JP2011508113A - 複合不織布ウェブ並びにこれの製造及び使用方法 - Google Patents
複合不織布ウェブ並びにこれの製造及び使用方法 Download PDFInfo
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- JP2011508113A JP2011508113A JP2010540768A JP2010540768A JP2011508113A JP 2011508113 A JP2011508113 A JP 2011508113A JP 2010540768 A JP2010540768 A JP 2010540768A JP 2010540768 A JP2010540768 A JP 2010540768A JP 2011508113 A JP2011508113 A JP 2011508113A
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
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Abstract
Description
本出願は、2007年12月28日に出願された米国特許仮出願第61/017,230号の利益を主張し、その開示内容全体を参照により本明細書に組み込むものとする。
本開示は複合不織布ウェブ、並びに、かかるウェブの製造及び使用方法に関する。本開示は更に、吸収性製品の製造に有用な、サブミクロン繊維及びマイクロファイバーの混合物を含む、低密度複合不織布ウェブに関する。
本明細書で使用する用語を以下に定義する。
本開示は、例えば表面洗浄用の吸収性拭取り布として、気体及び液体の吸収又は濾過媒体として、及び音の吸収用の遮蔽材として有用な吸収性製品に有益であり得る、複合不織布ウェブを対象とする。複合不織布ウェブの代表的実施形態は、様々な用途での使用を可能にする構造的特徴を有し、非常に優れた吸収特性を有し、低ソリディティにより高い気孔率及び透過性を示し、及び/又はコスト面で効率的な方法で製造することができる。弾力性、又は、耐崩壊(例えば破壊)耐性は、本開示の代表的な好ましい実施形態の、望ましい特徴の1つである。
一様態において、本開示は、メジアン直径が1マイクロメートル(μm)未満のサブミクロン繊維集団と、メジアン直径が少なくとも1μmであるマイクロファイバー集団とを含む、複合不織布ウェブに関する。繊維集団のうち少なくとも1つは配向されており、前記複合不織布ウェブは厚さを有し、10%未満のソリディティを示す。
本開示の複合不織布ウェブは、図1aに示す代表的複合不織布ウェブ302のサブミクロン繊維構成要素300のような、1つ以上の微細サブミクロン繊維構成要素を含むことができる。幾つかの実施形態においては、好ましい微細サブミクロン繊維構成要素は、メジアン繊維直径が1マイクロメートル(μm)未満の繊維を含む、サブミクロン繊維構成要素である。幾つかの代表的実施形態においては、サブミクロン繊維構成要素は、約0.2μm〜約0.9μmの範囲のメジアン繊維直径を有する繊維を含む。別の代表的実施形態においては、サブミクロン繊維構成要素は、約0.5μm〜約0.7μmの範囲のメジアン繊維直径を有する繊維を含む。
本開示の複合不織布ウェブは、図1aに示す代表的複合不織布ウェブ302のマイクロファイバー構成要素304のような、1つ以上の粗い繊維構成要素を含む。幾つかの実施形態においては、好ましい粗い繊維構成要素は、少なくとも1μmのメジアン繊維直径を有する繊維を含むマイクロファイバー構成要素である。幾つかの代表的実施形態においては、マイクロファイバー構成要素は、約2μm〜約100μmの範囲のメジアン繊維直径を有する繊維を含む。別の代表的実施形態においては、マイクロファイバー構成要素は、約5μm〜約50μmの範囲のメジアン繊維直径を有する繊維を含む。
本開示の複合不織布ウェブは、図1dに示す代表的多層複合不織布ウェブ602の支持層604のような支持層を更に含むことができる。支持層が存在する場合はこれが、複合不織布製品の強度の大部分を提供することができる。幾つかの実施形態では、上述のサブミクロン繊維構成要素は、強度が非常に低い傾向があり、通常の取り扱い中に損傷する可能性がある。サブミクロン繊維構成要素を支持層に取り付けることで、低ソリディティを保持しこれによりサブミクロン繊維構成要素の所望の吸収特性を保持しながら、サブミクロン繊維構成要素に強度を与える。多層複合不織布ウェブ構造も同様に、更なる処理に対する十分な強度を提供することができ、この処理は例えば、ウェブのロール形状への巻回、ウェブのロールからの取り外し、成形、ひだ付け、折り畳み、ステープル留め、製織などを含むが、これらに限られない。
本開示の複合不織布ウェブは、サブミクロン繊維構成要素、支持層、又はこの双方と組み合わせて、追加層を含んでいてもよい。サブミクロン繊維構成要素の外表面の上側又は下側(例えば、図1dの単層複合不織布ウェブ502の第1主表面505上側)や、支持層の外表面の下側(例えば、図1dの第2主表面505’と反対側である支持層604の下側)、又はこの双方に、1つ以上の追加層が存在していてもよい。
特定の代表的実施形態においては、本開示の複合不織布ウェブは、複合不織布製品を基材に取り付けることができるよう1つ以上の取付手段を更に備えていてもよい。上述のように、複合不織布製品は接着剤を用いて取り付けてもよい。接着剤に加えて、その他の取付手段を使用してもよい。好適な取付手段は、ネジ、釘、クリップ、ステープル、ステッチ、ねじ切り、フック及びループ材料などの任意の機械的ファスナを含むが、これらに限られない。
本開示はまた、複合不織布ウェブの製造方法も対象としている。別の様態においては、本開示は、メジアン繊維直径が1マイクロメートル(μm)未満のサブミクロン繊維集団を形成し、メジアン繊維直径が少なくとも1μmであるマイクロファイバー集団を形成し、前記サブミクロン繊維及びマイクロファイバーを混合して複合不織布ウェブとすることにより複合不織布ウェブを製造する方法に関する。繊維集団のうち少なくとも1つは配向されており、前記複合不織布ウェブは厚さを有し、10%未満のソリディティを示す。
サブミクロン繊維の製造及び堆積には数々の方法を用いることができ、これはメルトブロー法、溶融紡糸、電界紡糸、ガスジェットフィブリル化法、又はこれらの組み合わせを含むが、これらに限られない。特に好適な方法は、米国特許第3,874,886号(Levecqueら)、同第4,363,646号(Torobin)、同第4,536,361号(Torobin)、同第5,227,107号(Dickensonら)、同第6,183,670号(Torobin)、同第6,743,273号(Chungら)、同第6,800,226号(Gerking)、及びドイツ特許第19929709C2号(Gerking)に開示の方法を含むが、これらに限られない。
マイクロファイバー集団の製造及び堆積には数々の方法を用いることができ、これはメルトブロー法、溶融紡糸、フィラメント押出、プレキシフィラメント形成、スパンボンド、湿式紡糸、乾式紡糸、又はこれらの組み合わせを含むが、これらに限られない。好適なマイクロファイバー形成方法は、米国特許第6,315,806号(Torobin)、同第6,114,017号(Fabbricanteら)、同第6,382,526B1号(Renekerら)、及び同第6,861,025B2号(Ericksonら)に記載されている。あるいは、マイクロファイバー集団を、例えば米国特許第4,118,531号(Hauser)に記載の方法を用いて、形成又は短繊維に加工し、サブミクロン繊維集団に混合してもよい。特定の代表的実施形態においては、マイクロファイバー集団は、後述するように、熱結合、接着剤結合、粉末バインダ結合、水流交絡、ニードルパンチ、カレンダ加工、又はこれらの組み合わせを用いて結合させたマイクロファイバーのウェブを含んでいてもよい。
図2〜6は、複合不織布ウェブを形成する代表的装置の一部として、本開示の様々な実施形態を実施する例示の装置を示す。図2は全体の概略側面図であり、図2及び3は図2の装置の繊維形成部分の拡大図である。図4及び5は図2に示される装置の他の部分の拡大図である。図7は図1及び5に示す装置の斜視図である。
(2)1つ以上の追加層を、サブミクロン繊維構成要素、マイクロファイバー構成要素、及び/又は任意の支持層の外表面に接触させる工程、
(3)複合不織布ウェブをカレンダ加工する工程、
(4)複合不織布ウェブを表面処理剤又は他の組成物(例えば、難燃剤組成物、接着剤組成物、又は印刷層)でコーティングする工程、
(5)複合不織布ウェブを厚紙又はプラスチック管に取り付ける工程、
(6)複合不織布ウェブをロール形状に巻回する工程、
(7)複合不織布ウェブをスリット加工し、2つ以上のスリットロール及び/又は複数のスリットシートを形成する工程、
(8)複合不織布ウェブを成形型に配置し、複合不織布ウェブを新しい形状に成型する工程、
(9)任意の感圧接着剤層がある場合は露出したこの層上に剥離ライナーを塗布する工程、及び
(10)複合不織布ウェブを、接着剤又は、クリップ、ブラケット、ボルト/ネジ、釘、及びストラップを含むがこれに限られないその他いずれかの取付手段を介し、別の基材に取り付ける工程。
本開示はまた、本開示の複合不織布ウェブを様々な吸収用途において用いる方法を対象としている。更なる態様において、本開示は、メジアン直径が1マイクロメートル(μm)未満のサブミクロン繊維集団と、メジアン直径が少なくとも1μmであるマイクロファイバー集団とを含む複合不織布ウェブであって、繊維集団のうち少なくとも1つは配向されており、前記複合不織布ウェブは厚さを有し、10%未満のソリディティを示す、複合不織布ウェブを含む製品に関する。代表的実施形態においては、上記製品は、気体濾過用品、液体濾過用品、音吸収用品、表面洗浄用品、細胞増殖支持体用品、医薬品供給用品、個人的衛生用品、又は創傷包帯用品であってもよい。
スパンボンド工程から得られた繊維を、米国特許第4,536,361号に記載の方法から製作されたサブミクロン繊維に工程内混合することにより、実施例の複合不織布ウェブを形成した。使用したスパンボンド工程は、米国特許第6,824,372号に記載のように、配向繊維を製作することで知られるオープンシステムである。本工程は、サブミクロン繊維ダイからの繊維を、空気式細径化器の下方であってコレクタベルトの上方でスパンボンド繊維のカーテン内に吹き付けるよう構成した。
Claims (44)
- メジアン直径が1マイクロメートル(μm)未満のサブミクロン繊維集団と、
メジアン直径が少なくとも1μmであるマイクロファイバー集団と
を含む複合不織布ウェブであって、前記繊維集団のうち少なくとも1つは配向されており、更に、前記複合不織布ウェブは厚さを有し、10%未満のソリディティを示す、複合不織布ウェブ。 - 前記サブミクロン繊維集団が、約0.2μm〜約0.9μmの範囲のメジアン繊維直径を有する、請求項1に記載のウェブ。
- 前記マイクロファイバー集団が、約2μm〜約50μmの範囲のメジアン繊維直径を有する、請求項1に記載のウェブ。
- 前記サブミクロン繊維集団及び前記マイクロファイバー集団のうち少なくとも1つが、ポリマー繊維を含む、請求項1に記載のウェブ。
- 前記ポリマー繊維が、ポリプロピレン、ポリエチレン、ポリエステル、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリアミド、ポリウレタン、ポリブテン、ポリ乳酸、ポリビニルアルコール、ポリフェニレンサルファイド、ポリスルフォン、液晶ポリマー、ポリエチレン−コ−ビニルアセテート、ポリアクリロニトリル、環状ポリオレフィン、ポリオキシメチレン、ポリオレフィン系熱可塑性エラストマー、又はこれらの組合せを含む、請求項4に記載のウェブ。
- 前記ポリマー繊維が、ポリオレフィン繊維を含む、請求項4に記載のウェブ。
- 前記サブミクロン繊維集団が、前記マイクロファイバー集団を含む下層の上に上層を形成する、請求項1に記載のウェブ。
- 支持層を更に含む、請求項1に記載のウェブ。
- 前記支持層が、不織布、織布、編布、発泡体層、フィルム、紙の層、裏面粘着層、又はこれらの組み合わせを含む、請求項8に記載の方法。
- 前記支持層が、ポリマー不織布を含む、請求項8に記載のウェブ。
- 前記支持層が、短繊維が結合されたウェブを含み、更に、前記支持層が、熱結合、接着剤結合、粉末バインダ、水流交絡法、ニードルパンチ、カレンダ加工、又はこれらの組み合わせを用いて結合される、請求項8に記載のウェブ。
- 前記支持層の前記上層とは反対側に接着剤層を更に含む、請求項8に記載のウェブ。
- 前記マイクロファイバー集団が、前記サブミクロン繊維集団を含む下層の上に上層を形成する、請求項1に記載のウェブ。
- 前記下層の前記上層とは反対側に隣接する支持層を更に備える、請求項13に記載のウェブ。
- 前記支持層が、複数のマイクロファイバーを含む、請求項14に記載のウェブ。
- 前記支持層を含む前記複数のマイクロファイバーが、前記上層を形成する前記マイクロファイバー集団と組成的に同一である、請求項15に記載のウェブ。
- 前記サブミクロン繊維集団が前記マイクロファイバー集団と混合されて不均質な繊維混合物を形成する、請求項1に記載のウェブ。
- 前記マイクロファイバーの数に対する前記サブミクロン繊維の数の比が、前記複合不織布ウェブの厚さに渡って変化する、請求項17に記載のウェブ。
- 前記マイクロファイバーの数に対する前記サブミクロン繊維の数の比が、前記複合不織布ウェブの厚さに渡って減少する、請求項18に記載のウェブ。
- 前記マイクロファイバーの数に対する前記サブミクロン繊維の数の比が、前記複合不織布ウェブの厚さの半分により決定される中心線の近傍のピーク値から、前記複合不織布ウェブの主表面における、これより低い値まで変化する、請求項18に記載のウェブ。
- 複合不織布ウェブの製造方法であって、
a.メジアン繊維直径が1マイクロメートル(μm)未満のサブミクロン繊維集団を形成することと、
b.メジアン繊維直径が少なくとも1μmであるマイクロファイバー集団を形成することと、
c.前記サブミクロン繊維及びマイクロファイバーを混合して、複合不織布ウェブとすること、
とを含み、前記繊維集団のうち少なくとも1つは配向されており、更に、前記複合不織布ウェブは厚さを有し、10%未満のソリディティを示す、複合不織布ウェブの製造方法。 - 前記サブミクロン繊維集団が、約0.2μm〜約0.9μmの範囲のメジアン繊維直径を有する、請求項21に記載の方法。
- 前記マイクロファイバー集団が、約2μm〜約50μmの範囲のメジアン繊維直径を有する、請求項21に記載の方法。
- 前記サブミクロン繊維集団及び前記マイクロファイバー集団のうち少なくとも1つが、ポリマー繊維を含む、請求項21に記載の方法。
- 前記ポリマー繊維が、ポリプロピレン、ポリエチレン、ポリエステル、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリアミド、ポリウレタン、ポリブテン、ポリ乳酸、ポリビニルアルコール、ポリフェニレンサルファイド、ポリスルフォン、液晶ポリマー、ポリエチレン−コ−ビニルアセテート、ポリアクリロニトリル、環状ポリオレフィン、ポリオキシメチレン、ポリオレフィン系熱可塑性エラストマー、又はこれらの組合せを含む、請求項24に記載の方法。
- 前記ポリマー繊維が、ポリオレフィン繊維を含む、請求項24に記載の方法。
- 前記サブミクロン繊維集団が、前記マイクロファイバー集団を含む下層にの上に上層として形成される、請求項21に記載の方法。
- 前記サブミクロン繊維集団及び前記マイクロファイバー集団が、その上に堆積される支持層を形成することを更に含む、請求項21に記載の方法。
- 前記支持層が、不織布、織布、編布、発泡体層、フィルム、紙の層、裏面粘着層、又はこれらの組み合わせを含む、請求項28に記載の方法。
- 前記支持層が、ポリマー不織布を含む、請求項28に記載の方法。
- 前記支持層が、短繊維が結合されたウェブを含み、更に、前記支持層が、熱結合、接着剤結合、粉末バインダ、水流交絡法、ニードルパンチ、カレンダ加工、又はこれらの組み合わせを用いて結合される、請求項28に記載の方法。
- 前記上層とは反対側の前記支持層に隣接する接着剤層を塗布することを更に含む、請求項28に記載の方法。
- 前記マイクロファイバー集団の一部が、前記サブミクロン繊維集団を含む下層の上に上層を形成する、請求項10に記載の方法。
- 前記上層とは反対側の前記下層に隣接する支持層を更に備える、請求項33に記載の方法。
- 前記支持層が、複数のマイクロファイバーを含む、請求項34に記載の方法。
- 前記支持層を含む前記複数のマイクロファイバーが、前記上層を形成する前記マイクロファイバー集団と組成的に同一である、請求項34に記載の方法。
- 前記サブミクロン繊維集団が、前記マイクロファイバー集団と混合されて、不均質な繊維混合物を形成する、請求項21に記載の方法。
- 前記マイクロファイバーの数に対する前記サブミクロン繊維の数の比が、前記複合不織布ウェブの厚さに渡って変化する、請求項37に記載の方法。
- 前記マイクロファイバーの数に対する前記サブミクロン繊維の数の比が、前記複合不織布ウェブの厚さに渡って減少する、請求項38に記載の方法。
- 前記マイクロファイバーの数に対する前記サブミクロン繊維の数の比が、前記複合不織布ウェブの厚さの半分により決定される中心線の近傍のピーク値から、前記複合不織布ウェブの主表面における、これより低い値まで変化する、請求項38に記載の方法。
- 前記メジアン繊維直径が、1μm未満の前記サブミクロン繊維集団を形成することが、メルトブロー法、溶融紡糸、電界紡糸、ガスジェットフィブリル化法、又はこれらの組み合わせを含む、請求項21に記載の方法。
- 前記メジアン繊維直径が、少なくとも1μmの前記マイクロファイバー集団を形成することが、メルトブロー法、溶融紡糸、フィラメント押出成形、又はこれらの組み合わせを含む、請求項21に記載の方法。
- 前記サブミクロン繊維及び前記マイクロファイバーを混合して複合不織布ウェブとすることが、繊維流の混合、水流交絡、湿式形成、プレキシフィラメント形成、又はこれらの組み合わせを含む、請求項21に記載の方法。
- 請求項21に記載の方法で調製される前記複合不織布ウェブを含む製品であって、気体濾過用品、液体濾過用品、音吸収用品、表面洗浄用品、細胞増殖支持体用品、医薬品供給用品、個人的衛生用品、及び創傷包帯用品、からなる群から選択される、製品。
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CN109881363A (zh) * | 2019-03-22 | 2019-06-14 | 山东晶创新材料科技有限公司 | 超强定伸细旦聚丙烯纺粘针刺非织造布及其制造工艺 |
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US8906815B2 (en) | 2014-12-09 |
CN101946033B (zh) | 2012-11-28 |
EP2231912A4 (en) | 2011-05-11 |
CN101946033A (zh) | 2011-01-12 |
BRPI0821434A2 (pt) | 2015-06-16 |
US20100285101A1 (en) | 2010-11-11 |
WO2009085679A1 (en) | 2009-07-09 |
EP2231912B1 (en) | 2014-10-22 |
EP2231912A1 (en) | 2010-09-29 |
JP5654356B2 (ja) | 2015-01-14 |
JP2015007303A (ja) | 2015-01-15 |
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