CN1612959A - 具有拉伸能力改进的密封外表面的粘合聚酯填充纤维棉絮 - Google Patents

具有拉伸能力改进的密封外表面的粘合聚酯填充纤维棉絮 Download PDF

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CN1612959A
CN1612959A CNA038019396A CN03801939A CN1612959A CN 1612959 A CN1612959 A CN 1612959A CN A038019396 A CNA038019396 A CN A038019396A CN 03801939 A CN03801939 A CN 03801939A CN 1612959 A CN1612959 A CN 1612959A
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Abstract

用于服装和其他用途的具有增强的拉伸能力的聚酯填充纤维毛层用聚酯纤维和粘合用纤维制成，通过在某种特定条件下的烘箱粘合和热辊轧处理，用软化的树脂喷涂。这样提供的粘合棉絮的特征在于柔软性和悬垂性、良好的隔热性能、纤维通过面料泄漏或渗滤的水平低、当通过洗涤/干燥或通过干洗洗涤时具有增强的耐久性，以及增强的结构整体性，从而不必缝入小尺寸的饰条就能自由悬垂，以及改进的拉伸能力。

Description

具有拉伸能力改进的密封外表面的粘合聚酯填充纤维棉絮
技术领域
本发明涉及粘合聚酯填充纤维棉絮拉伸能力的改进。
背景技术
聚酯填充纤维(有时称为聚酯填充纤维材料)作为枕头、衬垫和其他装饰材料，包括床上用品材料的合理廉价的填充和/或隔热材料，以及在服装方面均是被广泛接受的，并且在商业上已大量制造和使用。对于许多这些用途，象例如Tolliver的US 3772137；Stanistreet的US 4068036；Scott的US 4129675；Pamm的US 4281042；Frankosky的US 4304817；Siniscalchi的US 4551383；和LeVan的US 4869771中公开的，理想的是例如通过喷涂通常为丙烯酸聚合物的树脂粘合剂，或通过将聚酯填充纤维与诸如现有技术中公知的粘合剂纤维共混，或通过同时使用树脂粘合剂和粘合剂纤维来制造粘合的棉絮。
为了改善聚酯填充纤维的外观，一般证明理想的是“磨光”带有耐久(即耐洗)涂料涂层的填充纤维，所述涂料通常为硅氧烷，即例如Hofmann的US 3271189；Mead等的US 3454422；Ryan的US3488217；Salamon等的US 4146674；LeVan的US 4869771；TakemotoOil and Fat Co.，Ltd.的日本公开申请58-214585(1983)公开的固化聚硅氧烷；或诸如由例如Marcus的US 4818599公开的聚烯化氧类的其他类型涂料。
US 5527600公开了一种容易制造的、均匀的棉絮，其特征是符合穿戴者身体的柔软性和悬垂性、良好的隔热性能、即使在洗涤后也具有的纤维穿过面料的低泄漏水平，增强的耐清洗/干燥或干洗的耐洗涤性，以及增强的结构整体性，从而使棉絮不需要将其缝入小尺寸的饰条就能自由悬垂。然而，对于某些用途，特别是在服装方面，希望提供具有一定程度“可拉伸”特征的棉絮，使得由可拉伸面料和可拉伸毛层制成的服装因具有增强的活动自由度而可舒适地控制。
发明概述
本发明通过提供可拉伸的毛层解决了现有技术的问题。本发明毛层的“可拉伸性”通过毛层的拉伸应变测量，因为拉伸应变是给定负载下材料中有多少拉伸的量度。因此，根据本发明，提供了一种粘合毛层，其包含与粘合用纤维紧密混和的聚酯填充纤维的混纺纱，其中该毛层在3磅负载下具有大于约35％的拉伸应变。
本发明的毛层的拉伸应变通过制造该毛层的加工条件实现。因此，根据本发明的另一方面，提供了制备粘合毛层的方法，包括形成与粘合用纤维紧密混和的聚酯填充纤维混纺纱，由所述混纺纱制备连续的毛层，所述毛层具有一个上表面和一个下表面，推进所述毛层通过一个或多个喷射区，使毛层的两面都喷上树脂，在烘箱中加热已喷涂的毛层以固化树脂并软化粘合剂材料，然后在200-220℃下将热毛层热辊约8秒，实现毛层表面上树脂与纤维间的紧密接触，并冷却辊轧的毛层。这种热辊轧用S形抱辊构型的热轧辊进行。轧辊可具有2-10mm间隙，取决于要求的最终棉絮厚度。
附图简述
图1表示根据现有技术制成的毛层的一组拉伸应变曲线。
图2表示根据本发明制成的毛层的一组拉伸应变曲线。
发明内容
因此，本发明通过首先制备聚酯填充纤维(占混纺纱重量的70-96％)和合适的粘合用纤维(占混纺纱重量的4-30％)的均匀混纺纱，提供了例如用于优质服装所需要的填充纤维毛层。该混纺纱可在梳理机或扯松机上转换成织物，然后成层或交叉搭接形成棉絮，并通过例如喷涂在其上表面(优选地也连续地在其下表面)上涂覆合适的胶乳(例如丙烯酸聚合物和/或共聚物在水中的胶态分散体，将在下文更详细讨论)。加热已喷涂的棉絮，例如方便地通过热烘箱加热，以干燥涂层和将聚合物组分聚合至高分子量，并活化粘合用纤维。可通过这种烘箱例如三遍来方便地干燥，两遍用于依次干燥并部分固化每一涂层，每一面都这样干燥后，最后一遍补充其他面，并保证准备进行任何热辊轧的粘合用纤维的活化，其中粘合毛层通过呈S形抱辊构型的热轧辊，以软化和分散固化的树脂，并保证树脂在毛层表面(大表面)中的纤维间完全且均匀的分布，以避免纤维通过毛层的这些表面泄漏，并同时保证毛层达到要求的厚度。
本文所用树脂根据不同制造商而分别称为“柔软”或“适中”或甚至“非常柔软”，但其特征是都具有约0℃或更低，且优选约0℃至约-30℃的二级玻璃化转变温度(Tg)。它们在用于例如服装时都给毛层提供柔软性和悬垂性，同时起到防止纤维从毛层漏出的阻挡层的作用。毛层中纤维(即聚酯填充纤维与粘合用纤维的混纺纱)的重量称为毛层的“基重”，即喷涂密封树脂前的重量。最终毛层可具有1.5至12oz/yd2(50至400g/m2)的基重和0.07至0.20英寸/oz/yd2(0.05至0.15mm/g/m2)的厚度。
因此本发明的毛层由聚酯填充纤维与粘合用纤维的混纺纱制备，且面层中的纤维用合适的柔软型树脂涂层密封。聚酯填充纤维可以都被磨光，例如本文描述的那样，或可以是磨光的和不磨光的纤维的混纺纱。填充纤维可以是实心的、中空的，或实心与中空纤维的混纺纱，且不限于任何纤维截面类型，即它可以是十字形、三叶形、Y形、哑铃形、荷叶形椭圆，和其他非圆形截面，以及圆形。填充纤维具有0.2至10的旦/丝(dpf)，非常有用的是约1.50至1.65的dpf，并构成混纺纱(重量)的约70-96％。两种计量单位，例如dtex和旦在本文都采用，1dtex等同于0.9旦/丝(dpf)。每根纤维都用传统方法提供卷曲，一般表现为5-15卷/英寸(cpi)，并具有3/4至3英寸的长度。粘合用纤维构成毛层(重量)的约4-30％，可以是壳/核型(s/c)、并列型(s/s)或单组分型。它们可以由(共)聚酯、聚烯烃、聚烯烃/聚酯、聚酰胺/聚酰胺等获得。粘合用纤维的可用类型及它们的作用模式描述在例如“Nonwovens World”，三月/四月，1990，37页中。混纺纱中合适的粘合用纤维的初始dpf一般在2-15的范围，常用dpf为4。可用的粘合用纤维包括上述Scott、Pamm、Frankosky和Marcus的美国专利中公开的那些，和Harris等的US 4732809；Taniguchi等的US 4789592；Tomioka等的US 4500384；Hirose等的日本专利公开Kokai 57-210015(1982)中公开的那些；以及将在本文公开的烘箱温度内起作用的现有技术中已知的其他纤维。优选的粘合用纤维包括市售的“Melty 4080”(Unitika Co.，日本)和“ES”及“EA”聚烯烃(Chisso Corporation，日本)。
毛层两个表面上的固化树脂涂层可方便地构成最终粘合毛层重量的约10-30％，对于1.5至1.65dpf(1.83dtex)优选的是12-25％，树脂用量太少会降低耐洗性和密封率，而用量太多又会增加硬度并降低隔热效率。而且表面上树脂的用量不必取决于棉絮的基重，因此，对于较重的棉絮，总树脂加入量可以低至3％，甚至对于磨光的填充纤维毛层也是如此。对于完全干燥的(未磨光的)纤维，比采用磨光的填充纤维时需要的树脂更少。
如上所述，合适的密封树脂具有约0℃或更低的Tg。可用的树脂从市售的丙烯酸和乙烯基胶乳组合物获得，其中包括例如Rhoplex E-32(Rohm and Haas Co.)、TR-934(Rohm and Haas Co.)、X-4280J(Kanebo，日本)，B.F.Goodrich Co.的这类Hycar□胶乳组合物：26146、26171、26322、26083、26092、2671、26120、2679、26796，National Starch and Chemical Corporation的这类胶乳产品：NACRYLIC X 4445、NACRYLIC X 788-6007、NACRYLIC X 4483、NACRYLICX 4460、NACRYLIC X 4260、NACRYLIC X 4425、NACRYLIC X 4465、NACRYLIC 4401、NACRYLIC X 78-3990、NACRYLIC X 78-3997、NACRYLICX 78-3905、NACRYLIC X 4280、NACRYLIC 4441、NACRYLIC 78-614、X-LINK 2873、X-LINK 2849、X-LINK 78-6119、X-LINK 2893、X-LINK2833、X-LINK 78-6004、X-LINK 2813、RESYN 2375、DUR-O-SET E-230、DUR-O-SET E-669，以及可固化成Tg值为约0℃或更低的树脂的其他市售胶乳。某些这种市售树脂及其Tg值列于手册中，例如B.F.Goodrich，1989年出版，标题为“HYCAR□Acrylic Latexes”的手册，和National Starch and Chemical Corporation，标题为“Binders，Saturants，Laminants”的手册。由于密封树脂的Tg达到(比0℃)低得多的温度，这种树脂往往变得更粘稠。尽管这种树脂能给棉絮表面提供良好的密封和良好的耐洗涤性能，但密封树脂的粘着性会带来缝纫问题，需要降低缝纫速度，而这一般是不优选的。因此，根据本发明采用的密封树脂的Tg优选的为约0℃至约-30℃。
毛层的制备一般从传统的打开和混合聚酯填充纤维和粘合用纤维开始，然后梳理或扯松而制造织物。该织物可与来自梳棉机组或扯松机组的其他织物层压，或与其他织物交叉搭接和结合，形成非粘合的棉絮。然后用胶乳组合物在棉絮的一面或两面上喷涂该棉絮，并送入烘箱中固化树脂和粘合粘合用纤维。烘箱处理在150-190℃下进行2-5分钟，可如上所述方便地将毛层烘干三遍。然后将粘合的毛层穿过/绕过(优选至少两个)表面温度为200-220℃的热辊(可用两个以上轧辊)。棉絮的构型是S型抱辊，使其与轧辊最大接触。轧辊可根据最终希望的棉絮厚度具有2-10mm的间隙。在该处理中，如果希望，可仅加热一个轧辊，即使要密封毛层的两面，也可穿过/绕过轧辊第二次，以加热毛层反面，如果希望密封两面。轧辊上的接触时间为约8秒。这种热辊处理软化和分散树脂，保证树脂彻底和均匀地分布在毛层表面，防止纤维泄漏，并提供无瘤节的均匀表面，赋予舒适和美观的使用性能。毛层表现出前文指出的基重和厚度范围。
本发明的毛层表现出理想的耐热或隔热水平，通常作为CLO等级报导(见Hwang的US 4514455)。本发明的毛层理想地表现出至少约0.36CLO/oz/yd2，优选0.48CLO/oz/yd2或更高的CLO值。
可以理解的是，此处描述的组分和方法的选择应能提供本发明的毛层。必须小心选择确实能提供如此效果的结合。例如，纤维上的磨光剂和施加到毛层的胶乳的选择应能充分地粘合，使最终毛层表现出例如足够的耐洗涤性能。
测试方法
CLO等级如上述Hwang的专利中描述的那样获得。
本发明以及比较例的毛层的耐洗涤性等级(“WD”)通过ASTMD-4770-88的方法评价，饰条的尺寸为24英寸×24英寸，并根据8.6.1段进行的测量报导。本发明的毛层表现出3或更高(8.5段标度)的等级。
穿过面料的纤维泄漏或渗滤通过LeVan的US 4869771中描述的方法作为密封等级(“SR”)测量(除非另外指出，均指三次洗涤循环后)，密封等级(SR)为5时优异，密封等级(SR)为1时差。本发明的毛层表现出3或更高(三次洗涤循环后)的密封等级(SR)。在表1和3中，另外报导了在一次洗涤(1W)后以及三次洗涤(3W)后的密封值，并与未进行任何洗涤前(NEW)的初始值比较。
本发明毛层的柔软性或悬垂性根据German Industrial Standard53362 Cantilever(DIN 53362 Cantilever)测量，该方法确定和概括了棉絮在机器方向和横向机器方向上的弯曲韧性(“B”)；结合的结果涉及悬垂性和柔软性。棉絮测试试样针对这些测量切成25cm长和2.5cm宽，测试试样针对这些测量在机器方向(MD)和横向机器方向(XD)上切断。对每个测试试样称重并记为“W”。然后通过在平台上水平滑动测试试样，直到弯曲测试试样前端达到41度30秒的角度，确定弯曲长度(“LU”)。然后进行以下计算：
B＝F1(LU/2)3
其中B＝弯曲韧度，cN/cm2
LU＝弯曲长度，cm
F1＝9.8×(W/L)
W＝样品试样的重量，g
L＝试样样品长度，cm
本发明的毛层表现出80cN/cm2或更低的弯曲韧度(“B”是由该毛层的MD和XD试样测定的值的和)，优选的是较低的弯曲韧度。
实施例
本发明在以下实施例中进一步说明，除非另外指出，所有份和百分比均为重量的，计算基于“BW”(基重，即仅基于聚酯填充纤维和粘合用纤维的量，即不包括表面喷涂添加以改善密封的树脂)。
实施例1
将(1)1.5dpf(1.66dtex)、实心、圆形截面、51mm切断长度、带有聚烯化氧磨光剂的聚对苯二甲酸乙二酯短纤维，(2)42.5％、1.5dpf、实心、圆形截面、51mm切断长度、无磨光剂的聚对苯二甲酸乙二酯短纤维和(3)15％(重量)的“Melty 4080”粘合用纤维(4dpf，2英寸切断长度)的混纺纱的82磅试样通过传统的机械开棉机开松并喂入给料斗。在该混纺纱中，粘合用纤维已在开松和梳理前与填充用纤维结合。
将混合纤维送入两个分开的扯松机(garnet)，分别制备约60英寸宽和约1oz/yd2(34g/m2)基重的连续织物。每种织物穿过分开的交叉搭接机，制备交叉搭接的毛层，并置于速度约为8yd/min(7.3m/min)的传送带上。传送带收集并结合两种交叉搭接的毛层，形成最终的基重约为2.7oz/yd2(90g/m2)的多层毛层。在连续运行中，该毛层通入喷射区，将Kanebo的X-4280J胶乳(Tg为-4℃)施加到毛层的上表面，然后通入3路径烘箱(施加足够的胶乳，在毛层上提供9％(重量)的固化树脂)。该路径为150℃，在烘箱中停留约1分钟期间固化树脂并活化粘合用纤维。毛层离开烘箱后，反转，在毛层顶面(“新”)施加胶乳，毛层通过第二传送带送入烘箱的第二路径(170℃)，固化树脂并活化粘合用纤维(在毛层的该表面上得到9％(重量)的树脂，制成共18％(重量)树脂的毛层)。将棉絮送入烘箱的第三路径(170℃)，另外再加热毛层几分钟(共加热3分钟)。
粘合的毛层通过呈S形抱辊构型的一对热轧辊(辊表面为220℃)，与辊的接触时间约8秒钟；辊分开6mm。该棉絮(18％树脂，15％粘合用纤维)具有3.33oz/yd2的重量、0.37英寸的厚度，表现出的洗涤耐久性(WD)等级为4，密封等级(SR)为5，总弯曲韧度(B)为37.8cN/cm2。测量所制备毛层的应力/应变性能示于下表2和图2中。该附图比较了本发明热轧辊方法的不同温度、时间和辊间隙的效果。在该附图中，同样的试样装载和卸载四次，得到四条曲线。该毛层的其他性能如下表1中的项目1所示。
比较例1
在该比较例中，由(1)1.5dpf(1.66dtex)、实心、圆形截面、带有硅氧烷磨光剂的聚对苯二甲酸乙二酯短纤维，(2)27％、1.65dpf、实心、圆形截面、51mm切断长度、无磨光剂的聚对苯二甲酸乙二酯短纤维和(3)18％(重量)的“Melty 4080”粘合用纤维的混纺纱制备另一种毛层。同样，如实施例1所示，在该混纺纱中，粘合用纤维已在开松和梳理前与填充纤维结合。
用与上述实施例1中相同的扯松方法，以及Tg低于约0℃的相同的密封树脂(Kanebo的X-4280J，Tg为-4℃)制备毛层。用于制备该棉絮的方法与实施例1相同，不同的是热轧辊过程。在该比较例中，粘合的毛层通过呈S形抱辊构型的一对热轧辊(辊表面为200℃)，与辊的接触时间约12秒钟；辊分开2mm。将毛层压紧到约一半的原始厚度，并卷成一卷。测量这样制备的毛层的应力/应变性能示于图1。同样，在该附图中，同样的试样装载和卸载四次，得到四条曲线。该毛层的其他性能如下表1中的项目2所示。
表1
项目 ％粘合用纤维 ％树脂   重量(oz/yd2)    厚度(英寸)                           弯曲韧度
    WD     SR     MD     CD     合计
1 15 18     3.33     0.37     4     5     18.5     19.3     37.8
2 18 18     3.07     0.30     4     5     11.7     11.4     23.2

Claims (10)

1.一种粘合毛层，包含与粘合用纤维紧密混合的聚酯填充纤维的混纺纱，其中毛层具有3磅负载下大于35％的拉伸应变。
2.权利要求1的粘合毛层，其中毛层与低熔点粘合剂材料以占毛层重量约2-25％(重量)的补足量完全粘合。
3.权利要求1的粘合毛层，其中聚酯填充纤维占毛层的约70-96％(重量)，粘合用纤维占毛层的约4-30％(重量)。
4.权利要求1的粘合毛层，其中毛层的上表面和下表面用玻璃化转变温度(Tg)为约0℃或更低的树脂密封，用量占毛层的约10-30％(重量)。
5.制备粘合毛层的方法，包括形成聚酯填充纤维与粘合用纤维的混纺纱，用该混纺纱制备连续的毛层，所述毛层具有上表面和下表面，将毛层推过至少一个喷涂区，从而用树脂喷涂毛层的两个表面，在烘箱中加热喷涂的毛层，固化树脂并软化粘合剂材料，然后在200-220℃热辊轧加热的毛层约8秒，实现毛层表面上树脂与纤维间的紧密接触，并冷却已辊轧的毛层。
6.权利要求5的方法，其中热辊轧通过S形抱辊构型的热轧辊进行。
7.权利要求5的方法，其中轧辊具有2-10mm的间隙。
8.权利要求5的方法，其中聚酯填充纤维占毛层的约70-96％(重量)，粘合用纤维占毛层的约4-30％(重量)。
9.权利要求5的方法，其中树脂占包括该树脂在内的已喷涂毛层的约10-300％(重量)。
10.权利要求4的方法，其中所选择的树脂在固化后提供玻璃化转变温度(Tg)约0℃或更低的固化树脂。
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CN107685457B (zh) * 2016-08-05 2020-07-17 菲西纤维合成有限公司 填充带元件及其制造方法

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WO2003057962A3 (en) 2003-10-16
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KR20040101994A (ko) 2004-12-03
TW200301792A (en) 2003-07-16
US20030232552A1 (en) 2003-12-18

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