CN1356424A - 带摩擦电荷的非织造织物的制造工艺 - Google Patents

带摩擦电荷的非织造织物的制造工艺 Download PDF

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CN1356424A
CN1356424A CN01142433A CN01142433A CN1356424A CN 1356424 A CN1356424 A CN 1356424A CN 01142433 A CN01142433 A CN 01142433A CN 01142433 A CN01142433 A CN 01142433A CN 1356424 A CN1356424 A CN 1356424A
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fiber
triboelectric charge
band
fiber web
supatex fabric
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CN1198005C (zh
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霍尔格·布赫瓦尔德
卡尔－海因茨·莫尔魏泽
克劳斯·韦瑟
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Abstract

本发明涉及带摩擦电荷的非织造织物的制造工艺,其特征是混纺纤维由纤度≤1.7分特的聚丙烯腈纤维和纤度≤1.7分特的聚烯烃纤维制成并冲洗掉润滑剂和抗静电剂,将其干燥到含水量按重量<1%并且在一纵向的或随机化的梳理机上梳理成单位面积质量为15～80g/m2的带摩擦电荷的纤维网。借助于两同步旋转的滚筒和一传送滚筒将该纤维网带走,以便将该纤维网铺放在沿加工方向的一输送带上,并且直接在一粘合装置内粘合,未粘合的纤维网只经由传送的1至2个点运送。

Description

带摩擦电荷的非织造织物的制造工艺
技术领域
本发明涉及带摩擦电荷的非织造材料的制造工艺及其应用。
背景技术
这样一些过滤介质由包括至少两种不同的纤维聚合物的混纺纤维组成，它们在它们的表面的负电性方面是如此的不同以致在通过梳理和通过随后的借助针刺粘合工艺制造纤维网的过程中给它们提供了静电荷。这些介质已描述于文件EP 0 246 811和EP 0 674 933中并且广泛地用作所谓“带摩擦电荷的驻极电介质过滤器”用以过滤气悬体。
为了在这些工艺的基础上制造过滤介质，必须在梳理以前将纤维处理剂洗掉，并且必须除掉所有的抗静电活性成分和辅助剂，它们通常保证纤维在梳理机上的良好加工性。
然而，这带来某些缺点，如洗过的混纺纤维比涂覆有纤维处理剂的标准纤维的加工性显著地较差，并因此至今它已不可能在细纤维(平均纤维纤度≤1.7分特(dtex))的基础上制造“带摩擦电荷的驻极电介质过滤器”。
特别在按照文件EP 0 246 811使用一梳理机制造纤维网时产生问题。一斩刀用作梳理机滚筒的梳理机制备系统，其使纤维网可以从梳理机上分离并传送到一输送带上。虽然由于斩刀机构在梳理机剥离器上反复地释放强电荷，从而引起纤维网叠料板的经常的失效，但这种工艺在常见的辊式剥离系统中仍占主要地位。
至今仍在上述工艺的基础上通过机械针刺法完成纤维网的粘合。在具有较大的单位面积的质量的纤维网方面，通过机械的纤维交织来达到适当的粘合，即使织针留下不希望有的通道也是如此，因此降低了非织造材料的过滤效率。
然而，对于具有低单位面积的质量的纤维网，为了达到适当的粘合性能，针刺工艺是不可能的。当单位面积的质量小于100g/m2时，薄的纤维网将对织针只产生微小的阻力，并因此难以按纤维引起足够高的纤维力流的方式来交织纤维。
这就是为什么针刺工艺过程只有在纤维网用一载体加强时才能制造轻质的“带摩擦电荷的驻极电介质过滤器”(单位面积的质量＜50g/m2)，该载体将在松弛的纤维网的针刺过程中产生足够大的阻力。
载体材料通常是轻质织物、稀松窗帘用布和非织造织物(优选纺粘的非织造织物)。虽然这些介质对细气悬体的过滤只产生很小的作用，但它们主要用来建立纤维网与载体之间的连结，并且用于满足该非织造材料的拉伸强度方面的最小要求。
采用载体所固有的缺点是所涉及的成本以及过滤介质的较差的孔隙度。
即使轻质纤维网通过采用载体在上述工艺的基础上能够被充分地粘合，纤维网结构的均匀度(纤维的分布)仍然是不满意的。当采用标准的2至3分特(dtex)的混纺纤维并且应用交叉铺网工艺时，由于粗纤维和所应用的编结工艺之故纤维网已呈现开口的和不匀的外表，因为交叉铺网工艺使纤维网能以V形沉积到通向粘合装置的供料装置，并因此在纤维网的内部造成相当的不均匀性。并且，机械针刺工艺强化了这种不均匀性，因为针刺引起纤维网的整个截面的移位，从而形成较大的穿孔。
然而，不均匀的纤维网结构对过滤器应用是不适宜的，因为不匀的纤维分布乃至穿孔强烈地影响过滤效率。
轻质带摩擦电荷的非织造织物的低密度可认为是另一个缺点。关于厚针刺毡，通过机械针刺法只能达到0.25g/cm3的密度。然而，如果通过针刺工艺装置粘合小于10m/m2的纤维网，则该数值被大大地降低。在这种情况下，纤维将在两表面上形成大的回线并产生密度为0.03～0.07g/cm3的膨松的非织造织物。
低密度的轻质带摩擦电荷的针刺毡只要它们以平面形状使用并不造成任何问题。然而如果它们设置在过滤器部件的内部，在一有限的空间内将必须充分容纳一最大的过滤面积。在这种情况下，与较薄的制品相比存在一严重的缺点。
发明内容
本发明的目的是提供轻质带摩擦电荷的非织造织物的制造工艺及其应用。
本发明这样来达到这个目的，即，通过将包括具有纤度≤1.7分特(dtex)的聚丙烯腈纤维和具有纤维≤1.7分特的聚烯烃纤维的、不含润滑剂和抗静电剂的混纺纤维干燥到含水率按重量＜1％，并且通过将其在一纵向的或随机化的梳理机上梳理成一具有单位面积的质量为15～80g/m2的带摩擦电荷的纤维网。在这种情况下，借助于两同步旋转的滚筒和一传送滚筒将纤维网带走，从而使纤维网能沿加工方向堆积到输送带上，并且粘合工序直接在一粘合装置内进行，未粘合的纤维网只经由传送的1至3个点运送。
采用纵向的或随机化的梳理机和沿梳理方向铺放纤维网使其能够防止纤维网在交叉铺网机上的变形和防止由于V形堆积板之故引起的重量的变动。
通常的包括一斩刀或一具有小直径的剥离滚筒的系统不选择用来将纤维网从梳理机上分离，而采用一装备有两具有较大直径(＞200mm)的同步旋转的滚筒之滚筒剥离系统，第一个滚筒用作压实滚筒而第二个用作剥离滚筒，再加上一有沟槽的传送滚筒。意外地发现这种剥离系统使其能够梳理具有高纤维网均匀性的细纤度的混纺纤维，并且同样可以将它们铺放到堆积带上。
为了防止梳理好的纤维网在铺放在输送带上以后沿加工方向被伸长，有必要在梳理机与粘合装置之间选择短的距离，并且在梳理机与粘合装置之间必须只有最少数目的传送点。理想地是，一连续的输送带应该将纤维网直接导向粘合装置。
得到的最好结果是通过根据喷水针刺工艺的粘合操作使其能够正确地粘合轻质的和细纤度的带摩擦电荷的纤维网，而不显著地影响纤维网的结构。
作为另一种方案，通过借助于超声波辊压机或加热的辊压滚筒的纤维网的网格式热粘合也可提供益处。
本发明中所涉及的粘合工艺，即喷水针刺工序和热网格式粘合操作不仅提供防止由于粘合工艺造成的纤维网的破坏或穿孔的益处，而且还提供制造更压实的非织造材料的优点。
以这种方式制造的非织造织物比具有相同单位面积质量的相当的机械针刺制品较薄，并因此它们可被容易地安装在过滤器部件内(例如，以打褶的形式)。
关于网格式热粘合工艺，优先选择将导致纤维网的最小压实和最小热应力的那些工艺。涉及超声波辊压机的网格式粘合特别适用于这个目的，但借助于加热的辊压滚筒可以采用其他型式的网格式粘合工艺。为了达到最高可能的孔隙度，为了使非织造织物对50mm宽的撕裂带具有4N的最小强度应该选择从6％至30％范围的粘合面积，以便满足涉及输送和使用方面的要求。
照例，对于任何型式的粘合通过增加摩擦电的非织造材料的单位面积质量或粘合面积来满足严格的强度和刚度要求是不合理的。
将包括聚丙烯和聚乙烯纤维或皮芯纤维的混纺纤维用作聚烯烃纤维可取得较大的益处，其为具有充当粘合纤维的低熔点的组分。通过采用充当粘合纤维的纤维可达到较高的强度。
当将由本发明制造的带摩擦电荷的非织造织物与其他的织物(如网格结构、织物、纸和非织造织物等)层压在一起而引起加强的效果时也可提供较大的益处。
根据本发明的带摩擦电荷的非织造织物的一个优点是多层过滤介质的制造，在带摩擦电荷的非织造织物的前面是在原有空气一侧的由纺粘的或干法成网的非织造材料制成的预过滤层，而在其后面是在清洁空气一侧的由微纤维的纤维网和/或纸制成的细过滤层。
在原有空气一侧设置高度多孔的过滤层使其能够防止由带摩擦电荷的纤维制成的层在早期被堵塞，并且能延长过滤介质的使用寿命，该过滤介质是用根据本发明的带摩擦电荷的非织造织物制成的。
在本发明的基础上制造的非织造织物对在安装过滤器部件的有限的空间内要求高过滤效率的应用中带来特别有价值的优点。包括曲折式打褶的过滤介质的过滤器盒或滤筒被制成用于小型环境空气净化的装置，例如汽车内部过滤器或引擎进气过滤器，它们在采用轻质带摩擦电荷的微纤维非织造织物时提供与过滤器相关的优点。这样的非织造织物与加强的非织造织物，例如一塑料网格或纸层压在一起以便为它们提供适当的打褶用的刚度。
根据本发明的非织造织物还可以成功地用作真空吸尘器袋的过滤介质。，对于这样的应用，将它们制成与过滤纸、纺粘的非织造织物和/或微纤维非织造织物一起层压的材料。带摩擦电荷的非织造织物用作真空吸尘器袋具有以下益处。
作为高效的驻极电介质过滤器，它们显著地提高通常的过滤介质(尤其是过滤纸)的过滤性能。当带摩擦电荷的非织造织物设置在沿流动方向纸层的上游时，它们还处于保护纸层防细尘的地置，并因此改进真空吸尘器的抽吸性能的稳定性。作为与纸的层压的材料，由于它们的厚度小可易于将它们打褶，并且借助于便宜的自动开口制袋机加工成过滤器袋。
具体实施方式
本发明详细说明于实例1至3。实例1：
形成包括60％的聚烯烃双组分纤维和40％的聚丙烯腈纤维的混纺纤维，其中聚烯烃双组分纤维的特征是纤维细度为1.0分特，纤维长度为38mm，而聚丙烯腈纤维的特征是40mm/1.3分特；然后从混纺纤维中洗掉纤维油化剂和润滑剂，并再将混纺纤维干燥到残余水分＜1％。通过在一随机化的梳理机上梳理该混纺纤维而形成单位面积质量约为50g/m2的纤维网并将其铺放到直接通向一热式加热的辊压机的辊压间隙的一接收带上，在其中纤维网利用点式刻花式样被部分地粘合(熔焊的面积为14％)。该过滤介质具有密布的微孔，并因此具有在低单位面积质量时良好的过滤效率。非织造织物沿加工方向的机械强度值为10N/50mm(撕裂带宽)并且对输送和使用是足够的。实例2：
形成包括60％的1.7分特/40mm的聚丙烯纤维和40％的1.7分特和40mm的聚丙烯腈纤维的混纺纤维，然后从混纺纤维内洗掉纤维油化剂和润滑剂，并再将混纺纤维干燥到残余水分＜1％。由该混纺纤维在一随机化的梳理机上形成约50g/m2的纤维网，铺放到一接收带上，然后将两个层通向一热式加热的辊压机的辊压间隙内，接着输入一具有11.5g/m2重量的挤压的聚丙烯网格，在其中纤维网利用点式刻花式样被部分地粘合，与此同时与聚丙烯网格层压在一起。成品的层压材料具有均匀的纤维网结构，其单位面积质量为60g/m2。实例3：
在实例2所述制造工艺的基础上制造的重量约为35g/m2的纤维网，集合有挤压的重量为11.5g/m2的聚丙烯网格，这样在粘合工艺完成以后制造出一具有单位面积质量为46g/m2的非织造的层压材料。后者的特征同样是良好的纤维分布。对比的实例：
对比的实例是基于按照至今传统采用的生产工艺、由60％的1.7分特和40mm的聚烯烃双组分纤维和40％的1.7分特和40mm的聚丙烯腈纤维制成的混纺纤维。将该混纺纤维混合、冲洗和干燥，如实例1所述。然后在一梳理机上梳理该混纺纤维，这样形成的纤维网借助于一斩刀脱离滚筒并转送到交叉铺网机上，其又将纤维网铺放在一带上。一具有单位面积质量为30g/m2的聚酯纺粘的非织造织物在针刺机的上游加到重量为40g/m2的纤维网层上。两个层的机械针刺制造出具有单位面积质量为70g/m2的非织造材料，其呈现出足够的机械强度值。这个样品显示出模糊的和不均匀的纤维网结构。
应用于这些实例和另一商业上通行的对比的样品的技术数值归纳于表1中。
表1
    样品  单位面积质量  厚度  透气性  渗透度         商L：(DNaCl·D) 纤维网结构指数
 测定的数量     g/m2   mm   l/m2   ％
 实例1     53  0.55   1800   5.2     629
 实例2     60  0.70   2150   10.4     294     3.2
 实例3     46  0.55   2560   12.5     373     4.9
 对比实例1     70  1.20   2900   15.0     160     9.4
 对比实例2(商业上通行的)     40  0.56   4600   45.0     182
实验方法：
厚度                            测定的面积为10cm2，测定压力12.5cN/cm2，
                                加载时间1sec(秒)。
透气性                          德国工业标准DIN 53887在200Pa下测定的
                                (面积为20cm2)。
对氯化钠测定的透气度            采用“TSI Certitest Model 8130”仪器
                                测定对氯化钠的渗透度。TSI 8118 Model用
                                作普通盐的气悬体发生器；产生带有平均直
                                径为0.26μm(质量)的氯化钠粒子。该测量
                                在过滤速度为0.08m/s下完成。
纤维结构的均匀性                采用光电测量方法测定纤维网结构的均匀
                                性。该均匀性用纤维网结构指数表达；纤维
                                网结构变得越不均匀和越模糊，该指数越高。
                                在具有很好的纤维分布的非织造织物上该指
                                数达到＜3.5的值。
商L(DNaCl·D)：                过滤器的品质基本上取决于孔隙度和过滤效
                                率。目的是尽可能在高孔隙度(作为透气性
                                L测定的)下拦住活性气悬体。换言之，透                        过过滤器的气悬体(作为渗透度DNaCl测定的)应该最少。为了评定具有不同的孔隙度值的制品，由透气性值与对氯化钠的渗透度组成商。具有高截止值和良好孔隙度的过滤器达到高的商L：DNaCl值。当包含低过滤介质厚度(D)时，有可能将较大有效的过滤面积容纳于一定的结构空间内。L：DNaCl指数用厚度值给予补充，以便评定由在过滤筒、盒等内部的薄介质提供的益处。

Claims (7)

1.带摩擦电荷的非织造材料的制造工艺，其特征是混纺纤维由具有纤度≤1.7分特的聚丙烯腈纤维和具有纤度≤1.7分特的聚烯烃纤维制成并且清洗掉润滑剂和抗静电剂，其被干燥到含水量按重量＜1％并且在一纵向的或随机化的梳理机上梳理成单位面积质量为15～80g/m2的带摩擦电荷的纤维网，借助于两同步旋转的滚筒和一传送滚筒将该纤维网带走，以便将该纤维网铺放到沿加工方向的输送带上，并且直接在一粘合装置内粘合，未粘合的纤维网只经由传送的1至3个点运送。
2.按照权利要求1所述的工艺，其特征在于粘合操作用喷水针刺法来完成。
3.按照权利要求1所述的工艺，其特征在于用包括在一超声波或加热的辊压机内的印刷粘合辊的热粘合来完成。
4.按照权利要求3所述的工艺，其特征在于，将聚丙烯和聚乙烯纤维或皮芯纤维的混纺纤维用作聚烯烃纤维，其为具有充当粘合纤维的低熔点的组分。
5.在权利要求1至4之一项或几项所述工艺的基础上制造的带摩擦电荷的非织造织物，其特征在于，其具有由纤维网结构指数≤5表达的均匀的纤维分布和均匀的粘合、≥0.07g/cm3的密度和由商L：(DNaCl·D)＞200表达的过滤性能。
6.权利要求5所述的带摩擦电荷的非织造材料用于制造多层过滤介质的用途，其特征在于该带摩擦电荷的非织造材料用作至少与另一织物形成的层压材料的活性组分。
7.权利要求5所述的带摩擦电荷的非织造材料用于制造多层过滤介质的用途，其特征在于，在该带摩擦电荷的非织造织物的前面是在原有空气一侧的纺粘的非织造织物或干法成网的非织造织物的预过滤层，而在其后面是在清洁空气一侧的由微纤维的纤维网和/或纸制成的细过滤层。
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