CN101918214A - 含有聚烯烃组合物的层压织物结构 - Google Patents

含有聚烯烃组合物的层压织物结构 Download PDF

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CN101918214A
CN101918214A CN2008801091299A CN200880109129A CN101918214A CN 101918214 A CN101918214 A CN 101918214A CN 2008801091299 A CN2008801091299 A CN 2008801091299A CN 200880109129 A CN200880109129 A CN 200880109129A CN 101918214 A CN101918214 A CN 101918214A
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goods
layer
polyolefin composition
adhesive
polyolefin
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C·A·卡夫利
D·K·法默
J·M·兰伯特
L·洪
R·O·瓦德鲍尔
Y·D·阮
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Invista Technologies SARL Switzerland
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Invista Technologies SARL Switzerland
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Abstract

本发明涉及含有聚烯烃组合物的层压织物结构。本发明包括含有多层的制品。该多层制品可以包括与聚烯烃组合物例如膜、粉末或无纺织物结合的织物、泡沫、膜、纤维。

Description

含有聚烯烃组合物的层压织物结构
相关申请的交叉引用
本申请要求2007年9月28日递交的申请号为60/975918的临时申请的优先权。
背景技术
技术领域
本发明涉及包括多层结构的制品。该层包括与聚烯烃组合物结合的织物和/或聚氨酯泡沫。
相关技术概述
聚烯烃可用作各种基底的胶粘剂。这种热塑性胶粘剂通常需要热和压力以形成足够的粘结强度。虽然热熔性胶粘剂是环保的且易于作为薄膜施加，但当遭受重复拉伸循环时，其通常具有高的永久变形和差的回复性。因此，需要克服热熔性胶粘剂性能缺陷的胶粘剂。合乎需要的是，相对于传统的热塑性聚氨酯和热熔性胶粘剂，这种胶粘剂也提供织物其它的优良性能例如柔韧性、外形保持性和透气性。
发明内容
一些实施例提供了包括至少两层的多层制品，其中之一是聚烯烃组合物。该聚烯烃组合物可在基底上形成所述层中的一层，例如作为聚烯烃组合物层。该聚烯烃组合物可以是任何适合的形式例如膜、无纺织物、粉末、分散粉剂、熔体，以及它们的组合。该聚烯烃组合物可以与所述层邻接或位于所述层之间，还可以为所述制品提供粘结性、可塑性、外形保持性和柔韧性。
一些实施例提供了包括多层的制品，其已经经过挤压、层压和/或模制。该制品包括至少两层，其中所述层中的一层是膜、无纺织物或熔体状态的聚烯烃组合物。
进一步的实施方式提供了制品，其包括至少一个织物层和至少一种聚烯烃组合物，该聚烯烃组合物选自膜、无纺织物、熔体、粉末、分散粉剂以及它们的组合。
发明详细描述
这里所用的术语“多孔的”指在该基底的表面、其内部或贯穿其厚度的任何点包括空隙或者孔的基底，或指本发明的制品可接触到的任何材料。该基底可以独立的和连续的或不连续的，且任意的包括一个附加的基底。
这里所用的术语“压制”或“压制的”指已经施加过热和/或压力以提供基本上平面的结构的制品。
这里所用的术语“泡沫”指任何可用于织物结构的合适的泡沫，例如聚氨酯泡沫。
这里所用的术语“分散体(dispersion)”指体系，其中分散相由细碎颗粒组成，并且连续相可以是液体、固体或气体。
这里所用的术语“制品”指包括膜、无纺织物、粉末、分散粉剂或成形制品和基底的制品，例如纺织织物，由于这里所述的分散体或成形制品的应用，其可以部分的具有或不具有至少一种弹性。该制品可以是任何适合的结构，例如一维、二维和/或三维。
这里所用的术语“织物”指针织、机织或无纺材料。针织织物可以是平针织物、圆筒形针织物、经编织物、窄松紧带(narrow elastic)和花边。机织织物可以是任何结构，例如纬缎、斜纹、平纹组织、变化重平组织(oxford weave)、方平组织和窄松紧带。无纺材料可以是熔喷、纺丝粘合、湿法成网、基于粗梳纤维的短纤维网(carded fiber-based staple web)等。
这里所用的术语“基底”指本发明的制品可能接触的任何材料。基底实质上可以是一维的例如纤维、二维的例如平面片材、或三维制品或不平的片。平面片材例如可以包括纺织织物、纸、植绒制品和网幅。三维制品例如可以包括皮革和泡沫。其它基底可以包括木材、纸、塑料、金属、和复合材料(composite)例如混凝土、沥青、体育馆用地板(gymnasium flooring)和塑料片(plastic chip)。
这里所用的术语“硬纱(hard yarn)”指基本上没有弹性的纱。
这里所用的术语“模制的”制品指制品或成形制品的形状响应热和/或压力的施加而改变的结果。
这里所用的术语“源于”指用另外一种材料制成的物质。例如，膜可能源于可以干燥的分散体。
这里所用的术语“模量”指在产品上的压力比，用力/每单位线密度或面积来表示。
这里所用的术语“聚烯烃”表示包括由C2到C20单体制备的聚烯烃。它包括共聚物和三元共聚物例如乙烯-丙烯共聚物。在此通过引用纳入了Datta等人的美国专利US 6,867,260给出的有用的聚烯烃共聚物的实施例。
一些实施方式中的多层制品包括至少一层聚烯烃组合物。这些制品具有包括至少一种聚烯烃组合物的至少两层。该聚烯烃组合物可以形成所述层中的一层，例如作为基底上的聚烯烃组合物。聚烯烃组合物可以是任意适合的形式例如膜、粉末、无纺织物、熔体、分散粉剂、干粉以及它们的组合。聚烯烃组合物可以与所述层相邻或位于所述层之间，还可以为所述制品提供拉伸和回复性、提高的弹性模量、粘结性、可塑性、外形保持性和柔韧性。这些制品可成形为织物和/或服装。
一些实施方式的制品中采用了多种不同的聚烯烃组合物。例如，一些实施方式中的制品可以包括聚烯烃溶液或由溶液(该溶液包括溶剂例如沸腾的二甲苯、沸腾的庚烷、热1，2，4-三氯苯、热乙二醇单丁醚或热邻二氯苯)浇铸(cast)水性分散体(该水性分散体包括聚烯烃粉末和任选地溶剂)或基本上不含溶剂的水性分散体形成的膜。例如，根据本发明的一些实施方式，聚烯烃溶液如纺丝溶液或凝胶也可用来浇铸形成膜。
在一个实施方式中，所述制片包括多层制品，该多层制品包括三层或更多层，其中一层是聚烯烃组合物，该聚烯烃组合物可以是两个织物层之间、两个泡沫层之间、织物层和泡沫层之间的中间层，或者是相邻于与织物层相邻的泡沫层。也可以考虑这些织物/泡沫/聚烯烃组合物排列的组合。例如，所述制品可以依次包括织物层、泡沫层、聚烯烃组合物层、泡沫层、和织物层。该制品包括两个单独的织物层、两个单独的泡沫层和聚烯烃组合物层。在这些实施方式的任何一个中，聚烯烃组合物可以是膜、无纺织物、粉末、熔体、分散粉剂或它们的组合。另外，该制品可以包括一个或多个聚烯烃膜和一层或多层不同形式的聚烯烃。
在包括两层或多层的实施方式中，聚烯烃组合物可以形成外层。在外表面包括聚烯烃组合物带来很多有利性能。例如，聚烯烃组合物可以提供固定或增加摩擦的区域以减少包括聚烯烃组合物的制品和外部基底之间的相对移动。当制品是包括皮肤接触面(其中穿戴者的皮肤是基底)的内衣时尤其有用。可选的，该基底可以是与本发明制品的聚烯烃组合物接触的外衣。其中该基底是穿戴者的外衣并且该制品被穿做内衣，该制品阻止或减少外衣的相对移动。另外，外衣(例如服装(dress))可以包括聚烯烃组合物以保持内衣的相对位置(例如滑动)。
在选定织物、泡沫和聚烯烃组合物层后，还可以接着通过压制或模制粘合以形成平的有形的制品。一些实施方式中制备压制和模制制品的过程包括必须使用压力和热。例如，可以施加热到大约150℃到大约200℃、或大约160℃到大约180℃、包括约165℃保持足够的时间以得到模制制品。加热的适合时间包括但不仅限于从大约30s到大约360s，包括从大约45s到大约120s。粘结可以以任何已知的方式实施，包括但不仅限于微波、红外线、导热(conduction)、超声波、持续加压(即夹紧)和它们的组合。
由于对包括聚烯烃膜或无纺织物、粉末和熔体的制品施加热和压力，并且如果膜和织物本身都是多孔材料，认为该膜或无纺织物可以部分或全部渗透(impregnate)该制品的织物或泡沫。例如，聚烯烃组合物可以形成与周围的层部分地分离的层，或者可以完全转移到周围的一层或多层以形成没有显著分离的聚烯烃组合物层的整体制品。
本发明多层制品的一个应用是塑身衣如胸罩(特别是罩杯或罩翼(wing)的)和男士内衣。这些制品可以提供所需的舒适、塑身和支撑的特征，同时也提供舒适性、透气性、空气透过性、湿气/水汽传递性(moisture/vapor transport)、吸湿性、和它们的组合。本发明的一些实施方式中的制品中，所述层可以使用预定形状，并且相互之间可以按照模制或成形制品的设计例如胸罩结构的罩杯，以预定的方向排列。这些织物的层可以单独使用或者与其它缝制、胶粘或其它方式应用到织物上的材料结合使用。
在一些实施方式中，具有塑身衣结构的***，其具有由织物提供的整体的塑形能力。该结构体系可用于多种不同的服装结构例如健身服(activewear)、运动服、男女贴身衣服比如胸罩、内衣、衬裤、塑身衣、袜类(legwear)和针织袜类(hosiery)例如裤袜，其中现成的衣服如粗布牛仔、贴身女背心(camisole)、裁制衬衫和裤子。该结构可用于任何可成形身体区域。在包括很多织物结构的优点的同时，也进一步认为其用途不仅限于衣服，而且可发现其可用于任何可成形的或成型的介质，包括家具垫，其也承受与可成形区域相接触的织物的移动和潜在的滑动。
为了增加额外的支撑和其它性能，可将聚烯烃组合物加入到制品的不同区域。例如当使用膜时，其可以延展遍布制品的整个区域或者到所选定的部分以提供不同的有益效果。例如，胸罩在罩杯部分可以包括一些实施例中的成层的织物。在胸罩罩杯中，有利的是使用部分的膜在罩杯的下部来提供支撑、在罩杯的中部提供约束(modesty)、在侧面部分提供塑形、或在特定部分提供修饰或装饰。
为满足织物的需要减少多层织物中薄膜的含量，也可以增强织物透气性。也可以通过改变该薄膜使其多孔或成为多孔性(即“潜在的”透气性)或通过将薄膜穿孔增加其透气性。
当用于衣服时聚烯烃组合物带来更多的益处。这些益处包括外形保持性、塑形性、粘合性、保护(maintain)部分基底、湿度调节、和透湿性。
根据所需的可以是视觉美学的功能将聚烯烃组合物添加到其它结构中。可以将聚烯烃膜、无纺织物、粉末、分散粉剂或熔体加入到制品、织物或衣服上模制成图案，以粘结标签或标志形式的装饰，例如装饰织物和亮片，以及它们的组合。
在一些实施例中，聚烯烃组合物可作为胶粘剂粘结两个或多个织物层或泡沫层，或将织物层粘结到泡沫层。实现这些的一个恰当方法就是通过任何适当的方法将粉末或分散粉剂或熔体施加到到某层上。一些实施方式中用于施加分散体的方法包括喷雾、轻触、印刷、刷涂、浸渍、填充(padding)、分散、计量(metering)、漆涂、喷洒和它们的组合。也可以接着施加热和/或压力。
本发明一些实施方式中的多层制品可以包括其它胶粘剂。胶粘剂例如包括热固性或热塑性胶粘剂、压敏胶粘剂、热熔胶粘剂、和它们的组合。胶粘剂可用于粘结不同的层，并且可施加于任何织物、泡沫或聚烯烃膜、无纺织物、粉末、分散粉剂、或熔体。另外，聚烯烃组合物也可以用做与一层或多层接触的胶粘剂，该一层或多层例如是任意的织物、泡沫或聚合物膜，例如美国专利US7240371中所述的聚氨酯脲膜。
如上所述，有多种织物结构可用于本发明的制品。在该制品中包括的聚烯烃组合物可以是在这些实施方式中的任何一个中的任何适当的形式。另外，该聚烯烃组合物可以提供结构性、柔韧性、粘结性、或它们的任何组合。这些层排列的顺序可以是(1)织物层、泡沫层、聚烯烃层；(2)织物层、泡沫层、聚烯烃层、泡沫层、织物层；(3)织物层、聚烯烃层、织物层；(4)泡沫层、聚烯烃层、泡沫层；(5)泡沫层、聚烯烃层；(6)织物层、聚烯烃层；或可组合以在织物结构中实现更多层的这些层的任何组合。可包括的胶粘剂与所述层相邻或所述在层之间以粘结任意的所述层。可选的，该聚烯烃组合物也可以是胶粘剂。
多种不同的纤维和纱可与一些实施方式中的织物一起使用。这些包括棉、毛、丙烯酸类、聚酰胺(尼龙)、聚酯、斯潘德克斯(弹性)、再生纤维素、橡胶(天然的或合成的)、竹、丝、大豆或它们的组合。
本发明也可以提供成形制品，其可以是带粘性的或可以是不带粘性的，其可以涂覆在脱膜纸上，本发明的聚烯烃组合物藉此可用来粘结并且层压到包括纺织织物的基底上。可以通过在基底上施加热和/或压力促进粘合，并且胶粘剂膜的停留时间(residence time)少于1分钟，例如从大约15秒到大约60秒。这种粘结的制品因此具有良好的拉伸/回复性能，并且预计在正常的损耗和洗涤周期内比较耐用。
一些实施例中的聚烯烃组合物尤其适用于粘性(adhesvie)成形制品，当在比较短的时间内施加热和压力时，其可用于织物粘接、层压、和粘结目的。根据所用的粘结方法，压力例如可以在大约大气压力到大约60psi的范围，及时间可以在少于大约1秒到大约30分钟。
这种成形制品可以通过以下过程制得：通过市场可获得的工艺，将熔体或分散粉剂浇铸到脱膜纸上并且在低于大约100℃的温度下干燥除去水份，以在纸上形成膜。成形的膜片层可以被切割成所需宽度的条并且卷绕成线轴，以在后序应用中用来成形拉伸制品，例如纺织织物。这种应用的例子包括：无缝合或无接缝服装结构；接缝密封和增强；粘接于衣服的标签和补缀；和局部的拉伸/回复增强。粘合粘接可以在从大约100℃到大约200℃，例如从大约130℃到大约200℃，如从大约140℃到大约180℃的温度范围内，在0.1秒到几分钟，如少于大约1分钟的时间段内进行。典型的粘接机器是Sew Free(可从英国Leicester的SewSystems获得)、Macpi缝边机(可从意大利Brescia的Macpi集团获得)、Framis热气焊机床(可从意大利Milano的意大利Framis Italy，sp.a获得)。当在纺织织物服装中受到重复磨损、冲洗和拉伸时，认为这种粘结是坚固和耐用的。
该膜、无纺织物、熔体或成形制品可以被着色或上色，并且也可以用作在那方面的设计元素。
另外，还可以模制带有层压膜或无纺织物的制品。例如，织物可以在适合织物中的硬纱的条件下模制。也可以在模制成形制品或分散体的温度下进行模制，但要在适合模制硬纱的温度以下的温度。
可以采用层压以确保使用任何方法将成形制品固定到织物，其中向层压件(laminate)表面施加热。热施加的方法包括，例如超声波、直接加热、间接加热和微波。
一些实施方式中施加聚烯烃组合物的方法和装置包括但不仅限于：辊涂(包括逆辊涂布(reverse roll coating))；使用金属工具或刀片(例如浇铸分散体到基底上，并且通过利用金属工具例如刀片将分散体涂覆遍布到基底面上，使其浇铸为均匀的厚度)；喷雾(例如，使用泵式喷雾瓶)；浸渍；漆涂；印刷；冲压(stamping)；和喷洒；浸透(impregnating)该制品。这些方法可用于将熔体、粉末、或分散粉剂直接施加到基底上，而不需另外的胶粘剂材料，并且如果需要附加的/更重的层，其可以重复。分散体、粉末或熔体可施加到由合成、天然或合成/天然混合材料制成的任何针织、机织或无纺织物上用于涂覆、粘结、层压和粘合目的。分散体中的水可以在处理过程中随着干燥而除去(例如，通过风干或使用烘箱)，留下在织物上的沉淀和凝结的聚烯烃层以形成胶粘粘结。
膜、熔体、溶液和分散体的厚度可以根据应用而改变。在干的成形制品的情况下，最终厚度的范围可以是，例如从大约0.1mil到大约250mil，如从大约0.5mil到大约25mil，包括从大约1mil到大约6mil(1mil＝千分之一英寸)。
合适的厚度包括大约0.5mil到大约12mil，大约0.5mil到大约10mil，和大约1.5mil到大约9mil。对于水性分散体，所用的量的范围可以是，例如从大约2.5g/m2到大约6.40kg/m2，例如从大约12.7到大约635g/m2，包括从大约25.4到大约152.4g/m2。
可以用聚烯烃组合物涂覆的平面片材和带材(tape)包括但不仅限于，纺织织物，包括机织织物和针织织物；无纺织物；稀松布(scrim)和皮革(天然的或合成的)，纸，金属，塑料，聚氨酯脲膜，和它们的组合。
在一些实施方式中可用聚烯烃组合物制造的其它制品包括但不仅限于：服装，其包括任意形式的服装或衣服制品；针织手套；室内装饰(upholstery)；头饰；床单；毯子和毯子背衬(carpet backing)；输送带；医学应用如拉伸绷带；私人护理物品，包括失禁和妇女卫生用品；和鞋类。涂覆有聚烯烃组合物的制品可用于噪声抑制产品。
压到聚烯烃组合物上的非弹性织物可以具有改善的拉伸和回复性能以及改进的成型性能。
可以模制一些实施方式中的聚烯烃组合物的制品。该制品可用基底和聚烯烃组合物的多层制作。也可模制多层制品。模制制品和非模制制品具有不同的拉伸和回复水平。模制制品可用于塑身或保持形体的衣服(body supportinggarment)，如胸罩。
一些实施方式中可使用聚烯烃组合物生产的服装或衣服的例子包括但不仅限于：内衣、胸罩、衬裤、女士内衣、泳衣、塑形衣、贴身女背心、针织袜类、睡衣、潜水衣、领带(tie)、抹布(scrub)、太空服、制服、帽子、吊袜带、吸汗带、腰带、健身服、外衣、雨衣、冷天夹克、裤子、衬衫衣料、连衣裙、罩衫、男上装和女上装、毛衣、女士紧身胸衣(corset)、背心、灯笼裤、短袜、及膝袜、连衣裙、罩衫、围裙、无尾夜礼服、男罩袍(bisht)、长袍(abaya)、盖头(hijab)、头巾(jilbab)、***大袍(thoub)、斗篷(burka)、披风、戏服(costume)、潜水服、苏格兰式短裙、和服、运动套衫、女士礼服(gown)、防护服、纱丽、纱笼、裙子、鞋罩(spat)、斯托拉(stola)、套装、紧身拘束衣(straitjacket)、礼服(toga)、紧身衣、毛巾、制服、面罩、潜水衣、医学压力衣、绷带、西服衬料、腰带、和所有其中的组件。
本发明的另一方面是包括成形制品和基底的制品，其中成形制品和基底相结合以形成层压制品，由此弹性层压制品的摩擦系数比单独的基底要大。例如，具有包括聚烯烃组合物的涂层或膜的腰带，其中聚烯烃组合物防止衣服与另一件衣服如罩衫或衬衣的滑动，或者另一方面，防止了腰带在衣服穿戴者的皮肤上的滑动。
以下说明性实施例进一步介绍了本发明的特征和优点，但本发明不以任何方式仅限于此。
实施例
表1中所列的各个聚烯烃组合物包含在胸罩的一个半模中，提供给在相同条件下同时模制的对比罩杯和发明罩杯(其包括聚烯烃组合物)。通常的泡沫胸罩罩杯模制装置要加热到180℃。将尼龙
Figure GPA00001127524100091
斯潘德克斯弹性纤维经编织物预层压到5mm厚的聚氨酯泡沫片材上，形成织物/泡沫材料层压件。两个这种织物/泡沫层压件以泡沫-对-泡沫方式放置，织物层面向外。四个聚烯烃组合物实例中的每一个，依次***到泡沫层中间并且覆盖该模具的一半，即一个罩杯。在5巴的压力下闭合模具并保持闭合120秒。然后打开模具并移去模制罩杯，并允许冷却。
评估成套的试验/对比罩杯(形状、外形保持性、高度、平滑度、和触感)。然后对罩杯实施5个家庭洗涤周期。再次评估该罩杯。试验结果如表2所示。
Figure GPA00001127524100092
由表2可以看出，包括聚烯烃组合物的本发明的层压结构证明了优于对比件的改进的性能。
虽然本发明已经举例说明，但要知道所用的术语倾向于自然词汇或描述而没有限制。另外，虽然本发明已经根据多个实施方式说明，但可以理解本领域技术人员还易于将其教导用于本发明的其它可能的改变。

Claims (25)

1.包括多层的制品，该多层包括至少两层，其中所述层包括至少一种选自膜、无纺织物、粉末、熔体、分散粉剂、和它们的组合的聚烯烃组合物。
2.权利要求1的制品，其中所述聚烯烃组合物由聚烯烃熔体浇铸而成。
3.权利要求1的制品，其中所述聚烯烃组合物位于至少两层之间。
4.权利要求1的制品，其中所述的至少两层选自织物层、泡沫层、聚合物膜层、纤维层、和它们的组合。
5.权利要求1的制品，其中所述的至少两层包括至少两个织物层和至少两个泡沫层。
6.权利要求5的制品，其中聚烯烃组合物与泡沫层的每一面相邻，且每个泡沫层相邻于织物层。
7.权利要求1的制品，其中制品为模制或压制。
8.权利要求1的制品，其中该聚烯烃组合物延展遍及到该多层制品的整个区域。
9.权利要求1的制品，其中该聚烯烃组合物延展遍及到该多层制品的部分区域。
10.权利要求1的制品，其中包括至少两种聚烯烃组合物。
11.权利要求1的制品，其中所述的聚烯烃组合物是多孔的或穿孔的。
12.权利要求1的制品，该制品呈服装的形式。
13.权利要求4的制品，在两个或多个层之间进一步包括至少一种胶粘剂。
14.权利要求13的制品，其中所述的胶粘剂是热熔胶粘剂，接触型胶粘剂，热固性、热塑性塑料、或聚氨酯脲水性分散体。
15.包括多层的制品包括：
(a)至少两层；和
(b)选自熔体、溶液、分散粉剂、和它们的组合的聚烯烃组合物。
16.权利要求15的制品，其中所述的聚烯烃组合物是胶粘剂。
17.权利要求15的制品，其中所述的聚烯烃组合物位于层之间。
18.权利要求15的制品，其中所述至少两层选自织物层、泡沫层、聚合物膜层、纤维层、和它们的组合。
19.权利要求15的制品，其中该聚烯烃组合物被喷洒到层上。
20.权利要求15的制品，进一步包括服装。
21.制品，包括：
(a)至少两层；和
(b)至少一种选自膜、无纺织物、熔体、溶液、分散粉剂、和它们的组合的聚烯烃组合物；
其中所述的聚烯烃组合物在所述的至少两层之间被层压，并且所述的制品已经被模制。
22.权利要求21的制品，其中所述的至少两层选自织物层、泡沫层、聚合物膜层、纤维层、和它们的组合。
23.权利要求21的制品，进一步包括选自熔体、溶液、分散粉剂、和它们的组合的附加聚烯烃组合物。
24.权利要求21的制品，其中所述制品是服装，并且所述聚烯烃组合物减少了服装和基底之间的相对移动。
25.权利要求21的制品，其中所述基底是皮肤。
CN2008801091299A 2007-09-28 2008-09-22 含有聚烯烃组合物的层压织物结构 Pending CN101918214A (zh)

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