CN1813089A - 包含纳米纤维的卫生制品 - Google Patents
包含纳米纤维的卫生制品 Download PDFInfo
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- CN1813089A CN1813089A CNA2004800184419A CN200480018441A CN1813089A CN 1813089 A CN1813089 A CN 1813089A CN A2004800184419 A CNA2004800184419 A CN A2004800184419A CN 200480018441 A CN200480018441 A CN 200480018441A CN 1813089 A CN1813089 A CN 1813089A
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Abstract
本发明涉及含有纳米纤维的卫生制品。卫生制品包含尿布、训练短裤、成人失禁衬垫、诸如女性护理衬垫和短裤护垫之类的经期用品、棉塞、个人清洁制品、个人护理制品和包含婴儿擦拭物、面擦拭物、身体擦拭物和女性擦拭物在内的个人护理擦拭物。纳米纤维可被用作防渗物、擦拭物、吸收材料和其它用途。尤其是,纳米纤维被用于尿布中作为芯部上的防渗物、表面和/或腿箍。也可将其用作用于降低液体的浓度差的擦拭物、材料的控制递送和其它用途。直径小于1微米的纳米纤维必须大量包含在卫生制品所包含的一层纤网中。纳米纤维由熔膜原纤化法进行生产。该方法一般包括以下步骤:提供聚合物熔体、利用中心流体流形成细长的中空聚合物膜管和使用这个和/或其它流体流由所述中空管制成多个纳米纤维。
Description
发明领域
本发明涉及由纳米纤维制成的卫生制品以及该卫生制品的有益效果。
发明背景
对由含有纳米纤维的非织造材料生产的制品的需求一直在持续增长。通常认为纳米纤维的直径小于约1000纳米或1微米。纳米纤维网因其比表面积高、孔径小和其它特性而受到欢迎。纳米纤维,也通称作微纤维或超细纤维,可通过多种方法和用多种材料进行生产。虽然有数种方法可以生产出纳米纤维,但是每种方法均有缺点,并且生产高性价比的纳米纤维仍有困难。因此,包含纳米纤维的卫生制品和其它一次性消费品仍未能上市。
生产纳米纤维的方法包含通过熔体原纤化法所描述的一类方法。熔体原纤化法是在一种或多种聚合物被熔融并挤出成很多可能的构型例如复合挤压成型、单组分或双组分薄膜或长丝,然后纤化或纤维化成纤维这点上所定义的制造纤维的一般类别。熔体原纤化法的非限制性实施例包含熔喷法、熔膜原纤化法和熔体纤维破裂法。不用熔体生产纳米纤维的方法为薄膜原纤化法、静电纺丝法和溶液纺丝法。生产纳米纤维的其它方法包含纺呈海岛型、分割饼形或其它构型的较大直径的双组分纤维,其中纤维在已经固化之后被进一步加工以便成形纳米纤维。
熔喷是生产纤维常用的方法。典型的纤维直径介于2微米和8微米之间。熔喷可被用来制造直径较小然而对工艺来说具有所需的明显变化的纤维。通常,需要重新设计过的喷丝头和喷丝板。这些方法的实施例包含Fabbricante等人的美国专利5,679,379和6,114,017以及Nyssen等人的美国专利5,260,003和5,114,631。这些方法利用较高的压力、温度和速度来获得小的纤维直径。
熔膜原纤化法是生产纤维的另一种方法。由熔体来产生熔膜管,然后用流体来由膜管制成纳米纤维。这种方法的两个实施例包含转让给University of Akron的Torobin的美国专利6,315,806、5,183,670和4,536,361;以及Reneker的美国专利6,382,526和6,520,425。尽管这些方法在纳米纤维形成之前首先形成熔膜管这点类似,然而这些方法使用不同的温度、流动速率和设备。
薄膜原纤化法是生产纳米纤维的另一种方法,虽然不是为生产被用于非织造纤网中的聚合物纳米纤维而设计。Perez等人转让给3M的美国专利6,110,588描述了一种给高度定向的、高度结晶的、熔融加工的聚合物薄膜表面赋予流体能量以成形纳米纤维的方法。薄膜和纤维用于高强度应用场合,例如聚合物的增强纤维或如混凝土这类浇注建筑材料。
静电纺丝是一种生产纳米纤维常用的方法。在该方法中,将聚合物溶解在一种溶剂中并放入一个一端密封的容器中,在另一端颈缩部分具有一个小开口。然后在聚合物溶液和靠近容器开口端的收集器之间施加高电压。这种方法的生产速度很慢并且纤维典型地以小批量进行生产。生产纳米纤维的另一种纺丝技术是利用溶剂的溶液纺丝或闪蒸纺丝。
生产纳米纤维的两步方法也为人所熟知。两步方法的定义是在其中第二步骤发生在整个纤维的平均温度处在明显低于包含在纤维中的聚合物熔点温度下形成纤维的一种方法。典型地,纤维将被固化或大部分固化。第一步骤是纺成海岛型、分割饼型或其它构型的较大直径的多组分纤维。在第二步骤中较大直径的多组分纤维被剥离或海部分被溶解以便产生纳米纤维。例如,Nishio等人转让给Chisso的美国专利5,290,626和Pike等人转让给Kimberly-Clark的美国专利5,935,883分别描述了海岛型和分割饼型方法。这些方法涉及两个连续的步骤,制造纤维和分离纤维。
希望生产一种具有商业竞争力的包含纳米纤维的一次性卫生制品,必须控制纳米纤维的成本。设备成本、加工成本、任何附加的加工助剂以及聚合物成本均是控制成本的方面。因此,生产成本低的纳米纤维是本发明的一个目标。
也希望成形具有多种用途和有益效果的包含纳米纤维的卫生制品。用途包含作为实施方案例如尿布、擦拭物和吸收材料等。使用极细纤维来制造非织造纤网已经持续增长。纤维的较大表面积已经使这些纤维适于各种用途,包含作为防渗层在内。
发明概述
本发明涉及包含纳米纤维的卫生制品。卫生制品包含尿布、训练短裤、成人失禁衬垫、诸如女性护理衬垫和短裤护垫之类的经期用品、棉塞、个人清洁制品、个人护理制品和包含婴儿擦拭物、面擦拭物、身体擦拭物和女性擦拭物在内的个人护理擦拭物。纳米纤维网可被用作防渗物、擦拭物、吸收材料和其它用途。尤其是,将纳米纤维网用于尿布中作为液体防渗物、表面和/或腿箍。也可将其用作用于降低液体的浓度差的擦拭物、材料的控制递送和其它用途。
直径小于1微米的纳米纤维必须包含大量的纤维,优选地大于卫生制品所包含的一层纤网中纤维的50%。纳米纤维由熔膜原纤化法进行生产。该方法一般包括以下步骤:提供聚合物熔体、利用中心流体流形成细长的中空聚合物膜管和使用这个或其它流体流由所述中空管制成多个纳米纤维。
发明详述
本发明涉及由纳米纤维制成的卫生制品。纳米纤维由一种或多种热塑性聚合物进行生产。适于本发明的热塑性聚合物的非限制性实施例包含聚烯烃、聚酯、聚酰胺、聚苯乙烯、聚氨酯、包含热塑性淀粉、PHA、PLA、淀粉组合物在内的可生物降解的聚合物以及它们的组合。均聚物、共聚物和它们的共混物均包含在本说明书内。最优选的聚合物为诸如聚丙烯、聚乙烯、尼龙和聚对苯二甲酸乙二醇酯之类的聚烯烃。
合适的热塑性聚合物包含适于熔体纺丝法的任何聚合物。聚合物的流变学性质必须使得聚合物可被熔融挤出并能够形成薄膜。聚合物的熔融温度通常为约25℃至400℃。本发明的聚合物在它们存在于喷丝板中时熔融流动速率可小于每分钟约400分克。采用ASTM方法D-1238测定熔融流动速率。优选地,熔融流动速率可小于每分钟约300分克,更优选小于每分钟约200分克,最优选小于每分钟约100分克。熔融流动速率的最优选范围为每分钟约1分克至每分钟约100分克。一般而言,熔融流动速率越低就越优选。因此,可使用熔融流动速率小于每分钟约50分克和每分钟40分克的聚合物。
纤维可为单组分或诸如双组分纤维之类的多组分纤维。纤维可具有芯鞘型或并列型或其它适用的几何构型。在纤维制成之后,在形成纤网之前可对纤维进行处理或包覆。另外,在纤网制成之后,可对其进行处理。任选地,可将添加剂掺和进聚合物树脂中并且这些添加剂可在纤维成形之后扩散到纤维的表面。迁移到表面的添加剂可能需要利用外部能量例如热量进行固化,或者表面上的添加剂可能需要与另一种组分进行化学反应,或者固化可能需要在另一种组分存在的情况下进行催化,使得可采用掺有添加剂的树脂在制造纤维的时候或在纤维制成之后将附加成分添加到加工过程中。合适的处理包含亲水或疏水处理。疏水处理剂的一个实施例为聚二甲基硅氧烷。具体的处理取决于使用的纤网、聚合物种类和其它因素。
任选地,所述聚合物可包含另外的材料以提供纤维的其它性能。这些材料可改变所得到的纤维的物理属性例如弹性、强度、热和/或化学稳定性、外观、吸收性、气味吸收性、表面性质和可印花性等。可添加合适的亲水熔融添加剂。任选的材料可多达所述总的聚合物混料的50%。
制造本发明的纳米纤维的方法为熔体原纤化法,更优选地为熔膜原纤化法。熔膜原纤化法包括以下步骤:提供聚合物熔体、利用中心流体流形成细长的中空聚合物膜管,然后使用一种流体由所述中空管制成多个纳米纤维。合适的方法详述于如授予Torobin的美国专利4,536,361以及授予Reneker的美国专利6,382,526和5,520,425中。熔膜原纤化法可利用各种不同的加工条件。Reneker的方法更具体地讲包含将聚合物喂入到一个环形柱中并在形成喷气区的环形柱的出口处形成一个薄膜或管的步骤。气柱然后提供聚合物管内圆周上的压力。当聚合物管离开喷气区时,由于中心气体膨胀的缘故,其被吹分成包含纳米纤维在内的很多小纤维。
熔膜原纤化法的一个实施例更具体地讲包含熔化聚合物来形成聚合物熔体的步骤。聚合物熔体将包含聚合物混料和任何其它成分。聚合物熔体通过一个又包含一个中心流体流的喷丝孔被挤出,使得聚合物挤成一个细长的中空管。喷丝孔可为喷丝头的一部分。对于本领域的技术人员来说显而易见的是,为加工稳定性,喷丝头的整体样式不得不进行优化。此外,中心流体流可为同心的或偏心的。成纤流体例如一个中心流体流的吹动使聚合物熔体形成一个细长的中空管。成纤流体然后将在细长中空管的内表面上提供压力。在中空管中可形成薄壁或薄弱部分,使包含纳米纤维在内的纤维形成更加容易或可控。薄弱部分可由位于中心流体喷射管的外表面上或聚合物喷丝孔的内表面上的沟槽或突起产生。细长的中空聚合物膜管然后受到流体的作用形成纳米纤维。这种流体可为中心流体流或输送流体或任何流体流以产生脉动或波动压力场并形成包含纳米纤维在内的多种纤维。如果有利,可采用喷丝头给所形成的纳米纤维提供冷却或加热流体。
聚合物典型地被加热到其形成液态以及容易流动为止。熔融聚合物的温度可处在约0℃至约400℃,优选地在约10℃至约300℃,以及更优选地在约20℃至约220℃的温度。聚合物的温度取决于聚合物或聚合物混料的熔点。聚合物的温度超过其熔点不到约50℃,优选地超过其熔点不到25℃,更优选地超过其熔点不到15℃,以及刚好处在其熔点或其熔化范围内或之上。熔点或熔化范围用ISO 3146方法进行测量。熔融聚合物的粘度将典型为约1Pa·s至约1000Pa·s,典型为约2Pa·s至约200Pa·s,以及更一般地为约4Pa·s至约100Pa·s。这些粘度在剪切速率在约100至约100,000每秒的范围内给出。熔融聚合物处在约大气压力或略高的压力下。
细长的中空聚合物管可为圆形的、椭圆形的、不规则形的或具有中空区域的任何其它形状。在某些情况下,细长的中空聚合物管可在形成之后即刻收缩。在收缩管的情况下,管上具有薄壁或薄弱部分以有助于原纤化法为优选的。成纤流体的非限制性实施例为诸如氮气之类的气体,或更优选地为空气。成纤流体可处在接近熔融聚合物温度的温度下。成纤流体温度可比熔融聚合物的温度更高以帮助聚合物的流动和中空管的成形。可供选择地,成纤流体温度可在熔融聚合物温度之下以有助于纳米纤维的成形和凝固。优选地,成纤流体温度低于聚合物熔点,更优选地在聚合物熔点以下超过50℃,更优选地在聚合物熔点以下超过100℃或刚好在环境温度下。成纤流体的压力足以成形纳米纤维并在略微高于熔融聚合物被挤出喷丝孔时的压力。
成纤流体的速度可为小于每秒约500米。优选地,成纤流体速度将低于每秒100米,更优选地低于每秒约60米,以及最优选地为每秒约10至约50米。成纤流体可脉动或可稳定流动。尽管这种成纤流体存在有助于形成中空聚合物膜管很关键,流量可很小。
聚合物处理量将主要取决于所用的具体聚合物、喷丝头样式和聚合物的温度和压力。聚合物处理量将超过1克每分钟每喷丝孔。优选地,聚合物处理量将超过每分钟每喷丝孔约10克,更优选地大于每分钟每喷丝孔约20克。将有可能几个喷丝孔同时喷丝,进一步增加总的生产量。处理量连同压力、温度和速度一起在喷丝板出口处进行测量。
纤维的原纤化法和凝固可发生在纤维和流体离开喷丝孔之前。在细长的中空管离开喷丝孔之后,就成形了纳米纤维。通常,纳米纤维的成形在离开喷丝孔时即刻发生。采用一个或多个流体流来成形多个纳米纤维。流体流可为中心流体流、输送流体或任何其它流体流。输送流体可被用来产生脉动或波动压力场,帮助成形多个纳米纤维。输送流体可通过一个横向喷口来提供,横向喷口用来导引输送流体在细长的中空管和纳米纤维成形区域上和周围流动。输送流体可具有低速度或高速度,例如近声速或超声速。低速度输送流体的速度典型地将为每秒约1至约100米,优选地每秒为约3至约50米。输送流体的温度可与上面的成纤流体相同,环境温度、或更高的温度、或低于环境温度。
也可采用附加的流体流,冷却或加热流体。这个附加的流体流用来将流体导引进纳米纤维以冷却或加热纤维。如果附加流体被用作快速冷却流体,则其温度为约-50℃至约100℃,优选地为约10℃至40℃。如果附加流体被用作加热流体,则其温度为约40℃至400℃、以及典型地为约100℃至约250℃。任何流体流均有助于聚合物熔体的纤维化并因此通常被称作成纤流体。
任何流体流,包含中心流体流、输送流体或附加流体流在内,可含有处理剂、添加剂、涂敷剂或其它物质或颗粒,用于改变所制纤维的表面、化学、物理或机械性能。
纳米纤维被铺在一个收集器上形成纤网。收集器典型地为传送带或转筒。收集器优选地为多孔的并可应用真空来提供吸力,帮助纤维铺在收集器上。对于所希望的纤网性质,喷丝孔至收集器的距离(通常称为喷丝板至收集器距离(DCD))可进行优化。为减少纤维成束或结束的量,DCD应该较小。这种较小的距离使纤维来不及缠结、彼此缠绕或成束。在一个纤网中采用一个以上的DCD、在生产期间改变DCD或采用可提供不同DCD的多个横梁,是所期望的。最理想的是通过改变DCD形成均匀性不同的纤网。
在形成了细长的中空膜管之后,管或纳米纤维可供选择地可经受补充加工,进一步加速纳米纤维的形成。进一步加工在细长的中空聚合物膜管形成之后即刻发生并在纳米纤维已经凝固之前仍被认为是单步方法。补充加工可利用一个或多个Laval喷丝头,将气体速度加速到声速和/或超声速范围。当聚合物熔体被暴露到这么高的气体速度下时,其破裂成多个细纤维。Laval喷丝头的实施例被描述于Nyssen等人的美国专利5,075,161中,其中公开了将对聚苯硫醚熔体破裂成细纤维的方法。当生产细长的中空聚合物膜管时,可将Laval喷丝头设置在纺丝喷丝头正后方。可供选择地,Laval喷丝头可刚好在纳米纤维已经形成之后进行设置以进一步降低纤维尺寸。聚合物纤维可通过将聚合物熔体流挤出到基本平行于聚合物熔体流并达到声速或超声速的气体介质中,并在该介质下聚合物熔体被牵伸并冷却到熔体温度以下得到。这种同时变形和冷却产生了有限长度的无定形的细的或超细纤维。纤维的高速破裂使纤维的表面氧化达到最小。纺丝速度、熔体温度和Laval喷嘴的位置被近似设定以实现细丝在它们的表面仅局部热氧化。
可采用各种方法和方法组合来制造本发明的纤网。如Sodemann等人在WO 04/020722中所公开的那样,在单条生产线上在两个单独的横梁上,熔体纤维破裂可与本发明的熔膜原纤化法相结合。可将熔体纤维破裂的各个方面引入到熔膜原纤化法中,例如生产不同强度和直径的纤维,以提供所期望的性能组合。可供选择地,通过利用一个细长的中空管来成形纤维,可将熔膜原纤化法的各方面包含在其它熔体原纤化法中,以增加处理率。例如,可改进本发明的熔膜原纤化法以包含一个Lava l喷丝头帮助牵伸纤维。牵伸可有助于进一步拉细并增加纤维的强度。对于诸如其中应力诱发结晶发生在超过4000m/min的速度下的聚酯之类的高Tg(玻璃化温度)聚合物而言,这可为尤其优选的。
本发明的纳米纤维被用来制造非织造纤网。纤网的定义是整体的非织造材料合成物。纤网可具有一个或几个层。一个层是在一个单独的纤网铺展或成形步骤中产生的纤网或纤网的一部分。本发明的纤网将包含一个或多个具有大量直径小于1微米的纳米纤维的层。大量的定义是至少约25%。大量纤维可为至少约35%、至少约50%、或超过层中纤维总数的75%。纤网可具有100%的直径小于约1微米的纤维。纤网的纤维直径采用扫描电子显微镜进行测量,根据视觉分析的需要,放大倍数为大于约500倍以及最多约10,000倍。要确定是否大量纤维的直径小于1微米,必须测量至少约100根纤维以及优选地更多的纤维。测量必须在涵盖整个层的不同区域进行。采样必须足够,以满足统计意义上的显著性。
余下的较大纤维(最多75%)的纤维直径可在任何范围内。典型地,较大的纤维直径将刚好在1微米之上至约10微米。
优选地,一个层中的大量纤维的纤维直径将小于约900纳米、以及更优选地为约100纳米至约900纳米。纤维的直径可小于约700纳米以及为约300纳米至约900纳米。优选的直径取决于纤网的预期用途。从加工和产品的角度出发,最理想的是在某些应用场合,有大量纤维的直径小于约1微米以及有大量纤维的直径大于约1微米。较大的纤维可捕集和固定纳米纤维。这可帮助减少纳米纤维的丛或束的量并防止纳米纤维被逸出的气流吹走。
在本发明纤网中的纳米纤维层可包含一种以上的聚合物。可将不同的聚合物或共混聚合物用于不同喷丝孔,生产具有不同纤维直径和不同聚合物混料的纤网中的层。
最理想的是生产具有不同纤维直径的单层非织造材料。可供选择地,希望生产其中每层具有不同纤维直径的具有多层的非织造纤网。改进的熔膜原纤化法即可生产小直径纤维也可生产大直径纤维以制造各种纤网。较小直径纤维被认为是具有大量的直径小于1微米的纤维。较大直径纤维包含从熔喷法范围(典型地3微米至5微米)至纺粘法(典型地15微米左右)或1微米以上的任何纤维直径范围的纤维。例如,可生产平均纤维直径小于1微米的一个层和平均纤维直径5微米左右的另一个层。这种结构类型可被用在传统的SMS纤网所用之处。另一个实施例是生产具有多层的纳米纤维网,其中每个层的平均纤维直径截然不同,例如一个层的平均直径为0.4微米以及第二个层的平均纤维直径为0.8微米。在同一条生产线上用同样的设备可生产具有不同纤维直径的纤网。这是一种低成本的方法,因为可使用相同的设备和部件。生产成本和设备成本均可得到控制。同样,如果需要,可使用同样的聚合物产生不同的纤维直径。
最理想的是成形几层的纤网。纳米纤维层可与一个、两个或多个层相复合。纺粘纤维-纳米纤维-纺粘纤维纤网是一个实施例。整个复合纤网的基重在约5gsm至约100gsm,优选地在约10gsm至约100gsm,以及更优选地在约10gsm至约50gsm范围内变化。供作为防渗层之用的复合纤网总基重可为约10gsm至约30gsm。只纳米纤维层的基重为约0.5gsm至约30gsm,优选地为约1gsm至约15gsm。
在非织造材料制成之后,可将其经受后续加工。后续加工的非限制性实施例包含固态成型、加固、层压、表面包覆、电晕和等离子处理、染色和印花。固态成型的非限制性实施例包含使用咬合对辊(例如在美国专利5,518,801中以及后续专利文献中称为“SELF”纤网,其代表“结构弹性状薄膜”)、纹理处理、拉伸、打孔、局部变形、微起绉、液压成型和真空成型的方法。固结的非限制性实施例包含热粘合、气流粘合、粘合剂粘合和水刺粘合。
本发明的卫生制品将包含上述非织造纤网。纤网可构成整个卫生制品例如擦拭物,或者纤网可构成卫生制品的一个组分例如尿布。卫生制品包含尿布、训练短裤、成人失禁衬垫、诸如女性护理衬垫和短裤护垫之类的经期用品、棉塞、个人清洁制品、个人护理制品和包含婴儿擦拭物、面擦拭物、身体擦拭物和女性擦拭物在内的卫生擦拭物。个人护理制品包含诸如伤口敷料、活性成分传输包裹物或贴剂和用于身体尤其是皮肤的其它基质之类的基材。
在尿布中,纤网可被用作防渗层或表面。纤网也可被用作具有高静压头的高防渗箍,实现舒适性和贴合性所希望的裆部又薄又窄的尿布的低渗透事故率。纤网可被用于擦拭物中,改善露剂处理性并降低液体的浓度差。纤网也可提供一种物质的控制递送。递送物质可为液体、露剂、活性物质或其它材料。由于纳米纤维的高比表面积,纤网可被用作擦拭物的吸收材料或女性护理产品护垫、尿布、训练短裤或成人失禁用品的芯部。纤网可增强流体的分散和/或保持性。另外,用于吸收性用途的纤网可用附加的颗粒或用于增加吸收性的吸收剂或天然纤维制造,或者纤网的某些层可具有不同的性能。也可将纳米纤维网用于希望具有不透明性的制品中。附加的不透明性可因小纤维直径和均匀性而产生;或可将颜料添加到聚合物熔体或纤网中。通常,纳米纤维层被结合在具有纺粘层的纤网中。可有一个纺粘层或在纳米纤维网的每一侧面上均有一个纺粘层。
在尿布或其它一次性吸收制品中,可将包含纳米纤维的非织造纤网用作防渗层。可将防渗层设置在一次性吸收制品的吸收芯和外层之间。吸收芯为制品主要起到诸如捕集、输送、分散和存储体液之类的液体处理性能作用的组件。吸收芯典型地位于液体可透过的身体侧内层和蒸汽可透过的、液体不可透过的表面之间。外层,也称作底片或外表面,位于一次性制品的外侧。在尿布的情况下,外层接触使用者的衣服或衣物。防渗层可可供选择地或也被设置在吸收芯和内层之间。内层,也称作顶片,位于紧贴使用者皮肤的一侧上。内层可接触使用者的皮肤或可接触与使用者的皮肤接触的单独的顶片。防渗层可为吸收材料。非织造纤网可包含围绕吸收芯的层并帮助分配或处理流体。非织造纤网可为流体分配层,其可邻近芯进行设置。防渗层最优选地具有空气的对流性和吸收防渗性之间的平衡。空气的对流性有效地降低吸收制品和穿着者的皮肤间的空间的相对湿度。液体吸收性和液体防渗性的组合保护制品免除透湿问题并在吸收制品处在碰撞和/或持续压力下时尤其有益。防渗层的进一步描述和有益效果可见于WO 01/97731中。
纤网可被用来制造干燥的或预湿的卫生擦拭物。纳米纤网可被用于擦拭物中,能够改善露剂处理性并降低液体的浓度差。纳米纤维层可提供部分防渗并可部分或完全不透液。纤网也可提供一种物质或诸如药物之类的活性物质的控制递送。递送物质可为液体、露剂、酶、催化剂、活性物质或诸如润滑剂、表面活性剂、润湿剂、抛光剂、油、有机和无机溶剂、糊剂、凝胶、颜料或染料之类的其它材料。纤网可增强流体的分散和/或保持性。另外,用于吸收性用途的纤网可用附加的颗粒或用于增加吸收性的吸收剂或天然纤维制造,或者纤网的某些层可具有不同的性能。可将纳米纤维生产成低密度或多孔的纳米纤维。纳米纤维可用膨胀或发泡剂进行生产。
由于纳米纤维的高比表面积,纤网可被用作擦拭物的吸收材料或女性护理产品护垫、尿布、训练短裤或成人失禁用品的芯部。高表面积也增强清洁性并可被用于卫生清洁擦拭物。纤网可增强流体的分散和/或保持性。另外,用于吸收性用途的纤网可用附加的颗粒或用于增加吸收性的吸收剂或天然纤维制造,或者纤网的某些层可具有不同的性能。
也可将纳米纤维用于希望具有不透明性的制品中。附加的不透明性可因小纤维直径和均匀性而产生;或可将颜料添加到聚合物熔体或纤网中。纤网也可具有低起毛性,其由纤网中长度较长的纤维或纤维的缠结而导致。本发明的纳米纤维网的拉伸强度可大于由其它方法制成的具有类似纤维直径和类似基重的纤网的拉伸强度。本发明的纳米纤维网将是柔软的并可比具有同样性能的其它纤网更软。
将受益于纳米纤维网的其它产品包含个人过滤器或诸如外科手术口罩之类的面罩。包含纳米纤维层的纤网的其它医疗用途包含外科手术衣、伤口敷料和医疗防渗。
纤维直径可采用扫描电子显微镜(SEM)和图像分析软件进行测量。选择500至10,000的放大倍数使得纤维被适当放大以便测量。图像分析软件对SEM图像中的纤维直径自动取样是可能的,但也可采用更加人工的程序。一般而言,寻找随机选取的纤维的边缘,然后横越宽度(在那点处垂直于纤维方向)至纤维的相对的边缘进行测量。带刻度的和标定过的图像分析工具提供标度以得到以mm或微米(μm)为单位的实际读数。从SEM中的纤网样本随机选择一些纤维。典型地,来自纤维网的几个样本被横向切断并以这种方式进行测定,并且进行至少约100次测量以及将所有的数据记录下来进行统计分析。如果结果要以旦为单位进行记录,那么需要进行下面的计算。以旦为单位的直径=横截面积*密度*9000m*1000g/kg。横截面积是π*直径2/4。密度例如对于PP,可取为910kg/m3。要获得分特(dtex),将9000m用10,000m替代。
基重可按照法定方法ASTM D 756、ISO 536和EDANA ERT-40.3-90进行测定。基重的定义是每单位面积的质量,其中克每平方米(gsm)为优选的单位。所需的仪器为一把剪刀或一个用于样本切割的压力切割器和一个精密的称重装置例如天平。将样本切割到每层总面积100cm2,准确度和精密度为±0.5%。天平需要具有0.001g的灵敏度、可读、标定过并精确到施加载荷的0.25%范围内。样本被置于摄氏23°(±2℃)和约50%的相对湿度下2小时达到平衡。在一个分析天平上称出样本总面积为1000cm2=0.1m2的10层切割样本的重量,精确到0.001g,并记录下重量。(对于比1mm厚的样本而言,称出仅1层的重量是优选的,然而应该要注意)。通过将重量除以样本面积(所测试的所有层的面积)计算基重,给出单位为gsm的基重。将所有的数据记录下来进行统计分析。
纤网均匀性可通过几种方法进行测定。均匀性测量的实施例包含孔径、基重、透气率和/或不透明性的低变异系数。均匀性也要求含有较少纤维束或粘结、或可见的孔洞、或其它此类疵点。均匀性可通过工艺改进例如缩短喷丝头到收集器的距离进行控制。该距离的缩短减少了纤维成束或粘结,并可提供更均匀的纤网。
孔径可通过本领域技术人员已知的方法进行确定。平均孔径优选小于约15微米,更优选小于约10微米,最优选小于约5微米。均匀纤网的所希望的变异系数小于20%,优选小于约15%,更优选约10%或更小。粘结这类疵点可通过计数纤网的测定面积上的纤维粗结或束的数量进行测定。孔洞这类疵点也通过纤网的测定面积上直径在某个阈值之上的孔洞的数目进行测定。如果孔洞是肉眼可见的或直径大于100微米,则可统计孔洞。
所有引用文献的相关部分均引入本文以供参考,任何文献的引用不可解释为对其作为本发明的现有技术的认可。
尽管已用具体实施方案来说明和描述了本发明,但对于本领域的技术人员显而易见的是,在不背离本发明的精神和保护范围的情况下可作出许多其它的更改和修改。因此,有意识地在附加的权利要求书中包括属于本发明范围内的所有这些变化和修改。
Claims (10)
1.一种包含非织造纤网的卫生制品,所述非织造纤网包含具有大量直径小于1微米的纳米纤维的层,其中所述纳米纤维由熔膜原纤化法制成,所述熔膜原纤化法包括以下步骤:
a.提供聚合物熔体,
b.利用中心流体流形成细长的中空聚合物膜管,和
c.由所述中空聚合物膜管用流体来形成多个纳米纤维。
2.如权利要求1所述的卫生制品,其中所述层包含至少35%的直径小于1微米的纳米纤维。
3.如权利要求1所述的卫生制品,其中所述聚合物为聚丙烯。
4.如权利要求1所述的卫生制品,其中所述非织造纤网包含一个具有大量直径小于1微米的纳米纤维的层,也包含一层或多层的纺粘纤维。
5.一种包含非织造纤网的尿布,所述非织造纤网包含一个具有大量直径小于1微米的纳米纤维的层,其中所述纳米纤维由熔膜原纤化法制成,所述熔膜原纤化法包含以下所述步骤:
a.提供聚合物熔体,
b.利用中心流体流形成细长的中空聚合物膜管,和
c.由所述中空管用流体来形成多个纳米纤维。
6.如权利要求5所述的尿布,其中所述包含纳米纤维的非织造纤网为防渗层。
7.一种包含非织造纤网的卫生擦拭物,所述非织造纤网包含一个具有大量直径小于1微米的纳米纤维的层,其中所述纳米纤维由熔膜原纤化法制成,所述熔膜原纤化法包括以下步骤:
a.提供聚合物熔体,
b.利用中心流体流形成细长的中空聚合物膜管,和
c.由所述中空管用流体来形成多个纳米纤维。
8.如权利要求7所述的卫生擦拭物,其中所述包含纳米纤维的非织造纤网提供液体的浓度差的降低。
9.如权利要求7所述的卫生擦拭物,其中所述包含纳米纤维的非织造纤网提供材料的控制递送。
10.如权利要求1所述的卫生制品,其中所述卫生制品为经期用品并且所述包含纳米纤维的非织造纤网为防渗层。
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-
2004
- 2004-06-25 US US10/877,458 patent/US8487156B2/en active Active
- 2004-06-30 DE DE200460028822 patent/DE602004028822D1/de not_active Expired - Lifetime
- 2004-06-30 EP EP20040756495 patent/EP1639172B1/en not_active Expired - Lifetime
- 2004-06-30 JP JP2006518752A patent/JP2007521841A/ja active Pending
- 2004-06-30 CN CN2004800184419A patent/CN1813089B/zh not_active Expired - Lifetime
- 2004-06-30 WO PCT/US2004/021127 patent/WO2005004767A2/en active Application Filing
- 2004-06-30 MX MXPA06000049A patent/MXPA06000049A/es active IP Right Grant
- 2004-06-30 AT AT04756495T patent/ATE478989T1/de not_active IP Right Cessation
-
2012
- 2012-09-25 US US13/625,952 patent/US9138359B2/en active Active
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2015
- 2015-08-12 US US14/824,276 patent/US10206827B2/en active Active
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN102065911A (zh) * | 2008-06-13 | 2011-05-18 | 宝洁公司 | 含有吸收性聚合物材料、润湿指示器和减少的表面活性剂迁移的吸收制品 |
CN110944613A (zh) * | 2017-09-27 | 2020-03-31 | 大王制纸株式会社 | 吸收性物品 |
Also Published As
Publication number | Publication date |
---|---|
MXPA06000049A (es) | 2006-03-21 |
WO2005004767A2 (en) | 2005-01-20 |
CN1813089B (zh) | 2011-05-11 |
WO2005004767A3 (en) | 2005-04-14 |
JP2007521841A (ja) | 2007-08-09 |
EP1639172A2 (en) | 2006-03-29 |
US20150342800A1 (en) | 2015-12-03 |
US9138359B2 (en) | 2015-09-22 |
ATE478989T1 (de) | 2010-09-15 |
EP1639172B1 (en) | 2010-08-25 |
US10206827B2 (en) | 2019-02-19 |
DE602004028822D1 (de) | 2010-10-07 |
US20130023836A1 (en) | 2013-01-24 |
US20050070866A1 (en) | 2005-03-31 |
US8487156B2 (en) | 2013-07-16 |
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