TW201538335A - 具有良好障壁性質的無膜背板 - Google Patents
具有良好障壁性質的無膜背板 Download PDFInfo
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Abstract
一多層不織布結構被描述如下，其中該不織布結構包含至少二紡絲黏合層及至少一易熔融層。該易熔融層係置於該至少二紡絲黏合層之間。該易熔融層係由一聚合物所組成，其具有一熔點至少比該包含紡絲黏合層中所含之纖維表層的聚合物之熔點低20℃，或係由一能輕易吸收某一形式輻射的聚合物所組成。在黏合條件下，組成該易熔融層的纖維可被熔解以形成膜，從而改善該不織布結構的障壁性質。
Description
一多層不織布結構，其包含一第一紡絲黏合層、一第二紡絲黏合層、及至少一置於該第一及第二紡絲黏合層間的易熔融層，其可為，例如，熔噴層、紡絲黏合層或甚至分梳短纖維層。該易熔融層係由具有一最大橫截面為5微米或更低的纖維所組成，及由一聚合物所組成，其熔點至少比該用於第一及第二紡絲黏合層之組成纖維外表面的聚合物之熔點低20℃。該(等)易熔融層能夠在黏合過程中熔解以使其可轉變為一膜狀的型態。
具可接受之障壁性質的紡織物及不織布在現今已普遍被實現，其係藉由將可透氣的或不可透氣的膜層壓成不織布或紡織物。排除上述的層壓方法同時維持所欲之輸送及障壁性是欲求的，如此一來可降低成本同時維持紡織物的觸感。
過去幾年，為減低在衛生用品市場用來製造紡絲黏合不織布的成本，藉由機器製造商的驅動，紡絲黏合技術已有顯著的發展。由於不斷增加的生產率，機器現今裝配達到6織軸，並以7織軸機器作為下一世代。該等機器典
型地具有組合的紡絲黏合及熔噴織軸。
因此，當尋求取代該用以結合膜及不織布的層壓步驟時，決定利用較新的多織軸技術內聯(inline)製造一結構，並在一或多SXnMXnS的內層包含一低熔點聚合物，其中n可為0至3(其中S代表一紡絲黏合層，M代表一熔噴層，X可任為一紡絲黏合層或一熔噴層，且n可為0至3)。一般認為，將如此低熔點的熔噴纖維暴露於一般紡絲黏合不織布製程中的黏合階段期間所遭遇的壓力及溫度下，可形成一膜狀結構，如此使得於上述之結構的可透氣性及障壁性可依其應用而調整。
因此，本發明係關於一種多層不織布結構，其包含至少二紡絲黏合層及至少一易熔融層，其中該易熔融層係置於該至少二紡絲黏合層之間，且其中該易熔融層係由一聚合物所組成，其具有一熔點低於包含該所不欲被熔解的熔噴或紡絲黏合層的纖維之外表面的聚合物之熔點。
本發明允許一更為類似紡織物的物件被製造，其中含有相同內容物如一膜-不織布疊層，但具有較佳的觸感，等效的可透氣性、及較低的製造成本。
如本文所用，術語“不織布網”或“不織布織物”或“不織布”意指一種網織物，其具有由個別的纖維或線製成
的結構，該等纖維或線交織，但不採用任何規則的、重複的方式。在過去，不織布已由多種方法被形成，例如，空氣鋪設法(air laying processes)、熔噴法、紡絲黏合法及分梳法(carding processes)，包含黏合分梳網織物法(bonded carded web processes)。
如本文所用，術語“熔噴”意指將一熔融的熱塑性材料經由多個微小、通常為圓形的毛細管模擠壓成熔融線材或絲狀纖維至高速氣體流體(例如，空氣)中的方法，其中該高速氣體流體使該熔融熱塑性材料的絲狀纖維變細，以降低其直徑，其可達微纖維直徑。接著，該熔噴纖維被該高速氣體流體承載並沉積在一收集面上，以形成一隨機分散之熔噴纖維織網。
如本文所用，術語“紡絲黏合”意指一種係將一熔融的熱塑性材料自多個微小、通常為圓形的毛細管紡嘴擠壓成絲狀纖維的方法，其中該毛細管紡嘴具有經擠壓的絲狀纖維的直徑，接著藉由拉引該纖維以迅速地降低其直徑及收集該纖維於一基板上。
如本文所用，術語“微纖維”意指具有一平均直徑不大於約100微米的小直徑纖維。纖維，及特別是，用於本發明之紡絲黏合及熔噴纖維可為微纖維。更特別地，該紡絲黏合纖維可有利地為具有一平均直徑約15至30微米的纖維，及具有自約1.5至3.0丹尼之單絲丹尼數(denier per filament)，而該熔噴纖維可有利地為具有一平均直徑低於約15微米，或更有利地10、8或甚至5微米的纖維。
如本文所用，術語“聚合物”一般包含但不限於均聚合物、共聚物，例如，嵌段共聚物、接枝共聚物、隨機共聚物及交替共聚物、三元共聚物等，及其等之混合與改質。此外，除非特別限定，否則術語“聚合物”應包含該材料所有可能的幾何形態。該等形態包含但不限於同排的、對排的及隨機的對稱性。
如本文所用，術語“聚丙烯基塑性體(PBP)或彈性體(PBE)”(該等可共同地當作“PBPE”)包含反應器級丙烯共聚物，其具有低於約100焦耳/克的熔解熱及MWD<3.5。該等PBP一般具有低於約100焦耳/克的熔解熱，而該等PBE一般具有低於約40焦耳/克的熔解熱。該等PBP典型地具有一介於約3至約10wt%範圍內的乙烯，及該等彈性體的PBE具有一乙烯含量自約10至15wt%。
本發明之不織布層狀結構較佳地具有一基重(單位面積的重量)自約每平方米10克(gsm)至約200gsm。該基重亦可為自約15gsm至約60gsm，且在一範例中其可為約20至35gsm，其特別適合供衛生方面的應用。對於醫學上的應用，較佳的基重可為50至100gsm，或對於工業上的應用可為80至5000gsm。
如本文所用，術語“拉伸強度”描述在一既有的基重下，當於機械方向(MD)或橫向(CD)之任一者拉伸一不織布至斷裂時的力的峰值。該力的峰值可能對應至或可能未對應至斷裂時的力或斷裂時的應變。“伸長量”除非特別說明，否則作為對應至拉伸強度的應變量。
“熔點”係根據ASTM D3418“藉由示差掃描量熱儀於轉換溫度及熔解焓及聚合物的結晶化之標準測試方法”所決定。“水蒸氣穿透率”(WVTR)有時係指如“濕氣穿透率”，其係根據伊達那測試法(Edana Test method)，WSP070.6.R3(12)所決定。
本發明係有關於一多層不織布結構，其包含至少二紡絲黏合層及至少一易熔融層，其中該易熔融層係置於該至少二紡絲黏合層之間。該易熔融層可為一熔噴層、一紡絲黏合層或甚至一分梳短纖維層。該易熔融層係由一聚合物所組成，該聚合物具有一熔點，其低於組成該紡絲黏合層之纖維表面組成聚合物的熔點。
用於該多層不織布結構之外部層的紡絲黏合層可為雙成分纖維或單成分纖維。若雙成分纖維被使用，該纖維較佳為鞘-芯形式。該纖維可自任意聚合物製成。較佳的單成分纖維包含丙烯均聚物(hPP)、丙烯隨機共聚物或聚乙烯(PE)，雙成分纖維包含hPP/PE、RCP/PE、聚烯烴彈性體/PE或hPP/hPP、聚對酞酸乙二酯(PET)/X或聚醯胺(PA/X)雙成分，其中X可為任一聚烯烴或任一彈性不織布紡絲黏合或PLA。該纖維應被選擇以確保該纖維表面的聚合物(例如，在雙成分鞘-芯纖維的鞘)具有一熔點其高於該用於形成膜的熔噴纖維層之聚合物。該用於紡絲黏合纖維表層的聚合物較佳地具有一熔點其至少係比該用於易熔融層的聚合物高20℃、30℃或甚至40℃。該用於纖維表層及外紡絲黏合層的聚合物，具有一熔點其大於125℃，或大於140℃或甚
至160℃。
該用於多層不織布結構中所必要的內層之易熔融層可為熔噴層、紡絲黏合層或分梳短纖維層，儘管對許多應用來說熔噴層可能係較佳的。該用在易熔融層的纖維可為基於hPP、PE、聚烯烴(PO)彈性體、PET、PA或其他極性共聚物，諸如乙烯酯酸乙烯酯、乙烯一氧化碳(ECO)、乙烯丙烯酸(EAA)、順丁烯二酐接枝共聚物(maleic anhydride grafted copolymer)、乙烯甲基丙烯酸(EMA)(其可為無線射頻或微波活化的)。PO彈性體包含丙烯基塑性體或彈性體(PBPE)，諸如Dow Chemical Company所販賣的VERSIFYTM彈性體或ExxonMobil所販賣的VISTAMAXXTM彈性體，及烯烴嵌段共聚物，諸如Dow Chemical Company所販賣的INFUSETM彈性體。聚乙烯纖維包含線性低密度聚乙烯(LLDPE)、高壓低密度聚乙烯(LDPE)、高密度聚乙烯(HDPE)等。較佳的聚乙烯纖維包含塑性的或彈性的LLDPE(亦即具有密度為約0.910g/cm3或更低的LLDPE)。該等材料可被單獨使用或與兩個或更多的上述成分混合。為易於熔解，該材料較佳地具有一至少比該用於纖維表面的聚合物低20℃、30℃或甚至40℃之熔點，其中該纖維表面構成該外紡絲黏合層。較佳地，該用於至少一易熔融層具有一熔點為100℃或低於90℃。替代地，若該易熔融層是RF、微波或超音波活化的，而該紡絲黏合層不是，則無線射頻、超音波或微波輻射可被用來熔解該內部的易熔融層，同時使該外紡絲黏合層處於纖維狀。用於本發明易熔融層中的纖維，其特
佳的材料包含丙烯基彈性體。若超過一熔噴層被使用，則該等熔噴層在組成上可為相同或相異的，以至於該較低熔點的聚合物可為該等層的任一者，其決定於所欲之整體的障壁性、通透性、或強度。
本發明的多層不織布結構包含二外部的紡絲黏合熔融層及至少一內部的易熔融層，但可能包含附加層。一般而言，該多層結構可被描述為SXnMXnS，其中S係一紡絲黏合層、M係一熔噴層、X係紡絲黏合或熔噴層任一者，且n可為0至3。
當該易熔融層被熔解時，該不織布結構一般較佳為具有一相對高的剛性/強度以支撐該結構。這可藉由下述達成，例如，使用較剛硬的材料所製成的附加層如hPP，及/或使用整體上較該易熔融層剛硬的聚合物，如具有較低乙烯含量的PBPE，例如5-7%。
將該等層結合後，其典型地係承受壓力及/或較高的溫度下以促進上述結構的黏合。該等較高的溫度及壓力可被選擇，以便熔解至少內部層之一者。當該聚合物整體上被限制在相鄰層之間時，一旦該壓力及/或溫度被移除，其將固化以形成一膜狀結構，此可幫助減少該不織布結構的水蒸氣穿透率。替代地，與其依靠熱及/或壓力以使該內部層熔解，若使用無線電或微波活化的材料，該不織布結構可受到無線電或微波輻射而導致熔解。一般認為，該內部層可根據其熔點及厚度的改變以致使上述結構的可透性及障壁性可依其應用而被調整。因此，本發明的不織布結
構可用於健康及衛生物件，諸如嬰兒尿布背板、成人失禁背板、女性衛生背板、外科長袍、醫用被單、及石膏繃帶或繃帶(plasters or bandages)。該不織布結構亦可用於工業用途，諸如屋頂防水層、地工薄膜(geo-membranes)、房屋繞布(housewrap)、或室內裝潢。
為闡示本發明，兩組不同系列的不織布結構被製備如下。第一組試驗係藉由結合不織布的不同層如下示，接著黏合該等層以形成一層合物而製成。該黏合係藉由使用兩個加熱的軋輥，其一係平滑的而另一者具有16%的黏合面積。該黏合係在一70N.mm的壓力、一油軋輥(calendar oil bonding)溫度設在145℃及25m/min的產線速率(line speed)所完成。
第二組試驗係藉由結合如下示不織布的不同層，接著黏合該等層以形成一層合物而製成。該等結構係如同第一組試驗達成初步黏合(亦即，在145℃的油軋輥黏合溫度，其中有一平滑軋輥且另一者具有16%的黏合面積、在70N.mm的壓力、及25m/min的產線速率)。該等接著做第二次黏合在95℃的溫度及於25m/min下30bar bip壓力，使用一100%黏合面積的軋輥。如下所見，使用100%的黏合面積大為改善水頭，其教示該易熔融層在第一組情況下沒有完全熔解。
範例1：A層/C層/G層/G層/C層/A層(50 FPM)
範例2：A層/C層/G層/G層/C層/A層(34 FPM)
範例3：A層/G層/G層/A層(24 FPM)
範例4：A層/C層/B層/C層/A層
範例5：A層/C層/B層/B層/C層/A層
範例6：A層/C層/D層/C層/A層
範例7：A層/C層/E層/C層/A層
範例8：A層/C層/E層/C層/A層
範例9(比較的)：SMS-A層/C層/A層
範例10：SMS-A層/B層/A層
範例11：SMS-A層/E層/A層
範例12：SMMMS A層/C層/B層/C層/A層
範例13：SMMMS A層/C層/B層/C層/A層
範例14：SMMMS A層/B層/B層/C層/A層
範例15：SMMMS A層/B層/E層/C層/A層
範例16：SMMMS A層/B層/E層/B層/A層
範例17：SMMMS A層/C層/D層/C層/A層
A層係一20克每平方米(GSM)基重的紡絲黏合不織布，其係以Reicofil紡絲黏合技術製造，自一聚丙烯均聚物(hPP)所製成，其具有25g/10min的MFR(2.16Kg,230℃)及167℃的熔點。
B層係一25 GSM基重的熔噴不織布，其係以Reicofil紡絲黏合技術製造，自一具有25g/10min MFR的丙烯基塑性體/彈性體(PBPE)所製成，其中具有5%的乙烯含量、110℃的熔點及添加2%的Irgatec CR76母料。
C層係一25 GSM基重的熔噴不織布，其係以Reicofil紡絲黏合技術製造，自一聚丙烯均聚物(hPP)所製成，其具有~800g/10min的MFR及167℃的熔點。
D層係一25 GSM基重的熔噴不織布，其係以Reicofil紡絲黏合技術製造，自一由氣相反應器所生成的線性低密度聚乙烯(LLDPE)所製成，其具有155g/10min的MI(2.16Kg,190℃)、0.933g/cm3的密度、及120℃的熔點。
E層係一25 GSM的熔噴不織布，其係由Reicofil紡絲黏合技術所製造，自一具有25g/10min MFR的丙烯基塑性體/彈性體(PBPE)所製成，其中具有9%的乙烯含量、85℃的熔點及添加2%的Irgatec CR76母料。
G層係一10 GSM(50feet/min)或15 GSM(34feet/min)或20 GSM(24feet/min)(如上所示)的熔噴不織布，其係以BIAX Film製造，其包含25g/10min MFR的丙烯基塑性體/彈性體(PBE1)，其中具有5%的乙烯含量、110℃的熔點及添加2%的Irgatec CR76母料。
紡絲黏合樣品是以Reicoful 3單經軸技術製造，其具有1.2米寬的紡絲黏合試生產線及每米5000個孔洞，且其中該孔洞係直徑0.6mm並有一L/D比率為4。該產線的產能係恆量的在0.6ghm以產線速率為150m/min。
熔噴樣品G層是以Biax Fibertilm的產線製造，其具有一帶有128個孔洞的15cm(6吋)寬的模具。該纖維藉由使用熱空氣而被變細，且以不同的速率被收集在一纖維滾筒上以改變基重，並被沉積在不織布層上。
熔噴樣品B、C、D及E係依Reicofil/Hills技術的熔噴產線製造，其具有1.2米的寬度及每吋50個孔洞。該孔洞具有0.25的直徑。該熔噴不織布係在20meters/min的產線速率集中製造25GSM的不織布。
Claims (11)
- 一種多層不織布結構，其包含至少二紡絲黏合層及至少一易熔融層，其中該易熔融層係置於該至少二紡絲黏合層之間，且其中該易熔融層係由纖維所組成，該纖維包含一聚合物，該聚合物具有一熔點至少比組成紡絲黏合層之組成纖維表面的聚合物之熔點低20℃。
- 一種多層不織布結構，其包含：a.一第一紡絲黏合外部層，其包含單成分或雙成分纖維，其中該纖維具有一表面，其係由一具有既定熔點的烯烴聚合物所組成；b.一易熔融層，其中該易熔融層係由具有一最大截面積為5微米或更低的纖維所組成，及由一聚合物所組成，該聚合物熔點至少比供用於第一及第二紡絲黏合外部層之組成纖維表面的聚合物的熔點低20℃；c.一第二熔融層，其包含單成分或雙成分纖維，其中該纖維具有一表面，其係由具有既定熔點之烯烴聚合物所組成；其中該易熔融層被置於該第一紡絲黏合層及第二紡絲黏合層之間；及其中該易熔融層係能夠在一黏合過程中被熔解，以使其可被轉變成一膜狀的型態。
- 如請求項1的多層不織布，其中熱及壓力被施加在該多層不織布結構上，導致該易熔融層中的纖維至少部分地 被熔解，藉以增加該易熔融層的障壁性。
- 如請求項2的多層不織布，其中構成該易熔融層中的纖維之聚合物，具有一低於125℃的熔點。
- 如請求項2的多層不織布，其中構成外部紡絲黏合層中的纖維之聚合物，具有一高於125℃的熔點。
- 如請求項2的多層不織布，其中該易熔融層係由一聚合物所組成，該聚合物具有一熔點至少比供用於第一及第二紡絲黏合外部層之組成纖維表面的聚合物的熔點低40℃。
- 一種用於改善一多層膜之障壁性的方法，其係藉由使用一內聯(inline)黏合步驟，以於紡絲黏合不織布之間形成一類障壁膜結構，其中包含步驟：a.選擇一多層不織布結構，其包含：i.一第一紡絲黏合外部層，其包含單成分或雙成分纖維，其中該纖維具有一表面，其係由具有既定熔點的烯烴聚合物所組成；ii.一易熔融層，其中該易熔融層係由具有一最大截面積為5微米或更低的纖維所組成，及由一聚合物所組成，其熔點比供用於第一及第二紡絲黏合外部層之組成纖維表面的聚合物的熔點低20℃；iii.一第二熔融層，其包含單成分或雙成分纖維，其中該纖維具有一表面，其係由具有既定熔點之烯烴聚合物所組成； 其中該易熔融層被置於該第一紡絲黏合層及第二紡絲黏合層之間；b.令該多層結構承受條件，該條件係足以使該易熔融層中的纖維至少部分地熔解，藉以增加該易熔融層的障壁性。
- 如請求項6的方法，其中該多層結構承受增加的熱及/或壓力，以至少部分地熔解該易熔融層中的纖維。
- 如請求項6的方法，其中該多層結構承受超音波振盪，以至少部分地熔解該易熔融層中的纖維。
- 如請求項6的方法，其中該多層結構承受RF輻射，以至少部分地熔解該易熔融層中的纖維。
- 一種多層不織布結構，其包含：a.一第一紡絲黏合外部層，其包含單成分或雙成分纖維，其中該纖維具有一表面，其係由具有既定熔點的烯烴聚合物所組成；b.一易熔融層，其中該易熔融層係由具有一最大截面積為5微米或更低的纖維所組成，及由一聚合物所組成，該聚合物係比用於外部層的聚合物更大幅度地吸收RF輻射；c.一第二紡絲黏合外部層，其包含單成分或雙成分的纖維，其中該纖維具有一表面，其係由具有既定熔點之烯烴聚合物所組成；其中該易熔融層被置於該第一紡絲黏合層及第二紡絲黏合層之間；及 其中該易熔融層係能夠在一黏合過程中被熔解，以使其可被轉變成一膜狀的型態。
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| US4600614A (en) | 1983-09-12 | 1986-07-15 | The Dow Chemical Company | High-frequency heatable plastics |
| US5194190A (en) | 1989-03-31 | 1993-03-16 | General Electric Company | Process for impregantion of glass fiber reinforcement with thermoplastic resins |
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| DE69309314T2 (de) * | 1993-08-02 | 1997-10-23 | Fiberweb North America Inc | Elastischer verbundvliesstoff |
| WO1995032091A1 (en) | 1994-05-24 | 1995-11-30 | Exxon Chemical Patents Inc. | Fibers and fabrics incorporating lower melting propylene polymers |
| WO1997030244A2 (de) | 1996-02-13 | 1997-08-21 | Klöber, Johannes | Diffusionsoffene dachunterspannbahn und verfahren zum herstellen derselben |
| JP3016361B2 (ja) | 1996-03-27 | 2000-03-06 | ユニチカ株式会社 | 一方向伸縮性不織布及びその製造方法 |
| US5679042A (en) | 1996-04-25 | 1997-10-21 | Kimberly-Clark Worldwide, Inc. | Nonwoven fabric having a pore size gradient and method of making same |
| DE19642958C2 (de) | 1996-10-17 | 1998-08-20 | Corovin Gmbh | Mehrschichtiges Vlies |
| US5918140A (en) | 1997-06-16 | 1999-06-29 | The Regents Of The University Of California | Deposition of dopant impurities and pulsed energy drive-in |
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| AR016248A1 (es) | 1998-05-01 | 2001-06-20 | Dow Global Technologies Inc | Metodo para fabricar capas o laminas fibrosas por soplado en fusion, las laminas o capas de material asi obtenidas |
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| EP3060711B1 (en) | 2020-11-25 |
| KR102286879B1 (ko) | 2021-08-10 |
| BR112016008314A2 (zh) | 2017-08-01 |
| WO2015061417A3 (en) | 2016-03-10 |
| EP3060711A2 (en) | 2016-08-31 |
| MX2016004688A (es) | 2016-07-26 |
| KR20160075557A (ko) | 2016-06-29 |
| MX366102B (es) | 2019-06-27 |
| US20150114546A1 (en) | 2015-04-30 |
| BR112016008314B1 (pt) | 2022-03-03 |
| WO2015061417A2 (en) | 2015-04-30 |
| AR098190A1 (es) | 2016-05-18 |
| CN105636782A (zh) | 2016-06-01 |
| TWI652176B (zh) | 2019-03-01 |
| CN105636782B (zh) | 2018-05-11 |
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