无纺布的所需的高抗磨性和小的起毛性，则在普通的气动伸展过程之后使初级长丝再经过另一道伸展和同时加热过程(“热通道伸展”)。
这样所产生的初级长丝则经专用设备无规则地被放置在一运动带上并接下去用常规水喷技术来预固化，亦即作机械缠绕。接下来对该预固化的初级长丝无纺布在穿有孔的鼓上多次从两侧用高压水喷枪冲击，其中该初级长丝实际上完全被分裂成它的各种成分，亦即分裂成各单一的超微长丝。通过这一工艺步骤来产生一种微纤维无纺布，该无纺布因其极不规则的和旋涡状的纤维结构一方面具有所需的高屏障作用，另一方面则仍具有足够的水蒸汽透过度。
为改善在水洗和清洗工艺过程中的尺寸稳定性，在进行水喷分裂和其后的烘干之后还将微纤维无纺布在压力作用下经受热空气—热固定工序处理。接下去将无纺布放在轧光机中用专门的雕纹辊轮进行轧光，以提高尺寸稳定性和抗磨性。这样制成的无纺布具有一个80～150g/m2的单位面积重量，优选地为95～115g/m2。
具体实施方式
首先举出一种无纺布例，它由一个95g/m2的单位面积重量、具有均匀厚度的由双成分长丝制成，该双成分长丝由70％的对苯二甲酸聚乙烯和30％的聚亚己基己二酰胺所组成。初级长丝具有一1.6分特的纤度且包含16个扇段，它们交替地由聚酯或聚酰胺所构成。由液态喷丝制成的长丝被经气动性伸展开、无规则地置于一带上并送入水喷处理，在处理中先对长丝作预固化。接下来用高压水喷对该预固化的无纺布作处理，其中初级长丝被分裂成单个的扇段而这些扇段则继续被卷绕成团。这种水喷分裂工艺被多次在无纺布两侧进行。所产生的超微长丝则具有一0.1分特的平均纤度且是不起皱的。该粘胶纤维其后被烘干并被轧平。这样制成的无纺布具有一个约60％的对直径≥0.5μm的颗粒的过滤效率以及一个约98％的对直径≥1μm的粒子的过滤效率。在用一种标准洗涤剂在40℃温度下经30次水洗处理之后，上述过滤效率对≥0.5μm的颗粒仅仅稍稍下降至约55％，而对≥1μm的颗粒仅下降至约95％。

Claims (13)

1.用于制造适于制作多次重复使用的净化间防护服的无纺布的方法，其中，通过熔融纺丝法形成纤度小于2分特的可分裂的多成分长丝作为初级长丝，把该初级长丝气动伸展、直接放置成一纤维网，其特征在于：上述放置的纤维网首先经受水喷预固化，这时上述初级长丝被机械地相互缠结；随后，通过高压水喷分裂方式，把初级长丝分裂成纤度小于0.2分特的超微长丝。
2.如权利要求1所述的方法，其特征在于：初级长丝在经气动伸展之后经受一附加的伸展和加温工艺过程。
3.如权利要求1或2所述的方法，其特征在于：对初级长丝的水喷分裂处理如下进行：用高压水喷流对预固化的无纺布反复交替地从布两侧对其进行喷射。
4.如权利要求3所述的方法，其特征在于：水喷分裂是在一种具有旋转筛鼓的设备上进行的。
5.如权利要求1或2所述的方法，其特征在于：无纺布在经水喷分裂处理和其后的烘干处理后被轧光。
6.如权利要求1或2所述的方法，其特征在于：无纺布在经水喷分裂处理后还附加地经受一种热固定和其后的热定形处理。
7.如权利要求6所述的方法，其特征在于：聚酯成分在无纺布总重量中位于60～70％之间。
8.如权利要求1或2所述的方法，其特征在于：无纺布的单位面积重量位于80～150g/m2之间。
9.如权利要求8所述的方法，其特征在于：无纺布的单位面积重量位于95～115g/m2之间。
10.如权利要求1或2所述的方法，其特征在于：初级长丝具有一种桔子式多扇形结构的截面，其中这些扇形交替地各自包含两种不兼容聚合物中的一种。
11.如权利要求1或2所述的方法，其特征在于：两种不兼容聚合物之一或两者包含一种永久性抗静电作用的添加剂、一种具有明显亲水特性的聚合物、或一种具有导电性能的聚合物。
12.如权利要求11所述的方法，其特征在于：上述永久性抗静电作用的添加剂为炭黑或石墨，上述具有明显亲水特性的聚合物为一种聚酰胺嵌段乙醚共聚物，上述具有导电性能的聚合物为一种聚苯胺或聚乙炔衍生物。
13.如权利要求1或2所述的方法，其特征在于：超微长丝是未起皱的。
CNB008108331A 1999-07-26 2000-07-21 用于制造适于制作净化间防护服的无纺布的方法 Expired - Fee Related CN1221698C (zh)

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