CN103835070A - 吸湿用不织布及其制法 - Google Patents

吸湿用不织布及其制法 Download PDF

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CN103835070A
CN103835070A CN201210546663.4A CN201210546663A CN103835070A CN 103835070 A CN103835070 A CN 103835070A CN 201210546663 A CN201210546663 A CN 201210546663A CN 103835070 A CN103835070 A CN 103835070A
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nonwovens
moisture absorption
fiber
polyethylene
fibre
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戴荣吉
杨合喜
苏建仲
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Kang Na Hsiung Enterprise Co Ltd
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Abstract

本发明是有关于一种吸湿用不织布，包含多条长度范围为10mm至76mm的长纤维、多条长度范围为1mm至10mm的具有热熔黏着性的复合短纤维，及多条纤维素纤维，该些纤维实质相互纠结。本发明通过使用具有热熔黏着性的复合短纤维及纤维素纤维，可降低以往吸湿用不织布的原料成本，并可提升其机械性质(如抗张强度及伸长率)及吸收率。

Description

吸湿用不织布及其制法
技术领域
本发明涉及一种吸湿用不织布，特别是涉及一种包含长纤维、短纤维及纤维素纤维的吸湿用不织布。
背景技术
纸巾是日常生活必需用品，用来擦拭并移除物体表面附着的污渍。一般纸巾可分为干纸巾及湿纸巾，但不论是干纸巾或湿纸巾皆需满足柔软性、抗张强度(tensile strength)、吸收率以及表面需平滑柔顺等特性。
以往的纸巾大都是将两层纤维网经水刺(water-jet)法所形成。该纤维网是由多条平均长度范围为10mm至76mm的长纤维经梳理(carding)处理所形成，且该长纤维为化学纤维。然，该纸巾完全使用化学纤维来制备，因化学纤维成本高，会导致所制得的纸巾原料成本高，不符合业者的成本效益。
TW182129专利公告案揭示一种高韧性柔湿巾。该高韧性柔湿巾包括两片擦拭层，及夹置于该些擦拭层间的吸湿层。该些擦拭层与吸湿层利用热轧法进行结合。该些擦拭层分别是由长度范围为1.25mm至5mm的木棉树种纤维所形成，且该吸湿层是将50wt%的嫘萦(rayon)人造纤维棉与50wt%的聚丙烯纤维混合并经由热风法所形成。然，该吸湿层使用的嫘萦(rayon)人造纤维棉成本高，且使用热风法所制得的高韧性柔湿巾会扁平且较硬。
有鉴于上述，提供一种更加柔软且成本低的纸巾，是此技术领域相关技术人员可再突破的课题。
发明内容
本发明的第一目的在于提供一种成本低、机械性质(如拉张强度及伸长率)佳，且吸收率佳的吸湿用不织布。
本发明的第二目的在于提供一种吸湿用不织布的制备方法。
本发明的目的及解决其技术问题是采用以下技术方案来实现的。本发明吸湿用不织布，包含：
多条长度范围为10mm至76mm的长纤维；
多条长度范围为1mm至10mm的具有热熔黏着性的复合短纤维；及
多条纤维素纤维，该些纤维实质相互纠结。
本发明的目的及解决其技术问题还可采用以下技术措施进一步实现。
较佳的，前述的吸湿用不织布，其中该长纤维的材质包括至少一种下列材料所组成的群组：聚乙烯、聚丙烯、聚对苯二甲酸乙二酯、嫘萦，及棉纤维。
较佳的，前述的吸湿用不织布，其中该具有热熔黏着性的复合短纤维是选自于聚乙烯-聚丙烯纤维、聚乙烯-聚对苯二甲酸乙二酯纤维、低温聚乳酸-高温聚乳酸纤维、经马来酸酐改质的聚乙烯-聚丙烯纤维、经马来酸酐改质的聚乙烯-聚对苯二甲酸乙二酯纤维，或它们的组合。
较佳的，前述的吸湿用不织布，其中以该吸湿用不织布的总量为100wt%计，该些纤维素纤维的使用量总和范围为5wt%至60wt%。
较佳的，前述的吸湿用不织布，其中以该吸湿用不织布的总量为100wt%计，所述具有热熔黏着性的复合短纤维的使用量总和范围为1wt%至20wt%。
较佳的，前述的吸湿用不织布，其中该纤维素纤维的长度范围为1mm至5mm。
本发明的目的及解决其技术问题是采用以下技术方案来实现的。本发明吸湿用不织布的制备方法，包含以下步骤：
(a)提供混合纤维，包含多条长度范围为1mm至10mm的具有热熔黏着性的复合短纤维与多条纤维素纤维；
(b)将该混合纤维进行气流成网处理及热处理，形成混合纤维布；
(c)提供两张长纤维网，该些长纤维网是由多条长度范围为10mm至76mm的长纤维的混合物经由梳理处理所形成；
(d)将该混合纤维布置于该些长纤维网间，并进行水刺处理，即可获得吸湿用不织布。
本发明的目的及解决其技术问题还可采用以下技术措施进一步实现。
较佳的，前述的吸湿用不织布的制备方法，其中以该吸湿用不织布的总量为100wt%计，所述纤维素纤维的使用量总和范围为5wt%至60wt%。
较佳的，前述的吸湿用不织布的制备方法，其中以该吸湿用不织布的总量为100wt%计，所述长纤维的使用量总和范围为10wt%至80wt%。
借由上述技术方案，本发明的有益效果在于：相较于以往仅使用长纤维制成的纸巾用不织布，本发明通过使用具有热熔黏着性的复合短纤维及纤维素纤维，取代部分长纤维，可降低以往吸湿用不织布的原料成本，并可提升其机械性质(如拉张强度及伸长率)及吸收率；且本发明制法可于一条生产线中结合气流成网处理、热处理、梳理处理以及水刺处理而制得吸湿用不织布。
上述说明仅是本发明技术方案的概述，为了能够更清楚了解本发明的技术手段，而可依照说明书的内容予以实施，并且为了让本发明的上述和其他目的、特征和优点能够更明显易懂，以下特举较佳实施例，并配合附图,详细说明如下。
附图说明
无
具体实施方式
为更进一步阐述本发明为达成预定发明目的所采取的技术手段及功效,以下结合附图及较佳实施例，对依据本发明提出的一种吸湿用不织布及其制法的具体实施方式、结构、特征及其功效，详细说明如后。
本发明吸湿用不织布，包含：
多条长度范围为10mm至76mm的长纤维(filament fiber)；
多条长度范围为1mm至10mm的具有热熔黏着性的复合短纤维(staplefiber)；及
多条纤维素纤维，该些纤维实质相互纠结。
该吸湿用不织布的基重范围为20g/m2至120g/m2。该吸湿用不织布的厚度范围为0.1mm至5mm。
本发明吸湿用不织布可做为或应用在纸巾(paper towel)、面膜或护垫等上。
以下将分别针对本发明吸湿用不织布中的各个成分进一步说明：
[长纤维]
该些长纤维选自于天然纤维、化学纤维，或它们的组合。该天然纤维选自于植物纤维、动物纤维，或它们的组合。该植物纤维可单独或混合使用，且该植物纤维例如但不限于种子纤维(如棉花等)、韧皮纤维(如亚麻或***等)、叶脉纤维(如马尼拉麻等)或果实纤维(如椰子)等。该动物纤维可单独或混合使用，且该动物纤维例如但不限于兽皮纤维或蚕丝纤维等。该化学纤维选自于再生纤维、半合成纤维、合成纤维，或它们的组合。该再生纤维可单独或混合使用，且该再生纤维例如但不限于嫘萦(rayon)等。该半合成纤维可单独或混合使用，且该半合成纤维例如但不限于醋酸纤维素等。该合成纤维可单独或混合使用，且该合成纤维例如但不限于聚乙烯(polyethylene，简称PE)、聚丙烯(polypropylene，简称PP)、聚对苯二甲酸乙二酯(polyethylene terephthalate，简称PET)，或聚酰胺(polyamide)等。以该吸湿用不织布的成本考量，较佳地，该些长纤维的材质包括至少一种由下列材料所组成的群组：聚乙烯、聚丙烯、聚对苯二甲酸乙二酯、嫘萦及棉纤维。
较佳地，以该吸湿用不织布的总量为100wt%计，该些长纤维的使用量总和范围为10wt%至80wt%。该些长纤维的细度范围为1丹尼(dyne)至6丹尼。
[具有热熔黏着性的复合短纤维]
该具有热熔黏着性的复合短纤维具有热熔粘着的能力，可将彼此相邻的纤维素纤维连结在一起，可避免该些纤维素纤维经水刺处理后而流失，继而造成吸湿用不织布的吸湿率不佳的问题产生，以及造成后续废水处理困难，继而增加废水处理成本。
该具有热熔黏着性的复合短纤维选自于聚乙烯-聚丙烯纤维、聚乙烯-聚对苯二甲酸乙二酯纤维、低温聚乳酸-高温聚乳酸纤维、经马来酸酐改质的聚乙烯-聚丙烯纤维、经马来酸酐改质的聚乙烯-聚对苯二甲酸乙二酯纤维，或它们的组合。在本发明的具体实施方式中，该些具有热熔黏着性的复合短纤维为聚乙烯-聚丙烯纤维。
较佳地，以该吸湿用不织布的总量为100wt%计，该些具有热熔黏着性的复合短纤维的使用量总和范围为1wt%至20wt%。该些具有热熔黏着性的复合短纤维的细度范围为1丹尼至6丹尼。
[纤维素纤维]
较佳地，以该吸湿用不织布的总量为100wt%计，该些纤维素纤维的使用量总和范围为5wt%至60wt%。该些纤维素纤维的细度范围为0.1丹尼至10丹尼。较佳地，该些纤维素纤维的长度范围为1mm至5mm。
该纤维素纤维的制备方法可采以往的方式，例如，从纸浆(pulp)或木浆(wood pulp)所获得。
[吸湿用不织布的制备]
本发明吸湿用不织布的制备方法，包含以下步骤：
(a)提供混合纤维，包含多条长度范围为1mm至10mm的具有热熔黏着性的复合短纤维与多条纤维素纤维；
(b)将该混合纤维进行气流成网(air-laid)处理及热处理，形成混合纤维布；
(c)提供两张长纤维网，该些长纤维网是由多条长度范围为10mm至76mm的长纤维的混合物经由梳理(carding)处理所形成；
(d)将该混合纤维布置于该些长纤维网间，并进行水刺(water-jet)处理，即可获得吸湿用不织布。
该具有热熔黏着性的复合短纤维、纤维素纤维及长纤维如上所述，所以不再赘述。较佳地，以该吸湿用不织布的总量为100wt%计，该长纤维的使用量总和范围为10wt%至80wt%。较佳地，以该吸湿用不织布的总量为100wt%计，该纤维素纤维的使用量总和范围为5wt%至60wt%。
该气流成网处理指的是利用气体(如空气)的气流，使混合纤维在气体中进行均匀分散，并吸附在网帘上，而形成混合纤维网。该气流成网处理可采用以往气流成网装置来进行。该气流成网处理的气流流量范围为100CMM至1,000CMM。
该热处理指的是让混合纤维彼此间连结在一起，达到固定的效果。该热处理可采用以往加热装置来进行。该热处理的操作温度范围为50℃至180℃。该混合纤维布的基重范围为5g/m2至100g/m2。该混合纤维布的厚度范围为0.1mm至10mm。
该梳理处理指的是将多条长纤维形成长纤维网的过程。该梳理处理可采用以往梳理装置来进行。该长纤维网的基重范围为5g/m2至100g/m2。该长纤维网的厚度范围为0.1mm至10mm。
该水刺处理指的是利用高压水流垂直射向该长纤维网，使该水流可将该些长纤维网中的长纤维与混合纤维布相互缠结而成的过程。该水刺处理可采用以往水刺装置来进行。
本发明将就以下实施例来作进一步说明，但应了解的是，该些实施例仅为例示说明用，而不应被解释为本发明实施的限制。
<实施例>
<实施例1>
将包含10wt%的多条平均长度为6mm的聚乙烯-聚丙烯短纤维与50wt%的纸浆混合，形成混合纤维，接着，将该混合纤维进行气流成网处理(气流流量为130CMM)及热处理(温度为135℃)，形成混合纤维布。
将20wt%的实心聚对苯二甲酸乙二酯长纤维，及20wt%的多条平均长度为38mm的4T聚对苯二甲酸乙二酯长纤维经由梳理处理形成一张长纤维网。
将该混合纤维布置于两张长纤维网间，并进行水刺处理(水压为50bar)，即可获得吸湿用不织布。
<实施例2至6及比较例1>
实施例2至6及比较例1分别是以与实施例1相同的步骤制作吸湿用不织布，不同的地方在于：改变长纤维材质、长纤维使用量、具有热熔黏着性的复合短纤维材质、具有热熔黏着性的复合短纤维使用量及纤维素纤维使用量，如表1所示。
【检测项目】
1.基重(Basis weight，g/m2)：
依据美国材料与试验学会(American Society for Testing and Materials,ASTM)编号D3776-85的检测标准在温度23±0.5℃、相对湿度65±2%，一般大气压力下，在电子天评量测试片质量，并计算试片单位面积质量。
2.抗张强度(tensile strength，Kgf/25mm)：
将实施例1至6及比较例1的吸湿用不织布剪裁为长度150mm及宽度25.4mm的试片，依ASTM D-1117规定进行测试，单位为Kgf/25mm。
3.伸长率(%)：
将实施例1至6及比较例1的吸湿用不织布剪裁为长度150mm及宽度25.4mm的试片，依ASTM D-1117规定进行测试，单位为%。
4.含水率(%)：
将实施例1至6及比较例1的吸湿用不织布秤重(W1)，接着，置于热风循环式烘箱内，在105±2℃温度下烘干约两小时，取出并放入干燥器中冷却20至30分钟后，再秤重(W2)，其含水率的计算方式如下：
含水率(%)=[(W1-W2)/W1]×100%。
5.吸收率(%)：
依据ISO 9073.6:2000纺织-不织布测试法。将七个尺寸规格为26cm×30cm×20cm的热风不织布袋子分别秤重(W1)，且将该些热风不织布袋子封口封好，并分别浸泡于纯水中5分钟，接着，取出后置于10网目的铁丝网上，自然滴漏1分钟，然后，分别秤重(W2)。
将实施例1至6及比较例1的吸湿用不织布秤重(W3)并分别置入该些热风不织布袋子中，且将该些热风不织布袋子封口封好，并分别浸泡于纯水中5分钟，接着，取出后置于10网目的铁丝网上，自然滴漏1分钟，然后，分别秤重(W4)，其吸收率的计算方式如下：
吸收率(%)={[W4-W3-(W2-W1)]/W3}×100%。
6.刚度(Stiffness)：
将实施例1至6及比较例1的吸湿用不织布分别剪裁为宽度为25mm且长度为250mm的试片，并分别置于23℃且相对湿度为50%下24小时，然后，依据ISO 9073.7:1995不织布抗张强度测试法、ASTM D-1117规定及使用柔软度试验机进行测试，单位为mN-cm。
测试方式为将该些试片徐徐向前移动，至该些试片下垂与45°斜面平行，记录向前移动的距离(cm)，纵向及横向各自的正面及反面分别进行六次测试，并将其平均，获得平均值(C，单位cm)，接着，以下公式计算求得刚性：
刚性(mN-cm)=基重(g/m2)×C×10-3(重力加速度为10/s2)。
表1
Figure BDA00002592677200071
由表1的实验结果可知，本发明使用具有热熔黏着性的复合短纤维及纤维素纤维来取代部分长纤维，相较于比较例1完全使用长纤维，本发明吸湿用不织布具有更佳的抗张强度、伸长率以及吸收率。
综上所述，相较于以往仅使用长纤维制成的纸巾用不织布，本发明通过使用具有热熔黏着性的复合短纤维及纤维素纤维，取代部分长纤维，可降低以往吸湿用不织布的原料成本，并可提升其机械性质(如拉张强度及伸长率)及吸收率。且本发明制法可于一条生产线中结合气流成网处理、热处理、梳理处理以及水刺处理而制得吸湿用不织布，所以确实能达成本发明的目的。
以上所述，仅是本发明的较佳实施例而已，并非对本发明作任何形式上的限制，虽然本发明已以较佳实施例揭露如上，然而并非用以限定本发明,任何熟悉本专业的技术人员，在不脱离本发明技术方案范围内,当可利用上述揭示的技术内容作出些许更动或修饰为等同变化的等效实施例,但凡是未脱离本发明技术方案的内容，依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与修饰，均仍属于本发明技术方案的范围内。

Claims (9)

1.一种吸湿用不织布，其特征在于包含：
多条长度范围为10mm至76mm的长纤维；
多条长度范围为1mm至10mm的具有热熔黏着性的复合短纤维；及
多条纤维素纤维，所述纤维实质相互纠结。
2.如权利要求1所述的吸湿用不织布，其特征在于：所述长纤维的材质包括至少一种下列材料所组成的群组：聚乙烯、聚丙烯、聚对苯二甲酸乙二酯、嫘萦，及棉纤维。
3.如权利要求1所述的吸湿用不织布，其特征在于：该具有热熔黏着性的复合短纤维是选自于聚乙烯-聚丙烯纤维、聚乙烯-聚对苯二甲酸乙二酯纤维、低温聚乳酸-高温聚乳酸纤维、经马来酸酐改质的聚乙烯-聚丙烯纤维、经马来酸酐改质的聚乙烯-聚对苯二甲酸乙二酯纤维，或它们的组合。
4.如权利要求1所述的吸湿用不织布，其特征在于：以该吸湿用不织布的总量为100wt%计，该些纤维素纤维的使用量总和范围为5wt%至60wt%。
5.如权利要求1所述的吸湿用不织布，其特征在于：以该吸湿用不织布的总量为100wt%计，所述具有热熔黏着性的复合短纤维的使用量总和范围为1wt%至20wt%。
6.如权利要求1所述的吸湿用不织布，其特征在于：所述纤维素纤维的长度范围为1mm至5mm。
7.一种吸湿用不织布的制备方法，其特征在于包含以下步骤：
(a)提供混合纤维，包含多条长度范围为1mm至10mm的具有热熔黏着性的复合短纤维与多条纤维素纤维；
(b)将该混合纤维进行气流成网处理及热处理，形成混合纤维布；
(c)提供两张长纤维网，所述长纤维网是由多条长度范围为10mm至76mm的长纤维的混合物经由梳理处理所形成；
(d)将该混合纤维布置于所述长纤维网间，并进行水刺处理，即可获得吸湿用不织布。
8.如权利要求7所述的吸湿用不织布的制备方法，其特征在于：以该吸湿用不织布的总量为100wt%计，所述纤维素纤维的使用量总和范围为5wt%至60wt%。
9.如权利要求7所述的吸湿用不织布的制备方法，其特征在于：以该吸湿用不织布的总量为100wt%计，所述长纤维的使用量总和范围为10wt%至80wt%。
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