JP6128712B2 - 多孔質ポリオレフィン繊維 - Google Patents
多孔質ポリオレフィン繊維 Download PDFInfo
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- JP6128712B2 JP6128712B2 JP2015563174A JP2015563174A JP6128712B2 JP 6128712 B2 JP6128712 B2 JP 6128712B2 JP 2015563174 A JP2015563174 A JP 2015563174A JP 2015563174 A JP2015563174 A JP 2015563174A JP 6128712 B2 JP6128712 B2 JP 6128712B2
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- Prior art keywords
- polyolefin
- polyolefin fiber
- fiber
- fibers
- polymer
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Description
本出願は米国仮出願番号第 61/833,981号(2013年6月12日出願)、および第61/907,580号(2013年11月22日)に対する優先権を主張し、同出願の全体が参照により本明細書に組み込まれる。
A. ポリオレフィンマトリクス
ポリオレフィンマトリクスは、一般的に、熱可塑性組成物の約60重量%〜約99重量%、一部の実施形態では約60重量%〜約98重量%、および一部の実施形態では約80重量%〜約95重量%を占める。ポリオレフィンは、約100°C〜約220°C、一部の実施形態では約120°C〜約200°C、および一部の実施形態では約140°C〜約180°Cの溶融温度を持ちうる。溶融温度は、ASTM D−3417に従い、示差走査熱量測定(「DSC」)を使用して決定されうる。適切なポリオレフィンには、例えば、エチレンポリマー(例えば、低密度ポリエチレン(「LDPE」)、高密度ポリエチレン(「HDPE」)、直鎖低密度ポリエチレン(「LLDPE」など)、プロピレンホモポリマー(例えば、シンジオタクチック、アタクチック、イソタクチックなど)、プロピレン共重合体などを含みうる。一つの特定実施形態では、ポリマーは、ホモポリプロピレンまたはプロピレンの共重合体など、プロピレンポリマーである。プロピレンポリマーは、例えば、実質的にイソタクチックポリプロピレン・ホモポリマーまたはその他のモノマーを約10重量%以下(すなわち、プロピレンの少なくとも約90重量%)含む共重合体から形成されうる。このようなホモポリマーは、約140°C〜約170°Cの融点を持ちうる。
本明細書で使用される場合、「ナノ包含添加剤」という用語は、ポリマーマトリクス内にナノスケールサイズの個別領域の形態で分散されることのできる材料を一般的に指す。例えば、延伸前に、領域は、約1〜約1000ナノメートル、一部の実施形態では約5〜約800ナノメートル、一部の実施形態では約10〜約500ナノメートル、および一部の実施形態では約20〜約200ナノメートルの平均断面寸法を持ちうる。領域は、楕円形、球形、円筒形、プレート状、管状などのさまざまな異なる形状を持ちうる。一つの実施形態では、領域は実質的に楕円の形状を持つ。ナノ包含添加剤は一般的に、連続相ポリオレフィンマトリクスの重量に基づいて、熱可塑性組成物の約0.05重量%〜約20重量%、一部の実施形態では、約0.1重量%〜約10重量%、および一部の実施形態では約0.5重量%〜約5重量%の量で使用される。熱可塑性組成物全体のナノ包含添加剤の濃度は、同様に、約0.01重量%〜約15重量%、一部の実施形態では約0.05重量%〜約10重量%、および一部の実施形態では約0.3重量%〜約6重量%でありうる。
必要ではないが、本発明の組成物は、マイクロ包含添加剤も用いうる。本明細書で使用される場合、「マイクロ包含添加剤」という用語は、ポリマーマトリクス内にマイクロスケールサイズの個別領域の形態で分散されることのできる任意の材料を一般的に指す。例えば、延伸前に、領域は約0.1μm〜約25μm、一部の実施形態では約0.5μm〜約20μm、および一部の実施形態では約1μm〜約10μmの平均断面寸法を持ちうる。使用された場合、変形および伸長ひずみ(例えば、延伸)を受ける時、マイクロスケールおよびナノスケール相領域はユニークな方法で相互作用して細孔のネットワークを作ることができることを本発明者らは発見した。すなわち、材料の不適合性から生じる応力集中の結果として、伸長ひずみは、マイクロスケールの個別相領域の近くに強い局所的せん断ゾーンおよび/または応力強度ゾーン(例えば、垂直応力)を開始することができる。これらのせん断および/または応力強度ゾーンは、マイクロスケール領域に隣接するポリオレフィンマトリクスにいくらかの初期剥離を生じる。しかし特に、ナノスケール個別相領域の近くに生成された局所的せん断および/または応力強度ゾーンはマイクロスケールゾーンと重複して、ポリマーマトリクスにさらなる剥離を起こし、それによって、ナノスケール領域および/またはマイクロスケール領域に隣接してかなりの数のナノ細孔を生成する。
さまざまな異なる理由で、組成物には多種多様な原料を使用しうる。例えば、一つの特定の実施形態では、熱可塑性組成物に相間修飾剤を使用して、ナノ包含添加剤および/またはマイクロ包含添加剤とポリオレフィンマトリクスの間の摩擦および結合性の程度を減らすのを助け、それにより剥離の程度および均一性を向上させうる。このように、細孔は、組成物全体に渡って実質的に均一な様式で分配されうる。修飾剤は、比較的低い粘度を持ち、熱可塑性組成物により容易に組み込むことができ、ポリマー表面に簡単に移動できるよう、室温(例えば、25°C)で液体または半固体の形態でありうる。ポリオレフィンマトリクスと添加剤との間の界面での物理的力を減らすことによって、修飾剤の低粘度、疎水性の性質が剥離の促進を助けることができると考えられる。本書で使用されるとき、「疎水性」という用語は、一般的に、空気中の水の接触角が約40°以上、一部の場合は約60°以上の材料を指す。対照的に、「親水性」という用語は、一般的に、空気中の水の接触角が約40°未満の材料を指す。接触角の測定のための一つの適切な試験はASTM D5725−99(2008年)である。
熱可塑性組成物を形成するために、成分は典型的には、さまざまな既知の技術のいずれかを使用して混合される。一つの実施形態では、例えば、組成物は別々に、または組み合わせて供給されうる。例えば、組成物は、まず乾燥混合されて基本的に均一な乾燥混合物を形成し、同様に、分散的に材料を混合する溶融処理装置に同時または順番に供給されうる。バッチおよび/または連続溶融処理技術を用いうる。例えば、ミキサー/混練機、バンバリーミキサー、ファレル連続ミキサー、単軸スクリュー押出機、二軸スクリュー押出機、ロールミルなどを使用して、材料を混合し溶融処理しうる。特に適切な溶融処理装置は、共回転、二軸スクリュー押出機(例えば、Werner & Pfleiderer Corporation(ニュージャージー州、ラムジー)から入手可能なZSK−30押出機またはThermo Electron Corp.(イギリス、ストーン)から入手可能なThermo Prism(商標) USALAB 16押出機でありうる。このような押出機は、供給ポートおよび換気ポートを含み、強力な分配・分散混合をもたらす。例えば、成分は二軸スクリュー押出機の同じまたは異なる供給ポートに供給され溶融混合されて、実質的に均一な溶融混合物を形成しうる。必要に応じて、その他の添加剤も、ポリマー溶解物に注入および/または押出機の長さに沿った異なる点で押出機に別々に供給されうる。
本書で使用される場合、「繊維」という用語は、金型などの成形口を通してポリマーを通過させることによって形成される細長い押出し物を一般的に指す。特に断りのない限り、「繊維」という用語は、明確な長さを持つ不連続繊維および実質的に連続するフィラメントの両方を含む。例えば、実質的にフィラメントは、長さと直径の比(「アスペクト比」)が約15,000対1よりも大きく、一部の場合は約50,000対1よりも大きいなど、直径よりもはるかに大きな長さを持ちうる。
Aは、溶融延伸後の繊維の線速度(例えば、ゴデット速度)であり直接測定され、
Bは、押し出された繊維の線速度であり以下のように計算できる:
Cは、一つの穴を通した押出し(グラム/分)であり、
Dはポリマーの溶融密度(グラム/立方センチメートル)であり、
Eは、繊維がそれを通して押し出される穴の直径(センチメートル)である。特定の実施形態では、ドローダウン比は約20:1〜約4000:1、一部の実施形態では、約25:1〜約2000:1、一部の辞し形態では約50:1〜約1000:1、および一部の実施形態では約75:1〜約800:1でありうる。
そのユニークで有益な特性のために、本発明の結果得られるポリオレフィン繊維は、吸収性物品、包装フィルム、バリアフィルム、医療製品(例えば、ガウン、外科用ドレープ、フェイスマスク、ヘッドカバー、手術帽、靴カバー、滅菌ラップ、保温毛布、加熱パッドなど)など、さまざまに異なるタイプの物品での使用に非常に適している。例えば、ポリオレフィン繊維は、水またはその他の流体を吸収できる「吸収性物品」に組み込まれうる。一部の吸収物品の例には、おむつ、トレーニングパンツ、吸収性下着、失禁物品、女性用衛生用品(例えば、生理用ナプキン)、水着、おしり拭き、ミットワイプなどのパーソナルケア吸収物品、衣類、穿孔材料、アンダーパッド、ベッドパッド、包帯、吸収性ドレープ、および医療用ワイプなどの医療用吸収性物品、食品サービスタオル、衣料物品、パウチなどを含むがこれに限定されない。このような物品の形成に適した材料およびプロセスは、当業者にはよく知られている。例えば吸収性物品は、一般的に、実質的に液体透過性の層(例えば、外側カバー)、液体透過性層(例えば、体側のライナー、サージ層など)、および吸収性コアを含む。一つの実施形態では、例えば、ポリオレフィン繊維は繊維状材料(例えば、不織布ウェブ)の形態の場合があり、吸収性物品の外側カバーを形成するために使用されうる。必要に応じて、不織布ウェブは、蒸気透過性または蒸気不透過性の液体不透過性フィルムへと積層されうる。同様にポリオレフィン繊維は、蒸気透過性または蒸気不透過性のいずれかである外側カバーの液体不透過性フィルムなど、吸収性物品に使用されるフィルムの形態でありうる。
メルトフローレート:
メルトフローレート(「MFR」)は、一般的に190°C、210°C,または230°Cで、2160グラム/10分の負荷をかけた時、押出レオメーター口(直径0.0825インチ)を通して押出されるポリマーの重量(グラム)である。別段の指示がない限り、メルトフローレートは、Tinius Olsen Extrusion PlastometerでASTM試験方法D1238に従って測定される。
ガラス転移温度(Tg)は、ASTM E1640−09に従って、動的機械分析(DMA)で決定されうる。TA Instruments社のA Q800機器を使用しうる。実験は、張力/張力形状で、−120°C〜150°Cの温度掃引モード、3°C/分の加熱率で実行されうる。歪振動振幅周波数は、試験中、一定(2Hz)に保ちうる。3つの独立サンプルを試験して、平均ガラス転移温度を得るが、これはtan δ曲線の最大値によって定義され、ここでδは、貯蔵弾性率に対する損失弾性率の比(tan δ = E”/E’)として定義される。
引張特性は、ASTM 638−10に従って23°Cで測定されうる。例えば、個別の繊維標本は、初めに38ミリメートルの長さまで短くされ(例えば、はさみで切断)、黒いベルベット布の上に別々に配置されうる。10〜15の標本がこのようにして集められる。繊維標本は次に、51ミリメートル×51ミリメートルの外側寸法および25ミリメートル×25ミリメートルの内側寸法を持つ長方形の紙フレーム上に実質的に真っ直ぐな状態で取り付けられうる。各繊維標本の端部は、接着テープでフレームの側部に繊維端部を固定することにより、操作可能なようにフレームに取り付けられうる。各繊維標本は、適正に較正され倍率40Xに設定されうる従来的な実験室顕微鏡を使用して、その外部の比較的短い繊維断面寸法を測定しうる。この繊維断面寸法は、個々の繊維標本の直径として記録されうる。フレームは、繊維標本への過剰な損傷を避ける方法で、サンプル繊維標本の端部を、一定割合延長タイプ引張試験機の上部および下部グリップに取り付けるのに役立つ。
密度および空隙容量パーセントを決定するために、延伸の前に、標本の幅(Wi)および厚さ(Ti)が最初に測定されうる。延伸前の長さ(Li)も、標本の表面上の二つのマークの間の距離を測定することによって決定された。その後、標本を延伸して細孔形成を開始しうる。次に、Digimatic Caliper(株式会社ミツトヨ)を使用して、標本の幅(Wf)、厚さ(Tf)、および長さ(Lf)が直近の0.01mmまで測定された。延伸の前の体積(Vi)は、WixTixLi=Viで計算されうる。延伸後の体積(Vf)も、WfxTfxLf=Vfで計算されうる。密度(Pf)は、Ρf=Pi/Φで計算され、ここでは、Piは前駆材料の密度であり、空隙容量パーセント(%Vv)は、%Vv=(1-1/Φ)x100で計算されうる。
静水圧試験は、静圧下の液体水による貫通に対する材料の抵抗の尺度であり、AATCC試験方法127−2008に従って実施される。各標本に対する結果は、平均されセンチメートル(cm)で記録される。高い値は水の貫通に対する抵抗がより高いことを示す。
材料のWVTRを決定するために使用される試験は、材料の性質に基づいて変わりうる。WVTR値を測定するための一つの技術は、ASTM E96/96M−12、手順Bである。別の方法にはINDA試験手順IST−70.4(01)の使用を伴う。INDA試験手順は以下のように要約される。恒久的ガードフィルムおよび試験されるサンプル材料によって、ドライチャンバーが既知の温度と湿度でウェットチャンバーから分離される。ガードフィルムの目的は、明確な空隙を定義し、空隙が特徴化される間に空隙の空気を静めるまたは鎮静化することである。乾燥チャンバー、ガードフィルム、および湿潤チャンバーは、その中に試験フィルムが密封される拡散セルを構成する。サンプルホルダーは、Mocon/Modem Controls, Inc.(ミネソタ州、ミネアポリス)社製のPermatran−Wモデル100Kとして知られている。第一の試験は、ガードフィルムおよび100%相対的湿度を生成する蒸発器組立品の間の空隙のWVTRから成る。水蒸気は空隙およびガードフィルムを通して拡散し、水蒸気濃度に比例する乾燥ガスの流れと混ざり合う。電気信号が処理のためにコンピュータに送られる。コンピュータは、空隙およびガードフィルムの透過速度を計算し、その値を将来使用するために保存する。
F = 水蒸気の流れ(cm3/分)、
ρsat(T) = 温度Tでの飽和空気中の水の密度、
RH = セルの特定場所での相対湿度、
A = セルの断面積、および
Psat(T) = 温度Tでの水蒸気の飽和蒸気圧。
熱伝導率(W/mK)および熱抵抗(m2K/W)は、ASTM E−1530−11(「保護熱流量技術による材料の熱貫流に対する抵抗」)に従い、Anter Unithermモデル2022試験機を使用して決定されうる。目標試験温度は25°C、適用負荷は0.17 MPaとしうる。試験前に、サンプルは温度23°C(±2°C)、相対湿度50%(±10%)で40+時間の間調整しうる。熱特性(W/m2K)も、1を熱抵抗で割ることで計算されうる。
フレーザー空隙率は、8インチストリップのサンプルを切り(流れ方向に沿って測定)、サンプルを(幅方向に)アコーディオンスタイルに折り畳んで6つの層を得て、Frazier(登録商標)低差圧透気度試験機(FAP−LP)で測定された。
Claims (41)
- 熱可塑性組成物によって形成されるポリオレフィン繊維であって、前記熱可塑性組成物が、ポリオレフィンマトリクスポリマーを含む連続相と、約1ナノメートル〜約1000ナノメートルの平均断面寸法を有するナノスケールの個別領域の形態で前記連続相内に分散されているポリマー製ナノ包含添加剤とを含有し、
前記ナノ包含添加剤が、前記熱可塑性組成物の重量に基づいて、前記熱可塑性組成物の約0.05重量%〜約10重量%を構成し、
前記繊維中に形成された多孔質ネットワークが、約800ナノメートル以下の平均断面寸法と約1〜約30のアスペクト比とを有する複数のナノ細孔を含む、ポリオレフィン繊維。 - 前記ナノ細孔が約5〜約700ナノメートルの平均断面寸法を持つ、請求項1に記載のポリオレフィン繊維。
- ナノ細孔が約100〜約5000ナノメートルの平均軸方向寸法を持つ、請求項1または2に記載のポリオレフィン繊維。
- 前記ポリオレフィンマトリクスポリマーが、2160グラムの負荷および230°CでASTM D1238に従って測定された場合、約0.5〜約80グラム/10分のメルトフローレートを持つ、請求項1〜3のいずれか一項に記載のポリオレフィン繊維。
- 前記ポリオレフィンマトリクスポリマーが、プロピレンホモポリマー、プロピレン/α−オレフィン共重合体、エチレン/α−オレフィン共重合体、またはそれらの組み合わせである、請求項1〜4のいずれか一項に記載のポリオレフィン繊維。
- 前記ポリオレフィンマトリクスポリマーが実質的にイソタクチックポリプロピレンホモポリマーまたは少なくとも約90重量%のプロピレンを含む共重合体である、請求項1〜5のいずれか一項に記載のポリオレフィン繊維。
- 前記連続相が、前記熱可塑性組成物の約60重量%〜約99重量%を構成する、請求項1〜6のいずれか一項に記載のポリオレフィン繊維。
- 前記ナノ包含添加剤が室温で液体または半固体である、請求項1〜7のいずれか一項に記載のポリオレフィン繊維。
- 前記ナノ包含添加剤が非極性成分を持つポリマーである、請求項1〜8のいずれか一項に記載のポリオレフィン繊維。
- 前記ポリマーが微結晶ポリオレフィンワックスである、請求項9に記載のポリオレフィン繊維。
- 前記ポリマーが極性成分をさらに含む、請求項9に記載のポリオレフィン繊維。
- 前記ポリマーが官能性ポリオレフィンである、請求項11に記載のポリオレフィン繊維。
- 前記官能性ポリオレフィンがポリエポキシドである、請求項12に記載のポリオレフィン繊維。
- 前記ナノ包含添加剤が、2160グラムの負荷および溶融温度より少なくとも40°C高い温度(例えば、約190°C)でASTM D1238に従って測定された場合、約0.1〜約100グラム/10分のメルトフローレートを持つ、請求項9に記載のポリオレフィン繊維。
- 前記ナノ包含添加剤のメルトフローレートに対する前記ポリオレフィン繊維のメルトフローレートの比が約0.2〜約8である、請求項7に記載のポリオレフィン繊維。
- 前記ナノ包含添加剤がナノスケール領域の形態であり、前記ナノスケール領域が約5ナノメートル〜約800ナノメートルの平均断面寸法を持つ、請求項1〜15のいずれか一項に記載のポリオレフィン繊維。
- 前記ナノ包含添加剤が、前記連続相の重量に基づいて、前記組成物の約0.1重量%〜約10重量%を構成する、請求項1〜16のいずれか一項に記載のポリオレフィン繊維。
- 前記組成物が、前記連続相内に個別領域の形態で分散されたマイクロ包含添加剤をさらに含む、請求項1〜17のいずれかに記載のポリオレフィン繊維。
- 前記マイクロ包含添加剤がポリマーである、請求項18に記載のポリオレフィン繊維。
- 前記マイクロ包含添加剤の前記ポリマーがスチレン共重合体、フッ素ポリマー、ポリビニルアルコール、ポリ酢酸ビニル、またはポリエステルである、請求項19に記載のポリオレフィン繊維。
- 前記マイクロ包含添加剤の前記ポリマーが、ポリ乳酸である、請求項19に記載のポリオレフィン繊維。
- 前記マイクロ包含添加剤の前記ポリマーが、約0°C以上のガラス転移温度を持つ、請求項19に記載のポリオレフィン繊維。
- 前記マイクロ包含添加剤が、2160グラムの負荷および210°Cの温度で測定された場合、約5〜約200グラム/10分のメルトフローレートを持つ、請求項19に記載のポリオレフィン繊維。
- 前記ポリオレフィンマトリクスポリマーのメルトフローレートに対する前記マイクロ包含添加剤のメルトフローレートの比が約0.5〜約10である、請求項19に記載のポリオレフィン繊維。
- 前記マイクロ包含添加剤のヤング弾性係数に対する前記ポリオレフィンマトリクスポリマーのヤング弾性係数の比が約1〜約250である、請求項18に記載のポリオレフィン繊維。
- 前記マイクロ包含添加剤が、約1マイクロメートル〜約400マイクロメートルの平均軸方向寸法を持つマイクロスケール領域の形態である、請求項18に記載のポリオレフィン繊維。
- 前記マイクロ包含添加剤が、前記連続相の重量に基づいて、前記組成物の約1重量%〜約30重量%を構成する、請求項18に記載のポリオレフィン繊維。
- 前記熱可塑性組成物が相間修飾剤をさらに含む、請求項1〜27のいずれか一項に記載のポリオレフィン繊維。
- 前記多孔質ネットワークがマイクロ細孔をさらに含む、請求項1〜28のいずれか一項に記載のポリオレフィン繊維。
- 前記多孔質ネットワークが、前記組成物の全体にわたって実質的に均一な形態で分配されている、請求項1〜29のいずれか一項に記載のポリオレフィン繊維。
- 前記ナノ細孔が概して平行なカラムに分配されている、請求項1〜30のいずれか一項に記載のポリオレフィン繊維。
- 前記ポリオレフィン繊維の合計細孔容量が立方センチメートル当たり約15%〜約80%である、請求項1〜31のいずれか一項に記載のポリオレフィン繊維。
- ナノ細孔が前記ポリオレフィン繊維の合計細孔容量の約20容量%以上を構成する、請求項1〜32のいずれか一項に記載のポリオレフィン繊維。
- 前記熱可塑性組成物が約0.90g/cm3以下の密度を持つ、請求項1〜33のいずれか一項に記載のポリオレフィン繊維。
- 前記熱可塑性組成物が一般的に発泡剤を含まない、請求項1〜34のいずれか一項に記載のポリオレフィン繊維。
- 請求項1〜35のいずれか一項に記載の前記ポリオレフィン繊維を含む不織布ウェブ。
- 請求項36に記載の前記不織布ウェブを含む吸収性物品であって、前記吸収性物品が実質的に液体不透過性の層、液体透過性の層、および吸収性コアを含む吸収性物品。
- 前記実質的に液体不透過性の層が前記不織布ウェブを含む、請求項37に記載の吸収性物品。
- ポリオレフィン繊維を形成するための方法であって、前記方法が、
ポリオレフィンマトリクスポリマーを含む連続相および約1ナノメートル〜約1000ナノメートルの平均断面寸法を有するナノスケールの個別領域の形態で前記連続相内に分散されているポリマー製ナノ包含添加剤を含有する熱可塑性組成物を形成する工程であって、前記ナノ包含添加剤が、前記熱可塑性組成物の重量に基づいて、前記熱可塑性組成物の約0.05重量%〜約10重量%を構成する工程と、
前記組成物を金型を通して押し出して前記繊維を形成する工程と、
前記マトリクスポリマーの溶融温度より低い温度で前記繊維を延伸し、それによって約800ナノメートル以下の平均断面寸法と約1〜約30のアスペクト比とを有する複数のナノ細孔を含む多孔質ネットワークを形成する工程とを含む方法。 - 前記熱可塑性組成物が約1.1〜約3.0の延伸比で伸張される、請求項39に記載の方法。
- 不織布ウェブを形成するための方法であって、前記方法が、
ポリオレフィンマトリクスポリマーを含む連続相および約1ナノメートル〜約1000ナノメートルの平均断面寸法を有するナノスケールの個別領域の形態で前記連続相内に分散されているポリマー製ナノ包含添加剤を含有する熱可塑性組成物を形成する工程であって、前記ナノ包含添加剤が、前記熱可塑性組成物の重量に基づいて、前記熱可塑性組成物の約0.05重量%〜約10重量%を構成する工程と、
前記熱可塑性組成物を金型を通して押し出して複数の繊維を形成する工程と、
前記延伸繊維を表面上に無作為に堆積させて不織布ウェブを形成する工程と、
前記不織布ウェブが形成される前および/または後に前記マトリクスポリマーの溶融温度より低い温度で前記繊維を延伸し、それによって約800ナノメートル以下の平均断面寸法と約1〜約30のアスペクト比とを有する複数のナノ細孔を含む多孔質ネットワークを形成する工程とを含む方法。
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