CN1906025A - 具有提高的蓬松感和弹性的三维无纺织物 - Google Patents

具有提高的蓬松感和弹性的三维无纺织物 Download PDF

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CN1906025A
CN1906025A CNA2004800406310A CN200480040631A CN1906025A CN 1906025 A CN1906025 A CN 1906025A CN A2004800406310 A CNA2004800406310 A CN A2004800406310A CN 200480040631 A CN200480040631 A CN 200480040631A CN 1906025 A CN1906025 A CN 1906025A
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fabric
adhesive
pattern
fluffy
bonded fabric
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拉尔夫·穆迪三世
奥古斯丁·里克
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Avintiv Specialty Materials Inc
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Abstract

本发明涉及一种用水刺缠绕的无纺织物，并且更具体的是涉及一种在三维图案传递装置上用水刺缠绕的蓬松的三维无纺织物，其中传递到织物中的图案包括显著的内部中空空间，这导致图案的蓬松和弹性。

Description

具有提高的蓬松感和弹性的三维无纺织物
技术领域
本发明大致涉及一种用水刺缠绕(hydroentangled)的无纺织物，并且更具体的是涉及一种在三维图案传递装置上用水刺缠绕的蓬松的三维无纺织物，其中传递到织物中的图案包括显著的内部中空空间，这使图案具有蓬松感和弹性。
背景技术
众所周知，通常的织物的生产是复杂的多个步骤的过程。利用短纤维生产织物的起始步骤是梳理工序，在梳理工序中，短纤维被打开，并且对齐成已知为梳条的喂入原料。多股梳条然后在并条机上被拉伸多倍以进一步对齐短纤维，混合、改善均匀度并且减小并条的直径。经过并条的梳条然后被喂入粗纱机以通过进一步减小它的直径并且使其具有轻微的假捻而产生粗纱。粗纱然后被喂入纺纱机中，在纺纱机中，粗纱被纺成纱线。纱线接下来被放置在络纱机上，在络纱机中，纱线被转换为较大的包装。纱线然后可用于产生织物。
对于机织物，纱线被指定成特定用作经纱或纬纱。纬纱(在Y轴上延伸，并且公知为纬纱(pick))被直的放到织机上用于织造。经纱(在X轴上延伸，并且公知为经纱(end))必须另外的处理。大包装的纱线被放置在整经机上，并且卷绕在分条整经轴上，在分条整经轴上，纱线被彼此平行地对齐。分条整经轴然后被送入浆纱机中，在那里，浆液被施加到纱线以使它们更加僵硬并且更加耐磨，这对于经受织造过程是需要的。当纱线离开浆纱机时，纱线被卷绕在织机经轴上，织机经轴然后被安装在织机的背面上。经纱穿过织机的织针，当纬纱垂直于交织图案时，所述织针抬高和降低单根纱线，由此将纱线织造成织物。一旦织物已经织造完成，它需要经过洗涤工序以在它可以被染色或修整之前从经纱去除浆液。目前，商业上高速的织机以1000到1500投梭/分钟的速度操作，其中一投梭是纬纱穿过织物的全部宽度的插入。被单和床单织物通常的织物经纬密度为80×80到200×200，分别是每平方英寸的经纱和每平方英寸的纬纱。织造的速度决定于纬纱被交织到经纱中的速度有多快；由此，生产床单织物的织机通常能够达到每分钟5英寸到18.75英寸的生产速度。
相反，众所周知，利用短纤维生产无纺织物比传统的纺织加工效率更高，因为织物直接利用梳理方法生产。
无纺织物适用于多种应用，其中与传统的纺织物相比，生产织物的效率对于这些织物提供了显著的经济上的优点。然而，当比较织物的特性时，特别是在多用途应用中表面的磨损、起球和耐用性方面，无纺织物通常具有缺陷。用水刺缠绕的织物已经发展具有了提高的特性，这是由于在织物中缠绕了纤维或长丝，这提供了提高的织物完整性。在上述缠绕之后，织物的耐用性可以通过施加粘合剂合成物和/或通过缠绕的纤维阵列的热稳定性而进一步提高。
Evans的美国专利No.3,485,706公开了用于实现无纺织物的水刺缠绕的方法，该专利在此引为参考。最近，水刺缠绕技术得到了发展，该技术通过在支撑的有小孔的表面上实现水刺缠绕从而将图案或图案传递到被缠绕的织物。
无纺织物通常包括凸出的图案，所述图案已经通过三维图案传递装置、凸纹筛网、具有三维表面的带子或穿孔的滚筒传递。James等人的美国专利No.5,674,591是这种无纺织物的代表，该专利在此引为参考。然而，这种织物包括这样的凸出图案，当放置成与固体表面接触时，所述图案由于本身几乎没有提供抵抗力并且恢复能力很差，因此图案很容易塌陷。对于清洁的目的来说有利的是：基底包括蓬松、弹性的凸出图案，从而正确地拾起颗粒并把颗粒保持在基底内。
存在对于具有三维图案的无纺织物的需要，其中整体织物具有提高的蓬松感，并且被传递的图案展示出抵抗固体表面的弹性。
发明内容
本发明涉及一种水刺缠绕的无纺织物，并且更具体的是涉及一种在三维图案传递装置上用水刺缠绕的蓬松的三维无纺织物，其中传递到织物中的图案包括显著的内部中空空间，这导致图案的蓬松性和弹性。
无纺织物可用在多种应用中，其中织物的工程质量被有利地使用。这些类型的织物与传统的织造或编织的织物的不同之处在于：织物直接利用纤维垫制成，消除了具有多个步骤的纱线制备和织造或编织的传统织物生产方法。织物的纤维或长丝的缠绕的作用是为织物提供有用程度的完整性。在上述缠绕之后，织物完整性可以通过施加粘合剂合成物和/或通过缠绕的纤维阵列的热稳定性得到进一步的提高。
本发明的无纺织物具有提高的蓬松感和弹性，其中织物具有在其一个平面中的基底部分和在其另一个平面中的凸出部分，如James等人的美国专利No.5,674,591中所描述的，在此引为参考。另外，无纺织物的凸出的纤维部分包括内部中空的空间。根据本发明，第一实施例包括第一纤维母体纤维网，所述纤维网被放置成与支撑层并置，支撑层例如纺粘无纺织物。在推进到有小孔的表面上之前，母体纤维网和支撑层可通过预缠绕硬化。一旦定位在有小孔的表面上，硬化的织物在低的压力水平经受增加量的水的作用，从而从支撑层转移一部分纤维以产生基底部分和凸出的纤维部分之间的内部中空空间。另外，从所述增加量的水以低的压力水平传递到织物的冲击产生了弹性的凸出部分，当把织物卷绕在滚动的物体上时，所述凸出部分不易受所施加的中间层压力的影响。
已经考虑过，有小孔的支撑件可包括但不限于有小孔的金属壳、穿孔筛网、凸纹筛网、具有三维表面的带子和烧蚀热塑性滚筒，其中无纺织物的纤维和/或长丝被水压迫使到嵌在有小孔的支撑件内的各个空腔中。在第二实施例中，本发明的无纺织物可包括三层或更多层，其中另外的层可以是织造的、无纺的、另外的支撑层和/或薄膜，取决于需要的终端应用。另外，具有图案的无纺织物可选择地利用一个或多个性能或美学改变合成物进行处理以另外改变织物结构或满足终端应用物品的要求，所述处理例如机械热压预缩、印花或染色。可以选择聚合的粘合剂合成物以提高织物的耐用性，同时保持具有三维图案的织物的适合的柔软度和悬垂度。可以施加表面活性剂从而使其具有吸水性。另外，静电改善复合物可用于辅助清洁和除尘应用。另外，织物内的一个或多个内部中空空间可起着存储单元的作用，所述存储单元可被各种干燥的或液体的清洁复合物浸渍。
在第三实施例中，本发明的具有图案的无纺织物可包括具有一个或多个开口的图案。所述开口可完全或部分地延伸穿过基底，和/或可以按照有组织的方式分布或者随机地散布在最终的织物上。
通过下面的详细说明、附图和权利要求，本发明的其它特征和优点将变得显而易见。
附图说明
图1是用于生产无纺织物的设备的示意性视图，体现了本发明的原理；
图2是根据本发明生产的无纺织物的显微照片；
图3是根据本发明生产的无纺织物的显微照片；和
图4和图5是示出目前的织物的内部中空空间的横截面视图。
具体实施方式
虽然本发明可具有各种形式的实施例，本发明目前优选的实施例示于附图中，并且下面将进行描述，应当理解，本公开说明应被认为是本发明的实例，并且不能用于将本发明限制到所示的具体
实施例。
本发明涉及一种蓬松的用水刺缠绕的无纺织物，所述织物包括基本平坦的基底(background)部分和至少一个凸出部分，所述凸出部分整体地形成从平坦的基底部分凸出的弹性三维图案和/或图案，其中水刺缠绕的方法从支撑层转移一部分纤维以形成基底部分和凸出的纤维部分之间的内部中空空间，其中所述用水刺缠绕的方法以低的压力水平利用了增大量的水。
参考图1，其中示出了用于实施用于形成无纺织物的本方法的设备。体现了本发明的原理的无纺织物的生产以提供母体(precursor)无纺纤维网而开始。母体纤维网可以由从具有一致或混合的纤维长度的天然或人造合成物中选择的纤维或长丝构成。适合的天然纤维包括但不限于：棉花、木浆和粘胶人造丝。可以整体或部分地混合的合成纤维包括热塑性和热固性的聚合物。适合于混合的热塑性聚合物包括聚烯烃、聚酰胺和聚酯。热塑性聚合物另外可以从均聚物中选择：共聚物，共轭物，以及包括那些具有结合的熔化添加剂或表面活化剂的热塑性聚合物的其它衍生物。纤维或长丝的轮廓不会限制本发明的适用性。扯样长度在0.25英寸到8英寸的范围中选择，优选在1到2英寸的范围中，并且纤维的旦尼尔值在1到15的范围中选择，1.5到6旦尼尔对于普通应用是优选的。纤维的轮廓不会限制本发明的适用性。母体纤维网优选被梳理，并且被气流成网或交叉堆叠以形成母体纤维网，用P表示。
根据本发明，支撑层被引入到母体无纺纤维网中。支撑层降低了最终的具有三维图案的无纺织物的可延展性，因此降低了三维图案扭曲的可能性，并且另外提高了织物的耐用性。优选的是，热塑性的纺粘纤维网起着支撑层的作用，但是其它适合的支撑层可包括单向单丝、双向单丝以及其它各种麻布材料。支撑层与母体纤维网并置放置。在前进到有小孔的表面上之前，母体纤维网和支撑层通过预先缠绕被硬化。一旦定位在有小孔的表面上，硬化的织物在低的压力水平受到增大量的水的作用，从而从支撑层转移一部分纤维，在基底部分和凸出的纤维部分之间形成内部中空空间。
为了转移纤维从而产生具有内部中空空间的弹性图案，如图4和5所示，纤维被大量的水压能量以低的压力冲击。优选的是，用水刺缠绕的无纺织物以大约13到30hp-hr-lbf/lbm冲击，并且更优选的是利用大约13到22hp-hr-lbf/lbm冲击。另外，由于上述的冲击使凸出的部分具有的弹性使得：当在大约0.5psi的压力下作用7到10天的时间中间层压力大小大约为0.2到2.0磅/平方英寸时，当释放中间层压力后，经过34小时后，凸出部分将恢复未压缩厚度的超过75％。中间层压力分布参考David R.Roisum，Ph.D的The Mechanics of Web Handling的30到33页，在此引为参考，其中它讨论了施加在织物上的卷绕张力会造成总体织物松密度的损失。
已经考虑过，本发明的织物可具有分层的结构，其中母体无纺纤维网可与三层或更多的另外的织物层结合。这种层包括但不限于：弹性体织物，纺熔织物、另外的粗梳纱织物和各种薄膜。通常，纺熔织物包括连续的以及不连续的长丝无纺织物的结构。由连续的长丝结构构成的无纺织物涉及纺粘法的实施。纺粘法包括供应熔化的聚合物，所述熔化的聚合物然后在压力的作用下通过已知为喷丝板或压出板的板中的许多喷丝孔挤出。所得到的连续的长丝被骤冷，并且通过多种方法中的任一种被拉伸，例如槽拉伸系统、再割喷枪(attenuator gun)，导丝辊。连续的长丝在移动的有小孔的表面上方被收集成松散的纤维网，所述表面例如金属丝网传送带。当在生产线中使用超过一个喷丝头以形成多层的织物时，后来的纤维网在先前形成的纤维网的最上方的表面上被收集。纤维网然后至少暂时地被硬化，通常通过包括热量和压力的方式，例如通过热点粘结。使用这种方法，多层纤维网中的纤维网或层穿过两个热的金属辊子之间，其中一个辊子具有凸出的图案以传递和获得适合程度的点粘结，通常量级为10％到40％的总体表面积被这样粘结。
与纺粘法相关的用于形成无纺织物层的方法是熔喷法。再次，熔化的聚合物在压力的作用下通过喷丝板或压出板中的喷丝孔被挤出。当长丝离开压出板时，高速空气冲击在长丝上并且输送长丝。这个步骤的能量使得：形成的长丝的直径被大大减小，并且被断开从而产生具有有限长度的微纤维。这不同于纺粘法，从而保持了长丝的连续性。所述形成单层或多层织物的过程是连续的，即所述过程的步骤从长丝的挤出以形成第一层直到粘合纤维网被卷绕到辊子中一直没有被中断。用于生产这些类型的织物的方法在美国专利No.4,041,203中进行了描述，在此引为参考。
另外，适合的纳米旦尼尔连续的长丝层可以通过纳米旦尼尔长丝的直接纺丝而形成，或者可以通过形成具有多个部分的长丝而形成，所述具有多个部分的长丝在沉积在基底层之前被分为纳米旦尼尔长丝。美国专利No.5,678,379和No.6,114,017以例子示出了可适合于支持本发明的丝束直接纺纱法，它们都在此引为参考。美国专利No.5,678,379和No.6,114,017以例子示出了可适合于支持本发明的丝束直接纺纱法，它们都在此引为参考。
本发明可包括网状薄膜、微孔薄膜或整体薄膜。用于形成网状薄膜的适合的方法是通过利用Reticulon技术，如Kelly的美国专利No.4,381,326中所描述的，在此引为参考。适合的微孔薄膜层可包括例如美国专利No.5,910,225中报道的那些材料，在此引为参考，其中小孔-成核剂用于形成微孔。如美国专利No.6,191,221中所报道的整体薄膜也可用作适合的薄膜层装置，所述专利在此引为参考。下面的事实也在本发明的范围内：粘合剂材料可作为易熔化的纤维结合在母体无纺纤维网的构造中，或作为在有图案的织物形成之后施加的液体纤维粘合剂。粘合剂材料另外将提高最终的有图案的无纺的织物在使用中的耐用性。
图1另外示出了用于根据本发明形成无纺织物的水刺缠绕的设备。该设备包括带子形式的有小孔的成形表面10，母体纤维网P被定位在其上用于通过缠绕歧管12进行预缠绕。在形成图案和图案之前，母体纤维网的预缠绕通过纤维网P顺序地在滚筒14上运动从而随后实现，所述滚筒14具有有小孔的成形表面，缠绕歧管16实现纤维网的缠绕。纤维网的另外的缠绕在滚筒18的有小孔的成形表面上通过缠绕歧管20实现，纤维网之后经过连续的有小孔的滚筒20上方，用于通过缠绕歧管24、24’进行连续的缠绕处理。施加三维图案和图案可以在三维图案传递装置24上通过歧管26的作用实现。在水刺缠绕之后，具有三维图案的织物可受到一种或多种缠绕之后的性能改变处理，例如在20处。这种处理可包括聚合粘合剂合成物的施加、机械热压预缩、表面活性剂或静电合成物的施加、印花或染色等工艺。织物可在适合的烘筒32上干燥。
本发明公开的无纺织物适用于各种家居、卫生、医疗和工业终端应用，包括个人护理擦拭巾和擦拭灰尘用的布。无纺织物适用于清洁目的，其中蓬松的、弹性的、凸起的图案有助于收集颗粒和将颗粒保持在基底内。具有图案的织物还可用在各种卫生应用中，其中织物的柔软的和触觉的特性适用于清洁皮肤。另外，内部中空的空间可利用肥皂和/或润肤剂浸渍以通过使使用者更方便地使用从而有助于清洁过程。无纺织物可用作吸水物品内的组件，例如液体捕获层，其中蓬松的、弹性的织物是适合的。其它的终端应用包括医疗织物，例如医护服和织物，以及工业织物，例如防护服和户外织物，包括但不限于汽车罩和其它户外设备罩。
已经考虑过，具有图案的无纺织物另外可以利用一种或多种性能或美学改变合成物进行另外的处理以进一步改变织物结构或者满足终端应用物品的要求。
如上所述，应当认为，在不脱离本发明的新颖性概念的实质和范围的情况下，可以实现多种修改和变化。应当认为，对于此处所示的具体实施例，不能或不应当推断为是一种限制。本公开内容用于通过权利要求覆盖落在权利要求内的所有这种的修改。

Claims (4)

1.一种制造蓬松的、三维的无纺织物的方法，所述织物包括基本平坦的基底部分和至少一个弹性的凸出部分，其中所述织物包括一个或多个位于所述基底部分和所述凸出部分之间的内部中空的空间，所述方法包括下列步骤：
a.提供母体纤维网；
b.提供支撑层；
c.提供有小孔的表面；
d.使所述母体纤维网和所述支撑层硬化；
e.将所述硬化的纤维网推进到所述有小孔的表面上；和
f.在所述有小孔的支撑件上用水刺缠绕所述硬化的纤维网，其中所述纤维网利用大约13到30hp-hr-lbf/lbm(马力-小时-磅力/磅质量)进行水压冲击。
2.一种蓬松的、具有三维图案的无纺织物，包括基底区域、至少一个凸出区域以及位于所述基底区域和所述凸出区域之间的内部中空空间，其中所述织物利用大约13到30hp-hr-lbf/lbm进行水压冲击。
3.一种蓬松的、具有三维图案的无纺织物，包括基底区域和至少一个凸出区域，其中所述织物包括在大约0.5psi的压力作用7天时间的情况下的大约0.2到2.0磅/平方英寸的中间层压力大小。
4.如权利要求3所述的蓬松的、具有三维图案的无纺织物，其特征在于，所述织物包括在大约0.5psi的压力作用10天的情况下的大约0.2到2.0磅/平方英寸的中间层压力大小。
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AU2004293776A1 (en) 2005-06-09
ES2371752T3 (es) 2012-01-09
WO2005052237A2 (en) 2005-06-09
US20050148267A1 (en) 2005-07-07
EP1684972B1 (en) 2011-08-17
ATE520524T1 (de) 2011-09-15
EP1684972A2 (en) 2006-08-02

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