KR102120511B1 - 수류-결합된 에어레이드 웹의 제조 방법 및 이로부터 수득된 제품 - Google Patents

수류-결합된 에어레이드 웹의 제조 방법 및 이로부터 수득된 제품 Download PDF

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KR102120511B1
KR102120511B1 KR1020157015636A KR20157015636A KR102120511B1 KR 102120511 B1 KR102120511 B1 KR 102120511B1 KR 1020157015636 A KR1020157015636 A KR 1020157015636A KR 20157015636 A KR20157015636 A KR 20157015636A KR 102120511 B1 KR102120511 B1 KR 102120511B1
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web
fiber
weight
nonwoven web
airlaid
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리차드 놀슨
에릭 마리아니
캐서린 다이르모스 페테르센
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야콥 홀름 운트 존스 아게
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K8/00—Cosmetics or similar toiletry preparations
    • A61K8/02—Cosmetics or similar toiletry preparations characterised by special physical form
    • A61K8/0208—Tissues; Wipes; Patches
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B1/00—Cleaning by methods involving the use of tools
    • B08B1/10—Cleaning by methods involving the use of tools characterised by the type of cleaning tool
    • B08B1/14—Wipes; Absorbent members, e.g. swabs or sponges
    • B08B1/143—Wipes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425—Cellulose series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425—Cellulose series
    • D04H1/4258—Regenerated cellulose series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING 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
    • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/02—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
    • D04H5/03—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling by fluid jet
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
    • D10B2201/01—Natural vegetable fibres
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    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
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    • D10B2509/00—Medical; Hygiene
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Abstract

우수한 MD 및 CD 강도를 갖고 수세성인 부직 웹을 제조하는 방법이 제공된다. 상기 방법은, 3.5 mm 이하의 섬유 길이를 갖는 천연 셀룰로스 섬유 50 중량% 이상 및 8.0 mm 이상의 섬유 길이를 갖는 스테이플 섬유 50 중량% 이하의 에어레이드 웹의 수류-결합을 포함한다. 상기 에어레이드 웹은 전구체 웹 상에 레이드되지 않으며, 접착제, 결합제 또는 열 결합 섬유가 사용되지 않는다. 이러한 에어레이드 및 수류-결합은 연속 작업으로 수행된다. 수세능에 대한 도시 지침을 만족시키는 제품이 본 발명의 방법에 따라 수득될 수 있다.

Description

수류-결합된 에어레이드 웹의 제조 방법 및 이로부터 수득된 제품{METHOD FOR PRODUCTION OF A HYDROENTANGLED AIRLAID WEB AND PRODUCTS OBTAINED THEREFROM}
본 발명은 최소 수의 작업을 이용하여 일회용 부직을 연속 제조하는 방법에 관한 것이며, 일회용 와이프 또는 와이퍼와 같은 수세성 또는 일회용 물품으로서 유용한 경제적 제품을 제공한다.
관련 출원의 상호 참조
본 출원은, 2012년 12월 13일자로 출원된 미국 특허 가출원 제 61/736837 호를 우선권으로 주장하며, 상기 가출원의 내용 전체를 본원에 참고로 인용한다.
일회용 부직 기재는, 일반적으로 한번 사용하고 버리는 각종 다양한 소비재의 제조에 사용된다. 이러한 제품은 일회용 세정 와이프, 일회용 기저귀, 일회용 성인 실금자용 제품, 체액 흡수를 위해 전형적으로 병원에서 사용되는 일회용 패드, 화장품 도포기 또는 메이크업을 제거하기 위한 화장품 패드, 및 케라틴성 기재로부터의 다른 재료를 포함한다.
이러한 상품은, 계속 증가하는 성장 가능성 및 이용 확대를 갖는 산업을 구성한다. 그러나, 실질적으로 이러한 모든 제품이 매립 또는 하수 시스템을 통해 잠재적으로 환경으로 도입되기 때문에, 제조하기 쉬우며, 불량한 생분해성을 갖는 화학 성분(예컨대, 결합제, 접착제 또는 열가소성 중합체)을 최소로 포함하거나 전혀 포함하지 않고, 성능에 필요한 우수한 습윤 인장 강도를 갖는 일회용 부직 재료가 필요하다. 또한, 제조하기에 경제적이면서, 최소한의 린트 함량을 갖도록 구성되고, 도시 및 개인 하수 시스템에 허용가능한 수세성 물품으로 분류되는 코드를 만족시키는 제품이 요구된다.
통상적으로는, 일회용 부직 와이프 제품은, "에어레이스(airlace)" 및 "하이드라스펀(hydraspun)" 공정으로 산업에서 공지된 2가지 기본 기술 중 하나를 통해 제조될 수 있다. 상이한 제조사는, 의도된 최종 용도 및 이용가능한 생산 장비에 기초한 변형을 사용하여 이러한 기술을 수행할 수 있지만, 작업의 기본 원리는 유지된다.
에어레이스 방법은, 스테이플 길이 섬유 및 목재 펄프 섬유의 에어레이드 웹을 부직 캐리어 층 또는 전구체 기재 부직 웹 상에 침착시키는 작업과, 에어레이드 층을 부직 캐리어와 수류-결합시키는 작업을 조합한다. 이러한 기술은 오우엘레트(Ouellette)의 미국 특허 제 8,250,719 호 및 여기에서 기술된 참고문헌에 기술되어 있다. 캐리어 웹을 사용하는 것에 더하여, 오우엘레트는 열풍 또는 분무 접착제를 사용하여 에어레이드 섬유들을 결합시키는 것을 기술하고 있다.
만닝(Manning) 등의 미국 특허 제 4,755,421 호에 기술된 바와 같은 "하이드라스펀" 방법에 따르면, 펄프 및 인조 섬유의 웨트레이드(wetlaid) 웹을 수류-결합하고, 건조한다. 그러나, 비아즈멘스키(Viazmensky) 등의 미국 특허 제 5,292,581 호는 이러한 제품이 불량한 습윤 강도를 가짐을 지적하며, 결합제의 첨가가 실질적으로 강도를 개선한다고 기술하고 있다. 보다 최근에, 안니스(Annis) 등의 미국 특허 제 7,732,357 호는, 가열시 적어도 부분적으로 용융됨으로써 활성화되어 섬유-대-섬유 결합을 형성하는 결합제 섬유를 부직 시트에 사용하는 것을 기술하고 있다. 이러한 결합제 섬유는 폴리에틸렌, 폴리프로필렌, 폴리에틸렌 프탈레이트 및 이들의 혼합물을 포함한다.
따라서, 접착제, 결합제 또는 결합제 섬유를 포함하지 않고, 수행하기 편리하고 경제적이며, 우수한 성능 강도를 갖고 도시 하수관 및 개인 정화 시스템용 수세성 제품으로서 허용가능한 일회용 부직 웹을 제공하는 부직 웹의 제조 방법에 대한 필요성이 남아 있다.
따라서, 본 발명의 목적은, 최소한의 처리 작업을 포함하고, 접착제, 결합제 또는 결합 섬유를 사용하지 않고, 와이프로서 사용하기에 충분한 습윤 인장 강도를 갖는 부직 웹을 제공하는 부직 웹의 제조 방법을 제공하는 것이다. 본 발명의 또다른 목적은, 하수구 및 정화 시스템에서의 처리에 허용가능한 와이프로서 사용되기에 충분한 습윤 인장 강도를 갖는 부직 웹을 제공하는 것이다.
이러한 목적 및 다른 목적이 본 발명에 따라 달성되었으며, 본 발명의 제 1 실시양태는, 천연 셀룰로스 섬유 및 스테이플 섬유의 혼합물을 제조하는 단계; 상기 혼합물을 에어포밍하여, 하나 이상의 균질 에어레이드 웹을 수득하는 단계; 상기 에어레이드 웹을 수류-결합시켜, 적어도 한쪽 면에서 상기 웹을 압밀화시키는 단계; 및 수류-결합된 웹을 건조하여 부직 웹을 수득하는 단계를 포함하는 부직 웹의 제조 방법을 포함하며, 이때 상기 에어포밍 및 상기 수류-결합은 연속 작업으로 수행되고, 섬유들의 혼합물 중의 상기 천연 셀룰로스 섬유의 함량은 50 중량% 이상이고, 상기 스테이플 섬유의 함량은 50 중량% 이하이고, 결합제, 접착제 또는 열 결합 섬유는 사용되지 않고, 상기 천연 셀룰로스 섬유의 섬유 길이는 3.5 mm 이하이고, 상기 스테이플 섬유의 섬유 길이는 8.0 mm 이상이고, 상기 부직 웹의 평량은 20 g/m2 내지 100 g/m2이고, 상기 부직 웹의 두께는 0.25 mm 내지 2 mm이다.
상기 제 1 실시양태의 바람직한 실시양태에서, 상기 에어레이드 웹은, 전구체 웹의 예비성형이나 연속 필라멘트 웹의 혼입 없이 에어포머의 캐리어 상에서 직접 형성된다.
추가로 매우 바람직한 실시양태에서, 접착제, 결합제 또는 결합제 섬유가 상기 부직 웹에 적용되지 않으며, 기계 방향에 대해 수직인 방향에서의 인장 강도에 대한 기계 방향에서의 인장 강도의 비(MD/CD)는 3 미만이다.
또한, 하나의 실시양태에서, 본 발명은, 상기 방법 실시양태 중 임의의 방법에 의해 수득된 부직 웹을 제공하며, 이때 상기 부직 웹은 75 중량%의 목재 펄프 및 25 중량%의 라이어셀을 포함한다. 이러한 실시양태에 따른 부직 웹의 평량은 40 g/m2 내지 60 g/m2이고, MD/CD 비는 3 미만이고, CD 습윤 인장 강도는 5 N/5 cm 이상이고, 상기 부직 웹은, 부직 소비재의 수세성을 평가하기 위한 2009년 7월판 에다나(EDANA)의 지침서에 따라 정의될 때, 수세성 제품이다.
또다른 실시양태에서, 본 발명은, 상기 방법 실시양태 중 임의의 방법에 의해 수득된 부직 웹을 제공하며, 이때 상기 부직 웹은 약 50 중량%의 목재 펄프 및 약 50 중량%의 비스코스를 포함하고, 상기 부직 웹의 평량은 40 g/m2 내지 60 g/m2이고, MD/CD 비는 3 미만이고, CD 습윤 인장 강도는 12 N/5 cm 이상이다.
도 1은, 본 발명의 하나의 실시양태에 따른 수류-결합 유닛 내의 워터 제트(water jet)의 배열의 개략도를 도시한다.
도 2는, 시판 와이프 대비 본 발명에 따른 분산성 및 비-분산성 부직 웹의 비교 데이터를 도시한다.
달리 명시되지 않는 한, 하기 상세한 설명에 따라 기술된 모든 수치 범위는 이들 사이의 모든 하위범위 및 모든 값들을 포함한다. 모든 중량 함량 값은 총 중량을 기초로 한다. 하기 상세한 설명은 본 발명의 일반적 설명 및 특정 바람직한 실시양태를 제공한다. 그러나, 당업자는 본 발명의 요지를 벗어나지 않고 본 발명의 많은 변형이 가능함을 인지할 것이다. 본 명세서 및 첨부된 특허청구범위는 이러한 모든 변형을 포함하는 것으로 의도된다.
제 1 실시양태에서, 본 발명은, 천연 셀룰로스 섬유 및 스테이플 섬유의 혼합물을 제조하는 단계; 상기 혼합물을 에어포밍하여, 하나 이상의 균질 에어레이드 웹을 수득하는 단계; 상기 에어레이드 웹을 수류-결합시켜, 적어도 한쪽 면에서 상기 웹을 압밀화시키는 단계; 및 수류-결합된 웹을 건조하여 부직 웹을 수득하는 단계를 포함하는 부직 웹의 제조 방법을 제공하며, 이때 상기 에어포밍 및 상기 수류-결합은 연속 작업으로 수행되고, 섬유들의 혼합물 중의 상기 천연 셀룰로스 섬유의 함량은 50 중량% 이상, 바람직하게는 60 중량% 이상, 가장 바람직하게는 75 중량% 이상이다. 상기 스테이플 섬유의 함량은 50 중량% 이하, 바람직하게는 40 중량% 이하, 가장 바람직하게는 25 중량% 이하이다. 본 발명에 따른 에어포밍 및 상기 수류-결합 작업에서 결합제, 접착제 또는 열 결합 섬유는 사용되지 않는다.
상기 천연 셀룰로스 섬유의 길이는 3.5 mm 이하, 바람직하게는 1.5 mm 내지 3.5 mm, 가장 바람직하게는 2.5 내지 3.5 mm이다. 임의의 천연 셀룰로스 섬유가 상기 혼합물의 단섬유로서 사용될 수 있다. 하나의 실시양태에서, 전술된 길이의 목재 펄프는 단섬유일 수 있고, 바람직한 실시양태에서, 써던 파인 크라프트(southern pine Kraft)가 상기 천연 셀룰로스 섬유일 수 있다. 설파이트 펄프화 공정으로부터 수득된 목재 펄프가 또한 상기 천연 셀룰로스 섬유의 공급원이 될 수 있다. 천연 셀룰로스 섬유들의 혼합물이 사용될 수 있다. 상기 천연 셀룰로스 섬유는 해머밀 내에서 섬유-분리되어(defibrated), 개별적인 느슨한(loose) 섬유들의 혼합물을 형성할 수 있다.
상기 스테이플 섬유는, 길이가 8.0 mm 이상, 바람직하게는 8.0 내지 100 mm, 가장 바람직하게는 8 mm 내지 25 mm인 임의의 비-열가소성 인조 섬유일 수 있다. 바람직하게는 상기 스테이플 섬유는 비스코스 또는 라이어셀이다. 비-열가소성 섬유들의 혼합물이 사용될 수 있다.
에어레이드 웹의 형성 방법은 일반적으로 라우르센(Laursen) 등의 미국 특허 제 4,640,810 호에 기술되어 있다. 상기 스테이플 및 섬유-분리된 천연 셀룰로스 섬유는 균질 혼합물로 배합되며, 분배기 유닛으로 이송되는 공기 스트림 내에 지지된다. 분배기 유닛은, 유공성(foraminous) 캐리어 상으로 섬유가 통과하도록 설계된 구멍, 슬롯 또는 다른 적합한 형태의 개구부(aperture)로 천공된 회전형 실린더 또는 드럼을 포함한다. 상기 드럼의 제작 및 개구부의 구조 및 크기는, 사용하여 독특한 웹 구조를 수득하기 위한 섬유 혼합물의 특성에 따라 달라질 수 있다. 공기 흐름, 드럼 내의 기계적 교반 및 캐리어 아래쪽으로부터의 흡입 중 임의의 조합의 영향 하에, 상기 섬유는 천공된 드럼의 개구부를 통해 유도되어, 캐리어 표면 상에 균질한 웹을 형성한다. 건조 웹의 매팅(matting)의 높이 및 정도는 섬유 함량 및 크기, 드럼 천공 크기 및 형태, 공기 흐름 속도, 캐리어의 하부로부터 적용되는 흡입의 정도 및 캐리어 스피드를 비롯한 공정 변수의 제어를 통해 달라질 수 있다. 독특한 매팅 구조를 제공하기 위해 다른 장비 제어도 달라질 수 있다.
웹의 폭은 사용되는 에어포머 장비의 유형에 의존하며, 1 m 내지 6 m로 달라질 수 있다. 예를 들어, 단-웹(Dan-Web), 엘리콘(Oerlikon) 및 안팝 오이(Anpap Oy)에서 공급되는 통상적인 상업적 유닛은 폭이 2 내지 5 m 범위이다.
본 발명에 따르면, 형성된 에어레이드 웹은 수류-결합 유닛 또는 스펀레이스 유닛으로 직접 연속적으로 이송되며, 여기서 에어레이드 매트는 일련의 고압 워터 제트에 부딪혀, 섬유를 기계적으로 얽힘 처리하거나 압밀화시키고, 부직 웹을 형성한다. 상기 제트는 캐리어 표면과 수직으로 배향되거나 비스듬히 놓여 웹에 독특한 특성을 제공할 수 있다. 상기 제트는 한쪽 면, 바람직하게는 상면, 또는 상면 및 하면 둘 다로부터 웹을 압밀화시키도록 배치될 수 있다. 상기 제트의 압력은 0.04 bar/kg/h/m 내지 15 bar/kg/h/m, 바람직하게는 0.1 bar/kg/h/m 내지 10 bar/kg/h/m, 가장 바람직하게는 0.3 bar/kg/h/m 내지 4 bar/kg/h/m일 수 있다.
양쪽 면으로부터 웹을 압밀화시키기 위한 제트의 배열을 도시하는 실시양태가 도 1에 개략적으로 도시되어 있다. 도 1에 도시된 바와 같이, 에어포머로부터 직접 수득된 에어레이드 웹은 일련의 캐리어 벨트를 따라 통과하여, 숫자 순서로 도시된 고압 제트에 노출된다. 제트 (11), (12) 및 (13)은 웹의 상부에 충돌하고, 제트 21 및 22는 이의 반대쪽 또는 하부에 충돌한다. 개략적인 제트는 상기 웹의 폭에 걸친 제트의 뱅크를 나타내며, 제트 뱅크는 상기 웹에 걸쳐 얽힘의 다양한 완성도를 제공하도록 배치되고 배열된다. 따라서, 이러한 얽힘은 상기 부직 웹의 의도된 최종 용도에 따라 패턴화되거나 랜덤화될 수 있다.
상기 부직 웹의 드레이프(drape), 유연성 및 편안함은, 고압 제트에 의해 전달되는 에너지 및 장비를 통한 웹의 이동 속도에 의해 제어될 수 있다. 본 발명에 따르면, 수압 및 스펀레이스 장비를 통한 웹의 속도를 둘 다 제어하고 접착제, 결합제 또는 결합 섬유가 없는 경우, 다양한 정도의 강도, 흡수도, 유연도 및 두께를 갖는 부직 웹이 수득될 수 있다.
스펀레이스 또는 수류-결합 유닛은 플레이쓰너(Fleissner GmbH, 독일) 및 앙드리츠 퍼포젯(Andritz Perfojet, 프랑스)으로부터 입수가능하다.
상기 기본적인 실시양태의 하나의 변형에서, 더 두꺼운 부직 웹을 제조할 수 있도록, 스펀레이스 이전에 다중 에어레이드 웹을 제조하고 적층할 수 있다. 개별적인 적층된 층들은 동일한 섬유 조성을 갖거나, 상기 부직 웹의 의도된 최종 용도를 위해 선택된 상이한 조성을 가질 수 있다. 이러한 각각의 가능한 실시양태에서, 얽힘은, 워터 제트 압력 및 스펀레이스 유닛을 통한 웹의 이동 속도의 변화에 의해 달성될 수 있다. 결합제, 접착제 또는 결합 섬유는 사용되지 않는다.
스펀레이스 이후에, 습윤 부직 웹은 건조되고, 이송 및 저장을 위해 권취될 수 있다. 추가의 실시양태에서, 건조 이전에, 얽힘 처리된 웹은 하이드로엠보싱(hydroembossing) 공정 또는 열 엠보싱 공정에 의해 엠보싱될 수 있다.
상기 부직 웹의 평량은, 두께가 0.25 mm 내지 2 mm인 부직 웹의 경우 20 g/m2 내지 100 g/m2, 바람직하게는 40 g/m2 내지 80 g/m2 일 수 있다. 그러나, 다중 에어레이드 웹을 적층하는 경우, 평량 및 두께는 이러한 범위가 아닐 수 있다. 평량은, 에어레이스 및 스펀레이스 작업 둘 다에 대해 기술된 공정 변수의 제어에 의해 및 현행 기술에서 당업자에게 통상적으로 공지된 다른 변수에 의해 달라질 수 있다.
본 발명에 따른 부직 웹은, 몇몇 통상적으로 이용가능한 부직 웹보다 더 전방향성(omnidirectional)인 강도 프로파일을 갖는다. 폭 방향(CD)에 대한 기계 방향(MD)에서의 습윤 인장 강도의 비는 3 미만이다. 도 2의 표에 도시된 바와 같이, 접착제, 결합제 또는 결합 섬유를 사용하지 않은 본 발명에 따른 JHI 제품은 비교용 시판 와이프에 비해 상당히 더 낮은 평량을 갖지만, 유사한 값의 MD 및 CD 인장 강도를 가진다. 이러한 특성은, 수세성에 대한 표준 지침을 만족시키는 제품에서는 CD 습윤 인장 강도가 수득되기 어렵다고 공지되어 있기 때문에 특히 놀랍다.
특히 바람직한 실시양태에서, 3.5 mm 이하의 길이를 갖는 섬유-분리된 목재 펄프 섬유 약 75 중량% 및 8 mm 이상의 섬유를 갖는 라이어셀 25 중량%의 조성을 갖는 수세성 제품이 본 발명에 따라 제조된다. 상기 에어레이드 웹은 0.35 bar/kg/h/m 내지 2.1 bar/kg/h/m의 제트 압력에서 수류-결합된다. 상기 부직 웹의 CD 습윤 인장 강도는 5.0 N/5 cm 이상이고, MD/CD 비는 3 미만이다. 이러한 부직 웹은, 부직 소비재의 수세성을 평가하기 위한 2009년 7월판 에다나의 지침서에 따라 정의될 때, 수세능에 대한 시험 표준을 만족시킨다. 중요하게는, 이러한 제품이 도시 하수 펌프 시험을 통과하며, 이때 60개의 와이프 각각에 대한 총 5회 시험에서 측정된 모든 데이터 포인트의 10% 미만이 10% 초과의 전력 증가를 가질 수 있으며, 바람직하게는 데이터 포인트의 10% 미만이 10%의 전력 증가를 유발한다.
더 높은 강도를 갖는 또다른 특정 실시양태에서, 3.5 mm 이하의 길이를 갖는 섬유-분리된 목재 펄프 섬유 약 50 중량% 및 8 mm 이상의 섬유를 갖는 비스코스 약 50 중량%의 혼합물을 갖는 부직 웹이 본 발명에 따라 제조된다. 상기 에어레이드 웹은 0.3 bar/kg/h/m 내지 15 bar/kg/h/m, 바람직하게는 0.4 bar/kg/h/m 내지 6 bar/kg/h/m의 제트 압력에서 수류-결합된다. 상기 부직 웹의 CD 습윤 인장 강도는 12 N/5 cm 이상이고, MD/CD 비는 3 미만이다. 의미 있게도, 이러한 제품의 린팅(linting) 특성은, 베이비 와이프 또는 경질 표면용 세정 와이프로서 현재 사용되는 상업적 제품보다 상당히 더 낮다.

Claims (20)

  1. 섬유-분리된(defibrated) 천연 셀룰로스 섬유 및 스테이플 섬유의 균질한 건조 혼합물을 제조하는 단계;
    상기 균질한 건조 혼합물을 유공성(foraminous) 캐리어 상으로 천공된 실린더를 통과시켜 상기 혼합물을 에어포밍(airforming)하여 하나 이상의 균질 에어레이드(airlaid) 웹을 수득하는 단계;
    상기 에어레이드 웹을 유공성 캐리어 상에서 수류-결합(hydroentangling)시켜, 적어도 한쪽 면에서 상기 웹을 압밀화시키는(consolidate) 단계; 및
    수류-결합된 웹(hydroentangled web)을 건조하여 부직 웹을 수득하는 단계
    를 포함하는
    부직 웹의 제조 방법으로서, 이때
    상기 에어포밍 및 상기 수류-결합이 연속 작업으로 수행되고,
    섬유들의 혼합물 중의 상기 천연 셀룰로스 섬유의 함량이 50 중량% 이상이고, 상기 스테이플 섬유의 함량이 50 중량% 이하이고,
    결합제, 접착제 또는 열 결합 섬유가 사용되지 않고,
    상기 천연 셀룰로스 섬유의 섬유 길이가 3.5 mm 이하이고,
    상기 스테이플 섬유의 섬유 길이가 8.0 mm 이상이고,
    상기 부직 웹의 평량(basis weight)이 20 g/m2 내지 100 g/m2이고,
    상기 부직 웹의 두께가 0.25 mm 내지 2 mm인, 방법.
  2. 제 1 항에 있어서,
    상기 혼합물 중의 천연 셀룰로스 섬유의 함량이 75 중량% 이상이고, 상기 스테이플 섬유의 함량이 25 중량% 이하인, 방법.
  3. 제 1 항에 있어서,
    상기 평량이 40 g/m2 내지 60 g/m2인, 방법.
  4. 제 1 항에 있어서,
    상기 천연 셀룰로스 섬유가 목재 펄프이고, 상기 스테이플 섬유가 비스코스(viscose) 또는 라이어셀(lyocell)인, 방법.
  5. 제 4 항에 있어서,
    상기 목재 펄프가 설파이트 펄프화(sulfite pulping)에 의해 수득된 설파이트 펄프인, 방법.
  6. 제 1 항에 있어서,
    상기 에어레이드 웹을 수류-결합시켜 상기 웹을 양쪽 면에서 압밀화시키는 방법.
  7. 제 1 항에 있어서,
    적용된 수류-결합 압력이 0.04 bar/kg/h/m 내지 15 bar/kg/h/m인, 방법.
  8. 제 7 항에 있어서,
    적용된 수류-결합 압력이 0.3 bar/kg/h/m 내지 4 bar/kg/h/m인, 방법.
  9. 제 1 항에 있어서,
    수류-결합된 웹을 엠보싱하는 단계를 추가로 포함하되, 상기 엠보싱 작업이 상기 에어포밍 및 상기 수류-결합과 연속적인, 방법.
  10. 제 1 항에 있어서,
    상기 에어레이드 웹의 에어포밍이 단일 에어포머(airformer) 내에서 수행되는, 방법.
  11. 제 1 항에 있어서,
    상기 에어레이드 웹의 에어포밍이 하나보다 많은 에어포머 내에서 수행되고,
    각각의 웹의 섬유 함량이 동일한, 방법.
  12. 제 1 항에 있어서,
    상기 에어레이드 웹의 에어포밍이 하나보다 많은 에어포머 내에서 수행되고,
    하나 이상의 웹의 섬유 함량이 또다른 웹의 섬유 함량과 상이한, 방법.
  13. 제 1 항에 있어서,
    결합제, 접착제 또는 열 결합 섬유가 상기 부직 웹에 적용되지 않는 방법.
  14. 제 1 항에 있어서,
    상기 에어레이드 웹이, 전구체 웹의 예비성형이나 연속 필라멘트 웹의 혼입 없이 상기 유공성 캐리어 상에서 직접 형성되는, 방법.
  15. 제 1 항에 있어서,
    상기 에어레이드 웹의 수류-결합 압력이 0.35 bar/kg/h/m 내지 15 bar/kg/h/m인, 방법.
  16. 제 15 항에 있어서,
    접착제, 결합제 또는 결합제 섬유가 상기 부직 웹에 적용되지 않고,
    기계 방향에 대해 수직인 방향에서의 인장 강도에 대한 기계 방향에서의 인장 강도의 비(MD/CD)가 3 미만인, 방법.
  17. 제 1 항에 따른 방법에 의해 수득된 부직 웹.
  18. 제 17 항에 있어서,
    상기 부직 웹이 75 중량%의 목재 펄프 및 25 중량%의 라이어셀을 포함하고,
    상기 부직 웹의 평량이 40 g/m2 내지 60 g/m2이고,
    MD/CD 비가 3 미만이고,
    CD 습윤 인장 강도가 5 N/5 cm 이상이고,
    상기 부직 웹이, 부직 소비재의 수세성을 평가하기 위한 2009년 7월판 에다나(EDANA)의 지침서에 따라 정의될 때, 수세성(flushable) 제품인, 부직 웹.
  19. 제 17 항에 있어서,
    상기 부직 웹이 50 중량%의 목재 펄프 및 50 중량%의 비스코스를 포함하고,
    상기 부직 웹의 평량이 40 g/m2 내지 60 g/m2이고,
    MD/CD 비가 3 미만이고,
    CD 습윤 인장 강도가 12 N/5 cm 이상인, 부직 웹.
  20. 제 18 항에 따른 부직 웹, 및
    세정제, 살균제, 탈취제, 소독제, 보습제 및 화장품 리무버(remover)로 이루어진 군으로부터 선택되는 적어도 하나
    를 포함하는 세정 와이프.
KR1020157015636A 2012-12-13 2013-08-06 수류-결합된 에어레이드 웹의 제조 방법 및 이로부터 수득된 제품 KR102120511B1 (ko)

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