CN1761786B - 图案粘接的非织造织物 - Google Patents

图案粘接的非织造织物 Download PDF

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CN1761786B
CN1761786B CN2004800077262A CN200480007726A CN1761786B CN 1761786 B CN1761786 B CN 1761786B CN 2004800077262 A CN2004800077262 A CN 2004800077262A CN 200480007726 A CN200480007726 A CN 200480007726A CN 1761786 B CN1761786 B CN 1761786B
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CN1761786A (zh
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S·E·马蒙
E·N·鲁迪西尔
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Abstract

一种图案粘接的非织造织物，其包括具有几何学上重复的和视觉上可辨别的粘结点基础图案的非织造纤维纤网，所述粘结点基础图案具有至少一个形状，至少一个区域由该形状定义，以及引入到所述基础图案中的第二个视觉上可区别的粘接图案。

Description

图案粘接的非织造织物
技术领域
本发明涉及图案粘接的非织造织物，其具有在第一粘接图案内粘接的第二图案。
背景技术
许多生产粘接的非织造织物的方法在本领域中是已知的。特别地，已知通过使非织造织物纤网通过加热的压延辊之间的钳口进行加热和施加压力，在非织造织物纤网的限制区域进行粘接，所述压延辊之一或两者可以在其表面上具有突出部分和凹陷部分的图案。在这种粘结过程中，取决于构成非织造织物纤网的纤维的类型，粘接区域可以自发形成，即纤网纤维至少在图案区域被熔融熔合，或者借助于粘合剂形成。
本领域中已知，粘接的非织造织物的物理性能与粘接的程度和图案有关。通常，可以施加大的粘接区域，以为非织造织物提供尺寸稳定性，但是柔顺性和孔隙度将降低，并且可以使用几何学上重复的粘接图案，以提供各向同性的尺寸稳定性。然而，不同应用所具有的不同性能要求可能需要使用随机的或者不规则的图案。
如果有一种方法，能使用视觉上可区别的粘接图案，以便识别织物，而不显著地改变织物的特性，例如表面耐磨性、纤网强度和尺寸稳定性，这将是有益的。Sayovitz等的美国专利号6,093,665公开了粘接区域的几何学上重复的基础图案，其中除去了某些粘接区域的规则图案，以产生视觉上可区别的粘接图案。然而，不存在某些粘接区域可能导致织物具有较少的结合，导致薄弱的织物和较多的织物绒毛。如果将若干邻近的粘结点除去，甚至将出现织物的较少结合，导致甚至较薄弱的织物和甚至较多的织物绒毛。因此，使图案粘接非织造织物保持粘结点的数目，以保持织物强度和织物起毛水平，同时充分地改变粘接图案，以产生视觉上可区别的第二结合图案，这将是所希望的。
发明内容
本发明的一个实施方案是图案粘接的非织造织物，其包括具有几何学上重复的和视觉上可辨别的粘结点基础图案的非织造纤维纤网，所述粘结点基础图案具有至少一个形状，至少一个区域由该形状定义，以及引入到所述基础图案中的第二个视觉上可区别的粘接图案。
本发明提供了非织造织物，其具有一个或多个视觉上可认识的并且可辨别的第二个粘接图案。视觉上可识别的第二个粘接图案作为非织造织物的鉴别机制是高度适合的，而不会显著地牺牲有益的织物性能，例如表面耐磨性、纤网强度和尺寸稳定性。因此，本发明可用于产生识别标志，用以表示各种来源、非织造织物的特性和性能，例如重量、组成、疏水性、亲水性等等，并且表示每种织物的指定用途，例如医疗应用，例如医疗或者外科长袍或者布帘，环境应用，例如防护服装制品，包括跳伞服、工作服、手套、实验工作服等等。此外，该粘接图案能够起排列或者分界点的作用，有助于从这类非织造织物组装或者生产制品的制造过程，所述制品例如是服装、尿布、防护服装等等。
本发明可用于非织造织物，其具有几何学上重复的基础粘接图案。基础粘接图案的粘结点的尺寸、形状、排列和样式可以在很大程度上变化，只要通过基础粘结点产生的图案是有规则的和重复的。取决于非织造织物的不同用途所要求的美学效果和物理性能，每个粘结点的尺寸和/或形状以及在重复的粘结图案中邻近的粘结点之间的距离可以变化。如上所述，织物的总粘结面积和粘结点的尺寸为非织造织物提供了不同的性能。例如，高度粘结的区域倾向于提供尺寸稳定性，而较少粘结的区域提供柔顺性、悬垂性和孔隙度。在各种基础粘结图案中，尤其有用的图案是均匀间隔的重复粘结图案，其粘结点具有均一的形状和尺寸。
本发明涉及图案粘结的非织造织物，其具有引入基础粘结图案中的视觉上可分辨的第二个粘结图案，其可用于识别织物，而不显著地改变织物的特性，例如表面耐磨性、纤网强度和尺寸稳定性。
这通过使用一种图案粘结非织造织物来获得，所述织物具有几何学上重复的并且视觉上可辨别的粘结点的基础粘结图案，其具有至少一种形状，至少一个区域由该形状限定，并且其中某些基础粘结点被不同于基础粘结点的粘结点替换，例如通过包括具有不同面积的相同形状粘结点，不同形状粘结点和相同面积，或者具有不同面积的不同形状粘结点来进行替换，以提供引入几何学的基础粘结图案中的不同的和视觉上可分辨的第二个粘结图案。在本发明的一个实施方案中，第二图案粘结点具有与基础图案粘结点相同的形状，具有不同的面积。
该基础粘结图案由粘结点组成，所述粘结点具有处于特定排列中的形状和尺寸的组合。这种图案可以变化，只要通过粘结点产生的图案是有规则的、重复的和视觉上可辨别的。
图案粘结非织造织物的粘结点(总的粘结面积)覆盖非织造织物表面的大约6％到大约50％、优选大约10％到大约40％。可识别的和基础粘结点分别地覆盖非织造织物表面的大约3％到大约47％、优选大约5％到大约35％。粘结过大的面积可能导致硬的、刚性的织物，而粘结过小的面积可能导致薄弱的织物。图案粘结非织造织物的粘结点密度为每平方厘米大约8到大约128个粘结点、优选每平方厘米大约12到大约64个粘结点。任何单个的粘结点的面积小于大约0.3平方厘米、优选小于大约0.2平方厘米。单个的可识别的第二粘结点的面积为单个的基础粘结点的面积的大约25％到大约300％、优选大约40％到大约250％。
能够使用许多形状的粘结点，包括，但不局限于，圆形、椭圆形、正方形、菱形、线和十字形。
适合于生产本发明非织造织物的非织造织物纤网是任何已知的非织造织物纤网，其可以进行图案粘结，包括，但是不局限于，从切断纤维、连续纤维或者其混合物制造的纤维纤网，并且所述纤维可以是天然的、合成的或者其混合物。此外，适当的纤维可以是卷曲的或者未卷曲的，并且合成纤维可以是单组分纤维或者多组分复合纤维，例如双组分并列式或者皮-芯式纤维。
适合的天然纤维的例子包括纤维素纤维、棉花、黄麻、纸浆、羊毛等等。当使用天然纤维纤网时，可以将纤维或者粉末形式的粘结剂或者粘合剂喷涂到纤网的纤维上，或者与纤网的纤维混合，以将构分纤维固定，或者进行施加以形成粘结区域。适合的粘结剂的例子包括乙烯乙酸乙烯酯、丙烯酸酯粘合剂、丙烯酸系粘合剂、胶乳等等。
适合于本发明的合成纤维是由已知能形成纤维的合成的热塑性聚合物生产的，所述热塑性聚合物包括，但是不局限于，聚烯烃，例如聚乙烯、聚丙烯、聚丁烯等等；聚酰胺，例如尼龙6、尼龙6/6、尼龙10、尼龙12等等；聚酯，例如聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯等等；聚碳酸酯；聚苯乙烯；热塑性弹性体；乙烯基聚合物；聚氨酯；以及其共混物和共聚物。另外的适合的纤维包括玻璃纤维、碳纤维、半合成纤维，例如粘胶人造丝纤维和醋酸纤维素纤维等等。按照每种聚合物的已知性能，合成的和半合成的聚合物纤维能够自发粘结，即纤网纤维在加热和压力下被熔融-熔合，或者使用粘结剂。例如，聚烯烃、聚酰胺、聚酯、乙烯基聚合物等等的纤维纤网能够自发粘结，而玻璃纤维和/或碳纤维的纤网要求使用粘结剂。
适合的切断纤维纤网可以通过使用羊毛或者棉花梳理机或者弹毛机梳理大量切断纤维来制备，并且适合的连续纤维纤网可以通过普通的从熔喷纤维和/或纺粘纤维生产纤网的空气敷设方法制备。在此使用的术语“熔喷纤维”表示通过以下过程形成的纤维：将熔融热塑性聚合物通过许多细的、通常圆形的模头毛细管挤出，成为熔融线状物或者长丝，进入高速气体流，该高速气体流将熔融热塑性聚合物的长丝拉细，以减小其直径。通常，熔喷纤维具有最高大约10微米的平均纤维直径。在形成纤维之后，它们被高速气体流携带并且沉积在聚集表面上，形成随机分散的熔喷纤维的纤网。这类方法公开于例如Butin的美国专利号3,849,241中。在此使用的术语“纺粘纤维”指小直径纤维，其通过将熔融热塑性聚合物作为长丝从喷丝板的许多细的、通常圆形的毛细管挤出而形成。挤出的长丝被随后借助于eductive或者其他众所周知的拉伸机理迅速地拉伸。得到的纤维通常具有与熔喷纤维相比较大的平均直径。通常，纺粘纤维具有的平均直径超过12微米，并且最高大约55微米。纺粘纤网的生产公开于例如Appe1等的美国专利号4,340,563和Dorschner等的3,692,618。
本发明的织物进一步包括两个或多个上述非织造织物纤网的层压制品以及非织造织物纤网和薄膜的层压制品。包含多个纤网的层压制品的有用的实例是在层压制品的外侧具有纺粘纤网的夹层结构，以提供强度，在层压制品内部具有一个或多个熔喷纤网，它们在所述纺粘纤网之间，以提供各种过滤能力。本领域中已知的各种薄膜，尤其是热塑性薄膜，可以粘结到非织造织物纤网上，这可以自发地或者使用粘结剂来进行，以提供附加的阻隔性能，例如水分、化学品以及香气的阻隔性能。有用的热塑性薄膜可以由以下材料生产，例如聚烯烃，例如聚乙烯、聚丙烯、聚丁烯等等；聚酰胺，例如尼龙6、尼龙6/6、尼龙10、尼龙12等等；聚酯，例如聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯等等；聚碳酸酯；聚苯乙烯；热塑性弹性体；乙烯基聚合物；聚氨酯；以及其共混物和共聚物。
本发明可以使用本领域已知的任何图案粘结形成方法来实施。优选，粘结图案使用普通的砑光粘结过程施加。通常，砑光粘结过程使用图案化辊子对，通过使纤网通过辊子之间的钳口而在纤网的限制区域上进行粘结，所述辊子的至少一个被加热并且在其表面上具有突出部分和凹陷部分的图案。可选择地，粘结图案可以通过使纤网通过由超声波喇叭和砧座形成的间隙来施加。所述砧座可以是辊子的形式，其具有鼓起部分，以提供图案粘合织物。
图案辊子的温度和钳口压力应该被选择，使得能够进行粘结，而不具有不希望的伴随的副作用，例如过度收缩或者纤网降解。虽然适当的辊子温度和钳口压力通常在一定程度上受纤网速度、纤网基础重量、纤维特性、是否存在粘合剂等等参数的影响，但是优选辊子温度处于组分纤维聚合物的软化和晶体熔融温度之间，并且鼓起点上的钳口压力(销钉(pin)压力)为大约7MPa到大约350MPa。可能不希望将纤网暴露于纤维发生大范围熔融的温度。例如，对于聚丙烯纤网，优选的图案粘结设定是大约127℃到160℃的辊子温度，和大约7MPa到大约700MPa的销钉压力。然而，当不同于熔融-粘合剂的粘合剂被用于固定和形成本发明粘结图案时，不需要显著的加热和压力，因为仅仅需要最小的销钉压力以将纤维保持在适当的位置，直到粘合剂固化形成永久的粘结。
本发明的适合的图案辊可以由众所周知的材料按照本领域中众所周知的方法生产，例如将钢用于图案化的辊子，和将高温橡胶用于平滑辊。图案辊子可以由包含需要的图案的模具生产。适合的图案辊形成过程在镂刻技术中是众所周知的。本发明的粘结图案，作为上述在线辊子图案化方法的替代方案，还可以由本领域已知的使用凸和凹模具的压印方法形成。
图1提供了本发明粘结图案的说明性的实例。在几何学上重复的基础粘结图案内，可以看到在椭圆形内的大写D的第二视觉上不同的粘结图案。图2提供了图1的放大部分。几何学上重复的基础粘结图案由圆形10和椭圆形12粘结点组成。圆形10由六个从圆形10向外辐射的椭圆形12围绕，产生嵌套的雏菊花图案。每个椭圆形12与两个圆形10邻接。基础粘结点能够完全是相同的形状或者不同的形状。视觉上可识别的第二粘结图案由菱形粘结点14组成。每个菱形14替代了圆形10或者椭圆形12。图1中的所有菱形在椭圆形内产生大写D。还注意到许多菱形粘结点14彼此接近。
图3提供了本发明粘结图案的另一个说明性的实例。在几何学上重复的基础粘结图案上能够看到视觉上可识别的十字粘结图案的轮廓线。
类似于图2，几何学上重复的基础粘结图案由圆形10和椭圆形12粘结点组成，产生嵌套的雏菊花图案。视觉上可识别的第二粘结图案由菱形粘结点14组成。每个菱形14替代了圆形10或者椭圆形12。图3中的所有菱形产生十字的轮廓线。
试验方法
以下实施例使用了以下试验方法。
ASTM指美国测试和材料学会。INDA指非织造织物工业协会。
基础重量是测量织物单位面积的质量的尺度，并且通过ASTMD3776测定，其在此引入作为参考，并且以g/m2报告。
抓取拉伸强度是测量织物的抗断强度的尺度，并且按照ASTM D5034进行，其在此引入作为参考，并且以牛顿(N)报告。
伸长率是测量在抓取拉伸强度测试中在破坏(断裂)之前织物拉伸量的尺度，并且按照ASTM D 5034进行测量，其在此引入作为参考，并且作为％报告。
织物手感测定是测量织物悬垂性的尺度，并且按照INDA 90.3-92测定，其在此引入作为参考，并且以克(g)报告。
附图说明
图1是本发明的说明性的粘接图案。
图2是图1中的粘接图案的放大部分。
图3是本发明的另一个说明性的粘接图案。
具体实施方式
实施例1
使用本发明的粘结图案生产了三层织物，其在图1中举例说明的几何学上重复的基础粘结点图案中包含视觉上可分辨的第二种粘结点图案。该三层织物包括两个纺粘纤维外层和熔喷纤维的中间层，按照Rudisill等的WO 0109425中公开的方法制造，该专利在此引入作为参考。纺粘纤维是皮-芯双组分纤雏，其中芯包括聚对苯二甲酸乙二醇酯，皮包括聚乙烯。皮与芯的比是50％重量。中间层由并列式双组分熔喷纤维制成，其中一个组分是聚对苯二甲酸乙二醇酯和另一个是聚乙烯。聚对苯二甲酸乙二醇酯树脂占纤维的大约65％重量。每个纺粘层的重量是21g/m2，熔喷层的重量是17g/m2。该三个层被进料到砑光设备的钳口，该砑光设备由上和下钢加热辊组成。上辊镂刻了菱形粘结要素的第二图案，其在椭圆形内产生大写D，被引入嵌套雏菊形的基础粘结图案中，如图1中举例说明的，并且下辊是平滑的支承辊。参考图2，圆形10和椭圆形12覆盖织物表面的15％。菱形14覆盖织物表面的20％。织物的粘结点密度是34点每平方厘米。两个辊子均具有大约46厘米的直径，并且加热到大约120℃，具有35kN每线性米的钳口压力设置值。织物手感测定和抓取拉伸以及伸长率数据在下表中给出。
对比例A
使用了与实施例1相同的三层织物，除了仅仅使用基础图案粘结点将织物粘结。织物手感测定和抓取拉伸以及伸长率数据如下表所列。
比较表中的数据，显然，本发明的粘结图案，在提供视觉上可识别的第二粘结图案的同时，没有显著地降低非织造织物的物理性能。
表
非织造织物纤网性能
实施例 H-O-M(MD)(g) H-O-M(XD)(g)   抓取拉伸(XD)(N)   伸长率(XD)(％)
    1     27.4     11.1     91.6     82.6
    A     25.6     10.1     87.6     81.1
H-O-M＝织物手感测定，XD＝横向
实施例2
图3显示本发明另一个实施例。在几何学上重复的基础粘结图案上能够看到视觉上可分辨的十字轮廓线的粘结图案。类似于图2，几何学上重复的基础粘结图案由圆形10和椭圆形12粘结点组成，产生嵌套的雏菊花图案。视觉上可识别的第二粘结图案由菱形粘结点14组成。每个菱形14替代了圆形10或者椭圆形12。
图3中的所有菱形产生十字的轮廓线。圆形10和椭圆形12覆盖织物表面的15％。菱形14覆盖织物表面的20％。织物的粘结点密度是30点每平方厘米。

Claims (11)

1.一种图案粘结的非织造织物，其包括具有几何学上重复的和视觉上可辨别的粘结点基础图案的非织造纤维纤网，所述粘结点基础图案具有至少一个形状，至少一个区域由该形状定义，以及引入到所述基础图案中的视觉上可区别的粘结点第二图案，其中基础图案的某些粘结点被替换为第二图案粘结点，该第二图案粘结点具有与基础图案的粘结点不同的形状和/或面积。
2.权利要求1的图案粘结非织造织物，其中第二图案粘结点具有与基础图案粘结点相同的形状，具有不同的面积。
3.权利要求1的图案粘结非织造织物，其中第二图案粘结点具有与基础图案粘结点不同的形状，具有相同的面积。
4.权利要求1的图案粘结非织造织物，其中第二图案粘结点具有与基础图案粘结点不同的形状和不同的面积。
5.权利要求1的图案粘结非织造织物，其中织物包括至少一个非织造纤维纤网和至少一个薄膜的层压制品。
6.权利要求1的图案粘结非织造织物，其中非织造纤维纤网选自切断纤维非织造纤网、纺粘非织造纤网和熔喷非织造纤网。
7.权利要求1的图案粘结非织造织物，其中该织物包括多个非织造纤网。
8.权利要求7的图案粘结非织造织物，其中该织物包括第一纺粘非织造纤网、至少一个熔喷非织造纤网和第二纺粘非织造纤网。
9.权利要求1的图案粘结非织造织物，其中单个第二图案粘结点的面积为单个基础图案粘结点的面积的25％到300％。
10.一种防护服装制品，其包括权利要求1的图案粘结非织造织物。
11.一种医疗帘布，其包括权利要求1的图案粘结非织造织物。
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CA2519470A1 (en) 2004-10-07
CN1761786A (zh) 2006-04-19
JP2006520863A (ja) 2006-09-14
WO2004085730A1 (en) 2004-10-07
US20040241399A1 (en) 2004-12-02
KR20050114665A (ko) 2005-12-06
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