TW202033372A - 含纖維之結構、其製造方法及其應用 - Google Patents

含纖維之結構、其製造方法及其應用 Download PDF

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TW202033372A
TW202033372A TW108107865A TW108107865A TW202033372A TW 202033372 A TW202033372 A TW 202033372A TW 108107865 A TW108107865 A TW 108107865A TW 108107865 A TW108107865 A TW 108107865A TW 202033372 A TW202033372 A TW 202033372A
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Taiwan
Prior art keywords
welded
fiber
elastomer
base
woven fabric
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TW108107865A
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English (en)
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TWI693154B (zh
Inventor
林至逸
馮崇智
楊高隆
朱格甫
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三芳化學工業股份有限公司
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Priority to TW108107865A priority Critical patent/TWI693154B/zh
Priority to CN201910312973.1A priority patent/CN111663339A/zh
Priority to US16/812,034 priority patent/US20200283938A1/en
Priority to EP20161585.3A priority patent/EP3705614B1/en
Application granted granted Critical
Publication of TWI693154B publication Critical patent/TWI693154B/zh
Publication of TW202033372A publication Critical patent/TW202033372A/zh
Priority to US18/065,532 priority patent/US20230116811A1/en

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Abstract

本發明係關於一種含纖維之結構，其包含交織且熔接的織布基材，及熔接彈性體層，且該織布基材與該熔接之彈性體之至少一部份彼此熔接。本發明亦提供一種製造前述含纖維之結構之方法及包含前述含纖維之結構之鞋型結構。

Description

含纖維之結構、其製造方法及其應用
本發明係關於一種含纖維之結構，具體而言，係關於一種可應用於製鞋的含纖維之結構、其製造方法及其應用。
人工皮革於紡織產業中至為重要，人工皮革大量使用於例如家具及製鞋之領域上，特別是鞋面材(Upper leather)。 舉例言之，目前鞋面材通常包含內裡布及人工皮革或網布當表層，表面再使用熱熔膠貼合聚胺酯賦予多彩的表面變化，即可製得成品鞋。但此製程繁複，而且當表層使用人工皮革時，有良好的防水性，但透氣性不佳；當表層使用網布時，有良好的透氣性，但無法防水。 為了改善此一繁複的製程，業界將例如熱塑性聚胺脂之熱塑性樹脂經由熔噴製程施予鞋楦模具上，可直接製成鞋型套，亦可進一步組裝成鞋成品。此熔噴熱塑性樹脂之製程具有產速快、無廢料產生，及材料和製程環保等優點。然而另一方面，因此製造方法係使用熔噴方式形成熱塑性樹脂纖維網，其係為堆疊之網狀結構，且因熱塑性樹脂具有彈性，造成物性及尺寸安定性不佳，如抗張強度低、伸長率高、易產生層間剝離，無法實際直接應用於鞋之製造。 為克服此問題，中華民國專利公開第200742671號揭示一纖維結構製品，其包括基布層以及第一緻密層，第一緻密層設置於基布層之一側表面，其中第一緻密層是由部分的基布層轉變而成的，且第一緻密層的平均密度大於基布層的平均密度。基布層與第一緻密層的纖維的結構包括核心以及外鞘，其中外鞘包覆核心，且核心與外鞘為不同的材質。此公開案利用由基布層轉變之緻密層，欲提高人工皮革之結構強度，然而此緻密層之設計改良有限，由熔噴或紡黏製得之基布仍為不織布，纖維與纖維間，並沒有傳統針軋不織布製程中，使纖維產生糾落以提高強度，而僅為堆疊之纖維網狀結構，仍舊無法解決網狀非織物的物性、尺寸安定性不佳之問題。 因此，本領域中亟需開發一新穎之纖維結構，以克服前述人工皮革之物性及尺寸安定性不佳之缺點。
本發明提供一織布基材，藉由該織布基材與彈性體的熔接，使纖維結構之物性及尺寸安定性大幅提升，改善先前技術之缺點，非常適合應用於鞋面材之製造。 本發明提供一種含纖維之結構，其包含： 織布基材，其包含交織之基材纖維，且該基材纖維於至少一交織處熔接；及 熔接彈性體層，其包含熔接之彈性體，且該基材纖維與該熔接之彈性體之至少一部份彼此熔接。 本發明亦提供一種製造根據前述含纖維之結構之方法，其包含： (a)提供一織布，該織布包含交織之基材纖維； (b)加熱該織布，使該基材纖維於至少一交織處上熔接，形成一織布基材；及 (c)於該織布基材上熔噴彈性體，形成熔接之彈性體，並使該基材纖維與該熔接之彈性體之至少一部份彼此熔接。 本發明再提供一種鞋型結構，其包含前述含纖維之結構。
參看圖1及圖2，本發明提供一種含纖維之結構1、2，其包含： 織布基材11、21，其包含交織之基材纖維，且該基材纖維於至少一交織處熔接；及 熔接彈性體層12、22，其包含熔接之彈性體，且該基材纖維與該熔接之彈性體之至少一部份彼此熔接。 本文中所使用之「織布基材」乙詞係指經由纖維交織形成並經熔接之基材，本文中所使用之「交織」或「織」包含但不限於以梭織、針織或編織方式進行纖維間的織造。舉例言之，利用纖維形成之經紗與緯紗互相交叉通過方式抱合；利用纖維形成之多根紗線環環相扣，將線圈（Loop）不斷套疊而成。較佳地，該交織係為編織，或利用纖維形成之多根紗線環環相扣，將線圈不斷套疊。可使用各式織造機器形成織布基材，例如使用襪管織造機、梭織機、圓編機或橫式編織機，織造而得之該織布可為片狀、捲狀或管狀。藉由織布之提供，根據本發明之含纖維之結構可明顯提升物性及尺寸安定性。 根據本發明交織形成該織布基材之纖維係為基材纖維。較佳地，複數個基材纖維可聚集形成紗線或長纖維，俾利於交織織造。較佳地，該基材纖維由選自由以下各物組成之群的至少一種材料製成：聚醯胺、聚對苯二甲醯對苯二胺、聚烯烴、聚甲基丙烯酸甲酯(PMMA)、聚對苯二甲酸乙二酯(PET)、聚對苯二甲酸丙二酯(PTT)、聚對苯二甲酸丁二酯(PBT)、聚丙烯腈(PAN)及其混合物。更佳地，該基材纖維之至少一部份係為熱塑性彈性體，尤佳地，該基材纖維之至少一部份係為熱塑性聚胺酯（thermoplastic polyurethane，TPU）或熱塑性聚酯彈性體（thermoplastic polyester elastomer，TPEE）或熱塑性聚烯烴（thermoplastic olefin，TPO）。 根據本發明之基材纖維係於織布基材之至少一交織處上熔接。本文中所使用之「熔接」乙詞係指加熱一聚合物至高於熔點溫度，使其軟化，並與另已加熱至高於熔點溫度之另一聚合物融合，並於溫度下降至兩聚合物之熔點溫度下，產生之融合連接。雖不願為理論所限制，但咸信因織布基材上基材纖維於至少一交織處上熔接，使整體之織布基材之物性及尺寸安定性大幅提高，例如抗張強度、撕裂強度及剝離強度，且本發明所屬技術領域中具通常知識者可藉由控制熔接之強度或密度，而製得物性及尺寸安定性合宜且仍保有織物柔軟韌性及手感之含纖維之結構，可控制之熔接條件包含但不限於熔接方式、溫度或時間。較佳地，織布基材上之基材纖維於至少一交織處熔接，且至少一交織處不熔接；或織布基材上之基材纖維於所有交織處皆熔接。 本文中使用之「基材纖維」乙詞指單絲纖維或複合纖維，較佳係指複合纖維。根據本發明之複合纖維係指使用不同材質之纖維材料複合形成者，依據不同之複合形式，可為蕊鞘複合纖維、並列複合纖維或分割複合纖維。於本發明之一較佳具體實施例中，該基材纖維包含一第一組份及一第二組份，其中該第一組份於該至少一交織處上熔接，該第二組份不熔接，該第一組份較佳係暴露於該基材纖維表面，並為熱塑性彈性體，俾利進行熔接，該第二組份則可視物性需要選擇合宜之材料，以與該第一組份配合提供所欲特性之基材纖維。舉例言之，該第二組份由選自由以下各物組成之群的至少一種材料製成：聚醯胺、聚對苯二甲醯對苯二胺、聚烯烴、聚甲基丙烯酸甲酯(PMMA)、聚對苯二甲酸乙二酯(PET)、聚對苯二甲酸丙二酯(PTT)、聚對苯二甲酸丁二酯(PBT)、聚丙烯腈(PAN)及其混合物；較佳係為聚對苯二甲酸乙二酯、聚對苯二甲酸丙二酯、聚對苯二甲酸丁二酯或尼龍6。於本發明之具體例中，該第一組份與第二組份之重量比例係自10：90至90：10，較佳為自30：70至70：30。 於本發明之一較佳具體實施例中，該基材纖維另包含一彈性纖維，可便於如下述製造方法之過程中進行包覆模具步驟，亦可使根據本發明之含纖維之結構具有所欲之彈性。 根據本發明之熔接彈性體層，其包含熔接之彈性體，且該基材纖維與該熔接之彈性體之至少一部份彼此熔接。根據本發明之該熔接彈性體層之彈性體係選自由以下各物組成之群：聚胺脂、聚醯胺、聚烯烴、聚甲基丙烯酸甲酯(PMMA)、聚對苯二甲酸乙二酯(PET)、聚對苯二甲酸丙二酯(PTT)、聚對苯二甲酸丁二酯(PBT)、聚丙烯腈(PAN)及其混合物。更佳地，該熔接彈性體層之彈性體係為熱塑性彈性體，尤佳地，該熔接彈性體層之彈性體係為熱塑性聚胺酯或熱塑性聚酯彈性體或熱塑性聚烯烴。該彈性體係彼此熔接形成熔接之彈性體，並與該基材纖維熔接，該熔接之彈性體與基材纖維可於基材纖維已熔接之交織處進一步熔接，亦可於基材纖維之非交織處熔接。 於本發明之一較佳具體實施例中，該基材纖維包含一第一組份及一第二組份，其中該第一組份與該熔接之彈性體之至少一部份彼此熔接，該第二組份不熔接。該第一組份較佳係暴露於該基材纖維表面，並為熱塑性彈性體，俾利進行熔接。 於本發明之一較佳具體實施例中，該熔接彈性體層包含一熔接網狀層，其包含交叉非交織之網狀纖維，且網狀纖維於至少一交叉非交織處上熔接，且該基材纖維與該網狀纖維之至少一部份彼此熔接。於本實施例中，該彈性體係形成網狀纖維，且該網狀纖維以非交織而僅交叉方式，熔接提供一網狀結構。較佳地，該網狀纖維層之網狀纖維於至少一交叉非交織處熔接，且至少一交叉非交織處不熔接；或該網狀纖維層之網狀纖維於所有交叉非交織處皆熔接。另一方面，該彈性體係彼此熔接形成熔接之彈性體，並與該基材纖維熔接，該熔接之彈性體與基材纖維可於熔接之彈性體已熔接之交叉非交織處進一步熔接，亦可於熔接之彈性體之非交叉非交織處熔接。 於本發明之一具體實施例中，該熔接彈性體層之厚度為約0.2mm至約5.0mm間；較佳為約0.3mm至約4.0mm間；更佳為約0.35mm至約3.0mm間。 於本發明之一較佳具體實施例中，該含纖維之結構另包含一黏著劑，其位於該織布基材與該熔接彈性體層間，該黏著劑可輔助該織布基材與該熔接彈性體層間之連結，且不妨礙該基材纖維與該熔接之彈性體之至少一部份彼此熔接。於本發明之一較佳具體實施例中，該黏著劑係為熱塑性彈性體，且該黏著劑與該織布基材及熔接彈性體層共同熔接，其具體材料包含但不限於熱塑性聚胺酯、熱塑性聚酯彈性體或熱塑性聚烯烴。 本發明亦提供一種製造根據前述含纖維之結構之方法，其包含： (a)提供一織布，該織布包含交織之基材纖維； (b)加熱該織布，使該基材纖維於至少一交織處上熔接，形成一織布基材；及 (c)於該織布基材上熔噴彈性體，形成熔接之彈性體，並使該基材纖維與該熔接之彈性體之至少一部份彼此熔接。 根據本發明之方法，其中步驟(a)係提供一織布，該提供之方式包含但不限於以梭織、針織或編織方式進行基材纖維間的交織織造。舉例言之，利用基材纖維形成之經紗與緯紗互相交叉通過方式抱合；利用基材纖維形成之多根紗線環環相扣，將線圈不斷套疊而成。可使用各式織造機器提供織布，例如使用襪管織造機、梭織機、圓編機或橫式編織機。 根據本發明之方法，其中步驟(b)包含加熱該織布，使該基材纖維於至少一交織處上熔接。於本發明之一具體實施例中，係加熱基材纖維之至少一部份至高於熔點溫度，使其軟化，並與另已加熱至高於熔點溫度之另一基材纖維部分融合，並於溫度下降至交織之基材纖維之熔點溫度下，產生之融合連接。本發明所屬技術領域中具通常知識者可藉由控制熔接之強度或密度，可控制之熔接條件包含但不限於熔接方式、溫度或時間。 於本發明之一較佳具體實施例中，步驟(b)進一步包含提供一內模具，並將該織布包覆該模具，並加熱該織布，使該基材纖維於至少一交織處上熔接。由於該基材纖維係於該內模具上熔接，故該織布基材大體上可具有固定且相應該內模具之外型，但仍具有纖維之柔軟度。於本發明之一較佳具體實施例中，該內模具係為一鞋楦。 根據本發明之方法，其中步驟(c)於該織布基材上熔噴彈性體，形成熔接之彈性體，並使該基材纖維與該熔接之彈性體之至少一部份彼此熔接。根據本發明之熔噴係指將已加熱熔融之彈性體利用空氣壓力噴出，可依所需之厚度、位置調整噴出之量及型態，且彈性體於噴出後冷卻，而可形成熔接之彈性體。較佳地，可於熔噴後進一步加熱該彈性體，以控制熔接之程度。根據本發明之加熱方式包含但不限於熱烘或紅外線加熱。 於本發明方法之一較佳具體實施例中，於步驟(c)前另包含施加一黏著劑於該織布上。該黏著劑之施加方式包含但不限於以熔噴方式施加於織布基材上。 於本發明方法之一較佳具體實施例中，步驟(c)進一步包含提供一外模具，使該外模具包覆該彈性體，並加熱該彈性體，形成熔接之彈性體，並使該基材纖維與該熔接之彈性體之至少一部份彼此熔接。較佳地，該外模具與該內模具彼此互為對應，可一起應用而使該含纖維之結構具有所欲之外型，且該外模具可進一步使該彈性體進一步熔接，具有更佳之剝離強度、抗張強度及撕裂強度。 較佳地，該方法另包含移除該內模具及/或外模具之步驟。 本發明再提供一種鞋型結構，其包含前述含纖維之結構，例如利用鞋楦作為內模具，以製得此鞋型結構，可一體成型，減少人工縫製各部位之時間及工序，增加生產效率及生產速度，再者，此含纖維之結構可使所製得之鞋具有透氣之特性，可增進使用者之足部健康。 根據本發明之含纖維之結構可明顯提昇物性，如抗張強度、撕裂強度、伸長率及層間剝離強度，另外也有良好的尺寸安定度，但仍保持相當之柔軟度、彈性、手感及韌性，且其材料及製造方法，無需使用溶劑，亦無廢料產生，具有環保之功效，再者，藉由熔噴之一體成形製造，增加生產效率及生產速度。 茲以下列實例予以詳細說明本發明，唯並不意謂本發明僅侷限於此等實例所揭示之內容。實施例一 1.  原料： 基材纖維第一組份原料：「Lubrizol，BF-85」熱塑性聚胺酯彈性體，蕭式硬度shore A為85A，Tm為125℃。以下以(A)代稱。 基材纖維第二組份原料：「新光，C03800」低熔點聚酯，Tm為170℃。以下以(B)代稱。 彈性體：「BASF，A8000」熱塑性聚胺酯彈性體，蕭式硬度shore A 為80A，Tm為140℃。以下以(C)代稱。 2.  乾燥： 分別將原料(A)、(B)及(C)進行乾燥，進而控制各材料之含水率至300ppm以下，乾燥溫度設定為70℃，時間6小時或以上。 3.  押出： 將原料(A)投入一#a押出機，及將原料(B)投入另一#b押出機。 押出機溫度設定： #a押出機，從原料入口到出口，分三段加熱區，溫度分別設定180℃、210℃、200℃。 #b押出機，從原料入口到出口，分三段加熱區，溫度分別設定190℃、230℃、240℃。 紡絲箱體溫度設定： #a區，設定為220℃。 #b區，設定為235℃。 產量設定： #a，計量泵(Gear Pump)轉速，設定為9.25 rpm。 #b，計量泵(Gear Pump)轉速，設定為9 rpm。 原料一起進入一紡絲組件(Spinneret)，噴出成絲，並經過一冷卻風區，將纖維進行冷卻，最後經卷繞機，以2400m/min速度進行卷繞後，可製得丹尼數為300den，伸長率為65%，斷裂強度為1.6g/den的TPU/CoPET複合長纖。 4.  交織織造： 使用單口圓編織造機，將該複合長纖，織造成可套入鞋楦的圓編織布，並套入鞋楦中。 5.  熔接塑形： 設定烘箱溫度為150℃，將已套上織布的鞋楦放入烘箱中，並加熱30 分鐘後取出。 6.  熔噴： 準備一押出機，分四段加熱區，溫度設定，從入料口到出料口，分別為180℃、200℃、220℃、225℃，並投入原料(C)，熔噴模頭溫度為250℃，空氣壓力為4.5 kg/cm2 ，將原料(C)熔噴到已熔接之織布基材上。 7.  成品： 將噴塗0.3mm厚度之熔噴彈性體纖維層於雙組份織布基材的半成品，再使用公母模進行熱壓，熱壓溫度為125℃，壓力2kg/cm2 ，熱壓時間30sec，即可製得新穎之鞋面結構。實施例二 1.  原料： 基材纖維第一組份原料：「Lubrizol，BF-92」熱塑性聚胺酯彈性體，蕭式硬度shore A為92A，Tm為130℃。以下以(A)代稱。 基材纖維第二組份原料：「新光，T-2164A」聚酯，Tm為250℃。以下以(B)代稱。 彈性體：「BASF，A8230」熱塑性聚胺酯彈性體，蕭式硬度shore A 為82A，Tm為160℃。以下以(C)代稱。 2.  乾燥： 分別將原料(A)、(B)及(C)進行乾燥，進而控制各材料之含水率至300ppm以下，乾燥溫度設定為70℃，時間6小時或以上。 3.  押出： 將原料(A)投入一#a押出機，及將原料(B)投入另一#b押出機。 押出機溫度設定： #a押出機，從原料入口到出口，分三段加熱區，溫度分別設定180℃、210℃、200℃。 #b押出機，從原料入口到出口，分三段加熱區，溫度分別設定230℃、280℃、285℃。 紡絲箱體溫度設定： #a區，設定為235℃。 #b區，設定為265℃。 產量設定： #a，計量泵(Gear Pump)轉速，設定為10.10 rpm。 #b，計量泵(Gear Pump)轉速，設定為12 rpm。 原料一起進入一紡絲組件(Spinneret)，噴出成絲，並經過一冷卻風區，將纖維進行冷卻，最後經卷繞機，以2800m/min速度進行卷繞後，可製得丹尼數為150den，伸長率為45%，斷裂強度為3.2g/den的TPU/PET複合長纖。 4.  交織織造： 使用單口圓編織造機，將該複合長纖，織造成可套入鞋楦的圓編織 布，並套入鞋楦中。 5.  熔接塑形： 設定烘箱溫度為150℃，將已套上織布的鞋楦放入烘箱中，並加熱30 分鐘後取出。 6.  熔噴： 準備一押出機，分四段加熱區，溫度設定，從入料口到出料口，分別為180℃、200℃、220℃、225℃，並投入原料(C)，熔噴模頭溫度為255℃，空氣壓力為4.5 kg/cm2 ，將原料(C)熔噴到已熔接之織布基材上。 7.  成品： 將噴塗0.3mm厚度之熔噴彈性體纖維層於雙組份織布基材的半成品，再使用公母模進行熱壓，熱壓溫度為130℃，壓力2.5kg/cm2 ，熱壓時間36sec，即可製得新穎之鞋面結構。 上述實施例僅為說明本發明之原理及其功效，而非限制本發明。本發明所屬技術領域中具通常知識者對上述實施例所做之修改及變化仍不違背本發明之精神。本發明之權利範圍應如後述之申請專利範圍所列。
1:本發明含纖維之結構 2:本發明含纖維之結構 11:織布基材 12:熔接彈性體層 21:織布基材 22:熔接彈性體層
圖1顯示根據本發明一具體實施例之含纖維之結構之剖視示意圖；及 圖2顯示根據本發明一具體實施例之含纖維之結構之外觀示意圖。
1:本發明含纖維之結構
11:織布基材
12:熔接彈性體層

Claims (10)

  1. 一種含纖維之結構，其包含： 織布基材，其包含交織之基材纖維，且該基材纖維於至少一交織處熔接；及 熔接彈性體層，其包含熔接之彈性體，且該基材纖維與該熔接之彈性體之至少一部份彼此熔接。
  2. 根據請求項1之結構，其中該基材纖維係為一複合纖維，其中該複合纖維係為蕊鞘複合纖維、並列複合纖維或分割複合纖維。
  3. 根據請求項1之結構，其中該基材纖維包含一第一組份及一第二組份，其中該第一組份於該至少一交織處上熔接，該第二組份不熔接。
  4. 根據請求項1之結構，其中該基材纖維包含一彈性纖維。
  5. 根據請求項1之結構，其中該熔接彈性體層包含一熔接網狀層，其包含交叉非織之網狀纖維，且網狀纖維於至少一交叉非織處上熔接，且該基材纖維與該網狀纖維之至少一部份彼此熔接。
  6. 根據請求項1之結構，其中該基材纖維包含一第一組份及一第二組份，其中該第一組份與該熔接之彈性體之至少一部份彼此熔接，該第二組份不熔接。
  7. 一種製造根據請求項1至6任何一項之結構之方法，其包含： (a)提供一織布，該織布包含交織之基材纖維； (b)加熱該織布，使該基材纖維於至少一交織處上熔接，形成一織布基材；及 (c)於該織布基材上熔噴彈性體，形成熔接之彈性體，並使該基材纖維與該熔接之彈性體之至少一部份彼此熔接。
  8. 根據請求項7之方法，其中步驟(b)進一步包含提供一內模具，並將該織布包覆該模具，並加熱該織布，使該基材纖維於至少一交織處上熔接。
  9. 根據請求項7之方法，其中步驟(c)進一步包含提供一外模具，使該外模具包覆該彈性體，並加熱該彈性體，形成熔接之彈性體，並使該基材纖維與該熔接之彈性體之至少一部份彼此熔接。
  10. 一種鞋型結構，其包含請求項1至6任何一項之結構。
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