EA029294B1 - Способ изготовления гидроперепутанного пневмоуложенного полотна и продукт, полученный из этого полотна - Google Patents
Способ изготовления гидроперепутанного пневмоуложенного полотна и продукт, полученный из этого полотна Download PDFInfo
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- EA029294B1 EA029294B1 EA201591110A EA201591110A EA029294B1 EA 029294 B1 EA029294 B1 EA 029294B1 EA 201591110 A EA201591110 A EA 201591110A EA 201591110 A EA201591110 A EA 201591110A EA 029294 B1 EA029294 B1 EA 029294B1
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Abstract
Представлен способ изготовления нетканых полотен, которые обладают высокой прочностью в направлениях MD и CD и способны к утилизации со сточными водами. Этот способ включает стадию гидроперепутывания пневмоуложенного полотна, содержащего не менее 50 мас.% натуральных целлюлозных волокон длиной не более 3,5 мм и не более 50 мас.% штапельных волокон длиной не менее 8,0 мм. Пневмоуложенное полотно не укладывают на полотно-прекурсор и не применяют в нем адгезив, связующее или волокна для термического соединения. Пневмоукладку и гидроперепутывание проводят в одной непрерывной операции. Продукты, которые могут быть изготовлены в соответствии со способом по изобретению, отвечают требованиям инструкции по смываемости.
Description
изобретение относится к непрерывному способу изготовления одноразовых нетканых полотен, который требует минимального числа операций и обеспечивает получение экономичного продукта, пригодного для использования в качестве смываемого в унитаз или одноразового изделия, такого как одноразовая салфетка или обтирочный материал.
Уровень техники
Одноразовые нетканые подложки применяют для изготовления широкого ассортимента потребительских продуктов, которые обычно используют однократно и выбрасывают. Такие продукты включают одноразовые дезинфицирующие салфетки, одноразовые пеленки, одноразовые прокладки при недержании для взрослых, одноразовые мягкие подкладки, обычно применяемые в больницах с целью поглощения физиологических жидкостей, а также косметические аппликаторы или косметические прокладки для удаления макияжа и других материалов с ороговевшего субстрата.
Такие коммерческие продукты составляют отрасль промышленности, обладающую постоянно растущим потенциалом развития и расширением применения. Однако, поскольку практически все такие продукты могут попасть в окружающую среду через свалки или системы канализации, существует потребность в одноразовом нетканом материале, который прост в изготовлении, не содержит или содержит минимальное количество химических компонентов с низкой биоразлагаемостью, таких как связующие, адгезивы или термопластичные полимеры, и, кроме того, обладает высокой прочностью на разрыв в мокром состоянии в соответствии с эксплуатационными требованиями. Кроме того, требуется продукт, который выполнен так, чтобы содержание в нем линта было минимальным, и соответствует кодам для классификации в качестве смывного изделия, приемлемого для муниципальных и частных систем канализации, при этом являясь экономичным в изготовлении.
Условно нетканые одноразовые протирочные изделия могут быть изготовлены за счет применения одного из двух основных методов, известных в промышленности как процессы "эйрлэйс" (аи1асе) и "гидраспан" (Ьубгакрии). Разные производители могут применять эти методы с изменениями, обусловленными предполагаемым конечным использованием и доступным производственным оборудованием, однако основные принципы технологического процесса остаются неизменными.
Методы "эйрлэйс" основаны на сочетании операций осаждения пневмоуложенного полотна из длинных штапельных волокон и волокон древесной целлюлозы на слой нетканого носителя или нетканого полотна на основе прекурсора и гидроперепутывания пневмоуложенного слоя с этим нетканым носителем. Упомянутый метод описан в И8 8250719, Оие11еИе и в ссылках, приведенных в этом документе. В дополнение к применению нетканого носителя, Оие11ейе описывает соединение пневмоуложенных волокон с помощью горячего воздуха или распыляемого адгезива.
В соответствии с методом "гидраспан", как описано в И8 4755421, Маишид е1 а1., полотно мокрого формования из пульпы и синтетические волокна подвергают гидроперепутыванию, а затем сушат. Однако в и8 5292581, У1а/теп5ку е1 а1., указано, что такие продукты обладают низкой прочностью в мокром состоянии, и описано, что введение связующих в значительной степени повышает эту прочность. В более позднем документе И8 7732357, Άηηίδ е1 а1., описано применение волокон связующего в нетканом листовом материале, которые активируются при нагревании вследствие, по меньшей мере, частичного плавления и образования соединений между волокнами. Эти волокна связующего содержат полиэтилен, полипропилен, полиэтилентерефталат и смеси из этих веществ.
Следовательно, остается потребность в способе изготовления нетканого полотна, которое не содержит адгезива, связующего или соединительных волокон, удобно и экономично для реализации и обеспечивает получение диспергируемого нетканого полотна, обладающего хорошими прочностными характеристиками и, кроме того, приемлемого в качестве пригодного для смывания в унитаз изделия для систем муниципальной канализации и частных систем очистки стоков.
Сущность изобретения
Таким образом, одна цель настоящего изобретения заключается в предоставлении такого способа изготовления нетканого полотна, который включает минимальное число операций обработки, не требует применения адгезивов, связующих или соединительных волокон, и обеспечивает получение нетканого полотна, обладающего достаточной прочностью в мокром состоянии для применения в качестве протирочного материала. Другая цель настоящего изобретения заключается в предоставлении нетканого полотна, обладающего прочностью в мокром состоянии, достаточной для использования в качестве протирочного материала, который пригоден для утилизации с помощью систем канализации и очистки стоков.
Эти и другие цели были достигнуты в соответствии с настоящим изобретением, первый вариант осуществления которого включает способ изготовления нетканого полотна, состоящий из приготовления смеси из натуральных целлюлозных волокон и штапельных волокон; пневмоформования этой смеси с получением по меньшей мере одного однородного пневмоуложенного полотна; гидроперепутывания этого полотна с целью консолидации, по меньшей мере, с одной стороны; сушки гидроперепутанного полотна с образованием упомянутого нетканого полотна. При этом пневмоформование и гидроперепутывание проводят в одной непрерывной операции. Содержание натуральных целлюлозных волокон в упомянутой смеси волокон составляет не менее 50 мас.%, и содержание штапельных волокон - не более
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50 мас.%. Связующее, адгезив или волокна для термического соединения не применяют. Длина натуральных целлюлозных волокон составляет не более 3,5 мм, а длина штапельных волокон составляет не менее 8,0 мм. Плотность нетканого полотна составляет от 20 до 100 г/м2, а его толщина - от 0,25 до 2 мм.
В предпочтительном первом варианте осуществления пневмоуложенное полотно непосредственно формуют на носителе устройства для пневмоформования без предварительного формования материалапрекурсора или введения полосы из непрерывных волокон.
В другом более предпочтительном варианте осуществления при изготовлении нетканого полотна не применяют адгезива, связующего или соединительного волокна, а отношение прочности на разрыв в машинном (продольном) направлении к этой прочности в направлении, перпендикулярном машинному направлению (отношение ΜΟ/СО), составляет менее 3.
Еще в одном варианте осуществления настоящее изобретение предоставляет нетканое полотно, полученное с помощью любого из упомянутых выше способов, причем это полотно содержит 75 мас.% древесной пульпы и 25 мас.% лиоцелла. Плотность упомянутого нетканого полотна в соответствии с этим вариантом осуществления составляет от 40 до 60 г/м2, отношение ΜΟ/СО менее 3, прочность на разрыв в мокром состоянии в направлении СО составляет по меньшей мере 5 Н/5 см, причем это нетканое полотно является пригодным для смывания в унитаз продуктом в соответствии с опубликованной в июле 2009 г. инструкцией ΕΟΛΝΛ (Европейская ассоциация производителей нетканых материалов и изделий одноразового использования), по оценке смываемости нетканых изделий потребительского назначения.
В другом варианте осуществления настоящее изобретение представляет собой нетканое полотно, полученное с помощью любого из упомянутых выше способов, причем это полотно содержит около 50 мас.% древесной пульпы и около 50 мас.% вискозы. Плотность упомянутого нетканого полотна в соответствии с этим вариантом осуществления составляет от 40 до 60 г/м2, отношение ΜΟ/СО менее 3, прочность на разрыв в мокром состоянии в направлении СО составляет по меньшей мере 12 Н/5 см.
Краткое описание чертежей
Фиг. 1 показывает схему расположения водяных струй в машине для гидроперепутывания в соответствии с одним вариантом осуществления настоящего изобретения.
Фиг. 2 показывает сравнительные данные для диспергируемых и недиспергируемых нетканых материалов в соответствии с настоящим изобретением в сравнении с коммерчески доступными протирочными материалами.
Подробное описание изобретения
В соответствии с последующим описанием все приведенные диапазоны числовых значений включают все поддиапазоны и все значения между ними, если не указано иное. Все значения массового содержания основаны на общей массе. Последующее описание предоставляет общую характеристику настоящего изобретения и определенные предпочтительные варианты осуществления. Однако обычный специалист в данной области техники поймет, что многие изменения в настоящем изобретении могут быть возможны без отклонения от сущности изобретения. Настоящее описание и последующая формула изобретения предназначены для того, чтобы включить все такие изменения.
В первом варианте осуществления настоящее изобретение предоставляет способ изготовления нетканого полотна, состоящий из приготовления смеси из натуральных целлюлозных волокон и штапельных волокон; пневмоформования этой смеси с получением по меньшей мере одного однородного пневмоуложенного полотна; гидроперепутывания этого полотна с целью его консолидации, по меньшей мере, с одной стороны; сушки гидроперепутанного полотна с образованием упомянутого нетканого полотна. При этом пневмоформование и гидроперепутывание проводят в одной непрерывной операции. Содержание натуральных целлюлозных волокон в упомянутой смеси волокон составляет не менее 50 мас.%, предпочтительно не менее 60 мас.% и наиболее предпочтительно по меньшей мере 75 мас.%. Содержание штапельных волокон не более 50 мас.%, предпочтительно не более 40 мас.% и наиболее предпочтительно не более 25 мас.%. В процессе пневмоформования и гидроперепутывания в соответствии с настоящим изобретением не применяют связующих, адгезивов или волокон для термического соединения.
Длина натуральных целлюлозных волокон составляет не менее 3,5 мм, предпочтительно 1,5-3,5 мм и наиболее предпочтительно 2,5-3,5 мм. В качестве любых натуральных целлюлозных волокон в смеси можно использовать короткие волокна. В одном варианте осуществления волокна древесной пульпы указанной длины могут быть короткими волокнами, а в предпочтительном варианте осуществления в качестве натуральных целлюлозных волокон можно использовать крафт-целлюлозу из южной сосны. Кроме того, в качестве источника упомянутых волокон можно использовать древесную пульпу, полученную в процессе сульфитной варки целлюлозы. Можно использовать смеси из натуральных целлюлозных волокон. Эти волокна можно разделять в молотковых мельницах, формируя смесь из отдельных волокон в массе.
В качестве штапельных волокон можно использовать любое нетермопластичное искусственное волокно длиной не менее 8,0 мм, предпочтительно 8,0-100 мм и наиболее предпочтительно 8-25 мм. Предпочтительно в качестве штапельного волокна используется вискоза или лиоцелл. Могут использоваться смеси из нетермопластичных волокон.
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Способ формования пневмоуложенного полотна в целом описан в И8 4640810 Ьаигкеп с1 а1. Штапельные и разделенные натуральные целлюлозные волокна смешивают до получения однородной смеси и, поддерживая смесь с помощью воздушного потока, транспортируют в распределитель. Этот распределитель содержит вращающийся цилиндр или барабан, в котором выполнены дыры, щели или другие отверстия подходящей формы, спроектированные так, чтобы обеспечить перенос волокон на перфорированном носителе. Конструкция барабана, а также конфигурация и размер этих отверстий могут изменяться в соответствии с характеристиками применяемой волокнистой смеси, обеспечивая получение уникальной структуры полотна. Под воздействием комбинации любых воздушных потоков, а также механического перемешивания в барабане и всасывания из-под носителя волокна направляются через упомянутые отверстия перфорированного барабана и образуют равномерное полотно на поверхности носителя. Высота и степень переплетения сухого полотна могут изменяться в зависимости от регулирования технологических параметров, включая содержание волокна и размеры волокон, размеры и форму отверстий в барабане, расход воздуха, степень разрежения, создаваемую под носителем, и скорость перемещения носителя. Другие параметры оборудования также можно изменять с целью обеспечения уникальной структуры переплетения.
Ширина полотна зависит от типа применяемого устройства для пневмоформования и может изменяться от 1 до 6 м. Серийные коммерческие устройства, поставляемые, например, компаниями Эап-\УеЬ. ОегЬкоп и Апрар Оу, имеют ширину от 2 до 5 м.
В соответствии с настоящим изобретением отформованное пневмоуложенное полотно непосредственно и непрерывно подают в блок для гидроперепутывания или в блок для гидросплетения, где пневмоуложенное полотно подвергают удару рядами струй воды высокого давления, механически перепутывая или консолидируя волокна и формируя нетканое полотно. Эти струи могут быть ориентированы перпендикулярно поверхности носителя или под наклоном к этой поверхности с целью получения уникальных свойств полотна. Струи воды могут направляться для консолидации полотна с одной стороны, предпочтительно сверху, или с нижней и верхней сторон. Давление струй воды может быть в диапазоне 0,04-15 бар/кг/ч/м (4,2-1575 Па/кг/ч/м), предпочтительно 0,1-10 бар/кг/ч/м (10,5-1050 Па/кг/ч/м) и более предпочтительно 0,3-4 бар/кг/ч/м (31,5-420 Па/кг/ч/м).
На фиг. 1 схематически показано расположение струй для консолидации полотна с обеих сторон. Как видно на фиг. 1, пневмоуложенное полотно, вытянутое непосредственно из устройства для пневмоформования, пропускают по ряду несущих лент и подвергают воздействию струй высокого давления, показанных в числовом порядке. Струи 11, 12 и 13 ударяют по верхней стороне полотна, тогда как струи 21 и 22 ударяют по противоположной (нижней) стороне. Схематически струи 11-13, 21-22, 31-33, 41-43 и 51-52 представлены рядами, вытянутыми вдоль ширины полотна, и эти ряды могут быть расположены и позиционированы так, чтобы создавать различную степень перепутывания волокон по всему полотну. В результате перепутывание может быть случайным или упорядоченным в зависимости от предполагаемого конечного использования нетканого полотна.
Драпируемость, мягкость и комфортность на ощупь упомянутого полотна можно регулировать с помощью энергии, подводимой струями высокого давления, а также за счет изменения скорости движения полотна в технологической линии. В соответствии с настоящим изобретением за счет контроля давления воды и скорости движения полотна в блоке для гидросплетения, а также из-за отсутствия адгезивов, связующих или соединительных волокон можно получить нетканое полотно, имеющее разную степень прочности, поглощающей способности, мягкости и толщины.
Блоки для гидроперепутывания или гидросплетения доступны от Р1е188пег СтЬН (Германия) и АпйгП/ РегГо)е1 (Франция).
После операции гидросплетения влажное нетканое полотно можно высушить и смотать в рулон для транспортировки и хранения. В другом варианте осуществления перед сушкой перепутанное полотно может быть подвергнуто тиснению, например, методом гидротиснения или термотиснения.
Плотность нетканого полотна может быть 20-100 г/м2, предпочтительно 40-80 г/м2 для полотна толщиной от 0,25 до 2 мм. Однако при складывании многочисленных пневмоуложенных полотен в стопу плотность и толщина этих полотен может выходить за пределы указанных диапазонов. Плотность можно изменять путем регулирования технологических параметров процесса пневмоукладки и процесса гидросплетения, а также за счет регулирования других параметров, обычно известных специалистам в данной области техники.
Нетканые полотна в соответствии с настоящим изобретением имеют характеристики прочности, которые являются более всенаправленными, чем аналогичные характеристики обычных коммерческих нетканых полотен. Отношение прочности на разрыв в мокром состоянии в машинном направлении (ΜΌ) к этой прочности в поперечном направлении (ΟΌ) составляет менее 3. Как показано в таблице на фиг. 2, изделия РН1 в соответствии с настоящим изобретением, не содержащие адгезива, связующего и соединительных волокон, обладают значительно меньшей плотностью по сравнению с коммерчески доступными протирочными изделиями, хотя обладают аналогичными величинами прочности в направлении ΜΌ и ΟΌ. Такие свойства особенно неожиданны, поскольку, как известно, СП-прочность в мокром состоянии затруднительно обеспечить в изделиях, соответствующих стандартным нормативам по пригодности к
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смываемости.
В особом предпочтительном варианте осуществления пригодное к смыванию в унитаз изделие изготовлено в соответствии с настоящим изобретением из композиции, содержащей около 75 мас.% разделенных древесных волокон длиной не более 3,5 мм и 25 мас.% лиоцелла, имеющего волокна длиной не менее 8 мм. В этом случае пневмоуложенное полотно подвергают гидроперепутыванию при давлении струй воды от 0,35 до 2,1 бар/кг/ч/м (от 36,75 до 220,5 Па/кг/ч/м). Прочность на разрыв этого нетканого полотна в направлении СЭ в мокром состоянии составляет не менее 5,0 Н/5 см, а отношение МЭ/СЭ менее 3. Это полотно соответствует стандартам по методике испытаний на пригодность к смыванию в унитаз в соответствии с опубликованной в июле 2009 г. инструкцией ΕΌΑΝΑ (Европейская ассоциация производителей нетканых материалов и изделий одноразового использования), по оценке смываемости нетканых изделий потребительского назначения. Важно отметить, что этот продукт проходит канализационный насосный тест, в котором меньше чем 10% всех базовых точек, измеренных в течение 5 общих испытаний 60 протирочных салфеток, и в каждой может быть увеличение мощности более чем на 10% и предпочтительно менее чем 10%, приводит к росту мощности на 10%.
В другом специальном варианте осуществления, обеспечивающем повышенную прочность, нетканое полотно изготавливают в соответствии со способом по настоящему изобретению из смеси, содержащей около 50 мас.% разделенных древесных волокон длиной не более 3,5 мм и около 50 мас.% вискозы, имеющей волокна длиной 8 мм или более. Это полотно подвергают гидроперепутыванию при давлении струи от 0,3 до 15 бар/кг/ч/м (от 31,5 до 1575 Па/кг/ч/м), предпочтительно, 0,4-6 бар/кг/ч/м (42-630 Па/кг/ч/м). Прочность на разрыв этого полотна в мокром состоянии в направлении СЭ по меньшей мере 12 Н/5 см, а отношение МЭ/СЭ менее 3. Важно отметить, что склонность к пухоотделению этого продукта заметно ниже по сравнению с коммерческими продуктами, применяемыми в настоящее время в качестве влажных салфеток для малышей или салфеток для очистки твердой поверхности.
Claims (5)
1. Способ изготовления нетканого полотна, при котором
приготавливают однородную сухую смесь, состоящую из натуральных целлюлозных волокон и штапельных волокон вискозы и/или лиоцелла;
пропускают однородную сухую смесь через перфорированный цилиндр на перфорированный носитель;
осуществляют пневмоформование этой сухой смеси с получением по меньшей мере одного однородного пневмоуложенного полотна;
осуществляют гидроперепутывание упомянутого пневмоуложенного полотна на перфорированном носителе с целью консолидации полотна, по меньшей мере, с одной стороны;
осуществляют сушку гидроперепутанного полотна с образованием упомянутого нетканого полотна, причем пневмоформование и гидроперепутывание проводят в одной непрерывной операции без добавления адгезива или волокон для термического соединения;
содержание натуральных целлюлозных волокон в упомянутой смеси волокон составляет не менее
50 мас.%, а содержание штапельных волокон составляет от 0 до 50 мас.%; длина натуральных целлюлозных волокон составляет не более 3,5 мм; длина штапельных волокон составляет не менее 8,0 мм;
плотность нетканого полотна составляет от 20 до 100 г/м2 и толщина нетканого полотна составляет от 0,25 до 2 мм.
2. Способ по п.1, в котором содержание натуральных целлюлозных волокон в упомянутой сухой смеси составляет по меньшей мере 75 мас.%.
3. Способ по п.1, в котором плотность полотна составляет от 40 до 60 г/м2.
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11. Способ по п.1, в котором пневмоформование пневмоуложенного полотна проводят более чем в одном устройстве для пневмоформования и содержание волокна по меньшей мере в одном полотне отличается от содержания волокна в другом полотне.
12. Способ по п.1, в котором пневмоуложенное полотно формуют непосредственно на носителе устройства для пневмоформования без предварительного формования полотна-прекурсора или введения полотна из непрерывных волокон.
13. Способ по п.1, в котором давление при гидроперепутывании пневмоуложенного полотна составляет от 0,35 до 15 бар/кг/ч/м (от 36,75 до 1575 Па/кг/ч/м).
14. Способ по п.13, в котором отношение прочности на разрыв полотна в направлении подачи полотна к прочности на разрыв в направлении, перпендикулярном направлению подачи полотна, ΜΏ/ΟΏ составляет менее 3.
15. Нетканое полотно, изготовленное способом по п.1, при этом нетканое полотно содержит
75 мас.% натуральных целлюлозных волокон;
25 мас.% лиоцелла,
причем плотность нетканого полотна составляет от 40 до 60 г/м2, отношение прочности на разрыв в направлении подачи полотна к прочности на разрыв в направлении, перпендикулярном направлению подачи полотна, ΜΏ/ΟΏ составляет менее 3;
прочность на разрыв в направлении, перпендикулярном направлению подачи полотна, СО в мокром состоянии составляет по меньшей мере 5 Н/5 см;
указанное нетканое полотно является пригодным для смывания в унитаз продуктом.
16. Нетканое полотно, изготовленное способом по п.1, при этом нетканое полотно содержит около 50 мас.% древесной пульпы;
около 50 мас.% вискозы,
причем плотность нетканого полотна составляет от 40 до 60 г/м2;
отношение прочности на разрыв в направлении подачи полотна к прочности на разрыв в направлении, перпендикулярном направлению подачи полотна, ΜΏ/ΟΏ составляет менее 3;
прочность на разрыв в направлении, перпендикулярном направлению подачи полотна, СО в мокром состоянии составляет по меньшей мере 12 Н/5 см.
17. Чистящая салфетка, выполненная из нетканого полотна по п.15 или 16 и содержащая по меньшей мере одно, выбранное из группы, состоящей из чистящего агента, стерилизующего вещества, дезодоранта, дезинфицирующего средства, увлажнителя и средства для удаления макияжа.
4. Способ по п.1, в котором натуральные целлюлозные волокна являются сульфитной целлюлозой, полученной в процессе сульфитной варки целлюлозы.
5. Способ по п.1, в котором пневмоуложенное полотно является гидроперепутанным с целью консолидации полотна с обеих сторон.
6. Способ по п.1, в котором давление, приложенное при гидроперепутывании, составляет от 0,04 до
15 бар/кг/ч/м (от 4,2 до 1575 Па/кг/ч/м).
7. Способ по п.6, в котором давление, приложенное при гидроперепутывании, составляет от 0,3 до 4 бар/кг/ч/м (от 31,5 до 420 Па/кг/ч/м).
8. Способ по п.1, при котором дополнительно осуществляют операцию тиснения гидроперепутанного полотна, при этом операция тиснения является непрерывной с пневмоформованием и гидроперепутыванием.
9. Способ по п.1, в котором пневмоформование пневмоуложенного полотна проводят в одном устройстве для пневмоформования.
10. Способ по п.1, в котором пневмоформование пневмоуложенного полотна проводят более чем в одном устройстве для пневмоформования и содержание волокна в каждом полотне одинаково.
- 5 029294
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US201261736837P | 2012-12-13 | 2012-12-13 | |
PCT/US2013/053756 WO2014092806A1 (en) | 2012-12-13 | 2013-08-06 | Method for production of a hydroentangled airlaid web and products obtained therefrom |
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