CN1296094A - 高膨松非织造复合织物 - Google Patents

高膨松非织造复合织物 Download PDF

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CN1296094A
CN1296094A CN00129674A CN00129674A CN1296094A CN 1296094 A CN1296094 A CN 1296094A CN 00129674 A CN00129674 A CN 00129674A CN 00129674 A CN00129674 A CN 00129674A CN 1296094 A CN1296094 A CN 1296094A
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索林·克拉伊尼克
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Abstract

一种擦拭用制品,其包括经湿法缠结制得的第一层。一个膨松的纸浆层覆盖在该第一层上。两层均包括可热熔融的粘结剂纤维。通过将热空气通过各层而使各层粘结在一起。

Description

说明书 高膨松非织造复合织物
本发明涉及具有高膨松度的非织造织物。具体地说，本发明涉及由一高膨松层粘结至一非织造基材层的复合非织造织物。
现有技术中包含了用作抹布、毛巾或其它吸收性制品的非织造织物的实例。这些织物可以是将一非织造吸收层与用于提供结构和强度的一非织造基材层结合而成。在现有的一类非织造吸收制品中，一高蓬松度、低密度层与一湿法缠结成形的基材织物(hydroentangled substrateweb)相结合。所得的织物是受欢迎的，因为它结合了第一层具有的高蓬松度和低密度与湿法缠结成形的基材层通常具有的柔软手感，例如当它们用作婴儿尿布时，它们是受欢迎的。
然而，这些现有的织物具有几个未能解决的问题。具体地说，当将高蓬松度层粘结至湿法缠结的无纺基材层上时，难于保持第一层的高蓬松度和膨松度。为了达到它的蓬松度，第一层通常是通过气流成网。接下来，将第一层粘结至基材层的方法通常包括湿法接结(hydrostitching)和湿法缠结(hydroentangling)。然而，这些方法导致所述气流成网的高蓬松度层的润湿和导致它们的永久压缩和压实。
除了包含一气流成网层的复合织物的相关问题外，它们中的现有技术气流成网的非织造层也存在问题。
因此，具有高蓬松度和高膨松度组分的非织造织物存在几个未解决的问题。
本发明的一个目的是提供一种非织造复合织物，其包含通过热粘结的一高蓬松度吸收层和一非织造基材层。
本发明的又一个目的是提供一种制备包含一高蓬松度吸收层和一非织造基材层的一种非织造复合织物的方法。
本发明的方法通常包括以下步骤：制备具有第一种粘结剂组分的一湿法缠结成网无纺层，和将具有高膨松度和高蓬松度的第二种无纺层覆盖在所述湿法缠结层上以制成一个未粘结的复合织物。所述第二层也具有一种熔融温度基本上等于第一种粘结剂熔融温度的粘结剂组分。
然后用加热至第一种和第二种粘结剂纤维的熔点温度范围内的空气将所述未粘结的复合织物进行热粘合。热粘结的步骤可包括将复合织物风干以从其湿法缠结层除去水分。而且，粘结步骤可在一加热炉中加热。随着它们开始熔融，每层的粘结剂纤维至少部分地流过两层之间的界面。这样，各层同时稳定化且复合材料粘结在一起且未将任何一层压实。有利地，各层之间的粘结由此发生，而没有润湿高蓬松度和膨松度层，从而保持了它的蓬松和膨松性。
图1是根据本发明制备高膨松非织造复合织物的方法示意图。
下面结合图1对本发明的一个实施例进行描述。将第一层织物2在湿法缠结台4上进行湿法缠结而制成。织物2至少包含一种粘结剂纤维部分。织物2可以是疏水性或亲水性。优选地，第一织物层2包含与粘结剂纤维湿法缠结在一起的人造短纤维。所述人造短纤维优选占该层的60-85重量％，且其是约1.7-6分特且长度为约30-70毫米。粘结剂纤维优选占该层的约15-40重量％。在湿法缠结之前，一种人造短纤维层可以通过现有技术中公知的任何方法制成，例如包括梳理法、无定向法和气流法。所述人造短纤维层然后可通过现有技术中熟知的任何方法进行湿法缠结。湿法缠结的一个例子已介绍在Evans的US3485706中，其在此引入作为参考。湿法缠结层2的基重优选为10-100gm/m2，最优选为20-70gm/m2。
然后湿法缠结层2可在干燥器6中于真空下进行预干燥。这个预干燥的步骤是选择性的。
然后成形车头8将一高蓬松度的第二织物层10覆盖在第一织物层上以形成未粘结的复合织物12。优选的第二层10包含60-85重量％的纸浆和15-40重量％的粘结剂纤维。最优选的纸浆是南方牛皮浆(Southern Kraft)，这是现有技术中公知的。优选地，第二层10基本上是经无接触热烘干的。US 3692622中提供了气流成网的实例，其在此引入作为参考。第二层的基重优选为10-100gm/m2，最优选是20-70gm/m2。第二层10可覆盖在湿法缠结层2的任一面上，且其可以是一制成的薄织物膜，而作为一个气流法成形网直接施加至短纤维成形网表面上，或作为一个在成形丝网上的气流法网而提供。两个织物层2和10的优选重量比为约1∶1，可调节的范围为1∶4至4∶1。
用于两个织物层2和10的粘结剂纤维优选为双组分纤维，其中聚乙烯作为外层而聚对苯二甲酸乙二醇酯或聚丙烯作为内层。双组分纤维相对于均相的纤维来说是优选的，因为在熔融期间双组分纤维将仅仅破坏它们的一部分结构，而剩下的结构部分是能够参与织物结构并增加弹性。可使用皮芯型结构和拼粘的双组分纤维。粘结剂纤维长度优选为30-70毫米，且为1.7-6分特。最优选的粘结剂纤维长度为40-60毫米，及2.2分特，并占每个织物层的20重量％。两个织物层2和10的粘结剂组分具有基本上相等的熔融温度，且该熔融温度通常是低的且对于聚乙烯部分优选为129-134℃。
然后将未粘结的复合织物12的两个织物层2和10通过加热炉14而使它们相互粘结，加热炉的温度为粘结剂纤维熔融温度的范围。两个织物层中的粘结剂组分的至少一部分在加热炉14中熔融并流进每个织物层中的纤维交叉叠合部分和流进两层的界面区域。这样，各层同时稳定化并相互粘结而没有提高各层的密度。粘结的复合织物16保留了织物层10的高蓬松性。
在本发明方法的一个最优选的实施例中，省去了图1中的预干燥器6，且高蓬松度层10是经无接触地热风干直接覆盖至润湿的湿法缠结层2上。然后在加热炉14中未粘结复合层的粘结与织物层2的干燥同时发生。通过同时进行干燥和粘结，本发明方法的这个最优选的实施例由此大大地节约了生产成本和时间。
在本发明的另一个实施例中，在进行热粘结步骤之前，将第二个湿法缠结层覆盖在所述高蓬松度层的外露侧面上。由此通过夹杂了高蓬松度层的两个湿法缠结层而制成一个未粘结的复合织物。所述第二个湿法缠结层基本上同于第一层，粘结剂组分也可是前述的粘结剂。该未粘结的复合织物然后通过加热至粘结剂纤维熔融温度的空气进行热粘结。这导致了所有三层的粘结剂组分熔融并至少部分地流过各层的界面。由此，各层同时稳定化且该复合织物粘结在一起而没有增加各层的密度。所得的粘结复合织物保持了浆层的高蓬松度以及相比于单独的高蓬松织物或其与单个湿法缠结层结合的织物，大大地降低了飞花和起尘。
除了上述的方法之外，本发明进一步包含由此制得的非织造织物。本发明的复合无纺织物通常包括：湿法缠结的第一层，其包括至少一种粘结剂纤维组分；一个高蓬松度的第二层，其也包含粘结剂纤维组分；以及覆盖在所述第一层上的第二个高蓬松度层。所述第二层的纤维组分至少部分地穿过层界面而流进第一层中，而所述第一层的纤维组分也同样至少部分地穿过层界面而流进第二层中，两层由此粘结在一起。各层由此有利地粘合而没有增加各层的密度。
优选地，本发明的织物的第一层包含与粘结剂纤维湿法缠结在一起的人造短纤维。该人造短纤维优选占该层的60-85重量％，且为约1.2-6分特和长度为约30-70毫米。粘结剂纤维优选为该层重量的约15-40％重量。在湿法缠结之前，一人造短纤维层可通过现有技术中公知的任何方法制成，例如梳理方法、无定向成形法和气流成形法。然后该层通过现有技术中通常公知的任何方法进行湿法缠结。US 3692622中提供了气流成网的实例，其在此引入作为参考。第二层的基重优选为10-100gm/m2，最优选是20-70gm/m2。
本发明织物的优选第二层包含60-85重量％的纸浆和15-40重量％的粘结纤维。最优选的纸浆是南方牛皮浆，这是现有技术中公知的。优选地，所述第二层基本上是干燥的。第二层的基重优选为10-100gm/m2，最优选是20-70gm/m2。该第二层可覆盖在湿法缠结的第一层的任一面上，且其可以是一制成的薄织物膜，而作为一个气流法成形网直接施加至短纤维成形网的表面上，或作为一个在成形丝网上的气流法网而提供。两个织物层的优选重量比为约1∶1，可调节的范围为1∶4至4∶1。
用于本发明的两个织物层的粘结剂纤维优选为双组分纤维，其中聚乙烯作为外层而聚对苯二甲酸乙二醇酯或聚丙烯作为内层。双组分纤维相对于均相的纤维来说是优选的，因为在熔融期间双组分纤维将仅仅破坏它们的一部分结构，而剩下的结构部分是能够参与织物结构并增加弹性。可使用皮芯型结构和拼粘的双组分纤维。粘结剂纤维长度优选为30-70毫米，且为1.7-6分特。最优选的粘结剂纤维长度为40-60毫米，及2.2分特，并且它们占每个织物层的20重量％。
在本发明织物的另一个实施例中，将第二个湿法缠结织物粘结至所述高蓬松度层的外露侧面上。由此高蓬松度层夹在两个湿法缠结层之间。所述第二个湿法缠结层基本上同于第一层，粘结剂组分也可以是如前述的粘结剂。粘结剂纤维组分至少部分地流过织物层的界面并流进高蓬松度层由此将两层粘结在一起。由此，三层同时稳定化且该复合织物粘结在一起而没有增加各层的密度。所得的粘结复合织物保持了浆层的高蓬松度以及相比于单独的高蓬松织物或其与单个湿法缠结层的结合织物，大大地降低了飞花和起尘。此种织物可证明是特别适用于婴儿尿布。
应理解的是，本发明的公开内容不将其的应用限于上述说明或附图中设定的细节。本发明可有其它实施方案，且可以本领域熟练人员意识的各种方式实践和实施。而且，应理解的是，在此适用的短语和术语仅用于说明而不用于限制。

Claims (28)

1、一种用于制备一种复合的非织造织物的方法，其包括以下步骤：
(a)制备包含第一种粘结剂纤维组分的一湿法缠结成网的无纺基材织物层，该第一种粘结剂纤维具有所需的熔融温度范围；
(b)将第二种无纺层覆盖在所述第一层上以制成一个未粘结的复合织物，所述第二层具有高膨松度和高蓬松度组分及第二个粘结剂纤维组分，该第二个粘结剂纤维组分具有所需的熔融温度范围，基本上等于第一个粘结剂纤维的熔融温度。
(c)用加热的气体介质热粘合所述的未粘结的复合织物，所述气体介质加热至第一种和第二种粘结剂纤维的熔点温度范围内；所述的第一种和第二种粘结剂纤维组分至少部分地熔融并流进所述第一层和第二层之间的界面区域；并冷却所述各层；所述各层由此稳定化且未增加任何一层的密度。
2、如权利要求1所述的方法，其中所述第一层包含有湿法缠结的人造短纤维。
3、如权利要求1所述的方法，其中所述第一层包含有60-85％的人造纤维和40-15％的双组分粘结剂纤维。
4、如权利要求3所述的方法，其中所述双组分粘结剂纤维包含一聚乙烯外层和一聚对苯二甲酸乙二醇酯和/或聚丙烯内层，其中所述双组分纤维长度优选为30-70毫米，且为1.7-6分特。
5、如权利要求1所述的方法，其中所述第二层为包含有60-85重量％的纸浆和40-15％的双组分粘结剂纤维的混合物，所述双组分粘结剂纤维包含一聚乙烯外层和一聚对苯二甲酸乙二醇酯和/或聚丙烯内层，其中所述双组分纤维长度优选为30-70毫米，且为1.7-6分特。
6、如权利要求5所述的方法，其中所述粘结剂纤维的长度优选为40-60毫米，且约为2.2分特。
7、如权利要求5所述的方法，其中所述纸浆包括南方牛皮浆。
8、如权利要求1所述的方法，其中所述的第二层基本上是干燥的。
9、如权利要求1所述的方法，其中所述的第一层是经湿法缠结成网的且包含有水分，所述的第二层基本上是干燥的，且热粘结所述各层的步骤包括对所述未粘结的复合织物进行热风干以从所述的第一层中除去水分。
10、如权利要求1所述的方法，其中所述第二层包括基本上干燥的薄织物。
11、如权利要求1所述的方法，其还包括提供第三层的步骤，所述的第三层由包含有熔融温度基本上等于所述第一和第二粘结剂纤维组分的第三种纤维粘结剂组分的湿法缠结的短纤维组成，所述的第二层夹杂在所述第一层和第三层之间以形成所述的未粘结复合织物，所述的未粘结复合织物通过温度处于所述粘结剂纤维熔点范围内的热空气进行热粘结。
12、如权利要求1所述的方法，其中所述的第一层和第二层每个的基重约为10-100gm/m2。
13、如权利要求1所述的方法，其中所述的第一层和第二层每个的基重约为20-70gm/m2。
14、一种复合的非织造织物，其包括：
(a)湿法缠结成网的第一层，该层至少包含第一种粘结剂纤维组分；
(b)覆盖在所述第一层上的第二层，以及两层之间的层界面；所述第二层包含高膨松度和高蓬松度组分并包含第二个粘结剂纤维组分，该第二个粘结剂纤维组分的熔融温度基本上等于第一个粘结剂组分；所述第二个粘结剂纤维组分至少部分地穿过层界面并流进所述第一层中；所述第一层粘结剂纤维组分至少部分地穿过所述的层界面并流进第二层中，所述的第一层和第二层由此相互粘结。
15、如权利要求14所述的织物，其中所述第一层包含有湿法缠结的人造短纤维。
16、如权利要求14所述的织物，其中所述第一层包含有60-85％的人造纤维和40-15％的双组分粘结剂纤维。
17、如权利要求14所述的织物，其中所述双组分粘结剂纤维包含一聚乙烯外层和一聚对苯二甲酸乙二醇酯和/或聚丙烯内层，其中所述双组分纤维长度优选为30-70毫米，且为1.7-6分特。
18、如权利要求14所述的织物，其中所述第二层为包含有60-85重量％的纸浆和40-15％的双组分粘结剂纤维的混合物，所述双组分粘结剂纤维包含一聚乙烯外层和一聚对苯二甲酸乙二醇酯和/或聚丙烯内层，其中所述双组分纤维长度优选为30-70毫米，且为1.7-6分特。
19、如权利要求18所述的织物，其中所述粘结剂纤维长度优选为40-60毫米，且为2.2分特。
20、如权利要求18所述的织物，其中所述纸浆包括南方牛皮浆。
21、如权利要求14所述的织物，其中所述的第二层基本上是干燥的。
22、如权利要求14所述的织物，其中所述的第一层是经湿法缠结成网的且包含有水分，所述的第二层基本上是干燥的，且热粘结所述各层的步骤包括对所述未粘结的复合织物进行热风干以从所述的第一层中除去水分。
23、如权利要求14所述的织物，其中所述第二层包括基本上干燥的薄织物。
24、如权利要求14所述的织物，其中所述的第二层包含纸浆。
25、如权利要求14所述的织物，其还包括提供第三层，所述的第三层由包含有熔融温度基本上等于所述第一和第二粘结剂纤维组分的第三种纤维粘结剂组分的湿法缠结的短纤维组成，所述的第二层夹杂在所述第一层和第三层之间以形成所述的未粘结复合织物，所述的未粘结复合织物通过温度处于所述粘结剂纤维熔点范围内的热空气进行热粘结。
26、如权利要求14所述的织物，其中所述的第一层和第二层每个的基重约为10-100gm/m2。
27、如权利要求14所述的织物，其中所述的第一层和第二层每个的基重约为20-70gm/m2。
28、一种制备高蓬松度的非织造织物的方法，其包括以下步骤：
(a)制备由第一种粘结剂纤维组分组成的一湿法缠结网；
(b)将一基本干燥的气流成形浆层覆盖在所述的湿法缠结网上，同时将所述的湿法缠结成形网基本上润湿以形成一个未粘结的复合织物；所述的浆层包含一种粘结剂纤维组分；和
(c)通过将所述的未粘结的复合织物暴露于加热的空气中而同时干燥所述的湿法缠结网并粘结所述的未粘结复合织物；所述的热空气至少部分地熔融所述粘结剂纤维，所述粘结剂纤维至少部分地流过浆层和缠结网界面并由此将各层和纤维网粘结在一起。
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