TWI758142B - Polypropylene composite film, hygiene item including the same and manufacture method thereof - Google Patents

Abstract

A polypropylene composite film is provided in some embodiments of the present disclosure, including a polypropylene fiber layer and a polypropylene waterproofing layer adhering to the polypropylene fiber layer, in which a water resistance of the polypropylene waterproofing layer is higher than 400mmH ₂O. A hygiene item including a polypropylene composite film and a method of manufacturing a polypropylene composite film are further provided in some embodiments of the present disclosure.

Description

Polypropylene composite film, hygienic product containing the same, and manufacturing method thereof

Some embodiments of the present disclosure relate to a polypropylene composite film, a sanitary article including the same, and a method of making the polypropylene composite film.

Hygiene articles for containing and retaining bodily exudates such as urine or feces are well known in the art. Examples of these sanitary products include diapers, sanitary napkins, pantiliners, breast pads, cleaning pads, and the like. For example, a diaper includes a wearer's body fluid permeable topsheet, a body fluid impermeable backsheet, and an absorbent core sandwiched between the topsheet and the backsheet.

It is estimated that around 6,000 metric tons of diapers are manufactured globally each day, and Taiwan also produces 2 million discarded diapers daily. The above-mentioned used sanitary products are usually transported to incinerators or landfills with garbage trucks.

Because the sanitary products are made of plastic that is not easily decomposed, and the weight increases greatly after use, it increases the difficulty of cleaning and transportation. For example, diapers contain a variety of plastic components, so that the recycled plastic pellets, including polyethylene and polypropylene and other materials, are not conducive to downstream applications, and it is difficult to achieve the purpose of circular economy. Taking a baby diaper as an example, the material of the skin contacting layer is polypropylene non-woven fabric, the outer layer is a polyethylene waterproof layer as a waterproof layer, and the waist part is designed with a sticky polypropylene material hook and loop. It contains at least two or more different plastics. When recycling, it is not only difficult to separate, but also time-consuming.

Therefore, how to provide a polypropylene composite membrane and a manufacturing method that are easy to produce, and that the single material is conducive to recycling and separation is a problem to be solved.

Some embodiments of the present disclosure provide a polypropylene composite film, comprising a polypropylene fiber layer and a polypropylene waterproof layer, wherein the polypropylene waterproof layer is adhered on the polypropylene fiber layer, wherein the water pressure resistance of the polypropylene waterproof layer is greater than 400 mm of water column.

In some embodiments, the polypropylene fiber layer is less resistant to water pressure than the polypropylene waterproof layer.

In some embodiments, an adhesive layer is further included, which is adhered between the polypropylene fiber layer and the polypropylene waterproof layer.

In some embodiments, an inorganic salt water-repellent agent is further included to adhere to the polypropylene waterproof layer.

In some embodiments, the inorganic salt water repellent comprises an aqueous silane resin solution, an aqueous organosiloxane solution, or a combination of the foregoing.

In some embodiments, the inorganic salt water-repellent agent includes a fluorine-free water-repellent agent.

Some embodiments of the present disclosure provide a sanitary article comprising the aforementioned polypropylene composite film.

In some embodiments, the material of the sanitary article comprises only polypropylene.

In some embodiments, the sanitary article comprises a diaper, sanitary napkin, pantiliner, breast pad, cleaning pad, or a combination of the foregoing.

Some embodiments of the present disclosure provide a method for manufacturing a polypropylene composite film, comprising: providing a polypropylene fiber layer and at least one polypropylene base layer; hot pressing at least one polypropylene base layer to obtain a polypropylene waterproof layer, wherein the poly The water pressure resistance of the propylene waterproof layer is greater than 400 mm water column; and the polypropylene fiber layer and the polypropylene waterproof layer are bonded to obtain a polypropylene composite membrane.

In some embodiments, the at least one polypropylene base layer has a denier of 1 denier to 2.5 denier.

In some embodiments, the polypropylene base layer has a basis weight of 10 grams/square meter to 60 grams/square meter.

In some embodiments, the step of hot pressing at least one polypropylene base layer includes using a roller with a temperature of 100°C to 180°C to hot press at least one polypropylene base layer.

In some embodiments, the step of hot pressing at least one polypropylene base layer includes hot pressing at least one polypropylene base layer with a roller at a speed of 0.6 cm/sec to 1.5 cm/sec.

In some embodiments, the at least one polypropylene base layer is plural in number, and the step of heat pressing the at least one polypropylene base layer includes laminating the polypropylene base layers, and heat pressing the laminated polypropylene base layers layer.

In some embodiments, after hot pressing at least one polypropylene base layer to obtain the polypropylene waterproof layer, the step further comprises: immersing the polypropylene waterproof layer in an inorganic salt water repellent; and performing pressure suction on the polypropylene waterproof layer deal with.

It is to be understood that both the foregoing general description and the following detailed description are examples and are intended to provide further explanation of the disclosure as claimed.

It will be appreciated that different implementations or examples provided in the following may implement different features of the subject matter of the present disclosure. The embodiments of specific components and arrangements are used to simplify the disclosure and not to limit the disclosure. Of course, these are only examples and are not intended to be limiting. For example, the description below that the first feature is formed on the second feature includes the two being in direct contact, or there are other additional features between the two that are not in direct contact. Furthermore, the present disclosure may repeat reference numerals and/or symbols in the various embodiments. Such repetition is for simplicity and clarity and does not represent a relationship between the various embodiments and/or configurations discussed.

Terms used in this specification generally have their ordinary meanings in the art and in the context in which they are used. The examples used in this specification, including examples of any terms discussed herein, are illustrative only and do not limit the scope and meaning of the disclosure or any exemplified terms. Likewise, the present disclosure is not limited to some of the implementations provided in this specification.

It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of the present embodiments.

As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

As used herein, the terms "comprising", "including", "having" and the like should be construed as open ended, ie, meaning including but not limited to.

As used herein, the term "basis weight" refers to the weight of the nonwoven fabric per unit square area.

In this article, the term "fineness" is the gram weight obtained by weighing 9000 meters long fiber, for example: 9000 meters long fiber weighing 70 grams, then this fiber is 70 denier yarn, which can be abbreviated as 70d .

As used herein, the term "moisture permeability" refers to the permeability of water vapor when the two sides of the fabric are subjected to a water vapor pressure difference.

In this article, the term "breathability" refers to the permeability of water vapor when the two sides of the fabric are subjected to a certain pressure difference.

As used herein, the term "water pressure resistance" refers to the water pressure value that can be withstood per unit area.

As used herein, the term "comfort" refers to the texture and softness of the fabric.

As previously described, some embodiments of the present disclosure provide a composite film comprising polypropylene, a sanitary article comprising a composite film of polypropylene, and a method of making a composite film of polypropylene. The polypropylene base layer is hot pressed to form a polypropylene waterproof layer with improved leak-proof performance compared to the polypropylene base layer. The polypropylene waterproof layer can replace other leak-proof materials (such as polyethylene), and form a polypropylene composite film with the polypropylene fiber layer, which is used in sanitary products to simplify the production line, simplify the composition of materials, and increase the convenience of recycling. It has beneficial effects such as reducing the impact of plastics on the environment.

In some embodiments of the present disclosure, a polypropylene composite film is provided, comprising: a polypropylene fiber layer and a polypropylene waterproof layer adhered on the polypropylene fiber layer, wherein the water pressure resistance of the polypropylene waterproof layer is greater than 400 mm water column, For example, 400mm water column to 1500mm water column (for example, 400mm water column, 450mm water column, 500mm water column, 550mm water column, 600mm water column, 650mm water column, 700mm water column, 750mm water column, 800mm water column, 900mm water column mmH2O, 1000mmH2O, 1100mmH2O, 1200mmH2O, 1300mmH2O, 1400mmH2O, 1500mmH2O, or any of the foregoing ranges). When the polypropylene composite film is used in sanitary products, the polypropylene waterproof layer can replace the conventional leak-proof material (eg polyethylene) for leak-proof purpose.

In some embodiments, the water pressure resistance of the polypropylene fiber layer is less than 400 mm water column, which is less than that of the polypropylene waterproof layer. That is, the waterproof effect of the polypropylene waterproof layer is better than that of the polypropylene fiber layer. In some embodiments, when the polypropylene composite film is used in sanitary products, the polypropylene waterproof layer can be used as a leak-proof layer, and the polypropylene fiber layer has better air permeability and can be used as a skin-friendly layer. In some embodiments, the polypropylene waterproof layer may be formed by heat pressing a polypropylene fiber layer.

In some embodiments, both the polypropylene fiber layer and the polypropylene waterproof layer are composed of polypropylene and contain no other plastics. In some embodiments, the polypropylene composite film may further comprise other polypropylene absorbent layers, and the polypropylene absorbent layer covers the surface of the polypropylene fiber layer or the polypropylene waterproof layer, or is located between the polypropylene fiber layer and the polypropylene waterproof layer , and the polypropylene absorbent layer is also composed of polypropylene. It is understandable that due to the simplification of materials, when recycling, there is no need to classify the composition of polypropylene composite films according to different plastics, which can simplify the recycling process of plastics, improve recycling efficiency, and reduce the burden on the environment.

In some embodiments, the polypropylene composite film further comprises an adhesive layer, which is adhered between the polypropylene fiber layer and the polypropylene waterproof layer. In one embodiment, the material of the adhesive layer is adhesive, such as hot melt adhesive.

In some embodiments, the polypropylene composite membrane further comprises an inorganic salt water repellent agent attached to the polypropylene waterproof layer. It can be understood that the inorganic salt water repellent is attached to the polypropylene waterproof layer, which can improve water pressure resistance and comfort (softer texture). In some embodiments, the inorganic salt water repellent comprises an aqueous silane resin solution, an aqueous solution of organosiloxane (eg, aqueous silicone), or a combination of the foregoing, such as a silane/fluorosilane mixture, dimethylsiloxane, octyl Triethoxysilane, (3-(2-Aminoethyl)amino)propyl, Sodium Methylsilicate, Potassium Methylsilicate, Butyltrimethoxysilane, Butyltriethoxysilane, Octyl Trimethoxysilane, Octyltriethoxysilane, Aqueous alkoxysilane emulsion, Dimethylmethylhydrosiloxane, Methyltrimethoxysilane, Ethylenedioxypropyltrimethoxysilane, Ethylenedi Oxypropyltriethoxysilane, ethylenedioxypropylmethyldimethoxysilane, ethylenedioxypropylmethyldiethoxysilane, epoxycyclohexylethyltrimethoxysilane, ammonia Propyltrimethoxysilane, Aminopropyltriethoxysilane, Aminopropylmethyldiethoxysilane, Aminoethylaminopropyltrimethoxysilane, Sodium Trihydroxysilylpropylmethylphosphonate or a combination thereof. In some embodiments, the inorganic salt water-repellent agent includes a fluorine-free water-repellent agent, which is a fluorine-free water-repellent agent, which can avoid the carcinogenic risk of conventional fluorine-containing substances to the human body and avoid the Environmental hazards of fluorine substances.

In some embodiments of the present disclosure, a sanitary article is provided, comprising the aforementioned polypropylene composite film. The polypropylene waterproof layer of the polypropylene composite membrane can replace the conventional anti-leakage materials, realize the simplification of materials, simplify the recycling process of sanitary products, improve the recycling efficiency, and reduce the burden on the environment. In some embodiments, the sanitary article comprises a diaper, sanitary napkin, pantiliner, breast pad, cleaning pad, or a combination of the foregoing. In one embodiment, the polypropylene composite film can be used as the backing film structure of the diaper to prevent the leakage of urine. In one embodiment, the sanitary article is made from a single material of polypropylene.

Some embodiments of the present disclosure provide a method for manufacturing a polypropylene composite film, comprising: providing a polypropylene fiber layer and a polypropylene base layer; hot pressing the polypropylene base layer to obtain a polypropylene waterproof layer, wherein the polypropylene waterproof layer has The water pressure resistance is greater than 400 mm water column; and the polypropylene fiber layer and the polypropylene waterproof layer are bonded to obtain a polypropylene composite membrane.

In some embodiments, please refer to FIG. 1 , which illustrates a schematic diagram of a specific process for manufacturing a polypropylene composite film in some embodiments of the present disclosure.

First, a polypropylene fiber layer 110 and a polypropylene base layer 120 are provided. The polypropylene base layer 120 and the polypropylene fiber layer 110 are respectively transported along the direction D of the production line 200 for subsequent processing, wherein the production line 200 includes a plurality of rollers 226 , and the rotation of the rollers 226 drives the polypropylene base layer 120 And the delivery of the polypropylene fiber layer 110 . The polypropylene base layer 120 and the polypropylene fiber layer 110 may be polypropylene non-woven fabrics, but with different fabric specifications such as basis weight or fineness. In some other embodiments, the polypropylene base layer 120 and the polypropylene fiber layer 110 may be polypropylene non-woven fabrics with the same fabric specification.

Next, the polypropylene base layer 120 is hot pressed using a first roller pair 222, wherein the temperature of at least one of the first roller pair 222 (eg, first roller 222A) is at least above 100°C. The polypropylene base layer 120 is heat-pressed to reduce the porosity of the polypropylene base layer 120, thereby obtaining the polypropylene waterproof layer 130, wherein the water pressure resistance of the polypropylene waterproof layer 130 is greater than 400 mm water column, compared to the polypropylene waterproof layer 130. The waterproof (or leak-proof) effect of the base layer 120 and the polypropylene waterproof layer 130 is improved.

On the other hand, during the conveying process of the polypropylene fiber layer 110 along the production line direction D, the adhesive layer 140 is formed on the surface of the polypropylene fiber layer 110 through the glue spraying treatment of the glue spraying element 230 .

Finally, the polypropylene waterproof layer 130 obtained by hot pressing, the polypropylene fiber layer 110 after being sprayed and the adhesive layer 140 adhered on the polypropylene fiber layer 110 are formed into polypropylene waterproof layer 130-adhesive layer 140-polypropylene The order of the acrylic fiber layers 110 (the adhesive layer 140 is located between the polypropylene waterproof layer 130 and the polypropylene fiber layer 110 ) is pressed by the second roller pair 224 (the first roller 224A and the second roller 224B), and the adhesive layer 140 is bonded Between the polypropylene waterproof layer 130 and the polypropylene fiber layer 110, the polypropylene composite film 100 is obtained.

In some embodiments, the polypropylene fiber layer and the polypropylene base layer can be the same or different. For example, the polypropylene fiber layer and the polypropylene base layer can both be the same polypropylene non-woven fabric or both are polypropylene non-woven fabrics, but have different fabric specifications such as basis weight or fineness.

In some embodiments, the polypropylene base layer has a denier of 1 denier to 2.5 denier, such as 1 denier, 1.5 denier, 2 denier, or 2.5 denier, or any value in the foregoing interval.

In some embodiments, the polypropylene base layer has a basis weight of 10 grams/square meter to 60 grams/square meter. For example, 10 g/m2, 20 g/m2, 30 g/m2, 40 g/m2, 50 g/m2, 60 g/m2 or any value in the aforementioned interval.

In some embodiments, the step of hot pressing at least one polypropylene base layer includes using a temperature of 100°C to 180°C (eg 100°C, 110°C, 120°C, 130°C, 140°C) , 150°C, 160°C, 170°C, 180°C or any value in the aforementioned range), hot-press at least one polypropylene base layer.

In some embodiments, the step of hot pressing at least one polypropylene base layer includes a speed of 0.6 cm/sec to 1.5 cm/sec (eg 0.6 cm/sec, 0.7 cm/sec, 0.8 cm/sec, 0.9 cm/sec) /sec, 1.0 cm/sec, 1.1 cm/sec, 1.2 cm/sec, 1.3 cm/sec, 1.4 cm/sec, 1.5 cm/sec or any value in the foregoing range), hot pressing at least one polypropylene base layer .

In some embodiments, the step of heat pressing at least one polypropylene base layer includes laminating multiple polypropylene base layers, and heat pressing the laminated polypropylene base layers. In one embodiment, after 2 to 3 layers, or more than 4 layers of polypropylene base layers can be stacked, the stacked polypropylene base layers can be hot-pressed. The higher the number of stacked layers, the better the water pressure resistance of the obtained polypropylene waterproof layer. However, it should be noted that as more layers are laminated and heat-pressed, the air permeability will also decrease. Therefore, compared with the polypropylene base layer of 2 to 3 layers laminated, the polypropylene waterproof layer obtained by hot pressing not only has the anti-leakage effect, but also has the advantages of relatively low leakage. Good breathability.

In some embodiments, after hot pressing at least one polypropylene base layer to obtain the polypropylene waterproof layer, the step further comprises: immersing the polypropylene waterproof layer in an inorganic salt water repellent; and performing pressure suction on the polypropylene waterproof layer deal with. Through the pressure and suction treatment, an inorganic salt water repellent can be attached to the polypropylene waterproof layer to improve water pressure resistance and comfort.

Example 1 and Example 2 are provided below to test the fabric specifications (texture and basis weight), hot pressing parameters (hot pressing temperature, drum speed) of different polypropylene base layers (this series of examples use polypropylene non-woven fabrics). , the number of hot-pressed layers), and whether it has been treated with a water repellent agent or not, the fabric properties (such as water pressure resistance) of the prepared fabric products.

The first embodiment is to test the fabric properties of the obtained fabric products under the regulation of various fabric specifications and different hot-pressing parameters of the single-layer polypropylene base layer. After further double-layer hot pressing and water repellent treatment, the fabric properties of the obtained fabric products were tested.

Example 1. Fabric specification and hot-pressing condition test of single-layer polypropylene base layer

The polypropylene base layer to be tested in the examples of this stage uses a commercially available polypropylene non-woven fabric produced by Taiwan Nanliu, with an area of 200 mm x 200 mm, and the basis weight test conditions include 18 g/m2, 30 g/m2 Meter and 50 grams/square meter, the test conditions of fineness include 1.5 denier and 3 denier.

The specific hot-pressing method is as follows: First, use a two-roll small hot-pressing testing machine (flat wheel + flat wheel; roller: 280 mm x 400 mm) and an electric heating system (manufactured by Taiwan Zhihong Machinery Co., Ltd., model: CROH-820 ), the polypropylene base layer was subjected to a heat press treatment with the fabric specifications, heat press temperatures and drum speeds shown in Table 1 below. Then, the polypropylene base layer after hot pressing of each sheet is tested for moisture permeability according to the weight method moisture permeability test standard (ASTM E96 method), and according to the textile moisture absorption and quick-drying performance test standard (AATCC 197 method) test respectively. Water pressure resistance, air permeability tested according to textile air permeability test standard (ASTM D737 method), and comfort tested according to the method of JP2004136678A patent. Finally, corresponding to the test conditions of each of the aforementioned manufacturing examples, various fabric properties obtained by the analysis are listed in Table 1.

In addition, in order to compare the fabric properties of the polypropylene base layer after hot pressing, the fabric of the commercially available diaper bottom film (polyethylene film) PE-18 (produced by Zhuhai Aixin Technology) for leakage prevention is also provided here. Performance values for comparison. Commercially available diaper bottom films have a water pressure resistance greater than 400 mm water column, a moisture permeability of 1.6 g/100 cm x hr to 8 g/100 cm x hr, and a breathability of 5000 mm/sec to 10000 mm/h Second.

Table 1. Comparison of the properties of the fabrics obtained after different fabric specifications and different hot-pressing conditions of the single-layer polypropylene base layer Manufacturing example number Specifications [fineness (Dan); basis weight (g/m2)] Drum temperature (°C) Roller speed (cm/s) Breathability (mm/sec) Water Pressure Resistance (mm H2O) 1/2 Denier: 1.5 Basis Weight: 18 110 0.8/1.3 13400/15650 260/180 3/4 130 0.8/1.3 9500/10000 450/400 5/6 150 0.8/1.3 4500/7550 650/550 7/8 200 1.3 N/A (coking crimp) N/A (coking crimp) 9/10 Denier: 1.5 Basis Weight: 30 110 0.8/1.3 8500/10000 380/300 11/12 130 0.8/1.3 6200/7000 650/550 13/14 150 0.8/1.3 3200/5100 500/380 15/16 Denier: 1.5 Basis Weight: 50 110 0.8/1.3 3900/5200 500/400 17/18 130 0.8/1.3 3300/3500 900/750 19/20 150 0.8/1.3 1800/2600 352/200 21/22 Denier: 3 Basis Weight: 18 110 0.8/1.3 17500/20300 80/50 23/24 130 0.8/1.3 10500/13000 150/120 25/26 150 0.8/1.3 5800/9800 230/180 27/28 Denier: 1 Basis Weight: 14 110/150 0.8 8000/2700 390/900 29/30 Denier: 5 Basis Weight: 14 110/150 0.8 23000/8700 60/160 31/32 Denier: 1 Basis Weight: 50 110/150 0.8 4800/5800 500/1200 33/34 Denier: 5 Basis Weight: 50 110/150 0.8 13500/6500 80/250

Table 1 shows that with regard to the hot pressing temperature (ie, the drum temperature), as the temperature increases from 110°C to 130°C, the water pressure resistance will increase and the air permeability will decrease (for example, compared to the drum temperature) It is the production example 1 of 110 ° C and the production example 3 of 130 ° C). However, in some of the manufacturing examples, when the temperature was further increased to 150°C, the water pressure resistance decreased as compared with the temperature of 130°C (for example, the comparison of the manufacturing example 12 with the temperature of 130°C and the temperature of 150 ° C of production example 14). In addition, when the temperature was 200°C, there was also a phenomenon of coking and curling (Production Example 7, Production Example 8). Therefore, it is not that the higher the hot-pressing temperature, the better the water pressure resistance. It is still necessary to properly match various fabric specifications and drum speeds to obtain fabric products with improved water pressure resistance.

Regarding the drum speed, under the same temperature conditions, the slower the drum speed, the worse the air permeability of the finished fabric and the better the water pressure resistance (for example, compare the drum speed of 1.3 cm/s in Manufacturing Example 6 and the drum speed of 0.8 cm/s). Production Example 5).

Regarding the fineness, if the fineness increases, the porosity increases after hot pressing, and the water pressure resistance is obviously poor. On the contrary, if the fineness decreases, the porosity decreases and the water pressure resistance increases, while the air permeability will be relatively decrease (for example, compare Production Example 3/Production Example 4 with a fineness of 1.5 denier and Production Example 23/Production Example 24 with a fineness of 3 denier). When the fineness is 3 denier or more, the water pressure resistance is lower than 400 mm water column, and it will be difficult to be used as a waterproof layer (for example, the production examples 23 to 26 with a fineness of 3 denier); when the fiber is less than 1 denier, because the If the fibers are too thin, there is a risk of insufficient fabric strength (data not shown here) (eg, Production Example 27, Production Example 28, Production Example 31, and Production Example 32).

Regarding the basis weight, as the basis weight increases, the water pressure resistance increases, and the air permeability decreases (for example, the basis weight is 18 g/m2 in Production Example 4, and the basis weight is 30 g/m2 in Production Example 4). Example 12, and Production Example 18 with a basis weight of 50 g/m2). If the basis weight is less than 18 g/m2, the water pressure resistance may even drop below 400 mm water column, which is not sufficient as a waterproof membrane (for example, compare the basis weight of 50 g/m2 in Production Example 15 and Example 16 and Production Example 1 and Production Example 2) with a basis weight of 18 g/m2). Although the basis weight is increased, the waterproof effect can be improved, but relatively, it may also lead to a decrease in air permeability and an increase in manufacturing cost. Therefore, it is necessary to cross-consider the waterproof effect, air permeability, and manufacturing cost of the finished fabric to be obtained, so as to select an appropriate basis weight range of the polypropylene base layer.

According to the results in Table 1, if the water pressure resistance should be at least 400 mm water column for the waterproof layer as a consideration, the fabric specifications of the polypropylene base layer and the appropriate conditions for heat pressing include: the fineness range from 1 Dan to 2.5 Dan, basis weight range from 10g/m² to 60g/m², drum temperature range from 100°C to 180°C, and drum speed range from 0.6cm/sec to 1.5cm/sec.

When compared with the commercial product (commercially available diaper bottom film (polyethylene film)), Production Example 3, Production Example 4, Production Example 6, Production Example 11, Production Example 12, and Production Example 16 were subjected to hot pressing. After that, the polypropylene base layer (or polypropylene waterproof layer) can not only achieve the same leak-proof effect as the commercial diaper bottom film (the same or even higher water pressure resistance), but also achieve the same breathability as the commercial diaper bottom film. The bottom film is comparable, or even better, so the finished fabrics of these manufacturing examples can be used as a waterproof layer for sanitary products.

Example 2. Multi-layer hot pressing of polypropylene base layer and water repellent addition test

In order to further compare the heat-pressed polypropylene base layers with different layers and the presence or absence of water repellent treatment, the effects on the air permeability, water pressure resistance and moisture permeability of the heat-pressed polypropylene base layers were used in Example 1. The fabric specifications (texture 1.5 denier, basis weight 18 g/m2) and hot pressing conditions (130°C, roller speed 1.3 cm/s) in Manufacturing Example 4 were performed according to the test conditions in Table 2 below. Heat-pressing (single-layer heat-pressing or double-layer lamination heat-pressing), water repellent treatment or both treatments, and the fabric properties of the obtained fabric products are recorded in Table 2.

The water repellent treatment in Table 2 is a polypropylene waterproof layer formed by hot pressing the polypropylene base layer or the polypropylene base layer, immersed in a water repellent (3% siloxane aqueous solution, commodity model XIAMETER™ OFS-6341 ), and perform a pressure suction treatment on the polypropylene base layer or the polypropylene waterproof layer, so that the water repellent is attached to the polypropylene base layer or the polypropylene waterproof layer.

The main difference between the comparative example and the test example in Table 2 is that the comparative example has not been heated. In addition, for the groups treated with hot pressing and water repellent (such as Test Example 2 and Test Example 4), the polypropylene base layer was first subjected to single-layer hot pressing or double-layer hot pressing to form a polypropylene waterproof layer. The polypropylene waterproof layer is then immersed in the water repellent layer, and the polypropylene waterproof layer is subjected to pressure and suction treatment, so that the water repellent layer is attached to the polypropylene waterproof layer.

Table 2. The comparison table of the fabric properties obtained after the polypropylene base layer is laminated, added with water repellent or treated with the aforementioned two Commercially available diaper bottom film (polyethylene film) Comparative example test case 1 2 3 4 1 (Manufacturing example 4) 2 3 4 single layer double layer single layer double layer Processing hot pressing X X X X X V V V V water repellent X X V X V X V X V fabric properties Moisture permeability (g/cm2 x hours) 1.6~8 7.8 7.5 5.5 5.3 7.0 6.5 4.9 4.6 Water Pressure Resistance (mm H2O) >400 <400 400 <400 450 450 500 600 750 Air permeability (mm/sec) 5000 to 10000 10000 8800 7800 7000 9500 7500 6000 5800 Comfort* (Texture) 5 3 4 3 4 4 5 4 5 *The score of comfort is based on the method of patent JP2004136678A. After touching the finished product with fingers, the score is from less (1 point) to most (5 points) according to the texture of hard to soft, 1 point means hard and poor texture, 2 A score is slightly firm and slightly uncomfortable, a 3 is elastic and comfortable, a 4 is soft and comfortable, and a 5 is the softest and most comfortable.

The results in Table 2 show that the groups (Comparative Example 1, Comparative Example 3) without hot pressing and without adding water repellent have too low water pressure resistance, less than 400 mm water column, and cannot meet the requirements of being a waterproof membrane.

In the part of the test example, the single-layer hot-pressed group (Test Example 1) not only has improved water pressure resistance compared with the non-hot-pressed group (Comparative Example 1), but also improved the water pressure resistance and air permeability. The effect of the group (Comparative Example 2) treated with an additional water-repellent agent was better than that without hot pressing. In addition, the water pressure resistance and comfort of the group after single-layer hot pressing and then treated with a water repellent agent (Test Example 2) were improved compared to the group that only underwent single-layer hot pressing (Test Example 1).

For the double-layer hot-pressed group, the water-pressure resistance of the double-layer hot-pressed group (Test Example 3) is higher than that of the single-layer hot-pressed group (Test Example 1). The water pressure resistance and comfort of the group after double-layer hot pressing and then treated with water repellent agent (Test Example 4) were improved compared to the group that only underwent double-layer hot pressing (Test Example 3).

In general, after the polypropylene base layer is hot-pressed (Comparative Example 1 and Comparative Example 3), the moisture permeability, water pressure resistance, and air permeability of the fabric properties are all in line with the polyethylene film (commercially available diaper bottom film). ), the water pressure resistance and comfort can be further improved by adding a water repellent (Comparative Example 2 and Comparative Example 4).

Some embodiments of the present disclosure provide a polypropylene composite film, a sanitary article comprising the polypropylene composite film, and a method for manufacturing the polypropylene composite film, wherein the porosity of the polypropylene base layer is reduced by means of hot pressing to obtain a leak-proof polypropylene film. The polypropylene waterproof layer with good effect (better water pressure resistance) breaks through the limitation of poor waterproof effect of conventional polypropylene materials.

Accordingly, the polypropylene waterproof layer can replace other leak-proof materials (such as polyethylene), and the polypropylene fiber layer is composed of a polypropylene composite film made of a single polypropylene material. It is used in sanitary products and does not need to be separated during recycling. procedures that increase the convenience of material recycling and reduce the impact on the environment.

In addition, the production process of the polypropylene composite film is simple and only needs to perform hot-pressing treatment in a single production line. The hot-pressing treatment has the advantages of easy processing, low technical threshold, low equipment cost and easy maintenance. The processing production line can directly process the compound, and the production line is easy to set up.

While the present disclosure has been described in detail in terms of certain implementations, other implementations are possible. Therefore, the spirit and scope of the appended claims should not be limited to the embodiments described herein.

100: Polypropylene composite film 110: Polypropylene fiber layer 120: Polypropylene base layer 130: Polypropylene waterproof layer 140: Adhesive layer 200: production line 220: Roller set 222: First Roller Pair 222A: First Roller 222B: Second Roller 224: Second Roller Pair 224A: First Roller 224B: Second Roller 226: Roller 230: Glue components D: production line direction

In order to make the above and other objects, features, advantages and embodiments of the present invention more clearly understood, the detailed description of the accompanying drawings is as follows: FIG. 1 illustrates a specific process flow diagram of manufacturing a polypropylene composite film in some embodiments of the present disclosure.

100: Polypropylene composite film

110: Polypropylene fiber layer

120: Polypropylene base layer

130: Polypropylene waterproof layer

140: Adhesive layer

200: production line

220: Roller set

222: First Roller Pair

222A: First Roller

222B: Second Roller

224: Second Roller Pair

224A: First Roller

224B: Second Roller

226: Roller

230: Glue components

D: direction

Claims (16)

A polypropylene composite film comprising: a layer of polypropylene fibers; and A polypropylene waterproof layer is bonded on the polypropylene fiber layer, wherein the water pressure resistance of the polypropylene waterproof layer is greater than 400 mm water column. The polypropylene composite membrane according to claim 1, wherein the water pressure resistance of the polypropylene fiber layer is smaller than that of the polypropylene waterproof layer. The polypropylene composite film according to claim 1, further comprising an adhesive layer, which is adhered between the polypropylene fiber layer and the polypropylene waterproof layer. The polypropylene composite membrane according to claim 1, further comprising an inorganic salt water repellent attached to the polypropylene waterproof layer. The polypropylene composite film according to claim 4, wherein the inorganic salt water repellent comprises a silane resin aqueous solution, an organosiloxane aqueous solution or a combination thereof. The polypropylene composite film according to claim 4, wherein the inorganic salt water-repellent agent comprises a fluorine-free water-repellent agent. A sanitary article, comprising the polypropylene composite film according to claim 1. The sanitary article of claim 7, wherein the material of the sanitary article comprises only polypropylene. The sanitary product according to claim 7, wherein the sanitary product comprises a diaper, a sanitary napkin, a pad, a breast pad, a cleaning pad or a combination thereof. A method of manufacturing a polypropylene composite film, comprising: providing a polypropylene fiber layer and at least one polypropylene base layer; Hot pressing the at least one polypropylene base layer to obtain a polypropylene waterproof layer, wherein the water pressure resistance of the polypropylene waterproof layer is greater than 400 mm water column; and The polypropylene fiber layer and the polypropylene waterproof layer are bonded to obtain a polypropylene composite film. The method of claim 10, wherein the at least one polypropylene base layer has a denier of 1 denier to 2.5 denier. The method of claim 10, wherein the polypropylene base layer has a basis weight of 10 g/m2 to 60 g/m2. The method of claim 10, wherein the step of hot pressing the at least one polypropylene base layer comprises using a roller with a temperature of 100°C to 180°C to hot press the at least one polypropylene base layer. The method of claim 10, wherein the step of hot pressing the at least one polypropylene base layer comprises hot pressing the at least one polypropylene base layer with a roller at a speed of 0.6 cm/sec to 1.5 cm/sec. The method of claim 10, wherein the number of the at least one polypropylene base layer is plural, and wherein the step of hot pressing the at least one polypropylene base layer comprises laminating the polypropylene base layers, and hot pressing the laminated these polypropylene base layers together. The method of claim 10, wherein after the step of hot pressing the at least one polypropylene base layer to obtain the polypropylene waterproof layer, further comprising: dipping the polypropylene waterproof layer in an inorganic salt water repellent; and A pressure suction process was performed on the polypropylene waterproof layer.

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