CN115516022B - 具有独特手感的强弹性双组分纤维 - Google Patents
具有独特手感的强弹性双组分纤维 Download PDFInfo
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- CN115516022B CN115516022B CN202180033484.8A CN202180033484A CN115516022B CN 115516022 B CN115516022 B CN 115516022B CN 202180033484 A CN202180033484 A CN 202180033484A CN 115516022 B CN115516022 B CN 115516022B
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Abstract
提供了一种包括至少一个皮以及芯的弹性体双组分纤维,其具有非粘连特性和类似衣服的感觉。所述芯包含两种或更多种聚丙烯基弹性体和仲酰胺,并且所述皮包含非弹性体聚乙烯。此外,所述皮能够作为总弹性体组合物的小部分存在,并且所述仲酰胺能够作为所述芯的小部分存在,同时形成具有非粘连特性和类似衣服的感觉的双组分纤维,同时保持良好的强度特性。
Description
背景技术
弹性或热塑性聚合物,诸如以织造网和非织造网的形式,用于各种各样的应用中,这些应用的实例包括有限用途的腰带、侧片、腿部衬垫和外覆层/底片,或者包括个人护理吸收制品在内的一次性产品。如本领域所已知,此类制品可以包括儿童和成人尿布、训练裤、泳装、失禁服装、女性卫生产品、殡葬产品、伤口敷料、绷带等等。弹性组合物还可用于防护罩领域,诸如汽车、船或其他物体覆盖部件、帐篷(户外休闲覆盖物)、农业织物(作物行覆盖物)以及与诸如手术单、医院长袍和开窗加固物等产品一起用于兽医和卫生保健领域。另外,此类材料还可用于洁净室和卫生保健环境的其他服装。
例如,纺粘织物由非织造网形成,并且已证明可用于许多不同的应用中。尽管完全适合于上述应用和其他应用,但已知现有非织造网具有类似塑料的感觉,使得非织造物与更“类似衣服”的织物相比,较不那么舒适,因为它们往往缺乏或具有更少的悬垂性、柔软性和其他触觉属性,包括凉爽感。例如,与塑料织物相比,布具有更令人愉悦的外观和感觉,以及具有改善的悬垂性和柔软性。此外,还证明难以生产具有类似布的感觉以及足够强度性能的非织造网。
此外,尽管弹性非织造物如纺粘织物具有许多用途,但弹性纤维倾向于自粘,这至少部分是由于弹性聚合物的低玻璃化转变温度(Tg)和高粘性的原因。这使得形成纤维和铺放非织造网很困难,因为弹性组合物倾向于在相邻层之间粘连,并且在纤维形成期间粘附到机器上。过去,试图将粘连组分添加到双组分纤维的外层或皮中。然而,发现粘连添加剂未能向纤维提供足够的粘连和可纺性特性。
因此,提供表现出非粘连特性的弹性纺粘物将是有益的。此外,提供一种双组分弹性纤维来形成具有良好弹性特性并且具有更类似布的感觉的非织造网将是有益的。将进一步有益的是,提供一种用于形成非织造网的弹性纤维,使得该纤维和/或非织造网表现出非粘连特性,并且可以层压到一个或多个附加层上。
发明内容
本公开一般涉及包括弹性体双组分纤维的非织造网。弹性体双组分纤维包括具有至少两种聚丙烯基弹性体和仲酰胺的芯以及至少一个皮。此外,至少一个皮占双组分纤维的总重量的小于50重量%。此外,非织造网表现出约1100gf或更大的峰值破裂负荷或约22gf/gsm的归一化峰值破裂负荷。
在一个方面,非织造网表现出约100gf或更小的压杯抗弯刚度或约2.1gf/gsm或更小的归一化压杯抗弯刚度。另外地或另选地,非织造网表现出约90Ws1/2/m2K或更大的扩散率。
在又其他的方面,至少两种聚丙烯基弹性体包括乙烯共聚物、α-烯烃共聚物或它们的组合。此外,在一个方面,基于芯的重量,芯还包含约5重量%或更少的聚丙烯均聚物。在另一个方面,皮包含非弹性体聚合物。在一个方面,至少两种聚丙烯基弹性体包括丙烯/乙烯共聚物。此外,在一个方面,皮包含聚乙烯聚合物。尽管如此,在另一个方面,皮和芯中的至少一者还包含颜料颗粒。在一个方面,基于皮或芯的重量,颜料颗粒以约0.1重量%至约5重量%的量存在于皮和芯中的至少一者中。
另外或另选地,基于芯的重量,仲酰胺以约0.1重量%至约10重量%的量存在于芯中。此外,在一个方面,基于芯的重量,仲酰胺以约0.25重量%至约5重量%的量存在于芯中。在一个方面,仲酰胺是脂肪酸酰胺。
本公开一般还涉及包括根据上述的纺粘非织造网和背衬的弹性体层合物。在一个方面,背衬包括弹性膜。
本公开一般还涉及由上述非织造网或层合物的任何方面形成的吸收制品。
此外,本公开一般还涉及一种弹性体双组分纤维。纤维包括具有至少两种聚丙烯基弹性体和仲酰胺的芯和至少一个皮。至少一个皮占双组分纤维的总重量的小于50重量%;并且所述弹性体双组分纤维表现出约0.525或更大的842cm-1峰与974cm-1峰的FTIR峰高比,如使用Perkin Elmer Frontier FTIR光谱仪基于在4cm-1分辨率下32次扫描的平均值所测量的。
在一个方面,弹性体双组分纤维的至少两种聚丙烯基弹性体包括第一聚丙烯基弹性体和第二聚丙烯基弹性体,其中基于所述芯的重量,所述第一聚丙烯基弹性体占所述芯的约30重量%或更多。在另一个方面,基于芯的重量,弹性体双组分纤维的第二聚丙烯基弹性体占芯的约60重量%或更少。此外,在一个方面,弹性体双组分纤维的芯还包含约15重量%或更少的聚丙烯均聚物。
本发明的其他特征和方面在下文进行更详细描述。
附图说明
呈现给本领域普通技术人员的本公开的完整且能够实现的公开内容在说明书的剩余部分中参照附图更具体地阐述,在附图中:
图1是根据本公开的可用于形成纺粘非织造网材料的设备的示意图;
图2A-图2D示出了灰度级%变异系数测试;并且
图3A-图3C示出了根据实施例2的FTIR峰比分析。
在本说明书和附图中对附图标记的反复使用旨在代表本公开的相同或类似的特征或元件。
具体实施方式
定义
如本文所用,术语“约”、“大约”或“大致上”在用于修饰值时表示该值可以增加或减少10%(例如,如7.5%、5%、如4%、如3%、如2%、如1%)并且保持在所公开的方面内。此外,术语“基本上不含”在用于描述材料中物质的量时,不限于彻底或完全不含,并且可以相当于该材料中缺少任何可察觉或可检测量的所列举物质。因此,例如,当材料中物质的量小于用于测量材料中物质的量的行业认可的仪器或测试的精度时,该材料“基本上不含”上述物质。在某些示例实施方案中,当材料中物质的量按材料的重量计小于10%、小于9%、小于8%、小于7%、小于6%、小于5%、小于4%、小于3%、小于2%、小于1%、小于0.5%或小于0.1%时,该材料可以“基本上不含”上述物质。
如本文所用,术语“弹性体”和“弹性”是指在施加拉伸力后可在至少一个方向(诸如CD或MD方向)上拉伸并在释放拉伸力后收缩/回到大约其原始尺寸的材料。例如,拉伸后的材料可具有比其松弛未拉伸长度大至少50%的拉伸长度,并将在释放拉伸力后回到其拉伸长度的至少50%以内。假想例将是这样一个一(1)英寸的材料样品:其可以拉伸到至少1.50英寸,并将在释放拉伸力后恢复到不超过1.25英寸的长度。有利地,材料收缩或恢复拉伸长度的至少50%,甚至更有利地至少80%。
如本文所用,术语“纤维”通常是指可通过使聚合物穿过成型孔口诸如模头而形成的细长挤出物。除非另外指明,否则术语“纤维”包括具有一定长度的不连续纤维(例如,稳定纤维)和基本上连续的长丝。基本上连续的长丝可例如具有远大于其直径的长度,诸如大于约15,000至1以及在一些情况下大于约50,000至1的长度与直径比(“长宽比”)。
如本文所用,术语“可延伸的”通常是指在外加力的方向(例如,CD或MD方向)上拉伸或延伸其松弛长度或宽度的约50%或更多,在一些方面约75%或更多,在一些方面约100%或更多以及在一些方面约200%或更多的材料。
如本文所用,术语“非织造网”通常是指具有成夹层的但不是以可识别方式的(如在针织织物中)各纤维或线的结构的网。合适的非织造织物或网的实例包括但不限于熔喷网、纺粘网、粘合梳理网、气流成网网、共成形网、水力缠结网等。
如本文所用,术语“熔喷网”泛指通过这样的工艺形成的非织造网,在该工艺中将熔融的热塑性材料通过多个细的、通常为圆形的模头毛细管作为熔融纤维挤出到会聚的高速气体(例如,空气)流中,空气流使熔融热塑性材料的纤维的直径减小,该直径可以为微纤维直径。此后,熔喷纤维由高速气流携载并且沉积在收集表面上以形成随机分散的熔喷网。这样的工艺例如在授予Butin等人的美国专利号3,849,241中有所公开,该专利全文以引用方式并入本文以用于所有目的。一般来讲,熔喷网可以是基本上连续的或不连续的、直径通常小于10微米的并在沉积到收集表面上时通常发粘的微纤维。
如本文所用,术语“纺粘网”通常是指包含小直径的基本上连续的纤维的网。该纤维通过以下方式形成:将熔融的热塑性材料从多个细的、通常为圆形的且具有挤出纤维直径的喷丝头的毛细管挤出,然后通过例如引出拉伸(eductive drawing)和/或其他熟知的纺粘机制迅速变细。纺粘网的制备例如在授予Appel等人的美国专利号4,340,563、授予Dorschner等人的美国专利号3,692,618、授予Matsuki等人的美国专利号3,802,817、授予Kinney等人的美国专利号3,338,992、授予Kinney等人的美国专利号3,341,394、授予Hartman等人的美国专利号3,502,763、授予Levy的美国专利号3,502,538、授予Dobo等人的美国专利号3,542,615和授予Pike等人的美国专利号5,382,400中描述和示出,这些专利全文以引用方式并入本文以用于所有目的。纺粘纤维在沉积到收集表面上时通常是不发粘的。纺粘纤维有时可具有小于约40微米的直径,并通常介于约5至约20微米之间。
如本文所用,术语“共成形”泛指包括热塑性纤维和第二非热塑性材料的混合物或稳定化基质的复合材料。例如,共成形材料可通过这样的工艺制成,其中所述将至少一个熔喷模头布置在斜槽附近,通过该斜槽在形成网的同时向网添加其他材料。这样的其他材料可包括但不限于纤维有机材料,诸如木质或非木质纸浆,诸如棉、人造丝、再生纸、浆绒毛,以及超吸收性颗粒、无机吸收材料和/或有机吸收材料、经处理的聚合物短纤维等。这样的共成形材料的一些实例在授予Anderson等人的美国专利号4,100,324、授予Everhart等人的美国专利号5,284,703和授予Georger等人的美国专利号5,350,624中有所公开,这些专利中的每一份均全文以引用方式并入本文以用于所有目的。
如本文所用,术语“热点粘结”通常是指例如通过使材料在图案化辊(例如,压延辊)与另一个可以或可以不图案化的辊(例如,砧辊)之间通过而执行的过程。通常对这两个辊之一或两者加热。
如本文所用,术语“超声粘结”通常是指例如通过使材料在超声变幅杆与图案化辊(例如砧辊)之间通过而执行的过程。例如,通过使用静止的变幅杆和旋转的图案化砧辊而进行的超声粘结在授予Grgach等人的美国专利号3,939,033、授予Rust Jr.的美国专利号3,844,869和授予Hill的美国专利号4,259,399中有所描述,这些专利全文以引用方式并入本文以用于所有目的。此外,通过使用旋转式变幅杆与旋转式图案化砧辊进行的超声粘结在授予Neuwirth等人的美国专利号5,096,532、授予Ehlert的美国专利号5,110,403和授予Brennecke等人的美国专利号5,817,199中有所描述,这些专利全文以引用方式并入本文以用于所有目的。当然,任何其他超声粘结技术也可用于本公开。
如本文所用,“形成特性”或“灰度级百分比变异系数”可以根据以下程序进行测量:
可以使用图像分析方法来确定非织造物和类似网的形成特性。所述方法通常使用黑色背景下的透射光或入射光来实施。此处使用的方法采用黑色背景下的入射光,黑色背景上放置有非织造物样品。漫射的入射光照明由放置在样品上方和周围的四个LED泛光灯提供,同时允许相机有足够的间距在它们之间向下观察样品表面。Leica MicrosystemsDFC 310相机通过c-mount使用和安装,配有f-stop设置为4的可调Nikon 35-mm镜头。相机和镜头组件在样品上方提供大约六英寸宽的图像视场尺寸的距离处安装在Polaroid MP4相机支架或等同物上。相机设置为单色模式,并且在分析之前在白色背景上实施平场校正。
通过将非织造物样本放置在相机支架或自动样品台上(如有)并将其置于LeicaDFC 310相机和Nikon镜头的光轴下方中心来进行分析。样本必须平放,并且注意确保消除或避免褶皱或类似的变形。图像分析软件包用于监测照度水平,获取图像,然后进行所述测量以确定形成。对于所述分析,Leica Microsystems LAS软件包用于通过8位灰度***在约185至190之间监测每个样品的灰度级照度。可以经由配备有用于调节的旋钮或滑块的共用电压控制器来控制LED泛光灯的照度水平。本领域的技术人员也可以使用替代软件包。一旦调节和设定照度水平,则获取图像并将其保存到分析计算机上。然后,软件用于测量所获取图像的平均灰度级和灰度级标准偏差。然后将数据以电子方式传输到分析计算机并保存在EXCEL电子表格中。形成的基本和主要度量之一是灰度级百分比变异系数,或者简称GL%COV。GL%COV计算如下:
GL%COV=灰度级标准偏差/平均灰度级×100%。
每个样本至少进行五次重复分析。这通过如上所述对每个样本的五个单独区域进行测量来完成。在获得形成结果之后,可以通过进行基本统计分析,诸如以90%置信度水平进行的Student T分析,将样本彼此进行比较。
如将在本文中更详细地讨论的,“傅里叶变换红外光谱(FTIR)峰比”可以使用本领域中已知的常见FTIR峰分配来确定并且由表1示出:
缩写:b=主链,m-中等,s=强,sh=肩,v=非常,w=弱,S=弯曲,v=拉伸,p=摇晃,τ=扭动,w=摇摆。
聚丙烯:AN A-Z Reference,1999,J.Krager-Kocsis第320-328页。
特别地,将纤维从形成的非织造物(或在形成非织造物之前获得的非织造物)中取出纤维,并在铝涂覆的载玻片上卷平。然后使用Spotlight 400N FT-IR成像***以单点模式和40x60 um的孔径尺寸获得FTIR光谱。将显微镜连接到Perkin Elmer Frontier FTIR光谱仪,并且通过在4cm-1分辨率下对每个样品的32次扫描求平均值来获取光谱。在获得光谱之后,选择两个或更多个峰用于分析,诸如,确定本领域已知的两个或更多个峰的高度,并且基于所确定的高度计算两个或更多个峰的相应比率。
详细描述
现在将详细参照本公开的各个方面,其一个或多个实例在下文示出。每个实例都以解释而不是限制本公开的方式提供。事实上,对于本领域技术人员将显而易见的是,在不背离本公开的范围或精神的情况下,可以对本公开做出各种修改和变化。例如,作为一个方面的一部分而说明或描述的特征可用于另一个方面以产生又一个方面。因此,本公开旨在涵盖这样的修改和变化。
一般而言,本公开涉及双组分纤维,其具有改善的可纺性、粘连性以及类似衣服的手感,而不牺牲强度。双组分纤维含有非弹性聚乙烯或聚丙烯皮和含有两种或更多种聚丙烯基弹性体和仲酰胺非粘连添加剂的聚丙烯基弹性体芯。特别地,本公开令人惊讶地发现,当根据本公开形成包括其中芯中包含至少两种聚丙烯基弹性体和仲酰胺的双组分纤维时,双组分纤维可表现出粘连特性、纺织特性和改善的类似衣服的感觉,同时还提供高强度纤维。此外,即使当皮通常不含仲酰胺粘连添加剂时,也表现出这些特征。
例如,如使用在下面的实例中更详细地讨论的压杯方法所测量,根据本公开的双组分纤维可具有改善的柔软性。具体而言,从压杯测试获得的峰值负荷越低,材料越软。因此,在一个方面,根据本公开的双组分纤维或由其形成的非织造物可以基于基重为约48gsm的非织造网而表现出约100克力(gf)或更小,例如约50gf或更小,例如约25gf或更小,例如约20gf或更小,例如约17.5gf或更小,例如约15gf或更小,例如约14gf或更小的压杯抗弯刚度。压杯峰值负荷也可报告为由样品基重归一化的值。因此,在一个方面,双组分纤维和/或由其形成的非织造网可表现出约2.1gf/gsm或更小,例如约2gf/gsm或更小,例如约1.9gf/gsm或更小,例如约1.8gf/gsm或更小,例如约1.7gf/gsm或更小,例如约1.6gf/gsm或更小,例如约1.5gf/gsm或更小,例如约1.4gf/gsm或更小,例如约1.3gf/gsm或更小,例如约1.2gf/gsm或更小,例如约1.1gf/gsm或更小,例如约1gf/gsm或更小,例如约0.9gf/gsm或更小,例如约0.8gf/gsm或更小,例如约0.7gf/gsm或更小,例如约0.6gf/gsm或更小,例如约0.5gf/gsm或更小,例如约0.4gf/gsm或更小,例如约0.3gf/gsm或更小,例如约0.25gf/gsm或更小的归一化压杯峰值负荷。
此外,根据本公开的双组分纤维或由其形成的非织造物也可以表现出优异的戳穿性,这表明该纤维具有优异的材料强度,同时保持柔软和弹性。因此,在一个方面,双组分纤维和/或由其形成的非织造物可以基于基重为约48gsm的非织造网而表现出约1100gf或更大,例如约1150gf或更大,例如约1200gf或更大,例如约1250gf或更大,例如约1300gf或更大,例如约1350gf或更大,例如约1400gf或更大的破裂峰值负荷。破裂峰值负荷也可报告为由样品基重归一化的值。因此,在一个方面,双组分纤维和/或由其形成的非织造网可表现出约22gf/gsm或更大,例如约22.5gf/gsm或更大,例如约23gf/gsm或更大,例如约24gf/gsm或更大,例如约25gf/gm或更大,例如约26gf/gsm或更大,例如约27gf/gsm或更大,例如约28gf/gsm或更大,例如约29gf/gsm或更大,例如约30gf/gsm或更大的归一化破裂峰值负荷。
另外,本公开还已发现,双组分纤维还表现出改善的纺织特性,同时保持良好的弹性和强度特性以及类似衣服的感觉。例如,如上文关于形成所论述,灰度级(GL)%变异系数(COV)是纺粘物的均匀性或形成的定量度量。深色区域看起来较暗,浅色区域较亮,每个区域均分配灰度级。然后定量评估所获取的纺粘物的代表性图像的灰度级的变化,以确定局部基重的变化,并因此,较低的灰度变化指示更均匀的材料。因此,在一个方面,使用根据本公开的双组分纤维形成的纺粘物可以基于基重为约17gsm的非织造网而表现出约27.5%或更小,例如约27%或更小,例如约26.5%或更小,例如约26%或更小,例如约25.5%或更小,例如约25%或更小,例如约24.5%或更小的GL%COV。此外,如图2A-2D、图2A和2C所示,其示出了由根据本公开的在芯中含有仲酰胺的双组分纤维形成的纺粘网,所述纺粘网与在芯中不含有仲酰胺而形成的纺粘物相比表现出更小的变化(例如,图2B和2D)。
此外,本公开已发现双组分纤维表现出如通过改善的热扩散率所表现出的类似布的感觉,其测量在以下实例中描述。例如,由双组分纤维形成的非织造网可表现出约90Ws1 /2/m2K或更高的热导率,例如约95Ws1/2/m2K或更高,例如约100Ws1/2/m2K或更高,例如约105Ws1/2/m2K或更高,例如约110Ws1/2/m2K或更高,例如约115Ws1/2/m2K或更高,例如约120Ws1 /2/m2K或更高,例如约125Ws1/2/m2K或更高,例如约130Ws1/2/m2K或更高,例如约135Ws1/2/m2K或更高,例如约150Ws1/2/m2K或更高,例如约155Ws1/2/m2K或更高。
在一个方面,仲酰胺可以是脂肪酸酰胺,例如源自脂肪酸和氨或含胺化合物(例如,含有伯胺基或仲胺基的化合物)之间生成仲酰胺的反应的合适的酰胺化合物。脂肪酸可以是任何合适的脂肪酸,诸如饱和或不饱和C8-C28脂肪酸或饱和或不饱和C12-C28脂肪酸。在某些方面,脂肪酸可以是芥酸(即,顺-13-二十二烯酸)、油酸(即,顺-9-十八烯酸)、硬脂酸(十八酸)、山萮酸(即,二十二酸)、花生酸(即,花生烷酸或二十酸)、棕榈酸(即,十六酸)以及它们的混合物或组合。含胺化合物可以是任何合适的含胺化合物,诸如脂肪胺(例如,硬脂胺或油胺)、乙二胺、2,2′-亚氨基二乙醇和1,1′-亚氨基二丙-2-醇。
在一个方面,仲酰胺可以是具有式(I)-(III)中的一个式的结构的脂肪酸酰胺:
其中,
R14、R15、R16和R18独立地选自C7-C27烷基基团和C7-C27烯基基团,以及在一些方面,C11-C27烷基基团和C11-C27烯基基团;并且
R17选自C8-C28烷基基团和C8-C28烯基基团,以及在一些方面,C12-C28烷基基团和C12-C28烯基基团。
例如,脂肪酸酰胺具有式(I)的结构,其中R14是-CH2(CH2)10CH=CH(CH2)7CH3(芥酸酰胺)并且R15是-CH2(CH2)15CH3,或者其中R15是-CH2(CH2)6CH=CH(CH2)7CH3(油酸酰胺)并且R15是-CH2(CH2)13CH3。同样地,在其他方面,脂肪酸酰胺可以具有式(II)的结构,其中R16是CH2(CH2)15CH3或-CH2(CH2)6CH=CH(CH2)7CH3。仲酰胺还可以含有两种或更多种这样的脂肪酸酰胺的混合物。然而,在一个方面,诸如下文讨论的实例,仲酰胺添加剂是芥酸酰胺、油酸酰胺、油基棕榈酰胺、亚乙基双油酸酰胺、硬脂基芥酸酰胺或它们的组合。当然,应理解,在一个方面,仲酰胺可以是非脂肪酸酰胺。
无论选择何种仲酰胺,在一个方面,基于芯的重量,仲酰胺以约0.1重量%至约10重量%的量存在于芯中,例如约0.25重量%至约5重量%,例如约0.5%至约2.5重量%,例如约0.6%至约1.5重量%,例如约0.7%至约1%,或者其间的任何范围或值。具体而言,本公开已发现,令人惊讶的是,芯中的仲酰胺即使在芯中少量使用时也为双组分纤维提供了改善的可纺性和非粘连性特性。
因此,在一个方面,基于纤维的重量(例如,芯的重量+任何皮的重量),仲酰胺可以约0.05%至约8%,例如约0.1%至约4%,例如约0.25%至约2%,例如约0.5%至约1%,或者其间的任何范围或值的量存在于纤维中。
在一个方面中,仲酰胺通常可以是分子量为约100g/mol至约1000g/mol,例如约200g/mol至约900g/mol,例如约300g/mol至约800g/mol,例如约400g/mol至约700g/mol,或者其间的任何范围或值的低分子量仲酰胺。
尽管选择了仲酰胺,但本公开还已发现,虽然仲酰胺还可改善纤维和所得非织造物的类似衣服的手感,但纤维的类似衣服的手感可通过形成双组分纤维来进一步改善,所述双组分纤维具有至少一个由非弹性体聚乙烯或聚丙烯聚合物形成的皮,以及含有两种或更多种与仲酰胺结合的聚丙烯基弹性体的聚丙烯基弹性体芯。因此,在一个实例中,根据本公开的双组分弹性体纤维可以在卷绕成辊或线轴之前和之后表现出弹性特性,并且还可以具有允许纤维从辊或线轴退绕同时保持类似衣服的感觉的粘连特性。此外,已经发现,即使当一个或多个皮构成弹性体组合物的总重量的不到约50%,例如约45%或更少,例如约40%重量或更少,例如约35%或更少,例如约30%或更少,例如约25%或更少,例如约20%或更少,例如约15%或更少,例如约10%或更少时,也会表现出优异的非粘连特性。
不管皮的数量如何,在一个方面,可用于芯的弹性体可以由多种热塑性弹性体和塑性体聚合物,例如弹性体聚酯、弹性体聚氨酯、弹性体聚酰胺、弹性体共聚物、弹性体聚烯烃等中的一者或多者形成。在一个特定方面,弹性体半结晶聚烯烃因其独特的机械和弹性体特性的组合而被使用。半结晶聚烯烃具有或能够表现出基本上规则的结构。例如,半结晶聚烯烃可在其未变形状态下为基本上无定形的,但在拉伸时形成晶畴。烯烃聚合物的结晶度可为约3%至约60%,在一些方面为约5%至约45%,在一些方面为约10%至约40%以及在一些方面为约15%至约35%。同样,半结晶聚烯烃可具有约15至约210焦耳/克(“J/g”),在一些方面约20至约100J/g,在一些方面约20至约65J/g以及在一些方面25至约50J/g的熔化潜热(·Hf),熔化潜热是结晶度的另一个指标。半结晶聚烯烃也可具有约10·C至约100·C,在一些方面约20·C至约80·C以及在一些方面约30·C至约60·C的维卡软化温度。半结晶聚烯烃可具有约20·C至约120·C,在一些方面约35·C至约90·C以及在一些方面约40·C至约80·C的熔融温度。熔化潜热(·Hf)和熔融温度可使用差示扫描量热法(“DSC”)根据ASTM D-3417测定,如本领域技术人员熟知的那样。维卡软化温度可根据ASTMD-1525测定。
示例性半结晶聚烯烃包括聚乙烯、聚丙烯以及它们的共混物和共聚物。在一个特定方面,采用作为乙烯和·-烯烃(诸如C3-C20·-烯烃或C3-C12·-烯烃)的共聚物的聚乙烯。合适的·-烯烃可以是直链的或支链的(例如,一个或多个C1-C3烷基支链,或芳基基团)。具体的实例包括1-丁烯;3-甲基-1-丁烯;3,3-二甲基-1-丁烯;1-戊烯;具有一个或多个甲基、乙基或丙基取代基的1-戊烯;具有一个或多个甲基、乙基或丙基取代基的1-己烯;具有一个或多个甲基、乙基或丙基取代基的1-庚烯;具有一个或多个甲基、乙基或丙基取代基的1-辛烯;具有一个或多个甲基、乙基或丙基取代基的1-壬烯;乙基、甲基或二甲基取代的1-癸烯;1-十二烯以及苯乙烯。特别期望的·-烯烃共聚单体是1-丁烯、1-己烯和1-辛烯。这样的共聚物的乙烯含量可以为约60摩尔%至约99摩尔%,在一些方面为约80摩尔%至约98.5摩尔%以及在一些方面为约87摩尔%至约97.5摩尔%。·-烯烃含量可同样在约1摩尔%至约40摩尔%,在一些方面约1.5摩尔%至约15摩尔%以及在一些方面约2.5摩尔%至约13摩尔%的范围内。
聚乙烯的密度可根据所用的聚合物的类型而变化,但通常在从约0.85g/cm3至约0.96g/cm3的范围内。聚乙烯“塑性体”例如可具有在从0.85g/cm3至0.91g/cm3范围内的密度。同样,“直链低密度聚乙烯”(LLDPE)可具有在从约0.91g/cm3至约0.94g/cm3范围内的密度;“低密度聚乙烯”(LDPE)可具有在从约0.91g/cm3至约0.94g/cm3范围内的密度;并且“高密度聚乙烯”(HDPE)可具有在从0.94g/cm3至0.96g/cm3范围内的密度。密度可根据ASTM1505测量。
尤其合适的聚乙烯共聚物是“直链的”或“基本上直链的”那些。术语“基本上直链的”意指:除了可归因于共聚单体的并入而产生的短链支链外,乙烯聚合物还在聚合物主链中包含长链支链。“长链支链”是指至少6个碳的链长。每条长链支链可具有与聚合物主链相同的共聚单体分布,并和其附接到的聚合物主链一样长。优选的基本上线性的聚合物被每1000个碳0.01条长链支链至每1000个碳1条长链支链取代,以及在一些方面被每1000个碳0.05条长链支链至每1000个碳1条长链支链取代。与术语“基本上直链的”相比之下,术语“直链的”意指聚合物缺乏可以测量的或显而易见的长链支链。也就是说,聚合物平均被每1000个碳低于0.01条长链支链取代。
直链乙烯/·-烯烃共聚物的密度是·-烯烃的长度和量两者的函数。也就是说,·-烯烃的长度越大且存在的·-烯烃的量越多,则共聚物的密度越低。虽然不是必需的,但是直链聚乙烯“塑性体”是尤其理想的,因为·-烯烃短链支化含量使得乙烯共聚物既表现出塑性也表现出弹性体特征,即“塑性体”。由于与·-烯烃共聚单体的聚合降低结晶度和密度,因此所得的塑性体通常具有低于聚乙烯热塑性聚合物(例如,LLDPE)但接近和/或重叠弹性体的密度。例如,聚乙烯塑性体的密度可以为0.91g/cm3或更低,在一些方面为约0.85g/cm3至约0.88g/cm3以及在一些方面为约0.85g/cm3至约0.87g/cm3。尽管具有类似于弹性体的密度,但是塑性体通常表现出更高的结晶度,并且可以形成不粘的且可相对自由流动的粒料。
·-烯烃共聚单体在聚乙烯塑性体内的分布在形成乙烯共聚物的不同分子量部分之中通常是随机和均匀的。共聚单体在塑性体内分布的这种均匀性可表示为60或更大,在一些方面80或更大以及在一些方面90或更大的共聚单体分布宽度指数值(“CDBI”)。另外,聚乙烯塑性体可通过DSC熔点曲线来表征,该曲线表现出在50至110·C(第二熔体塌陷(melt rundown))区域中出现单个熔点峰。
用于本公开的合适的塑性体是可以名称EXACTTM得自Texas、Houston的ExxonMobilChemical Company、以ENGAGETM和AFFINITYTM得自Michigan、Midland的Dow ChemicalCompany的基于乙烯的共聚物塑性体,以及以商品名INFUSETM,诸如INFUSETM 9807得自Michigan、Midland的Dow Chemical Company的烯烃嵌段共聚物。可用于本公开的纤维中的聚乙烯是DOWTM61800.41。另外其他适合的乙烯聚合物可以名称DOWLEXTM(LLDPE)、ASPUNTM(LLDPE)和ATTANE?(ULDPE)得自The Dow Chemical Company。其他合适的乙烯聚合物在授予Ewen等人的美国专利号4,937,299、授予Tsutsui等人的美国专利号5,218,071、授予Lai 等人的美国专利号5,272,236和授予Lai等人的美国专利号5,278,272中有所描述,这些专利全文以引用方式并入本文以用于所有目的。
然而,如上所述,应当理解,在一个方面,一个或多个皮由一种或多种乙烯或丙烯聚合物形成,诸如一种或多种大体上非弹性体乙烯或丙烯聚合物。因此,在一个方面,非弹性体聚烯烃可以包括通常无弹性的聚合物,诸如常规聚烯烃(例如,聚乙烯、低密度聚乙烯(LDPE)、齐格勒-纳塔催化的直链低密度聚乙烯(LLDPE)等、超低密度聚乙烯(ULDPE)、聚丙烯、聚丁烯等)、聚四氟乙烯、聚酯(例如,聚对苯二甲酸乙二醇酯(PET)等)、聚乙酸乙烯酯、聚氯乙烯-乙酸乙烯酯、聚乙烯醇缩丁醛、丙烯酸树脂(例如,聚丙烯酸酯、聚丙烯酸甲酯、聚甲基丙烯酸甲酯等)、聚酰胺(例如,尼龙)、聚氯乙烯、聚偏二氯乙烯、聚苯乙烯、聚乙烯醇、聚氨酯、聚乳酸、它们的共聚物和混合物等等。例如,皮可包括可得自Mich.、Midland的DowChemical Co.的LLDPE,诸如DOWLEXTM 2517或DOWLEXTM 2047或其组合,或Tex.、Houston的Westlake Chemical Corp.。此外,在一个方面,非粘连聚烯烃材料可以是其他适合的乙烯聚合物,诸如可以名称ASPUNTM(LLDPE)和ATTANETM(ULDPE)得自Dow Chemical Company的那些。可从Dow Chemical Company以名称DOWLEXTM(LLDPE),ASPUNTM(LLDPE)和ATTANETM(ULDPE)。
不考虑选择用于一个或多个皮的聚合物,芯可以由两种或更多种如上所述的半结晶聚烯烃形成。例如,丙烯聚合物也可适于用作半结晶聚烯烃。合适的塑性体丙烯聚合物可包括例如丙烯共聚物或三元共聚物,包括丙烯与·-烯烃(例如C3-C20)诸如乙烯、1-丁烯、2-丁烯、各种戊烯异构体、1-己烯、1-辛烯、1-壬烯、1-癸烯、1-十一烯、1-十二烯、4-甲基-1-戊烯、4-甲基-1-己烯、5-甲基-1-己烯、乙烯基环己烯、苯乙烯等的共聚物。丙烯聚合物的共聚单体含量可为约35重量%或更低,在一些方面为约1重量%至约20重量%以及在一些方面为约2重量%至约10重量%。优选地,聚丙烯(例如,丙烯/·-烯烃共聚物)的密度可以为0.91克每立方厘米(g/cm3)或更低,在一些方面为0.85至0.88g/cm3以及在一些方面为0.85g/cm3至0.87g/cm3。适合的基于丙烯的共聚物塑性体可以名称VISTAMAXXTM(例如,2330、6202和6102)(基于丙烯-乙烯共聚物的塑性体)从Houston,Texas的ExxonMobilChemical Co.商购获得,以名称FINATM(例如,8573)从Feluy,Belgium的Atofina Chemicals商购获得,以名称TAFMERTM从Mitsui Petrochemical Industries商购获得,以及以名称VERSIFYTM从Midland,Michigan的Dow Chemical Co.商购获得。合适的丙烯聚合物的其他实例在授予Datta等人的美国专利号6,500,563、授予Yang等人的美国专利号5,539,056和授予Resconi等人的美国专利号5,596,052中有所描述,这些专利全文以引用方式并入本文以用于所有目的。
然而,应理解,在一个方面,芯由丙烯聚合物和/或共聚物形成。因此,在一个方面,芯由基于丙烯的共聚物塑性体形成,例如以名称VISTAMAXXTM(例如,2330、6202、6102和7050)从Texas、Houston的ExxonMobil Chemical Co.商购获得的丙烯基共聚物(基于丙烯-乙烯共聚物的塑性体),以名称FINATM(例如,8573)从Belgium、Feluy的Atofina Chemicals商购获得,以名称TAFMERTM从Mitsui Petrochemical Industries商购获得,以及以名称VERSIFYTM从Michigan、Midland的Dow Chemical Co.商购获得。
然而,在一个方面,可以选择两种或更多种聚丙烯弹性体的组合以形成具有紧密排列的链的更有序的结构。因此,在一个方面,基于芯的重量,第一聚丙烯弹性体可以以约30重量%或更大,诸如约35重量%或更大,诸如约37.5重量%或更大,诸如约40重量%或更大,诸如约45重量%或更大,诸如约50重量%或更大,诸如约55重量%或更大,诸如约60重量%或更大,至多约95重量%,或其间的任何范围或值的量存在于芯中。第一聚丙烯弹性体可具有小于0.867g/m3,诸如约0.865g/m3或更小,诸如约0.862g/m3或更小,诸如低至约0.86g/m3的密度。在一个方面,第一聚丙烯弹性体可被认为是低密度聚丙烯弹性体。例如,此类聚丙烯弹性体可以商品名VISTAMAXXTM出售,诸如VISTAMAXX 7050。
此外,基于芯的重量,第二聚丙烯弹性体可以以约65重量%或更少,诸如约60重量%或更少,诸如约55重量%或更少,诸如约50重量%或更少,诸如约45重量%或更少,诸如约40重量%或更少,诸如约5重量%或更大,或其间的任何范围或值的量存在于芯中。第二聚丙烯弹性体可具有大于0.867g/m3,诸如约0.868g/m3或更大,诸如约0.87g/m3或更大,诸如约0.88g/m3或更大,诸如约0.89g/m3或更大,诸如至多约0.9g/m3的密度。在一个方面,第二聚丙烯弹性体可被认为是高密度聚丙烯弹性体。此类聚丙烯弹性体可以商品名VERSIFYTM出售,诸如VERSIFY 4301和/或VERSIFY 4200。
特别地,不希望受理论束缚,本公开已经发现,当如本文所述的聚丙烯聚合物的共混物用于形成芯时,观察到更有序和堆积的聚合物链。如将在下面更详细地讨论的,当使用如本文讨论的两种或更多种聚丙烯聚合物时,聚合物链能够以更有序的结构排列,这在单独使用低密度共聚物或高密度共聚物时是不能实现的。因此,在一个方面,基于上述量选择芯中第一聚丙烯弹性体的量和第二聚丙烯弹性体的量,以提供根据以上讨论的FTIR峰高比测量的约0.52或更大,诸如约0.55或更大,诸如约0.58或更大,诸如约0.6或更大,诸如约0.63或更大,诸如约0.65或更大的芯组合物的842cm-1FTIR峰与974cm-1FTIR峰的峰高比(指示更大的对齐和更有序的链)。
另外,在一个方面,在芯中可以包含少量的不含·-烯烃共聚单体的纺粘级聚丙烯,诸如聚丙烯均聚物,也称为纺粘级聚丙烯,以便进一步改善纤维的强度特性。然而,当存在时,基于芯制剂的重量,纺粘级聚丙烯的存在量为约15重量%或更少,诸如约12.5重量%或更少,诸如约10重量%或更少,诸如约7.5重量%或更少,诸如约5重量%或更少,诸如约4重量%或更少,诸如约3重量%或更少,诸如约2重量%或更少,诸如约1重量%或更少。特别地,当存在时,纺粘级聚丙烯以足以赋予强度特性而不影响类似布的感觉的量存在。
多种已知技术中的任一种通常都可以用于形成半结晶聚烯烃。例如,烯烃聚合物可以使用自由基或配位催化剂(例如,齐格勒-纳塔(Ziegler-Natta))形成。优选地,烯烃聚合物由单中心配位催化剂诸如茂金属催化剂形成。这样的催化剂体系产生这样的乙烯共聚物,其中共聚单体在分子链内无规分布而在不同分子量的部分中均匀分布。茂金属催化的聚烯烃例如在授予McAlpin等人的美国专利号5,571,619、授予Davis等人的美国专利号5,322,728、授予Obijeski等人的美国专利号5,472,775、授予Lai等人的美国专利号5,272,236和授予Wheat等人的美国专利号6,090,325中有所描述,这些专利全文以引用方式并入本文以用于所有目的。茂金属催化剂的实例包括双(正丁基环戊二烯基)二氯化钛、双(正丁基环戊二烯基)二氯化锆、双(环戊二烯基)氯化钪、双(茚基)二氯化锆、双(甲基环戊二烯基)二氯化钛、双(甲基环戊二烯基)二氯化锆、二茂钴、环戊二烯基三氯化钛、二茂铁、二氯二茂铪、异丙基(环戊二烯基-1-芴基)二氯化锆、二氯二茂钼、二茂镍、二氯二茂银、二茂钌、二氯二茂钛、氢氯二茂锆、二氯二茂锆等。用茂金属催化剂制得的聚合物通常具有窄分子量范围。例如,茂金属催化的聚合物可以具有4以下的多分散性数值(Mw/Mn)、受控的短链支化分布以及受控的全同立构规整度。
半结晶聚烯烃的熔体流动指数(MI)通常可以变化,但通常在约0.1克/10分钟至约100克/10分钟,在一些方面约0.5克/10分钟至约50克/10分钟以及在一些方面约1至约35克/10分钟,诸如约1.5至约25克/10分钟的范围内,这些值在190·C下测定。熔体流动指数是当在190·C下在10分钟内经受5000克力时被迫使通过挤出式流变仪孔口(0.0825英寸直径)的聚合物的重量(以克计)并可根据ASTM测试方法D1238-E测定。
虽然至此已针对芯和皮两者论述了弹性体,但应理解,芯和皮可含有相同的弹性体或不同的一种或多种弹性体。例如,在一个方面,芯可包含两种或更多种聚丙烯基共聚物弹性体,诸如如上所述的聚丙烯/乙烯共聚物(例如,单独的VISTAMAXXTM和/或VERSIFYTM或与其他丙烯聚合物组合),而皮可包含非弹性聚乙烯聚合物(例如,ASPUNTM)。
尽管如此,如上文所论述,本公开已发现,通过包含非弹性体聚烯烃材料与含有基于丙烯的弹性体和仲酰胺的芯组合,可形成表现出类似衣服的感觉的非封闭双组分纤维,并且即使仲酰胺包含在芯中,也显示出改善的可纺性和粘连性。
尽管为皮和芯选择了弹性体,和/或为皮选择了非弹性体聚烯烃,但是如上所述的单一聚合物可以用于形成芯、皮或芯和皮两者的弹性体和/或非弹性体聚烯烃,其量基于非织造网材料的总重量为至多100重量%,例如约75重量%至约99重量%,例如约80重量%至约98重量%,例如约85重量%至约95重量%。然而,在其他方面,弹性体和/或非弹性体聚烯烃可以包括来自上述聚合物的两种或更多种聚合物。
此外,不考虑所选择的弹性体和非弹性体聚烯烃,在一个方面,芯的存在量为弹性体组合物总重量的约50重量%至约97.5重量%,例如弹性体组合物总重量的约60重量%至约95重量%,例如约70重量%至约92.5重量%,例如约80重量%至约90重量%,例如约82.5重量%至约87.5重量%,或其间的任何范围或值。
此外,在一个方面,除了非弹性聚烯烃之外,或者代替非弹性聚烯烃,皮还可以包含一种或多种无机填料。因此,在一个方面,皮包含碳酸钙(CaCO3)、各种粘土、二氧化硅(SO2)、氧化铝、硫酸钡、碳酸钠、滑石、硫酸镁、二氧化钛、沸石、硫酸铝、纤维素型粉末、硅藻土、硫酸镁、碳酸镁、碳酸钡、高岭土、云母、碳、氧化钙、氧化镁、氢氧化铝、纸浆粉、木粉、纤维素衍生物、聚合物颗粒、甲壳质和甲壳质衍生物。在一个方面,无机颗粒可包括碳酸钙、硅藻土或它们的组合。
在一个方面,皮、芯或皮和芯两者可以包括颜料颗粒。在一个方面,皮、芯或皮和芯均包含基于皮的总重量约0.1%至约5%的颜料颗粒,例如约0.5%至约4.5%,例如约1%至约4%,例如约1.5%至约3.5%,或其间的任何范围或值。
此外,在一个方面,皮、芯或皮和芯两者可以包括润湿剂,以赋予双组分纤维润湿性。在此方面,基于相应的皮和/或芯的重量,皮、芯或皮和芯两者包括约10重量%或更小的润湿剂,例如约9重量%或更小,例如约8重量%或更小,例如约7重量%或更小,例如约5重量%或更小,例如约2.5重量%或更小。在一个方面,芯和皮两者都可以包括根据上述论述的量的润湿剂,然而应理解,上述参考量也可以关于皮和芯中的润湿剂的总量。此外,在一个方面,皮和芯不包含润湿剂。
尽管选择了一种或多种最终聚合物和添加剂,但根据本公开的含有仲酰胺的双组分纤维可表现出优异的特性。例如,在一个方面,基于基重为约48gsm的非织造网,根据本发明的纤维可表现出约80%或更小的滞后损失,例如约75%或更小,例如约72.5%或更小,例如约70%或更小,例如约67.5%或更小,对于该非织造网,测试方法在以下实施例中更详细地定义,或者其间的任何范围或值。
此外,纤维可以基于基重为约48gsm的非织造网,表现出约20%或更小,例如约17.5%或更小,例如约15%或更小,例如约12.5%或更小,例如约11%或更小的30%伸长率,如以下实施例中更详细地论述的,或其间的任何范围或值。
例如,在一些方面,纤维可具有皮-芯排列,其中皮可占纤维总重量的约50%或更少,例如约45%或更少,例如约40%或更少,例如约35%或更少,例如约30%或更少,例如约25%或更少,例如约20%或更少,例如约15%或更少,例如约10%或更少。此外,在一个方面,芯可以占纤维的总重量的约50重量%至约97.5重量%,诸如纤维的总重量的约60重量%至约95重量%,诸如约70重量%至约92.5重量%,诸如约80重量%至约90重量%,或者它们之间的任何范围或值。
尽管如此,在一个方面,本公开通常还可以包括使用根据本公开的弹性体双组分纤维形成纺粘网。
无论采用何种特定聚合物,通常可采用多种技术来形成由本公开的弹性体双组分纤维形成的纺粘网。例如,在一个方面中,纺粘网可通过纺粘工艺形成,在纺粘工艺中,将两种或多种聚合物组合物进料到挤出机中并通过导管挤出到喷丝头。用于挤出纤维的喷丝头是本领域技术人员熟知的。例如,喷丝头可以包括含有纺丝组(spin pack)的外壳,该纺丝组具有多个堆叠在彼此之上的板并具有排列成产生聚合物组合物的流路的开口图案。喷丝头也可以具有布置成一行或多行的开口,这些开口在当聚合物从中挤出时形成向下挤出的纤维帘。该工艺还可以采用紧邻从喷丝头中延伸的纤维帘定位的骤冷鼓风机。来自骤冷鼓风机的空气将纤维在其形成时骤冷。纤维牵伸单元或抽吸器也可定位在喷丝头下方以接收骤冷后的纤维。用于熔纺聚合物的纤维牵伸单元或抽吸器是本领域熟知的。纤维牵伸单元可包括细长的竖直通道,通过抽吸空气从通道侧面进入并穿过通道向下流动而从通道中牵伸纤维。加热器或鼓风机可向纤维牵伸单元供应抽吸空气,纤维牵伸单元牵伸纤维和环境空气从中通过。
一般来讲,所得纤维具有约100微米或更小的平均尺寸(例如,直径),在一些方面约0.1微米至约50微米,例如约0.5微米至约40微米,例如约1微米至约30微米,例如约2.5微米至约20微米,或其间的任何范围或值。
不管纺粘网的形式如何,添加剂也可以掺入纺粘网或由其形成的纤维中,例如熔体稳定剂、加工稳定剂、热稳定剂、光稳定剂、抗氧化剂、热老化稳定剂、增白剂、防粘连剂、粘度调节剂等。也可以采用粘度调节剂,诸如聚乙烯蜡(例如,得自Eastman Chemical的EPOLENETM C-10)。亚磷酸酯稳定剂(例如,可得自Tarrytown,N.Y.的Ciba SpecialtyChemicals的IRGAFOS和可得自Dover,Ohio的Dover Chemical Corp.的DOVERPHOS)是示例性的熔体稳定剂。此外,受阻胺稳定剂(例如,可得自Ciba Specialty Chemicals的CHIMASSORB)是示例性的热和光稳定剂。另外,受阻酚在膜制造中常用作抗氧化剂。一些合适的受阻酚包括可以商品名IRAGANOXTM诸如IRGANOXTM 1076、1010或E201得自CibaSpecialty Chemicals的那些。当采用时,此类添加剂(例如抗氧化剂、稳定剂等)可各自以非织造网材料的约0.001重量%至约25重量%,在一些方面约0.005重量%至约20重量%以及在一些方面0.01重量%至约15重量%的量存在。
现参考图1,将论述纤维形成过程的各个方面。参见图1,例如,更详细地示出了可用在本公开中的形成纤维的过程的一个方面。虽然绝不是必需的,但是图1中所示的过程被配置成形成具有A/B构型的基本上连续的双组分纤维。更具体地讲,聚合物组合物A和B最初被供应到纤维纺丝设备21以形成双组分纤维23。一旦形成后,纤维23便穿过纤维牵伸单元25并沉积在移动的成型线材27上。纤维的沉积通过由吸气箱29提供的线材下方的真空来辅助,该真空将纤维23向下拉到成型线材27上。成型线材27是多孔的,以使得由吸气箱29形成的垂直空气流可导致纤维落下。在本公开的一个方面中,该空气流的流量可保持相对较低,以增强纤维23保持在MD方向上取向的趋势。或者,吸气箱可包括在纵向上延伸以在纤维落到移动网上的地方破坏垂直空气流的区段,从而使得纤维可以具有更高程度的纵向取向。这样的技术的一个例子在例如美国专利号6,331,268中有所描述。当然,也可以采用其他技术来帮助纤维保持在纵向上取向。例如,可以采用偏转器导向板或其他机械元件,诸如在美国专利号5,366,793和7,172,398中所述。用于在形成纤维时使纤维变细的空气流的方向也可用于调整以实现纵向取向,诸如在美国专利号6,524,521中所述。除了上述过程以外,也可以采用其他已知的技术来形成纤维。在一个方面,例如,纤维可在其形成后被骤冷,然后直接沉积在成型线材上,而不用首先以上述方式牵伸。在此类方面,如上所述,可以保持这种气流的流动速率相对低,以增强纤维在MD方向上保持取向的取向,然而,应理解,在一个方面,纤维主要不在MD方向上取向。
再次参见图1,一旦形成纤维23后,它们即可通过扩散器33加热,扩散器可将热空气吹到纤维表面上以将它们轻轻粘结在一起以供进一步加工。热空气刀也可用作扩散器的替代选择。也可以采用用于使网整合的其他技术,诸如加热的压延辊。不管怎样,所得的纤维然后可以粘结以形成固结、连贯的非织造网结构。任何合适的粘结技术通常都可以用于本公开,诸如粘合剂或自发粘结(比如,纤维的融合和/或自粘,而不用施加外部粘合剂)。自发粘结例如可通过使纤维在它们为半熔融或发粘状态时接触,或只是通过将增粘树脂和/或溶剂与用于形成纤维的聚合物组合物共混而实现。合适的自发粘结技术可包括超声粘结、热粘结、空气穿透粘结等等。热点粘结例如通常采用在两根辊之间形成的辊隙,这两根辊中的至少一根图案化。在另一方面,超声粘结通常采用在超声变幅杆与图案化辊之间形成的间隙。
粘结图案的特定性质可以根据需要而变化。一种合适的粘结图案例如称为“S形编织”图案,并在授予McCormack等人的美国专利号5,964,742中有所描述。另一种合适的粘结图案称为“罗纹针织”图案并在授予Levy等人的美国专利号5,620,779中有所描述。又一种合适的图案是“线材编织”图案,其具有约200至约500个粘结部位每平方英寸以及在一些方面约250至约350个粘结部位每平方英寸的粘结密度。当然,也可以使用其他粘结图案,诸如在授予Hansen等人的美国专利号3,855,046、授予Haynes等人的美国专利号5,962,112、授予Sayovitz等人的美国专利号6,093,665、授予Edwards等人的D375,844、授予Romano等人的D428,267和授予Brown的D390,708中所述。此外,还可以采用结合模式,所述结合模式包含大体在纵向上取向并且具有约2至约100、在一些方面约4至约50、以及在一些方面约5至约20的纵横比的粘结区。粘结区的图案也通常选择为使得纺粘网的总粘合面积小于约50%(通过常规光学显微镜方法测定),在一些方面,小于约30%,例如小于约25%,例如小于约20%,例如小于约17.5%。
不论形成的非织造网材料的类型如何,非织造网材料的基重通常可以变化,诸如从约8克每平方米(“gsm”)至约150gsm,在一些方面中从约15gsm至约125gsm以及在一些方面中从约25gsm至约100gsm。当使用多种非织造网材料时,这样的材料可具有相同或不同的基重。
纺粘网也可接受一个或多个另外的后处理步骤,如本领域已知的那样。例如,纺粘网可用诸如拉幅机拉伸、凹槽辊拉伸等已知的技术在横向上拉伸。纺粘网还可以接受其他已知的加工步骤,诸如穿孔、热处理等。
在一个方面,利用根据本公开的弹性体双组分纤维形成的纺粘网可形成复合材料的非织造面料的全部或一部分。当然,还应当理解的是,非织造面料如果需要另外的层也可以包括另外的层(例如,非织造网、膜、股线等)。例如,面料可包括两(2)个或更多个层以及在一些方面中三(3)个至十(10)个层(例如,3或5个层)。在一个方面中,例如,非织造面料可包括定位在两个外部非织造层(例如,纺粘)之间的内部非织造层(例如,熔喷或纺粘)。例如,内部非织造层可由本公开的纺粘网形成,并且外部非织造层之一或两者可由本公开的纺粘网或常规非织造网形成。或者,内部非织造层可由本公开的纺粘网或常规非织造网形成,并且外部非织造层之一或两者可由本公开的纺粘网形成。形成具有该性质的层合物的各种技术在授予Brock等人的美国专利号4,041,203、授予Timmons等人的美国专利号5,213,881、授予Timmons等人的美国专利号5,464,688、授予Bornslaeger的美国专利号4,374,888、授予Collier等人的美国专利号5,169,706和授予Brock等人的美国专利号4,766,029中有所描述。面料可具有其他构造并具有任何所需数量的层,诸如纺粘/熔喷/熔喷/纺粘(“SMMS”)层合物、纺粘/熔喷(“SM”)层合物等。
无论纺粘非织造网形成的方法或面料中的层数如何,在一个方面,非织造面料可通过将非织造面料层合到弹性膜或其他背衬或如上所述的任何其他层上而用于层合物中。层合可使用多种技术实现,诸如通过粘合剂粘结、施热的点式粘结、超声粘结等。具体的粘结图案对于本公开不是关键的,并且上文关于纺粘网讨论的任何粘结图案、孔形成和拉伸也可用于层合。尽管如此,在一个方面,由于弹性体膜和由根据本公开的双组分纤维形成的可延展(或弹性体)非织造网材料以及层合工艺,上述层合物可具有改善的双轴拉伸和/或弯曲长度特性。
例如,在一个方面,使用约1.5或更大、或2至6、或2.5至7.0、或3.0至5.5的拉伸比以在层合期间在膜中实现期望程度的张力。拉伸比可通过将薄膜的最终长度除以其原始长度而确定。拉伸比可与牵伸比大致相同,其可通过膜在层合期间的线速度(例如,压料辊的速度)除以膜形成的线速度(例如,浇铸辊或吹塑压料辊的速度)进行确定。
无论是层合到背衬上还是单独用作非织造网,纺粘网均可用于多种应用中。例如,如上所述,纺粘网可被用于吸收制品。“吸收制品”通常是指能够吸收水或其他流体的任何制品。一些吸收制品的实例包括但不限于个人护理吸收制品,例如尿布、训练裤、吸收内裤、失禁制品、女性卫生产品(例如,卫生巾、短裤护垫等)、泳衣、婴儿擦拭物等;医用吸收制品,例如服装、开窗材料、衬垫、床垫、绷带、吸收性消毒盖布和医用擦拭物;食物服务擦拭器;衣服;等等,并且由于其改善的类似衣服的感觉,可以独特地定位用于可穿着制品。
这样的吸收制品的若干例子在授予DiPalma等人的美国专利号5,649,916、授予Kielpikowski的美国专利号6,110,158和授予Blaney等人的美国专利号6,663,611中有所描述。另外其他合适的制品在授予Fell等人的美国专利申请公开号2004/0060112 A1以及授予Damico等人的美国专利号4,886,512、授予Sherrod等人的美国专利号5,558,659、授予Fell等人的美国专利号6,888,044和授予Freiburger等人的美国专利号6,511,465中有所描述。形成这样的吸收制品的材料和工艺是本领域技术人员熟知的。通常,吸收制品包括基本上液体不可渗透的层(例如,外覆层)、液体可渗透的层(例如,身体侧衬里、涌流层等)和吸收芯。在一个特定方面,本公开的复合材料可用于提供腰部部分、腿箍/衬垫、耳片、侧片或外覆盖件。
通过参照以下实例可以更好地理解本发明。
测试方法
破裂强度
破裂强度是纤维结构在垂直于纤维结构平面发生变形时吸收能量的能力的量度。破裂强度可以根据ASTM D-6548进行测量,除了测试是在具有基于计算机的数据采集和框架控制***的定速延伸型(MTS Systems Corporation,Eden Prairie,Minn.)拉伸测试仪上进行,其中测力计定位在样本夹具上方,使得穿透构件降低到测试样本中,从而导致其破裂。测力计与样本的布置方式与ASTM D-6548的图1所示的相反。穿透组件由直径为1.588±0.005cm的半球形阳极化铝穿透部件构成,该穿透部件固定在具有球端承窝的可调节杆上。测试样本固定在样本夹钳内,该夹钳由上部和下部的铝制同心环组成,测试期间样品借助机械夹持被坚固地固定在这两个同心环之间。样本夹紧环具有8.89±0.03cm的内径。
设置拉伸测试仪,使得十字头速度为15.2cm/min,探头间距为104mm,断裂灵敏度为60%,松弛补偿为10gf,并且根据制造商的说明书校准仪器。
将样品在TAPPI条件下调节并切成127×127mm±5mm的正方形。针对每次测试,将共计3个产品片加以组合。这些片以使得它们的纵向对齐的方式堆叠在彼此顶部。在样品包含多个层片的情况下,不将这些层片分离开进行测试。在每种情况下,测试样品都包含3个产品片。例如,若产品为2层片式薄纸产品,则测试3个产品片,共计6个层片。若产品为单层片薄纸产品,则测试3个产品片,共计3个层片。
在测试之前,必要时调节探头高度,调节方式为:将破裂夹具***拉伸测试仪底部,然后降低探头,直到探头定位在对齐板上方约12.7mm为止。然后调节探头的长度,直到探头下降时停靠在对齐板的凹进区域内为止。
建议使用下述测力计,其中峰值负荷结果的大部分落在该测力计量程的10%与90%之间。为了确定最适合进行测试的测力计,初步测试样品以确定峰值负荷。如果峰值载荷<450gf,则使用10牛顿的测力计,如果峰值载荷>450gf,则使用50牛顿的测力计。
一旦已设置好设备并选定测力计,就将样品***样本夹钳中并将测试样品夹持就位,由此对样品进行测试。然后启动测试序列,致使穿透组件以上文指定的速率和距离下降。当测试样本在穿透组件作用下破裂时,显示并记录测得的穿透力阻力。然后释放样本夹具,移出样品,让设备准备好进行下一个测试。
记录峰值负载(gf)和峰值能量(g-cm)。
柔软性/压杯测试:
非织造织物的柔软性可根据“压杯”测试来测量。压杯测试通过测量峰值载荷(也称为“压杯载荷”或仅“压杯”)和压碎样品所需的能量来评价织物的硬度,并继而量化样品的柔软性。将样品置于成形杯中。然后将成形杯和样品放置在安装在拉伸测试仪上的负载板上。压脚通过成形杯的开口端下降,并“压碎”和扭曲内部的杯形样本。以克力(gf)测量的最大载荷和以克力-长度(gf-mm)测量的能量是结果。结果是材料硬度的表现。材料越硬,峰值载荷和能量值越高。材料越软,该值越低。
定速延伸型拉伸测试仪配备有计算机化的数据采集***(例如,MTS TestWorksfor Windows第4版,来自MTS Systems Corporation,Eden Prairie,Minn.55344-2290),该数据采集***能够优选地以20数据点每秒的最小数据捕获速率在压缩模式下在两个预定距离(15-60毫米)之间计算峰值负载和能量。用于测量压杯变形的合适装置是可从Schaevitz Company,Pennsauken,N.J.获得的FTD-G-500型测力计(500克范围),拉伸测试仪和测力计可从Instron Corporation,Canton,Mass.02021或Sintech,Inc.,P.O.Box14226,Research Triangle Park,N.C.27709-4226获得。
测量的能量是对于直径为4.5cm的半球形压脚将23cm×23cm的织物片压碎成直径为约6.5cm×6.5cm高的倒置杯所需的能量,同时杯形织物被直径为约6.5cm的圆柱体(成形杯)围绕以在测试期间保持杯形织物的均匀变形。使用3-5个读数的平均值。该测试在23±2℃和50±5%相对湿度的标准实验室气氛中进行。在测试之前,应该允许材料达到环境温度。通过将保持环放置在成形台上来制备样本。然后将材料放置在成形台上。将成形杯放置在样品和成形台上以使样品符合杯形。保持环与成形杯接合以将样品固定在成形杯中。取出成形杯,同时取出内部的现在成形的样品。样品通过保持环固定在成形杯内。将样品、成形杯和保持环倒置并放置在拉伸测试仪中。压脚和成形杯在拉伸测试仪中对齐,以避免杯壁和压脚之间的接触,这种接触会影响读数。压脚(0.5英寸,由轻质尼龙或金属制成)穿过倒置成形杯的底部中的开口以将杯形样品压碎在内部。在压脚以大约406mm每分钟的速率下降时测量峰值负荷,并以克为单位度量。杯形挤压测试还产生挤压样品所需的总能量(“压杯能量”)的值,该值是从测试开始到峰值加载点的能量,即由在一个轴上的以克为单位的载荷和在另一个轴上的以毫米为单位的压脚移动距离形成的曲线下的面积。因此,压杯能量以gf-mm报道。较低的压杯值表明较柔软的层合物。
原材料的多循环应力/应变测试
多循环应力/应变测试是一种用于测量弹性原材料和弹性材料复合材料的伸长和回复特征的两循环伸长和回复测试。特别地,该测试可以用于确定将所述制剂施加到基材上对其伸长和回复特征有什么影响(如果有的话)。通过该测试测量的基材性质劣化是表现为张力损失或抗伸长性的劣化,这可以导致在施加力时极端伸长,如下垂。
该测试测量放置于特定应变量(例如,伸长到特定伸长率)下的测试样品的载荷值。这种载荷值在测试的伸长和回复阶段二者期间以及两个循环中的每个期间确定。对于该实施例,载荷值设定为30%伸长率。通常,处理后保留的载荷量的减少表明对基材的弹性特征有负面影响,即使在基材没有明显劣化或脱层的情况下也是如此。
滞后是弹性材料在多次拉伸后保持其弹性性能的量度。其是在装载和卸载循环期间发生的机械能损失,并且它由装载和卸载曲线之间的面积示出。滞后损失越低,NBL/EMC保持其弹性行为越多,并且其作用越像橡胶带。这在尿布贴合性能方面是关键的,以确保甚至在多次拉伸之后耳片也能完成其扣紧工作。
永久变形百分比是由载荷引起的永久变形。因为NBL/EMC材料在被拉伸时损失了一些能量,所以当回缩循环回到0%伸长率时,它不会回到正好0克。永久变形率越低,弹性特性越好,并且材料表现得更像橡皮筋,这有助于贴合性能。
带材拉伸峰值载荷
在伸长完成之后,将样品保持在具有25.4毫米×76毫米的正面和背面的夹具之间。用橡胶处理夹具面,夹具的较长尺寸与牵拉方向垂直。夹具压力气动地保持在40磅每平方英寸的压力下。拉伸测试以每分钟300毫米的速率进行,标距长度为76毫米,断裂灵敏度为40%。
通过沿纵向施加测试载荷测试三个样品,通过沿横向施加测试载荷测试三个样品。除了拉伸强度之外,还测量了峰值载荷、峰值拉伸(即,峰值载荷下的伸长率%)和峰值能量。将每个测试样本的峰值条带拉伸载荷算术平均以确定MD或CD拉伸强度。
扩散率
根据ASTM D7984-16标准(“使用改进的瞬态平面源(MTPS)仪器测量织物的热扩散率的测试方法(Test Method for Measurement of Thermal Effusivity of FabricsUsing a Modified Transient Plane Source(MTPS)Instrument)”),使用C-Therm TCi热导率分析仪测量样品的热扩散系数。
默认的C-Therm TCi热导率分析器在表征材料的热导率和扩散率时采用改进的瞬态平面源(MTPS)技术。它采用了单侧的界面热反射传感器,该传感器向样品施加瞬时恒定热源。
实施例1
纺粘非织造网使用具有表2所示的芯组成的双组分纤维形成。皮是具有2重量%颜料的98%Dow6840A乙烯聚合物。在形成之后,对纺粘网进行强度、弹性、柔软度和可纺性的各种测试,其结果示于表2中。
表2
1-含有15重量%的如上所述的仲酰胺的浓缩物,其中芯中仲酰胺的活性量为0.75重量%
实施例2
以与实施例1相同的方式形成纤维,不同之处在于根据表3使用芯共混物。根据以上定义的FTIR峰比从由实施例2形成的纤维中获得FTIR光谱。如图3A和图3B所示,测量842cm-1处的峰,其表示CH2摇摆和C-CH3拉伸,并且是丙烯聚合物链更有序堆积的指示。另外,测量在974cm-1处的峰,其表示CH3摇摆和C-C拉伸并且与更无定形的聚丙烯相关。因此,根据实施例2,842cm-1峰与974cm-1的约0.5或更大的比率表明比单独使用Vistamax或Versify可获得的更有序的结构,这在图3C中进一步说明。
表3
虽然已经关于本公开的特定方面详细描述了本公开,但是将理解,本领域技术人员在获得对前述内容的理解后,可以容易地构想对这些方面的更改、变化和等效物。因此,本公开的范围应被评估为所附权利要求及其任何等同方案的范围。
Claims (17)
1.一种非织造网,所述非织造网包含弹性体双组分纤维,所述弹性体双组分纤维包括:
芯,所述芯包含至少两种聚丙烯基弹性体和仲酰胺;以及
至少一个皮;
其中所述至少一个皮占所述双组分纤维的总重量的小于50重量%;
其中基于基重为48克/平方米(gsm)的非织造网,所述非织造网表现出1100 gf或更大的峰值破裂负荷,或22 gf/gsm的归一化破裂峰值负荷,
其中所述至少两种聚丙烯基弹性体包括乙烯共聚物、α-烯烃共聚物或它们的组合并且所述皮包含非弹性体聚合物,并且
其中基于所述芯的重量,所述仲酰胺以0.1重量%至10重量%的量存在于所述芯中。
2.如权利要求1所述的非织造网,其中基于基重为48克/平方米(gsm)的非织造网,所述非织造网表现出100 gf或更小的压杯抗弯刚度,或2.1 gf/gsm或更小的归一化压杯抗弯刚度。
3.如权利要求1所述的非织造网,其中所述非织造网表现出90 Ws1/2/m2K或更大的扩散率。
4.如权利要求1所述的非织造网,其中所述皮包含聚乙烯聚合物。
5.如权利要求1所述的非织造网,其中基于所述芯的重量,所述仲酰胺以0.25重量%至5重量%的量存在于所述芯中。
6.如权利要求1所述的非织造网,其中所述仲酰胺为脂肪酸酰胺。
7.如权利要求1所述的非织造网,其中所述至少两种聚丙烯基弹性体包括丙烯/乙烯共聚物。
8.如权利要求1至7中任一项所述的非织造网,其中所述皮和所述芯中的至少一者还包含颜料颗粒。
9.如权利要求8所述的非织造网,其中基于所述皮或所述芯的重量,所述颜料颗粒以0.1重量%至5重量%的量存在于所述皮和所述芯中的至少一者中。
10.如权利要求1所述的非织造网,其中基于所述芯的重量,所述芯还包含5重量%或更少的聚丙烯均聚物。
11.一种弹性体层合物,所述弹性体层合物包括如权利要求1至10中任一项所述的非织造网和背衬。
12.如权利要求11所述的弹性体层合物,其中所述背衬包含弹性膜。
13.一种吸收制品,所述吸收制品由如权利要求1至10中任一项所述的非织造网或如权利要求11或12所述的层合物形成。
14. 一种弹性体双组分纤维,所述弹性体双组分纤维包括:
芯,所述芯包含至少两种聚丙烯基弹性体和仲酰胺;以及
至少一个皮;
其中所述至少一个皮占所述双组分纤维的总重量的小于50重量%;
其中所述至少两种聚丙烯基弹性体包括乙烯共聚物、α-烯烃共聚物或它们的组合并且所述皮包含非弹性体聚合物,
其中基于所述芯的重量,所述仲酰胺以0.1重量%至10重量%的量存在于所述芯中,并且
其中所述弹性体双组分纤维表现出0.525或更大的842 cm-1峰与974 cm-1峰的FTIR峰高比,是使用Perkin Elmer Frontier FTIR光谱仪基于在4 cm-1分辨率下32次扫描的平均值所测量的。
15.如权利要求14所述的弹性体双组分纤维,其中所述至少两种聚丙烯基弹性体包括第一聚丙烯基弹性体和第二聚丙烯基弹性体,其中基于所述芯的重量,所述第一聚丙烯基弹性体占所述芯的30重量%或更多。
16.如权利要求14所述的弹性体双组分纤维,其中基于所述芯的重量,所述第二聚丙烯基弹性体占所述芯的60重量%或更少。
17.如权利要求14至16中任一项所述的弹性双组分纤维,其中所述芯还包含15重量%或更少的聚丙烯均聚物。
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PCT/US2021/025216 WO2021202766A1 (en) | 2020-04-01 | 2021-03-31 | Strong elastic bicomponent fiber having unique handfeel |
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