CN1080342C - 低旦或亚旦非织造纤维状构造 - Google Patents
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Abstract
本发明涉及一种新型非织造材料,它具有非常高的弗雷泽透气性,同时具有相当高的抗液体渗透性。该材料由近似或低于1旦的纤维构成,该纤维具有不需要稀松布支持层的足够强度。该非织布由于透气性好因而感觉相当舒适,因具有特定的构造故而相当柔软,而且具有从防雨到防有害化学品等的防液保护作用。
Description
发明领域
本发明涉及非织造纤维状构造,更具体地说涉及由不经梭织或针织而结合成一体的纤维构成的透气性布料及片材构造。
发明背景
非织造纤维状构造已问世多年了,目前,已有许多不同的非织造技术付诸工业应用。为说明非织造技术包括的范围之广,纸恐怕要算最早开发的非织造纤维状构造的例子了。非织造技术还在继续寻求新的应用领域和扩大竞争优势。一个具有蓬松结构和更为经济,因而证明是倍受青睐的广阔市场就是防护服市场。这个市场包括用于诸如清理化学品跑冒滴漏时防止有害化学品的伤害、防止医用领域中诸如血液之类的液体沾污以及防止诸如涂漆及清除石棉时干颗粒及其他有害物质侵入的防护用品。许多相互竞争的技术正在争夺这一市场。
让我们先来看医用防护服市场,杜邦公司制造出Sontara射流喷网非织造布并广泛用作医用罩衣和布帘,还有医用领域中用于特定用途的Tyvek纺粘聚烯烃非织布。
Sontara射流喷网非织造布由于具有出众的性能和舒适性,长期以来被用于医护领域。医用防护服使用的Sontara射流喷网非织造布,就典型而言,包含短纤长度的聚酯纤维与木浆的水力缠结构造。这种非织布经过了拒水涂层整理,因而具有防湿透的能力。
Tyvek纺粘聚烯烃非织布作为医用包裹布特别有用,因为它提供诸如允许以包裹的形式接受消毒处理的宝贵优点。它还极少起毛,因而大大减少了手术室的污染。
在医用领域竞争的其他技术包括复合或层合产品。复合产品具有适合最终用途的均衡性能。一种颇具竞争力的技术是工业上通常称之为“SMS”的技术,意即纺粘/熔喷/纺粘。基本的SMS非织造材料公开在美国专利4,041,203,其进一步的改进公开在美国专利4,374,888及4,041,203中。其纺粘外层由提供强度的纺粘非织布组成,但它无法达到熔喷内层那样的抗渗性。制造熔喷纤维的技术极为适合制造细的低旦纤维,它具有阻断和透气性,但不适合用来获得适当的强度,经不起单独制成服装的使用。熔喷纤维网也公开在欧洲专利出版物EP-A-0674035中。
美国专利4,622,259及4,908,163涉及从改善熔喷纤维的抗张性能着手来改进SMS技术。通过提供更好的熔喷纤维,就可以避免采用稀松布增强材料,从而获得重量更轻的非织布。
本发明的一个目的是提供一种进一步改进的非织造构造,它具有更好地适应阻挡层最终用途的均衡性能。
本发明的另一个目的是提供一种阻断和透气性比目前已知的阻挡材料更好的非织造构造。
发明概述
本发明的上述及其他目的是由一种弗雷泽透气性至少约70m3/min-m2且无支持层静水压头至少约15厘米的柔性片材达到的。
本发明还涉及一种弗雷泽透气性至少约28m3/min-m2且无支持层静水压头至少约30厘米的柔性片材。
本发明还涉及一种弗雷泽透气性至少约15m3/min-m2且静水压头至少约40厘米的柔性片材。
本发明包括一种弗雷泽透气性至少约1m3/min-m2且静水压头至少约80厘米的柔性片材。
本发明的另一方面包括一种由熔纺非织造纤维组成的柔性片材,该纤维的平均长度至少约4厘米,绝大多数纤维的断面小于70平方微米且平均纤维强度至少是275N/mm2。
本发明的又一方面包括一种非织造纤维形成的柔性片材,其中该片材的单位重量至少约13克/平方米,最大约75克/平方米,基本上所有的纤维都是连续熔纺纤维,绝大部分(重量)纤维的断面小于约90微米,且该片材的弗雷泽透气性至少约1m3/min-m2,静水压头至少约25厘米。
本发明进一步涉及一种适用于制造热粘合非织布的辐射消毒稳定的皮芯型多组分纤维,其中芯聚合物是聚对苯二甲酸乙二醇酯,皮纤维是聚对苯二甲酸丙二醇酯。
附图简述
通过结合附图对本发明做详细的解释,本发明将会更容易理解。为此,下面附上一些特另适合用来解释本发明的附图;然而要知道,这些附图仅用于解释,不必用来界定。下面,简要说明附图:
图1是用于制造本发明织物的第一个优选实施方案的透视图;
图2是用于制造本发明织物的第二个优选实施方案的透视图;
图3是说明本发明新纤维的一种性能的曲线图;
图4是说明本发明新纤维的第二种性能的第二幅曲线图;
图5是说明本发明新纤维的第三种性能的第三幅曲线图;以及
图6是一种皮芯型双组分纤维的放大断面视图。
优选实施方案详述
现在来看附图,其中给出了数种可供制造本发明材料选择的技术。在图1中,画出了熔纺低旦纺丝***的第一个优选实施方案,整个***用数字10代表,用以制造连续的非织布卷。***10包括连续的输送带15,它沿一系列辊筒移动。输送带15在包括一个或多个纺丝箱体(spinning beams)的系列20下方沿大致水平的方向移动。每个箱体20中包含熔融聚合物并开有大量极细的小孔。聚合物经小孔挤出,在每个孔处形成一根纤维。该纤维优选有一定强度并抗收缩的硬化丝束纤维。就典型而言,硬化丝束纤维是通过对纺出后的纤维实施骤冷和牵伸,以便使纤维内的聚合物分子链取向而制成的。已发现,正如下面将要描述的,硬化丝束纤维也可借助高速纺丝制取。此种高速纺丝乃是获得适当纤维性能以及适当生产率,以便制造出价格有竞争力的织物的关键。
在有一定强度的纤维形成之后,该快速运动着的非常细的纤维随即被引导到移动的输送带15上。要做到这一点绝非易事,因为纤维数量巨大,而且它们极易受到附近的湍流风力的扰动。可设置适当的导向件,优选地包括空气挡板,以便在纤维无序地排列到输送带15上的时刻维持一定的控制。一种控制纤维的附加选择是让纤维带电,同时也许还可让输送带15带上相反的电荷,以便纤维一旦沉积下来便被吸牢在输送带上。随后,由纤维构成的网被粘合成一体,形成丝物。粘合可以通过任何合适的技术实现,包括热粘合或粘合剂粘合。虽然热空气粘合和超声波粘合不失为有吸引力的选择,但是优选的可能还要算使用图中所画的一对夹辊25与26的热粘合。又据知,对许多用途的片材可采用点粘合以提供类似织物样的手感,虽然对另一类最终用途,片材则优选用较为细腻的整理剂进行面粘合。当采用点粘合整理时,粘合图案及片材被粘部分的百分率应予以控制,以便限制纤维的脱出和起球以及满足其他方面的考虑。随后,将非织布卷绕在辊30上,以备贮存及按要求进行后续整理。
图2中表示出第二种制造本发明新材料的设备安排。在图2中,表示出一种湿法铺网的非织布成型***,整个***以数字代号50代表。湿法铺网***50包括沿一系列辊筒移动的多孔或网状带55。在网带55上方设有槽子60,向网带上沉积由液体与不连续纤维组成的淤浆。随着淤浆跟随网带55移动,液体经网带55上的开孔不断漏下并进入集液盘61(也称作收集槽)。纤维无序地排列并在夹辊65与66处粘合成一体。要知道,有着许许多多可将纤维粘合成一体的技术,包括空气穿透粘合、树脂粘合以及其他适用的粘合技术。随后,非织布卷绕在辊70上,以备贮存或后整理之需。
本发明织物中的纤维是细旦聚合物纤维,它们形成大量然而非常细小的孔。在织物中放入细旦纤维以获得高阻断性,乃是技术上普遍知道的,并非新技术。然而已发现,当采用硬化的熔纺丝束状微纤维来制成非织造纤维状构造时,生产出的织物具有异常高的弗雷泽透气性。这一发现则是新的。
此外还发现,熔纺微纤维具备足够的强度,制成的阻断性织物不需要任何类型的支持用稀松布,从而节省此类支持材料所带来的附加材料和成本。虽然强度对材料的买主将是一项重要的考虑因素,但是稳定性也很重要。已发现,可采用高速纺丝,制成低收缩率微纤维。一种具有高阻断性和透气性同时又有一定强度并且稳定的非织布,无论对于防护服的加工者还是对于使用者来说,都具有重要的价值。
一项本发明制造非织布成功的关键内在因素,也许就在于不经热处理和牵伸便创造出一种硬化的熔纺微纤维。特别是已发现,以高速纺制微纤维能使得纤维性能发生相当大的变化。曾采用2GT聚酯(对苯二甲酸乙二醇酯)在一系列纺丝速度下做过纺丝测试实验,以揭示纺丝速度的差异对性能的影响。如同图3、4及5中曲线所示,强度急剧增加,而断裂伸长和沸水收缩值急剧降低。有关数据也一并载于下表A中:
表A
纺丝速度(m/min) | 3998 | 5029 | 5761 | 5943 | 6401 |
单丝数 | 200 | 200 | 200 | 200 | 200 |
单丝纤度(旦) | 0.5 | 0.5 | 0.5 | 0.5 | 0.5 |
沸水收缩(%) | 50.1 | 15.1 | 12.1 | 7.8 | 8.1 |
强度(g/旦) | 3.3 | - | 3.9 | 3.9 | 3.8 |
断裂伸长(%) | 49.0 | - | 33.0 | 31.8 | 33.2 |
可相当清楚地看出,高纺速条件下制成的微纤维不需要再进行热处理和牵伸。该微纤维有一定强度而且稳定。这样高的生产速度对实现高生产效率制造非织布是理想的,虽然生产如此细的纤维在操作上对任何工业装置都是一个挑战。
在下面的表B~D中,给出了进一步的数据以验证上面的数据。下一组包括圆形断面聚酯以及双叶形断面聚酯:
表B
纺丝速度(m/min) | 2743 | 3200 | 3658 | 4115 | 4115 |
单丝数 | 100 | 100 | 100 | 100 | 100 |
单丝纤度(旦) | 0.7 | 0.7 | 0.7 | 0.63 | 0.55 |
断面 | 圆形 | 圆形 | 圆形 | 圆形 | 圆形 |
沸水收缩(%) | 34 | 18 | 5.8 | 4.0 | 4.2 |
强度(g/旦) | 2.7 | 3.0 | - | 3.2 | 3.3 |
断裂伸长(%) | 119 | 108 | 91 | 80 | 80 |
表C
纺丝速度(m/min) | 3658 | 4435 | 3200 | 3658 | 4115 |
单丝数 | 100 | 100 | 100 | 100 | 100 |
单丝纤度(旦) | 0.63 | 0.55 | 0.72 | 0.78 | 0.48 |
断面 | 圆形 | 圆形 | 双叶 | 双叶 | 双叶 |
沸水收缩(%) | 5.5 | 4.2 | 7.1 | 7.6 | 4.1 |
强度(g/旦) | 3.0 | 3.1 | 3.0 | 3.1 | 3.4 |
断裂伸长(%) | 86 | 70 | 102 | 96 | 75 |
表D
纺丝速度(m/min) | 3200 | 3200 |
单丝数 | 68 | 100 |
单丝纤度(旦) | 0.78 | 0.53 |
断面 | 圆形 | 圆形 |
沸水收缩(%) | 4.9 | 4.5 |
干热收缩(%) | 4.4 | 4.3 |
强度(g/旦) | 3.3 | 3.0 |
断裂伸长(%) | 132 | 103 |
显然,本发明在技术上的改进在于,不需要通常采用的附加加工步骤就可以以较高速度纺制一种性能理想的纤维。从改进非织造布技术的意义上说,这种方式具有特殊的优越性。
在本发明的一个方面中,非织布可经过冷夹辊加工以对非织布进行压实。显微镜下的分析表明,压实后织物的纤维呈现为彼此码放起来的状态,而纤维的基本断面形状则没有受损伤。看来,这正是本发明的一个恰当方面,因为每一根纤维看上去都没有发生会导致孔隙闭合的变形或显著压扁。结果,该非织布的阻断性,按照静水压头测定来表示,提高了,而同时似乎又维持了高孔隙率、低密度和非常高的弗雷泽透气性。
显微镜分析表明,本发明非织布的共同特征在于具有均衡的性能,即在表现出相当高的静水压头的同时又具有非常高的弗雷泽透气性。例如,在某些测试的织物中,初始静水压头可达约30厘米之高,同时弗雷泽值仍高于65m3/min-m2。其弗雷泽透气性和静水压头还可方便地加以改变,只需对本发明织物施以冷轧光即可。经过轧光以后,静水压头可提高到高达45~50厘米,同时弗雷泽值仍保持在25m3/min-m2以上。一种既具有高阻断性,又具有高透气性的织物,相信,在医疗领域以及可能许多其他领域作为防护服织物必将倍受青睐。
虽然至此有关本发明的描述一直涉及目前刚刚纺制的亚旦级熔纺纤维,然而很可能存在许多其他纺丝技术,不论现在已开发的还是有待发明的,都有可能提供合适的聚合物纤维。优选的纤维断面粗细一般介于约6~约90平方微米,其中更优选约20~约70平方微米的纤维,最优选介于约33~约54平方微米。纤维纤度习惯上表示为旦数或分特数。在本发明的情况下,各种性能据信部分地是由纤维物理尺寸的作用造成的。由于旦数和分特数与一根长纤维的重量有关,故聚合物的密度可能带来某些误导的信息。譬如,若两根纤维具有同样的断面面积,而一根由聚乙烯构成,而另一根包含的是聚酯,则那根聚酯纤维的旦数将会大一些,因为它往往比聚乙烯要密实。然而一般可以认为,纤维的旦数范围优选小于或近似等于约1。
上面提到,该纤维应为硬化的纤维。其断面形状,目前据信,不是本发明的关键所在,但是据推想,以最紧密的断面为最佳,因为,此时孔隙将极可能小而又不闭合。显然,通过改变纤维断面形状,可对本发明的织物做出一定改进。与此同时,优选纤维具有足以不需要支持层的拉伸强度。要做到这一点,可采用最低强度至少为约275MPa的纤维来制作。这样的纤维(所制成的非织布)应能很容易地达到,在归一化为单位重量后,超过1N/g/m2的片材抓样强度值。本发明的纤维强度可满足大多数用途的要求而不需要象在SMS中的熔喷层那样需要增强。由于纤维中的聚合物缺乏取向,典型的熔喷纤维的拉伸强度为约26~约42MPa。在本申请中,对各种片材试样按无支持的方式进行了静水压头测试,因此,如果片材包含一定强度值的纤维数量不足,便根本无法进行测定。故而,一个无支持层静水压头压力数值既是阻断性的度量,也表明该片材已具有支撑该静水压头压力的内在强度。
要知道,尽管已采用静水压头表征了本发明织物,但该非织布另外还具有孔隙细小的特点,这使其又具有良好的阻挡干颗粒物质的特性。而凭借其高弗雷泽透气性,该非织布还适合用于某些过滤材料的用途。要知道,片材的单位重量会对静水压头与透气性之间的平衡产生一定影响。在多数情况下,从经济和生产率的角度以及性能均衡的角度考虑,单位重量近似或低于75克/平方米,效果将是满意的。但是,仍然存在着一些潜在的最终用途,希望采用更为厚重或阻断性更高的片材,例如某些防护服用途。在后一种情况下,织物单位重量可大于约70克/平方米,可能相当重,譬如重达200克/平方米。
优选的纤维材料可以是多种多样聚合物或共聚物中的任何一种,包括聚乙烯、聚丙烯、聚酯,以及任何单丝低于1.2分特的其他可熔纺纤维。该纤维也可以是采用传统方法充分牵伸并热处理、具有强度和低收缩的硬化丝束。如上面所说,借助高速熔纺而硬化的纤维则可能更适合本发明的使用。织物的性能还可以通过改变纤维断面加以改变。
下面是所提供的若干本发明的实施例。
实例1~37
织物试样制备:采用实验室间歇湿法铺网设备以切断长度为5毫米的熔纺PET(涤纶)纤维为原料制成。该纤维系由Teijen(帝人)纤维公司制造并有商品供应。所有试样均经过丙烯酸类粘合剂(Barriercoat 1708)处理以赋予试样强度,又经过以拒水整理剂的(Freepel 114、Zonyl 8315、NaCl、异丙醇)整理以赋予疏水性。纤维纤度,按圆形纤维断面计,以分特为单位载于下表。正如上面提到的,用于本发明的纤维不一定要求是圆形的。因此认识到如下一点可能有助于清楚的理解:即给出的分特数是聚合物密度和纤维断面面积二者的度量。因而,对0.333分特(0.3旦)的PET纤维(2GT聚酯)来说,断面面积为约25微米(平方微米)。0.867分特PET纤维的断面面积将为65微米。
数据载于下表:
表I
实例1 | 实例2 | 实例3 | 实例4 | |
单位重量(g/m2) | 44.1 | 44.1 | 44.1 | 44.1 |
单丝纤度(分特) | 0.333 | 0.333 | 0.333 | 0.333 |
厚度(mm) | 0.33 | 0.34 | 0.36 | 0.38 |
弗雷泽透气性(m3/min-m2) | 27.7 | 29.3 | 32.0 | 36.6 |
静水压头(cm) | 45 | 47 | 44 | 44.5 |
密度(gm/cc) | 0.1336 | 0.1287 | 0.1241 | 0.1158 |
孔隙率(%) | 90.18 | 90.54 | 90.88 | 91.49 |
表II
实例5 | 实例6 | 实例7 | 实例8 | |
单位重量(g/m2) | 44.1 | 44.1 | 44.1 | 44.1 |
单丝纤度(分特) | 0.333 | 0.333 | 0.333 | 0.333 |
厚度(mm) | 0.38 | 0.41 | 0.48 | 0.56 |
弗雷泽透气性(m3/min-m2) | 44.8 | 43.6 | 42.1 | 51.2 |
静水压头(cm) | 40 | 40.5 | 39.5 | 38.5 |
密度(gm/cc) | 0.1158 | 0.1086 | 0.0914 | 0.0789 |
孔隙率(%) | 91.49 | 92.02 | 93.28 | 94.19 |
表III
实例9 | 实例10 | 实例11 | 实例12 | |
单位重量(g/m2) | 44.1 | 44.1 | 54.2 | 64.4 |
单丝纤度(分特) | 0.333 | 0.333 | 0.333 | 0.333 |
厚度(mm) | 0.58 | 0.58 | 0.63 | 0.53 |
弗雷泽透气性(m3/min-m2) | 45.1 | 56.4 | 46.6 | 25.3 |
静水压头(cm) | 41 | 34.33 | 35 | 46.5 |
密度(gm/cc) | 0.0755 | 0.0755 | 0.0855 | 0.1209 |
孔隙率(%) | 94.45 | 94.45 | 93.71 | 91.11 |
表IV
实例13 | 实例14 | 实例15 | 实例16 | |
单位重量(g/m2) | 64.4 | 43.1 | 43.4 | 53.6 |
单丝纤度(分特) | 0.333 | 0.867 | 0.867 | 0.867 |
厚度(mm) | 0.79 | 0.43 | 0.41 | 0.41 |
弗雷泽透气性(m3/min-m2) | 38.1 | 73.8 | 65.2 | 50.0 |
静水压头(cm) | 38 | 28 | 31 | 32 |
密度(gm/cc) | 0.0819 | 0.0998 | 0.1069 | 0.1319 |
孔隙率(%) | 93.98 | 92.66 | 92.14 | 90.30 |
表V
实例17 | 实例18 | 实例19 | 实例20 | |
单位重量(g/m2) | 54.2 | 62.0 | 63.4 | 50.56 |
单丝纤度(分特) | 0.867 | 0.867 | 0.867 | 0.11 |
厚度(mm) | 0.46 | 0.51 | 0.46 | 0.18 |
弗雷泽透气性(m3/min-m2) | 57.9 | 50.3 | 43.3 | 4.74 |
静水压头(cm) | 29 | 30 | 33 | 72 |
密度(gm/cc) | 0.1188 | 0.1223 | 0.1388 | |
孔隙率(%) | 91.27 | 91.01 | 89.79 |
表VI
实例21 | 实例22 | 实例23 | 实例24 | |
单位重量(g/m2) | 48.53 | 49.55 | 71.27 | 75.34 |
单丝纤度(分特) | 0.11 | 0.11 | 0.11 | 0.11 |
厚度(mm) | 0.20 | 0.20 | 0.23 | 0.30 |
弗雷泽透气性(m3/min-m2) | 9.12 | 8.57 | 3.04 | 5.17 |
静水压头(cm) | 73 | 60 | 99 | 77 |
表VII
实例25 | 实例26 | 实例27 | 实例28 | |
单位重量(g/m2) | 73.64 | 52.60 | 55.32 | 52.60 |
单丝纤度(分特) | 0.11 | 0.33 | 0.33 | 0.33 |
厚度(mm) | 0.30 | 0.20 | 0.30 | 0.36 |
弗雷泽透气性(m3/min-m2) | 4.86 | 15.14 | 25.69 | 31.62 |
静水压头(cm) | 63.5 | 48 | 43 | 38.5 |
表VIII
实例29 | 实例30 | 实例31 | 实例32 | |
单位重量(g/m2) | 70.93 | 75.68 | 75.68 | 53.96 |
单丝纤度(分特) | 0.33 | 0.33 | 0.33 | 0.56 |
厚度(mm) | 0.23 | 0.38 | 0.56 | 0.20 |
弗雷泽透气性(m3/min-m2) | 8.63 | 18.6 | 24.02 | 16.84 |
静水压头(cm) | 55.5 | 46.5 | 41.5 | 40.5 |
表IX
实例33 | 实例34 | 实例35 | 实例36 | |
单位重量(g/m2) | 54.64 | 52.94 | 76.70 | 67.87 |
单丝纤度(分特) | 0.56 | 0.56 | 0.56 | 0.56 |
厚度(mm) | 0.30 | 0.38 | 0.25 | 0.38 |
弗雷泽透气性(m3/min-m2) | 40.74 | 45.60 | 10.49 | 31.92 |
静水压头(cm) | 33 | 31 | 44 | 34 |
表X
实例37 | |
单位重量(g/m2) | 76.02 |
单丝纤度(分特) | 0.56 |
厚度(mm) | 0.56 |
弗雷泽透气性(m3/min-m2) | 33.44 |
静水压头(cm) | 32.5 |
实例38~40
织物试样38~40系手工制作,采用直径如表XI所示的聚丙烯连续纤维为原料。试样经过了如表XI所载粘合温度的热压。
表XI
实例38 | 实例39 | 实例40 | |
单位重量(g/m2) | 59.3 | 48.1 | 51.9 |
单丝纤度(μm) | 20 | 20 | 14-18 |
粘合温度(℃) | 152 | 154 | 154 |
弗雷泽透气性(m3/min-m2) | 75.0 | 60.0 | 288.3 |
静水压头(cm) | 20.1 | 15.0 | 17.0 |
实例41及42
织物试样41及42系手工制作,类似于试样38~40,不同的是,织物是采用两层该手工试样制成的。试样41和42的数据载于表XII。
表XII
实例41 | 实例42 | |
单位重量(g/m2) | 128.8 | 101.7 |
单丝纤度(μm) | 14-18 | 20 |
粘合温度(℃) | 154 | 154 |
弗雷泽透气性(m3/min-m2) | 35.1 | 20.7 |
静水压头(cm) | 158.0 | 228.1 |
表XI及XII的数据清楚表明,采用本发明织物可达到阻断性和透气性二者的独特结合,这在现有的其他非织布中是不具备的。鉴于两方面性能的兼顾或均衡体现在一种织物上迄今还从未真正设想过,故这种织物和构造的应用必将格外广泛。原则上,该织物可用于诸如外科手术罩衣之类的特殊用途服装上。预计它将当作一次性使用的(用即弃)服装,以保护外科大夫或其他医务人员免受诸如被污染的体液之类有害液体的侵扰。然而,在长时间和紧张的手术操作期间,医务人员却不会感觉太热,相反,穿着一种透气的衣服就会感觉到挺舒服。用过之后,该服装可优选地完全回收利用,因为它是由可方便地再生为组分单体的单一聚合物构成的,这一点与其他材料迥然不同,后者乃是不同聚合物构成的组合体或者其中至少一种成分为不可再生的聚合物。
尽管上面已公开了多种有关湿法铺网非织布的实施例,随后又讨论了不经热处理和牵伸就可纺制成的有一定强度而且稳定的纤维,然而,直接用纺出的原封纤维,即不需要热处理和牵伸就已经是有一定强度而且稳定的纤维,制成一种结合了本发明两个方面特性的非织布,才是本发明最起码的一种优选安排。
在本发明的各种优选安排的基础上尚存在着若干附加的方面。此种细旦纤维可纺成为双组分共轭纤维或多组分共轭纤维,然后再使纺出的纤维***为更细的纤维。采用共轭纤维纺丝的一个优点是,依靠共轭纤维的***机理可获得提高生产速率的潜力。最终***成的纤维,可各自具有盘形或其他形状的断面。
另一个方面是提供双组分或聚合物的诸如皮芯型的排列方式。图6中给出了一种皮芯双组分纤维,其中表示出纤维80的断面。皮聚合物82包围着芯聚合物84,可对聚合物的相对含量进行调节,使芯聚合物84占到大于或小于50%的断面面积。借助这种安排,可造成多种有吸引力的选择。例如,可仅在皮聚合物82中掺混颜料,以免浪费在芯聚合物中,从而既降低了颜料成本,又得到经适当着色的材料。还可将诸如碳氟化合物的疏水物质加入到皮聚合物中进行纺丝,以最低的成本获得所希望的拒液性能。在某些保健用途中加入抗微生物添加剂也是恰当的。在诸如受紫外能量照射之类的许多用途中可加入稳定剂,受户外日光的照射便是一例。对那些可能出现静电积聚并因而希望消除的场合,可采用静电放电添加剂。为了使片材适合作揩布或吸收材料,或者只允许液体透过非织布而将粒度极小的固体截留在片材的细孔中,可采用另一种合适的添加剂,如润湿剂。在建议片材由基本连续的长丝构成的场合,此种片材适于做成具有低起毛特性的揩布。
低熔点或低熔融温度的聚合物可用作皮层,以便在粘合期间容易熔融,而同时芯聚合物则不会***。一个非常有趣的例子是用2GT聚酯作为芯,用3GT(对苯二甲酸丙二醇酯)聚酯作为皮的皮芯安排。此种方案将适用于诸如电子束或γ射线消毒之类的辐射消毒场合而不致降解。还可设想出其他的多组分纤维的组合及纤维的掺混方案。多种多样聚合物的配合使用既提出挑战,又提供机遇。本发明的片材可包含聚酯(如聚对苯二甲酸乙二醇酯、聚对苯二甲酸丙二醇酯及聚对苯二甲酸丁二醇酯)的组合,以及聚酯、尼龙、诸如聚乙烯与聚丙烯之类的聚烯烃乃至弹性聚合物等的共混物。
以上提供的说明和附图意在解释和描述本发明,作为对公众知识库的贡献。而作为贡献出这种知识和理解的交换条件,本发明人保留独占的权力并要求予以尊重。此种独占权力的范围从任何意义上均不应受可能由本文得到的特定细节和优选实施方案的限制。显然,任何授予本申请的专利权范围均应根据下面的权利要求书来衡量和确定。
Claims (72)
1.一种柔性片材,其特征在于片材由熔融挤出的、通常为连续的长丝聚合物纤维构成,该聚合物纤维的最低纤维强度为约275N/mm2,其中,片材具有选自如下组的弗雷泽透气性和无支持层静水压头的组合:
弗雷泽透气性至少约70m3/min-m2且无支持层静水压头至少约15cm;
弗雷泽透气性至少28m3/min-m2且无支持层静水压头至少约30厘米;
弗雷泽透气性至少15m3/min-m2且无支持层静水压头至少约40厘米;以及
弗雷泽透气性至少1m3/min-m2且无支持层静水压头至少约80厘米。
2.按照权利要求1的片材,其中片材具有至少约20厘米的静水压头。
3.按照权利要求1的片材,其中绝大多数纤维的断面小于约70平方微米。
4.一种柔性片材,其特征在于片材由熔融挤出的、通常为连续的长丝聚合物纤维构成,该聚合物纤维的最低纤维强度为约275N/mm2,其中片材的单位重量为13克/平方米~75克/平方米,基本上全部纤维均为熔纺纤维,绝大多数(重量)纤维的断面小于90平方微米,并且其中片材的弗雷泽透气性至少1m3/min-m2,静水压头至少25厘米。
5.按照权利要求4的片材,其中片材具有至少约30厘米的静水压头。
6.照权利要求4的片材,其中片材具有至少约40厘米的静水压头。
7.按照权利要求3及4中任何一项的片材,其中弗雷泽透气性至少约5m3/min-m2。
8.按照权利要求4的片材,其中弗雷泽透气性至少约10m3/min-m2。
9.按照权利要求4的片材,其中弗雷泽透气性至少15m3/min-m2。
10.按照权利要求4的片材,其中弗雷泽透气性至少25m3/min-m2。
11.按照权利要求4的片材,其中弗雷泽透气性至少35m3/min-m2。
12.按照权利要求4的片材,其中弗雷泽透气性至少约45m3/min-m2。
13.按照权利要求4的片材,其中静水压头至少50厘米。
14.按照权利要求4的片材,其中静水压头至少60厘米。
15.按照权利要求1的片材,其中片材由纤维组成,该纤维具有小于约90平方微米的平均纤维纤度。
16.按照权利要求1及4中任何一项的片材,其中片材由纤维组成,其中平均纤维纤度小于约75平方微米。
17.按照权利要求1、3及4中任何一项的片材,其中片材由纤维组成,其中平均纤维纤度小于约60平方微米。
18.按照权利要求1、3及4中任何一项的片材,其中片材的抓样拉伸强度至少约1N/g/m2。
19.按照权利要求1、3及4中任何一项的片材,其中片材由纤维构成,且其中大多数纤维的沸水收缩小于10%。
20.按照权利要求1、3及4中任何一项的片材,其中片材由用较粗的共轭熔纺纤维生产的劈裂纤维构成。
21.按照权利要求1、3及4中任何一项的片材,其中片材由纤维构成,至少一部分纤维由至少两种独立的组分聚合物构成。
22.按照权利要求21的片材,其中所述组分聚合物之一按照皮芯排列方式上履在另一种上。
23.按照权利要求22的片材,其中纤维的皮组分包含至少一种掺混到其聚合物中的添加剂。
24.按照权利要求23的片材,其中添加剂是排斥液体的疏水添加剂。
25.按照权利要求24的片材,其中添加剂是碳氟化合物。
26.按照权利要求23的片材,其中添加剂是稳定剂。
27.按照权利要求26的片材,其中稳定剂是耐紫外能量照射的稳定剂。
28.按照权利要求24的片材,其中添加剂是润湿剂,旨在赋予片材以机械地吸收液体的能力。
29.按照权利要求24的片材,其中添加剂为纤维和片材提供颜色。
30.按照权利要求24的片材,其中添加剂可减少片材中静电的积聚。
31.按照权利要求24的片材,其中添加剂是抗微生物剂。
32.按照权利要求23的片材,其中占据皮层的聚合物的熔融温度低于占据芯部的聚合物。
33.按照权利要求23的片材,其中占据皮层的聚合物基本上不因辐射消毒处理而降解。
34.按照权利要求1、3及4中任何一项的片材,其中片材的纤维由第一聚合物构成的第一类纤维和第二聚合物构成的第二类纤维构成,其中所述第一与第二聚合物中的一种的熔融温度低于所述第一与第二聚合物中的另一种,从而促进热粘合。
35.按照权利要求1、3及4中任何一项的片材,其中片材的纤维由聚酯聚合物组成。
36.按照权利要求35的片材,其中纤维由聚对苯二甲酸乙二醇酯聚合物构成。
37.按照权利要求35的片材,其中纤维由聚对苯二甲酸丙二醇酯聚合物构成。
38.按照权利要求35的片材,其中纤维由聚对苯二甲酸丁二醇酯聚合物构成。
39.按照权利要求35的片材,其中纤维由聚酯聚合物以及掺混于其中的添加聚合物构成。
40.按照权利要求1、3及4中任何一项的片材,其中片材的纤维由尼龙聚合物构成。
41.按照权利要求1、3及4中任何一项的片材,其中片材的纤维由聚乙烯聚合物构成。
42.按照权利要求1、3及4中任何一项的片材,其中片材的纤维由聚丙烯聚合物构成。
43.按照权利要求1、3及4中任何一项的片材,其中片材的纤维由弹性聚合物构成。
44.按照权利要求1、3及4中任何一项的片材,其中片材的纤维包含不同聚合物的共混物。
45.按照权利要求1、3及4中任何一项的片材,其中片材的纤维由聚合物构成,至少一种添加剂掺混到该聚合物中。
46.按照权利要求45的片材,其中添加剂是排斥液体的疏水添加剂。
47.按照权利要求45的片材,其中添加剂是碳氟化合物。
48.按照权利要求45的片材,其中添加剂是稳定剂。
49.按照权利要求48的片材,其中稳定剂是耐紫外能量照射的稳定剂。
50.按照权利要求45的片材,其中添加剂是润湿剂,用以提高片材对液体的机械吸收。
51.按照权利要求45的片材,其中添加剂为纤维和片材提供颜色。
52.按照权利要求45的片材,其中添加剂可减少静电在片材中的积聚。
53.按照权利要求45的片材,其中添加剂是抗微生物剂。
54.按照权利要求1、3及4中任何一项的片材,其中片材纤维上施涂了防护整理剂。
55.按照权利要求54的片材,其中所述防护整理剂包含碳氟化合物。
56.按照权利要求1的片材,其中纤维是采用超声波粘合成一体的
57.按照权利要求1的片材,其中纤维由热粘合成一体。
58.按照权利要求1的片材,其中片材是由纤维组成的,该纤维是采用粘合剂粘合成一体的。
59.按照权利要求1、3及4中任何一项的片材,其中片材的断面孔隙率至少约85%。
60.按照权利要求59的片材,其中片材的断面孔隙率至少约89%。
61。按照权利要求1、3及4中任何一项的片材,其中由聚合物组成的该片材的纤维基本上不因辐射消毒处理而降解。
62.按照权利要求61的片材,其中聚合物基本上不因γ辐射的照射而降解。
63.按照权利要求61的片材,其中聚合物基本上不因电子束照射而降解。
64.按照权利要求1、3及4中任何一项的片材,其中该片材由若干成形为非织造片材的纤维层构成,其中所有的层都是直接铺成网状的通常连续的熔纺纤维。
65.按照权利要求1及3中任何一项的片材,其中片材的单位重量大于13克/平方米,小于100克/平方米。
66.按照权利要求22的片材,其中芯组分聚合物是聚对苯二甲酸乙二醇酯,皮组分聚合物是聚对苯二甲酸丙二醇酯。
67.按照权利要求66的片材,其中皮聚合物包含掺混于其中的颜料,芯聚合物则通常不含颜料。
68.按照权利要求67的片材,其中皮聚合物还包含掺混于其中的碳氟化合物。
69.按照权利要求67的片材,其中纤维的平均断面面积小于90平方微米。
70.一种柔性片材,其特征在于片材的单位重量为13克/平方米~75克/平方米,弗雷泽透气性至少1m3/min-m2,静水压头至少25厘米,其中,在片材中基本上全部纤维均为熔纺聚酯聚合物纤维,该聚合物纤维的断面小于约90平方微米,平均纤维强度为至少275N/mm2。
71.按照权利要求70的片材,其中大多数包含所述纤维的片材的沸水收缩小于10%。
72.按照权利要求71的片材,其中片材的弗雷泽透气性至少28m3/min-m2,无支持层静水压头至少约30厘米。
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- 1997-06-05 ES ES97928976T patent/ES2152681T3/es not_active Expired - Lifetime
- 1997-06-05 DE DE69703446T patent/DE69703446T2/de not_active Expired - Lifetime
- 1997-06-05 CA CA 2257272 patent/CA2257272C/en not_active Expired - Fee Related
- 1997-06-05 CN CN97195313A patent/CN1080342C/zh not_active Expired - Fee Related
- 1997-06-05 WO PCT/US1997/010358 patent/WO1997046750A1/en active IP Right Grant
- 1997-06-05 JP JP50094098A patent/JP2000511977A/ja not_active Ceased
- 1997-06-05 EP EP97928976A patent/EP0904442B1/en not_active Expired - Lifetime
- 1997-06-05 AU AU33115/97A patent/AU3311597A/en not_active Abandoned
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Also Published As
Publication number | Publication date |
---|---|
EP0904442A1 (en) | 1999-03-31 |
EP0904442B1 (en) | 2000-11-02 |
WO1997046750A1 (en) | 1997-12-11 |
JP2000511977A (ja) | 2000-09-12 |
CA2257272A1 (en) | 1997-12-11 |
ES2152681T3 (es) | 2001-02-01 |
AU3311597A (en) | 1998-01-05 |
DE69703446T2 (de) | 2001-06-21 |
CN1221463A (zh) | 1999-06-30 |
CA2257272C (en) | 2005-11-15 |
US5885909A (en) | 1999-03-23 |
DE69703446D1 (de) | 2000-12-07 |
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