CN1756640A - 三维膜及其制造方法 - Google Patents

三维膜及其制造方法 Download PDF

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Publication number
CN1756640A
CN1756640A CNA2004800057019A CN200480005701A CN1756640A CN 1756640 A CN1756640 A CN 1756640A CN A2004800057019 A CNA2004800057019 A CN A2004800057019A CN 200480005701 A CN200480005701 A CN 200480005701A CN 1756640 A CN1756640 A CN 1756640A
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film
molten polymer
supporting course
fabric
holding device
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约翰·豪斯勒尔
拉尔夫·Ⅲ·穆迪
尼克·卡特
罗伯特·戴尔
詹姆斯·谢弗
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PARRIMOE GROUP CO Ltd
Avintiv Specialty Materials Inc
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PARRIMOE GROUP CO Ltd
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Abstract

一种通过把聚合体融熔物(15)直接挤压到三维表面上，从而制造带三维图案的膜的方法，其中，至少一层连续挤压的无纺细丝被直接沉积在三维图案转印装置的多孔表面上。

Description

三维膜及其制造方法
技术领域
本发明通常涉及一种带有三维图案的织物和膜的制造方法，并且，尤其涉及一种通过把聚合体熔融物直接挤压到三维表面上而制造带图案的膜的方法。
背景技术
膜被广泛应用在其制造品质能够被有利地加以利用的应用领域。膜产品构造中所选用的热塑性聚合体，聚合体膜(处于熔化状态或一体化结构中)所选择的处理，以及膜被一体化成为有用结构时所选用的多种机构通常是可变的，以对合成聚合体膜产品的性能进行调节和改变。
由热塑性聚合体形成有限厚度膜是众所周知的操作。热塑性聚合体膜能够通过下面两种方法得以形成，即，通过把一些熔融态聚合体散布到具有所期望的终端产品的尺寸的型板中，称为热加工成型膜或注射成型膜，或通过型板对熔融态聚合体不断地施加压力，称为挤压膜。挤压的热塑性聚合体膜能够被形成为使膜作为完整的产品被冷却然后晾干，或者，挤压的热塑性聚合体膜能够被直接分配到衬底材料上以形成具有衬底层和膜层双重性能的复合材料。适当的衬底材料的例子包括其它膜、聚合体薄板或金属薄板，以及机织织物或无纺织物。
近来，人们开始希望把三维图案加入到聚合体膜中。网状膜是一种可提供某种程度三维性的膜，其中，这种膜的制造过程在申请人为Kelly的美国专利No.4,381,326中被公开。无纺织物结构的网状膜表面由加入到膜中造成网状孔的一系列凹陷构成。膜内的凹陷为最终的膜提供三维艺术特性。
聚合体膜已经被证明对于多种医学、卫生学和工业应用特别适合，因为这种结构允许低成本效益、一次性使用。由于膜的物理特性和特征能够被选择成适于特殊医学应用的需要，所以，这种材料在外科用帷帘、医用擦布和类似物方面的使用已经变得日益广泛。此外，膜的叠层结构能够用于上述应用，其中，膜与无纺的或附加的膜叠层相结合。
需要一种制造具有较高产品艺术特性和较高产品性能的带三维图案的聚合体膜的方法。此外，也需要一种制造低成本而高速度(能够达到的速度至少为300英尺/分钟)的三维膜的方法。
无纺织物被广泛应用在其制造品质能够被有利地加以利用的应用领域。在纤维织物成分的构造中所选的热塑性聚合体、纤维成分(处于纤维状态或一体化结构中)所选择的处理、以及纤维成分被一体化成为有用的织物时所选用的多种机构通常都是可变的，以对合成无纺织物的性能进行调节和改变。
在这些方法当中或这些方法本身，被称为“纺粘”的连续细丝衬底材料是相对多孔的，并通常需要附加的成分，以便达到所需要的屏障性能。通常，通过静压头或视野测量法(porimetry)进行测量的屏障性能可通过微米尺度细丝的屏障“熔喷”层的应用得到增强，细丝被高速气流拉伸和分段，并且在纺粘衬底材料上沉积成自退火块。通常，这种熔喷层显示出非常低的多孔性，增强了由纺粘和后续熔喷层形成的复合织物的屏障性能。这种无纺结构已经被用作屏障织物，如申请人为Brock等的美国专利No.4,041,203中公开的那样，所公开的内容在此引作参考。
最近，通过对织物使用三维图案转印装置，把图像或图案加入到无纺织物中的技术已经得到发展。这种三维图案转印装置在美国专利No.5,098,764中被公开，该专利加入在这里引作参考；使用这种图案转印装置为织物提供了令人满意的增强的物理特性以及艺术的美丽外观。
本发明期望提出一种制造由连续形成的细丝构成的无纺织物的方法，其中，熔融态聚合体被直接被挤压到三维图案转印装置的表面上。
发明内容
本发明的目的在于提供一种制造具有三维图案的膜的方法，并且，尤其是提供一种通过把聚合体融熔物直接挤压到三维表面上而制造带图案的膜的方法。
根据本发明，热塑性膜被先放到多孔表面上，并受到水力能量冲击，从而把图像或图案加入到膜中。在一优选实施例中，多孔表面是三维图案转印装置。三维图案转印装置(ITD)通常根据申请人为Drelich等的美国专利No.5,098,764中所教示的方法进行构造，该专利加入在这里引作参考。
膜衬底可以是多种烯属热塑性聚合体，包括、但不限定于等规聚丙烯、线性低密度聚乙烯、低密度聚乙烯、高密度聚乙烯、非晶聚丙烯、聚丁烯、乙烯/乙酸乙烯酯共聚物、乙烯/丙烯酸乙酯共聚物、乙烯/丙烯酸甲酯共聚物、聚苯乙烯、以及它们的组合。
在第一实施例中，聚合体膜被直接挤压到ITD上，其中，所述ITD包括支承真空辊。所述支承真空辊提供必要量的吸力，从而在熔融态膜上形成孔，以及把三维表面加入到有孔的膜中。然后，所述膜可以用可增强性能的化学物质进行处理，例如疏水或亲水的添加剂，或可增强艺术性的化学物质，例如热敏色差添加剂。
在第二实施例中，采用了至少一个支承衬底，其中，所述聚合体膜被挤压到所述支承衬底上。适当的支承衬底包括各种多孔人造短纤维网或连续细丝网，其在构成上可以是平面的或非平面的，以及，可以是有孔的或无孔的。根据本发明，所述熔融态膜被挤压到所述支承衬底上，所述支承衬底被安置在所述ITD上，并通过所述真空辊这样的机械装置与纤维网络或细丝网络成为一体。所述膜与所述支承衬底的粘附力由于所述膜与所述支承衬底成为一体而得到极大提高。
在本发明的范围内，所述膜和/或所述支承衬底在加入图案之后还要进行多种后处理。例如，膜可以被拉伸，从而通过所述真空辊ITD表面开始产生微孔裂缝，可以在平面或非平面的ITD表面上进行水刺法，可以进行压花，和/或通过本领域技术人员所知的多种机构最终完成。
本发明还提供一种制造带三维图案的无纺织物的方法，所述织物包括至少一层连续挤压的无纺细丝，其被直接沉积在三维图案转印装置的所述多孔表面上。
根据本发明，所述无纺织物由至少一层连续细丝网构成。此外，所述织物可以包含至少一层支承衬底。适当的支承衬底包括各种多孔人造短纤维网或连续细丝网，其在构成上可以是平面的或非平面的，以及，可以是有孔的或无孔的。
所述连续细丝网的热塑性聚合体可以选自聚烯烃、聚酰胺和聚酯的组中进行选择，其中，聚烯烃可选自聚丙烯、聚乙烯和它们的组合。在本发明的范围内，连续细丝网或多个连续细丝网可以由相同的或不同的热塑性聚合体构成。此外，连续细丝可以包括单一组分的、双组分的和/或多组分的剖面(profiles)，以及可改变性能的添加剂和它们的混合物。
本发明的其他特点和优点将在下面的详细叙述、附图和权利要求书中进行说明。
附图说明
图1是根据本发明的原理、用于生产膜或带图案的连续细丝织物的加工装置的示意图；
图2是根据本发明的原理、用于生产带图案的膜的三维图案转印装置的示意图；
图3是根据本发明的原理制造的带图案的膜的显微照片；
图4是根据本发明的原理制造的图3的带图案的膜的另一显微照片；
图5是根据本发明的原理制造的带图案的膜的显微照片；
图6是根据本发明的原理制造的带图案的膜叠层的显微照片；以及
图7是根据本发明的原理制造的图6的带图案的膜叠层的另一显微照片。
具体实施方式
虽然本发明可以有多种形式的实施例，在附图中被示出并将在下文中进行描述的是本发明现有的优选实施例，需要理解的是，本文所公开的内容只作为本发明的示例，不希望把本发明限定于所示出的特定实施例。
图1描述的是有代表性的直接挤压膜过程。混合和配料系统1包括至少两个用于聚合体碎片的料斗式装载器和混合料斗。两个料斗式装载器内部的多速螺丝钻把预定量的聚合体碎片和添加剂颗粒转移到混合料斗。混合料斗包括混合推进器，以促进均匀混合。以上所述的基本容积系统是对混合区域系统的最低要求。
将聚合体碎片和添加剂颗粒混合物装入由Wellex公司提供的多区域挤压器2中。在这个特定系统中，采用一带有2英寸水套孔的五区域挤压器，其长度和直径的比率为24∶1。
经过多区域挤压器2的混合和挤压，聚合体混合物经过筛选转换器3被输送通过加热的聚合体管7，其中，使用了具有不同筛选网孔的多孔板，以留住固体或半熔融态聚合体碎片，以及其他肉眼可见的碎片。然后，混合的聚合体被装入熔化泵5中。
熔化泵5的操作与多区域挤压器2的动态反馈相关，以保持期望的压力水平。采用齿轮型熔化泵，以便通过改变挤压器的速度对由压力设定窗口带来的偏差进行补偿，从而对压力水平做出响应。
然后，被计量和混合的聚合体混合物进入组合区域6。组合区域允许挤压出多膜层，这些膜层可以是相同成分，也可以如上所述由不同系统供料。组合区域6通过附加的加热的聚合体管7直接通到型板本体9内。
在本系统中使用的特定型板本体9是37英寸宽的EDI自动型板，带有由EDI提供的模栓控制(die bolt control)。型板本体9被安置在上方，使得挤压出的熔融态膜15被沉积在铸造台14内的夹点上，在压送辊10和铸造辊11之间。
图2描述了用于在生产过程中把三维特征加入到膜中的装置。图2包括图像和图案鼓24，其包括用于产生膜衬底上的图像和图案的三维图案转印装置(ITD)。
在第一实施例中，聚合体膜被直接挤压到ITD上，其中，ITD由支承真空辊构成。真空辊提供必要量的力，从而在熔融态膜上形成孔，以及把三维表面加入到有孔的膜中。然后，膜可以用可增强性能的化学物质进行处理，例如疏水或亲水的添加剂，或可增强艺术性的化学物质，例如热敏色差添加剂。图3-图5示出了根据本发明的原理制造的带三维图案的膜。
在第二实施例中，至少一个支承层被安置在ITD上，其中，聚合体膜被挤压到支承层上。适当的支承层包括各种多孔人造短纤维网或连续细丝网，其在形式上可以是平面的或非平面的，以及，可以是有孔的或无孔的。根据本发明，熔融态膜被挤压到安置在ITD上的支承层上，并通过真空辊这样的机械装置与纤维网络或细丝网络成为一体。膜与支承层的粘附力由于膜与支承层成为一体而得到极大提高。图6和图7示例出了根据本发明的原理制造的带三维图案的膜叠层。
本发明的膜衬底可以是多种烯属热塑性聚合体，包括、但不限定于等规聚丙烯、线性低密度聚乙烯、低密度聚乙烯、高密度聚乙烯、非晶态聚丙烯、聚丁烯、乙烯/乙酸乙烯酯共聚物、乙烯/丙烯酸乙酯共聚物、乙烯/丙烯酸甲酯共聚物、聚苯乙烯、以及它们的组合。
带图案的膜或膜叠层能够被用于多种卫生学、医学和工业应用。适合的最终用途包括、但不限定于外科用帷帘、外科用罩衣、医用擦布和类似物。此外，本发明的膜适用于多种卫生学的最终用途，其中，膜能够被用作吸附物品的组成成分，例如女性护理产品、失禁装置、尿布和类似物。
纺粘过程涉及提供熔融态聚合体，然后，熔融态聚合体在压力下被挤压通过被称为喷丝板或型板(die)的板内的大量的孔。所得到的连续细丝被淬火并通过多种方法中的任何一种方法被拉伸，例如槽拉伸系统、衰减器枪或导丝辊。连续细丝在移动的多孔表面上例如线网传送带上被集中成为松散的网。当为了形成多层织物而使用多个喷丝板时，后续的网在前面形成的网的最上层表面上被集中。然后，所述网通常通过涉及热和压力的方法被至少短暂固定，例如通过加热点结合法。使用这种结合方法，网或网的各层在两个热的金属辊之间经过，其中一个金属辊具有要加入并达到点结合的期望程度的压花图案，通常整个表面区域的大约百分之十到百分之四十被这样结合。
连续细丝纺粘层或多层连续细丝纺粘层的热塑性聚合体选自带有乙烯-碳氟共聚物，尤其是乙烯-氯三氟乙烯(ECTFE)的聚烯烃、聚酯、聚酰胺和卤代聚合物，其中，聚烯烃选自聚丙烯、聚乙烯以及它们的组合。在本发明的范围内，连续细丝网或多个连续细丝网可以由相同的或不同的热塑性聚合体构成。此外，连续细丝可以包括单一组分的、双组分的和/或多组分的轮廓，以及可改变性能的添加剂和它们的混合物。
此外，连续细丝网可以通过熔喷过程由不连续的细丝网构成。熔喷过程是与用于形成无纺织物层的纺粘过程相关的方法，其中，熔融态聚合体在压力下被挤压通过喷丝板或型板内的孔。当其从型板中脱出时，高速空气冲击其上并产生细丝。这个步骤的能量使得所形成细丝的直径被大大缩减，而且细丝被分段，从而产生限定长度的微纤维。这个过程与纺粘过程不同，在纺粘过程中连续的细丝被保存。形成单层或多层织物的过程是连续的，即，这个过程的步骤，从细丝被挤压出以形成第一层和后续层，到通过各层的合并以形成复合织物，是不中断的。在本发明的范围内，还包括把熔喷屏障层与附加层并置，附加层选自无纺织物、机织织物、膜和它们的组合。
毫微但尼尔细丝也可以合并到其中。适当的毫微但尼尔的连续细丝层能够通过下面两种方法形成，即，直接纺织出毫微但尼尔细丝，或者在沉积在衬底层上之前形成一种可被分成毫微但尼尔细丝的多成分细丝。两个美国专利No.5,678,379和No.6,114,017都加入在这里引作参考，可实行的直接纺织过程作为示例用于支持本专利。两个美国专利No.5,678,379和No.6,114,017都加入在这里引作参考，可实行的直接纺织过程作为示例用于支持本专利。
图1描述了在生产过程中用于把三维特征加入到连续细丝网或叠层中的装置。图1包括图像和图案鼓24，其包括用于在连续细丝衬底上产生图像和图案的三维图案转印装置(ITD)。
根据本发明，至少一层连续挤压的无纺细丝被直接沉积在三维图案转印装置的多孔表面上。ITD可以可选择地包括支承真空辊。真空辊设置抽吸部，从而在ITD内通过大量的孔拉出细丝。无纺织物包括至少一层连续细丝网。此外，织物可以包括至少一个支承衬底。适当的支承衬底包括各种多孔人造短纤维网或连续细丝网，其可以是平面的或非平面的，以及，可以是有孔的或无孔的。
在挤压之前，熔融态聚合体可以同例如热稳定剂、UV、抗静电剂、着色剂和成核剂的各种可增强性能的熔融添加剂进行混合。尤其可以混合成核剂，以产生更加稳定的纺织过程，并且，在同等的工艺条件下，能够使强度大大增加。织物形成之后，可以使用其他可增强性能的添加剂对织物进行处理。
带有图案的无纺织物可以应用在多种卫生学的、医学的和工业应用中。合适的最终用途包括、但不限定于外科用帷帘、外科用罩衣、医用擦布，还用于多种女性护理产品、失禁装置、尿布以及类似物的吸附物品的组成成分。此外，所述织物可以用在工业应用中，包括用于散热器护栅、草坪设备和汽车的户外保护性覆盖物，或用作蓄电池隔板、过滤装置或工业保护性服装。
由前述可以看到，在不背离本发明精神和范围的情况下，可以进行多种修改和变更。需要明白的是，这里示出的特殊实施例不希望或不应被推断为受到限定。通过附加的权利要求书，本文所公开的内容希望覆盖在权利要求书范围内的所有这种修改。

Claims (10)

1.一种用于制造带三维图案的膜的方法，包括下列步骤：
a.提供熔融态聚合体；
b.提供多孔表面；以及
c.把所述熔融态聚合体挤压到用于形成带图案的膜的所述多孔表面上。
2.根据权利要求1所述的制造带三维图案的膜的方法，其中，所述多孔表面是三维图案转印装置。
3.一种用于制造带三维图案的膜的方法，包括下列步骤：
a.提供熔融态聚合体；
b.提供多孔表面；
c.提供保持装置；以及
d.把所述熔融态聚合体挤压到所述多孔表面上，形成膜，其中，所述保持装置可穿通多个用于形成多孔的小孔而拉伸并形成所述带图案的膜。
4.根据权利要求3所述的制造带三维图案的膜的方法，其中，所述保持装置为真空装置。
5.一种用于制造带三维图案的膜的方法，包括下列步骤：
a.提供支承层；
b.提供熔融态聚合体；
c.提供多孔表面；
e.提供保持装置；
f.把所述支承层安置到所述多孔表面上；以及
g.把所述熔融态聚合体挤压到所述支承层上，形成膜叠层，其中，所述保持装置通过可造成带图案的膜叠层效果的多个孔拉出支承层和熔融态聚合体。
6.根据权利要求5所述的制造带三维图案的膜的方法，其中，所述支承层选自纤维的或细丝的无纺织物、机织织物、膜和它们的组合。
7.一种用于制造带三维图案的连续细丝无纺织物的方法，包括下列步骤：
a.提供熔融态聚合体；
b.提供三维图案转印装置；以及
c.把所述熔融态聚合体挤压到用于形成带图案的织物的所述三维图案转印装置上。
8.一种用于制造带三维图案的连续细丝无纺织物的方法，包括下列步骤：
a.提供支承层；
b.提供熔融态聚合体；
c.提供三维图案转印装置；
b.提供保持装置；
c.把所述支承层安置到所述三维图案转印装置上，以及
d.把所述熔融态聚合体挤压到所述支承层上，形成叠层，其中，所述保持装置通过可造成带图案的叠层效果的所述三维图案转印装置内的多个孔，拉出所述支承层和所述熔融态聚合体。
9.根据权利要求8所述的制造带三维图案的连续细丝无纺织物的方法，其中，所述保持装置为真空装置。
10.根据权利要求9所述的制造带三维图案的连续细丝无纺织物的方法，其中，所述支承层选自纤维的或细丝的无纺织物、纺织织物、膜和它们的组合。
CNA2004800057019A 2003-01-22 2004-01-22 三维膜及其制造方法 Pending CN1756640A (zh)

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