CN1288289C - 驻极体非织造织物用短纤维、驻极体非织造织物的制造方法及其制品 - Google Patents

驻极体非织造织物用短纤维、驻极体非织造织物的制造方法及其制品 Download PDF

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CN1288289C
CN1288289C CNB02104564XA CN02104564A CN1288289C CN 1288289 C CN1288289 C CN 1288289C CN B02104564X A CNB02104564X A CN B02104564XA CN 02104564 A CN02104564 A CN 02104564A CN 1288289 C CN1288289 C CN 1288289C
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heat
fabric
fiber
staple fibre
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CN1369580A (zh
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戴荣吉
胡衍荣
陈宜均
梶田笃史
林茂树
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KANGNAXIANG ENTERPRISE CO Ltd
Ube Exsymo Co Ltd
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Ube Nitto Kasei Co Ltd
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    • F24—HEATING; RANGES; VENTILATING
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    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
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    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • 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
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Abstract

一种驻极体非织造织物用短纤维，它是一种聚烯烃热粘合纤维，其上附着有0.05～1.0重量%的油剂，其特征在于：当进行热处理以将聚烯烃热粘合纤维形成非织造织物时和/或当由聚烯烃热粘合纤维形成的非织造织物进行热处理时，油剂附着量降低至0.001～0.2重量%，并且油剂附着量减少率可以达到至少60%。

Description

驻极体非织造织物用短纤维、 驻极体非织造织物的制造方法及其制品
技术领域
本发明涉及一种驻极体非织造织物用短纤维，驻极体非织造织物的制造方法，以及采用驻极体非织造织物的制品如过滤器材料和过滤器装置。
背景技术
对非织造织物进行带电处理(electric charging)的主要目的在于提高由这些非织造织物制作的过滤器材料或过滤器装置的过滤效率。
作为驻极体非织造织物，已知的是一种将按照熔喷法得到的熔喷非织造织物进行带电处理而制备的产品。然而，现阶段还没有以短纤维(staple fiber)为原料制作的任何驻极体非织造织物。这是因为在短纤维制造过程中需要使用一种油剂，因此油剂附着在短纤维表面上。由于油剂具有亲水性及导电性，因此从纤维表面会释放出所有静电荷，所以不可能直接对纤维施以带电处理，因此一般都是先除去油剂并干燥纤维后，再进行带电处理，这需要复杂的步骤且成本增加。
发明内容
本发明之第一目的是提供一种具有下列优点的驻极体非织造织物用短纤维：(a)该短纤维可提供一种可直接进行带电处理的非织造织物，而无需除去油剂，以及(b)通过带电处理，该短纤维可提供一种可长期保持优异驻极体性能的驻极体非织造织物。
本发明之第二目的是提供一种由达到本发明第一目的的短纤维来制造驻极体非织造织物的方法。
此外，本发明之第三目的是提供一种由达到本发明第二目的的制造方法得到的非织造织物来制作的制品(如过滤器材料或过滤器装置)。
为达到上述目的，本发明人经由不断努力研究，结果发现采用一种聚烯烃热粘合纤维可达到上述目的，这种热粘合纤维上附着有特定量的油剂，当进行热处理以将其形成非织造织物时或当由此形成的非织造织物进行热处理时，这种热粘合纤维可使该油剂附着量降低至预定范围内，且可使其减少率大于某一数值，基于以上发现完成了本发明。
也就是说，本发明提供：
(1)一种驻极体非织造织物用短纤维，它是一种聚烯烃热粘合纤维，其上附着有0.05～1.0重量％的油剂，其特征在于：当进行热处理以将聚烯烃热粘合纤维形成非织造织物时和/或当由聚烯烃热粘合纤维形成的非织造织物进行热处理时，油剂附着量降低至0.001～0.2重量％，并且由等式(I)表示的油剂附着量减少率可以达到至少60％，
油剂附着量减少率(％)＝[(A-B)/A]×100          …(I)
其中，A为热粘合纤维的油剂附着量(重量％)，B为热处理后非织造织物的油剂附着量(重量％)，
(2)一种驻极体非织造织物的制造方法，它包含：
第一步骤，提供一种短纤维作为原材料，油剂施用在该短纤维上，油剂含有由分子量为400到800的聚乙二醇和碳原子数为10到20的脂肪酸得到的一种酯作为主要成份，然后所述短纤维进行开纤和梳棉加工，以制成纤维网；
第二步骤，将纤维网粘合加工以得到非织造织物；
第三步骤，将非织造织物热处理；及
第四步骤，对热处理过的非织造织物进行带电处理，以得到驻极体非织造织物，以及
(3)一种由上述(2)的方法得到的驻极体非织造织物所制成的制品。
附图说明
图1是驻极体非织造织物制造方法的流程图。
具体实施方式
本发明提供的驻极体非织造织物用短纤维包含一种聚烯烃热粘合纤维和附着在该纤维上的油剂。聚烯烃热粘合纤维是一种皮芯型或并列型聚烯烃复合纤维，其中含有一种低熔点成份，选自高密度聚乙烯、低密度聚乙烯、线型低密度聚乙烯、乙丙无规共聚物或乙酸乙烯乙酯共聚物(EVA)，以及一种高熔点成份，选自聚丙烯、聚酯(PET、PBT或PPT)或聚酰胺(nylon 6或nylon 66)。尽管优选使用具有热粘合能力的聚烯烃热粘合纤维，但只要具有热粘合能力单纤维丝也可以使用。特别优选的是含有聚乙烯，特别是以高密度聚乙烯作为低熔点成份，且以聚丙烯作为高熔点成份的皮芯型热粘合复合纤维。
聚烯烃短纤维的纤度与纤维长度并没有特别的限制，考虑到所得驻极体非织造织物主要用于过滤器材料和擦拭布等，聚烯烃短纤维的尺寸大约为0.5至50.0分特(dTex)，优选为1.0至30.0分特(dTex)，而纤维长度大约为30到130mm。
本发明纤维所使用的油剂含有由分子量为400到800的聚乙二醇和碳原子数为10到20的脂肪酸所形成的酯作为主要成份。纤维上的油剂附着量范围是0.05到1.0重量％，优选0.2到0.6重量％。若聚乙二醇的分子量小于400，则油剂很难溶于水，这可能会导致使用上有问题。若上述分子量超过800，油剂的绝缘电阻变大，在开纤和梳棉加工时容易导致静电荷产生等不宜发生的问题。
考虑到本发明的效果，在上述酯的脂肪酸成份方面，优选碳原子数为10到20个。脂肪酸可以是任何一种饱和脂肪酸和不饱和脂肪酸，并且可以是任何一种直链脂肪酸和支化脂肪酸。以上脂肪酸的例子包括：癸酸、十二烷酸、十四烷酸、十六烷酸、十八烷酸、异十八烷酸和油酸。此外，尽管上述酯可以是任何一种二酯和单酯，但考虑到本发明的效果优选使用单酯。
根据用于本发明纤维的上述油剂在加热后所表现出的现象，可以假定其亲水基团迁徙至纤维内部，而疏水基团实际上则存在于纤维表面。在本发明中，油剂可以包含一种或多种由聚乙二醇和脂肪酸得到的酯，或者此外还可以包含其它已知油剂，只要不损害本发明的效果。
热粘合纤维或非织造织物的油剂附着量以下列方法来检测。
(油剂附着量的检测)
使用快速残余油剂萃取器(东海仪器公司(Tokai Keiki K.K)，R-II型)，用乙醇/甲醇混合溶剂(乙醇/甲醇的重量比为2∶1)从2g样品中将附着油剂萃取出来，测量萃取出来的油剂量，然后以下面的公式计算油剂附着量。
油剂附着量(重量％)＝[油剂萃取量(g)/样品重量(g)]×100
如图1所示，本发明的驻极体非织造织物的制造方法包含下列各步骤。
在第一步骤10中，提供一种短纤维，油剂施用在该短纤维上，油剂含有由分子量为400到800的聚乙二醇和碳原子数为10到20的脂肪酸得到的一种酯作为主要成份，将所述短纤维进行开纤和梳棉加工，以制成纤维网。
在第一步骤中，根据用作过滤器材料的需要，也可以将其它纤维以适当混合比例混合至本发明的上述聚烯烃短纤维中，制成混合纤维网。
在第二步骤11中，第一步骤所制成的纤维网经粘合加工，例如，针刺或缝编加工，以得到具有适当拉伸强度的非织造织物。
在第三步骤12中，对以上第二步骤中得到的非织造织物进行热处理。热处理优选在102℃到145℃的温度下进行。
以上第二步骤和第三步骤可以通过热粘合或热压粘合同时进行。
在第四步骤13中，对以上第三步骤中得到的非织造织物进行带电处理，以制成驻极体非织造织物14。
由上述方法得到的非织造织物14可以用来制作过滤器材料或过滤器装置，可以显著提高过滤效率。此外由非织造织物14还可以制作擦拭布.
以下参照实施例将更加详细地解释本发明。
至于实施例1的纤维，是以传统方法从高密度聚乙烯(PE)(作为外鞘成份)和聚丙烯(PP)(作为芯成份)来纺丝加工成皮芯型复合纤维，然后进行拉伸处理。将拉伸后的纤维用填塞箱以6卷/厘米的速率卷曲，然后用油剂(分子量为600的聚乙二醇与油酸所形成的单酯)处理纤维，接着对纤维进行热处理，得到纤度为2.2分特(dTex)、长51mm的PE/PP热粘合纤维。热粘合纤维的油剂附着量为0.3重量％。
至于实施例2的纤维，是按照与实施例1相同的方式，除了油剂替换为使用分子量为400的聚乙二醇和十二烷酸得到的单酯之外，得到的PE/PP热粘合纤维(纤度2.2分特(dTex)，长51mm，且油剂附着量为0.3重量％)。
至于比较例，是按照与实施例1相同的方式，除了油剂替换为烷基链上有8个碳原子的磷酸钾(C8磷酸钾盐)之外，得到的PE/PP热粘合纤维(纤度2.2分特(dTex)，长51mm，且油剂附着量为0.3重量％)。
接着在第一步骤10，对实施例1、实施例2和比较例的PE/PP热粘合纤维的每种短纤维进行开纤和梳棉加工，以形成每单位面积重量为60g/m2的纤维网。
接着在第二步骤11，对每种纤维网进行热风接头粘合(hot air-through bonding)的粘合加工。尽管在这些实施例中粘合加工和热处理(第三步骤12)是同时进行的，但第三步骤12也可以在第二步骤11之后进行。“热风接头粘合”是指用温度例如为138℃的热风将复合纤维中的聚乙烯熔化，使纤维和纤维之间相互粘合在一起，然后可以得到具有适当拉伸强度的非织造织物。热风接头粘合可以在热风温度为102℃到145℃之间进行。
在第四步骤13中，对以上第三步骤12得到的非织造织物进行带电处理，从而制成驻极体非织造织物14。
表1是短纤维及非织造织物加工后的油剂附着量及油剂附着量的减少率。
                               表1
  油剂   短纤维油剂附着量(wt％)   非织造织物油剂附着量(wt％)   油剂附着量的减少率(％)
  实施例1   聚乙二醇油酸单酯(PEG600)   0.3   0.04   86.7
  实施例2   聚乙二醇十二烷酸单酯(PEG400)   0.3   0.03   90.0
  比较例   C8磷酸钾盐   0.3   0.28   6.7
在实施例1和2中得到的驻极体非织造织物14可以用作普通空调系统的过滤器。例如，它们可以用作空调机的滤网，或用作空调系统管道入口或出口处的滤网。此外，上述驻极体非织造织物也可以用作中、低效率的滤网或者与除驻极体非织造织物14以外的过滤器材料相配合而作为袋式过滤器的过滤器材料。根据实验报告，带电处理之前的非织造织物，其过滤效率只有约5％，而经过带电处理后的非织造织物，其过滤效率大约是70％。此外，经过带电处理后的非织造织物，其差压在32升/分钟的流速下依然可维持0.1mm水柱。也就是说，不改变传统的差压，驻极体非织造织物仍然可以显著地表现出高过滤效率。
由以上方法得到的非织造织物14制作成过滤器材料或过滤器装置，可以提高过滤效率。
根据本发明的制造方法，当第二步骤11中进行的粘合处理是非加热粘合处理如针刺法或缝编法时，需要在上述第三步骤12中进行热处理。而当在第二步骤11中进行热粘合处理，如热风接头处理或热压处理时，则这些粘合处理可以与上述第三步骤12中的热处理作用相同，所以第二步骤之后可以直接进行第四步骤13中的带电处理，并且在这种情况下同样可以得到驻极体非织造织物。

Claims (14)

1.一种驻极体非织造织物用短纤维，它是一种聚烯烃热粘合纤维，其上附着有0.05～1.0重量％的油剂，其特征在于：当进行热处理以将聚烯烃热粘合纤维形成非织造织物时和/或当由聚烯烃热粘合纤维形成的非织造织物进行热处理时，油剂附着量降低至0.001～0.2重量％，并且由等式(I)表示的油剂附着量减少率可以达到至少60％，
油剂附着量减少率(％)＝[(A-B)/A]×100      …(I)
其中，A为热粘合纤维的油剂附着量(重量％)，B为热处理后非织造织物的油剂附着量(重量％)。
2.权利要求1的短纤维，其中该油剂含有由分子量为400到800的聚乙二醇和碳原子数为10到20的脂肪酸得到的一种酯作为主要成份。
3.权利要求1的短纤维，其中该聚烯烃热粘合纤维上附着有0.2到0.6重量％的油剂。
4.权利要求1的短纤维，该短纤维是一种聚烯烃复合纤维。
5.权利要求4的短纤维，其中该聚烯烃复合纤维是一种含有聚乙烯作为鞘层部分的皮芯型复合纤维。
6.一种驻极体非织造织物的制造方法，它包含：
第一步骤，提供一种短纤维作为原材料，油剂施用在该短纤维上，油剂含有由分子量为400到800的聚乙二醇和碳原子数为10到20的脂肪酸得到的一种酯作为主要成份，然后将所述短纤维进行开纤和梳棉加工，以制成纤维网；
第二步骤，将纤维网粘合加工以得到非织造织物；
第三步骤，将非织造织物热处理；及
第四步骤，对热处理过的非织造织物进行带电处理，以得到驻极体非织造织物。
7.权利要求6的方法，其中在第一步骤中，一种聚烯烃复合纤维被用作短纤维。
8.权利要求6的方法，其中在第一步骤中，一种含有聚乙烯作为鞘层部分的皮芯型复合纤维被用作短纤维。
9.权利要求6的方法，其中在第一步骤中，使用油剂附着量相对于纤维为0.2至0.6重量％的短纤维。
10.权利要求6的方法，其中在第二步骤中，纤维网是针刺或缝编加工的。
11.权利要求6的方法，其中通过热风接头粘合或热压粘合同时进行第二步骤中的粘合加工和第三步骤中的热处理。
12.权利要求6的方法，其中第三步骤中的热处理在102℃到145℃的温度下进行。
13.一种由权利要求6至12中任何一项所述方法得到的驻极体非织造织物制成的制品。
14.权利要求13的制品，该制品是过滤器材料、过滤器装置或擦拭布。
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