CN1606496A - 相对重量具有增强的阻隔性能的无纺阻隔织物 - Google Patents
相对重量具有增强的阻隔性能的无纺阻隔织物 Download PDFInfo
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Abstract
本发明涉及一种无纺复合织物,所述无纺复合织物包括一层或多层纳旦尼尔连续细丝以及至少一层强的耐用基体,其中,用静水压头与阻隔层基本重量比衡量,所述无纺复合织物具有改进的阻隔性能。在本发明中,形成一层或多层强的耐用基体层,每层包括连续热塑性细丝纺粘。阻隔层优选地包括有限长度的纳米纤维,其中,纳米纤维的平均纤维直径在等于或小于1000纳米的范围内,优选地等于或小于500纳米,所述阻隔层被应用于至少一层基体层。
Description
技术领域
本发明一般地涉及阻隔材料,具体地涉及一种无纺复合织物,所述无纺复合织物具有提高的阻隔(barrier)与基本重量(basis weight)比例的性能。改进无纺复合织物的制造是通过提供强的耐用基体层,然后在基体层上沉积一层纳旦尼尔、大体上连续的细丝阻隔层,从而得到无纺阻隔材料,这种材料与传统阻隔结构相比,表现出增强的阻隔性能。
背景技术
无纺织物在大量的应用中使用,这些应用中充分有利地利用了这种织物的工程性质。在制造纤维织物成分时使用选择的热塑性聚合物、纤维成分的选择处理(或者在纤维形成时,或者在集成后的结构中)、以及选择使用将纤维成分集成在有用织物中的多种机构,是调节和改变得到的无纺织物的性能的典型变量。
在上述情况中,连续细丝织物具有相当多的孔隙,为达到所需的阻隔性能通常需要额外的成分。利用静水压头(hydrostatic head)测量的阻隔性能已经通过使用微米级细丝的阻隔“熔体吹制(meltblown)”层进行增强,微米级细丝是通过高速气流拉拔和切断,并沉积成自退火物。通常,这种熔体吹制层表现出非常低的孔隙度、增强了由纺粘(spunbond)和随后熔体吹制层形成的复合织物的阻隔性能。这种无纺结构被作为阻隔织物而使用,如同Brock等人的美国专利No.4041203中描述的,其内容在此引用作为参考。
传统纺粘/熔体吹制/纺粘(SMS)型织物用于阻隔用途时,如一次性卫生用品和防护衣,为达到所需的阻隔功能,其制造时的基本重量范围为60-65g/m2,通常依赖于超过10g/m2的熔体吹制层。通常,在对具有耐酒精和抗静电化学物质的结构增添或表面处理之前,这些类型的织物具有大于45cm的静水压头额定值。
并且,通过使用多个重量轻的熔体吹制层取代单一的大重量熔体吹制层,研究了先前技术对SMS结构的改进,即SMMS织物。以这种方式制造可以减小静水压头失效,这是由于熔体吹制织物中常见的缺陷造成的;多层熔体吹制层弥补任何一层中存在的缺陷。虽然多个熔体吹制层满足制造效率,但这个方法对于每个随后的一层都需要额外的设备。并且,多个熔体吹制层的最终基本重量保持与单一较重熔体吹制层所达到的大致相同的大小。
美国专利No.5464688描述了使用较高熔体流动速率的改性聚丙烯树脂制造熔体吹制网,这种熔体吹制网的平均纤维直径为1到3微米,孔隙尺寸分布在7到12微米的范围,而先前报道的熔体吹制网的孔隙尺寸主要分布在10到15微米的范围。
美国专利No.6482765描述了在熔体吹制或纺粘层中加入氟代烃,以及熔体吹制层具有5到20%的聚丁烯。这种修改提供了具有改进的阻隔和强度与重量比的叠层。用静水压头与熔体吹制层基本重量之比测量的这种提高为115cm/osy(3.38cm/gsm)。
本发明的意图是提供一个或多个纳旦尼尔细丝层,明显提高复合织物(包括叠层和复合的结构)的整体阻挡性,同时也减小了整个结构的重量,并可以用作不同性能增强涂层和昂贵的和复杂的处理的另外方法。纳旦尼尔纺粘层也在复合无纺织物制造过程中为各层之间提供更加均匀的界面,使制造的制品的阻隔性能进一步提高。
发明内容
本发明涉及无纺复合织物,包括一层或多层纳旦尼尔连续细丝以及至少一层强的耐用基体,其中,利用静水压头与阻隔层基本重量比测量,所述无纺复合织物具有改进的阻隔性能。在本发明中,形成一层或多层强的耐用基体层,每层包括连续的热塑性细丝纺粘。优选地,阻隔层包括无限长度的纳米纤维,其中,纳米纤维的平均纤维直径在等于或小于1000纳米的范围内,并且优选地为等于或小于500纳米,阻隔层应用于至少一层基体层上。所述基体层或多个基体层和所述纳米纤维层、以及可选择的一个或多个辅助阻隔材料结合成单一的复合织物。
纳旦尼尔连续细丝阻隔的热塑性聚合物是从如下的组中选择的:聚烯烃、聚酰胺和聚酯,其中,聚烯烃是从如下的组中选择的:聚丙烯、聚乙烯及它们的组合。纳旦尼尔连续细丝阻隔层可以包括相同或不同的热塑性聚合物,这在本发明的范围内。并且,阻隔层的纳旦尼尔连续细丝可以包括均质的、双成分的和/或多成分的组成,以及性能改进添加剂和这些物质的混合。
强的耐用基体层包括从适合的介质中选择的材料,这些介质的例子是:连续细丝无纺织物、人造短纤维无纺织物、连续细丝或人造短纤维纺织物以及薄膜,但不限于此。基体层的成分可以从合成的和天然的材料以及它们的混合物中选择。
在根据本发明形成的织物中,使用一层或多层纳旦尼尔阻隔层对阻隔功能产生明显改进,允许减小满足阻隔性能标准所需的基体和/或阻隔层的总量。
本发明的另一个方面涉及在制造过程中纳旦尼尔阻隔层提供了更加均匀的支撑层,用于随后施加阻隔层或基体层,从而改进最终使用的制品的阻隔功能。
从纳旦尼尔阻隔材料形成织物,特别是当轻的基本重量纳旦尼尔阻隔层被涂覆在或“撒在”基体层上,或者与一个或多个传统阻隔层结合时,能够提供增强的阻隔性能。本发明允许制造具有改进阻隔性能的相同重量织物,或适于用作阻隔织物的较轻重量织物,特别是用于医疗外衣、工业防护衣和一次性卫生用品。使用本发明的织物作为过滤组成也是可以的。
从下面的详细描述、附图和权利要求中,可以容易地理解本发明的其它特征和优点。
具体实施方式
虽然本发明可以以不同形式的实施例实施,但下面描述的是目前优选的实施例,应该理解的是本说明书的内容是对本发明的解释,而不是将本发明限制在这里所述的具体实施例。
本发明涉及无纺复合织物,它由一层纳旦尼尔连续细丝和强的耐用材料的至少一个基体层形成。为了达到织物结构所需的阻隔性与重量比,纳旦尼尔连续细丝优选地具有小于或等于1000纳米的旦尼尔,并且优选地具有小于或等于500纳米的旦尼尔。
适合的纳旦尼尔连续细丝阻隔层可以通过直接纺织纳旦尼尔细丝、或者通过形成在沉积到基体层上之前分成纳旦尼尔细丝的多组分细丝来形成。美国专利No.5678879以及Bi 6114017给出了支撑本发明实施的直接纺纱方法的例子,这两个专利在此引用作为参考文献。分成纳旦尼尔细丝的多组分细丝纺纱可以按照美国专利5225018和5783503所述的原理实施,这两个专利在此引用作为参考文献。
能形成强的耐用基体层的技术包括那些形成连续细丝无纺织物、人造短纤维无纺织物、连续细丝或人造短纤维纺织物(包括编织物)以及薄膜。由于基体需要足够的物理性质经受制造和纺织过程,基体必须是强的和耐用的。组成强的耐用基体层的纤维和/或细丝从具有均匀的或混合的纤维长度的天然或合成物质中选择。适合的天然纤维包括棉花、木质纸浆和粘胶人造丝(viscose rayon),但不限于此。可以是整体或部分混合的合成纤维包括热塑性和热固性聚合物。适于与热塑性树脂混合的热塑性聚合物包括聚烯烃、聚酰胺和聚酯。热塑性聚合物也可以从如下物质中选择:均聚物、共聚物、轭合物(conjugate)以及包括那些具有熔化添加剂或表面活性剂的热塑性聚合物的其它衍生物。
一般地,连续细丝无纺织物的制造包括实施纺粘过程。纺粘过程包括供应熔化聚合物,接着在压力下通过一个板上的大量小孔挤出,这个板公知为喷丝头或模具。将得到的连续细丝淬火并拉拔,拉拔可以许多方法中的任一种,例如槽拉拔系统、衰减器枪或Godet辊。在一个运动的成形表面例如线网输送带上,将连续细丝收集成松散的网。当使用多于一个的喷丝头排成直线,用于形成多层织物时,后续网被收集在先前形成的网的最上层表面。接着,网至少被临时固定,通常采用包含热和压力的方法,例如热点粘结。利用这种方法,网或网的各个层通过两个热金属辊之间,其中一个具有浮凸形状,实现并达到所需的点粘结程度,通常总面积的10到40%被粘结。
用于形成无纺织物的人造短纤维开始是以束的形式形成一包压缩的纤维。为了解开纤维,并使纤维适于形成无纺织物,成包的纤维整体被送入很多的纤维开松机中,再送入梳理机。梳理机进一步使用同向转动和反向转动的线梳松开纤维,并将纤维沉积成膨松的毛层。接着,可以选择地将膨松毛层的人造短纤维进行纤维重定向,例如通过空气随机化和/或交叉重叠,取决于得到的无纺织物所需的极限抗拉性能。纤维毛层通过适当的粘结措施而形成无纺织物,包括使用粘性的粘合剂、通过砑光机或通气炉的热粘结以及水力缠结,但不限于此。
传统纺织织物的生产公知的是一种复杂的、多步骤的工艺。人造短纤维的生产包括梳理纤维,为粗纺机提供进料,粗纺机将成束的纤维扭结成粗纺纱。另外,连续的细丝形成束,公知的称为丝束,接着将丝束作为粗纺纱的组成成分。纺纱机将多个粗纺纱混合成适于织织物的纱线。纺织纱线的第一部分转换成经向束,其中含有机器方向的纱线,然后将送入织机。纺织纱线的辅助部分成为纬纱或充填纱,形成一片织物中的横向线。目前,商业的高速织机工作在每分钟1000-1500投梭的速度下,其中每投梭是单支纱。纺织过程在每分钟60到200英寸的制造速度下生产最终的织物。
由热塑性聚合物形成适于作为强的耐用基体层的有限厚度薄膜在实践中是公知的。热塑性聚合物薄膜的形成可以通过使大量熔化的聚合物分散在具有所需最终产品尺寸的模具内,这公知为铸造膜,或者通过连续地推动熔化的聚合物穿过模具,这公知为挤压膜。在挤压热塑性聚合物膜形成时,可以将膜冷却并接着缠绕成成品材料,或者直接分散到辅助基体材料上,形成同时具有基体和薄膜层性能的复合材料。适合的辅助基体材料的示例包括其它的薄膜、聚合物或金属薄片原料以及纺织织物或无纺织物。
利用本发明成分的挤压膜在制造时按照如下的各个直接挤压膜工艺。混合和定量配料装置包括用于热塑性聚合物片的至少一个料斗加料器以及可以选择的、用于热塑性载体树脂中造粒添加剂的一个,原料送入速度可变的螺旋推运器。速度可变的螺旋推运器将预定数量的聚合物片和添加剂粒输送到混合料斗。混合料斗含有混合螺旋桨,对混合物进一步均匀化。上述的基本容积系统是精确地将添加剂混入热塑性聚合物中的最小要求。聚合物片和添加剂粒混合物被输送到多区挤压器。在从多区挤压器混合和挤压时,聚合物的输送是通过将加热的聚合物管道输送通过一个过滤网更换器,在此将具有不同筛网目数的破碎板用于保持固态和半熔化态聚合物片以及其它的较大碎片。接着将混合的聚合物输送到熔体泵,然后输送到结合区。结合区允许挤压多个薄膜层,薄膜层或者具有相同的组成、或者来自于上述不同系统。结合区连接到挤压模具,挤压模具位于头上方向,使熔化膜挤压位于咬入辊与铸造辊之间的咬入区。
当辅助基体材料受到薄膜层挤压时,辅助基体材料源以卷的形式提供到拉力控制的开卷机上。辅助基体材料被开卷并在咬入辊上移动。挤压模具的熔化膜挤压在咬入辊和铸造辊之间的咬入点作用于辅助基体材料,形成强的耐用基体层。接着通过剥离器辊将刚形成的基体层从铸造辊上取下并缠绕在一个新的辊上。
辅助阻隔材料可以结合在纳旦尼尔阻隔层上,这也在本发明的范围内。适合的辅助阻隔材料可以从如下的代表性材料中选择:熔体吹制微孔膜和整体膜。
与形成一层无纺织物的纺粘工艺相关的方法是熔体吹制工艺。熔化聚合物在压力下从喷丝头或模具中的小孔中挤出。在细丝退出模具时,使用高速空气冲击并输送细丝。此步骤的能量使形成的细丝直径大大减小并且断裂,从而制成有限长度的微纤维。这与纺粘工艺不同,纺粘工艺中保持细丝的连续性。形成单一层或多层织物的工艺是连续的,即,从细丝的挤出到形成第一层直到结合的网缠绕成卷,工艺步骤是不能中断的。生产这种类型织物的方法见美国专利No.4043203。熔体吹制工艺,以及纺粘细丝或熔体吹制微纤维的横断面形状不是实施本发明的关键限制。
通过将透气阻隔膜与纳旦尼尔连接细丝结合,可以使透气阻隔膜具有改进的阻隔性能。如美国专利No.6191211所述的整体膜以及如美国专利No.6264864所述的微孔膜使用了形成这种透气阻隔膜的原理,这两个专利在此引用作为参考文献。
可以相信,通过提供随后的辅助阻隔层可以沉积的纳旦尼尔连续层,可以实现对织物的几种增强。对于给定基本重量的纺粘层,越细小旦尼尔的织物将给出越多数量的细丝和越小的单位面积平均孔隙尺寸。越小的平均孔隙尺寸将使辅助阻隔材料在纳旦尼尔阻隔层上的沉积越均匀。越均匀的辅助阻隔层也将使网中缺陷点越少,缺陷点处能出现阻隔性能的失效。纳旦尼尔阻隔层为辅助阻隔层提供较小的平均孔隙尺寸和较多的支撑点,这使未支撑辅助阻隔材料的跨度缩短。这个原理体现了公知的概念,即平均跨度距离的减小导致结构完整度的增强。
体现本发明原理的无纺复合织物制造包括使用具有不同成分的纤维和/或细丝。不同的热塑性聚合物可以与相同的或不同的性能改进添加剂混合。并且,纤维和/或细丝可以与被混合添加剂改性的纤维和/或细丝混合。
使用上述的基体和阻隔层制造技术,很多不同的结构都可以具有纳旦尼尔阻隔层,得到具有进一步改进阻隔性能的复合无纺材料。
很多最终使用的制品可以从本发明具有纳米纤维阻隔层的预置阻隔层的包含物或替代物中受益,这些制品包括:卫生吸收制品,如尿布和月经用品、以及医疗/工业防护制品。
美国专利No.4573986、No.5843056和No.6198018基本描述了一次性废物污染衣,这些专利在此引用作为参考文献。
具有本发明的改进阻隔织物的吸收制品用整个的一次性吸收制品代表,如图1所示的尿布20。这里所用的术语“尿布”是指一般由婴儿和身体不便的人穿戴的吸收制品,这种吸收制品穿戴在穿戴者驱干下部。但是,应该理解的是,本发明也可以用于其它的吸收制品,例如身体不便人的贴身短内裤、身体不便人的内衣、尿布的保持器和内衬、女性卫生巾、训练短裤、套衣等等。
图1是尿布20处于打开状态(即,将弹性引起的收缩展开)的平面图,其中为了清楚地表示尿布20的结构而去除了部分结构。如图1所示,尿布20优选地包括容纳部分22,容纳部分22包括透过液体的顶层24、与顶层接合的不透过液体的底层26以及位于顶层24和底层26之间的吸收芯28。吸收芯28具有一对相对的纵向边缘、内表面和外表面。尿布还包括弹性腿部件32、弹性腰部件34以及紧固系统36,紧固系统36优选地包括一对固定件37和搭接件38。
将本发明上述的包括纳旦尼尔阻隔层的改进阻隔织物实际应用于底层26将导致尿布在保持性能的同时重量减轻。重量较轻的底层材料预计更具有韧性,从而当应用和穿戴尿布时整个结构更容易变形。
月经用品例如女性卫生巾具有与上述尿布结构相同的基本结构。并且,顶层和底层固定在中间的吸收芯周围。月经用品的整体设计变得更好地适应人体形状和吸收人体排出物。制造这种制品的代表性先前工艺包括美国专利No.4029101、No.4184498、No.4195634、No.4408357和No.4886513,这些专利在此引用作为参考文献。
医疗和工业防护用品,例如CSR、医用长袍、外科织物以及外套大大受益于本发明上述的改进阻隔织物。在制造这种防护产品中的特别效果是使用具有改进阻隔与重量比的重量较轻的织物,因为这对于最终制品尽可能的轻并且仍执行其所需功能是重要的。一般地描述这种防护制品的专利包括美国专利No.4845779、No.4876746、No.5655374、No.6029274和No.6103647,所有这些专利在此引用作为参考文献。
下面参照图2,图中表示一次性外衣一般标记为110,它包括外科长袍112。长袍112包括主体部分114,主体部分114可以为一体式,具有用于覆盖穿戴者前面的前片116、以及从前片116相对两侧伸出而用于覆盖穿戴者后面的一对后片118和120。后片118和120分别具有一对侧边缘122和124,在长袍后面形成开口。长袍112具有一对袖子126和128,固定在长袍主体部分114上,用于穿戴者的胳膊。在使用时,后片118和120重叠在穿戴者后面,以便闭合长袍后面的开口,并且使用带装置(未图示)将后片118和120以重叠关系固定。
从前面可以得出,在不偏离本发明新颖概念的真实精神和范围的情况下,可以做出很多修改和变化。应该理解的是,这里给出的具体实施例并不是有意或推断用于限制。通过权利要求,本发明的内容将覆盖落在权利要求范围内的所有这种修改。
Claims (24)
1.一种无纺复合织物,包括纳旦尼尔阻隔层和基体层,纳旦尼尔阻隔层包括旦尼尔小于约1000纳米的多根连续热塑性细丝。
2.如权利要求1所述的无纺复合织物,其特征在于,所述连续热塑性细丝具有小于500纳米的旦尼尔。
3.如权利要求1所述的无纺复合织物,其特征在于,所述基体层从如下的组中选择:无纺织物、纺织织物、薄膜和它们的混合物。
4.如权利要求3所述的无纺复合织物,其特征在于,所述无纺织物从如下的组中选择:连续细丝、有限长度纤维和它们的混合物。
5.如权利要求4所述的无纺复合织物,其特征在于,所述无纺织物包括一层或多层连续细丝纺粘。
6.如权利要求4所述的无纺复合织物,其特征在于,所述无纺织物包括一或多个辅助阻隔层。
7.一种无纺复合织物,包括纳旦尼尔阻隔层、辅助阻隔层和基体层,纳旦尼尔阻隔层包括旦尼尔小于约1000纳米的多根连续热塑性细丝,其中,所述无纺复合织物具有比所述辅助阻隔层和所述基体层单独组合更大的静水压头与重量比。
8.如权利要求7所述的无纺复合织物,其特征在于,所述辅助阻隔层包括一或多个有限长度纤维层,所述纤维的直径大于1000纳米。
9.如权利要求7所述的无纺复合织物,其特征在于,所述辅助阻隔层包括一或多个无限长度细丝层,所述细丝的直径大于1000纳米。
10.如权利要求7所述的无纺复合织物,其特征在于,所述辅助阻隔层包括一或多个熔体吹制层。
11.如权利要求7所述的无纺复合织物,其特征在于,所述基体层包括一或多个纺粘层。
12.一种无纺复合织物,包括纳旦尼尔阻隔层、熔体吹制阻隔层和基体层,纳旦尼尔阻隔层包括旦尼尔小于约1000纳米的多根连续热塑性细丝,其中,所述无纺复合织物具有比所述熔体吹制阻隔层和所述基体层单独组合更大的静水压头与重量比。
13.一种无纺复合织物,包括纳旦尼尔阻隔层、辅助阻隔层和纺粘基体层,纳旦尼尔阻隔层包括旦尼尔小于约1000纳米的多根连续热塑性细丝,其中,所述无纺复合织物具有比所述辅助阻隔层和所述纺粘基体层单独组合更大的静水压头与重量比。
14.如权利要求13所述的无纺复合织物,其特征在于,所述辅助阻隔层包括熔体吹制阻隔层。
15.一种一次性废物污染用品,包括:
吸收芯;
透过液体的顶层;以及
不透过液体的底层;
所述不透过液体的底层包括无纺复合织物;
所述无纺复合织物包括纳旦尼尔阻隔层和基体层,所述纳旦尼尔阻隔层包括旦尼尔小于约1000纳米的多根连续热塑性细丝。
16.如权利要求15所述的一次性废物污染用品,其特征在于,所述用品是尿布。
17.如权利要求15所述的一次性废物污染用品,其特征在于,所述用品是月经用品。
18.如权利要求15所述的一次性废物污染用品,其特征在于,所述复合织物包括辅助阻隔层。
19.如权利要求15所述的一次性废物污染用品,其特征在于,所述复合织物还包括熔体吹制辅助阻隔层,所述基体层包括纺粘基体层。
20.一种一次性用品,包括一种外衣,所述外衣具有前片、从前片相对两侧伸出的一对后片、以及一对袖子,其中,所述前片、后片和袖子中的一个或多个包括纳旦尼尔阻隔层和基体层,所述纳旦尼尔阻隔层包括旦尼尔小于约1000纳米的多根连续热塑性细丝。
21.如权利要求20所述的一次性用品,其特征在于,所述外衣是医用外衣。
22.如权利要求20所述的一次性用品,其特征在于,所述外衣是工业防护外衣。
23.如权利要求20所述的一次性用品,其特征在于,所述前片、后片和袖子中的一个或多个包括辅助阻隔层。
24.如权利要求23所述的一次性用品,其特征在于,所述辅助阻隔层包括熔体吹制辅助阻隔层,所述基体层包括纺粘基体层。
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US33284701P | 2001-11-16 | 2001-11-16 | |
US60/332,847 | 2001-11-16 |
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CN1606496A true CN1606496A (zh) | 2005-04-13 |
CN1318205C CN1318205C (zh) | 2007-05-30 |
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US (1) | US20030129909A1 (zh) |
EP (1) | EP1448365A4 (zh) |
JP (1) | JP2005509546A (zh) |
CN (1) | CN1318205C (zh) |
AU (1) | AU2002352731A1 (zh) |
IL (1) | IL161954A0 (zh) |
MX (1) | MXPA04004533A (zh) |
WO (1) | WO2003043809A1 (zh) |
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- 2002-11-15 US US10/295,613 patent/US20030129909A1/en not_active Abandoned
- 2002-11-15 CN CNB028256689A patent/CN1318205C/zh not_active Expired - Fee Related
- 2002-11-15 EP EP02789680A patent/EP1448365A4/en not_active Withdrawn
- 2002-11-15 WO PCT/US2002/036732 patent/WO2003043809A1/en active Application Filing
- 2002-11-15 JP JP2003545468A patent/JP2005509546A/ja active Pending
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CN106393840A (zh) * | 2011-08-08 | 2017-02-15 | 阿文提特种材料公司 | 具有带状纤维的液体阻隔非织造织物 |
CN106393840B (zh) * | 2011-08-08 | 2021-02-12 | 阿文提特种材料公司 | 具有带状纤维的液体阻隔非织造织物 |
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WO2003043809A1 (en) | 2003-05-30 |
US20030129909A1 (en) | 2003-07-10 |
AU2002352731A1 (en) | 2003-06-10 |
EP1448365A1 (en) | 2004-08-25 |
IL161954A0 (en) | 2005-11-20 |
MXPA04004533A (es) | 2004-08-11 |
JP2005509546A (ja) | 2005-04-14 |
CN1318205C (zh) | 2007-05-30 |
EP1448365A4 (en) | 2007-07-18 |
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