CN1210458C - 非织造底衬及包含该底衬的地毯 - Google Patents

非织造底衬及包含该底衬的地毯 Download PDF

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CN1210458C
CN1210458C CNB998102121A CN99810212A CN1210458C CN 1210458 C CN1210458 C CN 1210458C CN B998102121 A CNB998102121 A CN B998102121A CN 99810212 A CN99810212 A CN 99810212A CN 1210458 C CN1210458 C CN 1210458C
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P·T·库仑
S·T·约翰逊三世
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Abstract

本发明涉及包含经粘合剂聚合物粘合的热塑性聚合物长丝或纤维的非织造地毯底衬，其中底衬包含至少一层可辨别的热塑性织造层，一层可辨别的热塑性连续层或一层还含经粘合剂聚合物粘合的长丝或纤维的可辨别的非织造层，该层起降低底衬脱层强度的作用，根据DIN54310测定的脱层强度相对于不含所述可辨别层同类底衬降低至少30%，优选至少50%。虽然根据本发明的未栽绒底衬的断裂强度较先有技术未栽绒底衬为低，但根据本发明的栽绒底衬的断裂强度和伸长率较先有技术栽绒的底衬为高。

Description

非织造底衬及包含该底衬的地毯
本发明涉及包含经粘合剂聚合物粘合的热塑性聚合物长丝或纤维的非织造地毯底衬。
包含经例如热塑性聚合物粘合剂粘合的长丝或纤维的非织造地毯底衬的制造，已问世多年，例如可从美国专利4842915中获知。该专利公开内容涉及由聚酯基质型长丝构成的纺粘织物，这种织物适用作地毯的栽绒基布并可通过以柔软的长丝、纤维、粉料和/或细微颗粒形态的粘合组分得以增强。该粘合组分是由熔点范围至少比聚酯基质型长丝或纤维熔点范围低90℃的聚丙烯组成的。
多年来，为了满足制造商和消费者越来越严格的要求，非织造地毯底衬已经不断得到改进。重要的改进是：提高栽绒后的断裂强度和断裂伸长率，提高栽绒和涂布后的抗撕裂性，一般改进制得地毯的外观，能修补栽绒过程中产生的缺陷并使易于栽绒，即在栽绒过程中产生较低的抵抗针刺的阻力，减少偏针，避免毛糙的回针针迹，增加毛圈簇以及降低栽绒过程的噪音。
本发明的一个目的是达到所述的改进。该目的已在第一段中所述的地毯底衬中实现，其中底衬包含至少一层可辨别的热塑性织造层，一层热塑性连续层或一层包含经粘合剂聚合物粘合的长丝或纤维的非织造层，该可辨别层起降低底衬脱层强度的作用，按照DIN 54310测得的脱层强度相对于不含所述可辨别层的同类底衬降低至少30％，优选至少50％。
一般来说，因为栽绒针的刺孔会引起破裂和/或损坏，因此，栽绒会降低非织造底衬的断裂强度(高初始断裂强度)。而且已经发现，通过(补充或附加)一层可辨别层来达到脱层强度的降低，也会明显地降低底衬的拉伸断裂强度，这种强度的降低乍看来似乎是缺点。然而，根据本发明的这种预定的断裂强度降低(即通过降低底衬的脱层强度)抑制了因栽绒引起的断裂强度和断裂伸长率的下降。虽然根据本发明的非栽绒底衬的断裂强度低于先有技术非栽绒底衬，但根据本发明的栽绒底衬实际上具有较先有技术栽绒底衬高的断裂强度和断裂伸长率。这种现象将通过以下实施例加以说明和证实。
一方面起着降低脱层强度(例如长丝或纤维有较高流动性和/或与其它层粘附性低)的作用，另一方又应具有足够的层合内聚力以便经得起(剧烈的)搬运和加工的可辨别层，它可呈许多不同的形态，例如干法成网非织造织物，湿法成网非织造织物或熔喷法非织造织物。其它实例是织造织物和连续层如薄膜或箔。然而，还可进行针刺或水力缠结(hydroentangled)的热法或化学法纺粘非织造织物是优选的。
应该指出，欧洲专利申请EP 822283涉及了包含皮/芯双组分(a)和(b)两类长丝的纺粘纤维网，其中芯组分是熔点高于作为皮组分的粘合聚合物的聚对苯二甲酸乙二醇酯。皮聚合物(a)类长丝与(b)类长丝的重量比为1∶3-1∶10。纤维网横截面上，(a)类长丝与(b)类长丝的重量比在15-70％间不等。在纤维网整个横截面平面上后一比率没有明显变化，或者没有可辨别的相界面，这样就避免了脱层。因此，这种技术是与本发明要求促进脱层的技术是背道而驰的。
日本专利申请JP 04-352861涉及了由复合长纤维A与复合长纤维B构成的非织造织物，其中复合长纤维A包含聚合物a1和熔点高于a1至少30℃的聚合物a2，复合长纤维B包含聚合物b1和熔点高于b1至少30℃的聚合物b2。而且，聚合物b1的熔点高于a1至少20℃。该织物由四层构成，第一层只含纤维A，第二层中纤维A多于纤维B，第三层中纤维B多于纤维A，第四层只含纤维B。纤维A和纤维B的浓度变化是连续的没有明显的界线，因此不会发生脱层。
美国专利3940302公开了一种适用作栽绒地毯底衬的非织造纤维网，该纤维网包含以聚丙烯为芯材和以共聚酰胺(“在高压饱和蒸汽中能变成为粘合剂，在该压力下芯组分基本上不受影响”)与聚丙烯单丝(homofilaments)一起为皮材的双组分长丝。并丝是沿纤维网纵向嵌入纤维网中的。在一个优选的实施方案中，双组分长丝在产品的至少一个表面的薄层内的浓度较在该产品中心为高，以改进底衬表面对染料的吸收。
日本专利JP 09291457涉及了一种包含多层纤维层的层合制品，其中纤维层包含由两类具有不同熔点的聚合物(即高密度聚乙烯和高密度聚丙烯)构成的平列型或皮/芯型复合长纤维。高密度聚乙烯在每层纤维层中的含量是不同的。该层合制品有极好的膨松度、手感和抗拉强度。
日本专利JP 06128855公开了一种包括表层、中间层和背层的三层结构非织造织物。表层和背层是由含热塑性聚合物组分A和与A相容的热塑性聚合物组分B的共轭型长纤维构成的。该长纤维是以组分A的熔融与组分B相粘合的。中间层包含只由A构成的纤维A和只由B构成的纤维B，其中这些纤维是通过共轭型长纤维的分丝而形成的。纤维A是与纤维B缠结的，基本上没有熔融。
美国专利5660910公开了一种包括无规铺置的连续基质长丝和连续增强长丝的纺粘型非织造复合纤维网，其中每根连续基质长丝的平均线密度低于25旦，增强长丝的平均线密度超过20旦，并超过每根所述基质长丝的平均线密度至少10旦；其中所述连续基质长丝是至少部分地粘合在一起而形成所述纤维网，而所述纤维网中的所述连续增强长丝基本上不与纤维网中其它长丝相粘合(emesh)，因此，纤维网按照ASTM D2261-83进行撕裂试验时，能拉出纤维网中三根以上增强长丝达1厘米以上。根据美国专利5660910中实施例的织物，该织物包含作为基质纱的每根为13.5旦的长丝和作为增强纱的单根300旦的尼龙66或聚对苯二甲酸乙二醇酯单丝，该织物经栽绒和模制以后，具有高的撕裂强度和具有拉出增强特性。
在本发明的框架中，包含两层可辨别层的地毯底衬是一种可行的选择，但底衬内嵌有有降低脱层强度作用的层(内层)是优选的，因此，底衬包含至少三层可辨别层。在这种结构中，外层能相对于另一层(局部地)移动，这样有助于保住栽绒纱和有助于达到所要求的稳定性和底衬其它物理性能。
每层包含(热塑性)粘合剂聚合物和热塑性聚合物长丝或纤维的、并经热粘合的底衬也是优选的，其中粘合剂聚合物在起降低脱层强度作用的层中的浓度和/或粘合温度较其它层中粘合剂聚合物低至少20％，优选至少30％和/或高4℃，优选至少6℃。通过降低粘合程度，可使脱层强度切实地降低，由于在所述层中的长丝或纤维有较大的移动性，因此栽绒纱(也称为“毛圈簇”或“毛圈保持”)的保持得到了进一步的增强。
另一方面，要仔细选择粘合剂聚合物，选择与邻近层中粘合剂聚合物不相容的粘合剂聚合物，可降低对所述层的粘合性，从而获得较低的脱层强度。
粘合剂聚合物的熔融或软化温度最好低于长丝或纤维的熔融或软化温度15-20℃，但对某些聚合物混合体来说，更小的温度差可能是适当的或者甚至是必要的。
当粘合剂聚合物是长丝或纤维的部分(粘合剂聚合物优选构成至少长丝或纤维的外表面部分)时，此时所用名词长丝或纤维是指双组分长丝或纤维，在长丝或纤维铺列时，粘合剂聚合物是均匀地分布在整个还未粘合的非织造织物中的。由于粘合剂聚合物在非织造织物中的均匀分布，因此实际上在长丝或纤维的所有接触处都会有粘合剂存在。因此，有大量的粘合点，此外，在热粘合过程中，还能保证向各接触点有效供给粘合剂。
双组分纤维和长丝或芯/皮型纤维或并列型纤维是特别适用于根据本发明的非织造织物中的。
另一种向热塑性长丝或纤维添加粘合剂的非常适用的方法是利用完全由或大部分由粘合剂聚合物制成的“粘合用长丝”或“粘合用纤维”。这些粘合用长丝或粘合用纤维与其它长丝或纤维铺置在一起，于是也得到了粘合剂均匀地分布在整个还未粘合的非织造织物中的结果。这种非织造织物有时也称为“双长丝非织造织物”。
就这点而言，本发明对上述粘合剂聚合物的形态没有限制。粘合剂也可以不同形态例如粉状、乳液或以纤条体添加到未粘合长丝或纤维中。
很适用作本发明非织造织物中粘合剂聚合物的聚合物和共聚合物的实例是聚酰胺6、共聚酰胺、共聚聚酯、聚丙烯、共聚丙烯、聚乙烯以及这些聚合物中一种或多种聚合物的混合物。另一种适用的材料的实例是聚对苯二甲酸丁二醇酯。粘合剂也可以单体形态添加，而这种单体在粘合过程中是会固化(即聚合)的。
在其它聚合物中，聚酯是很适用作热塑性长丝或纤维的。更适用的材料还包括(但不受此限制)聚酰胺6、聚酰胺46、聚酰胺66、共聚酰胺以及共聚酯。
如果起降低脱层强度的层是非织造织物层，那末粘合剂聚合物与形成长丝或纤维的聚合物之体积比优选低于20∶80，更优选低于1 5∶85。在其它非织造织物层中，所述比率优选为20∶80-50∶50，更优选为20∶80-35∶65。
长丝或纤维的线密度为5-20分特。在线密度低于约1分特时，则非织造织物材料会相当紧密(特别是较高基重时)，这会更易损坏底衬并在栽绒过程中会增加偏针的数目。在线密度超过约25分特时，则非织造织物会是很“松”(特别在较低基重时)，毛圈保持会下降。
根据本发明的地毯底衬的总基重优选至少为50克/平方米，更优选至少为70克/平方米。起降低脱层强度作用的层的基重优选低于地毯底衬总基重的50％，更优选低于地毯底衬总基重的40％。
虽然本发明底衬的脱层强度规定为相对于不含上述(取代的或额外的)可辨别层的底衬而言的，但按DIN 54310测定的脱层强度一般低于6牛为佳。
本发明还涉及包含上述非织造织物底衬的地毯。这种地毯具有高的强度和高伸长率，而且更均匀。
上述粘合温度是指(粘合剂)聚合物熔融和/或软化，并在长丝或纤维之间相接触形成粘合点的温度。这一粘合温度可通过多种方法加以控制，例如通过选择具有不同熔点和/或熔体流动指数或熔体粘度的粘合剂聚合物来达到。
熔融温度是采用众所周知的DSC(示差扫描量热法)技术测定的，其中将约5毫克试样(在氮气氛中)以每分钟10℃的加热速率加热。采用这种DSC技术得到的熔体吸热曲线的峰温度在本发明框架内被称为“熔融温度”。
名词“可辨别的”是指虽然在非织造织物中不同层的长丝或纤维的某些混合和/或缠结是不可避免的，但一层向其邻层的过渡实际上不是渐变的。优选的是，每层基本上都是均匀的(即在整个厚度内组成没有大的梯度)和/或每层是由单种长丝或纤维或由一种以上类型的长丝或纤维均匀共混物构成的。
层中粘合剂聚合物“浓度”的降低可通过不同方法来达到，例如通过采用较低皮/芯比率的皮/芯长丝或纤维，或通过共混少量“粘合用长丝”或“粘合用纤维”来达到。
实施例
所有试样都是采用公知技术将三层长丝可辨别层逐层叠置于收集器表面上经纺粘而成的。每个试样中，底衬的基重为120克/平方米。长丝全是以聚对苯二甲酸乙二醇酯为芯和以聚酰胺6为皮的皮/芯型。将试样置于收集器上后进行热粘合。
试样1a和1b(即对照样)由三层相同长丝层构成，每层的基重为40克/平方米，构成每层的长丝的皮/芯体积比为26/74，线密度为9分特。试样2a和2b(即按照本发明)是由两层相同的外层和一层内层所构成的，其中构成外层的长丝的皮/芯体积比为26/74，内层的皮/芯体积比为10/90。所有长丝的线密度为9分特，三层的基重都为40克/平方米。试样3(也是按照本发明)是由两层相同的外层和一层内层构成的，其中每一外层的基重为36克/平方米，构成外层的长丝的皮/芯体积比为26/74，线密度为9分特，而内层的基重为48克/平方米，构成内层的长丝的皮/芯体积比为10/90，线密度为6分特。制备试样1a和2a的粘合温度较制备试样1b、2b和试样3为低。
对试样的下列性能进行测定：按照DIN 53857-2测定栽绒前的断裂强度和断裂伸长率；按照ASTM D2646测定栽绒后的断裂强度和断裂伸长率；按照DIN 54310测定脱层强度；以及根据十位专家对栽绒试样外观进行打分，以“均匀”或“不均匀”作出鉴定。
表1栽绒前性能
 试样     强度(MD/CMD)/2(N/5cm)     伸长率(MD/CMD)/2(％)   脱层强度(N)
 1a对照     334     22     7.4
 1b对照     324     22     11.6
 2a本发明     194     11     2.3
 2b本发明     203     12     4.0
 3本发明     166     9     5.3
表2栽绒后性能
试样     强度(MD/CMD)/2(1bs)     伸长率(MD/CMD)/2(％)     外观
1a对照     112     65     不均匀
1b对照     105     64     不均匀
2a本发明     138     76     均匀
2b本发明     136     72     均匀
3本发明     144     73     均匀
这些实验清楚地表明，虽然根据本发明底衬栽绒前的强度和伸长率有所降低(见表1，与对照底衬比较降低了约35-60％)，但在栽绒后仍具有相当高的强度和伸长率(见表2，与对照底衬比较提高了约40％)。同时，以根据本发明底衬制成的地毯的外观也较以对照试样制成的地毯均匀得多。

Claims (11)

1.一种包含经粘合剂聚合物粘合的热塑性聚合物长丝或纤维的非织造地毯底衬，其特征在于该底衬包含至少一层可辨别的热塑性织造层，一层可辨别的热塑性连续层或一层还含经粘合剂聚合物粘合的热塑性聚合物长丝或纤维的可辨别非织造层，该层起降低底衬脱层强度的作用，按照DIN 54310测定的脱层强度相对于不含所述可辨别层的同类底衬降低至少30％，以及长丝或纤维的密度为5-20分特。
2.权利要求1的非织造地毯底衬，其中所述脱层强度相对于不含所述可辨别层的同类底衬降低至少50％。
3.根据权利要求1的非织造地毯底衬，其中所述起降低底衬脱层强度作用的层是嵌在两个包含热塑性聚合物长丝或纤维的可辨别织造和/或非织造层之间的，从而该非织造地毯底衬包含至少三层可辨别层。
4.根据权利要求1的非织造地毯底衬，其中所述每层都包含借助粘合剂聚合物经热粘的热塑性聚合物长丝或纤维，和其中粘合剂聚合物在起降低脱层强度作用的层中的浓度和/或粘合温度较其它层中的粘合剂聚合物浓度低至少20％，和/或较其它层的粘合温度高至少4℃。
5.根据权利要求4的非织造地毯底衬，其中粘合剂聚合物在起降低脱层强度作用的层中的浓度和/或粘合温度较其它层中的粘合剂聚合物浓度低至少30％，和/或较其它层的粘合温度高至少6℃。
6.根据权利要求1的非织造地毯底衬，其中在这些层中的至少一层中的粘合剂聚合物至少构成长丝或纤维的外表面部分。
7.根据权利要求6的非织造地毯底衬，其中长丝或纤维是以粘合剂聚合物形成皮的皮/芯型长丝或纤维。
8.根据权利要求1-7的任何一项非织造地毯底衬，其中在这些层中的至少一层中的粘合剂聚合物选自聚酰胺6、共聚酰胺、聚对苯二甲酸丁二醇酯、共聚聚酯、聚丙烯、共聚丙烯、聚乙烯以及这些聚合物的一种或多种的混合物。
9.根据权利要求1-7的任何一项非织造地毯底衬，其中构成这些层中至少一层的长丝或纤维的热塑性聚合物选自聚酯、聚酰胺6、聚酰胺46、聚酰胺66、共聚酰胺以及共聚聚酯。
10.根据权利要求1-7的任何一项非织造地毯底衬，其脱层强度低于6牛。
11.包含根据权利要求1-10的任何一项非织造地毯底衬的地毯。
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AU757063B2 (en) 2003-01-30
ATE294888T1 (de) 2005-05-15
US6207599B1 (en) 2001-03-27
DE69925140T2 (de) 2006-01-19
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DE69925140T3 (de) 2012-08-30
WO2000012800A3 (en) 2000-06-15
ID28841A (id) 2001-07-05
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KR100591494B1 (ko) 2006-06-20
KR20010072998A (ko) 2001-07-31
EP1117865A2 (en) 2001-07-25
JP4939687B2 (ja) 2012-05-30
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