TWI616570B - 不織布及強化積層體 - Google Patents

不織布及強化積層體 Download PDF

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TWI616570B
TWI616570B TW103135445A TW103135445A TWI616570B TW I616570 B TWI616570 B TW I616570B TW 103135445 A TW103135445 A TW 103135445A TW 103135445 A TW103135445 A TW 103135445A TW I616570 B TWI616570 B TW I616570B
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fabric
thermoplastic resin
layer
woven fabric
alignment
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TW201522737A (zh
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鈴木得仁
小野寺貴史
山田潤
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吉坤日礦日石能源股份有限公司
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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J123/00—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers
    • C09J123/02—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers not modified by chemical after-treatment
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    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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Abstract

本發明提供一種不織布，其可提高柔軟性或延性、觸感，單獨使用可謀求用途之擴大，於用作補強材料之情形時，可提高對被補強體之表面形狀之追隨性。
不織布1係將單軸配向體2、3以配向軸2a、3a交叉之方式經由各個第1或第2接著層進行經緯積層而形成，該單軸配向體2、3含有熱塑性樹脂層、及積層於該熱塑性樹脂層之兩面且熔點低於該熱塑性樹脂的第1、第2接著層。該不織布之單位面積重量為5~13g/m2，單軸配向體中之第1接著層、熱塑性樹脂層及第2接著層之層構成比為20/60/20~30/40/30，利用懸臂法(cantilever method)獲得之抗彎曲性之平均值為50mm以下。

Description

不織布及強化積層體
本發明係關於一種將熱塑性樹脂製之單軸配向體以配向軸相互交叉之方式進行經緯積層而成之不織布、及將該不織布積層於被強化體而用作補強材料之強化積層體。
於專利文獻1中，記載有一種網狀不織布之製造方法，該網狀不織布係將被配向於縱向(長度方向)之熱塑性樹脂製之單軸配向體(縱織物)、與被配向於橫向(寬度方向)之熱塑性樹脂製的單軸配向體(橫織物)積層而成。該網狀不織布係於使分開形成之縱織物與橫織物相互重合之狀態下進行按壓並加熱，藉此使縱織物與橫織物一體化而製造。
[專利文獻1]日本公報：專利第2983584號公報
另外，此種不織布之特點為薄、輕量、且高強度。將不織布積層於被強化體而用作補強材料之情形亦多，並要求強度或耐久性。因此，抗彎曲性相對變高，於單獨用作包裝材料之情形時，現狀為存在不適用於 容易受到損傷且會因傷痕而導致商品性降低者例如花、蔬菜、水果等，而使用途受到限制。又，不織布於透氣性、耐水性、耐化學品性等方面亦具有優異之特性，但對於如在醫療用或衛生用品等中要求柔軟性或延性、觸感之用途而言，仍有改良之餘地。
並且，於將不織布用作補強材料之情形時，由於如上所述般抗彎曲性相對較高而有韌性，未必適用於立體且表面有凹凸之構件的補強。又，在用於補強供人使用之用品(例如化妝用品或嬰幼兒用品之供人使用擦拭物(wiper))之情形時，於柔軟性或延性、觸感之方面期待進一步之改良，在用於補強供物使用之用品(例如清潔或擦拭用之擦拭物)之情形時，於附著物之捕捉性或擦拭性之方面期待進一步之改良。
本發明係鑒於如上所述之情況而完成者，其目的在於提供一種不織布及強化積層體，其等可提高柔軟性或延性、觸感，於單獨使用之情形時，可謀求用途之擴大，於用作補強材料之情形時，除上述以外，可提高對被補強體之表面形狀之追隨性，從而謀求可應用之被強化體之擴大。
根據本發明之一態樣，提供一種不織布，係將單軸配向體以配向軸交叉之方式經由各個第1或第2接著層進行經緯積層而成的網狀不織布，上述單軸配向體含有熱塑性樹脂層、及積層於上述熱塑性樹脂層之兩面且熔點低於上述熱塑性樹脂的第1、第2接著層，上述不織布之單位面積重量為5~13g/m2，上述單軸配向體中之上述第1接著層、上述熱塑性樹脂層及上述第2接著層的層構成比為20/60/20~30/40/30，使上述不織布之長度方向及寬度方向利用懸臂法(cantilever method)獲得的抗彎曲性之平均值為50mm以下。
又，根據本發明之另一態樣，提供一種將上述不織布積層於被強化體而用作補強材料之強化積層體。
根據本發明，不織布之單位面積重量為5~13g/m2，單軸配向體之層構成比為20/60/20~30/40/30，使不織布之長度方向及寬度方向之利用懸臂法獲得的抗彎曲性之平均值為50mm以下，藉此於單獨使用之情形時，可提高柔軟性或延性、觸感。又，於用作補強材料之情形時，可提高對被強化體之表面形狀之追隨性。
1‧‧‧不織布
2‧‧‧分裂織物
2a‧‧‧配向軸
3‧‧‧切條織物
3a‧‧‧配向軸
4‧‧‧幹纖維
5‧‧‧分支纖維
6、6'‧‧‧熱塑性樹脂層
7-1、7-1'‧‧‧接著層
7-2、7-2'‧‧‧接著層
圖1係表示本發明之第1實施形態之不織布之俯視圖。
圖2A係表示構成圖1所示之不織布的單軸配向體之構成例之立體圖。
圖2B係將圖2A之一部分放大而表示之立體圖。
圖3A係表示構成圖1所示之不織布的單軸配向體之構成例之立體圖。
圖3B係將圖3A之一部分放大而表示之立體圖。
圖4係表示圖2A及圖2B所示之單軸配向體的製造方法之立體圖。
圖5係表示本發明之第1實施形態之不織布的第1製造方法之立體圖。
圖6係用以對改變不織布之單位面積重量、單軸配向體之層構成比、及利用懸臂法獲得之抗彎曲性的樣品之研究進行說明之圖。
圖7係表示不織布之單位面積重量、與利用懸臂法獲得之抗彎曲性的關係之特性圖。
圖8係表示本發明之第1實施形態的不織布之第2製造方法之立體圖。
以下，參照圖式對本發明之實施形態進行說明。
[第1實施形態]
圖1表示本發明之第1實施形態之不織布。不織布1係以分裂織物(split web)2之配向軸2a與切條織物(slit web)3之配向軸3a相互交叉之方式進行經緯積層而形成。而且，鄰接之分裂織物2與切條織物3之接觸部位彼此以面接著而接合。
圖2A及圖3A分別表示構成圖1所示之不織布1的分裂織物2與切條織物3。圖2A所示之分裂織物2係使熱塑性樹脂製之膜於縱向(分裂織物2之配向軸2a的軸向)單軸延伸並於縱向割纖且擴寬而形成。分裂織物2係使用熱塑性樹脂、例如高密度聚乙烯、及熔點低於該熱塑性樹脂之熱塑性樹脂、例如第1、第2低密度聚乙烯。
詳細而言，使利用多層T模法等成形法製作且於高密度聚乙烯之兩面積層第1、第2低密度聚乙烯而成之多層膜(單軸配向體)於縱向(長度方向)至少延伸至3倍。之後，於該方向對十字針跡使用分裂器進行割纖(分裂處理)而成為網狀之膜，進而擴寬成特定寬度而形成。藉由擴寬而形成幹纖維4與分支纖維5，從而成為如圖示般之網狀體。該分裂織物2遍及寬度方向整體於縱向具有相對較高之強度。
圖2B係以圖2A之單點鏈線包圍之區域B之放大立體圖。分裂織物2成為於熱塑性樹脂層6之兩面積層有熔點低於該熱塑性樹脂之熱塑性樹脂層7-1、7-2的三層構造。熱塑性樹脂層7-1、7-2於形成不織布1時，作為與切條織物3一起被經緯積層時的織物相互之接著層(第1、第2 接著層)而發揮功能。
圖3A所示之切條織物3係在熱塑性樹脂製之膜於橫向(切條織物3之配向軸3a的軸向)形成多個切條後，使其於橫向單軸延伸而形成。詳細而言，切條織物3係利用例如熱刀等在上述多層膜之除兩耳部以外的部分於橫向(寬度方向)平行地形成十字針跡等斷續之切條後，使其於橫向延伸而形成。該切條織物3於橫向具有相對較高之強度。
圖3B係以圖3A之單點鏈線包圍之區域B的放大立體圖。切條織物3為於熱塑性樹脂層6'之兩面積層有熔點低於該熱塑性樹脂之熱塑性樹脂之層7-1'、7-2'的三層構造。該等熱塑性樹脂層7-1'、7-2'係於形成不織布1時，作為與分裂織物2一起被經緯積層時的織物相互之接著層(第1、第2接著層)而發揮功能。
<製造方法>
繼而，藉由圖4及圖5，對圖1、圖2A、圖2B、圖3A及圖3B所示之不織布1之製造方法進行說明。圖4表示分裂織物2之製造步驟的概況。又，圖5表示於分裂織物2積層切條織物3而製造不織布1之步驟的概況。
如圖4所示，分裂織物2主要經過多層膜之製膜步驟、多層膜之配向步驟、將配向多層膜與配向軸平行地分裂之分裂步驟、及將已分裂之膜捲取之捲取步驟等而製造。
多層膜之製膜步驟於本例中，係於擠出機10將熔融樹脂即作為第1、第2接著層發揮功能之熔點低的熱塑性樹脂、例如低密度聚乙烯、及熱塑性樹脂層、例如高密度聚乙烯分別送入平模中之各自分開之歧管。將該等樹脂於即將進入模唇(die lip)之前進行合流、接合而形成多層膜11。 各熔融樹脂之流量調整或製品厚度之調整係藉由模內之扼流桿(Choke bar)或模唇之調整而進行。
於配向步驟中，使多層膜11經由經鏡面處理之冷卻輥12a、12b之間，以相對於初始尺寸為特定之配向倍率進行輥配向。
於分裂(割纖)步驟中，使上述經配向之多層膜11滑動接觸高速旋轉之分裂器(旋轉刀)13，而對多層膜11進行分裂處理(割纖化)。
割纖而形成之分裂織物2於擴寬成特定寬度後，經過熱處理部14中之熱處理，於捲取步驟中被捲取成特定之長度，而成為分裂織物2之捲取體15。
如圖5所示，於自如上所述般形成之捲取體15捲出之縱織物(分裂織物2)，積層橫織物(切條織物3)。橫織物之製造步驟包括多層膜之製膜步驟、相對於多層膜之長度方向成直角地進行切條處理之切條步驟、及多層切條膜之配向步驟。而且，使縱織物積層於橫織物後進行熱壓接(壓接步驟)。
切條織物3用之多層膜之製膜步驟係與多層膜11同樣地於擠出機20，將熔融樹脂即作為第1、第2接著層發揮功能之熔點低的熱塑性樹脂、例如低密度聚乙烯、及熱塑性樹脂層、例如高密度聚乙烯分別送入平模中之各自分開之歧管。將該等樹脂於即將進入模唇之前進行合流、接合而形成多層之膜21。各熔融樹脂之流量調整或製品厚度之調整係藉由模內之扼流桿或模唇之調整而進行。
於切條步驟中，將上述製膜而成之多層膜21捏縮使其扁平化，繼而藉由壓延進行微配向，於橫切條步驟22中，相對於移行方向成直 角地於十字針跡形成橫切條。
於配向步驟中，於橫配向步驟23中對進行過上述切條處理之膜21實施橫配向。將如此般獲得之切條織物3(橫織物)搬送至熱壓接步驟24。
另一方面，自原片捲出輥25捲出縱織物(分裂織物2)，使其以特定之供給速度移行而送至擴寬步驟26，藉由擴寬機(未圖示)擴寬至數倍，並視需要進行熱處理。之後，將縱織物送至熱壓接步驟24，於此處使縱織物與橫織物以各自之配向軸交叉之方式積層而進行熱壓接。具體而言，將縱織物2及橫織物3依序引導至外周面為鏡面之熱氣缸24a與鏡面輥24b、24c之間，並對該等施加夾持壓，藉此使縱織物2與橫織物3相互熱壓接而一體化。藉此，將鄰接之縱織物2與橫織物3之接觸部位彼此整面地進行面接著。如此般一體化之縱織物及橫織物被搬送至捲取步驟而被捲取，成為不織布1之捲取體27。
本發明人等準備如上述般形成之不織布1中單位面積重量、單軸配向體之層構成比、長度方向及寬度方向之利用懸臂法獲得的抗彎曲性之平均值等不同的樣品，對柔軟性或延性、觸感、對被補強體之表面形狀之追隨性等進行驗證。其結果為獲得如下之見解。
於圖6中，於樣品編號S8，使用吉坤日礦日石能源股份有限公司製之被稱為Warifu(註冊商標)之分裂纖維不織布的製品編號3S(T)作為比較例1，於樣品編號S9，使用該不織布之製品編號S(F)EL作為比較例2，於樣品編號S10，使用該不織布之製品編號HS(T)作為比較例3。
樣品編號S8~S10中任一個之單位面積重量均為相對較重 之18~35g/m2，高密度聚乙烯之比例高(74~78%)，層構成比為13/74/13~11/78/11。因此，強度(拉伸強度)或耐久性高而有韌性。然而，無柔軟性或延性，利用懸臂法獲得之抗彎曲性的平均值變高為63~78mm。因此，不適用於容易受到損傷且會因傷痕導致商品性降低者、或如要求柔軟性或延性、觸感之用途。
相對於此，樣品編號S1~S7之單位面積重量為4~13g/m2之輕量，且利用懸臂法獲得之抗彎曲性的平均值為6~55mm。該等樣品編號S1~S7柔軟且柔韌，觸感亦良好。然而，於單位面積重量為4g/m2之樣品編號S1之情形時，長度方向(MD)之拉伸強度為MD=18(N/50mm)，寬度方向(CD)之拉伸強度為CD=15(N/50mm)，均為20N/50mm以下，並未滿足實用強度。
又，於樣品編號S4~S6中，使單位面積重量為固定(10g/m2)，並使層構成比變化，但樣品編號S4、S5於柔軟性或延性、觸感之方面不足。認為其原因係於樣品編號S4、S5中，高密度聚乙烯之比例高，利用懸臂法獲得之抗彎曲性的平均值分別為55mm、52mm而有韌性。
圖7係將上述圖6之單位面積重量、與抗彎曲性之平均值提取並進行繪圖所得之圖。如由圖7可知，於單位面積重量為十幾g/m2左右有反曲點，可推斷柔軟性、延性、觸感等發生變化。
由上述圖7及圖6之測量結果可知，柔軟性、延性、觸感良好，為獲得實用強度(拉伸強度)而較佳之單位面積重量為5~13g/m2之範圍內。又，獲得了較佳結果之層構成比為26/48/26，但認為若考慮其他樣品編號之資料、或市售之各種商品之層構成比等，則就幾%左右之變化 而言無急遽之變化，較佳之層構成比為20/60/20~30/40/30。並且，利用懸臂法獲得之抗彎曲性的平均值為50mm以下。完全滿足該等條件之樣品編號S2、S3、S6、S7獲得可充分達成預期之目的的良好結果。
此外，上述樣品編號S2、S3、S6、S7之厚度薄於80μm，開口率高於50%。確認到若處於此種數值範圍內，則可兼顧延性(抗彎曲性)與強度，並且使厚度較薄，藉此可提高延性。而且，若不織布1之開口率為50%，則於用作包裝體時，藉由可確認內部物品之程度的透明度亦提高透氣性，於用作補強材料時，發揮出作為被強化體之基材的素材感、質感。進而，於上述之製造步驟中，對於使不織布1之拉伸強度為20N/50mm以上，較理想為使多層膜11、21之延伸倍率為3倍以上。
完全滿足上述條件之不織布1可利用於習知品無法使用之用途。具體而言，於單獨使用之情形時，可用作容易受到損傷且會因傷痕而導致商品性降低之花、蔬菜、水果等之包裝材料。又，亦可應用於如在醫療用或衛生用品等中要求柔軟性或延性、觸感之用途，而可謀求用途之擴大。
再者，於不織布1之單位面積重量為5~13g/m2之情形時，拉伸強度稍微降低，但藉由製成袋狀，若為例如花、或蔬菜、水果等，則可確保充分必要之強度，而無破袋之虞。
<變形例1>
圖8係用以對上述之第1實施形態的變形例進行說明之圖，表示其他製造方法。該不織布係將圖2A及圖2B所示之分裂織物2積層2片而成者。於圖8中，自原片捲出輥30捲出如圖4所示般製造之縱織物(分裂織物 2-1)，使其以特定之供給速度移行而送至擴寬步驟31，藉由擴寬機(未圖示)擴寬至數倍，並視需要進行熱處理。
與縱織物同樣地自原片捲出輥32捲出另一分裂織物2-2(橫織物)，使其以特定之供給速度移行而送至擴寬步驟33，藉由擴寬機(未圖示)擴寬至數倍。視需要進行熱處理之後，切斷成與縱織物之寬度相等之長度，對縱織物之移行膜自直角之方向供給，於積層步驟34中，經由各接著層以各織物之配向軸相互正交之方式進行經緯積層。於熱壓接步驟35中，將已進行經緯積層之縱織物及橫織物依序引導至外周面為鏡面之熱氣缸35a與鏡面輥35b、35c之間，並施加夾持壓。藉此，將縱織物與橫織物相互熱壓接而一體化。又，鄰接之縱織物與橫織物之接觸部位彼此整面地面接。如此般一體化之縱織物及橫織物於捲取步驟中被捲取，而成為經緯積層不織布之捲取體36。
即便於如上述般製造之不織布中，亦完全滿足與第1實施形態相同之單位面積重量(5~13g/m2)、層構成比(20/60/20~30/40/30)、利用懸臂法獲得之抗彎曲性的平均值(50mm以下)之條件，藉此獲得同樣之效果。即便於此情形時，亦較佳為厚度薄於80μm，開口率高於50%。
<變形例2>
於上述第1實施形態及變形例1中，對單軸配向體將分裂織物2與切條織物3經緯積層之情形進行了說明，但亦可將平行地排列單軸配向帶者積層2組而形成。於此情形時，以其中一組之單軸配向帶之配向軸與另一組之單軸配向帶之配向軸相互正交之方式進行經緯積層。單軸配向帶使用 使三層之膜於縱向或橫向單軸配向，並進行裁斷而製成多層之延伸帶者，該三層之膜係與分裂織物2及切條織物3同樣地於熱塑性樹脂層之兩面積層熔點低於該熱塑性樹脂之第1、第2接著層(熱塑性樹脂)而成。
如此，即便於將平行地排列單軸配向帶者積層2組之情形時，亦完全滿足與第1實施形態相同之單位面積重量、層構成比、利用懸臂法獲得之抗彎曲性的平均值之條件，藉此獲得同樣之效果。當然亦較佳為厚度薄於80μm，開口率高於50%。
根據如上述之構成，可提高柔軟性或延性、觸感，故可用作對容易受到損傷且會因傷痕而導致商品性降低者、例如花、蔬菜、水果等之包裝材料。又，亦可利用於如於醫療用或衛生用品等中要求柔軟性或延性、觸感之用途。因此，可謀求用途之擴大。
[第2實施形態]
於上述之第1實施形態及第1、第2變形例中，對將不織布單獨使用之情形進行了說明，但本第2實施形態係將上述之不織布用作補強材料而製成強化積層體者。第1實施形態之不織布的柔軟性高，柔韌，且對被強化體之表面形狀之追隨性(凹凸追隨性)良好，故可用於一直以來係為困難之具有立體形狀的被強化體、例如表面有凹凸之胺甲酸乙酯之補強等而積層。即便為平面以外之形狀，亦可追隨，而可應用於各種被強化體之補強。
此外，在用於補強例如化妝或嬰幼兒用品等供人使用之用品之情形時，補強材料柔軟且柔韌，故可提高觸感。並且，在用於補強例如清潔或擦拭用之擦拭物等供物使用之用品之情形時，根據同樣之理由，可提高附著物之捕捉性或擦拭性。進而，由於薄、輕量且開口率亦高，故可 發揮出被強化體之素材感、質感而進行補強。
1‧‧‧不織布
2‧‧‧分裂織物
2a‧‧‧配向軸
3‧‧‧切條織物
3a‧‧‧配向軸

Claims (3)

  1. 一種不織布，係將單軸配向體以配向軸交叉之方式經由各個第1或第2接著層進行經緯積層而成的網狀不織布，該單軸配向體含有熱塑性樹脂層、及積層於該熱塑性樹脂層之兩面且熔點低於該熱塑性樹脂的第1、第2接著層，其特徵在於：單位面積重量為5~13g/m2，該單軸配向體中之該第1接著層、該熱塑性樹脂層及該第2接著層的層構成比為20/60/20~30/40/30，使該不織布之長度方向及寬度方向利用懸臂法(cantilever method)獲得的抗彎曲性之平均值為50mm以下。
  2. 如申請專利範圍第1項之不織布，其中，該熱塑性樹脂層含有高密度聚乙烯，該第1、第2接著層分別含有低密度聚乙烯。
  3. 一種強化積層體，其將申請專利範圍第1或2項之不織布積層於被強化體而用作補強材料。
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