CN1052766C - 含无纺和/或纺织废料中获得的回收纤维的无纺材料及制法 - Google Patents

含无纺和/或纺织废料中获得的回收纤维的无纺材料及制法 Download PDF

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CN1052766C
CN1052766C CN95115886A CN95115886A CN1052766C CN 1052766 C CN1052766 C CN 1052766C CN 95115886 A CN95115886 A CN 95115886A CN 95115886 A CN95115886 A CN 95115886A CN 1052766 C CN1052766 C CN 1052766C
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E·米尔丁
U·霍尔姆
G·拉莫斯
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Abstract

通过水缠绕一种纤维网来产生的无纺材料，所述纤维网包括纤维长度为5-60mm、细度为0.1-20分特的回收纤维，构成该网的纤维是机械地从无纺废料、纺织废料或类似物中分离出的，并且该纤维在一个湿法成形、发泡成形、空气成形或干法成形的纤维网中相互混合并且可能的话与新的纤维混合，用足够的能量对纤维网进行水缠绕来形成一种致密的吸收材料。

Description

含无纺和/或纺织废料中获得的回收纤维的无纺材料及制法
本发明涉及一种通过水缠绕(hydroentangling)纤维网来生产的无纺材料。
水缠绕或射流喷网成布法是一种在70年代产生的技术，例如见加拿大专利第841,938号。这种方法涉及在纤维缠绕后，即通过高压下很细小的水射流缠绕在一起后，用干法成网或湿法成网形成一个纤维网。一排排水射流被引向由一个移动的丝网(网筛)支撑的纤维网上。然后干燥缠绕的纤维。用于该材料中的该纤维主要由聚酯、人造丝、尼龙、聚丙烯和类似物的人造纤维、纸浆纤维或纸浆纤维和人造纤维的混合物构成。射流喷网法无纺材料的生产成本低并且有很高的吸水性。特别是可用作家务或工业使用的干燥材料并在健康保健等领域中作为可处理的材料。
增强的环境意识使得必然会越来越注意节约使用我们的原料和能源等的自然资源。由收集用过的纸和织物来回收纸纤维对公益收集已经很长时间了，并且今天已用于商业使用，来生产新的功能很好的产品。
例如射流成网型无纺废料可以通过将熔化成可用于生产新的人造纤维的塑性颗粒来回收。这是假设该废料是由相对“干净”的基于热塑性人造纤维的人造材料构成的。一个例子是从瓶中回收聚酯，来生产用于地毯生产的聚酯纤维。
还已知机械地破碎无纺和纺织废料并使用该分离的回收纤维。在这种情况下，可以使用既包括人造纤维也包括天然纤维的混合废料。通过热接合、针缝或粘接可从回收的纤维中生产例如用于隔音、过滤器和地膜织物(geotextile)的新材料。
然而，目前大量的来自无纺制造的生产废料被作为填筑物而倾倒或作为废品被焚烧掉。这种生产废料来源于材料网的切边、开头废料和由于各种原因被废弃的材料。往无纺废料中加入已用过的材料以及生产废料。
本发明的目的是获得一种具有好的吸收特性和在其它方面具有好的质量的无纺材料以及提供该无纺材料的制备方法。这里利用了上述类型的回收纤维。该目的通过本发明来解决，其中材料包括纤维长度在5-60mm之间且细度为0.1-20分特之间的回收纤维，而且它是由从无纺废料、纺织废料或类似物中经机械分离的纤维构成的，该纤维在湿成型、发泡成型、空气成型或干成型纤维网中互相混合或可与新的纤维混合，用足够的能量对其水缠绕以便形成致密的吸收性材料。因此，该纤维混合物湿法成形，发泡成形、空气成网或干燥成网成为纤维网，水缠绕该纤维网并成为一种致密吸收材料的形式。
回收的纤维可由人迁纤维、植物纤维、再生纤维素纤维或纸浆纤维构成。
另外，通过浸渍、喷涂、涂敷或类似方法来加入适当的粘接剂，可额外地改进一定的材料特性例如材料的湿强度和干强度。
用于回收纤维的原料纤维可部分地由以整边废料、开头废料形式的生产废料和其它不用的废弃材料构成。它也可以由其它的已用过的纤维材料例如无纺和纺织(纺织和针织)材料的形式的废料构成，这种材料需要根据其污染的程度进行一定的清洁处理。通过机械破碎废料并由此将该材料切成小块再用带尖的滚刀撕碎以便将纤维分解，来回收纤维。在这种情况下废料可由混合物材料构成，它不仅包括不同类型例如纸浆纤维、棉织品、黄麻纤维、苎麻等天然纤维，也包括例如聚酯、聚丙烯、再生纤维素等人造纤维。用于从无纺和织织材料中机械回收纤维的设备，可从许多不同的供应商中商业获得。
回收纤维可与新的天然和/或人造纤维混合并形成可通过干法成网、空气梳理成网、湿法成网或发泡成网获得的纤维网，发泡成网是将纤维分散于含有表面活性剂和水的发泡液体中然后将纤维分散体在一个线(网)上脱水。回收纤维的含量可为1-100％重量，最好至少为5％。然后这样形成的纤维网通过输入能量进行水缠绕，输入的能量在400到800KW/ton之间选定。水缠绕可通过现有技术并用机器制造商提供的设备来实现。在瑞典专利申请号9402470-0中描述的方法是一种较好的生产这种材料的方法，即一种发泡成形的纤维网在成形后直接水缠绕。发泡成形方法优点是可以选择很多种类的纤维，使得用发泡成形比用湿法成形可使用更长的纤维。另外，发泡成形的纤维网在纤维成形中具有高度的一致性。然而，如上所述，除了发泡成形外，该纤维网可由其它方法成形。
用机械撕扯废物材料，纤维的分离通常是不完全的，使得回收的纤维能部分地为絮片形式。这些絮片在产生的材料中显出不均匀性，它具有一定的积极效果，即材料更具有织物的外观，在该材料用作干燥材料的情况下，由于非均匀性产生的机械摩擦效果而增强了材料的清洁能力。然而一个负效果就是，在材料中的非均匀性可导致其强度降低。对于强度是重要的应用，其强度可通过附苯乙烯、胶乳等来加强。粘合剂的加入可以一种已知的方法通过浸渍、喷涂、涂覆等方式来实现。添加剂的恰当量以材料重量份计为0.1-10％重量，最好为1-5％重量。
如上所述，回收纤维可与新纤维混合。例如一种适当的方法为，使用来自其本身的例如喷网材料的无纺废料，经过撕碎并从这种生产废料中分离出纤维并将一定量的回收的纤维混入原料纤维中。这种方法的优点是回收的纤维与其它原料纤维的组成是相同的，它保证了生产的材料具有同一的质量。然而，如上前述，回收的纤维可由其它无纺和纺织废料构成，而且生产的材料或者可以全部地或者可以仅仅部分地来源于回收的纤维。
这种生产的材料主要是作为用于家庭和如车间、工业、医院和其它公共团体等之类的众多消费者的干燥材料。
生产并测试几种不同的具有各种含有回收纤维量的材料，由此与一种用100％新纤维生产的参考材料进行比较。新的纤维由60％的针叶树浆+40％的人造纤维(PP+PET)1.7分特×12mm的混合物构成。废料是由从包括纸浆、聚酯(1.7分特×12mm)和人造丝纤维(1.7分特×6mm)的混合物的射流喷网无纺废料中机械地回收的纤维构成的。纤维网是通过湿法成形或发泡成形来产生的，然后用大约600KWh/ton进行水缠绕，通过直吹进行轻压并且干燥。以相应于按照材料总重量的2％重量的干燥品的量在一定的材料中加入一种聚酰胺—表氯醇类的湿强剂(B)。在下面的表中给出了材料的特性。
                                表1
特性 单位 方法 100％新纤维 10废料 50％废料+2％B(+48％新纤维) 25％废料+2％B(+73％新纤维) 98％新纤维+2％B
表面重量厚度 g/m2μg SCAN-P6：75SCAN P-47：83 80420 83490 79400 86420 85450
拉伸强度 干L拉伸强度 干T N/mN/m SCAN-P 38：80SCAN-P 38：80     1400650     650460     1450640     1960930     2320760
拉伸强度 湿L拉伸强度 湿T N/mN/m SCAN-P 58：86SCAN-P 58：86     660320     250170     640320     950480     1130330
吸水性   5秒吸水性   总量 g/gg/g SIS 25 12 28*)SIS 25 12 28*)     3.84     4.14.1     3.83.8     3.94     4.14.1
可以总结出，用100％不附加粘合剂的废料纤维生产的材料比参考材料具有明显低的强度，同时吸收能力大致与参考材料相等。对于加入附加粘合剂并混入50％的废料纤维，所获得的材料与参考材料相同，而混入25％废料纤维所获得的材料在干强度和湿强度上均好于参考材料。

Claims (12)

1.通过水缠绕一种纤维网产生的无纺材料，其特征在于它包括纤维长度为5-60mm、细度为0.1-20分特的回收纤维，回收纤维由被机械地从无纺废料、纺织废料或类似物中分离出的纤维混合物构成，而且该纤维混合物湿法成形、发泡成形、空气成网或干燥成网成为纤维网，水缠绕该纤维网并成为一种致密吸收材料的形式。
2.如权利要求1的无纺材料，其特征在于湿法成形，发泡成形、空气成网或干燥成网纤维网包括新纤维。
3.如权利要求1的无纺材料，其特征在于回收纤维是由人造纤维、植物纤维、再生纤维素纤维或纸浆纤维构成。
4.如权利要求3的无纺纤维，其特征在于一定比例的回收纤维不是完全分离，而是形成在该材料中保持非均匀性的絮片。
5.如任一前面的权利要求的无纺材料，其特征在于该材料中一定比例的回收纤维高达1-100％。
6.如权利要求5的无纺材料，其特征在于通过喷涂、浸渍、涂覆等来向材料中加入湿强剂或粘合剂。
7.如权利要求6的无纺材料，其特征在于湿强剂或粘合剂的比例高达0.1-10％重量。
8.如权利要求7的无纺材料，其特征在于湿强剂或粘合剂的比例高达1-5％重量。
9.生产如权利要求1的无纺材料的方法，其特征在于纤维网是通过湿法成形、发泡成形、干法成形或空气成形法形成的，所述网包括1-100％纤维的长度为5-60mm、细度为0.1-20分特的回收纤维，回收纤维由通过机械撕碎无纺废料、纺织废料或类似物而分离出来的纤维构成，而且通过对该纤维网进行水缠绕并且随后干燥该材料而形成一种缠绕纤维的致密吸收材料。
10.如权利要求9的方法，其特征在于无纺废料是由生产废料和/或其它无纺材料或纺织废料构成的，将它撕碎，然后使其形成所述纤维网。
11.如权利要求10的方法，其特征在于，撕碎的无纺废料在使其形成所述纤维网之前与新纤维混合。
12.如权利要求9，10或11的方法，其特征在于在水缠绕后，通过喷涂、浸渍、涂覆的方法来向材料中加入湿强剂或粘合剂。
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