CN1997787A - Elastic nonwoven sheet - Google Patents

Elastic nonwoven sheet Download PDF

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Publication number
CN1997787A
CN1997787A CNA2005800203147A CN200580020314A CN1997787A CN 1997787 A CN1997787 A CN 1997787A CN A2005800203147 A CNA2005800203147 A CN A2005800203147A CN 200580020314 A CN200580020314 A CN 200580020314A CN 1997787 A CN1997787 A CN 1997787A
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China
Prior art keywords
nonwoven
elastomeric polymer
necked
substrates
untreated
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CNA2005800203147A
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Chinese (zh)
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CN1997787B (en
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K·E·马丁
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Invista Technologies SARL Switzerland
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Invista Technologies SARL Switzerland
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Classifications

    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00Other non-woven fabrics
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06MTREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/564Polyureas, polyurethanes or other polymers having ureide or urethane links; Precondensation products forming them
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length

Abstract

This invention relates to stretchable nonwoven sheets prepared by substantially uniformly impregnating a necked nonwoven substrate or an easily extensible as-made nonwoven substrate with an elastomeric polymer by treatment with an elastomeric polymer solution. The nonwoven sheet is useful in the manufacture of diapers and other hygiene articles.

Description

Elastic nonwoven sheet
Background of invention
The application requires the U.S. Provisional Application serial number 60/565 of submission on April 23rd, 2004,014 priority, provisional application serial number 60/565,014 requires the U.S. Patent application serial number 10/413 of submission on April 14th, 2003,172 priority, U.S. Patent application serial number 10/413,172 is the part continuation application of the U.S. Patent application serial number 10/353,677 (abandoning now) of submission on January 29th, 2003; These two applications are all incorporated herein by reference.
1. invention field
The present invention relates to be applicable to the stretchable nonwoven sheets of preparation personal hygiene articles.More especially, described stretchable nonwoven sheets is by flooding necked nonwoven substrate basically equably or the nonwoven substrates that is untreated of easily stretching prepares with elastomeric polymer.
2. description of Related Art
Non-woven elastic is well-known in the art.The example of non-woven elastic comprises " stretched bonded type " and " examples of neck-bonded type " laminated material.Stretched bonded type laminated material prepares by the following method: but the gathering layer is attached on the elastic layer, and described elastic layer is in extended state simultaneously, thereby when these layers are lax, but described gathering layer is by gathering.Examples of neck-bonded type laminated material prepares by constriction, nonelastic layer and elastic membrane are combined on the fibrage.Described elastic layer generally comprises elastic membrane or elastic non-woven net.These elastic non-woven laminated materials need prepare at least two independent non-woven or retes.
The U.S. Patent number 4 of Riedel (Riedel), 366,814 have described a kind of ventilative elastoplast material, described material comprises being impregnated into described fabric rather than filling the elastomer in described fabric hole of the Stretchable fabric (do not tear elongation be at least 30%) of at least 50% weight and at least 15% weight.
The U.S. Patent number 5 of Morman (Morman), 910, but 224 have described the method for preparation elastomeric compositions, but this method is by being applied to elastomer precursor neckable material such as nonwoven web, but the described neckable material of neck stretched, and described elastomer precursor handled (as by heating), but simultaneously described neckable material is under the constriction condition, forms the elastic layer that is bonded to described neckable material.Preferred elastomer precursor comprises latex or thermo-setting elastomer.It is 5g/m that but elastomer precursor is applied to the amount of described neckable material 2To about 50g/m 2Elastic layer generally is penetrated into net about 2 to about 10 fiber thickness, and the penetration degree of control elastomer precursor, so as not have to glue be seeped into described net dorsad elastic layer be applied the one side of face.Therefore, but the gained elastomeric compositions has film-sample feel in a side that comprises elastic layer, but and makes elastic layer dorsad simultaneously go up neckable material to keep initial soft feel.
The European Patent Application No. of announcing 0472942 has been described at Z-and has been soaked into nonwoven material to the elastomer with compressibility and recovery, described nonwoven material comprises fiber web, as the meltblown fibers nonwoven web, it uses polymeric material, soaks into as elastomeric propylene acid latex, polyurethane rubber latex or nitrile rubber latex.
The Japanese patent application No. 47-24479 that announces relates to the band that is used for conveying equipment and electric power transfer, and it is by preparing with rubber or synthetic resin dipping needled fabric.
To can preparing economy, have and soft stretch and well keep the elastic sheet material of intensity to have continuous demand, and described elastic sheet material two sides all has fabric-sample feel.
Summary of the invention
The present invention relates to form the method for stretchable nonwoven sheets, said method comprising the steps of:
Provide have certain thickness, necked nonwoven substrate that first and second outer surfaces, vertical and horizontal stretch, described necked nonwoven substrate is at least 30% at horizontal percentage percentage elongation;
Basically flood described necked nonwoven substrate equably with solution, described solution comprises the elastomeric polymer that is dissolved in solvent; With
Solidify by wet method, described solvent is removed from the nonwoven substrates of dipping, whole thickness at described nonwoven substrates deposits described elastomeric polymer basically equably, and does not form continuous basically elastomeric polymer layer on described first or second outer surface of described nonwoven substrates.
The invention still further relates to the method that forms stretchable nonwoven sheets, said method comprising the steps of:
The easy stretching nonwoven substrates that is untreated is provided, and this base material has certain thickness, first and second outer surfaces, vertical and horizontal and stretches, and is at least 30% at horizontal percentage percentage elongation, and basis weight is about 15g/m 2To about 100g/m 2, fracture strength is greater than 500g/in;
With the solution that comprises the elastomeric polymer that is dissolved in solvent, flood the described easy stretching nonwoven substrates that is untreated basically equably; With
Solidify by wet method, described solvent is removed from the described easy stretching nonwoven substrates that is untreated, whole thickness at described nonwoven substrates deposits described elastomeric polymer basically equably, and does not form continuous basically elastomeric polymer layer on described first or second outer surface of described nonwoven substrates.
The invention still further relates to stretchable nonwoven sheets, described stretchable nonwoven sheets comprises nonwoven substrates, described nonwoven substrates in necked direction by constriction, and with elastomeric polymer basically equably the dipping, described stretchable nonwoven sheets is after necked direction is stretched to 140%3 times, and the 3rd load cycle force rate rate when the three unloading cyclic force and 100% of this stretchable nonwoven sheets when 100% elongation extends is at least 0.3: 1.
The present invention also relates to stretchable nonwoven sheets in addition, described stretchable nonwoven sheets comprises the easy stretching nonwoven substrates that is untreated, described nonwoven substrates floods basically equably with elastomeric polymer, described stretchable nonwoven sheets is after laterally being stretched to 30%3 times, and the 3rd load cycle force rate rate when the three unloading cyclic force and 30% of this stretchable nonwoven sheets when 30% elongation extends is at least 0.15: 1.
Detailed Description Of The Invention
Among the present invention,, flood necked nonwoven substrate or the nonwoven substrates that is untreated that easily stretches, the composite nonwoven sheet material that can stretch is provided by with the solution that comprises solvent and elastomeric polymer.The described necked nonwoven substrate or the nonwoven substrates that is untreated that easily stretches do not flood under the condition that forms polymeric layer on its any surface in that described nonwoven substrates is flooded basically equably.Remove desolvate after, obtain the nonwoven sheet of gas permeability dipping, this sheet material has in the accident combination of laterally comparing feel as high unloading cyclic force (good maintenance intensity and soft the stretching) and the fabric with load cycle power.In addition, sheet material of the present invention is generally simpler and thinner than conventional multilayer stretched laminated material preparation.General thickness as sheet material of the present invention is about 0.25mm-0.75mm, and stretch laminate thickness generally surpasses 1.3mm.
Term " polymer " used herein " generally comprise but be not limited to homopolymers, copolymer (as block, grafting, random and alternate copolymer), terpolymer etc. and blend and modifier.In addition, unless concrete in addition qualification, term " polymer " " will comprise all possible geometric configuration of described material.These configurations include but not limited to isotaxy, syndiotaxy and atactic symmetries.
Term used herein " polyester " will comprise polymer, and wherein at least 85% repetitive is the condensation product of dicarboxylic acids and dihydroxylic alcohols, have ester units and form the key that produces.This comprises aromatics, aliphatic series, saturated and unsaturated diacid and glycol.Term used herein " polyester " also comprises copolymer (as block, grafting, random and alternate copolymer), its blend and modifier.The common instance of polyester is polyethylene terephthalate (PET), and it is the polycondensation product of ethylene glycol and terephthalic acid (TPA).
Term used herein " polyurethane " will comprise the block copolymer with difunctionality polyalcohol and vulcabond and difunctionality chain extender polycondensation preparation, as hereinafter described in detail.
Term used herein " polyolefin " is meant any most of saturated open chain polymeric hydrocarbon series of only being made up of carbon and hydrogen.General polyolefin includes but not limited to the various combinations of polyethylene, polypropylene, polymethylpentene and ethene, propylene and methylpentene monomers.
Term used herein " polyethylene " not only comprises the homopolymers of ethene, and at least 85% repetitive is the copolymer of ethylene unit but also comprise wherein.
Term used herein " polypropylene " not only comprises the homopolymers of propylene, and at least 85% repetitive is the copolymer of propylene units but also comprise wherein.
Term used herein " elastomeric polymer " is meant when forming sheet, fiber or film and applying inclined to one side power (biasing force), extending to tensile elongation for its lax no inclined to one side length at least about 160%, and extend any polymer that will make its elongation at least 55% answer after inclined to one side power discharges at this.As can being stretched at least 1.6 centimetres, and after applying power, be stretched to 1.6 centimetres and discharge this power after can be returned to the one centimetre of material sample that is no more than 1.27 centimetre lengths.Exist many stretching to substantially exceed the elastomeric material of its relaxed length 60% (as 100% or more), and wherein manyly after discharging tensile force, will be returned to their initial relaxed length substantially, as be returned to their initial relaxed length 105% in.
Term used herein " supatex fabric " or " nonwoven web " are meant the tissue of individual fibers, silk or line, compare with knitting or woven fabric, and described fiber, silk or line can be placed the formation planar materials at random, and do not have definite pattern.
Term used herein " spunbond " silk is meant by molten thermoplastic polymer material is extruded from spinning head a plurality of carefully, generally are circular pore as silk, and extrudes the silk that the diameter of silk reduces to form by stretching subsequently fast.Also can use other shape of cross section, as ellipse, leafy shape (multi-lobal) etc.Spunbond silk be generally continuous and average diameter greater than about 5 microns.Spunbonded non-woven fabrics or Netcom cross spunbond silk is placed on to collect on the surface (as hole sizer or band) at random and prepare.Spunbond net is general to adopt method as known in the art bonding, as the hot-rolling calendering, or makes described Netcom cross the saturated chamber of elevated pressures.Equally, described net can be positioned at the horizontal many heat bonding pins place thermal point bond of nonwoven fabric.
Term used herein " vertically " (MD) is meant the direction of nonwoven web preparation.Term " laterally " (XD) is meant and is generally perpendicular to direction longitudinally.
Term used herein " constriction " is meant a kind of method, described method relates to power is applied to supatex fabric, as be parallel to non-woven vertically, make described supatex fabric apply the direction elongation of power, and in direction, as laterally its width being reduced to aequum in the mode of controlling perpendicular to prolonging direction.Direction perpendicular to tensile force is called " necked direction " herein.The stretching of control and constriction can be carried out under the higher or lower temperature in room temperature or than room temperature, and are limited to be up in the increase of draw direction overall size and tear or tear the required elongation of fabric.
Term used herein " necked nonwoven fabric " and " necked nonwoven substrate " are meant by processing as stretching, any supatex fabric that shrinks at least one direction." but necked nonwoven fabric " is the supatex fabric that can shrink at least one direction in the constriction process.Term " percentage constriction rate " is meant measures constriction size not and poor between the constriction size (measuring in necked direction), then with this difference divided by constriction size not, and gained ratio be multiply by 100 ratios of determining.Constriction is non-woven generally can to stretch a certain amount ofly in necked direction, and this amount is corresponding to the percentage constriction rate in (but not being linear relationship) constriction process.The non-woven extensibility of constriction is in this article as the percentage percentage elongation, extremely at utmost possible by nonwoven material in necked direction stretching constriction, and do not have individual fibers in the draw nonwoven material, destroy in the nonwoven material any fiber-fiber in conjunction with or tear nonwoven material and measure.
Term used herein " nonwoven material that is untreated easily stretches " is meant the step of normal use in non-woven preparation method, nonwoven material without any other procedure of processing (as constriction), applying less than 200 gram/inches (g/in), when being generally less than the power of 100g/in, cross direction elongation is not destroyed at least 30% (general about 60% to about 150%), and described power is determined according to " extending 30% required power " method of describing in the Test Methods section.50% percentage elongation is meant that 10 inches wide samples are stretchable to 15 inches.The be untreated basis weight of nonwoven material example of suitable easy stretching can be about 15 to about 100 gram/square metre (g/m 2), be generally about 30 to about 80g/m 2, the longitudinal fracture intensity of measuring according to " the fracture strength analysis " described in the Test Methods section is greater than 500g/in.The nonwoven material that is untreated of easily stretching can be jet net-spraying method (being also referred to as the water acupuncture manipulation), melts and sprays or hot sticky nonwoven material, and can be by these known methods preparations.
Term used herein " jet net-spraying method nonwoven material " is meant by clash into the fabric that net (it can comprise prefabricated fabric, spunbond meltblown web, the air-flow net of justice and carded web) or wadding form with high-pressure water jet.The nonwoven material that is untreated of easily stretching comprises 8075 type Sontara  (Sontara  is the registration mark of E.I.DuPont de Nemours and Company) and flat pattern jet net-spraying method nonwoven material (the Item Number 4055-T that Taipei Sheng Hung Industrial Company prepares).
Term used herein " melt-blown non-woven material " is to instigate molten polymer to be expressed into the nonwoven material that high velocity, hot air or vapor stream (it makes the gained silk become carefully and relatively short fiber) form by mould.These fiber laydown are at diaphragm or be with, and subsequently by calendering, embossing, hot-air or the sclerosis of other heat bonding method.
Term used herein " hot sticky nonwoven material " is meant the fabric of being made up of fiber web or fleeces, described fabric contains thermo-sensitive material, the low melting point binder fiber or the thermoplasticity powder of the special through engineering approaches of network fiber as described in being lower than as fusing point, it is at pressurized or do not have and apply heat (as by hot-air, calendering, embossing, infra-red heat or other heat bonding method) fusion under the pressure, and with the bonding sclerosis nonwoven material that becomes of the fiber of described net or wadding.
Term used herein " nonwoven substrates " is meant base material, and this base material can be necked nonwoven substrate or the nonwoven substrates that is untreated that easily stretches.
Term used herein " supatex fabric " is meant fabric, and this fabric can be necked nonwoven fabric or the supatex fabric that is untreated that easily stretches.
Term used herein " evenly floods " basically or " evenly flooding basically " is meant even distribution process agent or solution in whole bulk volume.
A kind of method described in term used herein " wet method is solidified ", wherein nonwoven substrates is contacted with solidification liquid, this base material is dipping solution, this solution comprises the elastomeric polymer that is dissolved in solvent, described solidification liquid is the non-solvent of elastomeric polymer, but can dissolve each other with the solvent that is used to form elastic polymer solution.Also select solidification liquid to make it not dissolve nonwoven substrates.Described solidification liquid solidifies polymeric material, and makes the solvent of removing enter solidification liquid.Subsequently solidification liquid is removed from polymer impregnated nonwoven substrates, as passing through air drying or heating.
Be applicable to that but necked nonwoven fabric of the present invention comprises spunbond net, bonded carded webs and water gill net.Adopt method as known in the art in horizontal constriction but described necked nonwoven fabric is preferred general, obtain percentage constriction rate and be about 25% to about 75%, obtaining at horizontal percentage percentage elongation is about 30% to about 300% necked nonwoven substrate.But can be used for necked nonwoven fabric of the present invention and can comprise nonelastomeric polyolefins such as polyethylene, polypropylene, ethylene copolymer, polyamide, polyester, polystyrene and poly 4-methylpene-1 with many thermoplastic polymer preparations.But preferably comprise polypropylene, polyester or polypropylene-polyethylene and ethylene copolymers as necked nonwoven fabric.In preferred embodiments, but necked nonwoven fabric is spunbond polypropylene fabric or carding heat bonding polypropylene or polyester textile.But the preferred basis weight of necked nonwoven substrate raw material is generally about 10g/m 2To about 50g/m 2But the preferred especially low relatively necked nonwoven substrate of basis weight is about 10g/m as basis weight 2To about 20-30g/m 2Those.Nonwoven substrates is generally moisture permeable.But with the necked nonwoven substrate constriction, to provide general basis weight greater than about 15g/m 2Necked nonwoven substrate.
Necked nonwoven fabric is well known in the art, but and generally by preparing in the longitudinal stretching necked nonwoven fabric, be provided at the necked nonwoven fabric of horizontal constriction.The example of constriction method is open in as the U.S. Patent number 4,965,122,4,981,747 and 5,114,781 of the U.S. Patent number 4,443,513 of (Meitner) such as Meitner, Morman.Preferred constriction method is open in the US Re 35,206 of (Hassenboehler) such as Hassenboehler Jr..US Re35, the 206th, U.S. Patent number 5,244,482 second edition, and incorporated herein by reference.Nonwoven web according to the method constriction of Hassenboehler is also referred to as " deflation net " in this article.
Necked nonwoven can adopt the low relatively method preparation of cost, and more preferred than other Stretchable nonwoven fabric, because their cross direction elongation is higher, and stretching (load) power that requires when the cross directional stretch nonwoven material is low relatively.In addition, necked nonwoven fabric is generally vertically non-stretchable substantially, and promptly when being subjected to vertically partially power, their percentage percentage elongation is less than about 10%.As discussed below, in some final use, wish very much to stretch in a direction basically.
In preferred embodiments, necked nonwoven substrate is for adopting the deflation net of the method preparation of describing among the Hassenboehler.This method comprises makes the low relatively bonding thermoplastic nonwoven web of processing draftability by the thermal treatment zone such as baking oven, so that the temperature of net is brought up to the softening temperature of polymeric web and the temperature between the melt temperature, simultaneously at the longitudinal stretching net, make fiber plastic deformation at horizontal orientation, and laterally tightening (constriction) this net.Stretch and so carry out: with first linear velocity net is sent into this district, and surpassing under second linear velocity of first speed its extraction.As the second speed and first velocity rate is about 1.1: 1 to about 2: 1.But bonded nonwoven net raw material is non-resilient necked nonwoven fabric, and select to have in the hot procedure less than about 4.0: 1 and greater than about 1.4: 1 stretch ratio at break, be higher than softening point greater than 2500%/min and temperature but be lower than under the hot-stretch condition of polymeric web melt temperature at least 10  in strain rate and estimate.(strain) is 2-40% as the room temperature elongation at break, is generally 5-20%, adopts the Instron tester for elongation, measures according to method of testing ASTM D 1117-77.
Fiber in the raw material net can be by fiber-fibre fusion, fiber winding or heat bonding as bonding next bonding by putting.Usually, but the fiber diameter of fiber is little in the necked nonwoven fabric, as less than about 50 microns.For silk section local elongation, fold and bending not being influenced the integrality of net, bonding generally very strong (bonding) of spunbond precursor as high temperature dot.In the some adhesion process, generally select bonding pin and bonding patterns, make the area of bounding point account for about 5% to about 25% of web area.The shape of bonding pin can be rhombus or many other shapes well known in the art.
The hot-stretch step causes the deflation of transverse fiber plastic deformation and net, thereby a large amount of fibers are generally arranged along draw direction (vertically).With respect to the nonwoven material raw material, net is in horizontal deflation, because it is in longitudinal tensile strain and HEAT SETTING.
Can be used on cross direction elongation and be at least 30%, the necked nonwoven substrate as at least 50% prepares elastic nonwoven sheet of the present invention.In process of packing, the percentage constriction rate of nonwoven web is about 50% to about 75%, is generally about 60%-70%, the percentage elongation of respectively corresponding about 100-300% and 150-250%.
But the basis weight of constriction nonwoven web can be 3 times of constriction nonwoven web raw material basis weight or more.The basis weight of necked web is about 15g/m 2To about 100g/m 2, 20g/m according to appointment 2To about 100g/m 2, and be generally about 25g/m 2To about 100g/m 2According to required final use, select the basis weight of necked nonwoven substrate.As, when as flexible liner, the basis weight of necked nonwoven is generally about 30g/m 2-70g/m 2, and for health final use such as diaper, waistband etc., basis weight is generally about 15g/m 2-40g/m 2Also should select the basis weight of necked nonwoven substrate, so that the nonwoven material of final dipping obtains required elasticity.The nonwoven substrates of higher basis weight allows more elastomeric polymer to be impregnated in the nonwoven material, has improved the unload forces of the nonwoven sheet of dipping.
Adopt the low relatively nonwoven material of basis weight in the constriction method of preferably in Hassenboehler, describing, prepare material of the present invention.Use together and with behind the elastomeric polymer dipping, these factors combine provides stretchable nonwoven, and the required power of expanded material (load force) is low relatively, the retraction force (unload forces) of material production is high relatively when allowing it lax.For the final use that this material is estimated, this feature is preferred.The relation of unload forces and load force is relevant with the hysteresis of non-woven elastic.For the preferred laterally product of percentage percentage elongation at least 150% of the present invention, after between the nonwoven material that has flooded has been stretched to 140% 3 time and has stretched, allowing to relax, the load force ratio was at least 0.3: 1 when 100% when elongation, unload forces was extended with 100%, as greater than 0.45: 1.
Be used for elastomeric polymer of the present invention and comprise polyurethane, styrene-butadiene block copolymer and polyether ester block copolymer.In preferred embodiments, elastomeric polymer is a polyurethane.
Being used for elastic polyurethane of the present invention can prepare by the following method: make polymer diol and di-isocyanate reaction form the glycol of end-blocking, dissolve the glycol (in suitable solvent) of this end-blocking, make the glycol and difunctionality chain extender reaction of end-blocking subsequently with active hydrogen atom.This polyurethane is called " segmented polyurethane ", because they are by " firmly " ammonia ester and urea segment derived from vulcabond and chain extender, forms with main " soft " segment derived from polymer diol.The suitable solvent for preparing this base polymer solution is an amide solvent, as dimethylacetylamide (" DMAc "), dimethyl formamide (" DMF ") and N-Methyl pyrrolidone, but also can use other solvent such as dimethyl sulfoxide (DMSO) and tetramethylurea.
The polymer diol that is used to prepare elastic polyurethane comprises PTMEG, polyester-diol, PCDL and copolymer thereof.The example of this class glycol comprises poly-ether glycol, polytetramethylene ether diol, (tetramethylene-2-methyl-tetramethylene ether) diol copolymer, (ethene-tetramethylene adipate) diol copolymer, poly-(2,2-dimethyl-1, ammediol lauric acid ester) glycol, poly-(1,5-pentanediol carbonic acid ester) (poly (pentane-1,5-carbonate)) two pure and mild poly-(1,6-hexylene glycol carbonic acid ester) (poly (hexane-1,6-carbonate)) glycol.
Useful vulcabond comprises 1-isocyanate group-4-[(4-phenyl isocyanate base) methyl] benzene, 1-isocyanate group-2-[(4-phenyl isocyanate base) methyl] benzene, isophorone diisocyanate, 1,6-hexane diisocyanate and 2,4 toluene diisocyanate.
Chain extender can be glycol or diamines.Useful glycol comprises ethylene glycol, 1, ammediol, 1,4-butanediol and composition thereof.Adopt diol chain-extension agent to produce polyurethane.Useful diamines comprises ethylenediamine, 1,2-propane diamine, 2-methyl isophthalic acid, 5-pentanediamine, 1,3-pentanediamine, 1,4-cyclohexanediamine, 1,3-cyclohexanediamine and composition thereof.In this case, the polymer of generation is polyurethane-urea (subclass of polyurethane).When adopting PTMEG and diamine chain stretching agent, the polymer of generation is a polyether urethaneureas; When uniting use polyester-diol and diamine chain stretching agent, produce the poly ester urethane urea.Can add monofunctional amines chain terminating agent such as diethylamine, butylamine, cyclohexylamine etc., come the molecular weight of controlling polymers.In preferred embodiments, elastomeric polymer is the polyurethane elastomer of diamines-prolongation.
The solvent that is applicable to the preparation elastic polymer solution comprises dimethylacetylamide, dimethyl formamide and N-methyl-pyrrolidones.The viscosity of elastic polymer solution is directly related with the concentration of polymeric material in the solution, thereby solution viscosity can impact polymer penetrates into necked nonwoven fabric or easily stretches the degree of supatex fabric and the amount of the polymer of deposition wherein of being untreated.When solution viscosity is too low, can be deposited on necked nonwoven substrate or the be untreated elastomeric amount of nonwoven substrates of easily stretching not enough, cause unload forces low.When solution viscosity was too high, the solution that may reduce nonwoven substrates infiltrated, thereby caused polymer impregnated not exclusively or inhomogeneous in the nonwoven substrates, or formed polymeric layer on the nonwoven substrates surface.As be impregnated into necked nonwoven substrate, or the be untreated solution viscosity of elastic polymer solution of nonwoven substrates of easily stretching is about 1000-300,000 centipoise (" cPs ") is generally 10, and 000-40,000cPs is 25 ℃ of mensuration.Solution can comprise about 5% weight-20% weight polymer.
Necked nonwoven substrate or easily stretch is untreated nonwoven substrates can absorbing polymeric solution, and this polymer solution is fully basic and evenly the dipping nonwoven substrates be necessary.Therefore, necked nonwoven substrate or easily stretch be untreated nonwoven substrates should be not coated, or for example to prevent that polymer solution is absorbed into necked nonwoven fabric or the be untreated mode of supatex fabric of easily stretching is handled.Elastic polymer solution and/or supatex fabric can comprise surfactant, to promote that net is aggregated the thing solution impregnation.Suitable surfactant comprises the nonionic wetting agent, as polymeric surfactant.
A small amount of additive such as pigment, antioxidant, ultra-violet stabilizer and lubricant can be added in the elastic polymer solution, condition is that this class additive can not weaken advantage of the present invention.
Elastic polymer solution can comprise and is scattered in wherein, very short, fine fibre, and as cellulose fibre or other the synthetic or natural fabric that is obtained by wooden oar, flocking, its length is less than about 0.10 inch (2.5mm), as less than 0.5mm.Fiber is general enough tiny, fully to infiltrate in the supatex fabric during impregnation steps.Based on non-woven/elastomeric polymer composite gross weight meter, can be enough to about 3% staple fibre to about 12% weight is deposited on the amount of impregnated nonwoven sheet, staple fibre is added in the polymer solution.In the gross weight of staple fibre, elastomeric polymer and solvent, the amount that adds the staple fibre of elastic polymer solution is generally about 10% to about 30% weight, and 10% to about 20% weight according to appointment.By with containing the elastic polymer solution of powdered cellulose, the be untreated nonwoven sheet of the present invention of supatex fabric preparation of dipping necked nonwoven fabric or easily stretch can have than those soft hand feeling more with the dipping solution preparation that does not conform to staple fibre.The example that is applicable to the superfine fibre granular materials of polymer solution is a powdered cellulose, and this powdered cellulose can (Schoolcraft Michigan) obtains with trade name " Arbocel 30 " from J.Rettenmaier USA.
Can adopt elastic polymer solution to be coated to necked nonwoven substrate or easily to stretch and be untreated on the nonwoven substrates, or be untreated any appropriate method of nonwoven substrates of dipping necked nonwoven substrate or easily stretch, condition is that fabric is evenly flooded, and coating is not concentrated in necked nonwoven substrate or easily stretches and is untreated on one of nonwoven substrates or another surface.It should be noted, although can adopt coating process, handle nonwoven substrates with elastic polymer solution, but select solution and nonwoven material characteristic and coating process condition, make polymer solution complete wetting nonwoven substrates, thereby or be absorbed into or drive in nonwoven substrates fully and on the arbitrary surface of nonwoven substrates, do not form polymeric layer.Generally speaking, can adopt in necked nonwoven fabric or easily stretch to be untreated and keep the spreading implement of preset distance, the amount of used polymer solution in the control coating process on the nonwoven substrates.Also solution machinery can be pressed onto in the nonwoven substrates.Roller, pressing plate, curette, cutter etc. can be used as spreading implement and are used for the inventive method.Also can be effective to the nonwoven substrates with solution spraying, condition is that elastic sols floods nonwoven substrates substantially fully and equably.Can regulate spray power to help to obtain good infiltration.Can adopt in this area the method that is known as " padding " method, flood nonwoven substrates with elastic polymer solution, wherein fiber web is immersed or be immersed in the jar that contains elastic polymer solution, subsequently as between roll, push, remove excessive polymer solution.Preferred this method so that the difference that can stretch between composite nonwoven sheet material two surfaces minimize.
Necked nonwoven substrate or easy the stretching are untreated nonwoven substrates with enough polymer solution dippings, the required unloading of final impregnated nonwoven sheet/load force ratio is provided.Nonwoven substrates generally with enough polymer solution dippings, in the gross weight of elastomeric polymer and nonwoven substrates, deposits about 10% elastomeric polymer to about 80% weight, according to appointment 30% elastomeric polymer to about 50% weight therein.When elastomeric amount was too low, what unload forces and load force ratio may be nonconforming was low, and when elastomeric amount was too high, what the feel of sheet surface may be nonconforming was sticking.Can regulate solution concentration and/or solution impregnation to necked nonwoven fabric or the amount in the nonwoven substrates of being untreated that easily stretches, in impregnated sheet, to obtain required polymer content.As, observe in using the solution process, adopt than the low polymer solution concentration, the roll seam is wideer to make that elastomer content keeps similar on the impregnated sheet thereby make simultaneously, has produced the improved product of balance of feel and unloading/load force ratio.
In case nonwoven substrates has been full of the solution that comprises solvent and elastomeric polymer, and solvent is removed.Solvent solidifies by wet method to be removed, and removes solidification liquid subsequently.Wet method is solidified than heated drying to be provided unexpected softness, has had more the product of feel as the cloth.It is well-known in the art that wet method is solidified, and generally is used for the dermatine preparation.Preferred water is as solidification liquid, because its easy processing and cost are low.Other suitable solidification liquid comprises methyl alcohol, ethanol, isopropyl alcohol, acetone or methyl ethyl ketone.The solvent of elastomeric polymer such as dimethyl formamide, dimethylacetylamide or N-methyl-pyrrolidones or other additive such as surfactant can be added solidification liquid, regulate freezing rate.In addition, the temperature that can control coagulating bath changes freezing rate.Except that after desolvating, slower freezing rate is given the feel of dipping nonwoven material more attractive.
In the impregnated nonwoven sheet of the present invention, the mutually equally distributed necked nonwoven substrate of elastomeric polymer or easily the stretch nonwoven substrates that is untreated is breathed freely.Impregnated nonwoven sheet is generally also wet thoroughly.
Can improve the fiber on impregnated sheet surface by polishing or napping, cause more soft hand feeling, thereby improve the feel of impregnated nonwoven sheet.Napping comprises delivers to the rotation roller with fabric, contains little metal needle on the roller, and this pin effectively scrubbing brush wiping fabric makes fiber appear at the surface.In the polishing, metallic brush is replaced by the rotation roller that sand paper covers.Generally, with all napping or the polishings of impregnate fabric two sides.Can use the sand papering of 80-200 granularity as fabric.
The impregnated nonwoven sheet basis weight that stretches of the present invention is generally about 40g/m 2To about 100g/m 2In the side and other personal hygiene clothing such as underwear of waistband or diaper, they are particularly useful.Diaper grow, commercialization assembling on the high-speed production lines, wherein each diaper component is generally vertically adding in order to avoid processing is slowed down.Especially true for elastomeric material, it generally stretches before insertion.Diaper generally comprises about 20 or more stand-alone assemblies, and they must accurately put into the diaper tram in the high speed production process.If assembly (band, sheet, fiber etc.) is adding this just easier realization with diaper mobile phase direction together.In order laterally to add assembly (as waistband), preferably with material this in cross directional stretch, thereby as being with longitudinally, it can enter the diaper preparation process.Can be 7 inches wide and 1 inch long sheet only as this band, it can downcut in sheet material, and is adhered on the diaper or on other disposable underclothes.In this process, the diaper component that also preferably enters processing is vertically non-stretchable basically, to help entering processing.Stretchable nonwoven sheets of the present invention is vertically non-stretchable basically, and at the degree of drawing that laterally has high recovery, this makes them be specially adapted to this processing.
Stretchable nonwoven sheets of the present invention also can be used as the flexible liner of various clothes, particularly jacket and coat.Liner is the fabric that inserts between clothes skin and the internal layer, will give or improve shape retention, stuffing, insulation values, stiffness or the bulk density of clothes.Draw nonwoven sheet material of the present invention is specially adapted to this application, because their are low-cost and have permanent elasticity and provide to stretch and make the comfortable ability in the whole body.
Method of testing
Be stretched to 30% required power
This analysis is carried out having on Instron 5565 types of Merlin data collection software system.Merlin system and instrument hardware all available from Instron Corporation (Braintree, Massachusetts).With 1 inch+/-0.05 inch wide (2.54cm+/-0.13cm) and about 8 inches (20.32cm) long nonwoven sheet sample sandwich in the clamp of Instron machine, sample length is set to 3.00 inches (7.62cm).The length that the preparation sample makes this sample is laterally parallel with nonwoven material.With the speed of per minute 6 inches (15.24cm/min) sample being stretched to percentage elongation is 30%.Power during with 50% elongation of gram record.
Fracture strength is analyzed
This analysis is carried out having on Instron 5565 types of Merlin data collection software system.Merlin system and instrument hardware all available from Instron Corporation (Braintree, Massachusetts).With 1 inch+/-0.05 inch wide (2.54cm+/-0.13cm) and about 8 inches (20.32cm) long nonwoven sheet sample sandwich in the clamp of Instron machine, sample length is set to 3.00 inches (7.62cm).The length that the preparation sample makes this sample is laterally parallel with nonwoven material.Speed stretching sample with per minute 6 inches (15.24cm/min) becomes two parts up to sample breakage, with the maximum, force of gram record breakaway poing.
Basis weight
(the rectangle nonwoven sheet sample of 2.54cm * 20.32cm) is carefully lax, makes sample not have rivel or wrinkle with about 1.0 inches * 8.0 inches.The length of measuring samples and width are accurate to millimeter, and sample is weighed, and are accurate to 0.1 milligram.Weight divided by reference area, and is expressed as every square of Mick number with the result, is accurate to 0.1 gram.
Load and unload forces analysis
This analysis is carried out having on Instron 5565 types of Merlin data collection software system.Merlin system and instrument hardware all available from Instron Corporation (Braintree, Massachusetts).With 1 inch+/-0.05 inch wide (2.54cm+/-0.13cm) and about 8 inches (20.32cm) long nonwoven sheet sample sandwich in the clamp of Instron machine, sample length is set to 3.00 inches (7.62cm).The length that the preparation sample makes this sample is laterally parallel with nonwoven material.With the speed of per minute 6 inches (15.24cm/min) sample being stretched to percentage elongation is 140%, is relaxed to its initial length then.Repeat again twice, record was based on sample initial length elongation 50%, 100% and 135% o'clock, and is in the power (load force) that circulates the stretching recycled material is applied for the third time, same, also be recorded in relaxation cycles for the third time, the power (unload forces) that material produces in identical elongation points.With the 3rd repeated loading and unload forces, show the result of suitable percentage percentage elongation with the gram numerical table.
The percentage percentage elongation is analyzed
On the long lax supatex fabric bar of 1.0 inches (2.54cm) not having rivel or wrinkle wide and about 8 inches (20.32cm), making mark with pen apart from 4.0 inches (10.2cm) 2, make mark about equally to the distance of fabric end points.Firmly hold the end of fabric with the thumb and the forefinger of each hand then, and sample is extended fully, be not torn or stand any similar mechanical damage but be stretched to sample.For the personnel that test, when the stretch-resistance of fabric significantly increases, be conspicuous for the maximum elongation point.Measure the length between two gauge points on the nonwoven material subsequently, and calculate the percentage percentage elongation according to following formula, wherein initial length is 10.2cm:
Percentage percentage elongation={ (tensile elongation-initial length)/initial length } * 100%
When necked direction is measured the percentage percentage elongation, downcut fabric sample, its length is parallel with horizontal (necked direction).
Embodiment 1
With 30 inches (76.2cm) wide, 15g/m 2Wettable spunbond polypropylene nonwoven is (by Avgol Nonwovens, Israel) send into roll with per minute 89 feet (27m/min), and urgent wind baking ovens long by 72 inches (1.83m), 290  (143 ℃), arrival is winding on the take up roll then with second roll of 115 feet (35m/min) operations of per minute.In this process, 30 inches (76.2cm) wide nonwoven material is laterally by evenly and to tighten (" constriction ") to width smoothly be 10 inches (25.4cm).By applying minimum power, it can be stretched to its initial 30 inches (76.2cm) transverse widths.The nonwoven material longitudinal tensile strain rate of this constriction is zero substantially, and basis weight is 32.0g/m 2
Dimethylacetylamide (DMAC) solution with 15mil (0.38mm) scraping blade and 20% weight polyurethane-urea, one side to necked nonwoven applies, this polyurethane-urea is 1800 polytetramethylene ether diol, 1-isocyanate group-4-[(4-phenyl isocyanate base derived from molecular weight) methyl] benzene (mol ratio of vulcabond and glycol is 1.69), chain extender (mol ratio is 9: 1 ethylenediamine and a 2-methyl isophthalic acid, the 5-pentanediamine) and diethylamine.Two (4-isocyanate group cyclohexyl) methane of 0.5% weight) and (the 3-tert-butyl group-3-azepine-1 also use following additive:, the 5-pentanediol) polymer (Methacrol  2462B, the registration mark of E.I.du Pont de Nemours and Company), 2 of the silicone oil of the titanium dioxide of 0.3% weight, 0.6% weight, 1.4% weight, 4,6-three (2,6-dimethyl-4-the tert-butyl group-3-hydroxybenzyl) isocyanuric acid ester (Cyanox  1790, the registration mark of CytecIndustries) and the magnesium calcium carbonate of 4% weight and the mixture of hydromagnesite).(all percentages are based on polyurethane-urea weight meter).Polyurethane-urea-DMAC solution complete wetting nonwoven material.
With the basic vertical hanging of nonwoven material that applies in air about 1 minute, polymer solution is penetrated in the nonwoven material fully, immerse then in the 40% volume DMAC/ water-bath of 70  (21 ℃).After one minute, impregnate fabric is moved on to successively in the DMAC/ aqueous solution of 30% volume, 20% volume and 10% volume, each self-sustaining 1 minute is immersed in 100% water-bath at last, keeps 2 minutes.Under the room temperature, make impregnate fabric at air drying.
That impregnated nonwoven sheet two surfaces that obtain have is identical (dry and comfortable, fabric as) feel and quality.The microphoto of impregnated nonwoven sheet cross section shows that combining structure is even on the whole material thickness, and does not all have continuous polyurethane zone substantially on arbitrary surface.
Subsequently, with the 220 grit papers nonwoven sheet of polishing gently.Compare with the complete smooth surface of not giving prominence to fiber before the polishing, the material that obtains has obviously softer sensation, and visual observation shows that many independently staple fibres are outstanding from the surface.Unexpectedly, more soft hand feeling has successfully been given in this processing, and does not have obviously to weaken the visual sense of beauty or the elastic characteristic of sheet material.
The basis weight of the impregnated nonwoven sheet that obtains is 71.4g/m 2, show that polyurethane-urea content is every square metre 39.4 gram, or the elastomeric polymer of about 55% weight.
The gained material shows that percentage elongation is about 160%-180% laterally pulling to stretch.
Load force and unload forces analysis provide following result:
The 3rd load cycle power
Percentage elongation (%) Load force (gram)
50 67.3
100 211.2
135 409.7
The 3rd unloading cyclic force
Percentage elongation (%) Unload forces (gram)
50 22.7
100 114.7
135 340.7
Data comparison shows that in the table: unload forces and load force ratio are 0.54 during 100% elongation.
Embodiment 2
This embodiment adopts 10 inches 55g/m that (25.4cm) is wide of a volume 2Flat pattern jet net-spraying method nonwoven material (by Sheng Hung Industrial Co., 116 Hou Kang Street, Shih-LinDistrict, Taipei, Taiwan, ROC preparation, Article Number 4055-T) a part, is carried out in a continuous manner by about 30 feet long.At first, by flooding nonwoven substrates in dimethylacetylamide (DMAC) solution that immerses T-162 Lycra (R), this solution contains 12.5% solid, available from INVISTA Inc., Wilmington, DE.Fabric speed is 3ft/min, and the fabric total length is about 6 inches in the bath.By being 0.007 inch roll by the gap, finish the removal of excess polymeric solution with impregnate fabric.
Then, the gained impregnate fabric by in the bath of 40%DMAC/ water, is passed through two independently 100% water-baths then.Fabric is 3ft/min by the speed of these baths.The fabric total length was 8 feet during each was bathed.All are bathed in room temperature, about 72  (40 ℃) operation down.The gained fabric is through air drying, and obtaining having attractive elasticity and basis weight is 80g/m 2The ventilative draw nonwoven material of (45% weight T-162 Lycra (R)).
The gained non-woven elastic shows that in horizontal manual percentage percentage elongation analysis percentage elongation is 50%-60%.According to carrying out described in the Test Methods section, different is that sample is stretched to maximum 50% percentage elongation to the 3rd repeated loading and unload forces analysis, and load and unloading retraction force when writing down 20%, 30% and 40% elongation.The load of this correction and unload forces analysis provide following result:
The 3rd load cycle power
Percentage elongation (%) Load force (gram)
20 92.6
30 227.2
40 425.9
The 3rd unloading cyclic force
Percentage elongation (%) Unload forces (gram)
20 20.0
30 75.9
40 192.0
Data comparison shows that in the table: unload forces and load force ratio are 0.33 during 30% elongation.

Claims (19)

1. method that forms stretchable nonwoven sheets said method comprising the steps of:
Provide have certain thickness, necked nonwoven substrate that first and second outer surfaces, vertical and horizontal stretch, described necked nonwoven substrate is at least 30% at horizontal percentage percentage elongation;
Basically flood described necked nonwoven substrate equably with the solution that comprises elastomeric polymer, this elastomeric polymer is dissolved in the solvent; With
Solidify by wet method, described solvent is removed from the nonwoven substrates of this dipping, whole thickness at described nonwoven substrates deposits described elastomeric polymer basically equably, and does not form continuous basically elastomeric polymer layer on described first or second outer surface of described nonwoven substrates.
2. the process of claim 1 wherein described necked nonwoven substrate at percentage percentage elongation longitudinally less than about 10%, and be about 100% to about 300% at horizontal percentage percentage elongation.
3. the process of claim 1 wherein that described necked nonwoven substrate is that basis weight is about 15g/m 2To about 100g/m 2Necked nonwoven fabric.
4. method that forms stretchable nonwoven sheets said method comprising the steps of:
The easy stretching nonwoven substrates that is untreated is provided, and this base material has certain thickness, first and second outer surfaces, vertical and horizontal and stretches, and is at least 30% at horizontal percentage percentage elongation, and basis weight is about 15g/m 2To about 100g/m 2, fracture strength is greater than 500g/in;
With the solution that comprises elastomeric polymer, flood the described easy stretching nonwoven substrates that is untreated basically equably, this elastomeric polymer is dissolved in the solvent; With
Solidify by wet method, described solvent is removed from the described easy stretching nonwoven substrates that is untreated, whole thickness at described nonwoven substrates deposits described elastomeric polymer basically equably, and does not form continuous basically elastomeric polymer layer on described first or second outer surface of described nonwoven substrates.
5. the method for claim 4, the wherein said easy stretching nonwoven substrates that is untreated is about 60% to about 150% at horizontal percentage percentage elongation.
6. the method for claim 4, the wherein said easy stretching nonwoven substrates that is untreated is that basis weight is about 30g/m 2To about 80g/m 2The easy stretching supatex fabric that is untreated.
7. claim 1 or 4 method, wherein said elastomeric polymer is a polyurethane.
8. claim 1 or 4 method, wherein based on the gross weight meter of described base material and described elastomeric polymer, described elastomeric polymer is deposited on the described base material about 10% to about 80% weight.
9. claim 1 or 4 method, described method also comprises step: after removing described solvent, at least one outer surface polishing or napping with described nonwoven sheet increase the fiber on the described sheet surface.
10. stretchable nonwoven sheets, described sheet material comprises the necked nonwoven substrate of evenly flooding basically with elastomeric polymer, described stretchable nonwoven sheets is after necked direction is stretched to 140% 3 time, and the 3rd load cycle force rate rate when its 3rd unloading cyclic force and 100% when 100% elongation extends is at least 0.3: 1.
11. the stretchable nonwoven sheets of claim 10, wherein said unload forces and load force ratio are at least 0.45: 1.
12. stretchable nonwoven sheets, described sheet material comprises with the elastomeric polymer even easy stretching nonwoven substrates that is untreated of dipping basically, described stretchable nonwoven sheets is behind cross directional stretch to 50% three times, and the 3rd load cycle force rate rate when its 3rd unloading cyclic force and 30% when 30% elongation extends is at least 0.15: 1.
13. the stretchable nonwoven sheets of claim 12, wherein said unload forces and load force ratio are at least 0.3: 1.
14. the stretchable nonwoven sheets of claim 10 or 12, wherein based on the gross weight meter of elastomeric polymer and nonwoven substrates, described sheet material comprises the described elastomeric polymer of about 10-80% weight.
15. the stretchable nonwoven sheets of claim 10 or 12, the basis weight of described nonwoven sheet is about 40g/m 2To about 100g/m 2
16. a personal hygiene clothing, described sweat shirt comprises the stretchable nonwoven sheets of claim 10 or 12.
17. the personal hygiene clothing of claim 16, described sweat shirt comprises diaper.
18. the personal hygiene clothing of claim 16, described sweat shirt comprises underwear.
19. clothes, described clothes comprise the stretchable nonwoven sheets of claim 10 or 12, and wherein said stretchable nonwoven sheets is a liner.
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CN109688996A (en) * 2016-09-07 2019-04-26 服饰与高级纺织英国有限公司 Stretch nonwoven and film
CN115634313A (en) * 2022-09-30 2023-01-24 北京航空航天大学 Elastomer with high anisotropy coefficient and preparation method and application thereof

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CN105813491A (en) * 2013-12-02 2016-07-27 英威达技术有限公司 Shape enhancing garments with discontinuous elastic polymer composition
CN109688996A (en) * 2016-09-07 2019-04-26 服饰与高级纺织英国有限公司 Stretch nonwoven and film
CN109688996B (en) * 2016-09-07 2023-01-31 莱卡英国有限公司 Stretch nonwoven and film
CN115634313A (en) * 2022-09-30 2023-01-24 北京航空航天大学 Elastomer with high anisotropy coefficient and preparation method and application thereof
CN115634313B (en) * 2022-09-30 2023-12-22 北京航空航天大学 Elastomer with high anisotropy coefficient and preparation method and application thereof

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