CN1282782C - Meltblown web - Google Patents

Meltblown web Download PDF

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Publication number
CN1282782C
CN1282782C CNB018139019A CN01813901A CN1282782C CN 1282782 C CN1282782 C CN 1282782C CN B018139019 A CNB018139019 A CN B018139019A CN 01813901 A CN01813901 A CN 01813901A CN 1282782 C CN1282782 C CN 1282782C
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China
Prior art keywords
polymer
fibre web
polymers compositions
poly
ethene
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CNB018139019A
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Chinese (zh)
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CN1458989A (en
Inventor
E·N·鲁迪西尔
V·班萨尔
M·C·达维斯
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EIDP Inc
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EI Du Pont de Nemours and Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—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
    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/08—Melt spinning methods
    • D01D5/098—Melt spinning methods with simultaneous stretching
    • D01D5/0985—Melt spinning methods with simultaneous stretching by means of a flowing gas (e.g. melt-blowing)
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/06—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/697—Containing at least two chemically different strand or fiber materials

Abstract

The present invention is directed to a multiple component meltblown web comprised of at least 95% by weight of meltblown fibers having an average effective diameter of less than 10 microns, said multiple component meltblown web comprised of a first polymer component and a second polymer component distinct from said first polymer component, said first polymer component being comprised of from 1% to 99% by weight of a first polymer and from 99% to 1% by weight of a second polymer.

Description

Melt spray fibre web
Technical field
The complex nonwoven cloth material that the present invention relates to a kind of fibre web of meltblown fibers and comprise the fibre web of meltblown fibers.More particularly, the present invention relates to comprise the melt spray fibre web of multicomponent fibre, wherein a kind of component of fiber is made of blend polymer.
Background technology
It is fiber that thermoplastic resin is used to extrusion molding for many years.These resins comprise polyolefin, polyester, polyamide and polyurethane.The fiber of extruding is made into various non-weaving cloths, comprise such as spunbond-melt and spray-composite bed compound spunbond (" SMS ") composite sheet.In the SMS composite, skin is the spun-bonded fibre layer, give whole composite contribution intensity, and sandwich layer is the melt spray fibre web layer, and barrier property is provided.
United States Patent (USP) 5,616,408 disclose a kind of SMS Compound Fabric, and wherein meltblown fibers is made of the blend of polyethylene and PE Processing stabilisation component.This stabilisation component joins in the polyethylene, and the polyvinyl resin that can increase this softness very, can highly extend makes this resin be melted and sprayed and do not form the thing of the polymer globules of advancing to penetrate in a large number and so on.The stabilisation component is disclosed as another kind of polymer, for example, polyolefin, polyester or polyamide, their additions in polyethylene are benchmark between about 1～15wt% with polyethylene polymer weight.
United States Patent (USP) 4,547,420 disclose a kind of bicomponent meltblown fibers and plant the fibre web that fiber is made thus.One of component is crystallizable poly-(ethylene glycol terephthalate), and another kind is a polypropylene.
Summary of the invention
First kind of embodiment of the present invention relates to a kind of multicomponent melt spray fibre web, form less than the multicomponent meltblown fibers of 10 μ m by 95wt% mean effective diameter at least, this multicomponent meltblown fibers is made up of first polymers compositions and completely different second polymers compositions in first polymers compositions, wherein first polymers compositions is made up of 1%～99wt%, first polymer and 99%～1wt%, second polymer, and wherein first and second polymer is selected from polyolefin, polyester, polyamide, polystyrene, polyurethane, fluoropolymer, the alkene ionomer resin, the random copolymer of the random copolymer of ethene and methacrylic acid and ethene and vinyl acetate.
In another embodiment, the present invention relates to a kind of multicomponent melt spray fibre web, form less than the meltblown fibers of 10 μ m by 95wt% mean effective diameter at least, this meltblown fibers is made up of first polymers compositions and completely different second polymers compositions in first polymers compositions, first polymers compositions is made up of 1～99wt%, first polymer and 99%～1wt%, second polymer, and wherein first and second polymer is gone up by non-elastomer polymer substantially and formed.
In another embodiment, the present invention relates to a kind of multicomponent melt spray fibre web, form less than the meltblown fibers of 10 μ m by 95wt% mean effective diameter at least, this meltblown fibers is made up of first polymers compositions and completely different second polymers compositions in first polymers compositions, first polymers compositions is made up of 1～99wt%, first polymer and 99%～1wt%, second polymer, and wherein first and second polymer is gone up by elastomer polymer substantially and formed.
In another embodiment, the present invention relates to a kind of composite sheet, it comprises and has first and second opposite first fibrage, first fibrage is the multicomponent melt spray fibre web, form less than the multicomponent meltblown fibers of 10 μ m by 95wt% mean effective diameter at least, this multicomponent meltblown fibers is made up of first polymers compositions and completely different second polymers compositions in first polymers compositions, first polymers compositions is made up of 1%～99wt%, first polymer and 99%～1wt%, second polymer, and second fibrage is by the 95wt% mean effective diameter is fibrous greater than the second layer of the first fibrage meltblown fibers mean effective diameter at least.
Description of drawings
Accompanying drawing is included in this explanation and constitutes its part, and the present embodiment preferred of the present invention is described.
Fig. 1 is the perspective illustration of melt spray fibre web of the present invention
Fig. 2 is the sectional drawing that comprises the composite non-weaving cloth of Fig. 1 melt spray fibre web.
Fig. 3 is the sectional drawing that another kind comprises the composite non-weaving cloth of Fig. 1 melt spray fibre web.
Fig. 4 is the part schematic diagram that is used for the equipment of production melt spray fibre web of the present invention.
Fig. 5 is the equipment schematic diagram that is used for the used spunbonded nonwoven layer of cloth of production composite non-weaving cloth of the present invention.
Fig. 6 is the schematic diagram that is used for the equipment of production composite non-weaving cloth of the present invention.
Detailed Description Of The Invention
Term " polymer " " generally include when using in this article but be not limited to homopolymers, copolymer (for example, block, grafting, random and alternate copolymer), terpolymer etc., and blend and modifier.And, unless otherwise specifically limited, term " polymer " " should contain all possible geometric configuration of this material.These configurations include but not limited to, isotaxy, syndiotaxy and atactic symmetries phenomenon.
Term " polyolefin " is used to refer to any in a series of saturated substantially, open chains of only being made up of carbon and hydrogen, the polymerizing hydrocarbon in this article.Typical polyolefin includes but not limited to the various various combinations of polyethylene, polypropylene, polymethylpentene and ethene, propylene and methylpentene monomers.
Term " polyethylene " is used for not only containing the homopolymers of ethene in this article but also comprises that at least 85% of those its repetitives are the copolymers of ethylene unit.
Term " polypropylene " is used for not only containing the homopolymers of propylene in this article but also comprises that at least 85% of those its repetitives are the copolymers of propylene units.
Term " polyester " is used for containing the polymer that at least 85% of its repetitive is the condensation product of carboxylic acid and dihydroxy alcohol in this article, and wherein polymer bonds is by the generation of ester units and produce.This includes but not limited to, aromatics, aliphatic series, saturated and unsaturated acids and glycol.Term " polyester " also comprise in this article copolymer (as, block, grafting, random and alternate copolymer) and blend and modifier.A common examples of polyester is poly-(ethylene glycol terephthalate), and it is the condensation product of ethylene glycol and terephthalic acid (TPA).
Term " polystyrene " is used in this article not only comprising styrene homopolymers, and comprises that at least 85% of those repetitives are the copolymers of styrene units.
Term " meltblown fibers " is used to refer to as follows the fiber that is shaped in this article: molten thermoplastic from a plurality of very thin, be generally in the circular spinneret orifice and be expressed in the heated at high speed air-flow (for example air flow) with the fusion tow form.High velocity air is with the tow drawing-down of molten thermoplastic, and diameter is varied down to the scope of 0.5～10 μ m.The normally discontinuous fiber of meltblown fibers but also can be continuous.The entrained meltblown fibers of high velocity air is deposited on usually collects the fibre web that the random fiber that is scattered of formation is gone up on the surface.
Term " melt-spun fibre " is used to refer in this article and is meant that a class small diameter fibers, its manufacturing process comprise molten thermoplastic a plurality of very thin from spinning plate, and be generally circular spinneret orifice and extrude, the diameter of the silk of extruding subsequently dwindles rapidly.Melt-spun fibre generally be continuous and average diameter greater than about 5 μ m.
Term " non-weaving cloth, sheet material or fibre web " is used to refer in this article to be put by random fashion shop by single fiber or silk and forms a kind of planar materials, rather than spreads according to certain identifiable pattern as in knit goods and put.
Term " multicomponent fibre " and " multicomponent filaments " be used to refer in this article any by at least two kinds of completely different polymer but lump together spinning form single fiber or the silk, fiber that is constituted or long filament.Term " fiber " is used for both having referred to the discontinuous continuous fibers that also refers in this article.At least two kinds of completely different polymer of this that can here use (or fiber) component can be chemically different, perhaps they can be chemically identical but have different physical characteristics, as inherent viscosity, melt viscosity, extrusion swelling, density, degree of crystallinity and fusing point or softening point.For example, two kinds of fibre fractionations can be linear low density polyethylene (LLDPE) and high density polyethylene (HDPE), or high viscosity polypropylene and low viscosity polypropylene.At least two kinds of completely different polymer (or fiber) component preferred arrangement is in, position substantially invariable district clearly demarcated along boundary on the multicomponent fibre cross section and can extend continuously basically along fibre length.Preferably, multicomponent fibre is the bicomponent fiber of being made by two kinds of completely different polymer (or fiber) component.Multicomponent fibre is different from the fiber by the even mixture of melts extrusion molding of polymeric material.Be used to implement multicomponent fibre of the present invention and comprise core-skin and collateral fiber.Preferably, the multicomponent meltblown fibers that constitutes fibre web of the present invention is a bicomponent fiber, and wherein two kinds of different polymer are arranged in configuration arranged side by side.
Term " multicomponent fibre web " is used to refer to the nonwoven web that comprises multicomponent fibre or long filament in this article.Term " bicomponent web " is used to refer to the multicomponent fibre web that comprises bicomponent fiber in this article.The multicomponent fibre web both can comprise that one pack system also can comprise multicomponent fibre or long filament.Term " multicomponent melt spray fibre web " is used to refer to the fibre web that comprises the multicomponent meltblown fibers in this article, wherein this fiber spins from thin spinneret orifice becomes the fusion tow that comprises multiple and distinct polymers compositions, this fusion tow by the high velocity air drawing-down and be deposited on collect become on the surface a kind of by the random fibrous fibre web that is scattered.
To describe the present embodiment preferred of the present invention now in detail, the following describes these schemes
Embodiment.
The preferred embodiment of melt spray fibre web of the present invention is shown among Fig. 1.Fine fiber layer 14 comprises the multicomponent melt spray fibre web that side by side constitutes from the spun polymers compositions of a series of spinneret orifices by at least two kinds.According to the present invention, at least a polymers compositions comprises two or the blend of more kinds of polymer.The mean effective diameter of the fiber in the multicomponent melt spray fibre web 14 is generally between about 0.5 μ m～10 μ m, more preferably between about 1～6 μ m, most preferably from about 2～4 μ m." effective diameter " of employed here irregular section fiber equals to have the diameter of the imaginary circle fiber of same cross-sectional area.The fiber of melt spray fibre web 14 be long enough to fibre web in other fibre mattings.Shop postpone, the fiber of the entanglement of fibre web 14 forms the cohesion fibre net structure.
Fibre configuration in the bicomponent web 14 is preferably arranged side by side, and wherein most of fibers are made of two kinds of polymers compositionss arranged side by side along the total length extension of every fiber basically.Alternatively, these bicomponent fibers can have: sheath core arrangement, and wherein a kind of polymer is wrapped in by another kind of polymer; Arrange on " island ", and wherein a kind of multi-filament of polymer is embedded in the another kind of polymer; Perhaps any other multicomponent fibre structure.
According to the present invention, the fine fibre of layer 14 prepares according to the multicomponent meltblowing method, for example a kind of like this method: two or more extruders the molten polymer component is supplied to spinning plate, at this, all polymers compositionss pass very thin through hole (spinneret orifice) and flow out, and by one jet of drawing-off gas (for example, air) that surrounds the thin through hole of spinning plate by the strength drawing-off.Fiber laydown is being collected on the surface, as moving belt or net, gauze, perhaps another fibrage.The fiber of producing by meltblown can be discontinuous or continuous fiber, and effective diameter is between about 0.5～about 10 μ m.
The fiber of layer 14 multicomponent melt spray fibre web can adopt has as shown in Figure 4 that the melt-blowing equipment of spinneret orifice melts and sprays spinning.In the sectional drawing that melts and sprays filament spinning component 20 shown in Figure 4, two kinds of different polymers compositionss fusions in the extruder (not shown) that is connected in parallel to each other, and be metered in the passage of separating by plate 27 25 and 26 by the gear pump (not shown) respectively.At least a polymers compositions comprises different mixture of polymers or blend.Blend polymer can form like this: with different polymer, be fed in the screw extruder with pellet form.Extruder also mixes the blend polymer fusion, and then is fed in the filament spinning component 20.In filament spinning component 20, this blend polymer component, contacts with another or other component in a row spinneret orifice 21 process of flowing at it then.Second polymers compositions can be the blend of single polymers or polymer.
Alternatively, the fiber of layer 14 multicomponent melt spray fibre web can adopt as United States Patent (USP) 4,795, and the melt-blowing equipment of describing in 668 melts and sprays, and receives its disclosure for referencial use at this.In this kind equipment, the fusion in parallel extruding machine of different polymers compositionss also is metered in the spinning plate cavity by gear pump respectively.From the spinning plate cavity, all polymers compositionss are extruded together via a row spinneret orifice.According to another kind of replacement scheme, the form that all polymers compositionss can a kind of stratification is fed in the cavity of filament spinning component, and thus, multiply component polymer stream is supplied to spinneret orifice together.Also can use a kind of back in conjunction with spinning plate, as common unsettled provisional application number 60/223,040,2000-08-04 submits to, in disclosed, wherein distinct (two kinds) polymers compositions is extruded via the extrusion cavities that separates, and contacts with each other after leaving spinneret orifice and clinkering formation multicomponent meltblown fibers.
Leave after the spinneret orifice, one gas for example forms meltblown fibers by will the emerge polymer tow drawing-down of spinning plate of the heated air jets of passage 28 supply.Though do not intend being limited to theory but it is believed that air-spray can be broken for thinner fiber with a part of meltblown fibers.Formed meltblown fibers comprises bicomponent fiber, and its every fiber is made of two kinds of components of separating of arranging with configuration arranged side by side and extending along the meltblown fibers total length.Believe that also some broken fiber may only comprise a kind of polymers compositions.Layer 14 fine fibre alternately adopts other known meltblowing method production, for example adopts as United States Patent (USP) 4,380, and disclosed in 570, each spinneret orifice surrounded the spinning plate of a single air nozzle.
By one or more components of all blend polymer manufacturing multicomponent meltblown fibers, the applicant finds that spinning performance and melt spray fibre web quality can improve.The applicant also further finds, also can customize the performance of planting the melt spray fibre web that bicomponent fiber makes thus very particularly.For example, by adopt blend polymer in a kind of component of meltblown bicomponent webs, might make a kind of fibre web of fiber, wherein all polymers compositionss of comprising of fiber are very different but also can resist division.For example, can melt and spray a kind of bicomponent meltblown fibers of spinning, wherein a kind of component is a polyester as poly-(ethylene glycol terephthalate), and another kind of component mainly is polyolefin such as polyethylene.As poly-(mutual-phenenyl two acid bromide two alcohol ester) blending in polyethylene, polyethylene component is with easier sticking on poly-(ethylene glycol terephthalate) component by the small amount of polyester polymer.Alternatively, such as the fractionalism that the polymer the fluoropolymer can be able to be blended in one of all components with reinforcing fibre.According to a kind of embodiment preferred of the present invention, the blend polymer component can further comprise the compatilizer that is used for all polymer in the blend.
The polymer that is suitable for preparing multicomponent melt spray fibre web of the present invention comprises polyolefin, polyester, polyamide, polystyrene, polyurethane, comprising those by comprising 4,4-'-diphenylmethane diisocyanate hard segment and the polyurethane such as the Pellethane that make based on the combination between the polyalcohol soft chain segment of polyester or polyethers Polyurethane (supply of Dow Plastics company), the random copolymer of fluoropolymer, ethene and methacrylic acid such as Nucrel Resin, marketed by dupont, the random copolymer of alkene ionomer resin such as ethene and methacrylic acid, wherein methacrylic acid is used the metal ion neutralization such as sodium or magnesium, for example Surlyn in advance Ionomer resin, by marketed by dupont, and the random copolymer of ethene and vinyl acetate.Preferred polymer comprises polyethylene, polypropylene, poly-(ethylene glycol terephthalate), poly-(terephthalic acid (TPA) 1, ammediol ester), poly-(mutual-phenenyl two acid bromide two alcohol ester), poly-(adipyl 1,6-hexamethylene diamine) and poly-(epsilon-caprolactams).
The preferred compositions of polymers compositions comprises: polyester/polyester and polyolefinic blend, polyolefin/two kind of different polyolefinic blends, and the blend of polyester/polyolefin and alkene ionomer resin.At the multicomponent meltblown fibers is in the preferred embodiment of bicomponent fiber, the combination of preferred polymers compositions comprises: poly-(ethylene glycol terephthalate)/polyethylene and the blend, polypropylene, polyethylene and the polyacrylic blend that gather (mutual-phenenyl two acid bromide two alcohol ester), and the blend of poly-(ethylene glycol terephthalate)/polyethylene and ethylene-methyl methacrylate ionomer random copolymer.The polymers compositions of multicomponent meltblown fibers can mainly be made up of 100% elastomer polymer or they can mainly be made up of 100% non-elastomer polymer.So-called " elastomer polymer " is meant a kind of polymer, it is the monocomponent meltspun fibers form, does not contain diluent, its extension at break surpasses 100%, and when the twice that is stretched to its original length, keep 1min, when unclamping then, it will retract to 1.5 times of the less thaies of its original length in unclamping later 1min.Term used herein " non-elastomer polymer " is meant that any is not the polymer of elastomer polymer.
Composite sheet 10 shown in Figure 2 is three layers of composite material-feeding, and wherein internal layer is made of above-described multicomponent melt spray fibre web 14.Fine fibre melt spray fibre web 14 is sandwiched between outer 12 and 16, the latter two each by bigger and more solid and bonding fibrous.The very thin fiber of internal layer 14 can provide a kind of path superfine barrier layer when being configured as layer 14 the time. Binder fiber layer 12 and 16 is provided intensity to composite sheet, and in some cases, is provided iris action by thicker and more solid fibrous.Composite sheet of the present invention alternately is configured as two-layer composite 18, as shown in Figure 3.Under the situation of two-layer composite sheet, fine fiber layer 14 only with its one side attached on the thicker and more solid adhesive layer 12.According to another kind of the present invention embodiment alternatively, composite sheet can as layer 14, be made up of layers of fine fiber, and perhaps it can as layer 12 and 16, be made of fibrage thicker and more solid more than two.
According to the present invention, the thicker and more solid binder fiber of layer 12 and 16 is conventional melt spun fiber or the solid spun-bonded fibre of certain other types.Preferably, melt-spun fibre is continuous substantially fiber.Alternatively, layer 12 and 16 can be the staple web or the carded web of air-laid or wet method laying net, and wherein fiber adheres to each other and forms solid fibre net structure.Layer 12 and 16 fiber should constitute with the bonding polymer of the fine fibre of sandwich layer 14 by being easy to.
Layer 12 and 16 is preferably made by bi-component melt-spun fiber.The component of the melt-spun fibre of layer 12 and 16 can be made up of single polymers or blend polymer.According to a kind of embodiment preferred of the present invention, the melt-spun fibre of layer 12 and 16 comprises the polyester/polyethylene bicomponent fiber.Polyester components is contributed intensity to cloth, and polyethylene component makes cloth more soft, has more the sense of hanging down.In addition, the fusing point of the polyethylene component of fiber is lower than the polyester components, thereby makes fibrage 12 and 16 easier utilizations on the fine fibre that the heat bonding method is adhered to sandwich layer 14.Alternatively, layer 12 and 16 can be made of the blend of single polymers compositions fiber, for example is spunbond fibre web, and wherein the part fiber is a polyethylene fiber, and the part fiber is a polyester fiber.
According to the preferred embodiments of the invention, the thicker and more solid fiber of layer 12 and 16 is continuous substantially spun-bonded fibres, adopts the high speed melt spun processes, and for example United States Patent (USP) 3,802,817,5,545,371 and 5,885,909, for referencial use in these receipts, disclosed high speed spinning method is produced.According to this preferred high speed melt spun processes, one or more extruder is to the polymer of filament spinning component supply fusion, and in assembly, polymer is extruded via a large amount of spinneret orifices and is configured as silkscreen.Tow is subjected to the part cooling in air quenched district.Subsequently, tow reduces its fiber number and gains in strength by the strength drawing-off.Tow is deposited on mobile band, gauze or other fibrages.The fiber that adopts this preferred high speed melt spun processes preparation is continuous substantially and has the diameter of 5～30 μ m.These fibers can be made into homofil, make multicomponent fibre or certain combination of the two.The multiple component melt-spun fiber can be made into various known cross sectional configurations, comprises side by side, core-skin, tangerine lobe and island configuration.
Equipment with the nonwoven web of high-speed production high-strength bi-component melt-spun fibre schematically is illustrated among Fig. 5.In this equipment, two kinds of thermoplastic polymers are fed into respectively in hopper 40 and 42.Polymer in the hopper 40 is fed into extruder 44, and the polymer in the hopper 42 is fed in the extruder 46.Extruder 44 and 46 was pressed filter 48 and 50 with polymer melt with it respectively, and measuring pump 52 and 54.Thereby produce requirement multicomponent silk section above-mentioned with merging in filament spinning component 56 by known method from the polymer in the hopper 42 from the polymer of hopper 40, as, for example adopt United States Patent (USP) 5,162,074 disclosed multicomponent spinning assembly is such, the document is received for referencial use at this.Have at long filament under the situation of sheath-core cross-section, use usually than low melting point polymer and make cortex, to improve its heat bonding.Require, homofil can be by multicomponent equipment shown in Figure 5 spinning, only needs simply to add identical polymer at two hoppers 40 in 42.
Molten polymer flows out filament spinning component 56 by a large amount of spinneret orifices on the spinning plate 58 plate faces.Spinneret orifice can be arranged on the spinning plate face (rectangle, be staggered etc.) by tradition design, and the spacing between spinneret orifice and the spinneret orifice is determined according to the requirement that obtains optimum productivity and fiber quenching.The density of spinneret orifice is usually between the every meter element width in 500～8000 holes.Typical every pore polymer throughput is between 0.3～5.0g/min.
The tow of extruding from filament spinning component 56 60 at first is subjected to the cooling of quench air 62, is subjected to the drawing-off of strength draft nozzle 64 subsequently, is paved into fibre web then.Quench air is by one or more traditional quench drum supplies, and the latter guides air to brush facing to tow with the speed of about 0.3～2.5m/s and 5 ℃～25 ℃ temperature.With regard to the typical case, adopt two from being positioned at the relative aspectant quench drum in both sides of tow row, constitute so-called and stream (co-current) air configuration.Distance between spinneret orifice and the draft nozzle can specifically depend on desired fibre property between 30～130cm.The tow of quenching enters strength draft nozzle 64, and at this, tow is drawing to 2000～12 by air 66, the fiber speed of 000m/min.The tractive force that tow is subjected to is subjected to drawing-off and elongates when making tow be about to pass quench region near the spinning plate face.It is thinner and more solid than the tow when filament spinning component is extruded that tow 67 becomes when leaving draft nozzle 64.Substantially continuous tow 67 is that a kind of tensile strength is 1gpd (gram/dawn) at least, and preferred effective diameter is between the fiber that intensity is arranged of 5～30 μ m.Tow 67 is deposited on lapping belt or the forming net 68 with the form of basic continuous filament yarn.The outlet of draft nozzle 64 is different along with the desired performance of nonwoven web with distance between the lapping belt, but generally between 13～76cm.See through the lapping belt and generally apply vacuum draw, to help the anchoring fiber fibre web.Require, formed fibre web 12 can pass between heat bonding roller 72 and 74, and then is collected on the roller 78.
The equipment that composite non-weaving cloth of the present invention can adopt Fig. 6 schematically to represent is produced online.Alternatively, all layers of composite sheet can be produced independently, remerge after a while with bonding to form composite sheet.Equipment shown in Figure 6 comprises spunbond fibre web production section 80 and 94, and they preferably are similar to described high speed melt-spun equipment when relating to Fig. 5.The equipment of Fig. 6 also comprises melt spray fibre web production section 82, and it combines the melt-blowing equipment at the described type of Fig. 4.Illustrative purposes is expressed two spunbond fibre webs of making bicomponent fiber and is produced section 80 and 94 for example.According to the present invention imagination, spunbond fibre web production section 80 and 94 can change a kind of device that has only a kind of polymers compositions or have the spunbond fibre web of three kinds or more kinds of polymers compositionss that is intended to produce into.Consider that also spunbond fibre web production section can be lined up the fibre web that blend that the series connection form is used for producing different lists or multicomponent fibre is made more than one.Also consider, the polymer that uses in the section 94 can the section of being different from 80 in the polymer of use.Under the situation that requires to produce a kind of composite sheet that only has a spunbond layer and a fine fiber layer (as shown in Figure 3), the second spunbond fibre web production section 94 can close or cancel.
According to the preferred embodiments of the invention, to produce in the section 80 and 94 at the spunbond fibre web of equipment shown in Figure 6, (not shown) is filtered and be metered into to two kinds of thermoplastic polymer components A and B fusion in filament spinning component 56 and 96, as top described about Fig. 4.Molten polymer tow 60 and 100 passes spinning plate 58 and 98 and extrudes from filament spinning component respectively, as top described about Fig. 5.This tow can be extruded as has the requirement section, as the bicomponent filament of sheath-core yarn section.Preferably, as cortex, adopt polymer, and, adopt polymer than high melting temperature as sandwich layer than low melting glass.Formed tow 60 and 100 is by quench air 62 and 102 coolings, as mentioned above.Then, tow enters into strength draft nozzle 64 and 104, and drafted air 66 and 106 drawing-offs, as top during in conjunction with Fig. 5 as described in.Fiber 67 from spunbond fibre web production section 80 is deposited on the spunbond layer 12 that is formed on the forming net 68 on the conveyer belt.
According to the preferred embodiment of the invention, two kinds of thermoplastic polymer components C and D merge in melt spray fibre web production section 82 and make a kind of meltblown bicomponent fiber.These components comprise one of at least the blend of two or more different polymer.This blend polymer component preferably mixes by two kinds of polymeric aggregates and extrudes shaping.Second polymers compositions can be first polymer or the another kind of blend polymer that forms by same way as.Polymers compositions C and D filter and are metered into (not shown) then to melting and spraying in the filament spinning component 84 through fusion.Molten polymer merges to pass to be similar in conjunction with one in the described the sort of spinning plate of top Fig. 4 row spinneret orifice in filament spinning component 84 and is extruded filament spinning component.Preferably, filament spinning component 84 produces desired collateral fiber section.The filament spinning component arrangement that substitutes can be used for producing alternative fiber section, for example, and sheath-core cross-section.Gas jet 88 for example by the thermal air current of passage 90 supply, is left its spinneret orifice at every rhizoid and is impacted immediately later on and spin the relative both sides of tow 91 and with its drawing-down, form meltblown fibers.Thereby meltblown fibers 91 is deposited on and makes a kind of cohesion multicomponent melt spray fibre web layer 14 on the spunbond layer 12.
When adopting the second spunbond fibre web to produce section 94, can be deposited on the meltblown layer 14 from the basic spun-bonded fibre 107 continuously of spunbond fibre web production section 94, so on fibre web, form second spunbond layer 16.Layer 12 not necessarily has identical composition, thickness or basic weight with 16.
Spunbond-as to melt and spray-spunbond fibre net structure passes through between heat bonding roller 72 and 74, so that produce complex nonwoven fibre web 10, is collected in then on the roller 78.Preferably, bond roll 72 and 74 is warm-up mills, maintains the interior temperature of fusing point ± 20 ℃ scope of minimum melt temperature polymer in the composite.Under the situation that contains the polyethylene composite sheet, can adopt 115～120 ℃ tack temperature and the loading pressure of 350～700N/cm to obtain good heat bonding.The bonding alternative method of all layer of composite sheet comprise that knurling rolls are bonding, ultrasonic wave is bonding, penetrate that air is bonding, steam is bonding and adhesive is bonding.
Test method
In above explanation and following nonlimiting examples, following test method is used to determine various characteristics and the performance that provides in the literary composition.ASTM refers to ASTM; AATCC refers to American Association of Textile Chemists and Colorists.
Basic weight is the tolerance of the quality of unit are cloth or sheet material, and measures according to ASTM D-3776, and is at this that these standard content receipts are for referencial use, with g/m 2For unit provides.
Hydrostatic head is sheet material stops the ability that aqueous water permeates under static pressure a tolerance.This test is carried out according to AATCC-127, and is for referencial use in these receipts, centimetre being that unit provides.
Frazier air transmission rates is, air sees through the tolerance that sheet material flows under the described pressure reduction between sheet material two surfaces, for referencial use in these receipts according to ASTM D737, mensuration, and with m 3/ min/m 2For unit provides.
Now, will illustrate the present invention by following non-limiting example, the purpose that provides example only is to illustrate the present invention, but is not construed as limiting the invention from going up all in all senses.
Embodiment
Comparative Examples
This examples show is by inserting the last bonding process for preparing the SMS sheet material of double-component melt spray-up between two bicomponent spunbond layers.The double-component melt spray-up is made by the bicomponent meltblown fibers that comprises two kinds of polymers compositionss, and wherein every kind of polymers compositions all is a single polymers.
Meltblown bicomponent webs is made by polyethylene component and poly-(ethylene glycol terephthalate) component.Polyethylene component is made by linear low density polyethylene (LLDPE), and its melt index (MI) is 150g/10min (measuring according to ASTM D-1238), is supplied as ASPUN 6831A by Dow company.Polyester components is made by poly-(ethylene glycol terephthalate), and inherent viscosity equals 0.53 (according to United States Patent (USP) 4,743,504 method is measured), by E.I.Du Pont Company as Crystar Polyester (merging lot number Merge 4449) supply.Polymer is process crystallization and drying before extruding.In extruder separately, polyethylene polymer is heated to 450  (232 ℃), and polyester polymers is heated to 572  (300 ℃).Two kinds of polymer are extruded respectively, filter, and are metered into and arrange to be used to provide in the bi-component filament spinning component of section arranged side by side.The spinning plate of filament spinning component is heated to 599  (315 ℃).Spinning plate has 601 spinneret orifices, is arranged in a row of 24 inches (61cm).Polymer spins from each spinneret orifice with the polymer throughput of 0.80g/ hole/min.The drawing-off air heat is to the temperature of 612  (322 ℃), and with 420 standard cubic foot per minute (scfm) (11.9m 3/ min) speed is by two wide air duct supplies of 0.8mm.These two air ducts are along 24 inches spinneret orifices row's total length trend, locate since the spinneret orifice 1mm ground of drawing back in each passage of this group spinneret orifice row's both sides and each.Polyethylene is supplied to filament spinning component with the speed of 23.1kg/h; Polyester is supplied to filament spinning component with the speed of 5.8kg/h.The double-component melt spray fibre web of being produced contains 80wt% polyethylene and 20wt% polyester.Melt spray fibre web is collected in to move and is shaped on the net, thereby produces melt spray fibre web.Under the condition of this example, the operation of meltblowing method causes remarkable quantity " flyings ", that is, and and the broken end silk that the drawing-off air flow dispels from the lapping zone.Melt spray fibre web is collected on the roller.The basic weight of this melt spray fibre web is 17.5g/m 2
Spunbond skin is made of the sheath-core cross-section bicomponent fiber.This spun-bonded fibre employing is similar to top about the described device fabrication of Fig. 5.Produce basic weight 15g/m 2Spunbond fibre web as the skin of this composite sheet.Spunbond bicomponent fiber is by the linear low density polyethylene (LLDPE) (measuring according to ASTM D-1238) of melt index (MI) 27g/10min, supply as ASPUN 6811A by Dow company, and inherent viscosity 0.53 is (according to United States Patent (USP) 4,743,504 measure) poly-(ethylene glycol terephthalate), by E.I.Du Pont Company as Crystar Polyester (merging lot number Merge3949) supply.Before the use, mylar carries out crystallization 180 ℃ temperature, and is lower than 50ppm at 120 ℃ temperature drying to water capacity.
In extruder separately, polyester is heated to 290 ℃, and polyethylene is heated to 280 ℃.Polymer is through extruding, filter and be metered into maintain 295 ℃ and design provide the sheath-core yarn section the bi-component filament spinning component in.These two kinds of polymer spin through spinning plate and produce the bi-component silk with polyethylene cortex and poly-(ethylene glycol terephthalate) sandwich layer.The total polymer throughput of each spinneret orifice is 0.4g/min.The target that polymer is metered into provides and contains 30% polyethylene (cortex) and 70% polyester (sandwich layer), is benchmark with the fibre weight, fiber.It is the cooling of the quench air of 12 ℃ and speed 1m/s that tow is subjected in 15 inches (38.1cm) long quench region from two relative quench drums, temperature.Tow is fed to the strength draft nozzle at the spinneret orifice interval, below 20 inches (50.8cm) that is arranged in filament spinning component, and at this, tow is pulled with the speed of about 9000m/min.Form more carefully, more solid, continuous substantially tow in the auxiliary deposit of vacuum draw on the lapping band.The effective diameter of the fiber in the fibre web is between 6～8 μ m.The fibre web that forms passes between two heat bonding rollers, utilizes the some bond pattern under the nip pressure of 100 ℃ temperature and 100N/cm fibre web to be bonded together slightly so that transport.Linear velocity between joint aging time is 150m/min.Spunbond fibre web after slight bonding is collected on the roller separately.
The preparation process of composite non-weaving cloth sheet material is: 15g/m 2The spunbond fibre web of basic weight is unwound to mobile being with.The meltblown bicomponent webs unwinding also is layered on the spunbond fibre web in moving.The second volume 15g/m 2The spunbond fibre web unwinding of basic weight, and be layered on this spunbond-melt spray fibre web above, that the result produces is spunbond-melt and spray-spunbond complex nonwoven fibre web.This composite web carries out heat bonding between the metal smooth roll of heating carved pattern, oily, metal knurling rolls and heating.The diameter of two rollers all is 466mm.Figure roller has hardened steel chromium plating, non-surface has argyle design, spot size 0.466mm 2, some degree of depth 0.86mm, dot spacing 1.2mm, bond area 14.6%.Smooth roll has the steel surface of sclerosis.Composite web is 120 ℃ temperature, and is bonding under the nip pressure of 350N/cm and the linear velocity of 50m/min.Bonding composite sheet is collected on the roller.The final basic weight of this composite non-weaving cloth sheet material is 51.6g/m 2
Example 1
The preparation of this examples show SMS sheet material of the present invention.
This SMS sheet material is by inserting double-component melt spray-up and bonding making between two bicomponent spunbond layers.This SMS sheet material and comparative example A's SMS sheet material is basic identical, and different is, this double-component melt spray-up is to be made by two kinds of polymers compositionss, and wherein a kind of polymers compositions is the blend of two kinds of polymer, and another kind of polymers compositions is a single polymers.
Composite sheet is shaped according to comparative example A's program, and different is that the polyethylene component in the melt spray fibre web is to be made by the blend of 90wt%Dow ASPUN 6831A and 10wt%Hoechst Celanese 1300A poly-(mutual-phenenyl two acid bromide two alcohol ester).Poly-(mutual-phenenyl two acid bromide two alcohol ester) plays the promoter effect of polyethylene spinning.Also have, this meltblowing method has been made following modification: polyethylene/poly-(mutual-phenenyl two acid bromide two alcohol ester) blend is heated to 260 ℃, and the attenuating blast rapid change is 425scfm (12.04m 3/ min).The operating period of meltblowing method, do not observe the formation of " flyings ".The process conditions of the meltblowing method of comparative example A and example 1 are summed up in table 1.The physical property of melt spray fibre web and composite S MS sheet material is stated from table 2.
Comparative example 1 and comparative example A are as can be seen, in polyethylene component, adopt the hydrostatic head height of example 1 fibre web of poly-(mutual-phenenyl two acid bromide two alcohol ester) than Comparative Examples A fibre web, though comparative example A and example 1 fibre web are basic identical, difference only is to lack poly-(mutual-phenenyl two acid bromide two alcohol ester) in the polyethylene component of comparative example A's fibre web.The improvement that it is believed that example 1 hydrostatic head be because, when adopt blend polymer as the multicomponent meltblown fibers in during one of polymers compositions the homogeneity of fibre web improve and being caused.
Table 1
The melt-blown process condition
Example T PE (℃ ) T PET (℃) T Die(℃) Air-flow (scfm) ** Throughput (the g/ hole/min) PE weight (Kg/h) PET weight (Kg/h) Weight ratio (PE percentage)
A 1 * 232 260 300 300 315 315 420 425 0.8 0.8 23.1 23.1 5.8 5.8 80 80
T=temperature wherein, the PE=polyethylene, PET=gathers (ethylene glycol terephthalate)
* in example 1, polyethylene component is made of 90wt% polyethylene and poly-(mutual-phenenyl two acid bromide two alcohol ester) blend of 10wt%.
**1 scfm＝1.699m 3/h
Table 2
Nonwoven web character
Example Weight ratio (%PE) Melt spray fibre web basic weight (g/m 2) Composite sheet basic weight (g/m 2) Composite sheet hydrostatic head (cm) Frazier permeability (the m of composite sheet 3/min/m 2)
A 1 * 80 80 17.5 15.9 51.6 49.9 55.3 72.0 17.4 9.8
* in example 1, polyethylene component is made of 90wt% polyethylene and poly-(mutual-phenenyl two acid bromide two alcohol ester) blend of 10wt%.
Comparative Examples B
The shaping of a kind of double-component melt spray fibre web of this examples show, wherein first component is the high viscosity polypropylene, and second component is the low viscosity polypropylene.
Meltblown bicomponent webs is made by high viscosity polypropylene component (PP1) and low viscosity polypropylene component (PP2).The high viscosity polypropylene component equals 35 (ASTM D1238-00) acrylic resin by the Exxon as 3155 melt flow rates of supplying and makes.The melt flow rate that the low viscosity polypropylene component is supplied as 3546G by the Exxon is that the acrylic resin of 1200 (ASTM D1238-00) is made.Two kinds of polymer all are heated to 550  (288 ℃) in extruder separately.Two kinds of polymer are extruded respectively, filter and are metered into and arrange to be used to provide in the bi-component filament spinning component of silk section arranged side by side.The spinning plate of filament spinning component is heated to 550  (288 ℃).Spinning plate has 601 spinneret orifices, is arranged in a row of 24 inches (61cm).Polymer spins from each spinneret orifice with the polymer-through-put rate of 0.40g/ hole/min.The drawing-off air heat is to the temperature of 550  (288 ℃) and with 300 standard cubic foot per minute (8.5m 3/ min) speed is by two wide air duct supplies of 2mm.These two air ducts are along 24 inches spinneret orifice row total length trend, locate since the spinneret orifice 2mm that draws back in each passage of this group spinneret orifice row's both sides and each.Two kinds of acrylic resins all are supplied to filament spinning component with the speed of 9.0kg/h.Produce a kind of double-component melt spray fibre web, comprise 50wt% high viscosity polypropylene and 50wt% low viscosity polypropylene.Melt spray fibre web is collected in to move and is shaped on the net, thereby produces melt spray fibre web, is collected on the roller then.The basic weight of this melt spray fibre web is 19g/m 2
Example 2
The shaping of this examples show double-component melt spray fibre web of the present invention, wherein first component is the blend of high viscosity polypropylene and linear low density polyethylene (LLDPE), and second component is the low viscosity polypropylene.
The multicomponent melt spray fibre web is shaped according to the program of Comparative Examples B, and different is that high viscosity polypropylene component (PP1) is made of Equistar GA594 linear low density polyethylene (LLDPE) and Exxon 3155 polyacrylic blends.In example 2-1, high viscosity polypropylene and Equistar linear low density polyethylene (LLDPE) carry out blending, become a kind of blend that is made of 25wt% high viscosity polypropylene and 75wt% linear low density polyethylene (LLDPE); In example 2-2, high viscosity polypropylene and 50wt% linear low density polyethylene (LLDPE) carry out blending; And in example 2-3, high viscosity polypropylene and linear low density polyethylene (LLDPE) carry out blending, become the blend that is made of 75wt% high viscosity polypropylene and 25wt% linear low density polyethylene (LLDPE).The character of melt spray fibre web is provided in the table below in 3.
Do not exist in the fibre web of Comparative Examples B the polyethylene blend component, the visual observations of example 2 melt spray fibre webs that other are all identical with Comparative Examples B melt spray fibre web comparison shows that the vision homogeneity of example 2 fibre webs is much better than the homogeneity of Comparative Examples B fibre web.This observed result is confirmed by the lower Frazier air transmission rates numerical value of example 2 melt spray fibre webs, and is just as shown in table 3 below.Lower air transmission rates usually interrelates with fibre web shaping preferably with than the fine fibre diameter.
Table 3
Melt-blown process condition and melt spray fibre web character
Example Wt%PE among the P1 PP1 weight (kg/h) PP2 weight (kg/h) Weight ratio (%PP1) Melt and spray basic weight (g/m 2) Frazier air transmission rates (m 3/min/m 2)
B 2-1 * 2-2 * 2-3 * 0 75 50 25 9.0 4.5 9.0 13.5 9.0 13.5 9.0 4.5 50 25 50 75 19 20 20 20 166 40 77 123
Wherein PP1 is the high viscosity polypropylene component, and PP2 is the low viscosity polypropylene component
* in these examples, the PP1 component is made of linear low density polyethylene (LLDPE) and the polyacrylic blend of high viscosity.

Claims (23)

1. multicomponent melt spray fibre web contains that 95wt% mean effective diameter is less than the multicomponent meltblown fibers of 10 μ m at least, and this multicomponent meltblown fibers is made up of non-elastomer polymer, wherein
The blend that first polymers compositions is made up of 1%～99wt%, first polymer and 99%～1wt%, second polymer, wherein said polymer is a non-elastomer polymer, and it is selected from the random copolymer of copolymer, polyester, polyamide, polystyrene, fluoropolymer, alkene ionomer resin, ethene and methacrylic acid of polyethylene, polymethylpentene, ethene and methylpentene and the random copolymer of ethene and vinyl acetate; With
Second polymers compositions is the single polymers that is selected from polyolefin and polyester.
2. the fibre web of claim 1, wherein the polymer of first polymers compositions is made of 5%～95wt%, first polymer and 95～5wt%, second polymer.
3. the fibre web of claim 2, wherein the polymer of first polymers compositions is made of 10～90wt%, first polymer and 90%～10wt%, second polymer.
4. the fibre web of claim 3, wherein first and second polymer is selected from the copolymer of polyethylene, polymethylpentene, ethene and methylpentene, poly-(ethylene glycol terephthalate), poly-(terephthalic acid (TPA) 1, the ammediol ester), the ionomer random copolymer of random copolymer, ethene and the methacrylic acid of poly-(mutual-phenenyl two acid bromide two alcohol ester), poly-(adipyl 1,6-hexamethylene diamine), poly-(epsilon-caprolactams), ethene and methacrylic acid and the random copolymer of ethene and vinyl acetate.
5. the fibre web of claim 3, wherein first polymer is selected from the copolymer of polyethylene, polymethylpentene and ethene and methylpentene, and second polymer is a polyester.
6. the fibre web of claim 5, wherein second polymer is selected from poly-(ethylene glycol terephthalate), poly-(terephthalic acid (TPA) 1, ammediol ester) and gathers (mutual-phenenyl two acid bromide two alcohol ester).
7. the fibre web of claim 1, wherein second polymers compositions is a polyester.
8. the fibre web of claim 7, wherein first polymer is a polyethylene, second polymer is poly-(mutual-phenenyl two acid bromide two alcohol ester), and second polymers compositions is poly-(ethylene glycol terephthalate).
9. the fibre web of claim 3, wherein second polymers compositions is a polypropylene.
10. the fibre web of claim 3, wherein first polymer is selected from the copolymer of polyethylene, polymethylpentene and ethene and methylpentene, and second polymer is the alkene ionomer resin.
11. the fibre web of claim 10, wherein second polymers compositions is a polyester.
12. the fibre web of claim 11, wherein second polymer is the ionomer random copolymer of ethene and methacrylic acid, and second polymers compositions is poly-(ethylene glycol terephthalate).
13. the fibre web of claim 1, wherein first and second polymers compositions is arranged in and is arranged in juxtaposition.
14. the fibre web of claim 1, wherein first and second polymers compositions is arranged in the core-skin layout.
15. a composite sheet comprises:
First fibrage has first and opposite second;
Second fibrage is bonded on first fibrolaminar first;
First fibrage is to comprise at least the 95wt% mean effective diameter less than the multicomponent melt spray fibre web of the multicomponent meltblown fibers of 10 μ m, this multicomponent meltblown fibers is made up of the non-elastomer polymer of first polymers compositions and completely different second polymers compositions in first polymers compositions, wherein first polymers compositions is the blend of the non-elastomer polymer that is made of 1%～99wt%, first polymer and 99% 1 1wt%, second polymer, wherein said first polymer and second polymer are selected from polyethylene, polymethylpentene, the copolymer of ethene and methylpentene, polyester, polyamide, polystyrene, fluoropolymer, the alkene ionomer resin, the random copolymer of the random copolymer of ethene and methacrylic acid and ethene and vinyl acetate, and described second polymers compositions is the single polymers that is selected from polyolefin and polyester;
Second fibrage contains at least the 95wt% mean effective diameter greater than the second layer fiber of the first fibrage meltblown fibers mean effective diameter.
16. the composite sheet of claim 15, wherein the polymer of first polymers compositions is made of 5%～95wt%, first polymer and 95%～5wt%, second polymer.
17. the composite sheet of claim 16, wherein the polymer of first polymers compositions is made of 10%～90wt%, first polymer and 90%～10wt%, second polymer.
18. the composite sheet of claim 17, wherein first and second polymer are selected from the copolymer and the polyester of polyethylene, polymethylpentene, ethene and methylpentene, and second polymers compositions is selected from polyolefin and polyester.
19. the composite sheet of claim 18, wherein polyester is selected from poly-(ethylene glycol terephthalate), poly-(terephthalic acid (TPA) 1, ammediol ester) and poly-(mutual-phenenyl two acid bromide two alcohol ester).
20. the composite sheet of claim 19, wherein first polymer is a polyethylene, and second polymer is poly-(mutual-phenenyl two acid bromide two alcohol ester), and second polymers compositions is poly-(ethylene glycol terephthalate).
21. the composite sheet of claim 17, wherein the multicomponent meltblown fibers is a bicomponent fiber, and second fibrage is a spunbond layer.
22. the composite sheet of claim 21, wherein spunbond layer comprises the bicomponent spunbond fiber.
23. the composite sheet of claim 22, wherein the polymers compositions of meltblown fibers is arranged in configuration arranged side by side, and spun-bonded fibre then is a core-skin fibre.
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US20020037679A1 (en) 2002-03-28
CN1458989A (en) 2003-11-26

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