CN1854391A - 脱水织物 - Google Patents

脱水织物 Download PDF

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CN1854391A
CN1854391A CNA2006100793297A CN200610079329A CN1854391A CN 1854391 A CN1854391 A CN 1854391A CN A2006100793297 A CNA2006100793297 A CN A2006100793297A CN 200610079329 A CN200610079329 A CN 200610079329A CN 1854391 A CN1854391 A CN 1854391A
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fabric
district
long filament
region
fiber
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J·D·拜伯格
K·凯勒
G·E·西蒙兹
B·福克斯
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EIDP Inc
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EI Du Pont de Nemours and Co
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Abstract

本发明涉及可用于制造纸的织物。该织物优选具有至少三个具有特定孔径分布的织物区。对用于从初期纸除去水的常规脱水织物来说，此处公开的织物是有效的替换物，它可以在随后的高温干燥步骤中节约能源成本。

Description

脱水织物
技术领域
本发明涉及可用于制造纸的织物。该织物具有至少三个具有特定孔径分布的区。
背景技术
在造纸过程中，将纤维素纤维以含水淤浆的方式在筛网上沉积。将水去除以形成纸。往往，脱水织物用于含水淤浆脱水的第二阶段。
Eschmann(US5204171)描述了一种包括阻挡层的造纸织物。
Chuang等人(WO9616305)描述了一种毛细管的脱水方法和装置。
因为改善脱水的效率可以通过减少或消除对随后高温干燥步骤的需要而提供成本的节约，因此在造纸过程期间需要用于脱水的新织物。本发明涉及这些和其它重要方面。
发明内容
本发明的一个方面是一种织物结构物，包括至少三个区，所述三个区包括：
a)第一表面区；
b)具有1到10微米的平均水力孔径的材料的第二区；和
c)具有10微米或更小的平均水力孔径的材料的第三区。
附图说明
图1显示了根据本发明一个实施方案的织物的横截面。
图2显示了根据本发明第二个实施方案的织物的横截面。
图3显示了根据本发明第三个实施方案的织物的横截面。
图4显示了在整个织物厚度上具有连续变化的孔径的织物的横截面。
发明内容
本发明提供可用于在造纸过程期间脱水的织物。与已知的造纸织物对比，根据本发明的织物包括流动阻力区和毛细管区。
使用中，将脱水织物压在纸纤维幅上。将纸纤维以水悬浮液的方式沉积在筛网上并且该纸幅保留许多水。通过将本发明的脱水织物压在湿纸幅上有效地从该纸幅除去比一般结构的织物多10％的水。用来除去额外水的干燥可能仍然是需要的，但是因为通过本发明的脱水织物已经除去了大量水，因此大大减少了干燥时间和温度以及与此有关的能源成本。
根据本发明的织物包括至少三个区。该区可以是，例如，由合成聚合物人造短纤维或连续长丝制成的非织造材料。正如本领域技术人员理解的，此处使用的纤维是已经切断或斩碎成离散长度的长丝，而长丝是基本上连续的。表面区，它是朝着所要脱水的初期纸放置的，可以由相似的非织造或膜材料制造。为了强度和稳定性，可以将其它的非织造区附着到织造层。
根据本发明的织物的一个实施方案显示于图1中。图1显示了该织物的横截面。第一表面区，区1可以包括粗人造短纤维。该表面区使水以极小的流动阻力渗入织物。表面区是足够厚的以便在压榨操作期间提供下层区的机械保护并且还允许下层区在纸从该织物分离期间有效地作为流动控制区工作。接着向下，区2可以是具有1到10微米的平均水力孔径的多孔非织造材料或膜材料。如果非织造材料用于该织物的第二区，2，它可以包括人造短纤维或连续长丝。
第二区，区2是流动控制区并且优选至多100微米厚以免当该织物和纸在压区(press nip)时过度阻挡脱水。区2用来充当流动控制区以便当该纸在压榨之后从该织物分离时防止纸的再润湿。与具有较粗孔结构的区相比，它还提供改善的压力均一性。当该织物和纸处于压区时改善的压力均一性提高了脱水的速度。这个区具有约50％或更大的孔隙度。
区2的非织造材料可以使用如美国专利4,043,331所公开的电纺丝(electrospinning)技术来制造，或通过如WO2003/080905中所公开的电吹制(electroblowing)技术制造非织造材料。替换地，区2的材料可以是通过使用如公开于，例如，美国专利No.3,700,545、4,127,696和6,861,142中的海岛型技术制造的非织造材料。如果使用海岛型技术，可溶解的海聚合物是优选的类型，由此仅仅保留细岛长丝。可溶解的海聚合物的实例是线性聚酯，它能溶解于水或氢氧化钠溶液。一旦该海聚合物溶解，该区仅仅包含该细岛长丝。这些长丝优选具有0.1到5微米范围内的直径以便获得渴望的平均水力孔径和总孔隙度。较小的长丝导致较细的孔。如果使用非圆形横截面的长丝，术语“直径”是指该长丝的最小横截面尺寸。制造细的长丝或人造短纤维的非织造材料的替换方法包括易分裂长丝的纺丝、湿法成网和气流成网技术，它们全部都是沿用已久的并且是非织造物制造领域技术人员熟知的。用于构造区2的一般材料包括聚酰胺、聚酯、聚丙烯、聚乙烯、聚乳酸、聚对苯二甲酸亚丙基酯、聚酯酰胺和任何其它可熔纺的聚合物，包括双组分聚合物。聚酰胺是优选的。
该织物的第三区，3，可以包括人造短纤维或连续长丝，但是该长丝优选具有比区1中的长丝较细的旦尼尔。区3可以使用如用来生产区2的相同方法生产。区3中材料的平均水力孔径小于10微米并且同样小于正在脱水的纸幅的平均水力孔径。区3是毛细管区。当以纸和织物离开压区的方式释放压力时，区3中的毛细管力可以防止织物中的水再润湿纸幅。
区3的位置是该织物中所有区中最重要的。希望地是将它置于织物中的一个位置以致当压力释放时以及当该织物在压区中挤压后已展开时从该纸中压出的水的前端在区3的内部。如果该织物在脱水期间完全浸透，希望区3位于该织物的底层。区3优选足够薄以在脱水期间减小流动阻力，但足够厚以给移动穿过该织物的水的前端的移动提供宽容度。区3优选具有50％或者更大的孔隙度以减小流动阻力。
在图1中的区4和5包括粗长丝。该粗长丝可以是任何每长丝具有1.0或更大的旦尼尔的长丝。替换地，区4和/或5可以由压榨织物制造领域的专业人员所熟知结构的非织造材料来生产，如，例如，粗人造短纤维的梳理纤网。区4和5的平均水力孔径优选比区2或3的数量级大。区4和5使水以极小的流动阻力渗入织物并且充当从纸压出的水的容储器。
在本文中公开的方法中，与既没有流动控制区也没有毛细管区的织物相比、或与仅仅具有流动控制区的织物相比，流动控制区和毛细管区二者在脱水织物中的使用增加了压榨过程中从湿纸去除的水量。该织物的两个功能区共同工作，这样通过在压榨过程的不同时期抑制从织物流回到纸幅的水和使用不同的物理机理而改善脱水。
用于脱水纸的压榨过程顺序包括三个分别在不同时期作用于该织物一部分的连续阶段：脱水阶段，此时当该材料穿过压区时增加了对纸和织物的压力；再润湿阶段，此时在压区之后该纸和织物展开，同时该纸和织物保持接触；和分离阶段，此时该纸从该织物上分离。通常的做法是通过从该织物上快速除去纸从而使再润湿阶段尽可能地短。尽管如此，在它们可以分离以前纸和织物总要接触一段时间。在一般的压区中纸和织物之间的总接触时间一般小于约2秒。
当它们离开压区从该织物和纸去除压力时，该毛细管区使用毛细管力来防止该纸的再润湿。因此，该毛细管区具有小于湿纸幅平均水力孔径的平均水力孔径。这些小孔可以在压榨过程的脱水阶段强有力地抑制水流入该织物，因此高的孔数目是所希望的。因此，毛细管区的孔隙度优选大于50％。选择该毛细管区相对于该织物表面的位置来防止该纸的再润湿。希望地是将它置于织物中的一个位置以致当压力释放时以及当该织物在压区中挤压后已展开时从该纸中压出的水的前端在毛细管区的内部。如果该织物在脱水期间完全浸透，希望毛细管区位于该织物的底部。
该流动控制区主要的作用是当纸和织物分离时抑制从该织物进入纸内的流动。当纸和织物分离时，在纸和织物之间形成部分真空。该真空从该织物抽吸水。吸到纸和织物之间区域的水可以容易地由该纸吸收。由于与不包括该毛细管区的织物本体相比它具有相对小的孔径，该流动控制区会导致作用于水的剪切力的增加，它抵消了由部分真空所引起的压力梯度。然而，不同于毛细管层，它需要的孔径不是那么小使得在脱水状态期间足够地抑制水流。
本发明织物的第二个实施方案以横截面方式显示于图2中。区9、10和11是用粗长丝制成的，即，具有1.0或更大的旦尼尔的长丝。一个或多个区9、10或11可以替换地用压榨织物制造领域的专业人员所熟知结构的非织造材料制成，如粗人造短纤维的梳理纤网。区6、7和8与如图1所示的本发明第一个实施方案的区1、2和3对应。区7是流动控制区，区8是毛细管区。区9、10和11具有与第一实施方案中区4和5相似的结构和作用。仅仅区9、10和11的厚度与区4和5的厚度不同以便保证毛细管区8的合适放置。在其它方面，结构是相同的。区9、10和11的平均水力孔径比流动控制区或毛细管区的数量级大。区9、10和11使水以极小的流动阻力渗入织物并且充当从纸压出的水的容储器。这些区的厚度使得相对于该织物的表面确定区8的位置从而区8可以有效地作为毛细管区，如先前所描述的。区12是任选的织造层，为了给该织物增加强度和稳定性可以包括所述任选的织造层。
本发明织物的第三个实施方案以横截面的方式显示于图3中。在图2的实施方案中，毛细管区8位于织造层(区12)之上。在图3的实施方案中，毛细管区8位于织造层(区12)的下面。在第二或第三个实施方案中任选包含任何区9、10和11。
在有些实施方案中，该织物是毡的形式。
在本文中所公开的实施方案中，该织物的每个区可以是不同的层，或可以是较厚材料的一部分，其中厚度被分成具有不同孔隙结构(图1、2、和3)或如图4所示的连续变化的孔隙结构部分。
如图4所示，可以将多层织物的一或多层、或整个织物构造成使得平均水力孔径和孔隙度从该材料的一个表面到另一个表面连续地变化。这也可以通过在非织造物的构造期间铺设不同旦尼尔的长丝的各层来实现。它还可以通过以下方式实现：共混各种密度或旦尼尔的纤维，然后使用干法成网或湿法成网技术促使各类型纤维在材料的整个厚度上分层但是在各类型纤维之间没有明显的边界。它还可以通过多步涂布技术来实现，其中每个随后的涂层逐渐地改变孔隙结构而在各个涂层之间没有明显边界。
可以使用非织造物制造领域的技术人员所熟知的其它技术如压延以从一个表面到另一个表面产生孔径的改变。
可以由天然或合成材料独立地制造该织物的每个区。可以使用的天然材料的实例是羊毛、棉花、二氧化硅等并且可以是纤维、颗粒或涂层的形式。合成材料的实例是聚酰胺、聚酯和聚丙烯。该合成材料可以是人造短纤维、连续长丝、颗粒、薄膜或涂层的形式。可以使用已知的非织造或涂布技术来生产每个区希望的孔隙结构。合适的非织造技术的实例包括湿法成网、气流成网、熔纺、纺粘、射流喷网、熔喷、电纺丝、电吹制、梳理、交叉铺网、针刺、压延、层压、粘合剂结合法、热粘合和缝编法。合适的涂布技术的实例包括溅射、喷涂、电镀(plating)和浸渍。在一些实施方案中，这些区可以以商业可获得的独立的层制造或购买，然后使用一个或多个上述技术组装这些区。
例如，该织物可以通过将如下各层堆积来构造：
在底部的流动控制层2，随后是粗人造短纤维毛层(batt)4，然后毛细管层3，和最后另一粗人造短纤维毛层5。将该堆积的组件针刺以使刺针首先穿透层5并且最后穿透层2。在针刺操作期间，用这样的方式针刺将粗纤维从区4和5推过流动控制区2而产生表面区1。在针刺结束时，将该组装结构在表面区1上热压延以便使该表面光滑和稳定并且闭合了由刺针穿透所引起的任何大孔。然后将该织物倒置备用以使表面区1在压榨机中面对纤维素纤维纸结构。
在本中公开的脱水织物还可以用于其它涉及从固形物吸收液体的应用。这些应用包括尿布、干燥布、用于离心机的织物和细矿物的固/液分离。
实施例
当纸幅和织物通过压区时在纸幅和压榨织物体系中使用水流计算模型模拟下列实施例。该模型使用宏观机械能平衡动态地计算在纸幅/织物体系中水的位置。给出描述压榨过程、纸幅和织物结构以及压榨前纸幅和织物组成的输入数据，该模型预测压榨后纸中的固形物百分数含量。根据该计算模型，可推导出各织物结构对脱水性能的影响。
实施例1
这个实施例说明了与仅仅包含流动阻力层的织物和仅仅由粗纤维毛层制成的织物相比本发明脱水织物的效力。
使用具有70atm最大负荷和在压区中3毫秒停留时间的压榨机将75g/m2的纸脱水，该纸具有25％纤维素固形物的预压榨组成。压榨织物结构如图1所示，它具有2.0毫米的总织物厚度。流动控制区2位于自纸侧表面0.3毫米处并且是0.1毫米厚，它具有5μm的平均水力孔径和50％的孔隙度。该毛细管区3位于自该织物的纸侧表面1.2mm处，并且是0.5毫米厚，它具有0.5μm的平均水力孔径和75％的孔隙度。其余的压榨织物是由具有50％孔隙度的粗纤维毛层构造的。这些参数和数值是计算模型的输入数据。该模型预测，在这些条件下，带有毛细管区和流动控制区二者的织物具有54.8％的压榨后固形物。仅仅具有流动控制区的压榨织物具有51.3％的压榨后固形物，而仅仅由粗纤维毛层制成的压榨织物具有48％的压榨后固形物。毛细管区和流动控制区的使用与仅仅使用流动控制区相比改善了脱水3.5％固形物，与使用普通粗纤维毛层相比改善了脱水6.8％固形物。
实施例2
这个实施例说明了与仅仅包含流动阻力层的织物或仅仅由粗纤维毛层制成的织物相比本发明织物的脱水效力。
使用具有70atm最大负荷和在压区中3毫秒停留时间的压榨机将200g/m2的纸脱水，该纸具有25％纤维素固形物的预压榨组成。压榨织物结构如图1所示，它具有2.0毫米的总织物厚度。流动控制区2位于自纸侧表面0.3毫米处并且是0.1毫米厚，它具有5μm的平均水力孔径和50％的孔隙度。该毛细管区3位于自该织物的纸侧表面1.3mm处，并且是0.5毫米厚，它具有0.5μm的平均水力孔径和75％的孔隙度。其余的压榨织物是由具有50％孔隙度的粗纤维毛层构造的。在这些条件下，带有毛细管区和流动控制区二者的织物具有32.3％的压榨后固形物。仅仅具有流动控制区的压榨织物具有30.6％的压榨后固形物，而仅仅由粗纤维毛层制成的压榨织物具有30.4％的压榨后固形物。毛细管区和流动控制区的使用与仅仅使用流动控制区相比改善了脱水1.7％固形物，与使用普通粗纤维毛层相比改善了脱水1.9％固形物。
实施例3
这个实施例说明了用作流动控制层和毛细管层的两个试验材料的效力。
使用具有70atm最大负荷和在压区中3毫秒停留时间的压榨机将75g/m2的纸脱水，该纸具有25％纤维素固形物的预压榨组成。压榨织物结构如图1所示，它具有2.0毫米的总织物厚度。流动控制区2位于自纸侧表面0.3毫米处并且是0.1毫米厚。它是由海岛型聚酰胺非织造物制成的。为了形成流动控制层，使用标准双组分熔纺技术制造海岛型纤维的非织造毛层。纤维结构由18个岛组成，它使用DuPont Zytel 101尼龙6，6作为岛聚合物并使用Eastman AQ55S线性聚酯作为海聚合物。聚合物比值是75％尼龙和25％聚酯。总纤维旦尼尔是3.0且总织物的基重是84gm/平方米。然后将该毛层冷压延以提供允许使用的足够的机械均匀完整性。然后通过用95摄氏度的热水溶液冲洗30分钟来除去织物中的聚酯。所得的非织造毛层由直径为平均3.9微米的尼龙纤维组成。流动控制层具有4.8μm水力孔径、1.2μm最低水力孔径和19.7μm最大水力孔径的孔隙分布，和50％的孔隙度。毛细管区3位于自该织物的纸侧表面1.2毫米处，并且具有0.5毫米的厚度。毛细管层是由尼龙长丝的非织造毛层形成的，所述毛层是使用1微米直径长丝用电吹制技术以30.4gm/平方米的织物基重制造的。电吹制的聚酰胺非织造物具有3.0μm的水力孔径、0.7μm的最低水力孔径和11.8μm的最大水力孔径、以及70％的孔隙度。其余的压榨织物是由具有50％孔隙度的粗纤维毛层构造的。这些参数和数值是计算模型的输入数据。该模型预测，在这些条件下和使用所示构造的织物，用具有毛细管区和流动控制区的织物压榨的纸具有63.6％的压榨后固形物，而用仅仅由粗纤维毛层制成的压榨织物压榨的纸具有35.9％的压榨后固形物。

Claims (23)

1.一种包括至少三个区的多区织物结构物，所述三个区包括：
a)第一表面区；
b)具有1到10微米的平均水力孔径和100微米或更小的厚度的材料的第二区；和
c)具有10微米或更小的平均水力孔径的材料的第三区。
2.根据权利要求1的多区织物，进一步包括织造层。
3.根据权利要求1或2的多区织物，进一步包括至少一个粗长丝或人造短纤维区。
4.根据权利要求1或2的多区织物，其中第二区包括直径小于或等于5微米的纤维或长丝。
5.根据权利要求1或2的多区织物，其中第三区包括直径小于或等于5微米的纤维或长丝。
6.根据权利要求1或2的多区织物，其中第二区是电纺丝的纤维或长丝材料。
7.根据权利要求1或2的多区织物，其中第二区是电吹制的纤维或长丝材料。
8.根据权利要求1或2的多区织物，其中第二区是海岛型长丝或纤维的纺粘材料。
9.根据权利要求1或2的多区织物，其中第三区是电纺丝的长丝或纤维材料。
10.根据权利要求1或2的多区织物，其中第三区是电吹制的长丝或纤维材料。
11.根据权利要求1或2的多区织物，其中第三区是海岛型长丝或纤维的纺粘材料。
12.根据权利要求4的多区织物，其中该纤维或长丝是用选自聚酰胺、聚酯、聚丙烯、聚乙烯、聚乳酸、聚对苯二甲酸亚丙基酯和聚酯酰胺的材料制成的。
13.根据权利要求5的多区织物，其中该纤维或长丝是用选自聚酰胺、聚酯、聚乙烯和聚丙烯的材料制成的。
14.根据权利要求6的多区织物，其中该电纺丝的长丝或纤维材料选自聚酰胺、聚酯、聚乙烯和聚丙烯。
15.根据权利要求7的多区织物，其中该电吹制的长丝或纤维材料选自聚酰胺、聚酯、聚乙烯和聚丙烯。
16.根据权利要求8的多区织物，其中海岛型长丝或纤维的纺粘材料选自聚酰胺、聚酯、聚乙烯和聚丙烯。
17.根据权利要求9的多区织物，其中该电纺丝的长丝或纤维材料选自聚酰胺、聚酯、聚乙烯和聚丙烯。
18.根据权利要求10的多区织物，其中该电吹制的长丝或纤维材料选自聚酰按、聚酯、聚乙烯和聚丙烯。
19.根据权利要求3的多区织物，其中通过粗长丝或人造短纤维区来分隔第二区和第三区。
20.根据权利要求19的多区织物，其中第三区之后是粗长丝或纤维区，随后是织造层，随后是粗长丝或纤维区。
21.根据权利要求19的多区织物，其中第二区之后是粗长丝或纤维区，随后是织造层，随后是粗长丝或纤维区，随后是第三区，随后是粗长丝或纤维区。
22.一种方法，包括：
a)将织物与包括液体或液体和固形物的混合物的材料接触，以便在小于2秒的接触时间内从该混合物吸收液体到该织物内，所述织物包括
i)第一表面区
ii)具有1到10微米的平均水力孔径和100微米或更小的厚度的材料的第二区
iii)具有10微米或更小的平均水力孔径的材料的第三区。
23.根据权利要求22的方法，其中所述材料是纸幅。
CNA2006100793297A 2005-04-01 2006-03-31 脱水织物 Pending CN1854391A (zh)

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